John Deere 160GLC Excavator Diagnosis and Tests Service Technical Manual (TM12342)
Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere 160GLC Excavator, with workshop information to maintain, diagnose, and rebuild like professional mechanics.
John Deere Excavator 160GLC workshop Diagnosis & Tests 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.
TM12342 - John Deere 160GLC Excavator Operation and Test Technical Manual.pdf
tm12343 - John Deere Excavatrice 160GLC.pdf
tm12344 - John Deere Excavadora 160GLC.pdf
PRODUCT DETAILS:
Total Pages: 1,361 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English French Spanish
Models: John Deere - 160GLC Excavator - 1FF160GX__E055001 (iT4/S3B)
TABLE OF CONTENTS....1
Section 9000: General Information....19
Group 01: Safety....19
Recognize Safety Information....22
Follow Safety Instructions....23
Operate Only If Qualified....24
Wear Protective Equipment....25
Avoid Unauthorized Machine Modifications....26
Control Pattern Selector—If Equipped....27
Add Cab Guarding for Special Uses....28
Inspect Machine....29
Stay Clear of Moving Parts....30
Avoid High-Pressure Fluids....31
Avoid High-Pressure Oils....32
Work In Ventilated Area....33
Prevent Fires....34
Prevent Battery Explosions....35
Handle Chemical Products Safely....36
Decommissioning — Proper Recycling and Disposal of Fluids and Components....37
Exhaust Filter Ash Handling and Disposal....38
Prepare for Emergencies....39
Clean Debris from Machine....40
Use Steps and Handholds Correctly....41
Start Only From Operator's Seat....42
Use and Maintain Seat Belt....43
Prevent Unintended Machine Movement....44
Avoid Work Site Hazards....45
Keep Riders Off Machine....47
Avoid Backover Accidents....48
Inspect and Maintain ROPS....49
Avoid Machine Tip Over and Machine Damage....50
Use Special Care When Lifting Objects....52
Add and Operate Attachments Safely....53
Park and Prepare for Service Safely....54
Service Cooling System Safely....55
Remove Paint Before Welding or Heating....56
Make Welding Repairs Safely....57
Drive Metal Pins Safely....58
Clean Exhaust Filter Safely....59
Section 9001: Diagnostics....62
Group 10: Main Controller (MCZ) Diagnostic Trouble Codes....68
Main Controller (MCZ) Diagnostic Trouble Codes....68
Controller Area Network 0 (CAN 0) Circuit Diagnostics....69
Controller Area Network 1 (CAN 1) Circuit Diagnostics....70
Interface Controller Area Network (N-CAN) Diagnostics....71
Engine Controller Area Network (Engine CAN) Diagnostics....72
011000.02 - Abnormal EEPROM....62
011001.02 - Abnormal RAM....62
011002.02 - Abnormal A/D Converter....62
011003.03 - Abnormal Sensor Voltage....62
011006.02 - Engine Controller Communication Error....62
011007.02 - (CAN 0) Data Converter Communication Error 1....62
011008.02 - (CAN 1) Data Converter Communication Error 2....62
011009.02 - (CAN 0) Monitor Controller Communication Error 1....62
011010.02 - (CAN 1) Monitor Controller Communication Error 2....62
011100.02 - Abnormal Engine Speed....62
011101.03 - Engine Control Dial Sensor Circuit High Input....62
011101.04 - Engine Control Dial Sensor Circuit Low Input....62
011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input....62
011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input....62
011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input....62
011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input....62
011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input....62
011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input....62
011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input....62
011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input....62
011301.03 - Swing Pilot Pressure Sensor Circuit High Input....62
011301.04 - Swing Pilot Pressure Sensor Circuit Low Input....62
011302.03 - Boom Up Pilot Pressure Sensor Circuit High Input....62
011302.04 - Boom Up Pilot Pressure Sensor Circuit Low Input....62
011303.03 - Arm In Pilot Pressure Sensor Circuit High Input....62
011303.04 - Arm In Pilot Pressure Sensor Circuit Low Input....62
011304.03 - Travel Pilot Pressure Sensor Circuit High Input....63
011304.04 - Travel Pilot Pressure Sensor Circuit Low Input....63
011307.03 - Front Attachment Pilot Pressure Sensor Circuit High Input....63
011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input....63
011400.02 - Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback....63
011400.03 - Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current....63
011400.04 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current....63
011401.02 - Torque Control Solenoid Valve Abnormal Feedback....63
011401.03 - Torque Control Solenoid Valve Feedback High Current....63
011401.04 - Torque Control Solenoid Valve Feedback Low Current....63
011402.02 - 3-Spool Solenoid Valve Unit (SF) Abnormal Feedback....63
011402.03 - 3-Spool Solenoid Valve Unit (SF) Feedback High Input....63
011402.04 - 3-Spool Solenoid Valve Unit (SF) Feedback Low Input....63
011403.02 - 3-Spool Solenoid Valve Unit (SC) Abnormal Feedback....63
011403.03 - 3-Spool Solenoid Valve Unit (SC) Feedback High Input....63
011403.04 - 3-Spool Solenoid Valve Unit (SC) Feedback Low Input....63
011407.02 - 3-Spool Solenoid Valve Unit (SG) Abnormal Feedback....63
011407.03 - 3-Spool Solenoid Valve Unit (SG) Feedback High Input....63
011407.04 - 3-Spool Solenoid Valve Unit (SG) Feedback Low Input....63
011408.02 - 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback....63
011408.03 - 2-Spool Solenoid Valve Unit (SJ) Feedback High Input....63
011408.04 - 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input....63
011409.02 - 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback....63
011409.03 - 2-Spool Solenoid Valve Unit (SZ) Feedback High Input....63
011409.04 - 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input....63
011410.02 - Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback....63
011410.03 - Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current....63
011410.04 - Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current....63
011434.02 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal....63
011434.03 - Attachment Relief 1 (Upper) Proportional Solenoid Valve High....63
011434.04 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Low....63
011435.02 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal....63
011435.03 - Attachment Relief 2 (Lower) Proportional Solenoid Valve High....63
011435.04 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Low....64
011436.02 - Breaker Relief Proportional Solenoid Valve Abnormal....64
011436.03 - Breaker Relief Proportional Solenoid Valve High....64
011436.04 - Breaker Relief Proportional Solenoid Valve Low....64
011457.02 - 2-Speed Activation Solenoid Disconnected or Not Present....64
011458.02 - Selector Valve Solenoid Valve Disconnected or Not Present....64
011459.02 - Idle Stop Relay Circuit Malfunction....64
011810.03 - Electrical Lever Control Pressure 1 Sensor High....64
011810.04 - Electrical Lever Control Pressure 1 Sensor Low....64
011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input....64
011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input....64
020010.02 - Abnormal Exhaust Filter....776
020012.02 - Line Filter Restriction Alarm....64
020062.02 - Hydraulic Oil Temperature Alarm....64
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes....265
Engine Control Unit (ECU) Diagnostic Trouble Codes....265
000111.07 - Coolant Level Low—Moderately Severe Level....64
000111.17 - Coolant Level Low—Most Severe Level....64
000158.01 - Battery Voltage Low....64
000647.05 - Variable Speed Fan Solenoid Open Circuit....64
000647.06 - Variable Speed Fan Solenoid Short Circuit....64
000647.16 - Reversing Fan Switch Active Too Long....64
000676.05 - Glow Plug Relay Low Current....64
000676.06 - Glow Plug Relay High Current....64
000676.14 - Glow Plug Relay Output Low When Relay Active....64
000676.31 - Glow Plug Relay Output High When Relay Not Active....64
000898.09 - Requested Speed/Speed Limit....64
001638.09 - Hydraulic Temperature....64
001639.00 - Fan Speed High—Most Severe Level....64
001639.01 - Fan Speed Low—Most Severe Level....64
001639.18 - Fan Speed Low—Moderately Severe Level....64
003701.14 - Exhaust Filter Cleaning Not Required....64
005484.05 - Reversing Fan Solenoid Open Circuit....64
005484.06 - Reversing Fan Solenoid Short Circuit....65
Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes....300
Monitor Controller (DSZ) Diagnostic Trouble Codes....300
013002.02 - ECU Communication Error....65
013003.02 - Main Controller (MCZ) Communication Error 1....65
013004.02 - Main Controller (MCZ) Communication Error 2....65
013005.02 - Monitor Controller (DSZ) Communication Error 1....65
013006.02 - Monitor Controller (DSZ) Communication Error 2....65
013007.02 - Machine Controller (BCZ) Communication Error....65
020113.02 - System Error Alarm....65
Group 40: Information Controller (ICZ) Diagnostic Trouble Codes....309
Information Controller (ICZ) Diagnostic Trouble Codes....309
013303.02 - Abnormal Monitor Internal Temperature Sensor....65
013304.02 - Alternator Alarm....65
013311.03 - Fuel Level Sensor Open Circuit....65
013311.04 - Fuel Level Sensor Shorted Circuit....65
013334.02 - Radiator Coolant Error....65
014001.02 - Flash Memory Read\Write Error....65
014002.02 - External RAM Read\Write Error....65
014003.02 - Abnormal EEPROM....65
014023.02 - Security Error....65
020105.02 - Hydraulic Oil Filter Restriction Alarm....65
020109.02 - Pilot Control Shutoff Lever Alarm....65
020110.02 - Fuel Filter Restriction Alarm....65
Group 50: Air Conditioner Controller (ACF) Diagnostic Trouble Codes....328
Air Conditioner Controller (ACF) Diagnostic Trouble Codes....328
11 - Open Circuit in Air Recirculation Sensor....65
12 - Short-Circuited Air Recirculation Sensor....65
13 - Open Circuit in Ambient Air Temperature Sensor....65
14 - Short-Circuited Ambient Air Temperature Sensor....65
18 - Short-Circuited Solar Radiation Sensor....65
21 - Open Circuit in Air Conditioner Freeze Control Switch....65
22 - Short-Circuited Air Conditioner Freeze Control Switch....65
43 - Abnormal Air Conditioner and Heater Blower Port Change Servomotor....66
44 - Abnormal Air Conditioner and Heater Mixer Servomotor....66
91 - Communication Error....66
92 - CAN Bus Off Error....66
Section 9005: Operational Checkout Procedure....355
Group 10: Operational Checkout Procedure....355
Operational Checkout....422
Section 9010: Engine....488
Group 05: Theory of Operation....766
Engine Identification....492
John Deere Engine....512
Engine Fuel System Component Location....496
Engine Cooling System Component Location....497
Cold Weather Starting Aid....498
Engine Speed Control System Operation....766
Group 15: Diagnostic Information....488
John Deere Engine....512
Group 20: Adjustments....488
John Deere Engine....512
Group 25: Tests....488
John Deere Engine....512
Radiator Temperature Differential Check....513
Section 9015: Electrical System....516
Group 05: System Information....516
Electrical Diagram Information....529
Group 10: System Diagrams....516
Explanation of Wire Markings....538
Fuse and Relay Specifications....539
System Functional Schematic, Component Location, and Wiring Diagram Master Legend....548
System Functional Schematic....557
Cab Harness (W1) Component Location....578
Cab Harness (W1) Wiring Diagram....585
Machine Harness (W2) Component Location....594
Machine Harness (W2) Wiring Diagram....596
Monitor Harness (W3) Component Location....598
Monitor Harness (W3) Wiring Diagram....599
Engine Harness (W4) Component Location....601
Engine Harness (W4) Wiring Diagram....604
Engine Interface Harness (W5) Component Location....606
Engine Interface Harness (W5) Wiring Diagram....608
Pump Harness (W8) Component Location....610
Pump Harness (W8) Wiring Diagram....611
Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location....613
Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram....614
Service ADVISOR™ Remote (SAR) Harness (W10) Component Location....615
Service ADVISOR™ Remote (SAR) Switch Harness (W10) Wiring Diagram....616
Pilot Shutoff Switch Harness (W11) Component Location....618
Pilot Shutoff Switch Harness (W11) Wiring Diagram....619
Service ADVISOR™ Remote (SAR) Switch Resistor Harness (W12) Component Location....620
Service ADVISOR™ Remote (SAR) Switch Resistor Harness (W12) Wiring Diagram (S.N. 055984— )....621
Auxiliary Fuse Box Harness (W13) Component Location....622
Auxiliary Fuse Box Harness (W13) Wiring Diagram....623
Heated Air Seat Harness (W14) Component Location....625
Heated Air Seat Harness (W14) Wiring Diagram....626
Multi-Function Pilot Control Lever Harness (W15) Component Location....627
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram....629
Travel Alarm Cancel Switch Harness (W16) Component Location....630
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram....631
Attachment Harness (W17) Component Location....632
Attachment Harness (W17) Wiring Diagram....634
Rear Camera Harness (W19) Component Location....635
Rear Camera Harness (W19) Wiring Diagram....636
Pilot Shutoff Valve Harness (W21) Component Location....637
Pilot Shutoff Valve Harness (W21) Wiring Diagram....638
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location....639
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram....640
Reversing Fan Switch Harness (W23) Component Location....641
Reversing Fan Switch Harness (W23) Wiring Diagram....642
Seat Heater Switch Harness (W24) Component Location....643
Seat Heater Switch Harness (W24) Wiring Diagram....644
Travel Alarm Harness (W26) Component Location....645
Travel Alarm Harness (W26) Wiring Diagram....646
Starter Harness (W27) Component Location....647
Starter Harness (W27) Wiring Diagram....648
Starter Switch Harness (W29) Component Location....650
Starter Switch Harness (W29) Wiring Diagram....651
2-Speed Harness (W32) Component Location....652
2-Speed Harness (W32) Wiring Diagram....653
Fuel Injector Harness (W38) Component Location....654
Fuel Injector Harness (W38) Wiring Diagram....655
Glow Plug Harness (W40) Component Location....656
Glow Plug Harness (W40) Wiring Diagram....658
Heater and Air Conditioner Harness (W41) Component Location....659
Heater and Air Conditioner Harness (W41) Wiring Diagram....660
Starter Protection Jumper Harness (W42) Component Location....661
Starter Protection Jumper Harness (W42) Wiring Diagram....662
Heater and Air Conditioner Relay Harness (W51) Component Location....663
Heater and Air Conditioner Relay Harness (W51) Wiring Diagram....664
Auxiliary Solenoid Harness (W61) Component Location....666
Auxiliary Solenoid Harness (W61) Wiring Diagram....668
Satellite (SAT) Harness (W6003) Component Location....670
Satellite (SAT) Harness (W6003) Wiring Diagram....671
Group 15: Sub-System Diagnostics....518
Controller Area Network (CAN) Theory of Operation....766
Starting and Charging Circuit Theory of Operation....766
Monitor Controller (DSZ) Circuit Theory of Operation....766
Engine Control Unit (ECU) Circuit Theory of Operation....766
Exhaust Aftertreatment Circuit Theory of Operation....766
Main Controller (MCZ) Circuit Theory of Operation....766
Machine Controller (BCZ) Circuit Theory of Operation....766
Windshield Wiper and Washer Circuit Theory of Operation....766
Lighting Circuit Theory of Operation....766
Travel Alarm Circuit Theory of Operation....766
Pilot Shutoff Circuit Theory of Operation....766
Attachment Control Circuit Theory of Operation....766
Group 16: Monitor Operation....766
Service Menu....756
Troubleshooting....757
Monitoring....758
Controller Version....764
Issued Warning Record....765
Operation....766
Machine Setting....767
Monitor Setting....772
Alarm Setting....775
Exhaust Filter....776
Maintenance Mode....777
Rear View Camera Troubleshooting....778
Group 20: References....518
Reading Diagnostic Trouble Codes with Monitor Display....782
Service ADVISOR™ Diagnostic Application....783
Service ADVISOR™ Connection Procedure....784
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application....787
MPDr Application....790
MPDr Connection Procedure....791
Fuse Test....793
Relay Test....803
Pressure Sensor Test....804
Solenoid Test....807
Proportional Solenoid Test....808
Temperature Sensor Test....809
Alternator Test....811
Controller Area Network (CAN) Circuit Test....813
Electrical Component Checks....820
Engine Electrical Component Specifications....829
Battery Remove and Install....830
Rear Cover Remove and Install....832
Main Controller (MCZ) Remove and Install....834
Machine Controller (BCZ) Remove and Install....837
Engine Control Unit (ECU) Remove and Install....840
Data Converter Remove and Install....842
Monitor Controller (DSZ) Remove and Install....843
Heater Control Disable and Enable....845
Air Conditioner Controller (ACF) Remove and Install....846
Key Switch Remove and Install....847
Right Switch Console Remove and Install....848
Left Switch Console Remove and Install....850
Travel Alarm Remove and Install....852
Disconnect Tab Retainer Connectors....853
Disconnecting Spring Wire Clip Connectors....854
Replace DEUTSCH™ Connectors....855
Replace DEUTSCH™ Rectangular or Triangular Connectors....857
Install DEUTSCH™ Contact....859
Replace WEATHER PACK™ Connector....861
Install WEATHER PACK™ Contact....863
Replace (Pull Type) Metri-Pack™ Connectors....865
Replace (Push Type) Metri-Pack™ Connectors....867
Replace CINCH™ Connectors....868
Install CINCH™ Contact....870
Repair 32 and 48 Way CINCH™ Connectors....872
Remove Connector Body from Blade Terminals....876
Section 9020: Power Train....877
Group 05: Theory of Operation....766
Track Adjuster and Recoil Spring Operation....879
Travel Gear Case Operation....880
Group 15: Diagnostic Information....877
Noisy or Loose Track Chain....877
Tight Track Chain....877
Frequent Track Chain Sag Adjustment Required....877
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers....877
Bent Track Shoes....877
“Popping” of Track....877
Cracked Track Link....877
Chipped Link Rails....877
Individual Undercarriage Component Wear....877
Measure Swing Bearing Wear....898
Section 9025: Hydraulic System....902
Group 05: Theory of Operation....766
Hydraulic System Operation....907
Fan Drive Hydraulic System Operation....908
Pilot System Operation....912
Pilot Pump, Pressure Regulating Valve and Filter Operation....913
Pilot Shutoff Solenoid Valve Operation....915
Pilot Control Valve Operation....949
Travel Pilot Control Valve Operation....949
Pilot Operation of Control Valve Operation....949
Pilot Signal Manifold Operation....928
Pump 1, Pump 2, and Drive Gear Case Operation....937
Pump 1 and Pump 2 Regulator Operation....940
Engine Speed Sensing Control Circuit Operation....947
Control Valve Operation....949
Control Valve Check Valves Identification and Operation....964
Main Relief Valve Circuit Operation....968
Circuit Relief and Anticavitation Valve Operation....973
Travel Flow Combiner Valve Operation....975
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation....978
Boom Lower Meter-In Cut Valve Operation....983
Boom Regenerative Valve Circuit Operation....987
Dig Regenerative Valve Circuit Operation....990
Arm Regenerative Valve Circuit Operation....994
Bucket Regenerative Valve Circuit Operation....1002
Bucket Regenerative Valve Circuit Operation....1002
Boom and Arm Reduced Leakage Valves Operation....1005
Arm 1 Flow Rate Control Valve Circuit Operation....1007
Arm 2 Flow Rate Control Valve Circuit Operation....1011
Bucket Flow Rate Control Valve Circuit Operation....1015
Boom Flow Rate Control Valve Circuit Operation....1019
Auxiliary Flow Rate Control Valve Circuit Operation....1023
Swing Reduction Gear Case Operation....1028
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation....1029
Swing Motor Damper Valve....1033
Swing Motor Park Brake Release Circuit Operation....1044
Center Joint Operation....1045
Travel Motor and Park Brake Valve Operation....1046
Travel Motor Speed Circuit Operation....1054
Cylinder Operation....1058
Return Filter Operation....1060
Auxiliary System Operation....1061
Auxiliary Pilot Control Valve Operation....1062
Flow Rate Select Solenoid Valve Operation....1068
Flow Rate Pressure Reducing Valve Operation....1070
Secondary Auxiliary Relief Valve Solenoid Valve Operation....1072
Secondary Auxiliary Relief Control Valve Operation....1073
Secondary Auxiliary Relief Valve Operation....1074
Selector Valve Solenoid Valve Operation....1075
Selector Valve Operation....1076
Auxiliary Shuttle Valve Operation....1078
Auxiliary High Flow Line Kit Operation....1080
Two Way Solenoid Kit Operation....1084
Two Pump Combined Flow Kit Operation....1087
Secondary Auxiliary Relief Kit Operation....1094
Low Flow Kit Operation....1098
Group 15: Diagnostic Information....903
All Hydraulic Functions Slow....903
Hydraulic Oil Overheats....903
No Hydraulic Functions....903
Poor Combined Operation....766
All Functions Cannot Be Operated....903
Function Does Not Stop When Control Lever Released....903
Some Functions Cannot Be Operated, All Others Are Normal....903
All Functions Slow....903
Functions Move in Opposite Direction....903
All Dig Functions Slow or No Power....904
Some Dig Functions Slow (Not All)....904
Load Drifts Down When Control Lever is in Neutral Position....904
Load Falls When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle....904
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal....904
Swing Speed Slow in Both Directions....904
Swing Speed Slow or Does Not Operate in One Direction....904
Upperstructure Drift with Swing Valve in Neutral....904
Swing Function Does Not Operate....904
Travel Park Brakes Do Not Apply....904
Track Will Not Move in One Direction....904
Track Will Not Move in Either Direction....904
Machine Mistracks at All Speeds in Both Directions....904
Slow Travel Speed or Low Power....904
Combined Travel and Dig Functions Slow or No Power....904
Travel is “Jerky”....904
Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline....904
Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs....904
Pump 1, Pump 2, and Pilot Pump Line Identification....1165
Control Valve Line Identification....1166
Swing Motor Line Identification....1170
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern....1171
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern....1173
Pilot Signal Manifold-to-Control Valve Line Connection....1175
Travel System Component Location....1178
Travel Hydraulic System Line Connection....1180
Auxiliary Attachment Schematic....1182
Auxiliary System Line Connections....1190
Hydraulic System Schematic....1192
Hydraulic System Component Location....1201
Hydraulic System Line Connections....1203
Fan Drive Hydraulic System Component Location....1204
Fan Drive Hydraulic System Schematic....1205
Group 25: Tests....905
JT05800 Digital Thermometer Installation....1209
JT02156A Digital Pressure and Temperature Analyzer Kit Installation....1210
Hydraulic Oil Cleanup Procedure....1211
Hydraulic Oil Tank Pressure Release Procedure....1214
Hydraulic Oil Warm-Up Procedure....1215
Pilot Pressure Regulating Valve Test and Adjustment....1218
Control Valve Spool Actuating Pilot Pressure Test....1223
Dig Regenerative Solenoid Valve Test and Adjustment....1226
Arm Regenerative Solenoid Valve Test and Adjustment....1231
Power Dig Solenoid Valve Test and Adjustment....1236
Torque Control Solenoid Valve Test and Adjustment....1241
Pump Control Pilot Pressure Signal Test....1245
Main Relief and Power Dig Valve Test and Adjustment....1248
Circuit Relief Valve Test and Adjustment....1254
Swing Motor Crossover Relief Valve Test and Adjustment....1260
Travel Motor Crossover Relief Valve Test and Adjustment....1264
Pump Regulator Test and Adjustment—Minimum Flow....1269
Pump Regulator Test and Adjustment—Maximum Flow....1272
Pump Flow Test....1275
Comprehensive Pump Flow Test....1279
Swing Motor Leakage Test....1285
Travel Motor Leakage Test....1288
Cylinder Drift Test—Boom, Arm, and Bucket....1292
Fan Drive Pump Flow Test....1294
Fan Speed Test....1297
Section 9031: Heating and Air Conditioning....1300
Group 05: Theory of Operation....766
Air Conditioning System Cycle of Operation....1303
Group 15: Diagnostic Information....1300
Air Conditioning System Does Not Operate....1300
No Air Flow From Heater and Air Conditioner Vents....1300
Air Conditioning Does Not Cool Interior of Cab....1300
Air Conditioning Runs Constantly, Too Cold....1300
Interior Windows Continue to Fog Using Air Conditioner....1300
Heater System Does Not Operate....1300
Heater Does Not Warm Interior of Cab....1300
Interior Windows Continue to Fog Using Heater....1300
Heater and Air Conditioner Component Location....1338
Group 25: Tests....1300
Refrigerant Cautions and Proper Handling....1341
Heater and Air Conditioner Operational Checks....1342
Air Conditioner Compressor Clutch Test....1345
Refrigerant Leak Test....1346
Refrigerant Hoses and Tubing Inspection....1347
Air Conditioner Compressor Belt Check....1348
Air Conditioner High/Low-Pressure Switch Test....1349
Air Conditioner Freeze Control Switch Test....1352
Air Conditioning System Test....1353
Operating Pressure Diagnostic Chart....1356
Section 9900: Dealer Fabricated Tools....1357
Group 99: Dealer Fabricated Tools....1357
DFT1218 Split Flange Hose Cap....1359
John Deere 160GLC Excavator Diagnosis and Tests Service Technical Manual (TM12342)
