TECHNICALMANUAL 450DLCExcavatorOperationand Test
TM236124JUN08(ENGLISH)
Forcompleteserviceinformationalsosee:
450DLCExcavatorRepair ............... TM2362
UndercarriageAppraisalManual ......... SP326
450DLCOperator’sManual .............. OMT221101
JDLink /ZXLink MachineMonitoring System CTM10006
Thismanualiswrittenforanexperiencedtechnician. Essentialtoolsrequiredinperformingcertainservice workareidentifiedinthismanualandare recommendedforuse.
Livewithsafety:Readthesafetymessagesinthe introductionofthismanualandthecautionspresented throughoutthetextofthemanual.
Thisisthesafety-alertsymbol.Whenyouseethis symbolonthemachineorinthismanual,bealertto thepotentialforpersonalinjury.
Technicalmanualsaredividedintwoparts:repairand operationandtests.Repairsectionstellhowtorepair thecomponents.Operationandtestssectionshelpyou identifythemajorityofroutinefailuresquickly.
Informationisorganizedingroupsforthevarious componentsrequiringserviceinstruction.Atthe beginningofeachgrouparesummarylistingsofall applicableessentialtools,serviceequipmentandtools, othermaterialsneededtodothejob,servicepartskits, specifications,weartolerances,andtorquevalues.
TechnicalManualsareconciseguidesforspecific machines.Theyareon-the-jobguidescontainingonly thevitalinformationneededfordiagnosis,analysis, testing,andrepair.
Fundamentalserviceinformationisavailablefrom othersourcescoveringbasictheoryofoperation, fundamentalsoftroubleshooting,generalmaintenance, andbasictypeoffailuresandtheircauses.
DX,TMIFC–19–29SEP98–1/1
Weneedyourhelptocontinuallyimproveourtechnical publications.PleasecopythispageandFAXormailyour comments,ideasandimprovements.
SENDTO: JohnDeereDubuqueWorks P.O.Box538
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Preventfallsbyfacingthemachinewhengettingonand off.Maintain3-pointcontactwithstepsandhandrails. Neverusemachinecontrolsashandholds.
Useextracarewhenmud,snow,ormoisturepresent slipperyconditions.Keepstepscleanandfreeofgrease oroil.Neverjumpwhenexitingmachine.Nevermountor dismountamovingmachine.
Avoidunexpectedmachinemovement.Beforestarting engine,sitinoperator’sseat.Ensureparklockleverisin “lock”position.
Neverattempttostartenginefromthegroundortracks. Donotattempttostartenginebyshortingacrossthe startersolenoidterminals.
UseandMaintainSeatBelt
Useseatbeltwhenoperatingmachine.Rememberto fastenseatbeltwhenloadingandunloadingfromtrucks andduringotheruses.
Examineseatbeltfrequently.Besurewebbingisnotcut ortorn.Replaceseatbeltimmediatelyifanypartis damagedordoesnotfunctionproperly.
Thecompleteseatbeltassemblyshouldbereplaced every3years,regardlessofappearance.
Becarefulnottoaccidentallyactuatecontrolleverswhen co-workersarepresent.Pullpilotshutofflevertolocked positionduringworkinterruptions.Pullpilotshutoffleverto lockedposition,andstopenginebeforeallowinganyone toapproachmachine.
Alwayslowerworkequipmenttotheground,andpullpilot shutofflevertolockedpositionbeforestandingupor leavingtheoperator’sseat.Stopenginebeforeexiting.
DW90712,000005B–19–03FEB06–1/1
Avoidcontactwithgaslines,buriedcablesandwater lines.Callutilitylinelocationservicestoidentifyall undergroundutilitiesbeforeyoudig.
Prepareworksiteproperly.Avoidoperatingnear structuresorobjectsthatcouldfallontothemachine. Clearawaydebristhatcouldmoveunexpectedlyifrun over.
Avoidboomorarmcontactwithoverheadobstacles oroverheadelectricallines. Nevermoveanypartof machineorloadcloserthan3m(10ft)plustwicetheline insulatorlengthtooverheadwires.
Keepbystandersclearatalltimes. Keepbystanders awayfromraisedbooms,attachments,andunsupported loads.Avoidswingingorraisingbooms,attachments,or loadsoverornearpersonnel.Usebarricadesorasignal persontokeepvehiclesandpedestriansaway.Usea signalpersonifmovingmachineincongestedareasor wherevisibilityisrestricted.Alwayskeepsignalpersonin view.Coordinatehandsignalsbeforestartingmachine.
Operateonlyonsolidfooting withstrengthsufficientto supportmachine.Whenworkingclosetoanexcavation, positiontravelmotorsawayfromthehole.
Reducemachinespeed whenoperatingwithtoolonor neargroundwhenobstaclesmaybehidden(e.g.,during snowremovalorclearingmud,dirt,etc).Athighspeeds, hittingobstacles(rocks,unevenconcreteormanholes) cancauseasuddenstop.Alwayswearyourseatbelt.
Onlyallowoperatoronmachine.
Ridersaresubjecttoinjury.Theymayfallfrommachine, becaughtbetweenmachineparts,orbestruckbyforeign objects.
Ridersmayobstructoperator’svieworimpairhisabilityto operatemachinesafely.
Beforemovingmachine,besureallpersonsareclear ofbothtravelandswingpaths. Turnaroundandlook directlyforbestvisibility.Usemirrorstoassistinchecking allaroundmachine.Keepwindowsandmirrorsclean, adjusted,andingoodrepair.
Becertaintravelalarmisworkingproperly.
Useasignalpersonwhenbackingifviewis obstructedorwheninclosequarters. Keepsignal personinviewatalltimes.Useprearrangedhandsignals tocommunicate.
Useseatbeltatalltimes.
Donotjumpifthemachinetips. Youwillbeunlikelyto jumpclearandthemachinemaycrushyou.
Loadandunloadfromtrucksortrailerscarefully. Be suretruckiswideenoughandonafirmlevelsurface.Use loadingramps.Properlyattachrampstotruckbed.Avoid truckswithsteelbedsbecausetracksslipmoreeasilyon steel.
Becarefulonslopes. Useextracareonsoft,rockyor frozenground.Machinemayslipsidewaysinthese conditions.Whentravelingupordownslopes,keepthe bucketonuphillsideandjustabovegroundlevel.
Becarefulwithheavyloads. Usingoversizebucketsor liftingheavyobjectsreducesmachinestability.Extending aheavyloadorswingingitoversideofundercarriage maycausemachinetotip.
Ensuresolidfooting. Useextracarewhenoperating nearbanksorexcavationsthatmaycave-inandcause machinetotiporfall.
TX03679,00016F3–19–03JAN07–1/1
TX03679,00016DF–19–24JAN07–1/1
Neverusethismachinetoliftpeople.
Neverliftaloadaboveanotherperson.Keepbystanders clearofallareaswherealoadmightfallifitbreaksfree. Donotleavetheseatwhenthereisaraisedload.
Donotexceedliftcapacitylimitspostedonmachineand inthismanual.Extendingheavyloadstoofarorswinging overundercarriagesidemaycausemachinetotipover.
Useproperriggingtoattachandstabilizeloads.Besure slingsorchainshaveadequatecapacityandareingood condition.Usetetherlinestoguideloadsandprearranged handsignalstocommunicatewithco-workers.
Alwaysverifycompatibilityofattachmentsby contactingyourauthorizeddealer.Addingunapproved attachmentsmayaffectmachinestabilityorreliability, andmaycreateahazardforothersnearthemachine.
Ensurethataqualifiedpersonisinvolvedin attachmentinstallation.Addguardstomachineif operatorprotectionisrequiredorrecommended.Verify
Avoidseriousinjuryordeathfromanexplosionhazard. Deactivateallcellularorradiofrequencydeviceson equipmentstoredoroperatinginanarea,suchasa blastingzone,wheretheuseofradiotransmittingdevices areprohibited.
thatallconnectionsaresecureandattachment respondsproperlytocontrols.
Carefullyreadattachmentmanualandfollowall instructionsandwarnings.Inanareafreeof bystandersandobstructions,carefullyoperate attachmenttolearnitscharacteristicsandrangeof motion.
TX03679,00016F0–19–24JAN07–1/1
VD76477,0001543–19–08JAN08–1/1
Warnothersofservicework. Alwaysparkandprepare yourmachineforserviceorrepairproperly.
• Parkmachineonalevelsurfaceandlowerequipment totheground.
• Placepilotcontrolshutoffleverin“lock”position.Stop engineandremovekey.
• Attacha“DoNotOperate”taginanobviousplacein theoperator’sstation.
Securelysupportmachineorequipmentbeforeworking underit.
• Donotsupportmachinewithboom,arm,orother hydraulicallyactuatedattachments.
• Donotsupportmachinewithcinderblocksorwooden piecesthatmaycrumbleorcrush.
• Donotsupportmachinewithasinglejackorother devicesthatmayslipoutofplace.
Understandserviceproceduresbeforebeginningrepairs. Keepserviceareacleananddry.Usetwopeople whenevertheenginemustberunningforservicework.
TX03679,00016E9–19–24JAN07–1/1
Explosivereleaseoffluidsfrompressurizedcooling systemcancauseseriousburns.
Donotserviceradiatorthroughtheradiatorcap.Onlyfill throughthesurgetankfillercap.
Shutoffengine.Onlyremovesurgetankfillercapwhen coolenoughtotouchwithbarehands.Slowlyloosencap torelievepressurebeforeremovingcompletely.
DW90712,00003B1–19–27NOV06–1/1
Hazardousfumescanbegeneratedwhenpaintisheated byweldingorusingatorch.Dustfromsandingorgrinding paintcanalsobehazardous.
Removepainttoatleast76mm(3in.)fromareatobe heated.Wearanapprovedrespiratorwhensandingor grindingpaint.Ifasolventorpaintstripperisused,wash areawithsoapandwater.Removesolventorpaint strippercontainersfromworkareaandallowfumesto disperseatleast15minutesbeforeweldingorheating.
Workoutsideorinawell-ventilatedarea.Disposeof waste,paintandsolventsproperly.
IMPORTANT:Disableelectricalpowerbeforewelding. Turnoffmainbatteryswitchor disconnectpositivebatterycable. Separateharnessconnectorstoengine andvehiclemicroprocessors.
Avoidweldingorheatingnearpressurizedfluidlines. Flammablespraymayresultandcausesevereburnsif pressurizedlinesfailasaresultofheating.Donotletheat gobeyondworkareatonearbypressurizedlines.
Removepaintproperly.Donotinhalepaintdustorfumes. Useaqualifiedweldingtechnicianforstructuralrepairs. Makesurethereisgoodventilation.Weareyeprotection andprotectiveequipmentwhenwelding.
TX03679,00016D5–19–25APR08–1/1
Alwayswearprotectivegogglesorsafetyglassesand otherprotectiveequipmentbeforestrikinghardenedparts. Hammeringhardenedmetalpartssuchaspinsand bucketteethmaydislodgechipsathighvelocity.
Useasofthammerorabrassbarbetweenhammerand objecttopreventchipping.
TX03679,0001745–19–03JAN07–1/1
Group10—MainController(MCF)Diagnostic BoomUpPilotPressureSensor
TroubleCodes
MainController(MCF)DiagnosticTrouble 11302.04—BoomRaisePilotPressure Codes 9001-10-1
9001-10-29 11000.02—AbnormalEEPROM ......... 9001-10-1 BoomUpPilotPressureSensor
ControllerHardwareDiagnostics .......... 9001-10-1
9001-10-30 11001.02—AbnormalRAM ............. 9001-10-2 11303.03—ArmRoll-inPilotPressure
11002.02—AbnormalA/DConversion 9001-10-3 ArmInPilotPressureSensor ControllerHardwareDiagnostics 9001-10-3
11004.02—CANCommunicationError
SensorCircuitVoltageHigh 9001-10-19 BoomFlowRateSolenoid(SF)
Pump2DeliveryPressureSensor
9001-10-20 11404.03—PowerDigSolenoid(SG) 11202.04—Pump2DeliveryPressure
11301.03—SwingPilotPressureSensor PowerDigSolenoid(SG)Diagnostics 9001-10-41 CircuitVoltageHigh 9001-10-23 11405.03—TravelSpeedSolenoid(SI) Swingpilotpressuresensordiagnostics...9001-10-24 ValveCurrentFeedbackHigh 9001-10-42
11301.04—SwingPilotPressureSensor TravelSpeedSolenoid(SI)Diagnostics...9001-10-42 CircuitVoltageLow ................. 9001-10-25 11405.04—TravelSpeedSolenoid(SI)
SwingPilotPressureSensor ValveCurrentFeedbackLow 9001-10-43 Diagnostics 9001-10-26 TravelSpeedSolenoid(SI)Diagnostics...9001-10-43
11302.03—BoomRaisePilotPressure Continuedonnextpage SensorCircuitVoltageHigh ........... 9001-10-27
11410.03—Pump1(4-Spool)ControlControllerAreaNetwork(CAN) Diagnostics ....................... 9001-10-85 SolenoidValveFeedbackCurrent High ............................. 9001-10-4411976.03—AuxiliaryValve2Feedback CurrentHigh ...................... 9001-10-92
Pump1(4-Spool)ControlSolenoid Diagnostics ....................... 9001-10-4411976.04—AuxiliaryValve2Feedback CurrentLow 9001-10-92
11410.04—Pump1(4-Spool)Control
SolenoidValveFeedbackCurrent11977.03—AuxiliaryValve1Feedback CurrentHigh 9001-10-93 Low............................. 9001-10-45
Pump1(4-Spool)ControlSolenoid11977.04—AuxiliaryValve1Feedback CurrentLow 9001-10-93 Diagnostics 9001-10-45
11412.03—HydraulicFanPumpControl11980.03—ATTReliefChangeValve FeedbackCurrentHigh 9001-10-93 SolenoidValveFeedbackCurrent High ............................. 9001-10-4611980.04—ATTReliefChangeValve FeedbackCurrentLow............... 9001-10-93
HydraulicFanPumpControlSolenoid Diagnostics ....................... 9001-10-4711981.03—FanReversingSolenoid Valve2FeedbackCurrentHigh 9001-10-94 11412.04—HydraulicFanPump SolenoidValveFeedbackCurrentFanReversingSolenoid2Diagnostics 9001-10-94 11981.04—FanReversingSolenoid Low............................. 9001-10-47
HydraulicFanPumpControlSolenoidValve2FeedbackCurrentLow 9001-10-94 FanReversingSolenoid2Diagnostics 9001-10-94 Diagnostics 9001-10-48
11802.03—BoomBottomPressure11982.03—FanReversingSolenoid Valve1FeedbackCurrentHigh 9001-10-95 SensorCircuitVoltageHigh 9001-10-48
BoomBottomPressureSensorFanReversingSolenoid1Diagnostics .... 9001-10-95 11982.04—FanReversingSolenoid Diagnostics ....................... 9001-10-49
11802.04—BoomBottomPressureValve1FeedbackCurrentLow ........ 9001-10-96 FanReversingSolenoid1Diagnostics 9001-10-96 SensorCircuitVoltageLow 9001-10-50
BoomBottomPressureSensor11983.02—IntakeAirTemperature MessageError 9001-10-96 Diagnostics 9001-10-51
11901.03—HydraulicOilTemperatureControllerAreaNetwork(CAN) Diagnostics 9001-10-96
SensorCircuitVoltageHigh 9001-10-52
HydraulicOilTemperatureSensor11984.02—BoostTemperatureMessage Error 9001-10-104 Diagnostics 9001-10-53
11901.04—HydraulicOilTemperatureControllerAreaNetwork(CAN) Diagnostics ...................... 9001-10-104
SensorCircuitVoltageLow ........... 9001-10-54
HydraulicOilTemperatureSensor11989.03—BoomModeSolenoid(SC) ValveFeedbackCurrentHigh 9001-10-111 Diagnostics 9001-10-55
11910.02—ActualEngineSpeedBoomModeSolenoid(SC)Diagnostics...9001-10-111 11989.04—BoomModeSolenoid(SC) MessageError 9001-10-56
ControllerAreaNetwork(CAN)ValveFeedbackCurrentLow 9001-10-112 BoomModeSolenoid(SC)Diagnostics...9001-10-112 Diagnostics 9001-10-57
11911.02—SecuritySignalMessage11991.03—TravelRightPilotPressure SensorCircuitVoltageHigh 9001-10-113 Error 9001-10-64
ControllerAreaNetwork(CAN)TravelRightPilotPressureSensor Diagnostics ...................... 9001-10-113 Diagnostics ....................... 9001-10-64
11914.02—RadiatorWaterTemperature11991.04—TravelRightPilotPressure SensorCircuitVoltageLow 9001-10-114 MessageError 9001-10-71
ControllerAreaNetwork(CAN)TravelRightPilotPressureSensor Diagnostics 9001-10-115 Diagnostics 9001-10-71
11918.02—WorkModeMessageError...9001-10-7811992.03—Pump2(5-Spool)Control PressureSensorCircuitVoltage
ControllerAreaNetwork(CAN) Diagnostics 9001-10-78High 9001-10-116
11920.02—FuelFlowRateMessage Error ............................ 9001-10-85 Continuedonnextpage
Pump2(5-Spool)ControlPressureSensorBucketCurlPilotPressureSensor Diagnostics ...................... 9001-10-117 Diagnostics ......................
9001-10-143
11992.04—Pump2(5-Spool)Control 9001 PressureSensorCircuitVoltageLow...9001-10-119
Group20—EngineControlModule(ECM) Pump2(5-Spool)ControlPressureSensor DiagnosticTroubleCodes Diagnostics 9001-10-119 EngineControlModule(ECM)Diagnostic 11993.03—TravelLeftPilotPressure TroubleCodes 9001-20-1 SensorCircuitVoltageHigh 9001-10-121
91.02—AcceleratorSensor1-2Comparison TravelLeftPilotPressureSensor (P1271) ........................... 9001-20-1 Diagnostics 9001-10-121
11993.04—LeftTravelPilotPressure
100.03—EngineOilPressureSensor
VoltageLow(P0522)
100.04—EngineOilPressureSensor TravelLeftPilotPressureSensor
9001-20-2 SensorCircuitLowInput 9001-10-122
VoltageHigh(P0523) 9001-20-2 Diagnostics ...................... 9001-10-123
102.03—BoostPressureSensorVoltage
11994.03—Pump1(4-Spool)Control Low(P0237)
9001-20-2 PressureSensorCircuitVoltage
102.04—BoostPressureSensorVoltage High 9001-10-124 High(P0238) ....................... 9001-20-2 Pump1(4-Spool)ControlPressureSensor 105.03—BoostTemperatureSensorVoltage Diagnostics 9001-10-125 High(P1113) 9001-20-3
11994.04—Pump1(4-Spool)Control 105.04—BoostTemperatureSensorVoltage PressureSensorCircuitVoltageLow...9001-10-126
9001-20-3 Pump1(4-Spool)ControlPressureSensor 108.03—BarometricPressureSensor Diagnostics ...................... 9001-10-127
11995.03—ArmRoll-OutPilotPressure
108.04—BarometricPressureSensor SensorCircuitVoltageHigh .......... 9001-10-128 VoltageHigh(P0108) ................ 9001-20-3
ArmOutPilotPressureSensor
11995.04—ArmRoll-OutPilotPressure
110.03—EngineCoolantTemperature Diagnostics 9001-10-129 SensorVoltageHigh(P0118) 9001-20-4
ArmOutPilotPressureSensor
110.04—EngineCoolantTemperature SensorCircuitLowInput 9001-10-130 SensorVoltageLow(P0117) 9001-20-4
11997.03—BucketDumpPilotPressure
157.00—CommonRailPressure—First Diagnostics 9001-10-131 Stage(P088) ....................... 9001-20-4
BucketDumpPilotPressureSensor
157.00—CommonRailPressure—Second SensorCircuitVoltageHigh .......... 9001-10-132 Stage(P088) 9001-20-4
11997.04—BucketDumpPilotPressure
157.02—CommonRailPressureHigh Diagnostics ...................... 9001-10-133 (P0089) 9001-20-5
157.03—CommonRailPressureSensor SensorCircuitVoltageLow 9001-10-134
VoltageHigh(P0193) ................ 9001-20-5 BucketDumpPilotPressureSensor
157.03—CommonRailPressureSensor Diagnostics 9001-10-135
11998.03—BoomDownPilotPressure
VoltageLow(P0192) 9001-20-5
172.03—IntakeAirTemperatureSensor SensorCircuitVoltageHigh 9001-10-136
VoltageHigh(P0113) 9001-20-6 BoomDownPilotPressureSensor
172.04—IntakeAirTemperatureSensor Diagnostics ...................... 9001-10-137
11998.04—BoomDownPilotPressure
BoomDownPilotPressureSensor
VoltageLow(P0112) 9001-20-6
174.03—FuelTemperatureSensorVoltage SensorCircuitVoltageLow .......... 9001-10-138 High(P0183) ....................... 9001-20-6
11999.03—BucketCurlPilotPressure
174.04—FuelTemperatureSensorVoltage Diagnostics 9001-10-139 Low(P0182) 9001-20-6
190.00—EngineOverspeed(P0219) ...... 9001-20-7 SensorCircuitVoltageHigh 9001-10-140
628.02—ROMMalfunction(P0601) 9001-20-7
BucketCurlPilotPressureSensor Diagnostics 9001-10-141633.07—PressureLimiterOpen(P0601)...9001-20-7
11999.04—BucketCurlPilotPressure SensorCircuitVoltageLow .......... 9001-10-142 Continuedonnextpage
636.02—CamshaftPositionSensor10004.02—InjectionNozzleCommon#2 (G-Sensor)SignalMissing(P0340) ...... 9001-20-7 Malfunction(P1262) 9001-20-14
9001 Malfunction—Bank2(P0612) 9001-20-15
636.02—CamshaftPositionSensor 10005.01—ChargeCircuit (G-Sensor)SignalMismatch(P0341) ..... 9001-20-8 Malfunction—Bank1(P0611) 9001-20-15
636.07—CamshaftPositionSensor 10006.01—ChargeCircuit (G-Sensor)outofPhase(P1345) 9001-20-8
639.02—CANCommunicationError 10007.02—CPUMonitoringICMalfunction (U2104) 9001-20-8 (P0606) .......................... 9001-20-15
639.03—CANTimeout(U2106) 9001-20-8 10008.02—A/DConversionMalfunction
651.03—OpenCircuitinInjectionNozzle#1 (P1630) .......................... 9001-20-15 (P0201) 9001-20-9 10009.02—5VoltPowerSupply#3
652.03—OpenCircuitinInjectionNozzle#2 Malfunction(P1633) 9001-20-16 (P0202) ........................... 9001-20-9 10010.02—5VoltPowerSupply#4
653.03—OpenCircuitinInjectionNozzle#3 Malfunction(P1634) 9001-20-16 (P0203) ........................... 9001-20-9 10011.02—5VoltPowerSupply#5
654.03—OpenCircuitinInjectionNozzle#4 Malfunction(P1635) 9001-20-16 (P0204) 9001-20-9 10013.02—EEPROMMalfunction
655.03—OpenCircuitinInjectionNozzle#5 (P0603) .......................... 9001-20-16 (P0205) 9001-20-10
656.03—OpenCircuitinInjectionNozzle#6
Group30—InformationController(ICF)Diagnostic (P0206) 9001-20-10 TroubleCodes
723.02—CrankshaftPositionSensorSignal InformationController(ICF)Diagnostic Missing(P0335) .................... 9001-20-10
723.02—CrankshaftSensorMismatchTroubleCodes ...................... 9001-30-1 (P0336) .......................... 9001-20-10 14000.02—AbnormalCAN
987.03—CheckEngineLamp Communication 9001-30-1 Malfunction(P0650) 9001-20-11 14001.02—ICF:FlashMemory:
1077.02—CPUFaultMalfunction Read/WriteError 9001-30-1 (P0606) 9001-20-11 14002.02—ICF:ExternalRAM:
1079.02—5VoltPowerSupply#1 Read/WriteError 9001-30-2 Malfunction(P1631) 9001-20-11 14003.02—ICF:EEPROM:SumCheck 1080.02—5VoltPowerSupply#2 Error 9001-30-2 Malfunction(P1632) ................. 9001-20-11 14006.02—ICF:SatelliteCommunication 1239.01—NoPumpPressure—FirstStage Terminal:CommunicationError ......... 9001-30-2 (P1094) .......................... 9001-20-12 14008.02—ICF:AbnormalInternalRAM...9001-30-2 1240.01—NoPumpPressure 14100.02—SatelliteCommunication Feed—SecondStage(P1093) 9001-20-12
Terminal:AbnormalEEPROM 9001-30-3
1347.00—PCV#1OpenCircuitorShortto 14101.02—SatelliteCommunication Ground(P0092) 9001-20-12
Terminal:AbnormalIB/OBQueue 9001-30-3 1347.04—PCV#1ShorttoPower 14102.02—SatelliteCommunication (P0091) 9001-20-12
Terminal:AbnormalLocalLoopBack .... 9001-30-3 1348.00—PCV#2OpenCircuitorShortto 14103.02—SatelliteCommunication Ground(P1291) .................... 9001-20-13
Terminal:Thesatelliteisnotfound. 9001-30-3
1348.04—PCV#2ShorttoPower 14104.02—SatelliteCommunication (P1292) .......................... 9001-20-13
1485.02—EngineControlModuleRelay 14105.02—SatelliteCommunication Malfunction(P1625) 9001-20-13
Terminal:Fail1ofRemoteLoopBack .... 9001-30-4
10001.03—EGRPositionSensor 14106.02—SatelliteCommunication Malfunction(P0487) 9001-20-14
Terminal:Fail2ofRemoteLoopBack 9001-30-4
Terminal:Sendingandreceivingdataare
10002.02—EGRValveControlMalfunction (P0488) 9001-20-14mismatched 9001-30-4
10003.02—InjectionNozzleCommon#1 Malfunction(P1261) ................. 9001-20-14 Continuedonnextpage
Group40—AirConditionerController(ACF) 13308.02—AbnormalCAN Communication ..................... 9001-50-3
DiagnosticTroubleCodes ControllerAreaNetwork(CAN)
AirConditionerController(ACF)Diagnostic 9001 Diagnostics ........................ 9001-50-4 TroubleCodes 9001-40-1 13310.02—ShortedcircuitinCoolant
E11—CabAirTemperatureSensorOpen TemperatureSensor 9001-50-11 Circuit ............................ 9001-40-1
CoolantTemperatureSensor
HarnessDiagnostics ................... 9001-40-1 Diagnostics 9001-50-11
E12—CabAirTemperatureSensorShort 13311.02—ShortedcircuitinFuelLevel Circuit 9001-40-2 Sensor 9001-50-12
HarnessDiagnostics 9001-40-2
E13—AmbientAirTemperatureSensor 13311.04—OpencircuitinFuelLevel OpenCircuit
HarnessDiagnostics
FuelLevelSensorDiagnostics 9001-50-12
9001-40-2 Sensor ........................... 9001-50-13
9001-40-3
E14—AmbientAirTemperatureSensor ShortCircuit ........................ 9001-40-3
HarnessDiagnostics ................... 9001-40-3
E15—CoolantTemperatureSensor OpenCircuit
9001-40-4
HarnessDiagnostics ................... 9001-40-4
E16—CoolantTemperatureSensor ShortCircuit
9001-40-5
HarnessDiagnostics ................... 9001-40-5
E18—SolarSensorAbnormal 9001-40-6
HarnessDiagnostics 9001-40-6
E21—FreezeControlSwitchOpen Circuit 9001-40-7
HarnessDiagnostics 9001-40-7
E22—FreezeControlSwitchShort Circuit
9001-40-8
HarnessDiagnostics ................... 9001-40-8
E43—AbnormalDamper 9001-40-9
HarnessDiagnostics 9001-40-9
E44—AbnormalDamper ............... 9001-40-9
HarnessDiagnostics 9001-40-10
E45—AbnormalDamper 9001-40-10
HarnessDiagnostics .................. 9001-40-10
E51—AbnormalHigh/LowPressure Switch 9001-40-11
HarnessDiagnostics .................. 9001-40-11
Group50—MonitorController(MON)Diagnostic TroubleCodes
MonitorController(MON)Diagnostic TroubleCodes ...................... 9001-50-1
13303.02—AbnormalThermister Temperature 9001-50-1
MonitorTemperatureDiagnostics ......... 9001-50-1
13304.02—AbnormalREGInputH Level 9001-50-2
AlternatorOutputDiagnostics ............ 9001-50-2
13306.02—AbnormalEEPROM 9001-50-3
InformationControllerDiagnostics ......... 9001-50-3
FuelLevelSensorDiagnostics .......... 9001-50-13
Themaincontroller(MCF)diagnostictroublecodesmay beviewedonthemonitor,byusingDr.ZX,orbyusing SERVICEADVISOR.Seethefollowingproceduresfor viewingthemaincontrollerdiagnostictroublecodes.
• SeeReadingDiagnosticTroubleCodesWithMonitor Display.(Group9015-20.)
• SeeReadingDiagnosticTroubleCodesWithService ADVISOR DiagnosticApplication.(Group9015-20.)
• SeeReadingDiagnosticTroubleCodesWithDr.ZX. (Group9015-20.)
SERVICEADVISORisatrademarkofDeere&Company
11000.02—AbnormalEEPROM
LD30992,00001CC–19–10DEC05–1/1
MS12501,0000046–19–14JAN06–1/1
ControllerHardwareDiagnostics
1 CodeCheck Clearandre-checkdiagnostictroublecodes.
IsDTC11000.02-AbnormalEEPROMstillpresent?
YES: Codeisstillpresent andmachinedoesnot operate.Replacemain controller(MCF).See MainController(MCF) RemoveandInstall. (Group9015-20).
YES: Codeisstillpresent butmachineisstill operable.GotoMachine FunctionCheck.
NO: Maincontroller (MCF)isOK.
2 MachineFunction Check
Isoperationofmachinenormal?SeeOperationalCheckoutProcedure.(Group 9005-05).
YES: Machinemaybe operatedbutitis recommendedthatthe maincontroller(MCF)be replaced.
NO: Maincontroller (MCF)malfunction. Replace.SeeMain Controller(MCF)Remove andInstall.(Group 9015-20).
MS12501,0000047–19–14JAN06–1/1
ControllerHardwareDiagnostics
1 CodeCheck Clearandre-checkdiagnostictroublecodes.
IsDTC11001.02-AbnormalEEPROMstillpresent?
YES: Codeisstillpresent andmachinedoesnot operate.Replacemain controller(MCF).See MainController(MCF) RemoveandInstall. (Group9015-20).
YES: Codeisstillpresent butmachineisstill operable.GotoMachine FunctionCheck.
NO: Maincontroller (MCF)isOK.
2 MachineFunction Check Isoperationofmachinenormal?SeeOperationalCheckoutProcedure.(Group 9005-05).
YES: Machinemaybe operatedbutitis recommendedthatthe maincontroller(MCF)be replaced.
NO: Maincontroller (MCF)malfunction. Replace.SeeMain Controller(MCF)Remove andInstall.(Group 9015-20). MS12501,0000048–19–14JAN06–1/1
ControllerHardwareDiagnostics
1 CodeCheck Clearandre-checkdiagnostictroublecodes.
IsDTC11002.02-AbnormalEEPROMstillpresent?
YES: Codeisstillpresent andmachinedoesnot operate.Replacemain controller(MCF).See MainController(MCF) RemoveandInstall. (Group9015-20).
YES: Codeisstillpresent butmachineisstill operable.GotoMachine FunctionCheck.
NO: Maincontroller (MCF)isOK.
2 MachineFunction Check
Isoperationofmachinenormal?SeeOperationalCheckoutProcedure.(Group 9005-05).
YES: Machinemaybe operatedbutitis recommendedthatthe maincontroller(MCF)be replaced.
NO: Maincontroller (MCF)malfunction. Replace.SeeMain Controller(MCF)Remove andInstall.(Group 9015-20).
MS12501,0000049–19–14JAN06–1/1
Harnessdiagnostics
Otherindividualsensororcomponentdiagnostictroublecodes(DTC)mayalsobepresentwithinthiscode.Engine speeddialmaynotfunctioncorrectlywhenthiscodeispresent.
1 DiagnosticTrouble CodeCheck
Clearandre-checkDTCs.
IsDTC11003.03-AbnormalSensorVoltagestillpresent?
2 ContinuityCheck
Disconnectallconnectorsonmaincontroller(MCF)andtosensorscorrespondingwith codesdisplayed.Checkforcontinuitybetweenterminals1and3ofsensorharness connector.
Istherecontinuitybetweenterminals1and3?
YES: GotoContinuity Check.
NO: Sensormalfunction. Replacesensor.
–––1/1
YES: Shortcircuitin harnessbetweenmain controller(MCF)and sensor.Checkharness. Repairorreplace harness.SeeCab Harness(W1)Wiring Diagram,seeMachine Harness(W2)Wiring Diagram,seePump Harness(W8)Wiring Diagram,orseeControl ValveHarness(W7) WiringDiagram.(Group 9015-10.)
NO: Maincontroller (MCF)malfunction. Replace.SeeMain Controller(MCF)Remove andInstall(Group 9015-20).
–––1/1
Autoidlecontrol A
Controlautoidle 9010-05-19
A/I(auto-idle)circuit
Operationalcheck .................
9005-10-14
Autolubricationsystem
Diagnosemalfunctions ............. 9025-15-61
Auto-IdleDoesNotWork
Airconditioner Diagnostics
Componentlocation 9031-15-8
Compressorclutchbeltcheckand
Auto-idleswitch
9010-15-13
Removeandinstall 9015-20-115 adjustment ...................... 9031-25-6
Diagnostictroublecodecheck
Operatingpressurediagnosticchart 9031-25-7
Operationalchecks
Auxiliaryfuseboxharness(W9)
9031-15-7 Componentlocation 9015-10-62
Wiringdiagram
9031-25-2
Airconditionercompressorclutch Test 9031-25-5
Airconditionerharness(W6) B
Componentlocation 9015-10-50
Wiringdiagram ................... 9015-10-52
Airconditioning
9015-10-64
Backoveraccidents
Diagnosemalfunctions 9031-15-1 Battery Hosesandtubinginspection 9031-25-6
Refrigerantcautionsandproper Batteryexplosions
Batteryrelay R134asystemtest 9031-25-4
9000-01-10
......................... 9015-20-101 Systemcycleofoperation ............ 9031-05-1
Batteryvoltage
AirIntake Check ......................... 9015-20-101
Systemleakagetest 9010-25-9
Alarm
Belt
Airconditionercompressorcheckand Travel,removeandinstall 9015-20-116 adjustment 9031-25-6
Allhydraulicfunctionsslow Boom
Diagnosemalfunctions .............. 9025-15-3 Cylinderdrifttest
9025-25-67
Allhydraulicfunctionstoofast Modeswitchcheck 9005-10-22
Diagnosemalfunctions 9025-15-7
Regenerativevalveoperationcheck...9005-10-23
Alternator Up,armin,andbucketcombinedfunction
Test 9015-20-99 check ......................... 9005-10-22
Anticavitationvalve
Boomdownshocklessvalve Operation
9025-05-72 Operation
9025-05-15
Armreducedleakagevalve
Armregenerativevalve
Arm1flowrate,pilotvalve
Arm2flowratepilotvalve
BucketregenerativevalveElectrical,GlobalTRACS terminal(GTT)harness
Operation .......................
9025-05-81 (W51) 9015-10-82
Operationalcheck ................. 9005-10-24
Electrical,JDLink CANharness (W52) 9015-10-82
Electrical,JDLink jumperharness (W54) 9015-10-82
Electrical,JDLink powerharness C (W53) ........................ 9015-10-82
Electrical,machineinformationgateway(MIG) Cab harness(W50) .................. 9015-10-82
Rearcoverremoveandinstall 9015-20-108
CabGuarding 9000-01-3
Cabharness(W1)
Componentlocation 9015-10-22
Wiringdiagram 9015-10-24
Cabswitchharness(W10)
Engine
9010-05-1
Engineharness(W4) 9015-10-42
Engineinterfaceharness(W5) 9015-10-46
ComponentLocation
Fandrivesystem 9025-15-86
Componentlocation Componentlocation ............... 9015-10-65
Wiringdiagram ................... 9015-10-66
CANbusterminator
Heatedairseatharness(W12) ....... 9015-10-70
Heater 9031-15-8
Check 9015-20-105Hydraulicsystem 9025-15-90
Centerjoint Information 9015-05-1
Operation ...................... 9025-05-104 Machineharness(W2) ............. 9015-10-30
Chargingcircuit
Theoryofoperation 9015-15-3
Masterlegend 9015-10-6
Monitorharness(W3) 9015-10-38
Check Multi-functionpilotcontrolleverharness
Serpentinebelttension .............. 9010-25-1 (W14) ........................ 9015-10-76
Checkandadjust
Pilotcontrolvalve-to-pilotsignalmanifold—
Enginevalvelash 9010-25-4 backhoepattern 9025-15-78
Injectionpumptiming 9010-25-2
Pilotcontrolvalve-to-pilotsignalmanifold—
Checkvalves excavatorpattern 9025-15-76
Controlvalve,identificationand
Pilotshutoffswitchharness(W11) 9015-10-67 operation 9025-05-62
Chemicalproducts
Handling 9000-01-6
Cinchconnector
Installcontact ........ 9015-20-128,9015-20-129
Pilotshutoffvlaveharness(W17) 9015-10-81
Pumpharness(W8) ............... 9015-10-58
Reversingfanswitchharness(W16)...9015-10-80
Seatheaterswitchharness(W13) 9015-10-72
Travelalarmcancelswitchharness
Cinchconnector(32and48Way) (W15) ........................ 9015-10-79
Repair 9015-20-129
Cinchconnectors
ReplaceConnector ............... 9015-20-126
ComponentLocation
Travelhydraulicsystem 9025-15-82
Compressor Circuit
Airconditioner,beltcheckand
Windshieldwiperandwasher,theoryof adjustment 9031-25-6 operation 9015-15-37
Circuitreliefvalve
Operation ....................... 9025-05-72
Testandadjustment 9025-25-37
Componentlocation
Airconditioner ..................... 9031-15-8
Airconditionerharness(W6) 9015-10-50
Auxiliaryfuseboxharness(W9) 9015-10-62
Cabharness(W1) ................. 9015-10-22
Compressorclutch
Airconditioner,test ................. 9031-25-5
ConnectionProcedure
JDLink 9015-20-8
Controlareanetwork(CAN)
Theoryofoperation ................. 9015-15-1
Controldata:initialize
Informationcontroller(ICF) 9015-20-78
Controllever Cabswtichharness(W10) 9015-10-65
Controlvalveharness(W7) 9015-10-54Patternconversion 9025-15-71 TM2361(24JUN08)
ControlvalveReadingwithDr.ZX 9015-20-30
Checkvalvesidentificationand
Lineidentification ................. 9025-15-66
DiagnosticTroubleCodes Operation ....................... 9025-05-48
Pilotoperation 9025-05-26
Pilot,operation
Schematic,hydraulic 9025-15-94
Controlvalveharness(W7)
Controlvalveliftcheckvalve
Coolingfancircuit
Diagnostictroublecodes
Diagnostics
Informationcontroller(ICF) 9015-20-87
Digfunctiondrift
Cycletimescheck Operationalcheck 9005-10-20
Operationalcheck 9005-10-27
Digitalpressure/temperatureanalyzer
Cylinder Installation
Boom,arm,andbucket,operation...9025-05-109
Cylinderdrift
Digitalthermometerinstallation
Diode
9025-25-2
9025-25-1
Test,arm,boom,andbucket ........ 9025-25-67 Check ......................... 9015-20-104
Display
Monitor,removeandinstall 9015-20-111
DownloadinjectorIDcode D Tech2 9010-25-40 Dr.ZX
Dailyreportdatalist
Informationcontroller(ICF) 9015-20-87
Passwordchange 9015-20-60
Personaldigitalassistant(PDA)connectionto
Datadownload excavator 9015-20-27
Informationcontroller(ICF) 9015-20-82
Dateandtime
Informationcontroller(ICF) .......... 9015-20-75
Diagnosticapplication
Tech2diagnosticscantool,Data display 9015-20-24
Readingdiagnostictroublecodes ..... 9015-20-30
Drivingmetalpins 9000-01-14
Diagnosticconnection Indx 3
ServiceADVISOR 9015-20-11
Diagnostictroublecode
Check,airconditionerandheater 9031-15-7
Diagnostictroublecodes
E(economy)mode
Operationalcheck ................. 9005-10-12
ECM
Displayandcleartroublecodes 9005-10-1Removeandinstall 9015-20-110
EconomymodeEngineoillevel/coolantlevelswitch
Modeeconomy ................... 9010-05-19
Electrical
Monitordataitems
9015-20-1
Schematic,wiringdiagram,andcomponent
locationinformation 9015-05-1
Springwireretainerconnector 9015-20-118
Tabretainerconnector ............ 9015-20-117
ElectricalComponent
Checks ........................ 9015-20-100
Operationalcheck
Enginepreheatcircuit
9005-10-8
Theoryofoperation ................. 9015-15-6
Enginespeeddial
Operationalcheck
9005-10-12
Removeandinstall 9015-20-115
Enginevalvelash
Checkandadjust 9010-25-4
Exhaustfumes 9000-01-4
Exhaustgasrecirculation
Electricalcomponent Operation 9010-05-16
Masterlegend 9015-10-6
ExhaustSmoke
Electricaldiagnosticprocedures Black ........................... 9010-15-22
Electricalschematic 9015-10-12
Keyswitchcheck 9015-20-100 Gray ........................... 9010-15-22
Emergencypreparation ............... 9000-01-6
Exhaustsystem
Engineintake Engine Operation 9010-05-12
Componentlocation 9010-05-1
Explosion
Compressionpressuretest ........... 9010-25-7 Battery 9000-01-5
Coolingsystemoperation 9010-05-8
Fuelsystemoperation 9010-05-4
IsuzuAH-6WG1XYSA-01 ............ 9010-15-1
Lubricationsystemoperation 9010-05-9 F
Oilpressuretest 9010-25-15
Powertestusingturbochargerboost
Fandrive pressure 9010-25-11
Speedcontrolsystem 9010-05-19
Turbochargeroperation ............. 9010-05-13
Pumpregulatoroperation 9025-05-38
Schematic,hydraulic 9025-15-94
Systemreliefvalvetestand
Enginecontrol adjustment 9025-25-74
Theoryofoperation ................ 9015-15-18
Enginecontrolmodule
Removeandinstall 9015-20-110
Enginecontrolmodulecircuit
Theoryofoperation 9015-15-14
Enginecontroller(ECM)
DiagnosticsusingDr.ZX 9015-20-50
Fandrivehydraulicsystem
Diagnosemalfunctions 9025-15-10
Fandrivepump
Flowtest ........................ 9025-25-82
Torquecontroltestandadjustment .... 9025-25-80
FanDriveSystem
Componentlocation 9025-15-86
EngineEmits Filter
ExcessiveWhiteExhaustSmoke ..... 9010-15-20 Pilot,operation 9025-05-6
Engineemitsexcessiveblackorgrayexhaust Return,operation 9025-05-111 smoke .......................... 9010-15-22 Fireprevention 9000-01-5
Enginefluidlevelswitch
Flowratecircuit
Removeandinstall ............... 9015-20-117 Arm2,operation .................. 9025-05-94
Engineharness(W4)
Componentlocation ............... 9015-10-42
Frequencydistributionlist
Informationcontroller(ICF) .......... 9015-20-87
Wiringdiagram 9015-10-44 Fuelgauge
Engineintake Operationalcheck 9005-10-3
Exhaustsystem 9010-05-12 Fuelsystem
Engineinterfaceharness(W5)
Componentlocation 9010-05-4
Componentlocation 9015-10-46 Fuelinjectoroperation 9010-05-4
Wiringdiagram ................... 9015-10-48 Operation 9010-05-4
Enginemalfunctions Fuse Specifications 9015-10-2
Diagnose 9010-15-1
FusiblelinkHydraulicoil
Check
Cleanupprocedureusingportablefilter
9015-20-101 caddy ......................... 9025-25-3
Overheats ........................ 9025-15-8
Warmupprocedure ................. 9025-25-4
Hydraulicoiltankpressurization
Operationalcheck
Gearbox
Swing,operation ..................
9025-05-98
Travel,operation ................... 9020-05-2
Hydraulicschematic
Controlvalve
Counterweightremovalhydraulicsystem
GlobalTRACS terminal(GTT)harness(W51) schematic
Componentlocation 9015-10-82
Wiringdiagram 9015-10-86
Fandrive
Loadloweringcontrolvalves
Glowplugpreheatcircuit schematic .....................
Theoryofoperation 9015-15-6
Pilotcontrolvalve—backhoecontrol
Glowplugrelay pattern
Check
Handholduse
9015-20-103
9000-01-7
Avoiding ......................... 9000-01-9
9005-10-17
9025-15-94
9025-15-94
9025-15-94
9025-15-94
9025-15-94
Pilotcontrolvalve—excavatorcontrol pattern 9025-15-94
Pilotsignalmanifold—backhoecontrol pattern 9025-15-94
Pilotsignalmanifold—excavatorcontrol pattern 9025-15-94
Heatedairseatharness(W12)Travelmotor .....................
Componentlocation ............... 9015-10-70
Hydraulicsystem
Wiringdiagram 9015-10-71Componentlocation
Heatedseatswitch
9025-15-94
9025-15-90
Diagnosemalfunctions 9025-15-3
Removeandinstall 9015-20-117Lineconnections 9025-15-92
Heater
Componentlocation 9031-15-8
Diagnostictroublecodecheck 9031-15-7
Operationalchecks ................. 9031-25-2
Heaterandairconditioner
Controlscheck ...................
9005-10-29
Schematic,hydraulic 9025-15-94
HeaterandairconditioningIdlespeedupcontrol
Circuitcheck 9005-10-28
Controlidlespeedup 9010-05-19
HeatingInformationcontroller(ICF)
Controldata:initialize
HosesandtubinginspectionInformationcontroller(ICF)circuit Indx 5 Airconditioning 9031-25-6Theoryofoperation 9015-15-33
HourmeterInitialization
Operationalcheck
9005-10-3
Informationcontroller(ICF) 9015-20-67
Injectorbalancetest(injectormisfiretest)Liftingobjects
Tech2 9010-25-19
Inspectmachine ..................... 9000-01-3
JDLink CANharness(W52)
Componentlocation 9015-10-82
Wiringdiagram 9015-10-88
JDLink jumperharness(W54)
Componentlocation 9015-10-82
Wiringdiagram 9015-10-92
JDLink powerharness(W53)
Componentlocation ............... 9015-10-82
JDLink system
Specialcare 9000-01-11
Lightcircuit
Operationalcheck .................. 9005-10-6
Lineconnection
Pilotsignalmanifold-to-controlvalve...9025-15-80
LineConnection
Travelhydraulicsystem ............ 9025-15-84
Lineconnections
Hydraulicsystem .................. 9025-15-92
Lineidentification
Controlvalve ..................... 9025-15-66
Swingmotor 9025-15-70
Loaddumpcircuit
Theoryofoperation ................. 9015-15-3
Lubricationsystemoperation
Wiringdiagram ................... 9015-10-90 Engine .......................... 9010-05-9
Componentlocation 9015-10-82
Connectionprocedure 9015-20-8
Functionalschematic 9015-10-20
GlobalTRACS terminal(GTT)harness(W51) M
wiringdiagram 9015-10-86
JDLink CANharness(W52)wiring
Machineharness(W2) diagram ....................... 9015-10-88
Componentlocation 9015-10-30
JDLink jumperharness(W54)wiring Wiringdiagram 9015-10-32 diagram ....................... 9015-10-92
Machineinformationcenter(MIC)
JDLink powerharness(W53)wiring application 9015-20-66 diagram 9015-10-90
Machineinformationgateway(MIG)harness(W50)
JT02156Adigitalpressure/temperatureanalyzer
Machineinformationgateway(MIG)harness(W50)
Componentlocation 9015-10-82 wiringdiagram 9015-10-84 Wiringdiagram 9015-10-84
Machineinspection
9000-01-3 Installation 9025-25-2
Machinemodifications
JT05800digitalthermometerinstallation...9025-25-1 Avoid ........................... 9000-01-2
MachineMovement
Unintended 9000-01-8
Machinetipover Avoiding 9000-01-10
Keyswitch
Check 9015-20-100
Switchoff,engineoff,checks 9005-10-2
Switchon,engineoff,check 9005-10-3
Switchon,engineon,checks 9005-10-8
Leftconsoleswitch
Maincontroller
Theoryofoperation 9015-15-18
Maincontroller(MCF)
DiagnosticsusingDr.ZX 9015-20-33
Mainrelief
Powerdiggingvalveoperation ....... 9025-05-66
Mainreliefvalve
Testandadjustment 9025-25-32
Make-upvalve Operation 9025-05-73
Malfunctionsheating Removeandinstall 9015-20-117
Legend
Diagnoseheating 9031-15-5
Manifold
Master,systemfunctionalschematic,wiring diagram,andcomponentlocation 9015-10-6Pilotsignal,operation 9025-05-15
Masterlegend
Systemfunctionalschematic,wiringdiagram,and componentlocation ............... 9015-10-6Operatingpressurediagnosticchart
Menuoperation
Airconditioner ..................... 9031-25-7
Monitor .......................... 9015-16-1Operation
Metalpins
9000-01-14
Exhaustgasrecirculation
ModelandserialnumberQuickOnStartSystem
Informationcontroller(ICF) 9015-20-71
9010-05-16
9010-05-18
Operationqualification 9000-01-1
MonitorOperationalcheck
Dataitems 9015-20-1
A/I(autoidle)circuit
GaugesandbatterydisconnectrelayArmregenerativevalve
9005-10-14
9005-10-23
9005-10-22 checks 9005-10-5
Boommodeswitch
Menuoperation .................... 9015-16-1Boomregenerativevalve ...........
Monitorandgaugecircuitchecks ...... 9005-10-9
Boomup,armin,andbucketcombined
Readingdiagnostictroublecodes ..... 9015-20-3,function .......................
9005-10-23
9005-10-22
9005-10-24 9015-20-5
Bucketregenerativevalve
Servicemenuoperation 9015-16-1Controlvalveliftcheckvalve 9005-10-22
Startupcheck
9005-10-4
Cycletimescheck
MonitorcontrollerDiagnostictroublecodes
DiagnosticsusingDr.ZX
9015-20-55
Digfunctiondrift
Removeandinstall 9015-20-111Displayandcleartroublecodes
Theoryofoperation 9015-15-8
Dynamicbraking
9005-10-27
9005-10-1
9005-10-20
9005-10-1
9005-10-17
Theoryofoperation,alarmindicators...9015-15-8E(economy)mode ................ 9005-10-12
Theoryofoperation,hourmeterand gauges ........................ 9015-15-8Enginespeeddial .................
Theoryofoperation,statusindicators...9015-15-8
Engineoillevel/coolantlevelswitch...9005-10-8
9005-10-12
Fuelgauge .......................
Monitorharness(W3)Heaterandairconditionercontrols
Componentlocation
Wiringdiagram
Monitorsecurity
Circuittheoryofoperation
Motor
9015-10-38
9005-10-3
9005-10-29
Heaterandairconditioningcircuit 9005-10-28
9015-10-40Horncircuit
Hourmeter
9015-15-40HP(highpower)mode
Hydraulicoiltankpressurization
9005-10-2
9005-10-3
9005-10-13
9005-10-17
SwingcrossoverreliefvalvetestandKeyswitchoff,engineoff ............
adjustment ..................... 9025-25-52
9005-10-2
Keyswitchon,engineoff ............ 9005-10-3
Swing,lineidentification ............ 9025-15-70Keyswitchon,engineon ............
Swing,operation .................. 9025-05-99
9005-10-8
Lightcircuit ....................... 9005-10-6
Travel,fastspeedoperation 9025-05-107Monitorandgaugecircuit
Travel,slowspeedoperation 9025-05-107
Monitorstartup
MovingpartsMonitor,gauges,andbatterydisconnect relay
Safety 9000-01-3
Servicing 9000-01-3Pilotshutoffcircuit
Multi-functionpilotcontrolleverharness(W14)
9005-10-9
9005-10-4
9005-10-5
9005-10-10
Reversingcoolingfanswitch 9005-10-11
Componentlocation ............... 9015-10-76Swingparkbrakeandcircuitdrift ..... 9005-10-18
Wiringdiagram ................... 9015-10-78
Swingpower ..................... 9005-10-19
Swingprioritycircuit ...............
9005-10-21
Travelalarm .....................
9005-10-15
Travelalarmcancelswitchcircuit 9005-10-16
Travelleverandpedalneutralchecks...9005-10-6
Travelspeedselection 9005-10-24
NohydraulicfunctionTravelsystemmaneuverability 9005-10-26
Travelsystemtracking 9005-10-25 Diagnostics 9025-15-1
NohydraulicfunctionsTravelsystemtrackingwhileoperatingadig function 9005-10-25 Diagnosemalfunctions 9025-15-1
Windshieldwashercircuit
Windshieldwipercontrols ............
9005-10-7
9005-10-7 pattern
Schematic,hydraulic—backhoecontrol
9025-15-94
Schematic,hydraulic—excavatorcontrol
Operator’sseat pattern ........................ 9025-15-94
Startingmachine 9000-01-7
Parkbrake
Swingmotor,releaseoperation ...... 9025-05-103
Passwordchange
Dr.ZX..........................
Patternconversion
Control
9015-20-60
9025-15-71
Personaldigitalassistant(PDA)connectionto
Portablefiltercaddy
Hydraulicoilcleanupprocedure 9025-25-3
Powerdigsolenoidvalve
Testandadjustment 9025-25-14
Powerdigging
Mainreliefvalveoperation 9025-05-66
Powerdiggingvalve
Testandadjustment 9025-25-32
Powermode
Modepower ..................... 9010-05-19
Powermodeswitch
Removeandinstall 9015-20-115
Preheatcircuit,engine
Theoryofoperation ................. 9015-15-6 excavatorusingdr.zx 9015-20-27
Preventunintendeddetonationofexplosive Pilot devices 9000-01-11
Systemdiagramandoperation 9025-05-4
Pilotcircuit
Diagnosemalfunctions ............. 9025-15-11
Propelmotor
Leakagetest ..................... 9025-25-64
Pilotcontrol Pump Operation 9025-05-10
Pilotcontrolvalve
Schematic,hydraulic—backhoecontrol
Protectiveequipment 9000-01-2
Fandriveregulatoroperation ........ 9025-05-38
Fandrive,flowtest 9025-25-82
Fandrive,operation 9025-05-30 pattern
9025-15-94
Fandrive,torquecontroltestand
Schematic,hydraulic—excavatorcontrol adjustment ..................... 9025-25-80 pattern 9025-15-94
Flowrate(displacement)testand
Traveloperation .................. 9025-05-12 adjustment
Pilotfilter
Operation
Pilotpressureregulatingvalve
9025-05-6
9025-25-51,9025-25-79
Flowtest ........................ 9025-25-69
Lineidentification 9025-15-65
Servopistonmaximumflowtestand Operation 9025-05-6 adjustment 9025-25-48
Testandadjustment ................ 9025-25-7
Servopistonminimumflowtestand
Pilotshutoff adjustment ..................... 9025-25-46
Circuittheoryofoperation 9015-15-40
Pilotshutoffcircuit
Operationalcheck ................. 9005-10-10
1and2,operation 9025-05-30
Pumpandregulator
Schematic,hydraulic 9025-15-94
PilotShutoffLever ................... 9000-01-8 Pumpcontrol
Pilotshutoffsolenoidvalve
Theoryofoperation ................ 9015-15-18
Pumpflowratepilotvalve Operation 9025-05-7
Pilotshutoffswitchharness
Check ......................... 9015-20-105
Operation ....................... 9025-05-15
Pumpharness(W8)
Pilotshutoffswitchharness(W11) Wiringdiagram ................... 9015-10-60
Componentlocation 9015-10-67
Componentlocation 9015-10-58
Pump1and2 Wiringdiagram 9015-10-68
Pilotshutoffvalveharness(W17)
Componentlocation 9015-10-81
Regulatoroperation ................ 9025-05-34
Wiringdiagram 9015-10-81 Q
Pilotsignalmanifold
Operation
9025-05-15
Portidentification 9025-05-15
QuickOnStartSystem Operation 9010-05-18
Quickontime(QOS)circuitInformation
Theoryofoperation 9015-15-6
Readingdiagnostictroublecodes
ServiceADVISOR ................. 9015-20-12
Tech2diagnosticscantool ......... 9015-20-22
UsingDr.ZX ..................... 9015-20-30
Rearcover
Removeandinstall 9015-20-108
Seatbelt
9015-05-1
Useandmaintenance ............... 9000-01-7
Seatheaterswitchharness(W13)
Componentlocation ............... 9015-10-72
Wiringdiagram 9015-10-74
Serpentinebelt
Tensionercheck
ServiceADVISOR
9010-25-1
Connectionprocedure 9015-20-11
Overview
9015-20-10
Readingdiagnostictroublecodes 9015-20-12
Servicemenuoperation
Recordeddata Monitor .......................... 9015-16-1
Informationcontroller(ICF) 9015-20-87
Refrigerantcautionsandproperhandling
Airconditioning 9031-25-1
Servicingmachinesafely ............. 9000-01-12
Servopiston
FanDrivePumpminimumflowtestand
RegistrationinjectorIDcode adjustment 9025-25-77,9025-25-78
Tech2 ......................... 9010-25-27
Pumpmaximumflowtestand
Regulator adjustment
Fandrivepump,operation .......... 9025-05-38
Pumpminimumflowtestand
Pump1and2,operation 9025-05-34 adjustment
Relay
Battery,check 9015-20-101
Specifications 9015-10-2
Test 9015-20-94
Relief
Mainandpowerdiggingoperation
Returnfilter
Operation ......................
Reversingcoolingfanswitch
Operationalcheck
Reversingfanswitch
9025-05-66
9025-05-111
9005-10-11
Removeandinstall 9015-20-117
Reversingfanswitchharness(W16)
Componentlocation
9025-25-48
9025-25-46
Shuttlevalve
Operation ....................... 9025-05-15
Solenoidvalve
Boomflowrate,testandadjustment...9025-25-28
Boommode,testandadjustment 9025-25-24
Powerdig,testandadjustment 9025-25-14
Travelspeed,testandadjustment
Speedcontrolsystem
Engine
Spool
9015-10-80
Wiringdiagram 9015-10-80
Ridingmachine 9000-01-9
R134aairconditioning
Systemtest ....................... 9031-25-4
9025-25-19
9010-05-19
Valve,actuatingpilotpressuretest .... 9025-25-11
Starterprotectionrelay
Check ......................... 9015-20-102
Startingcircuit
Theoryofoperation
9015-15-3
Startingmachine 9000-01-7
Stepsuse
Swing
Dynamicbrakingcheck
Parkbrakeandcircuitdriftcheck
9000-01-7
9005-10-17
9005-10-18
9005-10-19 S
Safetyequipment .................... 9000-01-2
Powercheck .....................
Prioritycircuitcheck ...............
9005-10-21
Swingbearing
SafetyinformationMeasurewear ..................... 9020-15-6
Recognizing
9000-01-1Swingcircuit
Safetyinstructions 9000-01-1Diagnosemalfunctions 9025-15-31 Indx 9 Safetysymbols 9000-01-1Swinggearbox
SchematicOperation 9025-05-98
Swingmotor
Electrical,JDLink system functional 9015-10-20Crossoverreliefvalvetestand adjustment 9025-25-52
Electrical,systemfunctional 9015-10-12
Lineidentification
9025-15-70Relay 9015-20-94
Operation 9025-05-99
Theoryofoperation
Parkbrakereleaseoperation ....... 9025-05-103Chargingcircuit ....................
Schematic,hydraulic ............... 9025-15-94
9015-15-3
Controlareanetwork(CAN) .......... 9015-15-1
SwingparkbrakereleasepilotvalveEnginecontrol .................... 9015-15-18
Operation 9025-05-15
Enginecontrolmodule 9015-15-14
SwitchEnginecontrolmodule,enginestop...9015-15-14
Airfilterrestrictionindicatortest 9010-25-8
Enginecontrolmodule,exhaustgasrecirculation
Switchpanel(EGR) 9015-15-14
Removeandinstall 9015-20-115
Enginecontrolmodule,fuelinjection...9015-15-14
SystemEnginecontrolmodule,preheat 9015-15-14
Pilot,diagramandoperation 9025-05-4
Enginepreheatcircuit 9015-15-6
SystemcycleofoperationInformationcontroller(ICF)circuit ..... 9015-15-33
Airconditioning .................... 9031-05-1
Loaddumpcircuit .................. 9015-15-3
Systemfunctionalschematic .......... 9015-10-12Maincontroller ................... 9015-15-18
Information 9015-05-1
MiscMCFsystemcontrols 9015-15-18
Masterlegend 9015-10-6Monitorcontrollercircuit 9015-15-8
Systemreliefvalve
Monitorcontroller,alarmindicators 9015-15-8
Fandrive,testandadjustment 9025-25-74Monitorcontroller,hourmeterand gauges 9015-15-8
Monitorcontroller,statusindicators 9015-15-8
Monitorsecuitycircuit 9015-15-40 T Pilotshutoffcircuit ................. 9015-15-40
Pumpcontrol..................... 9015-15-18
Tech2
Startingcircuit ..................... 9015-15-3
EGRregulatingvalvetest ........... 9010-25-24Travelalarmcircuit ................ 9015-15-35
Injectorbalancetest(injectormisfire test)
Injectorforcedrivetest
Valvecontrol 9015-15-18
9010-25-19Windshieldwiperandwashercircuit...9015-15-37
9010-25-22
Thermometerinstallation,digital 9025-25-1
InjectorIDcodedownload 9010-25-40Tipover Avoiding 9000-01-10
InjectorIDcodeplate 9010-25-30
InjectorIDcoderegistration 9010-25-27Track
InjectorIDcodeupload ............. 9010-25-36
Adjusterandrecoilspringoperation .... 9020-05-1
InjectorIDcodeuploadcompleted...9010-25-39,Trackadjusterandrecoilspring Operation ........................ 9020-05-1 9010-25-44
Programmingfailed ................ 9010-25-44Travel
Qadjustinjectorcodelabel 9010-25-30
Alarmcancelswitchcircuitcheck 9005-10-16
Railpressurecontroltest 9010-25-16Alarmcheck 9005-10-15
Uploadfailed 9010-25-39
Leverandpedalneutralchecks 9005-10-6
Tech2diagnosticscantoolMotor,operation 9025-05-105
Connectionprocedure 9015-20-15
Speedselectioncheck 9005-10-24
Diagnosticapplication,Datadisplay...9015-20-24Systemmaneuverabilitycheck 9005-10-26
Readingdiagnostictroublecodes ..... 9015-20-22
Systemtrackingcheck ............. 9005-10-25
TestSystemtrackingcheckswhileoperatingadig function ....................... 9005-10-25
Airfilterrestrictionindicatorswitch ..... 9010-25-8
Airintakesystemleakage ............ 9010-25-9Travelalarm Check 9015-20-104
EGRregulatingvalve 9010-25-24
Enginecompressionpressure 9010-25-7Removeandinstall 9015-20-116
Engineoilpressure 9010-25-15
Travelalarmcancelswitch
EnginepowerusingturbochargerboostRemoveandinstall 9015-20-117
Injectorforcedrive 9010-25-22
pressure 9010-25-11Travelalarmcancelswitchharness(W15) Componentlocation 9015-10-79
Railpressurecontrol 9010-25-16Wiringdiagram 9015-10-79
Travelalarmcircuit
Theoryofoperation
Travelcircuit
Diagnosemalfunctions .............
Travelflowcombinerpilotvalve
Operation
9015-15-35
9025-15-37
9025-05-15
Bucketregenerative,operation 9025-05-81
Circuitreliefoperation .............. 9025-05-72
Circuitrelieftestandadjustment
Control,lineidentification
Control,operation
Fandrivesystemrelieftestand
Travelflowcombinervalve adjustment
Operation
9025-05-74
Mainreliefandpowerdigging,testand
Travelgearbox adjustment
Operation 9020-05-2
Travelhighpowermode
Modetravelhighpower
9025-25-37
9025-15-66
9025-05-48
9025-25-74
9025-25-32
Make-up,operation ................ 9025-05-73
Pilotcontrolvalve-to-pilotsignalmanifold
9010-05-19 componentlocation—backhoe
TravelHydraulicSystem pattern
Componentlocation ............... 9025-15-82
9025-15-78
Pilotcontrolvalve-to-pilotsignalmanifold
Lineconnection ................... 9025-15-84 componentlocation—excavator
Travelmotor pattern
Fastspeedoperation
9025-05-107
Operation 9025-05-105
Schematic,hydraulic 9025-15-94
9025-15-76
Pilotoperationofcontrol 9025-05-26
Pilotpressureregulating,operation 9025-05-6
Pilotpressureregulating,testand
Slowspeedoperation 9025-05-107 adjustment ......................
Travelpilotcontrolvalve
Operation 9025-05-12
9025-25-7
Pilotshutoffsolenoid,operation 9025-05-7
Pilotsignalmanifold-to-controlvalveline
Travelspeedsolenoidvalve connection 9025-15-80
Testandadjustment ............... 9025-25-19
Powerdigsolenoidtestand
Travelspeedswitch adjustment
Removeandinstall ............... 9015-20-115
Swingmotorcrossoverrelief,testand
Turbochargeroperation adjustment
Engine 9010-05-13
Undercarriage
9025-25-14
9025-25-52
Travelflowcombiner,operation ...... 9025-05-74
Travelspeedsolenoidtestand adjustment
Valvecontrol U
Diagnosecomponentsmalfunctions
9020-15-1
9025-25-19
Theoryofoperation 9015-15-18
Valvespool
Actuatingpilotpressuretest
Voltage
UploadinjectorIDcode Battery,check
9025-25-11
9015-20-101 Tech2
Valve
9010-25-36
Anticavitationoperation ............. 9025-05-72
Armreducedleakage,operation ...... 9025-05-83
Warm-upcircuit
Operation ....................... 9025-05-15
Warmupprocedure Armregenerative,operation ......... 9025-05-79
Boomflowratesolenoidtestand
Hydraulicoil
9025-25-4
9025-25-28
Wastedisposal
9000-01-6 adjustment
Welding Boommoderelieftestand Indx 11 Removepaint
9000-01-13 adjustment
Boommodesolenoidtestand
9025-25-42
Weldingrepairs 9000-01-13
Windshield adjustment
9025-25-24
Boomreducedleakage,operation 9025-05-83
Washercircuitcheck 9005-10-7
Boomregenerative,operation 9025-05-77Wipercontrolscheck
9005-10-7
Windshieldwasherswitch
Removeandinstall 9015-20-115
Windshieldwiperandwashercircuit
Theoryofoperation ................ 9015-15-37
Windshieldwiperswitch
Removeandinstall 9015-20-115
Wiremarkings 9015-10-1
Wiringdiagram
Airconditionerharness(W6) 9015-10-52
Auxiliaryfuseboxharness(W9) 9015-10-64
Cabharness(W1) 9015-10-24
Cabswitchharness(W10) 9015-10-66
Controlvalveharness(W7) .......... 9015-10-56
Engineharness(W4) .............. 9015-10-44
Engineinterfaceharness(W5) ....... 9015-10-48
GlobalTRACS terminal(GTT)harness (W51) 9015-10-86
Heatedairseatharness(W12) 9015-10-71
Information 9015-05-1
JDLink CANharness(W52) 9015-10-88
JDLink jumperharness(W54) 9015-10-92
JDLink powerharness(W53) 9015-10-90
Machineharness(W2) ............. 9015-10-32
Machineinformationgateway(MIG)harness (W50) ........................ 9015-10-84
Masterlegend ..................... 9015-10-6
Monitorharness(W3) 9015-10-40
Multi-functionpilotcontrolleverharness (W14) 9015-10-78
Pilotshutoffswitchharness(W11) 9015-10-68
Pilotshutoffvalveharness(W17) 9015-10-81
Pumpharness(W8) 9015-10-60
Reversingfanswitchharness(W16)...9015-10-80
Seatheaterswitchharness(W13) .... 9015-10-74
Travelalarmcancelswitchharness (W15) ........................ 9015-10-79
Worklightswitch
Removeandinstall 9015-20-115
Worksitehazards
Avoid 9000-01-9