Complete diagnosis & test manual with Electrical Wiring Diagrams for John Deere 75G Excavator, with all the workshop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 75G Excavator technical manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM12873 - John Deere 75G Excavator Technical Manual (Operation & Test).pdf
TM12873 - John Deere 75G Excavator Technical Manual (Operation & Test).epub

Total Pages: 1,203 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

It is Original Illustrated Factory Diagnostics, Operation and Test Service Manual for John Deere FT4 Excavator 75G

This manual contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your truck. This document is printable, without restrictions, contains searchable text, bookmarks, crosslinks for easy navigation.

Covered models:
  75G (PIN: 1FF075GX__J015001-)

MAIN SECTIONS
   Foreword
   Technical Information Feedback Form
   General Information
      Safety
   Diagnostics
      Main Controller (MCZ) Diagnostic Trouble Codes
      Engine Control Unit (ECU) Diagnostic Trouble Codes
      Monitor Controller (DSZ) Diagnostic Trouble Codes
      Air Conditioner Controller (ACF) Diagnostic Trouble Codes
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      Monitor Operation
      References
   Power Train
      Theory of Operation
      Diagnostic Information
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Tests
   Heating and Air Conditioning
      Theory of Operation
      Diagnostic Information
      Tests

tm12873 - 75G Excavator

Table of Contents - Expanded View

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Control Pattern Selector—If Equipped

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Work In Ventilated Area

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Exhaust Filter Ash Handling and Disposal

Prepare for Emergencies

Clean Debris from Machine

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Inspect and Maintain ROPS

Avoid Machine Tip Over

Use Special Care When Lifting Objects

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Clean Exhaust Filter Safely

Section 9001: Diagnostics

Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Main Controller (MCZ) Diagnostic Trouble Codes

Controller Area Network 0 (CAN 0) Circuit Diagnostics

Controller Area Network 1 (CAN 1) Circuit Diagnostics

Interface Controller Area Network (N-CAN) Diagnostics

011000.02 - Abnormal EEPROM

011001.02 - Abnormal RAM

011002.02 - Abnormal A/D Converter

011003.03 - Abnormal Sensor Voltage

011006.02 - Engine Controller Communication Error

011007.02 - (CAN 0) Data Converter Communication Error 1

011008.02 - (CAN 1) Data Converter Communication Error 2

011009.02 - (CAN 0) Monitor Controller Communication Error 1

011010.02 - (CAN 1) Monitor Controller Communication Error 2

011100.02 - Abnormal Engine Speed

011101.03 - Engine Control Dial Sensor Circuit High Input

011101.04 - Engine Control Dial Sensor Circuit Low Input

011304.03 - Travel Pilot Pressure Sensor Circuit High Input

011304.04 - Travel Pilot Pressure Sensor Circuit Low Input

011307.03 - Front Pilot Pressure Sensor Circuit High Input

011307.04 - Front Pilot Pressure Sensor Circuit Low Input

011401.02 - Torque Pressure Solenoid Valve Abnormal Feedback

011401.03 - Torque Pressure Solenoid Valve Feedback High Current

011401.04 - Torque Pressure Solenoid Valve Feedback Low Current

011407.02 - Travel Mode Selector Solenoid Valve Abnormal Feedback

011407.03 - Travel Mode Selector Solenoid Valve Feedback High Current

011407.04 - Travel Mode Selector Solenoid Valve Feedback Low Current

011408.02 - 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback

011408.03 - 2-Spool Solenoid Valve Unit (SJ) Feedback High Input

011408.04 - 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input

011409.02 - 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback

011409.03 - 2-Spool Solenoid Valve Unit (SZ) Feedback High Input

011409.04 - 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input

011434.02 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback

011434.03 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current

011434.04 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current

011435.02 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback

011435.03 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current

011435.04 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current

011436.02 - Breaker Relief Proportional Solenoid Valve Abnormal Feedback

011436.03 - Breaker Relief Proportional Solenoid Valve Feedback High Current

011436.04 - Breaker Relief Proportional Solenoid Valve Feedback Low Current

011458.02 - (Auxiliary) Discontinuity of Selector Valve

011459.02 - Discontinuity of Auto Shut-Down Control Power Line

011810.03 - Electric Lever Operating Pressure Sensor 1 High Voltage

011810.04 - Electric Lever Operating Pressure Sensor 1 Low Voltage

011811.03 - Electric Lever Operating Pressure Sensor 2 High Voltage

011811.04 - Electric Lever Operating Pressure Sensor 2 Low Voltage

011812.02 - OPT Electric Lever 1 Neutral Abnormal

011813.02 - OPT Electric Lever 1 Abnormal Operation

011814.02 - OPT Electric Lever 2 Neutral Abnormal

011815.02 - OPT Electric Lever 2 Abnormal Operation

011816.02 - OPT Solenoid 1 Feedback Abnormal

011816.03 - OPT Solenoid 1 Feedback Current High

011816.04 - OPT Solenoid 1 Feedback Current Low

011817.02 - OPT Solenoid 2 Feedback Abnormal

011817.03 - OPT Solenoid 2 Feedback Current High

011817.04 - OPT Solenoid 2 Feedback Current Low

011818.02 - OPT Solenoid 3 Feedback Abnormal

011818.03 - OPT Solenoid 3 Feedback Current High

011818.04 - OPT Solenoid 3 Feedback Current Low

011819.02 - OPT Solenoid 4 Feedback Abnormal

011819.03 - OPT Solenoid 4 Feedback Current High

011819.04 - OPT Solenoid 4 Feedback Current Low

015011.03 - Hydraulic Oil Temperature Sensor Circuit High Input (Pilot)

015011.04 - Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)

015016.03 - Right Analog Stroke Sensor Circuit High Input

015016.04 - Right Analog Stroke Sensor Circuit Low Input

015017.03 - Left Analog Stroke Sensor Circuit High Input

015017.04 - Left Analog Stroke Sensor Circuit Low Input

020010.02 - Exhaust Filter Alarm

020011.02 - Electric Lever Alarm

020012.02 - Line Filter Restriction Alarm

020303.02 - Electric Lever Pilot Cut Alarm

Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

000051.03 - Intake Throttle Opening Sensor Fault (High Voltage) (P02E9) (00033-03)

000051.04 - Intake Throttle Opening Sensor Fault (Low Voltage) (P02E8) (00033-04)

000091.03 - Acceleration Sensor 1 Fault (High Voltage) (P0123) (0005B-03)

000091.04 - Acceleration Sensor 1 Fault (Low Voltage) (P0122) (0005B-04)

000100.01 - Low Oil Pressure Fault Alarm (P1198) (00064-01)

000100.04 - Oil Pressure Switch Open Circuit (P1192) (00064-04)

000102.03 - Exhaust Gas Recirculation (EGR) Low Pressure Side Sensor Fault (High Voltage) (P0238) (00066-03)

000102.04 - Exhaust Gas Recirculation (EGR) Low Pressure Side Sensor Fault (Low Voltage) (P0237) (00066-04)

000105.03 - Intake Air Temperature Sensor Fault (High Voltage) (P040D) (00069-03)

000105.04 - Intake Air Temperature Sensor Fault (Low Voltage) (P040C) (00069-04)

000108.03 - Atmospheric Pressure Sensor Fault (High Voltage) (P2229) (0006C-03)

000108.04 - Atmospheric Pressure Sensor Fault (Low Voltage) (P2228) (0006C-04)

000108.10 - Atmospheric Pressure Sensor Characteristic Fault (P1231) (0006C-0A)

000110.00 - Cooling Water Temperature Sensor Temperature Abnormal High (Overheat) (P0217) (0006E-00)

000110.03 - Cooling Water Temperature Sensor Fault (High Voltage) (P0118) (0006E-03)

000110.04 - Cooling Water Temperature Sensor Fault (Low Voltage) (P0117) (0006E-04)

000157.00 - Actual Rail Pressure Rise Error (P0088) (0009D-00)

000157.03 - Rail Pressure Sensor Fault (High Voltage) (P0193) (0009D-03)

000157.04 - Rail Pressure Sensor Fault (Low Voltage) (P0192) (0009D-04)

000157.15 - Rail Pressure Deviation Error During the Actual Rail Pressure Rise (P0093) (0009D-0F)

000157.16 - Pressure Limit Valve (PLV) Open Valve (P000F) (0009D-10)

000157.18 - Rail Pressure Deviation Error During the Actual Rail Pressure Drop (P0094) (0009D-12)

000167.01 - Charge Alarm (P1568) (000A7-01)

000167.05 - Charge Switch Open Circuit (P1562) (000A7-05)

000172.03 - New Air Temperature Sensor Fault (High Voltage) (P0113) (000AC-03)

000172.04 - New Air Temperature Sensor Fault (Low Voltage) (P0112) (000AC-04)

000173.03 - Exhaust Air Temperature Sensor Fault (High Voltage) (P0546) (000AD-03)

000173.04 - Exhaust Air Temperature Sensor Fault (Low Voltage) (P0545) (000AD-04)

000174.00 - Fuel Temperature Sensor Temperature Abnormal High (P0168) (000AE-00)

000174.03 - Fuel Temperature Sensor Fault (High Voltage) (P0183) (000AE-03)

000174.04 - Fuel Temperature Sensor Fault (Low Voltage) (P0182) (000AE-04)

000190.00 - Overspeed (P0219) (000BE-00)

000412.03 - Exhaust Gas Recirculation (EGR) Gas Temperature Sensor Fault (High Voltage) (P041D) (0019C-03)

000412.04 - Exhaust Gas Recirculation (EGR) Gas Temperature Sensor Fault (Low Voltage) (P041C) (0019C-04)

000630.12 - EEPROM Memory Deletion Error (P0601) (00276-0C)

000633.05 - High Pressure Pump Drive Circuit (Open Circuit) (P0627) (00279-05)

000633.06 - High Pressure Pump Drive Circuit (High Side Ground Short Circuit) (P1642) (00279-06)

000651.03 - Injector 1 Short Circuit (4TNV) (P1271) (0028B-03)

000651.05 - Injector 1 Open Circuit (Inherent Location of the Injector) (4TNV) (P0204) (0028B-05)

000651.06 - Injector 1 Coil Short Circuit (4TNV) (P0271) (0028B-06)

000651.11 - Injector 1 Unclassified (4TNV) (P1272) (0028B-0B)

000652.03 - Injector 4 Short Circuit (P1268) (0028C-03)

000652.05 - Injector 4 Open Circuit (Inherent Location of the Injector) (P0203) (0028C-05)

000652.06 - Injector 4 Coil Short Circuit (P0268) (0028C-06)

000652.11 - Injector 4 Unclassified (P1269) (0028C-0B)

000653.03 - Injector 2 Short Circuit (P1265) (0028D-03)

000653.05 - Injector 2 Open Circuit (Inherent Location of the Injector) (P0202) (0028D-05)

000653.06 - Injector 2 Coil Short Circuit (P0265) (0028D-06)

000653.11 - Injector 2 Unclassified (P1266) (0028D-0B)

000654.03 - Injector 3 Short Circuit (P1262) (0028E-03)

000654.05 - Injector 3 Open Circuit (Inherent Location of the Injector) (P0201) (0028E-05)

000654.06 - Injector 3 Coil Short Circuit (P0262) (0028E-06)

000654.11 - Injector 3 Unclassified (P1263) (0028E-0B)

001209.03 - Exhaust Gas Recirculation (EGR) High Pressure Side Sensor Fault (High Voltage) (P0473) (004B9-03)

001209.04 - Exhaust Gas Recirculation (EGR) High Pressure Side Sensor Fault (Low Voltage) (P0472) (004B9-04)

001485.02 - Power Off Without Main Relay Self Holding (P068A) (005CD-02)

001485.07 - Main Relay Contact Stuck (P068B) (005CD-07)

002791.00 - Exhaust Gas Recirculation (EGR) High Voltage Malfunction (P0404) (00AE7-00)

002791.01 - Exhaust Gas Recirculation (EGR) Low Voltage Malfunction (P0404) (00AE7-01)

002791.01 - Exhaust Gas Recirculation (EGR) Low Voltage Malfunction (P1404) (00AE7-01)

002791.07 - Exhaust Gas Recirculation (EGR) Feedback Malfunction (P1409) (00AE7-07)

002791.09 - EGRECM Data Fault (U0401) (00AE7-09)

002791.12 - Open Circuit Between The Exhaust Gas Recirculation (EGR) Motor Coils (P0403) (00AE7-0C)

002797.06 - Injector Drive Circuit (Bank1) Short Circuit (P1146) (00AED-06)

002798.06 - Injector Drive Circuit (Bank 2) Short Circuit (4TN: Circuit For No. 2 And No. 3 Cylinders) (P1149) (00AEE-06)

002950.03 - Power Short Circuit of Throttle Valve Drive H Bridge Output 1 (P1658) (00B86-03)

002950.04 - Ground Short Circuit of Throttle Valve Drive H Bridge Output 1 (P1659) (00B86-04)

002950.05 - No Load of Throttle Valve Drive H Bridge Circuit (P0660) (00B86-05)

002951.03 - Power Short Circuit of Throttle Valve Drive H Bridge Output 2 (P1661) (00B87-03)

002951.04 - Ground Short Circuit of Throttle Valve Drive H Bridge Output 2 (P1662) (00B87-04)

003242.00 - DPF Inlet Temperature Sensor Temperature Abnormal High (P1436) (00CAA-00)

003242.03 - DPF Inlet Temperature Sensor Fault (High Voltage) (P1428) (00CAA-03)

003242.04 - DPF Inlet Temperature Sensor Fault (Low Voltage) (P1427) (00CAA-04)

003250.00 - DPF Intermediate Temperature Sensor Temperature Abnormal High (Post-Injection Error) (P1426) (00CB2-00)

003250.01 - DPF Intermediate Temperature Sensor Temperature Abnormal Low Temperature (P0420) (00CB2-01)

003250.03 - DPF Intermediate Temperature Sensor Fault (High Voltage) (P1434) (00CB2-03)

003250.04 - DPF Intermediate Temperature Sensor Fault (Low Voltage) (P1435) (00CB2-04)

003251.00 - DPF Differential Pressure Sensor Differential Pressure Abnormal High (P2452) (00CB3-00)

003251.03 - DPF Differential Pressure Sensor Fault (High Voltage) (P2455) (00CB3-03)

003251.04 - DPF Differential Pressure Sensor Fault (Low Voltage) (P2454) (00CB3-04)

003251.16 - Maintenance (Maintenance Not Performed For A Given Period of Time) (P1437) (00CB3-10)

003609.03 - DPF High Pressure Side Sensor Fault (High Voltage) (P1455) (00E19-03)

003609.04 - DPF High Pressure Side Sensor Fault (Low Voltage) (P1454) (00E19-04)

003719.00 - Backup Mode (P1424) (00E87-00)

003719.16 - Stationary Regeneration Standby (P1421) (00E87-10)

003720.00 - Ash Cleaning Request 2 (P1420) (00E88-00)

003720.16 - Ash Cleaning Request 1 (P242F) (00E88-10)

004257.12 - Injector Drive IC Error (P0611) (010A1-0C)

522243.05 - Start Assist Relay Interrupted (P0543) (7F803-05)

522243.06 - Startup Assist Relay Ground Interrupted (P0541) (7F803-06)

522323.00 - Air Cleaner Clogged Alarm (P1101) (7F853-00)

522329.00 - Oil/Water Separator Alarm (P1151) (7F859-00)

522400.02 - Crank Speed Sensor (P0336) (7F8A0-02)

522400.05 - No Crank Signal (P0337) (7F8A0-05)

522401.02 - Cam Signal Malfunction (P0341) (7F8A1-02)

522401.05 - No Cam Signal (P0342) (7F8A1-05)

522401.07 - Angle Offset Error (P1341) (7F8A1-07)

522571.03 - SCV (MPROP) High Pressure Pump Drive Circuit (Low Side VB Short Circuit) (P1641) (7F94B-03)

522571.06 - SCV (MPROP) High Pressure Pump Drive Circuit (Low Side Ground Short Circuit) (P1643) (7F94B-06)

522573.00 - Overaccumulation (Method C) (P2463) (7F94D-00)

522574.00 - Overaccumulation (Method P) (P1463) (7F94E-00)

522575.07 - Regeneration Defect (Stationary Regeneration Error) (P2458) (7F94F-07)

522577.11 - Regeneration Defect (Stationary Regeneration Not Performed) (P2459) (7F951-0B)

522596.09 - TSC1 Reception Time Out Error (SA1) (U0292) (7F964-09)

522597.09 - TSC1 Reception Time Out Error (U1301) (7F965-09)

522599.09 - Y_ECR1 Reception Time Out Error (U1292) (7F967-09)

522600.09 - Y_EC Reception Time Out Error (U1293) (7F968-09)

522609.09 - Y_ETCP1 Reception Time Out Error (U1300) (7F971-09)

522610.09 - CAN1 (For EGR) Reception Time Out Error (U010B) (7F972-09)

522610.19 - CAN1 (For EGR) Reception Data Length Error (U040C) (7F972-13)

522619.09 - Y_DPFIF Reception Time Out (U1303) (7F97B-09)

522994.03 - Actuator Drive Circuit 1 VB Short Circuit (P160A) (7FAF2-03)

522994.04 - Actuator Drive Circuit 1 Ground Short Circuit (P1626) (7FAF2-04)

522994.11 - SW Reset (Recovery) Execution 1 (P160B) (7FAF2-0B)

522994.12 - WDA/ABE Communication Error (P1607) (7FAF2-0C)

523249.05 - No Signal on Both Crank and Cam Speed Sensor (P0008) (7FBF1-05)

523489.00 - Rail Pressure Error (The Actual Rail Pressure is Too High During PRV Limp Home) (P1668) (7FCE1-00)

Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Monitor Controller (DSZ) Diagnostic Trouble Codes

013000.02 - Flash Memory Error 1

013001.02 - Flash Memory Error 2

013002.02 - ECU Communication Error

013003.02 - Main Controller (MCZ) Communication Error 1

013004.02 - Main Controller (MCZ) Communication Error 2

013005.02 - Monitor Controller (DSZ) Communication Error 1

013006.02 - Monitor Controller (DSZ) Communication Error 2

013007.02 - Machine Controller (BCZ) Communication Error

013303.02 - Abnormal Monitor Internal Temperature Sensor

013304.02 - Alternator Alarm

013310.03 - Shorted Circuit in Coolant Temperature Sensor

013311.03 - Fuel Level Sensor Open Circuit

013311.04 - Fuel Level Sensor Shorted Circuit

014001.02 - Flash Memory Read/Write Error

014002.02 - External RAM Read/Write Error

014003.02 - Abnormal EEPROM

014006.02 - Communication Terminal: Communication Error

014008.02 - Abnormal Internal RAM

014021.02 - Communication Terminal Security Error

014022.02 - SIM Card Error

014023.02 - Security Error

020100.02 - Overheat Alarm

020101.02 - Engine Warning Alarm

020102.02 - Engine Oil Pressure Alarm

020105.02 - Hydraulic Oil Filter Restriction Alarm

020106.02 - Air Cleaner Restriction Alarm

020107.02 - Water Separator Alarm

020109.02 - Pilot Control Shut-Off Lever Alarm

020110.02 - Fuel Filter Restriction Alarm

020113.02 - System Error Alarm

020114.02 - Overheat Alarm

020133.02 - Crane Function Alarm

020137.02 - Exhaust Filter Alarm

020141.02 - Muffler Temperature Alarm

020142.02 - Intake Air Temperature Alarm

020145.02 - Boost Temperature Increase Alarm

020146.02 - Fuel Temperature Increase Alarm

020149.02 - EGR Gas Temperature Alarm

Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Air Conditioner Controller (ACF) Diagnostic Trouble Codes

11 - Open Circuit in Air Recirculation Sensor

12 - Short-Circuited Air Recirculation Sensor

13 - Open Circuit in Ambient Air Temperature Sensor

14 - Short-Circuited Ambient Air Temperature Sensor

18 - Short-Circuited Solar Radiation Sensor

21 - Open Circuit in Air Conditioner Freeze Control Switch

22 - Short-Circuited Air Conditioner Freeze Control Switch

43 - Abnormal Air Conditioner and Heater Blower Port Change Servomotor

44 - Abnormal Air Conditioner and Heater Mixer Servomotor

51 - Abnormal High/Low Refrigerant Pressure

91 - Communication Error

92 - CAN Bus Off Error

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Yanmar Engine

Engine Fuel System Component Location

Engine Cooling System Component Location

Cold Weather Starting Aid

Engine Speed Control System Operation

Group 15: Diagnostic Information

Yanmar Engine

Group 20: Adjustments

Yanmar Engine

Group 25: Tests

Yanmar Engine

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Explanation of Wire Markings

Fuse and Relay Specifications

System Functional Schematic, Component Location, and Wiring Diagram Master Legend

System Functional Schematic

Cab Harness (W1) Component Location

Cab Harness (W1) Wiring Diagram

Machine Harness (W2) Component Location

Machine Harness (W2) Wiring Diagram

Monitor Harness (W3) Component Location

Monitor Harness (W3) Wiring Diagram

Engine Harness (W4) Component Location

Engine Harness (W4) Wiring Diagram

Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location

Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram

Pilot Shutoff Switch Harness (W11) Component Location

Pilot Shutoff Switch Harness (W11) Wiring Diagram

Auxiliary Fuse Box Harness (W13) Component Location

Auxiliary Fuse Box Harness (W13) Wiring Diagram

Multi-Function Pilot Control Lever Harness (W15) Component Location

Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram

Travel Alarm Cancel Switch Harness (W16) Component Location

Travel Alarm Cancel Switch Harness (W16) Wiring Diagram

Rear Camera Harness (W19) Component Location

Rear Camera Harness (W19) Wiring Diagram

9-Pin Service ADVISOR™ Connector (W20) Component Location

9-Pin Service ADVISOR™ Connector (W20) Wiring Diagram

Pilot Shutoff Valve Harness (W21) Component Location

Pilot Shutoff Valve Harness (W21) Wiring Diagram

Auxiliary 3-Button Cancel Switch Harness (W22) Component Location

Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram

12-Volt Power Converter Harness (W23) Component Location

12-Volt Power Converter Harness (W23) Wiring Diagram

Travel Alarm Cancel Switch Sub Harness (W27) Component Location

Travel Alarm Cancel Switch Sub Harness (W27) Wiring Diagram

Starter Switch Harness (W29) Component Location

Starter Switch Harness (W29) Wiring Diagram

Data Converter Harness (W30) Component Location

Data Converter Harness (W30) Wiring Diagram

Radiator Harness (W31) Component Location

Radiator Harness (W31) Wiring Diagram

Heater and Air Conditioner Harness (W41) Component Location

Heater and Air Conditioner Harness (W41) Wiring Diagram

Auxiliary Solenoid Harness (W61) Component Location

Auxiliary Solenoid Harness (W61) Wiring Diagram

Auxiliary Function Lever (AFL) Harness (W75) Component Location

Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram

Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location

Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram

Auxiliary Function Lever (AFL) Grip Harness (W77) Component Location

Auxiliary Function Lever (AFL) Grip Harness (W77) Wiring Diagram

Auxiliary Function Enable Switch Harness (W78) Component Location

Auxiliary Function Enable Switch Harness (W78) Wiring Diagram

Auxiliary Function Lever (AFL) Solenoid Jumper Harness (W80) Component Location

Auxiliary Function Lever (AFL) Solenoid Jumper Harness (W80) Wiring Diagram

Satellite (SAT) Harness (W6003) Component Location

Satellite (SAT) Harness (W6003) Wiring Diagram

JDLink™ Harness (W6004) Component Location

JDLink™ Harness (W6004) Wiring Diagram

Group 15: Sub-System Diagnostics

Controller Area Network (CAN) Theory of Operation

Starting and Charging Circuit Theory of Operation

Monitor Controller (DSZ) Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Exhaust Aftertreatment Circuit Theory of Operation

Main Controller (MCZ) Circuit Theory of Operation

Travel Alarm Circuit Theory of Operation

Machine Controller (BCZ) Circuit Theory of Operation

Windshield Wiper and Washer Circuit Theory of Operation

Lighting Circuit Theory of Operation

Pilot Shutoff Circuit Theory of Operation

Group 16: Monitor Operation

Service Menu

Troubleshooting

Monitoring

Controller Version

Issued Warning Record

Operation

Machine Setting

Monitor Setting

Engine Setting

Exhaust Filter

Group 20: References

Reading Diagnostic Trouble Codes with Monitor Display

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

Diesel Particulate Filter (DPF) Service Recovery With Service ADVISOR™ Diagnostic Application

MPDr Application

MPDr Connection Procedure

Fuse Test

Relay Test

Glow Plug Relay Test

Pressure Sensor Test

Solenoid Test

Proportional Solenoid Test

Temperature Sensor Test

Alternator Test

Electrical Component Checks

Battery Remove and Install

Rear Cover Remove and Install

Main Controller (MCZ) Remove and Install

Machine Controller (BCZ) Remove and Install

Engine Control Unit (ECU) Remove and Install

Data Converter Remove and Install

Monitor Controller (DSZ) Remove and Install

Air Conditioner Controller (ACF) Remove and Install

Key Switch Remove and Install

Right Switch Console Remove and Install

Left Switch Console Remove and Install

Travel Alarm Remove and Install

ECO Control Disable and Enable

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Clip Connectors

Replace DEUTSCH™ Connectors

Replace DEUTSCH™ Rectangular or Triangular Connectors

Install DEUTSCH™ Contact

Replace WEATHER PACK™ Connector

Install WEATHER PACK™ Contact

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

Replace CINCH™ Connectors

Install CINCH™ Contact

Repair 32 and 48 Way CINCH™ Connectors

Remove Connector Body from Blade Terminals

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Travel Gear Case Operation

Group 15: Diagnostic Information

Noisy or Loose Track Chain

Tight Track Chain

Frequent Track Chain Sag Adjustment Required

Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers

Bent Track Shoes (Steel Track Only)

“Popping” of Track

Cracked Track Link

Chipped Link Rails

Individual Undercarriage Component Wear

Measure Swing Bearing Wear

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Operation

Pilot System Operation

Pilot Pump, Pressure Regulating Valve, and Filter Operation

Pilot Shutoff Solenoid Valve Operation

Pilot Control Valve Operation

Control Lever Pattern Selector—If Equipped

Travel Pilot Control Valve Operation

Pilot Operation of Control Valve Operation

Flow Regulator Valve Operation

Hydraulic Pump 1, 2, and 3 Operation

Hydraulic Pump Regulator Operation

Engine Speed Sensing Control Circuit Operation

Control Valve Operation

Control Valve Check Valves Identification and Operation

Main Relief Valve Circuit Operation

Circuit Relief and Anticavitation Valve Operation

Flow Combiner Valve Operation

Auxiliary Flow Combiner Valve Operation

Travel and Arm In Combined Operation

Swing and Boom Up Combined Operation

Boom Reduced Leakage Valve Operation

Swing Reduction Gear Case Operation

Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation

Swing Motor Park Brake Release Circuit Operation

Center Joint Operation

Travel Motor and Park Brake Valve Operation

Travel Motor Speed Circuit Operation

Cylinder Operation

Return Filter Operation

Group 15: Diagnostic Information

All Hydraulic Functions Slow

Hydraulic Oil Overheats

No Hydraulic Functions

Poor Combined Operation

All Functions Cannot Be Operated

Function Does Not Stop When Control Lever Is Released

Some Functions Cannot Be Operated, All Others Are Normal

Functions Move in Opposite Direction

All Dig Functions Slow or No Power

Some Dig Functions Slow (Not All)

Load Drifts Down When Control Lever is in Neutral Position

Load Drifts Down When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle

Arm In Speed Slow

Swing Speed Slow in Both Directions

Swing Speed Slow or Does Not Operate in One Direction

Upperstructure Drift With Swing Valve in Neutral

Swing Function Does Not Operate

Engine Stops During Combined Operation of Swing and Front Attachment

Travel Park Brakes Do Not Apply

Track Will Not Move in One Direction

Track Will Not Move in Either Direction

Machine Mistracks at All Speeds in Both Directions

Slow Travel Speed or Low Power

Travel Speed Does Not Change to Slow Speed

Combined Travel and Dig Functions Slow or No Power

Travel is “Jerky”

Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline

Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs

Blade Does Not Move or Moves Slowly

Pump 1, Pump 2, Pump 3, and Pilot Pump Line Identification

Control Valve Line Identification

Pilot Control Line Identification

Swing Motor Line Identification

Travel System Component Location

Travel Hydraulic System Line Connection

Blade System Component Location

Blade Hydraulic System Line Identification

Blade Hydraulic System Line Connections

Hydraulic System Schematic

Hydraulic System Component Location

Hydraulic System Line Connections

Group 25: Tests

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure and Temperature Analyzer Kit Installation

General Hydraulic Oil Cleanup Procedure

Hydraulic Component Failure Cleanup Procedure

Hydraulic Oil Tank Pressure Release Procedure

Hydraulic Oil Warm-Up Procedure

Pilot Pressure Regulating Valve Test and Adjustment

Control Valve Spool Actuating Pilot Pressure Test

Travel Speed Solenoid Valve Test and Adjustment

Torque Control Solenoid Valve Test and Adjustment

Main Relief Valve Test and Adjustment

Circuit Relief Valve Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Travel Motor Crossover Relief Valve Test and Adjustment

Pump Flow Test

Swing Motor Leakage Test

Travel Motor Leakage Test

Cylinder Drift Test—Boom, Arm, Bucket, and Blade

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle of Operation

Group 15: Diagnostic Information

Air Conditioning System Does Not Operate

No Air Flow From Heater and Air Conditioner Vents

Air Conditioning Does Not Cool Interior of Cab

Air Conditioning Runs Constantly, Too Cold

Interior Windows Continue to Fog Using Air Conditioner

Heater System Does Not Operate

Heater Does Not Warm Interior of Cab

Interior Windows Continue to Fog Using Heater

Heater and Air Conditioner Diagnostic Trouble Code Check

Heater and Air Conditioner Component Location

Group 25: Tests

Refrigerant Cautions and Proper Handling

Heater and Air Conditioner Operational Checks

Air Conditioner Compressor Clutch Test

Refrigerant Leak Test

Refrigerant Hoses and Tubing Inspection

Air Conditioner Compressor Belt Check and Adjustment

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart