John Deere 350GLC Excavator Operation and Test TECHNICAL MANUAL TM12173 – PDF

Description

John Deere 350GLC Excavator Operation and Test TECHNICAL MANUAL TM12173 – PDF DOWNLOAD

FILE DETAILS:

John Deere 350GLC Excavator Operation and Test TECHNICAL MANUAL TM12173 – PDF DOWNLOAD

Language : English
Pages :926
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

John Deere 350GLC Excavator Operation and Test TECHNICAL MANUAL TM12173 – PDF DOWNLOAD

Foreword

• This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
• This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction.
• At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines.
• They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes

TABLE OF CONTENTS:

John Deere 350GLC Excavator Operation and Test TECHNICAL MANUAL TM12173 – PDF DOWNLOAD

Contents 5
General Information 7
Safety 9
Recognize Safety Information 9
Follow Safety Instructions 9
Operate Only If Qualified 9
Wear Protective Equipment 10
Avoid Unauthorized Machine Modifications 10
Add Cab Guarding For Special Uses 10
Inspect Machine 11
Stay Clear of Moving Parts 11
Avoid High-Pressure Fluids 11
Avoid High-Pressure Oils 12
Work In Ventilated Area 12
Prevent Fires 13
Prevent Battery Explosions 13
Handle Chemical Products Safely 14
Dispose of Waste Properly 14
Exhaust Filter Ash Handling and Disposal 14
Prepare for Emergencies 15
Clean Debris from Machine 15
Use Steps and Handholds Correctly 15
Start Only From Operator’s Seat 15
Use and Maintain Seat Belt 16
Prevent Unintended Machine Movement 16
Avoid Work Site Hazards 17
Keep Riders Off Machine 17
Avoid Backover Accidents 18
Inspect and Maintain ROPS 18
Operating or Traveling On Public Roads 18
Avoid Machine Tip Over 19
Use Special Care When Lifting Objects 19
Add and Operate Attachments Safely 19
Park and Prepare for Service Safely 20
Service Cooling System Safely 20
Remove Paint Before Welding or Heating 21
Make Welding Repairs Safely 21
Drive Metal Pins Safely 21
Clean Exhaust Filter Safely 22
Diagnostics 27
Main Controller (MCZ) Diagnostic Trouble Codes 29
Main Controller (MCZ) Diagnostic Trouble Codes 29
Controller Area Network 0 (CAN 0) Circuit Diagnostics 29
Controller Area Network (CAN 0) Diagnostics 29
Controller Area Network 1 (CAN 1) Circuit Diagnostics 44
Controller Area Network (CAN 1) Diagnostics 44
Interface Controller Area Network (N-CAN) Diagnostics 56
Interface Controller Area Network (N-CAN) Diagnostics 56
Engine Controller Area Network (Engine CAN) Diagnostics 65
Engine Controller Area Network (Engine CAN) Diagnostics 65
110002 — Abnormal EEPROM 70
Controller Hardware Diagnostics 70
110012 — Abnormal RAM 70
Controller Hardware Diagnostics 70
110022 — Abnormal A/D Converter 71
Controller Hardware Diagnostics 71
110033 — Abnormal Sensor Voltage 72
Harness diagnostics 72
110042 — CAN Communication Error 1 72
110052 — CAN Communication Error 2 73
110062 — Engine Controller Communication Error 73
110072 — (CAN 0) Data Converter Communication Error 1 73
110082 — (CAN 1) Data Converter Communication Error 2 73
110092 — (CAN 0) Monitor Controller Communication Error 1 73
110102 — (CAN 1) Monitor Controller Communication Error 2 74
111002 — Abnormal Engine Speed 74
Engine Speed Diagnostics 74
111013 — Engine Control Dial Sensor Circuit High 74
Engine Control Dial Sensor Circuit High Diagnostics 74
111014 — Engine Control Dial Sensor Circuit Low 76
Engine Control Dial Sensor Circuit High Diagnostics 76
112003 — Pump 1 Delivery Pressure Sensor Circuit High 78
Pump 1 Delivery Pressure Sensor Circuit High Diagnostics 78
112004 — Pump 1 Delivery Pressure Sensor Circuit Low 79
Pump 1 Delivery Pressure Sensor Circuit Low Diagnostics 79
112013 — Fan Pump Delivery Pressure Sensor Circuit High 81
Fan Pump Delivery Pressure Sensor Circuit High Diagnostics 81
112014 — Fan Pump Delivery Pressure Sensor Circuit Low 82
Fan Pump Delivery Pressure Sensor Circuit Low Diagnostics 82
112023 — Pump 2 Delivery Pressure Sensor Circuit High 84
Pump 2 Delivery Pressure Sensor Circuit High Diagnostics 84
112024 — Pump 2 Delivery Pressure Sensor Circuit Low 85
Pump 2 Delivery Pressure Sensor Circuit Low Diagnostics 85
112063 — Pump 1 Control Pressure Sensor Circuit High 87
Pump 1 Control Pressure Sensor Circuit High Diagnostics 87
112064 — Pump 1 Control Pressure Sensor Circuit Low 88
Pump 1 Control Pressure Sensor Circuit Low Diagnostics 88
112083 — Pump 2 Control Pressure Sensor Circuit High 90
Pump 2 Control Pressure Sensor Circuit High Diagnostics 90
112084 — Pump 2 Control Pressure Sensor Circuit Low 91
Pump 2 Control Pressure Sensor Circuit Low Diagnostics 91
113013 — Swing Pressure Sensor Circuit High 93
Swing Pressure Sensor Circuit High Diagnostics 93
113014 — Swing Pilot Pressure Sensor Circuit Low 95
Swing Pilot Pressure Sensor Circuit Low Diagnostics 95
113023 — Boom Up Pressure Sensor Circuit High 96
Boom Up Pressure Sensor Circuit High Diagnostics 96
113024 — Boom Up Pressure Sensor Circuit Low 98
Boom Up Pressure Sensor Circuit Low Diagnostics 98
113033 — Arm In Pressure Sensor Circuit High100
Arm In Pilot Pressure Sensor Circuit High Diagnostics100
113034 — Arm In Pressure Sensor Circuit Low102
Arm In Pilot Pressure Sensor Circuit Low Diagnostics102
113043 — Travel Pressure Sensor Circuit High104
Travel Pressure Sensor Circuit High Diagnostics104
113044 — Travel Pressure Sensor Circuit Low106
Travel Pressure Sensor Circuit Low Diagnostics106
113073 — Front Attachment Pressure Sensor Circuit High108
Front Attachment Pressure Sensor Circuit High Diagnostics108
113074 — Front Attachment Pressure Sensor Circuit Low110
Front Attachment Pressure Sensor Circuit Low Diagnostics110
114002 — Pump 2 Control Rate Limit Solenoid Feedback Abnormal112
Pump 2 Flow Rate Limit Solenoid Feedback Abnormal Diagnostics112
114003 — Pump 2 Control Rate Limit Solenoid Feedback High Curre113
Pump 2 Flow Rate Limit Solenoid Feedback High Current Diagnostic113
114004 — Pump 2 Control Rate Limit Solenoid Feedback Low Curren114
Pump 2 Flow Rate Limit Solenoid Feedback Low Current Diagnostics114
114012 — Torque Control Solenoid Abnormal Feedback115
Torque Control Solenoid Abnormal Feedback Diagnostics115
114013 — Torque Solenoid Feedback High Current116
Torque Solenoid Feedback High Current Diagnostics116
114014 — Torque Solenoid Valve Feedback Low Current117
Torque Solenoid Valve Feedback Low Current Diagnostics117
114022 — Dig Regenerative Solenoid Feedback Current Abnormal118
Dig Regenerative Solenoid Feedback Current Abnormal Diagnostics118
114023 — Dig Regenerative Solenoid Feedback Current High119
Dig Regenerative Solenoid Feedback Current High Diagnostics119
114024 — Dig Regenerative Solenoid Feedback Current Low120
Dig Regenerative Solenoid Diagnostics120
114032 — Arm Regenerative Solenoid Feedback Current Abnormal121
Arm Regenerative Solenoid Diagnostics121
114033 — Arm Regenerative Solenoid Feedback Current High122
Arm Regenerative Solenoid Diagnostics122
114034 — Arm Regenerative Solenoid Feedback Current Low123
Arm Regenerative Solenoid Diagnostics123
114042 — Power Dig Solenoid Feedback Current Abnormal124
Power Dig Solenoid Diagnostics124
114043 — Power Dig Solenoid Feedback Current High125
Power Dig Solenoid Diagnostics125
114044 — Power Dig Solenoid Feedback Current Low126
Power Dig Solenoid Diagnostics126
114052 — Travel Speed Solenoid Feedback Current Abnormal127
Travel Speed Solenoid Diagnostics127
114053 — Travel Speed Solenoid Feedback Current High128
Travel Speed Solenoid Diagnostics128
114054 — Travel Speed Solenoid Feedback Current Low129
Travel Speed Solenoid Diagnostics129
114122 — Hydraulic Fan Control Solenoid Feedback Current Abnorm130
Hydraulic Fan Control Solenoid Diagnostics130
114123 — Hydraulic Fan Control Solenoid Feedback Current High131
Hydraulic Fan Control Solenoid Diagnostics131
114124 — Hydraulic Fan Control Solenoid Feedback Current Low132
Hydraulic Fan Control Solenoid Diagnostics132
114572 — Diagnostic Trouble Code133
114582 — Diagnostic Trouble Code133
114592 — Diagnostic Trouble Code133
119013 — Hydraulic Oil Temperature Sensor Circuit High133
Hydraulic Oil Temperature Sensor Circuit High Diagnostics134
119014 — Hydraulic Oil Temperature Sensor Circuit Low135
Hydraulic Oil Temperature Sensor Diagnostics135
200092 — Hydraulic Oil Cooling System Abnormal137
Hydraulic Oil Cooling System Diagnostics137
200102 — Abnormal Exhaust Filter138
Abnormal Exhaust Filter Diagnostics138
200622 — Hydraulic Oil Temperature Alarm139
Engine Control Unit (ECU) Diagnostic Trouble Codes (Level 14 Con141
Engine Control Unit (ECU) Diagnostic Trouble Codes (Level 14 Con141
17103 — Intake Air Temperature Sensor Out of Range High141
Intake Air Temperature Sensor Diagnostics141
17104 — Intake Air Temperature Sensor Out of Range Low141
Intake Air Temperature Sensor Diagnostics141
64705 — Proportional Fan Speed Solenoid Driver Open142
Proportional Fan Speed Solenoid Diagnostics142
64731 — Fan Manual Reverse Mode Input Active Too Long143
Fan Manual Reverse Mode Input Diagnostics143
89809 — Engine Speed Request Not Received or Timed Out143
163809 — Hydraulic Oil Temperature Message Not Received or Time144
Engine Control Unit (ECU) Diagnostic Trouble Codes (Level 21 Con145
Engine Control Unit (ECU) Diagnostic Trouble Codes145
10700 — Air Filter Differential Pressure High—Most Severe Level145
Air Filter Differential Pressure High—Most Severe Level Diagnost145
11101 — Coolant Level Low—Most Severe Level145
Coolant Level Low—Most Severe Level Diagnostic Procedure145
11118 — Coolant Level Low—Moderately Severe Level146
Coolant Level Low—Moderately Severe Level Diagnostic Procedure146
19000 — Engine Speed High—Most Severe Level147
Engine Speed High—Most Severe Level Diagnostic Procedure147
62718 — Battery Voltage Below Normal—Moderately Severe Level147
Battery Voltage Below Normal—Moderately Severe Level Diagnostic 148
64705 — Proportional Fan Speed Valve Solenoid Driver Open148
Proportional Fan Speed Valve Solenoid Driver Open Diagnostic Pro148
64706 — Proportional Fan Speed Valve Solenoid Driver Short149
Proportional Fan Speed Valve Solenoid Driver Short Diagnostic Pr149
64716 — Manual Purge Mode Switch Active Too Long149
Manual Purge Mode Switch Active Too Long Diagnostic Procedure150
89809 — Requested Speed/Speed Limit150
Requested Speed/Speed Limit Diagnostic Procedure150
111031 — Engine Protection System has Shutdown151
Engine Protection System has Shutdown Diagnostic Procedure151
156802 — Torque Curve Selection151
Torque Curve Selection Diagnostic Procedure151
163809 — Hydraulic Temperature152
Hydraulic Temperature Diagnostic Procedure152
163901 — Fan Speed Low—Most Severe Level152
Fan Speed Low—Most Severe Level Diagnostic Procedure152
163916 — Fan Speed High—Moderately Severe Level153
Fan Speed High—Moderately Severe Level Diagnostic Procedure153
163918 — Fan Speed Low—Moderately Severe Level153
Fan Speed Low—Moderately Severe Level Diagnostic Procedure153
200013 — Security Violation154
Security Violation Diagnostic Procedure154
200309 — CAN Timeout or Invalid Data154
CAN Timeout or Invalid Data Diagnostic Procedure154
200313 — Security Violation155
Security Violation Diagnostic Procedure155
200509 — Abnormal Update Rate155
Abnormal Update Rate Diagnostic Procedure155
201709 — CAN Timeout or Invalid Data156
CAN Timeout or Invalid Data Diagnostic Procedure156
201713 — Security Violation157
Security Violation Diagnostic Procedure157
214609 — HCI Pump Message Missing157
HCI Pump Message Missing Diagnostic Procedure157
288303 — Idle Switch Voltage Out of Range High158
Idle Switch Voltage Out of Range High Diagnostic Procedure158
288304 — Idle Switch Voltage Out of Range Low158
Idle Switch Voltage Out of Range Low Diagnostic Procedure158
358705 — Cold Start Aid Solenoid Open159
Cold Start Aid Solenoid Open Diagnostic Procedure159
358706 — Cold Start Aid Solenoid Short160
Cold Start Aid Solenoid Short Diagnostic Procedure160
6537205 — Proportional Fan Speed Valve Solenoid Driver Open160
Proportional Fan Speed Valve Solenoid Driver Open Diagnostic Pro160
6537206 — Proportional Fan Speed Valve Solenoid Driver Short161
Proportional Fan Speed Valve Solenoid Driver Short Diagnostic Pr161
Monitor Controller (DSZ) Diagnostic Trouble Codes163
Monitor Controller (DSZ) Diagnostic Trouble Codes163
140012 — Flash Memory Read/Write Error163
Data Converter Diagnostics163
140022 — External RAM Read/Write Error163
Data Converter Diagnostics163
140032 — Abnormal EEPROM163
Data Converter Diagnostics163
140062 — Communication Terminal : Communication Error164
Communication Terminal : Communication Error164
140082 — Abnormal Internal RAM164
Data Converter Diagnostics165
140212 — Communication Terminal Security Error165
140222 — SIM Card Error165
140232 — Security Error165
201012 — Engine Warning Alarm165
201022 — Engine Oil Pressure Alarm165
201032 — Alternator Alarm166
Alternator Alarm166
201042 — Fuel Level Alarm166
Fuel Level Alarm166
201052 — Hydraulic Oil Filter Restriction Alarm167
Hydraulic Oil Filter Restriction Alarm167
201062 — Air Cleaner Restriction Alarm168
Air Cleaner Restriction Alarm168
201092 — Pilot Control Shut-Off Lever Alarm168
Pilot Control Shut-Off Lever Alarm168
201102 — Hydraulic Oil Filter Restriction Alarm169
201132 — System Error Alarm169
201332 — Crane Function Alarm169
201372 — Exhaust Filter Alarm170
201412 — Exhaust Temperature Alarm170
201422 — Intake Air Temperature Alarm170
201452 — Boost Temperature Increase Alarm170
201462 — Fuel Temperature Increase Alarm170
201492 — EGR Gas Temperature Alarm170
Air Conditioner Controller (ACF) Diagnostic Trouble Codes171
Air Conditioner Controller (ACF) Diagnostic Trouble Codes171
11 — Open Circuit In Air Recirculation Sensor171
Harness Diagnostics171
12 — Short-Circuited Air Recirculation Sensor171
Harness Diagnostics171
13 — Open Circuit In Ambient Air Temperature Sensor172
Harness Diagnostics172
14 — Short-Circuited Ambient Air Temperature Sensor172
Harness Diagnostics172
18 — Short-Circuited Solar Radiation Sensor173
Harness Diagnostics173
21 — Open Circuit In Air Conditioner Freeze Control Switch173
Harness Diagnostics173
22 — Short-Circuited Air Conditioner Freeze Control Switch174
Harness Diagnostics174
43 — Abnormal Air Conditioner And Heater Blower Port Change Serv174
Harness Diagnostics174
44 — Abnormal Air Conditioner And Heater Mixer Servomotor175
Harness Diagnostics175
51 — Abnormal Air Conditioner High/Low Pressure Switch175
Harness Diagnostics176
91 — Communication Error176
Harness Diagnostics176
92 — CAN Bus Off Error177
Harness Diagnostics177
Operational Checkout Procedure179
Operational Checkout Procedure181
Operational Checkout181
Diagnostic Trouble Code Check181
Operational Checks—Key Switch Off, Engine Off Checks181
Operational Checks—Key Switch On, Engine Off Checks184
Operational Checks—Key Switch On, Engine On Checks196
Engine229
Theory of Operation231
Engine Identification231
John Deere Engine233
Engine Fuel System Component Location235
Engine Cooling System Component Location241
Cold Weather Starting Aid242
Engine Speed Control System Operation243
Diagnostic Information245
John Deere Engine245
Adjustments247
John Deere Engine247
Tests249
John Deere Engine249
Radiator Temperature Differential Check250
Engine Power Test Using Turbocharger Boost Pressure253
Electrical System257
System Information259
Electrical Diagram Information259
System Diagrams267
Explanation of Wire Markings267
Fuse and Relay Specifications267
System Functional Schematic, Component Location, and Wiring Diag271
System Functional Schematic277
Cab Harness (W1) Component Location347
Cab Harness (W1) Wiring Diagram352
Machine Harness (W2) Component Location364
Machine Harness (W2) Wiring Diagram369
Monitor Harness (W3) Component Location384
Monitor Harness (W3) Wiring Diagram386
Engine Harness (W4) Component Location388
Engine Harness (W4) Wiring Diagram399
Engine Interface Harness (W5) Component Location414
Engine Interface Harness (W5) Wiring Diagram421
Pump Harness (W8) Component Location432
Pump Harness (W8) Wiring Diagram434
Exhaust Filter Parked Cleaning Switch Harness (W9) Component Loc435
Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagra435
Service ADVISOR™ Remote (SAR) Harness (W10) Component Location435
Service ADVISOR™ Remote (SAR) Harness (W10) Wiring Diagram436
Pilot Shutoff Switch Harness (W11) Component Location437
Pilot Shutoff Switch Harness (W11) Wiring Diagram439
Auxiliary Fuse Box Harness (W13) Component Location441
Auxiliary Fuse Box Harness (W13) Wiring Diagram443
Heated Air Seat Harness (W14) Component Location446
Heated Air Seat Harness (W14) Wiring Diagram447
Multi-Function Pilot Control Lever Harness (W15) Component Locat448
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram451
Travel Alarm Cancel Switch Harness (W16) Component Location453
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram453
Attachment Harness (W17) Component Location454
Attachment Harness (W17) Wiring Diagram457
Alternator Harness (W18) Component Location459
Alternator Harness (W18) Wiring Diagram460
Rear Camera Harness (W19) Component Location461
Rear Camera Harness (W19) Wiring Diagram462
Pilot Shutoff Valve Harness (W21) Component Location463
Pilot Shutoff Valve Harness (W21) Wiring Diagram464
Auxiliary 3-Button Cancel Switch Harness (W22) Component Locatio464
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram465
Reversing Fan Switch Harness (W23) Component Location465
Reversing Fan Switch Harness (W23) Wiring Diagram466
Seat Heater Switch Harness (W24) Component Location466
Seat Heater Switch Harness (W24) Wiring Diagram467
Travel Alarm Harness (W26) Component Location468
Travel Alarm Harness (W26) Wiring Diagram469
Starter Harness (W27) Component Location470
Starter Harness (W27) Wiring Diagram472
Starter Switch Harness (W29) Component Location473
Starter Switch Harness (W29) Wiring Diagram473
Air Throttle Valve Harness (W30) Component Location473
Air Throttle Valve Harness (W30) Wiring Diagram474
2-Speed Harness (W32) Component Location474
2-Speed Harness (W32) Wiring Diagram476
Heater and Air Conditioner Harness (W41) Component Location478
Heater and Air Conditioner Harness (W41) Wiring Diagram479
Alternator Jumper Harness (W42) Component Location481
Alternator Jumper Harness (W42) Wiring Diagram482
Satellite (SAT) Harness (W6003) Component Location483
Satellite (SAT) Harness (W6003) Wiring Diagram483
Sub-System Diagnostics485
Controller Area Network (CAN) Theory of Operation485
Starting and Charging Circuit Theory of Operation489
Monitor Controller (DSZ) Circuit Theory of Operation493
Engine Control Unit (ECU) Circuit Theory of Operation501
Exhaust Aftertreatment Circuit Theory of Operation527
Main Controller (MCZ) Circuit Theory of Operation531
Machine Controller (BCZ) Circuit Theory of Operation540
Windshield Wiper and Washer Circuit Theory of Operation541
Lighting Circuit Theory of Operation545
Travel Alarm Circuit Theory of Operation548
Pilot Shutoff Circuit Theory of Operation551
Attachment Control Circuit Theory of Operation554
Monitor Operation563
Service Menu563
Troubleshooting563
Monitoring564
Controller Version567
Issued Warning Record567
Operation567
Machine Setting568
Monitor Setting572
Exhaust Filter573
References575
Reading Diagnostic Trouble Codes with Monitor Display575
Service ADVISOR™ Diagnostic Application575
Service ADVISOR™ Connection Procedure576
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnosti577
MPDr Application579
MPDr Connection Procedure579
Fuse Test580
Relay Test583
Pressure Sensor Test584
Solenoid Test585
Proportional Solenoid Test585
Temperature Sensor Test585
Alternator Test586
Electrical Component Checks588
Component Checks588
Battery Remove and Install593
Rear Cover Remove and Install595
Main Controller (MCZ) Remove and Install596
Machine Controller (BCZ) Remove and Install597
Engine Control Unit (ECU) Remove and Install598
Data Converter Remove and Install599
Monitor Controller (DSZ) Remove and Install599
Air Conditioner Controller (ACF) Remove and Install600
Key Switch Remove and Install600
Right Switch Console Remove and Install601
Left Switch Console Remove and Install603
Travel Alarm Remove and Install604
Disconnect Tab Retainer Connectors604
Disconnecting Spring Wire Clip Connectors604
Replace DEUTSCHDEUTSCH is a trademark of the Deutsch Co™ Connec605
Replace DEUTSCHDEUTSCH is a trademark of Deutsch Co™ Rectangula606
Install DEUTSCHDEUTSCH is a trademark of the Deutsch Co™ Contac607
Replace WEATHER PACKWEATHER PACK is a trademark of Packard Elect608
Install WEATHER PACKWEATHER PACK is a trademark of Packard Elect609
Replace (Pull Type) Metri-Pack™ Connectors610
Replace (Push Type) Metri-Pack™ Connectors611
Replace CINCHCINCH is a trademark of the Cinch Co™ Connectors611
Install CINCHCINCH is a trademark of the Cinch Co™ Contact613
Repair 32 and 48 Way CINCHCINCH is a trademark of the Cinch Co™614
Remove Connector Body from Blade Terminals616
Power Train617
Theory of Operation619
Track Adjuster and Recoil Spring Operation619
Travel Gearbox Operation620
Diagnostic Information623
Noisy or Loose Track Chain623
Noisy or Loose Track Chain Diagnostic Procedure623
Tight Track Chain623
Tight Track Chain Diagnostic Procedure623
Frequent Track Chain Sag Adjustment Required624
Frequent Track Chain Sag Adjustment Required Diagnostic Procedur624
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrie624
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrie624
Bent Track Shoes624
Bent Track Shoes Diagnostic Procedure624
“Popping” of Track625
“Popping” of Track Diagnostic Procedure625
Cracked Track Link625
Cracked Track Link Diagnostic Procedure625
Chipped Link Rails626
Chipped Link Rails Diagnostic Procedure626
Individual Undercarriage Component Wear627
Individual Undercarriage Component Wear Diagnostic Procedure627
Measure Swing Bearing Wear628
Hydraulic System631
Theory of Operation633
Hydraulic System Operation633
Fan Drive Hydraulic System Operation634
Pilot System Operation636
Pilot Pump, Pressure Regulating Valve and Filter Operation637
Pilot Shutoff Solenoid Valve Operation638
Pilot Control Valve Operation641
Travel Pilot Control Valve Operation644
Pilot Operation of Control Valve Operation647
Pilot Signal Manifold Operation650
Pump 1, Pump 2 and Drive Gearbox Operation660
Pump 1 and Pump 2 Regulator Operation663
Engine Speed Sensing Control Circuit Operation668
Control Valve Operation670
Control Valve Check Valves Identification and Operation684
Main Relief Valve Circuit Operation687
Circuit Relief and Anticavitation Valve Operation691
Travel Flow Combiner Valve Operation692
Boom Lower Meter-In Cut Valve Operation694
Boom Regenerative Valve Circuit Operation696
Dig Regenerative Valve Circuit Operation698
Arm Regenerative Valve Circuit Operation702
Bucket Regenerative Valve Circuit Operation707
Boom and Arm Reduced Leakage Valves Operation710
Arm 1 Flow Rate Control Valve Circuit Operation713
Arm 2 Flow Rate Control Valve Circuit Operation717
Bucket Flow Rate Control Valve Circuit Operation721
Boom Flow Rate Control Valve Circuit Operation725
Swing Reduction Gearbox Operation728
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Ope729
Swing Motor Dampener Valve732
Swing Motor Park Brake Release Circuit Operation740
Center Joint Operation741
Travel Motor and Park Brake Valve Operation742
Travel Motor Speed Circuit Operation751
Cylinder Operation754
Return Filter Operation755
Diagnostic Information757
All Hydraulic Functions Slow757
All Hydraulic Functions Slow Diagnostic Procedure757
Hydraulic Oil Overheats759
Hydraulic Oil Overheats Diagnostic Procedure759
No Hydraulic Functions761
No Hydraulic Functions Diagnostic Procedure761
Poor Combined Operation762
Poor Combined Operation Diagnostic Procedure762
All Functions Cannot Be Operated763
All Functions Cannot Be Operated Diagnostic Procedure763
Function Does Not Stop When Control Lever Released763
Function Does Not Stop When Control Lever Released Diagnostic Pr763
Some Functions Cannot Be Operated, All Others Are Normal764
Some Functions Cannot Be Operated, All Others Are Normal Diagnos764
All Functions Slow765
All Functions Slow Diagnostic Procedure765
Functions Move in Opposite Direction766
Functions Move in Opposite Direction766
All Dig Functions Slow or No Power766
All Dig Functions Slow or No Power766
Some Dig Functions Slow (Not All)767
Some Dig Functions Slow (Not All)767
Load Drifts Down When Control Lever is in Neutral Position768
Load Drifts Down When Control Lever is in Neutral Position Diagn768
Load Falls When Control Valve is Actuated To Raise Load With Eng769
Load Falls When Control Valve is Actuated To Raise Load With Eng769
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is 770
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is 770
Swing Speed Slow in Both Directions771
Swing Speed Slow in Both Directions Diagnostic Procedure771
Swing Speed Slow or Does Not Operate in One Direction773
Swing Speed Slow or Does Not Operate in One Direction Diagnostic773
Upperstructure Drift with Swing Valve in Neutral774
Upperstructure Drift with Swing Valve in Neutral Diagnostic Proc774
Swing Function Does Not Operate774
Swing Function Does Not Operate Diagnostic Procedure774
Travel Park Brakes Do Not Apply775
Travel Park Brakes Do Not Apply Diagnostic Procedure775
Track Will Not Move in One Direction775
Track Will Not Move in One Direction Diagnostic Procedure776
Track Will Not Move in Either Direction777
Track Will Not Move in Either Direction Diagnostic Procedure777
Machine Mistracks at All Speeds in Both Directions778
Machine Mistracks at All Speeds in Both Directions Diagnostic Pr778
Slow Travel Speed or Low Power779
Slow Travel Speed or Low Power Diagnostic Procedure779
Combined Travel and Dig Functions Slow or No Power781
Combined Travel and Dig Functions Slow or No Power Diagnostic Pr781
Travel is “Jerky”781
Travel is “Jerky” Diagnostic Procedure781
Machine Will Not Hold Back and Park Brakes Engage and Disengage 782
Machine Will Not Hold Back and Park Brakes Engage and Disengage 782
Machine Will Not Turn Smoothly in One Direction or Park Brake Gr782
Machine Will Not Turn Smoothly in One Direction or Park Brake Gr782
Pump 1, Pump 2, and Pilot Pump Line Identification783
Control Valve Line Identification784
Swing Motor Line Identification787
Pilot Control Valve-to-Pilot Signal Manifold Component Location—789
Pilot Control Valve-to-Pilot Signal Manifold Component Location—793
Pilot Signal Manifold-to-Control Valve Line Connection796
Travel System Component Location800
Travel Hydraulic System Line Connection801
Hydraulic System Schematic805
Hydraulic System Component Location821
Hydraulic System Line Connections823
Fan Drive Hydraulic System Component Location827
Fan Drive Hydraulic System Schematic830
Tests833
JT05800 Digital Thermometer Installation833
JT02156A Digital Pressure and Temperature Analyzer Kit Installat833
Hydraulic Oil Cleanup Procedure834
Hydraulic Oil Tank Pressure Release Procedure835
Hydraulic Oil Warm-Up Procedure836
Pilot Pressure Regulating Valve Test and Adjustment838
Control Valve Spool Actuating Pilot Pressure Test840
Dig Regenerative Solenoid Valve Test and Adjustment842
Arm Regenerative Solenoid Valve Test and Adjustment844
Power Dig Solenoid Valve Test and Adjustment846
Travel Speed Solenoid Valve Test and Adjustment848
Torque Control Solenoid Valve Test and Adjustment850
Pump Control Pilot Pressure Signal Test852
Main Relief and Power Dig Valve Test and Adjustment854
Circuit Relief Valve Test and Adjustment857
Swing Motor Crossover Relief Valve Test and Adjustment860
Travel Motor Crossover Relief Valve Test and Adjustment862
Pump Regulator Test and Adjustment—Minimum Flow865
Pump Regulator Test and Adjustment—Maximum Flow867
Pump Flow Test869
Swing Motor Leakage Test875
Travel Motor Leakage Test876
Cylinder Drift Test—Boom, Arm, and Bucket878
Fan Drive Pump Flow Test879
Fan Speed Test881
Heating and Air Conditioning883
Theory of Operation885
Air Conditioning System Cycle of Operation885
Diagnostic Information887
No Air Flow From Heater and Air Conditioner Vents887
No Air Flow From Heater and Air Conditioner Vents Diagnostic Pro887
Air Conditioning System Does Not Operate889
Air Conditioning System Does Not Operate Diagnostic Procedure889
Air Conditioning Does Not Cool Interior of Cab890
Air Conditioning Does Not Cool Interior of Cab Diagnostic Proced890
Air Conditioning Runs Constantly, Too Cold892
Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure892
Interior Windows Continue to Fog Using Air Conditioner893
Interior Windows Continue to Fog Using Air Conditioner Diagnosti893
Heater System Does Not Operate894
Heater System Does Not Operate Diagnostic Procedure894
Heater Does Not Warm Interior of Cab895
Heater Does Not Warm Interior of Cab Diagnostic Procedure895
Interior Windows Continue to Fog Using Heater896
Interior Windows Continue to Fog using Heater Diagnostic Procedu896
Heater and Air Conditioner Component Location899
Tests903
Refrigerant Cautions and Proper Handling903
Heater and Air Conditioner Operational Checks903
Visual Inspection of Components903
Air Conditioner Compressor Clutch Test905
Refrigerant Leak Test905
Refrigerant Hoses and Tubing Inspection905
Air Conditioner Compressor Belt Check and Adjustment905
R134a Air Conditioning System Test906
Operating Pressure Diagnostic Chart907
Dealer Fabricated Tools909
Dealer Fabricated Tools911
DFT1218 Split Flange Hose Cap911
Page Number 5
Section 9000 7
Group 01 9
Section 9001 27
Group 10 29
Group 20141
Group 21145
Group 30163
Group 40171
Section 9005179
Group 10181
Section 9010229
Group 05231
Group 15245
Group 20247
Group 25249
Section 9015257
Group 05259
Group 10267
Group 15485
Group 16563
Group 20575
Section 9020617
Group 05619
Group 15623
Section 9025631
Group 05633
Group 15757
Group 25833
Section 9031883
Group 05885
Group 15887
Group 25903
Section 9900909
Group 99911

S.M 6/1/25