John Deere 650DLC Excavators Operation and Test Service Manual (TM10008)

TM10008 - John Deere 650DLC Excavators Technical Manual - Operation and Test.PDF

Complete Diagnostic, Operation and Test manual with Electrical Wiring Diagrams for John Deere 650DLC Excavators, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 650DLC Excavators 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.

Total Pages: 1,372 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   Technical Information Feedback Form
   General Information
      Safety
   Diagnostics
      Main Controller (MCF) Diagnostic Trouble Codes
      Engine Control Module (ECM) Diagnostic Trouble Codes
      Information Controller (ICF) Diagnostic Trouble Codes
      Air Conditioner Controller (ACF) Diagnostic Trouble Codes
      Monitor Controller (MON) Diagnostic Trouble Codes
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      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 System
      Theory Of Operation
      Diagnostic Information
      Tests
   Reference Material
      Terminology Cross Reference Chart

tm10008 - 650DLC Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

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

Avoid Machine Tip Over

Use Special Care When Lifting Objects

Add and Operate Attachments Safely

Prevent Unintended Detonation of Explosive Devices

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostics

Group 10: Main Controller (MCF) Diagnostic Trouble Codes

Main Controller (MCF) Diagnostic Trouble Codes

11000.02 - Abnormal EEPROM

11001.02 - Abnormal RAM

11002.02 - Abnormal A/D Conversion

11003.03 - Abnormal Sensor Voltage

11004.02 - CAN Communication Error

11101.03 - Engine Speed Dial sensor Circuit Voltage High Input

11101.04 - Engine Speed Dial Sensor Circuit Voltage Low Input

11200.03 - Pump 1 Delivery Pressure Sensor Circuit Voltage High

11200.04 - Pump 1 Delivery Pressure Sensor Voltage Low

11202.03 - Pump 2 Delivery Pressure Sensor Circuit Voltage High

11202.04 - Pump 2 Delivery Pressure Sensor Voltage Low

11301.03 - Swing Pilot Pressure Sensor Circuit Voltage High

11301.04 - Swing Pilot Pressure Sensor Circuit Voltage Low

11302.03 - Boom Raise Pilot Pressure Sensor Circuit Voltage High

11302.04 - Boom Raise Pilot Pressure Sensor Circuit Voltage Low

11303.03 - Arm Roll-in Pilot Pressure Sensor Circuit Voltage High

11303.04 - Arm Roll-in Pilot Pressure Sensor Circuit Voltage Low

11400.03 - Pump 2 (5-Spool) Control Solenoid Valve Feedback Current High

11400.04 - Pump 2 (5-Spool) Control Solenoid Valve Feedback Current Low

11402.03 - Boom Flow Rate Solenoid (SF) Valve Feedback Current High

11402.04 - Boom Flow Rate Solenoid (SF) Valve Feedback Current Low

11404.03 - Power Dig Solenoid (SG) Valve Feedback Current High

11404.04 - Power Dig Solenoid (SG) Valve Feedback Current Low

11405.03 - Travel Speed Solenoid (SI) Valve Current Feedback High

11405.04 - Travel Speed Solenoid (SI) Valve Current Feedback Low

11410.03 - Pump 1 (4-Spool) Control Solenoid Valve Feedback Current High

11410.04 - Pump 1 (4-Spool) Control Solenoid Valve Feedback Current Low

11412.03 - Hydraulic Fan Pump Control Solenoid Valve Feedback Current High

11412.04 - Hydraulic Fan Pump Solenoid Valve Feedback Current Low

11802.03 - Boom Pressure Sensor Circuit Voltage High

11802.04 - Boom Pressure Sensor Circuit Voltage Low

11901.03 - Hydraulic Oil Temperature Sensor Circuit Voltage High

11901.04 - Hydraulic Oil Temperature Sensor Circuit Voltage Low

11910.02 - Actual Engine Speed Message Error

11911.02 - Security Signal Message Error

11914.02 - Radiator Coolant Temperature Message Error

11918.02 - Work Mode Message Error

11920.02 - Fuel Flow Rate Message Error

11976.03 - Auxiliary Valve 2 Feedback Current High

11976.04 - Auxiliary Valve 2 Feedback Current Low

11977.03 - Auxiliary Valve 1 Feedback Current High

11977.04 - Auxiliary Valve 1 Feedback Current Low

11980.03 - ATT Relief Change Valve Feedback Current High

11980.04 - ATT Relief Change Valve Feedback Current Low

11981.03 - Fan Reversing Solenoid Valve 2 Feedback Current High

11981.04 - Fan Reversing Solenoid Valve 2 Feedback Current Low

11982.03 - Fan Reversing Solenoid Valve 1 Feedback Current High

11982.04 - Fan Reversing Solenoid Valve 1 Feedback Current Low

11983.02 - Intake Air Temperature Message Error

11984.02 - Boost Temperature Message Error

11989.03 - Boom Mode Solenoid (SC) Valve Feedback Current High

11989.04 - Boom Mode Solenoid (SC) Valve Feedback Current Low

11991.03 - Travel Right Pilot Pressure Sensor Circuit Voltage High

11991.04 - Travel Right Pilot Pressure Sensor Circuit Voltage Low

11992.03 - Pump 2 (5-Spool) Control Pressure Sensor Circuit Voltage High

11992.04 - Pump 2 (5-Spool) Control Pressure Sensor Circuit Voltage Low

11993.03 - Travel Left Pilot Pressure Sensor Circuit Voltage High

11993.04 - Left Travel Pilot Pressure Sensor Circuit Low Input

11994.03 - Pump 1 (4-Spool) Control Pressure Sensor Circuit Voltage High

11994.04 - Pump 1 (4-Spool) Control Pressure Sensor Circuit Voltage Low

11995.03 - Arm Roll-Out Pilot Pressure Sensor Circuit Voltage High

11995.04 - Arm Roll-Out Pilot Pressure Sensor Circuit Low Input

11997.03 - Bucket Dump Pilot Pressure Sensor Circuit Voltage High

11997.04 - Bucket Dump Pilot Pressure Sensor Circuit Voltage Low

11998.03 - Boom Down Pilot Pressure Sensor Circuit Voltage High

11998.04 - Boom Down Pilot Pressure Sensor Circuit Voltage Low

11999.03 - Bucket Curl Pilot Pressure Sensor Circuit Voltage High

11999.04 - Bucket Curl Pilot Pressure Sensor Circuit Voltage Low

Group 20: Engine Control Module (ECM) Diagnostic Trouble Codes

Engine Control Module (ECM) Diagnostic Trouble Codes

91.02 - Accelerator Sensor 1-2 Comparison (P1271)

100.03 - Engine Oil Pressure Sensor Voltage Low (P0522)

100.04 - Engine Oil Pressure Sensor Voltage High (P0523)

102.03 - Boost Pressure Sensor Voltage Low (P0237)

102.04 - Boost Pressure Sensor Voltage High (P0238)

105.03 - Boost Temperature Sensor Voltage High (P1113)

105.04 - Boost Temperature Sensor Voltage Low (P1112)

108.03 - Barometric Pressure Sensor Voltage Low (P0107)

108.04 - Barometric Pressure Sensor Voltage High (P0108)

110.03 - Engine Coolant Temperature Sensor Voltage High (P0118)

110.04 - Engine Coolant Temperature Sensor Voltage Low (P0117)

157.00 - Common Rail Pressure—First Stage (P088)

157.00 - Common Rail Pressure—Second Stage (P088)

157.02 - Common Rail Pressure High (P0089)

157.03 - Common Rail Pressure Sensor Voltage High (P0193)

157.04 - Common Rail Pressure Sensor Voltage Low (P0192)

172.03 - Intake Air Temperature Sensor Voltage High (P0113)

172.04 - Intake Air Temperature Sensor Voltage Low (P0112)

174.03 - Fuel Temperature Sensor Voltage High (P0183)

174.04 - Fuel Temperature Sensor Voltage Low (P0182)

190.00 - Engine Overspeed (P0219)

628.02 - ROM Malfunction (P0601)

633.07 - Pressure Limiter Open (P1095)

636.02 - Camshaft Position Sensor (G-Sensor) Signal Missing (P0340)

636.02 - Camshaft Position Sensor (G-Sensor) Signal Mismatch (P0341)

636.07 - Camshaft Position Sensor (G-Sensor) out of Phase (P1345)

639.02 - CAN Communication Error (U2104)

639.03 - CAN Timeout (U2106)

651.03 - Open Circuit in Injection Nozzle #1 (P0201)

652.03 - Open Circuit in Injection Nozzle #2 (P0202)

653.03 - Open Circuit in Injection Nozzle #3 (P0203)

654.03 - Open Circuit in Injection Nozzle #4 (P0204)

655.03 - Open Circuit in Injection Nozzle #5 (P0205)

656.03 - Open Circuit in Injection Nozzle #6 (P0206)

723.02 - Crankshaft Position Sensor Signal Missing (P0335)

723.02 - Crankshaft Sensor Mismatch (P0336)

987.03 - Check Engine Lamp Malfunction (P0650)

1077.02 - CPU Fault Malfunction (P0606)

1079.02 - 5 Volt Power Supply #1 Malfunction (P1631)

1080.02 - 5 Volt Power Supply #2 Malfunction (P1632)

1239.01 - No Pump Pressure—First Stage (P1094)

1240.01 - No Pump Pressure Feed—Second Stage (P1093)

1347.00 - PCV #1 Open Circuit or Short to Ground (P0092)

1347.04 - PCV #1 Short to Power (P0091)

1348.00 - PCV # 2 Open Circuit or Short to Ground (P1291)

1348.04 - PCV #2 Short to Power (P1292)

1381.03 - Fuel Filter Pressure Sensor Voltage High (P1294)

1381.04 - Fuel Filter Pressure Sensor Voltage Low (P1293)

1485.02 - Engine Control Module Relay Malfunction (P1625)

10001.03 - EGR Position Sensor Malfunction (P0487)

10002.02 - EGR Valve Control Malfunction (P0488)

10003.02 - Injection Nozzle Common #1 Malfunction (P1261)

10004.02 - Injection Nozzle Common #2 Malfunction (P1262)

10005.01 - Charge Circuit Malfunction—Bank 1 (P0611)

10006.01 - Charge Circuit Malfunction—Bank 2 (P0612)

10007.02 - CPU Monitoring IC Malfunction (P0606)

10008.02 - A/D Conversion Malfunction (P1630)

10009.02 - 5 Volt Power Supply #3 Malfunction (P1633)

10010.02 - 5 Volt Power Supply #4 Malfunction (P1634)

10011.02 - 5 Volt Power Supply #5 Malfunction (P1635)

10013.02 - EEPROM Malfunction (P0603)

20100.02 - Engine Coolant Temperature High

20101.02 - Engine Warning

20110.02 - Fuel Filter Restricted (Level 1)

20110.02 - Fuel Filter Restricted (Level 2)

Group 30: Information Controller (ICF) Diagnostic Trouble Codes

Information Controller (ICF) Diagnostic Trouble Codes

14000.02 - Abnormal CAN Communication

14001.02 - ICF: Flash Memory: Read/Write Error

14002.02 - ICF: External RAM: Read/Write Error

14003.02 - ICF: EEPROM: Sum Check Error

14006.02 - ICF: Satellite Communication Terminal: Communication Error

14008.02 - ICF: Abnormal Internal RAM

14100.02 - Satellite Communication Terminal: Abnormal EEPROM

14101.02 - Satellite Communication Terminal: Abnormal IB/OB Queue

14102.02 - Satellite Communication Terminal: Abnormal Local Loop Back

14103.02 - Satellite Communication Terminal: The satellite is not found.

14104.02 - Satellite Communication Terminal: Fail 1 of Remote Loop Back

14105.02 - Satellite Communication Terminal: Fail 2 of Remote Loop Back

14106.02 - Satellite Communication Terminal: Sending and receiving data are mismatched

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

Air Conditioner Controller (ACF) Diagnostic Trouble Codes

E11 - Cab Air Temperature Sensor Open Circuit

E12 - Cab Air Temperature Sensor Short Circuit

E13 - Ambient Air Temperature Sensor Open Circuit

E14 - Ambient Air Temperature Sensor Short Circuit

E15 - Coolant Temperature Sensor Open Circuit

E16 - Coolant Temperature Sensor Short Circuit

E18 - Solar Sensor Abnormal

E21 - Freeze Control Switch Open Circuit

E22 - Freeze Control Switch Short Circuit

E43 - Abnormal Damper

E44 - Abnormal Damper

E45 - Abnormal Damper

E51 - Abnormal High/Low Pressure Switch

Group 50: Monitor Controller (MON) Diagnostic Trouble Codes

Monitor Controller (MON) Diagnostic Trouble Codes

13303.02 - Abnormal Thermister Temperature

13304.02 - Abnormal REG Input H Level

13306.02 - Abnormal EEPROM

13308.02 - Abnormal CAN Communication

13310.02 - Shorted circuit in Coolant Temperature Sensor

13311.03 - Shorted circuit in Fuel Level Sensor

13311.04 - Open circuit in Fuel Level Sensor

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Engine Component Location

Engine Fuel System Operation

Engine Cooling System Operation

Engine Lubrication System Operation

Engine Intake and Exhaust System Operation

Engine Turbocharger Operation

Exhaust Gas Recirculation (EGR) Operation

Quick On Start (QOS) System Operation

Engine Speed Control System Operation

Group 15: Diagnostic Information

Isuzu AH-6WG1XYSA-02

Diagnose Engine Malfunctions

Engine Cranks But Will Not Start

Engine Misfires Or Runs Irregularly

Engine Does Not Develop Full Power

Engine Overheats

Auto-Idle Does Not Work

Coolant Temperature Too Low

Coolant in Oil or Oil in Coolant

Low Engine Oil Pressure

High Engine Oil Pressure

Engine Uses Too Much Oil

Engine Uses Too Much Fuel

Engine Emits Excessive White Exhaust Smoke

Engine Emits Excessive Black or Gray Exhaust Smoke

Turbocharger Excessively Noisy or Vibrates

Oil Dripping From Turbocharger Adapter

Excessive Drag in Turbocharger Rotating Members

Fuel In Oil

Group 25: Tests

Serpentine Belt Tension Check

Check and Adjust Injection Pump Timing

Engine Valve Lash (Clearance) Check and Adjust

Engine Compression Pressure Test

Air Filter Restriction Indicator Switch Test

Air Intake System Leakage Test

Engine Power Test Using Turbocharger Boost Pressure

Engine Oil Pressure Test

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, Wiring Diagram, and Component Location 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

Engine Interface Harness (W5) Component Location

Engine Interface Harness (W5) Wiring Diagram

Air Conditioner Harness (W6) Component Location

Air Conditioner Harness (W6) Wiring Diagram

Control Valve Harness (W7) Component Location

Control Valve Harness (W7) Wiring Diagram

Pump Harness (W8) Component Location

Pump Harness (W8) Wiring Diagram

Auxiliary Fuse Box Harness (W9) Component Location

Auxiliary Fuse Box Harness (W9) Wiring Diagram

Cab Switch Harness (W10) Component Location

Cab Switch Harness (W10) Wiring Diagram

Pilot Shutoff Switch Harness (W11) Component Location

Pilot Shutoff Switch Harness (W11) Wiring Diagram

Heated Air Seat Harness (W12) Component Location

Heated Air Seat Harness (W12) Wiring Diagram

Seat Heater Switch Harness (W13) Component Location

Seat Heater Switch Harness (W13) Wiring Diagram

Multi-Function Pilot Control Lever Harness (W14) Component Location

Multi-Function Pilot Control Lever Harness (W14) Wiring Diagram

Travel Alarm Cancel Switch Harness (W15) Component Location

Travel Alarm Cancel Switch Harness (W15) Wiring Diagram

Reversing Fan Switch Harness (W16) Component Location

Reversing Fan Switch Harness (W16) Wiring Diagram

Pilot Shutoff Valve Harness (W17) Component Location

Pilot Shutoff Valve Harness (W17) Wiring Diagram

Radiator Harness (W19) Component Location

Radiator Harness (W19) Wiring Diagram

Service Advisor Connector Harness (W22) Component Location

Service Advisor Connector Harness (W22) Wiring Diagram

JDLink™ System Harnesses Component Location—MIG/GTT

JDLink™ System Harnesses Component Location—MTG/SAT

JDLink™ System Wiring Diagrams—MIG/GTT

JDLink™ System Wiring Diagrams—MTG/SAT

Group 15: Sub-System Diagnostics

Controller Area Network (CAN) Theory of Operation

Starting and Charging Circuit Theory of Operation

Quick On System (QOS) Preheat Circuit Theory of Operation

Monitor Circuit Theory of Operation

Engine Control Module (ECM) Circuit Theory of Operation

Main Controller (MCF) Circuit Theory of Operation

Information Controller (ICF) Theory of Operation

Travel Alarm Circuit Theory of Operation

Windshield Wiper and Washer Circuit Theory of Operation

Pilot Shutoff Circuit Theory of Operation

JDLink™ Circuit Theory of Operation—If Equipped

Group 16: Monitor Operation

Monitor Menu Operation

Monitor Service Menu Operation

Group 20: References

Monitor Data Items

Monitor Data Items Using the Monitor Display

Reading Diagnostic Trouble Codes With Monitor Display

JDLink™ System Identification

JDLink™ Connection Procedure

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application

MPDr Application

MPDr Connection Procedure

Service ADVISOR™ Interactive Tests

Information Controller (ICF) Recorded Data

Pump Learning Procedure

Fuse Test

Relay Test

Pressure Sensor Test

Solenoid Test

Proportional Solenoid Test

Alternator Test

Electrical Component Checks

Battery Remove and Install

Rear Cover Remove and Install

Main Controller (MCF) Remove and Install

Engine Control Module (ECM) Remove and Install

Information Controller (ICF) Remove and Install

Monitor Controller Remove and Install

Key Switch Remove and Install

Switch Panel Remove and Install

Travel Alarm Remove and Install

Left Console Switch Remove and Install

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Clip Connectors

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

Replace CINCH CINCH is a trademark of the Cinch Co. Connectors

Install CINCH CINCH is a trademark of the Cinch Co. Contact

Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors

Remove Connector Body from Blade Terminals

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Travel Gearbox Operation

Group 15: Diagnostic Information

Diagnose Undercarriage Components Malfunctions

Measure Swing Bearing Wear

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Diagram and Operation

Fan Drive System Diagram and Operation

Pilot System Diagram and Operation

Pilot Pump, Pressure Regulating Valve, and Filter Operation

Pilot Check Valve Manifold and Accumulator Operation

Boom Lowering With Engine Stopped Circuit Operation

Pilot Shutoff Solenoid Valve Operation

Pilot Control Valve Operation

Travel Pilot Control Valve Operation

Boom Up Shockless Valve Operation

Pilot Signal Manifold Operation

Pilot Operation of Control Valve Operation

Pump 1 and 2, Fan Drive Pump, and Gearbox Operation

Pump 1 and 2 Regulator Operation

Fan Drive Pump Regulator Operation

Control Valve Operation

Control Valve Check Valves Identification and Operation

Main Relief and Power Digging Valve Circuit Operation

Circuit Relief and Anticavitation Valve Operation

Arm Make-Up Check Valve Operation

Travel Flow Combiner Valve Circuit Operation

Boom Regenerative Valve Circuit Operation

Arm Regenerative Valve Circuit Operation

Bucket Regenerative Valve Circuit Operation

Boom and Arm Reduced Leakage Valves Operation

Boom Flow Rate Circuit Operation

Arm 2 Flow Rate Circuit Operation

Boom Mode Circuit Operation

Counterweight Removal Circuit Operation

Swing Gearbox Operation

Swing Motor and Park Brake Circuit Operation

Swing Motor Park Brake Release Circuit Operation

Center Joint Operation

Travel Motor and Park Brake Circuit Operation

Travel Motor Speed Circuit Operation

Boom, Arm, and Bucket Cylinder Operation

Counterweight Removal Cylinder Operation

Return Filter Operation

Group 15: Diagnostic Information

Diagnose No Hydraulics Malfunctions

Diagnose All Hydraulics Slow Malfunctions

Diagnose All Hydraulic Functions Too Fast Malfunctions

Diagnose Hydraulic Overheating Malfunctions

Diagnose Fan Drive Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Diagnose Travel Circuit Malfunctions

Diagnose Counterweight Removal System Malfunctions

Diagnose Auto Lubrication System Malfunctions

Pump 1, Pump 2, Fan Drive Pump, and Pilot Pump Line Connections

Control Valve Line Identification

Swing Motor Line Identification

Control Lever Pattern Conversion

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 Connections

Travel Hydraulic System Component Location

Travel Hydraulic System Line Connection

Fan Drive System Component Location

Fan Drive System Line Connections

Hydraulic System Component Location

Hydraulic System Line Connections

Counterweight Removal Hydraulic System Component Location

Counterweight Removal Hydraulic System Line Connections

Hydraulic System Schematic

Group 25: Tests

Hydraulic Test Port Location

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic Oil Warm-Up Procedure

Pilot Pressure Regulating Valve Test and Adjustment

Control Valve Spool Actuating Pilot Pressure Test

Power Dig Solenoid Valve (port SG) Test and Adjustment

Travel Speed Solenoid Valve (port SI) Test and Adjustment

Boom Mode Solenoid Valve (port SC) Test and Adjustment

Boom Flow Rate Solenoid Valve (port SF) Test and Adjustment

Main Relief and Power Digging Valve Test and Adjustment

Circuit Relief Valve Test and Adjustment

Boom Mode Relief Valve Test and Adjustment

Pump Servo Piston Minimum Flow Test and Adjustment

Pump Servo Piston Maximum Flow Test and Adjustment

Pump Flow Rate (Displacement) Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Travel Motor Crossover Relief Valve Test and Adjustment

Swing Motor Leakage Test

Travel Motor Leakage Test

Cylinder Drift Test—Arm, Boom, and Bucket

Pump Flow Test

Fan Speed Tests

Fan Motor Case Drain Test

Fan Drive Pump Flow Test

Fan Drive System Relief Valve Test and Adjustment

Fan Drive Pump Servo Piston Minimum Flow Test and Adjustment

Fan Drive Pump Servo Piston Maximum Flow Test and Adjustment

Fan Drive Pump Flow Rate Test and Adjustment

Fan Drive Pump Torque Control Test and Adjustment

Section 9031: Heating and Air Conditioning System

Group 05: Theory Of Operation

Air Conditioning System Cycle of Operation

Group 15: Diagnostic Information

Diagnose Air Conditioning System Malfunctions

Diagnose Heating System Malfunctions

Air Conditioner and Heater Diagnostic Trouble Code Check

Heater and Air Conditioner Component Location

Group 25: Tests

Refrigerant Cautions and Proper Handling

Heating and Air Conditioning Operational Checks

R134a Air Conditioning System Test

Air Conditioner Compressor Clutch Test

Refrigerant Leak Test

Refrigerant Hoses and Tubing Inspection

Air Conditioner Compressor Belt Check and Adjustment

Operating Pressure Diagnostic Chart

Section 9050: Reference Material

Group 05: Terminology Cross Reference Chart

Terminology Cross Reference Chart