1_690elc test manual tm1508

690E LCExcavator

Operation and Tests

TECHNICAL MANUAL690E LC Excavator Operation and

Tests

TM1508 12JUL05 (ENGLISH)

For complete service information also see:

690E LC Excavator Repair . . . . . . . . . . . . . . TM15096068 Engine (Serial No. —559602) . . . . . . . . CTM86068 Engine (Serial No. 559603— ) . . . . . . . CTM104Alternators and Starting Motors . . . . . . . . . . CTM77Undercarriage Appraisal Manual . . . . . . . . . SP326

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.

Introduction

DX,TMIFC –19–29SEP98–1/1

Foreword

This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.

Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.

Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repairthe components. Operation and tests sections help youidentify the majority of routine failures quickly.

Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable 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 specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and repair.

Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic type of failures and their causes.

TM1508 (12JUL05) 690E LC Excavator Operation and Tests080805

PN=2

Introduction

TX,TM,FAX –19–03JUL01–1/1

Technical Information Feedback Form

We need your help to continually improve our technicalpublications. Please copy this page and FAX or mail yourcomments, ideas and improvements.

SEND TO: John Deere Dubuque WorksP.O. Box 538Attn: Publications Supervisor, Dept. 303Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

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PN=3

Introduction


PN=4

Contents9000

SECTION 9000—General InformationGroup 01—SafetyGroup 02—General SpecificationsGroup 03—Torque ValuesGroup 04—Fuels And Lubricants

9005

SECTION 9005—Operational Checkout ProcedureGroup 10—Operational Checkout Procedure

SECTION 9010—EngineGroup 05—Theory Of OperationGroup 10—System Operational ChecksGroup 15—Diagnostic InformationGroup 20—AdjustmentsGroup 25—Tests

9010

SECTION 9015—Electrical SystemGroup 05—System InformationGroup 10—System DiagramsGroup 15—Sub-System DiagnosticsGroup 20—References

SECTION 9020—Power TrainGroup 05—Theory Of OperationGroup 10—System Operational ChecksGroup 15—Diagnostic InformationGroup 20—Adjustments

9015

Group 25—Tests

SECTION 9025—Hydraulic SystemGroup 05—Theory Of OperationGroup 10—System Operational ChecksGroup 15—Diagnostic InformationGroup 20—AdjustmentsGroup 25—Tests

SECTION 9031—Air Conditioning SystemGroup 05—Theory Of Operation

9020

Group 10—System Operational ChecksGroup 15—Diagnostic InformationGroup 20—AdjustmentsGroup 25—Tests

All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.

9025

COPYRIGHT 2000DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 1997,1995,1993,1992,1991

9031

INDX

TM1508 (12JUL05) i 690E LC Excavator Operation and Tests080805

PN=1

Contents

9000

9005

9010

9015

9020

9025

9031

INDX

TM1508 (12JUL05) ii 690E LC Excavator Operation and Tests080805

PN=2

9000

Section 9000General Information

Contents

Page

Group 01—Safety . . . . . . . . . . . . . . . . . . . .9000-01-1

Group 02—General Specifications690E LC . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-1690E LC Long Front Specifications . . . . . . . .9000-02-3690E LC And 690E LC Long Front Drain And

Refill Capacities. . . . . . . . . . . . . . . . . . . . .9000-02-4

Group 03—Torque ValuesUnified Inch Bolt and Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-1Metric Bolt and Screw Torque Values . . . . . .9000-03-2Additional Metric Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-3Service Recommendations for O-Ring

Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .9000-03-4Service Recommendations For Flat Face

O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .9000-03-6Service Recommendations for 37° Flare

and 30° Cone Seat Connectors . . . . . . . . .9000-03-7Service Recommendations For Flared

Connections—Straight or TaperedThreads . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-8

Service Recommendations For InchSeries Four Bolt Flange Fittings. . . . . . . . .9000-03-9

Service Recommendations for MetricSeries Four Bolt Flange Fitting . . . . . . . .9000-03-10

Group 04—Fuels And LubricantsDiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1Low Sulfur Diesel Fuel Conditioner . . . . . . . .9000-04-1Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . .9000-04-2Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-3Propel Gearbox Oil . . . . . . . . . . . . . . . . . . . .9000-04-4Track Roller, Front Idler, And Carrier

Roller Oil . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-4Track Adjuster, Working Tool Pivot, Swing

Bearing, And Swing Bearing GearGrease. . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-5

Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-5Lubricant Storage . . . . . . . . . . . . . . . . . . . . .9000-04-6Alternative and Synthetic Lubricants . . . . . . .9000-04-6Mixing of Lubricants . . . . . . . . . . . . . . . . . . .9000-04-7

TM1508 (12JUL05) 9000-1 690E LC Excavator Operation and Tests080805

PN=1

Contents

9000


PN=2

Group 01Safety

9000011

TX,05,FF1611 –19–14JUN90–1/1

Follow Safe Procedures

TS

231

–19–

07O

CT

88

Unsafe work practices are dangerous. Understand serviceprocedure before doing work; do not attempt shortcuts.

DX,FIRE2 –19–03MAR93–1/1

Prepare for Emergencies

TS

291

–UN

–23A

UG

88

Be prepared if 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.

TM1508 (12JUL05) 9000-01-1 690E LC Excavator Operation and Tests080805

PN=9

Safety

900001

2

DX,POISON –19–21APR93–1/1

Prevent Acid Burns

TS

203

–UN

–23A

UG

88

Sulfuric acid in battery electrolyte is poisonous. It is strongenough to burn skin, eat holes in clothing, and causeblindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize the acid.3. Flush your eyes with water for 15—30 minutes. Get

medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.2. Drink large amounts of water or milk, but do not

exceed 2 L (2 quarts).3. Get medical attention immediately.


PN=10

Safety

9000013

DX,MSDS,NA –19–03MAR93–1/1

Handle Chemical Products Safely

TS

1132

–UN

–26N

OV

90

Direct exposure to hazardous chemicals can causeserious injury. Potentially hazardous chemicals used withJohn Deere equipment include such items as lubricants,coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specificdetails on chemical products: physical and health hazards,safety procedures, and emergency response techniques.

Check the MSDS before you start any job using ahazardous chemical. That way you will know exactly whatthe risks are and how to do the job safely. Then followprocedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemicalproducts used with John Deere equipment.)

TX,05,FF1622 –19–14JUN90–1/2

Handle Fluids Safely—Avoid Fires

TS

202

–UN

–23A

UG

88

Handle fuel with care; it is highly flammable. Do not refuelthe machine while smoking or when near open flame orsparks. Always stop engine before refueling machine. Fillfuel tank outdoors.

TX,05,FF1622 –19–14JUN90–2/2

TS

227

–UN

–23A

UG

88

Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burnspontaneously.


PN=11

Safety

900001

4

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Fluids

X98

11–U

N–2

3AU

G88

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.

TX,05,RR,566 –19–23JUL91–1/1

Warn Others of Service Work

T72

73A

P–U

N–0

8JU

N90

Unexpected machine movement can cause serious injury.

Before performing any work on the machine, attach a “DoNot Operate” tag on the right control lever.


PN=12

Safety

9000015

DX,LOWER –19–24FEB00–1/1

Support Machine Properly

TS

229

–UN

–23A

UG

88

Always lower the attachment or implement to the groundbefore you work on the machine. If the work requires thatthe machine or attachment be lifted, provide securesupport for them. If left in a raised position, hydraulicallysupported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles,or props that may crumble under continuous load. Do notwork under a machine that is supported solely by a jack.Follow recommended procedures in this manual.

When implements or attachments are used with amachine, always follow safety precautions listed in theimplement or attachment operator’s manual.

TX,05,FF1615 –19–14JUN90–1/1

Operate Only from Operator’s Seat

T66

07A

O–U

N–1

8OC

T88

Avoid possible injury or machine damage. Do not startengine by shorting across starter terminals.

NEVER start engine while standing on ground. Startengine only from operator’s seat.

CED,OUTX782,582 –19–18AUG99–1/1

Park Machine Safely

Before working on the machine:

• Park machine on a level surface.• Lower bucket to the ground.• Turn auto-idle switch off.• Run engine in light duty “L” mode without load for 2

minutes.• Set power mode to low idle “I” and turn key switch to

OFF to stop engine. Remove key from switch.• Pull pilot control shut-off lever to locked position.• Allow engine to cool.


PN=13

Safety

900001

6

TX,05,RR,572 –19–12JUN90–1/1

Stay Clear of Moving Parts

T72

73A

S–U

N–0

8JU

N90

Entanglements in moving parts can cause serious injury.

To prevent accidents, use care when working aroundrotating parts.

TX,05,RR,594 –19–12JUN90–1/1

Avoid Power Lines

T72

73A

D–U

N–0

8JU

N90

Serious injury or death can result from contact withelectric lines.

Never move any part of the machine or load closer toelectric line than 3 m (10 ft) plus twice the line insulatorlength.

TX,05,DH832 –19–16MAR92–1/1

Use Handholds and Steps

T69

81A

N–U

N–1

5JU

N89

Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain athree point contact with the steps and handrails and facethe machine. Do not use any controls as handholds.

Never jump on or off the machine. Never mount ordismount a moving machine.

Be careful of slippery conditions on platforms, steps, andhandrails when leaving the machine.


PN=14

Safety

9000017

TX,05,RR,560 –19–05OCT90–1/1

Keep Riders Off Machine

T72

73A

H–U

N–0

8JU

N90

Only allow the operator on the machine. Keep riders off.

Riders on machine are subject to injury such as beingstruck by foreign objects and being thrown off themachine. Riders also obstruct the operator’s view resultingin the machine being operated in an unsafe manner.

TX,05,FF1806 –19–05OCT90–1/1

Move and Operate Machine Safely

T72

73A

L–U

N–0

8JU

N90

Bystanders can be run over. Know the location ofbystanders before moving, swinging, or operating themachine.

Always keep the travel alarm in working condition. Itwarns people when the machine starts to move.

Use a signal person when moving, swinging, or operatingthe machine in congested areas. Coordinate hand signalsbefore starting the machine.

DX,WEAR2 –19–03MAR93–1/1

Wear Protective Clothing

TS

206

–UN

–23A

UG

88

Wear close fitting clothing and safety equipmentappropriate to the job.

Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.


PN=15

Safety

900001

8

TX,05,FF1613 –19–14JUN90–1/1

Protect Against Flying Debris

T66

42D

K–U

N–1

8OC

T88

Guard against injury from flying pieces of metal or debris;wear goggles or safety glasses.

DX,NOISE –19–03MAR93–1/1

Protect Against Noise

TS

207

–UN

–23A

UG

88

Prolonged exposure to loud noise can cause impairmentor loss of hearing.

Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

DX,LIGHT –19–04JUN90–1/1

Illuminate Work Area Safely

TS

223

–UN

–23A

UG

88

Illuminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignitespilled fuel or oil.

DX,LOOSE –19–04JUN90–1/1

Service Machines Safely

TS

228

–UN

–23A

UG

88

Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine tools or moving parts. If these items were to getcaught, severe injury could result.

Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.


PN=16

Safety

9000019

DX,PAINT –19–24JUL02–1/1

Remove Paint Before Welding or Heating

TS

220

–UN

–23A

UG

88

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from areato be affected by heating. If paint cannot be removed,wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

Do not use a chlorinated solvent in areas where weldingwill take place.

Do all work in an area that is well ventilated to carry toxicfumes and dust away.

Dispose of paint and solvent properly.

DX,TORCH –19–10DEC04–1/1

Avoid Heating Near Pressurized Fluid Lines

TS

953

–UN

–15M

AY

90

Flammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines canaccidentally burst when heat goes beyond the immediateflame area.


PN=17

Safety

90000110

02T,05,J9 –19–07JAN91–1/1

Beware of Exhaust Fumes

T64

58A

O–U

N–1

8OC

T88

Prevent asphyxiation. Engine exhaust fumes can causesickness or death.

If you must operate in a building, be positive there isadequate ventilation. Either use an exhaust pipe extensionto remove the exhaust fumes or open doors and windowsto bring enough outside air into the area.

DX,LIFT –19–04JUN90–1/1

Use Proper Lifting Equipment

TS

226

–UN

–23A

UG

88

Lifting heavy components incorrectly can cause severeinjury or machine damage.

Follow recommended procedure for removal andinstallation of components in the manual.

DX,RCAP –19–04JUN90–1/1

Service Cooling System Safely

TS

281

–UN

–23A

UG

88

Explosive release of fluids from pressurized coolingsystem can cause serious burns.

Shut off engine. Only remove filler cap when cool enoughto touch with bare hands. Slowly loosen cap to first stopto relieve pressure before removing completely.


PN=18

Safety

90000111

DX,DRAIN –19–03MAR93–1/1

Dispose of Waste Properly

TS

1133

–UN

–26N

OV

90

Improperly disposing of waste can threaten theenvironment and ecology. Potentially harmful waste usedwith John Deere equipment include such items as oil, fuel,coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

Do not pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants escaping into the air candamage the Earth’s atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.

TX,05,FF1624 –19–14JUN90–1/1

Work in a Clean Area

Before starting a job, clean the work area. Removeobjects that may be a safety hazard to the mechanic orbystanders.


PN=19

Safety

90000112

TX,05,FF1614 –19–14JUN90–1/1

Use Tools Properly

TS

779

–UN

–08N

OV

89

Use tools appropriate to the work. Makeshift tools, parts,and procedures can create safety hazards.

Use power tools only to loosen threaded tools andfasteners.

For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.

Use only recommended replacement parts. (See PartsCatalog.)

DX,SIGNS1 –19–04JUN90–1/1

Replace Safety Signs

TS

201

–UN

–23A

UG

88

Replace missing or damaged safety signs. See themachine operator’s manual for correct safety signplacement.

DX,LIVE –19–25SEP92–1/1

Live With Safety

TS

231

–19–

07O

CT

88Before returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.


PN=20

Group 02General Specifications

9000021

TX,115,FF2461 –19–12MAY93–1/2

690E LC

T75

27D

Q–U

N–2

7AP

R93

Continued on next page


PN=21

General Specifications

900002

2

TX,115,FF2461 –19–12MAY93–2/2

NOTE: Specifications and design subject to changewithout notice. Wherever applicable,

specifications are in accordance with PCSAand SAE standards.

A 3607 mm (11 ft 10 in.)

B 4445 mm (14 ft 7 in.)

C 1090 mm (3 ft 7 in.)

D 2630 mm (8 ft 8 in.)

D 1 Swing Radius 2740 mm (9 ft 0 in.)

E 2910 mm (9 ft 6 in.)

F 455 mm (1 ft 6 in.)

G 2380 mm (7 ft 10 in.)

H 650 mm (26 in.) or 750 mm (30 in.) or 800 mm (32 in.)

I With 2380 mm (7 ft 10 in.) undercarriage and 3030 mm (9 ft 11 in.)With 650 mm (26 in.) shoes 3130 mm (10 ft 3 in.)With 750 mm (30 in.) shoes 3180 mm (10 ft 5 in.)With 800 mm (32 in.) shoes

J 2780 mm (9 ft 1 in.)

K With 2200 mm (7 ft 3 in.) arm 9480 mm (31 ft 1 in.)With 2900 mm (9 ft 6 in.) arm 9410 mm (30 ft 10 in.)

L With 2200 mm (7 ft 3 in.) arm 2910 mm (9 ft 6 in.)

With 2900 mm (9 ft 6 in.) arm 2910 mm (9 ft 6 in.)


PN=22


9000023

TX,115,FF3345 –19–11JAN95–1/2

690E LC Long Front Specifications

T79

61A

E–U

N–0

2AP

R93



PN=23


900002

4

TX,115,FF3345 –19–11JAN95–2/2

NOTE: Specifications and design subject to changewithout notice. Wherever applicable,specifications are in accordance with PCSAand SAE Standards. Except where otherwisenoted these specifications are based on a unit

equipped with 379 kg (835 lb) bucket, 800 mm(32 in.) track shoes, 4.45 m (14 ft 7 in.)undercarriage, full fuel tank, 80 kg (175 lb)operator, and standard equipment.

A 3.66 m (12 ft 0 in.)

B 4.45 m (14 ft 7 in.)

C 1.09 m (3 ft 7 in.)

D 2.63 m (8 ft 8 in.)

D 1 Tailswing Radius 2.74 m (9 ft 0 in.)

E 2.84 m (9 ft 4 in.)

F 455 mm (1 ft 6 in.)

G 2.38 m (7 ft 10 in.)

H 800 mm (32 in.)

I 3.18 m (10 ft 5 in.)

J 2.77 m (9 ft 1 in.)

K 11.86 m (38 ft 11 in.)

L 3.15 m (10 ft 4 in.)

With 100 mm (4 in.) block under bucket linkage pivot a 3.25 m (10 ft 8 in.)aLubrication lines at boom cylinder rod ends may extend 100 mm (4 in.) over maximum machine height. If necessary, lines can be tied downto meet height requirements.

TX,9000,LG2 –19–27AUG97–1/1

690E LC And 690E LC Long Front Drain And Refill Capacities

Metric English

Fuel tank (Serial No. —536413) 322 L 85 gal

Fuel tank (Serial No. 536414—) 303 L 80 gal

Cooling system (Serial No. —559602) 34 L 9 gal

Cooling system (Serial No. 559603—) 41.5 L 11 gal

Engine lubrication, including filter 19 L 20 qt

Hydraulic tank 148 L 39 gal

Swing gear 21.8 kg 48 lb

Propel gearbox (each) 3.9 L 4.1 qt


PN=24

Group 03Torque Values

9000031

DX,TORQ1 –19–24APR03–1/1

Unified Inch Bolt and Screw Torque ValuesTS1671 –UN–01MAY03

Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2

Screw Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in

1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150

N•m lb-ft N•m lb-ft

5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26

N•m lb-ft N•m lb-ft

3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46

N•m lb-ft N•m lb-ft N•m lb-ft

7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74

N•m lb-ft

1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115

9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165

5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225

3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400

7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640

1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960

1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350

1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920

1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500

1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higherbolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of thetightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that youcrimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricateU-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel boltsbolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for thebolts with identical grade. specific application.aGrade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,and for all other types of bolts and screws of any length.b“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners withJDM F13C zinc flake coating.c“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.


PN=25

Torque Values

900003

2

DX,TORQ2 –19–24APR03–1/1

Metric Bolt and Screw Torque Values

4.84.8 8.8 9.8 10.9 12.9 12.9

12.912.910.99.88.84.8

TS

1670

–UN

–01M

AY

03

Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in

M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172

N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft

M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35

N•m lb-ft N•m lb-ft N•m lb-ft

M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70

N•m lb-ft

M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190

M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300

M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410

M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580

M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800

M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000

M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475

M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000

M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730

M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500

Torque values listed are for general use only, based on the strength Shear bolts are designed to fail under predetermined loads. Alwaysof the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fastenersvalue or tightening procedure is given for a specific application. For with the same or higher property class. If higher property classstainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Makeinstructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start threadcrimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fastenersshown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless differentspecific application. instructions are given for the specific application.a“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners withJDM F13C zinc flake coating.b“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.


PN=26

Torque Values

9000033

04T,90,M170 –19–29SEP99–1/2

Additional Metric Cap Screw Torque Values

T68

73A

A–U

N–1

8OC

T88

T68

73A

B–U

N–1

8OC

T88

T68

73A

C–U

N–1

8OC

T88

CAUTION: Use only metric tools on metrichardware. Other tools may not fit properly. Theymay slip and cause injury.

Check tightness of cap screws periodically. Torque valueslisted are for general use only. Do not use these values ifa different torque value or tightening procedure is listedfor a specific application.

Shear bolts are designed to fail under predeterminedloads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or highergrade. If higher grade fasteners are used, these shouldonly be tightened to the strength of the original.

Make sure fastener threads are clean and you properlystart thread engagement. This will prevent them fromfailing when tightening.

Tighten cap screws having lock nuts to approximately 50percent of amount shown in chart.



PN=27

Torque Values

900003

4

04T,90,M170 –19–29SEP99–2/2

METRIC CAP SCREW TORQUE VALUESa

T-Bolt H-Bolt M-Bolt

NominalDia N•m lb-ft N•m lb-ft N•m lb-ft

8 29 21 20 15 10 7

10 63 46 45 33 20 15

12 108 80 88 65 34 25

14 176 130 137 101 54 40

16 265 195 206 152 78 58

18 392 289 294 217 118 87

20 539 398 392 289 167 125

22 735 542 539 398 216 159

24 931 687 686 506 274 202

27 1372 1012 1029 759 392 289

30 1911 1410 1421 1049 539 398

33 2548 1890 1911 1410 735 542

36 3136 2314 2401 1772 931 687aTorque tolerance is ±10%.

04T,90,K66 –19–29SEP99–1/2

Service Recommendations for O-Ring BossFittings

T62

43A

E–U

N–1

8OC

T88

Straight Fitting

1. Inspect O-ring boss seat for dirt or defects.

2. Lubricate O-ring with petroleum jelly. Place electricaltape over threads to protect O-ring. Slide O-ring overtape and into O-ring groove of fitting. Remove tape.

3. Tighten fitting to torque value shown on chart.



PN=28

Torque Values

9000035

04T,90,K66 –19–29SEP99–2/2T

6520

AB

–UN

–18O

CT

88

Angle Fitting

1. Back-off lock nut (A) and back-up washer (B)completely to head-end (C) of fitting.

2. Turn fitting into threaded boss until back-up washercontacts face of boss.

3. Turn fitting head-end counterclockwise to proper index(maximum of one turn).

NOTE: Do not allow hoses to twist when tighteningfittings.

4. Hold fitting head-end with a wrench and tighten locknutand back-up washer to proper torque value.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft

3/8-24 UNF 8 6

7/16-20 UNF 12 9

1/2-20 UNF 16 12

9/16-18 UNF 24 18

3/4-16 UNF 46 34

7/8-14 UNF 62 46

1-1/16-12 UN 102 75

1-3/16-12 UN 122 90

1-5/16-12 UN 142 105

1-5/8-12 UN 190 140

1-7/8-12 UN 217 160

NOTE: Torque tolerance is ± 10%.


PN=29

Torque Values

900003

6

04T,90,K67 –19–02MAR00–1/1

Service Recommendations For Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces and O-ring. Theymust be free of dirt or defects.

2. Lubricate O-rings and install into grove usingpetroleum jelly to hold in place.

3. Index angle fittings and tighten by hand pressingjoint together to insure O-ring remains in place.

4. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tightening

fittings, use backup wrench on straight hosecouplings.

IMPORTANT: Tighten fittings to 150% of listedtorque value if indexing is necessaryor if fitting is attached to anactuating devise.

Tighten fittings to 50% of listedtorque value if used in aluminumhousing.

FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut

mm in. in. N•m lb-ft N•m lb-ft

6.35 0.250 9/16-18 16 12 12 9

9.52 0.375 11/16-16 24 18 24 18

12.70 0.500 13/16-16 50 37 46 34

15.88 0.625 1-14 69 51 62 46

19.05 0.750 1 3/16-12 102 75 102 75

22.22 0.875 1 3/16-12 102 75 102 75

25.40 1.000 1 7/16-12 142 105 142 105

31.75 1.250 1 11/16-12 190 140 190 140

38.10 1.500 2-12 217 160 217 160

*Torque tolerance is +15 -20% unless otherwise specified.

Stud End O-ring Seal Torque for Straight and Adjustable Fittings*

Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque

Inch Inch Inch N•m lb-ft

3/8-24 5/8 9/16 12 9

7/16-20 5/8 5/8 21 15

1/2-20 3/4 11/16 26 19

9/16-18 3/4 3/4 34 25

3/4-16 7/8 15/16 73 55

7/8-14 1 1/16 1 1/16 104 76

1 1/16-12 1 1/4 1 3/8 176 130

1 3/16-12 1 3/8 1 1/2 230 170

1 5/16-12 1 1/2 1 5/8 285 210

*Torque tolerance is +15 -20% unless otherwise specified.


PN=30

Torque Values

9000037

04T,90,C96 –19–21JAN92–1/1

Service Recommendations for 37° Flare and30° Cone Seat Connectors

T62

34A

C–U

N–1

8OC

T88

1. Inspect flare and flare seat. They must be free of dirtor obvious defects.

2. Defects in tube flare cannot be repaired.Overtightening a defective flared fitting will not stopleaks.

3. Align tube with fitting before attempting to start nut.

4. Lubricate male threads with hydraulic fluid or petroleumjelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on torquechart. Do not allow hoses to twist when tighteningfittings.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft

3/8 - 24 UNF 8 6

7/16 - 20 UNF 12 9

1/2 - 20 UNF 16 12

9/16 - 18 UNF 24 18

3/4 - 16 UNF 46 34

7/8 - 14 UNF 62 46

1-1/16 - 12 UN 102 75

1-3/16 - 12 UN 122 90

1-5/16 - 12 UN 142 105

1-5/8 - 12 190 140

1-7/8 - 12 UN 217 160

NOTE: Torque tolerance is ± 10%.


PN=31

Torque Values

900003

8

04T,90,M171 –19–28JAN92–1/1

Service Recommendations For FlaredConnections—Straight or Tapered Threads

T68

73A

E–U

N–1

8OC

T88

Straight Thread

T68

73A

D–U

N–1

8OC

T88

Tapered Thread

1. Inspect flare and flare seat. They must be free of dirtor obvious defects.

2. Defects in the tube flare cannot be repaired.Overtightening a defective flared fitting will not stopleaks.

3. Align the tube with the fitting before attempting to startthe nut.

4. Lubricate the male threads with hydraulic fluid orpetroleum jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tighteningfittings.

TORQUE CHART a

Straight Thread b Tapered Thread

ThreadSize N•m lb-ft N•m lb-ft

1/8 15 11

1/4 20 15 45 33

3/8 29 21 69 51

1/2 49 36 93 69

3/4 69 51 176 130

1 157 116 343 253

1-1/2 196 145 539 398

2 255 188 588 434aTorque tolerance is ±10%.bWith seat face.

NOTE: If female thread is cast iron (control valves, brakevalves motors, etc.), torque must be reducedapproximately 10%.


PN=32

Torque Values

9000039

04T,90,K174 –19–01AUG94–1/1

Service Recommendations For Inch Series Four Bolt Flange Fittings

T68

90B

B–U

N–0

1MA

R90

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

2. Install O-ring (and backup washer if required) intogroove using petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to port. Hand tighten cap screws tohold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line incenter of flange and install cap screws. Flangemust be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.

5. Tighten one cap screw, then tighten the diagonallyopposite cap screw. Tighten two remaining capscrews. Tighten all cap screws as specified in thechart below.

DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.

TORQUE CHART

N•m lb-ft

Nominal Cap ScrewFlange Size

Size Min Max Min Max

1/2 5/16-18 20 31 15 23UNC

3/4 3/8-16 UNC 28 54 21 40

1 3/8-16 UNC 37 54 27 40

1-1/4 7/16-14 47 85 35 63UNC

1-1/2 1/2-13 UNC 62 131 46 97

2 1/2-13 UNC 73 131 54 97

2-1/2 1/2-13 UNC 107 131 79 97

3 5/8-11 UNC 158 264 117 195

3-1/2 5/8-11 UNC 158 264 117 195

4 5/8-11 UNC 158 264 117 195

5 5/8-11 UNC 158 264 117 195


PN=33

Torque Values

90000310

04T,90,K175 –19–29SEP99–1/1

Service Recommendations for Metric Series Four Bolt Flange Fitting

T68

90B

B–U

N–0

1MA

R90

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

2. Install the correct O-ring (and backup washer ifrequired) into groove using petroleum jelly to hold itin place.

3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to the port. Hand tighten cap screwsto hold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line incenter of flange and install four cap screws. Flangemust be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.

5. After components are properly positioned and capscrews are hand tightened, tighten one cap screw,

then tighten the diagonally opposite cap screw.Tighten two remaining cap screws. Tighten all capscrews as specified in the chart below.

DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.

TORQUE CHARTa

Threadb N•m lb-ft

M6 12 9

M8 30 22

M10 57 42

M12 95 70

M14 157 116

M16 217 160

M18 334 246

M20 421 318aTolerance ± 10%. The torques given are enough for the givensize connection with the recommended working pressure.Increasing cap screw torque beyond these amounts will result inflange and cap screw bending and connection failures.bMetric standard thread.


PN=34

Group 04Fuels And Lubricants

9000041

TX,45,JC1132 –19–22MAY96–1/1

Diesel Fuel

Consult your local fuel distributor for properties of thediesel fuel available in your area.

In general, diesel fuels are blended to satisfy the lowtemperature requirements of the geographical area inwhich they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 arerecommended.

In all cases, the fuel shall meet the followingproperties:

Cetane number of 40 minimum. Cetane numbergreater than 50 is preferred, especially fortemperatures below -20°C (-4°F) or elevations above1500 m (5,000 ft).

Cold Filter Plugging Point (CFPP) below theexpected low temperature OR Cloud Point at least5°C (9°F) below the expected low temperature.

Fuel lubricity should pass a minimum of 3100 gramload level as measured by the BOCLE scuffing test.

Sulfur content:

• Sulfur content should not exceed 0.5%. Sulfurcontent less than 0.05% is preferred.

• If diesel fuel with sulfur content greater than 0.5%sulfur content is used, reduce the service interval forengine oil and filter by 50%.

• DO NOT use diesel fuel with sulfur content greaterthan 1.0%.

Bio-diesel fuels may be used ONLY if the fuelproperties meet DIN 51606 or equivalent specification.

DO NOT mix used engine oil or any other type oflubricant with diesel fuel.

TX,45,DH3124 –19–20OCT93–1/1

Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations for enginesused off-highway. This fuel will not require any additivesto provide good performance and engine reliability.However, many local fuel distributors will not carry bothlow and regular sulfur diesel fuels.

If the local fuel distributor will supply only low sulfur fuel,order and use John Deere PREMIUM DIESEL FUELCONDITIONER. It provides lubricating properties alongwith other useful benefits, such as cetane improver,anti-oxidant, fuel stabilizer, corrosion inhibitor and others.John Deere PREMIUM DIESEL FUEL CONDITIONER isspecifically for use with low sulfur fuels. Nearly all otherdiesel fuel conditioners only improve cold weather flowand stabilize long-term fuel storage. They do not containthe lubrication additives needed by rotary fuel injectionpumps.


PN=35

Fuels And Lubricants

900004

2

TX,45,JC1133 –19–22MAY96–1/1

Diesel Engine Oil

T10

1239

–19–

22M

AY

96

Use oil viscosity based on the expected airtemperature range during the period between oilchanges.

John Deere PLUS-50engine oil is preferred.

If John Deere PLUS-50engine oil and a John Deereoil filter are used, the service interval for oil and filterchanges may be extended by 50 hours.

John Deere TORQ-GARD SUPREME oil is alsorecommended.

Other oils may be used if they meet one or more ofthe following:

• John Deere UNI-GARD• API Service Classification CG-4• API Service Classification CF-4• API Service Classification CE• CCMC Specification D5 and Mercedes Benz

MB228.3• CCMC Specification D4 and Mercedes Benz

MB228.1

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% isused, reduce the service interval by 50%.

PLUS-50 is a trademark of Deere & Company.TORQ-GARD SUPREME is a registered trademark of Deere &Company.UNI-GARD is a trademark of Deere & Company.


PN=36


9000043

TX,45,DH3705 –19–30JUN95–1/1

Hydraulic Oil

T85

08A

D–1

9–27

JUN

95

Depending upon the expected air temperature rangebetween oil changes, use oil viscosity shown on thetemperature chart above.

The following oils may be used.

• John Deere HY-GARD Transmission and HydraulicOils.

• You may also use other oils meeting John DeereStandard J20C or J20D.

Manufacturer Oil

Mobil DTE 25

Shell Tellus 46

Caltex Oil Rando Oil HD46

Texaco Inc. Rando Oil HD46

Chevron U.S.A. Inc. Chevron AW46

Esso Standard Oil NUTO H46

HY-GARD is a registered trademark of Deere & Company.


PN=37


900004

4

02T,45,M2 –19–05MAR94–1/1

Propel Gearbox Oil

T11

0205

–19–

25JU

N97

Depending upon the expected air temperature rangebetween oil changes, use oil viscosity shown on thetemperature chart above.

The following oils are recommended:

• Oil meeting John Deere Standard J20A or J20C• John Deere API GL-5 Gear Oil• Oil meeting API Service GL-5 (MIL-L-2105B or

MIL-L-2105C)• Oil meeting MIL-L-10324A may be used as arctic oil.

TX,45,DH5142 –19–09AUG96–1/1

Track Roller, Front Idler, And Carrier RollerOil

Use SAE 30 oil meeting API Service GL-5 (MIL-L-2105Bor MIL-L-2105C).


PN=38


9000045

TX,45,DH5078 –19–01JUL96–1/1

Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease

T83

58A

I–1

9–27

MA

R95

Use grease based on NLGI consistency numbers andthe expected air temperature range during the serviceinterval.

The following greases are preferred:

• John Deere MOLY HIGH TEMPERATURE EPGREASE

• John Deere HIGH TEMPERATURE EP GREASE• John Deere GREASE-GARD

Other greases may be used if they meet NLGIPerformance Classification GC-LB.

GREASE-GARD is a registered trademark of Deere & Company.

DX,FILT –19–18MAR96–1/1

Oil Filters

Filtration of oils is critical to proper operation andlubrication.

Always change filters regularly as specified in this manual.

Use filters meeting John Deere performancespecifications.


PN=39


900004

6

DX,LUBST –19–18MAR96–1/1

Lubricant Storage

Your equipment can operate at top efficiency onlywhen clean lubricants are used.

Use clean containers to handle all lubricants.

Whenever possible, store lubricants and containers inan area protected from dust, moisture, and othercontamination. Store containers on their side to avoidwater and dirt accumulation.

Make certain that all containers are properly marked toidentify their contents.

Properly dispose of all old containers and any residuallubricant they may contain.

DX,ALTER –19–15JUN00–1/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may requirelubricant recommendations different from those printed inthis manual.

Some John Deere brand coolants and lubricants may notbe available in your location.

Consult your John Deere dealer to obtain information andrecommendations.

Synthetic lubricants may be used if they meet theperformance requirements as shown in this manual.

The temperature limits and service intervals shown in thismanual apply to both conventional and synthetic oils.

Re-refined base stock products may be used if thefinished lubricant meets the performance requirements.


PN=40


9000047

DX,LUBMIX –19–18MAR96–1/1

Mixing of Lubricants

In general, avoid mixing different brands or types of oil.Oil manufacturers blend additives in their oils to meetcertain specifications and performance requirements.

Mixing different oils can interfere with the properfunctioning of these additives and degrade lubricantperformance.

Consult your John Deere dealer to obtain specificinformation and recommendations.


PN=41


900004

8


PN=42

Section 9005Operational Checkout Procedure

Contents 9005

Page

Group 10—Operational Checkout ProcedureOperational Checkout Record Sheet—

690E LC . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-1Operational Checkout . . . . . . . . . . . . . . . . . .9005-10-4Cooling System Checks . . . . . . . . . . . . . . . .9005-10-4Operator Station Checks—Key Switch On,

Engine Off . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-9Operator Station Checks—Engine On . . . . .9005-10-13Undercarriage Checks. . . . . . . . . . . . . . . . .9005-10-23Hydraulic System Checks . . . . . . . . . . . . . .9005-10-27Accessory Checks. . . . . . . . . . . . . . . . . . . .9005-10-37Seat, Doors, Windows, Latches, And

Locks Check . . . . . . . . . . . . . . . . . . . . . .9005-10-41


PN=1

Contents

9005


PN=2

Group 10Operational Checkout Procedure

9005101

TX,9005,DY6285 –19–05SEP97–1/3

Operational Checkout Record Sheet—690ELC

OWNER DATE

HOURS P.I.N.

TECHNICIAN

Use this sheet to record Operational Checkout results.Bold face numbers in the Operational Checkout, Group9005-10 correspond to numbers on the record sheet.Perform the Operational Checks before making repairs orcalling your John Deere dealer.

OK NOT OK COMMENTS

1. Cooling System Checks

Radiator Cap ❒ ❒

Coolant Level and Condition in Recovery Tank ❒ ❒

Coolant Level and Condition in Radiator ❒ ❒

Radiator Internal Core ❒ ❒

Coolant Hoses and Clamps ❒ ❒

Water Pump ❒ ❒

Fan Blades ❒ ❒

Fan Direction ❒ ❒

Fan Shroud and Fan Guard ❒ ❒

Fan Belt ❒ ❒

Radiator Outside Air Flow ❒ ❒

Head Gasket Seal ❒ ❒

2. Operator Station Checks—Key Switch ON, Engine OFF

Key Switch Accessory ❒ ❒

Gauges, Monitor, Propel Speed Switches & Indicator ❒ ❒

Lights, Auto-Idle Switch & Indicator Light, and BatteryRelay

Work Mode Indicator Circuit ❒ ❒

Power Mode (Engine Speed) Switches ❒ ❒

Fluid Level (Coolant, Hydraulic Oil, and Engine Oil) ❒ ❒

Indicator Circuit

Pilot Control Shut-Off Valve Linkage ❒ ❒

Propel Lever and Pedal Cushion Cylinder ❒ ❒


PN=45


Operational Checkout Procedure

900510

2

TX,9005,DY6285 –19–05SEP97–2/3

OK NOT OK COMMENTS

3. Operator Station Checks—Engine ON

Monitor Circuit, Gauges and Hour Meter ❒ ❒

Accelerator and Decelerator Switches ❒ ❒

System Controller Indicator Light Bulb ❒ ❒

System Controller Mode ❒ ❒

System Controller Mode Check—Propel Transducer ❒ ❒

System Controller Mode Check—Sensing Signals ❒ ❒

System Controller Adjust Mode—Low And High Idle ❒ ❒

Manual Override Valve ❒ ❒

Pilot Shut-Off Valve ❒ ❒

Pump Regulator Adjustment ❒ ❒

Auto-Idle Circuit ❒ ❒

Power Mode (Engine Speed) Circuit ❒ ❒

Work Mode Indicator Circuit ❒ ❒

Machine Operating Modes ❒ ❒

Travel Alarm ❒ ❒

Travel Alarm Stop Circuit ❒ ❒

4. Undercarriage Checks

Track Sag, Roller and Idler Leakage ❒ ❒

Sprocket Wear ❒ ❒

Grouser Wear, Bent Track Shoe, and Loose ❒ ❒

Hardware

Track Link Wear ❒ ❒

Front Idler Wear ❒ ❒

5. Hydraulic System Checks

Visual Inspection ❒ ❒

Hydraulic Oil Tank Pressurization ❒ ❒

Hydraulic Control Lever Pattern (SAE Pattern) ❒ ❒

Hydraulic Control Lever Pattern (John Deere Pattern) ❒ ❒

Pilot Pressure Switches ❒ ❒

Swing Brake Release ❒ ❒

Dig Function Drift ❒ ❒

Control Valve Lift Checks ❒ ❒

Cycle Time ❒ ❒

Propel System Tracking ❒ ❒

Propel Speed ❒ ❒

Work Modes ❒ ❒


PN=46



9005103

TX,9005,DY6285 –19–05SEP97–3/3

OK NOT OK COMMENTS

6. Accessories Checks

Light Circuit ❒ ❒

Windshield Wiper Circuit ❒ ❒

Windshield Washer Circuit ❒ ❒

Cab Dome Light Circuit ❒ ❒

Travel Alarm Stop Circuit ❒ ❒

Horn Circuit Checks ❒ ❒

Cigar Lighter Circuit ❒ ❒

Heater Controls Check With Air Conditioning ❒ ❒

Heater Controls Check Without Air Conditioning ❒ ❒

Heater Vent Control Check With Air Conditioning ❒ ❒

Air Conditioner System ❒ ❒

7. Seat, Doors, Windows, Latches, and Locks Checks

Seat Controls (Serial No. —538404) ❒ ❒

Seat Controls (Serial No. 538405—) ❒ ❒

Upper Front Window ❒ ❒

Lower Front Window Stored Position ❒ ❒

Right and Left Side Window ❒ ❒

Roof Vent Panel ❒ ❒

Cab Door Latch ❒ ❒

Left Front Access Door ❒ ❒

Left Rear Access Door ❒ ❒

Air Cleaner Unloader Valve ❒ ❒

Air Cleaner Element ❒ ❒

Right Access Door ❒ ❒

Hood ❒ ❒


PN=47


900510

4

TX,9005,DW1340 –19–30MAY97–1/1

Operational Checkout

Use this procedure to check all systems and functionson the machine. It is designed so you can make aquick check of machine operation while doing both awalk around inspection and performing specific checksfrom the operator’s seat.

Should you experience a problem with your machine,you will find helpful diagnostic information in thischeckout that will pinpoint the cause. Use the table ofcontents to help find adjustment procedures. Thisinformation may allow you to perform simple repairsyourself, reducing machine down time.

The information obtained after completing theoperational checkout will allow you or your authorizeddealer to pinpoint a specific test or repair needed torestore the machine to specifications.

A location will be required which is level and hasadequate space to complete the checks. No tools orequipment are needed to perform this checkout.

Complete the necessary visual checks (oil levels, oilcondition, external leaks, loose hardware, linkage,wiring, etc.) prior to doing the checkout. The machinemust be at operating temperature for many of thechecks.

Locate the check to be performed at the top of the leftcolumn and read completely down the column beforeperforming the check. Follow this sequence from left toright. In the far right column, if no problem is found,you will be instructed to go to next check. If a problemis indicated, you will be referred to either a group inthis manual or to your authorized dealer for repair.

– – –1/1

1 Cooling System Checks


PN=48


9005105

– – –1/1

Radiator Cap

T6488FY –UN–19OCT88 T7690AB –UN–23JAN92

CAUTION: To avoid personal injury, DO NOT remove radiator cap unlessengine is cool. When engine is hot and cap is removed, hot coolant orsteam will spray out causing serious burns.

Engine stopped and cool.

Remove radiator cap.

If coolant is warmer than surrounding air temperature is a “whoosh” sound heard whencap is loosened?

Does cap have a stop position that requires it to be pushed down to remove?

Does cap have a good seal (C) and gasket (A)?

Is spring (B) in good condition?

YES: Go to next check.

NO: Replace radiatorcap.

– – –1/1

Coolant Level AndCoolant Condition InRecovery Tank Check(Serial No. —551585)

T7414AB –19–13DEC90

Engine stopped, radiator cool.

Inspect coolant level and condition in overflow tank.

Is coolant level between FULL and LOW marks onoverflow tank?

Is coolant free of oil, foam, or rust?


NO: Add coolant if low.Drain and flush overflowtank and radiator.Replace coolant if dirty orrusty. If coolant is oily,check for hydraulic orengine oil leaks intocooling system. Go toGroup 0510 or GeneralInformation section.

– – –1/1

Coolant Level AndCoolant Condition InRecovery Tank Check(Serial No. 551586—)

T109465 –UN–02JUN97


Inspect coolant level and condition in recovery tank.

Is coolant level 3/4 full in recovery tank?





PN=49


900510

6

– – –1/1

Coolant Level AndCoolant Condition InRadiator Check

Engine OFF.

Engine cold.

CAUTION: To avoid personal injury, DO NOT remove cap unless engineis cool.


Inspect coolant level.

Inspect coolant condition.

LOOK: With engine cold, coolant level must be to bottom of fill neck on radiator.

LOOK: Coolant must NOT be oily, foamy or rusty.

YES: Check complete.

NO: Add or replacecoolant. Go to Group0510 or GeneralInformation section.

– – –1/1

Radiator Internal CoreCheck

T6488FZ –UN–19OCT88

CAUTION: To avoid personal injury, DO NOTremove radiator cap unless engine is cool.When engine is hot and cap is removed, hotcoolant or steam will spray out causingserious burns.

Raise engine access door.


Drain coolant into a clean container until core tubes arevisible.

Is radiator core free of rust, lime, or corrosion? Arepassages in core clean, not plugged?


NO: Remove and cleanor replace radiator. Fillcooling system with cleancoolant. Go to GeneralInformation section.

– – –1/1

Coolant Hoses AndClamps Check

Are radiator and heater hoses free of twists, kinks, cracks, leaks or wear from rubbingon adjacent parts?

Are hose clamps tight and installed correctly?


NO: Replace or untwisthoses as required.Tighten or reinstall hoseclamps.


PN=50


9005107

– – –1/1

Water Pump Check

T7690AC –UN–27JAN92

Engine stopped.

Is coolant leaking from weep hole (A)?

YES: Seal (B) has failed.Replace seal or waterpump. Go to yourauthorized dealer.

NO: Go to next check.

– – –1/1

Fan Blades Check

T7694AH –UN–21MAY03

Are fan blades bent or twisted?

Are fan blades cracked or nicked?

YES: Replace fan.


– – –1/1

Fan Direction Check

T6488GB –UN–23AUG93

Is fan installed correctly with cupped portion side (Arrow)of fan away from radiator?

NOTE: If fan is installed backwards, about 50% of itscapacity is lost.


NO: Install fan correctly.


PN=51


900510

8

– – –1/1

Fan Shroud And FanGuard Check

T6488GC –UN–23AUG93

Check clearance between fan and fan shroud.

Is fan centered in shroud?

Is guard free of damage?

Are all mounting brackets and hardware tight?


NO: Adjust fan shroud iffan is not centered.Repair or replace guard.Tighten loose hardware.Replace fan shroud ifneeded.

– – –1/1

Fan Belt Check Is fan belt free of oil or grease?

Is inside surface of belt free of cracks or frayed edges?

Is belt aligned with pulleys?

NOTE: Fan belt is self-adjusting.

Is fan belt tightener operating to keep belt tight?


NO: Replace fan belt ifoily, greasy, cracked orotherwise damaged.Repair or replacetightener if belt is loose.

– – –1/1

Radiator Outside AirFlow

Are radiator fins free of mud, leaves, grass, and other debris?

Are fins straight—NOT broken or cracked?


NO: Clean outside ofradiator and radiator inletscreen. Straighten orreplace fins. Replaceradiator if severelydamaged.

– – –1/1

Engine Head Gasket SealCheck

T6171AR –UN–25MAY89

Engine at normal temperature.

Radiator full.

Install radiator cap and tighten.

Place radiator overflow tube in a clear jar of water.

Operate engine at fast idle. Load engine by holding ahydraulic function over relief.

Observe bubbles coming from overflow tube. Do bubblesflow from tube intermittently?

YES: Head gasket is OK.Go to next check.

NO: If there is a constantflow of bubbles from tube,loose or damagedcylinder head or a leakinghead gasket may beindicated. Go to CTM8 orCTM104 Engine Repair.


PN=52


900510

– – –1/1

2 Operator Station Checks—Key Switch On, Engine Off

9

– – –1/1

Key Switch AccessoryCheck

T7531BS –UN–07JUN91

Turn key to “ACC” position (B).

NOTE: Engine will stop when key switch is turned fromON to ACC. Turn key switch to OFF position to preventdischarging (draining) batteries.

Are all monitor gauges, indicator lights, and switch panelindicator lights OFF?


NO: Check key switch.Go to Group 9015-15.Replace key switch, go toGroup 1674.


PN=53


90051010

– – –1/1

Gauges, Monitor, PropelSpeed Switches AndIndicator Lights,Auto-Idle Switch AndIndicator Light, AndBattery Relay Checks

T109322 –UN–02JUN97

T7531AB –UN–07JUN91

NOTE: Monitor buzzer is not checked during this procedure.

If engine coolant temperature is below 26°C (80°F) coolant temperature gauge needlemay not move to the right. Run engine a few minutes to warm coolant before check.After warming coolant, stop engine and turn key switch to ACC position.

Turn key switch to ON position. Do not start engine.

Does battery relay “click”? (Located above batteries.)

Do needles for coolant temperature gauge (J) and fuel gauge (I) move to the right?

Do the eight monitor indicator lights come ON? After 2—3 seconds do only thealternator indicator light (A) and engine oil pressure indicator light (B) remain ON?

Is one of the propel mode indicator lights (E, F, or G) ON?

Push propel speed increase switch (D) until high speed propel mode indicator light(rabbit) (E) in ON.

Push propel speed decrease switch until low speed propel mode indicator light (turtle)(G) is ON.

Is one propel mode indicator light (E, F or G) ON and do the lights change insequence as the propel increase or decrease switch is pushed?

Push the auto-idle switch (C).

Does auto-idle indicator light (H) come ON or go OFF when switch is pushed?


NO: Check monitor fuseand indicator light bulbs.If OK, do SystemController SensingSignals Check in thisgroup or go to Group9015-15 to checkharnesses.


PN=54


90051011

– – –1/1

Work Mode IndicatorCircuit Check

T7531AC –UN–07JUN91

Engine stopped.

Key switch ON.

Push “M” (work mode) select switch (E).

Do mode indicator lights (A, B, C and D) come ON oneat a time, in sequence, as switch is pushed repeatedly?


NO: Check fuse. If fuse isOK, do System ControllerSensing Signals Check inthis group or go to Group9015-15 to checkharnesses.

– – –1/1

Power Mode (EngineSpeed) Switches Check

T7531AI –UN–07JUN91

Start engine.

NOTE: “L” (light duty) power mode is automaticallyselected by the system controller whenever the engine isstarted.

Push “I,” “L,” “E” and “P” power mode (engine speed)switches (A) one at a time.

Listen, does engine speed change as each switch ispushed?

Do corresponding indicator lights (B) come on as eachswitch is pushed?


NO: Check fuse. If fuse isOK, do System ControllerSensing Signals Check inthis group or go to Group9015-15 to checkharnesses.


PN=55


90051012

– – –1/1

Fluid Level (Coolant,Hydraulic Oil, AndEngine Oil) IndicatorCircuit Check

T109323 –UN–02JUN97

Engine stopped.

Key switch ON.

Push and hold pre-operation level check switch (A).

Are the coolant, hydraulic oil, and engine oil level indicator lights (B) ON?


NO: Check fluid levels inradiator, hydraulicreservoir, or engine. Iffluid level is OK, fluidlevel sensing switch orwiring has failed. Checkmonitor fuse. If fuse isOK, do System ControllerSensing Signals Check inthis group or go to Group9015-15.

– – –1/1

Pilot Control Shut-OffValve Linkage Check

T7351CM –UN–22AUG90

Engine stopped.

Slowly push pilot control shut-off lever forward and pullrearward.

Does lever move into forward and rearward detentposition easily?


NO: Repair linkage orreplace shut-off valve.


PN=56


90051013

– – –1/1

Propel Lever And PedalCushion Cylinder Check

T7531AO –UN–07JUN91

Engine OFF.

Key switch ON.

Push each propel lever and pedal forward (A), thenrelease.

Pull each propel lever and pedal rearward (B), thenrelease.

Does each lever and pedal have equal effort to operateforward and reverse?

Does each lever and pedal return to neutral at the sametime when released?


NO: Inspect pedalcushion gas cylinders(under propel pedals).Replace as required. Goto Group 3360.

– – –1/1

3 Operator Station Checks—Engine On


PN=57


90051014

– – –1/1

Monitor Circuit, GaugesAnd Hour Meter Check

T109324 –UN–02JUN97

Key switch ON.

All monitor indicator lights (A) come ON. After 2—3 seconds only alternator indicatorlight and engine oil pressure indicator light remain ON.

NOTE: Buzzer will not come on during this check.

Move pilot control shut-off lever to OFF position (rearward).

Start engine.

Are all monitor indicator lights (A) OFF after engine starts?

Push auto-idle switch so auto-idle indicator light (B) comes ON.

Does fuel gauge (D) indicate fuel level?

Is coolant temperature gauge needle (E) in normal operating zone after a few minutes?

Does the rectangular box on the far right side of hour meter (C) alternately rotate whitethen black approximately every five seconds?

Stop engine.


NO: Check Monitor fuseF6 if no monitor indicatorlights come ON or gaugeneedles do not move.Check alternator belt ifalternator indicator light ison after engine starts.Check engine oil level ifengine oil pressureindicator light remains ONafter engine starts.

Check alternator. Go toGroup 9015-15.


PN=58


90051015

– – –1/1

Accelerator AndDecelerator (EngineSpeed) Switches Check

T7531AD –UN–07JUN91

Start engine.

Auto idle switch OFF (indicator light OFF)

Push and release accelerator (engine speed increase)switch (A).

Does engine speed increase each time the switch ispushed?

Push and hold accelerator switch.

Does engine speed steadily increase to high idle? Is “P”(max. power) mode indicator light ON?

T7531AE –UN–07JUN91

Push and release decelerator (engine speed decrease)switch (A).

Does engine speed decrease each time the switch ispushed?

Push and hold decelerator switch.

Does engine speed steadily decrease to low idle? Is “I”(low idle) mode indicator light ON?


NO: Do SystemController Sensing SignalCheck in this group or goto Group 9015-15 tocheck harness.

– – –1/1

System ControllerIndicator Light BulbCheck

T7531BU –UN–07JUN91

Engine OFF.

Pilot shut-off lever OFF (rearward).

Remove fuse box cover (A). Loosen screws (B).

Remove rear panel cover (C).

While looking at system controller indicator lights, startengine.

NOTE: Light 1 is a two color light (red and green). Lights2—9 are red only.

Do all lights come ON (red) and then go out?

Does light 1 come ON red, then change to green andthen go OFF?


NO: Replace the SystemController.


PN=59


90051016

– – –1/1

System Controller ModeCheck

T7531BV –UN–07JUN91

Engine running.

Pilot shut-off lever OFF (rearward).

Push test switch (E) once.

Does light 1 (D) come ON red and stay ON?

Do all other lights go OFF?


NO: If a light(s) (2—9)stays ON a problem inthat circuit is indicated.Find the cause of theproblem. Go to Group9015-15.

– – –1/1

System Controller ModeCheck—PropelTransducer

T7531AQ –UN–07JUN91 T7563AA –UN–10JUL91

Swing upperstructure to side and raise one track off the ground.

Push propel lever for raised track while watching light 9 (B) (propel transducer).

Does light increase in brightness as propel lever is moved to full stroke?


NO: Do SystemController SensingSignals Check in thisgroup. A propeltransducer problem isindicated. Go to Group9015-15.


PN=60


90051017

– – –1/1

System Controller ModeCheck—Sensing Signals

T7563AA –UN–10JUL91

T7570AI –UN–10JUL91

CAUTION: Machine functions will move while performing this check.Operate machine in an open area.

Move both hydraulic control levers, one at a time, while watching light 3 (A) on systemcontroller.

Does light 3 come ON momentarily when control lever is moved?

Push each switch on switch panel 2 while watching light 3.

Does light 3 come ON momentarily when each switch is pushed?

Push power boost switch on top of right pilot controller.

Does light 3 come ON momentarily when power boost switch is actuated?


NO: Go to Group9015-15 to checkharness.


PN=61


90051018

– – –1/1

System Controller AdjustMode—Low And HighIdle Check

T7563AB –UN–10JUL91

Push test switch again (2nd time).

Does light 1 (green) come ON and stay ON?

Does engine speed decrease?

Do lights 2, 3, and 7 come ON and stay ON?

Push test switch again (3rd time).

Does light 1 (green) stay ON?

Does engine speed increase?


Push test switch again (4th time).

Does light 1 (green) stay ON?


Push test switch again (5th time).

Do all lights go OFF?


NO: Do Adjust EngineSpeed Control LinkageAdjustment, Group9010-20. Replace systemcontroller. Go to Group1675.

– – –1/1

Manual Override ValveCheck

T109325 –UN–02JUN97

Engine running.

Turn manual override valve (A) 1/4 turn (90°) counterclockwise.

Does engine speed increase to “P” (max. power) mode?

NOTE: When override valve is turned, system controller does not regulate engine orhydraulic pump. Engine runs in “P” mode and hydraulic pump flow remains 60—70%.High hydraulic demand can stall the engine. Use care when operating controls.

Do all dig and propel functions operate?

IMPORTANT: Starting or stopping engine with override valve actuated maycause engine damage. Turn override valve to normal operating mode beforestarting or stopping engine.


NO: See Manual OverrideValve Test andAdjustment, Group9025-25.


PN=62


90051019

– – –1/1

Pilot Shut-Off ValveCheck

T7351CC –UN–22AUG90

CAUTION: Machine functions may movewhile performing this check. Operatemachine in an open area.

Engine in “L” (light duty) mode.

Pilot control shut-off lever in OFF rearward position.

Operate all dig and propel function controls.

Do any dig or propel functions operate?

YES: Adjust linkage. Goto Group 9025-20.

NO: Continue check.

T7351CB –UN–22AUG90

CAUTION: Machine functions will move whileperforming this check. Operate machine inan open area.

Push pilot control shut-off lever to the ON (forward)position.

Carefully operate all dig and propel functions.



NO: Adjust linkage. Go toGroup 9025-20. Do PilotValve Test andAdjustment, Group9025-25.

– – –1/1

Pump RegulatorAdjustment Check

IMPORTANT: Boom will be raised and arm extended while machine is beingpropelled during this check. Move machine to an area free of overheadobstructions.

Start engine.

Select “HD” (heavy duty) work mode.

Select “P” (max. power) power mode.

Select high speed propel (rabbit).

Propel machine at full speed forward on a flat and level area.

Raise boom and extend arm while propelling.

Does engine stop?

YES: Differential pressureadjustment is incorrect.Go to Group 9025-25 todo Load Sense ValveDifferential Pressure Testand Adjustment.



PN=63


90051020

– – –1/1

Auto-Idle Circuit Check

T7531AF –UN–07JUN91

Start engine.

Push “P” (max. power) mode switch. (“P” indicator lightON.)

Auto-idle switch (B) OFF. (Indicator light OFF.)

Pilot control shut-off lever ON (Forward).

Push auto-idle switch (B) to ON.

Does auto-idle indicator light (A) come on?

Does engine speed decrease after 4—6 seconds?

Slowly actuate any dig function control lever.

Does engine speed return to high idle?


NO: Check fuse. If fuse isOK, do System ControllerSensing Signals Check inthis group or go to Group9015-15.

– – –1/1

Power Mode (EngineSpeed) Circuit Check

T7531AG –UN–07JUN91

Start engine.

Auto-idle OFF.

Push “P” (max. power) mode switch (A).

Does “P” (max. power) mode indicator light (H) comeON?

Does engine speed remain at high idle?

Push “E” (economy) mode switch (B).

Does engine speed decrease immediately?

Does “E” (economy) mode indicator light (G) come ON?

Push “L” (light duty) mode switch (C).


Does “L” (light duty) mode indicator light (F) come ON?

Push “I” (low idle) mode switch (D).


Does “I” (low idle) mode indicator light (E) come ON?


NO: Check monitor fuses.If fuse is OK, do SystemController SensingSignals Check in thisgroup or check harness,Group 9015-15.


PN=64


90051021

– – –1/1

Work Mode Circuit


Engine running

NOTE: When machine is started, “PR” work mode and“L” power mode are automatically selected.

Push work mode select switch (E). “EC” indicator (B)must light and engine speed must increase to powermode “E”.

Push work mode select switch again. “G” indicator (C)must light and engine speed must increase slightly and“P” power mode indicator must light.

Push work mode select switch again. “HD” indicator (D)must light and engine speed must increase to max.power. “P” power mode indicator must stay ON.

Do indicator lights and engine speeds change asindicated when work modes change?


NO: Check monitor fuses.If fuses are OK, doSystem ControllerSensing Signals Check inthis group or go to Group9015-15.


PN=65


90051022

– – –1/1

Machine OperatingModes Check (DigFunctions Only)

Refer to the table below to see the relationship between work modes, power modes,percentage of hydraulic flow available, and propel speeds available.

Work mode automatically sets the power mode; however, you can choose a differentpower mode by pushing one of the power mode switches.

Set the propel speed manually using the propel speed increase and decreaseswitches.

WORK MODE POWER(HD: Heavy MODE

Duty) (P: Max PROPEL(G: General) Power) HYDRAULIC SPEEDS

(EC: (E: Economy) FLOW AvailableEconomy) (L: Light POWER Maximum (H: High)

(PR: Duty) MODE RPM Percentage of (M: Medium)Precision) (I: Low Idle) ± 30 Available (L: Low)

HD Pa 2150 100% AllE 1800 100% AllL 1300 100% AllI 900 75% H & Lb

Gc Pa 1950 80% Alld

E 1800 80% Alld

L 1300 80% Alld

I 900 75% H & Lb

EC P 2150 80% Alld

E a 1800 80% Alld

L 1300 80% Alld

I 900 75% H & Lb

PRe P 2150 65%f H & Lb

E 1800 65%f H & Lg

L a 1300 65%f H & Lb

I 900 65%f H & Lb

aWork mode automatically selects this power mode.b"M" and "L" speeds are the same.cWhen "G" work mode is selected, the power mode is automatically set at "P" (1950rpm). If you push "P" power mode switch while operating in "G" work mode, max.power "P" mode rpm setting changes to 2150 rpm.dThere is only a 5% difference between "M" and "L" speeds.eWhen the engine is started, the machine is automatically set at "PR" work mode.fWhile propelling machine, available maximum hydraulic flow increases to 75%.g’M" and "L" speeds are the same.


NO: See specificinformation on workmodes and power modesin Groups 9020-05 and9025-05 or Chapter 35 ofoperator’s manual.

See specific informationon propel modes inGroup 9020-05 orChapter 30 of operator’smanual.


PN=66


90051023

– – –1/1

Travel Alarm Check

T7351CD –UN–22AUG90


Engine running.

Pilot control shut-off lever ON (forward).

Push propel pedals or levers forward (A).

Does travel alarm sound?

Pull propel pedals or levers rearward (B).

Does travel alarm sound?


NO: Check controller fuseand travel alarm fuse.Check wiring harness. Goto Group 9015-15.

– – –1/1

Travel Alarm Stop CircuitCheck

T7387AC –UN–03OCT90


NOTE: Travel alarm must operate for this check.

Push propel pedals or levers and allow travel alarm tooperate for a minimum of 10 seconds.

While continuing travel, push travel alarm cancel switch.(Located in panel behind left pilot controller.)

Does travel alarm stop sounding?


NO: Check travel alarmswitch and harness. Goto Group 9015-15.

– – –1/1

4 Undercarriage Checks


PN=67


90051024

– – –1/1

Track Sag, Roller AndIdler Leakage Check

T6915AN –UN–07APR89T109326 –UN–02JUN97

Swing upperstructure to side and raise track off ground.

Operate track in reverse.

Stop engine.

Measure distance between top of track shoe to center of lower surface of track frame.

SpecificationExcavator—Track Sag in Normal Soil 305—325 mm (12—12-3/4 in.).............................

Check rollers and idlers for oil leaks.

Is oil leaking from rollers or idlers?

Raise other side of machine and repeat checks.

NOTE: If track sag is less than specified, track chain wear will be accelerated. If it isless than specified on one side only, the machine may mistrack.

YES: Adjust track sag tospecification. Go to Group9020-20 or UndercarriageAppraisal Manual, SP326,Section 2. Repair rollersoridlers if oil leakage isnoted. Go to Group 0130.


– – –1/1

Sprocket Wear Check

T6981AC –UN–13MAR89

Inspect drive sprocket.

Is tooth wear excessive?

NOTE: Do not evaluate sprocket by condition of toothtip. Tooth tip wear does not affect sprocket operation if itdoes not extend into the bushing contact area.

NOTE: Reverse drive side wear is generally more thanforward drive side wear.

YES: Check sprocketwear specification. Go toUndercarriage AppraisalManual, SP326, Section4. Replace sprocket. Goto Group 0130.



PN=68


90051025

– – –1/1

Grouser Wear, BentTrack Shoe, And LooseHardware Check


Inspect tracks for worn grousers, bent shoes, and looseshoe hardware.

Are grouser bars worn excessively?

Are track shoes bent?

Is track shoe width appropriate for ground condition?

Is track shoe hardware tight?

NOTE: Excessive grouser wear weakens track shoesand may result in track shoes bending.

Are track shoes worn or damaged?

YES: Evaluate track shoeand hardware condition.Go to Group 9020-15 orUndercarriage AppraisalManual, SP326, Section4. Rebuild or replaceworn track shoes. Go toGroup 0130.



PN=69


90051026

– – –1/1

Track Link Wear Check

T7666AF –UN–18DEC91 T7666AG –UN–18DEC91

Inspect track links for wear or damage in the following areas:

Pin boss to roller flange (A)

Pin boss end to track guide (B)

Link rail to roller (C)

T7666AH –UN–18DEC91 T7666AI –UN–18DEC91

Link face to link face (D)

Rail chipping (F)

Link cracking (G)

T7666AJ –UN–18DEC91

Rail side wear (E).

Are track links worn or damaged?

YES: Evaluate track linkcondition. Go to Group9020-15 or UndercarriageAppraisal Manual, SP326,Sections 4 and 7. Asneeded, rebuild orreplace track link, Group0130.


– – –1/1

Front Idler Wear Check

T7666AM –UN–06DEC91

Inspect front idlers for wear and damage in the followingareas:

Tread wear or cracking (A)

Flange side wear (B)

Flange top wear (C)

Sidewall wear or cracking (D)

Are idlers worn or damaged?

YES: Evaluate front idlercondition. Go to Group9020-15 or UndercarriageAppraisal Manual, SP326,Section 4 and 7. Rebuildor replace idler. Go toGroup 0130.

NO: Check complete.


PN=70


900510

– – –1/1

5 Hydraulic System Checks

27

– – –1/1

Visual Inspection Park machine on level surface.

T7531BA –UN–07JUN91

Extend bucket cylinder 3/4 stroke as shown.

Extend arm cylinder fully.

Lower bucket to ground.

Are cylinders dirty and muddy, which may show signs ofleaks?

YES: Repair leaks.

NO: Continue check.

T7531BC –UN–07JUN91

Check hydraulic oil level.

Is oil level between ADD and FULL lines on sightgauge?

Inspect oil lines and hydraulic components for leaks ordamage.

Are lines or components damaged or leaking?

YES: Repair leaks.Repair bent or damagedlines or components andfill tank to correct level.


– – –1/1

Hydraulic Oil TankPressurization Check

T7531BD –UN–07JUN91

Raise boom to full height then lower boom to ground.

Move pilot shut-off lever to OFF.

Stop engine.

Loosen tank cap.

Is air heard escaping from tank?

NOTE: The tank is pressurized to create pressure athydraulic pump inlets. If cap does not seal, hydraulicpumps could cavitate and could be damaged.


NO: Replace breathervalve in breather filter.


PN=71


90051028

– – –1/1

Hydraulic Control LeverPattern (SAE Pattern)Check

T102070 –UN–16JUL96

T102071 –UN–16JUL96



Move pilot control shut-off lever to ON (forward).

Slowly move hydraulic control levers to all positions indicated on decals.

Do bucket, boom, arm and swing functions move as decals indicate?


NO: Install correct decalsfor operation pattern.

– – –1/1

Hydraulic Control LeverPattern (John DeerePattern) Check

T102197 –UN–19JUL96

T102198 –UN–19JUL96



Move pilot control shut-off lever to ON (forward).

Slowly move hydraulic control levers to all positions indicated on decals.

Do bucket, boom, arm, and swing functions move as decals indicate?


NO: Install correct decalsfor operation pattern.


PN=72


90051029

– – –1/1

Pilot Pressure SwitchCheck

Engine running at “P” (max. power) mode.

Auto-idle OFF.

Pilot control shut-off lever to ON (forward).

Push auto-idle switch ON.

Does engine speed decrease to auto idle in 4—6 seconds?

Move hydraulic control lever to activate boom up, then return lever to neutral.

Does engine speed increase when hydraulic control lever is moved, then return to autoidle 4—6 seconds after control lever is returned to neutral?

Move hydraulic control lever to activate arm in, then return lever to neutral.

Does engine speed increase when control lever is moved, then return to auto idle 4—6seconds after control lever is returned to neutral?

Move hydraulic control lever to activate swing either direction, then return lever toneutral.

Does engine speed increase when control lever is moved, then return to auto idle 4—6seconds after control lever is returned to neutral?

Move control hydraulic lever to activate bucket in either direction, then return lever toneutral.

Does engine speed increase when control lever is moved, then return to auto idlespeed 4—6 seconds after control lever is returned to neutral?

Move either propel pedal or lever forward or reverse.

Does engine speed increase when control is moved, then return to low idle 4—6seconds after control is returned to neutral?



– – –1/1

Swing Brake ReleaseCheck

Push swing brake release switch.

Engine running at “P” (max. power) mode.

Park machine on an incline.

Fill the bucket with dirt.

Swing the upperstructure halfway up the hill and stop by allowing the hydraulic controllever to return to neutral.

Does upperstructure drift slightly?

NOTE: Some machines may not drift if tolerances in the hydraulic system are tight.

YES: Go to the nextcheck.

NO: Swing brake may notbe releasing. Checkswing brake releasesignal to system controllercircuit. Go to Group9015-15.


PN=73


90051030

– – –1/1

Dig Function Drift Check

T7531AP –UN–07JUN91

Engine at “L” (light duty) mode.

Fill bucket with dirt and position bucket at maximumreach with bucket 95 mm (3-3/4 in.) above ground.

Observe bucket for one minute.

Does bucket drift down to ground within one minute?

YES: Excessive drift isindicated. Do CylinderDrift Test. Go to Group9025-25.


– – –1/1

Control Valve Lift CheckChecks

T7531BB –UN–07JUN91

Engine at “L” (light duty) mode.

Pilot control shut-off lever ON (forward).

Position machine as illustrated.

Slowly move control lever to the following positions, oneat a time: lower boom, extend arm (retract cylinder), anddump bucket (retract cylinder).

Do functions move in opposite direction as control leversare moved, then change direction as levers are movedfurther?

YES: If functions move inopposite direction first, aleak within the cylinder orbalance valve isindicated. Inspect andrepair. Go to Group 3360.



PN=74


90051031

– – –1/2

Cycle Time Checks

T6477AQ –UN–19OCT88

BoomT7884AE –UN–10NOV92

Arm, Bucket, Swing

CAUTION: Make sure area is clear and large enough to operate allfunctions of machine.

IMPORTANT: Warm hydraulic oil to operating temperature for this check.

Engine running.


Engine at “P” (max. power) mode.

Auto-idle switch OFF.

Extend bucket cylinder (bucket empty).

Retract arm cylinder.


NOTE: Three propel speeds are available in “HD” (heavy duty) work mode and “L”,“E”, or “P” power mode (engine speed).

Push propel speed increase switch until high speed propel (rabbit) mode indicator lightis ON.

Does machine perform within specifications?

SpecificationBoom Raise (ground level to full heightwith bucket curled, arm extended)—Cycle Time 3.6—3.8 sec typical new.................................................................................Cycle Time 4.5 sec service limit........................................................................................Arm Out (cylinder retract)—Cycle Time 3.6—3.8 sec typical new.....................................Cycle Time 4.5 sec service limit........................................................................................Arm In1 (cylinder extend)—Cycle Time 4.4—4.7 sec typical new......................................Cycle Time 5.5 sec service limit........................................................................................Bucket Dump (cylinder retract)—CycleTime 2.6—2.7 sec typical new............................................................................................Cycle Time 3.2 sec service limit........................................................................................Bucket Curl (cylinder extend)—CycleTime 3.8—4.1 sec typical new............................................................................................Cycle Time 4.8 sec service limit........................................................................................Swing Left or Right—3 Revolution FromRunning Start (bucket curled, armretracted)—Cycle Time 16.0 sec typical new....................................................................Cycle Time 23.0 sec service limit......................................................................................

1 Setting of arm cylinder restrictor affects cycle time.


PN=75


90051032

–19– –2/2

SpecificationTrack Raised—3 Revolutions FromRunning Start (check in forward andreverse)—Cycle Time 16.5 sec typical new.......................................................................Cycle Time 24.0 sec service limit......................................................................................Propel 20 m (65 ft) (check in forwardand reverse)—Cycle Time 12.0—15.5 sec typical new.....................................................Cycle Time 20.0 sec service limit......................................................................................


NO: For slow functions,check hydraulic pumpflow. Go to Group9025-25. For a slowfunction, check hydrauliccircuit for that function.Go to Groups 9020-20,9020-25, 9025-20 and9025-25.


PN=76


90051033

– – –1/2

Cycle Time For LongFront Machine Checks

T6477AQ –UN–19OCT88

Long Front BoomT7884AE –UN–10NOV92

Arm, Bucket, Swing

CAUTION: Make sure area is clear and large enough to operate allfunctions of machine.

IMPORTANT: Warm hydraulic oil to operating temperature for this check.

Engine running.




Extend bucket cylinder (bucket empty).

Retract arm cylinder.


NOTE: Three propel speeds are available in “HD” (heavy duty) work mode and “L”,“E”, or “P” power mode (engine speed).

Push propel speed increase switch until high speed propel (rabbit) mode indicator lightis ON.

IMPORTANT: Because of the extra length, the boom and arm can be damaged ifcycle times are faster (less) than the times given. Never adjust the spool stopscrews to get cycle times faster than the times given.

Does machine perform within specifications?

SpecificationBoom Raise (ground level to full heightwith bucket curled, arm extended)—Cycle Time 7.0 sec............................................................................................................Arm Out (cylinder retract)—Cycle Time 7.4 sec................................................................Arm In1 (cylinder extend)—Cycle Time 8.2 sec.................................................................Bucket Dump (cylinder retract)—CycleTime 2.3 sec.......................................................................................................................Bucket Curl (cylinder extend)—CycleTime 2.3 sec.......................................................................................................................Swing Left or Right—3 Revolutions FromRunning Start (bucket curl, armretracted)—Cycle Time 27.0 sec.......................................................................................

1 Setting of arm cylinder restrictor affects cycle time.


PN=77


90051034

–19– –2/2

SpecificationTrack Raised—3 Revolutions FromRunning Start (check in forward andreverse)—Cycle Time 16.5 sec typical new.......................................................................

24.0 sec service limitPropel 20 m (65 ft) (check in forwardand reverse)—Cycle Time 12.0—15.5 sec typical new.....................................................Cycle Time 20.0 sec service limit......................................................................................


NO: For slow functions,check hydraulic pumpflow. Go to Group9025-25. For a slowfunction, check hydrauliccircuit for that function.Go to Groups 9020-20,9020-25, 9025-20 and9025-25.

– – –1/1

Propel System TrackingCheck

T7005AX –UN–13MAR89

T7531AH –UN–07JUN91

NOTE: Track sag must be within specification, and track sag for both tracks must beequal before doing this check.

Select a level area with firm ground conditions. Mark out a course 20 m (65 ft) long.

Start engine.




Push propel speed increase switch (A) until high speed (rabbit) propel indicator light(C) is ON.

Activate both propel pedals in full forward.

Measure the longest distance between a straight 20 m (65 ft) line and the track madeby the machine.

Is machine mistrack less than 610 mm (2 ft)?

Push propel speed decrease switch (B) until low speed (turtle) propel indicator light (E)is ON.

Repeat tracking check.


NO: Machine mistrackcan be caused by apropel motor, rotarymanifold or control valve.Do the Propel ControlValve Spool Stop ScrewsAdjustment. Go to Group9020-20. Check propelhydraulic circuit. Go toGroup 9020-25.


PN=78


90051035

– – –1/1

Propel Speed Check



Start engine.



Push propel speed decrease switch (B) until low speedpropel (turtle) mode indicator light (E) comes ON.

Propel machine on a level area.

Push propel speed increase switch (A) until mediumspeed propel mode indicator light (D) comes ON.

Does propel speed increase?

Push propel speed increase switch (A) until high speedpropel (rabbit) mode indicator light (C) comes ON.


Repeat check using in reverse.




PN=79


90051036

– – –1/2

Work Mode Check

T7321AR1 –UN–30AUG90

CAUTION: Make sure area is clear and largeenough to operate all functions of machine.

Start engine.

Is “L” (light duty) power mode indicator light ON?

Is “PR” (precision) work mode indicator light ON?

Pilot shut-off lever ON (forward).

Operate all dig functions, one at a time, and note speedof operation.

Do all functions operate slowly?

Push work mode select switch (A) until “EC” (economy)work mode indicator light (B) comes ON.

Does “E” (economy) power mode indicator light comeON and engine speed increase?


Are function speeds faster than speeds in “PR”(precision) work mode?

Push work mode select switch until “G” (general) workmode indicator light (D) comes ON.

Does “P” (max. power) mode indicator light come ONand engine speed increase slightly?


Are function speeds faster than speeds in “EC”(economy) work mode?

Push work mode select switch until “HD” (heavy duty)work mode indicator light (E) comes ON.

Does “P” (max. power) power mode indicator light stayON and engine speed increase?


Are function speeds faster than speeds in “G” workmode?


PN=80


90051037

–19– –2/2


NOTE: Three propel speeds are available in “HD” (heavyduty), “G” (general), and “EC” (economy) work modes atpower modes “L”, “E” or “P”.

Work mode at “HD” (heavy duty) mode. “HD” indicatorlight is ON.

Engine at “P” (max. power) mode. “P” indicator light isON.

Push propel speed increase switch (A) until high speedpropel (rabbit) indicator light (C) comes ON.

Propel machine on a level area and note propel speed.

Push propel speed decrease switch (B) until mediumspeed indicator light (D) comes ON.

Does propel speed decrease?

Push propel speed decrease switch (B) until low speedpropel (turtle) indicator light (E) comes ON.

Does propel speed decrease?

Push work mode select switch until “G” (general) workmode indicator light comes ON.

Does propel speed decrease slightly?

Push propel speed increase switch until medium propelspeed indicator light is ON.

Does propel speed stay the same?

Push propel speed increase switch until high speedpropel (rabbit) indicator light is ON.



NO: Check Engine SpeedControl LinkageAdjustment. Go to Group9010-20.

Check fuses. If fuses areOK, do System ControllerSensing Signals Check inthis group or go to Group9015-15.

– – –1/1

6 Accessory Checks


PN=81


90051038

– – –1/1

Light Circuit Checks

T7531AJ –UN–07JUN91

Engine OFF.

Turn key switch ON.

Push light switch (A) to first ON position.

Are monitor panel back lights, front driving lights, andmonitor indicator light (B) ON?

Push light switch (A) to second ON position.

Are work lights (on boom), monitor panel back lights,and monitor indicator light (C) ON?

Push light switch (A) once more to OFF position.

Are monitor panel back lights, front driving lights, worklights and monitor indicator lights (A) and (B) OFF?


NO: Check fuse and/ormonitor panel back lightbulbs. Go to Group9015-15.

– – –1/1

Windshield Wiper CircuitCheck

T7531AK –UN–07JUN91

Key switch ON.

Push wiper switch (A) ON.

Does wiper operate intermittently?

Is intermittent indicator light (B) ON?

Push wiper switch to second ON position.

Does wiper operate continuously?

Is continuous indicator light (C) ON?

Push wiper switch to OFF position.

Does wiper arm stop in park position?

Are both indicator lights (B and C) OFF?


NO: Check wiper harnessconnection, or fuse. Go toGroup 9015-15.

– – –1/1

Windshield WasherCircuit Check

T7531AL –UN–07JUN91

Key switch ON.

Push washer switch (A) ON.

Does washer fluid squirt on windshield?


NO: Check washer fluidlevel and fuse. Go toGroup 9015-10.


PN=82


900510

– – –1/1

Cab Dome Light CircuitCheck

Key switch in “ACC” position.

Move cab dome light switch to ON position.

Is cab dome light ON?


NO: Check bulb. Checkfuse. Go to Group9015-10.

39

– – –1/1

Travel Alarm Stop CircuitCheck


Propel machine forward and reverse.

Does travel alarm sound when traveling in eachdirection?

Allow alarm to sound for 10 seconds or more.

Push travel alarm cancel switch. (On panel behind leftcontrol lever)

Does alarm stop sounding?


NO: Check fuse. Go toGroup 9015-10. Checktravel alarm and harness.Go to Group 9015-15.

– – –1/1

Horn Circuit Check

T7351AJ –UN–22AUG90

Key switch in “ACC” position.

Press horn switch. (On top of left control lever.)

Does horn sound?


NO: Check fuse. Go toGroup 9015-10.

– – –1/1

Cigar Lighter CircuitCheck

Key switch in ACC position.

Press cigar lighter in.

Does lighter “pop” out when hot?


NO: Check fuse, go toGroup 9015-10. Checkwire harness. Go toGroup 9015-15. Replacelighter.


PN=83


90051040

– – –1/1

Heater Controls CheckWith Air Conditioning

T7351CE –UN–22AUG90

NOTE: (Serial No. —541550) Factory A/C no longeravailable.

Key switch ON.

Turn fan control switch (A).

Does fan switch have four positions (including OFF)?

Does fan motor operate at three speeds?

YES: Continue check.


T7405CI –UN–15MAR91

Engine running and at operating temperature.

Fan control switch (B) ON.

Move heater temperature lever (A) to all positions andOFF.

Is warm air coming from heater vent?

Does heater temperature lever move freely through itsrange and does it have an OFF position?


NO: Check harness,blower motor. Go toGroup 9015-15.

– – –1/1

Heater Controls CheckWithout Air Conditioning

T7405CI –UN–15MAR91

Turn fan speed control switch knob (B) to low, medium,and high speed positions then back to OFF.

Does fan run in all three speeds, then stop in OFFposition?

With fan running at any speed, push temperature controllever (A) to warm temperature position (rearward).

Does warm air exit from vent located under seat?



Check harness, blowermotor. Go to Group9015-15.

– – –1/1

Heater Vent ControlCheck With AirConditioning

T7352BE –UN–22AUG90

NOTE: (Serial No. —541550) Factory A/C no longeravailable.

Move vent control lever (D) to upper vent position ratherthen lower vent position.

Do the upper vents have a greater air flow whencompared to the lower vents?


NO: Check linkage. Go toGroup 1830.


PN=84


90051041

– – –1/1

Air Conditioner SystemCheck

T7428AB –UN–30NOV90 T7382BG –UN–10OCT90

NOTE: (Serial No. —541550) Factory A/C no longer available.

Engine at “I” (low idle) power mode.

Turn fan switch (A) ON.

Move temperature control switch (B) to maximum cool.

Push air conditioner switch (E) in center of fan switch.

Does compressor clutch make a “click” sound?

Is cool air now coming from air vents.



– – –1/1

7 Seat, Doors, Windows, Latches, And Locks Check


PN=85


90051042

– – –1/1

Seat Controls Check(Serial No. —538404)

T7531BE –UN–07JUN91

Push in release button and move head rest (A) up tomaximum height then down to minimum height.

Does head rest have three adjustment positions? Doeshead rest move easily without binding, and remain ineach position?

Raise armrests (C) then lower armrests.

Do armrests raise and lower smoothly?

Move lever (D) rearward. Tilt seat back (B) forward andrearward. Release lever (D) to lock seat back in anyposition.

Does seat back tilt forward and rearward easily?

Does lever unlock and lock easily to hold seat back inposition?

Push lever (E) to right. Move seat forward and rearward.Release lever (E) to lock seat in any position.

Does lever move easily to unlock seat support?

Does lever lock seat support in position when released?

Does seat move forward and rearward easily?

Push lever (F) to right. Move seat and both sideconsoles forward and rearward. Release lever (F) to lockseat and side consoles in any position.

Does lever unlock easily and lock to hold seat andconsoles in position?

Does seat and consoles move forward and rearwardeasily?

Turn knob (G) clockwise then counterclockwise.

Does seat raise then lower? Does knob turn easily?

Turn knob (H) clockwise then counterclockwise.

Does suspension become stiffer then softer? Does knobturn easily?


NO: Inspect, repair orreplace any parts that donot operate properly. Goto Group 1821.


PN=86


90051043

– – –1/2

Seat Controls Check(Serial No. 538405—)

T8157CA –UN–10FEB94

T8157CB –UN–13JAN94

Move head rest (A) up to maximum height then down to minimum height.

Does head rest have two adjustment positions? Does head rest move easily withoutbinding, and remain in each position?

Pull up armrest lock button (G).

Raise armrests (F) then lower armrests.

Do armrests raise and lower smoothly?

Does button unlock and lock easily to hold armrest in position?

Move lever (H) forward. Tilt seat back forward and rearward. Release lever (H) to lockseat back in any position.

Does seat back tilt forward and rearward easily?

Does lever unlock and lock easily to hold seat back in position?

T8157CA –UN–10FEB94

T8157CB –UN–13JAN94

Push lever (B) to right. Move seat forward and rearward. Release lever (B) to lock seatin any position.


PN=87


90051044

–19– –2/2

Does lever move easily to unlock seat support?

Does lever lock seat support in position when released?

Does seat move forward and rearward easily?

Push lever (E) to right. Move seat and both side consoles forward and rearward.Release lever (E) to lock seat and side consoles in any position.

Does lever unlock easily and lock to hold seat and consoles in position?

Does seat and consoles move forward and rearward easily?

Turn knob (C) clockwise then counterclockwise.

Does seat raise then lower? Does knob turn easily?

Turn knob (D) clockwise then counterclockwise.

Does suspension become stiffer then softer? Does knob turn easily?


NO: Inspect, repair orreplace any parts that donot operate properly. Goto Group 1821.

– – –1/1

Upper Front WindowCheck

T7351AC –UN–22AUG90 T7351AD –UN–22AUG90

Move pins (B and C) toward center of the window to unlock.

Disconnect windshield wiper connector (A).

Pull window up and latch in full open position by engaging pins in holes (E). Lock rearlatch (D).

Do pins move smoothly to lock and unlock window?

Does windshield wiper harness connector unplug freely?

Does rear latch operate freely?

Do slide bolts engage rear holes and lock window securely in full open position?


NO: Inspect and repair asrequired.


PN=88


90051045

– – –1/1

Lower Front WindowStored Position Check

T7351AE –UN–22AUG90 T7351AF –UN–22AUG90

NOTE: Upper window must be raised before lower window can be removed from itsframe.

Move pins (A) inward to unlatch. Lift window and remove from frame.

Place window into storage position by inserting tabs (B) in bracket (D).

Move pins (A) into window holding bracket holes (C).

Do slide bolts move freely?

Does window lock securely into holding bracket?



– – –1/1

Right And Left SideWindow Check CAUTION: Avoid serious crushing injury from boom. Never place any

part of body beyond window bar or frame. It could be crushed by boomif boom control lever is accidentally bumped or otherwise engaged.

Latch and unlatch windows.

NOTE: Right front window has a built-in stop to restrict travel.

Slide both window panes open and closed.

Do both latches operate smoothly? Do windows remain open when latched open?

Do both windows slide freely to left and right?



– – –1/1

Roof Vent Panel Check

T7351AG –UN–22AUG90

Unlatch lock (C) on vent panel.

Turn and hold lever (B) counterclockwise on cylinder (A)to unlock.

Open vent panel desired amount.

Release lever (B) to lock vent panel in position.

Turn and hold lever counterclockwise.

Close vent panel and lock.

Does vent open, close, and lock easily?

Does cylinder hold vent in any desired position?




PN=89


90051046

– – –1/1

Cab Door Latch Check Open cab door.

Lock cab door in open position.

Release door from locked open position by pushing down on lever under left sidewindow.

Close cab door.

Does door unlatch easily, lock in open position securely, unlock from open positioneasily, latch closed securely?



– – –1/1

Left Front Access DoorCheck

T109327 –UN–02JUN97

Open left front access door.

Inspect hold open rod (B). Does rod hold door open?

Inspect windshield washer fluid container (A).

Inspect windshield washer fluid pump.

Inspect air cleaner.


NO: Repair or replacecomponents as needed.


PN=90


90051047

– – –1/2

Left Rear Access DoorCheck

T109328 –UN–02JUN97

Open left rear access door.

Inspect hold open rod (C). Does rod hold door open?

Inspect coolant recovery tank (A).

Inspect periodic Maintenance chart (B).

T7531BI –UN–07JUN91

T7698AT –UN–03FEB92

Inspect electrical relay cover (B), battery cover (C) and battery tiedowns (D).

Inspect radiator screen (A) and coolant overflow container.

Close and lock door.

Are parts free of visible damage.

Insert ignition key into lock and turn 180° clockwise to lock.

Turn key 180° counterclockwise to unlock.


PN=91


900510

–19– –2/2

Does lock key assembly rotate easily? YES: Go to next check.

NO: Repair or replacecomponents as needed.

48

– – –1/1

Air Cleaner UnloaderValve Check

T7531BF –UN–07JUN91


Inspect unloader valve (A).

Is unloader valve slightly open when the engine is notrunning?

Is rubber flexible and showing no sign of becoming hardor brittle?

Engine running.

Push “P” (max. power) mode select switch.

Does unloader valve close?


NO: Replace unloadervalve.

– – –1/1

Air Cleaner ElementCheck

T7531BG –UN–07JUN91

Remove air cleaner cover.

Inspect primary element (B).

Is element clean and in good condition?

Remove wing nut to remove primary element.

Inspect secondary element (A). Is element clean and ingood condition?


NO: Clean or replaceprimary element. Replacesecondary element ifprimary element isdamaged. Do not cleansecondary element.Replace if dirty.


PN=92


90051049

– – –1/1

Right Access DoorCheck

T7531BJ –UN–07JUN91

Open right access door.

Inspect hold-open rod (C). Engage rod to hold dooropen.

Inspect muffler clamps (A).

Are clamps tight?

Inspect hydraulic pump lines to and from pump (B).

Are lines free of leaks?

Close and lock door.

Does door latch operate easily?

Does lock securely lock door in closed position?

Are all parts free of visible damage?


NO: Inspect. Repair orreplace as needed.

– – –1/1

Hood Check

T7569BA –UN–15JUL91 T7569BB –UN–15JUL91

Unlock hood latch (A) with ignition key.

Open hood.

Does rod (B) hold hood open?

Close hood. Lock hood latch.

Does latch lock operate easily?

Does hood latch secure hood closed?

Is spring assist mechanism free of visible damage?

YES: OperationalCheckout complete.

NO: Repair or replace asneeded.


PN=93


90051050


PN=94

Section 9010Engine

Contents

Page

Group 05—Theory Of Operation6068 John Deere Engine (SN —559602) . . .9010-05-1 90106068 John Deere Engine (SN 559603—) . . .9010-05-1General Engine Description. . . . . . . . . . . . . .9010-05-2Engine—Sectional View . . . . . . . . . . . . . . . .9010-05-3Fan Drive

Operation (SN —559602) . . . . . . . . . . . . .9010-05-4Operation (SN 559603—) . . . . . . . . . . . . .9010-05-5

Engine Speed Control System Operation . . .9010-05-6Engine Power Mode and Work Mode . . . . . .9010-05-8

Group 10—System Operational Checks6068 John Deere Engine (SN —559602) . . .9010-10-16068 John Deere Engine (SN 559603—) . . .9010-10-1Engine Operational Checks. . . . . . . . . . . . . .9010-10-1Cooling System Checks . . . . . . . . . . . . . . . .9010-10-2Air Intake System Checks . . . . . . . . . . . . . . .9010-10-6Lubrication System Checks . . . . . . . . . . . . . .9010-10-8Fuel System Checks . . . . . . . . . . . . . . . . . .9010-10-10Engine Speed And Performance Checks. . .9010-10-12

Group 15—Diagnostic Information6068 John Deere Engine (SN —559602) . . .9010-15-16068 John Deere Engine (SN 559603—) . . .9010-15-1Diagnose Engine Malfunctions . . . . . . . . . . .9010-15-2

Group 20—Adjustments6068 John Deere Engine (SN —559602) . . .9010-20-16068 John Deere Engine (SN 559603—) . . .9010-20-1Electronic Tachometer Installation. . . . . . . . .9010-20-1Engine Speed Check . . . . . . . . . . . . . . . . . .9010-20-2Engine Speed Control Linkage . . . . . . . . . . .9010-20-4Engine Speed Sensor . . . . . . . . . . . . . . . . . .9010-20-7

Group 25—Tests6068 John Deere Engine (SN —559602) . . .9010-25-16068 John Deere Engine (SN 559603—) . . .9010-25-1Fuel Line Leakage. . . . . . . . . . . . . . . . . . . . .9010-25-2Air Filter Restriction Indicator Switch . . . . . . .9010-25-3Air Intake System Leakage . . . . . . . . . . . . . .9010-25-4Radiator Air Flow . . . . . . . . . . . . . . . . . . . . .9010-25-5Turbocharger Boost Pressure . . . . . . . . . . . .9010-25-7


PN=1

Contents

9010


PN=2

Group 05Theory Of Operation

9010051TX,9010,DW1341 –19–04JUN97–1/1

6068 John Deere Engine (Serial No. —559602)—Use CTM8

M44

215

–UN

–07S

EP

88

For additional engine information, the component technicalmanual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

TX,9010,DY2347 –19–31JAN97–1/1

6068 John Deere Engine (Serial No. 559603—)—Use CTM104

M44

215

–UN

–07S

EP

88




PN=97

Theory Of Operation

901005

2

TX,9010,DY2303 –19–17JAN97–1/1

General Engine Description

Engines are vertical, in-line, valve-in-head, 4-cycle(stroke) diesel engines.

Direct fuel injection is provided by a rotary-typeinjection pump or an in-line injection pump and 9.5 mminjection nozzles mounted in the cylinder head. Thecamshaft gear-driven injection pump is timed to thecrankshaft by the timing gear train.

Some engines are equipped with a turbocharger. Theturbocharger uses energy from exhaust gases tocompress intake air and force it into the combustionchamber.

The cylinder block is a one-piece casting. The block isavailable in structural or nonstructural configurations.

The camshaft is timed to the crankshaft through thetiming gear train. The camshaft rotates in honed boresin the cylinder block. All engines use a bushing in theNo. 1 camshaft bore. The camshaft lobes determinethe duration and lift of each valve, and operate the fuelsupply pump on rotary-type injection pumps.

Intake and exhaust valves are operated by camshaftfollowers, push rods and rocker arm assembly. Valveseat inserts in the cylinder head are used for intakeand exhaust valves.

The crankshaft is a one-piece, heat treated,nodular-iron or steel forging that operates inreplaceable two-piece main bearings. Crankshafts aredynamically balanced and are machined with undercutand rolled fillets. Two-piece main thrust bearing insertsare used to control crankshaft end-play.

Cylinder liners are “wet” sleeve type and areindividually replaceable. O-ring seals are used at the

lower connection between the cylinder block andliners.

Pistons are made of high-grade cast aluminum alloywith internal ribbing. The skirt is cam ground to allowfor expansion during operation. The piston crown hasa cutout combustion bowl with a truncated conecenter. All piston rings are located above the pistonpin. Two compression rings and one oil control ring areused. The top compression ring is a keystone shapedring located close to the top of the piston for improvedengine performance.

The hardened, fully-floating piston pins are held inplace by snap rings. Spray jets (piston cooling orifices)in the cylinder block spray pressurized oil on theunderside of the piston to lubricate piston pins andcool the pistons.

The forged steel connecting rods have replaceable pinbushing and bearing inserts. Some connecting rodshave a tapered pin end and others have a straight pinend.

The engine is equipped with a gear-driven oil pumpand full-flow oil filter. The oil filter has an internalbypass valve that opens if the filter element becomesrestricted. Engines are equipped with an oil coolermounted on the right side of the cylinder block. Theengine is equipped with a pressure regulator valve torelieve excessive pressure buildup in the main oilgallery, and a bypass valve to prevent oil starvation ifthe oil cooler and filter become plugged.

The engine has a pressurized cooling systemconsisting of radiator, water pump, multi-blade fan, andone or two thermostats.


PN=98

Theory Of Operation

9010053

TX,9010,LG3 –19–27AUG97–1/1

Engine—Sectional View

T10

6021

–UN

–18A

PR

97As Viewed From Flywheel End

A—Rocker Arm Shaft F—Cylinder Block K—Liner Packing Rings P—ValveB—Cylinder Head G—Crankshaft L—Cylinder Liner Q—Fuel Injection NozzleC—Push Rod H—Crankshaft Counterweight M—Piston R—Valve SpringD—Cam Follower I—Oil Pan N—Piston Pin S—Rocker ArmE—Camshaft J—Connecting Rod O—Piston Rings


PN=99

Theory Of Operation

901005

4

TX,9010,SS488 –19–21AUG91–1/1

Fan Drive Operation (Serial No. —559602)

T73

95D

E–1

9–13

DE

C90

The fan drive (C), driven by one fan belt from theengine crankshaft pulley (B), is self adjustable. The fan

belt tension adjuster (A) automatically adjusts the beltto correct tension.


PN=100

Theory Of Operation

9010055

TX,9010,LG4 –19–27AUG97–1/1

Fan Drive Operation (Serial No. 559603—)

T10

9759

–19–

08S

EP

97

The fan drive (D), driven by one fan belt from theengine crankshaft pulley (E), is self adjustable. The fan

belt tension adjuster (B) automatically adjusts the beltto correct tension.


PN=101

Theory Of Operation

901005

6

TX,9010,LG5 –19–27AUG97–1/2

Engine Speed Control System Operation

T75

67A

D–1

9–15

JUL9

1


PN=102


Theory Of Operation

9010057

TX,9010,LG5 –19–27AUG97–2/2

The engine speed control system allows the operatorto choose engine speed to match operating conditionsand operate engine as efficiently as possible.

A mode (I,L,E or P) is selected on the switch panel 2(A) located in cab.

• I=Low Idle Mode Switch• L=Light Duty Mode Switch• E=Economy Mode Switch• P=Max. Power Mode Switch

Voltage from a mode switch (I, L, E, or P) is sent tothe System Controller (B). The system controller

senses the signal and sends a signal to the enginespeed actuator solenoid (D). The solenoid regulatesthe amount of pilot oil routed to the actuator to controlits stroke.

The engine speed control actuator (E) moves andcontrols the fuel injection pump lever (F) and enginespeed.

The magnetic pickup (C) (located in the flywheelhousing) counts the flywheel teeth as the flywheelrotates. This senses actual engine speed. The sensingsignal is sent to the system controller (B) whichcalculates engine speed.


PN=103

Theory Of Operation

901005

8

TX,9010,SS590 –19–19MAR92–1/2

Engine Power Mode And Work Mode Operation

T76

89A

J–1

9–24

FE

B92


PN=104


Theory Of Operation

9010059

TX,9010,SS590 –19–19MAR92–2/2

NOTE: When starting the machine, work mode alwaysreset to “PR” precision mode.

When an operator selects a desired work mode (HD,G, EC, or PR), power mode will automatically beselected (see *) and maximum available hydraulicpump flow is determined. Power mode (rpm’s) can bechanged, but maximum available hydraulic flow willremain the same.

For example:

Operator selects work mode “EC” (economy) (Seediagram). The work mode will automatically selectpower mode “E” (economy) and maximum availablehydraulic oil flow will be 80%. If operator wants to bein a lower power mode such as “L” (light duty) he

pushes “L” light duty power mode switch. Work modewill remain at “EC” (economy), RPM’s (power mode)will drop, but maximum available hydraulic flow willremain the same (80%).

When “G” (general) work mode is selected, the powermode is automatically set at “P” (1950 rpm). If youpush any of the power mode switches while operatingin “G” work mode, max. power “P” mode rpm settingchanges to 2150 rpm.

Operator can use the engine speed increase anddecrease switches to change engine speed byapproximately 80 rpm’s per push. This will not changethe work mode or the maximum available hydraulicflow.


PN=105

Theory Of Operation

90100510


PN=106

Group 10System Operational Checks

9010101TX,9010,DW1341 –19–04JUN97–1/1


M44

215

–UN

–07S

EP

88



TX,9010,DY2347 –19–31JAN97–1/1


M44

215

–UN

–07S

EP

88



TX,9010,DY6320 –19–16SEP97–1/1

Engine Operational Checks

This procedure is designed so the mechanic can makea quick check of the engine using a minimum amountof diagnostic equipment. If you need additionalinformation, read Theory of Operation, Group 9010-05.

A location will be required which is level and hasadequate space to complete the driving checks.

The engine and all other major components must be atoperating temperature for some checks. A tachometeris required.

Locate system check in the left column and readcompletely, following this sequence from left to right.Read each check completely before performing.

At the end of each check, if no problem is found, thatcheck is complete or an additional check is needed. If

problem is indicated, you will be given repair requiredand group location or CTM number. If verification isneeded, you will be given next best source ofinformation:

Group 10 (System Operational Checks)

Group 15 (Diagnostic Information)

Group 20 (Adjustments)

Group 25 (Tests)

CTM (Component Technical Manual)


PN=107

System Operational Checks

– – –1/1

1 Cooling System Checks

901010

2

– – –1/1

Coolant Level AndCoolant Condition InRecovery Tank Check(Serial No. —551585)

T7414AB –19–13DEC90


Inspect coolant level and condition in overflow tank.

Is coolant level between FULL and LOW marks onoverflow tank?




– – –1/1

Coolant Level AndCoolant Condition InRecovery Tank Check(Serial No. 551586—)

T109465 –UN–02JUN97


Inspect coolant level and condition in recovery tank.

Is coolant level 3/4 full in recovery tank?




– – –1/1

Coolant Level AndCoolant Condition InRadiator Checks

CAUTION: To avoid personal injury, DO NOT remove cap unless engineis cool.

Engine OFF.

Engine cold.


With engine cold, is coolant level just below filler neck in radiator?

Is coolant free of oil, foam or rust?


NO: Add coolant iflow.Flush radiator andengine if coolant is dirtyor rusty. Add cleancoolant. Go to Section9000, Group 04. Ifcoolant is oily check forhydraulic or engine oilleaks into cooling system.Go to CTM8.


PN=108


9010103

– – –1/1

Radiator Cap

T6488FY –UN–19OCT88 T7690AB –UN–23JAN92

CAUTION: To avoid personal injury, DO NOT remove radiator cap unlessengine is cool. When engine is hot and cap is removed, hot coolant orsteam will spray out causing serious burns.

Engine stopped and cool.


If coolant is warmer than surrounding air temperature is a “whoosh” sound heard whencap is loosened?

Does cap have a stop position that requires it to be pushed down to remove?

Does cap have a good seal (C) and gasket (A)?

Is spring (B) in good condition?


NO: Replace radiatorcap.

– – –1/1

Radiator Internal CoreCheck

T6488FZ –UN–19OCT88

CAUTION: To avoid personal injury, DO NOTremove radiator cap unless engine is cool.When engine is hot and cap is removed, hotcoolant or steam will spray out causingserious burns.



Drain coolant into a clean container until core tubes arevisible.

Is radiator core free of rust, lime, or corrosion? Arepassages in core clean, not plugged?


NO: Remove and cleanor replace radiator. Fillcooling system with cleancoolant. Go to GeneralInformation section.


PN=109


901010

4 – – –1/1

Radiator Outside AirFlow Check

Open engine access door.

Open left rear access door.

Are radiator fins free of mud, leaves, grass, and other debris?

Is radiator damaged?

YES: Clean outside ofradiator and straightenfins if bent. Replaceradiator if severelydamaged.


– – –1/1

Coolant Hoses AndClamps Check

Are radiator and heater hoses free of twists, kinks, cracks, leaks or wear from rubbingon adjacent parts?

Are hose clamps tight and installed correctly?


NO: Replace or untwisthoses as required.Tighten or reinstall hoseclamps.

– – –1/1

Water Pump Check

T7690AC –UN–27JAN92

Engine stopped.

Is coolant leaking from weep hole (A)?

YES: Seal (B) has failed.Replace seal or waterpump. Go to CTM8,Cooling System.


– – –1/1

Engine Head Gasket SealCheck

T6171AR –UN–25MAY89

Engine at normal temperature.

Radiator full.

Install radiator cap and tighten.

Place radiator overflow tube in a clear jar of water.

Operate engine at fast idle. Load engine by holding ahydraulic function over relief.

Observe bubbles coming from overflow tube. Do bubblesflow from tube intermittently?

YES: Head gasket is OK.Go to next check.

NO: If there is a constantflow of bubbles from tube,loose or damagedcylinder head or a leakinghead gasket may beindicated. Go to CTM8Engine Repair.


PN=110


9010105

– – –1/1

Fan Blades Check

T7694AH –UN–21MAY03

Are fan blades bent or twisted?

Are fan blades cracked or nicked?

YES: Replace fan.


– – –1/1

Fan Direction Check

T6488GB –UN–23AUG93

Is fan installed correctly with cupped portion side (Arrow)of fan away from radiator?

NOTE: If fan is installed backwards, about 50% of itscapacity is lost.


NO: Install fan correctly.

– – –1/1

Fan Shroud And FanGuard Check

T6488GC –UN–23AUG93

Check clearance between fan and fan shroud.

Is fan centered in shroud?

Is guard free of damage?

Are all mounting brackets and hardware tight?


NO: Adjust fan shroud iffan is not centered.Repair or replace guard.Tighten loose hardware.Replace fan shroud ifneeded.


PN=111


901010

6 – – –1/1

Fan Belt Check Is fan belt free of oil or grease?

Is inside surface of belt free of cracks or frayed edges?

Is belt aligned with pulleys?

NOTE: Fan belt is self-adjusting.

Is fan belt tightener operating to keep belt tight?


NO: Replace fan belt ifoily, greasy, cracked orotherwise damaged.Repair or replacetightener if belt is loose.

– – –1/1

2 Air Intake System Checks

– – –1/1

Air Filter RestrictionIndicator And SwitchCheck

Run engine at slow idle.

Slowly cover air intake tube.

Does air filter restriction indicator light in cab come ON?


NO: Check monitor circuitfuse, air filter restrictionindicator light and switch.Go to Section 9015-15.

– – –1/1

Air Cleaner UnloaderValve Check

T7531BF –UN–07JUN91


Inspect unloader valve (A).

Is unloader valve slightly open when the engine is notrunning?

Is rubber flexible and showing no sign of becoming hardor brittle?

Engine running.

Push “P” (max. power) mode select switch.

Does unloader valve close?


NO: Replace unloadervalve.


PN=112


9010107– – –1/1

Air Cleaner ElementCheck

T7531BG –UN–07JUN91

Remove air cleaner cover.

Inspect primary element (B).

Is element clean and in good condition?

Remove wing nut to remove primary element.

Inspect secondary element (A). Is element clean and ingood condition?


NO: Clean or replaceprimary element. Replacesecondary element ifprimary element isdamaged. Do not cleansecondary element.Replace if dirty.

– – –1/1

Starting Aid Checks

T6477AP –UN–19OCT88

T106018 –UN–31MAR97

T7699AL –UN–03FEB92


Check cold weather starting aid (A).

For earlier start aid when a fluid can is not installed, turn canister so closed end isinstalled into base tight against valve in solenoid to prevent dust from entering engine.

For later start aid when a fluid can is not installed, install cap on valve in base toprevent dust from entering engine.

Is starting fluid line from starting aid to air intake manifold straight—NOT kinked orbroken?

Is arrow on starting aid nozzle pointing AGAINST air flow of air intake manifold?

NOTE: It may be necessary to scrape paint from nozzle to see arrow.


NO: Reposition startingfluid can canister or cap,replace plastic line andtighten nozzle until arrowis in correct position—pointing AGAINSTincoming air flow.


PN=113


901010

8

– – –1/1

Exhaust Smoke Check

T6488GF –UN–19OCT88

NOTE: Operate engine until coolant temperature gaugeneedle points to green zone before performing thischeck.

Run engine at fast idle.

Counter rotate tracks to put load to engine.

Observe exhaust smoke.

Is exhaust smoke dark black or blue smoke? Is exhaustsmoke gray or white?

NOTE: Dark black smoke can be caused by dirty air filteror poor fuel delivery. Blue smoke can be caused by wornor damaged piston rings or cylinder liners. Gray or whitesmoke can be caused by a cold engine, dirty injectionnozzles, or both.

YES: Go to DiagnoseEngine Malfunctions,Group 9010-15.


– – –1/1

3 Lubrication System Checks


PN=114


9010109

– – –1/1

Oil Level Check

T109323 –UN–02JUN97

T6488GH –19–23FEB89

Engine OFF.

Remove dipstick and check oil level.

Is oil above “full” mark or below “add” mark on dipstick.

If oil level is high, check for fuel or anti-freeze. Drain a small amount of engine oil intoa clear container. Watch oil in container to see if anti-freeze or water rises to top.

If oil level is low, check for oil leaks or oil seal problems in engine.

Adjust oil level to between “add” and “full” marks on dipstick.

Key switch ON.

Push pre-operation level check switch (A).

Is engine oil level indicator green light (A) ON?

YES: Add oil if low.Change oil and filter if toohigh. Go to Section 9000,Group 04. Check oil levelafter a few hoursoperation to determine ifa problem exists. Go toDiagnose EngineMalfunctions, Group9010-15.

NO: If oil level indicatorlight does not come ON,go to Monitor DiagnosticInformation in Group9015-15. If oil level is OK,go to next check.

– – –1/1

Engine Oil ConditionCheck

Remove dipstick and check oil condition.

Is oil milky or grainy?

If oil is milky, moisture or anti-freeze may be present.

If oil is grainy, carbon may be present.

Carbon in oil may result when engine runs at slow idle too long.

YES: Change oil andfilter. Check condition ofoil after a few hoursoperation to determine ifa problem exists. Go toSection 9000 Group 04 orDiagnose EngineMalfunctions, Group9010-15.



PN=115


90101010

– – –1/1

Engine Oil PressureSwitch And IndicatorCheck

T109782 –UN–09SEP97

Turn key switch from OFF to ON and observe engine oil pressure indicator.

Does indicator come ON and stay ON?

Start engine and observe engine oil pressure indicator.

Does indicator go OFF a few seconds after engine starts?


NO: Stop engine if engineoil pressure indicatorremains ON after enginestarts. Go to Group9010-15, DiagnoseEngine Malfunctions orCTM8. If engine oilpressure indicator doesnot come ON, go toGroup 9015-10 MonitorCircuit DiagnosticProcedures .

– – –1/1

4 Fuel System Checks

– – –1/1

Fuel Tank Interior CheckCAUTION: Be careful not to damage fuel gauge sender float or low fuellevel sending unit.

Remove fuel cap.

Use a flashlight to inspect bottom of fuel tank by shining light through the fuel.

Is dirt, debris or contamination seen in tank?

YES: Drain fuel, disposeof contaminated fuelproperly. Remove debris,clean bottom of tank.Replace fuel filters.Check water separator.



PN=116


90101011– – –1/1

Fuel Tank Sump Check

T7700AA –UN–18FEB92

Hold a clean container under fuel tank drain valve (A).

Open drain valve for a few seconds and catch fuel incontainer.

Check condition of fuel in container.

Is water present or is fuel cloudy?

YES: Drain until clear fuelflows or drain all fuel fromtank, dispose ofcontaminated fuelproperly. Replace fuelfilters, check waterseparator.


– – –1/1

Water Separator Check

T7700AB –UN–25FEB92

Inspect fuel in water separator.

Is water or other contamination present?

YES: Replace waterseparator filter.


– – –1/1

Fuel Supply Pump Check

T6488GR –UN–19OCT88

T106034 –UN–31MAR97

Open bleed screw on fuel filter and operate hand primer on fuel transfer pump.

Tighten bleed screw and again operate hand primer.

Does fuel come out of bleed screw when hand primer is operated?

Is resistance felt when hand primer is initially pumped but resistance decreases assystem pressure increases?


NO: Be certain fuel filteris clean. If not, replacefilter and check fuelsupply pump again.


PN=117


90101012

– – –1/1

Fuel System Check Engine OFF.

Disconnect fuel return hose from leak-off line.

Connect a hose to leak-off line to route excess fuel into a container.

Start engine and run at fast idle.

Put engine under load by operating a hydraulic function over relief.

Observe fuel flow from leak-off line.

Does fuel flow from leak-off line with engine at full load?

NOTE: Fuel that flows from leak-off line is excess fuel not required by the engine.


NO: Fuel supply isrestricted. Check forplugged fuel filters,plugged fuel tank capvent, restricted lines,stuck injection pumpoverflow valve, or amalfunctioning fuel pump.Repair or replace asnecessary.

– – –1/1

5 Engine Speed And Performance Checks


PN=118


90101013

– – –1/1

Engine Speed Check

T7573AD –UN–15JUL91

Install tachometer.

Start engine.

NOTE: Engine will be in light duty “L” mode afterstarting.

Push work mode switch until work mode “PR” indicatorcomes ON.

Auto-idle OFF.

Push low idle “I” mode switch (D).

Does tachometer indicate 900 ± 30 rpm?

Is low idle mode indicator (E) ON?

Push light duty mode “L” switch (C).

Does engine speed increase and indicator (F) ON?

Push economy mode “E” switch (B).

Does engine speed increase and indicator “E” (G) ON?

Push max. power mode “P” switch (I).

Does engine speed increase to (fast idle) 2150 ± 30rpm?

Is indicator “P” (H) ON?

Push auto-idle switch (J).

Is auto idle indicator (A) ON?

Does engine speed drop to auto idle speed within 4—6seconds?

Does tachometer indicate about 1300 ± 30 rpm?


NO: If either slow idleengine speed “I” or max.power engine speed “P”are not withinspecification, see EngineSpeed and ControlLinkage Adjustments inGroup 9010-20. Auto idlespeed cannot beadjusted.


PN=119


90101014

– – –1/1

Engine Power Check

T7531AQ –UN–07JUN91

Install tachometer.

Start engine, push mode select switch until Max. PowerMode “P” indicator is ON.

Push precision work mode switch. Precision modeindicator “PR” comes ON.

Move hydraulic control lever to curl bucket, (extendbucket cylinder.)

Swing upperstructure 90° and raise one track off ground.

Hold bucket curl over relief, observe exhaust smoke.

With bucket held over relief, move propel lever or pedalto operate track.

Observe tachometer and exhaust smoke as load isapplied to engine.

Is exhaust smoke evident at 2000 rpm (rated speed)?

Is exhaust smoke obvious but not excessive with engineat full load?


NO: If exhaust smoke isexcessive at either speed,see Diagnose EngineMalfunctions, Group9010-15.

– – –1/1

Engine Blow-By Check

T7700AC –UN–10FEB92

Run engine at fast idle and check blow-by tube.

Are fumes barely visible at the blow-by tube at fast idle,with no load?

NOTE: Excessive blow-by indicates that piston rings andcylinder liners do not seal off the combustion chamber.This is a comparative check that requires someexperience to determine excessive blow-by.


NO: If blow-by isexcessive. Go toCompression PressureTestin Group 9010-25.

– – –1/1

Loose Or Worn EngineParts

Run engine at slow idle.

Move hydraulic control lever to operate a hydraulic function over relief to put engineunder load.

Does engine run smooth, no knocking or rattling noise?

YES: OperationalCheckout complete.

NO: Go to AbnormalEngine Noise in Group9010-15.


PN=120

Group 15Diagnostic Information

9010151TX,9010,DW1341 –19–04JUN97–1/1


M44

215

–UN

–07S

EP

88



TX,9010,DY2347 –19–31JAN97–1/1


M44

215

–UN

–07S

EP

88




PN=121

Diagnostic Information

901015

2

TX,9010,LG7 –19–27AUG97–1/11

Diagnose Engine Malfunctions

NOTE: On machines (Serial No. —559602) use CTM8.On machines (Serial No. 559603—) use CTM104.

Diagnostic charts are arranged from mostprobable and simplest to verify, to least likely andmore difficult to verify. Remember the followingsteps when diagnosing a problem:

• Step 1. Operational Checkout Procedure (SeeGroup 9005-10).

• Step 2. Engine Operational Checkout Procedure(See Group 9010-10).

• Step 3. Diagnose Malfunction Charts (SeeGroup 9010-00).

• Step 4. Adjustments and/or Tests (See Group9010-20 and/or 9010-25).

Symptom Problem Solution

Engine Cranks But Will Not Start No fuel Add fuel. Bleed air.or Hard To Start

Wrong fuel Use correct fuel.

Water in fuel or water frozen in fuel Drain water from fuel tank trap.line Inspect fuel filter for water. Change

filter.

Fuel filter plugged Replace fuel filter. Bleed air cleanfuel tank strainer.

Debris in fuel Drain fuel tank. Clean tank strainer.Add clean fuel.

Air in fuel system Check for bubbles in fuel filter andtighten connections. Bleed air.

Fuel pump diaphragm leaking Check engine oil for fuel dilution.Replace fuel pump.

Fuel pump Check fuel pump pressure. SeeCTM8 or CTM104.

Low battery power Charge or install new batteries.


PN=122



9010153

TX,9010,LG7 –19–27AUG97–2/11


Slow cranking speed (poor electrical Clean and tighten battery and starterconnection) connections. Incorrect engine oil

(cold weather).

Wrong engine oil Use correct oil.

Air filter plugged Check air filter restriction indicatorand air filter elements. Clean.

Standby fuse or relay Replace fuse, relay or wiring. SeeSection 9015.

Injection pump metering valve Lightly tap injection pump housing. Ifsticking engine now starts, repair metering

valve. See your Local Fuel InjectionPump Service Center.

Electric shut-off Check shut-off solenoid. See Group9015-10. Inspect solenoid wiring andlinkage. See your Local FuelInjection Pump Service Center.

Injection pump Remove and test pump. See yourLocal Fuel Injection Pump ServiceCenter.

Injection nozzle(s) Remove and test nozzles. SeeCTM8 or CTM104.

Starter Replace starter.

Worn compression rings or low Check compression. Repair. Seecompression CTM8 or CTM104.

Starting ether used excessively Remove nozzles and add smallamount of oil to each cylinder. SeeCTM8 or CTM104.

Blown head gasket Route tube between radiator andoverflow tank into container of fluidand check for bubbles. Bubblesindicate head gasket leakage. SeeCTM8 or CTM104.


PN=123



901015

4

TX,9010,LG7 –19–27AUG97–3/11


Engine Knocks, Runs Irregularly Air in fuel Inspect filter for evidence of air inor Stops fuel. Tighten connections and bleed

fuel system.

Debris in fuel Drain fuel tank. Clean tank strainer.Add clean fuel.


Water in fuel Drain tank water trap, inspect filterelement for water. Replace filters.

Fuel filter plugged Replace filter.

Return line from injection pump to Route return line at the pump into atank restricted separate container. If engine now

operates normally, check return lineto tank for restriction. Replace.

Fuel injection pump out of time Time injection pump. See CTM8 orCTM104.

Restrictor fitting on top fitting in Remove, inspect and clean.injection pump plugged Determine source of debris. See

your Local Fuel Injection PumpService Center.

Injection pump metering valve Remove pump top cover andsticking inspect. Replace metering valve.

See your Local Fuel Injection PumpService Center.

Idle speeds adjustment too low Adjust slow idle speed. See Group9010-20.

Engine overheating Test cooling system. See Group9010-25.

Fuel pump Test pump pressure. See CTM8 orCTM104.

Fuel injection pump Remove and test fuel injectionpump. See your Local Fuel InjectionPump Service Center.


PN=124



9010155

TX,9010,LG7 –19–27AUG97–4/11


Injection nozzle(s) Remove and test nozzle(s). SeeCTM8 or CTM104.

Improper valve clearance Check and adjust valve clearance.See CTM8 or CTM104.

Valve sticking or burned Do compression pressure test. SeeCTM8 or CTM104.

Bent push rods Inspect. Replace. See CTM8 orCTM104.

Worn or broken compression rings Route tube between radiator andor cylinder head gasket leaking overflow tank into a container of fluid

and check for bubbles. Bubblesindicate head gasket leakage. SeeCTM8 or CTM104. Do compressionpressure test. See CTM8 orCTM104.

Engine Not Developing Full Fuel filter plugged Change filter. Bleed air.Power

Air filter plugged Clean or replace air cleanerelements.

Debris in fuel Drain fuel tank. Clean tank strainer.


Fuel tank outlet fitting plugged Clean.

Fast idle speed incorrect Do Fast Idle Speed Adjustment. SeeGroup 9010-20.

Hydraulic system leakage Do Hydraulic System LeakageCheck. See Group 9025-25.

Fuel line to pump or pump return to Check, repair.tank restricted

Fuel pump Do Fuel Pump Pressure Test. SeeCTM8 or CTM104.

Timing incorrect Check injection pump timing. SeeCTM8 or CTM104.


PN=125



901015

6

TX,9010,LG7 –19–27AUG97–5/11


Injection nozzles Remove and test injection nozzles.See CTM8 or CTM104.

Low compression Do Compression Pressure Test. SeeCTM8 or CTM104.

Injection pump delivery or governor Repair pump. See your Local FuelInjection Pump Service Center.

Valves burned, warped Repair valves. See CTM8 orCTM104.

Cam shaft worn Do Valve Lift Test. See CTM8 orCTM104.

Engine Overheats Coolant level low Fill cooling system and check forleaks.

Thermostat stuck closed or missing Test and/or reinstall. See Group0400 and CTM8 or CTM104.

Radiator screen plugged Remove and clean screen.

Radiator, oil cooler cores plugged Check air flow (see Group 9010-25).with dirt or fins bent Clean radiator. Straighten fins.

Air filter plugged Clean or replace elements.

Gauge or sender Check gauge and sender. SeeGroup 9015-10.

Fan belts loose, belts soaked with oil Inspect, replace. See Operator’sor pulleys worn excessively Manual or Repair Manual.

Shroud or baffles (foam rubber) Inspect. Repair or replace.missing

Fan blade on backward Reinstall. See CTM8 or CTM104.

Fan belt tension adjuster Replace.

Radiator cap or water in radiator Test, replace cap.

Operating in wrong mode Use correct operating mode.

Hydraulic system overheating Verify, repair. See Group 9025-25.


PN=126



9010157

TX,9010,LG7 –19–27AUG97–6/11


Cooling system passages dirty Flush cooling system.

Water pump Repair. See CTM8 or CTM104.

Fuel injection pump timing Check injection pump static timing.See CTM8 or CTM104.

Fuel delivery excessive Remove and adjust fuel injectionpump. See your Local Fuel InjectionPump Service Center.

Engine Stalls Easily Under Load Pump solenoid valve Check resistance of pump regulatorsolenoid. See Group 9015-15.

Engine speed sensor Check engine speed sensor. SeeGroup 9015-15.

System controller Check system controller. See Group9015-15.

Wiring harness Check wiring harness. See Group9015-15.

Pump piston Remove and inspect. See Group3360.

Engine Speed Does Not Change Engine speed control actuator Check engine speed control actuatorWhen Power Selector Switch Is solenoid solenoid. See Group 9015-15.Pushed.

Engine speed sensor Check engine speed sensor. SeeGroup 9015-15.

Switch panel 2 Check power selector switch inswitch panel 2. See Group 9015-15.



Engine Idle Speed Is Too Fast or Linkage not adjusted Adjust Linkage. See Group 9010-20.Slow


PN=127



901015

8

TX,9010,LG7 –19–27AUG97–7/11



Engine speed control actuator Check engine speed control actuatorsolenoid solenoid. See Group 9015-15.


Auto Idle Does Not Work Pilot oil pressure switches (swing, Check pilot oil pressure switches.auto idle, and travel) See Group 9015-15.

Switch panel 2 Check power selector switch inswitch panel 2. See Group 9015-15.

Engine speed control actuator Check engine speed control actuatorsolenoid. solenoid. See Group 9015-15.


Coolant Temperature Too Low Thermostat stuck open Replace thermostat. See CTM8 orCTM104.

Temperature gauge Install new gauge or sending unit.

Oil in Coolant or Coolant in Oil cooler leaking Test, repair. See CTM8 or CTM104.Crankcase

Head gasket leaking Inspect, and replace. See CTM8 orCTM104.

Cylinder head cracked Check, replace. See CTM8 orCTM104.

Liner packing leaking and/or cracked Remove pan, inspect bottom end,cylinder block repair, verify and replace if

necessary. See CTM8 or CTM104.

Low Engine Oil Pressure Oil level low Fill.

Oil filter plugged Install new oil filter.

Oil pump intake screen plugged or Clean. See CTM8 or CTM104.loose


PN=128



9010159

TX,9010,LG7 –19–27AUG97–8/11


Wrong grade of oil or fuel dilution Use correct grade of oil. See CTM8or CTM104.

Engine Oil pressure regulating valve Repair valve. See CTM8 orCTM104.

Internal oil passages leak and/or Check, repair. See CTM8 orspray cooling jet missing CTM104.

Pressure pipe from oil pump leaking Check. See CTM8 or CTM104.

Oil pump drive gear loose Check, repair drive gear. See CTM8or CTM104.

Oil pump gear and/or housing worn Repair. See CTM8 or CTM104.

Excessive main or connecting rod Replace main bearings orbearing clearance connecting rod bearings. See CTM8

or CTM104.

High Engine Oil Pressure Oil viscosity wrong (too thick) Drain and refill with correct oil. SeeSection 9000, Group 04.

Pressure regulating valve stuck or Verify, repair. See CTM8 ormisadjusted CTM104.

Piston cooling spray orifices plugged Verify, clean. See CTM8 or CTM104.

Engine oil has anti-freeze Verify, repair, change oil.

Engine Uses Too Much Oil Wrong oil Use correct oil. See Section 9000,Group 04.

Oil level too high Correct. Check to see if some otherfluid is leaking into oil.

Oil leaks Check engine oil drain plug.

Air cleaner plugged Clean air cleaner elements or installnew elements

Crankcase breather restricted Remove, clean. See CTM8 orCTM104.

Engine operating too hot or oil cooler Test cooling system. See Groupwater passage plugged 9010-25. Test thermostat. See

CTM8 or CTM104.


PN=129



90101510

TX,9010,LG7 –19–27AUG97–9/11


Main or connecting rod bearing Replace main bearings orclearance excessive connecting rod bearings. See CTM8

or CTM104.

Pistons or liners scored Check, repair pistons or liners. SeeCTM8 or CTM104.

Piston rings worn, broken or stuck Do Compression Pressure Test. SeeCTM8 or CTM104.

Oil return slots in piston clogged Clean. See CTM8 or CTM104.

Crankshaft thrust bearing worn Check piston and rod assembly. See(misaligned piston and rod) CTM8 or CTM104.

Valve guides or valve stems worn Check, repair. See CTM8 orCTM104.

Engine Uses Too Much Fuel Fuel system leakage Tighten connections. See CTM8 orCTM104.

Plugged or dirty air intake Clean air intake system.


Injection pump static timing Check, injection pump static timing.See CTM8 or CTM104.

Injection nozzles Test, repair nozzles. See CTM8 orCTM104.

Excessive Black Smoke Wrong fuel Use correct fuel.

Plugged or dirty air intake or exhaust Clean air intake and exhaust system.system.

Injection pump static timing Check injection pump timing. SeeCTM8 or CTM104.

Over-fueling Remove and adjust fuel injectionpump. See your Local Fuel InjectionPump Service Center.

Injection nozzle orifice plugged Check and repair. See CTM8 orCTM104.


PN=130



90101511

TX,9010,LG7 –19–27AUG97–10/11


Excessive Blue or White Smoke Cranking speed too slow Check batteries and connections.See Group 9015-10

Injection pump static timing Check injection pump timing. SeeCTM8.

Engine running too "cold" Check thermostat. See Group 0400and CTM8 or CTM104.


Liners have wear and/or piston ring Do Compression Pressure Test instuck CTM8 or CTM104.

Detonation Fuel injection pump static timing Check injection pump static timing.incorrect and/or injection pump See CTM8 or CTM104.advance faulty

Ether starting aid solenoid stuck Check and repair.

Abnormal Noise Oil level low Check and add oil.

Wrong engine oil Use correct oil.

Engine oil diluted with fuel Inspect engine oil. Inspect fuel pumpspindle, seal and housing.

Valve clearance excessive Check, adjust valve. See CTM8 orCTM104.

Engine static timing incorrect Check, adjust. See CTM8 orCTM104.

Push rods bent Inspect, replace push rods. SeeCTM8 or CTM104.

Main and/or connecting rod bearing Inspect main bearing cap screwscaps loose or worn and connecting rod cap screws. See

CTM8 or CTM104.

Piston scored Replace piston. See CTM8 orCTM104.

Piston pin bushings worn Replace pins and bushings. SeeCTM8 or CTM104.

Rocker arm shafts worn Check. See CTM8 or CTM104.


PN=131



90101512

TX,9010,LG7 –19–27AUG97–11/11


Crankshaft end play excessive Check, repair. See CTM8 orCTM104.

Balancer shafts out of time Retime. See CTM8 or CTM104.

Turbocharger Excessively Noisy Bearings not lubricated Insufficient oil pressure. Check foror Vibrates restricted turbocharger oil line.

Worn bearings Replace. See CTM8 or CTM104.

Air leak in engine, intake or exhaust Inspect and repair. See CTM8 ormanifold CTM104.

Improper clearance between turbine Remove exhaust elbow and air inletwheel and turbine housing hose. Inspect and repair. See CTM8

or CTM104.

Broken blades on turbine Remove exhaust elbow and air inlethose. Inspect and repair. See CTM8or CTM104.

Oil Dripping from Turbocharger Damaged or worn bearings and/or Inspect compressor and turbineAdapter worn seals wheel for damaged blades. Check

for proper engine service intervals ordirt entering engine. See CTM8 orCTM104.

Excessive crankcase pressure Check for plugged oil drain line.Clean.

Turbocharger oil return line carbon Remove line. Inspect and clean.buildup where line passes exhaustmanifold.

Excessive Drag in Turbocharger Carbon build-up behind turbine Inspect and clean. See CTM8 orRotating Members wheel caused by combustion CTM104.

deposits

Dirt build-up behind compressor Inspect and repair. See CTM8 orwheel caused by air intake leaks CTM104.

Bearing seizure or dirty or worn Check for plugged air filters. Seebearings caused by excessive CTM8 or CTM104.temperature, unbalanced wheel, dirtyoil, oil starvation, or insufficientlubrication.


PN=132

Group 20Adjustments

9010201TX,9010,DW1341 –19–04JUN97–1/1


M44

215

–UN

–07S

EP

88



TX,9010,DY2347 –19–31JAN97–1/1


M44

215

–UN

–07S

EP

88



901025,AA57 –19–05OCT90–1/1

JT05801 Clamp-On Electronic TachometerInstallation

T68

13A

G–U

N–2

8FE

B89

SERVICE EQUIPMENT AND TOOLS

Tachometer

A—Clamp-On Transducer. Remove paint with emery cloth andconnect to a straight section of injection line within 100 mm (4 in.) ofpump. Finger tighten only—DO NOT overtighten.

B—Black Clip (—). Connect to main frame.

C—Red Clip (+). Connect to transducer.

D—Tachometer Readout. Install cable.


PN=133

Adjustments

901020

2

TX,901020,SS636 –19–08SEP97–1/1

Engine Speed Check

SPECIFICATIONS

Engine Speed Fast Idle 2150 ± 30

Engine Speed Slow Idle 900 ± 30


Electronic Tachometer

1. Warm engine to normal operating temperature.

2. Connect a tachometer to check engine speeds

3. Push power mode select switch to Max. Power “P”mode to check fast idle.

SpecificationEngine Speed—Fast Idle 2150 ± 30.....................................................

4. Push power mode select switch to Low Idle “I”mode to check slow idle speed.

SpecificationEngine Speed—Slow Idle 900 ± 30......................................................

5. If engine speeds need adjustment, See EngineSpeed Control Linkage Adjustment in this group.


PN=134

Adjustments

9010203


PN=135

Adjustments

901020

4

TX,901020,SS582 –19–24FEB95–1/3

Engine Speed Control Linkage Adjustment

T84

19A

B–1

9–28

FE

B95

T75

77A

D–1

9–29

JUL9

1


PN=136


Adjustments

9010205

TX,901020,SS582 –19–24FEB95–2/3

SPECIFICATIONS

“Engine RPM Correct” Indicator 2175—2225 rpmON High Idle Stop ScrewRange

“Engine RPM Correct” Indicator 820—880 rpmON Low Idle Range

“Engine RPM Correct” and 2250—2300 rpm“Engine RPM High” IndicatorsBlinking Together High IdleRange

“Engine RPM Low” Indicator 0—800 rpmBlinks Engine Speed

“Engine RPM Low” Indicator On 800—820 rpmSteadily Engine Speed

“Engine RPM High” Indicator 900 rpm or greaterBlinks Engine Speed

“Engine RPM High” Indicator 880—900 rpmOn Steadily Engine Speed


Tachometer

1. Connect tachometer.

2. Start engine and run until it is at normal operatingtemperature.

3. Before leaving the cab, pull pilot control shut-offlever to locked position. Do not leave machineunattended while engine is running.

4. Loosen cap screws (J). Do not remove cap screws.Move actuator (I) away from roller bearing (L).

5. Loosen nut (H). Turn cap screw (G) in.

6. Hold injection pump lever (A) against slow idle stop(B). Slow idle must be 850 ± 30 rpm.

Hold injection pump lever against fast idle stop (C).Fast idle must be 2275 ± 25 rpm.

If specification is not reached, remove sealing wiresand turn adjusting screws to meet specifications.

NOTE: Rod (D) has left-hand and right-hand threads.

7. Measure rod (D) from center of balljoint to center ofballjoint. Rod length must be approximately 137 mm(5.39 in.) (M), so that the bellcrank slot forms a arcaround injection pump lever balljoint, when lever isagainst slow idle stop. Loosen nuts and turn rod toadjust length, if necessary. Tighten nuts.

8. Position rod so nut (F) is approximately 15 mm (0.6in.) (N) from top of bellcrank (E) slot. Tighten nut(F).

9. Inside the cab, remove four cap screws and thefuse box cover to remove the rear console cover.

10. Push system controller switch twice. Engine speedwill decrease. Actuator piston (K) will be fullyretracted.

11. Hold injection pump lever against slow idle stopand move actuator until piston contacts rollerbearing (L). Tighten cap screws (J).

NOTE: If “Engine RPM Correct” and “Engine RPMLow” or “Engine RPM High” indicators areblinking erratically, the engine linkageadjustment is close to specification.

12. Watch system controller indicators. “Adjust Mode”(green), “Pump Solenoid Valve Current,” and “LowIdle” indicators must be on.

In addition, one of the following indicators will beon.

• If “Engine RPM Correct” indicator is on, go tonext step.

Specification“Engine RPM Correct” IndicatorON—Low Idle Range 820—880 rpm....................................................

• If “Engine RPM Low” indicator is on, loosen rod(D) nuts and turn rod to shorten its length.


PN=137


Adjustments

901020

6

TX,901020,SS582 –19–24FEB95–3/3

Specification“Engine RPM Low” IndicatorBlinks—Engine Speed 0—800 rpm......................................................“Engine RPM Low” Indicator OnSteadily—Engine Speed 800—820 rpm...............................................

• If “Engine RPM High” indicator is on, loosen rod(D) nuts and turn rod to lengthen it.

Specification“Engine RPM High” IndicatorBlinks—Engine Speed 900 rpm or greater...........................................“Engine RPM High” IndicatorOn Steadily—Engine Speed 880—900 rpm.........................................

13. Push system controller switch the third time.Engine speed will increase. Actuator piston will befully extended.

“Adjust Mode” (green) “Pump Solenoid ValveCurrent,” and “High Idle” indicators must be on.

14. Loosen nut (F). While holding injection pump leveragainst fast idle stop, adjust position of nut (F) inbellcrank slot until roller bearing (L) contactsactuator piston (K).

15. Check system controller indicators.

• If both “Engine RPM Correct” and “Engine RPMHigh” indicators are BLINKING TOGETHER, goto next step. (Linkage is adjusted to high idlerange of 2250—2300 rpm.)

Specification“Engine RPM Correct” and“Engine RPM High” IndicatorsBlinking Together—High IdleRange 2250—2300 rpm.......................................................................

• If “Engine RPM High” indicator is on steadily(2225—2350 rpm) ORIf “Engine RPM Correct” indicator is on steadily(2200—2250) OR

Specification“Engine RPM Correct” IndicatorON—High Idle Stop ScrewRange 2175—2225 rpm.......................................................................

If “Engine RPM Low” indicator is blinking or onsteadily (0—2175 rpm),

THEN raise nut (F) in bellcrank slot.

• If “Engine RPM High” indicator is blinking (2350rpm or greater), lower nut (F) in bellcrank slot

16. Push system controller switch a fourth time. Thesystem controller will maintain engine speed at2200 rpm.

“Adjust Mode” (green) “Pump Solenoid ValveCurrent,” “High Idle Stop,” and “Engine RPMCorrect” indicators must be on.

17. Turn screw (G) out until it contacts bellcrank (E).Tighten nut (H).

18. Push system controller switch a fifth time to returnsystem controller to normal operation mode. Allindicators should go out.


PN=138

Adjustments

9010207

TX,9010,LG8 –19–27AUG97–1/1

Engine Speed Sensor Adjustment

T77

26A

B–U

N–1

2MA

R92

Earlier Machine Shown

1. Engine OFF.

2. Turn sensor clockwise (IN) into engine flywheelhousing by hand until sensor touches flywheel.

3. Turn sensor counterclockwise (OUT) 3/4 turn.

4. Turn locknut until it contacts flywheel housing. Tightenlocknut. DO NOT overtighten.

5. Connect sensor connector to harness connector.


PN=139

Adjustments

901020

8


PN=140

Group 25Tests

9010251TX,9010,DW1341 –19–08JUN97–1/1


M44

215

–UN

–07S

EP

88



TX,9010,DY2347 –19–31JAN97–1/1


M44

215

–UN

–07S

EP

88




PN=141

Tests

901025

2

TX,1025,MM,140 –19–28AUG95–1/1

Fuel Line Leakage Test

Connections may allow air to enter the fuel system withoutallowing fuel to leak out. Follow this procedure to find airleaks in the system.

Disconnect fuel supply and fuel return lines at fuel tank.

Drain all fuel from system, including fuel transfer pump,fuel injection pump, and fuel filter(s).

Close end of fuel return line using a plug, cap, or a shortlength of hose, plug, and clamps.

IMPORTANT: Never exceed 103 kPa (1 bar) (15 psi) toprevent damage to fuel systemcomponents.

Pressurize the system to 69 kPa (0.7 bar) (10 psi) at thefuel supply line using a regulated pressure air source.

Apply liquid soap and water solution to all joints andconnections in the fuel system and inspect for leaks.

Repair any leaks.

Connect supply and return lines and prime system.

Start machine and let run for approximately 10 minutes.

NOTE: For engines with an in-line fuel injection pump, aninternal leak path may allow air to enter the fuelsystem. If an internal pump leak is suspected,remove the pump and have a pressure testperformed by an authorized repair station.


PN=142

Tests

9010253

TX,9010,SS530 –19–07JAN93–1/1

Air Filter Restriction Indicator Switch Test

T73

50E

P–U

N–1

7DE

C90

A—SwitchB—TeeC—Barbed FittingD—TubeE—Barbed FittingF—CouplerG—Gauge

SPECIFICATIONS

Restriction Indicator Light 6.2 kPa (62 mbar) (25 in. water)Activation Pressure

ESSENTIAL TOOLS

JT05652 (1/8 F NPT x 1/8 F NPT x 1/8 M NPT) Tee

JT03246 (1/4 F NPT x 1/4 F NPT) (Parker No. 0202-4-4) Coupler


C—(1/8 in.) Barbed Fitting

E—(1/4 in.) Barb Fitting

15 kPa (0-150 mbar) (0-60 in. water) Vacuum Gauge

1. Remove air restriction indicator switch.

2. Install parts as shown.

3. Start engine and slowly cover the air cleaner inlet witha piece of paper or cardboard.

4. Air filter restriction indicator (light) must come on.

SpecificationRestriction Indicator Light—Activation Pressure 6.2 kPa (62 mbar) (25 in. water).................................

5. If reading is not within specifications, install a newindicator switch.


PN=143

Tests

901025

4

TX,9010,LG9 –19–27AUG97–1/1

Air Intake System Leakage Test

T59

06A

P–U

N–2

3FE

B89

T75

76A

E–U

N–3

0JU

L91


1. Remove air cleaner cover and main filter element.

2. Put large plastic bag into and over end of main filterelement as shown. Install main filter element andcover.

3. Remove plug from left side of intake manifold.

4. Connect air pressure regulator to manifold using hoseand fitting from manifold pressure tester.

5. Pressurize air intake system to 14—21 kPa (0.14—0.21 bar) (2—3 psi). If intake system cannot bepressurized, turn engine slightly to close valves.

6. Spray soap solution over all connections from the aircleaner to turbocharger or air intake manifold andcheck for leaks. Correct all leaks.

7. Apply thread lock and sealer (medium strength) toplug. Install plug into intake manifold and tighten.


PN=144

Tests

9010255

TX,901025,SS618 –19–25JUL94–1/2

Radiator Air Flow Test

T60

80A

H–U

N–0

1NO

V88

SPECIFICATIONS

Engine Speed Fast idle

Radiator Air Flow Test Typical 3.30 voltsVoltage Reading

ESSENTIAL TOOLS

JT05529 Air Flowmeter


Volt—Ohm Meter

1. Lower all equipment to the ground.

2. Position all levers and pedals in neutral.

3. Straighten any bent fins in radiator or hydraulic oilcooler.

4. Divide hydraulic oil cooler into 16 equal squares.

5. Connect air flowmeter to voltmeter. Set meter on A.C.volts.

6. Start and run engine at fast idle “P” mode.

SpecificationEngine—Speed Fast idle............................................................................

7. Put air flowmeter against oil cooler with meter centeredin square. Arrow on meter must point in direction of airflow.

8. Record voltage reading for each square.

SpecificationRadiator Air Flow Test—TypicalVoltage Reading 3.30 volts..........................................................................

9. Combined total of air flow test readings must beapproximately at specifications.

10. If readings are less than specifications, clean externalsurfaces of oil cooler and radiator. Repeat test.


PN=145


Tests

901025

6

TX,901025,SS618 –19–25JUL94–2/2

T65

00A

K–1

9–21

MA

R89

T82

88B

L–U

N–2

6JU

L94

11. Divide the surface of the grille into 16 equal squares.

12. Start engine.

13. Perform test at test specifications. Observe correct airflow and place air flow meter in direct contact withgrille. (Arrow pointing to grille.)

14. Record air flow in each square.

15. Combined total of air flow test readings must begreater than specifications.


PN=146

Tests

9010257

TX,9010,DY6287 –19–08SEP97–1/2

Engine Power Test Using TurbochargerBoost Pressure

T75

76A

E–U

N–3

0JU

L91


SPECIFICATIONS

Rated Engine Speed 2000 rpm

Turbocharger Boost Pressure (69 kPa min) (0.69—bar min)Using No. 2 Fuel Without Muffler (10.0 psi min)


Tachometer

0—200kPa (0—2 bar) (0-30 psi) Manifold Pressure Test Gauge

NOTE: Maximum boost pressure will be found with 100—200 rpm of fast idle.

This procedure should be used only as a guide todetermine engine condition.

NOTE: Reduce boost pressure specification by 7% ifusing No. 1 fuel.

1. Connect tachometer. (See procedure in this group.)

2. Remove plug from left side of intake manifold andinstall hose and test gauge.

3. Warm engine to normal operating temperature.

4. Set engine speed at max. power “P” mode switch.

5. Swing upperstructure to side, curl bucket, put bucketon ground and raise one track off the ground.

6. Actuate foot controller to propel raised track in forwardat maximum speed.

IMPORTANT: Gauge accuracy is very critical for thistest. DO NOT make adjustments toinjection pump fuel delivery on machineto raise or lower boost pressure.

NOTE: New engines will not develop specified boostpressure. Check after 50 hours of operation.

7. Watch engine rpm as you slowly activate bucket curlfunction over relief to load engine down below ratedspeed of 2000 rpm.


PN=147


Tests

901025

8

TX,9010,DY6287 –19–08SEP97–2/2

SpecificationRated Engine—Speed 2000 rpm.................................................................

Repeat this step at least six times and record highestreading. The test gauge will show a pressure rise asengine nears rated speed and then pressure will drop off.

If boost pressure is too high, remove and test fuelinjection pump for high fuel delivery.

SpecificationTurbocharger—Boost PressureUsing No. 2 Fuel Without Muffler (69 kPa min) (0.69—bar min)

(10.0 psi min)................

If boost pressure is low, check the following:

• Wrong fuel• Restricted air filter elements.• Restricted fuel filter elements.• Incorrect injection pump timing.• Incorrect fast idle adjustment.• Exhaust manifold leaks.• Intake manifold leaks.• Faulty fuel pump.• Low compression pressure.• Cam lobe wear (valve clearance).• Faulty fuel injection nozzles.• Carbon build-up in turbocharger.• Turbocharger compressor or turbine wheel rubbing

housing.

8. Remove gauge and apply thread lock and sealer(medium strength) to plug. Tighten plug.


PN=148

Section 9015Electrical System

Contents

Page Page

Group 05—System Information Starter Operation . . . . . . . . . . . . . . . . . . .9015-15-20Visually Inspect Electrical System . . . . . . . . .9015-05-1 Starting Circuit Diagnostic Procedures . . . .9015-15-22Circuit Malfunctions Windshield Wiper/Washer Circuit

Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 Operational Information . . . . . . . . . . . . . .9015-15-25High Resistance Circuit . . . . . . . . . . . . . . .9015-05-3 Theory of Operation. . . . . . . . . . . . . . . . .9015-15-26Open Circuit . . . . . . . . . . . . . . . . . . . . . . .9015-05-4 Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-27Grounded Circuit . . . . . . . . . . . . . . . . . . . .9015-05-6 Windshield Wiper And Washer Circuit 9015Shorted Circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-8 Diagnostic Procedures. . . . . . . . . . . . . . .9015-15-28

Using Test Equipment Light CircuitMultimeter . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-9 Operational Information . . . . . . . . . . . . . .9015-15-30Electrical Test Procedure. . . . . . . . . . . . .9015-05-10 Theory of Operation. . . . . . . . . . . . . . . . .9015-15-30Electrical Test Procedure. . . . . . . . . . . . .9015-05-11 Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-31

Wiring Diagram Information. . . . . . . . . . . . .9015-05-12 Light Circuit Diagnostic Procedures. . . . . . .9015-15-32Reading A Wiring Diagram . . . . . . . . . . . . .9015-05-13 Horn, Dome Light, Cigar Lighter and HeaterElectrical Schematic Symbols . . . . . . . . . . .9015-05-14

CircuitsOperational Information . . . . . . . . . . . . . .9015-15-34

Group 10—System Diagrams Theory of Operation. . . . . . . . . . . . . . . . .9015-15-34Component Identification Table . . . . . . . . . . .9015-10-1 Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-35Wiring And Schematic Diagram. . . . . . . . . . .9015-10-3 Horn, Dome Light, Cigar Lighter AndComponent Location Diagram . . . . . . . . . . . .9015-10-7 Heater Circuits Diagnostic Procedures. . .9015-15-36Fuse Specifications . . . . . . . . . . . . . . . . . . . .9015-10-8

Monitor CircuitFuse (Blade-Type) Color Codes . . . . . . . . . .9015-10-9

Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-38Vehicle Harness Wiring Diagram. . . . . . . . .9015-10-10

Operational Information . . . . . . . . . . . . . .9015-15-38Cab Harness Wiring Diagram . . . . . . . . . . .9015-10-11Theory of Operation. . . . . . . . . . . . . . . . .9015-15-39Engine Harness Wiring Diagram . . . . . . . . .9015-10-13Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-41System Functional Schematic . . . . . . . . . . .9015-10-14

Monitor, Monitor Controller And SwitchPanel 1 Circuit Diagnostic Procedures. . .9015-15-42

Group 15—Sub-System DiagnosticsAuto Idle Circuit

Power CircuitOperational Information . . . . . . . . . . . . . .9015-15-50Operational Information . . . . . . . . . . . . . . .9015-15-2Theory of Operation. . . . . . . . . . . . . . . . .9015-15-50Theory of Operation. . . . . . . . . . . . . . . . . .9015-15-2Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-51Schematic . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-3

Auto Idle Circuit Diagnostic Procedures . . .9015-15-52Power Circuit Diagnostic Procedures . . . . . .9015-15-4System Controller CircuitCharging Circuit

Operational Information . . . . . . . . . . . . . .9015-15-59Operational Information . . . . . . . . . . . . . . .9015-15-7Theory of Operation. . . . . . . . . . . . . . . . .9015-15-59Theory of Operation. . . . . . . . . . . . . . . . . .9015-15-8Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-60Schematic . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-9Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-61Alternator Operation—45 Amp Bosch

System Controller Circuit DiagnosticTheory of Operation. . . . . . . . . . . . . . . . .9015-15-10Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-61Alternator Operation—40 Amp Delco Remy

Switch Panel 1 CircuitTheory of Operation. . . . . . . . . . . . . . . . .9015-15-11Operational Information . . . . . . . . . . . . . .9015-15-80Charging Circuit Diagnostic Procedures . . .9015-15-12Theory of Operation. . . . . . . . . . . . . . . . .9015-15-80Starting Circuit

Operational Information . . . . . . . . . . . . . .9015-15-18 Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-81Theory of Operation. . . . . . . . . . . . . . . . .9015-15-18Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-19 Continued on next page


PN=1

Contents

Page

Switch Panel 1 Circuit DiagnosticProcedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-82

Switch Panel 2 CircuitOperational Information . . . . . . . . . . . . . .9015-15-84Theory of Operation. . . . . . . . . . . . . . . . .9015-15-84Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-85

Switch Panel 2 Circuit DiagnosticProcedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-86

Start Aid and Propel Alarm CircuitOperational Information . . . . . . . . . . . . . .9015-15-88Theory of Operation. . . . . . . . . . . . . . . . .9015-15-88Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-89

Start Aid And Propel Alarm Circuit DiagnosticProcedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-90

Group 20—ReferencesMonitor and Switch Panel . . . . . . . . . . . . . . .9015-20-1

9015

Monitor Panel . . . . . . . . . . . . . . . . . . . . . . . .9015-20-2Switch Panel 2 . . . . . . . . . . . . . . . . . . . . . . .9015-20-3Systems Controller Connector. . . . . . . . . . . .9015-20-4Tab Retainer Connector . . . . . . . . . . . . . . . .9015-20-5Connector Pin Location . . . . . . . . . . . . . . . . .9015-20-6Engine Speed Sensor Adjustment . . . . . . . . .9015-20-7Battery

Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-8Specifications. . . . . . . . . . . . . . . . . . . . . . .9015-20-9Diagnose Malfunctions. . . . . . . . . . . . . . .9015-20-10Check Electrolyte and Terminals . . . . . . .9015-20-11Testing. . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-13Booster . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-14Replacement . . . . . . . . . . . . . . . . . . . . . .9015-20-15

Alternator Test (Delco) . . . . . . . . . . . . . . . .9015-20-15Alternator Test (Bosch) . . . . . . . . . . . . . . . .9015-20-16Adding 12-Volt Accessories. . . . . . . . . . . . .9015-20-16Welding On Machine. . . . . . . . . . . . . . . . . .9015-20-17Travel Alarm Volume. . . . . . . . . . . . . . . . . .9015-20-18


PN=2

Group 05System Information

9015051

TX,901505,QQ369 –19–10AUG95–1/1

Visually Inspect Electrical System

Make the following visual electrical inspection prior tostarting the tractor after receiving customer complaint:

1. Look for bare wires that could ground a component orshort across to another component.

2. Look for missing or worn conduit. This could indicate awire problem.

3. Look for loose or broken connectors and wires.

4. Inspect batteries for:

• Corroded terminals• Loose terminals or battery posts• Dirty condition• Damp condition• Cracked case• Proper electrolyte level

5. Check alternator belt tension.

6. After machine has been shut down for five minutesinspect for overheated parts. They will often smell likeburned insulation. Put your hand on the alternator.Heat in these parts when the unit has not beenoperated for some time is a sure clue to chargingcircuit problems.

7. If your visual inspection does not indicate the possiblemalfunction, but your inspection does indicate that themachine can be run, turn the key switch to the IGNposition. Try out the accessory circuits, indicator lights,gauge lights,etc. How does each of these componentswork? Look for sparks or smoke which might indicateshorts.

8. Start machine. Check all gauges for good operationand check to see if system is charging or discharging.

9. In general, look for anything unusual.

Many electrical failures cannot be detected even if themachine is started. Therefore, a systematic andcomplete inspection of the electrical system isnecessary.


PN=151

System Information

901505

2

TX,9015,DY354 –19–24MAY96–1/1

Electrical Circuit Malfunctions

T77

13A

D–1

9–27

FE

B92

A—Battery C—Switch D—Light E—GroundB—Fuse

Malfunctions

1. There are four common circuit malfunctions.

• High-Resistance Circuit• Open Circuit• Grounded Circuit• Shorted Circuit

2. Three sections in a simple circuit where thesemalfunctions can occur;

• Before the controlling switch (C).• Between the controlling switch and before the

component, light (D).

• After the component.

Component malfunctions can easily be confused withcircuit malfunctions. Therefore, care must be exercisedwhen isolating the cause of a problem.

Example: Light does not operate or is dim when switchis turned ON, until switch connector is disconnectedand reconnected.

Reason: High resistance caused by a dirty switchconnector, caused a voltage drop which prevented theproper amount of current from flowing to the light.


PN=152

System Information

9015053

TX,901505,RP968 –19–10AUG95–1/1

High Resistance Circuit

T77

13A

G–1

9–26

FE

B92

A—Battery D—Switch Terminal F—Harness Connector H—LightB—Fuse E—High Resistance G—Light Terminal I—GroundC—Switch

A high resistance circuit can result in slow, dim or nocomponent operation.

Examples: Loose, corroded, dirty or oily terminals.Wire size too small. Strands broken inside the wire.Poor ground connection to frame.

To locate the cause of high resistance:

With switch (C) ON, check for battery voltage betweenswitch and ground (I) at an easily accessible location,like harness connector (F).

If less than battery voltage is measured, check againcloser to switch.

If battery voltage is measured, check closer to groundto locate point of voltage drop. The example showshigh resistance (E) between switch and harnessconnector.

Repair circuit as required. In the example, strandswere broken inside the wire, replace that section ofwire.

Repeat check-out procedure after repair.


PN=153

System Information

901505

4

TX,901505,RP964 –19–10AUG95–1/2

Open Circuit

T77

13A

F–1

9–27

FE

B92

A—Battery D—Switch Terminal F—Open Circuit H—LightB—Fuse E—Harness Connector G—Light Terminal I—GroundC—Switch

An open circuit will result in no components operating.Fuse may or may not be blown.

Example: Broken wire, disconnected componentterminal, pins inside a connector not making contact,blown fuse, open circuit breaker, failed switch orcomponent, or a disconnected ground wire.

To locate an open circuit:

Check fuse. If blown, replace and operate circuit. Iffuse blows a second time, continue check.

With switch (C) ON check for battery voltage at switchterminal (D).

If no voltage is measured, check switch, fuse andwiring to battery.

If battery voltage is measured, check for voltage closerto ground at harness connector (E).

If no voltage is measured, wire may be brokenbetween switch and connector.

If battery voltage is measured, inspect connector pins.If pins are OK check for voltage at light terminal (G).

In the example, zero voltage will be measured at lightterminal, indicating a broken wire between harnessconnector and light terminal.

If battery voltage had been measured, the next checkfor voltage would be at ground connection (I).

Normal measured voltage at a ground connectionshould be 0.0 to 0.5 volts.


PN=154


System Information

TX,901505,RP964 –19–10AUG95–2/2

If battery voltage is measured, poor connection toframe or broken wire is indicated.

When problem is located, repair as needed thenrepeat last check.

9015055


PN=155

System Information

901505

6

TX,901505,RP969 –19–10AUG95–1/2

Grounded Circuit

T77

13A

E–1

9–27

FE

B92

A—Battery D—Switch G—Harness Connector J—LightB—Fuse E—Switch Terminal H—Grounded Circuit K—GroundC—Fuse Terminal F—Harness Connector I—Light (Component) Terminal

If no component operates, the fuse is blown andreplacement fuses blow immediately or the circuitbreaker is open and reopens when reset, a groundedcircuit exists. (Example: power wire contacting frameor other metal component). A wire may be pinched orinsulation may be worn from a wire.

To isolate the location of a grounded circuit:

If circuit is grounded between battery and fuse, wirewill be burned and circuit will be open, fuse will not beblown.

If fuse is blown, remove fuse from circuit, disconnectcircuit near its center, such as harness connector (F),turn switch (D) ON, check for continuity to ground atharness connector (F). This will check harness fromharness connector to fuse.

If continuity to ground is measured, there is a pinchedor bare wire between fuse (C) and harness connector(F).

If continuity to ground does not exist, disconnectground (K) from frame. Measure continuity to groundat harness connector (G). This checks harness fromharness connector to ground terminal. In the examplecontinuity to ground will exist because circuit isgrounded (wire is pinched) at (H).

If continuity exists, disconnect circuit at light terminal(I) and measure continuity to ground on light terminal.This checks harness from light to ground terminal. Inthe example continuity will not exist, indicating agrounded circuit between the light and harnessconnector (G).


PN=156


System Information

TX,901505,RP969 –19–10AUG95–2/2


9015057


PN=157

System Information

901505

8

TX,901505,RP970 –19–10AUG95–1/2

Shorted Circuit

T77

13A

H–1

9–27

FE

B92

A—Battery E—Switch Terminal I—Harness Connector L—LightB—Fuse F—Switch J—Light M—GroundC—Fuse G—Harness Connector K—Light Terminal N—GroundD—Switch H—Shorted Circuit

A shorted circuit causes components in separatecircuits to operate when a switch in either circuit isturned ON. (Example: two harnesses rubbing togetheruntil insulation is worn through allowing bare wires totouch). Components can also become shorted.However, shorted components will usually blow thefuse.

To locate a shorted circuit:

Turn Switch (F) ON then OFF, turn switch (D) ON thenOFF, both lights (J and L) will be ON when eitherswitch (D or F) is ON.

Turn switch (F) ON. Both lights (J and L) will be ON,only light (L) should be ON.

Disconnect wire from switch of component that shouldnot be ON. In the example, disconnect wire fromterminal (E) at switch (D). Light (J) remains ON.

Disconnect circuit at convenient places like harnessconnectors (G), (I) and light terminal (K) until light (J)goes OFF.

The short circuit will be between the last two placesthe circuit was disconnected. In the example, it isbetween harness connectors (G and I). Light (J) will goOFF when harness connector (I) is disconnected.Inspect harness between connectors (G and I).


PN=158


System Information

TX,901505,RP970 –19–10AUG95–2/2

Repair or replace wires and harnesses as needed.Install tie bands and clamps on harnesses as requiredto prevent future failures.


9015059

TX,901505,QQ374 –19–10AUG95–1/1

Multimeter

T71

99A

I–1

9–17

JAN

90

The multimeter is an autoranging digital display thatallows very accurate readings to be taken.


PN=159

System Information

90150510

TX,901505,RP981 –19–19MAR92–1/1

Seven Step Electrical Test Procedure

T77

19A

A–1

9–05

MA

R92

A—Battery Ground D—Fuse Or Circuit Breaker G—Battery Side Of I—Ground Side Of ComponentB—Battery E—Component Side Of Fuse Component Terminal TerminalC—Battery Side Of Fuse Or Or Circuit Breaker H—Light (Component) J—Component Ground

Circuit Breaker F—Switch


PN=160

System Information

90150511

TX,901505,RP986 –19–18AUG99–1/1

Seven Step Electrical Test Procedure—Continued

Step 1—Switch ON

Check battery side of circuit breaker (C) for battery voltage Battery voltage normal. Go to Step 2.Low voltage, repair high resistance. Open circuit from battery.

Step 2—Switch OFF

Check component side of circuit breaker for battery voltage Battery voltage normal. Go to Step 4.Low voltage, repair high resistance.No voltage. Go to Step 3.

Step 3—Switch OFF

Check component side of circuit breaker for continuity to ground Continuity to ground. Repair grounded circuit at or before switch.No continuity to ground, replace circuit breaker.

Step 4—Switch ON

Check component side of circuit breaker for battery voltage Battery voltage normal. Go to Step 6.Low voltage, repair high resistance.No voltage. Go to Step 5.

Step 5a

Disconnect wire at battery side of component (G). Switch ON. Check Battery voltage repair component.wire at (G) for battery voltage No voltage, repair grounded or open circuit at or after switch.

Step 6—Switch ON

Check lead to component at (G) for battery voltage Battery voltage normal. Go to Step 7.Low voltage, repair high resistance or open circuit between fuse andcomponent.No voltage, repair high resistance or open circuit between fuse andcomponent.

Step 7—Switch ON

Check ground wire of component at (I) for voltage No voltage, good continuity to ground. Repair component.Voltage, poor continuity to ground. Repair high resistance or openground circuit.

aA multimeter will not apply a load to the circuit at Step 5. The multimeter result is tested as a voltage condition in the result column.


PN=161

System Information

90150512

TX,901505,RP548 –19–10AUG95–1/1

Wiring Diagram And Schematic Information

System Functional Schematic Diagram-The System Functional Schematic is a schematicdiagram of the complete machine. All harnesses areidentified by letter/number designation and description(W1 Engine Harness, W2 Dash Harness Etc.). Eachwire is identified by number and/or color (G01 BLK,R02 Red, RED/WHT, BLU/GRN Etc.). All componentsare identified by letter/number designation, descriptionand are represented by a schematic symbol.Component letter/number designation, (K1 Start Relay,S1 Key Switch, B9 Horn, Etc.) will indicate thatcomponent throughout the manual. The SystemFunctional Schematic Diagram is divided into Sections.Each section contains one or more electrical circuits.Each section is indicated by a number and circuit (SE1CHARGING CIRCUIT, SE2 STARTING CIRCUIT Etc).

Wiring Diagram-The Wiring Diagram shows each wiring harness, wirecolor, wire destination, harness connectors andschematic symbols for each electrical component

connected to that harness. Harnesses are identified bythe same letter/number designation and descriptionused in the System Functional Schematic Diagram(W1 Engine Harness, W2 Dash Harness Etc.). Eachcomponent schematic symbol will be identified by thesame letter/number designation used in the SystemFunctional Schematic Diagram. Harness connectorswill be identified by a letter/number designation anddescription (X1 CAB HARNESS TO ENGINEHARNESS CONNECTOR, X3 DASH HARNESS TOHEATER BLOWER HARNESS CONNECTOR Etc.).

Component Location Diagram-The Component Location Diagram is a pictorial viewby harness showing location of all electricalcomponents, connectors, harness main groundlocations and harness band and clamp location. Eachcomponent will be identified by the same identificationletter/number and description used in the SystemFunctional Schematic Diagram.


PN=162

System Information

90150513

TX,9015,RP971 –19–31AUG95–1/1

Reading A Wiring Diagram

T85

34A

C–1

9–10

AU

G95

A—Harness Connector D—Component Connector G—Harness Identification J—Wire Number and/or ColorLetter/Number E—Wire Number and/or Color Letter/Number and K—Harness Connector PinIdentification F—Component(s) Identification Description Number or Letter

B—Component Letter/Number Number/Letter Wire is H—Wiring HarnessIdentification Routed To I—Component(s) Identification

C—Component Connector Pin Number/Letter Wire isNumber or Letter Routed To

Each harness on the machine is drawn showingcomponents, connectors and wires. Harnesses (G) areidentified by a letter/number designation anddescription, (W3 PARK BRAKE HARNESS Etc.).

Each component (B) is represented by a schematicsymbol and is identified by the same letter/numberdesignation and description used in the SystemFunctional Schematic. Components with integralconnectors (D) have pin number/letters indicated (C).Wires from harness to components are identified byletter/number designation (E). Component identificationletter/number (F) indicates component wire is routedto.

Main harness connectors (A) are identified by aletter/number designation and description, (X2 PARKBRAKE HARNESS TO DASH HARNESSCONNECTOR Etc.). Harness connector descriptionindicates which harnesses connect together.Connector pin numbers or letters (K) are indicated asthey are marked on the connector. Wires attached toeach connector pin are identified by number and/orcolor designation (J). Component identificationnumber/letter (I) indicates destination of each wire.

Harness, harness connector and componentidentification letter/numbers and description are thesame as used on the System Functional Schematic.


PN=163

System Information

90150514

TX,901505,RP983 –19–26OCT93–1/3

Electrical Schematic Symbols

T77

19B

A–1

9–11

OC

T93


PN=164


System Information

90150515

TX,901505,RP983 –19–26OCT93–2/3

T77

19B

B–1

9–11

OC

T93


PN=165


System Information

90150516

TX,901505,RP983 –19–26OCT93–3/3

T77

19B

C–1

9–17

MA

R92


PN=166

Group 10System Diagrams

TX,901505,QQ381 –19–16SEP92–1/2

Component Identification Table

Each component (electrical device) and main connectorwill have and identification letter assigned to it. A numberis added to the letter to separate and indicate the totalcomponents within that letter group.

9015101



PN=167

System Diagrams

901510

2

TX,901505,QQ381 –19–16SEP92–2/2

Identification Letter Type Examples

A System, subassembly, parts group Control units, trigger boxes, two-way radios, logic module, FNR logicmodule

B Transducer for conversion of non-electrical Speed sensors, pressure sensors, pressure switches horns,variables to electrical and vice versa sensors, pickups, limit-value sensors, pulse generators,

loudspeakers, inductive pickups, probes, air-flow sensors,oil-pressure switches, temperature sensors, ignition-voltage pickups

C Condenser, capacitor Condensers and capacitors, general

D Binary device, memory Digital devices, integrated circuits, pulse counters, magnetic taperecorders

E Various devices and equipment Heating devices, air conditioners, light, headlights, spark plugs,ignition distributors

F Protection device Release mechanisms, polarity protection devices, fuses, currentprotection circuits

G Power supply, generator Batteries, generators, alternators, charging units

H Monitor, alarm, signalling device Audible alarms, indicator lights, turn-signal lights, brake lights,alarms, warning lights, buzzers

K Relay Battery relays, turn-signal relays, solenoid switches, starting relays,warning flashers

L Inductor Choke coils, coils, windings

M Motor Blower motors, fan motors, starter motors

N Regulator, amplifier Regulators (electronic or electromechanical), voltage stabilizers

P Measuring instrument Ammeter, diagnostic connectors, tachometers, fuel gauge, pressuregauges, measuring points, test points, speedometers

R Resistor Flame glow plugs, sheathed-element flame glow plugs, glow plugs,heating resistors, NTC resistors, PTC resistors, potentiometers,regulating resistors

S Switch Switches and pushbuttons, general key switch, light switch, hornswitch, flasher switch

T Transformer Ignition coil, ignition transformer

U Modulator, converter DC transformers

V Semiconductor, electron tubes Transistors, diodes, electron tubes, rectifiers, semiconductors,thyristors, zener diodes

W Transmission path, conductor, antenna Antennas, shielding components, shielded conductors, cableharnesses, conductors, ground conductors

X Terminal plug, plug and socket connection Terminal studs, electrical connections, connectors electrical linecouplers, line connectors, sockets, plugs, terminals, plug-and-socketconnections

Y Electrically actuated mechanical device Permanent magnets, (solenoid-operated) injection valves,electromagnetic clutches and brakes, air valves, fuel pumps,solenoids, switching valves, start valves, locking systems

Z Electrical filter Interference suppression filters


PN=168

System Diagrams

9015103

TX,9015,LG10 –19–27AUG97–1/4

Wiring And Schematic Diagram

B1—Engine Coolant Temperature Sender

B2—Fuel Gauge Sender

B3—Air Filter Restriction Indicator Switch

B4—Engine Oil Pressure Switch

B5—Engine Overheat Switch

B6—Swing Pilot Pressure Switch

B7—Horn

B8—Monitor Buzzer

B9—Engine Oil Level Switch

B10—Coolant Level Switch

B11—Hydraulic Oil Level Switch

B12—Fuel Level Switch

B13—Engine Speed Sensor

B14—Auto Idle Pressure Switch

B15—Propel Alarm

B16—Hydraulic Oil Temperature Switch

B17—Propel Pilot Pressure Transducer

B18—Radiator Level Switch

E1—Left Drive Light

E2—Boom Work Light

E3—Right Drive Light

E4—Dome Light

E5—Alternator Charge Indicator

E6—Engine Oil Pressure Indicator

E7—Air Filter Restriction Indicator

E8—Coolant/Hydraulic Oil Temperature Indicator

E9—Low Fuel Level Indicator

E10—Engine Oil Level Indicator

E11—Coolant Level Indicator

E12—Hydraulic Oil Level Indicator

E13—Compressor Clutch Coil Indicator

E14—Work Light Indicator

E15—Driving Light Indicator

F1—Back-up Fuse

F2—System Controller Fuse

F3—Standby Relay Fuse

F4—Not Used

F5—Power Boost, Speed Change Solenoid, SwingBrake, Propel Alarm, Inj. Pump, System ControllerFuse

F6—Monitor, Monitor Controller, Switch Panel 1

F7—Not Used

F8—Alternator Relay Fuse

F9—Not Used

F10—Not Used

F11—Work Light Fuse

F12—Wiper Fuse

F13—Heater And Air Cond. Clutch Fuse

F14—Not Used


PN=169


System Diagrams

901510

4

TX,9015,LG10 –19–27AUG97–2/4

F15—Horn and Alternator Fuse

F16—Not Used

F17—Lighter Fuse

F18—Interior Light Fuse

F19—Not Used

F20—Start Aid Fuse

F21—Battery Relay Fuse

G1—Battery

G2—Battery

G3—Alternator

H1—Work Light Indicator

H2—Drive Light Indicator

H3—Windshield Wiper Intermittent Indicator

H4—Windshield Wiper Continuous Indicator

H5—Auto Idle Indicator

H6—Low Idle Mode Indicator

H7—Light Duty Indicator

H8—Economy Mode Indicator

H9—Power Mode Indicator

H10—Hydraulic Oil Warm Up Indicator

H11—Slow Propel Speed Indicator

H12—Medium Propel Speed Indicator

H13—Fast Propel Speed Indicator

H14—Precision Mode Indicator

H15—Economy Mode Indicator

H16—General Mode Indicator

H17—Heavy Duty Mode Indicator

K1—Battery Relay

K2—Start Relay

K3—Alternator Relay (12 V, SN —541821) (24V,SN —541822)

K4—Start Aid Relay

K5—Safety Relay

K6—Load Dump Relay

K7—Horn Relay

K8—Work Light Relay

K9—Driving Light Relay

K10—Windshield Washer Relay

K11—Windshield Wiper Relay

K12—Propel Speed Change Relay

K13—Propel Alarm Relay

K14—Power Boost Relay

K15—Swing Brake Release Relay

K16—A/C Compressor Clutch Relay

K17—Swing Brake Delay Relay

K18—Standby Relay

M1—Blower Motor

M2—Windshield Wiper Motor

M3—Starter Motor

M4—Windshield Washer Motor


PN=170


System Diagrams

9015105

TX,9015,LG10 –19–27AUG97–3/4

N1—System Controller

N2—Monitor Controller

N3—Monitor

N4—Switch Panel 1

N5—Switch Panel 2

P1—Hour Meter

P2—Coolant Temperature Gauge

P3—Fuel Gauge

R1—Coolant Temperature Gauge Resister

R2—Fuel Gauge Resister

S1—A/C High Pressure Switch

S2—A/C Low Pressure Switch

S3—Key Switch

S4—Start Aid Switch

S5—Horn Switch

S6—Blower Fan Switch

S7—A/C Switch

S8—A/C Thermostat Switch

S9—Power Boost Switch

S10—Alarm Stop Switch

S11—Fluid Level Check Switch

S12—Windshield Wiper Switch

S13—Windshield Washer Switch

S14—Accelerator Switch

S15—Decelerator Switch

S16—Low Idle Mode Switch

S17—Light Duty Mode Switch

S18—Economy Mode Switch

S19—Maximum Power Mode Switch

S20—Auto Idle Switch

S21—Swing Brake Release Switch

S22—Propel Speed Increase Switch

S23—Propel Speed Decrease Switch

S24—Work Mode Select Switch

S24—Horn Switch

S25—Propel Alarm Cancel Switch

S26—Light Switch

S27—Hydraulic Filter Restriction Indicator PressureSwitch

S28—Auxiliary Switch 1

S29—Auxiliary Switch 2

T1—Boom Light Relay Transistor

T2—Drive Light Relay Transistor

T3—Windshield Wiper Relay Transistor

T4—Windshield Washer Relay Transistor

V1—Alternator Diode

V2—Start Aid Solenoid Diode

V3—Battery Relay Diode

V4—Power Boost Solenoid Diode

V5—Swing Brake Release Solenoid Diode


PN=171


System Diagrams

901510

6

TX,9015,LG10 –19–27AUG97–4/4

V6—Propel Speed Change Solenoid Diode

V7—Auxiliary Foot Controller Solenoid Diode

V8—Not Used

V9—Start Relay Diode

V10—Key Switch Diode

V11—Optional Equipment Diode

V12—Fuel Shut-Off Solenoid Diode

W1—Battery to Engine Ground Connection

W2—Engine to Frame Ground

W3—Battery Ground Strap to Frame

W4—System Controller Ground

W5—Cab Harness to Cab Ground

X1—Cab Harness to Vehicle Harness Connector

X2—Engine Harness to Vehicle Harness Connector

X3—Diagnostic Computer Connector (Not used)

X4—Monitor Controller Connector (Large)

X5—Vehicle Harness to A/C Pressure SwitchConnector

X6—Switch Panel 2 Connector (Small)

X7—Switch Panel 1 Connector

X8—System Controller Connector (Upper)

X9—System Controller Connector (Lower)

X10—Vehicle Harness to A/C Harness Connector

X11—Monitor Controller Connector (Rear)

X12—Monitor Connector (Small)

X13—Monitor Connector (Small)

X14—Key Switch Power Connector

X15—Optional Connectors

X16—12 Volt Accessory Connector

X17—12 Volt Accessory Connector (Earlier Machines)

X18—Auxiliary Foot Controller Connector

X19—Auxiliary Foot Controller Solenoid Connector

X20—Vehicle Harness to A/C Harness Connector

X21—Switch Panel 2 Connector (Large)

X22—Radio Connector

X23—Radio Speaker Connector

X24—A/C Pressure Switch Connector

Y1—Starter Solenoid

Y2—Fuel Shutoff Solenoid

Y3—Start Aid Solenoid

Y4—Swing Brake Release Solenoid

Y5—Engine Speed Actuator (Solenoid)

Y6—Pump Displacement Solenoid

Y7—Power Boost Solenoid

Y8—Propel Speed Change Solenoid


PN=172

System Diagrams

TX,9015,LG10Z –19–16FEB00–1/1

Component Location DiagramT110380 –19–28OCT97


PN=173

System Diagrams

901510

8

TX,901505,RP549 –19–29JUN93–1/1

Fuse Specifications

T77

13A

J–U

N–0

6MA

R92

F1—1 Amp Back upF2—1 Amp System ControllerF3—5 Amp Standby RelayF4—Not UsedF5—5 Amp Power Boost, Propel Speed Change

Solenoid, Swing Brake, Propel Alarm, Inj. Pump,System Controller

F6—10 Amp Monitor, Monitor Controller, Switch Panel1, Switch Panel 2, A/C Switch and Blower Relay

F7—Not UsedF8—5 Amp Alternator RelayF9—Not UsedF10—Not UsedF11—20 Amp Work LightsF12—5 Amp Wiper/WasherF13—20 Amp Blower and Air Cond. ClutchF14—Not UsedF15—10 Amp Horn and AlternatorF16—Not UsedF17—10 Amp LighterF18—5 Amp Cab Interior LightF19—10 Amp Circulation FanF20—20 Amp Start AidF21—1 Amp Battery Relay Fuse (Located in-line with

battery relay)

IMPORTANT: Install fuse with correct amperagerating to prevent electrical systemdamage from overload.

Fuse block is located behind the operators seat under afuse block cover.


PN=174

System Diagrams

9015109

04T,90,J22 –19–28SEP92–1/1

Fuse (Blade-Type) Color Codes

SpecificationBlack Blade-Type Fuse—Amperage 1 amp.........................................................................................Violet Blade-Type Fuse—Amperage 3 amp.........................................................................................Pink Blade-Type Fuse—Amperage 4 amp.........................................................................................Tan Blade-Type Fuse—Amperage 5 amp.........................................................................................Brown Blade-Type Fuse—Amperage 7-1/2 amp...................................................................................Red Blade-Type Fuse—Amperage 10 amp.......................................................................................Light Blue Blade-Type Fuse—Amperage 15 amp.......................................................................................Yellow Blade-Type Fuse—Amperage 20 amp.......................................................................................Natural (White) Blade-TypeFuse—Amperage 25 amp............................................................................Light Green Blade-Type Fuse—Amperage 30 amp.......................................................................................


PN=175

System Diagrams

TX,9015,DY6299 –19–16OCT97–1/1

Vehicle Harness Wiring DiagramT110381 –19–28OCT97


PN=176

System Diagrams

TX,901510,RP614 –19–23FEB95–1/2

Cab Harness Wiring DiagramT8327AF –19–23SEP97


PN=177

System Diagrams

TX,901510,RP614 –19–23FEB95–2/2

T8327AG –19–23SEP97


PN=178

System Diagrams

TX,9015,DY6298 –19–09SEP97–1/1

Engine Harness Wiring Diagram

G

R

21

BAT

G

B01

RE

D

MOTORSTARTERM3

G01

BLK

BATTERYTO G2

SOLENOIDSTARTERY1

GROUNDFRAMEENGINE TOW2

ENGINE HARNESS

SENDERTEMPERATURECOOLANTENGINEB1

SWITCHLEVELOILENGINEB9

SOLENOIDCLUTCH COILCOMPRESSORCONDITIONERAIRY9

SENSORSPEEDENGINEB13

SOLENOIDACTUATORSPEEDENGINEY5

SOLENOIDDISPLACEMENTPUMPY6

SWITCHPRESSUREOILENGINEB4

CONNECTORVEHICLE HARNESSENGINE HARNESS TOX2

SWITCHOVERHEATENGINEB5

BATTERYTO G1

SOLENOIDFUEL SHUTOFFY3

CONNECTORALTERNATORX11

ALTERNATORG3

Q

18 A04 ORG17 Y02 YEL16 X03 YEL15 X01 YEL14 R51 BLK13 P55 RED12 N02 YEL11 M01 PUR10 J03 TAN9 E63 WHT8 E01A WHT7 G03 BLK6 E01 WHT5 E62 WHT4 P58 RED3 H56 GRN2 P57 RED1 B03 RED

J03

TA

N

M01

PU

R

B0

3A

RE

D

B0

3A

RE

D

P5

5A

RE

D

X2

B03

RE

D

X2

J0

3 T

AN

X2

M01

PU

R

M3

G02

BLK

E6

2 W

HT

X2

E6

3 W

HT

X2

X2

E0

1 W

HT

X2

E0

1A

WH

T

B4

,B5

G0

4 B

LK

X2

G03

BLK

G3

G02

BLK

R51

RE

D X

2

A0

4 O

RG

X2

N0

2 Y

EL

X2

G04

BLK

M3

X0

1 Y

EL

X2

Y0

2 Y

EL

X2

M3

G04

BLK

X2

X0

3 Y

EL

X2

P55

RE

D

n

H56

GR

N X

2

P57

RE

D X

2

P58

RE

D X

2

G04

BLK

M3

NO

T U

SE

D

R S

M

P

T

DELCO(541821)BOSCH(541822)

G3ALTERNATOR

G

G

B03 RED

B03

A R

ED

G02

BLK

J03

TA

N

M01

PU

R

B03

A R

ED

ALTERNATORDIODE

WB+

D+

G3Y6Y6Y5

B17Y1

M3Y1

B13X11X11B4Y3

B13B1B5B9Y9

T110391 CV

T110391 –19–08SEP97


PN=179

System Diagrams

TX,9015,DY6297 –19–09SEP97–1/4

System Functional Schematic

CV

2 5 4

NCNOCOIL

COMCOIL

31

1O 2 5 4

NCNOCOIL

COMCOIL

31

2 5 4

NCNOCOIL

COMCOIL

31

2 5 4

NCNOCOIL

COMCOIL

31

2 5 4

NCNOCOIL

COMCOIL

31

2 5 4

NCNOCOIL

COMCOIL

31

2 5 4

NCNOCOIL

COMCOIL

31

BLK

1O

WH

TE

06

BL

KG

03

BLKG03

BL

KG

03

87

8586

87

A

30

87

8586

87

A

30

R

21

BAT

G

ST

G2

M

G1

BAT

2

01

ACC

3

1A

F21

W1

HORN, WINDSHIELD WIPER, WASHER AND WORK LIGHT CIRCUITCHARGING CIRCUITSTART CIRCUIT

RED/BLK

E2E3

E1

S5

M4

K9

K10HORNB7

K7

M02 PUR

BL

K

K5

K4

K6

BRN/WHT

K3

PU

RM

02

V2

V3

J02 TAN

V9

B03

RE

D

B01

RE

D

B03

RE

DR

03 B

LK

E0

1 W

HT

RED/WHT

RED/BLK

W3

Y1

W2G2

G3

S4

K1K2

Y2

S3

M3

87A

RED/BLK

RED/WHT

G04 BLKBLK

G03 BLK

R02

G50

G04 BLKBLK

G03 BLK

R02

G50

G04 BLKBLK

G03 BLK

R02

G50

RED/BLKRED

RED/WHT

REDB01

RE

D/W

HT

G0

3

SYSTEM FUNCTIONAL SCHEMATIC (1 OF 4)

L01

G0

3

G0

3 G0

3

YE

L/B

LK

RED/GRN

RE

D

BLUYEL/BLK

BLU/YEL

WHT

RED

A01

G0

3

PU

RP

UR

BL

K

RE

D

RE

D

RE

D

BLU/WHT

RE

D

BL

U/W

HT

RE

D/W

HT

J03 TAN

J03 TAN

G0

3 B

LK

G0

2 B

LK

RED/BLU

RED/BLKRED/BLK

BLK/WHT RED/BLKWHTBLK/

B01 RED

G5

0

-

+

-

+

B01

RE

D

STARTONACCOFF

G0

4 B

LK

A0

3 O

RG

M

30

8785

86

B03 RED

E06 WHT

M02 PUR

M01 PUR

J0

2 T

AN

J03

TA

N

J02 TAN

E0

2 W

HT

E01 WHT

R03 BLKG

03

BL

K

G0

3 B

LK

G01

BLK P02 RED

B0

3 R

ED

B03 RED

B01 RED

B01 RED

B01 RED

SB

M

CONTINUED ON NEXT PAGE

1 4

2

5

3

6

B G1 2G ACC M ST

1 2 3 4 5 6

G

D+

G3

B+W

T110392

START AIDSOLENOIDDIODE

V10KEYSWITCHDIODE

BATTERYFUSERELAY1 AMP

J02TAN

J02

TA

NJ0

2T

AN

BATTERYRELAYDIODE

STARTRELAYDIODE

E02

WH

T

ALTERNATORDELCO( 541821)

BATTERIES

BATTERYGROUND

ENGINETO FRAMEGROUND

STARTERMOTOR

STARTERSOLENOID

STARTRELAY

BATTERYRELAY

B03ARED

ALTERNATORBOSCH (541822)

B03RED

B03ARED

G03

BLK

J02TAN

M01PUR

ALTERNATORDIODE

ALTERNATORRLEAY

LOAD PUMPRELAY

HORNRELAY

WINDSHIELDWASHERRELAY

RED/GRN

RE

D/

GR

N

RE

D/

GR

N

RE

D/

GR

N

WORKLIGHTRELAY

K8DRIVELIGHTRELAY

BOOMWORKLIGHT

LEFTDRIVELIGHT

RIGHTDRIVELIGHT

WINDSHIELDWASHERMOTOR L0

2B

RN

RE

D/

WH

T

L01

BR

N

RE

D/

BLK

YE

L/G

RN

HORNSWITCH

SAFETYRELAY

YEL/WHT

STARTAIDRELAY

STARTAIDSWITCH

STARTAIDSOLENOID

KEYSWITCH

CAB TOFRAMEGROUND

RE

D/

WH

T

T110392 –19–08SEP97


PN=180

System Diagrams

TX,9015,DY6297 –19–09SEP97–2/4

T8395AD –19–23SEP97


PN=181

System Diagrams

TX,9015,DY6297 –19–09SEP97–3/4

T8041AI –19–23SEP97


PN=182

System Diagrams

TX,9015,DY6297 –19–09SEP97–4/4

T8395AE –19–22SEP97


PN=183

System Diagrams

90151018


PN=184

Group 15Sub-System Diagnostics

9015151


PN=185

Sub-System Diagnostics

901515

2

TX,901515,MD72 –19–29JUN93–1/1

Power Circuit Operational Information

The following conditions must be met for the circuit tofunction:

Voltage must be present at these points.

Key switch OFF:

• Battery positive terminals• Key switch terminal B• Battery relay terminal B• Fuses F1, F2 and F3

Key switch ACC:

• All the above locations plus;• Key switch ACC terminal• Fuses F15, F17, F18 and F19

Key switch ON:

• All the above locations plus;• Key switch terminal M• Battery relay terminal S and A• Battery relay fuse F21• Battery relay diode• Fuses F5, F6, F8, F11, F12, F13 and F20

TX,901515,MD73 –19–23FEB95–1/1

Power Circuit Theory Of Operation

The power circuit includes batteries, key switch,battery relay, battery relay fuse, battery relay diodeand all other fuses.

With key switch OFF, power from batteries goes toterminal B of key switch, terminal B of battery relay, F1Back up fuse, F2 System controller fuse, F3 Standbyrelay fuse.

With key switch turned to ACC, power goes to aboveplaces plus F15 Horn fuse, F17 Lighter fuse, F18Dome light fuse and F19 Circulation fan fuse.

The standby relay energizes and provides power to thesystem controller.

With key switch turned ON, power goes to all abovelisted components, plus battery relay terminal S, F5Systems controller fuse, F6 monitor fuse, F8 Alternatorfuse, F11 Work light fuse, F12 Wiper fuse, F13 Heaterfuse and F20 Start aid fuse.


PN=186


9015153

TX,901515,RP619 –19–13MAR95–1/1

Power Circuit Schematic

T80

33A

M–1

9–28

FE

B95


PN=187


– – –1/1

Power Circuit Diagnostic Procedures

IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to SystemController or other components may result. Disconnect connectors only when instructed during a test orcheck.

901515

4

– – –1/1

Battery State Of ChargeCAUTION: Engine may crank during this check.

Move light switch to ON position. Turn key to START. Do work lights go out or get verydim while cranking engine?

YES: Clean battery cableterminals. Repeat test.

If lights still get dim, testbattery.

If battery charge is low,recharge or replace it.

NO: Battery charge isgood. Go to next check.

– – –1/1

Battery Voltage Check

T7487AF –UN–20MAR91

Measure battery voltage by connecting a voltmeter to (-)negative battery terminal grounded to frame and (+)positive battery terminal connected to machine harness.

Is 24 to 28 volts measured?

YES: Batteries are OK.Go to next check.

NO: Batteries areundercharged. Go toBattery Test.


PN=188


9015155

– – –1/1

Key Switch Check

T8357AK –UN–09NOV94

Remove harness from key switch.

Turn key to ACC position.

Is continuity measured between terminals 1 and 4?

YES: Go to next step inthis check.

NO: Key switch has failedif continuity is notmeasured or continuity ismeasured between otherterminals. Replace.

T8357AL –UN–09NOV94


Turn key to ON position.

Is continuity measured between terminals 1 and 4 also 1and 5?





Turn key to START position.

Is continuity measured between terminals 1 and 3 also 1and 5 also 1 and 6?

YES: Key switch is OK.


– – –1/1

Battery Relay Check

T7586CA –UN–16AUG91

Disconnect harness from relay. Connect 24 volts to one small terminal and groundother small terminal. Measure continuity between large terminals.

Is continuity measured?

YES: Relay is OK. Checkwiring harness.

NO: Relay has failed.Replace relay.


PN=189


– – –1/1

Battery Relay DiodeCheck

T7961AA –UN–10MAR93

NOTE: A diode can fail in two modes, either shorted oropen. Continuity will be measured in one direction onlyin a serviceable diode.

Remove diode from connector.

Connect an ohmmeter to diode terminals.


Reverse ohmmeter probes.


YES: If continuity ismeasured in both checks,diode has failed in ashorted mode. Replace.

NO: If continuity is NOTmeasured in either checkdiode has failed in anopen mode. Replace.

NO: If continuity ismeasured in one checkand not the other, diodeis OK.

901515

6

– – –1/1

Fuse Check


Remove cover from fuse box.

Key switch ON.

Connect black (-) probe of multimeter to screw head in console to ground it.

Set multimeter to measure 24 volts.

Connect multimeter red (+) probe to the outside slot in each fuse.

Is 24 volts measured on each fuse.

YES: Fuses are OK. Goto next check.

NO: Replace any fusewithout 24 voltsmeasured on outside slot.Check wiring harness.


PN=190


9015157

TX,901515,RP554 –19–29JUN93–1/1

Charging Circuit Operational Information


Voltage must be present at these points:

Key switch OFF:

• Positive battery terminal• Key switch terminal B• Starter terminal B• Load dump relay terminals 1 and 3• Battery relay terminal B• Fuses F1, F2 and F3

Key switch ON:

Voltage is present at above listed locations plus:

• Key switch terminal ACC• Fuses F15, F17, F18 and F19• Key switch terminal M• Key switch diode• Battery relay fuse F21• Battery relay diode• Battery relay terminal S• Battery relay is energized• Battery relay terminal A• Start relay terminal 87• Alternator BAT terminal and Sense terminal #2• Fuses F6, F8, F11, F12, F13


PN=191


901515

8

TX,901515,MD75 –19–29JUN93–1/1

Charging Circuit Theory Of Operation

The charging circuit includes key switch, alternator,batteries, battery relay, alternator relay, start relay,load dump relay, safety relay, fuses, charge indicatorlight, systems controller, monitor controller andmonitor.

With key switch OFF, power from battery goes to keyswitch terminal B, starter motor terminal B, batteryrelay terminal B, alternator terminal BAT and 2, fusesF1, F2 and F3.

With key switch ON, current flows from key switchACC terminal to fuse F15, 17, 18 and 19. Current fromfuse F15 goes to alternator Excite terminal 1. Currentalso flows from terminal M to key switch diode, batteryrelay fuse, battery relay diode, battery relay terminal Senergizing it sending current to start relay terminal 87,alternator terminals BAT and Sense #2, fuses F6, F8,F11, F12, F17, F18 and F19.

As engine starts, 24 volts from alternator terminal Rflows to alternator relay terminal 86 energizing it(Alternator relay is a 12 volt relay). Alternator outputvoltage from BAT terminal is sent to fuse F8. Voltagefrom fuse F8 goes through terminals 87 and 30 ofalternator relay to monitor controller terminal 4 andzener diodes in monitor controller. Zener diodesbecome conductors as alternator output voltageincreases above 6 volts sending a signal to monitorcontroller circuit. When more than 6 volts is present at

monitor controller terminal 4, voltage is sent outterminal 8 to monitor terminal 9, turning chargeindicator light OFF. With more than 6 volts present atmonitor controller terminal 4, transistor at terminal 34is energized providing a ground for hour meter andload dump relay. When load dump relay is energized,it sends voltage to battery relay, "locking" it energized.If the key is momentarily turned OFF then ON,alternator output remains connected to batteriesthrough battery relay terminals A and B. Alternatorwould be damaged if it were disconnected frombatteries. Load dump relay remains energized as longas alternator produces voltage.

Output current from alternator BAT terminal goes tobatteries to charge them as needed, current also flowsto key switch terminal B supplying power to operatemachine functions.

Safety relay is energized whenever alternator isproducing voltage. When safety relay is energized itremoves ground from start relay coil. Start relay cannotsupply voltage to starter solenoid, preventing starterengagement with engine running.

As long as alternator is producing voltage, the safetyrelay, load dump relay, and battery relay remainenergized, even if the key switch is momentarily turnedOFF then back ON.


PN=192


TX,901515,RP620 –19–23FEB95–1/1

Charging Circuit SchematicT8396AA –19–23SEP97


PN=193


90151510

TX,9015,DT5085 –19–07JUL97–1/1

Alternator Operation—45 Amp Bosch

T77

51G

M–1

9–14

SE

P92

There are three basic stages for proper operation ofthe Bosch alternator. They are as follows:

Pre-excitation stage—when the key switch is turned toON, battery current flows to the excitation winding,through the regulator and then to ground.

This stage is necessary because the residualmagnetism (remanence) in the iron core of theexcitation winding is not sufficient for building up themagnetic field and thus to generate the desiredvoltage.

Excitation stage—throughout the entire operating timeof the alternator, a magnetic field in the excitationwinding of the rotor induces the desired voltage in thethree-phase winding of the stator. Some current fromthe stator is rectified by the exciter diodes and is

supplied to the carbon brushes and collector rings ofthe excitation winding. The current is then passedthrough the regulator, through the negative diodes andback to the three-phase winding of the stator.

When the alternator is operating, no external powersource is needed for self-excitation. Self-excitation isinitiated by the residual magnetism (remanence) in theiron core of the excitation winding. When the engineturns the alternator during initial start-up, the residualmagnetism, aided by pre-excitation, induces a slightvoltage in the stator winding. This voltage causes aslight current flow from the stator winding to theexcitation winding, strengthening the magnetic field inthe excitation winding. This, in turn, will increase thestator voltage. This will occur continuously until thealternator is fully excited and the generator voltage isreached.


PN=194


90151511

TX,901515,RP400 –19–22JUL92–1/2

Alternator Operation—40 Amp Delco Remy

T77

09A

E–1

9–27

FE

B92

A—Alternator E—Charge Indicator I—R Terminal M—StatorB—Battery F—Diode J—BAT Terminal N—Rotor (Field)C—Key Switch G—Terminal 1 K—Diode Trio O—RegulatorD—Excitation Resistor H—Terminal 2 L—Rectifier

This alternator produces 24 volts.

When key switch (C) is turned ON, voltage is appliedto terminal 1 (G) of the alternator. The regulator (O)switches the rotor (N) ON or OFF.

Once the engine reaches alternator cut in RPM, ACcurrent is produced in the stator windings (M). Thisalternating current is changed to DC current by therectifier (L) diodes. Voltage is available at BAT (J)terminal. The current is used to charge the battery (B)and supply electrical current to the machine electricalsystem. Once alternator is charging, field current issupplied by the diode trio (K). Diode (F) protects thediode trio from external loads.

The regulator (O) acts like a switch for the rotor (N). Awire runs from BAT terminal (J) to terminal 2 (H). If theregulator (O) senses a low battery voltage, rotor isswitched on. Field current increases and alternatoroutput increases.

When high battery voltage is sensed by the regulatorthe rotor is switched off, reducing current output fromstator. This on and off occurs many times a second.The voltage regulator is temperature compensated toprovide a slightly higher voltage at low temperature tocharge the battery.


PN=195



TX,901515,RP400 –19–22JUL92–2/2

When the alternator is operating, R terminal voltage is12-16 volts AC. This voltage is sometimes applied to arelay to control the charging indicator light. This

machine uses alternator relay K13 for this purpose.Relay K13 is a 12 volt relay.

90151512

– – –1/1

Charging Circuit Diagnostic Procedures


– – –1/1

Alternator Output

T6569AZ –UN–23AUG93

Key switch OFF.

Measure and record battery voltage.

Start and run engine at 1500 rpm, and check batteryvoltage.

Does battery voltage increase?

YES: Alternator is good.Check wiring harness.Check battery.

NO: Check alternator.

– – –1/1

Bosch Alternator Check

T7835AT –19–23SEP92

Harness connected. Key switch ON. Engine running.

Check for voltage at D+ and B+ alternator terminals.

Is 26—28 DC volts measured?

YES: Alternator is OK.Check harness fromalternator to monitor.

NO: Alternator is failed.Repair or replace.


PN=196


90151513

– – –1/1

Alternator Check(DELCO)

T7320AR –19–01AUG90

Connect a multimeter to battery positive (+) terminal and frame (ground).

Start engine and run at approximately 1500 RPM.

Insert a small screwdriver into test hole in rear of alternator and ground tab toalternator case while monitoring multimeter reading.

Does multimeter read about 24 volts before starting engine, and does reading increasesteadily to 28-30 volts after tab is grounded?

YES: Alternator is good.Replace regulator.

NO: Alternator is failed.Replace or repair.

– – –1/1

Charge Indicator LightCheck—BOSCHAlternator


Key switch ON.

Engine OFF.

Disconnect BLU/YEL wire from alternator D+ terminal.Connect a jumper wire from BLU/YEL wire to ground.

Is charge indicator light ON?

YES: Continue on.

NO: Check harnessbetween alternator andmonitor. Also checkcharge indicator bulb.

T6768CR –UN–18OCT88

Reconnect BLU/YEL wire to alternator.

Start engine.

Does charge indicator light go OFF.

YES: Charge indicatorlight and harness are OK.

NO: Check harness forshort circuits betweenmonitor and monitorcontroller. Also checkalternator output.


PN=197


90151514

– – –1/1

Charge Indicator LightHarness Check

T7586CL –UN–17JUL93

Key switch OFF.

Disconnect harness from monitor controller and cab harness to vehicle harnessconnector.

Measure continuity of purple wire M02 between monitor controller connector and cabharness connector.


YES: Harness is OK.Check alternator harness.

NO: Repair harness.

– – –1/1

Alternator HarnessCheck

T6768FP –UN–18OCT88

Measure continuity of purple wire M01 betweenalternator relay and alternator terminal R.


YES: Harness is OK.Check alternator relay.

NO: Repair harness.


PN=198


90151515

– – –1/2

Charge Indicator LightCheck

T6768FP –UN–18OCT88

Key switch ON.

Engine OFF.



NO: Check voltage onalternator terminal #1. 10volts or more, alternatorhas failed, checkalternator. Less than 10volts, continue check.

T7461AJ –UN–05MAR91

Key OFF. (Delco)

Key ON (Bosch)

Disconnect harness from monitor controller.

Measure continuity from alternator terminal #1 to pin #4 in harness side of monitorcontroller connector.


YES: Continue on.

NO: Repair harnessbetween alternator andmonitor controller.

T7461AK –UN–05MAR91

Key switch ON.

Measure voltage on pin #1 in harness side of monitor controller connector.

Is 24 volts measured?

YES: Continue on.

NO: Repair harnessbetween monitorcontroller and valvecontroller fuse.


PN=199


90151516

–19– –2/2

T7461AN –UN–01APR91 T7461AL –UN–05MAR91

Key OFF.

Reconnect harness connector to monitor controller.

Remove bottom cover from right monitor panel and pivot upwards to access wireharness.

Disconnect 12 pin connector to monitor panel.

Measure continuity between pin #9 and ground.


YES: Charge light hasfailed, replace monitorpanel.

NO: Repair harnessbetween monitor andmonitor controller.

– – –1/1

Alternator Relay Check


NOTE: Alternator relay is a 12 volt relay.

Disconnect harness from alternator relay.

Connect 12 volts to alternator terminal #86 and groundterminal #85.

Does relay “click”?

Connect ohmmeter to terminals 30 and 87.

Does ohmmeter read continuity?

Connect ohmmeter to terminals 30 and 87A.

Does ohmmeter read an open?

YES: Relay is OK.

NO: Relay has failed.Replace.


PN=200


90151517

– – –1/1

Battery Relay Check






– – –1/1

Load Dump Relay Check


Disconnect harness from alternator relay.



Connect ohmmeter to terminals #30 and #87.


YES: Relay is OK.



PN=201


90151518

TX,901515,RP391 –19–29JUN93–1/1

Starting Circuit Operational Information


Voltage must be present at these locations:

Key switch ON;

• Battery positive cable• Terminals B, A, and S of battery relay• Battery relay is energized• Fuel shut-off solenoid• Fuel shut-off diode• Key switch diode• Battery relay fuse• Battery relay diode

• BAT terminal and terminal 2 (excite) of alternator• Start relay terminal 87• Batt terminal of key switch• Starter terminal B• All fuses

Key switch in START;

• Key switch ST terminal• Start relay diode• Start relay terminals 86 and 85• Safety relay terminals 3 and 4 to ground• Start relay is energized• Starter terminal S• Starter is engaged

TX,901515,MD74 –19–29JUN93–1/1

Starting Circuit Theory Of Operation

With key switch ON current from terminal M goes tofuel shut-off solenoid energizing it. Current goesthrough key switch diode and battery fuse to batteryrelay diode then to battery relay energizing it.

When battery relay is energized, current is sent toalternator and start relay.

Current from key switch terminal ST goes to start relayterminal 86, if safety relay is de-energized it provides aground for start relay, which then energizes. Safety

relay is energized when the alternator producescurrent, which is sent to the monitor controller. Whenthe monitor controller receives current from alternator,it provides a ground for safety relay, energizing it,removing ground from start relay, preventing thestarter from engaging when the engine is running.

Current from start relay terminal 30 goes to startersolenoid energizing it sending current to starter motorto start engine.


PN=202


90151519

TX,9015,DY6296 –19–09SEP97–1/1

Starting Circuit Schematic

T11

0398

–19–

09S

EP

97


PN=203


90151520

901505,PP3 –19–12MAR93–1/2

Starter Operation

T64

63A

B–U

N–0

7NO

V88

A—Wire From RelayB—Cable From BatteryC—Pull-In WindingD—Hold-In WindingE—Solenoid PlungerF—Main ContactsG—Field WindingsH—Commutator BrushesI—ArmatureJ—Shunt WindingK—Starter SolenoidL—Starter

IMPORTANT: Never operate starter longer than 30seconds. Allow at least 2 minutes forcooling and battery recovery beforeoperating again. Overheating caused byexcessive operation will seriouslydamage starter.

When wire (A) from start relay is energized, current flowsto ground through both pull-in winding (C) and hold-inwinding (D). Current through windings engages solenoidplunger (E), which closes main contact (F). When maincontacts close, both ends of pull-in winding have samevoltage, so current through pull-in winding stops. Currentcontinues through hold-in winding, keeping solenoidengaged and main contacts closed.

With main contacts closed, current flows from batterycable (B) to starter. Four heavy field windings (G) carrycurrent to commutator brushes (H).

Light shunt windings (J) are wrapped together with two ofthe heavy field windings. Shunt windings are connected tosolenoid switch terminal and directly to ground. Theyprovide additional low speed torque to assist enginerotation and prevent overspeed of starter.

From field windings, current flows to ground througharmature windings (I), making contact through commutatorbrushes.

Strong magnetic fields are set up by current flow throughfield windings and armature windings. Windings arearranged so that magnetic fields constantly repel eachother, causing the armature to rotate.



PN=204


90151521

901505,PP3 –19–12MAR93–2/2

R25

228

–UN

–14N

OV

88

1—Snap Ring 7—Field Connector 13—Field Windings 19—Brake Washer2—Drive End Housing 8—End Frame Cover 14—Armature 20—Wear Pads3—Shift Lever 9—Brush 15—Pole Shoe 21—Overrunning Clutch4—Plunger 10—Bushing 16—Oil Seal 22—Pinion Stop5—Shunt Field Terminal 11—Thrust Washer 17—Bushing 23—Bushing6—Solenoid Assembly 12—Commutator 18—Felt

When solenoid (6) engages, it pulls shift lever (3). Shiftlever pushes overrunning clutch drive (21) to engagepinion in starter gear on flywheel. As armature (14)turns, it cranks engine.

When engine starts, overrunning clutch spins freely onshaft to prevent over-speeding of armature by flywheel.

When key switch is released, current to solenoidhold-in windings shuts off. Current can feed throughboth pull-in and hold-in windings from main contacts,

but direction of current is reversed in pull-in winding.The two windings cancel each other, and solenoid isreleased.

A spring pushes solenoid back to disengaged position.This opens main contacts and shuts off current to fieldwindings and armature.

Shift lever retracts overrunning clutch drive,disengaging pinion from flywheel. Brake washer (19)slows armature to a stop.


PN=205


– – –1/1

Starting Circuit Diagnostic Procedures


90151522

– – –1/1

Key Switch Check

T7395EJ –UN–15OCT90

Disconnect harness from key switch. Turn key switch toON.

Connect ohmmeter to BAT terminal and ACC then Mterminals.

Does ohmmeter read continuity on both terminals?

YES: Continue on.

NO: Key switch hasfailed. Replace.

T7395EK –UN–15OCT90

Disconnect harness from key switch.

Turn key switch to START.

Connect ohmmeter to BAT terminal and M then STterminals.

Does ohmmeter read continuity on both terminals?

YES: Key switch is OK.Check wiring harness.

NO: Key switch hasfailed. Replace.

– – –1/1

Starter Solenoid

T6534BI –UN–19OCT88

CAUTION: Starter will crank engine if metalstrap is NOT disconnected from motor.

Disconnect metal strap from starter motor large terminal.

Connect battery voltage to solenoid small terminal.

Ground metal strap from solenoid with heavy gaugewire.

Does solenoid click?

YES: Solenoid is good.Check wiring harness.

NO: Replace startersolenoid.


PN=206


– – –1/1

Starting Motor Check

T6534BJ –UN–07JAN97

CAUTION: Starter will crank engine if metalstrap is NOT disconnected from startingmotor.

Disconnect metal strap from starting motor largeterminal.

Connect a heavy gauge wire from battery positive cableto starting motor terminal.

Does starting motor turn, but NOT crank engine.

YES: Starting motor isgood. Check wiringharness.

NO: Repair or replacestarting motor.

90151523

– – –1/1

Start Relay Check






– – –1/1

Start Relay Diode Check












PN=207


– – –1/1

Safety Relay Check


Disconnect harness from relay.

Connect 24 volts to relay terminal #86 and groundterminal #85.




YES: Relay is OK.


90151524

– – –1/1

Fuel Shut-Off SolenoidCheck

T7568AD –19–19JUL91

Turn key switch ON. Measure voltage at shut-offsolenoid harness terminal.

Does voltmeter read 24 volts?

YES: Shut-off solenoid isfailed, or injection pumphas a mechanicalproblem.

NO: Fuse F5 has failed,or wiring harness fromkey switch terminal M hasfailed.

T7568AF –19–19JUL91

Key OFF. Disconnect harness from fuel shut-offsolenoid. Measure resistance of solenoid.

Does ohmmeter measure resistance?

YES: Fuel shut-offsolenoid is OK. Wireharness has failed.

NO: Fuel shut-offsolenoid has failed.Replace.

– – –1/1

Fuel Shut-Off SolenoidDiode Check












PN=208


TX,901515,RP76 –19–29JUN93–1/1

Windshield Wiper And Washer Circuit Operational Information


Voltage must be present at these points;

• Fuses F1, F6, F12

• Pin #1 and #12 of switch panel 1 harness connector• Terminals 86 and 30 of windshield washer relay• Terminal 86 of windshield wiper relay• Terminals B, P and S of windshield wiper motor

90151525


PN=209


90151526

TX,901515,RP348 –19–29JUN93–1/1

Windshield Wiper And Washer Circuit Theory Of Operation

The windshield wiper and washer circuit includeswindshield wiper motor, windshield wiper relay,windshield washer motor and pump, windshield washerrelay, switch panel 1 logic circuit, windshield wiperswitches, windshield washer switch, 10 amp monitorfuse F06, 1 amp backup fuse F1, and 5 amp wiperfuse F12.

With key switch ON power from fuse block goesthrough 5 amp wiper fuse F12 to terminals 86 and 30of windshield washer relay K10, terminal 86 ofwindshield wiper relay K11 and terminals B, P and Sof windshield wiper motor. Power also goes through 10amp monitor fuse F6 to terminal 1 of switch panel 1logic circuit and 1 amp backup fuse F1 to terminal 12of switch panel 1 logic circuit.

When windshield wiper switch S12 is OFF, pushing itonce activates logic circuit in switch panel 1 to apply apositive voltage to base of transistor T3. With positivevoltage applied to the base of transistor T3 it turns ONallowing voltage to flow through it, making a ground forwindshield wiper relay K11 energizing it. Logic circuitalso applies voltage to wiper continuous operationindicator H1 illuminating it.

With windshield wiper relay K11 energized, terminal 85of relay supplies ground to windshield wiper motor M2,causing it to operate in continuous mode.

When windshield wiper switch S12 is pushed again,logic circuit changes wiper motor operation tointermittent by turning transistor T3 ON and OFF andilluminating intermittent operation indicator H2.

When windshield wiper switch S12 is pushed oncemore it’s OFF. Logic circuit removes voltage fromtransistor T3 turning it OFF. When transistor T3 isOFF, ground is removed from windshield wiper relay,de-energizing it. Windshield wiper motor continues tooperate because park switch is operated by a cam onwindshield wiper motor shaft. As windshield wipermotor rotates, the cam opens and closes park switchto alternately connect it to ground or power.

When windshield wiper relay is de-energized, groundis removed from windshield wiper motor. The cam onwindshield wiper motor shaft closes park switch andsupplies ground for motor until cam opens park switchground connection and closes park switch powerconnection.

With park switch closed, 12 volts is applied towindshield wiper motor armature and field windingsstopping the motor. Voltage applied to armature andfield windings prevents motor from drifting so wiperblade stays in park position.

When windshield washer switch S13 is pushed,voltage is applied to base of transistor T4 causing it toconduct current energizing windshield washer relaysending current to windshield washer pump motor,causing it to run and drive pump to spray fluid onwindshield. When switch S13 is not pushed, washerpump motor stops.


PN=210


90151527

TX,901515,RP705 –19–07JUL93–1/1

Windshield Wiper And Washer Circuit Schematic

T75

71A

D–1

9–30

JUN

93


PN=211


– – –1/1

Windshield Wiper And Washer Circuit Diagnostic Procedures


90151528

– – –1/1

Windshield Wiper RelayCheck







YES: Relay is OK.


– – –1/1

Windshield WasherRelay Check







YES: Relay is OK.



PN=212


90151529

– – –1/1

Windshield Wiper SwitchCheck

T7395EA –UN–08MAY91

Disconnect harness from switch panel #1.

Ground harness terminal #7.

Does windshield wiper operate?

YES: Check switch panel#1.

NO: Check windshieldwiper motor.

T7395EC –UN–15OCT90



Does windshield washer operate?


NO: Check windshieldwasher motor.

– – –1/1

Windshield Wiper MotorCheck

T7395EF –UN–15OCT90

Disconnect harness from windshield wiper motor.

Connect 24 volts to wiper motor connector terminals withBLUE/YELLOW wire and YELLOW wire.

Ground wiper motor connector terminals withBLUE/WHITE wire and BLACK wire.

Does windshield wiper motor operate?

YES: Check harness.

NO: Replace windshieldwiper motor.

– – –1/1

Windshield Wiper MotorPark Circuit Check

T7395EH –UN–15OCT90

Connect 24 volts to BLUE/YELLOW wire terminal andYELLOW wire terminal in wiper motor connector.

Ground BLUE/WHITE wire terminal and BLACK wireterminal in wiper motor connector.

Disconnect wire from BLUE/WHITE wire terminal inwiper motor connector.

After wire is disconnected, does wiper motor continue tooperate until blade reaches park position?

YES: Check harness.

NO: Replace windshieldwiper motor.


PN=213


– – –1/1

Windshield WasherMotor Check

T7395EG –UN–15OCT90

Disconnect harness from windshield washer motor.

Connect 24 volts to BLUE wire terminal in washer motorconnector.

Ground BLUE/BLACK wire terminal in washer motorconnector.

Does windshield washer motor operate?

YES: Check wiringharness.

NO: Replace windshieldwasher motor.

90151530

TX,901515,MD78 –19–19MAR92–1/1

Light Circuit Operational Information



• Fuses F1, F6 and F11• Pin #1, 2, 3, 4 and 12 of switch panel #1 harness

connector.

TX,901515,MD43 –19–29JUN93–1/1

Light Circuit Theory Of Operation

With key switch ON or in ACC position power goesthrough 20 amp work light fuse F11 to drive light relayterminals 1 and 3, and work light relay terminals 1 and3. Power comes from 10 amp monitor fuse F6 toswitch panel 1 terminal 1 to logic circuit. Power alsocomes from 1 amp back-up fuse F1 to switch panel 1terminal 12 to logic circuit.

When light switch S9 is pushed once, power goesthrough logic circuit to base of transistor T2 and to H1driving light indicator. Positive voltage on base oftransistor T2 turns it ON allowing current to flowthrough it and provide a ground for driving light relayK9, energizing it. Current flows from terminal 5 ofdriving light relay K8 turning on right and left drivinglights and light switch back-lights.

When light switch S9 is pushed a second time powergoes through logic circuit to base of transistor T1 andto H2 drive light indicator. Positive voltage on base oftransistor T1 turns it ON allowing current to flowthrough it and provide a ground for work light relay K9energizing it. Currant flows from terminal 5 of worklight relay K9 turning driving lights. Work lights arealready ON.

Push light switch once more, logic circuit removesvoltage from transistors T1 and T2 turning all lightsOFF.


PN=214


90151531

TX,901515,RP461 –19–29JUN93–1/1

Light Circuit Schematic

T80

35A

C–1

9–30

JUN

93


PN=215


– – –1/1

Light Circuit Diagnostic Procedures


90151532

– – –1/1

Drive Light Relay Check



Connect 24 volts to relay terminal #86 and groundterminal #85.




YES: Relay is OK.


– – –1/1

Work Light Relay Check







YES: Relay is OK.


– – –1/1

Drive Light Switch Check

T7447BI –19–14JAN91

Disconnect harness from switch panel 1.


Does drive light operate?


NO: Check wire harness.


PN=216


90151533

– – –1/1

Work Light Switch Check

T7461AN –UN–01APR91 T7478AO –UN–11MAR91


Ground harness connector terminal #3.

Does work light operate?

YES: Switch panel #1has failed. Replace.

NO: Check wire harnessbetween work light relayand switch panel #1.


PN=217


TX,901515,RP433 –19–29JUN93–1/1

Horn, Dome Light, Cigar Lighter And Heater Circuits Operational Information

The following conditions must be met for the circuits tofunction:

Voltage must be present at these points:

• F13 heater blower fuse.

• F15 horn fuse.• F17 lighter fuse.• F18 dome light fuse.• Horn relay terminal 86 and 30.• Interior light bulb.• Cigarette lighter.

90151534

TX,9015,MD49 –19–18NOV92–1/1

Horn, Dome Light, Cigar Lighter And Heater Circuits Theory Of Operation

With key turned on power flows to 10 amp horn fuseF15, 20 amp heater blower fuse F13, 5 amp interiorlight fuse F18, and 10 amp cigar lighter fuse F7.

Power from 10 amp horn fuse F15 flows to horn relayK7 terminal 86 and 30. When horn switch S5 ispushed power flows through horn relay coil to ground,energizing relay. Power flows from terminal 30 toterminal 87 and to horn B11.

Power from 20 amp heater fuse F13 flows to heaterblower switch S31 terminal P. When blower motorswitch is turned to low, power flows through tworesistors and in-line fuse through blower motor, toground, blower motor runs at low speed. When blower

motor switch is turned to medium, power flows throughone resistor, in-line fuse through blower motor toground, blower motor runs at medium speed. Whenblower motor switch is turned to high, power by-passesresistors and in-line fuse and flows directly to blowermotor and to ground, blower motor runs at high speed.

Power from 5 amp interior light fuse F18 flows tointerior light E4. When switch is turned ON, powerflows through interior light to ground.

Power from 10 amp cigar lighter fuse F7 flows to cigarlighter R1. When cigar lighter is pushed, power flowsthrough lighter to ground causing lighter to get hot.


PN=218


90151535

TX,901515,RP623 –19–07JUL93–1/1

Horn, Dome Light, Cigar Lighter And Heater Circuits Schematic

T75

71A

G–1

9–30

JUN

93


PN=219


– – –1/1

Horn, Dome Light, Cigar Lighter And Heater Circuits Diagnostic Procedures


90151536

– – –1/1

Horn Relay Check



Connect 24 volts to relay #86 and ground terminal #85.




YES: Relay is OK.


– – –1/1

Horn Switch Check

T7469AE –UN–01APR91

Remove bottom cover from left arm rest. Disconnect wireharness from horn switch. Connect ohmmeter to bothwires, (pink and black). Push horn button. Doesohmmeter read continuity?

YES: Horn switch OK.Check wiring harness.

NO: Replace switch.

– – –1/1

Horn Check


Disconnect wire harness from horns. Connect 24 volts toone terminal of either horn. Connect other horn terminalto ground. Does horn sound? (Repeat check on otherhorn).

YES: Check wireharness.

NO: Replace horn.


PN=220


90151537

– – –1/1

Heater Blower SwitchCheck


Disconnect wire harness from heater blower switch (A).Connect ohmmeter to brown wire in switch connectorand to positive terminal of heater blower motor. Turnblower switch to Low speed. Does ohmmeter readcontinuity?

YES: Continue on.

NO: Replace heaterblower switch.


Turn heater blower switch (A) Medium speed. Doesohmmeter read continuity?

YES: Continue on.



Turn heater blower switch (A) to High speed. Doesohmmeter read continuity?

YES: Check heaterblower motor.


– – –1/1

Heater Blower MotorCheck

T7469AG –UN–11MAR91

Disconnect harness from motor.

Connect 24 volts to one motor terminal, ground otherterminal.

Does motor operate?

YES: Check harness.

NO: Replace motor.

– – –1/1

Interior Light Check

T7469AH –UN–05MAR91

Remove white lens from interior light.

Disconnect harness from dome light.

Connect 24 volts to connector from light, connect mountscrew to ground.

Light switch ON.

Does light come ON?

YES: Check harness orground connection atmount screw.

NO: Check bulb, replaceif failed. Replace light ifswitch has failed.


PN=221


90151538

TX,9015,RP965 –19–22JUL92–1/1

Monitor, Monitor Controller And Switch Panel 1 Circuit Specifications

SpecificationFuel Gauge Reads Full—Resistance 10 ± 5 ohms.......................................................................Fuel Gauge Reads Half—Resistance 38 ± 5 ohms.......................................................................Fuel Gauge Reads Empty—Resistance 90 ± 5 ohms.......................................................................Fuel Level Switch (NormallyOpen)—Closing Level Less than 110 mm (4 5/16 in.)

fuel in tank.........................

Engine Oil Pressure Switch(Normally Closed)—OpeningPressure Above 172 kPa (25 PSI)........................................................Closing Pressure Below 103 kPa (15 PSI)..........................................Engine Coolant TemperatureIndicator Switch (NormallyOpen)—Closing Temperature Above 110 ± 5°C (230 ± 35°F).............Alternator Charge IndicatorLight Illuminates—AlternatorOutput Voltage 10 ± 1.5 volts or less...................................................Alternator Charge IndicatorLight Goes Out—AlternatorOutput Voltage 23 ± 1.5 volts or more.................................................Air Filter Restriction Switch(Normally Open)—ClosingPressure 4.98—7.48 kPa (49.9—74.8

mbar) (1.47—2.21 in. Hg)(20—30 in. water) vacuum

..................................................

Coolant Temperature GaugeNeedle at Beginning of WhiteArea (Cold)—Temperature 67°C (153°F).............................................Coolant Temperature GaugeNeedle at End of White Area—Temperature 100°C (212°F).................................................................Coolant Temperature GaugeNeedle at Beginning of RedArea (Hot)—Temperature 103°C (217°)...............................................Coolant Temperature GaugeNeedle at End of Red Area(Hot)—Temperature 135°C (275°F)......................................................Coolant Temperature Sensor—Resistance at 67°C (153°F) 49.8 ohms...............................................Resistance at 100°C (212°F) 17.8 ohms.............................................Resistance at 103°C (217°F) 16.4 ohms.............................................Resistance at 135°C (275°F) 0 ohms..................................................Hydraulic Oil TemperatureSwitch (Normally Open)—Closing Temperature Above 102°C (212°F).........................................

TX,901515,MD80 –19–21AUG91–1/1

Monitor, Monitor Controller And Switch Panel 1 Circuit Operational Information



• Fuses F1 and F6• Monitor terminal #1

• Monitor controller terminal #1• Monitor controller terminal #4 with engine running• 1-7 volts, voltage varies at engine coolant gauge

sender and fuel gauge sender• 5 volts monitor controller terminals #18, 19, 20, 21,

22, 25, and 26


PN=222


90151539

TX,9015,RP556 –19–16OCT97–1/2

Monitor, Monitor Controller And Switch Panel 1 Circuit Theory Of Operation

The monitor circuit consists of hour meter, coolanttemperature gauge, fuel gauge, engine oil levelindicator, engine oil pressure indicator, coolant levelindicator, coolant temperature indicator, alternatorcharging indicator, fuel low level indicator, air cleanerrestriction indicator, hydraulic oil level indicator.

Hour meter operates when alternator is charging andload dump relay is energized. Monitor gauges receivesignals from sensors to indicate level or temperature.

Monitor controller contains a logic circuit andtransistors to control ground signals for monitorindicator lights. Monitor controller receives signals fromengine oil level switch, coolant level switch, hydraulicoil level switch, engine coolant temperature switch,engine oil pressure switch, fuel level switch and airfilter restriction switch.

Monitor controller provides voltage to transistors iftemperatures, pressures or levels are outside normallimits to illuminate indicator lights.

SpecificationAlternator Charge IndicatorLight Illuminates—AlternatorOutput Voltage 10 ± 1.5 volts or less...................................................Alternator Charge IndicatorLight Goes Out—AlternatorOutput Voltage 23 ± 1.5 volts or more.................................................Hydraulic Oil TemperatureSwitch (Normally Open)—Closing Temperature Above 102°C (212°F).........................................

Engine oil level switch is closed when oil level is OK.Coolant level switch is closed when coolant level inrecovery tank is OK. Hydraulic oil level switch is closedwhen level is OK. Fuel level switch is closed whenlevel is OK.

SpecificationFuel Level Switch (NormallyOpen)—Closing Level Less than 110 mm (4 5/16 in.)

fuel in tank.........................

Fuel Gauge Reads Full—Resistance 10 ± 5 ohms.......................................................................

Fuel Gauge Reads Half—Resistance 38 ± 5 ohms.......................................................................Fuel Gauge Reads Empty—Resistance 90 ± 5 ohms.......................................................................

Engine coolant temperature switch is open whentemperature is below normal operating temperature.

SpecificationEngine Coolant TemperatureIndicator Switch (NormallyOpen)—Closing Temperature Above 110 ± 5°C (230 ± 35°F).............Coolant Temperature GaugeNeedle at Beginning of WhiteArea (Cold)—Temperature 67°C (153°F).............................................Coolant Temperature GaugeNeedle at End of White Area—Temperature 100°C (212°F).................................................................Coolant Temperature GaugeNeedle at Beginning of RedArea (Hot)—Temperature 103°C (217°)...............................................Coolant Temperature GaugeNeedle at End of Red Area(Hot)—Temperature 135°C (275°F)......................................................Coolant Temperature Sensor—Resistance at 67°C (153°F) 49.8 ohms...............................................Resistance at 100°C (212°F) 17.8 ohms.............................................Resistance at 103°C (217°F) 16.4 ohms.............................................Resistance at 135°C (275°F) 0 ohms..................................................

Engine oil pressure switch opens above 172 kPa (25psi) and closes below 103 kPa (15 psi).

SpecificationEngine Oil Pressure Switch(Normally Closed)—OpeningPressure Above 172 kPa (25 PSI)........................................................Closing Pressure Below 103 kPa (15 PSI)..........................................

Engine air filter restriction switch closes when vacuumis above 635 mm (25 in.) water, and opens whenvacuum is below 520 mm (20.5 in.) water.

SpecificationAir Filter Restriction Switch(Normally Open)—ClosingPressure 4.98—7.48 kPa (49.9—74.8

mbar) (1.47—2.21 in. Hg)(20—30 in. water) vacuum

..................................................


PN=223



TX,9015,RP556 –19–16OCT97–2/2

Switch panel 1 contains: Work light switch andindicators, Monitor buzzer cancel switch, Fluid level

check switch, Windshield wiper switch and indicatorlight, Windshield washer switch and indicator light.

90151540


PN=224


TX,9015,RP560 –19–29JUN93–1/1

Monitor, Monitor Controller And Switch Panel 1 Circuit SchematicT8041AK –19–23SEP97


PN=225


– – –1/1

Monitor, Monitor Controller And Switch Panel 1 Circuit Diagnostic Procedures


90151542

– – –1/1

Charge Indicator LightCheck

T7469AI –UN–14MAR91

IMPORTANT: DO NOT start engine with jumperattached to alternator.

Key switch ON.

Engine OFF.

Disconnect harness from alternator. Connect a jumperwire to harness connector terminal #1 (indicator terminal)and ground.


YES: Continue on.

NO: Check harnessbetween alternator andmonitor.

T6768CR –UN–18OCT88

Remove jumper wire from alternator.

Reconnect harness to alternator.

Start engine.

Does charge indicator light go OFF.

YES: Charge indicatorlight OK.

NO: Check harness forshort circuits betweenmonitor and monitorcontroller.


PN=226


90151543

– – –1/1

Coolant Level IndicatorAnd Switch Check

T7469AK –UN–14MAR91 T7469AJ –UN–11MAR91

Check coolant level in overflow recovery tank, be sure level is between FULL andLOW marks.

Turn key switch to ON position.

Observe coolant level indicator.

Does indicator come ON then go OFF 2-3 seconds later?

YES: Indicator bulb isOK.

NO: Continue on.


T6768CS –UN–09MAY94

Push fluid level check switch.

Does coolant level indicator come ON?

YES: Coolant level switchis OK.

NO: Continue on.

T7469AL –UN–14MAR91

Disconnect harness from coolant level switch.

Connect a wire between harness wires.

Turn key switch ON.

Push fluid level check switch (A).

Does coolant indicator come ON?

YES: Coolant level switchhas failed. Replace.

NO: Check harnessbetween coolant levelswitch and monitorcontroller terminal #19.


PN=227


90151544

– – –1/1

Engine Oil LevelIndicator And SwitchCheck

T7469AM –UN–11MAR91 T7470AL –UN–05MAR91

Check oil level in engine pan, be sure level is between FULL and ADD marks on dipstick.

Turn key switch to ON position.

Observe engine oil level indicator.

Does indicator come ON then go OFF 2-3 seconds later?

YES: Indicator bulb isOK.

NO: Continue on.

T7470AH –UN–11MAR91


Disconnect harness from engine oil level switch.

Connect a wire from harness connector to ground.

Turn key switch ON.

Push fluid level check switch (A).

Does engine oil level indicator come ON?

YES: Coolant level switchhas failed. Replace.

NO: Check harnessbetween coolant levelswitch and monitorcontroller connector #19.


PN=228


90151545

– – –1/1

Hydraulic Oil LevelIndicator And SwitchCheck

T7470AI –UN–11MAR91 T6768CU –UN–09MAY94

Check oil level in hydraulic reservoir, be sure level is between red lines on sightgauge.

Turn key switch ON.

Press fluid level check switch.

Does hydraulic oil level indicator come ON?

YES: Hydraulic oil levelindicator bulb is OK.

NO: Continue on.

T7470AJ –UN–05MAR91

Disconnect harness from hydraulic oil level switch.

Connect a wire between harness terminals.

Turn key switch ON.

Push fluid level check switch.

Does hydraulic oil level indicator come ON?

YES: Hydraulic oil levelswitch has failed.Replace.

NO: Check harnessbetween hydraulic oillevel switch and monitorcontroller terminal #20.

– – –1/1

Engine TemperatureIndicator And SwitchCheck

T7470AN –UN–05MAR91

Turn key switch ON.

Observe engine temperature indicator.

Does indicator come ON when key switch is turned ON,then go OFF 2-3 seconds later?

YES: Indicator and switchare OK.

NO: Continue on.

T7470AM –UN–05MAR91

Disconnect harness from engine temperature indicatorswitch.

Connect a wire between harness connector terminals.

Start engine.

Observe engine temperature indicator.

Does engine temperature indicator come ON whenengine is started and stay ON?

YES: Engine temperatureswitch has failed.Replace.

NO: Check harnessbetween enginetemperature switch andmonitor controller terminal#22. Does indicator comeON when engine starts?


PN=229


90151546

– – –1/1

Engine Oil PressureIndicator And SwitchCheck

T7470AO –UN–05MAR91

Turn key switch ON.

Start engine.

Observe engine oil pressure indicator.

Does indicator come ON when key switch is turned ON,then go OFF after engine is started?

YES: Indicator and switchare OK.

NO: Continue on.

T7470AP –UN–05MAR91

Disconnect harness from engine temperature indicatorswitch.

Connect a wire between harness connector terminals.

Start engine.

Observe engine oil pressure indicator.

Does engine oil pressure indicator come ON whenengine is started and stay ON?

YES: Engine temperatureswitch has failed.Replace.

NO: Check harnessbetween enginetemperature switch andmonitor controller terminal#21.

– – –1/1

Air Filter RestrictionIndicator And SwitchCheck

T6768DC –UN–18OCT88

Turn key switch ON.

Observe air filter restriction indicator.

Does indicator come ON then go OFF 2-3 secondslater?

YES: Air filter restrictionindicator and switch areOK.

NO: Continue on.

T7472AB –UN–14MAR91

Disconnect harness from air filter restriction switch.

Connect a wire from harness connector to ground.

Start engine and observe air filter restriction indicator.

Does air filter restriction indicator come ON when engineis started and stay ON?

YES: Air filter restrictionswitch has failed.Replace.

NO: Check harnessbetween air filterrestriction switch andmonitor controller terminal#26.


PN=230


90151547

– – –1/1

Fuel Gauge Check

T7461AN –UN–01APR91 T7472AF –UN–11MAR91

Disconnect harness from both monitor connectors.

Connect 24 volts to monitor connector terminal #5.

Ground monitor connector terminal #18.

Does gauge needle point to “E” before test wires are connected and “F” after wires areconnected?

YES: Gauge and gaugeresistor is OK.

NO: Gauge or gaugeresistor has failed.Replace.

– – –1/1

Fuel Gauge SenderCheck

T7472AE –UN–11MAR91 T7472AD –UN–11MAR91

NOTE: Check fuel gauge before checking sender.

Disconnect harness from fuel gauge sender.

Observe fuel gauge.

Does gauge needle go to “E”?

Reconnect harness to fuel gauge sender.

Connect a wire between center wire connection of fuel gauge sender and ground.

Does gauge needle go to “F”?

YES: Sender has failed.Replace.

NO: Check harnessbetween fuel gaugesender and monitorterminal #5.


PN=231


90151548

– – –1/1

Engine TemperatureGauge Check


Disconnect harness from both monitor connectors.

Connect 24 volts to monitor connector terminal 4.

Ground monitor connector terminal 18.

Does gauge needle point to “C” before test wires are connected and “H” after wiresare connected?

YES: Gauge is OK.Check harness betweensender and monitor.

NO: Gauge or gaugeresistor has failed. Checkgauge resistor.

– – –1/1

Engine TemperatureGauge Resistor Check

T8366AE –UN–17NOV94

NOTE: Resistor is located under the monitor panel.Access resistor by removing bottom cover from monitorpanel.

Disconnect harness from resistor bullet-type connectors.

Connect ohmmeter to connectors.

Does ohmmeter read about 220 ohms?

YES: Gauge resistor isOK.

NO: Gauge resistor hasfailed. Replace.

– – –1/1

Coolant TemperatureGauge Sender Check

T8359AJ –UN–10NOV94

Disconnect harness from coolant temperature gaugesender.

Connect ohmmeter to sender and ground.

Start engine and observe ohmmeter.

Does ohmmeter reading decrease as engine becomeswarmer?

YES: Sender is OK.

NO: Sender has failed.Replace.


PN=232


90151549

– – –1/1

Hourmeter Check

T7461AN –UN–01APR91 T8423AA –UN–28FEB95

Disconnect monitor harness large connector.

Connect 24 volts to monitor connector terminal #1.

Ground monitor connector terminal #3.

Observe hourmeter.

Does hourmeter operate?

YES: Check harnessbetween fuse #6 andmonitor, also checkharness between monitorterminal #3 and monitorcontroller terminal #34.

NO: Hourmeter hasfailed. Replace.

– – –1/1

Horn Switch Check Remove bottom cover from left arm rest. Disconnect wire harness from horn switch.Connect ohmmeter to both wires, (pink and black). Push horn button. Does ohmmeterread continuity?

YES: Horn switch OK.Check wiring harness.

NO: Replace switch.


PN=233


TX,901515,MD77 –19–19MAR92–1/1

Auto Idle Circuit Operational Information



• Fuses F2 and F5.• System controller connector terminals #24, #26, #37,

#39

90151550

TX,9015,RP557 –19–19MAR92–1/1

Auto Idle Circuit Theory Of Operation

Auto idle circuit contains F2 system controller fuse, F5power boost fuse, Switch panel 2, System controller,Engine speed actuator, Engine speed sensor, Propelpilot pressure transducer, auto idle pressure switch,Swing pilot pressure switch.

Auto idle circuit is activated by pushing auto idle switchon switch panel 2. Auto idle indicator light is ON whenauto idle circuit is activated. Auto idle circuit controlsengine speed in E (Economy) mode, L (Light Duty)mode and P (Max. power) mode, I (Low idle) mode isnot controlled by auto idle. Signals from engine speedsensor allow system controller to monitor enginespeed. Engine injection pump linkage is controlled byengine speed actuator.

Auto idle pressure switch senses dig functions pilotpressure. Propel pressure transducer senses propelsystem pilot pressure. Swing pilot pressure switchsenses swing pilot pressure.

When engine is started with auto idle ON, engine runsin L mode until E or P mode switches are pushed.Engine speed actuator solenoid is then energizedallowing pilot oil to move piston rod against bellcrankof engine control linkage moving injection pump lever,increasing engine speed to E or P mode setting. If ahydraulic function is not used within 3-6 seconds,system controller returns engine speed to L mode.When a hydraulic function is used, auto idle pressureswitch or propel pressure transducer senses pilot oilpressure, sending a signal to system controller.System controller sends a signal to engine speedactuator to adjust engine speed to specified modesetting.

Auto idle will not change engine speed if I mode switchis pushed, Engine will remain at Idle mode speed untila different mode switch is pushed.


PN=234


90151551

TX,9015,RP624 –19–13MAR95–1/1

Auto Idle Circuit Schematic

T75

71A

I–1

9–28

FE

B95


PN=235


– – –1/1

Auto Idle Circuit Diagnostic Procedures


90151552

– – –1/1

Switch Panel 2 HarnessCheck

T7473AI –UN–11APR91 T7473AJ –UN–11MAR91

Disconnect white 10 pin connector from switch panel 2 harness.

With Key switch ON, measure voltage on pins 1 and 2 in harness side of connector.


YES: ReconnectHarness. Continue on.

NO: Harness from fusesF1 or F6 is failed. Repair.


PN=236


90151553

– – –1/1

Auto Idle Switch ToSystem ControllerHarness Check

T7473AI –UN–11APR91


Disconnect black 12 pin connector from switch panel 2.

Disconnect lower connector from system controller.

Measure continuity between pin #12 in black 12 pin connector and pin #18 in systemcontroller connector (Green/White wire).


YES: Wire to auto idleswitch is OK.

NO: Wire from systemcontroller to auto idleswitch failed. Repair.


PN=237


90151554

– – –1/1

Mode Switch HarnessFrom Switch Panel 2 ToSystem Controller Check

T7473AK –UN–10JUN93

NOTE: Auto idle circuit will operate normally if indicator light has failed. Indicator lightcannot be repaired, switch panel #2 must be replaced to repair.

Disconnect white 10 pin connector from switch panel 2.

Disconnect lower connector from system controller.

Measure continuity between pins in switch panel connector and pins in systemcontroller connector: Pin #4 to #17 to check accelerator switch harness. Pin #5 to #30to check decelerator switch harness. Pin #6 to #29 to check low idle mode switchharness. Pin #7 to #16 to check light duty mode switch harness. Pin #8 to #28 tocheck economy mode switch harness. Pin #9 to #15 to check power mode switchharness.



NO: Mode switch harnesshas failed. Repair.

– – –1/1

Switch Panel 2 Check


Connect all harness connectors.

Remove white plastic cover from rear of EC connector.

Measure voltage on wires in rear of EC connector with mode switches ON and OFF.

(A) I mode switch, ON 0-1 volt, OFF 4-5 volts at pin #29. (B) L mode switch, ON 0-1volt, OFF 4-5 volts at pin #16. (C) E mode switch, ON 0-1 volt, OFF 4-5 volts at pin#28. (D) P mode switch, ON 0-1 volt, OFF 4-5 volts at pin #17.

Is voltage measured as indicated?

YES: Check EC.

NO: Switch panel 2 hasfailed. Replace.


PN=238


– – –1/1

Engine Speed SensorCheck


Disconnect harness from engine speed sensor.

Measure resistance of sensor.

Does ohmmeter read 3000 ± 300 ohms?

YES: Sensor is OK.Check harness fromsensor to lower systemcontroller connector.

NO: Sensor has failed.Replace.

90151555

– – –1/1

Engine Speed SensorHarness Check

T8396AM –UN–28FEB95


Connect a jumper wire between terminals in engine speed sensor connector.

Disconnect system controller harness connector.

Measure continuity between system controller harness small connector terminal 4 and41 in large connector.



NO: Harness from enginespeed sensor and EC hasfailed. Repair.


PN=239


90151556

– – –1/1

Propel Pilot PressureTransducer HarnessCheck


Disconnect harness from transducer.

Connect a voltmeter to P56 RED wire and P54 BLK wirein harness.

Key switch ON.

Does voltmeter read 5 volts ± 0.5?

YES: Red and Blackwires from systemcontroller are OK.Continue on.

NO: Red wire, Black wireor system controller hasfailed. Replace or repair.



Connect an ohmmeter to R54 BLACK wire and ground.


YES: Black wire fromsystem controller is OK.Continue on.

NO: Black wire or groundconnection at systemcontroller has failed.Repair.



Connect voltmeter to P56 RED wire in harnessconnector.

Key switch ON.

Does voltmeter read 5.3 to 5.8 volts?

YES: Harness is OK.Check transducer.

NO: RED wire has failed.Repair.

– – –1/1

Propel Pilot PressureTransducer Check

T8037AA –UN–30JUN93

Disconnect pilot pressure transducer connector fromharness connector.

Connect an ohmmeter to RED wire P56 and YELLOWwire N50.

Raise one track off the ground.

Slowly actuate propel lever for the track raised off theground to full speed, while watching ohmmeter.

Does resistance change as propel lever is actuated andtrack speed changes?

YES: Propel pilotpressure transducer isOK. System controllermay have failed.

NO: Propel pilot pressuretransducer has failed.Replace.

– – –1/1

Engine Speed Actuator(Solenoid) Check

T7586DB –UN–16AUG91

Engine OFF.

Disconnect harness from solenoid.

Connect ohmmeter to solenoid connector.


YES: Solenoid is OK.Check wiring harness.

NO: Solenoid has failed.Replace.


PN=240


– – –1/1

Propel Speed ChangeSolenoid Harness Check

T8429BC –UN–28FEB95


Connect voltmeter to T60 BLUE wire and G03 BLACKwire.

Start engine.

Push propel speed switches until “low, medium and high”propel speeds are indicated on switch panel 2.

Does voltmeter read 24 Volts in “low and medium” and 0volts in “high”?

YES: T60 BLUE wire andG03 BLACK wire are OK.

NO: Harness, systemscontroller or speedchange relay has failed.Repair or replace.

90151557

– – –1/1

Speed Change RelayHarness Check

Engine running.

With harness connected to relay, measure voltage on RED wire P55, then Red wireP59.

Is 24 volts measured on P55 and P59?

YES: Harness is OK fromfuse and systemscontroller is OK. Continueon.

NO: Check power boostfuse or systemscontroller.

Engine running.

With harness connected to relay, measure voltage on BLUE wire T59 in relayconnector.

Push propel speed switches until “low, medium and high” propel speeds are indicatedon switch panel 2.

Does voltmeter read 0 Volts in “low and medium” and 24 volts in “high”?

YES: T59 BLUE wire isOK.

NO: Harness or systemscontroller has failed.Repair or replace.

– – –1/1

Swing Brake ReleasePressure Switch Check

T7516BH –UN–22APR91

Disconnect harness from pressure switch. Measureresistance on pressure switch connector contacts.

Does ohmmeter read infinity (open)?

YES: Pressure switch isOK. Check harness.

NO: Pressure switch hasfailed. Replace.


PN=241


– – –1/1

Swing Pressure SwitchHarness Check

T7502BM –UN–01APR91

Disconnect harness from swing pressure switch.

Connect a voltmeter to terminals #1 and #2 in harnessconnector.

Key switch ON.

Does voltmeter measure 5.0 ± 0.5 volts?

YES: Harness is OK.

NO: Harness or PVC hasfailed. Repair.

90151558


PN=242


TX,901515,RP558 –19–19MAR92–1/1

System Controller Circuit Operational Information



• Fuses F1, 2, 3, 5, 6, 8 and 9• Switch panel 2 connector terminals #1 and 2• System controller connector terminals #24, 26, 37,

39, and 302

90151559

TX,9015,RP559 –19–23FEB95–1/1

System Controller Circuit Theory Of Operation

The system controller circuit contains F1 Back up fuse,F6 Monitor fuse, F3 Standby relay fuse, F5 Powerboost fuse, F8 Alternator relay fuse, Stand by relay,Power boost switch, Switch panel 2, System controller,Engine speed actuator, Engine speed sensor, Propelpilot pressure transducer, Travel alarm cancel switch,Travel alarm relay, Load sense solenoid, Swing pilotpressure switch, Auto idle pressure switch, Powerboost relay, Power boost solenoid, Propel speedchange relay, Propel speed change solenoid, Swingbrake release relay, Swing brake release solenoid,Swing brake delay relay, and (Serial No. 544418—)Work mode memory circuit.

System controller is a micro processor that controlsengine speed and hydraulic pump output depending onswitch positions of switch panel 2. System controllerhas a test mode to provide failure diagnosis of wireharnesses, connections, solenoids, relays, sensors andswitch panel 2.

Check mode will check engine speed sensor, systemcontroller pressure switches, pump displacementsolenoid, engine speed solenoid, swing brake delayrelay, propel speed relay, heavy lift relay and propelpilot pressure transducer. Adjust mode will allow foradjustment of pump displacement solenoid pressure,engine low idle and high idle stop screws.

If machine cannot be repaired immediately, a manualoverride valve is provided on the dual solenoid block toeliminate system controller operation and operate the

engine at fast idle speed and hydraulic pump at60-70% output until repairs can be made.

Swing brake is released whenever a swing function isactuated, swing pilot pressure is sensed by the swingbrake release pressure switch. The pressure switchcloses, sending a signal to system controller. Whenpilot pressure switch closes. Swing brake release relayenergizes and signal is sent to system controller whichenergizes the swing brake delay relay. A delay circuitin the system controller keeps the swing brakereleased for a few seconds after swing function isreleased. There is a swing brake release switch onSwitch Panel 2. This switch energizes swing brakedelay relay and releases swing brake all the time.

NOTE: (Serial No. 544418—) A work mode memorycircuit is included in the system controller. Thewires that control this circuit are located in theright console, behind the bottom panel belowswitch panel 2.

The control wires, a white and a black wire areconnected to a small white two pin connector.This connector is removed and weather tightconnectors are installed.

To engage work mode memory, a jumper isinstalled between the black and white wires.When the machine is shutdown the controllerwill store the work mode setting and on startupwill restore the same setting.


PN=243


TX,9015,RP648 –19–23FEB95–1/1

System Controller Circuit SchematicT8396AC –19–23SEP97


PN=244


TX,901515,RP966 –19–23FEB95–1/1

System Controller Circuit Specifications

SpecificationPump Displacement SolenoidCoil—Resistance 26 ± 2 ohms.............................................................Swing Brake Release SolenoidCoil—Resistance 30 ± 2 ohms.............................................................Propel Speed Change SolenoidCoil—Resistance 30 ± 2 ohms.............................................................

Power Boost Solenoid Coil—Resistance 20 ± 2 ohms.......................................................................Engine Speed Actuator(Solenoid) Coil—Resistance 26 ± 2 ohms............................................

90151561

– – –1/1

System Controller Circuit Diagnostic Procedures


– – –1/1

Engine Speed SensorCheck



Measure resistance of sensor.


YES: Sensor is OK.Check harness fromsensor to lower systemcontroller connector.

NO: Sensor has failed.Replace.


PN=245


90151562

– – –1/1

Engine Speed SensorHarness Check

T8396AM –UN–28FEB95


Connect a jumper wire between terminals in engine speed sensor connector.

Disconnect system controller harness connector.

Measure continuity between system controller harness small connector terminal 4 and41 in large connector.



NO: Harness from enginespeed sensor and EC hasfailed. Repair.

– – –1/1

Engine Speed Actuator(Solenoid) Check


Engine OFF.






– – –1/1





Start engine.






PN=246


– – –1/1

Pump DisplacementSolenoid Check


Engine OFF.






90151563

– – –1/1

Swing Brake ReleaseRelay Check







YES: Relay is OK.


– – –1/1

Swing Brake ReleaseRelay Harness Check

NOTE: Unit may swing during this check.

Disconnect swing brake solenoid harness connector to prevent unit from swinging.

Start engine.

With swing brake release relay harness connected, measure voltage on RED wire P55in connector.


YES: Red wire P55 tosystem controller is OK.Continue on.

NO: Red wire or F5 fusehas failed. Repair orreplace.

With voltmeter connected to GREEN wire H55 as above, move swing pilot controllever.

Does voltmeter read 24 volts until lever is moved then read 0 volts?

YES: GREEN wire H55 isOK to systems controller.

NO: GREEN wire H55 orpilot switch has failed.Ground may be open.Repair or replace.


PN=247


90151564

– – –1/1

Swing Brake Delay RelayHarness Check

NOTE: Unit may swing during this check.

Disconnect swing brake solenoid harness connector to prevent unit from swinging.

Start engine.

With swing brake delay relay harness connected, connect a voltmeter to GREEN wireH59.


YES: GREEN wire tosystem controller andsystem controller are OK.Continue on.

NO: GREEN wire orsystem controller hasfailed. Repair or replace.

With voltmeter connected to H59 GREEN wire, move swing pilot control lever.

Does voltmeter read 0 volts, then 3 seconds after pilot control lever is moved back toneutral does voltmeter read 24 volts?

YES: GREEN wire H59 tosystems controller is OK.Check swing brakerelease solenoid.

NO: GREEN wire H59 orsystems controller hasfailed. Repair or replace.

– – –1/1

Swing Brake ReleaseSolenoid Check

T7586DC –UN–16AUG91


Connect an ohmmeter to both terminals of solenoid, readresistance.


YES: Solenoid is OK.Check harness.



PN=248


90151565

– – –1/1

Swing Brake ReleaseSolenoid Harness Check


Connect voltmeter to H01 Green wire in harness connector and frame ground.

Turn key switch ON.

Push swing brake release switch.

Does voltmeter read 0 volts until switch is pushed then 24 volts?

YES: H01 GREEN wirefrom Swing BrakeRelease Relay is OK.Continue on.

NO: H01 GREEN wire orhas failed. Repair orreplace.

T7491AD –UN–20MAR91


Connect ohmmeter to BLK wire G03 in harness connector and frame ground.


YES: BLACK wire G03 isOK. Check swing brakerelease pressure switch.

NO: BLACK wire G03has failed. Repair.

– – –1/1

Swing Brake ReleasePressure Switch Check


Remove pressure switch from machine.

Connect a hand-operated hydraulic pump to pressureswitch.

Connect ohmmeter to pressure switch connector.

Apply hydraulic pressure to pressure switch whilemonitoring hydraulic pressure and ohmmeter.

Does ohmmeter read continuity when hydraulic pressurereaches 413.7 ± 69 kPa (60 ± 10 PSI)?

Release hydraulic pressure slowly while monitoringpressure and ohmmeter.

Does ohmmeter read “open” when hydraulic pressurereaches 215.8 ± 103 kPa (40 ± 15 PSI)?

YES: Swing brakerelease pressure switch isOK.

NO: Swing brake releasepressure switch hasfailed. Replace.


PN=249


90151566

– – –1/1





Key switch ON.












Connect voltmeter to P56 RED wire in harnessconnector.

Key switch ON.

Does voltmeter read 5.3 to 5.8 volts?

YES: Harness is OK.Check transducer.

NO: RED wire has failed.Repair.

– – –1/1










– – –1/1

Swing Brake Delay RelayCheck







YES: Relay is OK.



PN=250


– – –1/1

Propel Alarm RelayCheck







YES: Relay is OK.


90151567


PN=251


90151568

– – –1/1

Propel Alarm RelayHarness Check

Harness connected to relay.

Engine running.

Measure voltage on RED wire P59 to ground at the relay connector.


YES: RED wire fromsystem controller topropel alarm relay is OK.Continue on.

NO: RED wire P59 hasfailed. Repair.



Engine stopped.

Connect an ohmmeter to BLACK wire G03 at terminal 87and ground at the relay connector.

Is 20 or less ohms measured? (This is consideredground).

YES: BLACK wire G03 isOK. Continue on.



Measure voltage on M50 PURPLE wire at the relay connector.

Slowly actuate propel lever for the track off the ground while watching voltmeter.

Does voltmeter read 24 volts until just before track starts to move, then read 0 voltswhen track is moving?

YES: PURPLE wire andsystems controller areOK. Continue on.

NO: PURPLE wire orsystem controller hasfailed. Repair or replace.


Connect a voltmeter to M51 PURPLE wire and ground at the relay connector.

Slowly actuate propel lever for the track off the ground while watching voltmeter.

Does voltmeter read 24 volts until just before track starts to move, then read 0 voltswhen track is moving?

YES: PURPLE wire andsystems controller areOK. Continue on.

NO: PURPLE wire orsystem controller hasfailed. Repair or replace.

T8037AW –UN–30JUN93

Connect ohmmeter to PURPLE wire M50 and ground.

Raise one track off ground.

Slowly actuate propel lever for that track.

Is continuity measured as track starts to move.

YES: Harness is OK.



PN=252


– – –1/1

Propel Alarm HarnessCheck


Key ON. Measure voltage at P55 RED wire on propelalarm.


YES: Harness and fuseare OK.

NO: P55 wire or F5 fusemay have failed.

90151569

– – –1/1




Engine stopped.

Connect an ohmmeter to BLACK wire G03 at terminal 87and ground at the relay connector.

Is 20 or less ohms measured? (This is consideredground).

YES: BLACK wire G03 isOK. Continue on.


– – –1/1

Propel Alarm Check


Connect 24 volts to RED wire P55 and ground PURPLEwire M51.

Does alarm sound?

YES: Alarm is OK.

NO: Alarm has failed.Replace.


PN=253


90151570

– – –1/1





Key switch ON.










– – –1/1










– – –1/1

Propel Speed ChangeSolenoid Check

T7586DC –UN–16AUG91

Engine OFF.







PN=254


– – –1/1





Start engine.





90151571

– – –1/1

Speed Change RelayCheck







YES: Relay is OK.



PN=255


90151572

– – –1/2

Speed Change RelayHarness Check

Engine running.

With harness connected to relay, measure voltage on RED wire P55, then Red wireP59.

Is 24 volts measured on P55 and P59?

YES: Harness is OK fromfuse and systemscontroller is OK. Continueon.

NO: Check power boostfuse or systemscontroller.

Engine running.

With harness connected to relay, measure voltage on BLUE wire T59 in relayconnector.

Push propel speed switches until “low, medium and high” propel speeds are indicatedon switch panel 2.

Does voltmeter read 0 Volts in “low and medium” and 24 volts in “high”?

YES: T59 BLUE wire isOK.


T8038AE –19–30JUN93

Disconnect harness from relay and disconnect X1 connector in cab.

Connect ohmmeter to BLUE wire T59 in relay connector and X1 connector section Fpin 1.


YES: T59 BLUE wire toX1 connector is OK.

NO: Harness has failed.Repair.


PN=256


90151573

–19– –2/2


Disconnect upper connector from systems controller.

Connect an ohmmeter to BLK/GRN wire from X1 connector section F pin 1 to upper(large) systems controller connector pin 2.


YES: BLK/GRN wire isOK. Systems controllermay have failed.

NO: Wire has failed.Repair.

– – –1/1

Power Boost RelayCheck







YES: Relay is OK.



PN=257


90151574

– – –1/2

Power Boost RelayHarness Check



Engine running.

Measure voltage on RED wire P55 and Red wire P59.

Is 24 volts DC measured?

Measure voltage on GREEN wire H57 as power boostswitch is pushed.

Is 24 volts measured until power boost switch is pushed,then 0 volts is measured, 10 seconds later is 24 voltsmeasured again?

YES: Harness fromsystems controller is OK.Check power boostsolenoid.

NO: Check power boostfuse, harness fromsystems controller orsystems controller.

T8039AF –19–30JUN93

Disconnect harness from relay and disconnect X1 connector in cab.

Connect ohmmeter to GREEN wire H57 in relay connector and X1 connector section Fpin 3.


YES: H57 GREEN wire toX1 connector is OK.



PN=258


90151575

–19– –2/2

T8039AE –UN–30JUN93

Disconnect upper (large) connector from systems controller.

Connect an ohmmeter to BLK/WHT wire from X1 connector section F pin 3 to upper(large) systems controller connector pin 1.


YES: BLK/WHT wire isOK. Systems controllermay have failed.


– – –1/1

Power Boost SolenoidCheck


Engine OFF.






– – –1/1

Power Boost SolenoidHarness Check

T7586CZ –UN–16AUG91

Disconnect harness from solenoid. Start engine.Measure voltage on harness connector as power boostswitch is pushed.

Is 0 volts measured until power boost switch is pushed,then is 24 volts measured, then after 10 seconds is 0volts measured again?

YES: Harness frompower boost relay is OK.

NO: Power boost switchor systems controller hasfailed. Repair or replace.


PN=259


90151576

– – –1/1

Power Boost SwitchHarness Check


Disconnect BLUE/ORANGE wire from power boost switch.

Disconnect upper (large) connector of system controller.

Connect ohmmeter to BLUE/ORANGE wire at power boost switch and BLUE/ORANGEwire on pin 29 of upper connector of system controller.


YES: BLUE/ORANGEwire is OK. Continue on.


T8039AG –UN–30JUN93

Disconnect BLACK wire from power boost switch.

Connect an ohmmeter to black wire and cab ground.


YES: Wire is OK. Checkpower boost switch.

NO: Wire has failed orcab ground connection toframe has failed.


PN=260


– – –1/1

Power Boost SwitchCheck

T8039AJ –UN–30JUN93

Remove bottom cover from right arm rest. Disconnectwires from power boost switch. Connect ohmmeter toswitch terminals. Push switch push button.


YES: Switch is OK.Check system controller.

NO: Switch has failed.Replace.

90151577

– – –1/1

Power Boost SolenoidDiode Check

NOTE: A diode can fail in two modes, either shorted or open. Continuity will bemeasured in one direction only in a serviceable diode.










– – –1/1

Standby Relay Check







YES: Relay is OK.



PN=261


90151578

– – –1/1

Standby Relay HarnessCheck



Measure voltage on BLACK/WHITE wires in relayconnector terminals 1 and 3.


YES: Wire to F3 fuse isOK.

NO: Continue on.

With relay connected to harness.

Engine OFF.

Measure voltage on BLUE/ORANGE wire in relay connector with key OFF then ON.

Is 24 volts measured with key OFF and 0 volts measured with key ON?

YES: Wire to systemcontroller is OK. Continueon.

NO: BLUE/ORANGE wirehas failed. Repair.

T8039AN –UN–30JUN93


Disconnect small connector from systems controller.

Connect an ohmmeter to PINK wire in terminal 5 of relay connector and terminal 102and 106 in systems controller connector.


YES: Wire is OK.Continue on.

NO: PINK wire has failed.Repair.


PN=262


90151579

– – –1/1

System ControllerGround Check

T8424AA –UN–28FEB95

Disconnect small connector from systems controller.

Connect an ohmmeter between black wire G50 at terminal 103 in small systemsconnector and ground.

Is continuity measured.

YES: Wire is OK.Continue on.

NO: G50 wire has failedopen.


PN=263


TX,901515,RP555 –19–19MAR92–1/1

Switch Panel 1 Circuit Operational Information



• F1 1 amp back up fuse

• F6 10 amp monitor fuse• Pins #1, 3, 4, 7, 8, 12 of switch panel harness

connector• Pin #2 has voltage when work lights are ON.• Pin #11 must be ground.

90151580

TX,901515,MD79 –19–19MAR92–1/1

Switch Panel 1 Circuit Theory Of Operation

Switch panel 1 circuit includes F1 1 amp backup fuse,F6 10 amp Monitor fuse, windshield wiper relay K11,windshield washer relay K10, monitor controller, worklight relay K8, drive light relay K9. Switch panel 1contains light switch S9, work light indicator H1, drivelight indicator H2, alarm cancel switch S10, fluid levelcheck switch S11, wiper switch S12, wiper operationindicators H3, H4, washer switch S13 and transistorsT1, T2, T3 and T4.

Current flows from fuses F6 and F1 goes to switchpanel 1 logic board. Logic circuit receives signals from

switch panel switches and controls transistors T1, T2,T3 and T4 to turn on work lights, drive lights, lightswitch indicator lights and operate windshield wiperand washer relays by controlling ground connections.

Logic circuit also provides signals to monitor controllerto check fluid level and operate travel alarm cancelcircuits.


PN=264


TX,901515,RP622 –19–29JUN93–1/1

Switch Panel 1 Circuit SchematicT8041AL –19–23SEP97


PN=265


– – –1/1

Switch Panel 1 Circuit Diagnostic Procedures


90151582

– – –1/1


T7437AQ –UN–01APR91 T7437AP –UN–15JAN91

To access harnesses, remove cover from bottom of right console. Remove cap screwsfrom right console support. Pivot right console upwards. Disconnect white harnessconnector for switch panel 1.

Turn key switch ON.

Measure voltage between RED/YELLOW wire (pin #1) and ground in harness fromfuses.

Measure voltage between RED/BLUE wire (pin #12) and ground in harness from fuses.



NO: Repair harness fromfuse #6 or #1 to switchpanel 1.

T7437AR –UN–01APR91

Measure voltage between RED/WHT wire (pin #3) andground.

Measure voltage between RED/BLACK wire (pin #4) andground.


YES: Replace switchpanel 1.

NO: Repair harness fromwork light relay K15 anddrive light relay K16 toswitch panel 1.

T7437AS –UN–01APR91

Measure voltage between BLUE wire (pin #7) andground.

Measure voltage between YELLOW/BLACK wire (pin #8)and ground.


YES: Replace switchpanel 1.

NO: Repair harness fromwindshield washer relayK17 and windshield wiperrelay K18 to switch panel1.


PN=266


90151583


PN=267


TX,901515,RP697 –19–23FEB95–1/1

Switch Panel 2 Circuit Operational Information



• F1 Monitor fuse• F6 Switch Box fuse

Ground signals are present at monitor controllerconnectors when switches are pushed;

• Pins 1, 2, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,17, 18 of switch panel connector

• Pin 19 must be ground.

90151584

TX,901515,SS689 –19–11MAY94–1/1

Switch Panel 2 Circuit Theory Of Operation

Switch panel 2 circuit includes F1 Monitor fuse, F6Switch Box fuse K16 drive light relay, N2 switch panel2. Switch panel 2 contains accelerator switch,decelerator switch, low idle mode switch and indicator,light duty mode switch and indicator, economy modeswitch and indicator, max power mode switch andindicator, work mode switch and indicators, auto idleswitch, propel speed increase and decrease switchand indicators, hydraulic warm-up switch and indicator,propel speed switches and indicators, hydraulic modeswitch and indicators.

Power from fuses F1 and F6 goes to switch panel 2logic board. Logic circuit receives signals from switchpanel switches engine controller and pump and valvecontroller.

Switch panel 2 sends signals to engine controller tochange engine speeds to match various hydraulicmodes and engine modes selected by the operator.


PN=268


90151585

TX,9015,RP563 –19–07JUL93–1/1

Switch Panel 2 Circuit Schematic

T75

71A

K–1

9–30

JUN

93


PN=269


– – –1/1

Switch Panel 2 Circuit Diagnostic Procedures


90151586

– – –1/1


T7473AI –UN–11APR91 T7473AJ –UN–11MAR91

Disconnect white 10 pin connector from switch panel 2 harness.

With Key switch ON, measure voltage on pins 1 and 2 in harness side of connector.


YES: ReconnectHarness. Continue on.

NO: Harness from fusesF1 or F6 is failed. Repair.

– – –1/1

Switch Panel 2 Check Push each switch on switch panel 2.

Watch indicator lights to assure correct light comes on.

Switch panel 2 cannot be serviced.

Replace if operation is erratic.

Does switch panel 2 operate correctly?


NO: Switch panel 2 hasfailed or system controllernot getting voltagethrough standby relay.


PN=270


90151587


PN=271


TX,901515,RP973 –19–19MAR92–1/1

Start Aid And Propel Alarm Circuit Operational Information



• F5 5 amp power boost fuse• F20 5 amp start aid fuse

90151588

TX,901515,RP562 –19–21AUG91–1/1

Start Aid And Propel Alarm Circuit Theory Of Operation

Start aid circuit contains: F20 20 amp Start Aid fuse,start aid relay, start aid switch, and start aid solenoid.When start aid switch is pushed, it makes a groundconnection for start aid relay energizing it. With startaid relay energized, current flows from terminal 87 tostart aid solenoid, energizing it, causing start fluid togo into engine air intake manifold.

Propel alarm circuit contains: F5 5 amp power boostfuse, propel alarm, propel alarm relay, systemcontroller, propel alarm cancel switch and propel pilot

pressure transducer. When propel levers are moved toforward or reverse position, propel pilot pressuretransducer senses propel pilot pressure and sends asignal to system controller. System controller providesground and power to propel relay, energizing it,providing a ground for propel alarm. Propel alarmsounds. After propel alarm sounds for 10 seconds,alarm cancel switch may be pushed to turn propelalarm off. System controller de-energizes propel alarmrelay.


PN=272


90151589

TX,9015,RP566 –19–07JUL93–1/1

Start Aid And Propel Alarm Circuit Schematic

T75

71A

L–1

9–30

JUN

93


PN=273


– – –1/1

Start Aid And Propel Alarm Circuit Diagnostic Procedures


90151590

– – –1/1

Start Aid Relay HarnessCheck



Measure voltage on RED/BLUE wires in relay connectorterminals 1 and 3.


YES: Wire to F20 fuse isOK.

NO: Continue on.

– – –1/1

Start Aid Relay Check







YES: Relay is OK.Continue on.



PN=274


90151591

– – –1/1

Start Aid Relay To StartAid Switch HarnessCheck

T7718BC –19–05MAR92

Disconnect harness from start aid switch and start aid relay.

Connect ohmmeter to BLACK/WHITE wire at switch and BLACK/WHITE wire at relayconnector.


YES: Harness fromswitch to relay is OK.Continue on.

NO: Harness has failed.Repair as needed.

– – –1/1

Start Aid Switch Check

T7718BA –UN–06MAR92

Remove bottom cover from left arm rest.

Disconnect wire harness from start aid switch wires.

Connect ohmmeter to both switch wires.

Push start aid switch button.


YES: Switch is OK.Continue on.

NO: Switch has failed.Replace.


PN=275


90151592

– – –1/1

Start Aid Relay To CabHarness ConnectorCheck

T8040AA –19–30JUN93

Disconnect harness from start aid relay, disconnect X1 cab harness to vehicle harnessconnector, (located behind operators seat).

Connect ohmmeter to RED/BLACK wire in relay connector and RED/BLACK wire incab harness connector pin 6 section C.


YES: Harness from relayto X1 connector is OK.Continue on.

NO: Harness has failed.Repair as needed.


PN=276


90151593

– – –1/1

Vehicle HarnessConnector (X1) To StartAid Solenoid HarnessCheck

T8396AG –UN–28FEB95

Disconnect harness from start aid solenoid.

Disconnect X1 vehicle harness from cab harness connector.

Connect an ohmmeter to WHITE wire in start aid solenoid connector and pin 6 sectionC of X1 vehicle harness connector.


YES: Harness from X1connector to start aidsolenoid is OK.

NO: White wire hasfailed. Repair.

– – –1/1

Start Aid Solenoid Check


Disconnect harness from start aid solenoid.

Connect an ohmmeter to both wires from solenoid.


YES: Start aid solenoid isOK. Continue on.



PN=277


– – –1/1

Start Aid Solenoid DiodeCheck

NOTE: A diode can fail in two modes, either shorted or open. Continuity will bemeasured in one direction only in a serviceable diode.










90151594

– – –1/1

Propel Alarm RelayCheck







YES: Relay is OK.


– – –1/1



Engine running.

Measure voltage on RED wire P59 to ground at the relay connector.


YES: RED wire fromsystem controller topropel alarm relay is OK.Continue on.

NO: RED wire P59 hasfailed. Repair.

T8037AW –UN–30JUN93

Connect ohmmeter to PURPLE wire M50 and ground.

Raise one track off ground.

Slowly actuate propel lever for that track.

Is continuity measured as track starts to move.

YES: Harness is OK.



Engine OFF.

Connect an ohmmeter from BLACK wire G03 to ground.


YES: BLACK wire andground connection areOK. Check Propel alarm.

NO: BLACK wire orground connection havefailed. Repair.


PN=278


– – –1/1

Propel Alarm HarnessCheck


Key ON. Measure voltage at P55 RED wire on propelalarm.


YES: Harness and fuseare OK.

NO: P55 wire or F5 fusemay have failed.

90151595

– – –1/1

Propel Alarm Check


Connect 24 volts to RED wire P55 and ground PURPLEwire M51.

Does alarm sound?

YES: Alarm is OK.

NO: Alarm has failed.Replace.


PN=279


90151596


PN=280

Group 20References

9015201

TX,9015,LG11 –19–27AUG97–1/1

Monitor Panel And Switch Panels

T10

9279

–UN

–02J

UN

97

A—Monitor PanelB—Switch Panel 1C—Key SwitchD—Switch Panel 2


PN=281

References

901520

2

TX,9015,LG12 –19–27AUG97–1/1

Monitor Panel

T83

26A

B–U

N–2

6SE

P94

A—Alternator IndicatorB—Engine Oil Pressure IndicatorC—Air Filter Restriction IndicatorD—Coolant/Hydraulic Oil Temperature IndicatorE—Low Fuel Level IndicatorF—Hydraulic Oil Filter Restriction IndicatorG—Engine Oil Level IndicatorH—Coolant Level IndicatorI—Hydraulic Oil Level IndicatorJ—Hour MeterK—Fuel GaugeL—Coolant Temperature Gauge


PN=282

References

9015203

TX,10,RP991 –19–19MAR92–1/1

Switch Panel 2

T75

27A

N–U

N–2

9MA

Y91

A—Engine Speed Decrease SwitchB—Engine Speed Increase SwitchC—Economy Mode SwitchD—Max. Power Mode SwitchE—Auto-Idle SwitchF—Swing Brake Release SwitchG—Work Mode Select SwitchH—Propel Speed Decrease SwitchI—Propel Speed Increase SwitchJ—High Speed Propel Mode IndicatorK—Medium Speed Propel Mode IndicatorL—Low Speed Propel Mode IndicatorM—Precision Mode IndicatorN—Economy Mode Indicator (Work Mode)O—General Mode IndicatorP—Heavy Duty Mode IndicatorQ—Auto-Idle IndicatorR—Swing Brake Disengage IndicatorS—Low Idle Mode SwitchT—Light Duty Mode SwitchU—Low Idle Mode IndicatorV—Light Duty Mode IndicatorW—Economy Mode Indicator (Power Mode)X—Max. Power Mode Indicator


PN=283

References

901520

4

TX,90,RP2538 –19–23FEB95–1/1

Connecting Systems Controller HarnessConnector

T75

35A

D–U

N–1

7OC

T94

T80

05A

Y–U

N–1

0MA

Y93

1. Push connector into Systems Controller while turningcap screw (B).

2. Tighten cap screw until orange indicator (A) extendsoutward indicating correct torque.


PN=284

References

9015205

TX,901520,RP979 –19–19MAR92–1/1

Disconnecting Tab Retainer Connectors

T75

35A

E–U

N–2

2MA

Y91

1. Push retainer tab (A).

2. Hold tab and pull connector halves apart; do not pullon wiring leads.

3. This type connector used for:

• Switch Panel 1 and 2• Heater• Monitor Panel• Monitor Controller


PN=285

References

901520

6

TX,901520,RP980 –19–13MAR95–1/1

Harness Side Of Connectors With Pin Locations

T84

22A

A–1

9–28

FE

B95


PN=286

References

9015207

TX,9015,LG13 –19–27AUG97–1/1

Engine Speed Sensor Adjustment

T77

26A

B–U

N–1

2MA

R92


1. Engine OFF.

2. Turn sensor clockwise (IN) into engine flywheelhousing by hand until sensor touches flywheel.

3. Turn sensor counterclockwise (OUT) 3/4 turn.

4. Turn locknut until it contacts flywheel housing. Tightenlocknut, DO NOT overtighten.

5. Connect sensor connector to harness connector.


PN=287

References

901520

8

TX,901505,QQ366 –19–16MAR93–1/1

Battery Operation

A battery is a device for converting chemical energy toelectrical energy. It is not a storage tank for electricity,but stores electrical energy in chemical form.

Because of the constant chemical to electrical change(self-discharge, discharge, or charge), the battery hasa limited life. Proper care (cleaning, adding water,charging) will extend the life of the battery.

The battery is made up of positive plates, negativeplates, separators, plate straps, and chemical solution(electrolyte). The electrolyte is a solution of sulfuricacid and water. Sulfuric acid is not lost duringovercharging; therefore, if the liquid solution is low,only water should be added.

In a fully charged battery, the positive plate is leadperoxide (PBQ2), the negative plate is "spongy" lead(Pb), and the electrolyte solution is about 1.270 timesheavier than water. The amount that the solution isheavier than water is called specific gravity.

All batteries will self discharge at a rate of .001 specificgravity point per 24 hour period at a constant 85 °F.The discharge rate increases as temperature increasesand decreases as temperature decreases. If themachine is not used for a period of time, the batteriesmust be maintained or stored in a cool place.

Wipe batteries with a damp cloth. If terminals arecorroded, use a stiff brush and wash with an ammoniasolution. After washing, flush battery and compartmentwith clear water. Keep caps in place when cleaningand charging.

Batteries should be maintained at an open circuitvoltage of 12.40 volts or greater. To determine opencircuit voltage use the following chart.

CHECK OPEN CIRCUIT VOLTAGE FOR STATE OFCHARGE

NOTE: Stabilize voltage by turning on high beams 15Amp load for 15 seconds.

STABILIZED OPEN CIRCUITVOLTAGE PERCENT CHARGED

12.6 Volts or More 100%

12.4 75%

12.2 50%

12.0 25%

11.7 or less 0%


PN=288

References

9015209

TX,9015,DY6288 –19–08SEP97–1/1

Battery Specifications

Item Measurement Specification

320-Minute Reserve Capacity Battery Volts 12 VoltsCold Cranking Power 1000 amps at —18°C (0°F)Reserve Capacity 320 Minutes at 25 ampsBCI Group Size 4DFully Charged Electrolyte Specific 1.265—1.280Gravity

160-Minute Reserve Capacity Battery Volts 12 VoltsCold Cranking Power 625 amps at —18°C (0°F)Reserve Capacity 160 Minutes at 25 ampsBCI Group Size 31Fully Charged Electrolyte Specific 1.265—1.280Gravity


PN=289

References

90152010

TX,901505,QQ365 –19–10AUG95–1/1

Diagnose Battery Malfunctions


Battery Using Too Much Water Shorted battery cell Check battery state of charge. (SeeProcedure for Testing Batteries.)

High ambient temperature Add distilled water.

Cracked battery case Check battery hold down clamps.Replace battery.

Regulator Do Alternator Output Check. (SeeCharging Circuit OperationalChecks.)

Cracked Battery Case Battery hold down clamp too tight, Install new battery. Install hold downtoo loose or missing clamps correctly.

Frozen battery Keep electrolyte at correct level andbattery fully charged during coldweather.

Low Battery Output Low water level See Battery Using Too Much Waterand Cracked Battery Casesymptoms.

Dirty or wet battery top, causing Clean battery top. Recharge battery.discharge

Corroded or loose battery cable Clean and tighten cable end clamps.ends Recharge battery.

Broken or loose battery posts Wiggle posts by hand. If posts areloose or will turn, replace battery.

Loose fan/alternator belt or worn Inspect belt or pulley. Adjust orpulleys replace as necessary.


PN=290

References

90152011

TX,FF,141 –19–29MAY91–1/2

Check Battery Electrolyte Level AndTerminals

TS

203

–UN

–23A

UG

88

CAUTION: Battery gas can explode. Keepsparks and flames away from batteries. Use aflashlight to check battery electrolyte level.

Never check battery charge by placing a metalobject across the posts. Use a voltmeter orhydrometer.

Always remove grounded (-) battery clamp firstand replace it last.

Sulfuric acid in battery electrolyte is poisonous.It is strong enough to burn skin, eat holes inclothing, and cause blindness if splashed intoeyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is

added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize

the acid.3. Flush your eyes with water for 10—15

minutes. Get medical attention immediately.

If acid is swallowed:

1. Drink large amounts of water or milk.2. Then drink milk of magnesia, beaten eggs, or

vegetable oil.3. Get medical attention immediately.

1. Remove hold-down clamps.

2. Remove battery covers.


PN=291


References

90152012

TX,FF,141 –19–29MAY91–2/2

T69

96D

B–U

N–0

9SE

P03

Single Level Fill Tube Application

T69

96D

A–U

N–0

9SE

P03

Dual Level Fill Tube Application

A—Battery PostB—Fill TubeC—Electrolyte Level Range

IMPORTANT: During freezing weather, batteries mustbe charged after water is added toprevent battery freezing. Charge batteryusing a battery charger or by runningthe engine.

3. Fill each cell to within specified range with distilledwater. DO NOT overfill.


PN=292

References

90152013

TX,901500,RP3113 –19–18JUL94–1/1

Procedure For Testing Batteries

Visual Check

1. Check for damage such as cracked or broken caseand electrolyte leakage.

If damage is seen, replace battery.

2. Check electrolyte level. (See procedure in thisgroup.)

If low, add distilled water to specified level andcharge battery.

3. Check terminals for corrosion.

If corroded, clean using a wire brush or battery postcleaner such as JT05838 Battery Post/ClampCleaner.

4. Check posts for looseness.

If posts are loose, replace battery.

Hydrometer Test

Check specific gravity with a hydrometer or batterytester such as JT05460 Coolant/Battery Tester.

Record specific gravity reading for each cell.

If high and low readings vary LESS than 0.050 andaverage specific gravity is between 1.225 and 1.280,battery is fully charged, go to LOAD TEST.

If high and low readings vary LESS than 0.050 andaverage specific gravity is LESS than 1.225, chargebattery and repeat test. If average specific gravity isstill LESS than 1.225, replace both batteries.

If high and low readings vary MORE than 0.050,charge battery and repeat test. If high and lowreadings still vary MORE than 0.050, replace bothbatteries.

Load Test

Check battery capacity with a load tester such asJT05832 Battery Load Tester. Follow testermanufacturer’s instructions for proper load testprocedures.

If one battery fails load test, replace both batteries.


PN=293

References

90152014

TX,901505,RP513 –19–05SEP91–1/1

Using Booster Batteries—24 Volt System

T67

13A

H1

–UN

–24O

CT

91

Two Battery Application

A—Machine BatteriesB—Booster Batteries

Before boost starting, machine must be properly shutdown and secured to prevent unexpected machinemovement when engine starts.

CAUTION: An explosive gas is produced whilebatteries are in use or being charged. Keepflames or sparks away from the battery area.Make sure the batteries are charged in a wellventilated area.

IMPORTANT: The machine electrical system is a 24volt negative (-) ground. Connect two 12volt booster batteries together asshown for 24 volts.

Make last booster cable connection to frame.


PN=294

References

90152015

TX,9015,LG14 –19–27AUG97–1/1

Replacing Batteries

Your machine is equipped with a negative (-) groundelectrical system. It uses two 12-volt batteries. If one ofthe two batteries fails, both batteries must be replaced.Use only batteries meeting following specifications.

Specification320-Minute Reserve CapacityBattery—Volts 12 Volts................................................................................Cold Cranking Power 1000 amps at — 18°C (0°F)....................................Reserve Capacity 320 Minutes at 25 amps................................................BCI Group Size 4D......................................................................................Fully Charged Electrolyte SpecificGravity 1.265—1.280...................................................................................160-Minute Reserve CapacityBattery—Volts 12 Volts................................................................................Cold Cranking Power 625 amps at — 18°C (0°F)......................................Reserve Capacity 160 Minutes at 25 amps................................................BCI Group Size 31......................................................................................Fully Charged Electrolyte SpecificGravity 1.265—1.280...................................................................................

TX,90,RP2030 –19–12NOV94–1/1

Alternator Voltage Output Test—Delco

T83

19B

W–1

9–17

OC

T94

1. With harness connected, connect multimeter toalternator output (BAT) terminal.

2. Start engine and run at approximately 1500. Insert asmall screwdriver into test hole and ground tab toalternator case.

3. Observe voltage at (BAT) terminal.

4. Voltage must increase to about 28—30 volts.

5. Lower readings probably mean alternator windingshave failed, higher readings probably mean regulatorhas failed.


PN=295

References

90152016

TX,9015,JH3058 –19–16OCT97–1/1

Alternator Voltage Output Test—Bosch

T78

35A

T–1

9–23

SE

P92

1. With harness connected, connect multimeter toalternator D+ terminal.

2. Start engine.

3. Observe voltage at D+ terminal.

4. Voltage must measure 26—28 volts.

5. Connect multimeter to alternator B+ terminal.

6. Voltage must measure 26—28 volts.

04T,90,M167 –19–23FEB95–1/1

Adding 12-Volt Accessories

IMPORTANT: This machine has a 24-volt electricalsystem. Installing 12-volt accessorieswithout addition of 24-volt to 12-voltconverter may cause battery failure.

When possible, use 24-volt accessories. If 12-voltaccessories are added, use a 24-volt to 12-volt converter.Converters are available from your authorized dealer.(See the Industrial Equipment Attachment Guide.)

NOTE: Wires for the large converter are already installedin machine.

Converter capacity requirements depend on the load ofthe accessories installed. Follow electronic dealer andmanufacturer’s recommendations to determine thecapacity of the converter required and its installationrequirements.

IMPORTANT: DO NOT connect an accessory to onebattery. Connecting a 12-volt accessoryto one battery will cause one battery toovercharge, and the other battery toundercharge, causing battery failure.


PN=296

References

90152017

TX,1675,GG265 –19–12MAY93–1/1

Welding On Machine

T75

09A

I–U

N–0

5SE

P91

T80

05A

Y–U

N–1

0MA

Y93

A—Red Torque Indicator PinB—Connector Cap ScrewC—Console Cover Cap ScrewD—Fuse Box CoverE—System Controller Upper ConnectorF—System Controller Lower Connector

IMPORTANT: Electrical current traveling from thewelder through the machine electricalsystem may damage the machineelectrical system, including battery andsystem controller. Disconnect batteryground cable and system controllerelectrical connectors before welding onthe machine.

Before welding on the machine, follow the steps listedbelow to protect the machine electrical system.

1. Disconnect the battery ground and positive cables.

2. Disconnect the system controller electrical connectors(E and F).

a. Inside the cab, remove four cap screws (C) and thefuse box cover (D) to remove the rear consolecover.

b. Loosen cap screws (B) on upper connector (E) andlower connector (F) to remove connectors.

NOTE: When connector is firmly seated in the receptacle,the red torque indicator pin (A) is level with thesurface of connector.


PN=297

References

90152018

TX,90,FF2487 –19–13AUG91–1/1

Changing Travel Alarm Volume

T75

11C

W–U

N–0

8AU

G91

IMPORTANT: It may be necessary to adjust travelalarm volume to meet local regulations.

NOTE: Alarm removed from machine for clarity ofphotograph.

Move switch (A) to adjust volume of travel alarm. Thealarm can be set at “HIGH,” “MED” (medium), or “LOW”volume.


PN=298

Section 9020Power Train

Contents

PagePage

Group 05—Theory Of Operation Measure Track Roller WearLower . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-15-8Power Train Components—(Serial No. —Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-15-9556935) . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-1

Measure Front Idler Wear . . . . . . . . . . . . . . .9020-15-9Power Train Components—(Serial No.Measure Track Pitch . . . . . . . . . . . . . . . . . .9020-15-10556936—) . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-2Measure Track Shoe Grouser Wear . . . . . .9020-15-11Propel Pilot Circuit (SN —556935) . . . . . . . .9020-05-4Propel Component Location . . . . . . . . . . . .9020-15-13Propel Pilot Circuit (SN 556936—) . . . . . . . .9020-05-6

Propel Circuit . . . . . . . . . . . . . . . . . . . . . . . .9020-05-8Group 20—AdjustmentsPropel Pilot Controller . . . . . . . . . . . . . . . . .9020-05-10Track Sag . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1Propel Pilot Check Valve Block . . . . . . . . . .9020-05-12Propel Valve Spool Stop Screw. . . . . . . . . . .9020-20-3Combined Function Shuttle Valve (SN —

556935) . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-159020Group 25—TestsCombined Function Shuttle Valve (SN

JT05801 Clamp-On Electronic Tachometer556936—) . . . . . . . . . . . . . . . . . . . . . . . .9020-05-16Installation . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-1Propel Control Valve . . . . . . . . . . . . . . . . . .9020-05-18

JT05800 Digital Thermometer Installation . . .9020-25-1Rotary Manifold . . . . . . . . . . . . . . . . . . . . . .9020-05-20JT02156A Digital Pressure And TemperaturePropel Motor . . . . . . . . . . . . . . . . . . . . . . . .9020-05-22

Analyzer Installation. . . . . . . . . . . . . . . . . .9020-25-1Propel Motor Cover . . . . . . . . . . . . . . . . . . .9020-05-24Hydraulic System Warm-Up . . . . . . . . . . . . .9020-25-2Supply Shuttle Valve . . . . . . . . . . . . . . . . . .9020-05-26Propel Motor Start-Up . . . . . . . . . . . . . . . . . .9020-25-3Counterbalance ValvePropel Speed Cycle Time . . . . . . . . . . . . . . .9020-25-4Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-27Propel Speed Change Solenoid Valve. . . . . .9020-25-5Propel . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-28Propel Motor Crossover Relief Valve. . . . . . .9020-25-7Braking . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-29Propel Brake Release Pressure ReducingPropel Speed Change Solenoid Valve. . . . .9020-05-30

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-10Propel Speed Change Valve . . . . . . . . . . . .9020-05-32Propel Motor Case Drain Flow . . . . . . . . . .9020-25-12Propel Crossover Relief and Shuttle

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-34Propel Brake and Pressure Reducing

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-36Propel Gearbox . . . . . . . . . . . . . . . . . . . . . .9020-05-38Track Adjuster . . . . . . . . . . . . . . . . . . . . . . .9020-05-39Front Idler . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-40Carrier Roller. . . . . . . . . . . . . . . . . . . . . . . .9020-05-41Track Roller. . . . . . . . . . . . . . . . . . . . . . . . .9020-05-42Swing Bearing. . . . . . . . . . . . . . . . . . . . . . .9020-05-44

Group 10—System Operational ChecksPower Train Operational Checks. . . . . . . . . .9020-10-1Propel System Checks . . . . . . . . . . . . . . . . .9020-10-1Undercarriage Checks. . . . . . . . . . . . . . . . . .9020-10-5

Group 15—Diagnostic InformationPropel System. . . . . . . . . . . . . . . . . . . . . . . .9020-15-1Measure Track Bushing Wear . . . . . . . . . . . .9020-15-6Measure Track Link Wear . . . . . . . . . . . . . . .9020-15-7


PN=1

Contents

9020


PN=2

Group 05Theory Of Operation

9020051

TX,9020,LG15 –19–27AUG97–1/1

Power Train Components—(Serial No. —556935)

T7585ACPOWER TRAIN HYDRAULIC COMPONENTS

(FORWARD)

SUPPLY OILI

REGULATED PRESSUREJ

PILOT OILK

RETURN OILL

A

PROPELPILOTCONTROLLER

C

E D

B

G

H

F ROTARYMANIFOLD

RIGHTPROPELMOTOR

LEFTPROPELMOTOR

DUALSOLENOIDBLOCK

PROPELPILOT CHECKVALVE BLOCK

PILOTSHUT-OFFVALVE

CONTROLVALVE

M

T75

85A

C–1

9–29

AU

G97


PN=301

Theory Of Operation

902005

2

TX,9020,LG16 –19–11MAY98–1/1

Power Train Components—(Serial No. 556936—)

T109875 POWER TRAIN HYDRAULIC COMPONENTS— FORWARD

SUPPLY OILJ

REGULATED PRESSUREK

PILOT OILL

RETURN OILM

G


D

A

E

C

H

I

F ROTARYMANIFOLD

RIGHTPROPELMOTOR

LEFTPROPELMOTOR

DUALSOLENOIDBLOCK

PROPELPILOT CHECKVALVE BLOCK

PILOTSHUT-OFFVALVE

B PROPEL, BUCKETCONTROLVALVE

BOOM, SWING, ARMCONTROL VALVE

M

T10

9875

–19–

28O

CT

97


PN=302

Theory Of Operation

9020053


PN=303

Theory Of Operation

TX,9020,DY6289 –19–08SEP97–1/2

Propel Pilot Circuit Operation—(Serial No. —556935)

T111731 PROPEL PILOT CIRCUIT—(S.N. —556935)P

RETURN OILO

BRAKE RELEASE OILN

PILOT OILM

J DUALSOLENOIDBLOCK

K RESERVOIR

LENGINE SPEED CONTROL ACTUATOR

BPILOTFILTER

APILOTPUMP

C

PILOTSHUT-OFFVALVE

D


EPROPELPILOTCHECKVALVEBLOCK

F

PRESSURECONTROLMANIFOLD

GMAINHYDRAULICCONTROLVALVE

H

ROTARYMANIFOLD

PROPELMOTORS

I

T111731 –19–28OCT97

The propel pilot circuit (P) consists of: • Pilot pump (A)


PN=304

Theory Of Operation

9020055

TX,9020,DY6289 –19–08SEP97–2/2

• Pilot filter (B)• Pilot shut-off valve (C)• Propel pilot controller (D)• Propel pilot check valve block (E)• Pressure control manifold (F)• Main hydraulic control valve (G)• Rotary manifold (H)• Propel motors (I)• Dual solenoid block (J)• Hydraulic reservoir (K).

Filtered pilot oil is routed to the pressure controlmanifold. The pressure control manifold contains thepilot pressure regulating valve. Pilot oil from themanifold is routed to the propel pilot controller.

Actuating propel pilot controller routes pilot oil to thepropel pilot check valve block. The block contains apressure transducer which provides an electrical

sensing signal to the system controller. The pilot checkvalve block also routes pilot oil to the combinedfunction shuttle valve in the pressure control manifold.The combined function shuttle valve provides smoothpropel metering when actuating other hydraulicfunctions.

Pilot oil from the propel pilot controller moves thepropel spools in the main hydraulic control valve.Return oil, from pilot caps in main valve, is routedthrough the propel pilot check valve block, the propelpilot controller, and pilot shut-off valve to the reservoir.

When high speed propel (rabbit) is selected, the propelspeed change solenoid valve in the dual solenoidblock is de-energized. Pilot oil flow through thesolenoid valve to the propel speed change valve inpropel motors is blocked. Propel motors shift tominimum displacement for high speed propel.


PN=305

Theory Of Operation

TX,9020,LG17 –19–27AUG97–1/2

Propel Pilot Circuit Operation—(Serial No. 556936—)

T109922

PROPEL PILOT CIRCUIT—(S.N. 556936— )P RETURN OILO

BRAKE RELEASE OILN

PILOT OILM

JDUALSOLENOIDBLOCKK

RESERVOIR

L ENGINESPEED CONTROLACTUATOR

B PILOTFILTER

PILOTPUMP

C

PILOTSHUT-OFFVALVE

D


EPROPELPILOTCHECKVALVEBLOCK

ROTARYMANIFOLD

PROPELMOTORS

I

H

PROPEL, BUCKETCONTROL VALVE

G

BOOM, SWING,ARM CONTROLVALVE

F

A

T109922 –19–28OCT97


PN=306

Theory Of Operation

9020057

TX,9020,LG17 –19–27AUG97–2/2

The propel pilot circuit (P) consists of:

• Pilot pump (A)• Pilot filter (B)• Pilot shut-off valve (C)• Propel pilot controller (D)• Propel pilot check valve block (E)• Boom, swing, and arm control valve (F)• Propel and bucket control valve (G)• Rotary manifold (H)• Propel motors (I)• Dual solenoid block (J)• Hydraulic reservoir (K).

Filtered pilot oil is routed to the boom, swing, and armcontrol valve (F). The control valve manifold containsthe pilot regulating valve. Filtered pilot oil is also routedto the dual solenoid block (J) and to the pilot shut-offvalve (C). Pilot oil from the pilot shut-off valve is routedto the propel pilot controller (D).

Actuating the propel pilot controller routes pilot oil tothe propel pilot check valve block. The block containsa pressure transducer that provides an electricalsensing signal to the system controller.

Pilot oil from the propel pilot controller moves thepropel spools in the propel and bucket control valve.Return oil, from the pilot caps, is routed through thepropel pilot check valve block, propel pilot controller,and pilot shut-off valve to the reservoir.

When high speed propel (rabbit) is selected, the propelspeed change solenoid valve in the dual solenoidblock is de-energized. Pilot oil flow through thesolenoid valve to the propel speed change valve inpropel motors is blocked. Propel motors shift tominimum displacement for high speed propel.


PN=307

Theory Of Operation

TX,9020,LG19 –19–27AUG97–1/2

Propel Circuit Operation

PROPEL PILOTCONTROLLER

TO PRESSURECONTROL MANIFOLD

TO RETURN

PROPEL PILOTCHECK VALVEBLOCK

DUAL SOLENOIDBLOCK

ROTARY MANIFOLD

BRAKE RELEASEVALVE

LEFTPROPELMOTOR

BRAKERELEASELINE

LOAD SENSING

RETURN

PUMPDISCHARGE

LOAD SENSING

RETURN

RIGHT PROPELCONTROL VALVE

FROMSHUT-OFFVALVE

LEFTPROPELCONTROLVALVE

C

E

RIGHTPROPELMOTOR

A

B

D

F

H

JK

L

N

O

P

O

M

PUMP SUPPLY OILQ

LOAD SENSE OILR

BRAKE RELEASE OILS

PILOT OILT

RETURN OILU

PROPEL CIRCUITVT7692AC CV

N

I

G

T7692AC –19–29AUG97


PN=308

Theory Of Operation

9020059

TX,9020,LG19 –19–27AUG97–2/2

The propel circuit (V) consists of two separate workcircuits, one for each track. The operator may movethe pedals on the pilot controller (C) different amountsfor different track speeds in order to steer the machine.Pump supply oil (Q) flows through the right and leftpropel control valves (A and M) to the right and leftpropel motors (I and K).

Propel control valve spools are moved by pilot oil (T)from the pilot controller. Pushing forward on the footpedals sends pilot oil to the forward pilot cap of eachpropel valve. The valve spools are moved rearwardand pump supply oil flows through the forward “A”work port of each control valve to drive each propelmotor in the forward direction. Pushing the foot pedalsin the other direction supplies pilot oil to the other pilotcaps of each propel valves. The spools move forwardwhich allows supply oil to flow out the rearward “B”work ports. This drives the propel motors in thereverse direction.

The propel valve spools also have a priority notch (notshown) on the outer surface of the control spool. Thenotch provides a supply of discharge oil between thevalve pump port and work port. This improves propelmetering during combined function operations.

The propel speed change solenoid valve in the dualsolenoid block (G) is used to hydraulically changepropel speed. In low and medium speed, the propelspeed change solenoid is energized. Pilot oil flowsthrough the solenoid valve to the propel speed changevalve in propel motors. The propel motors are atmaximum displacement. When high speed propel(rabbit) is selected, the propel speed change solenoidvalve in the dual solenoid block is de-energized. Pilotoil flow through the solenoid valve to the propel speedchange valve in propel motors is blocked. Propelmotors shift to minimum displacement for high speedpropel.

When in high speed propel, the propel motors will shiftautomatically depending on the load. As load

increases, the motors swash angle will increase andspeed will decrease.

The propel pilot check valve block (F) routes pilot oil tothe pressure control manifold (E) whenever the propelpilot controller is actuated. This pilot oil moves thecombined function shuttle valve in the pressure controlmanifold. The combined function shuttle valveimproves propel metering during combined functionoperation.

External brake release lines (J and L) are used torelease the propel brakes.

A pressure equalizing (crossover) line connecting theleft and right propel pilot caps together preventsmistracking. An orifice in the lines prevents the otherspool from moving if only one propel valve is actuated.The orifices are “captured” in the connections of hoseend fitting to tee fitting at the right propel valve frontand rear pilot caps. The orifice may be and can beinstalled at either end of hoses.

(Serial No. —543989)A pilot check valve with orifice is used in the inlet portof pilot caps for the left and right propel valve. Thecheck valves open allowing pilot oil to enter the capsquickly. Check valves close to restrict return flowthrough the orifices allowing the propel valve spool tomove slowly for more control of propel function.

(Serial No. 543990—556935)Orifices are installed in the pilot line connections to theleft and right propel valve pilot caps. The orifices are“captured” in the connections of pilot hose end fitting totee fitting at the pilot caps. The orifices restrict flow inboth directions for more control of the propel function.

(Serial No. 556936—)The right and left propel control valves and bucketcontrol valve are now located in a monoblock-stylevalve next to the left rear corner of the cab.


PN=309

Theory Of Operation

90200510

TX,902005,SS550 –19–23OCT97–1/2

Propel Pilot Controller Operation—Neutral

T7350BI CV

RETAINER

SHIMS

PEDAL

SLEEVEPLUNGER

I

BALANCESPRING

RETURNSPRING

TO RESERVOIR

TO CONTROLVALVEFROM PILOTPUMPTO RESERVOIR

PISTON

SPOOL

SPRINGGUIDE

PILOT OIL

PROPEL PILOT CONTROLLER-NEUTRAL

A

B

C

D

OJ

BE

K

P

E

F

G

H

I

J

K

L

N

M

RETURN OIL

Q

T73

50B

I–1

9–29

AU

G97


PN=310


Theory Of Operation

TX,902005,SS550 –19–23OCT97–2/2

One pilot controller is used to control the propelfunctions. The controller has four valve assemblies,one for each direction of each track. The pilotcontroller has a pedal (E), plunger (D), sleeve (F),spring guide (C), spool (B), piston (A), balance spring(G), and return spring (H). In neutral, the spool ispushed up by the return spring to block oil from the

pilot pump (K). With the spool up, the passage to thecontrol valve (J) is connected to the reservoir (I).

The propel pilot controller operates the same as thehand pilot controllers. For metering function see PilotController—Metering Operation in Group 9025-05.

90200511


PN=311

Theory Of Operation

90200512

TX,902005,IJ114 –19–08SEP97–1/2

Propel Pilot Check Valve Block Operation—Forward

H

G

I

FE

PRESSURETRANSDUCER

PROPELPRESSURE

TRANSDUCER

E

LEFTFORWARD

RIGHTFORWARD

LEFTREVERSEI

RIGHTREVERSE

H

PILOTSHUT-OFF

VALVEA

L

PROPELSHUTTLE

VALVE C

SHUTTLEVALVES

FG

IH

D

PROPELPRESSURE

TRANSDUCERE

PROPELPILOTVALVE

B

PILOT OILJ

RETURN OILK

T7692AD CVPROPEL CHECK VALVE BLOCK–FORWARD

F

GT

7692

AD

–19–

29A

UG

97


PN=312


Theory Of Operation

TX,902005,IJ114 –19–08SEP97–2/2

The propel pilot check valve block contains threeshuttle valves. When propel pilot controller is actuated,pilot oil enters the valve block through ports (G and F)in forward or ports (H and I) in reverse operation andthen out of valve block to the pilot caps on the propelcontrol valves. The shuttle valves move routing thehighest pressure pilot oil to the pressure transducer (E)and out the hose to the Z1 port in pressure control

manifold (Serial No. —556935) or control valvemanifold (Serial No. 556936—).

The pressure transducer (E) sends a electrical sensingsignal to the system controller whenever a propel pilotcontroller is actuated. The system controller sends acontrol signal to activate the propel alarm and autoidle.

90200513


PN=313

Theory Of Operation

90200514


PN=314

Theory Of Operation

TX,902005,JV293 –19–08SEP97–1/1

Combined Function Shuttle Valve Operation—(Serial No. —556935)

T111732

M

SUPPLY OIL

PILOT OIL

LOAD SENSE OIL

RETURN OIL

PROPEL ACTUATED

LOAD SENSEFROM MANIFOLD(DIG, SWING, AUXILIARY VALVE)

LOAD SENSEFROM CONTROLVALVE MANIFOLD(PROPEL VALVES)

COMBINE FUNCTIONSHUTTLE VALVESPOOL

SPRING

TO CONTROLVALVE MANIFOLD

TO PUMPREGULATOR

ORIFICE

CHECKVALVE

LOAD SENSESYSTEM RELIEFVALVE

Z1FROM PROPELPILOT CHECKVALVE

U

V

E

G

DIG FUNCTION ACTUATED

CA

D

J PILOT PRESSUREREGULATING VALVE

L

Z2 FROMBUCKET, ARMAND BOOMCONTROLVALVES

B

HSAFETYRELIEFVALVE

LOAD SENSEFROM MANIFOLD(DIG, SWING, AUXILIARY VALVES)

LOAD SENSEFROM CONTROLVALVE MANIFOLD(PROPEL VALVES)

SPOOL

SPRING

TO CONTROLVALVE MANIFOLD

TO PUMPREGULATOR

ORIFICE

CHECKVALVE


Z1FROM PROPELPILOT CHECKVALVE

M

U

F

V

G C

D

J PILOT PRESSUREREGULATING VALVE

L

Z2 FROMBUCKET, ARMAND BOOMCONTROLVALVES

B

SAFETYRELIEFVALVE

A

HE

F

N

O

P

Q

R

Z1

Z2

ORIFICE

CHECKVALVE

TO PUMPREGULATOR

FROM PROPELPILOT CHECKVALVE

POWERBOOSTSOLENOID

PILOT PRESSUREREGULATING VALVE

LOADSENSESYSTEMRELIEFVALVE

SAFETYRELIEFVALVE

FROMPILOTFILTERFROM ARM AND

BUCKET VALVES

PROPELACTUATED

DIG FUNCTIONACTUATED

COMBINEDFUNCTION SHUTTLEVALVE SPOOL

FROM BUCKET,ARM AND BOOMCONTROL VALVES

FROM PROPELCONTROL VALVES

AB

C

E

D

L

F

M M

AB

C

E

D

L

F

A

B

C

D

EF

G H

J

I

K

LM

R S

T

S

FROM BOOM,SWING, ANDAUXILIARY VALVES

L

PRESSURE CONTROL MANIFOLD (S.N. —556935)

T111732 –19–28OCT97


PN=315

Theory Of Operation

TX,9020,JH3056 –19–16OCT97–1/2

Combined Function Shuttle Valve Operation—(Serial No. 556936—)

F

G

HI

C

D

E

COMBINED FUNCTIONSHUTTLE VALVE SPOOL

TO PROPEL AND BUCKET AND PUMP REGULATOR

PILOT PRESSUREREGULATING VALVE

TO SWING TORQUECONTROL VALVE ANDSWING VALVE

TO ARMCONTROLVALVE

TO BOOMCONTROLVALVE

ARMREGENERATIVEVALVE

T2T

BOOMCYLINDERRESTRICTOR

POWER BOOSTSOLENOID


ARM CYLINDERRESTRICTOR

LSA PORT

Z2 PORTZ1 PORT

LSP

LS PORT

V

J

KL

M

A

P

N

O

SUPPLY OILR

PILOT OILS

LOAD SENSE OILT

RETURN OILUT110288 MAIN CONTROL VALVE MANIFOLD—(S.N. 556936— )

LG

Q

B

FJ

H

I

K

LG

FJ

H

I

KPROPELACTUATED DIG

FUNCTIONACTUATED

TO HYDRAULICRESERVOIR

OIL COOLERBYPASS VALVE

TO "T" PORTON PROPEL, BUCKETCONTROL VALVE

TO OIL COOLER

RETURNMANIFOLD

ORIFICE

FROM HYDRAULICPUMP

CHECK VALVE

POWERBOOSTSOLENOID

ARMREGENERATIVEVALVE

ARM SIDEFRONT VIEW

BOOM SIDEREAR VIEW

A

C

M

D

E

PILOTPRESSUREREGULATINGVALVE

BOOMCYLINDERRESTRICTOR

ARMCYLINDERRESTRICTOR

N

LOAD SENSESYSTEMRELIEFVALVE

J

COMBINEDFUNCTIONSHUTTLEVALVESPOOL

T110288 –19–28OCT97


PN=316

Theory Of Operation

90200517

TX,9020,JH3056 –19–16OCT97–2/2

NOTE: On machines (Serial No. —556935), thecombined function shuttle valve is located inthe pressure control manifold.

On machines (Serial No. 556936—), thecombined function shuttle valve is located inthe control valve manifold.

When only propel function is actuated (R), pilot oil (O)is routed to Z1 port (A) closing the combined functionshuttle valve (F). Load sense oil (P), from the propelvalves (M), is routed to the pump regulator (C) andalso opens check valve (D) routing load sense oil tothe load sense system relief valve (G) and to thespring side of the safety relief valve (H).

When bucket, arm or boom functions are actuated (S),pilot oil is routed to Z2 port (B) opening the combinedfunction shuttle valve (F). Load sense oil, from the dig,swing, and auxiliary control valves (L), is sensed by

the load sense system relief valve and routed to thespring side of the safety relief valve. Load sense oil isalso routed to orifice (E), spring side of check valve(D) and through the combined function shuttle valve(F) to the pump regulator (C).

During combined propel and cylinder functionoperation, position of the combined function shuttlevalve spool is determined by Z1 pilot pressure and Z2pilot pressure plus spring force.

When propel and swing are actuated, the spool (F) isclosed. Propel load sense pressure is normally higherthan swing load sense pressure, so propel load sensepressure is routed to the pump regulator.

When only swing is actuated, load sense oil willbypass the orifice (E). The combined function shuttlevalve and check valve are both closed.


PN=317

Theory Of Operation

90200518

TX,9020,LG22 –19–27AUG97–1/2

Propel Control Valve Operation

T7576AN CV

SUPPLY OIL

PROPEL CONTROL VALVE

P

Q RETURN OIL

R

PILOT CAP

SPRING

LOAD SENSING

TORETURN

POPPET

BALANCE VALVE

FROM PUMP

BALANCE VALVE

POPPET

TORETURN

LOAD SENSING

SPRING

NOTCH

SPOOLSTOPSCREW

PILOT CHECK

WORK PORT

WORKPORT

MAKE-UPVALVE

PILOT CAPRELIEF VALVE(AIR BLEED)

SPOOL

A

B

C

D

E

F

G

F

E

D

C

B

H

I

N

L

K

J

M

O

T75

76A

N–1

9–29

AU

G97


PN=318


Theory Of Operation

90200519

TX,9020,LG22 –19–27AUG97–2/2

The propel control valve (R) is the same design asboom, arm and bucket control valves except for threeareas. The valves are a smaller capacity valve thanthe cylinder valves. Make-up valves (K) are used, notcircuit relief and anti-cavitation valves. Inside thebalance valves (F) a poppet (E) is used, not a shuttlevalve.

The poppet acts the same as a shuttle valve except itis an ON and OFF valve that does not meter flow.

The balance valves acts the same as the balancevalves in the cylinder valves.

In neutral, work ports are open to return through thecontrol valve spools.

Control valve spools are different and notinterchangeable.

(Serial No. —543989)A pilot check valve with orifice (O) is used in the inlet

port of pilot caps for the left and right propel valvesections. The check valves open allowing pilot oil toenter the caps quickly. Check valves close to restrictreturn flow through the orifices, allowing the controlvalve spool to move slowly for more control of thefunction.

(Serial No. 543990—556935)Orifices are installed in the pilot line connections to theleft and right propel valve pilot caps. The orifices are“captured” in the connections of pilot hose end fitting totee fitting at the pilot caps. The orifices restrict flow inboth direction for more control of the propel function.

(Serial No. 556936—)The right and left propel control valves and bucketcontrol valve are now located in a monoblock-stylevalve next to the left rear corner of the cab.


PN=319

Theory Of Operation

90200520

TX,902005,SS681 –19–08SEP97–1/1

Rotary Manifold Operation

ROTARY MANIFOLDT8072AA CV G

LEFTPROPELREVERSE

B

CB DE

A F

F

E

D

F

B

C

LEFT PROPELFORWARD

C RIGHT PROPELREVERSE

D

RIGHT PROPELFORWARD

E

PROPEL BRAKE RELEASEF

RIGHT PROPEL DRAINA

RIGHT PROPEL FORWARDE

D RIGHT PROPEL REVERSE

PROPELBRAKERELEASE

LEFTPROPELDRAIN

LEFTPROPEL REVERSE

LEFT PROPEL FORWARD

C

F

B

SUPPLY OIL

RETURN OIL

REDUCED SUPPLY OIL

A

A

ADRAIN

T80

72A

A–1

9–29

AU

G97

The rotary manifold (G) is a 360° rotating joint. Itallows oil to flow to and from the propel motors withouttwisting hoses when the upper structure is rotated.

The inner spindle is connected to the upper structureand the housing is connected to the undercarriage.The housing rotates about the spindle during swingoperation.

Oil flows into and through the spindle to passages inthe housing, and then out of the housing to the propelmotors. Sealing rings stop oil from leaking between thespindle and housing into adjacent passages.


PN=320

Theory Of Operation

90200521


PN=321

Theory Of Operation

90200522

TX,902005,IJ116 –19–08SEP97–1/2

Propel Motor Operation

SHAFT

RETAININGRING

SPACER

SEAL

SWASHPLATE

SLIPPER

RETAINERBALLGUIDE

PISTON

CYLINDERBLOCK

PIN MAXIMUMDISPLACEMENTPISTON

SHIMS

PIN

SPRING MINIMUMDISPLACEMENTPISTON

WEARSLEEVE

COVER

BEARINGSHELL

PROPEL MOTOR

SUPPLY OIL

O

X

T

P

Q

R

S

A

B

C

D

EF

G

HI

J

K

L

M

N

LUBRICATION OILU

RETURN OILV

PILOT OILW

T7537AB CV

T75

37A

B–1

9–02

SE

P97


PN=322


Theory Of Operation

90200523

TX,902005,IJ116 –19–08SEP97–2/2

The propel motor is a variable displacementswashplate design. The motor is interchangeable fromside to side by reversing the shuttle valve andcounterbalance valve. The motor rotating groupconsists of a cylinder block (J) with nine pistons (I) andan output shaft (A) that is splined to the cylinder block.

Supply oil (T) from the propel control valve enters themotor through the cover (N) to the pistons. Duringoperation, high pressure supply oil enters the pistonbores in the cylinder block (J). This forces the pistonsagainst an angled swashplate (E). Piston sliding actioncauses the rotating group to turn. The cylinder block issplined to the output shaft (A) which causes the outputshaft to turn. During second half of the motor rotation,low pressure oil is discharge as the pistons ride up toa higher position on the swashplate. To reverserotation, oil flow is reversed. During operation, a smallamount of supply oil flows through the center of eachpiston. This oil lubricates the piston to slipper (F) jointand the slipper to swashplate area. High pressuresupply oil also flows through a tube to lubricate theswashplate to bearing shell area. Normal leakage andlubrication oil aid in flushing and cooling the motorduring propel operation.

The swashplate (E) angle is changed by the minimumdisplacement piston (O) and maximum displacementpiston (L). When supply oil acts on the minimumdisplacement piston (O), the motor runs at its highestspeed. When supply oil acts on the maximumdisplacement piston, the motor runs at its slowestspeed. The maximum displacement piston is largerthen the minimum piston and will hold the motor inmaximum displacement when equal pressure acts onboth pistons.

NOTE: Swashplate angle (motor displacement) islimited by the minimum and maximumdisplacement pistons contacting the minimumand maximum displacement adjustment stopsin the propel motor cover. For minimumdisplacement, the maximum displacementpiston contacts the minimum displacementadjustment stop. For maximum displacement,the minimum displacement piston contacts themaximum displacement adjustment stop.


PN=323

Theory Of Operation

90200524

TX,902005,IJ118 –19–03MAR95–1/2

Propel Motor Cover Operation

T84

33A

B–1

9–08

MA

R95


PN=324


Theory Of Operation

90200525

TX,902005,IJ118 –19–03MAR95–2/2

The propel motor cover (L) consists of severalcomponents to operate the propel functions andregulate the release of propel brakes.

The minimum displacement adjustment stop (A) limitsthe minimum angle the swashplate can move. Themaximum displacement adjustment stop (E) limits themaximum angle the swashplate can move.

NOTE: For minimum displacement, the maximumdisplacement piston contacts the minimumdisplacement adjustment stop. For maximumdisplacement, the minimum displacementpiston contacts the maximum displacementadjustment stop.

The crossover relief valve (B) protect the motor circuitfrom pressure spikes.

The shuttle valve (C) slides back and forth, dependingon direction of travel, to route supply oil to thecrossover relief valve (B) and minimum displacementpiston. The shuttle valve moves only when a propelfunction is actuated.

The propel brake release pressure reducing valve (D)reduces the higher supply oil pressure to the lower oilpressure used to release the propel brake. The highersupply oil pressure comes from the supply shuttlevalve when a propel function is actuated.

The edge filter (Serial No. 539108—) and pressurereducing valve orifice (J) are located in the passage

from the supply shuttle valve (F) to the propel brakerelease pressure reducing valve (D). The edge filterand orifice are accessible by removing the plug in faceof cover. The edge filter is used to break up smallparticles in the oil so they flow through the orifice. Theorifice causes a pressure drop in supply oil flow to thereducing valve and dampens pressure oil fluctuation.

The propel speed change valve (H) routes supply oil tothe maximum displacement piston to keep the propelmotor in the lowest speed.

The propel speed change orifice (K) is located in thepassage from the propel speed change valve to themaximum displacement piston. The orifice isaccessible by removing the plug in face of cover.Orifice is used to dampen pressure fluctuation.

The flushing orifice (long type) (I) is located in thebrake circuit to motor case passage. The orifice isaccessible by removing the plug in the face of cover.The orifice provides a passage for oil flow from thebrake circuit to the motor case for cooling and flushingduring propel operation. When the oil is cold the flowof oil is restricted by the long type orifice to prevent anexcessive build up of pressure in the propel motorcase. Orifice also provides a passage to release anyresidual pressure from the brake circuit to the motorcase when not propelling.

All the components in the propel motor cover will becovered in detail later in this section.


PN=325

Theory Of Operation

90200526

TX,902005,IJ120 –19–08SEP97–1/2

Supply Shuttle Valve Operation

SUPPLY SHUTTLE VALVE

SUPPLY OIL

J

H

RETURN OILI

C

G

BSEAT

B

C

E

G TOPROPELCONTROLVALVE

FROM PROPELCONTROL VALVE

SHUTTLEBALL

TO BRAKEPRESSUREREDUCINGVALVE

PLUG

F

A

A

DSLEEVE

T7694AB CV

T76

94A

B–1

9–02

SE

P97

The supply shuttle valve (J) is located between thepropel motor cover and the counterbalance valve. Theshuttle ball (B) moves when a propel function isactuated to route supply oil (H) to the brake pressure

reducing valve (C). When the machine is propelled inthe opposite direction the ball moves in the oppositedirection.


PN=326


Theory Of Operation

TX,902005,IJ120 –19–08SEP97–2/2

Two makeup check valves located in the supply shuttlevalve are not being used on this machine and will beeliminated. Some early production units will have them.

90200527

TX,902005,IJ122 –19–08SEP97–1/1

Counterbalance Valve Operation—Neutral

VALVEHOUSING

TO CONTROLVALVE

SPOOL

TO CONTROLVALVE

POPPET

SPRING

CHECKVALVE

ORIFICE

TO PROPELMOTOR

A

TO PROPELMOTOR

J I

H

G

F

E

D

C

B

COUNTERBALANCE VALVE NEUTRALMT7547BA

TRAPPED OIL

RETURN OIL

K

L

CV

T75

47B

A–1

9–02

SE

P97

When the propel valve spools in the main controlvalve, are in neutral position, the counterbalance valvespool (C) is held in the center position by spring (F).Both propel motor oil lines to the control valve (B andD) are connected to return through the control valve.

Oil in each motor is trapped by check poppets (E) andspool (C). They hold the motors stationary.


PN=327

Theory Of Operation

90200528

TX,902005,IJ123 –19–08SEP97–1/1

Counterbalance Valve Operation—Propel

T7576AC CV COUNTERBALANCE VALVE PROPEL

SUPPLY OILK

RETURN OILL

M

IJ

A

G TOPROPELMOTORH FROM

PROPELMOTOR

B TOCONTROLVALVE

D FROMCONTROLVALVE

E POPPETF SPRING

CHECKBALL

ORIFICE

VALVEHOUSING

C SPOOL

T75

76A

C–1

9–02

SE

P97

When the propel pilot controller is moved to forwardposition, supply oil (K) is routed from the propel valvesin the control valve to work port (D). If pilot controller ismoved to reverse position, supply oil would be routedto work port (B).

In forward direction, supply oil enters work port (D),flows through holes in the counterbalance spool (C),and pushes the check poppet (E) open. When thecheck poppet opens, supply oil flows through port (G)to the propel motor. Return oil (L) from propel motorport (H) is blocked by the check valve on the oppositeend of the spool. This along with the motor’sresistance to turning, causes the pressure in work port

(G) to increase. As supply oil pressure in the work portincreases, the pressure on the right end of the spoolincreases, pushing the spool to the left. When thespool moves to the left, oil from the motor (H) flows toreturn. The orifice (I) and the tolerance between thespool and valve housing, control the escape of the oilon the left end of the spool. This improves stability andrapid movement of the spool.

When the pilot controller is returned to neutral position,the oil in both work ports (B and D) are routed toreturn through the control valve. Both check poppets(E) will seat and spool (C) will center trapping oil in themotor to prevent rotation.


PN=328

Theory Of Operation

90200529

TX,902005,IJ124 –19–08SEP97–1/1

Counterbalance Valve Operation—Braking

T7576AD CV

SUPPLY OIL

RESTRICTED OIL

RETURN OIL

COUNTERBALANCE VALVE BRAKINGN

K

L

M

JFROM PROPELMOTOR

ITO PROPELMOTOR

H ORIFICE

F SPRING

G CHECKBALL

POPPET

D

FROM CONTROLVALVE

C SPOOLB

TO CONTROLVALVE

AVALVEHOUSING

E

T75

76A

D–1

9–02

SE

P97

When traveling down a hill, the weight of the machinemay begin to overrun the propel motors. This wouldcause faster travel than desired and would cavitate theinlet side of the motors. As pressure decreases in theinlet passage (D) of the motor, the pressure holding

the counterbalance spool (C) also decreases. Spring(F) force moves the spool to the right restricting flowfrom the propel motor port (J), slowing motor rotation.This is called “dynamic braking”.


PN=329

Theory Of Operation

90200530

TX,9020,LG23 –19–27AUG97–1/2

Propel Speed Change Solenoid Valve Operation

F

D

E

F

D

E

PROPEL SPEED CHANGE SOLENOID

PILOT OIL

K

I

RETURN OILJ

SOLENOIDVALVE

F

C

D

E

G H

B

FROMPILOTPUMP

NEUTRAL

TO PROPELMOTORS

TORETURN

SPOOL

ACTIVATED

COIL

A

T7567AA CVT

7567

AA

–19–

02S

EP

97

(Serial No. —556935)The propel speed change solenoid (K) is located in thedual solenoid valve block and is the solenoid closest tothe cab.

(Serial No. 556936—)The dual solenoid valve is mounted on the firewallnear the hydraulic reservoir. The propel speed change

solenoid (K) is located in the dual solenoid valve blockand is the solenoid closest the swing motor.

When the solenoid is in neutral (de-energized) (G),pilot oil (I) from the pilot pump (F) is blocked fromgoing to the propel motors (E). The line to the propelmotors is open to return (D). The propel motors are atminimum displacement for high speed.


PN=330


Theory Of Operation

TX,9020,LG23 –19–27AUG97–2/2

When the solenoid is activated (energized) (H), thespool is pulled up, blocking the passage to return androuting pilot oil to the low speed selector valve in both

motors. Both motors are now locked at maximumdisplacement for medium or low speed propel.

90200531


PN=331

Theory Of Operation

90200532

TX,902005,IJ126 –19–09SEP97–1/2

Propel Speed Change Valve Operation

PROPEL SPEED CHANGE VALVET8434AA CV

LOW SPEED MODE

AUTOMATIC MODE

SUPPLY OIL

TORESERVOIR A

M

J

RETURN OILK

PILOT OILL

B

D CEF

DC

B

A

TO MAXIMUMDISPLACEMENTPISTON

PISTON SHIMS FROMCONTROLVALVE

FROM PROPELSPEED CHANGESOLENOID VALVE

I

H

TORESERVOIR A

B

D CEF

DC

B

A

TO MAXIMUMDISPLACEMENTPISTON

PISTON SHIMS FROMCONTROLVALVE

FROM PROPELSPEED CHANGESOLENOID

G PROPEL SPEEDCHANGE ORIFICE

PROPEL SPEEDCHANGE ORIFICEG

G

G

T84

34A

A–1

9–02

SE

P97

Propel speed change valve (M) is located in the propelmotor cover. The valve controls the hydraulic pressuresignal to the maximum displacement piston (B) to shiftthe motor to maximum displacement for medium andlow speed.

In automatic mode (rabbit) (H), supply oil (J) forcespiston (F) against the spring. As supply oil pressureincreases, the piston moves further left allowing supplyoil to flow to the maximum displacement piston (B).The motor shifts to maximum displacement.


PN=332


Theory Of Operation

TX,902005,IJ126 –19–09SEP97–2/2

When low speed propel (turtle) is actuated, pilot oil (L)flows from the propel speed change solenoid valve (C)to the right end of piston (F). The pilot oil plus supplyoil pressure pushes the piston against the springallowing supply oil to flow to the maximumdisplacement piston. The motors shift to maximumdisplacement for low speed propel.

The propel speed change orifice (G) is used todampen the pressure fluctuation to the maximumdisplacement piston.

90200533


PN=333

Theory Of Operation

90200534

TX,902005,IJ127 –19–09SEP97–1/2

Propel Crossover Relief Valve And Shuttle Valve Operation

T8434AI CV

SUPPLY OIL

RETURN OIL

PROPEL CROSSOVER RELIEF VALVE AND SHUTTLE VALVE

PROPELCROSSOVER RELIEF VALVESPRINGS

SHIMS

FROMCONTROLVALVE

(TO MOTOR)TOCONTROLVALVE

(FROM MOTOR)

TO MINIMUMDISPLACEMENTPISTON

SHUTTLEVALVESPOOL

OVERRELIEF

RELIEFPOPPET

SHIMS

PROPELMOTORCOVER

FDC

B

M

C

E

A

JI H

K

L

G

T84

34A

I–1

9–02

SE

P97


PN=334


Theory Of Operation

TX,902005,IJ127 –19–09SEP97–2/2

The propel motor crossover relief valve and shuttlevalve (M) are located in the propel motor cover. Oilpassages in the propel motor cover direct supply oil(K) from the control valve (H) to the shuttle valve.Supply oil flows through a passage in the center of theshuttle valve spool (G). Pressure builds on the rightend of spool pushing it to the left. As the spool moves,the passages to the propel crossover relief valve (D)and the minimum displacement piston (I) opens.

When the direction of travel changes, supply oil fromthe control valve is reversed, shifting the shuttle valveto the right.

The propel crossover relief valve (D) is a direct actingrelief valve. During an overload condition, highpressure forces the relief poppet (E) off its seat againstspring (B). The relief poppet is shim (C) adjustable.

90200535


PN=335

Theory Of Operation

90200536

TX,902005,IJ129 –19–09SEP97–1/2

Propel Brake And Pressure Reducing Valve Operation

EDGEFILTER

Q ORIFICE

B SPOOL

C PROPEL MOTOR COVER

D METERING POINT

E TO BRAKE PISTON

F ADJUSTMENT SCREW

G SPRINGH FROM CONTROL VALVE

I

J BRAKE PRESURE REDUCING VALVE

P

ORIFICE

M DRIVE COUPLING

N PROPEL BRAKE

L SPRING

K

A ORIFICE

A E

N

L

G

Q

H I

O FINAL DRIVE HOUSING

E

FROM BRAKEPRESSUREREDUCINGVALVE

R SUPPPLY OIL

S REDUCED PRESSURE OILT BRAKE RELEASE PRESSUREU LUBRICATION OIL

V RETURN OIL

BRAKEPISTON

PROPEL BRAKE OPERATIONWT8434AJ CV

T84

34A

J–1

9–02

SE

P97


PN=336


Theory Of Operation

90200537

TX,902005,IJ129 –19–09SEP97–2/2

The propel brake (N) is a spring applied, hydraulicallyreleased park brake. The propel brakes are releasedwhen the propel pilot controllers are actuated.

Supply oil (R) flows around the reducing valve spool(B) and is metered (reduced) before it flows out thepassage (E) to the brake piston (K). Metering occurswhen the brake release pressure oil (R) acts on theleft end of spool partially closing the passage to thebrake piston. Spring force (G) works against the oilpressure to limit the pressure in the brake circuit. Theadjustment screw (F) on the right end of valve is usedto adjust the brake circuit pressure. The reducing valvemaintains adequate oil pressure to release the brake.

A 1.0 mm (0.040 in.) flushing orifice (long type) (A), inthe brake circuit passage, prevents any back pressurefrom building and partially releasing the brake when

not propelling. During a propel operation, oil flowsthrough the orifice to the motor case for cooling andflushing the propel motor. When the oil is cold the flowof oil is restricted by the long type orifice to prevent anexcessive build up of pressure in the propel motorcase. The orifice is accessible by removing the plug inthe face of cover.

The orifice (Q) in passage at end of spool is also usedfor cooling flow and flushing.

Brake circuit oil from the brake pressure reducingvalve is routed to the final drive housing through anexternal hose. The oil passes through a drilledpassage to the brake piston (K). Oil pressure pushesthe brake piston to the left releasing the brake. Whenthe propel pilot controllers are in neutral, the springs(L) push the piston to the right locking the brake on.


PN=337

Theory Of Operation

90200538

TX,902005,IJ45 –19–09SEP97–1/2

Propel Gearbox Operation

T7692AE CV

THIRD PLANETCARRIER

RTHIRD PLANETSUN GEAR

QSECOND PLANETSUN GEAR

P

FIRST PLANETRING GEAR

O

THRUSTPAD

N

FIRSTPLANETGEAR

M

COVERL

FIRSTPLANETCARRIER

KJ

SECONDPLANETGEAR

I

SECONDPLANETCARRIER

H

THIRDPLANETGEAR

G

RINGGEAR

F

FACE SEAL

EHOUSING

D

BRAKE

CPISTON

BSPRING

AINPUT SHAFT(FIRST PLANETSUN GEAR)

SCOUPLING

PROPEL GEARBOXU

LUBRICATION OILT

T76

92A

E–1

9–02

SE

P97

The propel gearbox is a triple reduction planetary driveand is interchangeable from right to left side. Thepropel motor is connected to the input shaft (A) with acoupling (S). The coupling is also used as a brake

hub. The splines on the outside of the coupling engagethe brake disks in the propel brake (D). The brake is aspring applied and hydraulic released.


PN=338


Theory Of Operation

TX,902005,IJ45 –19–09SEP97–2/2

The propel motor is attached to housing (E). Rotarymotion from the propel motor is transferred through theinput shaft to the first planet sun gear (A). The firstplanet sun gear rotates causing the first planet piniongears to orbit and rotate the first planet carrier (K). Thefirst planet carrier is splined to the second planet sun(P) that is in mesh with the second planet pinion gears(J). The second planet pinion gears also orbit around

ring gear (G) causing the second planet carrier (I) torotate. The second planet carrier is splined to the thirdplanet sun gear (Q) causing it to rotate. The thirdplanet sun gear rotation causes the third planet piniongears (H) to orbit around the ring gear (G). Orbiting ofthe pinion gears from the three planetaries, causes thering gear to rotate and drive the sprocket.

90200539

TX,902005,IJ40 –19–09SEP97–1/1

Track Adjuster Operation

TRACK ADJUSTERJT7391AB CV

CYLINDER BARREL

FITTING

ADAPTERSEAL

PISTONGREASE

SPRING

YOKE

IDLER

ED F

G

HI

A

B

C

T73

91A

B–1

9–02

SE

P97

The track adjuster (J) is supported by the track frame.The track spring (C) compresses and absorbs shockloads from the chain and front idler.

To increase track tension and decrease track sag,grease (D) is pumped into fitting (H). The greaseforces the cylinder (I) forward pushing the idler forwardreducing track sag. Continuing to pump grease into thecylinder may cause the spring to compress after thechain becomes tight. This will cause excessive wear

on the track bushings, sprockets, and require morepower to propel the machine.

Releasing track tension is accomplished by looseningthe adapter (G) allowing grease to escape through agroove cut in the adapter threads. The adapter hasthree holes 180° apart so the grease fitting can belocated for easy access with a grease gun. The twoholes not being used are plugged.


PN=339

Theory Of Operation

90200540

TX,902005,IJ131 –19–21AUG91–1/1

Front Idler Operation

T75

53C

L–1

9–06

AU

G91

The front idler (A) is a large wheel located at the frontof the track frame that guides and supports the trackchain. The front idler can also be moved forward orrearward on the track frame to adjust track sagtension. The idler shaft (D) is attached to the fork (G)by dowel pins (C). The idler rotates around the

stationary shaft when the machine propels. Bushings(B) pressed into each side of the idler are the bearingsurface for the assembly. A lubrication passage (F) isdrilled into the idler into the idler hub so oil can be putinto the idler for lubrication.


PN=340

Theory Of Operation

90200541

TX,902005,IJ132 –19–21AUG91–1/1

Carrier Roller Operation

T75

47B

B–1

9–13

AU

G91

The carrier roller is a metal wheel that supports theweight of the upper portion of the track. It helps to

guide the chain and prevents the track from saggingexcessively.


PN=341

Theory Of Operation

90200542

TX,902005,IJ133 –19–21AUG91–1/1

Track Roller Operation

T75

47B

C–1

9–13

AU

G91

Track rollers are flanged metal wheels mounted on thebottom of the track frame that roll over the rail portion

of the track chain links. The roller flanges guide thechain as it moves between the idler and the sprocket.


PN=342

Theory Of Operation

90200543


PN=343

Theory Of Operation

90200544

TX,902005,VV208 –19–21JUL93–1/1

Swing Bearing Operation

T80

48A

B–1

9–17

JUL9

3

A—Top Seal D—Inner Race G—Ball J—Bottom SealB—Lubrication Fitting 30° (2 E—Outer Race H—Support (Thin) K—Tapered Lock Pin

used) (No longer used) F—Lubrication Fitting, Straight I—Support (Thick) L—PlugC—Cap Screw (3 used)

The swing bearing supports the superstructure on theundercarriage and allows the superstructure to rotatesmoothly. The swing bearing is a single-row shear

ball-type bearing. The inner race gear (D) meshes withthe pinion gear on the swing motor.


PN=344

Group 10System Operational Checks

9020101

TX,9020,DY6325 –19–17SEP97–1/1

Power Train Operational Checks

This procedure is designed so the mechanic can makea quick check of the system using a minimum amountof diagnostic equipment. If you need additionalinformation, read Theory of Operation, Group 9020-05.

Choose a location that is level and has adequatespace to complete the checks.

The engine and all other major components must be atoperating temperature for some checks.

Locate system check in the left column and readcompletely, following this sequence from left to right.Read each check completely before performing.

In the far right column, if no problem is found, you willbe instructed to go to next check or check is complete.

If a problem is indicated, you will be given repairrequired and group location or CTM number. Ifverification is needed, you will be given next bestsource of information:

Group 10 (System Operational Checks)

Group 15 (Diagnostic Information)

Group 20 (Adjustments)

Group 25 (Tests)

CTM (Component Technical Manual)

– – –1/1

1 Propel System Checks


PN=345


902010

2

– – –1/1

Pilot Shut-Off ValveCheck

T7351CC –UN–22AUG90

CAUTION: Machine functions may movewhile performing this check. Operatemachine in an open area.


Pilot control shut-off lever in OFF rearward position.

Operate all dig and propel function controls.

Do any dig or propel functions operate?

YES: Adjust linkage, goto 9025-20.

NO: Continue check.

T7351CB –UN–22AUG90


Push pilot control shut-off lever to the ON (forward)position.

Carefully operate all dig and propel functions.



NO: Adjust linkage, go to9025-20. Do Pilot ValveTest and Adjustment, goto 9025-25.

– – –1/1

Propel Lever And PedalCushion Cylinder Checks

T7351CD –UN–22AUG90

Engine OFF.

Key switch ON.

Move each lever and pedal forward (A), then release.

Move each lever and pedal rearward (B), then release.

Does each lever and pedal have equal effort to operateforward and reverse?

Does each lever and pedal return to neutral at the sametime when released?


NO: Inspect propel pilotcontroller underoperator’s platform.Repair. Go to Group3360. Inspect pedalcushion cylinders. Repairor replace. Go to Group3360.


PN=346


– – –1/1

Propel FunctionPressure TransducerCheck


Engine running in max power.

Push max. power “P” mode switch.

Auto-idle switch (B) OFF.

Pilot control shut-off lever ON. (Forward)

Push auto-idle switch (B) to ON.

Does auto-idle indicator (A) come on?

Does engine speed decrease after 4 to 6 seconds?

Slowly actuate any propel function.

Does engine return to high idle?


NO: Check fuse andpressure switch wiring.Go to Section 9015.

9020103

– – –1/1

Propel System TrackingChecks

Engine running in max. power “P”.

Push propel speed increase switch until high speed (rabbit) propel mode indicator isON.

Propel machine at full speed forward on a flat and level area.

Repeat procedure in reverse.

Does machine mistrack excessively in forward or reverse?

YES: Note which trackdoes not move or ifmachine mistracks, notethe mistrack pattern. Pilotcontroller or main controlvalve malfunctioning.Inspect and repair. SeeGroup 3360. Worn propelmotor. Do Propel MotorLeakage Test. See Group9020-25. Propel controlvalve spool stop screwsmisadjusted. Makeadjustment. See Group9020-25



PN=347


– – –1/1

Propel MotorCounter-Balance ValveChecks

Engine running.

Speed mode switch in max. power “P” position.

Propel speed switch in high speed (rabbit) position.

T7321AE –UN–30AUG90

Propel machine at full speed forward down a slope.

Turn in each direction.

Repeat the procedure in reverse.

Does each track slow in response to pedal movement inorder to turn?

NOTE: Each motor has one counterbalance valve foreach direction.


NO: Inspect and repairCounterbalance Valve.Go to Group 0260.

902010

4

– – –1/1

Propel Speed Check


Engine running.

Push heavy duty work mode switch “HD”.

Push propel speed decrease switch (B) until low speedpropel mode (turtle) indicator (E) comes ON.

Propel machine on a level area.

Push propel speed increase switch (A) until mediumspeed propel mode indicator (D) comes ON.


Push propel speed increase switch (A) until high speedpropel mode (rabbit) indicator (C) comes ON.


Repeat check using reverse propel speeds.


NO: Do propel speedchange solenoid valvetest. Go to Group9020-25. Inspect andrepair hydraulic pump orpropel motor controlcircuit. Go to Group9020-15.


PN=348


– – –1/1

Propel Cycle TimeChecks

IMPORTANT: Hydraulic oil must be at operating temperature for this check.

NOTE: When at low idle engine speed “I” or when in precision “PR” work mode,medium speed propel is not available.

Engine running.

Push heavy duty work mode “HD”.

Run engine at max. power “P” mode.

Record cycle times as follows:

High speed propel (rabbit).

Propel forward or reverse for 20 m (65 ft).

Maximum cycle time is 20 sec.

Is cycle time correct?


NO: Inspect and repairhydraulic pump controlsystem. See Group9025-15. Inspect andrepair propel motor. SeeGroup 0260. Checkhydraulic pump flow rate.Go to 9025-25.

9020105

– – –1/1

2 Undercarriage Checks

– – –1/1

Track Sag, Roller AndIdler Leakage Check

T6915AN –UN–07APR89T109326 –UN–02JUN97

Swing upperstructure to side and raise track off ground.

Operate track in reverse.

Stop engine.

Measure distance between top of track shoe to center of lower surface of track frame.

Check rollers and idlers for oil leaks.

Is oil leaking from rollers or idlers?

Raise other side of machine and repeat checks.

NOTE: If track sag is less than specified, track chain wear will be accelerated. If it isless than specified on one side only, the machine may mistrack.

YES: Adjust track sag tospecification.

SpecificationExcavator—Track Sag in Normal Soil 305—325 mm (12—12-3/4 in.).............................

Go to Group 9020-20 orUndercarriage AppraisalManual, SP326, Section2. Repair rollers or idlersif oil leakage is noted. Goto Group 0130.



PN=349


– – –1/1

Sprocket Wear Check

T6981AC –UN–13MAR89

Inspect drive sprocket.

Is tooth wear excessive?

NOTE: Do not evaluate sprocket by condition of toothtip. Tooth tip wear does not affect sprocket operation if itdoes not extend into the bushing contact area.

Reverse drive side wear is generally more than forwarddrive side wear.

YES: Check sprocketwear specification. Go toUndercarriage AppraisalManual, SP326, Section4. Replace sprocket. Goto Group 0130.


902010

6

– – –1/1

Grouser Wear, BentTrack Shoe, And LooseHardware Check


Inspect tracks for worn grousers, bent shoes, and looseshoe hardware.

Are grouser bars worn excessively?

Are track shoes bent?

Is track shoe width appropriate for ground condition?

Is track shoe hardware tight?

NOTE: Excessive grouser wear weakens track shoesand may result in track shoes bending.

Are track shoes worn or damaged?

YES: Evaluate track shoeand hardware condition.Go to Group 9020-15 orUndercarriage AppraisalManual, SP326, Section4. Rebuild or replaceworn track shoes. Go toGroup 0130.



PN=350


9020107

– – –1/1

Track Link Wear Check

T7666AF –UN–18DEC91 T7666AG –UN–18DEC91

Inspect track links for wear or damage in the following areas:

Pin boss to roller flange (A)

Pin boss end to track guide (B)

Link rail to roller (C)


YES: Evaluate track linkcondition. Go to RepairManual Group 0130 orUndercarriage AppraisalManual Sections 4 and 7.

NO: Continue on.

T7666AH –UN–18DEC91 T7666AI –UN–18DEC91

Check links for wear or damage in the following areas:

Link face to link face (D)

Rail chipping (F)

Link cracking (G)



NO: Continue on.

T7666AJ –UN–18DEC91

Inspect track links for wear or damage.

Rail side wear (E).



NO: Continue on.


PN=351


– – –1/1

Front Idler Wear Check


Inspect front idlers for wear and damage in the followingareas:

Tread wear or cracking (A)

Flange side wear (B)

Flange top wear (C)

Sidewall wear or cracking (D)

Are idlers worn or damaged?

YES: Evaluate front idlercondition. Go to Group9020-15 or UndercarriageAppraisal Manual, SP326,Sections 4 and 7. Rebuildor replace idler. Go toGroup 0130.

NO: Check complete.

902010

8


PN=352

Group 15Diagnostic Information

9020151

902015,VV298 –19–03MAR95–1/5

Diagnose Malfunctions Of The Propel System

NOTE: Diagnose malfunction charts are arranged frommost probable and simplest to verify, to leastlikely and most difficult to verify.


Propel Brakes Do Not Apply Propel brake reducing valve orifices Remove valve and clean or replaceblocked orifices. See Group 0260.

Propel brake malfunction Remove and repair brake. SeeGroup 0260.

Track Will Not Move in One Pilot hydraulic system malfunction See Diagnose Malfunctions ofDirection Hydraulic System. See Group

9025-15.

Propel control valve spool stuck Remove pilot cap. Manually movespool. See Group 3360.

Propel control valve spool stop Check control valve spool stopscrew misadjusted screw adjustment. See Group

9020-20.

Propel brake valve housing Inspect counterbalance valve. Seecounterbalance valve spool stuck Group 0260.

Propel motor crossover relief valve Perform crossover relief valves testmalfunction and adjustment. See Group 9020-25.

Shuttle valve in propel motor brake Inspect shuttle valve. See Groupvalve assembly not seating or stuck. 0260.

Rotary manifold leakage Inspect rotary manifold. See Group0260.

Track Will Not Move in Either Pilot shut-off valve in Off position. Move pilot shut-off lever to OnDirection. position.

Pilot hydraulic system malfunction See Diagnose Malfunctions ofHydraulic System. See Group9025-15.

Pilot controller valve malfunction or Inspect pilot controller valve andpilot hoses are restricted hoses. See Group 3360.


PN=353



902015

2

902015,VV298 –19–03MAR95–2/5


Propel pilot check valve block Inspect check block, check valves.malfunction See Group 3360.

Propel hydraulic control valve Inspect control valve. See Groupmalfunction 3360.

Propel brake release pressure too Inspect pressure reducing valvelow orifice.

Pressure reducing valve spoolsticking (closed). Repair, see Group0260.

Inspect supply shuttle valve. SeeGroup 0260.

Brake piston seals leaking. Repair

Propel motor brake valve Inspect counterbalance valve. Seecounterbalance valve spools stuck Group 0260.

Mechanical failure of propel motor or Disassemble components togearbox determine cause of failure. See

Group 0260.


Tracks Keep Moving When Pedal dampeners misadjusted Adjust pedal dampeners. See GroupController Lever/Pedal Returned 3360.to Neutral

Pilot controller sticking Inspect pilot controller. See Group9005 or 3360.

Obstruction (dirt) under controller Clean cab.pedals

Excavator Mistracks at All Track tension is too tight Adjust track sag to specification. SeeSpeeds (Both Directions) Group 9020-20.

Pilot controller valve malfunction Inspect pilot controller valve. SeeGroup 3360.

Propel hydraulic control valve, spool Perform Operational Checkout. Seeshuttle valve or balance valve stuck Group 9025-10.


PN=354



9020153

902015,VV298 –19–03MAR95–3/5


Propel hydraulic control valve spool Check stop screw adjustment orstop screws misadjusted or shims install shims. See group 9020-20.missing

Propel motor crossover relief valve Perform Crossover Relief Valve Testmalfunction and Adjustment. See Group

9020-25.

Propel motor brake valve assembly Inspect check valve. See Groupcheck valve seat leakage 0260.

Leakage in motor Check tracking while descending ahill. If tracking is within specificationwhen descending a hill, but notwhen on the level or going uphill,motor leakage is likely. PerformPropel Motor Operating LeakageTest. See Group 9020-25.


9020-25.

Propel brake not releasing Inspect propel brake. See Group0260.

Rotary manifold leakage Inspect rotary manifold, see Group0260.

Slow Propel Speed or Low Propel Speed switch in slow (turtle) Move switch to fast (rabbit) position.Propel Power position

Track tension too tight Adjust track sag to specification. SeeGroup 9020-20.


9020-25.

Propel brake not releasing Inspect propel brake. See Group0260.

Engine performance low Test engine performance (Boostpressure). See Group 9010-25.


PN=355



902015

4

902015,VV298 –19–03MAR95–4/5


Worn propel motor Perform Propel Motor OperatingLeakage Test. See Group 9020-25.


Low pump flow Perform Hydraulic PumpPerformance with cycle time method.See Group 9025-25.

Propel Speed Will Not Change to Worn propel motor Perform Propel Motor OperatingFast (Rabbit) Position. Leakage Test. See Group 9020-25.


Propel Speed Change Solenoid Test Propel Speed ChangeValve malfunction. Solenoid. See Section 9015.

Switch panel 2 malfunction. Test switch panel 2 switches. SeeOperational Checkout Procedure.

System Controller malfunction Test System Controller. See Section9015.

Propel Speed Will Not Change to Switch panel 2 malfunction Test switch panel 2 switches. SeeSlow (Turtle) Position. Operational Checkout Procedure.

System controller malfunction Test system controller. See Section9015.

Propel Speed Change Solenoid Test Propel Speed ChangeValve malfunction. Solenoid. See Section 9015.

Propel Functions are “Jerky” Using front end hydraulic functions This is normal because front endwhile propelling. functions have priority over propel

and will interrupt propel power.

Track tension too tight or too loose Adjust track sag. See Group9020-20.

No oil or low oil level in rollers Inspect seals and fill with the properoil

Brake valve assembly check valve Inspect check valve. See Groupsticking or has leakage 0260.


PN=356



9020155

902015,VV298 –19–03MAR95–5/5


Propel brake leakage Inspect propel brake components.See Group 0260.

Sticking shuttle or balance valve in Inspect propel control valve spool.propel control valve See Group 3360.

Mechanical failure in propel motor or Inspect motor and gearbox. Seegearbox Group 0260.

Balance valve in control valve spool Remove and inspect. See Groupsticking 3360.

Deformed track frame See Undercarriage Appraisal ManualSP-326. Repair or replacecomponents.

Excavator Will Not Hold Back Propel motor brake valve Inspect counterbalance valve spool.and Brakes Cycle On and Off counterbalance valve spool stuck See Group 0260.When Traveling Down an Incline

Excavator Will Not Turn Propel motor brake valve Inspect counterbalance valve spool.Smoothly in One Direction or counterbalance valve spool stuck See Group 0260.Brake Grabs


PN=357


902015

6

TX,902015,VV299 –19–25FEB92–1/1

Measure Track Chain Bushing Wear

T82

865

–UN

–08N

OV

88

SPECIFICATIONS

Bushing New O.D. 58.70 mm (2.31 in.)

Bushing Minimum Used O.D. 54.50 mm (2.15 in.)


JT05518 or JT05523 Undercarriage Inspection Service Tool Kit

Minimum used is the maximum allowable wear for turningpins and bushings.

Measure bushing outer diameter at the two worn placesusing a caliper such as the D17524C1 100 mm Caliperfrom JT05518 or JT05523 Undercarriage InspectionService Tool Kit.

SpecificationBushing—New O.D. 58.70 mm (2.31 in.)...................................................Minimum Used O.D. 54.50 mm (2.15 in.)...................................................

NOTE: See Undercarriage Appraisal Manual SP-326 foradditional information.


PN=358


9020157

TX,902015,VV300 –19–25FEB92–1/1

Measure Track Chain Link Wear

T82

864

–UN

–08N

OV

88

SPECIFICATIONS

Link New Height 106.9 mm (4.17 in.)

Link Minimum Used Height 98.0 mm (3.86 in.)



Minimum used is the maximum allowable wear forrebuilding links.

Measure height of several links to find an average using adepth gauge such as the JT05521 200 mm Ruler,JT05534 Right Angle Attachment, and D05231ST 300 mmRuler from JT05518 or JT05523 Undercarriage InspectionService Tool Kit

SpecificationLink—New Height 106.9 mm (4.17 in.).......................................................Minimum Used Height 98.0 mm (3.86 in.)..................................................

.



PN=359


902015

8

TX,902015,VV301 –19–21FEB92–1/1

Measure Lower Track Roller Wear

T87

973

–UN

–08N

OV

88

SPECIFICATIONS

Roller Tread New Diameter 150 mm (5.91 in.)

Roller Tread Minimum Used 135 mm (5.31 in.)Diameter



Minimum used is the maximum allowable wear forrebuilding roller tread.

Under some conditions roller wear can be uneven. If wearis uneven, rollers may be interchanged to even out thewear.

Measure roller tread diameter using a caliper such as theJT05519 Special Roller Caliper from JT05518 or JT05523Undercarriage Inspection Service Tool Kit.

SpecificationRoller Tread—New Diameter 150 mm (5.91 in.)........................................Minimum Used Diameter 135 mm (5.31 in.)...............................................



PN=360


9020159

TX,0130,GG238 –19–21FEB92–1/1

Measure Upper Track Roller Wear

T68

13A

Q–U

N–2

9JA

N98

SPECIFICATIONS

Roller Tread New Diameter 120 mm (4.70 in.)

Roller Tread Minimum Used 108 mm (4.25 in.)Diameter



Minimum used is the maximum allowable wear forrebuilding wear surface.

Measure roller tread diameter using a caliper such as theJT05519 Special Roller Caliper From JT05518 or JT05523Undercarriage Inspection Service Tool Kit.

SpecificationRoller Tread—New Diameter 120 mm (4.70 in.)........................................Minimum Used Diameter 108 mm (4.25 in.)...............................................

NOTE: See SP-326 Undercarriage Appraisal Manual foradditional information.

TX,0130,GG237 –19–21FEB92–1/1

Measure Front Idler Wear

T87

972

–UN

–08N

OV

88

SPECIFICATIONS

Flange New Height 19 mm (0.750 in.)

Flange Maximum Height 25 mm (0.980 in.)



Maximum used is the maximum allowable height of flangefor rebuilding wear surface.

Measure height of flange using a depth gauge such as theJT05521 200 mm Ruler, JT05534 Right AngleAttachment, and D05231ST 300 mm Ruler from JT05518or JT05523 Undercarriage Inspection Service Tool Kit.

SpecificationFlange—New Height 19 mm (0.750 in.).....................................................Maximum Height 25 mm (0.980 in.)............................................................

NOTE: See SP-326 Undercarriage Appraisal Manual foradditional information.


PN=361


90201510

TX,902015,VV302 –19–25FEB92–1/1

Measure Track Chain Pitch

T68

13A

L–U

N–2

9JA

N98

SPECIFICATIONS

Track New Pitch 760 mm (29.92 in.)

Track Maximum Used Pitch 773 mm (30.43 in.)



Maximum used is the maximum allowable wear for turningpins and bushings.

1. Remove slack by putting a wooden block betweensprocket and chain, then slowly move machine inreverse to tighten chain.

2. Measure pitch across several four link sections (A),except section on either side of master pin, to findaverage chain wear. Use a tape measure such as theJT05520 Metric Tape from JT05518 or JT05523Undercarriage Inspection Service Tool Kit

SpecificationTrack—New Pitch 760 mm (29.92 in.)........................................................Maximum Used Pitch 773 mm (30.43 in.)..................................................

.



PN=362


90201511

TX,902015,VV303 –19–04MAY95–1/1

Measure Track Shoe Grouser Wear

T82

859

–UN

–08N

OV

88

SPECIFICATIONS

Grouser New Height 25.5 mm (1.00 in.)

Grouser Minimum Used Height 11.0 mm (0.43 in.)



Minimum used is the maximum allowable wear forrebuilding grouser bars with weld.

Measure grouser height of several track shoes to find anaverage using a depth gauge such as the JT05521 200mm Ruler, JT05534 Right Angle Attachment, andD05231ST 300 mm Ruler from JT05518 or JT05523Undercarriage Inspection Service Tool Kit.

SpecificationGrouser—New Height 25.5 mm (1.00 in.)..................................................Minimum Used Height 11.0 mm (0.43 in.)..................................................



PN=363


90201512


PN=364


TX,9020,LG24 –19–27AUG97–1/2

Propel Component LocationT111715 –19–28OCT97


PN=365


TX,9020,LG24 –19–27AUG97–2/2

T110161 –19–28OCT97


PN=366

Group 20Adjustments

TX,902020,VV313 –19–07MAR95–1/4

Measure And Adjust Track Sag

SPECIFICATIONS

Excavator Track Sag 305—325 mm (12—12-3/4 in.)

9020201

TX,902020,VV313 –19–07MAR95–2/4

T71

60A

L–U

N–0

3JA

N90

1. Swing upperstructure 90° to the side. Lower bucket toraise track off ground. Keep the angle between boomand arm at 90—100 degrees.

CAUTION: Support machine frame.

2. Place blocks under machine frame to support machine.

3. Slowly turn track in the forward and reverse directionseveral times. Stop the track while moving in thereverse direction.

TX,902020,VV313 –19–07MAR95–3/4

T64

57D

L–U

N–2

3FE

B89

4. Measure distance (A) at middle track roller from bottomof track frame to top surface of track shoe.

SpecificationExcavator—Track Sag 305—325 mm (12—12-3/4 in.)...............................



PN=367

Adjustments

902020

2

TX,902020,VV313 –19–07MAR95–4/4

T75

84A

C–U

N–2

9JU

L91

T75

84A

D–U

N–2

9JU

L91

A—Access HoleB—Grease FittingC—Valve HousingD—Grease Relief Passage

To decrease track sag, add multi-purpose grease to trackadjuster cylinder through the grease fitting (B) in trackframe access hole (A). Use a grease gun with a maximumcapacity of 68 950 kPa (690 bar) (10,000 psi).

CAUTION: High pressure grease in trackadjuster cylinder. Loosen valve housing only.Do not remove grease fitting or valve housing.

IMPORTANT: Use grease fitting on the track adjustingcylinder ONLY for track sag adjustment.Fitting NOT to be used for lubrication.

To increase track sag, slowly loosen valve housing (C) torelease grease from track adjuster cylinder. Grease willescape through grease relief passage (D) in the housing.Tighten valve housing.


PN=368

Adjustments

9020203

TX,9020,LG25 –19–27AUG97–1/3

Propel Control Valve Spool Stop ScrewAdjustment

SPECIFICATIONS

Propel Control Valve Spool Stop Engine StoppedScrew Initial Adjustment PowerMode (Engine Speed)

Propel Control Valve Spool Stop 10 1/2 turnsScrew Recommended InitialAdjustment

Propel Control Valve Spool Stop Medium or High speed propelScrew Final Adjustment Propel (rabbit)Speed

Propel Control Valve Spool Stop “HD” (heavy duty)Screw Final Adjustment WorkMode “M”

Propel Control Valve Spool Stop “P” (max. power)Screw Final Adjustment PowerMode (Engine Speed)

Oil Temperature 50 ± 6°C (120 ± 10°F)

Propel Control Valve Spool Stop 20 m (65 ft)Screw Final Adjustment TestTrack (Dirt) Length

Propel Control Valve Spool Stop 610 mm (2 ft)Screw Final Adjustment MaximumMistrack on Test Track

NOTE: The propel speed may be reduced by turningpropel stop screws in. Turning the stop screws outfurther than the factory setting will cause a slightincrease in propel speed. On machines (SerialNo. —556935), turning stop screws out too far willcause erratic boom operation (jerky) when boomis raised as the machine is being propelled.

The number of turns given are a starting point forsetting the function speed (cycle time). Use cycletimes as the final determination for setting thespeed of function.

1. Check track sag.

SpecificationPropel Control Valve Spool StopScrew Initial Adjustment—PowerMode (Engine Speed) Engine Stopped......................................................

(See procedure in this group)


PN=369


Adjustments

902020

4

TX,9020,LG25 –19–27AUG97–2/3

T76

99A

M–U

N–2

3FE

B92

(Serial No. —556935)

T76

95A

C–U

N–2

3FE

B92


T11

0199

–UN

–09S

EP

97

(Serial No. 556936— )

2. Loosen lock nut on each spool stop screw (A—D).

3. Turn screw in until it contacts end of spool.

4. Turn screw out to specification.

SpecificationPropel Control Valve Spool StopScrew—Recommended InitialAdjustment 10 1/2 turns...............................................................................

5. Tighten lock nuts.

6. Check the cycle time of propel function.

7. Check tracking on a firm flat dirt surface in medium orhigh speed propel both forward and reverse.

SpecificationPropel Control Valve Spool StopScrew Final Adjustment—PropelSpeed Medium or High speed propel

(rabbit).........................................................

Work Mode “M” “HD” (heavy duty).............................................................Power Mode (Engine Speed) “P” (max. power)..........................................


PN=370


Adjustments

9020205

TX,9020,LG25 –19–27AUG97–3/3

SpecificationOil—Temperature 50 ± 6°C (120 ± 10°F)...................................................

Mark a course per specifications.

SpecificationPropel Control Valve Spool StopScrew Final Adjustment—TestTrack (Dirt) Length 20 m (65 ft)..................................................................

8. If mistrack is more than specification, turn spool stopscrew in 1/8 turn on fast track.

SpecificationPropel Control Valve Spool StopScrew Final Adjustment—Maximum Mistrack on Test Track 610 mm (2 ft)........................................

If adjustment does not correct mistrack, check orifice inthe pilot crossover hose, check propel motor leakage,rotary manifold leakage, control valve or pumpmalfunction.

9. If spool stop screws are overly sensitive to adjustment,add a shim to shuttle valve spring at each end ofpropel valve spool. (See Group 0260).


PN=371

Adjustments

902020

6


PN=372

Group 25Tests

902025,AA75 –19–16SEP92–1/1

JT05801 Clamp-On Electronic TachometerInstallation

T68

13A

G–U

N–2

8FE

B89


Tachometer

A—Clamp-On Tachometer.Remove paint using emery cloth and connect to a straight section ofinjection line within 100 mm (4 in.) of pump. Finger tighten only—DONOT over tighten.

B—Black Clip (-). Connect to main frame.

C—Red Clip (+). Connect to transducer.

D—Tachometer Readout. Install cable.

9020251

902525,AA4 –19–28FEB95–1/1

JT05800 Digital Thermometer Installation

T68

08C

E–U

N–2

8FE

B89


Digital Thermometer

A—Temperature ProbeFasten to a bare metal line using a tie band. Wrap with shop towel.

B—Cable

C—Digital Thermometer

TX,9020,DW1349 –19–24JUN97–1/1

JT02156A Digital Pressure And TemperatureAnalyzer Installation

T85

43A

I–U

N–2

5AU

G95

A—Digital Pressure and Temperature AnalyzerB—3400 kPa (35 bar) (500 psi) Transducer34 000 kPa (350 bar) (5000 psi) Transducer70 000 kPa (700 bar) (10,000 psi) Transducer

Use the digital pressure and temperature analyzer inplace of analog gauges and a separate temperaturereader.

Transducers (B) are temperature sensitive. Allowtransducer to warm to system temperature. Aftertransducer is warmed and no pressure is applied, pushsensor zero button for one second to set true zero point.

When using for different pressures, turn selector to OFFfor two seconds and then to the pressure range. Readingsare inaccurate if proper range for transducer is not used.


PN=373

Tests

902025

2

TX,902525,GG158 –19–07MAR95–1/1

Hydraulic System Warm-Up Procedure

SPECIFICATIONS

Hydraulic Oil Temperature 50 ± 6°C (120 ± 10°F)


JT05800 Digital Thermometer

Below 0°C (32°F) an extended warm-up period may benecessary. Hydraulic functions will move slowly andlubrication of parts may not be adequate with cold oil.Do not attempt normal machine operation untilhydraulic functions move at or close to normal cycletimes.

Operate functions slowly and avoid suddenmovements until engine and hydraulic oils arethoroughly warmed. Operate a function by moving it ashort distance in each direction. Continue operatingthe function increasing the distance traveled in eachcycle until full stroke is reached.

For faster warm-up, restrict air flow through oil coolerusing cardboard or other similar material. Use correctviscosity oil to minimize warm-up period. (SeeHydraulic Oil in Fuels and Lubricants group.)

1. Install temperature probe on reservoir-to-pump inletline. (See JT05800 Digital Thermometer Installationin this group.)

CAUTION: Avoid possible serious injuryfrom machine movement during warm-upprocedure. Clear the area of all personnelbefore doing the warm-up procedure.

2. Clear the area of all personnel to allow for machinemovement.

3. Start engine.

4. Push auto-idle switch to turn off auto-idle function(auto-idle indicator OFF).

5. Turn upperstructure so boom is to the side.

CAUTION: Avoid possible serious injuryfrom machine sliding backwards. Keep anglebetween boom and arm at 90—110°.

6. Keeping the angle between boom and arm at 90—110°, lower boom to raise track off the ground.

7. Push “M” (work mode select) switch to operate in“HD” work mode (heavy duty mode—HD indicatorON) and max. power mode (P indicator ON).

8. Push propel speed increase (right arrow) switch tooperate at high speed propel (rabbit—high speedpropel mode indicator ON).

IMPORTANT: Holding a function over relief formore than 10 seconds can causedamage from hot spots in thecontrol valve.

9. Operate the bucket curl function over relief and thepropel function (with track off the ground) for 10seconds and then stop for 5 seconds. Repeat thecycle until oil is heated to specifications.

SpecificationHydraulic Oil—Temperature 50 ± 6°C (120 ± 10°F)............................

10. Stop periodically and operate all hydraulicfunctions to distribute the heated oil.


PN=374

Tests

9020253

TX,902025,GG192 –19–17JAN95–1/1

Propel Motor Start-Up Procedure

T75

86C

X–U

N–1

9AU

G91

ESSENTIAL TOOLS

38H1147 (—8 M ORFS) (Parker No. 8PNLO-S) Plug

IMPORTANT: Propel motor will be damaged if notfilled with oil before operating propelfunction. Procedure must be performedwhenever a new propel motor isinstalled or whenever oil has beendrained from the motor.

1. Disconnect propel motor drain line (A). Install plug inline to minimize loss of oil.

2. To let air escape, loosen the valve body for propelbrake reducing valve on the left side or the plug for lowspeed selector valve on the right side one turn. Valvesare next to the drain hose connection. Do not turn thelock nut or adjusting screw for the propel brakereducing valve.

3. Fill motor with oil through drain port. Add oil until levelis to the top of drain port. (See Propel Gearbox Oil inFuels and Lubricants group.)

4. Tighten valve body or plug.

5. Connect line.

6. Run each propel motor with track off the ground for 3track revolutions to remove air from the propel circuit.


PN=375

Tests

902025

4

TX,902025,GG193 –19–15MAR95–1/1

Propel Speed Cycle Time

T71

60A

L–U

N–0

3JA

N90

Propel 3-Revolution Position

SPECIFICATIONS


Work Mode “M” “HD” (heavy duty)

Power Mode Engine Speed “P” (max. power)

Propel Speed High speed propel (rabbit)

Test Course Length 20 m (65 ft)

Track Raised—3 Revolutions 16.5 sec typical newFrom Running Start (check inforward and reverse) Cycle Time

Track Raised—3 Revolutions 24.0 sec service limitFrom Running Start (check inforward and reverse) Cycle Time

Propel 20 m (65 ft) (check in 12.0—15.5 sec typical newforward and reverse) Cycle Time

Propel 20 m (65 ft) (check in 20.0 sec service limitforward and reverse) Cycle Time

Cycle times are the same for forward and reverse.

SpecificationOil—Temperature 50 ± 6°C (120 ± 10°F)...................................................Work—Mode “M” “HD” (heavy duty)...........................................................Power Mode—Engine Speed “P” (max. power)..........................................Propel—Speed High speed propel (rabbit).................................................Test Course—Length 20 m (65 ft)..............................................................Track Raised—3 RevolutionsFrom Running Start (check inforward and reverse)—CycleTime 16.5 sec typical new...........................................................................Track Raised—3 RevolutionsFrom Running Start (check inforward and reverse)—CycleTime 24.0 sec service limit..........................................................................Propel 20 m (65 ft) (check inforward and reverse)—CycleTime 12.0—15.5 sec typical new.................................................................Propel 20 m (65 ft) (check inforward and reverse)—CycleTime 20.0 sec service limit..........................................................................


PN=376

Tests

9020255

TX,9020,DY6290 –19–09SEP97–1/2

Propel Speed Change Solenoid Valve Test

SPECIFICATIONS

Oil Temperature 50 ± 6°C (120 ± 10°)


Power Mode Engine Speed “L” (Light duty)

Propel Speed Change Solenoid 3000—4200 kPa (30—42 bar)Valve Pressure in Low Speed (435—610 psi)Propel (Turtle)

Propel Speed Change Solenoid 3000—4200 kPa (30—42 bar)Valve Pressure in Medium Speed (435—610 psi)Propel (Two-Headed Arrow)

Propel Speed Change Solenoid 0 kPa (0 bar) (0 psi)Valve Pressure in High SpeedPropel (Rabbit)

ESSENTIAL TOOLS

38H1029 (—4 M x —4 F x —4 M ORFS) (Parker No. 4R6LO-S) Tee

JT03455 (7/16-20 M 37° x —4 F ORFS) Adapter


Digital Thermometer

Gauge 0—7000 kPa (0—70 bar) (0—1000 psi)

JT02156A Digital Pressure and Temperature Analyzer

JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)

Test will determine the mode setting of the propel speedsolenoid valve.

1. Install temperature probe on reservoir-to-pump inletline. (See JT05800 Digital Thermometer Installation inthis group.)

2. Remove reservoir fill cap to release air pressure.



PN=377

Tests

902025

6

TX,9020,DY6290 –19–09SEP97–2/2

T77

01A

W–U

N–2

3FE

B92


3. Install fittings (A and B) and gauge to “A” port in dualsolenoid block.

4. Heat hydraulic oil to specifications.

SpecificationOil—Temperature 50 ± 6°C (120 ± 10°).....................................................

(See Hydraulic System Warm-Up Procedure in thisgroup.)

5. Run engine at specifications.

SpecificationWork—Mode “M” “HD” (heavy duty)...........................................................Power Mode—Engine Speed “L” (Light duty).............................................

6. Operate propel at the three mode settings and recordpressure for each.

SpecificationPropel Speed Change SolenoidValve—Pressure in Low SpeedPropel (Turtle) 3000—4200 kPa (30—42 bar)

(435—610 psi).............................................

Pressure in Medium SpeedPropel (Two-Headed Arrow) 3000—4200 kPa (30—42 bar)

(435—610 psi).......................

Pressure in High Speed Propel(Rabbit) 0 kPa (0 bar) (0 psi)......................................................................

7. If pressure not to specifications, check pilot pressure orpropel speed change solenoid valve.


PN=378

Tests

9020257

TX,9020,LG26 –19–27AUG97–1/4

Propel Motor Crossover Relief Valve TestAnd Adjustment

SPECIFICATIONS




Propel Speed “P” (max. power)

Crossover Relief Valve Pressure 34 100—40 200 kPa (341—402Setting bar) (4946—5831 psi)

Each 0.127 mm (0.005 in.) Shim Approximately 690 kPa (6.9 bar)Changes Pressure (100 psi)

Each 0.508 mm (0.020 in.) Shim Approximately 3450 kPa (34.5Changes Pressure bar) (500 psi)

ESSENTIAL TOOLS

A—JT03111 (7/16-20 M 37°x 9/16-18 M ORB) Fitting

AH125760 (1/2 x 9/16-18 M ORB) Male Quick Coupler (Serial No. —556935)


Digital Thermometer

Gauge 0—70 000 kPa (0—700 bar) (0—10 000 psi)

JT02156A Digital Pressure and Temperature Analyzer

JT02160 Transducer 70 000 kPa (700 bar) (10,000 psi)

5 mm Hex Key Wrench

90 mm (3-1/2 in.) OD Pin or Length of Round Bar Stock to PutBetween Sprocket and Track Frame





PN=379

Tests

902025

8

TX,9020,LG26 –19–27AUG97–2/4

T76

95A

B–U

N–2

3FE

B92


T11

0209

–UN

–09S

EP

97

(Serial No. 556936—)

3. Install gauge or digital pressure and temperatureanalyzer to LS (load sense) test port.

For machines (Serial No. —556935), use fitting (A) ormale quick coupler.

For machines (Serial No. 556936—), use JT02160Transducer to LS (load sense) test port connector (A)in control valve manifold (B).

4. Heat hydraulic oil to specification.


(SeeHydraulic System Warm-Up Procedure in this group.)

5. Turn adjusting screw for system relief valve (C) inexactly 1/2 turn.


PN=380


Tests

TX,9020,LG26 –19–27AUG97–3/4

T75

86D

A–U

N–1

6AU

G91

6. Put pin (D) between sprocket and track frame.


SpecificationWork—Mode “M” “HD” (heavy duty)...........................................................Power Mode—Engine Speed “P” (max. power)..........................................Propel—Speed “P” (max. power)................................................................

8. For motor being stalled, slowly push propel pedal to fulltravel and hold to operate motor at stall. Recordpressure.

9020259

TX,9020,LG26 –19–27AUG97–4/4

T75

76A

X–U

N–1

9AU

G91

T75

76A

Y–U

N–1

6AU

G91

E—Crossover Relief ValveF—CapG—Shim (as required)H—Shim (as required)

9. Adjust pressure setting by adding or removing shims(G and H) in cap (F) of crossover relief valve (E).

SpecificationCrossover Relief Valve—PressureSetting 34 100—40 200 kPa (341—402

bar) (4946—5831 psi)......................................................

Each 0.127 mm (0.005 in.) ShimChanges—Pressure Approximately 690 kPa (6.9 bar)

(100 psi)...............................

Each 0.508 mm (0.020 in.) ShimChanges—Pressure Approximately 3450 kPa (34.5

bar) (500 psi)..................................

If pressure is less than specification and can not beincreased, system relief valve may be set too low.

10. Repeat adjustment procedure for the other crossoverrelief valve.

11. Turn system relief valve adjusting screw out exactly1/2 turn to original setting.


PN=381

Tests

90202510

TX,9020,JH3 –19–22OCT97–1/3

Propel Brake Release Pressure ReducingValve Test And Adjustment

SPECIFICATIONS

Reducing Valve Pressure Setting 3000—7000 kPa (30—70 bar)(435—1015 psi)


Work Mode “M” “HD” (heavy duty mode)

Power Mode Engine Speed “P” (max. power mode)

Propel Speed High speed propel (rabbit)

1/8 Turn of Adjusting Screw 345 kPa (3.4 bar) (50 psi)Changes Pressure

ESSENTIAL TOOLS

38H1093 (—4 M x —4 ORFS Sw) (Parker No. 4 4C6LO-S) Elbow

JT03455 (7/16-20 M 37° x —4 F ORFS) (Parker No. 4 XHL6-S) orJT03477 (1/2 x 9/16-18 F ORFS) Adapter or Quick Coupler


JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)

JT02156A Digital Pressure and Temperature Analyze

Digital Thermometer

Gauge 0—7000 kPa (0—70 bar) (0—1000 psi)

5 mm Hex Key Wrench

Test is to ensure there is sufficient pressure to release thebrakes and pressure returns to zero to allow brakes toengage.

SpecificationReducing Valve—PressureSetting 3000—7000 kPa (30—70 bar)

(435—1015 psi).........................................................

Also that pressure is the same in forward and reverseindicating supply shuttle valve operation.


2. Heat hydraulic oil to specification.



PN=382


Tests

TX,9020,JH3 –19–22OCT97–2/3


3. Stop engine. Remove reservoir fill cap to release airpressure.

90202511

TX,9020,JH3 –19–22OCT97–3/3T

7655

AD

–UN

–21N

OV

91

4. Disconnect line (A); leave line open. Install fittings (Band C) and gauge.

5. Start engine and run at specifications.

SpecificationWork—Mode “M” “HD” (heavy duty mode).................................................Power Mode—Engine Speed “P” (max. power mode)................................Propel—Speed High speed propel (rabbit).................................................

6. Operate propel at stall in forward and reverse.

7. Turn adjusting screw (D) in to increase pressure; turnscrew out to decrease pressure.

Specification1/8 Turn of Adjusting ScrewChanges—Pressure 345 kPa (3.4 bar) (50 psi).........................................

Check the brakes if propel motors are not held at stall. Ifpressure cannot be adjusted, check the pressure reducingvalve. If pressure is different for forward and reverse,check the supply shuttle valve. If pressure does not go tozero with propel in neutral, inspect orifice behind plug (E).


PN=383

Tests

90202512

TX,902025,GG196 –19–07MAR95–1/2

Propel Motor Case Drain Leakage Test

SPECIFICATIONS




Propel Speed Medium speed propel

Propel Motor Case Typical New 7.5 L (8 qt)Leakage

Propel Motor Case Maximum 15.2 L (16 qt)Leakage

ESSENTIAL TOOLS

X10FNL-S (—10 F ORFS) (Parker No. 10FNL-S) Cap


Digital Thermometer

20 L (5 gal) Calibrated Container


2. Heat hydraulic oil to specifications.



3. Stop engine.




PN=384

Tests

90202513

TX,902025,GG196 –19–07MAR95–2/2T

6964

AB

–UN

–23M

AR

89T

7160

AL

–UN

–03J

AN

90

5. Oil level is above the connection for drain hose (B).Pull a vacuum on reservoir to minimized the loss of oil.

Disconnect drain line (B) at reservoir. Put end of line ina calibrated container (A).

6. Install cap on fitting at reservoir.

7. Swing upperstructure to the side of machine for propelmotor being checked. Raise track off the ground.


SpecificationWork—Mode “M” “HD” (heavy duty)...........................................................Power Mode—Engine Speed “P” (max. power)..........................................Propel—Speed Medium speed propel........................................................

9. Operate propel motor for exactly one minute in forwardand than for one minute in reverse.

10. Measure oil in calibrated container and compare withspecification.

SpecificationPropel Motor Case—Typical NewLeakage 7.5 L (8 qt)....................................................................................Maximum Leakage 15.2 L (16 qt)...............................................................

11. If leakage is more than specification, check leakagefor propel motor at drain hose connection at bottom ofrotary manifold to isolate the leakage to propel motoror rotary manifold.


PN=385

1_690elc test manual tm1508

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