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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