Vermeer T655 III Tractor Attachments Service Manual – PDF DOWNLOAD

Description

Vermeer T655 III Tractor Attachments Service Manual – PDF DOWNLOAD

DESCRIPTION:

Vermeer T655 III Tractor Attachments Service Manual – PDF DOWNLOAD

USING THE MANUAL:

• This manual provides information and service procedures based upon current machine knowledge and configuration at the time the manual was written. The instructions, illustrations and specifications are based on the latest information available at the time of publication. Due to ongoing efforts to continuously improve the equipment, there may be changes on the machine not yet reflected in this manual.
• Vermeer Manufacturing Company reserves the right to make changes at any time without notice or obligation. Procedures given in this manual provide one method for completing a given task. Additional information may be available through Vermeer Service Support resources. Additional copies of this manual are available through the Vermeer Parts Center.
• Use the reorder number on the front cover to order additional manuals. Operating instructions are found in the T655111 Operator’s Manual. Lubrication and maintenance procedures are found in the T655111 Maintenance Manual. Refer to “Reference Publications,” for ordering information.
• This manual contains service requirements and procedures needed by an experienced service person to complete necessary service and repairs on the machine. Study and understand these requirements and procedures thoroughly before servicing or repairing the machine. There are also many components which are not user-serviceable. Do not attempt any service which you do not fully understand, nor any service that you cannot do adequately and safely with the tools and equipment available to you.
• Failure to do so could result in personal injury or equipment damage. If you encounter a problem that you do not understand or cannot solve, contact your Vermeer service representative. The instructions, illustrations and specifications in this manual are based on the latest information available at the time of publication.
• Your machine may have product improvements and options not yet contained in this manual. Vermeer Manufacturing Company reserves the right to make changes at any time without notice or obligation. Additional copies of this manual are available. When ordering, use the part number on the front cover.

TABLE OF CONTENTS:

Vermeer T655 III Tractor Attachments Service Manual – PDF DOWNLOAD

System MAP........................................................................  5
General Table of Contents.........................................................  6
	Chapter 1 - General Information SS:...........................................  6
	Chapter 2 - System Information SS:............................................  6
	Chapter 3 - Power Distribution SS:............................................  6
	Chapter 4 - Fluid Conditioning SS:............................................  6
	Chapter 5 - Engine SS:........................................................  6
	Chapter 6 - Implement SS:.....................................................  6
	Chapter 7 - Ground Drive SS:..................................................  7
	Chapter 8 - Attachment SS:....................................................  7
	Chapter 9 - Cross Conveyor SS:................................................  7
	Chapter 10 - Auxiliary SS:....................................................  7
	Chapter 11 - Load/Return Conveyor SS:.........................................  7
	Chapter 12 - Cab SS:..........................................................  7
Chapter 1: General Information.................................................... 11
	Using the Manual.............................................................. 11
		Reference Publications.................................................... 12
			Vermeer Publications.................................................. 12
			Vendor Publications................................................... 12
	Warranty Considerations....................................................... 12
		Vermeer Warranty.......................................................... 12
		John Deere Warranty....................................................... 12
	Safety........................................................................ 13
		Do Not Modify Machine..................................................... 13
		Maintain Operator Presence System......................................... 13
		Replace Shields........................................................... 13
		Safety Symbol Explanation................................................. 14
	Terminology................................................................... 16
		System.................................................................... 16
		Subsystem................................................................. 16
		Circuit................................................................... 16
		MAP (Machine Analysis Page)............................................... 16
		Inputs and Outputs........................................................ 16
		Reference Designators..................................................... 17
		Diagrams and Schematics................................................... 17
		Chapter Organization...................................................... 18
			Chapter 3............................................................. 18
			Chapter 4............................................................. 18
			Chapter 5............................................................. 18
			Chapter 6............................................................. 18
			Chapter 7............................................................. 18
			Chapter 8............................................................. 18
			Chapter 9............................................................. 18
			Chapter 10............................................................ 18
			Chapter 11............................................................ 18
			Chapter 12............................................................ 18
			Theory................................................................ 19
			Troubleshooting....................................................... 19
			Repair................................................................ 19
			Addendum.............................................................. 19
	Troubleshooting Guidelines.................................................... 19
		Problem-Solving Analysis.................................................. 19
		Fault Charts.............................................................. 20
		Electrical Troubleshooting................................................ 21
			Common Electrical Problems............................................ 21
		Hydraulic Troubleshooting................................................. 23
			Leakage Path Analysis................................................. 23
			Pumps and Motors...................................................... 23
			Directional Control Valves............................................ 24
			Cylinders............................................................. 25
		Required Tools............................................................ 25
		Hydraulic Connections..................................................... 25
			Avoid Trapped Pressure................................................ 25
			Avoid Oil Contamination............................................... 26
			Connecting Flow Meters................................................ 26
			Connecting A Needle Valve............................................. 26
			Connecting Pressure Gauges............................................ 27
		Thermometer or Pyrometer.................................................. 27
		Digital Multimeter........................................................ 28
			Measuring Voltage..................................................... 28
			Measuring Resistance.................................................. 28
			Testing for Continuity................................................ 29
			Measuring Current..................................................... 29
		Shop Requirements......................................................... 30
			Special Tools and Test Equipment...................................... 30
		Personnel and Lifting Requirements........................................ 30
		Replacement Parts......................................................... 30
			Part Numbers/Hose Lengths/Fitting Orientation......................... 30
			Parts Ordering........................................................ 30
		Torque Tables............................................................. 30
			Dynamic vs. Static Torque............................................. 30
			Flats After Finger- Tight............................................. 31
			Pipe Thread Fittings.................................................. 32
			Face Seal Fittings with O-Rings....................................... 33
			Flare Fittings........................................................ 34
			37 Flare JIC Tube Nuts & Swivel Nuts................................. 35
			45 Flare Fittings.................................................... 36
			Air Brake Fittings.................................................... 37
			Air Conditioning Fittings............................................. 38
			O-Ring Boss Plug...................................................... 39
			Drain Plugs........................................................... 40
			Hose Clamps........................................................... 40
			Constant Torque Hose Clamp............................................ 40
			Band Type Hose Clamp.................................................. 41
			Bulkhead Nut.......................................................... 41
			SAE Grade 2, Grade 5, and Grade 8 Cap Screws and Bolts................ 42
			Metric Grade 5.8, 6.9, 8.8, 10.9, & 12.9 Cap Screws and Bolts......... 43
			Grade B, C, F, and G Lock Nuts........................................ 44
Chapter 2: System Information..................................................... 47
	Shutdown Procedure............................................................ 47
	Emergency Stop Circuit........................................................ 48
		Switch - Reset............................................................ 48
	Intended Use.................................................................. 49
	T655III Specifications........................................................ 49
		Machine Reference and Orientation......................................... 49
		Power Distribution Subsystem.............................................. 50
			Batteries............................................................. 50
			Alternator............................................................ 50
		Engine Subsystem.......................................................... 50
		Implement Subsystem....................................................... 50
			Electrical............................................................ 50
			Hydraulic............................................................. 50
		Ground Drive Subsystem.................................................... 51
			Electrical............................................................ 51
			Hydraulic............................................................. 51
		Attachment Subsystem...................................................... 51
			Electrical............................................................ 51
			Hydraulic............................................................. 51
		Cross Conveyor Subsystem.................................................. 52
			Hydraulic............................................................. 52
		Auxiliary Subsystem....................................................... 52
			Electrical............................................................ 52
			Hydraulic............................................................. 52
		Load/Return Conveyor Subsystem............................................ 52
			Hydraulic............................................................. 52
		Fluid and Lubricants...................................................... 53
	Trencher Electronic Control................................................... 54
		TEC 2000 Microprocessor A5 & Display DS4.................................. 54
		Microprocessor Identification............................................. 56
		Pin Designations and Functions............................................ 57
		Machine Interlock Functions............................................... 59
			Engine Start Interlocks............................................... 59
			Operator Presence Interlock........................................... 60
		Default Screens........................................................... 61
		View Screens.............................................................. 62
			Steering Knob......................................................... 62
			Propel Lever.......................................................... 62
			Load Control Knob..................................................... 62
			Attachment Speed Knob................................................. 62
			Track Pumps EDC Command............................................... 62
			Track Pumps EDC Volts................................................. 62
			Track Motor Speed..................................................... 63
			Hydraulic Oil and Engine Coolant Temperatures......................... 63
			Sensor Supply......................................................... 63
			Machine Model......................................................... 63
			Software ID........................................................... 63
		Setup Screens............................................................. 63
			Maximum Propel in Trench Mode......................................... 63
			Maximum Load Control Adjustment....................................... 64
			Attachment ESL (Electronic Stroke Limiter)............................ 64
			Language Adjustment................................................... 64
			Display Units......................................................... 64
			Fault Mode............................................................ 64
			Slow Speed Mode....................................................... 64
			View Angle............................................................ 64
		Modify Screens............................................................ 65
			Trench Low (Slow Speed Mode).......................................... 65
		Fault Screens............................................................. 66
		Fault Table............................................................... 67
		Microprocessor Troubleshooting............................................ 68
			Welding Precautions................................................... 68
		Troubleshooting Table..................................................... 69
		Calibration............................................................... 71
			Calibrating Single Components......................................... 73
Chapter 3: Power Distribution Subsystem........................................... 77
	Overview...................................................................... 77
		Circuits/Components....................................................... 77
		Component Locations....................................................... 78
	Ignition ON Circuit........................................................... 79
		Operation................................................................. 79
			Batteries BT1 & BT2................................................... 80
			Ignition Switch S9.................................................... 80
			Ground Disconnect Switch S3........................................... 81
			Circuit Breaker CB1................................................... 81
			Emergency Stop Switch S8.............................................. 81
			Power Relays K3 & K4.................................................. 82
			Fuse Box A4........................................................... 82
Chapter 3: Power Distribution Subsystem........................................... 85
	Overview...................................................................... 85
		Pretest Inspection........................................................ 85
		Test Equipment Needed..................................................... 85
	Ignition ON Circuit........................................................... 85
		Electrical Troubleshooting................................................ 85
			Testing Sequence...................................................... 86
			Power Source Distribution MAP......................................... 86
			Component Pin/ Terminal Reference..................................... 87
			Source Voltage Test................................................... 88
			Open Circuit Test..................................................... 88
			High Resistance....................................................... 89
			Short Circuit Test.................................................... 89
Chapter 3: Power Distribution Subsystem........................................... 91
	Summary....................................................................... 91
Chapter 4: Fluid Conditioning Subsystem........................................... 95
	Overview...................................................................... 95
		Circuits/Components....................................................... 95
		Component Locations....................................................... 96
	Oil Supply and Return Circuits................................................ 97
		Operation................................................................. 97
Chapter 4: Fluid Conditioning Subsystem...........................................101
	Overview......................................................................101
		Possible Malfunctions.....................................................101
		Test Equipment Needed.....................................................101
	Oil Supply and Return Circuits................................................102
		Excessive Noise...........................................................102
			Noise Associated with a Pump..........................................102
			Filtering.............................................................103
			Noise Associated with a Relief Valve..................................104
		Excessive Vibration.......................................................104
		Excessive Heat............................................................104
			Oil Cooler and Thermal Bypass Valves..................................105
		Hydraulic Oil Sampling....................................................105
		Oil Leakage...............................................................107
Chapter 4: Fluid Conditioning Subsystem...........................................109
	Summary.......................................................................109
Chapter 5: Engine Subsystem.......................................................113
	Overview......................................................................113
		MAP.......................................................................113
		Circuits/Components.......................................................113
		Component Locations.......................................................115
	Engine ENG1...................................................................117
	Engine Control Unit...........................................................118
		Engine Shutdown...........................................................118
	Murphy PowerView..............................................................119
		Accessing Engine Fault Codes (PowerView)..................................119
		Clearing Engine Fault Codes (PowerView)...................................120
		Interpreting John Deere Engine Fault Codes................................121
	Engine Speed PPU Circuit......................................................125
		Magnetic Pickup PPU.......................................................125
	Coolant Circuit...............................................................126
	Air Intake/Exhaust Circuit....................................................127
		Air Cleaner...............................................................128
	Fuel Circuit..................................................................129
	Ignition START/RUN Circuit....................................................130
		Cold Start Circuit........................................................131
	Throttle Circuit..............................................................133
	Charge Circuit................................................................133
	Gauge Circuit.................................................................134
Chapter 5: Engine Subsystem.......................................................135
	Overview......................................................................135
		Pretest Inspection........................................................135
		Possible Malfunctions.....................................................135
		Test Equipment Needed.....................................................136
	Engine........................................................................136
		Engine Service............................................................136
		Engine Maintenance........................................................136
	Engine Speed PPU Circuit......................................................137
		Magnetic Pickup Sensor Hertz Test.........................................137
	Coolant Circuit...............................................................138
		Coolant Level Check.......................................................138
	Air Intake/Exhaust Circuit....................................................138
		Air Cleaner...............................................................139
		Turbocharger and Aftercooler..............................................139
	Fuel Circuit..................................................................140
		Fuel Tanks, Lines, Filters, and Strainers.................................140
			Water in Fuel.........................................................140
	Ignition START/RUN Circuit....................................................141
		Possible Malfunctions.....................................................141
			Engine Start Interlock Faults.........................................141
		Electrical Troubleshooting................................................142
			Circuit MAP...........................................................142
			Testing Sequence......................................................142
			Component Pin/ Terminal Reference.....................................143
			Open Circuit Test.....................................................144
			High Resistance.......................................................144
			Short Circuit Test....................................................144
		Cold Start Circuit........................................................145
	Throttle Circuit..............................................................145
	Charge Circuit................................................................146
		Alternator G1.............................................................146
	Fuel Gauge Circuit............................................................147
		Fuel Gauge................................................................147
			Voltage Test..........................................................147
			Open Sensor Test......................................................147
			Sensor Ground Test....................................................147
Chapter 5: Engine Subsystem.......................................................149
	Summary.......................................................................149
Chapter 6: Implement Subsystem....................................................155
	Overview......................................................................155
		MAP.......................................................................155
		Circuits/Components.......................................................156
		Component Locations.......................................................158
		Control Panel Component Locations.........................................160
		Hydraulic Hose Connections - Supply and Return............................161
		Hydraulic Hose Connections - Standard 6-Bank Valve Configuration..........162
		Hydraulic Hose Connections - (Optional) 10-Bank Valve Configuration.......163
	Pressure-Flow Standby Circuit.................................................164
		Hydraulic Pressure-Flow Compensated Pump PFC1.............................164
		Control Valve Assembly A1.................................................166
	Left Track Level Circuit......................................................167
		Operation.................................................................167
			Cylinder - Extend (Raise).............................................168
			Cylinder - Retract (Lower)............................................168
			Counterbalance Valves.................................................168
			Auto Level............................................................168
	Right Track Level Circuit.....................................................169
		Operation.................................................................169
			Cylinder - Extend (Raise).............................................169
			Cylinder - Retract (Lower)............................................169
			Counterbalance Valves.................................................169
			Auto Level............................................................169
	Left Track Tilt Circuit.......................................................170
		Operation.................................................................170
			Port Relief Valves....................................................170
			Cylinder - Extend (Tilt Inward).......................................171
			Cylinder - Retract (Tilt Outward).....................................171
	Right Track Tilt Circuit......................................................171
		Operation.................................................................171
			Port Relief Valves....................................................172
			Cylinder - Extend (Tilt Inward).......................................172
			Cylinder - Retract (Tilt Outward).....................................172
	Trench Cleaner Fold Circuit...................................................173
		Operation.................................................................173
			Port Relief Valve.....................................................173
			Cylinder - Extend (Lower).............................................174
			Cylinder - Retract (Raise)............................................174
			Counterbalance Valve..................................................174
	Trencher Boom Lift Circuit....................................................174
		Operation - Standard Configuration........................................174
			Cylinder - Extend (Lower).............................................175
			Cylinder - Retract (Raise)............................................175
			Lock Valve LCK1.......................................................175
			Counterbalance Valves.................................................175
		Operation - Optional Auto Down Pressure Configuration.....................176
			Cylinder - Extend (Lower).............................................176
			Cylinder - Retract (Raise)............................................176
			Lock Valve LCK1.......................................................177
			Counterbalance Valves.................................................177
	Trench Cleaner Shoe Circuit (Optional)........................................177
		Operation.................................................................177
			Cylinder - Extend (Lower).............................................178
			Cylinder - Retract (Raise)............................................178
			Lock Valve LCK3.......................................................178
			Counterbalance Valve..................................................178
	Conveyor Fold Circuit (Optional)..............................................178
		Operation.................................................................178
			Cylinder - Extend (Lower).............................................179
			Cylinder - Retract (Raise)............................................179
			Counterbalance Valve..................................................179
	Conveyor Shift Circuit (Optional).............................................179
		Operation.................................................................179
			Port Relief Valves....................................................180
			Conveyor - Shift Left.................................................180
			Conveyor - Shift Right................................................180
	Dirt Drags Circuit (Optional).................................................181
		Operation.................................................................181
			Cylinder - Extend (Lower).............................................181
			Cylinder - Retract (Raise)............................................181
			Lock Valve LCK2.......................................................181
Chapter 6: Implement Subsystem....................................................183
	Overview......................................................................183
		Pretest Inspection........................................................183
		Fault Chart...............................................................184
		Test Equipment Needed.....................................................184
		Component Repair/Replace..................................................184
	Fault Chart...................................................................185
	Shared Hydraulic Components...................................................186
		Fluid Conditioning Subsystem..............................................186
		Implement Pump PFC1.......................................................186
		Directional Control Valve Assembly A1.....................................186
		Pump PFC1 Hydraulic Test Procedure........................................187
			Analyzing Test Results................................................189
			Compensator - Check...................................................191
			Pump Port Designations................................................191
	Left and Right Machine Level Circuits.........................................192
		Electrical Troubleshooting................................................192
			Testing Sequence......................................................192
			Control Valve Reference...............................................193
			Component Pin/ Terminal Reference.....................................194
			Open Circuit Test.....................................................195
			High Resistance Test..................................................195
			Short Circuit Test....................................................196
		Auto Level Circuit........................................................196
		Hydraulic Troubleshooting.................................................197
			Cylinder Test Procedure...............................................197
			Analyzing Cylinder Test Results.......................................199
	Left and Right Track Tilt Circuits............................................200
		Electrical Troubleshooting................................................200
			Testing Sequence......................................................200
		Hydraulic Troubleshooting.................................................201
	Trench Cleaner Fold Circuit...................................................202
		Electrical Troubleshooting................................................202
			Testing Sequence......................................................202
		Hydraulic Troubleshooting.................................................203
	Trencher Boom Lift Circuit....................................................204
		Electrical Troubleshooting................................................204
			Testing Sequence......................................................204
		Hydraulic Troubleshooting.................................................205
	Trench Cleaner Shoe Circuit...................................................206
		Electrical Troubleshooting................................................206
			Testing Sequence......................................................206
		Hydraulic Troubleshooting.................................................207
	Conveyor Fold Circuit.........................................................208
		Electrical Troubleshooting................................................208
			Testing Sequence......................................................208
		Hydraulic Troubleshooting.................................................209
	Dirt Drags Circuit............................................................210
		Electrical Troubleshooting................................................210
			Testing Sequence......................................................210
		Hydraulic Troubleshooting.................................................211
	Conveyor Shift Circuit........................................................212
		Electrical Troubleshooting................................................212
			Testing Sequence......................................................212
		Hydraulic Troubleshooting.................................................212
	Pump Worksheet................................................................213
	Cylinder Worksheet............................................................214
Chapter 6: Implement Subsystem....................................................215
	Introduction..................................................................215
		Components................................................................215
	Hydraulic Repair..............................................................215
		Pump PFC1.................................................................216
			Remove................................................................216
			Install...............................................................216
		Pump Shaft Seal...........................................................216
			Replace...............................................................216
		Pump Pressure-Flow Compensator Assembly...................................217
			Replace...............................................................217
		Pump Start-Up Procedure...................................................218
		Directional Control Valve Assembly A1.....................................219
			Remove................................................................219
		Valve Section Seals.......................................................220
			Replace...............................................................220
		Valve Spool Seals.........................................................221
			Replace...............................................................221
		Valve Section Relief Valves...............................................221
			Seals - Replace.......................................................221
			Poppet / Piston Ring - Replace........................................222
		Valve Section Solenoid Cartridge Valve....................................222
			Seals - Replace.......................................................222
		Cylinders.................................................................223
		Special Tools.............................................................223
		Cylinder Disassembly Precautions..........................................224
		Cylinder Disassembly......................................................225
		Cylinder Rod Removal......................................................226
			For Threaded Gland....................................................226
			For Retaining Wire Gland..............................................226
		Stuck Rod Removal.........................................................228
			Manual Procedure......................................................228
			Pressure Procedure....................................................229
		Piston Removal............................................................231
		Seal Information Reference................................................233
		Piston Install............................................................234
		Rod Install...............................................................235
		Threaded Gland Tightening Procedures......................................237
		Retaining Wire Gland Tightening Procedures................................237
		Cylinder Post Repair Check................................................239
		Cylinder Lock Valves......................................................241
			Remove................................................................241
			Install...............................................................241
			Seals - Replace.......................................................242
		Conveyor Shift Motor B1...................................................242
			Remove................................................................242
			Install...............................................................242
			Motor Seals - Replace.................................................243
Chapter 7: Ground Drive Subsystem.................................................249
	Overview......................................................................249
		MAP.......................................................................249
		Circuits/Components.......................................................251
		Component Locations.......................................................252
		Hydraulic Hose Connections - (Right Track Shown)..........................254
	Left and Right Track Drive Circuits...........................................255
		Operation - Electrical Control Circuits/Components........................255
			TEC 2000 Microprocessor A5............................................256
			Propel Control........................................................256
			Drive Motor PPUs......................................................257
			REVERSE Travel Alarm Circuit..........................................257
			Steering Control......................................................258
			2-Speed/Park Brake Control............................................258
			2-Speed Operation.....................................................258
			Park Brake Operation..................................................260
			Brakes - Applied......................................................260
			Brakes - Released.....................................................261
		Operation - Track Drive Hydrostatic Circuits..............................262
			Pump PMP4.............................................................263
			EDC (Electronic Displacement Control).................................263
			Charge Pressure Circuit...............................................264
			Multifunction Valves MF1 & MF2........................................265
			Track Drive Motor B6..................................................265
Chapter 7: Ground Drive Subsystem.................................................267
	Overview......................................................................267
		Pretest Inspection........................................................267
		Fault Charts..............................................................268
		Test Equipment Needed.....................................................268
		Component Repair/Replace..................................................268
	Fault Charts..................................................................269
		Track Drive Function Does Not Operate in Either Direction.................269
		Track Drive Function Operates in One Direction Only.......................270
		Track Drive Function Response is Sluggish/Slow in Both Directions.........271
		Park Brake & 2-Speed Circuits.............................................272
	Left and Right Track Drive Circuits...........................................273
		Electrical Control Circuits/Components....................................273
			TEC 2000 Microprocessor...............................................273
			Display Faults........................................................273
			Troubleshooting Table.................................................274
		Testing Control Circuits..................................................276
			Control Circuits MAP..................................................276
			Component Pin/ Terminal Reference.....................................277
			Open Circuit Test.....................................................278
			High Resistance Test..................................................278
			Short Circuit Test....................................................278
		Track Motor PPUs..........................................................279
			PPU - Install/Adjust..................................................279
		Track Drive Hydrostatic Circuits..........................................280
			Charge Pressure.......................................................280
			Charge Pressure - Check...............................................280
			Charge Pressure - Adjust..............................................281
			System Pressure.......................................................282
			System Pressure - Check...............................................282
		Towing....................................................................283
			Releasing Bypass Valves...............................................283
			Releasing Park Brakes.................................................283
			Restoring System......................................................284
		Track Drive Motor Case Drain Flow Test....................................284
			Oil Sampling..........................................................284
			Analyzing Motor Test Results..........................................286
		Park Brake and 2-Speed Circuits...........................................286
			Pressure Reducing Valve...............................................287
		Park Brake Circuit........................................................288
			Electrical Troubleshooting............................................289
			Hydraulic Troubleshooting.............................................289
		2-Speed Circuit...........................................................289
			Electrical Troubleshooting............................................290
			Hydraulic Troubleshooting.............................................290
Chapter 7: Ground Drive Subsystem.................................................291
	Introduction..................................................................291
		Components................................................................291
	Hydraulic Repair..............................................................291
		General Guidelines When Servicing the Hydrostatic Drives..................291
			Avoid Oil Contamination...............................................292
		Track Drive Pumps PMP4 & PMP5.............................................293
			Remove................................................................293
			Install...............................................................294
		Pump Multifunction Valves.................................................295
			Remove................................................................295
			Install...............................................................296
			High Pressure Limiter - Adjust........................................296
		Pump EDC (Electric Displacement Control)..................................297
			PCP (Pressure Control Pilot) - Remove.................................297
			EDC - Remove..........................................................298
			Install...............................................................298
			EDC Neutral Setting - Adjust..........................................299
		Track Drive Motors B6 & B7................................................301
			Remove................................................................301
			Install...............................................................302
		Park Brake/2-Speed Valve A2...............................................302
			Remove................................................................302
			Install...............................................................302
		Cartridge Valves..........................................................303
			Remove................................................................303
			Install...............................................................303
			Seals - Replace.......................................................303
	Mechanical Repair.............................................................304
		Planetary Gearbox/Sprocket................................................304
			Remove................................................................304
			Install...............................................................305
		Planetary Brakes..........................................................306
			Replace...............................................................306
		Tracks....................................................................308
			Remove................................................................308
			Install...............................................................309
		Track Tension.............................................................311
			Adjust................................................................311
		Idler Wheel & Tensioning Cartridge........................................312
			Remove................................................................312
			Install...............................................................312
		Rollers...................................................................313
			Remove................................................................313
			Install...............................................................313
Chapter 8: Attachment Subsystem...................................................317
	Overview......................................................................317
		MAP.......................................................................317
		Circuits/Components.......................................................318
		Component Locations.......................................................319
		Hydraulic Hose Connections................................................321
	Attachment Drive Circuit......................................................322
		Operation.................................................................322
		Microprocessor A5.........................................................323
		Attachment Control Circuit................................................324
		Pumps PMP2 & PMP3.........................................................325
			EDC (Electronic Displacement Control).................................325
			Charge Pressure Circuit...............................................326
			Multifunction Valves MF1 & MF2........................................327
		Attachment Manifold A3 and Drive Motor B5.................................328
			High Pressure Circuit.................................................328
			Shuttle Valve SV1.....................................................328
			Thermal Bypass Valves FC1 & FC2.......................................329
			Pressure Relief Operation.............................................329
			Hydraulic Oil Temperature Switch TS1..................................330
Chapter 8: Attachment Subsystem...................................................331
	Overview......................................................................331
		Pretest Inspection........................................................331
		Fault Charts..............................................................331
		Test Equipment Needed.....................................................332
		Component Repair/Replace..................................................332
	Fault Charts..................................................................333
		Attachment Drive Function Does Not Operate in Either Direction............333
		Attachment Drive Function Operates in One Direction Only..................334
		Attachment Drive Function Response Is Sluggish/Slow in Both Directions....335
	Attachment Drive Circuit......................................................336
		Attachment Control Circuits/Components....................................336
			TEC 2000 Microprocessor...............................................336
			Display Faults........................................................336
			Troubleshooting Table.................................................337
		Testing Control Circuits..................................................338
			Control Circuits MAP..................................................338
			Component Pin/ Terminal Reference.....................................339
			Open Circuit Test.....................................................340
			High Resistance Test..................................................340
			Short Circuit Test....................................................340
		Attachment Drive Hydrostatic Circuit......................................341
			Charge Pressure.......................................................341
			Charge Pressure - Quick Check.........................................341
			Individual Pump - Check...............................................342
			Charge Pressure - Adjust..............................................343
			Charge Pressure - Filter Switches.....................................343
			System Pressure.......................................................344
			System Pressure - Check...............................................344
			Individual Pump - Check...............................................344
		Attachment Motor Case Drain Flow Test.....................................345
			Oil Sampling..........................................................345
			Analyzing Motor Test Results..........................................347
Chapter 8: Attachment Subsystem...................................................349
	Introduction..................................................................349
		Components................................................................349
	Hydraulic Repair..............................................................349
		General Guidelines When Servicing the Hydrostatic Drive...................349
			Avoid Oil Contamination...............................................350
		Attachment Drive Pumps PMP2 & PMP3........................................351
			Remove................................................................351
			Install...............................................................352
		Pump EDC (Electric Displacement Control)..................................353
			Replace/Repair........................................................353
		Pump Multifunction Valves.................................................353
			Replace/Repair........................................................353
			High Pressure Relief - Adjust.........................................353
			Shuttle Valve - Adjust................................................354
		Trencher Drive Motor B5...................................................355
			Remove................................................................355
			Install...............................................................356
		Manifold Valve Assembly...................................................357
			Remove................................................................357
			Seals - Replace.......................................................357
	Mechanical Repair.............................................................358
		Digging Chain.............................................................358
			Remove................................................................358
			Install...............................................................359
		Digging Chain Tension.....................................................360
			Adjust................................................................360
		Trench Cleaner............................................................362
			Adjust................................................................362
		End Idler Assembly........................................................363
			Remove................................................................363
			Install...............................................................364
		Headshaft Assembly........................................................365
			Remove................................................................365
		Headshaft Bearings........................................................368
			Remove................................................................368
			Install...............................................................370
			Heating Bearings......................................................370
Chapter 9: Cross Conveyor Subsystem...............................................375
	Overview......................................................................375
		Circuits/Components.......................................................376
		Component Locations.......................................................377
		Hydraulic Hose Connections................................................378
	Flat Conveyor Rotation Circuit................................................379
		Operation.................................................................379
			Spoil Discharge.......................................................380
	Curved Conveyor Rotation Circuit..............................................380
		Operation.................................................................380
Chapter 9: Cross Conveyor Subsystem...............................................381
	Overview......................................................................381
		Pretest Inspection........................................................381
		Fault Chart...............................................................381
		Test Equipment Needed.....................................................382
		Component Repair/Replace..................................................382
	Fault Chart...................................................................383
	Conveyor Rotation Circuit.....................................................384
		Hydraulic Troubleshooting.................................................384
			System Pressure - Check...............................................384
		Pressure Relief Valve PRL1 Test Procedure.................................385
			Analyzing Test Results................................................386
		Hydraulic Circuit Test Procedures.........................................387
			Pump PMP1 - Test......................................................387
			Analyzing Test Results................................................389
			Directional Control Valve DC1 - Test..................................390
			Analyzing Test Results................................................391
			Motors B2, B3, B4 - Test..............................................391
			Analyzing Test Results................................................394
			Pump Worksheet........................................................396
			Motor Worksheet (Flat Conveyor).......................................397
			Motor Worksheet (Curved Conveyor).....................................398
			Curved Conveyor Motor Connections.....................................399
Chapter 9: Cross Conveyor Subsystem...............................................401
	Introduction..................................................................401
		Components................................................................401
	Hydraulic Repair..............................................................401
		Pump PMP1.................................................................402
			Remove................................................................402
			Install...............................................................402
		Pump Seals................................................................403
			Replace...............................................................403
		Directional Control Valve DC1.............................................403
			Remove................................................................403
			Install...............................................................403
		Directional Control Valve Seals...........................................404
			Replace...............................................................404
		Neutral Safety Switch.....................................................404
			Replace...............................................................404
		Relief Valve PRL1.........................................................405
			Remove................................................................405
			Install...............................................................405
		Relief Valve Seals........................................................406
			Replace...............................................................406
		Relief Valve - Adjust.....................................................406
		Flat Conveyor Drive Motor B4..............................................407
			Remove................................................................407
			Install...............................................................407
		Curved Conveyor Drive Motors B2 & B3......................................408
			Remove................................................................408
			Install...............................................................408
	Mechanical Repair.............................................................409
		Complete Conveyor Assembly................................................409
			Remove................................................................409
			Install...............................................................409
		Conveyor Belt.............................................................410
			Remove................................................................410
			Install...............................................................410
			Belt - Adjust.........................................................410
		Conveyor Belt Flashing....................................................411
			Remove................................................................411
			Install...............................................................411
		Curved Conveyor Paddle Wheel Drive Bearings...............................412
			Remove................................................................412
			Install...............................................................413
		Flat Conveyor Paddle Wheel Drive Bearings.................................413
			Remove................................................................413
			Install...............................................................414
		Flat Conveyor Idler Wheel Bearings........................................414
			Remove................................................................414
			Install...............................................................415
		Conveyor Shift Gearbox and Bearing........................................415
			Remove................................................................415
			Install...............................................................416
Chapter 10: Auxiliary Subsystem...................................................419
	Overview......................................................................419
		MAP.......................................................................419
		Circuits/Components.......................................................420
		Hydraulic Hose Connections................................................421
		Implement Subsystem Pressure-Flow Standby.................................422
	Coulter Wheel Circuit.........................................................422
		Operation.................................................................422
			Cylinder - Extend (Lower).............................................422
			Cylinder - Retract (Raise)............................................422
	Crane Swing Circuit...........................................................423
		Operation.................................................................423
			Cylinder - Extend (Swing Crane Right).................................423
			Cylinder - Retract (Swing Crane Left).................................423
	Crane Lift Circuit............................................................424
		Operation.................................................................424
			Cylinder - Extend (Lower).............................................424
			Cylinder - Retract (Raise)............................................424
Chapter 10: Auxiliary Subsystem...................................................425
	Overview......................................................................425
		Pretest Inspection........................................................425
		Fault Chart...............................................................425
		Test Equipment Needed.....................................................426
		Component Repair/Replace..................................................426
	Fault Chart...................................................................427
	Shared Component Troubleshooting..............................................428
	Coulter Wheel Circuit.........................................................429
		Electrical Troubleshooting................................................429
			Testing Sequence......................................................429
			Control Valve Reference...............................................429
			Component Pin/ Terminal Reference.....................................430
			Open Circuit Test.....................................................431
			High Resistance Test..................................................431
			Short Circuit Test....................................................431
		Hydraulic Troubleshooting.................................................432
			Cylinder Test Procedure...............................................432
			Analyzing Cylinder Test Results.......................................434
	Crane Swing Circuit...........................................................435
		Electrical Troubleshooting................................................435
			Testing Sequence......................................................435
		Hydraulic Troubleshooting.................................................436
	Crane Lift Circuit............................................................437
		Electrical Troubleshooting................................................437
			Testing Sequence......................................................437
	Cylinder Worksheet............................................................439
Chapter 10: Auxiliary Subsystem...................................................441
	Introduction..................................................................441
		Components................................................................441
	Hydraulic Repair..............................................................441
		Control Valve Assembly A10................................................441
			Remove................................................................442
			Section Seals - Replace...............................................443
			Install...............................................................443
		Solenoid and Check Valve Cartridges.......................................443
			Seals - Replace.......................................................443
			Solenoid Coil - Replace...............................................444
		Cylinders.................................................................444
		Cylinder Lock Valve.......................................................444
			Remove................................................................445
			Install...............................................................445
			Seals - Replace.......................................................445
Chapter 11: Load/Return Conveyor Subsystem........................................449
	Overview......................................................................449
		Circuits/Components.......................................................450
		Component Locations.......................................................451
		Hydraulic Hose Connections................................................452
	Conveyor Rotation Circuit.....................................................453
		Operation.................................................................453
			Spoil Discharge.......................................................454
Chapter 11: Load/Return Conveyor Subsystem........................................455
	Overview......................................................................455
		Pretest Inspection........................................................455
		Fault Chart...............................................................455
		Test Equipment Needed.....................................................456
		Component Repair/Replace..................................................456
	Fault Chart...................................................................457
	Conveyor Rotation Circuit.....................................................458
		Hydraulic Troubleshooting.................................................458
			System Pressure - Check...............................................458
		Hydraulic Circuit Test Procedures.........................................459
			Pump PMP6 - Test......................................................459
			Analyzing Test Results................................................461
			Directional Control Valve DC2 - Test..................................462
			Analyzing Test Results................................................463
			Motors B8 & B9 - Test.................................................463
			Analyzing Test Results................................................466
			Pump Worksheet........................................................468
			Motor Worksheet.......................................................469
Chapter 11: Load/Return Conveyor Subsystem........................................471
	Summary.......................................................................471
Chapter 12: Cab Subsystem.........................................................475
	Overview......................................................................475
		Circuits/Components.......................................................475
		Component Locations.......................................................476
		Hose Connections..........................................................478
	Air Conditioning/Heater Circuits..............................................479
		Operation.................................................................479
			Control Circuits......................................................479
			Air Conditioning Circuit..............................................479
			Heater Circuit........................................................480
	Windshield Wipers and Accessory Circuits......................................481
		Operation.................................................................481
			Control Circuits......................................................481
	Horn Circuit..................................................................482
		Operation.................................................................482
Chapter 12: Cab Subsystem.........................................................483
	Overview......................................................................483
		Pretest Inspection........................................................483
		Test Equipment Needed.....................................................483
		Component Repair/Replace..................................................484
	Air Conditioning/Heater Circuits..............................................484
		Possible Malfunctions.....................................................484
		Cab Control Circuits Troubleshooting......................................485
			Open Circuit Test.....................................................485
			High Resistance Test..................................................485
			Short Circuit Test....................................................486
		Air Conditioner Circuit Troubleshooting...................................486
			Abnormal Cycle........................................................487
			Normal Cycle..........................................................488
		Heater Circuit Troubleshooting............................................488
	Horn Circuit..................................................................490
Chapter 12: Cab Subsystem.........................................................491
	Summary.......................................................................491

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