John Deere 870GLC Excavator Operation and Test TECHNICAL MANUAL TM12176 – PDF DOWNLOAD

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John Deere 870GLC Excavator Operation and Test TECHNICAL MANUAL TM12176 – PDF DOWNLOAD

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John Deere 870GLC Excavator Operation and Test TECHNICAL MANUAL TM12176 – PDF DOWNLOAD

Language : English
Pages :904
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

John Deere 870GLC Excavator Operation and Test TECHNICAL MANUAL TM12176 – 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 870GLC Excavator Operation and Test TECHNICAL MANUAL TM12176 – 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 10
Stay Clear of Moving Parts 11
Avoid High-Pressure Fluids 11
Avoid High-Pressure Oils 11
Work In Ventilated Area 12
Prevent Fires 12
Prevent Battery Explosions 13
Handle Chemical Products Safely 13
Dispose of Waste Properly 13
Exhaust Filter Ash Handling and Disposal 14
Prepare for Emergencies 14
Clean Debris from Machine 14
Use Steps and Handholds Correctly 14
Start Only From Operator’s Seat 15
Use and Maintain Seat Belt 15
Prevent Unintended Machine Movement 15
Avoid Work Site Hazards 16
Keep Riders Off Machine 16
Avoid Backover Accidents 17
Avoid Machine Tip Over 17
Use Special Care When Lifting Objects 18
Add and Operate Attachments Safely 18
Park and Prepare for Service Safely 18
Service Cooling System Safely 19
Remove Paint Before Welding or Heating 19
Make Welding Repairs Safely 19
Drive Metal Pins Safely 20
Clean Exhaust Filter Safely 21
Diagnostics 29
Main Controller (MCZ) Diagnostic Trouble Codes 31
Main Controller (MCZ) Diagnostic Trouble Codes 31
Controller Area Network 0 (CAN 0) Circuit Diagnostics 31
Controller Area Network (CAN 0) Diagnostics 31
Controller Area Network 1 (CAN 1) Circuit Diagnostics 41
Controller Area Network (CAN 1) Diagnostics 42
Interface Controller Area Network (N-CAN) Diagnostics 53
Interface Controller Area Network (N-CAN) Diagnostics 53
Engine Controller Area Network (Engine CAN) Diagnostics 63
Engine Controller Area Network (Engine CAN) Diagnostics 63
110002 — Abnormal EEPROM 68
Controller Hardware Diagnostics 68
110012 — Abnormal RAM 69
Controller Hardware Diagnostics 69
110022 — Abnormal A/D Converter 70
Controller Hardware Diagnostics 70
110033 — Abnormal Sensor Voltage 70
Harness Diagnostics 70
110042 — CAN Communication Error 1 71
110052 — CAN Communication Error 2 71
110062 — Engine Controller Communication Error 71
110072 — (CAN 0) Data Converter Communication Error 1 72
110082 — (CAN 1) Data Converter Communication Error 2 72
110092 — (CAN 0) Monitor Controller Communication Error 1 72
110102 — (CAN 1) Monitor Controller Communication Error 2 72
111002 — Abnormal Engine Speed 72
Engine Speed Diagnostics 72
111013 — Engine Control Dial Sensor Circuit High 73
Engine Control Dial Sensor Circuit High Diagnostics 73
111014 — Engine Control Dial Sensor Circuit Low 75
Engine Control Dial Sensor Circuit High Diagnostics 75
112003 — Pump 1 Delivery Pressure Sensor Circuit High 76
Pump 1 Delivery Pressure Sensor Circuit High Diagnostics 76
112004 — Pump 1 Delivery Pressure Sensor Circuit Low 77
Pump 1 Delivery Pressure Sensor Circuit Low Diagnostics 78
112023 — Pump 2 Delivery Pressure Sensor Circuit High 79
Pump 2 Delivery Pressure Sensor Circuit High Diagnostics 79
112024 — Pump 2 Delivery Pressure Sensor Circuit Low 80
Pump 2 Delivery Pressure Sensor Circuit Low Diagnostics 80
112063 — Pump 1 Control Pressure Sensor Circuit High 82
Pump 1 Control Pressure Sensor Circuit High Diagnostics 82
112064 — Pump 1 Control Pressure Sensor Circuit Low 83
Pump 1 Control Pressure Sensor Circuit Low Diagnostics 83
112083 — Pump 2 Control Pressure Sensor Circuit High 85
Pump 2 Control Pressure Sensor Circuit High Diagnostics 85
112084 — Pump 2 Control Pressure Sensor Circuit Low 86
Pump 2 Control Pressure Sensor Circuit Low Diagnostics 86
113013 — Swing Pressure Sensor Circuit High 88
Swing Pressure Sensor Circuit High Diagnostics 88
113014 — Swing Pressure Sensor Circuit Low 90
Swing Pressure Sensor Circuit Low Diagnostics 90
113023 — Boom Up Pressure Sensor Circuit High 91
Boom Up Pressure Sensor Circuit High Diagnostics 91
113024 — Boom Up Pressure Sensor Circuit Low 93
Boom Up Pressure Sensor Circuit Low Diagnostics 93
113033 — Arm In Pressure Sensor Circuit High 95
Arm In Pilot Pressure Sensor Circuit High Diagnostics 95
113034 — Arm In Pressure Sensor Circuit Low 97
Arm In Pilot Pressure Sensor Circuit Low Diagnostics 97
113043 — Travel Pressure Sensor Circuit High 99
Travel Pressure Sensor Circuit High Diagnostics 99
113044 — Travel Pressure Sensor Circuit Low101
Travel Pressure Sensor Circuit Low Diagnostics101
113253 — Bucket Curl Pressure Sensor Circuit High103
Bucket Curl Pressure Sensor Circuit High Diagnostics103
113254 — Bucket Curl Pressure Sensor Circuit Low105
Bucket Curl Pressure Sensor Circuit Low Diagnostics105
114052 — Travel Speed Solenoid Feedback Current Abnormal107
Travel Speed Solenoid Diagnostics107
114053 — Travel Speed Solenoid Feedback Current High108
Travel Speed Solenoid Diagnostics108
114054 — Travel Speed Solenoid Feedback Current Low109
Travel Speed Solenoid Diagnostics109
114082 — Exhaust Filter Regulator Solenoid Feedback Current Abnormal110
Exhaust Filter Regulator Solenoid Diagnostics110
114083 — Exhaust Filter Regulator Solenoid Feedback Current High111
Exhaust Filter Regulator Solenoid Diagnostics111
114084 — Exhaust Filter Regulator Solenoid Feedback Current Low112
Exhaust Filter Regulator Solenoid Diagnostics112
114122 — Fan Pump Control Solenoid Feedback Current Abnormal113
Fan Pump Control Solenoid Feedback Current Abnormal Diagnostics113
114123 — Fan Pump Control Solenoid 1 Feedback Current High114
Fan Pump Control Solenoid Feedback Current High Diagnostics114
114124 — Fan Pump Control Solenoid Feedback Current Low115
Fan Pump Control Solenoid Feedback Current Low Diagnostics115
114282 — Arm Flow Rate Control Solenoid Feedback Current Abnormal116
Arm Flow Rate Control Solenoid Diagnostics116
114283 — Arm Flow Rate Control Solenoid Feedback Current High117
Arm Flow Rate Control Solenoid Diagnostics117
114284 — Arm Flow Rate Control Solenoid Feedback Current Low118
Arm Flow Rate Control Solenoid Diagnostics118
118023 — Boom Bottom Pressure Sensor Circuit Voltage High119
Boom Bottom Pressure Sensor Diagnostics119
118024 — Boom Bottom Pressure Sensor Circuit Voltage Low121
Boom Bottom Pressure Sensor Diagnostics121
119013 — Hydraulic Oil Temperature Sensor Circuit High123
Hydraulic Oil Temperature Sensor Circuit High Diagnostics123
119014 — Hydraulic Oil Temperature Sensor Circuit Low125
Hydraulic Oil Temperature Sensor Diagnostics125
119423 — Attachment Pressure Sensor Circuit Voltage High126
Attachment Pressure Sensor Circuit Voltage High Diagnostics126
119424 — Attachment Pressure Sensor Circuit Voltage Low128
Attachment Pressure Sensor Circuit Voltage Low Diagnostics128
119433 — Counterweight Cylinder Pressure Sensor Circuit Voltage High130
Counterweight Cylinder Pressure Sensor Diagnostics130
119434 — Counterweight Cylinder Pressure Sensor Circuit Voltage Low132
Counterweight Cylinder Pressure Sensor Diagnostics132
119443 — Pilot Pressure Sensor (5-spool) Circuit Voltage High134
Pilot Pressure Sensor (5-spool) Diagnostics134
119444 — Pilot Pressure Sensor (5-spool) Circuit Voltage Low136
Pilot Pressure Sensor (5-spool) Diagnostics136
119453 — Pilot Pressure Sensor (4-spool) Circuit Voltage High138
Pilot Pressure Sensor (4-spool) Diagnostics138
119454 — Pilot Pressure Sensor (4-spool) Circuit Voltage Low140
Pilot Pressure Sensor (4-spool) Diagnostics140
119482 — Power Dig Solenoid Feedback Current Abnormal142
Power Dig Solenoid Diagnostics142
119483 — Power Dig Solenoid Feedback Current High143
Power Dig Solenoid Diagnostics143
119484 — Power Dig Solenoid Feedback Current Low144
Power Dig Solenoid Diagnostics144
119502 — Pump Control Valve Solenoid 2 Feedback Current Abnormal145
Pump Control Valve Solenoid 2 Feedback Current Abnormal Diagnostics145
119503 — Pump Control Valve Solenoid 2 Feedback Current High146
Pump Control Valve Solenoid 2 Feedback Current High Diagnostics146
119504 — Pump Control Valve Solenoid 2 Feedback Current Low147
Pump Control Valve Solenoid 2 Feedback Current Diagnostics147
119512 — Pump Control Valve Solenoid 1 Feedback Current Abnormal148
Pump Control Valve Solenoid 1 Feedback Current Abnormal Diagnostics148
119513 — Pump Control Valve Solenoid 1 Feedback Current High149
Pump Control Valve Solenoid 1 Feedback Current High Diagnostics149
119514 — Pump Control Valve Solenoid 1 Feedback Current Low150
Pump Control Valve Solenoid 1 Feedback Current Low Diagnostics150
119532 — Swing Flow Rate Solenoid Feedback Current Abnormal151
Swing Flow Rate Solenoid Feedback Current Abnormal Diagnostics151
119533 — Swing Flow Rate Solenoid Feedback Current High152
Swing Flow Rate Solenoid Feedback Current High Diagnostics152
119534 — Swing Flow Rate Solenoid Feedback Current Low153
Swing Flow Rate Solenoid Feedback Current Low Diagnostics153
119712 — Pump Control Valve Solenoid 1 Abnormal Learning154
Pump Control Valve Solenoid 1 Abnormal Learning Diagnostics154
119722 — Pump Control Valve Solenoid 2 Abnormal Learning155
Pump Control Valve Solenoid 2 Abnormal Learning Diagnostics155
119812 — Fan Reversing Solenoid 1 Feedback Current Abnormal156
Fan Reversing Control Solenoid 1 Feedback Current Abnormal Diagnostics156
119813 — Fan Reversing Solenoid 1 Feedback Current High157
Fan Reversing Solenoid 1 Feedback Current High Diagnostics157
119814 — Fan Reversing Solenoid 1 Feedback Current Low158
Fan Reversing Solenoid 1 Feedback Current Low Diagnostics158
119822 — Fan Reversing Solenoid 2 Feedback Current Abnormal159
Fan Reversing Solenoid 2 Feedback Current Abnormal Diagnostics159
119823 — Fan Reversing Solenoid 2 Feedback Current High160
Fan Reversing Solenoid 2 Feedback Current High Diagnostics160
119824 — Fan Reversing Solenoid 2 Feedback Current Low161
Fan Reversing Solenoid 2 Feedback Current Low Diagnostics161
119832 — Intake Air Temperature Receive Error162
Intake Air Temperature Receive Error Diagnostics162
119842 — Boost Temperature Receive Error162
Abnormal Exhaust Filter Diagnostics163
119852 — Pump Control Valve Solenoid 2 Learning Failure163
Pump Control Valve Solenoid 2 Learning Failure Diagnostics163
119862 — Pump Control Valve Solenoid 1 Learning Failure164
Pump Control Valve Solenoid 1 Learning Failure Diagnostics164
119892 — Boom Overload Relief Solenoid Feedback Current Abnormal165
Boom Overload Relief Solenoid Feedback Current Abnormal Diagnostics165
119893 — Boom Overload Relief Solenoid Feedback Current High166
Boom Overload Relief Solenoid Feedback Current High Diagnostics166
119894 — Boom Overload Relief Solenoid Feedback Current Low167
Boom Overload Relief Solenoid Feedback Current Low Diagnostics167
119903 — Counterweight Lever Pressure Sensor Circuit Voltage High168
Counterweight Lever Pressure Sensor Circuit Voltage High Diagnostics168
119904 — Counterweight Lever Pressure Sensor Circuit Voltage Low169
Counterweight Lever Pressure Sensor Circuit Voltage 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 pressure sensor is abnormal (P2456)183
813 — Exhaust Filter Differential Pressure Sensor Circuit High Input (P2455)183
814 — Exhaust Filter Differential Pressure Sensor Circuit Low Input (P2454)183
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 Exhaust Air Temperature Sensor 1 (DPF Inlet) (P0426)187
1733 — Exhaust Temperature Sensor 1 Circuit High Input (DPF Inlet) (P0428)188
1734 — Exhaust Temperature Sensor 1 Circuit Low Input (DPF Inlet) (P0427)188
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) (P0093)191
123917 — Pressure Decline in Common Rail (Lack of Pumping Pressure) (P1093)191
13473 — SCV Drive Circuit + Short Circuit B (P0092)191
13474 — SCV Drive Circuit Open or Short Circuited to GND (P0091)191
13813 — Fuel Filter Restriction Sensor Circuit High Input (P1294)192
13814 — Fuel Filter Restriction Sensor Circuit Low Input (P1293)192
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 (P0123)194
100224 — Intake Throttle Position Sensor Circuit Low Input (P0122)194
100232 — Abnormal CAN VGT Time-out/ISO-CAN VGT Communication Error (U0110)194
1002312 — Abnormal VGT Turbo (P0045)195
1002319 — VGT Communication Error (U0411)195
100243 — Exhaust Temperature Sensor 2 Circuit High Input (DOC Inlet) (P042D)195
100244 — Exhaust Temperature Sensor 2 Circuit Low Input (DOC Inlet) (P042C)195
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 Outlet) (P042B)196
100290 — Over Frequent Exhaust Filter Regeneration Time-Out (P2458)196
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
130022 — ECU Communication Error197
130032 — Main Controller (MCZ) Communication Error 1197
130042 — Main Controller (MCZ) Communication Error 2197
130052 — Monitor Controller (DSZ) Communication Error 1197
130062 — Monitor Controller (DSZ) Communication Error 2197
130072 — Machine Controller (BCZ) Communication Error197
133113 — Fuel Level Sensor Open Circuit197
Fuel Level Sensor Open Circuit Diagnostic Procedure197
133114 — Fuel Level Sensor Shorted Circuit198
Fuel Level Sensor Shorted Circuit Diagnostic Procedure198
140012 — Flash Memory Read/Write Error199
Data Converter Diagnostics199
140022 — External RAM Read/Write Error200
Data Converter Diagnostics200
140032 — Abnormal EEPROM200
Data Converter Diagnostics200
140062 — Communication Terminal : Communication Error200
Communication Terminal : Communication Error200
140082 — Abnormal Internal RAM201
Data Converter Diagnostics201
140212 — Communication Terminal Security Error202
140222 — SIM Card Error202
140232 — Security Error202
201012 — Engine Warning Alarm202
201022 — Engine Oil Pressure Alarm202
201032 — Alternator Alarm202
Alternator Alarm202
201052 — Hydraulic Oil Filter Restriction Alarm203
Hydraulic Oil Filter Restriction Alarm203
201062 — Air Cleaner Restriction Alarm204
Air Cleaner Restriction Alarm204
201092 — Pilot Control Shutoff Lever Alarm205
Pilot Control Shutoff Lever Alarm205
201102 — Fuel Filter Restriction Alarm206
201132 — System Error Alarm206
201332 — Crane Function Alarm206
201372 — Exhaust Filter Alarm206
201412 — Exhaust Temperature Alarm206
201422 — Intake Air Temperature Alarm206
201452 — Boost Temperature Increase Alarm206
201462 — Fuel Temperature Increase Alarm206
201492 — EGR Gas Temperature Alarm207
Air Conditioner Controller (ACF) Diagnostic Trouble Codes209
Air Conditioner Controller (ACF) Diagnostic Trouble Codes209
11 — Open Circuit In Air Recirculation Sensor209
Harness Diagnostics209
12 — Short-Circuited Air Recirculation Sensor209
Harness Diagnostics209
13 — Open Circuit In Ambient Air Temperature Sensor210
Harness Diagnostics210
14 — Short-Circuited Ambient Air Temperature Sensor210
Harness Diagnostics210
18 — Short-Circuited Solar Radiation Sensor211
Harness Diagnostics211
21 — Open Circuit In Air Conditioner Freeze Control Switch211
Harness Diagnostics211
22 — Short-Circuited Air Conditioner Freeze Control Switch212
Harness Diagnostics212
43 — Abnormal Air Conditioner And Heater Blower Port Change Servomotor212
Harness Diagnostics212
44 — Abnormal Air Conditioner And Heater Mixer Servomotor213
Harness Diagnostics213
51 — Abnormal Air Conditioner High/Low Pressure Switch214
Harness Diagnostics214
91 — Communication Error215
Harness Diagnostics215
92 — CAN Bus Off Error215
Harness Diagnostics215
Operational Checkout Procedure217
Operational Checkout Procedure219
Operational Checkout219
Diagnostic Trouble Code Check219
Operational Checks—Key Switch Off, Engine Off Checks219
Operational Checks—Key Switch On, Engine Off Checks222
Operational Checks—Key Switch On, Engine On Checks234
Engine271
Theory of Operation273
Engine Identification273
Isuzu Engine273
Engine Fuel System Component Location274
Engine Cooling System Component Location277
Cold Weather Starting Aid278
Engine Speed Control System Operation280
Diagnostic Information283
Isuzu Engine283
Adjustments285
Isuzu Engines285
Tests287
Isuzu Engine287
Electrical System291
System Information293
Electrical Diagram Information293
System Diagrams301
Explanation of Wire Markings301
Fuse and Relay Specifications301
System Functional Schematic, Component Location, and Wiring Diagram Master Legend304
System Functional Schematic309
Cab Harness (W1) Component Location349
Cab Harness (W1) Wiring Diagram351
Machine Harness (W2) Component Location364
Machine Harness (W2) Wiring Diagram365
Monitor Harness (W3) Component Location374
Monitor Harness (W3) Wiring Diagram376
Engine Harness (W4) Component Location378
Engine Harness (W4) Wiring Diagram380
Engine Sub Harness (W6) Component Location384
Engine Sub Harness (W6) Wiring Diagram385
Pump Harness (W8) Component Location389
Pump Harness (W8) Wiring Diagram393
Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location395
Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram395
Pilot Shutoff Switch Harness (W11) Component Location396
Pilot Shutoff Switch Harness (W11) Wiring Diagram397
Exhaust Filter Harness (W12) Component Location400
Exhaust Filter Harness (W12) Wiring Diagram402
Auxiliary Fuse Box Harness (W13) Component Location404
Auxiliary Fuse Box Harness (W13) Wiring Diagram405
Heated Air Seat Harness (W14) Component Location408
Heated Air Seat Harness (W14) Wiring Diagram409
Travel Alarm Cancel Switch Harness (W16) Component Location409
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram410
Rear Camera Harness (W19) Component Location411
Rear Camera Harness (W19) Wiring Diagram411
9-Pin Service ADVISOR™ Connector (W20) Component Location412
9-Pin Service ADVISOR™ Connector (W20) Wiring Diagram413
Pilot Shutoff Valve Harness (W21) Component Location413
Pilot Shutoff Valve Harness (W21) Wiring Diagram414
Fan Reversing Switch Harness (W23) Component Location414
Fan Reversing Switch Harness (W23) Wiring Diagram415
Seat Heater Switch Harness (W24) Component Location415
Seat Heater Switch Harness (W24) Wiring Diagram416
Optional Switch Harness (W25) Component Location416
Optional Switch Harness (W25) Wiring Diagram417
Starter Switch Harness (W29) Component Location417
Starter Switch Harness (W29) Wiring Diagram418
Oil Cooler Harness (W31) Component Location419
Oil Cooler Harness (W31) Wiring Diagram422
Heater and Air Conditioner Harness (W41) Component Location423
Heater and Air Conditioner Harness (W41) Wiring Diagram425
12 Volt Power Converter Harness (W42) Component Location427
12 Volt Power Converter Harness (W42) Wiring Diagram428
Control Valve Harness (W43) Component Location429
Control Valve Harness (W43) Wiring Diagram431
Data Converter CAN Harness (W44) Component Location433
Data Converter CAN Harness (W44) Wiring Diagram434
Data Converter Harness (W45) Component Location434
Data Converter Harness (W45) Wiring Diagram435
Counterweight Removal or Install Switch (W46) Component Location436
Counterweight Removal or Install Switch (W46) Wiring Diagram437
Boom Switch Harness (W47) Component Location438
Boom Switch Harness (W47) Wiring Diagram439
Cab Light Relay Harness (W48) Component Location440
Cab Light Relay Harness (W48) Wiring Diagram441
Cab Light Harness (W49) Component Location442
Cab Light Harness (W49) Wiring Diagram443
Satellite (SAT) Harness (W6003) Component Location—If Equipped444
Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped445
JDLink™ Harness (W6004) Component Location445
JDLink™ Harness (W6004) Wiring Diagram447
Sub-System Diagnostics451
Controller Area Network (CAN) Theory of Operation451
Starting and Charging Circuit Theory of Operation455
Monitor Controller (DSZ) Circuit Theory of Operation461
Engine Control Unit (ECU) Circuit Theory of Operation469
Travel Alarm Circuit Theory of Operation478
Machine Controller (BCZ) Circuit Theory of Operation479
Exhaust Aftertreatment Circuit Theory of Operation480
Main Controller (MCZ) Circuit Theory of Operation483
Windshield Wiper and Washer Circuit Theory of Operation503
Lighting Circuit Theory of Operation507
Pilot Shutoff Circuit Theory of Operation511
Monitor Operation515
Service Menu515
Troubleshooting515
Monitoring516
Controller Version520
Issued Warning Record520
Operation521
Machine Setting522
Monitor Setting525
Exhaust Filter526
References527
Reading Diagnostic Trouble Codes with Monitor Display527
Service ADVISOR™ Diagnostic Application527
Service ADVISOR™ Connection Procedure528
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application529
Clearing Engine Diagnostic Trouble Codes531
MPDr Application543
MPDr Connection Procedure544
Pump Learning Procedure545
Fuse Test548
Relay Test551
Pressure Sensor Test552
Solenoid Test553
Proportional Solenoid Test553
Temperature Sensor Test554
Alternator Test555
Electrical Component Checks557
Component Checks557
Battery Remove and Install563
Rear Cover Remove and Install565
Main Controller (MCZ) Remove and Install566
Engine Control Unit (ECU) Remove and Install567
Exhaust Differential Pressure Sensor Zero Point Calibration568
Machine Controller (BCZ) Remove and Install569
Data Converter Remove and Install570
Monitor Controller (DSZ) Remove and Install571
Air Conditioner Controller (ACF) Remove and Install572
Key Switch Remove and Install572
Right Switch Console Remove and Install573
Left Switch Console Remove and Install575
Travel Alarm Remove and Install576
Disconnect Tab Retainer Connectors577
Disconnecting Spring Wire Clip Connectors577
Replace DEUTSCHDEUTSCH is a trademark of the Deutsch Co™ Connectors578
Replace DEUTSCHDEUTSCH is a trademark of Deutsch Co™ Rectangular or Triangular Connectors579
Install DEUTSCHDEUTSCH is a trademark of the Deutsch Co™ Contact580
Replace WEATHER PACKWEATHER PACK is a trademark of Packard Electric™Connector581
Install WEATHER PACKWEATHER PACK is a trademark of Packard Electric™Contact582
Replace (Pull Type) Metri-Pack™ Connectors583
Replace (Push Type) Metri-Pack™ Connectors584
Replace CINCHCINCH is a trademark of the Cinch Co™ Connectors584
Install CINCHCINCH is a trademark of the Cinch Co™ Contact586
Repair 32 and 48 Way CINCHCINCH is a trademark of the Cinch Co™ Connectors587
Remove Connector Body from Blade Terminals589
Power Train591
Theory of Operation593
Track Adjuster and Recoil Spring Operation593
Travel Gearbox Operation594
Diagnostic Information597
Noisy or Loose Track Chain597
Noisy or Loose Track Chain Diagnostic Procedure597
Tight Track Chain597
Tight Track Chain Diagnostic Procedure597
Frequent Track Chain Sag Adjustment Required598
Frequent Track Chain Sag Adjustment Required Diagnostic Procedure598
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers598
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure598
Bent Track Shoes598
Bent Track Shoes Diagnostic Procedure598
“Popping” of Track599
“Popping” of Track Diagnostic Procedure599
Cracked Track Link599
Cracked Track Link Diagnostic Procedure599
Chipped Link Rails600
Chipped Link Rails Diagnostic Procedure600
Individual Undercarriage Component Wear601
Individual Undercarriage Component Wear Diagnostic Procedure601
Measure Swing Bearing Wear602
Hydraulic System607
Theory of Operation609
Hydraulic System Operation609
Fan Drive Hydraulic System Operation610
Pilot System Operation611
Pilot Pump, Pressure Regulating Valve and Filter Operation612
Pilot Shutoff Solenoid Valve Operation613
Pilot Control Valve Operation616
Travel Pilot Control Valve Operation618
Boom Up Shockless Valve Operation620
Pilot Operation of Control Valve Operation623
Pilot Signal Manifold Operation626
Pump 1, Pump 2, and Fan Drive Gear Case Operation635
Pump 1, Pump 2, Regulator Operation636
Fan Drive Pump Regulator Operation642
Engine Speed Sensing Control Circuit Operation646
Control Valve Operation648
Control Valve Check Valves Identification and Operation657
Main Relief Valve Circuit Operation662
Circuit Relief and Anticavitation Valve Operation667
Travel Flow Combiner Valve Circuit Operation668
Boom Lower Meter-In Cut Valve Operation671
Boom Regenerative Valve Circuit Operation675
Arm Regenerative Valve Circuit Operation678
Bucket Regenerative Valve Circuit Operation683
Boom and Arm Reduced Leakage Valves Operation686
Arm 1 Flow Rate Control Valve Circuit Operation689
Arm 2 Flow Rate Control Valve Circuit Operation693
Boom Flow Rate Control Valve Circuit Operation697
Auxiliary Flow Rate Control Valve Circuit Operation701
Swing Gear Case Operation701
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation702
Swing Motor Park Brake Release Circuit Operation705
Center Joint Operation706
Travel Motor and Park Brake Circuit Operation707
Travel Motor Speed Circuit Operation709
Counterweight Removal Circuit Operation712
Counterweight Removal Cylinder Operation717
Boom, Arm, and Bucket Cylinder Operation718
Return Filter Operation719
Diagnostic Information721
All Hydraulic Functions Slow721
All Hydraulic Functions Slow Diagnostic Procedure721
Hydraulic Oil Overheats723
Hydraulic Oil Overheats Diagnostic Procedure723
No Hydraulic Functions726
No Hydraulic Functions Diagnostic Procedure726
Poor Combined Operation728
Poor Combined Operation Diagnostic Procedure728
Function Does Not Stop When Control Lever Released729
Function Does Not Stop When Control Lever Released Diagnostic Procedure729
Some Functions Slow or Cannot Be Operated, All Others Are Normal730
Some Functions Cannot Be Operated, All Others Are Normal Diagnostic Procedure731
Functions Move in Opposite Direction732
Functions Move in Opposite Direction732
All Dig Functions Slow or No Power732
All Dig Functions Slow or No Power732
Some Dig Functions Slow (Not All)733
Some Dig Functions Slow (Not All)733
Load Drifts Down When Control Lever is in Neutral Position734
Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure734
Load Falls When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle736
Load Falls When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle Diagnostic Procedure736
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal737
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure737
Swing Speed Slow in Both Directions or Does Not Operate738
Swing Speed Slow in Both Directions Diagnostic Procedure738
Swing Speed Slow or Does Not Operate in One Direction740
Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure740
Upperstructure Drift with Swing Valve in Neutral741
Upperstructure Drift with Swing Valve in Neutral Diagnostic Procedure741
Travel Park Brakes Do Not Apply742
Travel Park Brakes Do Not Apply Diagnostic Procedure742
Track Will Not Move in One Direction742
Track Will Not Move in One Direction Diagnostic Procedure742
Track Will Not Move in Either Direction744
Track Will Not Move in Either Direction Diagnostic Procedure744
Machine Mistracks at All Speeds in Both Directions745
Machine Mistracks at All Speeds in Both Directions Diagnostic Procedure745
Slow Travel Speed or Low Power747
Slow Travel Speed or Low Power Diagnostic Procedure747
Combined Travel and Dig Functions Slow or No Power748
Combined Travel and Dig Functions Slow or No Power Diagnostic Procedure748
Travel is “Jerky”749
Travel is “Jerky” Diagnostic Procedure749
Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline750
Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline Diagnostic Procedure750
Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs751
Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs Diagnostic Procedure751
Pump 1, Pump 2, Fan Drive Pump, and Pilot Pump Line Identification753
Control Valve Line Identification755
Swing Motor Line Identification757
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern759
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern763
Pilot Signal Manifold-to-Control Valve Line Connection766
Travel Hydraulic System Component Location770
Travel Hydraulic System Line Connection773
Hydraulic System Schematic777
Hydraulic System Component Location798
Hydraulic System Line Connections801
Fan Drive Hydraulic System Schematic804
Fan Drive Hydraulic System Component Location807
Tests809
JT05800 Digital Thermometer Installation809
JT02156A Digital Pressure and Temperature Analyzer Kit Installation809
Hydraulic Oil Cleanup Procedure810
Hydraulic Oil Tank Pressure Release Procedure811
Hydraulic Oil Warm-Up Procedure812
Pilot Pressure Regulating Valve Test and Adjustment814
Control Valve Spool Actuating Pilot Pressure Test816
Travel Speed Solenoid Valve (port SC) Test and Adjustment818
Exhaust Filter Regulator Solenoid Valve (port SF) Test and Adjustment821
Power Dig Solenoid Valve (port SI) Test and Adjustment824
Arm Flow Rate Control Solenoid Valve (port SG) Test and Adjustment827
Boom Overload Relief Solenoid Valve (port SC) Test and Adjustment830
Swing Flow Rate Solenoid Valve (port SI) Test and Adjustment832
Main Relief and Power Dig Valve Test and Adjustment834
Circuit Relief Valve Test and Adjustment837
Boom Mode Relief Valve Test and Adjustment840
Pump Servo Piston Minimum Flow Test and Adjustment842
Pump Servo Piston Maximum Flow Test and Adjustment844
Pump Flow Rate (Displacement) Test and Adjustment845
Travel Motor Crossover Relief Valve Test and Adjustment846
Swing Motor Crossover Relief Valve Test and Adjustment849
Swing Motor Leakage Test851
Travel Motor Leakage Test853
Cylinder Drift Test—Boom, Arm, and Bucket854
Pump Flow Test855
Fan Speed Test858
Fan Motor Case Drain Test859
Fan Drive Pump Flow Test861
Fan Drive System Relief Valve Test and Adjustment863
Fan Drive Pump Servo Piston Minimum Flow Test and Adjustment865
Fan Drive Pump Servo Piston Maximum Flow Test and Adjustment866
Fan Drive Pump Flow Rate Test and Adjustment867
Heating and Air Conditioning869
Theory of Operation871
Air Conditioning System Cycle of Operation871
Diagnostic Information873
No Air Flow From Heater and Air Conditioner Vents873
No Air Flow From Heater and Air Conditioner Vents Diagnostic Procedure873
Air Conditioning System Does Not Operate875
Air Conditioning System Does Not Operate Diagnostic Procedure875
Air Conditioning Does Not Cool Interior of Cab876
Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure876
Air Conditioning Runs Constantly, Too Cold878
Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure878
Interior Windows Continue to Fog Using Air Conditioner879
Interior Windows Continue to Fog Using Air Conditioner Diagnostics Procedure879
Heater System Does Not Operate880
Heater System Does Not Operate Diagnostic Procedure880
Heater Does Not Warm Interior of Cab881
Heater Does Not Warm Interior of Cab Diagnostic Procedure881
Interior Windows Continue to Fog Using Heater882
Interior Windows Continue to Fog using Heater Diagnostic Procedure883
Heater and Air Conditioner Component Location884
Tests885
Refrigerant Cautions and Proper Handling885
Heater and Air Conditioner Operational Checks885
Visual Inspection of Components885
Air Conditioner Compressor Clutch Test887
Refrigerant Leak Test887
Refrigerant Hoses and Tubing Inspection887
Air Conditioner Compressor Belt Check and Adjustment887
Operating Pressure Diagnostic Chart888
Dealer Fabricated Tools889
Dealer Fabricated Tools891
DFT1218 Split Flange Hose Cap891
Page Number 5
Section 9000 7
Group 01 9
Section 9001 29
Group 10 31
Group 20183
Group 30197
Group 50209
Section 9005217
Group 10219
Section 9010271
Group 05273
Group 15283
Group 20285
Group 25287
Section 9015291
Group 05293
Group 10301
Group 15451
Group 16515
Group 20527
Section 9020591
Group 05593
Group 15597
Section 9025607
Group 05609
Group 15721
Group 25809
Section 9031869
Group 05871
Group 15873
Group 25885
Section 9900889
Group 99891

S.M 6/1/25