Complete workshop Operation & Test manual with electrical wiring diagrams for John Deere 135G Excavator. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This John Deere 135G Excavator Operation & Test manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

TM12666 - John Deere 135G Excavator Operation & Test Technical Manual.pdf
CONTENTS
Foreword
9000 - General Safety
9001 - Diagnostics
9005 - Operational Checkout
9010 - Engine
9015 - Electrical System
9020 - Power Train
9025 - Hydraulic System
9031 - Heating and Air Conditioning
9900 - Dealer Fabricated Tools

TABLE OF CONTENTS....1
Section 9000: General Information....25
  Group 01: Safety....25
    Recognize Safety Information....28
    Follow Safety Instructions....29
    Operate Only If Qualified....30
    Wear Protective Equipment....31
    Avoid Unauthorized Machine Modifications....32
    Control Pattern Selector—If Equipped....33
    Add Cab Guarding for Special Uses....34
    Inspect Machine....35
    Stay Clear of Moving Parts....36
    Avoid High-Pressure Fluids....37
    Avoid High-Pressure Oils....38
    Work In Ventilated Area....39
    Prevent Fires....40
    Prevent Battery Explosions....41
    Handle Chemical Products Safely....42
    Decommissioning — Proper Recycling and Disposal of Fluids and Components....43
    Exhaust Filter Ash Handling and Disposal....44
    Prepare for Emergencies....45
    Clean Debris from Machine....46
    Use Steps and Handholds Correctly....47
    Start Only From Operator's Seat....48
    Use and Maintain Seat Belt....49
    Prevent Unintended Machine Movement....50
    Avoid Work Site Hazards....51
    Keep Riders Off Machine....53
    Avoid Backover Accidents....54
    Inspect and Maintain ROPS....55
    Avoid Machine Tip Over....56
    Use Special Care When Lifting Objects....58
    Add and Operate Attachments Safely....59
    Park and Prepare for Service Safely....60
    Service Cooling System Safely....61
    Remove Paint Before Welding or Heating....62
    Make Welding Repairs Safely....63
    Drive Metal Pins Safely....64
    Clean Exhaust Filter Safely....65
Section 9001: Diagnostics....68
  Group 10: Main Controller (MCZ) Diagnostic Trouble Codes....77
    Main Controller (MCZ) Diagnostic Trouble Codes....77
    Controller Area Network 0 (CAN 0) Circuit Diagnostics....78
    Controller Area Network 1 (CAN 1) Circuit Diagnostics....92
    Interface Controller Area Network (N-CAN) Diagnostics....110
    011000.02 - Abnormal EEPROM....68
    011001.02 - Abnormal RAM....68
    011002.02 - Abnormal A/D Converter....68
    011003.03 - Abnormal Sensor Voltage....68
    011006.02 - Engine Controller Communication Error....68
    011007.02 - (CAN 0) Data Converter Communication Error 1....68
    011008.02 - (CAN 1) Data Converter Communication Error 2....68
    011009.02 - (CAN 0) Monitor Controller Communication Error 1....68
    011010.02 - (CAN 1) Monitor Controller Communication Error 2....68
    011100.02 - Abnormal Engine Speed....68
    011101.03 - Engine Control Dial Sensor Circuit High Input....68
    011101.04 - Engine Control Dial Sensor Circuit Low Input....68
    011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input....68
    011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input....68
    011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input....68
    011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input....68
    011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input....68
    011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input....68
    011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input....68
    011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input....68
    011301.03 - Swing Pilot Pressure Sensor Circuit High Input....68
    011301.04 - Swing Pilot Pressure Sensor Circuit Low Input....68
    011302.03 - Boom Up Pilot Pressure Sensor Circuit High Input....68
    011302.04 - Boom Up Pilot Pressure Sensor Circuit Low Input....68
    011303.03 - Arm In Pilot Pressure Sensor Circuit High Input....68
    011303.04 - Arm In Pilot Pressure Sensor Circuit Low Input....68
    011304.03 - Travel Pilot Pressure Sensor Circuit High Input....68
    011304.04 - Travel Pilot Pressure Sensor Circuit Low Input....69
    011307.03 - Front Attachment Pilot Pressure Sensor Circuit High Input....69
    011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input....69
    011400.02 - Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback....69
    011400.03 - Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current....69
    011400.04 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current....69
    011401.02 - Torque Control Solenoid Valve Abnormal Feedback....69
    011401.03 - Torque Control Solenoid Valve Feedback High Current....69
    011401.04 - Torque Control Solenoid Valve Feedback Low Current....69
    011402.02 - 4-Spool Solenoid Valve Unit (SF) Abnormal Feedback....69
    011402.03 - 4-Spool Solenoid Valve Unit (SF) Feedback High Input....69
    011402.04 - 4-Spool Solenoid Valve Unit (SF) Feedback Low Input....69
    011403.02 - 4-Spool Solenoid Valve Unit (SC) Abnormal Feedback....69
    011403.03 - 4-Spool Solenoid Valve Unit (SC) Feedback High Input....69
    011403.04 - 4-Spool Solenoid Valve Unit (SC) Feedback Low Input....69
    011407.02 - 4-Spool Solenoid Valve Unit (SG) Abnormal Feedback....69
    011407.03 - 4-Spool Solenoid Valve Unit (SG) Feedback High Input....69
    011407.04 - 4-Spool Solenoid Valve Unit (SG) Feedback Low Input....69
    011408.02 - 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback....69
    011408.03 - 2-Spool Solenoid Valve Unit (SJ) Feedback High Input....69
    011408.04 - 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input....69
    011409.02 - 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback....69
    011409.03 - 2-Spool Solenoid Valve Unit (SZ) Feedback High Input....69
    011409.04 - 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input....69
    011410.02 - Pump 1 Flow Rate Limit Solenoid Feedback Current Abnormal....69
    011410.03 - Pump 1 Flow Rate Limit Solenoid Feedback Current High....69
    011410.04 - Pump 1 Flow Rate Limit Solenoid Feedback Current Low....69
    011428.02 - 4-Spool Solenoid Valve Unit (SD) Abnormal Feedback....69
    011428.03 - 4-Spool Solenoid Valve Unit (SD) Feedback High Input....69
    011428.04 - 4-Spool Solenoid Valve Unit (SD) Feedback Low Input....69
    011434.02 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback....69
    011434.03 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current....69
    011434.04 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current....69
    011435.02 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback....70
    011435.03 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current....70
    011435.04 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current....70
    011436.02 - Breaker Relief Proportional Solenoid Valve Abnormal Feedback....70
    011436.03 - Breaker Relief Proportional Solenoid Valve Feedback High Current....70
    011436.04 - Breaker Relief Proportional Solenoid Valve Feedback Low Current....70
    011457.02 - 2-Speed Activation Solenoid Disconnected or Not Present....70
    011458.02 - (Auxiliary) Discontinuity of Selector Valve....70
    011459.02 - Idle Stop Relay Circuit Malfunction....70
    011810.03 - Electric Lever Operating Pressure Sensor 1 High Voltage....70
    011810.04 - Electric Lever Operating Pressure Sensor 1 Low Voltage....70
    011812.02 - OPT Electric Lever 1 Neutral Abnormal....70
    011813.02 - OPT Electric Lever 1 Abnormal Operation....893
    011816.02 - OPT Solenoid 1 Feedback Abnormal....70
    011816.03 - OPT Solenoid 1 Feedback Current High....70
    011816.04 - OPT Solenoid 1 Feedback Current Low....70
    011817.02 - OPT Solenoid 2 Feedback Abnormal....70
    011817.03 - OPT Solenoid 2 Feedback Current High....70
    011817.04 - OPT Solenoid 2 Feedback Current Low....70
    011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input....70
    011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input....70
    015011.03 - Hydraulic Oil Temperature Sensor Circuit High Input (Pilot)....70
    015011.04 - Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)....70
    015016.03 - Right Analog Stroke Sensor Circuit High Input....70
    015016.04 - Right Analog Stroke Sensor Circuit Low Input....70
    020010.02 - Exhaust Filter Alarm....70
    020011.02 - Electric Lever Alarm....70
    020012.02 - Line Filter Restriction Alarm....70
    020303.02 - Electric Lever Pilot Cut Alarm....70
  Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes....354
    Engine Control Unit (ECU) Diagnostic Trouble Codes....354
    000081.00 - High Exhaust Filter Differential Pressure (P2453)....70
    000081.01 - Low Exhaust Filter Differential Pressure (P2452)....70
    000081.02 - Zero-Point Calibration of Exhaust Filter Differential Pressure Sensor is Abnormal (P2456)....71
    000081.03 - Exhaust Filter Differential Pressure Sensor Circuit High Input (P2455)....71
    000081.04 - Exhaust Filter Differential Pressure Sensor Circuit Low Input (P2454)....71
    000091.02 - Accelerator Pedal Position Sensor 1-2 Correlation (P2138)....71
    000091.03 - Accelerator Pedal Position Sensor 1 High Input (P2123)....71
    000091.03 - Accelerator Pedal Position Sensor 2 High Input (P2128)....71
    000091.04 - Accelerator Pedal Position Sensor 1 Low Input (P2122)....71
    000091.04 - Accelerator Pedal Position Sensor 2 Low Input (P2127)....71
    000100.03 - Engine Oil Pressure Sensor Circuit High Input (P0523)....71
    000100.04 - Engine Oil Pressure Sensor Circuit Low Input (P0522)....71
    000102.00 - Over Boost-Pressure (P0234)....71
    000102.00 - Over Boost-Pressure (P0234)....71
    000102.01 - Declined Boost Pressure (P0299)....71
    000102.03 - Boost Pressure Sensor Circuit High Input (P0238)....71
    000102.04 - Boost Pressure Sensor Circuit Low Input (P0237)....71
    000105.03 - Boost Temperature Sensor Circuit High Input (P1113)....71
    000105.04 - Boost Temperature Sensor Circuit Low Input (P1112)....71
    000108.03 - Atmospheric Pressure Sensor Circuit High Input (P2229)....71
    000108.04 - Atmospheric Pressure Sensor Circuit Low Input (P2228)....71
    000110.00 - Overheat (P0217)....71
    000110.03 - Engine Coolant Temperature Circuit High Input (P0118)....71
    000110.04 - Engine Coolant Temperature Circuit Low Input (P0117)....71
    000132.03 - Air Flow Sensor Circuit High Input (P0103)....71
    000132.04 - Air Flow Sensor Circuit Low Input (P0102)....71
    000157.00 - Pressure Increase in Common Rail (Secondary) (P0088)....71
    000157.03 - Common Rail Pressure Sensor Circuit High Input (P0193)....71
    000157.04 - Common Rail Pressure Sensor Circuit Low Input (P0192)....71
    000157.15 - Abnormal Common Rail Pressure (Over Pumping) (P0089)....71
    000157.16 - Pressure Increase in Common Rail (Primary) (P0088)....71
    000158.03 - Abnormally High Battery System Voltage (P0563)....71
    000172.03 - Intake Air Temperature Sensor Circuit High Input (P0113)....71
    000172.04 - Intake Air Temperature Sensor Circuit Low Input (P0112)....71
    000173.00 - Abnormally High Exhaust Temperature Sensor 1 (DPF Inlet) (P0426)....72
    000173.03 - Exhaust Temperature Sensor 1 Circuit High Input (DPF Inlet) (P0428)....72
    000173.04 - Exhaust Temperature Sensor 1 Circuit Low Input (DPF Inlet) (P0427)....72
    000174.03 - Combustion Temperature Sensor Circuit High Input (P0183)....72
    000174.04 - Combustion Temperature Sensor Circuit Low Input (P0182)....72
    000190.00 - Engine Overrun (P0219)....72
    000628.02 - Abnormal ROM (P0601)....72
    000633.07 - Common Rail Pressure Limiter Open (P0087)....72
    000636.02 - Abnormal Cam Angle Sensor (No Signal) (P0340)....72
    000636.07 - Phase Difference Between Cam and Sensor (P0016)....72
    000639.02 - Abnormal CAN Time-Out (U0101)....72
    000639.19 - Abnormal CAN Bus (U0073)....72
    000651.05 - Cylinder 1 Injector Circuit Open (P0201)....72
    000652.05 - Cylinder 2 Injector Circuit Open (P0202)....72
    000653.05 - Cylinder 3 Injector Circuit Open (P0203)....72
    000654.05 - Cylinder 4 Injector Circuit Open (P0204)....72
    000723.02 - Crank Position Sensor Failure (No Signal) (P0335)....72
    000723.02 - Crank Position Sensor Failure (Abnormal Signal) (P0336)....72
    001077.02 - Abnormal CPU (P0606)....72
    001079.02 - Abnormal 5V-Electric Power Circuit #1 (P0641)....72
    001080.02 - Abnormal 5V-Electric Power Circuit #2 (P0651)....72
    001131.03 - Manifold Temperature Sensor Circuit High Input (P041C)....72
    001131.04 - Manifold Temperature Sensor Circuit Low Input (P041D)....72
    001239.01 - Pressure Decline in Common Rail (No Pumping Pressure) (P0093)....72
    001239.17 - Pressure Decline in Common Rail (Lack of Pumping Pressure) (P1093)....72
    001347.03 - SCV Drive Circuit + Short Circuit B (P0092)....72
    001347.04 - SCV Drive Circuit Open or Short Circuited to GND (P0091)....72
    001381.03 - Fuel Filter Restriction Sensor Circuit High Input (P1294)....72
    001381.04 - Fuel Filter Restriction Sensor Circuit Low Input (P1293)....72
    001485.05 - Abnormal Main Relay Circuit (Inactivation) (P0685)....72
    001485.06 - Abnormal Main Relay Circuit (Kept Closed) (P0687)....72
    010001.02 - EGR Position Error (Brushless Type) (P0409)....72
    010001.13 - Abnormal EGR Zero-Point Calibration (P1404)....72
    010002.02 - Abnormal EGR Valve Control Circuit (P0404)....73
    010003.02 - Abnormal Injector Common 1 Circuit (P2146)....73
    010004.02 - Abnormal Injector Common 2 Circuit (P2149)....73
    010005.01 - Abnormal Charge Circuit (Bank 1) (P1261)....73
    010006.01 - Abnormal Charge Circuit (Bank 2) (P1262)....73
    010007.02 - Abnormal CPU Monitor IC (P0606)....73
    010008.02 - Abnormal A/D Converter (P060B)....73
    010009.02 - Abnormal 5V-Electric Power Circuit #3 (P0697)....73
    010010.02 - Abnormal 5V-Electric Power Circuit #4 (P1655)....73
    010012.02 - Abnormal 12V Circuit (P0560)....73
    010013.02 - Abnormal EEPROM/Abnormal HDEEPROM (P1621)....73
    010022.02 - Abnormal Intake Throttle Control Circuit (P0638)....73
    010022.03 - Intake Throttle Position Sensor Circuit High Input (P0123)....73
    010022.04 - Intake Throttle Position Sensor Circuit Low Input (P0122)....73
    010023.03 - EVRV Vacuum Sensor High Input (P2528)....73
    010023.04 - EVRV Vacuum Sensor Low Input (P2527)....73
    010023.20 - Abnormal Turbo EVRV (P0045)....73
    010024.03 - Exhaust Temperature Sensor 2 Circuit High Input (DOC Inlet) (P042D)....73
    010024.04 - Exhaust Temperature Sensor 2 Circuit Low Input (DOC Inlet) (P042C)....73
    010025.05 - Exhaust Filter Light Failure (P1669)....73
    010026.00 - Exhaust Filter PM Over-Restriction 2 (P1455)....73
    010026.15 - Exhaust Filter PM Over-Restriction (P242F)....73
    010027.00 - Exhaust Filter Cleaning Decision Error (P1471)....73
    010028.00 - Abnormally High Exhaust Temperature Sensor 2 (DOC Outlet) (P042B)....73
    010029.00 - Over Frequent Exhaust Filter Regeneration Time-Out (P2458)....73
    010032.02 - QR Code Error (P0602)....73
    010033.02 - Abnormal RAM (P0604)....73
    010040.19 - Abnormal ISO-CAN Bus (U0001)....73
  Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes....451
    Monitor Controller (DSZ) Diagnostic Trouble Codes....451
    013002.02 - ECU Communication Error....73
    013003.02 - Main Controller (MCZ) Communication Error 1....73
    013004.02 - Main Controller (MCZ) Communication Error 2....73
    013005.02 - Monitor Controller (DSZ) Communication Error 1....74
    013006.02 - Monitor Controller (DSZ) Communication Error 2....74
    013007.02 - Machine Controller (BCZ) Communication Error....74
    020113.02 - System Error Alarm....74
  Group 40: Information Controller (ICZ) Diagnostic Trouble Codes....460
    Information Controller (ICZ) Diagnostic Trouble Codes....460
    013334.02 - Radiator Coolant Error....74
    014001.02 - Flash Memory Read/Write Error....74
    014002.02 - External RAM Read/Write Error....74
    014003.02 - Abnormal EEPROM....74
    014006.02 - Communication Terminal:Communication Error....74
    014008.02 - Abnormal Internal RAM....74
    014021.02 - Communication Terminal Security Error....74
    014022.02 - SIM Card Error....74
    014023.02 - Security Error....74
    020100.02 - Overheat Alarm....74
    020101.02 - Engine Warning Alarm....74
    020102.02 - Engine Oil Pressure Alarm....74
    020105.02 - Hydraulic Oil Filter Restriction Alarm....74
    020106.02 - Air Cleaner Restriction Alarm....74
    020109.02 - Pilot Control Shut-Off Lever Alarm....74
    020110.02 - Fuel Filter Restriction Alarm....74
    020114.02 - Overheat Alarm....74
    020133.02 - Crane Function Alarm....74
    020137.02 - Exhaust Filter Alarm....74
    020141.02 - Exhaust Temperature Alarm....74
    020142.02 - Intake Air Temperature Alarm....74
    020145.02 - Boost Temperature Increase Alarm....74
    020146.02 - Fuel Temperature Increase Alarm....74
    020149.02 - EGR Gas Temperature Alarm....74
  Group 50: Air Conditioner Controller (ACF) Diagnostic Trouble Codes....500
    Air Conditioner Controller (ACF) Diagnostic Trouble Codes....500
    11 - Open Circuit in Air Recirculation Sensor....74
    12 - Short-Circuited Air Recirculation Sensor....75
    13 - Open Circuit in Ambient Air Temperature Sensor....75
    14 - Short-Circuited Ambient Air Temperature Sensor....75
    18 - Short-Circuited Solar Radiation Sensor....75
    21 - Open Circuit in Air Conditioner Freeze Control Switch....75
    22 - Short-Circuited Air Conditioner Freeze Control Switch....75
    43 - Abnormal Air Conditioner and Heater Blower Port Change Servomotor....75
    44 - Abnormal Air Conditioner and Heater Mixer Servomotor....75
    51 - Abnormal High/Low Refrigerant Pressure....75
    91 - Communication Error....75
    92 - CAN Bus Off Error....75
Section 9005: Operational Checkout Procedure....533
  Group 10: Operational Checkout Procedure....533
    Operational Checkout....600
Section 9010: Engine....666
  Group 05: Theory of Operation....893
    Isuzu Engine....685
    Engine Fuel System Component Location....669
    Engine Cooling System Component Location....672
    Cold Weather Starting Aid....674
    Engine Speed Control System Operation....893
  Group 15: Diagnostic Information....666
    Isuzu Engine....685
  Group 20: Adjustments....666
    Isuzu Engine....685
  Group 25: Tests....666
    Isuzu Engine....685
Section 9015: Electrical System....686
  Group 05: System Information....686
    Electrical Diagram Information....699
  Group 10: System Diagrams....686
    Explanation of Wire Markings....708
    Fuse and Relay Specifications....709
    System Functional Schematic, Component Location, and Wiring Diagram Master Legend....714
    System Functional Schematic....722
    Cab Harness (W1) Component Location....734
    Cab Harness (W1) Wiring Diagram....737
    Machine Harness (W2) Component Location....741
    Machine Harness (W2) Wiring Diagram....744
    Monitor Harness (W3) Component Location....747
    Monitor Harness (W3) Wiring Diagram....749
    Engine Harness (W4) Component Location....751
    Engine Harness (W4) Wiring Diagram....753
    Pump Harness (W8) Component Location....755
    Pump Harness (W8) Wiring Diagram....756
    Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location....757
    Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram....758
    Pilot Shutoff Switch Harness (W11) Component Location....759
    Pilot Shutoff Switch Harness (W11) Wiring Diagram....760
    Auxiliary Fuse Box Harness (W13) Component Location....761
    Auxiliary Fuse Box Harness (W13) Wiring Diagram....763
    Heated Air Seat Harness (W14) Component Location....765
    Heated Air Seat Harness (W14) Wiring Diagram....767
    Multi-Function Pilot Control Lever Harness (W15) Component Location....768
    Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram....771
    Travel Alarm Cancel Switch Harness (W16) Component Location....773
    Travel Alarm Cancel Switch Harness (W16) Wiring Diagram....774
    Attachment Harness (W17) Component Location....775
    Attachment Harness (W17) Wiring Diagram....777
    Rear Camera Harness (W19) Component Location....779
    Rear Camera Harness (W19) Wiring Diagram....780
    9-Pin Service ADVISOR™ Connector (W20) Component Location....781
    9-Pin Service ADVISOR™ Connector (W20) Wiring Diagram....782
    Pilot Shutoff Valve Harness (W21) Component Location....783
    Pilot Shutoff Valve Harness (W21) Wiring Diagram....784
    Auxiliary 3-Button Cancel Switch Harness (W22) Component Location....785
    Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram....786
    Seat Heater Switch Harness (W24) Component Location....787
    Seat Heater Switch Harness (W24) Wiring Diagram....788
    Travel Alarm Harness (W26) Component Location....789
    Travel Alarm Harness (W26) Wiring Diagram....790
    Travel Sub Harness (W27) Component Location....791
    Travel Sub Harness (W27) Wiring Diagram....792
    Starter Switch Harness (W29) Component Location....793
    Starter Switch Harness (W29) Wiring Diagram....794
    Data Converter Harness (W30) Component Location....795
    Data Converter Harness (W30) Wiring Diagram....797
    Data Converter Interface Harness (W31) Component Location....798
    Data Converter Interface Harness (W31) Wiring Diagram....799
    2-Speed Harness (W32) Component Location....800
    2-Speed Harness (W32) Wiring Diagram....801
    Heater and Air Conditioner Harness (W41) Component Location....802
    Heater and Air Conditioner Harness (W41) Wiring Diagram....803
    Auxiliary Solenoid Harness (W61) Component Location....804
    Auxiliary Solenoid Harness (W61) Wiring Diagram....806
    Auxiliary Function Lever (AFL) Harness (W75) Component Location....808
    Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram....810
    Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location....811
    Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram....812
    Auxiliary Function Lever (AFL) Grip Harness (W77) Component Location....814
    Auxiliary Function Lever (AFL) Grip Harness (W77) Wiring Diagram....815
    Auxiliary Function Enable Switch Harness (W78) Component Location....816
    Auxiliary Function Enable Switch Harness (W78) Wiring Diagram....817
    Satellite (SAT) Harness (W6003) Component Location....818
    Satellite (SAT) Harness (W6003) Wiring Diagram....819
    JDLink™ Harness (W6004) Component Location....820
    JDLink™ Harness (W6004) Wiring Diagram....822
  Group 15: Sub-System Diagnostics....688
    Controller Area Network (CAN) Theory of Operation....893
    Starting and Charging Circuit Theory of Operation....893
    Monitor Controller (DSZ) Circuit Theory of Operation....893
    Engine Control Unit (ECU) Circuit Theory of Operation....893
    Exhaust Aftertreatment Circuit Theory of Operation....893
    Main Controller (MCZ) Circuit Theory of Operation....893
    Travel Alarm Circuit Theory of Operation....893
    Machine Controller (BCZ) Circuit Theory of Operation....893
    Windshield Wiper and Washer Circuit Theory of Operation....893
    Lighting Circuit Theory of Operation....893
    Pilot Shutoff Circuit Theory of Operation....893
    Attachment Control Circuit Theory of Operation....893
  Group 16: Monitor Operation....893
    Service Menu....880
    Troubleshooting....882
    Monitoring....883
    Controller Version....891
    Issued Warning Record....892
    Operation....893
    Machine Setting....894
    Monitor Setting....901
    Engine Setting....904
    Exhaust Filter No....905
  Group 20: References....688
    Reading Diagnostic Trouble Codes with Monitor Display....907
    Service ADVISOR™ Diagnostic Application....908
    Service ADVISOR™ Connection Procedure....909
    Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application....911
    Clearing Engine Diagnostic Trouble Codes....914
    MPDr Application....921
    MPDr Connection Procedure....922
    Fuse Test....924
    Relay Test....930
    Glow Plug Relay Test....931
    Pressure Sensor Test....932
    Solenoid Test....934
    Proportional Solenoid Test....935
    Temperature Sensor Test....936
    Alternator Test....938
    Electrical Component Checks....940
    Battery Remove and Install....947
    Rear Cover Remove and Install....949
    Main Controller (MCZ) Remove and Install....951
    Machine Controller (BCZ) Remove and Install....953
    Engine Control Unit (ECU) Remove and Install....955
    Exhaust Differential Pressure Sensor Zero Point Calibration....959
    Ash Reset....961
    No Load Max....962
    Data Converter Remove and Install....965
    Monitor Controller (DSZ) Remove and Install....966
    Air Conditioner Controller (ACF) Remove and Install....968
    Key Switch Remove and Install....970
    Right Switch Console Remove and Install....971
    Left Switch Console Remove and Install....973
    Travel Alarm Remove and Install....975
    Heater Control Disable and Enable....977
    Disconnect Tab Retainer Connectors....978
    Disconnecting Spring Wire Clip Connectors....979
    Replace DEUTSCH™ Connectors....980
    Replace DEUTSCH™ Rectangular or Triangular Connectors....982
    Install DEUTSCH™ Contact....984
    Replace WEATHER PACK™ Connector....986
    Install WEATHER PACK™ Contact....988
    Replace (Pull Type) Metri-Pack™ Connectors....990
    Replace (Push Type) Metri-Pack™ Connectors....992
    Replace CINCH™ Connectors....993
    Install CINCH™ Contact....995
    Repair 32 and 48 Way CINCH™ Connectors....997
    Remove Connector Body from Blade Terminals....1001
Section 9020: Power Train....1002
  Group 05: Theory of Operation....893
    Track Adjuster and Recoil Spring Operation....1005
    Travel Gear Case Operation....1007
  Group 15: Diagnostic Information....1002
    Noisy or Loose Track Chain....1002
    Tight Track Chain....1002
    Frequent Track Chain Sag Adjustment Required....1002
    Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers....1002
    Bent Track Shoes....1002
    “Popping” of Track....1002
    Cracked Track Link....1002
    Chipped Link Rails....1002
    Individual Undercarriage Component Wear....1002
    Measure Swing Bearing Wear....1025
Section 9025: Hydraulic System....1029
  Group 05: Theory of Operation....893
    Hydraulic System Operation....1034
    Pilot System Operation....1035
    Pilot Pump, Pressure Regulating Valve and Filter Operation....1036
    Pilot Shutoff Solenoid Valve Operation....1038
    Pilot Control Valve Operation....1072
    Travel Pilot Control Valve Operation....1072
    Pilot Operation of Control Valve Operation....1072
    Pilot Signal Manifold Operation....1051
    Pump 1, Pump 2, and Drive Gear Case Operation....1060
    Pump 1 and Pump 2 Regulator Operation....1063
    Engine Speed Sensing Control Circuit Operation....1070
    Control Valve Operation....1072
    Control Valve Check Valves Identification and Operation....1084
    Main Relief Valve Circuit Operation....1088
    Circuit Relief and Anticavitation Valve Operation....1092
    Travel Flow Combiner Valve Operation....1094
    Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation....1097
    Boom Lower Meter-In Cut Valve Operation....1102
    Boom Regenerative Valve Circuit Operation....1105
    Dig Regenerative Valve Circuit Operation....1107
    Arm Regenerative Valve Circuit Operation....1112
    Bucket Regenerative Valve Circuit Operation....1118
    Boom and Arm Reduced Leakage Valves Operation....1120
    Arm 1 Flow Rate Control Valve Circuit Operation....1123
    Arm 2 Flow Rate Control Valve Circuit Operation....1128
    Bucket Flow Rate Control Valve Circuit Operation....1133
    Boom Flow Rate Control Valve Circuit Operation....1139
    Auxiliary Flow Rate Control Valve Circuit Operation....1144
    Blade Circuit Operation—If Equipped....1150
    Swing Reduction Gear Case Operation....1152
    Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation....1153
    Swing Motor Park Brake Release Circuit Operation....1156
    Center Joint Operation....1158
    Travel Motor and Park Brake Valve Operation....1160
    Travel Motor Speed Circuit Operation....1167
    Diesel Particulate Filter (DPF) Burn Solenoid Valves....1171
    Cylinder Operation....1173
    Return Filter Operation....1175
    Auxiliary System Operation....1176
    Auxiliary Pilot Control Valve Operation....1177
    Flow Rate Select Solenoid Valve Operation....1182
    Flow Rate Pressure Reducing Valve Operation....1184
    Auxiliary Shuttle Valve Operation....1185
    Auxiliary High Flow Line Kit Operation....1187
    Two Way Solenoid Kit Operation....1190
    Two Pump Combined Flow Kit Operation....1193
  Group 15: Diagnostic Information....1030
    All Hydraulic Functions Slow....1030
    Hydraulic Oil Overheats....1030
    No Hydraulic Functions....1030
    Poor Combined Operation....893
    All Functions Cannot Be Operated....1030
    Function Does Not Stop When Control Lever Released....1030
    Some Functions Cannot Be Operated, All Others Are Normal....1030
    All Functions Slow....1030
    Functions Move in Opposite Direction....1030
    All Dig Functions Slow or No Power....1030
    Some Dig Functions Slow (Not All)....1030
    Load Drifts Down When Control Lever is in Neutral Position....1030
    Load Falls When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle....1030
    H-P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal....1030
    Swing Speed Slow in Both Directions....1030
    Swing Speed Slow or Does Not Operate in One Direction....1030
    Upperstructure Drift with Swing Valve in Neutral....1030
    Swing Function Does Not Operate....1031
    Travel Park Brakes Do Not Apply....1031
    Track Will Not Move in One Direction....1031
    Track Will Not Move in Either Direction....1031
    Machine Mistracks at All Speeds in Both Directions....1031
    Slow Travel Speed or Low Power....1031
    Combined Travel and Dig Functions Slow or No Power....1031
    Travel is "Jerky "....1031
    Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline....1031
    Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs....1031
    Pump 1, Pump 2, and Pilot Pump Line Identification....1264
    Control Valve Line Identification....1266
    Swing Motor Line Identification....1269
    Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern....1270
    Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern....1272
    Pilot Signal Manifold-to-Control Valve Line Connection....1274
    Travel System Component Location....1277
    Travel Hydraulic System Line Connection....1279
    Blade Hydraulic System Component Location....1303
    Auxiliary Attachment Schematic....1283
    Auxiliary System Line Connections....1288
    Hydraulic System Schematic....1290
    Hydraulic System Component Location....1303
    Hydraulic System Line Connections....1305
  Group 25: Tests....1031
    JT05800 Digital Thermometer Installation....1307
    JT02156A Digital Pressure and Temperature Analyzer Kit Installation....1308
    General Hydraulic Oil Cleanup Procedure....1309
    Hydraulic Component Failure Cleanup Procedure....1312
    Hydraulic Oil Tank Pressure Release Procedure....1315
    Hydraulic Oil Warm-Up Procedure....1317
    Pilot Pressure Regulating Valve Test and Adjustment....1320
    Control Valve Spool Actuating Pilot Pressure Test....1324
    Dig Regenerative Solenoid Valve Test and Adjustment....1327
    Arm Regenerative Solenoid Valve Test and Adjustment....1332
    Power Dig Solenoid Valve Test and Adjustment....1337
    Arm 2 Flow Control Solenoid Valve Test and Adjustment....1342
    Torque Control Solenoid Valve Test and Adjustment....1347
    Pump Control Pilot Pressure Signal Test....1352
    Main Relief and Power Dig Valve Test and Adjustment....1355
    Circuit Relief Valve Test and Adjustment....1362
    Blade Main Relief Valve Test and Adjustment....1368
    Swing Motor Crossover Relief Valve Test and Adjustment....1372
    Travel Motor Crossover Relief Valve Test and Adjustment....1377
    Pump Regulator Test and Adjustment—Minimum Flow....1383
    Pump Regulator Test and Adjustment—Maximum Flow....1386
    Pump Flow Test....1389
    Comprehensive Pump Flow Test....1393
    Swing Motor Leakage Test....1399
    Travel Motor Leakage Test....1402
    Cylinder Drift Test—Boom, Arm, and Bucket....1406
Section 9031: Heating and Air Conditioning....1409
  Group 05: Theory of Operation....893
    Air Conditioning System Cycle of Operation....1412
  Group 15: Diagnostic Information....1409
    Air Conditioning System Does Not Operate....1409
    No Air Flow From Heater and Air Conditioner Vents....1409
    Air Conditioning Does Not Cool Interior of Cab....1409
    Air Conditioning Runs Constantly, Too Cold....1409
    Interior Windows Continue to Fog Using Air Conditioner....1409
    Heater System Does Not Operate....1409
    Heater Does Not Warm Interior of Cab....1409
    Interior Windows Continue to Fog Using Heater....1409
    Heater and Air Conditioner Component Location....1441
  Group 25: Tests....1409
    Refrigerant Cautions and Proper Handling....1444
    Heater and Air Conditioner Operational Checks....1445
    Air Conditioner Compressor Clutch Test....1448
    Refrigerant Leak Test....1449
    Refrigerant Hoses and Tubing Inspection....1450
    Air Conditioner Compressor Belt Check....1451
    R134a Air Conditioning System Test....1452
    Operating Pressure Diagnostic Chart....1455
Section 9900: Dealer Fabricated Tools....1456
  Group 99: Dealer Fabricated Tools....1456
    DFT1218 Split Flange Hose Cap....1458

EXCERPT:
Track Adjuster and Recoil Spring Operation
TX1031305-UN: Track Adjuster and Recoil Spring
LEGEND:
1 - Grease Fitting
2 - Valve
3 - Grease Relief Passage
4 - Cylinder
5 - Yoke
6 - Front Idler
7 - Piston
8 - Recoil Spring
9 - Grease
The track adjuster and recoil spring is supported by the track frame. Shock loads on the track and front idler (6) are absorbed by the recoil spring (8).
To decrease track sag, grease (9) is pumped into the cylinder (4) through the grease fitting (1). The grease pushes the piston (7) against the yoke (5) moving the front idler (6) out, reducing track sag. The grease fitting (1) is protected from excess pressure by a check ball.
CAUTION:
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