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John Deere 270LC Excavator Operation & Test Technical Manual TM1667 – PDF DOWNLOAD
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Description
John Deere 270LC Excavator Operation & Test Technical Manual TM1667 – PDF DOWNLOAD
FILE DETAILS:
John Deere 270LC Excavator Operation & Test Technical Manual TM1667 – PDF DOWNLOAD
Language : English
Pages : 686
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 270LC Excavator Operation & Test Technical Manual TM1667 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment, service parts, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
John Deere 270LC Excavator Operation & Test Technical Manual TM1667 – PDF DOWNLOAD
Contents........................................................................................ 5 General Information......................................................................... 7 Safety.................................................................................. 9 Follow Safe Procedures.............................................................. 9 Prepare for Emergencies............................................................. 9 Handle Fluids Safely—Avoid Fires.................................................... 9 Prevent Battery Explosions.......................................................... 10 Handle Chemical Products Safely..................................................... 10 Prevent Acid Burns.................................................................. 11 Avoid High-Pressure Fluids.......................................................... 12 Warn Others of Service Work......................................................... 12 Park Machine Safely................................................................. 13 Support Machine Properly............................................................ 13 Operate Only from Operator's Seat................................................... 13 Stay Clear of Moving Parts.......................................................... 14 Avoid Power Lines................................................................... 14 Use Handholds and Steps............................................................. 14 Keep Riders Off Machine............................................................. 15 Move and Operate Machine Safely..................................................... 15 Wear Protective Clothing............................................................ 15 Protect Against Flying Debris....................................................... 16 Protect Against Noise............................................................... 16 Illuminate Work Area Safely......................................................... 16 Service Machines Safely............................................................. 16 Remove Paint Before Welding or Heating.............................................. 17 Avoid Heating Near Pressurized Fluid Lines.......................................... 17 Beware of Exhaust Fumes............................................................. 17 Use Proper Lifting Equipment........................................................ 18 Service Cooling System Safely....................................................... 18 Dispose of Waste Properly........................................................... 18 Work in a Clean Area................................................................ 19 Use Tools Properly.................................................................. 19 Use Tools Properly.................................................................. 19 Replace Safety Signs................................................................ 20 Live With Safety.................................................................... 20 General Specifications.................................................................. 21 270LC Specifications................................................................ 21 270LC Engine Specifications......................................................... 23 270LC Drain and Refill Capacities................................................... 23 Torque Values........................................................................... 25 Unified Inch Bolt and Cap Screw Torque Values....................................... 25 Metric Bolt and Cap Screw Torque Values............................................. 26 Additional Metric Cap Screw Torque Values........................................... 27 Check Oil Lines and Fittings........................................................ 29 Service Recommendations for O-Ring Boss Fittings.................................... 30 Service Recommendations for Flat Face O-Ring Seal Fittings.......................... 32 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.................. 33 Service Recommendations For Flared Connections—Straight or Tapered Threads.......... 34 Service Recommendations For Inch Series Four Bolt Flange Fittings................... 35 Service Recommendations for Metric Series Four Bolt Flange Fitting.................. 36 Fuels and Lubricants.................................................................... 37 Diesel Fuel......................................................................... 37 Lubricity Of Diesel Fuels........................................................... 37 Low Sulfur Diesel Fuel Conditioner.................................................. 38 Diesel Fuel Storage................................................................. 38 Fuel Tank........................................................................... 39 Do Not Use Galvanized Containers.................................................... 39 Diesel Engine Oil................................................................... 40 Hydraulic Oil....................................................................... 41 Swing Gearbox, Propel Gearbox and Pump Gearbox Oils................................. 42 Track Roller, Front Idler, and Carrier Roller Oil................................... 42 Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease.... 43 Oil Filters......................................................................... 43 Lubricant Storage................................................................... 44 Alternative and Synthetic Lubricants................................................ 44 Mixing of Lubricants................................................................ 45 Operational Checkout Procedure.............................................................. 47 Operational Checkout Procedure.......................................................... 49 Operational Checkout................................................................ 49 Operator Station Checks—Key Switch On, Engine Off................................... 49 .................................................................................... 50 .................................................................................... 50 .................................................................................... 51 .................................................................................... 52 Operator Station Checks—Engine On................................................... 52 .................................................................................... 52 .................................................................................... 53 .................................................................................... 53 .................................................................................... 54 .................................................................................... 54 .................................................................................... 55 .................................................................................... 55 .................................................................................... 56 .................................................................................... 56 .................................................................................... 57 .................................................................................... 57 .................................................................................... 57 Hydraulic System Checks............................................................. 57 .................................................................................... 58 .................................................................................... 58 .................................................................................... 58 .................................................................................... 59 .................................................................................... 59 .................................................................................... 60 .................................................................................... 60 .................................................................................... 61 .................................................................................... 61 .................................................................................... 61 .................................................................................... 62 .................................................................................... 62 .................................................................................... 62 .................................................................................... 62 .................................................................................... 63 .................................................................................... 63 .................................................................................... 64 Undercarriage Checks................................................................ 64 .................................................................................... 65 .................................................................................... 65 .................................................................................... 66 .................................................................................... 66 Accessories Checks.................................................................. 66 .................................................................................... 67 .................................................................................... 67 .................................................................................... 67 .................................................................................... 68 .................................................................................... 68 Heating and Air Conditioning Checks................................................. 68 .................................................................................... 68 .................................................................................... 69 .................................................................................... 69 .................................................................................... 70 .................................................................................... 70 .................................................................................... 70 .................................................................................... 70 Seat, Doors, Windows, Latches, and Locks Checks..................................... 71 .................................................................................... 72 .................................................................................... 73 .................................................................................... 73 .................................................................................... 74 .................................................................................... 74 .................................................................................... 74 .................................................................................... 75 .................................................................................... 75 .................................................................................... 75 .................................................................................... 76 .................................................................................... 76 Engine Cooling System Checks........................................................ 76 .................................................................................... 77 .................................................................................... 77 .................................................................................... 78 .................................................................................... 78 .................................................................................... 78 .................................................................................... 79 .................................................................................... 79 .................................................................................... 79 .................................................................................... 80 .................................................................................... 80 .................................................................................... 80 .................................................................................... 81 Air Intake System Checks............................................................ 81 .................................................................................... 81 .................................................................................... 82 .................................................................................... 82 .................................................................................... 83 .................................................................................... 83 Fuel System Checks.................................................................. 84 .................................................................................... 84 .................................................................................... 84 .................................................................................... 84 .................................................................................... 85 .................................................................................... 85 .................................................................................... 86 Visual Inspection................................................................... 86 .................................................................................... 86 Engine...................................................................................... 87 Theory of Operation..................................................................... 89 POWERTECH® 6.8 L (6068) John Deere Engine—Use CTM104................................ 89 Engine—Sectional View............................................................... 90 Fan Drive........................................................................... 91 Engine Speed Control................................................................ 92 System Operation................................................................ 92 Engine RPM Dial................................................................. 94 E (Economy) Mode................................................................ 96 HP (High Power) Mode............................................................ 98 Auto-Idle Mode..................................................................100 Engine Speed Learning...........................................................102 System Operational Checks...............................................................105 POWERTECH® 6.8 L (6068) John Deere Engine—Use CTM104................................105 Engine..............................................................................105 Operational Checks..............................................................105 Cooling System Checks...............................................................105 ....................................................................................106 ....................................................................................106 ....................................................................................107 ....................................................................................107 ....................................................................................108 ....................................................................................108 ....................................................................................108 ....................................................................................108 ....................................................................................109 ....................................................................................109 ....................................................................................109 ....................................................................................110 Air Intake System Checks............................................................110 ....................................................................................110 ....................................................................................110 ....................................................................................111 ....................................................................................111 ....................................................................................112 Lubrication System Checks...........................................................112 ....................................................................................113 ....................................................................................113 ....................................................................................114 Fuel System Checks..................................................................114 ....................................................................................114 ....................................................................................114 ....................................................................................115 ....................................................................................115 ....................................................................................115 Engine Speed and Performance Checks.................................................116 ....................................................................................116 ....................................................................................116 ....................................................................................117 ....................................................................................117 ....................................................................................118 ....................................................................................118 Diagnostic Information..................................................................119 POWERTECH® 6.8 L (6068) John Deere Engine—Use CTM104................................119 Engine..............................................................................120 Diagnose Malfunctions...........................................................120 Adjustments.............................................................................131 POWERTECH® 6.8 L (6068) John Deere Engine—Use CTM104................................131 JT05801 Clamp-On Electronic Tachometer..............................................131 Installation....................................................................131 Fuel Shut-Off Solenoid Linkage......................................................132 Check and Adjustment............................................................132 Engine..............................................................................135 Speed Check.....................................................................135 Injection Pump Fast and Slow Idle Stops.............................................136 Engine Speed Control Motor..........................................................138 Engine..............................................................................140 Speed Learning Procedure........................................................140 Cooling System Fill and Deareration.................................................142 Tests...................................................................................143 POWERTECH® 6.8 L (6068) John Deere Engine—Use CTM104................................143 JT05801 Clamp-On Electronic Tachometer..............................................143 Installation....................................................................143 Fuel Line Leakage...................................................................144 Air Filter Restriction Indicator Switch.............................................145 Air Intake System Leakage...........................................................146 Radiator Air Flow...................................................................147 Engine Power Test Using Turbocharger Boost Pressure.................................150 Torsional Dampener..................................................................154 Inspect.........................................................................154 Electrical System...........................................................................157 System Information......................................................................159 Electrical System...................................................................159 Visual Inspection...............................................................159 Electrical Circuit..................................................................160 Malfunctions....................................................................160 Circuit Malfunction.................................................................161 High Resistance.................................................................161 Open Circuit....................................................................163 Grounded Circuit................................................................166 Circuit Shorted.................................................................168 Sensor Circuit Shorted to Power.................................................170 Sensor Circuit Shorted to Itself................................................172 Sensor Circuit Shorted to Ground................................................174 Using Test Equipment................................................................175 Multimeter......................................................................175 Seven Step Electrical Test Procedure............................................176 Schematic, Wiring Diagram, and Component Location Information.......................178 Reading a System Functional Schematic...............................................180 Reading a Wiring Diagram............................................................182 Reading a Component Location Diagram................................................184 Reading a Connector End View Diagram................................................186 Electrical Schematic Symbols........................................................188 System Diagrams.........................................................................191 Fuse Specifications.................................................................191 Fuse................................................................................192 (Blade-Type) Color Codes........................................................192 Component Identification Table......................................................193 Functional Schematic and Component Location.........................................195 Legend..........................................................................195 System Functional Schematic ........................................................199 Legend..........................................................................199 System Functional Schematic (SE1--SE3)..............................................200 System Functional Schematic (SE4--6)................................................201 System Functional Schematic (SE7--SE9)..............................................202 System Functional Schematic (SE10--SE12)............................................203 System Functional Schematic (SE13--SE15)............................................204 System Functional Schematic (SE16--SE18)............................................205 Engine and Frame Harness (W1).......................................................206 Component Location..............................................................206 Connectors, Wire and Pin Location...............................................208 Cab Harness (W2)....................................................................211 Component Location..............................................................211 Component Location--Detail A (Harness Mating Connectors)........................212 Component Location--Detail B (Fuse Block).......................................213 Connectors, Wire and Pin Location...............................................214 Monitor and Relay Harness (W3)......................................................219 Component Location..............................................................219 Component Location--Detail A (Monitor Controller Connectors)....................220 Component Location--Detail B (Monitor Controller Indicators)....................221 Connectors, Wire and Pin Location...............................................222 Air Conditioner Harness (W9)........................................................224 Component Location--See Group 9031-15...........................................224 Connectors, Wire and Pin Location--See Group 9031-15............................224 Sub-System Diagnostics..................................................................225 Power Circuit.......................................................................225 Operational Information.........................................................225 Theory of Operation.............................................................226 Schematic.......................................................................227 Power Circuit Diagnostic Procedures.................................................228 ....................................................................................228 ....................................................................................228 ....................................................................................228 ....................................................................................229 ....................................................................................229 ....................................................................................230 ....................................................................................230 Charging Circuit....................................................................232 Operational Information.........................................................232 Theory of Operation.............................................................232 Schematic.......................................................................233 Altermator Operation 45 Amp BOSCH...............................................234 Charging Circuit Diagnostic Procedures..............................................235 ....................................................................................235 ....................................................................................236 ....................................................................................236 ....................................................................................237 ....................................................................................237 ....................................................................................237 Starting and Fuel Shutoff Circuit...................................................238 Operational Information.........................................................238 Theory of Operation.............................................................238 Starting Circuit and Fuel Shutoff Circuit...........................................239 Schematic.......................................................................239 Starting and Fuel Shutoff Circuit Diagnostic Procedures.............................240 ....................................................................................240 ....................................................................................241 ....................................................................................241 ....................................................................................241 ....................................................................................242 ....................................................................................242 ....................................................................................242 ....................................................................................243 ....................................................................................243 ....................................................................................244 ....................................................................................244 ....................................................................................245 Windshield Wiper and Washer Circuit.................................................246 Operational Information.........................................................246 Windshield Wiper And Washer Circuit.................................................247 Theory of Operation.............................................................247 Schematic.......................................................................250 Windshield Wiper and Washer Circuit Diagnostic Procedures...........................251 ....................................................................................251 ....................................................................................252 ....................................................................................252 ....................................................................................253 ....................................................................................253 ....................................................................................254 ....................................................................................254 ....................................................................................254 ....................................................................................255 ....................................................................................255 Light Circuit.......................................................................256 Operational Information.........................................................256 Work and Drive Light Circuit........................................................256 Theory of Operation.............................................................256 Schematic.......................................................................257 Work and Drive Light Circuit Diagnostic Procedures..................................258 ....................................................................................258 ....................................................................................258 ....................................................................................259 ....................................................................................259 ....................................................................................260 Accessory Circuits..................................................................262 Operational Information.........................................................262 Horn, Dome Light, and Power Plug Circuits...........................................262 Theory of Operation.............................................................262 Accessory Circuits..................................................................263 Schematic.......................................................................263 Accessory Circuits Diagnostic Procedures............................................264 ....................................................................................264 ....................................................................................264 ....................................................................................264 ....................................................................................265 ....................................................................................265 ....................................................................................265 Heater Circuit (Machines Without Air Conditioner)...................................266 Heater Circuit (Machines With Air Conditioner)......................................266 Monitor Controller and Display Circuit..............................................267 Specifications..................................................................267 Operational Information.........................................................268 Theory of Operation.............................................................269 Schematic.......................................................................275 Monitor Controller and Display Circuit Diagnostic Procedures........................276 ....................................................................................276 ....................................................................................276 ....................................................................................277 ....................................................................................277 ....................................................................................277 ....................................................................................278 ....................................................................................278 ....................................................................................278 ....................................................................................279 ....................................................................................279 ....................................................................................279 ....................................................................................280 ....................................................................................280 ....................................................................................281 ....................................................................................281 ....................................................................................282 ....................................................................................282 ....................................................................................283 ....................................................................................283 ....................................................................................284 ....................................................................................284 ....................................................................................284 ....................................................................................284 ....................................................................................285 ....................................................................................285 ....................................................................................285 ....................................................................................286 ....................................................................................286 ....................................................................................287 ....................................................................................287 ....................................................................................287 ....................................................................................288 ....................................................................................288 ....................................................................................288 ....................................................................................289 Engine and Pump Controller Circuit..................................................290 Operational Information.........................................................290 Theory of Operation.............................................................291 Engine and Pump Controller..........................................................293 Circuit Schematic...............................................................293 Engine and Pump Controller Circuit Diagnostic Procedures............................294 ....................................................................................294 ....................................................................................294 ....................................................................................294 ....................................................................................295 ....................................................................................295 ....................................................................................295 ....................................................................................296 ....................................................................................297 ....................................................................................298 ....................................................................................298 ....................................................................................299 ....................................................................................299 ....................................................................................300 ....................................................................................300 ....................................................................................301 ....................................................................................301 ....................................................................................302 ....................................................................................303 ....................................................................................304 ....................................................................................305 ....................................................................................306 ....................................................................................307 ....................................................................................308 ....................................................................................310 ....................................................................................310 ....................................................................................310 ....................................................................................311 ....................................................................................311 ....................................................................................311 ....................................................................................312 ....................................................................................313 ....................................................................................313 ....................................................................................314 ....................................................................................314 ....................................................................................314 ....................................................................................315 ....................................................................................315 ....................................................................................315 ....................................................................................316 ....................................................................................316 Start Aid and Propel Alarm Circuit..................................................318 Operational Information.........................................................318 Theory of Operation.............................................................318 Schematic.......................................................................319 Travel Alarm Circuit Diagnostic Procedures..........................................320 ....................................................................................320 ....................................................................................321 ....................................................................................322 ....................................................................................322 References..............................................................................323 Battery.............................................................................323 Operation.......................................................................323 Specification...................................................................323 Diagnose Malfunctions...........................................................324 Check Electrolyte Level and Terminals...........................................326 Batteries...........................................................................328 Procedure for Testing...........................................................328 Battery.............................................................................329 Using Booster Batteries---24 Volt System........................................329 Replacing.......................................................................330 Fuse Test...........................................................................330 Batteries...........................................................................333 Adding 12 or 24 Volt Accessories................................................333 Travel Alarm........................................................................334 Changing Volume.................................................................334 Proportional Solenoid...............................................................335 Test Harness....................................................................335 Pump Control........................................................................335 Test Harness....................................................................335 Pump Pressure Sensor................................................................335 Test Harness....................................................................335 Power Train.................................................................................337 Theory of Operation.....................................................................339 Track Adjuster......................................................................339 Propel Gearbox......................................................................340 Diagnostic Information..................................................................343 Undercarriage Components............................................................343 Measure Wear........................................................................345 Bushing, Track Chain............................................................345 Link Height, Track Chain........................................................346 Pitch, Track Chain..............................................................347 Track Shoe Grouser..............................................................348 Track Roller....................................................................349 Track Carrier Roller............................................................350 Front Idler.....................................................................351 Front Idler.....................................................................352 Swing Bearing...................................................................353 Adjustments.............................................................................355 Track Sag...........................................................................355 Hydraulic System............................................................................357 Theory of Operation.....................................................................360 Hydraulic System Diagram............................................................360 Pilot Pump..........................................................................362 Pilot Pressure Regulating Valve and Filter..........................................363 Pilot Shut-Off Valve................................................................364 Pilot Controller - Neutral..........................................................366 Pilot Controller - Metering and Full Stroke.........................................367 Propel Pilot Controller.............................................................368 Pilot Controller Operation of Control Valve.........................................370 Flow Regulator Valve................................................................372 Hydraulic Pump and Drive Gearbox....................................................374 Hydraulic Pump......................................................................376 Hydraulic Pump Regulator............................................................378 Components......................................................................378 Operation.......................................................................380 Increasing, Maximum and Decreasing..............................................382 Summation and Speed Sensing.....................................................384 Proportional Solenoid Valve.........................................................386 Manifold Operation..............................................................386 Arm Regenerative, Speed Sense, Propel Speed Change, and Power Boost.............388 Engine Speed Sense Control Circuit..................................................390 Control Valve.......................................................................392 Component Identification........................................................392 Circuit Schematic...............................................................396 Pilot Pressure Signal Passage...................................................398 Neutral and Power Passages......................................................400 System Releif Valve and Power Boost.................................................402 Power Boost Control Circuit.........................................................403 Circuit Relief Valve................................................................404 Pump Control Valve..................................................................406 Flow Combiner Valve.................................................................410 Arm Regenerative Valve..............................................................414 Boom and Arm Reduced Leakage Valve..................................................416 Bucket Flow Control Valve...........................................................418 Propel Flow Control Valve...........................................................420 Propel-Boom Down Selector Valve.....................................................421 Boom Regenerative Valve.............................................................422 Swing Gearbox.......................................................................424 Swing Motor.........................................................................426 Operation.......................................................................426 Crossover Relief Valve..........................................................428 Make-Up Valve...................................................................429 Park Brake Release Valve........................................................430 Rotary Manifold.....................................................................434 Propel Motor........................................................................436 Operation.......................................................................436 Slow Speed......................................................................438 Fast Speed......................................................................439 Speed Change Circuit............................................................440 Park Brake Valve Housing........................................................442 Park Brake Release Circuit......................................................444 Counterbalance Valve............................................................446 Cylinder............................................................................448 Boom, Arm, and Bucket...........................................................448 Return Filter.......................................................................449 Hydraulic System Circuit Symbols....................................................450 Schematic...........................................................................451 Pilot Controllers Circuit ......................................................451 Hydraulic Pump and Control Valve................................................452 Swing and Propel Motor..........................................................453 Diagnostic Information..................................................................455 Diagnostic Procedure................................................................455 Diagnose Malfunctions...............................................................456 Electronic and Control Valve Component..........................................456 Hydraulic System................................................................467 Pilot Circuit...................................................................470 Dig Circuit.....................................................................471 Swing Circuit...................................................................473 Propel System...................................................................475 Control Lever Pattern Conversion....................................................479 Control Valve.......................................................................482 Left Front Line Identification..................................................482 Right Rear Line Identification..................................................484 Bottom Line Identification......................................................486 Left Front Component Identification.............................................487 Right Rear Component Identification.............................................488 Bottom Component Identification.................................................489 Component Location..................................................................490 Main Hydraulic System...........................................................490 Pilot Controllers-to-Flow Regulator, SAE Pattern................................491 Pilot Controllers-to-Flow Regulator, John Deere Pattern.........................492 Pilot Flow Regulator-to-Control Valve...........................................493 Propel System ..................................................................494 Pressure and Return System......................................................495 Adjustment..............................................................................497 Pilot Shut-Off Valve Linkage........................................................497 Tests...................................................................................499 Laptop Computer ....................................................................499 General Description.............................................................499 Excavator Diagnostics Program.......................................................499 Overview........................................................................499 Install.........................................................................500 Uninstall.......................................................................505 Starting........................................................................506 Service Codes...................................................................510 Monitor Data....................................................................511 Saving Monitor Data.............................................................513 Engine Speed Adjustment Special Function........................................514 Service Codes List..............................................................518 Excavator Diagnostic Software.......................................................519 Monitor Data Items..............................................................519 Special Function Parameters.....................................................521 Engine Speed to Pump Flow Chart.....................................................522 Excavator Diagnostics Program.......................................................523 Troubleshooting.................................................................523 Reading Service Codes Without...................................................524 Engine and Pump Controller..........................................................526 Function........................................................................526 JT05801 Clamp-On Electronic Tachometer..............................................527 Installation....................................................................527 JT05800 Digital Thermometer Installation............................................528 JT02156 Digital Pressure and Temperature Analyzer...................................528 Start-Up Procedure..................................................................529 Hydraulic Pump..................................................................529 Swing Motor.....................................................................530 Swing Gearbox...................................................................531 Propel Motor....................................................................531 Hydraulic Oil Filter Inspection Procedure...........................................532 Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy.........................533 Hydraulic System Warm-Up Procedure..................................................534 Lower Boom with Engine Stopped......................................................535 Harness Test........................................................................536 Arm Regenerative (SC) Proportional Solenoid Valve ..............................536 Speed Sensing (SD) Proportional Solenoid Valve..................................538 Propel Speed Change (SI) Proportional Solenoid Valve............................540 Power Boost Proportional Solenoid Valve (SG)....................................542 Engine Control Sensor...........................................................544 Engine Control Motor............................................................546 Miscellaneous Component.........................................................547 Cycle Time..........................................................................548 Swing Dynamic Braking...............................................................550 Pilot Pressure Regulating Valve.....................................................552 Valve Spool Actuating Pilot Pressure................................................556 System Relief and Power Boost Valve.................................................558 Test and Adjustment.............................................................558 Circuit Relief Valve................................................................564 Swing Motor Crossover Relief Valve..................................................571 Propel Motor Crossover Relief Valve.................................................576 Proportional Solenoid Valve.........................................................582 Pump Control Valve..................................................................589 Hydraulic Pump Regulator............................................................594 Adjustments.....................................................................594 Minimum Flow....................................................................596 Maximum Flow....................................................................599 Engine Pulldown.................................................................601 Hydraulic Pump Flow.................................................................611 Pilot Pump Flow.....................................................................615 Propel System Tracking..............................................................617 Cylinder Drift......................................................................619 Swing Motor Leakage.................................................................621 Propel Motor Leakage................................................................624 Air Conditioning System.....................................................................627 Theory of Operation.....................................................................629 Proper Refrigerant Handling.........................................................629 R134a Refrigerant Cautions..........................................................629 Refrigerant Theory of Operation.....................................................630 Heater and Air Conditioner Circuit Operational Information..........................631 Heater and Air Conditioner Circuit Theory of Operation..............................632 Heater and Air Conditioner Circuit..................................................633 Functional Schematic............................................................633 Heater Circuit (Machines Without Air Conditioner)...................................634 Operational Information.........................................................634 Theory of Operation.............................................................634 Functional Schematic............................................................635 Receiver/Dryer Operation............................................................636 Expansion Valve Operation...........................................................638 Compressor Relief Valve Operation...................................................639 Temperature Control (Early Models)..................................................639 Heater and Air Conditioner Controller Operation (Later Models)......................640 System Operational Checks...............................................................641 Heating and Air Conditioning........................................................641 Operational Checks..............................................................641 Visual Inspection of Components.....................................................641 ....................................................................................641 ....................................................................................642 ....................................................................................642 ....................................................................................642 ....................................................................................642 System Operating Checks.............................................................643 ....................................................................................643 ....................................................................................644 ....................................................................................645 ....................................................................................645 Heater Circuit Checks (Machines Equipped with Heater Only)..........................645 ....................................................................................646 ....................................................................................646 ....................................................................................646 Heater and Air Conditioner Circuit Checks...........................................646 ....................................................................................647 ....................................................................................647 ....................................................................................647 ....................................................................................647 ....................................................................................648 ....................................................................................648 Diagnostic Information..................................................................649 Air Conditioning....................................................................649 Diagnose Electrical Malfunctions................................................649 Air Conditioner Harness (W9)........................................................650 Component Location..............................................................650 Connectors, Wire and Pin Location...............................................652 Adjustments.............................................................................655 Refrigerant.........................................................................655 Proper Handling.................................................................655 R134a Cautions..................................................................655 Compressor..........................................................................656 R134a Oil Charge Check..........................................................656 R134a Oil Removal...............................................................656 Oil Charge..........................................................................657 R134a Component.................................................................657 Refrigerant.........................................................................659 Recovery, Recycling and Charging Station Installation Procedure.................659 Recover.............................................................................660 R134a System....................................................................660 Evacuate............................................................................661 R134a System....................................................................661 Charge..............................................................................663 R134a System....................................................................663 Compressor..........................................................................665 Check and Adjust Belt Tension...................................................665 Tests...................................................................................667 Refrigerant.........................................................................667 Proper Handling.................................................................667 R134a Cautions..................................................................667 Air Conditioning....................................................................668 R134a System Test...............................................................668 Operating Pressure..................................................................671 Diagnostic Chart................................................................671 Switch..............................................................................672 High Pressure Test..............................................................672 Leak Testing........................................................................673 Refrigerant.........................................................................674 Hoses and Tubing Inspection.....................................................674 Page Numbers.................................................................................... 5 Section 9000................................................................................ 7 Group 01................................................................................ 9 1................................................................................... 9 2................................................................................... 10 3................................................................................... 11 4................................................................................... 12 5................................................................................... 13 6................................................................................... 14 7................................................................................... 15 8................................................................................... 16 9................................................................................... 17 10.................................................................................. 18 11.................................................................................. 19 12.................................................................................. 20 Group 02................................................................................ 21 1................................................................................... 21 2................................................................................... 22 3................................................................................... 23 4................................................................................... 24 Group 03................................................................................ 25 1................................................................................... 25 2................................................................................... 26 3................................................................................... 27 4................................................................................... 28 5................................................................................... 29 6................................................................................... 30 7................................................................................... 31 8................................................................................... 32 9................................................................................... 33 10.................................................................................. 34 11.................................................................................. 35 12.................................................................................. 36 Group 04................................................................................ 37 1................................................................................... 37 2................................................................................... 38 3................................................................................... 39 4................................................................................... 40 5................................................................................... 41 6................................................................................... 42 7................................................................................... 43 8................................................................................... 44 9................................................................................... 45 10.................................................................................. 46 11.................................................................................. 47 12.................................................................................. 48 Section 9005................................................................................ 47 Group 10................................................................................ 49 1................................................................................... 49 2................................................................................... 50 3................................................................................... 51 4................................................................................... 52 5................................................................................... 53 6................................................................................... 54 7................................................................................... 55 8................................................................................... 56 9................................................................................... 57 10.................................................................................. 58 11.................................................................................. 59 12.................................................................................. 60 13.................................................................................. 61 14.................................................................................. 62 15.................................................................................. 63 16.................................................................................. 64 17.................................................................................. 65 18.................................................................................. 66 19.................................................................................. 67 20.................................................................................. 68 21.................................................................................. 69 22.................................................................................. 70 23.................................................................................. 71 24.................................................................................. 72 25.................................................................................. 73 26.................................................................................. 74 27.................................................................................. 75 28.................................................................................. 76 29.................................................................................. 77 30.................................................................................. 78 31.................................................................................. 79 32.................................................................................. 80 33.................................................................................. 81 34.................................................................................. 82 35.................................................................................. 83 36.................................................................................. 84 37.................................................................................. 85 38.................................................................................. 86 39.................................................................................. 87 40.................................................................................. 88 Section 9010................................................................................ 87 Group 05................................................................................ 89 1................................................................................... 89 2................................................................................... 90 3................................................................................... 91 4................................................................................... 92 5................................................................................... 93 6................................................................................... 94 7................................................................................... 95 8................................................................................... 96 9................................................................................... 97 10.................................................................................. 98 11.................................................................................. 99 12..................................................................................100 13..................................................................................101 14..................................................................................102 15..................................................................................103 16..................................................................................104 Group 10................................................................................105 1...................................................................................105 2...................................................................................106 3...................................................................................107 4...................................................................................108 5...................................................................................109 6...................................................................................110 7...................................................................................111 8...................................................................................112 9...................................................................................113 10..................................................................................114 11..................................................................................115 12..................................................................................116 13..................................................................................117 14..................................................................................118 Group 15................................................................................119 1...................................................................................119 2...................................................................................120 3...................................................................................121 4...................................................................................122 5...................................................................................123 6...................................................................................124 7...................................................................................125 8...................................................................................126 9...................................................................................127 10..................................................................................128 11..................................................................................129 12..................................................................................130 Group 20................................................................................131 1...................................................................................131 2...................................................................................132 3...................................................................................133 4...................................................................................134 5...................................................................................135 6...................................................................................136 7...................................................................................137 8...................................................................................138 9...................................................................................139 10..................................................................................140 11..................................................................................141 12..................................................................................142 Group 25................................................................................143 1...................................................................................143 2...................................................................................144 3...................................................................................145 4...................................................................................146 5...................................................................................147 6...................................................................................148 7...................................................................................149 8...................................................................................150 9...................................................................................151 10..................................................................................152 11..................................................................................153 12..................................................................................154 13..................................................................................155 14..................................................................................156 15..................................................................................157 16..................................................................................158 Section 9015................................................................................157 Group 05................................................................................159 1...................................................................................159 2...................................................................................160 3...................................................................................161 4...................................................................................162 5...................................................................................163 6...................................................................................164 7...................................................................................165 8...................................................................................166 9...................................................................................167 10..................................................................................168 11..................................................................................169 12..................................................................................170 13..................................................................................171 14..................................................................................172 15..................................................................................173 16..................................................................................174 17..................................................................................175 18..................................................................................176 19..................................................................................177 20..................................................................................178 21..................................................................................179 22..................................................................................180 23..................................................................................181 24..................................................................................182 25..................................................................................183 26..................................................................................184 27..................................................................................185 28..................................................................................186 29..................................................................................187 30..................................................................................188 31..................................................................................189 32..................................................................................190 Group 10................................................................................191 1...................................................................................191 2...................................................................................192 3...................................................................................193 4...................................................................................194 5...................................................................................195 6...................................................................................196 7...................................................................................197 8...................................................................................198 9...................................................................................199 10..................................................................................200 11..................................................................................201 12..................................................................................202 13..................................................................................203 14..................................................................................204 15..................................................................................205 16..................................................................................206 17..................................................................................207 18..................................................................................208 19..................................................................................209 20..................................................................................210 21..................................................................................211 22..................................................................................212 23..................................................................................213 24..................................................................................214 25..................................................................................215 26..................................................................................216 27..................................................................................217 28..................................................................................218 29..................................................................................219 30..................................................................................220 31..................................................................................221 32..................................................................................222 33..................................................................................223 34..................................................................................224 Group 15................................................................................225 1...................................................................................225 2...................................................................................226 3...................................................................................227 4...................................................................................228 5...................................................................................229 6...................................................................................230 7...................................................................................231 8...................................................................................232 9...................................................................................233 10..................................................................................234 11..................................................................................235 12..................................................................................236 13..................................................................................237 14..................................................................................238 15..................................................................................239 16..................................................................................240 17..................................................................................241 18..................................................................................242 19..................................................................................243 20..................................................................................244 21..................................................................................245 22..................................................................................246 23..................................................................................247 24..................................................................................248 25..................................................................................249 26..................................................................................250 27..................................................................................251 28..................................................................................252 29..................................................................................253 30..................................................................................254 31..................................................................................255 32..................................................................................256 33..................................................................................257 34..................................................................................258 35..................................................................................259 36..................................................................................260 37..................................................................................261 38..................................................................................262 39..................................................................................263 40..................................................................................264 41..................................................................................265 42..................................................................................266 43..................................................................................267 44..................................................................................268 45..................................................................................269 46..................................................................................270 47..................................................................................271 48..................................................................................272 49..................................................................................273 50..................................................................................274 51..................................................................................275 52..................................................................................276 53..................................................................................277 54..................................................................................278 55..................................................................................279 56..................................................................................280 57..................................................................................281 58..................................................................................282 59..................................................................................283 60..................................................................................284 61..................................................................................285 62..................................................................................286 63..................................................................................287 64..................................................................................288 65..................................................................................289 66..................................................................................290 67..................................................................................291 68..................................................................................292 69..................................................................................293 70..................................................................................294 71..................................................................................295 72..................................................................................296 73..................................................................................297 74..................................................................................298 75..................................................................................299 76..................................................................................300 77..................................................................................301 78..................................................................................302 79..................................................................................303 80..................................................................................304 81..................................................................................305 82..................................................................................306 83..................................................................................307 84..................................................................................308 85..................................................................................309 86..................................................................................310 87..................................................................................311 88..................................................................................312 89..................................................................................313 90..................................................................................314 91..................................................................................315 92..................................................................................316 93..................................................................................317 94..................................................................................318 95..................................................................................319 96..................................................................................320 97..................................................................................321 98..................................................................................322 Group 20................................................................................323 1...................................................................................323 2...................................................................................324 3...................................................................................325 4...................................................................................326 5...................................................................................327 6...................................................................................328 7...................................................................................329 8...................................................................................330 9...................................................................................331 10..................................................................................332 11..................................................................................333 12..................................................................................334 13..................................................................................335 14..................................................................................336 15..................................................................................337 16..................................................................................338 Section 9020................................................................................337 Group 05................................................................................339 1...................................................................................339 2...................................................................................340 3...................................................................................341 4...................................................................................342 Group 15................................................................................343 1...................................................................................343 2...................................................................................344 3...................................................................................345 4...................................................................................346 5...................................................................................347 6...................................................................................348 7...................................................................................349 8...................................................................................350 9...................................................................................351 10..................................................................................352 11..................................................................................353 12..................................................................................354 Group 20................................................................................355 1...................................................................................355 2...................................................................................356 3...................................................................................357 4...................................................................................358 Section 9025................................................................................357 Group 05................................................................................360 1...................................................................................359 2...................................................................................360 3...................................................................................361 4...................................................................................362 5...................................................................................363 6...................................................................................364 7...................................................................................365 8...................................................................................366 9...................................................................................367 10..................................................................................368 11..................................................................................369 12..................................................................................370 13..................................................................................371 14..................................................................................372 15..................................................................................373 16..................................................................................374 17..................................................................................375 18..................................................................................376 19..................................................................................377 20..................................................................................378 21..................................................................................379 22..................................................................................380 23..................................................................................381 24..................................................................................382 25..................................................................................383 26..................................................................................384 27..................................................................................385 28..................................................................................386 29..................................................................................387 30..................................................................................388 31..................................................................................389 32..................................................................................390 33..................................................................................391 34..................................................................................392 35..................................................................................393 36..................................................................................394 37..................................................................................395 38..................................................................................396 39..................................................................................397 40..................................................................................398 41..................................................................................399 42..................................................................................400 43..................................................................................401 44..................................................................................402 45..................................................................................403 46..................................................................................404 47..................................................................................405 48..................................................................................406 49..................................................................................407 50..................................................................................408 51..................................................................................409 52..................................................................................410 53..................................................................................411 54..................................................................................412 55..................................................................................413 56..................................................................................414 57..................................................................................415 58..................................................................................416 59..................................................................................417 60..................................................................................418 61..................................................................................419 62..................................................................................420 63..................................................................................421 64..................................................................................422 65..................................................................................423 66..................................................................................424 67..................................................................................425 68..................................................................................426 69..................................................................................427 70..................................................................................428 71..................................................................................429 72..................................................................................430 73..................................................................................431 74..................................................................................432 75..................................................................................433 76..................................................................................434 77..................................................................................435 78..................................................................................436 79..................................................................................437 80..................................................................................438 81..................................................................................439 82..................................................................................440 83..................................................................................441 84..................................................................................442 85..................................................................................443 86..................................................................................444 87..................................................................................445 88..................................................................................446 89..................................................................................447 90..................................................................................448 91..................................................................................449 92..................................................................................450 93..................................................................................451 94..................................................................................452 95..................................................................................453 96..................................................................................454 Group 15................................................................................455 1...................................................................................455 2...................................................................................456 3...................................................................................457 4...................................................................................458 5...................................................................................459 6...................................................................................460 7...................................................................................461 8...................................................................................462 9...................................................................................463 10..................................................................................464 11..................................................................................465 12..................................................................................466 13..................................................................................467 14..................................................................................468 15..................................................................................469 16..................................................................................470 17..................................................................................471 18..................................................................................472 19..................................................................................473 20..................................................................................474 21..................................................................................475 22..................................................................................476 23..................................................................................477 24..................................................................................478 25..................................................................................479 26..................................................................................480 27..................................................................................481 28..................................................................................482 29..................................................................................483 30..................................................................................484 31..................................................................................485 32..................................................................................486 33..................................................................................487 34..................................................................................488 35..................................................................................489 36..................................................................................490 37..................................................................................491 38..................................................................................492 39..................................................................................493 40..................................................................................494 41..................................................................................495 42..................................................................................496 Group 20................................................................................497 1...................................................................................497 2...................................................................................498 Group 25................................................................................499 1...................................................................................499 2...................................................................................500 3...................................................................................501 4...................................................................................502 5...................................................................................503 6...................................................................................504 7...................................................................................505 8...................................................................................506 9...................................................................................507 10..................................................................................508 11..................................................................................509 12..................................................................................510 13..................................................................................511 14..................................................................................512 15..................................................................................513 16..................................................................................514 17..................................................................................515 18..................................................................................516 19..................................................................................517 20..................................................................................518 21..................................................................................519 22..................................................................................520 23..................................................................................521 24..................................................................................522 25..................................................................................523 26..................................................................................524 27..................................................................................525 28..................................................................................526 29..................................................................................527 30..................................................................................528 31..................................................................................529 32..................................................................................530 33..................................................................................531 34..................................................................................532 35..................................................................................533 36..................................................................................534 37..................................................................................535 38..................................................................................536 39..................................................................................537 40..................................................................................538 41..................................................................................539 42..................................................................................540 43..................................................................................541 44..................................................................................542 45..................................................................................543 46..................................................................................544 47..................................................................................545 48..................................................................................546 49..................................................................................547 50..................................................................................548 51..................................................................................549 52..................................................................................550 53..................................................................................551 54..................................................................................552 55..................................................................................553 56..................................................................................554 57..................................................................................555 58..................................................................................556 59..................................................................................557 60..................................................................................558 61..................................................................................559 62..................................................................................560 63..................................................................................561 64..................................................................................562 65..................................................................................563 66..................................................................................564 67..................................................................................565 68..................................................................................566 69..................................................................................567 70..................................................................................568 71..................................................................................569 72..................................................................................570 73..................................................................................571 74..................................................................................572 75..................................................................................573 76..................................................................................574 77..................................................................................575 78..................................................................................576 79..................................................................................577 80..................................................................................578 81..................................................................................579 82..................................................................................580 83..................................................................................581 84..................................................................................582 85..................................................................................583 86..................................................................................584 87..................................................................................585 88..................................................................................586 89..................................................................................587 90..................................................................................588 91..................................................................................589 92..................................................................................590 93..................................................................................591 94..................................................................................592 95..................................................................................593 96..................................................................................594 97..................................................................................595 98..................................................................................596 99..................................................................................597 100.................................................................................598 101.................................................................................599 102.................................................................................600 103.................................................................................601 104.................................................................................602 105.................................................................................603 106.................................................................................604 107.................................................................................605 108.................................................................................606 109.................................................................................607 110.................................................................................608 111.................................................................................609 112.................................................................................610 113.................................................................................611 114.................................................................................612 115.................................................................................613 116.................................................................................614 117.................................................................................615 118.................................................................................616 119.................................................................................617 120.................................................................................618 121.................................................................................619 122.................................................................................620 123.................................................................................621 124.................................................................................622 125.................................................................................623 126.................................................................................624 127.................................................................................625 128.................................................................................626 129.................................................................................627 130.................................................................................628 Section 9031................................................................................627 Group 05................................................................................629 1...................................................................................629 2...................................................................................630 3...................................................................................631 4...................................................................................632 5...................................................................................633 6...................................................................................634 7...................................................................................635 8...................................................................................636 9...................................................................................637 10..................................................................................638 11..................................................................................639 12..................................................................................640 Group 10................................................................................641 1...................................................................................641 2...................................................................................642 3...................................................................................643 4...................................................................................644 5...................................................................................645 6...................................................................................646 7...................................................................................647 8...................................................................................648 Group 15................................................................................649 1...................................................................................649 2...................................................................................650 3...................................................................................651 4...................................................................................652 5...................................................................................653 6...................................................................................654 Group 20................................................................................655 1...................................................................................655 2...................................................................................656 3...................................................................................657 4...................................................................................658 5...................................................................................659 6...................................................................................660 7...................................................................................661 8...................................................................................662 9...................................................................................663 10..................................................................................664 11..................................................................................665 12..................................................................................666 Group 25................................................................................667 1...................................................................................667 2...................................................................................668 3...................................................................................669 4...................................................................................670 5...................................................................................671 6...................................................................................672 7...................................................................................673 8...................................................................................674
S.S 24/02/2025
