John Deere 450DLC Excavator Operation and Tests TECHNICAL MANUAL TM2361 – PDF DOWNLOAD

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John Deere 450DLC Excavator Operation and Tests TECHNICAL MANUAL TM2361 – PDF DOWNLOAD

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John Deere 450DLC Excavator Operation and Tests TECHNICAL MANUAL TM2361 – PDF DOWNLOAD

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John Deere 450DLC Excavator Operation and Tests TECHNICAL MANUAL TM2361 – 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 450DLC Excavator Operation and Tests TECHNICAL MANUAL TM2361 – 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 11
Inspect Machine 11
Stay Clear of Moving Parts 11
Avoid High-Pressure Oils 12
Beware of Exhaust Fumes 12
Prevent Fires 13
Prevent Battery Explosions 13
Handle Chemical Products Safely 14
Dispose of Waste Properly 14
Prepare for Emergencies 14
Use Steps and Handholds Correctly 15
Start Only From Operator’s Seat 15
Use and Maintain Seat Belt 15
Prevent Unintended Machine Movement 16
Avoid Work Site Hazards 17
Keep Riders Off Machine 17
Avoid Backover Accidents 18
Avoid Machine Tip Over 18
Use Special Care When Lifting Objects 19
Add and Operate Attachments Safely 19
Prevent Unintended Detonation of Explosive Devices 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 22
Diagnostics 23
Main Controller (MCF) Diagnostic Trouble Codes 29
Main Controller (MCF) Diagnostic Trouble Codes 29
1100002 — Abnormal EEPROM 29
Controller Hardware Diagnostics 29
29
30
1100102 — Abnormal RAM 30
Controller Hardware Diagnostics 30
Engine Control Module (ECM) Diagnostic Trouble Codes173
Engine Control Module (ECM) Diagnostic Trouble Codes173
9102 — Accelerator Sensor 1-2 Comparison (P1271)173
10003 — Engine Oil Pressure Sensor Voltage Low (P0522)174
10004 — Engine Oil Pressure Sensor Voltage High (P0523)174
10203 — Boost Pressure Sensor Voltage Low (P0237)174
10204 — Boost Pressure Sensor Voltage High (P0238)174
10503 — Boost Temperature Sensor Voltage High (P1113)175
10504 — Boost Temperature Sensor Voltage Low (P1112)175
10803 — Barometric Pressure Sensor Voltage Low (P0107)175
10804 — Barometric Pressure Sensor Voltage High (P0108)175
11003 — Engine Coolant Temperature Sensor Voltage High (P0118)176
11004 — Engine Coolant Temperature Sensor Voltage Low (P0117)176
15700 — Common Rail Pressure—First Stage (P088)176
15700 — Common Rail Pressure—Second Stage (P088)176
15702 — Common Rail Pressure High (P0089)177
15703 — Common Rail Pressure Sensor Voltage High (P0193) 177
15703 — Common Rail Pressure Sensor Voltage Low (P0192)177
17203 — Intake Air Temperature Sensor Voltage High (P0113)178
17204 — Intake Air Temperature Sensor Voltage Low (P0112)178
17403 — Fuel Temperature Sensor Voltage High (P0183)178
17404 — Fuel Temperature Sensor Voltage Low (P0182)178
19000 — Engine Overspeed (P0219)179
62802 — ROM Malfunction (P0601)179
63307 — Pressure Limiter Open (P0601)179
63602 — Camshaft Position Sensor (G-Sensor) Signal Missing (P0340)179
63602 — Camshaft Position Sensor (G-Sensor) Signal Mismatch (P0341)180
63607 — Camshaft Position Sensor (G-Sensor) out of Phase (P1345)180
63902 — CAN Communication Error (U2104)180
63903 — CAN Timeout (U2106)180
65103 — Open Circuit in Injection Nozzle #1 (P0201)181
65203 — Open Circuit in Injection Nozzle #2 (P0202)181
65303 — Open Circuit in Injection Nozzle #3 (P0203)181
65403 — Open Circuit in Injection Nozzle #4 (P0204) 181
65503 — Open Circuit in Injection Nozzle #5 (P0205)182
65603 — Open Circuit in Injection Nozzle #6 (P0206)182
72302 — Crankshaft Position Sensor Signal Missing (P0335)182
72302 — Crankshaft Sensor Mismatch (P0336)182
98703 — Check Engine Lamp Malfunction (P0650)183
107702 — CPU Fault Malfunction (P0606)183
107902 — 5 Volt Power Supply #1 Malfunction (P1631)183
108002 — 5 Volt Power Supply #2 Malfunction (P1632)183
123901 — No Pump Pressure—First Stage (P1094)184
124001 — No Pump Pressure Feed—Second Stage (P1093)184
134700 — PCV #1 Open Circuit or Short to Ground (P0092)184
134704 — PCV #1 Short to Power (P0091)184
134800 — PCV # 2 Open Circuit or Short to Ground (P1291)185
134804 — PCV #2 Short to Power (P1292)185
148502 — Engine Control Module Relay Malfunction (P1625)185
1000103 — EGR Position Sensor Malfunction (P0487)186
1000202 — EGR Valve Control Malfunction (P0488)186
1000302 — Injection Nozzle Common #1 Malfunction (P1261)186
1000402 — Injection Nozzle Common #2 Malfunction (P1262)186
1000501 — Charge Circuit Malfunction—Bank 1 (P0611)187
1000601 — Charge Circuit Malfunction—Bank 2 (P0612)187
1000702 — CPU Monitoring IC Malfunction (P0606)187
1000802 — A/D Conversion Malfunction (P1630)187
1000902 — 5 Volt Power Supply #3 Malfunction (P1633)188
1001002 — 5 Volt Power Supply #4 Malfunction (P1634)188
1001102 — 5 Volt Power Supply #5 Malfunction (P1635)188
1001302 — EEPROM Malfunction (P0603)188
Information Controller (ICF) Diagnostic Trouble Codes189
Information Controller (ICF) Diagnostic Trouble Codes189
1400002 — Abnormal CAN Communication189
1400102 — ICF: Flash Memory: Read/Write Error189
1400202 — ICF: External RAM: Read/Write Error190
1400302 — ICF: EEPROM: Sum Check Error190
1400602 — ICF: Satellite Communication Terminal: Communication Error190
1400802 — ICF: Abnormal Internal RAM190
1410002 — Satellite Communication Terminal: Abnormal EEPROM191
1410102 — Satellite Communication Terminal: Abnormal IB/OB Queue191
1410202 — Satellite Communication Terminal: Abnormal Local Loop Back191
1410302 — Satellite Communication Terminal: The satellite is not found191
1410402 — Satellite Communication Terminal: Fail 1 of Remote Loop Back192
1410502 — Satellite Communication Terminal: Fail 2 of Remote Loop Back192
1410602 — Satellite Communication Terminal: Sending and receiving data are mismatched192
Air Conditioner Controller (ACF) Diagnostic Trouble Codes193
Air Conditioner Controller (ACF) Diagnostic Trouble Codes193
E11 — Cab Air Temperature Sensor Open Circuit193
Harness Diagnostics193ngine251
Theory of Operation253
Engine Component Location253
Engine Fuel System Operation256
Engine Cooling System Operation260
Engine Lubrication System Operation261
Engine Intake and Exhaust System Operation264
Engine Turbocharger Operation265
Exhaust Gas Recirculation (EGR) Operation268
Quick On Start (QOS) System Operation270
Engine Speed Control System Operation271
Diagnostic Information275
Isuzu AH-6WG1XYSA-01275
Diagnose Engine Malfunctions275
Engine Cranks But Will Not Start276
Engine Cranks But Will Not Start Diagnostic Procedure276
Engine Does Not Develop Full Power283
Engine Does Not Develop Full Power Diagnostic Procedure283
Engine Overheats286
Engine Overheats Diagnostics Procedure286
Auto-Idle Does Not Work287
Auto-Idle Does Not Work Diagnostics Procedure287
Coolant Temperature Too Low289
Coolant Temperature Too Low Diagnostics Procedure289
Coolant in Oil or Oil in Coolant289
Coolant in Oil or Oil in Coolant Diagnostics Procedure289
Low Engine Oil Pressure290
Low Engine Oil Pressure Diagnostics Procedure290
High Engine Oil Pressure291
High Engine Oil Pressure Diagnostics Procedure291
Engine Uses Too Much Oil291
Engine Uses Too Much Oil Diagnostics291
Engine Uses Too Much Fuel292
Engine Uses Too Much Fuel Diagnostic Procedure292
Engine Emits Excessive White Exhaust Smoke294
Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure294
Engine Emits Excessive Black or Gray Exhaust Smoke296
Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure296
Turbocharger Excessively Noisy or Vibrates298
Turbocharger Excessively Noisy or Vibrates Diagnostics Procedure298
Oil Dripping From Turbocharger Adapter299
Oil Dripping From Turbocharger Adapter Diagnostics Procedure299
Excessive Drag in Turbocharger Rotating Members299
Excessive Drag in Turbocharger Rotating Members Diagnostics Procedure300
Serpentine Belt Tension Check301
Check and Adjust Injection Pump Timing302
Engine Valve Lash (Clearance) Check and Adjust304
Engine Compression Pressure Test307
Air Filter Restriction Indicator Switch308
Air Intake System Leakage Test309
Engine Power Test Using Turbocharger Boost Pressure311
Engine Oil Pressure Test315
Rail Pressure Control Test316
Injector Balance Test (Injector Misfire Test)319
Injector Force Drive Test322
EGR Regulating Valve Test324
Injector ID Code Registration327
Injector ID Code Upload336
Injector ID Code Download340
Electrical System345
System Information349
Electrical Diagram Information349
System Diagrams359
Explanation of Wire Markings359
Fuse and Relay Specifications360
System Functional Schematic, Wiring Diagram, and Component Location Master Legend364
System Functional Schematic370
JDLink™ System Functional Schematic—If Equipped378
Cab Harness (W1) Component Location380
Cab Harness (W1) Wiring Diagram382
Machine Harness (W2) Component Location388
Machine Harness (W2) Wiring Diagram390
Monitor Harness (W3) Component Location396
Monitor Harness (W3) Wiring Diagram398
Engine Harness (W4) Component Location400
Engine Harness (W4) Wiring Diagram402
Engine Interface Harness (W5) Component Location404
Engine Interface Harness (W5) Wiring Diagram406
Air Conditioner Harness (W6) Component Location408
Air Conditioner Harness (W6) Wiring Diagram410
Control Valve Harness (W7) Component Location412
Control Valve Harness (W7) Wiring Diagram414
Pump Harness (W8) Component Location416
Pump Harness (W8) Wiring Diagram418
Auxiliary Fuse Box Harness (W9) Component Location420
Auxiliary Fuse Box Harness (W9) Wiring Diagram422
Cab Switch Harness (W10) Component Location423
Cab Switch Harness (W10) Wiring Diagram424
Pilot Shutoff Switch Harness (W11) Component Location425
Pilot Shutoff Switch Harness (W11) Wiring Diagram426
Heated Air Seat Harness (W12) Component Location428
Heated Air Seat Harness (W12) Wiring Diagram429
Seat Heater Switch Harness (W13) Component Location430
Seat Heater Switch Harness (W13) Wiring Diagram432
Multi-Function Pilot Control Lever Harness (W14) Component Location434
Multi-Function Pilot Control Lever Harness (W14) Wiring Diagram436
Travel Alarm Cancel Switch Harness (W15) Component Location437
Travel Alarm Cancel Switch Harness (W15) Wiring Diagram437
Reversing Fan Switch Harness (W16) Component Location438
Reversing Fan Switch Harness (W16) Wiring Diagram438
Pilot Shutoff Valve Harness (W17) Component Location439
Pilot Shutoff Valve Harness (W17) Wiring Diagram439
JDLink™ System Harnesses (W50, W51, W52, W53, and W54) Component Location—If Equipped440
Machine Information Gateway (MIG) Harness (W50) Wiring Diagram—If Equipped442
GlobalTRACS® Terminal (GTT) Harness (W51) Wiring Diagram—If Equipped444
JDLink™ CAN Harness (W52) Wiring Diagram—If Equipped446
JDLink™ Power Harness (W53) Wiring Diagram—If Equipped448
JDLink™ Jumper Harness (W54) Wiring Diagram—If Equipped450
Sub-System Diagnostics451
Controller Area Network (CAN) Theory of Operation451
Starting and Charging Circuit Theory of Operation453
Quick On System (QOS) Preheat Circuit Theory of Operation456
Monitor Circuit Theory of Operation458
Engine Control Module (ECM) Circuit Theory of Operation464
Main Controller (MCF) Circuit Theory of Operation468
Information Controller (ICF) Theory of Operation483
Travel Alarm Circuit Theory of Operation485
Windshield Wiper and Washer Circuit Theory of Operation487
Pilot Shutoff Circuit Theory of Operation490
Monitor Operation493
Monitor Menu Operation493
Monitor Service Menu Operation493
References497
Monitor Data Items497
Monitor Data Items Using the Monitor Display499
Reading Diagnostic Trouble Codes With Monitor Display501
JDLink™ Connection Procedure504
Service ADVISOR™ Diagnostic Application506
Service ADVISOR™ Connection Procedure507
Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application508
Tech 2 Diagnostic Scan Tool Connection Procedure511
Reading Diagnostic Trouble Codes With Tech 2 Diagnostic Scan Tool518
Tech 2 Data Display520
Dr ZX Diagnostic Application523
Personal Digital Assistant (PDA) Connection To Excavator Using Dr ZX Application523
Reading Diagnostic Trouble Codes With Dr ZX526
Main Controller (MCF) Diagnostics Using Dr ZX529
Engine Controller (ECM) Diagnostics Using Dr ZX546
Monitor Controller Diagnostics Using Dr ZX551
Dr ZX Password Change556
Pump Learning Procedure559
Machine Information Center (MIC) Application562
Information Controller (ICF) Initialization563
Information Controller (ICF) Model and Serial Number567
Information Controller (ICF) Date and Time571
Information Controller (ICF) Control Data: Initialize574
Information Controller (ICF) Satellite Terminal578
Information Controller (ICF) Data Download578
Information Controller (ICF) Recorded Data583
Fuse Test586
Relay Test590
Pressure Sensor Test591
Solenoid Test593
Proportional Solenoid Test594
Alternator Test595
Electrical Component Checks596
Component Checks596
Battery Remove and Install602
Rear Cover Remove and Install604
Main Controller (MCF) Remove and Install605
Engine Control Module (ECM) Remove and Install606
Information Controller (ICF) Remove and Install607
Monitor Controller Remove and Install607
Key Switch Remove and Install610
Switch Panel Remove and Install611
Travel Alarm Remove and Install612
Left Console Switch Remove and Install613
Disconnect Tab Retainer Connectors613
Disconnecting Spring Wire Clip Connectors614
Replace DEUTSCH™ Connectors614
Replace DEUTSCH™ Rectangular or Triangular Connectors615
Install DEUTSCH™ Contact616
Replace WEATHER PACK™Connector617
Install WEATHER PACK™Contact618
Replace (Pull Type) Metri-Pack™ Connectors620
Replace (Push Type) Metri-Pack™ Connectors621
Replace CINCH™ Connectors622
Install CINCH™ Contact624
Repair 32 and 48 Way CINCH™ Connectors625
Remove Connector Body from Blade Terminals628
Power Train629
Theory of Operation631
Track Adjuster and Recoil Spring Operation631
Travel Gearbox Operation632
Diagnostic Information635
Diagnose Undercarriage Components Malfunctions635
Noisy or Loose Track Chain Diagnostic Procedure635
Measure Swing Bearing Wear640
Hydraulic System643
Theory of Operation648
Hydraulic System Diagram and Operation648
Fan Drive System Diagram and Operation649
Pilot System Diagram and Operation650
Pilot Pump, Pressure Regulating Valve, and Filter Operation652
Pilot Check Valve Manifold and Accumulator Operation653
Boom Lowering With Engine Stopped Circuit Operation653
Pilot Shutoff Solenoid Valve Operation653
Pilot Control Valve Operation656
Travel Pilot Control Valve Operation658
Boom Up Shockless Valve Operation660
Pilot Signal Manifold Operation661
Pilot Operation of Control Valve Operation672
Pump 1 and 2, Fan Drive Pump, and Gearbox Operation676
Pump 1 and 2 Regulator Operation680
Fan Drive Pump Regulator Operation684
Control Valve Operation694
Control Valve Check Valves Identification and Operation708
Main Relief and Power Digging Valve Circuit Operation712
Circuit Relief and Anticavitation Valve Operation718
Arm Make-Up Check Valve Operation719
Travel Flow Combiner Valve Circuit Operation720
Boom Regenerative Valve Circuit Operation723
Arm Regenerative Valve Circuit Operation725
Bucket Regenerative Valve Circuit Operation727
Boom and Arm Reduced Leakage Valves Operation729
Boom Flow Rate Circuit Operation733
Arm 2 Flow Rate Circuit Operation740
Boom Mode Circuit Operation743
Counterweight Removal Circuit Operation743
Swing Gearbox Operation744
Swing Motor and Park Brake Circuit Operation745
Swing Motor Park Brake Release Circuit Operation749
Center Joint Operation750
Travel Motor and Park Brake Circuit Operation751
Travel Motor Speed Circuit Operation753
Boom, Arm, and Bucket Cylinder Operation755
Counterweight Removal Cylinder Operation756
Return Filter Operation757
Diagnostic Information759
Diagnose No Hydraulics Malfunctions759
No Hydraulic Functions Diagnostic Procedure759
Pump 1, Pump 2 and Pilot Pump Line Identification823
Control Valve Line Identification824
Swing Motor Line Identification828
Control Lever Pattern Conversion829
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern834
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern836
Pilot Signal Manifold-to-Control Valve Line Connections838
Travel Hydraulic System Component Location840
Travel Hydraulic System Line Connection842
Fan Drive Hydraulic System Component Location844
Fan Drive Hydraulic System Line Connections846
Hydraulic System Component Location848
Hydraulic System Line Connections850
Counterweight Removal Hydraulic System Component Location851
Counterweight Removal Hydraulic System Line Connections851
Hydraulic System Schematic852
Tests869
Hydraulic Test Port Location869
JT05800 Digital Thermometer Installation869
JT02156A Digital Pressure/Temperature Analyzer870
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy871
Hydraulic Oil Warm-Up Procedure872
Pilot Pressure Regulating Valve Test and Adjustment875
Control Valve Spool Actuating Pilot Pressure Test879
Power Dig Solenoid Valve (port SG) Test and Adjustment882
Travel Speed Solenoid Valve (port SI) Test and Adjustment887
Boom Mode Solenoid Valve (port SC) Test and Adjustment892
Solenoid Valve896
Boom Flow Rate (port SF) Test and Adjustment896
Main Relief and Power Digging Valve Test and Adjustment900
Circuit Relief Valve905
Test and Adjustment905
Boom Mode Relief Valve910
Test and Adjustment910
Pump Servo Piston914
Minimum Flow Test and Adjustment914
Maximum Flow Test and Adjustment916
Pump919
Flow Rate (Displacement) Test and Adjustment919
Swing Motor Crossover Relief Valve Test and Adjustment920
Travel Motor Crossover Relief Valve Test and Adjustment924
Swing Motor Leakage Test928
Travel Motor Leakage Test932
Cylinder Drift Test—Arm, Boom, and Bucket935
Pump Flow Test937
Fan Drive942
System Relief Valve Test and Adjustment942
Fan Drive Pump Servo Piston945
Minimum Flow Test and Adjustment945
Minimum Flow Test and Adjustment946
Pump947
Flow Rate (Displacement) Test and Adjustment947
Fan Drive Pump948
Torque Control Test and Adjustment948
Fan Drive Pump Flow Test950
Heating and Air Conditioning System957
Theory Of Operation959
Air Conditioning System Cycle of Operation959
Diagnostic Information961
Diagnose Air Conditioning System Malfunctions961
Diagnose Heating System Malfunctions965
Air Conditioner and Heater Diagnostic Trouble Code Check967
Heater and Air Conditioner Component Location968
Tests971
Refrigerant Cautions and Proper Handling971
Heating and Air Conditioning Operational Checks972
Visual Inspection of Components972
R134a Air Conditioning System Test974
Air Conditioner Compressor Clutch Test975
Refrigerant Leak Test975
Refrigerant Hoses and Tubing Inspection976
Air Conditioner Compressor Belt Check and Adjustment976
Operating Pressure Diagnostic Chart977
Reference Material979
Terminology Cross Reference Chart981
Terminology Cross Reference Chart981
Page Numbers 5
Section 9000 7
Group 01 9

S.M 6/1/25