JOHN DEERE 85G Excavator Operation & Test Technical Manual (TM12867)

The John Deere 85G Excavator (PIN 1FF085GX__J017001-) Operation & Test Technical Manual (TM12867) is a detailed guide designed for diagnostics, testing, and troubleshooting of the John Deere 85G excavator. It covers essential information about hydraulic, electrical, and powertrain systems, offering step-by-step procedures and test specifications. This manual is a vital resource for service technicians, ensuring accurate diagnostics and efficient repair to maintain the excavator’s optimal performance and reliability.

DOWNLOAD NOW JOHN DEERE 85G Excavator (PIN 1FF085GX_ _J017001-) OPERATION & TEST TECHNICAL MANUAL (TM12867)

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📑 Table of Contents:

- OPERATION & TEST TECHNICAL MANUAL
- General Information
- Safety
- Recognize Safety Information
- Follow Safety Instructions
- Operate Only If Qualified
- Wear Protective Equipment
- Avoid Unauthorized Machine Modifications
- Control Pattern Selector—If Equipped
- Add Cab Guarding for Special Uses
- Inspect Machine
- Stay Clear of Moving Parts
- Avoid High-Pressure Fluids
- Avoid High-Pressure Oils
- Work In Ventilated Area
- Prevent Fires
- Prevent Battery Explosions
- Handle Chemical Products Safely
- Decommissioning — Proper Recycling and Disposal of Fluids and Components
- Exhaust Filter Ash Handling and Disposal
- Prepare for Emergencies
- Clean Debris from Machine
- 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
- Inspect and Maintain ROPS
- Avoid Machine Tip Over
- Use Special Care When Lifting Objects
- 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
- Diagnostics
- Main Controller (MCZ) Diagnostic Trouble Codes
- Main Controller (MCZ) Diagnostic Trouble Codes
- Controller Area Network 0 (CAN 0) Circuit Diagnostics
- Controller Area Network (CAN 0) Diagnostic Procedure
- Controller Area Network 1 (CAN 1) Circuit Diagnostics
- Controller Area Network (CAN 1) Diagnostic Procedure
- Interface Controller Area Network (N-CAN) Diagnostics
- Interface Controller Area Network (N-CAN) Diagnostic Procedure
- 011000.02 — Abnormal EEPROM
- Abnormal EEPROM Diagnostic Procedure
- 011001.02 — Abnormal RAM
- Abnormal RAM Diagnostic Procedure
- 011002.02 — Abnormal A/D Converter
- Abnormal A/D Converter Diagnostic Procedure
- 011003.03 — Abnormal Sensor Voltage
- Abnormal Sensor Voltage Diagnostic Procedure
- 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
- Abnormal Engine Speed Diagnostic Procedure
- 011101.03 — Engine Control Dial Sensor Circuit High Input
- Engine Control Dial Sensor Circuit High Input Diagnostic Procedure
- 011101.04 — Engine Control Dial Sensor Circuit Low Input
- Engine Control Dial Sensor Circuit Low Input Diagnostic Procedure
- 011304.03 — Travel Pilot Pressure Sensor Circuit High Input
- Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure
- 011304.04 — Travel Pilot Pressure Sensor Circuit Low Input
- Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure
- 011307.03 — Front Pilot Pressure Sensor Circuit High Input
- Front Pilot Pressure Sensor Circuit High Input Diagnostic Procedure
- 011307.04 — Front Pilot Pressure Sensor Circuit Low Input
- Front Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure
- 011401.02 — Torque Pressure Solenoid Valve Abnormal Feedback
- Torque Pressure Solenoid Valve Abnormal Feedback Diagnostic Procedure
- 011401.03 — Torque Pressure Solenoid Valve Feedback High Current
- Torque Pressure Solenoid Valve Feedback High Current Diagnostic Procedure
- 011401.04 — Torque Pressure Solenoid Valve Feedback Low Current
- Torque Pressure Solenoid Valve Feedback Low Current Diagnostic Procedure
- 011407.02 — Travel Mode Selector Solenoid Valve Abnormal Feedback
- Travel Mode Selector Solenoid Valve Abnormal Feedback Diagnostic Procedure
- 011407.03 — Travel Mode Selector Solenoid Valve Feedback High Current
- Travel Mode Selector Solenoid Valve Feedback High Input Diagnostic Procedure
- 011407.04 — Travel Mode Selector Solenoid Valve Feedback Low Current
- Travel Mode Selector Solenoid Valve Feedback Low Input Diagnostic Procedure
- 011408.02 — 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback
- 011408.03 — 2-Spool Solenoid Valve Unit (SJ) Feedback High Input
- 011408.04 — 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input
- 011409.02 — 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback
- 011409.03 — 2-Spool Solenoid Valve Unit (SZ) Feedback High Input
- 011409.04 — 2-Spool Solenoid Valve Unit (SZ) 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
- 011458.02 — (Auxiliary) Discontinuity of Selector Valve
- 011459.02 — Discontinuity of Auto Shut-Down Control Power Line
- 011810.03 — Electric Lever Operating Pressure Sensor 1 High Voltage
- 011810.04 — Electric Lever Operating Pressure Sensor 1 Low Voltage
- 011811.03 — Electric Lever Operating Pressure Sensor 2 High Voltage
- 011811.04 — Electric Lever Operating Pressure Sensor 2 Low Voltage
- 011812.02 — OPT Electric Lever 1 Neutral Abnormal
- 011813.02 — OPT Electric Lever 1 Abnormal Operation
- 011814.02 — OPT Electric Lever 2 Neutral Abnormal
- 011815.02 — OPT Electric Lever 2 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
- 011818.02 — OPT Solenoid 3 Feedback Abnormal
- 011818.03 — OPT Solenoid 3 Feedback Current High
- 011818.04 — OPT Solenoid 3 Feedback Current Low
- 011819.02 — OPT Solenoid 4 Feedback Abnormal
- 011819.03 — OPT Solenoid 4 Feedback Current High
- 011819.04 — OPT Solenoid 4 Feedback Current 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
- 015017.03 — Left Analog Stroke Sensor Circuit High Input
- 015017.04 — Left Analog Stroke Sensor Circuit Low Input
- 020010.02 — Exhaust Filter Alarm
- 020011.02 — Electric Lever Alarm
- 020012.02 — Line Filter Restriction Alarm
- 020303.02 — Electric Lever Pilot Cut Alarm
- Engine Control Unit (ECU) Diagnostic Trouble Codes
- Engine Control Unit (ECU) Diagnostic Trouble Codes
- 000051.03 — Intake Throttle Opening Sensor Fault (High Voltage) (P02E9) (00033-03)
- 000051.04 — Intake Throttle Opening Sensor Fault (Low Voltage) (P02E8) (00033-04)
- 000091.03 — Acceleration Sensor 1 Fault (High Voltage) (P0123) (0005B-03)
- 000091.04 — Acceleration Sensor 1 Fault (Low Voltage) (P0122) (0005B-04)
- 000100.01 — Low Oil Pressure Fault Alarm (P1198) (00064-01)
- 000100.04 — Oil Pressure Switch Open Circuit (P1192) (00064-04)
- 000102.03 — Exhaust Gas Recirculation (EGR) Low Pressure Side Sensor Fault (High Voltage) (P0238) (00066-03)
- 000102.04 — Exhaust Gas Recirculation (EGR) Low Pressure Side Sensor Fault (Low Voltage) (P0237) (00066-04)
- 000105.03 — Intake Air Temperature Sensor Fault (High Voltage) (P040D) (00069-03)
- 000105.04 — Intake Air Temperature Sensor Fault (Low Voltage) (P040C) (00069-04)
- 000108.03 — Atmospheric Pressure Sensor Fault (High Voltage) (P2229) (0006C-03)
- 000108.04 — Atmospheric Pressure Sensor Fault (Low Voltage) (P2228) (0006C-04)
- 000108.10 — Atmospheric Pressure Sensor Characteristic Fault (P1231) (0006C-0A)
- 000110.00 — Cooling Water Temperature Sensor Temperature Abnormal High (Overheat) (P0217) (0006E-00)
- 000110.03 — Cooling Water Temperature Sensor Fault (High Voltage) (P0118) (0006E-03)
- 000110.04 — Cooling Water Temperature Sensor Fault (Low Voltage) (P0117) (0006E-04)
- 000157.00 — Actual Rail Pressure Rise Error (P0088) (0009D-00)
- 000157.03 — Rail Pressure Sensor Fault (High Voltage) (P0193) (0009D-03)
- 000157.04 — Rail Pressure Sensor Fault (Low Voltage) (P0192) (0009D-04)
- 000157.15 — Rail Pressure Deviation Error During the Actual Rail Pressure Rise (P0093) (0009D-0F)
- 000157.16 — Pressure Limit Valve (PLV) Open Valve (P000F) (0009D-10)
- 000157.18 — Rail Pressure Deviation Error During the Actual Rail Pressure Drop (P0094) (0009D-12)
- 000167.01 — Charge Alarm (P1568) (000A7-01)
- 000167.05 — Charge Switch Open Circuit (P1562) (000A7-05)
- 000172.03 — New Air Temperature Sensor Fault (High Voltage) (P0113) (000AC-03)
- 000172.04 — New Air Temperature Sensor Fault (Low Voltage) (P0112) (000AC-04)
- 000173.03 — Exhaust Air Temperature Sensor Fault (High Voltage) (P0546) (000AD-03)
- 000173.04 — Exhaust Air Temperature Sensor Fault (Low Voltage) (P0545) (000AD-04)
- 000174.00 — Fuel Temperature Sensor Temperature Abnormal High (P0168) (000AE-00)
- 000174.03 — Fuel Temperature Sensor Fault (High Voltage) (P0183) (000AE-03)
- 000174.04 — Fuel Temperature Sensor Fault (Low Voltage) (P0182) (000AE-04)
- 000190.00 — Overspeed (P0219) (000BE-00)
- 000412.03 — Exhaust Gas Recirculation (EGR) Gas Temperature Sensor Fault (High Voltage) (P041D) (0019C-03)
- 000412.04 — Exhaust Gas Recirculation (EGR) Gas Temperature Sensor Fault (Low Voltage) (P041C) (0019C-04)
- 000630.12 — EEPROM Memory Deletion Error (P0601) (00276-0C)
- 000633.05 — High Pressure Pump Drive Circuit (Open Circuit) (P0627) (00279-05)
- 000633.06 — High Pressure Pump Drive Circuit (High Side Ground Short Circuit) (P1642) (00279-06)
- 000651.03 — Injector 1 Short Circuit (4TNV) (P1271) (0028B-03)
- 000651.05 — Injector 1 Open Circuit (Inherent Location of the Injector) (4TNV) (P0204) (0028B-05)
- 000651.06 — Injector 1 Coil Short Circuit (4TNV) (P0271) (0028B-06)
- 000651.11 — Injector 1 Unclassified (4TNV) (P1272) (0028B-0B)
- 000652.03 — Injector 4 Short Circuit (P1268) (0028C-03)
- 000652.05 — Injector 4 Open Circuit (Inherent Location of the Injector) (P0203) (0028C-05)
- 000652.06 — Injector 4 Coil Short Circuit (P0268) (0028C-06)
- 000652.11 — Injector 4 Unclassified (P1269) (0028C-0B)
- 000653.03 — Injector 2 Short Circuit (P1265) (0028D-03)
- 000653.05 — Injector 2 Open Circuit (Inherent Location of the Injector) (P0202) (0028D-05)
- 000653.06 — Injector 2 Coil Short Circuit (P0265) (0028D-06)
- 000653.11 — Injector 2 Unclassified (P1266) (0028D-0B)
- 000654.03 — Injector 3 Short Circuit (P1262) (0028E-03)
- 000654.05 — Injector 3 Open Circuit (Inherent Location of the Injector) (P0201) (0028E-05)
- 000654.06 — Injector 3 Coil Short Circuit (P0262) (0028E-06)
- 000654.11 — Injector 3 Unclassified (P1263) (0028E-0B)
- 001209.03 — Exhaust Gas Recirculation (EGR) High Pressure Side Sensor Fault (High Voltage) (P0473) (004B9-03)
- 001209.04 — Exhaust Gas Recirculation (EGR) High Pressure Side Sensor Fault (Low Voltage) (P0472) (004B9-04)
- 001485.02 — Power Off Without Main Relay Self Holding (P068A) (005CD-02)
- 001485.07 — Main Relay Contact Stuck (P068B) (005CD-07)
- 002791.00 — Exhaust Gas Recirculation (EGR) High Voltage Malfunction (P0404) (00AE7-00)
- 002791.01 — Exhaust Gas Recirculation (EGR) Low Voltage Malfunction (P0404) (00AE7-01)
- 002791.01 — Exhaust Gas Recirculation (EGR) Low Voltage Malfunction (P1404) (00AE7-01)
- 002791.07 — Exhaust Gas Recirculation (EGR) Feedback Malfunction (P1409) (00AE7-07)
- 002791.09 — EGRECM Data Fault (U0401) (00AE7-09)
- 002791.12 — Open Circuit Between The Exhaust Gas Recirculation (EGR) Motor Coils (P0403) (00AE7-0C)
- 002797.06 — Injector Drive Circuit (Bank1) Short Circuit (P1146) (00AED-06)
- 002798.06 — Injector Drive Circuit (Bank 2) Short Circuit (4TN: Circuit For No. 2 And No. 3 Cylinders) (P1149) (00AEE-06)
- 002950.03 — Power Short Circuit of Throttle Valve Drive H Bridge Output 1 (P1658) (00B86-03)
- 002950.04 — Ground Short Circuit of Throttle Valve Drive H Bridge Output 1 (P1659) (00B86-04)
- 002950.05 — No Load of Throttle Valve Drive H Bridge Circuit (P0660) (00B86-05)
- 002951.03 — Power Short Circuit of Throttle Valve Drive H Bridge Output 2 (P1661) (00B87-03)
- 002951.04 — Ground Short Circuit of Throttle Valve Drive H Bridge Output 2 (P1662) (00B87-04)
- 003242.00 — DPF Inlet Temperature Sensor Temperature Abnormal High (P1436) (00CAA-00)
- 003242.03 — DPF Inlet Temperature Sensor Fault (High Voltage) (P1428) (00CAA-03)
- 003242.04 — DPF Inlet Temperature Sensor Fault (Low Voltage) (P1427) (00CAA-04)
- 003250.00 — DPF Intermediate Temperature Sensor Temperature Abnormal High (Post-Injection Error) (P1426) (00CB2-00)
- 003250.01 — DPF Intermediate Temperature Sensor Temperature Abnormal Low Temperature (P0420) (00CB2-01)
- 003250.03 — DPF Intermediate Temperature Sensor Fault (High Voltage) (P1434) (00CB2-03)
- 003250.04 — DPF Intermediate Temperature Sensor Fault (Low Voltage) (P1435) (00CB2-04)
- 003251.00 — DPF Differential Pressure Sensor Differential Pressure Abnormal High (P2452) (00CB3-00)
- 003251.03 — DPF Differential Pressure Sensor Fault (High Voltage) (P2455) (00CB3-03)
- 003251.04 — DPF Differential Pressure Sensor Fault (Low Voltage) (P2454) (00CB3-04)
- 003251.16 — Maintenance (Maintenance Not Performed For A Given Period of Time) (P1437) (00CB3-10)
- 003609.03 — DPF High Pressure Side Sensor Fault (High Voltage) (P1455) (00E19-03)
- 003609.04 — DPF High Pressure Side Sensor Fault (Low Voltage) (P1454) (00E19-04)
- 003719.00 — Backup Mode (P1424) (00E87-00)
- 003719.16 — Stationary Regeneration Standby (P1421) (00E87-10)
- 003720.00 — Ash Cleaning Request 2 (P1420) (00E88-00)
- 003720.16 — Ash Cleaning Request 1 (P242F) (00E88-10)
- 004257.12 — Injector Drive IC Error (P0611) (010A1-0C)
- 522243.05 — Start Assist Relay Interrupted (P0543) (7F803-05)
- 522243.06 — Startup Assist Relay Ground Interrupted (P0541) (7F803-06)
- 522323.00 — Air Cleaner Clogged Alarm (P1101) (7F853-00)
- 522329.00 — Oil/Water Separator Alarm (P1151) (7F859-00)
- 522400.02 — Crank Speed Sensor (P0336) (7F8A0-02)
- 522400.05 — No Crank Signal (P0337) (7F8A0-05)
- 522401.02 — Cam Signal Malfunction (P0341) (7F8A1-02)
- 522401.05 — No Cam Signal (P0342) (7F8A1-05)
- 522401.07 — Angle Offset Error (P1341) (7F8A1-07)
- 522571.03 — SCV (MPROP) High Pressure Pump Drive Circuit (Low Side VB Short Circuit) (P1641) (7F94B-03)
- 522571.06 — SCV (MPROP) High Pressure Pump Drive Circuit (Low Side Ground Short Circuit) (P1643) (7F94B-06)
- 522573.00 — Overaccumulation (Method C) (P2463) (7F94D-00)
- 522574.00 — Overaccumulation (Method P) (P1463) (7F94E-00)
- 522575.07 — Regeneration Defect (Stationary Regeneration Error) (P2458) (7F94F-07)
- 522577.11 — Regeneration Defect (Stationary Regeneration Not Performed) (P2459) (7F951-0B)
- 522596.09 — TSC1 Reception Time Out Error (SA1) (U0292) (7F964-09)
- 522597.09 — TSC1 Reception Time Out Error (U1301) (7F965-09)
- 522599.09 — Y_ECR1 Reception Time Out Error (U1292) (7F967-09)
- 522600.09 — Y_EC Reception Time Out Error (U1293) (7F968-09)
- 522609.09 — Y_ETCP1 Reception Time Out Error (U1300) (7F971-09)
- 522610.09 — CAN1 (For EGR) Reception Time Out Error (U010B) (7F972-09)
- 522610.19 — CAN1 (For EGR) Reception Data Length Error (U040C) (7F972-13)
- 522619.09 — Y_DPFIF Reception Time Out (U1303) (7F97B-09)
- 522994.03 — Actuator Drive Circuit 1 VB Short Circuit (P160A) (7FAF2-03)
- 522994.04 — Actuator Drive Circuit 1 Ground Short Circuit (P1626) (7FAF2-04)
- 522994.11 — SW Reset (Recovery) Execution 1 (P160B) (7FAF2-0B)
- 522994.12 — WDA/ABE Communication Error (P1607) (7FAF2-0C)
- 523249.05 — No Signal on Both Crank and Cam Speed Sensor (P0008) (7FBF1-05)
- 523489.00 — Rail Pressure Error (The Actual Rail Pressure is Too High During PRV Limp Home) (P1668) (7FCE1-00)
- Monitor Controller (DSZ) Diagnostic Trouble Codes
- Monitor Controller (DSZ) Diagnostic Trouble Codes
- 013000.02 — Flash Memory Error 1
- 013001.02 — Flash Memory Error 2
- 013002.02 — ECU 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
- 013303.02 — Abnormal Monitor Internal Temperature Sensor
- Monitor Internal Temperature Sensor Diagnostic Procedure
- 013304.02 — Alternator Alarm
- Alternator Alarm Diagnostic Procedure
- 013310.03 — Shorted Circuit in Coolant Temperature Sensor
- 013311.03 — Fuel Level Sensor Open Circuit
- Fuel Level Sensor Open Circuit Diagnostic Procedure
- 013311.04 — Fuel Level Sensor Shorted Circuit
- Fuel Level Sensor Shorted Circuit Diagnostic Procedure
- 014001.02 — Flash Memory Read/Write Error
- Flash Memory Read/Write Error Diagnostic Procedure
- 014002.02 — External RAM Read/Write Error
- External RAM Read/Write Error Diagnostic Procedure
- 014003.02 — Abnormal EEPROM
- Abnormal EEPROM Diagnostics Procedure
- 014006.02 — Communication Terminal:Communication Error
- 014008.02 — Abnormal Internal RAM
- Abnormal Internal RAM Diagnostic Procedure
- 014021.02 — Communication Terminal Security Error
- 014022.02 — SIM Card Error
- 014023.02 — Security Error
- 020100.02 — Overheat Alarm
- 020101.02 — Engine Warning Alarm
- Engine Warming Alarm Diagnostic Procedure
- 020102.02 — Engine Oil Pressure Alarm
- 020105.02 — Hydraulic Oil Filter Restriction Alarm
- Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure
- 020106.02 — Air Cleaner Restriction Alarm
- Air Cleaner Restriction Alarm Diagnostic Procedure
- 020107.02 — Water Separator Alarm
- Water Separator Alarm Diagnostic Procedure
- 020109.02 — Pilot Control Shut-Off Lever Alarm
- Pilot Control Shut-Off Lever Alarm Diagnostic Procedure
- 020110.02 — Fuel Filter Restriction Alarm
- 020113.02 — System Error Alarm
- 020114.02 — Overheat Alarm
- 020133.02 — Crane Function Alarm
- 020137.02 — Exhaust Filter Alarm
- 020141.02 — Muffler Temperature Alarm
- 020142.02 — Intake Air Temperature Alarm
- 020145.02 — Boost Temperature Increase Alarm
- 020146.02 — Fuel Temperature Increase Alarm
- 020149.02 — EGR Gas Temperature Alarm
- Air Conditioner Controller (ACF) Diagnostic Trouble Codes
- Air Conditioner Controller (ACF) Diagnostic Trouble Codes
- 11 — Open Circuit in Air Recirculation Sensor
- Open Circuit in Air Recirculation Sensor Diagnostic Procedure
- 12 — Short-Circuited Air Recirculation Sensor
- Short-Circuited Air Recirculation Sensor Diagnostic Procedure
- 13 — Open Circuit in Ambient Air Temperature Sensor
- Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure
- 14 — Short-Circuited Ambient Air Temperature Sensor
- Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure
- 18 — Short-Circuited Solar Radiation Sensor
- Short-Circuited Solar Radiation Sensor Diagnostic Procedure
- 21 — Open Circuit in Air Conditioner Freeze Control Switch
- Open Circuit in Air Conditioner Freeze Control Switch Diagnostic Procedure
- 22 — Short-Circuited Air Conditioner Freeze Control Switch
- Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure
- 43 — Abnormal Air Conditioner and Heater Blower Port Change Servomotor
- Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure
- 44 — Abnormal Air Conditioner and Heater Mixer Servomotor
- Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure
- 51 — Abnormal High/Low Refrigerant Pressure
- Abnormal High/Low Refrigerant Pressure Diagnostic Procedure
- 91 — Communication Error
- 92 — CAN Bus Off Error
- Operational Checkout Procedure
- Operational Checkout Procedure
- Operational Checkout
- Diagnostic Trouble Code Check
- Operational Checks—Key Switch Off, Engine Off Checks
- Operational Checks—Key Switch On, Engine Off Checks
- Operational Checks—Key Switch On, Engine On Checks
- Engine
- Theory of Operation
- Yanmar Engine
- Engine Fuel System Component Location
- Engine Cooling System Component Location
- Cold Weather Starting Aid
- Engine Speed Control System Operation
- Diagnostic Information
- Yanmar Engine
- Adjustments
- Yanmar Engine
- Tests
- Yanmar Engine
- Electrical System
- System Information
- Electrical Diagram Information
- 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
- Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location
- Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram
- Pilot Shutoff Switch Harness (W11) Component Location
- Pilot Shutoff Switch Harness (W11) Wiring Diagram
- Auxiliary Fuse Box Harness (W13) Component Location
- Auxiliary Fuse Box Harness (W13) 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
- Rear Camera Harness (W19) Component Location
- Rear Camera Harness (W19) Wiring Diagram
- Service ADVISOR™ Harness (W20) Component Location
- Service ADVISOR™ Harness (W20) 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
- 12-Volt Power Converter Harness (W23) Component Location
- 12-Volt Power Converter Harness (W23) Wiring Diagram
- Travel Alarm Cancel Switch Sub Harness (W27) Component Location
- Travel Alarm Cancel Switch Sub Harness (W27) Wiring Diagram
- Boom Light Harness (W28) Component Location
- Boom Light Harness (W28) 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
- Radiator Harness (W31) Component Location
- Radiator Harness (W31) 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
- Rear Cab Light Harness (W50) Component Location
- Rear Cab Light Harness (W50) Wiring Diagram
- Rear Cab Light Relay Harness (W51) Component Location
- Rear Cab Light Relay Harness (W51) Wiring Diagram
- Rear Cab Light Jumper Harness (W52) Component Location
- Rear Cab Light Jumper Harness (W52) Wiring Diagram
- Rear Cab Light Switch Harness (W53) Component Location
- Rear Cab Light Switch Harness (W53) 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 Lever (AFL) Harness 2 (W79) Component Location
- Auxiliary Function Lever (AFL) Harness 2 (W79) Wiring Diagram
- Auxiliary Function Lever (AFL) Solenoid Jumper Harness (W80) Component Location
- Auxiliary Function Lever (AFL) Solenoid Jumper Harness (W80) Wiring Diagram
- Auxiliary Function Lever (AFL) Left Grip Harness (W81) Component Location
- Auxiliary Function Lever (AFL) Left Grip Harness (W81) Wiring Diagram
- 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 Unit (ECU) Circuit Theory of Operation
- Exhaust Aftertreatment Circuit Theory of Operation
- Main Controller (MCZ) Circuit Theory of Operation
- Travel Alarm Circuit Theory of Operation
- Machine Controller (BCZ) Circuit Theory of Operation
- Windshield Wiper and Washer Circuit Theory of Operation
- Lighting Circuit Theory of Operation
- Pilot Shutoff Circuit Theory of Operation
- Monitor Operation
- Service Menu
- Troubleshooting
- Monitoring
- Controller Version
- Issued Warning Record
- Operation
- Machine Setting
- Monitor Setting
- Engine Setting
- Exhaust Filter
- 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
- Diesel Particulate Filter (DPF) Service Recovery With Service ADVISOR™ Diagnostic Application
- MPDr Application
- MPDr Connection Procedure
- Fuse Test
- Relay Test
- Glow Plug Relay Test
- Pressure Sensor Test
- Solenoid Test
- Proportional Solenoid Test
- Temperature Sensor Test
- Alternator Test
- Electrical Component Checks
- Component Checks
- Battery Remove and Install
- Rear Cover Remove and Install
- Rear Auxiliary Cover Remove and Install
- Main Controller (MCZ) Remove and Install
- Machine Controller (BCZ) Remove and Install
- Engine Control Unit (ECU) Remove and Install
- Data Converter Remove and Install
- Monitor Controller (DSZ) Remove and Install
- Air Conditioner Controller (ACF) Remove and Install
- Key Switch Remove and Install
- Right Switch Console Remove and Install
- Left Switch Console Remove and Install
- Travel Alarm Remove and Install
- ECO Control Disable and Enable
- Disconnect Tab Retainer Connectors
- Disconnecting Spring Wire Clip Connectors
- Replace DEUTSCH™ Connectors
- Replace DEUTSCH™ Rectangular or Triangular Connectors
- Install DEUTSCH™ Contact
- Replace WEATHER PACK™ Connector
- Install WEATHER PACK™ Contact
- Replace (Pull Type) Metri-Pack™ Connectors
- Replace (Push Type) Metri-Pack™ Connectors
- Replace CINCH™ Connectors
- Install CINCH™ Contact
- Repair 32 and 48 Way CINCH™ Connectors
- Remove Connector Body from Blade Terminals
- Power Train
- Theory of Operation
- Track Adjuster and Recoil Spring Operation
- Travel Gear Case Operation
- Diagnostic Information
- Noisy or Loose Track Chain
- Noisy or Loose Track Chain Diagnostic Procedure
- Tight Track Chain
- Tight Track Chain Diagnostic Procedure
- Frequent Track Chain Sag Adjustment Required
- Frequent Track Chain Sag Adjustment Required Diagnostic Procedure
- Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers
- Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure
- Bent Track Shoes (Steel Track Only)
- Bent Track Shoes (Steel Track Only) Diagnostic Procedure
- “Popping” of Track
- “Popping” of Track Diagnostic Procedure
- Cracked Track Link
- Cracked Track Link Diagnostic Procedure
- Chipped Link Rails
- Chipped Link Rails Diagnostic Procedure
- Individual Undercarriage Component Wear
- Individual Undercarriage Component Wear Diagnostic Procedure
- Measure Swing Bearing Wear
- Hydraulic System
- 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
- Control Lever Pattern Selector—If Equipped
- Travel Pilot Control Valve Operation
- Pilot Operation of Control Valve Operation
- Flow Regulator Valve Operation
- Swing Shockless Valve
- Hydraulic Pump 1, 2, and 3 Operation
- Hydraulic Pump 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
- Flow Combiner Valve Operation
- Auxiliary Flow Combiner Valve Operation
- Travel and Arm In Combined Operation
- Swing and Boom Up Combined Operation
- Boom Reduced Leakage Valve Operation
- 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
- Cylinder Operation
- Return Filter Operation
- Auxiliary Function Lever (AFL) Operation
- Diagnostic Information
- All Hydraulic Functions Slow
- All Hydraulic Functions Slow Diagnostic Procedure
- Hydraulic Oil Overheats
- Hydraulic Oil Overheats Diagnostic Procedure
- No Hydraulic Functions
- No Hydraulic Functions Diagnostic Procedure
- Poor Combined Operation
- Poor Combined Operation Diagnostic Procedure
- All Functions Cannot Be Operated
- All Functions Cannot Be Operated Diagnostic Procedure
- Function Does Not Stop When Control Lever Is Released
- Function Does Not Stop When Control Lever Released Diagnostic Procedure
- Some Functions Cannot Be Operated, All Others Are Normal
- Some Functions Cannot Be Operated, All Others Are Normal Diagnostic Procedure
- Functions Move in Opposite Direction
- Functions Move in Opposite Direction Diagnostic Procedure
- All Dig Functions Slow or No Power
- All Dig Functions Slow or No Power Diagnostic Procedure
- Some Dig Functions Slow (Not All)
- Some Dig Functions Slow (Not All) Diagnostic Procedure
- Load Drifts Down When Control Lever is in Neutral Position
- Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure
- Load Drifts Down When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle
- Load Drifts Down When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle Diagnostic Procedure
- Arm In Speed Slow
- Arm In Speed Slow Diagnostic Procedure
- Swing Speed Slow in Both Directions
- Swing Speed Slow in Both Directions Diagnostic Procedure
- Swing Speed Slow or Does Not Operate in One Direction
- Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure
- Upperstructure Drift With Swing Valve in Neutral
- Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure
- Swing Function Does Not Operate
- Swing Function Does Not Operate Diagnostic Procedure
- Engine Stops During Combined Operation of Swing and Front Attachment
- Engine Stops During Combined Operation of Swing and Front Attachment Diagnostic Procedure
- Travel Park Brakes Do Not Apply
- Travel Park Brakes Do Not Apply Diagnostic Procedure
- Track Will Not Move in One Direction
- Track Will Not Move in One Direction Diagnostic Procedure
- Track Will Not Move in Either Direction
- Track Will Not Move in Either Direction Diagnostic Procedure
- Machine Mistracks at All Speeds in Both Directions
- Machine Mistracks at All Speeds in Both Directions Diagnostic Procedure
- Slow Travel Speed or Low Power
- Slow Travel Speed or Low Power Diagnostic Procedure
- Travel Speed Does Not Change to Slow Speed
- Travel Speed Does Not Change to Slow Speed Diagnostic Procedure
- Combined Travel and Dig Functions Slow or No Power
- Combined Travel and Dig Functions Slow or No Power Diagnostic Procedure
- Travel is “Jerky”
- Travel is “Jerky” Diagnostic Procedure
- Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline
- Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline Diagnostic Procedure
- Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs
- Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs Diagnostic Procedure
- Blade Does Not Move or Moves Slowly
- Blade Does Not Move or Moves Slowly Diagnostic Procedure
- Boom Swing Does Not Move or Moves Slowly
- Boom Swing Does Not Move or Moves Slowly Diagnostic Procedure
- Pump 1, Pump 2, Pump 3, and Pilot Pump Line Identification
- Control Valve Line Identification
- Pilot Control Line Identification
- Swing Motor Line Identification
- Travel System Component Location
- Travel Hydraulic System Line Connection
- Blade System Component Location
- Blade Hydraulic System Line Identification
- Blade Hydraulic System Line Connections
- Auxiliary Function Lever (AFL) Hydraulic System Schematic
- Auxiliary Function Lever (AFL) Hydraulic System Line Connections
- Hydraulic System Schematic
- Hydraulic System Component Location
- Hydraulic System Line Connections
- 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
- Travel Speed Solenoid Valve Test and Adjustment
- Torque Control Solenoid Valve Test and Adjustment
- Main Relief Valve Test and Adjustment
- Circuit Relief Valve Test and Adjustment
- Swing Motor Crossover Relief Valve Test and Adjustment
- Travel Motor Crossover Relief Valve Test and Adjustment
- Pump Flow Test
- Swing Motor Leakage Test
- Travel Motor Leakage Test
- Cylinder Drift Test—Boom, Arm, Bucket, and Blade
- Heating and Air Conditioning
- Theory of Operation
- Air Conditioning System Cycle of Operation
- Diagnostic Information
- Air Conditioning System Does Not Operate
- Air Conditioning System Does Not Operate Diagnostic Procedure
- No Air Flow From Heater and Air Conditioner Vents
- No Air Flow From Heater and Air Conditioner Vents Diagnostic Procedure
- Air Conditioning Does Not Cool Interior of Cab
- Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure
- Air Conditioning Runs Constantly, Too Cold
- Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure
- Interior Windows Continue to Fog Using Air Conditioner
- Interior Windows Continue to Fog Using Air Conditioner Diagnostics Procedure
- Heater System Does Not Operate
- Heater System Does Not Operate Diagnostic Procedure
- Heater Does Not Warm Interior of Cab
- Heater Does Not Warm Interior of Cab Diagnostic Procedure
- Interior Windows Continue to Fog Using Heater
- Interior Windows Continue to Fog Using Heater Diagnostic Procedure
- Heater and Air Conditioner Diagnostic Trouble Code Check
- Heater and Air Conditioner Component Location
- Tests
- Refrigerant Cautions and Proper Handling
- Heater and Air Conditioner Operational Checks
- Visual Inspection of Components
- Air Conditioner Compressor Clutch Test
- Refrigerant Leak Test
- Refrigerant Hoses and Tubing Inspection
- Air Conditioner Compressor Belt Check and Adjustment
- R134a Air Conditioning System Test
- Operating Pressure Diagnostic Chart

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