John Deere 135G Excavator Operation & Tests Technical Manual (TM14053X19)

tm14053x19 - John Deere 135G Excavator Technical Manual - Operation & Tests.pdf

Complete service diagnostic operation test manual with Electrical Wiring Diagrams for John Deere 135G Excavator, with all the workshop information to maintain, diagnose, rebuild like professional mechanics.

John Deere 135G Excavator workshop service 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.

PRODUCT DETAILS:
Total Pages: 1,598 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

tm14053x19 - 135G Excavator

Table of Contents

Foreword

Manual Identification—READ THIS FIRST!

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Control Pattern Selector—If Equipped

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Work In Ventilated Area

Avoid Static Electricity Risk When Refueling

Prevent Fires

In Case of Machine Fire

Prevent Battery Explosions

Handle Chemical Products Safely

Handle Starting Fluid Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Exhaust Filter Ash Handling and Disposal

Prepare for Emergencies

Clean Debris from Machine

Add Cab Guarding for Special Uses

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

Inspect and Maintain ROPS

Travel Safely

Prevent Acid Burns

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Clean Exhaust Filter Safely

Section 9001: Diagnostics

Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Main Controller (MCZ) Diagnostic Trouble Codes

Controller Area Network 0 (CAN 0) Circuit Diagnostics

Controller Area Network 1 (CAN 1) Circuit Diagnostics

Interface Controller Area Network (N-CAN) Diagnostics

Engine Controller Area Network (Engine CAN) Diagnostics

Aftertreatment Controller Area Network (DCU CAN) Diagnostics

011000.02 - Abnormal EEPROM

011001.02 - Abnormal RAM

011002.02 - Abnormal A/D Converter

011003.03 - Abnormal Sensor Voltage

011006.02 - Engine Controller Communication Error

011007.02 - (CAN 0) Data Converter Communication Error 1

011008.02 - (CAN 1) Data Converter Communication Error 2

011009.02 - (CAN 0) Monitor Controller Communication Error 1

011010.02 - (CAN 1) Monitor Controller Communication Error 2

011100.02 - Abnormal Engine Speed

011101.03 - Engine Speed Dial Sensor Circuit High Input

011101.04 - Engine Speed Dial Sensor Circuit Low Input

011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input

011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input

011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input

011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input

011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input

011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input

011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input

011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input

011301.03 - Swing Pilot Pressure Sensor Circuit High Input

011301.04 - Swing Pilot Pressure Sensor Circuit Low Input

011302.03 - Boom Up Pilot Pressure Sensor Circuit High Input

011302.04 - Boom Up Pilot Pressure Sensor Circuit Low Input

011303.03 - Arm Roll-In Pilot Pressure Sensor Circuit High Input

011303.04 - Arm Roll-In Pilot Pressure Sensor Circuit Low Input

011304.03 - Travel Pilot Pressure Sensor Circuit High Input

011304.04 - Travel Pilot Pressure Sensor Circuit Low Input

011307.03 - Front Attachment Pilot Pressure Sensor Circuit High Input

011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input

011325.03 - Bucket Roll-In Pilot Pressure Sensor Circuit High Input

011325.04 - Bucket Roll-In Pilot Pressure Sensor Circuit Low Input

011400.02 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal

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

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

011401.02 - Torque Control Solenoid Valve Abnormal Feedback

011401.03 - Torque Control Solenoid Valve Feedback High Current

011401.04 - Torque Control Solenoid Valve Feedback Low Current

011402.02 - Dig Regenerative Solenoid Valve Feedback Current Abnormal

011402.03 - Dig Regenerative Solenoid Valve Feedback Current High

011402.04 - Dig Regenerative Solenoid Valve Feedback Current Low

011403.02 - Arm Regenerative Solenoid Valve Feedback Current Abnormal

011403.03 - Arm Regenerative Solenoid Valve Feedback Current High

011403.04 - Arm Regenerative Solenoid Valve Feedback Current Low

011407.02 - Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal

011407.03 - Power Dig/Travel Speed Solenoid Valve Feedback Current High

011407.04 - Power Dig/Travel Speed Solenoid Valve Feedback Current Low

011408.02 - Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal

011408.03 - Exhaust Aftertreatment Solenoid Valve Feedback Current High

011408.04 - Exhaust Aftertreatment Solenoid Valve Feedback Current Low

011409.02 - Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal

011409.03 - Exhaust Aftertreatment Solenoid Valve Feedback Current High

011409.04 - Exhaust Aftertreatment Solenoid Valve Feedback Current Low

011410.02 - Pump 1 Flow Rate Limit Solenoid Valve Feedback Abnormal

011410.03 - Pump 1 Flow Rate Limit Solenoid Valve Feedback High Input

011410.04 - Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Input

011428.02 - Arm 2 Flow Control Solenoid Valve Feedback Abnormal

011428.03 - Arm 2 Flow Control Solenoid Valve Feedback High Input

011428.04 - Arm 2 Flow Control Solenoid Valve Feedback Low Input

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

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

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

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

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

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

011436.02 - Breaker Relief Proportional Solenoid Valve Abnormal Feedback

011436.03 - Breaker Relief Proportional Solenoid Valve Feedback High Current

011436.04 - Breaker Relief Proportional Solenoid Valve Feedback Low Current

011457.02 - 2-Speed Activation Solenoid Disconnected or Not Present

011458.02 - Selector Valve Solenoid Valve Disconnected

011459.02 - Idle Stop Relay Circuit Malfunction

011810.03 - Electric Lever Operating Pressure Sensor 1 High Voltage

011810.04 - Electric Lever Operating Pressure Sensor 1 Low Voltage

011812.02 - OPT Electric Lever 1 Neutral Abnormal

011813.02 - OPT Electric Lever 1 Abnormal Operation

011816.02 - OPT Solenoid 1 Feedback Abnormal

011816.03 - OPT Solenoid 1 Feedback Current High

011816.04 - OPT Solenoid 1 Feedback Current Low

011817.02 - OPT Solenoid 2 Feedback Abnormal

011817.03 - OPT Solenoid 2 Feedback Current High

011817.04 - OPT Solenoid 2 Feedback Current Low

011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input

011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input

011995.03 - Arm Roll-Out Pilot Pressure Sensor Circuit High Input

011995.04 - Arm Roll-Out Pilot Pressure Sensor Circuit Low Input

011997.03 - Bucket Roll-Out Pressure Sensor Circuit High

011997.04 - Bucket Roll-Out Pressure Sensor Circuit Low

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

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

015016.03 - Right Analog Stroke Sensor Circuit High Input

015016.04 - Right Analog Stroke Sensor Circuit Low Input

020010.02 - Abnormal Aftertreatment Device

020011.02 - Electric Lever Alarm

020012.02 - Line Filter Restriction Alarm

020303.02 - Electric Lever Pilot Cut Alarm

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

Engine Control Module (ECM) Diagnostic Trouble Codes

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

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

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

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

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

000100.03 - Engine Oil Pressure Sensor Circuit High (P0523)

000100.04 - Engine Oil Pressure Sensor Circuit Low (P0522)

000102.00 - Turbocharger Overboost Condition (P0234)

000102.03 - Turbocharger Boost Sensor Circuit High (P0238)

000102.04 - Turbocharger Boost Sensor Circuit Low (P0237)

000105.03 - Compressor Outlet Temperature Sensor Circuit High (P1098)

000105.04 - Compressor Outlet Temperature Sensor Circuit Low (P1097)

000108.03 - Barometric Pressure Sensor Circuit High (P2229)

000108.04 - Barometric Pressure Sensor Circuit Low (P2228)

000110.00 - Engine Coolant Over Temperature Condition (P0217)

000110.03 - Engine Coolant Temperature Sensor Circuit High (P0118)

000110.04 - Engine Coolant Temperature Sensor Circuit Low (P0117)

000132.03 - Mass Air Flow Sensor Circuit High Input (P0103)

000132.04 - Mass Air Flow Sensor Circuit Low Input (P0102)

000157.03 - Fuel Rail Pressure Sensor Circuit High (P0193)

000157.04 - Fuel Rail Pressure Sensor Circuit Low (P0192)

000157.15 - Fuel Pressure Regulator Performance (P0089)

000158.03 - System Voltage High (P0563)

000172.03 - Intake Air Temperature Sensor Circuit High (P0113)

000172.04 - Intake Air Temperature Sensor Circuit Low (P0112)

000173.03 - Catalyst Temperature Sensor Circuit High Sensor 1 (P0428)

000173.04 - Catalyst Temperature Sensor Circuit Low Sensor 1 (P0427)

000174.03 - Fuel Temperature Sensor Circuit High (P0183)

000174.04 - Fuel Temperature Sensor Circuit Low (P0182)

000190.00 - Engine Overspeed Condition (P0219)

000628.02 - Internal Control Module Memory Check Sum Error (P0601)

000633.07 - Fuel Rail/System Pressure - Too Low (P0087)

000636.02 - Camshaft Position Sensor Circuit (P0340)

000636.07 - Crankshaft Position - Camshaft Position Correlation (P0016)

000639.02 - Lost Communication With CAN (U0101)

000639.19 - Control Module Communication Bus Off (U0073)

000651.05 - Injector Circuit Open - Cylinder 1 (P0201)

000652.05 - Injector Circuit Open - Cylinder 2 (P0202)

000653.05 - Injector Circuit Open - Cylinder 3 (P0203)

000654.05 - Injector Circuit Open - Cylinder 4 (P0204)

000676.05 - Glow Relay Circuit Error (P0380)

000677.05 - Starter Relay Circuit Error (P0615)

000723.02 - Crankshaft Position Sensor Circuit (P0335)

000723.08 - Crankshaft Position Sensor Circuit Range/Performance (P0336)

001077.02 - Internal Control Module CPU Error (P0606)

001079.02 - Sensor Reference Voltage 1 Circuit (P06A6)

001080.02 - Sensor Reference Voltage 2 Circuit (P06A7)

001131.03 - Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage (P0098)

001131.04 - Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage (P0097)

001239.01 - Fuel Rail Pressure Too Low (P1093)

001239.17 - Fuel Rail Pressure Too Low (P1093)

001239.31 - Fuel Rail Pressure Too Low (P3093)

001347.03 - Fuel Pressure Regulator Control Circuit High (P0092)

001347.04 - Fuel Pressure Regulator Control Circuit Low (P0091)

001485.05 - ECM Power Relay Control Circuit Open (P0685)

001485.06 - ECM Power Relay Control Circuit High (P0687)

002791.02 - EGR Flow Insufficient Detected (P0401)

004332.12 - Urea Fluid Concentration Too Low (P207F)

005285.01 - Charge Air Cooler Performance Failure (P1236)

010001.02 - EGR Sensor Circuit (P0409)

010001.13 - EGR Position Fault (P1404)

010002.02 - EGR Control Circuit Range/Performance (P0404)

010003.02 - Fuel Injector Group 1 Supply Voltage Circuit (P2146)

010004.02 - Fuel Injector Group 2 Supply Voltage Circuit (P2149)

010005.02 - Injector Positive Voltage Control Circuit Group 1 (P1261)

010006.02 - Injector Positive Voltage Control Circuit Group 2 (P1262)

010007.02 - Internal Control Module CPU IC Error (P060A)

010008.02 - Internal Control Module A/D Processing Performance (P060C)

010009.02 - Sensor Reference Voltage 3 Circuit (P06A8)

010010.02 - Sensor Reference Voltage 4 Circuit (P06A9)

010011.02 - Sensor Reference Voltage 5 Circuit (P06D5)

010012.02 - 12-Volt Circuit Error (P0560)

010013.02 - Control Module Long Term Memory Performance (P1621)

010014.03 - EGR Cooler Outlet 1 Temp Sensor Circuit High (P041D)

010014.04 - EGR Cooler Outlet 1 Temp Sensor Circuit Low (P041C)

010022.02 - Throttle Actuator Control Range/Performance (P0638)

010022.03 - Throttle Position Sensor Circuit High (P0123)

010022.04 - Throttle Position Sensor Circuit Low (P0122)

010023.20 - Abnormal Turbo EVRV (P0045)

010024.03 - Catalyst Temperature Sensor Circuit High Sensor 2 (P042D)

010024.04 - Catalyst Temperature Sensor Circuit Low Sensor 2 (P042C)

010025.05 - DPD Lamp Control Circuit (P1669)

010029.00 - Purge Time Out Error (P2458)

010032.02 - Internal Control Module QR Code Error (P0602)

010033.02 - Internal Control Module RAM Error (P0604)

010040.19 - CAN Bus Error (ISO-CAN) (U0001)

010041.02 - Lost Communications With Dosing Control Module (U010E)

010042.12 - SCR System Error (Inducement, No Purge) (P2BAA)

010043.02 - SCR System Error (No Inducement) (P204F)

010044.01 - SCR System Error (P20C9)

010045.02 - AD-IC Failure Error (P160B)

010046.02 - SWIC-1 Failure (P1606)

010047.02 - SWIC-2 Failure (P1606)

010048.02 - SWIC-1 Communication Failure (P1606)

010049.02 - SWIC-2 Communication Failure (P1606)

010050.02 - INJ-IC Failure (P06AF)

010051.03 - Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage (P1077)

010051.04 - Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage (P1076)

010053.03 - EGR Cooler Inlet 1 Temp Sensor Circuit High (P0546)

010053.04 - EGR Cooler Inlet 1 Temp Sensor Circuit Low (P0545)

010054.17 - Exhaust Gas Recirculation (EGR) Cooling System Performance (P2457)

010078.12 - AD-IC2 Failure Error (P160C)

010082.02 - INJ-IC Communication Failure (P06AF)

010083.02 - INJ-IC Checksum Failure (P06AF)

010500.12 - Urea Fluid Injector Circuit Abnormal (P2048) (P2049)

010501.12 - Urea Fluid Injector Stuck (P208E)

010502.12 - Exhaust Gas Temperature (EGT) Sensor 3 Circuit Abnormal (P242C) (P242D)

010503.12 - Exhaust Gas Temperature (EGT) Sensor 3 Performance (P242B)

010504.12 - NOx Sensor Heater Control Circuit Sensor 1 Abnormal (P2206) (P2207)

010505.12 - Upstream NOx Sensor Performance (P2201)

010506.12 - Urea Fluid Tank Temperature Sensor Performance (P205B)

010507.12 - Urea Fluid Tank Heater Coolant Control Valve Circuit Abnormal (P20B1) (P20B3) (P20B4)

010508.12 - Urea Fluid Pump Control Circuit Abnormal (P20AC) (P208A) (P208C) (P208D)

010509.12 - Urea Fluid Pump Performance (P208B)

010510.12 - Urea Fluid Reverting Valve Circuit Abnormal (P20A0) (P20A3)

010511.12 - Urea Fluid Pressure Sensor Circuit Abnormal (P204C) (P204D)

010512.12 - Urea Fluid Pressure Sensor Performance (P204B)

010513.12 - Urea Fluid Pump Temperature Sensor Performance (P20AC)

010514.12 - Control Module Malfunction (P0607) (P0641) (P060B) (P062F)

010515.12 - Actuator Supply Voltage Circuit Abnormal (P0641) (P0658) (P0659)

010516.12 - Urea Fluid Pump Module Temperature Sensor Performance (P20AD)

010517.12 - DCU High Temperature (P1468) (P1493)

010518.12 - Urea Fluid Over Pressure (P1491)

010519.12 - Urea Fluid Pressure Reduction Malfunction (P149C)

010520.12 - Urea Fluid Pressure Buildup Error (P20FE)

010521.12 - Urea Fluid Tank Overtemperature (P149D)

010522.12 - Urea Fluid Tank Level Sensor Stuck (P203B)

010523.12 - Urea Fluid Concentration Too Low (P207F)

010524.12 - Lost Communication With NOx Sensor 1 (U029D)

010525.12 - Lost Communication With Engine Control Module (ECM) (U0002) (U0100)

010526.12 - Urea Fluid Quality Sensor Timeout Error (P1462)

010527.12 - CAN Bus Off (U0002) (U029D)

010528.12 - Main Relay Performance (P1464)

010529.12 - Urea Fluid Quality Sensor Circuit Abnormal (P206A) (P206C) (P206D)

010530.12 - Urea Fluid Over Pressure (P20E9)

010531.12 - Urea Fluid Tank Level Sensor Abnormal (P203C) (P203D)

010532.12 - Urea Fluid Tank Temperature Sensor Abnormal (P205C) (P205D)

010533.12 - Urea Fluid Pressure Under Pressure (P20E8)

010534.12 - Urea Fluid Pressure Reduction Malfunction (P20EA) (P1464)

010535.12 - Urea Sensor Overtemperature Condition (P206B)

010536.12 - Urea Fluid Reverting Valve Circuit Low Voltage (P20A2)

010540.12 - NOx Sensor Heater Control Circuit Sensor 2 Abnormal (P2210) (P2211)

010541.12 - Lost Communication With NOx Sensor 2 (U029E)

010542.12 - NOx Purification Is Abnormal (P2000)

Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Monitor Controller (DSZ) Diagnostic Trouble Codes

013002.02 - ECM Communication Error

013003.02 - Main Controller (MCZ) Communication Error 1

013004.02 - Main Controller (MCZ) Communication Error 2

013005.02 - Monitor Controller (DSZ) Communication Error 1

013006.02 - Monitor Controller (DSZ) Communication Error 2

013007.02 - Machine Controller (BCZ) Communication Error

020113.02 - System Error Alarm

Group 40: Information Controller (ICZ) Diagnostic Trouble Codes

Information Controller (ICZ) Diagnostic Trouble Codes

013303.02 - Abnormal Monitor Internal Temperature Sensor

013304.02 - Alternator Alarm

013310.03 - Coolant Temperature Sensor Short Circuit

013311.03 - Fuel Level Sensor Open Circuit

013311.04 - Fuel Level Sensor Shorted Circuit

014001.02 - Flash Memory Read/Write Error

014002.02 - External RAM Read/Write Error

014003.02 - Abnormal EEPROM

014006.02 - Communication Terminal:Communication Error

014008.02 - Abnormal Internal RAM

014009.02 - CAN Communication Error 2

014021.02 - Communication Terminal Security Error

014022.02 - SIM Card Error

014023.02 - Security Error

020100.02 - Overheat Alarm

020101.02 - Engine Warning Alarm

020102.02 - Engine Oil Pressure Alarm

020103.02 - Alternator Alarm

020105.02 - Hydraulic Oil Filter Restriction Alarm

020106.02 - Air Cleaner Restriction Alarm

020107.02 - Water Separator Alarm

020109.02 - Pilot Control Shutoff Lever Alarm

020110.02 - Fuel Filter Restriction Alarm

020113.02 - System Error Alarm

020114.02 - Overheat Alarm (Immediately After the Key is Turned ON)

020149.02 - EGR Gas Temperature Alarm

Group 50: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Air Conditioner Controller (ACF) Diagnostic Trouble Codes

11 - Open Circuit in Air Recirculation Sensor

12 - Short-Circuited Air Recirculation Sensor

13 - Open Circuit in Ambient Air Temperature Sensor

14 - Short-Circuited Ambient Air Temperature Sensor

18 - Short-Circuited Solar Radiation Sensor

21 - Open Circuit in Air Conditioner Freeze Control Switch

22 - Short-Circuited Air Conditioner Freeze Control Switch

43 - Abnormal Air Conditioner and Heater Blower Port Change Servo Motor

44 - Abnormal Air Conditioner and Heater Mixer Servo Motor

51 - Abnormal High/Low Refrigerant Pressure

91 - Communication Error

92 - CAN Bus Off Error

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Isuzu Engine

Engine Fuel System Component Location

Engine Cooling System Component Location

Diesel Exhaust Fluid (DEF) System Component Location

Cold Weather Starting Aid

Engine Speed Control System Operation

Group 15: Diagnostic Information

Isuzu Engine

Group 20: Adjustments

Isuzu Engine

Group 25: Tests

Isuzu Engine

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Explanation of Wire Markings

Fuse and Relay Specifications

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

System Functional Schematic

Cab Harness (W1) Component Location

Cab Harness (W1) Wiring Diagram

Machine Harness (W2) Component Location

Machine Harness (W2) Wiring Diagram

Monitor Harness (W3) Component Location

Monitor Harness (W3) Wiring Diagram

Engine Harness (W4) Component Location

Engine Harness (W4) Wiring Diagram

Pump Harness (W8) Component Location

Pump Harness (W8) Wiring Diagram

Aftertreatment Device Regeneration Switch Harness (W9) Component Location

Aftertreatment Device Regeneration Switch Harness (W9) Wiring Diagram

Pilot Shutoff Switch Harness (W11) Component Location

Pilot Shutoff Switch Harness (W11) Wiring Diagram

Heated Air Seat Harness (W14) Component Location

Heated Air Seat Harness (W14) Wiring Diagram

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

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

Travel Alarm Cancel Switch Harness (W16) Component Location

Travel Alarm Cancel Switch Harness (W16) Wiring Diagram

Attachment Harness (W17) Component Location

Attachment Harness (W17) Wiring Diagram

Rear Camera Harness (W19) Component Location

Rear Camera Harness (W19) Wiring Diagram

Pilot Shutoff Valve Harness (W21) Component Location

Pilot Shutoff Valve Harness (W21) Wiring Diagram

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

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

Seat Heater Switch Harness (W24) Component Location

Seat Heater Switch Harness (W24) Wiring Diagram

Starter Switch Harness (W29) Component Location

Starter Switch Harness (W29) Wiring Diagram

Data Converter Harness (W30) Component Location

Data Converter Harness (W30) Wiring Diagram

2-Speed Harness (W32) Component Location

2-Speed Harness (W32) Wiring Diagram

Heater and Air Conditioner Harness (W41) Component Location

Heater and Air Conditioner Harness (W41) Wiring Diagram

Cab Roof Light Harness (W44) Component Location

Cab Roof Light Harness (W44) Wiring Diagram

Cab Roof Light Jumper Harness (W45) Component Location

Cab Roof Light Jumper Harness (W45) Wiring Diagram

Cab Roof Light 1 Relay Harness (W46) Component Location

Cab Roof Light 1 Relay Harness (W46) Wiring Diagram

Cab Roof Light 2 Relay Harness (W47) Component Location

Cab Roof Light 2 Relay Harness (W47) Wiring Diagram

Travel Alarm Cancel Switch Jumper Harness (W48) Component Location

Travel Alarm Cancel Switch Jumper Harness (W48) Wiring Diagram

Exhaust Aftertreatment Harness (W53) Component Location

Exhaust Aftertreatment Harness (W53) Wiring Diagram

12-Volt Power Harness (W55) Component Location

12-Volt Power Harness (W55) Wiring Diagram

Auxiliary Solenoid Harness (W61) Component Location

Auxiliary Solenoid Harness (W61) Wiring Diagram

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

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

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

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

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

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

Auxiliary Function Enable Switch Harness (W78) Component Location

Auxiliary Function Enable Switch Harness (W78) Wiring Diagram

Satellite (SAT) Harness (W6003) Component Location

Satellite (SAT) Harness (W6003) Wiring Diagram

JDLink™ Harness (W6004) Component Location

JDLink™ Harness (W6004) Wiring Diagram

Group 15: Sub-System Diagnostics

Controller Area Network (CAN) Theory of Operation

Starting and Charging Circuit Theory of Operation

Monitor Controller (DSZ) Circuit Theory of Operation

Engine Control Module (ECM) Circuit Theory of Operation

Exhaust Aftertreatment Circuit Theory of Operation

Main Controller (MCZ) Circuit Theory of Operation

Machine Controller (BCZ) Circuit Theory of Operation

Windshield Wiper and Washer Circuit Theory of Operation

Lighting Circuit Theory of Operation

Travel Alarm Circuit Theory of Operation

Pilot Shutoff Circuit Theory of Operation

Attachment Control Circuit Theory of Operation

Group 16: Monitor Operation

Service Menu

Troubleshooting

Monitoring

Controller Version

Issued Warning Record

Operation

Machine Setting

Monitor Setting

Engine Setting

Aftertreatment Device No.

Maintenance Mode

Group 20: References

Reading Diagnostic Trouble Codes With Monitor Display

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application

Clearing Engine Diagnostic Trouble Codes

Clearing Dosing Control Unit (DCU) Diagnostic Trouble Codes

MPDr Application

MPDr Connection Procedure

Coolant Bleeding With MPDr

Diesel Exhaust Fluid (DEF) Leak Test With MPDr

Electrical Component Specifications

Alternator Test

Electrical Component Checks

Battery Remove and Install

Rear Cover Remove and Install

Main Controller (MCZ) Remove and Install

Monitor Controller (DSZ) Remove and Install

Heater Control Disable and Enable

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Travel Gear Case Operation

Group 15: Diagnostic Information

Noisy or Loose Track Chain

Tight Track Chain

Frequent Track Chain Sag Adjustment Required

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

Bent Track Shoes

“Popping” of Track

Cracked Track Link

Chipped Link Rails

Individual Undercarriage Component Wear

Measure Swing Bearing Wear

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Operation

Pilot System Operation

Pilot Pump, Pressure Regulating Valve, and Filter Operation

Pilot Shutoff Solenoid Valve Operation

Pilot Control Valve Operation

Travel Pilot Control Valve Operation

Pilot Operation of Control Valve Operation

Pilot Signal Manifold Operation

Pump 1, Pump 2, and Drive Gear Case Operation

Pump 1 and Pump 2 Regulator Operation

Engine Speed Sensing Control Circuit Operation

Control Valve Operation

Control Valve Check Valves Identification and Operation

Main Relief Valve Circuit Operation

Circuit Relief and Anticavitation Valve Operation

Travel Flow Combiner Valve Operation

Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation

Boom Lower Meter-In Cut Valve Operation

Boom Regenerative Valve Circuit Operation

Dig Regenerative Valve Circuit Operation

Arm Regenerative Valve Circuit Operation

Bucket Regenerative Valve Circuit Operation

Boom and Arm Reduced Leakage Valves Operation

Arm 1 Flow Rate Control Valve Circuit Operation

Arm 2 Flow Rate Control Valve Circuit Operation

Bucket Flow Rate Control Valve Circuit Operation

Boom Flow Rate Control Valve Circuit Operation

Auxiliary Flow Rate Control Valve Circuit Operation

Blade Circuit Operation—If Equipped

Swing Reduction Gear Case Operation

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

Swing Motor Park Brake Release Circuit Operation

Center Joint Operation

Travel Motor and Park Brake Valve Operation

Travel Motor Speed Circuit Operation

Exhaust Aftertreatment Assembly Burn Solenoid Valves

Cylinder Operation

Return Filter Operation

Auxiliary System Operation

Auxiliary Pilot Control Valve Operation

Flow Rate Select Solenoid Valve Operation

Flow Rate Pressure Reducing Valve Operation

Selector Valve Solenoid Valve Operation

Selector Valve Operation

Auxiliary Shuttle Valve Operation

Auxiliary High Flow Line Kit Operation

Two Way Solenoid Kit Operation

Two Pump Combined Flow Kit Operation

Group 15: Diagnostic Information

All Hydraulic Functions Slow

Hydraulic Oil Overheats

No Hydraulic Functions

No Hydraulic Functions—Electrical Checks

Function Does Not Stop When Control Lever Released

Load Drifts Down When Control Lever is in Neutral Position

Load Falls When Control Valve is Actuated to Raise Load

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

Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal

Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal

Swing Speed Slow During Arm In Function

Boom Cannot Raise Track Off Ground

Swing Function Does Not Operate in Both Directions

Swing Speed Slow in Both Directions

Swing Speed Slow or Does Not Operate in One Direction

Upperstructure Drift with Swing Valve in Neutral

Machine Freewheels Down an Incline

Track Will Not Move in Either Direction

Machine Mistracks

Machine Mistracks Left During Combined Travel and Dig Functions

Machine Will Not Shift Into Fast (rabbit) Speed

Pump 1, Pump 2, and Pilot Pump Line Identification

Control Valve Line Identification

Swing Motor Line Identification

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

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

Pilot Signal Manifold-to-Control Valve Line Connection

Pilot Control Lever Pattern Selector Valve Line Connection

Travel System Component Location

Travel Hydraulic System Line Connection

Blade Hydraulic System Component Location

Auxiliary Attachment Schematic

Auxiliary System Line Connections

Hydraulic System Schematic

Hydraulic System Component Location

Hydraulic System Line Connections

Group 25: Tests

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure and Temperature Analyzer Kit Installation

General Hydraulic Oil Cleanup Procedure

Hydraulic Component Failure Cleanup Procedure

Hydraulic Oil Tank Pressure Release Procedure

Hydraulic Oil Warm-Up Procedure

Pilot Pressure Regulating Valve Test and Adjustment

Control Valve Spool Actuating Pilot Pressure Test

Dig Regenerative Solenoid Valve Test and Adjustment

Arm Regenerative Solenoid Valve Test and Adjustment

Power Dig/Travel Speed Solenoid Valve Test and Adjustment

Arm 2 Flow Control Solenoid Valve Test and Adjustment

Torque Control Solenoid Valve Test and Adjustment

Pump Control Pilot Pressure Signal Test

Main Relief and Power Dig Valve Test and Adjustment

Circuit Relief Valve Test and Adjustment

Blade Main Relief Valve Test and Adjustment

Blade Circuit Relief Valve Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Travel Motor Crossover Relief Valve Test and Adjustment

Pump Regulator Test and Adjustment—Minimum Flow

Pump Regulator Test and Adjustment—Maximum Flow

Pump Flow Test

Comprehensive Pump Flow Test

Swing Motor Leakage Test

Travel Motor Leakage Test

Cylinder Drift Test—Boom, Arm, and Bucket

Upperstructure Drift Test

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle of Operation

Group 15: Diagnostic Information

Air Conditioning System Does Not Operate

Air Conditioning System Does Not Cool Interior of Cab

Air Conditioning System Runs Constantly, Too Cold

Heating System Does Not Operate

Heating System Does Not Warm Interior of Cab

Interior Windows Continue to Fog

Heater and Air Conditioner Component Location

Group 25: Tests

R134a Refrigerant Cautions and Proper Handling

R134a Oil Charge Capacity

R134a Refrigerant Charge Capacity

Heater and Air Conditioner Operational Checks

Air Conditioner Compressor Clutch Test

R134a Refrigerant Leak Test

R134a Refrigerant Hoses and Tubing Inspection

Air Conditioner High/Low-Pressure Switch Test

Air Conditioner Freeze Control Switch Test

Air Conditioning System Test

Operating Pressure Diagnostic Chart

Section 9900: Dealer Fabricated Tools

Group 99: Dealer Fabricated Tools

DFT1218 Split Flange Hose Cap