John Deere Wheeled Excavator 230GW Operation and Test Service Manual (TM13249X19)
Complete Diagnostics, Operation and Test manual with Electrical Wiring Diagrams for John Deere Wheeled Excavator 230GW (PIN: 1FF230GW__E061001-), with all the workshop information to maintain, diagnose, and rebuild like professional mechanics.
John Deere Wheeled Excavator 230GW workshop Operation and 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.
TM13249X19 - John Deere 230GW Wheeled Excavator Technical Manual - Operation and Test.pdf
tm13249x28 - John Deere Excavatrice à roues 230GW.pdf
tm13249x63 - John Deere 230GW Excavadora sobre ruedas.pdf
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Total Pages: 1,543 pages
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Language: English Spanish French
John Deere - 230GW Excavator - 1FF230GW__E061001
MAIN SECTIONS
Foreword
Manual Identification-READ THIS FIRST!
Technical Information Feedback Form
General Information
Safety
Diagnostic Trouble Codes (DTC)
Main Controller (MCZ) Diagnostic Trouble Codes
Option Controller (MC2) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
Monitor Controller (DSZ) Diagnostic Trouble Codes
Information Controller (ICF) 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
Tests and Adjustments
Hydraulic System
Theory of Operation
Diagnostic Information
Tests
Heating and Air Conditioning
Theory of Operation
Diagnostic Information
Tests
Dealer Fabricated Tools
TABLE OF CONTENTS....1
Section 9000: General Information....30
Group 01: Safety....30
Recognize Safety Information....33
Follow Safety Instructions....34
Operate Only If Qualified....35
Wear Protective Equipment....36
Avoid Unauthorized Machine Modifications....37
Control Pattern Selector—If Equipped....38
Add Cab Guarding for Special Uses....39
Inspect Machine....40
Stay Clear of Moving Parts....41
Avoid High-Pressure Fluids....42
Avoid High-Pressure Oils....43
Work In Ventilated Area....44
Avoid Static Electricity Risk When Refueling....45
Prevent Fires....47
Prevent Battery Explosions....48
Handle Chemical Products Safely....49
Decommissioning — Proper Recycling and Disposal of Fluids and Components....50
Exhaust Filter Ash Handling and Disposal....51
Prepare for Emergencies....52
Clean Debris from Machine....53
Use Steps and Handholds Correctly....54
Start Only From Operator's Seat....55
Use and Maintain Seat Belt....56
Prevent Unintended Machine Movement....57
Avoid Work Site Hazards....58
Keep Riders Off Machine....60
Avoid Backover Accidents....61
Inspect and Maintain ROPS....62
Avoid Machine Tip Over....63
Operating or Traveling On Public Roads....64
Use Special Care When Lifting Objects....65
Travel Safely....66
Prevent Acid Burns....67
Add and Operate Attachments Safely....69
Park and Prepare for Service Safely....70
Service Cooling System Safely....71
Remove Paint Before Welding or Heating....72
Service Tires Safely....73
Follow Tire Recommendations....74
Make Welding Repairs Safely....75
Drive Metal Pins Safely....76
Clean Exhaust Filter Safely....77
Section 9001: Diagnostic Trouble Codes (DTC)....80
Group 10: Main Controller (MCZ) Diagnostic Trouble Codes....92
Main Controller (MCZ) Diagnostic Trouble Codes....92
Controller Area Network 0 (CAN 0) Circuit Diagnostics....93
Controller Area Network 1 (CAN 1) Circuit Diagnostics....110
Interface Controller Area Network (N-CAN) Diagnostics....133
Engine Controller Area Network (Engine CAN) Diagnostics....143
011000.02 - Abnormal EEPROM....80
011001.02 - Abnormal RAM....80
011002.02 - Abnormal A/D Converter....80
011003.03 - Abnormal Sensor Voltage....80
011006.02 - Engine Controller Communication Error....80
011007.02 - (CAN 0) Data Converter Communication Error 1....80
011008.02 - (CAN 1) Data Converter Communication Error 2....80
011009.02 - (CAN 0) Monitor Controller Communication Error 1....80
011010.02 - (CAN 1) Monitor Controller Communication Error 2....80
011016.02 - Main Controller to Option Controller Communication Error 2....80
011100.02 - Abnormal Engine Speed....80
011101.03 - Engine Speed Dial Sensor Circuit High Input....80
011101.04 - Engine Speed Dial Sensor Circuit Low Input....80
011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input....80
011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input....80
011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input....80
011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input....80
011205.03 - Steering Pump Delivery Pressure Sensor Circuit High Input....80
011205.04 - Steering Pump Delivery Pressure Sensor Circuit Low Input....80
011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input....80
011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input....80
011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input....80
011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input....80
011301.03 - Swing Pressure Sensor Circuit High Input....80
011301.04 - Swing Pressure Sensor Circuit Low Input....80
011302.03 - Boom Up Pressure Sensor Circuit High Input....80
011302.04 - Boom Up Pressure Sensor Circuit Low Input....81
011303.03 - Arm In Pressure Sensor Circuit High Input....81
011303.04 - Arm In Pressure Sensor Circuit Low Input....81
011305.03 - Forward Travel Pressure Sensor Circuit High Input....81
011305.04 - Forward Travel Pressure Sensor Circuit Low Input....81
011306.03 - Reverse Travel Pressure Sensor Circuit High Input....81
011306.04 - Reverse Travel Pressure Sensor Circuit Low Input....81
011307.03 - Front Attachment Pilot Pressure Sensor Circuit High Input....81
011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input....81
011310.03 - Work Brake Pressure Sensor Circuit High Input....81
011310.04 - Work Brake Pressure Sensor Circuit Low Input....81
011311.03 - Park Brake Remain Pressure Sensor Circuit High Input....81
011311.04 - Park Brake Remain Pressure Sensor Circuit Low Input....81
011400.02 - Pump 2 Flow Rate Limit Solenoid Feedback Abnormal....81
011400.03 - Pump 2 Flow Rate Limit Solenoid Feedback High Input....81
011400.04 - Pump 2 Flow Rate Limit Solenoid Feedback Low Input....81
011401.02 - Torque Control Solenoid Feedback Abnormal....81
011401.03 - Torque Control Solenoid Feedback High Input....81
011401.04 - Torque Control Solenoid Feedback Low Input....81
011403.02 - Arm Regenerative Solenoid Feedback Abnormal....81
011403.03 - Arm Regenerative Solenoid Feedback High Input....81
011403.04 - Arm Regenerative Solenoid Feedback Low Input....81
011404.02 - Power Dig Solenoid Feedback Abnormal....81
011404.03 - Power Dig Solenoid Feedback High Input....81
011404.04 - Power Dig Solenoid Feedback Low Input....81
011408.02 - Bypass Shutoff Valve Control Solenoid Feedback Abnormal....81
011408.03 - Bypass Shutoff Valve Control Solenoid Feedback High Input....81
011408.04 - Bypass Shutoff Valve Control Solenoid Feedback High Input....81
011409.02 - Pump 1 Secondary Flow Rate Control Solenoid Feedback Abnormal....81
011409.03 - Pump 1 Secondary Flow Rate Control Solenoid Feedback High Input....81
011409.04 - Pump 1 Secondary Flow Rate Control Solenoid Feedback Low Input....81
011410.02 - Pump 1 Flow Rate Limit Solenoid Feedback Abnormal....81
011410.03 - Pump 1 Flow Rate Limit Solenoid Feedback High Input....81
011410.04 - Pump 1 Flow Rate Limit Solenoid Feedback Low Input....82
011422.02 - Travel Speed Solenoid Feedback Abnormal....82
011422.03 - Travel Speed Solenoid Feedback High Input....82
011422.04 - Travel Speed Solenoid Feedback Low Input....82
011423.02 - Pump 2 Secondary Flow Control Solenoid Feedback Abnormal....82
011423.03 - Pump 2 Secondary Flow Control Solenoid Feedback High Input....82
011423.04 - Pump 2 Secondary Flow Control Solenoid Feedback Low Input....82
011424.02 - Axle Lock Solenoid Feedback Abnormal....82
011424.03 - Axle Lock Solenoid Feedback High Input....82
011424.04 - Axle Lock Solenoid Feedback Low Input....82
011425.02 - Work Brake Solenoid Feedback Abnormal....82
011425.03 - Work Brake Solenoid Feedback High Input....82
011425.04 - Work Brake Solenoid Feedback Low Input....82
011428.02 - Arm 2 Flow Rate Control Solenoid Feedback Abnormal....82
011428.03 - Arm 2 Flow Rate Control Solenoid Feedback High Input....82
011428.04 - Arm 2 Flow Rate Control Solenoid Feedback Low Input....82
011434.02 - Attachment Relief Solenoid 1 Feedback Abnormal....82
011434.03 - Attachment Relief Solenoid 1 Feedback High Input....82
011434.04 - Attachment Relief Solenoid 1 Feedback Low Input....82
011435.02 - Attachment Relief Solenoid 2 Feedback Abnormal....82
011435.03 - Attachment Relief Solenoid 2 Feedback High Input....82
011435.04 - Attachment Relief Solenoid 2 Feedback Low Input....82
011436.02 - Breaker Relief Solenoid Feedback Abnormal....82
011436.03 - Breaker Relief Solenoid Feedback High Input....82
011436.04 - Breaker Relief Solenoid Feedback Low Input....82
011458.02 - Selector Valve Solenoid Valve Disconnected....82
011459.02 - Idle Stop Relay Circuit Malfunction....82
011460.02 - Transmission Speed Control Solenoid (Fast) Feedback Abnormal....82
011461.02 - Transmission Speed Control Solenoid (Slow) Feedback Abnormal....82
011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input....82
011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input....82
020008.02 - Hydraulic Oil Temperature Alarm....82
020010.02 - Abnormal Exhaust Filter....82
020062.02 - Hydraulic Oil Temperature Alarm....83
Group 11: Option Controller (MC2) Diagnostic Trouble Codes....420
Option Controller (MC2) Diagnostic Trouble Codes....420
015000.02 - Engine Controller Communication Error (CAN 0)....83
015002.02 - Option Controller (MC2) Communication Error (CAN1)....83
015006.02 - Monitor Controller (DSZ) Communication Error (CAN 1)....83
015011.03 - Secondary Hydraulic Oil Temperature Sensor Circuit High Input....83
015011.04 - Secondary Hydraulic Oil Temperature Sensor Circuit Low Input....83
015012.03 - Positioning Pedal Stroke 1 (Main Signal) Sensor Circuit High Input....83
015012.04 - Positioning Pedal Stroke 1 (Main Signal) Sensor Circuit Low Input....83
015013.03 - Positioning Pedal Stroke 2 (Sub Signal) Sensor Circuit High Input....83
015013.04 - Positioning Pedal Stroke 2 (Sub Signal) Sensor Circuit Low Input....83
015014.03 - Blade or Outrigger Control Lever Stroke 1 (Main Signal) Sensor Circuit High Input....83
015014.04 - Blade or Outrigger Control Lever Stroke 1 (Main Signal) Sensor Circuit Low Input....83
015015.03 - Blade or Outrigger Control Lever Stroke 2 (Sub Signal) Sensor Circuit High Input....83
015015.04 - Blade or Outrigger Control Lever Stroke 2 (Sub Signal) Sensor Circuit Low Input....83
015016.03 - Assist Switch 1 Stroke Sensor Circuit High Input....83
015016.04 - Assist Switch 1 Stroke Sensor Circuit Low Input....83
015017.03 - Assist Switch 2 Stroke Sensor Circuit High Input....83
015017.04 - Assist Switch 2 Stroke Sensor Circuit Low Input....83
015018.03 - Positioning Monitoring Pressure Sensor Circuit High Input....83
015018.04 - Positioning Monitoring Pressure Sensor Circuit Low Input....83
015019.03 - Assist Monitoring Pressure Sensor Circuit High Input....83
015019.04 - Assist Monitoring Pressure Sensor Circuit Low Input....83
015020.03 - Auxiliary Monitoring Pressure Sensor Circuit High Input....83
015020.04 - Auxiliary Monitoring Pressure Sensor Circuit Low Input....83
015021.03 - Blade or Outrigger Monitoring Pressure Sensor Circuit High Input....83
015021.04 - Blade or Outrigger Monitoring Pressure Sensor Circuit Low Input....83
015022.02 - Blade or Outrigger Center Signal Fault....83
015023.02 - Blade or Outrigger Abnormal Operation....1231
015024.02 - Auxiliary Center Signal Fault....83
015025.02 - Auxiliary Abnormal Operation....1231
015026.02 - Positioning Center Signal Fault....83
015027.02 - Positioning Abnormal Operation....1231
015028.02 - Assist Center Signal Fault....84
015029.02 - Assist Abnormal Operation....1231
015030.03 - Positioning Pedal Signal Circuit High Input....84
015030.04 - Positioning Pedal Signal Circuit Low Input....84
015031.03 - Blade or Outrigger Control Lever Stroke Signal Circuit High Input....84
015031.04 - Blade or Outrigger Control Lever Stroke Signal Circuit Low Input....84
015032.03 - Positioning Pedal Signal Circuit Fatal High Input....84
015032.04 - Positioning Pedal Signal Circuit Fatal Low Input....84
015033.03 - Blade or Outrigger Control Lever Stroke Signal Circuit Fatal High Input....84
015033.04 - Blade or Outrigger Control Lever Stroke Signal Circuit Fatal Low Input....84
015501.02 - Initial Setting Value (EEPROM) Data Read Error....84
015502.02 - Abnormal EEPROM....84
015503.02 - Abnormal RAM....84
015504.02 - Abnormal A/D Converter....84
015506.03 - Abnormal Sensor Voltage....84
015520.02 - Auxiliary 1 Solenoid Valve Abnormal Feedback....84
015520.03 - Auxiliary 1 Solenoid Valve Feedback High Input....84
015520.04 - Auxiliary 1 Solenoid Valve Feedback Low Input....84
015521.02 - Auxiliary 2 Solenoid Valve Abnormal Feedback....84
015521.03 - Auxiliary 2 Solenoid Valve Feedback High Input....84
015521.04 - Auxiliary 2 Solenoid Valve Feedback Low Input....84
015522.02 - Blade or Outrigger 1 Solenoid Valve Abnormal Feedback....84
015522.03 - Blade or Outrigger 1 Solenoid Valve Feedback High Input....84
015522.04 - Blade or Outrigger 1 Solenoid Valve Feedback Low Input....84
015523.02 - Blade or Outrigger 2 Solenoid Valve Abnormal Feedback....84
015523.03 - Blade or Outrigger 2 Solenoid Valve Feedback High Input....84
015523.04 - Blade or Outrigger 2 Solenoid Valve Feedback Low Input....84
015524.02 - Swing Park Brake Release Solenoid Valve Abnormal Feedback....84
015524.03 - Swing Park Brake Release Solenoid Valve Feedback High Input....84
015524.04 - Swing Park Brake Release Solenoid Valve Feedback Low Input....84
015525.02 - Assist 1 Solenoid Valve Abnormal Feedback....84
015525.03 - Assist 1 Solenoid Valve Feedback High Input....84
015525.04 - Assist 1 Solenoid Valve Feedback Low Input....85
015526.02 - Assist 2 Solenoid Valve Abnormal Feedback....85
015526.03 - Assist 2 Solenoid Valve Feedback High Input....85
015526.04 - Assist 2 Solenoid Valve Feedback Low Input....85
015527.02 - Assist 3 Solenoid Valve Abnormal Feedback....85
015527.03 - Assist 3 Solenoid Valve Feedback High Input....85
015527.04 - Assist 3 Solenoid Valve Feedback Low Input....85
015528.02 - Assist 4 Solenoid Valve Abnormal Feedback....85
015528.03 - Assist 4 Solenoid Valve Feedback High Input....85
015528.04 - Assist 4 Solenoid Valve Feedback Low Input....85
015529.02 - Positioning 1 Solenoid Valve Abnormal Feedback....85
015529.03 - Positioning 1 Solenoid Valve Feedback High Input....85
015529.04 - Positioning 1 Solenoid Valve Feedback Low Input....85
015530.02 - Positioning 2 Solenoid Valve Abnormal Feedback....85
015530.03 - Positioning 2 Solenoid Valve Feedback High Input....85
015530.04 - Positioning 2 Solenoid Valve Feedback Low Input....85
015531.05 - Outrigger/Blade ON/OFF Valve 1 (Front Left) Low Input....85
015532.05 - Outrigger/Blade ON/OFF Valve 2 (Front Right) Low Input....85
015533.05 - Outrigger/Blade ON/OFF Valve 3 (Rear Left) Low Input....85
015532.05 - Outrigger/Blade ON/OFF Valve 4 (Rear Right) Low Input....85
015535.05 - Pilot Cut Valve Low Input....85
020011.02 - Electric Lever Alarm....85
020303.02 - Electric Lever Pilot Cut Alarm....85
020304.02 - Positioning Pedal Signal Failure Alarm....85
020305.02 - Blade or Outrigger Control Lever Signal Failure Alarm....85
020306.02 - Assist Switch 1, 2 Signal Failure Alarm....85
020307.02 - Electric Lever Assignment Error Warning....85
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes....639
Engine Control Unit (ECU) Diagnostic Trouble Codes....639
000081.00 - DPD Differential Pressure Sensor Circuit Range/Performance (P2453)....85
000081.01 - DPD Differential Pressure Sensor Circuit (P2452)....85
000081.02 - DPD Differential Pressure Sensor Learned Position (P2456)....85
000081.03 - DPD Differential Pressure Sensor Circuit High (P2455)....85
000081.04 - DPD Differential Pressure Sensor Circuit Low (P2454)....86
000091.02 - Pedal Position Sensor 1 - 2 Voltage Correlation (P2138)....86
000091.03 - Pedal Position Sensor 1 Circuit High Input (P2123)....86
000091.03 - Pedal Position Sensor 2 Circuit High Input (P2128)....86
000091.04 - Pedal Position Sensor 1 Circuit Low Input (P2122)....86
000091.04 - Pedal Position Sensor 2 Circuit Low Input (P2127)....86
000100.03 - Oil Pressure Sensor Circuit High (P0523)....86
000100.04 - Oil Pressure Sensor Circuit Low (P0522)....86
000102.00 - Turbocharger Overboost Condition (P0234)....86
000102.03 - Turbo Charger Boost Sensor Circuit High (P0238)....86
000102.04 - Turbo Charger Boost Sensor Circuit Low (P0237)....86
000105.03 - Boost Temperature Sensor Circuit High (P1113)....86
000105.04 - Boost Temperature Sensor Circuit Low (P1112)....86
000108.03 - Barometric Pressure Circuit High (P2229)....86
000108.04 - Barometric Pressure Circuit Low (P2228)....86
000110.00 - Engine Coolant Over Temperature Condition (P0217)....86
000110.03 - Engine Coolant Temperature Sensor Circuit High (P0118)....86
000110.04 - Engine Coolant Temperature Sensor Circuit Low (P0117)....86
000132.03 - Mass Air Flow Circuit High Input (P0103)....86
000132.04 - Mass Air Flow Circuit Low Input (P0102)....86
000157.00 - Fuel Rail/System Pressure - Too High (P0088)....86
000157.03 - Fuel Rail Pressure Sensor Circuit High (P0193)....86
000157.04 - Fuel Rail Pressure Sensor Circuit Low (P0192)....86
000157.15 - Fuel Pressure Regulator Performance (P0089)....86
000157.16 - Fuel Rail/System Pressure - Too High (P0088)....86
000158.03 - System Voltage High (P0563)....86
000172.03 - Intake Air Temperature Sensor Circuit High (P0113)....86
000172.04 - Intake Air Temperature Sensor Circuit Low (P0112)....86
000173.00 - Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 (P0426)....86
000173.03 - Catalyst Temperature Sensor Circuit High Sensor 1 (P0428)....86
000173.04 - Catalyst Temperature Sensor Circuit Low Sensor 1 (P0427)....86
000174.03 - Fuel Temperature Sensor Circuit High (P0183)....86
000174.04 - Fuel Temperature Sensor Circuit Low (P0182)....86
000190.00 - Engine Overspeed Condition (P0219)....87
000628.02 - Internal Control Module Memory Check Sum Error (P0601)....87
000633.07 - Fuel Rail/System Pressure - Too Low (P0087)....87
000636.02 - Camshaft Position Sensor Circuit (P0340)....87
000636.07 - Crankshaft Position - Camshaft Position Correlation (P0016)....87
000639.02 - Lost Communication with TCM (U0101)....87
000639.19 - Control Module Communication Bus Off (U0073)....87
000651.05 - Injector Circuit - Cylinder 1 (P0201)....87
000652.05 - Injector Circuit - Cylinder 2 (P0202)....87
000653.05 - Injector Circuit - Cylinder 3 (P0203)....87
000654.05 - Injector Circuit - Cylinder 4 (P0204)....87
000723.02 - Crankshaft Position Sensor Circuit (P0335)....87
000723.08 - Crankshaft Position Sensor Circuit Range/Performance (P0336)....87
001077.02 - ECM/PCM Processor (P0606)....87
001079.02 - Sensor Reference Voltage 1 Circuit (P0641)....87
001080.02 - Sensor Reference Voltage 2 Circuit (P0651)....87
001131.03 - Intake Manifold Temperature Sensor Circuit High (P041C)....87
001131.04 - Intake Manifold Temperature Sensor Circuit Low (P041D)....87
001239.01 - Fuel System Leak Detected (P0093)....87
001239.17 - Fuel Rail Pressure (FRP) Too Low (P1093)....87
001239.31 - Fuel System Leak Detected (P0093)....87
001239.31 - Fuel Rail Pressure (FRP) Too Low (P1093)....87
001347.03 - Fuel Pressure Regulator Control Circuit High (P0092)....87
001347.04 - Fuel Pressure Regulator Control Circuit Low (P0091)....87
001381.03 - Fuel Filter Pressure Sensor Circuit High (P1294)....87
001381.04 - Fuel Filter Pressure Sensor Circuit Low (P1293)....87
001485.05 - ECM/PCM Power Relay Control Circuit/Open (P0685)....87
001485.06 - ECM/PCM Power Relay Control Circuit High (P0687)....87
010001.02 - Exhaust Gas Recirculation 1 Sensor Circuit (P0409)....87
010001.13 - Exhaust Gas Recirculation 1 Closed Position Performance (P1404)....87
010002.02 - Exhaust Gas Recirculation 1 Control Circuit Range/Performance (P0404)....87
010003.02 - Fuel Injector Group 1 Supply Voltage Circuit (P2146)....87
010004.02 - Fuel Injector Group 2 Supply Voltage Circuit (P2149)....87
010005.01 - Injector Positive Voltage Control Circuit Group 1 (P1261)....88
010006.01 - Injector Positive Voltage Control Circuit Group 2 (P1262)....88
010007.02 - ECM/PCM Processor (P0606)....88
010008.02 - Internal Control Module A/D Processing Performance (P060B)....88
010009.02 - Sensor Reference Voltage 3 Circuit (P0697)....88
010010.02 - Sensor Reference Voltage Circuit (P1655)....88
010012.02 - System Voltage (P0560)....88
010013.02 - Control Module Long Term Memory Performance (P1621)....88
010022.02 - Throttle Actuator Control Range/Performance (P0638)....88
010022.03 - Throttle Position Sensor Circuit High (P0123)....88
010022.04 - Throttle Actuator Control Range/Performance (P0122)....88
010023.02 - Lost Communication with VNT System (U0110)....88
010023.12 - Turbocharger Boost Control Solenoid Circuit (P0045)....88
010023.19 - Turbo Charger Control Module Signal Malfunction (U0411)....88
010024.03 - Catalyst Temperature Sensor Circuit High Sensor 2 (P042D)....88
010024.04 - Catalyst Temperature Sensor Circuit Low Sensor 2 (P042C)....88
010025.05 - DPD Lamp Control Circuit (P1669)....88
010026.00 - PM Over Accumulation (P1455)....88
010026.15 - DPD Restriction (P242F)....88
010027.00 - DPD Insufficient Regeneration (P1471)....88
010028.00 - Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 (P042B)....88
010029.00 - DPD Regeneration Duration (P2458)....88
010032.02 - Control Module Programming Error (P0602)....88
010033.02 - Internal Control Module Random Access Memory (RAM) Error (P0604)....88
010040.19 - CAN-Bus Malfunction (U0001)....88
Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes....736
Monitor Controller (DSZ) Diagnostic Trouble Codes....736
013000.02 - Flash Memory Failure 1....88
013001.02 - Flash Memory Failure 2....88
013002.02 - ECU Communication Error....88
013003.02 - Main Controller (MCZ) Communication Error 1....88
013004.02 - Main Controller (MCZ) Communication Error 2....88
013005.02 - Monitor Controller (DSZ) Communication Error 1....88
013006.02 - Monitor Controller (DSZ) Communication Error 2....89
013007.02 - Machine Controller (BCZ) Communication Error....89
013008.02 - Column Display Communication Failure....89
013011.02 - Option Controller (MC2) Communication Error 1....89
013012.02 - Option Controller (MC2) Communication Error 2....89
020113.02 - System Malfunction Alarm....89
020133.02 - Crane Function Alarm....89
020137.02 - Exhaust Filter Alarm....89
Group 40: Information Controller (ICZ) Diagnostic Trouble Codes....752
Information Controller (ICZ) Diagnostic Trouble Codes....752
013303.02 - Abnormal Monitor Internal Temperature Sensor....89
013304.02 - Alternator Alarm....89
013310.03 - Coolant Temperature Sensor Short Circuit....89
013311.03 - Fuel Level Sensor Open Circuit....89
013311.04 - Fuel Level Sensor Shorted Circuit....89
014000.02 - CAN Communication Error 1....89
014001.02 - Flash Memory Read/Write Error....89
014002.02 - External RAM Read/Write Error....89
014003.02 - Abnormal EEPROM....89
014006.02 - Communication Terminal: Communication Error....89
014008.02 - Abnormal Internal RAM....89
014021.02 - Communication Terminal Security Error....89
014022.02 - SIM Card Error....89
014023.02 - Security Error....89
020100.02 - Overheat Alarm....89
020101.02 - Engine Warning Alarm....89
020102.02 - Engine Oil Pressure Alarm....89
020105.02 - Hydraulic Oil Filter Restriction Alarm....89
020106.02 - Air Cleaner Restriction Alarm....89
020107.02 - Water Separator Alarm....89
020109.02 - Pilot Control Shut-Off Lever Alarm....89
020110.02 - Fuel Filter Restriction Alarm....89
020114.02 - Overheat Alarm....89
020140.02 - Intake Air Temperature and Boost Temperature Difference Alarm....90
020141.02 - Exhaust Temperature Alarm....90
020142.02 - Intake Air Temperature Alarm....90
020145.02 - Boost Temperature Increase Alarm....90
020146.02 - Fuel Temperature Increase Alarm....90
020149.02 - EGR Gas Temperature Alarm....90
Group 50: Air Conditioner Controller (ACF) Diagnostic Trouble Codes....799
Air Conditioner Controller (ACF) Diagnostic Trouble Codes....799
11 - Open Circuit in Air Recirculation Sensor....90
12 - Short-Circuited Air Recirculation Sensor....90
13 - Open Circuit in Ambient Air Temperature Sensor....90
14 - Short-Circuited Ambient Air Temperature Sensor....90
18 - Short-Circuited Solar Radiation Sensor....90
21 - Open Circuit in Air Conditioner Freeze Control Switch....90
22 - Short-Circuited Air Conditioner Freeze Control Switch....90
43 - Abnormal Air Conditioner and Heater Blower Port Change Servomotor....90
44 - Abnormal Air Conditioner and Heater Mixer Servomotor....90
91 - Communication Error....90
92 - CAN Bus Off Error....90
Section 9005: Operational Checkout Procedure....829
Group 10: Operational Checkout Procedure....829
Operational Checkout....897
Section 9010: Engine....964
Group 05: Theory of Operation....1231
Isuzu Engine....984
Engine Fuel System Component Location....967
Engine Cooling System Component Location....969
Cold Weather Starting Aid....971
Engine Speed Control System Operation....1231
Group 15: Diagnostic Information....964
Isuzu Engine....984
Group 20: Adjustments....964
Isuzu Engine....984
Group 25: Tests....964
Isuzu Engine....984
Section 9015: Electrical System....985
Group 05: System Information....985
Electrical Diagram Information....997
Group 10: System Diagrams....985
Explanation of Wire Markings....1006
Fuse and Relay Specifications....1007
System Functional Schematic, Component Location, and Wiring Diagram Master Legend....1012
System Functional Schematic....1022
Cab Harness (W1) Component Location....1038
Cab Harness (W1) Wiring Diagram....1043
Machine Harness (W2) Component Location....1050
Machine Harness (W2) Wiring Diagram....1053
Monitor Harness (W3) Component Location....1057
Monitor Harness (W3) Wiring Diagram....1058
Engine Harness (W4) Component Location....1060
Engine Harness (W4) Wiring Diagram....1063
Pump Harness (W8) Component Location....1064
Pump Harness (W8) Wiring Diagram....1065
Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location....1066
Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram....1067
Pilot Shutoff Switch Harness (W11) Component Location....1068
Pilot Shutoff Switch Harness (W11) Wiring Diagram....1069
Rear Camera Harness (W19) Component Location....1070
Rear Camera Harness (W19) Wiring Diagram....1071
Floor Harness (W25) Component Location....1072
Floor Harness (W25) Wiring Diagram....1075
Starter Switch Harness (W29) Component Location....1077
Starter Switch Harness (W29) Wiring Diagram....1078
Data Converter Harness (W30) Component Location....1079
Data Converter Harness (W30) Wiring Diagram....1080
Data Converter Interface Harness (W31) Component Location....1082
Data Converter Interface Harness (W31) Wiring Diagram....1083
Front Cab Light 1 Relay Harness (W38) Component Location....1084
Front Cab Light 1 Relay Harness (W38) Wiring Diagram....1086
Front Cab Light 2 Relay Harness (W39) Component Location....1087
Front Cab Light 2 Relay Harness (W39) Wiring Diagram....1088
Beacon Relay Harness (W40) Component Location....1089
Beacon Relay Harness (W40) Wiring Diagram....1090
Heater and Air Conditioner Harness (W41) Component Location....1091
Heater and Air Conditioner Harness (W41) Wiring Diagram....1092
Chassis Harness (W44) Component Location....1093
Chassis Harness (W44) Wiring Diagram....1095
Right Console Harness (W45) Component Location....1096
Right Console Harness (W45) Wiring Diagram....1097
Left Console Harness (W46) Component Location....1098
Left Console Harness (W46) Wiring Diagram....1099
Right Pilot Control Lever Harness (W50) Component Location....1100
Right Pilot Control Lever Harness (W50) Wiring Diagram....1101
Left Pilot Control Lever Harness (W52) Component Location....1102
Left Pilot Control Lever Harness (W52) Wiring Diagram....1103
12-Volt Power Harness (W55) Component Location....1104
12-Volt Power Harness (W55) Wiring Diagram....1105
Blade and Outrigger Control Lever Harness (W59) Component Location....1106
Blade and Outrigger Control Lever Harness (W59) Wiring Diagram....1107
Auxiliary Solenoid Harness (W61) Component Location....1108
Auxiliary Solenoid Harness (W61) Wiring Diagram....1110
Swing Park Brake Solenoid Harness (W62) Component Location....1111
Swing Park Brake Solenoid Harness (W62) Wiring Diagram....1112
Boom Positioning Solenoid Harness (W63) Component Location....1113
Boom Positioning Solenoid Harness (W63) Wiring Diagram....1114
Boom Positioning Pressure Sensor Harness (W64) Component Location....1115
Boom Positioning Pressure Sensor Harness (W64) Wiring Diagram....1117
Assist Solenoid Harness (W65) Component Location....1118
Assist Solenoid Harness (W65) Wiring Diagram....1119
Assist Pressure Sensor Harness (W66) Component Location....1120
Assist Pressure Sensor Harness (W66) Wiring Diagram....1122
Attachment Speed Solenoid Harness (W68) Component Location....1123
Attachment Speed Solenoid Harness (W68) Wiring Diagram....1124
Attachment Pressure Sensor Harness (W69) Component Location....1125
Attachment Pressure Sensor Harness (W69) Wiring Diagram....1126
Rear Cab Light Relay Harness (W72) Component Location....1127
Rear Cab Light Relay Harness (W72) Wiring Diagram....1128
Front Cab Light Jumper Harness (W76) Component Location....1129
Front Cab Light Jumper Harness (W76) Wiring Diagram....1130
Front Cab Light Harness (W77) Component Location....1131
Front Cab Light Harness (W77) Wiring Diagram....1132
Rear Cab Light Jumper Harness (W78) Component Location....1133
Rear Cab Light Jumper Harness (W78) Wiring Diagram....1134
Satellite (SAT) Harness (W6003) Component Location....1135
Satellite (SAT) Harness (W6003) Wiring Diagram....1136
JDLink™ Harness (W6004) Component Location....1137
JDLink™ Harness (W6004) Wiring Diagram....1138
Group 15: Sub-System Diagnostics....987
Controller Area Network (CAN) Theory of Operation....1231
Starting and Charging Circuit Theory of Operation....1231
Monitor Controller (DSZ) Circuit Theory of Operation....1231
Engine Control Unit (ECU) Circuit Theory of Operation....1231
Exhaust Aftertreatment Circuit Theory of Operation....1231
Main Controller (MCZ) Circuit Theory of Operation....1231
Option Controller (MC2) Circuit Theory of Operation....1231
Travel Alarm Circuit Theory of Operation....1231
Machine Controller (BCZ) Circuit Theory of Operation....1231
Windshield Wiper and Washer Circuit Theory of Operation....1231
Lighting Circuit Theory of Operation....1231
Pilot Shutoff Circuit Theory of Operation....1231
Attachment Control Circuit Theory of Operation....1231
Group 16: Monitor Operation....1231
Service Menu....1215
Troubleshooting....1217
Monitoring....1218
Controller Version....1229
Issued Warning Record....1230
Operation....1231
Machine Setting....1232
Monitor Setting....1239
Alarm Setting....1243
Engine Setting....1244
Exhaust Filter No...1245
Maintenance Mode....1246
Rear View Camera Troubleshooting....1247
Group 20: References....988
Reading Diagnostic Trouble Codes with Monitor Display....1251
Service ADVISOR™ Diagnostic Application....1252
Service ADVISOR™ Connection Procedure....1253
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application....1255
Clearing Engine Diagnostic Trouble Codes....1258
MPDr Application....1265
MPDr Connection Procedure....1266
MPDr Enabling Hydraulic Assist....1268
Electrical Component Specifications....1270
Alternator Test....1275
Electrical Component Checks....1277
Battery Remove and Install....1286
Rear Cover Remove and Install....1288
Option Controller (MC2) Remove and Install....1290
Exhaust Differential Pressure Sensor Zero Point Calibration....1293
Ash Reset....1294
No Load Max....1295
Monitor Adjustable Relief Bleed Procedure....1298
Auxiliary Relief Pressure Adjustment....1301
Monitor Controller (DSZ) Remove and Install....1304
Heater Control Disable and Enable....1306
Section 9020: Power Train....1307
Group 05: Theory of Operation....1231
Travel Hydraulic System Diagram and Operation....1449
Brake System Diagram and Operation....1313
Travel Pilot Control Valve Operation....1500
Travel Motor Crossover Relief Valve....1317
Travel Shockless Valve Operation....1319
Travel Motor and Regulator Operation....1320
Counterbalance Valve Operation....1331
Transmission Operation....1335
Shift Interlock Operation....1341
Transmission Disconnect Operation....1342
Transmission Control Valve....1344
Parking Brake Operation....1349
Service Brake Circuit Operation....1351
Brake Accumulator Charging Valve Operation....1356
Axle Lock Circuit Operation....1362
Group 15: Diagnostic Information....1307
Machine Does Not Move....1307
Machine Only Moves in One Direction....1307
Both Forward and Reverse Travel Speeds Are Slow and Travel Power is Weak....1307
Travel Mode Does Not Shift Between Fast and Slow....1307
Axle Lock is Not Released....1307
Axle Lock is Not Operable....1307
Transmission Park Brake Is Not Operable (not applied)....1307
Service Brake Not Operable (not applied effectively)....1307
Work Brake Not Operable....1307
Travel Hydraulic System Schematic....1715
Travel Hydraulic System Component Location....1736
Travel Hydraulic System Line Identification....1408
Service Brake System Schematic....1409
Service Brake System and Axle Lock System Component Location....1411
Service Brake System and Axle Lock System Line Identification....1413
Axle Lock System Schematic....1414
Group 20: Tests and Adjustments....1308
Brake Accumulator Pressure Test....1420
Brake Bleeding Procedure....1423
Brake Warning Set Pressure (Decrease)....1426
Brake Warning Set Pressure (Increase)....1429
Front Brake Pressure Test....1432
Rear Brake Pressure Test....1435
Transmission Control Valve Pressure Test....1438
Transmission Manual Disconnection Procedure....1441
Section 9025: Hydraulic System....1443
Group 05: Theory of Operation....1231
Hydraulic System Diagram and Operation....1449
Pilot System Diagram and Operation....1451
Steering System Diagram and Operation....1457
Blade or Outrigger System Diagram and Operation....1458
Hydraulic Assist Diagram and Operation....1460
Two-Piece Boom Positioning Diagram and Operation....1462
Pilot Pressure Regulating Valve Operation....1464
Pilot Shutoff Solenoid Valve Operation....1466
Pilot Control Valve Operation....1500
Travel Pilot Control Valve Operation....1500
Pilot Operation of Control Valve Operation....1500
Pilot Signal Manifold Operation....1478
Pump 1, Pump 2, and Drive Gear Case Operation....1487
Pump 1 and Pump 2 Regulator Operation....1490
Engine Speed Sensing Control Circuit Operation....1497
Control Valve Operation....1500
Control Valve Check Valves Identification and Operation....1516
Main Relief Valve Circuit Operation....1521
Circuit Relief and Anticavitation Valve Operation....1526
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation....1528
Travel Flow Combiner Valve Operation....1533
Boom Lower Meter-In Cut Valve Operation....1536
Boom Regenerative Valve Circuit Operation....1539
Arm Regenerative Valve Circuit Operation....1541
Bucket Regenerative Valve Circuit Operation....1546
Boom and Arm Reduced Leakage Valves Operation....1548
Arm 1 Flow Rate Control Valve Circuit Operation....1550
Arm 2 Flow Rate Control Valve Circuit Operation....1554
Bucket Flow Rate Control Valve Circuit Operation....1558
Boom Flow Rate Control Valve Circuit Operation....1562
Auxiliary Flow Rate Control Valve Circuit Operation....1567
Swing Reduction Gear Case Operation....1572
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation....1573
Swing Motor Damper Valve....1577
Swing Motor Park Brake Release Circuit Operation....1588
Center Joint Operation....1589
Steering Valve Operation....1591
Blade or Outrigger Check Valve Operation....1596
Cylinder Operation....1597
Return Filter Operation....1599
Auxiliary System Operation....1600
Auxiliary Pilot Control Valve Operation....1601
Flow Rate Select Solenoid Valve Operation....1603
Flow Rate Pressure Reducing Valve Operation....1605
Auxiliary Shuttle Valve Operation....1607
Auxiliary High Flow Line Kit Operation....1609
Two Pump Combined Flow Kit Operation....1615
Group 15: Diagnostic Information....1444
All Hydraulic Functions Slow....1444
Hydraulic Oil Overheats....1444
No Hydraulic Functions....1444
No Hydraulic Functions—Electrical Checks....1444
Function Does Not Stop When Control Lever Released....1444
Load Drifts Down When Control Lever is in Neutral Position....1444
Load Falls When Control Valve is Actuated To Raise Load....1444
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal....1444
Boom Down Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal....1444
Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal....1444
Swing Speed Slow During Arm In Function....1444
Boom Cannot Raise Wheels Off Ground....1444
Swing Function Does Not Operate in Both Directions....1444
Swing Speed Slow in Both Directions....1444
Swing Speed Slow or Does Not Operate in One Direction....1444
Upperstructure Drift With Swing Valve in Neutral....1444
No Steering Function....1445
Constant Steering to Maintain Straight Travel....1445
Steering Wheel Turns but Front Axle Does Not Respond....1445
Erratic Steering....1445
No Blade or Outrigger Function....1445
Blade or Outriggers Will Not Raise....1445
Blade or Outrigger Will Not Lower....1445
Blade or Outrigger Cylinder Will Not Function....1445
Assist Functions Do Not Operate....1445
Assist Function Does Not Operate in One Direction....1445
Pump 1, Pump 2, Steering Pump, and Pilot Pump Line Identification....1695
Control Valve Line Identification....1698
Swing Motor Line Identification....1701
Pilot Control Line Connections....1702
Steering System Component Location....1706
Steering System Line Connection....1707
Auxiliary Attachment Schematic....1708
Auxiliary System Line Connections....1713
Hydraulic System Schematic....1715
Hydraulic System Component Location....1736
Hydraulic System Line Connections....1738
Group 25: Tests....1445
JT05800 Digital Thermometer Installation....1740
JT02156A Digital Pressure and Temperature Analyzer Kit Installation....1741
General Hydraulic Oil Cleanup Procedure....1742
Hydraulic Component Failure Cleanup Procedure....1745
Hydraulic Oil Tank Pressure Release Procedure....1748
Hydraulic Oil Warm-Up Procedure....1749
Pilot Pressure Regulating Valve Test and Adjustment....1752
Control Valve Spool Actuating Pilot Pressure Test....1757
Arm Regenerative Solenoid Valve Test and Adjustment....1760
Arm 2 Flow Rate Solenoid Valve Test and Adjustment....1765
Bypass Shutoff Control Solenoid Valve Test and Adjustment....1770
Power Dig Solenoid Valve Test and Adjustment....1775
Axle Lock Solenoid Valve Test and Adjustment....1780
Work Brake Solenoid Valve Test and Adjustment....1785
Pump 1 Secondary Flow Control Solenoid Valve Test and Adjustment....1790
Pump 2 Secondary Flow Control Solenoid Valve Test and Adjustment....1795
Torque Control Solenoid Valve Test and Adjustment....1800
Pump Control Pilot Pressure Signal Test....1805
Main Relief and Power Dig Valve Test and Adjustment....1808
Circuit Relief Valve Test and Adjustment....1814
Swing Motor Crossover Relief Valve Test and Adjustment....1821
Steering Relief Valve Pressure Test....1826
Two-Piece Boom Positioning and Hydraulic Assist Relief Valve Test and Adjustment....1829
Pump Flow Test....1834
Comprehensive Pump Flow Test....1838
Swing Motor Leakage Test....1844
Steering System Leakage Test....1847
Steering Cylinder Leakage Test....1849
Cylinder Drift Test—Boom, Arm, and Bucket....1851
Upperstructure Drift Test....1853
Section 9031: Heating and Air Conditioning....1856
Group 05: Theory of Operation....1231
Air Conditioning System Cycle of Operation....1859
Group 15: Diagnostic Information....1856
Air Conditioning System Does Not Operate....1856
Air Conditioning System Does Not Cool Interior of Cab....1856
Air Conditioning System Runs Constantly, Too Cold....1856
Heating System Does Not Operate....1856
Heating System Does Not Warm Interior of Cab....1856
Interior Windows Continue to Fog....1856
Heater and Air Conditioner Component Location....1883
Group 25: Tests....1856
R134a Refrigerant Cautions and Proper Handling....1886
R134a Oil Charge Capacity....1887
R134a Refrigerant Charge Capacity....1888
Heater and Air Conditioner Operational Checks....1889
Air Conditioner Compressor Clutch Test....1892
R134a Refrigerant Leak Test....1893
R134a Refrigerant Hoses and Tubing Inspection....1894
Air Conditioner High/Low-Pressure Switch Test....1895
Air Conditioner Freeze Control Switch Test....1898
Air Conditioning System Test....1899
Operating Pressure Diagnostic Chart....1902
Section 9900: Dealer Fabricated Tools....1904
Group 99: Dealer Fabricated Tools....1904
DFT1218 Split Flange Hose Cap....1906
John Deere Wheeled Excavator 230GW Operation and Test Service Manual (TM13249X19)
