John Deere 650DLC Excavator Operation & Test Service Manual PDF (TM10008) - Diagnostics & Wiring Diagrams - TM10008 - John Deere 650DLC Excavators Technical Manual - Operation and Test.PDF

John Deere 650DLC Excavator Operation & Test Service Manual (TM10008)

TM10008 — Technical manual covering the Operation and Test procedures for John Deere 650DLC Excavators, provided as a PDF file.

Complete Diagnostic, Operation and Test manual with Electrical Wiring Diagrams for John Deere 650DLC Excavators, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 650DLC Excavators workshop Operation and Test 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.

Total Pages: 1,372 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Language: English

MAIN SECTIONS

Foreword

Technical Information Feedback Form

General Information

Safety

Diagnostics

Main Controller (MCF) Diagnostic Trouble Codes

Engine Control Module (ECM) Diagnostic Trouble Codes

Information Controller (ICF) Diagnostic Trouble Codes

Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Monitor Controller (MON) Diagnostic Trouble Codes

Operational Checkout Procedure

Operational Checkout Procedure

Engine

Theory of Operation

Diagnostic Information

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 System

Theory Of Operation

Diagnostic Information

Tests

Reference Material

Terminology Cross Reference Chart

tm10008 - 650DLC Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

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

Avoid Machine Tip Over

Use Special Care When Lifting Objects

Add and Operate Attachments Safely

Prevent Unintended Detonation of Explosive Devices

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostics

Group 10: Main Controller (MCF) Diagnostic Trouble Codes

Main Controller (MCF) Diagnostic Trouble Codes

11000.02 - Abnormal EEPROM

11001.02 - Abnormal RAM

11002.02 - Abnormal A/D Conversion

11003.03 - Abnormal Sensor Voltage

11004.02 - CAN Communication Error

11101.03 - Engine Speed Dial sensor Circuit Voltage High Input

11101.04 - Engine Speed Dial Sensor Circuit Voltage Low Input

11200.03 - Pump 1 Delivery Pressure Sensor Circuit Voltage High

11200.04 - Pump 1 Delivery Pressure Sensor Voltage Low

11202.03 - Pump 2 Delivery Pressure Sensor Circuit Voltage High

11202.04 - Pump 2 Delivery Pressure Sensor Voltage Low

11301.03 - Swing Pilot Pressure Sensor Circuit Voltage High

11301.04 - Swing Pilot Pressure Sensor Circuit Voltage Low

11302.03 - Boom Raise Pilot Pressure Sensor Circuit Voltage High

11302.04 - Boom Raise Pilot Pressure Sensor Circuit Voltage Low

11303.03 - Arm Roll-in Pilot Pressure Sensor Circuit Voltage High

11303.04 - Arm Roll-in Pilot Pressure Sensor Circuit Voltage Low

11400.03 - Pump 2 (5-Spool) Control Solenoid Valve Feedback Current High

11400.04 - Pump 2 (5-Spool) Control Solenoid Valve Feedback Current Low

11402.03 - Boom Flow Rate Solenoid (SF) Valve Feedback Current High

11402.04 - Boom Flow Rate Solenoid (SF) Valve Feedback Current Low

11404.03 - Power Dig Solenoid (SG) Valve Feedback Current High

11404.04 - Power Dig Solenoid (SG) Valve Feedback Current Low

11405.03 - Travel Speed Solenoid (SI) Valve Current Feedback High

11405.04 - Travel Speed Solenoid (SI) Valve Current Feedback Low

11410.03 - Pump 1 (4-Spool) Control Solenoid Valve Feedback Current High

11410.04 - Pump 1 (4-Spool) Control Solenoid Valve Feedback Current Low

11412.03 - Hydraulic Fan Pump Control Solenoid Valve Feedback Current High

11412.04 - Hydraulic Fan Pump Solenoid Valve Feedback Current Low

11802.03 - Boom Pressure Sensor Circuit Voltage High

11802.04 - Boom Pressure Sensor Circuit Voltage Low

11901.03 - Hydraulic Oil Temperature Sensor Circuit Voltage High

11901.04 - Hydraulic Oil Temperature Sensor Circuit Voltage Low

11910.02 - Actual Engine Speed Message Error

11911.02 - Security Signal Message Error

11914.02 - Radiator Coolant Temperature Message Error

11918.02 - Work Mode Message Error

11920.02 - Fuel Flow Rate Message Error

11976.03 - Auxiliary Valve 2 Feedback Current High

11976.04 - Auxiliary Valve 2 Feedback Current Low

11977.03 - Auxiliary Valve 1 Feedback Current High

11977.04 - Auxiliary Valve 1 Feedback Current Low

11980.03 - ATT Relief Change Valve Feedback Current High

11980.04 - ATT Relief Change Valve Feedback Current Low

11981.03 - Fan Reversing Solenoid Valve 2 Feedback Current High

11981.04 - Fan Reversing Solenoid Valve 2 Feedback Current Low

11982.03 - Fan Reversing Solenoid Valve 1 Feedback Current High

11982.04 - Fan Reversing Solenoid Valve 1 Feedback Current Low

11983.02 - Intake Air Temperature Message Error

11984.02 - Boost Temperature Message Error

11989.03 - Boom Mode Solenoid (SC) Valve Feedback Current High

11989.04 - Boom Mode Solenoid (SC) Valve Feedback Current Low

11991.03 - Travel Right Pilot Pressure Sensor Circuit Voltage High

11991.04 - Travel Right Pilot Pressure Sensor Circuit Voltage Low

11992.03 - Pump 2 (5-Spool) Control Pressure Sensor Circuit Voltage High

11992.04 - Pump 2 (5-Spool) Control Pressure Sensor Circuit Voltage Low

11993.03 - Travel Left Pilot Pressure Sensor Circuit Voltage High

11993.04 - Left Travel Pilot Pressure Sensor Circuit Low Input

11994.03 - Pump 1 (4-Spool) Control Pressure Sensor Circuit Voltage High

11994.04 - Pump 1 (4-Spool) Control Pressure Sensor Circuit Voltage Low

11995.03 - Arm Roll-Out Pilot Pressure Sensor Circuit Voltage High

11995.04 - Arm Roll-Out Pilot Pressure Sensor Circuit Low Input

11997.03 - Bucket Dump Pilot Pressure Sensor Circuit Voltage High

11997.04 - Bucket Dump Pilot Pressure Sensor Circuit Voltage Low

11998.03 - Boom Down Pilot Pressure Sensor Circuit Voltage High

11998.04 - Boom Down Pilot Pressure Sensor Circuit Voltage Low

11999.03 - Bucket Curl Pilot Pressure Sensor Circuit Voltage High

11999.04 - Bucket Curl Pilot Pressure Sensor Circuit Voltage Low

Group 20: Engine Control Module (ECM) Diagnostic Trouble Codes

Engine Control Module (ECM) Diagnostic Trouble Codes

91.02 - Accelerator Sensor 1-2 Comparison (P1271)

100.03 - Engine Oil Pressure Sensor Voltage Low (P0522)

100.04 - Engine Oil Pressure Sensor Voltage High (P0523)

102.03 - Boost Pressure Sensor Voltage Low (P0237)

102.04 - Boost Pressure Sensor Voltage High (P0238)

105.03 - Boost Temperature Sensor Voltage High (P1113)

105.04 - Boost Temperature Sensor Voltage Low (P1112)

108.03 - Barometric Pressure Sensor Voltage Low (P0107)

108.04 - Barometric Pressure Sensor Voltage High (P0108)

110.03 - Engine Coolant Temperature Sensor Voltage High (P0118)

110.04 - Engine Coolant Temperature Sensor Voltage Low (P0117)

157.00 - Common Rail Pressure—First Stage (P088)

157.00 - Common Rail Pressure—Second Stage (P088)

157.02 - Common Rail Pressure High (P0089)

157.03 - Common Rail Pressure Sensor Voltage High (P0193)

157.04 - Common Rail Pressure Sensor Voltage Low (P0192)

172.03 - Intake Air Temperature Sensor Voltage High (P0113)

172.04 - Intake Air Temperature Sensor Voltage Low (P0112)

174.03 - Fuel Temperature Sensor Voltage High (P0183)

174.04 - Fuel Temperature Sensor Voltage Low (P0182)

190.00 - Engine Overspeed (P0219)

628.02 - ROM Malfunction (P0601)

633.07 - Pressure Limiter Open (P1095)

636.02 - Camshaft Position Sensor (G-Sensor) Signal Missing (P0340)

636.02 - Camshaft Position Sensor (G-Sensor) Signal Mismatch (P0341)

636.07 - Camshaft Position Sensor (G-Sensor) out of Phase (P1345)

639.02 - CAN Communication Error (U2104)

639.03 - CAN Timeout (U2106)

651.03 - Open Circuit in Injection Nozzle #1 (P0201)

652.03 - Open Circuit in Injection Nozzle #2 (P0202)

653.03 - Open Circuit in Injection Nozzle #3 (P0203)

654.03 - Open Circuit in Injection Nozzle #4 (P0204)

655.03 - Open Circuit in Injection Nozzle #5 (P0205)

656.03 - Open Circuit in Injection Nozzle #6 (P0206)

723.02 - Crankshaft Position Sensor Signal Missing (P0335)

723.02 - Crankshaft Sensor Mismatch (P0336)

987.03 - Check Engine Lamp Malfunction (P0650)

1077.02 - CPU Fault Malfunction (P0606)

1079.02 - 5 Volt Power Supply #1 Malfunction (P1631)

1080.02 - 5 Volt Power Supply #2 Malfunction (P1632)

1239.01 - No Pump Pressure—First Stage (P1094)

1240.01 - No Pump Pressure Feed—Second Stage (P1093)

1347.00 - PCV #1 Open Circuit or Short to Ground (P0092)

1347.04 - PCV #1 Short to Power (P0091)

1348.00 - PCV # 2 Open Circuit or Short to Ground (P1291)

1348.04 - PCV #2 Short to Power (P1292)

1381.03 - Fuel Filter Pressure Sensor Voltage High (P1294)

1381.04 - Fuel Filter Pressure Sensor Voltage Low (P1293)

1485.02 - Engine Control Module Relay Malfunction (P1625)

10001.03 - EGR Position Sensor Malfunction (P0487)

10002.02 - EGR Valve Control Malfunction (P0488)

10003.02 - Injection Nozzle Common #1 Malfunction (P1261)

10004.02 - Injection Nozzle Common #2 Malfunction (P1262)

10005.01 - Charge Circuit Malfunction—Bank 1 (P0611)

10006.01 - Charge Circuit Malfunction—Bank 2 (P0612)

10007.02 - CPU Monitoring IC Malfunction (P0606)

10008.02 - A/D Conversion Malfunction (P1630)

10009.02 - 5 Volt Power Supply #3 Malfunction (P1633)

10010.02 - 5 Volt Power Supply #4 Malfunction (P1634)

10011.02 - 5 Volt Power Supply #5 Malfunction (P1635)

10013.02 - EEPROM Malfunction (P0603)

20100.02 - Engine Coolant Temperature High

20101.02 - Engine Warning

20110.02 - Fuel Filter Restricted (Level 1)

20110.02 - Fuel Filter Restricted (Level 2)

Group 30: Information Controller (ICF) Diagnostic Trouble Codes

Information Controller (ICF) Diagnostic Trouble Codes

14000.02 - Abnormal CAN Communication

14001.02 - ICF: Flash Memory: Read/Write Error

14002.02 - ICF: External RAM: Read/Write Error

14003.02 - ICF: EEPROM: Sum Check Error

14006.02 - ICF: Satellite Communication Terminal: Communication Error

14008.02 - ICF: Abnormal Internal RAM

14100.02 - Satellite Communication Terminal: Abnormal EEPROM

14101.02 - Satellite Communication Terminal: Abnormal IB/OB Queue

14102.02 - Satellite Communication Terminal: Abnormal Local Loop Back

14103.02 - Satellite Communication Terminal: The satellite is not found.

14104.02 - Satellite Communication Terminal: Fail 1 of Remote Loop Back

14105.02 - Satellite Communication Terminal: Fail 2 of Remote Loop Back

14106.02 - Satellite Communication Terminal: Sending and receiving data are mismatched

Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Air Conditioner Controller (ACF) Diagnostic Trouble Codes

E11 - Cab Air Temperature Sensor Open Circuit

E12 - Cab Air Temperature Sensor Short Circuit

E13 - Ambient Air Temperature Sensor Open Circuit

E14 - Ambient Air Temperature Sensor Short Circuit

E15 - Coolant Temperature Sensor Open Circuit

E16 - Coolant Temperature Sensor Short Circuit

E18 - Solar Sensor Abnormal

E21 - Freeze Control Switch Open Circuit

E22 - Freeze Control Switch Short Circuit

E43 - Abnormal Damper

E44 - Abnormal Damper

E45 - Abnormal Damper

E51 - Abnormal High/Low Pressure Switch

Group 50: Monitor Controller (MON) Diagnostic Trouble Codes

Monitor Controller (MON) Diagnostic Trouble Codes

13303.02 - Abnormal Thermister Temperature

13304.02 - Abnormal REG Input H Level

13306.02 - Abnormal EEPROM

13308.02 - Abnormal CAN Communication

13310.02 - Shorted circuit in Coolant Temperature Sensor

13311.03 - Shorted circuit in Fuel Level Sensor

13311.04 - Open circuit in Fuel Level Sensor

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Engine Component Location

Engine Fuel System Operation

Engine Cooling System Operation

Engine Lubrication System Operation

Engine Intake and Exhaust System Operation

Engine Turbocharger Operation

Exhaust Gas Recirculation (EGR) Operation

Quick On Start (QOS) System Operation

Engine Speed Control System Operation

Group 15: Diagnostic Information

Isuzu AH-6WG1XYSA-02

Diagnose Engine Malfunctions

Engine Cranks But Will Not Start

Engine Misfires Or Runs Irregularly

Engine Does Not Develop Full Power

Engine Overheats

Auto-Idle Does Not Work

Coolant Temperature Too Low

Coolant in Oil or Oil in Coolant

Low Engine Oil Pressure

High Engine Oil Pressure

Engine Uses Too Much Oil

Engine Uses Too Much Fuel

Engine Emits Excessive White Exhaust Smoke

Engine Emits Excessive Black or Gray Exhaust Smoke

Turbocharger Excessively Noisy or Vibrates

Oil Dripping From Turbocharger Adapter

Excessive Drag in Turbocharger Rotating Members

Fuel In Oil

Group 25: Tests