Complete service manual with Electrical Wiring Diagrams for John Deere 210LC-8B Excavator, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 210LC-8B Excavator workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM11583 - John Deere XCG 210LC-8B Excavator Technical Manual (Operation and Test).pdf
tm11588 - John Deere XCG 210LC-8B Excavator Operation and Test.pdf

PRODUCT DETAILS:
Total Pages: 732 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Category: Operation and Test
Language: English Chinese
Published on 2011/10/05

MAIN CONTENTS
Foreword
   General Information
      Safety
   Diagnostics
      Advanced Display Unit (ADU) Diagnostic Trouble Codes
      Flex Load Controller (FLC) Diagnostic Trouble Codes
      Sealed Switch Module (SSM) Diagnostic Trouble Codes
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      Monitor Operation
      References
   Power Train
      Theory of Operation
      Diagnostic Information
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Tests
   Heating and Air Conditioning
      Theory of Operation
      Diagnostic Information
      Tests
   Dealer Fabricated Tools

TABLE OF CONTENTS
Section 9000: General Information................15
  Group 01: Safety................15
    Recognize Safety Information................17
    Follow Safety Instructions................18
    Operate Only If Qualified................19
    Wear Protective Equipment................20
    Avoid Unauthorized Machine Modifications................21
    Add Cab Guarding for Special Uses................22
    Inspect Machine................23
    Stay Clear of Moving Parts................24
    Avoid High-Pressure Fluids................25
    Avoid High-Pressure Oils................26
    Work In Ventilated Area................27
    Prevent Fires................28
    Prevent Battery Explosions................29
    Handle Chemical Products Safely................30
    Dispose of Waste Properly................31
    Prepare for Emergencies................32
    Use Steps and Handholds Correctly................33
    Start Only From Operator's Seat................34
    Use and Maintain Seat Belt................35
    Prevent Unintended Machine Movement................36
    Avoid Work Site Hazards................37
    Keep Riders Off Machine................39
    Avoid Backover Accidents................40
    Avoid Machine Tip Over................41
    Do Not Lift Objects................43
    Add and Operate Attachments Safely................44
    Park and Prepare for Service Safely................45
    Service Cooling System Safely................46
    Remove Paint Before Welding or Heating................47
    Make Welding Repairs Safely................48
    Drive Metal Pins Safely................49
Section 9001: Diagnostics................50
  Group 10: Advanced Display Unit (ADU) Diagnostic Trouble Codes................50
    000158.03 - Key Switch Voltage Voltage High................50
    000158.04 - Key Switch Voltage Voltage Low................50
    000168.03 - System Voltage Voltage High................50
    000168.04 - System Voltage Voltage Low................50
    000442.00 - Display Temperature Very High................50
    000442.01 - Display Temperature Very Low................50
    001491.11 - LCD Backlight Failure Cause Unknown................50
    003597.02 - 5.0 V Power Supply Intermittent................50
    003598.02 - 1.5 V Power Supply Intermittent................50
    003599.02 - 3.3 V Power Supply Intermittent................50
    523436.14 - ADU Watchdog See Manual................50
    523438.31 - Memory Error No Information................50
    523651.02 - Memory Stack Overflow Intermittent................50
    523773.03 - CAN High Voltage High................50
    523773.04 - CAN High Voltage Low................50
    523774.03 - CAN Low Voltage High................50
    523774.04 - CAN Low Voltage Low................50
    524076.10 - Info Button Stuck Bad Rate of Change................50
    524077.10 - Back Button Stuck Bad Rate of Change................50
    524078.10 - Menu Button Stuck Bad Rate of Change................50
    524080.10 - Down Arrow Button Stuck Bad Rate of Change................50
    524082.10 - Up Arrow Button Stuck Bad Rate of Change................50
  Group 20: Flex Load Controller (FLC) Diagnostic Trouble Codes................50
    000096.03 - Fuel Level Sensor Voltage High................50
    000096.04 - Fuel Level Sensor Voltage Low................50
    000100.01 - Engine Oil Pressure Very Low................50
    000100.03 - Engine Oil Pressure Voltage High................50
    000107.00 - Engine Air Filter Restriction Very High................50
    000107.03 - Engine Air Filter Restriction Voltage High................50
    000110.00 - Engine Coolant Temperature Very High................50
    000110.04 - Engine Coolant Temperature Voltage Low................50
    000167.03 - Alternator Output Voltage High................51
    000167.04 - Alternator Output Voltage Low................51
    000190.08 - Engine Speed Sensor Abnormal Frequency Input Data................51
    000632.06 - Engine Fuel Shutoff Current Above Normal................51
    000638.04 - Throttle Actuator Low Voltage................51
    000638.07 - Throttle Actuator Mechanical Failure or Calibration................51
    000638.09 - Throttle Actuator Abnormal Update Rate................51
    000638.12 - Throttle Actuator Bad Device or Component................51
    000638.13 - Throttle Actuator Out of Calibration................51
    000676.05 - Glow Plug Relay Current Low................51
    000676.06 - Glow Plug Relay Current High................51
    000677.05 - Engine Starter Relay Current Below Normal................51
    000677.06 - Engine Starter Relay Current Above Normal................51
    000742.05 - High Low Travel Speed Solenoid Current Below Normal................51
    000742.06 - High Low Travel Speed Solenoid Current Above Normal................51
    000882.05 - License Plate Light Current Below Normal................51
    000882.06 - License Plate Light Current Above Normal................51
    001041.04 - Start Signal Indicator Voltage Low................51
    001638.00 - Hydraulic Oil Temperature Very High................51
    001638.04 - Hydraulic Oil Temperature Voltage Low................51
    001713.01 - Hydraulic Oil Filter Restriction Very Low................51
    001713.03 - Hydraulic Oil Filter Switch Voltage High................51
    002040.09 - ADU CAN Communication Bad Update Rate................51
    002141.09 - SSM CAN Communication Bad Update Rate................51
    002177.09 - Throttle Actuator CAN Communication Bad Update Rate................51
    002354.05 - Right Frame Worklight Current Below Normal................51
    002354.06 - Right Frame Worklight Current Above Normal................51
    002386.05 - Rotary Beacon Light Current Below Normal................51
    002386.06 - Rotary Beacon Light Current Above Normal................51
    002400.05 - Boom Worklight Current Below Normal................51
    002400.06 - Boom Worklight Current Above Normal................51
    003509.03 - Sensor Supply 1 Voltage High................51
    003509.04 - Sensor Supply 1 Voltage Low................51
    003510.03 - Sensor Supply 2 Voltage High................52
    003510.04 - Sensor Supply 2 Voltage Low................52
    003511.03 - Sensor Supply 3 Voltage High................52
    003511.04 - Sensor Supply 3 Voltage Low................52
    003512.03 - Sensor Supply 4 Voltage High................52
    003512.04 - Sensor Supply 4 Voltage Low................52
    520544.01 - GPS Anti-Vandalism Switch Voltage Very Low................52
    520544.03 - GPS Anti-Vandalism Switch Voltage High................52
    520545.05 - Pressure Boost Solenoid Current Low................52
    520545.06 - Pressure Boost Solenoid Current High................52
    520546.04 - Pilot Enable Switch Voltage Low................52
    520547.04 - Pressure Boost Switch Voltage Low................52
    520548.04 - Travel Pressure Switch Voltage Low................52
    520549.04 - Boom Pressure Switch Voltage Low................52
    520551.06 - Travel Alarm Current High................52
    522141.05 - Main Pump Solenoid Current Below Normal................52
    522141.06 - Main Pump Solenoid Current Above Normal................52
    522427.04 - Front Wiper Park Voltage Low................52
    522429.05 - Pilot Enable Solenoid Current Below Normal................52
    522429.06 - Pilot Enable Solenoid Current Above Normal................52
    522434.05 - Front Wiper Low Speed Current Low................52
    522434.06 - Front Wiper Low Speed Current High................52
    522435.05 - Front Wiper High Speed Current Low................52
    522435.06 - Front Wiper High Speed Current High................52
    522797.05 - Front Washer Pump Current Low................52
    522797.06 - Front Washer Pump Current High................52
    522944.05 - Left Front Cab Worklight Current Below Normal................52
    522944.06 - Left Front Cab Worklight Current Above Normal................52
    522945.05 - Right Front Cab Worklight Current Below Normal................52
    522945.06 - Right Front Cab Worklight Current Above Normal................52
    523440.04 - Unswitched Power Voltage Low................52
    524089.03 - P1 Pump Pressure Sensor Voltage High................52
    524089.04 - P1 Pump Pressure Sensor Voltage Low................52
    524090.03 - P2 Pump Pressure Sensor Voltage High................53
    524090.04 - P2 Pump Pressure Sensor Voltage Low................53
    524096.02 - Throttle Dial Bad Input Data................53
  Group 30: Sealed Switch Module (SSM) Diagnostic Trouble Codes................53
    000629.12 - Controller Fault................53
    002033.09 - FLC CAN Communication Bad Update Rate................53
    520752.04 - Auto Idle Button Stuck................53
    520752.09 - Auto Idle Button Bad Update Rate................53
    520753.04 - Hydraulic Power Button Stuck................53
    520753.09 - Hydraulic Power Button Bad Update Rate................53
    520754.04 - Unused Button 19 Stuck................53
    520754.09 - Unused Button 19 Bad Update Rate................53
    520755.04 - Unused Button 20 Stuck................53
    520755.09 - Unused Button 20 Bad Update Rate................53
    523335.04 - Travel Alarm Cancel Button Stuck................53
    523335.09 - Travel Alarm Cancel Button Bad Update Rate................53
    523336.04 - Travel Setting Button Stuck................53
    523336.09 - Travel Setting Button Bad Update Rate................53
    523338.04 - Unused Button 23 Stuck................53
    523338.09 - Unused Button 23 Bad Update Rate................53
    523339.04 - Unused Button 22 Stuck................53
    523339.09 - Unused Button 22 Bad Update Rate................53
    523340.04 - Unused Button 21 Stuck................53
    523340.09 - Unused Button 21 Bad Update Rate................53
    523849.04 - Unused Button 16 Stuck................53
    523849.09 - Unused Button 16 Bad Update Rate................53
    523850.04 - Unused Button 15 Stuck................53
    523850.09 - Unused Button 15 Bad Update Rate................53
    523852.04 - Unused Button 14 Stuck................53
    523852.09 - Unused Button 14 Bad Update Rate................53
    523854.04 - Front Washer Button Stuck................53
    523854.09 - Front Washer Button Bad Update Rate................53
    523855.04 - Front Wiper Button Stuck................53
    523855.09 - Front Wiper Button Bad Update Rate................54
    523856.04 - Unused Button 11 Stuck................54
    523856.09 - Unused Button 11 Bad Update Rate................54
    523857.04 - Unused Button 10 Stuck................54
    523857.09 - Unused Button 10 Bad Update Rate................54
    523858.04 - Boom Worklight Button Stuck................54
    523858.09 - Boom Worklight Button Bad Update Rate................54
    523860.04 - Cab Front Worklight Button Stuck................54
    523860.09 - Cab Front Worklight Button Bad Update Rate................54
    523861.04 - Front Frame Worklight Button Stuck................54
    523861.09 - Front Frame Worklight Button Bad Update Rate................54
    523862.04 - Unused Button 6 Stuck................54
    523862.09 - Unused Button 6 Bad Update Rate................54
    523863.04 - Unused Button 5 Stuck................54
    523863.09 - Unused Button 5 Bad Update Rate................54
    523864.04 - Unused Button 4 Stuck................54
    523864.09 - Unused Button 4 Bad Update Rate................54
    523865.04 - Rotary Beacon Button Stuck................54
    523865.09 - Rotary Beacon Button Bad Update Rate................54
    523867.04 - Unused Button 2 Stuck................54
    523867.09 - Unused Button 2 Bad Update Rate................54
    523868.04 - Unused Button 1 Stuck................54
    523868.09 - Unused Button 1 Bad Update Rate................54
Section 9005: Operational Checkout Procedure................382
  Group 10: Operational Checkout Procedure................382
    Operational Checkout Procedure................382
Section 9010: Engine................412
  Group 05: Theory of Operation................412
    Engine Component Location................417
    Engine Fuel System Operation................421
    Start Aid Operation................422
    Engine Speed Control System Operation................423
  Group 15: Diagnostic Information................412
    Isuzu BB-6BG1TRP Engine................426
    Engine Cranks But Will Not Start................412
    Engine Does Not Stop With Key Switch................412
  Group 20: Adjustments................412
    Engine Speed Control Linkage Check and Adjustment................430
    Fuel Shut-Off Actuator Adjustment................431
  Group 25: Tests................412
    Engine Speed Test................434
    Clamp-On Tachometer Installation................435
Section 9015: Electrical System................436
  Group 05: System Information................436
    Electrical Diagram Information................442
    Electrical Schematic Symbols................446
  Group 10: System Diagrams................436
    Fuse and Relay Specifications................452
    System Functional Schematic, Component Location, and Wiring Diagram Master Legend................455
    System Functional Schematic................459
    Left Frame Harness (W10) Component Location................463
    Left Frame Harness (W10) Wiring Diagram................465
    Middle Frame Harness (W11) Component Location................467
    Middle Frame Harness (W11) Wiring Diagram................472
    Right Frame Harness (W12) Component Location................474
    Right Frame Harness (W12) Wiring Diagram................476
    Load Center Harness (W13) Component Location................477
    Load Center Harness (W13) Wiring Diagram................479
    Cab Harness (W14) Component Location................481
    Cab Harness (W14) Wiring Diagram................483
    Right Console Harness (W15) Component Location................484
    Right Console Harness (W15) Wiring Diagram................485
    Cab Roof Harness (W16) Component Location................486
    Cab Roof Harness (W16) Wiring Diagram................488
    Boom Light Harness (W17) Component Location................489
    Boom Light Harness (W17) Wiring Diagram................490
    Diesel Fired Coolant Heater Harness (W18) Component Location................491
    Diesel Fired Coolant Heater Harness (W18) Wiring Diagram................493
  Group 15: Sub-System Diagnostics................436
    Controller Area Network (CAN) Theory of Operation................496
    Starting and Charging Circuit Theory of Operation................498
    Flex Load Controller (FLC) Circuit Theory of Operation................501
    Advanced Display Unit (ADU) Circuit Theory of Operation................506
    Fuel Shutoff Actuator Theory of Operation................508
  Group 16: Monitor Operation................437
    Advanced Display Unit (ADU)—Service Mode................513
    Advanced Display Unit (ADU)—Clear Codes................515
    Advanced Display Unit (ADU)—Enable Options................516
    Advanced Display Unit (ADU)—Throttle Actuator Cal................517
    Advanced Display Unit (ADU)—Telematic................518
    Advanced Display Unit (ADU) Screen is Blank Diagnostic Procedure................437
  Group 20: References................437
    Fuse and Relay Test................526
    Controller Area Network (CAN) Circuit Test................530
    Electrical Component Checks................538
    Electrical Component Specifications................543
    Solenoid Test................437
    Alternator Test................554
    Engine Speed Control Actuator Calibration................556
    Fuel Shut-Off Actuator Check................557
    Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors................437
    Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors................437
    Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact................437
    Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector................437
    Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact................437
    Replace (Pull Type) Metri-Pack™ Connectors................572
    Replace (Push Type) Metri-Pack™ Connectors................574
    Replace CINCH CINCH is a trademark of the Cinch Co. Connectors................437
    Install CINCH CINCH is a trademark of the Cinch Co. Contact................437
    Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors................437
    Remove Connector Body from Blade Terminals................583
Section 9020: Power Train................584
  Group 05: Theory of Operation................584
    Track Adjuster and Recoil Spring Operation................586
    Travel Gearbox Operation................587
  Group 15: Diagnostic Information................584
    Noisy or Loose Track Chain................584
    Tight Track Chain................584
    Frequent Track Tension Adjustment Required................584
    Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers................584
    Bent Track Shoes................584
Section 9025: Hydraulic System................603
  Group 05: Theory of Operation................603
    Hydraulic System Operation................607
    Pilot System Operation................608
    Pilot Pump Operation................609
    Pilot Shutoff Solenoid Valve Operation................610
    Pilot Control Valve Operation................631
    Travel Pilot Control Valve Operation................631
    Pilot Operation of Control Valve Operation................631
    Pilot Accumulator Manifold Operation................616
    Pilot Supply Manifold Operation................618
    Pilot Distribution Manifold Operation................619
    Pump 1 and Pump 2 Operation................621
    Pump 1 and Pump 2 Regulator Operation................623
    Control Valve Operation................631
    Control Valve Check Valves Identification and Operation................644
    Main Relief Valve Circuit Operation................647
    Circuit Relief and Anticavitation Valve Operation................649
    Flow Control Valve Operation................651
    Flow Combiner Valve Operation................653
    Arm Regenerative Valve Circuit Operation................655
    Boom and Arm Reduced Leakage Valves Operation................657
    Swing Reduction Gear Case Operation................659
    Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation................661
    Swing Motor Park Brake Release Circuit Operation................663
    Rotary Manifold Operation................664
    Travel Motor and Park Brake Valve Operation................666
    Travel Motor Speed Circuit Operation................667
    Cylinder Operation................668
    Return Filter Operation................669
  Group 15: Diagnostic Information................603
    All Hydraulic Functions Slow................603
    Hydraulic Oil Overheats................603
    No Hydraulic Functions................604
    Poor Combined Operation................604
    Function Does Not Stop When Control Lever Released................604
    Some Functions Cannot Be Operated, All Others Are Normal................604
    Some Functions Slow................604
    Function Moves in Opposite Direction................604
    Load Drifts Down When Control Valve Is In Neutral Position................604
    Load Falls When Control Valve Is Actuated To Raise Load With Engine Running at Slow Idle................604
    H (high power) Function Does Not Operate, S (Standard power) and L (low power) Mode Is Normal................604
    Swing Speed Slow In Both Directions................604
    Swing Speed Slow or Does Not Operate In One Direction................604
    Upperstructure Drift With Swing Valve In Neutral................604
    Swing Function Does Not Operate................604
    Travel Park Brakes Do Not Apply................604
    Track Will Not Move In One Direction................604
    Track Will Not Move In Either Direction................604
    Machine Mistracks at All Speeds In Both Directions................604
    Slow Travel Speed or Low Power................604
    Travel Is "Jerky"................604
    Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline................604
    Machine Will Not Turn Smoothly In One Direction or Park Brake Grabs................604
    Pump 1, Pump 2, and Pilot Pump Line Identification................731
    Control Valve Line Identification................733
    Swing Motor Line Identification................736
    Pilot Control Valve-to-Pilot Distribution Manifold Component Location—Excavator Pattern................737
    Pilot Control Valve-to-Pilot Distribution Manifold Component Location—Backhoe Pattern................739
    Pilot Distribution Manifold-to-Control Valve Line Connections................741
    Travel Hydraulic System Line Connections................756
    Hydraulic System Schematic................744
    Hydraulic System Component Location................754
    Hydraulic System Line Connections................756
  Group 25: Tests................604
    JT05800 Digital Thermometer Installation................758
    JT02156A Digital Pressure and Temperature Analyzer Kit Installation................759
    Hydraulic Oil Cleanup Procedure................760
    Hydraulic Oil Tank Pressure Release Procedure................761
    Hydraulic Oil Warmup Procedure................762
    Pilot Pressure Regulating Valve Test and Adjustment................764
    Control Valve Spool Actuating Pilot Pressure Test................766
    Pressure Boost Solenoid Valve Test................769
    Travel Speed Solenoid Valve Test................771
    Pump Control Pilot Pressure Signal Test................773
    System Relief Valve Test and Adjustment................776
    Circuit Relief Valve Test and Adjustment................780
    Swing Motor Crossover Relief Valve Test and Adjustment................786
    Travel Motor Crossover Relief Valve Test and Adjustment................789
    Pump Regulator Test and Adjustment—Minimum Flow................792
    Pump Regulator Test and Adjustment—Maximum Flow................795
    Pump Flow Test................797
    Swing Motor Leakage Test................800
    Travel Motor Leakage Test................802
    Cylinder Drift Test—Boom, Arm, and Bucket................805
Section 9031: Heating and Air Conditioning................808
  Group 05: Theory of Operation................808
    Air Conditioning System Cycle of Operation................811
  Group 15: Diagnostic Information................808
    Air Conditioning System Does Not Operate................808
    Air Conditioner Does Not Cool Interior of Cab................808
    Heater System Does Not Operate................808
    Heater Does Not Warm Interior of Cab................808
    Interior Windows Continue to Fog................808
    Heater and Air Conditioner Component Location................826
  Group 25: Tests................808
    Refrigerant Cautions and Proper Handling................828
    Heater and Air Conditioner Operational Checks................829
    Air Conditioner Compressor Clutch Test................833
    Air Conditioner Compressor Clutch Test................833
    Refrigerant Leak Test................834
    Refrigerant Hoses and Tubing Inspection................835
    Operating Pressure Diagnostic Chart................836
Section 9900: Dealer Fabricated Tools................841
  Group 99: Dealer Fabricated Tools................841
    DFT1218 Split Flange Hose Cap................843
    
John Deere 210LC-8B Excavator Operation and Test Service Manual (TM11583)