200LC Technical Manual Operation and Tests TM1663 PDF

200LC
Excavator
Operation and Tests
TECHNICAL MANUAL
200LC Excavator Operation and
Tests
TM1663 28NOV01 (ENGLISH)
For complete service information also see:

200LC Excavator Repair . . . . . . . . . . . . . . . . TM1664
POWERTECH 4.5 L & 6.8 L (4045 and 6068)
Diesel Engines. . . . . . . . . . . . . . . . . . . . . . . . CTM104
Alternators and Starting Motors . . . . . . . . . . CTM77
Undercarriage Appraisal Manual . . . . . . . . . SP326
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC 1929SEP981/1
TM1663 (28NOV01) 200LC Excavator Operation & Tests

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Introduction
Technical Information Feedback Form
We need your help to continually improve our technical

publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO: John Deere Dubuque Works

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538
FAX NUMBER: 563-589-5800
Ideas, Comments (Please State Page Number):
OVERALL, how would you rate the quality of this publication? (Check one)
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THANK YOU!
TX,TM,FAX 1928NOV011/1

101603
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Introduction

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Contents
9000
SECTION 9000General Information
Group 01Safety
Group 02General Specifications
Group 03Torque Values
Group 04Fuels and Lubricants
9005
SECTION 9005Operational Checkout Procedure

Group 10Operational Checkout Procedure
SECTION 9010Engine
Group 05Theory of Operation 9010
Group 10System Operational Checks
Group 15Diagnostic Information
Group 20Adjustments
Group 25Tests
9015
SECTION 9015Electrical System
Group 05System Information
Group 10System Diagrams
Group 15Sub-System Diagnostics
Group 20References
9020
SECTION 9020Power Train
Group 05Theory of Operation
Group 20Adjustments
9025
SECTION 9025Hydraulic System
Group 20Adjustment
Group 25Tests
9031
SECTION 9031Air Conditioning System
Group 20Adjustments
INDX
Group 25Tests
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT 2002
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright 2000, 1998, 1996
TM1663 (28NOV01) i 200LC Excavator Operation & Tests

101603
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Contents
9000
9005
9010
9015
9020
9025
9031
INDX
TM1663 (28NOV01) ii 200LC Excavator Operation & Tests

101603
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9000
Section 9000
General Information
Contents
Page Page
Group 01Safety . . . . . . . . . . . . . . . . . . . .9000-01-1 Track Adjuster, Working Tool Pivot, Swing

Bearing, and Swing Bearing Gear
Group 02General Specifications Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7
Excavator Overview . . . . . . . . . . . . . . . . . . .9000-02-1 Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7
200LC Specifications. . . . . . . . . . . . . . . . . . .9000-02-2 Lubricant Storage . . . . . . . . . . . . . . . . . . . . .9000-04-8
Alternative and Synthetic Lubricants . . . . . . .9000-04-8
200LC Working Ranges . . . . . . . . . . . . . . . .9000-02-4
Mixing of Lubricants . . . . . . . . . . . . . . . . . . .9000-04-9
200LC Engine Specifications. . . . . . . . . . . . .9000-02-6
200LC Drain and Refill Capacities. . . . . . . . .9000-02-6
Group 03Torque Values

Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-1
Metric Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-2
Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-3
Check Oil Lines And Fittings . . . . . . . . . . . . .9000-03-5
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .9000-03-6
Service Recommendations For Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .9000-03-8
Service Recommendations for 37 Flare
and 30 Cone Seat Connectors . . . . . . . . .9000-03-9
Service Recommendations For Flared
ConnectionsStraight or Tapered
Threads . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-10
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . .9000-03-11
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . .9000-03-12
Group 04Fuels and Lubricants

Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1
Lubricity of Diesel Fuels . . . . . . . . . . . . . . . .9000-04-1
Low Sulfur Diesel Fuel Conditioner . . . . . . . .9000-04-2
Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . .9000-04-2
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-3
Do Not Use Galvanized Containers. . . . . . . .9000-04-3
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . .9000-04-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-5
Swing Gearbox, Propel Gearbox and Pump
Gearbox Oils . . . . . . . . . . . . . . . . . . . . . . .9000-04-6
Track Roller, Front Idler, and Carrier
Roller Oil . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-6
TM1663 (28NOV01) 9000-1 200LC Excavator Operation & Tests

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Contents
9000

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Group 01
Safety
9000
Follow Safe Procedures 01
1
Unsafe work practices are dangerous. Understand service

procedure before doing work; do not attempt shortcuts.
1907OCT88
TS231
TX,05,FF1611 1914JUN901/1
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
UN23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 1903MAR931/1
Handle Fluids SafelyAvoid Fires
Handle fuel with care; it is highly flammable. Do not refuel

the machine while smoking or when near open flame or
sparks. Always stop engine before refueling machine. Fill
fuel tank outdoors.
UN23AUG88
TS202
TX,05,FF1622 1914JUN901/2
Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn

spontaneously.
UN23AUG88
TS227
TX,05,FF1622 1914JUN902/2
TM1663 (28NOV01) 9000-01-1 200LC Excavator Operation & Tests

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Safety
9000
01 Prevent Battery Explosions
2
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.
UN23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16C (60F).
TS204
DX,SPARKS 1903MAR931/1
Handle Chemical Products Safely
Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
UN26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDSs on chemical

products used with John Deere equipment.)
DX,MSDS,NA 1903MAR931/1

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Safety
9000
Prevent Acid Burns 01
3
Sulfuric acid in battery electrolyte is poisonous. It is strong

enough to burn skin, eat holes in clothing, and cause
blindness 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 1530 minutes. Get
medical attention immediately.
UN23AUG88
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not
TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.
DX,POISON 1921APR931/1

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Safety
9000
01 Avoid High-Pressure Fluids
4
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
UN23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
X9811
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID 1903MAR931/1
Warn Others of Service Work
Unexpected machine movement can cause serious injury.
Before performing any work on the machine, attach a Do

Not Operate tag on the right control lever.
UN08JUN90
T7273AP
TX,05,RR,566 1923JUL911/1

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Safety
9000
Park Machine Safely 01
5
Before working on the machine:
Park machine on a level surface.

Lower bucket to the ground.
Turn auto-idle switch off.
Run engine with engine RPM dial at 1/3 position for 2
minutes.
Move engine RPM dial to slow idle position.
Turn key switch to OFF. Remove key from switch.
Pull pilot control shut-off lever to locked position.
Allow engine to cool.
TX,05,DH5002 1928MAY961/1
Support Machine Properly
Always lower the attachment or implement to the ground

before you work on the machine. If the work requires that
the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
UN23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
TS229
Follow recommended procedures in this manual.
When implements or attachments are used with a

machine, always follow safety precautions listed in the
implement or attachment operators manual.
DX,LOWER 1924FEB001/1
Operate Only from Operators Seat
Avoid possible injury or machine damage. Do not start

engine by shorting across starter terminals.
NEVER start engine while standing on ground. Start

UN18OCT88
engine only from operators seat.

T6607AO
TX,05,FF1615 1914JUN901/1

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Safety
9000
01 Stay Clear of Moving Parts
6
Entanglements in moving parts can cause serious injury.
To prevent accidents, use care when working around

rotating parts.
UN08JUN90
T7273AS
TX,05,RR,572 1912JUN901/1
Avoid Power Lines
Serious injury or death can result from contact with

electric lines.
Never move any part of the machine or load closer to
UN08JUN90
electric line than 3 m (10 ft) plus twice the line insulator
length.
T7273AD
TX,05,RR,594 1912JUN901/1
Use Handholds and Steps
Falling is one of the major causes of personal injury.
When you get on and off the machine, always maintain a

three point contact with the steps and handrails and face
UN15JUN89
the machine. Do not use any controls as handholds.
Never jump on or off the machine. Never mount or

dismount a moving machine.
T6981AN
Be careful of slippery conditions on platforms, steps, and

handrails when leaving the machine.
TX,05,DH832 1916MAR921/1

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Safety
9000
Keep Riders Off Machine 01
7
Only allow the operator on the machine. Keep riders off.
Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the
UN08JUN90
machine. Riders also obstruct the operators view resulting
in the machine being operated in an unsafe manner.
T7273AH
TX,05,RR,560 1905OCT901/1
Move and Operate Machine Safely
Bystanders can be run over. Know the location of

bystanders before moving, swinging, or operating the
machine.
UN08JUN90
Always keep the travel alarm in working condition. It
warns people when the machine starts to move.
Use a signal person when moving, swinging, or operating
T7273AL
the machine in congested areas. Coordinate hand signals
before starting the machine.
TX,05,FF1806 1905OCT901/1
Wear Protective Clothing
Wear close fitting clothing and safety equipment

appropriate to the job.
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
UN23AUG88
while operating machine.

TS206
DX,WEAR2 1903MAR931/1

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Safety
9000
01 Protect Against Flying Debris
8
Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.
UN18OCT88
T6642DK
TX,05,FF1613 1914JUN901/1
Protect Against Noise
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
UN23AUG88
uncomfortable loud noises.
TS207
DX,NOISE 1903MAR931/1
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
UN23AUG88
TS223
DX,LIGHT 1904JUN901/1
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
UN23AUG88
Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.
TS228
DX,LOOSE 1904JUN901/1

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Safety
9000
Remove Paint Before Welding or Heating 01
9
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
UN23AUG88
Remove paint before heating:
Remove paint a minimum of 76 mm (3 in.) from area to

be affected by heating.
TS220
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do all work in an area that is ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT 1922OCT991/1
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
UN15MAY90
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH 1903MAR931/1
Beware of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
If you must operate in a building, be positive there is

UN18OCT88
adequate ventilation. Either use an exhaust pipe extension

to remove the exhaust fumes or open doors and windows
to bring enough outside air into the area.
T6458AO
02T,05,J9 1907JAN911/1

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Safety
9000
01 Use Proper Lifting Equipment
10
Lifting heavy components incorrectly can cause severe

injury or machine damage.
Follow recommended procedure for removal and

installation of components in the manual.
UN23AUG88
TS226
DX,LIFT 1904JUN901/1
Service Cooling System Safely
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
UN23AUG88
to relieve pressure before removing completely.
TS281
DX,RCAP 1904JUN901/1
Dispose of Waste Properly
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
UN26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or into

any water source.
Air conditioning refrigerants escaping into the air can

damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN 1903MAR931/1

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Safety
9000
Work in a Clean Area 01
11
Before starting a job, clean the work area. Remove

objects that may be a safety hazard to the mechanic or
bystanders.
TX,05,FF1624 1914JUN901/1
Use Tools Properly
Use tools appropriate to the work. Makeshift tools, parts,

and procedures can create safety hazards.
Use power tools only to loosen threaded tools and

fasteners.
UN08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
Use only recommended replacement parts. (See Parts

Catalog.)
TX,05,FF1614 1914JUN901/1
Replace Safety Signs
Replace missing or damaged safety signs. See the

machine operators manual for correct safety sign
placement. UN23AUG88
TS201
DX,SIGNS1 1904JUN901/1

101603
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Safety
9000
01 Live With Safety
12
Before returning machine to customer, make sure

machine is functioning properly, especially the safety
systems. Install all guards and shields.
1907OCT88
TS231
DX,LIVE 1925SEP921/1

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Group 02
General Specifications
9000
Excavator Overview 02
1
UN02JUN98
T115683
CED,TX08227,2993 1910FEB981/1

101603
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9000
02 200LC Specifications
2
UN03FEB98
T113215
ASprocket Center To Idler DRear End Swing Radius HCenter Of Sprocket To JUndercarriage Width
Center EOverall Width Center Of Sprocket KOverall Length
BUndercarriage Length FCab Height ITrack Shoe Width LTransport Height
CCounterweight Clearance GMinimum Ground
Clearance
NOTE: Specifications and design subject to change machine equipped with 800 mm (32 in.) shoes,
without notice. Wherever applicable, counterweight, 2.91 m (9 ft 7 in.) arm, 723 kg
specifications are in accordance with PCSA (1590 lb) 0.86 m 3 (1.12 yd 3) bucket, full fuel
and SAE standards. Except where otherwise tank, 79 kg (175 lb) operator and standard
noted these specifications are based on a equipment.
Item Measurement Specification
ASprocket Center To Idler Center Distance 3660 mm (12 ft 0 in.)
BUndercarriage Length 4460 mm (14 ft 8 in.)
CCounterweight Clearance Distance 1030 mm (3 ft 5 in.)
DRear End Swing Radius Distance 2720 mm (8 ft 11 in.)
EOverall Width (Excluding Back Distance 2720 mm (8 ft 11 in.)

Mirrors)
FCab Height 2720 mm (8 ft 11 in.)
Continued on next page CED,TX14740,6954 1907SEP001/2

101603
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9000
Item Measurement Specification 02
3
GMinimum Ground Clearance Distance 450 mm (1 ft 6 in.)
HCenter Of Sprocket To Center Of Distance 2390 mm (7 ft 10 in.)

Sprocket
ITrack Shoe Width 600 mm (24 in.) or 700 mm (28 in.)

or 800 mm (32 in.)
JUndercarriage Width With 600 mm (24 in.) shoes: 2990

mm (9 ft 10 in.)
Width With 700 mm (28 in.) shoes: 3090
mm (10 ft 2 in.)
Width With 800 mm (32 in.) shoes: 3190
mm (10 ft 6 in.)
KMachine Overall Length With 2220 mm (7 ft 3 in.) Arm: 9620

mm (31 ft 7 in.)
Overall Length With 2910 mm (9 ft 7 in.) Arm: 9500
mm (31 ft 2 in.)
LMachine Transport Height With 2220 mm (7 ft 3 in.) Arm: 3090

mm (10 ft 2 in.)
Transport Height With 2910 mm (9 ft 7 in.) Arm: 2970
mm (9 ft 9 in.)
Machine Operating Weight 20 298 kg (44,750 lb)
CED,TX14740,6954 1907SEP002/2

101603
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9000
02 200LC Working Ranges
4
UN24MAR97
T102389
AMaximum Digging Reach BMaximum Digging Depth EMaximum Cutting Height GMinimum Swing Radius
A1Maximum Digging Reach CMaximum Vertical Wall FMaximum Dumping Height
At Ground Level DMaximum Digging Depth
(Flat Bottom)
AMaximum Digging Reach Distance With 2220 mm (7 ft 3 in.) Arm: 9250

mm (30 ft 4 in.)
Distance With 2910 mm (9 ft 7 in.) Arm: 9910
mm (32 ft 6 in.)
Continued on next page TX,115,DH5117 1915JUL961/2

101603
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9000
Item Measurement Specification 02
5
A1Maximum Digging Reach At Distance With 2220 mm (7 ft 3 in.) Arm: 9080

Ground Level mm (29 ft 9 in.)
Distance With 2910 mm (9 ft 7 in.) Arm: 9750
mm (32 ft 0 in.)
BMaximum Digging Depth Depth With 2220 mm (7 ft 3 in.) Arm: 5980

mm (19 ft 7 in.)
Depth With 2910 mm (9 ft 7 in.) Arm: 6670
mm (21 ft 11 in.)
CMaximum Vertical Wall Depth With 2220 mm (7 ft 3 in.) Arm: 5140

mm (16 ft 10 in.)
mm (19 ft 10 in.)
DMaximum Digging Depth (Flat Depth With 2220 mm (7 ft 3 in.) Arm: 5740
Bottom) mm (18 ft 10 in.)
mm (21 ft 4 in.)
EMaximum Cutting Height Height With 2220 mm (7 ft 3 in.) Arm: 9170

mm (30 ft 1 in.)
Height With 2910 mm (9 ft 7 in.) Arm: 9600
mm (31 ft 6 in.)
FMaximum Dumping Height Height With 2220 mm (7 ft 3 in.) Arm: 6390

mm (21 ft 0 in.)
Height With 2910 mm (9 ft 7 in.) Arm: 6780
mm (22 ft 3 in.)
GMinimum Swing Radius Radius With 2220 mm (7 ft 3 in.) Arm: 3540

mm (11 ft 7 in.)
Radius With 2910 mm (9 ft 7 in.) Arm: 3540
mm (11 ft 7 in.)
TX,115,DH5117 1915JUL962/2

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9000
02 200LC Engine Specifications
6
John Deere POWERTECH 6.8 Type 4-Stroke Cycle, Turbocharged,

Aftercooled
Bore And Stroke 106 x 127 mm (4.17 x 5.0 in.)
Cylinders 6
Displacement 6.785 L (414 cu in.)
Net Torque @ 1300 RPM 579 Nm (427 lb-ft)
Compression Ratio 17:1
Power At 2150 RPM 104 kW (140 hp) Net SAE
Lubrication Pressure System With Full-Flow
Filter
Cooling Fan Suction
Electrical system 24 Volt
Batteries (2) 12 volt 180 Minutes Reserve Capacity:
POWERTECH is a trademark of Deere & Company. CED,TX14740,6956 1907SEP001/1
200LC Drain and Refill Capacities
Fuel Tank Capacity 303 L (80 gal)
Cooling System Capacity 28.4 L (7.5 gal)
Engine Oil Capacity, Including Filter Change 19 L (5.0 gal)
Hydraulic System Capacity 250 L (66 gal)
Hydraulic Tank Capacity 130 L (34 gal)
Swing Gearbox Capacity 4.7 L (5.0 qt)
Propel Gearbox (Each) Capacity 5.2 L (5.5 qt)
Pump Drive Gearbox Capacity 1.0 L (1.1 qt)
TX,115,DH5114 1915JUL961/1

101603
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Group 03
Torque Values
9000
Unified Inch Bolt and Cap Screw Torque Values 03
1
UN27SEP99
TORQ1A
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher grade. If
higher grade fasteners are used, these should only be tightened to
the strength of the original.
DX,TORQ1 1901OCT991/1

101603
PN=27
Torque Values
9000
03 Metric Bolt and Cap Screw Torque Values
2
UN07SEP99
TORQ2
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
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)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical property class. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher property class.
If higher property class fasteners are used, these should only be
tightened to the strength of the original.
DX,TORQ2 1901OCT991/1

101603
PN=28
Torque Values
9000
Additional Metric Cap Screw Torque Values 03
3
UN18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
UN18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from
failing when tightening.
UN18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
Continued on next page 04T,90,M170 1929SEP991/2

101603
PN=29
Torque Values
9000
03 METRIC CAP SCREW TORQUE VALUESa
4
T-Bolt H-Bolt M-Bolt
Nominal
Dia Nm lb-ft Nm lb-ft Nm lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
Torque tolerance is 10%.
a
04T,90,M170 1929SEP992/2

101603
PN=30
Torque Values
9000
Check Oil Lines And Fittings 03
5
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
UN23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.
Tubing with dents may cause the oil to overheat. If you

find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified in torque

chart.
When you tighten connections, use two wrenches to

prevent bending or breaking tubing and fittings.
TX,90,DH1559 1901AUG941/1

101603
PN=31
Torque Values
9000
03 Service Recommendations for O-Ring Boss
6
Fittings
Straight Fitting
1. Inspect O-ring boss seat for dirt or defects.
UN18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
T6243AE
3. Tighten fitting to torque value shown on chart.
Continued on next page 04T,90,K66 1929SEP991/2

101603
PN=32
Torque Values
9000
Angle Fitting 03
7
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 washer
UN18OCT88
contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index

(maximum of one turn).
T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.
4. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size Nm 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%.
04T,90,K66 1929SEP992/2

101603
PN=33
Torque Values
9000
03 Service Recommendations For Flat Face O-Ring Seal Fittings
8
1. Inspect the fitting sealing surfaces and O-ring. They fittings, use backup wrench on straight hose
must be free of dirt or defects. couplings.
2. Lubricate O-rings and install into grove using IMPORTANT: Tighten fittings to 150% of listed
petroleum jelly to hold in place. torque value if indexing is necessary
or if fitting is attached to an
3. Index angle fittings and tighten by hand pressing actuating devise.
joint together to insure O-ring remains in place.
Tighten fittings to 50% of listed
4. Tighten fitting or nut to torque value shown on the torque value if used in aluminum
chart. Do not allow hoses to twist when tightening housing.
FLAT FACE O-RING SEAL FITTING TORQUE*

Nominal Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. Nm lb-ft Nm lb-ft
6.35 0.250 9/16-18 16 12 12 9
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 Nm 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.
04T,90,K67 1902MAR001/1

101603
PN=34
Torque Values
9000
Service Recommendations for 37 Flare and 03
9
30 Cone Seat Connectors
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
UN18OCT88
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6234AC
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or petroleum

jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on torque

chart. Do not allow hoses to twist when tightening
fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size Nm 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%.
T82,BHMA,EL 1929SEP991/1

101603
PN=35
Torque Values
9000
03 Service Recommendations For Flared
10
ConnectionsStraight or Tapered Threads
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
UN18OCT88
2. Defects in the tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6873AE
3. Align the tube with the fitting before attempting to start
the nut.
Straight Thread
4. Lubricate the male threads with hydraulic fluid or
petroleum jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on the

chart. Do not allow hoses to twist when tightening
UN18OCT88
fittings.
a
TORQUE CHART
T6873AD
b
Straight Thread Tapered Thread
Thread
Size Nm lb-ft Nm lb-ft
Tapered Thread
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434
Torque tolerance is 10%.
a
b
With seat face.
NOTE: If female thread is cast iron (control valves, brake

valves motors, etc.), torque must be reduced
approximately 10%.
04T,90,M171 1928JAN921/1

101603
PN=36
Torque Values
9000
Service Recommendations For Inch Series Four Bolt Flange Fittings 03
11
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches TORQUE CHART

cause leaks. Roughness causes seal wear. Nm lb-ft
Out-of-flat causes seal extrusion. If defects cannot Nominal Cap Screw
be polished out, replace component. Flange Size
Size Min Max Min Max
2. Install O-ring (and backup washer if required) into 1/2 5/16-18 20 31 15 23
groove using petroleum jelly to hold it in place. UNC
3/4 3/8-16 UNC 28 54 21 40
3. Split flange: Loosely assemble split flange (B) 1 3/8-16 UNC 37 54 27 40
halves. Make sure split is centrally located and 1-1/4 7/16-14 47 85 35 63
perpendicular to port. Hand tighten cap screws to UNC
hold parts in place. Do not pinch O-ring (C). 1-1/2 1/2-13 UNC 62 131 46 97
2 1/2-13 UNC 73 131 54 97
4. Single piece flange (D): Place hydraulic line in
center of flange and install cap screws. Flange 2-1/2 1/2-13 UNC 107 131 79 97
must be centrally located on port. Hand tighten cap 3 5/8-11 UNC 158 264 117 195
screws to hold flange in place. Do not pinch O-ring. 3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 5 5/8-11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
04T,90,K174 1901AUG941/1

101603
PN=37
Torque Values
9000
03 Service Recommendations for Metric Series Four Bolt Flange Fitting
12
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Thread b
Nm lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42
4. Single piece flange (D): Place hydraulic line in M12 95 70

center of flange and install four cap screws. Flange M14 157 116
must be centrally located on port. Hand tighten cap M16 217 160
screws to hold flange in place. Do not pinch O-ring. M18 334 246
M20 421 318
5. After components are properly positioned and cap a
Tolerance 10%. The torques given are enough for the given
screws are hand tightened, tighten one cap screw, size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
b
Metric standard thread.
04T,90,K175 1929SEP991/1

101603
PN=38
Group 04
Fuels and Lubricants
9000
Diesel Fuel 04
1
Consult your local fuel distributor for properties of the Fuel Lubricity should pass a minimum of 3100
diesel fuel available in your area. gram load level as measured by the BOCLE scuffing
test.
In general, diesel fuels are blended to satisfy the low Sulfur content:
temperature requirements of the geographical area in Sulfur content should not exceed 0.5% Sulfur
which they are marketed. content less than 0.05% is preferred.
If diesel fuel with sulfur content greater than 0.5%
Diesel fuels specified to EN 590 or ASTM D975 are sulfur content is used, reduce the service interval
recommended. for engine oil and filter by 50%.
DO NOT use diesel fuel with sulfur content
In all cases, the fuel shall meet the following greater than 1.0%.
properties: Bio-diesel fuels with properties and meeting DIN 51606
or equivalent specifications may be used.
Cetane Number 40 minimum. Cetane number
greater than 50 is preferred, especially for DO NOT mix used engine oil or any other type of
temperatures below -20C (-4F) or elevations above lubricant with diesel fuel.
1500 m (5000 ft).
Cold Filter Plugging Point(CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature.
TX,45,JC1132 1922MAY961/1
Lubricity of Diesel Fuels
Diesel fuel must have adequate lubricity to ensure engine speed instability, hard starting, low power, and
proper operation and durability of fuel injection system engine smoke.
components.
Fuel lubricity should pass a minimum of 3100 gram
Diesel fuels for highway use in the United States and load level as measured by the BOCLE scuffing test.
Canada now require sulfur content less than 0.05%.
Diesel fuel in the European Union require sulfur ASTM D975 and EN 590 specifications do not require
content less than 0.05% as of 1 October 1996. fuels to pass a fuel lubricity test.
Experience shows that some low sulfur diesel fuels If fuel of low or unknown lubricity is used, add John
may have inadequate lubricity and their use may Deere PREMIUM DIESEL FUEL CONDITIONER (or
reduce performance in fuel injection systems due to equivalent) at the specified concentration. John Deere
inadequate lubrication of injection pump components. PREMIUM DIESEL FUEL CONDITIONER is available
The lower concentration of aromatic compounds in in winter and summer formulas. Consult your John
these fuels also adversely affects injection pump seals Deere engine distributor or servicing dealer for more
and may result in leaks. information.
Use of low lubricity diesel fuels may also cause

accelerated wear, injection nozzle erosion or corrosion,
TX,45,JC1771 1908JAN971/1

101603
PN=39
9000
04 Low Sulfur Diesel Fuel Conditioner
2
When possible, use existing fuel formulations for engines

used off-highway. This fuel will not require any additives
to provide good performance and engine reliability.
However, many local fuel distributors will not carry both
low and regular sulfur diesel fuels.
If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere PREMIUM DIESEL FUEL
CONDITIONER. It provides lubricating properties along
with other useful benefits, such as cetane improver,
anti-oxidant, fuel stabilizer, corrosion inhibitor and others.
John Deere PREMIUM DIESEL FUEL CONDITIONER is
specifically for use with low sulfur fuels. Nearly all other
diesel fuel conditioners only improve cold weather flow
and stabilize long-term fuel storage. They do not contain
the lubrication additives needed by rotary fuel injection
pumps.
TX,45,DH5857 1915AUG971/1
Diesel Fuel Storage
Proper fuel storage is critically important. Use clean Store diesel fuel in plastic, aluminum, and steel
storage and transfer tanks. Periodically drain water containers specially coated for diesel fuel storage.
and sediment from bottom of tank. Store fuel in a
convenient place away from buildings. Avoid storing fuel over long periods of time. If fuel is
stored for more than a month prior to use, or there is a
IMPORTANT: DO NOT store diesel fuel in slow turnover in fuel tank or supply tank, add a fuel
galvanized containers. Diesel fuel conditioner such as John Deere PREMIUM DIESEL
stored in galvanized containers FUEL CONDITIONER or equivalent to stabilize the fuel
reacts with zinc coating on container and prevent water condensation. John Deere
to form zinc flakes. If fuel contains PREMIUM DIESEL FUEL CONDITIONER is available
water, a zinc gel will also form. The in winter and summer formulas. Fuel conditioner also
gel and flakes will quickly plug fuel reduces fuel gelling and controls wax separation during
filters, damage injection nozzles and cold weather.
injection pump.
Consult your John Deere engine distributor or servicing
DO NOT use brass-coated containers dealer for recommendations and local availability.
for fuel storage. Brass is an alloy of Always follow manufacturers directions on label.
copper and zinc.
TX,45,JC1772 1908JAN971/1

101603
PN=40
9000
Fuel Tank 04
3
CAUTION: Handle fuel carefully. If the engine is

hot or running, do not fill the fuel tank. Do not
smoke while you fill fuel tank or work on fuel
system.
To avoid condensation, fill the fuel tank at the end of each

days operation. Capacity is 303 L (80 gal).
TX,45,DH5077 1901JUL961/1
Do Not Use Galvanized Containers
IMPORTANT: Diesel fuel stored in galvanized Store fuel in:

containers reacts with zinc coating
on the container to form zinc flakes. plastic containers.
If fuel contains water, a zinc gel will aluminum containers.
also form. The gel and flakes will specially coated steel containers made for diesel
quickly plug fuel filters and damage fuel.
fuel injectors and fuel pumps.
DO NOT USE brass-coated containers: brass is an
DO NOT USE a galvanized container to store diesel alloy of copper and zinc.
fuel.
MX,FLBT,C 1904JUN901/1

101603
PN=41
9000
04 Diesel Engine Oil
4
Use oil viscosity based on the expected air temperature

range during the period between oil changes.
The following oil is preferred:
John Deere PLUS-50
The following oil is also recommended:
John Deere TORQ-GARD SUPREME
Other oils may be used if they meet one or more of the
UN10OCT97
following:
API Service Classification CG-4

API Service Classification CF-4

TS1661
ACEA Specification E3
ACEA Specification E2
Multi-viscosity diesel engine oils are preferred.
If diesel fuel with sulfur content greater than 0.5% is used,

reduce the service interval by 50%.
Extended service intervals may apply when John Deere

preferred engine oils are used. Consult your John Deere
dealer for more information.
PLUS-50 is a registered trademark of Deere & Company.

TORQ-GARD SUPREME is a trademark of Deere & Company DX,ENOIL 1910OCT971/1

101603
PN=42
9000
Hydraulic Oil 04
5

The following oils are preferred:
John Deere HY-GARD

John Deere Low Viscosity HY-GARD
Other oils may be used if they meet one of the following:
John Deere Standard JDM J20C

John Deere Standard JDM J20D
UN10OCT97
Use the following oil when a biodegradable fluid is
required:
John Deere1BIO-HY-GARD
TS1660
Manufacturer Oil
Mobil DTE 25
Shell Tellus 46
Caltex Oil Rando Oil HD46
Texaco Inc. Rando Oil HD46
Chevron U.S.A. Inc. Chevron AW46
Esso Standard Oil NUTO H46
HY-GARD is a trademark of Deere & Company

BIO-HY-GARD is a trademark of Deere & Company
1
BIO-HY-GARD meets or exceeds the minimum biodegradability of 80%
within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD
should not be mixed with mineral oils because this reduces the
biodegradability and makes proper oil recycling impossible.
CED,TX14740,6951 1907JAN001/1

101603
PN=43
9000
04 Swing Gearbox, Propel Gearbox and Pump
6
Gearbox Oils

The following oils are preferred:
John Deere GL-5 GEAR LUBRICANT

John Deere EXTREME-GARD
Other oils may be used if they meet API Service

Classification GL-5.
UN14MAR96
TS1653
EXTREME-GARD is a trademark of Deere & Company. OUOE003,0005424 1907SEP001/1
Track Roller, Front Idler, and Carrier Roller

Oil
Use SAE 30 oil meeting API Service GL-5 (MIL-L-2105B

or MIL-L-2105C).
TX,45,DH5142 1909AUG961/1

101603
PN=44
9000
Track Adjuster, Working Tool Pivot, Swing 04
7
Bearing, and Swing Bearing Gear Grease
Use grease based on NLGI consistency numbers and the

expected air temperature range during the service interval.
The following greases are preferred:
John Deere SD POLYUREA GREASE
The following greases are also recommended:
John Deere HD MOLY GREASE

John Deere HD LITHIUM COMPLEX GREASE

UN30JUN99
John Deere HD WATER RESISTANT GREASE
John Deere GREASE-GARD
Other greases may be used if they meet the following:
TS1667
NLGI Performance Classification GC-LB
IMPORTANT: Some types of grease thickener are not

compatible with others.
CED,TX14740,6952 1907JAN001/1
Oil Filters
Filtration of oils is critical to proper operation and

lubrication. Always change filters regularly as specified in
this manual.
Use filters meeting John Deere performance

specifications.
DX,FILT 1918MAR961/1

101603
PN=45
9000
04 Lubricant Storage
8
Your equipment can operate at top efficiency only Make certain that all containers are properly marked to
when clean lubricants are used. identify their contents.
Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
DX,LUBST 1918MAR961/1
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require

lubricant recommendations different from those printed in
this manual. Some John Deere brand coolants and
lubricants may not be available in your location. Consult
your John Deere dealer to obtain information and
recommendations.
Synthetic lubricants may be used if they meet the

performance requirements as shown in this manual.
The temperature limits and service intervals shown in this

manual apply to both conventional and synthetic oils.
Re-refined base stock products may be used if the

finished lubricant meets the performance requirements.
DX,ALTER 1918MAR961/1

101603
PN=46
9000
Mixing of Lubricants 04
9
In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet information and recommendations.
certain specifications and performance requirements.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
DX,LUBMIX 1918MAR961/1

101603
PN=47
9000
04
10

101603
PN=48
Section 9005
Operational Checkout Procedure
Contents 9005
Page
Group 10Operational Checkout Procedure

Operational Checkout . . . . . . . . . . . . . . . . . .9005-10-1
Operator Station ChecksKey Switch On,
Engine Off . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-1
Operator Station ChecksEngine On . . . . . .9005-10-4
Hydraulic System Checks . . . . . . . . . . . . . . .9005-10-9
Undercarriage Checks. . . . . . . . . . . . . . . . .9005-10-16
Accessories Checks . . . . . . . . . . . . . . . . . .9005-10-18
Heating and Air Conditioning Checks . . . . .9005-10-20
Seat, Doors, Windows, Latches, and
Locks Checks . . . . . . . . . . . . . . . . . . . . .9005-10-23
Engine Cooling System Checks . . . . . . . . .9005-10-28
Air Intake System Checks . . . . . . . . . . . . . .9005-10-33
Fuel System Checks . . . . . . . . . . . . . . . . . .9005-10-36
Visual Inspection . . . . . . . . . . . . . . . . . . . . .9005-10-38

101603
PN=1
Contents
9005

101603
PN=2
Group 10
Operational Checkout
Use this procedure to check all systems and functions on

the machine. It is designed so you can make a quick
check of machine operation while doing a walk around
9005
inspection and performing specific checks from the 10
operators seat. 1
Should you experience a problem with your machine, you

will find helpful diagnostic information in this checkout that
will pinpoint the cause. This information may allow you to
perform a simple adjustment yourself which will reduce
the down time of your machine. Use the table of contents
to help find adjustment procedures.
The information you provide after completing the

operational checkout will allow you or your authorized
dealer to pinpoint a specific test or repair needed to
restore the machine to design specifications.
A location will be required which is level and has

adequate space to complete the checks. No tools or
equipment are needed to perform the checkout.
Complete the necessary visual checks (oil levels, oil

condition, external leaks, loose hardware, linkage, wiring,
etc.) prior to doing the checkout. The machine must be at
operating temperature for many of the checks.
Start at the top of the left column and read completely

down column before performing check. Follow this
sequence from left to right. In the far right column, if no
problem is found, you will be instructed to go to next
check. If a problem is indicated, you will be referred to
either a section in this manual or to your authorized dealer
for repair.
TX,9005,GG2241 1907SEP001/1
1 Operator Station ChecksKey Switch On, Engine Off
1/1

101603
PN=51
Gauges, Monitor, and ATemperature Gauge YES: Go to next check.

Battery Disconnect Relay BFuel Gauge
Checks NO: Check monitor fuse.
NOTE: Monitor buzzer is not checked during this
procedure. NO: Check and replace
bulb if any bulb fails to
9005
If engine coolant temperature is below 30C (86F) come on. Go to Group
10
engine temperature gauge needle may not move to the 9015-15.
2
right. Run engine a few minutes to warm coolant before
check.
Key switch ON.
Engine OFF.
Does battery relay click?
Do engine temperature gauge (A) and fuel gauge (B)

needles move to the right?
T102096 UN26JUL96 Do all eight monitor lights come on and after 23

seconds only the alternator indicator and engine oil
pressure indicator remain on?
1/1
Fluid Level (Coolant, ALevel Check Switch YES: Go to next check.

Hydraulic Oil, and BEngine Oil Level Indicator
Engine Oil) Indicator CEngine Coolant Level Indicator NO: Check monitor fuse.
Circuit Checks DHydraulic Oil Level Indicator If OK, check fluid levels in
radiator, recovery tank,
Key switch ON. hydraulic oil tank, or
engine. If OK, check fluid
Engine OFF. level switch or wiring. Go
to Group 9015-15.
Push and hold level check switch (A).
Are the hydraulic oil level (B), coolant level (C), and
engine oil level (D) indicator lights ON?
T102097 UN26JUL96
1/1

101603
PN=52
Engine Oil Level and YES: Add oil if low.

Condition Check
Change oil and filter if too
high, milky or grainy. Go
to Group 9000-04. Check
oil level after a few hours
9005
operation to determine if
10
a problem exists. Go to
3
Diagnose Engine
T6488GH 1923FEB89
Malfunctions Group
9010-15.
NO: If engine oil level

indicator does not come
ON, go to Monitor
Diagnostic Information in
Group 9015-15.
If oil level is OK, go to

next check.
T103525 UN10SEP96
APre-Operation Level Check Switch

BEngine Oil Level Indicator
Engine OFF.
Remove dipstick and check oil level and condition.
Is oil above full mark or below add mark on dipstick.
Does the oil look milky or grainy?
If oil level is high, check for fuel or anti-freeze. Drain a small amount of engine oil into
a clear container. Watch oil in container to see if anti-freeze or water accumulates at
the bottom. If oil is milky, moisture or anti-freeze may be present.
If oil is grainy, carbon may be present. Carbon in oil may result when engine runs at
slow idle too long.
If oil level is low, check for oil leaks or oil seal problems in engine.
Adjust oil level to between add and full marks on dipstick.
Key switch ON.
Push pre-operation level check switch (A).
Is green light for engine oil level indicator (B) ON?

1/1

101603
PN=53
Propel Lever and Pedal APropel Lever and Pedal Forward YES: Go to next check.
Dampener Checks BPropel Lever and Pedal Rearward
NO: Repair or replace
Engine OFF. propel pedal dampeners.
Go to Group 3360.
Push each propel lever and pedal forward (A), then
9005
release.
10
4
Pull each propel lever and pedal rearward (B), then
T7531AO UN07JUN91
release.
Does each lever and pedal have equal effort to operate

forward and reverse?
Does each lever and pedal return to neutral at the same

time when released?
1/1
2 Operator Station ChecksEngine On
1/1
Monitor Circuit and ACoolant Temperature Gauge YES: Go to next check.

Gauge Checks BFuel Gauge
NO: Check engine
Start engine. lubrication system if
engine oil pressure
IMPORTANT: Stop the engine if alternator or engine indicator is on after
oil pressure indicators do not go OFF or a monitor engine starts. Go to
indicator comes ON after engine starts. Group 9010-10 or
CTM104.
Do alternator and engine oil pressure indicators go OFF
after engine starts? Check alternator belt if
alternator indicator is on
Do all monitor indicators remain OFF after engine starts? after engine starts. Go to
Group 0510. If OK, check
The buzzer will sound if engine oil pressure is low. fuses and alternator. Go
to Group 9015-15.
Is coolant temperature gauge needle (A) in normal
operating zone after a few minutes? Check switches, sensors,
and gauges. Go to Group
Does fuel gauge (B) indicate fuel level? 9015-15.
T102096 UN26JUL96
Stop engine. Check fluid levels.
1/1

101603
PN=54
Power Mode Circuit YES: Go to next check.

Checks
NO: Check controller
fuse. Go to Group
9015-15.
9005
10
5
T7351CC UN22AUG90
LOCKED
T102098 UN26JUL96
AHP (High Power) Mode Switch

BE (Economy) Mode Switch
Start engine.
Auto-idle switch OFF.
Pilot shut-off lever in LOCKED position.
Push power mode HP mode (A) and E mode (B) select switches one at a time.
Do corresponding indicator lights come on as each switch is pushed?
1/1
Work Mode Circuit AWork Mode Switch YES: Go to next check.

Checks BDig Mode Indicator
CGrading Mode Indicator NO: Check fuse. If OK,
DPrecision Mode Indicator check monitor and wiring
EAttachment Mode Indicator harness. Go to Group
9015-15.
Start engine.
Turn engine rpm dial to fast idle.
Pilot shut-off lever in LOCKED position.
Push work mode select switch (A) to select desired work

mode.
Do corresponding indicator lights (BE) come on as

each switch is pushed?
T102099 UN26JUL96 Does engine speed decrease when precision mode is

selected?
1/1

101603
PN=55
Engine RPM Dial Checks AEngine RPM Dial YES: Go to next check.
Start engine. NO: Check dial and

wiring harness. Go to
Auto-idle switch OFF. Group 9015-15. If OK,
check for control signal to
9005
Pilot shut-off lever in LOCKED position. EC motor. Go to harness
10
test in Group 9025-25.
6
Turn engine rpm dial (A) clockwise. Check that cable from EC
motor to injection pump
Does engine speed increase? lever moves freely. Go to
Group 0515.
Turn engine rpm dial counterclockwise.
Does engine speed decrease?
T102100 UN26JUL96
1/1
Auto-Idle Circuit Check AAuto Idle Switch YES: Go to next check.

BAuto Idle Indicator
NO: Check fuse. Check
Engine at fast idle. switches and wiring
harness. Go to Group
HP (High Power) and E (Economy) mode switches OFF. 9015-15.
Pilot shut-off lever in UNLOCKED position.
Push auto-idle switch (A) to ON.
Does auto-idle indicator (B) come on?
Does engine speed decrease after 46 seconds?
Slowly actuate any dig function control lever.
Does engine speed return to fast idle?

T102101 UN26JUL96
1/1

101603
PN=56
E (Economy) Mode YES: Go to next check.

Check
NO: Check switch,
indicator, and harness.
Go to Group 9015-15.
9005
10
T103545 UN09SEP96
7
T103546 UN09SEP96
AE (Economy) Mode Switch

BE (Economy) Mode Indicator
Start the engine.
Turn engine rpm dial clockwise to fast idle.
Push E (Economy) mode switch (A) on.
Does engine speed decrease?
Does E mode indicator (B) come on?
Push E mode switch again to turn it OFF.
Does E mode indicator go out and engine speed increase to fast idle?
1/1
HP (High Power) Mode YES: Go to next check.

Check
NO: Check switch,
indicator, arm in sensor,
pump pressure sensor,
and harness. Go to
Group 9015-15.
T111983 UN27OCT97
T112183 UN13NOV97
Check linkage and fast
idle speed stop at the
AHP (High Power) Mode Switch injection pump. Go to
BHP (High Power) Mode Indicator Group 9010-20.
Start the engine.
Push HP (High Power) mode switch (A) on.
Does HP (High Power) mode indicator (B) come on?
Operate the arm in function over relief (arm cylinder fully extended).
Does engine speed increase?
Push HP mode switch again to turn it OFF.
Does HP mode indicator go out?
1/1

101603
PN=57
Pilot Shut-Off Valve YES: Check adjustment.

Checks CAUTION: Machine may move during this Go to Group 9025-20.
check. Make sure area is clear and large Repair or replace pilot
enough to operate all machine functions. shut-off valve. Go to
Group 3360.
Run engine at slow idle.
9005
NO: Continue check.
10 Pilot shut-off lever in LOCKED (rearward) position.
8
T7351CC UN22AUG90
Actuate controls for dig and propel functions.
LOCKED
Do any dig or propel functions operate?
Push pilot shut-off lever to UNLOCKED position YES: Go to next check.

(forward).
NO: Check adjustment.
Actuate controls for dig and propel functions. Go to Group 9025-20.
Repair or replace pilot
Do all functions operate? shut-off valve. Go to
Group 3360.
T7351CB UN22AUG90
UNLOCKED
1/1
Travel Alarm Check APilot Shut-Off Lever YES: Go to next check.

BPropel Lever and Pedal Forward
CPropel Lever and Pedal Rearward NO: Check travel
(motion) alarm fuse.
Check motion alarm and
CAUTION: Machine will move during this wiring harness. Go to
check. Make sure area is clear and large Group 9015-15.
enough to operate the machine.
T7850AF UN22OCT92
Engine running.
Pilot shut-off lever (A) in UNLOCKED position (forward).
Push propel pedals or levers forward (B).
Does travel alarm sound?
Push propel pedals or pull levers rearward (C).
Does travel alarm sound?
1/1

101603
PN=58
Travel Alarm Stop Circuit ATravel Alarm Cancel Switch YES: Go to next check.
Check
NO: Check switch and
CAUTION: Machine will move during this wiring harness. Go to
check. Make sure area is clear, and large Group 9015-15.
enough to operate the machine.
9005
NOTE: Travel alarm must operate for this check. 10
9
T102919 UN08AUG96
Push propel pedals or levers and allow travel alarm to
operate for a minimum of 12 seconds.
While continuing travel, push travel alarm cancel switch

(A).
Does travel alarm stop sounding?
1/1
Engine Blow-By Check Run engine at fast idle and check engine blow-by tube. YES: Go to next check.
Are fumes barely visible at the blow-by tube at fast idle, NO: If blow-by is
with no load? excessive. Do
compression pressure
NOTE: Excessive blow-by indicates that piston rings and test. (See CTM104.)
cylinder liners do not seal off the combustion chamber.
This is a comparative check that requires some
T7700AC UN10FEB92
experience to determine excessive blow-by.
1/1
Engine Parts Loose or Run engine at slow idle. YES: Go to next check.
Worn Check
Move hydraulic control lever to operate a hydraulic function over relief to put engine NO: Go to Abnormal
under load. Engine Noise, in Group
9010-15.
Does engine run smooth, no knocking or rattling noise?
1/1
3 Hydraulic System Checks
1/1

101603
PN=59
Hydraulic Oil Tank Raise boom to full height, then lower boom to ground. YES: Go to next check.
Pressurization Check
Slowly loosen vent plug on hydraulic reservoir. NO: Replace cap.
Is air heard escaping from vent plug?

9005
NOTE: The pressurized oil tank creates pressure at the
10
inlet to the hydraulic pumps. If filler cap does not seal,
10
T7884AG UN12NOV92
hydraulic pumps could cavitate and be damaged.
1/1
Hydraulic Oil Level YES: Go to next check.

Check
NO: Add hydraulic oil so
level is between marks on
window. Go to Group
9000-04.
T6477AQ UN19OCT88 T7387AD UN03OCT90
Park machine on a level surface.
Extend bucket cylinder.
Retract arm cylinder.
Lower boom so bucket is on the ground.
Check the hydraulic oil level.
Is oil level between the marks on hydraulic oil level window?
1/1
Pump Gearbox Oil Level Pull dipstick from tube, check oil level. YES: Go to next check.
Check
Is oil level between marks? NO: Add oil if low.
T8187BB UN08MAR94
1/1

101603
PN=60
Swing Gearbox Oil Level Pull dipstick from tube, check oil level. YES: Go to next check.
Check
Is oil between marks? NO: Add oil if low.
9005
10
11
T8187BF UN08MAR94
1/1
Pilot Controller Pattern YES: Go to next check.

CheckSAE Pattern
NO: Install correct decals
for control pattern. To
change control pattern,
T102070 UN16JUL96
go to Control Lever
Left Control Lever Decal
Pattern Conversion in
Group 9025-15.
T102071 UN16JUL96
Right Control Lever Decal
Operate machine in clear area.
Push pilot shut-off lever to UNLOCKED position. Slowly move control levers to all
positions on decals.
Do bucket, boom, arm, and swing move as decals show?
1/1

101603
PN=61
Pilot Controller Pattern YES: Go to next check.

CheckJohn Deere
Pattern NO: Install correct decals
for control pattern. To
change control pattern,
go to Control Lever
9005
Pattern Conversion in
10
Group 9025-15.
12
T102197 UN19JUL96
Left Control Lever Decal
T102198 UN19JUL96
Right Control Lever Decal
Operate machine in clear area.
Push pilot shut-off lever to UNLOCKED position. Slowly move hydraulic levers to all
positions on decals.
Do bucket, boom, arm, and swing move as decals show?
1/1
Swing Dynamic Brake YES: Go to next check.

Check CAUTION: Make sure area is clear and large
enough to swing extended arm and bucket. NO: Check swing motor
Machine must be on level ground. leakage. Check swing
motor crossover relief
Position upperstructure with boom in front. valve. Go to Group
9025-25. Check swing
Put arm and bucket in fully extended position with bucket valve spool. Go to Group
900 mm (3 ft) above ground level. 3360.
T6479AY UN19OCT88
Operate engine at fast idle.
Actuate swing control valve to full stroke. Swing around

90 degrees and release lever.
Does upperstructure stop within 45 degrees (1/8 turn)

after releasing lever?
Repeat procedure in opposite direction.
1/1

101603
PN=62
Swing Circuit Leakage Run engine at slow idle. YES: Go to next check.
Check
Position machine on a side hill or raise one side of NO: Check swing circuit
machine 300 mm (1 ft) with the boom and put blocks leakage. Go to Group
under track. 9025-25.
9005
Position bucket 300 mm (1 ft) off the ground at
10
maximum reach.
13
T6479AZ UN19OCT88
Actuate bucket curl function over relief.
NOTE: Actuating the bucket function releases the

mechanical swing park brake.
Does upperstructure move only slightly?
1/1
Dig Function Drift Check Run engine at slow idle. YES: Check cylinder drift.
Go to 9025-25. Inspect
Fill bucket with dirt. Position bucket at maximum reach reduced leakage valves
with bucket 2 in. (50 mm) above ground. for boom down and arm
in functions. Go to Group
Observe bucket for 1 minute. 3360.
Does bucket drift down to ground within 1 minute? NO: Go to next check.
T6290AF UN19OCT88
1/1
Control Valve Lift Check Run engine at slow idle. YES: If functions move in
Test opposite direction first, a
Position machine as illustrated. leak at the lift check valve
is indicated. Inspect lift
Slowly actuate pilot controller to lower boom, extend arm check valves. Go to
(retract cylinder), and dump bucket (retract cylinder). Group 3360.
Do functions move in opposite direction as control levers NO: Go to next check.

T6292AZ UN19OCT88
are moved, then change direction as levers are moved
further?
1/1

101603
PN=63
Boom Up, Arm In, and Engine at fast idle. YES: Go to next check.
Bucket Combined
Operation Check Work mode selector in dig mode. NO: Inspect bucket flow
control valve in control
Actuate the boom up function, arm in function and then the bucket function. valve if boom speed
slows excessively. Go to
9005
Does boom continue to move at approximately the same speed after bucket function is Group 3360.
10
actuated?
14
1/1
Arm Regenerative Valve Engine at fast idle YES: Go to next check.

Operation Check
Work mode selector in dig mode. NO: Check the rear pump
pressure sensor, arm in
Extend the arm to full extension and then lower boom so bucket is on the ground. pressure sensor, boom
up pressure switch, and
Actuate the boom up and arm in functions in combined operation. arm regenerative solenoid
valve. Go to Group
Does the arm move smoothly through the complete cycle and not hesitate when it 9015-15.
goes through the vertical position?
IF OK: Check the arm
regenerative valve in the
control valve. Go to
Group 3360.
1/1
Propel System Tracking Engine at fast idle. YES: Go to next check.

Checks While Propelling
Work mode selector in dig mode. NO: Note which track
does not move or if
Propel speed switch in fast speed (rabbit). machine mistracks and
the mistrack pattern. Go
Propel machine at full speed forward on a flat and level area. to Propel System
Tracking Test in Group
Repeat procedure in reverse. 9025-25.
Do both tracks move and machine does not mistrack excessively in forward or
reverse?
1/1
Propel System Tracking Engine at fast idle. YES: Inspect flow

Checks While Operating combiner valve, propel
a Dig Function Propel speed switch in fast speed (rabbit). flow control valve, and
propel-boom down
Propel machine at full speed forward on a flat and level area. selector valve in the
control valve. Go to
After machine is moving, slowly move the arm control lever from neutral to full Group 3360.
actuation to extend the arm.
NO: Go to next check.
Does machine mistrack excessively when the arm is extended?
NOTE: Machine will slow down during this test.
1/1

101603
PN=64
Propel System Engine at fast idle. YES: Go to next check.

Maneuverability Check
Propel speed switch in fast speed (rabbit). NO: Inspect
counterbalance valve. Go
Propel machine at full speed forward down a slope. to Group 0260.
9005
Turn in each direction.
10
15
Repeat the procedure in reverse.
Does each track slow down in response to pedal or lever movement in order to turn?
1/1
Propel Speed Selection APropel Speed Switch YES: Go to next check.

Check
Engine at fast idle. NO: Check pressure
switches and sensors. Go
Turn propel speed switch (A) to slow speed (turtle). to Group 9015-15.Go to
Propel Speed Change
Actuate propel function to full speed. Circuit Operation in
Group 9025-05.
Turn propel speed switch to fast speed (rabbit).
Does machine travel speed increase?
Actuate a dig function and then return to neutral.
Does machine travel speed decrease and then increase?
Turn propel speed switch to slow speed (turtle).
Does machine travel speed decrease?
T102104 UN26JUL96
1/1

101603
PN=65
Cycle Times Check YES: Go to next check.

CAUTION: Make sure area is clear and large enough to operate all
functions of machine. NO: Check engine speed.
Check hydraulic pump
NOTE: Warm hydraulic oil to operating temperature for this check. flow. Go to Group
9010-20 and 9025-25.
9005 Engine at fast idle.
10
16 Auto-idle switch OFF.
T6477AQ UN19OCT88 T7884AE UN10NOV92

Boom Arm, Bucket, Swing
Move machine to position shown for each test.

Record cycle time for each function.
Does machine perform within specifications?
Cycle TimesSpecification
Boom Raise (Cylinder Extend)Cycle
Time .............................................................................................................. 3.0 0.3 sec
Boom Lower (Cylinder Retract)Cycle
Time .............................................................................................................. 2.4 0.3 sec
Arm In (Cylinder Extend)Cycle Time ........................................................ 3.6 0.3 sec
Arm Out (Cylinder Retract)Cycle Time ..................................................... 2.4 0.3 sec
Bucket Load (Cylinder Extend)Cycle
Time .............................................................................................................. 3.3 0.3 sec
Bucket Dump (Cylinder Retract)Cycle
Time .............................................................................................................. 2.1 0.3 sec
Swing Left or Right3 Revolutions From
a Running StartCycle Time .................................................................... 13.1 1.0 sec
Propel 20 m (65 ft) From a Running
StartCheck Time in Forward and
Reverse Fast Speed PropelCycle
Time ............................................................................................................ 13.0 0.6 sec
Propel 20 m (65 ft) From a Running
StartCheck Time in Forward and
Reverse Slow Speed PropelCycle
Time ............................................................................................................ 20.6 1.0 sec
1/1
4 Undercarriage Checks
1/1

101603
PN=66
Track Sag Roller and YES: Repair or replace

Idler Leakage Checks idlers or rollers that are
leaking. Go to Group
0130.

9005
10
17
T6915AN UN07APR89
T7850AI UN22OCT92
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.
Track sag specifications:
Specification
Top of Track Shoe-to-Center of Lower
Surface of Track FrameDistance ........................ 300335 mm (11-3/1613-3/16 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 is
less than specified on one side only, the machine may mistrack.
1/1
Sprocket Wear Check Inspect drive sprocket. YES: Replace sprocket.

Go to Group 0130.
Is tooth wear excessive?
NOTE: Do not evaluate sprocket by condition of tooth
tip. Tooth tip wear does not affect sprocket operation if it
does not extend into the bushing contact area.
T6981AC UN13MAR89
Reverse drive side wear is generally more than forward
drive side wear.
1/1

101603
PN=67
Grouser Wear, Bent Inspect for worn grousers, bent track shoes, and loose YES: If shoe hardware is
Track Shoe, and Loose shoe hardware. loose, remove shoe and
Hardware Checks clean joint before
Are grouser bars worn excessively? tightening. Go to Group
0130.
Are track shoes bent?
9005
10
Is track shoe width appropriate for ground condition?
18
T7322AF UN21JUN90
Is track shoe hardware tight?
NOTE: Excessive grouser wear weakens track shoes

and may result in track shoes bending.
1/1
Track Link Roller and Inspect track links for pin boss wear. YES: Go to
Front Idler Wear Checks Undercarriage Appraisal
Do link pin boss areas indicate contact with roller flanges Manual for more in
or track guides? information and
specifications.
NOTE: Some contact or wear is normal. Excessive
contact or wear indicates excessive rail wear. NO: Go to next check.
T6484AZ UN19OCT88
Inspect front idler flanges.
Do idler flanges contact bushings?
NOTE: Idler contact with bushings indicates excessive

chain rail wear and idler tread surface wear.
1/1
5 Accessories Checks
1/1

101603
PN=68
Light Circuit Checks ALight Switch YES: Go to next check.
NOTE: All accessories are powered from the fuse block. NO: Check fuses, monitor
If any accessories do not function, check fuses in fuse panel back light bulbs,
block. switches, and wiring. Go
to Group 9015-15.
9005
Turn key switch ON.
10
19
Turn light switch (A) to 1st position.
T102105 UN26JUL96
Are monitor panel back lights and front driving lights on?
Turn light switch to 2nd position.
Do work lights on boom come on also?
1/1
Windshield Wiper Circuit AWindshield Wiper Switch YES: Go to next check.

Check
Key switch ON. NO: Check that upper
right window lock pin
Turn wiper switch (A) to INT position. engages hole in cab
frame and is turned to
Does wiper operate intermittently? engage the lock to close
windshield wiper enable
T102106 UN26JUL96
Turn wiper switch to ON position. switch. Check fuse,
switch, and wiper
Does wiper operate continuously? harness. Go to Group
9015-15.
Move wiper switch to OFF position.
Does wiper arm stop in park position?
1/1
Windshield Washer AWindshield Washer Switch YES: Go to next check.

Circuit Check
IMPORTANT: Washer motor may be damaged if NO: Check washer fluid
washer switch is held for more than 20 seconds, or level. Check wiper fuse
continually operated with no fluid in the and wiring harness. Go to
Group 9015-15.
Key switch ON
Push washer switch (A)

T102107 UN26JUL96
Does washer fluid squirt on windshield?
1/1

101603
PN=69
Cab Dome Light Circuit ACab Dome Light Switch YES: Go to next check.
Check
Key switch ON. NO: Check fuse and
Move switch (A) to on position. Group 9015-15.
9005
Does cab dome light come on?
10
20
T102183 UN26JUL96
1/1
Horn Circuit Check AHorn Button YES: Go to next check.
Key switch ON. NO: Check fuse and

Push horn button (A) on top of left control lever. Group 9015-15.
Does horn sound?
T102195 UN26JUL96
1/1
6 Heating and Air Conditioning Checks
1/1
Heater Controls Check ABlower Control Switch YES: Go to next check.

(Machines Equipped with BTemperature Control Lever
Heater Only) NO: Check heater fuse,
Engine running and at normal operating temperature. wiring harness, and
motor. Go to Group
Turn blower control switch (A) to all four speed positions, 9031-10.
then back to OFF.
T102108 UN26JUL96
Does fan run in all four positions, then stop in OFF
position.
With fan running at any speed, move temperature control

lever (B) to warm temperature position (rearward).
Does warm air exit from vents?
1/1

101603
PN=70
Heater Controls Check YES: Go to next check.

(Machines Equipped with
Air Conditioning) NO: Check heater fuse,
wiring harness, and
motor. Go to Group
9031-15.
9005
10
21
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
Start engine and allow to warm several minutes.
Press heater temperature switch to maximum heat position. Press blower switch to
high speed position.
Does warm air exit from ducts?
1/1
Air Conditioning Checks YES: Go to next check.
NO: See Heater and Air

Conditioner Circuit
Checks in Group
9031-10. See Charging
the System in Group
9031-20.
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
Start engine and run at fast idle.
Push A/C switch to turn air conditioner on.
Push HI blower switch to run blower at high speed.
Wait for any warm air in duct system to dissipate.
Is air from ducts cool after a few minutes?

1/1

101603
PN=71
All Lines and Hoses Engine OFF. YES: Go to next check.
Inspect all lines and hoses. NO: Position hoses or

lines and tighten or
Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts replace clamps. Tighten
or "weather checked"? fittings or replace O-rings
9005
in fittings. Replace hoses
10
Are hose and line connections clean NOT showing signs of leakage, such as oil or or lines as required.
22
dust accumulation at fittings?
All hose and line clamps must be in place and tight. Clamps must have rubber inserts
or cushions in place to prevent clamps from crushing or wearing into hoses or lines?
1/1
Evaporator Core Check Engine ON. YES: Go to next check.
Blower switch on high NO: Repair, replace, or

clean evaporator.
Is air from ducts cool and air flow good?
Is water dripping from evaporator drain hose?
1/1
Condenser Check Engine OFF. YES: Go to next check.
Inspect condenser cores. NO: Clean, repair, or

replace condenser core.
Is condenser core free of dirt or debris? Replace engine fan.
Does condenser show signs of leakage, dust accumulation or oily areas?
Are condenser fins straight, not bent or damaged?
Inspect engine fan. Are fan blades in good condition, not worn, bent, broken, or
missing?
1/1
Compressor Clutch Engine OFF. YES: Go to next check.

Check
Key switch ON. NO: Replace compressor
clutch. Go to Group 1830.
Blower switch on LOW.
Air conditioner switch ON.
Does compressor clutch click as switch is pushed?
1/1

101603
PN=72
7 Seat, Doors, Windows, Latches, and Locks Checks
1/1 9005
10
23

101603
PN=73
Seat Control Checks YES: Go to next check.
NO: Inspect and repair or

replace any parts that do
not operate properly. Go
to Group 1821.
9005
10
24
T118478 UN02DEC98
T102507 UN29JUL96
AWeight Adjustment Knob

BSeat Height and Angle Adjustment Lever
CConsole and Seat Fore-Aft Adjustment Lever
DSeat Fore-Aft Adjustment Lever
EBackrest Adjustment Lever
FArmrest
GAdjustment Dial
Push seat height and angle adjustment lever (B) down. Raise and lower seat.
Does seat raise and lower easily?
Push seat height and angle adjustment lever (B) down. Adjust angle of seat.
Does seat angle change easily?
Push console and seat fore-aft adjustment lever (C) down. Move seat and both side
consoles forward and rearward. Release lever to lock seat and side consoles in
position.
Does lever unlock easily and then lock to hold seat and consoles in position?
Pull seat fore-aft adjustment lever (D) up. Move seat forward and rearward. Release
lever to lock seat in any position.
Does lever move easily to unlock seat support?
Does seat move forward and rearward easily?
Does lever lock seat support in position when released?
Pull backrest adjustment lever (E) up. Tilt seat back forward and rearward. Release
lever to lock seat back in any position.
Does seat back tilt forward and rearward easily?
Does lever unlock and lock easily to hold seat back in position?
Turn adjustment dial (G) to change angle of armrest (F).
Does armrest move up and down as adjustment dial is turned?
Does armrest hold its position?
1/1

101603
PN=74
Upper Front Window YES: Go to next check.

Check
NO: Inspect. Repair.
9005
10
25
T102109 UN26JUL96 T102110 UN26JUL96
ALock Pins
BRear Latch
CCab Frame Rear Holes
NOTE: The upper right window lock pin is also used to close the windshield wiper
enable switch so windshield wiper can operate. When window is closed, check that
lock pins engage holes in cab frame and are turned to engage lock.
Turn lock pins (A) and pull towards center of window.
Pull window up and back until it catches in rear latch (B) for convenient storage
overhead.
Slide the two lock pins into the cab frame rear holes (C) and turn to lock.
Do pins move smoothly to lock and unlock window?
Does rear latch operate freely?
Do pins engage cab frame rear holes and lock window securely in full open position?
1/1
Lower Front Window YES: Go to next check.

Storage Check
T102111 UN26JUL96 T106163 UN07JAN97
ALock Pins
BBrackets
CHoles
NOTE: Upper front window must be raised before lower window can be removed from
window frame.
Pull lock pins (A) towards center of window to unlock window.
Lift lower front window from the frame.
Store window behind the rear console. Slide lock pins into hole (C) in brackets (B).
Do the springs push lock pins out?
Is window held securely in brackets?
1/1

101603
PN=75
Right Rear Side Window ALatch Handle YES: Go to next check.

Check
Pull on latch handle (A) to unlock it. NO: Inspect. Repair or
Push latch handle to the over-center position to push replace. Go to Group
window open. 1810.
9005
Does latch operate smoothly?
10
26
Is window held open?
T102113 UN26JUL96
1/1
Cab Door Window Slide both windowpanes open and closed? YES: Go to next check.
Checks
Do both windowpanes slide freely in the molding? NO: Inspect and clean
channel in molding.
Slide windowpanes to the closed position. Repair or replace. Go to
Group 1810.
Do latches engage catches and hold windowpanes
closed.
T116423 UN15JUL98
1/1
Roof Exit Cover Check ALock Pins YES: Go to next check.

BHandle
NO: Inspect. Repair or
Pull lock pins (A) toward center of roof exit cover. replace.
Do air cylinders push cover open and hold cover in the

open position?
T102205 UN26JUL96 Pull on handle (B) to pull cover down until lock pins
click into position and hold cover closed.
Does cover open and close freely?
Do lock pins click into position and hold cover closed?
1/1

101603
PN=76
Cab Door Latch and ACab Door Catch Release Lever YES: Go to next check.
Catch Checks
Open cab door. Push door open until door engages NO: Inspect. Repair or
catch and is held in open position. replace.
Does catch hold door in the open position?

9005
10
Push down on cab door catch release lever (A) to
27
T102114 UN26JUL96 release door from catch.
Does release lever operate freely and is door released

from catch?
Pull door closed.
Does door latch operate easily and hold door securely in

the closed position?
1/1
Cab Door Lock Check From outside cab, close cab door. YES: Go to next check.
Insert ignition key into door lock, turn clockwise 1/4 turn NO: Inspect. Repair.
to lock.
Allow key to return to vertical.
Try to open door.

T7425AH UN10DEC90
Turn key 1/4 turn counterclockwise to unlock.
Allow key to return to vertical.
Remove key from lock.
Does lock turn easily?
Does lock prevent door from opening when locked?
1/1
Left and Right Access Insert ignition key into lock and turn 180 clockwise to YES: Go to next check.
Doors Lock Check lock.
Turn key 180 counterclockwise to unlock.
Does lock turn easily and lock door and cap in position?
Are all parts free of any visible damage?

T7425AG UN28NOV90
1/1

101603
PN=77
Fuel Cap Lock Check YES: Go to next check.
NO: Replace fuel cap.
9005
10
28
T7351AH UN22AUG90 T7425AF UN04DEC90
Turn lock cover to expose lock.
Insert ignition key into fuel cap lock.
Turn key 45 counterclockwise to lock fuel cap.
Does lock prevent cap from being removed?
Turn key 45 clockwise to unlock fuel cap.
Does lock turn easily to lock and unlock?
1/1
Hood Check AHood Hold-Open Rod YES: Go to next check.
Unlock hood latch with ignition key. NO: Inspect. Repair or

replace.
Release latches.
Open hood.
T102128 UN26JUL96
Engage hold-open rod (A).
Does rod hold hood open?
Close hood and engage latches.
Do latches operate easily?
Do latches hold hood closed?
1/1
8 Engine Cooling System Checks
1/1

101603
PN=78
Coolant Level and Engine OFF and cool. YES: Go to next check.
Condition In Recovery
Tank Checks Open radiator access door. NO: Add coolant if low.
Drain and flush overflow
Inspect coolant level and coolant condition in recovery tank and radiator, replace
tank. coolant if dirty or rusty. If
9005
coolant is oily check for
10
Is coolant level between FULL and LOW marks on hydraulic or engine oil
29
recovery tank? leaks into cooling system.
T7414AB 1913DEC90
Go to CTM104.
Is coolant clear, not oily, foamy, or rust colored?
1/1
Radiator Cap Check YES: Go to next check.
NO: Replace radiator

cap.
T6488FY UN19OCT88 T7690AB UN23JAN92
AGasket
BSpring
CSeal
CAUTION: Prevent possible injury. DO NOT remove radiator cap unless

engine is cool. When engine is hot and cap is removed, hot coolant or
steam will spray out causing serious burns.
Engine OFF and cool.
Remove radiator cap.
If coolant is warmer than surrounding air temperature, is a whoosh sound heard

when cap 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?

1/1

101603
PN=79
Coolant Level and YES: Go to next check.

Condition In Radiator CAUTION: Prevent possible injury. DO NOT
Checks remove radiator cap unless engine is cool. NO: Add coolant if low.
When engine is hot and cap is removed, hot Check hose to coolant
coolant or steam will spray out causing recovery tank. Flush
serious burns. radiator and engine if
9005
coolant is dirty or rusty.
10 Engine OFF and cool. Add clean coolant. Go to
30
T6488FY UN19OCT88
Group 9010-20. If coolant
Remove radiator cap. is oily check for engine oil
leaks into cooling system.
Inspect coolant level. Go to CTM104.
Inspect coolant condition.
Is coolant level at bottom of fill neck on radiator?
Is coolant clear, not oily, foamy or rust colored?
1/1
Radiator Internal Core YES: Go to next check.

Check CAUTION: Prevent personal injury, DO NOT
remove radiator cap unless engine is cool. NO: Remove and clean
When engine is hot and cap is removed, hot or replace radiator. Fill
coolant or steam will spray out causing cooling system with clean
serious burns. coolant.
Raise engine access door.
T6488FZ UN19OCT88
Drain coolant into a clean container until core tubes are

visible.
Is radiator core free of rust, lime, or corrosion? Are

passages in core clean, not plugged?
1/1
Coolant Hoses and Are radiator and heater hoses free of twists, kinks, cracks, leaks, or wear from rubbing YES: Go to next check.
Clamps Checks on adjacent parts?
NO: Replace hoses as
Are hose clamps tight and installed correctly? required. Install and
tighten hose clamps.
1/1

101603
PN=80
Fan Shroud and Fan Check fan to fan shroud clearance. YES: Go to next check.
Guard Checks
Is fan centered in shroud? NO: Adjust fan shroud to
center fan. Repair or
Is guard free of damage? replace guard. Tighten
loose hardware. Replace
9005
Are all mounting brackets and hardware tight? fan shroud if needed. Go
10
to Group 0510.
31
T6488GC UN23AUG93
1/1
Water Pump Check AWeep Hole YES: Seal (B) is leaking.

BSeal Replace seal or water
pump. Go to CTM104,
Engine stopped. Cooling System.
Is coolant leaking weep hole (A)? NO: Go to next check.
NOTE: For coolant leakage between water pump and

T7690AC UN27JAN92
engine block, replace gasket.
Water Pump
1/1
Fan Blades Check Are fan blades bent or twisted? YES: Replace fan. Go to
Group 0510.
Are fan blades cracked or nicked?
T7694AH UN21MAY03
1/1

101603
PN=81
Fan Direction Check Is fan installed correctly with concave (cupped) side YES: Go to next check.
(arrow) of fan blade towards engine?
NO: Install fan correctly.
NOTE: If fan is installed backwards, about 50% of its
capacity is lost.
9005
10
32
T6171CB UN25MAY89
1/1
Radiator Outside Air Inspect radiator screen for mud and debris. YES: Go to next check.
Flow Check
Inspect radiator fins for mud and debris. NO: Clean screen. Clean
outside of radiator.
Inspect radiator for bent or damaged fins. Straighten fins. Replace
radiator if severely
Are radiator fins free of mud, leaves, grass, and other debris? damaged.
Are fins straight, not broken or cracked?
1/1
Fan Belt Check Is fan belt free of oil or grease? YES: Go to next check.
Is inside surface of belt free of cracks or frayed edges? NO: Replace belt if oily,
greasy, cracked, or
Is belt aligned with pulleys? otherwise damaged.
Adjust fan belt if loose.
Is fan belt adjustment correct? Go to Group 0510.
1/1

101603
PN=82
Engine Head Gasket Seal Engine at normal temperature. YES: Head gasket is OK.
Check Go to next check.
Radiator full.
NO: If there is a constant
Install radiator cap and tighten. flow of bubbles from tube,
loose or damaged
9005
Place end of radiator overflow hose into a container of cylinder head or a leaking
10
clear water. head gasket may be
33
indicated. Go to CTM104,
T6171AR UN25MAY89
Operate engine at fast idle. Load engine by holding a Engine Repair.
hydraulic function over relief.
Look for bubbles coming from overflow tube. Do bubbles

flow from tube intermittently?
1/1
9 Air Intake System Checks
1/1
Air Filter Restriction Run engine at slow idle. YES: Go to next check.
Indicator and Switch
Check Slowly cover air intake tube. NO: Check monitor circuit
fuse, air filter restriction
Does air filter restriction indicator light in cab come ON? indicator light and switch.
Go to Section 9015-15.
T118761 UN03DEC98
1/1

101603
PN=83
Air Cleaner Unloader AAir Cleaner Unloader Valve YES: Go to next check.
Valve Check
Open right access door. NO: Replace unloader
valve.
Inspect air cleaner unloader valve (A).
9005
Is unloader valve slightly open when the engine is not
10
running?
34
Is rubber flexible and showing no sign of becoming hard
or brittle?
Engine running.
Turn auto-idle switch off and turn engine rpm dial to fast
idle.
Does unloader valve close?
T7531BF UN07JUN91
1/1
Air Cleaner Elements ASecondary Element YES: Go to next check.

Check BPrimary Element
NO: Clean or replace
Remove air cleaner cover. primary element. Replace
secondary element if
Inspect primary element (B). primary element is
damaged. Do not clean
Is element clean and in good condition? secondary element.
T7531BG UN07JUN91
Replace if dirty.
Remove wing nut to remove primary element.
Inspect secondary element (A).
Is element clean and in good condition?
1/1

101603
PN=84
Cold Weather Starting YES: Go to next check.

Aid Checks
NO: Install a starting fluid
can or the dust cover.
Replace plastic line.
Tighten nozzle until arrow
9005
or red dot is in correct
10
position to make sure
35
T103516 UN04SEP96 T128979 UN25APR00 orifice hole is pointing
T7699AL UN03FEB92
Later Models AGAINST incoming air
Early Models
flow.
AStarting Aid Solenoid
BDust Cover
COrifice Hole
Open left rear service door.
Check that starting fluid can is installed in starting aid solenoid (A).
If starting fluid can is NOT installed, check that dust cover (B) is installed.
Is starting fluid line from starting aid solenoid to air intake manifold straightNOT
kinked or broken?
(Early Models) Is arrow on starting aid nozzle pointing AGAINST air flow of air intake
manifold?
NOTE: It may be necessary to scrape paint from nozzle to see arrow or red dot.
(Later Models) Is starting aid nozzle installed so that orifice hole (C) is pointing
AGAINST air flow?
NOTE: Red dot on nozzle indicates orientation of orifice hole.
1/1
Exhaust Smoke Check Operate engine until engine coolant temperature gauge YES: Go to Diagnose
needle is in the GREEN zone before doing this check. Engine Malfunctions,
Group 9010-15.
Run engine at fast idle.
Counter rotate tracks to put load to engine.
Observe exhaust smoke.

T6488GF UN19OCT88
Is exhaust smoke dark black or blue smoke? Is exhaust
smoke gray or white?
NOTE: Dark black smoke can be caused by dirty air filter

or poor fuel delivery. Blue smoke can be caused by worn
or damaged piston rings or cylinder liners. Gray or white
smoke can be caused by a cold engine, dirty injection
nozzles, or both.
1/1

101603
PN=85
10 Fuel System Checks
9005 1/1
10
36
Fuel Tank Interior Check IMPORTANT: Be careful not to damage fuel gauge sender float or low fuel level YES: Drain fuel, dispose
sending unit. of contaminated fuel
properly. Remove debris,
Remove fuel cap. clean bottom of tank.
Replace fuel filters.
Use a flashlight to inspect bottom of fuel tank by shining light through the fuel. Check primary fuel filter
(water separator).
Is dirt, debris, or contamination seen in tank?
1/1
Fuel Tank Sump Check AFuel Tank Drain Valve YES: Drain until clear fuel
flows or drain all fuel from
Hold a clean container under fuel tank drain valve (A). tank, dispose of
contaminated fuel
Remove recessed hex plug. properly. Replace fuel
filters, check primary fuel
Open drain valve for a few seconds and catch fuel in filter (water separator).
container.
T7700AA UN18FEB92
Check condition of fuel in container.
Is water present or is fuel cloudy?
1/1
Primary Fuel Filter Inspect fuel in primary fuel filter (water separator) YES: Open drain valve to
(Water Separator) Check sediment bowl. drain water and
contamination into a
Is water or other contamination present? container. Dispose of
contaminated fuel
properly.

T7700AB UN25FEB92
1/1

101603
PN=86
Fuel Transfer Pump YES: Go to next check.

Check
NO: Be certain fuel filter
is clean. If not, replace
filter and recheck fuel
supply pump.
9005
10
37
T103528 UN04SEP96 T6493AA UN19OCT88
ABleed Screw
Open bleed screw (A) on fuel filter and operate hand primer on fuel transfer pump.
Does fuel come out of bleed screw when hand primer is operated?
Tighten bleed screw and again operate hand primer.
Is resistance felt when hand primer is initially pumped and increase as system
pressure increases?
1/1
Primary Fuel Filter YES: Go to next check.

(Water Separator) Hand
Primer Check NO: Repair or replace
hand primer on primary
fuel filter. Go to Group
0560.
T116778D UN03DEC98 T116899E UN03DEC98
ABleed Screw
BHand Primer
Open bleed screws (A) on final fuel filter and primary fuel filter.
Push and release hand primer (B) until fuel flows from bleed screw on primary fuel
filter. Tighten bleed screw.
Continued to operate hand primer until fuel flows from bleed screw on final fuel filter.
Tighten bleed screw.
Does fuel flow from bleed screws as hand primer is operated?

1/1

101603
PN=87
Fuel System Check Engine OFF. YES: Go to next check.
Disconnect fuel return hose at final fuel filter. NO: Fuel supply is
restricted, check for
Connect a hose to fitting on final fuel filter to route excess fuel into a container. plugged fuel filters,
plugged fuel tank cap
9005
Start engine and run at fast idle. vent, restricted lines,
10
stuck injection pump
38
Put engine under load by operating a hydraulic function over relief. overflow valve, or a
malfunctioning fuel
Observe fuel flow from hose. transfer pump. Repair or
replace as necessary.
Does fuel flow from hose with engine under load?
NOTE: Fuel that flows through the fuel return hose is excess fuel not required by the
engine and flows back to the fuel tank.
1/1
11 Visual Inspection
1/1
Visual Inspection Park machine on a level surface. YES: Replace damaged

O-rings or gaskets.
Extend the bucket cylinder. Tighten fittings or cap
screws.
Retract bucket cylinder.
Repair or replace bent or
Lower the boom so bucket is on the ground. damaged lines.
T6477AQ UN19OCT88
Stop the engine. Repair or replace
damaged components.
Inspect oil lines and hydraulic components for leaks or
damage. NO: Operational checkout
is complete.
Are lines or components damaged or leaking?
1/1

101603
PN=88
Section 9010
Engine
Contents
Page Page
Group 05Theory of Operation Fuel Line Leakage. . . . . . . . . . . . . . . . . . . . .9010-25-2

POWERTECH 6.8 L (6068) John Deere Air Filter Restriction Indicator Switch . . . . . . .9010-25-3 9010
EngineUse CTM104 . . . . . . . . . . . . . . . .9010-05-1 Air Intake System Leakage . . . . . . . . . . . . . .9010-25-4
EngineSectional View . . . . . . . . . . . . . . . .9010-05-2 Radiator Air Flow . . . . . . . . . . . . . . . . . . . . .9010-25-5
Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-3 Engine Power Test Using Turbocharger
Engine Speed Control Boost Pressure . . . . . . . . . . . . . . . . . . . . .9010-25-8
System Operation . . . . . . . . . . . . . . . . . . .9010-05-4 Torsional Dampener
Engine RPM Dial . . . . . . . . . . . . . . . . . . . .9010-05-6 Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-12
E (Economy) Mode . . . . . . . . . . . . . . . . . .9010-05-8
HP (High Power) Mode . . . . . . . . . . . . . .9010-05-10
Auto-Idle Mode . . . . . . . . . . . . . . . . . . . .9010-05-12
Engine Speed Learning . . . . . . . . . . . . . .9010-05-14

POWERTECH 6.8 L (6068) John Deere
EngineUse CTM104 . . . . . . . . . . . . . . . .9010-10-1
Engine
Operational Checks . . . . . . . . . . . . . . . . . .9010-10-1
Cooling System Checks . . . . . . . . . . . . . . . .9010-10-1
Air Intake System Checks . . . . . . . . . . . . . . .9010-10-6
Lubrication System Checks . . . . . . . . . . . . . .9010-10-8
Fuel System Checks . . . . . . . . . . . . . . . . . .9010-10-10
Engine Speed and Performance Checks . . .9010-10-12

EngineUse CTM104 . . . . . . . . . . . . . . . .9010-15-1
Engine
Diagnose Malfunctions. . . . . . . . . . . . . . . .9010-15-2
Group 20Adjustments
EngineUse CTM104 . . . . . . . . . . . . . . . .9010-20-1
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
Fuel Shut-Off Solenoid Linkage
Check and Adjust . . . . . . . . . . . . . . . . . . .9010-20-2
Engine Speed Check . . . . . . . . . . . . . . . . . .9010-20-5
Injection Pump Fast and Slow Idle Stops . . .9010-20-6
Engine Speed Control Motor . . . . . . . . . . . . .9010-20-8
Engine Speed Learning Procedure . . . . . . .9010-20-10
Cooling System Fill and Deaeration . . . . . .9010-20-12
Group 25Tests
EngineUse CTM104 . . . . . . . . . . . . . . . .9010-25-1

101603
PN=1
Contents
9010

101603
PN=2
Group 05
Theory of Operation
EngineUse CTM104
For additional engine information, the component technical

manual (CTM) is also required.
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
9010
05
POWERTECH is a trademark of Deere & Company. TX,9010,SB103 1906SEP961/1 1

101603
PN=91
Theory of Operation
EngineSectional View
9010
05
2
UN28NOV89
L103403
1Rocker Arm Shaft 7Crankshaft 12Cylinder Liner 17Fuel Injection Nozzle
2Cylinder Head 8Crankshaft Counterweight 13Piston 18Valve Spring
3Push Rod 9Oil Pan 14Piston Pin 19Rocker Arm
4Cam Follower 10Connecting Rod 15Piston Rings 20Balancer Shafts (some
5Camshaft 11Liner Packing Rings 16Valve 4-cylinder engines only)
6Cylinder Block
TX,9010,SB105 1906SEP961/1

101603
PN=92
Theory of Operation
Fan Drive Operation
The fan drive (C), driven by one fan belt from the engine
crankshaft (D), is self adjustable. The fan belt tension
adjuster (F) automatically adjusts the belt to correct
tension.
AAlternator Pulley
BIdler Pulley
CFan Pulley
DCrankshaft Pulley 9010
EWater Pump Pulley 05
FTension Adjuster 3
UN29AUG96
T103369
TX,9010,SB106 1906SEP961/1

101603
PN=93
Theory of Operation
Engine Speed Control System Operation
9010
05
4
1927MAY98
T115408
AEngine RPM Dial GEngine Learning Switch KPump Pressure Sensor OAuto-Idle Switch
CEngine and Pump HArm In Pilot Pressure (2 used) PEngine Speed Sensor
Controller Switch LEC Sensor (N Sensor)
DEngine Control Motor IPropel Pressure Switch ME Mode Switch QEngine Speed Control
EInjection Pump JDig Pressure Switch NHP Mode Switch Circuits
FKey Switch
The engine speed control circuits (Q) have the HP (high power) mode control
following control functions: E (economy) mode control
Auto-idle mode
Slow to fast idle in standard mode Engine learning control
Continued on next page CED,OUOE035,146 1918APR001/2

101603
PN=94
Theory of Operation
The engine speed control components allows the operator

to choose engine speeds to match operating conditions
and to operate the engine as efficiently as possible.
Engine speeds from slow idle to fast idle in standard

mode are selected by the engine rpm dial (A) located in
the right console panel in cab. The E (economy) mode
and HP (high power) mode are selected by switches
located in the right console panel just above the engine
rpm dial. The auto idle mode is selected by a switch
located in the switch panel (B). Indicators in the monitor 9010
panel are lit to indicate when the E mode, HP mode, and 05
5
auto-idle mode switches are pushed to activate the
function.
AI=Auto Idle Mode Switch

E=Economy Mode Switch
HP=High Power Mode Switch
Turning the engine rpm dial or pushing the AI, E, or HP
1927MAY98
mode switches sends an electrical signal to the engine
and pump controller (C). The controller senses the
electrical signal and then from the stored data sends an
electrical signal to the engine control motor (D). The
T115409
engine control motor regulates engine speed by a
push-pull cable attached to the fuel injection pump lever
located in the pump drive housing.
AEngine RPM Dial
BSwitch Panel
The engine speed sensor (P) (located in the pump drive
CEngine and Pump Controller
housing) counts the pump drive gear teeth as the gears DEngine Control Motor
rotate. This senses actual engine speed. The sensing EInjection Pump
signal is sent to the engine and pump controller (C) which PEngine Speed Sensor (N Sensor)
calculates engine speed.
CED,OUOE035,146 1918APR002/2

101603
PN=95
Theory of Operation
Engine RPM Dial Speed Control Circuit Operation
9010
05
6
1927MAY98
T115580
AEngine RPM Dial CEngine Control Motor DEngine and Pump EEngine RPM Dial Speed
BEC Sensor Controller Control Circuit
The function of the engine rpm dial speed control rpm dial. The EC (engine control) sensor (B) sends an
circuit (E) is to control engine speed from slow to fast electrical feedback signal to the controller indicating
idle in standard mode in response to the position of the motors position.
engine rpm dial (A).
The engine speed for slow idle is limited by the slow
As the engine rpm dial is turned to increase or idle stop bracket. The data for slow idle position is
decrease engine speed, the electrical signal sent from stored in the engine and pump controller and is used
the dial to the engine and pump controller (D) to calculate the positions for auto-idle, E (economy),
changes. Then, from data stored in the controller, the and HP (high power) modes. (See Engine Learning
controller sends an electrical signal to actuate the Control Circuit Operation in this group. For adjustment,
engine control motor (C). The control motor moves the see Injection Pump Fast and Slow Idle Stops
injection pump lever by a push-pull cable to change Adjustment in Group 9010-20.)
engine speed in response to the position of the engine

101603
PN=96
Theory of Operation
The engine speed for fast idle in standard mode is The fast idle stop bracket on the injection pump limits
controlled by data stored in the engine and pump the maximum engine speed for HP mode. (For
controller. The parameter for fast idle in standard adjustment, see Injection Pump Fast and Slow Idle
mode can be change from the factory setting within a Stops Adjustment in Group 9010-20.)
specified range. (See Excavator Diagnostic Program
Special FunctionEngine Speed in Group 9025-25.)
9010
05
CED,OUOE003,1053 1918APR002/2 7

101603
PN=97
Theory of Operation
E (Economy) Mode Speed Control Circuit Operation
9010
05
8
1927MAY98
T115581
AEngine RPM Dial CEngine Control Motor EE Mode Switch FE (Economy) Mode Speed
BEC Sensor DEngine and Pump Control Circuit
Controller
The function of E (economy) mode speed control When E mode is actuated, the engine and pump
circuit (F) is to operate the engine at a lower speed controller (D) sends electrical signals to the engine
range when full engine power is not needed. The control motor (C) to run the engine in a speed range
engine power is somewhat less but digging power is lower than standard mode. The adjustable range for
the same as in standard mode. Operating in E mode engine speed is from the specified speed for E mode
also improves fuel efficiency and reduces the noise down to slow idle and is in proportion to the engine
level. The E mode function is available when dig mode rpm dial position. The electrical signals to the motor
is selected as the work mode. The E mode indicator is are calculated from data stored in the engine and
ON when the E mode switch (E) is push down to show pump controller (D). The EC (engine control) sensor
that E mode is actuated. (B) sends an electrical feedback signal to the controller
indicating the motors position.
NOTE: Standard mode is when the E mode and HP
mode switches are OFF.

101603
PN=98
Theory of Operation
The parameter for engine speed in E (economy) mode Special FunctionEngine Speed Adjustment in Group
can be change from the factory setting within a 9025-25.)
specified range. (See Excavator Diagnostic Software
CED,OUOE003,1054 1918APR002/2
9010
05
9

101603
PN=99
Theory of Operation
HP (High Power) Mode Speed Control Circuit Operation
9010
05
10
1927MAY98
T115582
AHP Mode Switch DArm In Pressure Sensor GRear Pump JEC Sensor
BEngine RPM Dial EPump Pressure Sensors HEngine Control Motor KHP (High Power) Mode
CPilot Controller FFront Pump IEngine and Pump Controller Speed Control Circuit
The function of the HP (high power) mode speed Engine speed is approximately 1600 rpm or faster.
control circuit (K) is to increase engine speed when a The electrical signal from the engine rpm dial (B) to
little more hydraulic power is needed for arm in the engine and pump controller (I) indicates the
operation. The HP mode is available when in the dig engine speed.
work mode. HP mode is used in the standard and E Arm in function is actuated. The arm in pressure
(economy) modes. sensor (D) sends an electrical signal to the engine
and pump controller (I).
The HP mode is actuated with the following conditions: The pump delivery pressure is approximately 23 440
kPa (234 bar) (3400 psi) or higher. The pump
HP mode switch (A) is pushed down. The HP pressure sensors (E) send an electrical signal to the
indicator is ON. engine and pump controller.

101603
PN=100
Theory of Operation
When all conditions are meet, the engine and pump load on the engine. The maximum engine speed for
controller sends an electrical signal to the engine HP mode is limited by the fast idle stop bracket on the
control motor to increase the engine speed. The injection pump. (For adjustment, see Injection Pump
amount of engine speed increase is somewhat Fast and Slow Idle Stops Adjustment in Group
controlled by the pump regulators adjustment and the 9010-20.)
9010
05
CED,OUOE003,1055 1918APR002/2 11

101603
PN=101
Theory of Operation
Auto-Idle Mode Speed Control Circuit Operation
9010
05
12
1927MAY98
T115583
AEngine RPM Dial DEngine and Pump FPropel Pressure Switch HAuto-Idle Mode Speed
BEC Sensor Controller GDig Pressure Switch Control Circuit
CEngine Control Motor EAuto-Idle Switch
The function of the auto-idle mode speed control circuit motor reduces the engine speed to the specified
(H) is to automatically reduce engine speed when all auto-idle speed. The electrical signal sent to the motor
dig and propel function are in neutral to reduce fuel is calculated from data stored in the engine and pump
consumption and the noise level. The AI indicator is controller. The EC (engine control) sensor (B) sends
ON when the auto-idle switch (E) is pushed to show an electrical feedback signal to the controller indicating
that the auto-idle function is actuated. Pushing the the motors position.
switch again turns the auto-idle function off.
Actuating the propel or a dig function causes an
When auto-idle function is actuated and no electrical electrical signal to be sent from the propel or dig
signal is received from the propel or dig pressure pressure switch to the controller. The controller then
switches (F and G) for more than four seconds, the sends an electrical signal to the engine control motor
engine and pump controller (D) sends an electrical to increase engine speed back to the setting of engine
signal to the engine control motor (C). The control rpm dial.

101603
PN=102
Theory of Operation
The parameter for auto-idle engine speed can be range. (See Excavator Diagnostic Software Special
change from the factory setting within a specified FunctionEngine Speed in Group 9025-25.)
CED,OUOE003,1056 1918APR002/2
9010
05
13

101603
PN=103
Theory of Operation
Engine Speed Learning Control Circuit Operation
9010
05
14
1927MAY98
T115584
AEngine RPM Dial DEngine and Pump EKey Switch GEngine Speed Learning
BEC Sensor Controller FEngine Learning Switch Control Circuit
CEngine Control Motor
The function of the engine speed learning control the engine and pump controller by the EC (engine
circuit (G) is to learn the slow idle position as control) sensor (B). The slow idle position data is
determined by the slow idle stop bracket on the stored in the engine and pump controller.
injection pump and to store that data in the engine and
pump controller (D). The position of the engine control motor for auto-idle
mode, E (economy) mode, and fast idle in standard
When the engine learning switch (F) is pushed up to mode is based on the slow idle position data stored in
the learning position and the key switch (E) is turned the engine and pump controller.
on, the engine control motor (C) is driven by an
electrical signal from the engine and pump controller When the following components are repaired or
(D). The control motor moves the injection pump lever replaced, or when engine speeds deviate from
to the slow idle position (the end of slot in slow idle specification, the engine control motor adjustment and
stop bracket). An electrical feedback signal engine learning control procedure must be performed.
corresponding to the slow idle position is sent back to

101603
PN=104
Theory of Operation
Engine. (See Engine Control Motor and Sensor Adjustment

Engine speed control cable. and Engine Speed Learning Procedure in Group
Slow idle bracket at injection pump. 9010-20.)
Fast idle bracket at injection pump.
Engine control motor and sensor. The procedure is not necessary after the replacement
Engine and pump controller. of batteries.
9010
05
CED,OUOE003,1057 1918APR002/2 15

101603
PN=105
Theory of Operation
9010
05
16

101603
PN=106
Group 10
System Operational Checks
EngineUse CTM104

UN07SEP88
M44215
9010
10
Engine Operational Checks
This procedure is designed so the mechanic can make problem is indicated, you will be given repair required
a quick check of the engine using a minimum amount and group location or CTM number. If verification is
of diagnostic equipment. If you need additional needed, you will be given next best source of
information, read Theory of Operation, Group 9010-05. information:
A location will be required which is level and has Group 10 (System Operational Checks)
adequate space to complete the driving checks.
Group 15 (Diagnostic Information)
The engine and all other major components must be at
operating temperature for some checks. A tachometer Group 20 (Adjustments)
is required.
Group 25 (Tests)
Locate system check in the left column and read
completely, following this sequence from left to right. CTM (Component Technical Manual)
Read each check completely before performing.
At the end of each check, if no problem is found, that

check is complete or an additional check is needed. If
TX,9010,SB110 1918SEP001/1
1 Cooling System Checks
1/1

101603
PN=107
Coolant Level and Engine OFF and cool. YES: Go to next check.
Condition In Recovery
Tank Check Open radiator access door. NO: Add coolant if low.
Drain and flush overflow
Inspect coolant level and coolant condition in recovery tank and radiator, replace
tank. coolant if dirty or rusty. If
coolant is oily, check for
Is coolant level between FULL and LOW marks on hydraulic or engine oil
recovery tank? leaks into cooling system.
T7414AB 1913DEC90
Go to CTM104.
Is coolant clear, not oily, foamy, or rust colored?
9010
10
2 1/1
Coolant Level and YES: Go to next check.

Condition In Radiator CAUTION: Prevent possible injury. DO NOT
Checks remove radiator cap unless engine is cool. NO: Add coolant if low.
When engine is hot and cap is removed, hot Flush radiator and engine
coolant or steam will spray out causing if coolant is dirty or rusty.
serious burns. Add clean coolant. Go to
Group 9010-20. If coolant
Engine OFF and cool. is oily, check for hydraulic
T6488FY UN19OCT88
or engine oil leaks into
Remove radiator cap. cooling system. Go to
CTM104.
Inspect coolant level.
Inspect coolant condition.
Is coolant level at bottom of fill neck on radiator?
Is coolant clear, not oily, foamy or rust colored?
1/1

101603
PN=108
Radiator Cap Check YES: Go to next check.
NO: Replace radiator

cap.
T6488FY UN19OCT88 T7690AB UN23JAN92
AGasket
BSpring
CSeal 9010
10
3
CAUTION: Prevent possible injury. DO NOT remove radiator cap unless
engine is cool. When engine is hot and cap is removed, hot coolant or
steam will spray out causing serious burns.
Engine OFF and cool.
If coolant is warmer than surrounding air temperature, is a whoosh sound heard

when cap 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?

1/1
Radiator Internal Core YES: Go to next check.

Check CAUTION: Prevent personal injury, DO NOT
remove radiator cap unless engine is cool. NO: Remove and clean
When engine is hot and cap is removed, hot or replace radiator. Fill
coolant or steam will spray out causing cooling system with clean
serious burns. coolant. Go to Group
9010-20.
T6488FZ UN19OCT88
Drain coolant into a clean container until core tubes are

visible.
Is radiator core free of rust, lime, or corrosion? Are

passages in core clean, not plugged?
1/1

101603
PN=109
Radiator Outside Air Open engine access door. YES: Clean outside of
Flow Check radiator and straighten
Open left rear access door. fins if bent. Replace
radiator if severely
Inspect radiator screen for mud and debris. damaged.
Are radiator fins free of mud, leaves, grass, and other debris? NO: Go to next check.
Is radiator damaged?
9010
10
4 1/1
Coolant Hoses and Are radiator and heater hoses free of twists, kinks, cracks, leaks or wear from rubbing YES: Go to next check.
Clamps Check on adjacent parts?
NO: Replace or untwist
Are hose clamps tight and installed correctly? hoses as required.
Tighten or reinstall hose
clamps.
1/1
Water Pump Check AWeep Hole YES: Seal (B) has failed.
BSeal Replace seal or water
pump. Go to CTM104,
Engine stopped. Cooling System.
Is coolant leaking from weep hole (A)? NO: Go to next check.
T7690AC UN27JAN92
1/1
Engine Head Gasket Seal Engine at normal temperature. YES: Head gasket is OK.
Check Go to next check.
Radiator full.
NO: If there is a constant
Install radiator cap and tighten. flow of bubbles from tube,
loose or damaged
Place end of radiator overflow hose into a container of cylinder head or a leaking
clear water. head gasket may be
T6171AR UN25MAY89
indicated. Go to CTM104
Operate engine at fast idle. Load engine by holding a Engine Repair.
hydraulic function over relief.
Look for bubbles coming from overflow tube. Do bubbles

flow from tube intermittently?
1/1

101603
PN=110
Fan Blades Check Are fan blades bent or twisted? YES: Replace fan.
Are fan blades cracked or nicked? NO: Go to next check.
9010
10
T7694AH UN21MAY03 5
1/1
Fan Direction Check Is fan installed correctly with cupped portion side (Arrow) YES: Go to next check.
of fan away from radiator?
NO: Install fan correctly.
NOTE: If fan is installed backwards, about 50% of its
capacity is lost.
T6488GB UN23AUG93
1/1
Fan Shroud and Fan Check clearance between fan and fan shroud. YES: Go to next check.
Guard Check
Is fan centered in shroud? NO: Adjust fan shroud if
fan is not centered.
Is guard free of damage? Repair or replace guard.
Tighten loose hardware.
Are all mounting brackets and hardware tight? Replace fan shroud if
needed.
T6488GC UN23AUG93
1/1

101603
PN=111
Fan Belt Check Is fan belt free of oil or grease? YES: Go to next check.
Is inside surface of belt free of cracks or frayed edges? NO: Replace fan belt if
oily, greasy, cracked or
Is belt aligned with pulleys? otherwise damaged.
Repair or replace
NOTE: Fan belt is self-adjusting. tightener if belt is loose.
Is fan belt tightener operating to keep belt tight?
9010
10
6 1/1
2 Air Intake System Checks
1/1
Air Filter Restriction Run engine at slow idle. YES: Go to next check.
Indicator and Switch
Check Slowly cover air intake tube. NO: Check monitor circuit
fuse, air filter restriction
Does air filter restriction indicator light in cab come ON? indicator light and switch.
T118761 UN03DEC98
1/1
Air Cleaner Unloader AAir Cleaner Unloader Valve YES: Go to next check.
Valve Check
Open left front access door. NO: Replace unloader
valve.
Inspect unloader valve (A).
Is unloader valve slightly open when the engine is not

running?
Is rubber flexible and showing no sign of becoming hard

or brittle?
Engine running.
Turn auto-idle switch off and turn engine RPM control

fully clockwise.
Does unloader valve close?
T7531BF UN07JUN91
1/1

101603
PN=112
Air Cleaner Element ASecondary Element YES: Go to next check.

Check BPrimary Element
NO: Clean or replace
Remove air cleaner cover. primary element. Replace
secondary element if
Inspect primary element (B). primary element is
damaged. Do not clean
Is element clean and in good condition? secondary element.
Replace if dirty.
T7531BG UN07JUN91
Remove wing nut to remove primary element.
Inspect secondary element (A).

9010
Is element clean and in good condition? 10
7
1/1
Cold Weather Starting YES: Go to next check.

Aid Checks
NO: Install a starting fluid
can or the dust cover.
Replace plastic line.
Tighten nozzle until arrow
or red dot is in correct
position to make sure
T103516 UN04SEP96 T7699AL UN03FEB92
T128979 UN25APR00 orifice hole is pointing
Later Models AGAINST incoming air
Early Models
flow.
AStarting Aid Solenoid
BDust Cover
COrifice Hole
Open left rear service door.
Check that starting fluid can is installed in starting aid solenoid (A).
If starting fluid can is NOT installed, check that dust cover (B) is installed.
Is starting fluid line from starting aid solenoid to air intake manifold straightNOT
kinked or broken?
(Early Models) Is arrow on starting aid nozzle pointing AGAINST air flow of air intake
manifold?
NOTE: It may be necessary to scrape paint from nozzle to see arrow or red dot.
(Later Models) Is starting aid nozzle installed so that orifice hole (C) is pointing
AGAINST air flow.
NOTE: Red dot on nozzle indicates orientation of orifice hole.
1/1

101603
PN=113
Exhaust Smoke Check Operate engine until coolant temperature gauge needle YES: Go to Diagnose
is in the GREEN zone before doing this check. Engine Malfunctions,
Group 9010-15.
Counter rotate tracks to put load to engine.
Observe exhaust smoke.

T6488GF UN19OCT88
Is exhaust smoke dark black or blue smoke? Is exhaust
smoke gray or white?
9010 NOTE: Dark black smoke can be caused by dirty air filter
10 or poor fuel delivery. Blue smoke can be caused by worn
8 or damaged piston rings or cylinder liners. Gray or white
smoke can be caused by a cold engine, dirty injection
nozzles, or both.
1/1
3 Lubrication System Checks
1/1

101603
PN=114
Oil Level Check YES: Add oil if low.

Change oil and filter if too
high. Go to Group
9000-04. Check oil level
after a few hours
a problem exists. Go to
Diagnose Engine
Malfunctions in Group
T6488GH 1923FEB89
9010-15.
NO: If oil level indicator

light does not come ON, 9010
go to Monitor Diagnostic 10
Information in Group 9
9015-15. If oil level is OK,
go to next check.
T103525 UN10SEP96
ALevel Check Switch

BEngine Oil Level Indicator
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 into
a clear container. Watch oil in container to see if anti-freeze or water accumulates at
the bottom.
If oil level is low, check for oil leaks or oil seal problems in engine.
Adjust oil level to between "add" and "full" marks on dipstick.
Key switch ON.
Push pre-operation level check switch (A).
Is green light for engine oil level indicator (B) ON?
1/1
Engine Oil Condition Remove dipstick and check oil condition. YES: Change oil and
Check filter. Check condition of
Is oil milky or grainy? oil after a few hours
If oil is milky, moisture or anti-freeze may be present. a problem exists. Go to
Group 9000-04 or
If oil is grainy, carbon may be present. Diagnose Engine
Malfunctions Group
Carbon in oil may result when engine runs at slow idle too long. 9010-15.
1/1

101603
PN=115
Engine Oil Pressure DEngine Oil Pressure Indicator YES: Go to next check.
Switch and Indicator
Check Turn key switch from OFF to ON and observe engine oil NO: Stop engine if engine
pressure indicator. oil pressure indicator
remains ON after engine
Does indicator (D) come ON and stay ON? starts. Go to Group
9010-15 Diagnose Engine
Start engine and observe engine oil pressure indicator. Malfunctions or CTM104.
If engine oil pressure
Does indicator go OFF a few seconds after engine indicator does not come
starts? ON, go to Group 9015-15
Monitor Controller and
9010 Display Circuit Diagnostic
10 Procedures.
10
T103526 UN09SEP96
1/1
4 Fuel System Checks
1/1
Fuel Tank Interior Check IMPORTANT: Be careful not to damage fuel gauge sender float or low fuel level YES: Drain fuel, dispose
sending unit. of contaminated fuel
properly. Remove debris,
Remove fuel cap. clean bottom of tank.
Replace fuel filters.
Use a flashlight to inspect bottom of fuel tank by shining light through the fuel. Check water separator.
Is dirt, debris, or contamination seen in tank? NO: Go to next check.
1/1
Fuel Tank Sump Check ADrain Valve YES: Drain until clear fuel
flows or drain all fuel from
Hold a clean container under fuel tank drain valve (A). tank, dispose of
contaminated fuel
Remove recessed hex plug. properly. Replace fuel
filters, check water
Open drain valve for a few seconds and catch fuel in separator.
container.
T7700AA UN18FEB92
Check condition of fuel in container.
Is water present or is fuel cloudy?
1/1

101603
PN=116
Primary Fuel Filter Inspect fuel in primary fuel filter (water separator). YES: Replace primary
(Water Separator) Check fuel filter (water
Is water or other contamination present? separator) element.
T7700AB UN25FEB92
9010
10
1/1 11
Fuel Transfer Pump YES: Go to next check.

Check
NO: Be certain fuel filter
is clean. If not, replace
filter and recheck fuel
supply pump.
T103528 UN04SEP96 T6493AA UN19OCT88
ABleed Screw
Open bleed screw (A) on fuel filter and operate hand primer on fuel transfer pump.
Does fuel come out of bleed screw when hand primer is operated?
Tighten bleed screw and again operate hand primer.
Is resistance felt when hand primer is initially pumped and increase as system
pressure increases?
1/1
Fuel System Check Engine OFF. YES: Go to next check.
Disconnect fuel return hose from leak-off line. NO: Fuel supply is
restricted, check for
Connect a hose to leak-off line to route excess fuel into a container. plugged fuel filters,
plugged fuel tank cap
Start engine and run at fast idle. vent, restricted lines,
stuck injection pump
Put engine under load by operating a hydraulic function over relief. overflow valve, or a
malfunctioning fuel
Observe fuel flow from leak-off line. transfer pump. Repair or
replace as necessary.
Does fuel flow from leak-off line with engine at full load?
NOTE: Fuel that flows from leak-off line is excess fuel not required by the engine and
flows back to the fuel tank.
1/1

101603
PN=117
5 Engine Speed and Performance Checks
1/1
Engine RPM Dial Check AEngine RPM Dial YES: Go to next check.
Start the engine. NO: Check engine rpm

dial and harness. Go to
9010
Turn engine rpm dial (A) to the right to fast idle position. Group 9015-15.
10
12
Did engine speed increase to fast idle in standard
mode?
Turn engine rpm dial to the left to slow idle position.
Did engine speed decrease to slow idle?
NOTE: To check and verify engine speeds, see

procedure in Group 9010-20.
T102100 UN26JUL96
1/1
Auto-Idle Speed Check AAuto-Idle Switch YES: Go to next check.

BAuto-Idle Indicator
NO: See Auto Idle Does
Start engine. Not Work. (Go to
Diagnose Engine
Run engine at half speed. Malfunctions in Group
9010-15.)
Push auto-idle switch (A) on.
Does the auto-idle indicator (B) come on?
Does the engine speed decrease to auto-idle speed after

about 4 seconds?
Actuate the bucket function momentarily. Does the

engine speed increase immediately to the engine rpm
dial setting?
Does the engine speed return to auto-idle after 4

seconds?
T103536 UN09SEP96
Push auto-idle switch (A) again to turn it off.
Does the engine speed increase immediately to the

engine rpm dial setting and the indicator go out?
1/1

101603
PN=118
E (Economy) Mode YES: Go to next check.
NO: See engine speed

controls in Group
9015-15.
T103545 UN09SEP96 T103546 UN09SEP96
AE (Economy) Mode Switch

BE (Economy) Mode Indicator
9010
Start engine. 10
13
Push E mode switch (A) on.
Did you hear a decrease in engine speed?
Did the indicator light (B) come on?
Push the E mode switch again to turn it off.
Did indicator light go out and engine speed increase to fast idle?
1/1
HP (High Power) Mode YES: Go to next check.

Check
NO: Check switch,
indicator, and harness.
T111983 UN27OCT97
T112183 UN13NOV97
AHP (High Power) Mode Switch

BHP (High Power) Mode Indicator
Start engine.
Push HP (high power) mode switch (A) on.
Did HP (high power) mode indicator (B) come on?
Operate the arm in function over relief (arm cylinder fully extended).
Does the engine speed increase?
Push HP mode switch again to turn it off.
Does HP mode indicator go out?
1/1

101603
PN=119
Engine Blow-By Check Run engine at fast idle and check blow-by tube. YES: Go to next check.
Are fumes barely visible at the blow-by tube at fast idle, NO: If blow-by is
with no load? excessive, do
compression pressure
NOTE: Excessive blow-by indicates that piston rings and test. (See CTM104.)
cylinder liners do not seal off the combustion chamber.
This is a comparative check that requires some
T7700AC UN10FEB92
experience to determine excessive blow-by.
9010
10
14 1/1
Loose or Worn Engine Run engine at slow idle. YES: Operational

Parts Checkout complete.
Move hydraulic control lever to operate a hydraulic function over relief to put engine
under load. NO: Go to Abnormal
Engine Noise. (See
Does engine run smooth, no knocking or rattling noise? Diagnose Engine
Malfunctions in Group
9010-15.)
1/1

101603
PN=120
Group 15
Diagnostic Information
EngineUse CTM104

UN07SEP88
M44215
9010
15

101603
PN=121
Diagnose Engine Malfunctions
NOTE: Diagnostic charts are arranged from most

probable and simplest to verify, to least likely and
more difficult to verify.
Symptom Problem Solution
Engine Cranks But Will Not Start No fuel Add fuel. Bleed air.
Or Hard To Start
9010
15 Wrong fuel Use correct fuel.
2
Water in fuel or water frozen in fuel Drain water from fuel tank trap.
line Inspect fuel filter for water. Change
filter.
Fuel filter plugged Replace fuel filter. Bleed air. Clean

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

Add clean fuel.
Air in fuel system Check for bubbles in fuel filter and

tighten connections. Bleed air.
Fuel pump Check fuel pump pressure. See

CTM104.
Low battery power Charge or install new batteries.
Slow cranking speed (poor electrical Clean and tighten battery and starter
connection) connections.
Wrong engine oil Use correct oil.
Air filter plugged Check air filter restriction indicator

and air filter elements. Clean or
replace elements.
Standby fuse or relay Replace fuse, relay or wiring. See

Section 9015.
Injection pump metering valve Lightly tap injection pump housing. If

sticking engine now starts, repair metering
valve. See Local Fuel Injection
Pump Service Center.
Continued on next page TX,9010,SB112 1918SEP001/10

101603
PN=122
Electric shut-off solenoid Check shut-off solenoid. See Group

9015-15. Inspect solenoid wiring and
linkage. See your Local Fuel
Injection Pump Service Center.
Injection pump Remove and test pump. See your

Local Fuel Injection Pump Service
Center.
9010
Injection nozzle(s) Remove and test nozzles. See 15
3
CTM104.
Starter Replace starter.
Worn compression rings or low Check compression. Repair. See

compression CTM104.
Starting ether used excessively Remove nozzles and add small

amount of oil to each cylinder. See
CTM104.
Blown head gasket Route tube between radiator and

overflow tank into container of fluid
and check for bubbles. A constant
flow of bubbles indicates head
gasket leakage. See CTM104.
Engine Knocks, Runs Irregularly Air in fuel Inspect filter for evidence of air in
or Stops fuel. Tighten connections and bleed
fuel system.
Debris in fuel Drain fuel tank. Clean tank strainer.

Add clean fuel.
Wrong fuel Use correct fuel.
Water in fuel Drain tank water trap, inspect filter

element for water. Replace filters.
Fuel filter plugged Replace filter.
Fuel injection pump out of time Time injection pump. See CTM104.
Idle speeds adjustment too low Adjust slow idle speed. See Group
9010-20.

101603
PN=123
Engine overheating Test cooling system. See Group

9010-25.
Fuel transfer pump Test pump pressure. See CTM104.
Fuel injection pump Remove and test fuel injection

pump. See your Local Fuel Injection
9010
15 Injection nozzle(s) Remove and test nozzle(s). See
4
CTM104.
Improper valve clearance Check and adjust valve clearance.

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

CTM104.
Bent push rods Inspect. Replace. See CTM104.
Worn or broken compression rings Route tube between radiator and

or cylinder head gasket leaking overflow tank into a container of fluid
and check for bubbles. A constant
flow of bubbles indicates head
gasket leakage. See CTM104.
Do compression pressure test. See

CTM104.
Engine Not Developing Full Fuel filter plugged Change filter. Bleed air.
Power
Air filter plugged Clean or replace air cleaner

elements.
Debris in fuel Drain fuel tank. Clean Tank strainer.
Fuel tank outlet fitting plugged Clean.
Fast idle speed incorrect Do Fast Idle Speed Adjustment. See

Group 9010-20.
Hydraulic system leakage Do Hydraulic System Checks. See

Group 9005-10.

101603
PN=124
Fuel line to pump or pump return to Check, repair.

tank restricted
Fuel pump Do Fuel Pump Pressure Test. See

CTM104.
Timing incorrect Check injection pump timing. See

CTM104.
9010
Injection nozzles Remove and test injection nozzles. 15
5
See CTM104.
Low compression Do Compression Pressure Test. See

CTM104.
Injection pump delivery or governor Repair pump. See your Local Fuel
Injection Pump Service Center.
Turbocharger Do turbocharger inspection. See

CTM104.
Valves burned, warped Repair valves. See CTM104.
Cam shaft worn Do Valve Lift Test. See CTM104.
Engine Overheats Coolant level low Fill cooling system and check for
leaks.
Thermostat stuck closed or missing Test and/or reinstall. See Group

0510 and CTM104.
Radiator screen plugged Remove and clean screen.
Radiator, oil cooler cores plugged Check air flow. (See Group
with dirt or fins bent 9010-25). Clean radiator. Straighten
fins.
Air filter plugged Clean or replace elements.
Gauge or sender Check gauge and sender. See

Group 9005-10.
Fan belt soaked with oil or pulleys Inspect, replace. See Operators
worn excessively Manual or Repair Manual.
Shroud or baffles (foam rubber) Inspect. Repair or replace.

missing

101603
PN=125
Fan blade on backward Reinstall. See CTM104.
Fan belt tension adjuster Replace.
Radiator cap or water in radiator Test, replace cap.
Hydraulic system overheating Verify, repair. See Group 9025-15.
9010 Cooling system passages dirty Flush cooling system.

15
6
Water pump Repair. See CTM104.
Fuel injection pump timing Check injection pump static timing.

See CTM104.
Fuel delivery excessive Remove and adjust fuel injection

Engine Stalls Easily Under Load Engine speed sensor Check engine speed sensor. See
Group 9015-15.
Engine and pump controller Check engine and pump controller.

See Group 9015-15.
Wiring harness Check wiring harness. See Group

9015-15.
Fuel water separator filter plugged Change water separator filter.
Engine Speed Does Not Change Engine control motor Check engine speed control motor.
When RPM Dial Is Rotated See Group 9015-15.
Engine speed sensor Check engine speed sensor. See

Group 9015-15.

See Group 9015-15.

9015-15.
Engine Idle Speed Is Too Fast Or Linkage not adjusted Adjust linkage. See Group 9010-20.
Slow

See Group 9015-15.

101603
PN=126
Engine control motor Check engine speed control actuator

solenoid. See Group 9015-15.
Fuel injection pump Remove and test fuel injection


9015-15. 9010
15
7
Auto Idle Does Not Work Pilot oil pressure switches (boom up, Check pilot oil pressure switches.
dig, and propel) See Group 9015-15.
Engine control motor. Check engine control motor. See

Group 9015-15.
Engine and pump controller Check controller. See Group

9015-15.

9015-15.
Coolant Temperature Too Low Thermostat stuck open Replace thermostat. See CTM104.
Temperature gauge Install new gauge or sending unit.
Oil In Coolant Or Coolant In Oil cooler leaking Test, repair. See CTM104.
Crankcase
Head gasket leaking Inspect, and replace. See CTM104.
Cylinder head cracked Check, replace. See CTM104.
Liner packing leaking and/or cracked Remove pan, inspect bottom end,
cylinder block repair, verify and replace if
necessary. See CTM104.
Low Engine Oil Pressure Oil level low Fill to proper level.
Oil filter plugged Install new oil filter and oil.
Oil pump intake screen plugged or Clean. See CTM104.

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

101603
PN=127
Engine Oil pressure regulating valve Repair valve. See CTM104.
Internal oil passages leak and/or Check, repair. See CTM104.

spray cooling jet missing
Pressure pipe from oil pump leaking Check. See CTM104.
Oil pump drive gear loose Check, repair drive gear. See
9010 CTM104.
15
8
Oil pump gear and/or housing worn Repair. See CTM104.
Excessive main or connecting rod Replace main bearings or

bearing clearance connecting rod bearings. See
CTM104.
High Engine Oil Pressure Oil viscosity wrong (too thick) Drain and refill with correct oil. See
Section 9000, Group 04.
Pressure regulating valve stuck or Verify, repair. See CTM104.

misadjusted
Piston cooling spray orifices plugged Verify, clean. See 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 other

fluid is leaking into oil.
Oil leaks Check engine oil drain plug.
Air cleaner plugged Clean air cleaner elements or install

new elements
Crankcase breather restricted Remove, clean. See CTM104.
Engine operating too hot or oil cooler Test cooling system. See Group
water passage plugged 9010-25. Test thermostat. See
CTM104.
Main or connecting rod bearing Replace main bearings or

clearance excessive connecting rod bearings. See
CTM104.

101603
PN=128
Pistons or liners scored Check, repair pistons or liners. See

CTM104.
Piston rings worn, broken or stuck Do Compression Pressure Test. See

CTM104.
Oil return slots in piston clogged Clean. See CTM104.
Crankshaft thrust bearing worn Check piston and rod assembly. See 9010
(misaligned piston and rod) CTM104. 15
9
Valve guides or valve stems worn Check, repair. See CTM104.
Engine Uses Too Much Fuel Fuel system leakage Tighten connections. See CTM104.
Plugged or dirty air intake Clean air intake system.
Injection pump static timing Check, injection pump static timing.

See CTM104.
Injection nozzles Test, repair nozzles. See CTM104.
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. See

CTM104.
Over-fueling Remove and adjust fuel injection

Injection nozzle orifice plugged Check and repair. See CTM104.
Excessive Blue or White Smoke Cranking speed too slow Check batteries and connections.
See Group 9015-20.
Injection pump static timing Check injection pump timing. See

CTM104.
Engine running too "cold" Check thermostat. See Group 0510

and CTM104.

101603
PN=129
Liners have wear and/or piston ring Do Compression Pressure Test in

stuck CTM104.
Detonation Fuel injection pump static timing Check injection pump static timing.
incorrect and/or injection pump See CTM104.
advance faulty
9010
15 Ether starting aid solenoid stuck Check and repair.
10
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 pump
spindle, seal and housing.
Valve clearance excessive Check, adjust valve. See CTM104.
Engine static timing incorrect Check, adjust. See CTM104.
Push rods bent Inspect, replace push rods. See

CTM104.
Main and/or connecting rod bearing Inspect main bearing cap screws
caps loose or worn and connecting rod cap screws. See
CTM104.
Piston scored Replace piston. See CTM104.
Piston pin bushings worn Replace pins and bushings. See

CTM104.
Rocker arm shafts worn Check. See CTM104.
Crankshaft end play excessive Check, repair. See CTM104.
Balancer shafts out of time Retime. See CTM104.
Turbocharger Excessively Noisy Bearings not lubricated Insufficient oil pressure. Check for
or Vibrates restricted turbocharger oil line.
Worn bearings Replace. See CTM104.
Air leak in engine, intake or exhaust Inspect and repair. See CTM104.
manifold

101603
PN=130
Improper clearance between turbine Remove exhaust elbow and air inlet
wheel and turbine housing hose. Inspect and repair. See
CTM104.
Broken blades on turbine Remove exhaust elbow and air inlet

hose. Inspect and repair. See
CTM104.
Oil Dripping From Turbocharger Damaged or worn bearings and/or Inspect compressor and turbine 9010
Adapter worn seals wheel for damaged blades. Check 15
11
for proper engine service intervals or
dirt entering engine. See CTM104.
Excessive crankcase pressure Check for plugged oil drain line.

Clean.
Turbocharger oil return line carbon Remove line. Inspect and clean.
buildup where line passes exhaust
manifold.
Excessive Drag In Turbocharger Carbon build-up behind turbine Inspect and clean. See CTM104.
Rotating Members wheel caused by combustion
deposits
Dirt build-up behind compressor Inspect and repair. See CTM104.

wheel caused by air intake leaks
Bearing seizure or dirty or worn Check for plugged air filters. See
bearings caused by excessive CTM104.
temperature, unbalanced wheel, dirty
oil, oil starvation, or insufficient
lubrication.
TX,9010,SB112 1918SEP0010/10

101603
PN=131
9010
15
12

101603
PN=132
Group 20
Adjustments
EngineUse CTM104

UN07SEP88
M44215
9010
20

Installation
SERVICE EQUIPMENT AND TOOLS
UN28FEB89
1. Before installing clamp-on electronic tachometer,
remove the paint from a straight section of injection
line within 100 mm (4 in.) of No. 1 injection nozzle.
Use emery cloth to remove the paint.
T6813AG
2. Install the clamp-on transducer (A). Tighten finger tight
onlyDO NOT overtighten.
AClamp-On Transducer
BBlack Clip ()
3. Connect the red clip (+) (C) to the clamp-on CRed Clip (+)
transducer. DDigital Readout Unit
4. Connect the black clip (-) (B) to a ground connection

such as the head of a cap screw or other metal part on
engine.
5. Start the engine. Check for a reading on the digital

readout unit (D).
CED,TX08227,2879 1911NOV971/1

101603
PN=133
Adjustments
Check and Adjust Fuel Shut-Off Solenoid

Linkage
SPECIFICATIONS
Overtravel Needed Distance 36 mm (1/81/4 in.)
Ball Joint Hole-to-Shut-Off Lever 3 turns short
Hole Length
Fuel Shut-Off Solenoid 8 Nm (70 lb-in.)
Plunger-to-Ball Joint Torque
Fuel Shut-Off Lever-to-Run Less than 0.025 mm (0.001 in.)
9010 Position Stop Clearance with key switch ON and solenoid
20 plunger bottomed.
2
Shut-Off Lever Clearance Within 3 mm (0.125 in.) Of Stop
Position Stop

Feeler Gauge
Continued on next page TX,05,GG2305 1922APR981/3

101603
PN=134
Adjustments
1. Disconnect ball joint (C) from fuel shut-off lever (D).
2. Turn key switch to ON. It is not necessary to start

engine for this procedure.
3. Push plunger (F) into solenoid housing until the

plunger bottoms. With key switch ON, solenoid hold
coil is energized and will hold plunger in the run
position
UN04DEC96
4. Manually pull fuel shut-off lever (D) up against the run 9010
position stop (upper stop) (H). 20
3
5. Check that hole in ball joint (C) is 36 mm (1/81/4
T105518
in.) short of aligning with hole in fuel shut-off lever.
The 36 mm (1/81/4 in.) is the amount of overtravel

needed to compress the spring in the plunger to hold
the shut-off lever against the run position stop when
plunger is bottomed in the solenoid housing.
Specification
Overtravel NeededDistance ............................... 36 mm (1/81/4 in.)
6. Adjust ball joint as necessary.
Manually pull fuel shut-off lever up against the run
UN04DEC96
position stop (upper stop).
Adjust ball joint so hole is aligned with hole in shut-off

lever and then turn ball joint to shorten linkage by three
T105519
turns.
Specification
Ball Joint Hole-to-Shut-Off Lever AShut-Off Solenoid
HoleLength .......................................................................... 3 turns short BCap Screw
CBall Joint
DFuel Shut-Off Lever
Hold ball joint and tighten nut. ELock Nut
FPlunger
Specification GStop Position Stop (Lower Stop)
Fuel Shut-Off Solenoid HRun Position Stop (Upper Stop)
Plunger-to-Ball JointTorque .......................................... 8 Nm (70 lb-in.)
7. Turn key switch to OFF.
8. Connect ball joint to fuel shut-off lever using cap screw

(B) and nut (E).

101603
PN=135
Adjustments
IMPORTANT: Failure to have the shut-off lever tight

against run position stop (upper stop)
can result in low engine horsepower.
9. Turn the key switch to ON.
Push plunger into solenoid housing so hold coil holds

the plunger in the run position.
Check that shut-off lever is tight against run position

9010 stop using a 0.025 mm (0.001 in.) feeler gauge. If
20 feeler gauge passes between shut-off lever and stop,
4
shorten the linkage two more turns.
Specification
Fuel Shut-Off Lever-to-Run
Position StopClearance ....................... Less than 0.025 mm (0.001 in.)
with key switch ON and solenoid
plunger bottomed.
10. Turn key switch to OFF.
The spring inside the solenoid housing boot will

extend the plunger to push the shut-off lever down to
the stop position stop (lower stop) (G).
Check that shut-off lever is within 3 mm (0.125 in.) of

stop position stop.
Specification
Shut-Off LeverClearance ..................... Within 3 mm (0.125 in.) Of Stop
Position Stop
TX,05,GG2305 1922APR983/3

101603
PN=136
Adjustments
Engine Speed Check
SPECIFICATIONS 2. Warm engine to normal operating temperature.

Engine Fast Idle in Standard 2100 25 rpm
Mode Speed 3. Turn engine rpm dial fully clockwise to check fast
Engine Slow Idle Speed 900 25 rpm idle.
SERVICE EQUIPMENT AND TOOLS Specification

Engine Fast Idle in Standard
JT05801 Clamp-On Electronic Tachometer ModeSpeed .............................................................. 2100 25 rpm
JT07290 Laptop Computer
9010
JT07274J Excavator Diagnostics Program Disk 4. Turn engine rpm dial fully counterclockwise to 20
JT07273 Cable check slow idle. 5
Specification
1. Connect the tachometer or the laptop computer with Engine Slow IdleSpeed .............................................. 900 25 rpm
excavator diagnostics program. Select 14 Actual
engine speed from Monitor Data Items. (See 5. If engine speeds need adjustment, do Injection
JT05801 Clamp-On Electronic Tachometer Pump Fast and Slow Idle Stops Adjustment. (See
Installation in this group or for laptop computer procedure in this group.)
installation, see procedure in Group 9025-25.)
TX,9010,SB115 1907SEP001/1

101603
PN=137
Adjustments
Injection Pump Fast and Slow Idle Stops

Adjustment
SPECIFICATIONS
Engine
Engine Fast Idle Stop Screw 2300 25 rpm
Speed
Engine Slow Idle Stop Screw 900 25 rpm
Speed
9010 SERVICE EQUIPMENT AND TOOLS

20
6 JT05801 Clamp-On Electronic Tachometer
JT07274J Excavator Diagnostics Program Disk
JT07273 Cable
1. Connect the tachometer or the laptop computer with

excavator diagnostics program. Select 14 Actual
engine speed from Monitor Data Items. (See JT05801
Clamp-On Electronic Tachometer Installation in this
group or for laptop computer installation, see
procedure in Group 9025-25.)
2. Start the engine.
3. Warm engine to its normal operating temperature.
4. Stop the engine.
5. Disconnect speed control cable at the injection pump

lever.
6. Start the engine.

101603
PN=138
Adjustments
9010
20
7
UN16SEP96
T103678
ANut CNut ENut FFast Idle Stop Screw
BSlow Idle Stop Screw DSupplementary Idle Screw
7. Push injection pump lever against fast idle stop Adjust the slow idle stop screw to obtain an
screw (F). Record the engine speed. engine speed that is 3040 rpm less than the
slow idle specification.
Push injection pump lever against slow idle stop
screw (B). Record the engine speed. Hold screw and tighten nut.
EngineSpecification 11. Turn the supplementary idle screw in to increase

Engine Fast Idle Stop Screw
engine speed to the slow idle specification. Hold
Speed........................................................................... 2300 25 rpm
Engine Slow Idle Stop Screw screw and tighten nut.
Speed............................................................................. 900 25 rpm
For example, to obtain the 900 rpm slow idle
Adjust the fast and slow idle stop screws on injection speed, turn the slow idle stop screw (B) out to get
pump as needed. approximately 865 rpm. Hold screw and tighten
the nut. Then turn the supplementary idle screw
8. Loosen nut (C) on the supplementary idle screw (D) in to increase engine speed to 900 rpm. Hold
(D). Turn the screw out three turns. screw and tighten nut.
9. Loosen nut (A) on the slow idle stop screw (B) 12. Pull injection pump lever rapidly to fast idle then
decelerate to slow idle. Slow idle must be to
10. Hold injection pump lever against the slow idle specification.
stop screw.

101603
PN=139
Adjustments
NOTE: Increasing slow idle setting a small amount, NOTE: The fast idle stop screw on the injection pump
but no more than the maximum specifications, serves as the stop when the HP (high power)
may help to reduce surging or hunting. If mode is actuated.
surging or hunting continues, repair injection
pump. 14. Stop the engine. Connect the cable to lever.
13. Loosen nut (E) on fast idle stop screw (F). 15. Do Engine Control Motor and Sensor Adjustment
and then the Engine Speed Learning Procedure.
Pull lever against fast idle stop screw. Turn screw (See procedures in this group.)
in to decrease engine speed; turn screw out to
9010 increase engine speed. Hold screw and tighten
20 nut.
8
TX,9010,SB125 1907SEP003/3
Engine Control Motor and Sensor

Adjustment
SPECIFICATIONS
Arm-to-Engine Control Motor 13 Nm (115 lb-in.)
Shaft Cap Screw Torque
When the following components are repaired or replaced,

or when engine speeds deviate from specification, the
engine control motor and sensor adjustment and engine
learning control procedure must be performed.
Engine
Engine speed control cable
Engine control motor and sensor
Engine and pump controller
Fast and slow idle stop screws
NOTE: The engine control sensor is located inside the

engine control motor housing. Sensor is serviced
as an assembly with the engine control motor.
1. Check that fast and slow idle stop screws on the

injection pump are adjusted to specification. (See
Injection Pump Fast and Slow Idle Stops Adjustment in
this group.)
2. Turn key switch to ON.
Continued on next page CED,OUTX782,504 1915SEP001/3

101603
PN=140
Adjustments
3. Turn the engine rpm dial (A) to slow idle.
AEngine RPM Dial
UN27JUN96
T101749
9010
20
CED,OUTX782,504 1915SEP002/3 9
4. Check that engine speed control cable is connected to

the inner hole of engine control motor arm (B).
5. Loosen cap screw (A) in arm (B).
6. Adjust the arm on the shaft so injection pump lever just
UN11SEP96
contacts the slow idle stop screw.
7. Tighten cap screw (A).
T103663
Engine Control Motor and SensorSpecification
Arm-to-Engine Control Motor
Shaft Cap ScrewTorque ........................................... 13 Nm (115 lb-in.)
ACap Screw
8. Do the Engine Speed Learning Procedure. (See BArm
procedure in this group.)
CED,OUTX782,504 1915SEP003/3

101603
PN=141
Adjustments
Engine Speed Learning Procedure
SPECIFICATIONS
Engine Speed Learning Procedure
Engine Slow Idle Speed 900 25 rpm
Engine Auto-Idle Speed 1200 25 rpm
Engine E (Economy) Mode 1850 25 rpm
Speed
Mode Speed
9010
20
10 When the following components are repaired or replaced,
or when engine speeds deviate from specification, the
engine control motor adjustment and engine learning
control procedure must be performed.
Engine
Engine speed control cable
Engine control motor and sensor
Engine and pump controller
Fast and slow idle stop screws
1. Stop the engine.
2. Disconnect the laptop computer from the test

connector.
Wait for 5 seconds.

101603
PN=142
Adjustments
3. Push engine learning switch (C) up to top position. The

switch is a three position switch. Make sure it is in the
top position.
4. Turn key switch ON. Wait 5 seconds.
5. Turn key switch OFF. Wait 5 seconds.
6. Push engine learning switch to middle position.
7. Check engine speeds. 9010

20
Engine Speed Learning ProcedureSpecification 11
Engine Slow IdleSpeed .................................................... 900 25 rpm
25 rpm
UN11SEP96
Engine Auto-IdleSpeed ................................................... 1200
Engine E (Economy) Mode
Speed ................................................................................. 1850 25 rpm
ModeSpeed ..................................................................... 2100 25 rpm
T103674
NOTE: The laptop computer with the excavator diagnostic
software can be used to change the default
speeds for slow idle, auto-idle, economy mode, CEngine Learning Switch
and fast idle in standard mode. See Excavator
Diagnostics Program Special FunctionEngine
Speed Adjustment in Group 9025-25.
TX,9010,SB126 1912SEP002/2

101603
PN=143
Adjustments
Cooling System Fill and Deaeration
SPECIFICATIONS deaerate. It will NOT deaerate during

Cooling System Capacity 28.4 L (7.5 gal) normal operation. Only during
warm-up and cool down cycles will
Freezing Temperatures the system deaerate.
IMPORTANT: Use only permanent-type low silicate 1. Start engine. Run engine until coolant reaches a
ethylene glycol base antifreeze in warm temperature.
coolant solution. Other types of
9010 antifreeze may damage cylinder 2. Stop engine. Allow coolant to cool.
20
seals.
12
3. Check coolant level at recovery tank.
Fill cooling system with permanent-type, low silicate,
ethylene glycol antifreeze (without stop-leak additive) 4. If necessary, fill recovery tank to FULL mark.
and clean, soft water.
5. Repeat Steps 14 until recovery tank coolant level
Fill is repeatedly at the same level (stabilized).
1. Fill the radiator to the bottom of the fill neck. NOTE: The level of the coolant in the cooling system
MUST BE repeatedly checked after all drain
2. Fill the coolant recovery tank to the FULL mark. and refill procedures to ensure that all air is
out of the system which allows the coolant
Specification level to stabilize. Check coolant level only
Cooling SystemCapacity ......................................... 28.4 L (7.5 gal) when the engine is cold.
Deaeration 6. Install recovery tank and radiator caps.
IMPORTANT: The cooling system requires several

warm-up and cool down cycles to
CED,OUOE003,1058 1907SEP001/1

101603
PN=144
Group 25
Tests
EngineUse CTM104

UN07SEP88
M44215
9010
25

101603
PN=145
Tests
Fuel Line Leakage Test
SPECIFICATIONS
Fuel Line Leakage Test Pressure 69 kPa (0.7 bar) (10 psi)
To Prevent Fuel System 103 kPa (1 bar) (15 psi)
Component Damage Never
Exceed Maximum Pressure
Connections may allow air to enter the fuel system without

allowing fuel to leak out. Follow this procedure to find air
9010 leaks in the system.
25
2
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 short

length of hose, plug, and clamps.
IMPORTANT: Never exceed 103 kPa (1 bar) (15 psi) to

prevent damage to fuel system
components.
Pressurize the system to 69 kPa (0.7 bar) (10 psi) at the

fuel supply line using a regulated pressure air source.
Specification
Fuel Line Leakage Test
Pressure ............................................................. 69 kPa (0.7 bar) (10 psi)
To Prevent Fuel System
Component Damage Never
Exceed MaximumPressure .............................. 103 kPa (1 bar) (15 psi)
Apply liquid soap and water solution to all joints and

connections 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, an

internal leak path may allow air to enter the fuel
system. If an internal pump leak is suspected,
remove the pump and have a pressure test
performed by an authorized repair station.
TX,9010,SB119 1911AUG981/1

101603
PN=146
Tests
Air Filter Restriction Indicator Switch Test
SPECIFICATIONS
Air Filter Restriction Indicator 6.2 kPa (62 mbar) (25 in. water)
Must Come On At Vacuum
ESSENTIAL TOOLS
JT05652 (1/8 F NPT x 1/8 F NPT x 1/8 M NPT) Tee
JT03246 (1/4 F NPT x 1/4 F NPT) (Parker No. 0202-4-4) Coupler
SERVICE EQUIPMENT AND TOOLS 9010

25
(1/8 in.) Barbed Fitting 3
(1/4 in.) Barbed Fitting
015 kPa (0150 mbar) (060 in. water) Vacuum Gauge
1. Remove air restriction indicator switch (A).
2. Install parts as shown.
3. Start engine and slowly cover the air cleaner inlet with
UN17DEC90
a piece of paper or cardboard.
4. Air filter restriction indicator (light) must come on.
T7350EP
Specification
Air Filter Restriction Indicator
Must Come On AtVacuum .................. 6.2 kPa (62 mbar) (25 in. water)
ASwitch
BTee
5. If reading is not within specifications, install a new
CBarbed Fitting
indicator switch. DTube
EBarbed Fitting
FCoupler
GGauge
TX,9010,SB120 1930MAR001/1

101603
PN=147
Tests
Air Intake System Leakage Test
SPECIFICATIONS
Air Intake System Leakage Test 1421 kPa (0.140.21 bar) (2
Pressure 3 psi)
UN23FEB89
OTHER MATERIAL
T43512 U.S. Thread Lock and Sealer (Medium Strength)
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
T5906AP
242 Thread Lock and Sealer (Medium Strength)
9010
25
4 1. Remove air cleaner cover and main filter element.
2. Put large plastic bag into and over end of main filter
element as shown. Install main filter element and
cover.
3. Remove plug (A) from tube between turbocharger and
UN12SEP96
intake manifold.
4. Connect air pressure regulator to manifold using hose

and fitting from manifold pressure tester.
T103680
5. Pressurize air intake system to 1421 kPa (0.14
0.21 bar) (23 psi). If intake system cannot be
pressurized, turn engine slightly to close valves. APlug
Specification
Air Intake System Leakage
TestPressure ............................................. 1421 kPa (0.140.21 bar)
(23 psi)
6. Spray soap solution over all connections from the air

cleaner to turbocharger or air intake manifold and
check for leaks. Correct all leaks.
7. Apply thread lock and sealer (medium strength) to

plug. Install plug into intake manifold and tighten.
TX,9010,SB121 1917JUN981/1

101603
PN=148
Tests
Radiator Air Flow Test
SPECIFICATIONS
Engine Speed Fast Idle
Air Flow Meter Total Reading 7.20 V (typical new)
Equal to or Greater Than Voltage
ESSENTIAL TOOLS
JT05529 Air Flow Meter
SERVICE EQUIPMENT AND TOOLS 9010

25
JT07306 Analog/Digital Multimeter 5
1. Lower all equipment to the ground.
2. Position all levers and pedals in neutral.
3. Stop the engine.
4. Straighten any bent fins in radiator or oil cooler.
CED,OUOE003,653 1913JUN981/4
5. Divide the surface of trash screen into 36 equal

squares starting at the top.
6. Connect air flow meter to analog/digital multimeter. Set

multimeter to AC volts.
7. Start engine and run it at fast idle.
Specification
EngineSpeed ............................................................................ Fast Idle
1912SEP96
T103681
Continued on next page CED,OUOE003,653 1913JUN982/4

101603
PN=149
Tests
8. Put air flow meter against the trash screen so it is

centered in a square and air flow is through meter in
the direction of air flow arrow.
9. Record voltage reading for each square that is not

marked out with an X.
NOTE: Make a copy of the JT05529 Air Flow Meter Test

Record shown on the following page. Use to
make a record of the voltage readings and
9010 machine information.
25
6
10. Add the voltage readings. The total of readings must
be equal to or greater than the specification.
Specification
Air Flow Meter Total Reading
Equal to or Greater Than
Voltage........................................................................ 7.20 V (typical new)
11. If readings are less than specification, clean the trash
UN01NOV88
screen and external surfaces of oil cooler and
radiator. Repeat test.
T6080AH

101603
PN=150
Tests
9010
25
7
1921MAR89
T6500AK
1. Divide surface of trash screen into 36 equal squares
starting at the top.
2. Start engine and run it at fast idle.
Specification
3. Put air flow meter against the trash screen so it is

centered in a square and air flow is through meter in
the direction of air flow arrow.
4. Record voltage reading for each square not marked

out with an X.
1912SEP96
5. The combined total of voltage readings must be equal

to or greater than specification.
T103681
CED,OUOE003,653 1913JUN984/4

101603
PN=151
Tests
Engine Power Test Using Turbocharger

Boost Pressure
SPECIFICATIONS
Engine Fast Idle Speed 2100 25 rpm in standard mode
Combined Pump Engine 100 rpm approximate with arm in
Pulldown Speed over relief
HP Mode Switch Position On
Rated Engine Speed 2100 rpm
9010 Turbocharger Boost Pressure 68.989.6 kPa (0.690.90 bar)

25 (1013 psi) using No. 2 fuel and
8 no muffler
Turbocharger Boosta Pressure 64.183.4 kPa (0.640.83 bar)
(9.312.1 psi) using No. 1 fuel
and no muffler
a
Turbocharger boost pressure is reduced by 7% if using No. 1 fuel.

JT07273 Cable
JT07248 Turbo Boost Test Kit
OTHER MATERIAL
T43512 U.S. Thread Lock and Sealer (Medium Strength)
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
242 LOCTITE Thread Lock and Sealer (Medium Strength)
This procedure must only be used as a guide to

determine engine condition.
1. Connect tachometer or the laptop computer with

excavator diagnostics program. (See JT05801
Clamp-On Electronic Tachometer Installation in Group
9010-20. For laptop computer, see procedure in Group
9025-25. Select 14 Actual engine speed from Monitor
Data Items.)
LOCTITE is a trademark of Loctite Corp. Continued on next page CED,TX08227,3198 1907SEP001/4

101603
PN=152
Tests
2. Remove plug (A) from tube between turbocharger and

intake manifold.
3. Install fitting, hose, and pressure gauge.
4. Warm engine to normal operating temperature.
UN12SEP96
5. Turn engine rpm dial to fast idle.
Specification
T103680
Engine Fast IdleSpeed ...................... 2100 25 rpm in standard mode 9010
25
6. Check combined pump engine pulldown using arm in 9
function over relief. APlug
Specification
Combined Pump Engine
PulldownSpeed .................................. 100 rpm approximate with arm in
over relief
If combined pump engine pulldown is not approximately

100 rpm, turn the load adjusting cartridge on the pump
regulators in equal amounts to obtain 100 rpm combined
pump engine pulldown. (See Hydraulic Pump Regulator
Test and AdjustmentEngine Pulldown in Group
9025-25.)
Be sure to turn the load adjusting cartridges out to their

original setting at the end of test.
7. Push the HP mode switch on. The HP mode indicator

on.
Specification
HP Mode SwitchPosition ................................................................... On
NOTE: HP mode is actuated so the injection pump lever

is pushed against the fast idle stop on the
injection pump as the hydraulic pressure
increases. With the injection pump lever against
the fast idle stop, the maximum amount of fuel is
delivered to the engine.
8. Watch the engine speed and pressure.
9. Slowly actuate arm in function over relief to load the

engine pulling the speed down below rated engine
speed. Repeat this step at least six times.

101603
PN=153
Tests
Specification
Rated EngineSpeed ................................................................. 2100 rpm
NOTE: If using the JT07248 Turbo Boost Kit, a check

valve at the pressure gauge inlet traps the highest
reading for boost pressure and does not decrease
as the pressure decreases.
10. Record the highest pressure reading at rated engine

speed. The pressure increases as the engine speed
9010 is pulled down to rated engine speed and then
25 decreases.
10
Specification
Turbocharger BoostPressure .............. 68.989.6 kPa (0.690.90 bar)
(1013 psi) using No. 2 fuel and
no muffler
Turbocharged Boost1Pressure ............ 64.183.4 kPa (0.640.83 bar)
(9.312.1 psi) using No. 1 fuel
and no muffler
IMPORTANT: Pressure gauge accuracy is very critical

for this test. Do not make adjustments
to injection pump fuel delivery on the
machine to raise or lower boost
pressure.
New engine may not develop specified

boost pressure. Check after 50 hours of
operation.
11. If turbocharger boost pressure is low, check the

following:
Wrong fuel.
Restricted air filter elements.
Restricted fuel filter elements.
Incorrect injection pump timing.
Incorrect fast idle stop adjustment at injection pump
for HP mode. (See Injection Pump Fast and Slow
Stops Adjustment in this group.)
Exhaust manifold leaks.
Intake manifold leaks.
Faulty fuel pump.
Low compression pressure.
1
Turbocharger boost pressure is reduced by 7% if using No. 1 fuel.

101603
PN=154
Tests
Cam lobe wear (valve clearance).

Faulty fuel injection nozzles.
Carbon build-up in turbocharger.
Turbocharger compressor or turbine wheel rubbing
housing.
12. Remove gauge and fitting.
13. Apply thread lock and sealer (medium strength) to

plug.
9010
Tighten plug. 25
11
14. Turn the load adjusting cartridge on the pump

regulators out to their setting. (See Hydraulic Pump
Regulator Test and AdjustmentEngine Pulldown in
this group.)
CED,TX08227,3198 1907SEP004/4

101603
PN=155
Tests
Inspect Torsional Dampener
SPECIFICATIONS
Torsional Dampener Radial 1.50 mm (0.060 in.) maximum
Runout
Torsional Dampener Axial Runout 1.50 mm (0.060 in.) maximum
UN23NOV97
(Wobble)
ESSENTIAL TOOLS
JDG820 Flywheel Turning Tool
RG7507
9010
12
D17526CI Dial Indicator
IMPORTANT: Do not immerse the torsional dampener

in cleaning solvent or any petroleum
product. Rubber portion of dampener
may be damaged. Never apply thrust on
outer ring. Dampener is sensitive to
impact damage, such as being dropped
or struck with a hammer. The dampener
is not repairable. Replace dampener
whenever crankshaft is replaced or after
major engine overhaul.
1. Grasp outer ring of torsional dampener and attempt to

turn it in both directions. If rotation is felt, replace
dampener. Also, if rubber is separated, partially
missing, or displaced, replace dampener.
CED,OUOE003,1059 1912AUG981/3
2. Check radial runout by positioning a dial indicator so

probe contacts dampener OD.
3. With engine at operating temperature, rotate crankshaft

using flywheel turning tool.
UN23NOV97
4. Note dial indicator reading. If radial runout exceeds

specification, replace torsional dampener.
Specification
RG7508
Torsional DampenerRadial
Runout ........................................................ 1.50 mm (0.060 in.) maximum
Continued on next page CED,OUOE003,1059 1912AUG982/3

101603
PN=156
Tests
5. Check axial runout (wobble) using a dial indicator.

Measure axial runout at the outer edge of dampener
face (A).
6. Rotate crankshaft one complete revolution using

flywheel turning tool. Note total dial indicator reading. If
axial runout exceeds specification, replace torsional
dampener.
Specification
UN31OCT97
Torsional DampenerAxial 9010
Runout (Wobble) ........................................ 1.50 mm (0.060 in.) maximum 25
13
ATorsional Dampener Face
RG5679
CED,OUOE003,1059 1912AUG983/3

101603
PN=157
Tests
9010
25
14

101603
PN=158
Section 9015
Electrical System
Contents
Page Page
Group 05System Information System Functional Schematic (SE16

Electrical System SE18) . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-15
Visual Inspection . . . . . . . . . . . . . . . . . . . .9015-05-1 Engine and Frame Harness (W1)
Electrical Circuit Component Location . . . . . . . . . . . . . . . .9015-10-16
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 Connectors, Wire and Pin Location . . . . .9015-10-17
Circuit Malfunction Cab Harness (W2)
High Resistance. . . . . . . . . . . . . . . . . . . . .9015-05-3 Component Location . . . . . . . . . . . . . . . .9015-10-20 9015
Open Circuit . . . . . . . . . . . . . . . . . . . . . . .9015-05-5 Component Location--Detail A (Harness
Grounded Circuit . . . . . . . . . . . . . . . . . . . .9015-05-8 Mating Connectors) . . . . . . . . . . . . . . .9015-10-21
Circuit Shorted. . . . . . . . . . . . . . . . . . . . .9015-05-10 Component Location--Detail B (Fuse
Sensor Circuit Shorted to Power . . . . . . .9015-05-12 Block). . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-22
Sensor Circuit Shorted to Itself . . . . . . . .9015-05-14 Connectors, Wire and Pin Location . . . . .9015-10-23
Sensor Circuit Shorted to Ground . . . . . .9015-05-16 Monitor and Relay Harness (W3)
Using Test Equipment Component Location . . . . . . . . . . . . . . . .9015-10-28
Multimeter . . . . . . . . . . . . . . . . . . . . . . . .9015-05-17 Component Location--Detail A (Monitor
Seven Step Electrical Test Procedure . . .9015-05-18 Controller Connectors) . . . . . . . . . . . . .9015-10-29
Schematic, Wiring Diagram, and Component Component Location--Detail B (Monitor
Location Information . . . . . . . . . . . . . . . .9015-05-20 Controller Indicators) . . . . . . . . . . . . . .9015-10-30
Reading a System Functional Schematic . .9015-05-22 Connectors, Wire and Pin Location . . . . .9015-10-31
Reading a Wiring Diagram . . . . . . . . . . . . .9015-05-24 Air Conditioner Harness (W9)
Reading a Component Location Component Location--See Group
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-26 9031-15 . . . . . . . . . . . . . . . . . . . . . . . .9015-10-33
Reading a Connector End View Connectors, Wire and Pin Location--See
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-28 Group 9031-15 . . . . . . . . . . . . . . . . . . .9015-10-33
Electrical Schematic Symbols . . . . . . . . . . .9015-05-30
Group 15Sub-System Diagnostics
Group 10System Diagrams Power Circuit
Fuse Specifications . . . . . . . . . . . . . . . . . . . .9015-10-1 Operational Information . . . . . . . . . . . . . . .9015-15-1
Fuse Theory of Operation. . . . . . . . . . . . . . . . . .9015-15-2
(Blade-Type) Color Codes . . . . . . . . . . . . .9015-10-2 Schematic . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-3
Component Identification Table . . . . . . . . . . .9015-10-3 Power Circuit Diagnostic Procedures . . . . . .9015-15-4
Functional Schematic and Component Charging Circuit
Location Operational Information . . . . . . . . . . . . . . .9015-15-8
Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-5 Theory of Operation. . . . . . . . . . . . . . . . . .9015-15-8
System Functional Schematic Schematic . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-9
Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-9 Altermator Operation 45 Amp BOSCH . . .9015-15-10
System Functional Schematic (SE1 Charging Circuit Diagnostic Procedures . . .9015-15-11
SE3) . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-10 Starting and Fuel Shutoff Circuit
System Functional Schematic (SE4 Operational Information . . . . . . . . . . . . . .9015-15-14
SE6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-11 Theory of Operation. . . . . . . . . . . . . . . . .9015-15-14
System Functional Schematic (SE7 Starting Circuit and Fuel Shutoff Circuit
SE9) . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-12 Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-15
System Functional Schematic (SE10 Starting and Fuel Shutoff Circuit Diagnostic
SE12) . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-13 Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-16
System Functional Schematic (SE13
SE15) . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-14 Continued on next page

101603
PN=1
Contents
Page Page
Windshield Wiper and Washer Circuit Battery

Operational Information . . . . . . . . . . . . . .9015-15-22 Using Booster Batteries---24 Volt
Theory of Operation. . . . . . . . . . . . . . . . .9015-15-23 System . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-7
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-26 Replacing. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-8
Windshield Wiper and Washer Circuit Batteries
Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-27 Adding 12 or 24 Volt Accessories . . . . . . .9015-20-9
Light Circuit Travel Alarm
Operational Information . . . . . . . . . . . . . .9015-15-32 Changing Volume . . . . . . . . . . . . . . . . . .9015-20-10
Work and Drive Light Circuit Proportional Solenoid
Theory of Operation. . . . . . . . . . . . . . . . .9015-15-32 Test Harness . . . . . . . . . . . . . . . . . . . . . .9015-20-11
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-33 Pump Control
Work and Drive Light Circuit Diagnostic Test Harness . . . . . . . . . . . . . . . . . . . . . .9015-20-11
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-34 Pump Pressure Sensor
9015 Test Harness . . . . . . . . . . . . . . . . . . . . . .9015-20-11
Accessory Circuits
Operational Information . . . . . . . . . . . . . .9015-15-38
Theory of Operation. . . . . . . . . . . . . . . . .9015-15-38
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-39
Accessory Circuits Diagnostic
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-40
Heater Circuit (Machines Without Air
Conditioner) . . . . . . . . . . . . . . . . . . . . . . .9015-15-42
Heater Circuit (Machines With Air
Conditioner) . . . . . . . . . . . . . . . . . . . . . . .9015-15-42
Monitor Controller and Display Circuit
Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-42
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-51
Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-52
Engine and Pump Controller Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-69
Engine and Pump Controller Circuit
Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-70
Travel Alarm Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-95
Travel Alarm Circuit Diagnostic
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-96
Group 20References
Battery
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Specification . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Diagnose Malfunctions. . . . . . . . . . . . . . . .9015-20-2
Check Electrolyte Level and Terminals . . .9015-20-4
Batteries
Procedure for Testing . . . . . . . . . . . . . . . .9015-20-6

101603
PN=2
Group 05
System Information
Electrical System Visual Inspection
Make the following visual electrical inspection prior to

starting the machine after receiving customer complaint:
1. Look for bare wires that could ground a component or

short across to another component.
2. Look for missing or worn conduit. This could indicate a

wire problem.
3. Look for loose or broken connectors and wires.
4. Inspect batteries for:
Corroded terminals
9015
Loose terminals or battery posts 05
Dirty condition 1
Damp condition
Cracked case
Proper electrolyte level
5. Check alternator belt tension.
6. Turn the key switch to the IGN position. Try out the
accessory circuits, indicator lights, gauge lights. How
does each of these components work? Look for sparks
or smoke which might indicate shorts.
7. Start machine. Check all gauges for good operation

and check to see if system is charging or discharging.
8. After machine has been shut down for five minutes

inspect for overheated parts. They will often smell like
burned insulation. Put your hand on the alternator.
Heat in these parts when the unit has not been
operated for some time is a sure clue to charging
circuit problems.
9. In general, look for anything unusual.
Many electrical failures cannot be detected even if the

machine is started. Therefore, a systematic and complete
inspection of the electrical system is necessary.
CED,OUTX466,1353 1903FEB991/1

101603
PN=161
System Information
Electrical Circuit Malfunctions
9015
05
2
UN17JUL03
T128740
1Battery 3Switch 4Load (Light) 5Ground
2Fuse
CIRCUIT MALFUNCTIONS Between the component, light (4) and ground (5).
There are four common circuit malfunctions: Component malfunctions can easily be confused with
circuit malfunctions, as illustrated in the following
High-Resistance Circuit. example:
Open Circuit.
Grounded Circuit. Example: Light (4) does not operate switch (3) is
Shorted Circuit. turned ON. After disconnecting and connecting switch
(3), light (4) functions normally.
LOCATION OF CIRCUIT MALFUNCTIONS
Reason: Corrosion on the terminals of switch (3)
There are three sections in a simple circuit where have restricted or prevented the flow of current in the
these malfunctions can occur: circuit. The failure of light (4) to come ON appears to
be a component malfunction, but further examination
Between the battery (1) and the controlling switch of the circuit reveals a circuit malfunction in the form of
(3). a bad connection.
Between the controlling switch (3) and before the
component, light (4).
CED,TX17984,438 1924FEB001/1

101603
PN=162
System Information
High Resistance Circuit
9015
05
3
UN17JUL03
T128750
1Battery 4Switch Terminal 6Connector 8Load (Light)
2Fuse 5High Resistance 7Component Terminal 9Ground
3Switch
Definition of a High Resistance Circuit: A high until normal voltage is found. The malfunction is
resistance circuit has additional resistance which can between last two points of measurement.
prevent a component from operating normally. High
resistance can be caused by loose, dirty, corroded, or 4. If voltage at component terminal (7) is less than
oily terminals. Broken strands inside a wire or a wire voltage at switch terminal (4), the high resistance is
that is too small for an application may also cause high between these two points. Starting at component
resistance. In the above circuit, high resistance (5) terminal (7), continue measuring voltage toward
may cause light (8) to be dim or not to function. switch terminal (4) until normal voltage is found.
The malfunction is between last two points of
Troubleshooting a High Resistance Circuit: measurement.
1. Turn switch (3) ON. In the example, battery voltage will be present at
switch terminal (4), but voltage will be low at
2. Measure voltage at switch terminal (4) and component terminal (7). Checking voltage toward
component terminal (7). switch terminal (4), low voltage will be present at
connector (6), indicating high resistance (5) in the
3. If voltage is low at switch terminal (4), the harness between switch terminal (4) and connector
malfunction is between the switch (3) and battery (6).
(1). Continue measuring voltage toward battery (1)
Continued on next page CED,TX17984,446 1925FEB001/2

101603
PN=163
System Information
5. If voltage is normal at component terminal (7), the ground (9) until low voltage is found. The
malfunction is between the component (8) and malfunction is between last two points of
ground (9). Continue measuring voltage toward measurement.
CED,TX17984,446 1925FEB002/2
9015
05
4

101603
PN=164
System Information
Open Circuit
9015
05
5
UN17JUL03
T128784
1Battery 4Switch Terminal 6Connector 8Load (Light)
2Fuse 5Broken Wire 7Component Terminal 9Ground
3Switch
Definition of an Open Circuit: An open circuit has a 4. If no voltage is at switch terminal (4), the
physical break that prevents the flow of current and malfunction is between the switch (3) and battery
results in no component operation. Open circuits can (1). Continue check for voltage toward battery (1)
be caused by a broken wire (5), disconnected until normal voltage is found. The malfunction is
connector (6), blown fuse (2), or disconnected ground between last two points of measurement.
(9).
5. If battery voltage is indicated at switch terminal (4)
Troubleshooting an Open Circuit: but not at component terminal (7), the malfunction
is between these two points. Starting at component
1. Check fuse (2). If blown, replace and operate terminal (7), continue checking for voltage toward
circuit. If fuse blows a second time, continue check. switch terminal (4) until normal voltage is found.
The malfunction is between last two points of
2. Turn switch (3) ON. measurement. Connector (6) might be an easy
location to check for voltage or a disconnected pin.
3. Measure battery voltage between switch terminal
(4) and component terminal (7).

101603
PN=165
System Information
In the example, voltage will be present at switch 6. If voltage is normal at component terminal (7), the
terminal (4), but no voltage at component terminal malfunction is between the component (8) and
(7). Checking voltage toward switch terminal (4), ground (9). Continue checking for voltage toward
zero voltage will be present at connector (6), ground (9) until normal voltage is found. The
indicating a broken wire (5) in the harness between malfunction is between last two points of
switch terminal (4) and connector (6). measurement.
CED,TX17984,447 1925FEB002/2
9015
05
6

101603
PN=166
System Information
9015
05
7

101603
PN=167
System Information
Grounded Circuit
9015
05
8
UN17JUL03
T128751
1Battery 4Fuse Terminal (Circuit side) 7Wire Insulation Burned or 9Component Terminal
2Fuse 5Switch Worn 10Load (Light)
3Fuse Terminal (Battery 6Switch Terminal 8Short to Ground 11Ground
Side)
Definition of a Grounded Circuit: A grounded circuit 2. Turn switch (5) OFF.

occurs when a spot in the circuit is exposed, or has
zero resistance, to machine ground. This can be 3. Measure continuity to ground at fuse side of switch
caused when the insulation is worn or burned off of a (5).
wire and usually results in no component operation or
fuses repeatedly being blown. a. If continuity to ground is indicated, there is a
short to ground between fuse terminal (4) and
Troubleshooting a Grounded Circuit: switch (5). Inspect wire harness in this area.
1. Remove and inspect fuse (2). b. If continuity to ground does not exist, go to next
step.
a. If fuse is good, the circuit is grounded between
battery and fuse, wire will be burned and circuit 4. Disconnect component terminal (9).
will be open.
5. Measure continuity to ground at wire lead from
b. If fuse is blown, do not replace fuse and component terminal (9).
continue checking for short to ground.

101603
PN=168
System Information
a. If continuity to ground is indicated, there is a 6. Disconnect ground (11), leave component terminal
short to ground between switch terminal (6) and (9) disconnected.
component terminal (9). Inspect wire harness in
this area. 7. Measure continuity to ground at ground connection
(11).
In the example, continuity to ground will be
present at the wire lead from component a. If continuity to ground is indicated, there is a
terminal (9). Inspecting the wire harness toward short to ground between component (10) and
switch terminal (6), an area of burned wire ground connection (11). Inspect wire harness in
insulation (7) will be found making contact to this area.
machine ground (8).
b. If continuity to ground does not exist, replace
b. If continuity to ground does not exist, go to next component (10). The component may have an
step. internal short to ground.
9015
05
9
CED,TX17984,448 1925FEB002/2

101603
PN=169
System Information
Shorted Circuit
9015
05
10
UN29FEB00
T128752
1Battery 5Switch S2 8Light E2 11Light E1
2Fuse F1 6Circuit Wire Shorted to 9Circuit Ground 12Switch S1
3Fuse F2 Circuit 10Circuit Ground
4Battery Wire Shorted to 7Circuit Wire Shorted to
Circuit Ground
Definition of a Shorted Circuit: A shorted circuit has 2. Light E1 (11) remains ON.
a power wire with its insulation burned or rubbed
through, contacting a wire in another circuit causing a 3. A short to battery power (4) is located before switch
short (4, 6, or 7). This allows current to flow to several S2 (5) and after switch S1 (12).
components when a switch from either circuit is turned
ON. Fuse (3) will blow immediately when switch (5) is 4. Inspect wire harness for burned or pinched wires
turned ON, whenever a wire is shorted to ground (7). between switch S1 (12) and light E1 (11) of circuit 1
and between fuse F2 (3) and switch S2 (5) of circuit
Troubleshooting a Shorted Circuit: The above 2.
diagram shows two circuits shorted in three different
locations. A troubleshooting procedure is given for Power Wire Shorted to Circuit
each shorted location.
1. Turn switch S1 (12) ON and switch S2 (5) OFF.
Battery Wire Shorted to Circuit
2. Light E1 (11) and light E2 (8) come ON. One or
1. Turn switch S1 (12) and switch S2 (5) OFF. both lights may be dim.

101603
PN=170
System Information
3. Turn switch S1 (12) OFF and switch S2 (5) ON. 3. Turn switch S1 OFF.
4. Light E2 (8) and light E1 (11) come ON. One or 4. Turn switch S2 (5) ON.
both lights may be dim.
5. Fuse F2 (3) will blow immediately when switch S2
5. A short to switched power (6) is located between (5) is turned ON.
circuit 1 and 2, after switches S1 and S2 (12, 5),
and before light E1 and E2 (11, 8). 6. A short to ground (7) is located between switch S2
(5) and light E2 (8) of circuit 2, and after light E1 of
6. Inspect wire harness for burned or pinched wires circuit 1.
between switch S1 (12) and light E1 (11) of circuit 1
and between switch S2 (5) and light E2 (8) of circuit 7. Inspect wire harness for burned or pinched wires
2. between switch S2 (5) and light E2 (8) of circuit 2,
and between light E1 (11) and ground (10) of circuit
Power Wire Shorted to Ground 1.
9015
1. Turn switch S1 (12) ON, leave switch S2 (5) OFF. 05
11
2. Light E1 (11) and light E2 (8) come ON. One or
both lights may be dim. Light E1 and E2 (11, 8) can
come ON even if fuse F2 (3) is blown.
CED,TX17984,449 1925FEB002/2

101603
PN=171
System Information
Sensor Circuit Shorted to Power
9015
05
12
UN17JUL03
T128748
1Battery 5Sensor Power Wire Shorted 7Sensor Ground Wire 10Sensor
2Fuse F1 to Power Shorted to Power 11Controller
3Fuse F2 6Sensor Signal Wire Shorted 8Load (Light) 12Controller Ground
4Switch to Power 9Circuit Ground
Definition of a Sensor Circuit Shorted to Power: A Sensor Power Wire Shorted to Power (5)
sensor circuit shorted to power has one or more
sensor wires shorted to a power source. A sensor 1. The controller may display a maximum upper or
power wire shorted to power (5) may damage the lower reading.
sensor. A sensor signal wire shorted to battery power
(6) may cause the sensor to display a false reading, or 2. The sensor may be damaged, with no signal given
damage the sensor. A sensor ground wire shorted to to the controller.
power (7) may cause fuse F2 (3) to blow when switch
S2 (4) is turned ON. 3. The controller may be damaged, with no display for
that sensor.
Troubleshooting a Sensor Circuit Shorted to
Power: The above diagram shows a sensor circuit 4. The controller may or may not generate a service
shorted to power in three different locations. A few code.
symptoms for each shorted location are given below.
Due to the complexity of sensor and controller, not all Sensor Signal Wire Shorted to Power (6)
symptoms are listed.

101603
PN=172
System Information
1. The controller may display a maximum upper or Sensor Ground Wire Shorted to Power (7)
lower reading.
1. The sensor and controller may function normally
2. The sensor may be damaged, with no signal given when switch (4) is OFF.
to the controller.
2. Fuse F2 (3) may blow when switch (4) is turned
3. The controller may be damaged, with no display for ON.
that sensor.
3. The controller may generate a Short to Ground
4. The controller may or may not generate a service service code.
code.
5. The sensor and controller may function normally

when switch (4) is OFF.
9015
05
13
CED,TX17984,450 1928FEB002/2

101603
PN=173
System Information
Sensor Circuit Shorted to Itself
9015
05
14
UN17JUL03
T128785
1Battery 4Controller 6Sensor Power Wire Shorted 8Sensor
2Fuse 5Sensor Power Wire Shorted to Sensor Ground Wire
3Controller Ground to Sensor Signal Wire 7Sensor Signal Wire shorted
to Sensor Ground Wire
Definition of a Sensor Circuit Shorted to Itself: A Sensor Power Wire Shorted to Sensor Signal Wire (5)
sensor circuit shorted to itself has one or more sensor
wires making contact with another wire between the 1. The controller may display a maximum upper or
controller and sensor. A sensor power wire shorted to lower reading.
a sensor signal wire (5) may display a maximum upper
or lower reading. A sensor power wire shorted to a 2. The sensor may be damaged, with no signal given
sensor ground wire (6) may cause fuse (2) to blow. A to the controller.
sensor signal wire shorted to a sensor ground wire (7)
may allow the controller to display a false reading. 3. The controller may generate a Short to Power
service code, or the controller may shutdown for
Troubleshooting a Sensor Circuit Shorted to Itself: protection until the short to power is corrected.
The above diagram shows a sensor circuit shorted to
itself in three different locations. A few symptoms for Sensor Power Wire Shorted to a Sensor Ground Wire
each shorted location are given below. Due to the (6)
complexity of sensor and controller, not all symptoms
are listed.

101603
PN=174
System Information
1. The sensor may be damaged, with no signal given Sensor Signal Wire Shorted to a Sensor Ground Wire
to the controller. (7)
2. The controller may be damaged, with no display for 1. The controller may display a maximum upper or
that sensor. lower reading.
3. The controller may or may not generate a service 2. The controller may generate a Short to Ground
code. service code.
4. Fuse (2) may be blown. 3. Fuse (2) may be blown.
CED,TX17984,451 1928FEB002/2
9015
05
15

101603
PN=175
System Information
Sensor Circuit Shorted to Ground
9015
05
16
UN17JUL03
T128753
1Battery 4Sensor Power Wire Shorted 6Sensor Ground Wire 7Sensor
2Fuse to Ground Shorted to Ground 8Controller Ground
3Controller 5Sensor Signal Wire Shorted
to Ground
Definition of a Sensor Circuit Shorted to Ground: Sensor Power Wire Shorted to Ground (4)
A sensor circuit shorted to ground has one or more
sensor wires shorted to machine ground or a grounded 1. Fuse (2) may be blown.
wire. A sensor power wire shorted to a ground (4) may
blow a fuse or the controller may shutdown for 2. The controller may be damaged, with no display for
protection. A sensor signal wire shorted to ground (5) that sensor.
may cause a Short to Ground service code to be
generated. A sensor ground wire shorted to ground (6) 3. The controller may generate a Short to Ground
will allow the sensor to continue normal operation. service code, or the controller may shutdown for
protection until the short to ground is corrected.
Troubleshooting a Sensor Circuit Shorted to
Ground: The above diagram shows a sensor circuit Sensor Signal Wire Shorted to Ground (5)
shorted to ground in three different locations. A few
symptoms for each shorted location are given below. 1. The controller may display a maximum upper or
Due to the complexity of sensor and controller, not all lower reading.
symptoms are listed.

101603
PN=176
System Information
2. The controller may generate a Short to Ground 1. The sensor and controller may function normally.
service code.
Sensor Ground Wire Shorted to Ground (6)

CED,TX17984,452 1928FEB002/2
Multimeter
The multimeter is a handheld instrument use for taking

accurate measurements of electrical circuits.
1Ampere Input Terminal (Red Lead)

2Milliamp, Microamp Input Terminal (Red Lead)
3Volts AC (Alternating Current)
4Volts DC (Direct Current)
9015
5Millivolts DC (Direct Current)
05
6Display
17
7Continuity, Resistance, and Capacitance
8Diode Test
9Milliamps or Amperes
10Microamps
11Common or Ground Terminal (Black Lead)
12Volt, Ohms, Diode Test Input Terminal (Red Lead)
UN28FEB00
T128730
CED,TX17984,439 1925FEB001/1

101603
PN=177
System Information
Seven Step Electrical Test Procedure
9015
05
18
UN17JUL03
T128754
1Battery 4Component Side of Fuse or 6Battery Side of Component 8Ground Side of Component
2Fuse or Circuit Breaker Circuit Breaker Terminal Terminal
3Battery Side of Fuse or 5Switch 7Light (Component) 9Component Ground
Circuit Breaker
1. Turn switch (5) ON. Check battery side of circuit 3. Turn switch (5) OFF. Check component side of
breaker (3) for battery voltage. circuit breaker (4) for continuity to ground.
a. Battery voltage normal. Go to step 2. a. Continuity to ground. Repair grounded circuit at

or before switch (5).
b. Low voltage, repair high resistance
b. No continuity to ground, replace circuit breaker
c. Open circuit from battery (2).
2. Turn switch (5) OFF. Check component side of 4. Turn switch (5) ON. Check component side of
circuit breaker (4) for battery voltage. circuit breaker (4) for battery voltage.
a. Battery voltage normal. Go to step 4. a. Battery voltage normal. Go to step 6.
b. Low voltage, repair high resistance. b. Low voltage, repair high resistance.
c. No voltage. Go to step 3. c. No voltage. Go to step 5.

101603
PN=178
System Information
5. Turn switch (5) OFF. Disconnect wire at battery c. No voltage, repair high resistance or open circuit
side on component (6). between circuit breaker (2) and component (7).
Turn switch (5) ON. Check wire at (6) for battery 7. Turn switch (5) ON. Check ground wire of
voltage. component at (8) for voltage.
a. Battery voltage, repair component. a. No voltage, good continuity to ground.
b. No voltage, repair grounded or open circuit at or b. Repair component (7).

after switch (5).
c. Voltage, poor continuity to ground. Repair high
6. Turn switch (5) ON. Check lead on component at resistance or open ground circuit.
(6) for battery voltage.
a. Battery voltage normal. Go to step 7.

9015
b. Low voltage, repair high resistance or open 05
circuit between circuit breaker (2) and 19
component (7).
CED,TX17984,454 1928FEB002/2

101603
PN=179
System Information
Schematic, Wiring Diagram, and Component Location Information
System Functional Schematic Diagram will be identified by a letter/number designation and

description (X1 CAB HARNESS TO ENGINE
The System Functional Schematic is a schematic HARNESS CONNECTOR, X3 DASH HARNESS TO
diagram of the complete machine. Each wire is HEATER BLOWER HARNESS CONNECTOR, Etc.).
identified by number and/or color (G01 BLK, R02 RED,
RED/WHT, BLU/GRN, Etc.). All components are Component Location Diagram
identified by letter/number designation, description and
are represented by a schematic symbol. Component The Component Location Diagram is a pictorial view
letter/number designation, (K1 Start Relay, S1 Key by harness showing location of all electrical
Switch, B9 Horn, Etc.) will indicate that component components, connectors, harness main ground
throughout the manual. The System Functional locations and harness band and clamp location. Each
Schematic Diagram is divided into Sections. Each component will be identified by the same identification
section contains one or more electrical circuits. Each letter/number and description used in the System
section is indicated by a number and circuit (SE1 Functional Schematic Diagram.
9015
05 CHARGING CIRCUIT, SE2 STARTING CIRCUIT,
20 Etc.). NOTE: All System Functional Schematics, Circuit
Schematics, and Wiring Diagrams are shown
Wiring DiagramIf Provided with key switch in the OFF position.
The Wiring Diagram shows each wiring harness, wire Connector End View DiagramIf Provided
color, wire destination, harness connectors, and
schematic symbols for each electrical component The Connector End View Diagram is a pictorial end
connected to that harness. All harnesses are identified view of the component connectors showing the
by letter/number designation and description (W1 number of pins in the connector and the wire color and
Engine Harness, W2 Dash Harness, Etc.). Each identifier of the wire in every connector. Each
component schematic symbol will be identified by the component will be identified by the same identification
same letter/number designation used in the System letter/number and description used in the System
Functional Schematic Diagram. Harness connectors Functional Schematic Diagram.
CED,TX17984,455 1928FEB001/1

101603
PN=180
System Information
9015
05
21

101603
PN=181
System Information
Reading a System Functional Schematic
9015
05
22
UN29FEB00
T128818

101603
PN=182
System Information
1Continuity Chart 4Wire Identification 7Section Number 10Component Schematic

2Power Wires 5Ground Wires 8Component Name Symbol
3Routing Location 6Circuit Name 9Component Identification
Information Number
NOTE: A component identification number and name Each electrical component is shown by a schematic
will remain the same throughout the Operation symbol (10), the component name (8), and a
and Test Technical Manual. This will allow for component identification number (9). A continuity chart
easy cross-referencing of all electrical (1) is included for each multi-terminal switch.
drawings (Schematics, Wiring Diagrams, and
Component Location). Routing location information (3) is presented to let the
reader know when a wire is connected to a component
The System Functional Schematic is made up of in another section. TO and FROM statements identify
sections which contain one or more Subsystem when power is going To or coming From a
Functional Schematics laid out side by side in a logical component in a different location. The section and
sequence of related functions. Each subsystem is a component number are given in parenthesis at the
major group of components like starting components or bottom of the statement. In the example, power is 9015
charging components. Each section of the System going TO component F15 Horn Fuse, in section SE15. 05
Functional Schematic is assigned a number (7) and a 23
name (6) that reflects a group of components. The See Group 9015-10 for Component Identification
System Functional Schematic is formatted with power Legend.
supply wires (2) shown across the top of the drawing
and ground wires (5) across the bottom. The
schematic contains no harness or connector
information.
CED,TX17984,456 1928FEB002/2

101603
PN=183
System Information
Reading a Wiring Diagram
9015
05
24
UN29FEB00
T128819

101603
PN=184
System Information
1Harness Connector Pin 3Component Identification 6Component Connector 9Component Identification

Letter or Number Number 7Component Connector Pin Number Wire is Routed TO
2Harness Connector Number 4Wire Color or Number Letter or Number 10Wire Color or Number
Identification 5Component Identification 8Wiring Harness
Number Wire is Routed TO
NOTE: A component identification number and name Wires from harness to components are identified by
will remain the same throughout the Operation color or number designation (4). Component
and Test Technical Manual. This will allow for identification number (5) indicates the component a
easy cross-referencing of all electrical wire is routed TO.
drawings (Schematics, Wiring Diagrams, and
Component Location). Main harness connectors (2) are identified by a X
component identification number and description (X28
Each harness on the machine is drawn showing CAB TO ENGINE BULKHEAD CONNECTOR, Etc.).
components, connectors, and wires. Harnesses are Harness connector description indicates which
identified by a W component identification number harnesses connect together. Connector pin letters or
and description (W6 ENGINE HARNESS, Etc.). numbers (1) are indicated as they are marked on the 9015
connector. Wires attached to each connector pin are 05
Each component is represented by a schematic identified by color or number (10). Component 25
symbol and is identified by a component identification identification number (9) indicates destination of each
number and name (3). Components with integral wire.
connectors (6) have pin number/letters indicated (7).
CED,TX17984,457 1928FEB002/2

101603
PN=185
System Information
Reading a Component Location Diagram
9015
05
26
UN01MAR00
T128843

101603
PN=186
System Information
1Component Identification 4Connector Identification 7Wire Color or Number 9End View of Harness
Number Number 8Routing Destination of Wire Connector
2Component Name 5Connector Name (Shown as Component
3Additional Information 6Pin Number of Mating Identification Number)
Connector
NOTE: A component identification number and name component name (2). In the example shown, the
will remain the same throughout the Operation component is also identified by an R number (3) that is
and Test Technical Manual. This will allow for actually marked on the part.
easy cross-referencing of all electrical
drawings (Schematics, Wiring Diagrams, and Each connector that joins one harness to another is
Component Location). identified by an X component identification number
(4) and connector name (5). An end view of the
The component location by harness drawing is a connector (9) is shown. Also, a diagram view of the
pictorial representation that shows harness routing, connector shows pin number (6), wire color or number
component location and mating harness connector (7), and destination component (8) of each wire.
information. 9015
In the example shown, X23 Connector connects the 05
The location of each component that is connected to Monitor and Relay Harness to the Cab Harness. Pin 1 27
the harness is shown and identified by its (6) of the connector contains a BRN wire (7), which is
alpha-numeric identification number (1), and routed to component G4 (8) 24 volt power plug.
CED,TX17984,459 1929FEB002/2

101603
PN=187
System Information
Reading a Connector End View Diagram
9015
05
28
UN01MAR00
T128896
1Connector End View 4Component Name 6Wire Number 7Wire Color
2Connector Pins 5Terminal Pin Letter or
3Component Identification Number
Number
NOTE: A component identification number and name pictorial end view of a connector (1), shows the
will remain the same throughout the Operation location and number of pins (2) in the connector. The
and Test Technical Manual. This will allow for component identification number (3) and name (4) are
easy cross-referencing of all electrical given for each connector. A diagram view of the
drawings (Schematics, Wiring Diagrams, and connector shows connector pin number (5), wire
Component Location). number (6), and wire color (7).
The connector end view diagram gives a description of

the connector associated with each component. A
CED,TX17984,460 1901MAR001/1

101603
PN=188
System Information
9015
05
29

101603
PN=189
System Information
Electrical Schematic Symbols

T128823 UN03MAR00
CED,TX17984,458 1928FEB001/2

101603
PN=190
System Information
1Battery 24Sensor 46Resistor 62Momentary Switch

2Wire Splice 25Sensor with Normally 47Variable Resistor Normally Open
3Fuse Open Switch 48Multi-Pin Connector 63Momentary Switch
4Circuit Breaker 26Speed Sensor 49Single Pin Connector Normally Closed
5Fusible Link 27Rotary Sensor 50Connector 64Toggle Switch Normally
6Power Outlet 28Single Element Bulb 514 Pin Relay Open
7Alternator 29Dual Element Bulb 525 Pin Relay 65Toggle Switch Normally
8Air Conditioner 30Electrically Operated 535 Pin Relay With Internal Closed
Compressor hydraulic Valve Suppression Diode 662 Way Toggle Switch
9Compressor 31Solenoid Normally Open 545 Pin Relay With Internal Normally Open
10Liquid Pump 32Solenoid Normally Closed Suppression Resistor 672 Way Toggle Switch
11Antenna 33Starter Motor 55Key Switch Normally Closed
12Diode 34Starter Motor 56Temperature Switch 68Manual Switch Operation
13Zener Diode 35DC Motor Normally Open 69Push Switch Operation
14Capacitor 36DC Stepping Motor 57Temperature Switch 70Pull Switch Operation
15Magnet 37Wiper Motor Normally Closed 71Turn Switch Operation
16Flasher 38Blower Motor 58Pressure Switch Normally 72Toggle Switch Operation
17Buzzer 39Servo Motor Open 73Pedal Switch Operation
18Horn 40Speedometer 59Pressure Switch Normally 74Key Switch Operation
19Alarm 41Tachometer Closed 75Detent Switch Operation 9015
20Clock 42Temperature Gauge 60Liquid Level Switch 76Temperature Sensor 05
21Internal Ground 43Liquid Level Gauge Normally Open 77Solar Sensor 31
22Single Point Ground 44Gauge 61Liquid Level Switch 78Pressure Sensor
23External Ground 45Hourmeter Normally Closed 79Liquid Level Sensor
CED,TX17984,458 1928FEB002/2

101603
PN=191
System Information
9015
05
32

101603
PN=192
Group 10
System Diagrams
Fuse Specifications
IMPORTANT: Install fuse with correct amperage

rating to prevent electrical system
damage from overload.
NOTE: The marked name in parenthesis is the fuse

name shown on the fuseblock cover.
Fuse block is located behind the operators seat under a

fuse block cover.
F1Radio and Monitor Controller Backup 5-Amp
Fuse (marked Back Up)
F2Engine and Pump Controller 10-Amp Fuse
(marked Controller)
F3Engine Control (EC) Motor 10-Amp Fuse (marked
EC Motor) 9015
F4Solenoid 5-Amp Fuse (marked Solenoid) 10
F5Power On 10-Amp Fuse (marked Pow. On) 1
F6Monitor Controller and Display 5-Amp Fuse
(marked Sw. Box)
F7Switched Power 5-Amp Fuse (marked Option 1)
UN06MAR92
F8Switched Power 10-Amp Fuse (marked Option 2)
F9Battery Power 5-Amp Fuse (marked Option 3)
F10Travel Alarm 5-Amp Fuse (marked Travel)
F11Work and Drive Lights 20-Amp Fuse (marked
T7713AJ
Lamp)
F12Windshield Wiper 10-Amp Fuse (marked Wiper)
F13Blower Motor 20-Amp Fuse (marked Heater)
F14Air Conditioner Controller and Relays 5-Amp
Fuse (marked Air Con)
F15Horn 10-Amp Fuse (marked Horn)
F16Radio 5-Amp Fuse (marked Radio)
F17Lighter 10-Amp Fuse (marked Lighter)
F18Dome Light 5-Amp Fuse (marked Room Lamp)
F19Auxiliary 10-Amp Fuse (marked Auxiliary)
F20Start Aid 20-Amp Fuse (marked Start Aid) (Not
used)
CED,TX02661,227 1914DEC981/1

101603
PN=193
System Diagrams
Fuse (Blade-Type) Color Codes
Amperage Rating Color

1 Black
3 Violet
4 Pink
5 Tan
7-1/2 Brown
10 Red
15 Light Blue
20 Yellow
25 Natural (White)
30 Light Green
9015
10
2
CED,TX14795,4106 1922NOV971/1

101603
PN=194
System Diagrams
Component Identification Table
Each component (electrical device) and main connector

will have and identification letter assigned to it. A number
is added to the letter to separate and indicate the total
components within that letter group.
Identification Letter Type Examples

A System, subassembly, parts group Control units, trigger boxes, two-way radios, logic module, FNR
logic module
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 tape
recorders 9015
10
E Various devices and equipment Heating devices, air conditioners, light, headlights, spark plugs, 3
ignition distributors
F Protection device Release mechanisms, polarity protection devices, fuses, current
protection 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, pressure
gauges, 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
Continued on next page TX,10,111507 1922AUG961/2

101603
PN=195
System Diagrams
Identification Letter Type Examples

S Switch Switches and push-button, general key switch, light switch, horn
switch, 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, cable
harnesses, conductors, ground conductors
X Terminal, plug, plug and socket connection Terminal studs, electrical connections, connectors electrical line
couplers, line connectors, sockets, plugs, terminals, plug-and-socket
connections
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
9015
10
4
TX,10,111507 1922AUG962/2

101603
PN=196
System Diagrams
Functional Schematic And Component Location Legend
NOTE: A2Engine and Pump Controller (SE8, W2) B20Arm In Pressure Sensor (SE7, W1)
B21Rear Pump Control Pressure Sensor (SE7,
A2 indicates component identification number. W1)
B22Front Pump Control Pressure Sensor (SE7,
Engine and Pump Controller indicates W1)
component name. B23Right Speaker (SE14, W2)
B24Left Speaker (SE14, W2)
SE8 indicates section numbers of SYSTEM B25High Note Horn (SE15, W1)
FUNCTIONAL SCHEMATIC where component B26Low Note Horn (SE15, W1)
is located. B27Air Conditioner High and Low Pressure Switch
(SE17, W9)
W2 is the identification number of the B28Not Used
COMPONENT LOCATION and HARNESS B29Air Conditioner and Heater Thermistor (SE17,
CONNECTOR (WITH WIRE AND PIN W9)
9015
LOCATION) drawings for the component. This 10
would indicate that the Engine and Pump E1Work Light (SE13, W1) 5
Controller is connected to W2 Cab Harness. E2Drive Light (SE13, W1)
E3Cab Dome Light (SE15, W2)
A1Radio (SE14, W2) E4Monitor Controller and Display Backlight (SE5,
A2 Engine and Pump Controller (SE8, W2) W3)
A3 Air Conditioner Controller (SE17, W9) E5Engine RPM Dial Backlight (SE4, W2)
A4 Engine Mode and RPM Control Unit (SE4, W2)
A5 Monitor Controller and Display (SE5, W3) F1Radio and Monitor Controller Backup 5 Amp
Fuse (marked Back Up) (SE6, W2)
B1Air Filter Restriction Switch (SE6, W1) F2Engine and Pump Controller 10 Amp Fuse
B2Fuel Level Switch (SE6, W1) (marked Controller) (SE9, W2)
B3 Engine Coolant Temperature Switch (SE6, W1) F3Engine Control (EC) Motor 10 Amp Fuse
B4 Engine Oil Pressure Switch (SE6, W1) (marked EC Motor) (SE9, W2)
B5 Hydraulic Oil Level Switch (SE6, W1) F4Solenoid 5 Amp Fuse (marked Solenoid) (SE9,
B6 Engine Coolant Level Switch (SE6, W1) W2)
B7 Engine Oil Level Switch (SE6, W1) F5 Power On 10 Amp Fuse (marked Pow. On)
B8 Fuel Level Sensor (SE6, W1) (SE3, W2)
B9 Engine Coolant Temperature Sensor (SE4, F6Monitor Controller and Display 5 Amp Fuse
W1) (marked Sw. Box) (SE4, W2)
B10Not Used F7Switched Power 5 Amp Fuse (marked Option 1)
B11Not Used (SE18, W2)
B12Not Used F8Switched Power 10 Amp Fuse (marked Option
B13Boom Up Pressure Switch (SE7, W1) 2) (SE18, W2)
B14Dig Pressure Switch (SE7, W1) F9Battery Power 5 Amp Fuse (marked Option 3)
B15Propel Pressure Switch (SE7, W1) (SE18, W2)
B16Engine Speed (N) Sensor (SE8, W1) F10Travel Alarm 5 Amp Fuse (marked Option 1)
B17Engine Control (EC) Sensor (Located Inside (SE10, W2)
Engine Control Motor Housing) (SE7, W1) F11Work and Drive Lights 20 Amp Fuse (marked
B18Rear Pump Pressure Sensor (SE7, W1) Lamp) (SE13, W2)
B19Front Pump Pressure Sensor (SE7, W1)
Continued on next page CED,OUTX782,72 1904JAN991/4

101603
PN=197
System Diagrams
F12Windshield Wiper 10 Amp Fuse (marked H18Alternator Voltage Indicator Light (SE4, W3)
Wiper) (SE12, W2) H19Engine Oil Level Indicator Light (SE4, W3)
F13Blower Motor 20 Amp Fuse (marked Heater) H20Engine Coolant Level Indicator Light (SE4,
(SE16, W2) W3)
F14Air Conditioner Controller and Relays 5 Amp H21Spare Indicator Light (SE4, W3)
Fuse (marked Heater) (SE17, W2)
F15Horn 10 Amp Fuse (marked Horn) (SE15, W2) K1Alternator Shut Down Relay (Marked R1) (SE3,
F16Radio 5 Amp Fuse (marked Radio) (SE14, W3)
W2) K2Windshield Washer Relay (Marked R2) (SE11,
F17Lighter 10 Amp Fuse (marked Lighter) (SE15, W3)
W2) K3Work Light Relay (Marked R3) (SE13, W3)
F18Dome Light 5 Amp Fuse (marked Room K4Drive Light Relay (Marked R4) (SE13, W3)
Lamp) (SE15, W2) K5Horn Relay (Marked R5) (SE15, W3)
F19Auxiliary 10 Amp Fuse (marked Auxiliary) K6Windshield Wiper Relay (Motor Ground and
SE18, W2) Intermittent) (Marked R6) (SE11, W3)
F20Start Aid 20 Amp Fuse (marked Start Aid) (Not K7Windshield Wiper Relay (Wiper Run) (Marked
9015
10 UsedField Option) R7) (SE12, W3)
6 F21Battery Power 40 Amp Fusible Link (SE1, W1) K8Windshield Wiper Relay (Hold for Park)
F22Alternator Power 60 Amp Fusible Link (SE1, (Marked R8) (SE12, W3)
W1) K9Windshield Wiper Relay (Motor Ground for
F23Fuel Shutoff 40 Amp Fusible Link (SE1, W1) Park) (Marked R9) (SE12, W3)
K10Propel Auto Idle Relay (Marked R10) (SE7,
G1Battery (SE1, W1) W3)
G2Battery (SE1, W1) K11Starter Protection Relay (Marked R11) (SE2,
G3Alternator (SE3, W1) W3)
G424 Volt Power Plug (SE15, W3) K12Start Aid Relay (Marked R12) (Not Used
Field Option)
H1Dig Mode Indicator Light (SE5, W3) K13Starter Relay (SE2, W1)
H2Grading Mode Indicator Light (SE5, W3) K14Battery Relay (SE1, W1)
H3Precision Mode Indicator Light (SE5, W3) K15Fuel Shutoff Relay (SE3, W1)
H4Attachment Mode Indicator Light (SE5, W3) K16Not Used
H5High Power Mode Indicator Light (SE4, W3) K17Not Used
H6Economy Mode Indicator Light (SE4, W3) K18Not Used
H7Auto Idle Mode Indicator Light (SE4, W3) K19Not Used
H8Monitor Controller and Display Alarm (SE5, K20Not Used
W3) K21Not Used
H9Not Used K22Not Used
H10Travel Alarm (SE10, W1) K23Not Used
H11Spare Indicator Light (SE4, W3) K24Air Conditioner Blower Motor and Main Power
H12Hydraulic Oil Level Indicator Light (SE4, W3) (Low Speed) Relay (SE17, W9)
H13Fuel Level Indicator Light (SE4, W3) K25Air Conditioner Compressor Clutch Relay
H14Air Filter Restriction Indicator Light (SE4, W3) (SE17, W9)
H15Not Used K26Air Conditioner Blower Motor (Low Medium
H16Engine Coolant Temperature Indicator Light Speed) Relay (SE17, W9)
(SE4, W3) K27Air Conditioner Blower Motor (Medium Speed)
H17Engine Oil Pressure Indicator Light (SE4, W3) Relay (SE17, W9)

101603
PN=198
System Diagrams
K28Air Conditioner Blower Motor (High Speed) S7Work Mode Selection Switch (SE5, W3)
Relay (SE17, W9) S8Propel Speed Change Switch (SE5, W3)
S9Wiper Speed Switch (SE5, W3)
M1Starter (SE2, W1) S10Drive and Work Light Switch (SE5, W3)
M2Engine Control (EC) Motor (SE8, W1) S11Economy (E) Mode Switch (SE4, W2)
M3Windshield Wiper Motor (SE11, W3) S12High Power (HP) Mode Switch (SE4, W2)
M4Windshield Washer Motor (SE11, W1) S13Auto Idle Switch (SE5, W3)
M5Heater Blower Motor (Without Air Conditioner) S14Windshield Wiper Enable Switch (SE4, W2)
(SE16, W2) S15Windshield Washer Switch (SE5, W3)
M6Air Conditioner and Heater Blower Motor S16Learning Switch (SE9, W2)
(SE17, W9) S17Travel Alarm Cancel Switch (SE10, W2)
M7Not Used S18Start Aid Switch (Not UsedField Option)
M8Not Used S19Power Boost Switch (SE9, W2)
M9Air Conditioner Internal and External Cab Air
Servomotor (SE17, W9) V1Start Aid Diode (Not UsedField Option)
M10Air Conditioner Blower Port Change V2Alternator Shut Down Relay Isolation Diode
9015
Servomotor (SE17, W9) (SE3, W2) (Red/Wht and Red/Blk) 10
M11Air Conditioner Air Mixer Servomotor (SE17, V3Auxiliary Power Fuse (F19) Suppression Diode 7
W9) (SE18, W2) (Blk and Red)
V4Propel Auto Idle Relay (marked R10) Isolation
P1Hour Meter (SE5, W3) Diode (SE7, W2) (Wht/Blk and Yel)
P2Engine Coolant Temperature Gauge (SE4, W3) V5Windshield Wiper Relay (marked R8) Isolation
P3Fuel Gauge (SE4, W3) Diode (SE12, W3) (Blu/Blk and Blu/Red)
V6Windshield Wiper Motor Suppression Diode
R1Not Used (SE11, W3) (Blk and LGrn/Wht)
R2Heater Blower Motor Dropping Resistor Block V7Windshield Wiper Motor Suppression Diode
(Without Air Conditioner) (SE16, W2) (SE11, W3) (Blk and Blu/Wht)
R3Not Used V8Fuel Shutoff Solenoid Hold-In Coil Suppression
R4Engine Coolant Temperature Gauge Resistor Diode (SE3, W2) (Brn/Blk and Blk)
(150 ohms) (SE5, W3) V9Start Relay Coil Suppression Diode (SE2, W2)
R5Fuel Gauge Resistor (220 ohms) (SE5, W3) (Yel/Grn and Blk/Wht)
R6Alternator Excitation Resistor (SE3, W2) V10Fuel Shutoff Solenoid Pull-In Coil Suppression
R7Not Used Diode (SE3, W2) (Red/Blk and Blk)
R8Not Used V11Battery Relay Coil Suppression Diode (SE1,
R9Not Used W1) (Blk and Red/Wht)
R10Engine RPM Dial (SE4, W2)
R11Air Conditioner and Heater Blower Motor W1Engine and Frame Harness
Dropping Resistor Block (SE17, W9) W2Cab Harness
W3Monitor and Relay Harness
S1Key Switch (SE1, W2) W4Radio Antenna (SE14, W2)
S2Horn Switch (SE15, W2) W5Battery to Frame Ground (W1)
S3Dome Light Switch (SE15, W2) W6Engine and Frame Harness to Frame Ground
S4Heater Blower Motor Switch (Without Air (W1)
Conditioner) (SE16, W2) W7Cab Harness to Frame Ground (W2)
S5Fluid Level Check Switch (SE5, W3) W8Starter to Frame Ground (SE2, W1)
S6Buzzer Stop Switch (SE5, W3) W9Air Conditioner Harness

101603
PN=199
System Diagrams
X1Diagnostic Connector (SE9, W2) X18Air Conditioner Controller Connector (12-Pin)

X2Learning Switch Connector (SE9, W2) (SE17, W9)
X3Attachment Pressure Switch Connector (SE9, X19Monitor and Relay Harness to Cab Harness
W2) Connector (2-Pin) (W2, W3)
X4Accel Connector (SE8, W2) X20Monitor and Relay Harness to Cab Harness
X5Optional Connector (SE18, W2) Connector (6-Pin) (W2, W3)
X6Auxiliary Connector (SE18, W2) X21Monitor and Relay Harness to Cab Harness
X7Optional Right Speaker Connector (SE14, W2) Connector (12-Pin) (W2, W3)
X8Engine and Frame Harness to Cab Harness X22Monitor and Relay Harness to Cab Harness
Connector (W1, W2) Connector (16-Pin) (W2, W3)
X9Engine and Frame Harness to Cab Harness X23Monitor and Relay Harness to Cab Harness
Connector (W1, W2) Connector (8-Pin) (W2, W3)
X10Monitor Controller and Display Connector X24Optional Connector (W3)
(20-Pin) (W3) X25Optional Connector (W3)
X11Monitor Controller and Display Connector
(16-Pin) (W3) Y1Air Conditioner Compressor Clutch (SE17, W1
9015
10 X12Monitor Controller and Display Connector and W9)
8 (12-Pin) (W3) Y2Not Used
X13Engine and Pump Controller Connector Y3Not Used
(26-Pin) (W2) Y4Not Used
X14Engine and Pump Controller Connector Y5Power Boost Proportional Solenoid (SE7, W1)
(16-Pin) (W2) Y6Propel Speed Change Proportional Solenoid
X15Engine and Pump Controller Connector (SE8, W1)
(22-Pin) (W2) Y7Fuel Shutoff Solenoid (SE3, W1)
X16Air Conditioner Harness to Cab Harness Y8Speed Sense Proportional Solenoid (SE7, W1)
Connector (SE17, W2, W9) Y9Arm Regenerative Proportional Solenoid (SE7,
X17Air Conditioner Controller Connector (16-Pin) W1)
(SE17, W9)
CED,OUTX782,72 1904JAN994/4

101603
PN=200
System Diagrams
System Functional Schematic Section

Legend
NOTE: SE1Power Circuit
SE1 indicates section number of System

Functional Schematic where circuit is located.
Power Circuit indicates circuit name.
SE1Power Circuit
SE2Starting Circuit
SE3Charging and Fuel Shut-Off Circuit
SE4Monitor Controller and Display Circuit
SE5Monitor Controller and Display Circuit
SE6Monitor Controller and Display Circuit 9015
SE7Engine and Pump Controller Circuit 10
SE8Engine and Pump Controller Circuit 9
SE9Engine and Pump Controller Circuit
SE10Travel Alarm Circuit
SE11Windshield Wiper and Washer Circuit
SE12Windshield Wiper and Washer Circuit
SE13Work and Drive Light Circuit
SE14Radio Circuit
SE15Accessory Circuit
SE16Heater Circuit (Machines Without Air
Conditioner)
SE17Heater and Air Conditioner Circuit
SE18Optional Connector Circuit
CED,TX02661,229 1922DEC981/1

101603
PN=201
System Diagrams
System Functional Schematic (SE1SE3)

T118937 1923DEC98
CED,OUTX782,64 1922DEC981/1

101603
PN=202
System Diagrams

T118938 1904JAN99
CED,OUTX782,65 1921DEC981/1

101603
PN=203
System Diagrams

T118939 1923DEC98
CED,OUTX782,66 1921DEC981/1

101603
PN=204
System Diagrams

T118940 1923DEC98
CED,OUTX782,67 1917DEC981/1

101603
PN=205
System Diagrams

T118941 1923DEC98
CED,OUTX782,68 1921DEC981/1

101603
PN=206
System Diagrams

T118942 1905JAN99
CED,OUTX782,69 1921DEC981/1

101603
PN=207
System Diagrams
Engine and Frame Harness (W1) Component Location

T119116 1915JAN99
CED,OUTX782,70 1921DEC981/1

101603
PN=208
System Diagrams
Engine and Frame Harness (W1) Connectors, Wire and Pin Location
9015
10
17
1911DEC98
T118958
Continued on next page CED,OUTX782,71 1921DEC981/3

101603
PN=209
System Diagrams
9015
10
18
1911DEC98
T118959
Continued on next page CED,OUTX782,71 1921DEC982/3

101603
PN=210
System Diagrams
9015
10
19
1917NOV98
T118104
CED,OUTX782,71 1921DEC983/3

101603
PN=211
System Diagrams
Cab Harness (W2) Component Location

T118411 1923FEB00
CED,TX02661,242 1904NOV981/1

101603
PN=212
System Diagrams
Cab Harness (W2) Component LocationDetail A (Harness Mating Connectors)

T119184 1923DEC98
CED,OUTX782,73 1921DEC981/1

101603
PN=213
System Diagrams
Cab Harness (W2) Component LocationDetail B (Fuse Block)
9015
10
22
1917NOV98
T117202
CED,OUTX782,1 1917NOV981/1

101603
PN=214
System Diagrams
Cab Harness (W2) Connectors, Wire and Pin Location
9015
10
23
1917NOV98
T118464
Continued on next page CED,TX02661,244 1904NOV981/5

101603
PN=215
System Diagrams
9015
10
24
1914DEC98
T118465

101603
PN=216
System Diagrams
9015
10
25
1917NOV98
T118466

101603
PN=217
System Diagrams
9015
10
26
1905JAN99
T118493

101603
PN=218
System Diagrams
9015
10
27
1917NOV98
T118494
CED,TX02661,244 1904NOV985/5

101603
PN=219
System Diagrams
Monitor and Relay Harness (W3) Component Location

T119183 1923DEC98
CED,OUTX782,74 1921DEC981/1

101603
PN=220
System Diagrams
Monitor and Relay Harness (W3) Component LocationDetail A (Monitor Controller

Connectors)
9015
10
29
1923DEC98
T119181
CED,OUTX782,75 1922DEC981/1

101603
PN=221
System Diagrams
Monitor and Relay Harness (W3) Component LocationDetail B (Monitor Controller

Indicators)
9015
10
30
1919FEB99
T118900
CED,OUTX782,76 1921DEC981/1

101603
PN=222
System Diagrams
Monitor and Relay Harness (W3) Connectors, Wire and Pin Location
9015
10
31
1917NOV98
T118352

101603
PN=223
System Diagrams
9015
10
32
1917NOV98
T118497
CED,TX02661,248 1904NOV982/2

101603
PN=224
System Diagrams
Air Conditioner Harness (W9) Component

LocationSee Group 9031-15
CED,TX02661,249 1904NOV981/1
Air Conditioner Harness (W9) Connectors,

Wire and Pin LocationSee Group 9031-15
CED,TX02661,250 1904NOV981/1
9015
10
33

101603
PN=225
System Diagrams
9015
10
34

101603
PN=226
Group 15
Sub-System Diagnostics
Power Circuit Operational Information
The following conditions must be met for the circuits to Lighter 10-amp fuse F17
function: Dome light 5-amp fuse F18
Auxiliary 10-amp fuse F19
With key switch S1 OFF, voltage must be present at
the following: With key switch S1 ON, voltage must be present at the
following:
Battery positive terminals
Key switch S1 terminal BAT Alternator excitation resistor R6
Battery relay K14 terminal B Key switch S1 terminal M
Radio and monitor controller backup 5-amp fuse F1 Battery relay K14 terminal S and A
Engine and pump controller 10-amp fuse F2 Alternator power 60-amp fusible link F22
Engine control (EC) motor 10-amp fuse F3 Starter motor terminal B
Battery power 5-amp fuse F9 Solenoid 5-amp fuse F4
Battery power 40-amp fusible link F21 Power On 10-amp fuse F5
9015
Alternator shut down relay K1 terminals 1 and 3 Monitor controller and display 5-amp fuse F6 15
Starter protection relay K11 terminal 1 Switched power 5-amp fuse F7 1
Switched power 10-amp fuse F8
With key switch S1 in ACC position, voltage must be Travel alarm 5-amp fuse F10
present at the following: Work and drive lights 20-amp fuse F11
Windshield wiper 10-amp fuse F12
Key switch S1 terminal ACC Blower motor 20-amp fuse F13
Horn 10-amp fuse F15 Air conditioner controller and relays 5-amp fuse F14
Radio 5-amp fuse F16 Fuel shutoff 40-amp fusible link F23
CED,OUOE012,10 1914DEC981/1

101603
PN=227
Power Circuit Theory of Operation
The power circuit includes batteries, key switch, F17, dome light 5-amp fuse F18, auxiliary 10-amp fuse
battery relay, battery relay fuse, battery relay diode F19 and radio 5-amp fuse F16.
and all other fuses.
With key switch turned to ON, battery relay K14 is
With key switch OFF, battery power is available at energized by power from key switch S1 terminal M to
terminal BAT of key switch S1, terminals 1 and 3 of battery relay terminal S. Operating power from terminal
alternator shut down relay K1, terminal 1 of starter A of the battery relay is applied to starter motor M1
protection relay K11, and through battery power terminal B, fuel shutoff 40-amp fusible link F23, and
40-amp fusible link F21 to terminal B of battery relay through alternator power 60-amp fusible link F22 to
K14. Battery power is also applied to radio and monitor fuses F4, F6, F7, F8, F10, F11, F12, F13 and F14.
controller backup 5-amp fuse F1, engine and pump Operating power is also applied from key switch S1
controller 10-amp fuse F2, and engine control (EC) terminal M to alternator excitation resistor R6 and
motor 10-amp fuse F3 and battery power 5 amp fuse power on 10-amp fuse F5.
F9.
9015
15
2 With key switch turned to ACC, battery power is
available at horn 10-amp fuse F15, lighter 10-amp fuse
CED,OUOE012,11 1914DEC981/1

101603
PN=228
Power Circuit Schematic

T117940 1930NOV98
CED,OUOE012,39 1903FEB991/1

101603
PN=229
1 Power Circuit Diagnostic Procedures
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and
Pump Controller or other components may result. Disconnect connectors only when instructed during a
test or check.
1/1
Battery (G1, G2) Voltage Measure battery voltage by connecting a voltmeter to (-) YES: Batteries are OK.
Check negative battery terminal grounded to frame and (+) Go to next check.
9015
positive battery terminal connected to machine harness.
15
NO: Batteries are
4
Is 24 to 28 volts measured? undercharged. Charge
batteries.
T7487AF UN20MAR91
1/1
Battery Power 40 Amp Disconnect fusible link from battery relay. YES: Fusible link is OK.
Fusible Link (F21) Check Check wiring harness.
Connect ohmmeter to both ends of fusible link.
NO: Fusible link has
Is continuity measured? failed. Replace fusible
link.
T109319 UN28APR97
1/1
Alternator Power 60 Amp Disconnect fusible link from battery relay. YES: Fusible link is OK.
link.
T109319 UN28APR97
1/1

101603
PN=230
Key Switch (S1) Check 1B Terminal YES: Go to next step.

2G1 Terminal
3G2 Terminal NO: Key switch has failed
4ACC Terminal if continuity is not
5M Terminal measured or continuity is
6ST Terminal measured between other
terminals. Replace.
Remove harness from key switch.
T8357AK UN09NOV94
Turn key switch to ACC.
Is continuity measured between key switch terminals 1

and 4?
1B Terminal YES: Go to next step.

2G1 Terminal
5M Terminal measured or continuity is 9015
6ST Terminal measured between other 15
terminals. Replace. 5
T8357AL UN09NOV94
Turn key switch ON.

and 4, and terminals 1 and 5?
1B Terminal YES: Key switch is OK.

2G1 Terminal
5M Terminal measured or continuity is
6ST Terminal measured between other
terminals. Replace.
T8357AM UN02DEC98
Turn key switch to START.

and 5, and terminals 1 and 6?
1/1
Battery Relay (K14) Disconnect harness from relay. YES: Relay is OK. Check
Check wiring harness.
Connect 24 volts to small terminal S and ground small
terminal E. NO: Relay has failed.
Replace relay.
Does relay click?
Connect ohmmeter to large terminals A and B.

T8182AK UN03MAR94
Is continuity measured?
1/1

101603
PN=231
Battery Relay Coil NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Suppression Diode (V11) measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
Check meter when checking continuity. diode has failed in a
shorted mode. Replace.
NO: If continuity is NOT

measured in either check,
diode has failed in an
open mode. Replace.
NO: If continuity is
measured in one check
T118385 UN21NOV98 and not the other, diode
is OK.
Remove diode from connector.
Connect an ohmmeter to diode terminals.
9015
15
Reverse ohmmeter probes.
6
1/1
Fuse Check YES: Fuse is OK
NO: Replace fuse.
T7468AF UN14MAR91
Remove cover from fuse block.
Turn key switch ON.
Connect black (-) probe of multimeter to screw head (ground) in console.
Set multimeter to measure 24 volts.
Connect multimeter red (+) probe to the outside slot in each fuse.
Is 24 volts measured on each fuse?
1/1

101603
PN=232
9015
15
7

101603
PN=233
Charging Circuit Operational Information
The following conditions must be met for the circuit to Voltage present at alternator G3 terminals B+ and
function: D+
Engine running
Key switch ON
CED,OUOE012,12 1926OCT981/1
Charging Circuit Theory Of Operation

9015
15 The charging circuit includes batteries, key switch, at alternator terminal D+ drops below 6 volts, as a
8 alternator shut down relay, alternator excitation result of a charging circuit failure or the engine not
resistor, alternator shutdown relay and isolation diode, running, the monitor controller will turn on the
monitor controller and display. alternator voltage indicator light and sound the display
alarm.
With key switch S1 ON, battery power is applied
through alternator power 60-amp fusible link F22 to Once the monitor controller senses that the engine is
terminal B+ of alternator G3. Alternator excitation running (voltage at alternator terminal D+ is greater
power is applied from key switch S3 terminal M than 10 volts), monitor controller and display pin 18 is
through alternator shut down relay isolation diode V2 grounded. This provides a ground path for alternator
and alternator excitation resistor R6 to alternator shutdown relay K1, energizing the relay. With relay K1
terminal D+. The excitation voltage is monitored by energized, battery power is applied through contacts 3
controller and display monitor A5 at terminal 42. and 5 to alternator excitation resistor R6. This ensures
that power to the alternator excitation circuit (and the
With the engine running and the charging circuit alternator voltage output) is maintained as long as the
functioning properly, the voltage at alternator terminal engine is running, even if the key switch is turned to
D+ is greater than 10 volts, therefore, alternator OFF or ACC momentarily.
voltage indicator light H18 and monitor controller and
display alarm H8 are off. Output current from alternator Isolation diode V2 isolates the battery power at
terminal B charges the batteries as needed and terminal 5 of relay K1 from the key switch ON power
provides power to the machine circuits. If the voltage circuits.
CED,OUOE012,28 1902NOV981/1

101603
PN=234
Charging Circuit Schematic
9015
15
9
1918NOV98
T117942
CED,OUOE012,29 1902NOV981/1

101603
PN=235
Alternator Theory of Operation
9015
15
10
1921NOV98
T118584
AAlternator FPositive Diodes KRegulator OBattery
BInternal Ground GD+ Terminal LExternal Ground Terminal PKey Switch
CNegative Diodes HB+ Terminal MRotor QDisplay Monitor
DExciter Diodes INoise Filter NAlternator Excitation RBrushes
EStator Windings JExcitation Winding Resistor SSense Circuit
The alternator has three basic stages for proper magnetic field which induces current in the
operation. The operating principles are as follows. three-phase winding of the stator (E). The alternator
reaches cut-in RPM when the induced current is large
PRE-EXCITATION STAGE: enough to produce voltage equal to the battery voltage
plus 1.0 volt. At this time, some current from the stator
When key switch (P) is turned to ON, battery power is rectified by the exciter diodes (D) (producing battery
flows through the alternator excitation resistor (N) to voltage at the B+ terminal (G) and is supplied to the
terminal D+ (G) on alternator, excitation winding (J), carbon brushes and slip rings of the excitation winding,
through regulator (K) and to internal ground (B). strengthening the magnetic field in the excitation
winding. This in turn will increase the stator voltage.
EXCITATION STAGE: This will occur continuously until the alternator (A) is
fully excited and the alternator regulated voltage is
During alternator start (as the engine speeds up from 0 reached.
to idle) current supplied by the alternator excitation
resistor to the field coil of the rotor produces a NORMAL OPERATION:
Continued on next page CED,OUOE012,13 1921DEC981/2

101603
PN=236
The alternating current induced in the stator winding B+ voltage (H) and compares it to an internal
(E) is rectified by the positive and negative diodes (F reference. When the B+ voltage (H) starts to rise
and C) and delivered to the battery and current above the reference voltage, the regulator (K) switches
consuming accessories. The currents in the stator off the field current. When the B voltage (H) starts to
winding (E) are constantly changing magnitude and fall below the reference voltage the regulator (K)
direction. However, current flowing to the battery and switches on the field current. The regulator (K)
accessories always maintains the same direction. This switches the field on and off several thousand times a
is because no matter what position the rotor (M) is in, second in response to the current load placed on the
all the diodes are simultaneously involved in the alternator output and the engine RPM.
process of rectification. The regulator (K) measures the
CED,OUOE012,13 1921DEC982/2
1 Charging Circuit Diagnostic Procedures

9015
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and 15
Pump Controller or other components may result. Disconnect connectors only when instructed during a 11
test or check.
NOTE: For a problem that cannot be identified using the diagnostic procedures, check the wiring harnesses and
diodes in the circuits for shorts and opens.
1/1
Alternator (G3) Output Key switch OFF. YES: Alternator is OK.

Check
With voltmeter connected from battery (+) terminal to NO: Repair alternator.
vehicle ground, measure and record battery voltage. 24 -
25.5 volts is normal.
Start and run engine at 1500 rpm, and check battery

voltage.
T6569AZ UN23AUG93
Does battery voltage increase to 27.4 - 28.4 volts?
1/1

101603
PN=237
Alternator Voltage Turn key switch ON. YES: Go to next step.

Indicator Light (H18)
Check Engine OFF. NO: Check indicator
lamp. If OK go to next
Is alternator voltage indicator light ON? check.
T6768CR UN18OCT88
Start engine. YES: Indicator light is

OK.
Does alternator voltage indicator light go OFF?
9015
15
12
1/1
Alternator Voltage YES: Monitor controller

Indicator Light Harness may have failed.
Check
NO: Harness has failed.
Repair.
T118386 UN21NOV98
Turn key switch OFF.
Disconnect 20-pin harness connector from monitor controller and display.
Check wire from alternator terminal D+ to pin 42 of 20-pin harness connector for
continuity and for short to ground.
Is continuity measured and no short found?
1/1

101603
PN=238
Alternator Shut Down NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Relay Isolation Diode measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
(V2) Check meter when checking continuity. diode has failed in a

measured in either check
open mode. Replace.
is OK.
9015
15
13
1/1
link.
T109319 UN28APR97
1/1
Alternator Shut Down 124 Volt Terminal YES: Relay is OK.

Relay (K1) Check 2Ground Terminal
3Relay Common NO: Relay has failed.
4Relay Normally Closed Replace.
5Relay Normal Open
Disconnect harness from relay.
T7447BG 1914JAN91
Connect 24 volts to relay terminal 1 and ground terminal
2.
Does relay click?
Connect ohmmeter to terminals 3 and 5.
Does ohmmeter read continuity?
1/1

101603
PN=239
Starting and Fuel Shutoff Circuit Operational

Information
The following conditions must be met for the circuit to

function:
Key switch in START and voltage present at the following:
Starter relay K13 terminal B

Fuel shutoff relay K15 terminal B
Starter M1 terminal B
Fuel shutoff solenoid Y7 hold-in coil terminal
9015
15
14
CED,OUOE012,14 1927OCT981/1
Starting and Fuel Shutoff Circuit Theory of Operation
When key switch S1 is moved to START, power is When the engine is running and the alternator is
applied from key switch terminal ST to terminal e of producing output voltage, starter protection relay K11
starter relay K13 and terminal g of fuel shutoff relay is energized by ground applied to terminal 2 of the
K15, energizing both relays. (The ground path for the relay from pin 18 of monitor controller and display A5.
starter relay coil is provided through terminals 3 and 4 This prevents the starter motor from being activated if
of de-energized starter protection relay K11). Battery the key switch is moved to START while the engine is
power from alternator power fusible link F22 is applied running, by removing the ground path for starter relay
from terminals B and G of energized starter relay K13 K13.
to starter M1 solenoid terminal C, energizing the
solenoid. This applies battery voltage at starter Start relay coil suppression diode V9 limits the voltage
terminal B (from battery relay K14) to the motor spikes generated by the starter relay coil when the
winding, and the starter motor starts cranking the relay de-energizes.
engine.
Fuel shutoff solenoid pull-in and hold-in coil
At the same time, power from fuel shutoff fusible link suppression diodes V10 and V8 limit the voltage
F23 is applied through terminals B and G of the spikes generated by the solenoid coils when they are
energized fuel shutoff relay to the pull-in coil of fuel de-energized.
shutoff solenoid Y7, opening the fuel valve. Power
from power on 10-amp fuse F5 at the hold-in coil of
the fuel shutoff solenoid keeps the fuel valve open
after the key switch is returned to ON.
CED,OUOE012,15 1914DEC981/1

101603
PN=240
Starting and Fuel Shutoff Circuit Schematic

T117941 1925JAN99
CED,OUOE012,16 1903FEB991/1

101603
PN=241
1 Starting and Fuel Shutoff Circuit Diagnostic Procedures
test or check.
1/1
Key Switch (S1) Check 1B Terminal YES: Go to next step.

2G1 Terminal
9015
3G2 Terminal NO: Key switch has
15
4ACC Terminal failed. Replace.
16
5M Terminal
6ST Terminal

T8357AL UN09NOV94
Turn key switch to ON.
Is continuity measured between terminals 1 and 4, and 1

and 5?
1B Terminal YES: Key switch is OK.

2G1 Terminal
3G2 Terminal NO: Key switch has
4ACC Terminal failed. Replace.
5M Terminal
6ST Terminal

T8357AM UN02DEC98
Turn key switch to START.
Is continuity measured between terminals 1 and 5, and 1

and 6?
1/1

101603
PN=242
Starter (M1) Solenoid YES: Solenoid is OK.

Check Check wiring harness.
NO: Repair or replace

starter solenoid.
T118428 UN21NOV98
CAUTION: Starter will crank engine if metal strap 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 gauge wire.

9015
Does solenoid click? 15
17
1/1
Starter (M1) Motor Check Disconnect metal strap from starter motor large terminal. YES: Starter motor is OK.
Check wiring harness.
Connect a heavy gauge wire from battery positive cable
to starter motor terminal. NO: Repair or replace
starter.
Does starter motor turn, but NOT crank engine?
T6534BJ UN07JAN97
1/1
Starter Relay (K13) Disconnect harness from relay. Connect 24 volts to small YES: Relay is OK. Check
Check terminal e and ground small terminal g. Measure wiring harness.
continuity between large terminals B and G.
NO: Relay has failed.
Is continuity measured? Replace relay.
T7466AD UN14MAR91
1/1

101603
PN=243
Start Relay Coil NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Suppression Diode (V9) measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,

open mode. Replace.
is OK.
9015
15
18
1/1
Battery Relay (K14) SRelay Coil +24 Volt Terminal YES: Relay is OK. Check
Check ERelay Coil Ground Terminal wiring harness.
BRelay Battery Input Terminal
ARelay Battery Output Terminal NO: Relay has failed.
Replace relay.
Disconnect harness from relay. Connect 24 volts to small
terminal S and ground small terminal E. Measure
continuity between large terminals A and B.
T8182AK UN03MAR94
1/1
link.
T109319 UN28APR97
1/1

101603
PN=244
Starter Protection Relay 124 Volt Terminal YES: Relay is OK.

(K11) Check 2Ground Terminal
5Relay Normally Open
Disconnect harness from starter protection relay.

T7447BG 1914JAN91

2.
Does relay click?
Does ohmmeter read continuity? 9015

15
19
1/1
Fuel Shutoff Relay (K15) 124 Volt Terminal YES: Relay is OK.
Check 2Ground Terminal
Disconnect harness from starter protection relay.
T7447BG 1914JAN91

2.
Does relay click?
1/1

101603
PN=245
Fuel Shutoff Solenoid YES: Solenoid is OK.

(Y7) Check Check wiring harness.
NO: Solenoid has failed.

Replace.
T118387 UN21NOV98
Disconnect harness from fuel shutoff solenoid.
Connect 24 volts to solenoid connector pins 1 and 2, and ground pin 3.
Does solenoid energize and pull injection pump shutoff lever back?
Remove power from pin 1.
Does solenoid remain energized.

9015
15
20
1/1
Fuel Shutoff Solenoid NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Hold-In Coil Suppression measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
Diode (V8) Check meter when checking continuity. diode has failed in a

open mode. Replace.
is OK.
1/1

101603
PN=246
Fuel Shutoff Solenoid NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Pull-In Coil Suppression measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
Diode (V10) Check meter when checking continuity. diode has failed in a

open mode. Replace.
is OK.
9015
15
21
1/1

101603
PN=247
Windshield Wiper and Washer Circuit Operational Information
The following conditions must be met for the circuit to Key switch ON.
function:
Upper windshield in closed position with latch fully

engaged.
CED,OUOE012,8 1921OCT981/1
9015
15
22

101603
PN=248
Windshield Wiper And Washer Circuit Theory

of Operation
The windshield wiper and washer circuit has four modes

of operation: windshield wiper ON (continuous), windshield
wiper INT (intermittent), windshield wiper OFF (park), and
windshield wash. The operation of the windshield wiper
and washer circuit is controlled by signals from the
monitor controller and the state of the wiper motor internal
position status switch.
Windshield Wiper Continuous Operation
When wiper speed switch S9 is placed in the ON position,

windshield wiper relays K6 (motor ground and
intermittent), K7 (wiper run), and K8 (hold for park) are 9015
energized by grounds at pins 26 and 27 of monitor 15
controller and display A5. Windshield wiper relay K9 23
(motor ground for park) is de-energized by an open at pin
24 of the monitor controller and display.
Power for windshield wiper motor M3 is supplied from

windshield wiper 10-amp fuse F12 through contacts 3 and
5 of energized wiper run relay K7 to terminal L of the
wiper motor. Terminal E of the wiper motor is connected
to frame ground through contacts 3 and 5 of relay K6, and
the wiper motor runs. The wiper motor drives a Pittman
arm assembly which moves the wiper blade back and
forth across the windshield.
Windshield wiper motor suppression diodes V6 and V7

protect the circuit components from voltage transients
generated by the wiper motor.
Windshield Wiper Intermittent Operation
When wiper speed switch S9 is placed in the INT position,

monitor controller and display A5 grounds pins 27 and 28,
and windshield wiper motor M3 is started in the same
manner as described for continuous operation. After 1 to 2
seconds, the ground at pin 28 of the monitor controller
and display is removed by the controller, causing motor
ground and intermittent relay K6 to de-energize. However,
ground to wiper motor terminal E is now provided from
wiper motor terminal S through contacts 3 and 4 of
de-energized relay K6, and the wiper motor continues to
run.

101603
PN=249
When the wiper motor reaches the intermittent stop

position (wiper blade at right side of window), terminal S
(which is applied to wiper motor terminal E through
contacts 3 and 4 of de-energized relay K6) is switched
from ground to +24 volts (from motor terminal B) by the
wiper motor internal switch. With +24 volts now at both
wiper motor terminals, E and L, the motor stops running.
After a few seconds, the cycle is repeated by another 1 to
2 second ground pulse from pin 28 of the monitor
controller and display.
Windshield Wiper Park Operation
When wiper speed switch S9 is turned to the OFF

position, monitor controller and display A5 grounds pin 24,
energizing motor ground for park relay K9, and opens pins
9015
15 26, 27, and 28. If the wiper motor is running (not in the
24 intermittent stop position), ground from terminal S of the
wiper motor (applied through relay K8 contacts 3 and 5)
keeps windshield wiper relays K7 (wiper run) and K8 (hold
for park) energized. The ground from terminal S is also
supplied through the de-energized contacts of motor
ground and intermittent relay K6 to wiper motor terminal
E, and the wiper motor continues running.
When windshield wiper motor M3 reaches the intermittent

stop position, wiper motor terminal S is switched from
ground to +24 volts by the wiper motor internal switch.
The +24 volts is applied to wiper motor terminal E, and
also reverse biases windshield wiper relay isolation diode
V5, causing windshield wiper relays K7 (wiper run) and K8
(hold for park) to be de-energized. Ground is now applied
through contacts 5 and 3 of energized relay K9 and
contacts 3 and 4 of de-energized relay K7 to wiper motor
terminal L. With +24 volts on wiper motor terminal E and
ground on wiper motor terminal L, the motor runs
backwards until a cam in the Pittman arm assembly
causes the wiper to be driven off the right side of the
windshield into the park position on the windshield frame.
When the wiper motor reaches the park position, motor
terminal S is grounded by the motor internal switch, and
the motor stops.

101603
PN=250
Windshield Washer Operation
When windshield washer switch S15 is pressed,

windshield washer relay K2 is energized by a ground at
pin 24 of monitor controller and display A5. Power is
applied to windshield washer motor M4 from windshield
wiper 10amp fuse F12 through contacts 3 and 5 of
energized relay K2. The motor drives the windshield
washer pump, to spray fluid from the windshield washer
fluid reservoir onto the windshield. When the switch is
released, ground is removed from pin 24 of monitor
controller and display A5, and the washer motor stops.
9015
15
25
CED,OUOE012,7 1915DEC983/3

101603
PN=251
Windshield Wiper And Washer Circuit Schematic

T117933 1918NOV98
CED,OUOE012,9 1903FEB991/1

101603
PN=252
1 Windshield Wiper and Washer Circuit Diagnostic Procedures
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Monitor
Controller or other components may result. Disconnect connectors only when instructed during a test or
check.
NOTE: If windshield wiper does not operate, first check the latch on the upper right corner of the windshield. The
windshield must be all the way down and the right latch must be secured to contact the windshield wiper enable
switch, which allows the wiper to operate.
Before troubleshooting the circuits, clean all pins in the monitor controller and harness connectors using a
non-conductive lubricating contact cleaner, then try the circuit operation again before proceeding. TY16324 Contact
Cleaner can be used.
9015
15
27
1/1
Windshield Wiper 10 Remove fuse block cover. YES: Fuse is OK.

Amp Fuse (F12) Check
Remove fuse from fuse block. NO: Replace Fuse. If
fuse blows again, check
Using ohmmeter, check fuse for continuity. for short.
1/1

101603
PN=253
Windshield Wiper Motor YES: Check harness,

(M3) Run and wiper relays and monitor
Intermittent Stop Check controller.
NO: Replace windshield

wiper motor.
T118388 UN21NOV98
Disconnect harness from windshield wiper motor.
Connect wiper motor connector pin E to connector pin S.
Connect +24 volts to wiper motor connector pin L.
If the windshield wiper was in the park position, did it operate for one sweep, then stop
in the intermittent stop position?
9015
Connect wiper motor connector pin E to ground (while still connected to S).
15
28
Does windshield wiper operate?
Remove ground from pin E.
Does windshield wiper continue operating until wiper blade reaches intermittent park
position, then stop?
1/1
Windshield Wiper Motor YES: Check harness,

(M3) Park Circuit Check wiper relays and monitor
controller.

wiper motor.
T118388 UN21NOV98
With key switch ON, move windshield wiper switch to INT.
When wiper stops in intermittent stop position, turn key switch OFF, then turn
windshield wiper switch OFF.
Disconnect harness from windshield wiper motor.
Connect wiper motor connector pin L to connector pin B.
Connect +24 volts to wiper motor connector pin E.
Ground wiper motor connector pin S.
Does wiper motor operate until wiper blade reaches park position?
1/1

101603
PN=254
Windshield Wiper Motor NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Suppression Diode (V6, measured in one direction only in a serviceable diode. measured in both checks,
V7) Check diode has failed in a

open mode. Replace.
T118385 UN21NOV98 measured in one check
and not the other, diode
The windshield wiper diodes are located inside right console lower cover. is OK.
Remove diodes from connectors.

9015
15
29
Install diodes in connectors.
1/1
Windshield Wiper Relay NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Isolation Diode (V5) measured in one direction only in a serviceable diode. measured in both checks,
Check diode has failed in a

open mode. Replace.
T118385 UN21NOV98 measured in one check
and not the other, diode
The windshield wiper diodes are located inside right console lower cover. is OK.
Remove diodes from connectors.
Install diodes in connectors.
1/1

101603
PN=255
Windshield Wiper Relay 124-Volt Terminal YES: Relay is OK.

(Motor Ground and 2Ground Terminal
Intermittent) (K6), 3Relay Common NO: Relay has failed.
Windshield Wiper Relay 4Relay Normal Closed Replace.
(Wiper Run) (K7), 5Relay Normal Open
Windshield Wiper Relay
(Hold for Park) (K8) and Disconnect relay from harness.
Windshield Wiper Relay
(Motor Ground for Park) Connect ohmmeter to relay terminals 3 and 4.
T7447BG 1914JAN91
(K9) Check

2.
Does relay click?
With 24 volts still connected to terminal 1, connect

ohmmeter to terminals 3 and 5.
9015
15 Does ohmmeter read continuity?
30
1/1
Windshield Washer 124-Volt Terminal YES: Relay is OK.

Relay (K2) Check 2Ground Terminal
4Relay Normal Closed Replace.
5Relay Normal Open
Disconnect relay from harness.
T7447BG 1914JAN91
Connect ohmmeter to relay terminals 3 and 4.

2.
Does relay click?
With 24 volts still connected to terminal 1 connect

1/1
Windshield Washer Disconnect harness from windshield washer motor. YES: Check wiring
Motor (M4) Check harness and monitor
Connect 24 volts to BLUE wire pin in washer motor controller.
connector.
Ground BLUE/BLACK wire pin in washer motor washer motor.
connector.
Does windshield washer motor operate?

T7395EG UN15OCT90
1/1

101603
PN=256
Windshield Wiper Enable Slide upper windshield up. YES: Windshield wiper
Switch (S14) Check enable switch is OK.
Remove windshield wiper enable switch retaining plate located in upper right hand
corner of cab. NO: Go to next check.
Connect ohmmeter across pins 1 and 2 of the switch and actuate the switch.
Is continuity measured when switch is actuated and no continuity when switch is not
actuated?
1/1
Windshield Wiper Enable Slide upper windshield up. YES: Windshield wiper
Switch (S14) Harness enable switch harness is
9015
Check Remove windshield wiper enable switch retaining plate located in upper right hand OK.
15
corner of cab.
31
NO: Check monitor
Using an ohmmeter, measure resistance of harness wire from enable switch pin 1 to controller.
pin 6 of monitor controller 12-pin connector, and from enable switch pin 2 to ground.
Is continuity measured in both checks?
1/1

101603
PN=257
Work and Drive Light Circuit Operational Information
In order for the circuit to function, the key switch must

be in the ACC or ON position.
CED,OUOE012,18 1930OCT981/1
Work and Drive Light Circuit Theory of Operation
When the key switch is in the ON or ACC position, mode and RPM control unit A4, and the ILLUM pin of
power is applied from work and drive light 10-amp fuse radio A1 for panel illumination.
F11 to terminals 1 and 3 of work and drive light relays
K3 and K4. When the light switch is moved to position 2, pin 20 of
the monitor controller and display is also grounded (pin
When drive and work light switch S10 is moved to 19 remains grounded), energizing work light relay K3
9015 position 1, drive light relay K4 is energized by ground as well. With the work light relay energized, power is
15 applied to relay terminal 2 from pin 19 of monitor and applied to work light E1 through relay terminals 3 and
32 controller display A5. With the drive light relay 5.
energized, power is applied to drive light E2 through
relay terminals 3 and 5. Relays K3 and K4 also apply power to pins 5 (work
light) and 4 (drive light) of optional connector X5 to
Power from the drive light relay is also applied to pin provide for connection of additional lights.
41 of monitor controller and display A5, pin 8 of engine
CED,OUOE012,19 1914DEC981/1

101603
PN=258
Work and Drive Light Circuit Schematic
9015
15
33
1911DEC98
T117934
CED,OUOE012,20 1921DEC981/1

101603
PN=259
1 Work and Drive Light Circuit Diagnostic Procedures
test or check.
NOTE: Before troubleshooting the circuits, clean all pins in the monitor controller and harness connectors using a
1/1
Work and Drive Lights 20 Remove fuse block cover. YES: Fuse is OK.
Amp Fuse (F11) Check
9015
15
34
1/1
Drive Light Relay (K4) 124 Volt Terminal YES: Relay is OK.
T7447BG 1914JAN91

2.
Does relay click?

1/1

101603
PN=260
Work Light Relay (K3) 124-Volt Terminal YES: Relay is OK.


T7447BG 1914JAN91

2.
Does relay click?

9015
Does ohmmeter read continuity? 15
35
1/1
Drive Light (E2) Circuit YES: Light switch on

Check monitor controller and
display panel has failed.
Replace.
NO: Check drive light

bulb, wire harness and
drive light relay.
T118361 UN21NOV98
Disconnect 16-pin harness connector from monitor controller and display panel.
Ground harness connector pin 19.
Does drive light operate with key switch in ACC position?
1/1

101603
PN=261
Work Light (E1) Circuit YES: Light switch on

Check monitor controller and
display panel has failed.
Replace.
NO: Check work light

bulb, wire harness, and
work light relay.
T118360 UN21NOV98
Disconnect 16-pin harness connector from monitor controller and display panel.
Ground harness connector pin 20.
Does work light operate with key switch in ACC position?
9015
15
36
1/1

101603
PN=262
9015
15
37

101603
PN=263
Accessory Circuits Operational Information
In order for the circuits to function, the key switch must

be in the ACC or ON position.
CED,OUOE012,21 1931OCT981/1
Accessory Circuits Theory of Operation
The accessory circuits include the horns (B25, B26), Power from dome light 5-amp fuse F18 is applied to
the cab dome light (E3), and the 24-volt power plug dome light switch S3. When the switch is turned ON,
(G4). power is applied to cab dome light E3, turning the light
on.
Power from horn 10-amp fuse F15 is applied to
terminal 1 and 3 of horn relay K5. When horn switch Power from lighter 10-amp fuse F17 is applied to
9015 S2 is pressed, the closed contacts of the switch apply 24-volt power plug G4.
15 ground to terminal 2 of the horn relay, and the relay is
38 energized. With the relay is energized, power is
applied from relay terminal 5 to high and low note
horns B25 and B26, sounding the horns.
CED,OUOE012,22 1921DEC981/1

101603
PN=264
Accessory Circuits Schematic
9015
15
39
1918NOV98
T117936
CED,OUOE012,23 1921DEC981/1

101603
PN=265
1 Accessory Circuits Diagnostic Procedures
test or check.
1/1
Horn 10 Amp Fuse (F15) Remove fuse block cover. YES: Fuse is OK.
Check
9015
15
40
1/1
Dome Light 5 Amp Fuse Remove fuse block cover. YES: Fuse is OK.
(F18) Check
1/1
Lighter 10 Amp Fuse Remove fuse block cover. YES: Fuse is OK.
(F17) Check
1/1

101603
PN=266
Horn Relay (K5) Check 124-Volt Terminal YES: Relay is OK.

2Ground Terminal

T7447BG 1914JAN91

2.
Does relay click?

9015
Is continuity measured? 15
41
1/1
Horn Switch (S2) Check YES: Horn switch OK.

Check wiring harness and
horns.
NO: Replace switch.
T108586 UN31MAR97
Remove bottom cover from left arm rest.
Disconnect wire harness from horn switch.
Connect ohmmeter to both wires (pink and black) and push horn button.
1/1
High Note Horn (B25) Disconnect wire harness from horns. YES: Check wire
and Low Note Horn (B26) harness.
Check Connect 24 volts to one terminal of either horn and
connect other horn terminal to ground. NO: Replace horn.
Does horn sound?
Repeat check on other horn.

T7469AF UN11MAR91
1/1

101603
PN=267

Conditioner)
See Group 9031-05.

CED,OUOE012,43 1904OCT001/1
Heater Circuit (Machines With Air

Conditioner)
See Group 9031-05.

CED,OUOE012,44 1904OCT001/1
Monitor Controller and Display Circuit Specifications

9015
15 Specification Alternator Charge Light Goes
42 Fuel Sending UnitResistance.................. 10 +0 -4 Ohms With Fuel Out At Alternator Excitation
Gauge Reading Full Field OutputVoltage .................................... 13 1.5 Volts Or More
Fuel Sending UnitResistance......... 38 5 Ohms With Fuel Gauge Air Filter Restriction Switch
Reading Half Closes AtVacuum............................................ 6.23 kPa 1.25 kPa
Fuel Sending UnitResistance................ 90 +10 -0 Ohms With Fuel Vacuum ................................................................... 1.84 0.36 in. Hg
Gauge Reading Empty Vacuum .............................................................................. 25 2.3 in.
Fuel Level Switch Closes At Coolant Temperature Gauge
Level .................................................... 112 mm (4.4 in.) Fuel In Tank Needle Position At
Or Less (30.337.9 L) (810 Temperature ............................................. 60C (140F) Beginning Of
gal) Green Area (Cold)
Engine Oil Pressure Switch Temperature .................................................... 104C (219F) End Of
Opens AtPressure ......................... Above 172 kPa (1.72 bar) (24.9 Green Area (Cold)
psi) Temperature ........................................... 110C (230F) Beginning Of
Engine Oil Pressure Switch Red Area (Hot)
Closes AtPressure ........................ Below 103 kPa (1.03 bar) (14.9 Temperature ............................................. 135C (275F) End Of Red
psi) Area (Hot)
Engine Coolant Temperature Engine Coolant Temperature
Switch Closes OnIncreasing SensorResistance .................................. 63 Ohms At 60C (140F)
Temperature Maximum ........................... 110C 3C (230F 37F) Resistance ............................................... 14 Ohms At 104C (219F)
Engine Coolant Temperature Resistance ............................................... 15 Ohms At 110C (230F)
Switch Opens OnDecreasing Resistance ................................................. 3 Ohms At 135C (275F)
Temperature Minimum.................................................... 95C (203F)
Alternator Charge Light
Illuminates At Alternator
Excitation Field Output
Voltage ............................................................. 10 1.5 Volts Or Less
CED,OUTX782,143 1903FEB991/1

101603
PN=268
9015
15
43

101603
PN=269
Monitor Controller and Display Circuit Operational Information
The key switch must ON for the circuit to function.
CED,OUOE012,26 1931OCT981/1
9015
15
44

101603
PN=270

Theory of Operation
The monitor controller and display (A5) contains gauges

and indicators, sensor inputs, and switches. The gauges
and indicators display the status of machine systems and
control switches. The sensor inputs are used by the
monitor controller to monitor the status of the machine
systems, and the switches are used to control or select
machine functions by providing control signal outputs to
other machine systems. The illumination of the indicators
and the status of control signal outputs are controlled by
logic circuits and drivers in the monitor controller in
response to the sensor inputs and control switch settings.
Operating power to the controller and display is applied 9015

from monitor controller and display fuse F6 to pin 40. Cab 15
frame ground is applied to pin 37. Backup power for the 45
controller logic circuits is applied from radio and monitor
controller fuse F1 to monitor controller pin 39.
HOURMETER AND GAUGES
Operating power for the hourmeter is applied from fuse F6

to controller pin 29, and the controller monitors the
alternator excitation field at pin 42. When the engine is
running and the alternator excitation field voltage is
greater than 11.5 volts, the hourmeter operates.
The engine coolant temperature and fuel level gauges (P2

and P3) are controlled by coolant temperature and fuel
level sensors B9 and B8, which provide a variable
resistance to ground for the gauges.
Temperature sensor B9 is applied to controller pin 47, and

fuel level sensor B8 is applied to pin 46.
STATUS INDICATORS
When the key switch is turned to ON, the monitor

controller and display performs a lamp check by
illuminating all the status indicators. After 2 - 3 seconds
the lamp check mode ends, and indicator lamp
illumination is controlled by the sensor inputs.
Continued on next page CED,OUOE012,55 1904OCT001/6

101603
PN=271
Air Filter Restriction Indicator Light (H14)
The air filter restriction switch (B1) is a normally open

switch that closes to machine ground when a restriction is
sensed with the engine running. The machine ground is
applied to controller pin 3, causing the indicator to
illuminate.
Fuel Level Indicator Light (H13)
The fuel level switch (B2) is normally open when fuel is in

the tank, and closes to machine ground when the fuel
level is below 112 mm (4.4 in.). The machine ground is
applied to controller pin 2, causing the indicator to
illuminate.
9015
15 Engine Coolant Temperature indicator Light (H16)
46
The engine coolant temperature switch (B3) is a normally
open switch that closes to machine ground when the
coolant temperature exceeds 105 5C (221 35F). The
machine ground is applied to controller pin 1, causing the
indicator to illuminate.
Engine Oil Pressure Indicator (H17)
The engine oil pressure switch (B4) is normally closed

and opens with the engine running. When the oil pressure
falls below 39 kPa (0.039 bar) (5.7 psi) the switch closes
to machine ground. The machine ground is applied to
controller pin 10, causing the indicator to illuminate.
Hydraulic Oil Level Indicator (H12)
Hydraulic oil level switch (B5) is a normally open switch,

held closed when the oil level is adequate. When closed,
the switch applies machine ground to controller pin 9. The
monitor controller only checks the status of pin 9 when the
fluid level switch (S5) is pressed. If ground is present
when the switch is pressed, the indicator illuminates.

101603
PN=272
Engine Coolant Level Indicator (H20)
Engine coolant level switch (B6) is a normally open

switch, held closed when the coolant level is adequate.
When closed, the switch applies machine ground to
controller pin 8. The monitor controller only checks the
status of pin 8 when the fluid level switch (S5) is pressed.
If ground is present when the switch is pressed, the
indicator illuminates.
Engine Oil Level Indicator (H19)
Engine oil level switch (B7) is a normally open switch,

held closed with adequate oil level. When closed, the
switch applies machine ground to controller pin 7. The
monitor controller only checks the status of pin 7 when the
9015
fluid level switch (S5) is pressed. If ground is present 15
when the switch is pressed, the indicator illuminates. 47
Alternator Voltage Indicator (H18)
The alternator voltage indicator is controlled by the

alternator excitation field voltage monitored by the
controller at pin 42. When the alternator excitation field
voltage drops below 10 1.5 volts the indicator
illuminates. When the alternator excitation field voltage
goes above 13 1.5 volts the indicator goes out.
Monitor Controller and Display Alarm (H8)
The monitor controller and display alarm sounds when the

engine oil pressure is low, or the engine coolant
overheats. When the buzzer stop switch (S6) is pressed
and released, the buzzer stops sounding and the buzzer
function is automatically reset for the engine coolant
overheat function. The buzzer cannot be turned off when
the oil pressure is low.
The buzzer is reset by turning the key switch to OFF. The

buzzer will not sound more than once for the same
problem unless it has been reset.

101603
PN=273
CONTROL SWITCHES AND INDICATORS
Wiper Speed Switch (S9)
The wiper speed switch is used to select intermittent or

continuous windshield wiper operation. The monitor
controller provides ground switched outputs to the
windshield wiper circuit from controller pins 24, 26, 27,
and 28 based on the setting of the wiper speed switch. If
the windshield is open, a ground from windshield wiper
enable switch S14 is allied to monitor controller pin 6,
disabling the wiper speed switch.
Windshield Washer Switch (S15)
When the windshield washer switch is pressed, the

9015
15 monitor controller provides a ground switched output to
48 the windshield washer circuit from controller pin 25.
Drive and Work Light Switch (10)
The drive and work light switch provides ground switched

outputs to the light circuits. When the switch is moved to
position 1, controller pin 19 (drive light) is grounded.
When the switch is moved to position 2, controller pins 19
and 20 (work light) are grounded.
Work Mode Selection Switch (S7)
The work mode selection switch selects the machine

operating modes (dig, grading, precision, or attachment).
Each time the switch is pressed the mode selection is
stepped to the next mode and the corresponding mode
indicator (H1, H2, H3 or H4) is illuminated. The monitor
controller provides different combinations of ground
switched outputs to the engine and pump controller
depending on the mode selected. The outputs are applied
from mode 1 and mode 2 monitor controller pins 21 and
22 to engine controller pins D3 and D4.

101603
PN=274
Mode Pin 21a Pin 22a

Dig H H
Grading L H
Precision H L
Attachment L L
a
H=5 0.5 volts; L=less than 1.0 volt.
Propel Speed Change Switch (S8)
The propel speed change switch selects slow or fast

operating speed. When fast speed is selected, the switch
applies a ground from monitor controller pin 17 to engine
and pump controller pin B12.
Auto Idle (A/I) Switch (S13)

9015
15
When the auto idle (A/I) switch is pressed, the A/I 49
indicator illuminates and the monitor controller applies a
ground from monitor controller pin 13 to engine motor and
pump controller pin D6.
ENGINE MODE AND RPM CONTROL UNIT (A4)
Economy (E) Mode Switch (S11)
When the economy (E) mode switch is pressed, a ground

is applied from engine mode and RPM control unit pin 2
to monitor controller pin 35, causing the economy mode to
be selected. With the economy mode selected, the
monitor controller illuminates the economy mode indicator
light (H6), and provides a ground from pin 15 to engine
and pump controller pin D5. Ground for the mode switch
is applied to engine mode and RPM control unit pin 1.
High Power (HP) Mode Switch (S12)
When the high power (HP) mode switch is pressed, a

ground is applied from engine mode and RPM control unit
pin 4 to monitor controller pin 34, causing the high power
mode to be selected. With the high power mode selected,
the monitor controller illuminates the high power mode
indicator light (H5), and provides a ground from pin 23 to
engine and pump controller pin B11. Ground for the mode
switch is applied to engine mode and RPM control unit pin
3.

101603
PN=275
Engine RPM Dial (R10)
The engine RPM dial provides a variable voltage to

engine and pump controller pin D21 from engine mode
and RPM control unit pin 6 based on the setting of the
RPM dial. Power for the RPM dial is applied across
engine mode and RPM control unit pins 5 and 7.
CED,OUOE012,55 1904OCT006/6
9015
15
50

101603
PN=276
Monitor Controller and Display Circuit Schematic

T118919 1911DEC98
CED,OUTX782,77 1915JAN991/1

101603
PN=277
1 Monitor Controller and Display Circuit Diagnostic Procedures
test or check.
NOTE: Before troubleshooting the circuits, clean all pins in the monitor controller and harness connectors using a
1/1
Monitor Controller and Remove fuse block cover. YES: Fuse is OK.
Display 5 Amp Fuse (F6)
9015
Check Remove fuse from fuse block. NO: Replace Fuse. If
15
52
1/1
Monitor Controller And YES: Go to next check.

Display (A5) Harness
Power Check NO: Repair harness.
T118378 UN21NOV98
Measure voltage on pins 30, 39 and 40 of harness connector.
Is 24 volts measured?
1/1

101603
PN=278
Monitor Controller And YES: Monitor controller

Display (A5) Harness has failed. Replace.
Ground Check
NO: Repair wiring
harness.
T118378 UN21NOV98
Measure continuity from pin 37 of harness connector to cab frame.
9015
15
53
1/1
Economy Mode Indicator With key switch ON and economy mode OFF, push economy (E) mode switch. YES: Indicator and switch
Light (H6) Check are OK.
Does switch stay down and economy mode indicator light come ON?
Push economy (E) mode switch again.
Does switch return to original position and indicator go OFF?
1/1
Economy (E) Mode YES: Switch is OK. Go to

Switch (S11) Check next check.
NO: Switch has failed.

Replace.
T118513 UN21NOV98
Disconnect engine mode and RPM control unit (A4) connector.
Connect ohmmeter between pins 1 and 2 of connector.
Measure continuity with economy (E) mode switch in OFF and ON positions.
Does ohmmeter read open with switch in OFF position, and continuity with switch in
ON position?
Reconnect engine mode and RPM control unit connector.
1/1

101603
PN=279
Economy (E) Mode YES: Indicator lamp or

Switch (S11) Harness controller has failed.
Check Replace.

Repair.
T118512 UN21NOV98
Connect ohmmeter between pins 35 and 38 of harness connector.
Measure continuity with economy (E) mode switch in OFF and ON positions.
9015
ON position?
15
54
1/1
High Power Mode With key switch ON and high power mode OFF, push high power (HP) mode switch. YES: Indicator and switch
Indicator Light (H5) are OK.
Check Does switch stay down and high power mode indicator light come ON?
Push high power (HP) mode switch again.
Does switch return to original position and indicator go OFF?
1/1
High Power (HP) Mode YES: Switch is OK. Go to

Switch (S12) Check next check.

Replace.
T118515 UN21NOV98
Disconnect engine mode and RPM control unit (A4) connector.
Connect ohmmeter between pins 3 and 4 of connector.
Measure continuity with high power (HP) mode switch in OFF and ON positions.
ON position?
Reconnect engine mode and RPM control unit connector.
1/1

101603
PN=280
High Power (HP) Mode YES: Indicator lamp or

Switch (S12) Harness controller has failed.
Check Replace.

Repair.
T118514 UN21NOV98
Connect ohmmeter between pins 34 and 38 of harness connector.
Measure continuity with high power (HP) mode switch in OFF and ON positions.
9015
ON position?
15
55
1/1
Work Mode Selection Turn key switch ON. YES: Switch and
Switch (S7), Dig Mode indicators are OK.
Indicator Light (H1), Push WORK MODE switch several times to cycle through all work mode selections
Grading Mode Indicator (dig, grading precision, attachments). NO: If modes do not
Light (H2), Precision change, switch or monitor
Mode Indicator Light (H3) Does mode selection change when switch is pressed? controller has failed.
and Attachment Mode Repair or replace.
Indicator Light (H4) Does each mode indicator come ON as mode is selected?
Check Replace indicator lamp
that does not come ON.
1/1
Auto Idle Switch (S13) Turn key switch ON. YES: Switch and indicator
and Auto Idle Mode are OK
Indicator Light (H7) Push auto idle (A/I) switch.
Check NO: Check indicator
Does auto idle (A/I) indicator come ON? lamp. If lamp is OK,
switch or controller has
Push auto idle (A/I) again. failed. Replace.
Does auto idle (A/I) indicator go OFF?
1/1

101603
PN=281
Alternator Voltage Turn key switch ON. YES: Go to next step.

Indicator Light (H18)
Check Engine OFF. NO: Check indicator
lamp. If OK go to next
Is alternator voltage indicator light ON? check.
T6768CR UN18OCT88
Start engine. YES: Indicator light is

OK.
Does alternator voltage indicator light go OFF?
9015
15
56
1/1
Alternator Voltage YES: Monitor controller

Indicator Light Harness may have failed.
Check
Repair.
T118386 UN21NOV98
Check wire from alternator terminal D+ to pin 42 of 20-pin harness connector for
continuity and for short to ground.
Is continuity measured and no short found?
1/1

101603
PN=282
Engine Coolant Level Check coolant level in overflow recovery tank. Be sure YES: Indicator is OK. Go
Indicator Light (H20) level is between FULL and LOW marks. to next step.
Check
Turn key switch ON. NO: Check indicator
lamp.
Observe coolant level indicator.
Does indicator come ON, then go OFF 23 seconds

later?
T7469AK UN14MAR91
YES: Engine coolant level

switch is OK.
9015
15
57
T102542 UN29AUG96
AFluid Level Check Switch
Push fluid level check switch.
Does coolant level indicator come ON?
1/1
Engine Coolant Level Disconnect harness from engine coolant level switch. YES: Engine coolant level
Switch (B6) Check switch has failed.
Connect a jumper wire between harness connector pins. Replace.
Turn key switch ON. NO: Check wiring

harness.
T7469AL UN14MAR91
Does coolant level indicator come ON?
1/1

101603
PN=283
Engine Oil Level YES: Indicator is OK. Go

Indicator Light (H19) to next step.
Check
NO: Check indicator
lamp.
T7469AM UN11MAR91 T101681 UN29AUG96
Check oil level in engine pan, be sure level is between FULL and ADD marks on dip
stick.
Turn key switch ON.
Observe engine oil level indicator.
Does indicator come ON then go OFF 23 seconds later?

9015
15
YES: Engine oil level
58
switch is OK.
T102542 UN29AUG96
Does engine oil level indicator come ON?
1/1
Engine Oil Level Switch Disconnect harness from engine oil level switch. YES: Engine oil level
(B7) Check switch has failed.
Connect a jumper wire from harness connector to Replace.
ground.
NO: Check wiring
Turn key switch ON. harness.

T7470AH UN11MAR91
Does engine oil level indicator come ON?
1/1

101603
PN=284
Hydraulic Oil Level YES: Indicator is OK. Go

Indicator Light (H12) to next step.
Check
NO: Check indicator
lamp.
T7470AI UN11MAR91 T101683 UN29AUG96
Check oil level in hydraulic reservoir. Be sure level is between red lines on sight
gauge.
Turn key switch ON.
Observe hydraulic oil level indicator.
Does indicator come ON then go OFF 23 seconds later?

9015
15
YES: Hydraulic oil level
59
switch is OK.
T102542 UN29AUG96
Does hydraulic oil level indicator come ON?
1/1
Hydraulic Oil Level Disconnect harness from hydraulic oil level switch. YES: Hydraulic oil level
Connect a jumper wire between harness connector pins. Replace.
Turn key switch ON. NO: Check wiring

harness.
Does hydraulic oil level indicator come ON?

T7470AJ UN05MAR91
1/1

101603
PN=285
Engine Coolant With engine cool, turn key switch ON. YES: Indicator is OK. Go
Temperature Indicator to next check.
Light (H16) Check Observe engine temperature indicator.
NO: If indicator does not
Does indicator come ON when key switch is turned ON, come ON, check indicator
then go OFF 23 seconds later? lamp.
If indicator does not go

T101686 UN29AUG96 OFF, go to next check.
1/1
Engine Coolant Disconnect harness from engine coolant temperature YES: Engine coolant
Temperature Switch (B3) switch. temperature switch has
9015
Check failed. Replace.
15
If engine coolant temperature indicator was ON, did it go
60
OFF with harness disconnected and key switch ON? NO: Check harness.
If indicator was OFF, connect a jumper wire between

harness connector pins.
T7470AM UN05MAR91
Does indicator come ON when key switch is ON?
1/1
Engine Oil Pressure Disconnect harness from engine oil pressure switch. YES: Indicator is OK. Go
Indicator Light (H17) to next check.
Check Turn key switch ON and observe engine oil pressure
indicator. NO: If indicator does not
come ON, check indicator
Does indicator come ON when key switch is turned ON, lamp.
then go OFF 23 seconds later?
T101684 UN29AUG96 OFF, check harness for
short.
1/1
Engine Oil Pressure Connect harness to engine oil pressure switch. YES: Go to next step.
Switch (B4) Check
Does indicator come ON with key switch ON? NO: Check harness for
open. If harness is OK,
replace switch.
Start engine. YES: Engine oil pressure

switch is OK.
Observe engine oil pressure indicator.
NO: Engine oil pressure
Does indicator go OFF? switch has failed.
Replace.
1/1

101603
PN=286
Air Filter Restriction Turn key switch ON. YES: Indicator is OK. Go
Indicator Light (H14) to next check.
Check Observe air filter restriction indicator.
Does indicator come ON when key switch is turned ON, then go OFF 23 seconds come ON, check indicator
later? lamp.

OFF, go to next check.
1/1
Air Filter Restriction YES: Air filter restriction

9015
Replace.
15
61
NO: Check harness.
T118382 UN21NOV98
Disconnect two harness leads from air filter restriction switch.
If indicator was ON, did it go OFF with leads disconnected and key switch ON?
If indicator was OFF, connect two harness leads together.
1/1
Fuel Gauge (P3) Check YES: Gauge and gauge

resistor are OK. Go to
fuel level sensor (B8)
check.
T118389 UN30NOV98
Disconnect 20-pin harness connector from monitor display and controller connector.
Connect 24 volts to 20-pin monitor display and controller pin 30.
Then ground pin 46.
Does gauge needle point to E with 24 volts applied to pin 30, and F with pin 46
grounded?
1/1

101603
PN=287
Fuel Gauge Resistor (R5) YES: Gauge has failed.

Check Replace.
NO: Resistor has failed.

Replace.
T118391 UN21NOV98
NOTE: Check fuel gauge before checking resistor. Resistor is located on bottom of
monitor controller panel. Access resistor by removing bottom cover from monitor
controller panel.
Connect ohmmeter to resistor terminals.
Does ohmmeter read about 220 ohms?
9015
15
62
1/1
Fuel Level Sensor (B8) NOTE: Check fuel gauge before checking sensor. YES: Sensor has failed.
Check Replace.
Disconnect harness from fuel level sensor.
NO: Check harness.
Observe fuel gauge.
Does gauge needle go to E?
T7472AE UN11MAR91
Connect jumper wire between harness connector pins.
Does gauge needle go to F?
1/1
Fuel Level Indicator With adequate fuel in tank, turn key switch ON. YES: Indicator is OK. Go
Light (H13) Check to next check.
Observe fuel level indicator.
Does indicator come ON when key switch is turned ON, then go OFF 23 seconds come ON, check indicator
later? lamp.

OFF, go to next check.
1/1

101603
PN=288
Fuel Level Switch (B2) Disconnect harness from fuel level switch. YES: Fuel level switch
Check has failed. Replace.
If indicator was ON, did it go OFF with harness
disconnected and key switch ON? NO: Check harness.
If indicator was OFF, connect a jumper wire from

harness connector to ground.

T7472AB UN14MAR91
1/1
Engine Coolant YES: Gauge and gauge

Temperature Gauge (P2) resistor are OK. Go to
9015
Check engine coolant
15
temperature sensor (B9)
63
check.
T118390 UN21NOV98
Disconnect 20-pin harness connector from monitor display and controller connector.
Connect 24 volts to 20-pin monitor display and controller pin 30.
Then ground pin 47.
Does gauge needle point to C with 24 volts applied to pin 30, and H with pin 47
grounded?
1/1
Engine Coolant YES: Gauge has failed.

Temperature Gauge Replace.
Resistor (R4) Check
NO: Gauge resistor has
failed. Replace.
T118391 UN21NOV98
NOTE: Check engine coolant temperature gauge before checking resistor. Resistor is
located on bottom of the monitor controller panel. Access resistor by removing bottom
cover from monitor controller panel.
Connect ohmmeter to resistor terminals.
Does ohmmeter read about 220 ohms?
1/1

101603
PN=289
Engine Coolant NOTE: Check engine coolant temperature gauge before YES: Sensor is OK.
Temperature Sensor (B9) checking resistor. Check harness.
Check
Disconnect harness from temperature sensor. NO: Sensor has failed.
Replace.
Connect ohmmeter to sensor and ground.
Start engine and observe ohmmeter.

T8359AJ UN10NOV94
Does ohmmeter reading decrease as engine becomes
warmer?
1/1
9015
15
64

101603
PN=290
9015
15
65

101603
PN=291
Engine and Pump Controller Circuit Operational Information
The following conditions must be met for the circuit to Engine and pump controller connector pins B7, D1,
function: D2, A1, and A13
Relay K10 terminal 1
Key switch ON and voltage present at the following:
CED,TX14795,4140 1921DEC981/1
9015
15
66

101603
PN=292
Engine and Pump Controller Circuit Theory

of Operation
The engine and pump controller (EPC) A2 monitors and

controls engine speed and all digging functions, propel
functions, hydraulic pump functions, and pilot functions.
The EPC applies service codes from EPC pins B8, B15,
and B16 to diagnostic connector X1 for analysis of
hydraulic and electrical systems by the diagnostic
computer.
ENGINE CONTROL CIRCUITS
Engine Speed Control

9015
The engine speed control circuits monitor and adjust the 15
engine speed to match the operating modes selected. The 67
engine and pump controller (EPC) monitors the engine
speed via signals from the engine speed sensor (B16)
applied to EPC pins B6 and B13. The EPC controls the
engine speed by sending rotation control signals to the
engine control (EC) motor (M2) from pins A12, A24, A25,
and A26. The EC motor is mechanically linked to the
engine throttle linkage. As the motor rotates, the engine
throttle linkage is moved, changing the engine speed. The
engine control (EC) sensor (B17) provides a signal to
EPC at pin D15 indicating the amount of EC motor
rotation.
When the engine is started, the dig hydraulic work mode

is selected by logic circuit in the monitor controller. Each
time work mode select switch is pushed a different work
mode is selected (Dig, Grading, Precision, and
Attachment).
Operating mode selection signals from the monitor

controller and display are applied to EPC pins B11, D3,
D4, D5, and D6. The combination of signals instructs the
EPC which mode has been selected. When an operating
mode is changed, the EPC causes the EC motor to rotate,
changing the engine speed. When the engine speed
matches the requirement for the mode selected, the EC
motor stops rotating and the engine speed remains
constant. If another mode is selected, the process is
repeated until the engine speed has changed to match the
new mode speed requirement.

101603
PN=293
Auto A/I Idle Mode
An RPM dial is provided to vary engine speed to any

speed between slow idle and fast idle if E or HP modes
do not provide a speed adequate to the job. Each time the
engine is started, the EPC automatically activates the idle
mode to run the engine at the engine RPM dial setting.
When the auto idle mode is activated by the auto idle

switch, a signal from the monitor controller is applied to
EPC pin D6 informing the EPC that auto idle is selected.
With auto idle selected, mode switches E and HP control
engine speed during machine operation. However, if a
hydraulic function is not used for more than 4 seconds,
the EPC automatically reduces the engine speed to auto
idle.
9015
15
68 Learning Switch (S16)
If the engine and pump controller or EC sensor is

changed, the EPC learning sequence must be activated
the next time engine is started. The learning switch
activates the EPC learning sequence by applying a
ground to EPC pin B5. When the switch is activated, the
slow idle engine speed is registered in the EPC memory.
After maximum power engine speed is stored in EPC
memory, the EPC calculates the economy mode (E)
speed as a percentage of the slow idle speed.
HYDRAULIC CONTROL CIRCUITS
The hydraulic control circuits consist of pressure sensors

and switches, proportional control solenoids, and power
boost switch. The EPC utilizes input signals from the
pressure sensors and switches to monitor the machine
hydraulic functions. It then controls the propel speed, relief
valve pressure, pump swash, and arm regenerative
functions by sending control signals to the propel speed,
power boost, speed sense, and arm regenerative
proportional solenoids.
These circuits control the hydraulic functions of the

machine at the same time the EPC is controlling engine
speed to provide maximum machine quickness and
productivity for the load conditions and operating mode
selected.
CED,OUOE012,33 1915DEC982/2

101603
PN=294
Engine and Pump Controller Circuit Schematic

T117931 1907DEC98
CED,OUOE012,34 1903FEB991/1

101603
PN=295
1 Engine and Pump Controller Circuit Diagnostic Procedures
test or check.
NOTE: Before troubleshooting the circuits, clean all pins in the engine and pump controller, and harness connectors
using a non-conductive lubricating contact cleaner, then try the circuit operation again before proceeding. TY16324
Contact Cleaner can be used.
1/1
Engine and Pump Turn key switch OFF. YES: Fuse is OK. Check
Controller 10 Amp Fuse wiring harness
9015
(F2) Check Remove fuse block cover.
15
NO: Replace Fuse. If
70
Remove fuse from fuse block. fuse blows again, check
for short.
Using ohmmeter, check fuse for continuity.
1/1
Power On 10 Amp Fuse Turn key switch OFF. YES: Fuse is OK. Check
(F5) Check wiring harness
Remove fuse block cover.
Remove fuse from fuse block. fuse blows again, check
for short.
Using ohmmeter, check fuse for continuity.
1/1
Engine Control (EC) Turn key switch OFF. YES: Fuse is OK. Check
Motor 10 Amp Fuse (F3) wire from fuse to monitor
Check Remove fuse block cover. controller connector D,
pins 1 and 2. If OK, go to
Remove fuse from fuse block. next check.
Using ohmmeter, check fuse for continuity. NO: Replace Fuse. If

Is continuity measured? for short.
1/1

101603
PN=296
Solenoid 5 Amp Fuse Remove fuse block cover. YES: Fuse is OK. Check
(F4) Check wiring harness
Remove fuse from fuse block.
Using ohmmeter, check fuse for continuity. fuse blows again, check
for short.
1/1
Engine Control (EC) YES: EC motor is OK. Go

Motor (M2) Check to next check.
9015
15
NO: Motor has failed.
71
Replace.
T118380 UN21NOV98
Disconnect harness from EC motor.
Measure resistance between pin 1 and pin 3, and between pin 2 and pin 4.
Does ohmmeter read approximately the same resistance for both measurements?
1/1
Engine Control (EC) YES: EC motor harness

Motor (M2) Harness is OK. Go to next check.
Check
NO: Repair open wire.
T118393 UN30NOV98
Disconnect harness from EC motor.
Disconnect 26-pin connector A from engine and pump controller.
Measure continuity from pin 1 in EC motor connector to pin 24 in connector A.
Does ohmmeter read approximately the same resistance in all 4 measurements?

1/1

101603
PN=297
Engine Control (EC) YES: EC Sensor is OK.

Sensor (B17) Check Go to next check.
NO: Sensor has failed.

Replace.
T118392 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Disconnect harness from EC sensor.
Measure resistance of sensor from connector pin 1 to pin 3, and pin 1 to Pin 2.
Does ohmmeter read 2000 400 ohms from pin 1 to pin 3 and something less than
9015
that from pin 1 to pin 2?
15
72
1/1

101603
PN=298
Engine Control (EC) 1Positive Pin YES: Go to next step.

Sensor (B17) Harness 2Sense Pin
Check 3Negative Pin NO: Harness has failed.
Repair.
Turn key switch ON.

T118488 UN21NOV98
Measure voltage between pin 1 and pin 3 of EC sensor

harness connector.
YES: Harness is OK.

Repair. 9015
15
73
T118379 1930NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Connect jumper wire between sensor harness connector pins 1 and 2.
Disconnect 22-pin connector D and 16-pin connector B from engine and pump
controller.
Measure continuity between pin 9 of connector B and pin 15 of connector D.
1/1

101603
PN=299
Engine Speed (N) Sensor Turn key switch OFF. YES: Sensor is OK. Go
(B16) Check to next check.
Disconnect harness from engine speed sensor.
Measure resistance across speed sensor connector pins Replace.
1 and 2.
Does ohmmeter read 810 240 ohms?

T7502BM UN01APR91
Start engine.
Measure AC voltage at speed sensor terminals. Increase

engine speed.
Does AC voltage increase as engine speed increases?
9015
15
74
1/1
Engine Speed (N) Sensor YES: Harness is OK.

(B16) Harness Check
Repair.
T118373 1930NOV98
Disconnect harness from engine speed sensor.
Disconnect 16-pin connector B from engine and pump controller.
Measure continuity between pins 6 and 13 of connector B.
Does ohmmeter read open?
Connect jumper wire between sensor harness connector pins 1 and 2.
1/1

101603
PN=300
Economy (E) Mode YES: Harness wire is OK.

Output to Engine and
Pump Controller Harness NO: Harness wire is
Check open. Repair.
9015
T118394 1930NOV98 15
75
Disconnect 16-pin harness connector from monitor controller and display, and 22-pin
harness connector D from engine and pump controller.
Measure continuity between pin 15 of monitor controller harness connector and pin 5
of engine and pump controller harness connector D.
1/1
High Power (HP) Mode YES: Harness wire is OK.

Output to Engine and
Pump Controller Harness NO: Harness wire is
Check open. Repair.
T118376 1930NOV98
harness connector B from engine and pump controller.
of engine and pump controller harness connector B.
1/1

101603
PN=301
Mode 1 Output to Engine YES: Harness wire is OK.

and Pump Controller Go to next check.
Harness Check
NO: Harness wire is
open. Repair.
9015
15 T118395 1930NOV98
76
1/1
Mode 2 Output to Engine YES: Harness wire is OK.

and Pump Controller
Harness Check NO: Harness wire is
open. Repair.
T118396 1930NOV98
1/1

101603
PN=302
Auto Idle to System YES: Harness wire is OK.

Controller Harness
Check NO: Harness wire is
open. Repair.
9015
T118381 1921NOV98 15
77
Disconnect 16-pin harness connector from monitor controller, and 22-pin harness
connector D from engine and pump controller.
1/1
Engine RPM Dial (R10) YES: Engine RPM dial is

Check OK. Go to next check.
NO: Engine RPM dial has

failed. Replace.
T118383 UN17MAR99
Disconnect harness connector from engine mode and RPM control unit A4.
Measure resistance from engine mode and RPM control unit pin 5 to pin 7, and from
pin 5 to pin 6.
Is 5000 500 ohms measured from pin 5 to pin 7, and less than that from pin 5 to pin
6?
1/1

101603
PN=303
Engine RPM Dial (R10) YES: Engine RPM dial

Harness Check harness is OK.

Repair.
9015
15
78
T118397 1930NOV98
Disconnect 16-pin harness connector B and 22-pin harness connector D from engine
and pump controller.
Disconnect harness connector from engine mode and RPM control unit A4.
Measure continuity from pin 5 of engine mode and RPM control unit harness connector
to pin 9 of engine and pump controller harness connector B.
to pin 22 of engine and pump controller harness connector D.
to pin 21 of engine and pump controller harness connector D.
1/1

101603
PN=304
Power Boost Switch YES: Switch and harness

(S19) Check are OK.
NO: Go to next step.
T118538 1921NOV98
Disconnect 16-pin harness connector B from engine and pump controller.
Connect ohmmeter from pin 4 of harness connector B to ground.
Press power boost switch.
Does ohmmeter read continuity when switch is pressed?

9015
15
YES: Switch is OK. 79
Check harness wiring.

Replace.
T118486 UN21NOV98
Remove right console bottom cover.
NOTE: Do not disconnect wires other than power boost wires.
Disconnect two leads from power boost switch.
Connect ohmmeter to both leads from switch.
Press switch button.
1/1

101603
PN=305
Arm In Pressure Sensor YES: Harness wire is OK.

(B20) Harness Check Go to next step.
NO: Wire or engine and

pump controller has
failed. Repair.
T118372 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Disconnect harness from arm in pressure sensor.
Connect voltmeter to sensor harness connector pin 1 and ground.

9015
15
Turn key switch ON.
80
Does voltmeter read 5 volts?
YES: Harness wire is OK.

Go to next step.
NO: Wire has failed.

Repair.
T118371 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Connect ohmmeter to sensor harness connector pin 3 and ground.
1/2

101603
PN=306
YES: Wire harness is OK.

Go to next check.
NO: Wire from pin 18 of

connector D to pin 2 of
sensor harness connector
has failed. Repair.
9015
T118358 1921NOV98 15
81
Install jumper between sensor harness connector pins 1 and 2.
controller.
Measure continuity between pin 9 of harness connector B and pin 18 of harness

connector D.
19 2/2
Arm In Pressure Sensor Install pump control test harness JT07353 in series with wiring harness and sensor. YES: Sensor is OK.
(B20) Check Engine and pump
Connect voltmeter to test harness jacks. controller may have
failed.
With engine running, pilot control lever forward, and hydraulic functions in neutral,
observe voltage. NO: Sensor has failed.
Replace.
Is voltage between 0.5 and 0.7 volts?
Actuate arm in to achieve hydraulic function over relief.
Does voltage increase to between 3.3 and 3.5 volts with hydraulic function over relief?
1/1

101603
PN=307
Rear Pump Control YES: Harness wire is OK.

Pressure Sensor (B21) Go to next step.
and Front Control
Pressure Sensor (B22) NO: Wire or engine and
Harness Check pump controller has
failed. Repair.
T118372 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Disconnect wiring harness connector from front (B22) or rear (B21) pump control
pressure sensor.
9015
15
82
Turn key switch ON.

Go to next step.

Repair.
T118371 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
1/2

101603
PN=308

Go to next check.
NO: Wire from connector

D to sensor harness
connector pin 2 has
failed. Repair.
9015
T118359 1921NOV98 15
83
controller.

connector D (for front pressure sensor), or pin 14 of harness connector D (for front
pressure sensor) .
19 2/2
Rear Pump Control Install pump control test harness JT07353 in series with wiring harness and sensor. YES: Sensor is OK.
Pressure Sensor (B21) Engine and pump
and Front Control Connect voltmeter to test harness jacks. controller may have
Pressure Sensor (B22) failed.
Check With engine running, pilot control lever forward, and hydraulic functions in neutral,
observe voltmeter. NO: Sensor has failed.
Replace.
Is voltage 0.5 - 0.7 volts?
Slowly actuate boom up (for front pressure sensor B22) or left track (for rear pressure
sensor B21) until motion just begins.
Does voltage increase to 3.3 - 3.5 volts when motion begins?
1/1

101603
PN=309
Rear Pump Pressure YES: Harness wire is OK.

Sensor (B18) and Front Go to next step.
Pump Pressure Sensor
(B19) Sensor Harness NO: Wire or engine and
Check pump controller has
failed. Repair.
T118369 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Disconnect wiring harness connector from front (B19) or rear (B18) pump pressure
sensor.
9015
15
84
Turn key switch ON.

Go to next step.

Repair.
T118368 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
1/2

101603
PN=310

Go to next check.
NO: Wire from connector

D to sensor harness
connector pin 2 has
failed. Repair.
9015
T118370 1921NOV98 15
85
1Positive Pin
2Sense Pin
3Negative Pin
controller.

connector D (for front pressure sensor), or pin 17 of harness connector D (for rear
pressure sensor) .
19 2/2

101603
PN=311
Rear Pump Pressure YES: Sensor is OK.

Sensor (B18) and Front Engine and pump
Pump Pressure Sensor controller may have
(B19) Check failed.

Replace.
T118560 UN21NOV98
1Positive Pin
2Sense Pin
3Negative Pin
Install pump pressure sensor test harness JT07354 in series with wiring harness and
sensor.
Connect voltmeter to test harness jacks.

9015
With engine running, pilot control lever forward, and hydraulic functions in neutral,
15
observe voltmeter.
86
Is voltage 0.5 - 0.7 volts?
Actuate arm in to achieve hydraulic function over relief.
Does voltage increase to 3.3 - 3.5 volts with hydraulic function over relief?
1/1
Boom Up Pressure Turn key switch OFF. YES: Pressure switch is

Switch (B13) Check OK. Check switch
Disconnect wiring harness at boom up pressure switch. harness. If harness is OK,
engine and pump
Connect ohmmeter to pins 1 and 2 of pressure switch controller may have
connector. failed.
With engine running and pilot control lever forward, NO: Boom up pressure
T112437 UN05DEC97
actuate boom up lever. switch has failed.
Replace.
Is continuity measured when boom up lever is actuated?
1/1
Dig Pressure Switch Turn key switch OFF. YES: Pressure switch is
(B14) Check OK. Check switch
Disconnect wiring harness at dig pressure switch. harness. If harness is OK,
engine and pump
Connect ohmmeter to pins 1 and 2 of pressure switch controller may have
connector. failed.
With engine running and pilot control lever forward, NO: Dig pressure switch
T112437 UN05DEC97
slowly actuate arm in lever while observing ohmmeter. has failed. Replace.
Is continuity measured as arm in lever is actuated?
1/1

101603
PN=312
Propel Pressure Switch Turn key switch OFF. YES: Pressure switch is
(B15) Check OK. Check for continuity
Disconnect wiring harness at propel pressure switch. from harness connector
pin 1 to ground. If OK, go
Connect ohmmeter to pins 1 and 2 of pressure switch to next check.
connector.
NO: Propel pressure
With engine running and pilot control lever forward, switch has failed.
T112437 UN05DEC97
slowly actuate propel lever while observing ohmmeter. Replace.
Is continuity measured as propel lever is actuated and

track begins to move?
1/1
Propel Auto Idle Relay 124-Volt Terminal YES: Relay is OK.

(K10) Check 2Ground Terminal
9015
15
87
Disconnect relay from harness.
T7447BG 1914JAN91
Connect ohmmeter to relay terminals 3 and 4.
Connect 24 volts to relay terminal 1, and ground terminal

2.
Does relay click?

1/1
Travel Alarm 5 Amp Fuse Remove fuse block cover. YES: Fuse is OK. Go to
(F10) Check next check.
for short.
1/1

101603
PN=313
Propel Auto Idle Relay YES: Wire are OK. Go to

(K10) Harness Check next step.

Repair.
T118561 UN21NOV98
Remove harness connector from relay
With ohmmeter measure continuity from relay harness connector pin 5 to ground.
Connect voltmeter from relay harness connector pin 1 to ground.

9015
15
Turn key switch to ON and measure voltage at pin 1.
88
YES: Wire and isolation

diode V4 are OK. Go to
next step.
NO: Check wire for open.

If OK, go to diode V4
check.
T118362 UN21NOV98
124-Volt Pin
2Ground Pin
3Relay Common
4Relay Normally Closed
Disconnect wiring harness at propel pressure switch.
NOTE: Use diode checking mode on meter when checking this reading.
Connect an ohmmeter to relay harness connector pin 2 and pressure switch connector
pin 1.
Measure resistance, then reverse ohmmeter probes and measure resistance again.
Does resistance read approximately 500 ohms in one direction, and open in the other
direction?
1/2

101603
PN=314
124-Volt Pin YES: Harness is OK.

2Ground Terminal
3Relay Common 5 Volts To D9 NO: Harness or engine
4Relay Normally Closed and pump controller has
5Relay Normally Open To Ground failed. Repair or replace.
Connect voltmeter to relay harness connector pin 3 and

ground.
T102860 UN12AUG96
Turn key switch ON.
Does voltmeter read 5 volts.
19 2/2
Propel Auto Idle Relay NOTE: A diode can fail in two modes, either shorted or open. Continuity will be YES: If continuity is
Isolation Diode (V4) measured in one direction only in a serviceable diode. Use diode checking mode on measured in both checks,
9015
15
89
open mode. Replace.
is OK.
1/1
Propel Speed Change Turn key switch OFF. YES: Solenoid is OK. Go
Proportional Solenoid to next check.
(Y6) Check Remove wire clip from bottom of solenoid harness
connector. NO: Solenoid has failed.
Replace.
Disconnect harness from solenoid.
Connect ohmmeter to solenoid terminals.

T7491AC UN08APR91
Does ohmmeter read approximately 24 ohms?
1/1

101603
PN=315
Propel Speed Change Turn key switch OFF. YES: Harness and engine
Proportional Solenoid and pump controller are
(Y6) Harness Check Install proportional solenoid test harness JT07352 in series with wiring harness and OK.
sense solenoid.
NO: Harness or engine
Connect voltmeter to test harness jacks. and pump controller has
failed. Repair or replace.
Start engine and while observing voltmeter, drive machine at full propel speed until fast
speed kicks in.
Does voltmeter read approximately 6 volts in slow speed, and 12 volts in fast speed?
1/1
Arm Regenerative Turn key switch OFF. YES: Solenoid is OK. Go

9015
15
90
Replace.

T7491AC UN08APR91
1/1
Arm Regenerative Turn key switch OFF. YES: Harness and engine
sense solenoid.
Start engine and move arm all the way out and boom down.
Adjust idle to slow (voltmeter reading approximately 7 volts).
Move boom up and arm in at the same time.
Does voltmeter read higher voltage (approximately 9 volts) while boom and arm are
moving?
1/1

101603
PN=316
Power Boost Turn key switch OFF. YES: Solenoid is OK. Go

Replace.

T7491AC UN08APR91
1/1
Power Boost Turn key switch OFF. YES: Harness and engine
9015
15
sense solenoid.
91
Start engine and observe voltmeter while pressing power boost switch.
Does voltmeter read approximately 5 volts when switch is not pressed, and
approximately 9 volts when switch is pressed?
Hold power boost switch pressed.
Does the voltage drop to 5 volts after approximately 8 seconds?
1/1
Speed Sense Turn key switch OFF. YES: Solenoid is OK. Go

Replace.

T7491AC UN08APR91
1/1

101603
PN=317
Speed Sense Turn key switch OFF. YES: Harness and engine
sense solenoid.
Start engine, set auto idle mode to OFF, and set engine idle to medium speed so that
voltmeter reads approximately 5.5 volts (RPM dial set at first bar after mid range).
Bottom arm in to load engine.
Does voltmeter read approximately 7 volts with arm bottomed in?
1/1
Learning Switch (S16) YES: Switch and harness

Check are OK.
9015
15
NO: Switch or harness
92
has failed. Check and
repair or replace.
T118558 1921NOV98
Disconnect 16-pin connector B from engine and pump controller.
Turn switch to ON.
Measure continuity from pin 5 of connector B to ground.
1/1

101603
PN=318
9015
15
93

101603
PN=319
Travel Alarm Circuit Operational Information
The following conditions must be met for the circuit to Key switch ON
function: Voltage present at travel alarm 5-amp fuse F10
CED,OUOE012,36 1921DEC981/1
Travel Alarm Circuit Theory of Operation
The travel alarm circuit contains: travel alarm fuse F10, pilot pressure and closes. With the switch closed,
travel alarm H10, travel alarm cancel switch S17, and ground is applied to pin C of the travel alarm,
propel pressure switch B15. Operating voltage for the activating the alarm. After the travel alarm has
travel alarm is applied from fuse F10 to travel alarm sounded for 10 seconds, the travel alarm cancel switch
pin B. When the propel levers are moved to forward or may be pushed to turn the alarm off by grounding
reverse positions, propel pressure switch B15 senses alarm pin A.
9015
15
94
CED,OUOE012,37 1921DEC981/1

101603
PN=320
Travel Alarm Circuit Schematic
9015
15
95
1930NOV98
T117932
CED,OUOE012,38 1903FEB991/1

101603
PN=321
1 Travel Alarm Circuit Diagnostic Procedures
test or check.
NOTE: Before troubleshooting the circuits, clean all terminals in the engine and pump controller and harness
connectors using a non-conductive lubricating contact cleaner, then try circuit operation again before proceeding.
TY16324 John Deere Contact Cleaner can be used.
1/1
Travel Alarm 5 Amp Fuse Remove fuse block cover. YES: Fuse is OK. Go to
(F10) Check next check.
9015
15
96
for short.
1/1

101603
PN=322
Travel Alarm (H10) YES: Go to next step.

Harness Check
Repair.
T118563 UN21NOV98
Disconnect harness connector from travel alarm.
Connect voltmeter to harness connector pin B and ground.
Turn key switch ON.
9015
15
YES: Go to next step. 97

Repair.
T118562 UN21NOV98
Disconnect harness connector from propel pressure switch.
Connect ohmmeter from travel alarm harness connector pin C to propel pressure
switch harness connector pin 1.
YES: Harness is OK. Go

to next check.

Repair.
T118564 UN21NOV98
Connect ohmmeter from travel alarm harness connector pin D to ground.
1/1

101603
PN=323
Travel Alarm (H10) With harness connector disconnected, connect 24 volts YES: Alarm is OK.
Check to travel alarm terminal B, and ground terminal D. Then
ground terminal C. NO: Alarm has failed.
Replace.
Does alarm sound?
T8037BB UN30JUN93
1/1
Travel Alarm Cancel YES: Switch and harness

Switch (S17) Check are OK.
9015
15
NO: Switch or harness
98
has failed. Repair or
replace.
T118559 UN21NOV98
Disconnect harness connector from travel alarm.
Connect ohmmeter from travel alarm harness connector pin A to ground.
Push travel alarm cancel switch.
Is continuity measured when switch is pressed?
1/1

101603
PN=324
Group 20
References
Battery Operation
SPECIFICATIONS (Pb), and the electrolyte solution is about 1.270 times

Percent Charged For Stabilized 100% heavier than water. The amount that the solution is
Open Circuit Voltage 12.6 Volts heavier than water is called specific gravity.
or More
Percent Charged For Stabilized 75% All batteries will self discharge at a rate of .001 specific
Open Circuit Voltage 12.4 Volts gravity point per 24 hour period at a constant 85 F.
Percent Charged For Stabilized 50% The discharge rate increases as temperature increases
Open Circuit Voltage 12.2 Volts and decreases as temperature decreases. If the
Percent Charged For Stabilized 25% machine is not used for a period of time, the batteries
Open Circuit Voltage 12.0 must be maintained or stored in a cool place.
Percent Charged For Stabilized 0%
Open Circuit Voltage 11.7 or Wipe batteries with a damp cloth. If terminals are
Less
corroded, use a stiff brush and wash with an ammonia
solution. After washing, flush battery and compartment
A battery is a device for converting chemical energy to 9015
with clear water. Keep caps in place when cleaning 20
electrical energy. It is not a storage tank for electricity, and charging. 1
but stores electrical energy in chemical form.
Batteries should be maintained at an open circuit
Because of the constant chemical to electrical change voltage of 12.40 volts or greater. To determine open
(self-discharge, discharge, or charge), the battery has circuit voltage use the following chart.
a limited life. Proper care (cleaning, adding water,
charging) will extend the life of the battery. CHECK OPEN CIRCUIT VOLTAGE FOR STATE OF
CHARGE
The battery is made up of positive plates, negative
plates, separators, plate straps, and chemical solution NOTE: Stabilize voltage by turning on high beams 15
(electrolyte). The electrolyte is a solution of sulfuric Amp load for 15 seconds.
acid and water. Sulfuric acid is not lost during
overcharging; therefore, if the liquid solution is low, Specification
only water should be added. Percent Charged For Stabilized
Open Circuit Voltage12.6
In a fully charged battery, the positive plate is lead Volts or More .............................................................................. 100%
12.4 Volts ...................................................................................... 75%
peroxide (PBQ2), the negative plate is spongy lead 12.2 Volts ...................................................................................... 50%
12.0 ............................................................................................... 25%
11.7 or Less .................................................................................... 0%
CED,TX14795,4147 1905AUG971/1
Battery Specifications
Specification
Battery VoltageVolts .................................................................. 12 Volts
Cold Cranking PowerAmps......................... 1100 amps at 18C (0F)
Reserve CapacityMinutes ................................ 400 minutes at 25 amps
Fully Charged Electrolyte Specific
GravitySpecific Gravity....................................................... 1.2651.280
CED,TX14795,4148 1913AUG981/1

101603
PN=325
References
Diagnose Battery Malfunctions
Battery Using Too Much Water Shorted battery cell Check battery state of charge. (See
Procedure for Testing Batteries.)
High ambient temperature Add distilled water.
Cracked battery case Check battery hold down clamps.

Replace battery.
Regulator Do Alternator Output Check. (See

Charging Circuit Operational
Checks.)
9015
20 Cracked Battery Case Battery hold down clamp too tight, Install new battery. Install hold down
2 too loose or missing clamps correctly.
Frozen battery Keep electrolyte at correct level and

battery fully charged during cold
weather.
Low Battery Output Low water level See Battery Using Too Much Water
and Cracked Battery Case
symptoms.
Dirty or wet battery top, causing Clean battery top. Recharge battery.
discharge
Corroded or loose battery cable Clean and tighten cable end clamps.
ends Recharge battery.
Broken or loose battery posts Wiggle posts by hand. If posts are

loose or will turn, replace battery.
Loose fan/alternator belt or worn Inspect belt or pulley. Adjust or

pulleys replace as necessary.
CED,TX14795,4149 1905AUG971/1

101603
PN=326
References
9015
20
3

101603
PN=327
References
Check Battery Electrolyte Level and

Terminals
CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first

and replace it last.
Sulfuric acid in battery electrolyte is poisonous.

9015 It is strong enough to burn skin, eat holes in
20
clothing, and cause blindness if splashed into
4
eyes.
Avoid the hazard by:
UN23AUG88
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
TS203
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If 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 1015
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.
Continued on next page TX,16,UU3540 1901SEP951/2

101603
PN=328
References
IMPORTANT: During freezing weather, batteries must

be charged after water is added to
prevent battery freezing. Charge battery
using a battery charger or by running
the engine.
UN09SEP03
3. Fill each cell to within specified range with distilled
water. DO NOT overfill.
T6996DB
ABattery Post
BFill Tube
CElectrolyte Level Range
Single Level Fill Tube Application
9015
20
5
UN09SEP03
T6996DA
Dual Level Fill Tube Application
TX,16,UU3540 1901SEP952/2

101603
PN=329
References
Procedure for Testing Batteries
1. VISUAL CHECK b. Record specific gravity reading for each cell.
a. Check for damage such as cracked or broken c. If high and low readings vary LESS than 0.050
case and electrolyte leakage. and average specific gravity is between 1.225
and 1.280, battery is fully charged, go to LOAD
If damage is seen, replace battery. TEST.
b. Check electrolyte level. (See procedure in this d. If high and low readings vary LESS than 0.050
group.) and average specific gravity is LESS than 1.225,
charge battery and repeat test. If average
If low, add distilled water to specified level and specific gravity is still LESS than 1.225, replace
charge battery. both batteries.
c. Check terminals for corrosion. e. If high and low readings vary MORE than 0.050,
9015
20 charge battery and repeat test. If high and low
6 If corroded, clean using a wire brush or battery readings still vary MORE than 0.050, replace
post cleaner such as JT05838 Battery both batteries.
Post/Clamp Cleaner.
3. LOAD TEST
d. Check posts for looseness.
a. Check battery capacity with a load tester such
If posts are loose, replace battery. as JT05832 Battery Load Tester. Follow tester
manufacturers instructions for proper load test
2. HYDROMETER TEST procedures.
a. Check specific gravity with a hydrometer or b. If one battery fails load test, replace both
battery tester such as JT05460 Coolant/Battery batteries.
Tester.
TX,16,UU3538 1901SEP951/1

101603
PN=330
References
Using Booster Batteries24 Volt System
Before boost starting, machine must be properly shut

down and secured to prevent unexpected machine
movement when engine starts.
CAUTION: An explosive gas is produced while

batteries are in use or being charged. Keep
flames or sparks away from the battery area.
Make sure the batteries are charged in a well
ventilated area.
IMPORTANT: The machine electrical system is a

24-volt negative (-) ground. Connect two
12-volt booster batteries together in
series as shown for 24 volts. 9015
20
7
1. Connect one end of the positive cable to the positive
terminal of machine batteries (A) and the other end to
the positive terminal of booster batteries (B).
UN24OCT91
2. Connect one end of the negative cable to the negative
terminal of booster batteries. Then connect the other
end of negative cable to the machine frame as far
T6713AH1
away from the machine batteries as possible.
3. Start the engine. Two Battery Application
AMachine Batteries
4. Immediately after starting the engine, disconnect the BBooster Batteries
end of negative cable from the machine frame first.
Then disconnect the other end of negative cable from
the negative terminal of booster batteries.
5. Disconnect the positive cable from the booster

batteries and machine batteries.
CED,TX14795,4152 1914MAY981/1

101603
PN=331
References
Replacing Batteries
SPECIFICATIONS
Cold Cranking Amps at -18C 1100 Amps
(0F) amps
Minutes Reserve Capacity at 25 400 Minutes
amps Reserve Capacity
Your machine is equipped with a negative (-) ground

electrical system. It uses two 12-volt batteries. If one of
the two batteries fails, both batteries must be replaced.
Use only batteries meeting following specifications.
Specification
Cold Cranking Amps at -18C
(0F)Amps ............................................................................. 1100 amps
9015 Minutes Reserve Capacity at 25
20 ampsReserve Capacity ....................................................... 400 Minutes
8
CED,TX14795,4153 1925JUN961/1

101603
PN=332
References
Adding 12 or 24 Volt Accessories
IMPORTANT: This machine has a 24-volt electrical should be through a separate ground wire to the
system. Installing 12-volt converter (if equipped) or starter ground stud.
accessories without addition of
24-volt to 12-volt converter may 5. Twist the power and the ground wires from the
cause battery failure. device together and run as close to the vehicle
frame as possible. Twisting the wires helps to
When possible, use 24-volt accessories. If 12-volt cancel any radio frequency fields that form around
accessories are added, use a 24-volt to 12-volt the wire.
converter. Converters are available from your
authorized dealer. (See the Industrial Equipment 6. Use of shielded wire reduces radio frequency fields
Attachment Guide.) even more. Twist power and ground wire together
as above. Ground shield to frame at power source
Converter capacity requirements depend on the load of end and metal case of device at the opposite end.
the accessories installed. Follow electronic dealer and If device does not have a metal case, ground shield
9015
manufacturers recommendations to determine the on device end to frame. 20
capacity of the converter required and its installation 9
requirements. 7. DO NOT run the device from the electronic device
in parallel with the existing harnesses. DO NOT
The following precautions must be followed when band wires to vehicle harnesses.
adding electrical and/or electronic devices:
8. Install noise filters on positive end of all electronic
1. DO NOT mount 24 volt-to-12 volt converters in the devices. Noise filter should be located as close to
cab. Converters should be mounted as close to the the device as possible. Filters can be purchased at
battery as possible. Converters supplied through local electronic stores.
Deere parts system provide installation instructions
outlining proper installation procedures and location. 9. Mount antennas as far away from the engine and
pump controller as possible. It is best not to mount
2. DO NOT mount electrical devices directly in front of antennas on the cab at all. Best locations are at the
system controller (between controller and seat). back of the unit on the counterweight or sheet
Mounting above the controller on shelf behind seat metal above the batteries.
is acceptable.
IMPORTANT: DO NOT connect an accessory to
3. DO NOT mount electrical devices within 6 inches of one battery. Connecting a 12-volt
existing harnesses. accessory to one battery will cause
one battery to overcharge, and the
4. Isolate the case of the electrical device from the other battery to undercharge,
vehicle or cab frame. The ground for the device causing battery failure.
CED,TX14795,4154 1913AUG981/1

101603
PN=333
References
Changing Travel Alarm Volume
IMPORTANT: It may be necessary to adjust travel

alarm volume to meet local regulations.
NOTE: Alarm removed from machine for clarity of
UN07MAY97
photograph.
Move switch (B) to adjust volume of travel alarm. The

alarm can be set at HIGH, MED (medium), or LOW
T109427B
volume.
BSwitch
HHigh Level
LLow Level
9015 MMedium Level
20
10
CED,TX14795,4155 1925JUN961/1

101603
PN=334
References
Proportional Solenoid Test Harness
Test harness JT07352 is used to check proportional

solenoid Y5, Y6, Y8, and Y9 circuits.
CED,OUOE012,45 1923NOV981/1
Pump Control Test Harness
Test harness JT07353 is used to check arm in and pump

control pressure sensors B20, B21, and B22.
CED,OUOE012,46 1923NOV981/1
Pump Pressure Sensor Test Harness

9015
Test harness JT07354 is used to check front and rear 20
pump pressure sensors B18 and B19. 11
CED,OUOE012,47 1903FEB991/1

101603
PN=335
References
9015
20
12

101603
PN=336
Section 9020
Power Train
Contents
Page

Track Adjuster . . . . . . . . . . . . . . . . . . . . . . . .9020-05-1
Propel Gearbox . . . . . . . . . . . . . . . . . . . . . . .9020-05-2

Undercarriage Components. . . . . . . . . . . . . .9020-15-1
Track Chain
Measure Bushing Wear . . . . . . . . . . . . . . .9020-15-3
Measure Link Wear . . . . . . . . . . . . . . . . . .9020-15-4
Measure Pitch . . . . . . . . . . . . . . . . . . . . . .9020-15-5
Track Shoe
Measure Grouser Wear (SN499999) . . .9020-15-6
Measure Grouser Wear (SN 500000) . . .9020-15-7 9020
Track Roller
Measure Wear . . . . . . . . . . . . . . . . . . . . . .9020-15-8
Track Carrier Roller
Measure Wear . . . . . . . . . . . . . . . . . . . . . .9020-15-9
Front Idler
Measure Wear . . . . . . . . . . . . . . . . . . . . .9020-15-10
Measure Wear
Swing Bearing . . . . . . . . . . . . . . . . . . . . .9020-15-11
Group 20Adjustments
Track Sag . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1

101603
PN=1
Contents
9020

101603
PN=2
Group 05
Theory of Operation
Track Adjuster Operation
9020
05
1928OCT92
1
T7827AJ
ATrack Frame DSeal GYoke JAdapter
BNut EPiston HCylinder Barrel KFitting
CSpring FIdler IGrease LTrack Adjuster
The track adjuster (L) is supported by the track frame (G), the track becomes tighter. Loosen adapter (J),
(A). Shock loads on the track and front idler (F) are NOT the fitting (K) to release grease to loosen track.
absorbed by the track recoil spring (C). Grease will escape through a small passage that is
concealed by nut (B).
To tighten the track, pump grease (I) into fitting (K) to
force the piston (E) out. As it presses against the yoke
TX,05,GG2177 1919MAY981/1

101603
PN=339
Theory of Operation
Propel Gearbox Operation
9020
05
2
1912AUG96
T102862
ARing Gear FFirst Planet Carrier JSecond Planet Gear NHub

BThird Planet Carrier GFirst Planet Sun Gear KThird Planet Gear OPropel Motor
CThird Planet Sun Gear (Input Shaft) LSprocket PMetal Face Seal
DSecond Planet Carrier HThrust Pad MDrum QPropel Gearbox
ESecond Planet Sun Gear IFirst Planet Gear
Continued on next page TX,05,GG2170 1905SEP001/2

101603
PN=340
Theory of Operation
The propel gearbox (Q) is a triple reduction planetary are attached to the second planet carrier (D). As the
drive gearbox. The gearbox is interchangeable from second planet gears orbit around the ring gear they
the right to the left side of the machine. The propel turn the second planet carrier. The second planet
motor (O) is connected to and drives the first planet carrier is connected to the third planet sun gear (C).
sun gear (G). The third planet sun gear rotates the third planet gears
(K). The third planet carrier is connected to the propel
Rotary motion is transferred from the first planet sun motor housing through the hub (N) and does not turn
gear (G) to the sprocket (L) by the three planetary so the rotation of the third planet gears is transferred
gear sets that mesh with the ring gear (A). As the first to the ring gear. The ring gear, drum (M) and sprocket
planet sun gear rotates it turns the first planet gears (I) (L) are fastened together and turn as one unit.
which orbit, causing the first planet carrier (F) to rotate.
The first planet carrier is connected to the second A replaceable thrust pad (H) is used in the gearbox
planet sun gear (E) which is in mesh with and rotates cover to keep the floating input shaft in position.
the second planet gears (J). The second planet gears
TX,05,GG2170 1905SEP002/2
9020
05
3

101603
PN=341
Theory of Operation
9020
05
4

101603
PN=342
Group 15
Diagnose Undercarriage Components
Malfunctions
NOTE: Diagnose malfunction charts are arranged from

most probable and simplest to verify, to least
likely and most difficult to verify.
Noisy or Loose Track Chain Incorrect track tension adjustment Adjust track sag. (See Group
9020-20.)
Loose shoes Remove loose shoes to clean

material from between shoe and link.
Install shoes and tighten cap screws
to specified torque. (See Group
0130.)
Grease leaking from track adjuster Inspect between second and third
seals or relief valve roller, at base of relief valve, and at
hole in side of relief valve for
leakage. Replace seals or relief 9020
15
valve. (See Group 0130.)
1
Tight Track Chain Material packing in sprocket Adjust track sag with material
packed in sprocket. (See Group
9020-20.)
Track sag less than specification Adjust track sag. (See Group
9020-20.)
Frequent Track Chain Sag Grease leaking from track adjuster Inspect between second and third
Adjustment Required seals or relief valve roller, at base of relief valve, and at
hole in side of relief valve for
leakage. Replace seals or relief
valve. (See Group 0130.)
Excessive Oil Leakage From Loose plug, worn or damaged Repair roller or idler. (See Group
Idlers and Rollers O-ring, or metal faced seal 0130.)
Bent Track Shoes Excessive grouser wear Measure grouser height. (See
procedure in this group.) Rebuild
grousers or replace shoes.
Continued on next page 902015,H15 1903JUN931/2

101603
PN=343
Loose track shoes Remove loose shoes to clean

material from between shoe and link.
Install shoes and tighten cap screws
to specified torque. (See Group
0130.)
Excessive high speed operation on Slow propel speed on rough and

rough and rocky terrain rocky terrain.
Popping Of Track High propel loads in reverse High propel loads in reverse can
cause the recoil spring to retract
allowing sprocket to slip in chain.
Material packed in sprocket Material filling sprocket teeth can

cause sprocket tooth to bushing
impact.
Cracked Track Link Excessive high speed operation on Slow propel speed on rough and
rough and rocky terrain rocky terrain.
9020
15 Track shoes too wide for ground Use the narrowest shoes possible
2
conditions for required flotation.
Chipped Link Rails Repeated high impacts with roller Adjust track chain sag. (See Group
tread on flanges caused by a loose 9020-20.)
or snaky track, or using shoes that
are too wide Check track chain pitch. (See
Use the narrowest shoes possible

for required flotation.
Individual Undercarriage See Undercarriage Appraisal Manual Rebuild components using weld.
Component Wear SP326. Repair or replace components.
902015,H15 1903JUN932/2

101603
PN=344
Measure Track Chain Bushing Wear
SPECIFICATIONS
Track Chain
Track Chain Bushing OD 59.0 mm (2.32 in.) new
Track Chain Bushing OD 54.0 mm (2.13 in.) minimum used
UN08NOV88
D17524C1a 100 mm Caliper
T82865
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit.
Minimum used is the maximum allowable wear for turning

pins and bushings.
Measure bushing outer diameter at the two worn places

using a caliper such as the D17524C1 100 mm Caliper
from JT05518A or JT05523 Undercarriage Inspection
Service Tool Kit.
Track ChainSpecification
9020
Track Chain BushingOD .................................... 59.0 mm (2.32 in.) new
15
Track Chain BushingOD ................... 54.0 mm (2.13 in.) minimum used
3
NOTE: See Undercarriage Appraisal Manual SP326 for

additional information.
CED,OUOE003,615 1912SEP001/1

101603
PN=345
Measure Track Chain Link Wear
SPECIFICATIONS
Track Chain
Track Chain Link Height 104.0 mm (4.09 in.) new
UN08NOV88
Track Chain Link Height 97.0 mm (3.82 in.) minimum used

JT05521a Depth Gauge (200 mm Ruler)
T82864
JT05534a Right Angle Attachment
D05231STa 300 mm Ruler
a
Minimum used is the maximum allowable wear for

rebuilding links.
Measure height of several links to find an average using a

depth gauge such as the JT05521 200 mm Ruler,
JT05534 Right Angle Attachment, and D05231ST 300 mm
9020 Ruler from JT05518A or JT05523 Undercarriage
15 Inspection Service Tool Kit.
4
Track Chain LinkHeight ................................... 104.0 mm (4.09 in.) new
Track Chain LinkHeight .................... 97.0 mm (3.82 in.) minimum used

CED,OUOE003,655 1912SEP001/1

101603
PN=346
Measure Track Chain Pitch
SPECIFICATIONS
Track Chain
Track Chain Pitch 762.0 mm (30.00 in.) new
Track Chain Pitch 780.0 mm (30.71 in.) maximum
UN29JAN98
used

a
JT05520 Metric Tape Measure
T6813AL
a
Maximum used is the maximum allowable wear for turning

pins and bushings.
1. Remove slack by putting a wooden block between

sprocket and chain; then slowly move machine in
reverse to tighten chain.
2. Measure pitch across several four-link sections as

9020
shown, except section on either side of master pin, to 15
find average chain wear. Use a tape measure such as 5
the JT05520 Metric Tape from JT05518A or JT05523
Track ChainPitch............................................ 762.0 mm (30.00 in.) new
Track ChainPitch................................... 780.0 mm (30.71 in.) maximum
used

CED,OUOE003,617 1912SEP001/1

101603
PN=347
Measure Track Shoe Grouser Wear (S.N.

499999)
SPECIFICATIONS
Track Shoe (SN 499999)
UN08NOV88
Three Bar Grouser Height 26.0 mm (1.02 in.) new
Three Bar Grouser Height 15.0 mm (0.59 in.) minimum used
T82859
a
JT05521 Depth Gauge (200 mm Ruler)
a

rebuilding grouser bars with weld.
Measure grouser height of several track shoes to find an

average using a depth gauge such as the JT05521 200
9020 mm Ruler, JT05534 Right Angle Attachment, and
15
D05231ST 300 mm Ruler from JT05518A or JT05523
6
Track Shoe (SN 499999)Specification

Three Bar GrouserHeight .................................. 26.0 mm (1.02 in.) new
Three Bar GrouserHeight ................. 15.0 mm (0.59 in.) minimum used

TX,01,SB383 1911SEP001/1

101603
PN=348
Measure Track Shoe Grouser Wear

(S.N. 500000 )
SPECIFICATIONS
Track Shoe (SN 500000 )
UN08NOV88
Three Bar Grouser Height 25.5 mm (1.00 in.) new
Three Bar Grouser Height 15.0 mm (0.59 in.) minimum used
T82859
a
a

rebuilding grouser bars with weld.
Measure grouser height of several track shoes to find an

average using a depth gauge such as the JT05521 200
mm Ruler, JT05534 Right Angle Attachment, and 9020
15
D05231ST 300 mm Ruler from JT05518A or JT05523
7
Track Shoe (SN 500000 )Specification

Three Bar GrouserHeight .................................. 25.5 mm (1.00 in.) new
Three Bar GrouserHeight ................. 15.0 mm (0.59 in.) minimum used

CED,OUOE003,1131 1911SEP001/1

101603
PN=349
Measure Track Roller Wear
SPECIFICATIONS
Track Roller
Track Roller Tread OD 150.0 mm (5.91 in.) new
UN08NOV88
Track Roller Tread OD 132.0 mm (5.20 in.) minimum
used
T87973
a
JT05519 Special Roller Caliper
a

rebuilding roller tread.
Under some conditions roller wear can be uneven. If wear

is uneven, rollers may be interchanged to even out the
wear.
Measure roller tread diameter using a caliper such as the

9020
15 JT05519 Special Roller Caliper from JT05518A or
8 JT05523 Undercarriage Inspection Service Tool Kit
Track RollerSpecification
Track Roller TreadOD...................................... 150.0 mm (5.91 in.) new
OD ............................................................... 132.0 mm (5.20 in.) minimum
used

TX,15,GG2211 1912SEP001/1

101603
PN=350
Measure Track Carrier Roller Wear
SPECIFICATIONS
Track Carrier Roller
Track Carrier Roller Tread OD 120.0 mm (4.72 in.) new
Track Carrier Roller Tread OD 110.0 mm (4.33 in.) minimum
UN29JAN98
used

a
JT05519 Special Roller Caliper
T6813AQ
a
Used minimum tread diameter is the maximum allowable

wear for rebuilding wear surface.
Measure roller tread diameter using a caliper such as the

JT05519 Special Roller Caliper from JT05518A or
JT05523 Undercarriage Inspection Service Tool Kit.
Track Carrier RollerSpecification

Track Carrier Roller TreadOD ......................... 120.0 mm (4.72 in.) new 9020
Track Carrier Roller TreadOD ................. 110.0 mm (4.33 in.) minimum 15
used 9

TX,15,GG2210 1912SEP001/1

101603
PN=351
Measure Front Idler Wear
SPECIFICATIONS
Front Idler
Front Idler Flange Height 19.0 mm (0.75 in.) new
UN08NOV88
Front Idler Flange Height 28.0 mm (1.10 in.) maximum
used
T87972
a
a
Maximum used flange height is the maximum allowable

height of flange for rebuilding wear surface.
Measure height of flange using a depth gauge such as the

JT05521 200 mm Ruler, JT05534 Right Angle
9020 Attachment, and D05231ST 300 mm Ruler from
15 JT05518A or JT05523 Undercarriage Inspection Service
10 Tool Kit.
Front IdlerSpecification
Front Idler FlangeHeight .................................... 19.0 mm (0.75 in.) new
Front Idler FlangeHeight ........................... 28.0 mm (1.10 in.) maximum
used

TX,15,GG2212 1912SEP001/1

101603
PN=352
Measure Swing Bearing Wear
SPECIFICATIONS
Swing Bearing Play 1.2 mm (0.047 in.) or less new
Swing Bearing Play 4.0 mm (0.157 in.) maximum

D17526CI Dial Indicator
D17525CI Magnetic Base with Adjustable Arm
CAUTION: Stay clear of moving parts. Position

dial indicator so it can be seen while operator
can see you.
NOTE: Two people are needed to do the measurement.

One to operate the machine and one to take the
readings.
1. Check that swing bearing to main frame cap screws
UN23NOV92
are tight. (See Group 4350.)
9020
15
Check that bearing is lubricated with the specified
11
grease (See Track Adjuster, Working Tool Pivot, Swing
T7886AI
Bearing, and Swing Bearing Gear Grease in Section
9000.)
Check that bearing rotation is smooth and without

noise.
2. Install the dial indicator with needle point contacting

bottom face of swing bearing outer race.
3. Move boom and arm to position shown with bucket off

the ground.
4. Turn dial indicator to zero.
5. Lower boom to raise front idlers off the ground

approximately 500 mm (20 in.)
6. Record dial indicator reading.
If reading is more than maximum allowable, check for

steel ball and spacer wear. Repair or replace swing
bearing as needed. (See Group 4350.)
UN23NOV92
T7886AJ
Continued on next page TX,15,GG2213 1929MAY981/2

101603
PN=353
Specification
Swing BearingPlay ................................ 1.2 mm (0.047 in.) or less new
Play ............................................................... 4.0 mm (0.157 in.) maximum
TX,15,GG2213 1929MAY982/2
9020
15
12

101603
PN=354
Group 20
Adjustments
Adjust Track Sag
SPECIFICATIONS
Track Chain
Machine Weight 20 298 kg (44 750 lb)
approximate
UN06DEC88
Track Sag 300335 mm (11-13/16
13-3/16 in.)
Nut and Valve Assembly Torque 147 Nm (108 lb-ft)
T6876FG
ESSENTIAL TOOLS
Grease Gun
OTHER MATERIAL
TY2098 Multi-Purpose Grease
1. Swing upperstructure to side. Lower boom to raise

track off the ground.
Keep the angle between boom and arm at 90110

with the round side of bucket on the ground. 9020
20
1
CAUTION: Prevent possible injury from
unexpected machine movement. Put blocks or
shop stands under machine frame to support
machine while measuring track sag.
The approximate weight of machine is 20 298

kg (44 750 lb).
MachineWeight .................................................... 20 298 kg (44 750 lb)
approximate
2. Put blocks or shop stands under the machine to

support machine.
3. Slowly turn the track forward for two revolution and

then in reverse for two revolution. Stop the track while
moving in reverse direction so all track sag is at the
bottom.

101603
PN=355
Adjustments
4. Measure track sag (A) at middle track roller from the

bottom of tack frame to the top surface of track shoe.
TrackSag ........................................................................... 300335 mm
(11-13/1613-3/16 in.)
UN23FEB89
ATrack Sag
T6457DL
TX,20,GG2214 1905SEP002/3
CAUTION: High pressure grease in track

adjuster cylinder. Do not remove grease fitting
or nut and valve assembly to release grease.
IMPORTANT: Prevent possible damage to track

components. Do not use the grease
UN28NOV90
9020 fitting on track adjuster cylinder for
20 lubrication. Use this grease fitting only
2 for track sag adjustment.
T7396DZ
5. To decrease track sag, add multi-purpose grease to
track adjuster cylinder through grease fitting (A) located
in access hole (D) in track frame. Use a grease gun
with a maximum capacity of 68 950 kPa (690 bar) (10
000 psi).
To increase track sag, loosen nut and valve assembly

(B) one turn to release grease from track adjuster
UN22OCT92
cylinder through bleed hole (C) in rod.
Tighten nut and valve assembly when track sag is

correct.
T7869AQ
Nut and Valve AssemblyTorque .............................. 147 Nm (108 lb-ft)
AGrease Fitting
NOTE: If piston in track adjuster cylinder does not move,
BNut and Valve Assembly
remove the cylinder to make repairs. (See CBleed Hole
Remove and Install Track Adjuster in Group DAccess Hole
0130.)
TX,20,GG2214 1905SEP003/3

101603
PN=356
Section 9025
Hydraulic System
Contents
Page Page
Group 05Theory of Operation Swing Gearbox . . . . . . . . . . . . . . . . . . . . . .9025-05-72

Hydraulic System Diagram . . . . . . . . . . . . . .9025-05-2 Swing Motor
Pilot Pump Operation . . . . . . . . . . . . . . . . . .9025-05-4 Operation. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-74
Pilot Pressure Regulating Valve and Filter Crossover Relief Valve . . . . . . . . . . . . . .9025-05-76
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-5 Make-Up Valve . . . . . . . . . . . . . . . . . . . .9025-05-77
Pilot Shut-Off Valve Operation . . . . . . . . . . .9025-05-6 Park Brake Release Valve . . . . . . . . . . . .9025-05-80
Pilot Controller Rotary Manifold . . . . . . . . . . . . . . . . . . . . . .9025-05-82
Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-8 Propel Motor
Metering and Full Stroke . . . . . . . . . . . . . .9025-05-9 Operation. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-84
Propel Pilot Controller Slow Speed . . . . . . . . . . . . . . . . . . . . . . .9025-05-86
(SN 050305). . . . . . . . . . . . . . . . . . . . .9025-05-10 Fast Speed . . . . . . . . . . . . . . . . . . . . . . .9025-05-87
(SN 050306). . . . . . . . . . . . . . . . . . . . .9025-05-12 Speed Change Circuit . . . . . . . . . . . . . . .9025-05-88
Pilot Controller Park Brake Valve Housing . . . . . . . . . . . .9025-05-90
Operation of Control Valve. . . . . . . . . . . .9025-05-14 Park Brake Release Circuit . . . . . . . . . . .9025-05-92
Flow Regulator Valve . . . . . . . . . . . . . . . . .9025-05-16 Counterbalance Valve . . . . . . . . . . . . . . .9025-05-94
Hydraulic Pump and Drive Gearbox . . . . . .9025-05-18 Cylinder
Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . .9025-05-20 Boom, Arm, and Bucket. . . . . . . . . . . . . .9025-05-96
Hydraulic Pump Regulator Return Filter . . . . . . . . . . . . . . . . . . . . . . . .9025-05-97 9025
Components . . . . . . . . . . . . . . . . . . . . . .9025-05-22 Hydraulic System Circuit Symbols . . . . . . . .9025-05-98
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-24 Schematic
Increasing, Maximum and Decreasing . . .9025-05-26 Pilot Controllers Circuit . . . . . . . . . . . . . .9025-05-99
Summation and Speed Sensing. . . . . . . .9025-05-28 Hydraulic Pump and Control Valve . . . . 9025-05-100
Proportional Solenoid Valve Swing and Propel Motor . . . . . . . . . . . . 9025-05-101
Manifold Operation . . . . . . . . . . . . . . . . .9025-05-30
Arm Regenerative, Speed Sense, Group 15Diagnostic Information
Propel Speed Change, and Power Diagnostic Procedure . . . . . . . . . . . . . . . . . .9025-15-1
Boost . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-32 Diagnose Malfunctions
Engine Speed Sense Control Circuit . . . . . .9025-05-34 Electronic and Control Valve
Control Valve Component. . . . . . . . . . . . . . . . . . . . . . .9025-15-2
Component Identification . . . . . . . . . . . . .9025-05-35 Hydraulic System Malfunctions . . . . . . . . . .9025-15-13
Circuit Schematic. . . . . . . . . . . . . . . . . . .9025-05-40 Pilot Circuit Malfunctions . . . . . . . . . . . . . . .9025-15-16
Pilot Pressure Signal Passage. . . . . . . . .9025-05-42 Dig Circuit Malfunctions. . . . . . . . . . . . . . . .9025-15-17
Neutral and Power Passages. . . . . . . . . .9025-05-44 Swing Circuit Malfunctions . . . . . . . . . . . . .9025-15-19
System Releif Valve and Power Boost . . . .9025-05-46 Propel System Malfunctions . . . . . . . . . . . .9025-15-20
Power Boost Control Circuit . . . . . . . . . . . .9025-05-47 Control Lever Pattern Conversion . . . . . . . .9025-15-24
Circuit Relief Valve . . . . . . . . . . . . . . . . . . .9025-05-48 Control Valve
Pump Control Valve . . . . . . . . . . . . . . . . . .9025-05-50 Left Front Line Identification. . . . . . . . . . .9025-15-26
Flow Combiner Valve . . . . . . . . . . . . . . . . .9025-05-54 Right Rear Line Identification . . . . . . . . . .9025-15-28
Arm Regenerative Valve . . . . . . . . . . . . . . .9025-05-58 Bottom Line Identification. . . . . . . . . . . . .9025-15-30
Boom and Arm Reduced Leakage Valve. . .9025-05-60 Left Front Component Identification . . . . .9025-15-31
Bucket Flow Control Valve . . . . . . . . . . . . .9025-05-62 Right Rear Component Identification . . . .9025-15-32
Propel Flow Control Valve. . . . . . . . . . . . . .9025-05-64 Bottom Component Identification . . . . . . .9025-15-33
Propel-Boom Down Selector Valve . . . . . . .9025-05-65 Component Location
Boom Regenerative Valve. . . . . . . . . . . . . .9025-05-66 Main Hydraulic System . . . . . . . . . . . . . .9025-15-35
Propel and Arm In Combined . . . . . . . . . . .9025-05-68
Swing and Boom Up Combined . . . . . . . . .9025-05-70 Continued on next page

101603
PN=1
Contents
Page Page
Pilot Controller-to-Flow Regulator Valve Speed Sensing (SD) Proportional

SAE Pattern . . . . . . . . . . . . . . . . . . . . .9025-15-36 Solenoid Valve . . . . . . . . . . . . . . . . . . .9025-25-41
Pilot Controller-to-Flow Regulator Valve Propel Speed Change (SI) Proportional
John Deere Pattern . . . . . . . . . . . . . . .9025-15-37 Solenoid Valve . . . . . . . . . . . . . . . . . . .9025-25-43
Pilot Flow Regulator-to-Control Valve . . .9025-15-38 Power Boost Proportional Solenoid
Propel System . . . . . . . . . . . . . . . . . . . .9025-15-39 Valve (SG) . . . . . . . . . . . . . . . . . . . . . .9025-25-45
Pressure and Return System . . . . . . . . . .9025-15-40 Engine Control Sensor. . . . . . . . . . . . . . .9025-25-47
Engine Control Motor. . . . . . . . . . . . . . . .9025-25-49
Group 20Adjustment Miscellaneous Component . . . . . . . . . . . .9025-25-51
Pilot Shut-Off Valve Linkage . . . . . . . . . . . . .9025-20-1 Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-52
Swing Dynamic Braking . . . . . . . . . . . . . . .9025-25-54
Group 25Tests Pilot Pressure Regulating Valve . . . . . . . . .9025-25-56
Laptop Computer Valve Spool Actuating Pilot Pressure . . . . .9025-25-60
General Description . . . . . . . . . . . . . . . . . .9025-25-1 System Relief Valve . . . . . . . . . . . . . . . . . .9025-25-62
Excavator Diagnostics Program Circuit Relief Valve . . . . . . . . . . . . . . . . . . .9025-25-68
Overview . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1 Swing Motor Crossover Relief Valve . . . . . .9025-25-75
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-2 Propel Motor Crossover Relief Valve. . . . . .9025-25-80
Uninstall. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-7 Proportional Solenoid Valve . . . . . . . . . . . .9025-25-86
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8 Pump Control Valve . . . . . . . . . . . . . . . . . .9025-25-93
Service Codes . . . . . . . . . . . . . . . . . . . . .9025-25-12 Hydraulic Pump Regulator
Monitor Data . . . . . . . . . . . . . . . . . . . . . .9025-25-13 Adjustments. . . . . . . . . . . . . . . . . . . . . . .9025-25-98
Saving Monitor Data . . . . . . . . . . . . . . . .9025-25-15 Minimum Flow . . . . . . . . . . . . . . . . . . . . 9025-25-101
Engine Speed Adjustment Special Maximum Flow . . . . . . . . . . . . . . . . . . . 9025-25-104
Function . . . . . . . . . . . . . . . . . . . . . . . .9025-25-16 Engine Pulldown . . . . . . . . . . . . . . . . . . 9025-25-106
9025 Service Codes List. . . . . . . . . . . . . . . . . .9025-25-20 Hydraulic Pump Flow . . . . . . . . . . . . . . . . 9025-25-117
Monitor Data Items . . . . . . . . . . . . . . . . .9025-25-21 Pilot Pump Flow . . . . . . . . . . . . . . . . . . . . 9025-25-121
Engine Speed Factory Settings Special Propel System Tracking . . . . . . . . . . . . . . 9025-25-123
Function . . . . . . . . . . . . . . . . . . . . . . . .9025-25-23 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . 9025-25-125
Engine Speed to Pump Flow Rate Swing Motor Leakage . . . . . . . . . . . . . . . . 9025-25-128
Chart . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-24 Propel Motor Leakage . . . . . . . . . . . . . . . . 9025-25-131
Troubleshooting . . . . . . . . . . . . . . . . . . . .9025-25-26
Reading Service Codes Without . . . . . . .9025-25-27
Engine and Pump Controller
Function. . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-29
Installation . . . . . . . . . . . . . . . . . . . . . . . .9025-25-30
JT05800 Digital Thermometer
Installation . . . . . . . . . . . . . . . . . . . . . . . .9025-25-30
JT02156 Digital Pressure and Temperature
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-31
Start-Up Procedure
Hydraulic Pump . . . . . . . . . . . . . . . . . . . .9025-25-32
Swing Motor . . . . . . . . . . . . . . . . . . . . . .9025-25-33
Swing Gearbox . . . . . . . . . . . . . . . . . . . .9025-25-34
Propel Motor . . . . . . . . . . . . . . . . . . . . . .9025-25-34
Hydraulic Oil Filter Inspection Procedure. . .9025-25-35
Hydraulic Oil Cleanup Procedure Using
Portable Filter Caddy . . . . . . . . . . . . . . . .9025-25-36
Hydraulic System Warm-Up Procedure . . . .9025-25-37
Lower Boom with Engine Stopped. . . . . . . .9025-25-38
Harness Test
Arm Regenerative (SC) Proportional
Solenoid Valve . . . . . . . . . . . . . . . . . . .9025-25-39

101603
PN=2
Group 05
Theory of Operation
9025
05
1

101603
PN=359
Theory of Operation
Hydraulic System Diagram
9025
05
2
1924AUG98
T116659

101603
PN=360
Theory of Operation
1Left Pilot Controller 10Rotary Manifold 17Left Propel Valve Section 25Pilot Pump
2Right Pilot Controller 11Hydraulic Oil Tank 18Auxiliary Valve Section 26Oil Cooler
3Propel Pilot Controller 12Suction Screen 19Boom Valve Section 27Restriction Valve
4Pilot Shut-Off Valve 13Return Filter 20Arm Valve Section 28Oil Cooler Bypass Valve
5Solenoid Valve Manifold 14Swing Motor 21Swing Valve Section 29Left Propel Motor
6Flow Regulator 15Right Propel Valve 22Front Pump 30Right Propel Motor
7Arm Cylinder Section 23Rear Pump 31Hydraulic System
8Boom Cylinder 16Bucket Valve Section 24Pilot Filter and Pressure
9Bucket Cylinder Regulating Valve
TX,9025,GG2136 1906SEP002/2
9025
05
3

101603
PN=361
Theory of Operation
Pilot Pump Operation
1917DEC97
T112516
9025
05
4
ADowel Pin DOil Seal GDriven Gear JInlet Port
BBearing and Key ESnap Ring HSeal and Backup Retainer KPilot Pump
CDrive Gear FDrive Shaft IOutlet Port
The pilot pump (K) is a fixed-displacement, external port (I) is connected to the pilot pressure regulating
gear pump. The pilot pump is attached to the pump valve and pilot filter. The outlet is also connected by a
drive gearbox just to the rear of the rear pump. The tube and passages in pump housing to the small end
pump is driven through a gear train by the rear pump. of the front and rear pump servo piston and the pump
regulators.
The inlet port (J) is connected by a suction line to the
suction line for the front and rear pumps. The outlet
TX,9025,GG2283 1906SEP001/1

101603
PN=362
Theory of Operation
Pilot Pressure Regulating Valve and Filter Operation
UN01AUG96
T102044
9025
05
5
APlug DRegulated Pilot Oil to GPilot Filter and Bypass JPilot Pressure Regulating
BRegulated Pilot Oil to Pilot Control Valve Valve Valve Spool
Shutoff Valve EPilot Pressure Regulating HShim KOrifice
CReturn Oil to Hydraulic Oil Valve ISpring LPilot Oil From Pilot Filter
Tank FPilot Oil From Pilot Pump
The pilot filter and pilot pressure regulating valve are The pilot pressure regulating valve (E) is a bypass flow
incorporated into one assembly. regulating valve and is used to regulate the pilot oil
pressure in the pilot oil circuit. Pilot oil flows through
The pilot filter (G) consists of a filter element and a the orifice (K) to the end of the pilot pressure
bypass valve. The bypass valve senses the differential regulating valve spool (J). When the pressure in the
pressure between the inlet side and outlet side of the pilot circuit increases to the pressure setting of the
filter element. During normal operation, the bypass spring (I), the spool is pushed right against the spring.
valve is held closed by a spring and pilot oil flows Regulated pilot oil flows to the pilot shutoff valve (B)
through the filter element and out to the pilot pressure and the control valve (D). Oil not needed to maintain
regulating valve. If the filter element becomes plugged, the pressure in the pilot circuit flows to the hydraulic oil
pressure on the inlet side increases forcing the bypass tank as return oil (C).
valve open. Pilot oil now bypasses the filter element
and unfiltered oil flows to the pilot pressure regulating
valve.
TX,05,GG2149 1907APR971/1

101603
PN=363
Theory of Operation
Pilot Shut-Off Valve Operation
A TO LEFT PILOT C TO RIGHT PILOT

CONTROLLER CONTROLLER
B TO PROPEL
PILOT D TO SOLENOID
CONTROLLER VALVE MANIFOLD
P2
A
P1
H B
P3 C
E
D
I J H T5
I
K T4
J
T6
F K
E FROM PILOT F TO HYDRAULIC

PRESURE OIL TANK G
REGULATING VALVE
G PILOT SHUT-OFF VALVE ON
9025
05 H TO FLOW REGULATOR
6
I FROM LEFT
PILOT CONTROLLER
A B C D L
J FROM RIGHT
PILOT
CONTROLLER P2
A
P1
B
P3 C
E
D
T5
I
H
T4
K
T6
F J
E F K FROM PROPEL
PILOT CONTROLLER
1906MAY98
L PILOT SHUT-OFF VALVE OFF M PILOT OIL

N RETURN OIL
T101854
T101854

101603
PN=364
Theory of Operation
ATo Left Pilot Controller EFrom Pilot Pressure HTo Flow Regulator LPilot Shut-Off Valve OFF
BTo Propel Pilot Controller Regulating Valve IFrom Left Pilot Controller MPilot Oil
CTo Right Pilot Controller FTo Hydraulic Oil Tank JFrom Right Pilot Controller NReturn Oil
DTo Solenoid Valve Manifold GPilot Shut-Off Valve ON KFrom Propel Pilot
Controller
The pilot shut-off valve is a manual-operated, In the off (L) position, shut-off lever is pulled rearward
two-position, three-way rotary valve. The shut-off valve to the locked position, pilot oil to the controllers and
is rotated by pushing or pulling the pilot shut-off lever. solenoid valve manifold is blocked and the pilot oil now
The valve is located under the cab. flows to the flow regulator valve (H). Pilot oil that flows
to the flow regulator when shut-off valve is locked is
In the on (G) position, shut-off lever is pushed forward part of the warm-up circuit. The inlet ports for the
to the unlocked position, pilot oil flows to inlet ports of controllers are open to hydraulic oil tank through the
the pilot controllers, propel pilot controller, and shut-off valve and solenoid valve manifold.
solenoid valve manifold. Return oil from the controllers
flows to the shut-off valve and then through the
solenoid valve manifold and back to the hydraulic oil
tank.
TX,9025,GG2284 1906SEP002/2
9025
05
7

101603
PN=365
Theory of Operation
Pilot Controller OperationNeutral
B E
N RETAINER
K I
LEVER E
F SLEEVE
PLUNGER D
G BALANCE SPRING O SHIMS

SPRING C
GUIDE H RETURN SPRING
I TO HYDRAULIC OIL TANK
SPOOL B
J TO CONTROL VALVE
1925APR00
PISTON A K FROM PILOT PUMP L PILOT OIL
I TO HYDRAULIC OIL TANK M RETURN OIL
T129715
T129715
9025 P PILOT CONTROLLER - NEUTRAL
05
8
APiston ELever ITo Hydraulic Oil Tank MReturn Oil
BSpool FSleeve JTo Control Valve NRetainer
CSpring Guide GBalance Spring KFrom Pilot Pump OShims
DPlunger HReturn Spring LPilot Oil PPilot ControllerNeutral
Two hand-operated pilot controllers (right and left) are for correct operation of controller. The balance and
used to control the dig functions. Each controller return springs used in ports 1 and 3 are different than
assembly contains four pressure reducing valve the balance and return springs used in ports 2 and 4.
assemblies, one for each direction of each function. The ports numbers are stamped on the housing.
The pilot controller consists of the plunger (D), sleeve In neutral (P), the spool is pushed up by the return
(F), spring guide (C), retainer (N), spool (B), piston (A), spring to block oil from the pilot pump (K) to control
balance spring (G), shims (O), and return spring (H). valve (J) pilot cap. With the spool up, the passage to
The spools are select fitted to the bores in the the control valve pilot cap is connected to the hydraulic
housing. The quantity of shims for each balance spring oil tank (I).
and spool assembly has been determine at the factory
TX,9025,GG2285 1929MAR001/1

101603
PN=366
Theory of Operation
Pilot Controller OperationMetering and Full Stroke
E LEVER J
E
PLUNGER D F SLEEVE
K
I
G BALANCE SPRING
SPRING C H RETURN SPRING

GUIDE
I TO HYDRAULIC OIL TANK
J TO CONTROL VALVE
SPOOL B K FROM PILOT PUMP L PILOT OIL
1925APR00
PISTON A I TO HYDRAULIC M RETURN OIL
OIL TANK
N PILOT CONTROLLER METERING
T129716
T129716
9025
05
9
APiston ELever ITo Hydraulic Oil Tank LPilot Oil
BSpool FSleeve JTo Control Valve MReturn Oil
CSpring Guide GBalance Spring KFrom Pilot Pump NPilot ControllerMetering
DPlunger HReturn Spring
To meter a function, the lever (E) is moved slightly. by the plunger. As the lever is moved further, the
This moves the plunger (D) and spring guide (C) plunger applies more force to the balance spring and
against the balance spring (G) which moves the spool the pressure to control valve pilot cap again increases
(B) down. The spool blocks the hydraulic oil tank to balance the spool.
passage (I) and opens the passage from the pilot
pump (K) to control valve (J) pilot cap. When the lever (E) is moved to full stroke, the plunger
(D) movement is transmitted directly to the spool (B).
Pilot oil (L) also acts on piston (A) in the spool, moving This forces the spool down connecting the passage
the spool up against the balance spring which closes from pilot pump (K) with the passage to the control
the passage to the control valve pilot cap. This valve (J) pilot cap. Oil pressure to the control valve
maintains pressure in the control valve pilot cap pilot cap now equals pilot circuit pressure.
passage according to the force on the balance spring
TX,9025,GG2286 1929MAR001/1

101603
PN=367
Theory of Operation
Propel Pilot Controller Operation (S.N. 050305)
5
2
10
14 RETAINER
11 9
15 SHIMS
5 PEDAL
9025
05 PLUNGER 4 6 SLEEVE
10
SPRING 3 7 BALANCE
GUIDE SPRING
8 RETURN
SPRING
SPOOL 2 9 TO HYDRAULIC
OIL TANK
10 TO CONTROL
VALVE
11 FROM PILOT
PISTON 1 PUMP
1921SEP00
12 PILOT OIL
13 RETURN OIL
T133811
T133811 16 PROPEL PILOT CONTROLLER-NEUTRAL
Continued on next page CED,OUOE003,677 1918SEP001/2

101603
PN=368
Theory of Operation
1Piston 6Sleeve 10To Control Valve 14Retainer

2Spool 7Balance Spring 11From Pilot Pump 15Shims
3Spring Guide 8Return Spring 12Pilot Oil 16Propel Pilot Controller
4Plunger 9To Hydraulic Oil Tank 13Return Oil Neutral
5Pedal
One pilot controller is used to control the propel In neutral, the spool is pushed up by the return spring
functions. The controller contains four valve to block oil from the pilot pump (11). With the spool up,
assemblies, one for each direction for each track. the passage to the control valve (10) is connected to
the hydraulic oil tank (9). The propel pilot controller
The pilot controller consists of the pedal (5), plunger operates the same as the pilot controllers.
(5), sleeve (6), spring guide (3), spool (2), piston (1),
balance spring (7), and return spring (8).
CED,OUOE003,677 1918SEP002/2
9025
05
11

101603
PN=369
Theory of Operation
Propel Pilot Controller Operation (S.N. 050306 )
CAM
E AND
PEDAL
PLUNGER D
F SLEEVE
SPRING C
GUIDE BALANCE
G SPRING
RETURN
H
SPRING
9025 WASHER B
05 TO HYDRAULIC
I
12 OIL TANK
FROM PILOT
J
SPOOL A SHUT-OFF
VALVE
TO CONTROL
E K VALVE PILOT
G
CAP
A K
K
1906MAY98
J I L PILOT OIL
M RETURN OIL
T108942
T108942 N PROPEL PILOT CONTROLLER - FULL STROKE

101603
PN=370
Theory of Operation
ASpool ECam and Pedal ITo Hydraulic Oil Tank MReturn Oil
BWasher FSleeve JFrom Pilot Shut-Off Valve NPropel Pilot Controller
CSpring Guide GBalance Spring KTo Control Valve Pilot Cap Full Stroke
DPlunger HReturn Spring LPilot Oil
One pilot controller is used to control the propel balance spring pushes the spool down. As the spool is
functions. The controller contains four valve pushed down the passage from the control valve pilot
assemblies, one for each direction of travel for each cap to the hydraulic oil tank (I) is closed and then is
track. opened to the pilot oil from pilot shut-off valve. When
the pilot oil pressure to the control valve pilot cap is
The pilot controller consists of the cam and pedal (E), equal to the force applied by the balance spring the
plunger (D), sleeve (F), spring guide (C), spool (A), spool moves up trapping the oil to the pilot cap.
balance spring (G), and return spring (H).
When the pedal and cam is moved to full stroke, the
In neutral, the spool is pushed up by the return spring plunger is pushed down further by the balance spring
to block pilot oil from the pilot shut-off valve (J). With opening the passage through the spool more to the
the spool up, the passage to the control valve pilot cap pilot oil. When pressure to the control valve pilot cap is
(K) is connected to the hydraulic oil tank (I) by the equal to the force applied by the balance spring, the
passage through the spool (A). spool moves up until it contacts the plunger. The
plunger holds the spool down so the passage through
When the pedal is pushed to move the machine, the spool remains open to pilot oil. Oil pressure to the
cam (E) pushes the plunger and spring guide down control valve pilot cap now equals pilot oil pressure.
against the return spring and balance spring. The
CED,OUOE003,2 1906SEP002/2
9025
05
13

101603
PN=371
Theory of Operation
Pilot Controller Operation of Control Valve
BUCKET
SECTION 1
2
PILOT
CONTROLLER
1
4
CONTROL
3 VALVE
1921SEP00
5 PILOT OIL
FROM PILOT PUMP 4 6 RETURN OIL
T133813
9025 T133813 7 PILOT OPERATION OF MAIN CONTROL VALVE
05
14
1Pilot Controller 3Control Valve 5Pilot Oil 7Pilot Operation of Main
2Bucket Section 4From Pilot Pump 6Return Oil Control Valve
The pilot controllers (1) are connected to the control pilot cap is routed through the pilot controller to the
valve (3) by pilot control hoses through the flow hydraulic oil tank.
regulator valve. When the pilot controller is actuated,
pilot oil (5) from pilot pump (4) is routed to the control The pilot hoses for the propel pilot controller are not
valve pilot cap. In this illustration, the bucket section connected to the flow regulator valve but are
(2) is actuated. Return oil (6) from the control valve connected directly to the control valve pilot caps.
TX,9025,GG2288 1906SEP001/1

101603
PN=372
Theory of Operation
9025
05
15

101603
PN=373
Theory of Operation
Flow Regulator Valve Operation
VALVE FOR 2 3 BOOM UP PILOT

BOOM UP PRESSURE SWITCH
FROM PILOT
CONTROLLER 1
ARM IN PILOT
PRESSURE 8
SENSOR
4 TO PILOT CAP
VALVE 7
FOR
ARM IN 5 CHECK VALVE
6 FROM PILOT SHUT-OFF VALVE
9 9
1 4 1 4
9025 11 11
05 10 10
16
12 12
5 5
13 BOOM UP OR 14 BOOM DOWN

ARM OUT 3 OR ARM IN 3
SPOOL 10
TO
PILOT
CAP 11 ORIFICE
PLATE
4
15 WARM-UP
FROM 1 OIL
PILOT PASSAGE
CONTROLLER
5 CHECK
VALVE
1921SEP00
16 PILOT OIL
17 RETURN OIL
T133812
T133812 18 FLOW REGULATOR VALVE

101603
PN=374
Theory of Operation
1From Pilot Controller 5Check Valve 9Check Valve 14Boom Down or Arm In
2Valve for Boom Up 6From Pilot Shut-Off Valve 10Spool 15Warm-Up Oil Passage
3Boom Up Pilot Pressure 7Valve for Arm In 11Orifice Plate 16Pilot Oil
Switch 8Arm In Pilot Pressure 12From Pilot Shut-Off Valve 17Return Oil
4To Pilot Cap Sensor 13Boom Up or Arm Out 18Flow Regulator Valve
NOTE: The cross section of flow regulator valve When the boom down or arm in (14) function is
shown in the illustration is in the boom up pilot actuated, the pilot oil to move the control valve spool
circuit. flows from the pilot controller through the manifold to
the pilot cap. Return oil from the opposite end of
The pilot lines for boom, arm, bucket, and swing control valve spool flows from the pilot cap to the
functions are connected through the flow regulator to manifold and through the orifice plate (11) in the spool
the pilot caps on the control valve. The pilot lines for (10). As the return pressure increases, the spool is
propel function are connected directly to the pilot caps. pushed down in proportion to the pressure increase
regulating the return oil flow to provide precise
The flow regulator valve (18) is a manifold containing movement of a function. From here, oil flows to the
similar flow regulator valve spools (10) in the arm out pilot controller.
and boom up pilot circuits. Check valves (5) are also
included in the warm-up oil passage (15) for arm in, Warm-Up Circuit Operation
arm out, boom down, and boom up pilot circuits; no
check valves are used in the bucket and swing pilot When the pilot shut-off valve is in the OFF position
circuits. Each valve spool contains an orifice plate (11) and the engine is running, pilot oil flows from the pilot
and springs. The size of the orifice is 2.5 mm (0.098 shut-off valve (6) to the flow regulator valve manifold.
in.). The oil is heated as it flows through a restriction at the
inlet to manifold. The warm-up oil from pilot shut-off
When the boom up or arm out (13) function is valve (12) flows through the warm-up oil passage (15)
actuated, pilot oil from the pilot controller (1) flows past the check valves (5) and out to the left and right
through the spool into the bottom spring chamber and pilot controllers and top pilot caps to warm the pilot 9025
through the orifice plate (11) to the pilot cap (4). As the circuit. At the pilot controllers, the warm-up oil flows 05
pressure increases the spool pushes upward allowing through the pilot controllers, out the return port, 17
pilot oil to flow unrestricted to the pilot cap to move the through the pilot shut-off valve to the solenoid valve
control valve spool. The spool acts as a check valve manifold, and then to the hydraulic oil tank. At the pilot
(9). Return oil from the opposite end of control valve caps, warm-up oil flows through orifices into a return
spool flows from the pilot cap and through the manifold passage in the pilot caps and then to the hydraulic oil
to the pilot controller. tank.
TX,9025,GG2290 1906SEP002/2

101603
PN=375
Theory of Operation
Hydraulic Pump and Drive Gearbox Operation
9025
05
18
1906AUG96
T102053

101603
PN=376
Theory of Operation
AFront Pump Discharge Port GPump Drive Gearbox KFill Plug and Breather OPump Inlet Port
BFront Pump HRear Pump Drive Shaft LRear Pump Regulator PRear Pump Pressure
CRear Pump IEngine Speed Sensor (N MFront Pump Regulator Sensor
DRear Pump Discharge Port Sensor) NFront Pump Pressure QHydraulic Pumps and Drive
EDipstick JAir Bleed Plug Sensor Gearbox
FPilot Pump
The front pump (B), rear pump (C) and pilot pump (F) drive shaft for the pump drive gearbox. The rear pump
are driven by the engine at engine speed through a drive shaft is connected to the engine flywheel through
pump drive gearbox (G). The rear pump drive shaft (H) a dampener drive (flex coupling).
as well as driving the rear pump also servers as the
TX,05,GG2150 1906SEP002/2
9025
05
19

101603
PN=377
Theory of Operation
Hydraulic Pump Operation
9025
05
20
1906AUG96
T102060

101603
PN=378
Theory of Operation
AFront Pump Discharge Port EFront Pump Drive Shaft ICenter Shaft MCylinder Block
BPump Inlet Port FFeedback Link JPiston (7 per Pump) NFront and Rear Hydraulic
CRear Pump Discharge Port GPump Regulator KServo Piston Pumps
DRear Pump Drive Shaft HHousing LValve Plate
The front and rear hydraulic pumps (M) are variable pump drive shaft (D) as well as driving the rear pump
displacement, bent-axis, piston type pump. Two also servers as the drive shaft for the pump drive
identical pumps are used to generate oil flow in the gearbox. The drive shafts drive the cylinder blocks (M)
hydraulic system. The pump can vary from minimum through the center shafts (I). The cylinder block is
displacement to maximum displacement depending on positioned at an angle to the drive shaft. As the
hydraulic demand of the system. cylinder block and drive shaft rotate, the pistons (D)
move in and out of their bores because of the angle.
A regulator (G) is attached to the top of housing (H) for The pistons which are moving out of their bores draw
each pump. A pilot oil signal to the regulator moves a oil from the hydraulic oil tank (C) through an pump
piston which then directs pilot oil to the servo piston (J) inlet port and ports in the valve plate (K). The pistons
which moves the valve plate (K) and cylinder block (L) which are moving back into their bores push oil
changing the pump displacement. The feedback link through ports in the valve plate out the front and rear
(F), connected to the valve plate, also moves providing discharge ports (A and C) and to the control valve.
a mechanical feedback to the remote control sleeve in
the regulator. The remote control sleeve blocks the The pump displacement, or flow rate, is varied by
flow of pilot oil to the servo piston and also traps the changing the angle of the cylinder block with respect to
oil at both ends of the servo piston stopping its the drive shaft. Increasing the angle increases the
movement. distance that each piston travels into and out of the
bore which increases displacement. Decreasing the
The front and rear pumps and pilot pump are driven at angle reduces the distance that each piston travels
engine speed through a pump drive gearbox. The rear into out of the bore which decreases displacement.
9025
05
21
TX,05,GG2151 1906SEP002/2

101603
PN=379
Theory of Operation
Hydraulic Pump Regulator Component Operation
FLOW ADJUSTING
CARTRIDGE MAXIMUM FLOW REMOTE REMOTE MINIMUM FLOW
(TRACK CYCLE ADJUSTING CONTROL CONTROL ADJUSTING
TIME) SCREW SLEEVE SPOOL PISTON SCREW
A B C D E F
G LOAD
ADJUSTING
SCREW
M L K J I H (INNER SPRING)
LOAD LOAD LOAD OUTER INNER LOAD (ENGINE
PISTON SPOOL SLEEVE SPRING SPRING ADJUSTING PULLDOWN AT
CARTRIDGE HIGH PRESSURE)
1923APR97
(OUTER SPRING)
9025
(ENGINE
05
PULLDOWN AT
22
MEDIUM PRESSURE)
T101949
T101949 N PUMP REGULATOR COMPONENTS
AFlow Adjusting Cartridge ESpool HLoad Adjusting Cartridge KLoad Sleeve

(Track Cycle Time) FMinimum Flow Adjusting (Outer Spring) (Engine Pull LLoad Spool
BMaximum Flow Adjusting Screw down at Medium Pressure) MLoad Piston
Screw GLoad Adjusting Screw IInner Spring NPump Regulator
CRemote Control Sleeve (Inner Spring) (Engine Pull JOuter Spring Components
DRemote Control Spool down at High Pressure)
The pump regulators are mounted on the top of the sleeve (K), load spool (L), and load piston (M). Each
hydraulic pump housing. The major pump regulator regulator controls the flow of pilot oil to the large end
components (N) are the flow adjusting cartridge (A), of its servo piston using the spools and sleeves.
maximum flow (displacement) adjusting screw (B),
remote control sleeve (C), remote control spool (D), The remote control spool (D) is moved by a reduced
piston (E), minimum flow (displacement) adjusting pilot oil control signal from front and rear pump control
screw (F), load adjusting screw (inner spring) (engine valve. There is a pump control valve located in the left
pull down at high pressure) (G), load adjusting and right control valves. The control signal acts on the
cartridge (outer spring) (engine pull down at medium end of the piston (E) to control the position of remote
pressure) (H), inner spring (I), outer spring (J), load control spool against the spring.

101603
PN=380
Theory of Operation
The load spool (L) is moved by the load piston (M) well as the outer spring. The pump supply oil pressure
against the springs to decrease pump flow is sense on one shoulder of the load piston and the
(displacement) and avoid overloading the engine when pump supply oil pressure from the other pump is
main system pressure becomes too high. At lower sensed on the other shoulder. The end of the load
system pressures the spool is moved against only the piston receives a reduced pilot oil control signal from
outer spring (J). At higher pressures, the spool the speed sensing solenoid valve when the actual
contacts and is moved against the inner spring (I) as engine speed pulls down to the target engine speed.
TX,05,GG2148 1924APR002/2
9025
05
23

101603
PN=381
Theory of Operation
Hydraulic Pump Regulator Operation
27 PILOT OIL
28 REDUCED PILOT OIL
29 REAR PUMP SUPPLY OIL
30 FRONT PUMP SUPPLY OIL
FROM SOLENOID 1
31 CONTROL VALVE VALVE MANIFOLD
NEUTRAL PASSAGE OIL CONTROL VALVE 2
32 TRAPPED OIL NEUTRAL PASSAGE
33 RETURN OR PRESSURE REAR PUMP
REMOTE CONTROL 3
FREE OIL VALVE
TO SERVO CONTROL
PISTON SPOOL REMOTE
LARGE END 4 5 CONTROL 7 PISTON
SLEEVE 26 PRESSURE
6 SENSOR
RETURN
TO PUMP 8 PILOT OIL
HOUSING 14 INLET
SPEED SENSE 13
SIGNAL PORT
9025
05
PUMP PRESSURE 12
24
INLET
LOAD PISTON 11 9 LOAD SLEEVE
LOAD SPOOL 10 15 FEEDBACK LINK
16 TO LEFT CONTROL VALVE
TO RIGHT CONTROL VALVE 25 TO FRONT PUMP
17 REGULATOR
TO FRONT PUMP 24
REGULATOR 18
PILOT
PUMP
19
23 22
20 PILOT
SERVO FRONT PRESSURE
PISTON PUMP REAR REGULATING
21 PUMP VALVE
SERVO
PISTON
1929MAY97
34 REGULATOR OPERATION
T108968
T108968

101603
PN=382
Theory of Operation
1From Solenoid Valve 9Load Sleeve 19Pilot Pressure Regulating 28Pump Control Valve
Manifold 10Load Spool Valve Signal Oil
2Control Valve Neutral 11Load Piston 20Rear Pump 29Rear Pump Supply Oil
Passage 12Pump Pressure Inlet 21Servo Piston 30Front Pump Supply Oil
3Front Pump Control Valve 13Speed Sense Signal Port 22Front Pump 31Control Valve Neutral
4To Servo Piston Large End 14Return To Pump Housing 23Servo Piston Passage Oil
5Remote Control Spool 15Feedback Link 24To Front Pump Regulator 32Trapped Oil
6Remote Control Sleeve 16To Left Control Valve 25To Right Control Valve 33Return or Pressure Free
7Piston 17To Front Pump Regulator 26Pressure Sensor Oil
8Pilot Oil Inlet 18Pilot Pump 27Pilot Oil 34Regulator Operation
The function of regulators is to control the flow of pilot through hoses from control valve to a port at the top of
oil to and from the servo piston large end (4) in its respective regulator.
response to control signals from the front and rear
pump control valves (3), front and rear pumps (22 and The pump supply oil (29 and 30) from front and rear
20) and speed sensing solenoid valve. Pump pumps is sensed through drilled passages in the pump
displacement (flow) is changed by sending pilot oil to housing to the pump pressure inlets (12) in each
or releasing pilot oil from the servo piston large end. regulator.
Pilot oil from the pilot pump (18) flows through drilled The control signal from the speed sensing solenoid
passages in the pump housing to the small end of valve is sensed through a hose to the speed sense
servo pistons and to the pilot oil inlet (8) at each signal port (13) at the rear pump regulator and then by
regulator. Pilot oil pressure is maintain at the small end a steel line to the front pump regulator.
of servo pistons and at the inlet of both regulators.
The reduced pilot oil (28) control signal from the front
or rear pump control valve is sensed by the piston (7)
9025
05
25
TX,05,GG2152 1924APR002/2

101603
PN=383
Theory of Operation
Hydraulic Pump Regulator Increasing, Maximum, and Decreasing Operation
27 PILOT OIL
31 CONTROL VALVE FROM SOLENOID 1
NEUTRAL PASSAGE OIL VALVE MANIFOLD
32 RETURN OR PRESSURE CONTROL VALVE 2
FREE OIL NEUTRAL PASSAGE
REAR PUMP
REMOTE CONTROL 3
CONTROL VALVE
TO SERVO
PISTON SPOOL REMOTE
SLEEVE 26 PRESSURE
6 SENSOR
RETURN
TO PUMP 8 PILOT OIL
HOUSING 14 INLET
SPEED SENSE 13
9025 SIGNAL PORT
05
26 PUMP PRESSURE 12
INLET
17 REGULATOR
TO FRONT PUMP 24
REGULATOR 18
PILOT
PUMP
19
23 22
20 PILOT
21 PUMP VALVE
SERVO
1909OCT00
PISTON
33 PUMP FLOW INCREASING

T134255
T134255
Continued on next page TX,05,GG2153 1916OCT001/2

101603
PN=384
Theory of Operation
5Remote Control Spool 15Feedback Link 24To Front Pump Regulator 32Return or Pressure Free
6Remote Control Sleeve 16To Left Control Valve 25To Right Control Valve Oil
7Piston 17To Front Pump Regulator 26Pressure Sensor 33Pump Flow Increasing
8Pilot Oil Inlet 18Pilot Pump 27Pilot Oil
NOTE: For operation of the front and rear pump housing (14). Pilot oil on the small end of servo piston
control valves, see Pump Control Valve pushes the piston down increasing pump displacement
Operation in this group. (flow). As the pump displacement increases, the
movement is transmitted to the remote control sleeve
Increasing Flow (Displacement)When a function is (6) and load sleeve (10) by the feedback link (15). The
actuated, the reduced pilot oil (28) control signal from sleeves move left until the path to return is closed. The
the pump control valve (3) to the piston (7) increases. oil at the large end of servo piston is now trapped
The control signal pushes the piston and remote holding the pump at maximum displacement (flow rate)
control spool (5) to the left against the spring. that is proportional to the pressure of the pump control
Movement of spool opens a path from the large end of valve control signal.
servo piston to return in the pump housing (14). Pilot
oil on the small end of servo piston pushes the piston Decreasing Flow (Displacement)As the function is
down increasing pump angle which increases the returned to neutral, the reduced pilot oil (28) control
displacement (flow). As the pump displacement signal sensed at the piston (7) also decreases. The
increases, the movement is transmitted to the remote spring pushes the remote control spool and piston to
control sleeve (6) and load sleeve (9) by the feedback the right. Movement of the spool opens a path for pilot
link (15). The sleeves move left until the path to return oil (27) to flow to the servo piston large end (4). The
is closed. The oil at the large end of servo piston is pilot oil pressure applied to the servo piston large end 9025
now trapped holding the pump at the displacement pushes the piston up against the pressure applied to 05
(flow rate) that is proportional to the pressure of the the small end decreasing pump flow. The remote 27
pump control valve control signal. control spool will continue to move to the right in
response to the decreasing control signal until it
Maximum Flow (Displacement)When the pilot contacts the piston cylinder. As the pump displacement
controller lever is actuated to full stroke, the reduced decreases, the movement is transmitted to the remote
pilot oil (28) control signal from the pump control valve control sleeve (6) and load sleeve (9) by the feedback
(3) to the piston (7) increases to its maximum. The link (15). The sleeves move right until the path for pilot
control signal pushes the piston and remote control oil is closed. The oil at the large end of servo piston is
spool to the left until the spool contacts the maximum now trapped holding the pump at the displacement
flow adjusting screw. Movement of spool opens a path (flow rate) that is proportional to the pressure of the
from the large end of servo piston to return in pump pump control valve control signal.
TX,05,GG2153 1916OCT002/2

101603
PN=385
Theory of Operation
Hydraulic Pump Regulator Summation and Speed Sensing Operation
27 PILOT OIL
31 CONTROL VALVE FROM SOLENOID 1
NEUTRAL PASSAGE OIL VALVE MANIFOLD
32 RETURN OR PRESSURE CONTROL VALVE 2
FREE OIL NEUTRAL PASSAGE
REAR PUMP
REMOTE CONTROL 3
CONTROL VALVE
TO SERVO
PISTON SPOOL REMOTE
SLEEVE 26 PRESSURE
6 SENSOR
RETURN
TO PUMP 8 PILOT OIL
HOUSING 14 INLET
SPEED SENSE 13
9025 SIGNAL PORT
05
28 PUMP PRESSURE 12
INLET
17 REGULATOR
TO FRONT PUMP 24
REGULATOR 18
PILOT
PUMP
19
23 22
20 PILOT
21 PUMP VALVE
SERVO
1909OCT00
PISTON
33 PUMP FLOW INCREASING

T134255
T134255

101603
PN=386
Theory of Operation
5Remote Control Spool 15Feedback Link 24To Front Pump Regulator 32Return or Pressure Free
6Remote Control Sleeve 16To Left Control Valve 25To Right Control Valve Oil
7Piston 17To Front Pump Regulator 26Pressure Sensor 33Pump Flow Increasing
8Pilot Oil Inlet 18Pilot Pump 27Pilot Oil
Summation (flow rate control by monitoring both pump Speed SensingWhen the actual engine speed, as
pressures)The pump supply oil pressure (load) for measured by engine speed sensor, is pulled down to
each pump is sensed at the load piston (11) through the target engine speed, as set by engine rpm dial, the
the pump pressure inlets (12) at its regulator and at speed sensing solenoid valve coil is energized by an
the regulator of other pump. The average pressure on electrical signal from the engine and pump controller.
the load piston is applied through the load spool (10) The pilot oil control signal is sent to the end of load
to the inner and outer springs. The springs are piston at the speed sense signal port (13) in the front
adjusted against the average pressure so the flow rate and rear pump regulators. The pilot oil control signal
of the pumps are approximately equal and each pump along with the pump supply oil pressure shift the load
uses approximately half the engine output. If the load spools against the springs opening a path for pilot oil
on either pump increases, the average pressure on the to the large end of servo pistons to decrease the pump
load pistons shift the load spools against the springs angle. The flow rate of both pumps decrease so the
opening a path for pilot oil to the servo pistons. The load on the engine decreases and the actual engine
flow rate of both pumps decrease so the load on the speed can increase. (See Engine Speed Sensing
pumps do not exceed the engine output. Also engine Control Circuit Operation in this group.)
output is not exceeded even if one pump is loaded
relatively high while the other pump stays relatively
low. 9025
05
29
TX,05,GG2205 1916OCT002/2

101603
PN=387
Theory of Operation
Proportional Solenoid Valve Manifold Operation
E TO SWING MOTOR PARK

FROM PILOT D BRAKE RELEASE VALVE
SHUT-OFF VALVE
F TO REAR PUMP CONTROL
VALVE
FROM PROPEL G TO HYDRAULIC

OIL TANK
FLOW CONTROL C
VALVE
H TO SYSTEM RELIEF
VALVE POWER
TO FRONT PUMP BOOST PORT
CONTROL VALVE
B P POWER BOOST
O PROPEL SPEED CHANGE
TO PROPEL
I MOTOR SPEED
CHANGE VALVE
K FROM BUCKET FLOW

CONTROL VALVE
TO ARM
9025 REGENERATIVE L J TO PUMP REGULATORS
05 VALVE SPEED SENSING PORT
30 FROM PILOT ARM M N
SHUT-OFF A REGENERATIVE SPEED
VALVE SENSING
E H B I F J L
PG PH PI PE
SG SI SD SC
P O N M
PD
A G
PE
1921MAY97
D DP DE DD DS
K C Q PILOT OIL
R RETURN OR
T109045
PRESSURE
T109045 S SOLENOID VALVE MANIFOLD FREE OIL

101603
PN=388
Theory of Operation
AFrom Pilot Shut-Off Valve FTo Rear Pump Control JTo Pump Regulators Speed OPropel Speed Change
BTo Front Pump Control Valve Sense Port PPower Boost
Valve GTo Hydraulic Oil Tank KFrom Bucket Flow Control QPilot Oil
CFrom Propel Flow Control HTo System Relief Valve Valve RReturn or Pressure Free
Valve Power Boost Port LTo Arm Regenerative Valve Oil
DFrom Pilot Shut-Off Valve ITo Propel Motor Speed MArm Regenerative SSolenoid Valve Manifold
ETo Swing Motor Park Brake Change Valve NSpeed Sense
Release Valve
The solenoid valve manifold (S) is mounted on the Return oil (R) from the pilot shut-off valve (D), propel
right control valve. The manifold serves as the central flow control valve (C), bucket flow control valve (K),
distribution point for pilot oil (Q) to the arm and the solenoid valves, when solenoid valves are
regenerative (M), speed sensing (N), propel speed de-energizes, flows through the manifold to the
change (H), and power boost (P) solenoid valves, the hydraulic oil tank (G).
front (B) and rear (F) pump control valves, and the
swing motor park brake release valve (E). Pilot oil The identification letters shown on the hydraulic
flows to the manifold when the pilot shut-off valve (A) schematic are on the manifold housing next to the
is in unlock position, shut-off lever forward. ports.
TX,9025,GG2609 1906SEP002/2
9025
05
31

101603
PN=389
Theory of Operation
Proportional Solenoid Valve Operation
A SOLENOID
VALVE MANIFOLD
ARM
REGENERATIVE B
SPEED SENSING C
I
L
PROPEL SPEED CHANGE D E POWER J
BOOST F
F SPOOL M
K
ADJUSTING
SCREW
J L
9025 M
05
32 G DE-ENERGIZED I
H PRESSURE EQUALS
I SOLENOID L
J
MAGNETIC FORCE
F
M
L
TO VALVE
J FUNCTION PILOT OIL FROM O PILOT OIL
M PILOT SHUT-OFF
TO
1923APR97
VALVE P REDUCED PILOT

HYDRAULIC OIL
OIL TANK N ENERGIZED Q RETURN OIL
T109046
T109046 R PROPORTIONAL SOLENOID VALVE

101603
PN=390
Theory of Operation
ASolenoid Valve Manifold GDe-Energized KAdjusting Screw OPilot Oil

BArm Regenerative HPressure Equals Magnetic LTo Valve Function PReduced Pilot Oil
CSpeed Sense Force MPilot Oil From Pilot QReturn Oil
DPropel Speed Change ISolenoid Shut-Off Valve RProportional Solenoid
EPower Boost JTo Hydraulic Oil Tank NEnergized Valve
FSpool
The arm regenerative (SC) (B), speed sense (SD) (C), as the control signal to the valve function increases.
propel speed change (SI) (D) and power boost (SG) When the control signal becomes equals to or greater
(E) solenoid valve are proportional solenoid valve (R) than the magnetic force, the spool is pushed to the
type. The solenoid valve is activated by an electrical right closing the passage stopping the control increase.
signal from the engine and pump controller (EPC). The The reduced pilot oil control signal to the valve
signal is a DC voltage that is turned on and off to form function is trapped. The spool is moving constantly to
a pulse width modulated signal. The solenoid (I) reacts maintain the control signal in response to the electrical
to the average voltage to create a magnetic force to signal to the solenoid.
shift the spool (F) left against a spring. The reduced
pilot oil control signal sent to the valve function (L) For circuit operation of arm regenerative solenoid
depends on how long the electrical signal in on verses valve, see Arm Regenerative Valve Operation in this
on how long it is off. The reduced pilot oil control group.
signal is in proportion to the electrical signal to the
solenoid. For circuit operation of speed sense solenoid valve,
see Engine Speed Sense Control Circuit Operation in
When de-energized (G), the spool is pushed to the this group.
right by a spring. The valve function port is connected
to the hydraulic oil tank (J) port. For circuit operation of propel speed change solenoid
valve, see Propel Speed Change Circuit Operation in
When energized (N), the magnetic force shifts the this group.
spool left against the spring. Pilot oil (O) flows past the
9025
spool flange and out the valve function port as a For circuit operation of power boost solenoid valve, 05
reduced pilot oil (P) control signal. Because the flange see Power Boost Control Circuit Operation in this 33
on the right is larger than the flange on the left, the group.
spool is pushed to the right against the magnetic force
TX,9025,GG2095 1924APR002/2

101603
PN=391
Theory of Operation
Engine Speed Sensing Control Circuit Operation
1907SEP96
T103218
9025
05
34
AEngine RPM Dial CEngine Speed Sensor (N ERear Pump Regulator GEngine Speed Sensing
BEngine and Pump Sensor) FSpeed Sensing Solenoid Control Circuit
Controller DFront Pump Regulator Valve
The function of engine speed sensing control circuit speed is a function of the engine and pump controller
(G) is to reduce the hydraulic load on the engine if it and is selected when the engine rpm dial (A) is turned
exceeds the output torque of the engine. to the desired actual engine speed.
The speed sensing solenoid valve (F) coil is energized The pilot oil control signal is sent to the end of the load
by an electrical signal from the engine and pump piston in the front and rear pump regulators (D and E)
controller (B) when the actual engine speed, as which then operate to reduce pump flow. (See
sensed by the engine speed sensor (C), is pulled Hydraulic Pump Regulator Operation in this group.)
down to the target engine speed. The target engine
TX,05,GG2201 1906SEP001/1

101603
PN=392
Theory of Operation
Control Valve Operation
9025
05
35
UN15APR97
T109048
Left Front
1Left Control Valve (5-Spool) 63Solenoid Valve Manifold 73Swing Valve 80Auxiliary Power Passage
2Right Control Valve 64Arm II Valve 74Arm Reduced Leakage Check Valve (Lift Check)
(4-Spool) 65Boom I Valve and Boom Valve 81Propel Flow Control Valve
56System Relief Valve Regenerative Valve 75Arm Out Circuit Relief and 82Propel Power and Neutral
Isolation Check Valve 66Boom Reduced Leakage Anti-Cavitation Valve Passage Check Valves
57System Relief Valve and Valve 76Plug (Lift Checks)
Power Boost 67Bucket Valve 77Swing Lift Check Valve 83Rear Pump Control Valve
58Dig Pressure Switch 68Right Propel Valve 78Arm I Power and Neutral 84Filter and Orifice for Pilot
59Flow Combiner Valve 69Left Propel Valve Passage Check Valves Pressure to Rear Pump
Circuit Check Valve 70Auxiliary Valve (Lift Checks), and Control Valve
60System Relief Valve 71Boom II Valve Restriction Orifice 84ACheck Valve and Orifice
Isolation Check Valve 71APropel-Boom Down 79Boom II Power Passage for Propel Flow Control
61Propel Pressure Switch Selector Valve Check Valve (Lift Check) Valve
62FilterPilot Pressure Inlet 72Arm I Valve

101603
PN=393
Theory of Operation
The control valve consists of two monoblock valve All valves are accessible from the outside of control
housings called the left control valve (1) and right valve by removing a plug, cover, or the pilot caps. For
control valve (2). The control valves are mounted line connections to the control valves, see Control
back-to-back to connect the interconnected oil Valve Component and Line Identification in Group
passages through ports in the mounting faces. The left 9025-15. The solenoid valve manifold is also located
control valve is a 5-spool section valve consisting of on the right control valve.
left propel (69), auxiliary (70), boom II (71), arm I (72),
and swing (73). The right control valve is a 4-spool The control valve is an open-center valve. Each valve
section valve consisting of right propel (68), bucket section controls the flow rate and direction for its
(67), boom I (65), and arm II (64). Each spool is hydraulic circuit. The rear (83) and front (98) pump
selectively fitted to its bore in the housings. The spools control valves, located in neutral passage of the left (1)
are moved by pilot oil controlled by the pilot controllers and right (2) control valves, are used to send a control
located in the cab. signal to the front and rear pump regulators when a
function is actuated. (See Pump Control Valve
For the location of all valves used in the control valve, Operation in this group.) Two pressure switches (58
see the three illustrations labeled Left Front, Right and 61) located on the front of the control valve are
Rear, and Bottom and the legends. Also see the closed to send an electrical signal to the engine and
Control Valve Circuit Schematic for location of pump controller when a dig or propel function is
components. actuated.

9025
05
36

101603
PN=394
Theory of Operation
9025
05
37
UN15APR97
T109052
Right Rear
1Left Control Valve (5-Spool) 69Left Propel Valve 90Propel Speed Change 96Boom I Power and Neutral
2Right Control Valve 70Auxiliary Valve Solenoid Valve Passage Check Valves
(4-Spool) 71Boom II Valve 91Speed Sensing Solenoid (Lift Checks)
57System Relief Valve and 72Arm I Valve Valve 97Right Control Valve to
Power Boost 73Swing Valve 92Arm Regenerative Arm I Power Passage
63Solenoid Valve Manifold 85Arm Regenerative Valve Solenoid Valve Check Valves and
64Arm II Valve 86Arm II to Arm I Neutral 93Flow Combiner Valve Restriction Orifice
65Boom I Valve and Boom Passage Check Valve 94Bucket Flow Control Valve 98Front Pump Control Valve
Regenerative Valve 87Boom Up Circuit Relief Pilot Valve A and B, and 99Filter and Orifice for Pilot
66Boom Reduced Leakage Valve Poppet Valve Pressure to Front Pump
Valve 88Bucket Dump Circuit 95Bucket Check Valve (Lift Control Valve
67Bucket Valve Relief Valve Check) 105Oil Cooler Bypass Valve
68Right Propel Valve 89Power Boost Solenoid
Valve

101603
PN=395
Theory of Operation
UN15APR97
T109053
9025 Bottom
05
38 1Left Control Valve (5-Spool) 68Right Propel Valve 94Bucket Flow Control Valve 102Bucket Curl Circuit Relief
2Right Control Valve 69Left Propel Valve 100Arm Regenerative Circuit and Anti-Cavitation Valve
(4-Spool) 70Auxiliary Valve Check Valve 103Plug
64Arm II Valve 71Boom II Valve 101Boom Down Circuit 104Arm In Circuit Relief and
65Boom I Valve 72Arm I Valve Relief and Anti-Cavitation Anti-Cavitation Valve
67Bucket Valve 73Swing Valve Valve
TX,05,GG2154 1920MAY984/4

101603
PN=396
Theory of Operation
9025
05
39

101603
PN=397
Theory of Operation
Control Valve Circuit Schematic
9025
05
40
UN16APR97
T109055

101603
PN=398
Theory of Operation
1Left Control Valve (5-Spool) 71Boom II Valve 81Propel Flow Control Valve 96Boom I Power and Neutral
2Right Control Valve 71APropel-Boom Down 82Propel Power and Neutral Passage Check Valves
(4-Spool) Selector Valve Passage Check Valves (Lift Checks)
56System Relief Valve 72Arm I Valve (Lift Checks) 97Right Control Valve to
Isolation Check Valve 73Swing Valve 83Rear Pump Control Valve Arm I Power Passage
57System Relief Valve and 74Arm Reduced Leakage 85Arm Regenerative Valve Check Valves and
Power Boost Valve 86Arm II Neutral Passage to Restriction Orifice
59Flow Combiner Valve 75Arm Out Circuit Relief and Arm I Power Passage 98Front Pump Control Valve
Circuit Check Valve Anti-Cavitation Valve Check Valve 100Arm Regenerative Circuit
60System Relief Valve 76Plug 87Boom Up Circuit Relief Check Valve
Isolation Check Valve 77Swing Lift Check Valve Valve 101Boom Down Circuit
64Arm II Valve 78Arm I Power and Neutral 88Bucket Dump Circuit Relief and Anti-Cavitation
65Boom I Valve and Boom Passage Check Valves Relief Valve Valve
Regenerative Valve (Lift Checks), and 93Flow Combiner Valve 102Bucket Curl Circuit Relief
66Boom Reduced Leakage Restriction Orifice 94Bucket Flow Control Valve and Anti-Cavitation Valve
Valve 79Boom II Power Passage Pilot Valve A and B, and 103Plug
67Bucket Valve Check Valve (Lift Check) Poppet Valve 104Arm In Circuit Relief and
68Right Propel Valve 80Auxiliary Power Passage 95Bucket Check Valve (Lift Anti-Cavitation Valve
69Left Propel Valve Check Valve (Lift Check) Check) 105Control Valve Circuits
70Auxiliary Valve
TX,9025,GG2610 1920MAY982/2
9025
05
41

101603
PN=399
Theory of Operation
Control Valve Pilot Control Signal Passage Operation
9025
05
42
1928APR00
T129505

101603
PN=400
Theory of Operation
AOrifice and Check Valve HDig Pilot Control Signal NFront Pump TPropel Flow Control Valve
BSwing Park Brake Release Passage ORear Pump UAuxiliary
Valve IRight Propel PSwing VReturn Passage
CDig Pressure Switch JBucket QArm I WLeft Propel
DOrifice KBoom I RPropel-Boom Down XReturn Passage
EPropel Pressure Switch LArm II Selector Valve YDig and Propel Pilot
FFlow Combiner Valve MPilot Pump SBoom II Control Signal
GPropel Pilot Control Signal
Passage
Pilot oil from the pilot pump (M) flows to the control passage (V). The flow of oil through the orifices
valve and through the orifices (D) into the propel pilot causes a pressure drop; the pressure of oil
control signal passage (G) and dig pilot control signal downstream of each orifice is less than the pressure
passage (H). The oil in the propel pilot control signal upstream of the orifices. None of the switches or
passage flows to the propel pressure switch (E), the valves in the signal passages are actuated.
propel-boom down selector valve (R), past the top end
of the right (I) and left (W) propel valve spools, and When a function is actuated, the valve spools shifts
then to the return passage (X). The oil in the dig pilot blocking the flow of oil through the signal passage.
control signal passage flows to the dig pressure switch The oil pressure upstream of the valve spool increases
(C), the propel flow control valve (T), flow combiner to approximately the pressure setting of pilot pressure
valve (F), past the top end of bucket (J), boom I (K), regulating valve and actuate the switch and valves in
arm II (L), swing (P), arm I (Q), boom II (S), and that signal passage.
auxiliary (U) valve spools, and then to the return
TX,05,GG2192 1924APR002/2
9025
05
43

101603
PN=401
Theory of Operation
Control Valve Neutral and Power Passages Operation
9025
05
44
1907SEP96
T101397

101603
PN=402
Theory of Operation
ASystem Relief Valve HBoom I NPower Passage TBoom II

BFlow Combiner Valve ICircuit Relief and ORear Pump UPropel Flow Control Valve
CNeutral Passage Anti-Cavitation Valves PNeutral Passage WAuxiliary
DReturn Passage JArm II QSwing XRear Pump Control Valve
ERight Propel KFront Pump Control Valve RArm I YLeft Propel
FBucket LPilot Pump SCircuit Relief and ZNeutral and Power Passage
GCircuit Relief and MFront Pump Anti-Cavitation Valves
Anti-Cavitation Valves
Supply oil from the front pump (M) flows to the right (C and P), through the pump control valves (K and X),
control valve. Supply oil from the rear pump (O) flows and into the return passage (D). Power passages (N)
to the left control valve. When all functions are in in the left and right control valves are used to route
neutral supply oil flows through the neutral passages supply oil for the combined operation of functions.
TX,05,GG2191 1906SEP002/2
9025
05
45

101603
PN=403
Theory of Operation
System Relief and Power Boost Valve Operation

FIRST
ADJUSTING A O PUMP SUPPLY OIL
PLUG P PILOT OIL
TOP NUT B Q RETURN OR
PRESSURE
SECOND FREE OIL
ADJUSTING C
PLUG
BOTTOM NUT D E PISTON
LEFT CONTOL
F VALVE HOUSING
PILOT POPPET
G
SPRING
H PILOT POPPET
MAIN POPPET
I
SPRING
J MAIN POPPET
K RETURN PASSAGE
9025
05 L POWER PASSAGE
46
1923APR97
M DIGGING N POWER BOOST
R SYSTEM RELIEF AND POWER BOOST VALVE
T102821
T102821
AFirst Adjusting Plug FLeft Control Valve Housing KReturn Passage PPilot Oil
BTop Nut GPilot Poppet Spring LLower Passage QReturn or Pressure Free
CSecond Adjusting Plug HPilot Poppet MDigging Oil
DBottom Nut IMain Poppet Spring NPower Boost RSystem Relief and Power
EPiston JMain Poppet OPump Supply Oil Boost Valve
The function of system relief and power boost valve flows out faster than oil can flow through orifice in
(R) is to limit the main hydraulic system operating poppet. The main poppet is pushed open to relieve
pressure. System relief and power boost valve is pressure oil to return passage.
pilot-operated poppet type relief valve with a piston
(E). For power boost operation (N), pilot oil (P) from the
power boost solenoid valve pushes the piston (E)
When the pump supply oil in the power passage (L) down increasing the pressure setting of the pilot
pressure exceeds the relief valve setting, pilot poppet poppet spring (G). The main hydraulic system can now
(E) is pushed off its seat letting oil behind main poppet operate at a higher operating pressure for
(J) flow to the return passage (K). A pressure approximately 8 seconds.
differences is created across main poppet because oil
TX,05,GG2155 1924APR001/1

101603
PN=404
Theory of Operation
Power Boost Control Circuit Operation
1929APR97
T109063
9025
05
47
APower Boost Switch CSystem Relief Valve DPower Boost Solenoid EPower Boost Control
BEngine and Pump Valve Circuit
Controller
The function of power boost control circuit (E) is to pressure setting. The main hydraulic system can now
temporarily increase the main hydraulic system operate at a higher operating pressure for
operating pressure by increasing the system relief approximately 8 seconds as long as the power boost
valve pressure. switch is held down.
The power boost solenoid valve is also actuated in The power boost function stays actuated for
precision work mode when the boom up function is approximately 8 seconds as long as the switch is held
actuated. down. If the switch is released before 8 seconds, the
power boost function is turned off. After 8 seconds, the
When the power boost switch (A) is pushed and held, switch must be released and pushed again to actuate
the engine and pump controller (B) sends an electrical the power boost function. The length of time the power
signal to energize the power boost solenoid valve (D) boost function is actuated is controlled by a timer
coil. The pilot oil pressure signal pushes the piston in circuit in the engine and pump controller.
the system relief valve (C) down increasing the
TX,05,GG2202 1924APR001/1

101603
PN=405
Theory of Operation
Circuit Relief Valve Operation
P RELIEF OPERATION Q ANTICAVITATION OPERATION

PILOT POPPET E CHECK VALVE SPRING
F
G PILOT POPPET SPRING
CHECK VALVE D H SCREW
K RELIEF PRESSURE OIL

C
L OPERATING PRESSURE OIL
FROM WORK
CIRCUIT M REDUCED PRESSURE OIL
N RETURN OIL
1903NOV97
PISTON B I PISTON SPRING
TO RETURN A J MAIN POPPET O LOW PRESSURE OIL
IT4579
R CIRCUIT RELIEF - ANTICAVITATION VALVE
IT4579
9025
05 ATo Return Oil FCheck Valve Spring KRelief Pressure Oil PRelief Operation
48 BPiston GPilot Poppet Spring LOperating Pressure Oil QAnticavitation Operation
COil From Work Circuit HScrew MReduced Pressure Oil RCircuit Relief -
DCheck Valve IPiston Spring NReturn Oil Anticavitation Valve
EPilot Poppet JMain Poppet OLow Pressure Oil
At pressures below the circuit relief setting the main During anti-cavitation operation (Q) the check valve (D)
poppet (J) remains closed. In relief operation (P), the retracts to allow oil to flow from the return passage into
relief valve opens in three steps. In the first step, the the work circuit. During normal operation the operating
pilot poppet (E) is opened. Flow restriction through the oil pressure (L) on the inner shoulder holds the check
hollow piston (B) causes the pressure in the cavity valve against its seat. This pressure decreases as
behind the main poppet to decrease. In the second pressure in the work circuit decreases. The return oil
step of relief operation the piston seats against the pressure (N) on the outer shoulder moves the check
pilot poppet (E). This further reduces oil flow into the valve, main poppet, and piston against the springs to
cavity and greatly decreases the pressure against the open the valve.
back side of main poppet. The main poppet opens in
the third step of relief operation.
TX,05,GG2146 1924APR001/1

101603
PN=406
Theory of Operation
9025
05
49

101603
PN=407
Theory of Operation
Pump Control Valve Operation
9025
05
50
1925APR00
T129510

101603
PN=408
Theory of Operation
APilot Oil Inlet From FFlow Sense Spring JRelief Valve Spool MRear Pump Control Valve
Solenoid Valve Manifold GFlow Sense Spool KControl Signal-to-Pump NFront Pump Control Valve
BFilter Screen HControl Valve Neutral Regulator OSwing Valve
COrifice Passage LPump Control Valve PSystem Relief Valve
DRelief Valve Spring ITo Hydraulic Oil Tank Pressure Sensor QPump Control Valves
EControl Valve Return
Passage
9025
05
51

101603
PN=409
Theory of Operation
1925APR00
T129512
9025
APilot Oil Inlet From EControl Valve Return ITo Hydraulic Oil Tank LPump Control Valve
05
Solenoid Valve Manifold Passage JRelief Valve Spool Pressure Sensor
52
BFilter Screen FFlow Sense Spring KControl Signal-to-Pump QPump Control Valves
COrifice GFlow Sense Spool Regulator
DRelief Valve Spring HControl Valve Neutral
Passage
A pump control valve (Q) is located at the downstream relief valve spool is pushed open to direct pilot oil to
end of the control valve neutral passage (H) in the left the hydraulic oil tank (I) decreasing the control signal
and right control valves. The function of pump control to the pump regulator (K).
valve is to send regulated control signal to the front
and rear pump regulators to change pump flow in Control Valve Spool Actuated: When a single or
response to the actuation of control valve spools. combine functions are actuated the control valve spool
shift decreasing flow through the neutral passage and
Control Valve Spools in Neutral: When all control flow sense spool. As flow through the flow sense spool
valve spools are in neutral the neutral passage through decreases, the spool is shifted to the left by the flow
the control valve is not restricted and full flow from the sense spring increasing the pressure setting on the
pump flows through the neutral passage and flow relief valve spring. The relief valve spool shifts more
sense spool (G) to the control valve return passage closed decreasing pilot oil flow to the hydraulic oil tank
(E). Full flow causes the flow sense spool to move to and increasing the control signal to the pump regulator
the right against the flow sense spring (F) decreasing which causes pump flow to increase. (See Hydraulic
the pressure setting of the relief valve spool (J). The Pump Regulator Operation in this group.)

101603
PN=410
Theory of Operation
In addition, the pressure signal to pump regulators is for the propel speed change function. (See Propel
senses by the pump control pressure sensors sending Motor Speed Change Circuit Operation in this group.)
an electrical signal to the engine and pump controller
TX,05,GG2178 1924APR004/4
9025
05
53

101603
PN=411
Theory of Operation
Flow Combiner Valve Operation
1927APR00
T129513
9025
05
54
ALeft Control Valve DFlow Combiner Valve FFrom Front Pump HFlow Combiner Valve
BRight Control Valve ETo Left Propel Valve GDig Pilot Control Signal
CFrom Pilot Control Pump Passage
Pilot oil from the pilot pump (C) flows through the machine does not mistrack during combined propel
orifice (L), into the dig pilot control signal passage (G), and dig function operations. The flow combiner check
past each dig function valve spools, and then to the valve (N) prevents back flow past the flow combiner
return circuit. The flow combiner valve (D), propel flow valve. The left propel valve does not receive supply oil
control valve (M), and the swing motor park brake from the rear pump (Q) except through the propel flow
release valve (K) are connected to the signal passage control valve if the upstream pressure is higher than
between the orifice and spools. the pressure in the flow combiner circuit.
When one or more dig functions are actuated, pilot oil The dig and propel pressure switches are actuated to
flow through the signal passage to return is blocked by send and electrical signal to engine and pump
a valve spool (arm II valve shown) (O). The pressure controller when the propel and dig functions are
in the blocked portion of the signal passage increases actuated.
shifting the flow combiner, propel flow control, and
swing park brake release valve spools. When just the propel function is actuated, the left
propel valve is supplied with oil from the rear pump
Supply oil from the front pump (P) now flows through and the right propel valve is supplied with oil from the
the flow combiner valve to the left propel valve (E) as front pump.
will as the right propel valve to ensure that the

101603
PN=412
Theory of Operation
9025
05
55

101603
PN=413
Theory of Operation
9025
05
56
1927APR00
T129506

101603
PN=414
Theory of Operation
ALeft Control Valve GDig Pilot Control Signal LOrifice PFront Pump
BRight Control Valve Passage MPropel Flow Control Valve QRear Pump
CFrom Pilot Control Pump ILeft Propel Motor NFlow Combiner Check RFlow Combiner Valve
DFlow Combiner Valve JRight Propel Motor Valve Circuit
ETo Left Propel Valve KTo Swing Motor Park Brake OValve Spool
Release Valve
TX,05,GG2179 1924APR003/3
9025
05
57

101603
PN=415
Theory of Operation
Arm Regenerative Valve Operation
1917AUG96
T102962
9025
05
58
AArm Cylinder DArm Regenerative Solenoid FArm II Valve HArm Regenerative Valve
BArm I Valve Valve GRear Pump
CArm Regenerative Circuit EArm Regenerative Valve
Check Valve Spool
The arm regenerative valve (H) is used to improve arm engine and pump controller sends an electrical signal
controllability and prevent arm cylinder (A) cavitation to the arm regenerative solenoid valve (D) to energizes
during arm IN operation by combining the return oil the coil. The solenoid valve then sends a pressure
from arm cylinder rod end with the pump supply oil to signal to the arm regenerative valve spool (E) to shift it
the arm cylinder head end. blocking the passage to return. The return oil from the
rod end of arm cylinder now flows through the arm
Under the following operating conditions: low rear regenerative circuit check valve (C) and then to the
pump delivery pressure, high pilot pressure to the pilot head end of arm cylinder with the pump supply oil.
cap for arm in, and boom up actuated, gravity can pull Return oil not used flows through the orifice (J) to the
the arm in faster than the pump can supply oil to the return passage.
arm cylinder head end. The operating conditions are
sensed by the rear pump pressure sensor (I), arm in There are five check valves located in the passages to
pressure sensor (K), and boom up pressure switch (L). the arm I valve to prevent back flow through the
The pressure switch and sensors send electrical control valve. For arm in function, return and supply oil
signals to the engine and pump controller (M). The flows through the arm I valve only.

101603
PN=416
Theory of Operation
9025
05
59
1917AUG96
T102986
AArm Cylinder EArm Regenerative Valve JOrifice NArm Regenerative Valve
BArm I Valve Spool KArm In Pressure Sensor Circuit
CArm Regenerative Circuit GRear Pump LBoom Up Pressure Switch
Check Valve IRear Pump Pressure Sensor MEngine and Pump
DArm Regenerative Solenoid Controller
Valve
TX,05,GG2185 1924APR002/2

101603
PN=417
Theory of Operation
Boom and Arm Reduced Leakage Valves Operation
1927MAY98
T115414
9025
05
60
Reduced leakage valves (G) are used in the boom shifts the pilot valve (F). The oil pressure from the
head end circuit and arm rod end circuit. The function cylinder is blocked by the pilot valve. The oil pressure
of a reduced leakage valve is to reduce cylinder drift at the top (spring end) of check valve poppet can now
by stopping leakage from the cylinder back through the flow through the pilot valve to the warm-up passage in
control valve. the pilot caps and then to the hydraulic oil tank. The oil
pressure from the cylinder pushes the poppet off its
When the control valve is in neutral, the oil pressure seat opening the passage for oil to flow into the control
generated in the boom cylinder head end or arm valve return passage. The poppet is pushed off its seat
cylinder rod end by the load on the cylinders is applied because the OD of upper land at the head end of
to the top (spring end) of check valve poppet (E) poppet is slightly larger than the lower land.
through the pilot valve (F). The poppet is held closed
against the seat in housing trapping the oil from the The boom manual lower screw (H) is used to lower the
cylinder at the work port. boom if the engine should stop with the boom in the
raised position. (See Lower Boom With Engine
When boom down or arm in function is actuated, the Stopped in Group 9025-25.)
pilot pressure signal (C) from the pilot controller also
TX,05,GG2186 1920MAY981/1

101603
PN=418
Theory of Operation
9025
05
61

101603
PN=419
Theory of Operation
Bucket Flow Control Valve Operation
9025
05
62
1920AUG96
T103012

101603
PN=420
Theory of Operation
ALeft Propel Valve EPilot Valve A HBucket Valve KBucket Cylinder

BRight Propel Valve FReturn To Solenoid Valve IPilot Valve B LAuxiliary Valve
CBoom Up Pilot Pressure Manifold JBucket Pilot Pressure MBucket Flow Control Valve
DArm In Pilot Pressure GPoppet Valve
The bucket flow control valve (M) restricts oil flow to actuated the pilot pressure also flows through pilot
the bucket cylinder in the combined operations of valve A to shift pilot valve B (I) closing the passage
bucket, arm in, and boom up to ensure supply oil flow from the poppet valve (G). The pressure on the back
goes to the higher-loaded boom function to raise the side of the poppet valve increases closing the poppet
boom. valve causing a restriction for supply oil flow through
the poppet valve to the bucket valve (H).
When arm in function is actuated the pilot pressure
also shifts pilot valve A (E). If boom up function is
TX,05,GG2187 1906SEP002/2
9025
05
63

101603
PN=421
Theory of Operation
Propel Flow Control Valve Operation
1927APR00
T129771
9025
05
64
AOrifice and Check Valve EPropel Power Passage GPower Passage JReturn
BLeft Propel Valve Check Valve HDig Function Valve Spool KPropel Flow Control Valve
CPilot Control Signal FPropel Neutral Passage IRight Propel Valve
DPropel Flow Control Valve Check Valve
Spool
The propel flow control valve (K) is used to reduce in the orifice and check valve (A) assembly to
shock loads from the power passage (G). The shock gradually shift the propel flow control valve spool (D).
loads are cause by the operation of dig functions The gradual shift of spool slowly restrict the flow of
upstream of the left propel valve (B). supply oil to the left propel valve reducing any shock
loads.
The propel flow control valve is located in the power
passage to the left propel control valve. The pilot control signal is released quickly through the
check valve when all dig functions are returned to
When a dig function (H) is actuated while propelling, neutral. The propel flow control valve spool is shifted
the pilot pressure signal also flows through the orifice quickly to the open position by the spring.
TX,05,GG2188 1924APR001/1

101603
PN=422
Theory of Operation
Propel-Boom Down Selector Valve Operation
1927APR00
T129774
9025
05
65
ABoom II Valve DPropel Pilot Control Signal GTo Boom Cylinder Rod IPropel-Boom Down Selector
BBoom I Valve ERight Propel Valve End Valve
CPropel-Boom Down FPilot Controller Pressure HRear Pump
Selector Valve Spool Signal
The function of propel-boom down selector valve (I) is However, in a propel and boom down combined
to route the pilot controller pressure signal (F) to shift operations front pump supply oil is block by the right
the boom II valve (A) also when the combined propel propel valve (E) and does not flow to the boom I valve
and boom down functions are actuated. (B). To get supply oil to the rod end of boom cylinders,
the boom II valve (A) is shifted to route rear pump (H)
When just the boom down function is actuated, the supply oil to the cylinders. When the right propel valve
pilot controller pressure signal (F) flows to the pilot cap (E) is actuated, the propel pilot control signal (D)
to shift the boom I valve only. Pilot oil to the boom II increases shifting the propel-boom down selector valve
valve is blocked by the propel-boom down selector spool (C). The pilot controller control signal can now
valve spool (C). Front pump supply oil flows through flow through the selector valve and shift the boom II
the right propel valve (E) neutral passage to the boom valve.
I valve and out to the rod end of boom cylinders.
Return oil from the head end flows through the boom I The return oil from the head end of boom cylinders still
valve to return. flows through the boom I valve to return.
TX,05,GG2189 1924APR001/1

101603
PN=423
Theory of Operation
Boom Regenerative Valve Operation
1912MAY97
T109129
9025
05
66
ABoom II Valve DBoom Regenerative Valve FPilot Controller Pressure GBoom Cylinders
BBoom I Valve Orifice Signal HBoom Regenerative Valve
CBoom Regenerative Valve EBoom I Neutral Passage
Poppet Check Valve
The function of boom regenerative valve (H) during head end the return oil pushes the boom regenerative
boom down operation is to combine the return oil flow valve poppet (C) open and flows to the rod end.
from head end of boom cylinders (G) with the pump Return oil not used flows through the boom
supply oil to the rod end to prevent cavitation. regenerative valve orifice (D) to the return passage.
During boom down operation, if pump supply oil The boom I neutral passage check valve (E) prevents
pressure is lower than the return oil pressure from the back flow through the control valve.
TX,05,GG2190 1906SEP001/1

101603
PN=424
Theory of Operation
9025
05
67

101603
PN=425
Theory of Operation
Propel and Arm In Combined Operation
9025
05
68
1924AUG98
T116658

101603
PN=426
Theory of Operation
ALeft Propel Motor FPilot Pump KArm II Valve PArm I Valve

BPropel Flow Control Valve GDig Pilot Pressure Signal LRight Control Valve QArm Cylinder
CFlow Combiner Valve Passage MLeft Control Valve RLeft Propel Valve
DTo Swing Park Brake HCheck Valve NFront Pump SPropel and Arm In
Release Valve IRight Propel Motor ORear Pump Combined
EOrifice JRight Propel Valve
Actuating the propel and arm in functions in combined propel valve (R) to turn the left propel motor (A).
operation (S) shifts the left (R) and right (J) propel Because one pump is used to supply oil to both propel
valves and the arm II (K) and arm I (P) valves. With motors, the machine can propel straight even when the
the valves shifted, pilot oil flow through the dig pilot arm in function is actuated in combined operation with
pressure signal passage (G) is blocked by the arm II the propel function. The check valve (H) prevents back
valve causing the pilot oil pressure in the passage to flow through the flow combiner valve.
increase. The increased pressure shifts the flow
combiner valve (C), propel flow control valve (B), and Supply oil from the rear pump (O) flows through the
swing park brake release valve (D). arm I valve (P) to move the arm cylinder (Q). Supply
oil from the rear pump can flow through the check
Supply oil from the front pump (N) flows through the valve and propel flow control valve (B) if upstream
right propel valve (J) to turn the right propel motor (I) pressure is higher than pressure in the flow combiner
as well as through the flow combiner valve (C) and left valve passage.
CED,OUOE035,132 1906SEP002/2
9025
05
69

101603
PN=427
Theory of Operation
Swing and Boom Up Combined Operation
9025
05
70
1921SEP00
T133815

101603
PN=428
Theory of Operation
1Power Passage 4Power Passage 7Rear Pump 10Swing and Boom Up

2Boom I Valve 5Swing Valve 8Swing Motor Combined
3Boom Cylinder 6Front Pump 9Boom II Valve
Actuating the swing and boom up in combined Pressure oil not used by the swing function flows
operation (10) shifts the swing valve (5), boom I valve through the power passage (4) and boom II valve (9).
(2), and boom II valve (9). The pressure oil combines with the pressure oil from
the front pump and flows to the boom cylinders. The
Pressure oil from the front pump (6) flows through the boom is raised by combined oil flow from the front and
power passage (1) and boom I valve and out to the rear pumps.
boom cylinders (3) to raise the boom. At the same
time pressure oil from the rear pump (7) flows through
the swing valve (5) and out to the swing motor to
swing the upperstructure.
CED,TX08227,2991 1906SEP002/2
9025
05
71

101603
PN=429
Theory of Operation
Swing Gearbox Operation
9025
05
72
1907SEP96
T103086

101603
PN=430
Theory of Operation
ASwing Motor EDrain Pipe ISecond Planet Carrier LFirst Planet Sun Gear
BFirst Planet Gear FOil Seal JSecond Planet Sun Gear MFirst Planet Carrier
CSecond Planet Gear GOutput Pinion KRing Gear NSwing Gearbox
DBearing HBearing
The swing gearbox (N) is a double reduction planetary planet sun gear is located between thrust washers.
drive type gearbox. The swing motor (A) is mounted Second planet gears (C) rotate around shafts in the
on the swing gearbox and encloses the top side of second planet carrier (I). The second planet carrier is
gearbox. The output pinion (G) is in mesh with swing connected to the output pinion (G) and this causes the
gear. Swing motor rotational speed is reduced by the output pinion to rotate.
double reduction planetary gear set.
The pinion rotates in two spherical roller bearings (D
The first planet sun gear (L) is connected to motor and H). Downward movement of pinion is prevented by
output shaft and is located between a retaining ring a retaining ring seated against upper bearing. Upward
and thrust washer. The first planet gears (B) rotate movement is prevented by second sun pinion. Oil seal
around roller bearings on shafts in the first planet (F) prevents oil from leaking out of swing gearbox and
carrier (M). Rotation of the first planet carrier causes keeps grease from coming in.
the second planet sun gear (J) to rotate. The second
TX,05,GG2193 1906SEP002/2
9025
05
73

101603
PN=431
Theory of Operation
Swing Motor Operation
9025
05
74
1912SEP96
T103087
ACylinder Block FSwing Crossover Relief JForce Pin OThrust Plate

BPort Valve KBall Bushing PPiston and Slipper
CSpring GSpring LRetainer QSwing Park Brake Release
DCover HPiston MOutput Shaft Valve
EValve Plate IBrake Pack NOil Seal RSwing Motor

101603
PN=432
Theory of Operation
The swing motor (R) consists of the rotating group, Swing speed varies depending on the amount of
park brake, and cover (D). The cover contains the supply oil delivered by the pump through the control
swing crossover relief valves (F), make-up check valve.
valves and inlet and outlet ports. The valve plate (E) is
held in position by dowel pins in the cover. The swing During the second half of motors revolution, low
motor is a fixed displacement, axial piston, fixed pressure oil is discharged as pistons slide back up the
position thrust plate (O) motor. It is bidirectional so the inclined thrust plate. To reverse rotation, oil flow is
upperstructure can swing in both directions. reversed. A small amount of supply oil flows through
the center of each piston to ball joint and to face of
The rotating group consists of a cylinder block (A) with slipper for lubrication.
nine pistons and slippers (P). The cylinder block is
connected to the output shaft (M). Each piston is The motor is internally lubricated from leakage inside
connected to a slipper by a ball joint. Slippers slide on the motor. Lubrication oil is routed up through the
the inclined thrust plate (O) forcing the cylinder block cover to the hydraulic oil tank.
to turn. Retainer (L) holds the slippers on the thrust
plate and the retainer itself is held against the slippers The swing motor park brake is spring applied and
by force pins (J) and spring (C). hydraulically released. The plates in the brake pack (I)
are connected to the housing. The disks are connected
Oil from swing control valve is routed through cover to and rotate with the cylinder block. When the pilot
(D), valve plate (E), and port (B) to the pistons. controllers are in neutral, pilot oil is blocked from the
piston (H) by the swing park brake release valve (Q).
In operation, high pressure supply oil enters the The brake springs squeeze the plates and disks
cylinder bores through ports forcing pistons down together to prevent the upperstructure from swinging.
against inclined thrust plate. The slippers slide down The swing park brake is released when the swing,
the inclined thrust plate causing the rotating group to boom, arm, or bucket function is actuated.
turn. The output shaft is turned by the cylinder block.
9025
05
75
TX,05,GG2194 1906SEP002/2

101603
PN=433
Theory of Operation
Swing Motor Crossover Relief Valve Operation
1920AUG96
T103106
ASpring DReturn Passage GOrifice JSwing Motor Crossover
BSpring Guide EChamber HRelief Poppet Relief Valve
CPiston FSpring IPort
9025 The function of swing crossover relief valve (J) is to seat to relieve pressure oil to return. The pressure is
05 relieve the high pressure generated in the swing circuit also sensed in the chamber (E) through the orifice (G).
76 when starting or stopping the swing operation. The oil The opening of the relief poppet is further dampened
pressure in the swing circuit becomes high because of by the action of the piston (C), spring guide (B), and
the inertia of the upperstructure to starting and spring (A). Oil from the spring (A) chamber is release
stopping. through the orifices in the spring guide and piston to
the return passage (D). The relief poppet is pushed
When the oil pressure in port (I) increases to the valve back to the right by the spring (F) and the pressure in
pressure setting, the relief poppet (H) is pushed off its the chamber.
TX,05,GG2195 1906SEP001/1

101603
PN=434
Theory of Operation
Swing Motor Make-Up Valve Operation
9025
05
77
1920AUG96
T103116
ASwing Motor Crossover BMake-Up Oil Port DInlet Port EMake-Up Valves
Relief Valves CMake-Up Valve Poppet
While stopping the swing function the control valve For a few seconds the motor acts like a pump. The
spools go to neutral and the lines to inlet ports (D) at relief poppet in the crossover relief valve opens to
the swing motor are blocked at the control valve. relieve the high pressure oil to the make-up oil port
Because of the inertia of the upperstructure the oil (B).
pressure in one side of the swing motor becomes high.

101603
PN=435
Theory of Operation
Because the lines to the motor are blocked the port. The return oil flows in and prevents cavitation.
continued rotation of the upperstructure lowers the The make-up oil port is connected to the return
pressure on the other side of the motor until cavitation passage in the control valve. The return oil pressure is
starts. When cavitation starts the make-up poppet (C) maintained by the restriction valve located downstream
is pushed open by the return oil in the make-up oil of the oil cooler.
TX,05,GG2196 1906SEP002/2
9025
05
78

101603
PN=436
Theory of Operation
9025
05
79

101603
PN=437
Theory of Operation
Swing Motor Park Brake Release Valve Operation
9025
05
80
1921APR97
T109165

101603
PN=438
Theory of Operation
ADig Pilot Pressure Signal EPilot Pump HValve Spool KBrake Pack
BPiston FSwing Motor Park Brake IPark Brake Released LSwing Motor Park Brake
COrifice and Check Valve Release Valve Spool JPark Brake Applied Release Valve
DPilot Pressure Oil GSwing Motor
The function of swing motor park brake release valve pressure signal passage to the return passage causing
(L) is to route pilot oil pressure (D) to the piston the pressure signal to decrease. The release valve
releasing the brake pack when a dig or swing function spool (F) is shifted by the spring blocking the flow of
is actuated. pilot oil pressure to the piston (B) chamber. The oil in
the piston chamber flows through the orifice (C) to
Park Brake Released (I): When a swing or dig return as the springs push the piston down applying
function is actuated, the flow of pilot oil through dig the park brake. The oil is metered through the orifice
pilot pressure signal passage in the control valve is to slow engagement to ensure that park brake is only
blocked by a valve spool (H). The dig pilot pressure fully applied after the upperstructure has stopped. The
signal (A) increases and shifts the swing motor park orifice and check valve is located in the swing motor
brake release valve spool (F). Pilot pressure oil (D) housing adjacent to the swing motor park brake
from the solenoid valve manifold flows through the release valve.
spool to piston (B) chamber. The pilot pressure oil
pushes the piston up against the spring releasing the Pilot oil pressure (D) is maintained at the release valve
brake pack (K). The upperstructure is now free to turn. spool (F) as long as the pilot shutoff valve is ON. The
circuit for pilot oil pressure is from the pilot pump (E),
Park Brake Applied (J): When the valve spool (H) is through the pilot shutoff valve, solenoid valve manifold,
returned to neutral, pilot oil flows through the dig pilot and then to the release valve spool.
TX,05,GG2197 1906SEP002/2
9025
05
81

101603
PN=439
Theory of Operation
Rotary Manifold Operation
LEFT PROPEL C D RIGHT PROPEL B C E D

FORWARD REVERSE
F PROPEL SPEED CHANGE
LEFT B E RIGHT PROPEL
PROPEL FORWARD
REVERSE A F
A RIGHT PROPEL DRAIN
D RIGHT PROPEL REVERSE
DRAIN A
F F
F PROPEL
SPEED B
CHANGE
D
C LEFT PROPEL A LEFT
PROPEL C
FORWARD DRAIN
E
B LEFT E RIGHT
PROPEL
1923JUN98
PROPEL A
REVERSE FORWARD G SUPPLY OIL
H RETURN OIL
T109474
T109474 J ROTARY MANIFOLD I PILOT OIL
9025
05
82
ALeft Propel Drain DRight Propel Reverse GSupply Oil IPilot Oil
BLeft Propel Reverse ERight Propel Forward HReturn Oil JRotary Manifold
CLeft Propel Forward FPropel Speed Change
The rotary manifold (J) is a 360 rotary joint. It allows Oil flows into and through the spindle to passages in
oil to flow to and from the propel motors without the housing, and then out of the housing to the propel
twisting hoses when the upper structure is rotated. motors. Sealing rings stop oil from leaking between the
spindle and housing into adjacent passages.
The inner spindle is connected to the upper structure
and the housing is connected to the undercarriage.
The housing rotates about the spindle during swing
operation.
TX,05,GG2171 1906SEP001/1

101603
PN=440
Theory of Operation
9025
05
83

101603
PN=441
Theory of Operation
Propel Motor Operation
VALVE
PLATE SPRING
PLATE B C
A
SPRING
D CENTER
SHAFT
E
F HOUSING
G DRIVE
SHAFT
LINK P
9025
05
84
SERVO O
PISTON H ROLLER
BEARING
I
J ROLLER
BEARING
BRAKE
K DISKS
PLATES
N
ROTOR M L
PISTON BRAKE
PISTON Q SUPPLY OIL
R RETURN OIL
1923APR97
T7499AA
TXC7499AA S PROPEL MOTOR

101603
PN=442
Theory of Operation
APlate FHousing KPlates PLink

BValve Plate GDrive Shaft LBrake Piston QSupply Oil
CSpring HRoller Bearing MPiston RReturn Oil
DSpring IRoller Bearing NRotor SPropel Motor
ECenter Shaft JBrake Disks OServo Piston
The propel motor (S) is a variable-displacement, drive shaft (G). As the angle is changed the motor
bent-axis, axial-piston type motor that includes the displacement changes which changes propel motor
brake valve housing and propel park brake. The speed.
counterbalance valve, crossover relief valves, park
brake release shuttle valve, pressure reducing valve, Supply oil flows through the valve plate (B) to half of
servo piston shuttle valve, and the servo piston (O) are the pistons (M) in the rotor (N). The oil forces the
integral components of the brake valve housing. The pistons to slide down the cylinder block bores
speed selector valve spool is located in the servo transferring the force to the drive shaft (G) turning the
piston. drive shaft. As the cylinder block and drive shaft rotate,
half of the pistons move out of their bores while the
The servo piston (O) controls the angle of rotor (N), remaining pistons in the other half of the cylinder block
pistons (M) and center shaft (E) with respect to the move back in their bores to discharge oil to return.
TX,05,GG2167 1906SEP002/2
9025
05
85

101603
PN=443
Theory of Operation
Propel Motor Slow Speed Operation
VALVE A B ROTARY
PLATE GROUP
D H
SERVO TO MOTOR
PISTON CASE DRAIN
I
G CHAMBER
SPRING A
J
FROM
C LINK MOTOR
PORT
D SERVO
PISTON F K
SPOOL FROM PROPEL
SPEED CHANGE
E SOLENOID
VALVE
ORIFICE
1906MAY98
L
CHAMBER B
M SUPPLY OIL
T102854
T102854 N RETURN OIL
O SLOW SPEED
9025
05
86 AValve Plate EOrifice IChamber A LChamber B
BRotary Group FSpeed Selector Valve Spool JFrom Motor Port MSupply Oil
CLink GSpring KFrom Propel Speed NReturn Oil
DServo Piston HTo Motor Case Drain Change Solenoid Valve OSlow Speed
The servo piston (D) is connected by a link (C) to the For circuit operation, see Propel Motor Speed Change
valve plate (A). When servo piston is extended or Circuit Operation in this group.)
retracted by supply oil pressure the angle of the rotary
group (B) changes and the propel speed changes Supply oil from motor port (J) is now applied to both
accordingly. chamber A (I) and chamber B (L) at the same time.
Supply oil pressure in chamber B acts on a larger
When propel speed is set to slow speed the bottom of area than the supply oil pressure in chamber A
speed selector valve spool (F) is open to return causing the servo piston to move upward increasing
through the propel speed change solenoid valve. The rotary group swash angle. As the swash angle
spool (F) is pushed down by the spring (G). (For increases, the stroke of each piston is increased
operation of propel speed change solenoid valve, see resulting in slower revolution of the propel motor for
Proportional Solenoid Valve Operation in this group. slower propel speed.
TX,05,GG2168 1906SEP001/1

101603
PN=444
Theory of Operation
Propel Motor Fast Speed Operation
A VALVE B ROTARY
PLATE GROUP SERVO
D PISTON TO MOTOR
CASE DRAIN
H
CHAMBER
A
I
G FROM
SPRING J MOTOR
PORT
C LINK
D SERVO F
PISTON SPOOL K
ORIFICE FROM PROPEL
E SPEED CHANGE
SOLENOID
VALVE
1906MAY98
M SUPPLY OIL
L CHAMBER N PILOT OIL
B
T102855
T102855 O RETURN OIL
P FAST SPEED 9025
05
87
AValve Plate FSpeed Selector Valve Spool JFrom Motor Port MSupply Oil
BRotary Group GSpring KFrom Propel Speed NPilot Oil
CLink HTo Motor Case Drain Change Solenoid Valve OReturn Oil
DServo Piston IChamber A LChamber B PFast Speed
EOrifice
In fast speed the pilot oil (N), from the propel speed NOTE: For operation of propel speed change solenoid
change solenoid valve (K), is higher than spring force valve, see Proportional Solenoid Valve
and spool (F) is pushed up. The oil in chamber B is Operation in this group. For circuit operation,
routed to return through motor case drain (H). Supply see Propel Motor Speed Change Circuit
oil (M) from the motor port (J) is applied to chamber Operation in this group.
A, servo piston (D) moves down to reduce rotary
group (B) swash angle. With reduced swash angle the
piston stroke is reduced which increases rotary group
turning speed that increases propel speed.
TX,05,GG2169 1906SEP001/1

101603
PN=445
Theory of Operation
Propel Motor Speed Change Circuit Operation
9025
05
88
1923APR97
T109188

101603
PN=446
Theory of Operation
APropel Speed Switch FRight Propel Motor KPump Pressure Sensors OEngine and Pump
BLeft Propel Valve GDig Pressure Switch LFront Pump Controller
CRear Pump Control HPropel Pressure Switch MRear Pump PPropel Speed Change
Pressure Sensor IRight Propel Valve NPropel Speed Change Circuit
DLeft Propel Motor JFront Pump Control Solenoid Valve
ESpeed Selector Valve Pressure Sensor
Spool
When the propel speed switch (A) is in slow speed, Electrical signal for rear (C) and front (J) pump
the propel speed change solenoid valve (N) coil is control pressure sensors increases because pilot oil
de-energized. The speed selector valve spools (E) are control signals from front and rear pump control
open to return through the solenoid valve. The propel valves are increasing.
motors (D and F) are at maximum displacement Rear and front pump pressure sensors (K) are
causing the machine to travel at slow speed. sensing low pressure.
The propel speed goes to fast with the following When the electrical signals are received at the engine
operating conditions: and pump controller (O), the controller send an
electrical signal to energize the solenoid valve (N) coil.
Propel speed switch is at fast speed (rabbit). The pilot oil pressure signal shift the speed selector
Propel pressure switch (H) in closed (propel function valve spool (E) causing the motor to go to minimum
actuated). displacement and the machine to travel at fast speed.
Dig pressure switch (G) is open (no dig function (See Propel Motor Fast Speed Operation in this
actuated). group.)
TX,05,GG2200 1924APR002/2
9025
05
89

101603
PN=447
Theory of Operation
Propel Motor Park Brake Valve Housing Operation
9025
05
90
1923APR97
T109195
APark Brake Release Shuttle CCrossover Relief Valve ECounterbalance Valve GPropel Motor Park Brake
Valve DCheck Valve FServo Piston Shuttle Valve Valve
BPressure Reducing Valve

101603
PN=448
Theory of Operation
The propel motor park brake valve (G) housing Check valves (D) ensure smooth starts and stops, and
contains the park brake release shuttle valve (A), park prevent motor cavitation by working together with the
brake pressure reducing valve (B), crossover relief counterbalance valve (E).
valve (C), check valves (D), counterbalance valve (E),
servo piston shuttle valve (F) and servo piston. Counterbalance valve (E) is used for smooth starting
and stopping and helps prevent overrunning of the
Park brake release shuttle valve (A) routes supply oil motor when traveling down a slope.
from the pressurized motor port through a groove in
the counterbalance valve (E), to the park brake Servo piston shuttle valve (F) routes supply oil from
pressure reducing valve (B), and then to the park the pressurized motor port to the servo piston. (For
brake piston to release the park brake. operation of servo piston and speed selector valve,
see Propel Motor Slow Speed Operation and Propel
Park brake pressure reducing valve (B) reduces the Motor Fast Speed Operation in this group.)
supply oil pressure routed to the park brake to prevent
sudden brake application.
Crossover relief valves (C) protect the motor circuit

from pressure spikes.
TX,9025,GG2612 1906SEP002/2
9025
05
91

101603
PN=449
Theory of Operation
Propel Motor Park Brake Release Circuit Operation
9025
05
92
1918APR97
T109202

101603
PN=450
Theory of Operation
APark Brake Pressure DPark Brake Pack HPark Brake Release Shuttle JChamber
Reducing Valve EDrive Shaft Valve KPropel Motor Park Brake
BDisk Spring FTo Propel Motor Housing IGroove Release
CBrake Piston GCounterbalance Valve
Propel park brake is spring applied and hydraulically brake pressure reducing valve. The pressure reducing
released type brake. Brake is applied by a disk spring valve operates to reduce the supply oil pressure.
(B) whenever the propel control valve spools are in Reduced pressure oil flows to the brake piston (C) to
neutral. The plates in the brake pack (D) are move it against the disk spring (B) force and releases
connected to the motor housing. The disks are the park brake. Oil not used to release the park brake
connected to and rotate with the drive shaft (E). The flows through the orifice in the reducing valve spool
disk spring pushes against the piston to squeeze the and into the propel motor housing (F).
plates and disks together to keep the machine from
moving. When propel pilot controllers are returned to neutral,
supply oil is blocked by the valve spools and the
When the propel pilot controllers are actuated the propel motor work ports are open to the control valve
propel valve spools route supply oil to the bottom work return passage. The counterbalance valve (G) returns
port of propel motor for forward travel or the top work to its neutral position causing the machine to slow and
port for reverse travel. The supply oil flows into the then stop (dynamic braking). The pressure reducing
chamber (J) at the end of counterbalance valve (G). At valve (A) is shifted by its spring. The disk spring (B)
the same time supply oil moves the park brake release pushing against the brake piston (C) forces the oil to
shuttle valve (H) to route supply oil to the park brake flow through the orifice in the reducing valve and into
pressure reducing valve (A) but is blocked by the the propel motor housing (F). The delay caused by the
counterbalance valve. When supply oil pressure oil flowing through the orifice is enough to slow
increases enough to shift the counterbalance valve, engagement to ensure that park brake is only fully
supply oil flows through the groove (I) to the park applied after the machine has stopped.
9025
05
93
TX,9025,GG2613 1906SEP002/2

101603
PN=451
Theory of Operation
Propel Motor Counterbalance Valve Operation
9025
05
94
1923APR97
T109206

101603
PN=452
Theory of Operation
APark Brake Pressure DPark Brake Pack HPark Brake Release Shuttle JChamber
Reducing Valve EDrive Shaft Valve KPropel Motor Park Brake
BDisk Spring FTo Propel Motor Housing IGroove Release
CBrake Piston GCounterbalance Valve
When the propel valve spools in the main control valve to control valve return passage. Both check valves will
are in neutral position, counterbalance valve (J) is held seat and counterbalance valve will center trapping oil
in the center position by springs (B) on both ends of in the motor to prevent rotation. Oil will also flow back
counterbalance valve. Both propel motor oil lines are through the brake passage to the motor housing and
connected to the control valve return passage. Oil in the park brake will engage after the propel motor stops
each motor is trapped by check valves (C and F) and rotating. At the same time, the shock pressure caused
counterbalance valve (J) holding the motors stationary. by the inertia force of the motor stopping is released
The park brake release circuit is also routed to return through the crossover relief valves (D and E). Check
and the brake spring hold the brake on. valves (C and F) have a make-up function to prevent
cavitation in the motor.
When the propel pilot controller is moved to forward
position, supply oil is routed from the propel valves in When traveling down a hill, the weight of the machine
the control valve to bottom work port (G). If propel pilot may begin to overrun the propel motors. This would
controller is moved to reverse position, supply oil cause faster travel than desired and cause cavitation
would be routed to top work port (A). at the inlet side of motors. As pressure decreases in
the inlet passage of the motor, the pressure holding
In forward direction, supply oil enters bottom work port the counterbalance valve also decreases. Spring (B)
(G), flows around counterbalance valve to check valve force moves the counterbalance valve down thus
(F). Check valve opens and oil flows into the motor. restricting return flow from the motor slowing motor
rotation. This is called dynamic braking.
Return oil from the motor is blocked by check valve
(C) and counterbalance valve (J). This, along with the During normal operation supply oil from the control
motors resistance to turning, causes pressure in valve is routed past the counterbalance valve and 9025
bottom work port (G) to increase. The increasing check valve to the motor. Supply oil is also routed to 05
pressure is also sensed at the end of counterbalance the crossover relief valves (D and E). The crossover 95
valve through orifice (H). As pressure increases, the relief valves are direct acting relief valves with a
spool is pushed upward against the spring force. As cushion sleeve. Supply oil is sensed on the end of
spool moves up, oil from the motor flows past notches poppet of one relief valve. Oil also pushes the sleeve
in the counterbalance valve to the top work port (A) up on the other relief valve to help keep its poppet
and the propel motors start to turn. Supply oil is also closed.
routed to the park brake release circuit (I) to release
the park brake. (For park brake release circuit During relief operation oil pressure overcomes spring
operation, see Propel Motor Park Brake Release force pushing the poppet off its seat. Pressure oil is
Circuit Operation in this group.) relieved from the passage that is pressurized to the
passage that is at return pressure bypassing the
When the propel pilot controller is returned to neutral motor.
position, the oil in both work ports (A and G) is routed
TX,9025,GG2614 1906SEP002/2

101603
PN=453
Theory of Operation
Cylinder Operation
1921APR97
T109208
9025
05
96
ASnap Ring FWear Ring KCap Seal OBarrel
BWiper Seal GSnap Ring LSet Screw PCylinder Rod
CBackup Ring HPiston LNut QRod Guide
DU-Cup Seal IBuffer Ring NCushion RBucket Cylinder
EBuffer Ring JWear Ring
The boom, arm, and bucket cylinders are similar in Boom, bucket and arm cylinders have a cushion (N) in
design. The bucket cylinder (R) is illustrated. The rod front of the piston to provide cushioning action in
guide (Q) is fastened to the cylinder barrel with cap cylinder extension. As the cylinder nears the end of
screws and is fitted with a wear guide (F) held in place stroke the cushion enters a bore in the rod guide. The
by a snap ring (G). A buffer ring (E), U-cup seal (D), remaining return oil ahead of piston must flow through
backup ring (C), and wiper seal (B) are used in the rod a small clearance between the cushion and rod guide.
guide. A snap ring (A) is used to help hold wiper seal Only the arm cylinder is cushioned in retraction. The
in place. The U-cup seal (D) is protected against high end of the rod enters a bore in the head end of the
pressure by the buffer ring (E) and stops the small cylinder. The remaining return oil ahead of the piston
amount of oil which may pass by the buffer ring. and nut must flow through this small clearance as the
cylinder bottoms out in this direction.
The piston (H) is a slip fit on the cylinder rod (P) and is
retained with a nut (M). A set screw (L) prevents
loosening of the nut. The piston is fitted with a cap
seal (K), wear rings (J), and buffer rings (I).
TX,9025,GG2624 1906SEP001/1

101603
PN=454
Theory of Operation
Return Filter Operation
UN11JUL96
T101917
9025
05
97
AFilter Element CBypass Operation EFrom Control Valve FReturn Filter Operation
BBypass Valve DFrom Oil Cooler
The filter element (A) is located in a chamber inside pressure surges in the return circuit and allows a path
the hydraulic oil tank. O-rings are used at each end of for return oil if the filter element becomes plugged.
the filter element to prevent leakage. A spring holds During bypass operation, oil flows into the chamber
the filter element on its seat. faster than it can flow through the filter element
causing the pressure to increase. The higher pressure
Return oil from the oil cooler (D) and the control valve forces the bypass valve open allowing oil to flow down
(E) flow through the filter element from the outside to the center of the filter element and into the hydraulic
the center. Filtered oil flows out the bottom of filter into oil tank. The bypass valve closes when the pressure
the hydraulic oil tank. decreases below the pressure setting of the bypass
valve.
A bypass valve (B) is located at the top of the filter.
The valve opens to protects the filter element against
TX,05,GG2147 1924APR001/1

101603
PN=455
Theory of Operation
Hydraulic System Circuit Symbols
9025
05
98
1928SEP89
TS700
TX,15,GG2166 1905AUG961/1

101603
PN=456
Theory of Operation
Pilot Controllers Circuit Schematic

T109209 1913MAY97
BUCKET SWING LEFT 5

3 SWING RIGHT 6 NOTE: Numbers 1 thru 12 are used on the schematic
CURL
BUCKET CURL only to show the connections for pilot lines from
7 flow regulator to left and right control valve pilot caps.
BUCKET DUMP 8 Numbers not used on the machine
DUMP FLOW
1 REGULATOR
4
UP
BOOM UP 1
T TO
HYDRAULIC
P BOOM UP OIL TANK
DOWN PRESSURE
SWITCH TO RIGHT PILOT PRESSURE
BOOM CONTROL VALVE REGULATING VALVE
2
RIGHT PILOT FROM
CONTROLLER HYDRAULIC
PILOT
SWING BOOM DOWN FILTER OIL TANK
3 2
LEFT PILOT FILTER PILOT PUMP
TO REAR PUMP BYPASS VALVE
CONTROL VALVE
IN LEFT CONTROL
ARM OUT VALVE
RIGHT 3
1
TO FRONT PUMP
4 CONTROL VALVE TO SWING
IN PARK BRAKE
ARM IN IN RIGHT CONTROL TO FRONT
T VALVE RELEASE AND REAR PUMP
PRESSURE VALVE
SENSOR REGULATORS
PROPEL
P POWER SPEED SPEED ARM
OUT ARM IN 4 BOOST CHANGE SENSING REGENERATIVE
SOLENOID SOLENOID SOLENOID SOLENOID
ARM VALVE VALVE VALVE VALVE
2
LEFT PILOT
CONTROLLER
PROPEL RIGHT REVERSE SG SI SD SC
12
3 PROPEL RIGHT FORWARD 11
RIGHT PROPEL LEFT REVERSE
REVERSE 10
PROPEL LEFT FORWARD 9
T6 SOLENOID
VALVE
RIGHT T4 MANIFOLD
FORWARD 4
T5
2 PILOT OIL
LEFT
REVERSE P3 PILOT
T SHUT-OFF RETURN OR
VALVE TO PRESSURE
P1 HYDRAULIC FREE OIL
P OIL TANK
LEFT P2
FORWARD FROM BUCKET FROM PROPEL
FLOW CONTROL FLOW CONTROL
1 VALVE IN RIGHT VALVE IN LEFT
T109209 PROPEL PILOT CONTROL VALVE CONTROL VALVE
CONTROLLER PILOT CIRCUIT FOR PILOT CONTROLLERS SCHEMATIC
TX,9025,GG2615 1919APR971/1

101603
PN=457
Theory of Operation
Hydraulic Pump and Control Valve Schematic

T115417 1923OCT98
OIL COOLER HYDRAULIC

BYPASS VALVE OIL TANK
SUPPLY OIL
PILOT OIL 11 TO 8 1 3
RIGHT TO FRONT PUMP
TRAPPED OIL PROPEL 3A RIGHT CONTROL
RETURN OR BUCKET CYLINDER MOTOR CONTROL PRESSURE SENSOR
BUCKET VALVE
PRESSURE FLOW REAR PUMP
FREE OIL BOOM
CONTROL REDUCED CONTROL
VALVE LEAKAGE PRESSURE SENSOR
TO VALVE FRONT
SWING PUMP
MOTOR CONTROL PILOT
MAKE-UP VALVE PUMP PUMP
PORT REGULATOR
PROPEL RIGHT BUCKET BOOM I ARM II
PRESSURE PROPEL
SWITCH LEFT
CONTROL
FROM VALVE
PILOT FLOW
BOOM CYLINDERS PRESSURE COMBINER
REGULATING VALVE
VALVE SEVRO
PRESSURE FRONT PISTON
DIG PUMP
PRESSURE SENSOR
12 7 PROPEL-BOOM 4
SWITCH DOWN SELECTOR 2
TO SWING VALVE 6
10
PARK BRAKE SYSTEM
RELEASE RELIEF
VALVE VALVE
FLOW
CONTROL
VALVE SEVRO
TO SWING REAR REAR
PARK BRAKE PUMP PISTON
PUMP
RELEASE PROPEL CONTROL
VALVE SPEED ARM CYLINDER VALVE N
POWER PUMP
CHANGE ARM LEFT AUXILIARY BOOM II ARM I SWING SENSOR REGULATOR
BOOST SOLENOID SPEED PROPEL
SOLENOID REGENERATIVE
VALVE SENSING SOLENOID
VALVE SOLENOID VALVE
VALVE
ARM
SG SI SD SC REDUCED
LEAKAGE
VALVE TO
FROM TO SWING
PILOT LEFT ARM MOTOR
SHUT- PROPEL REGENERATIVE
OFF MOTOR 9 3A VALVE 5
VALVE
RESTRICTION
OIL VALVE
SOLENOID VALVE COOLER
MANIFOLD
T115417
HYDRAULIC PUMP AND CONTROL VALVE SCHEMATIC
CED,OUOE035,134 1920MAY981/1

101603
PN=458
Theory of Operation
Swing and Propel Motor Schematic

T115418 1929MAY98
RIGHT PROPEL MOTOR

FROM TO BOOM
FRONT PUMP TO BUCKET CYLINDERS CYLINDERS
SUPPLY OIL
ROTARY 11 8 1A 3 RIGHT PILOT OIL
MANIFOLD TO CONTROL
3A OIL COOLER TRAPPED OIL
VALVE BYPASS VALVE
BUCKET RETURN OR
FLOW PRESSURE
CONTROL BOOM FRONT FREE OIL
VALVE REDUCED PUMP
LEAKAGE CONTROL
VALVE VALVE TO
FRONT PUMP
REGULATORS
RIGHT BUCKET BOOM I

PROPEL PROPEL
PRESSURE ARM II LEFT
SWITCH CONTROL
VALVE
FROM FROM
PILOT REAR
PRESSURE PUMP
REGULATING 7
LEFT PROPEL MOTOR VALVE 12 4
DIG FLOW PROPEL-
PRESSURE COMBINER BOOM DOWN 6
10 2 SELECTOR VALVE
SWITCH SYSTEM VALVE TO FRONT
RELIEF AND REAR
VALVE PUMP
PROPEL REGULATORS
FLOW
CONTROL PROPEL
MAKE-UP REAR VALVE ARM
PUMP SPEED REGENER-
VALVES CHANGE
CONTROL ATIVE
VALVE
LEFT AUX- BOOM II ARM I SWING
SWING PROPEL ILIARY
PARK POWER SPEED
BRAKE BOOST SENSING
CROSSOVER
RELIEF SG SI SD SC
VALVES
ARM
REDUCED
LEAKAGE
VALVE
SWING
PARK TO ARM
BRAKE TO OIL
REAR PUMP REGENER- COOLER
RELEASE REGULATOR 9 ATIVE VALVE
VALVE 3A 5
SWING MOTOR
TO ARM FROM
CYLINDER PILOT
SHUT-OFF
VALVE SOLENOID VALVE
MANIFOLD
T115418 SWING AND PROPEL MOTOR CIRCUIT SCHEMATIC
CED,OUOE035,135 1920MAY981/1

101603
PN=459
Theory of Operation
9025
05
,102

101603
PN=460
Group 15
Diagnostic Procedure
Follow the six basic steps below to carry out Check all systems and functions on the machine.
troubleshooting efficiently. Use the helpful diagnostic information in the
checkout to pinpoint the possible cause of the
1. Know the system. problem.
Study the machine technical manual. Understand 5. Preform troubleshooting.

the system and circuits. Use schematics,
component location drawings, and theory of Connect the laptop computer with excavator
operation for each circuit and circuit components to diagnostic software, if available. The self-diagnosing
better understand how the system, circuits and function lists any fault codes and gives corrective
components work. action information.
2. Ask the operator. Before starting any troubleshooting first check

battery voltage, fusible link, and fuses.
What type of work was the machine doing when the
trouble was noticed? Go to test groups to check pressures and voltages.
Make sure adjustment are correct.
Did the trouble start suddenly or has it been getting
worse? 6. Trace a cause.
Did the machine have any previous problems? If Before reaching a conclusion, check the most
so, which parts were repaired? probable and simplest to verify. Use the flow charts
and symptom, problem, solution charts to help
3. Inspect the machine. identify probable problem components.
9025
Check all daily maintenance points. (See the Make a plan for appropriate repair to avoid other 15
operators manual.) Check batteries, fuses, fusible malfunctions. 1
link, and electrical connections.
4. Perform Operational Checkout.
TX,15,GG2234 1925APR971/1

101603
PN=461
Diagnose Electronic and Control Valve

Component Malfunctions
Part Name Engine Control Motor (EC Motor) Engine Control Sensor (EC Engine rpm Dial
Sensor)
Operational Function Move fuel injection pump lever. Senses position of EC motor Signal to EC motor to set target
engine speed.
Control Problem Fuel injection pump lever does not Loss of EC motor position sensing. Speed does not change when
move dial is turned.
Machine Symptoms Turning engine rpm dial does not Engine speeds slower than speed Speed is held at 1600 rpm.
increase or decrease speed. selected by engine rpm dial and E (Auto-idle function operates and
mode switch. Cannot control speed. engine stops by turning key
switch off.)
Laptop Computer with 01 Fault code is displayed 07 Fault code is displayed.
Excavator Diagnostic
Program Self-Diagnostic
Functions
Laptop Computer with Monitor No. 2, EC angle. Typical Monitor No. 13, Target Engine
Excavator Diagnostic voltage for slow idle is 2.3 volts. Speed.
Program Monitoring
Function
Harness Check Install JT07065 Test Harness. Check Install JT07066 Test Harness.
for control signal. Check for control signal.
Note Engine stopped by fuel shut-off If EC sensor has failed, engine
solenoid. If solenoid fails, engine learning control does not work.
turns over but does not start.
Description of Operation See Engine Speed Control System See Engine Speed Learning Control See Engine RPM Dial Speed
Operation in Group 9010-05. Circuit Operation in Group 9010-05. Control Circuit Operation in
9025 Group 9010-05.
15
2

101603
PN=462
Part Name Pump Control Pressure Sensor Pump Pressure Sensor Engine Speed Sensor (N
Sensor)
Operational Function Senses pump control valve pressure Senses front and rear pump Senses actual engine speed for
in control valve to control propel delivery pressure. the speed sensing system.
motor speed change
Control Problems No sensor output signal. No control Loss of propel speed control and Speed sensing system does not
signal to propel speed change HP (high power) mode. function.
solenoid valve.
Machine Symptoms Propel motor operates at slow speed Propel speed does not increase Does not affect machine
when propel speed switch is turned when propel speed switch in fast operation except speed sensing.
to fast speed. speed (rabbit). HP mode does not
work.
Laptop Computer with 04 and 05 Fault codes are displayed. 02 and 03 Fault codes are
Excavator Diagnostic displayed.
Functions
Laptop Computer with Monitor No. 1 and 6, Front and rear Monitor No. 14, Actual engine
Excavator Diagnostic pump control pressure. speed.
Program Monitoring
Function
Harness Check
Notes At slow idle with functions in neutral During combined operation, arm
typical pressure is 17251930 kPa speed is slow if malfunction is at
(1719 bar) (250280 psi). A lower sensor for rear pump.
pressure may be an open circuit. A
higher pressure may be a short
circuit.
Description of Operation See Propel Motor Speed Change See Propel Motor Speed Change
Circuit Operation in Group 9025-05. Circuit Operation in Group 9025-05
or HP (High Power) Mode Speed 9025
Control Circuit Operation in Group 15
9010-05. 3

101603
PN=463
Part Name Power Boost Solenoid Valve (SG) Speed Sensing Solenoid Valve Arm Regenerative Solenoid
(SD) Valve (SC)
Operational Function Sends a pilot pressure signal to Sends a pilot pressure signal to Sends a pilot pressure signal to
temporary increase system relief load piston in pump regulators to shift the arm regenerative valve.
valve pressure setting. reduce pump flow.
Control Problems No pressure signal sent to system No pressure signal sent to load No pressure signal sent to shift
relief valve. System relief valve piston in pump regulators. arm regenerative valve.
pressure setting does not increase.
Machine Symptoms Digging or lifting force does not Torque required to drive pumps During arm in operation, there is
increase. exceed engine output power. arm cylinder cavitation and
Engine speed can decrease below controllability becomes less.
rated speed.
Laptop Computer with
Functions
Laptop Computer with Monitor No. 12, Power boost control Monitor No. 11, Speed sense Monitor No. 9, Arm regenerative
Excavator Diagnostic pressure. control pressure. control pressure.
Program Monitoring
Function
Harness Check Install JT07352 Test Harness. Install JT07352 Test Harness. Install JT07352 Test Harness.
Check that indicator light is on. Check that indicator light is on. Check that indicator light is on.
Notes If indicator light is off, check wiring If indicator light is off, check wiring If indicator light is off, check
harness. harness. wiring harness.
Description of Operation See Power Boost Control Circuit See Engine Speed Sensing Control See Arm Regenerative Valve
Operation in Group 9025-25. Circuit Operation in Group 9025-25 Operation in Group 9025-05.
9025
15
4

101603
PN=464
Part Name Propel Speed Change Solenoid Propel Pressure Switch Dig Pressure Switch
Valve (SI)
Operational Function Sends a pilot pressure signal to shift Senses when propel function is Senses when a dig function is
speed selector valve spool in propel actuated. actuated.
motors.
Control Problems No pressure signal sent to shift No electrical signal sent to engine No electrical signal sent to
speed selector valve spool. and pump controller. engine and pump controller.
Machine Symptoms Travel speed does not increase Engine speed does not increase Engine speed does not increase
when propel speed switch is turned from auto-idle speed when propel from auto-idle speed when a dig
to fast speed (rabbit). function actuated. Propel speed does function actuated.
not increases with propel speed
switch in fast speed (rabbit). Travel
alarm does not sound.
Functions
Laptop Computer with Monitor No. 10, Propel motor control Monitor No. 20, Pressure switch. Monitor No. 20, Pressure switch.
Excavator Diagnostic pressure.
Program Monitoring
Function
Harness Check Install JT07352 Test Harness.
Check that indicator light in on.
Notes If indicator light is off, check wiring Located at the front of right control Located at the front of left control
harness. Also check switches and valve. valve.
sensors in propel motor speed
change circuit.
Description of Operation See Propel Motor Speed Change See Propel Motor Speed Change See Auto-Idle Mode Speed
Circuit Operation in Group 9025-05. Circuit Operation in Group 9025-05 Control Circuit Operation in
or Auto-Idle Mode Speed Control Group 9010-05. 9025
Circuit Operation in Group 9010-05. 15
5

101603
PN=465
Part Name Boom Up Pressure Switch Arm In Pressure Sensor Learning Switch
Operational Function Senses boom up pilot pressure Senses arm in pilot pressure To start engine speed learning function.
signal. signal.
Control Problems No electrical signal sent to engine No electrical signal sent to Engine speed learning function does
and pump controller. engine and pump controller. not operate.
Machine Symptoms No regenerative function during HP (high power) mode does For an open circuit, engine speed
boom up and arm in. not function. Arm speed slow control system operates normally.
when leveling. Engine speed learning control cannot
be actuated. For a short circuit, learning
control is actuated when key switch is
turned ON.
Software Self-Diagnostic
Functions
Laptop Computer with Monitor No. 20, Pressure switch. Monitor No. 20, Pressure Monitor No. 28, Engine learning control.
Excavator Diagnostic switch.
Software Monitoring
Function
Harness Check
Notes Switch needed for arm Sensor needed for HP mode
regenerative operation. and arm regenerative
operation.
Description of Operation See Arm Regenerative Valve See Arm Regenerative Valve See Engine Speed Learning Control
Operation in Group 9025-05. Operation in Group 9025-05 Circuit Operation in Group 9010-05.
and HP (High Power) Mode
Speed Operation in Group
9010-05.
9025
15
6

101603
PN=466
Part Name Power Boost Switch HP (High Power) Mode Switch E (Economy) Mode Switch
Operational Function To actuate the power boost To actuate the HP mode function. To actuate the E mode function
function.
Control Problems For open circuit, no electrical No electrical signal to engine and For open circuit, no electrical
signal to engine and pump pump controller. For short circuit, signal to engine and pump
controller. For short circuit, electrical signal to engine and controller. For short circuit,
operates for 8 seconds when key pump controller at all times. electrical signal to engine and
switch turned on, but then pump controller at all times.
becomes inoperative.
Machine Symptoms Digging or lifting force does not For open circuit, engine speed For open circuit, engine speed
increase. does not increase when hydraulic does not decrease from fast idle.
pressure increases to specified For short circuit, engine speed
pressure. For short circuit, engine does not increase to fast idle.
speed increases even with switch
off (up).
Functions
Laptop Computer with Monitor No. 25, Power boost Monitor No. 24, HP mode switch. Monitor No. 22, E mode switch.
Excavator Diagnostic switch
Program Monitoring
Function
Harness Check
Notes Power boost function operates for HP indicator light on when switch E indicator light on when switch is
8 seconds after switch is pushed is on (down). on (down).
and held.
Description of Operation See Power Boost Control Circuit See HP (High Power) Mode Speed See E (Economy) Mode Speed
Operation in Group 9025-25. Circuit Operation in Group Control Circuit Operation in Group
9025-05. 9010-05. 9025
15
7

101603
PN=467
Part Name Propel Speed Switch Engine and Pump Controller Front and Rear Pump Control
(EPC) Valve
Operational Function To change propel speed. To control engine speed, pump and To send a regulated pilot pressure
valve operations. signal to pump regulators in
responds to the flow rate through
neutral passages in control valve.
Control Problems No electrical signal sent to Problems may differ depending on Pressure signal to regulator does
engine and pump controller. the malfunction. not increase when a function is
actuated. Pump stays at minimum
flow.
Machine Symptoms For open circuit, propel speed Problems listed indicate malfunction For rear pump control valve: left
stays at slow speed when in EPC. With key switch on, EC propel cycle time slow, swing also
switch is turned to fast speed motor does not go to start position; slow; cycle time for bucket, boom or
(rabbit). engine starts and run at slow idle. arm almost normal. For front pump
Engine speed does not change. control valve: bucket cycle time very
Pump stays at minimum, all slow, boom not raised when
functions are slow. leveling, right propel cycle time
slow; cycle time for boom, arm, or
swing almost normal.
Functions
Laptop Computer with Monitor No. 26, Propel speed Monitor No. 1, Front pump control
Excavator Diagnostic switch. pressure and No. 6, Rear pump
Program Monitoring Function control pressure.
Harness Check
Notes Check switches and sensors Check fuses before replacing EPC.
in propel speed control circuit.
9025 Description of Operation See Propel Motor Speed See Engine and Pump Controller See Pump Control Valve Operation
15 Change Circuit Operation in Circuit Theory of Operation in Group in Group 9025-05.
8 Group 9025-05. 9015-15.

101603
PN=468
Part Name Flow Combiner Valve Arm I Power Passage Check Arm I Neutral Passage Check
Valve and Restriction Orifice Valve and Restriction Orifice
Operational Function To supply oil to left and right propel
spools during combined operation of
dig and propel functions.
Control Problems Sticking or stuck spool. Oil is Oil from left control valve power Oil from right control valve
insufficient or not supplied to left passage insufficient or not supplied neutral passage insufficient or
propel spool. to arm I spool. not supplied to arm I spool.
Machine Symptoms While traveling straight, machine Arm speed slow when leveling. When check valve is stuck
mistracks when swing is actuated. closed or orifice clogged, arm
speed is slow when leveling
Functions
Program Monitoring
Function
Harness Check
Notes
Description of Operation See Flow Combiner Valve Operation See Control Valve Circuit See Control Valve Circuit
in Group 9025-05. Schematic in Group 9025-05. Schematic in Group 9025-05.
9025
15
9

101603
PN=469
Part Name Arm Regenerative Valve Propel Flow Control Valve Propel-Boom Down Selector
Valve
Operational Function To route oil from rod end to head end To reduce shock load created by To ensure boom down force
of cylinder during arm in when shifted going from propel operation to during combined operation of
by arm regenerative solenoid valve. combined operation of propel propel and boom down.
and dig by gradually restricting
oil flow from power passage.
Control Problems No pressure signal from arm Oil flow not restricted because Boom II spool not shifted during
regenerative solenoid valve to shift arm spool is stuck or no pressure combined operation of propel
regenerative valve spool. Valve spool is signal to shift propel flow control and boom down. Boom II spool
sticking or stuck. valve spool. is shifted during just boom down
operation.
Machine Symptoms During arm in, there is arm cylinder When stuck closed, shocks felt When stuck closed: boom down
cavitation and controllability becomes when changing from propel to speed is fast, swing speed slow
less. combined propel and dig at full stroke during combined
operation. When stuck open, no swing and boom down operation.
boom up when combined with
propel down a slope or with
bucket loading.
Functions
Program Monitoring
Function
Harness Check
Notes
9025 Description of Operation See Arm Regenerative Valve Operation See Propel Flow Control Valve See Propel-Boom Down Selector
15 in Group 9025-05. Operation in Group 9025-05. Valve Operation in Group
10 9025-05.

101603
PN=470
Part Name Arm Reduced Leakage Valve Boom Reduced Leakage Valve Boom Regenerative Valve
Operational Function To prevent arm in drift caused by To prevent boom down drift To route return oil from head end
leakage from the cylinder back caused by leakage from the to rod end of boom cylinder to
through control valve. cylinders back through control prevent cavitation when lowering.
valve.
Control Problems Sticking or stuck check valve or pilot Sticking or stuck check valve or Sticking or stuck check valve.
valve. No pilot pressure signal to shift pilot valve. No pilot pressure signal
pilot spool. to shift pilot spool.
Machine Symptoms Arm drifts down. Arm in speed is Boom drifts down. Boom down Boom lower speed becomes
slow or jerky if check valve sticking or speed is slow or jerky if check slow with check valve stuck
does not open. valve sticking or does not open. closed. Cannot raise tracks off
the ground using boom down
with check valve stuck open.
Functions
Program Monitoring
Function
Harness Check
Notes
Description of Operation See Boom and Arm Reduced See Boom and Arm Reduced See Boom Regenerative Valve
Leakage Valve Operation in Group Leakage Valve Operation in Group Operation in Group 9025-05.
9025-05. 9025-05.
9025
15
11

101603
PN=471
Part Name Bucket Flow Control Valve

Operational Function To restrict oil flow to bucket circuit in
combined operation of bucket, arm
in, and boom up to ensure oil flows
to higher-loaded boom function to
raise boom.
Control Problems Pilot valves and poppet valve sticking
or stuck.
Machine Symptoms Bucket speed is slow if poppet valve
is stuck closed. Boom is not raised in
combined operation with poppet
valve stuck open or pilot valves are
stuck open keeping the poppet valve
open.
Functions
Program Monitoring
Function
Harness Check
Notes
Description of Operation See Bucket Flow Control Valve
Operation in Group 9025-05.
9025
15
12
TX,15,GG2238 1904OCT0011/11

101603
PN=472
Diagnose Hydraulic System Malfunctions

All Hydraulic Functions Slow Low oil level Check oil level in hydraulic oil tank.
Cold hydraulic oil Heat hydraulic oil.
Oil viscosity too heavy Use the recommended oil (see

General Information Section).
Slow engine speed Check engine fast and slow idle stop
adjustment at injection pump. Do
Adjustment and Engine Speed
Learning Procedure. See Group
9010-20.
Air leak in pump suction line Check for air bubbles in oil. Tighten
clamps, replace O-rings.
Pilot circuit malfunction See Diagnose Pilot Circuit

Malfunctions. See Group 9025-15.
9025
15
Restricted pump suction screen Clean pump suction screen. See 13
Group 3360.
Front and rear pump regulators Adjust pump regulators. See Group
9025-25.
Worn pumps Check flow rate using propel cycle

times. Do hydraulic pump flow test.
See Group 9025-25.
System relief valve setting too low or Check system relief valve setting.
malfunctioning See Group 9025-25. Inspect. See
Group 3360.
Front and rear pump control valves Check circuit relief valve setting. See
Group 9025-25. Inspect. See Group
Circuit relief valve setting too low or 3360.
malfunctioning
Continued on next page TX,15,GG2162 1913AUG981/3

101603
PN=473
Low pilot oil pressure Check pilot pressure regulating

valve. See Group 9025-25.
Check pressure. See Group

9025-25. Inspect. See Group 3360.
Hydraulic Oil Overheats Low oil level Check oil level in hydraulic oil tank.
Plugged oil cooler Test air flow through oil cooler.
Oil viscosity too light Use recommended oil. See General

Information Section.
Return filter plugged Replace filter. See Group 3360.
System relief valve malfunction Test system relief valve. See Group
9025-25.
Oil cooler bypass valve stuck open Repair or replace. See Group 3360.
Restriction valve stuck closed Repair or replace. See Group 3360.
Fan belt slipping Check for worn belt. Check tension

adjuster. See Remove and Install
Fan Belt in Group 0510.
9025
15
14 Pump stuck at maximum Check flow rate using propel cycle
displacement times. Do hydraulic pump flow test.
See Group 9025-25.
No Hydraulic Functions Pilot shut-off lever in LOCK position Push shut-off lever to UNLOCK
(rearward) position (forward).
No oil Check oil level in hydraulic oil tank.
Pump drive failure Check pump drive coupling. See

Group 3360.
Restricted pump suction screen Clean pump suction screen. See

Group 3360.
Poor Combined Operation Dig or propel pressure switch Check pressure switches. Check
wiring harness. See Group 9015-15.

See Group 9015-15.

101603
PN=474
Pilot controller Check pilot pressure at control valve.

See Group 9025-25.
Pilot pressure regulating valve Check pilot pressure regulating valve

pressure setting. See Group
9025-25.
Check valves and flow control valves Inspect valves. See Group 3360.
in control valve
TX,15,GG2162 1913AUG983/3
9025
15
15

101603
PN=475
Diagnose Pilot Circuit Malfunctions

All Functions Cannot Be Pilot shut-off lever in LOCK position Push shut-off lever to UNLOCK
Operated (rearward) position (forward).
Pilot pressure regulating valve stuck Test pilot pressure regulating valve.
open See Group 9025-25.Inspect. See
Group 3360.
Pilot pump failure Remove and inspect pilot pump. See

Group 3360.
Function Does Not Stop When Control valve spool stuck Manually move spool to check for
Control Lever Released sticking. See Group 3360.
Pilot controller Check for sticking spool. See Group

3360.
Some Functions Cannot Be Pilot cap Inspect for leakage at pilot cap. See
Operated, All Others Are Normal Group 3360.
9025
15 Pilot controller or hoses to function Check pilot controller hoses or pilot
16 that cannot be operated controller. See Group 3360.
Flow regulator valve Check for stuck spools or check

valves. See Group 3360.
Control valve spool stuck. Manually move spool to check for

sticking. See Group 3360.
All Functions Slow Pilot filter plugged Replace pilot filter.
Low pilot system pressure Check pilot pressure regulating valve

pressure setting. See Group
9025-25.
Restriction in pilot shut-off valve Check pilot shut-off lever position.

See Group 9025-20.
Function Moves in Opposite Pilot control hoses connected Check installation of pilot control
Direction backwards hoses. See Group 9025-15.
TX,15,GG2163 1913AUG981/1

101603
PN=476
Diagnose Dig Circuit Malfunctions

All Dig Functions Slow or No Hydraulic system malfunction See Diagnose Hydraulic System
Power Malfunctions. See Group 9025-15.
Pilot circuit malfunction See Diagnose Pilot Circuit

Malfunctions. See Group 9025-15.
Front or rear pump regulator Do Hydraulic Pump Regulator

Adjustments. See Group 9025-25.
System relief valve Test system relief valve. See Group

9025-25.
Front or rear pump control valve Check pressure. See Group

Hydraulic pumps Check pumps using cycle time. Do

Hydraulic Pump Flow Test. See
Group 9025-25.
9025
Some Dig Functions Slow (Not Pilot circuit malfunction See Diagnose Pilot Circuit 15
All) Malfunctions. See Group 9025-15. 17
Control valve leakage Check dig functions for drift. See

Group 9025-25.
Cylinder leakage Test cylinder for leakage. See Group

9025-25.
Circuit relief valve Test circuit relief valves. See Group

9025-25.
Valve spool sticking Manually move spool to check for

Front and rear pump control valves Check pressure. See Group
Load Drifts Down When Control Cylinder leakage Test cylinder for leakage. See Group
Valve Is In Neutral Position 9025-25.

101603
PN=477
Circuit relief valve Test circuit relief valves. See Group

9025-25.
Reduced leakage valve for boom Inspect reduced leakage valve. See
down and arm in Group 3360.
Boom manual lower screw loose Tighten screw to specification. See

Group 9025-25.
Control valve leakage Inspect control valve. See Group

3360.
Load Falls When Control Valve Is Lift check valve leakage Inspect lift check valve in control
Actuated To Raise Load With valve. See Group 3360.
Engine Running At Slow Idle
Function Moves in Opposite Pilot control hoses connected Check installation of pilot control
Direction backwards hoses. See Group 9025-15.
TX,15,GG2164 1913AUG982/2
9025
15
18

101603
PN=478
Diagnose Swing Circuit Malfunctions

Swing Speed Slow In Both Low pilot system pressure All other functions are slow. See
Directions Diagnose Pilot Circuit Malfunctions.
See Group 9025-15.
Crossover relief valve Test crossover relief valve pressure.

See Group 9025-25.
Swing valve leakage Inspect swing valve. See Group

3360.
Swing motor leakage Test swing motor for leakage. See

Group 9025-25.
Swing park brake Check pilot pressure to swing brake

release valve. See Group 9025-25.
Worn rear pump Check left track cycle time. It will be

slow if rear pump is worn. See
Group 9025-25.
9025
15
Swing Speed Slow or Does Not Pilot circuit malfunction See Diagnose Pilot Circuit 19
Operate In One Direction Malfunctions. See Group 9025-15.
Swing make-up valve leakage Inspect make-up valves. See Group

3360.
Swing crossover relief valve Test swing crossover relief valves.

malfunction See Group 9025-25.
Upperstructure Drift With Swing Swing park brake Inspect swing park brake. See
Valve In Neutral Group 4360.
Swing crossover relief valve leakage Test swing crossover relief valves.
See Group 9025-25.
Swing make-up check valve leakage Inspect make-up valves. See Group
4360.
Swing motor leakage Test swing motor for leakage. See

Group 9025-25.

101603
PN=479
Swing Function Does Not Pilot circuit malfunction See Diagnose Pilot Circuit
Operate Malfunctions. See Group 9025-15.
Swing brake release valve Inspect swing brake release valve.

malfunction See Group 4360.
Swing valve spool stuck Manually move spool to check for

Mechanical failure of swing motor or Disassemble components to

gearbox determine cause of failure. See
Groups 4350 and 4360.
TX,15,GG2165 1913AUG982/2
Diagnose Propel System Malfunctions

Propel Park Brakes Do Not Apply Pressure reducing valve stuck, oil Remove valve and clean or replace.
9025 not released from piston cavity See Group 0260.
15
20
Propel park brake Remove and repair brake. See
Group 0260.
Track Will Not Move In One Pilot Circuit malfunction See Diagnose Pilot Circuit
Direction Malfunctions. See Group 9025-15.
Propel crossover relief valve Do Crossover Relief Valve Test and

Adjustment. See Group 9025-25.
Propel control valve spool stuck Manually move spool to check for
Counterbalance valve spool stuck Inspect counterbalance valve. See

Group 0260.
Shuttle valve in brake valve Inspect shuttle valve. See Group

assembly not seating 0260.
Rotary manifold leakage Inspect rotary manifold. See Group

0260.

101603
PN=480
Track Will Not Move In Either Pilot Circuit Malfunction See Diagnose Pilot Circuit
Direction Malfunctions. See Group 9025-15.
Crossover relief valve Do Crossover Relief Valve Test and

Propel pilot controller Inspect propel pilot controller. See

Group 3360.
Propel valve spool Manually move spool to check for

Counterbalance valve spools stuck Inspect counterbalance valve. See

Group 0260.
Mechanical failure of propel motor or Disassemble components to

gearbox determine cause of failure. See
Group 0250 and 0260.

0260.

9025
15
21

101603
PN=481
Excavator Mistracks at All Track sag adjustment Adjust track sag. See Group
Speeds In Both Directions 9020-20.
Propel pilot controller malfunction Inspect propel pilot controller. See

Group 3360.
Propel motor crossover relief valve Do Crossover Relief Valve Test and
malfunction Adjustment. See 9025-25.
Brake valve shuttle valve or servo Inspect check valve and seat. See
piston shuttle valve seat leakage. Group 0260.
Leakage in motor Check tracking while descending a

hill. If tracking is within specification
when descending a hill, but not
when on the level or going up hill,
motor leakage is indicated. Do
Propel Motor Leakage Test. See
Group 9025-25.

0260.
Front and rear pump regulators Do pump regulators adjustment. See

Group 9025-25.
9025
15
22

101603
PN=482
Slow Propel Speed Or Low Track sag adjustment Adjust track sag. See Adjust Track
Power Sag in Group 9020-20.
Propel motor crossover relief valve Do Crossover Relief Valve Test and
Propel brake not releasing Inspect propel brake. See Group

0260.
Propel motor Do Propel Motor Operating Leakage

Test. See Group 9025-25.

0260.
Low pump flow Check propel cycle times. Do

Hydraulic Pump Flow Test. See
Group 9025-25.
Engine performance low Test engine performance. See

Group 9010-25.
Combined Propel and Dig Flow combiner valve Check for sticking or stuck valve
Functions Slow or No Power spool. See Group 3360.
9025
Propel-boom down selector valve Check for sticking or stuck valve 15
spool. See Group 3360. 23
Propel Is Jerky Track sag too tight or too loose Adjust track sag. See Adjust Track
Sag in Group 9020-20.
No oil or low oil level in rollers Fill with correct oil. See General
Information Section.
Brake valve shuttle valve or servo Inspect shuttle valve seat. See
piston shuttle valve seat leakage. Group 0260.
Propel park brake leakage Inspect propel park brake piston.

See Group 0260.
Mechanical failure in propel motor or Inspect motor and gearbox. See

gearbox Groups 0250 and 0260.
Deformed track frame See Undercarriage Appraisal Manual

SP326. Repair or replace
components.

101603
PN=483
Excavator Will Not Hold Back Propel pilot controller counterbalance Inspect counterbalance valve spool.
and Park Brakes Engage and valve spool stuck See Group 0260.
Disengage When Traveling Down
An Incline
Excavator Will Not Turn Propel pilot controller counterbalance Inspect counterbalance valve spool.
Smoothly In One Direction Or valve spool stuck See Group 0260.
Park Brake Grabs
TX,15,GG2235 1918SEP005/5
Control Lever Pattern Conversion
To change your machine pilot control levers from the

standard pattern to a John Deere pattern:
1. Lower bucket to the ground.
2. Turn auto-idle switch off. Run engine with engine rpm

dial at 1/3 position without load for 2 minutes.
3. Turn engine rpm dial to slow idle position.
9025 Turn key switch to OFF to stop engine. Remove key

15 from switch.
24
4. Pull pilot control shut-off lever to LOCK position.
CAUTION: High pressure release of oil from

pressurized system can cause serious burns or
penetrating injury. The hydraulic tank is
pressurized. Do not remove vent plug. Release
air pressure by loosening vent plug.
5. Release air pressure from hydraulic oil tank by loosing

vent plug.
6. Open door on storage compartment behind cab.

101603
PN=484
NOTE: Do not use manufacturers identification tags or

markings on line ends to identify lines for this
conversion procedure. The conversion must be 1
done on the side of flow regulator valve that is
connected to the pilot controllers. 2
Letters for the flow regulator valve ports are

stamped on the housing next to the ports.
7. Switch hoses (14) on the pilot controller side of the G

flow regulator valve for standard (SAE) or John Deere
pattern as shown. Hoses are switched in an X pattern.
UN28APR00
CAUTION: Prevent injury from unexpected
control lever function. Install new decals on F
control consoles.
4 3
T128763
8. Install new decals (black on yellow) on control T128763
consoles near the base of control levers. Decals are
enclosed in Operators Manual package. Additional SAE Pattern
decals are available through parts.
1Hose F from Right Pilot Controller Port 4

2Hose B from Left Pilot Controller Port 2 3
3Hose A from Left Pilot Controller Port 4
4
4Hose E from Right Pilot Controller Port 2
9025
15
25
UN28APR00
F
2 1
T128778
T128778
John Deere Pattern
TX,9025,GG2511 1904APR002/2

101603
PN=485
Control Valve Line IdentificationLeft Front
9025
15
26
UN07MAY97
T109233
Left Front

101603
PN=486
1Left Control Valve (5-Spool) 10Return to Hydraulic Tank 18Arm In Pilot From Left 25To Hydraulic Oil Cooler
2Right Control Valve 11Return From Pilot Pilot ControllerSAE 26To Swing Motor Front
(4-Spool) Shut-Off Valve Pattern PortLeft Swing
3To Rear Pump Control 12Pilot Pressure to Swing 19Boom Down Pilot From 27To Swing Motor Rear
Valve Pressure Sensor and Motor Park Brake Release Right Pilot Controller PortRight Swing
Rear Pump Regulator Valve Top Port SAE Pattern 28To Arm Cylinder Rod
4Pilot Pressure Signal to 13Return From Bucket Flow 20Bucket Load Pilot From EndArm Out
Propel Flow Control Valve Control Valve to Solenoid Right Pilot Controller 29To Arm Cylinder Head
5To Rear Pump Control Valve Manifold 21Right Propel Reverse Pilot EndArm In
Valve 14Return From Propel Flow From Propel Pilot 30Left Propel Forward to
6Inlet Flow From Front Control Valve to Solenoid Controller Rotary Manifold Left Front
Pump Valve Manifold 22Swing Right Pilot From Port
7Pilot Pressure Signal to 15Pilot Pressure From Pilot Left Pilot Controller 31Left Propel Reverse to
Swing Motor Park Brake Shut-Off Valve to Solenoid 23Left Propel Reverse Pilot Rotary Manifold Left Rear
Release ValveBottom Valve Manifold From Propel Pilot Port
Port 16Pilot Pressure to Front Controller
8Pilot Pressure From Pilot Pump Control Valve 24To Swing Motor Make-Up
Pressure Regulating Valve 17Arm In Pilot to Bucket Oil Port
9Power Boost Solenoid Flow Control ValveFront
Valve to System Relief Bottom Port
Valve
TX,9025,GG2628 1920MAY982/2
9025
15
27

101603
PN=487
Control Valve Line IdentificationRight Rear
9025
15
28
UN25APR97
T109234
Right Rear
Continued on next page TX,9025,GG2629 1908JUN981/2

101603
PN=488
1Left Control Valve (5-Spool) 16Pilot Pressure to Front 24To Swing Motor Make-Up 39To Bucket Cylinder Head
2Right Control Valve Pump Control Valve Oil Port EndBucket Curl
(4-Spool) 17Arm In Pilot to Bucket 25To Hydraulic Oil Cooler 40To Boom Cylinder Head
5To Rear Pump Control Flow Control ValveFront 32To Propel Motor Speed EndBoom Up
Valve Bottom Port Change Valve 41To Boom Cylinder Rod
7To Swing Motor Park Brake 18Arm In Pilot From Left 33Speed Sensing Solenoid EndBoom Down
Release ValveBottom Pilot ControllerSAE Valve to Front and Rear 42Pilot Pressure From Boom
Port Pattern Pump Regulator Speed Up Pilot Cap to Bucket
9Power Boost Solenoid 19Boom Down Pilot From Sensing Port Flow Control Valve
Valve to System Relief Right Pilot Controller 34Arm Regenerative 43Return to Hydraulic Oil
Valve SAE Pattern Solenoid Valve to Arm Tank
10Return to Hydraulic Tank 20Bucket Curl Pilot From Regenerative Valve 44Supply Oil From Rear
11Return From Pilot Right Pilot Controller 35Supply Oil From Front Pump
Shut-Off Valve 21Right Propel Reverse Pilot Pump 45To Front Pump Control
12Pilot Pressure Signal to From Propel Pilot 36Right Propel Forward to Valve Pressure Sensor
Swing Motor Park Brake Controller Rotary Manifold Right and Front Pump Regulator
Release ValveTop Port 22Swing Right Pilot From Front Port 46Return From Front Pump
13Return From Bucket Flow Left Pilot Controller 37Right Propel Reverse to Control Valve and
Control Valve to Solenoid 23Left Propel Reverse Pilot Rotary Manifold Right Warm-Up Circuit to
Valve Manifold From Propel Pilot Rear Port Hydraulic Oil Tank
14Return From Propel Flow Controller 38To Bucket Cylinder Rod
Control Valve to Solenoid EndBucket Dump
Valve Manifold
TX,9025,GG2629 1908JUN982/2
9025
15
29

101603
PN=489
Control Valve Line IdentificationBottom
UN08MAY97
T109235
9025
15
30 Bottom
13Return From Bucket Flow 41To Boom Cylinder Rod 49Swing Left Pilot From Left 53Right Propel Forward Pilot
Control Valve to Solenoid EndBoom Down Pilot Controller From Propel Pilot
Valve Manifold 42Bucket Flow Control Valve 50Bucket Dump Pilot From Controller
17Arm In Pilot to Bucket Front Top Port to Right Right Pilot Controller 54Left Propel Forward Pilot
Flow Control ValveFront Side Boom Up Pilot Cap 51Boom Up Pilot From Right From Propel Pilot
Bottom Port 47Arm II to Arm I PilotArm Pilot ControllerSAE Controller
37Right Propel Reverse to Out Pattern 55To Hydraulic Oil Tank
Rotary Manifold Right 48Arm Out Pilot From Left 52Boom II to Boom I Pilot Return From Rear Pump
Rear Port Pilot ControllerSAE Boom Up Control Valve
39To Bucket Cylinder Head Pattern
EndBucket Curl
TX,9025,GG2630 1921APR971/1

101603
PN=490
Control Valve Component IdentificationLeft Front
9025
15
31
UN15APR97
T109048
Left Front
1Left Control Valve (5-Spool) 63Solenoid Valve Manifold 73Swing Valve 80Auxiliary Power Passage
2Right Control Valve 64Arm II Valve 74Arm Reduced Leakage Check Valve (Lift Check)
(4-Spool) 65Boom I Valve and Boom Valve 81Propel Flow Control Valve
56System Relief Valve Regenerative Valve 75Arm Out Circuit Relief and 82Propel Power and Neutral
Isolation Check Valve 66Boom Reduced Leakage Anti-Cavitation Valve Passage Check Valves
57System Relief Valve and Valve 76Plug (Lift Checks)
Power Boost 67Bucket Valve 77Swing Lift Check Valve 83Rear Pump Control Valve
58Dig Pressure Switch 68Right Propel Valve 78Arm I Power and Neutral 84Filter and Orifice for Pilot
59Flow Combiner Valve 69Left Propel Valve Passage Check Valves Pressure to Rear Pump
Circuit Check Valve 70Auxiliary Valve (Lift Checks), and Control Valve
60System Relief Valve 71Boom II Valve Restriction Orifice 84ACheck Valve and Orifice
Isolation Check Valve 71APropel-Boom Down 79Boom II Power Passage for Propel Flow Control
61Propel Pressure Switch Selector Valve Check Valve (Lift Check) Valve
62Pilot Pressure Inlet Filter 72Arm I Valve
TX,9025,GG2625 1920MAY981/1

101603
PN=491
Control Valve Component IdentificationRight Rear
9025
15
32
UN15APR97
T109052
Right Rear
1Left Control Valve (5-Spool) 68Right Propel Valve 89Power Boost Solenoid 96Boom I Power and Neutral
2Right Control Valve 69Left Propel Valve Valve Passage Check Valves
(4-Spool) 70Auxiliary Valve 90Propel Speed Change (Lift Checks)
57System Relief Valve and 71Boom II Valve Solenoid Valve 97Arm II Power and Neutral
Power Boost 72Arm I Valve 91Speed Sensing Solenoid Passage Check Valves
63Solenoid Valve Manifold 73Swing Valve Valve and Restriction Orifice
64Arm II Valve 85Arm Regenerative Valve 92Arm Regenerative 98Front Pump Control Valve
65Boom I Valve and Boom 86Arm II to Arm I Neutral Solenoid Valve 99Filter and Orifice for Pilot
Regenerative Valve Passage Check Valve 93Flow Combiner Valve Pressure to Front Pump
66Boom Reduced Leakage 87Boom Up Circuit Relief 94Bucket Flow Control Valve Control Valve
Valve Valve 95Bucket Check Valve (Lift 105Oil Cooler Bypass Valve
67Bucket Valve 88Bucket Dump Circuit Check)
Relief Valve
TX,9025,GG2626 1921APR971/1

101603
PN=492
Control Valve Component IdentificationBottom
UN15APR97
T109053
9025
15
Bottom 33
1Left Control Valve (5-Spool) 68Right Propel Valve 94Bucket Flow Control Valve 102Bucket Load Circuit
2Right Control Valve 69Left Propel Valve 100Arm Regenerative Circuit Relief and Anti-Cavitation
(4-Spool) 70Auxiliary Valve Check Valve Valve
64Arm II Valve 71Boom II Valve 101Boom Down Circuit 103Plug
65Boom I Valve 72Arm I Valve Relief and Anti-Cavitation 104Arm In Circuit Relief and
67Bucket Valve 73Swing Valve Valve Anti-Cavitation Valve
TX,9025,GG2627 1920MAY981/1

101603
PN=493
9025
15
34

101603
PN=494
Main Hydraulic System Component Location

T109224 1919JAN00
TX,9025,GG2618 1919APR971/1

101603
PN=495
Pilot Controllers-to-Flow Regulator Valve Component LocationSAE Pattern

T129491 1925APR00
TX,9025,GG2272 1904APR001/1

101603
PN=496
Pilot Controllers-to-Flow Regulator Valve Component LocationJohn Deere Pattern

T129493 1908MAY00
TX,9025,GG2273 1904APR001/1

101603
PN=497
Pilot Flow Regulator-to-Control Valve Component Location

T109225 1919JAN00
TX,9025,GG2620 1919APR971/1

101603
PN=498
Propel System Component Location

T101405 1912SEP96
SHOWN
ROTATED 180 MAIN CONTROL
VALVE
RIGHT
PROPEL
MOTOR
LEFT
PROPEL
MOTOR
ROTARY
MANIFOLD
PROPEL PILOT
CONTROLLER
PILOT
SHUT-OFF FLOW
VALVE REGULATOR
T101405 PROPEL SYSTEM
TX,9025,GG2621 1919APR971/1

101603
PN=499
Pressure and Return System Component Location

T109226 1919JAN00
TX,9025,GG2622 1919APR971/1

101603
PN=500
Group 20
Adjustment
Pilot Shut-Off Valve Linkage Adjustment
1906DEC91
T7660AL
9025
20
1
APilot Shut-Off Lever CPilot Shut-Off Valve DLever ECap Screw
BRod
SPECIFICATIONS 4. Adjust ball joints on rod (B) to get the specified

Pilot Shut-Off Valve clearance between valve lever (D) and head of cap
Pilot Shut-Off Valve 1.5 0.5 mm (0.06 0.02 in.) screw (E).
Lever-to-Cap Screw Head
Clearance Pilot Shut-Off ValveSpecification
Pilot Shut-Off Valve
Lever-to-Cap Screw Head
1. Stop engine. Clearance............................................. 1.5 0.5 mm (0.06 0.02 in.)
2. Remove cover underneath operators station. 5. Pull pilot shut-off lever to the OFF position. Check
that lever is against the rear stop.
3. Push pilot shut-off lever (A) forward to the ON
position. Check that lever is against the front stop.

101603
PN=501
Adjustment
move with the pilot shut-off lever in the OFF

CAUTION: Machine may move if adjustment
position. If hydraulic function move, repeat
is incorrect. Before checking pilot shut-off
adjustment procedure.
lever adjustment, make sure the area around
machine is clear.
6. Start the engine. Run engine at slow idle. Actuate

the hydraulic functions. Hydraulic functions must not
TX,9025,GG2108 1913SEP002/2
9025
20
2

101603
PN=502
Group 25
Tests
Laptop Computer General Description
NOTE: The laptop cannot be connected to excavator

system without 5 volts from the system supply. If
laptop cannot establish a successful RS232
connection, check for approximately 5 volts on
1929AUG96
any of the 5-volt sensors power wire. A grounded
5-volt sensor power wire will prevent a successful
RS232 connection. Without system 5-volt supply,
RS232 connection is disabled.
T102900
The JT07274J Excavator Diagnostics Program Disk is
designed to run on a laptop computer, such as JT07294
Computer Kit, with the following minimal hardware
requirements:
486 Processor
16 megs of RAM
WINDOWS 95 or
WINDOWS NT
Standard RS232 Serial Port
The laptop computer is connected to the John Deere

excavator by the JT07273 Cable with a standard RS232
connector fitted with a filter to accommodate the voltage
levels of the engine and pump controller.
9025
25
1
WINDOWS is a trademark of MICROSOFT CORPORATION.

NT is a trademark of MICROSOFT CORPORATION. CED,TX08227,2893 1904APR001/1
Excavator Diagnostics ProgramOverview
The JT07274J Excavator Diagnostics Program Disk is to

be used to monitor information available from the Engine
and Pump Controller (EPC) on the John Deere excavator.
In general, the functions provided for John Deere

excavators include:
Identification of Excavator.
Displaying of Diagnostic Service Codes and Corrective
Actions.
Monitoring Data.
Adjustment of Parameters.
On-Line Help.
CED,TX08227,2894 1904APR001/1

101603
PN=503
Tests
Excavator Diagnostics ProgramInstall
9025
25
2
1904SEP96
T102901
Continued on next page TX,9025,CR94 1928JAN991/5

101603
PN=504
Tests
NOTE: The laptop cannot be connected to excavator 2. Connect floppy disk drive to the computer. As
system without 5 volts from the system supply. needed, connect an external power source to floppy
If laptop cannot establish a successful RS232 disk drive.
any of the 5-volt sensors power wire. A NOTE: If floppy disk drive is not connected when the
grounded 5-volt sensor power wire will prevent computer is first booted (turned on) the
a successful RS232 connection. Without floppy disk drive (e:) may not be recognized.
system 5-volt supply, RS232 connection is To reboot, push Ctrl and Alt and Delete at
disabled. the same time or push and hold both left and
right mouse buttons down for 10 seconds
The complete excavator diagnostics program is
contained on a single floppy disk. The program 3. Turn the computer on. This is done on the
requires approximately twelve megabytes upon recommended computer by pushing function Fn
installation. Installation of the program or software and ON at the same time.
updates is best accomplished using the following
procedure: 4. Adjust brightness of screen. Push Fn and F4 or F5
on computer.
NOTE: The latest version of the excavator diagnostics
program now contains a list of supported 5. Using the mouse, push the Start button at the
excavator models in the About John Deere lower left corner of screen.
window. To check the list of excavator models
supported, click on the About button on the NOTE: The mouse is a short post located below the
Toolbar or the Help drop down menu on the space bar. Push the post in direction you want
Menu Bar and then click on About John the cursor to move. Click the buttons on the
Deere. left of the mouse when cursor is in desired
location. The tip of the cursor must be on the
1. Insert floppy disk in floppy disk drive. menu button for menu to open.
9025
25
3

101603
PN=505
Tests
6. From the Start menu, click on Run.
NOTE: To use the Windows 95 Add/Remove Programs

feature, click on Settings in the Start menu, then
Control Panel, Add/Rem... Programs, and then
follow the instruction in each window as they are
displayed.
1929AUG96
T102902
9025
25
4

101603
PN=506
Tests
1919SEP96
T102903
7. Type e: and then a (backslash) in the Run dialog NOTE: Your computer will remember which drive a
window. Then type setup (or use the Browse disk is loaded on the last time it was done.
button to find and select setup from the floppy Therefore pushing the enter key may be all
disk and then select Open). See illustration for an that is required after a disk has been loaded
example. the first time.
NOTE: Some computers use a: as the floppy disk 9. Setup prompts you with a welcome dialog window
drive. Repeat previous step with a: instead of that describes the program and lets you continue or
e: if computer doesnt recognize the floppy exit
disk drive.
Click NEXT
9025
8. Once the dialog window contains the correct drive 25
and file name, click on the OK button. 5

101603
PN=507
Tests
10. Click Next to select default location for software

placement or click Browse to select desired location.
Congratulations! The program is now installed.
1929AUG96
T102904
TX,9025,CR94 1928JAN995/5
9025
25
6

101603
PN=508
Tests
Excavator Diagnostics ProgramUninstall
1911FEB97
T107199
9025
25
7
An Uninstall feature has been created for your NOTE: If John Deere App Group window is open, just
convenience to efficiently remove the program from click on Uninstall Shield.
your computer. Click on Start, Programs, John Deere
App Group, and then Uninstall Shield which is below
the Excavator Diagnostics menu. Follow on-screen
instructions.
TX,9025,CR100 1922APR981/1

101603
PN=509
Tests
Excavator Diagnostics ProgramStarting

1906SEP96
T102905
The John Deere Excavator Diagnostics Software program
is started using the Excavator Diagnostics icon on the
desktop. Also, can be started from the John Deere App
Group in the Programs menu. The Excavator
Diagnostics icon is automatically put on the desktop
when the program is loaded.
Continued on next page TX,9025,GG2670 1928JAN991/5

9025
25
8

101603
PN=510
Tests
9025
25
9
1913MAY97
T109483
NOTE: To install the Excavator Diagnostics icon if the desktop using the mouse. Release the
not on the desktop, use the following mouse button when icon in on the desktop.
procedure: 7. Click on Create Shortcut(s) Here using the
left mouse button.
1. Click on Start using the right mouse button. 8. Using the left mouse button, click on the X
2. Click Open using the left mouse button. in the upper right corner of each open
3. Double click on Programs in Start Menu window to close it.
window using the left mouse button.
4. Double click on John Deere App Group 1. Double click on Excavator Diagnostics icon to
icon using the left mouse button. start program from the desktop (also can click once
5. Put the mouse pointer on the Excavator on the icon and then press the Enter key).
Diagnostics icon.
6. Click and hold the right mouse button down For starting from the Programs menu:
and then drag the icon to an empty area on

101603
PN=511
Tests
a. Click on Start button in lower left corner of d. Click on Excavator Diagnostics.

screen.
2. The John Deere Main Menu screen opens. The
b. Click on Programs in Start menu. menu screen is the gateway to the excavator
diagnostic program.
c. Click on John Deere App Group in the
Programs menu.
TX,9025,GG2670 1928JAN993/5
9025
25
1914MAY97
10
T109495
3. The first time the excavator diagnostics program is b. When the Communication Setup window
used on the laptop computer, a communication port opens, click on the communication port your
must be selected. computer needs for communication with the
excavator. Most computers use Comm 1.
a. Click on the Setup button on the Toolbar or on
the Connection drop down menu on the Menu c. Using the left mouse button, click on the X in the
Bar and then click on Setup. upper right corner of Communication Setup
window to close it.
NOTE: If the Toolbar is not displayed, click on the
View drop menu and then click on Toolbar.
Also click on Status Bar if not displayed at
bottom of window.

101603
PN=512
Tests
1914MAY97
T109499
4. Click on the Connect button on the Toolbar or on The current mode for the software is listed in the
the Connection drop down menu on the Menu Bar middle of the Status Bar and the model number to
and then click on Connect. the right. The modes are Main Mode and Service 9025
Mode. 25
NOTE: If the Toolbar is not displayed, click on the 11
View drop menu and then click on Toolbar. The Disconnect button on the Toolbar will
Also click on Status Bar if not displayed at disconnect the communication with the excavator
bottom of window. being diagnosed, no further communication can be
performed by the software.
5. The John Deere Model window opens displaying
the Model number. Confirm the model number and
then click on OK or press Enter to continue.
6. When the connection is made, the Toolbar button

for Connect becomes gray and the Disconnect,
Codes, and Monitor buttons become black.
TX,9025,GG2670 1928JAN995/5

101603
PN=513
Tests
Excavator Diagnostics Program FeatureService Codes
1902SEP97
T111267
9025
25
12
1. Click on the Codes button on Toolbar or on the is selectable and not grayed out. Service
Features drop down menu on the Menu Bar and Codes-History are requested only once from the
then click on Service Codes. (See Excavator engine and pump controller.
Diagnostics Program List of Service Codes in this
group.) 2. After Service Codes-History have been cleared, the
Service Codes-Current are displayed and updated
The first group of service codes shown is the periodicallyat least 4 samples per minute. Click
Service Codes-History. If there are any codes on a specific service code to get Corrective Action
found, the option to clear the Service Codes-History window to display diagnostic advice.
TX,9025,GG2672 1922APR981/2
3. If communication is interrupted, such as the key switch

being turned off by mistake during service code
reading, the Communication Interruption! window will
display. Click OK or press Enter to disconnect. Then
1929AUG96
turn the key switch back on and click on the Connect

button or on the Connectiondrop down menu on the
Menu Bar and then click on Connect to continue.
T102910
TX,9025,GG2672 1922APR982/2

101603
PN=514
Tests
Excavator Diagnostics Program FeatureMonitor Data
1902SEP97
T111272
9025
25
13
1. Click on the Monitor button on Toolbar or on the down cursor keys and the Enter key also works for
Features drop down menu on the Menu Bar and selecting data items.
then click on Monitor Data to open the Data Item
Selection window. (See Excavator Diagnostic After your first choice has been made, the next
Software Monitor Data Items in this group.) Graph Position is highlighted and allows you to
make your second choice. You may choose a data
2. Double click (or click once and press the Enter key) item for each of the four Graph Positions.
on a data item and its ID number appears in the
Data Item Selected box at the Graph Position that 3. After choices have been made, click OK to view
is highlighted on the left of the screen. The up and data in graph form in the Monitor Data window.

101603
PN=515
Tests
1929AUG96
T102911
4. To change a data item in the Monitor Data 5. The data items are polled at about 4 samples per
window, click Select Items to toggle back to Data second. You can freeze the data by clicking on
Item Selection window. Freeze button. When you click Unfreeze, data
reading will resume. When highlighted, you can
Then highlight the Graph Position by clicking on it also press the Enter key to toggle between Freeze
or use the tab key and then select a data item as and Unfreeze. To highlight a button, press the tab
9025 before. key to highlight the button desired.
25
14
TX,9025,GG2673 1922APR982/3
6. If communication is interrupted, such as the key switch

being turned off by mistake while reading data, the
Communication Interruption! window will display.
Turn the key switch back on and then click Retry or
press Enter to continue. When communication is again
established, the Monitor Data window opens to its last
1929AUG96
settings.
T103375
TX,9025,GG2673 1922APR983/3

101603
PN=516
Tests
Excavator Diagnostics Program FeatureSaving Monitor Data
9025
25
15
1928APR97
T109321
1. You can save a copy of frozen data to a disk d. When Paint opens, paste frozen data by
following these steps: pressing Control and the V keys.
a. Click on the application to make it the active e. Click on Edit and then on Copy To.
window.
f. Type in a File name, select a drive to Save in
b. Press Alt and the PrtScn keys. and then click on Save.
c. Click on Start, Programs, Accessories, and 2. The saved file may be opened and printed in either
then Paint. a paint or page layout program.
TX,9025,GG2674 1922APR981/1

101603
PN=517
Tests
Excavator Diagnostics Program Special

FunctionEngine Speed Adjustment
Special Function allows you to adjust the following engine

speed factory settings parameters: (For factory settings,
see Excavator Diagnostics Program Special Function
Engine Speed Factory Settings Parameters in this group.)
Slow idle (RPM)

Economy (RPM)
Fast idle (RPM)
Auto idle (RPM)
Attachment (RPM)
Attachment (RPM) is used to adjust the engine speed for

an attachment connected to the machines hydraulic
system that requires a specified pump flow rate. When in
Attachment Mode and the proper pressure switch and
wiring harness are installed, the engine speed changes to
the adjusted speed when the attachment is actuated.
See the Engine Speed to Pump Flow Rate Chart in this

group for the engine speed to get the specified pump flow
rate.
To change a parameter, the excavator must be in Service

9025 Mode. Follow the steps below for placing the excavator in
25 service mode and adjusting parameters.
16
NOTE: If computer is currently connected, click on the
Disconnect button on the Toolbar or on the
Connection drop down menu on the Menu Bar
and then click on Disconnect.
1. Turn the key switch off.
2. Connect the laptop computer cable to the diagnostic

test port.

101603
PN=518
Tests
3.
Push the learning switch (C) up to the top position and

wait for 10 seconds.
4. Turn the key switch on.
5. Click on the Connect button on the Toolbar or on the

Connection drop down menu on the Menu Bar and
then click on Connect.
The John Deere Model window opens displaying the

Model number. Confirm the model number and then
click on OK or press Enter to continue.
UN11SEP96
6. The Warning Service Mode window opens warning
that excavator is in Service Mode. Click OK.
T103674
NOTE: Service Mode and machine model number is
displayed in the Status Bar at bottom of window.
CLearning Switch
In Service mode, the Service Codes and Monitor
Data cannot be accessed.

9025
25
17

101603
PN=519
Tests
1914OCT97
T111739
9025
25 7. Click on the Adjust button on the Toolbar or on the The Parameter Change window contains:
18 Features drop down menu on the Menu Bar and
then click on Special Function to open the Special Parameter (to be changed)
Function window. Adjustable Range
Initial (deviation from factory set rpm)
The Special Function window allows the user to Minimum Adjusting Deviation
select the Adjustable Parameters for adjustment Current (deviation from factory setting)
and view the values under Learning Data Display. Adjustment (were change is made)
8. Use the cursor keys to move the highlight to the

parameter you wish to change then press Enter to
bring up the Parameter Change screen.

101603
PN=520
Tests
1929AUG96
T103378
9025
9. Use the up and down cursor keys on keyboard to 11. Click on Exit to close the Special Function 25
change the value which appears in the Adjustment window. 19
box.
12. Click on Disconnect Toolbar button.
NOTE: Clicking on the up and down arrows next to
box will also change the value. 13. Turn the key switch off.
10. Press the Enter key or click OK and the 14. Push learning switch down to the center position
Adjustment was made as follows: window and wait 10 seconds.
opens. Confirm the value and then press the Enter
key or click OK button to return to the Adjustable NOTE: Check the Status Bar at bottom of window that
Parameters. computer is in Main Mode after connecting.
NOTE: Only one parameter can be change at a time. 15. Start the engine and then check the adjusted
Repeat procedure from Adjustable Parameters parameter using a tachometer
to adjust additional parameters.
TX,9025,GG2862 1922APR984/4

101603
PN=521
Tests
Excavator Diagnostics ProgramService

Codes List
LIST OF SERVICE CODES
Service Code Trouble Corrective Action
01 EC sensor failure 1. Press Clear.
2. Check harness.
3. Replace the EC sensor.
02 Front pump delivery pressure sensor failure. 1. Press Clear.
2. Check harness.
3. Replace the pump delivery pressure sensor.
03 Rear pump delivery pressure sensor failure 1. Press Clear.
2. Check harness.
3. Replace the pump delivery pressure sensor.
04 Front pump control pressure sensor failure 1. Press Clear.
2. Check harness.
3. Replace the pump control pressure sensor.
05 Rear pump control pressure sensor failure 1. Press Clear.
2. Check harness.
3. Replace the pump control pressure sensor.
06 Arm Roll-in pilot pressure sensor failure 1. Press Clear.
2. Check harness.
3. Replace the arm in pilot pressure sensor.
07 Engine rpm dial failure 1. Press Clear.
2. Check harness
3. Replace the engine rpm dial.
9025
25
20
TX,9025,GG2643 1922APR981/1

101603
PN=522
Tests
Excavator Diagnostics ProgramMonitor

Data Items
NOTE: This chart lists engine and pump controller

dynamic data items that can be monitored by the
excavator diagnostics program.
200LC EXCAVATOR MONITOR DATA ITEMS

Item Display List Units Description
1 Front pump control pressure psi Pilot signal from the front pump control valve to pump regulator
2 EC angle V Feedback signal from the engine control sensor to the engine and pump
controller
3 Front pump delivery pressure psi Pump supply pressure at front pump outlet.
4 Rear pump delivery pressure psi Pump supply pressure at rear pump outlet.
5 Arm in pilot pressure psi Pilot pressure from pilot controller to control valve pilot cap. Pressure
measured at flow regulator valve.
6 Rear pump control pressure psi Pilot signal from rear pump control valve to pump regulator.
8 RPM dial angle V Electrical signal from engine rpm dial.
9 Arm regenerative control psi Pilot pressure from arm regenerative solenoid valve to arm regenerative
pressure valve in left control valve. A calculated pressure, not actual pressure.
10 Propel motor control pressure psi Pilot pressure from propel speed change solenoid valve to speed selector
valve in propel motors. A calculated pressure, not actual pressure.
11 Speed sense control pressure psi Pilot pressure from speed sense solenoid valve to front and rear pump
regulators. A calculated pressure, not actual pressure.
12 Power boost control pressure psi Pilot pressure from power boost solenoid valve to the piston in the system
relief valve. This is a calculated pressure, not the actual pressure.
9025
13 Target engine speed rpm Set by engine rpm dial. Target speed for engine pull down when under 25
load. (Approximately 150 rpm difference from engine speed under no 21
load.)
14 Actual engine speed rpm Engine speed sensed by engine speed sensor. Sensor is located in the
pump drive gearbox adjacent to front pump.
15 EC motor position steps Electrical signal from engine and pump controller to engine control motor.
20 Pressure switch Boom Up, Dig, Electrical signal from pressure switches to engine and pump controller
Propel when function is actuated. Boom up is located on flow regulator valve.
Dig and propel are located on control valve.
21 Selected work mode switch Dig, Grading, Signal from control module to engine and pump controller for selected
Precision, work mode.
Attachment
22 E mode switch On, Off Signal from control module to engine and pump controller for preset
engine speed.
23 Auto-idle switch On, Off Signal from control module to engine and pump controller to actuate
auto-idle function.
24 HP mode switch On, Off Signal from control module to engine and pump controller to actuate High
power mode.
25 Power boost switch On, Off Signal from power boost switch, in right control lever, to engine and pump
controller to actuate power boost function.
Continued on next page CED,OUOE035,137 1920MAY981/2

101603
PN=523
Tests
200LC EXCAVATOR MONITOR DATA ITEMS

Item Display List Units Description
26 Selected propel speed switch Fast, Slow Signal from control module to engine and pump controller to change
propel speed.
27 Key switch On, Off Signal from key switch to engine and pump controller.
28 Engine learning control Done, Undone, Engine and pump controller has to be originally matched to each
Interruption machine. See engine learning procedure.
29 Attachment mode pressure On, Off Signal to engine and pump controller when attachment mode is active.
switch
CED,OUOE035,137 1920MAY982/2
9025
25
22

101603
PN=524
Tests
Excavator Diagnostics Program Special

FunctionEngine Speed Factory Settings
Parameters
SPECIFICATIONS
Engine Slow Idle Speed 900 25 rpm
Engine Auto Idle Speed 1200 25 rpm
Engine E (Economy) Mode 1850 25 rpm
Speed
Mode Speed
Engine Attachment Mode Speed (As specified by supplier)
The factory settings for engine speeds can be changed

using the excavator diagnostic program special function.
(See Excavator Diagnostics Program Special Function
Engine Speed Adjustment in this group.)
Specification
Engine Slow IdleSpeed .................................................... 900 25 rpm
Engine Auto IdleSpeed ................................................... 1200 25 rpm
Engine E (Economy) Mode
Speed ................................................................................. 1850 25 rpm
ModeSpeed ..................................................................... 2100 25 rpm
Engine Attachment ModeSpeed .................... (As specified by supplier)
NOTE: For the engine speed to get a specified pump flow 9025
rate, see Engine Speed to Pump Flow Rate Chart 25
23
in this group.
CED,OUOE003,1073 1904OCT001/1

101603
PN=525
Tests
Engine Speed to Pump Flow Rate Chart
SPECIFICATIONS
a
200LC Excavator Pump Flow 132 L/min (35 gpm)
Rate to Engine Speed at 1425 rpm and
14 479 kPa (145 bar) (2100 psi)
200LC Excavator Pumpa Flow 151 L/min (40 gpm)
14 479 kPa (145 bar) (2100 psi)
14 479 kPa (145 bar) (2100 psi)
14 479 kPa (145 bar) (2100 psi)
14 479 kPa (145 bar) (2100 psi)
a
For engine speeds below the adjustable range, operate in Dig Mode
and turn the engine rpm dial to obtain the desired engine speed.
The adjustable range is a (minus) -500 to 200 rpm for

Attachment in Attachment Mode. The minimum adjusting
deviation is 10 rpm.
Specification
200LC Excavator Pump1Flow
Rate to Engine Speed ................................................ 132 L/min (35 gpm)
9025 at 1425 rpm and
25 14 479 kPa (145 bar) (2100 psi)
24 Flow Rate to Engine Speed ....................................... 151 L/min (40 gpm)
at 1580 rpm and
14 479 kPa (145 bar) (2100 psi)
200LC Excavator PumpFlow
Rate to Engine Speed ................................................ 170 L/min (45 gpm)
at 1740 rpm and
14 479 kPa (145 bar) (2100 psi)
Flow Rate to Engine Speed ....................................... 189 L/min (50 gpm)
at 1890 rpm and
14 479 kPa (145 bar) (2100 psi)
Flow Rate to Engine Speed ....................................... 204 L/min (55 gpm)
at 2050 rpm and
14 479 kPa (145 bar) (2100 psi)
1
For engine speeds below the adjustable range, operate in Dig Mode
and turn the engine rpm dial to obtain the desired engine speed.

101603
PN=526
Tests
For an engine speeds below the adjustable range, operate

in Dig Mode and turn the engine rpm dial to obtain the
desired engine speed.
For adjustment procedure, see Excavator Diagnostics

Program Special FunctionEngine Speed Adjustment in
this group.
CED,OUOE003,663 1913JUN982/2
9025
25
25

101603
PN=527
Tests
Excavator Diagnostics Program

Troubleshooting

Most software problems can be solved by the following:
1. Questions:
Is the key switch on the excavator turned on?
Are the connectors push in all of the way?
Is the software connected? If communication is
broken momentarily between the computer and the
engine and pump controller?
Is the program in the Main Mode or Service Mode?
The program will tell you the current mode in the
Status Bar at the bottom of window. If it is not in one
of these modes you need to click on Connection
and Connect.
9025 2. Turn key switch Off. Wait for 10 seconds.

25 3. Turn key switch ON.
26
NOTE: Disconnect and Connect does NOT mean to
unplug and plug in computer cable.
4. Click on Disconnect and Connect under the

Connection menu.
5. Try again.
TX,9025,CR103 1928JAN991/1

101603
PN=528
Tests
Reading Service Codes Without Excavator Diagnostics Program
1913FEB98
T113360
9025
25
27
AEngine and Pump BService Code Indicator CDiagnostic Port EFuse Box
Controller Light (LED) DJumper Wire
With practice the self-diagnostic service codes can be 4. Turn the key switch ON.
read by counting the flashes of the Service Code
Indicator Light (LED) (B) in the engine and pump The LED comes ON steady for several seconds
controller (A). and then goes OFF.
Read the LED in the engine and pump controller 5. For an existing service code, the LED starts a
several times to make sure the correct service code is flashing sequence of 1 second ON, 1 second OFF
read. intervals. After the last ON in a sequence, the LED
remains OFF for approximately 3 seconds and then
1. Lower the bucket to the ground. Stop the engine. repeats the flashing sequence.
2. Remove the rear console cover from behind the Count the number of times LED is ON in a
operators seat. Remove the bracket that is over the sequence for the service code number.
engine and pump controller.
Example, for a service code 03 Rear pump
3. Install a jumper wire (D) into the two top terminals delivery pressure sensor failure, the LED flashes
of the diagnostic port (C). ON three times in each sequence.
Continued on next page CED,TX08227,2997 1917APR001/2

101603
PN=529
Tests
For more than one, the LED will have a flashing 9. Use the following procedure to clear existing
sequence for each existing service code with an service codes:
approximate 3 second interval between each
sequence. The flashing sequence continues as long a. Install jumper wire into the top two terminals of
as the key switch in ON and jumper wire is diagnostic port.
installed.
b. Turn the key switch ON.
NOTE: If no service codes exist or trouble is beyond
the scope of self-diagnosing function, the LED c. Remove jumper wire from diagnostic port.
is ON for several seconds then goes OFF and
remains OFF. d. Wait for two second.
With key switch ON but no jumper wire e. Install jumper wire into the top two terminals of
installed in the diagnostic port, the LED comes diagnostic port.
ON for several seconds, goes OFF, and then
starts a steady one seconds ON, one seconds f. Check for service codes. The LED is ON for
OFF flashing sequence. several seconds then goes OFF and remains
OFF if all necessary repairs were made.
6. Turn the key switch OFF.
g. Turn the key switch OFF
7. Remove jumper wire from diagnostic port.
h. Remove jumper wire from diagnostic port.
8. Make necessary repairs.
CED,TX08227,2997 1917APR002/2
9025
25
28

101603
PN=530
Tests
Engine and Pump Controller Functions
9025
25
29
1927MAY98
T115419

101603
PN=531
Tests
The engine and pump controller (EPC) is used to switches (13, 57, and 1416) are sent to the
control machine operation. Electronic input signals controller.
from the engine rpm dial (4), sensors (913), and
TX,9025,GG2603 1921MAY982/2

Installation
UN28FEB89
1. Before installing clamp-on electronic tachometer,
remove the paint from a straight section of injection
line within 100 mm (4 in.) of No. 1 injection nozzle.
Use emery cloth to remove the paint.
T6813AG
2. Install the clamp-on transducer (A). Tighten finger tight
onlyDO NOT overtighten.
AClamp-On Transducer
BBlack Clip ()
3. Connect the red clip (+) (C) to the clamp-on CRed Clip (+)
transducer. DDigital Readout Unit
4. Connect the black clip (-) (B) to a ground connection

such as the head of a cap screw or other metal part on
9025 engine.
25
30
5. Start the engine. Check for a reading on the digital
readout unit (D).
CED,TX08227,2879 1911NOV971/1
JT05800 Digital Thermometer Installation

1. Fasten temperature probe (A) to a bare metal hydraulic

UN28FEB89
line using a tie band.
2. Wrap temperature probe and line with a shop towel.

T6808CE
ATemperature Probe
BCable
CJT05800 Digital Thermometer
CED,TX08227,2895 1919NOV971/1

101603
PN=532
Tests
JT02156A Digital Pressure And Temperature

Analyzer Installation
JT02156A Digital Pressure and Temperature Analyzer
UN25AUG95
Use the digital pressure and temperature analyzer (A),
and transducers (B) in place of analog gauges and a
separate temperature reader.
T8543AI
Transducers are temperature sensitive. Allow transducer
to warm to system temperature. After transducer is
warmed and no pressure applied, push sensor zero button
ADigital Pressure and Temperature Analyzer
for one second to set the true zero point. B3 400 kPa (35 bar) (500 psi) Transducer
34 000 kPa (350 bar) (5 000 psi) Transducer
When using for different pressures, turn selector to OFF 70 000 kPa (700 bar) (10 000 psi) Transducer
for two seconds and then to the pressure range. Readings
are inaccurate if proper range for transducer is not used.
CED,TX08227,2896 1919NOV971/1
9025
25
31

101603
PN=533
Tests
Hydraulic Pump Start-Up Procedure
IMPORTANT: Hydraulic pump will be damaged if not

filled with oil before starting engine.
Procedure must be performed whenever
a new hydraulic pump is installed or oil
has been drained from the pump or
hydraulic oil tank.
Procedure is to ensure the pumps are filled with oil and

air is bled from suction side of pumps to prevent
cavitation.
1. Add oil until it is between marks on hydraulic oil tank

sight glass. (See Hydraulic Oil in Group 9000-04.)
2. Remove air bleed plugs (C) from the top of pump

regulators to allow housing to fill with oil from the
hydraulic tank and to let air escape.
3. When pump housing is full of oil, install plugs.
UN15JUL96
4. Check oil level in hydraulic tank. Add oil as necessary.
Tighten hydraulic oil tank cap. Tighten vent plug.
T101875
5. Start engine and run at slow idle. Slowly raise boom to
full height and then lower to pressurize hydraulic oil
9025
25 tank. CAir Bleed Plugs
32
6. Purge air from the hydraulic system by slowly
operating each function through three cycles. Air in
pilot circuits are purged automatically.
TX,25,GG2226 1914SEP001/1

101603
PN=534
Tests
Swing Motor Start-Up Procedure
IMPORTANT: Swing motor will be damaged if not

filled with oil before operating swing
function. Procedure must be performed
whenever a new swing motor is
installed or oil has been drained from
the motor.
Procedure is to ensure the swing motor is filled with oil.
1. Disconnect swing motor drain line (A).
2. Fill motor with hydraulic oil through drain port until oil
reaches the level of drain port. (See Hydraulic Oil in
Group 9000-04.)
NOTE: Air must be allowed to escape from the swing

motor while filling.
UN11DEC91
3. Connect drain line.
ASwing Motor Drain Line
T7670AE
9025
25
33
TX,25,GG2227 1913AUG981/1

101603
PN=535
Tests
Swing Gearbox Start-Up Procedure
IMPORTANT: Swing gearbox will be damaged if not

filled with oil before operating swing
function. Procedure must be performed
whenever a new swing gearbox is
installed or oil has been drained from
the gearbox.
1. Check that drain line (A) plug is installed.
2. Remove fill cap (B). Add oil. (See Swing Gearbox,

Propel Gearbox and Pump Gearbox Oils in Fuels and
Lubricants group.)
3. Install fill cap. Check oil level on dipstick.
ASwing Gearbox Drain Line

BFill Cap
UN30JUL96
T102305
TX,25,GG2228 1914SEP001/1
9025
25
34
Propel Motor Start-Up Procedure
ESSENTIAL TOOLS
JT03221 (Parker No. 03CP8) Plug
IMPORTANT: Propel motor will be damaged if not
UN11DEC91
filled with oil before starting engine.
Procedure must be performed whenever
a new propel motor is installed or oil
has been drained from the motor.
T7660BG
1. Disconnect motor drain line (A). Install plug.

APropel Motor Drain Line
2. Fill motor with hydraulic oil until oil reaches the top of
the drain port. (See Hydraulic Oil in Group 9000-04.)
Use a funnel with suitable diameter neck to allow air to
escape while filling.
3. Connect drain line.
TX,25,GG2229 1908JUN981/1

101603
PN=536
Tests
Hydraulic Oil Filter Inspection Procedure

JT05536 Oil Filter Cutting Tool
1. Pour oil out of filter to inspect for water contamination.
UN19JAN90
2. Use an oil filter cutting tool to cut top off filter.
3. Remove element and inspect for metal particles and
IT4633
debris in bottom of filter can.
Excessive amounts of brass and steel particles can

indicate a failed hydraulic pump or a pump failure in
process.
A rubber type of material can indicate cylinder packing

failure.
TX,25,GG2231 1920NOV971/1
9025
25
35

101603
PN=537
Tests
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
SPECIFICATIONS NOTE: Filtering time for hydraulic tank is 0.089 minute

Hydraulic Oil Cleanup Procedure x number of liters (0.33 minutes x number of
Hydraulic Oil Tank Capacity 130 L (34 gal) approximate gallons).
Hydraulic Oil Tank Filtering 12 minutes approximate
Time 4. Leave filter caddy operating for the next step.
Hydraulic System Capacity 250 L (66 gal) approximate
5. Start the engine and run it at fast idle.
Hydraulic System Filtering Time 40 minutes approximate
IMPORTANT: For the most effective results,

cleaning procedure must start with
Portable Filter Caddy
the smallest capacity circuit then
3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2 proceed to the next larger capacity
used)
circuit.
Quick Disconnect Fittings
Suction Wand 6. Starting with the smallest capacity circuit, operate
Discharge Wand each function through a complete cycle.
1. Install new return filter elements. Repeat procedure until the total system capacity
has circulated through filter caddy seven times.
NOTE: For a failure that creates a lot of debris, Each function must go through a minimum of three
remove access cover from hydraulic tank. complete cycles for a thorough cleaning of oil.
Drain hydraulic tank. Connect filter caddy
Hydraulic Oil Cleanup ProcedureSpecification
suction line to drain port. Add a minimum of 19 Hydraulic SystemCapacity ................... 250 L (66 gal) approximate
L (5 gal) of oil to reservoir. Operate filter caddy Hydraulic SystemFiltering
9025 and wash out the hydraulic tank. Time ............................................................... 40 minutes approximate
25
36 IMPORTANT: The minimum ID for a connector is NOTE: Filtering time for complete hydraulic system is
13 mm (1/2 in.) to prevent cavitation 0.158 minute x number of liters (0.6 minute x
of filter caddy pump. number of gallons). Filtering time for machines
with auxiliary hydraulic functions must be
2. Put filter caddy suction and discharge wands into increased because system capacity is larger.
hydraulic tank filler hole so ends are as far apart as
possible to obtain a thorough cleaning of oil. 7. Stop the engine. Remove the filter caddy.
3. Start the filter caddy. Check to be sure oil is flowing 8. Install new return filter elements.
through the filters.
9. Check oil level in hydraulic tank, add oil if
Operate filter caddy until all the oil in hydraulic tank necessary. (See Hydraulic Oil in Group 9000-04.)
has been circulated through the filter a minimum of
four times.
Hydraulic Oil Cleanup ProcedureSpecification

Hydraulic Oil TankCapacity.................. 130 L (34 gal) approximate
Hydraulic Oil TankFiltering
Time ............................................................... 12 minutes approximate
TX,9025,GG2114 1913SEP001/1

101603
PN=538
Tests
Hydraulic System Warm-Up Procedure
SPECIFICATIONS procedure. Clear the area of all bystanders

Hydraulic System Warm-Up Oil 50 5C (120 10F) before doing the warm-up procedure.
Temperature
2. Clear the area of all bystanders to allow for
SERVICE EQUIPMENT AND TOOLS machine movement.
3. Start engine. Run engine at 1/2 speed for
IMPORTANT: If machine temperature is below approximately 5 minutes before operating any
-18C (0F), start procedure with functions. Do not run engine at fast or slow idle.
engine running at 1/2 speed. Failure
to do this could cause pump 4. Check that work mode is in Dig Mode and power
cavitation. Once oil temperature is mode is in Standard Mode (no buttons pushed
above -18C (0F) the engine speed down, indicator lights off). Push auto-idle switch to
can be increased to fast idle. turn off auto-idle function (auto-idle indicator off).
Below -18C (0F) an extended warm-up period may 5. Slowly turn upperstructure so boom is to the side.
be necessary. Hydraulic function will move slowly and
lubrication of parts may not be adequate with cold oil. CAUTION: Avoid possible serious injury
Do not attempt normal machine operation until from machine sliding backwards. Keep angle
hydraulic functions move at or close to normal cycle between boom and arm at 90110
times.
6. Keeping the angle between boom and arm at 90
Specification
Hydraulic System Warm-Up
110, lower boom to raise one track off the ground.
OilTemperature ............................................ 50 5C (120 10F)
7. Operate propel function for approximately 5 minute. 9025
25
Operate functions slowly and avoid sudden
37
movements until engine and hydraulic oils are 8. Once oil temperature is above -18C (0F), increase
thoroughly warmed. Operate a function by moving it a engine speed to fast idle.
short distance in each direction. Continue operating
the function increasing the distance traveled in each IMPORTANT: Holding a function over relief for
cycle until full stroke is reached. more than 10 seconds can cause
damage from hot spots in the
For faster warm-up, restrict air flow through oil cooler control valve.
using cardboard or other similar material. Use correct
viscosity oil to minimize warm-up period. (See 9. Operate the propel function (side with track off the
Hydraulic Oil in Group 9000-04.) ground). Also operate the bucket curl function over
relief for 10 seconds and then stop for 5 seconds.
1. Connect digital thermometer. Install temperature Repeat the cycle until oil is heated to specifications.
probe on hydraulic oil tank-to-pump inlet line. (See
JT05800 Digital Thermometer Installation in this 10. Stop periodically and operate all hydraulic
group.) functions to distribute the heated oil.
CAUTION: Avoid possible serious injury

from machine movement during warm-up
TX,25,GG2232 1913AUG981/1

101603
PN=539
Tests
Lower Boom with Engine Stopped
SPECIFICATIONS
Lower Boom (with Engine Stopped)
Boom Manual Lower Screw 6.9 Nm (60 lb-in.)
Torque
UN23AUG88
Boom Manual Lower 13 Nm (115 lb-in.)
Screw-to-Housing Nut Torque
X9811
4 mm Hex Key Wrench
When an engine stops during operation, the boom cannot

be lowered using the pilot controller because there is no
pilot pressure oil to move the boom valve spool.
CAUTION: Prevent possible injury from

unexpected machine movement. Clear all
persons from the area before lowering the
boom with the engine stopped.
1. Remove the control valve access cover.
CAUTION: To avoid injury from escaping fluid

under pressure, never loosen screw more than
9025 two turns as screw may come out. Tighten
25 screw and nut before applying pressure.
38
2. Loosen the small nut (B) on the boom reduced leakage
valve housing (C).
Slowly loosen boom manual lower screw (A) 1/2 turn
UN07AUG96
using a 4 mm hex key wrench. The boom will start to
lower.
The boom lowering speed can be increased somewhat
T102664
by loosening screw an additional 1-1/2 turns. Never
loosen screw more than two turns. Boom Manual Lower Screw
3. After the bucket is lowered to the ground, tighten the ABoom Manual Lower Screw
screw to specification, and then the nut. BSmall Nut
CBoom Reduced Leakage Valve Housing
Lower Boom (with Engine Stopped)Specification
Boom Manual Lower Screw
Torque ........................................................................... 6.9 Nm (60 lb-in.)
Boom Manual Lower
Screw-to-Housing NutTorque ................................... 13 Nm (115 lb-in.)
CED,OUOE003,1198 1903OCT001/1

101603
PN=540
Tests
Arm Regenerative Proportional Solenoid

Valve (SC) Harness Test
ESSENTIAL TOOLS
JT07352 Test Harness
UN19MAR91
The purpose of harness test is to check continuity in
wiring harness to the arm regenerative solenoid valve (A)
coil and there is a electrical signal from engine and pump
controller.
T7486AL
NOTE: Pressure reading shown on the laptop computer
for Arm regenerative control pressure is a
calculated pressure from the electrical signal in
the engine and pump controller. A typical reading
is 399.3 psi while operating the boom up and arm
in functions in combined operation with engine
speed at 1200 rpm or less. The reading indicates
that the rear pump pressure sensor, arm in
UN28AUG96
pressure sensor, and boom up pressure switch
are OK and a electrical signal is generated. When
all functions are in neutral, a typical reading of
170.4 psi is displayed at fast or slow idle. (For
T103345
circuit operation, see Arm Regenerative Valve
Operation in Group 9025-05.)
AArm Regenerative Solenoid Valve (SC)
IMPORTANT: Disconnecting electrical connectors BSpeed Sensing Solenoid Valve (SD) 9025
while engine is running or with key CPropel Speed Change Solenoid (SI) 25
switch on can damage engine and DPower Boost Solenoid Valve (SG) 39
pump controller or other electrical
components.
1. Stop engine. Turn key switch to OFF.
IMPORTANT: Wiggle connector to remove from

solenoid. It is not necessary to remove
wire retainer clip.
2. Wiggle connector half and pull apart; do not pull on

wiring leads.
3. Install test harness in series with wiring harness and

arm regenerative solenoid valve (A).
4. Turn key switch to ON but do not start engine.

101603
PN=541
Tests
Indicator light must come ON indicating there is

continuity in the wiring harness and there is a signal
from engine and pump controller.
5. Start engine.
6. Actuate boom up function and then arm in function.
Indicator light must be ON and the brightness must

increase slightly.
If light goes OUT or brightness does not increase,

check wiring harnesses, solenoid coil, rear pump
pressure sensor, arm in pilot pressure sensor, and
boom up pressure switch. (See procedure in Group
9015-15.)
TX,25,GG2220 1925APR002/2
9025
25
40

101603
PN=542
Tests
Speed Sensing Solenoid Valve (SD) Harness

Test
ESSENTIAL TOOLS
UN19MAR91
The purpose of test is to check continuity in wiring
harness to the speed sensing solenoid valve (B) coil and
there is a electrical signal from engine and pump
controller.
T7486AL
for Speed sense control pressure is a calculated
pressure from the electrical signal in the engine
and pump controller. When all functions are in
neutral, a typical reading of 532.8 psi is displayed
at slow idle and 0 psi is displayed at fast idle. Run
the engine at approximately 1700 rpm so the
reading is less than 100 psi. Then actuate arm in
UN28AUG96
to bottom the function. The pressure reading will
increase momentarily and then return to its
original reading. The readings indicates that the
engine speed sensor is OK and a electrical signal
T103345
is generated. (For circuit operation, see Engine
Speed Sensing Control Circuit Operation in Group
9025-05.) AArm Regenerative Solenoid Valve (SC)
BSpeed Sensing Solenoid Valve (SD) 9025
IMPORTANT: Disconnecting electrical connectors CPropel Speed Change Solenoid (SI) 25
while engine is running or with key DPower Boost Solenoid Valve (SG) 41
switch on can damage engine and
components.

wire retainer clip.

wiring leads.

speed sensing solenoid valve (B).

101603
PN=543
Tests

5. Start engine.
6. Actuate arm in function over relief to load the engine.
Indicator light must be ON.
If indicator light goes OUT, check wiring harnesses,

solenoid coil, engine rpm dial, and engine speed
sensor. (See procedure in Group 9015-15.)
TX,25,GG2221 1925APR002/2
9025
25
42

101603
PN=544
Tests
Propel Speed Change Proportional Solenoid

Valve (SI) Harness Test
ESSENTIAL TOOLS
UN19MAR91
The purpose of test is to check continuity in wiring
harness to the propel speed change solenoid valve (C)
coil and there is a signal from engine and pump controller.
T7486AL
for Propel motor control pressure is a calculated
and pump controller. A typical reading of 65.9 psi
is displayed when propel function is in neutral or
propelling in slow speed. A typical reading of 426
psi is displayed when propelling in fast speed with
no other function actuated. The readings indicates
that the propel speed switch, propel and dig
UN28AUG96
pressure switches, front and rear pump control
pressure sensors, and front and rear pump
pressure sensors are OK and a electrical signal is
generated. (For circuit operation, see Propel
T103345
Motor Speed Change Circuit Operation in Group
9025-05.)
IMPORTANT: Disconnecting electrical connectors BSpeed Sensing Solenoid Valve (SD) 9025
while engine is running or with key CPropel Speed Change Solenoid (SI) 25
switch on can damage engine and DPower Boost Solenoid Valve (SG) 43
components.

wire retainer clip.

wiring leads.

propel speed change solenoid valve (C).
5. Turn propel speed switch to fast speed (rabbit).

101603
PN=545
Tests
Turn propel speed switch to slow speed propel (turtle).
Indicator light must be ON indicating there is continuity

in the wiring harness and there is a signal from engine
and pump controller.
6. Start engine.
7. Actuate propel function.
8. Turn propel speed switch to fast speed (rabbit).
The brightness of indicator light must increase slightly

while propelling in fast speed.
If light goes OUT or brightness does not increase,

check wiring harnesses, solenoid coil, propel pressure
switch, pump pressure, and pump control valve
pressure sensors. (See procedure in Group 9015-15.)
NOTE: No dig functions can be actuated. The dig

pressure switch must be OFF so it does not send
an electrical signal to engine and pump controller.
TX,25,GG2219 1925APR002/2
9025
25
44

101603
PN=546
Tests
Power Boost Proportional Solenoid Valve

(SG) Harness Test
ESSENTIAL TOOLS
UN19MAR91
The purpose of test is to check continuity in the wiring
harness to the power boost solenoid valve (D) coil and
there is a signal from the engine and pump controller.
T7486AL
for Power boost control pressure is a calculated
and pump controller. A typical reading of 426 psi
is displayed when power boost switch on the right
control lever is pushed. A reading of 0 psi is
displayed when the switch is not pushed. The
readings indicates that the power boost switch is
OK and a electrical signal is generated. (For
UN28AUG96
circuit operation, see Power Boost Control Circuit
Operation in Group 9025-05.)
IMPORTANT: Disconnecting electrical connectors
T103345
while engine is running or with key
pump controller or other electrical AArm Regenerative Solenoid Valve (SC)
components. BSpeed Sensing Solenoid Valve (SD) 9025
CPropel Speed Change Solenoid (SI) 25
1. Stop engine. Turn key switch to OFF. DPower Boost Solenoid Valve (SG) 45

wire retainer clip.

wiring leads.

power boost solenoid valve (D).

5. Push the power boost switch on the right control lever.

101603
PN=547
Tests
The brightness of indicator light must increase slightly.
If light goes OUT or brightness does not increase

slightly, check wiring harnesses, solenoid coil, and
power boost switch. (See procedure in Group
9015-15.)
TX,9025,GG2713 1925APR002/2
9025
25
46

101603
PN=548
Tests
Engine Control Sensor (EC Sensor) Harness

Test
SPECIFICATIONS
Fast Idle in Standard Mode 3.12 volts
Voltage
UN19MAR91
E (Economy) Mode Voltage 3.00 volts
Auto-Idle Mode Voltage 2.57 volts
Slow Idle Voltage 2.42 volts
T7482AH
ESSENTIAL TOOLS

JT07306 Analog/Digital Multimeter
JT07273 Cable
UN19MAR91
The purpose of test is to check continuity in engine control
sensor (EC sensor) wiring harness and there is a signal
from the engine and pump controller (EPC).
T7486AB
switch on can damage engine and 9025
pump controller or other electrical 25
47
components.
UN07FEB97
IMPORTANT: Retainer tab on male half of wiring
harness connector halves must be
pushed down before pulling halves
apart. Never pull on wiring leads
T106991
2. Push retainer tab down then pull connector halves
apart. AOutside Terminal
BInside Terminal
3. Measure resistance between the outside terminals (A COutside Terminal
and C) of EC sensor. If resistance is 1700 400 ohms, DEngine Control Motor
EEngine Control Motor Sensor Wiring Harness
go to next step. If resistance is not as specified,
FEngine Control Motor Wiring Harness
replace EC sensor.

101603
PN=549
Tests
NOTE: EC sensor is inside the EC motor.
4. When using a voltmeter, install test harness in series

with wiring harness for EC sensor. Connect voltmeter.
When using the laptop computer and excavator

diagnostic Program, connect the laptop computer. (See
the installation procedure in this group.) Select 2 EC
angle from the Monitor Data menu.
5. Turn the engine rpm dial to the slow idle position.
6. Turn key switch ON. EC motor goes to the start

position.
7. Measure voltage for each mode. Turn engine rpm dial

to fast idle, push E mode switch, push auto-idle switch
then wait 4 seconds, and then turn engine rpm dial to
slow idle. EC motor must move to each position.
Typical voltage readings for each mode (engine speed)

is:
Specification
Fast Idle in Standard Mode
Voltage......................................................................................... 3.12 volts
E (Economy) ModeVoltage ...................................................... 3.00 volts
9025 Auto-Idle ModeVoltage ............................................................ 2.57 volts
25 Slow IdleVoltage ...................................................................... 2.42 volts
48
For HP (high power) mode, run engine at fast idle, push
HP mode switch, and then actuate arm in over relief.
Typical voltage for HP mode is 3.5 volts.
TX,9025,GG2710 1913OCT002/2

101603
PN=550
Tests
Engine Control Motor (EC Motor) Harness

Tests
ESSENTIAL TOOLS
UN19MAR91
The purpose of test is to check continuity of EC motor
wiring harness (F) and there is a signal from engine and
pump controller (EPC).
T7486AD
NOTE: The laptop computer with excavator diagnostics
program can be used to check the electrical signal
from the engine and pump controller to the engine
control motor. Select 15 EC motor position from
Monitor Data Items. Typical readings are 7276
steps at slow idle to 525550 steps at fast idle.
The readings can vary from machine to machine.
What to look for is that the readings change when
the engine rpm dial is turned, and the E mode,
UN07FEB97
HP mode, or auto-idle mode is actuated.

T106991
components.
DEngine Control Motor
EEngine Control Sensor Wiring Harness 9025
1. Stop engine. Turn key switch to OFF. FEngine Control Motor Wiring Harness 25
49
IMPORTANT: Retainer tab on male half of wiring
harness connector halves must be
apart. Never pull on wiring leads.
2. Push retainer tab down then pull connector halves

apart.
3. Install test harness in series with the engine control

motor wiring harness (F).
4. Turn key switch to ON.
5. While observing test indicator lights,
a. Turn engine rpm dial from slow idle to fast idle,
b. Push E mode switch,

101603
PN=551
Tests
c. Push auto-idle switch; wait approximately 4

seconds,
d. And then turn engine rpm dial to slow idle.
EC motor (D) must move the speed control linkage to

each position. Indicators must be ON and change
randomly from bright to dim or dim to bright as engine
rpm dial and switches are pushed to indicate there is
from the engine and pump controller (EPC).
If one indicator is OFF, check continuity in that circuit.

If both indicators are OFF, check the wiring harness
and relay. (See procedure in Group 9015-15.)
TX,25,GG2223 1913AUG982/2
9025
25
50

101603
PN=552
Tests
Miscellaneous Component Harness Test
ESSENTIAL TOOLS
The purpose of tests are to check continuity in
UN19MAR91
miscellaneous circuits and wiring harnesses when a volt
meter is not available.
T7486AG
components. ABullet Connector
BHarness
CEyelet
Retainer tab on male half of wiring DBullet Connector
harness connector halves must be EIndicator Light
apart. Never pull on wiring leads.
1. Test harness may be used as a probe light. Indicator

light (E) comes ON when connector (A) contacts 24
volts while eyelet (C) or bullet connector (D) is
grounded.
2. Test harness may also be connected in series with

components using bullet connectors (A and D). When 9025
circuit is energized, indicator light (E) comes ON. 25
51
NOTE: Indicator light will not come ON if test harness is
connected to the ground side of a component.
3. Energize circuit being tested.
4. Observe indicator light (E). If light come ON, the fuses,

wiring harness, and switches to accessory have
continuity to the battery.
TX,25,GG2224 1922APR981/1

101603
PN=553
Tests
Cycle Time Test
SPECIFICATIONS
Hydraulic Oil Temperature 50 5C (120 10F)
Engine Speed Fast Idle
Work Mode Selector Position Dig Mode
UN11JAN93
E Mode Switch Position Off
HP Mode Switch Position Off
Auto-Idle Switch Position Off
T7918AO
Boom Raise (Cylinder Extend) 3.0 0.3 sec
Cycle Time
Boom Lower (Cylinder Retract) 2.4 0.3 sec Boom Position
Cycle Time
Arm In (Cylinder Extend) Cycle 3.6 0.3 sec
Time
Arm Out (Cylinder Retract) Cycle 2.4 0.3 sec
Time
Bucket Load (Cylinder Extend) 3.3 0.3 sec
Cycle Time
UN11JAN93
Bucket Dump (Cylinder Retract) 2.1 0.3 sec
Cycle Time
Swing Left or Right3 13.1 1.0 sec
Revolutions From a Running Start
T7918AP
Cycle Time
Propel 20 m (65 ft) From a 13.0 0.6 sec
Running StartCheck Time in Arm, Bucket and Swing Position
9025 Forward and Reverse Fast Speed
25 Propel Cycle Time
52
Propel 20 m (65 ft) From a 20.6 1.0 sec
Running StartCheck Time in
Forward and Reverse Slow
Speed Propel Cycle Time
UN03JAN90
Stop Watch
T7160AL
Test is used as an indication of overall engine and
hydraulic system performance. A slow cycle time is an
indication of a leaky or malfunctioning hydraulic system Propel 3-Revolution Position
component or a weak engine.

101603
PN=554
Tests
1.
Adjust track sag to specifications. (See procedure in

Group 9020-20.)
2. Install the temperature probe on the hydraulic
UN11JAN93
tank-to-pump suction line. (See JT05800 Digital
Thermometer Installation in this group.)
3. Heat hydraulic oil to the specified temperature. (See
T7918AO
Hydraulic System Warm-Up Procedure in this group.)
Specification Boom Position

Hydraulic OilTemperature ................................... 50 5C (120 10F)
4. Move machine to position shown for each test. Run

machine at specifications.
Specification
Work Mode SelectorPosition ................................................... Dig Mode
UN11JAN93
E Mode SwitchPosition ...................................................................... Off
HP Mode SwitchPosition ................................................................... Off
Auto-Idle SwitchPosition .................................................................... Off
T7918AP
5. Actuate control valve to full stroke for each function.
Record the cycle time for each function.
Arm, Bucket and Swing Position
Specification 9025
Boom Raise (Cylinder Extend) 25
Cycle Time............................................................................. 3.0 0.3 sec 53
Boom Lower (Cylinder Retract)
Cycle Time............................................................................. 2.4 0.3 sec
Arm In (Cylinder Extend)Cycle
Time ....................................................................................... 3.6 0.3 sec
Arm Out (Cylinder Retract)
UN03JAN90
Cycle Time............................................................................. 2.4 0.3 sec
Bucket Load (Cylinder Extend)
Cycle Time............................................................................. 3.3 0.3 sec
Bucket Dump (Cylinder Retract)
Cycle Time............................................................................. 2.1 0.3 sec
T7160AL
Swing Left or Right3
Revolutions From a Running
StartCycle Time ............................................................... 13.1 1.0 sec Propel 3-Revolution Position
Propel 20 m (65 ft) From a
Forward and Reverse Fast Speed
PropelCycle Time............................................................. 13.0 0.6 sec
Propel 20 m (65 ft) From a
Forward and Reverse Slow
Speed PropelCycle Time ................................................. 20.6 1.0 sec
TX,9025,GG2116 1918SEP002/2

101603
PN=555
Tests
Swing Dynamic Braking Test
UN19OCT88
SPECIFICATIONS
Oil Temperature 50 5C (120 10F)
Engine Speed in Standard Mode Fast Idle
T6479AY
After 90 (1/4 turn) Swing, 45 (1/8 turn)
Upperstructure Must Stop After
Releasing Control Lever Within
Distance



Specification
OilTemperature ................................................... 50 5C (120 10F)
9025
25
54 CAUTION: Check that area is clear and large
enough to swing upperstructure with arm and
bucket extended. Machine must be on level
ground.
3. Turn upperstructure so boom is to the front
4. Extend the arm and bucket. Lower boom so bucket is

approximately 900 mm (3 ft) above the ground.
5. Operate machine at specifications.
Specification
EngineSpeed in Standard
Mode ............................................................................................. Fast Idle
Continued on next page CED,OUOE003,1075 1913AUG981/2

101603
PN=556
Tests
6. Actuate the swing control lever to full stroke. Swing 90

(1/4 turn) and then release control lever.
Upperstructure must come to a stop within 45 (1/8

turn) after releasing control lever.
Specification
After 90 (1/4 turn) Swing,
Upperstructure Must Stop After
Releasing Control Lever Within
Distance ................................................................................. 45 (1/8 turn)
Repeat procedure in the opposite direction.
If upperstructure does not stop within 45 (1/8 turn), check

the following:
Swing motor leakage. (See procedure in this group.)

Swing motor crossover relief valves. (See procedure
in this group.)
Inspect swing valve spool. (See procedure in Group
3360.)
NOTE: The swing park brake does not stop the

upperstructure. The engagement of swing park
brake is delayed several seconds because
hydraulic oil is released from the piston cavity
through an orifice to return. 9025
25
55
CED,OUOE003,1075 1913AUG982/2

101603
PN=557
Tests
Pilot Pressure Regulating Valve Test and

Adjustment
SPECIFICATIONS
Standard Mode Engine Speed Fast idle
Pilot System Pressure 3925 + 980 - 490 kPa (39.2 + 9.8
- 4.9 bar) (570 + 140 - 70 psi)
Pilot Pressure Regulating Valve 3925 980 kPa (39.2 9.8 bar)
at Slow Idle Pressure (570 140 psi)
Pilot Pressure Regulating Valve 4410 980 kPa (44.1 9.8 bar)
at Fast Idle Pressure (640 140 psi)
Per 0.25 mm (0.010 in.) Shim 78 kPa (0.75 bar) (11 psi)
Approximate Change Pressure
Plug to Pilot Pressure Regulating 25 Nm (215 lb-in.)
Valve Housing Torque
ESSENTIAL TOOLS
9025
25 202862 (3/4-16 M 37 x 3/4-16 F 37 Sw x 7/16-20 M 37) Tee
56 TH108328 Adapter
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler

JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
7000 kPa (70 bar) (1000 psi) Gauge
Purpose of test is to ensure there is enough pilot pressure

to operate all the pilot system functions and to adjust the
pressure as necessary. The pilot pressure regulating valve
is used to regulate the pilot system pressure.

101603
PN=558
Tests
NOTE: The laptop computer with the excavator diagnostic

Program can be used to make a quick check of
the pilot system pressure using the arm in
function. Connect the computer and select 5 Arm
roll-in pilot pressure from monitor data menu.
Run engine at fast idle and then actuate arm in
function over relief. The pressure reading
displayed is from the arm in pressure sensor
located in the flow regulator valve.
Before making any adjustments, check the pilot

pressure at the pilot pump using a pressure
gauge.
1. Stop the engine.
TX,9025,GG2646 1925APR002/5
2. Loosen vent plug (K) to release the air pressure in

hydraulic oil tank.
KVent Plug
9025
UN29APR97
25
57
T109340

101603
PN=559
Tests
3. Disconnect pilot pressure line (D) at pilot filter. Install

tee (B) and male quick coupler. Connect the digital
pressure and temperature analyzer, and transducer, or
a gauge (C).
Pressure can also be checked at the test port in fitting
UN11SEP96
at the pilot pump (F) outlet port. Use adapter (G) in
test port.
NOTE: Because the plug is installed dry at the factory,
T103346
the plug can be difficult to remove.


UN12MAY97
Specification
6. Run machine at specifications.
T109473
Specification
Standard ModeEngine Speed................................................... Fast idle
Work Mode SelectorPosition ................................................... Dig Mode APlug
E Mode SwitchPosition ...................................................................... Off B202862 Tee
9025
HP Mode SwitchPosition ................................................................... Off C7000 kPa (70 bar) (1000 psi) Gauge
25
Auto-Idle SwitchPosition .................................................................... Off DPilot Pressure Line
58
EShim
7. Record pressure reading for pilot pressure regulating FPilot Pump
valve (A). GTH108328 Adapter
Specification
Pilot SystemPressure........................ 3925 + 980 - 490 kPa (39.2 + 9.8
- 4.9 bar) (570 + 140 - 70 psi)

101603
PN=560
Tests
8. As necessary, remove plug for pilot pressure regulating

valve (A). Add shims (E) to increase pressure; remove
shims to decrease pressure.
Specification
Pilot Pressure Regulating Valve
at Slow IdlePressure ........................... 3925 980 kPa (39.2 9.8 bar)
UN11SEP96
(570 140 psi)
Pilot Pressure Regulating Valve
at Fast IdlePressure ........................... 4410 980 kPa (44.1 9.8 bar)
(640 140 psi)
T103347
Per 0.25 mm (0.010 in.) Shim
Approximate ChangePressure ...................... 78 kPa (0.75 bar) (11 psi)
Per 0.5 mm (0.020 in.) Shim
Approximate ChangePressure .................... 157 kPa (1.57 bar) (23 psi)
APilot Pressure Regulating Valve Plug
Per 1.0 mm (0.040 in.) Shim
EShims
Approximate ChangePressure .................... 304 kPa (3.04 bar) (44 psi)
9. Tighten plug to pilot pressure regulating valve housing.
Specification
Plug to Pilot Pressure Regulating
Valve HousingTorque ............................................... 25 Nm (215 lb-in.)
TX,9025,GG2646 1925APR005/5
9025
25
59

101603
PN=561
Tests
Valve Spool Actuating Pilot Pressure Test
SPECIFICATIONS
Engine in Standard Mode Speed Slow Idle and Fast Idle
Valve Spool Actuating Pressure 33353920 kPa (33.339.2 bar)
at Slow Idle and Fast Idle (485570 psi)
Pressure
ESSENTIAL TOOLS
203836 (9/16-18 M 37 x 9/16-18 Sw 37 x 7/16-20 M 37) Tee

Purpose of test is to ensure that the pilot pressure to the

valve spools is enough to shift the spools.
9025
25
60 1. Stop engine.
TX,9025,GG2647 1925APR001/3

hydraulic oil tank.
KVent Plug
UN29APR97
T109340

101603
PN=562
Tests
3. Disconnect a pilot line (A) at pilot cap fitting. Install tee

(B) and male quick coupler. Install the digital pressure
and temperature analyzer, and transducer, or a gauge
(C) .


Specification
UN18JUN96
6. Start and run engine at specification.
Specification
Engine in Standard Mode
T101596
Speed .................................................................... Slow Idle and Fast Idle
HP Mode SwitchPosition ................................................................... Off APilot Line
Auto-Idle SwitchPosition .................................................................... Off BTee
CPressure Gauge
NOTE: Spool actuating pressure can be checked for each
function by installing the tee and gauge in that
pilot line and then actuating that function.
9025
7. Actuate the function being checked to full stroke. 25
61
Specification
Valve Spool Actuating Pressure
at Slow Idle and Fast Idle
Pressure ............................................... 33353920 kPa (33.339.2 bar)
(485570 psi)
If valve spool actuating pressure is not to specification,

check pilot system pressure. (See Pilot Pressure
Regulating Valve Test and Adjustment in this group.
If pilot system pressure is to specification, then check pilot

pressure at the pilot shut-off valve, pilot controllers, and
flow regulator.
TX,9025,GG2647 1925APR003/3

101603
PN=563
Tests
System Relief and Power Boost Valve Test and Adjustment
SPECIFICATIONS The purpose of the system relief valve is to limit the

System Relief and Power Boost Valve maximum system pressure in the hydraulic system.
Hydraulic Oil Temperature 4555C (110130F) Power boost is a temporary increase of the system
Engine Fast Idle in Standard 20752125 rpm pressure. The valve is checked and adjusted to protect
Mode Speed components from damage cause by excessive
pressures.
1. Install the temperature reader. Install probe on
HP Mode Switch Position Off hydraulic oil tank-to-pump suction line. (See
Auto-Idle Switch Position Off JT05800 Digital Thermometer Installation in this
System Relief Valve Pressure 34 32536 285 kPa (343.0 group.)
362.6 bar) (49805265 psi)
Power Boost Valve Pressure 35 30538 245 kPa (353.1 NOTE: Test can be done using one of three types of
382.5 bar) (51255550 psi) test equipment.
First Adjusting Plug Pressure 7110 kPa (71.1 bar) (1030 psi)
Change approximate per 1/4 turn 2. Go to the step for instructions to connect preferred
32 mm Nut Torque 7888 Nm (5865 lb-ft) test equipment to the machine:
Second Adjusting Plug 5295 kPa (53.0 bar) (770 psi)
Pressure Change approximate per 1/4 turn ServiceEXPERT Application,
27 mm Nut Torque 5968 Nm (4351 lb-ft) Excavator Diagnostics Program,
Digital Pressure/Temperature Analyzer or Gauge.
ESSENTIAL TOOLS
TH108328 Adapter (2 used)
9025
62
9239-096 CED W9 Cable
Laptop Computer with ServiceEXPERT Application
JT07273 Cable
JT02156A Digital Pressure/Temperature Analyzer
JT02160 Transducer 70 000 kPa (700 bar) (10,000 psi)
Gauge 70 000 kPa (700 bar) (10,000 psi)
6 mm Hex Key Wrench
15, 17, 19, 27 and 32 mm Combination Wrenches

101603
PN=564
Tests
3. ServiceEXPERT Application connection
a. Connect the laptop computer to the diagnostic port

(2) using the CED W9 Cable. Port is located behind
the left rear corner of operators seat.
1929AUG96
b. Select the System Relief and Power Boost Valve
Test template.
NOTE: Front and rear pump control pressures are
T102900
monitored to check that pump control pressure
signals to the main hydraulic pump regulators
increases as function is actuated. A low pump
control pressure signal can cause system
pressure to be low because pump displacement
does not increase to generate enough oil flow.
c. Go to Test and Adjustment step.
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
63
T133476
ServiceEXPERT is a trademark of Deere & Company Continued on next page TX,9025,GG2648 1924OCT002/6

101603
PN=565
Tests
4. Excavator Diagnostics Program connection

(2) using the cable. Port is located behind the left
rear corner of operators seat.
1929AUG96
b. Start the engine.
c. Select items from the Monitor Data menu:
T102900
3-Front pump delivery pressure,
4-Rear pump delivery pressure,
1-Front pump control pressure,
6-Rear pump control pressure,
14-Actual engine speed.

monitored to check that pump control pressure
d. Go to Test and Adjustment step.
UN28AUG00
9025 1Fuse Box
25 2Diagnostic Port
64 3Learning Switch
T133476

101603
PN=566
Tests
5. Digital Pressure/Temperature Analyzer or Gauge

connection
a. Stop the engine.
b. Loosen vent plug (K) to release the air pressure in
UN29APR97
hydraulic oil tank.
c. Install adapter (A) and male quick coupler to test

port on front pump (C) or rear pump (B). Connect
T109340
the analyzer and transducers or gauges.
d. Install a tachometer. (See JT05801 Clamp-On

Electronic Tachometer Installation in this group.)
e. Go to Test and Adjustment step.
6. Test and Adjustment
a. Raise and lower boom to pressurize hydraulic oil

tank.
b. Do Hydraulic System Warm-Up Procedure to heat

hydraulic oil. (See procedure in this group.)
System Relief and Power Boost ValveSpecification

Hydraulic OilTemperature ................................. 4555C (110130F)
UN18JUN96
9025
25
65
c. Run machine at specification.
T101614
ModeSpeed .................................................................. 20752125 rpm
AAdapter
BRear Pump
CFront Pump
KVent Plug
d. Actuate the arm in function over relief. Record the

pressure reading.
e. Actuate bucket dump function over relief and then

push the power boost button on right control lever.
Record pressure reading for power boost.

101603
PN=567
Tests
f. Adjust the system relief and power boost valve (D)

pressures as needed.

System Relief ValvePressure ................................ 34 32536 285 kPa
(343.0362.6 bar) (49805265
psi)
Power Boost ValvePressure .................................. 35 30538 245 kPa
(353.1382.5 bar) (51255550
psi)
g. Disconnect pilot line from elbow in system relief

valve so adjustment can be made without twisting
UN18JUN96
power boost pilot line. Connect pilot line before
starting engine and applying pressure.
h. Loosen 27 mm nut (F).
T101616
i. Turn first adjusting plug (E) in until piston (I) is
against bottom of bore in second adjusting plug (G).
Tighten nut. Connect pilot line. DSystem Relief Valve
EFirst Adjusting Plug
F27 mm Nut
j. Loosen 32 mm nut (H). GSecond Adjusting Plug
H32 mm Nut
k. Start engine. Actuate the arm in function over relief. IPiston
9025
l. Turn second adjusting plug in to increase power
25
66 boost pressure; turn adjusting plug out to decrease
pressure.
Hold adjusting plug and tighten 32 mm nut.

First Adjusting PlugPressure
Change ..................................................... 7110 kPa (71.1 bar) (1030 psi)
approximate per 1/4 turn
32 mm NutTorque ......................................... 7888 Nm (5865 lb-ft)
m. Loosen 27 mm nut (F).
n. Actuate the arm in function over relief.
o. Turn first adjusting plug (E) out to decrease

pressure to get specified pressure for system relief
valve.

101603
PN=568
Tests
Hold adjusting plug and tighten 27 mm nut.

Second Adjusting PlugPressure
Change ....................................................... 5295 kPa (53.0 bar) (770 psi)
27 mm NutTorque ......................................... 5968 Nm (4351 lb-ft)
p. Check the pressures again.
TX,9025,GG2648 1924OCT006/6
9025
25
67

101603
PN=569
Tests
Circuit Relief Valve Test and Adjustment
SPECIFICATIONS The purpose of circuit relief valves is to relieve high

Circuit Relief Valve pressure spike caused by external forces when
Hydraulic Oil Temperature 4555C (110130F) functions are in neutral. The valves are checked and
Engine Slow Idle in Standard 875925 rpm adjusted to specification to protect components from
Mode Speed damage.
1. Install the temperature reader. Install probe on
hydraulic oil tank-to-pump suction line. (See
HP Mode Switch Position Off JT05800 Digital Thermometer Installation in this
Power Boost Switch Position Off group.)
Boom Up (Head End) Pressure 37 26538 245 kPa (372.7 NOTE: Test can be done using one of three types of
382.5 bar) (54055545 psi) test equipment.
Arm In (Head End) Pressure 37 26538 245 kPa (372.7
382.5 bar) (54055545 psi) 2. Go to the step for instructions to connect preferred
Bucket Curl (Head End) 37 26538 245 kPa (372.7 test equipment to the machine:
Pressure 382.5 bar) (54055545 psi)
Boom Down (Rod End) 37 26538 245 kPa (372.7 ServiceEXPERT Application,
Pressure 382.5 bar) (54055545 psi) Excavator Diagnostics Program,
Arm Out (Rod End) Pressure 39 22540 205 kPa (392.3 Digital Pressure/Temperature Analyzer or Gauge.
402.1 bar) (56905830 psi)
Bucket Dump (Rod End) 39 22540 205 kPa (392.3
Circuit Relief Valve Adjusting 5295 kPa (53 bar) (770 psi)
Screw Pressure Change approximate per 1/4 turn
9025
25
68 ESSENTIAL TOOLS

JT07273 Cable
Gauge 70 000 kPa (700 bar) (10,000 psi)
6 mm Hex Key Wrench
17 mm Combination Wrench

101603
PN=570
Tests

1929AUG96
b. Select the Circuit Relief Valve template.

monitored to check that the pump control pressure
T102900
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
69
T133476

101603
PN=571
Tests

(2) using the cable. Port is located behind the left
rear corner of operators seat.
1929AUG96
T102900

UN28AUG00
9025 1Fuse Box
25 2Diagnostic Port
70 3Learning Switch
T133476

101603
PN=572
Tests

connection
a. Stop the engine.
UN29APR97
hydraulic oil tank.

T109340

AAdapter
BRear Pump
CFront Pump
KVent Plug
UN18JUN96
9025
25
71
T101614

101603
PN=573
Tests
a. Turn the second adjusting plug (G) for system relief

valve (D) in 1/4 turn to increase the pressure
setting.
b. Raise and lower boom to pressurize hydraulic oil

tank.
c. Do Hydraulic System Warm-Up Procedure to heat

Circuit Relief ValveSpecification

UN18JUN96
d. Extend the cylinder to check a head end circuit
T101616
relief valve; retract the cylinder to check a rod end
circuit relief valve.
e. Run machine at specifications. DSystem Relief Valve

Circuit Relief ValveSpecification F27 mm Nut
Engine Slow Idle in Standard GSecond Adjusting Plug
ModeSpeed ...................................................................... 875925 rpm H32 mm Nut
Work Mode SelectorPosition ................................................... Dig Mode IPiston
9025 HP Mode SwitchPosition ................................................................... Off
25 Power Boost SwitchPosition .............................................................. Off
72 Auto-Idle SwitchPosition .................................................................... Off

101603
PN=574
Tests
UN29APR97
UN29APR97
T109335
T109334
NOTE: If pressure reading fluctuates increase engine
speed slightly.
f. Actuate function over relief for circuit relief valve (J, 9025
K, L, M, N, and O) being checked. Record pressure 25
73
reading.

Boom Up (Head End)Pressure .............................. 37 26538 245 kPa
(372.7382.5 bar) (54055545
psi)
Arm In (Head End)Pressure .................................. 37 26538 245 kPa
(372.7382.5 bar) (54055545
psi)
UN29APR97
Bucket Curl (Head End)
Pressure .................................................................... 37 26538 245 kPa
(372.7382.5 bar) (54055545
psi)
T109336
Boom Down (Rod End)
Pressure .................................................................... 37 26538 245 kPa
(372.7382.5 bar) (54055545
psi)
Arm Out (Rod End)Pressure ................................. 39 22540 205 kPa DSystem Relief Valve
(392.3402.1 bar) (56905830 JArm Out Circuit Relief Valve
psi) KBoom Up Circuit Relief Valve
Bucket Dump (Rod End) LBucket Dump Circuit Relief Valve
Pressure .................................................................... 39 22540 205 kPa MBoom Down Circuit Relief Valve
(392.3402.1 bar) (56905830 NBucket Curl Circuit Relief Valve
psi) OArm In Circuit Relief Valve

101603
PN=575
Tests
g. Adjust the circuit relief valve as needed. Turn

adjusting screw IN to increase pressure setting; turn
adjusting screw out to decrease pressure setting.
Hold screw and tighten nut.

Circuit Relief Valve Adjusting
ScrewPressure Change ............................. 5295 kPa (53 bar) (770 psi)
h. Turn the second adjusting plug (G) for system relief

and power boost valve out to its original setting.
Hold plug and tighten 32 mm nut.
i. Do System Relief and Power Boost Valve Test and

Adjustment to check pressure. (See procedure in
this group.)
TX,9025,GG2649 1925OCT007/7
9025
25
74

101603
PN=576
Tests
Swing Motor Crossover Relief Valve Test and Adjustment
SPECIFICATIONS The purpose of swing crossover relief valves is to limit

Swing Motor Crossover Relief Valve pressure in the swing circuit, to relieve high pressure
Hydraulic Oil Temperature 4555C (110130F) spike caused by starting and stopping the swing
Engine Slow Idle in Standard 875925 rpm function and to relieve pressure spikes caused by
Mode Speed external forces when function is in neutral. The valves
are checked and adjusted to specification to protect
components from damage.
HP Mode Switch Position Off 1. Install the temperature reader. Install probe on
Auto-Idle Switch Position Off hydraulic tank-to-pump suction line. (See JT05800
Crossover Relief Valve 27 65529 615 kPa (276.6 Digital Thermometer Installation this group.)
Relief Valve Adjusting Plug 2940 kPa (29.4 bar) (430 psi) NOTE: Test can be done using one of three types of
Pressure Change approximate per 1/4 turn test equipment.
ESSENTIAL TOOLS 2. Go to the step for instructions to connect preferred

TH108328 Adapter (2 used) test equipment to the machine:
ServiceEXPERT Application,
SERVICE EQUIPMENT AND TOOLS Excavator Diagnostics Program,
JT05800 Digital Thermometer Digital Pressure/Temperature Analyzer or Gauge.
9025
JT07274J Excavator Diagnostics Program Disk 25
JT07273 Cable 75
Gauge 70 000 kPa (700 bar) (10,000 psi)
8 mm Hex Key Wrench
17, 32, and 36 mm Combination Wrench

101603
PN=577
Tests

1929AUG96
b. Select the Swing Motor Crossover Relief Valve Test
template.
T102900
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
76
T133476

101603
PN=578
Tests
a. Connect the laptop computer to diagnostic port (2)

using the cable. Port is located behind the left rear
corner of operators seat.
1929AUG96
T102900

UN28AUG00
1Fuse Box 9025
2Diagnostic Port 25
3Learning Switch 77
T133476

101603
PN=579
Tests

connection
a. Stop the engine.
UN29APR97
hydraulic oil tank.

T109340

a. Raise and lower boom to pressurize hydraulic oil

tank.
b. Do Hydraulic System Warm-Up Procedure to heat

Swing Motor Crossover Relief ValveSpecification

UN18JUN96
9025
25
78
c. Run machine at specifications.
T101614
Engine Slow Idle in Standard
ModeSpeed ...................................................................... 875925 rpm
AAdapter
BRear Pump
CFront Pump
KVent Plug
d. Operate the swing function at stall. To stall swing

function, put bucket against an immovable object or
in a trench then slowly actuate the control lever to
full stroke.
Record the pressure reading.

101603
PN=580
Tests
e. Repeat procedure for the opposite direction. Record

the pressure reading.

Crossover Relief ValvePressure ............................ 27 65529 615 kPa
(276.6296.2 bar) (40104295
psi)
TX,9025,GG2650 1925OCT005/6
f. Adjust the left and right swing crossover relief valves

(C or D) as needed. Loosen nut (E). Turn adjusting
plug (F) in to increase pressure setting; turn
adjusting plug out to decrease pressure setting.

Relief Valve Adjusting Plug
Pressure Change........................................ 2940 kPa (29.4 bar) (430 psi)
CRight Swing Crossover Relief Valve

DLeft Swing Crossover Relief Valve
ENut
FAdjusting Plug 9025
25
79
UN20JUN96
T101716
TX,9025,GG2650 1925OCT006/6

101603
PN=581
Tests
Propel Motor Crossover Relief Valve Test and Adjustment
SPECIFICATIONS The purpose of propel crossover relief valves is to

Propel Motor Crossover Relief Valve relieve high pressure spike caused by starting and
Hydraulic Oil Temperature 4555C (110130F) stopping the propel function and to relieve pressure
Engine Slow Idle in Standard 875925 rpm spikes caused by external forces while propelling. The
Mode Speed valves are checked and adjusted to specification to
protect components from damage.
1. Install the temperature reader. Install probe on the
HP Mode Switch Position Off hydraulic oil tank-to-pump suction line. (See
Auto-Idle Switch Position Off JT05800 Digital Thermometer Installation in this
Crossover Relief Valve 34 815 36 775 kPa (348.1 group.)
Crossover Relief Valve 2940 kPa (29.4 bar) (430 psi) NOTE: Test can be done using one of three types of
Adjusting Screw Pressure approximate per 1/4 turn test equipment.
Change
2. Go to the step for instructions to connect preferred

ESSENTIAL TOOLS
test equipment to the machine:
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler ServiceEXPERT Application,
Excavator Diagnostics Program,
SERVICE EQUIPMENT AND TOOLS Digital Pressure/Temperature Analyzer or Gauge.
9025 JT07290 Laptop Computer
25
80 JT07274J Excavator Diagnostics Program Disk
JT07273 Cable
Gauge 70 000 kPa (700 bar) (10,000 psi)
85 mm (3-3/8 in.) OD Pin or Length of Round Bar Stock (2 used)
6 mm Hex Key Wrench

101603
PN=582
Tests

1929AUG96
b. Select the Propel Motor Crossover Relief Valve Test
template.
T102900
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
81
T133476

101603
PN=583
Tests

1929AUG96
T102900

UN28AUG00
9025 1Fuse Box
25 2Diagnostic Port
82 3Learning Switch
T133476

101603
PN=584
Tests

connection
a. Stop the engine.
UN29APR97
hydraulic oil tank
c. Install adapters (A) and male quick coupler to test

T109340

AAdapters
BRear Pump
CFront Pump
KVent Plug
UN18JUN96
9025
25
83
T101614

101603
PN=585
Tests
NOTE: The pressure setting for propel motor crossover

relief valves are higher than the system relief and
power boost valve.
a. Turn the second adjusting plug (G) for system relief

and power boost valve (D) in 1/4 turn to increase
the pressure setting.
b. Raise and lower boom to pressurize hydraulic oil

tank.
c. Do Hydraulic System Warm-Up Procedure to heat
UN18JUN96
Propel Motor Crossover Relief ValveSpecification

T101616
DSystem Relief and Power Boost Valve
F27 mm Nut
GSecond Adjusting Plug
H32 mm Nut
IPiston
9025
25
84
TX,9025,GG2651 1926OCT005/7
d. Install pins or round bar stock (D) between the

sprockets and track frame to stall both propel
motors.
e. Run machine at specifications.

UN02JUL96

Engine Slow Idle in Standard
ModeSpeed ...................................................................... 875925 rpm
T101856

DPin Or Round Bar Stock

101603
PN=586
Tests
f. Slowly push propel pedal, for propel motor being

stalled, to full travel in the direction for the crossover
relief valve (E and F) being checked.
Record the pressure reading.
UN02JUL96
Crossover Relief ValvePressure ........................... 34 815 36 775 kPa
(348.1367.8 bar) (50505335
psi)
T101857
g. Adjust the crossover relief valves as needed. Turn EForward Crossover Relief Valve
adjusting screw in to increase the pressure setting; FReverse Crossover Relief Valve
turn adjusting screw out to decrease pressure.

Crossover Relief Valve Adjusting
ScrewPressure Change .......................... 2940 kPa (29.4 bar) (430 psi)
h. Repeat procedure for the other crossover relief

valves.
i. Turn second adjusting plug for system relief and

power boost valve out to its original setting. Hold 9025
25
plug and tighten 32 mm nut.
85
j. Do System Relief and Power Boost Valve Test and

Adjustment to check pressure. (See procedure in
this group.)
TX,9025,GG2651 1926OCT007/7

101603
PN=587
Tests
Proportional Solenoid Valve Test and Adjustment
SPECIFICATIONS SERVICE EQUIPMENT AND TOOLS

Proportional Solenoid Valves JT02156A Digital Pressure/Temperature Analyzer
Hydraulic Oil Temperature 4555C (110130F) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
Engine in Standard Mode as specified for each function 7000 kPa (70 bar) (1000 psi) Gauge
Speed JT05800 Digital Thermometer
E Mode Switch Position Off Laptop Computer with ServiceEXPERT Application
HP Mode Switch Position Off JT07290 Laptop Computer
Auto-Idle Switch Position Off JT07274J Excavator Diagnostics Program
Arm Regenerative (SC) Laptop Computer Reading JT07273 Cable
Pressure 196 kPa (1.96 bar) (28 psi)
4 mm Hex Key Wrench
Speed Sensing (SD) Pressure Laptop Computer Reading
196 kPa (1.96 bar) (28 psi) 13 mm Combination Wrench
Propel Speed Change (SI) Laptop Computer Reading
Pressure 196 kPa (1.96 bar) (28 psi) Procedure is to check that the output pressure from
Power Boost (SG) Pressure Laptop Computer Reading the proportional solenoid valves to the functions are
196 kPa (1.96 bar) (28 psi) within the specified pressure range of readings shown
Solenoid Valve Adjusting Screw 98 kPa (0.98 bar) (14 psi) on the computer screen. Pressure readings shown on
Pressure Change approximate per 1/4 turn the computer screen are calculated from the electrical
End of Adjusting Screw to Nut 4 mm (0.157 in.) signal in the engine and pump controller (EPC). These
Must Not Exceed Length readings do not change as the valve adjustments are
Solenoid Valve Adjusting 8.8 Nm (78 lb-in.) made.
Screw-to-Housing Nut Torque
A laptop computer with ServiceEXPERT Application
9025
ESSENTIAL TOOLS or Excavator Diagnostics Program loaded is used
25
86 JT03191 (7/16-20M 37 x 7/16-20 F 37 x 7/16-20 M 37) (Parker along with transducers or pressure gauges to perform
No. 063T-4-4) Tee the proportional solenoid valve test and adjustment.
JT03464 (1/4 M BSPP ORB x 7/16-20 M 37 x M14-1.5 M 45)
(for the steel line) Tee

101603
PN=588
Tests
1. Stop the engine.

hydraulic oil tank.
3. Disconnect the line (D, E, F, or G) at solenoid valve
UN29APR97
manifold (A) for solenoid valve (H) being checked.
4. Install test connection (B and C). For steel line (D)

from the arm regenerative solenoid valve (SC) use the
T109340
JT03464 Tee. Use the JT03191 Tee for the others.
5. Connect the digital pressure/temperature analyzer and

transducer or a gauge.
6. Install the temperature reader. Install probe on the

hydraulic tank-to-pump suction line. (See JT05800
Digital Thermometer Installation in this group.)
ASolenoid Valve Manifold

BJT03464 Tee or JT03191 Tee
CGauge
DArm Regenerative Solenoid Valve (SC) Line
ESpeed Sensing Solenoid Valve (SD) Line
FPropel Speed Change Solenoid Valve (SI) Line
GPower Boost Solenoid Valve (SG) Line
HSolenoid Valve (4 used)
KVent Plug
UN20JUN96
9025
25
87
T101708

101603
PN=589
Tests
7. Connect the laptop computer to diagnostic port (2)

a. For ServiceEXPERT Application select the

template for proportional solenoid valve being
1929AUG96
checked:
Arm Regenerative Proportional Solenoid Valve

Test
T102900
Speed Sensing Proportional Solenoid Valve Test
Propel Speed Change Proportional Solenoid
Valve Test
Power Boost Proportional Solenoid Valve Test
b. For Excavator Diagnostics Program select items

from the Monitor Data menu for each test:
9-Arm regenerative control pressure,

10-Propel motor control pressure and 26-Selected
propel speed switch,
11-Speed sense control pressure,
12-Power boost control pressure and 25-Power
boost switch,
UN28AUG00
9025
25
88 8. Do Hydraulic System Warm-Up Procedure to heat
T133476
Proportional Solenoid ValvesSpecification
9. Run the machine at specification. 1Fuse Box

2Diagnostic Port
Proportional Solenoid ValvesSpecification 3Learning Switch
Speed .......................................................... as specified for each function

101603
PN=590
Tests
10. Operate the machine as follows to check each

solenoid valve (AD). Record the pressure readings
from gauge and computer screen:
Arm regenerative solenoid valve (SC)

Speed sensing solenoid valve (SD)
UN28AUG96
Propel speed change solenoid valve (SI)
Power boost solenoid valve (SG)
a. Arm regenerative solenoid valve (SC)fill bucket
T103345
with dirt, run engine at less than 1200 rpm then
operate boom up and arm in functions in combined
operation.
BSpeed Sensing Solenoid Valve (SD)
NOTE: Pressure reading shown on the computer screen CPropel Speed Change Solenoid Valve (SI)
for Arm regenerative control pressure is a DPower Boost Solenoid Valve (SG)
calculated pressure from the electrical signal in
the engine and pump controller. A typical reading
increases to 399.3 psi while operating the boom
up and arm in functions in combined operation
with engine speed at 1200 rpm or less. The
reading indicates that the rear pump pressure
sensor, arm in pressure sensor, and boom up
pressure switch are OK and a electrical signal is
generated. When all functions are in neutral, a
typical reading of 170.4 psi is displayed at fast or
slow idle. See Arm Regenerative Valve Operation
9025
for circuit operation. (See theory of operation in 25
Group 9025-05.) 89
b. Speed sensing solenoid valve (SD)run engine at

875925 rpm, operate a function over relief to
load the engine if needed.

101603
PN=591
Tests
NOTE: Pressure reading shown on the computer screen

for Speed sense control pressure is a calculated
and pump controller. When all functions are in
neutral, a typical reading of 532.8 psi is displayed
at slow idle and 0 psi at fast idle. The pressure
reading decreases as the engine speed increases.
The reading indicates that the engine speed
sensor is OK, the signal for target engine speed is
selected by the engine rpm dial, and a electrical
signal is generated. See Engine Speed Sensing
Control Circuit Operation. (See theory of operation
in Group 9025-05.)
c. Propel speed change solenoid valve (SI)run

engine at 1200 rpm or more, drive the machine at
fast speed propel.

for Propel motor control pressure is a calculated
and pump controller. A typical reading of 65.9 psi
is displayed when propel function is in neutral or
propelling in slow speed. A typical reading of 426
psi is displayed when propelling in fast speed with
no other function actuated. The reading for Propel
Speed Switch goes to FAST. The readings
9025
25 indicates that the propel speed switch, propel and
90 dig pressure switches, front and rear pump control
pressure sensors, and front and rear pump
pressure sensors are OK and a electrical signal is
generated. See Propel Motor Speed Change
Circuit Operation. (See theory of operation in
Group 9025-05.)
d. Power boost solenoid valve (SG)run engine at

875925 rpm, push and release power boost
button on right control lever.

101603
PN=592
Tests

for Power boost control pressure is a calculated
and pump controller. A typical reading of 426 psi
is displayed when power boost switch on the right
control lever is pushed. A reading of 0 psi is
displayed when the switch is not pushed. The
readings indicates that the power boost switch is
OK and a electrical signal is generated. The
power boost solenoid valve is also actuated in
precision work mode when boom up function is
actuated. See Power Boost Control Circuit
Operation. (See theory of operation in Group
9025-05.)
11. Compare the pressure readings. The pressure

reading on gauge must be within the specified range
of calculated pressure reading on the computer
screen.
Proportional Solenoid ValvesSpecification

Arm Regenerative (SC)
Pressure ................................................ Laptop Computer Reading 196
kPa (1.96 bar) (28 psi)
Speed Sensing (SD)Pressure............ Laptop Computer Reading 196
kPa (1.96 bar) (28 psi)
Propel Speed Change (SI)
Pressure ................................................ Laptop Computer Reading 196
kPa (1.96 bar) (28 psi) 9025
Power Boost (SG)Pressure ............... Laptop Computer Reading 196 25
kPa (1.96 bar) (28 psi) 91

101603
PN=593
Tests
12. Adjust the solenoid valve (H) as needed.
a. Make a mark on the end of adjusting screw (I) to

indicate the original position of screw. Do not mark
on threads of screw.
UN20JUN96
IMPORTANT: Turning adjusting screw out too far may
cause oil leakage because the O-ring
has come off its seat.
T101709
b. Loosen nut (J) just enough so adjusting screw can
be turned.
c. Turn adjusting screw (I) IN to increase pressure HSolenoid Valve

IAdjusting Screw
setting; turn adjusting screw OUT to decrease JNut
pressure setting. Remember, the length from end
of adjusting screw to nut must not exceed 4 mm
(0.157 in.).
Proportional Solenoid ValveSpecification

Solenoid Valve Adjusting Screw
Pressure Change.............................................. 98 kPa (0.98 bar) (14 psi)
End of Adjusting Screw to Nut
Must Not ExceedLength .............................................. 4 mm (0.157 in.)
9025
25 d. Hold adjusting screw and then tighten nut.
92
Proportional Solenoid ValveSpecification
Solenoid Valve Adjusting
Screw-to-Housing NutTorque .................................... 8.8 Nm (78 lb-in.)
e. Check the pressure setting again.
TX,9025,GG2121 1924OCT007/7

101603
PN=594
Tests
Pump Control Valve Test
SPECIFICATIONS The function of pump control valves is to send a

Pump Control Valve regulated pilot oil control signal to its respective pump
Hydraulic Oil Temperature 4555C (110130F) regulator to change pump flow in response to the
Engine Slow to Fast Idle in 8752125 rpm actuation of control valve spools.
Standard Mode Speed
The purpose of test is to check that the regulated pilot
oil control signals from the pump control valves to the
pump regulators increases as a function is actuated
HP Mode Switch Position Off and decreases when function is returned to neutral.
Auto-Idle Switch Position Off The control signal is checked by monitoring the front
Front or Rear Pump Control 9801570 kPa (9.815.7 bar) and rear pump control pressure sensor readings. The
Valve Control Signal Pressure (142228 psi) all functions in valves are adjusted at the factory and there should
neutral, engine at slow to fast never be any need for an adjustment in the field. For
idle
operation, go to Pump Control Valve Operation. (See
Front or Rear Pump Control 35163723 kPa (35.237.2
theory of operation in Group 9025-05.)
Valve Control Signal Pressure bar) (425570 psi) with track
raised at full speed, engine at
fast idle 1. Install the temperature reader. Install probe on the
hydraulic oil tank-to-pump suction line. (See
ESSENTIAL TOOLS JT05800 Digital Thermometer Installation in this
JT03191 (7/16-20 M 37 x 7/16-20 M 37 x 7/16-20 F 37) (Parker
group.)
No. 063T4) Tee (2 used)
XPD34BTX (1/8 x 7/16-20 F 37) Male Quick Coupler NOTE: Test can be done using one of three types of
test equipment.
2. Go to the step for instructions to connect preferred
JT05800 Digital Thermometer 9025
test equipment to the machine: 25
93
Laptop Computer with ServiceEXPERT Application ServiceEXPERT Application,
JT07290 Laptop Computer Excavator Diagnostics Program,
JT07274J Excavator Diagnostics Program Disk Digital Pressure/Temperature Analyzer or Gauge.
JT07273 Cable
8 mm Hex Key Wrench

101603
PN=595
Tests

1929AUG96
b. Select the Pump Control Valve Test template.
T102900
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
94
T133476

101603
PN=596
Tests

1929AUG96
T102900
1Fuse Box
2Diagnostic Port
3Learning Switch
UN28AUG00
9025
25
95
T133476

101603
PN=597
Tests

connection
a. Stop the engine.
UN29APR97
hydraulic oil tank
c. Install tees (C) and male quick couplers in line with

control valve pilot lines at rear (A) and front (B)
T109340
pump regulators. Connect the analyzer and
transducer, or gauge (D).

a. Do Hydraulic System Warm-Up Procedure to heat

Pump Control ValveSpecification

UN11SEP96
9025
25
b. Run machine at specification.
96
T103348
Engine Slow to Fast Idle in
Standard ModeSpeed .................................................... 8752125 rpm
HP Mode SwitchPosition ................................................................... Off ARear Pump Regulator
Auto-Idle SwitchPosition .................................................................... Off BFront Pump Regulator
CTee(s)
DGauge(s)
KVent Plug
c. Run engine at slow to fast idle with all functions in

neutral.
Record pressure readings for pump control valves

at slow and fast idle. The pressure decreases as
engine speed increases.
d. Raise left track off the ground to check rear pump

control valve or right track for front pump control
valve.

101603
PN=598
Tests
Actuate the raised track to full speed. Increase

engine speed to fast idle.
Record pressure reading at fast idle. The pressure

increases as engine speed increases.
TX,9025,GG2652 1926OCT005/6
e. A pressure reading not in the ranges given can be

an indication of contamination or sticking spools in
the front (F) or rear (H) pump control valve.
Before making any adjustments, check the front and

rear pump control valve pressure sensors and the
operation of remote control spool in front and rear
pump regulators.

Front or Rear Pump Control
Valve Control SignalPressure ............... 9801570 kPa (9.815.7 bar)
(142228 psi) all functions in
neutral, engine at slow to fast idle 9025
Front or Rear Pump Control 25
UN13SEP96
Valve Control SignalPressure ........... 35163723 kPa (35.237.2 bar) 97
(425570 psi) with track raised
at full speed, engine at fast idle
T103491
For an adjustment to the front pump control valve, use
the right propel with track raised or bucket function
over relief. For an adjustment to the rear pump control
valve use the left propel with track raised or swing
function over relief for the rear pump control valve.
Turn the adjusting screw in to increase pressure
reading; turn adjusting screw out to decrease pressure
reading. Tighten nut.
ERight Control Valve

FFront Pump Control Valve
GLeft Control Valve
HRear Pump Control Valve
UN13SEP96
T103492
TX,9025,GG2652 1926OCT006/6

101603
PN=599
Tests
Hydraulic Pump Regulator Adjustments
UN15MAY01
T141914
9025
25
98 A13 mm Nut D30 mm Nut HLoad Adjusting Screw J30 mm Nut
BMaximum Flow Adjusting EMinimum Flow Adjusting (Inner Spring) (Engine
Screw Screw Pulldown at High Pressure)
CFlow Adjusting Cartridge F17 mm Nut ILoad Adjusting Cartridge
(Track Cycle Time) G17 mm Nut (Outer Spring) (Engine
Pulldown at Medium
Pressure)

101603
PN=600
Tests
SPECIFICATIONS Flow Adjusting Cartridge (Track Cycle Time) (C):

Regulator Maximum Flow 1/4 turn IN decreases Turning adjusting cartridge IN decreases pump flow
Adjusting Screw Turn maximum pump flow rate rate.
approximately 11 L/min
(3 gpm) Specification
Regulator Flow Adjusting 1/4 turn IN decreases pump Regulator Flow Adjusting
Cartridge (Track Cycle Time) flow rate approximately 22.5 Cartridge (Track Cycle Time)
Turn L/min (6 gpm) Turn......................................................... 1/4 turn IN decreases pump
flow rate approximately 22.5
Regulator Minimum Flow 1/4 turn IN increases minimum
L/min (6 gpm)
Adjusting Screw Turn pump flow rate approximately
13.6 L/min (3.6 gpm)
Regulator Load Adjusting 1/4 turn IN increases pump flow Do not turn adjusting cartridge more than one turn.
Screw (Inner Spring) (Engine rate approximately 5.46 L/min Tighten nut (D) after adjustment. When flow adjusting
Pulldown at High Pressure) (1.45 gpm) cartridge (C) is turned in or out the maximum flow rate
Turn for the pump also changes. To maintain the pumps
Regulator Load Adjusting 1/4 turn IN increases pump flow maximum flow rate, turn maximum flow adjusting
Cartridge (Outer Spring) rate approximately 22.5 L/min screw (B) out twice as much as flow adjusting
(Engine Pulldown at Medium (6 gpm)
cartridge (C) is turned in; turn maximum flow adjusting
Pressure) Turn
screw (B) in twice as much as flow adjusting cartridge
(C) is turned out.
The pumps are driven at engine speed.
For adjustment, see Hydraulic Pump Regulator Test
IMPORTANT: Random adjustment will cause and AdjustmentMaximum Flow in this group.
engine and hydraulic systems
malfunctions. See Pump Regulator Minimum Flow Adjusting Screw (E):
Tests and Adjustment for Minimum Turning adjusting screw IN increases minimum flow
Flow , Maximum Flow and Engine rate.
Pulldown in this group.
9025
Specification
25
Maximum Flow Adjusting Screw (B): Regulator Minimum Flow
99
Turning adjusting screw IN decreases maximum pump Adjusting ScrewTurn ....................... 1/4 turn IN increases minimum
pump flow rate approximately
flow rate.
13.6 L/min (3.6 gpm)
Specification
Regulator Maximum Flow For adjustment, see Hydraulic Pump Regulator Test
Adjusting ScrewTurn ..................................... 1/4 turn IN decreases and AdjustmentMinimum Flow in this group.
maximum pump flow rate
approximately 11 L/min Do not turn adjusting more than two turns. Tighten nut
(3 gpm)
(F) after adjustment.
Do not turn adjusting screw in more than two turns.
Load Adjusting Screw (Inner Spring) (Engine
Tighten nut (A) after adjustment. Maximum flow
Pulldown at High Pressure) (H):
adjusting screw must not be turned out to try to
Turning load adjusting screw IN increases flow rate.
increase pump flow rate except after the adjustment of
flow adjusting cartridge (C). For adjustment, see
Hydraulic Pump Regulator Test and Adjustment
Maximum Flow in this group.

101603
PN=601
Tests
Specification
Regulator Load Adjusting
Turning adjusting cartridge IN increases flow rate.
Screw (Inner Spring) (Engine
Pulldown at High Pressure)
Turn................................................... 1/4 turn IN increases pump flow Specification
rate approximately 5.46 L/min Regulator Load Adjusting
(1.45 gpm) Cartridge (Outer Spring)
(Engine Pulldown at Medium
Pressure)Turn ............................... 1/4 turn IN increases pump flow
Do not turn adjusting screw more than one turn. rate approximately 22.5 L/min
Tighten nut (G) after adjustment. (6 gpm)
For adjustment, see Hydraulic Pump Regulator Test Do not turn adjusting cartridge more than one turn.
and AdjustmentEngine Pulldown in this group. Tighten nut (J) after adjustment.
Load Adjusting Cartridge (Outer Spring) (Engine For adjustment, see Hydraulic Pump Regulator Test
Pulldown at Medium Pressure) (I): and AdjustmentEngine Pulldown in this group.
TX,9025,GG2109 1907MAY013/3
9025
25
,100

101603
PN=602
Tests
Hydraulic Pump Regulator Test and

AdjustmentMinimum Flow
SPECIFICATIONS
Engine in Standard Mode Speed Fast Idle
Work Mode Position Dig Mode
Propel Speed Switch Position Slow Speed (Turtle)
Slow Speed Propel With Track 36 1 sec for one revolution from
Raised Cycle Time a running start with pump control
valve pilot line disconnect
ESSENTIAL TOOLS
7/16-20 M 37 (Parker No. 03CP-4) Plug (2 used)

Stop Watch
Flat Blade Screwdriver
The purpose of check is to test and adjust the minimum

9025
flow rate of pumps using the cycle time for propel as an 25
indicator of pump flow rate. ,101
1. Adjust the track sag for both tracks to specification.

(See procedure in Group 9020-20.)


Specification
4. Stop the engine.

101603
PN=603
Tests

hydraulic oil tank.
KVent Plug
UN29APR97
T109340
TX,9025,GG2125 1915JUN982/4
6. Disconnect pump control valve pilot lines at rear pump

regulator (A) and front pump regulator (B). Install plug
(C) in lines. Leave the fittings on regulator open. Lay a
shop towel over the fittings.
7. Run machine as specified.
Specification
Speed ........................................................................................... Fast Idle
Work ModePosition .................................................................. Dig Mode
9025 Auto-Idle SwitchPosition .................................................................... Off
25 Propel Speed SwitchPosition.................................. Slow Speed (Turtle)
,102
8. Raise the left track off ground for rear pump or the
right track for front pump.
9. Actuate propel function to full speed. Record the cycle

time for one revolution.
UN11SEP96
ARear Pump Regulator
BFront Pump Regulator
CPlugs
T103501

101603
PN=604
Tests
10. Adjust the minimum flow adjusting screw (E) as

needed to obtain the specified cycle time. Turn screw
in to decrease the cycle time (the minimum flow rate
increases), turn screw out to increase the cycle time
(the minimum flow rate decreases). Hold the screw
and tighten the nut (F).
Specification
Slow Speed Propel With Track
RaisedCycle Time ............................ 36 1 sec for one revolution from
a running start with pump control
valve pilot line disconnect
11. Repeat procedure for other pump.
Adjust regulators so cycle times are the same.
EMinimum Flow Adjusting Screw

F17 mm Nut
UN24AUG98
T103502
TX,9025,GG2125 1915JUN984/4
9025
25
,103

101603
PN=605
Tests

AdjustmentMaximum Flow
SPECIFICATIONS
Track Raised3 Revolutions 28.2 1.0 sec.
From a Running Start Cycle Time

Stop Watch
17, 22, and 32 mm Combination Wrenches
Purpose of check is to test and adjust the maximum flow

rate of pumps so the cycle times (travel speed) for left
and right propel are approximately the same.
1. Adjust track sag for both tracks to specification. (See

9025
25 procedure in Group 9020-20.)
,104
2. Install temperature probe on the hydraulic oil

Specification
4. Run machine as specified.
Specification
Speed ........................................................................................... Fast Idle
Propel Speed SwitchPosition.................................. Slow Speed (Turtle)
Continued on next page TX,9025,GG2126 1928NOV011/3

101603
PN=606
Tests
5. Raise the left track off ground for rear pump or the
right track for front pump.
6. Actuate propel function to full speed. Record cycle time

for three revolutions.
Repeat procedure for the other pump.
TX,9025,GG2126 1928NOV012/3
7. Adjust flow adjusting cartridge (C) on front and rear

pump regulators so cycle times are within the
specification and are the same.
Specification
Track Raised3 Revolutions
From a Running StartCycle
Time .................................................................................... 28.2 1.0 sec.
Loosen 30 mm nut (D). Turn flow adjusting cartridge (C)

in to increase (lengthen) cycle time; turn flow adjusting
cartridge out to decrease (reduce) cycle time. Never turn
flow adjusting cartridge more than one turn. Tighten 30
mm nut after adjustment. 9025
25
,105
When flow adjusting cartridge (C) is turned in or out the
maximum flow rate for the pump also changes. To
maintain the pumps maximum flow rate, turn maximum
flow adjusting screw (B) out twice as much as flow
adjusting cartridge (C) is turned in; turn maximum flow
adjusting screw (B) in twice as much as flow adjusting
UN18SEP96
cartridge (C) is turned out.
A13 mm Nut
BMaximum Flow Adjusting Screw
T103535
CFlow Adjusting Cartridge (Track Cycle Time)

D30 mm Nut
TX,9025,GG2126 1928NOV013/3

101603
PN=607
Tests

AdjustmentEngine Pulldown
SPECIFICATIONS
Engine Fast Idle in Standard 21002125 rpm
Mode Speed
Load Adjusting Cartridge (Outer 19501975 rpm at 15 170 kPa
Spring)Combined Pump Engine (152 bar) (2200 psi) with tracks
Pulldown Speed stalled
Load Adjusting Screw (Inner 19501975 rpm at 20 000 kPa
Spring)Combined Pump Engine (200 bar) (2900 psi) with tracks
Pulldown Speed stalled
System Relief Valve Pressure 34 325 + 1960 - 0 kPa (343 +
19.6 - 0 bar) (4980 + 285 - 0 psi)
ESSENTIAL TOOLS

9025
25 JT07290 Laptop Computer
,106 JT07274J Excavator Diagnostics Program Disk
JT07273 Cable
Gauge 70 000 kPa (700 bar) (10,000 psi)
85 mm (3-3/8 in.) OD Pin or Length of Round Bar Stock (2 used)
13, 17, 19, 27, 30 and 32 mm Combination Wrenches

101603
PN=608
Tests
IMPORTANT: In this procedure the pump regulators

are adjusted to load the engine to rated
speed so all available engine
horsepower is used. Prior to performing
this adjustment, proper engine
performance with number two diesel
1929AUG96
fuel must be verified. The fast idle
speed must be adjusted to
specifications.
T102900
Pump regulators are sensitive to adjust.
1. Connect the laptop computer. (See the installation

a. Start the engine.
b. Select 3 Front pump delivery pressure and 4

Rear pump delivery pressure from the Monitor Data
menu.

9025
25
,107

101603
PN=609
Tests
If laptop computer with excavator diagnostic program is

not available, use the digital pressure and temperature
analyzer, and transducer, or a gauge.
a. Stop the engine.
UN29APR97
hydraulic oil tank.
c. Install adapters (A) and male quick coupler to test
T109340
ports in rear (B) and front (C) pumps. Connect the
analyzer and transducer or gauges.
2. Install the temperature probe on the hydraulic oil

3. Install the electronic tachometer. (See JT05801

Clamp-On Electronic Tachometer Installation in this
group.)

Specification
UN18JUN96
9025 5. Check that fast idle is to specification. Adjust as
25
needed before continuing test. Record the fast idle
,108
speed.
T101614
Specification
ModeSpeed .................................................................. 21002125 rpm
E Mode SwitchPosition ...................................................................... Off AAdapters
HP Mode SwitchPosition ................................................................... Off BRear Pump
Auto-Idle SwitchPosition .................................................................... Off CFront Pump
Propel Speed SwitchPosition.................................. Slow Speed (Turtle) KVent Plug

101603
PN=610
Tests
NOTE: Procedure is written using the propel functions

operated over relief. Procedure will also work
using dig functions over relief. Front pumpright
propel or bucket function. Rear pumpleft propel
or swing function. Both front and rear pumps
both propel functions or arm in function.
UN02JUL96
6. Install two 85 mm (3-3/8 in.) OD pins or round bar
stock between both sprockets and track frame to stall
the propel motors.
T101856
DPin or Round Bar Stock
TX,9025,GG2242 1907SEP004/13
7. Adjust the Load Adjusting Cartridge (Outer Spring)

(Engine Pulldown at Medium Pressure) (L):
NOTE: The load adjusting screw (K) and load adjusting

cartridge (L) are located on the end of regulator
towards the engine. 9025
25
,109
a. Loosen 13 mm nut (J) on both regulators.
b. Turn load adjusting screws (K) out 1-1/2 turns.

Tighten nuts.
c. Loosen 30 mm nuts (M) on both regulators.
d. Turn load adjusting cartridges (L) out 1-1/4 turns.

Leave nuts loose.
J13 mm Nut
KLoad Adjusting Screw (Inner Spring)
LLoad Adjusting Cartridge (Outer Spring)
UN18SEP96
M30 mm Nut
T103527

101603
PN=611
Tests
e. Adjust system relief valve (D):

Actuate and hold both propel functions over relief.
Loosen 32 mm nut (H). Turn second adjusting
plug (G) out to obtain 15 170 kPa (152 bar) (2200
psi). Tighten nut.
f. Run engine at fast idle.
g. Actuate and hold both propel functions over relief.
DSystem Relief Valve

UN18JUN96
F27 mm Nut
H32 mm Nut
IPiston
T101616
9025
25
,110

101603
PN=612
Tests
NOTE: Initial procedure is to adjust the load adjusting

cartridges (L) to match the two pumps before
making the final adjustment to get the combined
pump engine pulldown at medium pressure.
Hydraulic pressure increases as the load adjusting

cartridges are turned in because the pump flow is
increasing.
h. Turn the load adjusting cartridge (L) on front pump

regulator in until engine speed just starts to
decrease. Then, slowly turn the load adjusting
cartridge out and in to verify the exact point where
engine speed starts to decrease (010 rpm).
i. Turn the load adjusting cartridge (L) on rear pump

decrease. Then, slowly turn the load adjusting
cartridge out and in to verify the exact point where
engine speed starts to decrease (010 rpm).
UN18SEP96
j. Release both propel functions.
NOTE: To avoid heating the oil excessively, only operate
T103527
the propel functions over relief to check the
pulldown after each adjustment of cartridge.
J13 mm Nut 9025

k. Turn both load adjusting cartridges (L) in equal 25
amounts. Start with 1/4 turn. ,111
M30 mm Nut
l. Actuate and hold both propel functions over relief to
check that engine pulldown speed is to specification.
Record the rpm reading. Release propel functions.
Specification
Load Adjusting Cartridge (Outer
Spring)Combined Pump Engine
PulldownSpeed .................................... 19501975 rpm at 15 170 kPa
(152 bar) (2200 psi) with tracks
stalled
m. Hold the cartridge and tighten large nut on both

regulators.

101603
PN=613
Tests
IMPORTANT: If the load adjusting cartridge are not

turned in equal amounts, the engine
speed will pulldown to the specified
rpm but the pump flow rates will not be
equal and the machine will mistrack.
n. Check the adjustments:
Run the engine at fast idle.

Actuate and hold right propel function over relief.
Record rpm reading. Release propel function.
Actuate and hold left propel function over relief.
Record rpm reading. Release propel function.
The rpm reading for front and rear pumps must
be within 10 rpm of each other to prevent
machine from mistracking.
TX,9025,GG2242 1907SEP008/13
8. Adjust the Load Adjusting Screw (Inner Spring)

(Engine Pulldown at High Pressure):
a. Adjust the system relief valve (D):
9025 Run engine at fast idle.

25 Actuate and hold both propel functions over relief.
,112
plug (G) in to obtain 20 000 kPa (200 bar) (2900
psi). Tighten nut.
b. Run engine at fast idle.
c. Actuate and hold both propel functions over relief.
UN18JUN96
F27 mm Nut T101616
H32 mm Nut
IPiston

101603
PN=614
Tests
NOTE: Initial procedure is to adjust the load adjusting

screws (K) to match the two pumps before making
the final adjustment to get the combined pump
engine pulldown at high pressure.
d. Turn load adjusting screw (K) on front pump

decrease. Then, slowly turn load adjusting screw
out and in to verify the exact point where the engine
speed just starts to decrease (010 rpm).
e. Turn load adjusting screw (K) on rear pump

decrease. Then, slowly turn load adjusting screw
out and in to verify the exact point where the engine
speed just starts to decrease (010 rpm).
f. Release both propel functions.
NOTE: To avoid heating the oil excessively, only operate
UN18SEP96
the propel function over relief to check the
pulldown after each adjustment of screws
g. Turn both load adjusting screws in equal amounts.
T103527
Start with 1/4 turn.
h. Actuate and hold both propel functions over relief to

J13 mm Nut 9025
check that engine pulldown speed is to 25
specification. ,113
M30 mm Nut
Specification
Load Adjusting Screw (Inner
Spring)Combined Pump Engine
PulldownSpeed .................................... 19501975 rpm at 20 000 kPa
(200 bar) (2900 psi) with tracks
stalled
i. Hold the load adjusting screw and tighten nut on

both regulators.

101603
PN=615
Tests
j. Adjust the system relief valve (D) to operating

pressure:
Run the engine at fast idle.

Actuate and hold both propel functions over relief.
plug (G) in to obtain specified pressure. Tighten
32 mm nut.
Specification
System Relief ValvePressure ................. 34 325 + 1960 - 0 kPa (343 +
19.6 - 0 bar) (4980 + 285 - 0 psi)
UN18JUN96
F27 mm Nut
H32 mm Nut
IPiston
T101616
9025
25
,114

101603
PN=616
Tests
k. Check the adjustments:
Actuate and hold right propel function over relief.

Engine pulldown must not go below 1975 rpm. If
it does, turn front pump load adjusting cartridge
(L) out until pulldown is 19751995 rpm. Record
rpm reading. Release propel function.
Actuate and hold left propel function over relief.
Engine pulldown must not go below 1975 rpm. If
it does, turn rear pump load adjusting cartridge
(L) out until pulldown is 19751995 rpm. Record
rpm reading. Release propel function.
The pulldown rpm reading for front and rear
pumps must be within 10 rpm of each other to
prevent machine from mistracking.
l. Make final pump regulator adjustments by observing

how straight the machine tracks under load.
J13 mm Nut
UN18SEP96
M30 mm Nut
T103527
9025
25
,115

101603
PN=617
Tests
9. Do the Final Tracking Checks:
a. Propel machine forward on a flat area of naturally

compacted soil and then on a slope of naturally
compacted soil.
b. If machine mistracks to the left on the flat area, turn

the load adjusting cartridge (L) on the front pump
regulator out to slow the right track.
c. If the machine mistracks to the right under load on

the slope, turn the load adjusting screw (K) on the
rear pump regulator out to slow the left track.
d. If the machine mistracks to the left under load on

the slope, turn the load adjusting screw (K) on the
front pump regulator out to slow the right track.
J13 mm Nut
UN18SEP96
M30 mm Nut
T103527
TX,9025,GG2242 1907SEP0013/13
9025
25
,116

101603
PN=618
Tests
Hydraulic Pump Flow Test
SPECIFICATIONS
Engine in Standard Mode Speed 2000 10 rpm
Pump at 2000 10 rpm and 20 125 4 L/min (33 1 gpm)
685 kPa (207 bar) (3000 psi) typical flow new
Flow Rate
790 kPa (138 bar) (2000 psi) typical flow new
Flow Rate
685 kPa (207 bar) (3000 psi) minimum flow used
Flow Rate
790 kPa (138 bar) (2000 psi) minimum flow used
Flow Rate
ESSENTIAL TOOLS
TH108325 (1 M BSPP ORB x 16 M ORFS) Elbow
JT03410 (SAE Code 62 Split Flange High Pressure 1 SF x 1-5/16-12
M 37) 90 Flange Fitting (2 used) 9025
25
JT03452 Split Flange Connector Plate Kit
,117
202862 (3/4-16 M 37 x 3/4-16 F 37 Sw x 7/16-20 M 37) Tee (2
used)
JT05484 (7/16-20 F 37) (Parker No. 06CP-4) Cap (2 used)

Flow Meter
JT07273 Cable
Gauge 70 000 kPa (700 bar) (10,000 psi) (2 used)
Test is used to determine pump condition and should be

performed only if a comparison of actual machine cycle
times to specified cycle times indicates low pump flow.

101603
PN=619
Tests
1. Stop the engine.

hydraulic oil tank.
KVent Plug
UN29APR97
T109340
9025
25
,118

101603
PN=620
Tests
9025
25
,119
UN16SEP96
T103554
APilot Pressure Inlet Line EPump Control Valve Pilot GTH108328 Adapter KFront Pump Outlet Port
B202862 Tee (2 used) Lines HTH108325 Elbow LRear Pump Outlet Port
CJT05484 Cap FFront and Rear Pump IReturn Manifold MJT03410 90 Flange Fitting
DTest Port Regulator Valves JBulkhead
3. Connect the flow meter using 90 flange fitting (M). (G) and gauges to test ports (D) in pump housing,
If available, connect a flow meter to front (K) and or use the laptop computer.
rear (L) pumps.
4. Disconnect pilot pressure inlet line (A) at pilot filter.
Connect the return hose from flow meter to the Install tees (B). Connect pilot pressure inlet line to
return manifold (I). Install plates, from the split tee.
flange connector plate kit, on end of hoses to
control valve. Disconnect the two pump control valve pilot lines
(E) at bulkhead (J) on hydraulic oil tank. Connect
To monitor pump delivery pressure, use the the pilot lines to the tees installed at pilot filter.
pressure gauge on flow meter, or install adapters Install caps (C) on fittings at bulkhead.

101603
PN=621
Tests
NOTE: Pilot pressure is routed to the pump regulator Specification

valves so the pumps operate at maximum OilTemperature ............................................ 50 5C (120 10F)
displacement.
10. Adjust the flow meter loading valve to obtain the
5. Install the temperature probe on the hydraulic specified test pressures. Adjust engine speed to
tank-to-pump suction line. (See JT05800 Digital specified rpm. Record pump flow at each
Thermometer Installation in this group.) pressure.
6. Install the tachometer. (See JT05801 Clamp-On If pump flow in low, repair or replace pump.
Specification
Pump at 2000 10 rpm and 20
7. Check that the flow meter loading valve is open. 685 kPa (207 bar) (3000 psi)
Flow Rate................................................. 125 4 L/min (33 1 gpm)
8. Operate the machine at specification. typical flow new
Specification 790 kPa (138 bar) (2000 psi)
Engine in Standard Mode Flow Rate................................................. 190 4 L/min (50 1 gpm)
Speed........................................................................... 2000 10 rpm typical flow new
Work Mode SelectorPosition............................................. Dig Mode Pump at 2000 10 rpm and 20
E Mode SwitchPosition ............................................................... Off 685 kPa (207 bar) (3000 psi)
HP Mode SwitchPosition............................................................. Off Flow Rate............................................... 106 15 L/min (28 4 gpm)
Auto-Idle SwitchPosition ............................................................. Off minimum flow used
790 kPa (138 bar) (2000 psi)
9. Heat the hydraulic oil to the specified temperature Flow Rate............................................... 159 15 L/min (42 4 gpm)
by closing flow meter loading valve to increase minimum flow used
pressure to 20 685 kPa (207 bar) (3000 psi).
9025
25
,120
TX,9025,GG2128 1907SEP004/4

101603
PN=622
Tests
Pilot Pump Flow Test
SPECIFICATIONS
Engine in Standard Mode Speed 2000 rpm
Pilot Pump Flow Rate 25.0 L/min (6.6 gpm) minimum at
3925 kPa (39 bar) (570 psi) and
2000 rpm

Flow Meter
Test will determine the condition of pilot pump. The pump

is driven at engine speed. Inspect pilot filter and suction
screen for indications of hydraulic system problems.
TX,9025,GG2663 1908JUN981/3
9025
25
,121
1. Stop the engine.
Loosen vent plug (K) to release the air pressure in

hydraulic oil tank.
KVent Plug
UN29APR97
T109340

101603
PN=623
Tests
2. Connect flow meter in series with pilot pressure inlet

line (A) at pilot filter (B).
Open the flow meter loading valve.


Specification
NOTE: The pilot pressure regulating valve will regulate

pump discharge pressure. It is not necessary to
load the pump using flow meter loading valve.
5. Run engine at test specifications. Record flow meter

reading.
UN11SEP96
If pressure is low, check the pilot pressure regulating
valve.
T103571
If flow is low, check inlet hose to pump for restriction. If
there is no restriction, replace pump.
9025
25 APilot Pressure Inlet Line
Specification BPilot Filter
,122 Engine in Standard Mode
Speed .......................................................................................... 2000 rpm
Pilot PumpFlow Rate ........................ 25.0 L/min (6.6 gpm) minimum at
3925 kPa (39 bar) (570 psi) and
2000 rpm
TX,9025,GG2663 1908JUN983/3

101603
PN=624
Tests
Propel System Tracking Test
SPECIFICATIONS
Mistrack at 20 m (65 ft) Distance 200 mm (7-7/8 in.) or less

Tape Measure
Test is used to check the overall condition of the propel

system from the hydraulic pumps to the propel motors.
1. Lay out a course on a hard flat surface that is 20 m

(65 ft) in length plus an additional 35 m (1015 ft)
at each end for acceleration and deceleration. Mark a
straight line the length of course.
2. Adjust the track sag so both sides are equal and within
specification before doing test. (See Adjust Track Sag 9025
25
in Group 9020-20.)
,123
Specification
Speed ........................................................................................... Fast Idle


Specification

101603
PN=625
Tests
5. Lower the boom so bucket is approximately 300500

mm (1220 in.) off the ground with the arm retracted
and the bucket curled.
6. Start propelling with the machine at the end of course

and the tracks aligned with the straight line. Actuate
the propel pilot controller to full stroke.
TX,9025,GG2664 1908JUN982/3
7. Measure the amount of mistrack from the straight line

to the track at the 20 m (65 ft) mark. The amount of
mistrack has a tendency to be less if done on a
concrete surface.
Specification
UN23MAR89
Mistrack at 20 m (65 ft)
Distance ............................................................ 200 mm (7-7/8 in.) or less
Turn the upperstructure 180 degrees and repeat

procedure for reverse propel.
T6998AS
TX,9025,GG2664 1908JUN983/3
9025
25
,124

101603
PN=626
Tests
Cylinder Drift TestBoom, Arm, and Bucket
SPECIFICATIONS
Engine in Standard Mode Speed Off
Arm Length 2.91 (9 ft 7 in.)
Bucket Capacity 0.86 m3 (1.12 yd3)
Bucket Load Weight 1065 kg (2350 lb)
Arm Cylinder Length 50 mm (2.00 in.) approximate
extension
Bucket Cylinder Length 50 mm (2.00 in.) approximate
retraction
Boom Cylinder Height Bucket pivot pin at the same
height as boom-to-main frame pin
Engine Speed Off
Arm Cylinder Drift 20 mm (13/16 in.)
maximum allowable for five
minutes
Bucket Cylinder Drift 20 mm (13/16 in.)
minutes
Boom Cylinder Drift 20 mm (13/16 in.)
minutes
Bottom of Bucket to Ground Drift 150 mm (6 in.)
minutes 9025
25
SERVICE EQUIPMENT AND TOOLS ,125
Tape Measure
Procedure is used to check the leakage past the cylinder

piston seals, control valve spools, circuit relief valves,
boom reduced leakage valve, and arm reduced leakage
valve.


Specification
Speed .................................................................................................... Off

101603
PN=627
Tests
3. Fill the bucket to get the specified bucket load with the
standard arm and bucket.
Specification
ArmLength....................................................................... 2.91 (9 ft 7 in.)
BucketCapacity .......................................................... 0.86 m3 (1.12 yd3)
Bucket LoadWeight ..................................................... 1065 kg (2350 lb)
9025
25
,126

101603
PN=628
Tests
4. Position arm cylinder so rod is extended the specified

length from the retracted position.
Specification
Arm CylinderLength ................................ 50 mm (2.00 in.) approximate
extension
UN06DEC88
5. Position bucket cylinder so rod is retracted the
specified length from the extended position.
Specification
T6904AG
Bucket CylinderLength ............................ 50 mm (2.00 in.) approximate
retraction
6. Position the boom cylinders so bucket pivot pin is at

the same height as the boom-to-main frame pin.
Specification
Boom CylinderHeight ................................ Bucket pivot pin at the same
height as boom-to-main frame pin
7. Stop the engine.
Specification
EngineSpeed ..................................................................................... Off
8. After 5 minutes, measure the amount of movement for

boom, arm and bucket cylinders and from bottom of
bucket to the ground. 9025
25
Specification ,127
Arm CylinderDrift........................................................ 20 mm (13/16 in.)
minutes
Bucket CylinderDrift ................................................... 20 mm (13/16 in.)
minutes
Boom CylinderDrift ..................................................... 20 mm (13/16 in.)
minutes
Bottom of Bucket to Ground
Drift ..................................................................................... 150 mm (6 in.)
minutes
TX,9025,GG2129 1909MAY973/3

101603
PN=629
Tests
Swing Motor Leakage Test
SPECIFICATIONS
Oil Temperature 50 5C (120 10 F)
Swing Motor Leakage 0.21.0 L/min (0.050.26 gpm)
new acceptable while swinging
Swing Motor Leakage 2 L/min (0.53 gpm) used
maximum acceptable while
swinging
Swing Motor Leakage 8 L/min (2.2 gpm) new
acceptable while stalled
Swing Motor Leakage 16 L/min (4.2 gpm) used
stalled
ESSENTIAL TOOLS
JT03023 (9/16-18 F 37) (Parker No. 06CP-6) Cap

Calibrated Container
9025
25
,128 The purpose of test is to check the efficiency of swing
motor. Leakage can occur between the cylinder block and
valve plate and the slippers and swash plate when parts
are worn or damaged. The motor must be checked in
more than one position in order to check all pistons and
the circumference of valve plate and cylinder block.


Specification
OilTemperature .................................................. 50 5C (120 10 F)
3. Stop the engine.

101603
PN=630
Tests

hydraulic oil tank.
KVent Plug
UN29APR97
T109340
9025
25
,129

101603
PN=631
Tests
5. Disconnect drain line (A) from return manifold. Install a

cap on elbow. Put drain line in a calibrated container.
CAUTION: To avoid personnel injury, clear area

of all bystanders before doing test. Slowly
swing through one complete revolution to
ensure that the area is clear of objects before
doing test.
6. Raise and lower boom to pressurize hydraulic oil tank.
7. Operate swing function for one minute. Compare

amount of leakage to specifications. Repeat for swing
in opposite direction.
Specification
Speed ........................................................................................... Fast Idle
UN10JUL96
Swing MotorLeakage ......................... 0.21.0 L/min (0.050.26 gpm)
new acceptable while swinging
Leakage .............................................................. 2 L/min (0.53 gpm) used
T101868
swinging
9025 8. Operate swing function at stall for one minute. Put the
25 ASwing Motor Drain Line
bucket against an immovable object or in a trench then
,130 BCap
hold swing control lever fully actuated to stall swing
function. Compare the amount of leakage to
specifications.
Specification
Swing MotorLeakage .......................................... 8 L/min (2.2 gpm) new
acceptable while stalled
Leakage .............................................................. 16 L/min (4.2 gpm) used
stalled
Repeat procedure by stalling the motor in several position

and then take an average of the readings.
Repeat procedure in the opposite direction.
9. If leakage is greater than the maximum specified,

repair or replace swing motor.
10. Connect drain line to return manifold.
TX,9025,GG2666 1908JUN983/3

101603
PN=632
Tests
Propel Motor Leakage Test
SPECIFICATIONS
Oil Temperature 50 5C (120 10 F)
Propel Motor Leakage 1.52.0 L/min (0.40.53 gpm)
new acceptable while propelling
with track raised
Propel Motor Leakage 3.4 L/min (0.80 gpm) used
propelling with track raised
Propel Motor Leakage 1.54.8 L/min (0.401.20 gpm)
new acceptable while stalled
Propel Motor Leakage 5.2 L/min (1.40 gpm) used
stalled
ESSENTIAL TOOLS
JT03025 (3/4-16 F 37) (Parker No. 06CP8) Cap
JT03221 (3/4-16 M 37) (Parker No. 03CP8) Plug
9025
25
JT05800 Digital Thermometer ,131
Calibrated Container
85 mm (3-3/8 in.) OD Pin or Round Bar Stock (2 used)
1. Stop the engine.

Specification
OilTemperature .................................................. 50 5C (120 10 F)
3. Stop the engine.

101603
PN=633
Tests

hydraulic oil tank.
KVent Plug
UN29APR97
T109340
9025
25
,132

101603
PN=634
Tests
5. Disconnect the drain line (A) at return manifold. Put

line in a calibrated container (D). Install a cap (B) on
the open fitting (C).
6. Raise track off the ground for side being checked.
7. Run machine at specifications.
Specification
Speed ........................................................................................... Fast Idle
Propel Speed SwitchPosition.................................. Slow Speed (Turtle)
8. For propel motor being checked, actuate propel

forward function at full speed for one minute. Record
amount of leakage. Repeat procedure for reverse.
If leakage is more than specification, repair or replace
UN11DEC91
motor.
Specification
Propel MotorLeakage........................... 1.52.0 L/min (0.40.53 gpm)
T7660BE
new acceptable while propelling
with track raised
Leakage ........................................................... 3.4 L/min (0.80 gpm) used
maximum acceptable while 9025
propelling with track raised 25
,133
If leakage is substantially more in one direction than the

other, a seal in the rotary manifold may be leaking. To
isolate leakage to the propel motor or rotary manifold,
check leakage at the propel motor.
UN06DEC88
BCap
CFitting
T6876FG
DCalibrated Container

101603
PN=635
Tests
9. To check propel motor for leakage at stall, install pins

or round bar stock (D) between the sprockets and track
frame.
Specification
Propel MotorLeakage......................... 1.54.8 L/min (0.401.20 gpm)
new acceptable while stalled
UN02JUL96
Leakage ........................................................... 5.2 L/min (1.40 gpm) used
stalled
T101856
Actuate propel pedal for function being checked to full
stroke for one minute. Record the amount of leakage.
Repeat procedure by stalling the motor in several APin or Round Bar Stock
positions and then take an average of readings.
Repeat procedure for the opposite direction.
TX,9025,GG2667 1909MAY974/5
9025
25
,134
10.
To check leakage at the propel motor, disconnect

drain line (A) at propel motor. Install JT03221 Plug in
the line. Connect a line to fitting on motor. Put line in
a calibrated container.
UN11JAN93
Repeat Steps 7 and 8. If leakage is more than
specification, repair or replace motor. If leakage is
within specification, repair or replace rotary manifold.
T7915BB
TX,9025,GG2667 1909MAY975/5

101603
PN=636
Section 9031
Air Conditioning System
Contents
Page Page
Group 05Theory of Operation Oil Charge

Proper Refrigerant Handling . . . . . . . . . . . . .9031-05-1 R134a Component. . . . . . . . . . . . . . . . . . .9031-20-3
R134a Refrigerant Cautions . . . . . . . . . . . . .9031-05-1 Refrigerant
Refrigerant Theory of Operation . . . . . . . . . .9031-05-2 Recovery, Recycling and Charging Station
Heater and Air Conditioner Circuit Installation Procedure. . . . . . . . . . . . . . .9031-20-5
Operational Information . . . . . . . . . . . . . . .9031-05-3 Recover
Heater and Air Conditioner Circuit Theory of R134a System . . . . . . . . . . . . . . . . . . . . . .9031-20-6
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-4 Evacuate
Heater and Air Conditioner Circuit R134a System . . . . . . . . . . . . . . . . . . . . . .9031-20-7
Functional Schematic. . . . . . . . . . . . . . . . .9031-05-5 Charge
Heater Circuit (Machines Without Air R134a System . . . . . . . . . . . . . . . . . . . . .9031-20-10
Conditioner) Compressor
Operational Information . . . . . . . . . . . . . . .9031-05-6 Check and Adjust Belt Tension . . . . . . . .9031-20-12
Theory of Operation. . . . . . . . . . . . . . . . . .9031-05-6
Functional Schematic. . . . . . . . . . . . . . . . .9031-05-7 Group 25Tests
Receiver/Dryer Operation . . . . . . . . . . . . . . .9031-05-8 Refrigerant
Expansion Valve Operation . . . . . . . . . . . . .9031-05-10 Proper Handling. . . . . . . . . . . . . . . . . . . . .9031-25-1
Compressor Relief Valve Operation . . . . . .9031-05-11 R134a Cautions . . . . . . . . . . . . . . . . . . . . .9031-25-1
Temperature Control (Early Models) . . . . . .9031-05-11 Air Conditioning
Heater and Air Conditioner Controller R134a System Test . . . . . . . . . . . . . . . . . .9031-25-2
Operation (Later Models) . . . . . . . . . . . . .9031-05-12 Operating Pressure
Diagnostic Chart . . . . . . . . . . . . . . . . . . . .9031-25-5
Group 10System Operational Checks Switch
Heating and Air Conditioning High Pressure Test . . . . . . . . . . . . . . . . . .9031-25-6 9031
Operational Checks . . . . . . . . . . . . . . . . . .9031-10-1 Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-7
Visual Inspection of Components . . . . . . . . .9031-10-1 Refrigerant
System Operating Checks. . . . . . . . . . . . . . .9031-10-3 Hoses and Tubing Inspection. . . . . . . . . . .9031-25-8
Heater Circuit Checks (Machines
Equipped with Heater Only) . . . . . . . . . . . .9031-10-5
Heater and Air Conditioner Circuit
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-10-6

Air Conditioning
Diagnose Electrical Malfunctions . . . . . . . .9031-15-1
Air Conditioner Harness (W9)
Component Location . . . . . . . . . . . . . . . . .9031-15-2
Connectors, Wire and Pin Location . . . . . .9031-15-4
Group 20Adjustments
Refrigerant
Proper Handling. . . . . . . . . . . . . . . . . . . . .9031-20-1
R134a Cautions . . . . . . . . . . . . . . . . . . . . .9031-20-1
Compressor
R134a Oil Charge Check . . . . . . . . . . . . . .9031-20-2
R134a Oil Removal . . . . . . . . . . . . . . . . . .9031-20-2

101603
PN=1
Contents
9031

101603
PN=2
Group 05
Theory of Operation
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits It must be recovered using the
discharge of any refrigerant into the atmosphere, and appropriate recovery stations.
requires that refrigerant be recovered using the
approved recovery equipment. IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations. DO
IMPORTANT: To meet government standards NOT mix refrigerants, hoses, fittings,
relating to the use of refrigerants, components or refrigerant oils.
R134a is used in the air conditioning
system. Because it does not contain Recovery, recycling and charging stations for R12 and
chlorine, R134a is not detrimental to R134a refrigerants MUST NOT be interchanged.
the ozone in the atmosphere. Systems containing R12 refrigerant use a different oil
However, it is illegal to discharge than systems using R134a. Certain seals are not
any refrigerant into the atmosphere. compatible with both types of refrigerants.
TX,9031,UU3135 1913AUG961/1
R134a Refrigerant Cautions
Keep refrigerant containers away from heat

CAUTION: DO NOT allow liquid refrigerant to
sources. Store refrigerant in a cool place.
contact eyes or skin. Liquid refrigerant will
freeze eyes or skin on contact. Wear
DO NOT handle damp refrigerant container
goggles, gloves and protective clothing.
with your bare hands. Skin may freeze to
container. Wear gloves.
If liquid refrigerant contacts eyes or skin, DO
NOT rub the area. Splash large amounts of
If skin freezes to container, pour COOL
COOL water on affected area. Go to a
water over container to free the skin. Go to a
physician or hospital immediately for 9031
treatment.
treatment. 1
DO NOT allow refrigerant to contact open

(R12 ONLY) Refrigerant exposed to high
flames or very hot surfaces such as electric
temperature forms phosgene gas. Inhaling
welding arc, electric heating element and
toxic phosgene gas may result in serious
lighted smoking materials.
illness or death. Phosgene gas has an odor
like new mown hay or green corn. If you
DO NOT heat refrigerant over 52C (125F) in
inhale phosgene gas, go to a physician or
a closed container. Heated refrigerant will
hospital immediately for treatment.
develop high pressure which can burst the
container.
TX,9031,UU3136 1913AUG961/1

101603
PN=639
Theory of Operation
Refrigerant Theory of Operation
1930NOV98
T118692
AB27 A/C High and Low DEngine Fan HLow Pressure Gas LLow Pressure Liquid
Pressure Switch ECondenser IEvaporator MB29 A/C Heater Thermistor
BReceiver/Dryer FHigh Pressure Gas JExpansion Valve NM6 A/C and Heater Blower
9031 CHigh Pressure Liquid GCompressor KNot Used Motor
05
2 The compressor (G) draws low pressure gas (H) from condenser fan (D). Cooling the refrigerant causes it to
the evaporator (I) and compresses it into high pressure condense and it leaves the condenser as a high
gas (F). This causes the temperature of the refrigerant pressure liquid (C). The high pressure liquid flows into
to rise higher than that of the outside air. the receiver-dryer (B) where moisture and
contaminants (acid, solids, etc.) are removed. The
High pressure gas leaves the compressor and is receiver-dryer also acts as a reservoir for refrigerant.
sensed by the high pressure part of the B27 A/C high
and low pressure switch (A). The switch monitors The refrigerant flows from the receiver-dryer to the
refrigerant pressure. If the pressure becomes too high, expansion valve (J) and is sensed by the low pressure
the switch will open and stop the compressor, part of the B27 A/C high and lower pressure switch
interrupting the cycle. (A). The switch monitors refrigerant pressure. If the
pressure becomes too low from refrigerant loss, the
As the high pressure gas flows through the condenser switch will open and stop the compressor, interrupting
(E), heat is removed and transferred to the outside air the cycle.
being drawn through the condenser core by the
Continued on next page TX,9031,UU3137 1913AUG961/2

101603
PN=640
Theory of Operation
The actual cooling and drying of cab air takes place at tube. The switch closes when the evaporator is above
the evaporator. Flow of the high pressure liquid the switch setting and opens when the evaporator is
refrigerant is controller by the expansion valve. The cooled to the switch setting. The switch has a low
expansion valve causes the temperature and pressure temperature setting that prevents the evaporator from
of the refrigerant to drop, where it becomes a low becoming cold enough to freeze moisture that
pressure liquid (L). The expansion valve is a valve that condenses on the coil.
uses a variable orifice to control the flow of high
pressure liquid refrigerant into the evaporator to The B28 A/C and heater thermistor senses
maintain a constant pressure and temperature. temperature of the evaporator coil through a refrigerant
filled capillary tube.
The M6 A/C and heater blower motor (N) pulls a
mixture of warm cab and outside air through the The moisture, from the warm air, is condensed as it
evaporator where it is cooled by the refrigerant. The contacts the cool evaporator coil during the cooling
heat absorbed by the evaporator causes the refrigerant process and is drained away through drain tubes
to vaporize into a low pressure gas. connected to the drain pan under the evaporator. With
the cab air cooled and dehumidified, the refrigerant
A freeze control switch (M) senses temperature of the cycle is complete.
evaporator coil through a refrigerant filled capillary
TX,9031,UU3137 1913AUG962/2
Heater and Air Conditioner Circuit

Operational Information
The following conditions must exist for air conditioning 9031

circuit to function: 05
3
Key switch On
Machine running
Air conditioning switch turned On
Any of the four blower motor On speeds selected on air
conditioner controller
TX,9031,UU3138 1913AUG961/1

101603
PN=641
Theory of Operation
Heater and Air Conditioner Circuit Theory of Operation
Power flows from the A/C Controller and Relays 5 amp selected, the resistor block is bypassed and the blower
Fuse to the air conditioner controller and energizes the motor operates at maximum speed.
following relays:
With air conditioning switch turned ON in the air
A/C compressor clutch relay (K25) conditioner controller, power flows to the A/C high and
A/C blower motor (medium low speed) relay (K26) low pressure switch (B27). The switch (B27) contains
A/C blower motor (medium speed) relay (K27) both a low pressure switch and a high pressure switch.
A/C blower motor (high speed) relay (K28) With low pressure switch closed, power flows through
A/C blower motor and main power (low speed) relay high pressure switch. With high pressure switch
(K24) closed, power flows through the A/C compressor clutch
relay (K25) to operate the A/C compressor clutch (Y1).
Power from the blower motor 20 amp fuse is applied to
terminal 1 of the A/C compressor clutch relay (K25). The low pressure switch opens if the air conditioning
system loses its refrigerant charge. The switch opens
Power from the 20 amp fuse also goes through the to stop current flow to the compressor, which prevents
A/C blower motor and main power (low speed) relay to compressor engagement.
operate the A/C and heater blower motor (M6).
The high pressure switch protects the system from
The air conditioner controller (A3) operates the blower high pressure. If a malfunction or line restriction
motor in four different speeds: causes the high pressure to increase above the setting
of the switch, will open to stop current flow to the
Low speed compressor clutch.
Medium low speed
Medium speed The A/C and heater thermistor (B29) is used to sense
High speed the temperature in the evaporator core. When the
temperature in the evaporator core raises, the blower
When any of the first three speeds is selected, power thermistor senses the warmer temperature and the air
flows through the dropping resistor block (R11) and conditioner controller applies voltage to the
then to the blower motor. When the high speed is compressor.
9031
05
4
TX,9031,UU3139 1913AUG961/1

101603
PN=642
Theory of Operation
Heater and Air Conditioner Circuit Functional Schematic

T117938 1930NOV98
TX,9031,UU3140 1904NOV981/1

101603
PN=643
Theory of Operation

Conditioner) Operational Information
The key switch must be in the ACC or On position for the

heater circuit to function.
CED,OUTX782,3 1918NOV981/1

Conditioner) Theory of Operation
Power from the F13 Blower Motor 20 amp Fuse is applied

to the plus (+) terminal of the S4 Heater Blower Motor
Switch. On machines equipped with air conditioner, power
is also applied to the X16 Air Conditioner Harness to Cab
Harness Connector.
Power from the blower motor switch is applied through R2

Heater Blower Motor Dropping Resistor Block. The
resistor block applies different voltages to the motor,
depending on the blower speed selected. For low speed,
power is applied through the maximum resistance,
resulting in the lowest voltage. For high speed, the
resistors are bypassed and full voltage is applied to the
motor. Motor ground is applied to the minus (-) motor
terminal.
9031
05
6
CED,OUTX782,4 1918NOV981/1

101603
PN=644
Theory of Operation
Heater Circuit (Machines Without Air Conditioner) Functional Schematic
9031
05
7
1918NOV98
T117937
CED,TX02661,251 1904NOV981/1

101603
PN=645
Theory of Operation
Receiver/Dryer Operation
The receiver/dryer is a reservoir to store excess liquid

refrigerant in the system. Excess refrigerant is required for
two reasons:
Outside air temperature and humidity have an effect on

the minimum quantity of refrigerant required in the system
for the air conditioner to operate at maximum efficiency.
The higher the temperature and humidity, the more
refrigerant required in the system. More refrigerant is
required due to the expansion valve opening farther
allowing more refrigerant into the low pressure side of the
system.
Refrigerant hoses allow a small amount of refrigerant to

migrate through their walls. Extra refrigerant stored in the
system allows for a longer period of time before additional
refrigerant is needed.
UN19OCT93
The receiver/dryer also contains two filters (E) and
desiccant (F) between the filters. The filters remove solid
materials which could be generated by a compressor
failure, debris left in the system due to improper service
T8104AE
procedures, or particles caused by corrosion of metal
parts due to moisture and acids in the system (also
caused by improper service procedures).
Desiccant is used to absorb moisture. If too much

moisture gets into the system, the desiccant may not be
able to absorb it all. When moisture is combined with
refrigerant oil, a sludge is formed. This sludge does not
9031 permit moving parts to be adequately lubricated. When
05 moisture is combined with refrigerant, hydrofluoric and
UN10JAN94
8
hydrochloric acids are formed. These acids are very
corrosive to metal surfaces and leakage will eventually
develop. If the air conditioning system is left open for a
T8104AF
period of time or if the plugs are removed from the
receiver/dryer, the desiccant will also absorb moisture
from the air. The receiver/dryer contains a color moisture
indicator. (Blue) indicates dryer is dry. (Pink) indicates AInlet Port
moisture in the desiccant. Evacuating the system will not BSight Glass
remove moisture from the desiccant. You must replace COutlet Port
DPickup Tube
the receiver/dryer.
EFilter
FDesiccant
GStrainer
HSpring
IReceiver/Dryer
JWet/Dry Indicator
Continued on next page TX,9031,UU3144 1913AUG961/2

101603
PN=646
Theory of Operation
A sight glass is installed in the receiver/dryer outlet port. If

the refrigerant level is low, a steady stream of gas
bubbles will be present in the liquid flowing from the
receiver/dryer. These gas bubbles can be seen in the
sight glass and are an indication that the system needs
charging. However, bubbles may be present when the
compressor clutch first engages but must disappear after
a few seconds. If the sight glass is clear, the system
either has a sufficient charge or is completely discharged.
TX,9031,UU3144 1913AUG962/2
9031
05
9

101603
PN=647
Theory of Operation
Expansion Valve Operation
1924SEP92
T7828AY
AValve Diaphragm DOperating Pin GValve Spring JDischarge from Evaporator
BSealed Sensing Bulb EInlet Flow HBall Seat KInternal Equalization
COutlet to Compressor FMetering Orifice IOutlet to Evaporator Passage
9031
05 The expansion valve is used to regulate the amount of The metering orifice (F) and ball seat area (H) in the
10 refrigerant flowing into the evaporator. At this point in expansion valve is relatively small. The rapidly
the system, the high pressure/high temperature liquid expanding refrigerant passing through this area can
is sprayed into the evaporator where it changes state cause any moisture in the system to freeze at this
and becomes a gas. point and block refrigerant flow. Other contaminants in
the system can also cause a valve to malfunction. If
The valve diaphragm (A) is activated by sensing expansion valve malfunctions, it must be replaced.
temperature and pressure within the valve body. The Expansion valve is not repairable.
sealed sensing bulb (B) senses the evaporator outlet
(I) or discharge temperature and pressure of the
refrigerant as it passes through the valve back to the
low pressure or suction side of the compressor.
TX,9031,UU3145A 1913AUG961/1

101603
PN=648
Theory of Operation
Compressor Relief Valve Operation
The compressor relief valve is a direct acting pressure If the relief valve opens, a loud popping noise will be
limiting valve. If a malfunction in the system occurs heard. Some oil may also be lost from the system.
that would cause high pressure, such as a restricted Correct any condition that would cause the valve to
line, the valve will open near 4137 kPa (41.4 bar) (600 open.
psi) and remain open until pressure drops to below the
valve setting.
TX,9031,UU3146 1913AUG961/1
Temperature Control (Early Models)
1929AUG96
Temperature control is adjusted by the position of the
heater temperature switch in the cab. This switch is
mechanically connected to the water valve at the base of
T103130
the heater core. Turning the heater temperature switch
towards maximum and/or towards off opens and closes
the water valve controlling engine coolant flow through the
heater core, thus controlling the temperature inside the
cab.
In certain conditions when the air conditioning switch is

turned on and the blower switch is in low position, the cab
temperature may still be too cool. It may be necessary to
blend heat with cooling to get a comfortable cab
temperature.
9031
05
CED,OUTX817,50 1905APR001/1
11

101603
PN=649
Theory of Operation
Heater and Air Conditioner Controller

Operation (Later Models)
Temperature control can be manually adjusted by

temperature control switch (J). This switch operates the
A/C air mixture servomotor which opens and closes a
UN16JUL99
valve to control engine coolant into the heater core. Eight
temperature indicator lights above switch display a
selected temperature range from 2030C (6886F).
The cab temperature can be selected in 13 different
T122361
increments between maximum cooling and maximum
heating. The indicators illuminate one or two at a time and
move left and right to show increasing or decreasing
temperature as switch (J) is pressed. AMode Switch
BMode Switch
CMode Switch
Air is directed to different locations in the cab by the A/C DAir Conditioner Switch
blower port change servomotor M10. This servomotor is EAUTO Switch
controlled by mode switches (A, B and C). Switch (A) FAir Circulation Mode Switch
directs air to the defrost and front vents located in the GFresh Air Mode Switch
HBlower Speed Switches
front console, switch (B) directs air to the defrost vent, IBlower OFF Switch
front vent, and vents behind the seat, and switch (C) JTemperature Control Switches
directs air underneath the seat.
Blower speed can be manually selected by blower speed

switches (H). Switches (F and G) control the internal and
external cab air servomotor M9 which opens and closes
the fresh air vent on the blower intake. When switch (G) is
pressed, M9 servomotor open vent and allows fresh air to
be drawn through blower. When switch (F) is pressed,
fresh air vent will be closes and cab air will be recirculated
through the blower.
9031 When AUTO switch (E) is pressed, the controller

05
automatically adjusts temperature control and blower
12
speed to maintain the cab temperature selected by the
operator. The automatic mode will function with or without
the air conditioner on and can be turned off by pressing
the OFF switch (I) or selecting any of the four blower
speed switches (H). In cold weather conditions when
engine coolant temperature is cold and AUTO switch (E)
and mode switch (C) are selected, blower automatically
runs on low speed until coolant temperature heats up.
This prevents cool air from entering the cab.
CED,OUTX817,51 1906APR001/1

101603
PN=650
Group 10
Heating and Air Conditioning Operational Checks
This procedure is designed so the mechanic can make additional checks or repair information will be given.
a quick check of the system using a minimum amount The technical manual group or CTM number required
of diagnostic equipment. If you need additional for repair will be given. If verification is needed, you
information, read Theory of Operation (Group will be given next best source of information:
9031-05).
Group: 10 (System Operational Checks)
The engine or other major components must be at
operating temperature for some checks. Group: 15 (Diagnostic Information)
Locate system check in the left column and read Group: 20 (Adjustments)
completely, following this sequence from left to right.
Read each check completely before performing. Group: 25 (Tests)
At the end of each check, if no problem is found, that CTM (Component Technical Manual)
check is complete. When a problem is indicated,
TX,9031,UU3148 1925APR001/1
1 Visual Inspection of Components
9031
10
1/1
1
All Lines and Hoses Engine OFF. YES: Check complete.
Inspect all lines and hoses. NO: Reposition hoses or

lines and tighten or
Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts replace clamps. Tighten
or weather checked? fittings or replace O-rings
in fittings. Replace hoses
Are hose and line connections clean NOT showing signs of leakage, such as oil or or lines as required.
dust accumulation at fittings?
All hose and line clamps must be in place and tight. Clamps must have rubber inserts
or cushions in place to prevent clamps from crushing or wearing into hoses or lines?
1/1

101603
PN=651
Condenser Check Engine OFF. YES: Check complete.
Inspect condenser cores. NO: Clean, repair or

replace condenser core.
Is condenser core free of dirt or debris? Replace engine fan.
Does condenser show signs of leakage, dust accumulation or oily areas?
Are condenser fins straight, not bent or damaged?
Inspect engine fan.
Are fan blades in good condition, not worn, bent, broken or missing?
1/1
Evaporator Core Check Engine OFF. YES: Check complete.
Inspect core. NO: Repair, replace or

clean evaporator.
Are fins straight?
Is evaporator core free of dirt and debris?
1/1
Air Conditioner Engine OFF. YES: Go to next check.

Compressor Check
Inspect compressor. NO: Repair or replace
components as required.
9031 Is compressor drive belt tight? Is belt in good condition? Is belt tightening strap
10 straight?
2
Is compressor belt pulley in good condition?
Are compressor to bracket and bracket to engine mounting cap screws tight?
Is compressor pulley aligned with engine pulley?
Are electrical connections to compressor clutch clean and tight? Is wiring to

compressor in good condition?
1/1
Cab Door and Window Open and close door and windows. Inspect seals. YES: Check complete.
Seals Check
Do door and windows contact seals evenly? NO: Adjust door and
windows to close against
Are seals in position and in good condition? seals properly. Replace
seals as necessary.
1/1

101603
PN=652
2 System Operating Checks
1/1
Blower Motor Check YES: Check complete.
NO: See Circuit Checks

in this group. Check
wiring harness.
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
Engine OFF. Key switch ON.
Press blower motor switch to select each of the four speeds.
Does fan operate in four speeds?
Does air exit from ducts?

9031
Press the blower OFF switch. 10
3
Does fan stop?
1/1

101603
PN=653
Heater YES: Check complete.
NO: See Circuit Checks

in this group. Check
wiring harness.
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
Start engine and allow to warm several minutes.
Press heater temperature switch to maximum heat position. Press blower switch to
high speed position.
Does warm air exit from ducts?
1/1
9031
10
4

101603
PN=654
Air Conditioner Check YES: Check complete.
NO: See Heater and Air

Conditioner Circuit
Checks in this group. See
Charging the system in
Group 9031-20.
T103130 1929AUG96
Early Models
T124602 UN15SEP99
Later Models
Start engine and run at fast idle.
Press air conditioner switch to ON position.
Press blower switch to high speed position.
Press left temperature control switch to maximum cool position.
Wait for any warm air in duct system to dissipate.
Is air from ducts cool?
9031
10
1/1
5
Compressor Clutch Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner switch ON. YES: Check complete.
Check
Does compressor clutch click as switch is pushed? NO: Replace compressor
clutch.
1/1
3 Heater Circuit Checks (Machines Equipped with Heater Only)
1/1

101603
PN=655
3a Blower Motor 20 Remove fuse block cover. YES: Fuse is OK.

Amp Fuse (F13)
Check Remove fuse from fuse block. NO: Replace fuse. If fuse
blows again, check for
Using ohmmeter, check fuse for continuity. short.
1/1
3b Heater Blower Motor YES: Go to next check.

Switch (S4) Check
(Machines Equipped NO: Replace heater
with Heater Only) blower motor switch.
T111030 UN07AUG97
AHeater Blower Motor Switch
Disconnect wire harness from heater blower motor switch.
Connect ohmmeter to brown wire in switch connector and positive terminal of heater
blower motor.
Turn heater blower motor switch to Low speed. Does ohmmeter read approximately
7.6 ohms resistance?
Turn heater blower motor switch to Medium Low speed. Does ohmmeter read
9031 approximately 3.7 ohms resistance?
10
6 Turn heater blower motor switch to Medium High speed. Does ohmmeter read
approximately 1.2 ohms resistance?
Turn heater blower motor switch to High speed. Does ohmmeter read a lower
resistance than 1.2 ohms?
1/1
3c Heater Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
(M5) Check motor is good. Check
(Machines Equipped Connect 24 volts to heater blower motor, and ground motor. wiring harness.
with Heater Only)
Does heater blower motor operate? NO: Replace heater
blower motor.
1/1
4 Heater and Air Conditioner Circuit Checks
1/1

101603
PN=656
Blower Motor 20 Amp Remove fuse block cover. YES: Fuse is OK.
Fuse (F13) Check
Remove fuse from fuse block. NO: Replace fuse. If fuse
1/1
A/C Controller and Remove fuse block cover. YES: Fuse is OK.
Relays 5 Amp Fuse (F14)
Check Remove fuse from fuse block. NO: Replace fuse. If fuse
1/1
Air Conditioner Relay Disconnect harness from relay. YES: Relay is OK.
(K24, K25, K26, K27 and
K28) Check Connect 24 volts to relay terminal 1 and ground terminal NO: Relay has failed.
2. Replace.
9031
Does relay click? 10
7
T118624 UN23NOV98
1/1
Air Conditioner High and Disconnect harness from switch. YES: Switch is good.
Low Pressure Switch
(B27) Check Check for continuity between terminals. NO: Go to High and Low
Pressure Switch Test,
Is continuity measured? Group 9031-25.
T101619 1913JUN96
1/1

101603
PN=657
A/C and Heater Blower Disconnect harness from blower motor. YES: Blower motor is
Motor (M6) Check good. Check wiring
Ground blk/red wire terminal in connector. Connect 24 volts to red/wht wire pin in harness.
connector.
NO: Replace blower
Does blower motor operate in high speed? motor.
1/1
Air Conditioning Disconnect harness from clutch. YES: A/C compressor

Compressor Clutch (Y1) clutch coil is good. Check
Check Connect battery voltage to clutch connector pin that has wiring harness.
black/yellow wire. Ground black wire pin.
NO: Replace clutch coil.
Does clutch "click"?
T6534CV UN19OCT88
1/1
9031
10
8

101603
PN=658
Group 15
Diagnose Air Conditioning Electrical
Malfunctions
NOTE: Diagnostic charts are arranged from most

probable and simplest to verify, to least likely
more difficult to verify. Remember the following
steps when diagnosing a problem:
Step 1. Operational Check Out Procedure

Step 2. Diagnostic Charts
Step 3. Adjustments and/or Tests
Heating System Does Not Blower motor 20 amp fuse (F13) Replace fuse. (See Replacing Fuses
Operate in Group 1674.)
Heater blower motor switch (S4) Check heater blower motor switch,
Group 9031-10.
Heater blower motor (M5) Check heater blower motor, Group

9031-10.
Air Conditioning System Does A/C controller and relays 5 amp fuse Replace fuse.
Not Operate (F14)
Blower motor 20 amp fuse (F13) Replace fuse. (See Replacing Fuses
in Group 1674.)
Air conditioner relays (K24, K25, Check air conditioner relays, Group
K26, K27, or K28) 9031-10.
A/C high and low pressure switch Check high and low pressure switch, 9031
15
(B27) Group 9031-10.
1
A/C and heater blower motor (M6) Check A/C and heater blower motor,
Group 9031-10.
Compressor clutch (Y1) Check compressor clutch, Group

9031-10.
TX,9031,UU3149 1904OCT001/1

101603
PN=659
Air Conditioner Harness (W9) Component Location

T118135 1930NOV98
A3
AIR
CONDITIONER M10
CONTROLLER AIR CONDITIONER K24 PIN 3, K25 PIN 3 YEL 1
BLOWER PORT K26 PIN 4, K27 PIN 4, K28 PIN 4,
CHANGE SERVOMOTOR R11 R11 PIN 4, X17 PIN 14 BLK 2
AIR CONDITIONER
K25 PIN 4, Y1 BLK/YEL 3
AND HEATER
BLOWER MOTOR K24 PIN 1, K25 PIN 1, K26 PIN 1,
DROPPING RESISTOR K27 PIN 1, K28 PIN 1, X17 PIN 1 YEL 4 ENGINE
X18 BLOCK
X17 AIR CONDITIONER
AIR CONDITIONER CONTROLLER M6 X16
CONTROLLER CONNECTOR AIR CONDITIONER AIR CONDITIONER AIR CONDITIONER
CONNECTOR (12-PIN) AND HEATER HARNESS TO COMPRESSOR
(16-PIN) HEATER CORE BLOWER MOTOR CAB HARNESS
AIR CONDITIONER CONNECTOR Y1
EVAPORATOR COMPRESSOR
2 1
M11 CLUTCH
K28 3 4
AIR CONDITIONER AIR CONDITIONER
BLOWER MOTOR AIR MIXER
(HIGH SPEED) RELAY SERVOMOTOR
K27
AIR CONDITIONER
BLOWER MOTOR
(MEDIUM SPEED)
RELAY
K26
AIR CONDITIONER
BLOWER MOTOR
(LOW MEDIUM SPEED)
RELAY B29
K25 AIR CONDITIONER
AIR CONDITIONER AND HEATER
COMPRESSOR THERMISTOR
K24
CLUTCH RELAY
AIR CONDITIONER M9
BLOWER MOTOR B27
AIR CONDITIONER AIR CONDITIONER
AND MAIN POWER INTERNAL AND
(LOW SPEED) RELAY HIGH AND LOW
EXTERNAL CAB PRESSURE SWITCH
AIR SERVOMOTOR (SEE DETAIL A -
EVAPORATOR
CONNECTIONS)
CONDENSER
T118135 AIR CONDITIONER HARNESS (W9) COMPONENT LOCATION
TX,9031,GG2243 1912SEP961/2

101603
PN=660
1924NOV98
T118670
Air Conditioner Harness (W9) Component Location--Detail
A
TX,9031,GG2243 1912SEP962/2
9031
15
3

101603
PN=661
Air Conditioner Harness (W9) Connectors, Wire and Pin Location
9031
15
4
1918NOV98
T118195
Continued on next page CED,OUTX782,5 1918NOV981/2

101603
PN=662
9031
15
5
1918NOV98
T118196
CED,OUTX782,5 1918NOV982/2

101603
PN=663
9031
15
6

101603
PN=664
Group 20
Adjustments
TX,9031,UU3151 1913AUG961/1

treatment.
treatment. 1

container.
TX,9031,UU3152 1913AUG961/1

101603
PN=665
Adjustments
R134a Compressor Oil Charge Check
Remove compressor if R134a leakage was detected 3. Flush the complete system with TY16134 air
and repaired. See Remove and Install Compressor in conditioning flushing solvent.
Repair Manual.
4. If the compressor is serviceable, pour flushing
Drain oil from the compressor and record the amount. solvent in the manifold ports and internally wash out
See Compressor Oil Removal procedure in this group. the old oil.
NOTE: Drain oil and save if this is a new compressor. 5. Install a new receiver-dryer.
If the oil drained from a compressor removed from 6. Install required amount of TY22025 refrigerant oil in
operation is very black or the amount of oil is less than the compressor. (See R134a Component Oil
6 mL (0.2 fl oz), perform the following: Charge in this group.)
1. Remove and discard the receiver-dryer. 7. Connect all components, evacuate and charge the
system.
2. Remove, clean, but do not disassemble the
expansion valve.
TX,9031,UU3153 1913AUG961/1
R134a Compressor Oil Removal
1. Remove compressor from machine. See Remove and

9031 Install Compressor in Repair Manual.
20
2 2. Remove inlet/outlet manifold from compressor, and
clutch dust cover.
3. Drain oil into graduated container while rotating

compressor shaft.
4. Record measured oil and discard oil properly.
5. Install new oil. See R134a Component Oil Charge in

this group.
6. Install compressor. See Remove and Install

Compressor in Repair Manual.
TX,9031,UU3154 1913AUG961/1

101603
PN=666
Adjustments
R134a Component Oil Charge
SPECIFICATIONS 100 mL (3.4 fl oz) of new oil.

New Compressor Oil Capacity 230 20 mL (7.7 0.7 fl oz)
Amount Of New Oil Capacity 100 mL (3.4 fl oz) Specification
Amount Of New OilCapacity ............................... 100 mL (3.4 fl oz)
Flushed Compressor New Oil 330 20 mL (11.1 0.7 fl oz)
Capacity
New Compressor, Drained Oil 45 mL (1.5 fl oz)
Capacity
Used compressor removed from operation, oil
Used Compressor, Drained Oil 45 mL (1.5 fl oz) drained, and flushed requires 330 20 mL (11.1
Capacity
0.7 fl oz) of new oil.
Evaporator Oil Charge 130 mL (4.4 fl oz)
Condenser Oil Charge 65 mL (2.2 fl oz) Specification
Receiver-Dryer Oil Charge 30 mL (1.0 fl oz) Flushed Compressor New Oil
Capacity ............................................... 330 20 mL (11.1 0.7 fl oz)
Hoses Oil Charge 60 mL (2.0 fl oz) or 3 mL per
30 cm (0.1 fl oz per ft)
Hoses Approximate Total 600 cm (20 ft)
Length
2. When the complete system was not flushed add the

CAUTION: All new compressors are charged correct amount of oil for the compressor plus
with a mixture of nitrogen, R134a refrigerant amount of oil for each component that was
and TY22025 (R134a) refrigerant oil. Wear serviced.
safety goggles and discharge the
compressor slowly to avoid possible injury. New compressor from parts depot, drain and
return 45 mL (1.5 fl oz) of oil to the compressor.
Compressors can be divided into three categories
when determining the correct oil charge for the system. Specification
New Compressor, Drained
OilCapacity ............................................................ 45 mL (1.5 fl oz)
New compressor from parts depot
Used compressor removed from operation (See Compressor Oil Removal procedure in this
Compressor internally washed with flushing solvent group.) 9031
20
Determining the amount of system oil charge prior to Used compressor removed from operation and oil 3
installation of compressor on a machine. drained. (See Compressor Oil Removal
procedure in this group.) Add 45 mL (1.5 fl oz) of
1. When the complete system, lines, and components new oil.
were flushed add the correct amount of oil as
described. Specification
Used Compressor, Drained
New compressor from parts depot contains the OilCapacity ............................................................ 45 mL (1.5 fl oz)
amount of new oil of 230 20 mL (7.7 0.7 fl
oz).
Specification Used compressor removed from operation, oil

New Compressor OilCapacity ............ 230 20 mL (7.7 0.7 fl oz) drained, and flushed add 60 mL (2.0 fl oz) of new
oil.
System requires an additional amount of new oil of
Continued on next page CED,TX14795,4338 1904MAR981/2

101603
PN=667
Adjustments
Components listed which have been removed, formula to determine the correct amount of oil to be
drained or flushed, require the removal of the added.
compressor to determine the correct oil charge.
Use the chart as a guide for adding oil to
CAUTION: DO NOT leave the system or
components.
R134a compressor oil containers open. This
Specification
oil easily absorbs moisture. DO NOT spill
EvaporatorOil Charge ......................................... 130 mL (4.4 fl oz) R134a compressor oil on acrylic or ABS
CondenserOil Charge ........................................... 65 mL (2.2 fl oz) plastic. This oil will deteriorate these
Receiver-DryerOil Charge ..................................... 30 mL (1.0 fl oz) materials rapidly. Identify R134a oil
HosesOil Charge ............................... 60 mL (2.0 fl oz) or 3 mL per containers and measures to eliminate
30 cm (0.1 fl oz per ft)
Approximate Total Length ............................................ 600 cm (20 ft)
accidental mixing of different oils.
If any section of hose is removed and flushed or

replaced, measure the length of hose and use the
CED,TX14795,4338 1904MAR982/2
9031
20
4

101603
PN=668
Adjustments
R134a Refrigerant Recovery, Recycling, and

Charging Station Installation Procedure
ESSENTIAL TOOLS
JT02045 HFC134a Refrigerant Recovery/Recycling and Charging
Station
JT02046 HFC134a Charging Station (Alternate)
JT02050 HFC134a Recovery/Recycling and Charging Station
(Alternate)
UN01DEC98
CAUTION: Do not remove high pressure relief
valve (H). Air conditioning system will
discharge rapidly causing possible injury.
T118687
IMPORTANT: Use correct refrigerant recovery,
NOT mix refrigerant, hoses, fittings,
AHigh Pressure Test Port
components or refrigerant oils.
BBlue Hose
CRed Hose
NOTE: JT02046 and JT02050 HFC134a Refrigerant DHigh Pressure Hose
Recovery/Recycling and Charging Station can be ELow Pressure Hose
substituted for the JT02045 HFC134a Refrigerant FLow Pressure Test Port
GRefrigerant Recovery/Recycling and Charging
Recovery/Recycling and Charging Station.
Station
HHigh Pressure Relief Valve
1. Close both high and low pressure valves on refrigerant
recovery, recycling and charging station (G).
2. Remove cap from low pressure test port (F).
3. Connect low pressure blue hose (B) from refrigerant

recovery, recycling and charging station (G) to low
pressure test port (F) on compressor. 9031
20
4. Connect high pressure red hose (C) to high pressure 5
quick disconnect.
5. Follow the manufacturers instructions when using the

refrigerant recovery, recycling and charging station.
CED,TX14795,4339 1904OCT001/1

101603
PN=669
Adjustments
Recover R134a System
ESSENTIAL TOOLS
Station
(Alternate)
UN01DEC98
T118687
BBlue Hose
NOTE: JT02046 and JT02050 HFC134a Refrigerant
CRed Hose
Recovery/Recycling and Charging Station can be DHigh Pressure Hose
substituted for the JT02045 HFC134a Refrigerant ELow Pressure Hose
Recovery/Recycling and Charging Station. FLow Pressure Test Port
Station
1. Run the air conditioning system for three minutes to
help in the recovery process. Turn air conditioning
system off before proceeding with recovery steps.
2. Connect refrigerant recovery, recycling and charging

station. (See installation procedure in this group.)

9031 refrigerant recovery, recycling and charging station.
20
6
CED,TX14795,4340 1904OCT001/1

101603
PN=670
Adjustments
Evacuate R134a System
SPECIFICATIONS
System Evacuation Vacuum 98 kPa (980 mbar) (29 in Hg)
Pressure
Subtract Pressure For Each 3.4 kPa (34 bar) (1 in. Hg)
300m (1000 ft) Elevation
Pressure
If System Evacuation Vacuum 15 Minutes
Cannot Be Obtained, Test
System For Leaks. Time
UN01DEC98
Evacuation Time 15 minutes
Leak If Vacuum Decreases More 3.4 kPa (34 mbar) (1 in. Hg)
Than Pressure
Evacuate System Time For 30 min. After 98 kPa (980
T118687
mbar) (29 in. Hg) Vacuum
ESSENTIAL TOOLS
BBlue Hose
Station
CRed Hose
JT02046 HFC134a Charging Station (Alternate) DHigh Pressure Hose
JT02050 HFC134a Recovery/Recycling and Charging Station ELow Pressure Hose
(Alternate) FLow Pressure Test Port
Station

9031
20
Do not run compressor while 7
evacuating.

Recovery/Recycling and Charging Station can be
substituted for the JT02045 HFC134a Refrigerant

2. Open low and high pressure valves on refrigerant

recovery, recycling and charging station.
Continued on next page CED,TX14795,4341 1904OCT001/3

101603
PN=671
Adjustments
3. Follow the manufacturers instructions and evacuate

the system.
NOTE: The vacuum specifications listed are for sea level

conditions.
4. Evacuate system until low pressure gauge registers 98

kPa (980 mbar) (29 in. Hg) vacuum.
Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa

(980 mbar) (29 in. Hg) for each 300 m (1000 ft)
elevation above sea level.
Specification
System Evacuation Vacuum
Pressure ..................................................... 98 kPa (980 mbar) (29 in Hg)
Subtract Pressure For Each
300m (1000 ft) Elevation
Pressure .......................................................... 3.4 kPa (34 bar) (1 in. Hg)
If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be

obtained in 15 minutes, test the system for leaks.
Specification
If System Evacuation Vacuum
Cannot Be Obtained, Test
System For Leaks.Time ........................................................ 15 Minutes
(See Leak Testing in Group 9031-25).
Specification
EvacuationTime .................................................................... 15 minutes
Correct any leaks.

9031
20 5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close
8
low-side and high-side valves. Turn vacuum pump off.
6. If the vacuum decreases more than 3.4 kPa (34 mbar)

(1 in. Hg) in 5 minutes, there is a leak in the system.
Specification
Leak If Vacuum Decreases More
ThanPressure............................................ 3.4 kPa (34 mbar) (1 in. Hg)
7. Repair leak.
8. Start to evacuate.
9. Open low-side and high-side valves.
Continued on next page CED,TX14795,4341 1904OCT002/3

101603
PN=672
Adjustments
10. Evacuate system for 30 minutes after 98 kPa (980

mbar) (29 in. Hg) vacuum is reached.
Specification
Evacuate SystemTime ............................ For 30 min. After 98 kPa (980
mbar) (29 in. Hg) Vacuum
11. Close low-side and high-side valves. Stop evacuation.
12. Charge the system. (See procedure in this group.)
CED,TX14795,4341 1904OCT003/3
9031
20
9

101603
PN=673
Adjustments
Charge R134a System
SPECIFICATIONS
Pump Must Be Capable Of 28.6 in. Hg at Sea Level
Pulling Vacuum
Subtract From Standard Vacuum 3.4 kPa (34 mbar) (1 in. Hg)
For Each 300 m (1000 ft) Above
Sea Level Vacuum
Refrigerant Charge Weight 0.95 kg (2.1 lb)
ESSENTIAL TOOLS
UN01DEC98
Station
T118687
(Alternate)
CAUTION: Do not remove high pressure relief AHigh Pressure Test Port
BBlue Hose
CRed Hose
discharge rapidly causing possible injury. DHigh Pressure Hose
ELow Pressure Hose
IMPORTANT: Use correct refrigerant recovery, FLow Pressure Test Port
recycling and charging stations. DO GRefrigerant Recovery/Recycling and Charging
Station

Recovery/Recycling and Charging Station can be
substituted for the JT02045 HFC134a Refrigerant
9031 1. Connect refrigerant recovery, recycling and charging

20 station. (See installation procedure in this group.)
10
2. Evacuate the system. (See Evacuate Air Conditioning
System, this group.)

101603
PN=674
Adjustments
NOTE: Before beginning to charge air conditioning

system, the following conditions must exist:
Engine STOPPED, the pump must be capable of
pulling at least 28.6 in. Hg vacuum (sea level).
Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa
(980 mbar) (29 in. Hg) for each 300 m (1000 ft)
elevation above sea level.
Specification
Pump Must Be Capable Of
PullingVacuum ................................................. 28.6 in. Hg at Sea Level
Subtract From Standard Vacuum
For Each 300 m (1000 ft) Above
Sea LevelVacuum ..................................... 3.4 kPa (34 mbar) (1 in. Hg)
3. Follow the manufacturers instructions and charge the

system.
4. Add refrigerant to charge system.
Specification
Refrigerant ChargeWeight .............................................. 0.95 kg (2.1 lb)
5. Do air conditioner checks and tests in Groups 9031-10

and 9031-25.
9031
20
CED,TX14795,4342 1922NOV002/2
11

101603
PN=675
Adjustments
Check and Adjust Compressor Belt Tension
SPECIFICATIONS (0.75 in.) at 400 N (90 lb force).

Belt Deflection at 400 N (90 lb 19 mm (0.75 in.)
force) Deflection Specification
If Belt Deflection Not To 810 Minutes Belt DeflectionDeflection .................. 19 mm (0.75 in.) at 400 N (90
lb force)
Specification Cool Time
SERVICE EQUIPMENT AND TOOLS If belt deflection excessive , allow belt to cool for 8
10 minutes and try again.
Belt Tension Gauge
Specification
IMPORTANT: Never over tighten belt. Over If Belt Deflection Excessive
tightening may cause belt cord Cool............................................................................... 810 Minutes
damage and excessive load on
bearings. IMPORTANT: Force to adjust belt must be applied
to front of compressor housing only
1. Run engine for five minutes. Stop the engine, then to prevent damage to compressor.
immediately check tension using a belt tension
gauge. 3. Loosen compressor mounting cap screws. Apply
force to front of compressor housing to tighten belt.
2. Measure strand tension or deflection at a point Tighten cap screws.
halfway between pulleys. Belt must deflect 19 mm
4. Repeat Steps 1 and 2 to check belts.
CED,TX14795,4343 1904MAR981/1
9031
20
12

101603
PN=676
Group 25
Tests
TX,9031,UU3151 1913AUG961/1

treatment.
treatment. 1

container.
TX,9031,UU3152 1913AUG961/1

101603
PN=677
Tests
R134a Air Conditioning System Test
SPECIFICATIONS
Engine Speed 2180 rpm
Temperature Control Switch Maximum Cooling
Position
Blower Speed High
Run Unit For At Least Time 5 Minutes
Ambient Temperature Air Duct Temperature Low Pressure Gauge High Pressure Gauge
16C (60F) 13C (55F) 7165 kPa (0.071.6 bar) (124 psi) 6301095 kPa (611 bar) (90160
psi)
21C (70F) 16C (60F) 7180 kPa (0.071.8 bar) (126 psi) 7851225 kPa (7.612 bar) (110
175 psi)
27C (80F) 18C (65F) 7205 kPa (0.072.1 bar) (130 psi) 9551410 kPa (9.614.1 bar) (140
205 psi)
32C (90F) 21C (70F) 7240 kPa (0.072.4 bar) (135 psi) 11451645 kPa (11.416.5 bar)
(165240 psi)
(195280 psi)
(230330 psi)
ESSENTIAL TOOLS
Station
(Alternate)

9031 recycling and charging stations. DO
25 NOT use refrigerant, hoses, fittings,
2 components or refrigerant oils intended
for R12 refrigerant.

2. Close both low and high pressure valves on refrigerant

recovery, recycling and charging station.
3. Open cab doors and windows.

101603
PN=678
Tests
4. Connect low pressure blue hose (B) from refrigerant

recovery, recycling and charging station (G) to low
pressure test port (F) on compressor.
5. Connect high pressure red hose (D) to high pressure

quick-disconnect on compressor.

refrigerant recovery, recycling and charging station.
7. Start engine and run at fast idle.
UN01DEC98
Specification
EngineSpeed ........................................................................... 2180 rpm
T118687
8. Press temperature control switch at the maximum
cooling position.
Specification AHigh Pressure Test Port

Temperature Control Switch BBlue Hose
Position .......................................................................... Maximum Cooling CRed Hose
DHigh Pressure Hose
ELow Pressure Hose
9. Press blower switch at high speed position.
FLow Pressure Test Port
Specification Station
BlowerSpeed .................................................................................... High HHigh Pressure Relief Valve
10. Check sight glass in receiver-dryer for bubbles or if

clean.
11. Run unit for at least 5 minutes.
Specification
Run Unit For At LeastTime ..................................................... 5 Minutes
9031
25
12. Measure air temperature at condenser air inlet and at 3
air ducts in air conditioning unit. Record readings.
13. Read low and high pressure gauges on refrigerant

recovery, recycling and charging station. Record
readings.
14. Compare pressure and temperature readings to the

specifications shown.

101603
PN=679
Tests
Ambient Temperature Air Duct Temperature Low Pressure Gauge High Pressure Gauge
16C (60F) 13C (55F) 7165 kPa (0.071.6 bar) (124 psi) 6301095 kPa (611 bar) (90160
psi)
21C (70F) 16C (60F) 7180 kPa (0.071.8 bar) (126 psi) 7851225 kPa (7.612 bar) (110
175 psi)
27C (80F) 18C (65F) 7205 kPa (0.072.1 bar) (130 psi) 9551410 kPa (9.614.1 bar) (140
205 psi)
(165240 psi)
(195280 psi)
(230330 psi)
15. Use the Operating Pressure Diagnostic Chart in this

group to diagnose the malfunction.
CED,OUOE003,1079 1904OCT003/3
9031
25
4

101603
PN=680
Tests
Operating Pressure Diagnostic Chart
9031
25
5
1928FEB89
T6609AB
TX,9031,UU3164 1919AUG981/1

101603
PN=681
Tests
High and Low Pressure Switch Test
SPECIFICATIONS
Low Pressure Switch (Normally 345 35 kPa (3.45 0.3 bar) (50
Open) Closes on Increasing 5 psi)
Pressure
UN06MAR95
Low Pressure Switch (Normally 173 35 kPa (1.73 0.3 bar) (25
Open) Opens on Decreasing 53 psi)
Pressure
High Pressure Switch (Normally 2760 138 kPa (27.6 1.38 bar)
(400 20 psi)
T8426AE
Closed) Opens on Increasing
Pressure
High Pressure Switch (Normally 1310 138 kPa (13.11 1.38
Closed) Closes on Decreasing bar) (190 20 psi)
Pressure

Volt-Ohm-Amp Meter
JT02051 3-Gauge Manifold w/Hose And Quick Coupler
NOTE: The line that attaches the high and low pressure
switch has a valve installed to prevent discharging
the air conditioning system when switch is
removed. The high pressure switch is normally
closed when removed from the machine. It does
not open when installed in the A/C system until
pressure exceeds specification.
1. Remove high and low pressure switch.
2. Connect a portable pressure source, such as a

hydraulic hand pump, to high and low pressure switch.
9031
25 3. Using an ohmmeter measure continuity between
6 terminals A and B until low pressure switch pressure
increases to switch closing pressure specification.
Specification
Low Pressure Switch (Normally
Open)Closes on Increasing
Pressure ............................................... 345 35 kPa (3.45 0.3 bar) (50
5 psi)
Low Pressure Switch (Normally
Open)Opens on Decreasing
Pressure ............................................... 173 35 kPa (1.73 0.3 bar) (25
53 psi)
Continued on next page CED,TX14795,4346 1904MAR981/2

101603
PN=682
Tests
4. Slowly increase pressure. Switch must have continuity

until pressure increases to high pressure switch
opening pressure specification.
Specification
High Pressure Switch (Normally
Closed)Opens on Increasing
Pressure ............................................... 2760 138 kPa (27.6 1.38 bar)
(400 20 psi)
High Pressure Switch (Normally
Closed)Closes on Decreasing
Pressure ..................................................... 1310 138 kPa (13.11 1.38
bar) (190 20 psi)
5. The low pressure switch can also be checked when

installed in air conditioning system, however, pressure
is slow to increase to test specification. High test
switch is not easily tested in system.
Connect an 3-gauge manifold for R134a to service

fittings at compressor. Cover condenser with paper or
plastic to stop air flow. Operate air conditioner on
maximum cooling. Note high-side pressure when high
pressure switch opens and then closes.
CED,TX14795,4346 1904MAR982/2
Leak Testing
1. Inspect all lines, fittings, and components for oily or 3. If a leak detector is used, move the leak detector
dusty spots. When refrigerant leaks from the probe under the hoses and around the connections 9031
system, a small amount of oil is carried out with it. at a rate of 25 mm (1 in.) per second. 25
7
2. A soap and water solution can be sprayed on the 4. Some refrigerant manufacturers add dye to
components in the system to form bubbles at the refrigerant to aid in leak detection.
source of the leak.
TX,9031,UU3168 1913AUG961/1

101603
PN=683
Tests
Refrigerant Hoses and Tubing Inspection
When a component is disconnected from the system, hose and tube connections. Dip O-rings in correct
special care should be given to inspecting hoses and viscosity oil before assembling.
tubing for moisture, grease, dirt, rust, or other foreign
material. If such contamination is present in hoses, IMPORTANT: Hose used for air conditioning
tubing, or fittings and cannot be removed by cleaning, systems contains special barriers in
then replace parts. its walls to prevent migration of
refrigerant gas.
Fittings that have grease or dirt on them should be
wiped clean with a cloth dampened with alcohol. DO NOT use hydraulic hoses as
Chlorinated solvents (such as trichloroethylene) are replacement hoses in the air
contaminants, and must not be used for cleaning. conditioning system. Use ONLY
certified hose meeting SAE J51B
To assist in making leak-proof joints, use a small requirements.
amount of clean correct viscosity refrigerant oil on all
TX,9031,UU3169 1913AUG961/1
9031
25
8

101603
PN=684
Index
Page Page
A Arm in and propel combined

Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-68
Accessory Arm reduced leakage valve
Electrical . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-9 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-60
Operational checkout . . . . . . . . . . . . . .9005-10-18 Arm regenerative solenoid valve
Adjuster Harness test . . . . . . . . . . . . . . . . . . . . .9025-25-39
Track, operation . . . . . . . . . . . . . . . . . . .9020-05-1 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-32
Adjustment Arm regenerative valve
Travel alarm volume . . . . . . . . . . . . . . .9015-20-10 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-58
Air conditioner harness Auto-idle mode
Component location . . . . . . . . . . . . . . . .9031-15-2 Speed control circuit . . . . . . . . . . . . . . .9010-05-12
Connectors . . . . . . . . . . . . . . . . . . . . . . .9031-15-4
Air conditioning
Charge R134a system . . . . . . . . . . . . .9031-20-10
Circuit checks . . . . . . . . . . . . . . . . . . . . .9031-10-6 B
Compressor belt tension . . . . . . . . . . . .9031-20-12
Compressor oil removal . . . . . . . . . . . . .9031-20-2 Battery
Compressor relief valve operation . . . . .9031-05-11 Booster . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-7
Controller operation (later models) . . . .9031-05-12 Check terminals . . . . . . . . . . . . . . . . . . .9015-20-4
Electrical circuit . . . . . . . . . . . . . . . . . . . .9031-05-3 Electrolyte level. . . . . . . . . . . . . . . . . . . .9015-20-4
Evacuate R134a system . . . . . . . . . . . . .9031-20-7 Malfunctions . . . . . . . . . . . . . . . . . . . . . .9015-20-2
Expansion valve . . . . . . . . . . . . . . . . . .9031-05-10 Operation . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
High pressure switch test . . . . . . . . . . . .9031-25-6 Specification . . . . . . . . . . . . . 9015-20-1, 9015-20-8
Hoses and tubing inspection . . . . . . . . . .9031-25-8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-6
Leak testing . . . . . . . . . . . . . . . . . . . . . .9031-25-7 Boom
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9031-15-1 Cylinder drift . . . . . . . . . . . . . . . . . . . . 9025-25-125
Operating checks . . . . . . . . . . . . . . . . . .9031-10-3 Lower with engine stopped . . . . . . . . . .9025-25-38
Receiver and dryer operation . . . . . . . . .9031-05-8 Boom reduced leakage valve
Recover R134a system. . . . . . . . . . . . . .9031-20-6 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-60
Recovery, recycling and charging Boom regenerative valve
R134a . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-5 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-66
Refrigerant handling . . . . . . 9031-05-1, 9031-20-1, Boom up and swing combined
9031-25-1 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-70
Refrigerant (R12 and R134a) caution . . .9031-05-1 Boost pressure
Refrigerant (R134a) caution . . . . . . . . . 9031-20-1, Engine power test using turbocharger . . .9010-25-8
9031-25-1 Brake valve
R12 refrigerant operation . . . . . . . . . . . .9031-05-2 Propel motor park, housing Indx
System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-2 operation . . . . . . . . . . . . . . . . . . . . . .9025-05-90 1
Temperature control (early models). . . .9031-05-11 Swing motor park, operation . . . . . . . . .9025-05-80
Temperature control (later models) . . . .9031-05-12 Bucket
Visual inspection of components . . . . . . .9031-10-1 Cylinder drift . . . . . . . . . . . . . . . . . . . . 9025-25-125
Air filter Bucket flow control valve
Restriction indicator switch test . . . . . . . .9010-25-3 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-62
Air flow Bushing
Radiator . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-5 Track chain, measure wear . . . . . . . . . . .9020-15-3
Air intake
System checks . . . . . . . . . . . . . . . . . . . .9010-10-6
Air intake system
Operational checkout . . . . . . . . . . . . . .9005-10-33 C
Air intake system leakage
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-4 Cab harness (W2)
Arm Component location . . . . . . . . . . . . . . .9015-10-20
Cylinder drift . . . . . . . . . . . . . . . . . . . . 9025-25-125 Connectors . . . . . . . . . . . . . . . . . . . . . .9015-10-23
TM1663 (28NOV01) Index-1 200LC Excavator Operation & Tests

101603
PN=1
Index
Page Page
Capacities Connector end view diagram

Drain and refill . . . . . . . . . . . . . . . . . . . .9000-02-6 Reading an end view diagram. . . . . . . .9015-05-28
Carrier roller oil specification . . . . . . . . . . .9000-04-6 Control lever pattern conversion . . . . . . . .9025-15-24
Circuit Malfunction Control valve
Electrical . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 Circuit schematic. . . . . . . . . . . . . . . . . .9025-05-40
Circuit relief valve Component identification . . . . . . . . . . . .9025-05-35
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-48 Component identification, bottom . . . . .9025-15-33
Test and adjustment . . . . . . . . . . . . . . .9025-25-68 Component identification, left front . . . .9025-15-31
Circuit symbols Component identification, right rear. . . .9025-15-32
Hydraulic system. . . . . . . . . . . . . . . . . .9025-05-98 Line identification, bottom . . . . . . . . . . .9025-15-30
Circuit, windshield wiper and washer Line identification, left front . . . . . . . . . .9025-15-26
Schematic . . . . . . . . . . . . . . . . . . . . . . .9015-15-26 Line identification, right rear . . . . . . . . .9025-15-28
Theory of operation. . . . . . . . . . . . . . . .9015-15-23 Neutral and power passages
Component operation . . . . . . . . . . . . . . . . . . . . . .9025-05-44
Harness test, miscellaneous . . . . . . . . .9025-25-51 Pilot operation. . . . . . . . . . . . . . . . . . . .9025-05-14
Component location Pilot pressure signal passage
Cab harness (W2). . . . . . . . . . . . . . . . .9015-10-20 operation . . . . . . . . . . . . . . . . . . . . . .9025-05-42
Engine and frame harness (W1) . . . . . .9015-10-16 Schematic . . . . . . . . . . . . . . . . . . . . . . 9025-05-100
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20 Controller
Main hydraulic system. . . . . . . . . . . . . .9025-15-35 Engine and pump, function . . . . . . . . . .9025-25-29
Monitor and relay harness (W3) . . . . . 9015-10-28, Pilot
9015-10-31 Metering and full stroke operation . . . .9025-05-9
Pilot controller-to-flow regulator valve John Deere Controller, pilot
pattern . . . . . . . . . . . . . . . . . . . . . . . .9025-15-37 Neutral operation . . . . . . . . . . . . . . . . . .9025-05-8
Pilot controller-to-flow regulator valve SAE Operation of control valve . . . . . . . . . . .9025-05-14
pattern . . . . . . . . . . . . . . . . . . . . . . . .9025-15-36 Cooling
Pilot flow regulator valve-to-control System checks . . . . . . . . . . . . . . . . . . . .9010-10-1
valve . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-38 Cooling system
Pressure and return system . . . . . . . . .9025-15-40 Fill and deaeration . . . . . . . . . . . . . . . .9010-20-12
Propel system . . . . . . . . . . . . . . . . . . . .9025-15-39 Cooling system checks. . . . . . . . . . . . . . . .9010-10-1
Reading a component diagram . . . . . . .9015-05-26 Counterbalance valve
Computer, laptop Propelling operation . . . . . . . . . . . . . . .9025-05-94
Excavator diagnostics program Crossover relief valve
Engine speed adjustment . . . . . . . . .9025-25-16 Propel motor test . . . . . . . . . . . . . . . . .9025-25-80
Engine speed factory settings . . . . . .9025-25-23 Swing motor, test . . . . . . . . . . . . . . . . .9025-25-75
Engine speed to pump flow rate Cycle time . . . . . . . . . . . . . . . . . . . . . . . .9025-25-52
Indx chart. . . . . . . . . . . . . . . . . . . . . . . .9025-25-24 Cylinder
2 Monitor data . . . . . . . . . . . . . . . . . . .9025-25-13 Boom, arm, and bucket operation . . . . .9025-05-96
Monitor data items. . . . . . . . . . . . . . .9025-25-21 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-96
Saving monitor data. . . . . . . . . . . . . .9025-25-15 Cylinder drift
Service codes . . . . . . . . . . . . . . . . . .9025-25-12 Boom, arm, and bucket. . . . . . . . . . . . 9025-25-125
Service codes list . . . . . . . . . . . . . . .9025-25-20
Troubleshooting. . . . . . . . . . . . . . . . .9025-25-26
Excavator diagnostics program install . . .9025-25-2
Excavator diagnostics program D
overview . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Excavator diagnostics program Deaeration
starting . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8 Cooling system . . . . . . . . . . . . . . . . . . .9010-20-12
Excavator diagnostics program Definition
uninstall . . . . . . . . . . . . . . . . . . . . . . . .9025-25-7 Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-8
General description . . . . . . . . . . . . . . . . .9025-25-1 High resistance circuit . . . . . . . . . . . . . . .9015-05-3
Reading service codes without diagnostics Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-5
program. . . . . . . . . . . . . . . . . . . . . . .9025-25-27 Sensor circuit shorted to ground . . . . . .9015-05-16

101603
PN=2
Index
Page Page
Sensor circuit shorted to itself . . . . . . . .9015-05-14 Sensor circuit shorted to power. . . . . . .9015-05-12
Sensor circuit shorted to power. . . . . . .9015-05-12 Shorted circuit. . . . . . . . . . . . . . . . . . . .9015-05-10
Shorted circuit. . . . . . . . . . . . . . . . . . . .9015-05-10 Switch specifications . . . . . . . . . . . . . . .9015-15-42
Diagnose malfunctions System functional schematic . . . . . . . . .9015-10-10
Dig circuit . . . . . . . . . . . . . . . . . . . . . . .9025-15-17 System functional schematic, reading a
Electronic component . . . . . . . . . . . . . . .9025-15-2 schematic . . . . . . . . . . . . . . . . . . . . .9015-05-22
Hydraulic system. . . . . . . . . . . . . . . . . .9025-15-13 Test equipment . . . . . . . . . . . . . . . . . . .9015-05-17
Pilot circuit . . . . . . . . . . . . . . . . . . . . . .9025-15-16 Test procedure . . . . . . . . . . . . . . . . . . .9015-05-18
Propel system . . . . . . . . . . . . . . . . . . . .9025-15-20 Visual inspection . . . . . . . . . . . . . . . . . . .9015-05-1
Swing circuit . . . . . . . . . . . . . . . . . . . . .9025-15-19 Wiring diagram, reading . . . . . . . . . . . .9015-05-24
Diagnostic malfunctions Electrical circuit
Control valve components. . . . . . . . . . . .9025-15-2 Accessory . . . . . . . . . . . . . . . . . . . . . . .9015-15-38
Diagnostic procedure . . . . . . . . . . . . . . . . .9025-15-1 Charging . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-8
Diesel engine oil. . . . . . . . . . . . . . . . . . . . .9000-04-4 Engine and pump controller . . . . . . . . .9015-15-66
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1 Fuel shutoff . . . . . . . . . . . . . . . . . . . . . .9015-15-14
Dig circuit Monitor . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-44
Diagnose malfunctions . . . . . . . . . . . . .9025-15-17 Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-2
Dig pilot pressure signal passage Starting . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-14
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-42 Travel alarm . . . . . . . . . . . . . . . . . . . . .9015-15-94
Digital pressure and temperature analyzer Windshield wiper and washer . . . . . . . .9015-15-22
Installation. . . . . . . . . . . . . . . . . . . . . . .9025-25-31 Work and Drive Light . . . . . . . . . . . . . .9015-15-32
Digital thermometer installation. . . . . . . . .9025-25-30 Electrical diagnostic procedures
Door Charging circuit . . . . . . . . . . . . . . . . . . .9015-15-11
Operational checkout . . . . . . . . . . . . . .9005-10-23 Cigarette lighter. . . . . . . . . . . . . . . . . . .9015-15-40
Drain and refill Dome light . . . . . . . . . . . . . . . . . . . . . .9015-15-40
Capacities . . . . . . . . . . . . . . . . . . . . . . . .9000-02-6 Engine and pump controller circuit . . . .9015-15-70
Drive gearbox and pump Heater. . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-40
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-18 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-40
Dynamic braking Key switch check . . . . . . . . . . . . . . . . .9015-15-16
Swing . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-54 Monitor circuit . . . . . . . . . . . . . . . . . . . .9015-15-52
Power circuit . . . . . . . . . . . . . . . . . . . . . .9015-15-4
Starting and fuel shutoff circuit . . . . . . .9015-15-16
Travel alarm circuit . . . . . . . . . . . . . . . .9015-15-96
E Windshield washer circuit . . . . . . . . . . .9015-15-27
Winshield wiper Circuit . . . . . . . . . . . . .9015-15-27
E (economy) mode Work and drive light circuit . . . . . . . . . .9015-15-34
Speed control circuit . . . . . . . . . . . . . . . .9010-05-8 Electronic tachometer installation . . . . . . . 9010-20-1, Indx
Electrical 9025-25-30 3
Battery specification . . . . . . . . . . . . . . . .9015-20-1 Engine
Circuit Malfunction . . . . . . . . . . . . . . . . .9015-05-2 Auto-idle mode speed control circuit . . .9010-05-12
Component identification . . . . . . . . . . . . .9015-10-3 Boost starting . . . . . . . . . . . . . . . . . . . . .9015-20-7
Component location . . . . . . . . . . . . . . .9015-05-26 Cooling system operational
Connector end view diagram. . . . . . . . .9015-05-28 checkout . . . . . . . . . . . . . . . . . . . . . .9005-10-28
Fuse specifications . . . . . . . . . . . . . . . . .9015-10-1 Diagnose malfunctions . . . . . . . . . . . . . .9010-15-2
Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-8 E (economy) mode speed control
High resistance circuit . . . . . . . . . . . . . . .9015-05-3 circuit. . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-8
Monitor specifications . . . . . . . . . . . . . .9015-15-42 Engine rpm dial speed control circuit . . .9010-05-6
Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-5 Engine speed learning control circuit. . .9010-05-14
Schematic symbols . . . . . . . . . . . . . . . .9015-05-30 HP (high power) mode speed control
Schematic, wiring diagram, and component circuit. . . . . . . . . . . . . . . . . . . . . . . . .9010-05-10
location information . . . . . . . . . . . . . .9015-05-20 Injection pump fast and slow idle stop
Sensor circuit shorted to ground . . . . . .9015-05-16 adjutment . . . . . . . . . . . . . . . . . . . . . .9010-20-6
Sensor circuit shorted to itself . . . . . . . .9015-05-14 Operational . . . . . . . . . . . . . . . . . . . . . . .9010-10-1

101603
PN=3
Index
Page Page
Power test using turbocharger boost Fast and slow idle

pressure . . . . . . . . . . . . . . . . . . . . . . .9010-25-8 Injection pump stops adjustment . . . . . . .9010-20-6
Sectional view. . . . . . . . . . . . . . . . . . . . .9010-05-2 Filter
Speed adjust, excavator diagnostics program Hydraulic oil, inspection procedure . . . .9025-25-35
special function . . . . . . . . . . . . . . . . .9025-25-16 Pilot
Speed check . . . . . . . . . . . . . . . . . . . . . .9010-20-5 Operation . . . . . . . . . . . . . . . . . . . . . .9025-05-5
Speed control motor adjustment . . . . . . .9010-20-8 Return, operation . . . . . . . . . . . . . . . . .9025-05-97
Speed control system . . . . . . . . . . . . . . .9010-05-4 Flow combiner valve
Speed factory setting, diagnostic program special Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-54
function . . . . . . . . . . . . . . . . . . . . . . .9025-25-23 Flow regulator valve
Speed learning procedure . . . . . . . . . . .9010-20-10 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-16
Speed to pump flow rate chart . . . . . . .9025-25-24 Front idler
Engine and frame harness (W1) Measure wear . . . . . . . . . . . . . . . . . . . .9020-15-10
Component location . . . . . . . . . . . . . . .9015-10-16 Fuel
Connectors . . . . . . . . . . . . . . . . . . . . . .9015-10-17 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1
Engine and pump controller System checks . . . . . . . . . . . . . . . . . . .9010-10-10
Function . . . . . . . . . . . . . . . . . . . . . . . .9025-25-29
Fuel line
Engine control motor
Leakage test . . . . . . . . . . . . . . . . . . . . . .9010-25-2
Harness test . . . . . . . . . . . . . . . . . . . . .9025-25-49
Fuel shut-off solenoid
Engine control sensor
Check & adjust linkage . . . . . . . . . . . . . .9010-20-2
Harness test . . . . . . . . . . . . . . . . . . . . .9025-25-47
Fuel system
Engine oil
Operational checkout . . . . . . . . . . . . . .9005-10-36
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-4
Engine rpm dial Functional schematic and component location
Speed control circuit . . . . . . . . . . . . . . . .9010-05-6 Legend . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-5
Engine speed Fuse
Pump flow rate to engine speed Color codes . . . . . . . . . . . . . . . . . . . . . .9015-10-2
chart . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-24 Specification . . . . . . . . . . . . . . . . . . . . . .9015-10-1
Engine speed and performance
System checks . . . . . . . . . . . . . . . . . . .9010-10-12
Engine speed learning G
Control circuit . . . . . . . . . . . . . . . . . . . .9010-05-14
Switch, engine learning . . . . . . . . . . . . .9010-20-10 Gearbox
Engine speed sensing control circuit Propel, operation. . . . . . . . . . . . . . . . . . .9020-05-2
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-34 Swing, operation . . . . . . . . . . . . . . . . . .9025-05-72
Excavator diagnostics program Swing, start-up procedure . . . . . . . . . . .9025-25-34
Engine speed adjust special function . .9025-25-16
Grease
Indx Engine speed factory settings, special
Extreme pressure and multipurpose . . . .9000-04-7
4 function . . . . . . . . . . . . . . . . . . . . . . .9025-25-23
Specification . . . . . . . . . . . . . . . . . . . . . .9000-04-7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-2
Grouser
Monitor data items . . . . . . . . . . . . . . . .9025-25-21
Monitor data, feature. . . . . . . . . . . . . . .9025-25-13 Track shoe, measure wear (S.N.
Overview. . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1 499999) . . . . . . . . . . . . . . . . . . . . . . . .9020-15-6
Saving monitor data, feature . . . . . . . . .9025-25-15 Track shoe, measure wear (S.N.
Service codes list . . . . . . . . . . . . . . . . .9025-25-20 500000) . . . . . . . . . . . . . . . . . . . . . . . .9020-15-7
Service codes, feature . . . . . . . . . . . . .9025-25-12
Starting . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8
Troubleshooting . . . . . . . . . . . . . . . . . .9025-25-26 H
Uninstall . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-7
Harness
F Cab (W2) component location. . . . . . . .9015-10-20
Cab (W2) connectors . . . . . . . . . . . . . .9015-10-23
Fan drive Engine and frame (W1) component
Operation . . . . . . . . . . . . . . . . . . . . . . . .9010-05-3 location . . . . . . . . . . . . . . . . . . . . . . .9015-10-16

101603
PN=4
Index
Page Page
Engine and frame (W1) connectors. . . .9015-10-17 I

Monitor and relay (W3) component
location . . . . . . . . . . . . . 9015-10-28, 9015-10-31 Idler
Heater Front, measure wear. . . . . . . . . . . . . . .9020-15-10
Circuit checks . . . . . . . . . . . . . . . . . . . . .9031-10-5 Inch torque values . . . . . . . . . . . . . . . . . . .9000-03-1
Heater and air conditioner circuit
Functional schematic . . . . . . . . . . . . . . .9031-05-5
Heater circuit
Operational information . . . . . . . . . . . . . .9031-05-6 J
Theory of operation. . . . . . . . . . . . . . . . .9031-05-6
Heater Circuit (Machines without A/C) JT02156 digital pressure and temperature analyzer
Functional schematic . . . . . . . . . . . . . . .9031-05-7 Installation. . . . . . . . . . . . . . . . . . . . . . .9025-25-31
Heating and air conditioning JT05800 digital thermometer
Operational checkout . . . . . . . . . . . . . .9005-10-20 installation. . . . . . . . . . . . . . . . . . . . . . .9025-25-30
Jump starting . . . . . . . . . . . . . . . . . . . . . . .9015-20-7
HP (high power) mode
Speed control circuit . . . . . . . . . . . . . . .9010-05-10
Hydraulic
Fittings, 30° cone seat. . . . . . . . . . .9000-03-9 L
Fittings, 37° flare . . . . . . . . . . . . . . .9000-03-9
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-5 Laptop computer
Hydraulic fitting Excavator diagnostics program
Flared connections . . . . . . . . . . . . . . . .9000-03-10 Engine speed adjustment . . . . . . . . .9025-25-16
Hydraulic oil Engine speed factory settings . . . . . .9025-25-23
Cleanup procedure using portable filter Engine speed to pump flow rate
caddy . . . . . . . . . . . . . . . . . . . . . . . .9025-25-36 chart. . . . . . . . . . . . . . . . . . . . . . . .9025-25-24
Hydraulic oil filter Monitor data . . . . . . . . . . . . . . . . . . .9025-25-13
Inspection procedure. . . . . . . . . . . . . . .9025-25-35 Monitor data items. . . . . . . . . . . . . . .9025-25-21
Hydraulic pump Saving monitor data. . . . . . . . . . . . . .9025-25-15
Flow test . . . . . . . . . . . . . . . . . . . . . . . 9025-25-117 Service codes . . . . . . . . . . . . . . . . . .9025-25-12
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-20 Service codes list . . . . . . . . . . . . . . .9025-25-20
Regulator adjustments . . . . . . . . . . . . .9025-25-98 Troubleshooting. . . . . . . . . . . . . . . . .9025-25-26
Regulator component operation . . . . . .9025-05-22 Excavator diagnostics program install . . .9025-25-2
Regulator minimum flow test . . . . . . . . 9025-25-101 Excavator diagnostics program
Regulator operation. . . . . . . . . . . . . . . .9025-05-24 overview . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Regulator test engine pulldown . . . . . . 9025-25-106 Excavator diagnostics program
Regulator, maximum flow . . . . . . . . . . 9025-25-104 starting . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8 Indx
Excavator diagnostics program 5
Schematic . . . . . . . . . . . . . . . . . . . . . . 9025-05-100
uninstall . . . . . . . . . . . . . . . . . . . . . . . .9025-25-7
Start-up procedure . . . . . . . . . . . . . . . .9025-25-32
General description . . . . . . . . . . . . . . . . .9025-25-1
Hydraulic pump and drive gearbox
Reading service codes without diagnostics
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-18
program. . . . . . . . . . . . . . . . . . . . . . .9025-25-27
Hydraulic pump regulator Latch
Increasing, maximum, and decreasing Operational checkout . . . . . . . . . . . . . .9005-10-23
operation . . . . . . . . . . . . . . . . . . . . . .9025-05-26 Leakage
Summation and speed sensing . . . . . . .9025-05-28 Air intake system test . . . . . . . . . . . . . . .9010-25-4
Hydraulic system Fuel line . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-2
Circuit symbols . . . . . . . . . . . . . . . . . . .9025-05-98 Leakage test
Diagnostic malfunctions . . . . . . . . . . . .9025-15-13 Propel motor . . . . . . . . . . . . . . . . . . . . 9025-25-131
Diagram . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-2 Swing motor . . . . . . . . . . . . . . . . . . . . 9025-25-128
Main, component location . . . . . . . . . . .9025-15-35 Legend
Operational checkout . . . . . . . . . . . . . . .9005-10-9 Functional schematic and component
Warm-up procedure . . . . . . . . . . . . . . .9025-25-37 location . . . . . . . . . . . . . . . . . . . . . . . .9015-10-5

101603
PN=5
Index
Page Page
Link Swing, start-up procedure . . . . . . . . . . .9025-25-33

Track, measure wear . . . . . . . . . . . . . . .9020-15-4 Multimeter
Linkage Basic description. . . . . . . . . . . . . . . . . .9015-05-17
Fuel shut-off solenoid, check & adjust. . .9010-20-2
Lock
Lubricant O
Alternative. . . . . . . . . . . . . . . . . . . . . . . .9000-04-8
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-9 O-ring boss fittings . . . . . . . . . . . . . . . . . . .9000-03-6
Storage . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-8 Oil
Lubrication Lines and fittings. . . . . . . . . . . . . . . . . . .9000-03-5
System checks . . . . . . . . . . . . . . . . . . . .9010-10-8 Specification front idler . . . . . . . . . . . . . .9000-04-6
Specification hydraulic. . . . . . . . . . . . . . .9000-04-5
Specification swing gearbox . . . . . . . . . .9000-04-6
Specification track gearbox . . . . . . . . . . .9000-04-6
M Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7
Oil lines and fittings . . . . . . . . . . . . . . . . . .9000-03-5
Machine specifications . . . . . . . . . . . . . . . .9000-02-2 Operational check
Main hydraulic system Air conditioning . . . . . . . . . . . . . . . . . . .9005-10-21
Component location . . . . . . . . . . . . . . .9025-15-35 Arm regenerative valve . . . . . . . . . . . . .9005-10-14
Make-up valve Auto-idle circuit . . . . . . . . . . . . . . . . . . . .9005-10-6
Swing motor, operation . . . . . . . . . . . . .9025-05-77 Boom up, arm in, and bucket
Malfunctions combined. . . . . . . . . . . . . . . . . . . . . .9005-10-14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . .9010-15-2 Cab dome light circuit . . . . . . . . . . . . . .9005-10-20
Manifold Cold weather starting aid . . . . . . . . . . . .9010-10-7
Rotary, operation . . . . . . . . . . . . . . . . .9025-05-82 Compressor clutch . . . . . . . . . . . . . . . .9005-10-22
Metric torque values . . . . . . . . . . . . . . . . . .9000-03-2 Condenser . . . . . . . . . . . . . . . . . . . . . .9005-10-22
Miscellaneous component Control valve lift check valve. . . . . . . . .9005-10-13
Harness test . . . . . . . . . . . . . . . . . . . . .9025-25-51 Cycle times . . . . . . . . . . . . . . . . . . . . . .9005-10-16
Mixing lubricants. . . . . . . . . . . . . . . . . . . . .9000-04-9 Dig function drift . . . . . . . . . . . . . . . . . .9005-10-13
Monitor and relay harness (W3) E (economy) mode . . . . . . . . . . . . . . . . .9005-10-7
Component location . . . . . 9015-10-28, 9015-10-31 Engine blow-by . . . . . . . . . . . . . . . . . . . .9005-10-9
Monitor data Engine oil lever and condition check . . . .9005-10-3
Excavator diagnostics program Engine parts loose or worn . . . . . . . . . . .9005-10-9
feature . . . . . . . . . . . . . . . . . . . . . . . .9025-25-13 Engine rpm dial. . . . . . . . . . . . . . . . . . . .9005-10-6
Saving, excavator diagnostics program Evaporator core . . . . . . . . . . . . . . . . . .9005-10-22
Indx feature . . . . . . . . . . . . . . . . . . . . . . . .9025-25-15 Fluid level (coolant, hydraulic, and engine oil)
6 Monitor data items indicator circuit . . . . . . . . . . . . . . . . . .9005-10-2
Excavator diagnostics program . . . . . . .9025-25-21 Gauges, monitor, and battery disconnect
Motor relay . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2
Engine control, adjustment . . . . . . . . . . .9010-20-8 Grouser wear, bent track shoe, and loose
Harness test, engine control . . . . . . . . .9025-25-49 hardware . . . . . . . . . . . . . . . . . . . . . .9005-10-18
Leakage test, propel . . . . . . . . . . . . . . 9025-25-131 Heater controls . . . . . . . . . 9005-10-20, 9005-10-21
Leakage test, swing . . . . . . . . . . . . . . 9025-25-128 Horn circuit . . . . . . . . . . . . . . . . . . . . . .9005-10-20
Propel, fast speed operation . . . . . . . . .9025-05-87 HP (high power) mode . . . . . . . . . . . . . .9005-10-7
Propel, operation. . . . . . . . . . . . . . . . . .9025-05-84 Hydraulic oil level . . . . . . . . . . . . . . . . .9005-10-10
Propel, park brake release circuit . . . . .9025-05-92 Light circuit . . . . . . . . . . . . . . . . . . . . . .9005-10-19
Propel, schematic . . . . . . . . . . . . . . . . 9025-05-101 Lines and hoses . . . . . . . . . . . . . . . . . .9005-10-22
Propel, slow speed operation . . . . . . . .9025-05-86 Monitor circuit and gauge . . . . . . . . . . . .9005-10-4
Propel, start-up procedure. . . . . . . . . . .9025-25-34 Pilot controller pattern, John Deere
Swing crossover relief valve test . . . . . .9025-25-75 pattern . . . . . . . . . . . . . . . . . . . . . . . .9005-10-12
Swing, operation . . . . . . . . . . . . . . . . . .9025-05-74 Pilot controller pattern, SAE pattern . . .9005-10-11
Swing, schematic . . . . . . . . . . . . . . . . 9025-05-101 Pilot shut-off valve . . . . . . . . . . . . . . . . .9005-10-8

101603
PN=6
Index
Page Page
Power mode circuit indicators . . . . . . . . .9005-10-5 Fuel cap lock . . . . . . . . . . . . . . . . . . . .9005-10-28

Propel lever and pedal dampener . . . . . .9005-10-4 Fuel system . . . . . . . . . . . . . . . . . . . . .9005-10-38
Propel speed selection . . . . . . . . . . . . .9005-10-15 Fuel tank interior . . . . . . . . . . . . . . . . . .9005-10-36
Propel system maneuverability . . . . . . .9005-10-15 Fuel tank sump . . . . . . . . . . . . . . . . . . .9005-10-36
Propel system tracking while operating a dig Fuel transfer pump . . . . . . . . . . . . . . . .9005-10-37
function . . . . . . . . . . . . . . . . . . . . . . .9005-10-14 Hood. . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-28
Propel system tracking while Left and right access doors lock . . . . . .9005-10-27
propelling. . . . . . . . . . . . . . . . . . . . . .9005-10-14 Lower front window storage . . . . . . . . .9005-10-25
Pump gearbox oil level . . . . . . . . . . . . .9005-10-10 Primary fuel filter hand primer . . . . . . . .9005-10-37
Sprocket wear. . . . . . . . . . . . . . . . . . . .9005-10-17 Radiator cap . . . . . . . . . . . . . . . . . . . . .9005-10-29
Swing circuit leakage . . . . . . . . . . . . . .9005-10-13 Radiator internal core . . . . . . . . . . . . . .9005-10-30
Swing dynamic brake . . . . . . . . . . . . . .9005-10-12 Radiator outside air flow . . . . . . . . . . . .9005-10-32
Swing gearbox oil level . . . . . . . . . . . . .9005-10-11 Right rear side window . . . . . . . . . . . . .9005-10-26
Track link, roller, and front idler Roof exit cover . . . . . . . . . . . . . . . . . . .9005-10-26
wear . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-18 Seat control . . . . . . . . . . . . . . . . . . . . .9005-10-24
Track sag, roller, and idler leakage . . . .9005-10-17 Seat, door, window, and lock . . . . . . . .9005-10-23
Travel alarm . . . . . . . . . . . . . . . . . . . . . .9005-10-8 Upper front window . . . . . . . . . . . . . . . .9005-10-25
Travel alarm stop circuit . . . . . . . . . . . . .9005-10-9 Visual inspection . . . . . . . . . . . . . . . . . .9005-10-38
Windshield washer circuit . . . . . . . . . . .9005-10-19 Water pump . . . . . . . . . . . . . . . . . . . . .9005-10-31
Windshield wiper circuit. . . . . . . . . . . . .9005-10-19 Water separator . . . . . . . . . . . . . . . . . .9005-10-36
Work mode circuit . . . . . . . . . . . . . . . . . .9005-10-5
Operational checkout
Accessories . . . . . . . . . . . . . . . . . . . . .9005-10-18
Air intake system . . . . . . . . 9005-10-33, 9010-10-6
P
Engine cooling system . . . . . . . . . . . . .9005-10-28
Engine lubrication system . . . . . . . . . . . .9010-10-8
Engine speed and performance . . . . . .9010-10-12 Park brake pressure reducing valve
Fuel system . . . . . . . . . . . 9005-10-36, 9010-10-10 Circuit operation . . . . . . . . . . . . . . . . . .9025-05-92
Heating and air conditioning . . . . . . . . .9005-10-20 Park brake release shuttle valve
Hydraulic system. . . . . . . . . . . . . . . . . . .9005-10-9 Circuit operation . . . . . . . . . . . . . . . . . .9025-05-92
Operation station, engine on . . . . . . . . . .9005-10-4 Pattern conversion
Operator station, key off . . . . . . . . . . . . .9005-10-1 Control levers . . . . . . . . . . . . . . . . . . . .9025-15-24
Undercarriage . . . . . . . . . . . . . . . . . . . .9005-10-16 Pilot circuit
Visual inspection . . . . . . . . . . . . . . . . . .9005-10-38 Diagnose malfunctions . . . . . . . . . . . . .9025-15-16
Operational checks Warm-up circuit operation . . . . . . . . . . .9025-05-16
Air cleaner elements . . . . . . . . . . . . . . .9005-10-34 Pilot controller
Air cleaner unloader valve. . . . . . . . . . .9005-10-34 Metering and full stroke operation . . . . . .9025-05-9 Indx
Air filter restriction indicator and Neutral operation . . . . . . . . . . . . . . . . . .9025-05-8 7
switch . . . . . . . . . . . . . . . . . . . . . . . .9005-10-33 Schematic . . . . . . . . . . . . . . . . . . . . . . .9025-05-99
Cab door latch and catch . . . . . . . . . . .9005-10-27 Pilot controller, propel
Cab door lock . . . . . . . . . . . . . . . . . . . .9005-10-27 (S.N. 050305) . . . . . . . . . . . . . . . . . .9025-05-10
Cab door window . . . . . . . . . . . . . . . . .9005-10-26 (S.N. 050306) . . . . . . . . . . . . . . . . . .9025-05-12
Coolant hoses and clamps . . . . . . . . . .9005-10-30 Pilot filter
Coolant level and condition In Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-5
radiator . . . . . . . . . . . . . . . . . . . . . . .9005-10-30 Pilot pressure regulating valve
Coolant level and condition In recovery Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-5
tank . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-29 Test and adjustment . . . . . . . . . . . . . . .9025-25-56
Engine head gasket seal. . . . . . . . . . . .9005-10-33 Pilot pump
Exhaust smoke . . . . . . . . . . . . . . . . . . .9005-10-35 Flow test . . . . . . . . . . . . . . . . . . . . . . . 9025-25-121
Fan belt . . . . . . . . . . . . . . . . . . . . . . . .9005-10-32 Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-4
Fan blades . . . . . . . . . . . . . . . . . . . . . .9005-10-31 Pilot shut-off valve
Fan direction . . . . . . . . . . . . . . . . . . . . .9005-10-32 Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-6
Fan shroud and guard. . . . . . . . . . . . . .9005-10-31 Operational check . . . . . . . . . . . . . . . . . .9005-10-8

101603
PN=7
Index
Page Page
Pilot system Propel speed change solenoid valve

Component location Circuit operation . . . . . . . . . . . . . . . . . .9025-05-88
Flow regulator valve-to-control Harness test . . . . . . . . . . . . . . . . . . . . .9025-25-43
valve . . . . . . . . . . . . . . . . . . . . . . .9025-15-38 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-32
Component location controller-to-flow regulator Propel system
valve John Deere pattern . . . . . . . . .9025-15-37 Component location . . . . . . . . . . . . . . .9025-15-39
Component location controller-to-flow regulator Tracking test . . . . . . . . . . . . . . . . . . . . 9025-25-123
valve SAE pattern . . . . . . . . . . . . . . .9025-15-36 Propel-boom down selector valve
Pitch Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-65
Track chain, measure . . . . . . . . . . . . . . .9020-15-5 Proportional Solenoid
Portable filter caddy Test Harness . . . . . . . . . . . . . . . . . . . .9015-20-11
Hydraulic oil cleanup procedure . . . . . .9025-25-36 Proportional solenoid valve
Power boost Arm regenerative (SC) harness test . . .9025-25-39
Control circuit operation . . . . . . . . . . . .9025-05-47 Manifold operation . . . . . . . . . . . . . . . .9025-05-30
Power boost solenoid valve Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-32
Harness test . . . . . . . . . . . . . . . . . . . . .9025-25-45 Power boost (SG) harness test . . . . . . .9025-25-45
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-32 Propel speed change (SI) harness
test . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-43
Power boost valve
Speed sensing (SD) harness test . . . . .9025-25-41
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-46
Test and adjustment . . . . . . . . . . . . . . .9025-25-86
Pressure and return system
Pump
Component location . . . . . . . . . . . . . . .9025-15-40
Engine speed to flow rate chart. . . . . . .9025-25-24
Propel
Hydraulic flow test. . . . . . . . . . . . . . . . 9025-25-117
Gearbox oil specification . . . . . . . . . . . . .9000-04-6
Hydraulic operation . . . . . . . . . . . . . . . .9025-05-20
Propel and arm in combined Hydraulic, regulator minimum flow
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-68 test . . . . . . . . . . . . . . . . . . . . . . . . . 9025-25-101
Propel flow control valve Hydraulic, schematic . . . . . . . . . . . . . . 9025-05-100
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-64 Pilot flow test . . . . . . . . . . . . . . . . . . . 9025-25-121
Propel gearbox Pilot, operation . . . . . . . . . . . . . . . . . . . .9025-05-4
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-2 Regulator component operation . . . . . .9025-05-22
Propel motor Regulator operation. . . . . . . . . . . . . . . .9025-05-24
Counterbalance valve propelling Regulator, engine pulldown test . . . . . 9025-25-106
operation . . . . . . . . . . . . . . . . . . . . . .9025-05-94 Regulator, maximum flow . . . . . . . . . . 9025-25-104
Crossover relief valve test. . . . . . . . . . .9025-25-80 Start-up procedure . . . . . . . . . . . . . . . .9025-25-32
Fast speed operation . . . . . . . . . . . . . .9025-05-87 Pump and drive gearbox
Leakage test . . . . . . . . . . . . . . . . . . . . 9025-25-131 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-18
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-84 Pump Control
Indx
Park brake release circuit . . . . . . . . . . .9025-05-92 Test Harness . . . . . . . . . . . . . . . . . . . .9015-20-11
8
Park brake valve housing operation . . .9025-05-90 Pump control valve
Schematic . . . . . . . . . . . . . . . . . . . . . . 9025-05-101 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-50
Slow speed operation . . . . . . . . . . . . . .9025-05-86 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-93
Speed change circuit operation . . . . . . .9025-05-88 Pump Pressure Sensor
Start-up procedure . . . . . . . . . . . . . . . .9025-25-34 Test Harness . . . . . . . . . . . . . . . . . . . .9015-20-11
Propel pilot controller Pump, hydraulic
Schematic . . . . . . . . . . . . . . . . . . . . . . .9025-05-99 Regulator increasing, maximum and decreasing
Propel pilot controller (S.N. 050305) operation . . . . . . . . . . . . . . . . . . . . . .9025-05-26
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-10 Regulator summation and speed
Propel pilot controller (S.N. 050306) sensing . . . . . . . . . . . . . . . . . . . . . . .9025-05-28
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-12
Propel pilot pressure signal passage R
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-42
Propel speed change circuit Radiator
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-88 Air flow test. . . . . . . . . . . . . . . . . . . . . . .9010-25-5

101603
PN=8
Index
Page Page
Receiver and dryer Excavator diagnostics program

Operation . . . . . . . . . . . . . . . . . . . . . . . .9031-05-8 overview . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Regulator Install excavator diagnostics program . . .9025-25-2
Adjustments, hydraulic pump . . . . . . . .9025-25-98 Monitor data items, excavator diagnostics
Component operation, hydraulic program. . . . . . . . . . . . . . . . . . . . . . .9025-25-21
pump . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-22 Monitor data, excavator diagnostics program
Engine pulldown test, hydraulic feature . . . . . . . . . . . . . . . . . . . . . . . .9025-25-13
pump . . . . . . . . . . . . . . . . . . . . . . . . 9025-25-106 Reading service codes without . . . . . . .9025-25-27
Hydraulic pump, maximum flow. . . . . . 9025-25-104 Saving monitor data, excavator diagnostics
Hydraulic pump, operation . . . . . . . . . .9025-05-24 program feature . . . . . . . . . . . . . . . . .9025-25-15
Minimum flow test, hydraulic pump . . . 9025-25-101 Service codes list, excavator diagnostics
Return filter program. . . . . . . . . . . . . . . . . . . . . . .9025-25-20
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-97 Service codes, excavator diagnostics program
Roller feature . . . . . . . . . . . . . . . . . . . . . . . .9025-25-12
Track carrier, measure wear . . . . . . . . . .9020-15-9 Starting excavator diagnostics
Track, measure wear . . . . . . . . . . . . . . .9020-15-8 program. . . . . . . . . . . . . . . . . . . . . . . .9025-25-8
Rotary manifold Troubleshooting, excavator diagnostics
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-82 program. . . . . . . . . . . . . . . . . . . . . . .9025-25-26
Uninstall excavator diagnostic
program. . . . . . . . . . . . . . . . . . . . . . . .9025-25-7
Solenoid
S
Fuel shut-off, check & adjust linkage. . . .9010-20-2
Valve harness test, arm
Schematic regenerative . . . . . . . . . . . . . . . . . . .9025-25-39
Control valve circuit. . . . . . . . . . . . . . . .9025-05-40 Valve harness test, power boost . . . . . .9025-25-45
Electrical, system functional . . . . . . . . .9015-10-10
Valve harness test, propel speed
Hydraulic pump and control valve . . . . 9025-05-100
change . . . . . . . . . . . . . . . . . . . . . . .9025-25-43
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20
Valve harness test, speed sensing . . . .9025-25-41
Pilot controllers circuit . . . . . . . . . . . . . .9025-05-99
Valve test, proportional . . . . . . . . . . . . .9025-25-86
Reading a schematic . . . . . . . . . . . . . .9015-05-22
Solenoid valve
Swing and propel motor . . . . . . . . . . . 9025-05-101
Arm regenerative . . . . . . . . . . . . . . . . .9025-05-32
Symbols . . . . . . . . . . . . . . . . . . . . . . . .9015-05-30
Engine speed sensing control circuit . . .9025-05-34
Schematic section, system functional
Manifold operation . . . . . . . . . . . . . . . .9025-05-30
Legend . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-9
Power boost . . . . . . . . . . . . . . . . . . . . .9025-05-32
Seat
Propel speed change . . . . . . . . . . . . . .9025-05-32
Sectional view Propel speed change circuit
Indx
Engine . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-2 operation . . . . . . . . . . . . . . . . . . . . . .9025-05-88 9
Sensor Speed sensing . . . . . . . . . . . . . . . . . . .9025-05-32
Harness test, engine control sensor . . .9025-25-47 Special function
Service code Engine speed to pump flow rate
Excavator diagnostics program chart . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-24
feature . . . . . . . . . . . . . . . . . . . . . . . .9025-25-12 Specification
List, excavator diagnostics program . . .9025-25-20 Battery . . . . . . . . . . . . . . . . .9015-20-1, 9015-20-8
Reading without laptop computer and diagnostics Front idler oil. . . . . . . . . . . . . . . . . . . . . .9000-04-6
program. . . . . . . . . . . . . . . . . . . . . . .9025-25-27 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-1
Slow and fast idle Grease . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7
Injection pump stops adjustment . . . . . . .9010-20-6 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .9000-04-5
Software Monitor gauges . . . . . . . . . . . . . . . . . . .9015-15-42
Engine speed adjust, excavator diagnostics Pressure switches . . . . . . . . . . . . . . . . .9015-15-42
program special function . . . . . . . . . .9025-25-16 Propel gearbox oil. . . . . . . . . . . . . . . . . .9000-04-6
Engine speed factory settings, diagnostics program Swing gearbox oil . . . . . . . . . . . . . . . . . .9000-04-6
special function . . . . . . . . . . . . . . . . .9025-25-23 Track roller oil . . . . . . . . . . . . . . . . . . . . .9000-04-6

101603
PN=9
Index
Page Page
Speed Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20

Engine . . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-5 Legend . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-9
Speed control Reading a schematic . . . . . . . . . . . . . .9015-05-22
Injection pump fast and slow idle stops System relief valve
adjustment. . . . . . . . . . . . . . . . . . . . . .9010-20-6 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-46
Speed control motor Test and adjustment . . . . . . . . . . . . . . .9025-25-62
Adjustment . . . . . . . . . . . . . . . . . . . . . . .9010-20-8
Speed control system
Auto-idle mode . . . . . . . . . . . . . . . . . . .9010-05-12
E (economy) mode . . . . . . . . . . . . . . . . .9010-05-8 T
Engine . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-4
Engine rpm dial. . . . . . . . . . . . . . . . . . . .9010-05-6 Tachometer
Engine speed learning . . . . . . . . . . . . .9010-05-14 Electronic, installation . . . . . 9010-20-1, 9025-25-30
HP mode control circuit. . . . . . . . . . . . .9010-05-10 Testing electrical circuits
Speed sensing solenoid valve Seven step procedure . . . . . . . . . . . . . .9015-05-18
Control circuit operation . . . . . . . . . . . .9025-05-34 Thermometer installation, digital . . . . . . . .9025-25-30
Harness test . . . . . . . . . . . . . . . . . . . . .9025-25-41 Torque value
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-32 Flared connections . . . . . . . . . . . . . . . .9000-03-10
Spool Flat face O-ring seal fitting . . . . . . . . . . .9000-03-8
Actuating pilot pressure, valve . . . . . . .9025-25-60 Inch SAE four bolt flange fitting. . . . . . .9000-03-11
Start-up procedure Metric cap screw. . . . . . . . . . . . . . . . . . .9000-03-3
Hydraulic pump . . . . . . . . . . . . . . . . . . .9025-25-32 Metric four bolt flange fitting . . . . . . . . .9000-03-12
Swing gearbox . . . . . . . . . . . . . . . . . . .9025-25-34 O-Ring boss fitting . . . . . . . . . . . . . . . . .9000-03-6
Swing motor . . . . . . . . . . . 9025-25-33, 9025-25-34 30° cone seat hydraulic fittings . . . .9000-03-9
Storing lubricants . . . . . . . . . . . . . . . . . . . .9000-04-8 37° flare hydraulic fittings . . . . . . . .9000-03-9
Swing Torque values
Gearbox oil specification . . . . . . . . . . . . .9000-04-6 Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-1
Swing and boom up combined Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-2
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-70 Torsional dampener
Swing bearing Inspect . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-12
Measure wear . . . . . . . . . . . . . . . . . . . .9020-15-11 Track
Swing dynamic braking Adjuster operation . . . . . . . . . . . . . . . . . .9020-05-1
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-54 Roller oil specification . . . . . . . . . . . . . . .9000-04-6
Swing gearbox Track adjuster
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-72 Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-1
Start-up procedure . . . . . . . . . . . . . . . .9025-25-34 Track carrier roller
Indx Swing motor Measure wear . . . . . . . . . . . . . . . . . . . . .9020-15-9
10 Crossover relief valve operation . . . . . .9025-05-76 Track chain
Crossover relief valve test. . . . . . . . . . .9025-25-75 Track sag, adjust . . . . . . . . . . . . . . . . . .9020-20-1
Leakage test . . . . . . . . . . . . . . . . . . . . 9025-25-128 Track shoe grouser, measure wear (S.N.
Make-up valve operation . . . . . . . . . . . .9025-05-77 499999) . . . . . . . . . . . . . . . . . . . . . . . .9020-15-6
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-74 Track shoe grouser, measure wear (S.N.
Park brake release valve operation . . . .9025-05-80 500000) . . . . . . . . . . . . . . . . . . . . . . . .9020-15-7
Schematic . . . . . . . . . . . . . . . . . . . . . . 9025-05-101 Track chain bushing
Start-up procedure . . . . . . . . . . . . . . . .9025-25-33 Measure wear . . . . . . . . . . . . . . . . . . . . .9020-15-3
Swing motor crossover relief valve Track chain link
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-76 Measure wear . . . . . . . . . . . . . . . . . . . . .9020-15-4
Switch Track chain pitch
Air filter restriction test . . . . . . . . . . . . . .9010-25-3 Measure . . . . . . . . . . . . . . . . . . . . . . . . .9020-15-5
Engine speed learning procedure . . . . .9010-20-10 Track roller
Synthetic Lubricants . . . . . . . . . . . . . . . . . .9000-04-8 Measure wear . . . . . . . . . . . . . . . . . . . . .9020-15-8
System functional schematic Track sag
Electrical . . . . . . . . . . . . . . . . . . . . . . . .9015-10-10 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1

101603
PN=10
Index
Page Page
Track shoe grouser Harness test, propel speed change

Measure wear (S.N.499999) . . . . . . . .9020-15-6 solenoid. . . . . . . . . . . . . . . . . . . . . . .9025-25-43
Measure wear (S.N.500000) . . . . . . . .9020-15-7 Harness test, speed sensing
Tracking solenoid. . . . . . . . . . . . . . . . . . . . . . .9025-25-41
Propel system . . . . . . . . . . . . . . . . . . . 9025-25-123 Main control circuit schematic . . . . . . . .9025-05-40
Travel alarm Main control identification . . . . . . . . . . .9025-05-35
Volume adjustment . . . . . . . . . . . . . . . .9015-20-10 Park brake pressure reducing, circuit
Troubleshooting operation . . . . . . . . . . . . . . . . . . . . . .9025-05-92
Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-8 Park brake release shuttle, circuit
High resistance . . . . . . . . . . . . . . . . . . . .9015-05-3 operation . . . . . . . . . . . . . . . . . . . . . .9025-05-92
Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-5 Pilot operation of control . . . . . . . . . . . .9025-05-14
Sensor circuit shorted to ground . . . . . .9015-05-16 Pilot pressure regulating
Sensor circuit shorted to itself . . . . . . . .9015-05-14 Operation . . . . . . . . . . . . . . . . . . . . . .9025-05-5
Sensor circuit shorted to power. . . . . . .9015-05-12 Pilot pressure regulating, test . . . . . . . .9025-25-56
Shorted circuit. . . . . . . . . . . . . . . . . . . .9015-05-10 Power boost control circuit operation . .9025-05-47
Turbocharger boost pressure Power boost operation . . . . . . . . . . . . .9025-05-46
Engine power test . . . . . . . . . . . . . . . . . .9010-25-8 Power boost solenoid . . . . . . . . . . . . . .9025-05-32
Propel flow control, operation . . . . . . . .9025-05-64
Propel motor counterbalance, propelling
operation . . . . . . . . . . . . . . . . . . . . . .9025-05-94
U Propel motor crossover relief test . . . . .9025-25-80
Propel motor park brake, housing
Undercarriage operation . . . . . . . . . . . . . . . . . . . . . .9025-05-90
Operational checkout . . . . . . . . . . . . . .9005-10-16 Propel speed change solenoid . . . . . . .9025-05-32
Propel-boom down selector,
operation . . . . . . . . . . . . . . . . . . . . . .9025-05-65
Proportional solenoid test . . . . . . . . . . .9025-25-86
V Proportional solenoid, operation . . . . . .9025-05-32
Pump control, operation . . . . . . . . . . . .9025-05-50
Valve Pump cotrol, test. . . . . . . . . . . . . . . . . .9025-25-93
Arm regenerative solenoid . . . . . . . . . .9025-05-32 Speed sensing solenoid . . . . . . . . . . . .9025-05-32
Arm regenerative solenoid, harness Swing motor crossover relief,
test . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-39 operation . . . . . . . . . . . . . . . . . . . . . .9025-05-76
Arm regenerative, operation . . . . . . . . .9025-05-58 Swing motor crossover, test . . . . . . . . .9025-25-75
Boom regenerative, operation . . . . . . . .9025-05-66 Swing motor make-up, opertion . . . . . .9025-05-77
Bucket flow control, operation . . . . . . . .9025-05-62 Swing motor park brake release,
Circuit relief operation . . . . . . . . . . . . . .9025-05-48 operation . . . . . . . . . . . . . . . . . . . . . .9025-05-80 Indx
Circuit relief, test . . . . . . . . . . . . . . . . . .9025-25-68 System relief . . . . . . . . . . . . . . . . . . . . .9025-05-46 11
Control, component identification, System relief test & adjustment. . . . . . .9025-25-62
bottom . . . . . . . . . . . . . . . . . . . . . . . .9025-15-33 Valve operation
Control, component identification, left Arm reduced leakage . . . . . . . . . . . . . .9025-05-60
front. . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-31 Boom reduced leakage . . . . . . . . . . . . .9025-05-60
Control, component identification, right Valve spool
rear . . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-32 Actuating pilot pressure test . . . . . . . . .9025-25-60
Control, line identification, bottom . . . . .9025-15-30 Valve, circuit relief
Control, line identification, left front . . . .9025-15-26 Test and adjustment . . . . . . . . . . . . . . .9025-25-68
Control, line identification, right rear . . .9025-15-28 Valve, control
Control, schematic . . . . . . . . . . . . . . . 9025-05-100 Neutral and power passages
Counterbalance, propelling operation . . . . . . . . . . . . . . . . . . . . . .9025-05-44
operation . . . . . . . . . . . . . . . . . . . . . .9025-05-94 Valve, pilot shut-off
Flow combiner, operation . . . . . . . . . . .9025-05-54 Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-6
Flow regulator, operation . . . . . . . . . . .9025-05-16 Valve, proportional solenoid
Harness test, power boost . . . . . . . . . .9025-25-45 Manifold operation . . . . . . . . . . . . . . . .9025-05-30

101603
PN=11
Index
Page
Visual inspection
Warm-up circuit
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-16
Warm-up procedure
Hydraulic system. . . . . . . . . . . . . . . . . .9025-25-37
Window
Windshield wiper and washer circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . .9015-15-26
Theory of operation. . . . . . . . . . . . . . . .9015-15-23
Wiring diagram
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20
Reading a wiring diagram . . . . . . . . . . .9015-05-24
Indx
12

101603
PN=12

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200LC

For complete service information also see:

TM1663 (28NOV01) 200LC Excavator Operation & Tests

Technical Information Feedback Form

We need your help to continually improve our technical

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FAX NUMBER: 563-589-5800

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TM1663 (28NOV01) 200LC Excavator Operation & Tests

TM1663 (28NOV01) 200LC Excavator Operation & Tests

SECTION 9005Operational Checkout Procedure

All information, illustrations and specifications in this manual are based on

TM1663 (28NOV01) i 200LC Excavator Operation & Tests

TM1663 (28NOV01) ii 200LC Excavator Operation & Tests

Group 01Safety . . . . . . . . . . . . . . . . . . . .9000-01-1 Track Adjuster, Working Tool Pivot, Swing

Group 03Torque Values

Group 04Fuels and Lubricants

TM1663 (28NOV01) 9000-1 200LC Excavator Operation & Tests

TM1663 (28NOV01) 9000-2 200LC Excavator Operation & Tests

Unsafe work practices are dangerous. Understand service

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

Handle Fluids SafelyAvoid Fires

Handle fuel with care; it is highly flammable. Do not refuel

Store flammable fluids away from fire hazards. Do not

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

Do not store oily rags; they can ignite and burn

TM1663 (28NOV01) 9000-01-1 200LC Excavator Operation & Tests

Keep sparks, lighted matches, and open flame away from

Never check battery charge by placing a metal object

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause

(See your John Deere dealer for MSDSs on chemical

TM1663 (28NOV01) 9000-01-2 200LC Excavator Operation & Tests

Sulfuric acid in battery electrolyte is poisonous. It is strong

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

1. Do not induce vomiting.

TM1663 (28NOV01) 9000-01-3 200LC Excavator Operation & Tests

Escaping fluid under pressure can penetrate the skin

Avoid the hazard by relieving pressure before

Search for leaks with a piece of cardboard. Protect hands

If an accident occurs, see a doctor immediately. Any fluid

Warn Others of Service Work

Unexpected machine movement can cause serious injury.

Before performing any work on the machine, attach a Do

TM1663 (28NOV01) 9000-01-4 200LC Excavator Operation & Tests

Before working on the machine:

Park machine on a level surface.

Support Machine Properly

Always lower the attachment or implement to the ground

When implements or attachments are used with a

Operate Only from Operators Seat

Avoid possible injury or machine damage. Do not start

NEVER start engine while standing on ground. Start

engine only from operators seat.

TM1663 (28NOV01) 9000-01-5 200LC Excavator Operation & Tests