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John Deere 245GLC Excavator Operation & Test Technical Manual TM12660 – PDF DOWNLOAD
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John Deere 245GLC Excavator Operation & Test Technical Manual TM12660 – PDF DOWNLOAD
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Description
John Deere 245GLC Excavator Operation & Test Technical Manual TM12660 – PDF DOWNLOAD
FILE DETAILS:
John Deere 245GLC Excavator Operation & Test Technical Manual TM12660 – PDF DOWNLOAD
Language : English
Pages : 1018
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 245GLC Excavator Operation & Test Technical Manual TM12660 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and test sections help to quickly identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- 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 245GLC Excavator Operation & Test Technical Manual TM12660 – PDF DOWNLOAD
Contents............................................................................................................................... 5 General Information................................................................................................................ 7 Safety......................................................................................................................... 9 Recognize Safety Information............................................................................................... 9 Follow Safety Instructions................................................................................................. 9 Operate Only If Qualified.................................................................................................. 9 Wear Protective Equipment.................................................................................................. 10 Avoid Unauthorized Machine Modifications................................................................................... 10 Control Pattern Selector—If Equipped....................................................................................... 11 Add Cab Guarding for Special Uses.......................................................................................... 11 Inspect Machine............................................................................................................ 11 Stay Clear of Moving Parts................................................................................................. 11 Avoid High-Pressure Fluids................................................................................................. 12 Avoid High-Pressure Oils................................................................................................... 12 Work In Ventilated Area.................................................................................................... 13 Prevent Fires.............................................................................................................. 13 Prevent Battery Explosions................................................................................................. 14 Handle Chemical Products Safely............................................................................................ 14 Decommissioning — Proper Recycling and Disposal of Fluids and Components................................................... 15 Exhaust Filter Ash Handling and Disposal................................................................................... 15 Prepare for Emergencies.................................................................................................... 15 Clean Debris from Machine.................................................................................................. 16 Use Steps and Handholds Correctly.......................................................................................... 16 Start Only From Operator's Seat............................................................................................ 16 Use and Maintain Seat Belt................................................................................................. 16 Prevent Unintended Machine Movement........................................................................................ 17 Avoid Work Site Hazards.................................................................................................... 17 Keep Riders Off Machine.................................................................................................... 18 Avoid Backover Accidents................................................................................................... 18 Inspect and Maintain ROPS.................................................................................................. 18 Avoid Machine Tip Over..................................................................................................... 19 Use Special Care When Lifting Objects...................................................................................... 19 Add and Operate Attachments Safely......................................................................................... 20 Park and Prepare for Service Safely........................................................................................ 21 Service Cooling System Safely.............................................................................................. 21 Remove Paint Before Welding or Heating..................................................................................... 22 Make Welding Repairs Safely................................................................................................ 22 Drive Metal Pins Safely.................................................................................................... 22 Clean Exhaust Filter Safely................................................................................................ 23 Diagnostics........................................................................................................................ 33 Main Controller (MCZ) Diagnostic Trouble Codes................................................................................. 35 Main Controller (MCZ) Diagnostic Trouble Codes............................................................................. 35 Controller Area Network 0 (CAN 0) Circuit Diagnostics...................................................................... 35 Controller Area Network 1 (CAN 1) Circuit Diagnostics...................................................................... 35 Interface Controller Area Network (N-CAN) Diagnostics...................................................................... 35 Engine Controller Area Network (Engine CAN) Diagnostics.................................................................... 35 011000.02 — Abnormal EEPROM................................................................................................ 35 Abnormal EEPROM Diagnostic Procedure................................................................................... 35 011001.02 — Abnormal RAM................................................................................................... 36 Abnormal RAM Diagnostic Procedure...................................................................................... 36 011002.02 — Abnormal A/D Converter......................................................................................... 37 Abnormal A/D Converter Diagnostic Procedure............................................................................ 37 011003.03 — Abnormal Sensor Voltage........................................................................................ 37 Abnormal Sensor Voltage Diagnostic Procedure........................................................................... 37 011006.02 — Engine Controller Communication Error.......................................................................... 38 011007.02 — (CAN 0) Data Converter Communication Error 1................................................................... 38 011008.02 — (CAN 1) Data Converter Communication Error 2................................................................... 38 011009.02 — (CAN 0) Monitor Controller Communication Error 1............................................................... 39 011010.02 — (CAN 1) Monitor Controller Communication Error 2............................................................... 39 011100.02 — Abnormal Engine Speed.......................................................................................... 39 Abnormal Engine Speed Diagnostic Procedure............................................................................. 39 011101.03 — Engine Control Dial Sensor Circuit High Input.................................................................. 39 Engine Control Dial Sensor Circuit High Input Diagnostic Procedure..................................................... 40 011101.04 — Engine Control Dial Sensor Circuit Low Input................................................................... 41 Engine Control Dial Sensor Circuit Low Input Diagnostic Procedure...................................................... 41 011200.03 — Pump 1 Delivery Pressure Sensor Circuit High Input............................................................. 42 Pump 1 Delivery Pressure Sensor Circuit High Diagnostics............................................................... 42 011200.04 — Pump 1 Delivery Pressure Sensor Circuit Low Input.............................................................. 44 Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure................................................. 44 011202.03 — Pump 2 Delivery Pressure Sensor Circuit High Input............................................................. 46 Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure................................................ 46 011202.04 — Pump 2 Delivery Pressure Sensor Circuit Low Input.............................................................. 48 Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure................................................. 48 011203.03 — Pump 3 Delivery Pressure Sensor Circuit High Input............................................................. 50 Pump 3 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure................................................ 50 011203.04 — Pump 3 Delivery Pressure Sensor Circuit Low Input.............................................................. 51 Pump 3 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure................................................. 51 011206.03 — Pump 1 Flow Control Pressure Sensor Circuit High Input......................................................... 53 Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure............................................ 53 011206.04 — Pump 1 Flow Control Pressure Sensor Circuit Low Input.......................................................... 54 Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure............................................. 54 011207.03 — Pump 3 Flow Control Pressure Sensor Circuit High Input......................................................... 56 Pump 3 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure............................................ 56 011207.04 — Pump 3 Flow Control Pressure Sensor Circuit Low Input.......................................................... 57 Pump 3 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure............................................. 57 011208.03 — Pump 2 Flow Control Pressure Sensor Circuit High Input......................................................... 59 Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure............................................ 59 011208.04 — Pump 2 Flow Control Pressure Sensor Circuit Low Input.......................................................... 60 Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure............................................. 60 011301.03 — Swing Pressure Sensor Circuit High Input....................................................................... 62 Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.................................................... 62 011301.04 — Swing Pilot Pressure Sensor Circuit Low Input.................................................................. 63 Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure..................................................... 63 011302.03 — Boom Up Pilot Pressure Sensor Circuit High Input............................................................... 64 Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.................................................. 64 011302.04 — Boom Up Pilot Pressure Sensor Circuit Low Input................................................................ 66 Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure................................................... 66 011303.03 — Arm In Pressure Sensor Circuit High Input...................................................................... 67 Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure................................................... 67 011303.04 — Arm In Pressure Sensor Circuit Low Input....................................................................... 68 Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure.................................................... 68 011304.03 — Travel Pilot Pressure Sensor Circuit High Input................................................................ 70 Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure................................................... 70 011304.04 — Travel Pilot Pressure Sensor Circuit Low Input................................................................. 71 Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure.................................................... 71 011307.03 — Front Attachment Pilot Pressure Sensor Circuit High Input...................................................... 73 Front Attachment Pilot Pressure Sensor Circuit High Input Diagnostic Procedure......................................... 73 011307.04 — Front Attachment Pilot Pressure Sensor Circuit Low Input....................................................... 74 Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure.......................................... 74 011325.03 — Bucket Roll-In Pilot Pressure Sensor Circuit High Input........................................................ 75 Bucket Roll-In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure........................................... 75 011325.04 — Bucket Roll-In Pilot Pressure Sensor Circuit Low Input......................................................... 77 Bucket Roll-In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................ 77 011400.02 — Pump 2 Flow Rate Limit Solenoid Feedback Abnormal Feedback..................................................... 78 Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback Diagnostic Procedure........................................... 78 011400.03 — Pump 2 Flow Rate Limit Solenoid Feedback High Current.......................................................... 80 Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure....................................... 80 011400.04 — Pump 2 Flow Rate Limit Solenoid Feedback Low Current........................................................... 81 Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure........................................ 81 011401.02 — Pump 1 and 2 Torque P/S Valve Abnormal Feedback................................................................ 83 Pump 1 and 2 Torque P/S Valve Abnormal Feedback Diagnostic Procedure................................................... 83 011401.03 — Pump 1 and 2 Torque P/S Valve Feedback High Current............................................................ 85 Pump 1 and 2 Torque P/S Valve Feedback High Current Diagnostic Procedure............................................... 85 011401.04 — Pump 1 and 2 Torque P/S Valve Feedback Low Current............................................................. 86 Pump 1 and 2 Torque P/S Valve Feedback Low Current Diagnostic Procedure................................................ 86 011402.02 — 5-Spool Solenoid Valve Unit (SF) Abnormal Feedback............................................................. 88 5-Spool Solenoid Valve Unit (SF) Abnormal Feedback Diagnostic Procedure................................................ 88 011402.03 — 5-Spool Solenoid Valve Unit (SF) Feedback High Input........................................................... 90 5-Spool Solenoid Valve Unit (SF) Feedback High Input Diagnostic Procedure.............................................. 90 011402.04 — 5-Spool Solenoid Valve Unit (SF) Feedback Low Input............................................................ 91 5-Spool Solenoid Valve Unit (SF) Feedback Low Input Diagnostic Procedure............................................... 91 011403.02 — 5-Spool Solenoid Valve Unit (SC) Abnormal Feedback............................................................. 93 5-Spool Solenoid Valve Unit (SC) Abnormal Feedback Diagnostic Procedure................................................ 93 011403.03 — 5-Spool Solenoid Valve Unit (SC) Feedback High Input........................................................... 95 5-Spool Solenoid Valve Unit (SC) Feedback High Input Diagnostic Procedure.............................................. 95 011403.04 — 5-Spool Solenoid Valve Unit (SC) Feedback Low Input............................................................ 96 5-Spool Solenoid Valve Unit (SC) Feedback Low Input Diagnostic Procedure............................................... 96 011406.02 — Pump 3 Torque P/S Valve Abnormal Feedback...................................................................... 98 Pump 3 Torque P/S Valve Abnormal Feedback Diagnostic Procedure......................................................... 98 011406.03 — Pump 3 Torque P/S Valve Feedback High Current.................................................................. 100 Pump 3 Torque P/S Valve Feedback High Current Diagnostic Procedure..................................................... 100 011406.04 — Pump 3 Torque P/S Valve Feedback Low Current................................................................... 101 Pump 3 Torque P/S Valve Feedback Low Current Diagnostic Procedure...................................................... 101 011407.02 — 5-Spool Solenoid Valve Unit (SI) Abnormal Feedback............................................................. 103 5-Spool Solenoid Valve Unit (SI) Abnormal Feedback Diagnostic Procedure................................................ 103 011407.03 — 5-Spool Solenoid Valve Unit (SI) Feedback High Input........................................................... 105 5-Spool Solenoid Valve Unit (SI) Feedback High Input Diagnostic Procedure.............................................. 105 011407.04 — 5-Spool Solenoid Valve Unit (SI) Feedback Low Input............................................................ 106 5-Spool Solenoid Valve Unit (SI) Feedback Low Input Diagnostic Procedure............................................... 106 011408.02 — 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback............................................................. 108 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback Diagnostic Procedure................................................ 108 011408.03 — 2-Spool Solenoid Valve Unit (SJ) Feedback High Input........................................................... 110 2-Spool Solenoid Valve Unit (SJ) Feedback High Input Diagnostic Procedure.............................................. 110 011408.04 — 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input............................................................ 111 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input Diagnostic Procedure............................................... 111 011409.02 — 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback............................................................. 113 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback Diagnostic Procedure................................................ 113 011409.03 — 2-Spool Solenoid Valve Unit (SZ) Feedback High Input........................................................... 115 2-Spool Solenoid Valve Unit (SZ) Feedback High Input Diagnostic Procedure.............................................. 115 011409.04 — 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input............................................................ 116 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input Diagnostic Procedure............................................... 116 011427.02 — 5-Spool Solenoid Valve Unit (SE) Abnormal Feedback............................................................. 118 5-Spool Solenoid Valve Unit (SE) Abnormal Feedback Diagnostic Procedure................................................ 118 011427.03 — 5-Spool Solenoid Valve Unit (SE) Feedback High Current......................................................... 120 5-Spool Solenoid Valve Unit (SE) Feedback High Current Diagnostic Procedure............................................ 120 011427.04 — 5-Spool Solenoid Valve Unit (SE) Feedback Low Current.......................................................... 121 5-Spool Solenoid Valve Unit (SE) Feedback Low Current Diagnostic Procedure............................................. 121 011428.02 — 5-Spool Solenoid Valve Unit (SD) Abnormal Feedback............................................................. 122 5-Spool Solenoid Valve Unit (SD) Abnormal Feedback Diagnostic Procedure................................................ 123 011428.03 — 5-Spool Solenoid Valve Unit (SD) Feedback High Current......................................................... 124 5-Spool Solenoid Valve Unit (SG) Feedback High Current Diagnostic Procedure............................................ 124 011428.04 — 5-Spool Solenoid Valve Unit (SD) Feedback Low Current.......................................................... 125 5-Spool Solenoid Valve Unit (SD) Feedback Low Current Diagnostic Procedure............................................. 125 011434.02 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback...................................... 127 Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback Diagnostic Procedure......................... 127 011434.03 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current.................................. 129 Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current Diagnostic Procedure..................... 129 011434.04 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current................................... 130 Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current Diagnostic Procedure...................... 130 011435.02 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback...................................... 132 Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback Diagnostic Procedure......................... 132 011435.03 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current.................................. 134 Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current Diagnostic Procedure..................... 134 011435.04 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current................................... 135 Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current Diagnostic Procedure...................... 135 011436.02 — Breaker Relief Proportional Solenoid Valve Abnormal Feedback................................................... 137 Breaker Relief Proportional Solenoid Valve Abnormal Feedback Diagnostic Procedure...................................... 137 011436.03 — Breaker Relief Proportional Solenoid Valve Feedback High Current............................................... 139 Breaker Relief Proportional Solenoid Valve Feedback High Current Diagnostic Procedure.................................. 139 011436.04 — Breaker Relief Proportional Solenoid Valve Feedback Low Current................................................ 140 Breaker Relief Proportional Solenoid Valve Feedback Low Current Diagnostic Procedure................................... 140 011437.02 — 2-Spool Solenoid Valve Unit (A1) Abnormal Feedback............................................................. 141 2-Spool Solenoid Valve Unit (A1) Abnormal Feedback Diagnostic Procedure................................................ 141 011437.03 — 2-Spool Solenoid Valve Unit (A1) Feedback High Current......................................................... 143 2-Spool Solenoid Valve Unit (A1) Feedback High Current Diagnostic Procedure............................................ 143 011437.04 — 2-Spool Solenoid Valve Unit (A1) Feedback Low Current.......................................................... 144 2-Spool Solenoid Valve Unit (A1) Feedback Low Current Diagnostic Procedure............................................. 144 011438.02 — 2-Spool Solenoid Valve Unit (A2) Abnormal Feedback............................................................. 146 2-Spool Solenoid Valve Unit (A2) Abnormal Feedback Diagnostic Procedure................................................ 146 011438.03 — 2-Spool Solenoid Valve Unit (A2) Feedback High Current......................................................... 147 2-Spool Solenoid Valve Unit (A2) Feedback High Current Diagnostic Procedure............................................ 147 011438.04 — 2-Spool Solenoid Valve Unit (A2) Feedback Low Current.......................................................... 149 2-Spool Solenoid Valve Unit (A2) Feedback Low Current Diagnostic Procedure............................................. 149 011457.02 — 2-Speed Activation Solenoid Disconnected or Not Present........................................................ 150 2-Speed Activation Solenoid Disconnected or Not Present Diagnostic Procedure.......................................... 150 011458.02 — (Auxiliary) Discontinuity of Selector Valve.................................................................... 152 5-Spool Solenoid Valve Unit (SE) Abnormal Feedback Diagnostic Procedure................................................ 152 011459.02 — Idle Stop Relay Circuit Malfunction............................................................................ 154 Idle Stop Relay Circuit Malfunction Diagnostic Procedure............................................................... 154 015011.03 — Hydraulic Oil Temperature Sensor Circuit High Input (Pilot)................................................... 155 Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure..................................... 155 015011.04 — Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot).................................................... 156 Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure...................................... 156 015016.03 — Right Analog Stroke Sensor Circuit High Input.................................................................. 158 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure.............. 158 015016.04 — Right Analog Stroke Sensor Circuit Low Input................................................................... 158 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit Low Input Diagnostic Procedure............... 159 011810.03 — Electric Lever Operating Pressure Sensor 1 High Voltage........................................................ 160 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure............. 160 011810.04 — Electric Lever Operating Pressure Sensor 1 Low Voltage......................................................... 161 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure.............. 161 011812.02 — OPT Electric Lever 1 Neutral Abnormal.......................................................................... 162 OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure............................................................. 162 011813.02 — OPT Electric Lever 1 Abnormal Operation........................................................................ 163 OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure........................................................... 163 011816.02 — OPT Solenoid 1 Feedback Abnormal............................................................................... 165 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Feedback Diagnostic Procedure..................... 165 011816.03 — OPT Solenoid 1 Feedback Current High........................................................................... 167 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback High Current Diagnostic Procedure................. 167 011816.04 — OPT Solenoid 1 Feedback Current Low............................................................................ 169 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback Low Current Diagnostic Procedure.................. 169 011817.02 — OPT Solenoid 2 Feedback Abnormal............................................................................... 171 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Feedback Diagnostic Procedure..................... 171 011817.03 — OPT Solenoid 2 Feedback Current High........................................................................... 172 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback High Current Diagnostic Procedure................. 173 011817.04 — OPT Solenoid 2 Feedback Current Low............................................................................ 174 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback Low Current Diagnostic Procedure.................. 174 011901.03 — Hydraulic Oil Temperature Sensor Circuit High Input............................................................ 176 Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure............................................... 176 011901.04 — Hydraulic Oil Temperature Sensor Circuit Low Input............................................................. 177 Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure................................................ 177 020010.02 — Abnormal Exhaust Filter........................................................................................ 178 Abnormal Exhaust Filter Diagnostic Procedure........................................................................... 178 020011.02 — Electric Lever Alarm........................................................................................... 178 Electric Control Lever Alarm Diagnostic Procedure...................................................................... 179 020012.02 — Line Filter Restriction Alarm.................................................................................. 179 020303.02 — Electric Lever Pilot Cut Alarm................................................................................. 179 Attachment Pedal or Blade and Outrigger Control Lever Alarm Diagnostic Procedure....................................... 179 Engine Control Unit (ECU) Diagnostic Trouble Codes............................................................................. 181 Engine Control Unit (ECU) Diagnostic Trouble Codes......................................................................... 181 000081.00 — High Exhaust Filter Differential Pressure (P2453).............................................................. 181 000081.01 — Low Exhaust Filter Differential Pressure (P2452)............................................................... 181 000081.02 — Zero-Point Calibration of Exhaust Filter Differential Pressure Sensor is Abnormal (P2456)...................... 181 000081.03 — Exhaust Filter Differential Pressure Sensor Circuit High Input (P2455)......................................... 181 000081.04 — Exhaust Filter Differential Pressure Sensor Circuit Low Input (P2454).......................................... 181 000091.02 — Accelerator Pedal Position Sensor 1-2 Correlation (P2138)...................................................... 181 000091.03 — Accelerator Pedal Position Sensor 1 High Input (P2123)......................................................... 182 000091.03 — Accelerator Pedal Position Sensor 2 High Input (P2128)......................................................... 182 000091.04 — Accelerator Pedal Position Sensor 1 Low Input (P2122).......................................................... 182 000091.04 — Accelerator Pedal Position Sensor 2 Low Input (P2127).......................................................... 182 000100.03 — Engine Oil Pressure Sensor Circuit High Input (P0523).......................................................... 182 000100.04 — Engine Oil Pressure Sensor Circuit Low Input (P0522)........................................................... 182 000102.00 — Over Boost-Pressure (P0234).................................................................................... 182 000102.03 — Boost Pressure Sensor Circuit High Input (P0238)............................................................... 183 000102.04 — Boost Pressure Sensor Circuit Low Input (P0237)................................................................ 183 000105.03 — Boost Temperature Sensor Circuit High Input (P1113)............................................................ 183 000105.04 — Boost Temperature Sensor Circuit Low Input (P1112)............................................................. 183 000108.03 — Atmospheric Pressure Sensor Circuit High Input (P2229)......................................................... 183 000108.04 — Atmospheric Pressure Sensor Circuit Low Input (P2228).......................................................... 183 000110.00 — Overheat (P0217)............................................................................................... 183 000110.03 — Engine Coolant Temperature Circuit High Input (P0118).......................................................... 184 000110.04 — Engine Coolant Temperature Circuit Low Input (P0117)........................................................... 184 000132.03 — Air Flow Sensor Circuit High Input (P0103)..................................................................... 184 000132.04 — Air Flow Sensor Circuit Low Input (P0102)...................................................................... 184 000157.00 — Pressure Increase in Common Rail (Secondary) (P0088)........................................................... 184 000157.03 — Common Rail Pressure Sensor Circuit High Input (P0193)......................................................... 184 000157.04 — Common Rail Pressure Sensor Circuit Low Input (P0192).......................................................... 184 000157.15 — Abnormal Common Rail Pressure (Over Pumping) (P0089)........................................................... 185 000157.16 — Pressure Increase in Common Rail (Primary) (P0088)............................................................. 185 000158.03 — Abnormally High Battery System Voltage (P0563)................................................................. 185 000172.03 — Intake Air Temperature Sensor Circuit High Input (P0113)....................................................... 185 000172.04 — Intake Air Temperature Sensor Circuit Low Input (P0112)........................................................ 185 000173.00 — Abnormally High Exhaust Temperature Sensor 1 (DPF Inlet) (P0426)............................................... 185 000173.03 — Exhaust Temperature Sensor 1 Circuit High Input (DPF Inlet) (P0428)............................................ 185 000173.04 — Exhaust Temperature Sensor 1 Circuit Low Input (DPF Inlet) (P0427)............................................. 186 000174.03 — Combustion Temperature Sensor Circuit High Input (P0183)....................................................... 186 000174.04 — Combustion Temperature Sensor Circuit Low Input (P0182)........................................................ 186 000190.00 — Engine Overrun (P0219)......................................................................................... 186 000628.02 — Abnormal ROM (P0601)........................................................................................... 186 000633.07 — Common Rail Pressure Limiter Open (P0087)...................................................................... 186 000636.02 — Abnormal Cam Angle Sensor (No Signal) (P0340).................................................................. 186 000636.07 — Phase Difference Between Cam and Sensor (P0016)................................................................ 187 000639.02 — Abnormal CAN Time-Out (U0101).................................................................................. 187 000639.19 — Abnormal CAN Bus (U0073)....................................................................................... 187 000651.05 — Cylinder 1 Injector Circuit Open (P0201)....................................................................... 187 000652.05 — Cylinder 2 Injector Circuit Open (P0202)....................................................................... 187 000653.05 — Cylinder 3 Injector Circuit Open (P0203)....................................................................... 187 000654.05 — Cylinder 4 Injector Circuit Open (P0204)....................................................................... 187 000723.02 — Crank Position Sensor Failure (No Signal) (P0335).............................................................. 188 000723.02 — Crank Position Sensor Failure (Abnormal Signal) (P0336)........................................................ 188 001077.02 — Abnormal CPU (P0606)........................................................................................... 188 001079.02 — Abnormal 5V-Electric Power Circuit #1 (P0641).................................................................. 188 001080.02 — Abnormal 5V-Electric Power Circuit #2 (P0651).................................................................. 188 001131.03 — Manifold Temperature Sensor Circuit High Input (P041C)......................................................... 188 001131.04 — Manifold Temperature Sensor Circuit Low Input (P041D).......................................................... 188 001239.01 — Pressure Decline in Common Rail (No Pumping Pressure) (P0093).................................................. 189 001239.31 — Pressure Decline in Common Rail (No Pumping Pressure) (Fuel Temperature less than 5° C) (P0093)................ 189 001239.17 — Pressure Decline in Common Rail (Lack of Pumping Pressure) (P1093)............................................. 189 001239.31 — Pressure Decline in Common Rail (Lack of Pumping Pressure) (Fuel Temperature less than 5° C) (P1093)........... 189 001347.03 — SCV Drive Circuit + Short Circuit B (P0092).................................................................... 189 001347.04 — SCV Drive Circuit Open or Short Circuited to GND (P0091)....................................................... 189 001381.03 — Fuel Filter Restriction Sensor Circuit High Input (P1294)...................................................... 190 001381.04 — Fuel Filter Restriction Sensor Circuit Low Input (P1293)....................................................... 190 001485.05 — Abnormal Main Relay Circuit (Inactivation) (P0685)............................................................. 190 001485.06 — Abnormal Main Relay Circuit (Kept Closed) (P0687).............................................................. 190 010001.02 — EGR Position Error (Brushless Type) (P0409).................................................................... 190 010001.13 — Abnormal EGR Zero-Point Calibration (P1404).................................................................... 190 010002.02 — Abnormal EGR Valve Control Circuit (P0404)..................................................................... 190 010003.02 — Abnormal Injector Common 1 Circuit (P2146)..................................................................... 191 010004.02 — Abnormal Injector Common 2 Circuit (P2149)..................................................................... 191 010005.01 — Abnormal Charge Circuit (Bank 1) (P1261)....................................................................... 191 010006.01 — Abnormal Charge Circuit (Bank 2) (P1262)....................................................................... 191 010007.02 — Abnormal CPU Monitor IC (P0606)................................................................................ 191 010008.02 — Abnormal A/D Converter (P060B)................................................................................. 191 010009.02 — Abnormal 5V-Electric Power Circuit #3 (P0697).................................................................. 191 010010.02 — Abnormal 5V-Electric Power Circuit #4 (P1655).................................................................. 192 010012.02 — Abnormal 12V Circuit (P0560)................................................................................... 192 010013.02 — Abnormal EEPROM/Abnormal HDEEPROM (P1621)...................................................................... 192 010022.02 — Abnormal Intake Throttle Control Circuit (P0638)............................................................... 192 010022.03 — Intake Throttle Position Sensor Circuit High Input (P0123)..................................................... 192 010022.04 — Intake Throttle Position Sensor Circuit Low Input (P0122)...................................................... 192 010023.02 — Abnormal CAN VNT Time-out/ISO-CAN VNT Communication Error (U0110).............................................. 192 010023.12 — Abnormal VNT Turbo (P0045)..................................................................................... 193 010023.19 — VNT Communication Error (U0411)................................................................................ 193 010024.03 — Exhaust Temperature Sensor 2 Circuit High Input (DOC Inlet) (P042D)............................................ 193 010024.04 — Exhaust Temperature Sensor 2 Circuit Low Input (DOC Inlet) (P042C)............................................. 193 010025.05 — Exhaust Filter Light Failure (P1669)........................................................................... 193 010026.00 — Exhaust Filter PM Over-Restriction 2 (P1455)................................................................... 193 010026.15 — Exhaust Filter PM Over-Restriction (P242F)..................................................................... 193 010027.00 — Exhaust Filter Cleaning Decision Error (P1471)................................................................. 194 010028.00 — Abnormally High Exhaust Temperature Sensor 2 (DOC Outlet) (P042B).............................................. 194 010029.00 — Over Frequent Exhaust Filter Regeneration Time-Out (P2458)..................................................... 194 010032.02 — QR Code Error (P0602).......................................................................................... 194 010033.02 — Abnormal RAM (P0604)........................................................................................... 194 010040.19 — Abnormal ISO-CAN Bus (U0001)................................................................................... 194 Monitor Controller (DSZ) Diagnostic Trouble Codes.............................................................................. 195 Monitor Controller (DSZ) Diagnostic Trouble Codes.......................................................................... 195 013002.02 — ECU Communication Error........................................................................................ 195 013003.02 — Main Controller (MCZ) Communication Error 1.................................................................... 195 013004.02 — Main Controller (MCZ) Communication Error 2.................................................................... 195 013005.02 — Monitor Controller (DSZ) Communication Error 1................................................................. 195 013006.02 — Monitor Controller (DSZ) Communication Error 2................................................................. 195 013007.02 — Machine Controller (BCZ) Communication Error................................................................... 195 020113.02 — System Error Alarm............................................................................................. 195 Information Controller (ICZ) Diagnostic Trouble Codes.......................................................................... 197 Information Controller (ICZ) Diagnostic Trouble Codes...................................................................... 197 013303.02 — Abnormal Monitor Internal Temperature Sensor................................................................... 197 Monitor Internal Temperature Sensor Diagnostic Procedure............................................................... 197 013304.02 — Alternator Alarm............................................................................................... 197 Alternator Alarm Diagnostic Procedure.................................................................................. 197 013310.03 — Shorted Circuit in Coolant Temperature Sensor.................................................................. 198 Shorted Circuit in Coolant Temperature Sensor Diagnostic Procedure..................................................... 198 013311.03 — Fuel Level Sensor Open Circuit................................................................................. 198 Fuel Level Sensor Open Circuit Diagnostic Procedure.................................................................... 199 013311.04 — Fuel Level Sensor Shorted Circuit.............................................................................. 200 Fuel Level Sensor Shorted Circuit Diagnostic Procedure................................................................. 200 013334.02 — Radiator Coolant Error......................................................................................... 201 014001.02 — Flash Memory Read/Write Error.................................................................................. 201 Flash Memory Read/Write Error Diagnostic Procedure..................................................................... 201 014002.02 — External RAM Read/Write Error.................................................................................. 202 External RAM Read/Write Error Diagnostic Procedure..................................................................... 202 014003.02 — Abnormal EEPROM................................................................................................ 202 Abnormal EEPROM Diagnostics Procedure.................................................................................. 202 014006.02 — Communication Terminal:Communication Error..................................................................... 202 Communication Terminal:Communication Error Diagnostic Procedure........................................................ 202 014008.02 — Abnormal Internal RAM.......................................................................................... 203 Abnormal Internal RAM Diagnostic Procedure............................................................................. 203 014021.02 — Communication Terminal Security Error.......................................................................... 203 014022.02 — SIM Card Error................................................................................................. 204 014023.02 — Security Error................................................................................................. 204 020100.02 — Overheat Alarm................................................................................................. 204 020101.02 — Engine Warning Alarm........................................................................................... 205 Engine Warming Alarm Diagnostic Procedure.............................................................................. 205 020102.02 — Engine Oil Pressure Alarm...................................................................................... 206 020105.02 — Hydraulic Oil Filter Restriction Alarm......................................................................... 206 Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure............................................................ 206 020106.02 — Air Cleaner Restriction Alarm.................................................................................. 207 Air Cleaner Restriction Alarm Diagnostic Procedure..................................................................... 207 020107.02 — Water Separator Alarm.......................................................................................... 208 Water-in-Fuel Separator Alarm.......................................................................................... 208 020109.02 — Pilot Control Shut-Off Lever Alarm............................................................................. 209 Pilot Control Shut-Off Lever Alarm Diagnostic Procedure................................................................ 209 020110.02 — Fuel Filter Restriction Alarm.................................................................................. 210 Fuel Filter Restriction Alarm Diagnostic Procedure..................................................................... 210 020114.02 — Overheat Alarm................................................................................................. 212 Overheat Alarm......................................................................................................... 212 020137.02 — Exhaust Filter Alarm........................................................................................... 213 020141.02 — Exhaust Temperature Alarm...................................................................................... 213 020142.02 — Intake Air Temperature Alarm................................................................................... 213 020145.02 — Boost Temperature Increase Alarm............................................................................... 213 020146.02 — Fuel Temperature Increase Alarm................................................................................ 213 020149.02 — EGR Gas Temperature Alarm...................................................................................... 214 Air Conditioner Controller (ACF) Diagnostic Trouble Codes...................................................................... 215 Air Conditioner Controller (ACF) Diagnostic Trouble Codes.................................................................. 215 11 — Open Circuit in Air Recirculation Sensor.............................................................................. 215 Open Circuit in Air Recirculation Sensor Diagnostic Procedure.......................................................... 215 12 — Short-Circuited Air Recirculation Sensor.............................................................................. 216 Short-Circuited Air Recirculation Sensor Diagnostic Procedure.......................................................... 216 13 — Open Circuit in Ambient Air Temperature Sensor........................................................................ 218 Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure................................................... 218 14 — Short-Circuited Ambient Air Temperature Sensor........................................................................ 219 Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure.................................................... 219 18 — Short-Circuited Solar Radiation Sensor................................................................................ 221 Short-Circuited Solar Radiation Sensor Diagnostic Procedure............................................................ 221 21 — Open Circuit in Air Conditioner Freeze Control Switch................................................................. 222 Open Circuit in Air Conditioner Freeze Control Switch Diagnostic Procedure............................................. 222 22 — Short-Circuited Air Conditioner Freeze Control Switch................................................................. 224 Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure............................................. 224 43 — Abnormal Air Conditioner and Heater Blower Port Change Servomotor..................................................... 225 Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure................................. 225 44 — Abnormal Air Conditioner and Heater Mixer Servomotor.................................................................. 226 Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure.............................................. 227 51 — Abnormal High/Low Refrigerant Pressure................................................................................ 228 Abnormal High/Low Refrigerant Pressure Diagnostic Procedure............................................................ 228 91 — Communication Error................................................................................................... 229 92 — CAN Bus Off Error..................................................................................................... 229 Operational Checkout Procedure..................................................................................................... 231 Operational Checkout Procedure................................................................................................. 233 Operational Checkout....................................................................................................... 233 Diagnostic Trouble Code Check.......................................................................................... 233 Operational Checks—Key Switch Off, Engine Off Checks................................................................... 233 Operational Checks—Key Switch On, Engine Off Checks.................................................................... 236 Operational Checks—Key Switch On, Engine On Checks..................................................................... 248 Engine............................................................................................................................. 283 Theory of Operation............................................................................................................ 285 Isuzu Engine............................................................................................................... 285 Engine Fuel System Component Location...................................................................................... 286 Engine Cooling System Component Location................................................................................... 288 Cold Weather Starting Aid.................................................................................................. 289 Engine Speed Control System Operation...................................................................................... 290 Diagnostic Information......................................................................................................... 293 Isuzu Engine............................................................................................................... 293 Adjustments.................................................................................................................... 295 Isuzu Engine............................................................................................................... 295 Tests.......................................................................................................................... 297 Isuzu Engine............................................................................................................... 297 Electrical System.................................................................................................................. 301 System Information............................................................................................................. 303 Electrical Diagram Information............................................................................................. 303 System Diagrams................................................................................................................ 311 Explanation of Wire Markings............................................................................................... 311 Fuse and Relay Specifications.............................................................................................. 312 System Functional Schematic, Component Location, and Wiring Diagram Master Legend.......................................... 316 System Functional Schematic................................................................................................ 323 Cab Harness (W1) Component Location........................................................................................ 361 Cab Harness (W1) Wiring Diagram............................................................................................ 365 Machine Harness (W2) Component Location.................................................................................... 383 Machine Harness (W2) Wiring Diagram........................................................................................ 387 Monitor Harness (W3) Component Location.................................................................................... 400 Monitor Harness (W3) Wiring Diagram........................................................................................ 402 Engine Harness (W4) Component Location..................................................................................... 405 Engine Harness (W4) Wiring Diagram......................................................................................... 413 Side Camera Harness (W5) Component Location................................................................................ 416 Side Camera Harness (W5) Wiring Diagram.................................................................................... 417 Side Monitor Harness (W6) Component Location............................................................................... 418 Side Monitor Harness (W6) Wiring Diagram................................................................................... 421 Pump Harness (W8) Component Location....................................................................................... 424 Pump Harness (W8) Wiring Diagram........................................................................................... 427 Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location...................................................... 429 Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram.......................................................... 429 Pilot Shutoff Switch Harness (W11) Component Location...................................................................... 430 Pilot Shutoff Switch Harness (W11) Wiring Diagram.......................................................................... 431 Auxiliary Fuse Box Harness (W13) Component Location........................................................................ 434 Auxiliary Fuse Box Harness (W13) Wiring Diagram............................................................................ 437 Heated Air Seat Harness (W14) Component Location........................................................................... 440 Heated Air Seat Harness (W14) Wiring Diagram............................................................................... 441 Multi-Function Pilot Control Lever Harness (W15) Component Location........................................................ 442 Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram............................................................ 447 Travel Alarm Cancel Switch Harness (W16) Component Location................................................................ 453 Travel Alarm Cancel Switch Harness (W16) Wiring Diagram.................................................................... 453 Attachment Harness (W17) Component Location................................................................................ 454 Attachment Harness (W17) Wiring Diagram.................................................................................... 456 Rear Camera Harness (W19) Component Location............................................................................... 458 Rear Camera Harness (W19) Wiring Diagram................................................................................... 459 9-Pin Service ADVISOR™ Connector (W20) Component Location.................................................................. 459 9-Pin Service ADVISOR™ Connector (W20) Wiring Diagram...................................................................... 460 Pilot Shutoff Valve Harness (W21) Component Location....................................................................... 461 Pilot Shutoff Valve Harness (W21) Wiring Diagram........................................................................... 462 Auxiliary 3-Button Cancel Switch Harness (W22) Component Location.......................................................... 462 Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram.............................................................. 463 Seat Heater Switch Harness (W24) Component Location........................................................................ 463 Seat Heater Switch Harness (W24) Wiring Diagram............................................................................ 464 Travel Alarm Harness (W26) Component Location.............................................................................. 465 Travel Alarm Harness (W26) Wiring Diagram.................................................................................. 466 Travel Sub Harness (W27) Component Location................................................................................ 466 Travel Sub Harness (W27) Wiring Diagram.................................................................................... 467 Starter Switch Harness (W29) Component Location............................................................................ 468 Starter Switch Harness (W29) Wiring Diagram................................................................................ 468 Data Converter Harness (W30) Component Location............................................................................ 470 Data Converter Harness (W30) Wiring Diagram................................................................................ 472 Data Converter Interface Harness (W31) Component Location.................................................................. 473 Data Converter Interface Harness (W31) Wiring Diagram...................................................................... 474 2-Speed Harness (W32) Component Location................................................................................... 475 2-Speed Harness (W32) Wiring Diagram....................................................................................... 476 Heater and Air Conditioner Harness (W41) Component Location................................................................ 477 Heater and Air Conditioner Harness (W41) Wiring Diagram.................................................................... 479 Spool Control Harness (W43) Component Location............................................................................. 481 Spool Control Harness (W43) Wiring Diagram................................................................................. 482 Auxiliary Solenoid Harness (W61) Component Location........................................................................ 484 Auxiliary Solenoid Harness (W61) Wiring Diagram............................................................................ 486 Auxiliary Function Lever (AFL) Harness (W75) Component Location............................................................ 488 Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram................................................................ 491 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location................................................... 493 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram....................................................... 494 Auxiliary Function Lever (AFL) Grip Harness (W77) Component Location....................................................... 495 Auxiliary Function Lever (AFL) Grip Harness (W77) Wiring Diagram........................................................... 495 Auxiliary Function Enable Switch Harness (W78) Component Location.......................................................... 495 Auxiliary Function Enable Switch Harness (W78) Wiring Diagram.............................................................. 496 Satellite (SAT) Harness (W6003) Component Location......................................................................... 496 Satellite (SAT) Harness (W6003) Wiring Diagram............................................................................. 497 JDLink™ Harness (W6004) Component Location................................................................................. 498 JDLink™ Harness (W6004) Wiring Diagram..................................................................................... 501 Sub-System Diagnostics......................................................................................................... 505 Controller Area Network (CAN) Theory of Operation.......................................................................... 505 Starting and Charging Circuit Theory of Operation.......................................................................... 509 Monitor Controller (DSZ) Circuit Theory of Operation....................................................................... 515 Engine Control Unit (ECU) Circuit Theory of Operation...................................................................... 523 Exhaust Aftertreatment Circuit Theory of Operation......................................................................... 532 Main Controller (MCZ) Circuit Theory of Operation.......................................................................... 535 Travel Alarm Circuit Theory of Operation................................................................................... 550 Machine Controller (BCZ) Circuit Theory of Operation....................................................................... 551 Windshield Wiper and Washer Circuit Theory of Operation.................................................................... 553 Lighting Circuit Theory of Operation....................................................................................... 557 Pilot Shutoff Circuit Theory of Operation.................................................................................. 561 Attachment Control Circuit Theory of Operation............................................................................. 564 Monitor Operation.............................................................................................................. 573 Service Menu............................................................................................................... 573 Troubleshooting............................................................................................................ 573 Monitoring................................................................................................................. 574 Controller Version......................................................................................................... 578 Issued Warning Record...................................................................................................... 579 Operation.................................................................................................................. 579 Side Monitor Operation..................................................................................................... 579 Machine Setting............................................................................................................ 580 Monitor Setting............................................................................................................ 585 Alarm Setting.............................................................................................................. 587 Engine Setting............................................................................................................. 587 Exhaust Filter No.......................................................................................................... 587 References..................................................................................................................... 589 Reading Diagnostic Trouble Codes with Monitor Display...................................................................... 589 Service ADVISOR™ Diagnostic Application.................................................................................... 589 Service ADVISOR™ Connection Procedure...................................................................................... 590 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application.............................................. 591 Clearing Engine Diagnostic Trouble Codes................................................................................... 593 MPDr Application........................................................................................................... 598 MPDr Connection Procedure.................................................................................................. 599 Fuse Test.................................................................................................................. 600 Relay Test................................................................................................................. 603 Glow Plug Relay Test....................................................................................................... 603 Pressure Sensor Test....................................................................................................... 604 Solenoid Test.............................................................................................................. 605 Proportional Solenoid Test................................................................................................. 606 Temperature Sensor Test.................................................................................................... 607 Alternator Test............................................................................................................ 608 Controller Area Network (CAN) Circuit Test................................................................................. 611 Controller Area Network (CAN) Diagnostics ............................................................................. 613 Electrical Component Checks................................................................................................ 615 Component Checks....................................................................................................... 615 Battery Remove and Install................................................................................................. 621 Rear Cover Remove and Install.............................................................................................. 624 Main Controller (MCZ) Remove and Install................................................................................... 625 Machine Controller (BCZ) Remove and Install................................................................................ 627 Engine Control Unit (ECU) Remove and Install............................................................................... 628 Exhaust Differential Pressure Sensor Zero Point Calibration................................................................ 630 Ash Reset.................................................................................................................. 631 No Load Max................................................................................................................ 632 Data Converter Remove and Install.......................................................................................... 633 Monitor Adjustable Relief Bleed Procedure.................................................................................. 634 Monitor Controller (DSZ) Remove and Install................................................................................ 635 Air Conditioner Controller (ACF) Remove and Install........................................................................ 635 Key Switch Remove and Install.............................................................................................. 637 Right Switch Console Remove and Install.................................................................................... 638 Left Switch Console Remove and Install..................................................................................... 640 Travel Alarm Remove and Install............................................................................................ 641 Heater Control Disable and Enable.......................................................................................... 642 Disconnect Tab Retainer Connectors......................................................................................... 642 Disconnecting Spring Wire Clip Connectors.................................................................................. 642 Replace DEUTSCH™ Connectors................................................................................................ 643 Replace DEUTSCH™ Rectangular or Triangular Connectors...................................................................... 644 Install DEUTSCH™ Contact................................................................................................... 645 Replace WEATHER PACK™ Connector............................................................................................ 646 Install WEATHER PACK™ Contact.............................................................................................. 647 Replace (Pull Type) Metri-Pack™ Connectors................................................................................. 648 Replace (Push Type) Metri-Pack™ Connectors................................................................................. 649 Replace CINCH™ Connectors.................................................................................................. 649 Install CINCH™ Contact..................................................................................................... 651 Repair 32 and 48 Way CINCH™ Connectors..................................................................................... 652 Remove Connector Body from Blade Terminals................................................................................. 654 Power Train........................................................................................................................ 655 Theory of Operation............................................................................................................ 657 Track Adjuster and Recoil Spring Operation................................................................................. 657 Travel Gear Case Operation................................................................................................. 658 Diagnostic Information......................................................................................................... 661 Noisy or Loose Track Chain................................................................................................. 661 Noisy or Loose Track Chain Diagnostic Procedure........................................................................ 661 Tight Track Chain.......................................................................................................... 661 Tight Track Chain Diagnostic Procedure................................................................................. 661 Frequent Track Chain Sag Adjustment Required............................................................................... 662 Frequent Track Chain Sag Adjustment Required Diagnostic Procedure...................................................... 662 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers.................................................. 662 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure......................... 662 Bent Track Shoes........................................................................................................... 662 Bent Track Shoes Diagnostic Procedure.................................................................................. 662 “Popping” of Track......................................................................................................... 663 “Popping” of Track Diagnostic Procedure................................................................................ 663 Cracked Track Link......................................................................................................... 663 Cracked Track Link Diagnostic Procedure................................................................................ 663 Chipped Link Rails......................................................................................................... 664 Chipped Link Rails Diagnostic Procedure................................................................................ 664 Individual Undercarriage Component Wear.................................................................................... 665 Individual Undercarriage Component Wear Diagnostic Procedure........................................................... 665 Measure Swing Bearing Wear................................................................................................. 666 Hydraulic System................................................................................................................... 669 Theory of Operation............................................................................................................ 671 Hydraulic System Operation................................................................................................. 671 Pilot System Operation..................................................................................................... 671 Pilot Pump, Pressure Regulating Valve, and Filter Operation................................................................ 672 Pilot Shutoff Solenoid Valve Operation..................................................................................... 673 Pilot Control Valve Operation.............................................................................................. 676 Travel Pilot Control Valve Operation....................................................................................... 678 Pilot Operation of Control Valve Operation................................................................................. 681 Pilot Signal Manifold Operation............................................................................................ 684 Pump 1, Pump 2, Pump 3, and Drive Gear Case Operation...................................................................... 694 Pump 1, Pump 2, and Pump 3 Regulator Operation............................................................................. 697 Engine Speed Sensing Control Circuit Operation............................................................................. 703 Control Valve Operation.................................................................................................... 705 Control Valve Check Valves Identification and Operation.................................................................... 719 Main Relief Valve Circuit Operation........................................................................................ 723 Circuit Relief and Anticavitation Valve Operation.......................................................................... 727 Travel Flow Combiner Valve Operation....................................................................................... 728 Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation........................................................... 732 Boom Lower Meter-In Cut Valve Operation.................................................................................... 735 Boom Regenerative Valve Circuit Operation.................................................................................. 737 Dig Regenerative Valve Circuit Operation................................................................................... 739 Arm Regenerative Valve Circuit Operation................................................................................... 745 Bucket Regenerative Valve Circuit Operation................................................................................ 750 Boom and Arm Reduced Leakage Valves Operation.............................................................................. 754 Arm 1 Flow Rate Control Valve Circuit Operation............................................................................ 756 Arm 2 Flow Rate Control Valve Circuit Operation............................................................................ 760 Auxiliary Flow Rate Control Valve Circuit Operation........................................................................ 762 Arm 3 and Boom 3 Spool Control Solenoid Valve Operation.................................................................... 765 Swing Reduction Gear Case Operation........................................................................................ 768 Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation..................................................... 769 Swing Motor Damper Valve................................................................................................... 772 Swing Motor Park Brake Release Circuit Operation........................................................................... 780 Center Joint Operation..................................................................................................... 781 Travel Motor and Park Brake Valve Operation................................................................................ 782 Travel Motor Speed Circuit Operation....................................................................................... 791 Diesel Particulate Filter (DPF) Burn Solenoid Valves....................................................................... 795 Cylinder Operation......................................................................................................... 798 Return Filter Operation.................................................................................................... 799 Auxiliary System Operation................................................................................................. 800 Auxiliary Pilot Control Valve Operation.................................................................................... 800 Flow Rate Select Solenoid Valve Operation.................................................................................. 810 Flow Rate Pressure Reducing Valve Operation................................................................................ 811 Secondary Auxiliary Relief Valve Solenoid Valve Operation.................................................................. 811 Secondary Auxiliary Relief Control Valve Operation......................................................................... 812 Secondary Auxiliary Relief Valve Operation................................................................................. 812 Selector Valve Solenoid Valve Operation.................................................................................... 813 Selector Valve Operation................................................................................................... 813 Auxiliary Shuttle Valve Operation.......................................................................................... 814 Auxiliary High Flow Line Kit Operation..................................................................................... 815 Two Way Solenoid Kit Operation............................................................................................. 819 Two Pump Combined Flow Kit Operation....................................................................................... 823 Secondary Auxiliary Relief Kit Operation................................................................................... 829 Low Flow Kit Operation..................................................................................................... 833 Diagnostic Information......................................................................................................... 841 All Hydraulic Functions Slow............................................................................................... 841 All Hydraulic Functions Slow Diagnostic Procedure...................................................................... 841 Hydraulic Oil Overheats.................................................................................................... 843 Hydraulic Oil Overheats Diagnostic Procedure........................................................................... 843 No Hydraulic Functions..................................................................................................... 845 No Hydraulic Functions Diagnostic Procedure............................................................................ 845 Poor Combined Operation.................................................................................................... 846 Poor Combined Operation Diagnostic Procedure........................................................................... 846 All Functions Cannot Be Operated........................................................................................... 847 All Functions Cannot Be Operated Diagnostic Procedure.................................................................. 847 Function Does Not Stop When Control Lever Released......................................................................... 848 Function Does Not Stop When Control Lever Released Diagnostic Procedure................................................ 848 Some Functions Cannot Be Operated, All Others Are Normal................................................................... 848 Some Functions Cannot Be Operated, All Others Are Normal Diagnostic Procedure.......................................... 848 All Functions Slow......................................................................................................... 849 All Functions Slow Diagnostic Procedure................................................................................ 849 Functions Move in Opposite Direction....................................................................................... 850 Functions Move in Opposite Direction Diagnostic Procedure.............................................................. 850 All Dig Functions Slow or No Power......................................................................................... 850 All Dig Functions Slow or No Power..................................................................................... 851 Some Dig Functions Slow (Not All).......................................................................................... 851 Some Dig Functions Slow (Not All) Diagnostic Procedure................................................................. 851 Load Drifts Down When Control Lever is in Neutral Position................................................................. 853 Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure........................................ 853 Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle................................... 853 Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle Diagnostic Procedure.......... 854 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal..................................................... 854 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure............................ 854 Swing Speed Slow in Both Directions........................................................................................ 855 Swing Speed Slow in Both Directions Diagnostic Procedure............................................................... 856 Swing Speed Slow or Does Not Operate in One Direction...................................................................... 857 Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure............................................. 857 Upperstructure Drift With Swing Valve in Neutral........................................................................... 858 Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure.................................................. 858 Swing Function Does Not Operate............................................................................................ 859 Swing Function Does Not Operate Diagnostic Procedure................................................................... 859 Travel Park Brakes Do Not Apply............................................................................................ 860 Travel Park Brakes Do Not Apply Diagnostic Procedure................................................................... 860 Track Will Not Move in One Direction....................................................................................... 861 Track Will Not Move in One Direction Diagnostic Procedure.............................................................. 861 Track Will Not Move in Either Direction.................................................................................... 862 Track Will Not Move in Either Direction Diagnostic Procedure........................................................... 862 Machine Mistracks at All Speeds in Both Directions......................................................................... 863 Machine Mistracks at All Speeds in Both Directions Diagnostic Procedure................................................ 863 Slow Travel Speed or Low Power............................................................................................. 865 Slow Travel Speed or Low Power Diagnostic Procedure.................................................................... 865 Combined Travel and Dig Functions Slow or No Power......................................................................... 866 Combined Travel and Dig Functions Slow or No Power Diagnostic Procedure................................................ 866 Travel is “Jerky”.......................................................................................................... 867 Travel is “Jerky” Diagnostic Procedure................................................................................. 867 Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline............................. 868 Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline Diagnostic Procedure.... 868 Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs........................................................ 868 Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs Diagnostic Procedure............................... 868 Pump 1, Pump 2, Pump 3, and Pilot Pump Line Identification................................................................. 869 Control Valve Line Identification.......................................................................................... 870 Swing Motor Line Identification............................................................................................ 873 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern.......................................... 875 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern............................................ 879 Pilot Signal Manifold-to-Control Valve Line Connection..................................................................... 882 Travel System Component Location........................................................................................... 886 Travel Hydraulic System Line Connection.................................................................................... 889 Hydraulic System Schematic................................................................................................. 893 Hydraulic System Component Location........................................................................................ 910 Hydraulic System Line Connections.......................................................................................... 913 Tests.......................................................................................................................... 917 JT05800 Digital Thermometer Installation................................................................................... 917 JT02156A Digital Pressure and Temperature Analyzer Kit Installation........................................................ 917 General Hydraulic Oil Cleanup Procedure.................................................................................... 918 Hydraulic Component Failure Cleanup Procedure.............................................................................. 920 Hydraulic Oil Cleanup Procedure............................................................................................ 922 Hydraulic Oil Tank Pressure Release Procedure.............................................................................. 923 Hydraulic Oil Warm-Up Procedure............................................................................................ 924 Pilot Pressure Regulating Valve Test and Adjustment........................................................................ 926 Control Valve Spool Actuating Pilot Pressure Test.......................................................................... 928 Dig Regenerative Solenoid Valve Test and Adjustment........................................................................ 930 Arm Regenerative Solenoid Valve Test and Adjustment........................................................................ 932 Power Dig Solenoid Valve Test and Adjustment............................................................................... 934 Arm 2 Flow Control Solenoid Valve Test and Adjustment...................................................................... 936 Torque Control Solenoid Valve Test and Adjustment.......................................................................... 938 Arm 3 and Boom 3 Control Solenoid Valve Test and Adjustment................................................................ 941 Pump Control Pilot Pressure Signal Test.................................................................................... 943 Main Relief and Power Dig Valve Test and Adjustment........................................................................ 945 Circuit Relief Valve Test and Adjustment................................................................................... 949 Swing Motor Crossover Relief Valve Test and Adjustment..................................................................... 952 Travel Motor Crossover Relief Valve Test and Adjustment.................................................................... 954 Pump Regulator Test and Adjustment—Minimum Flow............................................................................ 957 Pump Regulator Test and Adjustment—Maximum Flow............................................................................ 959 Pump Flow Test............................................................................................................. 961 Swing Motor Leakage Test................................................................................................... 968 Travel Motor Leakage Test.................................................................................................. 969 Cylinder Drift Test—Boom, Arm, and Bucket.................................................................................. 971 Heating and Air Conditioning....................................................................................................... 973 Theory of Operation............................................................................................................ 975 Air Conditioning System Cycle of Operation................................................................................. 975 Diagnostic Information......................................................................................................... 977 Air Conditioning System Does Not Operate................................................................................... 977 Air Conditioning System Does Not Operate Diagnostic Procedure.......................................................... 977 No Air Flow From Heater and Air Conditioner Vents.......................................................................... 978 No Air Flow From Heater and Air Conditioner Vents Diagnostic Procedure................................................. 978 Air Conditioning Does Not Cool Interior of Cab............................................................................. 980 Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure.................................................... 980 Air Conditioning Runs Constantly, Too Cold................................................................................. 982 Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure........................................................ 982 Interior Windows Continue to Fog Using Air Conditioner..................................................................... 983 Interior Windows Continue to Fog Using Air Conditioner Diagnostics Procedure........................................... 983 Heater System Does Not Operate............................................................................................. 983 Heater System Does Not Operate Diagnostic Procedure.................................................................... 984 Heater Does Not Warm Interior of Cab....................................................................................... 986 Heater Does Not Warm Interior of Cab Diagnostic Procedure.............................................................. 986 Interior Windows Continue to Fog Using Heater.............................................................................. 987 Interior Windows Continue to Fog Using Heater Diagnostic Procedure..................................................... 987 Heater and Air Conditioner Component Location.............................................................................. 989 Tests.......................................................................................................................... 993 Refrigerant Cautions and Proper Handling................................................................................... 993 Heater and Air Conditioner Operational Checks.............................................................................. 993 Visual Inspection of Components........................................................................................ 993 Air Conditioner Compressor Clutch Test..................................................................................... 995 Refrigerant Leak Test...................................................................................................... 995 Refrigerant Hoses and Tubing Inspection.................................................................................... 995 Air Conditioner Compressor Belt Check...................................................................................... 996 Air Conditioner High/Low-Pressure Switch Test.............................................................................. 997 Air Conditioner Freeze Control Switch Test................................................................................. 998 R134a Air Conditioning System Test......................................................................................... 999 Operating Pressure Diagnostic Chart........................................................................................1000 Dealer Fabricated Tools............................................................................................................1001 Dealer Fabricated Tools........................................................................................................1003 DFT1218 Split Flange Hose Cap..............................................................................................1003 Page Number............................................................................................................................ 5 Section 9000....................................................................................................................... 7 Group 01....................................................................................................................... 9 Section 9001....................................................................................................................... 33 Group 10....................................................................................................................... 35 Group 20....................................................................................................................... 181 Group 30....................................................................................................................... 195 Group 40....................................................................................................................... 197 Group 50....................................................................................................................... 215 Section 9005....................................................................................................................... 231 Group 10....................................................................................................................... 233 Section 9010....................................................................................................................... 283 Group 05....................................................................................................................... 285 Group 15....................................................................................................................... 293 Group 20....................................................................................................................... 295 Group 25....................................................................................................................... 297 Section 9015....................................................................................................................... 301 Group 05....................................................................................................................... 303 Group 10....................................................................................................................... 311 Group 15....................................................................................................................... 505 Group 16....................................................................................................................... 573 Group 20....................................................................................................................... 589 Section 9020....................................................................................................................... 655 Group 05....................................................................................................................... 657 Group 15....................................................................................................................... 661 Section 9025....................................................................................................................... 669 Group 05....................................................................................................................... 671 Group 15....................................................................................................................... 841 Group 25....................................................................................................................... 917 Section 9031....................................................................................................................... 973 Group 05....................................................................................................................... 975 Group 15....................................................................................................................... 977 Group 25....................................................................................................................... 993 Section 9900.......................................................................................................................1001 Group 99.......................................................................................................................1003
S.S 24/02/2025
