Description
Table of contents
FOREWORD
TECHNICAL INFORMATION FEEDBACK FORM
Section 9000 – GENERAL INFORMATION
Group 01 – Safety
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Work In Ventilated Area
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Clean Debris from Machine
Add Cab Guarding for Special Uses
Use Steps and Handholds Correctly
Start Only From Operator′s Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Inspect and Maintain ROPS
Add and Operate Attachments Safely
Park and Prepare for Service Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Section 9005 – OPERATIONAL CHECKOUT PROCEDURE
Group 10 – Operational Checkout Procedure
Ignition ON, Engine ON Checks
Horn Circuit Check
Travel Lever and Pedal Neutral Check
Monitor Indicators and Gauge Circuit Check
Lights Circuit Check
Wiper Circuit Check—Cab Only
Washer Circuit Check—Cab Only
Engine Preheat Circuit Check
Monitor Indicators and Gauge Circuit Check
Heater and Air Conditioning Circuit Check—If Equipped
Pilot Control Shutoff Switch Check
Travel Alarm Circuit Check
Hydraulic Oil Tank Pressurization Check
Pilot Controller Pattern Check—SAE Backhoe Pattern
Pilot Controller Pattern Check—ISO Excavator Pattern
Swing Dynamic Braking Check
Dig Function Drift Check
Control Valve Lift Check Test
Travel System Tracking Check
Travel System Tracking Checks While Operating a Dig Function
Travel Speed Change Check
Blade Function Check
Cycle Times Check
Horn Circuit Check
Travel Lever and Pedal Neutral Check
Monitor Indicators and Gauge Circuit Check
Lights Circuit Check
Wiper Circuit Check—Cab Only
Washer Circuit Check—Cab Only
Engine Preheat Circuit Check
Monitor Indicators and Gauge Circuit Check
Heater and Air Conditioning Circuit Check—If Equipped
Pilot Control Shutoff Switch Check
Travel Alarm Circuit Check
Hydraulic Oil Tank Pressurization Check
Pilot Controller Pattern Check—SAE Backhoe Pattern
Pilot Controller Pattern Check—ISO Excavator Pattern
Swing Dynamic Braking Check
Dig Function Drift Check
Control Valve Lift Check Test
Travel System Tracking Check
Travel System Tracking Checks While Operating a Dig Function
Travel Speed Change Check
Blade Function Check
Cycle Times Check
Section 9010 – ENGINE
Group 05 – Theory of Operation
Engine Component Location
Engine Cooling System Operation
Engine Lubrication System Operation
Engine Fuel System Operation
Group 15 – Diagnostic Information
Yanmar 3-Cylinder Engine Troubleshooting Manual
Engine Cranks But Will Not Start Diagnostic Procedure
Preliminary Check
Starting System Check
Fuel System Test
Fuel Injector Check
Mechanical Engine Check
Fuel Injection Pump Timing Check
Preliminary Check
Starting System Check
Fuel System Test
Fuel Injector Check
Mechanical Engine Check
Fuel Injection Pump Timing Check
Engine Misfires Or Runs Irregularly Diagnostic Procedure
Possible causes
Recreate Conditions
Fuel System Check
Fuel Injection Nozzle Check
Engine Compression Pressure Test
Engine Valve Lash (Clearance) Check and Adjust
Fuel Injection Pump Timing Check
Possible causes
Recreate Conditions
Fuel System Check
Fuel Injection Nozzle Check
Engine Compression Pressure Test
Engine Valve Lash (Clearance) Check and Adjust
Fuel Injection Pump Timing Check
Engine Does Not Develop Full Power Diagnostic Procedure
Preliminary Check
Engine Coolant Temperature Check
Air Intake Check
Exhaust Emission Check
Fuel System Test
Exhaust System Check
Fuel Injection Nozzle Check
Mechanical Engine Check
Fuel Injection Pump Timing Check
Preliminary Check
Engine Coolant Temperature Check
Air Intake Check
Exhaust Emission Check
Fuel System Test
Exhaust System Check
Fuel Injection Nozzle Check
Mechanical Engine Check
Fuel Injection Pump Timing Check
Engine Overheats Diagnostics Procedure
Preliminary Checks
Air Filter Check
Air Intake Check
Electrical Check
Cooling Fan System Check
Preliminary Checks
Air Filter Check
Air Intake Check
Electrical Check
Cooling Fan System Check
Coolant Temperature Too Low Diagnostics Procedure
Coolant Temperature Check
Thermostat Check
Coolant Temperature Check
Thermostat Check
Coolant in Oil or Oil in Coolant Diagnostics Procedure
Head Gasket Check
Cracked Cylinder Head or Block
Head Gasket Check
Cracked Cylinder Head or Block
Low Engine Oil Pressure Diagnostics Procedure
Preliminary Checks
Oil Pressure Switch/Sensor Check
Oil Pressure Regulating Valve Check
Oil Supply System Check
Preliminary Checks
Oil Pressure Switch/Sensor Check
Oil Pressure Regulating Valve Check
Oil Supply System Check
High Engine Oil Pressure Diagnostics Procedure
Preliminary Checks
Oil Pressure Switch or Sensor Check
Oil Pressure Regulating Valve Check
Mechanical Engine Check
Preliminary Checks
Oil Pressure Switch or Sensor Check
Oil Pressure Regulating Valve Check
Mechanical Engine Check
Engine Uses Too Much Oil Diagnostics
Oil Check
Coolant Check
Air System Check
Compression Check
Mechanical Engine Check
Oil Check
Coolant Check
Air System Check
Compression Check
Mechanical Engine Check
Engine Uses Too Much Fuel Diagnostic Procedure
Fuel System Test
Air Filter Check
Air Intake Check
Fuel Injector Check
Compression Check
Engine Valve Lash (Clearance) Check and Adjust
Injection Pump Timing
Fuel System Test
Air Filter Check
Air Intake Check
Fuel Injector Check
Compression Check
Engine Valve Lash (Clearance) Check and Adjust
Injection Pump Timing
Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure
Preliminary Procedure
Fuel Injector Check
Compression Check
Engine Valve Lash (Clearance) Check and Adjust
Injection Pump Timing
Preliminary Procedure
Fuel Injector Check
Compression Check
Engine Valve Lash (Clearance) Check and Adjust
Injection Pump Timing
Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure
Preliminary Check
Air Intake Check
Fuel System Test
Exhaust System Check
Fuel Injector Check
Mechanical Engine Check
Fuel Injection Pump Timing Check
Preliminary Check
Air Intake Check
Fuel System Test
Exhaust System Check
Fuel Injector Check
Mechanical Engine Check
Fuel Injection Pump Timing Check
Fuel In Oil Diagnostics Procedure
Seal Check
Seal Check
Group 25 – Tests
JT05801 Clamp-On Electronic Tachometer Installation
Engine Speed Check
Engine Speed Control Lever and Cable Adjustment
Fuel Injection Nozzle Check
Fuel Transfer Pump PressureTest
Injection Pump Timing Check and Adjustment
Fan Belt Tension Adjustment
Engine Valve Lash (Clearance) Check and Adjustment
Air Intake System Leakage Test
Cooling System Pressure Test
Radiator Cap Test
Engine Thermostat Test
Engine Compression Pressure Test
Engine Oil Pressure Test
Head Gasket Failure Check
Bleed Fuel System
Section 9015 – ELECTRICAL SYSTEM
Group 05 – System Information
Electrical Diagram Information
Component Identification Table
Fuse (Blade-Type) Color Codes
Group 10 – System Diagrams
Fuse Specifications
System Functional Schematic, Wiring Diagrams, and Component Locations Master Legend
System Functional Schematic
Battery and Power Cable (W6 and W7) Component Location
Main Harness (W8) Component Location
Main Harness (W8) Wiring Diagram
Platform Harness (W9) Component Location
Platform Harness (W9) Wiring Diagram
Engine Harness (W10) Component Location
Engine Harness (W10) Wiring Diagram
Heating and A/C Control Harness (W11) Component Location
Heating and A/C Control Harness (W11) Wiring Diagram
A/C Compressor Harness (W12) Component Location
A/C Compressor Harness (W12) Wiring Diagram
Cab Harness (W13) Component Location
Cab Harness (W13) Wiring Diagram
Boom Work Light Harness (W14) Component Location
Boom Work Light Harness (W14) Wiring Diagram
ROPS Work Light Harness (W15) Component Location
ROPS Work Light Harness (W15) Wiring Diagram
Auxiliary Function Control Harness (W19) Component Location
Auxiliary Function Control Harness (W19) Wiring Diagram
Group 15 – Sub-System Diagnostics
Start Circuit Theory of Operation
Charge Circuit Theory of Operation
Fuel Shutoff Circuit Theory of Operation
Monitor Controller Circuit Theory of Operation
Pilot Control Shutoff Circuit Theory of Operation
Travel Speed Control and Alarm Circuit Theory of Operation
Heating and Air Conditioning Control Circuit Theory of Operation
Preheating Circuit Theory of Operation
Auxiliary Function Control Lever Circuit Theory of Operation
Group 20 – References
Alternator and Starting Motors
Electrical Component Specifications
Alternator Test
Relay Test
Pressure Sensor Test
Solenoid Test
Fuel Shutoff Circuit Test
Fuse Check
Fuel Shutoff Pull-In Coil Relay (K3) Check
Fuel Shutoff Pull-In Coil Timer Check
Fuel Shutoff Solenoid Circuit Check
Fuse Check
Fuel Shutoff Pull-In Coil Relay (K3) Check
Fuel Shutoff Pull-In Coil Timer Check
Fuel Shutoff Solenoid Circuit Check
Component Checks
Key Switch Check
Battery Voltage Check
Main Fuse Check
Diode Check
Travel Alarm (H2) Check
Monitor Buzzer (H1) Check
Key Switch Check
Battery Voltage Check
Main Fuse Check
Diode Check
Travel Alarm (H2) Check
Monitor Buzzer (H1) Check
Monitor Controller Remove and Install
Disconnect Tab Retainer Connectors
Disconnecting Spring Wire Clip Connectors
Replace Metri-Pack® (Push Type) Connectors
Replace Metri-Pack® Connectors
Replace DEUTSCH® Circular Connectors
Replace DEUTSCH® Rectangular or Triangular Connectors
Install DEUTSCH® Contact
Replace WEATHER PACK® Connector
Install WEATHER PACK® Contact
Replace CINCH™ Connectors
Install CINCH™ Contact
Repair 32 and 48 Way CINCH™ Connectors
Remove Connector Body from Blade Terminals
Section 9020 – POWER TRAIN
Group 05 – Theory of Operation
Track Adjuster and Recoil Spring Operation
Travel Gearbox Operation
Group 15 – Diagnostic Information
Diagnose Undercarriage Components Malfunctions
Measure Swing Bearing Wear
Section 9025 – HYDRAULIC SYSTEM
Group 05 – Theory of Operation
Hydraulic System Diagram
Pilot System Diagram
Pilot Pump Operation
Pilot Filter Operation
Solenoid Valve Manifold Operation
Pilot Control Valve Operation
Travel Pilot Control Valve Operation
Blade, Swing Boom, and Auxiliary Pilot Control Valve Operation
Hydraulic Pump 1 and 2 Operation
Hydraulic Pump Regulator Operation
Hydraulic Pump 3 and Pilot Pump Operation
A/C Torque Control Solenoid Valve Operation
Control Valve Operation
System Relief Valve Operation
Circuit Relief Valve Operation
Swing Boom Make-Up Check Valve Operation
Flow Combiner Valve Operation
Auxiliary Flow Combiner Valve Operation
Auxiliary Flow Selector Solenoid Valve Operation (Optional)
Auxiliary Function Control Valve Operation
Arm Regenerative Valve Operation
Swing Gearbox Operation
Swing Motor Operation
Swing Motor Crossover Relief Valve Operation
Swing Motor Make-Up Check Valve Operation
Swing Motor Park Brake Release Circuit Operation
Center Joint Operation
Travel Motor and Brake Valve Housing Operation
Travel Motor Speed Circuit Operation
Blade Circuit Operation
Auxiliary Selector Valve Operation—If Equipped
Hydraulic Cylinder Operation
Hydraulic Oil Return Filter Operation
Hydraulic System Circuit Symbols
Hydraulic System Schematics
Group 15 – Diagnostic Information
Diagnostic Procedure
Diagnose Hydraulic System Malfunctions
Diagnose Pilot Circuit Malfunctions
Diagnose Dig Circuit Malfunctions
Diagnose Swing Circuit Malfunctions
Diagnose Travel System Malfunctions
Major Component Location
Main Hydraulic Pilot System Line Identification
Main Hydraulic Working System Line Identification
Blade Hydraulic System Line Identification
Travel Hydraulic System Line Identification
Pilot Control Valve to Pattern Selector Valve Line Connection
Group 25 – Tests
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
JT05800 Digital Thermometer Installation
JT02156A Digital Pressure/Temperature Analyzer Installation
Hydraulic System Warm-Up Procedure
Cylinder Drift Test—Boom, Arm, Bucket, and Blade
Pilot Pressure Regulating Valve Test and Adjustment
Control Valve Spool Pilot Actuating Pressure Test
Hydraulic Pumps 1, 2, and 3 System Relief Valve Test and Adjustment
Circuit Relief Valve Test and Adjustment
Swing Motor Crossover Relief Valve Test and Adjustment
Hydraulic Pumps 1 and 2 Regulator Test and Adjustment—Engine Pulldown
Hydraulic Pump 1 and 2 Flow Test
Hydraulic Pump 3 Flow Test
Swing Motor Leakage Test
Travel Motor Leakage Test
Section 9031 – HEATING AND AIR CONDITIONING
Group 05 – Theory of Operation
Air Conditioning System Cycle Of Operation
Group 15 – Diagnostic Information
Diagnose Air Conditioning System Malfunctions
Diagnose Heater System Malfunctions
Air Conditioner and Heater Component Location
Group 25 – Tests
Refrigerant Cautions and Proper Handling
Visual Inspection Of Components
Lines and Hoses Check
Air Conditioner Compressor Check
Condenser Check
Cooling Fan Check
Heater Core and Evaporator Check
Cab Air Filter Check
Cab Door and Windows Check
Lines and Hoses Check
Air Conditioner Compressor Check
Condenser Check
Cooling Fan Check
Heater Core and Evaporator Check
Cab Air Filter Check
Cab Door and Windows Check
Refrigerant Leak Test
Air Conditioner Compressor Clutch Test
R134a Air Conditioning System Test
Operating Pressure Diagnostic Chart
