Professional Documents
Culture Documents
Excavator
Operation and Tests
TECHNICAL MANUAL
200LC Excavator Operation and
Tests
TM1663 28NOV01 (ENGLISH)
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC 1929SEP981/1
OVERALL, how would you rate the quality of this publication? (Check one)
Company Name:
Technician Name:
Address:
Phone:
Fax No.:
THANK YOU!
TX,TM,FAX 1928NOV011/1
SECTION 9010Engine
Group 05Theory of Operation 9010
Group 10System Operational Checks
Group 15Diagnostic Information
Group 20Adjustments
Group 25Tests
9015
SECTION 9015Electrical System
Group 05System Information
Group 10System Diagrams
Group 15Sub-System Diagnostics
Group 20References
9020
SECTION 9020Power Train
Group 05Theory of Operation
Group 15Diagnostic Information
Group 20Adjustments
9025
SECTION 9025Hydraulic System
Group 05Theory of Operation
Group 15Diagnostic Information
Group 20Adjustment
Group 25Tests
9031
SECTION 9031Air Conditioning System
Group 05Theory of Operation
Group 10System Operational Checks
Group 15Diagnostic Information
Group 20Adjustments
INDX
Group 25Tests
9000
9005
9010
9015
9020
9025
9031
INDX
Section 9000
General Information
Contents
Page Page
9000
1907OCT88
TS231
TX,05,FF1611 1914JUN901/1
UN23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 1903MAR931/1
UN23AUG88
TS202
TX,05,FF1622 1914JUN901/2
TX,05,FF1622 1914JUN902/2
9000
01 Prevent Battery Explosions
2
UN23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16C (60F).
TS204
DX,SPARKS 1903MAR931/1
UN26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
DX,MSDS,NA 1903MAR931/1
9000
Prevent Acid Burns 01
3
UN23AUG88
If acid is swallowed:
TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.
DX,POISON 1921APR931/1
9000
01 Avoid High-Pressure Fluids
4
UN23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
and body from high pressure fluids.
DX,FLUID 1903MAR931/1
UN08JUN90
T7273AP
TX,05,RR,566 1923JUL911/1
9000
Park Machine Safely 01
5
TX,05,DH5002 1928MAY961/1
UN23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
TS229
Follow recommended procedures in this manual.
DX,LOWER 1924FEB001/1
TX,05,FF1615 1914JUN901/1
9000
01 Stay Clear of Moving Parts
6
UN08JUN90
T7273AS
TX,05,RR,572 1912JUN901/1
UN08JUN90
electric line than 3 m (10 ft) plus twice the line insulator
length.
T7273AD
TX,05,RR,594 1912JUN901/1
UN15JUN89
the machine. Do not use any controls as handholds.
TX,05,DH832 1916MAR921/1
9000
Keep Riders Off Machine 01
7
UN08JUN90
machine. Riders also obstruct the operators view resulting
in the machine being operated in an unsafe manner.
T7273AH
TX,05,RR,560 1905OCT901/1
UN08JUN90
Always keep the travel alarm in working condition. It
warns people when the machine starts to move.
T7273AL
the machine in congested areas. Coordinate hand signals
before starting the machine.
TX,05,FF1806 1905OCT901/1
DX,WEAR2 1903MAR931/1
9000
01 Protect Against Flying Debris
8
UN18OCT88
T6642DK
TX,05,FF1613 1914JUN901/1
UN23AUG88
uncomfortable loud noises.
TS207
DX,NOISE 1903MAR931/1
UN23AUG88
TS223
DX,LIGHT 1904JUN901/1
DX,LOOSE 1904JUN901/1
9000
Remove Paint Before Welding or Heating 01
9
UN23AUG88
Remove paint before heating:
TS220
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
DX,PAINT 1922OCT991/1
UN15MAY90
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH 1903MAR931/1
02T,05,J9 1907JAN911/1
9000
01 Use Proper Lifting Equipment
10
UN23AUG88
TS226
DX,LIFT 1904JUN901/1
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
UN23AUG88
to relieve pressure before removing completely.
TS281
DX,RCAP 1904JUN901/1
UN26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
DX,DRAIN 1903MAR931/1
9000
Work in a Clean Area 01
11
TX,05,FF1624 1914JUN901/1
UN08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
TX,05,FF1614 1914JUN901/1
DX,SIGNS1 1904JUN901/1
9000
01 Live With Safety
12
1907OCT88
TS231
DX,LIVE 1925SEP921/1
UN02JUN98
T115683
CED,TX08227,2993 1910FEB981/1
9000
02 200LC Specifications
2
UN03FEB98
T113215
ASprocket Center To Idler DRear End Swing Radius HCenter Of Sprocket To JUndercarriage Width
Center EOverall Width Center Of Sprocket KOverall Length
BUndercarriage Length FCab Height ITrack Shoe Width LTransport Height
CCounterweight Clearance GMinimum Ground
Clearance
NOTE: Specifications and design subject to change machine equipped with 800 mm (32 in.) shoes,
without notice. Wherever applicable, counterweight, 2.91 m (9 ft 7 in.) arm, 723 kg
specifications are in accordance with PCSA (1590 lb) 0.86 m 3 (1.12 yd 3) bucket, full fuel
and SAE standards. Except where otherwise tank, 79 kg (175 lb) operator and standard
noted these specifications are based on a equipment.
9000
Item Measurement Specification 02
3
CED,TX14740,6954 1907SEP002/2
9000
02 200LC Working Ranges
4
UN24MAR97
T102389
AMaximum Digging Reach BMaximum Digging Depth EMaximum Cutting Height GMinimum Swing Radius
A1Maximum Digging Reach CMaximum Vertical Wall FMaximum Dumping Height
At Ground Level DMaximum Digging Depth
(Flat Bottom)
9000
Item Measurement Specification 02
5
DMaximum Digging Depth (Flat Depth With 2220 mm (7 ft 3 in.) Arm: 5740
Bottom) mm (18 ft 10 in.)
Depth With 2910 mm (9 ft 7 in.) Arm: 6490
mm (21 ft 4 in.)
TX,115,DH5117 1915JUL962/2
9000
02 200LC Engine Specifications
6
TX,115,DH5114 1915JUL961/1
UN27SEP99
TORQ1A
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher grade. If
higher grade fasteners are used, these should only be tightened to
the strength of the original.
DX,TORQ1 1901OCT991/1
9000
03 Metric Bolt and Cap Screw Torque Values
2
UN07SEP99
TORQ2
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical property class. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher property class.
If higher property class fasteners are used, these should only be
tightened to the strength of the original.
DX,TORQ2 1901OCT991/1
9000
Additional Metric Cap Screw Torque Values 03
3
UN18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
UN18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
UN18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
Continued on next page 04T,90,M170 1929SEP991/2
9000
03 METRIC CAP SCREW TORQUE VALUESa
4
T-Bolt H-Bolt M-Bolt
Nominal
Dia Nm lb-ft Nm lb-ft Nm lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
Torque tolerance is 10%.
a
04T,90,M170 1929SEP992/2
9000
Check Oil Lines And Fittings 03
5
UN23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.
TX,90,DH1559 1901AUG941/1
9000
03 Service Recommendations for O-Ring Boss
6
Fittings
Straight Fitting
UN18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
T6243AE
3. Tighten fitting to torque value shown on chart.
9000
Angle Fitting 03
7
UN18OCT88
contacts face of boss.
T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.
04T,90,K66 1929SEP992/2
9000
03 Service Recommendations For Flat Face O-Ring Seal Fittings
8
1. Inspect the fitting sealing surfaces and O-ring. They fittings, use backup wrench on straight hose
must be free of dirt or defects. couplings.
2. Lubricate O-rings and install into grove using IMPORTANT: Tighten fittings to 150% of listed
petroleum jelly to hold in place. torque value if indexing is necessary
or if fitting is attached to an
3. Index angle fittings and tighten by hand pressing actuating devise.
joint together to insure O-ring remains in place.
Tighten fittings to 50% of listed
4. Tighten fitting or nut to torque value shown on the torque value if used in aluminum
chart. Do not allow hoses to twist when tightening housing.
04T,90,K67 1902MAR001/1
9000
Service Recommendations for 37 Flare and 03
9
30 Cone Seat Connectors
UN18OCT88
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6234AC
3. Align tube with fitting before attempting to start nut.
T82,BHMA,EL 1929SEP991/1
9000
03 Service Recommendations For Flared
10
ConnectionsStraight or Tapered Threads
UN18OCT88
2. Defects in the tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6873AE
3. Align the tube with the fitting before attempting to start
the nut.
Straight Thread
4. Lubricate the male threads with hydraulic fluid or
petroleum jelly.
UN18OCT88
fittings.
a
TORQUE CHART
T6873AD
b
Straight Thread Tapered Thread
Thread
Size Nm lb-ft Nm lb-ft
Tapered Thread
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434
Torque tolerance is 10%.
a
b
With seat face.
04T,90,M171 1928JAN921/1
9000
Service Recommendations For Inch Series Four Bolt Flange Fittings 03
11
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
04T,90,K174 1901AUG941/1
9000
03 Service Recommendations for Metric Series Four Bolt Flange Fitting
12
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Thread b
Nm lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42
04T,90,K175 1929SEP991/1
Consult your local fuel distributor for properties of the Fuel Lubricity should pass a minimum of 3100
diesel fuel available in your area. gram load level as measured by the BOCLE scuffing
test.
In general, diesel fuels are blended to satisfy the low Sulfur content:
temperature requirements of the geographical area in Sulfur content should not exceed 0.5% Sulfur
which they are marketed. content less than 0.05% is preferred.
If diesel fuel with sulfur content greater than 0.5%
Diesel fuels specified to EN 590 or ASTM D975 are sulfur content is used, reduce the service interval
recommended. for engine oil and filter by 50%.
DO NOT use diesel fuel with sulfur content
In all cases, the fuel shall meet the following greater than 1.0%.
properties: Bio-diesel fuels with properties and meeting DIN 51606
or equivalent specifications may be used.
Cetane Number 40 minimum. Cetane number
greater than 50 is preferred, especially for DO NOT mix used engine oil or any other type of
temperatures below -20C (-4F) or elevations above lubricant with diesel fuel.
1500 m (5000 ft).
Cold Filter Plugging Point(CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature.
TX,45,JC1132 1922MAY961/1
Diesel fuel must have adequate lubricity to ensure engine speed instability, hard starting, low power, and
proper operation and durability of fuel injection system engine smoke.
components.
Fuel lubricity should pass a minimum of 3100 gram
Diesel fuels for highway use in the United States and load level as measured by the BOCLE scuffing test.
Canada now require sulfur content less than 0.05%.
Diesel fuel in the European Union require sulfur ASTM D975 and EN 590 specifications do not require
content less than 0.05% as of 1 October 1996. fuels to pass a fuel lubricity test.
Experience shows that some low sulfur diesel fuels If fuel of low or unknown lubricity is used, add John
may have inadequate lubricity and their use may Deere PREMIUM DIESEL FUEL CONDITIONER (or
reduce performance in fuel injection systems due to equivalent) at the specified concentration. John Deere
inadequate lubrication of injection pump components. PREMIUM DIESEL FUEL CONDITIONER is available
The lower concentration of aromatic compounds in in winter and summer formulas. Consult your John
these fuels also adversely affects injection pump seals Deere engine distributor or servicing dealer for more
and may result in leaks. information.
TX,45,JC1771 1908JAN971/1
9000
04 Low Sulfur Diesel Fuel Conditioner
2
If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere PREMIUM DIESEL FUEL
CONDITIONER. It provides lubricating properties along
with other useful benefits, such as cetane improver,
anti-oxidant, fuel stabilizer, corrosion inhibitor and others.
John Deere PREMIUM DIESEL FUEL CONDITIONER is
specifically for use with low sulfur fuels. Nearly all other
diesel fuel conditioners only improve cold weather flow
and stabilize long-term fuel storage. They do not contain
the lubrication additives needed by rotary fuel injection
pumps.
TX,45,DH5857 1915AUG971/1
Proper fuel storage is critically important. Use clean Store diesel fuel in plastic, aluminum, and steel
storage and transfer tanks. Periodically drain water containers specially coated for diesel fuel storage.
and sediment from bottom of tank. Store fuel in a
convenient place away from buildings. Avoid storing fuel over long periods of time. If fuel is
stored for more than a month prior to use, or there is a
IMPORTANT: DO NOT store diesel fuel in slow turnover in fuel tank or supply tank, add a fuel
galvanized containers. Diesel fuel conditioner such as John Deere PREMIUM DIESEL
stored in galvanized containers FUEL CONDITIONER or equivalent to stabilize the fuel
reacts with zinc coating on container and prevent water condensation. John Deere
to form zinc flakes. If fuel contains PREMIUM DIESEL FUEL CONDITIONER is available
water, a zinc gel will also form. The in winter and summer formulas. Fuel conditioner also
gel and flakes will quickly plug fuel reduces fuel gelling and controls wax separation during
filters, damage injection nozzles and cold weather.
injection pump.
Consult your John Deere engine distributor or servicing
DO NOT use brass-coated containers dealer for recommendations and local availability.
for fuel storage. Brass is an alloy of Always follow manufacturers directions on label.
copper and zinc.
TX,45,JC1772 1908JAN971/1
9000
Fuel Tank 04
3
TX,45,DH5077 1901JUL961/1
MX,FLBT,C 1904JUN901/1
9000
04 Diesel Engine Oil
4
UN10OCT97
following:
TS1661
ACEA Specification E3
ACEA Specification E2
9000
Hydraulic Oil 04
5
UN10OCT97
Use the following oil when a biodegradable fluid is
required:
John Deere1BIO-HY-GARD
TS1660
Manufacturer Oil
Mobil DTE 25
Shell Tellus 46
Caltex Oil Rando Oil HD46
Texaco Inc. Rando Oil HD46
Chevron U.S.A. Inc. Chevron AW46
Esso Standard Oil NUTO H46
1
BIO-HY-GARD meets or exceeds the minimum biodegradability of 80%
within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD
should not be mixed with mineral oils because this reduces the
biodegradability and makes proper oil recycling impossible.
CED,TX14740,6951 1907JAN001/1
9000
04 Swing Gearbox, Propel Gearbox and Pump
6
Gearbox Oils
UN14MAR96
TS1653
EXTREME-GARD is a trademark of Deere & Company. OUOE003,0005424 1907SEP001/1
TX,45,DH5142 1909AUG961/1
9000
Track Adjuster, Working Tool Pivot, Swing 04
7
Bearing, and Swing Bearing Gear Grease
UN30JUN99
John Deere HD WATER RESISTANT GREASE
John Deere GREASE-GARD
TS1667
NLGI Performance Classification GC-LB
CED,TX14740,6952 1907JAN001/1
Oil Filters
DX,FILT 1918MAR961/1
9000
04 Lubricant Storage
8
Your equipment can operate at top efficiency only Make certain that all containers are properly marked to
when clean lubricants are used. identify their contents.
Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
DX,LUBST 1918MAR961/1
DX,ALTER 1918MAR961/1
9000
Mixing of Lubricants 04
9
In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet information and recommendations.
certain specifications and performance requirements.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
DX,LUBMIX 1918MAR961/1
9000
04
10
Page
9005
TX,9005,GG2241 1907SEP001/1
1/1
Engine OFF.
1/1
Are the hydraulic oil level (B), coolant level (C), and
engine oil level (D) indicator lights ON?
T102097 UN26JUL96
1/1
Engine OFF.
If oil level is high, check for fuel or anti-freeze. Drain a small amount of engine oil into
a clear container. Watch oil in container to see if anti-freeze or water accumulates at
the bottom. If oil is milky, moisture or anti-freeze may be present.
If oil is grainy, carbon may be present. Carbon in oil may result when engine runs at
slow idle too long.
If oil level is low, check for oil leaks or oil seal problems in engine.
Propel Lever and Pedal APropel Lever and Pedal Forward YES: Go to next check.
Dampener Checks BPropel Lever and Pedal Rearward
NO: Repair or replace
Engine OFF. propel pedal dampeners.
Go to Group 3360.
Push each propel lever and pedal forward (A), then
9005
release.
10
4
Pull each propel lever and pedal rearward (B), then
T7531AO UN07JUN91
release.
1/1
1/1
1/1
T102098 UN26JUL96
Start engine.
Push power mode HP mode (A) and E mode (B) select switches one at a time.
1/1
1/1
Engine RPM Dial Checks AEngine RPM Dial YES: Go to next check.
T102100 UN26JUL96
1/1
1/1
Does E mode indicator go out and engine speed increase to fast idle?
1/1
T111983 UN27OCT97
T112183 UN13NOV97
Check linkage and fast
idle speed stop at the
AHP (High Power) Mode Switch injection pump. Go to
BHP (High Power) Mode Indicator Group 9010-20.
Operate the arm in function over relief (arm cylinder fully extended).
1/1
T7351CB UN22AUG90
UNLOCKED
1/1
T7850AF UN22OCT92
Engine running.
1/1
Travel Alarm Stop Circuit ATravel Alarm Cancel Switch YES: Go to next check.
Check
NO: Check switch and
CAUTION: Machine will move during this wiring harness. Go to
check. Make sure area is clear, and large Group 9015-15.
enough to operate the machine.
9005
NOTE: Travel alarm must operate for this check. 10
9
T102919 UN08AUG96
Push propel pedals or levers and allow travel alarm to
operate for a minimum of 12 seconds.
1/1
Engine Blow-By Check Run engine at fast idle and check engine blow-by tube. YES: Go to next check.
Are fumes barely visible at the blow-by tube at fast idle, NO: If blow-by is
with no load? excessive. Do
compression pressure
NOTE: Excessive blow-by indicates that piston rings and test. (See CTM104.)
cylinder liners do not seal off the combustion chamber.
This is a comparative check that requires some
T7700AC UN10FEB92
experience to determine excessive blow-by.
1/1
Engine Parts Loose or Run engine at slow idle. YES: Go to next check.
Worn Check
Move hydraulic control lever to operate a hydraulic function over relief to put engine NO: Go to Abnormal
under load. Engine Noise, in Group
9010-15.
Does engine run smooth, no knocking or rattling noise?
1/1
1/1
Hydraulic Oil Tank Raise boom to full height, then lower boom to ground. YES: Go to next check.
Pressurization Check
Slowly loosen vent plug on hydraulic reservoir. NO: Replace cap.
1/1
1/1
Pump Gearbox Oil Level Pull dipstick from tube, check oil level. YES: Go to next check.
Check
Is oil level between marks? NO: Add oil if low.
T8187BB UN08MAR94
1/1
Swing Gearbox Oil Level Pull dipstick from tube, check oil level. YES: Go to next check.
Check
Is oil between marks? NO: Add oil if low.
9005
10
11
T8187BF UN08MAR94
1/1
T102071 UN16JUL96
Right Control Lever Decal
Push pilot shut-off lever to UNLOCKED position. Slowly move control levers to all
positions on decals.
1/1
T102198 UN19JUL96
Right Control Lever Decal
Push pilot shut-off lever to UNLOCKED position. Slowly move hydraulic levers to all
positions on decals.
1/1
1/1
Swing Circuit Leakage Run engine at slow idle. YES: Go to next check.
Check
Position machine on a side hill or raise one side of NO: Check swing circuit
machine 300 mm (1 ft) with the boom and put blocks leakage. Go to Group
under track. 9025-25.
9005
Position bucket 300 mm (1 ft) off the ground at
10
maximum reach.
13
T6479AZ UN19OCT88
Actuate bucket curl function over relief.
1/1
Dig Function Drift Check Run engine at slow idle. YES: Check cylinder drift.
Go to 9025-25. Inspect
Fill bucket with dirt. Position bucket at maximum reach reduced leakage valves
with bucket 2 in. (50 mm) above ground. for boom down and arm
in functions. Go to Group
Observe bucket for 1 minute. 3360.
Does bucket drift down to ground within 1 minute? NO: Go to next check.
T6290AF UN19OCT88
1/1
Control Valve Lift Check Run engine at slow idle. YES: If functions move in
Test opposite direction first, a
Position machine as illustrated. leak at the lift check valve
is indicated. Inspect lift
Slowly actuate pilot controller to lower boom, extend arm check valves. Go to
(retract cylinder), and dump bucket (retract cylinder). Group 3360.
1/1
Boom Up, Arm In, and Engine at fast idle. YES: Go to next check.
Bucket Combined
Operation Check Work mode selector in dig mode. NO: Inspect bucket flow
control valve in control
Actuate the boom up function, arm in function and then the bucket function. valve if boom speed
slows excessively. Go to
9005
Does boom continue to move at approximately the same speed after bucket function is Group 3360.
10
actuated?
14
1/1
Do both tracks move and machine does not mistrack excessively in forward or
reverse?
1/1
1/1
Does each track slow down in response to pedal or lever movement in order to turn?
1/1
T102104 UN26JUL96
1/1
Cycle TimesSpecification
Boom Raise (Cylinder Extend)Cycle
Time .............................................................................................................. 3.0 0.3 sec
Boom Lower (Cylinder Retract)Cycle
Time .............................................................................................................. 2.4 0.3 sec
Arm In (Cylinder Extend)Cycle Time ........................................................ 3.6 0.3 sec
Arm Out (Cylinder Retract)Cycle Time ..................................................... 2.4 0.3 sec
Bucket Load (Cylinder Extend)Cycle
Time .............................................................................................................. 3.3 0.3 sec
Bucket Dump (Cylinder Retract)Cycle
Time .............................................................................................................. 2.1 0.3 sec
Swing Left or Right3 Revolutions From
a Running StartCycle Time .................................................................... 13.1 1.0 sec
Propel 20 m (65 ft) From a Running
StartCheck Time in Forward and
Reverse Fast Speed PropelCycle
Time ............................................................................................................ 13.0 0.6 sec
Propel 20 m (65 ft) From a Running
StartCheck Time in Forward and
Reverse Slow Speed PropelCycle
Time ............................................................................................................ 20.6 1.0 sec
1/1
4 Undercarriage Checks
1/1
T7850AI UN22OCT92
Stop engine.
Measure distance between top of track shoe to center of lower surface of track frame.
Specification
Top of Track Shoe-to-Center of Lower
Surface of Track FrameDistance ........................ 300335 mm (11-3/1613-3/16 in.)
NOTE: If track sag is less than specified, track chain wear will be accelerated. If it is
less than specified on one side only, the machine may mistrack.
1/1
T6981AC UN13MAR89
Reverse drive side wear is generally more than forward
drive side wear.
1/1
Grouser Wear, Bent Inspect for worn grousers, bent track shoes, and loose YES: If shoe hardware is
Track Shoe, and Loose shoe hardware. loose, remove shoe and
Hardware Checks clean joint before
Are grouser bars worn excessively? tightening. Go to Group
0130.
Are track shoes bent?
9005
NO: Go to next check.
10
Is track shoe width appropriate for ground condition?
18
T7322AF UN21JUN90
Is track shoe hardware tight?
1/1
Track Link Roller and Inspect track links for pin boss wear. YES: Go to
Front Idler Wear Checks Undercarriage Appraisal
Do link pin boss areas indicate contact with roller flanges Manual for more in
or track guides? information and
specifications.
NOTE: Some contact or wear is normal. Excessive
contact or wear indicates excessive rail wear. NO: Go to next check.
T6484AZ UN19OCT88
Inspect front idler flanges.
1/1
5 Accessories Checks
1/1
NOTE: All accessories are powered from the fuse block. NO: Check fuses, monitor
If any accessories do not function, check fuses in fuse panel back light bulbs,
block. switches, and wiring. Go
to Group 9015-15.
9005
Turn key switch ON.
10
19
Turn light switch (A) to 1st position.
T102105 UN26JUL96
Are monitor panel back lights and front driving lights on?
1/1
1/1
1/1
Cab Dome Light Circuit ACab Dome Light Switch YES: Go to next check.
Check
Key switch ON. NO: Check fuse and
wiring harness. Go to
Move switch (A) to on position. Group 9015-15.
9005
Does cab dome light come on?
10
20
T102183 UN26JUL96
1/1
T102195 UN26JUL96
1/1
1/1
T102108 UN26JUL96
Does fan run in all four positions, then stop in OFF
position.
1/1
T124602 UN15SEP99
Later Models
Press heater temperature switch to maximum heat position. Press blower switch to
high speed position.
1/1
T124602 UN15SEP99
Later Models
All hose and line clamps must be in place and tight. Clamps must have rubber inserts
or cushions in place to prevent clamps from crushing or wearing into hoses or lines?
1/1
1/1
Inspect engine fan. Are fan blades in good condition, not worn, bent, broken, or
missing?
1/1
1/1
1/1 9005
10
23
T102507 UN29JUL96
Push seat height and angle adjustment lever (B) down. Raise and lower seat.
Push seat height and angle adjustment lever (B) down. Adjust angle of seat.
Push console and seat fore-aft adjustment lever (C) down. Move seat and both side
consoles forward and rearward. Release lever to lock seat and side consoles in
position.
Does lever unlock easily and then lock to hold seat and consoles in position?
Pull seat fore-aft adjustment lever (D) up. Move seat forward and rearward. Release
lever to lock seat in any position.
Pull backrest adjustment lever (E) up. Tilt seat back forward and rearward. Release
lever to lock seat back in any position.
Does lever unlock and lock easily to hold seat back in position?
1/1
9005
10
25
T102109 UN26JUL96 T102110 UN26JUL96
ALock Pins
BRear Latch
CCab Frame Rear Holes
NOTE: The upper right window lock pin is also used to close the windshield wiper
enable switch so windshield wiper can operate. When window is closed, check that
lock pins engage holes in cab frame and are turned to engage lock.
Pull window up and back until it catches in rear latch (B) for convenient storage
overhead.
Slide the two lock pins into the cab frame rear holes (C) and turn to lock.
Do pins engage cab frame rear holes and lock window securely in full open position?
1/1
ALock Pins
BBrackets
CHoles
NOTE: Upper front window must be raised before lower window can be removed from
window frame.
Store window behind the rear console. Slide lock pins into hole (C) in brackets (B).
1/1
1/1
Cab Door Window Slide both windowpanes open and closed? YES: Go to next check.
Checks
Do both windowpanes slide freely in the molding? NO: Inspect and clean
channel in molding.
Slide windowpanes to the closed position. Repair or replace. Go to
Group 1810.
Do latches engage catches and hold windowpanes
closed.
T116423 UN15JUL98
1/1
T102205 UN26JUL96 Pull on handle (B) to pull cover down until lock pins
click into position and hold cover closed.
1/1
Cab Door Latch and ACab Door Catch Release Lever YES: Go to next check.
Catch Checks
Open cab door. Push door open until door engages NO: Inspect. Repair or
catch and is held in open position. replace.
1/1
Cab Door Lock Check From outside cab, close cab door. YES: Go to next check.
Insert ignition key into door lock, turn clockwise 1/4 turn NO: Inspect. Repair.
to lock.
1/1
Left and Right Access Insert ignition key into lock and turn 180 clockwise to YES: Go to next check.
Doors Lock Check lock.
NO: Inspect. Repair.
Turn key 180 counterclockwise to unlock.
Does lock turn easily and lock door and cap in position?
1/1
9005
10
28
T7351AH UN22AUG90 T7425AF UN04DEC90
1/1
Open hood.
T102128 UN26JUL96
Engage hold-open rod (A).
1/1
1/1
Coolant Level and Engine OFF and cool. YES: Go to next check.
Condition In Recovery
Tank Checks Open radiator access door. NO: Add coolant if low.
Drain and flush overflow
Inspect coolant level and coolant condition in recovery tank and radiator, replace
tank. coolant if dirty or rusty. If
9005
coolant is oily check for
10
Is coolant level between FULL and LOW marks on hydraulic or engine oil
29
recovery tank? leaks into cooling system.
T7414AB 1913DEC90
Go to CTM104.
Is coolant clear, not oily, foamy, or rust colored?
1/1
AGasket
BSpring
CSeal
Does cap have a stop position that requires it to be pushed down to remove?
1/1
T6488FZ UN19OCT88
Remove radiator cap.
1/1
Coolant Hoses and Are radiator and heater hoses free of twists, kinks, cracks, leaks, or wear from rubbing YES: Go to next check.
Clamps Checks on adjacent parts?
NO: Replace hoses as
Are hose clamps tight and installed correctly? required. Install and
tighten hose clamps.
1/1
Fan Shroud and Fan Check fan to fan shroud clearance. YES: Go to next check.
Guard Checks
Is fan centered in shroud? NO: Adjust fan shroud to
center fan. Repair or
Is guard free of damage? replace guard. Tighten
loose hardware. Replace
9005
Are all mounting brackets and hardware tight? fan shroud if needed. Go
10
to Group 0510.
31
T6488GC UN23AUG93
1/1
1/1
Fan Blades Check Are fan blades bent or twisted? YES: Replace fan. Go to
Group 0510.
Are fan blades cracked or nicked?
NO: Go to next check.
T7694AH UN21MAY03
1/1
Fan Direction Check Is fan installed correctly with concave (cupped) side YES: Go to next check.
(arrow) of fan blade towards engine?
NO: Install fan correctly.
NOTE: If fan is installed backwards, about 50% of its
capacity is lost.
9005
10
32
T6171CB UN25MAY89
1/1
Radiator Outside Air Inspect radiator screen for mud and debris. YES: Go to next check.
Flow Check
Inspect radiator fins for mud and debris. NO: Clean screen. Clean
outside of radiator.
Inspect radiator for bent or damaged fins. Straighten fins. Replace
radiator if severely
Are radiator fins free of mud, leaves, grass, and other debris? damaged.
1/1
Fan Belt Check Is fan belt free of oil or grease? YES: Go to next check.
Is inside surface of belt free of cracks or frayed edges? NO: Replace belt if oily,
greasy, cracked, or
Is belt aligned with pulleys? otherwise damaged.
Adjust fan belt if loose.
Is fan belt adjustment correct? Go to Group 0510.
1/1
Engine Head Gasket Seal Engine at normal temperature. YES: Head gasket is OK.
Check Go to next check.
Radiator full.
NO: If there is a constant
Install radiator cap and tighten. flow of bubbles from tube,
loose or damaged
9005
Place end of radiator overflow hose into a container of cylinder head or a leaking
10
clear water. head gasket may be
33
indicated. Go to CTM104,
T6171AR UN25MAY89
Operate engine at fast idle. Load engine by holding a Engine Repair.
hydraulic function over relief.
1/1
1/1
Air Filter Restriction Run engine at slow idle. YES: Go to next check.
Indicator and Switch
Check Slowly cover air intake tube. NO: Check monitor circuit
fuse, air filter restriction
Does air filter restriction indicator light in cab come ON? indicator light and switch.
Go to Section 9015-15.
T118761 UN03DEC98
1/1
Air Cleaner Unloader AAir Cleaner Unloader Valve YES: Go to next check.
Valve Check
Open right access door. NO: Replace unloader
valve.
Inspect air cleaner unloader valve (A).
9005
Is unloader valve slightly open when the engine is not
10
running?
34
Is rubber flexible and showing no sign of becoming hard
or brittle?
Engine running.
Turn auto-idle switch off and turn engine rpm dial to fast
idle.
T7531BF UN07JUN91
1/1
1/1
Check that starting fluid can is installed in starting aid solenoid (A).
If starting fluid can is NOT installed, check that dust cover (B) is installed.
Is starting fluid line from starting aid solenoid to air intake manifold straightNOT
kinked or broken?
(Early Models) Is arrow on starting aid nozzle pointing AGAINST air flow of air intake
manifold?
NOTE: It may be necessary to scrape paint from nozzle to see arrow or red dot.
(Later Models) Is starting aid nozzle installed so that orifice hole (C) is pointing
AGAINST air flow?
1/1
Exhaust Smoke Check Operate engine until engine coolant temperature gauge YES: Go to Diagnose
needle is in the GREEN zone before doing this check. Engine Malfunctions,
Group 9010-15.
Run engine at fast idle.
NO: Go to next check.
Counter rotate tracks to put load to engine.
1/1
9005 1/1
10
36
Fuel Tank Interior Check IMPORTANT: Be careful not to damage fuel gauge sender float or low fuel level YES: Drain fuel, dispose
sending unit. of contaminated fuel
properly. Remove debris,
Remove fuel cap. clean bottom of tank.
Replace fuel filters.
Use a flashlight to inspect bottom of fuel tank by shining light through the fuel. Check primary fuel filter
(water separator).
Is dirt, debris, or contamination seen in tank?
NO: Go to next check.
1/1
Fuel Tank Sump Check AFuel Tank Drain Valve YES: Drain until clear fuel
flows or drain all fuel from
Hold a clean container under fuel tank drain valve (A). tank, dispose of
contaminated fuel
Remove recessed hex plug. properly. Replace fuel
filters, check primary fuel
Open drain valve for a few seconds and catch fuel in filter (water separator).
container.
T7700AA UN18FEB92
NO: Go to next check.
Check condition of fuel in container.
1/1
Primary Fuel Filter Inspect fuel in primary fuel filter (water separator) YES: Open drain valve to
(Water Separator) Check sediment bowl. drain water and
contamination into a
Is water or other contamination present? container. Dispose of
contaminated fuel
properly.
1/1
ABleed Screw
Open bleed screw (A) on fuel filter and operate hand primer on fuel transfer pump.
Does fuel come out of bleed screw when hand primer is operated?
Is resistance felt when hand primer is initially pumped and increase as system
pressure increases?
1/1
ABleed Screw
BHand Primer
Open bleed screws (A) on final fuel filter and primary fuel filter.
Push and release hand primer (B) until fuel flows from bleed screw on primary fuel
filter. Tighten bleed screw.
Continued to operate hand primer until fuel flows from bleed screw on final fuel filter.
Tighten bleed screw.
Disconnect fuel return hose at final fuel filter. NO: Fuel supply is
restricted, check for
Connect a hose to fitting on final fuel filter to route excess fuel into a container. plugged fuel filters,
plugged fuel tank cap
9005
Start engine and run at fast idle. vent, restricted lines,
10
stuck injection pump
38
Put engine under load by operating a hydraulic function over relief. overflow valve, or a
malfunctioning fuel
Observe fuel flow from hose. transfer pump. Repair or
replace as necessary.
Does fuel flow from hose with engine under load?
NOTE: Fuel that flows through the fuel return hose is excess fuel not required by the
engine and flows back to the fuel tank.
1/1
11 Visual Inspection
1/1
T6477AQ UN19OCT88
Stop the engine. Repair or replace
damaged components.
Inspect oil lines and hydraulic components for leaks or
damage. NO: Operational checkout
is complete.
Are lines or components damaged or leaking?
1/1
Page Page
Group 20Adjustments
POWERTECH 6.8 L (6068) John Deere
EngineUse CTM104 . . . . . . . . . . . . . . . .9010-20-1
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
Fuel Shut-Off Solenoid Linkage
Check and Adjust . . . . . . . . . . . . . . . . . . .9010-20-2
Engine Speed Check . . . . . . . . . . . . . . . . . .9010-20-5
Injection Pump Fast and Slow Idle Stops . . .9010-20-6
Engine Speed Control Motor . . . . . . . . . . . . .9010-20-8
Engine Speed Learning Procedure . . . . . . .9010-20-10
Cooling System Fill and Deaeration . . . . . .9010-20-12
Group 25Tests
POWERTECH 6.8 L (6068) John Deere
EngineUse CTM104 . . . . . . . . . . . . . . . .9010-25-1
9010
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
9010
05
POWERTECH is a trademark of Deere & Company. TX,9010,SB103 1906SEP961/1 1
EngineSectional View
9010
05
2
UN28NOV89
L103403
1Rocker Arm Shaft 7Crankshaft 12Cylinder Liner 17Fuel Injection Nozzle
2Cylinder Head 8Crankshaft Counterweight 13Piston 18Valve Spring
3Push Rod 9Oil Pan 14Piston Pin 19Rocker Arm
4Cam Follower 10Connecting Rod 15Piston Rings 20Balancer Shafts (some
5Camshaft 11Liner Packing Rings 16Valve 4-cylinder engines only)
6Cylinder Block
TX,9010,SB105 1906SEP961/1
The fan drive (C), driven by one fan belt from the engine
crankshaft (D), is self adjustable. The fan belt tension
adjuster (F) automatically adjusts the belt to correct
tension.
AAlternator Pulley
BIdler Pulley
CFan Pulley
DCrankshaft Pulley 9010
EWater Pump Pulley 05
FTension Adjuster 3
UN29AUG96
T103369
TX,9010,SB106 1906SEP961/1
9010
05
4
1927MAY98
T115408
AEngine RPM Dial GEngine Learning Switch KPump Pressure Sensor OAuto-Idle Switch
CEngine and Pump HArm In Pilot Pressure (2 used) PEngine Speed Sensor
Controller Switch LEC Sensor (N Sensor)
DEngine Control Motor IPropel Pressure Switch ME Mode Switch QEngine Speed Control
EInjection Pump JDig Pressure Switch NHP Mode Switch Circuits
FKey Switch
The engine speed control circuits (Q) have the HP (high power) mode control
following control functions: E (economy) mode control
Auto-idle mode
Slow to fast idle in standard mode Engine learning control
1927MAY98
mode switches sends an electrical signal to the engine
and pump controller (C). The controller senses the
electrical signal and then from the stored data sends an
electrical signal to the engine control motor (D). The
T115409
engine control motor regulates engine speed by a
push-pull cable attached to the fuel injection pump lever
located in the pump drive housing.
AEngine RPM Dial
BSwitch Panel
The engine speed sensor (P) (located in the pump drive
CEngine and Pump Controller
housing) counts the pump drive gear teeth as the gears DEngine Control Motor
rotate. This senses actual engine speed. The sensing EInjection Pump
signal is sent to the engine and pump controller (C) which PEngine Speed Sensor (N Sensor)
calculates engine speed.
CED,OUOE035,146 1918APR002/2
9010
05
6
1927MAY98
T115580
AEngine RPM Dial CEngine Control Motor DEngine and Pump EEngine RPM Dial Speed
BEC Sensor Controller Control Circuit
The function of the engine rpm dial speed control rpm dial. The EC (engine control) sensor (B) sends an
circuit (E) is to control engine speed from slow to fast electrical feedback signal to the controller indicating
idle in standard mode in response to the position of the motors position.
engine rpm dial (A).
The engine speed for slow idle is limited by the slow
As the engine rpm dial is turned to increase or idle stop bracket. The data for slow idle position is
decrease engine speed, the electrical signal sent from stored in the engine and pump controller and is used
the dial to the engine and pump controller (D) to calculate the positions for auto-idle, E (economy),
changes. Then, from data stored in the controller, the and HP (high power) modes. (See Engine Learning
controller sends an electrical signal to actuate the Control Circuit Operation in this group. For adjustment,
engine control motor (C). The control motor moves the see Injection Pump Fast and Slow Idle Stops
injection pump lever by a push-pull cable to change Adjustment in Group 9010-20.)
engine speed in response to the position of the engine
The engine speed for fast idle in standard mode is The fast idle stop bracket on the injection pump limits
controlled by data stored in the engine and pump the maximum engine speed for HP mode. (For
controller. The parameter for fast idle in standard adjustment, see Injection Pump Fast and Slow Idle
mode can be change from the factory setting within a Stops Adjustment in Group 9010-20.)
specified range. (See Excavator Diagnostic Program
Special FunctionEngine Speed in Group 9025-25.)
9010
05
CED,OUOE003,1053 1918APR002/2 7
9010
05
8
1927MAY98
T115581
AEngine RPM Dial CEngine Control Motor EE Mode Switch FE (Economy) Mode Speed
BEC Sensor DEngine and Pump Control Circuit
Controller
The function of E (economy) mode speed control When E mode is actuated, the engine and pump
circuit (F) is to operate the engine at a lower speed controller (D) sends electrical signals to the engine
range when full engine power is not needed. The control motor (C) to run the engine in a speed range
engine power is somewhat less but digging power is lower than standard mode. The adjustable range for
the same as in standard mode. Operating in E mode engine speed is from the specified speed for E mode
also improves fuel efficiency and reduces the noise down to slow idle and is in proportion to the engine
level. The E mode function is available when dig mode rpm dial position. The electrical signals to the motor
is selected as the work mode. The E mode indicator is are calculated from data stored in the engine and
ON when the E mode switch (E) is push down to show pump controller (D). The EC (engine control) sensor
that E mode is actuated. (B) sends an electrical feedback signal to the controller
indicating the motors position.
NOTE: Standard mode is when the E mode and HP
mode switches are OFF.
The parameter for engine speed in E (economy) mode Special FunctionEngine Speed Adjustment in Group
can be change from the factory setting within a 9025-25.)
specified range. (See Excavator Diagnostic Software
CED,OUOE003,1054 1918APR002/2
9010
05
9
9010
05
10
1927MAY98
T115582
AHP Mode Switch DArm In Pressure Sensor GRear Pump JEC Sensor
BEngine RPM Dial EPump Pressure Sensors HEngine Control Motor KHP (High Power) Mode
CPilot Controller FFront Pump IEngine and Pump Controller Speed Control Circuit
The function of the HP (high power) mode speed Engine speed is approximately 1600 rpm or faster.
control circuit (K) is to increase engine speed when a The electrical signal from the engine rpm dial (B) to
little more hydraulic power is needed for arm in the engine and pump controller (I) indicates the
operation. The HP mode is available when in the dig engine speed.
work mode. HP mode is used in the standard and E Arm in function is actuated. The arm in pressure
(economy) modes. sensor (D) sends an electrical signal to the engine
and pump controller (I).
The HP mode is actuated with the following conditions: The pump delivery pressure is approximately 23 440
kPa (234 bar) (3400 psi) or higher. The pump
HP mode switch (A) is pushed down. The HP pressure sensors (E) send an electrical signal to the
indicator is ON. engine and pump controller.
When all conditions are meet, the engine and pump load on the engine. The maximum engine speed for
controller sends an electrical signal to the engine HP mode is limited by the fast idle stop bracket on the
control motor to increase the engine speed. The injection pump. (For adjustment, see Injection Pump
amount of engine speed increase is somewhat Fast and Slow Idle Stops Adjustment in Group
controlled by the pump regulators adjustment and the 9010-20.)
9010
05
CED,OUOE003,1055 1918APR002/2 11
9010
05
12
1927MAY98
T115583
AEngine RPM Dial DEngine and Pump FPropel Pressure Switch HAuto-Idle Mode Speed
BEC Sensor Controller GDig Pressure Switch Control Circuit
CEngine Control Motor EAuto-Idle Switch
The function of the auto-idle mode speed control circuit motor reduces the engine speed to the specified
(H) is to automatically reduce engine speed when all auto-idle speed. The electrical signal sent to the motor
dig and propel function are in neutral to reduce fuel is calculated from data stored in the engine and pump
consumption and the noise level. The AI indicator is controller. The EC (engine control) sensor (B) sends
ON when the auto-idle switch (E) is pushed to show an electrical feedback signal to the controller indicating
that the auto-idle function is actuated. Pushing the the motors position.
switch again turns the auto-idle function off.
Actuating the propel or a dig function causes an
When auto-idle function is actuated and no electrical electrical signal to be sent from the propel or dig
signal is received from the propel or dig pressure pressure switch to the controller. The controller then
switches (F and G) for more than four seconds, the sends an electrical signal to the engine control motor
engine and pump controller (D) sends an electrical to increase engine speed back to the setting of engine
signal to the engine control motor (C). The control rpm dial.
The parameter for auto-idle engine speed can be range. (See Excavator Diagnostic Software Special
change from the factory setting within a specified FunctionEngine Speed in Group 9025-25.)
CED,OUOE003,1056 1918APR002/2
9010
05
13
9010
05
14
1927MAY98
T115584
AEngine RPM Dial DEngine and Pump EKey Switch GEngine Speed Learning
BEC Sensor Controller FEngine Learning Switch Control Circuit
CEngine Control Motor
The function of the engine speed learning control the engine and pump controller by the EC (engine
circuit (G) is to learn the slow idle position as control) sensor (B). The slow idle position data is
determined by the slow idle stop bracket on the stored in the engine and pump controller.
injection pump and to store that data in the engine and
pump controller (D). The position of the engine control motor for auto-idle
mode, E (economy) mode, and fast idle in standard
When the engine learning switch (F) is pushed up to mode is based on the slow idle position data stored in
the learning position and the key switch (E) is turned the engine and pump controller.
on, the engine control motor (C) is driven by an
electrical signal from the engine and pump controller When the following components are repaired or
(D). The control motor moves the injection pump lever replaced, or when engine speeds deviate from
to the slow idle position (the end of slot in slow idle specification, the engine control motor adjustment and
stop bracket). An electrical feedback signal engine learning control procedure must be performed.
corresponding to the slow idle position is sent back to
9010
05
CED,OUOE003,1057 1918APR002/2 15
9010
05
16
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
9010
10
POWERTECH is a trademark of Deere & Company. TX,9010,SB109 1906SEP961/1 1
This procedure is designed so the mechanic can make problem is indicated, you will be given repair required
a quick check of the engine using a minimum amount and group location or CTM number. If verification is
of diagnostic equipment. If you need additional needed, you will be given next best source of
information, read Theory of Operation, Group 9010-05. information:
A location will be required which is level and has Group 10 (System Operational Checks)
adequate space to complete the driving checks.
Group 15 (Diagnostic Information)
The engine and all other major components must be at
operating temperature for some checks. A tachometer Group 20 (Adjustments)
is required.
Group 25 (Tests)
Locate system check in the left column and read
completely, following this sequence from left to right. CTM (Component Technical Manual)
Read each check completely before performing.
TX,9010,SB110 1918SEP001/1
1/1
Coolant Level and Engine OFF and cool. YES: Go to next check.
Condition In Recovery
Tank Check Open radiator access door. NO: Add coolant if low.
Drain and flush overflow
Inspect coolant level and coolant condition in recovery tank and radiator, replace
tank. coolant if dirty or rusty. If
coolant is oily, check for
Is coolant level between FULL and LOW marks on hydraulic or engine oil
recovery tank? leaks into cooling system.
T7414AB 1913DEC90
Go to CTM104.
Is coolant clear, not oily, foamy, or rust colored?
9010
10
2 1/1
1/1
AGasket
BSpring
CSeal 9010
10
3
CAUTION: Prevent possible injury. DO NOT remove radiator cap unless
engine is cool. When engine is hot and cap is removed, hot coolant or
steam will spray out causing serious burns.
Does cap have a stop position that requires it to be pushed down to remove?
T6488FZ UN19OCT88
Remove radiator cap.
1/1
Radiator Outside Air Open engine access door. YES: Clean outside of
Flow Check radiator and straighten
Open left rear access door. fins if bent. Replace
radiator if severely
Inspect radiator screen for mud and debris. damaged.
Are radiator fins free of mud, leaves, grass, and other debris? NO: Go to next check.
Is radiator damaged?
9010
10
4 1/1
Coolant Hoses and Are radiator and heater hoses free of twists, kinks, cracks, leaks or wear from rubbing YES: Go to next check.
Clamps Check on adjacent parts?
NO: Replace or untwist
Are hose clamps tight and installed correctly? hoses as required.
Tighten or reinstall hose
clamps.
1/1
Water Pump Check AWeep Hole YES: Seal (B) has failed.
BSeal Replace seal or water
pump. Go to CTM104,
Engine stopped. Cooling System.
T7690AC UN27JAN92
1/1
Engine Head Gasket Seal Engine at normal temperature. YES: Head gasket is OK.
Check Go to next check.
Radiator full.
NO: If there is a constant
Install radiator cap and tighten. flow of bubbles from tube,
loose or damaged
Place end of radiator overflow hose into a container of cylinder head or a leaking
clear water. head gasket may be
T6171AR UN25MAY89
indicated. Go to CTM104
Operate engine at fast idle. Load engine by holding a Engine Repair.
hydraulic function over relief.
1/1
Fan Blades Check Are fan blades bent or twisted? YES: Replace fan.
9010
10
T7694AH UN21MAY03 5
1/1
Fan Direction Check Is fan installed correctly with cupped portion side (Arrow) YES: Go to next check.
of fan away from radiator?
NO: Install fan correctly.
NOTE: If fan is installed backwards, about 50% of its
capacity is lost.
T6488GB UN23AUG93
1/1
Fan Shroud and Fan Check clearance between fan and fan shroud. YES: Go to next check.
Guard Check
Is fan centered in shroud? NO: Adjust fan shroud if
fan is not centered.
Is guard free of damage? Repair or replace guard.
Tighten loose hardware.
Are all mounting brackets and hardware tight? Replace fan shroud if
needed.
T6488GC UN23AUG93
1/1
Fan Belt Check Is fan belt free of oil or grease? YES: Go to next check.
Is inside surface of belt free of cracks or frayed edges? NO: Replace fan belt if
oily, greasy, cracked or
Is belt aligned with pulleys? otherwise damaged.
Repair or replace
NOTE: Fan belt is self-adjusting. tightener if belt is loose.
9010
10
6 1/1
1/1
Air Filter Restriction Run engine at slow idle. YES: Go to next check.
Indicator and Switch
Check Slowly cover air intake tube. NO: Check monitor circuit
fuse, air filter restriction
Does air filter restriction indicator light in cab come ON? indicator light and switch.
Go to Group 9015-15.
T118761 UN03DEC98
1/1
Air Cleaner Unloader AAir Cleaner Unloader Valve YES: Go to next check.
Valve Check
Open left front access door. NO: Replace unloader
valve.
Inspect unloader valve (A).
Engine running.
T7531BF UN07JUN91
1/1
1/1
Check that starting fluid can is installed in starting aid solenoid (A).
If starting fluid can is NOT installed, check that dust cover (B) is installed.
Is starting fluid line from starting aid solenoid to air intake manifold straightNOT
kinked or broken?
(Early Models) Is arrow on starting aid nozzle pointing AGAINST air flow of air intake
manifold?
NOTE: It may be necessary to scrape paint from nozzle to see arrow or red dot.
(Later Models) Is starting aid nozzle installed so that orifice hole (C) is pointing
AGAINST air flow.
1/1
Exhaust Smoke Check Operate engine until coolant temperature gauge needle YES: Go to Diagnose
is in the GREEN zone before doing this check. Engine Malfunctions,
Group 9010-15.
Run engine at fast idle.
NO: Go to next check.
Counter rotate tracks to put load to engine.
9010 NOTE: Dark black smoke can be caused by dirty air filter
10 or poor fuel delivery. Blue smoke can be caused by worn
8 or damaged piston rings or cylinder liners. Gray or white
smoke can be caused by a cold engine, dirty injection
nozzles, or both.
1/1
1/1
T103525 UN10SEP96
Engine OFF.
If oil level is high, check for fuel or anti-freeze. Drain a small amount of engine oil into
a clear container. Watch oil in container to see if anti-freeze or water accumulates at
the bottom.
If oil level is low, check for oil leaks or oil seal problems in engine.
1/1
Engine Oil Condition Remove dipstick and check oil condition. YES: Change oil and
Check filter. Check condition of
Is oil milky or grainy? oil after a few hours
operation to determine if
If oil is milky, moisture or anti-freeze may be present. a problem exists. Go to
Group 9000-04 or
If oil is grainy, carbon may be present. Diagnose Engine
Malfunctions Group
Carbon in oil may result when engine runs at slow idle too long. 9010-15.
1/1
Engine Oil Pressure DEngine Oil Pressure Indicator YES: Go to next check.
Switch and Indicator
Check Turn key switch from OFF to ON and observe engine oil NO: Stop engine if engine
pressure indicator. oil pressure indicator
remains ON after engine
Does indicator (D) come ON and stay ON? starts. Go to Group
9010-15 Diagnose Engine
Start engine and observe engine oil pressure indicator. Malfunctions or CTM104.
If engine oil pressure
Does indicator go OFF a few seconds after engine indicator does not come
starts? ON, go to Group 9015-15
Monitor Controller and
9010 Display Circuit Diagnostic
10 Procedures.
10
T103526 UN09SEP96
1/1
1/1
Fuel Tank Interior Check IMPORTANT: Be careful not to damage fuel gauge sender float or low fuel level YES: Drain fuel, dispose
sending unit. of contaminated fuel
properly. Remove debris,
Remove fuel cap. clean bottom of tank.
Replace fuel filters.
Use a flashlight to inspect bottom of fuel tank by shining light through the fuel. Check water separator.
1/1
Fuel Tank Sump Check ADrain Valve YES: Drain until clear fuel
flows or drain all fuel from
Hold a clean container under fuel tank drain valve (A). tank, dispose of
contaminated fuel
Remove recessed hex plug. properly. Replace fuel
filters, check water
Open drain valve for a few seconds and catch fuel in separator.
container.
NO: Go to next check.
T7700AA UN18FEB92
Check condition of fuel in container.
1/1
Primary Fuel Filter Inspect fuel in primary fuel filter (water separator). YES: Replace primary
(Water Separator) Check fuel filter (water
Is water or other contamination present? separator) element.
T7700AB UN25FEB92
9010
10
1/1 11
ABleed Screw
Open bleed screw (A) on fuel filter and operate hand primer on fuel transfer pump.
Does fuel come out of bleed screw when hand primer is operated?
Is resistance felt when hand primer is initially pumped and increase as system
pressure increases?
1/1
Disconnect fuel return hose from leak-off line. NO: Fuel supply is
restricted, check for
Connect a hose to leak-off line to route excess fuel into a container. plugged fuel filters,
plugged fuel tank cap
Start engine and run at fast idle. vent, restricted lines,
stuck injection pump
Put engine under load by operating a hydraulic function over relief. overflow valve, or a
malfunctioning fuel
Observe fuel flow from leak-off line. transfer pump. Repair or
replace as necessary.
Does fuel flow from leak-off line with engine at full load?
NOTE: Fuel that flows from leak-off line is excess fuel not required by the engine and
flows back to the fuel tank.
1/1
1/1
Engine RPM Dial Check AEngine RPM Dial YES: Go to next check.
T102100 UN26JUL96
1/1
1/1
Did indicator light go out and engine speed increase to fast idle?
1/1
T111983 UN27OCT97
T112183 UN13NOV97
Start engine.
Operate the arm in function over relief (arm cylinder fully extended).
1/1
Engine Blow-By Check Run engine at fast idle and check blow-by tube. YES: Go to next check.
Are fumes barely visible at the blow-by tube at fast idle, NO: If blow-by is
with no load? excessive, do
compression pressure
NOTE: Excessive blow-by indicates that piston rings and test. (See CTM104.)
cylinder liners do not seal off the combustion chamber.
This is a comparative check that requires some
T7700AC UN10FEB92
experience to determine excessive blow-by.
9010
10
14 1/1
1/1
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
9010
15
POWERTECH is a trademark of Deere & Company. TX,9010,SB111 1906SEP961/1 1
Engine Cranks But Will Not Start No fuel Add fuel. Bleed air.
Or Hard To Start
9010
15 Wrong fuel Use correct fuel.
2
Water in fuel or water frozen in fuel Drain water from fuel tank trap.
line Inspect fuel filter for water. Change
filter.
Slow cranking speed (poor electrical Clean and tighten battery and starter
connection) connections.
Engine Knocks, Runs Irregularly Air in fuel Inspect filter for evidence of air in
or Stops fuel. Tighten connections and bleed
fuel system.
Fuel injection pump out of time Time injection pump. See CTM104.
Idle speeds adjustment too low Adjust slow idle speed. See Group
9010-20.
Engine Not Developing Full Fuel filter plugged Change filter. Bleed air.
Power
Injection pump delivery or governor Repair pump. See your Local Fuel
Injection Pump Service Center.
Engine Overheats Coolant level low Fill cooling system and check for
leaks.
Radiator, oil cooler cores plugged Check air flow. (See Group
with dirt or fins bent 9010-25). Clean radiator. Straighten
fins.
Fan belt soaked with oil or pulleys Inspect, replace. See Operators
worn excessively Manual or Repair Manual.
Engine Stalls Easily Under Load Engine speed sensor Check engine speed sensor. See
Group 9015-15.
Engine Speed Does Not Change Engine control motor Check engine speed control motor.
When RPM Dial Is Rotated See Group 9015-15.
Engine Idle Speed Is Too Fast Or Linkage not adjusted Adjust linkage. See Group 9010-20.
Slow
Coolant Temperature Too Low Thermostat stuck open Replace thermostat. See CTM104.
Oil In Coolant Or Coolant In Oil cooler leaking Test, repair. See CTM104.
Crankcase
Liner packing leaking and/or cracked Remove pan, inspect bottom end,
cylinder block repair, verify and replace if
necessary. See CTM104.
Low Engine Oil Pressure Oil level low Fill to proper level.
Wrong grade of oil or fuel dilution Use correct grade of oil. See
CTM104.
Oil pump drive gear loose Check, repair drive gear. See
9010 CTM104.
15
8
Oil pump gear and/or housing worn Repair. See CTM104.
High Engine Oil Pressure Oil viscosity wrong (too thick) Drain and refill with correct oil. See
Section 9000, Group 04.
Engine Uses Too Much Oil Wrong oil Use correct oil. See Section 9000,
Group 04.
Engine operating too hot or oil cooler Test cooling system. See Group
water passage plugged 9010-25. Test thermostat. See
CTM104.
Crankshaft thrust bearing worn Check piston and rod assembly. See 9010
(misaligned piston and rod) CTM104. 15
9
Engine Uses Too Much Fuel Fuel system leakage Tighten connections. See CTM104.
Plugged or dirty air intake or exhaust Clean air intake and exhaust system.
system.
Excessive Blue or White Smoke Cranking speed too slow Check batteries and connections.
See Group 9015-20.
Detonation Fuel injection pump static timing Check injection pump static timing.
incorrect and/or injection pump See CTM104.
advance faulty
9010
15 Ether starting aid solenoid stuck Check and repair.
10
Engine oil diluted with fuel Inspect engine oil. Inspect fuel pump
spindle, seal and housing.
Main and/or connecting rod bearing Inspect main bearing cap screws
caps loose or worn and connecting rod cap screws. See
CTM104.
Turbocharger Excessively Noisy Bearings not lubricated Insufficient oil pressure. Check for
or Vibrates restricted turbocharger oil line.
Air leak in engine, intake or exhaust Inspect and repair. See CTM104.
manifold
Improper clearance between turbine Remove exhaust elbow and air inlet
wheel and turbine housing hose. Inspect and repair. See
CTM104.
Oil Dripping From Turbocharger Damaged or worn bearings and/or Inspect compressor and turbine 9010
Adapter worn seals wheel for damaged blades. Check 15
11
for proper engine service intervals or
dirt entering engine. See CTM104.
Turbocharger oil return line carbon Remove line. Inspect and clean.
buildup where line passes exhaust
manifold.
Excessive Drag In Turbocharger Carbon build-up behind turbine Inspect and clean. See CTM104.
Rotating Members wheel caused by combustion
deposits
Bearing seizure or dirty or worn Check for plugged air filters. See
bearings caused by excessive CTM104.
temperature, unbalanced wheel, dirty
oil, oil starvation, or insufficient
lubrication.
TX,9010,SB112 1918SEP0010/10
9010
15
12
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
9010
20
POWERTECH is a trademark of Deere & Company. TX,9010,SB109 1906SEP961/1 1
UN28FEB89
1. Before installing clamp-on electronic tachometer,
remove the paint from a straight section of injection
line within 100 mm (4 in.) of No. 1 injection nozzle.
Use emery cloth to remove the paint.
T6813AG
2. Install the clamp-on transducer (A). Tighten finger tight
onlyDO NOT overtighten.
AClamp-On Transducer
BBlack Clip ()
3. Connect the red clip (+) (C) to the clamp-on CRed Clip (+)
transducer. DDigital Readout Unit
CED,TX08227,2879 1911NOV971/1
UN04DEC96
4. Manually pull fuel shut-off lever (D) up against the run 9010
position stop (upper stop) (H). 20
3
T105518
in.) short of aligning with hole in fuel shut-off lever.
Specification
Overtravel NeededDistance ............................... 36 mm (1/81/4 in.)
UN04DEC96
position stop (upper stop).
T105519
turns.
Specification
Ball Joint Hole-to-Shut-Off Lever AShut-Off Solenoid
HoleLength .......................................................................... 3 turns short BCap Screw
CBall Joint
DFuel Shut-Off Lever
Hold ball joint and tighten nut. ELock Nut
FPlunger
Specification GStop Position Stop (Lower Stop)
Fuel Shut-Off Solenoid HRun Position Stop (Upper Stop)
Plunger-to-Ball JointTorque .......................................... 8 Nm (70 lb-in.)
Specification
Fuel Shut-Off Lever-to-Run
Position StopClearance ....................... Less than 0.025 mm (0.001 in.)
with key switch ON and solenoid
plunger bottomed.
Specification
Shut-Off LeverClearance ..................... Within 3 mm (0.125 in.) Of Stop
Position Stop
TX,05,GG2305 1922APR983/3
Specification
1. Connect the tachometer or the laptop computer with Engine Slow IdleSpeed .............................................. 900 25 rpm
excavator diagnostics program. Select 14 Actual
engine speed from Monitor Data Items. (See 5. If engine speeds need adjustment, do Injection
JT05801 Clamp-On Electronic Tachometer Pump Fast and Slow Idle Stops Adjustment. (See
Installation in this group or for laptop computer procedure in this group.)
installation, see procedure in Group 9025-25.)
TX,9010,SB115 1907SEP001/1
9010
20
7
UN16SEP96
T103678
ANut CNut ENut FFast Idle Stop Screw
BSlow Idle Stop Screw DSupplementary Idle Screw
7. Push injection pump lever against fast idle stop Adjust the slow idle stop screw to obtain an
screw (F). Record the engine speed. engine speed that is 3040 rpm less than the
slow idle specification.
Push injection pump lever against slow idle stop
screw (B). Record the engine speed. Hold screw and tighten nut.
9. Loosen nut (A) on the slow idle stop screw (B) 12. Pull injection pump lever rapidly to fast idle then
decelerate to slow idle. Slow idle must be to
10. Hold injection pump lever against the slow idle specification.
stop screw.
NOTE: Increasing slow idle setting a small amount, NOTE: The fast idle stop screw on the injection pump
but no more than the maximum specifications, serves as the stop when the HP (high power)
may help to reduce surging or hunting. If mode is actuated.
surging or hunting continues, repair injection
pump. 14. Stop the engine. Connect the cable to lever.
13. Loosen nut (E) on fast idle stop screw (F). 15. Do Engine Control Motor and Sensor Adjustment
and then the Engine Speed Learning Procedure.
Pull lever against fast idle stop screw. Turn screw (See procedures in this group.)
in to decrease engine speed; turn screw out to
9010 increase engine speed. Hold screw and tighten
20 nut.
8
TX,9010,SB125 1907SEP003/3
Engine
Engine speed control cable
Engine control motor and sensor
Engine and pump controller
Fast and slow idle stop screws
UN27JUN96
T101749
9010
20
CED,OUTX782,504 1915SEP002/3 9
UN11SEP96
contacts the slow idle stop screw.
T103663
Engine Control Motor and SensorSpecification
Arm-to-Engine Control Motor
Shaft Cap ScrewTorque ........................................... 13 Nm (115 lb-in.)
ACap Screw
8. Do the Engine Speed Learning Procedure. (See BArm
procedure in this group.)
CED,OUTX782,504 1915SEP003/3
SPECIFICATIONS
Engine Speed Learning Procedure
Engine Slow Idle Speed 900 25 rpm
Engine Auto-Idle Speed 1200 25 rpm
Engine E (Economy) Mode 1850 25 rpm
Speed
Engine Fast Idle in Standard 2100 25 rpm
Mode Speed
9010
20
10 When the following components are repaired or replaced,
or when engine speeds deviate from specification, the
engine control motor adjustment and engine learning
control procedure must be performed.
Engine
Engine speed control cable
Engine control motor and sensor
Engine and pump controller
Fast and slow idle stop screws
UN11SEP96
Engine Auto-IdleSpeed ................................................... 1200
Engine E (Economy) Mode
Speed ................................................................................. 1850 25 rpm
Engine Fast Idle in Standard
ModeSpeed ..................................................................... 2100 25 rpm
T103674
NOTE: The laptop computer with the excavator diagnostic
software can be used to change the default
speeds for slow idle, auto-idle, economy mode, CEngine Learning Switch
and fast idle in standard mode. See Excavator
Diagnostics Program Special FunctionEngine
Speed Adjustment in Group 9025-25.
TX,9010,SB126 1912SEP002/2
IMPORTANT: Use only permanent-type low silicate 1. Start engine. Run engine until coolant reaches a
ethylene glycol base antifreeze in warm temperature.
coolant solution. Other types of
9010 antifreeze may damage cylinder 2. Stop engine. Allow coolant to cool.
20
seals.
12
3. Check coolant level at recovery tank.
Fill cooling system with permanent-type, low silicate,
ethylene glycol antifreeze (without stop-leak additive) 4. If necessary, fill recovery tank to FULL mark.
and clean, soft water.
5. Repeat Steps 14 until recovery tank coolant level
Fill is repeatedly at the same level (stabilized).
1. Fill the radiator to the bottom of the fill neck. NOTE: The level of the coolant in the cooling system
MUST BE repeatedly checked after all drain
2. Fill the coolant recovery tank to the FULL mark. and refill procedures to ensure that all air is
out of the system which allows the coolant
Specification level to stabilize. Check coolant level only
Cooling SystemCapacity ......................................... 28.4 L (7.5 gal) when the engine is cold.
CED,OUOE003,1058 1907SEP001/1
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
9010
25
POWERTECH is a trademark of Deere & Company. TX,9010,SB118 1906SEP961/1 1
SPECIFICATIONS
Fuel Line Leakage Test Pressure 69 kPa (0.7 bar) (10 psi)
To Prevent Fuel System 103 kPa (1 bar) (15 psi)
Component Damage Never
Exceed Maximum Pressure
Specification
Fuel Line Leakage Test
Pressure ............................................................. 69 kPa (0.7 bar) (10 psi)
To Prevent Fuel System
Component Damage Never
Exceed MaximumPressure .............................. 103 kPa (1 bar) (15 psi)
TX,9010,SB119 1911AUG981/1
SPECIFICATIONS
Air Filter Restriction Indicator 6.2 kPa (62 mbar) (25 in. water)
Must Come On At Vacuum
ESSENTIAL TOOLS
JT05652 (1/8 F NPT x 1/8 F NPT x 1/8 M NPT) Tee
JT03246 (1/4 F NPT x 1/4 F NPT) (Parker No. 0202-4-4) Coupler
3. Start engine and slowly cover the air cleaner inlet with
UN17DEC90
a piece of paper or cardboard.
T7350EP
Specification
Air Filter Restriction Indicator
Must Come On AtVacuum .................. 6.2 kPa (62 mbar) (25 in. water)
ASwitch
BTee
5. If reading is not within specifications, install a new
CBarbed Fitting
indicator switch. DTube
EBarbed Fitting
FCoupler
GGauge
TX,9010,SB120 1930MAR001/1
SPECIFICATIONS
Air Intake System Leakage Test 1421 kPa (0.140.21 bar) (2
Pressure 3 psi)
UN23FEB89
OTHER MATERIAL
T43512 U.S. Thread Lock and Sealer (Medium Strength)
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
T5906AP
242 Thread Lock and Sealer (Medium Strength)
9010
25
4 1. Remove air cleaner cover and main filter element.
2. Put large plastic bag into and over end of main filter
element as shown. Install main filter element and
cover.
UN12SEP96
intake manifold.
T103680
5. Pressurize air intake system to 1421 kPa (0.14
0.21 bar) (23 psi). If intake system cannot be
pressurized, turn engine slightly to close valves. APlug
Specification
Air Intake System Leakage
TestPressure ............................................. 1421 kPa (0.140.21 bar)
(23 psi)
TX,9010,SB121 1917JUN981/1
SPECIFICATIONS
Engine Speed Fast Idle
Air Flow Meter Total Reading 7.20 V (typical new)
Equal to or Greater Than Voltage
ESSENTIAL TOOLS
JT05529 Air Flow Meter
CED,OUOE003,653 1913JUN981/4
Specification
EngineSpeed ............................................................................ Fast Idle
1912SEP96
T103681
Specification
Air Flow Meter Total Reading
Equal to or Greater Than
Voltage........................................................................ 7.20 V (typical new)
UN01NOV88
screen and external surfaces of oil cooler and
radiator. Repeat test.
T6080AH
Continued on next page CED,OUOE003,653 1913JUN983/4
9010
25
7
1921MAR89
T6500AK
1. Divide surface of trash screen into 36 equal squares
starting at the top.
Specification
EngineSpeed ............................................................................ Fast Idle
CED,OUOE003,653 1913JUN984/4
OTHER MATERIAL
T43512 U.S. Thread Lock and Sealer (Medium Strength)
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
242 LOCTITE Thread Lock and Sealer (Medium Strength)
UN12SEP96
5. Turn engine rpm dial to fast idle.
Specification
T103680
Engine Fast IdleSpeed ...................... 2100 25 rpm in standard mode 9010
25
6. Check combined pump engine pulldown using arm in 9
function over relief. APlug
Specification
Combined Pump Engine
PulldownSpeed .................................. 100 rpm approximate with arm in
over relief
Specification
HP Mode SwitchPosition ................................................................... On
Specification
Rated EngineSpeed ................................................................. 2100 rpm
Wrong fuel.
Restricted air filter elements.
Restricted fuel filter elements.
Incorrect injection pump timing.
Incorrect fast idle stop adjustment at injection pump
for HP mode. (See Injection Pump Fast and Slow
Stops Adjustment in this group.)
Exhaust manifold leaks.
Intake manifold leaks.
Faulty fuel pump.
Low compression pressure.
1
Turbocharger boost pressure is reduced by 7% if using No. 1 fuel.
Continued on next page CED,TX08227,3198 1907SEP003/4
CED,TX08227,3198 1907SEP004/4
SPECIFICATIONS
Torsional Dampener Radial 1.50 mm (0.060 in.) maximum
Runout
Torsional Dampener Axial Runout 1.50 mm (0.060 in.) maximum
UN23NOV97
(Wobble)
ESSENTIAL TOOLS
JDG820 Flywheel Turning Tool
RG7507
9010
25 SERVICE EQUIPMENT AND TOOLS
12
D17526CI Dial Indicator
CED,OUOE003,1059 1912AUG981/3
Specification
RG7508
Torsional DampenerRadial
Runout ........................................................ 1.50 mm (0.060 in.) maximum
Specification
UN31OCT97
Torsional DampenerAxial 9010
Runout (Wobble) ........................................ 1.50 mm (0.060 in.) maximum 25
13
ATorsional Dampener Face
RG5679
CED,OUOE003,1059 1912AUG983/3
9010
25
14
Page Page
Page Page
Group 20References
Battery
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Specification . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Diagnose Malfunctions. . . . . . . . . . . . . . . .9015-20-2
Check Electrolyte Level and Terminals . . .9015-20-4
Batteries
Procedure for Testing . . . . . . . . . . . . . . . .9015-20-6
Corroded terminals
9015
Loose terminals or battery posts 05
Dirty condition 1
Damp condition
Cracked case
Proper electrolyte level
6. Turn the key switch to the IGN position. Try out the
accessory circuits, indicator lights, gauge lights. How
does each of these components work? Look for sparks
or smoke which might indicate shorts.
CED,OUTX466,1353 1903FEB991/1
9015
05
2
UN17JUL03
T128740
1Battery 3Switch 4Load (Light) 5Ground
2Fuse
CIRCUIT MALFUNCTIONS Between the component, light (4) and ground (5).
There are four common circuit malfunctions: Component malfunctions can easily be confused with
circuit malfunctions, as illustrated in the following
High-Resistance Circuit. example:
Open Circuit.
Grounded Circuit. Example: Light (4) does not operate switch (3) is
Shorted Circuit. turned ON. After disconnecting and connecting switch
(3), light (4) functions normally.
LOCATION OF CIRCUIT MALFUNCTIONS
Reason: Corrosion on the terminals of switch (3)
There are three sections in a simple circuit where have restricted or prevented the flow of current in the
these malfunctions can occur: circuit. The failure of light (4) to come ON appears to
be a component malfunction, but further examination
Between the battery (1) and the controlling switch of the circuit reveals a circuit malfunction in the form of
(3). a bad connection.
Between the controlling switch (3) and before the
component, light (4).
CED,TX17984,438 1924FEB001/1
9015
05
3
UN17JUL03
T128750
1Battery 4Switch Terminal 6Connector 8Load (Light)
2Fuse 5High Resistance 7Component Terminal 9Ground
3Switch
Definition of a High Resistance Circuit: A high until normal voltage is found. The malfunction is
resistance circuit has additional resistance which can between last two points of measurement.
prevent a component from operating normally. High
resistance can be caused by loose, dirty, corroded, or 4. If voltage at component terminal (7) is less than
oily terminals. Broken strands inside a wire or a wire voltage at switch terminal (4), the high resistance is
that is too small for an application may also cause high between these two points. Starting at component
resistance. In the above circuit, high resistance (5) terminal (7), continue measuring voltage toward
may cause light (8) to be dim or not to function. switch terminal (4) until normal voltage is found.
The malfunction is between last two points of
Troubleshooting a High Resistance Circuit: measurement.
1. Turn switch (3) ON. In the example, battery voltage will be present at
switch terminal (4), but voltage will be low at
2. Measure voltage at switch terminal (4) and component terminal (7). Checking voltage toward
component terminal (7). switch terminal (4), low voltage will be present at
connector (6), indicating high resistance (5) in the
3. If voltage is low at switch terminal (4), the harness between switch terminal (4) and connector
malfunction is between the switch (3) and battery (6).
(1). Continue measuring voltage toward battery (1)
5. If voltage is normal at component terminal (7), the ground (9) until low voltage is found. The
malfunction is between the component (8) and malfunction is between last two points of
ground (9). Continue measuring voltage toward measurement.
CED,TX17984,446 1925FEB002/2
9015
05
4
Open Circuit
9015
05
5
UN17JUL03
T128784
1Battery 4Switch Terminal 6Connector 8Load (Light)
2Fuse 5Broken Wire 7Component Terminal 9Ground
3Switch
Definition of an Open Circuit: An open circuit has a 4. If no voltage is at switch terminal (4), the
physical break that prevents the flow of current and malfunction is between the switch (3) and battery
results in no component operation. Open circuits can (1). Continue check for voltage toward battery (1)
be caused by a broken wire (5), disconnected until normal voltage is found. The malfunction is
connector (6), blown fuse (2), or disconnected ground between last two points of measurement.
(9).
5. If battery voltage is indicated at switch terminal (4)
Troubleshooting an Open Circuit: but not at component terminal (7), the malfunction
is between these two points. Starting at component
1. Check fuse (2). If blown, replace and operate terminal (7), continue checking for voltage toward
circuit. If fuse blows a second time, continue check. switch terminal (4) until normal voltage is found.
The malfunction is between last two points of
2. Turn switch (3) ON. measurement. Connector (6) might be an easy
location to check for voltage or a disconnected pin.
3. Measure battery voltage between switch terminal
(4) and component terminal (7).
In the example, voltage will be present at switch 6. If voltage is normal at component terminal (7), the
terminal (4), but no voltage at component terminal malfunction is between the component (8) and
(7). Checking voltage toward switch terminal (4), ground (9). Continue checking for voltage toward
zero voltage will be present at connector (6), ground (9) until normal voltage is found. The
indicating a broken wire (5) in the harness between malfunction is between last two points of
switch terminal (4) and connector (6). measurement.
CED,TX17984,447 1925FEB002/2
9015
05
6
9015
05
7
Grounded Circuit
9015
05
8
UN17JUL03
T128751
1Battery 4Fuse Terminal (Circuit side) 7Wire Insulation Burned or 9Component Terminal
2Fuse 5Switch Worn 10Load (Light)
3Fuse Terminal (Battery 6Switch Terminal 8Short to Ground 11Ground
Side)
1. Remove and inspect fuse (2). b. If continuity to ground does not exist, go to next
step.
a. If fuse is good, the circuit is grounded between
battery and fuse, wire will be burned and circuit 4. Disconnect component terminal (9).
will be open.
5. Measure continuity to ground at wire lead from
b. If fuse is blown, do not replace fuse and component terminal (9).
continue checking for short to ground.
a. If continuity to ground is indicated, there is a 6. Disconnect ground (11), leave component terminal
short to ground between switch terminal (6) and (9) disconnected.
component terminal (9). Inspect wire harness in
this area. 7. Measure continuity to ground at ground connection
(11).
In the example, continuity to ground will be
present at the wire lead from component a. If continuity to ground is indicated, there is a
terminal (9). Inspecting the wire harness toward short to ground between component (10) and
switch terminal (6), an area of burned wire ground connection (11). Inspect wire harness in
insulation (7) will be found making contact to this area.
machine ground (8).
b. If continuity to ground does not exist, replace
b. If continuity to ground does not exist, go to next component (10). The component may have an
step. internal short to ground.
9015
05
9
CED,TX17984,448 1925FEB002/2
Shorted Circuit
9015
05
10
UN29FEB00
T128752
1Battery 5Switch S2 8Light E2 11Light E1
2Fuse F1 6Circuit Wire Shorted to 9Circuit Ground 12Switch S1
3Fuse F2 Circuit 10Circuit Ground
4Battery Wire Shorted to 7Circuit Wire Shorted to
Circuit Ground
Definition of a Shorted Circuit: A shorted circuit has 2. Light E1 (11) remains ON.
a power wire with its insulation burned or rubbed
through, contacting a wire in another circuit causing a 3. A short to battery power (4) is located before switch
short (4, 6, or 7). This allows current to flow to several S2 (5) and after switch S1 (12).
components when a switch from either circuit is turned
ON. Fuse (3) will blow immediately when switch (5) is 4. Inspect wire harness for burned or pinched wires
turned ON, whenever a wire is shorted to ground (7). between switch S1 (12) and light E1 (11) of circuit 1
and between fuse F2 (3) and switch S2 (5) of circuit
Troubleshooting a Shorted Circuit: The above 2.
diagram shows two circuits shorted in three different
locations. A troubleshooting procedure is given for Power Wire Shorted to Circuit
each shorted location.
1. Turn switch S1 (12) ON and switch S2 (5) OFF.
Battery Wire Shorted to Circuit
2. Light E1 (11) and light E2 (8) come ON. One or
1. Turn switch S1 (12) and switch S2 (5) OFF. both lights may be dim.
3. Turn switch S1 (12) OFF and switch S2 (5) ON. 3. Turn switch S1 OFF.
4. Light E2 (8) and light E1 (11) come ON. One or 4. Turn switch S2 (5) ON.
both lights may be dim.
5. Fuse F2 (3) will blow immediately when switch S2
5. A short to switched power (6) is located between (5) is turned ON.
circuit 1 and 2, after switches S1 and S2 (12, 5),
and before light E1 and E2 (11, 8). 6. A short to ground (7) is located between switch S2
(5) and light E2 (8) of circuit 2, and after light E1 of
6. Inspect wire harness for burned or pinched wires circuit 1.
between switch S1 (12) and light E1 (11) of circuit 1
and between switch S2 (5) and light E2 (8) of circuit 7. Inspect wire harness for burned or pinched wires
2. between switch S2 (5) and light E2 (8) of circuit 2,
and between light E1 (11) and ground (10) of circuit
Power Wire Shorted to Ground 1.
9015
1. Turn switch S1 (12) ON, leave switch S2 (5) OFF. 05
11
2. Light E1 (11) and light E2 (8) come ON. One or
both lights may be dim. Light E1 and E2 (11, 8) can
come ON even if fuse F2 (3) is blown.
CED,TX17984,449 1925FEB002/2
9015
05
12
UN17JUL03
T128748
1Battery 5Sensor Power Wire Shorted 7Sensor Ground Wire 10Sensor
2Fuse F1 to Power Shorted to Power 11Controller
3Fuse F2 6Sensor Signal Wire Shorted 8Load (Light) 12Controller Ground
4Switch to Power 9Circuit Ground
Definition of a Sensor Circuit Shorted to Power: A Sensor Power Wire Shorted to Power (5)
sensor circuit shorted to power has one or more
sensor wires shorted to a power source. A sensor 1. The controller may display a maximum upper or
power wire shorted to power (5) may damage the lower reading.
sensor. A sensor signal wire shorted to battery power
(6) may cause the sensor to display a false reading, or 2. The sensor may be damaged, with no signal given
damage the sensor. A sensor ground wire shorted to to the controller.
power (7) may cause fuse F2 (3) to blow when switch
S2 (4) is turned ON. 3. The controller may be damaged, with no display for
that sensor.
Troubleshooting a Sensor Circuit Shorted to
Power: The above diagram shows a sensor circuit 4. The controller may or may not generate a service
shorted to power in three different locations. A few code.
symptoms for each shorted location are given below.
Due to the complexity of sensor and controller, not all Sensor Signal Wire Shorted to Power (6)
symptoms are listed.
1. The controller may display a maximum upper or Sensor Ground Wire Shorted to Power (7)
lower reading.
1. The sensor and controller may function normally
2. The sensor may be damaged, with no signal given when switch (4) is OFF.
to the controller.
2. Fuse F2 (3) may blow when switch (4) is turned
3. The controller may be damaged, with no display for ON.
that sensor.
3. The controller may generate a Short to Ground
4. The controller may or may not generate a service service code.
code.
9015
05
13
CED,TX17984,450 1928FEB002/2
9015
05
14
UN17JUL03
T128785
1Battery 4Controller 6Sensor Power Wire Shorted 8Sensor
2Fuse 5Sensor Power Wire Shorted to Sensor Ground Wire
3Controller Ground to Sensor Signal Wire 7Sensor Signal Wire shorted
to Sensor Ground Wire
Definition of a Sensor Circuit Shorted to Itself: A Sensor Power Wire Shorted to Sensor Signal Wire (5)
sensor circuit shorted to itself has one or more sensor
wires making contact with another wire between the 1. The controller may display a maximum upper or
controller and sensor. A sensor power wire shorted to lower reading.
a sensor signal wire (5) may display a maximum upper
or lower reading. A sensor power wire shorted to a 2. The sensor may be damaged, with no signal given
sensor ground wire (6) may cause fuse (2) to blow. A to the controller.
sensor signal wire shorted to a sensor ground wire (7)
may allow the controller to display a false reading. 3. The controller may generate a Short to Power
service code, or the controller may shutdown for
Troubleshooting a Sensor Circuit Shorted to Itself: protection until the short to power is corrected.
The above diagram shows a sensor circuit shorted to
itself in three different locations. A few symptoms for Sensor Power Wire Shorted to a Sensor Ground Wire
each shorted location are given below. Due to the (6)
complexity of sensor and controller, not all symptoms
are listed.
1. The sensor may be damaged, with no signal given Sensor Signal Wire Shorted to a Sensor Ground Wire
to the controller. (7)
2. The controller may be damaged, with no display for 1. The controller may display a maximum upper or
that sensor. lower reading.
3. The controller may or may not generate a service 2. The controller may generate a Short to Ground
code. service code.
CED,TX17984,451 1928FEB002/2
9015
05
15
9015
05
16
UN17JUL03
T128753
1Battery 4Sensor Power Wire Shorted 6Sensor Ground Wire 7Sensor
2Fuse to Ground Shorted to Ground 8Controller Ground
3Controller 5Sensor Signal Wire Shorted
to Ground
Definition of a Sensor Circuit Shorted to Ground: Sensor Power Wire Shorted to Ground (4)
A sensor circuit shorted to ground has one or more
sensor wires shorted to machine ground or a grounded 1. Fuse (2) may be blown.
wire. A sensor power wire shorted to a ground (4) may
blow a fuse or the controller may shutdown for 2. The controller may be damaged, with no display for
protection. A sensor signal wire shorted to ground (5) that sensor.
may cause a Short to Ground service code to be
generated. A sensor ground wire shorted to ground (6) 3. The controller may generate a Short to Ground
will allow the sensor to continue normal operation. service code, or the controller may shutdown for
protection until the short to ground is corrected.
Troubleshooting a Sensor Circuit Shorted to
Ground: The above diagram shows a sensor circuit Sensor Signal Wire Shorted to Ground (5)
shorted to ground in three different locations. A few
symptoms for each shorted location are given below. 1. The controller may display a maximum upper or
Due to the complexity of sensor and controller, not all lower reading.
symptoms are listed.
2. The controller may generate a Short to Ground 1. The sensor and controller may function normally.
service code.
Multimeter
UN28FEB00
T128730
CED,TX17984,439 1925FEB001/1
9015
05
18
UN17JUL03
T128754
1Battery 4Component Side of Fuse or 6Battery Side of Component 8Ground Side of Component
2Fuse or Circuit Breaker Circuit Breaker Terminal Terminal
3Battery Side of Fuse or 5Switch 7Light (Component) 9Component Ground
Circuit Breaker
1. Turn switch (5) ON. Check battery side of circuit 3. Turn switch (5) OFF. Check component side of
breaker (3) for battery voltage. circuit breaker (4) for continuity to ground.
2. Turn switch (5) OFF. Check component side of 4. Turn switch (5) ON. Check component side of
circuit breaker (4) for battery voltage. circuit breaker (4) for battery voltage.
b. Low voltage, repair high resistance. b. Low voltage, repair high resistance.
5. Turn switch (5) OFF. Disconnect wire at battery c. No voltage, repair high resistance or open circuit
side on component (6). between circuit breaker (2) and component (7).
Turn switch (5) ON. Check wire at (6) for battery 7. Turn switch (5) ON. Check ground wire of
voltage. component at (8) for voltage.
CED,TX17984,454 1928FEB002/2
The Wiring Diagram shows each wiring harness, wire Connector End View DiagramIf Provided
color, wire destination, harness connectors, and
schematic symbols for each electrical component The Connector End View Diagram is a pictorial end
connected to that harness. All harnesses are identified view of the component connectors showing the
by letter/number designation and description (W1 number of pins in the connector and the wire color and
Engine Harness, W2 Dash Harness, Etc.). Each identifier of the wire in every connector. Each
component schematic symbol will be identified by the component will be identified by the same identification
same letter/number designation used in the System letter/number and description used in the System
Functional Schematic Diagram. Harness connectors Functional Schematic Diagram.
CED,TX17984,455 1928FEB001/1
9015
05
21
9015
05
22
UN29FEB00
T128818
NOTE: A component identification number and name Each electrical component is shown by a schematic
will remain the same throughout the Operation symbol (10), the component name (8), and a
and Test Technical Manual. This will allow for component identification number (9). A continuity chart
easy cross-referencing of all electrical (1) is included for each multi-terminal switch.
drawings (Schematics, Wiring Diagrams, and
Component Location). Routing location information (3) is presented to let the
reader know when a wire is connected to a component
The System Functional Schematic is made up of in another section. TO and FROM statements identify
sections which contain one or more Subsystem when power is going To or coming From a
Functional Schematics laid out side by side in a logical component in a different location. The section and
sequence of related functions. Each subsystem is a component number are given in parenthesis at the
major group of components like starting components or bottom of the statement. In the example, power is 9015
charging components. Each section of the System going TO component F15 Horn Fuse, in section SE15. 05
Functional Schematic is assigned a number (7) and a 23
name (6) that reflects a group of components. The See Group 9015-10 for Component Identification
System Functional Schematic is formatted with power Legend.
supply wires (2) shown across the top of the drawing
and ground wires (5) across the bottom. The
schematic contains no harness or connector
information.
CED,TX17984,456 1928FEB002/2
9015
05
24
UN29FEB00
T128819
NOTE: A component identification number and name Wires from harness to components are identified by
will remain the same throughout the Operation color or number designation (4). Component
and Test Technical Manual. This will allow for identification number (5) indicates the component a
easy cross-referencing of all electrical wire is routed TO.
drawings (Schematics, Wiring Diagrams, and
Component Location). Main harness connectors (2) are identified by a X
component identification number and description (X28
Each harness on the machine is drawn showing CAB TO ENGINE BULKHEAD CONNECTOR, Etc.).
components, connectors, and wires. Harnesses are Harness connector description indicates which
identified by a W component identification number harnesses connect together. Connector pin letters or
and description (W6 ENGINE HARNESS, Etc.). numbers (1) are indicated as they are marked on the 9015
connector. Wires attached to each connector pin are 05
Each component is represented by a schematic identified by color or number (10). Component 25
symbol and is identified by a component identification identification number (9) indicates destination of each
number and name (3). Components with integral wire.
connectors (6) have pin number/letters indicated (7).
CED,TX17984,457 1928FEB002/2
9015
05
26
UN01MAR00
T128843
1Component Identification 4Connector Identification 7Wire Color or Number 9End View of Harness
Number Number 8Routing Destination of Wire Connector
2Component Name 5Connector Name (Shown as Component
3Additional Information 6Pin Number of Mating Identification Number)
Connector
NOTE: A component identification number and name component name (2). In the example shown, the
will remain the same throughout the Operation component is also identified by an R number (3) that is
and Test Technical Manual. This will allow for actually marked on the part.
easy cross-referencing of all electrical
drawings (Schematics, Wiring Diagrams, and Each connector that joins one harness to another is
Component Location). identified by an X component identification number
(4) and connector name (5). An end view of the
The component location by harness drawing is a connector (9) is shown. Also, a diagram view of the
pictorial representation that shows harness routing, connector shows pin number (6), wire color or number
component location and mating harness connector (7), and destination component (8) of each wire.
information. 9015
In the example shown, X23 Connector connects the 05
The location of each component that is connected to Monitor and Relay Harness to the Cab Harness. Pin 1 27
the harness is shown and identified by its (6) of the connector contains a BRN wire (7), which is
alpha-numeric identification number (1), and routed to component G4 (8) 24 volt power plug.
CED,TX17984,459 1929FEB002/2
9015
05
28
UN01MAR00
T128896
1Connector End View 4Component Name 6Wire Number 7Wire Color
2Connector Pins 5Terminal Pin Letter or
3Component Identification Number
Number
NOTE: A component identification number and name pictorial end view of a connector (1), shows the
will remain the same throughout the Operation location and number of pins (2) in the connector. The
and Test Technical Manual. This will allow for component identification number (3) and name (4) are
easy cross-referencing of all electrical given for each connector. A diagram view of the
drawings (Schematics, Wiring Diagrams, and connector shows connector pin number (5), wire
Component Location). number (6), and wire color (7).
CED,TX17984,460 1901MAR001/1
9015
05
29
CED,TX17984,458 1928FEB001/2
CED,TX17984,458 1928FEB002/2
9015
05
32
UN06MAR92
F8Switched Power 10-Amp Fuse (marked Option 2)
F9Battery Power 5-Amp Fuse (marked Option 3)
F10Travel Alarm 5-Amp Fuse (marked Travel)
F11Work and Drive Lights 20-Amp Fuse (marked
T7713AJ
Lamp)
F12Windshield Wiper 10-Amp Fuse (marked Wiper)
F13Blower Motor 20-Amp Fuse (marked Heater)
F14Air Conditioner Controller and Relays 5-Amp
Fuse (marked Air Con)
F15Horn 10-Amp Fuse (marked Horn)
F16Radio 5-Amp Fuse (marked Radio)
F17Lighter 10-Amp Fuse (marked Lighter)
F18Dome Light 5-Amp Fuse (marked Room Lamp)
F19Auxiliary 10-Amp Fuse (marked Auxiliary)
F20Start Aid 20-Amp Fuse (marked Start Aid) (Not
used)
CED,TX02661,227 1914DEC981/1
9015
10
2
CED,TX14795,4106 1922NOV971/1
TX,10,111507 1922AUG962/2
NOTE: A2Engine and Pump Controller (SE8, W2) B20Arm In Pressure Sensor (SE7, W1)
B21Rear Pump Control Pressure Sensor (SE7,
A2 indicates component identification number. W1)
B22Front Pump Control Pressure Sensor (SE7,
Engine and Pump Controller indicates W1)
component name. B23Right Speaker (SE14, W2)
B24Left Speaker (SE14, W2)
SE8 indicates section numbers of SYSTEM B25High Note Horn (SE15, W1)
FUNCTIONAL SCHEMATIC where component B26Low Note Horn (SE15, W1)
is located. B27Air Conditioner High and Low Pressure Switch
(SE17, W9)
W2 is the identification number of the B28Not Used
COMPONENT LOCATION and HARNESS B29Air Conditioner and Heater Thermistor (SE17,
CONNECTOR (WITH WIRE AND PIN W9)
9015
LOCATION) drawings for the component. This 10
would indicate that the Engine and Pump E1Work Light (SE13, W1) 5
Controller is connected to W2 Cab Harness. E2Drive Light (SE13, W1)
E3Cab Dome Light (SE15, W2)
A1Radio (SE14, W2) E4Monitor Controller and Display Backlight (SE5,
A2 Engine and Pump Controller (SE8, W2) W3)
A3 Air Conditioner Controller (SE17, W9) E5Engine RPM Dial Backlight (SE4, W2)
A4 Engine Mode and RPM Control Unit (SE4, W2)
A5 Monitor Controller and Display (SE5, W3) F1Radio and Monitor Controller Backup 5 Amp
Fuse (marked Back Up) (SE6, W2)
B1Air Filter Restriction Switch (SE6, W1) F2Engine and Pump Controller 10 Amp Fuse
B2Fuel Level Switch (SE6, W1) (marked Controller) (SE9, W2)
B3 Engine Coolant Temperature Switch (SE6, W1) F3Engine Control (EC) Motor 10 Amp Fuse
B4 Engine Oil Pressure Switch (SE6, W1) (marked EC Motor) (SE9, W2)
B5 Hydraulic Oil Level Switch (SE6, W1) F4Solenoid 5 Amp Fuse (marked Solenoid) (SE9,
B6 Engine Coolant Level Switch (SE6, W1) W2)
B7 Engine Oil Level Switch (SE6, W1) F5 Power On 10 Amp Fuse (marked Pow. On)
B8 Fuel Level Sensor (SE6, W1) (SE3, W2)
B9 Engine Coolant Temperature Sensor (SE4, F6Monitor Controller and Display 5 Amp Fuse
W1) (marked Sw. Box) (SE4, W2)
B10Not Used F7Switched Power 5 Amp Fuse (marked Option 1)
B11Not Used (SE18, W2)
B12Not Used F8Switched Power 10 Amp Fuse (marked Option
B13Boom Up Pressure Switch (SE7, W1) 2) (SE18, W2)
B14Dig Pressure Switch (SE7, W1) F9Battery Power 5 Amp Fuse (marked Option 3)
B15Propel Pressure Switch (SE7, W1) (SE18, W2)
B16Engine Speed (N) Sensor (SE8, W1) F10Travel Alarm 5 Amp Fuse (marked Option 1)
B17Engine Control (EC) Sensor (Located Inside (SE10, W2)
Engine Control Motor Housing) (SE7, W1) F11Work and Drive Lights 20 Amp Fuse (marked
B18Rear Pump Pressure Sensor (SE7, W1) Lamp) (SE13, W2)
B19Front Pump Pressure Sensor (SE7, W1)
F12Windshield Wiper 10 Amp Fuse (marked H18Alternator Voltage Indicator Light (SE4, W3)
Wiper) (SE12, W2) H19Engine Oil Level Indicator Light (SE4, W3)
F13Blower Motor 20 Amp Fuse (marked Heater) H20Engine Coolant Level Indicator Light (SE4,
(SE16, W2) W3)
F14Air Conditioner Controller and Relays 5 Amp H21Spare Indicator Light (SE4, W3)
Fuse (marked Heater) (SE17, W2)
F15Horn 10 Amp Fuse (marked Horn) (SE15, W2) K1Alternator Shut Down Relay (Marked R1) (SE3,
F16Radio 5 Amp Fuse (marked Radio) (SE14, W3)
W2) K2Windshield Washer Relay (Marked R2) (SE11,
F17Lighter 10 Amp Fuse (marked Lighter) (SE15, W3)
W2) K3Work Light Relay (Marked R3) (SE13, W3)
F18Dome Light 5 Amp Fuse (marked Room K4Drive Light Relay (Marked R4) (SE13, W3)
Lamp) (SE15, W2) K5Horn Relay (Marked R5) (SE15, W3)
F19Auxiliary 10 Amp Fuse (marked Auxiliary) K6Windshield Wiper Relay (Motor Ground and
SE18, W2) Intermittent) (Marked R6) (SE11, W3)
F20Start Aid 20 Amp Fuse (marked Start Aid) (Not K7Windshield Wiper Relay (Wiper Run) (Marked
9015
10 UsedField Option) R7) (SE12, W3)
6 F21Battery Power 40 Amp Fusible Link (SE1, W1) K8Windshield Wiper Relay (Hold for Park)
F22Alternator Power 60 Amp Fusible Link (SE1, (Marked R8) (SE12, W3)
W1) K9Windshield Wiper Relay (Motor Ground for
F23Fuel Shutoff 40 Amp Fusible Link (SE1, W1) Park) (Marked R9) (SE12, W3)
K10Propel Auto Idle Relay (Marked R10) (SE7,
G1Battery (SE1, W1) W3)
G2Battery (SE1, W1) K11Starter Protection Relay (Marked R11) (SE2,
G3Alternator (SE3, W1) W3)
G424 Volt Power Plug (SE15, W3) K12Start Aid Relay (Marked R12) (Not Used
Field Option)
H1Dig Mode Indicator Light (SE5, W3) K13Starter Relay (SE2, W1)
H2Grading Mode Indicator Light (SE5, W3) K14Battery Relay (SE1, W1)
H3Precision Mode Indicator Light (SE5, W3) K15Fuel Shutoff Relay (SE3, W1)
H4Attachment Mode Indicator Light (SE5, W3) K16Not Used
H5High Power Mode Indicator Light (SE4, W3) K17Not Used
H6Economy Mode Indicator Light (SE4, W3) K18Not Used
H7Auto Idle Mode Indicator Light (SE4, W3) K19Not Used
H8Monitor Controller and Display Alarm (SE5, K20Not Used
W3) K21Not Used
H9Not Used K22Not Used
H10Travel Alarm (SE10, W1) K23Not Used
H11Spare Indicator Light (SE4, W3) K24Air Conditioner Blower Motor and Main Power
H12Hydraulic Oil Level Indicator Light (SE4, W3) (Low Speed) Relay (SE17, W9)
H13Fuel Level Indicator Light (SE4, W3) K25Air Conditioner Compressor Clutch Relay
H14Air Filter Restriction Indicator Light (SE4, W3) (SE17, W9)
H15Not Used K26Air Conditioner Blower Motor (Low Medium
H16Engine Coolant Temperature Indicator Light Speed) Relay (SE17, W9)
(SE4, W3) K27Air Conditioner Blower Motor (Medium Speed)
H17Engine Oil Pressure Indicator Light (SE4, W3) Relay (SE17, W9)
K28Air Conditioner Blower Motor (High Speed) S7Work Mode Selection Switch (SE5, W3)
Relay (SE17, W9) S8Propel Speed Change Switch (SE5, W3)
S9Wiper Speed Switch (SE5, W3)
M1Starter (SE2, W1) S10Drive and Work Light Switch (SE5, W3)
M2Engine Control (EC) Motor (SE8, W1) S11Economy (E) Mode Switch (SE4, W2)
M3Windshield Wiper Motor (SE11, W3) S12High Power (HP) Mode Switch (SE4, W2)
M4Windshield Washer Motor (SE11, W1) S13Auto Idle Switch (SE5, W3)
M5Heater Blower Motor (Without Air Conditioner) S14Windshield Wiper Enable Switch (SE4, W2)
(SE16, W2) S15Windshield Washer Switch (SE5, W3)
M6Air Conditioner and Heater Blower Motor S16Learning Switch (SE9, W2)
(SE17, W9) S17Travel Alarm Cancel Switch (SE10, W2)
M7Not Used S18Start Aid Switch (Not UsedField Option)
M8Not Used S19Power Boost Switch (SE9, W2)
M9Air Conditioner Internal and External Cab Air
Servomotor (SE17, W9) V1Start Aid Diode (Not UsedField Option)
M10Air Conditioner Blower Port Change V2Alternator Shut Down Relay Isolation Diode
9015
Servomotor (SE17, W9) (SE3, W2) (Red/Wht and Red/Blk) 10
M11Air Conditioner Air Mixer Servomotor (SE17, V3Auxiliary Power Fuse (F19) Suppression Diode 7
W9) (SE18, W2) (Blk and Red)
V4Propel Auto Idle Relay (marked R10) Isolation
P1Hour Meter (SE5, W3) Diode (SE7, W2) (Wht/Blk and Yel)
P2Engine Coolant Temperature Gauge (SE4, W3) V5Windshield Wiper Relay (marked R8) Isolation
P3Fuel Gauge (SE4, W3) Diode (SE12, W3) (Blu/Blk and Blu/Red)
V6Windshield Wiper Motor Suppression Diode
R1Not Used (SE11, W3) (Blk and LGrn/Wht)
R2Heater Blower Motor Dropping Resistor Block V7Windshield Wiper Motor Suppression Diode
(Without Air Conditioner) (SE16, W2) (SE11, W3) (Blk and Blu/Wht)
R3Not Used V8Fuel Shutoff Solenoid Hold-In Coil Suppression
R4Engine Coolant Temperature Gauge Resistor Diode (SE3, W2) (Brn/Blk and Blk)
(150 ohms) (SE5, W3) V9Start Relay Coil Suppression Diode (SE2, W2)
R5Fuel Gauge Resistor (220 ohms) (SE5, W3) (Yel/Grn and Blk/Wht)
R6Alternator Excitation Resistor (SE3, W2) V10Fuel Shutoff Solenoid Pull-In Coil Suppression
R7Not Used Diode (SE3, W2) (Red/Blk and Blk)
R8Not Used V11Battery Relay Coil Suppression Diode (SE1,
R9Not Used W1) (Blk and Red/Wht)
R10Engine RPM Dial (SE4, W2)
R11Air Conditioner and Heater Blower Motor W1Engine and Frame Harness
Dropping Resistor Block (SE17, W9) W2Cab Harness
W3Monitor and Relay Harness
S1Key Switch (SE1, W2) W4Radio Antenna (SE14, W2)
S2Horn Switch (SE15, W2) W5Battery to Frame Ground (W1)
S3Dome Light Switch (SE15, W2) W6Engine and Frame Harness to Frame Ground
S4Heater Blower Motor Switch (Without Air (W1)
Conditioner) (SE16, W2) W7Cab Harness to Frame Ground (W2)
S5Fluid Level Check Switch (SE5, W3) W8Starter to Frame Ground (SE2, W1)
S6Buzzer Stop Switch (SE5, W3) W9Air Conditioner Harness
CED,OUTX782,72 1904JAN994/4
SE1Power Circuit
SE2Starting Circuit
SE3Charging and Fuel Shut-Off Circuit
SE4Monitor Controller and Display Circuit
SE5Monitor Controller and Display Circuit
SE6Monitor Controller and Display Circuit 9015
SE7Engine and Pump Controller Circuit 10
SE8Engine and Pump Controller Circuit 9
SE9Engine and Pump Controller Circuit
SE10Travel Alarm Circuit
SE11Windshield Wiper and Washer Circuit
SE12Windshield Wiper and Washer Circuit
SE13Work and Drive Light Circuit
SE14Radio Circuit
SE15Accessory Circuit
SE16Heater Circuit (Machines Without Air
Conditioner)
SE17Heater and Air Conditioner Circuit
SE18Optional Connector Circuit
CED,TX02661,229 1922DEC981/1
CED,OUTX782,64 1922DEC981/1
CED,OUTX782,65 1921DEC981/1
CED,OUTX782,66 1921DEC981/1
CED,OUTX782,67 1917DEC981/1
CED,OUTX782,68 1921DEC981/1
CED,OUTX782,69 1921DEC981/1
CED,OUTX782,70 1921DEC981/1
Engine and Frame Harness (W1) Connectors, Wire and Pin Location
9015
10
17
1911DEC98
T118958
9015
10
18
1911DEC98
T118959
9015
10
19
1917NOV98
T118104
CED,OUTX782,71 1921DEC983/3
CED,TX02661,242 1904NOV981/1
CED,OUTX782,73 1921DEC981/1
9015
10
22
1917NOV98
T117202
CED,OUTX782,1 1917NOV981/1
9015
10
23
1917NOV98
T118464
9015
10
24
1914DEC98
T118465
9015
10
25
1917NOV98
T118466
9015
10
26
1905JAN99
T118493
9015
10
27
1917NOV98
T118494
CED,TX02661,244 1904NOV985/5
CED,OUTX782,74 1921DEC981/1
9015
10
29
1923DEC98
T119181
CED,OUTX782,75 1922DEC981/1
9015
10
30
1919FEB99
T118900
CED,OUTX782,76 1921DEC981/1
Monitor and Relay Harness (W3) Connectors, Wire and Pin Location
9015
10
31
1917NOV98
T118352
9015
10
32
1917NOV98
T118497
CED,TX02661,248 1904NOV982/2
CED,TX02661,249 1904NOV981/1
CED,TX02661,250 1904NOV981/1
9015
10
33
9015
10
34
The following conditions must be met for the circuits to Lighter 10-amp fuse F17
function: Dome light 5-amp fuse F18
Auxiliary 10-amp fuse F19
With key switch S1 OFF, voltage must be present at
the following: With key switch S1 ON, voltage must be present at the
following:
Battery positive terminals
Key switch S1 terminal BAT Alternator excitation resistor R6
Battery relay K14 terminal B Key switch S1 terminal M
Radio and monitor controller backup 5-amp fuse F1 Battery relay K14 terminal S and A
Engine and pump controller 10-amp fuse F2 Alternator power 60-amp fusible link F22
Engine control (EC) motor 10-amp fuse F3 Starter motor terminal B
Battery power 5-amp fuse F9 Solenoid 5-amp fuse F4
Battery power 40-amp fusible link F21 Power On 10-amp fuse F5
9015
Alternator shut down relay K1 terminals 1 and 3 Monitor controller and display 5-amp fuse F6 15
Starter protection relay K11 terminal 1 Switched power 5-amp fuse F7 1
Switched power 10-amp fuse F8
With key switch S1 in ACC position, voltage must be Travel alarm 5-amp fuse F10
present at the following: Work and drive lights 20-amp fuse F11
Windshield wiper 10-amp fuse F12
Key switch S1 terminal ACC Blower motor 20-amp fuse F13
Horn 10-amp fuse F15 Air conditioner controller and relays 5-amp fuse F14
Radio 5-amp fuse F16 Fuel shutoff 40-amp fusible link F23
CED,OUOE012,10 1914DEC981/1
The power circuit includes batteries, key switch, F17, dome light 5-amp fuse F18, auxiliary 10-amp fuse
battery relay, battery relay fuse, battery relay diode F19 and radio 5-amp fuse F16.
and all other fuses.
With key switch turned to ON, battery relay K14 is
With key switch OFF, battery power is available at energized by power from key switch S1 terminal M to
terminal BAT of key switch S1, terminals 1 and 3 of battery relay terminal S. Operating power from terminal
alternator shut down relay K1, terminal 1 of starter A of the battery relay is applied to starter motor M1
protection relay K11, and through battery power terminal B, fuel shutoff 40-amp fusible link F23, and
40-amp fusible link F21 to terminal B of battery relay through alternator power 60-amp fusible link F22 to
K14. Battery power is also applied to radio and monitor fuses F4, F6, F7, F8, F10, F11, F12, F13 and F14.
controller backup 5-amp fuse F1, engine and pump Operating power is also applied from key switch S1
controller 10-amp fuse F2, and engine control (EC) terminal M to alternator excitation resistor R6 and
motor 10-amp fuse F3 and battery power 5 amp fuse power on 10-amp fuse F5.
F9.
9015
15
2 With key switch turned to ACC, battery power is
available at horn 10-amp fuse F15, lighter 10-amp fuse
CED,OUOE012,11 1914DEC981/1
CED,OUOE012,39 1903FEB991/1
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and
Pump Controller or other components may result. Disconnect connectors only when instructed during a
test or check.
1/1
Battery (G1, G2) Voltage Measure battery voltage by connecting a voltmeter to (-) YES: Batteries are OK.
Check negative battery terminal grounded to frame and (+) Go to next check.
9015
positive battery terminal connected to machine harness.
15
NO: Batteries are
4
Is 24 to 28 volts measured? undercharged. Charge
batteries.
T7487AF UN20MAR91
1/1
Battery Power 40 Amp Disconnect fusible link from battery relay. YES: Fusible link is OK.
Fusible Link (F21) Check Check wiring harness.
Connect ohmmeter to both ends of fusible link.
NO: Fusible link has
Is continuity measured? failed. Replace fusible
link.
T109319 UN28APR97
1/1
Alternator Power 60 Amp Disconnect fusible link from battery relay. YES: Fusible link is OK.
Fusible Link (F22) Check Check wiring harness.
Connect ohmmeter to both ends of fusible link.
NO: Fusible link has
Is continuity measured? failed. Replace fusible
link.
T109319 UN28APR97
1/1
1/1
Battery Relay (K14) Disconnect harness from relay. YES: Relay is OK. Check
Check wiring harness.
Connect 24 volts to small terminal S and ground small
terminal E. NO: Relay has failed.
Replace relay.
Does relay click?
1/1
Battery Relay Coil NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Suppression Diode (V11) measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
Check meter when checking continuity. diode has failed in a
shorted mode. Replace.
NO: If continuity is
measured in one check
T118385 UN21NOV98 and not the other, diode
is OK.
Remove diode from connector.
Is continuity measured?
9015
15
Reverse ohmmeter probes.
6
Is continuity measured?
1/1
T7468AF UN14MAR91
Connect multimeter red (+) probe to the outside slot in each fuse.
1/1
9015
15
7
The following conditions must be met for the circuit to Voltage present at alternator G3 terminals B+ and
function: D+
Engine running
Key switch ON
CED,OUOE012,12 1926OCT981/1
CED,OUOE012,28 1902NOV981/1
9015
15
9
1918NOV98
T117942
CED,OUOE012,29 1902NOV981/1
9015
15
10
1921NOV98
T118584
AAlternator FPositive Diodes KRegulator OBattery
BInternal Ground GD+ Terminal LExternal Ground Terminal PKey Switch
CNegative Diodes HB+ Terminal MRotor QDisplay Monitor
DExciter Diodes INoise Filter NAlternator Excitation RBrushes
EStator Windings JExcitation Winding Resistor SSense Circuit
The alternator has three basic stages for proper magnetic field which induces current in the
operation. The operating principles are as follows. three-phase winding of the stator (E). The alternator
reaches cut-in RPM when the induced current is large
PRE-EXCITATION STAGE: enough to produce voltage equal to the battery voltage
plus 1.0 volt. At this time, some current from the stator
When key switch (P) is turned to ON, battery power is rectified by the exciter diodes (D) (producing battery
flows through the alternator excitation resistor (N) to voltage at the B+ terminal (G) and is supplied to the
terminal D+ (G) on alternator, excitation winding (J), carbon brushes and slip rings of the excitation winding,
through regulator (K) and to internal ground (B). strengthening the magnetic field in the excitation
winding. This in turn will increase the stator voltage.
EXCITATION STAGE: This will occur continuously until the alternator (A) is
fully excited and the alternator regulated voltage is
During alternator start (as the engine speeds up from 0 reached.
to idle) current supplied by the alternator excitation
resistor to the field coil of the rotor produces a NORMAL OPERATION:
The alternating current induced in the stator winding B+ voltage (H) and compares it to an internal
(E) is rectified by the positive and negative diodes (F reference. When the B+ voltage (H) starts to rise
and C) and delivered to the battery and current above the reference voltage, the regulator (K) switches
consuming accessories. The currents in the stator off the field current. When the B voltage (H) starts to
winding (E) are constantly changing magnitude and fall below the reference voltage the regulator (K)
direction. However, current flowing to the battery and switches on the field current. The regulator (K)
accessories always maintains the same direction. This switches the field on and off several thousand times a
is because no matter what position the rotor (M) is in, second in response to the current load placed on the
all the diodes are simultaneously involved in the alternator output and the engine RPM.
process of rectification. The regulator (K) measures the
CED,OUOE012,13 1921DEC982/2
NOTE: For a problem that cannot be identified using the diagnostic procedures, check the wiring harnesses and
diodes in the circuits for shorts and opens.
1/1
1/1
T6768CR UN18OCT88
9015
15
12
1/1
T118386 UN21NOV98
Check wire from alternator terminal D+ to pin 42 of 20-pin harness connector for
continuity and for short to ground.
1/1
Alternator Shut Down NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Relay Isolation Diode measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
(V2) Check meter when checking continuity. diode has failed in a
shorted mode. Replace.
NO: If continuity is
measured in one check
T118385 UN21NOV98 and not the other, diode
is OK.
Remove diode from connector.
Is continuity measured?
9015
15
Reverse ohmmeter probes.
13
Is continuity measured?
1/1
Alternator Power 60 Amp Disconnect fusible link from battery relay. YES: Fusible link is OK.
Fusible Link (F22) Check Check wiring harness.
Connect ohmmeter to both ends of fusible link.
NO: Fusible link has
Is continuity measured? failed. Replace fusible
link.
T109319 UN28APR97
1/1
T7447BG 1914JAN91
Connect 24 volts to relay terminal 1 and ground terminal
2.
1/1
9015
15
14
CED,OUOE012,14 1927OCT981/1
When key switch S1 is moved to START, power is When the engine is running and the alternator is
applied from key switch terminal ST to terminal e of producing output voltage, starter protection relay K11
starter relay K13 and terminal g of fuel shutoff relay is energized by ground applied to terminal 2 of the
K15, energizing both relays. (The ground path for the relay from pin 18 of monitor controller and display A5.
starter relay coil is provided through terminals 3 and 4 This prevents the starter motor from being activated if
of de-energized starter protection relay K11). Battery the key switch is moved to START while the engine is
power from alternator power fusible link F22 is applied running, by removing the ground path for starter relay
from terminals B and G of energized starter relay K13 K13.
to starter M1 solenoid terminal C, energizing the
solenoid. This applies battery voltage at starter Start relay coil suppression diode V9 limits the voltage
terminal B (from battery relay K14) to the motor spikes generated by the starter relay coil when the
winding, and the starter motor starts cranking the relay de-energizes.
engine.
Fuel shutoff solenoid pull-in and hold-in coil
At the same time, power from fuel shutoff fusible link suppression diodes V10 and V8 limit the voltage
F23 is applied through terminals B and G of the spikes generated by the solenoid coils when they are
energized fuel shutoff relay to the pull-in coil of fuel de-energized.
shutoff solenoid Y7, opening the fuel valve. Power
from power on 10-amp fuse F5 at the hold-in coil of
the fuel shutoff solenoid keeps the fuel valve open
after the key switch is returned to ON.
CED,OUOE012,15 1914DEC981/1
CED,OUOE012,16 1903FEB991/1
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and
Pump Controller or other components may result. Disconnect connectors only when instructed during a
test or check.
1/1
1/1
T118428 UN21NOV98
1/1
Starter (M1) Motor Check Disconnect metal strap from starter motor large terminal. YES: Starter motor is OK.
Check wiring harness.
Connect a heavy gauge wire from battery positive cable
to starter motor terminal. NO: Repair or replace
starter.
Does starter motor turn, but NOT crank engine?
T6534BJ UN07JAN97
1/1
Starter Relay (K13) Disconnect harness from relay. Connect 24 volts to small YES: Relay is OK. Check
Check terminal e and ground small terminal g. Measure wiring harness.
continuity between large terminals B and G.
NO: Relay has failed.
Is continuity measured? Replace relay.
T7466AD UN14MAR91
1/1
Start Relay Coil NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Suppression Diode (V9) measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
Check meter when checking continuity. diode has failed in a
shorted mode. Replace.
NO: If continuity is
measured in one check
T118385 UN21NOV98 and not the other, diode
is OK.
Remove diode from connector.
Is continuity measured?
9015
15
Reverse ohmmeter probes.
18
Is continuity measured?
1/1
Battery Relay (K14) SRelay Coil +24 Volt Terminal YES: Relay is OK. Check
Check ERelay Coil Ground Terminal wiring harness.
BRelay Battery Input Terminal
ARelay Battery Output Terminal NO: Relay has failed.
Replace relay.
Disconnect harness from relay. Connect 24 volts to small
terminal S and ground small terminal E. Measure
continuity between large terminals A and B.
T8182AK UN03MAR94
Is continuity measured?
1/1
Alternator Power 60 Amp Disconnect fusible link from battery relay. YES: Fusible link is OK.
Fusible Link (F22) Check Check wiring harness.
Connect ohmmeter to both ends of fusible link.
NO: Fusible link has
Is continuity measured? failed. Replace fusible
link.
T109319 UN28APR97
1/1
1/1
Fuel Shutoff Relay (K15) 124 Volt Terminal YES: Relay is OK.
Check 2Ground Terminal
3Relay Common NO: Relay has failed.
4Relay Normally Closed Replace.
5Relay Normally Open
T7447BG 1914JAN91
Connect ohmmeter to terminals 3 and 4.
1/1
T118387 UN21NOV98
Does solenoid energize and pull injection pump shutoff lever back?
1/1
Fuel Shutoff Solenoid NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Hold-In Coil Suppression measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
Diode (V8) Check meter when checking continuity. diode has failed in a
shorted mode. Replace.
NO: If continuity is
measured in one check
T118385 UN21NOV98 and not the other, diode
is OK.
Remove diode from connector.
Is continuity measured?
Is continuity measured?
1/1
Fuel Shutoff Solenoid NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Pull-In Coil Suppression measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
Diode (V10) Check meter when checking continuity. diode has failed in a
shorted mode. Replace.
NO: If continuity is
measured in one check
T118385 UN21NOV98 and not the other, diode
is OK.
Remove diode from connector.
Is continuity measured?
9015
15
Reverse ohmmeter probes.
21
Is continuity measured?
1/1
The following conditions must be met for the circuit to Key switch ON.
function:
CED,OUOE012,8 1921OCT981/1
9015
15
22
9015
15
25
CED,OUOE012,7 1915DEC983/3
CED,OUOE012,9 1903FEB991/1
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Monitor
Controller or other components may result. Disconnect connectors only when instructed during a test or
check.
NOTE: If windshield wiper does not operate, first check the latch on the upper right corner of the windshield. The
windshield must be all the way down and the right latch must be secured to contact the windshield wiper enable
switch, which allows the wiper to operate.
Before troubleshooting the circuits, clean all pins in the monitor controller and harness connectors using a
non-conductive lubricating contact cleaner, then try the circuit operation again before proceeding. TY16324 Contact
Cleaner can be used.
9015
15
27
1/1
Is continuity measured?
1/1
T118388 UN21NOV98
If the windshield wiper was in the park position, did it operate for one sweep, then stop
in the intermittent stop position?
9015
Connect wiper motor connector pin E to ground (while still connected to S).
15
28
Does windshield wiper operate?
Does windshield wiper continue operating until wiper blade reaches intermittent park
position, then stop?
1/1
T118388 UN21NOV98
When wiper stops in intermittent stop position, turn key switch OFF, then turn
windshield wiper switch OFF.
Does wiper motor operate until wiper blade reaches park position?
1/1
Windshield Wiper Motor NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Suppression Diode (V6, measured in one direction only in a serviceable diode. measured in both checks,
V7) Check diode has failed in a
shorted mode. Replace.
NO: If continuity is
T118385 UN21NOV98 measured in one check
and not the other, diode
The windshield wiper diodes are located inside right console lower cover. is OK.
Is continuity measured?
1/1
Windshield Wiper Relay NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Isolation Diode (V5) measured in one direction only in a serviceable diode. measured in both checks,
Check diode has failed in a
shorted mode. Replace.
NO: If continuity is
T118385 UN21NOV98 measured in one check
and not the other, diode
The windshield wiper diodes are located inside right console lower cover. is OK.
Is continuity measured?
Is continuity measured?
1/1
1/1
T7447BG 1914JAN91
Connect ohmmeter to relay terminals 3 and 4.
1/1
Windshield Washer Disconnect harness from windshield washer motor. YES: Check wiring
Motor (M4) Check harness and monitor
Connect 24 volts to BLUE wire pin in washer motor controller.
connector.
NO: Replace windshield
Ground BLUE/BLACK wire pin in washer motor washer motor.
connector.
1/1
Windshield Wiper Enable Slide upper windshield up. YES: Windshield wiper
Switch (S14) Check enable switch is OK.
Remove windshield wiper enable switch retaining plate located in upper right hand
corner of cab. NO: Go to next check.
Connect ohmmeter across pins 1 and 2 of the switch and actuate the switch.
Is continuity measured when switch is actuated and no continuity when switch is not
actuated?
1/1
Windshield Wiper Enable Slide upper windshield up. YES: Windshield wiper
Switch (S14) Harness enable switch harness is
9015
Check Remove windshield wiper enable switch retaining plate located in upper right hand OK.
15
corner of cab.
31
NO: Check monitor
Using an ohmmeter, measure resistance of harness wire from enable switch pin 1 to controller.
pin 6 of monitor controller 12-pin connector, and from enable switch pin 2 to ground.
1/1
CED,OUOE012,18 1930OCT981/1
When the key switch is in the ON or ACC position, mode and RPM control unit A4, and the ILLUM pin of
power is applied from work and drive light 10-amp fuse radio A1 for panel illumination.
F11 to terminals 1 and 3 of work and drive light relays
K3 and K4. When the light switch is moved to position 2, pin 20 of
the monitor controller and display is also grounded (pin
When drive and work light switch S10 is moved to 19 remains grounded), energizing work light relay K3
9015 position 1, drive light relay K4 is energized by ground as well. With the work light relay energized, power is
15 applied to relay terminal 2 from pin 19 of monitor and applied to work light E1 through relay terminals 3 and
32 controller display A5. With the drive light relay 5.
energized, power is applied to drive light E2 through
relay terminals 3 and 5. Relays K3 and K4 also apply power to pins 5 (work
light) and 4 (drive light) of optional connector X5 to
Power from the drive light relay is also applied to pin provide for connection of additional lights.
41 of monitor controller and display A5, pin 8 of engine
CED,OUOE012,19 1914DEC981/1
9015
15
33
1911DEC98
T117934
CED,OUOE012,20 1921DEC981/1
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and
Pump Controller or other components may result. Disconnect connectors only when instructed during a
test or check.
NOTE: Before troubleshooting the circuits, clean all pins in the monitor controller and harness connectors using a
non-conductive lubricating contact cleaner, then try the circuit operation again before proceeding. TY16324 Contact
Cleaner can be used.
1/1
Work and Drive Lights 20 Remove fuse block cover. YES: Fuse is OK.
Amp Fuse (F11) Check
9015
Remove fuse from fuse block. NO: Replace Fuse. If
15
fuse blows again, check
34
Using ohmmeter, check fuse for continuity. for short.
Is continuity measured?
1/1
Drive Light Relay (K4) 124 Volt Terminal YES: Relay is OK.
Check 2Ground Terminal
3Relay Common NO: Relay has failed.
4Relay Normally Closed Replace.
5Relay Normally Open
T7447BG 1914JAN91
Connect ohmmeter to terminals 3 and 4.
1/1
1/1
Disconnect 16-pin harness connector from monitor controller and display panel.
1/1
Disconnect 16-pin harness connector from monitor controller and display panel.
9015
15
36
1/1
9015
15
37
CED,OUOE012,21 1931OCT981/1
The accessory circuits include the horns (B25, B26), Power from dome light 5-amp fuse F18 is applied to
the cab dome light (E3), and the 24-volt power plug dome light switch S3. When the switch is turned ON,
(G4). power is applied to cab dome light E3, turning the light
on.
Power from horn 10-amp fuse F15 is applied to
terminal 1 and 3 of horn relay K5. When horn switch Power from lighter 10-amp fuse F17 is applied to
9015 S2 is pressed, the closed contacts of the switch apply 24-volt power plug G4.
15 ground to terminal 2 of the horn relay, and the relay is
38 energized. With the relay is energized, power is
applied from relay terminal 5 to high and low note
horns B25 and B26, sounding the horns.
CED,OUOE012,22 1921DEC981/1
9015
15
39
1918NOV98
T117936
CED,OUOE012,23 1921DEC981/1
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and
Pump Controller or other components may result. Disconnect connectors only when instructed during a
test or check.
1/1
Horn 10 Amp Fuse (F15) Remove fuse block cover. YES: Fuse is OK.
Check
9015
Remove fuse from fuse block. NO: Replace Fuse. If
15
fuse blows again, check
40
Using ohmmeter, check fuse for continuity. for short.
Is continuity measured?
1/1
Dome Light 5 Amp Fuse Remove fuse block cover. YES: Fuse is OK.
(F18) Check
Remove fuse from fuse block. NO: Replace Fuse. If
fuse blows again, check
Using ohmmeter, check fuse for continuity. for short.
Is continuity measured?
1/1
Lighter 10 Amp Fuse Remove fuse block cover. YES: Fuse is OK.
(F17) Check
Remove fuse from fuse block. NO: Replace Fuse. If
fuse blows again, check
Using ohmmeter, check fuse for continuity. for short.
Is continuity measured?
1/1
1/1
T108586 UN31MAR97
Connect ohmmeter to both wires (pink and black) and push horn button.
Is continuity measured?
1/1
High Note Horn (B25) Disconnect wire harness from horns. YES: Check wire
and Low Note Horn (B26) harness.
Check Connect 24 volts to one terminal of either horn and
connect other horn terminal to ground. NO: Replace horn.
1/1
CED,OUTX782,143 1903FEB991/1
9015
15
43
CED,OUOE012,26 1931OCT981/1
9015
15
44
STATUS INDICATORS
CED,OUOE012,55 1904OCT006/6
9015
15
50
CED,OUTX782,77 1915JAN991/1
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and
Pump Controller or other components may result. Disconnect connectors only when instructed during a
test or check.
NOTE: Before troubleshooting the circuits, clean all pins in the monitor controller and harness connectors using a
non-conductive lubricating contact cleaner, then try the circuit operation again before proceeding. TY16324 Contact
Cleaner can be used.
1/1
Monitor Controller and Remove fuse block cover. YES: Fuse is OK.
Display 5 Amp Fuse (F6)
9015
Check Remove fuse from fuse block. NO: Replace Fuse. If
15
fuse blows again, check
52
Using ohmmeter, check fuse for continuity. for short.
Is continuity measured?
1/1
T118378 UN21NOV98
Is 24 volts measured?
1/1
T118378 UN21NOV98
Is continuity measured?
9015
15
53
1/1
Economy Mode Indicator With key switch ON and economy mode OFF, push economy (E) mode switch. YES: Indicator and switch
Light (H6) Check are OK.
Does switch stay down and economy mode indicator light come ON?
NO: Go to next check.
Push economy (E) mode switch again.
1/1
T118513 UN21NOV98
Measure continuity with economy (E) mode switch in OFF and ON positions.
Does ohmmeter read open with switch in OFF position, and continuity with switch in
ON position?
1/1
T118512 UN21NOV98
Measure continuity with economy (E) mode switch in OFF and ON positions.
Does ohmmeter read open with switch in OFF position, and continuity with switch in
9015
ON position?
15
54
1/1
High Power Mode With key switch ON and high power mode OFF, push high power (HP) mode switch. YES: Indicator and switch
Indicator Light (H5) are OK.
Check Does switch stay down and high power mode indicator light come ON?
NO: Go to next check.
Push high power (HP) mode switch again.
1/1
T118515 UN21NOV98
Measure continuity with high power (HP) mode switch in OFF and ON positions.
Does ohmmeter read open with switch in OFF position, and continuity with switch in
ON position?
1/1
T118514 UN21NOV98
Measure continuity with high power (HP) mode switch in OFF and ON positions.
Does ohmmeter read open with switch in OFF position, and continuity with switch in
9015
ON position?
15
55
1/1
Work Mode Selection Turn key switch ON. YES: Switch and
Switch (S7), Dig Mode indicators are OK.
Indicator Light (H1), Push WORK MODE switch several times to cycle through all work mode selections
Grading Mode Indicator (dig, grading precision, attachments). NO: If modes do not
Light (H2), Precision change, switch or monitor
Mode Indicator Light (H3) Does mode selection change when switch is pressed? controller has failed.
and Attachment Mode Repair or replace.
Indicator Light (H4) Does each mode indicator come ON as mode is selected?
Check Replace indicator lamp
that does not come ON.
1/1
Auto Idle Switch (S13) Turn key switch ON. YES: Switch and indicator
and Auto Idle Mode are OK
Indicator Light (H7) Push auto idle (A/I) switch.
Check NO: Check indicator
Does auto idle (A/I) indicator come ON? lamp. If lamp is OK,
switch or controller has
Push auto idle (A/I) again. failed. Replace.
1/1
T6768CR UN18OCT88
9015
15
56
1/1
T118386 UN21NOV98
Check wire from alternator terminal D+ to pin 42 of 20-pin harness connector for
continuity and for short to ground.
1/1
Engine Coolant Level Check coolant level in overflow recovery tank. Be sure YES: Indicator is OK. Go
Indicator Light (H20) level is between FULL and LOW marks. to next step.
Check
Turn key switch ON. NO: Check indicator
lamp.
Observe coolant level indicator.
9015
15
57
T102542 UN29AUG96
1/1
Engine Coolant Level Disconnect harness from engine coolant level switch. YES: Engine coolant level
Switch (B6) Check switch has failed.
Connect a jumper wire between harness connector pins. Replace.
T7469AL UN14MAR91
Does coolant level indicator come ON?
1/1
Check oil level in engine pan, be sure level is between FULL and ADD marks on dip
stick.
T102542 UN29AUG96
1/1
Engine Oil Level Switch Disconnect harness from engine oil level switch. YES: Engine oil level
(B7) Check switch has failed.
Connect a jumper wire from harness connector to Replace.
ground.
NO: Check wiring
Turn key switch ON. harness.
1/1
Check oil level in hydraulic reservoir. Be sure level is between red lines on sight
gauge.
T102542 UN29AUG96
1/1
Hydraulic Oil Level Disconnect harness from hydraulic oil level switch. YES: Hydraulic oil level
Switch (B5) Check switch has failed.
Connect a jumper wire between harness connector pins. Replace.
1/1
Engine Coolant With engine cool, turn key switch ON. YES: Indicator is OK. Go
Temperature Indicator to next check.
Light (H16) Check Observe engine temperature indicator.
NO: If indicator does not
Does indicator come ON when key switch is turned ON, come ON, check indicator
then go OFF 23 seconds later? lamp.
1/1
Engine Coolant Disconnect harness from engine coolant temperature YES: Engine coolant
Temperature Switch (B3) switch. temperature switch has
9015
Check failed. Replace.
15
If engine coolant temperature indicator was ON, did it go
60
OFF with harness disconnected and key switch ON? NO: Check harness.
1/1
Engine Oil Pressure Disconnect harness from engine oil pressure switch. YES: Indicator is OK. Go
Indicator Light (H17) to next check.
Check Turn key switch ON and observe engine oil pressure
indicator. NO: If indicator does not
come ON, check indicator
Does indicator come ON when key switch is turned ON, lamp.
then go OFF 23 seconds later?
If indicator does not go
T101684 UN29AUG96 OFF, check harness for
short.
1/1
Engine Oil Pressure Connect harness to engine oil pressure switch. YES: Go to next step.
Switch (B4) Check
Does indicator come ON with key switch ON? NO: Check harness for
open. If harness is OK,
replace switch.
1/1
Air Filter Restriction Turn key switch ON. YES: Indicator is OK. Go
Indicator Light (H14) to next check.
Check Observe air filter restriction indicator.
NO: If indicator does not
Does indicator come ON when key switch is turned ON, then go OFF 23 seconds come ON, check indicator
later? lamp.
1/1
T118382 UN21NOV98
If indicator was ON, did it go OFF with leads disconnected and key switch ON?
1/1
T118389 UN30NOV98
Disconnect 20-pin harness connector from monitor display and controller connector.
Does gauge needle point to E with 24 volts applied to pin 30, and F with pin 46
grounded?
1/1
T118391 UN21NOV98
NOTE: Check fuel gauge before checking resistor. Resistor is located on bottom of
monitor controller panel. Access resistor by removing bottom cover from monitor
controller panel.
9015
15
62
1/1
Fuel Level Sensor (B8) NOTE: Check fuel gauge before checking sensor. YES: Sensor has failed.
Check Replace.
Disconnect harness from fuel level sensor.
NO: Check harness.
Observe fuel gauge.
T7472AE UN11MAR91
Connect jumper wire between harness connector pins.
1/1
Fuel Level Indicator With adequate fuel in tank, turn key switch ON. YES: Indicator is OK. Go
Light (H13) Check to next check.
Observe fuel level indicator.
NO: If indicator does not
Does indicator come ON when key switch is turned ON, then go OFF 23 seconds come ON, check indicator
later? lamp.
1/1
Fuel Level Switch (B2) Disconnect harness from fuel level switch. YES: Fuel level switch
Check has failed. Replace.
If indicator was ON, did it go OFF with harness
disconnected and key switch ON? NO: Check harness.
1/1
T118390 UN21NOV98
Disconnect 20-pin harness connector from monitor display and controller connector.
Does gauge needle point to C with 24 volts applied to pin 30, and H with pin 47
grounded?
1/1
T118391 UN21NOV98
NOTE: Check engine coolant temperature gauge before checking resistor. Resistor is
located on bottom of the monitor controller panel. Access resistor by removing bottom
cover from monitor controller panel.
1/1
Engine Coolant NOTE: Check engine coolant temperature gauge before YES: Sensor is OK.
Temperature Sensor (B9) checking resistor. Check harness.
Check
Disconnect harness from temperature sensor. NO: Sensor has failed.
Replace.
Connect ohmmeter to sensor and ground.
1/1
9015
15
64
9015
15
65
The following conditions must be met for the circuit to Engine and pump controller connector pins B7, D1,
function: D2, A1, and A13
Relay K10 terminal 1
Key switch ON and voltage present at the following:
CED,TX14795,4140 1921DEC981/1
9015
15
66
The EPC applies service codes from EPC pins B8, B15,
and B16 to diagnostic connector X1 for analysis of
hydraulic and electrical systems by the diagnostic
computer.
CED,OUOE012,33 1915DEC982/2
CED,OUOE012,34 1903FEB991/1
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and
Pump Controller or other components may result. Disconnect connectors only when instructed during a
test or check.
NOTE: Before troubleshooting the circuits, clean all pins in the engine and pump controller, and harness connectors
using a non-conductive lubricating contact cleaner, then try the circuit operation again before proceeding. TY16324
Contact Cleaner can be used.
1/1
Engine and Pump Turn key switch OFF. YES: Fuse is OK. Check
Controller 10 Amp Fuse wiring harness
9015
(F2) Check Remove fuse block cover.
15
NO: Replace Fuse. If
70
Remove fuse from fuse block. fuse blows again, check
for short.
Using ohmmeter, check fuse for continuity.
Is continuity measured?
1/1
Power On 10 Amp Fuse Turn key switch OFF. YES: Fuse is OK. Check
(F5) Check wiring harness
Remove fuse block cover.
NO: Replace Fuse. If
Remove fuse from fuse block. fuse blows again, check
for short.
Using ohmmeter, check fuse for continuity.
Is continuity measured?
1/1
Engine Control (EC) Turn key switch OFF. YES: Fuse is OK. Check
Motor 10 Amp Fuse (F3) wire from fuse to monitor
Check Remove fuse block cover. controller connector D,
pins 1 and 2. If OK, go to
Remove fuse from fuse block. next check.
1/1
Solenoid 5 Amp Fuse Remove fuse block cover. YES: Fuse is OK. Check
(F4) Check wiring harness
Remove fuse from fuse block.
NO: Replace Fuse. If
Using ohmmeter, check fuse for continuity. fuse blows again, check
for short.
Is continuity measured?
1/1
T118380 UN21NOV98
Measure resistance between pin 1 and pin 3, and between pin 2 and pin 4.
Does ohmmeter read approximately the same resistance for both measurements?
1/1
T118393 UN30NOV98
T118392 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Measure resistance of sensor from connector pin 1 to pin 3, and pin 1 to Pin 2.
Does ohmmeter read 2000 400 ohms from pin 1 to pin 3 and something less than
9015
that from pin 1 to pin 2?
15
72
1/1
Is 5 volts measured?
T118379 1930NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Disconnect 22-pin connector D and 16-pin connector B from engine and pump
controller.
Is continuity measured?
1/1
Engine Speed (N) Sensor Turn key switch OFF. YES: Sensor is OK. Go
(B16) Check to next check.
Disconnect harness from engine speed sensor.
NO: Sensor has failed.
Measure resistance across speed sensor connector pins Replace.
1 and 2.
9015
15
74
1/1
T118373 1930NOV98
Is continuity measured?
1/1
9015
T118394 1930NOV98 15
75
Disconnect 16-pin harness connector from monitor controller and display, and 22-pin
harness connector D from engine and pump controller.
Measure continuity between pin 15 of monitor controller harness connector and pin 5
of engine and pump controller harness connector D.
Is continuity measured?
1/1
T118376 1930NOV98
Disconnect 16-pin harness connector from monitor controller and display, and 16-pin
harness connector B from engine and pump controller.
Measure continuity between pin 23 of monitor controller harness connector and pin 11
of engine and pump controller harness connector B.
Is continuity measured?
1/1
9015
15 T118395 1930NOV98
76
Disconnect 16-pin harness connector from monitor controller and display, and 22-pin
harness connector D from engine and pump controller.
Measure continuity between pin 21 of monitor controller harness connector and pin 3
of engine and pump controller harness connector D.
Is continuity measured?
1/1
T118396 1930NOV98
Disconnect 16-pin harness connector from monitor controller and display, and 22-pin
harness connector D from engine and pump controller.
Measure continuity between pin 22 of monitor controller harness connector and pin 4
of engine and pump controller harness connector D.
Is continuity measured?
1/1
9015
T118381 1921NOV98 15
77
Disconnect 16-pin harness connector from monitor controller, and 22-pin harness
connector D from engine and pump controller.
Measure continuity between pin 13 of monitor controller harness connector and pin 6
of engine and pump controller harness connector D.
Is continuity measured?
1/1
T118383 UN17MAR99
Disconnect harness connector from engine mode and RPM control unit A4.
Measure resistance from engine mode and RPM control unit pin 5 to pin 7, and from
pin 5 to pin 6.
Is 5000 500 ohms measured from pin 5 to pin 7, and less than that from pin 5 to pin
6?
1/1
9015
15
78
T118397 1930NOV98
Disconnect 16-pin harness connector B and 22-pin harness connector D from engine
and pump controller.
Disconnect harness connector from engine mode and RPM control unit A4.
Measure continuity from pin 5 of engine mode and RPM control unit harness connector
to pin 9 of engine and pump controller harness connector B.
Measure continuity from pin 7 of engine mode and RPM control unit harness connector
to pin 22 of engine and pump controller harness connector D.
Measure continuity from pin 6 of engine mode and RPM control unit harness connector
to pin 21 of engine and pump controller harness connector D.
Is continuity measured?
1/1
T118538 1921NOV98
T118486 UN21NOV98
1/1
T118372 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
T118371 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
1/2
9015
T118358 1921NOV98 15
81
Install jumper between sensor harness connector pins 1 and 2.
Disconnect 22-pin connector D and 16-pin connector B from engine and pump
controller.
Is continuity measured?
19 2/2
Arm In Pressure Sensor Install pump control test harness JT07353 in series with wiring harness and sensor. YES: Sensor is OK.
(B20) Check Engine and pump
Connect voltmeter to test harness jacks. controller may have
failed.
With engine running, pilot control lever forward, and hydraulic functions in neutral,
observe voltage. NO: Sensor has failed.
Replace.
Is voltage between 0.5 and 0.7 volts?
Does voltage increase to between 3.3 and 3.5 volts with hydraulic function over relief?
1/1
T118372 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Disconnect wiring harness connector from front (B22) or rear (B21) pump control
pressure sensor.
9015
Connect voltmeter to sensor harness connector pin 1 and ground.
15
82
Turn key switch ON.
T118371 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
1/2
9015
T118359 1921NOV98 15
83
Install jumper between sensor harness connector pins 1 and 2.
Disconnect 22-pin connector D and 16-pin connector B from engine and pump
controller.
Is continuity measured?
19 2/2
Rear Pump Control Install pump control test harness JT07353 in series with wiring harness and sensor. YES: Sensor is OK.
Pressure Sensor (B21) Engine and pump
and Front Control Connect voltmeter to test harness jacks. controller may have
Pressure Sensor (B22) failed.
Check With engine running, pilot control lever forward, and hydraulic functions in neutral,
observe voltmeter. NO: Sensor has failed.
Replace.
Is voltage 0.5 - 0.7 volts?
Slowly actuate boom up (for front pressure sensor B22) or left track (for rear pressure
sensor B21) until motion just begins.
1/1
T118369 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Disconnect wiring harness connector from front (B19) or rear (B18) pump pressure
sensor.
9015
Connect voltmeter to sensor harness connector pin 1 and ground.
15
84
Turn key switch ON.
T118368 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
1/2
9015
T118370 1921NOV98 15
85
1Positive Pin
2Sense Pin
3Negative Pin
Disconnect 22-pin connector D and 16-pin connector B from engine and pump
controller.
Is continuity measured?
19 2/2
T118560 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Install pump pressure sensor test harness JT07354 in series with wiring harness and
sensor.
Does voltage increase to 3.3 - 3.5 volts with hydraulic function over relief?
1/1
With engine running and pilot control lever forward, NO: Boom up pressure
T112437 UN05DEC97
actuate boom up lever. switch has failed.
Replace.
Is continuity measured when boom up lever is actuated?
1/1
Dig Pressure Switch Turn key switch OFF. YES: Pressure switch is
(B14) Check OK. Check switch
Disconnect wiring harness at dig pressure switch. harness. If harness is OK,
engine and pump
Connect ohmmeter to pins 1 and 2 of pressure switch controller may have
connector. failed.
With engine running and pilot control lever forward, NO: Dig pressure switch
T112437 UN05DEC97
slowly actuate arm in lever while observing ohmmeter. has failed. Replace.
1/1
Propel Pressure Switch Turn key switch OFF. YES: Pressure switch is
(B15) Check OK. Check for continuity
Disconnect wiring harness at propel pressure switch. from harness connector
pin 1 to ground. If OK, go
Connect ohmmeter to pins 1 and 2 of pressure switch to next check.
connector.
NO: Propel pressure
With engine running and pilot control lever forward, switch has failed.
T112437 UN05DEC97
slowly actuate propel lever while observing ohmmeter. Replace.
1/1
T7447BG 1914JAN91
Connect ohmmeter to relay terminals 3 and 4.
1/1
Travel Alarm 5 Amp Fuse Remove fuse block cover. YES: Fuse is OK. Go to
(F10) Check next check.
Remove fuse from fuse block.
NO: Replace Fuse. If
Using ohmmeter, check fuse for continuity. fuse blows again, check
for short.
Is continuity measured?
1/1
T118561 UN21NOV98
With ohmmeter measure continuity from relay harness connector pin 5 to ground.
Is continuity measured?
T118362 UN21NOV98
124-Volt Pin
2Ground Pin
3Relay Common
4Relay Normally Closed
5Relay Normally Open
NOTE: Use diode checking mode on meter when checking this reading.
Connect an ohmmeter to relay harness connector pin 2 and pressure switch connector
pin 1.
Measure resistance, then reverse ohmmeter probes and measure resistance again.
Does resistance read approximately 500 ohms in one direction, and open in the other
direction?
1/2
19 2/2
Propel Auto Idle Relay NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Isolation Diode (V4) measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
9015
Check meter when checking continuity. diode has failed in a
15
shorted mode. Replace.
89
NO: If continuity is NOT
measured in either check,
diode has failed in an
open mode. Replace.
NO: If continuity is
measured in one check
T118385 UN21NOV98 and not the other, diode
is OK.
Remove diode from connector.
Is continuity measured?
Is continuity measured?
1/1
Propel Speed Change Turn key switch OFF. YES: Solenoid is OK. Go
Proportional Solenoid to next check.
(Y6) Check Remove wire clip from bottom of solenoid harness
connector. NO: Solenoid has failed.
Replace.
Disconnect harness from solenoid.
1/1
Propel Speed Change Turn key switch OFF. YES: Harness and engine
Proportional Solenoid and pump controller are
(Y6) Harness Check Install proportional solenoid test harness JT07352 in series with wiring harness and OK.
sense solenoid.
NO: Harness or engine
Connect voltmeter to test harness jacks. and pump controller has
failed. Repair or replace.
Start engine and while observing voltmeter, drive machine at full propel speed until fast
speed kicks in.
Does voltmeter read approximately 6 volts in slow speed, and 12 volts in fast speed?
1/1
1/1
Arm Regenerative Turn key switch OFF. YES: Harness and engine
Proportional Solenoid and pump controller are
(Y9) Harness Check Install proportional solenoid test harness JT07352 in series with wiring harness and OK.
sense solenoid.
NO: Harness or engine
Connect voltmeter to test harness jacks. and pump controller has
failed. Repair or replace.
Start engine and move arm all the way out and boom down.
Does voltmeter read higher voltage (approximately 9 volts) while boom and arm are
moving?
1/1
1/1
Power Boost Turn key switch OFF. YES: Harness and engine
Proportional Solenoid and pump controller are
9015
(Y5) Harness Check Install proportional solenoid test harness JT07352 in series with wiring harness and OK.
15
sense solenoid.
91
NO: Harness or engine
Connect voltmeter to test harness jacks. and pump controller has
failed. Repair or replace.
Start engine and observe voltmeter while pressing power boost switch.
Does voltmeter read approximately 5 volts when switch is not pressed, and
approximately 9 volts when switch is pressed?
1/1
1/1
Speed Sense Turn key switch OFF. YES: Harness and engine
Proportional Solenoid and pump controller are
(Y8) Harness Check Install proportional solenoid test harness JT07352 in series with wiring harness and OK.
sense solenoid.
NO: Harness or engine
Connect voltmeter to test harness jacks. and pump controller has
failed. Repair or replace.
Start engine, set auto idle mode to OFF, and set engine idle to medium speed so that
voltmeter reads approximately 5.5 volts (RPM dial set at first bar after mid range).
1/1
T118558 1921NOV98
Is continuity measured?
1/1
9015
15
93
The following conditions must be met for the circuit to Key switch ON
function: Voltage present at travel alarm 5-amp fuse F10
CED,OUOE012,36 1921DEC981/1
The travel alarm circuit contains: travel alarm fuse F10, pilot pressure and closes. With the switch closed,
travel alarm H10, travel alarm cancel switch S17, and ground is applied to pin C of the travel alarm,
propel pressure switch B15. Operating voltage for the activating the alarm. After the travel alarm has
travel alarm is applied from fuse F10 to travel alarm sounded for 10 seconds, the travel alarm cancel switch
pin B. When the propel levers are moved to forward or may be pushed to turn the alarm off by grounding
reverse positions, propel pressure switch B15 senses alarm pin A.
9015
15
94
CED,OUOE012,37 1921DEC981/1
9015
15
95
1930NOV98
T117932
CED,OUOE012,38 1903FEB991/1
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and
Pump Controller or other components may result. Disconnect connectors only when instructed during a
test or check.
NOTE: Before troubleshooting the circuits, clean all terminals in the engine and pump controller and harness
connectors using a non-conductive lubricating contact cleaner, then try circuit operation again before proceeding.
TY16324 John Deere Contact Cleaner can be used.
1/1
Travel Alarm 5 Amp Fuse Remove fuse block cover. YES: Fuse is OK. Go to
(F10) Check next check.
9015
Remove fuse from fuse block.
15
NO: Replace Fuse. If
96
Using ohmmeter, check fuse for continuity. fuse blows again, check
for short.
Is continuity measured?
1/1
T118563 UN21NOV98
Is 24 volts measured?
9015
15
YES: Go to next step. 97
T118562 UN21NOV98
Connect ohmmeter from travel alarm harness connector pin C to propel pressure
switch harness connector pin 1.
Is continuity measured?
T118564 UN21NOV98
Is continuity measured?
1/1
Travel Alarm (H10) With harness connector disconnected, connect 24 volts YES: Alarm is OK.
Check to travel alarm terminal B, and ground terminal D. Then
ground terminal C. NO: Alarm has failed.
Replace.
Does alarm sound?
T8037BB UN30JUN93
1/1
T118559 UN21NOV98
1/1
CED,TX14795,4147 1905AUG971/1
Battery Specifications
Specification
Battery VoltageVolts .................................................................. 12 Volts
Cold Cranking PowerAmps......................... 1100 amps at 18C (0F)
Reserve CapacityMinutes ................................ 400 minutes at 25 amps
Fully Charged Electrolyte Specific
GravitySpecific Gravity....................................................... 1.2651.280
CED,TX14795,4148 1913AUG981/1
Battery Using Too Much Water Shorted battery cell Check battery state of charge. (See
Procedure for Testing Batteries.)
Low Battery Output Low water level See Battery Using Too Much Water
and Cracked Battery Case
symptoms.
Dirty or wet battery top, causing Clean battery top. Recharge battery.
discharge
Corroded or loose battery cable Clean and tighten cable end clamps.
ends Recharge battery.
CED,TX14795,4149 1905AUG971/1
9015
20
3
UN23AUG88
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
TS203
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If acid is swallowed:
UN09SEP03
3. Fill each cell to within specified range with distilled
water. DO NOT overfill.
T6996DB
ABattery Post
BFill Tube
CElectrolyte Level Range
Single Level Fill Tube Application
9015
20
5
UN09SEP03
T6996DA
Dual Level Fill Tube Application
TX,16,UU3540 1901SEP952/2
a. Check for damage such as cracked or broken c. If high and low readings vary LESS than 0.050
case and electrolyte leakage. and average specific gravity is between 1.225
and 1.280, battery is fully charged, go to LOAD
If damage is seen, replace battery. TEST.
b. Check electrolyte level. (See procedure in this d. If high and low readings vary LESS than 0.050
group.) and average specific gravity is LESS than 1.225,
charge battery and repeat test. If average
If low, add distilled water to specified level and specific gravity is still LESS than 1.225, replace
charge battery. both batteries.
c. Check terminals for corrosion. e. If high and low readings vary MORE than 0.050,
9015
20 charge battery and repeat test. If high and low
6 If corroded, clean using a wire brush or battery readings still vary MORE than 0.050, replace
post cleaner such as JT05838 Battery both batteries.
Post/Clamp Cleaner.
3. LOAD TEST
d. Check posts for looseness.
a. Check battery capacity with a load tester such
If posts are loose, replace battery. as JT05832 Battery Load Tester. Follow tester
manufacturers instructions for proper load test
2. HYDROMETER TEST procedures.
a. Check specific gravity with a hydrometer or b. If one battery fails load test, replace both
battery tester such as JT05460 Coolant/Battery batteries.
Tester.
TX,16,UU3538 1901SEP951/1
UN24OCT91
2. Connect one end of the negative cable to the negative
terminal of booster batteries. Then connect the other
end of negative cable to the machine frame as far
T6713AH1
away from the machine batteries as possible.
AMachine Batteries
4. Immediately after starting the engine, disconnect the BBooster Batteries
end of negative cable from the machine frame first.
Then disconnect the other end of negative cable from
the negative terminal of booster batteries.
CED,TX14795,4152 1914MAY981/1
Replacing Batteries
SPECIFICATIONS
Cold Cranking Amps at -18C 1100 Amps
(0F) amps
Minutes Reserve Capacity at 25 400 Minutes
amps Reserve Capacity
Specification
Cold Cranking Amps at -18C
(0F)Amps ............................................................................. 1100 amps
9015 Minutes Reserve Capacity at 25
20 ampsReserve Capacity ....................................................... 400 Minutes
8
CED,TX14795,4153 1925JUN961/1
IMPORTANT: This machine has a 24-volt electrical should be through a separate ground wire to the
system. Installing 12-volt converter (if equipped) or starter ground stud.
accessories without addition of
24-volt to 12-volt converter may 5. Twist the power and the ground wires from the
cause battery failure. device together and run as close to the vehicle
frame as possible. Twisting the wires helps to
When possible, use 24-volt accessories. If 12-volt cancel any radio frequency fields that form around
accessories are added, use a 24-volt to 12-volt the wire.
converter. Converters are available from your
authorized dealer. (See the Industrial Equipment 6. Use of shielded wire reduces radio frequency fields
Attachment Guide.) even more. Twist power and ground wire together
as above. Ground shield to frame at power source
Converter capacity requirements depend on the load of end and metal case of device at the opposite end.
the accessories installed. Follow electronic dealer and If device does not have a metal case, ground shield
9015
manufacturers recommendations to determine the on device end to frame. 20
capacity of the converter required and its installation 9
requirements. 7. DO NOT run the device from the electronic device
in parallel with the existing harnesses. DO NOT
The following precautions must be followed when band wires to vehicle harnesses.
adding electrical and/or electronic devices:
8. Install noise filters on positive end of all electronic
1. DO NOT mount 24 volt-to-12 volt converters in the devices. Noise filter should be located as close to
cab. Converters should be mounted as close to the the device as possible. Filters can be purchased at
battery as possible. Converters supplied through local electronic stores.
Deere parts system provide installation instructions
outlining proper installation procedures and location. 9. Mount antennas as far away from the engine and
pump controller as possible. It is best not to mount
2. DO NOT mount electrical devices directly in front of antennas on the cab at all. Best locations are at the
system controller (between controller and seat). back of the unit on the counterweight or sheet
Mounting above the controller on shelf behind seat metal above the batteries.
is acceptable.
IMPORTANT: DO NOT connect an accessory to
3. DO NOT mount electrical devices within 6 inches of one battery. Connecting a 12-volt
existing harnesses. accessory to one battery will cause
one battery to overcharge, and the
4. Isolate the case of the electrical device from the other battery to undercharge,
vehicle or cab frame. The ground for the device causing battery failure.
CED,TX14795,4154 1913AUG981/1
UN07MAY97
photograph.
T109427B
volume.
BSwitch
HHigh Level
LLow Level
9015 MMedium Level
20
10
CED,TX14795,4155 1925JUN961/1
CED,OUOE012,45 1923NOV981/1
CED,OUOE012,46 1923NOV981/1
CED,OUOE012,47 1903FEB991/1
9015
20
12
Page
Group 20Adjustments
Track Sag . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1
9020
9020
05
1928OCT92
1
T7827AJ
ATrack Frame DSeal GYoke JAdapter
BNut EPiston HCylinder Barrel KFitting
CSpring FIdler IGrease LTrack Adjuster
The track adjuster (L) is supported by the track frame (G), the track becomes tighter. Loosen adapter (J),
(A). Shock loads on the track and front idler (F) are NOT the fitting (K) to release grease to loosen track.
absorbed by the track recoil spring (C). Grease will escape through a small passage that is
concealed by nut (B).
To tighten the track, pump grease (I) into fitting (K) to
force the piston (E) out. As it presses against the yoke
TX,05,GG2177 1919MAY981/1
9020
05
2
1912AUG96
T102862
The propel gearbox (Q) is a triple reduction planetary are attached to the second planet carrier (D). As the
drive gearbox. The gearbox is interchangeable from second planet gears orbit around the ring gear they
the right to the left side of the machine. The propel turn the second planet carrier. The second planet
motor (O) is connected to and drives the first planet carrier is connected to the third planet sun gear (C).
sun gear (G). The third planet sun gear rotates the third planet gears
(K). The third planet carrier is connected to the propel
Rotary motion is transferred from the first planet sun motor housing through the hub (N) and does not turn
gear (G) to the sprocket (L) by the three planetary so the rotation of the third planet gears is transferred
gear sets that mesh with the ring gear (A). As the first to the ring gear. The ring gear, drum (M) and sprocket
planet sun gear rotates it turns the first planet gears (I) (L) are fastened together and turn as one unit.
which orbit, causing the first planet carrier (F) to rotate.
The first planet carrier is connected to the second A replaceable thrust pad (H) is used in the gearbox
planet sun gear (E) which is in mesh with and rotates cover to keep the floating input shaft in position.
the second planet gears (J). The second planet gears
TX,05,GG2170 1905SEP002/2
9020
05
3
9020
05
4
Noisy or Loose Track Chain Incorrect track tension adjustment Adjust track sag. (See Group
9020-20.)
Grease leaking from track adjuster Inspect between second and third
seals or relief valve roller, at base of relief valve, and at
hole in side of relief valve for
leakage. Replace seals or relief 9020
15
valve. (See Group 0130.)
1
Tight Track Chain Material packing in sprocket Adjust track sag with material
packed in sprocket. (See Group
9020-20.)
Track sag less than specification Adjust track sag. (See Group
9020-20.)
Frequent Track Chain Sag Grease leaking from track adjuster Inspect between second and third
Adjustment Required seals or relief valve roller, at base of relief valve, and at
hole in side of relief valve for
leakage. Replace seals or relief
valve. (See Group 0130.)
Excessive Oil Leakage From Loose plug, worn or damaged Repair roller or idler. (See Group
Idlers and Rollers O-ring, or metal faced seal 0130.)
Bent Track Shoes Excessive grouser wear Measure grouser height. (See
procedure in this group.) Rebuild
grousers or replace shoes.
Popping Of Track High propel loads in reverse High propel loads in reverse can
cause the recoil spring to retract
allowing sprocket to slip in chain.
Cracked Track Link Excessive high speed operation on Slow propel speed on rough and
rough and rocky terrain rocky terrain.
9020
15 Track shoes too wide for ground Use the narrowest shoes possible
2
conditions for required flotation.
Chipped Link Rails Repeated high impacts with roller Adjust track chain sag. (See Group
tread on flanges caused by a loose 9020-20.)
or snaky track, or using shoes that
are too wide Check track chain pitch. (See
procedure in this group.)
Individual Undercarriage See Undercarriage Appraisal Manual Rebuild components using weld.
Component Wear SP326. Repair or replace components.
902015,H15 1903JUN932/2
SPECIFICATIONS
Track Chain
Track Chain Bushing OD 59.0 mm (2.32 in.) new
Track Chain Bushing OD 54.0 mm (2.13 in.) minimum used
UN08NOV88
SERVICE EQUIPMENT AND TOOLS
D17524C1a 100 mm Caliper
T82865
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit.
Track ChainSpecification
9020
Track Chain BushingOD .................................... 59.0 mm (2.32 in.) new
15
Track Chain BushingOD ................... 54.0 mm (2.13 in.) minimum used
3
CED,OUOE003,615 1912SEP001/1
SPECIFICATIONS
Track Chain
Track Chain Link Height 104.0 mm (4.09 in.) new
UN08NOV88
Track Chain Link Height 97.0 mm (3.82 in.) minimum used
T82864
JT05534a Right Angle Attachment
D05231STa 300 mm Ruler
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit.
CED,OUOE003,655 1912SEP001/1
SPECIFICATIONS
Track Chain
Track Chain Pitch 762.0 mm (30.00 in.) new
Track Chain Pitch 780.0 mm (30.71 in.) maximum
UN29JAN98
used
T6813AL
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit.
Track ChainSpecification
Track ChainPitch............................................ 762.0 mm (30.00 in.) new
Track ChainPitch................................... 780.0 mm (30.71 in.) maximum
used
CED,OUOE003,617 1912SEP001/1
UN08NOV88
Three Bar Grouser Height 26.0 mm (1.02 in.) new
Three Bar Grouser Height 15.0 mm (0.59 in.) minimum used
T82859
a
JT05521 Depth Gauge (200 mm Ruler)
JT05534a Right Angle Attachment
D05231STa 300 mm Ruler
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit.
TX,01,SB383 1911SEP001/1
UN08NOV88
Three Bar Grouser Height 25.5 mm (1.00 in.) new
Three Bar Grouser Height 15.0 mm (0.59 in.) minimum used
T82859
a
JT05521 Depth Gauge (200 mm Ruler)
JT05534a Right Angle Attachment
D05231STa 300 mm Ruler
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit.
CED,OUOE003,1131 1911SEP001/1
SPECIFICATIONS
Track Roller
Track Roller Tread OD 150.0 mm (5.91 in.) new
UN08NOV88
Track Roller Tread OD 132.0 mm (5.20 in.) minimum
used
T87973
a
JT05519 Special Roller Caliper
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit.
Track RollerSpecification
Track Roller TreadOD...................................... 150.0 mm (5.91 in.) new
OD ............................................................... 132.0 mm (5.20 in.) minimum
used
TX,15,GG2211 1912SEP001/1
SPECIFICATIONS
Track Carrier Roller
Track Carrier Roller Tread OD 120.0 mm (4.72 in.) new
Track Carrier Roller Tread OD 110.0 mm (4.33 in.) minimum
UN29JAN98
used
T6813AQ
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit.
TX,15,GG2210 1912SEP001/1
SPECIFICATIONS
Front Idler
Front Idler Flange Height 19.0 mm (0.75 in.) new
UN08NOV88
Front Idler Flange Height 28.0 mm (1.10 in.) maximum
used
T87972
a
JT05521 Depth Gauge (200 mm Ruler)
JT05534a Right Angle Attachment
D05231STa 300 mm Ruler
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit.
Front IdlerSpecification
Front Idler FlangeHeight .................................... 19.0 mm (0.75 in.) new
Front Idler FlangeHeight ........................... 28.0 mm (1.10 in.) maximum
used
TX,15,GG2212 1912SEP001/1
SPECIFICATIONS
Swing Bearing Play 1.2 mm (0.047 in.) or less new
Swing Bearing Play 4.0 mm (0.157 in.) maximum
UN23NOV92
are tight. (See Group 4350.)
9020
15
Check that bearing is lubricated with the specified
11
grease (See Track Adjuster, Working Tool Pivot, Swing
T7886AI
Bearing, and Swing Bearing Gear Grease in Section
9000.)
Specification
Swing BearingPlay ................................ 1.2 mm (0.047 in.) or less new
Play ............................................................... 4.0 mm (0.157 in.) maximum
TX,15,GG2213 1929MAY982/2
9020
15
12
SPECIFICATIONS
Track Chain
Machine Weight 20 298 kg (44 750 lb)
approximate
UN06DEC88
Track Sag 300335 mm (11-13/16
13-3/16 in.)
Nut and Valve Assembly Torque 147 Nm (108 lb-ft)
T6876FG
ESSENTIAL TOOLS
Grease Gun
OTHER MATERIAL
TY2098 Multi-Purpose Grease
Track ChainSpecification
MachineWeight .................................................... 20 298 kg (44 750 lb)
approximate
Track ChainSpecification
TrackSag ........................................................................... 300335 mm
(11-13/1613-3/16 in.)
UN23FEB89
ATrack Sag
T6457DL
TX,20,GG2214 1905SEP002/3
UN28NOV90
9020 fitting on track adjuster cylinder for
20 lubrication. Use this grease fitting only
2 for track sag adjustment.
T7396DZ
5. To decrease track sag, add multi-purpose grease to
track adjuster cylinder through grease fitting (A) located
in access hole (D) in track frame. Use a grease gun
with a maximum capacity of 68 950 kPa (690 bar) (10
000 psi).
UN22OCT92
cylinder through bleed hole (C) in rod.
T7869AQ
Track ChainSpecification
Nut and Valve AssemblyTorque .............................. 147 Nm (108 lb-ft)
AGrease Fitting
NOTE: If piston in track adjuster cylinder does not move,
BNut and Valve Assembly
remove the cylinder to make repairs. (See CBleed Hole
Remove and Install Track Adjuster in Group DAccess Hole
0130.)
TX,20,GG2214 1905SEP003/3
Page Page
Page Page
9025
05
1
9025
05
2
1924AUG98
T116659
1Left Pilot Controller 10Rotary Manifold 17Left Propel Valve Section 25Pilot Pump
2Right Pilot Controller 11Hydraulic Oil Tank 18Auxiliary Valve Section 26Oil Cooler
3Propel Pilot Controller 12Suction Screen 19Boom Valve Section 27Restriction Valve
4Pilot Shut-Off Valve 13Return Filter 20Arm Valve Section 28Oil Cooler Bypass Valve
5Solenoid Valve Manifold 14Swing Motor 21Swing Valve Section 29Left Propel Motor
6Flow Regulator 15Right Propel Valve 22Front Pump 30Right Propel Motor
7Arm Cylinder Section 23Rear Pump 31Hydraulic System
8Boom Cylinder 16Bucket Valve Section 24Pilot Filter and Pressure
9Bucket Cylinder Regulating Valve
TX,9025,GG2136 1906SEP002/2
9025
05
3
1917DEC97
T112516
9025
05
4
ADowel Pin DOil Seal GDriven Gear JInlet Port
BBearing and Key ESnap Ring HSeal and Backup Retainer KPilot Pump
CDrive Gear FDrive Shaft IOutlet Port
The pilot pump (K) is a fixed-displacement, external port (I) is connected to the pilot pressure regulating
gear pump. The pilot pump is attached to the pump valve and pilot filter. The outlet is also connected by a
drive gearbox just to the rear of the rear pump. The tube and passages in pump housing to the small end
pump is driven through a gear train by the rear pump. of the front and rear pump servo piston and the pump
regulators.
The inlet port (J) is connected by a suction line to the
suction line for the front and rear pumps. The outlet
TX,9025,GG2283 1906SEP001/1
UN01AUG96
T102044
9025
05
5
APlug DRegulated Pilot Oil to GPilot Filter and Bypass JPilot Pressure Regulating
BRegulated Pilot Oil to Pilot Control Valve Valve Valve Spool
Shutoff Valve EPilot Pressure Regulating HShim KOrifice
CReturn Oil to Hydraulic Oil Valve ISpring LPilot Oil From Pilot Filter
Tank FPilot Oil From Pilot Pump
The pilot filter and pilot pressure regulating valve are The pilot pressure regulating valve (E) is a bypass flow
incorporated into one assembly. regulating valve and is used to regulate the pilot oil
pressure in the pilot oil circuit. Pilot oil flows through
The pilot filter (G) consists of a filter element and a the orifice (K) to the end of the pilot pressure
bypass valve. The bypass valve senses the differential regulating valve spool (J). When the pressure in the
pressure between the inlet side and outlet side of the pilot circuit increases to the pressure setting of the
filter element. During normal operation, the bypass spring (I), the spool is pushed right against the spring.
valve is held closed by a spring and pilot oil flows Regulated pilot oil flows to the pilot shutoff valve (B)
through the filter element and out to the pilot pressure and the control valve (D). Oil not needed to maintain
regulating valve. If the filter element becomes plugged, the pressure in the pilot circuit flows to the hydraulic oil
pressure on the inlet side increases forcing the bypass tank as return oil (C).
valve open. Pilot oil now bypasses the filter element
and unfiltered oil flows to the pilot pressure regulating
valve.
TX,05,GG2149 1907APR971/1
P2
A
P1
H B
P3 C
E
D
I J H T5
I
K T4
J
T6
F K
9025
05 H TO FLOW REGULATOR
6
I FROM LEFT
PILOT CONTROLLER
A B C D L
J FROM RIGHT
PILOT
CONTROLLER P2
A
P1
B
P3 C
E
D
T5
I
H
T4
K
T6
F J
E F K FROM PROPEL
PILOT CONTROLLER
1906MAY98
T101854
ATo Left Pilot Controller EFrom Pilot Pressure HTo Flow Regulator LPilot Shut-Off Valve OFF
BTo Propel Pilot Controller Regulating Valve IFrom Left Pilot Controller MPilot Oil
CTo Right Pilot Controller FTo Hydraulic Oil Tank JFrom Right Pilot Controller NReturn Oil
DTo Solenoid Valve Manifold GPilot Shut-Off Valve ON KFrom Propel Pilot
Controller
The pilot shut-off valve is a manual-operated, In the off (L) position, shut-off lever is pulled rearward
two-position, three-way rotary valve. The shut-off valve to the locked position, pilot oil to the controllers and
is rotated by pushing or pulling the pilot shut-off lever. solenoid valve manifold is blocked and the pilot oil now
The valve is located under the cab. flows to the flow regulator valve (H). Pilot oil that flows
to the flow regulator when shut-off valve is locked is
In the on (G) position, shut-off lever is pushed forward part of the warm-up circuit. The inlet ports for the
to the unlocked position, pilot oil flows to inlet ports of controllers are open to hydraulic oil tank through the
the pilot controllers, propel pilot controller, and shut-off valve and solenoid valve manifold.
solenoid valve manifold. Return oil from the controllers
flows to the shut-off valve and then through the
solenoid valve manifold and back to the hydraulic oil
tank.
TX,9025,GG2284 1906SEP002/2
9025
05
7
B E
N RETAINER
K I
LEVER E
F SLEEVE
PLUNGER D
1925APR00
PISTON A K FROM PILOT PUMP L PILOT OIL
I TO HYDRAULIC OIL TANK M RETURN OIL
T129715
T129715
9025 P PILOT CONTROLLER - NEUTRAL
05
8
APiston ELever ITo Hydraulic Oil Tank MReturn Oil
BSpool FSleeve JTo Control Valve NRetainer
CSpring Guide GBalance Spring KFrom Pilot Pump OShims
DPlunger HReturn Spring LPilot Oil PPilot ControllerNeutral
Two hand-operated pilot controllers (right and left) are for correct operation of controller. The balance and
used to control the dig functions. Each controller return springs used in ports 1 and 3 are different than
assembly contains four pressure reducing valve the balance and return springs used in ports 2 and 4.
assemblies, one for each direction of each function. The ports numbers are stamped on the housing.
The pilot controller consists of the plunger (D), sleeve In neutral (P), the spool is pushed up by the return
(F), spring guide (C), retainer (N), spool (B), piston (A), spring to block oil from the pilot pump (K) to control
balance spring (G), shims (O), and return spring (H). valve (J) pilot cap. With the spool up, the passage to
The spools are select fitted to the bores in the the control valve pilot cap is connected to the hydraulic
housing. The quantity of shims for each balance spring oil tank (I).
and spool assembly has been determine at the factory
TX,9025,GG2285 1929MAR001/1
E LEVER J
E
PLUNGER D F SLEEVE
K
I
G BALANCE SPRING
1925APR00
PISTON A I TO HYDRAULIC M RETURN OIL
OIL TANK
T129716
T129716
9025
05
9
APiston ELever ITo Hydraulic Oil Tank LPilot Oil
BSpool FSleeve JTo Control Valve MReturn Oil
CSpring Guide GBalance Spring KFrom Pilot Pump NPilot ControllerMetering
DPlunger HReturn Spring
To meter a function, the lever (E) is moved slightly. by the plunger. As the lever is moved further, the
This moves the plunger (D) and spring guide (C) plunger applies more force to the balance spring and
against the balance spring (G) which moves the spool the pressure to control valve pilot cap again increases
(B) down. The spool blocks the hydraulic oil tank to balance the spool.
passage (I) and opens the passage from the pilot
pump (K) to control valve (J) pilot cap. When the lever (E) is moved to full stroke, the plunger
(D) movement is transmitted directly to the spool (B).
Pilot oil (L) also acts on piston (A) in the spool, moving This forces the spool down connecting the passage
the spool up against the balance spring which closes from pilot pump (K) with the passage to the control
the passage to the control valve pilot cap. This valve (J) pilot cap. Oil pressure to the control valve
maintains pressure in the control valve pilot cap pilot cap now equals pilot circuit pressure.
passage according to the force on the balance spring
TX,9025,GG2286 1929MAR001/1
5
2
10
14 RETAINER
11 9
15 SHIMS
5 PEDAL
9025
05 PLUNGER 4 6 SLEEVE
10
SPRING 3 7 BALANCE
GUIDE SPRING
8 RETURN
SPRING
SPOOL 2 9 TO HYDRAULIC
OIL TANK
10 TO CONTROL
VALVE
11 FROM PILOT
PISTON 1 PUMP
1921SEP00
12 PILOT OIL
13 RETURN OIL
T133811
One pilot controller is used to control the propel In neutral, the spool is pushed up by the return spring
functions. The controller contains four valve to block oil from the pilot pump (11). With the spool up,
assemblies, one for each direction for each track. the passage to the control valve (10) is connected to
the hydraulic oil tank (9). The propel pilot controller
The pilot controller consists of the pedal (5), plunger operates the same as the pilot controllers.
(5), sleeve (6), spring guide (3), spool (2), piston (1),
balance spring (7), and return spring (8).
CED,OUOE003,677 1918SEP002/2
9025
05
11
CAM
E AND
PEDAL
PLUNGER D
F SLEEVE
SPRING C
GUIDE BALANCE
G SPRING
RETURN
H
SPRING
9025 WASHER B
05 TO HYDRAULIC
I
12 OIL TANK
FROM PILOT
J
SPOOL A SHUT-OFF
VALVE
TO CONTROL
E K VALVE PILOT
G
CAP
A K
K
1906MAY98
J I L PILOT OIL
M RETURN OIL
T108942
ASpool ECam and Pedal ITo Hydraulic Oil Tank MReturn Oil
BWasher FSleeve JFrom Pilot Shut-Off Valve NPropel Pilot Controller
CSpring Guide GBalance Spring KTo Control Valve Pilot Cap Full Stroke
DPlunger HReturn Spring LPilot Oil
One pilot controller is used to control the propel balance spring pushes the spool down. As the spool is
functions. The controller contains four valve pushed down the passage from the control valve pilot
assemblies, one for each direction of travel for each cap to the hydraulic oil tank (I) is closed and then is
track. opened to the pilot oil from pilot shut-off valve. When
the pilot oil pressure to the control valve pilot cap is
The pilot controller consists of the cam and pedal (E), equal to the force applied by the balance spring the
plunger (D), sleeve (F), spring guide (C), spool (A), spool moves up trapping the oil to the pilot cap.
balance spring (G), and return spring (H).
When the pedal and cam is moved to full stroke, the
In neutral, the spool is pushed up by the return spring plunger is pushed down further by the balance spring
to block pilot oil from the pilot shut-off valve (J). With opening the passage through the spool more to the
the spool up, the passage to the control valve pilot cap pilot oil. When pressure to the control valve pilot cap is
(K) is connected to the hydraulic oil tank (I) by the equal to the force applied by the balance spring, the
passage through the spool (A). spool moves up until it contacts the plunger. The
plunger holds the spool down so the passage through
When the pedal is pushed to move the machine, the spool remains open to pilot oil. Oil pressure to the
cam (E) pushes the plunger and spring guide down control valve pilot cap now equals pilot oil pressure.
against the return spring and balance spring. The
CED,OUOE003,2 1906SEP002/2
9025
05
13
BUCKET
SECTION 1
2
PILOT
CONTROLLER
1
4
CONTROL
3 VALVE
1921SEP00
5 PILOT OIL
FROM PILOT PUMP 4 6 RETURN OIL
T133813
9025 T133813 7 PILOT OPERATION OF MAIN CONTROL VALVE
05
14
1Pilot Controller 3Control Valve 5Pilot Oil 7Pilot Operation of Main
2Bucket Section 4From Pilot Pump 6Return Oil Control Valve
The pilot controllers (1) are connected to the control pilot cap is routed through the pilot controller to the
valve (3) by pilot control hoses through the flow hydraulic oil tank.
regulator valve. When the pilot controller is actuated,
pilot oil (5) from pilot pump (4) is routed to the control The pilot hoses for the propel pilot controller are not
valve pilot cap. In this illustration, the bucket section connected to the flow regulator valve but are
(2) is actuated. Return oil (6) from the control valve connected directly to the control valve pilot caps.
TX,9025,GG2288 1906SEP001/1
9025
05
15
ARM IN PILOT
PRESSURE 8
SENSOR
4 TO PILOT CAP
VALVE 7
FOR
ARM IN 5 CHECK VALVE
6 FROM PILOT SHUT-OFF VALVE
9 9
1 4 1 4
9025 11 11
05 10 10
16
12 12
5 5
TO
PILOT
CAP 11 ORIFICE
PLATE
4
15 WARM-UP
FROM 1 OIL
PILOT PASSAGE
CONTROLLER
5 CHECK
VALVE
1921SEP00
16 PILOT OIL
17 RETURN OIL
T133812
1From Pilot Controller 5Check Valve 9Check Valve 14Boom Down or Arm In
2Valve for Boom Up 6From Pilot Shut-Off Valve 10Spool 15Warm-Up Oil Passage
3Boom Up Pilot Pressure 7Valve for Arm In 11Orifice Plate 16Pilot Oil
Switch 8Arm In Pilot Pressure 12From Pilot Shut-Off Valve 17Return Oil
4To Pilot Cap Sensor 13Boom Up or Arm Out 18Flow Regulator Valve
NOTE: The cross section of flow regulator valve When the boom down or arm in (14) function is
shown in the illustration is in the boom up pilot actuated, the pilot oil to move the control valve spool
circuit. flows from the pilot controller through the manifold to
the pilot cap. Return oil from the opposite end of
The pilot lines for boom, arm, bucket, and swing control valve spool flows from the pilot cap to the
functions are connected through the flow regulator to manifold and through the orifice plate (11) in the spool
the pilot caps on the control valve. The pilot lines for (10). As the return pressure increases, the spool is
propel function are connected directly to the pilot caps. pushed down in proportion to the pressure increase
regulating the return oil flow to provide precise
The flow regulator valve (18) is a manifold containing movement of a function. From here, oil flows to the
similar flow regulator valve spools (10) in the arm out pilot controller.
and boom up pilot circuits. Check valves (5) are also
included in the warm-up oil passage (15) for arm in, Warm-Up Circuit Operation
arm out, boom down, and boom up pilot circuits; no
check valves are used in the bucket and swing pilot When the pilot shut-off valve is in the OFF position
circuits. Each valve spool contains an orifice plate (11) and the engine is running, pilot oil flows from the pilot
and springs. The size of the orifice is 2.5 mm (0.098 shut-off valve (6) to the flow regulator valve manifold.
in.). The oil is heated as it flows through a restriction at the
inlet to manifold. The warm-up oil from pilot shut-off
When the boom up or arm out (13) function is valve (12) flows through the warm-up oil passage (15)
actuated, pilot oil from the pilot controller (1) flows past the check valves (5) and out to the left and right
through the spool into the bottom spring chamber and pilot controllers and top pilot caps to warm the pilot 9025
through the orifice plate (11) to the pilot cap (4). As the circuit. At the pilot controllers, the warm-up oil flows 05
pressure increases the spool pushes upward allowing through the pilot controllers, out the return port, 17
pilot oil to flow unrestricted to the pilot cap to move the through the pilot shut-off valve to the solenoid valve
control valve spool. The spool acts as a check valve manifold, and then to the hydraulic oil tank. At the pilot
(9). Return oil from the opposite end of control valve caps, warm-up oil flows through orifices into a return
spool flows from the pilot cap and through the manifold passage in the pilot caps and then to the hydraulic oil
to the pilot controller. tank.
TX,9025,GG2290 1906SEP002/2
9025
05
18
1906AUG96
T102053
AFront Pump Discharge Port GPump Drive Gearbox KFill Plug and Breather OPump Inlet Port
BFront Pump HRear Pump Drive Shaft LRear Pump Regulator PRear Pump Pressure
CRear Pump IEngine Speed Sensor (N MFront Pump Regulator Sensor
DRear Pump Discharge Port Sensor) NFront Pump Pressure QHydraulic Pumps and Drive
EDipstick JAir Bleed Plug Sensor Gearbox
FPilot Pump
The front pump (B), rear pump (C) and pilot pump (F) drive shaft for the pump drive gearbox. The rear pump
are driven by the engine at engine speed through a drive shaft is connected to the engine flywheel through
pump drive gearbox (G). The rear pump drive shaft (H) a dampener drive (flex coupling).
as well as driving the rear pump also servers as the
TX,05,GG2150 1906SEP002/2
9025
05
19
9025
05
20
1906AUG96
T102060
AFront Pump Discharge Port EFront Pump Drive Shaft ICenter Shaft MCylinder Block
BPump Inlet Port FFeedback Link JPiston (7 per Pump) NFront and Rear Hydraulic
CRear Pump Discharge Port GPump Regulator KServo Piston Pumps
DRear Pump Drive Shaft HHousing LValve Plate
The front and rear hydraulic pumps (M) are variable pump drive shaft (D) as well as driving the rear pump
displacement, bent-axis, piston type pump. Two also servers as the drive shaft for the pump drive
identical pumps are used to generate oil flow in the gearbox. The drive shafts drive the cylinder blocks (M)
hydraulic system. The pump can vary from minimum through the center shafts (I). The cylinder block is
displacement to maximum displacement depending on positioned at an angle to the drive shaft. As the
hydraulic demand of the system. cylinder block and drive shaft rotate, the pistons (D)
move in and out of their bores because of the angle.
A regulator (G) is attached to the top of housing (H) for The pistons which are moving out of their bores draw
each pump. A pilot oil signal to the regulator moves a oil from the hydraulic oil tank (C) through an pump
piston which then directs pilot oil to the servo piston (J) inlet port and ports in the valve plate (K). The pistons
which moves the valve plate (K) and cylinder block (L) which are moving back into their bores push oil
changing the pump displacement. The feedback link through ports in the valve plate out the front and rear
(F), connected to the valve plate, also moves providing discharge ports (A and C) and to the control valve.
a mechanical feedback to the remote control sleeve in
the regulator. The remote control sleeve blocks the The pump displacement, or flow rate, is varied by
flow of pilot oil to the servo piston and also traps the changing the angle of the cylinder block with respect to
oil at both ends of the servo piston stopping its the drive shaft. Increasing the angle increases the
movement. distance that each piston travels into and out of the
bore which increases displacement. Decreasing the
The front and rear pumps and pilot pump are driven at angle reduces the distance that each piston travels
engine speed through a pump drive gearbox. The rear into out of the bore which decreases displacement.
9025
05
21
TX,05,GG2151 1906SEP002/2
FLOW ADJUSTING
CARTRIDGE MAXIMUM FLOW REMOTE REMOTE MINIMUM FLOW
(TRACK CYCLE ADJUSTING CONTROL CONTROL ADJUSTING
TIME) SCREW SLEEVE SPOOL PISTON SCREW
A B C D E F
G LOAD
ADJUSTING
SCREW
M L K J I H (INNER SPRING)
LOAD LOAD LOAD OUTER INNER LOAD (ENGINE
PISTON SPOOL SLEEVE SPRING SPRING ADJUSTING PULLDOWN AT
CARTRIDGE HIGH PRESSURE)
1923APR97
(OUTER SPRING)
9025
(ENGINE
05
PULLDOWN AT
22
MEDIUM PRESSURE)
T101949
T101949 N PUMP REGULATOR COMPONENTS
The pump regulators are mounted on the top of the sleeve (K), load spool (L), and load piston (M). Each
hydraulic pump housing. The major pump regulator regulator controls the flow of pilot oil to the large end
components (N) are the flow adjusting cartridge (A), of its servo piston using the spools and sleeves.
maximum flow (displacement) adjusting screw (B),
remote control sleeve (C), remote control spool (D), The remote control spool (D) is moved by a reduced
piston (E), minimum flow (displacement) adjusting pilot oil control signal from front and rear pump control
screw (F), load adjusting screw (inner spring) (engine valve. There is a pump control valve located in the left
pull down at high pressure) (G), load adjusting and right control valves. The control signal acts on the
cartridge (outer spring) (engine pull down at medium end of the piston (E) to control the position of remote
pressure) (H), inner spring (I), outer spring (J), load control spool against the spring.
The load spool (L) is moved by the load piston (M) well as the outer spring. The pump supply oil pressure
against the springs to decrease pump flow is sense on one shoulder of the load piston and the
(displacement) and avoid overloading the engine when pump supply oil pressure from the other pump is
main system pressure becomes too high. At lower sensed on the other shoulder. The end of the load
system pressures the spool is moved against only the piston receives a reduced pilot oil control signal from
outer spring (J). At higher pressures, the spool the speed sensing solenoid valve when the actual
contacts and is moved against the inner spring (I) as engine speed pulls down to the target engine speed.
TX,05,GG2148 1924APR002/2
9025
05
23
27 PILOT OIL
28 REDUCED PILOT OIL
29 REAR PUMP SUPPLY OIL
30 FRONT PUMP SUPPLY OIL
FROM SOLENOID 1
31 CONTROL VALVE VALVE MANIFOLD
NEUTRAL PASSAGE OIL CONTROL VALVE 2
32 TRAPPED OIL NEUTRAL PASSAGE
33 RETURN OR PRESSURE REAR PUMP
REMOTE CONTROL 3
FREE OIL VALVE
TO SERVO CONTROL
PISTON SPOOL REMOTE
LARGE END 4 5 CONTROL 7 PISTON
SLEEVE 26 PRESSURE
6 SENSOR
RETURN
TO PUMP 8 PILOT OIL
HOUSING 14 INLET
SPEED SENSE 13
SIGNAL PORT
9025
05
PUMP PRESSURE 12
24
INLET
LOAD PISTON 11 9 LOAD SLEEVE
LOAD SPOOL 10 15 FEEDBACK LINK
16 TO LEFT CONTROL VALVE
TO RIGHT CONTROL VALVE 25 TO FRONT PUMP
17 REGULATOR
TO FRONT PUMP 24
REGULATOR 18
PILOT
PUMP
19
23 22
20 PILOT
SERVO FRONT PRESSURE
PISTON PUMP REAR REGULATING
21 PUMP VALVE
SERVO
PISTON
1929MAY97
34 REGULATOR OPERATION
T108968
T108968
1From Solenoid Valve 9Load Sleeve 19Pilot Pressure Regulating 28Pump Control Valve
Manifold 10Load Spool Valve Signal Oil
2Control Valve Neutral 11Load Piston 20Rear Pump 29Rear Pump Supply Oil
Passage 12Pump Pressure Inlet 21Servo Piston 30Front Pump Supply Oil
3Front Pump Control Valve 13Speed Sense Signal Port 22Front Pump 31Control Valve Neutral
4To Servo Piston Large End 14Return To Pump Housing 23Servo Piston Passage Oil
5Remote Control Spool 15Feedback Link 24To Front Pump Regulator 32Trapped Oil
6Remote Control Sleeve 16To Left Control Valve 25To Right Control Valve 33Return or Pressure Free
7Piston 17To Front Pump Regulator 26Pressure Sensor Oil
8Pilot Oil Inlet 18Pilot Pump 27Pilot Oil 34Regulator Operation
The function of regulators is to control the flow of pilot through hoses from control valve to a port at the top of
oil to and from the servo piston large end (4) in its respective regulator.
response to control signals from the front and rear
pump control valves (3), front and rear pumps (22 and The pump supply oil (29 and 30) from front and rear
20) and speed sensing solenoid valve. Pump pumps is sensed through drilled passages in the pump
displacement (flow) is changed by sending pilot oil to housing to the pump pressure inlets (12) in each
or releasing pilot oil from the servo piston large end. regulator.
Pilot oil from the pilot pump (18) flows through drilled The control signal from the speed sensing solenoid
passages in the pump housing to the small end of valve is sensed through a hose to the speed sense
servo pistons and to the pilot oil inlet (8) at each signal port (13) at the rear pump regulator and then by
regulator. Pilot oil pressure is maintain at the small end a steel line to the front pump regulator.
of servo pistons and at the inlet of both regulators.
The reduced pilot oil (28) control signal from the front
or rear pump control valve is sensed by the piston (7)
9025
05
25
TX,05,GG2152 1924APR002/2
27 PILOT OIL
28 REDUCED PILOT OIL
29 REAR PUMP SUPPLY OIL
30 FRONT PUMP SUPPLY OIL
31 CONTROL VALVE FROM SOLENOID 1
NEUTRAL PASSAGE OIL VALVE MANIFOLD
32 RETURN OR PRESSURE CONTROL VALVE 2
FREE OIL NEUTRAL PASSAGE
REAR PUMP
REMOTE CONTROL 3
CONTROL VALVE
TO SERVO
PISTON SPOOL REMOTE
LARGE END 4 5 CONTROL 7 PISTON
SLEEVE 26 PRESSURE
6 SENSOR
RETURN
TO PUMP 8 PILOT OIL
HOUSING 14 INLET
SPEED SENSE 13
9025 SIGNAL PORT
05
26 PUMP PRESSURE 12
INLET
LOAD PISTON 11 9 LOAD SLEEVE
LOAD SPOOL 10 15 FEEDBACK LINK
16 TO LEFT CONTROL VALVE
TO RIGHT CONTROL VALVE 25 TO FRONT PUMP
17 REGULATOR
TO FRONT PUMP 24
REGULATOR 18
PILOT
PUMP
19
23 22
20 PILOT
SERVO FRONT PRESSURE
PISTON PUMP REAR REGULATING
21 PUMP VALVE
SERVO
1909OCT00
PISTON
T134255
1From Solenoid Valve 9Load Sleeve 19Pilot Pressure Regulating 28Pump Control Valve
Manifold 10Load Spool Valve Signal Oil
2Control Valve Neutral 11Load Piston 20Rear Pump 29Rear Pump Supply Oil
Passage 12Pump Pressure Inlet 21Servo Piston 30Front Pump Supply Oil
3Front Pump Control Valve 13Speed Sense Signal Port 22Front Pump 31Control Valve Neutral
4To Servo Piston Large End 14Return To Pump Housing 23Servo Piston Passage Oil
5Remote Control Spool 15Feedback Link 24To Front Pump Regulator 32Return or Pressure Free
6Remote Control Sleeve 16To Left Control Valve 25To Right Control Valve Oil
7Piston 17To Front Pump Regulator 26Pressure Sensor 33Pump Flow Increasing
8Pilot Oil Inlet 18Pilot Pump 27Pilot Oil
NOTE: For operation of the front and rear pump housing (14). Pilot oil on the small end of servo piston
control valves, see Pump Control Valve pushes the piston down increasing pump displacement
Operation in this group. (flow). As the pump displacement increases, the
movement is transmitted to the remote control sleeve
Increasing Flow (Displacement)When a function is (6) and load sleeve (10) by the feedback link (15). The
actuated, the reduced pilot oil (28) control signal from sleeves move left until the path to return is closed. The
the pump control valve (3) to the piston (7) increases. oil at the large end of servo piston is now trapped
The control signal pushes the piston and remote holding the pump at maximum displacement (flow rate)
control spool (5) to the left against the spring. that is proportional to the pressure of the pump control
Movement of spool opens a path from the large end of valve control signal.
servo piston to return in the pump housing (14). Pilot
oil on the small end of servo piston pushes the piston Decreasing Flow (Displacement)As the function is
down increasing pump angle which increases the returned to neutral, the reduced pilot oil (28) control
displacement (flow). As the pump displacement signal sensed at the piston (7) also decreases. The
increases, the movement is transmitted to the remote spring pushes the remote control spool and piston to
control sleeve (6) and load sleeve (9) by the feedback the right. Movement of the spool opens a path for pilot
link (15). The sleeves move left until the path to return oil (27) to flow to the servo piston large end (4). The
is closed. The oil at the large end of servo piston is pilot oil pressure applied to the servo piston large end 9025
now trapped holding the pump at the displacement pushes the piston up against the pressure applied to 05
(flow rate) that is proportional to the pressure of the the small end decreasing pump flow. The remote 27
pump control valve control signal. control spool will continue to move to the right in
response to the decreasing control signal until it
Maximum Flow (Displacement)When the pilot contacts the piston cylinder. As the pump displacement
controller lever is actuated to full stroke, the reduced decreases, the movement is transmitted to the remote
pilot oil (28) control signal from the pump control valve control sleeve (6) and load sleeve (9) by the feedback
(3) to the piston (7) increases to its maximum. The link (15). The sleeves move right until the path for pilot
control signal pushes the piston and remote control oil is closed. The oil at the large end of servo piston is
spool to the left until the spool contacts the maximum now trapped holding the pump at the displacement
flow adjusting screw. Movement of spool opens a path (flow rate) that is proportional to the pressure of the
from the large end of servo piston to return in pump pump control valve control signal.
TX,05,GG2153 1916OCT002/2
27 PILOT OIL
28 REDUCED PILOT OIL
29 REAR PUMP SUPPLY OIL
30 FRONT PUMP SUPPLY OIL
31 CONTROL VALVE FROM SOLENOID 1
NEUTRAL PASSAGE OIL VALVE MANIFOLD
32 RETURN OR PRESSURE CONTROL VALVE 2
FREE OIL NEUTRAL PASSAGE
REAR PUMP
REMOTE CONTROL 3
CONTROL VALVE
TO SERVO
PISTON SPOOL REMOTE
LARGE END 4 5 CONTROL 7 PISTON
SLEEVE 26 PRESSURE
6 SENSOR
RETURN
TO PUMP 8 PILOT OIL
HOUSING 14 INLET
SPEED SENSE 13
9025 SIGNAL PORT
05
28 PUMP PRESSURE 12
INLET
LOAD PISTON 11 9 LOAD SLEEVE
LOAD SPOOL 10 15 FEEDBACK LINK
16 TO LEFT CONTROL VALVE
TO RIGHT CONTROL VALVE 25 TO FRONT PUMP
17 REGULATOR
TO FRONT PUMP 24
REGULATOR 18
PILOT
PUMP
19
23 22
20 PILOT
SERVO FRONT PRESSURE
PISTON PUMP REAR REGULATING
21 PUMP VALVE
SERVO
1909OCT00
PISTON
T134255
1From Solenoid Valve 9Load Sleeve 19Pilot Pressure Regulating 28Pump Control Valve
Manifold 10Load Spool Valve Signal Oil
2Control Valve Neutral 11Load Piston 20Rear Pump 29Rear Pump Supply Oil
Passage 12Pump Pressure Inlet 21Servo Piston 30Front Pump Supply Oil
3Front Pump Control Valve 13Speed Sense Signal Port 22Front Pump 31Control Valve Neutral
4To Servo Piston Large End 14Return To Pump Housing 23Servo Piston Passage Oil
5Remote Control Spool 15Feedback Link 24To Front Pump Regulator 32Return or Pressure Free
6Remote Control Sleeve 16To Left Control Valve 25To Right Control Valve Oil
7Piston 17To Front Pump Regulator 26Pressure Sensor 33Pump Flow Increasing
8Pilot Oil Inlet 18Pilot Pump 27Pilot Oil
Summation (flow rate control by monitoring both pump Speed SensingWhen the actual engine speed, as
pressures)The pump supply oil pressure (load) for measured by engine speed sensor, is pulled down to
each pump is sensed at the load piston (11) through the target engine speed, as set by engine rpm dial, the
the pump pressure inlets (12) at its regulator and at speed sensing solenoid valve coil is energized by an
the regulator of other pump. The average pressure on electrical signal from the engine and pump controller.
the load piston is applied through the load spool (10) The pilot oil control signal is sent to the end of load
to the inner and outer springs. The springs are piston at the speed sense signal port (13) in the front
adjusted against the average pressure so the flow rate and rear pump regulators. The pilot oil control signal
of the pumps are approximately equal and each pump along with the pump supply oil pressure shift the load
uses approximately half the engine output. If the load spools against the springs opening a path for pilot oil
on either pump increases, the average pressure on the to the large end of servo pistons to decrease the pump
load pistons shift the load spools against the springs angle. The flow rate of both pumps decrease so the
opening a path for pilot oil to the servo pistons. The load on the engine decreases and the actual engine
flow rate of both pumps decrease so the load on the speed can increase. (See Engine Speed Sensing
pumps do not exceed the engine output. Also engine Control Circuit Operation in this group.)
output is not exceeded even if one pump is loaded
relatively high while the other pump stays relatively
low. 9025
05
29
TX,05,GG2205 1916OCT002/2
H TO SYSTEM RELIEF
VALVE POWER
TO FRONT PUMP BOOST PORT
CONTROL VALVE
B P POWER BOOST
TO PROPEL
I MOTOR SPEED
CHANGE VALVE
PG PH PI PE
SG SI SD SC
P O N M
PD
A G
PE
1921MAY97
D DP DE DD DS
K C Q PILOT OIL
R RETURN OR
T109045
PRESSURE
T109045 S SOLENOID VALVE MANIFOLD FREE OIL
AFrom Pilot Shut-Off Valve FTo Rear Pump Control JTo Pump Regulators Speed OPropel Speed Change
BTo Front Pump Control Valve Sense Port PPower Boost
Valve GTo Hydraulic Oil Tank KFrom Bucket Flow Control QPilot Oil
CFrom Propel Flow Control HTo System Relief Valve Valve RReturn or Pressure Free
Valve Power Boost Port LTo Arm Regenerative Valve Oil
DFrom Pilot Shut-Off Valve ITo Propel Motor Speed MArm Regenerative SSolenoid Valve Manifold
ETo Swing Motor Park Brake Change Valve NSpeed Sense
Release Valve
The solenoid valve manifold (S) is mounted on the Return oil (R) from the pilot shut-off valve (D), propel
right control valve. The manifold serves as the central flow control valve (C), bucket flow control valve (K),
distribution point for pilot oil (Q) to the arm and the solenoid valves, when solenoid valves are
regenerative (M), speed sensing (N), propel speed de-energizes, flows through the manifold to the
change (H), and power boost (P) solenoid valves, the hydraulic oil tank (G).
front (B) and rear (F) pump control valves, and the
swing motor park brake release valve (E). Pilot oil The identification letters shown on the hydraulic
flows to the manifold when the pilot shut-off valve (A) schematic are on the manifold housing next to the
is in unlock position, shut-off lever forward. ports.
TX,9025,GG2609 1906SEP002/2
9025
05
31
A SOLENOID
VALVE MANIFOLD
ARM
REGENERATIVE B
SPEED SENSING C
I
L
PROPEL SPEED CHANGE D E POWER J
BOOST F
F SPOOL M
K
ADJUSTING
SCREW
J L
9025 M
05
32 G DE-ENERGIZED I
H PRESSURE EQUALS
I SOLENOID L
J
MAGNETIC FORCE
F
M
L
TO VALVE
J FUNCTION PILOT OIL FROM O PILOT OIL
M PILOT SHUT-OFF
TO
1923APR97
The arm regenerative (SC) (B), speed sense (SD) (C), as the control signal to the valve function increases.
propel speed change (SI) (D) and power boost (SG) When the control signal becomes equals to or greater
(E) solenoid valve are proportional solenoid valve (R) than the magnetic force, the spool is pushed to the
type. The solenoid valve is activated by an electrical right closing the passage stopping the control increase.
signal from the engine and pump controller (EPC). The The reduced pilot oil control signal to the valve
signal is a DC voltage that is turned on and off to form function is trapped. The spool is moving constantly to
a pulse width modulated signal. The solenoid (I) reacts maintain the control signal in response to the electrical
to the average voltage to create a magnetic force to signal to the solenoid.
shift the spool (F) left against a spring. The reduced
pilot oil control signal sent to the valve function (L) For circuit operation of arm regenerative solenoid
depends on how long the electrical signal in on verses valve, see Arm Regenerative Valve Operation in this
on how long it is off. The reduced pilot oil control group.
signal is in proportion to the electrical signal to the
solenoid. For circuit operation of speed sense solenoid valve,
see Engine Speed Sense Control Circuit Operation in
When de-energized (G), the spool is pushed to the this group.
right by a spring. The valve function port is connected
to the hydraulic oil tank (J) port. For circuit operation of propel speed change solenoid
valve, see Propel Speed Change Circuit Operation in
When energized (N), the magnetic force shifts the this group.
spool left against the spring. Pilot oil (O) flows past the
9025
spool flange and out the valve function port as a For circuit operation of power boost solenoid valve, 05
reduced pilot oil (P) control signal. Because the flange see Power Boost Control Circuit Operation in this 33
on the right is larger than the flange on the left, the group.
spool is pushed to the right against the magnetic force
TX,9025,GG2095 1924APR002/2
1907SEP96
T103218
9025
05
34
AEngine RPM Dial CEngine Speed Sensor (N ERear Pump Regulator GEngine Speed Sensing
BEngine and Pump Sensor) FSpeed Sensing Solenoid Control Circuit
Controller DFront Pump Regulator Valve
The function of engine speed sensing control circuit speed is a function of the engine and pump controller
(G) is to reduce the hydraulic load on the engine if it and is selected when the engine rpm dial (A) is turned
exceeds the output torque of the engine. to the desired actual engine speed.
The speed sensing solenoid valve (F) coil is energized The pilot oil control signal is sent to the end of the load
by an electrical signal from the engine and pump piston in the front and rear pump regulators (D and E)
controller (B) when the actual engine speed, as which then operate to reduce pump flow. (See
sensed by the engine speed sensor (C), is pulled Hydraulic Pump Regulator Operation in this group.)
down to the target engine speed. The target engine
TX,05,GG2201 1906SEP001/1
9025
05
35
UN15APR97
T109048
Left Front
1Left Control Valve (5-Spool) 63Solenoid Valve Manifold 73Swing Valve 80Auxiliary Power Passage
2Right Control Valve 64Arm II Valve 74Arm Reduced Leakage Check Valve (Lift Check)
(4-Spool) 65Boom I Valve and Boom Valve 81Propel Flow Control Valve
56System Relief Valve Regenerative Valve 75Arm Out Circuit Relief and 82Propel Power and Neutral
Isolation Check Valve 66Boom Reduced Leakage Anti-Cavitation Valve Passage Check Valves
57System Relief Valve and Valve 76Plug (Lift Checks)
Power Boost 67Bucket Valve 77Swing Lift Check Valve 83Rear Pump Control Valve
58Dig Pressure Switch 68Right Propel Valve 78Arm I Power and Neutral 84Filter and Orifice for Pilot
59Flow Combiner Valve 69Left Propel Valve Passage Check Valves Pressure to Rear Pump
Circuit Check Valve 70Auxiliary Valve (Lift Checks), and Control Valve
60System Relief Valve 71Boom II Valve Restriction Orifice 84ACheck Valve and Orifice
Isolation Check Valve 71APropel-Boom Down 79Boom II Power Passage for Propel Flow Control
61Propel Pressure Switch Selector Valve Check Valve (Lift Check) Valve
62FilterPilot Pressure Inlet 72Arm I Valve
The control valve consists of two monoblock valve All valves are accessible from the outside of control
housings called the left control valve (1) and right valve by removing a plug, cover, or the pilot caps. For
control valve (2). The control valves are mounted line connections to the control valves, see Control
back-to-back to connect the interconnected oil Valve Component and Line Identification in Group
passages through ports in the mounting faces. The left 9025-15. The solenoid valve manifold is also located
control valve is a 5-spool section valve consisting of on the right control valve.
left propel (69), auxiliary (70), boom II (71), arm I (72),
and swing (73). The right control valve is a 4-spool The control valve is an open-center valve. Each valve
section valve consisting of right propel (68), bucket section controls the flow rate and direction for its
(67), boom I (65), and arm II (64). Each spool is hydraulic circuit. The rear (83) and front (98) pump
selectively fitted to its bore in the housings. The spools control valves, located in neutral passage of the left (1)
are moved by pilot oil controlled by the pilot controllers and right (2) control valves, are used to send a control
located in the cab. signal to the front and rear pump regulators when a
function is actuated. (See Pump Control Valve
For the location of all valves used in the control valve, Operation in this group.) Two pressure switches (58
see the three illustrations labeled Left Front, Right and 61) located on the front of the control valve are
Rear, and Bottom and the legends. Also see the closed to send an electrical signal to the engine and
Control Valve Circuit Schematic for location of pump controller when a dig or propel function is
components. actuated.
9025
05
37
UN15APR97
T109052
Right Rear
1Left Control Valve (5-Spool) 69Left Propel Valve 90Propel Speed Change 96Boom I Power and Neutral
2Right Control Valve 70Auxiliary Valve Solenoid Valve Passage Check Valves
(4-Spool) 71Boom II Valve 91Speed Sensing Solenoid (Lift Checks)
57System Relief Valve and 72Arm I Valve Valve 97Right Control Valve to
Power Boost 73Swing Valve 92Arm Regenerative Arm I Power Passage
63Solenoid Valve Manifold 85Arm Regenerative Valve Solenoid Valve Check Valves and
64Arm II Valve 86Arm II to Arm I Neutral 93Flow Combiner Valve Restriction Orifice
65Boom I Valve and Boom Passage Check Valve 94Bucket Flow Control Valve 98Front Pump Control Valve
Regenerative Valve 87Boom Up Circuit Relief Pilot Valve A and B, and 99Filter and Orifice for Pilot
66Boom Reduced Leakage Valve Poppet Valve Pressure to Front Pump
Valve 88Bucket Dump Circuit 95Bucket Check Valve (Lift Control Valve
67Bucket Valve Relief Valve Check) 105Oil Cooler Bypass Valve
68Right Propel Valve 89Power Boost Solenoid
Valve
UN15APR97
T109053
9025 Bottom
05
38 1Left Control Valve (5-Spool) 68Right Propel Valve 94Bucket Flow Control Valve 102Bucket Curl Circuit Relief
2Right Control Valve 69Left Propel Valve 100Arm Regenerative Circuit and Anti-Cavitation Valve
(4-Spool) 70Auxiliary Valve Check Valve 103Plug
64Arm II Valve 71Boom II Valve 101Boom Down Circuit 104Arm In Circuit Relief and
65Boom I Valve 72Arm I Valve Relief and Anti-Cavitation Anti-Cavitation Valve
67Bucket Valve 73Swing Valve Valve
TX,05,GG2154 1920MAY984/4
9025
05
39
9025
05
40
UN16APR97
T109055
1Left Control Valve (5-Spool) 71Boom II Valve 81Propel Flow Control Valve 96Boom I Power and Neutral
2Right Control Valve 71APropel-Boom Down 82Propel Power and Neutral Passage Check Valves
(4-Spool) Selector Valve Passage Check Valves (Lift Checks)
56System Relief Valve 72Arm I Valve (Lift Checks) 97Right Control Valve to
Isolation Check Valve 73Swing Valve 83Rear Pump Control Valve Arm I Power Passage
57System Relief Valve and 74Arm Reduced Leakage 85Arm Regenerative Valve Check Valves and
Power Boost Valve 86Arm II Neutral Passage to Restriction Orifice
59Flow Combiner Valve 75Arm Out Circuit Relief and Arm I Power Passage 98Front Pump Control Valve
Circuit Check Valve Anti-Cavitation Valve Check Valve 100Arm Regenerative Circuit
60System Relief Valve 76Plug 87Boom Up Circuit Relief Check Valve
Isolation Check Valve 77Swing Lift Check Valve Valve 101Boom Down Circuit
64Arm II Valve 78Arm I Power and Neutral 88Bucket Dump Circuit Relief and Anti-Cavitation
65Boom I Valve and Boom Passage Check Valves Relief Valve Valve
Regenerative Valve (Lift Checks), and 93Flow Combiner Valve 102Bucket Curl Circuit Relief
66Boom Reduced Leakage Restriction Orifice 94Bucket Flow Control Valve and Anti-Cavitation Valve
Valve 79Boom II Power Passage Pilot Valve A and B, and 103Plug
67Bucket Valve Check Valve (Lift Check) Poppet Valve 104Arm In Circuit Relief and
68Right Propel Valve 80Auxiliary Power Passage 95Bucket Check Valve (Lift Anti-Cavitation Valve
69Left Propel Valve Check Valve (Lift Check) Check) 105Control Valve Circuits
70Auxiliary Valve
TX,9025,GG2610 1920MAY982/2
9025
05
41
9025
05
42
1928APR00
T129505
AOrifice and Check Valve HDig Pilot Control Signal NFront Pump TPropel Flow Control Valve
BSwing Park Brake Release Passage ORear Pump UAuxiliary
Valve IRight Propel PSwing VReturn Passage
CDig Pressure Switch JBucket QArm I WLeft Propel
DOrifice KBoom I RPropel-Boom Down XReturn Passage
EPropel Pressure Switch LArm II Selector Valve YDig and Propel Pilot
FFlow Combiner Valve MPilot Pump SBoom II Control Signal
GPropel Pilot Control Signal
Passage
Pilot oil from the pilot pump (M) flows to the control passage (V). The flow of oil through the orifices
valve and through the orifices (D) into the propel pilot causes a pressure drop; the pressure of oil
control signal passage (G) and dig pilot control signal downstream of each orifice is less than the pressure
passage (H). The oil in the propel pilot control signal upstream of the orifices. None of the switches or
passage flows to the propel pressure switch (E), the valves in the signal passages are actuated.
propel-boom down selector valve (R), past the top end
of the right (I) and left (W) propel valve spools, and When a function is actuated, the valve spools shifts
then to the return passage (X). The oil in the dig pilot blocking the flow of oil through the signal passage.
control signal passage flows to the dig pressure switch The oil pressure upstream of the valve spool increases
(C), the propel flow control valve (T), flow combiner to approximately the pressure setting of pilot pressure
valve (F), past the top end of bucket (J), boom I (K), regulating valve and actuate the switch and valves in
arm II (L), swing (P), arm I (Q), boom II (S), and that signal passage.
auxiliary (U) valve spools, and then to the return
TX,05,GG2192 1924APR002/2
9025
05
43
9025
05
44
1907SEP96
T101397
Supply oil from the front pump (M) flows to the right (C and P), through the pump control valves (K and X),
control valve. Supply oil from the rear pump (O) flows and into the return passage (D). Power passages (N)
to the left control valve. When all functions are in in the left and right control valves are used to route
neutral supply oil flows through the neutral passages supply oil for the combined operation of functions.
TX,05,GG2191 1906SEP002/2
9025
05
45
LEFT CONTOL
F VALVE HOUSING
PILOT POPPET
G
SPRING
H PILOT POPPET
MAIN POPPET
I
SPRING
J MAIN POPPET
K RETURN PASSAGE
9025
05 L POWER PASSAGE
46
1923APR97
M DIGGING N POWER BOOST
T102821
T102821
AFirst Adjusting Plug FLeft Control Valve Housing KReturn Passage PPilot Oil
BTop Nut GPilot Poppet Spring LLower Passage QReturn or Pressure Free
CSecond Adjusting Plug HPilot Poppet MDigging Oil
DBottom Nut IMain Poppet Spring NPower Boost RSystem Relief and Power
EPiston JMain Poppet OPump Supply Oil Boost Valve
The function of system relief and power boost valve flows out faster than oil can flow through orifice in
(R) is to limit the main hydraulic system operating poppet. The main poppet is pushed open to relieve
pressure. System relief and power boost valve is pressure oil to return passage.
pilot-operated poppet type relief valve with a piston
(E). For power boost operation (N), pilot oil (P) from the
power boost solenoid valve pushes the piston (E)
When the pump supply oil in the power passage (L) down increasing the pressure setting of the pilot
pressure exceeds the relief valve setting, pilot poppet poppet spring (G). The main hydraulic system can now
(E) is pushed off its seat letting oil behind main poppet operate at a higher operating pressure for
(J) flow to the return passage (K). A pressure approximately 8 seconds.
differences is created across main poppet because oil
TX,05,GG2155 1924APR001/1
1929APR97
T109063
9025
05
47
APower Boost Switch CSystem Relief Valve DPower Boost Solenoid EPower Boost Control
BEngine and Pump Valve Circuit
Controller
The function of power boost control circuit (E) is to pressure setting. The main hydraulic system can now
temporarily increase the main hydraulic system operate at a higher operating pressure for
operating pressure by increasing the system relief approximately 8 seconds as long as the power boost
valve pressure. switch is held down.
The power boost solenoid valve is also actuated in The power boost function stays actuated for
precision work mode when the boom up function is approximately 8 seconds as long as the switch is held
actuated. down. If the switch is released before 8 seconds, the
power boost function is turned off. After 8 seconds, the
When the power boost switch (A) is pushed and held, switch must be released and pushed again to actuate
the engine and pump controller (B) sends an electrical the power boost function. The length of time the power
signal to energize the power boost solenoid valve (D) boost function is actuated is controlled by a timer
coil. The pilot oil pressure signal pushes the piston in circuit in the engine and pump controller.
the system relief valve (C) down increasing the
TX,05,GG2202 1924APR001/1
1903NOV97
PISTON B I PISTON SPRING
IT4579
R CIRCUIT RELIEF - ANTICAVITATION VALVE
IT4579
9025
05 ATo Return Oil FCheck Valve Spring KRelief Pressure Oil PRelief Operation
48 BPiston GPilot Poppet Spring LOperating Pressure Oil QAnticavitation Operation
COil From Work Circuit HScrew MReduced Pressure Oil RCircuit Relief -
DCheck Valve IPiston Spring NReturn Oil Anticavitation Valve
EPilot Poppet JMain Poppet OLow Pressure Oil
At pressures below the circuit relief setting the main During anti-cavitation operation (Q) the check valve (D)
poppet (J) remains closed. In relief operation (P), the retracts to allow oil to flow from the return passage into
relief valve opens in three steps. In the first step, the the work circuit. During normal operation the operating
pilot poppet (E) is opened. Flow restriction through the oil pressure (L) on the inner shoulder holds the check
hollow piston (B) causes the pressure in the cavity valve against its seat. This pressure decreases as
behind the main poppet to decrease. In the second pressure in the work circuit decreases. The return oil
step of relief operation the piston seats against the pressure (N) on the outer shoulder moves the check
pilot poppet (E). This further reduces oil flow into the valve, main poppet, and piston against the springs to
cavity and greatly decreases the pressure against the open the valve.
back side of main poppet. The main poppet opens in
the third step of relief operation.
TX,05,GG2146 1924APR001/1
9025
05
49
9025
05
50
1925APR00
T129510
APilot Oil Inlet From FFlow Sense Spring JRelief Valve Spool MRear Pump Control Valve
Solenoid Valve Manifold GFlow Sense Spool KControl Signal-to-Pump NFront Pump Control Valve
BFilter Screen HControl Valve Neutral Regulator OSwing Valve
COrifice Passage LPump Control Valve PSystem Relief Valve
DRelief Valve Spring ITo Hydraulic Oil Tank Pressure Sensor QPump Control Valves
EControl Valve Return
Passage
9025
05
51
1925APR00
T129512
9025
APilot Oil Inlet From EControl Valve Return ITo Hydraulic Oil Tank LPump Control Valve
05
Solenoid Valve Manifold Passage JRelief Valve Spool Pressure Sensor
52
BFilter Screen FFlow Sense Spring KControl Signal-to-Pump QPump Control Valves
COrifice GFlow Sense Spool Regulator
DRelief Valve Spring HControl Valve Neutral
Passage
A pump control valve (Q) is located at the downstream relief valve spool is pushed open to direct pilot oil to
end of the control valve neutral passage (H) in the left the hydraulic oil tank (I) decreasing the control signal
and right control valves. The function of pump control to the pump regulator (K).
valve is to send regulated control signal to the front
and rear pump regulators to change pump flow in Control Valve Spool Actuated: When a single or
response to the actuation of control valve spools. combine functions are actuated the control valve spool
shift decreasing flow through the neutral passage and
Control Valve Spools in Neutral: When all control flow sense spool. As flow through the flow sense spool
valve spools are in neutral the neutral passage through decreases, the spool is shifted to the left by the flow
the control valve is not restricted and full flow from the sense spring increasing the pressure setting on the
pump flows through the neutral passage and flow relief valve spring. The relief valve spool shifts more
sense spool (G) to the control valve return passage closed decreasing pilot oil flow to the hydraulic oil tank
(E). Full flow causes the flow sense spool to move to and increasing the control signal to the pump regulator
the right against the flow sense spring (F) decreasing which causes pump flow to increase. (See Hydraulic
the pressure setting of the relief valve spool (J). The Pump Regulator Operation in this group.)
In addition, the pressure signal to pump regulators is for the propel speed change function. (See Propel
senses by the pump control pressure sensors sending Motor Speed Change Circuit Operation in this group.)
an electrical signal to the engine and pump controller
TX,05,GG2178 1924APR004/4
9025
05
53
1927APR00
T129513
9025
05
54
ALeft Control Valve DFlow Combiner Valve FFrom Front Pump HFlow Combiner Valve
BRight Control Valve ETo Left Propel Valve GDig Pilot Control Signal
CFrom Pilot Control Pump Passage
Pilot oil from the pilot pump (C) flows through the machine does not mistrack during combined propel
orifice (L), into the dig pilot control signal passage (G), and dig function operations. The flow combiner check
past each dig function valve spools, and then to the valve (N) prevents back flow past the flow combiner
return circuit. The flow combiner valve (D), propel flow valve. The left propel valve does not receive supply oil
control valve (M), and the swing motor park brake from the rear pump (Q) except through the propel flow
release valve (K) are connected to the signal passage control valve if the upstream pressure is higher than
between the orifice and spools. the pressure in the flow combiner circuit.
When one or more dig functions are actuated, pilot oil The dig and propel pressure switches are actuated to
flow through the signal passage to return is blocked by send and electrical signal to engine and pump
a valve spool (arm II valve shown) (O). The pressure controller when the propel and dig functions are
in the blocked portion of the signal passage increases actuated.
shifting the flow combiner, propel flow control, and
swing park brake release valve spools. When just the propel function is actuated, the left
propel valve is supplied with oil from the rear pump
Supply oil from the front pump (P) now flows through and the right propel valve is supplied with oil from the
the flow combiner valve to the left propel valve (E) as front pump.
will as the right propel valve to ensure that the
9025
05
55
9025
05
56
1927APR00
T129506
ALeft Control Valve GDig Pilot Control Signal LOrifice PFront Pump
BRight Control Valve Passage MPropel Flow Control Valve QRear Pump
CFrom Pilot Control Pump ILeft Propel Motor NFlow Combiner Check RFlow Combiner Valve
DFlow Combiner Valve JRight Propel Motor Valve Circuit
ETo Left Propel Valve KTo Swing Motor Park Brake OValve Spool
Release Valve
TX,05,GG2179 1924APR003/3
9025
05
57
1917AUG96
T102962
9025
05
58
AArm Cylinder DArm Regenerative Solenoid FArm II Valve HArm Regenerative Valve
BArm I Valve Valve GRear Pump
CArm Regenerative Circuit EArm Regenerative Valve
Check Valve Spool
The arm regenerative valve (H) is used to improve arm engine and pump controller sends an electrical signal
controllability and prevent arm cylinder (A) cavitation to the arm regenerative solenoid valve (D) to energizes
during arm IN operation by combining the return oil the coil. The solenoid valve then sends a pressure
from arm cylinder rod end with the pump supply oil to signal to the arm regenerative valve spool (E) to shift it
the arm cylinder head end. blocking the passage to return. The return oil from the
rod end of arm cylinder now flows through the arm
Under the following operating conditions: low rear regenerative circuit check valve (C) and then to the
pump delivery pressure, high pilot pressure to the pilot head end of arm cylinder with the pump supply oil.
cap for arm in, and boom up actuated, gravity can pull Return oil not used flows through the orifice (J) to the
the arm in faster than the pump can supply oil to the return passage.
arm cylinder head end. The operating conditions are
sensed by the rear pump pressure sensor (I), arm in There are five check valves located in the passages to
pressure sensor (K), and boom up pressure switch (L). the arm I valve to prevent back flow through the
The pressure switch and sensors send electrical control valve. For arm in function, return and supply oil
signals to the engine and pump controller (M). The flows through the arm I valve only.
9025
05
59
1917AUG96
T102986
AArm Cylinder EArm Regenerative Valve JOrifice NArm Regenerative Valve
BArm I Valve Spool KArm In Pressure Sensor Circuit
CArm Regenerative Circuit GRear Pump LBoom Up Pressure Switch
Check Valve IRear Pump Pressure Sensor MEngine and Pump
DArm Regenerative Solenoid Controller
Valve
TX,05,GG2185 1924APR002/2
1927MAY98
T115414
9025
05
60
Reduced leakage valves (G) are used in the boom shifts the pilot valve (F). The oil pressure from the
head end circuit and arm rod end circuit. The function cylinder is blocked by the pilot valve. The oil pressure
of a reduced leakage valve is to reduce cylinder drift at the top (spring end) of check valve poppet can now
by stopping leakage from the cylinder back through the flow through the pilot valve to the warm-up passage in
control valve. the pilot caps and then to the hydraulic oil tank. The oil
pressure from the cylinder pushes the poppet off its
When the control valve is in neutral, the oil pressure seat opening the passage for oil to flow into the control
generated in the boom cylinder head end or arm valve return passage. The poppet is pushed off its seat
cylinder rod end by the load on the cylinders is applied because the OD of upper land at the head end of
to the top (spring end) of check valve poppet (E) poppet is slightly larger than the lower land.
through the pilot valve (F). The poppet is held closed
against the seat in housing trapping the oil from the The boom manual lower screw (H) is used to lower the
cylinder at the work port. boom if the engine should stop with the boom in the
raised position. (See Lower Boom With Engine
When boom down or arm in function is actuated, the Stopped in Group 9025-25.)
pilot pressure signal (C) from the pilot controller also
TX,05,GG2186 1920MAY981/1
9025
05
61
9025
05
62
1920AUG96
T103012
The bucket flow control valve (M) restricts oil flow to actuated the pilot pressure also flows through pilot
the bucket cylinder in the combined operations of valve A to shift pilot valve B (I) closing the passage
bucket, arm in, and boom up to ensure supply oil flow from the poppet valve (G). The pressure on the back
goes to the higher-loaded boom function to raise the side of the poppet valve increases closing the poppet
boom. valve causing a restriction for supply oil flow through
the poppet valve to the bucket valve (H).
When arm in function is actuated the pilot pressure
also shifts pilot valve A (E). If boom up function is
TX,05,GG2187 1906SEP002/2
9025
05
63
1927APR00
T129771
9025
05
64
AOrifice and Check Valve EPropel Power Passage GPower Passage JReturn
BLeft Propel Valve Check Valve HDig Function Valve Spool KPropel Flow Control Valve
CPilot Control Signal FPropel Neutral Passage IRight Propel Valve
DPropel Flow Control Valve Check Valve
Spool
The propel flow control valve (K) is used to reduce in the orifice and check valve (A) assembly to
shock loads from the power passage (G). The shock gradually shift the propel flow control valve spool (D).
loads are cause by the operation of dig functions The gradual shift of spool slowly restrict the flow of
upstream of the left propel valve (B). supply oil to the left propel valve reducing any shock
loads.
The propel flow control valve is located in the power
passage to the left propel control valve. The pilot control signal is released quickly through the
check valve when all dig functions are returned to
When a dig function (H) is actuated while propelling, neutral. The propel flow control valve spool is shifted
the pilot pressure signal also flows through the orifice quickly to the open position by the spring.
TX,05,GG2188 1924APR001/1
1927APR00
T129774
9025
05
65
ABoom II Valve DPropel Pilot Control Signal GTo Boom Cylinder Rod IPropel-Boom Down Selector
BBoom I Valve ERight Propel Valve End Valve
CPropel-Boom Down FPilot Controller Pressure HRear Pump
Selector Valve Spool Signal
The function of propel-boom down selector valve (I) is However, in a propel and boom down combined
to route the pilot controller pressure signal (F) to shift operations front pump supply oil is block by the right
the boom II valve (A) also when the combined propel propel valve (E) and does not flow to the boom I valve
and boom down functions are actuated. (B). To get supply oil to the rod end of boom cylinders,
the boom II valve (A) is shifted to route rear pump (H)
When just the boom down function is actuated, the supply oil to the cylinders. When the right propel valve
pilot controller pressure signal (F) flows to the pilot cap (E) is actuated, the propel pilot control signal (D)
to shift the boom I valve only. Pilot oil to the boom II increases shifting the propel-boom down selector valve
valve is blocked by the propel-boom down selector spool (C). The pilot controller control signal can now
valve spool (C). Front pump supply oil flows through flow through the selector valve and shift the boom II
the right propel valve (E) neutral passage to the boom valve.
I valve and out to the rod end of boom cylinders.
Return oil from the head end flows through the boom I The return oil from the head end of boom cylinders still
valve to return. flows through the boom I valve to return.
TX,05,GG2189 1924APR001/1
1912MAY97
T109129
9025
05
66
ABoom II Valve DBoom Regenerative Valve FPilot Controller Pressure GBoom Cylinders
BBoom I Valve Orifice Signal HBoom Regenerative Valve
CBoom Regenerative Valve EBoom I Neutral Passage
Poppet Check Valve
The function of boom regenerative valve (H) during head end the return oil pushes the boom regenerative
boom down operation is to combine the return oil flow valve poppet (C) open and flows to the rod end.
from head end of boom cylinders (G) with the pump Return oil not used flows through the boom
supply oil to the rod end to prevent cavitation. regenerative valve orifice (D) to the return passage.
During boom down operation, if pump supply oil The boom I neutral passage check valve (E) prevents
pressure is lower than the return oil pressure from the back flow through the control valve.
TX,05,GG2190 1906SEP001/1
9025
05
67
9025
05
68
1924AUG98
T116658
Actuating the propel and arm in functions in combined propel valve (R) to turn the left propel motor (A).
operation (S) shifts the left (R) and right (J) propel Because one pump is used to supply oil to both propel
valves and the arm II (K) and arm I (P) valves. With motors, the machine can propel straight even when the
the valves shifted, pilot oil flow through the dig pilot arm in function is actuated in combined operation with
pressure signal passage (G) is blocked by the arm II the propel function. The check valve (H) prevents back
valve causing the pilot oil pressure in the passage to flow through the flow combiner valve.
increase. The increased pressure shifts the flow
combiner valve (C), propel flow control valve (B), and Supply oil from the rear pump (O) flows through the
swing park brake release valve (D). arm I valve (P) to move the arm cylinder (Q). Supply
oil from the rear pump can flow through the check
Supply oil from the front pump (N) flows through the valve and propel flow control valve (B) if upstream
right propel valve (J) to turn the right propel motor (I) pressure is higher than pressure in the flow combiner
as well as through the flow combiner valve (C) and left valve passage.
CED,OUOE035,132 1906SEP002/2
9025
05
69
9025
05
70
1921SEP00
T133815
Actuating the swing and boom up in combined Pressure oil not used by the swing function flows
operation (10) shifts the swing valve (5), boom I valve through the power passage (4) and boom II valve (9).
(2), and boom II valve (9). The pressure oil combines with the pressure oil from
the front pump and flows to the boom cylinders. The
Pressure oil from the front pump (6) flows through the boom is raised by combined oil flow from the front and
power passage (1) and boom I valve and out to the rear pumps.
boom cylinders (3) to raise the boom. At the same
time pressure oil from the rear pump (7) flows through
the swing valve (5) and out to the swing motor to
swing the upperstructure.
CED,TX08227,2991 1906SEP002/2
9025
05
71
9025
05
72
1907SEP96
T103086
ASwing Motor EDrain Pipe ISecond Planet Carrier LFirst Planet Sun Gear
BFirst Planet Gear FOil Seal JSecond Planet Sun Gear MFirst Planet Carrier
CSecond Planet Gear GOutput Pinion KRing Gear NSwing Gearbox
DBearing HBearing
The swing gearbox (N) is a double reduction planetary planet sun gear is located between thrust washers.
drive type gearbox. The swing motor (A) is mounted Second planet gears (C) rotate around shafts in the
on the swing gearbox and encloses the top side of second planet carrier (I). The second planet carrier is
gearbox. The output pinion (G) is in mesh with swing connected to the output pinion (G) and this causes the
gear. Swing motor rotational speed is reduced by the output pinion to rotate.
double reduction planetary gear set.
The pinion rotates in two spherical roller bearings (D
The first planet sun gear (L) is connected to motor and H). Downward movement of pinion is prevented by
output shaft and is located between a retaining ring a retaining ring seated against upper bearing. Upward
and thrust washer. The first planet gears (B) rotate movement is prevented by second sun pinion. Oil seal
around roller bearings on shafts in the first planet (F) prevents oil from leaking out of swing gearbox and
carrier (M). Rotation of the first planet carrier causes keeps grease from coming in.
the second planet sun gear (J) to rotate. The second
TX,05,GG2193 1906SEP002/2
9025
05
73
9025
05
74
1912SEP96
T103087
The swing motor (R) consists of the rotating group, Swing speed varies depending on the amount of
park brake, and cover (D). The cover contains the supply oil delivered by the pump through the control
swing crossover relief valves (F), make-up check valve.
valves and inlet and outlet ports. The valve plate (E) is
held in position by dowel pins in the cover. The swing During the second half of motors revolution, low
motor is a fixed displacement, axial piston, fixed pressure oil is discharged as pistons slide back up the
position thrust plate (O) motor. It is bidirectional so the inclined thrust plate. To reverse rotation, oil flow is
upperstructure can swing in both directions. reversed. A small amount of supply oil flows through
the center of each piston to ball joint and to face of
The rotating group consists of a cylinder block (A) with slipper for lubrication.
nine pistons and slippers (P). The cylinder block is
connected to the output shaft (M). Each piston is The motor is internally lubricated from leakage inside
connected to a slipper by a ball joint. Slippers slide on the motor. Lubrication oil is routed up through the
the inclined thrust plate (O) forcing the cylinder block cover to the hydraulic oil tank.
to turn. Retainer (L) holds the slippers on the thrust
plate and the retainer itself is held against the slippers The swing motor park brake is spring applied and
by force pins (J) and spring (C). hydraulically released. The plates in the brake pack (I)
are connected to the housing. The disks are connected
Oil from swing control valve is routed through cover to and rotate with the cylinder block. When the pilot
(D), valve plate (E), and port (B) to the pistons. controllers are in neutral, pilot oil is blocked from the
piston (H) by the swing park brake release valve (Q).
In operation, high pressure supply oil enters the The brake springs squeeze the plates and disks
cylinder bores through ports forcing pistons down together to prevent the upperstructure from swinging.
against inclined thrust plate. The slippers slide down The swing park brake is released when the swing,
the inclined thrust plate causing the rotating group to boom, arm, or bucket function is actuated.
turn. The output shaft is turned by the cylinder block.
9025
05
75
TX,05,GG2194 1906SEP002/2
1920AUG96
T103106
ASpring DReturn Passage GOrifice JSwing Motor Crossover
BSpring Guide EChamber HRelief Poppet Relief Valve
CPiston FSpring IPort
9025 The function of swing crossover relief valve (J) is to seat to relieve pressure oil to return. The pressure is
05 relieve the high pressure generated in the swing circuit also sensed in the chamber (E) through the orifice (G).
76 when starting or stopping the swing operation. The oil The opening of the relief poppet is further dampened
pressure in the swing circuit becomes high because of by the action of the piston (C), spring guide (B), and
the inertia of the upperstructure to starting and spring (A). Oil from the spring (A) chamber is release
stopping. through the orifices in the spring guide and piston to
the return passage (D). The relief poppet is pushed
When the oil pressure in port (I) increases to the valve back to the right by the spring (F) and the pressure in
pressure setting, the relief poppet (H) is pushed off its the chamber.
TX,05,GG2195 1906SEP001/1
9025
05
77
1920AUG96
T103116
ASwing Motor Crossover BMake-Up Oil Port DInlet Port EMake-Up Valves
Relief Valves CMake-Up Valve Poppet
While stopping the swing function the control valve For a few seconds the motor acts like a pump. The
spools go to neutral and the lines to inlet ports (D) at relief poppet in the crossover relief valve opens to
the swing motor are blocked at the control valve. relieve the high pressure oil to the make-up oil port
Because of the inertia of the upperstructure the oil (B).
pressure in one side of the swing motor becomes high.
Because the lines to the motor are blocked the port. The return oil flows in and prevents cavitation.
continued rotation of the upperstructure lowers the The make-up oil port is connected to the return
pressure on the other side of the motor until cavitation passage in the control valve. The return oil pressure is
starts. When cavitation starts the make-up poppet (C) maintained by the restriction valve located downstream
is pushed open by the return oil in the make-up oil of the oil cooler.
TX,05,GG2196 1906SEP002/2
9025
05
78
9025
05
79
9025
05
80
1921APR97
T109165
ADig Pilot Pressure Signal EPilot Pump HValve Spool KBrake Pack
BPiston FSwing Motor Park Brake IPark Brake Released LSwing Motor Park Brake
COrifice and Check Valve Release Valve Spool JPark Brake Applied Release Valve
DPilot Pressure Oil GSwing Motor
The function of swing motor park brake release valve pressure signal passage to the return passage causing
(L) is to route pilot oil pressure (D) to the piston the pressure signal to decrease. The release valve
releasing the brake pack when a dig or swing function spool (F) is shifted by the spring blocking the flow of
is actuated. pilot oil pressure to the piston (B) chamber. The oil in
the piston chamber flows through the orifice (C) to
Park Brake Released (I): When a swing or dig return as the springs push the piston down applying
function is actuated, the flow of pilot oil through dig the park brake. The oil is metered through the orifice
pilot pressure signal passage in the control valve is to slow engagement to ensure that park brake is only
blocked by a valve spool (H). The dig pilot pressure fully applied after the upperstructure has stopped. The
signal (A) increases and shifts the swing motor park orifice and check valve is located in the swing motor
brake release valve spool (F). Pilot pressure oil (D) housing adjacent to the swing motor park brake
from the solenoid valve manifold flows through the release valve.
spool to piston (B) chamber. The pilot pressure oil
pushes the piston up against the spring releasing the Pilot oil pressure (D) is maintained at the release valve
brake pack (K). The upperstructure is now free to turn. spool (F) as long as the pilot shutoff valve is ON. The
circuit for pilot oil pressure is from the pilot pump (E),
Park Brake Applied (J): When the valve spool (H) is through the pilot shutoff valve, solenoid valve manifold,
returned to neutral, pilot oil flows through the dig pilot and then to the release valve spool.
TX,05,GG2197 1906SEP002/2
9025
05
81
DRAIN A
F F
F PROPEL
SPEED B
CHANGE
D
C LEFT PROPEL A LEFT
PROPEL C
FORWARD DRAIN
E
B LEFT E RIGHT
PROPEL
1923JUN98
PROPEL A
REVERSE FORWARD G SUPPLY OIL
H RETURN OIL
T109474
T109474 J ROTARY MANIFOLD I PILOT OIL
9025
05
82
ALeft Propel Drain DRight Propel Reverse GSupply Oil IPilot Oil
BLeft Propel Reverse ERight Propel Forward HReturn Oil JRotary Manifold
CLeft Propel Forward FPropel Speed Change
The rotary manifold (J) is a 360 rotary joint. It allows Oil flows into and through the spindle to passages in
oil to flow to and from the propel motors without the housing, and then out of the housing to the propel
twisting hoses when the upper structure is rotated. motors. Sealing rings stop oil from leaking between the
spindle and housing into adjacent passages.
The inner spindle is connected to the upper structure
and the housing is connected to the undercarriage.
The housing rotates about the spindle during swing
operation.
TX,05,GG2171 1906SEP001/1
9025
05
83
VALVE
PLATE SPRING
PLATE B C
A
SPRING
D CENTER
SHAFT
E
F HOUSING
G DRIVE
SHAFT
LINK P
9025
05
84
SERVO O
PISTON H ROLLER
BEARING
I
J ROLLER
BEARING
BRAKE
K DISKS
PLATES
N
ROTOR M L
PISTON BRAKE
PISTON Q SUPPLY OIL
R RETURN OIL
1923APR97
T7499AA
The propel motor (S) is a variable-displacement, drive shaft (G). As the angle is changed the motor
bent-axis, axial-piston type motor that includes the displacement changes which changes propel motor
brake valve housing and propel park brake. The speed.
counterbalance valve, crossover relief valves, park
brake release shuttle valve, pressure reducing valve, Supply oil flows through the valve plate (B) to half of
servo piston shuttle valve, and the servo piston (O) are the pistons (M) in the rotor (N). The oil forces the
integral components of the brake valve housing. The pistons to slide down the cylinder block bores
speed selector valve spool is located in the servo transferring the force to the drive shaft (G) turning the
piston. drive shaft. As the cylinder block and drive shaft rotate,
half of the pistons move out of their bores while the
The servo piston (O) controls the angle of rotor (N), remaining pistons in the other half of the cylinder block
pistons (M) and center shaft (E) with respect to the move back in their bores to discharge oil to return.
TX,05,GG2167 1906SEP002/2
9025
05
85
VALVE A B ROTARY
PLATE GROUP
D H
SERVO TO MOTOR
PISTON CASE DRAIN
I
G CHAMBER
SPRING A
J
FROM
C LINK MOTOR
PORT
D SERVO
PISTON F K
SPOOL FROM PROPEL
SPEED CHANGE
E SOLENOID
VALVE
ORIFICE
1906MAY98
L
CHAMBER B
M SUPPLY OIL
T102854
T102854 N RETURN OIL
O SLOW SPEED
9025
05
86 AValve Plate EOrifice IChamber A LChamber B
BRotary Group FSpeed Selector Valve Spool JFrom Motor Port MSupply Oil
CLink GSpring KFrom Propel Speed NReturn Oil
DServo Piston HTo Motor Case Drain Change Solenoid Valve OSlow Speed
The servo piston (D) is connected by a link (C) to the For circuit operation, see Propel Motor Speed Change
valve plate (A). When servo piston is extended or Circuit Operation in this group.)
retracted by supply oil pressure the angle of the rotary
group (B) changes and the propel speed changes Supply oil from motor port (J) is now applied to both
accordingly. chamber A (I) and chamber B (L) at the same time.
Supply oil pressure in chamber B acts on a larger
When propel speed is set to slow speed the bottom of area than the supply oil pressure in chamber A
speed selector valve spool (F) is open to return causing the servo piston to move upward increasing
through the propel speed change solenoid valve. The rotary group swash angle. As the swash angle
spool (F) is pushed down by the spring (G). (For increases, the stroke of each piston is increased
operation of propel speed change solenoid valve, see resulting in slower revolution of the propel motor for
Proportional Solenoid Valve Operation in this group. slower propel speed.
TX,05,GG2168 1906SEP001/1
A VALVE B ROTARY
PLATE GROUP SERVO
D PISTON TO MOTOR
CASE DRAIN
H
CHAMBER
A
I
G FROM
SPRING J MOTOR
PORT
C LINK
D SERVO F
PISTON SPOOL K
ORIFICE FROM PROPEL
E SPEED CHANGE
SOLENOID
VALVE
1906MAY98
M SUPPLY OIL
L CHAMBER N PILOT OIL
B
T102855
T102855 O RETURN OIL
P FAST SPEED 9025
05
87
AValve Plate FSpeed Selector Valve Spool JFrom Motor Port MSupply Oil
BRotary Group GSpring KFrom Propel Speed NPilot Oil
CLink HTo Motor Case Drain Change Solenoid Valve OReturn Oil
DServo Piston IChamber A LChamber B PFast Speed
EOrifice
In fast speed the pilot oil (N), from the propel speed NOTE: For operation of propel speed change solenoid
change solenoid valve (K), is higher than spring force valve, see Proportional Solenoid Valve
and spool (F) is pushed up. The oil in chamber B is Operation in this group. For circuit operation,
routed to return through motor case drain (H). Supply see Propel Motor Speed Change Circuit
oil (M) from the motor port (J) is applied to chamber Operation in this group.
A, servo piston (D) moves down to reduce rotary
group (B) swash angle. With reduced swash angle the
piston stroke is reduced which increases rotary group
turning speed that increases propel speed.
TX,05,GG2169 1906SEP001/1
9025
05
88
1923APR97
T109188
APropel Speed Switch FRight Propel Motor KPump Pressure Sensors OEngine and Pump
BLeft Propel Valve GDig Pressure Switch LFront Pump Controller
CRear Pump Control HPropel Pressure Switch MRear Pump PPropel Speed Change
Pressure Sensor IRight Propel Valve NPropel Speed Change Circuit
DLeft Propel Motor JFront Pump Control Solenoid Valve
ESpeed Selector Valve Pressure Sensor
Spool
When the propel speed switch (A) is in slow speed, Electrical signal for rear (C) and front (J) pump
the propel speed change solenoid valve (N) coil is control pressure sensors increases because pilot oil
de-energized. The speed selector valve spools (E) are control signals from front and rear pump control
open to return through the solenoid valve. The propel valves are increasing.
motors (D and F) are at maximum displacement Rear and front pump pressure sensors (K) are
causing the machine to travel at slow speed. sensing low pressure.
The propel speed goes to fast with the following When the electrical signals are received at the engine
operating conditions: and pump controller (O), the controller send an
electrical signal to energize the solenoid valve (N) coil.
Propel speed switch is at fast speed (rabbit). The pilot oil pressure signal shift the speed selector
Propel pressure switch (H) in closed (propel function valve spool (E) causing the motor to go to minimum
actuated). displacement and the machine to travel at fast speed.
Dig pressure switch (G) is open (no dig function (See Propel Motor Fast Speed Operation in this
actuated). group.)
TX,05,GG2200 1924APR002/2
9025
05
89
9025
05
90
1923APR97
T109195
APark Brake Release Shuttle CCrossover Relief Valve ECounterbalance Valve GPropel Motor Park Brake
Valve DCheck Valve FServo Piston Shuttle Valve Valve
BPressure Reducing Valve
The propel motor park brake valve (G) housing Check valves (D) ensure smooth starts and stops, and
contains the park brake release shuttle valve (A), park prevent motor cavitation by working together with the
brake pressure reducing valve (B), crossover relief counterbalance valve (E).
valve (C), check valves (D), counterbalance valve (E),
servo piston shuttle valve (F) and servo piston. Counterbalance valve (E) is used for smooth starting
and stopping and helps prevent overrunning of the
Park brake release shuttle valve (A) routes supply oil motor when traveling down a slope.
from the pressurized motor port through a groove in
the counterbalance valve (E), to the park brake Servo piston shuttle valve (F) routes supply oil from
pressure reducing valve (B), and then to the park the pressurized motor port to the servo piston. (For
brake piston to release the park brake. operation of servo piston and speed selector valve,
see Propel Motor Slow Speed Operation and Propel
Park brake pressure reducing valve (B) reduces the Motor Fast Speed Operation in this group.)
supply oil pressure routed to the park brake to prevent
sudden brake application.
TX,9025,GG2612 1906SEP002/2
9025
05
91
9025
05
92
1918APR97
T109202
APark Brake Pressure DPark Brake Pack HPark Brake Release Shuttle JChamber
Reducing Valve EDrive Shaft Valve KPropel Motor Park Brake
BDisk Spring FTo Propel Motor Housing IGroove Release
CBrake Piston GCounterbalance Valve
Propel park brake is spring applied and hydraulically brake pressure reducing valve. The pressure reducing
released type brake. Brake is applied by a disk spring valve operates to reduce the supply oil pressure.
(B) whenever the propel control valve spools are in Reduced pressure oil flows to the brake piston (C) to
neutral. The plates in the brake pack (D) are move it against the disk spring (B) force and releases
connected to the motor housing. The disks are the park brake. Oil not used to release the park brake
connected to and rotate with the drive shaft (E). The flows through the orifice in the reducing valve spool
disk spring pushes against the piston to squeeze the and into the propel motor housing (F).
plates and disks together to keep the machine from
moving. When propel pilot controllers are returned to neutral,
supply oil is blocked by the valve spools and the
When the propel pilot controllers are actuated the propel motor work ports are open to the control valve
propel valve spools route supply oil to the bottom work return passage. The counterbalance valve (G) returns
port of propel motor for forward travel or the top work to its neutral position causing the machine to slow and
port for reverse travel. The supply oil flows into the then stop (dynamic braking). The pressure reducing
chamber (J) at the end of counterbalance valve (G). At valve (A) is shifted by its spring. The disk spring (B)
the same time supply oil moves the park brake release pushing against the brake piston (C) forces the oil to
shuttle valve (H) to route supply oil to the park brake flow through the orifice in the reducing valve and into
pressure reducing valve (A) but is blocked by the the propel motor housing (F). The delay caused by the
counterbalance valve. When supply oil pressure oil flowing through the orifice is enough to slow
increases enough to shift the counterbalance valve, engagement to ensure that park brake is only fully
supply oil flows through the groove (I) to the park applied after the machine has stopped.
9025
05
93
TX,9025,GG2613 1906SEP002/2
9025
05
94
1923APR97
T109206
APark Brake Pressure DPark Brake Pack HPark Brake Release Shuttle JChamber
Reducing Valve EDrive Shaft Valve KPropel Motor Park Brake
BDisk Spring FTo Propel Motor Housing IGroove Release
CBrake Piston GCounterbalance Valve
When the propel valve spools in the main control valve to control valve return passage. Both check valves will
are in neutral position, counterbalance valve (J) is held seat and counterbalance valve will center trapping oil
in the center position by springs (B) on both ends of in the motor to prevent rotation. Oil will also flow back
counterbalance valve. Both propel motor oil lines are through the brake passage to the motor housing and
connected to the control valve return passage. Oil in the park brake will engage after the propel motor stops
each motor is trapped by check valves (C and F) and rotating. At the same time, the shock pressure caused
counterbalance valve (J) holding the motors stationary. by the inertia force of the motor stopping is released
The park brake release circuit is also routed to return through the crossover relief valves (D and E). Check
and the brake spring hold the brake on. valves (C and F) have a make-up function to prevent
cavitation in the motor.
When the propel pilot controller is moved to forward
position, supply oil is routed from the propel valves in When traveling down a hill, the weight of the machine
the control valve to bottom work port (G). If propel pilot may begin to overrun the propel motors. This would
controller is moved to reverse position, supply oil cause faster travel than desired and cause cavitation
would be routed to top work port (A). at the inlet side of motors. As pressure decreases in
the inlet passage of the motor, the pressure holding
In forward direction, supply oil enters bottom work port the counterbalance valve also decreases. Spring (B)
(G), flows around counterbalance valve to check valve force moves the counterbalance valve down thus
(F). Check valve opens and oil flows into the motor. restricting return flow from the motor slowing motor
rotation. This is called dynamic braking.
Return oil from the motor is blocked by check valve
(C) and counterbalance valve (J). This, along with the During normal operation supply oil from the control
motors resistance to turning, causes pressure in valve is routed past the counterbalance valve and 9025
bottom work port (G) to increase. The increasing check valve to the motor. Supply oil is also routed to 05
pressure is also sensed at the end of counterbalance the crossover relief valves (D and E). The crossover 95
valve through orifice (H). As pressure increases, the relief valves are direct acting relief valves with a
spool is pushed upward against the spring force. As cushion sleeve. Supply oil is sensed on the end of
spool moves up, oil from the motor flows past notches poppet of one relief valve. Oil also pushes the sleeve
in the counterbalance valve to the top work port (A) up on the other relief valve to help keep its poppet
and the propel motors start to turn. Supply oil is also closed.
routed to the park brake release circuit (I) to release
the park brake. (For park brake release circuit During relief operation oil pressure overcomes spring
operation, see Propel Motor Park Brake Release force pushing the poppet off its seat. Pressure oil is
Circuit Operation in this group.) relieved from the passage that is pressurized to the
passage that is at return pressure bypassing the
When the propel pilot controller is returned to neutral motor.
position, the oil in both work ports (A and G) is routed
TX,9025,GG2614 1906SEP002/2
Cylinder Operation
1921APR97
T109208
9025
05
96
ASnap Ring FWear Ring KCap Seal OBarrel
BWiper Seal GSnap Ring LSet Screw PCylinder Rod
CBackup Ring HPiston LNut QRod Guide
DU-Cup Seal IBuffer Ring NCushion RBucket Cylinder
EBuffer Ring JWear Ring
The boom, arm, and bucket cylinders are similar in Boom, bucket and arm cylinders have a cushion (N) in
design. The bucket cylinder (R) is illustrated. The rod front of the piston to provide cushioning action in
guide (Q) is fastened to the cylinder barrel with cap cylinder extension. As the cylinder nears the end of
screws and is fitted with a wear guide (F) held in place stroke the cushion enters a bore in the rod guide. The
by a snap ring (G). A buffer ring (E), U-cup seal (D), remaining return oil ahead of piston must flow through
backup ring (C), and wiper seal (B) are used in the rod a small clearance between the cushion and rod guide.
guide. A snap ring (A) is used to help hold wiper seal Only the arm cylinder is cushioned in retraction. The
in place. The U-cup seal (D) is protected against high end of the rod enters a bore in the head end of the
pressure by the buffer ring (E) and stops the small cylinder. The remaining return oil ahead of the piston
amount of oil which may pass by the buffer ring. and nut must flow through this small clearance as the
cylinder bottoms out in this direction.
The piston (H) is a slip fit on the cylinder rod (P) and is
retained with a nut (M). A set screw (L) prevents
loosening of the nut. The piston is fitted with a cap
seal (K), wear rings (J), and buffer rings (I).
TX,9025,GG2624 1906SEP001/1
UN11JUL96
T101917
9025
05
97
AFilter Element CBypass Operation EFrom Control Valve FReturn Filter Operation
BBypass Valve DFrom Oil Cooler
The filter element (A) is located in a chamber inside pressure surges in the return circuit and allows a path
the hydraulic oil tank. O-rings are used at each end of for return oil if the filter element becomes plugged.
the filter element to prevent leakage. A spring holds During bypass operation, oil flows into the chamber
the filter element on its seat. faster than it can flow through the filter element
causing the pressure to increase. The higher pressure
Return oil from the oil cooler (D) and the control valve forces the bypass valve open allowing oil to flow down
(E) flow through the filter element from the outside to the center of the filter element and into the hydraulic
the center. Filtered oil flows out the bottom of filter into oil tank. The bypass valve closes when the pressure
the hydraulic oil tank. decreases below the pressure setting of the bypass
valve.
A bypass valve (B) is located at the top of the filter.
The valve opens to protects the filter element against
TX,05,GG2147 1924APR001/1
9025
05
98
1928SEP89
TS700
TX,15,GG2166 1905AUG961/1
4
UP
BOOM UP 1
T TO
HYDRAULIC
P BOOM UP OIL TANK
DOWN PRESSURE
SWITCH TO RIGHT PILOT PRESSURE
BOOM CONTROL VALVE REGULATING VALVE
2
RIGHT PILOT FROM
CONTROLLER HYDRAULIC
PILOT
SWING BOOM DOWN FILTER OIL TANK
3 2
LEFT PILOT FILTER PILOT PUMP
TO REAR PUMP BYPASS VALVE
CONTROL VALVE
IN LEFT CONTROL
ARM OUT VALVE
RIGHT 3
1
TO FRONT PUMP
4 CONTROL VALVE TO SWING
IN PARK BRAKE
ARM IN IN RIGHT CONTROL TO FRONT
T VALVE RELEASE AND REAR PUMP
PRESSURE VALVE
SENSOR REGULATORS
PROPEL
P POWER SPEED SPEED ARM
OUT ARM IN 4 BOOST CHANGE SENSING REGENERATIVE
SOLENOID SOLENOID SOLENOID SOLENOID
ARM VALVE VALVE VALVE VALVE
2
LEFT PILOT
CONTROLLER
PROPEL RIGHT REVERSE SG SI SD SC
12
3 PROPEL RIGHT FORWARD 11
RIGHT PROPEL LEFT REVERSE
REVERSE 10
PROPEL LEFT FORWARD 9
T6 SOLENOID
VALVE
RIGHT T4 MANIFOLD
FORWARD 4
T5
2 PILOT OIL
LEFT
REVERSE P3 PILOT
T SHUT-OFF RETURN OR
VALVE TO PRESSURE
P1 HYDRAULIC FREE OIL
P OIL TANK
LEFT P2
FORWARD FROM BUCKET FROM PROPEL
FLOW CONTROL FLOW CONTROL
1 VALVE IN RIGHT VALVE IN LEFT
T109209 PROPEL PILOT CONTROL VALVE CONTROL VALVE
CONTROLLER PILOT CIRCUIT FOR PILOT CONTROLLERS SCHEMATIC
TX,9025,GG2615 1919APR971/1
T115417
HYDRAULIC PUMP AND CONTROL VALVE SCHEMATIC
CED,OUOE035,134 1920MAY981/1
FROM FROM
PILOT REAR
PRESSURE PUMP
REGULATING 7
LEFT PROPEL MOTOR VALVE 12 4
DIG FLOW PROPEL-
PRESSURE COMBINER BOOM DOWN 6
10 2 SELECTOR VALVE
SWITCH SYSTEM VALVE TO FRONT
RELIEF AND REAR
VALVE PUMP
PROPEL REGULATORS
FLOW
CONTROL PROPEL
MAKE-UP REAR VALVE ARM
PUMP SPEED REGENER-
VALVES CHANGE
CONTROL ATIVE
VALVE
LEFT AUX- BOOM II ARM I SWING
SWING PROPEL ILIARY
PARK POWER SPEED
BRAKE BOOST SENSING
CROSSOVER
RELIEF SG SI SD SC
VALVES
ARM
REDUCED
LEAKAGE
VALVE
SWING
PARK TO ARM
BRAKE TO OIL
REAR PUMP REGENER- COOLER
RELEASE REGULATOR 9 ATIVE VALVE
VALVE 3A 5
SWING MOTOR
TO ARM FROM
CYLINDER PILOT
SHUT-OFF
VALVE SOLENOID VALVE
MANIFOLD
T115418 SWING AND PROPEL MOTOR CIRCUIT SCHEMATIC
CED,OUOE035,135 1920MAY981/1
9025
05
,102
Follow the six basic steps below to carry out Check all systems and functions on the machine.
troubleshooting efficiently. Use the helpful diagnostic information in the
checkout to pinpoint the possible cause of the
1. Know the system. problem.
Did the machine have any previous problems? If Before reaching a conclusion, check the most
so, which parts were repaired? probable and simplest to verify. Use the flow charts
and symptom, problem, solution charts to help
3. Inspect the machine. identify probable problem components.
9025
Check all daily maintenance points. (See the Make a plan for appropriate repair to avoid other 15
operators manual.) Check batteries, fuses, fusible malfunctions. 1
link, and electrical connections.
TX,15,GG2234 1925APR971/1
Part Name Pump Control Pressure Sensor Pump Pressure Sensor Engine Speed Sensor (N
Sensor)
Operational Function Senses pump control valve pressure Senses front and rear pump Senses actual engine speed for
in control valve to control propel delivery pressure. the speed sensing system.
motor speed change
Control Problems No sensor output signal. No control Loss of propel speed control and Speed sensing system does not
signal to propel speed change HP (high power) mode. function.
solenoid valve.
Machine Symptoms Propel motor operates at slow speed Propel speed does not increase Does not affect machine
when propel speed switch is turned when propel speed switch in fast operation except speed sensing.
to fast speed. speed (rabbit). HP mode does not
work.
Laptop Computer with 04 and 05 Fault codes are displayed. 02 and 03 Fault codes are
Excavator Diagnostic displayed.
Program Self-Diagnostic
Functions
Laptop Computer with Monitor No. 1 and 6, Front and rear Monitor No. 14, Actual engine
Excavator Diagnostic pump control pressure. speed.
Program Monitoring
Function
Harness Check
Notes At slow idle with functions in neutral During combined operation, arm
typical pressure is 17251930 kPa speed is slow if malfunction is at
(1719 bar) (250280 psi). A lower sensor for rear pump.
pressure may be an open circuit. A
higher pressure may be a short
circuit.
Description of Operation See Propel Motor Speed Change See Propel Motor Speed Change
Circuit Operation in Group 9025-05. Circuit Operation in Group 9025-05
or HP (High Power) Mode Speed 9025
Control Circuit Operation in Group 15
9010-05. 3
Part Name Power Boost Solenoid Valve (SG) Speed Sensing Solenoid Valve Arm Regenerative Solenoid
(SD) Valve (SC)
Operational Function Sends a pilot pressure signal to Sends a pilot pressure signal to Sends a pilot pressure signal to
temporary increase system relief load piston in pump regulators to shift the arm regenerative valve.
valve pressure setting. reduce pump flow.
Control Problems No pressure signal sent to system No pressure signal sent to load No pressure signal sent to shift
relief valve. System relief valve piston in pump regulators. arm regenerative valve.
pressure setting does not increase.
Machine Symptoms Digging or lifting force does not Torque required to drive pumps During arm in operation, there is
increase. exceed engine output power. arm cylinder cavitation and
Engine speed can decrease below controllability becomes less.
rated speed.
Laptop Computer with
Excavator Diagnostic
Program Self-Diagnostic
Functions
Laptop Computer with Monitor No. 12, Power boost control Monitor No. 11, Speed sense Monitor No. 9, Arm regenerative
Excavator Diagnostic pressure. control pressure. control pressure.
Program Monitoring
Function
Harness Check Install JT07352 Test Harness. Install JT07352 Test Harness. Install JT07352 Test Harness.
Check that indicator light is on. Check that indicator light is on. Check that indicator light is on.
Notes If indicator light is off, check wiring If indicator light is off, check wiring If indicator light is off, check
harness. harness. wiring harness.
Description of Operation See Power Boost Control Circuit See Engine Speed Sensing Control See Arm Regenerative Valve
Operation in Group 9025-25. Circuit Operation in Group 9025-25 Operation in Group 9025-05.
9025
15
4
Part Name Propel Speed Change Solenoid Propel Pressure Switch Dig Pressure Switch
Valve (SI)
Operational Function Sends a pilot pressure signal to shift Senses when propel function is Senses when a dig function is
speed selector valve spool in propel actuated. actuated.
motors.
Control Problems No pressure signal sent to shift No electrical signal sent to engine No electrical signal sent to
speed selector valve spool. and pump controller. engine and pump controller.
Machine Symptoms Travel speed does not increase Engine speed does not increase Engine speed does not increase
when propel speed switch is turned from auto-idle speed when propel from auto-idle speed when a dig
to fast speed (rabbit). function actuated. Propel speed does function actuated.
not increases with propel speed
switch in fast speed (rabbit). Travel
alarm does not sound.
Laptop Computer with
Excavator Diagnostic
Program Self-Diagnostic
Functions
Laptop Computer with Monitor No. 10, Propel motor control Monitor No. 20, Pressure switch. Monitor No. 20, Pressure switch.
Excavator Diagnostic pressure.
Program Monitoring
Function
Harness Check Install JT07352 Test Harness.
Check that indicator light in on.
Notes If indicator light is off, check wiring Located at the front of right control Located at the front of left control
harness. Also check switches and valve. valve.
sensors in propel motor speed
change circuit.
Description of Operation See Propel Motor Speed Change See Propel Motor Speed Change See Auto-Idle Mode Speed
Circuit Operation in Group 9025-05. Circuit Operation in Group 9025-05 Control Circuit Operation in
or Auto-Idle Mode Speed Control Group 9010-05. 9025
Circuit Operation in Group 9010-05. 15
5
Part Name Boom Up Pressure Switch Arm In Pressure Sensor Learning Switch
Operational Function Senses boom up pilot pressure Senses arm in pilot pressure To start engine speed learning function.
signal. signal.
Control Problems No electrical signal sent to engine No electrical signal sent to Engine speed learning function does
and pump controller. engine and pump controller. not operate.
Machine Symptoms No regenerative function during HP (high power) mode does For an open circuit, engine speed
boom up and arm in. not function. Arm speed slow control system operates normally.
when leveling. Engine speed learning control cannot
be actuated. For a short circuit, learning
control is actuated when key switch is
turned ON.
Laptop Computer with
Excavator Diagnostic
Software Self-Diagnostic
Functions
Laptop Computer with Monitor No. 20, Pressure switch. Monitor No. 20, Pressure Monitor No. 28, Engine learning control.
Excavator Diagnostic switch.
Software Monitoring
Function
Harness Check
Notes Switch needed for arm Sensor needed for HP mode
regenerative operation. and arm regenerative
operation.
Description of Operation See Arm Regenerative Valve See Arm Regenerative Valve See Engine Speed Learning Control
Operation in Group 9025-05. Operation in Group 9025-05 Circuit Operation in Group 9010-05.
and HP (High Power) Mode
Speed Operation in Group
9010-05.
9025
15
6
Part Name Power Boost Switch HP (High Power) Mode Switch E (Economy) Mode Switch
Operational Function To actuate the power boost To actuate the HP mode function. To actuate the E mode function
function.
Control Problems For open circuit, no electrical No electrical signal to engine and For open circuit, no electrical
signal to engine and pump pump controller. For short circuit, signal to engine and pump
controller. For short circuit, electrical signal to engine and controller. For short circuit,
operates for 8 seconds when key pump controller at all times. electrical signal to engine and
switch turned on, but then pump controller at all times.
becomes inoperative.
Machine Symptoms Digging or lifting force does not For open circuit, engine speed For open circuit, engine speed
increase. does not increase when hydraulic does not decrease from fast idle.
pressure increases to specified For short circuit, engine speed
pressure. For short circuit, engine does not increase to fast idle.
speed increases even with switch
off (up).
Laptop Computer with
Excavator Diagnostic
Program Self-Diagnostic
Functions
Laptop Computer with Monitor No. 25, Power boost Monitor No. 24, HP mode switch. Monitor No. 22, E mode switch.
Excavator Diagnostic switch
Program Monitoring
Function
Harness Check
Notes Power boost function operates for HP indicator light on when switch E indicator light on when switch is
8 seconds after switch is pushed is on (down). on (down).
and held.
Description of Operation See Power Boost Control Circuit See HP (High Power) Mode Speed See E (Economy) Mode Speed
Operation in Group 9025-25. Circuit Operation in Group Control Circuit Operation in Group
9025-05. 9010-05. 9025
15
7
Part Name Propel Speed Switch Engine and Pump Controller Front and Rear Pump Control
(EPC) Valve
Operational Function To change propel speed. To control engine speed, pump and To send a regulated pilot pressure
valve operations. signal to pump regulators in
responds to the flow rate through
neutral passages in control valve.
Control Problems No electrical signal sent to Problems may differ depending on Pressure signal to regulator does
engine and pump controller. the malfunction. not increase when a function is
actuated. Pump stays at minimum
flow.
Machine Symptoms For open circuit, propel speed Problems listed indicate malfunction For rear pump control valve: left
stays at slow speed when in EPC. With key switch on, EC propel cycle time slow, swing also
switch is turned to fast speed motor does not go to start position; slow; cycle time for bucket, boom or
(rabbit). engine starts and run at slow idle. arm almost normal. For front pump
Engine speed does not change. control valve: bucket cycle time very
Pump stays at minimum, all slow, boom not raised when
functions are slow. leveling, right propel cycle time
slow; cycle time for boom, arm, or
swing almost normal.
Laptop Computer with
Excavator Diagnostic
Program Self-Diagnostic
Functions
Laptop Computer with Monitor No. 26, Propel speed Monitor No. 1, Front pump control
Excavator Diagnostic switch. pressure and No. 6, Rear pump
Program Monitoring Function control pressure.
Harness Check
Notes Check switches and sensors Check fuses before replacing EPC.
in propel speed control circuit.
9025 Description of Operation See Propel Motor Speed See Engine and Pump Controller See Pump Control Valve Operation
15 Change Circuit Operation in Circuit Theory of Operation in Group in Group 9025-05.
8 Group 9025-05. 9015-15.
Part Name Flow Combiner Valve Arm I Power Passage Check Arm I Neutral Passage Check
Valve and Restriction Orifice Valve and Restriction Orifice
Operational Function To supply oil to left and right propel
spools during combined operation of
dig and propel functions.
Control Problems Sticking or stuck spool. Oil is Oil from left control valve power Oil from right control valve
insufficient or not supplied to left passage insufficient or not supplied neutral passage insufficient or
propel spool. to arm I spool. not supplied to arm I spool.
Machine Symptoms While traveling straight, machine Arm speed slow when leveling. When check valve is stuck
mistracks when swing is actuated. closed or orifice clogged, arm
speed is slow when leveling
Laptop Computer with
Excavator Diagnostic
Program Self-Diagnostic
Functions
Laptop Computer with
Excavator Diagnostic
Program Monitoring
Function
Harness Check
Notes
Description of Operation See Flow Combiner Valve Operation See Control Valve Circuit See Control Valve Circuit
in Group 9025-05. Schematic in Group 9025-05. Schematic in Group 9025-05.
9025
15
9
Part Name Arm Regenerative Valve Propel Flow Control Valve Propel-Boom Down Selector
Valve
Operational Function To route oil from rod end to head end To reduce shock load created by To ensure boom down force
of cylinder during arm in when shifted going from propel operation to during combined operation of
by arm regenerative solenoid valve. combined operation of propel propel and boom down.
and dig by gradually restricting
oil flow from power passage.
Control Problems No pressure signal from arm Oil flow not restricted because Boom II spool not shifted during
regenerative solenoid valve to shift arm spool is stuck or no pressure combined operation of propel
regenerative valve spool. Valve spool is signal to shift propel flow control and boom down. Boom II spool
sticking or stuck. valve spool. is shifted during just boom down
operation.
Machine Symptoms During arm in, there is arm cylinder When stuck closed, shocks felt When stuck closed: boom down
cavitation and controllability becomes when changing from propel to speed is fast, swing speed slow
less. combined propel and dig at full stroke during combined
operation. When stuck open, no swing and boom down operation.
boom up when combined with
propel down a slope or with
bucket loading.
Laptop Computer with
Excavator Diagnostic
Program Self-Diagnostic
Functions
Laptop Computer with
Excavator Diagnostic
Program Monitoring
Function
Harness Check
Notes
9025 Description of Operation See Arm Regenerative Valve Operation See Propel Flow Control Valve See Propel-Boom Down Selector
15 in Group 9025-05. Operation in Group 9025-05. Valve Operation in Group
10 9025-05.
Part Name Arm Reduced Leakage Valve Boom Reduced Leakage Valve Boom Regenerative Valve
Operational Function To prevent arm in drift caused by To prevent boom down drift To route return oil from head end
leakage from the cylinder back caused by leakage from the to rod end of boom cylinder to
through control valve. cylinders back through control prevent cavitation when lowering.
valve.
Control Problems Sticking or stuck check valve or pilot Sticking or stuck check valve or Sticking or stuck check valve.
valve. No pilot pressure signal to shift pilot valve. No pilot pressure signal
pilot spool. to shift pilot spool.
Machine Symptoms Arm drifts down. Arm in speed is Boom drifts down. Boom down Boom lower speed becomes
slow or jerky if check valve sticking or speed is slow or jerky if check slow with check valve stuck
does not open. valve sticking or does not open. closed. Cannot raise tracks off
the ground using boom down
with check valve stuck open.
Laptop Computer with
Excavator Diagnostic
Program Self-Diagnostic
Functions
Laptop Computer with
Excavator Diagnostic
Program Monitoring
Function
Harness Check
Notes
Description of Operation See Boom and Arm Reduced See Boom and Arm Reduced See Boom Regenerative Valve
Leakage Valve Operation in Group Leakage Valve Operation in Group Operation in Group 9025-05.
9025-05. 9025-05.
9025
15
11
9025
15
12
TX,15,GG2238 1904OCT0011/11
All Hydraulic Functions Slow Low oil level Check oil level in hydraulic oil tank.
Slow engine speed Check engine fast and slow idle stop
adjustment at injection pump. Do
Engine Control Motor and Sensor
Adjustment and Engine Speed
Learning Procedure. See Group
9010-20.
Air leak in pump suction line Check for air bubbles in oil. Tighten
clamps, replace O-rings.
Front and rear pump regulators Adjust pump regulators. See Group
9025-25.
System relief valve setting too low or Check system relief valve setting.
malfunctioning See Group 9025-25. Inspect. See
Group 3360.
Front and rear pump control valves Check circuit relief valve setting. See
Group 9025-25. Inspect. See Group
Circuit relief valve setting too low or 3360.
malfunctioning
Hydraulic Oil Overheats Low oil level Check oil level in hydraulic oil tank.
System relief valve malfunction Test system relief valve. See Group
9025-25.
Oil cooler bypass valve stuck open Repair or replace. See Group 3360.
No Hydraulic Functions Pilot shut-off lever in LOCK position Push shut-off lever to UNLOCK
(rearward) position (forward).
Poor Combined Operation Dig or propel pressure switch Check pressure switches. Check
wiring harness. See Group 9015-15.
Check valves and flow control valves Inspect valves. See Group 3360.
in control valve
TX,15,GG2162 1913AUG983/3
9025
15
15
All Functions Cannot Be Pilot shut-off lever in LOCK position Push shut-off lever to UNLOCK
Operated (rearward) position (forward).
Pilot pressure regulating valve stuck Test pilot pressure regulating valve.
open See Group 9025-25.Inspect. See
Group 3360.
Function Does Not Stop When Control valve spool stuck Manually move spool to check for
Control Lever Released sticking. See Group 3360.
Some Functions Cannot Be Pilot cap Inspect for leakage at pilot cap. See
Operated, All Others Are Normal Group 3360.
9025
15 Pilot controller or hoses to function Check pilot controller hoses or pilot
16 that cannot be operated controller. See Group 3360.
Function Moves in Opposite Pilot control hoses connected Check installation of pilot control
Direction backwards hoses. See Group 9025-15.
TX,15,GG2163 1913AUG981/1
All Dig Functions Slow or No Hydraulic system malfunction See Diagnose Hydraulic System
Power Malfunctions. See Group 9025-15.
Front and rear pump control valves Check pressure. See Group
9025-25. Inspect. See Group 3360.
Load Drifts Down When Control Cylinder leakage Test cylinder for leakage. See Group
Valve Is In Neutral Position 9025-25.
Reduced leakage valve for boom Inspect reduced leakage valve. See
down and arm in Group 3360.
Load Falls When Control Valve Is Lift check valve leakage Inspect lift check valve in control
Actuated To Raise Load With valve. See Group 3360.
Engine Running At Slow Idle
Function Moves in Opposite Pilot control hoses connected Check installation of pilot control
Direction backwards hoses. See Group 9025-15.
TX,15,GG2164 1913AUG982/2
9025
15
18
Swing Speed Slow In Both Low pilot system pressure All other functions are slow. See
Directions Diagnose Pilot Circuit Malfunctions.
See Group 9025-15.
Upperstructure Drift With Swing Swing park brake Inspect swing park brake. See
Valve In Neutral Group 4360.
Swing crossover relief valve leakage Test swing crossover relief valves.
See Group 9025-25.
Swing make-up check valve leakage Inspect make-up valves. See Group
4360.
Swing Function Does Not Pilot circuit malfunction See Diagnose Pilot Circuit
Operate Malfunctions. See Group 9025-15.
TX,15,GG2165 1913AUG982/2
Propel Park Brakes Do Not Apply Pressure reducing valve stuck, oil Remove valve and clean or replace.
9025 not released from piston cavity See Group 0260.
15
20
Propel park brake Remove and repair brake. See
Group 0260.
Track Will Not Move In One Pilot Circuit malfunction See Diagnose Pilot Circuit
Direction Malfunctions. See Group 9025-15.
Propel control valve spool stuck Manually move spool to check for
sticking. See Group 3360.
Track Will Not Move In Either Pilot Circuit Malfunction See Diagnose Pilot Circuit
Direction Malfunctions. See Group 9025-15.
Excavator Mistracks at All Track sag adjustment Adjust track sag. See Group
Speeds In Both Directions 9020-20.
Propel motor crossover relief valve Do Crossover Relief Valve Test and
malfunction Adjustment. See 9025-25.
Brake valve shuttle valve or servo Inspect check valve and seat. See
piston shuttle valve seat leakage. Group 0260.
Slow Propel Speed Or Low Track sag adjustment Adjust track sag. See Adjust Track
Power Sag in Group 9020-20.
Propel motor crossover relief valve Do Crossover Relief Valve Test and
Adjustment. See Group 9025-25.
Combined Propel and Dig Flow combiner valve Check for sticking or stuck valve
Functions Slow or No Power spool. See Group 3360.
9025
Propel-boom down selector valve Check for sticking or stuck valve 15
spool. See Group 3360. 23
Propel Is Jerky Track sag too tight or too loose Adjust track sag. See Adjust Track
Sag in Group 9020-20.
No oil or low oil level in rollers Fill with correct oil. See General
Information Section.
Brake valve shuttle valve or servo Inspect shuttle valve seat. See
piston shuttle valve seat leakage. Group 0260.
Excavator Will Not Hold Back Propel pilot controller counterbalance Inspect counterbalance valve spool.
and Park Brakes Engage and valve spool stuck See Group 0260.
Disengage When Traveling Down
An Incline
Excavator Will Not Turn Propel pilot controller counterbalance Inspect counterbalance valve spool.
Smoothly In One Direction Or valve spool stuck See Group 0260.
Park Brake Grabs
TX,15,GG2235 1918SEP005/5
UN28APR00
CAUTION: Prevent injury from unexpected
control lever function. Install new decals on F
control consoles.
4 3
T128763
8. Install new decals (black on yellow) on control T128763
consoles near the base of control levers. Decals are
enclosed in Operators Manual package. Additional SAE Pattern
decals are available through parts.
UN28APR00
F
2 1
T128778
T128778
TX,9025,GG2511 1904APR002/2
9025
15
26
UN07MAY97
T109233
Left Front
1Left Control Valve (5-Spool) 10Return to Hydraulic Tank 18Arm In Pilot From Left 25To Hydraulic Oil Cooler
2Right Control Valve 11Return From Pilot Pilot ControllerSAE 26To Swing Motor Front
(4-Spool) Shut-Off Valve Pattern PortLeft Swing
3To Rear Pump Control 12Pilot Pressure to Swing 19Boom Down Pilot From 27To Swing Motor Rear
Valve Pressure Sensor and Motor Park Brake Release Right Pilot Controller PortRight Swing
Rear Pump Regulator Valve Top Port SAE Pattern 28To Arm Cylinder Rod
4Pilot Pressure Signal to 13Return From Bucket Flow 20Bucket Load Pilot From EndArm Out
Propel Flow Control Valve Control Valve to Solenoid Right Pilot Controller 29To Arm Cylinder Head
5To Rear Pump Control Valve Manifold 21Right Propel Reverse Pilot EndArm In
Valve 14Return From Propel Flow From Propel Pilot 30Left Propel Forward to
6Inlet Flow From Front Control Valve to Solenoid Controller Rotary Manifold Left Front
Pump Valve Manifold 22Swing Right Pilot From Port
7Pilot Pressure Signal to 15Pilot Pressure From Pilot Left Pilot Controller 31Left Propel Reverse to
Swing Motor Park Brake Shut-Off Valve to Solenoid 23Left Propel Reverse Pilot Rotary Manifold Left Rear
Release ValveBottom Valve Manifold From Propel Pilot Port
Port 16Pilot Pressure to Front Controller
8Pilot Pressure From Pilot Pump Control Valve 24To Swing Motor Make-Up
Pressure Regulating Valve 17Arm In Pilot to Bucket Oil Port
9Power Boost Solenoid Flow Control ValveFront
Valve to System Relief Bottom Port
Valve
TX,9025,GG2628 1920MAY982/2
9025
15
27
9025
15
28
UN25APR97
T109234
Right Rear
1Left Control Valve (5-Spool) 16Pilot Pressure to Front 24To Swing Motor Make-Up 39To Bucket Cylinder Head
2Right Control Valve Pump Control Valve Oil Port EndBucket Curl
(4-Spool) 17Arm In Pilot to Bucket 25To Hydraulic Oil Cooler 40To Boom Cylinder Head
5To Rear Pump Control Flow Control ValveFront 32To Propel Motor Speed EndBoom Up
Valve Bottom Port Change Valve 41To Boom Cylinder Rod
7To Swing Motor Park Brake 18Arm In Pilot From Left 33Speed Sensing Solenoid EndBoom Down
Release ValveBottom Pilot ControllerSAE Valve to Front and Rear 42Pilot Pressure From Boom
Port Pattern Pump Regulator Speed Up Pilot Cap to Bucket
9Power Boost Solenoid 19Boom Down Pilot From Sensing Port Flow Control Valve
Valve to System Relief Right Pilot Controller 34Arm Regenerative 43Return to Hydraulic Oil
Valve SAE Pattern Solenoid Valve to Arm Tank
10Return to Hydraulic Tank 20Bucket Curl Pilot From Regenerative Valve 44Supply Oil From Rear
11Return From Pilot Right Pilot Controller 35Supply Oil From Front Pump
Shut-Off Valve 21Right Propel Reverse Pilot Pump 45To Front Pump Control
12Pilot Pressure Signal to From Propel Pilot 36Right Propel Forward to Valve Pressure Sensor
Swing Motor Park Brake Controller Rotary Manifold Right and Front Pump Regulator
Release ValveTop Port 22Swing Right Pilot From Front Port 46Return From Front Pump
13Return From Bucket Flow Left Pilot Controller 37Right Propel Reverse to Control Valve and
Control Valve to Solenoid 23Left Propel Reverse Pilot Rotary Manifold Right Warm-Up Circuit to
Valve Manifold From Propel Pilot Rear Port Hydraulic Oil Tank
14Return From Propel Flow Controller 38To Bucket Cylinder Rod
Control Valve to Solenoid EndBucket Dump
Valve Manifold
TX,9025,GG2629 1908JUN982/2
9025
15
29
UN08MAY97
T109235
9025
15
30 Bottom
13Return From Bucket Flow 41To Boom Cylinder Rod 49Swing Left Pilot From Left 53Right Propel Forward Pilot
Control Valve to Solenoid EndBoom Down Pilot Controller From Propel Pilot
Valve Manifold 42Bucket Flow Control Valve 50Bucket Dump Pilot From Controller
17Arm In Pilot to Bucket Front Top Port to Right Right Pilot Controller 54Left Propel Forward Pilot
Flow Control ValveFront Side Boom Up Pilot Cap 51Boom Up Pilot From Right From Propel Pilot
Bottom Port 47Arm II to Arm I PilotArm Pilot ControllerSAE Controller
37Right Propel Reverse to Out Pattern 55To Hydraulic Oil Tank
Rotary Manifold Right 48Arm Out Pilot From Left 52Boom II to Boom I Pilot Return From Rear Pump
Rear Port Pilot ControllerSAE Boom Up Control Valve
39To Bucket Cylinder Head Pattern
EndBucket Curl
TX,9025,GG2630 1921APR971/1
9025
15
31
UN15APR97
T109048
Left Front
1Left Control Valve (5-Spool) 63Solenoid Valve Manifold 73Swing Valve 80Auxiliary Power Passage
2Right Control Valve 64Arm II Valve 74Arm Reduced Leakage Check Valve (Lift Check)
(4-Spool) 65Boom I Valve and Boom Valve 81Propel Flow Control Valve
56System Relief Valve Regenerative Valve 75Arm Out Circuit Relief and 82Propel Power and Neutral
Isolation Check Valve 66Boom Reduced Leakage Anti-Cavitation Valve Passage Check Valves
57System Relief Valve and Valve 76Plug (Lift Checks)
Power Boost 67Bucket Valve 77Swing Lift Check Valve 83Rear Pump Control Valve
58Dig Pressure Switch 68Right Propel Valve 78Arm I Power and Neutral 84Filter and Orifice for Pilot
59Flow Combiner Valve 69Left Propel Valve Passage Check Valves Pressure to Rear Pump
Circuit Check Valve 70Auxiliary Valve (Lift Checks), and Control Valve
60System Relief Valve 71Boom II Valve Restriction Orifice 84ACheck Valve and Orifice
Isolation Check Valve 71APropel-Boom Down 79Boom II Power Passage for Propel Flow Control
61Propel Pressure Switch Selector Valve Check Valve (Lift Check) Valve
62Pilot Pressure Inlet Filter 72Arm I Valve
TX,9025,GG2625 1920MAY981/1
9025
15
32
UN15APR97
T109052
Right Rear
1Left Control Valve (5-Spool) 68Right Propel Valve 89Power Boost Solenoid 96Boom I Power and Neutral
2Right Control Valve 69Left Propel Valve Valve Passage Check Valves
(4-Spool) 70Auxiliary Valve 90Propel Speed Change (Lift Checks)
57System Relief Valve and 71Boom II Valve Solenoid Valve 97Arm II Power and Neutral
Power Boost 72Arm I Valve 91Speed Sensing Solenoid Passage Check Valves
63Solenoid Valve Manifold 73Swing Valve Valve and Restriction Orifice
64Arm II Valve 85Arm Regenerative Valve 92Arm Regenerative 98Front Pump Control Valve
65Boom I Valve and Boom 86Arm II to Arm I Neutral Solenoid Valve 99Filter and Orifice for Pilot
Regenerative Valve Passage Check Valve 93Flow Combiner Valve Pressure to Front Pump
66Boom Reduced Leakage 87Boom Up Circuit Relief 94Bucket Flow Control Valve Control Valve
Valve Valve 95Bucket Check Valve (Lift 105Oil Cooler Bypass Valve
67Bucket Valve 88Bucket Dump Circuit Check)
Relief Valve
TX,9025,GG2626 1921APR971/1
UN15APR97
T109053
9025
15
Bottom 33
1Left Control Valve (5-Spool) 68Right Propel Valve 94Bucket Flow Control Valve 102Bucket Load Circuit
2Right Control Valve 69Left Propel Valve 100Arm Regenerative Circuit Relief and Anti-Cavitation
(4-Spool) 70Auxiliary Valve Check Valve Valve
64Arm II Valve 71Boom II Valve 101Boom Down Circuit 103Plug
65Boom I Valve 72Arm I Valve Relief and Anti-Cavitation 104Arm In Circuit Relief and
67Bucket Valve 73Swing Valve Valve Anti-Cavitation Valve
TX,9025,GG2627 1920MAY981/1
9025
15
34
TX,9025,GG2618 1919APR971/1
TX,9025,GG2272 1904APR001/1
TX,9025,GG2273 1904APR001/1
TX,9025,GG2620 1919APR971/1
SHOWN
ROTATED 180 MAIN CONTROL
VALVE
RIGHT
PROPEL
MOTOR
LEFT
PROPEL
MOTOR
ROTARY
MANIFOLD
PROPEL PILOT
CONTROLLER
PILOT
SHUT-OFF FLOW
VALVE REGULATOR
TX,9025,GG2621 1919APR971/1
TX,9025,GG2622 1919APR971/1
1906DEC91
T7660AL
9025
20
1
APilot Shut-Off Lever CPilot Shut-Off Valve DLever ECap Screw
BRod
2. Remove cover underneath operators station. 5. Pull pilot shut-off lever to the OFF position. Check
that lever is against the rear stop.
3. Push pilot shut-off lever (A) forward to the ON
position. Check that lever is against the front stop.
TX,9025,GG2108 1913SEP002/2
9025
20
2
1929AUG96
any of the 5-volt sensors power wire. A grounded
5-volt sensor power wire will prevent a successful
RS232 connection. Without system 5-volt supply,
RS232 connection is disabled.
T102900
The JT07274J Excavator Diagnostics Program Disk is
designed to run on a laptop computer, such as JT07294
Computer Kit, with the following minimal hardware
requirements:
486 Processor
16 megs of RAM
WINDOWS 95 or
WINDOWS NT
Standard RS232 Serial Port
Identification of Excavator.
Displaying of Diagnostic Service Codes and Corrective
Actions.
Monitoring Data.
Adjustment of Parameters.
On-Line Help.
CED,TX08227,2894 1904APR001/1
9025
25
2
1904SEP96
T102901
NOTE: The laptop cannot be connected to excavator 2. Connect floppy disk drive to the computer. As
system without 5 volts from the system supply. needed, connect an external power source to floppy
If laptop cannot establish a successful RS232 disk drive.
connection, check for approximately 5 volts on
any of the 5-volt sensors power wire. A NOTE: If floppy disk drive is not connected when the
grounded 5-volt sensor power wire will prevent computer is first booted (turned on) the
a successful RS232 connection. Without floppy disk drive (e:) may not be recognized.
system 5-volt supply, RS232 connection is To reboot, push Ctrl and Alt and Delete at
disabled. the same time or push and hold both left and
right mouse buttons down for 10 seconds
The complete excavator diagnostics program is
contained on a single floppy disk. The program 3. Turn the computer on. This is done on the
requires approximately twelve megabytes upon recommended computer by pushing function Fn
installation. Installation of the program or software and ON at the same time.
updates is best accomplished using the following
procedure: 4. Adjust brightness of screen. Push Fn and F4 or F5
on computer.
NOTE: The latest version of the excavator diagnostics
program now contains a list of supported 5. Using the mouse, push the Start button at the
excavator models in the About John Deere lower left corner of screen.
window. To check the list of excavator models
supported, click on the About button on the NOTE: The mouse is a short post located below the
Toolbar or the Help drop down menu on the space bar. Push the post in direction you want
Menu Bar and then click on About John the cursor to move. Click the buttons on the
Deere. left of the mouse when cursor is in desired
location. The tip of the cursor must be on the
1. Insert floppy disk in floppy disk drive. menu button for menu to open.
9025
25
3
1929AUG96
T102902
Continued on next page TX,9025,CR94 1928JAN993/5
9025
25
4
1919SEP96
T102903
7. Type e: and then a (backslash) in the Run dialog NOTE: Your computer will remember which drive a
window. Then type setup (or use the Browse disk is loaded on the last time it was done.
button to find and select setup from the floppy Therefore pushing the enter key may be all
disk and then select Open). See illustration for an that is required after a disk has been loaded
example. the first time.
NOTE: Some computers use a: as the floppy disk 9. Setup prompts you with a welcome dialog window
drive. Repeat previous step with a: instead of that describes the program and lets you continue or
e: if computer doesnt recognize the floppy exit
disk drive.
Click NEXT
9025
8. Once the dialog window contains the correct drive 25
and file name, click on the OK button. 5
1929AUG96
T102904
TX,9025,CR94 1928JAN995/5
9025
25
6
1911FEB97
T107199
9025
25
7
An Uninstall feature has been created for your NOTE: If John Deere App Group window is open, just
convenience to efficiently remove the program from click on Uninstall Shield.
your computer. Click on Start, Programs, John Deere
App Group, and then Uninstall Shield which is below
the Excavator Diagnostics menu. Follow on-screen
instructions.
TX,9025,CR100 1922APR981/1
1906SEP96
any of the 5-volt sensors power wire. A grounded
5-volt sensor power wire will prevent a successful
RS232 connection. Without system 5-volt supply,
RS232 connection is disabled.
T102905
The John Deere Excavator Diagnostics Software program
is started using the Excavator Diagnostics icon on the
desktop. Also, can be started from the John Deere App
Group in the Programs menu. The Excavator
Diagnostics icon is automatically put on the desktop
when the program is loaded.
9025
25
9
1913MAY97
T109483
NOTE: To install the Excavator Diagnostics icon if the desktop using the mouse. Release the
not on the desktop, use the following mouse button when icon in on the desktop.
procedure: 7. Click on Create Shortcut(s) Here using the
left mouse button.
1. Click on Start using the right mouse button. 8. Using the left mouse button, click on the X
2. Click Open using the left mouse button. in the upper right corner of each open
3. Double click on Programs in Start Menu window to close it.
window using the left mouse button.
4. Double click on John Deere App Group 1. Double click on Excavator Diagnostics icon to
icon using the left mouse button. start program from the desktop (also can click once
5. Put the mouse pointer on the Excavator on the icon and then press the Enter key).
Diagnostics icon.
6. Click and hold the right mouse button down For starting from the Programs menu:
and then drag the icon to an empty area on
TX,9025,GG2670 1928JAN993/5
9025
25
1914MAY97
10
T109495
3. The first time the excavator diagnostics program is b. When the Communication Setup window
used on the laptop computer, a communication port opens, click on the communication port your
must be selected. computer needs for communication with the
excavator. Most computers use Comm 1.
a. Click on the Setup button on the Toolbar or on
the Connection drop down menu on the Menu c. Using the left mouse button, click on the X in the
Bar and then click on Setup. upper right corner of Communication Setup
window to close it.
NOTE: If the Toolbar is not displayed, click on the
View drop menu and then click on Toolbar.
Also click on Status Bar if not displayed at
bottom of window.
1914MAY97
T109499
4. Click on the Connect button on the Toolbar or on The current mode for the software is listed in the
the Connection drop down menu on the Menu Bar middle of the Status Bar and the model number to
and then click on Connect. the right. The modes are Main Mode and Service 9025
Mode. 25
NOTE: If the Toolbar is not displayed, click on the 11
View drop menu and then click on Toolbar. The Disconnect button on the Toolbar will
Also click on Status Bar if not displayed at disconnect the communication with the excavator
bottom of window. being diagnosed, no further communication can be
performed by the software.
5. The John Deere Model window opens displaying
the Model number. Confirm the model number and
then click on OK or press Enter to continue.
TX,9025,GG2670 1928JAN995/5
1902SEP97
T111267
9025
25
12
1. Click on the Codes button on Toolbar or on the is selectable and not grayed out. Service
Features drop down menu on the Menu Bar and Codes-History are requested only once from the
then click on Service Codes. (See Excavator engine and pump controller.
Diagnostics Program List of Service Codes in this
group.) 2. After Service Codes-History have been cleared, the
Service Codes-Current are displayed and updated
The first group of service codes shown is the periodicallyat least 4 samples per minute. Click
Service Codes-History. If there are any codes on a specific service code to get Corrective Action
found, the option to clear the Service Codes-History window to display diagnostic advice.
TX,9025,GG2672 1922APR981/2
TX,9025,GG2672 1922APR982/2
1902SEP97
T111272
9025
25
13
1. Click on the Monitor button on Toolbar or on the down cursor keys and the Enter key also works for
Features drop down menu on the Menu Bar and selecting data items.
then click on Monitor Data to open the Data Item
Selection window. (See Excavator Diagnostic After your first choice has been made, the next
Software Monitor Data Items in this group.) Graph Position is highlighted and allows you to
make your second choice. You may choose a data
2. Double click (or click once and press the Enter key) item for each of the four Graph Positions.
on a data item and its ID number appears in the
Data Item Selected box at the Graph Position that 3. After choices have been made, click OK to view
is highlighted on the left of the screen. The up and data in graph form in the Monitor Data window.
1929AUG96
T102911
4. To change a data item in the Monitor Data 5. The data items are polled at about 4 samples per
window, click Select Items to toggle back to Data second. You can freeze the data by clicking on
Item Selection window. Freeze button. When you click Unfreeze, data
reading will resume. When highlighted, you can
Then highlight the Graph Position by clicking on it also press the Enter key to toggle between Freeze
or use the tab key and then select a data item as and Unfreeze. To highlight a button, press the tab
9025 before. key to highlight the button desired.
25
14
TX,9025,GG2673 1922APR982/3
settings.
T103375
TX,9025,GG2673 1922APR983/3
9025
25
15
1928APR97
T109321
1. You can save a copy of frozen data to a disk d. When Paint opens, paste frozen data by
following these steps: pressing Control and the V keys.
a. Click on the application to make it the active e. Click on Edit and then on Copy To.
window.
f. Type in a File name, select a drive to Save in
b. Press Alt and the PrtScn keys. and then click on Save.
c. Click on Start, Programs, Accessories, and 2. The saved file may be opened and printed in either
then Paint. a paint or page layout program.
TX,9025,GG2674 1922APR981/1
3.
UN11SEP96
6. The Warning Service Mode window opens warning
that excavator is in Service Mode. Click OK.
T103674
NOTE: Service Mode and machine model number is
displayed in the Status Bar at bottom of window.
CLearning Switch
In Service mode, the Service Codes and Monitor
Data cannot be accessed.
1914OCT97
T111739
9025
25 7. Click on the Adjust button on the Toolbar or on the The Parameter Change window contains:
18 Features drop down menu on the Menu Bar and
then click on Special Function to open the Special Parameter (to be changed)
Function window. Adjustable Range
Initial (deviation from factory set rpm)
The Special Function window allows the user to Minimum Adjusting Deviation
select the Adjustable Parameters for adjustment Current (deviation from factory setting)
and view the values under Learning Data Display. Adjustment (were change is made)
1929AUG96
T103378
9025
9. Use the up and down cursor keys on keyboard to 11. Click on Exit to close the Special Function 25
change the value which appears in the Adjustment window. 19
box.
12. Click on Disconnect Toolbar button.
NOTE: Clicking on the up and down arrows next to
box will also change the value. 13. Turn the key switch off.
10. Press the Enter key or click OK and the 14. Push learning switch down to the center position
Adjustment was made as follows: window and wait 10 seconds.
opens. Confirm the value and then press the Enter
key or click OK button to return to the Adjustable NOTE: Check the Status Bar at bottom of window that
Parameters. computer is in Main Mode after connecting.
NOTE: Only one parameter can be change at a time. 15. Start the engine and then check the adjusted
Repeat procedure from Adjustable Parameters parameter using a tachometer
to adjust additional parameters.
TX,9025,GG2862 1922APR984/4
9025
25
20
TX,9025,GG2643 1922APR981/1
CED,OUOE035,137 1920MAY982/2
9025
25
22
Specification
Engine Slow IdleSpeed .................................................... 900 25 rpm
Engine Auto IdleSpeed ................................................... 1200 25 rpm
Engine E (Economy) Mode
Speed ................................................................................. 1850 25 rpm
Engine Fast Idle in Standard
ModeSpeed ..................................................................... 2100 25 rpm
Engine Attachment ModeSpeed .................... (As specified by supplier)
NOTE: For the engine speed to get a specified pump flow 9025
rate, see Engine Speed to Pump Flow Rate Chart 25
23
in this group.
CED,OUOE003,1073 1904OCT001/1
SPECIFICATIONS
a
200LC Excavator Pump Flow 132 L/min (35 gpm)
Rate to Engine Speed at 1425 rpm and
14 479 kPa (145 bar) (2100 psi)
200LC Excavator Pumpa Flow 151 L/min (40 gpm)
Rate to Engine Speed at 1580 rpm and
14 479 kPa (145 bar) (2100 psi)
200LC Excavator Pump Flow 170 L/min (45 gpm)
Rate to Engine Speed at 1740 rpm and
14 479 kPa (145 bar) (2100 psi)
200LC Excavator Pump Flow 189 L/min (50 gpm)
Rate to Engine Speed at 1890 rpm and
14 479 kPa (145 bar) (2100 psi)
200LC Excavator Pump Flow 204 L/min (55 gpm)
Rate to Engine Speed at 2050 rpm and
14 479 kPa (145 bar) (2100 psi)
a
For engine speeds below the adjustable range, operate in Dig Mode
and turn the engine rpm dial to obtain the desired engine speed.
Specification
200LC Excavator Pump1Flow
Rate to Engine Speed ................................................ 132 L/min (35 gpm)
9025 at 1425 rpm and
25 14 479 kPa (145 bar) (2100 psi)
24 Flow Rate to Engine Speed ....................................... 151 L/min (40 gpm)
at 1580 rpm and
14 479 kPa (145 bar) (2100 psi)
200LC Excavator PumpFlow
Rate to Engine Speed ................................................ 170 L/min (45 gpm)
at 1740 rpm and
14 479 kPa (145 bar) (2100 psi)
Flow Rate to Engine Speed ....................................... 189 L/min (50 gpm)
at 1890 rpm and
14 479 kPa (145 bar) (2100 psi)
Flow Rate to Engine Speed ....................................... 204 L/min (55 gpm)
at 2050 rpm and
14 479 kPa (145 bar) (2100 psi)
1
For engine speeds below the adjustable range, operate in Dig Mode
and turn the engine rpm dial to obtain the desired engine speed.
Continued on next page CED,OUOE003,663 1913JUN981/2
CED,OUOE003,663 1913JUN982/2
9025
25
25
1. Questions:
Is the key switch on the excavator turned on?
Are the connectors push in all of the way?
Is the software connected? If communication is
broken momentarily between the computer and the
engine and pump controller?
Is the program in the Main Mode or Service Mode?
The program will tell you the current mode in the
Status Bar at the bottom of window. If it is not in one
of these modes you need to click on Connection
and Connect.
TX,9025,CR103 1928JAN991/1
1913FEB98
T113360
9025
25
27
AEngine and Pump BService Code Indicator CDiagnostic Port EFuse Box
Controller Light (LED) DJumper Wire
With practice the self-diagnostic service codes can be 4. Turn the key switch ON.
read by counting the flashes of the Service Code
Indicator Light (LED) (B) in the engine and pump The LED comes ON steady for several seconds
controller (A). and then goes OFF.
Read the LED in the engine and pump controller 5. For an existing service code, the LED starts a
several times to make sure the correct service code is flashing sequence of 1 second ON, 1 second OFF
read. intervals. After the last ON in a sequence, the LED
remains OFF for approximately 3 seconds and then
1. Lower the bucket to the ground. Stop the engine. repeats the flashing sequence.
2. Remove the rear console cover from behind the Count the number of times LED is ON in a
operators seat. Remove the bracket that is over the sequence for the service code number.
engine and pump controller.
Example, for a service code 03 Rear pump
3. Install a jumper wire (D) into the two top terminals delivery pressure sensor failure, the LED flashes
of the diagnostic port (C). ON three times in each sequence.
For more than one, the LED will have a flashing 9. Use the following procedure to clear existing
sequence for each existing service code with an service codes:
approximate 3 second interval between each
sequence. The flashing sequence continues as long a. Install jumper wire into the top two terminals of
as the key switch in ON and jumper wire is diagnostic port.
installed.
b. Turn the key switch ON.
NOTE: If no service codes exist or trouble is beyond
the scope of self-diagnosing function, the LED c. Remove jumper wire from diagnostic port.
is ON for several seconds then goes OFF and
remains OFF. d. Wait for two second.
With key switch ON but no jumper wire e. Install jumper wire into the top two terminals of
installed in the diagnostic port, the LED comes diagnostic port.
ON for several seconds, goes OFF, and then
starts a steady one seconds ON, one seconds f. Check for service codes. The LED is ON for
OFF flashing sequence. several seconds then goes OFF and remains
OFF if all necessary repairs were made.
6. Turn the key switch OFF.
g. Turn the key switch OFF
7. Remove jumper wire from diagnostic port.
h. Remove jumper wire from diagnostic port.
8. Make necessary repairs.
CED,TX08227,2997 1917APR002/2
9025
25
28
9025
25
29
1927MAY98
T115419
The engine and pump controller (EPC) is used to switches (13, 57, and 1416) are sent to the
control machine operation. Electronic input signals controller.
from the engine rpm dial (4), sensors (913), and
TX,9025,GG2603 1921MAY982/2
UN28FEB89
1. Before installing clamp-on electronic tachometer,
remove the paint from a straight section of injection
line within 100 mm (4 in.) of No. 1 injection nozzle.
Use emery cloth to remove the paint.
T6813AG
2. Install the clamp-on transducer (A). Tighten finger tight
onlyDO NOT overtighten.
AClamp-On Transducer
BBlack Clip ()
3. Connect the red clip (+) (C) to the clamp-on CRed Clip (+)
transducer. DDigital Readout Unit
CED,TX08227,2879 1911NOV971/1
ATemperature Probe
BCable
CJT05800 Digital Thermometer
CED,TX08227,2895 1919NOV971/1
UN25AUG95
Use the digital pressure and temperature analyzer (A),
and transducers (B) in place of analog gauges and a
separate temperature reader.
T8543AI
Transducers are temperature sensitive. Allow transducer
to warm to system temperature. After transducer is
warmed and no pressure applied, push sensor zero button
ADigital Pressure and Temperature Analyzer
for one second to set the true zero point. B3 400 kPa (35 bar) (500 psi) Transducer
34 000 kPa (350 bar) (5 000 psi) Transducer
When using for different pressures, turn selector to OFF 70 000 kPa (700 bar) (10 000 psi) Transducer
for two seconds and then to the pressure range. Readings
are inaccurate if proper range for transducer is not used.
CED,TX08227,2896 1919NOV971/1
9025
25
31
UN15JUL96
4. Check oil level in hydraulic tank. Add oil as necessary.
Tighten hydraulic oil tank cap. Tighten vent plug.
T101875
5. Start engine and run at slow idle. Slowly raise boom to
full height and then lower to pressurize hydraulic oil
9025
25 tank. CAir Bleed Plugs
32
6. Purge air from the hydraulic system by slowly
operating each function through three cycles. Air in
pilot circuits are purged automatically.
TX,25,GG2226 1914SEP001/1
2. Fill motor with hydraulic oil through drain port until oil
reaches the level of drain port. (See Hydraulic Oil in
Group 9000-04.)
UN11DEC91
3. Connect drain line.
T7670AE
9025
25
33
TX,25,GG2227 1913AUG981/1
UN30JUL96
T102305
TX,25,GG2228 1914SEP001/1
9025
25
34
Propel Motor Start-Up Procedure
ESSENTIAL TOOLS
JT03221 (Parker No. 03CP8) Plug
UN11DEC91
filled with oil before starting engine.
Procedure must be performed whenever
a new propel motor is installed or oil
has been drained from the motor.
T7660BG
TX,25,GG2229 1908JUN981/1
UN19JAN90
2. Use an oil filter cutting tool to cut top off filter.
IT4633
debris in bottom of filter can.
TX,25,GG2231 1920NOV971/1
9025
25
35
1. Install new return filter elements. Repeat procedure until the total system capacity
has circulated through filter caddy seven times.
NOTE: For a failure that creates a lot of debris, Each function must go through a minimum of three
remove access cover from hydraulic tank. complete cycles for a thorough cleaning of oil.
Drain hydraulic tank. Connect filter caddy
Hydraulic Oil Cleanup ProcedureSpecification
suction line to drain port. Add a minimum of 19 Hydraulic SystemCapacity ................... 250 L (66 gal) approximate
L (5 gal) of oil to reservoir. Operate filter caddy Hydraulic SystemFiltering
9025 and wash out the hydraulic tank. Time ............................................................... 40 minutes approximate
25
36 IMPORTANT: The minimum ID for a connector is NOTE: Filtering time for complete hydraulic system is
13 mm (1/2 in.) to prevent cavitation 0.158 minute x number of liters (0.6 minute x
of filter caddy pump. number of gallons). Filtering time for machines
with auxiliary hydraulic functions must be
2. Put filter caddy suction and discharge wands into increased because system capacity is larger.
hydraulic tank filler hole so ends are as far apart as
possible to obtain a thorough cleaning of oil. 7. Stop the engine. Remove the filter caddy.
3. Start the filter caddy. Check to be sure oil is flowing 8. Install new return filter elements.
through the filters.
9. Check oil level in hydraulic tank, add oil if
Operate filter caddy until all the oil in hydraulic tank necessary. (See Hydraulic Oil in Group 9000-04.)
has been circulated through the filter a minimum of
four times.
TX,9025,GG2114 1913SEP001/1
Below -18C (0F) an extended warm-up period may 5. Slowly turn upperstructure so boom is to the side.
be necessary. Hydraulic function will move slowly and
lubrication of parts may not be adequate with cold oil. CAUTION: Avoid possible serious injury
Do not attempt normal machine operation until from machine sliding backwards. Keep angle
hydraulic functions move at or close to normal cycle between boom and arm at 90110
times.
6. Keeping the angle between boom and arm at 90
Specification
Hydraulic System Warm-Up
110, lower boom to raise one track off the ground.
OilTemperature ............................................ 50 5C (120 10F)
7. Operate propel function for approximately 5 minute. 9025
25
Operate functions slowly and avoid sudden
37
movements until engine and hydraulic oils are 8. Once oil temperature is above -18C (0F), increase
thoroughly warmed. Operate a function by moving it a engine speed to fast idle.
short distance in each direction. Continue operating
the function increasing the distance traveled in each IMPORTANT: Holding a function over relief for
cycle until full stroke is reached. more than 10 seconds can cause
damage from hot spots in the
For faster warm-up, restrict air flow through oil cooler control valve.
using cardboard or other similar material. Use correct
viscosity oil to minimize warm-up period. (See 9. Operate the propel function (side with track off the
Hydraulic Oil in Group 9000-04.) ground). Also operate the bucket curl function over
relief for 10 seconds and then stop for 5 seconds.
1. Connect digital thermometer. Install temperature Repeat the cycle until oil is heated to specifications.
probe on hydraulic oil tank-to-pump inlet line. (See
JT05800 Digital Thermometer Installation in this 10. Stop periodically and operate all hydraulic
group.) functions to distribute the heated oil.
TX,25,GG2232 1913AUG981/1
SPECIFICATIONS
Lower Boom (with Engine Stopped)
Boom Manual Lower Screw 6.9 Nm (60 lb-in.)
Torque
UN23AUG88
Boom Manual Lower 13 Nm (115 lb-in.)
Screw-to-Housing Nut Torque
X9811
4 mm Hex Key Wrench
UN07AUG96
using a 4 mm hex key wrench. The boom will start to
lower.
T102664
by loosening screw an additional 1-1/2 turns. Never
loosen screw more than two turns. Boom Manual Lower Screw
3. After the bucket is lowered to the ground, tighten the ABoom Manual Lower Screw
screw to specification, and then the nut. BSmall Nut
CBoom Reduced Leakage Valve Housing
Lower Boom (with Engine Stopped)Specification
Boom Manual Lower Screw
Torque ........................................................................... 6.9 Nm (60 lb-in.)
Boom Manual Lower
Screw-to-Housing NutTorque ................................... 13 Nm (115 lb-in.)
CED,OUOE003,1198 1903OCT001/1
UN19MAR91
The purpose of harness test is to check continuity in
wiring harness to the arm regenerative solenoid valve (A)
coil and there is a electrical signal from engine and pump
controller.
T7486AL
NOTE: Pressure reading shown on the laptop computer
for Arm regenerative control pressure is a
calculated pressure from the electrical signal in
the engine and pump controller. A typical reading
is 399.3 psi while operating the boom up and arm
in functions in combined operation with engine
speed at 1200 rpm or less. The reading indicates
that the rear pump pressure sensor, arm in
UN28AUG96
pressure sensor, and boom up pressure switch
are OK and a electrical signal is generated. When
all functions are in neutral, a typical reading of
170.4 psi is displayed at fast or slow idle. (For
T103345
circuit operation, see Arm Regenerative Valve
Operation in Group 9025-05.)
AArm Regenerative Solenoid Valve (SC)
IMPORTANT: Disconnecting electrical connectors BSpeed Sensing Solenoid Valve (SD) 9025
while engine is running or with key CPropel Speed Change Solenoid (SI) 25
switch on can damage engine and DPower Boost Solenoid Valve (SG) 39
pump controller or other electrical
components.
5. Start engine.
TX,25,GG2220 1925APR002/2
9025
25
40
UN19MAR91
The purpose of test is to check continuity in wiring
harness to the speed sensing solenoid valve (B) coil and
there is a electrical signal from engine and pump
controller.
T7486AL
NOTE: Pressure reading shown on the laptop computer
for Speed sense control pressure is a calculated
pressure from the electrical signal in the engine
and pump controller. When all functions are in
neutral, a typical reading of 532.8 psi is displayed
at slow idle and 0 psi is displayed at fast idle. Run
the engine at approximately 1700 rpm so the
reading is less than 100 psi. Then actuate arm in
UN28AUG96
to bottom the function. The pressure reading will
increase momentarily and then return to its
original reading. The readings indicates that the
engine speed sensor is OK and a electrical signal
T103345
is generated. (For circuit operation, see Engine
Speed Sensing Control Circuit Operation in Group
9025-05.) AArm Regenerative Solenoid Valve (SC)
BSpeed Sensing Solenoid Valve (SD) 9025
IMPORTANT: Disconnecting electrical connectors CPropel Speed Change Solenoid (SI) 25
while engine is running or with key DPower Boost Solenoid Valve (SG) 41
switch on can damage engine and
pump controller or other electrical
components.
5. Start engine.
TX,25,GG2221 1925APR002/2
9025
25
42
UN19MAR91
The purpose of test is to check continuity in wiring
harness to the propel speed change solenoid valve (C)
coil and there is a signal from engine and pump controller.
T7486AL
NOTE: Pressure reading shown on the laptop computer
for Propel motor control pressure is a calculated
pressure from the electrical signal in the engine
and pump controller. A typical reading of 65.9 psi
is displayed when propel function is in neutral or
propelling in slow speed. A typical reading of 426
psi is displayed when propelling in fast speed with
no other function actuated. The readings indicates
that the propel speed switch, propel and dig
UN28AUG96
pressure switches, front and rear pump control
pressure sensors, and front and rear pump
pressure sensors are OK and a electrical signal is
generated. (For circuit operation, see Propel
T103345
Motor Speed Change Circuit Operation in Group
9025-05.)
AArm Regenerative Solenoid Valve (SC)
IMPORTANT: Disconnecting electrical connectors BSpeed Sensing Solenoid Valve (SD) 9025
while engine is running or with key CPropel Speed Change Solenoid (SI) 25
switch on can damage engine and DPower Boost Solenoid Valve (SG) 43
pump controller or other electrical
components.
6. Start engine.
TX,25,GG2219 1925APR002/2
9025
25
44
UN19MAR91
The purpose of test is to check continuity in the wiring
harness to the power boost solenoid valve (D) coil and
there is a signal from the engine and pump controller.
T7486AL
NOTE: Pressure reading shown on the laptop computer
for Power boost control pressure is a calculated
pressure from the electrical signal in the engine
and pump controller. A typical reading of 426 psi
is displayed when power boost switch on the right
control lever is pushed. A reading of 0 psi is
displayed when the switch is not pushed. The
readings indicates that the power boost switch is
OK and a electrical signal is generated. (For
UN28AUG96
circuit operation, see Power Boost Control Circuit
Operation in Group 9025-05.)
T103345
while engine is running or with key
switch on can damage engine and
pump controller or other electrical AArm Regenerative Solenoid Valve (SC)
components. BSpeed Sensing Solenoid Valve (SD) 9025
CPropel Speed Change Solenoid (SI) 25
1. Stop engine. Turn key switch to OFF. DPower Boost Solenoid Valve (SG) 45
TX,9025,GG2713 1925APR002/2
9025
25
46
UN19MAR91
E (Economy) Mode Voltage 3.00 volts
Auto-Idle Mode Voltage 2.57 volts
Slow Idle Voltage 2.42 volts
T7482AH
ESSENTIAL TOOLS
JT07066 Test Harness
UN19MAR91
The purpose of test is to check continuity in engine control
sensor (EC sensor) wiring harness and there is a signal
from the engine and pump controller (EPC).
T7486AB
IMPORTANT: Disconnecting electrical connectors
while engine is running or with key
switch on can damage engine and 9025
pump controller or other electrical 25
47
components.
UN07FEB97
IMPORTANT: Retainer tab on male half of wiring
harness connector halves must be
pushed down before pulling halves
apart. Never pull on wiring leads
T106991
2. Push retainer tab down then pull connector halves
apart. AOutside Terminal
BInside Terminal
3. Measure resistance between the outside terminals (A COutside Terminal
and C) of EC sensor. If resistance is 1700 400 ohms, DEngine Control Motor
EEngine Control Motor Sensor Wiring Harness
go to next step. If resistance is not as specified,
FEngine Control Motor Wiring Harness
replace EC sensor.
Specification
Fast Idle in Standard Mode
Voltage......................................................................................... 3.12 volts
E (Economy) ModeVoltage ...................................................... 3.00 volts
9025 Auto-Idle ModeVoltage ............................................................ 2.57 volts
25 Slow IdleVoltage ...................................................................... 2.42 volts
48
For HP (high power) mode, run engine at fast idle, push
HP mode switch, and then actuate arm in over relief.
Typical voltage for HP mode is 3.5 volts.
TX,9025,GG2710 1913OCT002/2
UN19MAR91
The purpose of test is to check continuity of EC motor
wiring harness (F) and there is a signal from engine and
pump controller (EPC).
T7486AD
NOTE: The laptop computer with excavator diagnostics
program can be used to check the electrical signal
from the engine and pump controller to the engine
control motor. Select 15 EC motor position from
Monitor Data Items. Typical readings are 7276
steps at slow idle to 525550 steps at fast idle.
The readings can vary from machine to machine.
What to look for is that the readings change when
the engine rpm dial is turned, and the E mode,
UN07FEB97
HP mode, or auto-idle mode is actuated.
T106991
switch on can damage engine and
pump controller or other electrical
components.
DEngine Control Motor
EEngine Control Sensor Wiring Harness 9025
1. Stop engine. Turn key switch to OFF. FEngine Control Motor Wiring Harness 25
49
IMPORTANT: Retainer tab on male half of wiring
harness connector halves must be
pushed down before pulling halves
apart. Never pull on wiring leads.
TX,25,GG2223 1913AUG982/2
9025
25
50
ESSENTIAL TOOLS
JT07067 Test Harness
UN19MAR91
miscellaneous circuits and wiring harnesses when a volt
meter is not available.
T7486AG
while engine is running or with key
switch on can damage engine and
pump controller or other electrical
components. ABullet Connector
BHarness
CEyelet
Retainer tab on male half of wiring DBullet Connector
harness connector halves must be EIndicator Light
pushed down before pulling halves
apart. Never pull on wiring leads.
TX,25,GG2224 1922APR981/1
SPECIFICATIONS
Hydraulic Oil Temperature 50 5C (120 10F)
Engine Speed Fast Idle
Work Mode Selector Position Dig Mode
UN11JAN93
E Mode Switch Position Off
HP Mode Switch Position Off
Auto-Idle Switch Position Off
T7918AO
Boom Raise (Cylinder Extend) 3.0 0.3 sec
Cycle Time
Boom Lower (Cylinder Retract) 2.4 0.3 sec Boom Position
Cycle Time
Arm In (Cylinder Extend) Cycle 3.6 0.3 sec
Time
Arm Out (Cylinder Retract) Cycle 2.4 0.3 sec
Time
Bucket Load (Cylinder Extend) 3.3 0.3 sec
Cycle Time
UN11JAN93
Bucket Dump (Cylinder Retract) 2.1 0.3 sec
Cycle Time
Swing Left or Right3 13.1 1.0 sec
Revolutions From a Running Start
T7918AP
Cycle Time
Propel 20 m (65 ft) From a 13.0 0.6 sec
Running StartCheck Time in Arm, Bucket and Swing Position
9025 Forward and Reverse Fast Speed
25 Propel Cycle Time
52
Propel 20 m (65 ft) From a 20.6 1.0 sec
Running StartCheck Time in
Forward and Reverse Slow
Speed Propel Cycle Time
UN03JAN90
SERVICE EQUIPMENT AND TOOLS
JT05800 Digital Thermometer
Stop Watch
T7160AL
Test is used as an indication of overall engine and
hydraulic system performance. A slow cycle time is an
indication of a leaky or malfunctioning hydraulic system Propel 3-Revolution Position
component or a weak engine.
1.
UN11JAN93
tank-to-pump suction line. (See JT05800 Digital
Thermometer Installation in this group.)
T7918AO
Hydraulic System Warm-Up Procedure in this group.)
Specification
EngineSpeed ............................................................................ Fast Idle
Work Mode SelectorPosition ................................................... Dig Mode
UN11JAN93
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
T7918AP
5. Actuate control valve to full stroke for each function.
Record the cycle time for each function.
Arm, Bucket and Swing Position
Specification 9025
Boom Raise (Cylinder Extend) 25
Cycle Time............................................................................. 3.0 0.3 sec 53
Boom Lower (Cylinder Retract)
Cycle Time............................................................................. 2.4 0.3 sec
Arm In (Cylinder Extend)Cycle
Time ....................................................................................... 3.6 0.3 sec
Arm Out (Cylinder Retract)
UN03JAN90
Cycle Time............................................................................. 2.4 0.3 sec
Bucket Load (Cylinder Extend)
Cycle Time............................................................................. 3.3 0.3 sec
Bucket Dump (Cylinder Retract)
Cycle Time............................................................................. 2.1 0.3 sec
T7160AL
Swing Left or Right3
Revolutions From a Running
StartCycle Time ............................................................... 13.1 1.0 sec Propel 3-Revolution Position
Propel 20 m (65 ft) From a
Running StartCheck Time in
Forward and Reverse Fast Speed
PropelCycle Time............................................................. 13.0 0.6 sec
Propel 20 m (65 ft) From a
Running StartCheck Time in
Forward and Reverse Slow
Speed PropelCycle Time ................................................. 20.6 1.0 sec
TX,9025,GG2116 1918SEP002/2
UN19OCT88
SPECIFICATIONS
Oil Temperature 50 5C (120 10F)
Engine Speed in Standard Mode Fast Idle
T6479AY
Work Mode Selector Position Dig Mode
E Mode Switch Position Off
HP Mode Switch Position Off
Auto-Idle Switch Position Off
After 90 (1/4 turn) Swing, 45 (1/8 turn)
Upperstructure Must Stop After
Releasing Control Lever Within
Distance
Specification
OilTemperature ................................................... 50 5C (120 10F)
9025
25
54 CAUTION: Check that area is clear and large
enough to swing upperstructure with arm and
bucket extended. Machine must be on level
ground.
Specification
EngineSpeed in Standard
Mode ............................................................................................. Fast Idle
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
Specification
After 90 (1/4 turn) Swing,
Upperstructure Must Stop After
Releasing Control Lever Within
Distance ................................................................................. 45 (1/8 turn)
CED,OUOE003,1075 1913AUG982/2
ESSENTIAL TOOLS
9025
25 202862 (3/4-16 M 37 x 3/4-16 F 37 Sw x 7/16-20 M 37) Tee
56 TH108328 Adapter
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler
TX,9025,GG2646 1925APR002/5
KVent Plug
9025
UN29APR97
25
57
T109340
Continued on next page TX,9025,GG2646 1925APR003/5
UN11SEP96
at the pilot pump (F) outlet port. Use adapter (G) in
test port.
T103346
the plug can be difficult to remove.
UN12MAY97
Specification
Hydraulic OilTemperature ................................... 50 5C (120 10F)
T109473
Specification
Standard ModeEngine Speed................................................... Fast idle
Work Mode SelectorPosition ................................................... Dig Mode APlug
E Mode SwitchPosition ...................................................................... Off B202862 Tee
9025
HP Mode SwitchPosition ................................................................... Off C7000 kPa (70 bar) (1000 psi) Gauge
25
Auto-Idle SwitchPosition .................................................................... Off DPilot Pressure Line
58
EShim
7. Record pressure reading for pilot pressure regulating FPilot Pump
valve (A). GTH108328 Adapter
Specification
Pilot SystemPressure........................ 3925 + 980 - 490 kPa (39.2 + 9.8
- 4.9 bar) (570 + 140 - 70 psi)
Specification
Pilot Pressure Regulating Valve
at Slow IdlePressure ........................... 3925 980 kPa (39.2 9.8 bar)
UN11SEP96
(570 140 psi)
Pilot Pressure Regulating Valve
at Fast IdlePressure ........................... 4410 980 kPa (44.1 9.8 bar)
(640 140 psi)
T103347
Per 0.25 mm (0.010 in.) Shim
Approximate ChangePressure ...................... 78 kPa (0.75 bar) (11 psi)
Per 0.5 mm (0.020 in.) Shim
Approximate ChangePressure .................... 157 kPa (1.57 bar) (23 psi)
APilot Pressure Regulating Valve Plug
Per 1.0 mm (0.040 in.) Shim
EShims
Approximate ChangePressure .................... 304 kPa (3.04 bar) (44 psi)
Specification
Plug to Pilot Pressure Regulating
Valve HousingTorque ............................................... 25 Nm (215 lb-in.)
TX,9025,GG2646 1925APR005/5
9025
25
59
SPECIFICATIONS
Hydraulic Oil Temperature 50 5C (120 10F)
Engine in Standard Mode Speed Slow Idle and Fast Idle
Work Mode Selector Position Dig Mode
E Mode Switch Position Off
HP Mode Switch Position Off
Auto-Idle Switch Position Off
Valve Spool Actuating Pressure 33353920 kPa (33.339.2 bar)
at Slow Idle and Fast Idle (485570 psi)
Pressure
ESSENTIAL TOOLS
203836 (9/16-18 M 37 x 9/16-18 Sw 37 x 7/16-20 M 37) Tee
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler
TX,9025,GG2647 1925APR001/3
KVent Plug
UN29APR97
T109340
Specification
Hydraulic OilTemperature ................................... 50 5C (120 10F)
UN18JUN96
6. Start and run engine at specification.
Specification
Engine in Standard Mode
T101596
Speed .................................................................... Slow Idle and Fast Idle
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off APilot Line
Auto-Idle SwitchPosition .................................................................... Off BTee
CPressure Gauge
NOTE: Spool actuating pressure can be checked for each
function by installing the tee and gauge in that
pilot line and then actuating that function.
9025
7. Actuate the function being checked to full stroke. 25
61
Specification
Valve Spool Actuating Pressure
at Slow Idle and Fast Idle
Pressure ............................................... 33353920 kPa (33.339.2 bar)
(485570 psi)
TX,9025,GG2647 1925APR003/3
1929AUG96
b. Select the System Relief and Power Boost Valve
Test template.
T102900
monitored to check that pump control pressure
signals to the main hydraulic pump regulators
increases as function is actuated. A low pump
control pressure signal can cause system
pressure to be low because pump displacement
does not increase to generate enough oil flow.
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
63
T133476
ServiceEXPERT is a trademark of Deere & Company Continued on next page TX,9025,GG2648 1924OCT002/6
1929AUG96
b. Start the engine.
T102900
3-Front pump delivery pressure,
4-Rear pump delivery pressure,
1-Front pump control pressure,
6-Rear pump control pressure,
14-Actual engine speed.
UN28AUG00
9025 1Fuse Box
25 2Diagnostic Port
64 3Learning Switch
T133476
Continued on next page TX,9025,GG2648 1924OCT003/6
UN29APR97
hydraulic oil tank.
T109340
the analyzer and transducers or gauges.
UN18JUN96
9025
25
65
T101614
System Relief and Power Boost ValveSpecification
Engine Fast Idle in Standard
ModeSpeed .................................................................. 20752125 rpm
AAdapter
Work Mode SelectorPosition ................................................... Dig Mode
BRear Pump
E Mode SwitchPosition ...................................................................... Off
CFront Pump
HP Mode SwitchPosition ................................................................... Off
KVent Plug
Auto-Idle SwitchPosition .................................................................... Off
UN18JUN96
power boost pilot line. Connect pilot line before
starting engine and applying pressure.
T101616
i. Turn first adjusting plug (E) in until piston (I) is
against bottom of bore in second adjusting plug (G).
Tighten nut. Connect pilot line. DSystem Relief Valve
EFirst Adjusting Plug
F27 mm Nut
j. Loosen 32 mm nut (H). GSecond Adjusting Plug
H32 mm Nut
k. Start engine. Actuate the arm in function over relief. IPiston
9025
l. Turn second adjusting plug in to increase power
25
66 boost pressure; turn adjusting plug out to decrease
pressure.
TX,9025,GG2648 1924OCT006/6
9025
25
67
1929AUG96
b. Select the Circuit Relief Valve template.
T102900
signals to the main hydraulic pump regulators
increases as function is actuated. A low pump
control pressure signal can cause system
pressure to be low because pump displacement
does not increase to generate enough oil flow.
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
69
T133476
ServiceEXPERT is a trademark of Deere & Company Continued on next page TX,9025,GG2649 1925OCT002/7
1929AUG96
b. Start the engine.
T102900
3-Front pump delivery pressure,
4-Rear pump delivery pressure,
1-Front pump control pressure,
6-Rear pump control pressure,
14-Actual engine speed.
UN28AUG00
9025 1Fuse Box
25 2Diagnostic Port
70 3Learning Switch
T133476
Continued on next page TX,9025,GG2649 1925OCT003/7
UN29APR97
hydraulic oil tank.
T109340
the analyzer and transducers or gauges.
AAdapter
BRear Pump
CFront Pump
KVent Plug
UN18JUN96
9025
25
71
T101614
Continued on next page TX,9025,GG2649 1925OCT004/7
UN18JUN96
d. Extend the cylinder to check a head end circuit
T101616
relief valve; retract the cylinder to check a rod end
circuit relief valve.
UN29APR97
UN29APR97
T109335
T109334
NOTE: If pressure reading fluctuates increase engine
speed slightly.
f. Actuate function over relief for circuit relief valve (J, 9025
K, L, M, N, and O) being checked. Record pressure 25
73
reading.
UN29APR97
Bucket Curl (Head End)
Pressure .................................................................... 37 26538 245 kPa
(372.7382.5 bar) (54055545
psi)
T109336
Boom Down (Rod End)
Pressure .................................................................... 37 26538 245 kPa
(372.7382.5 bar) (54055545
psi)
Arm Out (Rod End)Pressure ................................. 39 22540 205 kPa DSystem Relief Valve
(392.3402.1 bar) (56905830 JArm Out Circuit Relief Valve
psi) KBoom Up Circuit Relief Valve
Bucket Dump (Rod End) LBucket Dump Circuit Relief Valve
Pressure .................................................................... 39 22540 205 kPa MBoom Down Circuit Relief Valve
(392.3402.1 bar) (56905830 NBucket Curl Circuit Relief Valve
psi) OArm In Circuit Relief Valve
TX,9025,GG2649 1925OCT007/7
9025
25
74
1929AUG96
b. Select the Swing Motor Crossover Relief Valve Test
template.
T102900
monitored to check that the pump control pressure
signals to the main hydraulic pump regulators
increases as function is actuated. A low pump
control pressure signal can cause system
pressure to be low because pump displacement
does not increase to generate enough oil flow.
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
76
T133476
ServiceEXPERT is a trademark of Deere & Company Continued on next page TX,9025,GG2650 1925OCT002/6
1929AUG96
b. Start the engine.
T102900
3-Front pump delivery pressure,
4-Rear pump delivery pressure,
1-Front pump control pressure,
6-Rear pump control pressure,
14-Actual engine speed.
UN28AUG00
1Fuse Box 9025
2Diagnostic Port 25
3Learning Switch 77
T133476
Continued on next page TX,9025,GG2650 1925OCT003/6
UN29APR97
hydraulic oil tank.
T109340
the analyzer and transducers or gauges.
UN18JUN96
9025
25
78
T101614
Swing Motor Crossover Relief ValveSpecification
Engine Slow Idle in Standard
ModeSpeed ...................................................................... 875925 rpm
AAdapter
Work Mode SelectorPosition ................................................... Dig Mode
BRear Pump
E Mode SwitchPosition ...................................................................... Off
CFront Pump
HP Mode SwitchPosition ................................................................... Off
KVent Plug
Auto-Idle SwitchPosition .................................................................... Off
TX,9025,GG2650 1925OCT005/6
UN20JUN96
T101716
TX,9025,GG2650 1925OCT006/6
1929AUG96
b. Select the Propel Motor Crossover Relief Valve Test
template.
T102900
monitored to check that the pump control pressure
signals to the main hydraulic pump regulators
increases as function is actuated. A low pump
control pressure signal can cause system
pressure to be low because pump displacement
does not increase to generate enough oil flow.
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
81
T133476
ServiceEXPERT is a trademark of Deere & Company Continued on next page TX,9025,GG2651 1926OCT002/7
1929AUG96
b. Start the engine.
T102900
3-Front pump delivery pressure,
4-Rear pump delivery pressure,
1-Front pump control pressure,
6-Rear pump control pressure,
14-Actual engine speed.
UN28AUG00
9025 1Fuse Box
25 2Diagnostic Port
82 3Learning Switch
T133476
Continued on next page TX,9025,GG2651 1926OCT003/7
UN29APR97
hydraulic oil tank
T109340
the analyzer and transducers or gauges.
AAdapters
BRear Pump
CFront Pump
KVent Plug
UN18JUN96
9025
25
83
T101614
Continued on next page TX,9025,GG2651 1926OCT004/7
UN18JUN96
hydraulic oil. (See procedure in this group.)
T101616
DSystem Relief and Power Boost Valve
EFirst Adjusting Plug
F27 mm Nut
GSecond Adjusting Plug
H32 mm Nut
IPiston
9025
25
84
TX,9025,GG2651 1926OCT005/7
UN02JUL96
Propel Motor Crossover Relief ValveSpecification
Crossover Relief ValvePressure ........................... 34 815 36 775 kPa
(348.1367.8 bar) (50505335
psi)
T101857
g. Adjust the crossover relief valves as needed. Turn EForward Crossover Relief Valve
adjusting screw in to increase the pressure setting; FReverse Crossover Relief Valve
turn adjusting screw out to decrease pressure.
TX,9025,GG2651 1926OCT007/7
ServiceEXPERT is a trademark of Deere & Company Continued on next page TX,9025,GG2121 1924OCT001/7
UN29APR97
manifold (A) for solenoid valve (H) being checked.
T109340
JT03464 Tee. Use the JT03191 Tee for the others.
UN20JUN96
9025
25
87
T101708
Continued on next page TX,9025,GG2121 1924OCT002/7
1929AUG96
checked:
T102900
Speed Sensing Proportional Solenoid Valve Test
Propel Speed Change Proportional Solenoid
Valve Test
Power Boost Proportional Solenoid Valve Test
UN28AUG00
9025
25
88 8. Do Hydraulic System Warm-Up Procedure to heat
hydraulic oil. (See procedure in this group.)
T133476
Proportional Solenoid ValvesSpecification
Hydraulic OilTemperature ................................. 4555C (110130F)
UN28AUG96
Propel speed change solenoid valve (SI)
Power boost solenoid valve (SG)
T103345
with dirt, run engine at less than 1200 rpm then
operate boom up and arm in functions in combined
operation.
AArm Regenerative Solenoid Valve (SC)
BSpeed Sensing Solenoid Valve (SD)
NOTE: Pressure reading shown on the computer screen CPropel Speed Change Solenoid Valve (SI)
for Arm regenerative control pressure is a DPower Boost Solenoid Valve (SG)
calculated pressure from the electrical signal in
the engine and pump controller. A typical reading
increases to 399.3 psi while operating the boom
up and arm in functions in combined operation
with engine speed at 1200 rpm or less. The
reading indicates that the rear pump pressure
sensor, arm in pressure sensor, and boom up
pressure switch are OK and a electrical signal is
generated. When all functions are in neutral, a
typical reading of 170.4 psi is displayed at fast or
slow idle. See Arm Regenerative Valve Operation
9025
for circuit operation. (See theory of operation in 25
Group 9025-05.) 89
UN20JUN96
IMPORTANT: Turning adjusting screw out too far may
cause oil leakage because the O-ring
has come off its seat.
T101709
b. Loosen nut (J) just enough so adjusting screw can
be turned.
9025
25 d. Hold adjusting screw and then tighten nut.
92
Proportional Solenoid ValveSpecification
Solenoid Valve Adjusting
Screw-to-Housing NutTorque .................................... 8.8 Nm (78 lb-in.)
TX,9025,GG2121 1924OCT007/7
1929AUG96
b. Select the Pump Control Valve Test template.
T102900
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
94
T133476
ServiceEXPERT is a trademark of Deere & Company Continued on next page TX,9025,GG2652 1926OCT002/6
1929AUG96
b. Start the engine.
T102900
1-Front pump control pressure,
6-Rear pump control pressure,
14-Actual engine speed.
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
95
T133476
Continued on next page TX,9025,GG2652 1926OCT003/6
UN29APR97
hydraulic oil tank
T109340
pump regulators. Connect the analyzer and
transducer, or gauge (D).
UN11SEP96
9025
25
b. Run machine at specification.
96
T103348
Engine Slow to Fast Idle in
Standard ModeSpeed .................................................... 8752125 rpm
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off ARear Pump Regulator
Auto-Idle SwitchPosition .................................................................... Off BFront Pump Regulator
CTee(s)
DGauge(s)
KVent Plug
TX,9025,GG2652 1926OCT005/6
UN13SEP96
Valve Control SignalPressure ........... 35163723 kPa (35.237.2 bar) 97
(425570 psi) with track raised
at full speed, engine at fast idle
T103491
For an adjustment to the front pump control valve, use
the right propel with track raised or bucket function
over relief. For an adjustment to the rear pump control
valve use the left propel with track raised or swing
function over relief for the rear pump control valve.
Turn the adjusting screw in to increase pressure
reading; turn adjusting screw out to decrease pressure
reading. Tighten nut.
TX,9025,GG2652 1926OCT006/6
UN15MAY01
T141914
9025
25
98 A13 mm Nut D30 mm Nut HLoad Adjusting Screw J30 mm Nut
BMaximum Flow Adjusting EMinimum Flow Adjusting (Inner Spring) (Engine
Screw Screw Pulldown at High Pressure)
CFlow Adjusting Cartridge F17 mm Nut ILoad Adjusting Cartridge
(Track Cycle Time) G17 mm Nut (Outer Spring) (Engine
Pulldown at Medium
Pressure)
Specification
Regulator Maximum Flow For adjustment, see Hydraulic Pump Regulator Test
Adjusting ScrewTurn ..................................... 1/4 turn IN decreases and AdjustmentMinimum Flow in this group.
maximum pump flow rate
approximately 11 L/min Do not turn adjusting more than two turns. Tighten nut
(3 gpm)
(F) after adjustment.
Do not turn adjusting screw in more than two turns.
Load Adjusting Screw (Inner Spring) (Engine
Tighten nut (A) after adjustment. Maximum flow
Pulldown at High Pressure) (H):
adjusting screw must not be turned out to try to
Turning load adjusting screw IN increases flow rate.
increase pump flow rate except after the adjustment of
flow adjusting cartridge (C). For adjustment, see
Hydraulic Pump Regulator Test and Adjustment
Maximum Flow in this group.
Specification
Regulator Load Adjusting
Turning adjusting cartridge IN increases flow rate.
Screw (Inner Spring) (Engine
Pulldown at High Pressure)
Turn................................................... 1/4 turn IN increases pump flow Specification
rate approximately 5.46 L/min Regulator Load Adjusting
(1.45 gpm) Cartridge (Outer Spring)
(Engine Pulldown at Medium
Pressure)Turn ............................... 1/4 turn IN increases pump flow
Do not turn adjusting screw more than one turn. rate approximately 22.5 L/min
Tighten nut (G) after adjustment. (6 gpm)
For adjustment, see Hydraulic Pump Regulator Test Do not turn adjusting cartridge more than one turn.
and AdjustmentEngine Pulldown in this group. Tighten nut (J) after adjustment.
Load Adjusting Cartridge (Outer Spring) (Engine For adjustment, see Hydraulic Pump Regulator Test
Pulldown at Medium Pressure) (I): and AdjustmentEngine Pulldown in this group.
TX,9025,GG2109 1907MAY013/3
9025
25
,100
ESSENTIAL TOOLS
7/16-20 M 37 (Parker No. 03CP-4) Plug (2 used)
Specification
OilTemperature ................................................... 50 5C (120 10F)
KVent Plug
UN29APR97
T109340
TX,9025,GG2125 1915JUN982/4
Specification
Engine in Standard Mode
Speed ........................................................................................... Fast Idle
Work ModePosition .................................................................. Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
9025 Auto-Idle SwitchPosition .................................................................... Off
25 Propel Speed SwitchPosition.................................. Slow Speed (Turtle)
,102
8. Raise the left track off ground for rear pump or the
right track for front pump.
UN11SEP96
ARear Pump Regulator
BFront Pump Regulator
CPlugs
T103501
Specification
Slow Speed Propel With Track
RaisedCycle Time ............................ 36 1 sec for one revolution from
a running start with pump control
valve pilot line disconnect
UN24AUG98
T103502
TX,9025,GG2125 1915JUN984/4
9025
25
,103
Specification
OilTemperature ................................................... 50 5C (120 10F)
Specification
Engine in Standard Mode
Speed ........................................................................................... Fast Idle
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
Propel Speed SwitchPosition.................................. Slow Speed (Turtle)
5. Raise the left track off ground for rear pump or the
right track for front pump.
TX,9025,GG2126 1928NOV012/3
Specification
Track Raised3 Revolutions
From a Running StartCycle
Time .................................................................................... 28.2 1.0 sec.
A13 mm Nut
BMaximum Flow Adjusting Screw
T103535
TX,9025,GG2126 1928NOV013/3
ESSENTIAL TOOLS
TH108328 Adapter (2 used)
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler
1929AUG96
fuel must be verified. The fast idle
speed must be adjusted to
specifications.
T102900
Pump regulators are sensitive to adjust.
UN29APR97
b. Loosen vent plug (K) to release the air pressure in
hydraulic oil tank.
T109340
ports in rear (B) and front (C) pumps. Connect the
analyzer and transducer or gauges.
Specification
OilTemperature ................................................... 50 5C (120 10F)
UN18JUN96
9025 5. Check that fast idle is to specification. Adjust as
25
needed before continuing test. Record the fast idle
,108
speed.
T101614
Specification
Engine Fast Idle in Standard
ModeSpeed .................................................................. 21002125 rpm
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off AAdapters
HP Mode SwitchPosition ................................................................... Off BRear Pump
Auto-Idle SwitchPosition .................................................................... Off CFront Pump
Propel Speed SwitchPosition.................................. Slow Speed (Turtle) KVent Plug
UN02JUL96
6. Install two 85 mm (3-3/8 in.) OD pins or round bar
stock between both sprockets and track frame to stall
the propel motors.
T101856
DPin or Round Bar Stock
TX,9025,GG2242 1907SEP004/13
J13 mm Nut
KLoad Adjusting Screw (Inner Spring)
LLoad Adjusting Cartridge (Outer Spring)
UN18SEP96
M30 mm Nut
T103527
UN18JUN96
F27 mm Nut
GSecond Adjusting Plug
H32 mm Nut
IPiston
T101616
Continued on next page TX,9025,GG2242 1907SEP006/13
9025
25
,110
UN18SEP96
j. Release both propel functions.
T103527
the propel functions over relief to check the
pulldown after each adjustment of cartridge.
Specification
Load Adjusting Cartridge (Outer
Spring)Combined Pump Engine
PulldownSpeed .................................... 19501975 rpm at 15 170 kPa
(152 bar) (2200 psi) with tracks
stalled
TX,9025,GG2242 1907SEP008/13
UN18JUN96
DSystem Relief Valve
EFirst Adjusting Plug
F27 mm Nut T101616
GSecond Adjusting Plug
H32 mm Nut
IPiston
UN18SEP96
the propel function over relief to check the
pulldown after each adjustment of screws
T103527
Start with 1/4 turn.
Specification
System Relief ValvePressure ................. 34 325 + 1960 - 0 kPa (343 +
19.6 - 0 bar) (4980 + 285 - 0 psi)
UN18JUN96
EFirst Adjusting Plug
F27 mm Nut
GSecond Adjusting Plug
H32 mm Nut
IPiston
T101616
Continued on next page TX,9025,GG2242 1907SEP0011/13
9025
25
,114
J13 mm Nut
UN18SEP96
KLoad Adjusting Screw (Inner Spring)
LLoad Adjusting Cartridge (Outer Spring)
M30 mm Nut
T103527
9025
25
,115
J13 mm Nut
KLoad Adjusting Screw (Inner Spring)
UN18SEP96
LLoad Adjusting Cartridge (Outer Spring)
M30 mm Nut
T103527
TX,9025,GG2242 1907SEP0013/13
9025
25
,116
SPECIFICATIONS
Engine in Standard Mode Speed 2000 10 rpm
Work Mode Selector Position Dig Mode
E Mode Switch Position Off
HP Mode Switch Position Off
Auto-Idle Switch Position Off
Oil Temperature 50 5C (120 10F)
Pump at 2000 10 rpm and 20 125 4 L/min (33 1 gpm)
685 kPa (207 bar) (3000 psi) typical flow new
Flow Rate
Pump at 2000 10 rpm and 13 190 4 L/min (50 1 gpm)
790 kPa (138 bar) (2000 psi) typical flow new
Flow Rate
Pump at 2000 10 rpm and 20 106 15 L/min (28 4 gpm)
685 kPa (207 bar) (3000 psi) minimum flow used
Flow Rate
Pump at 2000 10 rpm and 13 159 15 L/min (42 4 gpm)
790 kPa (138 bar) (2000 psi) minimum flow used
Flow Rate
ESSENTIAL TOOLS
TH108328 Adapter (2 used)
TH108325 (1 M BSPP ORB x 16 M ORFS) Elbow
JT03410 (SAE Code 62 Split Flange High Pressure 1 SF x 1-5/16-12
M 37) 90 Flange Fitting (2 used) 9025
25
JT03452 Split Flange Connector Plate Kit
,117
202862 (3/4-16 M 37 x 3/4-16 F 37 Sw x 7/16-20 M 37) Tee (2
used)
JT05484 (7/16-20 F 37) (Parker No. 06CP-4) Cap (2 used)
KVent Plug
UN29APR97
T109340
Continued on next page TX,9025,GG2128 1907SEP002/4
9025
25
,118
9025
25
,119
UN16SEP96
T103554
APilot Pressure Inlet Line EPump Control Valve Pilot GTH108328 Adapter KFront Pump Outlet Port
B202862 Tee (2 used) Lines HTH108325 Elbow LRear Pump Outlet Port
CJT05484 Cap FFront and Rear Pump IReturn Manifold MJT03410 90 Flange Fitting
DTest Port Regulator Valves JBulkhead
3. Connect the flow meter using 90 flange fitting (M). (G) and gauges to test ports (D) in pump housing,
If available, connect a flow meter to front (K) and or use the laptop computer.
rear (L) pumps.
4. Disconnect pilot pressure inlet line (A) at pilot filter.
Connect the return hose from flow meter to the Install tees (B). Connect pilot pressure inlet line to
return manifold (I). Install plates, from the split tee.
flange connector plate kit, on end of hoses to
control valve. Disconnect the two pump control valve pilot lines
(E) at bulkhead (J) on hydraulic oil tank. Connect
To monitor pump delivery pressure, use the the pilot lines to the tees installed at pilot filter.
pressure gauge on flow meter, or install adapters Install caps (C) on fittings at bulkhead.
displacement.
10. Adjust the flow meter loading valve to obtain the
5. Install the temperature probe on the hydraulic specified test pressures. Adjust engine speed to
tank-to-pump suction line. (See JT05800 Digital specified rpm. Record pump flow at each
Thermometer Installation in this group.) pressure.
6. Install the tachometer. (See JT05801 Clamp-On If pump flow in low, repair or replace pump.
Electronic Tachometer Installation in this group.)
Specification
Pump at 2000 10 rpm and 20
7. Check that the flow meter loading valve is open. 685 kPa (207 bar) (3000 psi)
Flow Rate................................................. 125 4 L/min (33 1 gpm)
8. Operate the machine at specification. typical flow new
Pump at 2000 10 rpm and 13
Specification 790 kPa (138 bar) (2000 psi)
Engine in Standard Mode Flow Rate................................................. 190 4 L/min (50 1 gpm)
Speed........................................................................... 2000 10 rpm typical flow new
Work Mode SelectorPosition............................................. Dig Mode Pump at 2000 10 rpm and 20
E Mode SwitchPosition ............................................................... Off 685 kPa (207 bar) (3000 psi)
HP Mode SwitchPosition............................................................. Off Flow Rate............................................... 106 15 L/min (28 4 gpm)
Auto-Idle SwitchPosition ............................................................. Off minimum flow used
Pump at 2000 10 rpm and 13
790 kPa (138 bar) (2000 psi)
9. Heat the hydraulic oil to the specified temperature Flow Rate............................................... 159 15 L/min (42 4 gpm)
by closing flow meter loading valve to increase minimum flow used
pressure to 20 685 kPa (207 bar) (3000 psi).
9025
25
,120
TX,9025,GG2128 1907SEP004/4
SPECIFICATIONS
Oil Temperature 50 6C (120 10F)
Engine in Standard Mode Speed 2000 rpm
Work Mode Selector Position Dig Mode
E Mode Switch Position Off
HP Mode Switch Position Off
Auto-Idle Switch Position Off
Pilot Pump Flow Rate 25.0 L/min (6.6 gpm) minimum at
3925 kPa (39 bar) (570 psi) and
2000 rpm
TX,9025,GG2663 1908JUN981/3
9025
25
,121
1. Stop the engine.
KVent Plug
UN29APR97
T109340
Continued on next page TX,9025,GG2663 1908JUN982/3
Specification
OilTemperature ................................................... 50 6C (120 10F)
UN11SEP96
If pressure is low, check the pilot pressure regulating
valve.
T103571
If flow is low, check inlet hose to pump for restriction. If
there is no restriction, replace pump.
9025
25 APilot Pressure Inlet Line
Specification BPilot Filter
,122 Engine in Standard Mode
Speed .......................................................................................... 2000 rpm
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
Pilot PumpFlow Rate ........................ 25.0 L/min (6.6 gpm) minimum at
3925 kPa (39 bar) (570 psi) and
2000 rpm
TX,9025,GG2663 1908JUN983/3
SPECIFICATIONS
Engine in Standard Mode Speed Fast Idle
Work Mode Selector Position Dig Mode
E Mode Switch Position Off
HP Mode Switch Position Off
Auto-Idle Switch Position Off
Oil Temperature 50 5C (120 10F)
Mistrack at 20 m (65 ft) Distance 200 mm (7-7/8 in.) or less
2. Adjust the track sag so both sides are equal and within
specification before doing test. (See Adjust Track Sag 9025
25
in Group 9020-20.)
,123
Specification
Engine in Standard Mode
Speed ........................................................................................... Fast Idle
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
Specification
OilTemperature ................................................... 50 5C (120 10F)
TX,9025,GG2664 1908JUN982/3
Specification
UN23MAR89
Mistrack at 20 m (65 ft)
Distance ............................................................ 200 mm (7-7/8 in.) or less
T6998AS
TX,9025,GG2664 1908JUN983/3
9025
25
,124
SPECIFICATIONS
Oil Temperature 50 5C (120 10F)
Engine in Standard Mode Speed Off
Arm Length 2.91 (9 ft 7 in.)
Bucket Capacity 0.86 m3 (1.12 yd3)
Bucket Load Weight 1065 kg (2350 lb)
Arm Cylinder Length 50 mm (2.00 in.) approximate
extension
Bucket Cylinder Length 50 mm (2.00 in.) approximate
retraction
Boom Cylinder Height Bucket pivot pin at the same
height as boom-to-main frame pin
Engine Speed Off
Arm Cylinder Drift 20 mm (13/16 in.)
maximum allowable for five
minutes
Bucket Cylinder Drift 20 mm (13/16 in.)
maximum allowable for five
minutes
Boom Cylinder Drift 20 mm (13/16 in.)
maximum allowable for five
minutes
Bottom of Bucket to Ground Drift 150 mm (6 in.)
maximum allowable for five
minutes 9025
25
SERVICE EQUIPMENT AND TOOLS ,125
JT05800 Digital Thermometer
Tape Measure
Specification
OilTemperature ................................................... 50 5C (120 10F)
Engine in Standard Mode
Speed .................................................................................................... Off
3. Fill the bucket to get the specified bucket load with the
standard arm and bucket.
Specification
ArmLength....................................................................... 2.91 (9 ft 7 in.)
BucketCapacity .......................................................... 0.86 m3 (1.12 yd3)
Bucket LoadWeight ..................................................... 1065 kg (2350 lb)
9025
25
,126
Specification
Arm CylinderLength ................................ 50 mm (2.00 in.) approximate
extension
UN06DEC88
5. Position bucket cylinder so rod is retracted the
specified length from the extended position.
Specification
T6904AG
Bucket CylinderLength ............................ 50 mm (2.00 in.) approximate
retraction
Specification
Boom CylinderHeight ................................ Bucket pivot pin at the same
height as boom-to-main frame pin
Specification
EngineSpeed ..................................................................................... Off
TX,9025,GG2129 1909MAY973/3
SPECIFICATIONS
Oil Temperature 50 5C (120 10 F)
Engine in Standard Mode Speed Fast Idle
Work Mode Selector Position Dig Mode
E Mode Switch Position Off
HP Mode Switch Position Off
Auto-Idle Switch Position Off
Swing Motor Leakage 0.21.0 L/min (0.050.26 gpm)
new acceptable while swinging
Swing Motor Leakage 2 L/min (0.53 gpm) used
maximum acceptable while
swinging
Swing Motor Leakage 8 L/min (2.2 gpm) new
acceptable while stalled
Swing Motor Leakage 16 L/min (4.2 gpm) used
maximum acceptable while
stalled
ESSENTIAL TOOLS
JT03023 (9/16-18 F 37) (Parker No. 06CP-6) Cap
Specification
OilTemperature .................................................. 50 5C (120 10 F)
KVent Plug
UN29APR97
T109340
Continued on next page TX,9025,GG2666 1908JUN982/3
9025
25
,129
Specification
Engine in Standard Mode
Speed ........................................................................................... Fast Idle
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
UN10JUL96
Auto-Idle SwitchPosition .................................................................... Off
Swing MotorLeakage ......................... 0.21.0 L/min (0.050.26 gpm)
new acceptable while swinging
Leakage .............................................................. 2 L/min (0.53 gpm) used
maximum acceptable while
T101868
swinging
9025 8. Operate swing function at stall for one minute. Put the
25 ASwing Motor Drain Line
bucket against an immovable object or in a trench then
,130 BCap
hold swing control lever fully actuated to stall swing
function. Compare the amount of leakage to
specifications.
Specification
Swing MotorLeakage .......................................... 8 L/min (2.2 gpm) new
acceptable while stalled
Leakage .............................................................. 16 L/min (4.2 gpm) used
maximum acceptable while
stalled
TX,9025,GG2666 1908JUN983/3
SPECIFICATIONS
Oil Temperature 50 5C (120 10 F)
Engine in Standard Mode Speed Fast Idle
Work Mode Selector Position Dig Mode
E Mode Switch Position Off
HP Mode Switch Position Off
Auto-Idle Switch Position Off
Propel Speed Switch Position Slow Speed (Turtle)
Propel Motor Leakage 1.52.0 L/min (0.40.53 gpm)
new acceptable while propelling
with track raised
Propel Motor Leakage 3.4 L/min (0.80 gpm) used
maximum acceptable while
propelling with track raised
Propel Motor Leakage 1.54.8 L/min (0.401.20 gpm)
new acceptable while stalled
Propel Motor Leakage 5.2 L/min (1.40 gpm) used
maximum acceptable while
stalled
ESSENTIAL TOOLS
JT03025 (3/4-16 F 37) (Parker No. 06CP8) Cap
JT03221 (3/4-16 M 37) (Parker No. 03CP8) Plug
9025
SERVICE EQUIPMENT AND TOOLS
25
JT05800 Digital Thermometer ,131
Calibrated Container
85 mm (3-3/8 in.) OD Pin or Round Bar Stock (2 used)
Specification
OilTemperature .................................................. 50 5C (120 10 F)
KVent Plug
UN29APR97
T109340
Continued on next page TX,9025,GG2667 1909MAY972/5
9025
25
,132
Specification
Engine in Standard Mode
Speed ........................................................................................... Fast Idle
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
Propel Speed SwitchPosition.................................. Slow Speed (Turtle)
UN11DEC91
motor.
Specification
Propel MotorLeakage........................... 1.52.0 L/min (0.40.53 gpm)
T7660BE
new acceptable while propelling
with track raised
Leakage ........................................................... 3.4 L/min (0.80 gpm) used
maximum acceptable while 9025
propelling with track raised 25
,133
UN06DEC88
APropel Motor Drain Line
BCap
CFitting
T6876FG
DCalibrated Container
Specification
Propel MotorLeakage......................... 1.54.8 L/min (0.401.20 gpm)
new acceptable while stalled
UN02JUL96
Leakage ........................................................... 5.2 L/min (1.40 gpm) used
maximum acceptable while
stalled
T101856
Actuate propel pedal for function being checked to full
stroke for one minute. Record the amount of leakage.
Repeat procedure by stalling the motor in several APin or Round Bar Stock
positions and then take an average of readings.
TX,9025,GG2667 1909MAY974/5
9025
25
,134
10.
UN11JAN93
Repeat Steps 7 and 8. If leakage is more than
specification, repair or replace motor. If leakage is
within specification, repair or replace rotary manifold.
T7915BB
TX,9025,GG2667 1909MAY975/5
Page Page
Group 20Adjustments
Refrigerant
Proper Handling. . . . . . . . . . . . . . . . . . . . .9031-20-1
R134a Cautions . . . . . . . . . . . . . . . . . . . . .9031-20-1
Compressor
R134a Oil Charge Check . . . . . . . . . . . . . .9031-20-2
R134a Oil Removal . . . . . . . . . . . . . . . . . .9031-20-2
9031
The U.S. Environmental Protection Agency prohibits It must be recovered using the
discharge of any refrigerant into the atmosphere, and appropriate recovery stations.
requires that refrigerant be recovered using the
approved recovery equipment. IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations. DO
IMPORTANT: To meet government standards NOT mix refrigerants, hoses, fittings,
relating to the use of refrigerants, components or refrigerant oils.
R134a is used in the air conditioning
system. Because it does not contain Recovery, recycling and charging stations for R12 and
chlorine, R134a is not detrimental to R134a refrigerants MUST NOT be interchanged.
the ozone in the atmosphere. Systems containing R12 refrigerant use a different oil
However, it is illegal to discharge than systems using R134a. Certain seals are not
any refrigerant into the atmosphere. compatible with both types of refrigerants.
TX,9031,UU3135 1913AUG961/1
TX,9031,UU3136 1913AUG961/1
1930NOV98
T118692
AB27 A/C High and Low DEngine Fan HLow Pressure Gas LLow Pressure Liquid
Pressure Switch ECondenser IEvaporator MB29 A/C Heater Thermistor
BReceiver/Dryer FHigh Pressure Gas JExpansion Valve NM6 A/C and Heater Blower
9031 CHigh Pressure Liquid GCompressor KNot Used Motor
05
2 The compressor (G) draws low pressure gas (H) from condenser fan (D). Cooling the refrigerant causes it to
the evaporator (I) and compresses it into high pressure condense and it leaves the condenser as a high
gas (F). This causes the temperature of the refrigerant pressure liquid (C). The high pressure liquid flows into
to rise higher than that of the outside air. the receiver-dryer (B) where moisture and
contaminants (acid, solids, etc.) are removed. The
High pressure gas leaves the compressor and is receiver-dryer also acts as a reservoir for refrigerant.
sensed by the high pressure part of the B27 A/C high
and low pressure switch (A). The switch monitors The refrigerant flows from the receiver-dryer to the
refrigerant pressure. If the pressure becomes too high, expansion valve (J) and is sensed by the low pressure
the switch will open and stop the compressor, part of the B27 A/C high and lower pressure switch
interrupting the cycle. (A). The switch monitors refrigerant pressure. If the
pressure becomes too low from refrigerant loss, the
As the high pressure gas flows through the condenser switch will open and stop the compressor, interrupting
(E), heat is removed and transferred to the outside air the cycle.
being drawn through the condenser core by the
The actual cooling and drying of cab air takes place at tube. The switch closes when the evaporator is above
the evaporator. Flow of the high pressure liquid the switch setting and opens when the evaporator is
refrigerant is controller by the expansion valve. The cooled to the switch setting. The switch has a low
expansion valve causes the temperature and pressure temperature setting that prevents the evaporator from
of the refrigerant to drop, where it becomes a low becoming cold enough to freeze moisture that
pressure liquid (L). The expansion valve is a valve that condenses on the coil.
uses a variable orifice to control the flow of high
pressure liquid refrigerant into the evaporator to The B28 A/C and heater thermistor senses
maintain a constant pressure and temperature. temperature of the evaporator coil through a refrigerant
filled capillary tube.
The M6 A/C and heater blower motor (N) pulls a
mixture of warm cab and outside air through the The moisture, from the warm air, is condensed as it
evaporator where it is cooled by the refrigerant. The contacts the cool evaporator coil during the cooling
heat absorbed by the evaporator causes the refrigerant process and is drained away through drain tubes
to vaporize into a low pressure gas. connected to the drain pan under the evaporator. With
the cab air cooled and dehumidified, the refrigerant
A freeze control switch (M) senses temperature of the cycle is complete.
evaporator coil through a refrigerant filled capillary
TX,9031,UU3137 1913AUG962/2
TX,9031,UU3138 1913AUG961/1
Power flows from the A/C Controller and Relays 5 amp selected, the resistor block is bypassed and the blower
Fuse to the air conditioner controller and energizes the motor operates at maximum speed.
following relays:
With air conditioning switch turned ON in the air
A/C compressor clutch relay (K25) conditioner controller, power flows to the A/C high and
A/C blower motor (medium low speed) relay (K26) low pressure switch (B27). The switch (B27) contains
A/C blower motor (medium speed) relay (K27) both a low pressure switch and a high pressure switch.
A/C blower motor (high speed) relay (K28) With low pressure switch closed, power flows through
A/C blower motor and main power (low speed) relay high pressure switch. With high pressure switch
(K24) closed, power flows through the A/C compressor clutch
relay (K25) to operate the A/C compressor clutch (Y1).
Power from the blower motor 20 amp fuse is applied to
terminal 1 of the A/C compressor clutch relay (K25). The low pressure switch opens if the air conditioning
system loses its refrigerant charge. The switch opens
Power from the 20 amp fuse also goes through the to stop current flow to the compressor, which prevents
A/C blower motor and main power (low speed) relay to compressor engagement.
operate the A/C and heater blower motor (M6).
The high pressure switch protects the system from
The air conditioner controller (A3) operates the blower high pressure. If a malfunction or line restriction
motor in four different speeds: causes the high pressure to increase above the setting
of the switch, will open to stop current flow to the
Low speed compressor clutch.
Medium low speed
Medium speed The A/C and heater thermistor (B29) is used to sense
High speed the temperature in the evaporator core. When the
temperature in the evaporator core raises, the blower
When any of the first three speeds is selected, power thermistor senses the warmer temperature and the air
flows through the dropping resistor block (R11) and conditioner controller applies voltage to the
then to the blower motor. When the high speed is compressor.
9031
05
4
TX,9031,UU3139 1913AUG961/1
TX,9031,UU3140 1904NOV981/1
CED,OUTX782,3 1918NOV981/1
CED,OUTX782,4 1918NOV981/1
9031
05
7
1918NOV98
T117937
CED,TX02661,251 1904NOV981/1
Receiver/Dryer Operation
UN19OCT93
The receiver/dryer also contains two filters (E) and
desiccant (F) between the filters. The filters remove solid
materials which could be generated by a compressor
failure, debris left in the system due to improper service
T8104AE
procedures, or particles caused by corrosion of metal
parts due to moisture and acids in the system (also
caused by improper service procedures).
UN10JAN94
8
hydrochloric acids are formed. These acids are very
corrosive to metal surfaces and leakage will eventually
develop. If the air conditioning system is left open for a
T8104AF
period of time or if the plugs are removed from the
receiver/dryer, the desiccant will also absorb moisture
from the air. The receiver/dryer contains a color moisture
indicator. (Blue) indicates dryer is dry. (Pink) indicates AInlet Port
moisture in the desiccant. Evacuating the system will not BSight Glass
remove moisture from the desiccant. You must replace COutlet Port
DPickup Tube
the receiver/dryer.
EFilter
FDesiccant
GStrainer
HSpring
IReceiver/Dryer
JWet/Dry Indicator
TX,9031,UU3144 1913AUG962/2
9031
05
9
1924SEP92
T7828AY
AValve Diaphragm DOperating Pin GValve Spring JDischarge from Evaporator
BSealed Sensing Bulb EInlet Flow HBall Seat KInternal Equalization
COutlet to Compressor FMetering Orifice IOutlet to Evaporator Passage
9031
05 The expansion valve is used to regulate the amount of The metering orifice (F) and ball seat area (H) in the
10 refrigerant flowing into the evaporator. At this point in expansion valve is relatively small. The rapidly
the system, the high pressure/high temperature liquid expanding refrigerant passing through this area can
is sprayed into the evaporator where it changes state cause any moisture in the system to freeze at this
and becomes a gas. point and block refrigerant flow. Other contaminants in
the system can also cause a valve to malfunction. If
The valve diaphragm (A) is activated by sensing expansion valve malfunctions, it must be replaced.
temperature and pressure within the valve body. The Expansion valve is not repairable.
sealed sensing bulb (B) senses the evaporator outlet
(I) or discharge temperature and pressure of the
refrigerant as it passes through the valve back to the
low pressure or suction side of the compressor.
TX,9031,UU3145A 1913AUG961/1
The compressor relief valve is a direct acting pressure If the relief valve opens, a loud popping noise will be
limiting valve. If a malfunction in the system occurs heard. Some oil may also be lost from the system.
that would cause high pressure, such as a restricted Correct any condition that would cause the valve to
line, the valve will open near 4137 kPa (41.4 bar) (600 open.
psi) and remain open until pressure drops to below the
valve setting.
TX,9031,UU3146 1913AUG961/1
1929AUG96
Temperature control is adjusted by the position of the
heater temperature switch in the cab. This switch is
mechanically connected to the water valve at the base of
T103130
the heater core. Turning the heater temperature switch
towards maximum and/or towards off opens and closes
the water valve controlling engine coolant flow through the
heater core, thus controlling the temperature inside the
cab.
9031
05
CED,OUTX817,50 1905APR001/1
11
UN16JUL99
valve to control engine coolant into the heater core. Eight
temperature indicator lights above switch display a
selected temperature range from 2030C (6886F).
The cab temperature can be selected in 13 different
T122361
increments between maximum cooling and maximum
heating. The indicators illuminate one or two at a time and
move left and right to show increasing or decreasing
temperature as switch (J) is pressed. AMode Switch
BMode Switch
CMode Switch
Air is directed to different locations in the cab by the A/C DAir Conditioner Switch
blower port change servomotor M10. This servomotor is EAUTO Switch
controlled by mode switches (A, B and C). Switch (A) FAir Circulation Mode Switch
directs air to the defrost and front vents located in the GFresh Air Mode Switch
HBlower Speed Switches
front console, switch (B) directs air to the defrost vent, IBlower OFF Switch
front vent, and vents behind the seat, and switch (C) JTemperature Control Switches
directs air underneath the seat.
CED,OUTX817,51 1906APR001/1
This procedure is designed so the mechanic can make additional checks or repair information will be given.
a quick check of the system using a minimum amount The technical manual group or CTM number required
of diagnostic equipment. If you need additional for repair will be given. If verification is needed, you
information, read Theory of Operation (Group will be given next best source of information:
9031-05).
Group: 10 (System Operational Checks)
The engine or other major components must be at
operating temperature for some checks. Group: 15 (Diagnostic Information)
Locate system check in the left column and read Group: 20 (Adjustments)
completely, following this sequence from left to right.
Read each check completely before performing. Group: 25 (Tests)
At the end of each check, if no problem is found, that CTM (Component Technical Manual)
check is complete. When a problem is indicated,
TX,9031,UU3148 1925APR001/1
9031
10
1/1
1
All hose and line clamps must be in place and tight. Clamps must have rubber inserts
or cushions in place to prevent clamps from crushing or wearing into hoses or lines?
1/1
Are fan blades in good condition, not worn, bent, broken or missing?
1/1
1/1
Are compressor to bracket and bracket to engine mounting cap screws tight?
1/1
Cab Door and Window Open and close door and windows. Inspect seals. YES: Check complete.
Seals Check
Do door and windows contact seals evenly? NO: Adjust door and
windows to close against
Are seals in position and in good condition? seals properly. Replace
seals as necessary.
1/1
1/1
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
1/1
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
Press heater temperature switch to maximum heat position. Press blower switch to
high speed position.
1/1
9031
10
4
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
9031
10
1/1
5
Compressor Clutch Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner switch ON. YES: Check complete.
Check
Does compressor clutch click as switch is pushed? NO: Replace compressor
clutch.
1/1
1/1
Is continuity measured?
1/1
T111030 UN07AUG97
Connect ohmmeter to brown wire in switch connector and positive terminal of heater
blower motor.
Turn heater blower motor switch to Low speed. Does ohmmeter read approximately
7.6 ohms resistance?
Turn heater blower motor switch to Medium Low speed. Does ohmmeter read
9031 approximately 3.7 ohms resistance?
10
6 Turn heater blower motor switch to Medium High speed. Does ohmmeter read
approximately 1.2 ohms resistance?
Turn heater blower motor switch to High speed. Does ohmmeter read a lower
resistance than 1.2 ohms?
1/1
3c Heater Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
(M5) Check motor is good. Check
(Machines Equipped Connect 24 volts to heater blower motor, and ground motor. wiring harness.
with Heater Only)
Does heater blower motor operate? NO: Replace heater
blower motor.
1/1
1/1
Blower Motor 20 Amp Remove fuse block cover. YES: Fuse is OK.
Fuse (F13) Check
Remove fuse from fuse block. NO: Replace fuse. If fuse
blows again, check for
Using ohmmeter, check fuse for continuity. short.
Is continuity measured?
1/1
A/C Controller and Remove fuse block cover. YES: Fuse is OK.
Relays 5 Amp Fuse (F14)
Check Remove fuse from fuse block. NO: Replace fuse. If fuse
blows again, check for
Using ohmmeter, check fuse for continuity. short.
Is continuity measured?
1/1
Air Conditioner Relay Disconnect harness from relay. YES: Relay is OK.
(K24, K25, K26, K27 and
K28) Check Connect 24 volts to relay terminal 1 and ground terminal NO: Relay has failed.
2. Replace.
9031
Does relay click? 10
7
Connect ohmmeter to terminals 3 and 4.
T118624 UN23NOV98
Does ohmmeter read continuity?
1/1
Air Conditioner High and Disconnect harness from switch. YES: Switch is good.
Low Pressure Switch
(B27) Check Check for continuity between terminals. NO: Go to High and Low
Pressure Switch Test,
Is continuity measured? Group 9031-25.
T101619 1913JUN96
1/1
A/C and Heater Blower Disconnect harness from blower motor. YES: Blower motor is
Motor (M6) Check good. Check wiring
Ground blk/red wire terminal in connector. Connect 24 volts to red/wht wire pin in harness.
connector.
NO: Replace blower
Does blower motor operate in high speed? motor.
1/1
T6534CV UN19OCT88
1/1
9031
10
8
Heating System Does Not Blower motor 20 amp fuse (F13) Replace fuse. (See Replacing Fuses
Operate in Group 1674.)
Heater blower motor switch (S4) Check heater blower motor switch,
Group 9031-10.
Air Conditioning System Does A/C controller and relays 5 amp fuse Replace fuse.
Not Operate (F14)
Blower motor 20 amp fuse (F13) Replace fuse. (See Replacing Fuses
in Group 1674.)
Air conditioner relays (K24, K25, Check air conditioner relays, Group
K26, K27, or K28) 9031-10.
A/C high and low pressure switch Check high and low pressure switch, 9031
15
(B27) Group 9031-10.
1
A/C and heater blower motor (M6) Check A/C and heater blower motor,
Group 9031-10.
TX,9031,UU3149 1904OCT001/1
A3
AIR
CONDITIONER M10
CONTROLLER AIR CONDITIONER K24 PIN 3, K25 PIN 3 YEL 1
BLOWER PORT K26 PIN 4, K27 PIN 4, K28 PIN 4,
CHANGE SERVOMOTOR R11 R11 PIN 4, X17 PIN 14 BLK 2
AIR CONDITIONER
K25 PIN 4, Y1 BLK/YEL 3
AND HEATER
BLOWER MOTOR K24 PIN 1, K25 PIN 1, K26 PIN 1,
DROPPING RESISTOR K27 PIN 1, K28 PIN 1, X17 PIN 1 YEL 4 ENGINE
X18 BLOCK
X17 AIR CONDITIONER
AIR CONDITIONER CONTROLLER M6 X16
CONTROLLER CONNECTOR AIR CONDITIONER AIR CONDITIONER AIR CONDITIONER
CONNECTOR (12-PIN) AND HEATER HARNESS TO COMPRESSOR
(16-PIN) HEATER CORE BLOWER MOTOR CAB HARNESS
AIR CONDITIONER CONNECTOR Y1
EVAPORATOR COMPRESSOR
2 1
M11 CLUTCH
K28 3 4
AIR CONDITIONER AIR CONDITIONER
BLOWER MOTOR AIR MIXER
(HIGH SPEED) RELAY SERVOMOTOR
K27
AIR CONDITIONER
BLOWER MOTOR
(MEDIUM SPEED)
RELAY
K26
AIR CONDITIONER
BLOWER MOTOR
(LOW MEDIUM SPEED)
RELAY B29
K25 AIR CONDITIONER
AIR CONDITIONER AND HEATER
COMPRESSOR THERMISTOR
K24
CLUTCH RELAY
AIR CONDITIONER M9
BLOWER MOTOR B27
AIR CONDITIONER AIR CONDITIONER
AND MAIN POWER INTERNAL AND
(LOW SPEED) RELAY HIGH AND LOW
EXTERNAL CAB PRESSURE SWITCH
AIR SERVOMOTOR (SEE DETAIL A -
EVAPORATOR
CONNECTIONS)
CONDENSER
TX,9031,GG2243 1912SEP961/2
1924NOV98
T118670
Air Conditioner Harness (W9) Component Location--Detail
A
TX,9031,GG2243 1912SEP962/2
9031
15
3
9031
15
4
1918NOV98
T118195
9031
15
5
1918NOV98
T118196
CED,OUTX782,5 1918NOV982/2
9031
15
6
The U.S. Environmental Protection Agency prohibits It must be recovered using the
discharge of any refrigerant into the atmosphere, and appropriate recovery stations.
requires that refrigerant be recovered using the
approved recovery equipment. IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations. DO
IMPORTANT: To meet government standards NOT mix refrigerants, hoses, fittings,
relating to the use of refrigerants, components or refrigerant oils.
R134a is used in the air conditioning
system. Because it does not contain Recovery, recycling and charging stations for R12 and
chlorine, R134a is not detrimental to R134a refrigerants MUST NOT be interchanged.
the ozone in the atmosphere. Systems containing R12 refrigerant use a different oil
However, it is illegal to discharge than systems using R134a. Certain seals are not
any refrigerant into the atmosphere. compatible with both types of refrigerants.
TX,9031,UU3151 1913AUG961/1
TX,9031,UU3152 1913AUG961/1
Remove compressor if R134a leakage was detected 3. Flush the complete system with TY16134 air
and repaired. See Remove and Install Compressor in conditioning flushing solvent.
Repair Manual.
4. If the compressor is serviceable, pour flushing
Drain oil from the compressor and record the amount. solvent in the manifold ports and internally wash out
See Compressor Oil Removal procedure in this group. the old oil.
NOTE: Drain oil and save if this is a new compressor. 5. Install a new receiver-dryer.
If the oil drained from a compressor removed from 6. Install required amount of TY22025 refrigerant oil in
operation is very black or the amount of oil is less than the compressor. (See R134a Component Oil
6 mL (0.2 fl oz), perform the following: Charge in this group.)
1. Remove and discard the receiver-dryer. 7. Connect all components, evacuate and charge the
system.
2. Remove, clean, but do not disassemble the
expansion valve.
TX,9031,UU3153 1913AUG961/1
TX,9031,UU3154 1913AUG961/1
Components listed which have been removed, formula to determine the correct amount of oil to be
drained or flushed, require the removal of the added.
compressor to determine the correct oil charge.
Use the chart as a guide for adding oil to
CAUTION: DO NOT leave the system or
components.
R134a compressor oil containers open. This
Specification
oil easily absorbs moisture. DO NOT spill
EvaporatorOil Charge ......................................... 130 mL (4.4 fl oz) R134a compressor oil on acrylic or ABS
CondenserOil Charge ........................................... 65 mL (2.2 fl oz) plastic. This oil will deteriorate these
Receiver-DryerOil Charge ..................................... 30 mL (1.0 fl oz) materials rapidly. Identify R134a oil
HosesOil Charge ............................... 60 mL (2.0 fl oz) or 3 mL per containers and measures to eliminate
30 cm (0.1 fl oz per ft)
Approximate Total Length ............................................ 600 cm (20 ft)
accidental mixing of different oils.
CED,TX14795,4338 1904MAR982/2
9031
20
4
UN01DEC98
CAUTION: Do not remove high pressure relief
valve (H). Air conditioning system will
discharge rapidly causing possible injury.
T118687
IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations. DO
NOT mix refrigerant, hoses, fittings,
AHigh Pressure Test Port
components or refrigerant oils.
BBlue Hose
CRed Hose
NOTE: JT02046 and JT02050 HFC134a Refrigerant DHigh Pressure Hose
Recovery/Recycling and Charging Station can be ELow Pressure Hose
substituted for the JT02045 HFC134a Refrigerant FLow Pressure Test Port
GRefrigerant Recovery/Recycling and Charging
Recovery/Recycling and Charging Station.
Station
HHigh Pressure Relief Valve
1. Close both high and low pressure valves on refrigerant
recovery, recycling and charging station (G).
CED,TX14795,4339 1904OCT001/1
ESSENTIAL TOOLS
JT02045 HFC134a Refrigerant Recovery/Recycling and Charging
Station
JT02046 HFC134a Charging Station (Alternate)
JT02050 HFC134a Recovery/Recycling and Charging Station
(Alternate)
UN01DEC98
valve (H). Air conditioning system will
discharge rapidly causing possible injury.
T118687
recycling and charging stations. DO
NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
AHigh Pressure Test Port
BBlue Hose
NOTE: JT02046 and JT02050 HFC134a Refrigerant
CRed Hose
Recovery/Recycling and Charging Station can be DHigh Pressure Hose
substituted for the JT02045 HFC134a Refrigerant ELow Pressure Hose
Recovery/Recycling and Charging Station. FLow Pressure Test Port
GRefrigerant Recovery/Recycling and Charging
Station
1. Run the air conditioning system for three minutes to
HHigh Pressure Relief Valve
help in the recovery process. Turn air conditioning
system off before proceeding with recovery steps.
CED,TX14795,4340 1904OCT001/1
SPECIFICATIONS
System Evacuation Vacuum 98 kPa (980 mbar) (29 in Hg)
Pressure
Subtract Pressure For Each 3.4 kPa (34 bar) (1 in. Hg)
300m (1000 ft) Elevation
Pressure
If System Evacuation Vacuum 15 Minutes
Cannot Be Obtained, Test
System For Leaks. Time
UN01DEC98
Evacuation Time 15 minutes
Leak If Vacuum Decreases More 3.4 kPa (34 mbar) (1 in. Hg)
Than Pressure
Evacuate System Time For 30 min. After 98 kPa (980
T118687
mbar) (29 in. Hg) Vacuum
ESSENTIAL TOOLS
AHigh Pressure Test Port
JT02045 HFC134a Refrigerant Recovery/Recycling and Charging
BBlue Hose
Station
CRed Hose
JT02046 HFC134a Charging Station (Alternate) DHigh Pressure Hose
JT02050 HFC134a Recovery/Recycling and Charging Station ELow Pressure Hose
(Alternate) FLow Pressure Test Port
GRefrigerant Recovery/Recycling and Charging
Station
HHigh Pressure Relief Valve
CAUTION: Do not remove high pressure relief
valve (H). Air conditioning system will
discharge rapidly causing possible injury.
Specification
System Evacuation Vacuum
Pressure ..................................................... 98 kPa (980 mbar) (29 in Hg)
Subtract Pressure For Each
300m (1000 ft) Elevation
Pressure .......................................................... 3.4 kPa (34 bar) (1 in. Hg)
Specification
If System Evacuation Vacuum
Cannot Be Obtained, Test
System For Leaks.Time ........................................................ 15 Minutes
Specification
EvacuationTime .................................................................... 15 minutes
Specification
Leak If Vacuum Decreases More
ThanPressure............................................ 3.4 kPa (34 mbar) (1 in. Hg)
7. Repair leak.
8. Start to evacuate.
Specification
Evacuate SystemTime ............................ For 30 min. After 98 kPa (980
mbar) (29 in. Hg) Vacuum
CED,TX14795,4341 1904OCT003/3
9031
20
9
SPECIFICATIONS
Pump Must Be Capable Of 28.6 in. Hg at Sea Level
Pulling Vacuum
Subtract From Standard Vacuum 3.4 kPa (34 mbar) (1 in. Hg)
For Each 300 m (1000 ft) Above
Sea Level Vacuum
Refrigerant Charge Weight 0.95 kg (2.1 lb)
ESSENTIAL TOOLS
UN01DEC98
JT02045 HFC134a Refrigerant Recovery/Recycling and Charging
Station
JT02046 HFC134a Charging Station (Alternate)
T118687
JT02050 HFC134a Recovery/Recycling and Charging Station
(Alternate)
CAUTION: Do not remove high pressure relief AHigh Pressure Test Port
BBlue Hose
valve (H). Air conditioning system will
CRed Hose
discharge rapidly causing possible injury. DHigh Pressure Hose
ELow Pressure Hose
IMPORTANT: Use correct refrigerant recovery, FLow Pressure Test Port
recycling and charging stations. DO GRefrigerant Recovery/Recycling and Charging
Station
NOT mix refrigerant, hoses, fittings,
HHigh Pressure Relief Valve
components or refrigerant oils.
Specification
Pump Must Be Capable Of
PullingVacuum ................................................. 28.6 in. Hg at Sea Level
Subtract From Standard Vacuum
For Each 300 m (1000 ft) Above
Sea LevelVacuum ..................................... 3.4 kPa (34 mbar) (1 in. Hg)
Specification
Refrigerant ChargeWeight .............................................. 0.95 kg (2.1 lb)
9031
20
CED,TX14795,4342 1922NOV002/2
11
SERVICE EQUIPMENT AND TOOLS If belt deflection excessive , allow belt to cool for 8
10 minutes and try again.
Belt Tension Gauge
Specification
IMPORTANT: Never over tighten belt. Over If Belt Deflection Excessive
tightening may cause belt cord Cool............................................................................... 810 Minutes
damage and excessive load on
bearings. IMPORTANT: Force to adjust belt must be applied
to front of compressor housing only
1. Run engine for five minutes. Stop the engine, then to prevent damage to compressor.
immediately check tension using a belt tension
gauge. 3. Loosen compressor mounting cap screws. Apply
force to front of compressor housing to tighten belt.
2. Measure strand tension or deflection at a point Tighten cap screws.
halfway between pulleys. Belt must deflect 19 mm
4. Repeat Steps 1 and 2 to check belts.
CED,TX14795,4343 1904MAR981/1
9031
20
12
The U.S. Environmental Protection Agency prohibits It must be recovered using the
discharge of any refrigerant into the atmosphere, and appropriate recovery stations.
requires that refrigerant be recovered using the
approved recovery equipment. IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations. DO
IMPORTANT: To meet government standards NOT mix refrigerants, hoses, fittings,
relating to the use of refrigerants, components or refrigerant oils.
R134a is used in the air conditioning
system. Because it does not contain Recovery, recycling and charging stations for R12 and
chlorine, R134a is not detrimental to R134a refrigerants MUST NOT be interchanged.
the ozone in the atmosphere. Systems containing R12 refrigerant use a different oil
However, it is illegal to discharge than systems using R134a. Certain seals are not
any refrigerant into the atmosphere. compatible with both types of refrigerants.
TX,9031,UU3151 1913AUG961/1
TX,9031,UU3152 1913AUG961/1
SPECIFICATIONS
Engine Speed 2180 rpm
Temperature Control Switch Maximum Cooling
Position
Blower Speed High
Run Unit For At Least Time 5 Minutes
Ambient Temperature Air Duct Temperature Low Pressure Gauge High Pressure Gauge
16C (60F) 13C (55F) 7165 kPa (0.071.6 bar) (124 psi) 6301095 kPa (611 bar) (90160
psi)
21C (70F) 16C (60F) 7180 kPa (0.071.8 bar) (126 psi) 7851225 kPa (7.612 bar) (110
175 psi)
27C (80F) 18C (65F) 7205 kPa (0.072.1 bar) (130 psi) 9551410 kPa (9.614.1 bar) (140
205 psi)
32C (90F) 21C (70F) 7240 kPa (0.072.4 bar) (135 psi) 11451645 kPa (11.416.5 bar)
(165240 psi)
38C (100F) 27C (80F) 7280 kPa (0.072.7 bar) (140 psi) 13551935 kPa (13.419.3 bar)
(195280 psi)
43C (110F) 29C (85F) 7330 kPa (0.073.3 bar) (148 psi) 15802275 kPa (15.822.7 bar)
(230330 psi)
ESSENTIAL TOOLS
JT02045 HFC134a Refrigerant Recovery/Recycling and Charging
Station
JT02046 HFC134a Charging Station (Alternate)
JT02050 HFC134a Recovery/Recycling and Charging Station
(Alternate)
UN01DEC98
Specification
EngineSpeed ........................................................................... 2180 rpm
T118687
8. Press temperature control switch at the maximum
cooling position.
Specification
Run Unit For At LeastTime ..................................................... 5 Minutes
9031
25
12. Measure air temperature at condenser air inlet and at 3
air ducts in air conditioning unit. Record readings.
Ambient Temperature Air Duct Temperature Low Pressure Gauge High Pressure Gauge
16C (60F) 13C (55F) 7165 kPa (0.071.6 bar) (124 psi) 6301095 kPa (611 bar) (90160
psi)
21C (70F) 16C (60F) 7180 kPa (0.071.8 bar) (126 psi) 7851225 kPa (7.612 bar) (110
175 psi)
27C (80F) 18C (65F) 7205 kPa (0.072.1 bar) (130 psi) 9551410 kPa (9.614.1 bar) (140
205 psi)
32C (90F) 21C (70F) 7240 kPa (0.072.4 bar) (135 psi) 11451645 kPa (11.416.5 bar)
(165240 psi)
38C (100F) 27C (80F) 7280 kPa (0.072.7 bar) (140 psi) 13551935 kPa (13.419.3 bar)
(195280 psi)
43C (110F) 29C (85F) 7330 kPa (0.073.3 bar) (148 psi) 15802275 kPa (15.822.7 bar)
(230330 psi)
CED,OUOE003,1079 1904OCT003/3
9031
25
4
9031
25
5
1928FEB89
T6609AB
TX,9031,UU3164 1919AUG981/1
SPECIFICATIONS
Low Pressure Switch (Normally 345 35 kPa (3.45 0.3 bar) (50
Open) Closes on Increasing 5 psi)
Pressure
UN06MAR95
Low Pressure Switch (Normally 173 35 kPa (1.73 0.3 bar) (25
Open) Opens on Decreasing 53 psi)
Pressure
High Pressure Switch (Normally 2760 138 kPa (27.6 1.38 bar)
(400 20 psi)
T8426AE
Closed) Opens on Increasing
Pressure
High Pressure Switch (Normally 1310 138 kPa (13.11 1.38
Closed) Closes on Decreasing bar) (190 20 psi)
Pressure
NOTE: The line that attaches the high and low pressure
switch has a valve installed to prevent discharging
the air conditioning system when switch is
removed. The high pressure switch is normally
closed when removed from the machine. It does
not open when installed in the A/C system until
pressure exceeds specification.
Specification
Low Pressure Switch (Normally
Open)Closes on Increasing
Pressure ............................................... 345 35 kPa (3.45 0.3 bar) (50
5 psi)
Low Pressure Switch (Normally
Open)Opens on Decreasing
Pressure ............................................... 173 35 kPa (1.73 0.3 bar) (25
53 psi)
Specification
High Pressure Switch (Normally
Closed)Opens on Increasing
Pressure ............................................... 2760 138 kPa (27.6 1.38 bar)
(400 20 psi)
High Pressure Switch (Normally
Closed)Closes on Decreasing
Pressure ..................................................... 1310 138 kPa (13.11 1.38
bar) (190 20 psi)
CED,TX14795,4346 1904MAR982/2
Leak Testing
1. Inspect all lines, fittings, and components for oily or 3. If a leak detector is used, move the leak detector
dusty spots. When refrigerant leaks from the probe under the hoses and around the connections 9031
system, a small amount of oil is carried out with it. at a rate of 25 mm (1 in.) per second. 25
7
2. A soap and water solution can be sprayed on the 4. Some refrigerant manufacturers add dye to
components in the system to form bubbles at the refrigerant to aid in leak detection.
source of the leak.
TX,9031,UU3168 1913AUG961/1
When a component is disconnected from the system, hose and tube connections. Dip O-rings in correct
special care should be given to inspecting hoses and viscosity oil before assembling.
tubing for moisture, grease, dirt, rust, or other foreign
material. If such contamination is present in hoses, IMPORTANT: Hose used for air conditioning
tubing, or fittings and cannot be removed by cleaning, systems contains special barriers in
then replace parts. its walls to prevent migration of
refrigerant gas.
Fittings that have grease or dirt on them should be
wiped clean with a cloth dampened with alcohol. DO NOT use hydraulic hoses as
Chlorinated solvents (such as trichloroethylene) are replacement hoses in the air
contaminants, and must not be used for cleaning. conditioning system. Use ONLY
certified hose meeting SAE J51B
To assist in making leak-proof joints, use a small requirements.
amount of clean correct viscosity refrigerant oil on all
TX,9031,UU3169 1913AUG961/1
9031
25
8
Page Page
Page Page
Sensor circuit shorted to itself . . . . . . . .9015-05-14 Sensor circuit shorted to power. . . . . . .9015-05-12
Sensor circuit shorted to power. . . . . . .9015-05-12 Shorted circuit. . . . . . . . . . . . . . . . . . . .9015-05-10
Shorted circuit. . . . . . . . . . . . . . . . . . . .9015-05-10 Switch specifications . . . . . . . . . . . . . . .9015-15-42
Diagnose malfunctions System functional schematic . . . . . . . . .9015-10-10
Dig circuit . . . . . . . . . . . . . . . . . . . . . . .9025-15-17 System functional schematic, reading a
Electronic component . . . . . . . . . . . . . . .9025-15-2 schematic . . . . . . . . . . . . . . . . . . . . .9015-05-22
Hydraulic system. . . . . . . . . . . . . . . . . .9025-15-13 Test equipment . . . . . . . . . . . . . . . . . . .9015-05-17
Pilot circuit . . . . . . . . . . . . . . . . . . . . . .9025-15-16 Test procedure . . . . . . . . . . . . . . . . . . .9015-05-18
Propel system . . . . . . . . . . . . . . . . . . . .9025-15-20 Visual inspection . . . . . . . . . . . . . . . . . . .9015-05-1
Swing circuit . . . . . . . . . . . . . . . . . . . . .9025-15-19 Wiring diagram, reading . . . . . . . . . . . .9015-05-24
Diagnostic malfunctions Electrical circuit
Control valve components. . . . . . . . . . . .9025-15-2 Accessory . . . . . . . . . . . . . . . . . . . . . . .9015-15-38
Diagnostic procedure . . . . . . . . . . . . . . . . .9025-15-1 Charging . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-8
Diesel engine oil. . . . . . . . . . . . . . . . . . . . .9000-04-4 Engine and pump controller . . . . . . . . .9015-15-66
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1 Fuel shutoff . . . . . . . . . . . . . . . . . . . . . .9015-15-14
Dig circuit Monitor . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-44
Diagnose malfunctions . . . . . . . . . . . . .9025-15-17 Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-2
Dig pilot pressure signal passage Starting . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-14
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-42 Travel alarm . . . . . . . . . . . . . . . . . . . . .9015-15-94
Digital pressure and temperature analyzer Windshield wiper and washer . . . . . . . .9015-15-22
Installation. . . . . . . . . . . . . . . . . . . . . . .9025-25-31 Work and Drive Light . . . . . . . . . . . . . .9015-15-32
Digital thermometer installation. . . . . . . . .9025-25-30 Electrical diagnostic procedures
Door Charging circuit . . . . . . . . . . . . . . . . . . .9015-15-11
Operational checkout . . . . . . . . . . . . . .9005-10-23 Cigarette lighter. . . . . . . . . . . . . . . . . . .9015-15-40
Drain and refill Dome light . . . . . . . . . . . . . . . . . . . . . .9015-15-40
Capacities . . . . . . . . . . . . . . . . . . . . . . . .9000-02-6 Engine and pump controller circuit . . . .9015-15-70
Drive gearbox and pump Heater. . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-40
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-18 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-40
Dynamic braking Key switch check . . . . . . . . . . . . . . . . .9015-15-16
Swing . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-54 Monitor circuit . . . . . . . . . . . . . . . . . . . .9015-15-52
Power circuit . . . . . . . . . . . . . . . . . . . . . .9015-15-4
Starting and fuel shutoff circuit . . . . . . .9015-15-16
Travel alarm circuit . . . . . . . . . . . . . . . .9015-15-96
E Windshield washer circuit . . . . . . . . . . .9015-15-27
Winshield wiper Circuit . . . . . . . . . . . . .9015-15-27
E (economy) mode Work and drive light circuit . . . . . . . . . .9015-15-34
Speed control circuit . . . . . . . . . . . . . . . .9010-05-8 Electronic tachometer installation . . . . . . . 9010-20-1, Indx
Electrical 9025-25-30 3
Battery specification . . . . . . . . . . . . . . . .9015-20-1 Engine
Circuit Malfunction . . . . . . . . . . . . . . . . .9015-05-2 Auto-idle mode speed control circuit . . .9010-05-12
Component identification . . . . . . . . . . . . .9015-10-3 Boost starting . . . . . . . . . . . . . . . . . . . . .9015-20-7
Component location . . . . . . . . . . . . . . .9015-05-26 Cooling system operational
Connector end view diagram. . . . . . . . .9015-05-28 checkout . . . . . . . . . . . . . . . . . . . . . .9005-10-28
Fuse specifications . . . . . . . . . . . . . . . . .9015-10-1 Diagnose malfunctions . . . . . . . . . . . . . .9010-15-2
Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-8 E (economy) mode speed control
High resistance circuit . . . . . . . . . . . . . . .9015-05-3 circuit. . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-8
Monitor specifications . . . . . . . . . . . . . .9015-15-42 Engine rpm dial speed control circuit . . .9010-05-6
Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-5 Engine speed learning control circuit. . .9010-05-14
Schematic symbols . . . . . . . . . . . . . . . .9015-05-30 HP (high power) mode speed control
Schematic, wiring diagram, and component circuit. . . . . . . . . . . . . . . . . . . . . . . . .9010-05-10
location information . . . . . . . . . . . . . .9015-05-20 Injection pump fast and slow idle stop
Sensor circuit shorted to ground . . . . . .9015-05-16 adjutment . . . . . . . . . . . . . . . . . . . . . .9010-20-6
Sensor circuit shorted to itself . . . . . . . .9015-05-14 Operational . . . . . . . . . . . . . . . . . . . . . . .9010-10-1
Page Page
Page Page
Page Page
Page Page
Page Page
Page Page
Page Page
Page Page
Page
Visual inspection
Operational checkout . . . . . . . . . . . . . .9005-10-38
Warm-up circuit
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-16
Warm-up procedure
Hydraulic system. . . . . . . . . . . . . . . . . .9025-25-37
Window
Operational checkout . . . . . . . . . . . . . .9005-10-23
Windshield wiper and washer circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . .9015-15-26
Theory of operation. . . . . . . . . . . . . . . .9015-15-23
Wiring diagram
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20
Reading a wiring diagram . . . . . . . . . . .9015-05-24
Indx
12