John Deere 470GLC Excavator Operation and Test TECHNICAL MANUAL TM12174 PDF

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John Deere 470GLC Excavator Operation and Test TECHNICAL MANUAL TM12174 –  PDF DOWNLOAD

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John Deere 470GLC Excavator Operation and Test TECHNICAL MANUAL TM12174 –  PDF DOWNLOAD

Language : English
Pages :870
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

John Deere 470GLC Excavator Operation and Test TECHNICAL MANUAL TM12174 –  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 470GLC Excavator Operation and Test TECHNICAL MANUAL TM12174 –  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 Fluids 12
Avoid High-Pressure Oils 12
Work In Ventilated Area 13
Prevent Fires 13
Prevent Battery Explosions 14
Handle Chemical Products Safely 14
Dispose of Waste Properly 14
Exhaust Filter Ash Handling and Disposal 15
Prepare for Emergencies 15
Clean Debris from Machine 15
Use Steps and Handholds Correctly 15
Start Only From Operator’s Seat 16
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
Avoid Machine Tip Over 19
Use Special Care When Lifting Objects 19
Add and Operate Attachments Safely 20
Park and Prepare for Service Safely 20
Service Cooling System Safely 21
Remove Paint Before Welding or Heating 21
Make Welding Repairs Safely 21
Drive Metal Pins Safely 22
Clean Exhaust Filter Safely 23
Diagnostics 31
Main Controller (MCZ) Diagnostic Trouble Codes 33
Main Controller (MCZ) Diagnostic Trouble Codes 33
Controller Area Network 0 (CAN 0) Circuit Diagnostics 33
Controller Area Network (CAN 0) Diagnostics 33
Controller Area Network 1 (CAN 1) Circuit Diagnostics 43
Controller Area Network (CAN 1) Diagnostics 44
Interface Controller Area Network (N-CAN) Diagnostics 55
Interface Controller Area Network (N-CAN) Diagnostics 55
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 71
Controller Hardware Diagnostics 71
110022 — Abnormal A/D Converter 72
Controller Hardware Diagnostics 72
110033 — Abnormal Sensor Voltage 72
Harness Diagnostics 72
110042 — CAN Communication Error 1 73
110052 — CAN Communication Error 2 73
110062 — Engine Controller Communication Error 73
110072 — (CAN 0) Data Converter Communication Error 1 74
110082 — (CAN 1) Data Converter Communication Error 2 74
110092 — (CAN 0) Monitor Controller Communication Error 1 74
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 75
Engine Control Dial Sensor Circuit High Diagnostics 75
111014 — Engine Control Dial Sensor Circuit Low 77
Engine Control Dial Sensor Circuit High Diagnostics 77
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 80
112023 — Pump 2 Delivery Pressure Sensor Circuit High 81
Pump 2 Delivery Pressure Sensor Circuit High Diagnostics 81
112024 — Pump 2 Delivery Pressure Sensor Circuit Low 82
Pump 2 Delivery Pressure Sensor Circuit Low Diagnostics 82
112063 — Pump 1 Control Pressure Sensor Circuit High 84
Pump 1 Control Pressure Sensor Circuit High Diagnostics 84
112064 — Pump 1 Control Pressure Sensor Circuit Low 85
Pump 1 Control Pressure Sensor Circuit Low Diagnostics 85
112083 — Pump 2 Control Pressure Sensor Circuit High 87
Pump 2 Control Pressure Sensor Circuit High Diagnostics 87
112084 — Pump 2 Control Pressure Sensor Circuit Low 88
Pump 2 Control Pressure Sensor Circuit Low Diagnostics 88
113013 — Swing Pressure Sensor Circuit High 90
Swing Pressure Sensor Circuit High Diagnostics 90
113014 — Swing Pressure Sensor Circuit Low 92
Swing Pressure Sensor Circuit Low Diagnostics 92
113023 — Boom Up Pressure Sensor Circuit High 93
Boom Up Pressure Sensor Circuit High Diagnostics 93
113024 — Boom Up Pressure Sensor Circuit Low 95
Boom Up Pressure Sensor Circuit Low Diagnostics 95
113033 — Arm In Pressure Sensor Circuit High 97
Arm In Pilot Pressure Sensor Circuit High Diagnostics 97
113034 — Arm In Pressure Sensor Circuit Low 99
Arm In Pilot Pressure Sensor Circuit Low Diagnostics 99
113043 — Travel Pressure Sensor Circuit High101
Travel Pressure Sensor Circuit High Diagnostics101
113044 — Travel Pressure Sensor Circuit Low103
Travel Pressure Sensor Circuit Low Diagnostics103
113253 — Bucket Curl Pressure Sensor Circuit High105
Bucket Curl Pressure Sensor Circuit High Diagnostics105
113254 — Bucket Curl Pressure Sensor Circuit Low107
Bucket Curl Pressure Sensor Circuit Low Diagnostics107
114052 — Travel Speed Solenoid Feedback Current Abnormal109
Travel Speed Solenoid Diagnostics109
114053 — Travel Speed Solenoid Feedback Current High110
Travel Speed Solenoid Diagnostics110
114054 — Travel Speed Solenoid Feedback Current Low111
Travel Speed Solenoid Diagnostics111
114082 — Exhaust Filter Regulator Solenoid Feedback Current Abn112
Exhaust Filter Regulator Solenoid Diagnostics112
114083 — Exhaust Filter Regulator Solenoid Feedback Current Hig113
Exhaust Filter Regulator Solenoid Diagnostics113
114084 — Exhaust Filter Regulator Solenoid Feedback Current Low114
Exhaust Filter Regulator Solenoid Diagnostics114
114122 — Fan Pump Control Solenoid Feedback Current Abnormal115
Fan Pump Control Solenoid Feedback Current Abnormal Diagnostics115
114123 — Fan Pump Control Solenoid 1 Feedback Current High116
Fan Pump Control Solenoid Feedback Current High Diagnostics116
114124 — Fan Pump Control Solenoid Feedback Current Low117
Fan Pump Control Solenoid Feedback Current Low Diagnostics117
114282 — Arm Flow Rate Control Solenoid Feedback Current Abnorm118
Arm Flow Rate Control Solenoid Diagnostics118
114283 — Arm Flow Rate Control Solenoid Feedback Current High119
Arm Flow Rate Control Solenoid Diagnostics119
114284 — Arm Flow Rate Control Solenoid Feedback Current Low120
Arm Flow Rate Control Solenoid Diagnostics120
118023 — Boom Bottom Pressure Sensor Circuit Voltage High121
Boom Bottom Pressure Sensor Diagnostics121
118024 — Boom Bottom Pressure Sensor Circuit Voltage Low123
Boom Bottom Pressure Sensor Diagnostics123
119013 — Hydraulic Oil Temperature Sensor Circuit High125
Hydraulic Oil Temperature Sensor Circuit High Diagnostics125
119014 — Hydraulic Oil Temperature Sensor Circuit Low127
Hydraulic Oil Temperature Sensor Diagnostics127
119423 — Attachment Pressure Sensor Circuit Voltage High128
Attachment Pressure Sensor Circuit Voltage High Diagnostics128
119424 — Attachment Pressure Sensor Circuit Voltage Low130
Attachment Pressure Sensor Circuit Voltage Low Diagnostics130
119433 — Counterweight Cylinder Pressure Sensor Circuit Voltage132
Counterweight Cylinder Pressure Sensor Diagnostics132
119434 — Counterweight Cylinder Pressure Sensor Circuit Voltage134
Counterweight Cylinder Pressure Sensor Diagnostics134
119443 — Pilot Pressure Sensor (5-spool) Circuit Voltage High136
Pilot Pressure Sensor (5-spool) Diagnostics136
119444 — Pilot Pressure Sensor (5-spool) Circuit Voltage Low138
Pilot Pressure Sensor (5-spool) Diagnostics138
119453 — Pilot Pressure Sensor (4-spool) Circuit Voltage High140
Pilot Pressure Sensor (4-spool) Diagnostics140
119454 — Pilot Pressure Sensor (4-spool) Circuit Voltage Low142
Pilot Pressure Sensor (4-spool) Diagnostics142
119482 — Power Dig Solenoid Feedback Current Abnormal144
Power Dig Solenoid Diagnostics144
119483 — Power Dig Solenoid Feedback Current High145
Power Dig Solenoid Diagnostics145
119484 — Power Dig Solenoid Feedback Current Low146
Power Dig Solenoid Diagnostics146
119502 — Pump Control Valve Solenoid 2 Feedback Current Abnorma147
Pump Control Valve Solenoid 2 Feedback Current Abnormal Diagnost147
119503 — Pump Control Valve Solenoid 2 Feedback Current High148
Pump Control Valve Solenoid 2 Feedback Current High Diagnostics148
119504 — Pump Control Valve Solenoid 2 Feedback Current Low149
Pump Control Valve Solenoid 2 Feedback Current Diagnostics149
119512 — Pump Control Valve Solenoid 1 Feedback Current Abnorma150
Pump Control Valve Solenoid 1 Feedback Current Abnormal Diagnost150
119513 — Pump Control Valve Solenoid 1 Feedback Current High151
Pump Control Valve Solenoid 1 Feedback Current High Diagnostics151
119514 — Pump Control Valve Solenoid 1 Feedback Current Low152
Pump Control Valve Solenoid 1 Feedback Current Low Diagnostics152
119532 — Swing Flow Rate Solenoid Feedback Current Abnormal153
Swing Flow Rate Solenoid Feedback Current Abnormal Diagnostics153
119533 — Swing Flow Rate Solenoid Feedback Current High154
Swing Flow Rate Solenoid Feedback Current High Diagnostics154
119534 — Swing Flow Rate Solenoid Feedback Current Low155
Swing Flow Rate Solenoid Feedback Current Low Diagnostics155
119712 — Pump Control Valve Solenoid 1 Abnormal Learning156
Pump Control Valve Solenoid 1 Abnormal Learning Diagnostics156
119722 — Pump Control Valve Solenoid 2 Abnormal Learning157
Pump Control Valve Solenoid 2 Abnormal Learning Diagnostics157
119812 — Fan Reversing Solenoid 1 Feedback Current Abnormal158
Fan Reversing Control Solenoid 1 Feedback Current Abnormal Diagn158
119813 — Fan Reversing Solenoid 1 Feedback Current High159
Fan Reversing Solenoid 1 Feedback Current High Diagnostics159
119814 — Fan Reversing Solenoid 1 Feedback Current Low160
Fan Reversing Solenoid 1 Feedback Current Low Diagnostics160
119822 — Fan Reversing Solenoid 2 Feedback Current Abnormal161
Fan Reversing Solenoid 2 Feedback Current Abnormal Diagnostics161
119823 — Fan Reversing Solenoid 2 Feedback Current High162
Fan Reversing Solenoid 2 Feedback Current High Diagnostics162
119824 — Fan Reversing Solenoid 2 Feedback Current Low163
Fan Reversing Solenoid 2 Feedback Current Low Diagnostics163
119832 — Intake Air Temperature Receive Error164
Intake Air Temperature Receive Error Diagnostics164
119842 — Boost Temperature Receive Error164
Abnormal Exhaust Filter Diagnostics165
119852 — Pump Control Valve Solenoid 2 Learning Failure165
Pump Control Valve Solenoid 2 Learning Failure Diagnostics165
119862 — Pump Control Valve Solenoid 1 Learning Failure166
Pump Control Valve Solenoid 1 Learning Failure Diagnostics166
119892 — Boom Overload Relief Solenoid Feedback Current Abnorma167
Boom Overload Relief Solenoid Feedback Current Abnormal Diagnost167
119893 — Boom Overload Relief Solenoid Feedback Current High168
Boom Overload Relief Solenoid Feedback Current High Diagnostics168
119894 — Boom Overload Relief Solenoid Feedback Current Low169
Boom Overload Relief Solenoid Feedback Current Low Diagnostics169
119953 — Arm Out Pressure Sensor Circuit High170
Arm Out Pilot Pressure Sensor Circuit High Diagnostics170
119954 — Arm Out Pressure Sensor Circuit Low172
Arm Out Pilot Pressure Sensor Circuit Low Diagnostics172
119973 — Bucket Dump Pressure Sensor Circuit High174
Bucket Dump Pressure Sensor Circuit High Diagnostics174
119974 — Bucket Dump Pressure Sensor Circuit Low176
Bucket Dump Pressure Sensor Circuit Low Diagnostics176
113023 — Boom Down Pressure Sensor Circuit High178
Boom Down Pressure Sensor Circuit High Diagnostics178
113024 — Boom Down Pressure Sensor Circuit Low180
Boom Down Pressure Sensor Circuit Low Diagnostics180
200622 — Hydraulic Oil Temperature Alarm182
Engine Control Unit (ECU) Diagnostic Trouble Codes183
Engine Control Unit (ECU) Diagnostic Trouble Codes183
810 — High Exhaust Filter Differential Pressure (P2453)183
811 — Low Exhaust Filter Differential Pressure (P2452)183
812 — Zero-point calibration of Exhaust Filter differential pre183
813 — Exhaust Filter Differential Pressure Sensor Circuit High 183
814 — Exhaust Filter Differential Pressure Sensor Circuit Low I183
912 — Accelerator Pedal Position Sensor 1-2 Correlation (P2138)183
913 — Accelerator Pedal Position Sensor 1 High Input (P2123)184
913 — Accelerator Pedal Position Sensor 2 High Input (P2128)184
914 — Accelerator Pedal Position Sensor 1 Low Input (P2122)184
914 — Accelerator Pedal Position Sensor 2 Low Input (P2127)184
1003 — Engine Oil Pressure Sensor Circuit High Input (P0523)184
1004 — Engine Oil Pressure Sensor Circuit Low Input (P0522)184
1020 — Overboost-Pressure (P0234)184
1021 — Declined Boost Pressure (P0299)185
1023 — Boost Pressure Sensor Circuit High Input (P0108)185
1024 — Boost Pressure Sensor Circuit Low Input (P0107)185
1053 — Boost Temperature Sensor Circuit High Input (P1113)185
1054 — Boost Temperature Sensor Circuit Low Input (P1112)185
1083 — Atmospheric Pressure Sensor Circuit High Input (P2229)185
1084 — Atmospheric Pressure Sensor Circuit Low Input (P2228)185
1100 — Overheat (P0217)186
1103 — Engine Coolant Temperature Circuit High Input (P0118)186
1104 — Engine Coolant Temperature Circuit Low Input (P0117)186
1323 — Air Flow Sensor Circuit High Input (P0103)186
1324 — Air Flow Sensor Circuit Low Input (P0102)186
1570 — Pressure Increase in Common Rail (Secondary) (P0088)186
1573 — Common Rail Pressure Sensor Circuit High Input (P0193)186
1574 — Common Rail Pressure Sensor Circuit Low Input (P0192)187
15715 — Abnormal Common Rail Pressure (Over Pumping) (P0089)187
15716 — Pressure Increase in Common Rail (Primary) (P0088)187
1583 — Abnormally High Battery System Voltage (P0563)187
1723 — Intake Air Temperature Sensor Circuit High Input (P0113)187
1724 — Intake Air Temperature Sensor Circuit Low Input (P0112)187
1730 — Abnormally High Intake Air Temperature Sensor 1 (DPF Inl187
1733 — Exhaust Temperature Sensor 1 Circuit High Input (DPF Inl188
1734 — Exhaust Temperature Sensor 1 Circuit Low Input (DPF Inle188
1743 — Combustion Temperature Sensor Circuit High Input (P0183)188
1744 — Combustion Temperature Sensor Circuit Low Input (P0182)188
1900 — Engine Overrun (P0219)188
6282 — Abnormal ROM (P0601)188
6337 — Common Rail Pressure Limiter Open (P0087)188
6362 — Abnormal Cam Angle Sensor (No Signal) (P0340)189
6367 — Phase Difference between Cam and Sensor (P0016)189
6392 — Abnormal CAN Time-out (U0101)189
63919 — Abnormal CAN Bus (U0073)189
6515 — Cylinder 1 Injector Circuit Open (P0201)189
6525 — Cylinder 2 Injector Circuit Open (P0202)189
6535 — Cylinder 3 Injector Circuit Open (P0203)189
6545 — Cylinder 4 Injector Circuit Open (P0204)190
6555 — Cylinder 5 Injector Circuit Open (P0205)190
6565 — Cylinder 6 Injector Circuit Open (P0206)190
7232 — Crank Position Sensor Failure (No Signal) (P0335)190
7232 — Crank Position Sensor Failure (Abnormal Signal) (P0336)190
10772 — Abnormal CPU (P0606)190
10792 — Abnormal 5V-Electric Power Circuit #1 (P0641)190
10802 — Abnormal 5V-Electric Power Circuit #2 (P0651)191
11313 — Manifold Temperature Sensor Circuit High Input (P041C)191
11314 — Manifold Temperature Sensor Circuit Low Input (P041D)191
12391 — Pressure Decline in Common Rail (No Pumping Pressure) (191
123917 — Pressure Decline in Common Rail (Lack of Pumping Press191
13473 — SCV Drive Circuit + Short Circuit B (P0092)191
13474 — SCV Drive Circuit Open or Short Circuited to GND (P0091191
13813 — Fuel Filter Restriction Sensor Circuit High Input (P129192
13814 — Fuel Filter Restriction Sensor Circuit Low Input (P1293192
14855 — Abnormal Main Relay Circuit (Inactivation) (P0685)192
14856 — Abnormal Main Relay Circuit (Kept closed) (P0687)192
100012 — EGR Position Error (Brushless Type) (P0409)192
1000113 — Abnormal EGR Zero-point calibration (P1404)192
100022 — Abnormal EGR Valve Control Circuit (P0404)192
100032 — Abnormal Injector Common 1 Circuit (P2146)193
100042 — Abnormal Injector Common 2 Circuit (P2149)193
100052 — Abnormal Charge Circuit (Bank 1) (P1261)193
100062 — Abnormal Charge Circuit (Bank 2) (P1262)193
100072 — Abnormal CPU Monitor IC (P0606)193
100082 — Abnormal A/D Converter (P060B)193
100092 — Abnormal 5V-Electric Power Circuit #3 (P0697)193
100102 — Abnormal 5V-Electric Power Circuit #4 (P1655)194
100122 — Abnormal 12V Circuit (P0560)194
100132 — Abnormal EEPROM/Abnormal HDEEPROM (P1621)194
100222 — Abnormal Intake Throttle Control Circuit (P0638)194
100223 — Intake Throttle Position Sensor Circuit High Input (P0194
100224 — Intake Throttle Position Sensor Circuit Low Input (P01194
100232 — Abnormal CAN VGT Time-out/ISO-CAN VGT Communication Er194
1002312 — Abnormal VGT Turbo (P0045)195
1002319 — VGT Communication Error (U0411)195
100243 — Exhaust Temperature Sensor 2 Circuit High Input (DOC I195
100244 — Exhaust Temperature Sensor 2 Circuit Low Input (DOC In195
100255 — Exhaust Filter Light Failure (P1669)195
100260 — Exhaust Filter PM Over-Restriction 2 (P1455)195
1002615 — Exhaust Filter PM Over-Restriction (P242F)195
100270 — Exhaust Filter Cleaning Decision Error (P1471)196
100280 — Abnormally High Exhaust Temperature Sensor 2 (DOC Outl196
100290 — Over Frequent Exhaust Filter Regeneration Time-Out (P2196
100322 — Injector QR Code Error (P0602)196
100332 — Abnormal RAM (P0604)196
1004019 — Abnormal ISO-CAN Bus (U0001)196
Monitor Controller (DSZ) Diagnostic Trouble Codes197
Monitor Controller (DSZ) Diagnostic Trouble Codes197
140012 — Flash Memory Read/Write Error197
Data Converter Diagnostics197
140022 — External RAM Read/Write Error197
Data Converter Diagnostics197
140032 — Abnormal EEPROM197
Data Converter Diagnostics197
140062 — Communication Terminal : Communication Error198
Communication Terminal : Communication Error198
140082 — Abnormal Internal RAM198
Data Converter Diagnostics199
140212 — Communication Terminal Security Error199
140222 — SIM Card Error199
140232 — Security Error199
201012 — Engine Warning Alarm199
201022 — Engine Oil Pressure Alarm199
201032 — Alternator Alarm200
Alternator Alarm200
201042 — Fuel Level Alarm200
Fuel Level Alarm200
201052 — Hydraulic Oil Filter Restriction Alarm201
Hydraulic Oil Filter Restriction Alarm201
201062 — Air Cleaner Restriction Alarm202
Air Cleaner Restriction Alarm202
201092 — Pilot Control Shutoff Lever Alarm202
Pilot Control Shutoff Lever Alarm202
201102 — Fuel Filter Restriction Alarm203
201132 — System Error Alarm204
201332 — Crane Function Alarm204
201372 — Exhaust Filter Alarm204
201412 — Exhaust Temperature Alarm204
201422 — Intake Air Temperature Alarm204
201452 — Boost Temperature Increase Alarm204
201462 — Fuel Temperature Increase Alarm204
201492 — EGR Gas Temperature Alarm204
Air Conditioner Controller (ACF) Diagnostic Trouble Codes205
Air Conditioner Controller (ACF) Diagnostic Trouble Codes205
11 — Open Circuit In Air Recirculation Sensor205
Harness Diagnostics205
12 — Short-Circuited Air Recirculation Sensor205
Harness Diagnostics205
13 — Open Circuit In Ambient Air Temperature Sensor206
Harness Diagnostics206
14 — Short-Circuited Ambient Air Temperature Sensor206
Harness Diagnostics206
18 — Short-Circuited Solar Radiation Sensor207
Harness Diagnostics207
21 — Open Circuit In Air Conditioner Freeze Control Switch207
Harness Diagnostics207
22 — Short-Circuited Air Conditioner Freeze Control Switch208
Harness Diagnostics208
43 — Abnormal Air Conditioner And Heater Blower Port Change Serv208
Harness Diagnostics208
44 — Abnormal Air Conditioner And Heater Mixer Servomotor209
Harness Diagnostics209
51 — Abnormal Air Conditioner High/Low Pressure Switch210
Harness Diagnostics210
91 — Communication Error211
Harness Diagnostics211
92 — CAN Bus Off Error211
Harness Diagnostics211
Operational Checkout Procedure213
Operational Checkout Procedure215
Operational Checkout215
Diagnostic Trouble Code Check215
Operational Checks—Key Switch Off, Engine Off Checks215
Operational Checks—Key Switch On, Engine Off Checks218
Operational Checks—Key Switch On, Engine On Checks230
Engine265
Theory of Operation267
Engine Identification267
Isuzu Engine267
Engine Fuel System Component Location268
Engine Cooling System Component Location272
Cold Weather Starting Aid274
Engine Speed Control System Operation276
Diagnostic Information279
Isuzu Engine279
Adjustments281
Isuzu Engine281
Tests283
Isuzu Engines283
Electrical System287
System Information289
Electrical Diagram Information289
System Diagrams297
Explanation of Wire Markings297
Fuse and Relay Specifications297
System Functional Schematic, Component Location, and Wiring Diag300
System Functional Schematic305
Cab Harness (W1) Component Location343
Cab Harness (W1) Wiring Diagram348
Machine Harness (W2) Component Location360
Machine Harness (W2) Wiring Diagram361
Monitor Harness (W3) Component Location370
Monitor Harness (W3) Wiring Diagram372
Engine Harness (W4) Component Location374
Engine Harness (W4) Wiring Diagram375
Engine Sub Harness (W6) Component Location381
Engine Sub Harness (W6) Wiring Diagram385
Pump Harness (W8) Component Location388
Pump Harness (W8) Wiring Diagram389
Exhaust Filter Parked Cleaning Switch Harness (W9) Component Loc391
Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagra391
Pilot Shutoff Switch Harness (W11) Component Location392
Pilot Shutoff Switch Harness (W11) Wiring Diagram393
Exhaust Filter Harness (W12) Component Location396
Exhaust Filter Harness (W12) Wiring Diagram397
Auxiliary Fuse Box Harness (W13) Component Location398
Auxiliary Fuse Box Harness (W13) Wiring Diagram399
Heated Air Seat Harness (W14) Component Location402
Heated Air Seat Harness (W14) Wiring Diagram403
Travel Alarm Cancel Switch Harness (W16) Component Location403
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram404
Rear Camera Harness (W19) Component Location404
Rear Camera Harness (W19) Wiring Diagram405
9-Pin Service ADVISOR™ Connector (W20) Component Location406
9-Pin Service ADVISOR™ Connector (W20) Wiring Diagram407
Pilot Shutoff Valve Harness (W21) Component Location407
Pilot Shutoff Valve Harness (W21) Wiring Diagram408
Fan Reversing Switch Harness (W23) Component Location408
Fan Reversing Switch Harness (W23) Wiring Diagram409
Seat Heater Switch Harness (W24) Component Location409
Seat Heater Switch Harness (W24) Wiring Diagram410
Optional Switch Harness (W25) Component Location410
Optional Switch Harness (W25) Wiring Diagram411
Starter Switch Harness (W29) Component Location411
Starter Switch Harness (W29) Wiring Diagram412
Heater and Air Conditioner Harness (W41) Component Location413
Heater and Air Conditioner Harness (W41) Wiring Diagram415
12 Volt Power Converter Harness (W42) Component Location417
12 Volt Power Converter Harness (W42) Wiring Diagram418
Control Valve Harness (W43) Component Location419
Control Valve Harness (W43) Wiring Diagram421
Data Converter CAN Harness (W44) Component Location423
Data Converter CAN Harness (W44) Wiring Diagram424
Data Converter Harness (W45) Component Location424
Data Converter Harness (W45) Wiring Diagram425
Counterweight Removal or Install Switch (W46) Component Location426
Counterweight Removal or Install Switch (W46) Wiring Diagram427
Boom Switch Harness (W47) Component Location428
Boom Switch Harness (W47) Wiring Diagram429
Cab Light Relay Harness (W48) Component Location430
Cab Light Relay Harness (W48) Wiring Diagram431
Cab Light Harness (W49) Component Location432
Cab Light Harness (W49) Wiring Diagram433
Satellite (SAT) Harness (W6003) Component Location—If Equipped435
Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped437
JDLink™ Harness (W6004) Component Location437
JDLink™ Harness (W6004) Wiring Diagram439
Sub-System Diagnostics443
Controller Area Network (CAN) Theory of Operation443
Starting and Charging Circuit Theory of Operation447
Monitor Controller (DSZ) Circuit Theory of Operation451
Engine Control Unit (ECU) Circuit Theory of Operation459
Travel Alarm Circuit Theory of Operation468
Machine Controller (BCZ) Circuit Theory of Operation469
Exhaust Aftertreatment Circuit Theory of Operation470
Main Controller (MCZ) Circuit Theory of Operation473
Windshield Wiper and Washer Circuit Theory of Operation493
Lighting Circuit Theory of Operation497
Pilot Shutoff Circuit Theory of Operation501
Monitor Operation505
Service Menu505
Troubleshooting505
Monitoring506
Controller Version510
Issued Warning Record510
Operation511
Machine Setting512
Monitor Setting515
Exhaust Filter516
References517
Reading Diagnostic Trouble Codes with Monitor Display517
Service ADVISOR™ Diagnostic Application517
Service ADVISOR™ Connection Procedure518
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnosti519
MPDr Application521
MPDr Connection Procedure521
Pump Learning Procedure522
Fuse Test523
Relay Test526
Pressure Sensor Test527
Solenoid Test528
Proportional Solenoid Test528
Temperature Sensor Test529
Alternator Test530
Electrical Component Checks531
Component Checks531
Battery Remove and Install537
Rear Cover Remove and Install539
Main Controller (MCZ) Remove and Install540
Engine Control Unit (ECU) Remove and Install541
Machine Controller (BCZ) Remove and Install542
Data Converter Remove and Install543
Monitor Controller (DSZ) Remove and Install544
Air Conditioner Controller (ACF) Remove and Install545
Key Switch Remove and Install545
Right Switch Console Remove and Install546
Left Switch Console Remove and Install548
Travel Alarm Remove and Install549
Disconnect Tab Retainer Connectors550
Disconnecting Spring Wire Clip Connectors550
Replace DEUTSCHDEUTSCH is a trademark of the Deutsch Co™ Connec551
Replace DEUTSCHDEUTSCH is a trademark of Deutsch Co™ Rectangula552
Install DEUTSCHDEUTSCH is a trademark of the Deutsch Co™ Contac553
Replace WEATHER PACKWEATHER PACK is a trademark of Packard Elect554
Install WEATHER PACKWEATHER PACK is a trademark of Packard Elect555
Replace (Pull Type) Metri-Pack™ Connectors556
Replace (Push Type) Metri-Pack™ Connectors557
Replace CINCHCINCH is a trademark of the Cinch Co™ Connectors557
Install CINCHCINCH is a trademark of the Cinch Co™ Contact559
Repair 32 and 48 Way CINCHCINCH is a trademark of the Cinch Co™560
Remove Connector Body from Blade Terminals562
Power Train563
Theory of Operation565
Track Adjuster and Recoil Spring Operation565
Travel Gearbox Operation566
Diagnostic Information569
Noisy or Loose Track Chain569
Noisy or Loose Track Chain Diagnostic Procedure569
Tight Track Chain569
Tight Track Chain Diagnostic Procedure569
Frequent Track Chain Sag Adjustment Required570
Frequent Track Chain Sag Adjustment Required Diagnostic Procedur570
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrie570
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrie570
Bent Track Shoes570
Bent Track Shoes Diagnostic Procedure570
“Popping” of Track571
“Popping” of Track Diagnostic Procedure571
Cracked Track Link571
Cracked Track Link Diagnostic Procedure571
Chipped Link Rails572
Chipped Link Rails Diagnostic Procedure572
Individual Undercarriage Component Wear573
Individual Undercarriage Component Wear Diagnostic Procedure573
Measure Swing Bearing Wear574
Hydraulic System579
Theory of Operation581
Hydraulic System Operation581
Fan Drive Hydraulic System Operation582
Pilot System Operation584
Pilot Pump, Pressure Regulating Valve and Filter Operation585
Pilot Shutoff Solenoid Valve Operation586
Pilot Control Valve Operation589
Travel Pilot Control Valve Operation592
Boom Up Shockless Valve Operation594
Pilot Operation of Control Valve Operation597
Pilot Signal Manifold Operation600
Pump 1, Pump 2, and Fan Drive Gear Case Operation609
Pump 1, Pump 2, Regulator Operation610
Fan Pump Control Solenoid Valve Operation613
Engine Speed Sensing Control Circuit Operation616
Control Valve Operation618
Control Valve Check Valves Identification and Operation627
Main Relief Valve Circuit Operation632
Circuit Relief and Anticavitation Valve Operation637
Travel Flow Combiner Valve Circuit Operation638
Boom Lower Meter-In Cut Valve Operation641
Arm Regenerative Valve Circuit Operation645
Bucket Regenerative Valve Circuit Operation650
Boom and Arm Reduced Leakage Valves Operation653
Arm 1 Flow Rate Control Valve Circuit Operation657
Arm 2 Flow Rate Control Valve Circuit Operation661
Boom Flow Rate Control Valve Circuit Operation665
Auxiliary Flow Rate Control Valve Circuit Operation669
Swing Gear Case Operation669
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Ope670
Swing Motor Park Brake Release Circuit Operation673
Center Joint Operation674
Travel Motor and Park Brake Circuit Operation675
Travel Motor Speed Circuit Operation677
Counterweight Removal Circuit Operation680
Counterweight Removal Cylinder Operation682
Boom, Arm, and Bucket Cylinder Operation683
Return Filter Operation684
Diagnostic Information685
All Hydraulic Functions Slow685
All Hydraulic Functions Slow Diagnostic Procedure685
Hydraulic Oil Overheats687
Hydraulic Oil Overheats Diagnostic Procedure687
No Hydraulic Functions690
No Hydraulic Functions Diagnostic Procedure690
Poor Combined Operation692
Poor Combined Operation Diagnostic Procedure692
Function Does Not Stop When Control Lever Released693
Function Does Not Stop When Control Lever Released Diagnostic Pr693
Some Functions Slow or Cannot Be Operated, All Others Are Normal694
Some Functions Cannot Be Operated, All Others Are Normal Diagnos695
Functions Move in Opposite Direction696
Functions Move in Opposite Direction696
All Dig Functions Slow or No Power696
All Dig Functions Slow or No Power696
Some Dig Functions Slow (Not All)697
Some Dig Functions Slow (Not All)697
Load Drifts Down When Control Lever is in Neutral Position698
Load Drifts Down When Control Lever is in Neutral Position Diagn698
Load Falls When Control Valve is Actuated To Raise Load With Eng700
Load Falls When Control Valve is Actuated To Raise Load With Eng700
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is 701
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is 701
Swing Speed Slow in Both Directions or Does Not Operate702
Swing Speed Slow in Both Directions Diagnostic Procedure702
Swing Speed Slow or Does Not Operate in One Direction704
Swing Speed Slow or Does Not Operate in One Direction Diagnostic704
Upperstructure Drift with Swing Valve in Neutral705
Upperstructure Drift with Swing Valve in Neutral Diagnostic Proc705
Travel Park Brakes Do Not Apply706
Travel Park Brakes Do Not Apply Diagnostic Procedure706
Track Will Not Move in One Direction706
Track Will Not Move in One Direction Diagnostic Procedure706
Track Will Not Move in Either Direction708
Track Will Not Move in Either Direction Diagnostic Procedure708
Machine Mistracks at All Speeds in Both Directions709
Machine Mistracks at All Speeds in Both Directions Diagnostic Pr709
Slow Travel Speed or Low Power711
Slow Travel Speed or Low Power Diagnostic Procedure711
Combined Travel and Dig Functions Slow or No Power712
Combined Travel and Dig Functions Slow or No Power Diagnostic Pr712
Travel is “Jerky”713
Travel is “Jerky” Diagnostic Procedure713
Machine Will Not Hold Back and Park Brakes Engage and Disengage 714
Machine Will Not Hold Back and Park Brakes Engage and Disengage 714
Machine Will Not Turn Smoothly in One Direction or Park Brake Gr715
Machine Will Not Turn Smoothly in One Direction or Park Brake Gr715
Pump 1, Pump 2, Fan Drive Pump and Pilot Pump Line Identificatio717
Control Valve Line Identification720
Swing Motor Line Identification722
Pilot Control Valve-to-Pilot Signal Manifold Component Location—725
Pilot Control Valve-to-Pilot Signal Manifold Component Location—729
Pilot Signal Manifold-to-Control Valve Line Connection732
Travel Hydraulic System Component Location736
Travel Hydraulic System Line Connection739
Hydraulic System Schematic743
Hydraulic System Component Location764
Hydraulic System Line Connections767
Fan Drive Hydraulic System Schematic770
Fan Drive Hydraulic System Component Location773
Tests777
JT05800 Digital Thermometer Installation777
JT02156A Digital Pressure and Temperature Analyzer Kit Installat777
Hydraulic Oil Cleanup Procedure778
Hydraulic Oil Tank Pressure Release Procedure779
Hydraulic Oil Warm-Up Procedure780
Pilot Pressure Regulating Valve Test and Adjustment782
Control Valve Spool Actuating Pilot Pressure Test784
Travel Speed Solenoid Valve (port SC) Test and Adjustment786
Exhaust Filter Regulator Solenoid Valve (port SF) Test and Adjus789
Power Dig Solenoid Valve (port SI) Test and Adjustment792
Arm Flow Rate Control Solenoid Valve (port SG) Test and Adjustme795
Boom Overload Relief Solenoid Valve (port SC) Test and Adjustmen798
Swing Flow Rate Solenoid Valve (port SI) Test and Adjustment800
Main Relief and Power Dig Valve Test and Adjustment802
Circuit Relief Valve Test and Adjustment806
Boom Mode Relief Valve Test and Adjustment809
Pump Servo Piston Minimum Flow Test and Adjustment811
Pump Servo Piston Maximum Flow Test and Adjustment813
Pump Flow Rate (Displacement) Test and Adjustment814
Swing Motor Crossover Relief Valve Test and Adjustment815
Travel Motor Crossover Relief Valve Test and Adjustment817
Swing Motor Leakage Test820
Travel Motor Leakage Test823
Cylinder Drift Test—Boom, Arm, and Bucket824
Pump Flow Test825
Fan Speed Test828
Fan Motor Case Drain Test828
Fan Drive Pump Flow Test830
Fan Drive System Relief Valve Test and Adjustment832
Heating and Air Conditioning835
Theory of Operation837
Air Conditioning System Cycle of Operation837
Diagnostic Information839
No Air Flow From Heater and Air Conditioner Vents839
No Air Flow From Heater and Air Conditioner Vents Diagnostic Pro839
Air Conditioning System Does Not Operate841
Air Conditioning System Does Not Operate Diagnostic Procedure841
Air Conditioning Does Not Cool Interior of Cab842
Air Conditioning Does Not Cool Interior of Cab Diagnostic Proced842
Air Conditioning Runs Constantly, Too Cold844
Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure844
Interior Windows Continue to Fog Using Air Conditioner845
Interior Windows Continue to Fog Using Air Conditioner Diagnosti845
Heater System Does Not Operate846
Heater System Does Not Operate Diagnostic Procedure846
Heater Does Not Warm Interior of Cab847
Heater Does Not Warm Interior of Cab Diagnostic Procedure847
Interior Windows Continue to Fog Using Heater848
Interior Windows Continue to Fog using Heater Diagnostic Procedu848
Heater and Air Conditioner Component Location850
Tests851
Refrigerant Cautions and Proper Handling851
Heater and Air Conditioner Operational Checks851
Visual Inspection of Components851
Air Conditioner Compressor Clutch Test853
Refrigerant Leak Test853
Refrigerant Hoses and Tubing Inspection853
Air Conditioner Compressor Belt Check and Adjustment853
Operating Pressure Diagnostic Chart854
Dealer Fabricated Tools855
Dealer Fabricated Tools857
DFT1218 Split Flange Hose Cap857
Page Number 5
Section 9000 7
Group 01 9
Section 9001 31
Group 10 33
Group 20183
Group 30197
Group 50205
Section 9005213
Group 10215
Section 9010265
Group 05267
Group 15279
Group 20281
Group 25283
Section 9015287
Group 05289
Group 10297
Group 15443
Group 16505
Group 20517
Section 9020563
Group 05565
Group 15569
Section 9025579
Group 05581
Group 15685
Group 25777
Section 9031835
Group 05837
Group 15839
Group 25851
Section 9900855
Group 99857

S.M 6/1/25