John Deere 135G Excavator Operation & Test Technical Service Manual (TM12666)

TM12666 - John Deere 135G Excavator Operation & Test Technical Manual.pdf

Complete operation & test manual with electrical wiring diagrams for John Deere 135G Excavator. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

John Deere 135G Excavator workshop diagnosis & test 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.

Total Pages: 1,501 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
Covered models (S.N. 1FF135GX__E400001-):

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
   Dealer Fabricated Tools

tm12666 - 135G Excavator

Table of Contents

Foreword

Manual Identification—READ THIS FIRST!

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

011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input

011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input

011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input

011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input

011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input

011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input

011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input

011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input

011301.03 - Swing Pilot Pressure Sensor Circuit High Input

011301.04 - Swing Pilot Pressure Sensor Circuit Low Input

011302.03 - Boom Up Pilot Pressure Sensor Circuit High Input

011302.04 - Boom Up Pilot Pressure Sensor Circuit Low Input

011303.03 - Arm In Pilot Pressure Sensor Circuit High Input

011303.04 - Arm In Pilot Pressure 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 Attachment Pilot Pressure Sensor Circuit High Input

011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input

011400.02 - Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback

011400.03 - Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current

011400.04 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current

011401.02 - Torque Control Solenoid Valve Abnormal Feedback

011401.03 - Torque Control Solenoid Valve Feedback High Current

011401.04 - Torque Control Solenoid Valve Feedback Low Current

011402.02 - 4-Spool Solenoid Valve Unit (SF) Abnormal Feedback

011402.03 - 4-Spool Solenoid Valve Unit (SF) Feedback High Input

011402.04 - 4-Spool Solenoid Valve Unit (SF) Feedback Low Input

011403.02 - 4-Spool Solenoid Valve Unit (SC) Abnormal Feedback

011403.03 - 4-Spool Solenoid Valve Unit (SC) Feedback High Input

011403.04 - 4-Spool Solenoid Valve Unit (SC) Feedback Low Input

011407.02 - 4-Spool Solenoid Valve Unit (SG) Abnormal Feedback

011407.03 - 4-Spool Solenoid Valve Unit (SG) Feedback High Input

011407.04 - 4-Spool Solenoid Valve Unit (SG) Feedback Low Input

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

011410.02 - Pump 1 Flow Rate Limit Solenoid Feedback Current Abnormal

011410.03 - Pump 1 Flow Rate Limit Solenoid Feedback Current High

011410.04 - Pump 1 Flow Rate Limit Solenoid Feedback Current Low

011428.02 - 4-Spool Solenoid Valve Unit (SD) Abnormal Feedback

011428.03 - 4-Spool Solenoid Valve Unit (SD) Feedback High Input

011428.04 - 4-Spool Solenoid Valve Unit (SD) 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

011457.02 - 2-Speed Activation Solenoid Disconnected or Not Present

011458.02 - (Auxiliary) Discontinuity of Selector Valve

011459.02 - Idle Stop Relay Circuit Malfunction

011810.03 - Electric Lever Operating Pressure Sensor 1 High Voltage

011810.04 - Electric Lever Operating Pressure Sensor 1 Low Voltage

011812.02 - OPT Electric Lever 1 Neutral Abnormal

011813.02 - OPT Electric Lever 1 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

011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input

011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input

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

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

000081.00 - High Exhaust Filter Differential Pressure (P2453)

000081.01 - Low Exhaust Filter Differential Pressure (P2452)

000081.02 - Zero-Point Calibration of Exhaust Filter Differential Pressure Sensor is Abnormal (P2456)

000081.03 - Exhaust Filter Differential Pressure Sensor Circuit High Input (P2455)

000081.04 - Exhaust Filter Differential Pressure Sensor Circuit Low Input (P2454)

000091.02 - Accelerator Pedal Position Sensor 1-2 Correlation (P2138)

000091.03 - Accelerator Pedal Position Sensor 1 High Input (P2123)

000091.03 - Accelerator Pedal Position Sensor 2 High Input (P2128)

000091.04 - Accelerator Pedal Position Sensor 1 Low Input (P2122)

000091.04 - Accelerator Pedal Position Sensor 2 Low Input (P2127)

000100.03 - Engine Oil Pressure Sensor Circuit High Input (P0523)

000100.04 - Engine Oil Pressure Sensor Circuit Low Input (P0522)

000102.00 - Over Boost-Pressure (P0234)

000102.00 - Over Boost-Pressure (P0234)

000102.01 - Declined Boost Pressure (P0299)

000102.03 - Boost Pressure Sensor Circuit High Input (P0238)

000102.04 - Boost Pressure Sensor Circuit Low Input (P0237)

000105.03 - Boost Temperature Sensor Circuit High Input (P1113)

000105.04 - Boost Temperature Sensor Circuit Low Input (P1112)

000108.03 - Atmospheric Pressure Sensor Circuit High Input (P2229)

000108.04 - Atmospheric Pressure Sensor Circuit Low Input (P2228)

000110.00 - Overheat (P0217)

000110.03 - Engine Coolant Temperature Circuit High Input (P0118)

000110.04 - Engine Coolant Temperature Circuit Low Input (P0117)

000132.03 - Air Flow Sensor Circuit High Input (P0103)

000132.04 - Air Flow Sensor Circuit Low Input (P0102)

000157.00 - Pressure Increase in Common Rail (Secondary) (P0088)

000157.03 - Common Rail Pressure Sensor Circuit High Input (P0193)

000157.04 - Common Rail Pressure Sensor Circuit Low Input (P0192)

000157.15 - Abnormal Common Rail Pressure (Over Pumping) (P0089)

000157.16 - Pressure Increase in Common Rail (Primary) (P0088)

000158.03 - Abnormally High Battery System Voltage (P0563)

000172.03 - Intake Air Temperature Sensor Circuit High Input (P0113)

000172.04 - Intake Air Temperature Sensor Circuit Low Input (P0112)

000173.00 - Abnormally High Exhaust Temperature Sensor 1 (DPF Inlet) (P0426)

000173.03 - Exhaust Temperature Sensor 1 Circuit High Input (DPF Inlet) (P0428)

000173.04 - Exhaust Temperature Sensor 1 Circuit Low Input (DPF Inlet) (P0427)

000174.03 - Combustion Temperature Sensor Circuit High Input (P0183)

000174.04 - Combustion Temperature Sensor Circuit Low Input (P0182)

000190.00 - Engine Overrun (P0219)

000628.02 - Abnormal ROM (P0601)

000633.07 - Common Rail Pressure Limiter Open (P0087)

000636.02 - Abnormal Cam Angle Sensor (No Signal) (P0340)

000636.07 - Phase Difference Between Cam and Sensor (P0016)

000639.02 - Abnormal CAN Time-Out (U0101)

000639.19 - Abnormal CAN Bus (U0073)

000651.05 - Cylinder 1 Injector Circuit Open (P0201)

000652.05 - Cylinder 2 Injector Circuit Open (P0202)

000653.05 - Cylinder 3 Injector Circuit Open (P0203)

000654.05 - Cylinder 4 Injector Circuit Open (P0204)

000723.02 - Crank Position Sensor Failure (No Signal) (P0335)

000723.02 - Crank Position Sensor Failure (Abnormal Signal) (P0336)

001077.02 - Abnormal CPU (P0606)

001079.02 - Abnormal 5V-Electric Power Circuit #1 (P0641)

001080.02 - Abnormal 5V-Electric Power Circuit #2 (P0651)

001131.03 - Manifold Temperature Sensor Circuit High Input (P041C)

001131.04 - Manifold Temperature Sensor Circuit Low Input (P041D)

001239.01 - Pressure Decline in Common Rail (No Pumping Pressure) (P0093)

001239.17 - Pressure Decline in Common Rail (Lack of Pumping Pressure) (P1093)

001347.03 - SCV Drive Circuit + Short Circuit B (P0092)

001347.04 - SCV Drive Circuit Open or Short Circuited to GND (P0091)

001381.03 - Fuel Filter Restriction Sensor Circuit High Input (P1294)

001381.04 - Fuel Filter Restriction Sensor Circuit Low Input (P1293)

001485.05 - Abnormal Main Relay Circuit (Inactivation) (P0685)

001485.06 - Abnormal Main Relay Circuit (Kept Closed) (P0687)

010001.02 - EGR Position Error (Brushless Type) (P0409)

010001.13 - Abnormal EGR Zero-Point Calibration (P1404)

010002.02 - Abnormal EGR Valve Control Circuit (P0404)

010003.02 - Abnormal Injector Common 1 Circuit (P2146)

010004.02 - Abnormal Injector Common 2 Circuit (P2149)

010005.01 - Abnormal Charge Circuit (Bank 1) (P1261)

010006.01 - Abnormal Charge Circuit (Bank 2) (P1262)

010007.02 - Abnormal CPU Monitor IC (P0606)

010008.02 - Abnormal A/D Converter (P060B)

010009.02 - Abnormal 5V-Electric Power Circuit #3 (P0697)

010010.02 - Abnormal 5V-Electric Power Circuit #4 (P1655)

010012.02 - Abnormal 12V Circuit (P0560)

010013.02 - Abnormal EEPROM/Abnormal HDEEPROM (P1621)

010022.02 - Abnormal Intake Throttle Control Circuit (P0638)

010022.03 - Intake Throttle Position Sensor Circuit High Input (P0123)

010022.04 - Intake Throttle Position Sensor Circuit Low Input (P0122)

010023.03 - EVRV Vacuum Sensor High Input (P2528)

010023.04 - EVRV Vacuum Sensor Low Input (P2527)

010023.20 - Abnormal Turbo EVRV (P0045)

010024.03 - Exhaust Temperature Sensor 2 Circuit High Input (DOC Inlet) (P042D)

010024.04 - Exhaust Temperature Sensor 2 Circuit Low Input (DOC Inlet) (P042C)

010025.05 - Exhaust Filter Light Failure (P1669)

010026.00 - Exhaust Filter PM Over-Restriction 2 (P1455)

010026.15 - Exhaust Filter PM Over-Restriction (P242F)

010027.00 - Exhaust Filter Cleaning Decision Error (P1471)

010028.00 - Abnormally High Exhaust Temperature Sensor 2 (DOC Outlet) (P042B)

010029.00 - Over Frequent Exhaust Filter Regeneration Time-Out (P2458)

010032.02 - QR Code Error (P0602)

010033.02 - Abnormal RAM (P0604)

010040.19 - Abnormal ISO-CAN Bus (U0001)

Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Monitor Controller (DSZ) Diagnostic Trouble Codes

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

020113.02 - System Error Alarm

Group 40: Information Controller (ICZ) Diagnostic Trouble Codes

Information Controller (ICZ) Diagnostic Trouble Codes

013334.02 - Radiator Coolant Error

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

020109.02 - Pilot Control Shut-Off Lever Alarm

020110.02 - Fuel Filter Restriction Alarm

020114.02 - Overheat Alarm

020133.02 - Crane Function Alarm

020137.02 - Exhaust Filter Alarm

020141.02 - Exhaust 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 50: 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

Isuzu Engine

Engine Fuel System Component Location

Engine Cooling System Component Location

Cold Weather Starting Aid

Engine Speed Control System Operation

Group 15: Diagnostic Information

Isuzu Engine

Group 20: Adjustments

Isuzu Engine

Group 25: Tests

Isuzu 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

Pump Harness (W8) Component Location

Pump Harness (W8) 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

Heated Air Seat Harness (W14) Component Location

Heated Air Seat Harness (W14) 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

Attachment Harness (W17) Component Location

Attachment Harness (W17) 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

Seat Heater Switch Harness (W24) Component Location

Seat Heater Switch Harness (W24) Wiring Diagram

Travel Alarm Harness (W26) Component Location

Travel Alarm Harness (W26) Wiring Diagram

Travel Sub Harness (W27) Component Location

Travel 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

Data Converter Interface Harness (W31) Component Location

Data Converter Interface Harness (W31) Wiring Diagram

2-Speed Harness (W32) Component Location

2-Speed Harness (W32) 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

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

Attachment Control 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 No.

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

Clearing Engine Diagnostic Trouble Codes

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

Exhaust Differential Pressure Sensor Zero Point Calibration

Ash Reset

No Load Max

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

Heater 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

“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

Travel Pilot Control Valve Operation

Pilot Operation of Control Valve Operation

Pilot Signal Manifold Operation

Pump 1, Pump 2, and Drive Gear Case Operation

Pump 1 and Pump 2 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

Travel Flow Combiner Valve Operation

Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation

Boom Lower Meter-In Cut Valve Operation

Boom Regenerative Valve Circuit Operation

Dig Regenerative Valve Circuit Operation

Arm Regenerative Valve Circuit Operation

Bucket Regenerative Valve Circuit Operation

Boom and Arm Reduced Leakage Valves Operation

Arm 1 Flow Rate Control Valve Circuit Operation

Arm 2 Flow Rate Control Valve Circuit Operation

Bucket Flow Rate Control Valve Circuit Operation

Boom Flow Rate Control Valve Circuit Operation

Auxiliary Flow Rate Control Valve Circuit Operation

Blade Circuit Operation—If Equipped

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

Diesel Particulate Filter (DPF) Burn Solenoid Valves

Cylinder Operation

Return Filter Operation

Auxiliary System Operation

Auxiliary Pilot Control Valve Operation

Flow Rate Select Solenoid Valve Operation

Flow Rate Pressure Reducing Valve Operation

Auxiliary Shuttle Valve Operation

Auxiliary High Flow Line Kit Operation

Two Way Solenoid Kit Operation

Two Pump Combined Flow Kit 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 Released

Some Functions Cannot Be Operated, All Others Are Normal

All Functions Slow

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

H-P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal

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

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

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

Pump 1, Pump 2, and Pilot Pump Line Identification

Control Valve Line Identification

Swing Motor Line Identification

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern

Pilot Signal Manifold-to-Control Valve Line Connection

Travel System Component Location

Travel Hydraulic System Line Connection

Blade Hydraulic System Component Location

Auxiliary Attachment Schematic

Auxiliary 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

Dig Regenerative Solenoid Valve Test and Adjustment

Arm Regenerative Solenoid Valve Test and Adjustment

Power Dig Solenoid Valve Test and Adjustment

Arm 2 Flow Control Solenoid Valve Test and Adjustment

Torque Control Solenoid Valve Test and Adjustment

Pump Control Pilot Pressure Signal Test

Main Relief and Power Dig Valve Test and Adjustment

Circuit Relief Valve Test and Adjustment

Blade Main Relief Valve Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Travel Motor Crossover Relief Valve Test and Adjustment

Pump Regulator Test and Adjustment—Minimum Flow

Pump Regulator Test and Adjustment—Maximum Flow

Pump Flow Test

Comprehensive Pump Flow Test

Swing Motor Leakage Test

Travel Motor Leakage Test

Cylinder Drift Test—Boom, Arm, and Bucket

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 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

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

Section 9900: Dealer Fabricated Tools

Group 99: Dealer Fabricated Tools

DFT1218 Split Flange Hose Cap