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200LC Technical Manual Operation and Tests TM1663 PDF
200LC Technical Manual Operation and Tests TM1663 PDF
Excavator
Operation and Tests
TECHNICAL MANUAL
200LC Excavator Operation and
Tests
TM1663 28NOV01 (ENGLISH)
TM1664
CTM104
CTM77
SP326
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC 1929SEP981/1
TM1663 (28NOV01)
PN=2
Introduction
FAX NUMBER:
563-589-5800
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THANK YOU!
TX,TM,FAX 1928NOV011/1
TM1663 (28NOV01)
PN=3
Introduction
TM1663 (28NOV01)
PN=4
Contents
9000
9005
9010
9015
9020
9031
INDX
TM1663 (28NOV01)
PN=1
Contents
9000
9005
9010
9015
9020
9025
9031
INDX
TM1663 (28NOV01)
ii
PN=2
9000
Section 9000
General Information
Contents
Page
Page
9000-1
PN=1
Contents
9000
TM1663 (28NOV01)
9000-2
PN=2
Group 01
Safety
9000
01
1
TS231
1907OCT88
TX,05,FF1611 1914JUN901/1
TS291
UN23AUG88
DX,FIRE2 1903MAR931/1
TS202
UN23AUG88
TX,05,FF1622 1914JUN901/2
TS227
UN23AUG88
TX,05,FF1622 1914JUN902/2
TM1663 (28NOV01)
9000-01-1
PN=9
Safety
TS204
UN23AUG88
DX,SPARKS 1903MAR931/1
UN26NOV90
TS1132
9000
01
2
DX,MSDS,NA 1903MAR931/1
TM1663 (28NOV01)
9000-01-2
PN=10
Safety
9000
01
3
TS203
If acid is swallowed:
UN23AUG88
DX,POISON 1921APR931/1
TM1663 (28NOV01)
9000-01-3
PN=11
Safety
X9811
UN23AUG88
DX,FLUID 1903MAR931/1
UN08JUN90
T7273AP
9000
01
4
TX,05,RR,566 1923JUL911/1
TM1663 (28NOV01)
9000-01-4
PN=12
Safety
9000
01
5
TX,05,DH5002 1928MAY961/1
TS229
UN23AUG88
DX,LOWER 1924FEB001/1
T6607AO
UN18OCT88
TX,05,FF1615 1914JUN901/1
TM1663 (28NOV01)
9000-01-5
PN=13
Safety
T7273AS
UN08JUN90
TX,05,RR,572 1912JUN901/1
T7273AD
UN08JUN90
TX,05,RR,594 1912JUN901/1
UN15JUN89
T6981AN
9000
01
6
TX,05,DH832 1916MAR921/1
TM1663 (28NOV01)
9000-01-6
PN=14
Safety
9000
01
7
T7273AH
UN08JUN90
TX,05,RR,560 1905OCT901/1
T7273AL
UN08JUN90
TX,05,FF1806 1905OCT901/1
TS206
UN23AUG88
DX,WEAR2 1903MAR931/1
TM1663 (28NOV01)
9000-01-7
PN=15
Safety
T6642DK
UN18OCT88
TX,05,FF1613 1914JUN901/1
TS207
UN23AUG88
DX,NOISE 1903MAR931/1
TS223
UN23AUG88
DX,LIGHT 1904JUN901/1
UN23AUG88
TS228
9000
01
8
DX,LOOSE 1904JUN901/1
TM1663 (28NOV01)
9000-01-8
PN=16
Safety
9000
01
9
TS220
UN23AUG88
DX,PAINT 1922OCT991/1
TS953
UN15MAY90
DX,TORCH 1903MAR931/1
T6458AO
UN18OCT88
02T,05,J9 1907JAN911/1
TM1663 (28NOV01)
9000-01-9
PN=17
Safety
TS226
UN23AUG88
DX,LIFT 1904JUN901/1
TS281
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
UN23AUG88
DX,RCAP 1904JUN901/1
UN26NOV90
TS1133
9000
01
10
DX,DRAIN 1903MAR931/1
TM1663 (28NOV01)
9000-01-10
PN=18
Safety
9000
01
11
TX,05,FF1624 1914JUN901/1
TS779
UN08NOV89
TX,05,FF1614 1914JUN901/1
TS201
UN23AUG88
DX,SIGNS1 1904JUN901/1
TM1663 (28NOV01)
9000-01-11
PN=19
Safety
1907OCT88
TS231
9000
01
12
DX,LIVE 1925SEP921/1
TM1663 (28NOV01)
9000-01-12
PN=20
Group 02
General Specifications
9000
02
1
T115683
UN02JUN98
Excavator Overview
CED,TX08227,2993 1910FEB981/1
TM1663 (28NOV01)
9000-02-1
PN=21
General Specifications
UN03FEB98
200LC Specifications
T113215
9000
02
2
HCenter Of Sprocket To
Center Of Sprocket
ITrack Shoe Width
JUndercarriage Width
KOverall Length
LTransport Height
Item
Measurement
Specification
Distance
BUndercarriage
Length
CCounterweight Clearance
Distance
1030 mm (3 ft 5 in.)
Distance
2720 mm (8 ft 11 in.)
Distance
2720 mm (8 ft 11 in.)
FCab
Height
2720 mm (8 ft 11 in.)
TM1663 (28NOV01)
9000-02-2
CED,TX14740,6954 1907SEP001/2
PN=22
General Specifications
9000
02
3
Item
Measurement
Specification
Distance
450 mm (1 ft 6 in.)
2390 mm (7 ft 10 in.)
ITrack Shoe
Width
JUndercarriage
Width
Width
Width
KMachine
Overall Length
Overall Length
LMachine
Transport Height
Transport Height
Machine
Operating Weight
CED,TX14740,6954 1907SEP002/2
TM1663 (28NOV01)
9000-02-3
PN=23
General Specifications
UN24MAR97
T102389
9000
02
4
Item
Measurement
Specification
Distance
Distance
TM1663 (28NOV01)
9000-02-4
TX,115,DH5117 1915JUL961/2
PN=24
General Specifications
9000
02
5
Item
Measurement
Specification
Distance
Distance
Depth
Depth
Depth
Depth
Depth
Depth
Height
Height
Height
Height
Radius
Radius
TX,115,DH5117 1915JUL962/2
TM1663 (28NOV01)
9000-02-5
PN=25
General Specifications
9000
02
6
Measurement
Specification
Type
CED,TX14740,6956 1907SEP001/1
Measurement
Specification
Fuel Tank
Capacity
Cooling System
Capacity
Engine Oil
19 L (5.0 gal)
Hydraulic System
Capacity
Hydraulic Tank
Capacity
Swing Gearbox
Capacity
Capacity
Capacity
TX,115,DH5114 1915JUL961/1
TM1663 (28NOV01)
9000-02-6
PN=26
Group 03
Torque Values
9000
03
1
TORQ1A
UN27SEP99
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark)
Size
1/4
Grade 8 or 8.2
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
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)
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)
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.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
DX,TORQ1 1901OCT991/1
TM1663 (28NOV01)
9000-03-1
PN=27
Torque Values
UN07SEP99
TORQ2
9000
03
2
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8
Class 10.9
Class 12.9
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
M6
4.7 (3.5)
6 (4.4)
9 (6.6)
11.5 (8.5)
13 (9.5)
16.5 (12.2)
15.5 (11.5)
19.5 (14.5)
M8
11.5 (8.5)
14.5 (10.7)
22 (16)
28 (20.5)
32 (23.5)
40 (29.5)
37 (27.5)
47 (35)
M10
23 (17)
29 (21)
43 (32)
55 (40)
63 (46)
80 (59)
75 (55)
95 (70)
M12
40 (29.5)
50 (37)
75 (55)
95 (70)
110 (80)
140 (105)
130 (95)
165 (120)
M14
63 (46)
80 (59)
120 (88)
150 (110)
175 (130)
220 (165)
205 (150)
260 (190)
Size
M16
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
M22
265 (195)
330 (245)
510 (375)
650 (480)
725 (535)
920 (680)
850 (625)
1080 (800)
M24
330 (245)
425 (315)
650 (480)
820 (600)
920 (680)
1150 (850)
1080 (800)
1350 (1000)
M27
490 (360)
625 (460)
950 (700)
1200 (885)
1350 (1000)
1700 (1250)
1580 (1160)
2000 (1475)
M30
660 (490)
850 (625)
1290 (950)
1630 (1200)
1850 (1350)
2300 (1700)
2140 (1580)
2700 (2000)
M33
900 (665)
1150 (850)
1750 (1300)
2200 (1625)
2500 (1850)
3150 (2325)
2900 (2150)
3700 (2730)
M36
1150 (850)
1450 (1075)
2250 (1650)
2850 (2100)
3200 (2350)
4050 (3000)
3750 (2770)
4750 (3500)
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
DX,TORQ2 1901OCT991/1
TM1663 (28NOV01)
9000-03-2
PN=28
Torque Values
9000
03
3
UN18OCT88
T6873AA
UN18OCT88
T6873AB
UN18OCT88
T6873AC
TM1663 (28NOV01)
9000-03-3
04T,90,M170 1929SEP991/2
PN=29
Torque Values
9000
03
4
H-Bolt
Nm
lb-ft
29
21
Nm
lb-ft
M-Bolt
Nm
lb-ft
20
15
10
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
04T,90,M170 1929SEP992/2
TM1663 (28NOV01)
9000-03-4
PN=30
Torque Values
9000
03
5
X9811
UN23AUG88
TX,90,DH1559 1901AUG941/1
TM1663 (28NOV01)
9000-03-5
PN=31
Torque Values
T6243AE
9000
03
6
TM1663 (28NOV01)
9000-03-6
04T,90,K66 1929SEP991/2
PN=32
Torque Values
9000
03
7
Angle Fitting
T6520AB
UN18OCT88
Nm
lb-ft
3/8-24 UNF
7/16-20 UNF
12
1/2-20 UNF
16
12
9/16-18 UNF
24
18
3/4-16 UNF
46
34
7/8-14 UNF
62
46
1-1/16-12 UN
102
75
1-3/16-12 UN
122
90
1-5/16-12 UN
142
105
1-5/8-12 UN
190
140
1-7/8-12 UN
217
160
04T,90,K66 1929SEP992/2
TM1663 (28NOV01)
9000-03-7
PN=33
Torque Values
9000
03
8
Thread Size
Swivel Nut
Bulkhead Nut
mm
in.
in.
Nm
lb-ft
Nm
lb-ft
6.35
0.250
9/16-18
16
12
12
9.52
0.375
11/16-16
24
18
24
18
12.70
0.500
13/16-16
50
37
46
34
15.88
0.625
1-14
69
51
62
46
19.05
0.750
1 3/16-12
102
75
102
75
22.22
0.875
1 3/16-12
102
75
102
75
25.40
1.000
1 7/16-12
142
105
142
105
31.75
1.250
1 11/16-12
190
140
190
140
38.10
1.500
2-12
217
160
217
160
Inch
Inch
Inch
lb-ft
3/8-24
5/8
9/16
12
7/16-20
5/8
5/8
21
15
1/2-20
3/4
11/16
26
19
9/16-18
3/4
3/4
34
25
3/4-16
7/8
15/16
73
55
7/8-14
1 1/16
1 1/16
104
76
1 1/16-12
1 1/4
1 3/8
176
130
1 3/16-12
1 3/8
1 1/2
230
170
1 5/16-12
1 1/2
1 5/8
285
210
04T,90,K67 1902MAR001/1
TM1663 (28NOV01)
9000-03-8
PN=34
Torque Values
9000
03
9
T6234AC
UN18OCT88
Nm
lb-ft
3/8 - 24 UNF
7/16 - 20 UNF
12
1/2 - 20 UNF
16
12
9/16 - 18 UNF
24
18
3/4 - 16 UNF
46
34
7/8 - 14 UNF
62
46
1-1/16 - 12 UN
102
75
1-3/16 - 12 UN
122
90
1-5/16 - 12 UN
142
105
1-5/8 - 12
190
140
1-7/8 - 12 UN
217
160
T82,BHMA,EL 1929SEP991/1
TM1663 (28NOV01)
9000-03-9
PN=35
Torque Values
UN18OCT88
T6873AE
TORQUE CHART
Straight Thread
UN18OCT88
T6873AD
9000
03
10
Tapered Thread
Thread
Size
Nm
lb-ft
1/8
15
11
1/4
20
3/8
29
1/2
49
36
93
69
3/4
69
51
176
130
Nm
lb-ft
15
45
33
21
69
51
157
116
343
253
1-1/2
196
145
539
398
255
188
588
434
Tapered Thread
a
b
04T,90,M171 1928JAN921/1
TM1663 (28NOV01)
9000-03-10
PN=36
Torque Values
9000
03
11
T6890BB
UN01MAR90
ASealing Surface
BSplit Flange
CPinched O-Ring
Nominal
Flange
Size
1/2
lb-ft
Cap Screw
Size
5/16-18
UNC
Min
Max
Min
Max
20
31
15
23
3/4
3/8-16 UNC
28
54
21
40
3/8-16 UNC
37
54
27
40
1-1/4
7/16-14
UNC
47
85
35
63
1-1/2
1/2-13 UNC
62
131
46
97
1/2-13 UNC
73
131
54
97
2-1/2
1/2-13 UNC
107
131
79
97
5/8-11 UNC
158
264
117
195
3-1/2
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
04T,90,K174 1901AUG941/1
TM1663 (28NOV01)
9000-03-11
PN=37
Torque Values
UN01MAR90
T6890BB
9000
03
12
ASealing Surface
BSplit Flange
CPinched O-Ring
TORQUE CHARTa
Thread
Nm
lb-ft
M6
12
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
M8
30
22
M10
57
42
Tolerance 10%. The torques given are enough for the given
size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
a
04T,90,K175 1929SEP991/1
TM1663 (28NOV01)
9000-03-12
PN=38
Group 04
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended.
In all cases, the fuel shall meet the following
properties:
Cetane Number 40 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20C (-4F) or elevations above
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
TX,45,JC1771 1908JAN971/1
TM1663 (28NOV01)
9000-04-1
PN=39
TX,45,DH5857 1915AUG971/1
TX,45,JC1772 1908JAN971/1
TM1663 (28NOV01)
9000-04-2
PN=40
Fuel Tank
CAUTION: Handle fuel carefully. If the engine is
hot or running, do not fill the fuel tank. Do not
smoke while you fill fuel tank or work on fuel
system.
To avoid condensation, fill the fuel tank at the end of each
days operation. Capacity is 303 L (80 gal).
TX,45,DH5077 1901JUL961/1
MX,FLBT,C 1904JUN901/1
TM1663 (28NOV01)
9000-04-3
PN=41
UN10OCT97
TS1661
9000
04
4
TM1663 (28NOV01)
DX,ENOIL 1910OCT971/1
9000-04-4
PN=42
Hydraulic Oil
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
The following oils are preferred:
John Deere HY-GARD
John Deere Low Viscosity HY-GARD
Other oils may be used if they meet one of the following:
UN10OCT97
Manufacturer
Oil
Mobil
DTE 25
Shell
Tellus 46
Caltex Oil
Texaco Inc.
Chevron AW46
NUTO H46
TS1660
John Deere1BIO-HY-GARD
CED,TX14740,6951 1907JAN001/1
TM1663 (28NOV01)
9000-04-5
PN=43
UN14MAR96
TS1653
9000
04
6
OUOE003,0005424 1907SEP001/1
TX,45,DH5142 1909AUG961/1
TM1663 (28NOV01)
9000-04-6
PN=44
John
John
John
John
Deere
Deere
Deere
Deere
HD MOLY GREASE
HD LITHIUM COMPLEX GREASE
HD WATER RESISTANT GREASE
GREASE-GARD
TS1667
UN30JUN99
CED,TX14740,6952 1907JAN001/1
Oil Filters
Filtration of oils is critical to proper operation and
lubrication. Always change filters regularly as specified in
this manual.
Use filters meeting John Deere performance
specifications.
DX,FILT 1918MAR961/1
TM1663 (28NOV01)
9000-04-7
PN=45
Lubricant Storage
Your equipment can operate at top efficiency only
when clean lubricants are used.
DX,LUBST 1918MAR961/1
DX,ALTER 1918MAR961/1
TM1663 (28NOV01)
9000-04-8
PN=46
Mixing of Lubricants
In general, avoid mixing different brands or types of oil.
Oil manufacturers blend additives in their oils to meet
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
TM1663 (28NOV01)
9000-04-9
PN=47
TM1663 (28NOV01)
9000-04-10
PN=48
Section 9005
9005
Page
TM1663 (28NOV01)
9005-1
PN=1
Contents
9005
TM1663 (28NOV01)
9005-2
PN=2
Group 10
9005
10
1
TX,9005,GG2241 1907SEP001/1
1/1
TM1663 (28NOV01)
9005-10-1
PN=51
ATemperature Gauge
BFuel Gauge
1/1
T102097 UN26JUL96
1/1
TM1663 (28NOV01)
9005-10-2
PN=52
T6488GH 1923FEB89
TM1663 (28NOV01)
9005-10-3
PN=53
Engine OFF.
Push each propel lever and pedal forward (A), then
release.
9005
10
4
T7531AO UN07JUN91
1/1
1/1
Start engine.
IMPORTANT: Stop the engine if alternator or engine
oil pressure indicators do not go OFF or a monitor
indicator comes ON after engine starts.
Do alternator and engine oil pressure indicators go OFF
after engine starts?
Do all monitor indicators remain OFF after engine starts?
The buzzer will sound if engine oil pressure is low.
Is coolant temperature gauge needle (A) in normal
operating zone after a few minutes?
Stop engine.
T102096 UN26JUL96
1/1
TM1663 (28NOV01)
9005-10-4
PN=54
LOCKED
T102098 UN26JUL96
1/1
Start engine.
Turn engine rpm dial to fast idle.
Auto-idle switch OFF.
Pilot shut-off lever in LOCKED position.
Push work mode select switch (A) to select desired work
mode.
Do corresponding indicator lights (BE) come on as
each switch is pushed?
T102099 UN26JUL96
TM1663 (28NOV01)
9005-10-5
PN=55
Start engine.
T102100 UN26JUL96
1/1
1/1
TM1663 (28NOV01)
9005-10-6
PN=56
T103545 UN09SEP96
9005
10
7
T103546 UN09SEP96
1/1
T112183 UN13NOV97
TM1663 (28NOV01)
9005-10-7
PN=57
LOCKED
T7351CB UN22AUG90
UNLOCKED
1/1
Engine running.
Pilot shut-off lever (A) in UNLOCKED position (forward).
Push propel pedals or levers forward (B).
Does travel alarm sound?
Push propel pedals or pull levers rearward (C).
Does travel alarm sound?
1/1
TM1663 (28NOV01)
9005-10-8
PN=58
1/1
T7700AC UN10FEB92
NO: If blow-by is
excessive. Do
compression pressure
test. (See CTM104.)
1/1
Move hydraulic control lever to operate a hydraulic function over relief to put engine
under load.
NO: Go to Abnormal
Engine Noise, in Group
9010-15.
1/1
TM1663 (28NOV01)
9005-10-9
PN=59
1/1
T6477AQ UN19OCT88
T7387AD UN03OCT90
1/1
T8187BB UN08MAR94
1/1
TM1663 (28NOV01)
9005-10-10
PN=60
9005
10
11
T8187BF UN08MAR94
1/1
T102070 UN16JUL96
T102071 UN16JUL96
1/1
TM1663 (28NOV01)
9005-10-11
PN=61
9005
10
12
T102197 UN19JUL96
T102198 UN19JUL96
1/1
TM1663 (28NOV01)
9005-10-12
PN=62
1/1
T6290AF UN19OCT88
1/1
T6292AZ UN19OCT88
1/1
TM1663 (28NOV01)
9005-10-13
PN=63
Actuate the boom up function, arm in function and then the bucket function.
9005
10
14
Does boom continue to move at approximately the same speed after bucket function is
actuated?
1/1
Extend the arm to full extension and then lower boom so bucket is on the ground.
Actuate the boom up and arm in functions in combined operation.
Does the arm move smoothly through the complete cycle and not hesitate when it
goes through the vertical position?
1/1
1/1
TM1663 (28NOV01)
9005-10-14
PN=64
NO: Inspect
counterbalance valve. Go
to Group 0260.
9005
10
15
1/1
1/1
TM1663 (28NOV01)
9005-10-15
PN=65
T6477AQ UN19OCT88
Boom
T7884AE UN10NOV92
0.3 sec
0.3 sec
0.3 sec
0.3 sec
0.3 sec
0.3 sec
1.0 sec
0.6 sec
1.0 sec
1/1
4 Undercarriage Checks
1/1
TM1663 (28NOV01)
9005-10-16
PN=66
T6915AN UN07APR89
T7850AI UN22OCT92
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
1/1
TM1663 (28NOV01)
9005-10-17
PN=67
9005
10
17
9005
10
18
YES: Go to
Undercarriage Appraisal
Manual for more in
information and
specifications.
NO: Go to next check.
1/1
5 Accessories Checks
1/1
TM1663 (28NOV01)
9005-10-18
PN=68
ALight Switch
1/1
1/1
Windshield Washer
Circuit Check
Key switch ON
T102107 UN26JUL96
1/1
TM1663 (28NOV01)
9005-10-19
PN=69
9005
10
19
1/1
AHorn Button
1/1
1/1
1/1
TM1663 (28NOV01)
9005-10-20
PN=70
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
Start engine and allow to warm several minutes.
Press heater temperature switch to maximum heat position. Press blower switch to
high speed position.
Does warm air exit from ducts?
1/1
Early Models
T124602 UN15SEP99
Later Models
Start engine and run at fast idle.
Push A/C switch to turn air conditioner on.
Push HI blower switch to run blower at high speed.
Wait for any warm air in duct system to dissipate.
Is air from ducts cool after a few minutes?
1/1
TM1663 (28NOV01)
9005-10-21
PN=71
9005
10
21
Engine OFF.
Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts
or "weather checked"?
9005
10
22
Are hose and line connections clean NOT showing signs of leakage, such as oil or
dust accumulation at fittings?
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
Engine ON.
1/1
Condenser Check
Engine OFF.
1/1
Compressor Clutch
Check
Engine OFF.
1/1
TM1663 (28NOV01)
9005-10-22
PN=72
1/1
TM1663 (28NOV01)
9005-10-23
PN=73
9005
10
23
9005
10
24
T118478 UN02DEC98
T102507 UN29JUL96
TM1663 (28NOV01)
9005-10-24
PN=74
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.
Turn lock pins (A) and pull towards center of window.
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 move smoothly to lock and unlock window?
Does rear latch operate freely?
Do pins engage cab frame rear holes and lock window securely in full open position?
1/1
T102111 UN26JUL96
T106163 UN07JAN97
ALock Pins
BBrackets
CHoles
NOTE: Upper front window must be raised before lower window can be removed from
window frame.
Pull lock pins (A) towards center of window to unlock window.
Lift lower front window from the frame.
Store window behind the rear console. Slide lock pins into hole (C) in brackets (B).
Do the springs push lock pins out?
Is window held securely in brackets?
1/1
TM1663 (28NOV01)
9005-10-25
PN=75
9005
10
26
ALatch Handle
1/1
T116423 UN15JUL98
1/1
ALock Pins
BHandle
1/1
TM1663 (28NOV01)
9005-10-26
PN=76
T102114 UN26JUL96
9005
10
27
1/1
Insert ignition key into door lock, turn clockwise 1/4 turn
to lock.
1/1
1/1
TM1663 (28NOV01)
9005-10-27
PN=77
9005
10
28
T7351AH UN22AUG90
T7425AF UN04DEC90
1/1
Hood Check
Release latches.
Open hood.
T102128 UN26JUL96
1/1
1/1
TM1663 (28NOV01)
9005-10-28
PN=78
T7414AB 1913DEC90
1/1
T6488FY UN19OCT88
T7690AB UN23JAN92
AGasket
BSpring
CSeal
TM1663 (28NOV01)
9005-10-29
PN=79
9005
10
30
1/1
1/1
Are radiator and heater hoses free of twists, kinks, cracks, leaks, or wear from rubbing
on adjacent parts?
Are hose clamps tight and installed correctly?
TM1663 (28NOV01)
9005-10-30
PN=80
1/1
AWeep Hole
BSeal
T7690AC UN27JAN92
Engine stopped.
Water Pump
1/1
T7694AH UN21MAY03
1/1
TM1663 (28NOV01)
9005-10-31
PN=81
9005
10
31
T6171CB UN25MAY89
1/1
1/1
1/1
TM1663 (28NOV01)
9005-10-32
PN=82
Radiator full.
Install radiator cap and tighten.
Place end of radiator overflow hose into a container of
clear water.
T6171AR UN25MAY89
1/1
1/1
T118761 UN03DEC98
1/1
TM1663 (28NOV01)
9005-10-33
PN=83
T7531BF UN07JUN91
1/1
ASecondary Element
BPrimary Element
1/1
TM1663 (28NOV01)
9005-10-34
PN=84
T103516 UN04SEP96
T7699AL UN03FEB92
T128979 UN25APR00
Early Models
Later Models
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
YES: Go to Diagnose
Engine Malfunctions,
Group 9010-15.
1/1
TM1663 (28NOV01)
9005-10-35
PN=85
9005
10
36
1/1
IMPORTANT: Be careful not to damage fuel gauge sender float or low fuel level
sending unit.
Remove fuel cap.
Use a flashlight to inspect bottom of fuel tank by shining light through the fuel.
1/1
1/1
T7700AB UN25FEB92
1/1
TM1663 (28NOV01)
9005-10-36
PN=86
T103528 UN04SEP96
T6493AA UN19OCT88
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?
Tighten bleed screw and again operate hand primer.
Is resistance felt when hand primer is initially pumped and increase as system
pressure increases?
1/1
T116778D UN03DEC98
T116899E UN03DEC98
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.
Does fuel flow from bleed screws as hand primer is operated?
1/1
TM1663 (28NOV01)
9005-10-37
PN=87
9005
10
37
Engine OFF.
Connect a hose to fitting on final fuel filter to route excess fuel into a container.
9005
10
38
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
Visual Inspection
1/1
TM1663 (28NOV01)
9005-10-38
PN=88
Section 9010
Engine
Contents
Page
Page
9010-1
PN=1
9010
Contents
9010
TM1663 (28NOV01)
9010-2
PN=2
Group 05
Theory of Operation
POWERTECH 6.8 L (6068) John Deere
EngineUse CTM104
M44215
UN07SEP88
TM1663 (28NOV01)
TX,9010,SB103 1906SEP961/1
9010-05-1
PN=91
9010
05
1
Theory of Operation
EngineSectional View
L103403
UN28NOV89
9010
05
2
7Crankshaft
8Crankshaft Counterweight
9Oil Pan
10Connecting Rod
11Liner Packing Rings
12Cylinder Liner
13Piston
14Piston Pin
15Piston Rings
16Valve
TX,9010,SB105 1906SEP961/1
TM1663 (28NOV01)
9010-05-2
PN=92
Theory of Operation
T103369
UN29AUG96
9010
05
3
TX,9010,SB106 1906SEP961/1
TM1663 (28NOV01)
9010-05-3
PN=93
Theory of Operation
T115408
1927MAY98
9010
05
4
TM1663 (28NOV01)
OAuto-Idle Switch
PEngine Speed Sensor
(N Sensor)
QEngine Speed Control
Circuits
9010-05-4
CED,OUOE035,146 1918APR001/2
PN=94
Theory of Operation
The engine speed control components allows the operator
to choose engine speeds to match operating conditions
and to operate the engine as efficiently as possible.
Engine speeds from slow idle to fast idle in standard
mode are selected by the engine rpm dial (A) located in
the right console panel in cab. The E (economy) mode
and HP (high power) mode are selected by switches
located in the right console panel just above the engine
rpm dial. The auto idle mode is selected by a switch
located in the switch panel (B). Indicators in the monitor
panel are lit to indicate when the E mode, HP mode, and
auto-idle mode switches are pushed to activate the
function.
9010
05
5
T115409
1927MAY98
CED,OUOE035,146 1918APR002/2
TM1663 (28NOV01)
9010-05-5
PN=95
Theory of Operation
T115580
1927MAY98
9010
05
6
TM1663 (28NOV01)
9010-05-6
CED,OUOE003,1053 1918APR001/2
PN=96
Theory of Operation
The engine speed for fast idle in standard mode is
controlled by data stored in the engine and pump
controller. The parameter for fast idle in standard
mode can be change from the factory setting within a
specified range. (See Excavator Diagnostic Program
Special FunctionEngine Speed in Group 9025-25.)
CED,OUOE003,1053 1918APR002/2
TM1663 (28NOV01)
9010-05-7
PN=97
9010
05
7
Theory of Operation
T115581
1927MAY98
9010
05
8
EE Mode Switch
TM1663 (28NOV01)
9010-05-8
CED,OUOE003,1054 1918APR001/2
PN=98
Theory of Operation
The parameter for engine speed in E (economy) mode
can be change from the factory setting within a
specified range. (See Excavator Diagnostic Software
CED,OUOE003,1054 1918APR002/2
9010
05
9
TM1663 (28NOV01)
9010-05-9
PN=99
Theory of Operation
T115582
1927MAY98
9010
05
10
GRear Pump
HEngine Control Motor
IEngine and Pump Controller
TM1663 (28NOV01)
JEC Sensor
KHP (High Power) Mode
Speed Control Circuit
9010-05-10
CED,OUOE003,1055 1918APR001/2
PN=100
Theory of Operation
When all conditions are meet, the engine and pump
controller sends an electrical signal to the engine
control motor to increase the engine speed. The
amount of engine speed increase is somewhat
controlled by the pump regulators adjustment and the
CED,OUOE003,1055 1918APR002/2
TM1663 (28NOV01)
9010-05-11
PN=101
9010
05
11
Theory of Operation
T115583
1927MAY98
9010
05
12
TM1663 (28NOV01)
9010-05-12
CED,OUOE003,1056 1918APR001/2
PN=102
Theory of Operation
The parameter for auto-idle engine speed can be
change from the factory setting within a specified
CED,OUOE003,1056 1918APR002/2
9010
05
13
TM1663 (28NOV01)
9010-05-13
PN=103
Theory of Operation
T115584
1927MAY98
9010
05
14
EKey Switch
FEngine Learning Switch
TM1663 (28NOV01)
9010-05-14
CED,OUOE003,1057 1918APR001/2
PN=104
Theory of Operation
Engine.
Engine speed control cable.
Slow idle bracket at injection pump.
Fast idle bracket at injection pump.
Engine control motor and sensor.
Engine and pump controller.
CED,OUOE003,1057 1918APR002/2
TM1663 (28NOV01)
9010-05-15
PN=105
9010
05
15
Theory of Operation
9010
05
16
TM1663 (28NOV01)
9010-05-16
PN=106
Group 10
UN07SEP88
M44215
TX,9010,SB109 1906SEP961/1
Group 20 (Adjustments)
Group 25 (Tests)
TX,9010,SB110 1918SEP001/1
1/1
TM1663 (28NOV01)
9010-10-1
PN=107
9010
10
1
T7414AB 1913DEC90
9010
10
2
1/1
1/1
TM1663 (28NOV01)
9010-10-2
PN=108
T6488FY UN19OCT88
T7690AB UN23JAN92
AGasket
BSpring
CSeal
9010
10
3
1/1
TM1663 (28NOV01)
9010-10-3
PN=109
Are radiator fins free of mud, leaves, grass, and other debris?
Is radiator damaged?
9010
10
4
1/1
Are radiator and heater hoses free of twists, kinks, cracks, leaks or wear from rubbing
on adjacent parts?
1/1
AWeep Hole
BSeal
Engine stopped.
T7690AC UN27JAN92
1/1
Radiator full.
Install radiator cap and tighten.
Place end of radiator overflow hose into a container of
clear water.
T6171AR UN25MAY89
1/1
TM1663 (28NOV01)
9010-10-4
PN=110
9010
10
5
T7694AH UN21MAY03
1/1
T6488GB UN23AUG93
1/1
1/1
TM1663 (28NOV01)
9010-10-5
PN=111
9010
10
6
1/1
1/1
T118761 UN03DEC98
1/1
T7531BF UN07JUN91
1/1
TM1663 (28NOV01)
9010-10-6
PN=112
ASecondary Element
BPrimary Element
1/1
T103516 UN04SEP96
T7699AL UN03FEB92
T128979 UN25APR00
Early Models
Later Models
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
TM1663 (28NOV01)
9010-10-7
PN=113
YES: Go to Diagnose
Engine Malfunctions,
Group 9010-15.
9010
10
8
1/1
1/1
TM1663 (28NOV01)
9010-10-8
PN=114
T6488GH 1923FEB89
T103525 UN10SEP96
1/1
1/1
TM1663 (28NOV01)
9010-10-9
PN=115
T103526 UN09SEP96
1/1
1/1
IMPORTANT: Be careful not to damage fuel gauge sender float or low fuel level
sending unit.
Use a flashlight to inspect bottom of fuel tank by shining light through the fuel.
1/1
ADrain Valve
Hold a clean container under fuel tank drain valve (A).
Remove recessed hex plug.
Open drain valve for a few seconds and catch fuel in
container.
T7700AA UN18FEB92
1/1
TM1663 (28NOV01)
9010-10-10
PN=116
T7700AB UN25FEB92
1/1
T103528 UN04SEP96
T6493AA UN19OCT88
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?
Tighten bleed screw and again operate hand primer.
Is resistance felt when hand primer is initially pumped and increase as system
pressure increases?
1/1
Engine OFF.
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
TM1663 (28NOV01)
9010-10-11
PN=117
9010
10
11
1/1
9010
10
12
Turn engine rpm dial (A) to the right to fast idle position.
Did engine speed increase to fast idle in standard
mode?
Turn engine rpm dial to the left to slow idle position.
Did engine speed decrease to slow idle?
T102100 UN26JUL96
1/1
AAuto-Idle Switch
BAuto-Idle Indicator
Start engine.
Run engine at half speed.
Push auto-idle switch (A) on.
Does the auto-idle indicator (B) come on?
Does the engine speed decrease to auto-idle speed after
about 4 seconds?
Actuate the bucket function momentarily. Does the
engine speed increase immediately to the engine rpm
dial setting?
Does the engine speed return to auto-idle after 4
seconds?
T103536 UN09SEP96
1/1
TM1663 (28NOV01)
9010-10-12
PN=118
T103545 UN09SEP96
T103546 UN09SEP96
Start engine.
Turn engine rpm dial clockwise to fast idle.
Push E mode switch (A) on.
Did you hear a decrease in engine speed?
Did the indicator light (B) come on?
Push the E mode switch again to turn it off.
Did indicator light go out and engine speed increase to fast idle?
1/1
T111983 UN27OCT97
T112183 UN13NOV97
1/1
TM1663 (28NOV01)
9010-10-13
PN=119
T7700AC UN10FEB92
NO: If blow-by is
excessive, do
compression pressure
test. (See CTM104.)
9010
10
14
1/1
YES: Operational
Checkout complete.
Move hydraulic control lever to operate a hydraulic function over relief to put engine
under load.
Does engine run smooth, no knocking or rattling noise?
NO: Go to Abnormal
Engine Noise. (See
Diagnose Engine
Malfunctions in Group
9010-15.)
1/1
TM1663 (28NOV01)
9010-10-14
PN=120
Group 15
Diagnostic Information
POWERTECH 6.8 L (6086) John Deere
EngineUse CTM104
M44215
UN07SEP88
TM1663 (28NOV01)
TX,9010,SB111 1906SEP961/1
9010-15-1
PN=121
9010
15
1
Diagnostic Information
Problem
Solution
No fuel
Wrong fuel
Debris in fuel
Fuel pump
9010
15
2
TM1663 (28NOV01)
9010-15-2
TX,9010,SB112 1918SEP001/10
PN=122
Diagnostic Information
Symptom
Problem
Solution
Injection pump
Injection nozzle(s)
Starter
Replace starter.
Air in fuel
Debris in fuel
Wrong fuel
Water in fuel
Replace filter.
TM1663 (28NOV01)
9010
15
3
9010-15-3
TX,9010,SB112 1918SEP002/10
PN=123
Diagnostic Information
Symptom
9010
15
4
Problem
Solution
Engine overheating
Injection nozzle(s)
Debris in fuel
Wrong fuel
Clean.
TM1663 (28NOV01)
9010-15-4
TX,9010,SB112 1918SEP003/10
PN=124
Diagnostic Information
Symptom
Engine Overheats
Problem
Solution
Check, repair.
Fuel pump
Timing incorrect
Injection nozzles
Low compression
Turbocharger
Gauge or sender
TM1663 (28NOV01)
9010
15
5
9010-15-5
TX,9010,SB112 1918SEP004/10
PN=125
Diagnostic Information
Symptom
9010
15
6
Problem
Solution
Replace.
Water pump
Wiring harness
Wiring harness
TM1663 (28NOV01)
9010-15-6
TX,9010,SB112 1918SEP005/10
PN=126
Diagnostic Information
Symptom
Problem
Solution
Wiring harness
Wiring harness
Temperature gauge
TM1663 (28NOV01)
9010
15
7
9010-15-7
TX,9010,SB112 1918SEP006/10
PN=127
Diagnostic Information
Symptom
9010
15
8
Problem
Solution
Wrong oil
Oil leaks
TM1663 (28NOV01)
9010-15-8
TX,9010,SB112 1918SEP007/10
PN=128
Diagnostic Information
Symptom
Problem
Solution
Wrong fuel
Injection nozzles
Wrong fuel
Over-fueling
TM1663 (28NOV01)
9010-15-9
TX,9010,SB112 1918SEP008/10
PN=129
9010
15
9
Diagnostic Information
Symptom
Detonation
9010
15
10
Abnormal Noise
Problem
Solution
Wrong fuel
Piston scored
Worn bearings
TM1663 (28NOV01)
9010-15-10
TX,9010,SB112 1918SEP009/10
PN=130
Diagnostic Information
Symptom
Problem
Solution
TX,9010,SB112 1918SEP0010/10
TM1663 (28NOV01)
9010-15-11
PN=131
9010
15
11
Diagnostic Information
9010
15
12
TM1663 (28NOV01)
9010-15-12
PN=132
Group 20
Adjustments
POWERTECH 6.8 L (6068) John Deere
EngineUse CTM104
UN07SEP88
M44215
TX,9010,SB109 1906SEP961/1
UN28FEB89
T6813AG
AClamp-On Transducer
BBlack Clip ()
CRed Clip (+)
DDigital Readout Unit
CED,TX08227,2879 1911NOV971/1
TM1663 (28NOV01)
9010-20-1
PN=133
9010
20
1
Adjustments
9010
20
2
36 mm (1/81/4 in.)
3 turns short
8 Nm (70 lb-in.)
TM1663 (28NOV01)
9010-20-2
TX,05,GG2305 1922APR981/3
PN=134
Adjustments
1. Disconnect ball joint (C) from fuel shut-off lever (D).
2. Turn key switch to ON. It is not necessary to start
engine for this procedure.
UN04DEC96
T105518
T105519
AShut-Off Solenoid
BCap Screw
CBall Joint
DFuel Shut-Off Lever
ELock Nut
FPlunger
GStop Position Stop (Lower Stop)
HRun Position Stop (Upper Stop)
TM1663 (28NOV01)
9010-20-3
TX,05,GG2305 1922APR982/3
PN=135
9010
20
3
Adjustments
IMPORTANT: Failure to have the shut-off lever tight
against run position stop (upper stop)
can result in low engine horsepower.
9. Turn the key switch to ON.
Push plunger into solenoid housing so hold coil holds
the plunger in the run position.
9010
20
4
TX,05,GG2305 1922APR983/3
TM1663 (28NOV01)
9010-20-4
PN=136
Adjustments
2100 25 rpm
900 25 rpm
9010
20
5
Specification
Engine Slow IdleSpeed .............................................. 900 25 rpm
TX,9010,SB115 1907SEP001/1
TM1663 (28NOV01)
9010-20-5
PN=137
Adjustments
9010
20
6
2300 25 rpm
900 25 rpm
TM1663 (28NOV01)
9010-20-6
TX,9010,SB125 1907SEP001/3
PN=138
Adjustments
T103678
UN16SEP96
9010
20
7
ANut
BSlow Idle Stop Screw
CNut
DSupplementary Idle Screw
ENut
TM1663 (28NOV01)
9010-20-7
TX,9010,SB125 1907SEP002/3
PN=139
Adjustments
NOTE: Increasing slow idle setting a small amount,
but no more than the maximum specifications,
may help to reduce surging or hunting. If
surging or hunting continues, repair injection
pump.
9010
20
8
TX,9010,SB125 1907SEP003/3
13 Nm (115 lb-in.)
Engine
Engine speed control cable
Engine control motor and sensor
Engine and pump controller
Fast and slow idle stop screws
TM1663 (28NOV01)
9010-20-8
CED,OUTX782,504 1915SEP001/3
PN=140
Adjustments
3. Turn the engine rpm dial (A) to slow idle.
T101749
UN27JUN96
CED,OUTX782,504 1915SEP002/3
T103663
ACap Screw
BArm
CED,OUTX782,504 1915SEP003/3
TM1663 (28NOV01)
9010-20-9
PN=141
9010
20
9
Adjustments
9010
20
10
900 25 rpm
1200 25 rpm
1850 25 rpm
2100 25 rpm
Engine
Engine speed control cable
Engine control motor and sensor
Engine and pump controller
Fast and slow idle stop screws
TM1663 (28NOV01)
9010-20-10
TX,9010,SB126 1912SEP001/2
PN=142
Adjustments
3. Push engine learning switch (C) up to top position. The
switch is a three position switch. Make sure it is in the
top position.
4. Turn key switch ON. Wait 5 seconds.
5. Turn key switch OFF. Wait 5 seconds.
6. Push engine learning switch to middle position.
7. Check engine speeds.
UN11SEP96
25 rpm
25 rpm
25 rpm
25 rpm
T103674
9010
20
11
TX,9010,SB126 1912SEP002/2
TM1663 (28NOV01)
9010-20-11
PN=143
Adjustments
Freezing Temperatures
9010
20
12
Fill
Specification
Cooling SystemCapacity ......................................... 28.4 L (7.5 gal)
Deaeration
CED,OUOE003,1058 1907SEP001/1
TM1663 (28NOV01)
9010-20-12
PN=144
Group 25
Tests
POWERTECH 6.8 L (6068) John Deere
EngineUse CTM104
M44215
UN07SEP88
TM1663 (28NOV01)
TX,9010,SB118 1906SEP961/1
9010-25-1
PN=145
9010
25
1
Tests
9010
25
2
TX,9010,SB119 1911AUG981/1
TM1663 (28NOV01)
9010-25-2
PN=146
Tests
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
9010
25
3
3. Start engine and slowly cover the air cleaner inlet with
a piece of paper or cardboard.
T7350EP
ASwitch
BTee
CBarbed Fitting
DTube
EBarbed Fitting
FCoupler
GGauge
TX,9010,SB120 1930MAR001/1
TM1663 (28NOV01)
9010-25-3
PN=147
Tests
OTHER MATERIAL
T43512 U.S. Thread Lock and Sealer (Medium Strength)
T5906AP
UN12SEP96
T103680
9010
25
4
APlug
Specification
Air Intake System Leakage
TestPressure ............................................. 1421 kPa (0.140.21 bar)
(23 psi)
TX,9010,SB121 1917JUN981/1
TM1663 (28NOV01)
9010-25-4
PN=148
Tests
Fast Idle
ESSENTIAL TOOLS
JT05529 Air Flow Meter
9010
25
5
CED,OUOE003,653 1913JUN981/4
T103681
1912SEP96
Specification
EngineSpeed ............................................................................ Fast Idle
TM1663 (28NOV01)
9010-25-5
CED,OUOE003,653 1913JUN982/4
PN=149
Tests
8. Put air flow meter against the trash screen so it is
centered in a square and air flow is through meter in
the direction of air flow arrow.
9. Record voltage reading for each square that is not
marked out with an X.
UN01NOV88
T6080AH
9010
25
6
TM1663 (28NOV01)
9010-25-6
CED,OUOE003,653 1913JUN983/4
PN=150
Tests
T6500AK
1921MAR89
9010
25
7
T103681
1912SEP96
CED,OUOE003,653 1913JUN984/4
TM1663 (28NOV01)
9010-25-7
PN=151
Tests
9010
25
8
On
2100 rpm
TM1663 (28NOV01)
9010-25-8
CED,TX08227,3198 1907SEP001/4
PN=152
Tests
2. Remove plug (A) from tube between turbocharger and
intake manifold.
3. Install fitting, hose, and pressure gauge.
UN12SEP96
T103680
Specification
Engine Fast IdleSpeed ...................... 2100 25 rpm in standard mode
APlug
Specification
Combined Pump Engine
PulldownSpeed .................................. 100 rpm approximate with arm in
over relief
TM1663 (28NOV01)
9010-25-9
CED,TX08227,3198 1907SEP002/4
PN=153
9010
25
9
Tests
Specification
Rated EngineSpeed ................................................................. 2100 rpm
9010
25
10
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.
TM1663 (28NOV01)
9010-25-10
CED,TX08227,3198 1907SEP003/4
PN=154
Tests
Tighten plug.
14. Turn the load adjusting cartridge on the pump
regulators out to their setting. (See Hydraulic Pump
Regulator Test and AdjustmentEngine Pulldown in
this group.)
CED,TX08227,3198 1907SEP004/4
TM1663 (28NOV01)
9010-25-11
PN=155
Tests
ESSENTIAL TOOLS
RG7507
CED,OUOE003,1059 1912AUG981/3
UN23NOV97
RG7508
9010
25
12
TM1663 (28NOV01)
9010-25-12
CED,OUOE003,1059 1912AUG982/3
PN=156
Tests
5. Check axial runout (wobble) using a dial indicator.
Measure axial runout at the outer edge of dampener
face (A).
Specification
Torsional DampenerAxial
Runout (Wobble) ........................................ 1.50 mm (0.060 in.) maximum
9010
25
13
RG5679
UN31OCT97
CED,OUOE003,1059 1912AUG983/3
TM1663 (28NOV01)
9010-25-13
PN=157
Tests
9010
25
14
TM1663 (28NOV01)
9010-25-14
PN=158
Section 9015
Electrical System
Contents
Page
Page
9015-1
PN=1
9015
Contents
9015
Page
Page
Battery
Using Booster Batteries---24 Volt
System . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-7
Replacing. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-8
Batteries
Adding 12 or 24 Volt Accessories . . . . . . .9015-20-9
Travel Alarm
Changing Volume . . . . . . . . . . . . . . . . . .9015-20-10
Proportional Solenoid
Test Harness . . . . . . . . . . . . . . . . . . . . . .9015-20-11
Pump Control
Test Harness . . . . . . . . . . . . . . . . . . . . . .9015-20-11
Pump Pressure Sensor
Test Harness . . . . . . . . . . . . . . . . . . . . . .9015-20-11
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
TM1663 (28NOV01)
9015-2
PN=2
Group 05
System Information
Electrical System Visual Inspection
Make the following visual electrical inspection prior to
starting the machine after receiving customer complaint:
1. Look for bare wires that could ground a component or
short across to another component.
2. Look for missing or worn conduit. This could indicate a
wire problem.
3. Look for loose or broken connectors and wires.
4. Inspect batteries for:
Corroded terminals
Loose terminals or battery posts
Dirty condition
Damp condition
Cracked case
Proper electrolyte level
9015
05
1
CED,OUTX466,1353 1903FEB991/1
TM1663 (28NOV01)
9015-05-1
PN=161
System Information
T128740
UN17JUL03
9015
05
2
1Battery
2Fuse
3Switch
4Load (Light)
5Ground
CIRCUIT MALFUNCTIONS
High-Resistance Circuit.
Open Circuit.
Grounded Circuit.
Shorted Circuit.
CED,TX17984,438 1924FEB001/1
TM1663 (28NOV01)
9015-05-2
PN=162
System Information
T128750
UN17JUL03
9015
05
3
1Battery
2Fuse
3Switch
4Switch Terminal
5High Resistance
6Connector
7Component Terminal
TM1663 (28NOV01)
8Load (Light)
9Ground
9015-05-3
CED,TX17984,446 1925FEB001/2
PN=163
System Information
5. If voltage is normal at component terminal (7), the
malfunction is between the component (8) and
ground (9). Continue measuring voltage toward
CED,TX17984,446 1925FEB002/2
9015
05
4
TM1663 (28NOV01)
9015-05-4
PN=164
System Information
Open Circuit
T128784
UN17JUL03
9015
05
5
1Battery
2Fuse
3Switch
4Switch Terminal
5Broken Wire
6Connector
7Component Terminal
8Load (Light)
9Ground
TM1663 (28NOV01)
9015-05-5
CED,TX17984,447 1925FEB001/2
PN=165
System Information
In the example, voltage will be present at switch
terminal (4), but no voltage at component terminal
(7). Checking voltage toward switch terminal (4),
zero voltage will be present at connector (6),
indicating a broken wire (5) in the harness between
switch terminal (4) and connector (6).
CED,TX17984,447 1925FEB002/2
9015
05
6
TM1663 (28NOV01)
9015-05-6
PN=166
System Information
9015
05
7
TM1663 (28NOV01)
9015-05-7
PN=167
System Information
Grounded Circuit
T128751
UN17JUL03
9015
05
8
1Battery
2Fuse
3Fuse Terminal (Battery
Side)
TM1663 (28NOV01)
9Component Terminal
10Load (Light)
11Ground
9015-05-8
CED,TX17984,448 1925FEB001/2
PN=168
System Information
a. If continuity to ground is indicated, there is a
short to ground between switch terminal (6) and
component terminal (9). Inspect wire harness in
this area.
In the example, continuity to ground will be
present at the wire lead from component
terminal (9). Inspecting the wire harness toward
switch terminal (6), an area of burned wire
insulation (7) will be found making contact to
machine ground (8).
b. If continuity to ground does not exist, go to next
step.
TM1663 (28NOV01)
9015-05-9
PN=169
System Information
Shorted Circuit
T128752
UN29FEB00
9015
05
10
1Battery
2Fuse F1
3Fuse F2
4Battery Wire Shorted to
Circuit
5Switch S2
6Circuit Wire Shorted to
Circuit
7Circuit Wire Shorted to
Ground
8Light E2
9Circuit Ground
10Circuit Ground
11Light E1
12Switch S1
TM1663 (28NOV01)
9015-05-10
CED,TX17984,449 1925FEB001/2
PN=170
System Information
3. Turn switch S1 (12) OFF and switch S2 (5) ON.
CED,TX17984,449 1925FEB002/2
TM1663 (28NOV01)
9015-05-11
PN=171
System Information
T128748
UN17JUL03
9015
05
12
1Battery
2Fuse F1
3Fuse F2
4Switch
TM1663 (28NOV01)
10Sensor
11Controller
12Controller Ground
9015-05-12
CED,TX17984,450 1928FEB001/2
PN=172
System Information
1. The controller may display a maximum upper or
lower reading.
2. The sensor may be damaged, with no signal given
to the controller.
3. The controller may be damaged, with no display for
that sensor.
4. The controller may or may not generate a service
code.
TM1663 (28NOV01)
9015-05-13
PN=173
System Information
T128785
UN17JUL03
9015
05
14
1Battery
2Fuse
3Controller Ground
4Controller
5Sensor Power Wire Shorted
to Sensor Signal Wire
TM1663 (28NOV01)
8Sensor
9015-05-14
CED,TX17984,451 1928FEB001/2
PN=174
System Information
1. The sensor may be damaged, with no signal given
to the controller.
CED,TX17984,451 1928FEB002/2
9015
05
15
TM1663 (28NOV01)
9015-05-15
PN=175
System Information
T128753
UN17JUL03
9015
05
16
1Battery
2Fuse
3Controller
TM1663 (28NOV01)
7Sensor
8Controller Ground
9015-05-16
CED,TX17984,452 1928FEB001/2
PN=176
System Information
2. The controller may generate a Short to Ground
service code.
Multimeter
The multimeter is a handheld instrument use for taking
accurate measurements of electrical circuits.
1Ampere Input Terminal (Red Lead)
2Milliamp, Microamp Input Terminal (Red Lead)
3Volts AC (Alternating Current)
4Volts DC (Direct Current)
5Millivolts DC (Direct Current)
6Display
7Continuity, Resistance, and Capacitance
8Diode Test
9Milliamps or Amperes
10Microamps
11Common or Ground Terminal (Black Lead)
12Volt, Ohms, Diode Test Input Terminal (Red Lead)
T128730
UN28FEB00
9015
05
17
CED,TX17984,439 1925FEB001/1
TM1663 (28NOV01)
9015-05-17
PN=177
System Information
T128754
UN17JUL03
9015
05
18
1Battery
2Fuse or Circuit Breaker
3Battery Side of Fuse or
Circuit Breaker
c. No voltage. Go to step 3.
c. No voltage. Go to step 5.
TM1663 (28NOV01)
9015-05-18
CED,TX17984,454 1928FEB001/2
PN=178
System Information
5. Turn switch (5) OFF. Disconnect wire at battery
side on component (6).
Turn switch (5) ON. Check wire at (6) for battery
voltage.
CED,TX17984,454 1928FEB002/2
TM1663 (28NOV01)
9015-05-19
PN=179
System Information
9015
05
20
CED,TX17984,455 1928FEB001/1
TM1663 (28NOV01)
9015-05-20
PN=180
System Information
9015
05
21
TM1663 (28NOV01)
9015-05-21
PN=181
System Information
T128818
UN29FEB00
9015
05
22
TM1663 (28NOV01)
9015-05-22
CED,TX17984,456 1928FEB001/2
PN=182
System Information
1Continuity Chart
2Power Wires
3Routing Location
Information
4Wire Identification
5Ground Wires
6Circuit Name
7Section Number
8Component Name
9Component Identification
Number
10Component Schematic
Symbol
CED,TX17984,456 1928FEB002/2
TM1663 (28NOV01)
9015-05-23
PN=183
9015
05
23
System Information
T128819
UN29FEB00
9015
05
24
TM1663 (28NOV01)
9015-05-24
CED,TX17984,457 1928FEB001/2
PN=184
System Information
1Harness Connector Pin
Letter or Number
2Harness Connector Number
Identification
3Component Identification
Number
4Wire Color or Number
5Component Identification
Number Wire is Routed TO
6Component Connector
7Component Connector Pin
Letter or Number
8Wiring Harness
9Component Identification
Number Wire is Routed TO
10Wire Color or Number
CED,TX17984,457 1928FEB002/2
TM1663 (28NOV01)
9015-05-25
PN=185
9015
05
25
System Information
T128843
UN01MAR00
9015
05
26
TM1663 (28NOV01)
9015-05-26
CED,TX17984,459 1929FEB001/2
PN=186
System Information
1Component Identification
Number
2Component Name
3Additional Information
4Connector Identification
Number
5Connector Name
6Pin Number of Mating
Connector
CED,TX17984,459 1929FEB002/2
TM1663 (28NOV01)
9015-05-27
PN=187
9015
05
27
System Information
T128896
UN01MAR00
9015
05
28
4Component Name
5Terminal Pin Letter or
Number
6Wire Number
7Wire Color
CED,TX17984,460 1901MAR001/1
TM1663 (28NOV01)
9015-05-28
PN=188
System Information
9015
05
29
TM1663 (28NOV01)
9015-05-29
PN=189
System Information
CED,TX17984,458 1928FEB001/2
TM1663 (28NOV01)
9015-05-30
PN=190
System Information
1Battery
2Wire Splice
3Fuse
4Circuit Breaker
5Fusible Link
6Power Outlet
7Alternator
8Air Conditioner
Compressor
9Compressor
10Liquid Pump
11Antenna
12Diode
13Zener Diode
14Capacitor
15Magnet
16Flasher
17Buzzer
18Horn
19Alarm
20Clock
21Internal Ground
22Single Point Ground
23External Ground
24Sensor
25Sensor with Normally
Open Switch
26Speed Sensor
27Rotary Sensor
28Single Element Bulb
29Dual Element Bulb
30Electrically Operated
hydraulic Valve
31Solenoid Normally Open
32Solenoid Normally Closed
33Starter Motor
34Starter Motor
35DC Motor
36DC Stepping Motor
37Wiper Motor
38Blower Motor
39Servo Motor
40Speedometer
41Tachometer
42Temperature Gauge
43Liquid Level Gauge
44Gauge
45Hourmeter
46Resistor
47Variable Resistor
48Multi-Pin Connector
49Single Pin Connector
50Connector
514 Pin Relay
525 Pin Relay
535 Pin Relay With Internal
Suppression Diode
545 Pin Relay With Internal
Suppression Resistor
55Key Switch
56Temperature Switch
Normally Open
57Temperature Switch
Normally Closed
58Pressure Switch Normally
Open
59Pressure Switch Normally
Closed
60Liquid Level Switch
Normally Open
61Liquid Level Switch
Normally Closed
62Momentary Switch
Normally Open
63Momentary Switch
Normally Closed
64Toggle Switch Normally
Open
65Toggle Switch Normally
Closed
662 Way Toggle Switch
Normally Open
672 Way Toggle Switch
Normally Closed
68Manual Switch Operation
69Push Switch Operation
70Pull Switch Operation
71Turn Switch Operation
72Toggle Switch Operation
73Pedal Switch Operation
74Key Switch Operation
75Detent Switch Operation
76Temperature Sensor
77Solar Sensor
78Pressure Sensor
79Liquid Level Sensor
9015
05
31
CED,TX17984,458 1928FEB002/2
TM1663 (28NOV01)
9015-05-31
PN=191
System Information
9015
05
32
TM1663 (28NOV01)
9015-05-32
PN=192
Group 10
System Diagrams
Fuse Specifications
IMPORTANT: Install fuse with correct amperage
rating to prevent electrical system
damage from overload.
UN06MAR92
9015
10
1
T7713AJ
CED,TX02661,227 1914DEC981/1
TM1663 (28NOV01)
9015-10-1
PN=193
System Diagrams
Color
Black
Violet
Pink
Tan
7-1/2
Brown
10
Red
15
Light Blue
20
Yellow
25
Natural (White)
30
Light Green
9015
10
2
CED,TX14795,4106 1922NOV971/1
TM1663 (28NOV01)
9015-10-2
PN=194
System Diagrams
Type
Examples
Condenser, capacitor
9015
10
3
Protection device
Relay
Inductor
Motor
Regulator, amplifier
Measuring instrument
Resistor
TM1663 (28NOV01)
9015-10-3
TX,10,111507 1922AUG961/2
PN=195
System Diagrams
Identification Letter
9015
10
4
Type
Examples
Switch
Transformer
Modulator, converter
DC transformers
Electrical filter
TX,10,111507 1922AUG962/2
TM1663 (28NOV01)
9015-10-4
PN=196
System Diagrams
TM1663 (28NOV01)
9015-10-5
CED,OUTX782,72 1904JAN991/4
PN=197
9015
10
5
System Diagrams
9015
10
6
TM1663 (28NOV01)
9015-10-6
CED,OUTX782,72 1904JAN992/4
PN=198
System Diagrams
K28Air Conditioner Blower Motor (High Speed)
Relay (SE17, W9)
TM1663 (28NOV01)
9015-10-7
CED,OUTX782,72 1904JAN993/4
PN=199
9015
10
7
System Diagrams
9015
10
8
CED,OUTX782,72 1904JAN994/4
TM1663 (28NOV01)
9015-10-8
PN=200
System Diagrams
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
SE7Engine and Pump Controller Circuit
SE8Engine and Pump Controller Circuit
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
9015
10
9
CED,TX02661,229 1922DEC981/1
TM1663 (28NOV01)
9015-10-9
PN=201
System Diagrams
CED,OUTX782,64 1922DEC981/1
TM1663 (28NOV01)
9015-10-10
PN=202
System Diagrams
CED,OUTX782,65 1921DEC981/1
TM1663 (28NOV01)
9015-10-11
PN=203
System Diagrams
CED,OUTX782,66 1921DEC981/1
TM1663 (28NOV01)
9015-10-12
PN=204
System Diagrams
CED,OUTX782,67 1917DEC981/1
TM1663 (28NOV01)
9015-10-13
PN=205
System Diagrams
CED,OUTX782,68 1921DEC981/1
TM1663 (28NOV01)
9015-10-14
PN=206
System Diagrams
CED,OUTX782,69 1921DEC981/1
TM1663 (28NOV01)
9015-10-15
PN=207
System Diagrams
CED,OUTX782,70 1921DEC981/1
TM1663 (28NOV01)
9015-10-16
PN=208
System Diagrams
Engine and Frame Harness (W1) Connectors, Wire and Pin Location
T118958
1911DEC98
9015
10
17
TM1663 (28NOV01)
9015-10-17
CED,OUTX782,71 1921DEC981/3
PN=209
System Diagrams
T118959
1911DEC98
9015
10
18
TM1663 (28NOV01)
9015-10-18
CED,OUTX782,71 1921DEC982/3
PN=210
System Diagrams
T118104
1917NOV98
9015
10
19
CED,OUTX782,71 1921DEC983/3
TM1663 (28NOV01)
9015-10-19
PN=211
System Diagrams
CED,TX02661,242 1904NOV981/1
TM1663 (28NOV01)
9015-10-20
PN=212
System Diagrams
CED,OUTX782,73 1921DEC981/1
TM1663 (28NOV01)
9015-10-21
PN=213
System Diagrams
T117202
1917NOV98
9015
10
22
CED,OUTX782,1 1917NOV981/1
TM1663 (28NOV01)
9015-10-22
PN=214
System Diagrams
T118464
1917NOV98
9015
10
23
TM1663 (28NOV01)
9015-10-23
CED,TX02661,244 1904NOV981/5
PN=215
System Diagrams
T118465
1914DEC98
9015
10
24
TM1663 (28NOV01)
9015-10-24
CED,TX02661,244 1904NOV982/5
PN=216
System Diagrams
T118466
1917NOV98
9015
10
25
TM1663 (28NOV01)
9015-10-25
CED,TX02661,244 1904NOV983/5
PN=217
System Diagrams
T118493
1905JAN99
9015
10
26
TM1663 (28NOV01)
9015-10-26
CED,TX02661,244 1904NOV984/5
PN=218
System Diagrams
T118494
1917NOV98
9015
10
27
CED,TX02661,244 1904NOV985/5
TM1663 (28NOV01)
9015-10-27
PN=219
System Diagrams
CED,OUTX782,74 1921DEC981/1
TM1663 (28NOV01)
9015-10-28
PN=220
System Diagrams
T119181
1923DEC98
9015
10
29
CED,OUTX782,75 1922DEC981/1
TM1663 (28NOV01)
9015-10-29
PN=221
System Diagrams
T118900
1919FEB99
9015
10
30
CED,OUTX782,76 1921DEC981/1
TM1663 (28NOV01)
9015-10-30
PN=222
System Diagrams
Monitor and Relay Harness (W3) Connectors, Wire and Pin Location
T118352
1917NOV98
9015
10
31
TM1663 (28NOV01)
9015-10-31
CED,TX02661,248 1904NOV981/2
PN=223
System Diagrams
T118497
1917NOV98
9015
10
32
CED,TX02661,248 1904NOV982/2
TM1663 (28NOV01)
9015-10-32
PN=224
System Diagrams
CED,TX02661,249 1904NOV981/1
CED,TX02661,250 1904NOV981/1
9015
10
33
TM1663 (28NOV01)
9015-10-33
PN=225
System Diagrams
9015
10
34
TM1663 (28NOV01)
9015-10-34
PN=226
Group 15
Sub-System Diagnostics
Power Circuit Operational Information
The following conditions must be met for the circuits to
function:
With key switch S1 OFF, voltage must be present at
the following:
CED,OUOE012,10 1914DEC981/1
TM1663 (28NOV01)
9015-15-1
PN=227
9015
15
1
Sub-System Diagnostics
9015
15
2
CED,OUOE012,11 1914DEC981/1
TM1663 (28NOV01)
9015-15-2
PN=228
Sub-System Diagnostics
CED,OUOE012,39 1903FEB991/1
TM1663 (28NOV01)
9015-15-3
PN=229
Sub-System Diagnostics
1 Power Circuit Diagnostic Procedures
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
9015
15
4
Is 24 to 28 volts measured?
T7487AF UN20MAR91
1/1
Is continuity measured?
T109319 UN28APR97
1/1
T109319 UN28APR97
1/1
TM1663 (28NOV01)
9015-15-4
PN=230
Sub-System Diagnostics
Key Switch (S1) Check
1B Terminal
2G1 Terminal
3G2 Terminal
4ACC Terminal
5M Terminal
6ST Terminal
1B Terminal
2G1 Terminal
3G2 Terminal
4ACC Terminal
5M Terminal
6ST Terminal
1B Terminal
2G1 Terminal
3G2 Terminal
4ACC Terminal
5M Terminal
6ST Terminal
1/1
Is continuity measured?
1/1
TM1663 (28NOV01)
9015-15-5
PN=231
Sub-System Diagnostics
Battery Relay Coil
Suppression Diode (V11)
Check
NOTE: A diode can fail in two modes, either shorted or open. Continuity will be
measured in one direction only in a serviceable diode. Use diode checking mode on
meter when checking continuity.
YES: If continuity is
measured in both checks,
diode has failed in a
shorted mode. Replace.
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
and not the other, diode
is OK.
T118385 UN21NOV98
9015
15
6
Fuse Check
YES: Fuse is OK
NO: Replace fuse.
T7468AF UN14MAR91
1/1
TM1663 (28NOV01)
9015-15-6
PN=232
Sub-System Diagnostics
9015
15
7
TM1663 (28NOV01)
9015-15-7
PN=233
Sub-System Diagnostics
CED,OUOE012,12 1926OCT981/1
CED,OUOE012,28 1902NOV981/1
TM1663 (28NOV01)
9015-15-8
PN=234
Sub-System Diagnostics
T117942
1918NOV98
9015
15
9
CED,OUOE012,29 1902NOV981/1
TM1663 (28NOV01)
9015-15-9
PN=235
Sub-System Diagnostics
T118584
1921NOV98
9015
15
10
AAlternator
BInternal Ground
CNegative Diodes
DExciter Diodes
EStator Windings
FPositive Diodes
GD+ Terminal
HB+ Terminal
INoise Filter
JExcitation Winding
KRegulator
LExternal Ground Terminal
MRotor
NAlternator Excitation
Resistor
TM1663 (28NOV01)
OBattery
PKey Switch
QDisplay Monitor
RBrushes
SSense Circuit
9015-15-10
CED,OUOE012,13 1921DEC981/2
PN=236
Sub-System Diagnostics
The alternating current induced in the stator winding
(E) is rectified by the positive and negative diodes (F
and C) and delivered to the battery and current
consuming accessories. The currents in the stator
winding (E) are constantly changing magnitude and
direction. However, current flowing to the battery and
accessories always maintains the same direction. This
is because no matter what position the rotor (M) is in,
all the diodes are simultaneously involved in the
process of rectification. The regulator (K) measures the
CED,OUOE012,13 1921DEC982/2
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: 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
TM1663 (28NOV01)
9015-15-11
PN=237
Sub-System Diagnostics
Alternator Voltage
Indicator Light (H18)
Check
Engine OFF.
T6768CR UN18OCT88
Start engine.
9015
15
12
1/1
Alternator Voltage
Indicator Light Harness
Check
T118386 UN21NOV98
1/1
TM1663 (28NOV01)
9015-15-12
PN=238
Sub-System Diagnostics
Alternator Shut Down
Relay Isolation Diode
(V2) Check
NOTE: A diode can fail in two modes, either shorted or open. Continuity will be
measured in one direction only in a serviceable diode. Use diode checking mode on
meter when checking continuity.
YES: If continuity is
measured in both checks,
diode has failed in a
shorted mode. Replace.
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
and not the other, diode
is OK.
T118385 UN21NOV98
9015
15
13
Is continuity measured?
T109319 UN28APR97
1/1
1/1
TM1663 (28NOV01)
9015-15-13
PN=239
Sub-System Diagnostics
9015
15
14
CED,OUOE012,14 1927OCT981/1
CED,OUOE012,15 1914DEC981/1
TM1663 (28NOV01)
9015-15-14
PN=240
Sub-System Diagnostics
CED,OUOE012,16 1903FEB991/1
TM1663 (28NOV01)
9015-15-15
PN=241
Sub-System Diagnostics
1 Starting and Fuel Shutoff Circuit Diagnostic Procedures
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
1B Terminal
2G1 Terminal
3G2 Terminal
4ACC Terminal
5M Terminal
6ST Terminal
9015
15
16
1B Terminal
2G1 Terminal
3G2 Terminal
4ACC Terminal
5M Terminal
6ST Terminal
1/1
TM1663 (28NOV01)
9015-15-16
PN=242
Sub-System Diagnostics
Starter (M1) Solenoid
Check
T118428 UN21NOV98
1/1
T6534BJ UN07JAN97
1/1
T7466AD UN14MAR91
1/1
TM1663 (28NOV01)
9015-15-17
PN=243
Sub-System Diagnostics
Start Relay Coil
Suppression Diode (V9)
Check
NOTE: A diode can fail in two modes, either shorted or open. Continuity will be
measured in one direction only in a serviceable diode. Use diode checking mode on
meter when checking continuity.
YES: If continuity is
measured in both checks,
diode has failed in a
shorted mode. Replace.
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
and not the other, diode
is OK.
T118385 UN21NOV98
9015
15
18
Is continuity measured?
1/1
T109319 UN28APR97
1/1
TM1663 (28NOV01)
9015-15-18
PN=244
Sub-System Diagnostics
Starter Protection Relay
(K11) Check
1/1
1/1
TM1663 (28NOV01)
9015-15-19
PN=245
Sub-System Diagnostics
Fuel Shutoff Solenoid
(Y7) Check
T118387 UN21NOV98
9015
15
20
1/1
NOTE: A diode can fail in two modes, either shorted or open. Continuity will be
measured in one direction only in a serviceable diode. Use diode checking mode on
meter when checking continuity.
YES: If continuity is
measured in both checks,
diode has failed in a
shorted mode. Replace.
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
and not the other, diode
is OK.
T118385 UN21NOV98
TM1663 (28NOV01)
9015-15-20
PN=246
Sub-System Diagnostics
Fuel Shutoff Solenoid
Pull-In Coil Suppression
Diode (V10) Check
NOTE: A diode can fail in two modes, either shorted or open. Continuity will be
measured in one direction only in a serviceable diode. Use diode checking mode on
meter when checking continuity.
YES: If continuity is
measured in both checks,
diode has failed in a
shorted mode. Replace.
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
and not the other, diode
is OK.
T118385 UN21NOV98
9015
15
21
TM1663 (28NOV01)
9015-15-21
PN=247
Sub-System Diagnostics
CED,OUOE012,8 1921OCT981/1
9015
15
22
TM1663 (28NOV01)
9015-15-22
PN=248
Sub-System Diagnostics
9015
15
23
TM1663 (28NOV01)
9015-15-23
CED,OUOE012,7 1915DEC981/3
PN=249
Sub-System Diagnostics
When the wiper motor reaches the intermittent stop
position (wiper blade at right side of window), terminal S
(which is applied to wiper motor terminal E through
contacts 3 and 4 of de-energized relay K6) is switched
from ground to +24 volts (from motor terminal B) by the
wiper motor internal switch. With +24 volts now at both
wiper motor terminals, E and L, the motor stops running.
After a few seconds, the cycle is repeated by another 1 to
2 second ground pulse from pin 28 of the monitor
controller and display.
Windshield Wiper Park Operation
9015
15
24
TM1663 (28NOV01)
9015-15-24
CED,OUOE012,7 1915DEC982/3
PN=250
Sub-System Diagnostics
Windshield Washer Operation
When windshield washer switch S15 is pressed,
windshield washer relay K2 is energized by a ground at
pin 24 of monitor controller and display A5. Power is
applied to windshield washer motor M4 from windshield
wiper 10amp fuse F12 through contacts 3 and 5 of
energized relay K2. The motor drives the windshield
washer pump, to spray fluid from the windshield washer
fluid reservoir onto the windshield. When the switch is
released, ground is removed from pin 24 of monitor
controller and display A5, and the washer motor stops.
9015
15
25
CED,OUOE012,7 1915DEC983/3
TM1663 (28NOV01)
9015-15-25
PN=251
Sub-System Diagnostics
CED,OUOE012,9 1903FEB991/1
TM1663 (28NOV01)
9015-15-26
PN=252
Sub-System Diagnostics
1 Windshield Wiper and Washer Circuit Diagnostic Procedures
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
Windshield Wiper 10
Amp Fuse (F12) Check
1/1
TM1663 (28NOV01)
9015-15-27
PN=253
Sub-System Diagnostics
Windshield Wiper Motor
(M3) Run and
Intermittent Stop Check
T118388 UN21NOV98
Connect wiper motor connector pin E to ground (while still connected to S).
Does windshield wiper operate?
Remove ground from pin E.
Does windshield wiper continue operating until wiper blade reaches intermittent park
position, then stop?
1/1
T118388 UN21NOV98
1/1
TM1663 (28NOV01)
9015-15-28
PN=254
Sub-System Diagnostics
Windshield Wiper Motor
Suppression Diode (V6,
V7) Check
NOTE: A diode can fail in two modes, either shorted or open. Continuity will be
measured in one direction only in a serviceable diode.
YES: If continuity is
measured in both checks,
diode has failed in a
shorted mode. Replace.
NO: If continuity is NOT
measured in either check,
diode has failed in an
open mode. Replace.
T118385 UN21NOV98
The windshield wiper diodes are located inside right console lower cover.
NO: If continuity is
measured in one check
and not the other, diode
is OK.
Is continuity measured?
Reverse ohmmeter probes.
Is continuity measured?
Install diodes in connectors.
1/1
NOTE: A diode can fail in two modes, either shorted or open. Continuity will be
measured in one direction only in a serviceable diode.
YES: If continuity is
measured in both checks,
diode has failed in a
shorted mode. Replace.
NO: If continuity is NOT
measured in either check,
diode has failed in an
open mode. Replace.
T118385 UN21NOV98
The windshield wiper diodes are located inside right console lower cover.
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
TM1663 (28NOV01)
9015-15-29
PN=255
Sub-System Diagnostics
Windshield Wiper Relay
(Motor Ground and
Intermittent) (K6),
Windshield Wiper Relay
(Wiper Run) (K7),
Windshield Wiper Relay
(Hold for Park) (K8) and
Windshield Wiper Relay
(Motor Ground for Park)
(K9) Check
124-Volt Terminal
2Ground Terminal
3Relay Common
4Relay Normal Closed
5Relay Normal Open
9015
15
30
1/1
Windshield Washer
Relay (K2) Check
124-Volt Terminal
2Ground Terminal
3Relay Common
4Relay Normal Closed
5Relay Normal Open
1/1
Windshield Washer
Motor (M4) Check
1/1
TM1663 (28NOV01)
9015-15-30
PN=256
Sub-System Diagnostics
Windshield Wiper Enable
Switch (S14) Check
Remove windshield wiper enable switch retaining plate located in upper right hand
corner of cab.
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
1/1
TM1663 (28NOV01)
9015-15-31
PN=257
9015
15
31
Sub-System Diagnostics
9015
15
32
mode and RPM control unit A4, and the ILLUM pin of
radio A1 for panel illumination.
When the light switch is moved to position 2, pin 20 of
the monitor controller and display is also grounded (pin
19 remains grounded), energizing work light relay K3
as well. With the work light relay energized, power is
applied to work light E1 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
provide for connection of additional lights.
CED,OUOE012,19 1914DEC981/1
TM1663 (28NOV01)
9015-15-32
PN=258
Sub-System Diagnostics
T117934
1911DEC98
9015
15
33
CED,OUOE012,20 1921DEC981/1
TM1663 (28NOV01)
9015-15-33
PN=259
Sub-System Diagnostics
1 Work and Drive Light Circuit Diagnostic Procedures
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
9015
15
34
1/1
1/1
TM1663 (28NOV01)
9015-15-34
PN=260
Sub-System Diagnostics
Work Light Relay (K3)
Check
124-Volt Terminal
2Ground Terminal
3Relay Common
4Relay Normally Closed
5Relay Normally Open
1/1
Disconnect 16-pin harness connector from monitor controller and display panel.
Ground harness connector pin 19.
Does drive light operate with key switch in ACC position?
1/1
TM1663 (28NOV01)
9015-15-35
PN=261
Sub-System Diagnostics
Work Light (E1) Circuit
Check
Disconnect 16-pin harness connector from monitor controller and display panel.
Ground harness connector pin 20.
Does work light operate with key switch in ACC position?
9015
15
36
1/1
TM1663 (28NOV01)
9015-15-36
PN=262
Sub-System Diagnostics
9015
15
37
TM1663 (28NOV01)
9015-15-37
PN=263
Sub-System Diagnostics
9015
15
38
CED,OUOE012,22 1921DEC981/1
TM1663 (28NOV01)
9015-15-38
PN=264
Sub-System Diagnostics
T117936
1918NOV98
9015
15
39
CED,OUOE012,23 1921DEC981/1
TM1663 (28NOV01)
9015-15-39
PN=265
Sub-System Diagnostics
1 Accessory Circuits Diagnostic Procedures
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
9015
15
40
1/1
1/1
1/1
TM1663 (28NOV01)
9015-15-40
PN=266
Sub-System Diagnostics
Horn Relay (K5) Check
124-Volt Terminal
2Ground Terminal
3Relay Common
4Relay Normally Closed
5Relay Normally Open
Is continuity measured?
1/1
T108586 UN31MAR97
1/1
1/1
TM1663 (28NOV01)
9015-15-41
PN=267
Sub-System Diagnostics
Specification
Fuel Sending UnitResistance.................. 10 +0 -4 Ohms With Fuel
Gauge Reading Full
Fuel Sending UnitResistance......... 38 5 Ohms With Fuel Gauge
Reading Half
Fuel Sending UnitResistance................ 90 +10 -0 Ohms With Fuel
Gauge Reading Empty
Fuel Level Switch Closes At
Level .................................................... 112 mm (4.4 in.) Fuel In Tank
Or Less (30.337.9 L) (810
gal)
Engine Oil Pressure Switch
Opens AtPressure ......................... Above 172 kPa (1.72 bar) (24.9
psi)
Engine Oil Pressure Switch
Closes AtPressure ........................ Below 103 kPa (1.03 bar) (14.9
psi)
Engine Coolant Temperature
Switch Closes OnIncreasing
Temperature Maximum ........................... 110C 3C (230F 37F)
Engine Coolant Temperature
Switch Opens OnDecreasing
Temperature Minimum.................................................... 95C (203F)
Alternator Charge Light
Illuminates At Alternator
Excitation Field Output
Voltage ............................................................. 10 1.5 Volts Or Less
CED,OUTX782,143 1903FEB991/1
TM1663 (28NOV01)
9015-15-42
PN=268
Sub-System Diagnostics
9015
15
43
TM1663 (28NOV01)
9015-15-43
PN=269
Sub-System Diagnostics
CED,OUOE012,26 1931OCT981/1
9015
15
44
TM1663 (28NOV01)
9015-15-44
PN=270
Sub-System Diagnostics
9015
15
45
TM1663 (28NOV01)
9015-15-45
CED,OUOE012,55 1904OCT001/6
PN=271
Sub-System Diagnostics
Air Filter Restriction Indicator Light (H14)
The air filter restriction switch (B1) is a normally open
switch that closes to machine ground when a restriction is
sensed with the engine running. The machine ground is
applied to controller pin 3, causing the indicator to
illuminate.
Fuel Level Indicator Light (H13)
The fuel level switch (B2) is normally open when fuel is in
the tank, and closes to machine ground when the fuel
level is below 112 mm (4.4 in.). The machine ground is
applied to controller pin 2, causing the indicator to
illuminate.
9015
15
46
TM1663 (28NOV01)
9015-15-46
CED,OUOE012,55 1904OCT002/6
PN=272
Sub-System Diagnostics
Engine Coolant Level Indicator (H20)
Engine coolant level switch (B6) is a normally open
switch, held closed when the coolant level is adequate.
When closed, the switch applies machine ground to
controller pin 8. The monitor controller only checks the
status of pin 8 when the fluid level switch (S5) is pressed.
If ground is present when the switch is pressed, the
indicator illuminates.
Engine Oil Level Indicator (H19)
Engine oil level switch (B7) is a normally open switch,
held closed with adequate oil level. When closed, the
switch applies machine ground to controller pin 7. The
monitor controller only checks the status of pin 7 when the
fluid level switch (S5) is pressed. If ground is present
when the switch is pressed, the indicator illuminates.
9015
15
47
TM1663 (28NOV01)
9015-15-47
CED,OUOE012,55 1904OCT003/6
PN=273
Sub-System Diagnostics
CONTROL SWITCHES AND INDICATORS
Wiper Speed Switch (S9)
The wiper speed switch is used to select intermittent or
continuous windshield wiper operation. The monitor
controller provides ground switched outputs to the
windshield wiper circuit from controller pins 24, 26, 27,
and 28 based on the setting of the wiper speed switch. If
the windshield is open, a ground from windshield wiper
enable switch S14 is allied to monitor controller pin 6,
disabling the wiper speed switch.
Windshield Washer Switch (S15)
9015
15
48
TM1663 (28NOV01)
9015-15-48
CED,OUOE012,55 1904OCT004/6
PN=274
Sub-System Diagnostics
Mode
Pin 21a
Pin 22a
Dig
Grading
Precision
Attachment
9015
15
49
TM1663 (28NOV01)
9015-15-49
CED,OUOE012,55 1904OCT005/6
PN=275
Sub-System Diagnostics
Engine RPM Dial (R10)
The engine RPM dial provides a variable voltage to
engine and pump controller pin D21 from engine mode
and RPM control unit pin 6 based on the setting of the
RPM dial. Power for the RPM dial is applied across
engine mode and RPM control unit pins 5 and 7.
CED,OUOE012,55 1904OCT006/6
9015
15
50
TM1663 (28NOV01)
9015-15-50
PN=276
Sub-System Diagnostics
CED,OUTX782,77 1915JAN991/1
TM1663 (28NOV01)
9015-15-51
PN=277
Sub-System Diagnostics
1 Monitor Controller and Display Circuit Diagnostic Procedures
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
1/1
T118378 UN21NOV98
1/1
TM1663 (28NOV01)
9015-15-52
PN=278
Sub-System Diagnostics
Monitor Controller And
Display (A5) Harness
Ground Check
T118378 UN21NOV98
With key switch ON and economy mode OFF, push economy (E) mode switch.
Does switch stay down and economy mode indicator light come ON?
NO: Go to next check.
Push economy (E) mode switch again.
Does switch return to original position and indicator go OFF?
1/1
T118513 UN21NOV98
TM1663 (28NOV01)
9015-15-53
PN=279
Sub-System Diagnostics
Economy (E) Mode
Switch (S11) Harness
Check
T118512 UN21NOV98
9015
15
54
1/1
With key switch ON and high power mode OFF, push high power (HP) mode switch.
Does switch stay down and high power mode indicator light come ON?
NO: Go to next check.
Push high power (HP) mode switch again.
Does switch return to original position and indicator go OFF?
1/1
T118515 UN21NOV98
TM1663 (28NOV01)
9015-15-54
PN=280
Sub-System Diagnostics
High Power (HP) Mode
Switch (S12) Harness
Check
T118514 UN21NOV98
9015
15
55
1/1
Push WORK MODE switch several times to cycle through all work mode selections
(dig, grading precision, attachments).
Does mode selection change when switch is pressed?
1/1
1/1
TM1663 (28NOV01)
9015-15-55
PN=281
Sub-System Diagnostics
Alternator Voltage
Indicator Light (H18)
Check
Engine OFF.
T6768CR UN18OCT88
Start engine.
9015
15
56
1/1
Alternator Voltage
Indicator Light Harness
Check
T118386 UN21NOV98
1/1
TM1663 (28NOV01)
9015-15-56
PN=282
Sub-System Diagnostics
Engine Coolant Level
Indicator Light (H20)
Check
T7469AK UN14MAR91
9015
15
57
T102542 UN29AUG96
1/1
1/1
TM1663 (28NOV01)
9015-15-57
PN=283
Sub-System Diagnostics
Engine Oil Level
Indicator Light (H19)
Check
T7469AM UN11MAR91
T101681 UN29AUG96
Check oil level in engine pan, be sure level is between FULL and ADD marks on dip
stick.
Turn key switch ON.
Observe engine oil level indicator.
Does indicator come ON then go OFF 23 seconds later?
9015
15
58
T102542 UN29AUG96
1/1
1/1
TM1663 (28NOV01)
9015-15-58
PN=284
Sub-System Diagnostics
Hydraulic Oil Level
Indicator Light (H12)
Check
T7470AI UN11MAR91
T101683 UN29AUG96
Check oil level in hydraulic reservoir. Be sure level is between red lines on sight
gauge.
Turn key switch ON.
Observe hydraulic oil level indicator.
Does indicator come ON then go OFF 23 seconds later?
T102542 UN29AUG96
1/1
1/1
TM1663 (28NOV01)
9015-15-59
PN=285
9015
15
59
Sub-System Diagnostics
Engine Coolant
Temperature Indicator
Light (H16) Check
T101686 UN29AUG96
1/1
Engine Coolant
Temperature Switch (B3)
9015
Check
15
60
1/1
T101684 UN29AUG96
1/1
Start engine.
1/1
TM1663 (28NOV01)
9015-15-60
PN=286
Sub-System Diagnostics
Air Filter Restriction
Indicator Light (H14)
Check
1/1
T118382 UN21NOV98
1/1
T118389 UN30NOV98
Disconnect 20-pin harness connector from monitor display and controller connector.
Connect 24 volts to 20-pin monitor display and controller pin 30.
Then ground pin 46.
Does gauge needle point to E with 24 volts applied to pin 30, and F with pin 46
grounded?
1/1
TM1663 (28NOV01)
9015-15-61
PN=287
9015
15
61
Sub-System Diagnostics
Fuel Gauge Resistor (R5)
Check
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.
Connect ohmmeter to resistor terminals.
Does ohmmeter read about 220 ohms?
9015
15
62
1/1
1/1
1/1
TM1663 (28NOV01)
9015-15-62
PN=288
Sub-System Diagnostics
Fuel Level Switch (B2)
Check
1/1
Engine Coolant
Temperature Gauge (P2)
Check
Disconnect 20-pin harness connector from monitor display and controller connector.
Connect 24 volts to 20-pin monitor display and controller pin 30.
Then ground pin 47.
Does gauge needle point to C with 24 volts applied to pin 30, and H with pin 47
grounded?
1/1
Engine Coolant
Temperature Gauge
Resistor (R4) Check
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.
Connect ohmmeter to resistor terminals.
Does ohmmeter read about 220 ohms?
1/1
TM1663 (28NOV01)
9015-15-63
PN=289
9015
15
63
Sub-System Diagnostics
Engine Coolant
Temperature Sensor (B9)
Check
1/1
9015
15
64
TM1663 (28NOV01)
9015-15-64
PN=290
Sub-System Diagnostics
9015
15
65
TM1663 (28NOV01)
9015-15-65
PN=291
Sub-System Diagnostics
CED,TX14795,4140 1921DEC981/1
9015
15
66
TM1663 (28NOV01)
9015-15-66
PN=292
Sub-System Diagnostics
TM1663 (28NOV01)
9015-15-67
CED,OUOE012,33 1915DEC981/2
PN=293
Sub-System Diagnostics
Auto A/I Idle Mode
An RPM dial is provided to vary engine speed to any
speed between slow idle and fast idle if E or HP modes
do not provide a speed adequate to the job. Each time the
engine is started, the EPC automatically activates the idle
mode to run the engine at the engine RPM dial setting.
9015
15
68
CED,OUOE012,33 1915DEC982/2
TM1663 (28NOV01)
9015-15-68
PN=294
Sub-System Diagnostics
CED,OUOE012,34 1903FEB991/1
TM1663 (28NOV01)
9015-15-69
PN=295
Sub-System Diagnostics
1 Engine and Pump Controller Circuit Diagnostic Procedures
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
1/1
1/1
1/1
TM1663 (28NOV01)
9015-15-70
PN=296
Sub-System Diagnostics
Solenoid 5 Amp Fuse
(F4) Check
1/1
T118380 UN21NOV98
1/1
T118393 UN30NOV98
TM1663 (28NOV01)
9015-15-71
PN=297
9015
15
71
Sub-System Diagnostics
Engine Control (EC)
Sensor (B17) Check
T118392 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Disconnect harness from EC sensor.
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
that from pin 1 to pin 2?
9015
15
72
1/1
TM1663 (28NOV01)
9015-15-72
PN=298
Sub-System Diagnostics
Engine Control (EC)
Sensor (B17) Harness
Check
1Positive Pin
2Sense Pin
3Negative Pin
T118379 1930NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Turn key switch OFF.
Disconnect harness from EC sensor.
Connect jumper wire between sensor harness connector pins 1 and 2.
Disconnect 22-pin connector D and 16-pin connector B from engine and pump
controller.
Measure continuity between pin 9 of connector B and pin 15 of connector D.
Is continuity measured?
1/1
TM1663 (28NOV01)
9015-15-73
PN=299
9015
15
73
Sub-System Diagnostics
Engine Speed (N) Sensor
(B16) Check
Start engine.
Measure AC voltage at speed sensor terminals. Increase
engine speed.
Does AC voltage increase as engine speed increases?
9015
15
74
1/1
T118373 1930NOV98
1/1
TM1663 (28NOV01)
9015-15-74
PN=300
Sub-System Diagnostics
Economy (E) Mode
Output to Engine and
Pump Controller Harness
Check
9015
15
75
T118394 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 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
TM1663 (28NOV01)
9015-15-75
PN=301
Sub-System Diagnostics
Mode 1 Output to Engine
and Pump Controller
Harness Check
9015
15
76
T118395 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 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
TM1663 (28NOV01)
9015-15-76
PN=302
Sub-System Diagnostics
Auto Idle to System
Controller Harness
Check
9015
15
77
T118381 1921NOV98
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
TM1663 (28NOV01)
9015-15-77
PN=303
Sub-System Diagnostics
Engine RPM Dial (R10)
Harness Check
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
TM1663 (28NOV01)
9015-15-78
PN=304
Sub-System Diagnostics
Power Boost Switch
(S19) Check
T118538 1921NOV98
9015
15
79
T118486 UN21NOV98
1/1
TM1663 (28NOV01)
9015-15-79
PN=305
Sub-System Diagnostics
Arm In Pressure Sensor
(B20) Harness Check
T118372 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Turn key switch OFF.
Disconnect harness from arm in pressure sensor.
Connect voltmeter to sensor harness connector pin 1 and ground.
9015
15
80
T118371 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Turn key switch OFF.
Connect ohmmeter to sensor harness connector pin 3 and ground.
Does ohmmeter read continuity?
1/2
TM1663 (28NOV01)
9015-15-80
PN=306
Sub-System Diagnostics
YES: Wire harness is OK.
Go to next check.
NO: Wire from pin 18 of
connector D to pin 2 of
sensor harness connector
has failed. Repair.
9015
15
81
T118358 1921NOV98
Install pump control test harness JT07353 in series with wiring harness and sensor.
Connect voltmeter to test harness jacks.
With engine running, pilot control lever forward, and hydraulic functions in neutral,
observe voltage.
1/1
TM1663 (28NOV01)
9015-15-81
PN=307
Sub-System Diagnostics
Rear Pump Control
Pressure Sensor (B21)
and Front Control
Pressure Sensor (B22)
Harness Check
T118372 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Turn key switch OFF.
Disconnect wiring harness connector from front (B22) or rear (B21) pump control
pressure sensor.
9015
15
82
T118371 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Turn key switch OFF.
Connect ohmmeter to sensor harness connector pin 3 and ground.
Does ohmmeter read continuity?
1/2
TM1663 (28NOV01)
9015-15-82
PN=308
Sub-System Diagnostics
YES: Wire harness is OK.
Go to next check.
NO: Wire from connector
D to sensor harness
connector pin 2 has
failed. Repair.
9015
15
83
T118359 1921NOV98
Install pump control test harness JT07353 in series with wiring harness and sensor.
Connect voltmeter to test harness jacks.
With engine running, pilot control lever forward, and hydraulic functions in neutral,
observe voltmeter.
TM1663 (28NOV01)
9015-15-83
PN=309
Sub-System Diagnostics
Rear Pump Pressure
Sensor (B18) and Front
Pump Pressure Sensor
(B19) Sensor Harness
Check
T118369 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Turn key switch OFF.
Disconnect wiring harness connector from front (B19) or rear (B18) pump pressure
sensor.
9015
15
84
T118368 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Turn key switch OFF.
Connect ohmmeter to sensor harness connector pin 3 and ground.
Does ohmmeter read continuity?
1/2
TM1663 (28NOV01)
9015-15-84
PN=310
Sub-System Diagnostics
YES: Wire harness is OK.
Go to next check.
NO: Wire from connector
D to sensor harness
connector pin 2 has
failed. Repair.
9015
15
85
T118370 1921NOV98
1Positive Pin
2Sense Pin
3Negative Pin
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.
Measure continuity between pin 9 of harness connector B and pin 16 of harness
connector D (for front pressure sensor), or pin 17 of harness connector D (for rear
pressure sensor) .
Is continuity measured?
19 2/2
TM1663 (28NOV01)
9015-15-85
PN=311
Sub-System Diagnostics
Rear Pump Pressure
Sensor (B18) and Front
Pump Pressure Sensor
(B19) Check
1Positive Pin
2Sense Pin
3Negative Pin
Install pump pressure sensor test harness JT07354 in series with wiring harness and
sensor.
Connect voltmeter to test harness jacks.
9015
15
86
With engine running, pilot control lever forward, and hydraulic functions in neutral,
observe voltmeter.
Is voltage 0.5 - 0.7 volts?
Actuate arm in to achieve hydraulic function over relief.
Does voltage increase to 3.3 - 3.5 volts with hydraulic function over relief?
1/1
Boom Up Pressure
Switch (B13) Check
T112437 UN05DEC97
1/1
T112437 UN05DEC97
1/1
TM1663 (28NOV01)
9015-15-86
PN=312
Sub-System Diagnostics
Propel Pressure Switch
(B15) Check
T112437 UN05DEC97
1/1
124-Volt Terminal
2Ground Terminal
3Relay Common
4Relay Normally Closed
5Relay Normally Open
1/1
Is continuity measured?
1/1
TM1663 (28NOV01)
9015-15-87
PN=313
Sub-System Diagnostics
Propel Auto Idle Relay
(K10) Harness Check
T118561 UN21NOV98
9015
15
88
124-Volt Pin
2Ground Pin
3Relay Common
4Relay Normally Closed
5Relay Normally Open
Turn key switch OFF.
Disconnect wiring harness at propel pressure switch.
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
TM1663 (28NOV01)
9015-15-88
PN=314
Sub-System Diagnostics
124-Volt Pin
2Ground Terminal
3Relay Common 5 Volts To D9
4Relay Normally Closed
5Relay Normally Open To Ground
19 2/2
NOTE: A diode can fail in two modes, either shorted or open. Continuity will be
measured in one direction only in a serviceable diode. Use diode checking mode on
meter when checking continuity.
YES: If continuity is
measured in both checks,
9015
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
and not the other, diode
is OK.
T118385 UN21NOV98
1/1
TM1663 (28NOV01)
9015-15-89
PN=315
Sub-System Diagnostics
Propel Speed Change
Proportional Solenoid
(Y6) Harness Check
1/1
Arm Regenerative
Proportional Solenoid
9015
(Y9) Check
15
90
1/1
Arm Regenerative
Proportional Solenoid
(Y9) Harness Check
1/1
TM1663 (28NOV01)
9015-15-90
PN=316
Sub-System Diagnostics
Power Boost
Proportional Solenoid
(Y5) Check
1/1
Power Boost
Proportional Solenoid
(Y5) Harness Check
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?
Hold power boost switch pressed.
Does the voltage drop to 5 volts after approximately 8 seconds?
1/1
Speed Sense
Proportional Solenoid
(Y8) Check
1/1
TM1663 (28NOV01)
9015-15-91
PN=317
Sub-System Diagnostics
Speed Sense
Proportional Solenoid
(Y8) Harness Check
1/1
9015
15
92
T118558 1921NOV98
1/1
TM1663 (28NOV01)
9015-15-92
PN=318
Sub-System Diagnostics
9015
15
93
TM1663 (28NOV01)
9015-15-93
PN=319
Sub-System Diagnostics
Key switch ON
Voltage present at travel alarm 5-amp fuse F10
CED,OUOE012,36 1921DEC981/1
9015
15
94
CED,OUOE012,37 1921DEC981/1
TM1663 (28NOV01)
9015-15-94
PN=320
Sub-System Diagnostics
T117932
1930NOV98
9015
15
95
CED,OUOE012,38 1903FEB991/1
TM1663 (28NOV01)
9015-15-95
PN=321
Sub-System Diagnostics
1 Travel Alarm Circuit Diagnostic Procedures
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
9015
15
96
Is continuity measured?
1/1
TM1663 (28NOV01)
9015-15-96
PN=322
Sub-System Diagnostics
Travel Alarm (H10)
Harness Check
T118563 UN21NOV98
9015
15
97
T118562 UN21NOV98
T118564 UN21NOV98
1/1
TM1663 (28NOV01)
9015-15-97
PN=323
Sub-System Diagnostics
Travel Alarm (H10)
Check
T8037BB UN30JUN93
1/1
9015
15
98
T118559 UN21NOV98
1/1
TM1663 (28NOV01)
9015-15-98
PN=324
Group 20
References
Battery Operation
SPECIFICATIONS
Percent Charged For Stabilized
Open Circuit Voltage 12.6 Volts
or More
100%
75%
50%
25%
0%
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
TM1663 (28NOV01)
9015-20-1
PN=325
9015
20
1
References
9015
20
2
Symptom
Problem
Solution
Regulator
Frozen battery
CED,TX14795,4149 1905AUG971/1
TM1663 (28NOV01)
9015-20-2
PN=326
References
9015
20
3
TM1663 (28NOV01)
9015-20-3
PN=327
References
TS203
9015
20
4
TM1663 (28NOV01)
9015-20-4
TX,16,UU3540 1901SEP951/2
PN=328
References
UN09SEP03
T6996DB
T6996DA
UN09SEP03
9015
20
5
TM1663 (28NOV01)
9015-20-5
PN=329
References
1. VISUAL CHECK
a. Check for damage such as cracked or broken
case and electrolyte leakage.
If damage is seen, replace battery.
b. Check electrolyte level. (See procedure in this
group.)
If low, add distilled water to specified level and
charge battery.
9015
20
6
TX,16,UU3538 1901SEP951/1
TM1663 (28NOV01)
9015-20-6
PN=330
References
9015
20
7
UN24OCT91
T6713AH1
AMachine Batteries
BBooster Batteries
CED,TX14795,4152 1914MAY981/1
TM1663 (28NOV01)
9015-20-7
PN=331
References
Replacing Batteries
SPECIFICATIONS
Cold Cranking Amps at -18C
(0F) amps
1100 Amps
400 Minutes
9015
20
8
Specification
Cold Cranking Amps at -18C
(0F)Amps ............................................................................. 1100 amps
Minutes Reserve Capacity at 25
ampsReserve Capacity ....................................................... 400 Minutes
CED,TX14795,4153 1925JUN961/1
TM1663 (28NOV01)
9015-20-8
PN=332
References
CED,TX14795,4154 1913AUG981/1
TM1663 (28NOV01)
9015-20-9
PN=333
9015
20
9
References
T109427B
BSwitch
HHigh Level
LLow Level
MMedium Level
9015
20
10
CED,TX14795,4155 1925JUN961/1
TM1663 (28NOV01)
9015-20-10
PN=334
References
TM1663 (28NOV01)
9015-20-11
PN=335
References
9015
20
12
TM1663 (28NOV01)
9015-20-12
PN=336
Section 9020
Power Train
Contents
Page
9020
Group 20Adjustments
Track Sag . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1
TM1663 (28NOV01)
9020-1
PN=1
Contents
9020
TM1663 (28NOV01)
9020-2
PN=2
Group 05
Theory of Operation
T7827AJ
1928OCT92
ATrack Frame
BNut
CSpring
DSeal
EPiston
FIdler
GYoke
HCylinder Barrel
IGrease
JAdapter
KFitting
LTrack Adjuster
TX,05,GG2177 1919MAY981/1
TM1663 (28NOV01)
9020-05-1
PN=339
9020
05
1
Theory of Operation
T102862
1912AUG96
9020
05
2
ARing Gear
BThird Planet Carrier
CThird Planet Sun Gear
DSecond Planet Carrier
ESecond Planet Sun Gear
TM1663 (28NOV01)
9020-05-2
NHub
OPropel Motor
PMetal Face Seal
QPropel Gearbox
TX,05,GG2170 1905SEP001/2
PN=340
Theory of Operation
The propel gearbox (Q) is a triple reduction planetary
drive gearbox. The gearbox is interchangeable from
the right to the left side of the machine. The propel
motor (O) is connected to and drives the first planet
sun gear (G).
Rotary motion is transferred from the first planet sun
gear (G) to the sprocket (L) by the three planetary
gear sets that mesh with the ring gear (A). As the first
planet sun gear rotates it turns the first planet gears (I)
which orbit, causing the first planet carrier (F) to rotate.
The first planet carrier is connected to the second
planet sun gear (E) which is in mesh with and rotates
the second planet gears (J). The second planet gears
TX,05,GG2170 1905SEP002/2
9020
05
3
TM1663 (28NOV01)
9020-05-3
PN=341
Theory of Operation
9020
05
4
TM1663 (28NOV01)
9020-05-4
PN=342
Group 15
Diagnostic Information
Diagnose Undercarriage Components
Malfunctions
NOTE: Diagnose malfunction charts are arranged from
most probable and simplest to verify, to least
likely and most difficult to verify.
Symptom
Problem
Solution
Loose shoes
TM1663 (28NOV01)
9020-15-1
902015,H15 1903JUN931/2
PN=343
9020
15
1
Diagnostic Information
Symptom
Popping Of Track
Problem
Solution
Individual Undercarriage
Component Wear
902015,H15 1903JUN932/2
TM1663 (28NOV01)
9020-15-2
PN=344
Diagnostic Information
T82865
UN08NOV88
Track Chain
9020
15
3
CED,OUOE003,615 1912SEP001/1
TM1663 (28NOV01)
9020-15-3
PN=345
Diagnostic Information
T82864
UN08NOV88
Track Chain
9020
15
4
CED,OUOE003,655 1912SEP001/1
TM1663 (28NOV01)
9020-15-4
PN=346
Diagnostic Information
T6813AL
UN29JAN98
Track Chain
9020
15
5
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
TM1663 (28NOV01)
9020-15-5
PN=347
Diagnostic Information
T82859
UN08NOV88
9020
15
6
TX,01,SB383 1911SEP001/1
TM1663 (28NOV01)
9020-15-6
PN=348
Diagnostic Information
T82859
UN08NOV88
9020
15
7
CED,OUOE003,1131 1911SEP001/1
TM1663 (28NOV01)
9020-15-7
PN=349
Diagnostic Information
T87973
UN08NOV88
Track Roller
TX,15,GG2211 1912SEP001/1
TM1663 (28NOV01)
9020-15-8
PN=350
Diagnostic Information
T6813AQ
UN29JAN98
9020
15
9
TX,15,GG2210 1912SEP001/1
TM1663 (28NOV01)
9020-15-9
PN=351
Diagnostic Information
T87972
UN08NOV88
Front Idler
9020
15
10
TX,15,GG2212 1912SEP001/1
TM1663 (28NOV01)
9020-15-10
PN=352
Diagnostic Information
UN23NOV92
T7886AI
T7886AJ
UN23NOV92
TM1663 (28NOV01)
9020-15-11
TX,15,GG2213 1929MAY981/2
PN=353
9020
15
11
Diagnostic Information
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
TM1663 (28NOV01)
9020-15-12
PN=354
Group 20
Adjustments
Adjust Track Sag
SPECIFICATIONS
Track Sag
300335 mm (11-13/16
13-3/16 in.)
T6876FG
Machine Weight
UN06DEC88
Track Chain
ESSENTIAL TOOLS
Grease Gun
OTHER MATERIAL
TY2098 Multi-Purpose Grease
9020
20
1
TM1663 (28NOV01)
9020-20-1
TX,20,GG2214 1905SEP001/3
PN=355
Adjustments
4. Measure track sag (A) at middle track roller from the
bottom of tack frame to the top surface of track shoe.
UN23FEB89
Track ChainSpecification
TrackSag ........................................................................... 300335 mm
(11-13/1613-3/16 in.)
T6457DL
ATrack Sag
TX,20,GG2214 1905SEP002/3
UN28NOV90
T7396DZ
UN22OCT92
T7869AQ
9020
20
2
Track ChainSpecification
Nut and Valve AssemblyTorque .............................. 147 Nm (108 lb-ft)
AGrease Fitting
BNut and Valve Assembly
CBleed Hole
DAccess Hole
TX,20,GG2214 1905SEP003/3
TM1663 (28NOV01)
9020-20-2
PN=356
Section 9025
Hydraulic System
Contents
Page
Page
TM1663 (28NOV01)
9025-1
PN=1
9025
Contents
Page
Page
Group 20Adjustment
Pilot Shut-Off Valve Linkage . . . . . . . . . . . . .9025-20-1
9025
Group 25Tests
Laptop Computer
General Description . . . . . . . . . . . . . . . . . .9025-25-1
Excavator Diagnostics Program
Overview . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-2
Uninstall. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-7
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8
Service Codes . . . . . . . . . . . . . . . . . . . . .9025-25-12
Monitor Data . . . . . . . . . . . . . . . . . . . . . .9025-25-13
Saving Monitor Data . . . . . . . . . . . . . . . .9025-25-15
Engine Speed Adjustment Special
Function . . . . . . . . . . . . . . . . . . . . . . . .9025-25-16
Service Codes List. . . . . . . . . . . . . . . . . .9025-25-20
Monitor Data Items . . . . . . . . . . . . . . . . .9025-25-21
Engine Speed Factory Settings Special
Function . . . . . . . . . . . . . . . . . . . . . . . .9025-25-23
Engine Speed to Pump Flow Rate
Chart . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-24
Troubleshooting . . . . . . . . . . . . . . . . . . . .9025-25-26
Reading Service Codes Without . . . . . . .9025-25-27
Engine and Pump Controller
Function. . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-29
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . .9025-25-30
JT05800 Digital Thermometer
Installation . . . . . . . . . . . . . . . . . . . . . . . .9025-25-30
JT02156 Digital Pressure and Temperature
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-31
Start-Up Procedure
Hydraulic Pump . . . . . . . . . . . . . . . . . . . .9025-25-32
Swing Motor . . . . . . . . . . . . . . . . . . . . . .9025-25-33
Swing Gearbox . . . . . . . . . . . . . . . . . . . .9025-25-34
Propel Motor . . . . . . . . . . . . . . . . . . . . . .9025-25-34
Hydraulic Oil Filter Inspection Procedure. . .9025-25-35
Hydraulic Oil Cleanup Procedure Using
Portable Filter Caddy . . . . . . . . . . . . . . . .9025-25-36
Hydraulic System Warm-Up Procedure . . . .9025-25-37
Lower Boom with Engine Stopped. . . . . . . .9025-25-38
Harness Test
Arm Regenerative (SC) Proportional
Solenoid Valve . . . . . . . . . . . . . . . . . . .9025-25-39
TM1663 (28NOV01)
9025-2
PN=2
Group 05
Theory of Operation
9025
05
1
TM1663 (28NOV01)
9025-05-1
PN=359
Theory of Operation
T116659
1924AUG98
9025
05
2
TM1663 (28NOV01)
9025-05-2
TX,9025,GG2136 1906SEP001/2
PN=360
Theory of Operation
1Left Pilot Controller
2Right Pilot Controller
3Propel Pilot Controller
4Pilot Shut-Off Valve
5Solenoid Valve Manifold
6Flow Regulator
7Arm Cylinder
8Boom Cylinder
9Bucket Cylinder
10Rotary Manifold
11Hydraulic Oil Tank
12Suction Screen
13Return Filter
14Swing Motor
15Right Propel Valve
Section
16Bucket Valve Section
25Pilot Pump
26Oil Cooler
27Restriction Valve
28Oil Cooler Bypass Valve
29Left Propel Motor
30Right Propel Motor
31Hydraulic System
TX,9025,GG2136 1906SEP002/2
9025
05
3
TM1663 (28NOV01)
9025-05-3
PN=361
Theory of Operation
T112516
1917DEC97
9025
05
4
ADowel Pin
BBearing and Key
CDrive Gear
DOil Seal
ESnap Ring
FDrive Shaft
GDriven Gear
HSeal and Backup Retainer
IOutlet Port
JInlet Port
KPilot Pump
TX,9025,GG2283 1906SEP001/1
TM1663 (28NOV01)
9025-05-4
PN=362
Theory of Operation
T102044
UN01AUG96
APlug
BRegulated Pilot Oil to Pilot
Shutoff Valve
CReturn Oil to Hydraulic Oil
Tank
TX,05,GG2149 1907APR971/1
TM1663 (28NOV01)
9025-05-5
PN=363
9025
05
5
Theory of Operation
C TO RIGHT PILOT
CONTROLLER
B TO PROPEL
PILOT
CONTROLLER
D TO SOLENOID
VALVE MANIFOLD
P2
P1
A
B
C
P3
D
I
T5
T4
T6
F
E FROM PILOT
F TO HYDRAULIC
PRESURE
OIL TANK
REGULATING VALVE
I
J
K
H TO FLOW REGULATOR
I FROM LEFT
PILOT CONTROLLER
A
D
J FROM RIGHT
PILOT
CONTROLLER
P2
P1
A
B
C
P3
D
T5
H
F
F
T6
K
J
K FROM PROPEL
PILOT CONTROLLER
L PILOT SHUT-OFF VALVE OFF
M PILOT OIL
T101854
N RETURN OIL
T101854
TM1663 (28NOV01)
1906MAY98
T4
9025-05-6
TX,9025,GG2284 1906SEP001/2
PN=364
Theory of Operation
ATo
BTo
CTo
DTo
TX,9025,GG2284 1906SEP002/2
TM1663 (28NOV01)
9025-05-7
PN=365
9025
05
7
Theory of Operation
N RETAINER
LEVER E
F SLEEVE
PLUNGER D
O SHIMS
G BALANCE SPRING
SPRING C
GUIDE
H RETURN SPRING
I TO HYDRAULIC OIL TANK
SPOOL B
9025
05
8
T129715
APiston
BSpool
CSpring Guide
DPlunger
L PILOT OIL
M RETURN OIL
T129715
PISTON A
1925APR00
J TO CONTROL VALVE
MReturn Oil
NRetainer
OShims
PPilot ControllerNeutral
TX,9025,GG2285 1929MAR001/1
TM1663 (28NOV01)
9025-05-8
PN=366
Theory of Operation
E LEVER
B
F SLEEVE
PLUNGER D
K
I
G BALANCE SPRING
SPRING C
GUIDE
H RETURN SPRING
I TO HYDRAULIC OIL TANK
K FROM PILOT PUMP
L PILOT OIL
PISTON A
I TO HYDRAULIC
OIL TANK
M RETURN OIL
APiston
BSpool
CSpring Guide
DPlunger
ELever
FSleeve
GBalance Spring
HReturn Spring
T129716
T129716
1925APR00
J TO CONTROL VALVE
SPOOL B
LPilot Oil
MReturn Oil
NPilot ControllerMetering
TX,9025,GG2286 1929MAR001/1
TM1663 (28NOV01)
9025-05-9
PN=367
9025
05
9
Theory of Operation
15 SHIMS
5 PEDAL
PLUNGER 4
6 SLEEVE
SPRING 3
GUIDE
7 BALANCE
SPRING
8 RETURN
SPRING
9 TO HYDRAULIC
OIL TANK
SPOOL 2
PISTON 1
1921SEP00
10 TO CONTROL
VALVE
11 FROM PILOT
PUMP
12 PILOT OIL
13 RETURN OIL
T133811
TM1663 (28NOV01)
T133811
9025
05
10
9025-05-10
CED,OUOE003,677 1918SEP001/2
PN=368
Theory of Operation
1Piston
2Spool
3Spring Guide
4Plunger
5Pedal
6Sleeve
7Balance Spring
8Return Spring
9To Hydraulic Oil Tank
14Retainer
15Shims
16Propel Pilot Controller
Neutral
CED,OUOE003,677 1918SEP002/2
9025
05
11
TM1663 (28NOV01)
9025-05-11
PN=369
Theory of Operation
CAM
E AND
PEDAL
PLUNGER D
F SLEEVE
SPRING C
GUIDE
BALANCE
G SPRING
H
WASHER B
I
SPOOL A
FROM PILOT
SHUT-OFF
VALVE
TO CONTROL
K VALVE PILOT
CAP
E
K
TO HYDRAULIC
OIL TANK
1906MAY98
L PILOT OIL
M RETURN OIL
T108942
TM1663 (28NOV01)
T108942
9025
05
12
RETURN
SPRING
9025-05-12
CED,OUOE003,2 1906SEP001/2
PN=370
Theory of Operation
ASpool
BWasher
CSpring Guide
DPlunger
MReturn Oil
NPropel Pilot Controller
Full Stroke
CED,OUOE003,2 1906SEP002/2
TM1663 (28NOV01)
9025-05-13
PN=371
9025
05
13
Theory of Operation
PILOT
CONTROLLER
1
4
1921SEP00
CONTROL
3 VALVE
5 PILOT OIL
FROM PILOT PUMP 4
T133813
1Pilot Controller
2Bucket Section
T133813
9025
05
14
6 RETURN OIL
5Pilot Oil
6Return Oil
TX,9025,GG2288 1906SEP001/1
TM1663 (28NOV01)
9025-05-14
PN=372
Theory of Operation
9025
05
15
TM1663 (28NOV01)
9025-05-15
PN=373
Theory of Operation
VALVE FOR 2
BOOM UP
3 BOOM UP PILOT
PRESSURE SWITCH
FROM PILOT
CONTROLLER 1
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
1
9025
05
16
4
11
10
12
11
10
12
13 BOOM UP OR
ARM OUT
14 BOOM DOWN
OR ARM IN
SPOOL 10
TO
PILOT
CAP
4
11 ORIFICE
PLATE
15 WARM-UP
OIL
PASSAGE
FROM 1
PILOT
CONTROLLER
1921SEP00
5 CHECK
VALVE
16 PILOT OIL
18 FLOW REGULATOR VALVE
TM1663 (28NOV01)
9025-05-16
17 RETURN OIL
T133812
T133812
TX,9025,GG2290 1906SEP001/2
PN=374
Theory of Operation
1From Pilot Controller
2Valve for Boom Up
3Boom Up Pilot Pressure
Switch
4To Pilot Cap
5Check Valve
6From Pilot Shut-Off Valve
7Valve for Arm In
8Arm In Pilot Pressure
Sensor
9Check Valve
10Spool
11Orifice Plate
12From Pilot Shut-Off Valve
13Boom Up or Arm Out
TX,9025,GG2290 1906SEP002/2
TM1663 (28NOV01)
9025-05-17
PN=375
9025
05
17
Theory of Operation
T102053
1906AUG96
9025
05
18
TM1663 (28NOV01)
9025-05-18
TX,05,GG2150 1906SEP001/2
PN=376
Theory of Operation
AFront Pump Discharge Port
BFront Pump
CRear Pump
DRear Pump Discharge Port
EDipstick
FPilot Pump
The front pump (B), rear pump (C) and pilot pump (F)
are driven by the engine at engine speed through a
pump drive gearbox (G). The rear pump drive shaft (H)
as well as driving the rear pump also servers as the
drive shaft for the pump drive gearbox. The rear pump
drive shaft is connected to the engine flywheel through
a dampener drive (flex coupling).
TX,05,GG2150 1906SEP002/2
9025
05
19
TM1663 (28NOV01)
9025-05-19
PN=377
Theory of Operation
T102060
1906AUG96
9025
05
20
TM1663 (28NOV01)
9025-05-20
TX,05,GG2151 1906SEP001/2
PN=378
Theory of Operation
AFront Pump Discharge Port
BPump Inlet Port
CRear Pump Discharge Port
DRear Pump Drive Shaft
ICenter Shaft
JPiston (7 per Pump)
KServo Piston
LValve Plate
MCylinder Block
NFront and Rear Hydraulic
Pumps
TX,05,GG2151 1906SEP002/2
TM1663 (28NOV01)
9025-05-21
PN=379
Theory of Operation
L
LOAD
SPOOL
9025
05
22
T101949
K
LOAD
SLEEVE
REMOTE
CONTROL
SPOOL
PISTON
D
E
G LOAD
ADJUSTING
SCREW
(INNER SPRING)
J
I
H
(ENGINE
OUTER INNER LOAD
PULLDOWN AT
SPRING SPRING ADJUSTING
HIGH PRESSURE)
CARTRIDGE
(OUTER SPRING)
(ENGINE
PULLDOWN AT
MEDIUM PRESSURE)
ESpool
FMinimum Flow Adjusting
Screw
GLoad Adjusting Screw
(Inner Spring) (Engine Pull
down at High Pressure)
KLoad Sleeve
LLoad Spool
MLoad Piston
NPump Regulator
Components
sleeve (K), load spool (L), and load piston (M). Each
regulator controls the flow of pilot oil to the large end
of its servo piston using the spools and sleeves.
The remote control spool (D) is moved by a reduced
pilot oil control signal from front and rear pump control
valve. There is a pump control valve located in the left
and right control valves. The control signal acts on the
end of the piston (E) to control the position of remote
control spool against the spring.
TM1663 (28NOV01)
MINIMUM FLOW
ADJUSTING
SCREW
F
1923APR97
M
LOAD
PISTON
T101949
FLOW ADJUSTING
CARTRIDGE
(TRACK CYCLE
TIME)
A
9025-05-22
TX,05,GG2148 1924APR001/2
PN=380
Theory of Operation
The load spool (L) is moved by the load piston (M)
against the springs to decrease pump flow
(displacement) and avoid overloading the engine when
main system pressure becomes too high. At lower
system pressures the spool is moved against only the
outer spring (J). At higher pressures, the spool
contacts and is moved against the inner spring (I) as
TX,05,GG2148 1924APR002/2
9025
05
23
TM1663 (28NOV01)
9025-05-23
PN=381
Theory of Operation
FROM SOLENOID 1
VALVE MANIFOLD
2
CONTROL VALVE
NEUTRAL PASSAGE
32 TRAPPED OIL
REAR PUMP
33 RETURN OR PRESSURE
CONTROL 3
REMOTE
FREE OIL
VALVE
CONTROL
TO SERVO
SPOOL
REMOTE
PISTON
CONTROL 7 PISTON
LARGE END 4
5
SLEEVE
6
26 PRESSURE
SENSOR
RETURN
TO PUMP
HOUSING 14
8 PILOT OIL
INLET
SPEED SENSE 13
SIGNAL PORT
PUMP PRESSURE 12
INLET
LOAD PISTON 11
9 LOAD SLEEVE
15 FEEDBACK LINK
16 TO LEFT CONTROL VALVE
LOAD SPOOL 10
TO FRONT PUMP
17 REGULATOR
25
TO FRONT PUMP 24
REGULATOR
23
SERVO
PISTON
18
PILOT
PUMP
22
FRONT
PUMP
21
SERVO
PISTON
20
REAR
PUMP
34 REGULATOR OPERATION
T108968
TM1663 (28NOV01)
19
PILOT
PRESSURE
REGULATING
VALVE
1929MAY97
T108968
9025
05
24
9025-05-24
TX,05,GG2152 1924APR001/2
PN=382
Theory of Operation
1From Solenoid Valve
Manifold
2Control Valve Neutral
Passage
3Front Pump Control Valve
4To Servo Piston Large End
5Remote Control Spool
6Remote Control Sleeve
7Piston
8Pilot Oil Inlet
9Load Sleeve
10Load Spool
11Load Piston
12Pump Pressure Inlet
13Speed Sense Signal Port
14Return To Pump Housing
15Feedback Link
16To Left Control Valve
17To Front Pump Regulator
18Pilot Pump
Pilot oil from the pilot pump (18) flows through drilled
passages in the pump housing to the small end of
servo pistons and to the pilot oil inlet (8) at each
regulator. Pilot oil pressure is maintain at the small end
of servo pistons and at the inlet of both regulators.
The pump supply oil (29 and 30) from front and rear
pumps is sensed through drilled passages in the pump
housing to the pump pressure inlets (12) in each
regulator.
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
TM1663 (28NOV01)
9025-05-25
PN=383
Theory of Operation
FROM SOLENOID 1
VALVE MANIFOLD
2
CONTROL VALVE
NEUTRAL PASSAGE
32 RETURN OR PRESSURE
FREE OIL
REAR PUMP
CONTROL 3
REMOTE
VALVE
CONTROL
TO SERVO
SPOOL
REMOTE
PISTON
CONTROL 7 PISTON
LARGE END 4
5
SLEEVE
6
26 PRESSURE
SENSOR
RETURN
TO PUMP
HOUSING 14
SPEED SENSE 13
SIGNAL PORT
PUMP PRESSURE 12
INLET
LOAD PISTON 11
9 LOAD SLEEVE
15 FEEDBACK LINK
16 TO LEFT CONTROL VALVE
LOAD SPOOL 10
TO FRONT PUMP
17 REGULATOR
T134255
22
FRONT
PUMP
21
SERVO
PISTON
20
REAR
PUMP
TM1663 (28NOV01)
19
PILOT
PRESSURE
REGULATING
VALVE
1909OCT00
23
SERVO
PISTON
18
PILOT
PUMP
9025-05-26
T134255
9025
05
26
8 PILOT OIL
INLET
TX,05,GG2153 1916OCT001/2
PN=384
Theory of Operation
1From Solenoid Valve
Manifold
2Control Valve Neutral
Passage
3Front Pump Control Valve
4To Servo Piston Large End
5Remote Control Spool
6Remote Control Sleeve
7Piston
8Pilot Oil Inlet
9Load Sleeve
10Load Spool
11Load Piston
12Pump Pressure Inlet
13Speed Sense Signal Port
14Return To Pump Housing
15Feedback Link
16To Left Control Valve
17To Front Pump Regulator
18Pilot Pump
TX,05,GG2153 1916OCT002/2
TM1663 (28NOV01)
9025-05-27
PN=385
9025
05
27
Theory of Operation
FROM SOLENOID 1
VALVE MANIFOLD
2
CONTROL VALVE
NEUTRAL PASSAGE
32 RETURN OR PRESSURE
FREE OIL
REAR PUMP
CONTROL 3
REMOTE
VALVE
CONTROL
TO SERVO
SPOOL
REMOTE
PISTON
CONTROL 7 PISTON
LARGE END 4
5
SLEEVE
6
26 PRESSURE
SENSOR
RETURN
TO PUMP
HOUSING 14
SPEED SENSE 13
SIGNAL PORT
PUMP PRESSURE 12
INLET
LOAD PISTON 11
9 LOAD SLEEVE
15 FEEDBACK LINK
16 TO LEFT CONTROL VALVE
LOAD SPOOL 10
TO FRONT PUMP
17 REGULATOR
T134255
22
FRONT
PUMP
21
SERVO
PISTON
20
REAR
PUMP
TM1663 (28NOV01)
19
PILOT
PRESSURE
REGULATING
VALVE
1909OCT00
23
SERVO
PISTON
18
PILOT
PUMP
9025-05-28
T134255
9025
05
28
8 PILOT OIL
INLET
TX,05,GG2205 1916OCT001/2
PN=386
Theory of Operation
1From Solenoid Valve
Manifold
2Control Valve Neutral
Passage
3Front Pump Control Valve
4To Servo Piston Large End
5Remote Control Spool
6Remote Control Sleeve
7Piston
8Pilot Oil Inlet
9Load Sleeve
10Load Spool
11Load Piston
12Pump Pressure Inlet
13Speed Sense Signal Port
14Return To Pump Housing
15Feedback Link
16To Left Control Valve
17To Front Pump Regulator
18Pilot Pump
9025
05
29
TX,05,GG2205 1916OCT002/2
TM1663 (28NOV01)
9025-05-29
PN=387
Theory of Operation
FROM PILOT D
SHUT-OFF VALVE
FROM PROPEL
FLOW CONTROL C
VALVE
H TO SYSTEM RELIEF
VALVE POWER
BOOST PORT
TO FRONT PUMP
CONTROL VALVE
B
P POWER BOOST
TO ARM
REGENERATIVE L
VALVE
M
ARM
REGENERATIVE
FROM PILOT
SHUT-OFF A
VALVE
E
PI
SI
SG
N
SPEED
SENSING
F
PH
PG
J TO PUMP REGULATORS
SPEED SENSING PORT
PE
SD
SC
PD
A
DP
DE
DD
C
K
T109045
TM1663 (28NOV01)
9025-05-30
DS
Q PILOT OIL
R RETURN OR
PRESSURE
FREE OIL
1921MAY97
PE
T109045
9025
05
30
TX,9025,GG2609 1906SEP001/2
PN=388
Theory of Operation
AFrom Pilot Shut-Off Valve
BTo Front Pump Control
Valve
CFrom Propel Flow Control
Valve
DFrom Pilot Shut-Off Valve
ETo Swing Motor Park Brake
Release Valve
Return oil (R) from the pilot shut-off valve (D), propel
flow control valve (C), bucket flow control valve (K),
and the solenoid valves, when solenoid valves are
de-energizes, flows through the manifold to the
hydraulic oil tank (G).
The identification letters shown on the hydraulic
schematic are on the manifold housing next to the
ports.
TX,9025,GG2609 1906SEP002/2
TM1663 (28NOV01)
9025-05-31
PN=389
9025
05
31
Theory of Operation
ARM
REGENERATIVE
SPEED SENSING
SOLENOID
VALVE MANIFOLD
I
L
POWER
BOOST
SPOOL
ADJUSTING
SCREW
9025
05
32
DE-ENERGIZED
I
I
PRESSURE EQUALS
MAGNETIC FORCE
SOLENOID
J
F
M
TO VALVE
FUNCTION
TO
HYDRAULIC
OIL TANK
T109046
N
R
ENERGIZED
PILOT OIL
REDUCED PILOT
OIL
RETURN OIL
TM1663 (28NOV01)
9025-05-32
T109046
1923APR97
TX,9025,GG2095 1924APR001/2
PN=390
Theory of Operation
ASolenoid Valve Manifold
BArm Regenerative
CSpeed Sense
DPropel Speed Change
EPower Boost
FSpool
GDe-Energized
HPressure Equals Magnetic
Force
ISolenoid
JTo Hydraulic Oil Tank
KAdjusting Screw
LTo Valve Function
MPilot Oil From Pilot
Shut-Off Valve
NEnergized
OPilot Oil
PReduced Pilot Oil
QReturn Oil
RProportional Solenoid
Valve
TX,9025,GG2095 1924APR002/2
TM1663 (28NOV01)
9025-05-33
PN=391
Theory of Operation
T103218
1907SEP96
9025
05
34
AEngine RPM Dial
BEngine and Pump
Controller
The pilot oil control signal is sent to the end of the load
piston in the front and rear pump regulators (D and E)
which then operate to reduce pump flow. (See
Hydraulic Pump Regulator Operation in this group.)
TX,05,GG2201 1906SEP001/1
TM1663 (28NOV01)
9025-05-34
PN=392
Theory of Operation
T109048
UN15APR97
9025
05
35
Left Front
1Left Control Valve (5-Spool)
2Right Control Valve
(4-Spool)
56System Relief Valve
Isolation Check Valve
57System Relief Valve and
Power Boost
58Dig Pressure Switch
59Flow Combiner Valve
Circuit Check Valve
60System Relief Valve
Isolation Check Valve
61Propel Pressure Switch
62FilterPilot Pressure Inlet
73Swing Valve
74Arm Reduced Leakage
Valve
75Arm Out Circuit Relief and
Anti-Cavitation Valve
76Plug
77Swing Lift Check Valve
78Arm I Power and Neutral
Passage Check Valves
(Lift Checks), and
Restriction Orifice
79Boom II Power Passage
Check Valve (Lift Check)
TM1663 (28NOV01)
9025-05-35
TX,05,GG2154 1920MAY981/4
PN=393
Theory of Operation
The control valve consists of two monoblock valve
housings called the left control valve (1) and right
control valve (2). The control valves are mounted
back-to-back to connect the interconnected oil
passages through ports in the mounting faces. The left
control valve is a 5-spool section valve consisting of
left propel (69), auxiliary (70), boom II (71), arm I (72),
and swing (73). The right control valve is a 4-spool
section valve consisting of right propel (68), bucket
(67), boom I (65), and arm II (64). Each spool is
selectively fitted to its bore in the housings. The spools
are moved by pilot oil controlled by the pilot controllers
located in the cab.
For the location of all valves used in the control valve,
see the three illustrations labeled Left Front, Right
Rear, and Bottom and the legends. Also see the
Control Valve Circuit Schematic for location of
components.
9025
05
36
TM1663 (28NOV01)
9025-05-36
TX,05,GG2154 1920MAY982/4
PN=394
T109052
UN15APR97
Theory of Operation
Right Rear
1Left Control Valve (5-Spool)
2Right Control Valve
(4-Spool)
57System Relief Valve and
Power Boost
63Solenoid Valve Manifold
64Arm II Valve
65Boom I Valve and Boom
Regenerative Valve
66Boom Reduced Leakage
Valve
67Bucket Valve
68Right Propel Valve
TM1663 (28NOV01)
9025-05-37
TX,05,GG2154 1920MAY983/4
PN=395
9025
05
37
T109053
UN15APR97
Theory of Operation
9025
05
38
Bottom
1Left Control Valve (5-Spool)
2Right Control Valve
(4-Spool)
64Arm II Valve
65Boom I Valve
67Bucket Valve
TX,05,GG2154 1920MAY984/4
TM1663 (28NOV01)
9025-05-38
PN=396
Theory of Operation
9025
05
39
TM1663 (28NOV01)
9025-05-39
PN=397
Theory of Operation
T109055
UN16APR97
9025
05
40
TM1663 (28NOV01)
9025-05-40
TX,9025,GG2610 1920MAY981/2
PN=398
Theory of Operation
1Left Control Valve (5-Spool)
2Right Control Valve
(4-Spool)
56System Relief Valve
Isolation Check Valve
57System Relief Valve and
Power Boost
59Flow Combiner Valve
Circuit Check Valve
60System Relief Valve
Isolation Check Valve
64Arm II Valve
65Boom I Valve and Boom
Regenerative Valve
66Boom Reduced Leakage
Valve
67Bucket Valve
68Right Propel Valve
69Left Propel Valve
70Auxiliary Valve
71Boom II Valve
71APropel-Boom Down
Selector Valve
72Arm I Valve
73Swing Valve
74Arm Reduced Leakage
Valve
75Arm Out Circuit Relief and
Anti-Cavitation Valve
76Plug
77Swing Lift Check Valve
78Arm I Power and Neutral
Passage Check Valves
(Lift Checks), and
Restriction Orifice
79Boom II Power Passage
Check Valve (Lift Check)
80Auxiliary Power Passage
Check Valve (Lift Check)
TX,9025,GG2610 1920MAY982/2
TM1663 (28NOV01)
9025-05-41
PN=399
9025
05
41
Theory of Operation
T129505
1928APR00
9025
05
42
TM1663 (28NOV01)
9025-05-42
TX,05,GG2192 1924APR001/2
PN=400
Theory of Operation
AOrifice and Check Valve
BSwing Park Brake Release
Valve
CDig Pressure Switch
DOrifice
EPropel Pressure Switch
FFlow Combiner Valve
GPropel Pilot Control Signal
Passage
Pilot oil from the pilot pump (M) flows to the control
valve and through the orifices (D) into the propel pilot
control signal passage (G) and dig pilot control signal
passage (H). The oil in the propel pilot control signal
passage flows to the propel pressure switch (E), the
propel-boom down selector valve (R), past the top end
of the right (I) and left (W) propel valve spools, and
then to the return passage (X). The oil in the dig pilot
control signal passage flows to the dig pressure switch
(C), the propel flow control valve (T), flow combiner
valve (F), past the top end of bucket (J), boom I (K),
arm II (L), swing (P), arm I (Q), boom II (S), and
auxiliary (U) valve spools, and then to the return
NFront Pump
ORear Pump
PSwing
QArm I
RPropel-Boom Down
Selector Valve
SBoom II
TX,05,GG2192 1924APR002/2
TM1663 (28NOV01)
9025-05-43
PN=401
9025
05
43
Theory of Operation
T101397
1907SEP96
9025
05
44
TM1663 (28NOV01)
9025-05-44
TX,05,GG2191 1906SEP001/2
PN=402
Theory of Operation
ASystem Relief Valve
BFlow Combiner Valve
CNeutral Passage
DReturn Passage
ERight Propel
FBucket
GCircuit Relief and
Anti-Cavitation Valves
HBoom I
ICircuit Relief and
Anti-Cavitation Valves
JArm II
KFront Pump Control Valve
LPilot Pump
MFront Pump
Supply oil from the front pump (M) flows to the right
control valve. Supply oil from the rear pump (O) flows
to the left control valve. When all functions are in
neutral supply oil flows through the neutral passages
NPower Passage
ORear Pump
PNeutral Passage
QSwing
RArm I
SCircuit Relief and
Anti-Cavitation Valves
TBoom II
UPropel Flow Control Valve
WAuxiliary
XRear Pump Control Valve
YLeft Propel
ZNeutral and Power Passage
TX,05,GG2191 1906SEP002/2
9025
05
45
TM1663 (28NOV01)
9025-05-45
PN=403
Theory of Operation
TOP NUT B
Q RETURN OR
PRESSURE
FREE OIL
SECOND
ADJUSTING C
PLUG
BOTTOM NUT D
E PISTON
LEFT CONTOL
F VALVE HOUSING
PILOT POPPET
G
SPRING
H PILOT POPPET
I
MAIN POPPET
SPRING
J MAIN POPPET
K RETURN PASSAGE
9025
05
46
N POWER BOOST
T102821
1923APR97
L POWER PASSAGE
M DIGGING
KReturn Passage
LLower Passage
MDigging
NPower Boost
OPump Supply Oil
PPilot Oil
QReturn or Pressure Free
Oil
RSystem Relief and Power
Boost Valve
TX,05,GG2155 1924APR001/1
TM1663 (28NOV01)
9025-05-46
PN=404
Theory of Operation
T109063
1929APR97
TX,05,GG2202 1924APR001/1
TM1663 (28NOV01)
9025-05-47
PN=405
9025
05
47
Theory of Operation
Q ANTICAVITATION OPERATION
P RELIEF OPERATION
PILOT POPPET E
CHECK VALVE D
H SCREW
K RELIEF PRESSURE OIL
C
FROM WORK
CIRCUIT
IT4579
9025
05
48
I PISTON SPRING
N RETURN OIL
O LOW PRESSURE OIL
J MAIN POPPET
1903NOV97
TO RETURN A
IT4579
PISTON B
PRelief Operation
QAnticavitation Operation
RCircuit Relief Anticavitation Valve
TX,05,GG2146 1924APR001/1
TM1663 (28NOV01)
9025-05-48
PN=406
Theory of Operation
9025
05
49
TM1663 (28NOV01)
9025-05-49
PN=407
Theory of Operation
T129510
1925APR00
9025
05
50
TM1663 (28NOV01)
9025-05-50
TX,05,GG2178 1924APR001/4
PN=408
Theory of Operation
APilot Oil Inlet From
Solenoid Valve Manifold
BFilter Screen
COrifice
DRelief Valve Spring
EControl Valve Return
Passage
TX,05,GG2178 1924APR002/4
9025
05
51
TM1663 (28NOV01)
9025-05-51
PN=409
T129512
1925APR00
Theory of Operation
9025
05
52
TM1663 (28NOV01)
9025-05-52
TX,05,GG2178 1924APR003/4
PN=410
Theory of Operation
In addition, the pressure signal to pump regulators is
senses by the pump control pressure sensors sending
an electrical signal to the engine and pump controller
TX,05,GG2178 1924APR004/4
9025
05
53
TM1663 (28NOV01)
9025-05-53
PN=411
Theory of Operation
T129513
1927APR00
9025
05
54
ALeft Control Valve
BRight Control Valve
CFrom Pilot Control Pump
Pilot oil from the pilot pump (C) flows through the
orifice (L), into the dig pilot control signal passage (G),
past each dig function valve spools, and then to the
return circuit. The flow combiner valve (D), propel flow
control valve (M), and the swing motor park brake
release valve (K) are connected to the signal passage
between the orifice and spools.
Supply oil from the front pump (P) now flows through
the flow combiner valve to the left propel valve (E) as
will as the right propel valve to ensure that the
TM1663 (28NOV01)
9025-05-54
TX,05,GG2179 1924APR001/3
PN=412
Theory of Operation
9025
05
55
TM1663 (28NOV01)
9025-05-55
PN=413
Theory of Operation
T129506
1927APR00
9025
05
56
TM1663 (28NOV01)
9025-05-56
TX,05,GG2179 1924APR002/3
PN=414
Theory of Operation
ALeft Control Valve
BRight Control Valve
CFrom Pilot Control Pump
DFlow Combiner Valve
ETo Left Propel Valve
LOrifice
MPropel Flow Control Valve
NFlow Combiner Check
Valve
OValve Spool
PFront Pump
QRear Pump
RFlow Combiner Valve
Circuit
TX,05,GG2179 1924APR003/3
9025
05
57
TM1663 (28NOV01)
9025-05-57
PN=415
Theory of Operation
T102962
1917AUG96
9025
05
58
AArm Cylinder
BArm I Valve
CArm Regenerative Circuit
Check Valve
FArm II Valve
GRear Pump
TM1663 (28NOV01)
9025-05-58
TX,05,GG2185 1924APR001/2
PN=416
T102986
1917AUG96
Theory of Operation
AArm Cylinder
BArm I Valve
CArm Regenerative Circuit
Check Valve
DArm Regenerative Solenoid
Valve
JOrifice
KArm In Pressure Sensor
LBoom Up Pressure Switch
MEngine and Pump
Controller
TX,05,GG2185 1924APR002/2
TM1663 (28NOV01)
9025-05-59
PN=417
9025
05
59
Theory of Operation
T115414
1927MAY98
9025
05
60
shifts the pilot valve (F). The oil pressure from the
cylinder is blocked by the pilot valve. The oil pressure
at the top (spring end) of check valve poppet can now
flow through the pilot valve to the warm-up passage in
the pilot caps and then to the hydraulic oil tank. The oil
pressure from the cylinder pushes the poppet off its
seat opening the passage for oil to flow into the control
valve return passage. The poppet is pushed off its seat
because the OD of upper land at the head end of
poppet is slightly larger than the lower land.
The boom manual lower screw (H) is used to lower the
boom if the engine should stop with the boom in the
raised position. (See Lower Boom With Engine
Stopped in Group 9025-25.)
TX,05,GG2186 1920MAY981/1
TM1663 (28NOV01)
9025-05-60
PN=418
Theory of Operation
9025
05
61
TM1663 (28NOV01)
9025-05-61
PN=419
Theory of Operation
T103012
1920AUG96
9025
05
62
TM1663 (28NOV01)
9025-05-62
TX,05,GG2187 1906SEP001/2
PN=420
Theory of Operation
ALeft Propel Valve
BRight Propel Valve
CBoom Up Pilot Pressure
DArm In Pilot Pressure
EPilot Valve A
FReturn To Solenoid Valve
Manifold
GPoppet Valve
HBucket Valve
IPilot Valve B
JBucket Pilot Pressure
KBucket Cylinder
LAuxiliary Valve
MBucket Flow Control Valve
TX,05,GG2187 1906SEP002/2
9025
05
63
TM1663 (28NOV01)
9025-05-63
PN=421
Theory of Operation
T129771
1927APR00
9025
05
64
AOrifice and Check Valve
BLeft Propel Valve
CPilot Control Signal
DPropel Flow Control Valve
Spool
GPower Passage
HDig Function Valve Spool
IRight Propel Valve
JReturn
KPropel Flow Control Valve
TX,05,GG2188 1924APR001/1
TM1663 (28NOV01)
9025-05-64
PN=422
Theory of Operation
T129774
1927APR00
ABoom II Valve
BBoom I Valve
CPropel-Boom Down
Selector Valve Spool
TX,05,GG2189 1924APR001/1
TM1663 (28NOV01)
9025-05-65
PN=423
9025
05
65
Theory of Operation
T109129
1912MAY97
9025
05
66
ABoom II Valve
BBoom I Valve
CBoom Regenerative Valve
Poppet
GBoom Cylinders
HBoom Regenerative Valve
TX,05,GG2190 1906SEP001/1
TM1663 (28NOV01)
9025-05-66
PN=424
Theory of Operation
9025
05
67
TM1663 (28NOV01)
9025-05-67
PN=425
Theory of Operation
T116658
1924AUG98
9025
05
68
TM1663 (28NOV01)
9025-05-68
CED,OUOE035,132 1906SEP001/2
PN=426
Theory of Operation
ALeft Propel Motor
BPropel Flow Control Valve
CFlow Combiner Valve
DTo Swing Park Brake
Release Valve
EOrifice
FPilot Pump
GDig Pilot Pressure Signal
Passage
HCheck Valve
IRight Propel Motor
JRight Propel Valve
KArm II Valve
LRight Control Valve
MLeft Control Valve
NFront Pump
ORear Pump
PArm I Valve
QArm Cylinder
RLeft Propel Valve
SPropel and Arm In
Combined
CED,OUOE035,132 1906SEP002/2
TM1663 (28NOV01)
9025-05-69
PN=427
9025
05
69
Theory of Operation
T133815
1921SEP00
9025
05
70
TM1663 (28NOV01)
9025-05-70
CED,TX08227,2991 1906SEP001/2
PN=428
Theory of Operation
1Power Passage
2Boom I Valve
3Boom Cylinder
4Power Passage
5Swing Valve
6Front Pump
7Rear Pump
8Swing Motor
9Boom II Valve
CED,TX08227,2991 1906SEP002/2
9025
05
71
TM1663 (28NOV01)
9025-05-71
PN=429
Theory of Operation
T103086
1907SEP96
9025
05
72
TM1663 (28NOV01)
9025-05-72
TX,05,GG2193 1906SEP001/2
PN=430
Theory of Operation
ASwing Motor
BFirst Planet Gear
CSecond Planet Gear
DBearing
EDrain Pipe
FOil Seal
GOutput Pinion
HBearing
TX,05,GG2193 1906SEP002/2
TM1663 (28NOV01)
9025-05-73
PN=431
9025
05
73
Theory of Operation
T103087
1912SEP96
9025
05
74
ACylinder Block
BPort
CSpring
DCover
EValve Plate
JForce Pin
KBall Bushing
LRetainer
MOutput Shaft
NOil Seal
TM1663 (28NOV01)
9025-05-74
OThrust Plate
PPiston and Slipper
QSwing Park Brake Release
Valve
RSwing Motor
TX,05,GG2194 1906SEP001/2
PN=432
Theory of Operation
The swing motor (R) consists of the rotating group,
park brake, and cover (D). The cover contains the
swing crossover relief valves (F), make-up check
valves and inlet and outlet ports. The valve plate (E) is
held in position by dowel pins in the cover. The swing
motor is a fixed displacement, axial piston, fixed
position thrust plate (O) motor. It is bidirectional so the
upperstructure can swing in both directions.
The rotating group consists of a cylinder block (A) with
nine pistons and slippers (P). The cylinder block is
connected to the output shaft (M). Each piston is
connected to a slipper by a ball joint. Slippers slide on
the inclined thrust plate (O) forcing the cylinder block
to turn. Retainer (L) holds the slippers on the thrust
plate and the retainer itself is held against the slippers
by force pins (J) and spring (C).
Oil from swing control valve is routed through cover
(D), valve plate (E), and port (B) to the pistons.
In operation, high pressure supply oil enters the
cylinder bores through ports forcing pistons down
against inclined thrust plate. The slippers slide down
the inclined thrust plate causing the rotating group to
turn. The output shaft is turned by the cylinder block.
TX,05,GG2194 1906SEP002/2
TM1663 (28NOV01)
9025-05-75
PN=433
Theory of Operation
T103106
1920AUG96
ASpring
BSpring Guide
CPiston
9025
05
76
DReturn Passage
EChamber
FSpring
GOrifice
HRelief Poppet
IPort
TX,05,GG2195 1906SEP001/1
TM1663 (28NOV01)
9025-05-76
PN=434
Theory of Operation
T103116
1920AUG96
9025
05
77
DInlet Port
TM1663 (28NOV01)
EMake-Up Valves
9025-05-77
TX,05,GG2196 1906SEP001/2
PN=435
Theory of Operation
Because the lines to the motor are blocked the
continued rotation of the upperstructure lowers the
pressure on the other side of the motor until cavitation
starts. When cavitation starts the make-up poppet (C)
is pushed open by the return oil in the make-up oil
TX,05,GG2196 1906SEP002/2
9025
05
78
TM1663 (28NOV01)
9025-05-78
PN=436
Theory of Operation
9025
05
79
TM1663 (28NOV01)
9025-05-79
PN=437
Theory of Operation
T109165
1921APR97
9025
05
80
TM1663 (28NOV01)
9025-05-80
TX,05,GG2197 1906SEP001/2
PN=438
Theory of Operation
ADig Pilot Pressure Signal
BPiston
COrifice and Check Valve
DPilot Pressure Oil
EPilot Pump
FSwing Motor Park Brake
Release Valve Spool
GSwing Motor
HValve Spool
IPark Brake Released
JPark Brake Applied
KBrake Pack
LSwing Motor Park Brake
Release Valve
TX,05,GG2197 1906SEP002/2
TM1663 (28NOV01)
9025-05-81
PN=439
9025
05
81
Theory of Operation
D RIGHT PROPEL
REVERSE
B C
E D
E RIGHT PROPEL
FORWARD
A
F PROPEL
SPEED
CHANGE
B
D
A LEFT
PROPEL
DRAIN
B LEFT
PROPEL
REVERSE
C
E
E RIGHT
PROPEL
FORWARD
1923JUN98
C LEFT PROPEL
FORWARD
A
G SUPPLY OIL
9025
05
82
T109474
J ROTARY MANIFOLD
DRight Propel Reverse
ERight Propel Forward
FPropel Speed Change
GSupply Oil
HReturn Oil
T109474
H RETURN OIL
I PILOT OIL
IPilot Oil
JRotary Manifold
TX,05,GG2171 1906SEP001/1
TM1663 (28NOV01)
9025-05-82
PN=440
Theory of Operation
9025
05
83
TM1663 (28NOV01)
9025-05-83
PN=441
Theory of Operation
PLATE
A
VALVE
PLATE
B
SPRING
C
SPRING
D
CENTER
SHAFT
E
F HOUSING
G DRIVE
SHAFT
LINK P
9025
05
84
SERVO O
PISTON
H ROLLER
BEARING
K
PLATES
J
BRAKE
DISKS
I
ROLLER
BEARING
N
M
PISTON
L
BRAKE
PISTON
Q SUPPLY OIL
TXC7499AA
S PROPEL MOTOR
TM1663 (28NOV01)
9025-05-84
T7499AA
R RETURN OIL
1923APR97
ROTOR
TX,05,GG2167 1906SEP001/2
PN=442
Theory of Operation
APlate
BValve Plate
CSpring
DSpring
ECenter Shaft
FHousing
GDrive Shaft
HRoller Bearing
IRoller Bearing
JBrake Disks
KPlates
LBrake Piston
MPiston
NRotor
OServo Piston
PLink
QSupply Oil
RReturn Oil
SPropel Motor
TX,05,GG2167 1906SEP002/2
TM1663 (28NOV01)
9025-05-85
PN=443
9025
05
85
Theory of Operation
B ROTARY
GROUP
D
SERVO
PISTON
H
TO MOTOR
CASE DRAIN
I
CHAMBER
A
G
SPRING
J
FROM
MOTOR
PORT
C LINK
E
ORIFICE
1906MAY98
K
FROM PROPEL
SPEED CHANGE
SOLENOID
VALVE
F
SPOOL
L
CHAMBER B
M SUPPLY OIL
T102854
9025
05
86
AValve Plate
BRotary Group
CLink
DServo Piston
N RETURN OIL
O SLOW SPEED
EOrifice
FSpeed Selector Valve Spool
GSpring
HTo Motor Case Drain
IChamber A
JFrom Motor Port
KFrom Propel Speed
Change Solenoid Valve
T102854
D SERVO
PISTON
LChamber B
MSupply Oil
NReturn Oil
OSlow Speed
TX,05,GG2168 1906SEP001/1
TM1663 (28NOV01)
9025-05-86
PN=444
Theory of Operation
B ROTARY
GROUP
SERVO
D PISTON
TO MOTOR
CASE DRAIN
H
CHAMBER
A
I
G
SPRING
FROM
J MOTOR
PORT
C LINK
F
SPOOL
ORIFICE
E
1906MAY98
K
FROM PROPEL
SPEED CHANGE
SOLENOID
VALVE
M SUPPLY OIL
L CHAMBER
B
T102855
AValve Plate
BRotary Group
CLink
DServo Piston
EOrifice
P FAST SPEED
FSpeed Selector Valve Spool
GSpring
HTo Motor Case Drain
IChamber A
In fast speed the pilot oil (N), from the propel speed
change solenoid valve (K), is higher than spring force
and spool (F) is pushed up. The oil in chamber B is
routed to return through motor case drain (H). Supply
oil (M) from the motor port (J) is applied to chamber
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.
N PILOT OIL
O RETURN OIL
T102855
D SERVO
PISTON
MSupply Oil
NPilot Oil
OReturn Oil
PFast Speed
TX,05,GG2169 1906SEP001/1
TM1663 (28NOV01)
9025-05-87
PN=445
9025
05
87
Theory of Operation
T109188
1923APR97
9025
05
88
TM1663 (28NOV01)
9025-05-88
TX,05,GG2200 1924APR001/2
PN=446
Theory of Operation
APropel Speed Switch
BLeft Propel Valve
CRear Pump Control
Pressure Sensor
DLeft Propel Motor
ESpeed Selector Valve
Spool
TX,05,GG2200 1924APR002/2
TM1663 (28NOV01)
9025-05-89
PN=447
9025
05
89
Theory of Operation
T109195
1923APR97
9025
05
90
ECounterbalance Valve
FServo Piston Shuttle Valve
TM1663 (28NOV01)
9025-05-90
TX,9025,GG2612 1906SEP001/2
PN=448
Theory of Operation
The propel motor park brake valve (G) housing
contains the park brake release shuttle valve (A), park
brake pressure reducing valve (B), crossover relief
valve (C), check valves (D), counterbalance valve (E),
servo piston shuttle valve (F) and servo piston.
Park brake release shuttle valve (A) routes supply oil
from the pressurized motor port through a groove in
the counterbalance valve (E), to the park brake
pressure reducing valve (B), and then to the park
brake piston to release the park brake.
Park brake pressure reducing valve (B) reduces the
supply oil pressure routed to the park brake to prevent
sudden brake application.
TX,9025,GG2612 1906SEP002/2
TM1663 (28NOV01)
9025-05-91
PN=449
9025
05
91
Theory of Operation
T109202
1918APR97
9025
05
92
TM1663 (28NOV01)
9025-05-92
TX,9025,GG2613 1906SEP001/2
PN=450
Theory of Operation
APark Brake Pressure
Reducing Valve
BDisk Spring
CBrake Piston
JChamber
KPropel Motor Park Brake
Release
TX,9025,GG2613 1906SEP002/2
TM1663 (28NOV01)
9025-05-93
PN=451
Theory of Operation
T109206
1923APR97
9025
05
94
TM1663 (28NOV01)
9025-05-94
TX,9025,GG2614 1906SEP001/2
PN=452
Theory of Operation
APark Brake Pressure
Reducing Valve
BDisk Spring
CBrake Piston
JChamber
KPropel Motor Park Brake
Release
TX,9025,GG2614 1906SEP002/2
TM1663 (28NOV01)
9025-05-95
PN=453
9025
05
95
Theory of Operation
T109208
1921APR97
Cylinder Operation
9025
05
96
ASnap Ring
BWiper Seal
CBackup Ring
DU-Cup Seal
EBuffer Ring
FWear Ring
GSnap Ring
HPiston
IBuffer Ring
JWear Ring
KCap Seal
LSet Screw
LNut
NCushion
OBarrel
PCylinder Rod
QRod Guide
RBucket Cylinder
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
TM1663 (28NOV01)
9025-05-96
PN=454
Theory of Operation
T101917
UN11JUL96
AFilter Element
BBypass Valve
CBypass Operation
DFrom Oil Cooler
TX,05,GG2147 1924APR001/1
TM1663 (28NOV01)
9025-05-97
PN=455
9025
05
97
Theory of Operation
TS700
1928SEP89
9025
05
98
TX,15,GG2166 1905AUG961/1
TM1663 (28NOV01)
9025-05-98
PN=456
Theory of Operation
BUCKET
CURL
DUMP
1
SWING LEFT
SWING RIGHT
BUCKET CURL
BUCKET DUMP
5
6
7
8
BOOM UP
FLOW
REGULATOR
UP
T
DOWN
BOOM
RIGHT PILOT
CONTROLLER
BOOM UP
PRESSURE
SWITCH
TO RIGHT
CONTROL VALVE
SWING
LEFT
TO
HYDRAULIC
OIL TANK
BOOM DOWN
3
ARM OUT
RIGHT
PILOT PRESSURE
REGULATING VALVE
FROM
HYDRAULIC
OIL TANK
PILOT
FILTER
PILOT FILTER
BYPASS VALVE
TO REAR PUMP
CONTROL VALVE
IN LEFT CONTROL
VALVE
PILOT PUMP
1
IN
ARM IN
PRESSURE
SENSOR
T
OUT
ARM
LEFT PILOT
CONTROLLER
RIGHT
REVERSE
TO FRONT PUMP
CONTROL VALVE
IN RIGHT CONTROL
VALVE
ARM IN
12
11
10
9
TO SWING
PARK BRAKE
RELEASE
VALVE
POWER
BOOST
SOLENOID
VALVE
SG
PROPEL
SPEED
CHANGE
SOLENOID
VALVE
SI
TO FRONT
AND REAR PUMP
REGULATORS
SPEED
SENSING
SOLENOID
VALVE
SD
ARM
REGENERATIVE
SOLENOID
VALVE
SC
SOLENOID
VALVE
MANIFOLD
T6
RIGHT
FORWARD
T4
T5
LEFT
REVERSE
2
T
P3
P1
LEFT
FORWARD
T109209
PROPEL PILOT
CONTROLLER
TO
HYDRAULIC
OIL TANK
P
P2
1
TM1663 (28NOV01)
PILOT OIL
PILOT
SHUT-OFF
VALVE
9025-05-99
PN=457
FROM BUCKET
FLOW CONTROL
VALVE IN RIGHT
CONTROL VALVE
FROM PROPEL
FLOW CONTROL
VALVE IN LEFT
CONTROL VALVE
RETURN OR
PRESSURE
FREE OIL
Theory of Operation
HYDRAULIC
OIL TANK
OIL COOLER
BYPASS VALVE
SUPPLY OIL
PILOT OIL
TRAPPED OIL
RETURN OR
PRESSURE
FREE OIL
11
BUCKET CYLINDER
PROPEL
PRESSURE
SWITCH
TO
SWING
MOTOR
MAKE-UP
PORT
DIG
PRESSURE
SWITCH
TO SWING
PARK BRAKE
RELEASE
VALVE
SG
PROPEL
SPEED
CHANGE
SOLENOID
VALVE
ARM CYLINDER
ARM
SPEED
REGENERATIVE
SENSING SOLENOID
SOLENOID VALVE
VALVE
SI
SD
TO
3A
BUCKET
FLOW
CONTROL
VALVE
BOOM
REDUCED
LEAKAGE
VALVE
BUCKET
12
FRONT
PUMP
CONTROL
VALVE
PILOT
PUMP PUMP
REGULATOR
ARM II
BOOM I
PRESSURE
SENSOR
PROPEL-BOOM
DOWN SELECTOR 2
VALVE
FRONT
PUMP
FLOW
CONTROL
VALVE
REAR
PUMP
CONTROL
VALVE
REAR
PUMP
LEFT
PROPEL
AUXILIARY
BOOM II
ARM I
N
SENSOR
SWING
ARM
REDUCED
LEAKAGE
VALVE
SC
SEVRO
PISTON
3A
TO
SWING
MOTOR
ARM
REGENERATIVE
VALVE
SEVRO
PISTON
PUMP
REGULATOR
5
OIL
COOLER
SOLENOID VALVE
MANIFOLD
T115417
REAR PUMP
CONTROL
PRESSURE SENSOR
LEFT
CONTROL
VALVE
7
10
SYSTEM
RELIEF
VALVE
FRONT PUMP
CONTROL
PRESSURE SENSOR
RIGHT
CONTROL
VALVE
FLOW
COMBINER
VALVE
TO
LEFT
PROPEL
MOTOR
FROM
PILOT
SHUTOFF
VALVE
RIGHT
PROPEL
FROM
PILOT
PRESSURE
REGULATING
VALVE
BOOM CYLINDERS
TO SWING
PARK BRAKE
RELEASE
VALVE
POWER
BOOST
SOLENOID
VALVE
TO
RIGHT
PROPEL
MOTOR
RESTRICTION
VALVE
TM1663 (28NOV01)
9025-05-100
PN=458
Theory of Operation
TO BOOM
CYLINDERS
TO BUCKET CYLINDERS
1A
11
BUCKET
FLOW
CONTROL
VALVE
DIG
PRESSURE
SWITCH
FLOW
COMBINER
VALVE
10
SYSTEM
RELIEF
VALVE
6
TO FRONT
AND REAR
PUMP
REGULATORS
AUXILIARY
BOOM II
ARM
REGENERATIVE
SWING
ARM I
POWER
BOOST
SG
SPEED
SENSING
SI
SD
SC
ARM
REDUCED
LEAKAGE
VALVE
TO
REAR PUMP
REGULATOR
3A
TO ARM
CYLINDER
T115418
9025-05-101
PROPEL
SPEED
CHANGE
SWING MOTOR
TM1663 (28NOV01)
PROPELBOOM DOWN
SELECTOR VALVE
PROPEL
FLOW
CONTROL
VALVE
CROSSOVER
RELIEF
VALVES
SWING
PARK
BRAKE
RELEASE
VALVE
LEFT
CONTROL
VALVE
ARM II
LEFT
PROPEL
SWING
PARK
BRAKE
TO
FRONT PUMP
REGULATORS
BOOM I
12
REAR
PUMP
CONTROL
VALVE
MAKE-UP
VALVES
BUCKET
FRONT
PUMP
CONTROL
VALVE
OIL COOLER
BYPASS VALVE
FROM
REAR
PUMP
FROM
PILOT
PRESSURE
REGULATING
VALVE
BOOM
REDUCED
LEAKAGE
VALVE
RIGHT
PROPEL
PROPEL
PRESSURE
SWITCH
RIGHT
CONTROL
VALVE
TO
3A
SUPPLY OIL
PILOT OIL
TRAPPED OIL
RETURN OR
PRESSURE
FREE OIL
PN=459
ARM
REGENERATIVE VALVE
TO OIL
COOLER
5
FROM
PILOT
SHUT-OFF
VALVE
SOLENOID VALVE
MANIFOLD
Theory of Operation
9025
05
,102
TM1663 (28NOV01)
9025-05-102
PN=460
Group 15
Diagnostic Information
Diagnostic Procedure
Check all systems and functions on the machine.
Use the helpful diagnostic information in the
checkout to pinpoint the possible cause of the
problem.
5. Preform troubleshooting.
Connect the laptop computer with excavator
diagnostic software, if available. The self-diagnosing
function lists any fault codes and gives corrective
action information.
Before starting any troubleshooting first check
battery voltage, fusible link, and fuses.
TX,15,GG2234 1925APR971/1
TM1663 (28NOV01)
9025-15-1
PN=461
Diagnostic Information
Operational Function
Control Problem
Machine Symptoms
Harness Check
Note
Description of Operation
9025
15
2
TM1663 (28NOV01)
9025-15-2
TX,15,GG2238 1904OCT001/11
PN=462
Diagnostic Information
Part Name
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
TM1663 (28NOV01)
9025-15-3
9025
15
3
TX,15,GG2238 1904OCT002/11
PN=463
Diagnostic Information
Part Name
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
9025
15
4
TM1663 (28NOV01)
9025-15-4
TX,15,GG2238 1904OCT003/11
PN=464
Diagnostic Information
Part Name
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
TM1663 (28NOV01)
9025-15-5
9025
15
5
TX,15,GG2238 1904OCT004/11
PN=465
Diagnostic Information
Part Name
Learning Switch
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
9025
15
6
TM1663 (28NOV01)
9025-15-6
TX,15,GG2238 1904OCT005/11
PN=466
Diagnostic Information
Part Name
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
TM1663 (28NOV01)
9025-15-7
TX,15,GG2238 1904OCT006/11
PN=467
9025
15
7
Diagnostic Information
9025
15
8
Part Name
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
TM1663 (28NOV01)
9025-15-8
TX,15,GG2238 1904OCT007/11
PN=468
Diagnostic Information
Part Name
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
9025
15
9
TM1663 (28NOV01)
9025-15-9
TX,15,GG2238 1904OCT008/11
PN=469
Diagnostic Information
9025
15
10
Part Name
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
TM1663 (28NOV01)
9025-15-10
TX,15,GG2238 1904OCT009/11
PN=470
Diagnostic Information
Part Name
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
9025
15
11
TM1663 (28NOV01)
9025-15-11
TX,15,GG2238 1904OCT0010/11
PN=471
Diagnostic Information
Part Name
Operational Function
Control Problems
Machine Symptoms
Harness Check
Notes
Description of Operation
9025
15
12
TX,15,GG2238 1904OCT0011/11
TM1663 (28NOV01)
9025-15-12
PN=472
Diagnostic Information
Problem
Solution
Worn pumps
TM1663 (28NOV01)
9025
15
13
9025-15-13
TX,15,GG2162 1913AUG981/3
PN=473
Diagnostic Information
Symptom
Problem
Solution
9025
15
14
No Hydraulic Functions
No oil
TM1663 (28NOV01)
9025-15-14
TX,15,GG2162 1913AUG982/3
PN=474
Diagnostic Information
Symptom
Problem
Solution
Pilot controller
TX,15,GG2162 1913AUG983/3
9025
15
15
TM1663 (28NOV01)
9025-15-15
PN=475
Diagnostic Information
Problem
Solution
Pilot controller
Pilot cap
TX,15,GG2163 1913AUG981/1
TM1663 (28NOV01)
9025-15-16
PN=476
Diagnostic Information
Problem
Solution
Hydraulic pumps
Cylinder leakage
Cylinder leakage
TM1663 (28NOV01)
9025-15-17
9025
15
17
TX,15,GG2164 1913AUG981/2
PN=477
Diagnostic Information
Symptom
Problem
Solution
TX,15,GG2164 1913AUG982/2
9025
15
18
TM1663 (28NOV01)
9025-15-18
PN=478
Diagnostic Information
Problem
Solution
TM1663 (28NOV01)
9025-15-19
TX,15,GG2165 1913AUG981/2
PN=479
9025
15
19
Diagnostic Information
Symptom
Problem
Solution
Disassemble components to
determine cause of failure. See
Groups 4350 and 4360.
TX,15,GG2165 1913AUG982/2
Problem
Solution
9025
15
20
TM1663 (28NOV01)
9025-15-20
TX,15,GG2235 1918SEP001/5
PN=480
Diagnostic Information
Symptom
Problem
Solution
Disassemble components to
determine cause of failure. See
Group 0250 and 0260.
TM1663 (28NOV01)
9025-15-21
TX,15,GG2235 1918SEP002/5
PN=481
9025
15
21
Diagnostic Information
Symptom
Problem
Solution
Leakage in motor
9025
15
22
TM1663 (28NOV01)
9025-15-22
TX,15,GG2235 1918SEP003/5
PN=482
Diagnostic Information
Symptom
Problem
Solution
Propel motor
Propel Is Jerky
TM1663 (28NOV01)
9025-15-23
9025
15
23
TX,15,GG2235 1918SEP004/5
PN=483
Diagnostic Information
Symptom
Problem
Solution
TX,15,GG2235 1918SEP005/5
TM1663 (28NOV01)
9025-15-24
TX,9025,GG2511 1904APR001/2
PN=484
Diagnostic Information
NOTE: Do not use manufacturers identification tags or
markings on line ends to identify lines for this
conversion procedure. The conversion must be
done on the side of flow regulator valve that is
connected to the pilot controllers.
1
2
F
4
1Hose
2Hose
3Hose
4Hose
T128763
UN28APR00
T128763
SAE Pattern
3
4
9025
15
25
F
2
T128778
UN28APR00
T128778
TX,9025,GG2511 1904APR002/2
TM1663 (28NOV01)
9025-15-25
PN=485
Diagnostic Information
T109233
UN07MAY97
9025
15
26
Left Front
TM1663 (28NOV01)
9025-15-26
TX,9025,GG2628 1920MAY981/2
PN=486
Diagnostic Information
1Left Control Valve (5-Spool)
2Right Control Valve
(4-Spool)
3To Rear Pump Control
Valve Pressure Sensor and
Rear Pump Regulator
4Pilot Pressure Signal to
Propel Flow Control Valve
5To Rear Pump Control
Valve
6Inlet Flow From Front
Pump
7Pilot Pressure Signal to
Swing Motor Park Brake
Release ValveBottom
Port
8Pilot Pressure From Pilot
Pressure Regulating Valve
9Power Boost Solenoid
Valve to System Relief
Valve
TX,9025,GG2628 1920MAY982/2
TM1663 (28NOV01)
9025-15-27
PN=487
9025
15
27
Diagnostic Information
T109234
UN25APR97
9025
15
28
Right Rear
TM1663 (28NOV01)
9025-15-28
TX,9025,GG2629 1908JUN981/2
PN=488
Diagnostic Information
1Left Control Valve (5-Spool)
2Right Control Valve
(4-Spool)
5To Rear Pump Control
Valve
7To Swing Motor Park Brake
Release ValveBottom
Port
9Power Boost Solenoid
Valve to System Relief
Valve
10Return to Hydraulic Tank
11Return From Pilot
Shut-Off Valve
12Pilot Pressure Signal to
Swing Motor Park Brake
Release ValveTop Port
13Return From Bucket Flow
Control Valve to Solenoid
Valve Manifold
14Return From Propel Flow
Control Valve to Solenoid
Valve Manifold
TX,9025,GG2629 1908JUN982/2
TM1663 (28NOV01)
9025-15-29
PN=489
9025
15
29
Diagnostic Information
T109235
UN08MAY97
9025
15
30
Bottom
13Return From Bucket Flow
Control Valve to Solenoid
Valve Manifold
17Arm In Pilot to Bucket
Flow Control ValveFront
Bottom Port
37Right Propel Reverse to
Rotary Manifold Right
Rear Port
39To Bucket Cylinder Head
EndBucket Curl
TX,9025,GG2630 1921APR971/1
TM1663 (28NOV01)
9025-15-30
PN=490
Diagnostic Information
T109048
UN15APR97
9025
15
31
Left Front
1Left Control Valve (5-Spool)
2Right Control Valve
(4-Spool)
56System Relief Valve
Isolation Check Valve
57System Relief Valve and
Power Boost
58Dig Pressure Switch
59Flow Combiner Valve
Circuit Check Valve
60System Relief Valve
Isolation Check Valve
61Propel Pressure Switch
62Pilot Pressure Inlet Filter
73Swing Valve
74Arm Reduced Leakage
Valve
75Arm Out Circuit Relief and
Anti-Cavitation Valve
76Plug
77Swing Lift Check Valve
78Arm I Power and Neutral
Passage Check Valves
(Lift Checks), and
Restriction Orifice
79Boom II Power Passage
Check Valve (Lift Check)
TX,9025,GG2625 1920MAY981/1
TM1663 (28NOV01)
9025-15-31
PN=491
Diagnostic Information
T109052
UN15APR97
9025
15
32
Right Rear
1Left Control Valve (5-Spool)
2Right Control Valve
(4-Spool)
57System Relief Valve and
Power Boost
63Solenoid Valve Manifold
64Arm II Valve
65Boom I Valve and Boom
Regenerative Valve
66Boom Reduced Leakage
Valve
67Bucket Valve
TX,9025,GG2626 1921APR971/1
TM1663 (28NOV01)
9025-15-32
PN=492
Diagnostic Information
T109053
UN15APR97
Bottom
1Left Control Valve (5-Spool)
2Right Control Valve
(4-Spool)
64Arm II Valve
65Boom I Valve
67Bucket Valve
TX,9025,GG2627 1920MAY981/1
TM1663 (28NOV01)
9025-15-33
PN=493
9025
15
33
Diagnostic Information
9025
15
34
TM1663 (28NOV01)
9025-15-34
PN=494
Diagnostic Information
TX,9025,GG2618 1919APR971/1
TM1663 (28NOV01)
9025-15-35
PN=495
Diagnostic Information
TX,9025,GG2272 1904APR001/1
TM1663 (28NOV01)
9025-15-36
PN=496
Diagnostic Information
TX,9025,GG2273 1904APR001/1
TM1663 (28NOV01)
9025-15-37
PN=497
Diagnostic Information
TX,9025,GG2620 1919APR971/1
TM1663 (28NOV01)
9025-15-38
PN=498
Diagnostic Information
SHOWN
ROTATED 180
MAIN CONTROL
VALVE
RIGHT
PROPEL
MOTOR
LEFT
PROPEL
MOTOR
ROTARY
MANIFOLD
PROPEL PILOT
CONTROLLER
PILOT
SHUT-OFF
VALVE
PROPEL SYSTEM
T101405
TX,9025,GG2621 1919APR971/1
TM1663 (28NOV01)
9025-15-39
PN=499
FLOW
REGULATOR
Diagnostic Information
TX,9025,GG2622 1919APR971/1
TM1663 (28NOV01)
9025-15-40
PN=500
Group 20
Adjustment
T7660AL
1906DEC91
DLever
SPECIFICATIONS
Pilot Shut-Off Valve
Pilot Shut-Off Valve
Lever-to-Cap Screw Head
Clearance
1. Stop engine.
2. Remove cover underneath operators station.
3. Push pilot shut-off lever (A) forward to the ON
position. Check that lever is against the front stop.
TM1663 (28NOV01)
ECap Screw
9025-20-1
TX,9025,GG2108 1913SEP001/2
PN=501
9025
20
1
Adjustment
TX,9025,GG2108 1913SEP002/2
9025
20
2
TM1663 (28NOV01)
9025-20-2
PN=502
Group 25
Tests
T102900
1929AUG96
486 Processor
16 megs of RAM
WINDOWS 95 or
WINDOWS NT
Standard RS232 Serial Port
CED,TX08227,2893 1904APR001/1
CED,TX08227,2894 1904APR001/1
TM1663 (28NOV01)
9025-25-1
PN=503
Tests
T102901
1904SEP96
9025
25
2
TM1663 (28NOV01)
9025-25-2
TX,9025,CR94 1928JAN991/5
PN=504
Tests
NOTE: The laptop cannot be connected to excavator
system without 5 volts from the system supply.
If laptop cannot establish a successful RS232
connection, check for approximately 5 volts on
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.
The complete excavator diagnostics program is
contained on a single floppy disk. The program
requires approximately twelve megabytes upon
installation. Installation of the program or software
updates is best accomplished using the following
procedure:
TM1663 (28NOV01)
9025-25-3
TX,9025,CR94 1928JAN992/5
PN=505
9025
25
3
Tests
6. From the Start menu, click on Run.
T102902
1929AUG96
9025
25
4
TM1663 (28NOV01)
9025-25-4
TX,9025,CR94 1928JAN993/5
PN=506
T102903
1919SEP96
Tests
9025
25
5
TM1663 (28NOV01)
9025-25-5
TX,9025,CR94 1928JAN994/5
PN=507
Tests
10. Click Next to select default location for software
placement or click Browse to select desired location.
T102904
1929AUG96
TX,9025,CR94 1928JAN995/5
9025
25
6
TM1663 (28NOV01)
9025-25-6
PN=508
Tests
T107199
1911FEB97
TX,9025,CR100 1922APR981/1
TM1663 (28NOV01)
9025-25-7
PN=509
9025
25
7
Tests
T102905
1906SEP96
9025
25
8
TM1663 (28NOV01)
9025-25-8
TX,9025,GG2670 1928JAN991/5
PN=510
Tests
T109483
1913MAY97
9025
25
9
TM1663 (28NOV01)
9025-25-9
TX,9025,GG2670 1928JAN992/5
PN=511
Tests
a. Click on Start button in lower left corner of
screen.
TX,9025,GG2670 1928JAN993/5
T109495
1914MAY97
9025
25
10
TM1663 (28NOV01)
9025-25-10
TX,9025,GG2670 1928JAN994/5
PN=512
T109499
1914MAY97
Tests
TX,9025,GG2670 1928JAN995/5
TM1663 (28NOV01)
9025-25-11
PN=513
9025
25
11
Tests
T111267
1902SEP97
9025
25
12
T102910
1929AUG96
TX,9025,GG2672 1922APR981/2
TX,9025,GG2672 1922APR982/2
TM1663 (28NOV01)
9025-25-12
PN=514
Tests
T111272
1902SEP97
down cursor keys and the Enter key also works for
selecting data items.
After your first choice has been made, the next
Graph Position is highlighted and allows you to
make your second choice. You may choose a data
item for each of the four Graph Positions.
3. After choices have been made, click OK to view
data in graph form in the Monitor Data window.
TM1663 (28NOV01)
9025-25-13
TX,9025,GG2673 1922APR981/3
PN=515
9025
25
13
T102911
1929AUG96
Tests
1929AUG96
TX,9025,GG2673 1922APR982/3
T103375
9025
25
14
TX,9025,GG2673 1922APR983/3
TM1663 (28NOV01)
9025-25-14
PN=516
Tests
T109321
1928APR97
9025
25
15
TM1663 (28NOV01)
9025-25-15
PN=517
Tests
9025
25
16
TM1663 (28NOV01)
9025-25-16
TX,9025,GG2862 1922APR981/4
PN=518
Tests
3.
Push the learning switch (C) up to the top position and
wait for 10 seconds.
4. Turn the key switch on.
5. Click on the Connect button on the Toolbar or on the
Connection drop down menu on the Menu Bar and
then click on Connect.
UN11SEP96
T103674
TM1663 (28NOV01)
9025-25-17
TX,9025,GG2862 1922APR982/4
PN=519
9025
25
17
T111739
1914OCT97
Tests
9025
25
18
TM1663 (28NOV01)
9025-25-18
TX,9025,GG2862 1922APR983/4
PN=520
T103378
1929AUG96
Tests
9025
25
19
TX,9025,GG2862 1922APR984/4
TM1663 (28NOV01)
9025-25-19
PN=521
Tests
Trouble
Corrective Action
01
EC sensor failure
1. Press Clear.
2. Check harness.
3. Replace the EC sensor.
02
1. Press Clear.
2. Check harness.
3. Replace the pump delivery pressure sensor.
03
1. Press Clear.
2. Check harness.
3. Replace the pump delivery pressure sensor.
04
1. Press Clear.
2. Check harness.
3. Replace the pump control pressure sensor.
05
1. Press Clear.
2. Check harness.
3. Replace the pump control pressure sensor.
06
1. Press Clear.
2. Check harness.
3. Replace the arm in pilot pressure sensor.
07
1. Press Clear.
2. Check harness
3. Replace the engine rpm dial.
9025
25
20
TX,9025,GG2643 1922APR981/1
TM1663 (28NOV01)
9025-25-20
PN=522
Tests
Display List
Units
Description
psi
Pilot signal from the front pump control valve to pump regulator
EC angle
Feedback signal from the engine control sensor to the engine and pump
controller
psi
psi
psi
Pilot pressure from pilot controller to control valve pilot cap. Pressure
measured at flow regulator valve.
psi
psi
10
psi
Pilot pressure from propel speed change solenoid valve to speed selector
valve in propel motors. A calculated pressure, not actual pressure.
11
psi
Pilot pressure from speed sense solenoid valve to front and rear pump
regulators. A calculated pressure, not actual pressure.
12
psi
Pilot pressure from power boost solenoid valve to the piston in the system
relief valve. This is a calculated pressure, not the actual pressure.
13
rpm
Set by engine rpm dial. Target speed for engine pull down when under
load. (Approximately 150 rpm difference from engine speed under no
load.)
14
rpm
15
EC motor position
steps
Electrical signal from engine and pump controller to engine control motor.
20
Pressure switch
21
Dig, Grading,
Precision,
Attachment
Signal from control module to engine and pump controller for selected
work mode.
22
E mode switch
On, Off
Signal from control module to engine and pump controller for preset
engine speed.
23
Auto-idle switch
On, Off
24
HP mode switch
On, Off
Signal from control module to engine and pump controller to actuate High
power mode.
25
On, Off
Signal from power boost switch, in right control lever, to engine and pump
controller to actuate power boost function.
TM1663 (28NOV01)
9025-25-21
CED,OUOE035,137 1920MAY981/2
PN=523
9025
25
21
Tests
200LC EXCAVATOR MONITOR DATA ITEMS
Item
Display List
Units
Description
26
Fast, Slow
27
Key switch
On, Off
28
Done, Undone,
Interruption
29
On, Off
CED,OUOE035,137 1920MAY982/2
9025
25
22
TM1663 (28NOV01)
9025-25-22
PN=524
Tests
900 25 rpm
1200 25 rpm
1850 25 rpm
2100 25 rpm
9025
25
23
CED,OUOE003,1073 1904OCT001/1
TM1663 (28NOV01)
9025-25-23
PN=525
Tests
For engine speeds below the adjustable range, operate in Dig Mode
and turn the engine rpm dial to obtain the desired engine speed.
9025
25
24
Specification
200LC Excavator Pump1Flow
Rate to Engine Speed ................................................ 132 L/min (35 gpm)
at 1425 rpm and
14 479 kPa (145 bar) (2100 psi)
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)
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
TM1663 (28NOV01)
9025-25-24
CED,OUOE003,663 1913JUN981/2
PN=526
Tests
For an engine speeds below the adjustable range, operate
in Dig Mode and turn the engine rpm dial to obtain the
desired engine speed.
For adjustment procedure, see Excavator Diagnostics
Program Special FunctionEngine Speed Adjustment in
this group.
CED,OUOE003,663 1913JUN982/2
9025
25
25
TM1663 (28NOV01)
9025-25-25
PN=527
Tests
TX,9025,CR103 1928JAN991/1
TM1663 (28NOV01)
9025-25-26
PN=528
Tests
T113360
1913FEB98
CDiagnostic Port
DJumper Wire
EFuse Box
TM1663 (28NOV01)
9025-25-27
CED,TX08227,2997 1917APR001/2
PN=529
9025
25
27
Tests
For more than one, the LED will have a flashing
sequence for each existing service code with an
approximate 3 second interval between each
sequence. The flashing sequence continues as long
as the key switch in ON and jumper wire is
installed.
CED,TX08227,2997 1917APR002/2
9025
25
28
TM1663 (28NOV01)
9025-25-28
PN=530
Tests
T115419
1927MAY98
9025
25
29
TM1663 (28NOV01)
9025-25-29
TX,9025,GG2603 1921MAY981/2
PN=531
Tests
The engine and pump controller (EPC) is used to
control machine operation. Electronic input signals
from the engine rpm dial (4), sensors (913), and
TX,9025,GG2603 1921MAY982/2
UN28FEB89
AClamp-On Transducer
BBlack Clip ()
CRed Clip (+)
DDigital Readout Unit
CED,TX08227,2879 1911NOV971/1
UN28FEB89
T6808CE
9025
25
30
T6813AG
ATemperature Probe
BCable
CJT05800 Digital Thermometer
CED,TX08227,2895 1919NOV971/1
TM1663 (28NOV01)
9025-25-30
PN=532
Tests
UN25AUG95
T8543AI
CED,TX08227,2896 1919NOV971/1
TM1663 (28NOV01)
9025-25-31
PN=533
9025
25
31
Tests
9025
25
32
T101875
TX,25,GG2226 1914SEP001/1
TM1663 (28NOV01)
9025-25-32
PN=534
Tests
UN11DEC91
T7670AE
9025
25
33
TX,25,GG2227 1913AUG981/1
TM1663 (28NOV01)
9025-25-33
PN=535
Tests
T102305
UN30JUL96
TX,25,GG2228 1914SEP001/1
UN11DEC91
T7660BG
9025
25
34
TX,25,GG2229 1908JUN981/1
TM1663 (28NOV01)
9025-25-34
PN=536
Tests
IT4633
UN19JAN90
TX,25,GG2231 1920NOV971/1
TM1663 (28NOV01)
9025-25-35
PN=537
9025
25
35
Tests
12 minutes approximate
40 minutes approximate
Suction Wand
Discharge Wand
9025
25
36
TX,9025,GG2114 1913SEP001/1
TM1663 (28NOV01)
9025-25-36
PN=538
Tests
50 5C (120 10F)
TX,25,GG2232 1913AUG981/1
TM1663 (28NOV01)
9025-25-37
PN=539
9025
25
37
Tests
13 Nm (115 lb-in.)
UN23AUG88
X9811
UN07AUG96
T102664
9025
25
38
CED,OUOE003,1198 1903OCT001/1
TM1663 (28NOV01)
9025-25-38
PN=540
Tests
UN19MAR91
T7486AL
T103345
UN28AUG96
9025
25
39
TM1663 (28NOV01)
9025-25-39
TX,25,GG2220 1925APR001/2
PN=541
Tests
Indicator light must come ON indicating there is
continuity in the wiring harness and there is a signal
from engine and pump controller.
5. Start engine.
6. Actuate boom up function and then arm in function.
Indicator light must be ON and the brightness must
increase slightly.
If light goes OUT or brightness does not increase,
check wiring harnesses, solenoid coil, rear pump
pressure sensor, arm in pilot pressure sensor, and
boom up pressure switch. (See procedure in Group
9015-15.)
TX,25,GG2220 1925APR002/2
9025
25
40
TM1663 (28NOV01)
9025-25-40
PN=542
Tests
UN19MAR91
T7486AL
T103345
UN28AUG96
9025
25
41
TM1663 (28NOV01)
9025-25-41
TX,25,GG2221 1925APR001/2
PN=543
Tests
Indicator light must come ON indicating there is
continuity in the wiring harness and there is a signal
from engine and pump controller.
5. Start engine.
6. Actuate arm in function over relief to load the engine.
Indicator light must be ON.
If indicator light goes OUT, check wiring harnesses,
solenoid coil, engine rpm dial, and engine speed
sensor. (See procedure in Group 9015-15.)
TX,25,GG2221 1925APR002/2
9025
25
42
TM1663 (28NOV01)
9025-25-42
PN=544
Tests
UN19MAR91
T7486AL
T103345
UN28AUG96
9025
25
43
TM1663 (28NOV01)
9025-25-43
TX,25,GG2219 1925APR001/2
PN=545
Tests
Turn propel speed switch to slow speed propel (turtle).
Indicator light must be ON indicating there is continuity
in the wiring harness and there is a signal from engine
and pump controller.
6. Start engine.
7. Actuate propel function.
8. Turn propel speed switch to fast speed (rabbit).
The brightness of indicator light must increase slightly
while propelling in fast speed.
If light goes OUT or brightness does not increase,
check wiring harnesses, solenoid coil, propel pressure
switch, pump pressure, and pump control valve
pressure sensors. (See procedure in Group 9015-15.)
TX,25,GG2219 1925APR002/2
9025
25
44
TM1663 (28NOV01)
9025-25-44
PN=546
Tests
UN19MAR91
T7486AL
UN28AUG96
T103345
9025
25
45
TM1663 (28NOV01)
9025-25-45
TX,9025,GG2713 1925APR001/2
PN=547
Tests
The brightness of indicator light must increase slightly.
If light goes OUT or brightness does not increase
slightly, check wiring harnesses, solenoid coil, and
power boost switch. (See procedure in Group
9015-15.)
TX,9025,GG2713 1925APR002/2
9025
25
46
TM1663 (28NOV01)
9025-25-46
PN=548
Tests
3.00 volts
2.57 volts
2.42 volts
T7482AH
3.12 volts
UN19MAR91
SPECIFICATIONS
Fast Idle in Standard Mode
Voltage
ESSENTIAL TOOLS
JT07066 Test Harness
SERVICE EQUIPMENT AND TOOLS
JT07306 Analog/Digital Multimeter
JT07290 Laptop Computer
JT07274J Excavator Diagnostics Program Disk
UN19MAR91
JT07273 Cable
T7486AB
9025
25
47
UN07FEB97
T106991
AOutside Terminal
BInside Terminal
COutside Terminal
DEngine Control Motor
EEngine Control Motor Sensor Wiring Harness
FEngine Control Motor Wiring Harness
TM1663 (28NOV01)
9025-25-47
TX,9025,GG2710 1913OCT001/2
PN=549
Tests
NOTE: EC sensor is inside the EC motor.
4. When using a voltmeter, install test harness in series
with wiring harness for EC sensor. Connect voltmeter.
When using the laptop computer and excavator
diagnostic Program, connect the laptop computer. (See
the installation procedure in this group.) Select 2 EC
angle from the Monitor Data menu.
5. Turn the engine rpm dial to the slow idle position.
6. Turn key switch ON. EC motor goes to the start
position.
7. Measure voltage for each mode. Turn engine rpm dial
to fast idle, push E mode switch, push auto-idle switch
then wait 4 seconds, and then turn engine rpm dial to
slow idle. EC motor must move to each position.
Typical voltage readings for each mode (engine speed)
is:
9025
25
48
Specification
Fast Idle in Standard Mode
Voltage.........................................................................................
E (Economy) ModeVoltage ......................................................
Auto-Idle ModeVoltage ............................................................
Slow IdleVoltage ......................................................................
3.12
3.00
2.57
2.42
volts
volts
volts
volts
TX,9025,GG2710 1913OCT002/2
TM1663 (28NOV01)
9025-25-48
PN=550
Tests
UN19MAR91
T7486AD
UN07FEB97
T106991
9025
25
49
TM1663 (28NOV01)
9025-25-49
TX,25,GG2223 1913AUG981/2
PN=551
Tests
c. Push auto-idle switch; wait approximately 4
seconds,
d. And then turn engine rpm dial to slow idle.
EC motor (D) must move the speed control linkage to
each position. Indicators must be ON and change
randomly from bright to dim or dim to bright as engine
rpm dial and switches are pushed to indicate there is
continuity in the wiring harness and there is a signal
from the engine and pump controller (EPC).
If one indicator is OFF, check continuity in that circuit.
If both indicators are OFF, check the wiring harness
and relay. (See procedure in Group 9015-15.)
TX,25,GG2223 1913AUG982/2
9025
25
50
TM1663 (28NOV01)
9025-25-50
PN=552
Tests
T7486AG
UN19MAR91
ABullet Connector
BHarness
CEyelet
DBullet Connector
EIndicator Light
9025
25
51
TX,25,GG2224 1922APR981/1
TM1663 (28NOV01)
9025-25-51
PN=553
Tests
Off
Off
Off
T7918AO
Dig Mode
Boom Position
UN11JAN93
T7918AP
Fast Idle
UN03JAN90
50 5C (120 10F)
Engine Speed
T7160AL
9025
25
52
UN11JAN93
SPECIFICATIONS
TM1663 (28NOV01)
9025-25-52
TX,9025,GG2116 1918SEP001/2
PN=554
Tests
1.
Adjust track sag to specifications. (See procedure in
Group 9020-20.)
UN11JAN93
Specification
Hydraulic OilTemperature ................................... 50 5C (120 10F)
T7918AO
T7918AP
UN11JAN93
Specification
EngineSpeed ............................................................................ Fast Idle
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
9025
25
53
0.3 sec
0.3 sec
UN03JAN90
0.3 sec
0.3 sec
0.3 sec
0.3 sec
1.0 sec
T7160AL
Specification
Boom Raise (Cylinder Extend)
Cycle Time............................................................................. 3.0
Boom Lower (Cylinder Retract)
Cycle Time............................................................................. 2.4
Arm In (Cylinder Extend)Cycle
Time ....................................................................................... 3.6
Arm Out (Cylinder Retract)
Cycle Time............................................................................. 2.4
Bucket Load (Cylinder Extend)
Cycle Time............................................................................. 3.3
Bucket Dump (Cylinder Retract)
Cycle Time............................................................................. 2.1
Swing Left or Right3
Revolutions From a Running
StartCycle Time ............................................................... 13.1
Propel 20 m (65 ft) From a
Running StartCheck Time in
Forward and Reverse Fast Speed
PropelCycle Time............................................................. 13.0
Propel 20 m (65 ft) From a
Running StartCheck Time in
Forward and Reverse Slow
Speed PropelCycle Time ................................................. 20.6
0.6 sec
1.0 sec
TX,9025,GG2116 1918SEP002/2
TM1663 (28NOV01)
9025-25-53
PN=555
Tests
UN19OCT88
50 5C (120 10F)
Fast Idle
Dig Mode
Off
Off
Off
45 (1/8 turn)
T6479AY
SPECIFICATIONS
TM1663 (28NOV01)
9025-25-54
CED,OUOE003,1075 1913AUG981/2
PN=556
Tests
6. Actuate the swing control lever to full stroke. Swing 90
(1/4 turn) and then release control lever.
Upperstructure must come to a stop within 45 (1/8
turn) after releasing control lever.
Specification
After 90 (1/4 turn) Swing,
Upperstructure Must Stop After
Releasing Control Lever Within
Distance ................................................................................. 45 (1/8 turn)
9025
25
55
CED,OUOE003,1075 1913AUG982/2
TM1663 (28NOV01)
9025-25-55
PN=557
Tests
9025
25
56
50 5C (120 10F)
Fast idle
Dig Mode
Off
Off
Off
25 Nm (215 lb-in.)
ESSENTIAL TOOLS
202862 (3/4-16 M 37 x 3/4-16 F 37 Sw x 7/16-20 M 37) Tee
TH108328 Adapter
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler
SERVICE EQUIPMENT AND TOOLS
JT02156A Digital Pressure and Temperature Analyzer
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
7000 kPa (70 bar) (1000 psi) Gauge
JT05800 Digital Thermometer
TM1663 (28NOV01)
9025-25-56
TX,9025,GG2646 1925APR001/5
PN=558
Tests
NOTE: The laptop computer with the excavator diagnostic
Program can be used to make a quick check of
the pilot system pressure using the arm in
function. Connect the computer and select 5 Arm
roll-in pilot pressure from monitor data menu.
Run engine at fast idle and then actuate arm in
function over relief. The pressure reading
displayed is from the arm in pressure sensor
located in the flow regulator valve.
Before making any adjustments, check the pilot
pressure at the pilot pump using a pressure
gauge.
1. Stop the engine.
TX,9025,GG2646 1925APR002/5
T109340
UN29APR97
KVent Plug
TM1663 (28NOV01)
9025-25-57
TX,9025,GG2646 1925APR003/5
PN=559
9025
25
57
Tests
3. Disconnect pilot pressure line (D) at pilot filter. Install
tee (B) and male quick coupler. Connect the digital
pressure and temperature analyzer, and transducer, or
a gauge (C).
UN11SEP96
T103346
UN12MAY97
9025
25
58
T109473
APlug
B202862 Tee
C7000 kPa (70 bar) (1000 psi) Gauge
DPilot Pressure Line
EShim
FPilot Pump
GTH108328 Adapter
TM1663 (28NOV01)
9025-25-58
TX,9025,GG2646 1925APR004/5
PN=560
Tests
T103347
Specification
Pilot Pressure Regulating Valve
at Slow IdlePressure ........................... 3925 980 kPa (39.2 9.8 bar)
(570 140 psi)
Pilot Pressure Regulating Valve
at Fast IdlePressure ........................... 4410 980 kPa (44.1 9.8 bar)
(640 140 psi)
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)
Per 1.0 mm (0.040 in.) Shim
Approximate ChangePressure .................... 304 kPa (3.04 bar) (44 psi)
UN11SEP96
TX,9025,GG2646 1925APR005/5
TM1663 (28NOV01)
9025-25-59
PN=561
9025
25
59
Tests
50 5C (120 10F)
Dig Mode
Off
Off
Off
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
SERVICE EQUIPMENT AND TOOLS
JT02156A Digital Pressure and Temperature Analyzer
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
7000 kPa (70 bar) (1000 psi) Gauge
JT05800 Digital Thermometer
1. Stop engine.
TX,9025,GG2647 1925APR001/3
UN29APR97
KVent Plug
T109340
9025
25
60
TM1663 (28NOV01)
9025-25-60
TX,9025,GG2647 1925APR002/3
PN=562
Tests
3. Disconnect a pilot line (A) at pilot cap fitting. Install tee
(B) and male quick coupler. Install the digital pressure
and temperature analyzer, and transducer, or a gauge
(C) .
4. Install the temperature probe on the hydraulic
tank-to-pump suction line. (See JT05800 Digital
Thermometer Installation in this group.)
5. Heat hydraulic oil to the specified temperature. (See
Hydraulic System Warm-Up Procedure in this group.)
UN18JUN96
Specification
Hydraulic OilTemperature ................................... 50 5C (120 10F)
Specification
Engine in Standard Mode
Speed .................................................................... Slow Idle and Fast Idle
Work Mode SelectorPosition ................................................... Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
T101596
APilot Line
BTee
CPressure Gauge
TX,9025,GG2647 1925APR003/3
TM1663 (28NOV01)
9025-25-61
PN=563
Tests
4555C (110130F)
20752125 rpm
Dig Mode
Off
Off
Off
32 mm Nut Torque
27 mm Nut Torque
ESSENTIAL TOOLS
TH108328 Adapter (2 used)
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler
9025
25
62
TM1663 (28NOV01)
9025-25-62
TX,9025,GG2648 1924OCT001/6
PN=564
Tests
3. ServiceEXPERT Application connection
1929AUG96
T102900
T133476
UN28AUG00
1Fuse Box
2Diagnostic Port
3Learning Switch
TM1663 (28NOV01)
9025-25-63
TX,9025,GG2648 1924OCT002/6
PN=565
9025
25
63
Tests
4. Excavator Diagnostics Program connection
1929AUG96
T102900
1Fuse Box
2Diagnostic Port
3Learning Switch
T133476
9025
25
64
UN28AUG00
TM1663 (28NOV01)
9025-25-64
TX,9025,GG2648 1924OCT003/6
PN=566
Tests
5. Digital Pressure/Temperature Analyzer or Gauge
connection
a. Stop the engine.
UN29APR97
T109340
UN18JUN96
T101614
AAdapter
BRear Pump
CFront Pump
KVent Plug
TM1663 (28NOV01)
9025-25-65
TX,9025,GG2648 1924OCT004/6
PN=567
9025
25
65
Tests
f. Adjust the system relief and power boost valve (D)
pressures as needed.
System Relief and Power Boost ValveSpecification
System Relief ValvePressure ................................ 34 32536 285 kPa
(343.0362.6 bar) (49805265
psi)
Power Boost ValvePressure .................................. 35 30538 245 kPa
(353.1382.5 bar) (51255550
psi)
UN18JUN96
T101616
TM1663 (28NOV01)
9025-25-66
TX,9025,GG2648 1924OCT005/6
PN=568
Tests
Hold adjusting plug and tighten 27 mm nut.
System Relief and Power Boost ValveSpecification
Second Adjusting PlugPressure
Change ....................................................... 5295 kPa (53.0 bar) (770 psi)
approximate per 1/4 turn
27 mm NutTorque ......................................... 5968 Nm (4351 lb-ft)
TX,9025,GG2648 1924OCT006/6
9025
25
67
TM1663 (28NOV01)
9025-25-67
PN=569
Tests
9025
25
68
4555C (110130F)
875925 rpm
Dig Mode
Off
Off
Off
Off
ESSENTIAL TOOLS
TH108328 Adapter (2 used)
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler
SERVICE EQUIPMENT AND TOOLS
JT05800 Digital Thermometer
9239-096 CED W9 Cable
Laptop Computer with ServiceEXPERT Application
JT07290 Laptop Computer
JT07274J Excavator Diagnostics Program Disk
JT07273 Cable
JT02156A Digital Pressure/Temperature Analyzer
JT02160 Transducer 70 000 kPa (700 bar) (10,000 psi)
Gauge 70 000 kPa (700 bar) (10,000 psi)
JT05801 Clamp-On Electronic Tachometer
6 mm Hex Key Wrench
17 mm Combination Wrench
TM1663 (28NOV01)
9025-25-68
TX,9025,GG2649 1925OCT001/7
PN=570
Tests
3. ServiceEXPERT Application connection
1929AUG96
T102900
T133476
UN28AUG00
1Fuse Box
2Diagnostic Port
3Learning Switch
TM1663 (28NOV01)
9025-25-69
TX,9025,GG2649 1925OCT002/7
PN=571
9025
25
69
Tests
4. Excavator Diagnostics Program connection
1929AUG96
T102900
1Fuse Box
2Diagnostic Port
3Learning Switch
T133476
9025
25
70
UN28AUG00
TM1663 (28NOV01)
9025-25-70
TX,9025,GG2649 1925OCT003/7
PN=572
Tests
5. Digital Pressure/Temperature Analyzer or Gauge
connection
a. Stop the engine.
UN29APR97
T109340
T101614
UN18JUN96
AAdapter
BRear Pump
CFront Pump
KVent Plug
TM1663 (28NOV01)
9025-25-71
TX,9025,GG2649 1925OCT004/7
PN=573
9025
25
71
Tests
6. Test and Adjustment
a. Turn the second adjusting plug (G) for system relief
valve (D) in 1/4 turn to increase the pressure
setting.
b. Raise and lower boom to pressurize hydraulic oil
tank.
c. Do Hydraulic System Warm-Up Procedure to heat
hydraulic oil. (See procedure in this group.)
UN18JUN96
T101616
9025
25
72
TM1663 (28NOV01)
9025-25-72
TX,9025,GG2649 1925OCT005/7
PN=574
UN29APR97
UN29APR97
T109335
T109334
Tests
9025
25
73
T109336
UN29APR97
TM1663 (28NOV01)
9025-25-73
TX,9025,GG2649 1925OCT006/7
PN=575
Tests
g. Adjust the circuit relief valve as needed. Turn
adjusting screw IN to increase pressure setting; turn
adjusting screw out to decrease pressure setting.
Hold screw and tighten nut.
Circuit Relief ValveSpecification
Circuit Relief Valve Adjusting
ScrewPressure Change ............................. 5295 kPa (53 bar) (770 psi)
approximate per 1/4 turn
TX,9025,GG2649 1925OCT007/7
9025
25
74
TM1663 (28NOV01)
9025-25-74
PN=576
Tests
4555C (110130F)
875925 rpm
Dig Mode
Off
Off
Off
ESSENTIAL TOOLS
TH108328 Adapter (2 used)
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler
SERVICE EQUIPMENT AND TOOLS
JT05800 Digital Thermometer
TM1663 (28NOV01)
9025-25-75
TX,9025,GG2650 1925OCT001/6
PN=577
Tests
3. ServiceEXPERT Application connection
1929AUG96
T102900
UN28AUG00
1Fuse Box
2Diagnostic Port
3Learning Switch
T133476
9025
25
76
TM1663 (28NOV01)
9025-25-76
TX,9025,GG2650 1925OCT002/6
PN=578
Tests
4. Excavator Diagnostics Program connection
1929AUG96
T102900
UN28AUG00
T133476
1Fuse Box
2Diagnostic Port
3Learning Switch
TM1663 (28NOV01)
9025-25-77
TX,9025,GG2650 1925OCT003/6
PN=579
9025
25
77
Tests
5. Digital Pressure/Temperature Analyzer or Gauge
connection
a. Stop the engine.
UN29APR97
T109340
UN18JUN96
T101614
AAdapter
BRear Pump
CFront Pump
KVent Plug
TM1663 (28NOV01)
9025-25-78
TX,9025,GG2650 1925OCT004/6
PN=580
Tests
e. Repeat procedure for the opposite direction. Record
the pressure reading.
Swing Motor Crossover Relief ValveSpecification
Crossover Relief ValvePressure ............................ 27 65529 615 kPa
(276.6296.2 bar) (40104295
psi)
TX,9025,GG2650 1925OCT005/6
T101716
UN20JUN96
9025
25
79
TX,9025,GG2650 1925OCT006/6
TM1663 (28NOV01)
9025-25-79
PN=581
Tests
4555C (110130F)
875925 rpm
Dig Mode
Off
Off
Off
ESSENTIAL TOOLS
TH108328 Adapter (2 used)
ServiceEXPERT Application,
Excavator Diagnostics Program,
Digital Pressure/Temperature Analyzer or Gauge.
TM1663 (28NOV01)
9025-25-80
TX,9025,GG2651 1926OCT001/7
PN=582
Tests
3. ServiceEXPERT Application connection
1929AUG96
T102900
T133476
UN28AUG00
1Fuse Box
2Diagnostic Port
3Learning Switch
TM1663 (28NOV01)
9025-25-81
TX,9025,GG2651 1926OCT002/7
PN=583
9025
25
81
Tests
4. Excavator Diagnostics Program connection
1929AUG96
T102900
1Fuse Box
2Diagnostic Port
3Learning Switch
T133476
9025
25
82
UN28AUG00
TM1663 (28NOV01)
9025-25-82
TX,9025,GG2651 1926OCT003/7
PN=584
Tests
5. Digital Pressure/Temperature Analyzer or Gauge
connection
a. Stop the engine.
UN29APR97
T109340
T101614
UN18JUN96
AAdapters
BRear Pump
CFront Pump
KVent Plug
TM1663 (28NOV01)
9025-25-83
TX,9025,GG2651 1926OCT004/7
PN=585
9025
25
83
Tests
6. Test and Adjustment
T101616
9025
25
84
TX,9025,GG2651 1926OCT005/7
UN02JUL96
T101856
TM1663 (28NOV01)
9025-25-84
TX,9025,GG2651 1926OCT006/7
PN=586
Tests
f. Slowly push propel pedal, for propel motor being
stalled, to full travel in the direction for the crossover
relief valve (E and F) being checked.
UN02JUL96
T101857
9025
25
85
TX,9025,GG2651 1926OCT007/7
TM1663 (28NOV01)
9025-25-85
PN=587
Tests
9025
25
86
4555C (110130F)
Dig Mode
Off
Off
Off
JT07273 Cable
4 mm (0.157 in.)
ESSENTIAL TOOLS
JT03191 (7/16-20M 37 x 7/16-20 F 37 x 7/16-20 M 37) (Parker
No. 063T-4-4) Tee
TM1663 (28NOV01)
9025-25-86
TX,9025,GG2121 1924OCT001/7
PN=588
Tests
1. Stop the engine.
2. Loosen vent plug (K) to release the air pressure in
hydraulic oil tank.
UN29APR97
T109340
T101708
UN20JUN96
TM1663 (28NOV01)
9025-25-87
TX,9025,GG2121 1924OCT002/7
PN=589
9025
25
87
Tests
7. Connect the laptop computer to diagnostic port (2)
using the cable. Port is located behind the left rear
corner of operators seat.
1929AUG96
T102900
UN28AUG00
T133476
9025
25
88
1Fuse Box
2Diagnostic Port
3Learning Switch
TM1663 (28NOV01)
9025-25-88
TX,9025,GG2121 1924OCT003/7
PN=590
Tests
10. Operate the machine as follows to check each
solenoid valve (AD). Record the pressure readings
from gauge and computer screen:
Arm regenerative solenoid valve (SC)
Speed sensing solenoid valve (SD)
Propel speed change solenoid valve (SI)
Power boost solenoid valve (SG)
UN28AUG96
T103345
9025
25
89
TM1663 (28NOV01)
9025-25-89
TX,9025,GG2121 1924OCT004/7
PN=591
Tests
NOTE: Pressure reading shown on the computer screen
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 at fast idle. The pressure
reading decreases as the engine speed increases.
The reading indicates that the engine speed
sensor is OK, the signal for target engine speed is
selected by the engine rpm dial, and a electrical
signal is generated. See Engine Speed Sensing
Control Circuit Operation. (See theory of operation
in Group 9025-05.)
c. Propel speed change solenoid valve (SI)run
engine at 1200 rpm or more, drive the machine at
fast speed propel.
9025
25
90
TM1663 (28NOV01)
9025-25-90
TX,9025,GG2121 1924OCT005/7
PN=592
Tests
NOTE: Pressure reading shown on the computer screen
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. The
power boost solenoid valve is also actuated in
precision work mode when boom up function is
actuated. See Power Boost Control Circuit
Operation. (See theory of operation in Group
9025-05.)
11. Compare the pressure readings. The pressure
reading on gauge must be within the specified range
of calculated pressure reading on the computer
screen.
Proportional Solenoid ValvesSpecification
Arm Regenerative (SC)
Pressure ................................................ Laptop Computer Reading 196
kPa (1.96 bar) (28 psi)
Speed Sensing (SD)Pressure............ Laptop Computer Reading 196
kPa (1.96 bar) (28 psi)
Propel Speed Change (SI)
Pressure ................................................ Laptop Computer Reading 196
kPa (1.96 bar) (28 psi)
Power Boost (SG)Pressure ............... Laptop Computer Reading 196
kPa (1.96 bar) (28 psi)
9025
25
91
TM1663 (28NOV01)
9025-25-91
TX,9025,GG2121 1924OCT006/7
PN=593
Tests
12. Adjust the solenoid valve (H) as needed.
UN20JUN96
T101709
HSolenoid Valve
IAdjusting Screw
JNut
9025
25
92
TX,9025,GG2121 1924OCT007/7
TM1663 (28NOV01)
9025-25-92
PN=594
Tests
4555C (110130F)
8752125 rpm
Dig Mode
Off
Off
Off
ESSENTIAL TOOLS
JT03191 (7/16-20 M 37 x 7/16-20 M 37 x 7/16-20 F 37) (Parker
No. 063T4) Tee (2 used)
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler
SERVICE EQUIPMENT AND TOOLS
JT05800 Digital Thermometer
ServiceEXPERT Application,
Excavator Diagnostics Program,
Digital Pressure/Temperature Analyzer or Gauge.
JT07273 Cable
JT02156A Digital Pressure/Temperature Analyzer
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
7000 kPa (70 bar) (1000 psi) Gauge
JT05801 Clamp-On Electronic Tachometer
8 mm Hex Key Wrench
22 mm Combination Wrench
TM1663 (28NOV01)
9025-25-93
TX,9025,GG2652 1926OCT001/6
PN=595
9025
25
93
Tests
3. ServiceEXPERT Application connection
1929AUG96
T102900
UN28AUG00
1Fuse Box
2Diagnostic Port
3Learning Switch
T133476
9025
25
94
TM1663 (28NOV01)
9025-25-94
TX,9025,GG2652 1926OCT002/6
PN=596
Tests
4. Excavator Diagnostics Program connection
1929AUG96
T102900
T133476
UN28AUG00
1Fuse Box
2Diagnostic Port
3Learning Switch
TM1663 (28NOV01)
9025-25-95
TX,9025,GG2652 1926OCT003/6
PN=597
9025
25
95
Tests
5. Digital Pressure/Temperature Analyzer or Gauge
connection
a. Stop the engine.
UN29APR97
T109340
T103348
9025
25
96
UN11SEP96
TM1663 (28NOV01)
9025-25-96
TX,9025,GG2652 1926OCT004/6
PN=598
Tests
Actuate the raised track to full speed. Increase
engine speed to fast idle.
Record pressure reading at fast idle. The pressure
increases as engine speed increases.
TX,9025,GG2652 1926OCT005/6
T103491
UN13SEP96
T103492
UN13SEP96
TX,9025,GG2652 1926OCT006/6
TM1663 (28NOV01)
9025-25-97
PN=599
9025
25
97
Tests
9025
25
98
T141914
UN15MAY01
A13 mm Nut
BMaximum Flow Adjusting
Screw
CFlow Adjusting Cartridge
(Track Cycle Time)
D30 mm Nut
EMinimum Flow Adjusting
Screw
F17 mm Nut
G17 mm Nut
TM1663 (28NOV01)
9025-25-98
J30 mm Nut
TX,9025,GG2109 1907MAY011/3
PN=600
Tests
SPECIFICATIONS
Specification
Regulator Flow Adjusting
Cartridge (Track Cycle Time)
Turn......................................................... 1/4 turn IN decreases pump
flow rate approximately 22.5
L/min (6 gpm)
TM1663 (28NOV01)
9025-25-99
TX,9025,GG2109 1907MAY012/3
PN=601
9025
25
99
Tests
Specification
Regulator Load Adjusting
Screw (Inner Spring) (Engine
Pulldown at High Pressure)
Turn................................................... 1/4 turn IN increases pump flow
rate approximately 5.46 L/min
(1.45 gpm)
Specification
Regulator Load Adjusting
Cartridge (Outer Spring)
(Engine Pulldown at Medium
Pressure)Turn ............................... 1/4 turn IN increases pump flow
rate approximately 22.5 L/min
(6 gpm)
TX,9025,GG2109 1907MAY013/3
9025
25
,100
TM1663 (28NOV01)
9025-25-100
PN=602
Tests
Oil Temperature
Engine in Standard Mode Speed
Fast Idle
Dig Mode
Off
Off
Off
ESSENTIAL TOOLS
7/16-20 M 37 (Parker No. 03CP-4) Plug (2 used)
SERVICE EQUIPMENT AND TOOLS
JT05800 Digital Thermometer
Stop Watch
17 mm Combination Wrench
Flat Blade Screwdriver
9025
25
,101
TM1663 (28NOV01)
9025-25-101
TX,9025,GG2125 1915JUN981/4
PN=603
Tests
5. Loosen vent plug (K) to release the air pressure in
hydraulic oil tank.
T109340
UN29APR97
KVent Plug
TX,9025,GG2125 1915JUN982/4
8. Raise the left track off ground for rear pump or the
right track for front pump.
UN11SEP96
T103501
9025
25
,102
Specification
Engine in Standard Mode
Speed ........................................................................................... Fast Idle
Work ModePosition .................................................................. Dig Mode
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
Propel Speed SwitchPosition.................................. Slow Speed (Turtle)
TM1663 (28NOV01)
9025-25-102
TX,9025,GG2125 1915JUN983/4
PN=604
Tests
10. Adjust the minimum flow adjusting screw (E) as
needed to obtain the specified cycle time. Turn screw
in to decrease the cycle time (the minimum flow rate
increases), turn screw out to increase the cycle time
(the minimum flow rate decreases). Hold the screw
and tighten the nut (F).
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
T103502
UN24AUG98
TX,9025,GG2125 1915JUN984/4
TM1663 (28NOV01)
9025-25-103
PN=605
9025
25
,103
Tests
Oil Temperature
Engine in Standard Mode Speed
Fast Idle
Dig Mode
Off
Off
Off
TM1663 (28NOV01)
9025-25-104
TX,9025,GG2126 1928NOV011/3
PN=606
Tests
5. Raise the left track off ground for rear pump or the
right track for front pump.
6. Actuate propel function to full speed. Record cycle time
for three revolutions.
Repeat procedure for the other pump.
TX,9025,GG2126 1928NOV012/3
T103535
A13 mm Nut
BMaximum Flow Adjusting Screw
CFlow Adjusting Cartridge (Track Cycle Time)
D30 mm Nut
UN18SEP96
9025
25
,105
TX,9025,GG2126 1928NOV013/3
TM1663 (28NOV01)
9025-25-105
PN=607
Tests
50 5C (120 10F)
21002125 rpm
Dig Mode
Off
Off
Off
ESSENTIAL TOOLS
TH108328 Adapter (2 used)
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler
9025
25
,106
TM1663 (28NOV01)
9025-25-106
TX,9025,GG2242 1907SEP001/13
PN=608
Tests
T102900
1929AUG96
TM1663 (28NOV01)
9025-25-107
TX,9025,GG2242 1907SEP002/13
PN=609
9025
25
,107
Tests
If laptop computer with excavator diagnostic program is
not available, use the digital pressure and temperature
analyzer, and transducer, or a gauge.
UN29APR97
T109340
T101614
9025
25
,108
UN18JUN96
Specification
OilTemperature ................................................... 50 5C (120 10F)
AAdapters
BRear Pump
CFront Pump
KVent Plug
TM1663 (28NOV01)
9025-25-108
TX,9025,GG2242 1907SEP003/13
PN=610
Tests
UN02JUL96
T101856
TX,9025,GG2242 1907SEP004/13
9025
25
,109
T103527
UN18SEP96
J13 mm Nut
KLoad Adjusting Screw (Inner Spring)
LLoad Adjusting Cartridge (Outer Spring)
M30 mm Nut
TM1663 (28NOV01)
9025-25-109
TX,9025,GG2242 1907SEP005/13
PN=611
Tests
e. Adjust system relief valve (D):
Run engine at fast idle.
Actuate and hold both propel functions over relief.
Loosen 32 mm nut (H). Turn second adjusting
plug (G) out to obtain 15 170 kPa (152 bar) (2200
psi). Tighten nut.
f. Run engine at fast idle.
g. Actuate and hold both propel functions over relief.
T101616
UN18JUN96
9025
25
,110
TM1663 (28NOV01)
9025-25-110
TX,9025,GG2242 1907SEP006/13
PN=612
Tests
NOTE: Initial procedure is to adjust the load adjusting
cartridges (L) to match the two pumps before
making the final adjustment to get the combined
pump engine pulldown at medium pressure.
Hydraulic pressure increases as the load adjusting
cartridges are turned in because the pump flow is
increasing.
h. Turn the load adjusting cartridge (L) on front pump
regulator in until engine speed just starts to
decrease. Then, slowly turn the load adjusting
cartridge out and in to verify the exact point where
engine speed starts to decrease (010 rpm).
UN18SEP96
T103527
9025
25
,111
J13 mm Nut
KLoad Adjusting Screw (Inner Spring)
LLoad Adjusting Cartridge (Outer Spring)
M30 mm Nut
TM1663 (28NOV01)
9025-25-111
TX,9025,GG2242 1907SEP007/13
PN=613
Tests
IMPORTANT: If the load adjusting cartridge are not
turned in equal amounts, the engine
speed will pulldown to the specified
rpm but the pump flow rates will not be
equal and the machine will mistrack.
n. Check the adjustments:
Run the engine at fast idle.
Actuate and hold right propel function over relief.
Record rpm reading. Release propel function.
Actuate and hold left propel function over relief.
Record rpm reading. Release propel function.
The rpm reading for front and rear pumps must
be within 10 rpm of each other to prevent
machine from mistracking.
TX,9025,GG2242 1907SEP008/13
T101616
9025
25
,112
TM1663 (28NOV01)
9025-25-112
TX,9025,GG2242 1907SEP009/13
PN=614
Tests
NOTE: Initial procedure is to adjust the load adjusting
screws (K) to match the two pumps before making
the final adjustment to get the combined pump
engine pulldown at high pressure.
d. Turn load adjusting screw (K) on front pump
regulator in until engine speed just starts to
decrease. Then, slowly turn load adjusting screw
out and in to verify the exact point where the engine
speed just starts to decrease (010 rpm).
e. Turn load adjusting screw (K) on rear pump
regulator in until engine speed just starts to
decrease. Then, slowly turn load adjusting screw
out and in to verify the exact point where the engine
speed just starts to decrease (010 rpm).
f. Release both propel functions.
UN18SEP96
T103527
9025
25
,113
J13 mm Nut
KLoad Adjusting Screw (Inner Spring)
LLoad Adjusting Cartridge (Outer Spring)
M30 mm Nut
TM1663 (28NOV01)
9025-25-113
TX,9025,GG2242 1907SEP0010/13
PN=615
Tests
j. Adjust the system relief valve (D) to operating
pressure:
Run the engine at fast idle.
Actuate and hold both propel functions over relief.
Loosen 32 mm nut (H). Turn second adjusting
plug (G) in to obtain specified pressure. Tighten
32 mm nut.
Specification
System Relief ValvePressure ................. 34 325 + 1960 - 0 kPa (343 +
19.6 - 0 bar) (4980 + 285 - 0 psi)
T101616
UN18JUN96
9025
25
,114
TM1663 (28NOV01)
9025-25-114
TX,9025,GG2242 1907SEP0011/13
PN=616
Tests
k. Check the adjustments:
Actuate and hold right propel function over relief.
Engine pulldown must not go below 1975 rpm. If
it does, turn front pump load adjusting cartridge
(L) out until pulldown is 19751995 rpm. Record
rpm reading. Release propel function.
Actuate and hold left propel function over relief.
Engine pulldown must not go below 1975 rpm. If
it does, turn rear pump load adjusting cartridge
(L) out until pulldown is 19751995 rpm. Record
rpm reading. Release propel function.
The pulldown rpm reading for front and rear
pumps must be within 10 rpm of each other to
prevent machine from mistracking.
l. Make final pump regulator adjustments by observing
how straight the machine tracks under load.
T103527
UN18SEP96
J13 mm Nut
KLoad Adjusting Screw (Inner Spring)
LLoad Adjusting Cartridge (Outer Spring)
M30 mm Nut
9025
25
,115
TM1663 (28NOV01)
9025-25-115
TX,9025,GG2242 1907SEP0012/13
PN=617
Tests
9. Do the Final Tracking Checks:
a. Propel machine forward on a flat area of naturally
compacted soil and then on a slope of naturally
compacted soil.
b. If machine mistracks to the left on the flat area, turn
the load adjusting cartridge (L) on the front pump
regulator out to slow the right track.
c. If the machine mistracks to the right under load on
the slope, turn the load adjusting screw (K) on the
rear pump regulator out to slow the left track.
d. If the machine mistracks to the left under load on
the slope, turn the load adjusting screw (K) on the
front pump regulator out to slow the right track.
T103527
UN18SEP96
J13 mm Nut
KLoad Adjusting Screw (Inner Spring)
LLoad Adjusting Cartridge (Outer Spring)
M30 mm Nut
TX,9025,GG2242 1907SEP0013/13
9025
25
,116
TM1663 (28NOV01)
9025-25-116
PN=618
Tests
2000 10 rpm
Dig Mode
Off
Off
Off
Oil Temperature
50 5C (120 10F)
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
,117
TM1663 (28NOV01)
9025-25-117
TX,9025,GG2128 1907SEP001/4
PN=619
Tests
1. Stop the engine.
2. Loosen vent plug (K) to release the air pressure in
hydraulic oil tank.
T109340
UN29APR97
KVent Plug
TX,9025,GG2128 1907SEP002/4
9025
25
,118
TM1663 (28NOV01)
9025-25-118
PN=620
T103554
UN16SEP96
Tests
GTH108328 Adapter
HTH108325 Elbow
IReturn Manifold
JBulkhead
TM1663 (28NOV01)
9025-25-119
TX,9025,GG2128 1907SEP003/4
PN=621
9025
25
,119
Tests
NOTE: Pilot pressure is routed to the pump regulator
valves so the pumps operate at maximum
displacement.
5. Install the temperature probe on the hydraulic
tank-to-pump suction line. (See JT05800 Digital
Thermometer Installation in this group.)
6. Install the tachometer. (See JT05801 Clamp-On
Electronic Tachometer Installation in this group.)
7. Check that the flow meter loading valve is open.
8. Operate the machine at specification.
Specification
Engine in Standard Mode
Speed........................................................................... 2000 10 rpm
Work Mode SelectorPosition............................................. Dig Mode
E Mode SwitchPosition ............................................................... Off
HP Mode SwitchPosition............................................................. Off
Auto-Idle SwitchPosition ............................................................. Off
Specification
OilTemperature ............................................ 50 5C (120 10F)
9025
25
,120
TX,9025,GG2128 1907SEP004/4
TM1663 (28NOV01)
9025-25-120
PN=622
Tests
50 6C (120 10F)
2000 rpm
Dig Mode
Off
Off
Off
TX,9025,GG2663 1908JUN981/3
T109340
UN29APR97
KVent Plug
TM1663 (28NOV01)
9025-25-121
TX,9025,GG2663 1908JUN982/3
PN=623
9025
25
,121
Tests
2. Connect flow meter in series with pilot pressure inlet
line (A) at pilot filter (B).
Open the flow meter loading valve.
3. Install the temperature probe on the hydraulic
tank-to-pump suction line. (See JT05800 Digital
Thermometer Installation in this group.)
4. Heat hydraulic oil to the specified temperature. (See
Hydraulic System Warm-Up Procedure in this group.)
Specification
OilTemperature ................................................... 50 6C (120 10F)
UN11SEP96
T103571
Specification
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
TM1663 (28NOV01)
9025-25-122
PN=624
Tests
Fast Idle
Dig Mode
Off
Off
Off
Oil Temperature
50 5C (120 10F)
9025
25
,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
TM1663 (28NOV01)
9025-25-123
TX,9025,GG2664 1908JUN981/3
PN=625
Tests
5. Lower the boom so bucket is approximately 300500
mm (1220 in.) off the ground with the arm retracted
and the bucket curled.
6. Start propelling with the machine at the end of course
and the tracks aligned with the straight line. Actuate
the propel pilot controller to full stroke.
TX,9025,GG2664 1908JUN982/3
Specification
Mistrack at 20 m (65 ft)
Distance ............................................................ 200 mm (7-7/8 in.) or less
T6998AS
UN23MAR89
TX,9025,GG2664 1908JUN983/3
9025
25
,124
TM1663 (28NOV01)
9025-25-124
PN=626
Tests
50 5C (120 10F)
Off
Arm Length
2.91 (9 ft 7 in.)
Bucket Capacity
Engine Speed
Off
20 mm (13/16 in.)
maximum allowable for five
minutes
20 mm (13/16 in.)
maximum allowable for five
minutes
20 mm (13/16 in.)
maximum allowable for five
minutes
150 mm (6 in.)
maximum allowable for five
minutes
9025
25
,125
TM1663 (28NOV01)
9025-25-125
TX,9025,GG2129 1909MAY971/3
PN=627
Tests
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)
TX,9025,GG2129 1909MAY972/3
9025
25
,126
TM1663 (28NOV01)
9025-25-126
PN=628
Tests
4. Position arm cylinder so rod is extended the specified
length from the retracted position.
UN06DEC88
Specification
Bucket CylinderLength ............................ 50 mm (2.00 in.) approximate
retraction
T6904AG
Specification
Arm CylinderLength ................................ 50 mm (2.00 in.) approximate
extension
9025
25
,127
Specification
Arm CylinderDrift........................................................ 20 mm (13/16 in.)
maximum allowable for five
minutes
Bucket CylinderDrift ................................................... 20 mm (13/16 in.)
maximum allowable for five
minutes
Boom CylinderDrift ..................................................... 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
TX,9025,GG2129 1909MAY973/3
TM1663 (28NOV01)
9025-25-127
PN=629
Tests
50 5C (120 10 F)
Fast Idle
Dig Mode
Off
Off
Off
Calibrated Container
TM1663 (28NOV01)
9025-25-128
TX,9025,GG2666 1908JUN981/3
PN=630
Tests
4. Loosen vent plug (K) to release the air pressure in
hydraulic oil tank.
T109340
UN29APR97
KVent Plug
TX,9025,GG2666 1908JUN982/3
9025
25
,129
TM1663 (28NOV01)
9025-25-129
PN=631
Tests
5. Disconnect drain line (A) from return manifold. Install a
cap on elbow. Put drain line in a calibrated container.
CAUTION: To avoid personnel injury, clear area
of all bystanders before doing test. Slowly
swing through one complete revolution to
ensure that the area is clear of objects before
doing test.
6. Raise and lower boom to pressurize hydraulic oil tank.
7. Operate swing function for one minute. Compare
amount of leakage to specifications. Repeat for swing
in opposite direction.
9025
25
,130
T101868
UN10JUL96
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
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
swinging
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
TM1663 (28NOV01)
9025-25-130
PN=632
Tests
50 5C (120 10 F)
Fast Idle
Dig Mode
Off
Off
Off
TM1663 (28NOV01)
9025-25-131
TX,9025,GG2667 1909MAY971/5
PN=633
Tests
4. Loosen vent plug (K) to release the air pressure in
hydraulic oil tank.
T109340
UN29APR97
KVent Plug
TX,9025,GG2667 1909MAY972/5
9025
25
,132
TM1663 (28NOV01)
9025-25-132
PN=634
Tests
5. Disconnect the drain line (A) at return manifold. Put
line in a calibrated container (D). Install a cap (B) on
the open fitting (C).
6. Raise track off the ground for side being checked.
7. Run machine at specifications.
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)
T7660BE
Specification
Propel MotorLeakage........................... 1.52.0 L/min (0.40.53 gpm)
new acceptable while propelling
with track raised
Leakage ........................................................... 3.4 L/min (0.80 gpm) used
maximum acceptable while
propelling with track raised
9025
25
,133
UN06DEC88
T6876FG
TM1663 (28NOV01)
9025-25-133
TX,9025,GG2667 1909MAY973/5
PN=635
Tests
9. To check propel motor for leakage at stall, install pins
or round bar stock (D) between the sprockets and track
frame.
T101856
UN02JUL96
Specification
Propel MotorLeakage......................... 1.54.8 L/min (0.401.20 gpm)
new acceptable while stalled
Leakage ........................................................... 5.2 L/min (1.40 gpm) used
maximum acceptable while
stalled
TX,9025,GG2667 1909MAY974/5
UN11JAN93
10.
T7915BB
9025
25
,134
TX,9025,GG2667 1909MAY975/5
TM1663 (28NOV01)
9025-25-134
PN=636
Section 9031
Page
Oil Charge
R134a Component. . . . . . . . . . . . . . . . . . .9031-20-3
Refrigerant
Recovery, Recycling and Charging Station
Installation Procedure. . . . . . . . . . . . . . .9031-20-5
Recover
R134a System . . . . . . . . . . . . . . . . . . . . . .9031-20-6
Evacuate
R134a System . . . . . . . . . . . . . . . . . . . . . .9031-20-7
Charge
R134a System . . . . . . . . . . . . . . . . . . . . .9031-20-10
Compressor
Check and Adjust Belt Tension . . . . . . . .9031-20-12
Group 25Tests
Refrigerant
Proper Handling. . . . . . . . . . . . . . . . . . . . .9031-25-1
R134a Cautions . . . . . . . . . . . . . . . . . . . . .9031-25-1
Air Conditioning
R134a System Test . . . . . . . . . . . . . . . . . .9031-25-2
Operating Pressure
Diagnostic Chart . . . . . . . . . . . . . . . . . . . .9031-25-5
Switch
High Pressure Test . . . . . . . . . . . . . . . . . .9031-25-6
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-7
Refrigerant
Hoses and Tubing Inspection. . . . . . . . . . .9031-25-8
9031-1
PN=1
9031
Contents
9031
TM1663 (28NOV01)
9031-2
PN=2
Group 05
Theory of Operation
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits
discharge of any refrigerant into the atmosphere, and
requires that refrigerant be recovered using the
approved recovery equipment.
IMPORTANT: To meet government standards
relating to the use of refrigerants,
R134a is used in the air conditioning
system. Because it does not contain
chlorine, R134a is not detrimental to
the ozone in the atmosphere.
However, it is illegal to discharge
any refrigerant into the atmosphere.
TX,9031,UU3135 1913AUG961/1
TX,9031,UU3136 1913AUG961/1
TM1663 (28NOV01)
9031-05-1
PN=639
9031
05
1
Theory of Operation
T118692
1930NOV98
9031
05
2
DEngine Fan
ECondenser
FHigh Pressure Gas
GCompressor
TM1663 (28NOV01)
9031-05-2
TX,9031,UU3137 1913AUG961/2
PN=640
Theory of Operation
The actual cooling and drying of cab air takes place at
the evaporator. Flow of the high pressure liquid
refrigerant is controller by the expansion valve. The
expansion valve causes the temperature and pressure
of the refrigerant to drop, where it becomes a low
pressure liquid (L). The expansion valve is a valve that
uses a variable orifice to control the flow of high
pressure liquid refrigerant into the evaporator to
maintain a constant pressure and temperature.
The M6 A/C and heater blower motor (N) pulls a
mixture of warm cab and outside air through the
evaporator where it is cooled by the refrigerant. The
heat absorbed by the evaporator causes the refrigerant
to vaporize into a low pressure gas.
A freeze control switch (M) senses temperature of the
evaporator coil through a refrigerant filled capillary
TX,9031,UU3137 1913AUG962/2
9031
05
3
Key switch On
Machine running
Air conditioning switch turned On
Any of the four blower motor On speeds selected on air
conditioner controller
TX,9031,UU3138 1913AUG961/1
TM1663 (28NOV01)
9031-05-3
PN=641
Theory of Operation
Low speed
Medium low speed
Medium speed
High speed
9031
05
4
TX,9031,UU3139 1913AUG961/1
TM1663 (28NOV01)
9031-05-4
PN=642
Theory of Operation
TX,9031,UU3140 1904NOV981/1
TM1663 (28NOV01)
9031-05-5
PN=643
Theory of Operation
CED,OUTX782,3 1918NOV981/1
9031
05
6
CED,OUTX782,4 1918NOV981/1
TM1663 (28NOV01)
9031-05-6
PN=644
Theory of Operation
T117937
1918NOV98
9031
05
7
CED,TX02661,251 1904NOV981/1
TM1663 (28NOV01)
9031-05-7
PN=645
Theory of Operation
Receiver/Dryer Operation
The receiver/dryer is a reservoir to store excess liquid
refrigerant in the system. Excess refrigerant is required for
two reasons:
Outside air temperature and humidity have an effect on
the minimum quantity of refrigerant required in the system
for the air conditioner to operate at maximum efficiency.
The higher the temperature and humidity, the more
refrigerant required in the system. More refrigerant is
required due to the expansion valve opening farther
allowing more refrigerant into the low pressure side of the
system.
UN19OCT93
UN10JAN94
T8104AF
9031
05
8
T8104AE
AInlet Port
BSight Glass
COutlet Port
DPickup Tube
EFilter
FDesiccant
GStrainer
HSpring
IReceiver/Dryer
JWet/Dry Indicator
TM1663 (28NOV01)
9031-05-8
TX,9031,UU3144 1913AUG961/2
PN=646
Theory of Operation
A sight glass is installed in the receiver/dryer outlet port. If
the refrigerant level is low, a steady stream of gas
bubbles will be present in the liquid flowing from the
receiver/dryer. These gas bubbles can be seen in the
sight glass and are an indication that the system needs
charging. However, bubbles may be present when the
compressor clutch first engages but must disappear after
a few seconds. If the sight glass is clear, the system
either has a sufficient charge or is completely discharged.
TX,9031,UU3144 1913AUG962/2
9031
05
9
TM1663 (28NOV01)
9031-05-9
PN=647
Theory of Operation
T7828AY
1924SEP92
AValve Diaphragm
BSealed Sensing Bulb
COutlet to Compressor
9031
05
10
DOperating Pin
EInlet Flow
FMetering Orifice
GValve Spring
HBall Seat
IOutlet to Evaporator
The metering orifice (F) and ball seat area (H) in the
expansion valve is relatively small. The rapidly
expanding refrigerant passing through this area can
cause any moisture in the system to freeze at this
point and block refrigerant flow. Other contaminants in
the system can also cause a valve to malfunction. If
expansion valve malfunctions, it must be replaced.
Expansion valve is not repairable.
TX,9031,UU3145A 1913AUG961/1
TM1663 (28NOV01)
9031-05-10
PN=648
Theory of Operation
TX,9031,UU3146 1913AUG961/1
T103130
1929AUG96
CED,OUTX817,50 1905APR001/1
TM1663 (28NOV01)
9031-05-11
PN=649
9031
05
11
Theory of Operation
T122361
UN16JUL99
AMode Switch
BMode Switch
CMode Switch
DAir Conditioner Switch
EAUTO Switch
FAir Circulation Mode Switch
GFresh Air Mode Switch
HBlower Speed Switches
IBlower OFF Switch
JTemperature Control Switches
CED,OUTX817,51 1906APR001/1
TM1663 (28NOV01)
9031-05-12
PN=650
Group 10
Group: 20 (Adjustments)
Group: 25 (Tests)
TX,9031,UU3148 1925APR001/1
1/1
Engine OFF.
Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts
or weather checked?
Are hose and line connections clean NOT showing signs of leakage, such as oil or
dust accumulation at fittings?
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
TM1663 (28NOV01)
9031-10-1
PN=651
9031
10
1
Engine OFF.
1/1
Engine OFF.
Inspect core.
1/1
Air Conditioner
Compressor Check
Engine OFF.
Inspect compressor.
Is compressor drive belt tight? Is belt in good condition? Is belt tightening strap
straight?
9031
10
2
1/1
1/1
TM1663 (28NOV01)
9031-10-2
PN=652
1/1
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
Engine OFF. Key switch ON.
Press blower motor switch to select each of the four speeds.
Does fan operate in four speeds?
Does air exit from ducts?
9031
10
3
1/1
TM1663 (28NOV01)
9031-10-3
PN=653
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
Start engine and allow to warm several minutes.
Press heater temperature switch to maximum heat position. Press blower switch to
high speed position.
Does warm air exit from ducts?
1/1
9031
10
4
TM1663 (28NOV01)
9031-10-4
PN=654
Early Models
T124602 UN15SEP99
Later Models
Start engine and run at fast idle.
Press air conditioner switch to ON position.
Press blower switch to high speed position.
Press left temperature control switch to maximum cool position.
Wait for any warm air in duct system to dissipate.
Is air from ducts cool?
1/1
Compressor Clutch
Check
Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner switch ON.
1/1
1/1
TM1663 (28NOV01)
9031-10-5
PN=655
9031
10
5
1/1
T111030 UN07AUG97
9031
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
1/1
TM1663 (28NOV01)
9031-10-6
PN=656
1/1
1/1
1/1
Is continuity measured?
T101619 1913JUN96
1/1
TM1663 (28NOV01)
9031-10-7
PN=657
1/1
Air Conditioning
Compressor Clutch (Y1)
Check
T6534CV UN19OCT88
1/1
9031
10
8
TM1663 (28NOV01)
9031-10-8
PN=658
Group 15
Diagnostic Information
Diagnose Air Conditioning Electrical
Malfunctions
NOTE: Diagnostic charts are arranged from most
probable and simplest to verify, to least likely
more difficult to verify. Remember the following
steps when diagnosing a problem:
Step 1. Operational Check Out Procedure
Step 2. Diagnostic Charts
Step 3. Adjustments and/or Tests
Symptom
Problem
Solution
Replace fuse.
TX,9031,UU3149 1904OCT001/1
TM1663 (28NOV01)
9031-15-1
PN=659
9031
15
1
Diagnostic Information
A3
AIR
CONDITIONER
CONTROLLER
X17
AIR CONDITIONER
CONTROLLER
CONNECTOR
(16-PIN)
M10
AIR CONDITIONER
BLOWER PORT
CHANGE SERVOMOTOR
X18
AIR CONDITIONER
CONTROLLER
CONNECTOR
(12-PIN)
HEATER CORE
AIR CONDITIONER
EVAPORATOR
R11
AIR CONDITIONER
AND HEATER
BLOWER MOTOR
DROPPING RESISTOR
BLOCK
M6
AIR CONDITIONER
AND HEATER
BLOWER MOTOR
YEL
BLK
K25 PIN 4, Y1
K24 PIN 1, K25 PIN 1, K26 PIN 1,
K27 PIN 1, K28 PIN 1, X17 PIN 1
BLK/YEL
YEL
X16
AIR CONDITIONER
HARNESS TO
CAB HARNESS
CONNECTOR
M11
AIR CONDITIONER
AIR MIXER
SERVOMOTOR
K28
AIR CONDITIONER
BLOWER MOTOR
(HIGH SPEED) RELAY
2 1
3 4
ENGINE
AIR CONDITIONER
COMPRESSOR
Y1
COMPRESSOR
CLUTCH
K27
AIR CONDITIONER
BLOWER MOTOR
(MEDIUM SPEED)
RELAY
K26
AIR CONDITIONER
BLOWER MOTOR
(LOW MEDIUM SPEED)
RELAY
K25
AIR CONDITIONER
COMPRESSOR
K24
CLUTCH RELAY
AIR CONDITIONER
BLOWER MOTOR
AND MAIN POWER
(LOW SPEED) RELAY
B29
AIR CONDITIONER
AND HEATER
THERMISTOR
M9
AIR CONDITIONER
INTERNAL AND
EXTERNAL CAB
AIR SERVOMOTOR
B27
AIR CONDITIONER
HIGH AND LOW
PRESSURE SWITCH
(SEE DETAIL A EVAPORATOR
CONNECTIONS)
CONDENSER
T118135
TM1663 (28NOV01)
9031-15-2
PN=660
T118670
1924NOV98
Diagnostic Information
TX,9031,GG2243 1912SEP962/2
9031
15
3
TM1663 (28NOV01)
9031-15-3
PN=661
Diagnostic Information
T118195
1918NOV98
9031
15
4
TM1663 (28NOV01)
9031-15-4
CED,OUTX782,5 1918NOV981/2
PN=662
Diagnostic Information
T118196
1918NOV98
9031
15
5
CED,OUTX782,5 1918NOV982/2
TM1663 (28NOV01)
9031-15-5
PN=663
Diagnostic Information
9031
15
6
TM1663 (28NOV01)
9031-15-6
PN=664
Group 20
Adjustments
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits
discharge of any refrigerant into the atmosphere, and
requires that refrigerant be recovered using the
approved recovery equipment.
IMPORTANT: To meet government standards
relating to the use of refrigerants,
R134a is used in the air conditioning
system. Because it does not contain
chlorine, R134a is not detrimental to
the ozone in the atmosphere.
However, it is illegal to discharge
any refrigerant into the atmosphere.
TX,9031,UU3151 1913AUG961/1
TX,9031,UU3152 1913AUG961/1
TM1663 (28NOV01)
9031-20-1
PN=665
9031
20
1
Adjustments
TX,9031,UU3153 1913AUG961/1
9031
20
2
TX,9031,UU3154 1913AUG961/1
TM1663 (28NOV01)
9031-20-2
PN=666
Adjustments
45 mL (1.5 fl oz)
45 mL (1.5 fl oz)
65 mL (2.2 fl oz)
30 mL (1.0 fl oz)
Specification
Amount Of New OilCapacity ............................... 100 mL (3.4 fl oz)
Specification
Flushed Compressor New Oil
Capacity ............................................... 330 20 mL (11.1 0.7 fl oz)
TM1663 (28NOV01)
9031-20-3
CED,TX14795,4338 1904MAR981/2
PN=667
9031
20
3
Adjustments
Components listed which have been removed,
drained or flushed, require the removal of the
compressor to determine the correct oil charge.
Use the chart as a guide for adding oil to
components.
Specification
EvaporatorOil Charge ......................................... 130 mL (4.4 fl oz)
CondenserOil Charge ........................................... 65 mL (2.2 fl oz)
Receiver-DryerOil Charge ..................................... 30 mL (1.0 fl oz)
HosesOil Charge ............................... 60 mL (2.0 fl oz) or 3 mL per
30 cm (0.1 fl oz per ft)
Approximate Total Length ............................................ 600 cm (20 ft)
CED,TX14795,4338 1904MAR982/2
9031
20
4
TM1663 (28NOV01)
9031-20-4
PN=668
Adjustments
UN01DEC98
T118687
9031
20
5
CED,TX14795,4339 1904OCT001/1
TM1663 (28NOV01)
9031-20-5
PN=669
Adjustments
UN01DEC98
T118687
9031
20
6
CED,TX14795,4340 1904OCT001/1
TM1663 (28NOV01)
9031-20-6
PN=670
Adjustments
15 Minutes
Evacuation Time
15 minutes
T118687
UN01DEC98
SPECIFICATIONS
ESSENTIAL TOOLS
AHigh Pressure Test Port
BBlue Hose
CRed Hose
DHigh Pressure Hose
ELow Pressure Hose
FLow Pressure Test Port
GRefrigerant Recovery/Recycling and Charging
Station
HHigh Pressure Relief Valve
9031
20
7
TM1663 (28NOV01)
9031-20-7
CED,TX14795,4341 1904OCT001/3
PN=671
Adjustments
3. Follow the manufacturers instructions and evacuate
the system.
7. Repair leak.
8. Start to evacuate.
9. Open low-side and high-side valves.
TM1663 (28NOV01)
9031-20-8
CED,TX14795,4341 1904OCT002/3
PN=672
Adjustments
10. Evacuate system for 30 minutes after 98 kPa (980
mbar) (29 in. Hg) vacuum is reached.
Specification
Evacuate SystemTime ............................ For 30 min. After 98 kPa (980
mbar) (29 in. Hg) Vacuum
CED,TX14795,4341 1904OCT003/3
9031
20
9
TM1663 (28NOV01)
9031-20-9
PN=673
Adjustments
UN01DEC98
ESSENTIAL TOOLS
JT02045 HFC134a Refrigerant Recovery/Recycling and Charging
Station
T118687
TM1663 (28NOV01)
9031-20-10
CED,TX14795,4342 1922NOV001/2
PN=674
Adjustments
NOTE: Before beginning to charge air conditioning
system, the following conditions must exist:
Engine STOPPED, the pump must be capable of
pulling at least 28.6 in. Hg vacuum (sea level).
Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa
(980 mbar) (29 in. Hg) for each 300 m (1000 ft)
elevation above sea level.
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)
CED,TX14795,4342 1922NOV002/2
TM1663 (28NOV01)
9031-20-11
PN=675
9031
20
11
Adjustments
19 mm (0.75 in.)
810 Minutes
Specification
If Belt Deflection Excessive
Cool............................................................................... 810 Minutes
CED,TX14795,4343 1904MAR981/1
9031
20
12
TM1663 (28NOV01)
9031-20-12
PN=676
Group 25
Tests
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits
discharge of any refrigerant into the atmosphere, and
requires that refrigerant be recovered using the
approved recovery equipment.
IMPORTANT: To meet government standards
relating to the use of refrigerants,
R134a is used in the air conditioning
system. Because it does not contain
chlorine, R134a is not detrimental to
the ozone in the atmosphere.
However, it is illegal to discharge
any refrigerant into the atmosphere.
TX,9031,UU3151 1913AUG961/1
TX,9031,UU3152 1913AUG961/1
TM1663 (28NOV01)
9031-25-1
PN=677
9031
25
1
Tests
2180 rpm
Maximum Cooling
Blower Speed
High
5 Minutes
Ambient Temperature
16C (60F)
13C (55F)
21C (70F)
16C (60F)
27C (80F)
18C (65F)
32C (90F)
21C (70F)
38C (100F)
27C (80F)
43C (110F)
29C (85F)
ESSENTIAL TOOLS
JT02045 HFC134a Refrigerant Recovery/Recycling and Charging
Station
JT02046 HFC134a Charging Station (Alternate)
JT02050 HFC134a Recovery/Recycling and Charging Station
(Alternate)
9031
25
2
TM1663 (28NOV01)
9031-25-2
CED,OUOE003,1079 1904OCT001/3
PN=678
Tests
4. Connect low pressure blue hose (B) from refrigerant
recovery, recycling and charging station (G) to low
pressure test port (F) on compressor.
5. Connect high pressure red hose (D) to high pressure
quick-disconnect on compressor.
6. Follow the manufacturers instructions when using the
refrigerant recovery, recycling and charging station.
UN01DEC98
T118687
Specification
EngineSpeed ........................................................................... 2180 rpm
Specification
Temperature Control Switch
Position .......................................................................... Maximum Cooling
9031
25
3
TM1663 (28NOV01)
9031-25-3
CED,OUOE003,1079 1904OCT002/3
PN=679
Tests
Ambient Temperature
16C (60F)
13C (55F)
21C (70F)
16C (60F)
27C (80F)
18C (65F)
32C (90F)
21C (70F)
38C (100F)
27C (80F)
43C (110F)
29C (85F)
CED,OUOE003,1079 1904OCT003/3
9031
25
4
TM1663 (28NOV01)
9031-25-4
PN=680
Tests
T6609AB
1928FEB89
9031
25
5
TX,9031,UU3164 1919AUG981/1
TM1663 (28NOV01)
9031-25-5
PN=681
Tests
T8426AE
UN06MAR95
SPECIFICATIONS
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.
1. Remove high and low pressure switch.
2. Connect a portable pressure source, such as a
hydraulic hand pump, to high and low pressure switch.
9031
25
6
TM1663 (28NOV01)
9031-25-6
CED,TX14795,4346 1904MAR981/2
PN=682
Tests
4. Slowly increase pressure. Switch must have continuity
until pressure increases to high pressure switch
opening pressure specification.
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
dusty spots. When refrigerant leaks from the
system, a small amount of oil is carried out with it.
TX,9031,UU3168 1913AUG961/1
TM1663 (28NOV01)
9031-25-7
PN=683
9031
25
7
Tests
TX,9031,UU3169 1913AUG961/1
9031
25
8
TM1663 (28NOV01)
9031-25-8
PN=684
Index
Page
A
Accessory
Electrical . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-9
Operational checkout . . . . . . . . . . . . . .9005-10-18
Adjuster
Track, operation . . . . . . . . . . . . . . . . . . .9020-05-1
Adjustment
Travel alarm volume . . . . . . . . . . . . . . .9015-20-10
Air conditioner harness
Component location . . . . . . . . . . . . . . . .9031-15-2
Connectors . . . . . . . . . . . . . . . . . . . . . . .9031-15-4
Air conditioning
Charge R134a system . . . . . . . . . . . . .9031-20-10
Circuit checks . . . . . . . . . . . . . . . . . . . . .9031-10-6
Compressor belt tension . . . . . . . . . . . .9031-20-12
Compressor oil removal . . . . . . . . . . . . .9031-20-2
Compressor relief valve operation . . . . .9031-05-11
Controller operation (later models) . . . .9031-05-12
Electrical circuit . . . . . . . . . . . . . . . . . . . .9031-05-3
Evacuate R134a system . . . . . . . . . . . . .9031-20-7
Expansion valve . . . . . . . . . . . . . . . . . .9031-05-10
High pressure switch test . . . . . . . . . . . .9031-25-6
Hoses and tubing inspection . . . . . . . . . .9031-25-8
Leak testing . . . . . . . . . . . . . . . . . . . . . .9031-25-7
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9031-15-1
Operating checks . . . . . . . . . . . . . . . . . .9031-10-3
Receiver and dryer operation . . . . . . . . .9031-05-8
Recover R134a system. . . . . . . . . . . . . .9031-20-6
Recovery, recycling and charging
R134a . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-5
Refrigerant handling . . . . . . 9031-05-1, 9031-20-1,
9031-25-1
Refrigerant (R12 and R134a) caution . . .9031-05-1
Refrigerant (R134a) caution . . . . . . . . . 9031-20-1,
9031-25-1
R12 refrigerant operation . . . . . . . . . . . .9031-05-2
System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-2
Temperature control (early models). . . .9031-05-11
Temperature control (later models) . . . .9031-05-12
Visual inspection of components . . . . . . .9031-10-1
Air filter
Restriction indicator switch test . . . . . . . .9010-25-3
Air flow
Radiator . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-5
Air intake
System checks . . . . . . . . . . . . . . . . . . . .9010-10-6
Air intake system
Operational checkout . . . . . . . . . . . . . .9005-10-33
Air intake system leakage
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-4
Arm
Cylinder drift . . . . . . . . . . . . . . . . . . . . 9025-25-125
TM1663 (28NOV01)
Page
B
Battery
Booster . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-7
Check terminals . . . . . . . . . . . . . . . . . . .9015-20-4
Electrolyte level. . . . . . . . . . . . . . . . . . . .9015-20-4
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9015-20-2
Operation . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Specification . . . . . . . . . . . . . 9015-20-1, 9015-20-8
Testing . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-6
Boom
Cylinder drift . . . . . . . . . . . . . . . . . . . . 9025-25-125
Lower with engine stopped . . . . . . . . . .9025-25-38
Boom reduced leakage valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-60
Boom regenerative valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-66
Boom up and swing combined
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-70
Boost pressure
Engine power test using turbocharger . . .9010-25-8
Brake valve
Propel motor park, housing
operation . . . . . . . . . . . . . . . . . . . . . .9025-05-90
Swing motor park, operation . . . . . . . . .9025-05-80
Bucket
Cylinder drift . . . . . . . . . . . . . . . . . . . . 9025-25-125
Bucket flow control valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-62
Bushing
Track chain, measure wear . . . . . . . . . . .9020-15-3
C
Cab harness (W2)
Component location . . . . . . . . . . . . . . .9015-10-20
Connectors . . . . . . . . . . . . . . . . . . . . . .9015-10-23
Index-1
PN=1
Indx
1
Index
Indx
2
Page
Page
Capacities
Drain and refill . . . . . . . . . . . . . . . . . . . .9000-02-6
Carrier roller oil specification . . . . . . . . . . .9000-04-6
Circuit Malfunction
Electrical . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-2
Circuit relief valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-48
Test and adjustment . . . . . . . . . . . . . . .9025-25-68
Circuit symbols
Hydraulic system. . . . . . . . . . . . . . . . . .9025-05-98
Circuit, windshield wiper and washer
Schematic . . . . . . . . . . . . . . . . . . . . . . .9015-15-26
Theory of operation. . . . . . . . . . . . . . . .9015-15-23
Component
Harness test, miscellaneous . . . . . . . . .9025-25-51
Component location
Cab harness (W2). . . . . . . . . . . . . . . . .9015-10-20
Engine and frame harness (W1) . . . . . .9015-10-16
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20
Main hydraulic system. . . . . . . . . . . . . .9025-15-35
Monitor and relay harness (W3) . . . . . 9015-10-28,
9015-10-31
Pilot controller-to-flow regulator valve John Deere
pattern . . . . . . . . . . . . . . . . . . . . . . . .9025-15-37
Pilot controller-to-flow regulator valve SAE
pattern . . . . . . . . . . . . . . . . . . . . . . . .9025-15-36
Pilot flow regulator valve-to-control
valve . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-38
Pressure and return system . . . . . . . . .9025-15-40
Propel system . . . . . . . . . . . . . . . . . . . .9025-15-39
Reading a component diagram . . . . . . .9015-05-26
Computer, laptop
Excavator diagnostics program
Engine speed adjustment . . . . . . . . .9025-25-16
Engine speed factory settings . . . . . .9025-25-23
Engine speed to pump flow rate
chart. . . . . . . . . . . . . . . . . . . . . . . .9025-25-24
Monitor data . . . . . . . . . . . . . . . . . . .9025-25-13
Monitor data items. . . . . . . . . . . . . . .9025-25-21
Saving monitor data. . . . . . . . . . . . . .9025-25-15
Service codes . . . . . . . . . . . . . . . . . .9025-25-12
Service codes list . . . . . . . . . . . . . . .9025-25-20
Troubleshooting. . . . . . . . . . . . . . . . .9025-25-26
Excavator diagnostics program install . . .9025-25-2
Excavator diagnostics program
overview . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Excavator diagnostics program
starting . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8
Excavator diagnostics program
uninstall . . . . . . . . . . . . . . . . . . . . . . . .9025-25-7
General description . . . . . . . . . . . . . . . . .9025-25-1
Reading service codes without diagnostics
program. . . . . . . . . . . . . . . . . . . . . . .9025-25-27
TM1663 (28NOV01)
D
Deaeration
Cooling system . . . . . . . . . . . . . . . . . . .9010-20-12
Definition
Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-8
High resistance circuit . . . . . . . . . . . . . . .9015-05-3
Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-5
Sensor circuit shorted to ground . . . . . .9015-05-16
Index-2
PN=2
Index
Page
Page
E
E (economy) mode
Speed control circuit . . . . . . . . . . . . . . . .9010-05-8
Electrical
Battery specification . . . . . . . . . . . . . . . .9015-20-1
Circuit Malfunction . . . . . . . . . . . . . . . . .9015-05-2
Component identification . . . . . . . . . . . . .9015-10-3
Component location . . . . . . . . . . . . . . .9015-05-26
Connector end view diagram. . . . . . . . .9015-05-28
Fuse specifications . . . . . . . . . . . . . . . . .9015-10-1
Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-8
High resistance circuit . . . . . . . . . . . . . . .9015-05-3
Monitor specifications . . . . . . . . . . . . . .9015-15-42
Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-5
Schematic symbols . . . . . . . . . . . . . . . .9015-05-30
Schematic, wiring diagram, and component
location information . . . . . . . . . . . . . .9015-05-20
Sensor circuit shorted to ground . . . . . .9015-05-16
Sensor circuit shorted to itself . . . . . . . .9015-05-14
TM1663 (28NOV01)
Index-3
PN=3
Indx
3
Index
Indx
4
Page
Page
F
Fan drive
Operation . . . . . . . . . . . . . . . . . . . . . . . .9010-05-3
TM1663 (28NOV01)
G
Gearbox
Propel, operation. . . . . . . . . . . . . . . . . . .9020-05-2
Swing, operation . . . . . . . . . . . . . . . . . .9025-05-72
Swing, start-up procedure . . . . . . . . . . .9025-25-34
Grease
Extreme pressure and multipurpose . . . .9000-04-7
Specification . . . . . . . . . . . . . . . . . . . . . .9000-04-7
Grouser
Track shoe, measure wear (S.N.
499999) . . . . . . . . . . . . . . . . . . . . . . . .9020-15-6
Track shoe, measure wear (S.N.
500000) . . . . . . . . . . . . . . . . . . . . . . . .9020-15-7
H
Harness
Cab (W2) component location. . . . . . . .9015-10-20
Cab (W2) connectors . . . . . . . . . . . . . .9015-10-23
Engine and frame (W1) component
location . . . . . . . . . . . . . . . . . . . . . . .9015-10-16
Index-4
PN=4
Index
Page
Page
I
Idler
Front, measure wear. . . . . . . . . . . . . . .9020-15-10
Inch torque values . . . . . . . . . . . . . . . . . . .9000-03-1
J
JT02156 digital pressure and temperature analyzer
Installation. . . . . . . . . . . . . . . . . . . . . . .9025-25-31
JT05800 digital thermometer
installation. . . . . . . . . . . . . . . . . . . . . . .9025-25-30
Jump starting . . . . . . . . . . . . . . . . . . . . . . .9015-20-7
L
Laptop computer
Excavator diagnostics program
Engine speed adjustment . . . . . . . . .9025-25-16
Engine speed factory settings . . . . . .9025-25-23
Engine speed to pump flow rate
chart. . . . . . . . . . . . . . . . . . . . . . . .9025-25-24
Monitor data . . . . . . . . . . . . . . . . . . .9025-25-13
Monitor data items. . . . . . . . . . . . . . .9025-25-21
Saving monitor data. . . . . . . . . . . . . .9025-25-15
Service codes . . . . . . . . . . . . . . . . . .9025-25-12
Service codes list . . . . . . . . . . . . . . .9025-25-20
Troubleshooting. . . . . . . . . . . . . . . . .9025-25-26
Excavator diagnostics program install . . .9025-25-2
Excavator diagnostics program
overview . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Excavator diagnostics program
starting . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8
Excavator diagnostics program
uninstall . . . . . . . . . . . . . . . . . . . . . . . .9025-25-7
General description . . . . . . . . . . . . . . . . .9025-25-1
Reading service codes without diagnostics
program. . . . . . . . . . . . . . . . . . . . . . .9025-25-27
Latch
Operational checkout . . . . . . . . . . . . . .9005-10-23
Leakage
Air intake system test . . . . . . . . . . . . . . .9010-25-4
Fuel line . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-2
Leakage test
Propel motor . . . . . . . . . . . . . . . . . . . . 9025-25-131
Swing motor . . . . . . . . . . . . . . . . . . . . 9025-25-128
Legend
Functional schematic and component
location . . . . . . . . . . . . . . . . . . . . . . . .9015-10-5
Index-5
PN=5
Indx
5
Index
Page
Page
Link
Track, measure wear . . . . . . . . . . . . . . .9020-15-4
Linkage
Fuel shut-off solenoid, check & adjust. . .9010-20-2
Lock
Operational checkout . . . . . . . . . . . . . .9005-10-23
Lubricant
Alternative. . . . . . . . . . . . . . . . . . . . . . . .9000-04-8
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-9
Storage . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-8
Lubrication
System checks . . . . . . . . . . . . . . . . . . . .9010-10-8
Indx
6
O
O-ring boss fittings . . . . . . . . . . . . . . . . . . .9000-03-6
Oil
Lines and fittings. . . . . . . . . . . . . . . . . . .9000-03-5
Specification front idler . . . . . . . . . . . . . .9000-04-6
Specification hydraulic. . . . . . . . . . . . . . .9000-04-5
Specification swing gearbox . . . . . . . . . .9000-04-6
Specification track gearbox . . . . . . . . . . .9000-04-6
Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7
Oil lines and fittings . . . . . . . . . . . . . . . . . .9000-03-5
Operational check
Air conditioning . . . . . . . . . . . . . . . . . . .9005-10-21
Arm regenerative valve . . . . . . . . . . . . .9005-10-14
Auto-idle circuit . . . . . . . . . . . . . . . . . . . .9005-10-6
Boom up, arm in, and bucket
combined. . . . . . . . . . . . . . . . . . . . . .9005-10-14
Cab dome light circuit . . . . . . . . . . . . . .9005-10-20
Cold weather starting aid . . . . . . . . . . . .9010-10-7
Compressor clutch . . . . . . . . . . . . . . . .9005-10-22
Condenser . . . . . . . . . . . . . . . . . . . . . .9005-10-22
Control valve lift check valve. . . . . . . . .9005-10-13
Cycle times . . . . . . . . . . . . . . . . . . . . . .9005-10-16
Dig function drift . . . . . . . . . . . . . . . . . .9005-10-13
E (economy) mode . . . . . . . . . . . . . . . . .9005-10-7
Engine blow-by . . . . . . . . . . . . . . . . . . . .9005-10-9
Engine oil lever and condition check . . . .9005-10-3
Engine parts loose or worn . . . . . . . . . . .9005-10-9
Engine rpm dial. . . . . . . . . . . . . . . . . . . .9005-10-6
Evaporator core . . . . . . . . . . . . . . . . . .9005-10-22
Fluid level (coolant, hydraulic, and engine oil)
indicator circuit . . . . . . . . . . . . . . . . . .9005-10-2
Gauges, monitor, and battery disconnect
relay . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2
Grouser wear, bent track shoe, and loose
hardware . . . . . . . . . . . . . . . . . . . . . .9005-10-18
Heater controls . . . . . . . . . 9005-10-20, 9005-10-21
Horn circuit . . . . . . . . . . . . . . . . . . . . . .9005-10-20
HP (high power) mode . . . . . . . . . . . . . .9005-10-7
Hydraulic oil level . . . . . . . . . . . . . . . . .9005-10-10
Light circuit . . . . . . . . . . . . . . . . . . . . . .9005-10-19
Lines and hoses . . . . . . . . . . . . . . . . . .9005-10-22
Monitor circuit and gauge . . . . . . . . . . . .9005-10-4
Pilot controller pattern, John Deere
pattern . . . . . . . . . . . . . . . . . . . . . . . .9005-10-12
Pilot controller pattern, SAE pattern . . .9005-10-11
Pilot shut-off valve . . . . . . . . . . . . . . . . .9005-10-8
Index-6
PN=6
Index
Page
Page
TM1663 (28NOV01)
P
Park brake pressure reducing valve
Circuit operation . . . . . . . . . . . . . . . . . .9025-05-92
Park brake release shuttle valve
Circuit operation . . . . . . . . . . . . . . . . . .9025-05-92
Pattern conversion
Control levers . . . . . . . . . . . . . . . . . . . .9025-15-24
Pilot circuit
Diagnose malfunctions . . . . . . . . . . . . .9025-15-16
Warm-up circuit operation . . . . . . . . . . .9025-05-16
Pilot controller
Metering and full stroke operation . . . . . .9025-05-9
Neutral operation . . . . . . . . . . . . . . . . . .9025-05-8
Schematic . . . . . . . . . . . . . . . . . . . . . . .9025-05-99
Pilot controller, propel
(S.N. 050305) . . . . . . . . . . . . . . . . . .9025-05-10
(S.N. 050306) . . . . . . . . . . . . . . . . . .9025-05-12
Pilot filter
Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-5
Pilot pressure regulating valve
Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-5
Test and adjustment . . . . . . . . . . . . . . .9025-25-56
Pilot pump
Flow test . . . . . . . . . . . . . . . . . . . . . . . 9025-25-121
Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-4
Pilot shut-off valve
Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-6
Operational check . . . . . . . . . . . . . . . . . .9005-10-8
Index-7
PN=7
Indx
7
Index
Indx
8
Page
Page
Pilot system
Component location
Flow regulator valve-to-control
valve . . . . . . . . . . . . . . . . . . . . . . .9025-15-38
Component location controller-to-flow regulator
valve John Deere pattern . . . . . . . . .9025-15-37
Component location controller-to-flow regulator
valve SAE pattern . . . . . . . . . . . . . . .9025-15-36
Pitch
Track chain, measure . . . . . . . . . . . . . . .9020-15-5
Portable filter caddy
Hydraulic oil cleanup procedure . . . . . .9025-25-36
Power boost
Control circuit operation . . . . . . . . . . . .9025-05-47
Power boost solenoid valve
Harness test . . . . . . . . . . . . . . . . . . . . .9025-25-45
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-32
Power boost valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-46
Pressure and return system
Component location . . . . . . . . . . . . . . .9025-15-40
Propel
Gearbox oil specification . . . . . . . . . . . . .9000-04-6
Propel and arm in combined
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-68
Propel flow control valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-64
Propel gearbox
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-2
Propel motor
Counterbalance valve propelling
operation . . . . . . . . . . . . . . . . . . . . . .9025-05-94
Crossover relief valve test. . . . . . . . . . .9025-25-80
Fast speed operation . . . . . . . . . . . . . .9025-05-87
Leakage test . . . . . . . . . . . . . . . . . . . . 9025-25-131
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-84
Park brake release circuit . . . . . . . . . . .9025-05-92
Park brake valve housing operation . . .9025-05-90
Schematic . . . . . . . . . . . . . . . . . . . . . . 9025-05-101
Slow speed operation . . . . . . . . . . . . . .9025-05-86
Speed change circuit operation . . . . . . .9025-05-88
Start-up procedure . . . . . . . . . . . . . . . .9025-25-34
Propel pilot controller
Schematic . . . . . . . . . . . . . . . . . . . . . . .9025-05-99
Propel pilot controller (S.N. 050305)
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-10
Propel pilot controller (S.N. 050306)
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-12
Propel pilot pressure signal passage
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-42
Propel speed change circuit
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-88
TM1663 (28NOV01)
R
Radiator
Air flow test. . . . . . . . . . . . . . . . . . . . . . .9010-25-5
Index-8
PN=8
Index
Page
Page
S
Schematic
Control valve circuit. . . . . . . . . . . . . . . .9025-05-40
Electrical, system functional . . . . . . . . .9015-10-10
Hydraulic pump and control valve . . . . 9025-05-100
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20
Pilot controllers circuit . . . . . . . . . . . . . .9025-05-99
Reading a schematic . . . . . . . . . . . . . .9015-05-22
Swing and propel motor . . . . . . . . . . . 9025-05-101
Symbols . . . . . . . . . . . . . . . . . . . . . . . .9015-05-30
Schematic section, system functional
Legend . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-9
Seat
Operational checkout . . . . . . . . . . . . . .9005-10-23
Sectional view
Engine . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-2
Sensor
Harness test, engine control sensor . . .9025-25-47
Service code
Excavator diagnostics program
feature . . . . . . . . . . . . . . . . . . . . . . . .9025-25-12
List, excavator diagnostics program . . .9025-25-20
Reading without laptop computer and diagnostics
program. . . . . . . . . . . . . . . . . . . . . . .9025-25-27
Slow and fast idle
Injection pump stops adjustment . . . . . . .9010-20-6
Software
Engine speed adjust, excavator diagnostics
program special function . . . . . . . . . .9025-25-16
Engine speed factory settings, diagnostics program
special function . . . . . . . . . . . . . . . . .9025-25-23
TM1663 (28NOV01)
Index-9
PN=9
Indx
9
Index
Indx
10
Page
Page
Speed
Engine . . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-5
Speed control
Injection pump fast and slow idle stops
adjustment. . . . . . . . . . . . . . . . . . . . . .9010-20-6
Speed control motor
Adjustment . . . . . . . . . . . . . . . . . . . . . . .9010-20-8
Speed control system
Auto-idle mode . . . . . . . . . . . . . . . . . . .9010-05-12
E (economy) mode . . . . . . . . . . . . . . . . .9010-05-8
Engine . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-4
Engine rpm dial. . . . . . . . . . . . . . . . . . . .9010-05-6
Engine speed learning . . . . . . . . . . . . .9010-05-14
HP mode control circuit. . . . . . . . . . . . .9010-05-10
Speed sensing solenoid valve
Control circuit operation . . . . . . . . . . . .9025-05-34
Harness test . . . . . . . . . . . . . . . . . . . . .9025-25-41
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-32
Spool
Actuating pilot pressure, valve . . . . . . .9025-25-60
Start-up procedure
Hydraulic pump . . . . . . . . . . . . . . . . . . .9025-25-32
Swing gearbox . . . . . . . . . . . . . . . . . . .9025-25-34
Swing motor . . . . . . . . . . . 9025-25-33, 9025-25-34
Storing lubricants . . . . . . . . . . . . . . . . . . . .9000-04-8
Swing
Gearbox oil specification . . . . . . . . . . . . .9000-04-6
Swing and boom up combined
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-70
Swing bearing
Measure wear . . . . . . . . . . . . . . . . . . . .9020-15-11
Swing dynamic braking
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-54
Swing gearbox
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-72
Start-up procedure . . . . . . . . . . . . . . . .9025-25-34
Swing motor
Crossover relief valve operation . . . . . .9025-05-76
Crossover relief valve test. . . . . . . . . . .9025-25-75
Leakage test . . . . . . . . . . . . . . . . . . . . 9025-25-128
Make-up valve operation . . . . . . . . . . . .9025-05-77
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-74
Park brake release valve operation . . . .9025-05-80
Schematic . . . . . . . . . . . . . . . . . . . . . . 9025-05-101
Start-up procedure . . . . . . . . . . . . . . . .9025-25-33
Swing motor crossover relief valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-76
Switch
Air filter restriction test . . . . . . . . . . . . . .9010-25-3
Engine speed learning procedure . . . . .9010-20-10
Synthetic Lubricants . . . . . . . . . . . . . . . . . .9000-04-8
System functional schematic
Electrical . . . . . . . . . . . . . . . . . . . . . . . .9015-10-10
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20
Legend . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-9
Reading a schematic . . . . . . . . . . . . . .9015-05-22
System relief valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-46
Test and adjustment . . . . . . . . . . . . . . .9025-25-62
TM1663 (28NOV01)
T
Tachometer
Electronic, installation . . . . . 9010-20-1, 9025-25-30
Testing electrical circuits
Seven step procedure . . . . . . . . . . . . . .9015-05-18
Thermometer installation, digital . . . . . . . .9025-25-30
Torque value
Flared connections . . . . . . . . . . . . . . . .9000-03-10
Flat face O-ring seal fitting . . . . . . . . . . .9000-03-8
Inch SAE four bolt flange fitting. . . . . . .9000-03-11
Metric cap screw. . . . . . . . . . . . . . . . . . .9000-03-3
Metric four bolt flange fitting . . . . . . . . .9000-03-12
O-Ring boss fitting . . . . . . . . . . . . . . . . .9000-03-6
30° cone seat hydraulic fittings . . . .9000-03-9
37° flare hydraulic fittings . . . . . . . .9000-03-9
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-1
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-2
Torsional dampener
Inspect . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-12
Track
Adjuster operation . . . . . . . . . . . . . . . . . .9020-05-1
Roller oil specification . . . . . . . . . . . . . . .9000-04-6
Track adjuster
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-1
Track carrier roller
Measure wear . . . . . . . . . . . . . . . . . . . . .9020-15-9
Track chain
Track sag, adjust . . . . . . . . . . . . . . . . . .9020-20-1
Track shoe grouser, measure wear (S.N.
499999) . . . . . . . . . . . . . . . . . . . . . . . .9020-15-6
Track shoe grouser, measure wear (S.N.
500000) . . . . . . . . . . . . . . . . . . . . . . . .9020-15-7
Track chain bushing
Measure wear . . . . . . . . . . . . . . . . . . . . .9020-15-3
Track chain link
Measure wear . . . . . . . . . . . . . . . . . . . . .9020-15-4
Track chain pitch
Measure . . . . . . . . . . . . . . . . . . . . . . . . .9020-15-5
Track roller
Measure wear . . . . . . . . . . . . . . . . . . . . .9020-15-8
Track sag
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1
Index-10
PN=10
Index
Page
Page
U
Undercarriage
Operational checkout . . . . . . . . . . . . . .9005-10-16
V
Valve
Arm regenerative solenoid . . . . . . . . . .9025-05-32
Arm regenerative solenoid, harness
test . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-39
Arm regenerative, operation . . . . . . . . .9025-05-58
Boom regenerative, operation . . . . . . . .9025-05-66
Bucket flow control, operation . . . . . . . .9025-05-62
Circuit relief operation . . . . . . . . . . . . . .9025-05-48
Circuit relief, test . . . . . . . . . . . . . . . . . .9025-25-68
Control, component identification,
bottom . . . . . . . . . . . . . . . . . . . . . . . .9025-15-33
Control, component identification, left
front. . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-31
Control, component identification, right
rear . . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-32
Control, line identification, bottom . . . . .9025-15-30
Control, line identification, left front . . . .9025-15-26
Control, line identification, right rear . . .9025-15-28
Control, schematic . . . . . . . . . . . . . . . 9025-05-100
Counterbalance, propelling
operation . . . . . . . . . . . . . . . . . . . . . .9025-05-94
Flow combiner, operation . . . . . . . . . . .9025-05-54
Flow regulator, operation . . . . . . . . . . .9025-05-16
Harness test, power boost . . . . . . . . . .9025-25-45
TM1663 (28NOV01)
Index-11
PN=11
Indx
11
Index
Page
Visual inspection
Operational checkout . . . . . . . . . . . . . .9005-10-38
W
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
TM1663 (28NOV01)
Index-12
PN=12