Complete diagnostic technical manual with Electrical Wiring Diagrams for John Deere 240LC-8B Excavators, with all the shop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere XCG240LC-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.
...

TM11478 English - John Deere XCG240LC-8B Excavator Technical Manual (Operation and Test).pdf
tm11607 Chinese - XCG240LC-8B Excavator Operation and Test

PRODUCT DETAILS:
Total Pages: 621 pages
File Format: PDF (Windows & Mac & Linux)
Language: English

MAIN SECTIONS
  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

TABLE OF CONTENTS...1
Section 9000: General Information...15
  Group 01: Safety...15
    Recognize Safety Information...18
    Follow Safety Instructions...19
    Operate Only If Qualified...20
    Wear Protective Equipment...21
    Avoid Unauthorized Machine Modifications...22
    Add Cab Guarding for Special Uses...23
    Inspect Machine...24
    Stay Clear of Moving Parts...25
    Avoid High-Pressure Fluids...26
    Avoid High-Pressure Oils...27
    Work In Ventilated Area...28
    Prevent Fires...29
    Prevent Battery Explosions...30
    Handle Chemical Products Safely...31
    Dispose of Waste Properly...32
    Prepare for Emergencies...33
    Use Steps and Handholds Correctly...34
    Start Only From Operator's Seat...35
    Use and Maintain Seat Belt...36
    Prevent Unintended Machine Movement...37
    Avoid Work Site Hazards...38
    Keep Riders Off Machine...40
    Avoid Backover Accidents...41
    Avoid Machine Tip Over...42
    Do Not Lift Objects...44
    Add and Operate Attachments Safely...45
    Park and Prepare for Service Safely...46
    Service Cooling System Safely...47
    Remove Paint Before Welding or Heating...48
    Make Welding Repairs Safely...49
    Drive Metal Pins Safely...50
Section 9001: Diagnostics...51
  Group 10: Advanced Display Unit (ADU) Diagnostic Trouble Codes...51
    000158.03 - Key Switch Voltage Voltage High...51
    000158.04 - Key Switch Voltage Voltage Low...51
    000168.03 - System Voltage Voltage High...51
    000168.04 - System Voltage Voltage Low...51
    000442.00 - Display Temperature Very High...51
    000442.01 - Display Temperature Very Low...51
    001491.11 - LCD Backlight Failure Cause Unknown...51
    003597.02 - 5.0 V Power Supply Intermittent...51
    003598.02 - 1.5 V Power Supply Intermittent...51
    003599.02 - 3.3 V Power Supply Intermittent...51
    523436.14 - ADU Watchdog See Manual...51
    523438.31 - Memory Error No Information...51
    523651.02 - Memory Stack Overflow Intermittent...51
    523773.03 - CAN High Voltage High...51
    523773.04 - CAN High Voltage Low...51
    523774.03 - CAN Low Voltage High...51
    523774.04 - CAN Low Voltage Low...51
    524076.10 - Info Button Stuck Bad Rate of Change...51
    524077.10 - Back Button Stuck Bad Rate of Change...51
    524078.10 - Menu Button Stuck Bad Rate of Change...51
    524080.10 - Down Arrow Button Stuck Bad Rate of Change...51
    524082.10 - Up Arrow Button Stuck Bad Rate of Change...51
  Group 20: Flex Load Controller (FLC) Diagnostic Trouble Codes...51
    000096.03 - Fuel Level Sensor Voltage High...51
    000096.04 - Fuel Level Sensor Voltage Low...51
    000100.01 - Engine Oil Pressure Very Low...51
    000100.03 - Engine Oil Pressure Voltage High...51
    000107.00 - Engine Air Filter Restriction Very High...51
    000107.03 - Engine Air Filter Restriction Voltage High...51
    000110.00 - Engine Coolant Temperature Very High...51
    000110.04 - Engine Coolant Temperature Voltage Low...52
    000167.03 - Alternator Output Voltage High...52
    000167.04 - Alternator Output Voltage Low...52
    000190.08 - Engine Speed Sensor Abnormal Frequency Input Data...52
    000632.06 - Engine Fuel Shutoff Current Above Normal...52
    000638.04 - Throttle Actuator Low Voltage...52
    000638.07 - Throttle Actuator Mechanical Failure or Calibration...52
    000638.09 - Throttle Actuator Abnormal Update Rate...52
    000638.12 - Throttle Actuator Bad Device or Component...52
    000638.13 - Throttle Actuator Out of Calibration...52
    000676.05 - Glow Plug Relay Current Low...52
    000676.06 - Glow Plug Relay Current High...52
    000677.05 - Engine Starter Relay Current Below Normal...52
    000677.06 - Engine Starter Relay Current Above Normal...52
    000742.05 - High Low Travel Speed Solenoid Current Below Normal...52
    000742.06 - High Low Travel Speed Solenoid Current Above Normal...52
    000882.05 - License Plate Light Current Below Normal...52
    000882.06 - License Plate Light Current Above Normal...52
    001041.04 - Start Signal Indicator Voltage Low...52
    001638.00 - Hydraulic Oil Temperature Very High...52
    001638.04 - Hydraulic Oil Temperature Voltage Low...52
    001713.01 - Hydraulic Oil Filter Restriction Very Low...52
    001713.03 - Hydraulic Oil Filter Switch Voltage High...52
    002040.09 - ADU CAN Communication Bad Update Rate...52
    002141.09 - SSM CAN Communication Bad Update Rate...52
    002177.09 - Throttle Actuator CAN Communication Bad Update Rate...52
    002354.05 - Right Frame Worklight Current Below Normal...52
    002354.06 - Right Frame Worklight Current Above Normal...52
    002386.05 - Rotary Beacon Light Current Below Normal...52
    002386.06 - Rotary Beacon Light Current Above Normal...52
    002400.05 - Boom Worklight Current Below Normal...52
    002400.06 - Boom Worklight Current Above Normal...52
    003509.03 - Sensor Supply 1 Voltage High...52
    003509.04 - Sensor Supply 1 Voltage Low...53
    003510.03 - Sensor Supply 2 Voltage High...53
    003510.04 - Sensor Supply 2 Voltage Low...53
    003511.03 - Sensor Supply 3 Voltage High...53
    003511.04 - Sensor Supply 3 Voltage Low...53
    003512.03 - Sensor Supply 4 Voltage High...53
    003512.04 - Sensor Supply 4 Voltage Low...53
    520544.01 - GPS Anti-Vandalism Switch Voltage Very Low...53
    520544.03 - GPS Anti-Vandalism Switch Voltage High...53
    520545.05 - Pressure Boost Solenoid Current Low...53
    520545.06 - Pressure Boost Solenoid Current High...53
    520546.04 - Pilot Enable Switch Voltage Low...53
    520547.04 - Pressure Boost Switch Voltage Low...53
    520548.04 - Travel Pressure Switch Voltage Low...53
    520549.04 - Boom Pressure Switch Voltage Low...53
    520551.06 - Travel Alarm Current High...53
    522141.05 - Main Pump Solenoid Current Below Normal...53
    522141.06 - Main Pump Solenoid Current Above Normal...53
    522427.04 - Front Wiper Park Voltage Low...53
    522429.05 - Pilot Enable Solenoid Current Below Normal...53
    522429.06 - Pilot Enable Solenoid Current Above Normal...53
    522434.05 - Front Wiper Low Speed Current Low...53
    522434.06 - Front Wiper Low Speed Current High...53
    522435.05 - Front Wiper High Speed Current Low...53
    522435.06 - Front Wiper High Speed Current High...53
    522797.05 - Front Washer Pump Current Low...53
    522797.06 - Front Washer Pump Current High...53
    522944.05 - Left Front Cab Worklight Current Below Normal...53
    522944.06 - Left Front Cab Worklight Current Above Normal...53
    522945.05 - Right Front Cab Worklight Current Below Normal...53
    522945.06 - Right Front Cab Worklight Current Above Normal...53
    523440.04 - Unswitched Power Voltage Low...53
    524089.03 - P1 Pump Pressure Sensor Voltage High...53
    524089.04 - P1 Pump Pressure Sensor Voltage Low...54
    524090.03 - P2 Pump Pressure Sensor Voltage High...54
    524090.04 - P2 Pump Pressure Sensor Voltage Low...54
    524096.02 - Throttle Dial Bad Input Data...54
  Group 30: Sealed Switch Module (SSM) Diagnostic Trouble Codes...54
    000629.12 - Controller Fault...54
    002033.09 - FLC CAN Communication Bad Update Rate...54
    520752.04 - Auto Idle Button Stuck...54
    520752.09 - Auto Idle Button Bad Update Rate...54
    520753.04 - Hydraulic Power Button Stuck...54
    520753.09 - Hydraulic Power Button Bad Update Rate...54
    520754.04 - Unused Button 19 Stuck...54
    520754.09 - Unused Button 19 Bad Update Rate...54
    520755.04 - Unused Button 20 Stuck...54
    520755.09 - Unused Button 20 Bad Update Rate...54
    523335.04 - Travel Alarm Cancel Button Stuck...54
    523335.09 - Travel Alarm Cancel Button Bad Update Rate...54
    523336.04 - Travel Setting Button Stuck...54
    523336.09 - Travel Setting Button Bad Update Rate...54
    523338.04 - Unused Button 23 Stuck...54
    523338.09 - Unused Button 23 Bad Update Rate...54
    523339.04 - Unused Button 22 Stuck...54
    523339.09 - Unused Button 22 Bad Update Rate...54
    523340.04 - Unused Button 21 Stuck...54
    523340.09 - Unused Button 21 Bad Update Rate...54
    523849.04 - Unused Button 16 Stuck...54
    523849.09 - Unused Button 16 Bad Update Rate...54
    523850.04 - Unused Button 15 Stuck...54
    523850.09 - Unused Button 15 Bad Update Rate...54
    523852.04 - Unused Button 14 Stuck...54
    523852.09 - Unused Button 14 Bad Update Rate...54
    523854.04 - Front Washer Button Stuck...54
    523854.09 - Front Washer Button Bad Update Rate...54
    523855.04 - Front Wiper Button Stuck...55
    523855.09 - Front Wiper Button Bad Update Rate...55
    523856.04 - Unused Button 11 Stuck...55
    523856.09 - Unused Button 11 Bad Update Rate...55
    523857.04 - Unused Button 10 Stuck...55
    523857.09 - Unused Button 10 Bad Update Rate...55
    523858.04 - Boom Worklight Button Stuck...55
    523858.09 - Boom Worklight Button Bad Update Rate...55
    523860.04 - Cab Front Worklight Button Stuck...55
    523860.09 - Cab Front Worklight Button Bad Update Rate...55
    523861.04 - Front Frame Worklight Button Stuck...55
    523861.09 - Front Frame Worklight Button Bad Update Rate...55
    523862.04 - Unused Button 6 Stuck...55
    523862.09 - Unused Button 6 Bad Update Rate...55
    523863.04 - Unused Button 5 Stuck...55
    523863.09 - Unused Button 5 Bad Update Rate...55
    523864.04 - Unused Button 4 Stuck...55
    523864.09 - Unused Button 4 Bad Update Rate...55
    523865.04 - Rotary Beacon Button Stuck...55
    523865.09 - Rotary Beacon Button Bad Update Rate...55
    523867.04 - Unused Button 2 Stuck...55
    523867.09 - Unused Button 2 Bad Update Rate...55
    523868.04 - Unused Button 1 Stuck...55
    523868.09 - Unused Button 1 Bad Update Rate...55
Section 9005: Operational Checkout Procedure...377
  Group 10: Operational Checkout Procedure...377
    Operational Checkout Procedure...377
Section 9010: Engine...404
  Group 05: Theory of Operation...404
    Engine Component Location...409
    Engine Fuel System Operation (S.N. —1000012)...413
    Engine Fuel System Operation (S.N. 1000013—)...414
    Engine Start Aid Operation...415
    Engine Speed Control System Operation...416
  Group 15: Diagnostic Information...404
    Isuzu CC-6BG1TRP Engine...418
    Engine Cranks But Will Not Start...404
    Engine Does Not Stop With Key Switch...404
  Group 20: Adjustments...404
    Engine Speed Control Linkage Check and Adjustment...422
    Fuel Shut-Off Actuator Adjustment...423
  Group 25: Tests...404
    Engine Speed Test...427
    Clamp-On Tachometer Installation...428
Section 9015: Electrical System...429
  Group 05: System Information...429
    Electrical Diagram Information...435
    Electrical Schematic Symbols...439
  Group 10: System Diagrams...429
    Fuse and Relay Specifications...444
    System Functional Schematic, Component Location, and Wiring Diagram Master Legend...447
    System Functional Schematic...451
    Left Frame Harness (W10) Component Location...455
    Left Frame Harness (W10) Wiring Diagram...457
    Middle Frame Harness (W11) Component Location...459
    Middle Frame Harness (W11) Wiring Diagram...464
    Right Frame Harness (W12) Component Location...466
    Right Frame Harness (W12) Wiring Diagram...468
    Load Center Harness (W13) Component Location...469
    Load Center Harness (W13) Wiring Diagram...471
    Cab Harness (W14) Component Location...473
    Cab Harness (W14) Wiring Diagram...475
    Right Console Harness (W15) Component Location...476
    Right Console Harness (W15) Wiring Diagram...477
    Cab Roof Harness (W16) Component Location...478
    Cab Roof Harness (W16) Wiring Diagram...480
    Boom Light Harness (W17) Component Location...481
    Boom Light Harness (W17) Wiring Diagram...482
    Diesel Fired Coolant Heater Harness (W18) Component Location...484
    Diesel Fired Coolant Heater Harness (W18) Wiring Diagram...486
  Group 15: Sub-System Diagnostics...429
    Controller Area Network (CAN) Theory of Operation...489
    Starting and Charging Circuit Theory of Operation...491
    Flex Load Controller (FLC) Circuit Theory of Operation...494
    Advanced Display Unit (ADU) Circuit Theory of Operation...499
    Fuel Shutoff Actuator Theory of Operation...501
  Group 16: Monitor Operation...430
    Advanced Display Unit (ADU)—Service Mode...506
    Advanced Display Unit (ADU)—Clear Codes...508
    Advanced Display Unit (ADU)—Enable Options...509
    Advanced Display Unit (ADU)—Throttle Actuator Cal...510
    Advanced Display Unit (ADU)—Telematic...511
    Advanced Display Unit (ADU) Screen is Blank Diagnostic Procedure...430
  Group 20: References...430
    Fuse and Relay Test...519
    Controller Area Network (CAN) Circuit Test...523
    Electrical Component Checks...531
    Electrical Component Specifications...536
    Solenoid Test...430
    Alternator Test...547
    Engine Speed Control Actuator Calibration...549
    Fuel Shut-Off Actuator Check...550
    Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors...430
    Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors...430
    Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact...430
    Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector...430
    Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact...430
    Replace (Pull Type) Metri-Pack™ Connectors...564
    Replace (Push Type) Metri-Pack™ Connectors...566
    Replace CINCH CINCH is a trademark of the Cinch Co. Connectors...430
    Install CINCH CINCH is a trademark of the Cinch Co. Contact...430
    Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors...430
    Remove Connector Body from Blade Terminals...575
Section 9020: Power Train...576
  Group 05: Theory of Operation...576
    Track Adjuster and Recoil Spring Operation...578
    Travel Gearbox Operation...579
  Group 15: Diagnostic Information...576
    Noisy or Loose Track Chain...576
    Tight Track Chain...576
    Frequent Track Tension Adjustment Required...576
    Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers...576
    Bent Track Shoes...576
Section 9025: Hydraulic System...594
  Group 05: Theory of Operation...594
    Hydraulic System Operation...598
    Pilot System Operation...599
    Pilot Pump Operation...600
    Pilot Shutoff Solenoid Valve Operation...601
    Pilot Control Valve Operation...622
    Travel Pilot Control Valve Operation...622
    Pilot Operation of Control Valve Operation...622
    Pilot Accumulator Manifold Operation...607
    Pilot Supply Manifold Operation...609
    Pilot Distribution Manifold Operation...610
    Pump 1 and Pump 2 Operation...612
    Pump 1 and Pump 2 Regulator Operation...614
    Control Valve Operation...622
    Control Valve Check Valves Identification and Operation...635
    Main Relief Valve Circuit Operation...638
    Circuit Relief and Anticavitation Valve Operation...640
    Flow Control Valve Operation...642
    Flow Combiner Valve Operation...644
    Arm Regenerative Valve Circuit Operation...646
    Boom and Arm Reduced Leakage Valves Operation...648
    Swing Reduction Gear Case Operation...650
    Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation...652
    Swing Motor Park Brake Release Circuit Operation...654
    Rotary Manifold Operation...655
    Travel Motor and Park Brake Valve Operation...657
    Travel Motor Speed Circuit Operation...658
    Cylinder Operation...659
    Return Filter Operation...660
  Group 15: Diagnostic Information...594
    All Hydraulic Functions Slow...594
    Hydraulic Oil Overheats...595
    No Hydraulic Functions...595
    Poor Combined Operation...595
    Function Does Not Stop When Control Lever Released...595
    Some Functions Cannot Be Operated, All Others Are Normal...595
    Some Functions Slow...595
    Function Moves in Opposite Direction...595
    Load Drifts Down When Control Valve Is In Neutral Position...595
    Load Falls When Control Valve Is Actuated To Raise Load With Engine Running at Slow Idle...595
    H (high power) Function Does Not Operate, S (Standard power) and L (low power) Mode Is Normal...595
    Swing Speed Slow In Both Directions...595
    Swing Speed Slow or Does Not Operate In One Direction...595
    Upperstructure Drift With Swing Valve In Neutral...595
    Swing Function Does Not Operate...595
    Travel Park Brakes Do Not Apply...595
    Track Will Not Move In One Direction...595
    Track Will Not Move In Either Direction...595
    Machine Mistracks at All Speeds In Both Directions...595
    Slow Travel Speed or Low Power...595
    Travel Is "Jerky"...595
    Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline...595
    Machine Will Not Turn Smoothly In One Direction or Park Brake Grabs...595
    Pump 1, Pump 2, and Pilot Pump Line Identification...722
    Control Valve Line Identification...724
    Swing Motor Line Identification...727
    Pilot Control Valve-to-Pilot Distribution Manifold Component Location—Excavator Pattern...729
    Pilot Control Valve-to-Pilot Distribution Manifold Component Location—Backhoe Pattern...731
    Pilot Distribution Manifold-to-Control Valve Line Connections...733
    Travel Hydraulic System Line Connections...747
    Hydraulic System Schematic...736
    Hydraulic System Component Location...745
    Hydraulic System Line Connections...747
  Group 25: Tests...596
    JT05800 Digital Thermometer Installation...749
    JT02156A Digital Pressure and Temperature Analyzer Kit Installation...750
    Hydraulic Oil Cleanup Procedure...751
    Hydraulic Oil Tank Pressure Release Procedure...752
    Hydraulic Oil Warmup Procedure...753
    Pilot Pressure Regulating Valve Test and Adjustment...755
    Control Valve Spool Actuating Pilot Pressure Test...757
    Pressure Boost Solenoid Valve Test...760
    Travel Speed Solenoid Valve Test and Adjustment...762
    Pump Control Pilot Pressure Signal Test...764
    System Relief Valve Test and Adjustment...766
    Circuit Relief Valve Test and Adjustment...770
    Swing Motor Crossover Relief Valve Test and Adjustment...776
    Travel Motor Crossover Relief Valve Test and Adjustment...779
    Pump Regulator Test and Adjustment—Minimum Flow...782
    Pump Regulator Test and Adjustment—Maximum Flow...785
    Pump Flow Test...787
    Swing Motor Leakage Test...790
    Travel Motor Leakage Test...792
    Cylinder Drift Test—Boom, Arm, and Bucket...795
Section 9031: Heating and Air Conditioning...798
  Group 05: Theory of Operation...798
    Air Conditioning System Cycle of Operation...801
  Group 15: Diagnostic Information...798
    Air Conditioning System Does Not Operate...798
    Air Conditioner Does Not Cool Interior of Cab...798
    Heater System Does Not Operate...798
    Heater Does Not Warm Interior of Cab...798
    Interior Windows Continue to Fog...798
    Heater and Air Conditioner Component Location...816
  Group 25: Tests...798
    Refrigerant Cautions and Proper Handling...818
    Heater and Air Conditioner Operational Checks...819
    Air Conditioner Compressor Clutch Test...822
    Refrigerant Leak Test...823
    Refrigerant Hoses and Tubing Inspection...824
    Operating Pressure Diagnostic Chart...825
Section 9900: Dealer Fabricated Tools...829
  Group 99: Dealer Fabricated Tools...829
    DFT1218 Split Flange Hose Cap...831

John Deere 240LC-8B Excavator Operation and Test Technical Manual (TM11478)