PDF Operation & Test Technical Manual John Deere 245G LC Excavator - 10 MB
This technical manual for the John Deere 245G LC Excavator focuses on operation and testing procedures.
It is a vital resource for technicians needing to perform diagnostics and functional tests on the machine's various systems.
The manual provides specifications, testing steps, and troubleshooting charts to accurately identify and resolve performance issues.
Use this guide to ensure all systems are operating within factory specifications for optimal performance and reliability.
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--- Page 1 ---
245GLC
Excavator
Operation and Test
(PIN: 1FF245GX_ _E600001β )
OPERATION & TEST TECHNICAL
MANUAL
245GLC Excavator (PIN: 1FF245GX_
_E600001β )
TM12660 18APR18 (ENGLISH)
Worldwide Construction
And Forestry Division
PRINTED IN U.S.A.
--- Page 3 ---
Safety
Control Pattern SelectorβIf Equipped and area is large enough to operate machine functions.
Verify the machine response to each control movement.
This machine may be equipped with a control pattern
selector valve. Ensure all bystanders are clear of machine
DB84312,00000A5 -19-07JUL15-1/1
Add Cab Guarding for Special Uses Additional level II FOPS (falling object protective
Special work situations or machine attachments could structure), forestry protection packages, and special
create an environment with falling or flying objects. screens or guarding should be installed when falling
Working near an overhead bank, demolition work, using or flying objects could enter or damage the machine.
a hydraulic hammer or winch, working in a forestry A rear screen should always be used with a winch to
application or wooded area, or working in a waste protect against a snapping cable. Before operating in any
management application, for example, could require special work environments, follow the operator protection
added guarding to protect the operator. recommendations of the manufacturer of any specialized
attachment or equipment. Contact your authorized John
Deere dealer for information on protective guarding.
TX,CABGUARD -19-12FEB13-1/1
Inspect Machine
Inspect machine carefully each day by walking around it
before starting.
Keep all guards and shields in good condition and properly
installed. Fix damage and replace worn or broken parts
T6607AQ βUNβ15APR13
immediately. Pay special attention to hydraulic hoses and
electrical wiring.
TX,INSPECT -19-08SEP10-1/1
Stay Clear of Moving Parts
T133592 βUNβ15APR13
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting, or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard
or shield that has been removed for access as soon as
service or repair is complete.
TX,MOVING,PARTS -19-20JAN11-1/1
TM12660 (18APR18) 9000-01-3 041818
PN=11
--- Page 4 ---
Safety
Park and Prepare for Service Safely
Warn others of service work. Always park and prepare
machine for service or repair properly.
β’ Park machine on a level surface and lower equipment
to the ground.
T133332 β19β17APR13
β’ Place pilot shutoff lever in locked (UP) position. Stop
engine and remove key.
β’ Attach a βDo Not Operateβ tag in an obvious place in
the operator's station.
Securely support machine or attachment before working
under it.
Do Not Operate Tag
β’ Do not support machine with any hydraulically actuated
equipment.
β’ Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
β’ Do not support machine with a single jack or other
devices that may slip out of place.
Understand service procedures before beginning repairs.
TS229 βUNβ23AUG88
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
Support Machine Properly
OUT4001,000089A -19-02JUL15-1/1
Service Cooling System Safely
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
TS281 βUNβ15APR13
DX,RCAP -19-04JUN90-1/1
TM12660 (18APR18) 9000-01-13 041818
PN=21
--- Page 5 ---
Contents
Page Page
000172.04 β Intake Air Temperature 001239.01 β Pressure Decline
Sensor Circuit Low Input in Common Rail (No Pumping
(P0112)..................................................9001-20-5 Pressure) (P0093).................................9001-20-9
000173.00 β Abnormally High Exhaust 001239.31 β Pressure Decline
Temperature Sensor 1 (DPF Inlet) in Common Rail (No Pumping
(P0426) .................................................9001-20-5 Pressure) (Fuel Temperature less
000173.03 β Exhaust Temperature than 5Β° C) (P0093) ................................9001-20-9
Sensor 1 Circuit High Input (DPF 001239.17 β Pressure Decline in
Inlet) (P0428) ........................................9001-20-5 Common Rail (Lack of Pumping
000173.04 β Exhaust Temperature Pressure) (P1093).................................9001-20-9
Sensor 1 Circuit Low Input (DPF 001239.31 β Pressure Decline in
Inlet) (P0427) ........................................9001-20-6 Common Rail (Lack of Pumping
000174.03 β Combustion Pressure) (Fuel Temperature less
Temperature Sensor Circuit High than 5Β° C) (P1093) ................................9001-20-9
Input (P0183) ........................................9001-20-6 001347.03 β SCV Drive Circuit +
000174.04 β Combustion Short Circuit B (P0092) .........................9001-20-9
Temperature Sensor Circuit Low 001347.04 β SCV Drive Circuit
Input (P0182) ........................................9001-20-6 Open or Short Circuited to GND
000190.00 β Engine Overrun (P0091) .................................................9001-20-9
(P0219) .................................................9001-20-6 001381.03 β Fuel Filter Restriction
000628.02 β Abnormal ROM Sensor Circuit High Input
(P0601) .................................................9001-20-6 (P1294) ...............................................9001-20-10
000633.07 β Common Rail Pressure 001381.04 β Fuel Filter Restriction
Limiter Open (P0087)............................9001-20-6 Sensor Circuit Low Input
000636.02 β Abnormal Cam Angle (P1293) ...............................................9001-20-10
Sensor (No Signal) (P0340) ..................9001-20-6 001485.05 β Abnormal Main Relay
000636.07 β Phase Difference Circuit (Inactivation) (P0685)...............9001-20-10
Between Cam and Sensor 001485.06 β Abnormal Main
(P0016) .................................................9001-20-7 Relay Circuit (Kept Closed)
000639.02 β Abnormal CAN Time-Out (P0687) ...............................................9001-20-10
(U0101) .................................................9001-20-7 010001.02 β EGR Position Error
000639.19 β Abnormal CAN Bus (Brushless Type) (P0409) ...................9001-20-10
(U0073) .................................................9001-20-7 010001.13 β Abnormal EGR
000651.05 β Cylinder 1 Injector Circuit Zero-Point Calibration
Open (P0201)........................................9001-20-7 (P1404) ...............................................9001-20-10
000652.05 β Cylinder 2 Injector Circuit 010002.02 β Abnormal EGR Valve
Open (P0202)........................................9001-20-7 Control Circuit (P0404)........................9001-20-10
000653.05 β Cylinder 3 Injector Circuit 010003.02 β Abnormal Injector
Open (P0203)........................................9001-20-7 Common 1 Circuit (P2146)..................9001-20-11
000654.05 β Cylinder 4 Injector Circuit 010004.02 β Abnormal Injector
Open (P0204)........................................9001-20-7 Common 2 Circuit (P2149)..................9001-20-11
000723.02 β Crank Position Sensor 010005.01 β Abnormal Charge Circuit
Failure (No Signal) (P0335) ..................9001-20-8 (Bank 1) (P1261).................................9001-20-11
000723.02 β Crank Position 010006.01 β Abnormal Charge Circuit
Sensor Failure (Abnormal Signal) (Bank 2) (P1262).................................9001-20-11
(P0336) .................................................9001-20-8 010007.02 β Abnormal CPU Monitor
001077.02 β Abnormal CPU IC (P0606)...........................................9001-20-11
(P0606) .................................................9001-20-8 010008.02 β Abnormal A/D Converter
001079.02 β Abnormal 5V-Electric (P060B) ...............................................9001-20-11
Power Circuit #1 (P0641) ......................9001-20-8 010009.02 β Abnormal 5V-Electric
001080.02 β Abnormal 5V-Electric Power Circuit #3 (P0697) ....................9001-20-11
Power Circuit #2 (P0651) ......................9001-20-8 010010.02 β Abnormal 5V-Electric
001131.03 β Manifold Temperature Power Circuit #4 (P1655) ....................9001-20-12
Sensor Circuit High Input 010012.02 β Abnormal 12V Circuit
(P041C).................................................9001-20-8 (P0560) ...............................................9001-20-12
001131.04 β Manifold Temperature 010013.02 β Abnormal
Sensor Circuit Low Input EEPROM/Abnormal HDEEPROM
(P041D).................................................9001-20-8 (P1621) ...............................................9001-20-12
Continued on next page
TM12660 (18APR18) 9001-7 041818
PN=7
--- Page 6 ---
Main Controller (MCZ) Diagnostic Trouble Codes
011101.04 β Engine Control Dial Sensor Specification
Circuit Low Input 100-Pin Connector
(X3)βTorque.................................................................................10 NΒ·m
Engine control sensor circuit signal voltage is 89 lb.-in.
low. (Below 0.22 V)
NOTE: Machine controller (MCZ) has detected an
IMPORTANT: Avoid connector damage. Do not install electrical short in the 5 V signal circuit for multiple
connector with impact wrench or power tools. sensors and the engine speed dial (R15). Multiple
Over torquing will result in permanent damage MCZ diagnostic trouble codes (DTCs) may be
to connector. Torque only to specification. present. Continue following this procedure if DTCs
are only for the engine speed dial (R15).
RH60123,0000C6C -19-16APR18-1/6
Engine Control Dial Sensor Circuit Low Input Diagnostic Procedure
RH60123,0000C6C -19-16APR18-2/6
β’1 Connector Check Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
β’ Cab harness-to-switch panel connector 3 (X29) and cab harness-to-main controller
26-pin connector E (X36). See Cab Harness (W1) Component Location. (Group
9015-10.)
β’ Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness
(W2) Component Location. (Group 9015-10.)
β’ Cab harness-to-main controller 24-Pin connector E (X34). See Cab Harness (W1) YES: Go to Component
Component Location. (Group 9015-10.) Check.
Are connectors in good condition and free of corrosion and debris? NO: Repair or replace
connector. See appropriate
harness.
RH60123,0000C6C -19-16APR18-3/6
β’2 Voltage Check Key switch in OFF position.
Disconnect cab harness-to-switch panel connector 3 (X29).
Turn key switch to ON position.
Check voltage between pins 4 and 6 of cab harness-to-switch panel connector 3 (X29). YES: Go to Open Circuit
Check.
Is approximately 5 volts indicated? NO: Repair or replace
harness. See appropriate
harness.
RH60123,0000C6C -19-16APR18-4/6
β’3 Open Circuit Check Key switch in OFF position.
Cab harness-to-switch panel connector 3 (X29) disconnected.
Disconnect cab harness-to-main controller 24-pin connector D (X35).
Disconnect cab harness-to-main controller 26-pin connector E (X36).
Check for continuity between pin 5 of cab harness-to-switch panel connector 3 (X29) YES: Repair or replace
and pin 16 of cab harness-to-main controller 24-pin connector E (X35). harness. See appropriate
harness.
Is continuity indicated? NO: Go to Short Circuit
Check.
Continued on next page RH60123,0000C6C -19-16APR18-5/6
TM12660 (18APR18) 9001-10-7 PN=41
041818
--- Page 7 ---
Main Controller (MCZ) Diagnostic Trouble Codes
β’3 Voltage Check Key switch in OFF position.
Disconnect pump 3 delivery pressure sensor (B56).
Turn key switch to ON position.
Check between pin 2 of pump 3 delivery pressure sensor connector (B56) and machine YES: Go to Harness
ground for approximately 0.0 V. Check.
Is correct voltage indicated? NO: Repair or replace
harness. See appropriate
harness.
RH60123,0000C71 -19-12AUG15-5/6
β’4 Harness Check Key switch in OFF position.
Disconnect pump 3 delivery pressure sensor (B56).
Disconnect main controller connectors (X31βX36).
Check for continuity between pin 27 of cab harness-to-main controller 30-pin connector YES: Repair or replace
D (X34) to all pins on all main controller connectors. harness. See appropriate
harness.
Is continuity indicated between any circuits? NO: Checks complete.
RH60123,0000C71 -19-12AUG15-6/6
011203.04 β Pump 3 Delivery Pressure Over torquing will result in permanent damage
Sensor Circuit Low Input to connector. Torque only to specification.
Specification
Pump 3 delivery pressure sensor (B56) signal 100-Pin Connector
voltage is low. (Below 0.1 V) (X3)βTorque.................................................................................10 NΒ·m
89 lb.-in.
IMPORTANT: Avoid connector damage. Do not install
connector with impact wrench or power tools.
RH60123,0000C72 -19-12AUG15-1/7
Pump 3 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure
RH60123,0000C72 -19-12AUG15-2/7
β’1 Connector Check Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
β’ Pump 3 delivery pressure sensor (B56) and pump harness splice connector (X97).
See Pump Harness (W8) Component Location. (Group 9015-10.)
β’ Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main
controller 30-pin connector D (X34). See Cab Harness (W1) Component Location.
(Group 9015-10.)
β’ Pump harness-to-machine harness connector (X40). See Machine Harness (W2) YES: Go to Component
Component Location. (Group 9015-10.) Check.
Are connectors in good condition and free of corrosion and debris? NO: Repair or replace
connector. See appropriate
harness.
Continued on next page RH60123,0000C72 -19-12AUG15-3/7
TM12660 (18APR18) 9001-10-17 PN=51
041818
--- Page 8 ---
Main Controller (MCZ) Diagnostic Trouble Codes
β’2 Component Check NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 2 control pressure sensor (B38).
Disconnect pump 1 control pressure sensor (B36).
Connect pump 2 control pressure sensor connector (B38) to pump 1 control pressure
sensor (B36).
Clear MCZ diagnostic trouble codes.
Operate machine.
Check for active MCZ diagnostic trouble code 011208.04βPump 2 Flow Control YES: Go to Voltage Check.
Pressure Sensor Circuit Low Input.
Is code active? NO: Pump 2 control
pressure sensor (B38)
malfunction. Replace
sensor.
RH60123,0000C78 -19-20AUG12-4/7
β’3 Voltage Check Key switch in OFF position.
Disconnect pump 2 control pressure sensor (B38).
Turn key switch to ON position.
Check voltage between pin 1 and pin 3 of pump 2 control pressure sensor connector YES: Go to Open Circuit
(B38) for approximately 5 V.. Check.
Is correct voltage indicated? NO: Repair or replace
harness. See appropriate
harness.
RH60123,0000C78 -19-20AUG12-5/7
β’4 Open Circuit Check Key switch in OFF position.
Pump 2 control pressure sensor (B38) disconnected.
Disconnect cab harness-to-main controller 17-pin connector C (X33).
Check for continuity between pin 2 of pump 2 control pressure sensor connector (B38) YES: Go to Short Circuit
and pin 13 of cab harness-to-main controller 17-pin connector C (X33). Check.
Is continuity indicated? NO: Repair or replace
harness. See appropriate
harness.
RH60123,0000C78 -19-20AUG12-6/7
β’5 Short Circuit Check Key switch in OFF position.
Pump 2 control pressure sensor (B38) disconnected.
Check for continuity between pin 2 of pump 2 control pressure sensor connector (B38) YES: Repair or replace
and machine ground. harness. See appropriate
harness.
Is continuity indicated? NO: Checks complete.
RH60123,0000C78 -19-20AUG12-7/7
TM12660 (18APR18) 9001-10-27 041818
PN=61
--- Page 9 ---
Main Controller (MCZ) Diagnostic Trouble Codes
β’3 Voltage Check Key switch in OFF position.
Disconnect travel pressure sensor (B34).
Turn key switch to ON position.
Check between pin 2 of travel pressure sensor connector (B34) and machine ground YES: Go to Harness
for approximately 0.0 V. Check.
Is correct voltage indicated? NO: Repair or replace
harness. See appropriate
harness.
RH60123,0000C7F -19-12AUG15-5/6
β’4 Harness Check Key switch in OFF position.
Disconnect travel pressure sensor (B34).
Disconnect main controller connectors (X31βX36).
Check for continuity between pin 9 of cab harness-to-main controller 30-pin connector YES: Circuit is short to
D (X34) to all pins on all main controller connectors. power. Repair or replace
harness. See appropriate
harness.
Is continuity indicated between any circuits? NO: Checks complete.
RH60123,0000C7F -19-12AUG15-6/6
011304.04 β Travel Pilot Pressure Sensor Over torquing will result in permanent damage
Circuit Low Input to connector. Torque only to specification.
Specification
Travel pressure sensor (B34) signal voltage is 100-Pin Connector
low. (Below 0.1 V) (X3)βTorque.................................................................................10 NΒ·m
89 lb.-in.
IMPORTANT: Avoid connector damage. Do not install
connector with impact wrench or power tools.
RH60123,0000C80 -19-12AUG15-1/7
Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure
RH60123,0000C80 -19-12AUG15-2/7
β’1 Connector Check Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
β’ Travel pressure sensor (B34) and machine harness splice connector (X98). See
Machine Harness (W2) Component Location. (Group 9015-10.)
β’ Cab harness-to-machine harness 100-pin connector (X3), cab harness-to-main YES: Go to Component
controller 30-pin connector D (X34), and cab harness-to-main controller 26-pin Check.
connector E (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
Are connectors in good condition and free of corrosion and debris? NO: Repair or replace
connector. See appropriate
harness.
Continued on next page RH60123,0000C80 -19-12AUG15-3/7
TM12660 (18APR18) 9001-10-37 PN=71
041818
--- Page 10 ---
Main Controller (MCZ) Diagnostic Trouble Codes
β’3 Continuity Check Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (Y20).