Operation and T est
OPERA TION & TEST TECHNICAL MANUAL
225DLC Excavator
TM10082 28MA Y19 (ENGLISH)
DOWNLOAD Op MANUAL
Introduction
Foreword
This manual written for experienced Essential tools required performing certain service work are identified this manual and are recommended for use.
Live with safety: Read the safety messages the introduction this manual and the cautions presented throughout the text the
This the safety - alert symbol. When you see this symbol the machine this alert the potential for personal injury
T echnical manuals are divided two parts: repair and operation and Repair sections tell how repair the components. Operation and tests sections help you identify the majority routine failures quickly
Information organized groups for the various components requiring service the beginning each group are summary listings all applicable essential tools, service equipment and tools, other materials needed the job, service parts wear and torque
T echnical Manuals are concise guides for specific They are - the - job guides containing only the vital information needed for diagnosis, analysis, testing, and repair
Fundamental service information available from other sources covering basic theory fundamentals troubleshooting, general maintenance, and basic type failures and their causes.
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Section Information
Group
Section 9001—Diagnostics
Group Controller (MCF) Diagnostic T rouble Codes
Group Control Module (ECM) Diagnostic T rouble Codes
Group Controller (ICF) Diagnostic T rouble Codes
Group Conditioner Controller (ACF) Diagnostic T rouble Codes
Group Controller (MON) Diagnostic T rouble Codes
Section Checkout Procedure
Group Checkout Procedure
Section 9010—Engine
Group Operation
Group Information
Group ests
Section 9015—Electrical System
Group Information
Group Diagrams
Group - System Diagnostics
Group Operation
Group
Section T rain
Group Operation
Group Information
Section System
Group Operation
Group Information
Group ests
Group Fabricated T ools
Section and Air Conditioning
Group Operation
Group Information
Group ests
Section Material
Group erminology Cross Reference Chart
Section 9900—Dealer Fabricated T ools
Original Instructions. All information, illustrations and specifications this manual are based the latest information available the time publication. The right reserved make changes any time without
Use Special Care When Lifting Objects
Recognize Safety Information
This the safety alert When this symbol noticed the machine this manual, alert for the potential personal injury .
Follow the precautions and safe operating practices highlighted this symbol.
A signal word W CAUTION used with the safety alert DANGER identifies the most serious
the machine, DANGER signs are red color , W ARNING signs are and CAUTION signs are yellow DANGER and W ARNING signs are located near specific General precautions are CAUTION
Follow Safety Instructions
Read the safety messages this manual and the Follow these warnings and instructions carefully Review them frequently
Keep safety signs good condition.
sure new equipment components and repair parts include the current safety
Operate Only Qualified
not operate this machine unless the manual has been read carefully , and you have been qualified supervised training and instruction.
Operator should familiar with the job site and surroundings before T all controls and
W ear Protective Equipment
Guard against injury from flying pieces metal debris; wear goggles safety
W ear close fitting clothing and safety equipment appropriate the
sure all operators this machine understand every safety Replace manual and safety signs immediately missing Replacement safety signs are available from your authorized dealer
machine functions with the machine open area before starting
Know and observe all safety rules that may apply every work situation and work
Prolonged exposure loud noise can cause impairment loss W ear suitable hearing protection such earmuf earplugs protect against objectionable uncomfortable loud
A void Unauthorized Machine Modifications
John Deere recommends using only genuine John Deere replacement parts ensure machine Never substitute genuine John Deere parts with alternate parts not intended for the application these can create hazardous situations hazardous Non - John Deere any damage malfunctions resulting from their are not covered any John Deere warranty
reliability , and may create a hazard for the operator others near the The installer any modification which may fect the electronic controls this machine responsible for establishing that the modification does not adversely fect the machine its
Modifications this addition unapproved products may fect machine stability
Always contact authorized dealer before making machine modifications that change the intended weight balance the machine, that alter machine reliability
Add Cab Guarding for Special Uses
Special work situations machine attachments may create environment with falling flying W orking near overhead doing demolition using a hydraulic hammer , working a wooded for may require added guarding protect the operator
FOPS (falling object protective structures) and special screens guarding should installed when falling flying objects may enter damage the Contact your authorized dealer for information devices intended provide protection special work
Inspect Machine
Inspect machine carefully each day walking around before
Inspect and Clean the Polycarbonate Windows. See Inspect and Clean Polycarbonate Windows. (Section 41.)
Keep all guards and shields good condition and properly Fix damage and replace worn broken parts immediately Pay special attention hydraulic hoses and electrical wiring.
Stay Clear Moving Parts
Entanglements moving parts can cause serious injury
Stop engine before adjusting maintaining any part machine with moving
Keep guards and shields place. Replace any guard shield that has been removed for access soon service repair
A void High-Pressure Fluids
Inspect hydraulic hoses periodically – least once per year – for exposed wire braid any other signs wear
Replace worn damaged hose assemblies immediately with John Deere approved replacement
Escaping fluid under pressure can penetrate the skin causing serious injury
A void the hazard relieving pressure before disconnecting hydraulic other T ighten all connections before applying
Search for leaks with a piece Protect hands and body from high - pressure fluids.
with this type injury should reference a knowledgeable medical Such information available English from Deere & Company Medical Department Moline, Illinois, U.S.A., calling 1 - 800 - 822 -
accident see a doctor immediately Any fluid injected into the skin must surgically removed within a few hours gangrene may Doctors unfamiliar
309 - 748 -
A void High-Pressure Oils
This machine uses a high - pressure hydraulic Escaping oil under pressure can penetrate the skin causing serious injury
Never search for leaks with your hands. Protect hands. Use a piece cardboard find location escaping oil. Stop engine and relieve pressure before disconnecting lines working hydraulic
hydraulic oil penetrates your skin, see a doctor immediately . Injected oil must removed surgically within hours gangrene may Contact a knowledgeable medical source the Deere & Company Medical Department
Beware Exhaust Fumes
Prevent Engine exhaust fumes can cause sickness
you must operate enclosed provide adequate ventilation. Use exhaust pipe extension remove the exhaust fumes open doors and windows bring outside air into the
Prevent Fires
Handle Fuel Safely: Store flammable fluids away from fire Never refuel machine while smoking when near sparks
Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating engine around fuel hydraulic exhaust and electrical Never store oily rags flammable materials inside a machine
Maintain Hoses and W iring: Replace hydraulic hoses immediately they begin and clean any oil Examine electrical wiring and connectors frequently for
Keep A Fire Extinguisher A vailable: Always keep a multipurpose fire extinguisher near the machine. Know how use extinguisher properly
Prevent Battery Explosions
Battery gas can Keep lighted and open flame away from the top battery
Never check battery charge placing a metal object across the Use a voltmeter hydrometer
not charge a frozen battery; may W arm battery 16°C (60°F).
T133546
T133552
T133553
T133554
Handle Chemical Products Safely
Exposure hazardous chemicals can cause serious injury Under certain paints and adhesives used with this machine may
uncertain about safe handling use these chemical contact your authorized dealer for a Material Safety Data Sheet (MSDS) internet website http://www The MSDS describes physical and health safe use and emergency response techniques for chemical substances. Follow
Dispose W aste Properly
Improper disposal waste can threaten the filters and batteries used with this machine may harmful not disposed properly .
Never pour waste onto the down a into any water
MSDS recommendations handle chemical products safely .
Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center recover and recycle used uncertain about the safe disposal contact your local environmental recycling center your authorized dealer for more information.
Prepare for Emergencies
prepared emergency occurs a fire
Keep a first aid kit and fire extinguisher handy . Keep emergency numbers for ambulance and fire department near your
Use Steps and Handholds Correctly
Prevent falls facing the machine when getting and Maintain 3 - point contact with steps and Never use machine controls
Use extra care when mud, snow , moisture present slippery conditions. Keep steps clean and free grease Never jump when exiting Never mount dismount a moving
Start Only From Seat
A void unexpected machine Start engine only while sitting Ensure all controls and working tools are proper position for a parked
Never attempt start engine from the ground. not attempt start engine shorting across the starter solenoid
Use and Maintain Seat Belt
Use seat belt when operating machine Remember fasten seat belt when loading and unloading from trucks and during other uses.
Examine seat belt frequently sure webbing not cut Replace seat belt immediately any part damaged does not function properly
The complete seat belt assembly should replaced every 3 regardless
Prevent Unintended Machine Movement
careful not accidentally actuate control levers when coworkers are present. Pull pilot control shutof f lever locked position during work Pull pilot control shutof f lever locked position and stop engine before allowing anyone approach
Always lower work equipment the ground and pull pilot control shutof f lever locked position before standing leaving the Stop engine before
A void W orksite Hazards
A void contact with gas buried cables and water lines. Call utility line location services identify all underground utilities before starting work.
Prepare worksite properly . A void operating near structures objects that could fall onto the machine. Clear away debris that could move unexpectedly run over
A void boom attachment contact with overhead obstacles overhead electrical lines. Never move machine closer than 3 m (10 ft) plus twice the line insulator length overhead wires.
Keep bystanders clear all times. Keep bystanders away from raised attachments and unsupported A void swinging raising loads over near personnel. Use barricades a signal person keep vehicles and pedestrians away . Use a signal person moving machine congested areas where visibility Always keep signal person view Coordinate hand signals before starting
Operate only solid footing with strength suf ficient support machine. especially alert working near embankments
A void working under over - hanging embankments stockpiles that could collapse under
Reduce machine speed when operating with tool near ground when obstacles may hidden during
Keep Riders Off Machine
Only allow operator machine.
Riders are subject injury They may fall from caught between machine struck foreign
Riders may obstruct operator ’ s view impair the ability operate machine safely
snow removal clearing mud, dirt, etc.).
hitting obstacles (rocks, uneven concrete manholes) can cause a sudden Always wear your seat
Keep Riders Off Machine
A void Backover Accidents
Before moving sure all persons are clear both travel and swing paths. T urn around and look directly for best visibility Use mirrors assist checking all around Keep windows and mirrors adjusted, and good repair .
certain travel alarm working properly
Use a signal person when backing view obstructed when close quarters. Keep signal person view all times. Use prearranged hand signals communicate.
A void Machine T Over
Use seat belt all times.
not jump the machine tips. Operator will unlikely jump clear and the machine may crush the operator .
Load and unload from trucks trailers carefully . sure truck wide enough and a firm level
Use loading ramps and attach them properly truck A void trucks with steel beds because tracks slip more easily steel.
careful slopes. Use extra care rocky frozen Machine may slip sideways these When traveling down keep the bucket uphill side and just above ground level.
careful with heavy Using oversize buckets lifting heavy objects reduces machine stability Extending a heavy load swinging over side undercarriage may cause machine
Ensure solid Use extra care when operating near banks excavations that may cave - and cause machine tip
Use Seat Belt
Unloading Machine
Not Jump
Use Special Care When Lifting Objects
Never use this machine lift
Never lift a load above another Keep bystanders clear all areas where a load might fall breaks not leave the seat when there a raised load. not exceed lift capacity limits posted machine and this Extending heavy loads too far swinging over undercarriage side may cause machine tip over
Use proper rigging attach and stabilize loads. sure slings chains have adequate capacity and are good Use tether lines guide loads and prearranged hand signals communicate with -
Add and Operate Attachments Safely
required V erify that all connections are secure and attachment responds properly controls.
Always verify compatibility attachments contacting your authorized dealer Adding unapproved attachments may fect machine stability reliability and may create a hazard for others near the
Carefully read attachment manual and follow all instructions and area free bystanders and carefully operate attachment learn its characteristics and range
Ensure that a qualified person involved attachment installation. Add guards machine operator protection
Park and Prepare for Service Safely
W arn others service work. Always park and prepare your machine for service repair properly .
• Park machine a level surface and lower equipment and attachments the
• Place pilot shutof f lever Stop engine and remove key
• Attach a Not tag obvious place the station.
Securely support machine attachment before working under
• not support machine with boom, arm, other hydraulically actuated attachments.
• not support machine with cinder blocks wooden pieces that may crumble
• not support machine with a single jack other devices that may slip out
Understand service procedures before beginning repairs. Keep service area clean and dry Use two people whenever the engine must running for service
Service Cooling System Safely
Explosive release fluids from pressurized cooling system can cause serious
Shut f Only remove filler cap when cool enough touch with bare hands. Slowly loosen cap first stop relieve pressure before removing completely .
Remove Paint Before W elding Heating
A void potentially toxic fumes and dust.
Hazardous fumes can generated when paint heated using a
Remove paint before heating:
• Remove paint a minimum 100 from area fected paint cannot wear approved respirator before heating
• you sand grind avoid breathing the W ear approved respirator
• you use solvent paint stripper , remove stripper with soap and water before welding. Remove solvent paint stripper containers and other flammable material from Allow fumes disperse least minutes before welding
not use a chlorinated solvent areas where welding will take
Make W elding Repairs Safely
IMPORT ANT : Disable electrical power before welding. T urn off main battery switch disconnect positive battery cable. Separate harness connectors engine and vehicle microprocessors.
A void welding heating near pressurized fluid
Flammable spray may result and cause severe burns pressurized lines fail a result heating. not let heat beyond work area nearby pressurized
Remove paint properly not inhale paint dust
Use a qualified welding technician for structural
all work area that well ventilated carry toxic fumes and dust away .
Dispose paint and solvent properly
Make sure there good W ear eye protection and protective equipment when
Drive Metal Pins Safely
Always wear protective goggles safety glasses and other protective equipment before striking hardened Hammering hardened metal parts such pins and bucket teeth may dislodge chips high velocity
Use a soft hammer a brass bar between hammer and object prevent
T133738
Group —Main Controller (MCF)
Diagnostic T rouble Codes
Controller (MCF) Diagnostic T rouble Codes 9001 - - 1
Controller Hardware tics 9001 - - 1 1 Abnormal RAM 9001 - - 1
Controller Hardware Diagnostics 9001 - - 2
Abnormal Sensor V oltage 9001 - - 3 Abnormal Sensor V oltage Diagnostic Procedure
9001 - - 3
Abnormal CAN Communication 9001 - - 4
Controller Area Network (CAN) Diagnostics 9001 - - 4 1 1 100.02 Abnormal Engine Speed
. 9001 - -
Engine Speed Diagnostics 9001 - -
1 1 Engine Control Dial V oltage High 9001 - -
Engine Speed Dial Diagnostics 9001 - -
1 1 101.04 Engine Control Dial V oltage Low
9001 - -
Engine Speed Dial Diagnostics 9001 - -
1 Pump 1 Delivery Pressure
Sensor V oltage High 9001 - -
Pump 1 Delivery Pressure Sensor Diagnostics .
9001 - -
1200.04 Pump 1 Delivery Pressure Sensor V oltage Low 9001 -Pump 1 Delivery Pressure Sensor Diagnostics 9001 -1 Pump 2 Delivery Pressure Sensor V oltage High
9001 - -
Pump 2 Delivery Pressure Sensor Diagnostics 9001 -1 Pump 2 Delivery Pressure Sensor V oltage Low 9001 -Pump 2 Delivery Pressure Sensor Diagnostics 9001 -1
1206.03 Pump 1
orque Control Solenoid
Feedback Current High 9001 - -
T orque Control Solenoid
Diagnostics 9001 -1 T orque Control Solenoid
Feedback Current Low
9001 -T orque Control Solenoid
Diagnostics 9001 - -
1 Dig Regenerative Solenoid
Feedback Current Abnormal 9001 - -
Dig Regenerative Solenoid Diagnostics .
9001 - -
1 1402.03 Dig Regenerative Solenoid
Feedback Current High 9001 - -
Dig Regenerative Solenoid
Diagnostics 9001 - -
1 Dig Regenerative Solenoid
Feedback Current Low
. 9001 - -
Dig Regenerative Solenoid Diagnostics 9001 - -
1 Arm Regenerative
Solenoid Feedback Current Abnormal 9001 - -
Arm Regenerative Solenoid Diagnostics
1 Arm Regenerative
9001 - -
Solenoid Feedback Current High 9001 - -
Arm Regenerative Solenoid Diagnostics
9001 -1 1403.04 Arm Regenerative
Solenoid Feedback Current Low 9001 - -
Arm Regenerative Solenoid Diagnostics 9001 -1
Power Dig Solenoid
Feedback Current Abnormal 9001 - -
Power Dig Solenoid tics
Power Dig Solenoid
Feedback Current High 9001 - -
Power Dig Solenoid tics 9001 - -
Feedback Current Low
Feedback Current Abnormal
9001 -1 T ravel Speed Solenoid
Feedback Current High 9001 -T ravel Speed Solenoid tics 9001 -1 T ravel Speed Solenoid Feedback Current Low
9001 -1 Hydraulic Oil T emperature
Sensor V oltage Low 9001 -Hydraulic Oil T emperature Sensor Diagnostics 9001 -1 Actual Engine Speed Message Error
9001 -Controller Area Network (CAN) Diagnostics 9001 -1 191 Security Signal Received from ECM 9001 - -
Controller Area Network (CAN) Diagnostics .
9001 -1 1914.02 Radiator Coolant T emperature Message Error 9001 - -
Controller Area Network (CAN) Diagnostics 9001 -1 W ork Mode Received Message Error
Controller Area Network (CAN)
9001 - -
Diagnostics 9001 -1 Fuel Flow Rate Message Error 9001 - -
Controller Area Network (CAN)
Diagnostics
9001 - -
20100.02 Engine Coolant Overheat Message 9001 - -