John deere 50C ZTS TM2056 Operation and test Manual - Technical manual #2 PRIME 314 páginas www.rapidmanuales.com

50C ZTS Excavator
Diagnostic
OPERATION AND TEST MANUAL
Compact models 50CZTS
TM2056 22OCT14 (ENGLISH)
For complete service information also see:

50C ZTS Excavator Repair TM2057
120 Series Hydraulic Cylinders CTM114319
JDG10274 Ultrasonic Undercarriage
CTM10001
Measurement Gauge
John Deere Construction and Forestry
www.rapidmanuales.com Whatsapp +57 314 6104175

50C ZTS Excavator Diagnostic (g) by Belgreen v2.1
Table of contents
FOREWORD
TECHNICAL INFORMATION FEEDBACK FORM
Section 9000 - GENERAL INFORMATION
Group 01 - Safety
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10 - Operational Checkout Procedure
Section 9010 - ENGINE
Group 05 - Theory of Operation
Group 15 - Diagnostic Information
Group 25 - Tests
Section 9015 - ELECTRICAL SYSTEM
Group 05 - System Information
Group 10 - System Diagrams
Group 15 - Sub-System Diagnostics
Group 20 - References
Section 9020 - POWER TRAIN
Section 9025 - HYDRAULIC SYSTEM
Group 25 - Tests
Section 9031 - HEATER
Group 25 - Tests
<- Go to Global Table of contents 50C ZTS Excavator Diagnostic


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.
CAUTION:
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.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are
summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service
parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of
troubleshooting, general maintenance, and basic type of failures and their causes.

GENERAL INFORMATION (g) by Belgreen v2.0
Technical Information Feedback Form

We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments,
ideas and improvements.
Technical Manual Fax
SEND TO: John Deere Dubuque Works
18600 South John Deere Road
Attn: Publications, Dept. 324
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USA
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<- Go to Section TOC Section 9000 page 1 50C ZTS Excavator Diagnostic

Section 9000 - GENERAL INFORMATION

Table of contents
Group 01 - Safety ..................................................................................................................................... 1
Recognize Safety Information ............................................................................................................... 1
Follow Safety Instructions ..................................................................................................................... 1
Operate Only If Qualified ...................................................................................................................... 2
Wear Protective Equipment .................................................................................................................. 3
Avoid Unauthorized Machine Modifications .......................................................................................... 3
Add Cab Guarding for Special Uses ...................................................................................................... 3
Inspect Machine ................................................................................................................................... 4
Stay Clear of Moving Parts ................................................................................................................... 4
Avoid High-Pressure Oils ...................................................................................................................... 4
Beware of Exhaust Fumes .................................................................................................................... 5
Prevent Fires ........................................................................................................................................ 6
Prevent Battery Explosions ................................................................................................................... 6
Handle Chemical Products Safely ......................................................................................................... 7
Dispose of Waste Properly .................................................................................................................... 7
Prepare for Emergencies ...................................................................................................................... 8
Use Steps and Handholds Correctly ..................................................................................................... 8
Start Only From Operator′s Seat ........................................................................................................... 8
Use and Maintain Seat Belt .................................................................................................................. 9
Prevent Unintended Machine Movement .............................................................................................. 9
Avoid Work Site Hazards .................................................................................................................... 11
Keep Riders Off Machine .................................................................................................................... 12
Avoid Backover Accidents .................................................................................................................. 12
Avoid Machine Tip Over ...................................................................................................................... 12
Use Special Care When Lifting Objects ............................................................................................... 13
Add and Operate Attachments Safely ................................................................................................ 14
Park and Prepare for Service Safely ................................................................................................... 14
Service Cooling System Safely ........................................................................................................... 15
Remove Paint Before Welding Or Heating .......................................................................................... 15
Make Welding Repairs Safely ............................................................................................................. 16
Drive Metal Pins Safely ....................................................................................................................... 16

Section 9000 - GENERAL INFORMATION Group 01: Safety
Group 01 - Safety
Recognize Safety Information
Safety Alert Symbols
Safety Alert Symbols
This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for the
potential of personal injury.
Follow the precautions and safe operating practices highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious
hazards.
On the machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and
WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
Follow Safety Instructions
Follow Safety Instructions
Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them
frequently.

Be sure all operators of this machine understand every safety message. Replace operator′s manual and safety labels
immediately if missing or damaged.
Operate Only If Qualified

Do not operate this machine unless the operator′s manual has been read carefully, and you have been qualified by supervised
training and instruction.
Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the
machine in an open area before starting to work.
Know and observe all safety rules that may apply to every work situation and work site.

Wear Protective Equipment
Protective Equipment
Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs
or earplugs to protect against objectionable or uncomfortable loud noises.
Avoid Unauthorized Machine Modifications

Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability,
and may create a hazard for the operator or others near the machine.
Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of
the machine, or that alter machine controls, performance or reliability.
Add Cab Guarding for Special Uses
Cab Guarding

Special work situations or machine attachments may create an environment with falling or flying objects. Working near an
overhead bank, doing demolition work, using a hydraulic hammer, or working in a wooded area, for example, may require
added guarding to protect the operator.
FOPS (falling object protective structures) and special screens or guarding should be installed when falling or flying objects may
enter or damage the machine. Contact your authorized dealer for information on devices intended to provide protection in
special work situations.
Inspect Machine
Inspect Machine
Inspect machine carefully each day by walking around it before starting.
Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts
immediately. Pay special attention to hydraulic hoses and electrical wiring.
Stay Clear of Moving Parts
Stay Clear Of Moving Parts
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is
complete.
Avoid High-Pressure Oils

Avoid High Pressure Oils
Avoid High-Pressure Oils
This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.
Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop
engine and relieve pressure before disconnecting lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within
hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in
Moline, Illinois, U.S.A.
Beware of Exhaust Fumes
Beware Of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.
If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust

fumes or open doors and windows to bring outside air into the area.
Prevent Fires
Handle Fuel Safely
Clean Machine Regularly
Carry A Fire Extinguisher
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks
or flame.
Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines,
hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine
compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine
electrical wiring and connectors frequently for damage.
Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use
extinguisher properly.
Prevent Battery Explosions

Battery Explosions
Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Handle Chemical Products Safely
Handle Chemical Products Safely
Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives
used with this machine may be hazardous.
If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data
Sheet (MSDS). The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for
chemical substances. Follow MSDS recommendations to handle chemical products safely.
Dispose of Waste Properly
Dispose Of Waste Properly


Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may
be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center
to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for
more information.
Prepare for Emergencies
First Aid Kit
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Use Steps and Handholds Correctly
Use Handholds and Steps
Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use
machine controls as handholds.
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never
jump when exiting machine. Never mount or dismount a moving machine.
Start Only From Operator′s Seat

Operate Only From Operators Seat
Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure all controls and working tools
are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid
terminals.
Use and Maintain Seat Belt
Use and Maintain Seat Belt
Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks and during
other uses.
Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does
not function properly.
The complete seat belt assembly should be replaced every 3 years, regardless of appearance.
Prevent Unintended Machine Movement
Unintended Machine Movement
Be careful not to accidentally actuate control levers when co-workers are present. Pull pilot control shutoff lever to locked
position during work interruptions. Pull pilot control shutoff lever to locked position and stop engine before allowing anyone to

approach machine.
Always lower work equipment to the ground and pull pilot control shutoff lever to locked position before standing up or leaving
the operator′s seat. Stop engine before exiting.

Avoid Work Site Hazards
Work Site Hazards
Work Site Hazards
Work Site Hazards
Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all
underground utilities before you dig.
Prepare work site properly . Avoid operating near structures or objects that could fall onto the machine. Clear away debris
that could move unexpectedly if run over.
Avoid boom or arm contact with overhead obstacles or overhead electrical lines. Never move any part of machine or
load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.
Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid
swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles
and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep
signal person in view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to support machine. When working close to an excavation, position
travel motors away from the hole.
Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow

removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden
stop. Always wear your seat belt.
Keep Riders Off Machine
Keep Riders Off Machine
Only allow operator on machine.
Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.
Riders may obstruct operator’s view or impair his ability to operate machine safely.
Avoid Backover Accidents
Backover Warning
Before moving machine, be sure all persons are clear of both travel and swing paths. Turn around and look directly
for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good
repair.
Be certain travel alarm is working properly.
Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all
times. Use prearranged hand signals to communicate.
Avoid Machine Tip Over

Use Seat Belt
Unloading Machine
Do Not Jump
Use seat belt at all times.
Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading
ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel.
Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these conditions. When
traveling up or down slopes, keep the bucket on uphill side and just above ground level.
Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy
load or swinging it over side of undercarriage may cause machine to tip.
Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or
fall.
Use Special Care When Lifting Objects

Use Special Care When Lifting Objects
Never use this machine to lift people.
Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free. Do not leave
the seat when there is a raised load.
Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or swinging over
undercarriage side may cause machine to tip over.
Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good condition. Use
tether lines to guide loads and prearranged hand signals to communicate with co-workers.
Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect
machine stability or reliability and may create a hazard for others near the machine.
Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or
recommended. Verify that all connections are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions,
carefully operate attachment to learn its characteristics and range of motion.
Park and Prepare for Service Safely
Do Not Operate Tag

Support Machine Properly
Warn others of service work. Always park and prepare your machine for service or repair properly.
Park machine on a level surface and lower equipment and attachments to the ground.
Place pilot shutoff lever in “lock” position. Stop engine and remove key.
Attach a “Do Not Operate” tag in an obvious place in the operator′s station.
Securely support machine or attachment before working under it.
Do not support machine with boom, arm, or other hydraulically actuated attachments.
Do not support machine with cinder blocks or wooden pieces that may crumble or crush.
Do not support machine with a single jack or other devices that may slip out of place.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the
engine must be running for service work.
Service Cooling System Safely
Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve
pressure before removing completely.
Remove Paint Before Welding Or Heating

Toxic Fumes
Hazardous fumes can be generated when paint is heated by welding or using a torch. Dust from sanding or grinding paint can
also be hazardous.
Remove paint to at least 76 mm (3 in.) from area to be heated. Wear an approved respirator when sanding or grinding paint. If
a solvent or paint stripper is used, wash area with soap and water. Remove solvent or paint stripper containers from work area
and allow fumes to disperse at least 15 minutes before welding or heating.
Work outside or in a well-ventilated area. Dispose of waste, paint and solvents properly.
Make Welding Repairs Safely
Avoid Heating Near Pressurized Fluid Lines
IMPORTANT:
Disable electrical power before welding. Turn off main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and vehicle microprocessors.
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines
fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure
there is good ventilation. Wear eye protection and protective equipment when welding.
Drive Metal Pins Safely

OPERATIONAL CHECKOUT PROCEDURE (g) by Belgreen v2.0
Hardened Metal Parts
Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering
hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and object to prevent chipping.

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Table of contents
Group 10 - Operational Checkout Procedure ....................................................................................... 1
Operational Checks—Engine On ........................................................................................................... 1

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure
Group 10 - Operational Checkout Procedure

Operational Checkout
Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of
machine operation while doing a walk around inspection and performing specific checks from the operator′s seat.
Should you experience a problem with your machine, you will find helpful diagnostic information in this checkout that will
pinpoint the cause. This information may allow you to perform a simple adjustment which will reduce the down time of the
machine. Use the table of contents to help find adjustment procedures.
The information you provide after completing the operational checkout will allow you to pinpoint a specific test or repair
needed to restore the machine to design specifications.
A location will be required which is level and has adequate space to complete the checks. No tools or equipment are needed to
perform the checkout.
Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) prior to
doing the checkout. The machine must be at operating temperature for many of the checks.
Start at the top of the left column and read completely down column before performing check. Follow this sequence from left to
right. In the far right column, if no problem is found, you will be instructed to go to next check. If a problem is indicated, you
will be referred to a section in this manual for the repair.
Operator Station Checks—Key Switch On, Engine Off

( 1 ) Monitor and Gauge Circuit Check
Action:
LEGEND:
1 Glow Plug Indicator
2 Engine Oil Pressure Indicator
3 Alternator Voltage Indicator
4 Fuel Gauge and Fuel Level Indicator
5 Engine Coolant Temperature Gauge
6 Hour Meter
7 Light Switch Indicator
8 Light Switch
Monitor Panel
→NOTE:
Monitor buzzer is not checked during this procedure.
If engine coolant temperature is below 30°C (86°F), engine temperature gauge segment may not come
on. Run engine a few minutes to warm coolant before check.
Engine OFF.
Key switch ON.
Do engine coolant temperature gauge (5) and fuel gauge (4) segments come on?
Do all monitor lights come on and after 2—3 seconds only the alternator indicator and engine oil pressure indicator light remain

on?
Result:
YES:Go to next check.
NO: Go to Fuse Test to check F10 Monitor Controller And Display 5 Amp fuse. (Group 9015-20.) Check and replace bulb if any
bulb fails to come on.
( 2 ) Glow Plug Circuit Check
Action:
Glow Plug Indicator Light
Turn key switch to ON position.
Does the glow plug indicator light come ON and then go OFF?
Does a relay “click” when the indicator light goes OUT?
→NOTE:
Glow plug indicator light will stay on longer when engine is cold. Glow plug activation time will shorten as
engine starting temperature is increased.
Result:
NO: Go to Fuse Test to check F5 Engine Power 10 Amp fuse. (Group 9015-20). Go to Relay Test to test glow plug relay. (Group
9015-20.)
( 3 ) Propel Lever and Pedal Neutral Check
Action:

Propel Levers
Engine OFF.
Push each propel lever forward, then release.
Push each propel lever rearward, then release.
Does each lever have equal effort to operate forward and reverse?
Does each lever return to neutral at the same time when released?
Result:
NO:Repair or replace pilot controller. Go to Propel Pilot Controller Repair . (Group 3360.)
( 4 ) Light Circuit Check
Action:
LEGEND:
1 Work Light Switch
2 Work Light Indicator
3 Drive Light
4 Boom Work Light
Work Light Switch/Indicator
Work Lights
→NOTE:
All accessories are powered from the fuse block. If any accessories do not function, check fuses in fuse
block.

Turn key switch ON.
Push work light switch (1) to turn on work lights.
Is indicator light (2) on?
Are the work lights (3 and 4) on the boom and left front corner of upperstructure ON?
Push work light switch to turn off the work lights.
Do all the lights go OFF?
Result:
NO: Go to Fuse Test to check F2 Drive And Boom Work Light 20 Amp fuse. (Group 9015-20.) Go to System Functional
Schematic to check wiring. (Group 9015-10.) Go to Main Harness (W1) Wiring Diagram to check wiring harness. (Group
9015-10.)
( 5 ) Windshield Wiper Circuit Check—Cab Only
Action:
LEGEND:
1 Windshield Wiper And Windshield Washer Switch
Windshield Wiper And Windshield Washer Switch
Key switch ON.
Push windshield wiper switch (1) to turn on the windshield wiper.
Does windshield wiper operate continuously?
Push windshield wiper switch to turn off windshield wiper.
Does wiper arm stop in park position at left side of windshield?
Result:
NO: Go to Fuse Test to check F6 Heater and Wiper 15 Amp fuse. (Group 9015-20.) Go to Key Switch Check to check switch.
(Group 9015-20.) Go to System Functional Schematic to check wiring (Group 9015-10.) Go to Cab Harness (W5) Wiring Diagram
to check harness. (Group 9015-10.)
( 6 ) Windshield Washer Circuit Check—Cab Only

Action:
LEGEND:
1 Windshield Wiper And Windshield Washer Switch
Windshield Wiper And Windshield Washer Switch
Key switch ON.
Push windshield wiper and windshield washer switch to activate washer motor.
Does washer motor operate?
Push windshield wiper and windshield washer switch to turn on the windshield wiper and activate the windshield washer.
Does the washer motor and the windshield wiper operate?
Result:
YES:Go to next check
NO: Go to Fuse Test to check F6 Heater and Wiper 15 Amp fuse. (Group 9015-20.) Go to Key Switch Check to check switch.
(Group 9015-20.) Go to System Functional Schematic to check wiring (Group 9015-10.) Go to Cab Harness (W5) Wiring Diagram
to check harness. (Group 9015-10.)
( 7 ) Horn Circuit Check
Action:
LEGEND:
1 Horn Button
Left Control Lever and Horn Button
Key switch ON.
Push horn button (1) on top of left control lever.
Does horn sound?

Result:
NO: Go to Fuse Test to check F3 Horn 10 Amp fuse. (Group 9015-20.) Go to System Functional Schematic to check wiring.
(Group 9015-10.) Go to Main Harness (W1) Wiring Diagram to check harness. (Group 9015-10.) Go to Main Harness (W1)
Component Location to check switch. (Group 9015-10.)
Operational Checks—Engine On
( 1 ) Monitor and Gauge Circuit Check
Action:
LEGEND:
1 Glow Plug Indicator
2 Engine Oil Pressure Indicator
3 Alternator Voltage Indicator
4 Fuel Gauge and Fuel Level Indicator
5 Engine Coolant Temperature Gauge
6 Hour Meter
7 Light Switch Indicator
8 Light Switch
Monitor Panel
Start engine.
Do alternator voltage (3) and engine oil pressure (2) indicators go OFF after engine starts?
Do all monitor indicators remain OFF after engine starts?
IMPORTANT:
Stop the engine if alternator or engine oil pressure indicators do not go OFF or a monitor indicator comes
ON after engine starts.
Are engine coolant temperature gauge (5) segments in normal operating zone after a few minutes?
Does fuel gauge (4) indicate fuel level?
Result:
NO: Go to Engine Oil Pressure Test if engine oil pressure indicator is on after engine starts. (Group 9010-25.) Check fluid levels.
Go to Fusible Link Check to test fusible link F22 45 Amp fuse if alternator indicator is on after engine starts. (Group 9015-20.)
Go to Alternator Output Check to test alternator output. (Group 9015-20.) Go to Adjust Fan Belt Tension to adjust belt tension.
(Group 9010-15.).
( 2 ) Heater Control Circuit Check
Action:

LEGEND:
1 Heater Blower Motor Switch
Heater Blower Motor Switch
Engine running and at normal operating temperature.
Turn heater blower motor switch (1) to both speed positions, then back to OFF.
Does fan run both positions, then stop in OFF position?
Does warm air flow from vents?
Result:
NO: Go to Fuse Test to check F6 Heater And Wiper 15 Amp fuse. (Group 9015-20.) Go to System Functional Schematic to check
wiring. (Group 9015-10.) Go to Heater Harness (W10) to check harness. (Group 9015-10.)
( 3 ) Pilot Control Shut-Off Switch Check
Action:
Pilot Control Shut-Off Lever—LOCKED
CAUTION:
Machine will move during this check. Make sure area is clear and large enough to operate all machine
functions.
Run engine at slow idle.
Pilot control shut-off lever in LOCKED (rearward) position.
Actuate all dig and propel function controls.

Do any dig or propel functions operate?
Result:
YES: Go to Solenoid Test to check pilot control shut-off solenoid. (Group 9015-20.) Go to System Functional Schematic to check
wiring. (Group 9015-10.) Go to Floor Harness (W2) Component Location to check switch. (Group 9015-10.) Go to Floor Harness
(W2) Wiring Diagram to check harness. (Group 9015-10.) Go to Solenoid Valve Manifold Repair to repair or replace solenoid.
(Group 3360.)
NO:Go to next step in this check.
Action:
Pilot Control Shut-Off Lever—UNLOCKED
Move pilot control shut-off lever to UNLOCKED position (forward).
Actuate all dig and propel functions.
Do all functions operate?
Result:
NO: Go to Solenoid Test to check pilot control shut-off solenoid. (Group 9015-20.) Go to System Functional Schematic to check
wiring. (Group 9015-10.) Go to Floor Harness (W2) Component Location to check switch. (Group 9015-10.) Go to Floor Harness
(W2) Wiring Diagram to check harness. (Group 9015-10.) Go to Solenoid Valve Manifold Repair to repair or replace solenoid.
(Group 3360.)
( 4 ) Propel Alarm Check
Action:
Pilot Control Shut-Off Lever—UNLOCKED

CAUTION:
Machine will move during this check. Make sure area is clear and large enough to operate the machine.
Engine running.
Pilot control shut-off lever in UNLOCKED position (forward).
Push propel levers or pedals forward for forward travel.
Does propel alarm sound?
Pull levers or push propel pedals rearward for reverse travel.
Does propel alarm sound?
Result:
NO: Go to Fuse Test to check F9 Propel Alarm 5 Amp fuse. (Group 9015-20.) Go to Propel Alarm Check to test alarm. (Group
9015-20.) See Propel Alarm Circuit Theory of Operation to check wiring. (Group 9015-15.) Go to Propel Alarm Harness (W11)
And Propel Alarm Cancel Switch Harness (W12) Wiring Diagram to check harness. (Group 9015-10.) Go to Propel Alarm Harness
(W11) And Propel Alarm Cancel Switch Harness (W12) Component Location to check switch. (Group 9015-10.) If all OK, replace
Propel Alarm Controller.
( 5 ) Propel Alarm Cancel Switch Check
Action:
Pilot Control Shut-Off Lever UNLOCKED
CAUTION:
Engine running.
Pilot control shut-off lever in UNLOCKED position (forward).
Push propel levers or pedals forward for forward travel.
Press and release the propel alarm cancel switch.
Does the propel alarm stop?

Result:
NO: Go to System Functional Schematic to check wiring. (Group 9015-10.) Go to Propel Alarm Harness (W11) And Propel Alarm
Cancel Switch Harness (W12) Wiring Diagram to check harness. (Group 9015-10.) Go to Propel Alarm Harness (W11) And Propel
Alarm Cancel Switch Harness (W12) Component Location to check switch. (Group 9015-10.) If all OK, replace Propel Alarm
Controller.
( 6 ) Hydraulic Oil Tank Pressurization Check
Action:
Hydraulic Oil Tank Cap
Engine running.
Raise boom to full height, then lower boom to ground.
Slowly loosen cap on hydraulic oil tank.
Is air heard escaping?
→NOTE:
The pressurized hydraulic oil tank creates pressure at the inlet to the hydraulic pumps. If filler cap does
not seal, hydraulic pumps could cavitate and be damaged.
Result:
NO:Replace cap.
( 7 ) Pilot Controller Pattern Check—SAE Backhoe Pattern
Action:
LEGEND:
1 SAE Backhoe Pattern
2 Backhoe Position
Pilot Controller—SAE Backhoe Decals

Pilot Controller—Backhoe Position
CAUTION:
Operate machine in clear area.
Push pilot shut-off lever to UNLOCKED position. Slowly move pilot control levers to all positions on decals.
Do bucket, boom, arm, and swing move as shown on decals?
Result:
NO:Check pilot controller pattern conversion valve position. Go to Pilot Controller To Pattern Conversion Valve Line Connection
to check line connections. (Group 9025-15.)
( 8 ) Pilot Controller Pattern Check—ISO Excavator Pattern
Action:
LEGEND:
1 ISO Excavator Pattern
2 Excavator Position
Pilot Controller—ISO Excavator Decals

Pilot Controller—Excavator Position
CAUTION:
Operate machine in clear area.
Push pilot shut-off lever to UNLOCKED position. Slowly move pilot control levers to all positions on decals.
Do bucket, boom, arm, and swing move as shown on decals?
Result:
NO:Check pilot controller pattern conversion valve position. Go to Pilot Controller To Pattern Conversion Valve Line Connection
to check line connections. (Group 9025-15.)
( 9 ) Swing Dynamic Braking Check
Action:
Machine Test Position
CAUTION:

Position upperstructure with boom in front.
Extend arm and curl the bucket. Lower boom so bucket pivot pin is at the same level as boom-to-main frame pin.
Run engine at fast idle.
Actuate swing control valve to full stroke. Swing around 90 degrees (1/4 turn) and then release lever.
Does upperstructure stop within 45 degrees (1/8 turn) after releasing lever?
Repeat procedure in opposite direction.
Result:
NO: Go to Swing Motor Leakage Test to check swing motor. (Group 9025-25.) Go to Swing Motor Crossover Relief Valve Test
And Adjustment to check swing motor. (Group 9025-25.) Go to Control Valve Remove and Install to check swing valve spool.
(Group 3360.)
( 10 ) Dig Function Drift Check
Action:
CAUTION:
Fill bucket with dirt. Position bucket at maximum reach with bucket 50 mm (2 in.) above ground.
Observe bucket for 1 minute.
Does bucket drift down to ground within 1 minute?
Result:
YES: Go to Cylinder Drift Test to check cylinder drift. (Group 9025-25.) Go to Control Valve Remove and Install to check boom
reduced leakage valve and boom reduced leakage valve check valve. (Group 3360.) Go to Control Valve Remove and Install to
check bucket valve spool, boom valve spool, and arm valve spool. (Group 3360.) Go to Bucket Cylinder Remove and Install to
repair bucket cylinder. (Group 3360.) Go to Arm Cylinder Remove and Install to repair arm cylinder. (Group 3360.) Go to Boom
Cylinder Remove and Install to repair boom cylinder. (Group 3360.)
NO:Go to next check.

( 11 ) Control Valve Lift Check Test
Action:
CAUTION:
Position machine as illustrated.
Slowly actuate pilot controller to lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder).
Do functions move in opposite direction as control levers are moved, then change direction as levers are moved further?
Result:
YES: See Hydraulic System Schematics to check control valve schematic. (Group 9025-05.) Go to Control Valve Remove and
Install to repair or replace control valve. (Group 3360.)
NO:Go to next check.
( 12 ) Propel System Tracking Check
Action:
CAUTION:
Prevent possible injury from unexpected machine movement. Clear all persons from the area before
operating machine.
Warm hydraulic oil to operating temperature for this check. See Hydraulic System Warm-Up Procedure . (Group 9025-25.)

Machine Position
LEGEND:
9 Bucket Height
Fully extend arm cylinder and bucket cylinder.
Position boom so bucket height (9) is approximately 400 mm (16 in.) above ground.
LEGEND:
1 Propel Speed Change Switch
Propel Speed Change Switch

Tracking Check
LEGEND:
5 Distance of Mistrack
6 Acceleration and Deceleration Zone (approximate): 3—5 m (10—16 ft.)
7 Test Line (distance): 20 m (66 ft.)
8 Track Print
Engine at fast idle.
Depress and hold propel speed change switch (1) in fast speed.
Operate machine at full travel forward speed on a flat and level surface approximately 30 m (99 ft.).
Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8).
Measure and record greatest distance of mistrack (5) between inside edge of track print and test line.
Repeat procedure in reverse.
sss:
Does machine mistrack less than 200 mm (7.87 in.)?
Result:
NO: See Propel Motor Leakage Test to check propel motors. (Group 9020-25.)

NO: See Hydraulic Pump Flow Test to check main pump flow. (Group 9025-25.)
( 13 ) Propel Speed Change Check
Action:
LEGEND:
1 Propel Speed Change Switch
Propel Speed Change Switch
CAUTION:
Run engine at fast idle.
Actuate propel function to full speed forward.
Depress and hold propel speed change switch (1) to change to fast speed.
Does machine travel speed increase?
Result:
NO: Go to Fuse Test to check F3 Horn 10 Amp fuse. (Group 9015-20.) Go to System Functional Schematic to check wiring.
(Group 9015-10.) Go to Floor Harness (W2) Wiring Diagram to check harness. (Group 9015-10.) Go to Floor Harness (W2)
Component Location to check switch. (Group 9015-10.) Go to Solenoid Test to check propel speed solenoid. (Group 9015-20.)
Go to Solenoid Valve Manifold Repair to repair solenoid. (Group 3360.) Go to Propel Motor Disassemble and Assemble to check
propel speed change valve. (Group 0260.)
( 14 ) Blade Function Check
Action:
CAUTION:

Pull blade control lever rearward.
Does blade raise?
Release lever.
Does lever return to neutral and the blade stop?
Push lever forward.
Does blade lower?
Release lever.
Does lever return to neutral and the blade stop?
Result:
NO: Go to Blade Pilot Controller Repair to check blade pilot controller. (Group 3260.) Go to Control Valve Remove and Install to
check blade valve spool. (Group 3360.)
( 15 ) Cycle Times Check
Action:
CAUTION:
Make sure area is clear and large enough to operate all functions of machine.
IMPORTANT:
Warm hydraulic oil to operating temperature for this check.
Engine at fast idle.
Record cycle time for each function.
Boom

ENGINE (g) by Belgreen v2.0
Arm, Bucket, Swing, Boom Swing
Item Measurement Specification
Cycle Times
Boom Raise (Cylinder Extend) Cycle Time 1.8—2.4 sec
Boom Lower (Cylinder Retract) Cycle Time 2.5—3.1 sec
Arm In (Cylinder Extend) Cycle Time 2.8—3.4 sec
Arm Out (Cylinder Retract) Cycle Time 2.4—3.0 sec
Bucket Load (Cylinder Extend) Cycle Time 3.1—3.7 sec
Bucket Dump (Cylinder Retract) Cycle Time 2.0—2.6 sec
Boom Swing Right (Cylinder Extend) Cycle Time 7.5—8.5 sec
Boom Swing Left (Cylinder Retract) Cycle Time 5.5—6.5 sec
Blade Cycle Time 2.1—3.1 sec to raise
2.6—3.6 sec to lower
Swing Function
Swing Left or Right 3 Revolutions From a Running Start Cycle Time 17.5—20.5 sec
Propel Function
Propel 20 m (65 ft) From a Running Start (Check in Forward and Reverse with Propel 14.2—17.2 sec with rubber track 15.4—18.4
Cycle Time
Speed Change Switch in FAST Position) sec with steel track
Propel 20 m (65 ft) From a Running Start (Check in Forward and Reverse with Propel 26.5—29.5 sec with rubber track 28.6—31.6
Cycle Time
Speed Change Switch in SLOW Position) sec with steel track
Does machine perform within specifications?
Result:
YES:Check complete.
NO: Go to Engine Speed Check to check engine speed. (Group 9010-25.) Go to Hydraulic Pump Flow Test to check pump flow.
(Group 9025-25.)

Section 9010 - ENGINE

Table of contents
Group 05 - Theory of Operation ............................................................................................................. 1
Engine Component Location ................................................................................................................. 1
Engine Cooling System Operation ........................................................................................................ 3
Engine Lubrication System Operation .................................................................................................. 4
Engine Fuel System Operation ............................................................................................................. 6
Group 15 - Diagnostic Information ........................................................................................................ 8
Diagnose Engine Malfunction ............................................................................................................... 8
Group 25 - Tests ..................................................................................................................................... 11
JT05801 Clamp- On Electronic Tachometer ........................................................................................ 11
Engine Speed Check ........................................................................................................................... 12
Engine Speed Control Cable Adjustment ............................................................................................ 13
Check Fuel Injection Nozzle ................................................................................................................ 15
Check and Adjust Injection Pump Timing ........................................................................................... 17
Adjust Fan Belt Tension ...................................................................................................................... 20
Check and Adjust Engine Valve Lash (Clearance) ............................................................................... 22
Air Intake System Leakage Test ......................................................................................................... 24
Radiator Air Flow Test ......................................................................................................................... 26
Engine Compression Pressure Test .................................................................................................... 29
Engine Oil Pressure Test ..................................................................................................................... 31
Check for Head Gasket Failures .......................................................................................................... 33

Section 9010 - ENGINE Group 05: Theory of Operation

Engine Component Location
Engine Component Location
LEGEND:
1 Cooling Fan and Spacer

2 Water Pump Assembly

3 Fan Pulley
4 Fan Belt
5 Alternator
6 Oil Pan Drain
7 Starter Motor
8 Muffler
9 Valve Cover and Air Intake Pipe
10 Water Outlet Pipe and Thermostat
11 Exhaust Manifold
12 Injection Pipe (4 used)
13 Engine Stop Solenoid
14 Oil Filter
15 Fuel Injection Pump Housing Cover
16 Governor
17 Fuel Injection Pump and Shim (4 used)
18 Fuel Hose
19 Breather Pipe
20 Fuel Leak Off Pipe
21 Oil Dipstick

Engine Cooling System Operation
Cooling System
The cooling system consists of a radiator, water pump, and thermostat.
During engine warm-up, the thermostat remains closed and coolant is directed through the bypass passage to the suction side
of the water pump. Coolant circulates through the cylinder block and water pump to provide a uniform and fast warm-up.
When the coolant temperature increases to normal operating temperature, the thermostat opens. This allows the coolant to
flow to the top of the radiator and also blocks the flow through the bypass passage. If the engine is operated without a
thermostat, only a small amount of water is directed to the radiator. Enough coolant will flow through the bypass passage to
cause overheating.
When the engine is operated, the coolant temperature rises. It is cooled by the radiator to prevent further temperature rise. If
the engine is overloaded or operated continuously for a long period of time, coolant temperature may continue to rise past the
radiator cap opening pressure setting. The pressurized radiator cap will then open and exhaust excess pressure through the
overflow hose to the coolant reservoir tank.

Engine Lubrication System Operation
Engine Lubrication System
The engine lubrication system consists of an oil strainer, oil pump (with pressure regulating valve), and oil filter (with bypass
valve).
Oil is drawn through the oil strainer screen by the oil pump.
The oil pump incorporates a built-in pressure regulating valve that maintains the correct pressure in the lubricating system
regardless of engine speed or the oil temperature. When pressure exceeds the setting of the valve, the valve will open, routing
the excess oil to the oil pan.
Pressurized oil is directed to the oil filter. The filter element is equipped with an integral bypass valve. When pressure exceeds
the spring force, the valve will open if the filter becomes plugged.
Filtered oil is routed to the main oil gallery in the cylinder block. Oil flows to each crankshaft main bearing and through cross-

drilled passages in the crankshaft-to-connecting rod bearings.
The oil gallery also supplies pressure oil to the idler gear bush and timing gear. Pressure oil is also supplied to the cylinder
head, rocker shaft and rocker arms.

Engine Fuel System Operation

Fuel Injection Pump Operation
A single fire fuel injection pump is used for each cylinder. It is actuated by a roller tappet riding on a lobe camshaft. It is timed
to pump fuel to the fuel injection nozzle of the same cylinder on the compression stroke. Pressurized fuel from the electric fuel
pump is maintained in the fuel injection pump until the camshaft lobe opens a passage to discharge fuel to the fuel injection
nozzle which injects fuel into the cylinder. Excess fuel from the fuel injection pump and fuel injection nozzle is returned to the
fuel tank by means of return lines.
Fuel Injection Nozzle Operation
Fuel Injection Nozzle
LEGEND:
A Fuel Return Pipe
B Nozzle Cover
C Dowel Pin
D Stop Plate
E Nozzle Nut
F Nozzle Body
G Nozzle Valve
H Nozzle Spring Seat
I Nozzle Spring
J Fuel Starting Pressure Adjusting Shim
K Nozzle Holder
The fuel injection nozzle is a hole-type nozzle. The nozzle valve (G) is shim (J) adjustable to regulate the opening pressure.
High pressure fuel from the injection pump flows through a fuel inlet passage. Pressure builds beneath the nozzle valve. When
the fuel pressure reaches specified pressure, it overcomes the nozzle spring (I) tension. The nozzle valve (G) retracts into the
nozzle body (F) and fuel is injected into the engine.
The nozzle valve is automatically pushed down by the nozzle spring (I) and closed after fuel is injected.

Section 9010 - ENGINE Group 15: Diagnostic Information
Leakage (return fuel) flows from between the nozzle valve and nozzle body to the hole on top of the nozzle spring, through the
fuel return pipe fitting (A) and back into the fuel tank.

Section 9010 - ENGINE Group 15: Diagnostic Information

Diagnose Engine Malfunction
→NOTE:
Diagnostic charts are arranged from most probable and simplest to verify, to least likely and more
difficult to verify.

Section 9010 - ENGINE Group 25: Tests
Symptom Problem Solution
Engine Cranks But Will Not
No fuel Add fuel. Perform Bleed Fuel System . (Group 0560.)
Start or Hard to Start
Incorrect fuel Use correct fuel. See Diesel Fuel . (Operator′s Manual.)
Perform Drain Fuel Tank Sump and Perform Drain Water Separator to drain water. (Operator′s Manual.)
Water in fuel or water frozen in fuel line
Inspect final fuel filter for water. Go to Replace Final Fuel Filter to replace. (Operator′s Manual.)
Fuel filter and/or water separator plugged Go to Replace Final Fuel Filter and/or Perform Replace Water Separator as necessary. (Operator′s Manual.)
Debris in fuel Drain fuel tank. Clean tank strainer. Add clean fuel.
Air in fuel system Check for bubbles in fuel filter. Tighten connections. Perform Bleed Fuel System . (Group 0560.)
Disconnect fuel line at delivery end of electric fuel pump. Turn key ON. If fuel is not delivered, Perform Fuse Test on fuel pump fuse. (Group 9015-20.) See Fuse Specifications for fuse location. (Group 9015-10.) If fuse is good, disconnect fuel pump from harness. Check for 12V at terminal 2 of harness end
Electric fuel pump
connector with key switch ON. If ok, replace electric fuel pump. If 12V is not present, check harness.
Go to Alternator Output Check . (Group 9015-20.)

Low battery power Go to Battery Voltage Check . (Group 9015-20.) Charge batteries. See Using Battery Charger . (Operator′s Manual.)
Install new batteries. See Battery Remove and Install . (Group 9015-20.)
Slow cranking speed—poor electrical connection Clean and tighten battery and starter connections.
Incorrect engine oil Use correct oil for cold weather. See Diesel Engine Oil . (Operator′s Manual.)
Air filter elements plugged Check air filter restriction indicator. See Clean Air Cleaner Element . (Operator′s Manual.) Clean or replace elements.
Starter and electrical system Go to Electrical Component Checks . (Group 9015-20.)
Injection pump Remove and test pump. Go to Fuel Injection Pump Remove and Install for removal procedure. (Group 0400.) See your local fuel injection pump service center.
Injection nozzle(s) Remove and test injection nozzle. Go to Check Fuel Injection Nozzle . (Group 9010-25.)
Worn compression rings or low compression See Engine Compression Pressure Test . (Group 9010-25.) See Piston and Connecting Rod Repair for ring replacement. (Group 0400.)
Blown cylinder head gasket Perform Check for Head Gasket Failures . (Group 9010-25.)
Engine Knocks, Runs

Air in fuel Check for bubbles in fuel filter. Tighten connections. Perform Bleed Fuel System . (Group 0560.)
Irregularly or Stops
Perform Drain Fuel Tank Sump and Perform Drain Water Separator to drain water. (Operator′s Manual.)
Water in fuel
Inspect final fuel filter for water. Go to Replace Final Fuel Filter to replace. (Operator′s Manual.)
Fuel filter elements plugged Go to Replace Final Fuel Filter . (Operator′s Manual.)
Slow idle speeds adjustment too low See Engine Speed Control Cable Adjustment . (Group 9010-25.)
Perform Radiator Air Flow Test . (9010-25.)

Engine overheating
Go to Drain Cooling System . (Operator′s Manual.)
Electric fuel pump
Fuel injection pump Remove and test specific fuel injection pump. Go to Fuel Injection Pump Remove and Install for removal procedure. (Group 0400.) See your local fuel injection pump service center.
Improper valve clearance Go to Check And Adjust Engine Valve Lash (Clearance) . (Group 9010-25.)
Valve(s) sticking or burned See Engine Compression Pressure Test . (Group 9010-25.) Repair or replace valve(s) as necessary. See Cylinder Head Repair for valve replacement. (Group 0400.)
Bent push rods Inspect. See Cylinder Head Repair . (Group 0400.) Replace as necessary.
Worn or broken compression rings See Engine Compression Pressure Test . (Group 9010-25.) Repair as necessary.
Engine Not Developing

Full Power
Air filter plugged Check air filter restriction indicator. See Clean Air Cleaner Element . (Operator′s Manual.) Clean or replace elements.
Fuel tank outlet fitting plugged Clean.
Fast idle speed incorrect See Engine Speed Control Cable Adjustment . (Group 9010-25.)
Hydraulic system leakage Go to Cylinder Drift Test—Boom, Arm, Bucket, and Blade . (Group 9025-25.) If problem exists, See Load Drifts Down When Control Valve Is In Neutral Position. (Group 9025-15.)
Fuel line to pump or pump return line to tank restricted Check, repair.
Electric fuel pump
Timing incorrect Go to Check and Adjust Injection Pump Timing . (Group 9010-25.)
Low compression See Engine Compression Pressure Test . (Group 9010-25.) Repair as necessary.
Injection pump delivery or governor Repair specific pump. See your local fuel injection pump service center.
Valve(s) burned, warped Inspect. Repair or replace valve(s) as necessary. See Cylinder Head Repair for valve replacement. (Group 0400.)
Camshaft worn See Camshaft Repair . (Group 0400.)
Engine Overheats Coolant level low Fill cooling system. Check for leaks.
Thermostat stuck closed or missing Test. Go to Thermostat Remove and Install . (Group 0400.) Replace if necessary.
Radiator, oil cooler cores plugged with dirt or fins bent Perform Radiator Air Flow Test . (Group 9010-25.) Clean radiator. Straighten fins.
Air filter elements plugged Check air filter restriction indicator. See Clean Air Cleaner Element . (Operator′s Manual.) Clean or replace elements.
Coolant temperature sender Perform Temperature Sensor Test . (Group 9015-20.) Replace if necessary.
Coolant temperature gauge Perform Monitor and Gauge Circuit Checks . Replace if necessary. (Group 9005-10.)
Fan belt soaked with oil. Belt or pulleys worn excessively Inspect. Replace if necessary. See Fan Belt Repair . (Group 0510.)
Shroud or baffles (foam rubber) missing Inspect. Repair or replace. See Radiator And Oil Cooler Remove and Install . (Group 0510.)
Fan blade on backward Check that fan blade is installed with concave (cupped) side of blade towards engine. Perform Fan, Shroud, and Guards Repair . (Group 0510.)
Fan belt tension Go to Adjust Fan Belt Tension . (Group 9010-25.)
Incorrect coolant mixture Drain coolant and refill with correct coolant mixture.
Hydraulic system overheating See Hydraulic Oil Overheats. (9025-15.)
Cooling system passages dirty Flush coolant system. Go to Drain Cooling System . (Operator′s Manual.)
Water pump Inspect. Repair if necessary. See Water Pump Repair . (Group 0400.)
Engine Stalls Easily Under

Load
Air cleaner elements Check air filter restriction indicator. See Clean Air Cleaner Element . (Operator′s Manual.) Clean or replace elements.
Fuel tank outlet fitting plugged Clean.
Fuel line to pump or pump return line to tank restricted Check, repair.
Electric fuel pump
Timing incorrect Go to Check and Adjust Injection Pump Timing . (Group 9010-25.)
Low compression See Engine Compression Pressure Test . (Group 9010-25.) Repair as necessary.
Injection pump delivery or governor Repair pump. See your local fuel injection pump service center.
Valve(s) burned, warped Inspect. Repair or replace valve(s) as necessary. See Cylinder Head Repair for valve replacement. (Group 0400.)
Camshaft worn See Camshaft Repair . (Group 0400.)
Hydraulic pump Swash plate or control pistons sticking. See Hydraulic Pump Remove and Install . (Group 3360.)
Coolant Temperature Too

Thermostat stuck open Test. Go to Thermostat Remove and Install . (Group 0400.) Replace if necessary.
Low
Coolant temperature sensor Perform Temperature Sensor Test . (Group 9015-20.) Replace if necessary.
Coolant temperature gauge Perform Monitor and Gauge Circuit Checks . (Group 9005-10.) Replace if necessary.
Oil in Coolant or Coolant in

Crankcase
Inspect cylinder head. See Cylinder Head Repair . (Group 0400.) Replace if cracked.
Cracked cylinder head or block
Inspect block. See Cylinder Block Repair . (Group 0400.) Replace if cracked.
Low Engine Oil Pressure Oil level low Fill to proper level.
Oil filter plugged Perform Change Engine Oil And Replace Filter . (Operator′s Manual.)
Oil pump intake screen plugged or loose Inspect. Clean. See Oil Pump Repair for more information. (Group 0400.)
Incorrect grade of oil or fuel dilution Drain and refill with correct oil. See Diesel Engine Oil . (Operator′s Manual.)
Oil pump Oil pressure relief valve stuck open, drive gear loose, gear and/or housing worn. Inspect. See Oil Pump Repair . (Group 0400.) Repair as necessary.
Inspect main bearings. See Crankshaft Repair . (Group 0400.) Replace as necessary.
Excessive main or connecting rod bearing clearance
Inspect connecting rod bearings. See Piston and Connecting Rod Repair . (Group 0400.) Replace as necessary.
Excessive camshaft bearing clearance Inspect camshaft bearings. See Camshaft Repair . (Group 0400.) Replace as necessary.
High Engine Oil Pressure Incorrect oil viscosity Drain and refill with correct oil. See Diesel Engine Oil . (Operator′s Manual.)
Crankshaft or camshaft bearings spun in journal
Inspect camshaft bearings. See Camshaft Repair . (Group 0400.) Replace as necessary.
Oil pressure relief valve stuck or misadjusted See Oil Pump Repair . (Group 0400.) Repair as necessary.
Coolant in engine oil Perform Check for Head Gasket Failures . (Group 9010-25.)
Engine Uses Too Much Oil Incorrect oil Drain and refill with correct oil. See Diesel Engine Oil . (Operator′s Manual.)
Oil level too high Check oil level. Drain excess oil. Check to see if some other fluid is leaking into oil.
Oil leaks Check engine oil drain plug.
Air cleaner elements plugged Check air filter restriction indicator. See Clean Air Cleaner Element . (Operator′s Manual.) Clean or replace elements.
Crankcase breather restricted Inspect. Replace as necessary.
Perform Radiator Air Flow Test . (9010-25.)

Engine operating too hot
Go to Drain Cooling System . (Operator′s Manual.)
Main or connecting rod bearing clearance excessive
Inspect connecting rod bearings. See Piston and Connecting Rod Repair . (Group 0400.) Replace as necessary.
Cylinder liners scored Inspect cylinder liners. See Cylinder Block Repair . (Group 0400.) Replace as necessary.
Piston rings worn, broken or stuck See Engine Compression Pressure Test . (Group 9010-25.) See Piston and Connecting Rod Repair for ring replacement. (Group 0400.)
Camshaft bearing clearance excessive Inspect camshaft bearings. See Camshaft Repair . (Group 0400.) Replace as necessary.
Oil return slots in piston clogged Clean. See Piston and Connecting Rod Repair . (Group 0400.)
Inspect thrust bearing. See Crankshaft Repair . (Group 0400.) Replace bearings as necessary.
Crankshaft thrust bearing worn (misaligned piston and rod)
Inspect connecting rod bearings. See Piston and Connecting Rod Repair . (Group 0400.) Adjust or replace as necessary.
Valve guides or valve stems worn Inspect. See Cylinder Head Repair . (Group 0400.) Replace valve(s) and/or head as necessary.
Engine Uses Too Much

Fuel system leakage Check fuel lines for leaks.
Fuel
Air cleaner elements or intake manifold dirty or plugged Check air filter restriction indicator. See Clean Air Cleaner Element . (Operator′s Manual.) Clean or replace elements.
Excessive Black Smoke Incorrect fuel Use correct fuel. See Diesel Fuel . (Operator′s Manual.)
Check air filter restriction indicator. See Clean Air Cleaner Element . (Operator′s Manual.) Clean or replace elements.
Air cleaner elements or intake manifold dirty or plugged
Check intake manifold. Clean manifold.
Plugged exhaust system or muffler Clean exhaust system. Replace muffler. See Engine Remove and Install . (Group 0400.)
Over-fueling Remove and adjust fuel injection pump. See your local fuel injection pump service center.
Injection nozzle orifice plugged Inspect. See Fuel Injection Nozzle Repair . (Group 0400.) Clean as necessary.
Go to Alternator Output Check . (Group 9015-20.)

Excessive Blue or White
Cranking speed too slow Go to Battery Voltage Check . (Group 9015-20.) Charge batteries. See Using Battery Charger . (Operator′s Manual.)
Smoke
Install new batteries. See Battery Remove and Install . (Group 9015-20.)
Engine running too “cold” Test. Go to Thermostat Remove and Install . (Group 0400.) Replace if necessary.
See Engine Compression Test . (Group 9010-25.) See Piston and Connecting Rod Repair for ring replacement. (Group 0400.)
Liners have wear and/or piston ring stuck
Inspect cylinder liners. See Cylinder Block Repair . (Group 0400.) Replace as necessary.
Abnormal Noise Oil level low Check and add oil.
Incorrect engine oil Drain and refill with correct oil. See Diesel Engine Oil . (Operator′s Manual.)
Engine oil diluted with fuel Inspect engine oil. Inspect fuel pump spindle, seal and housing.
Valve clearance excessive Go to Check And Adjust Engine Valve Lash (Clearance) . (Group 9010-25.)
Engine static timing incorrect Inspect. Go to Cylinder Block Repair . (Group 0400.) Adjust camshaft timing.
Push rods bent Inspect. See Cylinder Head Repair . (Group 0400.) Replace as necessary.
Inspect connecting rod bearing cap screws. See Piston and Connecting Rod Repair . (Group 0400.) Torque to specification.
Main and/or connecting rod bearing caps loose or worn
Inspect main bearing cap screws. See Crankshaft Repair . (Group 0400.) Torque to specification.
Piston scored Inspect pistons and piston rings. See Piston and Connecting Rod Repair . (Group 0400.) Replace as necessary.
Piston pin bushings worn Inspect piston pin bushings. See Piston and Connecting Rod Repair . (Group 0400.) Replace pins and bushings as necessary.
Rocker arm shafts worn Inspect rocker arm shafts. See Cylinder Head Repair . (Group 0400.) Replace.
Crankshaft end play excessive Inspect. See Crankshaft Repair . (Group 0400.) Repair as necessary.


Group 25 - Tests
JT05801 Clamp- On Electronic Tachometer
LEGEND:
A Clamp-On Transducer
B Black Clip (-)
C Red Clip (+)
D Digital Readout Unit
JT05801 Clamp-On Electronic Tachometer
Service Equipment and Tools
SERVICE EQUIPMENT AND TOOLS
[1] - Before installing clamp-on electronic tachometer, remove the paint from a straight section of injection line within 100 mm
(4 in.) of No. 1 injection nozzle. Use emery cloth to remove the paint.
Clamp-On Electronic Tachometer
JT05801
To measure engine speed.
[2] - Install the clamp-on transducer (A). Tighten finger tight only—DO NOT overtighten.
[3] - Connect the red clip (+) (C) to the clamp-on transducer.
[4] - Connect the black clip (-) (B) to a ground connection such as the head of a cap screw or other metal part on engine.
[5] - Start the engine. Check for a reading on the digital readout unit (D).

Engine Speed Check

Specifications
SPECIFICATIONS
Engine Speed Check
Slow Idle Speed 1025—1125 rpm
Fast Idle Speed 2280—2380 rpm
[1] - Move engine speed control lever from slow idle to fast idle. Confirm that fuel injection pump governor lever contacts slow
idle and fast idle stops.
[2] - Start engine and warm to operating temperature.
[3] - Connect tachometer. See JT05801 Clamp-On Electronic Tachometer . (Group 9010-25.)
JT05801
[4] - Move engine speed control lever to slow idle position and measure engine rpm.
Engine Speed Check

Slow Idle Speed 1025—1125 rpm
[5] - Move engine speed control lever to fast idle position and measure engine rpm.
Engine Speed Check

Fast Idle Speed 2280—2380 rpm
[6] - Repeat measurement three times to ensure accuracy. Adjust as necessary.

Engine Speed Control Cable Adjustment

LEGEND:
1 24 mm (0.94 in.) Length
2 Fast Idle Stop Screw
3 Lock Nut (2 used)
4 30 mm (1.2 in.) Length
5 Slow Idle Stop Screw
6 Lock Nut (2 used)
7 Engine Speed Control Lever
8 Engine Control Cable
9 Fast Idle Adjusting Screw
10 Slow Idle Adjusting Screw
11 Governor Lever
Adjust Engine Speed Control Table
Adjusting Screws and Governor Lever
Specifications
SPECIFICATIONS
Engine Speed Control Cable
Slow Idle Stop Screw Length 30 mm (1.2 in.)
Fast Idle Stop Screw Length 24 mm (0.94 in.)
Engine Speed Control Lever-to-Fast Idle Stop Screw Clearance 1—2 mm (0.04—0.08 in.)
[1] - Remove engine speed control lever cover.
[2] - Loosen lock nuts (6) on slow idle stop screw (5).
[3] - Adjust slow idle stop screw to length (4).


Slow Idle Stop Screw Length 30 mm (1.2 in.)
[4] - Move engine speed control lever (7) until it contacts slow idle stop screw (5). Make sure governor lever (11) contacts slow
idle adjusting screw (10). If it does not, adjust length of engine control cable (8).
[5] - Move engine speed control lever (7) until governor lever (11) contacts fast idle adjusting screw (9).
[6] - Loosen lock nuts (3) on fast idle stop screw (2).
[7] - Adjust fast idle stop screw to length (1), then ensure proper clearance between engine speed control lever (7) and fast
idle stop screw (2).

Fast Idle Stop Screw Length 24 mm (0.94 in.)
Engine Speed Control Lever-to-Fast Idle Stop Screw Clearance 1—2 mm (0.04—0.08 in.)
[8] - Tighten lock nuts (3).
[9] - Install engine speed control lever cover.

Check Fuel Injection Nozzle
Adjust Fuel Injection Nozzle
Adjusting Shim
Spray Pattern
Specifications
SPECIFICATIONS
Fuel Injection Nozzle Pressure 17 700 kPa (177 bar) (2567 psi)

Essential Tools
ESSENTIAL TOOLS
Isuzu Part No. 5-8840-9016-0 (J-28829) Fuel Injection Nozzle Tester
[1] - Remove fuel injection nozzle from engine.
[2] - Install fuel injection nozzle in nozzle tester.
[3] -
CAUTION:
Never touch spray from fuel injection nozzle. Spray may penetrate skin and cause blood toxication in
blood stream.
Pump tester to inject fuel. Then pump tester at approximately 60 pumps per minute to test fuel injection nozzle pressure.
Fuel Injection Nozzle Tester
Isuzu Part No. 5-8840-9016-0 (J-28829)
To test fuel injection nozzle pressure.

Fuel Injection Nozzle Pressure 17 700 kPa (177 bar) (2567 psi)
→NOTE:
To increase pressure, increase number of shims. To decrease pressure, decrease number of shims.
Pressure variation per 0.1 mm shim is 206 kPa (2.06 bar) (30 psi).
[4] - Check spray pattern and observe for:
Uniform spray pattern

No sideways sprays
No coarse fuel distribution
No intermittent spray indicating blockage
No post injection dripping

Check and Adjust Injection Pump Timing

LEGEND:
1 No. 1 Injection Pipe
2 No. 1 Delivery Valve Holder
3 Spring
4 Delivery Valve
5 Injection Pump
6 Nut (2 used)
7 Cap Screw (2 used)
8 Shim (As Required)
9 Body
Align Mark Groove on Crank Pulley
No. 1 Injection Pipe
Pull Out Delivery Valve and Spring

Adjust Timing Position
Specifications
SPECIFICATIONS
Injection Pump Timing
Delivery Valve Holder Torque 39—44 N˙m (29—33 lb-ft)
Preparation
[1] - Rotate crank pulley until No. 1 cylinder is at TDC of the compression stroke.
Align “Mark Groove” on the crank pulley with “TDC Mark” on the timing gear case cover.
[2] - Rotate crank pulley approximately 100° counterclockwise.
[3] - Remove No. 1 injection pipe (1).
[4] - Remove No. 1 delivery valve holder (2) on injection pump (5) to pull out delivery valve (4) and spring (3). Reinstall
delivery valve holder (2) into injection pump (5). Tighten delivery valve holder.

Delivery Valve Holder Torque 39—44 N˙m (29—33 lb-ft)
[5] - Turn key switch to ON. While supplying fuel from fuel pump, rotate crank pulley clockwise slowly until fuel leak stops at
the tip of the delivery valve holder. At this moment, the “Mark Groove” on the crank pulley should be aligned with 11.5° BTDC
on the timing gear case cover. If not, adjust the injection timing to specification.

Injection Pump Timing 11.5° BTDC (Before Top Dead Center)
Adjustment
[1] - Remove cap screws (7) and nuts (6) from injection pump (5).
[2] - Adjust timing position by increasing or decreasing the number of shims (8) between injection pump (5) and body (9).
[3] - When delaying timing, increase the number of shims (8). When advancing timing, decrease the number of shims.

IMPORTANT:
All injection pumps must have equal number of shims.
→NOTE:
The crank angle will vary 1° per 0.1 mm shim.

Adjust Fan Belt Tension

LEGEND:
1 Crank
2 Fan Pulley
3 Alternator
4 Cap Screw (3 used)
5 Adjusting Strap
Belt Deflection
Adjust Fan Belt Tension
Specifications
SPECIFICATIONS
Fan Belt
Fan Belt Deflection 7—9 mm at 99 N (0.27—0.35 in. at 22 lb)
JDG529 Belt Tension Gauge
[1] - Check belt regularly for wear. Replace if necessary
[2] - Remove wing nut to remove panel from behind seat.
Check belt tension with belt deflection gauge at midway between crank (1) and fan pulley (2).
Belt Tension Gauge
JDG529
To measure fan belt tension.
Fan Belt
Fan Belt Deflection 7—9 mm at 99 N (0.27—0.35 in. at 22 lb)

[3] - If deflection is not within specifications, loosen cap screws (4) for adjusting strap (5).
[4] - Move alternator (3) until tension is correct.
[5] - Tighten cap screws.

Check and Adjust Engine Valve Lash (Clearance)
Align Mark Groove and TDC Mark
Valve Clearance
Specifications
SPECIFICATIONS
Engine Valve Lash
Intake and Exhaust Valve (Cold) Clearance 0.35—0.45 mm (0.014—0.018 in.)
→NOTE:
Engine must be cold before performing this procedure.
[1] -
→NOTE:
Clean area around valve cover before removing.
Remove valve cover from engine.
[2] - Rotate crank pulley until No. 1 cylinder is at TDC of the compression stroke. Align “Mark Groove” on the crank pulley with
“TDC Mark” on the timing gear case cover.

→NOTE:
Remove glow plugs to ease flywheel rotation.
[3] - Measure valve lash for No. 1 at TDC per chart below marked (O).
[4] - Rotate crank pulley 360° to align “Mark Groove” and “TDC Mark” on timing gear case cover. This positions No. 4 cylinder
at TDC.
[5] - Measure valve lash for No. 4 at TDC per chart marked (X).
Valve Lash
Cylinder No. 1 2 3 4
Valve I E I E I E I E
Cylinder No. 1 at top dead center O O O O
Cylinder No. 4 at top dead center X X X X
Valve lash must be the same for both intake and exhaust valves.
Engine Valve Lash

Intake and Exhaust Valve (Cold) Clearance 0.35—0.45 mm (0.014—0.018 in.)
[6] - If lash needs to be adjusted, loosen lock nut and adjust by turning adjusting screw. Tighten lock nut while holding
adjusting screw.

Air Intake System Leakage Test

LEGEND:
1 Barb Fitting
2 Tee Fitting
3 Air Pressure Regulator
4 0-30 PSI Pressure Gauge
Air Cleaner Element
27C ZTS shown
Specifications
SPECIFICATIONS
Air Intake System
Air Intake System Pressure 14—21 kPa (0.14—0.21 bar) (2—3 psi)
Barb Fitting
Tee Fitting
0-30 PSI Pressure Gauge
Air Pressure Regulating Valve
[1] - Remove air cleaner cover and element.
[2] - Put large plastic bag into and over end of element as shown. Install element and cover.
[3] - Remove air filter restriction switch at the air cleaner.
[4] - Connect barb fitting (1) to hose.
Barb Fitting
To connect test equipment to air intake system.
[5] - Use shop fittings to connect hose to tee fitting (2).
Tee Fitting

To connect pressure source to gauge and intake system.
[6] - Connect pressure gauge (4) and air pressure regulator (3) to tee fitting (2).
Pressure Gauge 0-30 PSI
To measure test pressure.
Air Pressure Regulating Valve
To regulate test pressure.
[7] - Connect air pressure regulator (3) to pressurized air source.
[8] - Pressurize air intake system to specification. If intake system cannot be pressurized, turn engine slightly to close valves.
Air Intake System

Air Intake System Pressure 14—21 kPa (0.14—0.21 bar) (2—3 psi)
[9] - Spray soap solution over all connections from the air cleaner to air intake manifold. Check for leaks. Repair all leaks.

Radiator Air Flow Test
Radiator Air Flow Test
Specifications
SPECIFICATIONS
Radiator Air Flow
Engine Speed Fast Idle
Total Reading Voltage Equal to or greater than 1.4 volts (typical new)
Essential Tools
ESSENTIAL TOOLS
JT05529 Air Flow Meter
JT07306 Analog/Digital Multimeter
[1] - Lower all equipment to the ground.
[2] - Position all levers and pedals in neutral.
[3] - Stop the engine.
[4] - Straighten any bent fins in radiator or oil cooler.
[5] - Mark off seven squares as shown.
[6] - Connect air flow meter to analog/digital multimeter. Set multimeter to AC volts.

[7] - Start engine and run it at fast idle.
Radiator Air Flow

[8] -
JT05529 Air Flow Meter
Put air flow meter against the radiator so it is centered in a square and air flow is through meter in the direction of air flow
arrow.
Air Flow Meter
JT05529
To measure air flow through radiator.
Analog/Digital Multimeter
JT07306
To measure the voltage of air flow meter.
IMPORTANT:
This machine has a draw-in type fan blade installed.

[9] - Record voltage reading for each square.
[10] - Add the voltage readings. The total of readings must be equal to or greater than the specification.
Radiator Air Flow

Total Reading Voltage Equal to or greater than 1.4 volts (typical new)
[11] - If readings are less than specification, clean the external surfaces of the oil cooler and radiator. Repeat test.
→NOTE:
Metering air flow with meter reversed will result in approximately 55% of expected reading.

Engine Compression Pressure Test
Engine Compression Pressure
Specifications
SPECIFICATIONS
Engine Compression Pressure 3040 kPa (30.40 bar) (441 psi)
Essential Tools
ESSENTIAL TOOLS
Isuzu Part No. 5-8840-2675-0 Compression Gauge
Isuzu Part No. 5-8840-9029-0 Adapter
[1] - Batteries must be fully charged.
[2] - Clean area around glow plugs.
[3] - Run engine until it reaches normal operating temperature.
[4] - Disconnect battery negative (-) terminal and engine stop solenoid connectors.
[5] - Remove all glow plugs from engine.
[6] - Reconnect battery negative terminal.
[7] - Connect adapter to compression gauge and install in a glow plug bore.
Compression Gauge
Isuzu Part No. 5-8840-2675-0
To check engine compression pressure.
Adapter
Isuzu Part No. 5-8840-9029-0
To connect compression gauge.

[8] - Crank engine until compression reading is stabilized. Perform test three times for each cylinder and record readings.

Engine Compression Pressure 3040 kPa (30.40 bar) (441 psi)
[9] - Readings should be approximately the same for each cylinder. A variation exceeding 196 kPa (1.96 bar) (28.45 psi) is not
acceptable and must be corrected.
Inspect piston rings for broken or stuck rings. See Piston and Connecting Rod Repair . (Group 0400.)
Inspect cylinder linings for wear. See Cylinder Block Repair . (Group 0400.)
Inspect intake and exhaust valves for improper travel and fit. See Cylinder Head Repair . (Group 0400.)

Engine Oil Pressure Test
Right-Hand Side
Specifications
SPECIFICATIONS
Engine Oil Pressure
Engine Oil Pressure 345—414 kPa (3.45—4.14 bar) (50—60 psi) at fast idle
Essential Tools
ESSENTIAL TOOLS
JT05412 Industrial Universal Pressure Test Kit
JT03017 Hose
JT05487 Fitting
JT03115 Pressure Gauge
→NOTE:
Before performing test, make sure oil filter is clean. A dirty oil filter will limit the flow of filtered oil.

[1] - Warm engine to normal operating temperature.
[2] - Shut off engine.
[3] - Remove engine oil pressure switch.
[4] - Install JT03115 gauge, JT03017 hose and JT05487 fitting from universal pressure test kit.
Industrial Universal Pressure Test Kit
JT05412
To measure oil pressure.
Pressure Gauge
JT03115
To measure oil pressure.
Hose
JT03017
To connect gauge to fitting.
Fitting
JT05487
To connect hose and gauge to oil passage in engine block.
[5] - Start engine and run at specification.
Engine Oil Pressure

[6] - Record oil pressure.
Engine Oil Pressure

Engine Oil Pressure 345—414 kPa (3.45—4.14 bar) (50—60 psi) at fast idle

Check for Head Gasket Failures

LEGEND:
A Combustion Sealing Area
B Oil Sealing Areas
C Coolant Sealing Areas
Diagnosing Head Gasket Joint Failures
Head gasket failures generally fall into three categories:
Combustion seal failures.

Coolant seal failures.
Oil seal failures.
Combustion seal failures occur when combustion gases escape between cylinder head and head gasket combustion flange, or
between combustion flange and cylinder liner. Leaking combustion gases may vent to an adjacent cylinder, to a coolant or oil
passage, or externally.
Coolant or oil seal failures occur when oil or coolant escapes between cylinder head and gasket body, or between cylinder
block and gasket body. The oil or coolant may leak to an adjacent coolant or oil passage, or externally. Since oil and coolant
passages are primarily on right-hand (camshaft) side of engine, fluid leaks are most likely to occur in that area.
Follow these diagnostic procedures when a head gasket joint failure occurs or is suspected.
[1] - Before starting or disassembling engine, conduct a visual inspection of machine and note any of the following:
Oil or coolant in head gasket seam, or on adjacent surfaces. Especially right rear corner of gasket joint
Displacement of gasket from normal position
Discoloration or soot from combustion gas leakage
Leaking radiator, overflow tank, or hoses
Leaking coolant from water pump weep hole
Damaged or incorrect radiator, fan, or shroud
Obstructed air flow or coolant flow
Worn or slipping belts
Damaged or incorrect pressure cap

Presence of oil in coolant

Low coolant levels or incorrect coolant
Unusually high or low oil levels
Oil degradation, dilution, or contamination
Incorrectly specified injection pump
Indications of fuel or timing adjustments
Unburned fuel or coolant in exhaust system
[2] - Obtain coolant and oil samples for further analysis.
[3] - Start and warm up engine if it can be safely operated. Examine all potential leakage areas again as outlined previously.
Using appropriate test and measurement equipment, check for the following:
White smoke, excessive raw fuel, or moisture in exhaust system

Rough, irregular exhaust sound, or misfiring
Air bubbles, gas trapped in radiator or overflow tank
Loss of coolant from overflow
Excessive cooling system pressure
Coolant overheating
Low coolant flow
Loss of cab heating (air lock)
[4] - Shut engine down. Recheck crankcase, radiator, and overflow tank for any significant differences in fluid levels, viscosity,
or appearance.
[5] - Compare your observations from above steps with the diagnostic charts earlier in this group. If diagnostic evaluations
provide conclusive evidence of combustion gas, coolant, or oil leakage from head gasket joint, the cylinder head must be
removed for inspection and repair of gasket joint components. See Cylinder Head Repair for head gasket replacement. (Group
0400.)
COMBUSTION SEAL LEAKAGE
Symptoms:
Exhaust from head gasket crevice

Air bubbles in radiator or overflow tank
Coolant discharge from overflow tube
Engine overheating
Power loss
Engine runs rough
White exhaust smoke
Loss of cab heat
Gasket section dislodged, missing (blown)
Coolant in cylinder
Coolant in crankcase oil
Low coolant level
Possible Causes:
Insufficient liner standout

Excessive liner standout differential between cylinders
Low head bolt clamping loads
Rough/damaged liner flange surface
Cracked/deformed gasket combustion flange
Out-of-flat/damaged/rough cylinder head surface
Missing/mislocated gasket fire ring
Block cracked in liner support area
Excessive fuel delivery
Advanced injection pump timing

ELECTRICAL SYSTEM (g) by Belgreen v2.0
Hydraulic or mechanical disturbance of combustion seal
→NOTE:
Cracked cylinder head or liners may also allow combustion gas leakage into coolant.
COOLANT SEAL LEAKAGE
Symptoms:
Coolant discharge from head gasket crevice

Coolant in crankcase oil
Low coolant level
High oil level
Coolant discharge from crankcase vent
Possible Causes:
Excessive liner standout

Out-of-flat/damaged/rough block surface
Oil or coolant overheating
Cracks/creases in gasket body surfaces
Damage/voids in elastomer beading
OIL SEAL LEAKAGE
Symptoms:
Oil discharge from head gasket crevice

Oil in coolant
Low crankcase oil level
Reduced oil to rocker arms (noisy)
Possible Causes:
Excessive liner standout

Out-of-flat/damaged/rough block surface
Oil or coolant overheating
Cracks/creases in gasket body surfaces
Damage/voids in elastomer beading
Damaged/missing O-ring seal at oil port to rocker arms

Section 9015 - ELECTRICAL SYSTEM

Table of contents
Group 05 - System Information ............................................................................................................. 1
Electrical Diagram Information ............................................................................................................. 1
Group 10 - System Diagrams ................................................................................................................. 4
Explanation of Wire Markings ............................................................................................................... 4
FUSE SPECIFICATIONS .......................................................................................................................... 5
Functional Schematic and Component Location Master Legend .......................................................... 7
System Functional Schematic ............................................................................................................... 9
Main Harness (W1) Component Location ............................................................................................ 16
Main Harness (W1) Wiring Diagram .................................................................................................... 18
Floor Harness (W2) Component Location ........................................................................................... 20
Floor Harness (W2) Wiring Diagram ................................................................................................... 22
Engine Harness (W3) Component Location ........................................................................................ 24
Engine Harness (W3) Wiring Diagram ................................................................................................ 26
Cab Harness (W5) Component Location ............................................................................................. 28
Cab Harness (W5) Wiring Diagram ..................................................................................................... 30
Heater Harness (W10) Wiring Diagram .............................................................................................. 32
Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12) Component Location
..................................................................................................................................................... 34
Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12) Wire Diagram ............ 36
Group 15 - Sub-System Diagnostics ................................................................................................... 38
Starting and Charging Circuit Theory of Operation ............................................................................. 39
Monitor Controller Circuit Theory of Operation ................................................................................... 41
Pilot Control Shut-Off Circuit Theory of Operation .............................................................................. 43
Propel Alarm Circuit Theory of Operation ........................................................................................... 45
Group 20 - References ........................................................................................................................... 47
Fuse Test ............................................................................................................................................ 47
Relay Test ........................................................................................................................................... 47
Pressure Sensor Test .......................................................................................................................... 49
Solenoid Test ...................................................................................................................................... 49
Temperature Sensor Test ................................................................................................................... 50
Component Checks ............................................................................................................................. 51
Battery Remove and Install ................................................................................................................ 58
Propel Alarm Cancel Switch Remove and Install ................................................................................. 60
Key Switch Remove and Install ........................................................................................................... 62
Monitor Controller and Display (A5) Remove and Install .................................................................... 64
Glow Plug Timer Remove and Install .................................................................................................. 67
Propel Alarm Controller Remove and Install ....................................................................................... 69
Disconnect Tab Retainer Connectors .................................................................................................. 70
Disconnect Spring Wire Clip Connectors ............................................................................................ 71
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors ..................................... 72
Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contacts ............................................ 74
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector .................. 77
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contacts ........................ 79
Remove Connector Body from Blade Terminals ................................................................................. 80

Section 9015 - ELECTRICAL SYSTEM Group 05: System Information
Group 05 - System Information

Electrical Diagram Information
→NOTE:
All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key switch in
the OFF position.
System Functional Schematic Diagram

LEGEND:
System Functional Schematic Example 1 Continuity Chart
2 Power Wires
3 Routing Location Information
4 Wire Identification
5 Ground Wires
6 Circuit Name
7 Section Number
8 Component Name
9 Component Identification Number
10 Component Schematic Symbol
The System Functional Schematic is made up of equal sections to simplify searching the schematic. Each section of the System
Functional Schematic is assigned a number (7). The System Functional Schematic is formatted with power supply wires (2)
shown across the top of the drawing and ground wires (5) across the bottom. The schematic contains no harness or connector
information.
Each electrical component is shown by a schematic symbol (10), the component name (8), and a component identification
number (9). A component identification number and name will remain the same throughout the Operation and Test Technical
Manual. This will allow for easy cross-referencing of all electrical drawings (Schematics, Wiring Diagrams, and Component
Location).
Routing location information (3) is presented to let the reader know when a wire is connected to a component in another
section. TO and FROM statements identify when power is going “To” or coming “From” a component in a different location. The
section and component number are given in parenthesis at the bottom of the statement. In the example, power is going TO
component F15 Horn Fuse, in section SE15.
Wiring Diagram—If Provided

LEGEND:
Wiring Diagram Example 1 Harness Connector Pin Letter or Number
2 Harness Connector Number Identification
3 Component Identification Number
4 Wire Color or Number
5 Component Identification Number Wire is Routed TO
6 Component Connector
7 Component Connector Pin Letter or Number
8 Wiring Harness
9 Component Identification Number Wire is Routed TO
10 Wire Color or Number
Each harness on the machine is drawn showing components, connectors, and wires. Harnesses are identified by a “W”
component identification number and description (W6 ENGINE HARNESS, Etc.).
Each component is represented by a schematic symbol and is identified by a component identification number and name (3).
Components with integral connectors (6) have pin number/letters indicated (7). Wires from harness to components are
identified by color or number designation (4). Component identification number (5) indicates the component a wire is routed
TO.
Main harness connectors (2) are identified by a “X” component identification number and description (X28 CAB TO ENGINE
BULKHEAD CONNECTOR, Etc.). Harness connector description indicates which harnesses connect together. Connector pin

Section 9015 - ELECTRICAL SYSTEM Group 05: System Information
letters or numbers (1) are indicated as they are marked on the connector. Wires attached to each connector pin are identified
by color or number (10). Component identification number (9) indicates destination of each wire.
Component Location Diagram
The Component Location Diagram is a pictorial view by harness showing location of all electrical components, connectors,
harness main ground locations and harness band and clamp location. Each component will be identified by the same
identification letter/number and description used in the System Functional Schematic Diagram.
Connector End View Diagram—If Provided
The Connector End View Diagram is a pictorial end view of the component connectors showing the number of pins in the
connector and the wire color and identifier of the wire in every connector. Each component will be identified by the same
identification letter/number and description used in the System Functional Schematic Diagram.
Electrical Schematic Symbols

LEGEND:
1 Battery
2 Wire Splice
3 Fuse
4 Circuit Breaker
5 Fusible Link
6 Power Outlet
7 Alternator
8 Air Conditioner Compressor
9 Compressor
10 Liquid Pump
Electrical Schematic Symbols 11 Antenna
12 Diode
13 Zener Diode
14 Capacitor
15 Magnet
16 Flasher
17 Buzzer
18 Horn
19 Alarm
20 Clock
21 Internal Ground
22 Single Point Ground
23 External Ground
24 Sensor
25 Sensor with Normally Open Switch
26 Speed Sensor
27 Rotary Sensor
28 Single Element Bulb
29 Dual Element Bulb
Solenoid Operated Hydraulic Valve With Suppression
30
Diode
31 Solenoid Normally Open
32 Solenoid Normally Closed
33 Starter Motor
34 Starter Motor
35 DC Motor
36 DC Stepping Motor
37 Wiper Motor
38 Blower Motor
39 Servo Motor
40 Speedometer
41 Tachometer
42 Temperature Gauge
43 Liquid Level Gauge
44 Gauge
45 Hourmeter
46 Resistor
47 Variable Resistor

Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
48 Manually Adjusted Variable Resistor

49 Multi-Pin Connector
50 Single Pin Connector
51 Connector
52 4 Pin Relay
53 5 Pin Relay
54 5 Pin Relay With Internal Suppression Diode
55 5 Pin Relay With Internal Suppression Resistor
56 Key Switch
57 Temperature Switch Normally Open
58 Temperature Switch Normally Closed
59 Pressure Switch Normally Open
60 Pressure Switch Normally Closed
61 Liquid Level Switch Normally Open
62 Liquid Level Switch Normally Closed
63 Momentary Switch Normally Open
64 Momentary Switch Normally Closed
65 Toggle Switch Normally Open
66 Toggle Switch Normally Closed
67 2 Way Toggle Switch Normally Open
68 2 Way Toggle Switch Normally Closed
69 Manual Switch Operation
70 Push Switch Operation
71 Pull Switch Operation
72 Turn Switch Operation
73 Toggle Switch Operation
74 Pedal Switch Operation
75 Key Switch Operation
76 Detent Switch Operation
77 Temperature Sensor
78 Solar Sensor
79 Pressure Sensor
80 Liquid Level Sensor

Group 10 - System Diagrams

Explanation of Wire Markings
Electrical harness wires are identified by color, with no number stamped on wire. Wire numbers are used on some connector
drawings simply as reference numbers, useful in tracing wires through the harness.
Some wires are solid wire colors. These would be identified by one color name such as Red or Blk or Grn.
Other wire colors are identified with two color names. These are solid wires with a narrow stripe. For example, a wire identified
as Red/Wht would be a primarily Red wire, with a Wht stripe. A wire identified as Wht/Red would be a primarily Wht wire with a
Red stripe.
Following is a listing of wire color abbreviations used on drawings.
Blk—Black
Blu—Blue
Brn—Brown
Grn—Green
Gry—Grey
LtGrn—Light Green
Org—Orange
Pnk—Pink
Pur—Purple
Red—Red
Vlt—Violet
Wht—White
Yel—Yellow
A limited number of wire colors are not available at time of first production. In those cases the wire is identified by a number
only. Wire color will be added as soon as it is available.

FUSE SPECIFICATIONS
Fuse Specifications
LEGEND:
F1 Pilot Control Shut-Off 5 Amp Fuse
F2 Drive and Boom Work Light 20 Amp Fuse
F3 Horn 10 Amp Fuse
F4 12V Power Outlet 10 Amp Fuse
F5 Engine Power 10 Amp Fuse
F6 Heater and Wiper 15 Amp Fuse
F7 Not Used
F8 Fuel Pump 5 Amp Fuse
F9 Propel Alarm 5 Amp Fuse
F10 Monitor Controller and Display 5 Amp Fuse
F11 Back-Up Power 5 Amp Fuse
F12 Auto Idle 5 Amp Fuse (Not Used)
F13 Radio 5 Amp Fuse (Field Option)

IMPORTANT:
Install fuse with correct amperage rating to prevent electrical system damage from overload.
Fuse block is located in the toolbox and operator manual compartment.

Functional Schematic and Component Location Master Legend

A5 — Monitor Controller and Display ( SE4 )( W2 )
A8 — Starter Protection Controller ( SE2 )( W2 )
A10 — Propel Alarm Controller ( SE8 )( W11 )
B4 — Engine Oil Pressure Switch ( SE3 )( W3 )
B9 — Coolant Temperature Gauge Sensor ( SE3 )( W3 )
B10 — Glow Plug Timer ( SE2 )( W2 )
B15 — Left Propel Pressure Sensor ( SE9 )( W11 )
B16 — Right Propel Pressure Sensor ( SE9 )( W11 )
B24 — Left Speaker ( SE7 )( W5 )
B25 — Horn ( SE5 )( W1 )
B46 — Coolant Overheat Switch ( SE2 )( W3 )
B53 — Glow Timer Engine Coolant Sensor ( SE2 )( W3 )
E2 — Drive Light ( SE5 )( W1 )
E3 — Cab Dome Light ( SE6 )( W5 )
E4 — Monitor Controller and Display Backlight ( SE4 )( W2 )
E12 — Boom Work Light ( SE5 )( W1 )
F1 — Pilot Shut-Off 5 Amp Fuse ( SE4 )( W2 )
F2 — Drive and Boom Work Light 20 Amp Fuse ( SE5 )( W2 )
F3 — Horn 10 Amp Fuse ( SE5 )( W2 )
F4 — 12V Power Outlet 10 Amp Fuse ( SE8 )( W2 )
F5 — Engine Power 10 Amp Fuse ( SE1 )( W2 )
F6 — Heater and Wiper 15 Amp Fuse ( SE6 )( W2 )
F7 — Not Used ( SE6 )( W2 )
F8 — Fuel Pump 5 Amp Fuse ( SE1 )( W2 )
F9 — Propel Alarm 5 Amp Fuse ( SE8 )( W2 )
F10 — Monitor Controller and Display 5 Amp Fuse ( SE3 )( W2 )
F11 — Back-Up Power 5 Amp Fuse ( SE3 )( W2 )
F12 — Auto Idle 5 Amp Fuse (Not Used)( SE4 )( W2 )
F13 — Radio 5 Amp Fuse (Field Option)( SE6 )( W2 )
F19 — Radio 5 Amp In-Line Fuse (Field Option)( SE7 )( W5 )
F21 — Battery Power 45 Amp Fusible Link ( SE1 )( W1 )
F22 — Alternator 45 Amp Fusible Link ( SE1 )( W1 )
F27 — Radio Backup Inline 1 Amp Fuse (Field Option)( SE6 )( W5 )
G1 — Battery ( SE1 )( W1 )
G3 — Alternator ( SE2 )( W3 )
G4 — 12V Power Outlet ( SE8 )( W2 )
H3 — Propel Alarm ( SE9 )( W11 )
H8 — Monitor Controller and Display Alarm ( SE4 )( W2 )
H9 — Glow Plug Indicator ( SE4 )( W2 )
H17 — Engine Oil Pressure Indicator ( SE3 )( W2 )
H18— Alternator Indicator ( SE3 )( W2 )
K3 — Drive and Boom Work Light Relay ( SE5 )( W2 )
K5 — Horn Relay ( SE5 )( W2 )
K12 — Starter Relay ( SE1 )( W2 )
K29 — Glow Plug Relay ( SE2 )( W2 )
M1 — Starter (SE1)( W3 )
M3 — Windshield Wiper Motor ( SE7 )( W5 )
M4 — Windshield Washer Motor ( SE8 )( W5 )
M5 — Heater Blower Motor ( SE8 )( W10 )
R5 — Fuel Level Sender ( SE3 )( W1 )
R12 — Glow Plug ( SE2 )( W3 )
R15 — Glow Plug (50C ZTS Only)( SE2 )( W3 )
S1 — Key Switch ( SE1 )( W2 )
S2 — Horn Switch ( SE5 )( W2 )
S3 — Dome Light Switch ( SE7 )( W5 )
S4 — Heater Blower Motor Switch ( SE7 )( W10 )
S6 — Drive and Boom Work Light Switch ( SE4 )( W2 )

S8 — Propel Speed Switch ( SE5 )( W2 )

S9 — Windshield Wiper and Washer Switch ( SE8 )( W5 )
S10 — Propel Alarm Cancel Switch ( SE9 )( W11 )
S21 — Left Pilot Shut-Off Switch ( SE4 )( W2 )
W1 — Main Harness
W2 — Floor Harness
W3 — Engine Harness
W4 — Antenna
W5 — Cab Harness
W6 — Main Harness Ground
W7 — Battery to Frame Ground
W8 — Engine to Frame Ground
W11 — Propel Alarm Harness
W12 — Propel Alarm Cancel Switch Harness
X1 — Main Harness to Floor Harness 11 Pin Connector ( W1 , W2 )
X2 — Engine Harness to Floor Harness 8 Pin Connector ( W2 , W3 )
X3 — Floor Harness to Monitor Controller and Display Harness 12 Pin Connector ( SE3 )( W2 )
X4 — Floor Harness to Cab Harness 10 Pin Connector ( SE6 )( W2 , W5 )
X5 — Floor Harness to Engine Harness 4 Pin Connector ( W2 , W3 )
X6 — Engine Harness to Main Harness 1 Pin Connector ( W1 , W3 )
X7 — Engine Harness to Fuel Transfer Pump 2 Pin Connector ( W3 )
X8 — Engine Harness to Fuel Shut-Off Solenoid 3 Pin Connector ( W3 )
X9 — Engine Harness to Alternator 3 Pin Connector ( W3 )
X10 — Main Harness to Floor Harness 1 Pin Connector ( W1 , W2 )
X11 — Main Harness to Battery 2 Pin Connector ( W1 )
X12 — Main Harness to Pilot Shut-Off Solenoid ( W1 )
X13 — Main Harness to Propel Speed Change Solenoid ( W1 )
X14 — Main Harness to Alternator Fusible Link 2 Pin Connector ( W1 )
X15 — Main Harness to Battery Power Fusible Link 2 Pin Connector ( W1 )
X16 — SATE 3 Pin Connector (Not Used)( SE8 )( W2 , W5 )
X17 — Floor Harness to Heater Harness 2 Pin Connector ( SE7 )( W2 , W5 )
X18 — Starter Protection Controller to Floor Harness 4 Pin Connector ( W2 )
X19 — Glow Plug Timer to Floor Harness 6 Pin Connector ( W2 )
X20 — Glow Plug Relay to Floor Harness 2 Pin Connector ( W2 )
X21 — Floor Harness to Left Pilot Control Shut-Off Switch 2 Pin Connector ( W2 )
X22 — Floor Harness to Right Pilot Control Shut-Off Switch Jumper 2 Pin Connector ( SE4 )( W2 )
X23 — Main Harness to Fuel Level Sender 3 Pin Connector ( W1 )
X24 — PAT Connector (Not Used)( SE8 )( W2 )
X25 — Floor Harness to Propel Alarm Harness Connector ( W2 , W11 )
X26 — 12V Power Outlet Connector ( W2 )
X29 — Floor Harness to Auto Idle 1 Pin Connector ( SE4 )( W2 )
X30 — Floor Harness to Auto Idle 1 Pin Connector ( SE4 )( W2 )
X31 — Air Conditioner Harness 3 Pin Connector ( SE6 )( W5 )
X32 — Fuse Block ( W2 )
X33 — Propel Alarm Harness to Propel Alarm Cancel Switch Harness Connector ( SE9 )( W11 )
X34 — Radio to Cab Harness Connector ( SE7 )( W5 )
X35 — Radio Harness to Right Speaker Connector ( SE7 )( W5 )
Y6 — Propel Speed Solenoid ( SE5 )( W1 )
Y7 — Fuel Shut-Off Solenoid ( SE2 )( W3 )
Y8 — Pilot Control Shut-Off Solenoid ( SE4 )( W1 )
Y14 — Fuel Transfer Pump ( SE1 )( W3 )

System Functional Schematic

System Functional Schematic—27C ZTS/35C ZTS/50C ZTS (SE1, SE2 and SE3)






Main Harness (W1) Component Location
Main Harness (W1) Component Location

LEGEND:
B25 Horn
E2 Drive Light
E12 Boom Work Light
R5 Fuel Level Sender
S8 Propel Speed Switch
W6 Main Harness Ground
X1 Main Harness to Floor Harness 11 Pin Connector
X6 Engine Harness to Main Harness 1 Pin Connector
X11 Main Harness to Battery 2 Pin Connector
X12 Main Harness to Pilot Control Shut-Off Solenoid
X13 Main Harness to Propel Speed Change Solenoid
X14 Main Harness to Alternator Fusible Link 2 Pin Connector
X15 Main Harness to Battery Power Fusible Link 2 Pin Connector
X23 Main Harness to Fuel Level Sender 3 Pin Connector
Y6 Propel Speed Solenoid
Y8 Pilot Control Shut-Off Solenoid

Main Harness (W1) Wiring Diagram
Main Harness (W1) Wiring Diagram
LEGEND:
B25 Horn
E2 Drive Light
E12 Boom Work Light

F21 Battery Power 45 Amp Fusible Link

F22 Alternator 45 Amp Fusible Link
G1 Battery
S8 Propel Speed Switch
W8 Engine to Frame Ground
X11 Main Harness to Battery 2 Pin Connector
X12 Main Harness to Pilot Control Shut-Off Solenoid
X13 Main Harness to Propel Speed Change Solenoid
X14 Main Harness to Alternator Fusible Link 2 Pin Connector
X15 Main Harness to Battery Power Fusible Link 2 Pin Connector
X23 Main Harness to Fuel Level Sender 3 Pin Connector
Y6 Propel Speed Solenoid
Trace wires through the following mating connectors and machine harnesses:
X1— See Floor Harness (W2) Wiring Diagram . (Group 9015-10)

X6— See Engine Harness (W3) Wiring Diagram . (Group 9015-10)

Floor Harness (W2) Component Location
Floor Harness (W2) Component Location

LEGEND:
A5 Monitor Controller and Display
A8 Starter Protection Controller
B10 Glow Plug Timer
G4 12V Power Outlet
K3 Drive and Boom Work Light Relay
K5 Horn Relay
K12 Starter Relay
K29 Glow Plug Relay
S1 Key Switch
S2 Horn Switch
S21 Left Pilot Control Shut-Off Switch
X2 Engine Harness to Floor Harness 8 Pin Connector
X3 Floor Harness to Monitor Controller and Display Harness 12 Pin Connector
X4 Floor Harness to Cab Harness 10 Pin Connector
X5 Floor Harness to Engine Harness 4 Pin Connector
X16 SATE 3 Pin Connector (Not Used)
X17 Floor Harness to Heater Harness 2 Pin Connector
X18 Starter Protection Controller to Floor Harness 4 Pin Connector
X19 Glow Plug Timer to Floor Harness 6 Pin Connector
X20 Glow Plug Relay to Floor Harness 2 Pin Connector
X21 Floor Harness to Left Pilot Control Shut-Off Switch 2 Pin Connector
X22 Floor Harness to Right Pilot Control Shut-Off Jumper 2 Pin Connector
X24 PAT Connector (Not Used)
X25 Floor Harness to Propel Alarm Harness Connector
X26 12V Power Outlet Connector
X29 Floor Harness to Auto Idle Harness 1 Pin Connector (Not Used)
X32 Fuse Block

Floor Harness (W2) Wiring Diagram
Floor Harness (W2) Wiring Diagram

LEGEND:
B10 Glow Plug Timer
E4 Monitor Controller and Display Backlight
F1 Pilot Shut-Off 5 Amp Fuse
F3 Horn 10 Amp Fuse
F4 12V Power Outlet 10 Amp Fuse
F6 Heater and Wiper 15 Amp Fuse
F7 Not Used
F11 Back-Up Power 5 Amp Fuse
F12 Auto Idle 5 Amp Fuse (Not Used)
F13 Radio 5 Amp Fuse (Field Option)
G4 12V Power Outlet
H8 Monitor Controller and Display Alarm
H9 Glow Plug Indicator
H17 Engine Oil Pressure Indicator
H18 Alternator Indicator
K5 Horn Relay
K12 Starter Relay
K29 Glow Plug Relay
S1 Key Switch
S2 Horn Switch
S6 Drive and Boom Work Light Switch
X16 SATE 3 Pin Connector (Not Used)
X21 Floor Harness to Left Pilot Control Shut-Off Switch 2 Pin Connector
X22 Floor Harness to Right Pilot Control Shut-Off Jumper 2 Pin Connector
X24 PAT Connector (Not Used)
X1— See Main Harness (W1) Wiring Diagram . (Group 9015-10)

X4— See Cab Harness (W5) Wiring Diagram . (Group 9015-10)
X17— See Heater Harness (W10) Wiring Diagram . (Group 9015-10)

Engine Harness (W3) Component Location
Engine Harness (W3) Component Location
LEGEND:
B4 Engine Oil Pressure Switch
B9 Coolant Temperature Gauge Sensor

B46 Coolant Overheat Switch

B53 Glow Timer Engine Coolant Sensor
G3 Alternator
M1 Starter
R12 Glow Plug
R13 Glow Plug
R14 Glow Plug
R15 Glow Plug
X7 Engine Harness to Fuel Transfer Pump 2 Pin Connector
X8 Engine Harness to Fuel Shut-Off Solenoid 3 Pin Connector
X9 Engine Harness to Alternator 3 Pin Connector
Y7 Fuel Shut-Off Solenoid
Y14 Fuel Transfer Pump

Engine Harness (W3) Wiring Diagram
Engine Harness (W3) Wiring Diagram
LEGEND:
B46 Coolant Overheat Switch


G3 Alternator
M1 Starter
R12 Glow Plug
R13 Glow Plug
R14 Glow Plug
R15 Glow Plug
X7 Engine Harness to Fuel Transfer Pump 2 Pin Connector
X8 Engine Harness to Fuel Shut-Off Solenoid 3 Pin Connector
X9 Engine Harness to Alternator 3 Pin Connector


Cab Harness (W5) Component Location
Cab Harness (W5) Component Location

LEGEND:
B24 Left Speaker
E3 Cab Dome Light
F19 Radio 5 Amp In-Line Fuse (Field Option)
F27 Radio Backup Inline 1 Amp Fuse (Field Option)
M3 Windshield Wiper Motor
M4 Windshield Washer Motor
S3 Dome Light Switch
S9 Windshield Wiper and Washer Switch
W4 Antenna
X31 Air Conditioner Harness 3 Pin Connector
X34 Radio to Cab Harness Connector
X35 Radio Harness to Right Speaker Connector

Cab Harness (W5) Wiring Diagram
Cab Harness (W5) Wiring Diagram
LEGEND:
B24 Left Speaker
E3 Cab Dome Light
F19 Radio 5 Amp In-Line Fuse (Field Option)

F27 Radio Backup Inline 1 Amp Fuse (Field Option)

M3 Windshield Wiper Motor
M4 Windshield Washer Motor
S3 Dome Light Switch
S9 Windshield Wiper and Washer Switch
X31 Air Conditioner Harness 3 Pin Connector
X35 Radio Harness to Right Speaker Connector

Heater Harness (W10) Wiring Diagram
Heater Harness (W10) Wiring Diagram
LEGEND:
M5 Heater Blower Motor
S4 Heater Blower Motor Switch

X17— See Cab Harness (W5) Wiring Diagram . (Group 9015-10)


LEGEND:
A10 Propel Alarm Controller
B15 Left Propel Pressure Sensor
B16 Right Propel Pressure Sensor
H3 Propel Alarm
S10 Propel Alarm Cancel Switch
W11 Propel Alarm Harness
W12 Propel Alarm Cancel Switch Harness
X33 Propel Alarm Harness to Propel Alarm Cancel Switch Harness Connector

Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12) Wire Diagram
Propel Alarm Harness (W11) Wiring Diagram

Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
H3 Propel Alarm
X33 Propel Alarm Harness to Propel Alarm Cancel Switch Harness Connector

Group 15 - Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation
Starting and Charging Circuit Schematic

LEGEND:
B10 Glow Plug Timer
F22 Alternator 45 Amp Fusible Link
G1 Battery
G3 Alternator
K12 Starter Relay
K29 Glow Plug Relay
M1 Starter
R12 Glow Plug
R13 Glow Plug
R14 Glow Plug
R15 Glow Plug (50C ZTS Only)
S1 Key Switch
W7 Battery To Frame Ground
Starting Circuit Theory of Operation
When the key switch (S1) is turned to the ON position, battery voltage is routed to the fuel transfer pump (Y14), pin 3 of fuel
shut-off solenoid (Y7), glow plug relay (K29), and glow plug timer (B10). The voltage to pin 3 of the fuel shut-off solenoid will
not cause the solenoid to open. This voltage will hold the solenoid open once it is opened by a signal at pin 2. When the glow
plug timer receives the voltage signal, it grounds pins 2 and 5, turning on the glow plug indicator (H9) and activating the glow
plug relay. The length of time that pins 2 and 5 remain grounded depends on the signal that the glow plug timer receives from
the glow timer engine coolant sensor (B53). When the engine is cold, the glow plugs and glow plug indicator will stay on for
approximately five seconds. When the engine is warm, the glow plugs and glow plug indicator will turn on, but will turn back off
after less than a second.
When the key switch is turned to the START position, battery voltage is routed to the same components as in the ON position
as well as to pin 1 of the glow plug timer, pin 2 of the fuel shut-off solenoid, and through the starter relay (K12) to the starter
(M1). The glow plug timer activates the glow plug indicator and the glow plugs any time the key switch is in the start position.
The starter motor rotates and cranks the engine. Once the engine is started, a signal from the L terminal of the alternator (G3)
is sent to the starter protection controller (A8). This causes pin 4 of the starter protection controller to be routed to ground and
activates the starter relay so that the starter motor cannot be activated when the engine is running. The voltage at pin 2 of the
fuel shut-off solenoid causes the solenoid to activate so that fuel can be delivered to the engine. The voltage at pin 3 will hold
the solenoid in the activated position once the key switch is returned to the ON position.
Charging Circuit Theory of Operation
When the engine is running, the alternator provides power to all machine circuits and charges the battery.
When the key switch is ON and the engine is not running, the voltage at terminal L is 0 and current flows from the battery
indicator lamp on the meter panel through terminal L, lighting the alternator voltage indicator light (H18).
When the key switch is ON and the engine is running, the voltage at alternator terminal L is equal to or greater than the battery
voltage. This results in no current flow through the monitor controller and display (A5) and terminal L of alternator (G3),
causing alternator voltage indicator light (H18) to go out.
If the alternator fails while the engine is running, causing the voltage at terminal L to drop below the battery voltage, current
will flow through the alternator voltage indicator light (H18), illuminating the light. The lower the voltage at terminal L, the
greater the current flow through the alternator voltage indicator light (H18), and the brighter the light will illuminate.

Monitor Controller Circuit Theory of Operation
Monitor Controller and Display Circuit Schematic

LEGEND:
B10 Glow Plug Timer
B46 Coolant Overheat Sensor
E2 Drive Light
E4 Monitor Controller and Display Backlight
E12 Boom Work Light
F11 Backup Power 5 Amp Fuse
G1 Battery
H8 Monitor Controller and Display Alarm
H17 Engine Oil Pressure Indicator
H18 Alternator Indicator
S1 Key Switch
S6 Drive and Boom Work Light Switch
W7 Battery to Frame Ground
X30 Floor Harness to Auto-Idle Harness 1 Pin Connector
The monitor controller and display (A5) receives signals from the engine coolant overheat switch (B46), engine oil pressure
switch (B4), fuel level sender (R5), glow plug timer (B10), alternator (G3), and coolant temperature gauge sensor (B9). The
controller takes this information and turns on warning lights, activates alarms, or actuates the gauges. The monitor controller
and display activates the monitor controller and display alarm (H8) when the coolant overheat switch closes, the engine oil
pressure switch opens, or the fuel level gets low.
The monitor controller and display is powered by the monitor controller and display 5 amp fuse (F10) and the back-up power 5
amp fuse (F11). Both fuses must be intact for the monitor controller and display to function, however, the indicator lights will
function without the back-up power 5 amp fuse.
The drive and boom work light switch (S6), when pressed, sends a ground signal to the monitor controller and display which in
turn sends a ground path to the drive and boom work light relay (K3) and to the monitor controller and display backlight (E4),
turning the backlight on. The drive and boom work light relay is then activated, providing power to the drive light (E2), boom
work light (E12), and the radio to cab harness connector (X34).
The glow plug indicator (H9) illuminates when the glow plug timer (B10) provides a ground path to the indicator lamp during
the preheating of the glow plugs (R12, R13, R14, R15).

Pilot Control Shut-Off Circuit Theory of Operation
Pilot Shut-Off Circuit Schematic
LEGEND:
F1 Pilot Control Shut-Off 5 Amp Fuse
G1 Battery

S1 Key Switch
W7 Battery To Frame Ground
X22 Floor Harness to Right Pilot Control Shut-Off Switch 2 Pin Connector
The pilot control shut-off circuit consists of the pilot control shut-off solenoid valve (Y8), and pilot control shut-off switch (S21).
The pilot control shut-off switch is designed to shut off hydraulic pilot pressure to all pilot controllers and the shut-off valve.
This prevents accidental machine movement when operator enters and exits the machine.
When the engine is running and left armrest is down, the pilot control shut-off switch (S21) is enabled (closed). This completes
ground circuit to pilot control shut-off solenoid (Y8), allowing hydraulic pilot pressure to all pilot controllers and the shut-off
valve.
If the pilot control shut-off switch (S10) or the harness fail, the emergency pilot control shut-off 2 pin connector (X36) can be
used to restore temporary power to the pilot control shut-off solenoid (Y8) to return the machine to a safe position. With the
emergency pilot control shut-off 2 pin connector (X36) in place of the main harness to propel speed change connector (X13),
the propel speed switch (S8) provides the ground path to the pilot control shut-off solenoid (Y8). The pilot control shut-off
solenoid (Y8) will only stay activated as long as the propel speed switch (S8) is pressed.

Propel Alarm Circuit Theory of Operation
Propel Alarm Circuit Schematic
LEGEND:

Section 9015 - ELECTRICAL SYSTEM Group 20: References

G1 Battery
H3 Propel Alarm
S1 Key Switch
W7 Battery to Frame Ground
X33 Propel Alarm Harness to Propel Alarm Cancel Switch Harness 3 Pin Connector
The propel alarm circuit consists of a left and right propel pressure sensors (B15 and B16), propel alarm controller (A10), propel
alarm (H3), and a propel alarm cancel switch (S10).
The circuit is designed to warn bystanders of machine movement by signaling with an audible alarm any time the propel levers
are moved.
When the propel levers are moved, propel pressure sensor (B15) left or (B16) right sense pilot pressure and send a signal to
the propel alarm controller (A10). The propel alarm controller then provides ground to the propel alarm (H3), activating the
alarm.
When pressed, the propel alarm cancel switch (S10) applies ground to pin 7 of the propel alarm controller (A10). The propel
alarm cancel switch (S10) must be pressed and released in order to cancel the alarm. The propel alarm controller (A10) is reset
when the control levers are returned to the neutral position. The propel alarm cancel switch (S10) must be pressed and
released again to cancel the alarm.

Group 20 - References
Fuse Test
Some symptoms may indicate an expensive component failure, when in fact a fuse has failed. Machine functions can be
performed without test equipment to determine if fuses have failed. If certain circuits or components operate, fuses are
considered to be OK.
For location of fuses See Fuse Specifications . (Group 9015-10.)
Fuse Test
Fuse Test
Fuse Test Results of Fuse Failure
Start Engine.
F1—Pilot Control Shut-off 5 Amp (Marked PILOT-SHUT OFF) Operate hydraulic function. Pilot functions will not work.
If hydraulics operate, fuse is OK.
Turn key ON.

F2—Drive and Boom Work Light 20 Amp (Marked LIGHT) Turn light switch ON. Drive and boom work lights will not operate.
If drive and boom lights operate, fuse is OK.
Turn key switch ON.

F3—Horn 10 Amp Fuse (Marked HORN TRAVEL MODE) Horn will not operate.
Push horn switch. If horn operates, fuse is OK.
F4—12V Power Outlet 10 Amp (Marked ACC) Check fuse with multimeter. 12V power outlet will not operate.
Turn key switch ON.

Glow plug timer and starter protection
F5—Engine Power 10 Amp (Marked ENG) If glow plug indicator lights for bulb check, fuse is
controller will not operate.
OK.
Turn key switch ON.

Turn heater blower motor ON, or turn windshield
Heater blower motor and windshield wiper will
F6—Heater and Wiper 15 Amp (Marked COOLER WIPER) wiper ON.
not operate.
If heater blower motor or windshield wiper
operates, fuse is OK.
F7—Not Used 20 Amp (Marked COOLER HEATER)
F8—Fuel Pump 5 Amp (Marked PUMP) Check fuse with multimeter. Engine may not operate.
Start engine.
F9—Propel Alarm 5 Amp (Marked PAT. TRAVEL) Operate propel function. Propel alarm will not operate.
If alarm sounds, fuse is OK.
Turn key switch ON.

F10—Monitor Controller and Display 5 Amp (Marked MONITOR) If indicator lights and monitor display are on, fuse Monitor controller and display will not operate.
is OK.
Turn key switch ON.

F11—Back Up Power 5Amp (Marked BACK UP) Monitor display will not operate.
If monitor display is on, fuse is OK.
F12—Not Used 5 Amp (Marked AI)
Turn key switch ON.

F13—Radio (field option) 5 Amp (Marked RADIO) Radio will not operate.
Turn radio ON. If radio operates fuse is OK.
Turn key switch ON.

F19—Radio (Field Option) inline 5 Amp Radio will not operate.
Turn radio ON. If radio operates fuse is OK
F21—Fusible Link 45 Amp If engine starts, fuse is OK Engine will not start.
Glow plugs will not operate and battery will not

F22—Fusible Link 45 Amp Check fuse with multimeter.
charge.
F27—Radio backup (field option) inline 1 Amp Check fuse with multimeter. Radio presets will be lost.
Relay Test
For location of relays see Floor Harness (W2) Component Location Diagram . (Group 9015-10.)

Relay Test
[1] - Connect ohmmeter to terminals 3 and 4.
About 0.0—0.4 ohms must be measured. If not, relay has failed.
Multimeter
To measure resistance on electrical component
[2] - Connect ohmmeter to terminals 3 and 5, then 4 and 5.
Ohmmeter must read open in both connections. If not, relay has failed.
[3] - Connect 12 volts to terminal 1, ground terminal 2.
Connect ohmmeter to terminals 3 and 5.
Ohmmeter must read continuity. If not, relay has failed.

Pressure Sensor Test

Pressure Sensor Resistance Test
Left Propel Pressure Sensor (B15) Resistance 5k—15k ohms (Terminals 1—2)
30k—50k ohms (Terminals 2—3)
Right Propel Pressure Sensor (B16) Resistance 5k—15k ohms (Terminals 1—2)
30k—50k ohms (Terminals 2—3)
[1] - A suspect pressure sensor can be checked by switching positions with a known good sensor. If the problem follows the
suspect pressure sensor, it has failed.
If the problem remains, the harness has failed.
[2] - To check a pressure sensor using a multimeter, remove it from the machine.
[3] - For location of pressure sensors see Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12)
Component Location . (Group 9015-10.)
[4] - Measure resistance as indicated. Resistance may vary from one sensor to another.
Multimeter
Measure resistance on electrical component
Pressure Sensor Voltage Test
Left Propel Pressure Sensor (B15) Voltage 4.5—5.5 volts
Right Propel Pressure Sensor (B16) Voltage 4.5—5.5 volts
[1] - Disconnect harness connector from a pressure sensor.
[2] - With key switch ON, measure voltage between terminals 1 and 3 of pressure sensor harness connector.
Multimeter
To measure voltage
Solenoid Test
Propel Speed Solenoid (Y6) Resistance 10—15 ohms
Pilot Shut-Off Solenoid (Y8) Resistance 10—15 ohms
[1] - A suspect solenoid can be checked by switching positions with a known good solenoid. If the problem follows the suspect
solenoid, it has failed.
If the problem remains, the harness has failed.
[2] - To check a solenoid using an multimeter, remove it from the machine.
[3] - For location of solenoids see Main Harness (W1) Component Location . (Group 9015-10.)
[4] - Measure resistance as indicated. Resistance may vary from one solenoid to another.

Multimeter
Temperature Sensor Test

Temperature Sensor Test

Coolant Temperature Gauge Sensor (B9) Resistance 450—550 Ω at 21 °C (70 °F) approximate
1600—1700 Ω at 0 °C (32 °F) approximate
Glow Timer Engine Coolant Sensor (B53) Resistance 1800—1900 Ω at 21 °C (70 °F) approximate
5200—5400 Ω at 0 °C (32 °F) approximate
[1] - To check a temperature sensor using an multimeter, remove it from the machine.
Multimeter
[2] - Measure resistance as indicated. Resistance may vary from one sensor to another.
[3] - For location of temperature sensors, See Engine Harness (W3) Component Location . (Group 9015-10.)

Electrical Component Checks

The following checks can be used to test electrical components in all machine circuits.
Component Checks
( 1 ) Key Switch Check
Action:
Key Switch in ON Position
Disconnect battery ground cable.
Turn key to ON position.
Is continuity measured between terminals:
Multimeter
To measure continuity
(B) and (ACC)?

(B) and (R2)?
(B) and (BR)?
Result:
YES:Go to next step in this check.
NO:Key switch has failed. Replace key switch.
Action:
Key Switch in START Position

Turn key to START position.
Is continuity measured between terminals:
(B) and (ACC)?

(B) and (R1)?
(B) and (C)?
(B) and (BR)?
Result:
YES:Key switch is OK.
NO:Key switch has failed. Replace key switch.
( 2 ) Starter (M1) Solenoid Check
Action:
Starter Solenoid Check
CAUTION:
Starter will crank engine if metal strap is NOT disconnected from motor.
Disconnect metal strap from solenoid terminal.
Connect battery voltage to solenoid small terminal.
Does solenoid click?
Result:
YES:Solenoid is OK. Check wiring harness. See Engine Harness (W3) Component Location and See Engine Harness (W3) Wiring
Diagram . (Group 9015-10.)
NO:Repair or replace starter solenoid. See Engine Harness (W3) Component Location . (Group 9015-10.)
( 3 ) Starter (M1) Motor Check
Action:

Starter Motor Check
Connect a heavy gauge wire from battery positive cable to starter motor terminal.
Does starter motor turn, but NOT crank engine?
Result:
YES:Starter motor is OK. Check wiring harness. See Engine Harness (W3) Component Location and See Engine Harness (W3)
Wiring Diagram . (Group 9015-10.)
NO:Repair or replace starter. See Engine Harness (W3) Component Location . (Group 9015-10.)
( 4 ) Battery Voltage Check
Action:
Battery Voltage Check
Measure battery voltage by connecting a multimeter to (-) negative battery terminal grounded to frame and (+) positive
battery terminal connected to machine harness.
Multimeter
To read voltage.
Is 12 to 13 volts measured?
Result:
YES:Batteries are OK.
NO:Batteries are undercharged. Charge batteries.

( 5 ) Fusible Link Check
Action:
Fusible Link Check
Press locking tab on side of fusible link and lift from holder.
Connect a multimeter to terminals inside fusible link.
Multimeter
To read continuity.
Does multimeter read continuity?
Result:
YES:Fusible link is OK. Check wiring harness. See Main Harness (W1) Component Location and See Main Harness (W1) Wiring
NO:Fusible link has failed. Replace. See Main Harness (W1) Component Location . (Group 9015-10.)
( 6 ) Alternator Output Check
Action:
Alternator Output Check
Key switch OFF.
With multimeter connected from battery (+) terminal to vehicle ground, measure and record battery voltage. 12 - 13 volts is

normal.
Multimeter
To measure voltage
Start and run engine at slow idle, and check battery voltage.
Does battery voltage increase?
Result:
YES:Alternator is OK.
NO:Repair or replace alternator.
( 7 ) Propel Alarm Check
Action:
Propel Alarm Check
Engine OFF
Disconnect harness from propel alarm.
Apply battery voltage to (RED) wire terminal of propel alarm and ground (BLK) wire terminal.
Does alarm sound?
Result:
YES:Alarm is OK. Harness has failed. Repair. See Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12)
Component Location . (Group 9015-10.)
NO:Alarm has failed. Replace.
( 8 ) Monitor Controller and Display Alarm Check
Action:
Key OFF.
Disconnect harness connector from coolant overheat switch (B46).
Connect a jumper wire between terminals in harness connector.
Key ON.
Does monitor controller and display alarm sound?

Result:
YES:Alarm and harness are OK.
NO:Monitor controller and display or harness has failed. Repair or replace. See Monitor Controller and Display (A5) Remove and
Install . (Group 9015-20.)
( 9 ) Fuel Shut-Off Solenoid Check
Action:
LEGEND:
1 Pin 1
2 Pin 2
3 Pin 3
4 Fuel Shut-Off Solenoid
Fuel Shut-Off Solenoid
Ground pin 1.
Apply 12 V to pin 2. Does solenoid click?
Remove 12 V from pin 2. Does solenoid click?
Result:
YES:Go to next step in this check.
NO:Solenoid has failed. Replace.
Action:
Ground pin 1.
Apply 12 V to pins 2 and 3.
Remove 12 V from pin 2. Does solenoid click?
→NOTE:
Voltage at pin 3 will not activate the solenoid, but will hold the solenoid in the activated position once
the solenoid is activated by voltage at pin 2.
Result:
YES:Solenoid has failed. Replace.
NO:Go to next step.
( 10 ) Windshield Wiper and Washer Switch Check

Action:
LEGEND:
1 Pin 1
2 Pin 2
3 Pin 3
5 Pin 5
6 Pin 6
Windshield Wiper And Washer Switch Connector
Remove windshield wiper and washer switch.
Connect multimeter to pins 5 and 6.
Multimeter
To measure continuity.
Is continuity measured when switch is in the wiper OFF position?
Is continuity measured when switch is in the wiper OFF and washer ON position?
Is continuity measured when switch is in the wiper ON position?
Is continuity measured when switch is in the wiper ON and Washer ON position?
Is continuity measured when switch is in the wiper OFF and washer ON position?
Is continuity measured when switch is in the wiper ON and washer ON position?
Result:
YES:Windshield wiper and washer switch is OK.
NO:Windshield wiper and washer switch has failed. Replace.

Battery Remove and Install

[1] -
CAUTION:
Prevent personal injury from exploding battery. Keep sparks and flames away from battery.
Remove wing screw (1).

LEGEND:
1 Wing Screw
Prevent Battery Explosions
Battery Cover
[2] -

LEGEND:
2 Wing Screw
Battery Tray
Remove wing screw (2).
[3] -
LEGEND:
3 Negative Battery Cable
4 Battery Bracket
5 Hex Nut (2 Used)
6 Washer
7 Positive Battery Cable
Battery Bracket
Remove parts (3—7).
[4] - Remove battery. Replace as needed.
[5] - Check cables and terminals for wear or corrosion. Make sure new battery is fully charged. See Battery Voltage Check .
(Group 9015-20)
[6] - Install battery.

Propel Alarm Cancel Switch Remove and Install

LEGEND:
1 Screw (2 Used)
2 Screw
Bottom Cover Front Screws
Bottom Cover Rear Screws
[1] - Disconnect battery ground (-) cable.

[2] - Remove screws (1) and (2).
[3] - Remove console bottom cover.
[4] -
LEGEND:
3 Propel Alarm Cancel Switch
4 Key Switch
Propel Alarm Cancel Switch
Push propel alarm cancel switch up and out of console.
[5] - Remove propel alarm cancel switch (3).
[6] - Replace switch as necessary.
[7] - Install switch.

Key Switch Remove and Install

LEGEND:
1 Screw (2 Used)
2 Screw
Console Cover Front Screws
Console Cover Rear Screws
[1] - Disconnect battery ground (-) cable.

[2] - Remove screws (1) and (2).
[3] - Remove key switch cover (3).

LEGEND:
3 Key Switch Cover
Key Switch Cover
[4] - Remove key switch.
[5] - Replace key switch as necessary.
[6] - Install key switch.

Monitor Controller and Display (A5) Remove and Install

[1] -
LEGEND:
1 Screw (2 Used)
2 Screw (2 Used)
Bottom Cover Front Screws
Console Cover Rear Screws
Remove screws (1) and (2).

[2] - Remove console bottom cover.
[3] - Remove screws (3) and plates (4).

LEGEND:
3 Screw (4 Used)
4 Plate (2 Used)
Pilot Controller Screws and Plates
[4] - Remove cap screws (5) and arm rest.

LEGEND:
5 Cap Screw (2 Used)
Arm Rest
[5] - Disconnect harness from monitor controller display from back side of monitor.
[6] -
LEGEND:
6 Screw (4 Used)
Monitor Controller And Display
Remove screws (6).
[7] - Remove monitor controller and display.

[8] - Repair or replace as necessary.
[9] - Install monitor controller and display.

Glow Plug Timer Remove and Install

[1] -
LEGEND:
2 Toolbox And Operator Manual Compartment Door
3 Screw (3 Used) (Cab Only)
4 Bracket (Cab Only)
5 Floor Mat
Floor Mat And Toolbox Compartment—Cab
[2] -
LEGEND:
7 Cover
Outer Relay Cover
Remove cap screws (6) and cover (7).
[3] -
LEGEND:
10 Plate
Relay Plate
Remove parts (8—10)

[4] -
LEGEND:
11 Screw (2 Used)
12 Glow Plug Timer (B10)
13 Drive and Boom Work Light Relay (K3)
14 Horn Relay (K5)
15 Starter Protection Controller (A8)
16 Starter Relay (K12)
17 Glow Plug Relay (K29)
Relay Panel
Remove screws (11).
[5] - Remove glow plug timer.
[6] - Replace glow plug timer as necessary.
[7] - Install glow plug timer.

Propel Alarm Controller Remove and Install

[1] -
LEGEND:
2 Toolbox And Operator Manual Compartment Door
3 Screw (3 Used) (Cab Only)
4 Bracket (Cab Only)
5 Floor Mat
Floor Mat And Toolbox Compartment—Cab
[2] -
LEGEND:
7 Floor Panel
Floor Panel
Remove screws (6) and panel (7).
[3] -

LEGEND:
8 Screw (3 Used)
9 Propel Alarm Controller (A10)
10 Cab Floor
Propel Alarm Controller
Remove screws (8).
[4] - Remove propel alarm controller (9).
[5] - Replace as necessary.
[6] - Install propel alarm controller.
Disconnect Tab Retainer Connectors
IMPORTANT:
Do not disconnect electrical connectors while the engine is running. Damage to controllers or other
components may result. Disconnect connectors only when instructed during a test or check.
DO NOT pull on wires to disconnect connector or damage to wires or connector may result. Grasp both
halves of the connector to pull connector apart.
[1] -

LEGEND:
A Retainer Tab
Retainer Tab
Push retainer tab (A).
[2] - While holding tab in, grasp other half of connector and pull connector halves apart.
[3] - To connect, push connector halves together until retainer “clicks”.
Disconnect Spring Wire Clip Connectors
Spring Wire Clip Connectors
[1] - Remove wire clip from connector.
Grasp connector; move connector halves from side-to-side as they′re being pulled apart. Do not pull on wiring leads.
[2] - To reconnect, install wire clip on connector half, push connector halves together until wire retainer “clicks” over tabs.

Replace DEUTSCH ™ Connectors

[1] - Select correct size extractor tool for size of wire to be removed:
DEUTSCH ™ Electrical Repair Tool Kit
JDG359
To repair DEUTSCH ™ electrical connector bodies.
Crimper
JDG360
To adjust selector for correct wire size.
Extractor Tool (Set of Two)
JDG361
To remove 12 to 14 gauge wire.
JDG362
JDG363
To remove 20 gauge wire.
JDG361 Extractor Tool

[ Included in JDG359 DEUTSCH Electrical Repair Kit. ]
for 12 to 14 gauge wire.
for 16 to 18 gauge wire.
for 20 gauge wire.
[2] -
LEGEND:
A Extractor Tool Handle
Extractor Tool

Slide Extractor Tool
Start correct size extractor tool over wire at handle (A).
[3] - Slide extractor tool rearward along wire until tool tip snaps onto wire.
[4] -
IMPORTANT:
Do NOT twist tool when inserting in connector.
Slide extractor tool along wire into connector body until it is positioned over terminal contact.
[5] - Pull wire out of connector body, using extractor tool.
[6] -
IMPORTANT:
Install contact in proper location using correct size grommet.
Push Contact
Push contact straight into connector body until positive stop is felt.
[7] - Pull on wire slightly to be certain contact is locked in place.
[8] - Transfer remaining wires to correct terminal in new connector.

Install DEUTSCH ™ Contacts

LEGEND:
A Crimper Selector
B Lock Nut
C Adjusting Screw
JDG360 Crimper
[1] - Strip 6 mm (1/4 in.) insulation from wire.
[2] - Adjust selector (A) on JDG360 Crimper
[ Included in JDG359 Deutsch Electrical Repair Kit. ]

for correct wire size.
DEUTSCH ™ Electrical Repair Tool Kit
JDG359
To repair DEUTSCH ™ electrical connector bodies.
Crimper
JDG360
To adjust selector for correct wire size.
JDG361
JDG362
JDG363
To remove 20 gauge wire.
[3] - Loosen lock nut (B) and turn adjusting screw (C) in until it stops.
[4] -
IMPORTANT:
Select proper size contact “sleeve” or “pin” to fit connector body.

LEGEND:
A Contact
B Cover
C Lock Nut
D Adjusting Screw
Adjusting Screw
Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B).
[5] - Tighten lock nut (C).
[6] -
IMPORTANT:
Contact must remain centered between indentors while crimping.
Crimp
Insert wire in contact and crimp until handle touches stop.
[7] - Release handle and remove contact.
[8] -
IMPORTANT:
If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation
procedures.
→NOTE:
Readjust crimping tool for each crimping procedure.

Inspect Contact
Inspect contact to be certain all wires are in crimped barrel.

Replace WEATHER PACK ™ Connector
Terminal Contact
IMPORTANT:
Identify wire color locations with connector terminal letters.
[1] - Open connector body.
[2] - Insert JDG364 Extraction Tool
[ Included in JT07195A Electrical Repair Kit. ]

over terminal contact in connector body.
WEATHER PACK ™ Extraction Tool
JDG364
Used to replace terminal contact in WEATHER PACK ™ connector body.
[3] - Hold extractor tool fully seated and pull wire from connector body.
→NOTE:
If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal
contact from connector.
[4] -
IMPORTANT:
Connector Body
Carefully spread contact lances to assure good seating on connector body.
→NOTE:
Connector bodies are “keyed” for proper contact mating. Be sure contacts are in proper alignment.

Push contact into new connector body until fully seated.
[5] - Pull on wire slightly to be certain contact is locked in place.
[6] - Transfer remaining wires to correct terminal in new connector.
[7] - Close connector body.

Install WEATHER PACK ™ Contacts
Correct Size Cable
Strip Insulation
→NOTE:
Cable seals are color coded for three sizes of wire:
Green - 18 to 20 gauge wire

Gray - 14 to 16 gauge wire
Blue - 10 to 12 gauge wire
[1] - Slip correct size cable seal on wire.
[2] - Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.
[3] -
→NOTE:
Contacts have numbered identification for two sizes of wire:
#15 for 14 to 16 gauge wire

#19 for 18 to 20 gauge wire
Put proper size contact on wire and crimp in place with a “W” type crimp, using JDG783 Crimping Tool.
WEATHER PACK ™ Crimping Tool
JDG783
Use to crimp WEATHER PACK ™ terminals.
[4] -

POWER TRAIN (g) by Belgreen v2.0
IMPORTANT:
Contact Installation
LEGEND:
A Sleeve
B Pin
Proper contact installation for “sleeve” (A) and “pin” (B) is shown.
Secure cable seal to contact as shown, using JDG783 Crimping Tool.
WEATHER PACK ™ Crimping Tool
JDG783
Use to crimp WEATHER PACK ™ terminals.
Remove Connector Body from Blade Terminals

LEGEND:
A Locking Tang (Depressed Position)
B Locking Tang (Original Position)
Blade Terminals
[1] - Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off.
[2] - Be sure to bend locking tang back to its original position (B) before installing connector body.

Section 9020 - POWER TRAIN

Table of contents
Track Adjuster and Recoil Spring Operation ......................................................................................... 1
Propel Gearbox Operation .................................................................................................................... 2
Diagnose Undercarriage Components Malfunctions ............................................................................. 4
Measure Swing Bearing Wear ............................................................................................................... 5

Section 9020 - POWER TRAIN Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation
Track Adjuster and Recoil Spring
LEGEND:
1 Track Frame
2 Fitting
3 Nut
4 Spring
5 Seal
6 Piston
7 Idler
8 Yoke
9 Cylinder Barrel
10 Grease
11 Adapter
12 Track Adjuster
The track adjuster (12) is supported by the track frame (1). Shock loads on the track and front idler (7) are absorbed by the
recoil spring (4).
To tighten the track, pump grease (10) into fitting (2) to force the piston (6) out. As it presses against the yoke (8), the track
becomes tighter. Loosen adapter (11), NOT the fitting (2) to release grease to loosen track. Grease will escape through a small
passage that is concealed by nut (3).

Section 9020 - POWER TRAIN Group 05: Theory of Operation
Propel Gearbox Operation
Propel Gearbox
LEGEND:
1 Propel Motor
2 Ball Bearing
3 Sprocket
4 Second Planet Sun Gear
5 First Planet Carrier
6 First Planet Sun Gear
7 Thrust Plug
8 Cover
9 First Planet Gear
10 Ring Gear
11 Second Planet Carrier
12 Second Planet Gear
13 Input Shaft

Section 9020 - POWER TRAIN Group 15: Diagnostic Information
14 Drum
15 Metal Face Seal
The propel gearbox is a double reduction planetary drive. The gearboxes are interchangeable from the right to the left side of
machine. The propel motor (1) is connected to and turns the gearbox input shaft (13) through a spline connection. The function
of the propel gearbox is to convert fast rotary speed and low torque from the propel motor to a slow rotary speed and high
torque to rotate the sprocket (3).
Rotary motion is transferred from the input shaft (13) to the sprocket (3) by the two planetary gear sets that mesh with the
ring gear (10). As the input shaft turns, it turns the first planet gears (9) against the ring gear causing the first planet carrier (5)
to rotate. The first planet carrier turns the second planet sun gear (4) through a spline connection. The second planet sun gear
is in mesh with and turns the second planet gears (12) in the second planet carrier (11). The second planet carrier is fixed to
the propel motor housing and does not rotate so the rotation of the second planet gears is transferred to and turns the ring
gear. The ring gear (10), drum (14) and sprocket (3) all turn as a unit driving the track chain to move the machine.
A replaceable thrust plug (7) is used in the cover (8) to keep the floating input shaft in position.


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.

Noisy or Loose Track Perform Check Track Sag—Rubber Track . (Operator′s Manual.)
Incorrect track tension adjustment
Chain Perform Check Track Sag—Steel Track . (Operator′s Manual.)
Track shoe loose Perform Steel Track Repair . (Group 0130.)
Grease leaking from track adjuster Perform Track Adjuster Cylinder Disassemble and Assemble . (Group
seals, grease fitting, or valve 0130.)
Material filling sprocket teeth can cause sprocket tooth to bushing

Tight Track Chain Material packing in sprocket impact. Perform Check Track Sag—Rubber Track . (Operator′s Manual.)
Perform Check Track Sag—Steel Track . (Operator′s Manual.)
Perform Check Track Sag—Rubber Track . (Operator′s Manual.)

Track sag less than specification
Frequent Track Sag Grease leaking from track adjuster Perform Track Adjuster Cylinder Disassemble and Assemble . (Group
Adjustment Required seals, grease fitting, or valve 0130.)
Excessive Oil Leakage

Perform Front Idler Repair . (Group 0130.)
From Front Idlers, Loose plug, worn or damaged O-
Perform Track Roller Repair . (Group 0130.)
Track, And Carrier ring or metal faced seal
Perform Track Carrier Roller Remove and Install . (Group 0130.)
Rollers
Measure grouser height. See SP326 Undercarriage Appraisal Manual .

Bent Track Shoes Excessive grouser wear
Perform Steel Track Repair to replace track shoes. (Group 0130.)
Loose track shoes Perform Steel Track Repair . (Group 0130.)
Excessive high speed operation on

Slow propel speed on rough and rocky terrain.
rough and rocky terrain
High propel loads in reverse can cause the recoil spring to retract
"Popping" Of Track High propel loads in reverse
allowing sprocket to slip in chain.
Material filling sprocket teeth can cause sprocket tooth to bushing

Material packed in sprocket impact. Perform Check Track Sag—Rubber Track . (Operator′s Manual.)
Excessive high speed operation on

Cracked Track Link Slow propel speed on rough and rocky terrain.
rough and rocky terrain
Track shoes too wide for ground Use the narrowest shoes possible for required flotation. See SP326
conditions Undercarriage Appraisal Manual .
Repeated high impacts with roller

tread on flanges caused by a loose Perform Check Track Sag—Rubber Track . (Operator′s Manual.)
Chipped Link Rails
or “snaky” track, or using shoes Perform Check Track Sag—Steel Track . (Operator′s Manual.)
that are too wide
Check track pitch. See SP326 Undercarriage Appraisal Manual .
Use the narrowest shoes possible for required flotation. See SP326
Undercarriage Appraisal Manual .
Individual
Measure components to determine if they can be rebuilt using weld.
Undercarriage Some wear is normal
See SP326 Undercarriage Appraisal Manual .
Component Wear

Measure Swing Bearing Wear
Dial Indicator Location

Machine Position For Measurement
Specifications
SPECIFICATIONS
Swing Bearing
Outer Race to Inner Race Play 0.3 mm (0.012 in.) or less new
D17526CI Dial Indicator
D17525CI Magnetic Base with Adjustable Arm
CAUTION:
Stay clear of moving parts. Position dial indicator so it can be seen while operator can see you.
[1] -
→NOTE:
Two people are needed to do the measurement. One to operate the machine and one to take the
readings.

HYDRAULIC SYSTEM (g) by Belgreen v2.0
Check that swing bearing to upperstructure and undercarriage cap screws are tight. See Swing Bearing Remove and Install .
(Group 4350.)
Check that bearing is lubricated with the specified grease. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing
Bearing Gear Grease . (Operator′s Manual.)
Check that bearing rotation is smooth and without noise.
[2] - Install the dial indicator with needle point contacting bottom face of swing bearing outer race.
Dial Indicator
D17526CI
To measure swing bearing play.
Magnetic Base with Adjustable Arm
D17525CI
To hold the dial indicator.
[3] - Move boom and arm to position shown with bucket off the ground.
[4] - Turn dial indicator to zero.
[5] - Lower boom to raise front idlers off the ground approximately 500 mm (20 in.)
[6] - Record dial indicator reading.
If reading is more than maximum allowable, check for steel ball and spacer wear. See Swing Bearing Remove and Install .
(Group 4350.)
Swing Bearing
Outer Race to Inner Race Play 0.3 mm (0.012 in.) or less new

Section 9025 - HYDRAULIC SYSTEM

Table of contents
Hydraulic System Diagram ................................................................................................................... 1
Pilot System Diagram ........................................................................................................................... 3
Pilot Pump Operation ............................................................................................................................ 5
Pilot Filter Operation ............................................................................................................................. 6
Solenoid Valve Manifold Operation ....................................................................................................... 7
Pilot Flow Rate Sensing Manifold Operation ....................................................................................... 10
Pilot Controller Operation ................................................................................................................... 13
Propel Pilot Controller Operation ........................................................................................................ 15
Blade, Boom Swing, and Auxiliary Pilot Controller Operation ............................................................. 17
Hydraulic Pump Operation .................................................................................................................. 18
Hydraulic Pump Regulator Operation ................................................................................................. 19
Control Valve Operation ..................................................................................................................... 21
System Relief Valve Operation ........................................................................................................... 25
Variable Relief Valve Operation .......................................................................................................... 26
Boom Swing Anti-Cavitation Valve Operation ..................................................................................... 26
Circuit Relief Valve Operation ............................................................................................................. 28
Shut-Off Valve Operation .................................................................................................................... 29
Unload Valve Operation ...................................................................................................................... 30
Control Valve Differential Reducing Valve Operation ......................................................................... 32
Pressure Compensator Operation ....................................................................................................... 33
Boom Reduced Leakage Valve Operation ........................................................................................... 35
Swing Gearbox Operation ................................................................................................................... 38
Swing Motor Operation ....................................................................................................................... 40
Swing Motor Crossover Relief Valve Operation ................................................................................... 42
Swing Motor Make-Up Check Valve Operation .................................................................................... 44
Swing Motor Park Brake Release Circuit Operation ............................................................................ 45
Rotary Manifold Operation .................................................................................................................. 47
Propel Motor and Brake Valve Housing Operation .............................................................................. 49
Propel Motor Speed Circuit Operation ................................................................................................ 54
Blade Circuit Operation ...................................................................................................................... 56
One Way/Two Way Valve Operation ................................................................................................... 57
Hydraulic Cylinder Operation .............................................................................................................. 59
Hydraulic Oil Return Filter Operation .................................................................................................. 60
Hydraulic System Circuit Symbols ...................................................................................................... 61
Hydraulic System Schematics ............................................................................................................ 62
Group 15 - Diagnostic Information ...................................................................................................... 72
Diagnostic Procedure .......................................................................................................................... 72
Diagnose Hydraulic System Malfunctions ........................................................................................... 73
Diagnose Pilot Circuit Malfunctions .................................................................................................... 74
Diagnose Dig Circuit Malfunctions ...................................................................................................... 75
Diagnose Swing Circuit Malfunctions .................................................................................................. 76
Diagnose Propel System Malfunctions ................................................................................................ 77
Pilot Controller to Pattern Conversion Valve Line Connection ............................................................ 79
Blade Hydraulic System Component Location .................................................................................... 81
Propel Hydraulic System Line Identification ....................................................................................... 83
Main Hydraulic System Component Location ..................................................................................... 85
Group 25 - Tests ..................................................................................................................................... 87
JT05800 Digital Thermometer Installation .......................................................................................... 87
JT02156A Digital Pressure/Temperature Analyzer Installation ............................................................ 88

Hydraulic System Warm-Up Procedure ............................................................................................... 90

Cylinder Drift Test—Boom, Arm, Bucket, and Blade ........................................................................... 92
Pilot Pressure Regulating Valve Test and Adjustment ........................................................................ 94
Control Valve Spool Pilot Actuation Pressure Test .............................................................................. 97
System Relief Valve Test and Adjustment ........................................................................................ 100
Variable Relief Valve Test and Adjustment ....................................................................................... 103
Variable Metering Valve Test and Adjustment .................................................................................. 106
Differential Reducing Valve Test and Adjustment ............................................................................ 109
Unload Valve Test and Adjustment ................................................................................................... 112
Control Valve Differential Reducing Valve ........................................................................................ 115
Circuit Relief Valve Test and Adjustment ......................................................................................... 118
Swing Motor Crossover Relief Valve Test and Adjustment ............................................................... 122
Propel Motor Crossover Relief Valve Test and Adjustment ............................................................... 126
Hydraulic Pump Regulator Test and Adjustment (Engine Pulldown) ................................................. 129
Hydraulic Pump Flow Test ................................................................................................................ 131
Swing Motor Leakage Test ................................................................................................................ 134
Propel Motor Leakage Test ............................................................................................................... 136

Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Hydraulic System Diagram
Hydraulic System Diagram
LEGEND:
1 Hydraulic Pump

17 Oil Cooler
18 Oil Cooler Bypass Valve
19 Hydraulic Oil Tank
20 Return Filter and Bypass Valve
27 Variable Relief Valve
28 System Relief Valve
29 Unload Valve
30 Control Valve Differential Reducing Valve
34 Shut-Off Valve
36 Swing Valve Spool
38 Pressure Compensator (Swing)
42 Boom Valve Spool
44 Pressure Compensator (Boom)
50 Arm Valve Spool
52 Pressure Compensator (Arm)
57 Bucket Valve Spool
59 Pressure Compensator (Bucket)
62 Boom Swing Valve Spool
64 Pressure Compensator (Boom Swing)
66 Auxiliary Valve Spool
68 Pressure Compensator (Auxiliary)
70 Right Propel Valve Spool
72 Pressure Compensator (Right Propel)
76 Left Propel Valve Spool
77 Pressure Compensator (Left Propel)
80 Blade Valve Spool
82 Pressure Compensator (Blade)
87 Swing Motor and Gearbox
89 Boom Cylinder
90 Arm Cylinder
91 Blade Cylinder
92 Left Propel Motor
100 Right Propel Motor
101 Rotary Manifold
102 Bucket Cylinder
103 Boom Swing Cylinder
A Supply Oil
B Return or Pressure Free Oil
The main hydraulic system is a closed-center hydraulic system.
The hydraulic pump housing contains two pumps; hydraulic pump (1) and a pilot pump. The hydraulic pump is fastened to the
engine flywheel housing and driven at engine speed through a flex coupling. The hydraulic pump is a swashplate type variable
displacement axial piston pump that supplies high pressure to the control valve. Hydraulic oil flows from the hydraulic oil tank
(19) through a suction screen to the hydraulic pump. The hydraulic oil tank is pressurized to create a head of oil to ensure oil
flows from the tank, through the suction line, and into the pumps.
Being a closed-center system, when the pilot control shut-off lever is in the locked (armrest up) position, shut-off valve (34)
routes supply pressure to hold pressure compensators (38, 44, 52, 59, 64, 68, 72, 77, and 82) closed blocking supply oil flow.
When the pilot control shut-off lever is in the unlocked (armrest down) and all valves are in the neutral position, supply oil flow
is blocked by the valve spools (36, 42, 50, 57, 62, 66, 70, 76, 77, and 80). Supply oil pressure builds and is relieved through the
unload valve (29) and returned to the hydraulic oil tank. Oil cooler bypass valve (18) opens to route return oil around oil cooler
(17) and directly into the hydraulic oil tank when resistance is high because the oil is cold (high viscosity), there is a surge of
return oil, or the oil cooler becomes plugged.
Functions are actuated when supply oil is routed to motors (87, 92, and 100) and cylinders (89, 90, 91, 102, and 103) by the
shifting of control valve spools by pilot controller regulated pilot pressure.

Pilot System Diagram
Pilot System Diagram
LEGEND:
1 Hydraulic Pump
2 Pilot Pump
3 Pump Delivery Flow Rate Valve

7 Pilot Filter
8 Pilot Filter and Bypass Valve
9 Pilot Flow Rate Sensing Manifold
10 Differential Reducing Valve
11 Variable Metering Valve
14 Pilot Pressure Regulating Valve
15 Pilot Controller Shut-Off Solenoid Valve
16 Propel Speed Solenoid Valve
21 Left Pilot Controller
22 Right Pilot Controller
23 Propel Pilot Controller
24 Boom Swing Pilot Controller
25 Blade Pilot Controller
29 Unload Valve
34 Shut-Off Valve
42 Boom Valve Spool
50 Arm Valve Spool
86 Swing Park Brake
95 Propel Speed Change Valve
104 Auxiliary Pilot Controller
A Swing Left
B Swing Right
C Arm Out
D Arm In
E Boom Up
F Boom Down
G Bucket Dump
H Bucket Curl
I Left Propel Forward
J Left Propel Reverse
K Right Propel Reverse
L Right Propel Forward
M Boom Swing Right
N Boom Swing Left
O Blade Lower
P Blade Raise
Q Auxiliary Function
R Auxiliary Function
S Pilot Oil Pressure PLS
T Pilot Oil Pressure PGR
U Pilot Oil
V Return or Pressure Free Oil
The pilot system operates the control circuits with regulated pilot oil pressure for each of the following circuits:
Control Valve Operation: The control valve consists of nine individual function control valves (36, 42, 50, 57, 62, 66, 70, 75,
and 80). Pilot pressure shifts control valve spools allowing work port pressure to actuate selected functions. Pilot controllers
(21, 22, 23, 24, 25, and 104) supply regulated pilot oil (U) to the control valve pilot caps which in turn controls the valve spool
operation. See Control Valve Operation for more information. (Group 9025-05.)
Pump Flow Rate Control: Pilot oil pressures control the hydraulic pump (1) swash angle. This circuit consists of the pilot flow
rate sensing manifold (9) and the control valve differential reducing valve (30). Pilot oil pressure PGR (T) from the pilot flow
rate sensing manifold and pilot oil pressure PLS (S) from the control valve differential reducing valve are supplied to both spool

ends of the pump delivery flow rate valve (3) respectively. The pump delivery flow rate valve controls the hydraulic pump
swash angle in response to the pressure difference between PGR and PLS pressures.
The following will provide more information on hydraulic pump flow rate control:
See Hydraulic Pump Operation . (Group 9025-05.)

See Hydraulic Pump Regulator Operation . (Group 9025-05.)
See Pilot Flow Rate Sensing Manifold Operation . (Group 9025-05.)
See Control Valve Differential Reducing Valve Operation . (Group 9025-05.)
Propel Speed Change Circuit: Pilot oil pressure is used to control propel fast and slow speed modes. This circuit consists of
the propel speed solenoid valve (16) and the propel speed change valve (95). When the fast speed pedal is pressed, the propel
speed change switch is on. This energizes the propel speed solenoid valve (16) which sends pilot oil to shift the propel speed
change valve (95) in the propel motors (92 and 100).
The following will provide more information on the propel speed change circuit:
See Solenoid Valve Manifold Operation . (Group 9025-05.)

See Propel Motor and Brake Valve Housing Operation . (Group 9025-05.)
See Propel Motor Speed Circuit Operation . (Group 9025-05.)
Swing Park Brake Release Circuit: Pilot oil pressure is used to release the swing park brake (86). This circuit consists of the
pilot shut-off switch and the pilot control shut-off solenoid valve (15). When the pilot control shut-off lever is in the unlocked
position (armrest down), the pilot shut-off switch is on. This energizes the pilot control shut-off solenoid valve supply pilot oil to
release the swing park brake (86).
The following will provide more information on the swing park brake release circuit:
See Solenoid Valve Manifold Operation . (Group 9025-05.)

See Swing Motor Park Brake Release Circuit Operation . (Group 9025-05.)
Pilot Pump Operation

LEGEND:
1 Pilot Pump
2 Hydraulic Pump
Pilot Pump

Pilot Pump Operation
The purpose of the pilot pump is to supply pilot pressure for the operation of the control valves. This pressure is directed to the
control valves through the operation of the pilot controllers.
The pilot pump is a gear pump. A drive gear is mounted on the shaft engaging the driven gear.
When the drive gear rotates, the driven gear also rotates. Hydraulic oil from the suction port fills the spaces between the gears,
then flows along the inner surfaces of the housing and discharges through the delivery port.
Pilot Filter Operation

Pilot filter bypass valve senses pressure difference between inlet side and outlet side of filter element. During normal
operation, bypass valve is held closed by spring and oil flows through filter element to pilot pressure regulating valve. If filter
element becomes plugged, pressure on inlet side increases forcing bypass valve open. Pilot oil now bypasses filter element and
unfiltered oil flows to pilot pressure regulating valve spool.

Solenoid Valve Manifold Operation

LEGEND:
9 Pilot Control Shut-Off Solenoid Valve
A From Pilot Pump
B To Pilot Controllers and Swing Park Brake
C To Hydraulic Oil Tank
D To Propel Motors (Propel Speed Change Valves)
Solenoid Valve Manifold
The solenoid valve manifold contains the propel speed solenoid valve (8), pilot control shut-off solenoid valve (9), and pilot
pressure regulating valve (7). This assembly is mounted on a bracket located at the right side of the machine, under the
hydraulic oil tank access cover.
Pilot Control Shut-Off Solenoid Valve

LEGEND:
1 Pilot Control Shut-Off Lever
2 Pilot Shut-Off Switch
3 Armrest
4 Pilot Controller
Pilot Control Shut-Off Lever and Pilot Shut-Off Switch.
The pilot control shut-off solenoid valve is switched ON/OFF by the position of the pilot control shut-off lever (1).
When the pilot control shut-off lever is in the LOCK position (armrest up), the pilot shut-off switch (2) is OFF. By this action, the
pilot control shut-off solenoid valve is de-energized so that pilot pressure is blocked by the solenoid valve spool; pressure oil is
not delivered to the pilot controllers.

When the pilot control shut-off lever is in the UNLOCK position (armrest down), the pilot shut-off switch is ON. By this action,
the pilot control shut-off solenoid valve is energized so pilot pressure is supplied to the pilot controllers and the swing motor
park brake through the solenoid valve spool.
Propel Speed Solenoid Valve

LEGEND:
1 Propel Speed Switch
Propel Speed Switch
The propel speed is controlled by the propel speed switch (1) that is actuated by a pedal.
When the foot pedal is in the slow speed position (not being pressed), the propel speed switch is OFF. By this action, the propel
speed solenoid valve is de-energized so that pilot pressure is blocked by the solenoid valve spool; pilot oil is not being applied
to the propel speed change valves in the propel motors.
When the foot pedal is pressed, the propel speed switch is ON. By this action, the propel speed solenoid valve is energized so
that pilot pressure is delivered through the solenoid valve spool to the propel speed change valves in the propel motors .
Pilot Pressure Regulating Valve

LEGEND:
A From Pilot Pump
B Poppet
C Spring
D To Hydraulic Oil Tank
Pilot Pressure Regulating Valve
The pilot pressure regulating valve prevents pressure in the circuit from exceeding a preset pressure. When the pressure in the
pilot circuit increases to the pressure setting of spring (C), the poppet (B) moves to relieve hydraulic oil pressure through the

poppet hole. The oil then passes into the return passage of the solenoid valve manifold back to the hydraulic oil tank.

Pilot Flow Rate Sensing Manifold Operation
Pilot Flow Rate Sensing Manifold
LEGEND:
12 Variable Metering Orifice
A PPLO Port (Reduced Pilot Pressure)
B PPHI Port (Pilot Pressure)
C DR Port (To Hydraulic Oil Tank)
D PGR Port (Pump Flow Rate Signal Pressure)
The pilot flow rate sensing manifold (9) senses pilot pump delivery flow rate and produces a signal pressure PGR to control the
hydraulic pump flow rate. The pilot pump is a fixed displacement pump so that the delivery flow rate changes directly in
proportion to engine speed.
The pilot flow rate sensing manifold is located in the pilot circuit between the pilot pump and the solenoid valve manifold. In
response to change in engine speed, pressure signal PGR is routed from PGR port (D) to the hydraulic pump delivery flow rate
valve to regulate the pump swash plate angle. The pilot flow rate sensing manifold consists of the differential reducing valve
(10), variable metering valve (11), and variable metering orifice (12).

LEGEND:
2 Pilot Pump
A PPLO Port (Reduced Pilot Pressure)
B PPHI Port (Pilot Pressure)
C DR Port (To Hydraulic Oil Tank)
D PGR Port (Pump Flow Rate Signal Pressure)
E Spring
F Variable Metering Valve Spool
G Spring
H Differential Reducing Valve Spool
I Piston
J Spring
K Notch A
L Notch B
M Area S3 (PGR Pressure Acting on Spool)
N Area S2 (Reduced Pilot Pressure Acting on Spool)

O Area S1 (Pilot Pressure Acting on Piston)

P Pilot Oil
Q Reduced Pilot Oil
R PGR Signal Pressure
S Return or Pressure Free Oil
Actuating machine functions cause engine speed to constantly change due to the varying loads on the hydraulic pump. The
pilot pump is a fixed displacement pump so changes in engine speed directly effect the pilot pump delivery rate. Pilot oil (P) is
routed to the PPHI port (B), variable metering orifice (12), variable metering valve spool (F), and piston (I). The differential
pressure across the variable metering orifice changes due to the pilot pump delivery rate changes. Variable metering valve
spool (F) and differential reducing valve spool (H) shift so that the pressure force balances as follows: (Pressure PGR x Area S3
+ Pressure PPLO x Area S2 = Pressure PPHI x Area S1). Thereby, pressure PGR becomes equal to the differential pressure
across the variable metering orifice: (Pressure PPHI - Pressure PPLO).
The differential pressure between PPHI port (B) and PPLO port (A) determines which way the differential reducing valve spool is
shifted. The differential reducing valve (10) regulates pressure PGR at PGR port (D).
When (Pressure PGR x Area S3 + Pressure PPLO x Area S2) is greater than (Pressure PPHI x Area S1) the differential
reducing valve spool (H) shifts to the right; pressure PGR is connected to return at notch B (L), reducing pressure PGR
When (Pressure PGR x Area S3 + Pressure PPLO x Area S2) is less than (Pressure PPHI x Area S1) piston (I) and differential
reducing valve spool (H) shifts to the left so that PPLO port (A) is opened at notch A (K), increasing pressure PGR.
When pressure PPHI force increases more then the spring force of spring (E), the variable metering valve spool (F) is shifted to
the left. When the spool is shifted to the left, pressure PPHI is routed through notch A (K) of the differential reducing valve (10)
so that the differential pressure between PPHI port (B) and PPLO port (A) doesn′t increase more then specified value.

Pilot Controller Operation
Metering and Full Stroke
LEGEND:
1 Control Lever
2 Plunger
3 Spring Guide
4 Balance Spring
5 Return Spring
6 Orifice
7 Spool
8 Hole
9 Housing
10 Work Port 1, 2, 3, or 4 To Control Valve Pilot Caps
11 Port P From Pilot Control Shut-Off Solenoid Valve
12 Port T To Hydraulic Oil Tank
13 Deadband Area
14 Initial Movement
15 Pilot Oil
16 Return Oil
The pilot controllers regulate the pilot oil (15) pressure to shift the control valve spools to actuate the dig functions. See Control
Valve Operation for control valve operation. (Group 9025-05.)
Each controller contains four valves. The ports (10, 11, and 12) in housing (9) are identified by numbers and letters next to
each port. The valves are pressure reducing valves controlled by the movement of the control lever (1) and plunger (2).
Moving the control lever to actuate a function pushes the plunger and spring guide (3) against the balance spring (4) which
moves the spool (7) down. During the initial movement (14) there is a deadband area (13) where the return oil (16) flow
through the holes (8) to port T is blocked before pilot oil can flow from port P through the spool to the work port and out to the
control valve pilot caps (10). Pilot oil pressure also flows through the orifice (6) to the top of the spool to dampen the upward
movement of spool. Pilot oil pressure increases until the pressure is equal to the force of the balance spring. The balance
spring pushes the spool up until the oil flow through the holes is blocked in the deadband area. With the oil flow blocked, the

control valve spool is held stationary until the control lever is again actuated.
When the control lever is actuated to full stroke, the plunger contacts the spool pushing it down until the plunger contacts a
shoulder in the housing. Oil pressure to the control valve pilot caps is now approximately equal to pilot system pressure.
When the control lever is returned to neutral, the spool is pulled up by the return spring (5) and pushes the plunger up. The
return springs hold the control lever in the center position. With the spool up, the passage to the control valve pilot cap is open
to port T and pilot oil from port P is blocked.

Propel Pilot Controller Operation
Propel Pilot Controller—Metering and Full Stroke
LEGEND:
1 Cam
2 Plunger
3 Plunger Spring Guide
4 Plunger Spring
5 Spool Spring Guide
6 Spool
7 Return Spring
8 Balance Spring
9 Port T to Hydraulic Oil Tank
10 Hole
11 Port P from Pilot Control Shut-Off Valve
12 Work Port to Control Valve Propel Spool Pilot Cap
13 Pilot Oil
14 Return Oil
One pilot controller is used to control the propel functions. The controller contains four valve assemblies, one for each direction
of travel for each track.
The pilot controller consists of the cam (1), plunger (2), plunger spring guide (3), plunger spring (4), spool spring guide (5),
spool (6), return spring (7), and balance spring (8).
In neutral, the spool is pushed up by the return spring blocking pilot oil at port P from the pilot control shut-off valve (11). With
the spool up, hole (10) connects the work port to control valve propel spool pilot cap (12) to port T to hydraulic oil tank (9) by
the passage through the spool.
When the pedal or lever is pushed to move the machine, the cam pushes the plunger and spool spring guide down against the
return spring and balance spring. The balance spring pushes the spool down. As the spool is pushed down the passage from
the control valve propel spool pilot cap to the hydraulic oil tank is closed and then is opened to the pilot oil from pilot control
shut-off valve. When the pilot oil pressure to the control valve propel spool pilot cap is equal to the force applied by the balance
spring the spool moves up trapping the oil to the pilot cap.

When the pedal or lever moves the cam to full stroke, the plunger compresses plunger spring (4) and return spring (7) allowing
the plunger to push directly on the spool. The plunger holds the spool down so the passage through spool remains open to pilot
oil. Oil pressure to the control valve propel spool pilot cap now equals pilot oil pressure.

Blade, Boom Swing, and Auxiliary Pilot Controller Operation
Boom and Auxiliary Pilot Controller—Metering and Full Stroke
LEGEND:
1 Cam
2 Plunger
3 Spring Guide
4 Balance Spring
5 Return Spring
6 Spool
7 Port T to Hydraulic Oil Tank
8 Hole
9 Port P from Pilot Control Shut-Off Solenoid Valve
10 Work Port to Control Valve Propel Spool Pilot Cap
11 Pilot Oil
12 Return Oil
The pilot controller consists of the cam (1), plunger (2), spring guide (3), balance spring (4), return spring (5), and spool (6).
In neutral, the spool blocks pilot oil at port P from the pilot control shut-off valve (9). With the spool in the neutral position, hole
(8) connects the work port to control valve propel spool pilot cap (10) to port T to hydraulic oil tank (7) by the passage through
the spool.
When the pedal or lever is pushed to activate a function, the cam pushes the plunger down against the spring guide. The
spring guide compresses the balance spring and return spring. The return spring pushes the spool down. As the spool is pushed
down the passage from the control valve propel spool pilot cap to the hydraulic oil tank is closed and then is opened to the pilot
oil from pilot control shut-off valve. When the pilot oil pressure to the control valve propel spool pilot cap is equal to the force
applied by the balance spring the spool moves up trapping the oil to the pilot cap.
When the pedal or lever moves the cam to full stroke, the plunger pushes down on the spring guide compressing balance
spring and return spring allowing the plunger to push directly on the spool. The plunger holds the spool down so the passage
through spool remains open to pilot oil. Oil pressure to the control valve propel spool pilot cap now equals pilot oil pressure.
Blade Controller Operation

The blade controller is operated by a lever located to the right of the operator′s seat. When the lever is pulled back, pilot oil is
routed to the control valve blade valve spool blade raise pilot cap. When the lever is pushed forward, pilot oil is routed to the
control valve blade valve spool blade lower pilot cap. When the lever is released, it returns to the neutral (center) position.
Boom Swing Controller Operation
The boom swing controller is operated by a pedal located on the right side of the cab floor. When the pedal is rocked to the left,
pilot oil is routed to the control valve boom swing spool swing left pilot cap. When the pedal is rocked to the right, pilot oil is
routed to the control valve boom swing spool swing right pilot cap. When the pedal is released, it returns to the neutral (center)
position.
Auxiliary Controller Operation
The auxiliary controller is used for any add on accessories such as an auger, pile driver, etc. The controller is operated by a
pedal located on the left side of the cab floor. The operation of the rocking of the pedal is determined by the accessory
attached. The auxiliary control valve works in conjunction with the one way/two way valve. See One Way/Two Way Valve
Operation for more information. (Group 9025-05.)
Hydraulic Pump Operation

LEGEND:
1 Shaft
2 Cylinder Block
3 Piston
4 Thrust Plate
5 Swash Plate
Hydraulic Pump
The pump shaft (1) is splined to the cylinder block (2) and pistons (3) are inserted in the cylinder block.
The engine rotation drives the shaft directly and rotates the cylinder block and pistons together. The pistons slide on the thrust
plate (4) and reciprocate in the cylinder block by the tilt of the swash plate (5).

Hydraulic Pump Regulator Operation
Hydraulic Pump Regulator
LEGEND:
1 Piston
2 Swash Plate
3 Oscillation Pin
4 Spring
5 Control Piston
Power Control
To prevent the load of hydraulic pump and pilot pump from exceeding the engine torque, the hydraulic pump regulates
delivery flow rate.
When the hydraulic pump delivery pressure increases more than the load pressure, the increased pressure acts on the pistons
(1). The pressure force on the pistons pushes the swash plate (2) around the oscillation pin (3) until the pressure force equals
the spring (4) force. As a result, the hydraulic pump decreases delivery flow rate. Depending on the delivery oil pressure, the
delivery flow rate from the hydraulic pump is controlled so that the total power required to drive hydraulic pump and pilot
pump does not exceed engine power.
Flow Rate Control
Flow rate control regulates the pump delivery flow rate in response to change in loads on pump pistons and motors.
Pilot oil PGR varies in proportion to engine speed and is sent from the pilot flow rate sensing manifold. Pilot oil PLS varies in
response to the pressure change from the actuators and is sent from the control valve differential reducing valve. Until
pressure PGR becomes equal to pressure PLS, the pump delivery flow rate valve regulates the pump delivery flow rate.
Pilot oil from the pump delivery flow rate valve is routed to the control piston (5). The control piston pushes the swash plate (2)
around the oscillation pin (3) until force equals the spring (4) force.
As the delivery flow rate from hydraulic pump varies, the pressure oil supplied to the control valve varies. As the pressure oil to
the control valve varies, pilot oil pressure PLS, from the control valve differential reducing valve, varies. Pilot oil PLS and PGR

are routed to the pump delivery flow rate valve. When these pressures become equal, the hydraulic pump swash plate stops
tilting.
Pump Delivery Flow Rate Valve

LEGEND:
1 Spool
2 Sleeve
3 Spring
Pump Delivery Flow Rate Valve
The pump delivery flow rate valve controls the hydraulic pump delivery flow rate in response to a change in pressure difference
between pilot oil PGR and pilot oil PLS.
Pilot oil PGR varies in proportion to engine speed and is sent from the pilot flow rate sensing manifold. Pilot oil PLS varies in
response to the pressure change from the actuators and is sent from the control valve differential reducing valve. The flow rate
valve consists of spool (1), sleeve (2) and springs (3).
Pilot oil PGR and PLS are routed to either end of the flow rate valve, moving the spool to either the right or the left. Then, the
oil ports in the flow rate valve are shifted. The oil pressure routed from the flow rate valve to the control piston in the hydraulic
pump varies in response to spool movement. The control piston pushes the swash plate around the oscillation pin until force
equals the spring force.
When pressure PGR is greater than pressure PLS, actuator load has increased. Delivery flow rate from the hydraulic pump is
increased.
When pressure PLS is greater than pressure PGR, actuator load has decreased. Delivery flow rate from the hydraulic pump is
reduced.

Control Valve Operation
Control Valve Components
LEGEND:
29 Unload Valve


34 Shut-Off Valve
39 Boom Up Circuit Relief and Anti-Cavitation Valve
41 Boom Down Circuit Relief and Anti-Cavitation Valve
47 Arm Out Circuit Relief and Anti-Cavitation Valve
49 Arm In Circuit Relief and Anti-Cavitation Valve
54 Bucket Curl Circuit Relief and Anti-Cavitation Valve
56 Bucket Dump Circuit Relief and Anti-Cavitation Valve
79 Blade Circuit Relief and Anti-Cavitation Valve
105 Auxiliary Circuit Relief and Anti-Cavitation Valve
106 Auxiliary Circuit Relief and Anti-Cavitation Valve
A Blade Valve Section
B Left Propel Valve Section
C Right Propel Valve Section
D Auxiliary Valve Section
E Boom Swing Valve Section
F Bucket Valve Section
G Arm Valve Section
H Boom Valve Section
I Swing Valve Section
J Supply Oil and Shut-Off Valve Section
K Load Sense Valve Section
The control valve is an assembly consisting of eleven valve sections (A—K), nine of which are function control valves. The
remaining two sections are for the supply oil inlet and shut-off (J) and load sense (K). The control valve is a closed circuit
system. The function control valves control flow rate and direction for each of their respective hydraulic circuits. The valve
spools are controlled by pilot pressure. All valve spools are accessible by removal of a plug or pilot cap.
Individual circuits are protected by circuit relief valves (39, 41, 47, 49, 54, 56, 79, 105, and 106). The system relief valve (28)
prevents hydraulic pump delivery pressure from exceeding set pressure. See System Relief Valve Operation for more
information. (Group 9025-05.)
When the spools in the control valve are in the neutral position (all pilot controllers in neutral), the delivery pressure from the
hydraulic pump flows back to the hydraulic oil tank through unload valve (29). See Unload Valve Operation for more
information. (Group 9025-05.).
The control valve differential reducing valve (30) supplies pressure PLS to the pump delivery flow rate valve to regulate pump
flow rate. See Control Valve Differential Reducing Valve Operation for more information. (Group 9025-05.).
The variable relief valve (27) prevents the maximum load pressure PLMAX in the circuit after the spool from exceeding
hydraulic pump delivery pressure. See Variable Relief Valve Operation for more information. (Group 9025-05.).
See Hydraulic System Schematics for Control Valve Schematic. (Group 9025-05)
Control Valve Pressure and Return Line Identification

Control Valve Pressure and Return Line Identification
LEGEND:
1 To Rotary Manifold Port E (Blade Lower)
2 To Rotary Manifold Port F (Blade Raise)
3 To Rotary Manifold Port C (Left Propel Reverse)
4 To Rotary Manifold Port D (Left Propel Forward)
5 To Rotary Manifold Port A (Right Propel Reverse)
6 To Rotary Manifold Port B (Right Propel Forward)
7 To One Way/Two Way Valve Top Port
8 To Auxiliary Attachment Manifold Rear Bottom Port
9 To Boom Swing Cylinder Head End
10 To Boom Swing Cylinder Rod End
11 To Bucket Cylinder Head End
12 To Bucket Cylinder Rod End
13 To Arm Cylinder Head End
14 To Arm Cylinder Rod End
15 To Boom Cylinder Rod End
16 To Boom Cylinder Head End
17 To Swing Motor Port B
18 To Swing Motor Port A
19 From Hydraulic Pump
20 To Oil Cooler
21 To Hydraulic Oil Tank (D1)
22 To Swing Motor Port M
23 To Tee on Top of Load Sense Valve Section (Pressure PGR)
24 To Hydraulic Oil Tank (D6)
25 To Pilot Flow Rate Sensing Manifold (Pressure PGR)
26 To Pump Delivery Flow Rate Valve (Pressure PLS)
27 To Solenoid Valve Manifold Top Middle Port (S1)
28 To Solenoid Valve Manifold Front Left Port and Swing Motor Park Brake (PB)
Control Valve Pilot Pressure Line Identification

Control Valve Pilot Line Identification
LEGEND:
1A Swing Right
2A Boom Down
3A Arm In
4A Bucket Dump
5A Boom Swing Right

6A Auxiliary Function Supply

7A Right Propel Reverse
8A Left Propel Forward
9A Blade Lower
1B Swing Left
2B Boom Up
3B Arm Out
4B Bucket Curl
5B Boom Swing Left
6B Auxiliary Function Return
7B Right Propel Forward
8B Left Propel Reverse
9B Blade Raise
System Relief Valve Operation
LEGEND:
1 Main Poppet
2 Orifice
3 Spring
4 Orifice
5 Seat
6 Passage
7 Spring
8 Pilot Poppet
9 Spring Chamber
System Relief Valve
The system relief valve prevents hydraulic pump delivery pressure from exceeding set pressure.
The pressure on port HP acts on pilot poppet (8) through orifice (2) in main poppet (1) and orifice (4) in seat (5).
When the pressure in port HP exceeds the set pressure, pilot poppet (8) opens to release a small quantity of pressure oil to port
LP (tank) via passage (6) of seat (5).
At this time, a pressure difference between port HP and spring chamber (9) occurs, caused by orifice (2). By this pressure
difference, main poppet (1) opens when it becomes greater than spring (3) force, to relieve the pressure oil from port HP to
port LP (tank).

Variable Relief Valve Operation

LEGEND:
1 Pilot Oil PGR
2 Chamber A
3 Area S1
4 Poppet
5 Pressure Oil PLMAX
6 Chamber B
7 Area S2
8 Spring
9 To Hydraulic Oil Tank
Variable Relief Valve
The variable relief valve prevents the maximum load pressure PLMAX in the circuit after the spool from exceeding hydraulic
pump delivery pressure.
When circuit pressure is relieved, pressure PLMAX and pressure P1 are equal. Pressure PLMAX and pressure PGR, from the
differential reducing valve, are routed to the variable relief valve and act against spring force. When the spring force is
overcome, the valve opens allowing pressure PLMAX to flow to the hydraulic oil tank. The variable relief valve and system relief
valve have the same relief pressure setting.
Pilot oil PGR (1) flows into chamber A (2). Pressure increases in chamber A and acts against area S1 (3). Pressure oil PLMAX (5)
flows into chamber B (6). Pressure increases in chamber B and acts against area S2 (7). The combined forces of PGR and
PLMAX working against the poppet will force the poppet to move right against the spring. Spring (8) force pushes the poppet to
the left. The pressure forces pushing the spool from both ends is expressed as: (Pressure PGR x Area S1) + (Pressure PLMAX x
Area S2) = (Spring Force).
When the engine is running, pressure PGR and pressure PLMAX act on the poppet before pressure PLMAX increases to the
system relief pressure setting. When pressure PGR and pressure PLMAX overcome the spring force, the poppet opens allowing
pressure PLMAX to flow to the hydraulic oil tank (9).
Boom Swing Anti-Cavitation Valve Operation
Blade/Boom Swing Anti-Cavitation Valve
The anti-cavitation valve prevents cavitation in the boom swing circuit.
The pressure on port HP acts on the spring chamber through the poppet passage, so the pressure on port HP and spring
chamber becomes equal. When the pressure on port HP is higher, the closing force (Pressure in Spring Chamber x Pressurized
Area S2) becomes greater than the opening force of the poppet (Port HP x Pressurized Area S1), the poppet closes.

When the pressure on port HP is lower than the return pressure on port LP (pressure on port HP is almost zero), the closing
force of the poppet is only the spring force. When return pressure is higher than HP, return pressure acting on the shoulder of
the poppet will move it right and allow oil from the return passage to flow into the work port.

Circuit Relief Valve Operation

LEGEND:
1 Main Poppet
2 Spring
3 Seat
4 Pilot Poppet
5 Spring
6 Passage
7 Spring Chamber
8 Orifice
9 Piston
10 Sleeve
Circuit Relief and Anti-Cavitation Valve
The circuit relief valve has two operations; one is the relief operation which prevents the pressure in the actuator circuit from
exceeding the set pressure, and the other is the make-up operation which prevents cavitation. The circuit relief valve is
provided in boom, arm, bucket and blade circuits.
Relief Operation
When the pressure in the actuator circuit rises, pressure oil is relieved to the hydraulic oil tank. The pressure on port HP acts on
pilot poppet (4) via passage (8) in piston (9).
When the pressure on port HP exceeds the set pressure, pilot poppet (4) opens. Then, the pressure oil can flow to port LP
(tank) via passage (6) in seat (3). At this time, the pressure difference between port HP and spring chamber (7) occurs, caused
by orifice (8). By this pressure difference, main poppet (1) opens when it becomes greater than spring (2) force, to relieve the
pressure oil from HP to port LP (tank).
Make-Up Operation
When actuator speed increases faster than the pressure used to actuate it, the circuit relief valve supplies hydraulic oil from
the hydraulic oil tank into the actuator circuit to prevent cavitation.
Oil pressure in port HP becomes less than return oil pressure in port LP (tank). The higher pressure of return oil acts on face of
main poppet (1) and sleeve (10) to overcome spring (2) force. Return oil flows from port LP (tank) into port HP preventing
cavitation.

Shut-Off Valve Operation

Pressure oil from hydraulic pump flows to the control valve spool through the pressure compensator. The shut-off valve is
activated by the pilot control shut-off solenoid valve. When the shut-off valve is deactivated, pressure oil from hydraulic pump
is routed to the end of the pressure compensator spool from the shut-off valve, closing the pressure compensator circuit.
Therefore, pressure oil from hydraulic pump cannot flow through the pressure compensator to the valve spool even when a
pilot control lever is operated.
Shut-Off Valve Closed
LEGEND:
3 Retainer
4 Spool
5 To Pressure Compensator
7 Pilot Oil
8 Spring
A Notch A
B Notch B
Shut-Off Valve—Closed
When the pilot control shut-off solenoid valve is deactivated, pilot oil is not routed to the shut-off valve. The spool (4) in the
shut-off valve is held to the right by spring (8) force. Therefore, notch (A) is closed and notch (B) is opened. As a result,
pressure oil from the hydraulic pump (6) is routed to the end of the pressure compensator through holes in the retainer (3) and
notch (B) causing the pressure compensator to close the circuit.
Shut-Off Valve Opened
LEGEND:
3 Retainer
4 Spool
5 From Pressure Compensator
7 Pilot Oil
8 Spring
A Notch A
B Notch B
Shut-Off Valve—Open
When the pilot control shut-off valve is activated, pilot oil is routed to the shut-off valve. The spool (4) in the shut-off valve is
moved to the left. Therefore, notch (A) is opened and notch (B) is closed. As a result, pressure oil from hydraulic pump (6) is
blocked by the valve spool and is not routed to the pressure compensator. Port DR1 is opened to the end of the pressure
compensator spool. Oil from the pressure compensator is routed through holes in the retainer (3) and notch (A) to the hydraulic
oil tank. Thereby, the pressure compensator is allowed to move and pressure oil can flow to the control valve spool.

Unload Valve Operation
Unload Valve Operation
LEGEND:
1 Chamber A
2 Chamber B
3 Chamber C
4 Area S1
5 Area S2
6 Area S3
7 Port P (Pressure P1)
8 Port PGR (Pressure PGR)
9 Port PLMAX (Pressure PLMAX)
10 Port T
11 Spool
12 Notch
13 Unload Valve
The unload valve (13) operates in response to hydraulic pump pressure, maximum load pressure PLMAX, and PGR pressure to
control the differential pressure before and after the spool in the control valve.
Pilot oil PGR (8) flows into chamber A (1). As pressure increases in chamber A and acts against area S1 (4) and pressure oil
PLMAX (9) flows into chamber B (2) and acts against area S2 (5), the spool is pushed to the right. Pressure oil P1 from port P
flows into chamber C (3) through the spool. As pressure increases in chamber C and acts against area S3 (6), the spool is
pushed to the left. The pressure forces pushing the spool from both ends is expressed as: (Pressure PGR x Area S1) + (Pressure
PLMAX x Area S2) = (Pressure P1 x Area S3).

When pressure P1 increases until spool left pushing force (Pressure P1 x Area S3) overcomes spool right pushing force
(Pressure PGR x Area S1) + (Pressure PLMAX x Area S2), the spool is moved to the left. Then, notch (12) is opened, and
pressure oil P1 is routed to port T (10) through the spool. The opening area at notch varies in proportion to the spool stroke.

Control Valve Differential Reducing Valve Operation
Control Valve Differential Reducing Valve
LEGEND:
1 Chamber A
2 Chamber B
3 Chamber C
4 Area S1
5 Area S2
6 Area S3
7 Port PLS
8 Port PLMAX
10 Sleeve
11 Spool
12 Notch
The differential reducing valve, located in the control valve, supplies pilot oil PLS to the pump delivery flow rate valve and
pressure compensators.
Pressure oil PLS, from port PLS (7), is routed into chamber A (1) through hole in sleeve (10) and passage in spool (11). Pressure
increases in chamber A and acts against area S1. Pressure oil PLMAX, from port PLMAX (8), is routed into chamber B (2). The
combined forces in chambers A and B act to move the spool to the right. Pressure oil, from hydraulic pump (9), is routed into
chamber C (3). As pressure increases in chamber C and acts against area S3 (6), the spool may move to the left. The pressure
forces pushing the spool from both ends is expressed as: (Pressure PLS x Area S1) + (Pressure PLMAX x Area S2) = (Pressure
P1 x Area S3).
When pressure P1 increases until spool left pushing force (Pressure P1 x Area S3) overcomes spool right pushing force
(Pressure PLS x Area S1) + (Pressure PLMAX x Area S2), the spool is moved to the left. Then, notch (12) is opened, and pilot oil
is routed into chamber A and port PLS. Port DR1 (13), to the hydraulic oil tank, is blocked.
When pressure P1 decreases until spool right pushing force (Pressure PLS x Area S1) + (Pressure PLMAX x Area S2) overcomes
spool left pushing force (Pressure P1 x Area S3), the spool is moved to the right. Then, notch (12) is closed. Pilot oil is not
routed into chamber A and port PLS. Port DR1 (13) is opened. Oil pressure in chamber A and port PLS is routed through port
DR1 to the hydraulic oil tank.

Pressure Compensator Operation
Pressure Compensator Operation
LEGEND:
1 Pressure Oil P1
2 Spool
3 Piston
4 Area S3
5 Chamber C
6 Passage
7 Spool
8 Area S2
9 Chamber B
10 Area S1
11 Chamber A
12 Pressure Oil PL
13 Notch
14 Pilot Oil PLS
The pressure compensator is used to make sure oil is routed to all functions when operating multiple functions at one time. It
regulates oil flow passing through the control valve spool (2) so that the differential pressure in the circuit before and after the
spool is kept constant. The pressure compensator is located before the valve spool in each control valve section.
Pressure oil PL (12), pressure oil after the spool, is routed into chamber A (11). Pressure PL acts against area S1 (10) pushing
the spool to the right. Pilot oil PLS (14), from the differential reducing valve, is routed into chamber B (9). Pressure PLS acts
against area S2 (8) pushing the spool to the right. Pressure oil P1 (1), pressure oil before the spool, is routed into chamber C (5)
through passage (6) in spool (7). Pressure P1 acts against area S3 (4) and piston (3) pushing the spool to the left. The pressure
forces pushing the spool from both ends is expressed as: (Pressure PL x Area S1) + (Pressure PLS x Area S2) = (Pressure P1 x
Area S3).
When the pressure difference between pressure P1 and pressure PL is higher than pressure PLS, the spool is pushed to the left.
Then, notch (13) gradually closes, reducing hydraulic oil flow through the spool. As a result, the pressure oil routed into the
circuit before the spool is reduced. Therefore, pressure P1 is decreased, reducing the differential pressure before and after the
spool.

When the differential pressure between pressure P1 and pressure PL is lower than pressure PLS, the spool is pushed to the
right. Then, notch (13) gradually opens, increasing hydraulic oil flow through the spool. As a result, the pressure oil routed into
the circuit before the spool is increased. Therefore, pressure P1 is increased, increasing the differential pressure before and
after the spool.

Boom Reduced Leakage Valve Operation

To reduce boom cylinder drift, a boom reduced leakage valve is provided on the bottom side circuit of boom cylinder.
Boom Spool in Neutral
Boom Spool in Neutral
LEGEND:
1 Spring Chamber
2 Orifice
3 Poppet
4 Ball
5 Sleeve
6 Spool
8 Boom Cylinder
With the boom raised, pressure occurs in the bottom side circuit of boom cylinder (8). This is caused by the weight of the front
attachment.
At this time, pressure on the bottom side circuit acts on the spring chamber (1) through an orifice (2) in the poppet (3). The
pressure in the spring chamber holds the ball (4) against the sleeve (5) and forces the poppet closed. Thereby, pressure oil in
the bottom side circuit is blocked by the poppet, so cylinder drift is reduced.
Boom Raise Operation

Boom Raise Operation
LEGEND:
1 Spring Chamber
2 Orifice
3 Poppet
4 Ball
5 Sleeve
6 Spool
8 Boom Cylinder
When boom raise operation is performed, the pressure oil from the boom spool (6) pushes the poppet (3) open, so hydraulic oil
flows into the bottom side circuit of the boom cylinder (8).
Boom Lower Operation

Boom Lower Operation
LEGEND:
3 Poppet
6 Spool
8 Boom Cylinder
When boom lower operation is performed, the boom lower pilot pressure (9) acts on the piston (7). As the piston moves, it
pushes the ball (4) from the sleeve (5). Thereby, the return oil from the bottom side circuit of boom cylinder (8) acts on the ball
from the orifice (2) in the poppet (3). When ball opens, return oil flows to the hydraulic oil tank. When this occurs, pressure in
the spring chamber (1) decreases, so the poppet moves to the right.
As a result, return oil from the bottom side circuit of boom cylinder pushes the poppet open and allows hydraulic oil to flow to
the hydraulic oil tank.

Swing Gearbox Operation
Swing Gearbox
LEGEND:
1 First Stage Sun Gear
2 First Stage Carrier
3 First Stage Planet Gear
4 Second Stage Planet Gear
5 Second Stage Carrier
6 Ring Gear
7 Second Stage Sun Gear
8 Shaft
9 Swing Motor Output Shaft
The swing gearbox is a two-stage planetary type gearbox.
The swing motor is mounted on the swing gearbox housing and encloses the top of gearbox housing. The ring gear (6) is part
of the gearbox housing. The first stage planet gears (3) rotate around needle bearings on the shafts in the first stage carrier
(2). The second stage planet gears (4) and bushings rotate on the shafts in the second stage carrier (5). The output shaft (8) is
in mesh with the swing gear. Swing motor rotational speed is reduced and output torque is increased by the two-stage
planetary gear set to turn the upperstructure.
The swing motor output shaft (9) drives the first stage sun gear (1) turning the first stage planet gears against the stationary
ring gear. Rotary power is transmitted through the shafts to the first stage carrier. The first stage carrier turns, transmitting
rotary power to the second stage sun gear (7). The second stage sun gear turns the second stage planet gears against the

stationary ring gear. Then, rotary power is transmitted through the shafts to the second stage carrier which turns the output
shaft.
The output shaft rotates in two roller bearings. The output shaft and bearings are retained in the housing by a nut. The lower
bearing is isolated from the oil in the gearbox by an oil seal. The cavity for the lower bearing is filled with grease at assembly.

Swing Motor Operation
Swing Motor
LEGEND:
1 Ball Guide
2 Retainer
3 Pin
4 Disk Plate
5 Collar
6 O-Ring
7 O-Ring
8 Socket Bolt
9 Spring
10 Valve Plate
11 Spring
12 Cover
13 Retaining Ring
14 Washer
15 Bearing
16 Shaft
17 Pin
18 Disk Spring
19 Pin
20 Cylinder Block
21 Brake Piston
22 O-Ring
23 O-Ring
24 Piston and Slipper
25 Housing
26 Swash Plate
27 Bearing
The swing motor is a fixed-displacement, axial piston motor.
The motor consists of the cylinder block (20) and shaft (16), pistons and slippers (24), valve plate (10), disk plate (4), brake
piston (21), and cover (12). The cover contains the crossover relief valves, anti-cavitation valves, and work ports.
The cylinder block and output shaft are one assembly. Each piston is connected to a slipper by a ball joint. The slippers slide on
the inclined swash plate (26) forcing the cylinder block to turn when pressure oil is applied to the pistons. Retainer (2) holds the
slippers on the swash plate and the retainer itself is held against the slippers by the ball guide. The valve plate is held

stationary by dowel pins in the cover.
Oil from swing control valve is routed through the work ports and valve plate to the pistons.
In operation, high pressure supply oil enters the cylinder block bores through ports forcing pistons down against the inclined
swash plate. The slippers slide down the inclined swash plate causing the cylinder block and output shaft to turn. Swing speed
varies depending on the amount of supply oil delivered by the hydraulic pump through the control valve.
During the second half of motor′s revolution, low pressure oil is discharged as pistons slide back up the inclined swash plate. To
reverse rotation, oil flow is reversed. A small amount of supply oil flows through the center of each piston to ball joint and to
face of slipper for lubrication.
The swing park brake is spring applied and hydraulically released. The disk plate (4) is connected by splines to rotate with the
cylinder block. When the pilot control shut-off switch is off, pilot oil is blocked from the park brake piston by the pilot control
shut-off solenoid valve. The brake springs squeeze the plate and disk together to prevent the upperstructure from swinging.
The park brake is released when the pilot control shut-off switch is on and the pilot control shut-off solenoid is energized.

Swing Motor Crossover Relief Valve Operation

LEGEND:
1 Swing Motor Cover
2 Crossover Relief Valve (2 used)
Crossover Relief Valve—Location In Cover
Relief Valve—Shockless Operation

Relief Valve—Relief Operation
There are two crossover relief valves (2) located in the swing motor cover (1). The relief valves function to reduce shocks
developed when starting or stopping swing movement (shockless) and to protect the circuit from overloading (relief).
When the pressure in the circuit increases, the pressure oil enters the piston chamber via orifice in poppet and housing to
move the piston. The pressure in the spring chamber is kept low during the movement of the piston. Therefore, when the
pressure on port HP exceeds the spring set force, the poppet opens to relieve hydraulic oil.
When the piston moves to the stroke end, pressure in the spring chamber becomes equal to the pressure on port HP. As a
result, the relief set force overcomes the normal pressure, so the poppet closes.
When operating the swing suddenly in the reverse direction, pressure will be routed to the opposite side (port LP, in this case)
of the piston to return the piston to its original position.
When the pressure in the circuit exceeds the relief set pressure, the force acting on the poppet [Pressurized Area (S1—S2) x
Pressure on Port HP] exceeds the spring force, causing the poppet to open and allow hydraulic oil to be relieved.

Swing Motor Make-Up Check Valve Operation

LEGEND:
1 Swing Motor Cover
2 Make-Up Check Valve (2 used)
Make-Up Check Valve—Location on Cover
There are two make-up check valves (2) located in swing motor cover (1).
The make-up check valve prevents cavitation in the circuit.
When the upperstructure swings downward on a slope, the upperstructure is accelerated by its own weight and moves quicker
than the swing motor drive speed developed by the hydraulic pump oil flow rate. Therefore, cavitation can occur in the circuit.
To prevent cavitation when oil pressure in the circuit is lower than pressure at port M (hydraulic oil tank pressure), the poppet
opens, drawing hydraulic oil into the circuit.

Swing Motor Park Brake Release Circuit Operation
Swing Motor Park Brake
Swing Motor Park Brake
The park brake is a wet-type, single disk, negative type brake. A negative type brake is spring applied and hydraulically
released. The park brake is released only when the brake release pressure oil is routed into the brake piston chamber.
Brake Released
When the pilot control shut-off lever is in the UNLOCKED position, the pilot shut-off switch is ON. By this action, the pilot shut-

off solenoid valve is energized, so that the brake release pressure (pilot pressure) is guided to the brake piston chamber to
push the brake piston upward, allowing the brake piston and the disc plate contact to free, which releases the brake.
Brake Applied
When the pilot control shut-off lever is in the LOCKED position, the pilot shut-off switch is OFF. By this action, the pilot shut-off
solenoid valve is de-energized, so that the brake release pressure (pilot pressure) is not guided to the brake piston chamber.
The brake release pressure oil in the brake piston chamber flows back to the hydraulic oil tank via the pilot shut-off solenoid
valve.
Accordingly, by the spring, the brake piston gradually moves downward, allowing the brake piston to slowly come in contact
with the disc plate to apply the swing brake.

Rotary Manifold Operation
Rotary Manifold Oil Flow
LEGEND:
1 To Blade Cylinder—Lower
2 To Blade Cylinder—Raise
3 To Propel Speed Changeover Valve
5 Body
6 To Right Propel Motor—Reverse
7 To Left Propel Motor—Reverse
8 To Right Propel Motor—Forward
9 To Left Propel Motor—Forward
10 Inner Spindle
11 Oil Seal
12 Propel Motor (2 used)
13 Backfill Blade Cylinder

The rotary manifold is a 360° rotary joint. It allows oil to flow to and from the propel motors (12) and blade cylinder (13)
without twisting hoses when the upperstructure is rotated.
The inner spindle (10) is connected to the undercarriage and the body (5) is connected to the upperstructure. The body rotates
around the spindle during swing operation.
Oil flows into and through the body to passages in the spindle, and then out of the spindle to the propel motors and the blade
cylinder. Oil seal (11) prevents oil from leaking between the spindle and body into adjacent passages.

Propel Motor and Brake Valve Housing Operation

LEGEND:
1 Drive Shaft
2 Propel Motor
3 Swash Plate
4 Cylinder Block
5 Park Brake
6 Valve Plate
7 Brake Valve Housing
8 Piston and Slipper
9 Control Piston
Propel Motor
The propel motor (2) is a swash plate design, two-speed, axial piston motor that includes the brake valve housing (7), propel
park brake (5), and propel motor speed change valve. The counterbalance valve, propel speed change valve, and relief valves
are integral components of the brake valve housing.
Supply oil flows through the valve plate (6) to half of the pistons (8) in the cylinder block (4). The supply oil forces the pistons
against the swash plate (3). The piston slippers slide down the angle face of the swash plate causing the cylinder block and
drive shaft (1) to rotate. The drive shaft rotation is transferred to the propel gearbox driving the machine. As the cylinder block
and drive shaft turn, half of the pistons are being forced against the swash plate while the remaining pistons in the other half of
the cylinder block are being pushed back into bores by the angle of the swash plate to discharge oil to return.
Forward or reverse travel direction is determined by which half of the valve plate ports and pistons are pressurized by supply
oil from the control valve. swash plate position determines the propel speed of machine actuated by control piston (9).

Propel Motor Brake Valve
LEGEND:
1 Counterbalance Valve
3 Relief Valve
The propel motor brake valve consists of counterbalance valve (1), propel speed change valve (2), and relief valves (3). The
counterbalance valve has two functions; one is to start and stop the propel smoothly and the other is to prevent the machine
from running away while descending slopes.
The relief valve prevents the pressure in the propel circuit from exceeding the set pressure.
The propel speed change valve is switched by pressure oil from the propel speed solenoid valve. It switches the propel speed
by the control piston.
Counterbalance Valve

Propel Motor Counterbalance Valve
The counterbalance valve has two functions; one is to start and stop the propel smoothly and the other is to prevent the
machine from running away while descending slopes.
Propel Operation— When pressure oil from the control valve is supplied to port P1, the pressure oil flows to motor port AM
through the inside of the spool of counterbalance valve and opens the check valve. The return oil from motor port BM is
blocked by the check valve and spool. Thereby, the pressure on port P1 side increases gradually. The pressure on port P1
enters into the spring chamber through an orifice which moves the spool to the right by the pressure at the end surface of the
spool. As a result, the spool notch opens, so port BM and port P2 connect, and the propel motor rotates.
Down Hill Operation— When the machine propels down a slope, the propel motors are forcibly driven by the machine weight
so that the motor draws oil like a pump. The pressure oil in port P1 is drawn into the propel motor so the pressure on port P1
decreases. Thereby, the spool returns to the left and returning oil from port BM to port P2 is restricted, slowing the motor.
Relief Valve

Propel Motor Relief Valve
By the following two staged relief operation, the relief valve functions to reduce shocks developed when the propel motor is
started or stopped, and also to prevent overload in the propel circuit.
→NOTE:
The force equal to (Pressure on Port HP x Pressurized Area of Poppet S1) is applied on the poppet to the
opening direction, and force equal to (Pressure in Spring Chamber x Pressurized Area of Poppet S2) +
(Spring Force)] is applied to the closing direction. The pressurized area of poppet S2 is smaller than S1.
Shock Reducing Operation— When the pressure in the circuit increases, the pressure oil enters into the piston chamber
through the orifices of the poppet and seat to move the piston.
While the piston moves, the pressure in the spring chamber is kept low. For this reason, the force applied in the closing
direction of the poppet becomes the same as the spring force.
Accordingly, when the force acting in the opening direction of the poppet (Pressure on Port HP x Pressurized Area of Poppet S1)
becomes greater than the set force of the spring, the poppet opens to relieve the hydraulic oil.
Relief Operation— When the piston moves to the stroke end, the pressure in the spring chamber becomes equal to the
pressure on port HP. (The relief set force overcomes the normal setting pressure, so the poppet closes.)
For this reason, the force equal to (Pressure on Port HP x Pressurized Area of Poppet S1) acts on the opening direction and the
force equal to (Pressure in Spring Chamber x Pressurized Area of Poppet S2) + (Spring Force) acts on the closing direction.
Accordingly, when the force acting on the opening direction of the poppet (Pressure on Port HP x Pressurized Area of Poppet
S1) becomes greater than (Pressure on Spring Chamber x Pressurized Area of Poppet S2) + (Spring Force), the poppet opens to
relieve the hydraulic oil.
Propel Speed Change Valve
The propel speed change valve is switched by pressure oil from the propel speed solenoid valve. It switches the propel speed
by moving the control piston. See Propel Motor Speed Circuit Operation . (Group 9025-05.)

Park Brake
Propel Park Brake
The propel park brake is a wet type, multi-disk, negative type brake. A negative type brake is spring applied and hydraulically
released. The plates are connected to the propel motor housing by teeth and splines and remain stationary with the housing.
The disks are connected to the cylinder block by teeth and splines and rotate with the cylinder block.
Park Brake Released— Actuating the propel function sends supply oil to the propel motors. A small amount of the supply oil
is routed to the piston chamber by the counterbalance valve. When the supply oil pressure overcomes the spring force, the
park brake piston is pushed against the spring. The contact pressure between the plates and disks is reduced so the propel
motor can rotate.
Park Brake Applied— When the propel function is returned to neutral, supply oil to the propel motor is blocked at the control
valve. The counterbalance valve returns to its neutral position opening a passage for oil in the brake chamber to flow out of the
brake chamber. The spring, pushing against the park brake piston, forces the oil in the piston chamber to flow through the
counterbalance valve and into the drain circuit and then back to the hydraulic oil tank. As the piston moves, the opening for oil
to flow from the piston chamber becomes less causing a restriction. The delay caused by the oil flowing through the restriction
is enough to slow the engagement of the park brake to ensure it is only fully applied after the machine has stopped. The spring
pushes the park brake piston against the plates and disks squeezing them together creating enough friction to hold the
machine.

Propel Motor Speed Circuit Operation

LEGEND:
1 Slow Speed
2 Fast Speed
3 Swash Plate
4 Piston
5 Cylinder Block
Propel Motor—Slow Speed
There are two surfaces on the swash plate; surface (1) and surface (2). Surface (1) makes contact with the housing at slow
speed and surface (2) makes contact with the housing at fast speed.
Two balls are located off the center line on the swash plate so they can roll freely.
Slow Speed Operation
When the propel is in slow speed, the pressure oil from the propel speed solenoid valve is not supplied to the propel speed
change valve. Surface (1) of the swash plate makes contact with the housing by the oil pressure acting on the piston and the
spring force in the cylinder block.
As a result, the angle of the swash plate increases which makes the stroke of the piston longer. The motor capacity increases,
causing the propel motor to rotate in slow speed.
Fast Speed Operation

LEGEND:
1 Slow Speed
2 Fast Speed
3 Swash Plate
4 Piston
5 Cylinder Block
6 Control Piston
7 From Propel Speed Change Valve
Propel Motor—Fast Speed
When the propel is in fast speed, the pressure oil from the propel speed solenoid valve is supplied to the propel speed change
valve. The propel speed change valve switches to supply the propel pressure oil to the control piston. The swash plate is
pushed by the control piston which makes surface (2) contact with the housing.
As a result, the angle of the swash plate decreases which makes the stroke of the piston shorter. The motor capacity
decreases, causing the propel motor to rotate in fast speed.
When Engine Stops
When the engine stops, pressure oil applied to the control piston returns to the hydraulic oil tank through the propel speed
change valve. Surface (1) of the swash plate then makes contact with the housing by the spring force in the cylinder block.
As a result, the propel motor is in slow speed position whenever the engine is started.

Blade Circuit Operation
Blade Control Valve
LEGEND:
1 Blade Valve Spool
2 Circuit Relief and Anti-Cavitation Valve
3 Pressure Compensator
4 Lift Check Valve
5 Work Port (2 used)
The blade control valve is a three-position, closed-center type valve. The valve spool (1) is pilot actuated through the use of a
pilot controller (lever actuated). A circuit relief and anti-cavitation valve (2), pressure compensator (3) and lift check valve (4)
are also incorporated. The work ports (5) are connected to the blade cylinder through the rotary manifold.

One Way/Two Way Valve Operation
One Way/Two Way Valve
LEGEND:
1 One Way/Two Way Valve
2 Auxiliary Control Valve
4 One Way Valve Operation
5 Two Way Valve Operation

The one way/two way valve is used with the auxiliary control valve to operate front attachments. When turned, it selects either
single or double work port usage. See illustration for valve positions for each operation.
One Way Operation
When auxiliary pedal is rocked to the left, work port pressure is directed to front attachment to operate. Return oil then passes
through the valve to the hydraulic oil tank. No action is accomplished when pedal is rocked to the right as pressure is stopped
at valve.
Two Way Operation
When auxiliary pedal is rocked either left or right, work port pressure is directed to front attachment to operate two modes of
use. For example, up-down, in-out, left-right. Return oil then passes through the control valve to the hydraulic oil tank.

Hydraulic Cylinder Operation
Boom Hydraulic Cylinder
LEGEND:
1 Piston Rod
2 Wiper Ring
3 Nut
4 O-Ring
5 Cylinder Barrel
6 Cushion
7 Piston
8 O-Ring
9 Backup Ring
10 Retainer
11 Bushing
All cylinders are similar in design. The boom cylinder is illustrated. A large nut (3) acts as a rod guide and retains piston rod (1)
from over extension in cylinder barrel (5). It houses a wiper ring (2), O-ring (4), and bushing (11). The cylinder barrel houses O-
rings (8), backup rings (9), and retainer (10). Some cylinders provide a cushion (6) to provide cushioning action during cylinder
full extension. Incoming pressure for extension moves piston (7). As the piston nears the end of its stroke, the cushion enters a
bore in the rod guide. The remaining return oil ahead of piston flows through a clearance between cushion and rod guide.

Hydraulic Oil Return Filter Operation
Hydraulic Oil Return Filter Operation
LEGEND:
1 Filter Element
2 Bypass Valve
3 Bypass Operation
4 Return Oil from Oil Cooler
5 Control Valve
6 Return Filter Operation
The filter element (1) is located in a chamber inside the hydraulic oil tank. O-rings are used at each end of the filter element to
prevent leakage. A spring holds the filter element on its seat.
Return oil from the oil cooler (4) and the control valve (5) flows through the filter element from the outside to the center.
Filtered oil flows out the bottom of filter into the hydraulic oil tank.
A bypass valve (2) is located at the top of the filter. The valve opens to protect the filter element against pressure surges in the
return circuit and allows a path for return oil if the filter element becomes plugged. During bypass operation, oil flows into the
chamber faster than it can flow through the filter element causing the pressure to increase. The higher pressure forces the
bypass valve open allowing oil to flow down the center of the filter element and into the hydraulic oil tank. The bypass valve
closes when the pressure decreases below the pressure setting of the bypass valve.

Hydraulic System Circuit Symbols
Hydraulic System Circuit Symbols

Hydraulic System Schematics
Pilot Controller Schematic
LEGEND:

24 Boom Swing Pilot Controller

26 Pilot Controller Pattern Conversion Valve
A Swing Left
B Swing Right
C Arm Out
D Arm In
E Boom Up
F Boom Down
G Bucket Dump
H Bucket Curl
I Left Propel Forward
J Left Propel Reverse
K Right Propel Reverse
L Right Propel Forward
M Blade Lower
N Blade Raise
O Boom Swing Right
P Boom Swing Left
Q From Solenoid Valve Manifold
R To Hydraulic Oil Tank
S To Arm Valve Spool (Arm Out)
T To Arm Valve Spool (Arm In)
U To Boom Valve Spool (Boom Up)
V To Boom Valve Spool (Boom Down)

Control Valve Schematic

LEGEND:
29 Unload Valve
31 Orifice
32 Orifice
33 Orifice
34 Shut-Off Valve
35 Shuttle Valve (Swing)
37 Swing Lift Check
38 Pressure Compensator (Swing)
39 Boom Up Circuit Relief and Anti-Cavitation Valve
40 Boom Reduced Leakage Valve
41 Boom Down Circuit Relief and Anti-Cavitation Valve
42 Boom Valve Spool
43 Shuttle Valve (Boom)
44 Pressure Compensator (Boom)
45 Boom Lift Check
46 Orifice
47 Arm Out Circuit Relief and Anti-Cavitation Valve
48 Shuttle Valve (Arm)
49 Arm In Circuit Relief and Anti-Cavitation Valve
50 Arm Valve Spool
51 Arm Lift Check
52 Pressure Compensator (Arm)
53 Orifice
54 Bucket Curl Circuit Relief and Anti-Cavitation Valve
55 Shuttle Valve (Bucket)
56 Bucket Dump Circuit Relief and Anti-Cavitation Valve
58 Bucket Lift Check
59 Pressure Compensator (Bucket)
60 Shuttle Valve (Boom Swing)
61 Boom Swing Anti-Cavitation Valve
63 Boom Swing Lift Check
64 Pressure Compensator (Boom Swing)
65 Shuttle Valve (Auxiliary)
67 Auxiliary Lift Check
68 Pressure Compensator (Auxiliary)
69 Shuttle Valve (Right Propel)
71 Right Propel Lift Check
72 Pressure Compensator (Right Propel)
73 Orifice
74 Shuttle Valve (Left Propel)
76 Left Propel Lift Check
77 Pressure Compensator (Left Propel)
78 Orifice
79 Blade Circuit Relief and Anti-Cavitation Valve
81 Blade Lift Check
82 Pressure Compensator (Blade)
89 Boom Cylinder
90 Arm Cylinder
91 Blade Cylinder
102 Bucket Cylinder
A From Pilot Control Shut-Off Solenoid Valve
B From Hydraulic Pump
C To Swing Motor and Gearbox
H To Right Propel Motor
I To Left Propel Motor

K From Solenoid Valve Manifold

L From Differential Reducing Valve
M To Hydraulic Oil Tank
N To Pump Delivery Flow Rate Valve
O From Swing Motor and Gearbox

Hydraulic Pump, Pilot Flow Rate Sensing, Solenoid Manifold and Hydraulic Oil Tank Schematic

LEGEND:
1 Hydraulic Pump
2 Pilot Pump
3 Pump Delivery Flow Rate Valve
4 Orifice
5 Pump Delivery Rate Control Piston
6 Pump Supply Pressure Control Piston
7 Pilot Filter
8 Pilot Filter Bypass Valve
13 Solenoid Valve Manifold
15 Pilot Control Shut-Off Solenoid Valve
17 Oil Cooler
18 Oil Cooler Bypass Valve
20 Return Filter and Bypass Valve
A From Control Valve
B From Control Valve Differential Reducing Valve
C To Shut-Off Valve
D To Control Valve
E To Unload Valve and Variable Relief Valve
F To Control Valve Differential Reducing Valve
G To Swing Park Brake
H To Propel Speed Change Valve
I From Pilot Controllers

Propel Motor Schematic
LEGEND:
A From Left Propel Valve Spool
B From Right Propel Valve Spool
D From Propel Speed Solenoid Valve

93 Swash Plate Piston

94 Fast Speed Orifice
96 Counterbalance Valve Orifices
97 Counterbalance Valve
98 Propel Crossover Relief Valves with Cushion
99 Propel Make-Up Check Valves
101 Rotary Manifold

Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Swing Motor Schematic
LEGEND:
A From Pilot Control Shut-Off Solenoid Valve
B From Swing Valve Spool
D From Swing Valve Spool
E To Hydraulic Oil Tank
83 Make-Up Check Valve
84 Crossover Relief Orifice
85 Swing Crossover Relief Valve with Cushion
86 Swing Park Brake
88 Orifice (Return Line)


Diagnostic Procedure
Follow the six basic steps below to carry out troubleshooting efficiently.
[1] - Know the system.
Study the machine technical manual. Understand the system and circuits. Use schematics, component location drawings, and
theory of operation for each circuit and circuit components to better understand how the system, circuits and components
work.
[2] - Ask the operator.
What type of work was the machine doing when the trouble was noticed?
Did the trouble start suddenly or has it been getting worse?
Did the machine have any previous problems? If so, which parts were repaired?
[3] - Inspect the machine.
Check all daily maintenance points. See Check Engine Oil Level . (Operator′s Manual.) Check batteries, fuses, fusible link, and
electrical connections.
[4] - Perform Operational Checkout.
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] - Perform troubleshooting.
Before starting any troubleshooting first check battery voltage, fusible link, and fuses.
Go to test groups to check pressures and voltages. Make sure adjustments are correct.
[6] - Trace a cause.
Before reaching a conclusion, check the most probable and simplest to verify. Use the flow charts and symptom, problem,
solution charts to help identify probable problem components.
Make a plan for appropriate repair to avoid other malfunctions.

Diagnose Hydraulic System Malfunctions
→NOTE:

All Hydraulic
Functions Low oil level Check oil level in hydraulic oil tank.
Slow
Heat hydraulic oil.

Cold hydraulic oil
Perform Hydraulic System Warm-Up Procedure . (Group 9025-25.)
Use the recommended oil.

Oil viscosity too heavy
See Hydraulic Oil . (Operator′s Manual.)
Slow engine speed Check engine speeds. See Engine Speed Check . (Group 9010-25.)
Check for air bubbles in oil. Tighten clamps and check hoses. See Check Hydraulic Oil Tank Level .
Air leak in pump suction line
(Operator′s Manual.)
Pilot circuit malfunction See Diagnose Pilot Circuit Malfunctions . (Group 9025-15.)
Restricted pump suction screen See Change Hydraulic Tank Oil, Clean Suction Screen . (Operator′s Manual.)
Worn pump Check pump flow rate. Perform Hydraulic Pump Flow Test . (Group 9025-25.)
System relief valve setting too low or Check system relief valve setting. See System Relief Valve Test and Adjustment . (Group 9025-25.)
malfunction Inspect system relief valve. See Hydraulic Pump Remove and Install . (Group 3360.)
Circuit relief valve setting too low or Check circuit relief valve setting. See Circuit Relief Valve Test and Adjustment . (Group 9025-25.)
malfunction Inspect circuit relief valve. See Control Valve Remove and Install . (Group 3360.)
Low pilot oil pressure Check pilot pressure regulating valve. See Solenoid Valve Manifold Repair . (Group 3360.)
Inspect variable relief valve. See Variable Relief Valve Test and Adjustment . (Group 9025-25.) See
Variable relief valve malfunction
Control Valve Remove and Install . (Group 3360.)
Inspect unload valve. See Unload Valve Test and Adjustment . (Group 9025-25.) See Control Valve
Unload valve malfunction
Remove and Install . (Group 3360.)
Control valve differential reducing valve Inspect control valve differential reducing valve. See Control Valve Differential Reducing Valve Test and
malfunction Adjustment . (Group 9025-25.) See Control Valve Remove and Install . (Group 3360.)
Hydraulic Oil
Low oil level Check oil level in hydraulic oil tank.
Overheats
Plugged oil cooler Test air flow through oil cooler. Perform Radiator Air Flow Test . (Group 9010-25.)
Oil viscosity too light Use recommended oil. See Hydraulic Oil . (Operator′s Manual.)
Return filter plugged Replace filter. See Hydraulic Oil Tank Repair . (Group 3360.)
System relief valve malfunction Test system relief valve. Perform System Relief Valve Test and Adjustment . (Group 9025-25.)
Oil cooler bypass valve stuck open Repair or replace bypass valve. See Hydraulic Oil Tank Repair . (Group 3360.)
Fan belt slipping Check for worn belt. Check tension adjuster. See Fan Belt Repair . (Group 0510.)
Pump stuck at maximum displacement Perform Hydraulic Pump Flow Test . (Group 9025-25.)
No Hydraulic
Functions
(Pilot No oil Check oil level in hydraulic oil tank.
Pressure
Actuated)
Pilot shut-off lever in LOCK position

Push shut-off lever to UNLOCK position (forward).
(rearward)
Pilot shut-off switch in left armrest Check pilot shut-off switch. See Floor Harness (W2) Component Location . (Group 9015-10.)
Pilot control shut-off switch bypass

Check that connector is in place and jumper wire is not broken.
connector in right armrest
Check pilot control shut-off solenoid valve. See Solenoid Test . (Group 9015-20.) Repair or replace pilot
Pilot control shut-off solenoid valve
control shut-off solenoid valve. See Solenoid Valve Manifold Repair . (Group 3360.)
Pilot control shut-off fuse Check fuse. See Fuse Specifications . (Group 9015-10.)
Pump drive failure Check pump drive coupling. See Dampener Drive (Flex Coupling) Repair . (Group 3360.)
Restricted pump suction screen Clean pump suction screen. See Change Hydraulic Tank Oil, Clean Suction Screen . (Operator′s Manual.)
System relief valve malfunction Test system relief valve. Perform System Relief Valve Test and Adjustment . (Group 9025-25.)
Inspect variable relief valve. See Variable Relief Valve Test and Adjustment . (Group 9025-25.) See
Control Valve Remove and Install . (Group 3360.)
Inspect unload valve. See Unload Valve Test and Adjustment . (Group 9025-25.) See Control Valve
Control valve differential reducing valve Inspect control valve differential reducing valve. See Control Valve Differential Reducing Valve Test and
malfunction Adjustment . (Group 9025-25.) See Control Valve Remove and Install . (Group 3360.)
Poor
Check pilot pressure at control valve. Perform Control Valve Spool Pilot Actuation Pressure Test . (Group
Combined Pilot controller
9025-25.)
Operation
Check pilot pressure regulating valve pressure setting. Perform Pilot Pressure Regulating Valve Test and
Pilot pressure regulating valve
Adjustment . (Group 9025-25.)
Load check valves in control valve Inspect valves. See Control Valve Remove and Install . (Group 3360.)

Diagnose Pilot Circuit Malfunctions
→NOTE:

All Functions
Pilot shut-off lever in LOCK
Cannot be Push shut-off lever to UNLOCK position (forward).
position (rearward)
Operated
Check pilot pressure regulating valve. Perform Pilot Pressure Regulating Valve
Pilot pressure regulating valve
Test and Adjustment . (Group 9025-25.) Inspect pilot pressure regulating valve.
stuck open
See Solenoid Valve Manifold Repair . (Group 3360.)
Remove and inspect pilot pump. See Hydraulic Pump Remove and Install .
Pilot pump failure
(Group 3360.)
Pilot shut-off switch in left Check pilot shut-off switch. See Floor Harness (W2) Component Location .
armrest (Group 9015-10.)
Pilot control shut-off switch

bypass connector in right Check that connector is in place and jumper wire is not broken.
armrest
Check pilot control shut-off solenoid valve. See Solenoid Test . (Group 9015-20.)
Pilot control shut-off solenoid
Repair or replace pilot control shut-off solenoid valve. See Solenoid Valve
valve
Manifold Repair . (Group 3360.)
Pilot control shut-off fuse Check fuse. See Fuse Specifications . (Group 9015-10.)
Check pump drive coupling. See Hydraulic Pump Remove and Install . (Group
Pump drive failure
3360.)
Clean pump suction screen. See Change Hydraulic Tank Oil, Clean Suction
Restricted pump suction screen
Screen . (Operator′s Manual.)
Test system relief valve. Perform System Relief Valve Test and Adjustment .
System relief valve malfunction
(Group 9025-25.)
Inspect variable relief valve. See Variable Relief Valve Test and Adjustment .
(Group 9025-25.) See Control Valve Remove and Install . (Group 3360.)
Inspect unload valve. See Unload Valve Test and Adjustment . (Group 9025-25.)
See Control Valve Remove and Install . (Group 3360.)
Inspect control valve differential reducing valve. See Control Valve Differential
Control valve differential
Reducing Valve Test and Adjustment . (Group 9025-25.) See Control Valve
reducing valve malfunction
Function Does
Not Stop When
Control valve spool stuck Check for sticking spool. See Control Valve Remove and Install . (Group 3360.)
Control Lever
Released
Pilot controller Check for sticking spool. See Pilot Controller Repair . (Group 3360.)
Some Functions
Cannot be
Inspect for leakage at pilot cap. See Control Valve Remove and Install . (Group
Operated, All Pilot cap
3360.)
Others Are
Normal
Pilot controller or hoses to Check pilot controller or pilot controller hoses. See Pilot Controller Repair .
function that cannot be operated (Group 3360.)
All Functions
Pilot filter plugged Replace pilot filter.
Slow
Check pilot pressure regulating valve pressure setting. Perform Pilot Pressure
Low pilot system pressure
Regulating Valve Test and Adjustment . (Group 9025-25.)
Inspect hoses and check pilot control shut-off solenoid valve. See Solenoid Test .
Restriction in pilot control shut-
(Group 9015-20.) Repair or replace pilot control shut-off solenoid valve. See
off solenoid valve
Solenoid Valve Manifold Repair . (Group 3360.)
Function Moves In Pilot control hoses connected

Check installation of hoses. See Control Valve Line Identification . (Group
Opposite incorrectly at pilot controller or
9025-15.) See Main Hydraulic System Component Location . (Group 9025-15.)
Direction control valve
Arm And Boom

Functions Do Not
Pilot controller pattern Check position of pilot controller pattern conversion valve. See Control Lever
Operate Or Do
conversion valve Pattern Conversion . (Operator′s Manual.)
Not Operate As
Expected

Diagnose Dig Circuit Malfunctions
→NOTE:

All Dig Functions
Hydraulic system malfunction See Diagnose Hydraulic System Malfunctions . (Group 9025-15.)
Slow or No Power
Check pump flow rate. Perform Hydraulic Pump Flow Test . (Group
Hydraulic pump malfunction
9025-25.)
Some Dig Functions

Slow (Not All)
Check dig functions for drift. Perform Cylinder Drift Test-Boom, Arm,
Control valve leakage
Bucket, and Blade . (Group 9025-25.)
Test system relief valve. Perform System Relief Valve Test and
Specific system relief valve stuck
Test cylinder for leakage. Perform Cylinder Drift Test-Boom, Arm,

Cylinder leakage
Test circuit relief valves. Perform Circuit Relief Valve Test and
Specific circuit relief valve stuck
Specific pressure compensator Disassemble pressure compensator in control valve. See Control Valve
malfunction Remove and Install . (Group 3360.)
Check for sticking spool. See Control Valve Remove and Install . (Group
Control valve spool stuck
3360.)
Make-up valve/circuit relief anti- Replace valve corresponding to cylinder and check if symptom
cavitation valve malfunction disappears.
Load Drifts Down

Test cylinder for leakage. Perform Cylinder Drift Test-Boom, Arm,
When Control Valve Cylinder leakage
Is In Neutral Position
Test circuit relief valves. Perform Circuit Relief Valve Test and
Specific circuit relief valve stuck
Boom reduced leakage valve for Inspect boom reduced leakage valve. See Control Valve Remove and
boom down inoperative Install . (Group 3360.)
Inspect control valve. See Control Valve Remove and Install . (Group
Control valve leakage
3360.)
Load Falls When

Control Valve is
Inspect lift check valve. See Control Valve Remove and Install . (Group
Actuated to Raise Lift check valve leakage
3360.)
Load With Engine
Running At Slow Idle
Pilot control hoses connected Check installation of hoses. See Control Valve Line Identification .
Function Moves In
incorrectly at pilot controller or (Group 9025-15.) See Main Hydraulic System Component Location .
Opposite Direction
control valve (Group 9025-15.)
Blade Function Slow Inspect rotary manifold. See Rotary Manifold Remove and Install .
Rotary manifold leakage
or Inoperative (Group 0260.)
Damaged hoses to blade cylinder Inspect and repair hoses.
3360.)
Auxiliary Function
One way/two way valve Check for proper position according to attachment used.
Inoperative

Diagnose Swing Circuit Malfunctions
→NOTE:

Swing Speed Slow In All other functions are slow. See Diagnose Pilot Circuit Malfunctions .
Low pilot system pressure
Both Directions (Group 9025-15.)
Swing motor crossover relief valve Test swing motor crossover relief valve pressure. Perform Swing Motor
leakage Crossover Relief Valve Test and Adjustment . (Group 9025-25.)
Inspect swing valve. See Control Valve Remove and Install . (Group
Swing valve leakage
3360.)
Test swing motor for leakage. Perform Swing Motor Leakage Test .
Swing motor leakage
(Group 9025-25.)
Swing park brake not releasing See Swing Motor and Park Brake Remove and Install . (Group 4360.)
Check pump flow rate. Perform Hydraulic Pump Flow Test . (Group
Worn pump
9025-25.)
3360.)
Swing Speed Slow or

Does Not Operate In Pilot circuit malfunction See Diagnose Pilot Circuit Malfunctions . (Group 9025-15.)
One Direction
Swing motor crossover relief valve Test swing motor crossover relief valves. Perform Swing Motor Crossover
malfunction Relief Valve Test and Adjustment . (Group 9025-25.)
Specific pressure compensator

Disassemble pressure compensator in control valve.
malfunction
3360.)
Upperstructure Drift
Inspect swing park brake. See Swing Motor and Park Brake Remove and
With Swing Valve In Swing park brake not holding
Install . (Group 4360.)
Neutral
Swing motor crossover relief valve Test swing motor crossover relief valves. Perform Swing Motor Crossover
leakage Relief Valve Test and Adjustment . (Group 9025-25.)
Test swing motor for leakage. Perform Swing Motor Leakage Test .
Swing motor leakage
(Group 9025-25.)
Swing Function Does

Not Operate
Swing park brake malfunction See Swing Motor and Park Brake Remove and Install . (Group 4360.)
Repair or replace swing motor or gearbox. See Swing Motor and Park
Mechanical failure of swing motor or
Brake Remove and Install . (Group 4360.) See Swing Gearbox Remove
gearbox.
and Install . (Group 4350.)
Specific pressure compensator

Disassemble pressure compensator in control valve.
malfunction
3360.)

Diagnose Propel System Malfunctions
→NOTE:

Propel Park Brake Check for leakage from propel motor drain hose. Perform Propel Motor Leakage Test . (Group
Oil not released from piston cavity
Does Not Apply 9025-25.)
Propel park brake piston and brake

Repair or replace park brake. See Propel Motor Disassemble and Assemble . (Group 0260.)
pack
Track Will Not Move

In One Direction
Inspect propel motor crossover relief valve. See Propel Motor Disassemble and Assemble .
Propel motor crossover relief valve
(Group 0260.)
Inspect counterbalance and crossover relief valve. See Propel Motor Disassemble and
Counterbalance valve spool stuck
Assemble . (Group 0260.)
Rotary manifold leakage Inspect rotary manifold. See Rotary Manifold Remove and Install . (Group 0260.)
Specific pressure compensator Disassemble pressure compensator in control valve. See Control Valve Remove and Install .
malfunction (Group 3360.)
Track Will Not Move

In Either Direction
Propel motor crossover relief valve Inspect propel motor crossover relief valve. See Propel Motor Disassemble and Assemble .
Propel pilot controller malfunction Inspect propel pilot controller. See Propel Pilot Controller Repair . (Group 3360.)
Inspect counterbalance and crossover relief valve. See Propel Motor Disassemble and
Assemble . (Group 0260.)
Mechanical failure of propel motor or Repair or replace propel motor or gearbox. See Propel Motor Disassemble and Assemble .
gearbox. (Group 0260.) See Propel Gearbox Remove and Install . (Group 0250.)
Excavator Mistracks
Adjust track sag. Perform Check Track Sag—Rubber Track . (Operator′s Manual.) Perform
at All Speeds in Track sag adjustment
Check Track Sag—Steel Track . (Operator′s Manual.)
Both Directions
Propel pilot controller malfunction Inspect propel pilot controller. See Propel Pilot Controller Repair . (Group 3360.)
Check tracking while descending a hill. If tracking is within specification when descending a
Leakage in motor hill, but not when on the level or going up hill, motor leakage is indicated. Perform Propel
Motor Leakage Test . (Group 9025-25.)
Flow combiner valve malfunction Check flow combiner valve operation. See Control Valve Remove and Install . (Group 3360.)
Rotary manifold leakage See Rotary Manifold Remove and Install . (Group 0260.)
Slow Propel Speed Adjust track sag. Perform Check Track Sag—Rubber Track . (Operator′s Manual.) Perform
Track sag adjustment
or Low Power Check Track Sag—Steel Track . (Operator′s Manual.)
Propel park brake not releasing Inspect propel park brake. See Propel Motor Disassemble and Assemble . (Group 0260.)
Propel motor Check propel motor for leakage. Perform Propel Motor Leakage Test . (Group 9025-25.)
Check pump flow rate. Perform Hydraulic Pump Flow Test . (Group 9025-25.) Check propel
Low pump flow
cycle times. See Cycle Times Check . (Group 9005-10.)
Specific pressure compensator Disassemble pressure compensator in control valve. See Control Valve Remove and Install .
Engine performance low Check engine performance. Perform Engine Compression Pressure Test . (Group 9010-25.)
Combined Propel
and Dig Functions Flow combiner valve malfunction Check flow combiner valve operation. See Control Valve Remove and Install . (Group 3360.)
Slow or No Power
Check valves Inspect check valve operation. See Control Valve Remove and Install . (Group 3360.)
Adjust track sag. Perform Check Track Sag—Rubber Track . (Operator′s Manual.) Perform
Propel Is “Jerky” Track sag too tight or too loose
Check Track Sag—Steel Track . (Operator′s Manual.)
No oil or low oil level in rollers Fill with recommended oil. See Hydraulic Oil . (Operator′s Manual.)
Inspect propel park brake piston. See Propel Motor Disassemble and Assemble . (Group
Propel park brake leakage
0260.)
Mechanical failure in propel motor or Repair or replace propel motor or gearbox. See Propel Motor Disassemble and Assemble .
gearbox (Group 0260.) See Propel Gearbox Remove and Install . (Group 0250.)
Deformed track frame Repair or replace components.
Excavator Will Not

Hold Back and Park
Brakes Engage and Inspect counterbalance and crossover relief valve. See Propel Motor Disassemble and
Disengage When Assemble . (Group 0260.)
Traveling Down an
Incline
Excavator Will Not

Turn Smoothly In Inspect counterbalance and crossover relief valve. See Propel Motor Disassemble and
One Direction or Assemble . (Group 0260.)
Park Brake Grabs

Pilot Controller to Pattern Conversion Valve Line Connection
Excavator Pattern Shown
LEGEND:
P Port P
T Port T
1 Port 1

2 Port 2
3 Port 3
4 Port 4
19 Pilot Controller Pattern Conversion Valve

Blade Hydraulic System Component Location
Blade Hydraulic System Component Location

LEGEND:
1 Hydraulic Pump
2 Pilot Pump
7 Pilot Filter
91 Blade Cylinder
101 Rotary Manifold

Propel Hydraulic System Line Identification
Propel Hydraulic System Line Identification

LEGEND:
1 Hydraulic Pump
2 Pilot Pump
7 Pilot Filter
101 Rotary Manifold

Main Hydraulic System Component Location
Main Hydraulic System Component Location

Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
LEGEND:
1 Hydraulic Pump
2 Pilot Pump
7 Pilot Filter
17 Oil Cooler
89 Boom Cylinder
90 Arm Cylinder
91 Blade Cylinder
101 Rotary Manifold
102 Bucket Cylinder

Group 25 - Tests
JT05800 Digital Thermometer Installation
LEGEND:
A Temperature Probe
B Cable
C JT05800 Digital Thermometer
JT05800 Digital Thermometer
[1] - Fasten temperature probe (A) to a bare metal hydraulic line using a tie band.
Digital Thermometer
JT05800
To measure the temperature of hydraulic oil.
[2] - Wrap temperature probe and line with a shop towel.

JT02156A Digital Pressure/Temperature Analyzer Installation
JT02156A Digital Pressure/Temperature Analyzer
LEGEND:
A Digital Pressure/Temperature Analyzer
B 3 400 kPa (35 bar) (500 psi) Transducer
34 000 kPa (350 bar) (5000 psi) Transducer
70 000 kPa (700 bar) (10,000 psi Transducer
JT02158 Digital Pressure/Temperature Analyzer
JT02159 20 ft Cable with Couplers
JT02161 500 psi Transducer
JT02162 5000 psi Transducer
JT05969 Thermo-Coupler
312883 Carry Case
JT02160 10,000 psi Transducer (Optional, Order Separately)
Use the digital pressure/temperature analyzer (A), and transducers (B) in place of analog gauges and a separate temperature
reader.
Digital Pressure/Temperature Analyzer
JT02156A
Kit contains the analyzer, cable, two transducers, thermo-coupler, and a carry case.
JT02158
To display digital readings for temperature and single, multiple or differential hydraulic oil pressure. Also reads vacuum when
used with 500 psi transducer.
20 ft Cable with Couplers
JT02159
To connect tranducers to digital pressure/temperature analyzer.
500 psi Transducer
JT02161

To measure hydraulic oil pressure and vacuum.
5000 psi Transducer
JT02162
To measure hydraulic oil pressure.
Thermo-Coupler
JT05969
To measure hydraulic oil temperature.
Carry Case
312883
Storage for analyzer and components.
10,000 psi Transducer (Optional, Order Separately)
JT02160
To measure hydraulic oil pressure.
Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is warmed and no
pressure applied, push sensor zero button for one second to set the true zero point.
When using for different pressures, turn selector to OFF for two seconds and then to the pressure range. Readings are
inaccurate if proper range for transducer is not used.

Hydraulic System Warm-Up Procedure

Specifications
SPECIFICATIONS
Hydraulic System
Hydraulic Oil Temperature 45—55 °C (110—130 °F)
IMPORTANT:
If machine temperature is below -18°C (0°F), start procedure with engine running at 1/2 speed. Failure to
do this could cause pump cavitation. Once oil temperature is above -18°C (0°F) the engine speed can be
increased to fast idle.
Below -18°C (0°F) an extended warm-up period may be necessary. Hydraulic function will move slowly and lubrication of parts
may not be adequate with cold oil. Do not attempt normal machine operation until hydraulic functions move at or close to
normal cycle times.
Operate functions slowly and avoid sudden movements until engine and hydraulic oils are thoroughly warmed. Operate a
function by moving it a short distance in each direction. Continue operating the function increasing the distance traveled in
each cycle until full stroke is reached.
For faster warm-up, restrict air flow through oil cooler using cardboard or other similar material. Use correct viscosity oil to
minimize warm-up period. Go to Hydraulic Oil . (Operator′s Manual)
[1] - Perform JT05800 Digital Thermometer Installation . (See procedure in this group.)
Digital Thermometer
JT05800
[2] -
CAUTION:
Avoid possible serious injury from machine movement during warm-up procedure. Clear the area of all
bystanders before doing the warm-up procedure.
Clear the area of all bystanders to allow for machine movement.
[3] - Start engine. Do not accelerate engine rapidly during warm up. Run engine at 1/2 speed for approximately 5 minutes
before operating any functions. Do not run engine at fast or slow idle.
[4] - Slowly turn upperstructure so boom is to the side.
[5] -

CAUTION:
Avoid possible serious injury from machine sliding backwards. Keep angle between boom and arm at
90—110°
Keeping the angle between boom and arm at 90—110°, lower boom to raise one track off the ground.
[6] - Operate propel function for approximately 5 minutes.
[7] - Once oil temperature is above -18°C (0°F), increase engine speed to fast idle.
[8] -
IMPORTANT:
Holding a function over relief for more than 10 seconds can cause damage from hot spots in the control
valve.
Operate the propel function (side with track off the ground). Also operate the bucket curl function over relief for 10 seconds
and then stop for 5 seconds. Repeat the cycle until oil is heated to specifications.
[9] - Stop periodically and operate all hydraulic functions to distribute the heated oil.
[10] - Continue procedure until oil temperature is within specifications.
Hydraulic System

Cylinder Drift Test—Boom, Arm, Bucket, and Blade
Machine Position
Specifications
SPECIFICATIONS
Bucket Load Weight 240 kg (530 lb) approximate
Arm Cylinder Length 50 mm (2.00 in.) approximate extension
Bucket Cylinder Length 50 mm (2.00 in.) approximate retraction
Boom Cylinder Height Bucket pivot pin at the same height as boom-to-main frame pin
Blade Height Top of Stroke
Engine Speed 0 rpm
Boom Cylinder Drift 5 mm (3/16 in.) maximum allowable for 5 minutes
Arm Cylinder Drift 8 mm (5/16 in.) maximum allowable for 5 minutes
Bucket Cylinder Drift 5 mm (3/16 in.) maximum allowable for 5 minutes
Blade Cylinder Drift 3 mm (1/8 in.) maximum allowable for 5 minutes with blade raised
Bottom of Bucket-to-Ground Drift 70 mm (2 3/4 in.) maximum allowable for 5 minutes
Blade Cylinder Drift 10 mm (3/8 in.) maximum allowable for 5 minutes with blade lowered
Essential Tools
ESSENTIAL TOOLS
Tape Measure
Procedure is used to check the leakage past the cylinder piston seals, control valve spools, circuit relief valves, and boom
reduced leakage valve.
[1] - Perform Hydraulic System Warm-Up Procedure . (See procedure in this group.)
[2] - Fill the bucket to get the specified bucket load with the standard arm and bucket.
Bucket Load Weight 240 kg (530 lb) approximate
[3] - Position arm cylinder so rod is extended the specified length from full retraction.

Arm Cylinder Length 50 mm (2.00 in.) approximate extension
[4] - Position bucket cylinder so rod is retracted the specified length from full extension.
Bucket Cylinder Length 50 mm (2.00 in.) approximate retraction
[5] - Position the boom cylinder so bucket pivot pin is at the same height as the boom-to-main frame pin.
Boom Cylinder Height Bucket pivot pin at the same height as boom-to-main frame pin
[6] - Raise blade to top of stroke.
Blade Height Top of Stroke
Engine Speed 0 rpm
[8] - After 5 minutes, measure the amount of movement for boom, arm, bucket, and blade cylinders and from bottom of
bucket to the ground.
Boom Cylinder Drift 5 mm (3/16 in.) maximum allowable for 5 minutes
Arm Cylinder Drift 8 mm (5/16 in.) maximum allowable for 5 minutes
Bucket Cylinder Drift 5 mm (3/16 in.) maximum allowable for 5 minutes
Blade Cylinder Drift 3 mm (1/8 in.) maximum allowable for 5 minutes with blade raised
Bottom of Bucket-to-Ground Drift 70 mm (2 3/4 in.) maximum allowable for 5 minutes
Tape Measure
To measure the amount of cylinder drift.
[9] - Start engine.
[10] - Lower blade completely to lift front of machine off ground.
[11] - Stop engine.
[12] - After 5 minutes, measure the amount of movement for blade cylinder.
Blade Cylinder Drift 10 mm (3/8 in.) maximum allowable for 5 minutes with blade lowered

Pilot Pressure Regulating Valve Test and Adjustment
Pilot Pressure Regulating Valve Test Connections
LEGEND:
1 Adjusting Screw
2 Nut
3 Hose

Specifications
SPECIFICATIONS
Pilot Pressure Regulating Valve Pressure 4270— 4410 kPa (42.7—44.1 bar) (620—640 psi) at fast idle
Nut-to-Pilot Pressure Regulating Valve Housing Torque 25 N˙m (18 lb-ft)
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
JT03523-13 (3/8 BSPP) Swivel Run Tee
JT03523-4 (7/16 M 37° x 3/8 MBSPP) Adapter
XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler
JT02161 Transducer 35 000 kPa (350 bar) (5000 psi)
Gauge 7000 kPa (70 bar) (1000 psi)
17 mm Combination Wrench
5 mm Hex Key Wrench
The purpose of this test is to ensure there is enough pilot pressure to operate all the pilot system functions and to adjust the
pressure as necessary.
[2] - Loosen cap to release the air pressure in hydraulic oil tank.
[3] - Disconnect hose (3) at pilot flow rate sensing manifold. Install tee fitting and male quick coupler. Connect the digital
pressure/temperature analyzer and transducer or a gauge.
Test Kit
JT03523
Used to test system pressures.
Swivel Run Tee
JT03523-13 (3/8 BSPP)
To test pilot pressure.
Adapter
JT03523-4 (7/16 M 37° x 3/8 MBSPP)
To adapt BSPP style fittings to 37° quick coupler.
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
To connect the transducer to an adapter.

JT02156A
To display pressure reading.
Transducer 35 000 kPa (350 bar) (5000 psi)
JT02161
To measure pressure setting of pilot pressure regulating valve.
[5] - Run machine at specifications.
[6] - Record pressure reading for pilot pressure regulating valve.
[7] - As necessary, loosen nut (2) on pilot pressure regulating valve. Turn adjusting screw (1) in to increase pressure or out to
decrease pressure.
Pilot Pressure Regulating Valve Pressure 4270— 4410 kPa (42.7—44.1 bar) (620—640 psi) at fast idle
Combination Wrench
17 mm
Loosen and tighten pilot pressure regulating valve nut.
Hex Key Wrench
5 mm
Adjust pilot pressure regulating valve.
[8] - Tighten nut (2).
Nut-to-Pilot Pressure Regulating Valve Housing Torque 25 N˙m (18 lb-ft)

Control Valve Spool Pilot Actuation Pressure Test
Valve Spool Actuating Pressure Test Connections
LEGEND:
1 Gauge
2 Adapter
3 Pilot Cap Fitting
4 Tee
5 Pilot Line
Specifications
SPECIFICATIONS
Control Valve Spool
Hydraulic Oil Temperature 45—55° C (110—130° F)
Engine Speed Control Lever Position Fast Idle
3920—4900 kPa (39.2—49.0 bar) (570—710 psi)

Pilot Actuation Pressure
at fast idle and full stroke
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
Procedure is used to check that there is enough pilot oil pressure to the pilot cap to completely shift the valve spools when pilot
controllers are actuated.

CAUTION:
[3] -
→NOTE:
Spool actuation pressure can be checked for each function by installing the tee and gauge in respective
pilot line, then actuating that function.
Disconnect a pilot line (5) at pilot cap fitting (3). Install tee (4), adapter (2), and male quick coupler. Install the digital pressure
and temperature analyzer and transducer or a gauge (1).
Test Kit
JT03523
Swivel Run Tee
JT03523-12 (1/4 BSPP)
Adapter
JT03523-4 (7/16 M 37° x 1/4 MBSPP)
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
To connect the transducer to the tee.
JT02156A
JT02161
To measure the valve spool actuating pilot pressure.
To measure the valve spool actuating pilot pressure.

[4] - Perform Hydraulic System Warm-Up Procedure . (Group 9025-05.)
[5] - Start and run engine at specification.
Engine Speed Control Lever Position Fast Idle
[6] -
→NOTE:
Spool actuation pressure can be checked for each function by installing a tee and gauge in respective
pilot line, then actuating that function.
Actuate the function being checked to full stroke.
If valve spool actuation pressure is not to specification, perform Pilot Pressure Regulating Valve Test and Adjustment . (Group
9025-25.)
Pilot Actuation Pressure 3920— 4900 kPa (39.2—49.0 bar) (570—710 psi) at fast idle and full stroke
If pilot system pressure is still not to specification, check pilot filter for restrictions, pilot pressure at the pilot shut-off valve, and
pilot controllers.

System Relief Valve Test and Adjustment

LEGEND:
1 Adapter
2 Quick Coupler
3 Gauge
System Relief Valve Test Connections
Specifications
SPECIFICATIONS
System Relief Valve Pressure 24 100—26 100 kPa (241—261 bar) (3500—3785 psi)
Per 1/4 Turn of Adjusting Screw Pressure Change 690 kPa (69 bar) (100 psi) approximate
17 mm Nut Torque 37 N˙m (27 lb-ft)
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
JT03523-5 Adapter
Gauge 35 000 kPa (350 bar) (5000 psi)
The system relief valve is used to limit the maximum pressure in the hydraulic system. The purpose of test is to check and
adjust system relief valve to specification to protect components from damage caused by excessive pressure.

[2] - Install adapter (1) and male quick coupler (2) to pump delivery port. Connect the digital pressure/temperature analyzer
and a transducer or a gauge (3).
Test Kit
JT03523
Test system pressure.
Adapter
JT03523-5
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
To connect transducer to adapter.
JT02156A
JT02161
To measure system pressure.
Gauge 35 000 kPa (350 bar) (5000 psi)
[3] - Raise and lower boom to pressurize hydraulic oil tank.
[5] - Run machine at specification.
[6] - Slowly actuate boom swing to full actuation. Record the pressure reading.
[7] -

System Relief Valve
LEGEND:
4 Adjusting Screw
5 Nut
Adjust the system relief valve pressure setting as needed.
System Relief Valve Pressure 24 100—26 100 kPa (241—261 bar) (3500—3785 psi)
[8] - Loosen the nut (5).
[9] - Turn adjusting screw (4) in to increase pressure or turn adjusting screw out to decrease pressure to specification.
Per 1/4 Turn of Adjusting Screw Pressure Change 690 kPa (69 bar) (100 psi) approximate
[10] - Hold adjusting screw and tighten 14 mm nut.
17 mm Nut Torque 37 N˙m (27 lb-ft)
[11] - Check the pressure setting again.
[12] - Perform Variable Relief Valve Test and Adjustment . (Group 9025-25)

Variable Relief Valve Test and Adjustment

LEGEND:
1 Gauge
2 Quick Coupler
3 Adapter
4 Tee Fitting
5 Hose
Variable Relief Valve Test Connections
Specifications
SPECIFICATIONS
Variable Relief Valve Pressure 1310—1450 kPa (190—210 psi) with arm in over relief
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
JT03523-2 Adapter
JT03523-12 Tee Fitting
Gauge 4 000 kPa (40 bar) (600 psi)
The purpose of this test is to test and adjust the variable relief valve to ensure that pilot oil to the pump delivery flow rate valve
and the pressure compensator valves is properly regulated.
The variable relief valve should be adjusted only after the system relief valve, pilot pressure regulating valve, variable
metering valve, differential reducing valve, unload valve, and control valve differential reducing valve are properly adjusted.
If machine operation is normal and the system relief valve is the only other valve adjusted, the variable relief valve can be
adjusted without checking the adjustment of the pilot pressure regulating valve, variable metering valve, differential reducing
valve, unload valve, or control valve differential reducing valve.
[1] - Disconnect hose (5) from fitting in hydraulic pump.
[2] - Install tee fitting (4), adapter (3), and quick coupler (2).
Test Kit
JT03523
Adapter

JT03523-2
Adapt BSPP fittings to JIC.
Tee Fitting
JT03523-12
Read machine pressures.
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
JT02156A
JT02161
[3] - Connect hose (5) and the digital pressure and temperature analyzer or a gauge (1).
[6] - Fully actuate arm-in function and hold. Record pressure reading.
Variable Relief Valve Pressure 1310—1450 kPa (190—210 psi) with arm in over relief
[7] -

Variable Relief Valve
Loosen nut (7).
[8] - Turn adjusting screw (6) in to decrease pressure or out to increase pressure.
[9] - Tighten nut.
[10] - Operate arm-in function and check pressure setting.

Variable Metering Valve Test and Adjustment
Variable Metering Valve Test Connections
LEGEND:
2 Nut
3 Adjusting Screw
4 Hose

Specifications
SPECIFICATIONS
Engine Speed Slow Idle
Variable Metering Valve Pressure 4550 kPa (660 psi) approximate
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
The purpose of this test is to ensure that the variable metering valve is functioning properly and is adjusted to specification.
[1] - Perform System Relief Valve Test and Adjustment . (Group 9025-25)
[2] - Perform Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25)
[3] - Disconnect hose (4) from pilot filter.
[4] - Install tee fitting and gauge or pressure transducer.
Test Kit
JT03523
Swivel Run Tee
JT03523-13 (3/8 BSPP)
Adapter
JT03523-4 (7/16 M 37° x 3/8 MBSPP)
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
To connect the transducer to an adapter.

JT02156A
JT02161
[7] - Record pressure reading.
Variable Metering Valve Pressure 4550 kPa (660 psi) approximate
[8] - Loosen nut (2).
[9] - Turn adjusting screw (3) in to increase pressure or out to decrease pressure.
[10] - Tighten nut.
[11] - Check pressure setting again.
[12] - Perform Differential Reducing Valve Test and Adjustment . (Group 9025-25)
[13] - Perform Unload Valve Test and Adjustment . (Group 9025-25)
[14] - Perform Control Valve Differential Reducing Valve Test and Adjustment . (Group 9025-25)

Differential Reducing Valve Test and Adjustment
Differential Reducing Valve Test Connection
LEGEND:
1 Adjusting Screw
2 Nut
4 Hose

Specifications
SPECIFICATIONS
Differential Reducing Valve Pressure 450 kPa (65 psi) approximate
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
JT03523-2 Adapter
The purpose of this test is to test the output of the differential reducing valve and adjust it to specification.
[3] - Perform Variable Metering Valve Test and Adjustment . (Group 9025-25)
[4] - Install gauge or pressure transducer using tee fitting and adapter.
Test Kit
JT03523
Adapter
JT03523-2
Tee Fitting
JT03523-12
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)

JT02156A
JT02161
[5] - Perform Hydraulic System Warm-Up Procedure . (Group 9025-25)
Differential Reducing Valve Pressure 450 kPa (65 psi) approximate
[8] - Loosen nut (2).
[10] - Tighten nut.

Unload Valve Test and Adjustment

LEGEND:
1 Adapter
2 Quick Coupler
3 Gauge
System Relief Valve Test Connections
Specifications
SPECIFICATIONS
Unload Valve Pressure 1310 kPa (190 psi) approximate
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
JT03523-5 Adapter
Gauge 35 000 kPa (350 bar) (5000 psi)
The purpose of this test is to check the function of the unload valve and to adjust it to specification using pump discharge
pressure as an indication of unload valve adjustment.

[5] - Remove plug from pump discharge fitting and install adapter (1), quick coupler (2), and a gauge (3) or transducer.
Test Kit
JT03523
Adapter
JT03523-5
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
JT02156A
JT02161
Gauge 35 000 kPa (350 bar) (5000 psi)
Unload Valve Pressure 1310 kPa (190 psi) approximate
[9] -

Unload Valve
LEGEND:
4 Unload Valve
5 Nut
6 Adjusting Screw
Loosen nut (5).
[11] - Tighten nut.


LEGEND:
1 Gauge
2 Quick Coupler
3 Adapter
4 Tee Fitting
5 Hose
Control Valve Differential Reducing Valve Test

Connections
Specifications
SPECIFICATIONS
Control Valve Differential Reducing Valve Pressure 2690 kPa (390 psi) approximate
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
JT03523-2 Adapter
The purpose of this test is to check the output of the control valve differential reducing valve and adjust it to specification.
[6] - Disconnect hose (5) from fitting in hydraulic pump.
[7] - Install tee fitting (4), adapter (3), and quick coupler (2).

Test Kit
JT03523
Adapter
JT03523-2
Tee Fitting
JT03523-12
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
JT02156A
JT02161
[8] - Connect hose (5) and the digital pressure and temperature analyzer or a gauge (1).
Control Valve Differential Reducing Valve Pressure 2690 kPa (390 psi) approximate
[12] -

LEGEND:
6 Adjusting Screw
7 Nut
Loosen nut (7).
[13] - Turn adjusting screw (6) in to decrease pressure or out to increase pressure.
[14] - Tighten nut.
[15] - Check pressure setting.

Circuit Relief Valve Test and Adjustment

LEGEND:
1 Adapter
2 Quick Coupler
3 Gauge
Circuit Relief Valve Test Connections
Specifications
SPECIFICATIONS
Engine Speed Slow idle
Boom Up Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Boom Down Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Arm In Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Arm Out Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Bucket Curl Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Bucket Dump Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Blade (Cylinder Rod End) Pressure 11 800—12 800 kPa (118—128 bar) (1700—1845 psi)
Auxiliary Pressure Auxiliary circuit relief valves must be adjusted to the manufacturer′s specification for the attachment being used.
Circuit Relief Valve Pressure Change 2 700 kPa (27.0 bar) (390 psi) approximate per 1/4
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
JT03523-5 Adapter

Gauge 35 000 kPa (350 bar) (5000 psi)
The purpose of circuit relief valves is to relieve high pressure spikes caused by external forces when functions are in neutral.
The valves are checked and adjusted to specification to protect components from damage.
[2] - Install a tachometer. See JT05801 Clamp-On Electronic Tachometer Installation . (Group 9010-25.)
[3] - Loosen cap to release the air pressure in the hydraulic oil tank.
[4] - Install adapter (1) and male quick coupler (2) to test port in pump outlet line. Connect the digital pressure/temperature
analyzer and transducer or gauge (3)
Test Kit
JT03523
Adapter
JT03523-5
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
JT02156A
JT02161
Gauge 35 000 kPa (350 bar) (5000 psi)
[5] - Heat hydraulic oil to the specified temperature. Perform Hydraulic System Warm-Up Procedure . (Group 9025-25.)
[6] -

System and Circuit Relief Valve Locations
LEGEND:
39 Boom Up Circuit Relief Valve
41 Boom Down Circuit Relief Valve
47 Arm Out Circuit Relief Valve
49 Arm In Circuit Relief Valve
54 Bucket Curl Circuit Relief Valve
56 Bucket Dump Circuit Relief Valve
79 Blade Circuit Relief Valve (Blade Cylinder Rod End)
105 Auxiliary Circuit Relief Valve
106 Auxiliary Circuit Relief Valve
→NOTE:
The pressure setting for circuit relief valves are normally higher than the system relief valve (28). The
pressure setting for system relief valve must be adjusted to a higher pressure setting to check the circuit
relief valve pressure settings.
Turn system relief valve adjusting screw in 1/4 turn to increase the system pressure setting.
To loosen and tighten nut on system and circuit relief valve adjusting screw.
6 mm Hex Key Wrench
To turn adjusting screw on system and circuit relief valve.


[8] - Actuate the function over relief for circuit relief valve (39, 41, 47, 49, 54, 56, 79, 105, and 106) being checked. Record
pressure reading.
Boom Up Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Boom Down Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Arm In Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Arm Out Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Bucket Curl Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Bucket Dump Pressure 26 500—27 500 kPa (265—275 bar) (3840—3980 psi)
Blade (Cylinder Rod End) Pressure 11 800—12 800 kPa (118—128 bar) (1700—1845 psi)
Auxiliary Pressure Auxiliary circuit relief valves must be adjusted to the manufacturer′s specification for the attachment being used.
[9] -
→NOTE:
Auxiliary circuit relief valves must be adjusted to the manufacturer′s specification for the attachment
being used.
LEGEND:
1 Nut
2 Adjusting Screw
Circuit Relief Valve Adjustment
Adjust the circuit relief valve as needed. Loosen nut (1). Turn adjusting screw (2) IN to increase pressure setting; turn adjusting
screw OUT to decrease pressure setting.
Circuit Relief Valve Pressure 270 kPa (27 bar) (390 psi) approximate per 1/4
[10] - Hold adjusting screw and tighten nut.
[11] - Check pressures again
[12] - Turn the adjusting screw for system relief valve out to original setting. Perform System Relief Valve Test and Adjustment
. (Group 9025-25.)

Swing Motor Crossover Relief Valve Test and Adjustment

LEGEND:
1 Adapter
2 Quick Coupler
3 Gauge
Swing Motor Crossover Relief Valve Test Connection
Specifications
SPECIFICATIONS
Swing Motor Crossover Relief Valve
Engine Speed 1700 rpm
Swing Crossover Relief Valve Pressure 19 120—20 100 kPa (191—210 bar) (2770—2920 psi)
Swing Crossover Relief Valve Pressure Adjustment 2450 kPa (24.5 bar) (360 psi) approximate per 1/4 turn
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
JT03523-5 Adapter
Gauge 35 000 kPa (350 bar) (5000 psi)
6 mm Hex Wrench
The purpose of swing crossover relief valves is to limit pressure in the swing circuit, to relieve high pressure spikes caused by

starting and stopping the swing function and to relieve pressure spikes caused by external forces when functions are in neutral
. The valves are checked and adjusted to specification to protect components from damage.
JT05801
[4] - Install adapter (1) and male quick coupler (2). Connect the digital pressure/temperature analyzer and transducer or gauge
(3).
Test Kit
JT03523
Adapter
JT03523-5
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
JT02156A
JT02161
Gauge 35 000 kPa (350 bar) (5000 psi)


Engine Speed 1700 rpm
[8] - Operate the swing function at stall.
[9] - Record the pressure reading.
Repeat procedure for the opposite direction. Record the pressure reading.
[10] -
LEGEND:
1 Right Swing Crossover Relief Valve
2 Left Swing Crossover Relief Valve
Swing Motor Crossover Relief Valves
Adjust the right and left swing crossover relief valves (1 or 2) as needed.
Swing Crossover Relief Valve Pressure 19 120—20 100 kPa (191—210 bar) (2770—2920 psi)
[11] -
LEGEND:
3 Nut
4 Adjusting Screw
Nut and Adjusting Screw
Loosen nut (3). Turn adjusting screw (4) in to increase pressure setting; turn screw out to decrease pressure setting.

Swing Crossover Relief Valve Adjustment Pressure 2450 kPa (24.5 bar) (360 psi) approximate per 1/4 turn
To loosen and tighten nut on swing crossover relief valve adjusting screw.
6 mm Hex Wrench
To adjust crossover relief valve.
Hold adjusting screw and tighten nut.

Propel Motor Crossover Relief Valve Test and Adjustment

LEGEND:
1 Adapter
2 Quick Coupler
3 Gauge
Propel Motor Crossover Relief Valve Test Connection
Specifications
SPECIFICATIONS
Propel Motor Crossover Relief Valve
Propel Crossover Relief Valve Pressure 24 030—26 000kPa (240—260 bar) (3500—3770 psi)
Essential Tools
ESSENTIAL TOOLS
JT03523 Test Kit
JT03523-5 Adapter
Gauge 35 000 kPa (350 bar) (5000 psi)
The purpose of propel crossover relief valves is to relieve high pressure spikes caused by starting and stopping the propel
function and to relieve pressure spikes caused by external forces while propelling. The valves set pressure are checked to
specification to protect components from damage.

JT05801
[4] - Install adapter (1) and male quick coupler (2). Connect the digital pressure/temperature analyzer and transducer or gauge
(3).
Test Kit
JT03523
Adapter
JT03523-5
Male Quick Coupler
XPD34BTX (1/8 x 7/16-20 F 37°)
JT02156A
JT02161
Gauge 35 000 kPa (350 bar) (5000 psi)

[8] - Turn the system relief valve in 1/2 turn to increase system pressure. See System Relief Valve Test and Adjustment .
(Group 9025-25.)
[9] - Operate the propel function for valve (1 or 2) being checked at stall.
[10] - Record the pressure reading.
[11] -
LEGEND:
1 Forward Propel Crossover Relief Valve
2 Reverse Propel Crossover Relief Valve
Propel Motor Crossover Relief Valves
Replace or adjust propel crossover relief valves (1 or 2) as needed.
Propel Crossover Relief Valve Pressure 24 030—26 000 kPa (240—260 bar) (3500—3770 psi)
[12] - Turn the adjusting screw for system relief valve out to original setting. Perform System Relief Valve Test and Adjustment
. (Group 9025-25.)

Hydraulic Pump Regulator Test and Adjustment (Engine Pulldown)

LEGEND:
1 Adjustment Screw
2 Nut
Hydraulic Pump Regulator Adjustment Screw
IMPORTANT:
The adjustment to load the engine to rated speed so all available engine horsepower is used is made at
the factory. Adjustment is not recommended except after a repair that requires the replacement of
regulator components. Adjusting the flow rate adjusting screw may not change the engine pulldown
speed.
Before doing the adjustment, proper engine performance with number two diesel fuel must be verified.
Also the engine fast idle speed with no load must be adjusted to specifications.
[2] - Perform JT05801 Clamp- On Electronic Tachometer installation. (Group 9010-25)
[3] - Perform Engine Speed Check and adjust engine speeds to specification. (Group 9010-25)
[4] - Run the engine at fast idle.
[5] - Actuate boom up over relief.
[6] - Record the engine speed.
[7] - If engine speed is not to specification, loosen nut (2) and turn the adjustment screw (1) in to decrease engine speed or
out to increase engine speed.
Combination Wrench
13 mm
Adjust engine pulldown.
Hex Key Wrench
4 mm
Adjust engine pulldown.

Engine Speed 2200—2300 rpm with boom up over relief
[8] - Tighten nut (2).
Adjustment Screw Nut Torque 12 N˙m (96 lb-in)
[9] - Check the engine speed again.

Hydraulic Pump Flow Test
Hydraulic Pump Flow Test Connections
LEGEND:
1 Hose From Flow Meter
2 Fitting
3 Fitting
4 Hose To Flow Meter
5 Hydraulic Pump-to-Control Valve Hose
6 Fitting
7 Fitting
8 Pump Discharge Fitting
9 Elbow Fitting
10 Plug
11 Hose (PA)
12 Cap
Specifications
SPECIFICATIONS
Hydraulic Pump Pressure 13 790 kPa (2000 psi) to heat oil
Hydraulic Oil Temperature 50 ± 5°C (125 ± 10°F)
Engine Speed 2000 ± 10 rpm
Hydraulic Pump Flow Rate 71.5 L/min (18.9 gpm) at 13 790 kPa (2000 psi) typical new
Hydraulic Pump Flow Rate 57.2 L/min (15.1 gpm) at 13 790 kPa (2000 psi) minimum acceptable
Essential Tools
ESSENTIAL TOOLS
Parker number 12F63MX Fitting (2 Used)
Parker number 12G63P4 Fitting
Parker number 12G3P4 Fitting

Flow Meter
Test is used to determine pump condition and should be performed only if a comparison of actual machine cycle times to
specified cycle times indicates low pump flow.
[2] - Disconnect the hydraulic pump-to-control valve hose (5) from the hydraulic pump discharge fitting (8).
Connect hose (4) from flow meter inlet to pump discharge fitting (8) using fittings (6 and 7).
Fitting
Parker number 12F63MX
To adapt excavator fittings to flow meter.
Fitting
Parker number 12G63P4
To adapt excavator fittings to flow meter.
Flow Meter
To measure the pump flow rate.
[3] - Connect the return hose (1) from flow meter to the hydraulic pump-to-control valve hose (5) using fittings (2 and 3).
Fitting
Parker number 12G3P4
To adapt flow meter to excavator fittings.
Fitting
Parker number 12F63MX
To adapt flow meter to excavator fittings.
[4] - Disconnect hose (10) from elbow fitting (8) and install cap (11) and plug (9).
[5] - Perform JT05801 Clamp- On Electronic Tachometer installation. (Group 9010-25)
[6] - Check that the flow meter loading valve is open.
[7] - Heat the hydraulic oil to the specified temperature by closing flow meter loading valve to increase pressure to
specification.
Digital Thermometer
JT05800


Hydraulic Pump Pressure 13 790 kPa (2000 psi) to heat oil
Hydraulic Oil Temperature 50 ± 5°C (125 ± 10°F)
[8] - Operate the machine at specification.
Engine Speed 2000 ± 10 rpm
[9] - Adjust the flow meter loading valve to obtain the specified test pressures. Adjust engine speed to specified rpm. Record
pump flow at each pressure.
If pump flow is low, repair or replace pump.

Swing Motor Leakage Test
Swing Motor Drain Hose and Make-Up Oil Hose
LEGEND:
1 Make-Up Oil Hose
2 Drain Hose
Specifications
SPECIFICATIONS
Swing Motor
Swing Motor Leakage 0.5 or less L/min (17.0 or less oz/min) typical new while swinging
Essential Tools
ESSENTIAL TOOLS
JT03023 (9/16-18 F 37°) (Parker No. 06CP-6) Cap (2 used)
JT03391 (9/16-18 M 37°) (Parker No. 03CP-6) Plug (2 used)
Calibrated Container
Purpose of test is to check the efficiency of swing motor. Leakage can occur between the cylinder block and valve plate, and
the slippers and swash plate when parts are worn or damaged.
Swing Motor
Loosen hydraulic oil tank cap to release the air pressure in hydraulic oil tank.

[3] - Disconnect drain hose (2) at the tee on the rotary manifold. Install a cap on rotary manifold port.
Place opposite end of drain hose (1) in a calibrated container.
Cap
JT03023 (9/16-18 F 37°) (Parker No. 06CP-6)
To close drain hose fitting at rotary manifold to minimize oil loss during test.
To measure the amount of leakage.
[4] - Disconnect the make-up oil hose at the swing motor. Install cap and plug on disconnected hose and swing motor port.
Cap
JT03023 (9/16-18 F 37°) (Parker No. 06CP-6)
To close make-up oil fitting on swing motor to minimize oil loss during test.
Plug
JT03391 (9/16-18 M 37°) (Parker No. 03CP-6)
To close make-up oil hose to minimize oil loss during test.
[5] -
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.
Raise and lower boom to pressurize hydraulic tank.
[6] - Operate the machine at specifications.
Swing Motor
Engine Engine Speed Fast Idle
[7] - Operate swing function for one minute. Record the amount of leakage. Repeat for swing in opposite direction. Record the
amount of leakage. Compare amount of leakage to specifications.
Swing Motor Leakage 0.5 or less L/min (17.0 oz/min or less gpm)
If leakage is greater than specified, see Swing Motor and Park Brake Remove and Install . (Group 4360.)
[8] - Connect drain hose and make-up oil hose to swing motor.

Propel Motor Leakage Test

LEGEND:
1 Drain Hose
Propel Motor Drain Hose
Specifications
SPECIFICATIONS
Propel Motor
Propel Speed Slow Speed
Propel Motor Leakage 0.7 L/min (23.0 oz/min) acceptable while propelling with track raised
Essential Tools
ESSENTIAL TOOLS
JT03391 (9/16-18 M 37°) (Parker No. 03CP-6) Plug
Propel Motor
[3] - Loosen cap (1) to release the air pressure in hydraulic oil tank.
[4] - Disconnect the drain hose (1) at propel motor and plug hose.
Install a test hose to propel motor drain port. Place opposite end of test hose in a calibrated container.
To measure the amount of leakage.
[5] - Raise track off the ground for side being checked.


HEATER (g) by Belgreen v2.0
Propel Speed Slow Speed
[7] - For propel motor being checked, actuate propel forward function at full speed for one minute. Record amount of leakage.
Repeat procedure for reverse.
[8] - Compare amount of leakage to specifications. If leakage is more than specification, repair or replace motor. See Propel
Motor Disassemble and Assemble . (Group 0260.)
Propel Motor
Propel Motor Leakage 0.7 L/min (23.0 oz/min) acceptable while propelling with track raised

Section 9031 - HEATER

Table of contents
Heater System ...................................................................................................................................... 1
Diagnose Heater System Malfunction ................................................................................................... 2
Heater Component Location Diagram .................................................................................................. 3
Group 25 - Tests ....................................................................................................................................... 5
Visual Inspection of Components ......................................................................................................... 5

Section 9031 - HEATER Group 15: Diagnostic Information

Heater System
Engine coolant is forced through the heater system by the engine water pump. The coolant passes through the heater core
then back to the coolant passages in the engine.
As the time that the engine has been operating increases, the coolant absorbs heat from the engine and increases in
temperature. This heat is then transferred into the cab through the heater core. The blower fan moves air across the fins of the
heater core, increasing the amount of heat transferred to the cab.
The speed of the blower fan is controlled by the blower speed switch. The H position applies voltage across the blower motor to
run it at HIGH speed. The L position applies voltage across a resistor and the blower motor, which reduces the amount of
current applied to the blower motor. This setting runs the blower motor at LOW speed. The O position removes voltage from
the blower motor, turning the blower motor off.


Diagnose Heater System Malfunction
→NOTE:
Perform Heater System Checks prior to diagnosis and component tests. (Group 9031-25.) These
conditions may affect diagnostic and test results.

Heater System Air conditioner and heater 15 amp
Replace fuse. See Fuse Specifications. (Group 9015-10.)
Does Not Operate fuse (F7)
Check Cab Harness wiring. See System Functional Schematic and Master
Wiring harness
Legend. (Group 9015-10.)
Replace heater blower motor switch. See Heater Component Location

Heater blower motor switch failed
Heater Does Not

Heater hose kinked, pinched or Re-route or re-index hoses. Replace collapsed hoses. See Heater Component
Warm Interior of
collapsed Location Diagram . (Group 9031-15.)
Cab
Clean heater fins. See Heater Component Location Diagram . (Group

Heater core plugged
9031-15.)
Heater fan motor failed or operating Check fan motor.

too slowly See Heater Component Location Diagram . (Group 9031-15.)
Open heater valve. See Heater Component Location Diagram . (Group

Heater valve is closed
9031-15.)

Heater Component Location Diagram
Heater Component Location

Section 9031 - HEATER Group 25: Tests
LEGEND:
1 Heater Core
2 Low Speed Resistor
3 Floor Harness to Heater Harness 2 Pin Connector (X17)
4 Heater Blower Motor (M5)
5 Heater Blower Motor Switch (S4)
6 Heater Assembly
7 Coolant Flow Control Valve

Group 25 - Tests
Heater System Checks
Visual Inspection of Components
( 1 ) Lines and Hoses Check
Action:
[1] - Inspect all hoses. See Heater Component Location Diagram . (Group 9031-15.)
[2] - Are all hoses straight, NOT kinked or worn from rubbing on other machine parts or "weather checked"?
[3] - Are hose connections clean, NOT showing signs of leakage, such as oil or dust accumulation at fittings?
[4] - All hose 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.
Result:
YES:Check complete. Go on to next check.
NO:Reposition hoses and tighten or replace clamps. Tighten fittings. Replace hoses as required. See Heater Component
Location Diagram . (Group 9031-15.)
( 2 ) Heater/Evaporator Core Check
Action:
[1] - Inspect core. See Heater Component Location Diagram . (Group 9031-15.)
[2] - Are fins straight?
[3] - Is core free of dirt and debris?
[4] - Are heater core drain tubes free of obstructions?
Result:
YES:Check complete. Go on to next check.
NO:Repair or clean heater core and drain tubes.
( 3 ) Cab Door and Window Seals Check
Action:
[1] - Open and close door and windows. Inspect seals.
[2] - Do door and windows contact seals evenly?
[3] - Are seals in position and in good condition?

Result:
YES:Checks complete.
NO:Adjust door and windows to close against seals properly. Replace seals as necessary. See Windowpane and Molding Repair
. (Group 1810.)

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50C ZTS Excavator

OPERATION AND TEST MANUAL

Compact models 50CZTS

TM2056 22OCT14 (ENGLISH)

For complete service information also see:

John Deere Construction and Forestry

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<- Go to Global Table of contents 50C ZTS Excavator Diagnostic

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<- Go to Global Table of contents 50C ZTS Excavator Diagnostic

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Technical Information Feedback Form

Technical Manual Fax

SEND TO: John Deere Dubuque Works

18600 South John Deere Road

Attn: Publications, Dept. 324

FAX NUMBER: 1-563-589-5800 (USA)

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Section 9000 - GENERAL INFORMATION

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Safety Alert Symbols

Safety Alert Symbols

Follow Safety Instructions

Follow Safety Instructions

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Operate Only If Qualiﬁed

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Wear Protective Equipment

Avoid Unauthorized Machine Modiﬁcations

Add Cab Guarding for Special Uses

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Inspect machine carefully each day by walking around it before starting.

Stay Clear of Moving Parts

Stay Clear Of Moving Parts

Entanglements in moving parts can cause serious injury.

Avoid High-Pressure Oils

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Avoid High Pressure Oils

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Beware Of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

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Handle Fuel Safely

Clean Machine Regularly

Carry A Fire Extinguisher

Prevent Battery Explosions

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Handle Chemical Products Safely

Handle Chemical Products Safely

Dispose of Waste Properly

Dispose Of Waste Properly

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Prepare for Emergencies

First Aid Kit

Be prepared if an emergency occurs or a ﬁre starts.

Keep a ﬁrst aid kit and ﬁre extinguisher handy.

Use Steps and Handholds Correctly

Use Handholds and Steps

Start Only From Operator′s Seat

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Operate Only From Operators Seat