John Deere 160GLC Excavator 1FF160GX Repair Diagnostics & Tests Manual TM12342 (iT4/S3B) PDF - MJODTM12342.zip
Full Diagnosis & Tests Technical Guide, complete with electrical wiring schematics for the John Deere 160GLC Excavator, offering shop-level details so you can service, troubleshoot, and overhaul the machine like a seasoned professional technician.
The John Deere 160GLC Excavator Diagnosis & Tests service manual contains the following:
* 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.
TM12342 - John Deere 160GLC Excavator Operation and Test Technical Manual.pdf
tm12343 - John Deere Excavatrice 160GLC.pdf
tm12344 - John Deere Excavadora 160GLC.pdf
PRODUCT DETAILS:
Total Pages: 1,361 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English French Spanish
Models: John Deere - 160GLC Excavator - 1FF160GX__E055001 (iT4/S3B)
TABLE OF CONTENTS....1
Section 9000: General Information....19
Group 01: Safety....19
Recognize Safety Information....22
Follow Safety Instructions....23
Operate Only If Qualified....24
Wear Protective Equipment....25
Avoid Unauthorized Machine Modifications....26
Control Pattern Selector—If Equipped....27
Add Cab Guarding for Special Uses....28
Inspect Machine....29
Stay Clear of Moving Parts....30
Avoid High-Pressure Fluids....31
Avoid High-Pressure Oils....32
Work In Ventilated Area....33
Prevent Fires....34
Prevent Battery Explosions....35
Handle Chemical Products Safely....36
Decommissioning — Proper Recycling and Disposal of Fluids and Components....37
Exhaust Filter Ash Handling and Disposal....38
Prepare for Emergencies....39
Clean Debris from Machine....40
Use Steps and Handholds Correctly....41
Start Only From Operator's Seat....42
Use and Maintain Seat Belt....43
Prevent Unintended Machine Movement....44
Avoid Work Site Hazards....45
Keep Riders Off Machine....47
Avoid Backover Accidents....48
Inspect and Maintain ROPS....49
Avoid Machine Tip Over and Machine Damage....50
Use Special Care When Lifting Objects....52
Add and Operate Attachments Safely....53
Park and Prepare for Service Safely....54
Service Cooling System Safely....55
Remove Paint Before Welding or Heating....56
Make Welding Repairs Safely....57
Drive Metal Pins Safely....58
Clean Exhaust Filter Safely....59
Section 9001: Diagnostics....62
Group 10: Main Controller (MCZ) Diagnostic Trouble Codes....68
Main Controller (MCZ) Diagnostic Trouble Codes....68
Controller Area Network 0 (CAN 0) Circuit Diagnostics....69
Controller Area Network 1 (CAN 1) Circuit Diagnostics....70
Interface Controller Area Network (N-CAN) Diagnostics....71
Engine Controller Area Network (Engine CAN) Diagnostics....72
011000.02 - Abnormal EEPROM....62
011001.02 - Abnormal RAM....62
011002.02 - Abnormal A/D Converter....62
011003.03 - Abnormal Sensor Voltage....62
011006.02 - Engine Controller Communication Error....62
011007.02 - (CAN 0) Data Converter Communication Error 1....62
011008.02 - (CAN 1) Data Converter Communication Error 2....62
011009.02 - (CAN 0) Monitor Controller Communication Error 1....62
011010.02 - (CAN 1) Monitor Controller Communication Error 2....62
011100.02 - Abnormal Engine Speed....62
011101.03 - Engine Control Dial Sensor Circuit High Input....62
011101.04 - Engine Control Dial Sensor Circuit Low Input....62
011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input....62
011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input....62
011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input....62
011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input....62
011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input....62
011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input....62
011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input....62
011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input....62
011301.03 - Swing Pilot Pressure Sensor Circuit High Input....62
011301.04 - Swing Pilot Pressure Sensor Circuit Low Input....62
011302.03 - Boom Up Pilot Pressure Sensor Circuit High Input....62
011302.04 - Boom Up Pilot Pressure Sensor Circuit Low Input....62
011303.03 - Arm In Pilot Pressure Sensor Circuit High Input....62
011303.04 - Arm In Pilot Pressure Sensor Circuit Low Input....62
011304.03 - Travel Pilot Pressure Sensor Circuit High Input....63
011304.04 - Travel Pilot Pressure Sensor Circuit Low Input....63
011307.03 - Front Attachment Pilot Pressure Sensor Circuit High Input....63
011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input....63
011400.02 - Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback....63
011400.03 - Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current....63
011400.04 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current....63
011401.02 - Torque Control Solenoid Valve Abnormal Feedback....63
011401.03 - Torque Control Solenoid Valve Feedback High Current....63
011401.04 - Torque Control Solenoid Valve Feedback Low Current....63
011402.02 - 3-Spool Solenoid Valve Unit (SF) Abnormal Feedback....63
011402.03 - 3-Spool Solenoid Valve Unit (SF) Feedback High Input....63
011402.04 - 3-Spool Solenoid Valve Unit (SF) Feedback Low Input....63
011403.02 - 3-Spool Solenoid Valve Unit (SC) Abnormal Feedback....63
011403.03 - 3-Spool Solenoid Valve Unit (SC) Feedback High Input....63
011403.04 - 3-Spool Solenoid Valve Unit (SC) Feedback Low Input....63
011407.02 - 3-Spool Solenoid Valve Unit (SG) Abnormal Feedback....63
011407.03 - 3-Spool Solenoid Valve Unit (SG) Feedback High Input....63
011407.04 - 3-Spool Solenoid Valve Unit (SG) Feedback Low Input....63
011408.02 - 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback....63
011408.03 - 2-Spool Solenoid Valve Unit (SJ) Feedback High Input....63
011408.04 - 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input....63
011409.02 - 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback....63
011409.03 - 2-Spool Solenoid Valve Unit (SZ) Feedback High Input....63
011409.04 - 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input....63
011410.02 - Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback....63
011410.03 - Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current....63
011410.04 - Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current....63
011434.02 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal....63
011434.03 - Attachment Relief 1 (Upper) Proportional Solenoid Valve High....63
011434.04 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Low....63
011435.02 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal....63
011435.03 - Attachment Relief 2 (Lower) Proportional Solenoid Valve High....63
011435.04 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Low....64
011436.02 - Breaker Relief Proportional Solenoid Valve Abnormal....64
011436.03 - Breaker Relief Proportional Solenoid Valve High....64
011436.04 - Breaker Relief Proportional Solenoid Valve Low....64
011457.02 - 2-Speed Activation Solenoid Disconnected or Not Present....64
011458.02 - Selector Valve Solenoid Valve Disconnected or Not Present....64
011459.02 - Idle Stop Relay Circuit Malfunction....64
011810.03 - Electrical Lever Control Pressure 1 Sensor High....64
011810.04 - Electrical Lever Control Pressure 1 Sensor Low....64
011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input....64
011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input....64
020010.02 - Abnormal Exhaust Filter....776
020012.02 - Line Filter Restriction Alarm....64
020062.02 - Hydraulic Oil Temperature Alarm....64
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes....265
Engine Control Unit (ECU) Diagnostic Trouble Codes....265
000111.07 - Coolant Level Low—Moderately Severe Level....64
000111.17 - Coolant Level Low—Most Severe Level....64
000158.01 - Battery Voltage Low....64
000647.05 - Variable Speed Fan Solenoid Open Circuit....64
000647.06 - Variable Speed Fan Solenoid Short Circuit....64
000647.16 - Reversing Fan Switch Active Too Long....64
000676.05 - Glow Plug Relay Low Current....64
000676.06 - Glow Plug Relay High Current....64
000676.14 - Glow Plug Relay Output Low When Relay Active....64
000676.31 - Glow Plug Relay Output High When Relay Not Active....64
000898.09 - Requested Speed/Speed Limit....64
001638.09 - Hydraulic Temperature....64
001639.00 - Fan Speed High—Most Severe Level....64
001639.01 - Fan Speed Low—Most Severe Level....64
001639.18 - Fan Speed Low—Moderately Severe Level....64
003701.14 - Exhaust Filter Cleaning Not Required....64
005484.05 - Reversing Fan Solenoid Open Circuit....64
005484.06 - Reversing Fan Solenoid Short Circuit....65
Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes....300
Monitor Controller (DSZ) Diagnostic Trouble Codes....300
013002.02 - ECU Communication Error....65
013003.02 - Main Controller (MCZ) Communication Error 1....65
013004.02 - Main Controller (MCZ) Communication Error 2....65
013005.02 - Monitor Controller (DSZ) Communication Error 1....65
013006.02 - Monitor Controller (DSZ) Communication Error 2....65
013007.02 - Machine Controller (BCZ) Communication Error....65
020113.02 - System Error Alarm....65
Group 40: Information Controller (ICZ) Diagnostic Trouble Codes....309
Information Controller (ICZ) Diagnostic Trouble Codes....309
013303.02 - Abnormal Monitor Internal Temperature Sensor....65
013304.02 - Alternator Alarm....65
013311.03 - Fuel Level Sensor Open Circuit....65
013311.04 - Fuel Level Sensor Shorted Circuit....65
013334.02 - Radiator Coolant Error....65
014001.02 - Flash Memory Read\Write Error....65
014002.02 - External RAM Read\Write Error....65
014003.02 - Abnormal EEPROM....65
014023.02 - Security Error....65
020105.02 - Hydraulic Oil Filter Restriction Alarm....65
020109.02 - Pilot Control Shutoff Lever Alarm....65
020110.02 - Fuel Filter Restriction Alarm....65
Group 50: Air Conditioner Controller (ACF) Diagnostic Trouble Codes....328
Air Conditioner Controller (ACF) Diagnostic Trouble Codes....328
11 - Open Circuit in Air Recirculation Sensor....65
12 - Short-Circuited Air Recirculation Sensor....65
13 - Open Circuit in Ambient Air Temperature Sensor....65
14 - Short-Circuited Ambient Air Temperature Sensor....65
18 - Short-Circuited Solar Radiation Sensor....65
21 - Open Circuit in Air Conditioner Freeze Control Switch....65
22 - Short-Circuited Air Conditioner Freeze Control Switch....65
43 - Abnormal Air Conditioner and Heater Blower Port Change Servomotor....66
44 - Abnormal Air Conditioner and Heater Mixer Servomotor....66
91 - Communication Error....66
92 - CAN Bus Off Error....66
Section 9005: Operational Checkout Procedure....355
Group 10: Operational Checkout Procedure....355
Operational Checkout....422
Section 9010: Engine....488
Group 05: Theory of Operation....766
Engine Identification....492
John Deere Engine....512
Engine Fuel System Component Location....496
Engine Cooling System Component Location....497
Cold Weather Starting Aid....498
Engine Speed Control System Operation....766
Group 15: Diagnostic Information....488
John Deere Engine....512
Group 20: Adjustments....488
John Deere Engine....512
Group 25: Tests....488
John Deere Engine....512
Radiator Temperature Differential Check....513
Section 9015: Electrical System....516
Group 05: System Information....516
Electrical Diagram Information....529
Group 10: System Diagrams....516
Explanation of Wire Markings....538
Fuse and Relay Specifications....539
System Functional Schematic, Component Location, and Wiring Diagram Master Legend....548
System Functional Schematic....557
Cab Harness (W1) Component Location....578
Cab Harness (W1) Wiring Diagram....585
Machine Harness (W2) Component Location....594
Machine Harness (W2) Wiring Diagram....596
Monitor Harness (W3) Component Location....598
Monitor Harness (W3) Wiring Diagram....599
Engine Harness (W4) Component Location....601
Engine Harness (W4) Wiring Diagram....604
Engine Interface Harness (W5) Component Location....606
Engine Interface Harness (W5) Wiring Diagram....608
Pump Harness (W8) Component Location....610
Pump Harness (W8) Wiring Diagram....611
Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location....613
Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram....614
Service ADVISOR™ Remote (SAR) Harness (W10) Component Location....615
Service ADVISOR™ Remote (SAR) Switch Harness (W10) Wiring Diagram....616
Pilot Shutoff Switch Harness (W11) Component Location....618
Pilot Shutoff Switch Harness (W11) Wiring Diagram....619
Service ADVISOR™ Remote (SAR) Switch Resistor Harness (W12) Component Location....620
Service ADVISOR™ Remote (SAR) Switch Resistor Harness (W12) Wiring Diagram (S.N. 055984— )....621
Auxiliary Fuse Box Harness (W13) Component Location....622
Auxiliary Fuse Box Harness (W13) Wiring Diagram....623
Heated Air Seat Harness (W14) Component Location....625
Heated Air Seat Harness (W14) Wiring Diagram....626
Multi-Function Pilot Control Lever Harness (W15) Component Location....627
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram....629
Travel Alarm Cancel Switch Harness (W16) Component Location....630
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram....631
Attachment Harness (W17) Component Location....632
Attachment Harness (W17) Wiring Diagram....634
Rear Camera Harness (W19) Component Location....635
Rear Camera Harness (W19) Wiring Diagram....636
Pilot Shutoff Valve Harness (W21) Component Location....637
Pilot Shutoff Valve Harness (W21) Wiring Diagram....638
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location....639
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram....640
Reversing Fan Switch Harness (W23) Component Location....641
Reversing Fan Switch Harness (W23) Wiring Diagram....642
Seat Heater Switch Harness (W24) Component Location....643
Seat Heater Switch Harness (W24) Wiring Diagram....644
Travel Alarm Harness (W26) Component Location....645
Travel Alarm Harness (W26) Wiring Diagram....646
Starter Harness (W27) Component Location....647
Starter Harness (W27) Wiring Diagram....648
Starter Switch Harness (W29) Component Location....650
Starter Switch Harness (W29) Wiring Diagram....651
2-Speed Harness (W32) Component Location....652
2-Speed Harness (W32) Wiring Diagram....653
Fuel Injector Harness (W38) Component Location....654
Fuel Injector Harness (W38) Wiring Diagram....655
Glow Plug Harness (W40) Component Location....656
Glow Plug Harness (W40) Wiring Diagram....658
Heater and Air Conditioner Harness (W41) Component Location....659
Heater and Air Conditioner Harness (W41) Wiring Diagram....660
Starter Protection Jumper Harness (W42) Component Location....661
Starter Protection Jumper Harness (W42) Wiring Diagram....662
Heater and Air Conditioner Relay Harness (W51) Component Location....663
Heater and Air Conditioner Relay Harness (W51) Wiring Diagram....664
Auxiliary Solenoid Harness (W61) Component Location....666
Auxiliary Solenoid Harness (W61) Wiring Diagram....668
Satellite (SAT) Harness (W6003) Component Location....670
Satellite (SAT) Harness (W6003) Wiring Diagram....671
Group 15: Sub-System Diagnostics....518
Controller Area Network (CAN) Theory of Operation....766
Starting and Charging Circuit Theory of Operation....766
Monitor Controller (DSZ) Circuit Theory of Operation....766
Engine Control Unit (ECU) Circuit Theory of Operation....766
Exhaust Aftertreatment Circuit Theory of Operation....766
Main Controller (MCZ) Circuit Theory of Operation....766
Machine Controller (BCZ) Circuit Theory of Operation....766
Windshield Wiper and Washer Circuit Theory of Operation....766
Lighting Circuit Theory of Operation....766
Travel Alarm Circuit Theory of Operation....766
Pilot Shutoff Circuit Theory of Operation....766
Attachment Control Circuit Theory of Operation....766
Group 16: Monitor Operation....766
Service Menu....756
Troubleshooting....757
Monitoring....758
Controller Version....764
Issued Warning Record....765