John Deere 27C ZTS & 35C ZTS Excavator Operation & Tests Technical Manual (TM2052) (1)

27C ZTS and 35C ZTS Excavator Operation and Tests

TECHNICAL MANUAL 27C ZTS and 35C ZTS Excavator Operation and Tests TM2052 17JUL18

(ENGLISH)

Worldwide Construction And Forestry Division PRINTED IN U.S.A.

Introduction Foreword This manual is written for an experienced technician.

Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

DX,TMIFC -19-15APR14-1/1

TM2052 (17JUL18)

27C ZTS and 35C ZTS Operation & Tests 071718 PN=2

Introduction

Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.

SEND TO:

John Deere Dubuque Works 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 USA

FAX NUMBER: 1-563-589-5800 (USA) Publication Number: Page Number: Ideas, Comments:

Name: Phone: Email Address: THANK YOU! TX,TM,FAX -19-03JUL01-1/1

TM2052 (17JUL18)

27C ZTS and 35C ZTS Operation & Tests 071718 PN=3

Introduction

TM2052 (17JUL18)

27C ZTS and 35C ZTS Operation & Tests 071718 PN=4

Contents Section 9000—General Information Group 01—Safety

Section 9005—Operational Checkout Procedure Group 10—Operational Checkout Procedure

Section 9010—Engine Group 05—Theory of Operation Group 15—Diagnostic Information Group 25—Tests

Section 9015—Electrical System Group Group Group Group

05—System Information 10—System Diagrams 15—Sub-System Diagnostics 20—References

Section 9020—Power Train Group 05—Theory of Operation Group 15—Diagnostic Information

Section 9025—Hydraulic System Group 05—Theory of Operation Group 15—Diagnostic Information Group 25—Tests

Section 9031—Heater Group 05—Theory of Operation Group 15—Diagnostic Information Group 25—Tests

Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication.

The right is reserved to make changes at any time without notice.

COPYRIGHT © 2018 DEERE & COMPANY Moline, Illinois All rights reserved.

A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2002, 2006,2012, 2014

TM2052 (17JUL18)

i

27C ZTS and 35C ZTS Operation & Tests 071718 PN=1

Contents

TM2052 (17JUL18)

ii

27C ZTS and 35C ZTS Operation & Tests 071718 PN=2

Contents

Section 9000 General Information

Page

Group 01—Safety Recognize Safety Information ................... 9000-01-1 Follow Safety Instructions.......................... 9000-01-1 Operate Only If Qualified ........................... 9000-01-1 Wear Protective Equipment....................... 9000-01-2 Avoid Unauthorized Machine Modifications.......................................... 9000-01-2 Add Cab Guarding for Special Uses ...................................................... 9000-01-2 Inspect Machine ........................................ 9000-01-2 Stay Clear of Moving Parts........................ 9000-01-3 Avoid High-Pressure Oils .......................... 9000-01-3 Beware of Exhaust Fumes ........................ 9000-01-3 Prevent Fires ............................................. 9000-01-4 Prevent Battery Explosions ....................... 9000-01-4 Handle Chemical Products Safely.............. 9000-01-4 Dispose of Waste Properly ........................ 9000-01-5 Prepare for Emergencies........................... 9000-01-5 Use Steps and Handholds Correctly ................................................ 9000-01-5 Start Only From Operator's Seat ............... 9000-01-5 Use and Maintain Seat Belt ....................... 9000-01-6 Prevent Unintended Machine Movement.............................................. 9000-01-6 Avoid Work Site Hazards........................... 9000-01-6 Keep Riders Off Machine .......................... 9000-01-7 Avoid Backover Accidents ......................... 9000-01-7 Avoid Machine Tip Over ............................ 9000-01-8 Use Special Care When Lifting Objects .................................................. 9000-01-8 Add and Operate Attachments Safely..................................................... 9000-01-8 Park and Prepare for Service Safely..................................................... 9000-01-9 Service Cooling System Safely ................. 9000-01-9 Remove Paint Before Welding Or Heating .................................................. 9000-01-9 Make Welding Repairs Safely ................. 9000-01-10 Drive Metal Pins Safely ........................... 9000-01-10

TM2052 (17JUL18)

9000-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=1

Contents

TM2052 (17JUL18)

9000-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=2

Group 01

Safety Recognize Safety Information T133555 —UN—15APR13

This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for the potential of personal injury.

Follow the precautions and safe operating practices highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

T133588 —19—28AUG00

On the machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

TX03679,00016CC -19-03JAN07-1/1

Follow Safety Instructions T133556 —UN—24AUG00

Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully.

Review them frequently.

Be sure all operators of this machine understand every safety message. Replace operator's manual and safety labels immediately if missing or damaged.

TX03679,00016F9 -19-03JAN07-1/1

Operate Only If Qualified Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified by supervised training and instruction.

Operator should be familiar with the job site and surroundings before operating. Try all controls and

machine functions with the machine in an open area before starting to work.

Know and observe all safety rules that may apply to every work situation and work site.

TX03679,00016FA -19-03JAN07-1/1

TM2052 (17JUL18)

9000-01-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=9

Safety

Wear Protective Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

TS206 —UN—15APR13

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

TX03679,00016D0 -19-03JAN07-1/1

Avoid Unauthorized Machine Modifications Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine.

Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

TX03679,00016B7 -19-30OCT00-1/1

Special work situations or machine attachments may create an environment with falling or flying objects.

Working near an overhead bank, doing demolition work, using a hydraulic hammer, or working in a wooded area, for example, may require added guarding to protect the operator.

FOPS (falling object protective structures) and special screens or guarding should be installed when falling or flying objects may enter or damage the machine. Contact your authorized dealer for information on devices intended to provide protection in special work situations.

T133733 —UN—15SEP00

Add Cab Guarding for Special Uses

TX03679,00016CE -19-03JAN07-1/1

Inspect Machine

Inspect and Clean the Polycarbonate Windows. See Inspect and Clean Polycarbonate Windows. (Section 4-1.)

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

T6607AQ —UN—15APR13

Inspect machine carefully each day by walking around it before starting.

TX03679,0001734 -19-17DEC14-1/1

TM2052 (17JUL18)

9000-01-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=10

Safety

Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining any part of machine with moving parts.

Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

T133592 —UN—15APR13

Stay Clear of Moving Parts

TX03679,00016D2 -19-03JAN07-1/1

Avoid High-Pressure Oils

Never search for leaks with your hands. Protect hands.

Use a piece of cardboard to find location of escaping oil.

Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

T133840 —UN—20SEP00

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

T133509 —UN—15APR13

This machine uses a high-pressure hydraulic system.

Escaping oil under pressure can penetrate the skin causing serious injury.

TX03679,00016D3 -19-03NOV08-1/1

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.

T133546 —UN—24AUG00

Beware of Exhaust Fumes

TX03679,00016D4 -19-03NOV08-1/1

TM2052 (17JUL18)

9000-01-3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=11

Safety

T133552 —UN—15APR13

Prevent Fires Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.

Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

T133553 —UN—07SEP00

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage.

Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine.

Know how to use extinguisher properly.

T133554 —UN—07SEP00

TX03679,00016F5 -19-03NOV08-1/1

Prevent Battery Explosions Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

TS204 —UN—15APR13

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

TX03679,000174A -19-03NOV08-1/1

Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous.

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS). The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely.

T133580 —UN—25AUG00

Handle Chemical Products Safely

TX03679,00016D7 -19-31JAN07-1/1

TM2052 (17JUL18)

9000-01-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=12

Safety

Improper disposal of waste can threaten the environment.

Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified service center to recover and recycle used refrigerants.

T133567 —UN—25AUG00

Dispose of Waste Properly

If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for more information.

TX03679,0001733 -19-03JAN07-1/1

Prepare for Emergencies Be prepared if an emergency occurs or a fire starts.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

TS291 —UN—15APR13

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B -19-03JAN07-1/1

Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails.

Never use machine controls as handholds.

Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.

T133468 —UN—15APR13

Use Steps and Handholds Correctly

TX03679,00016F2 -19-24APR13-1/1

Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure all controls and working tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

T133715 —UN—15APR13

Start Only From Operator's Seat

TX03679,0001799 -19-22APR10-1/1

TM2052 (17JUL18)

9000-01-5

27C ZTS and 35C ZTS Operation & Tests 071718 PN=13

Safety

Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses.

Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.

T133716 —19—17APR13

Use and Maintain Seat Belt

The complete seat belt assembly should be replaced every 3 years, regardless of appearance.

TX03679,00016DD -19-03NOV08-1/1

Be careful not to accidentally actuate control levers when co-workers are present. Pull pilot control shutoff lever to locked position during work interruptions. Pull pilot control shutoff lever to locked position and stop engine before allowing anyone to approach machine.

Always lower work equipment to the ground and pull pilot control shutoff lever to locked position before standing up or leaving the operator's seat. Stop engine before exiting.

T133863 —UN—20SEP00

Prevent Unintended Machine Movement

TX03679,0001746 -19-24JAN07-1/1

Avoid boom or arm contact with overhead obstacles or overhead electrical lines. Never move any part of machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient to support machine. When working close to an excavation, position travel motors away from the hole.

Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seat belt.

T153096 —UN—01APR02

Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over.

T153097 —UN—01APR02

Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before you dig.

T153094 —UN—01APR02

Avoid Work Site Hazards

TX14740,0001E9F -19-30JUN10-1/1

TM2052 (17JUL18)

9000-01-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=14

Safety

Keep Riders Off Machine Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.

Riders may obstruct operator’s view or impair his ability to operate machine safely.

T120807 —UN—14APR99

Only allow operator on machine.

TX14740,0001E7A -19-19MAR02-1/1

Before moving machine, be sure all persons are clear of both travel and swing paths. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair.

Be certain travel alarm is working properly.

Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.

T120806 —UN—14APR99

Avoid Backover Accidents

TX14740,0001E7B -19-19MAR02-1/1

TM2052 (17JUL18)

9000-01-7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=15

Safety

Avoid Machine Tip Over T133716 —19—17APR13

Use seat belt at all times.

Do not jump if the machine tips. Operator will be unlikely to jump clear and the machine may crush the operator.

Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface.

Use loading ramps and attach them properly to truck bed.

Avoid trucks with steel beds because tracks slip more easily on steel.

Use Seat Belt

T133545 —UN—15SEP00

Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these conditions. When traveling up or down slopes, keep the bucket on uphill side and just above ground level.

Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy load or swinging it over side of undercarriage may cause machine to tip.

Unloading Machine

T133803 —UN—27SEP00

Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or fall.

Do Not Jump TX03679,00016DF -19-30JUN16-1/1

Use Special Care When Lifting Objects T133839 —UN—27SEP00

Never use this machine to lift people.

Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free.

Do not leave the seat when there is a raised load.

Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or swinging over undercarriage side may cause machine to tip over.

Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good

Use Special Care When Lifting Objects

condition. Use tether lines to guide loads and prearranged hand signals to communicate with co-workers.

TX03679,00016E1 -19-08JUL15-1/1

Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability and may create a hazard for others near the machine.

Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection

is required or recommended. Verify that all connections are secure and attachment responds properly to controls.

Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.

TX03679,00016F0 -19-12FEB07-1/1

TM2052 (17JUL18)

9000-01-8

27C ZTS and 35C ZTS Operation & Tests 071718 PN=16

Safety

Park and Prepare for Service Safely Warn others of service work. Always park and prepare your machine for service or repair properly. and attachments to the ground.

• Place pilot shutoff lever in “lock” position. Stop engine and remove key.

• Attach a “Do Not Operate” tag in an obvious place in the operator's station.

Securely support machine or attachment before working under it.

T133332 —19—17APR13

• Park machine on a level surface and lower equipment

• Do not support machine with boom, arm, or other hydraulically actuated attachments.

• Do not support machine with cinder blocks or wooden pieces that may crumble or crush.

• Do not support machine with a single jack or other Understand service procedures before beginning repairs.

Keep service area clean and dry. Use two people whenever the engine must be running for service work.

TS229 —UN—23AUG88

devices that may slip out of place.

TX03679,00016E9 -19-03JAN07-1/1

Service Cooling System Safely

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

TS281 —UN—15APR13

Explosive release of fluids from pressurized cooling system can cause serious burns.

DX,RCAP -19-04JUN90-1/1

Hazardous fumes can be generated when paint is heated by welding or using a torch. Dust from sanding or grinding paint can also be hazardous.

Remove paint to at least 76 mm (3 in.) from area to be heated. Wear an approved respirator when sanding or grinding paint. If a solvent or paint stripper is used, wash area with soap and water. Remove solvent or paint stripper containers from work area and allow fumes to disperse at least 15 minutes before welding or heating.

T133546 —UN—24AUG00

Remove Paint Before Welding Or Heating

Work outside or in a well-ventilated area. Dispose of waste, paint and solvents properly.

TX03679,0001732 -19-06SEP00-1/1

TM2052 (17JUL18)

9000-01-9

27C ZTS and 35C ZTS Operation & Tests 071718 PN=17

Safety

Make Welding Repairs Safely

Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.

Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.

T133547 —UN—15APR13

IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable.

Separate harness connectors to engine and vehicle microprocessors.

Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

TX03679,00016D5 -19-25APR08-1/1

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.

Use a soft hammer or a brass bar between hammer and object to prevent chipping.

T133738 —UN—15APR13

Drive Metal Pins Safely

TX03679,0001745 -19-03JAN07-1/1

TM2052 (17JUL18)

9000-01-10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=18

Contents

Section 9005 Operational Checkout Procedure

Page

Group 10—Operational Checkout Procedure Operational Checkout................................9005-10-1 Operator Station Checks—Key Switch On, Engine Off ......................................9005-10-1 Operational Checks—Engine On .........................................................9005-10-6

TM2052 (17JUL18)

9005-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=1

Contents

TM2052 (17JUL18)

9005-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=2

Group 10

Operational Checkout Procedure Operational Checkout Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of machine operation while doing a walk around inspection and performing specific checks from the operator's seat.

Should you experience a problem with your machine, you will find helpful diagnostic information in this checkout that will pinpoint the cause. This information may allow you to perform a simple adjustment which will reduce the down time of the machine. Use the table of contents to help find adjustment procedures.

The information you provide after completing the operational checkout will allow you to pinpoint a specific test or repair needed to restore the machine to design specifications.

A location will be required which is level and has adequate space to complete the checks. No tools or equipment are needed to perform the checkout.

Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) prior to doing the checkout. The machine must be at operating temperature for many of the checks.

Start at the top of the left column and read completely down column before performing check. Follow this sequence from left to right. In the far right column, if no problem is found, you will be instructed to go to next check. If a problem is indicated, you will be referred to a section in this manual for the repair.

CED,OUOE003,1506 -19-10DEC12-1/30

Operator Station Checks—Key Switch On, Engine Off CED,OUOE003,1506 -19-10DEC12-2/30

Monitor and Gauge Circuit Check

T120708 —UN—10MAY99

1— Glow Plug Indicator 2— Engine Oil Pressure Indicator 3— Alternator Voltage Indicator 4— Fuel Gauge and Fuel Level Indicator 5— Engine Coolant Temperature Gauge 6— Hour Meter 7— Light Switch Indicator 8— Light Switch NOTE: Monitor buzzer is not checked during this procedure.

If engine coolant temperature is below 30°C (86°F), engine temperature gauge segment may not come on. Run engine a few minutes to warm coolant before check.

Engine OFF. Key switch ON. Do engine coolant temperature gauge (5) and fuel gauge (4) segments come on?

YES: Go to next check.

Do all monitor lights come on and after 2—3 seconds only the alternator indicator and engine oil pressure indicator light remain on?

NO: Go to Fuse Test to check F10 Monitor Controller And Display 5 Amp fuse. (Group 9015-20.)

Check and replace bulb if any bulb fails to come on.

Continued on next page

TM2052 (17JUL18)

9005-10-1

CED,OUOE003,1506 -19-10DEC12-3/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=21

Operational Checkout Procedure Glow Plug Circuit Check

T102341 —UN—29AUG96

Turn key switch to ON position.

Does the glow plug indicator light come ON and then go OFF? Does a relay “click” when the indicator light goes OUT?

YES: Go to next check.

NOTE: Glow plug indicator light will stay on longer when engine is cold. Glow plug activation time will shorten as engine starting temperature is increased.

NO: Go to Fuse Test to check F5 Engine Power 10 Amp fuse. (Group 9015-20). Go to Relay Test to test glow plug relay.

(Group 9015-20.)

CED,OUOE003,1506 -19-10DEC12-4/30

Propel Lever and Pedal Neutral Check

T121794 —UN—16JUN99

Engine OFF. Push each propel lever forward, then release.

Push each propel lever rearward, then release.

Does each lever have equal effort to operate forward and reverse?

YES: Go to next check.

Does each lever return to neutral at the same time when released?

NO: Repair or replace pilot controller. Go to Propel Pilot Controller Repair. (Group 3360.)

Continued on next page

TM2052 (17JUL18)

9005-10-2

CED,OUOE003,1506 -19-10DEC12-5/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=22

Operational Checkout Procedure Light Circuit Check

T121802 —UN—16JUN99

T121803 —UN—16JUN99

1— Work Light Switch 2— Work Light Indicator 3— Drive Light 4— Boom Work Light NOTE: All accessories are powered from the fuse block. If any accessories do not function, check fuses in fuse block.

Turn key switch ON. Push work light switch (1) to turn on work lights.

Is indicator light (2) on?

Are the work lights (3 and 4) on the boom and left front corner of upperstructure ON? Push work light switch to turn off the work lights.

YES: Go to next check.

Do all the lights go OFF?

NO: Go to Fuse Test to check F2 Drive And Boom Work Light 20 Amp fuse. (Group 9015-20.)

Go to System Functional Schematic to check wiring.

(Group 9015-10.) Go to Main Harness (W1) Wiring Diagram to check wiring harness. (Group 9015-10.)

Continued on next page

TM2052 (17JUL18)

9005-10-3

CED,OUOE003,1506 -19-10DEC12-6/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=23

Operational Checkout Procedure Windshield Wiper Circuit Check—Cab Only

T124151 —UN—17SEP99

1— Windshield Wiper And Windshield Washer Switch Key switch ON. Push windshield wiper switch (1) to turn on the windshield wiper.

Does windshield wiper operate continuously?

Push windshield wiper switch to turn off windshield wiper.

YES: Go to next check.

Does wiper arm stop in park position at left side of windshield?

NO: Go to Fuse Test to check F6 Heater and Wiper 15 Amp fuse. (Group 9015-20.) Go to Key Switch Check to check switch. (Group 9015-20.)

Go to System Functional Schematic to check wiring (Group 9015-10.) Go to Cab Harness (W5) Wiring Diagram to check harness.

(Group 9015-10.)

Continued on next page

TM2052 (17JUL18)

9005-10-4

CED,OUOE003,1506 -19-10DEC12-7/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=24

Operational Checkout Procedure Windshield Washer Circuit Check—Cab Only

T124151 —UN—17SEP99

1— Windshield Wiper And Windshield Washer Switch Key switch ON. Push windshield wiper and windshield washer switch to activate washer motor.

Does washer motor operate?

Push windshield wiper and windshield washer switch to turn on the windshield wiper and activate the windshield washer.

YES: Go to next check

Does the washer motor and the windshield wiper operate?

NO: Go to Fuse Test to check F6 Heater and Wiper 15 Amp fuse. (Group 9015-20.)Go to Key Switch Check to check switch.

(Group 9015-20.) Go to System Functional Schematic to check wiring (Group 9015-10.) Go to Cab Harness (W5) Wiring Diagram to check harness.

(Group 9015-10.)

Continued on next page

TM2052 (17JUL18)

9005-10-5

CED,OUOE003,1506 -19-10DEC12-8/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=25

Operational Checkout Procedure Horn Circuit Check

T121809 —UN—17JUN99

1— Horn Button Key switch ON. Push horn button (1) on top of left control lever.

YES: Go to next check.

Does horn sound?

NO: Go to Fuse Test check F3 Horn 10 Amp fuse. (Group 9015-20.)

Go to System Functional Schematic to check wiring.

(Group 9015-10.)Go to Main Harness (W1) Wiring Diagram to check harness.

(Group 9015-10.) Go to Main Harness (W1) Component Location to check switch. (9015-10.)

CED,OUOE003,1506 -19-10DEC12-9/30

Operational Checks—Engine On Continued on next page

TM2052 (17JUL18)

9005-10-6

CED,OUOE003,1506 -19-10DEC12-10/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=26

Operational Checkout Procedure Monitor and Gauge Circuit Check

T120708 —UN—10MAY99

1— Glow Plug Indicator 2— Engine Oil Pressure Indicator 3— Alternator Voltage Indicator 4— Fuel Gauge and Fuel Level Indicator 5— Engine Coolant Temperature Gauge 6— Hour Meter 7— Light Switch Indicator 8— Light Switch Start engine.

Do alternator voltage (3) and engine oil pressure (2) indicators go OFF after engine starts?

Do all monitor indicators remain OFF after engine starts?

IMPORTANT: Stop the engine if alternator or engine oil pressure indicators do not go OFF or a monitor indicator comes ON after engine starts.

Are engine coolant temperature gauge (5) segments in normal operating zone after a few minutes?

YES: Go to next check.

Does fuel gauge (4) indicate fuel level?

NO: Go to Engine Oil Pressure Test if engine oil pressure indicator is on after engine starts. (Group 9010-25.)

Check fluid levels.

Go to Fusible Link Check to test fusible link F22 45 Amp fuse if alternator indicator is on after engine starts.

(Group 9015-20.) Go to Alternator Output Check to test alternator output.

(Group 9015-20.) Go to Adjust Fan Belt Tension to adjust belt tension. (Group 9010-25.)

Continued on next page

TM2052 (17JUL18)

9005-10-7

CED,OUOE003,1506 -19-10DEC12-11/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=27

Operational Checkout Procedure Heater Control Circuit Check

T155807B —UN—06JUN02

1— Heater Blower Motor Switch Engine running and at normal operating temperature.

Turn heater blower motor switch (1) to both speed positions, then back to OFF. Does fan run both positions, then stop in OFF position?

YES: Go to next check.

Does warm air flow from vents?

NO: Go to Fuse Test to check F6 Heater And Wiper 15 Amp fuse. (Group 9015-20.) Go to System Functional Schematic to check wiring. (Group 9015-10.) Go to Heater Harness (W10) to check harness. (Group 9015-10.)

Continued on next page

TM2052 (17JUL18)

9005-10-8

CED,OUOE003,1506 -19-10DEC12-12/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=28

Operational Checkout Procedure Pilot Control Shut-Off Switch Check

T122006 —UN—25JUN99

CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate all machine functions.

Run engine at slow idle.

Pilot control shut-off lever in LOCKED (rearward) position.

Actuate all dig and propel function controls.

YES: Go to Solenoid Test to check pilot control shut-off solenoid. (Group 9015-20.) Go to System Functional Schematic to check wiring. (Group 9015-10.) Go to Floor Harness (W2) Component Location to check switch.

(Group 9015-10.) Go to Floor Harness (W2) Wiring Diagram to check harness.

(Group 9015-10.) Go to Solenoid Valve Manifold Repair to repair or replace solenoid. (Group 3360.)

Do any dig or propel functions operate?

NO: Go to next step in this check.

T122007 —UN—25JUN99

Move pilot control shut-off lever to UNLOCKED position (forward).

Actuate all dig and propel functions.

YES: Go to next check.

Do all functions operate?

NO: Go to Solenoid Test to check pilot control shut-off solenoid. (Group 9015-20.) Go to System Functional Schematic to check wiring. (Group 9015-10.) Go to Floor Harness (W2) Component Location to check switch.

(Group 9015-10.) Go to Floor Harness (W2) Wiring Diagram to check harness.

(Group 9015-10.) Go to Solenoid Valve Manifold Repair to repair or replace solenoid. (Group 3360.)

Continued on next page

TM2052 (17JUL18)

9005-10-9

CED,OUOE003,1506 -19-10DEC12-13/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=29

Operational Checkout Procedure Propel Alarm Check

T122007 —UN—25JUN99

CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Engine running.

Pilot control shut-off lever in UNLOCKED position (forward).

Push propel levers or pedals forward for forward travel.

Does propel alarm sound?

Pull levers or push propel pedals rearward for reverse travel.

YES: Go to next check.

Does propel alarm sound?

NO: Go to Fuse Test to check F9 Propel Alarm 5 Amp fuse. (Group 9015-20.)

Go to Propel Alarm Check to test alarm. (Group 9015-20.) See Propel Alarm Circuit Theory of Operation to check wiring. (Group 9015-15.) Go to Propel Alarm Harness (W11) And Propel Alarm Cancel Switch Harness (W12) Wiring Diagram to check harness.

(Group 9015-10.) Go to Propel Alarm Harness (W11) And Propel Alarm Cancel Switch Harness (W12) Component Location to check switch. (Group 9015-10.) If all OK, replace Propel Alarm Controller.

Continued on next page

TM2052 (17JUL18)

9005-10-10

CED,OUOE003,1506 -19-10DEC12-14/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=30

Operational Checkout Procedure Propel Alarm Cancel Switch Check

T122007 —UN—25JUN99

CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Engine running.

Pilot control shut-off lever in UNLOCKED position (forward).

Push propel levers or pedals forward for forward travel.

Press and release the propel alarm cancel switch.

YES: Go to next check.

Does the propel alarm stop?

NO: Go to System Functional Schematic to check wiring. (Group 9015-10.) Go to Propel Alarm Harness (W11) And Propel Alarm Cancel Switch Harness (W12) Wiring Diagram to check harness.

(Group 9015-10.) Go to Propel Alarm Harness (W11) And Propel Alarm Cancel Switch Harness (W12) Component Location to check switch. (Group 9015-10.) If all OK, replace Propel Alarm Controller.

CED,OUOE003,1506 -19-10DEC12-15/30

Hydraulic Oil Tank Pressurization Check

T122008 —UN—25JUN99

Engine running.

Raise boom to full height, then lower boom to ground.

Slowly loosen cap on hydraulic oil tank.

Is air heard escaping?

YES: Go to next check.

NOTE: The pressurized hydraulic oil tank creates pressure at the inlet to the hydraulic pumps. If filler cap does not seal, hydraulic pumps could cavitate and be damaged.

NO: Replace cap.

Continued on next page

TM2052 (17JUL18)

9005-10-11

CED,OUOE003,1506 -19-10DEC12-16/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=31

Operational Checkout Procedure Pilot Controller Pattern Check—SAE Backhoe Pattern

T124098 —UN—17SEP99

T155735B —UN—05JUN02

1— SAE Backhoe Pattern 2— Backhoe Position CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Run engine at slow idle.

Operate machine in clear area.

Push pilot shut-off lever to UNLOCKED position. Slowly move control levers to all positions on decals.

YES: Go to next check.

Do bucket, boom, arm, and swing move as shown on decals?

NO: Check pilot controller pattern conversion valve position. Go to Pilot Controller To Pattern Conversion Valve Line Connection to check line connections. (Group 9025-15.)

Continued on next page

TM2052 (17JUL18)

9005-10-12

CED,OUOE003,1506 -19-10DEC12-17/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=32

Operational Checkout Procedure Pilot Controller Pattern Check—ISO Excavator Pattern

T124099 —UN—17SEP99

T155734B —UN—05JUN02

1— ISO Excavator Pattern 2— Excavator Position CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Run engine at slow idle.

Operate machine in clear area.

Push pilot shut-off lever to UNLOCKED position. Slowly move hydraulic levers to all positions on decals.

YES: Go to next check.

Do bucket, boom, arm, and swing move as shown on decals?

NO: Check pilot controller pattern conversion valve position. Go to Pilot Controller To Pattern Conversion Valve Line Connection to check line connections. (Group 9025-15.)

Continued on next page

TM2052 (17JUL18)

9005-10-13

CED,OUOE003,1506 -19-10DEC12-18/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=33

Operational Checkout Procedure Swing Dynamic Braking Check

T6479AY —UN—19OCT88

CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Position upperstructure with boom in front.

Extend arm and curl the bucket. Lower boom so bucket pivot pin is at the same level as boom-to-main frame pin.

Run engine at fast idle.

Actuate swing control valve to full stroke. Swing around 90 degrees (1/4 turn) and then release lever.

Does upperstructure stop within 45 degrees (1/8 turn) after releasing lever?

YES: Go to next check.

Repeat procedure in opposite direction.

NO: Go to Swing Motor Leakage Test to check swing motor. (Group 9025-25.) Go to Swing Motor Crossover Relief Valve Test And Adjustment to check swing motor.

(Group 9025-25.) Go to Control Valve Disassemble and Assemble to check swing valve spool. (Group 3360.)

Continued on next page

TM2052 (17JUL18)

9005-10-14

CED,OUOE003,1506 -19-10DEC12-19/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=34

Operational Checkout Procedure Dig Function Drift Check

T6290AF —UN—19OCT88

CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Run engine at slow idle.

Fill bucket with dirt. Position bucket at maximum reach with bucket 50 mm (2 in.) above ground.

Observe bucket for 1 minute.

YES: Go to Cylinder Drift Test to check cylinder drift.

(Group 9025-25.) Go to Control Valve Disassemble and Assemble to check boom reduced leakage valve and boom reduced leakage valve check valve.

(Group 3360.) Go to Control Valve Repair to check bucket valve spool, boom valve spool, and arm valve spool. (Group 3360.)

Go to Bucket Cylinder Disassemble and Assemble to repair bucket cylinder.

(Group 3360.) Go to Arm Cylinder Disassemble and Assemble to repair arm cylinder. (Group 3360.)

Go to Boom Cylinder Disassemble and Assemble to repair boom cylinder.

(Group 3360.)

Does bucket drift down to ground within 1 minute?

Continued on next page

TM2052 (17JUL18)

9005-10-15

NO: Go to next check.

CED,OUOE003,1506 -19-10DEC12-20/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=35

Operational Checkout Procedure Control Valve Lift Check Test

T6292AZ —UN—19OCT88

CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Run engine at slow idle.

Position machine as illustrated.

Slowly actuate pilot controller to lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder).

YES: See Hydraulic System Schematic check control valve schematic.

(Group 9025-05.) Go to Control Valve Remove and Install to repair or replace control valve. (Group 3360.)

Do functions move in opposite direction as control levers are moved, then change direction as levers are moved further?

NO: Go to next check.

Continued on next page

TM2052 (17JUL18)

9005-10-16

CED,OUOE003,1506 -19-10DEC12-21/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=36

Operational Checkout Procedure Propel System Tracking Check

CAUTION: Prevent possible injury from unexpected machine movement.

Clear all persons from the area before operating machine.

Warm hydraulic oil to operating temperature for this check. See Hydraulic System Warm-Up Procedure. (Group 9025-25.)

9

TX1120783 —UN—20AUG12

Machine Position 9— Bucket Height Fully extend arm cylinder and bucket cylinder.

Position boom so bucket height (9) is approximately 400 mm (16 in.) above ground.

T124102 —UN—17SEP99

1— Propel Speed Change Switch

Continued on next page

TM2052 (17JUL18)

9005-10-17

CED,OUOE003,1506 -19-10DEC12-22/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=37

Operational Checkout Procedure

6

8

7 5

6 TX1120481 —UN—17AUG12

Tracking Check 5— Distance of Mistrack 6— Acceleration and Deceleration Zone (approximate): 3—5 m (10—16 ft.)

7— Test Line (distance): 20 m (66 ft.)

8— Track Print Engine at fast idle.

Depress and hold propel speed change switch (1) in fast speed.

Operate machine at full travel forward speed on a flat and level surface approximately 30 m (99 ft.).

Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8).

Measure and record greatest distance of mistrack (5) between inside edge of track print and test line.

YES: Go to next check.

Repeat procedure in reverse.

NO: See Propel Motor Leakage Test to check propel motors. (Group 9020-25.)

LOOK: Does machine mistrack less than 200 mm (7.87 in.)?

NO: See Hydraulic Pump 1 And 2 Flow Test to check main pump flow. (Group 9025-25.)

Continued on next page

TM2052 (17JUL18)

9005-10-18

CED,OUOE003,1506 -19-10DEC12-23/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=38

Operational Checkout Procedure Propel System Tracking Checks While Operating a Dig Function

T124102 —UN—17SEP99

1— Propel Speed Change Switch CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Engine at fast idle.

Depress and hold propel speed change switch (1) in fast speed.

Propel machine at full speed forward on a flat and level area.

After machine is moving, slowly move the arm control lever from neutral to full actuation to extend the arm.

Does machine mistrack excessively when the arm is extended?

NOTE: Machine will slow down during this test.

Continued on next page

TM2052 (17JUL18)

9005-10-19

YES: Go to Control Valve Repair to check flow combiner valve. (Group 3360.)

NO: Go to next check.

CED,OUOE003,1506 -19-10DEC12-24/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=39

Operational Checkout Procedure Propel Speed Change Check

T124102 —UN—17SEP99

1— Propel Speed Change Switch CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Run engine at fast idle.

Actuate propel function to full speed forward.

Depress and hold propel speed change switch (1) to change to fast speed.

YES: Go to next check.

Does machine travel speed increase?

NO: Go to Fuse Test to check F3 Horn 10 Amp fuse. (Group 9015-20.)

Go to System Functional Schematic to check wiring. (Group 9015-10.)

Go to Floor Harness (W2) Wiring Diagram to check harness. (Group 9015-10.) Go to Floor Harness (W2) Component Location to check switch.

(Group 9015-10.) Go to Solenoid Test to check propel speed solenoid.

(Group 9015-20.) Go to Solenoid Valve Manifold Repair to repair solenoid.

(Group 3360.) Go to Propel Motor Disassemble and Assemble—27C ZTS and Go to Propel Motor Disassemble and Assemble—35C ZTS to check propel speed change valve. (Group 0260.)

Continued on next page

TM2052 (17JUL18)

9005-10-20

CED,OUOE003,1506 -19-10DEC12-25/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=40

Operational Checkout Procedure Blade Function Check CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

Run engine at slow idle.

Pull blade control lever rearward.

Does blade raise?

Release lever.

Does lever return to neutral and the blade stop?

Push lever forward.

Does blade lower?

Release lever.

YES: Go to next check.

Does lever return to neutral and the blade stop?

NO: Go to Blade Pilot Controller Repair to check blade pilot controller.

(Group 3260.) Go to Control Valve Repair to check blade valve spool. (Group 3360.)

Continued on next page

TM2052 (17JUL18)

9005-10-21

CED,OUOE003,1506 -19-10DEC12-26/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=41

Operational Checkout Procedure Cycle Times Check—27C ZTS

CAUTION: Make sure area is clear and large enough to operate all functions of machine.

IMPORTANT: Warm hydraulic oil to operating temperature for this check.

Engine at fast idle.

Continued on next page

TM2052 (17JUL18)

9005-10-22

CED,OUOE003,1506 -19-10DEC12-27/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=42

Operational Checkout Procedure YES: Check complete.

Record cycle time for each function.

T6477AQ —UN—19OCT88

Boom

T7884AE —UN—10NOV92

Arm, Bucket, Swing, Boom Swing Cycle Times—Specification Boom Raise (Cylinder Extend)—Cycle Time............................................................................................................. 2.6—3.2 sec Boom Lower (Cylinder Retract)—Cycle Time............................................................................................................. 2.1—2.7 sec Arm In (Cylinder Extend)—Cycle Time........................................................ 3.1—4.1 sec Arm Out (Cylinder Retract)—Cycle Time...................................................... 2.5—3.1 sec Bucket Load (Cylinder Extend)—Cycle Time............................................................................................................. 2.2—2.8 sec Bucket Dump (Cylinder Retract)—Cycle Time............................................................................................................. 1.5—2.1 sec Boom Swing Right (Cylinder Extend)—Cycle Time................................................................................... 8.0—9.0 sec Boom Swing Left (Cylinder Retract)—Cycle Time................................................................................... 5.8—6.8 sec Blade—Cycle Time......................................................................... 1.7—2.7 sec to raise 2.3—3.3 sec to lower Swing Function—Specification Swing Left or Right 3 Revolutions From a Running Start—Cycle Time.................................................................. 19.1—22.1 sec Propel Function—Specification Propel 20 m (65 ft) From a Running Start (Check in Forward and Reverse with Propel Speed Change Switch in FAST Position)—Cycle Time................................................. 17.0—20.0 sec with rubber track 17.5—20.5 sec with steel track Propel 20 m (65 ft) From a Running Start (Check in Forward and Reverse with Propel Speed Change Switch in SLOW Position)—Cycle Time................................................. 29.3—32.3 sec with rubber track 30.2—33.2 sec with steel track Does machine perform within specifications?

Continued on next page

TM2052 (17JUL18)

9005-10-23

NO: Go to Engine Speed Check to check engine speed. (Group 9010-25.)

Go to Hydraulic Pump 1 And 2 Flow Test to check pump flow. (Group 9025-25.)

CED,OUOE003,1506 -19-10DEC12-28/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=43

Operational Checkout Procedure Cycle Times Check—35C ZTS

CAUTION: Make sure area is clear and large enough to operate all functions of machine.

IMPORTANT: Warm hydraulic oil to operating temperature for this check.

Engine at fast idle.

Continued on next page

TM2052 (17JUL18)

9005-10-24

CED,OUOE003,1506 -19-10DEC12-29/30

27C ZTS and 35C ZTS Operation & Tests 071718 PN=44

Operational Checkout Procedure YES: Check complete.

Record cycle time for each function.

T6477AQ —UN—19OCT88

Boom

T7884AE —UN—10NOV92

Arm, Bucket, Swing, Boom Swing Cycle Times—Specification Boom Raise (Cylinder Extend)—Cycle Time............................................................................................................. 2.1—2.7 sec Boom Lower (Cylinder Retract)—Cycle Time............................................................................................................. 1.9—2.5 sec Arm In (Cylinder Extend)—Cycle Time........................................................ 3.0—4.0 sec Arm Out (Cylinder Retract)—Cycle Time...................................................... 2.3—2.9 sec Bucket Load (Cylinder Extend)—Cycle Time............................................................................................................. 1.9—2.5 sec Bucket Dump (Cylinder Retract)—Cycle Time............................................................................................................. 1.3—1.9 sec Boom Swing Right (Cylinder Extend)—Cycle Time................................................................................... 6.6—7.6 sec Boom Swing Left (Cylinder Retract)—Cycle Time................................................................................... 4.8—5.8 sec Blade—Cycle Time......................................................................... 1.1—2.1 sec to raise 1.6—2.6 sec to lower Swing Function—Specification Swing Left or Right 3 Revolutions From a Running Start—Cycle Time.................................................................. 19.1—22.1 sec Propel Function—Specification Propel 20 m (65 ft) From a Running Start (Check in Forward and Reverse with Propel Speed Change Switch in FAST Position)—Cycle Time................................................. 15.5—18.5 sec with rubber track 15.0—18.0 sec with steel track Propel 20 m (65 ft) From a Running Start (Check in Forward and Reverse with Propel Speed Change Switch in SLOW Position)—Cycle Time................................................. 22.8—25.8 sec with rubber track 23.5—26.5 sec with steel track Does machine perform within specifications?

NO: Go to Engine Speed Check to check engine speed. (Group 9010-25.)

Go to Hydraulic Pump 1 And 2 Flow Test to check pump flow. (Group 9025-25.)

CED,OUOE003,1506 -19-10DEC12-30/30

TM2052 (17JUL18)

9005-10-25

27C ZTS and 35C ZTS Operation & Tests 071718 PN=45

Operational Checkout Procedure

TM2052 (17JUL18)

9005-10-26

27C ZTS and 35C ZTS Operation & Tests 071718 PN=46

Section 9010 Engine Contents Page

Group 05—Theory of Operation Engine Component Location ..................... 9010-05-1 Cooling System .........................................9010-05-2 Engine Lubrication System........................9010-05-3 Engine Fuel System Operation.................. 9010-05-4 Group 15—Diagnostic Information Diagnose Malfunctions Engine ...................................................9010-15-1 Group 25—Tests JT05801 Clamp-On Electronic Tachometer Installation .............................................9010-25-1 Engine Speed Check ....................................................9010-25-1 Control Cable Adjustment .....................9010-25-2 Fuel Injection Nozzle Check and Adjust ..................................9010-25-3 Injection Pump Timing Check and Adjust ..................................9010-25-4 Fan Belt Adjust Tension.......................................9010-25-5 Engine Valve Lash (Clearance) Check and Adjust ..................................9010-25-6 Air Intake System Leakage........................9010-25-7 Radiator Air Flow .......................................9010-25-8 Engine Compression Pressure................9010-25-10 Engine Oil Pressure.................................9010-25-11 Check for Head Gasket Failures ............. 9010-25-12

TM2052 (17JUL18)

9010-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=1

Group 05

Theory of Operation

T155843 —UN—10JUN02

Engine Component Location

Continued on next page

TM2052 (17JUL18)

9010-05-1

OUT1738,0000020 -19-02JUL02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=48

Theory of Operation 1— Cooling Fan and Spacer 2— Water Pump Assembly 3— Fan Pulley 4— Fan Belt 5— Alternator 6— Oil Pan Drain 7— Starter Motor

8— Muffler 9— Valve Cover and Air Intake Pipe 10— Water Outlet Pipe and Thermostat 11— Exhaust Manifold 12— Injection Pipe (3 used)

13— Engine Stop Solenoid 14— Oil Filter 15— Fuel Injection Pump Housing Cover 16— Governor 17— Fuel Injection Pump and Shim (3 used)

18— Fuel Hose 19— Breather Pipe 20— Fuel Leak Off Pipe 21— Oil Dipstick

OUT1738,0000020 -19-02JUL02-2/2

T125876 —19—19NOV99

Engine Cooling System Operation

The cooling system consists of a radiator, water pump, and thermostat.

During engine warm-up, the thermostat remains closed and coolant is directed through the bypass passage to the suction side of the water pump. Coolant circulates through the cylinder block and water pump to provide a uniform and fast warm-up.

When the coolant temperature increases to normal operating temperature, the thermostat opens. This allows the coolant to flow to the top of the radiator and also blocks the flow through the bypass passage. If the engine

is operated without a thermostat, only a small amount of water is directed to the radiator. Enough coolant will flow through the bypass passage to cause overheating.

When the engine is operated, the coolant temperature rises. It is cooled by the radiator to prevent further temperature rise. If the engine is overloaded or operated continuously for a long period of time, coolant temperature may continue to rise past the radiator cap opening pressure setting. The pressurized radiator cap will then open and exhaust excess pressure through the overflow hose to the coolant reservoir tank.

OUT1738,0000021 -19-02JUL02-1/1

TM2052 (17JUL18)

9010-05-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=49

Theory of Operation

T126165 —19—24NOV99

Engine Lubrication System Operation

The engine lubrication system consists of an oil strainer, oil pump (with pressure regulating valve), and oil filter (with bypass valve).

Oil is drawn through the oil strainer screen by the oil pump.

The oil pump incorporates a built-in pressure regulating valve that maintains the correct pressure in the lubricating system regardless of engine speed or the oil temperature.

When pressure exceeds the setting of the valve, the valve will open, routing the excess oil to the oil pan.

Pressurized oil is directed to the oil filter. The filter element is equipped with an integral bypass valve. When pressure exceeds the spring force, the valve will open if the filter becomes plugged.

Filtered oil is routed to the main oil gallery in the cylinder block. Oil flows to each crankshaft main bearing and through cross-drilled passages in the crankshaft-to-connecting rod bearings.

Continued on next page

TM2052 (17JUL18)

9010-05-3

OUT1738,0000022 -19-02JUL02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=50

Theory of Operation

The oil gallery also supplies pressure oil to the camshaft bearings, idler gear bush and timing gear. Pressure oil is

also supplied to the cylinder head, rocker shaft and rocker arms.

OUT1738,0000022 -19-02JUL02-2/2

Engine Fuel System Operation Fuel Injection Pump Operation

Fuel Injection Nozzle Operation

T104266 —19—02JAN97

A single fire fuel injection pump is used for each cylinder.

It is actuated by a roller tappet riding on a camshaft lobe.

It is timed to pump fuel to the fuel injection nozzle of the same cylinder on the compression stroke. Pressurized fuel from the electric fuel pump is maintained in the fuel

injection pump until the camshaft lobe opens a passage to discharge fuel to the fuel injection nozzle which injects fuel into the cylinder. Excess fuel from the fuel injection pump and fuel injection nozzle is returned to the fuel tank by means of return lines.

A—Fuel Return Pipe B—Nozzle Cover C—Dowel Pin D—Stop Plate

E—Nozzle Nut F— Nozzle Body G—Nozzle Valve H—Nozzle Spring Seat

I— Nozzle Spring J— Fuel Starting Pressure Adjusting Shim

The fuel injection nozzle is a hole-type nozzle. The nozzle valve (G) is shim (J) adjustable to regulate the opening pressure.

High pressure fuel from the injection pump flows through a fuel inlet passage. Pressure builds beneath the nozzle valve. When the fuel pressure reaches specified pressure, it overcomes the nozzle spring (I) tension. The nozzle valve (G) retracts into the nozzle body (F) and fuel is injected into the engine.

K—Nozzle Holder

The nozzle valve is automatically pushed down by the nozzle spring (I) and closed after fuel is injected.

Leakage (return fuel) flows from between the nozzle valve and nozzle body to the hole on top of the nozzle spring, through the fuel return pipe fitting (A) and back into the fuel tank.

OUT1738,0000023 -19-02JUL02-1/1

TM2052 (17JUL18)

9010-05-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=51

Theory of Operation

TM2052 (17JUL18)

9010-05-5

27C ZTS and 35C ZTS Operation & Tests 071718 PN=52

Group 15

Diagnostic Information Diagnose Engine Malfunctions NOTE: Diagnostic charts are arranged from most probable and simplest to verify, to least likely and more difficult to verify. See TM2053 for repair information.

Symptom

Problem

Solution

Engine Cranks But Will Not Start or No fuel Hard to Start

Add fuel. Perform Bleed Fuel System.

(Group 0560.)

Incorrect fuel

Use correct fuel. See Diesel Fuel.

(Operator's Manual.)

Water in fuel or water frozen in fuel line Perform Drain Fuel Tank Sump and Perform Drain Water Separator to drain water. (Operator's Manual.)

Inspect final fuel filter for water. See Replace Final Fuel Filter to replace.

(Operator's Manual.)

Fuel filter and/or water separator plugged

See Replace Final Fuel Filter and/or Perform Replace Water Separator as necessary. (Operator's Manual.)

Debris in fuel

Drain fuel tank. Clean tank strainer.

Add clean fuel.

Air in fuel system

Check for bubbles in fuel filter. Tighten connections. Perform Bleed Fuel System (Group 0560.)

Electric fuel pump

Disconnect fuel line at delivery end of electric fuel pump. Turn key ON. If fuel is not delivered, Perform Fuse Test on fuel pump fuse. (Group 9015-20.) See Fuse Specifications for fuse location.

(Group 9015-10.) If fuse is good, disconnect fuel pump from harness.

Check for 12V at terminal 2 of harness end connector with key switch ON. If ok, replace electric fuel pump. If 12V is not present, check harness.

Low battery power

Go To Alternator Output Check.

(Group 9015-20.)

Go To Battery Voltage Check. (Group 9015-20.) Charge batteries. See Using Battery Charger. (Operator's Manual.)

Install new batteries. See Battery Remove and Install. (Group 9015-20.)

Slow cranking speed—poor electrical Clean and tighten battery and starter connection connections.

Continued on next page

TM2052 (17JUL18)

9010-15-1

OUT1738,0000024 -19-02JUL02-1/10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=53

Diagnostic Information Symptom

Problem

Solution

Incorrect engine oil

Use correct oil for cold weather.

See Diesel Engine Oil. (Operator's Manual.)

Air filter elements plugged

Check air filter restriction indicator.

See Clean Air Cleaner Element.

(Operator's Manual.) Clean or replace elements.

Starter and electrical system

Go To Electrical Component Checks.

(Group 9015-20.)

Injection pump

Remove and test pump. Go To Fuel Injection Pump Remove and Install for removal procedure. (Group 0400.)

See your local fuel injection pump service center.

Injection nozzle(s)

Remove and test injection nozzle.

Go To Check Fuel Injection Nozzle.

(Group 9010-25.)

Worn compression rings or low compression

Perform Engine Compression Pressure Test. (Group 9010-25.) See Piston and Connecting Rod Repair for ring replacement. (Group 0400.)

Blown cylinder head gasket

Perform Check for Head Gasket Failures. (Group 9010-25.)

Engine Knocks, Runs Irregularly or Air in fuel Stops

Check for bubbles in fuel filter. Tighten connections. Perform Bleed Fuel System. (Group 0560.)

Debris in fuel

Drain fuel tank. Clean tank strainer.

Add clean fuel.

Incorrect fuel

Use correct fuel. See Diesel Fuel.

(Operator's Manual.)

Water in fuel

Perform Drain Fuel Tank Sump and Perform Drain Water Separator to drain water. (Operator's Manual.)

Inspect final fuel filter for water. See Replace Final Fuel Filter to replace.

(Operator's Manual.)

Fuel filter elements plugged

See Replace Final Fuel Filter.

(Operator's Manual.)

Slow idle speeds adjustment too low

See Engine Speed Control Cable Adjustment. (Group 9010-25.)

Continued on next page

TM2052 (17JUL18)

9010-15-2

OUT1738,0000024 -19-02JUL02-2/10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=54

Diagnostic Information Symptom

Problem

Solution

Engine overheating

Perform Radiator Air Flow Test.

(9010-25.)

Go To Drain Cooling System.

(Operator's Manual.)

Engine Not Developing Full Power

Electric fuel pump

Disconnect fuel line at delivery end of electric fuel pump. Turn key ON. If fuel is not delivered, Perform Fuse Test on fuel pump fuse. (Group 9015-20.) See Fuse Specifications for fuse location.

(Group 9015-10.) If fuse is good, disconnect fuel pump from harness.

Check for 12V at terminal 2 of harness end connector with key switch ON. If ok, replace electric fuel pump. If 12V is not present, check harness.

Fuel injection pump

Remove and test specific fuel injection pump. Go To Fuel Injection Pump Remove and Install for removal procedure. (Group 0400.) See your local fuel injection pump service center.

Injection nozzle(s)

Remove and test injection nozzle.

Go To Check Fuel Injection Nozzle.

(Group 9010-25.)

Improper valve clearance

Go To Check And Adjust Engine Valve Lash (Clearance). (Group 9010-25.)

Valve(s) sticking or burned

Perform Engine Compression Pressure Test. (Group 9010-25.)

Repair or replace valve(s) as necessary. See Cylinder Head Repair for valve replacement. (Group 0400.)

Bent push rods

Inspect. See Cylinder Head Repair.

(Group 0400.) Replace as necessary.

Cylinder head gasket leaking

Perform Check for Head Gasket Failures. (Group 9010-25.)

Worn or broken compression rings

See Engine Compression Pressure Test. (Group 9010-25.) Repair as necessary.

Fuel filter elements plugged

See Replace Final Fuel Filter.

(Operator's Manual.)

Air filter plugged

Check air filter restriction indicator.

See Clean Air Cleaner Element.

(Operator's Manual.) Clean or replace elements.

Continued on next page

TM2052 (17JUL18)

9010-15-3

OUT1738,0000024 -19-02JUL02-3/10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=55

Diagnostic Information Symptom

Engine Overheats

Problem

Solution

Debris in fuel

Drain fuel tank. Clean tank strainer.

Add clean fuel.

Incorrect fuel

Use correct fuel. See Diesel Fuel.

(Operator's Manual.)

Fuel tank outlet fitting plugged

Clean.

Fast idle speed incorrect

See Engine Speed Control Cable Adjustment. (Group 9010-25.)

Hydraulic system leakage

Go To Cylinder Drift Test—Boom, Arm, Bucket, and Blade—27C ZTS or Go To Cylinder Drift Test—Boom, Arm, Bucket, and Blade—35C ZTS. (Group 9025-25.) If problem exists, See Load Drifts Down When Control Valve Is In Neutral Position. (Group 9025-15.)

Fuel line to pump or pump return line to tank restricted Electric fuel pump

Check, repair.

Timing incorrect

Go To Check and Adjust Injection Pump Timing. (Group 9010-25.)

Injection nozzle(s)

Remove and test injection nozzle.

Go To Check Fuel Injection Nozzle.

(Group 9010-25.)

Low compression

Perform Engine Compression Pressure Test. (Group 9010-25.)

Repair as necessary.

Injection pump delivery or governor

Repair specific pump. See your local fuel injection pump service center.

valve(s) burned, warped

Inspect. Repair or replace valve(s) as necessary. See Cylinder Head Repair for valve replacement. (Group 0400.)

Camshaft worn

See Camshaft Repair. (Group 0400.)

Coolant level low

Fill cooling system. Check for leaks.

Continued on next page

TM2052 (17JUL18)

Disconnect fuel line at delivery end of electric fuel pump. Turn key ON. If fuel is not delivered, Perform Fuse Test on fuel pump fuse. (Group 9015-20.) See Fuse Specifications for fuse location.

(Group 9015-10.) If fuse is good, disconnect fuel pump from harness.

Check for 12V at terminal 2 of harness end connector with key switch ON. If ok, replace electric fuel pump. If 12V is not present, check harness.

9010-15-4

OUT1738,0000024 -19-02JUL02-4/10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=56

Diagnostic Information Symptom

Problem

Solution

Thermostat stuck closed or missing

Test. Go To Thermostat Remove and Install. (Group 0400.) Replace if necessary.

Radiator, oil cooler cores plugged with Perform Radiator Air Flow Test. dirt or fins bent (Group 9010-25.) Clean radiator.

Straighten fins.

Engine Stalls Easily Under Load

Air filter elements plugged

Check air filter restriction indicator.

See Clean Air Cleaner Element.

(Operator's Manual.) Clean or replace elements.

Coolant temperature sender

Perform Temperature Sensor Test. (Group 9015-20.) Replace if necessary.

Coolant temperature gauge

Perform Monitor and Gauge Circuit Checks. Replace if necessary. (Group 9005-10.)

Fan belt soaked with oil. Belt or pulleys worn excessively

Inspect. Replace if necessary. See Fan Belt Repair. (Group 0510.)

Shroud or baffles (foam rubber) missing

Inspect. Repair or replace. See Radiator And Oil Cooler Remove and Install. (Group 0510.)

Fan blade on backward

Check that fan blade is installed with concave (cupped) side of blade towards engine. Perform Fan, Shroud, and Guard Repair. (Group 0510.)

Fan belt tension

Go To Adjust Fan Belt Tension.

(Group 9010-25.)

Incorrect coolant mixture

Drain coolant and refill with correct coolant mixture.

Hydraulic system overheating

See Hydraulic Oil Overheats.

(9025-15.)

Cooling system passages dirty

Flush coolant system. Go To Drain Cooling System. (Operator's Manual.)

Water pump

Inspect. Repair if necessary. See Water Pump Repair. (Group 0400.)

Fuel filter elements plugged

See Replace Final Fuel Filter.

(Operator's Manual.)

Continued on next page

TM2052 (17JUL18)

9010-15-5

OUT1738,0000024 -19-02JUL02-5/10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=57

Diagnostic Information Symptom

Coolant Temperature Too Low

Problem

Solution

Air cleaner elements

Check air filter restriction indicator.

See Clean Air Cleaner Element.

(Operator's Manual.) Clean or replace elements.

Debris in fuel

Drain fuel tank. Clean tank strainer.

Add clean fuel.

Incorrect fuel

Use correct fuel. See Diesel Fuel.

(Operator's Manual.)

Fuel tank outlet fitting plugged

Clean.

Fuel line to pump or pump return line to tank restricted Electric fuel pump

Check, repair.

Timing incorrect

Go To Check and Adjust Injection Pump Timing. (Group 9010-25.)

Injection nozzle(s)

Remove and test injection nozzle.

Go To Check Fuel Injection Nozzle.

(Group 9010-25.)

Low compression

See Engine Compression Pressure Test. (Group 9010-25.) Repair as necessary.

Injection pump delivery or governor

Repair pump. See your local fuel injection pump service center.

valve(s) burned, warped

Inspect. Repair or replace valve(s) as necessary. See Cylinder Head Repair for valve replacement. (Group 0400.)

Camshaft worn

See Camshaft Repair. (Group 0400.)

Hydraulic pump

Swash plate or control pistons sticking.

See Hydraulic Pump Remove and Install. (Group 3360.)

Thermostat stuck open

Test. Go To Thermostat Remove and Install. (Group 0400.) Replace if necessary.

Continued on next page

TM2052 (17JUL18)

Disconnect fuel line at delivery end of electric fuel pump. Turn key ON. If fuel is not delivered, Perform Fuse Test on fuel pump fuse. (Group 9015-20.) See Fuse Specifications for fuse location.

(Group 9015-10.) If fuse is good, disconnect fuel pump from harness.

Check for 12V at terminal 2 of harness end connector with key switch ON. If ok, replace electric fuel pump. If 12V is not present, check harness.

9010-15-6

OUT1738,0000024 -19-02JUL02-6/10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=58

Diagnostic Information Symptom

Oil in Coolant or Coolant in Crankcase

Problem

Solution

Coolant temperature sensor

Perform Temperature Sensor Test. (Group 9015-20.) Replace if necessary.

Coolant temperature gauge

Perform Monitor and Gauge Circuit Checks. (Group 9005-10.) Replace if necessary.

Blown cylinder head gasket

Perform Check for Head Gasket Failures. (Group 9010-25.)

Cracked cylinder head or block

Inspect cylinder head. See Cylinder Head Repair. (Group 0400.) Replace if cracked.

Inspect block. See Cylinder Block Repair. (Group 0400.) Replace if cracked.

Low Engine Oil Pressure

Oil level low

Fill to proper level.

Oil filter plugged

Perform Change Engine Oil And Replace Filter. (Operator's Manual.)

Oil pump intake screen plugged or loose

Inspect. Clean. See Oil Pump Repair for more information. (Group 0400.)

Incorrect grade of oil or fuel dilution

Drain and refill with correct oil.

See Diesel Engine Oil. (Operator's Manual.)

Oil pump

Oil pressure relief valve stuck open, drive gear loose, gear and/or housing worn. Inspect. See Oil Pump Repair.

(Group 0400.) Repair as necessary.

Excessive main or connecting rod bearing clearance

Inspect main bearings. See Crankshaft Repair. (Group 0400.)

Replace as necessary.

Inspect connecting rod bearings. See Piston and Connecting Rod Repair.

(Group 0400.) Replace as necessary.

Excessive camshaft bearing clearance Inspect camshaft bearings. See Camshaft Repair. (Group 0400.)

Replace as necessary.

High Engine Oil Pressure

Incorrect oil viscosity

Continued on next page

TM2052 (17JUL18)

9010-15-7

Drain and refill with correct oil.

See Diesel Engine Oil. (Operator's Manual.)

OUT1738,0000024 -19-02JUL02-7/10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=59

Diagnostic Information Symptom

Problem

Solution

Crankshaft or camshaft bearings spun Inspect main bearings. See in journal Crankshaft Repair. (Group 0400.)

Replace as necessary.

Inspect camshaft bearings. See Camshaft Repair. (Group 0400.)

Replace as necessary.

Engine Uses Too Much Oil

Oil pressure relief valve stuck or misadjusted

See Oil Pump Repair. (Group 0400.)

Repair as necessary.

Coolant in engine oil

Perform Check for Head Gasket Failures. (Group 9010-25.)

Incorrect oil

Drain and refill with correct oil.

See Diesel Engine Oil. (Operator's Manual.)

Oil level too high

Check oil level. Drain excess oil.

Check to see if some other fluid is leaking into oil.

Oil leaks

Check engine oil drain plug.

Air cleaner elements plugged

Check air filter restriction indicator.

See Clean Air Cleaner Element.

(Operator's Manual.) Clean or replace elements.

Crankcase breather restricted

Inspect. Replace as necessary.

Engine operating too hot

Perform Radiator Air Flow Test.

(9010-25.)

Go To Drain Cooling System.

(Operator's Manual.)

Main or connecting rod bearing clearance excessive

Inspect main bearings. See Crankshaft Repair. (Group 0400.)

Replace as necessary.

Inspect connecting rod bearings. See Piston and Connecting Rod Repair.

(Group 0400.) Replace as necessary.

Cylinder liners scored

Inspect cylinder liners. See Cylinder Block Repair. (Group 0400.) Replace as necessary.

Piston rings worn, broken or stuck

See Engine Compression Pressure Test. (Group 9010-25.) See Piston and Connecting Rod Repair for ring replacement. (Group 0400.)

Continued on next page

TM2052 (17JUL18)

9010-15-8

OUT1738,0000024 -19-02JUL02-8/10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=60

Diagnostic Information Symptom

Problem

Solution

Camshaft bearing clearance excessive

Inspect camshaft bearings. See Camshaft Repair. (Group 0400.)

Replace as necessary.

Oil return slots in piston clogged

Clean. See Piston and Connecting Rod Repair. (Group 0400.)

Crankshaft thrust bearing worn (misaligned piston and rod)

Inspect thrust bearing. See Crankshaft Repair. (Group 0400.)

Replace bearings as necessary.

Inspect connecting rod bearings. See Piston and Connecting Rod Repair.

(Group 0400.) Adjust or replace as necessary.

Engine Uses Too Much Fuel

Excessive Black Smoke

Valve guides or valve stems worn

Inspect. See Cylinder Head Repair.

(Group 0400.) Replace valve(s) and/or head as necessary.

Fuel system leakage

Check fuel lines for leaks.

Air cleaner elements or intake manifold dirty or plugged

Check air filter restriction indicator.

See Clean Air Cleaner Element.

(Operator's Manual.) Clean or replace elements.

Incorrect fuel

Use correct fuel. See Diesel Fuel.

(Operator's Manual.)

Injection nozzle(s)

Remove and test injection nozzle.

Go To Check Fuel Injection Nozzle.

(Group 9010-25.)

Incorrect fuel

Use correct fuel. See Diesel Fuel.

(Operator's Manual.)

Air cleaner elements or intake manifold dirty or plugged

Check air filter restriction indicator.

See Clean Air Cleaner Element.

(Operator's Manual.) Clean or replace elements.

Check intake manifold. Clean manifold.

Plugged exhaust system or muffler

Clean exhaust system. Replace muffler. See Exhaust Manifold Remove and Install. (Group 0400.)

Over-fueling

Remove and adjust fuel injection pump. See your local fuel injection pump service center.

Continued on next page

TM2052 (17JUL18)

9010-15-9

OUT1738,0000024 -19-02JUL02-9/10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=61

Diagnostic Information Symptom

Excessive Blue or White Smoke

Problem

Solution

Injection nozzle orifice plugged

Inspect. See Fuel Injection Nozzle Repair. (Group 0400.) Clean as necessary.

Cranking speed too slow

Go To Battery Voltage Check. (Group 9015-20.) Charge batteries. See Using Battery Charger. (Operator's Manual.)

Install new batteries. See Battery Remove and Install. (Group 9015-20.)

Engine running too “cold”

Test. Go To Thermostat Remove and Install. (Group 0400.) Replace if necessary.

Incorrect fuel

Use correct fuel. See Diesel Fuel.

(Operator's Manual.)

Liners have wear and/or piston ring stuck

See Engine Compression Pressure Test. (Group 9010-25.) See Piston and Connecting Rod Repair for ring replacement. (Group 0400.)

Inspect cylinder liners. See Cylinder Block Repair. (Group 0400.) Replace as necessary.

Abnormal Noise

Oil level low

Check and add oil.

Incorrect engine oil

Drain and refill with correct oil.

See Diesel Engine Oil. (Operator's Manual.)

Engine oil diluted with fuel

Inspect engine oil. Inspect fuel pump spindle, seal and housing.

Valve clearance excessive

Go To Check And Adjust Engine Valve Lash (Clearance). (Group 9010-25.)

Engine static timing incorrect

Inspect. See Cylinder Block Repair.

(Group 0400.) Adjust camshaft timing.

Push rods bent

Inspect. See Cylinder Head Repair.

(Group 0400.) Replace as necessary.

Main and/or connecting rod bearing caps loose or worn

Inspect connecting rod bearing cap screws. See Piston and Connecting Rod Repair. (Group 0400.) Torque to specification.

Inspect main bearing cap screws. See Crankshaft Repair. (Group 0400.)

Torque to specification.

OUT1738,0000024 -19-02JUL02-10/10

TM2052 (17JUL18)

9010-15-10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=62

Diagnostic Information Symptom

Problem

Solution

Piston scored

Inspect pistons and piston rings. See Piston and Connecting Rod Repair.

(Group 0400.) Replace as necessary.

Piston pin bushings worn

Inspect piston pin bushings. See Piston and Connecting Rod Repair.

(Group 0400.) Replace pins and bushings as necessary.

Rocker arm shafts worn

Inspect rocker arm shafts. See Cylinder Head Repair. (Group 0400.)

Replace.

Crankshaft end play excessive

Inspect. See Crankshaft Repair.

(Group 0400.) Repair as necessary.

OUT1738,0000024 -19-02JUL02-11/10

TM2052 (17JUL18)

9010-15-11

27C ZTS and 35C ZTS Operation & Tests 071718 PN=63

Diagnostic Information

TM2052 (17JUL18)

9010-15-12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=64

Group 25

Tests JT05801 Clamp-On Electronic Tachometer Installation SERVICE EQUIPMENT AND TOOLS

T6813AG —UN—28FEB89

JT05801 Clamp-On Electronic Tachometer

1. Before installing clamp-on electronic tachometer, remove the paint from a straight section of injection line within 100 mm (4 in.) of No. 1 injection nozzle.

Use emery cloth to remove the paint.

2. Install the clamp-on transducer (A). Tighten finger tight only—DO NOT overtighten.

3. Connect the red clip (+) (C) to the clamp-on transducer.

4. Connect the black clip (-) (B) to a ground connection such as the head of a cap screw or other metal part on engine.

A—Clamp-On Transducer B—Black Clip (-)

C—Red Clip (+) D—Digital Readout Unit

5. Start the engine. Check for a reading on the digital readout unit (D).

OUT1738,0000025 -19-02JUL02-1/1

Engine Speed Check

4. Move engine speed control lever to slow idle position and measure engine rpm.

SPECIFICATIONS Engine Speed Check Slow Idle Speed

1200—1300 rpm

Fast Idle Speed

2475—2575 rpm

Engine Speed Check—Specification Slow Idle—Speed.......................................................... 1200—1300 rpm

5. Move engine speed control lever to fast idle position and measure engine rpm.

SERVICE EQUIPMENT AND TOOLS JT05801 Clamp-On Electronic Tachometer

Engine Speed Check—Specification Fast Idle—Speed........................................................... 2475—2575 rpm

1. Move engine speed control lever from slow idle to fast idle. Confirm that fuel injection pump governor lever contacts slow idle and fast idle stops.

6. Repeat measurement three times to ensure accuracy.

Adjust as necessary.

2. Start engine and warm to operating temperature.

3. Connect tachometer. See JT05801 Clamp-On Electronic Tachometer Installation. (Group 9010-25.)

OUT1738,0000026 -19-02JUL02-1/1

TM2052 (17JUL18)

9010-25-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=65

Tests

Engine Speed Control Cable Adjustment SPECIFICATIONS Engine Speed Control Cable Slow Idle Stop Screw Length

25 mm (0.98 in.)

Fast Idle Stop Screw Length

19 mm (0.75 in.)

Engine Speed Control Lever-to-Fast Idle Stop Screw Clearance

1—2 mm (0.04—0.08 in.)

T124781 —UN—29SEP99

1. Remove engine speed control lever cover.

2. Loosen lock nuts (6) on slow idle stop screw (5).

3. Adjust slow idle stop screw to length (4).

Engine Speed Control Cable—Specification Slow Idle Stop Screw—Length............................................................... 25 mm (0.98 in.)

4. Move engine speed control lever (7) until it contacts slow idle stop screw (5). Make sure governor lever (11) contacts slow idle adjusting screw (10). If it does not, adjust length of engine control cable (8).

5. Move engine speed control lever (7) until governor lever (11) contacts fast idle adjusting screw (9).

6. Loosen lock nuts (3) on fast idle stop screw (2).

T124780 —UN—29SEP99

7. Adjust fast idle stop screw to length (1), then ensure proper clearance between engine speed control lever (7) and fast idle stop screw (2).

Engine Speed Control Cable—Specification Fast Idle Stop Screw—Length............................................................... 19 mm (0.75 in.)

Engine Speed Control Lever-to-Fast Idle Stop Screw—Clearance...........................................1—2 mm (0.04—0.08 in.)

8. Tighten lock nuts (3).

1— Fast Idle Stop Screw Length 2— Fast Idle Stop Screw 3— Lock Nut (2 used) 4— Slow Idle Stop Screw Length 5— Slow Idle Stop Screw 6— Lock Nut (2 used)

9. Install engine speed control lever cover.

7— Engine Speed Control Lever 8— Engine Control Cable 9— Fast Idle Adjusting Screw 10— Slow Idle Adjusting Screw 11— Governor Lever

OUT1738,0000027 -19-02JUL02-1/1

TM2052 (17JUL18)

9010-25-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=66

Tests

Check Fuel Injection Nozzle SPECIFICATIONS Fuel Injection Nozzle 11 800 kPa (118 bar) (1712 psi)

ESSENTIAL TOOLS Isuzu Part No. 5-8840-9016-0 (J-28829) Fuel Injection Nozzle Tester

1. Remove fuel injection nozzle from engine.

2. Install fuel injection nozzle in nozzle tester.

T124875 —UN—29SEP99

Fuel Injection Nozzle Pressure

3. Pump tester to inject fuel. Then pump tester at approximately 60 pumps per minute to test fuel injection nozzle pressure.

Fuel Injection Nozzle—Specification Fuel Injection Nozzle—Pressure.................................. 11 800 kPa (118 bar) (1712 psi)

NOTE: To increase pressure, increase number of shims.

To decrease pressure, decrease number of shims.

T124876 —19—29SEP99

CAUTION: Never touch spray from fuel injection nozzle. Spray may penetrate skin and cause blood toxication in blood stream.

Pressure variation per 0.1 mm shim is 206 kPa (2.06 bar) (30 psi).

4. Check spray pattern and observe for: T124877 —19—30SEP99

• Uniform spray pattern • No sideways sprays • No coarse fuel distribution • No intermittent spray indicating blockage • No post injection dripping

OUT1738,0000028 -19-02JUL02-1/1

TM2052 (17JUL18)

9010-25-3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=67

Tests

Check and Adjust Injection Pump Timing SPECIFICATIONS Delivery Valve Holder Torque

39—44 N·m (29—33 lb-ft)

Timing

10.5—12.5° BTDC (Before Top Dead Center)

T124878 —19—29SEP99

Injection Pump Timing

Preparation 1. Rotate crank pulley until No. 1 cylinder is at TDC of the compression stroke.

Align “Mark Groove” on the crank pulley with “TDC Mark” on the timing gear case cover.

2. Rotate crank pulley approximately 100° counterclockwise.

Injection Pump Timing—Specification Delivery Valve Holder—Torque............................................... 39—44 N·m (29—33 lb-ft)

5. Turn key switch to ON. While supplying fuel from fuel pump, rotate crank pulley clockwise slowly until fuel leak stops at the tip of the delivery valve holder. At this moment, the “Mark Groove” on the crank pulley should be aligned with 10.5—12.5° BTDC on the timing gear case cover. If not, adjust the injection timing to specification.

Injection Pump Timing—Specification Injection Pump—Timing.... 10.5—12.5° BTDC (Before Top Dead Center) 1— No. 1 Injection Pipe 2— No. 1 Delivery Valve Holder 3— Spring

4— Delivery Valve 5— Injection Pump

Continued on next page

TM2052 (17JUL18)

9010-25-4

T124880 —UN—29SEP99

4. Remove No. 1 delivery valve holder (2) on injection pump (5) to pull out delivery valve (4) and spring (3).

Reinstall delivery valve holder into injection pump.

Tighten delivery valve holder.

T124879 —UN—30SEP99

3. Remove No. 1 injection pipe (1).

OUT1738,0000029 -19-02JUL02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=68

Tests Adjustment 1. Remove cap screws (7) and nuts (6) from injection pump (5).

T124881 —UN—29SEP99

2. Adjust timing position by increasing or decreasing the number of shims (8) between injection pump (5) and body (9).

3. When delaying timing, increase the number of shims (8). When advancing timing, decrease the number of shims.

IMPORTANT: All injection pumps must have equal number of shims.

NOTE: The crank angle will vary 1° per 0.1 mm shim.

5— Injection Pump 6— Nut (2 used) 7— Cap Screw (2 used)

8— Shim (As Required) 9— Body

OUT1738,0000029 -19-02JUL02-2/2

Adjust Fan Belt Tension SPECIFICATIONS Fan Belt 7—9 mm at 98N (0.28—0.35 in. at 22 lb)

SERVICE EQUIPMENT AND TOOLS JDG529 Belt Tension Gauge

1. Check belt regularly for wear. Replace if necessary 2. Remove wing nut to remove panel from behind seat.

T158632 —UN—19AUG02

Fan Belt Deflection

Check belt tension with belt deflection gauge at midway between crank (1) and fan pulley (2).

3. If deflection is not within specifications, loosen cap screws (4) for adjusting strap (5).

4. Move alternator (3) until tension is correct.

5. Tighten cap screws.

1— Crank 2— Fan Pulley 3— Alternator

4— Cap Screw (3 used) 5— Adjusting Strap

T121913 —UN—22JUN99

Fan Belt—Specification Fan Belt—Deflection............... 7—9 mm at 98N (0.28—0.35 in. at 22 lb)

OUT1738,000002A -19-02JUL02-1/1

TM2052 (17JUL18)

9010-25-5

27C ZTS and 35C ZTS Operation & Tests 071718 PN=69

Tests

Check and Adjust Engine Valve Lash (Clearance) SPECIFICATIONS Engine Valve Lash 0.15—0.25 mm (0.006—0.01 in)

T124878 —19—29SEP99

Intake and Exhaust Valve (cold) Clearance

NOTE: Engine must be cold before performing this procedure.

NOTE: Clean area around valve cover before removing.

1. Remove valve cover from engine.

NOTE: Remove glow plugs to ease flywheel rotation.

T124887 —19—30SEP99

NOTE: Number 1 cylinder is located at front of engine, the same end where the thermostat is located.

2. Rotate crank pulley until No. 1 cylinder is at TDC of the compression stroke. Align “Mark Groove” on the crank pulley with “TDC Mark” on the timing gear case cover.

3. Measure valve lash marked (O) per chart below.

4. Rotate crank pulley 360° to align “Mark Groove” and “TDC Mark” on timing gear case cover. This positions No. 1 cylinder at overlap.

Engine Valve Lash—Specification Intake and Exhaust Valve (cold)—Clearance.................................0.15—0.25 mm (0.006—0.01 in)

5. Measure valve lash marked (X) per chart below.

1

Cylinder No. Valve Cylinder No. 1 at top dead center Cylinder No. 1 at overlap

2

I

E

I

O

O

O

3 E

I

E O

X

X

6. If lash needs to be adjusted, loosen lock nut and adjust by turning adjusting screw. Tighten lock nut while holding adjusting screw.

Valve lash must be the same for both intake and exhaust valves.

OUT1738,000002B -19-10JUL17-1/1

TM2052 (17JUL18)

9010-25-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=70

Tests

Air Intake System Leakage Test SPECIFICATIONS Air Intake System 14—21 kPa (0.14—0.21 bar) (2—3 psi) T5906AP —UN—23FEB89

Air Intake System Pressure

SERVICE EQUIPMENT AND TOOLS Barb Fitting Tee Fitting 0-30 PSI Pressure Gauge Air Pressure Regulating Valve

1. Remove air cleaner cover and element.

2. Put large plastic bag into and over end of element as shown. Install element and cover.

T156490B —UN—24JUN02

3. Remove hose connected to air filter restriction switch at air cleaner.

4. Connect barb fitting (1) to hose.

5. Use shop fittings to connect hose to tee fitting (2).

6. Connect pressure gauge (4) and air pressure regulator (3) to tee fitting (2).

7. Connect air pressure regulator (3) to pressurized air source.

8. Pressurize air intake system to specification. If intake system cannot be pressurized, turn engine slightly to close valves.

27C ZTS shown 1— Barb Fitting 2— Tee Fitting

3— Air Pressure Regulator 4— 0-30 PSI Pressure Gauge

Air Intake System—Specification Air Intake System—Pressure.....................14—21 kPa (0.14—0.21 bar) (2—3 psi)

9. Spray soap solution over all connections from the air cleaner to air intake manifold. Check for leaks. Repair all leaks.

OUT1738,000002C -19-02JUL02-1/1

TM2052 (17JUL18)

9010-25-7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=71

Tests

Radiator Air Flow Test SPECIFICATIONS Radiator Air Flow Engine Speed

Fast Idle

Total Reading Voltage

Equal to or greater than 0.60 volts (typical new) ESSENTIAL TOOLS

JT05529 Air Flow Meter SERVICE EQUIPMENT AND TOOLS JT07306 Analog/Digital Multimeter

1. Lower all equipment to the ground.

2. Position all levers and pedals in neutral.

T155912B —UN—11JUN02

3. Stop the engine.

4. Straighten any bent fins in radiator or oil cooler.

5. Remove coolant overflow tank from radiator.

6. Mark off four squares as shown.

7. Connect air flow meter to analog/digital multimeter.

Set multimeter to AC volts.

8. Start engine and run it at fast idle.

Radiator Air Flow—Specification Engine—Speed.......................................................................... Fast Idle Continued on next page

TM2052 (17JUL18)

9010-25-8

OUT1738,000002D -19-02JUL02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=72

Tests

9. Put air flow meter against the radiator so it is centered in a square and air flow is through meter in the direction of air flow arrow.

IMPORTANT: This machine has a draw-in type fan blade.

10. Record voltage reading for each square.

11. Add the voltage readings. The total of readings must be equal to or greater than the specification.

Radiator Air Flow—Specification Total Reading—Voltage...........................................................Equal to or greater than 0.60 volts (typical new)

12. If readings are less than specification, clean the external surfaces of the oil cooler and radiator. Repeat test.

T6080AH —UN—01NOV88

NOTE: Metering air flow with meter reversed will result in approximately 55% of expected reading.

OUT1738,000002D -19-02JUL02-2/2

TM2052 (17JUL18)

9010-25-9

27C ZTS and 35C ZTS Operation & Tests 071718 PN=73

Tests

Engine Compression Pressure Test SPECIFICATIONS Engine Compression Pressure 2910 kPa (29.1 bar) (422 psi) T124892 —UN—29SEP99

Engine Compression Pressure

ESSENTIAL TOOLS Isuzu Part No. 5-8840-2675-0 Compression Gauge Isuzu Part No. 5-8840-9029-0 Adapter

1. Batteries must be fully charged.

2. Clean area around glow plugs.

3. Run engine until it reaches normal operating temperature.

4. Disconnect battery negative (-) terminal and engine stop solenoid connectors.

Engine Compression Pressure—Specification Engine Compression—Pressure.......................................... 2910 kPa (29.1 bar) (422 psi)

9. Readings should be approximately the same for each cylinder. A variation exceeding 200 kPa (2 bar) (29 psi) is not acceptable and must be corrected.

5. Remove all glow plugs from engine.

6. Reconnect battery negative terminal.

7. Connect adapter to compression gauge and install in a glow plug bore.

8. Crank engine until compression reading is stabilized.

Perform test three times for each cylinder and record readings.

• Inspect piston rings for broken or stuck rings.

• •

See Piston and Connecting Rod Repair. (Group 0400.)

Inspect cylinder linings for wear. See Cylinder Block Repair. (Group 0400.)

Inspect intake and exhaust valves for improper travel and fit. See Cylinder Head Repair. (Group 0400.)

OUT1738,000002E -19-13AUG14-1/1

TM2052 (17JUL18)

9010-25-10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=74

Tests

Engine Oil Pressure Test SPECIFICATIONS Engine Oil Pressure Engine Speed

Fast Idle

Engine Oil Pressure

448—515 kPa (4.48—5.15 bar) (65—75 psi) at fast idle ESSENTIAL TOOLS

JT05412 Industrial Universal Pressure Test Kit JT03017 Hose JT05487 Fitting SERVICE EQUIPMENT AND TOOLS JT03115 Pressure Gauge

NOTE: Before performing test, make sure oil filter is clean.

A dirty oil filter will limit the flow of filtered oil.

2. Shut off engine.

3. Remove engine oil pressure switch.

4. Install JT03115 gauge, JT03017 hose and JT05487 fitting from universal pressure test kit.

5. Start engine and run at specification.

T125877 —UN—22NOV99

1. Warm engine to normal operating temperature.

Engine Oil Pressure—Specification Engine—Speed.......................................................................... Fast Idle

6. Record oil pressure.

Engine Oil Pressure—Specification Engine Oil—Pressure........................................................ 448—515 kPa (4.48—5.15 bar) (65—75 psi) at fast idle OUT1738,000002F -19-02JUL02-1/1

TM2052 (17JUL18)

9010-25-11

27C ZTS and 35C ZTS Operation & Tests 071718 PN=75

Tests

Check for Head Gasket Failures Head gasket failures generally fall into three categories:

• Combustion seal failures.

• Coolant seal failures.

• Oil seal failures.

Combustion seal failures occur when combustion gases escape between cylinder head and head gasket combustion flange, or between combustion flange and cylinder liner. Leaking combustion gases may vent to an adjacent cylinder, to a coolant or oil passage, or externally.

Coolant or oil seal failures occur when oil or coolant escapes between cylinder head and gasket body, or between cylinder block and gasket body. The oil or coolant may leak to an adjacent coolant or oil passage, or externally. Since oil and coolant passages are primarily on right-hand (camshaft) side of engine, fluid leaks are most likely to occur in that area.

RG6432 —UN—03NOV97

Follow these diagnostic procedures when a head gasket joint failure occurs or is suspected.

1. Before starting or disassembling engine, conduct a visual inspection of machine and note any of the following:

• Oil or coolant in head gasket seam, or on adjacent

surfaces. Especially right rear corner of gasket joint

Diagnosing Head Gasket Joint Failures

• Displacement of gasket from normal position • Discoloration or soot from combustion gas leakage • Leaking radiator, overflow tank, or hoses • Leaking coolant from water pump weep hole • Damaged or incorrect radiator, fan, or shroud • Obstructed air flow or coolant flow • Worn or slipping belts • Damaged or incorrect pressure cap • Presence of oil in coolant • Low coolant levels or incorrect coolant • Unusually high or low oil levels • Oil degradation, dilution, or contamination • Incorrectly specified injection pump • Indications of fuel or timing adjustments • Unburned fuel or coolant in exhaust system

A—Combustion Sealing Area B—Oil Sealing Areas

4. Shut engine down. Recheck crankcase, radiator, and overflow tank for any significant differences in fluid levels, viscosity, or appearance.

5. Compare your observations from above steps with the diagnostic charts earlier in this group. If diagnostic evaluations provide conclusive evidence of combustion gas, coolant, or oil leakage from head gasket joint, the cylinder head must be removed for inspection and repair of gasket joint components. See Cylinder Head Repair for head gasket replacement. (Group 0400.)

2. Obtain coolant and oil samples for further analysis 3. Start and warm up engine if it can be safely operated.

Examine all potential leakage areas again as outlined previously. Using appropriate test and measurement equipment, check for the following:

• White smoke, excessive raw fuel, or moisture in exhaust system

• Rough, irregular exhaust sound, or misfiring • Air bubbles, gas trapped in radiator or overflow tank • Loss of coolant from overflow • Excessive cooling system pressure • Coolant overheating • Low coolant flow • Loss of cab heating (air lock)

COMBUSTION SEAL LEAKAGE Symptoms:

• Exhaust from head gasket crevice • Air bubbles in radiator or overflow tank • Coolant discharge from overflow tube • Engine overheating • Power loss • Engine runs rough • White exhaust smoke • Loss of cab heat • Gasket section dislodged, missing (blown) • Coolant in cylinder • Coolant in crankcase oil • Low coolant level

Continued on next page

TM2052 (17JUL18)

C—Coolant Sealing Areas

9010-25-12

OUT1738,00000A4 -19-15AUG02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=76

Tests

Possible Causes:

• Excessive liner standout differential between cylinders • Low head bolt clamping loads • Out-of-flat/damaged/rough block surface • Out-of-flat/damaged/rough cylinder head surface • Oil or coolant overheating • Cracks/creases in gasket body surfaces • Damage/voids in elastomer beading

• Insufficient liner standout • Excessive liner standout differential between cylinders • Low head bolt clamping loads • Rough/damaged liner flange surface • Cracked/deformed gasket combustion flange • Out-of-flat/damaged/rough cylinder head surface OIL SEAL LEAKAGE • Missing/mislocated gasket fire ring Symptoms: • Block cracked in liner support area • Excessive fuel delivery • Oil discharge from head gasket crevice • Advanced injection pump timing Oil in coolant • • Hydraulic or mechanical disturbance of combustion seal • Low crankcase oil level NOTE: Cracked cylinder head or liners may also allow • Reduced oil to rocker arms (noisy) combustion gas leakage into coolant.

COOLANT SEAL LEAKAGE Symptoms:

• Coolant discharge from head gasket crevice • Coolant in crankcase oil • Low coolant level • High oil level • Coolant discharge from crankcase vent Possible Causes:

Possible Causes:

• Excessive liner standout • Excessive liner standout differential between cylinders • Low head bolt clamping loads • Out-of-flat/damaged/rough block surface • Out-of-flat/damaged/rough cylinder head surface • Oil or coolant overheating • Cracks/creases in gasket body surfaces • Damage/voids in elastomer beading • Damaged/missing O-ring seal at oil port to rocker arms

• Excessive liner standout OUT1738,00000A4 -19-15AUG02-2/2

TM2052 (17JUL18)

9010-25-13

27C ZTS and 35C ZTS Operation & Tests 071718 PN=77

Tests

TM2052 (17JUL18)

9010-25-14

27C ZTS and 35C ZTS Operation & Tests 071718 PN=78

Section 9015 Electrical System Contents Page Page

Group 05—System Information Electrical Diagram Information .................. 9015-05-1 Group 10—System Diagrams Explanation of Wire Markings....................9015-10-1 Fuse Specifications ........................................9015-10-1 Component Location Drawing Cab, Frame and Engine Legend ...........9015-10-2 System Functional Schematic ................... 9015-10-5 Main Harness (W1) Component Location ................................................. 9015-10-9 Main Harness (W1) Wiring Diagram ............................................... 9015-10-12 Floor Harness (W2) Component Location ............................................... 9015-10-15 Floor Harness (W2) Wiring Diagram ............................................... 9015-10-19 Engine Harness (W3) Component Location ............................................... 9015-10-22 Engine Harness (W3) Wiring Diagram ............................................... 9015-10-24 Cab Harness (W5) Component Location ............................................... 9015-10-27 Cab Harness (W5) Wiring Diagram ............................................... 9015-10-30 Heater Harness (W10) Wiring Diagram ............................................... 9015-10-32 Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12) Component Location ............................................... 9015-10-35 Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12) Wire Diagram ............. 9015-10-39

Battery Remove and Install ..................... 9015-20-10 Propel Alarm Cancel Switch Remove and Install.............................. 9015-20-11 Key Switch Remove and Install ............... 9015-20-13 Monitor Controller and Display (A5) Remove and Install.............................. 9015-20-15 Glow Plug Timer Remove and Install ................................................... 9015-20-17 Tab Retainer Connectors Disconnecting......................................9015-20-18 Spring Wire Retainer Connector Disconnecting......................................9015-20-19 Replace DEUTSCH™ Connectors .......................................... 9015-20-19 Install DEUTSCH™ Contacts .................. 9015-20-20 Replace WEATHER PACK™ Connector ............................................ 9015-20-21 Install WEATHER PACK™ Contacts .............................................. 9015-20-22 Remove Connector Body from Blade Terminals ................................... 9015-20-23

Group 15—Sub-System Diagnostics Starting and Charging Circuit Theory of Operation............................... 9015-15-1 Monitor Controller Circuit Theory of Operation ..............................9015-15-3 Pilot Control Shut-Off Circuit Theory of Operation............................... 9015-15-8 Propel Alarm Circuit Theory of Operation ............................9015-15-10 Group 20—References Fuse Test ................................................... 9015-20-1 Relay Test.................................................. 9015-20-1 Pressure Sensor Test ................................ 9015-20-2 Solenoid Test ............................................. 9015-20-2 Temperature Sensor Test .......................... 9015-20-3 Electrical Component Checks ................... 9015-20-3 Component Checks ...................................9015-20-3 TM2052 (17JUL18)

9015-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=1

Contents

TM2052 (17JUL18)

9015-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=2

Group 05

System Information Electrical Diagram Information NOTE: All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key switch in the OFF position.

Continued on next page

TM2052 (17JUL18)

9015-05-1

TX13067,000013B -19-27NOV01-1/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=81

System Information

T128818 —UN—16MAR09

System Functional Schematic Diagram

Continued on next page

TM2052 (17JUL18)

9015-05-2

TX13067,000013B -19-27NOV01-2/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=82

System Information 1— Continuity Chart 4— Wire Identification 2— Power Wires 5— Ground Wires 3— Routing Location Information 6— Circuit Name 7— Section Number

8— Component Name 9— Component Identification Number 10— Component Schematic Symbol

The System Functional Schematic is made up of equal sections to simplify searching. Each section of the System Functional Schematic is assigned a number (7). The System Functional Schematic is formatted with power supply wires (2) shown across the top of the drawing and ground wires (5) across the bottom. The schematic contains no harness or connector information.

Each electrical component is shown by a schematic symbol (10), the component name (8), and a component identification number (9). A component identification number and name will remain the same throughout the Operation and Test Technical Manual. This will allow

for easy cross-referencing of all electrical drawings (Schematics, Wiring Diagrams, and Component Location).

A continuity chart (1) is included for each multi-terminal switch.

Routing location information (3) is presented to let the reader know when a wire is connected to a component in another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a different location. The section and component number are given in parenthesis at the bottom of the statement.

In the example, power is going TO component F15 Horn Fuse, in section SE15.

Continued on next page

TM2052 (17JUL18)

9015-05-3

TX13067,000013B -19-27NOV01-3/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=83

System Information

T128819 —UN—16JUN09

Wiring Diagram—If Provided

Continued on next page

TM2052 (17JUL18)

9015-05-4

TX13067,000013B -19-27NOV01-4/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=84

System Information 1— Harness Connector Pin Letter 4— Wire Color or Number or Number 5— Component Identification 2— Harness Connector Number Number Wire is Routed TO Identification 6— Component Connector 3— Component Identification Number

7— Component Connector Pin Letter or Number 8— Wiring Harness 9— Component Identification Number Wire is Routed TO

Each harness on the machine is drawn showing components, connectors, and wires. Harnesses are identified by a “W” component identification number and description (W6 ENGINE HARNESS, Etc.).

Component Location Diagram

Each component is represented by a schematic symbol and is identified by a component identification number and name (3). Components with integral connectors (6) have pin number/letters indicated (7). Wires from harness to components are identified by color or number designation (4). Component identification number (5) indicates the component a wire is routed TO. Main harness connectors (2) are identified by a “X” component identification number and description (X28 CAB TO ENGINE BULKHEAD CONNECTOR, Etc.).

Harness connector description indicates which harnesses connect together. Connector pin letters or numbers (1) are indicated as they are marked on the connector. Wires attached to each connector pin are identified by color or number (10). Component identification number (9) indicates destination of each wire.

The Component Location Diagram is a pictorial view by harness showing location of all electrical components, connectors, harness main ground locations and harness band and clamp location. Each component will be identified by the same identification letter/number and description used in the System Functional Schematic Diagram.

Connector End View Diagram—If Provided The Connector End View Diagram is a pictorial end view of the component connectors showing the number of pins in the connector and the wire color and identifier of the wire in every connector. Each component will be identified by the same identification letter/number and description used in the System Functional Schematic Diagram.

Continued on next page

TM2052 (17JUL18)

10— Wire Color or Number

9015-05-5

TX13067,000013B -19-27NOV01-5/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=85

System Information

TM2052 (17JUL18)

9015-05-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=86

System Information

Electrical Schematic Symbols T143000 —UN—21JUN01

TX13067,000013B -19-27NOV01-6/6 TM2052 (17JUL18)

9015-05-7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=87

System Information

TM2052 (17JUL18)

9015-05-8

27C ZTS and 35C ZTS Operation & Tests 071718 PN=88

System Information 1— Battery 2— Wire Splice 3— Fuse 4— Circuit Breaker 5— Fusible Link 6— Power Outlet 7— Alternator 8— Air Conditioner Compressor 9— Compressor 10— Liquid Pump 11— Antenna 12— Diode 13— Zener Diode 14— Capacitor 15— Magnet 16— Flasher 17— Buzzer 18— Horn 19— Alarm 20— Clock 21— Internal Ground 22— Single Point Ground 23— External Ground 24— Sensor 25— Sensor with Normally Open Switch 26— Speed Sensor 27— Rotary Sensor 28— Single Element Bulb 29— Dual Element Bulb

30— Solenoid Operated Hydraulic Valve With Suppression Diode 31— Solenoid Normally Open 32— Solenoid Normally Closed 33— Starter Motor 34— Starter Motor 35— DC Motor 36— DC Stepping Motor 37— Wiper Motor 38— Blower Motor 39— Servo Motor 40— Speedometer 41— Tachometer 42— Temperature Gauge 43— Liquid Level Gauge 44— Gauge 45— Hourmeter 46— Resistor 47— Variable Resistor 48— Manually Adjusted Variable Resistor 49— Multi-Pin Connector 50— Single Pin Connector

51— Connector 52— 4 Pin Relay 53— 5 Pin Relay 54— 5 Pin Relay With Internal Suppression Diode 55— 5 Pin Relay With Internal Suppression Resistor 56— Key Switch 57— Temperature Switch Normally Open 58— Temperature Switch Normally Closed 59— Pressure Switch Normally Open 60— Pressure Switch Normally Closed 61— Liquid Level Switch Normally Open 62— Liquid Level Switch Normally Closed 63— Momentary Switch Normally Open 64— Momentary Switch Normally Closed 65— Toggle Switch Normally Open

66— Toggle Switch Normally Closed 67— 2 Way Toggle Switch Normally Open 68— 2 Way Toggle Switch Normally Closed 69— Manual Switch Operation 70— Push Switch Operation 71— Pull Switch Operation 72— Turn Switch Operation 73— Toggle Switch Operation 74— Pedal Switch Operation 75— Key Switch Operation 76— Detent Switch Operation 77— Temperature Sensor 78— Solar Sensor 79— Pressure Sensor 80— Liquid Level Sensor

TX13067,000013B -19-27NOV01-7/6

TM2052 (17JUL18)

9015-05-9

27C ZTS and 35C ZTS Operation & Tests 071718 PN=89

System Information

TM2052 (17JUL18)

9015-05-10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=90

Group 10

System Diagrams Explanation of Wire Markings Electrical harness wires are identified by color, with no number stamped on wire. Wire numbers are used on some connector drawings simply as reference numbers, useful in tracing wires through the harness.

Some wires are solid wire colors. These would be identified by one color name such as Red or Blk or Grn. Other wire colors are identified with two color names.

These are solid wires with a narrow stripe. For example, a wire identified as Red/Wht would be a primarily Red wire, with a Wht stripe. A wire identified as Wht/Red would be a primarily Wht wire with a Red stripe.

Following is a listing of wire color abbreviations used on drawings.

• Blu—Blue • Brn—Brown • Grn—Green • Gry—Grey • LtGrn—Light Green • Org—Orange • Pnk—Pink • Pur—Purple • Red—Red • Vlt—Violet • Wht—White • Yel—Yellow A limited number of wire colors are not available at time of first production. In those cases the wire is identified by a number only. Wire color will be added as soon as it is available.

• Blk—Black TX13067,000013C -19-27NOV01-1/1

Fuse Specifications

20A

5A

5A 5A

10A 10A 10A 15A 20A 5A 5A 5A

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10

T155450 —UN—31MAY02

F8— Fuel Pump 5 Amp Fuse F9— Propel Alarm 5 Amp Fuse F10— Monitor Controller and Display 5 Amp Fuse F11— Back-Up Power 5 Amp Fuse F12— Auto Idle 5 Amp Fuse (Not Used) F13— Radio 5 Amp Fuse (Field Option)

F13

5A

20A

F1— Pilot Control Shut-Off 5 Amp Fuse F2— Drive and Boom Work Light 20 Amp Fuse F3— Horn 10 Amp Fuse F4— 12V Power Outlet 10 Amp Fuse F5— Engine Power 10 Amp Fuse F6— Heater and Wiper 15 Amp Fuse F7— Not Used

F12

5A

10A

Fuse block is located in the toolbox and operator manual compartment.

F11

15A

IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload.

CED,OUOE003,1914 -19-30AUG99-1/1

TM2052 (17JUL18)

9015-10-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=91

System Diagrams

Functional Schematic and Component Location Master Legend

• A5 — Monitor Controller and Display (SE4)(W2) • A8 — Starter Protection Controller (SE2)(W2) • A10 — Propel Alarm Controller (SE8)(W11) • B4 — Engine Oil Pressure Switch (SE3)(W3) • B9 — Coolant Temperature Gauge Sensor (SE3)(W3) • B10 — Glow Plug Timer (SE2)(W2) • B15 — Left Propel Pressure Sensor (SE9)(W11) • B16 — Right Propel Pressure Sensor (SE9)(W11) • B24 — Left Speaker (SE7)(W5) • B25 — Horn (SE5)(W1) • B46 — Coolant Overheat Switch (SE2)(W3) • B53 — Glow Timer Engine Coolant Sensor (SE2)(W3) • E2 — Drive Light (SE5)(W1) • E3 — Cab Dome Light (SE6)(W5) • E4 — Monitor Controller and Display Backlight (SE4)(W2)

• E12 — Boom Work Light (SE5)(W1) • F1 — Pilot Shut-Off 5 Amp Fuse (SE4)(W2) • F2 — Drive and Boom Work Light 20 Amp Fuse (SE5)(W2)

• F3 — Horn 10 Amp Fuse (SE5)(W2) • F4 — 12V Power Outlet 10 Amp Fuse (SE8)(W2) • F5 — Engine Power 10 Amp Fuse (SE1)(W2) • F6 — Heater and Wiper 15 Amp Fuse (SE6)(W2) • F7 — Not Used (SE6)(W2) • F8 — Fuel Pump 5 Amp Fuse (SE1)(W2) • F9 — Propel Alarm 5 Amp Fuse (SE8)(W2) • F10 — Monitor Controller and Display 5 Amp Fuse (SE3)(W2)

• F11 — Back-Up Power 5 Amp Fuse (SE3)(W2) • F12 — Auto Idle 5 Amp Fuse (Not Used)(SE4)(W2) • F13 — Radio 5 Amp Fuse (Field Option)(SE6)(W2) • F19 — Radio 5 Amp In-Line Fuse (Field • • • • • • • • • • • • • • • • • • • • • • • •

Option)(SE7)(W5) F21 — Battery Power 45 Amp Fusible Link (SE1)(W1) F22 — Alternator 45 Amp Fusible Link (SE1)(W1) F27 — Radio Backup Inline 1 Amp Fuse (Field Option)(SE6)(W5) G1 — Battery (SE1)(W1) G3 — Alternator (SE2)(W3) G4 — 12V Power Outlet (SE8)(W2) H3 — Propel Alarm (SE9)(W11) H8 — Monitor Controller and Display Alarm (SE4)(W2) H9 — Glow Plug Indicator (SE4)(W2) H17 — Engine Oil Pressure Indicator (SE3)(W2) H18— Alternator Indicator (SE3)(W2) K3 — Drive and Boom Work Light Relay (SE5)(W2) K5 — Horn Relay (SE5)(W2) K12 — Starter Relay (SE1)(W2) K29 — Glow Plug Relay (SE2)(W2) M1 — Starter (SE1)(W3) M3 — Windshield Wiper Motor (SE7)(W5) M4 — Windshield Washer Motor (SE8)(W5) M5 — Heater Blower Motor (SE8)(W10) R5 — Fuel Level Sender (SE3)(W1) R12 — Glow Plug (SE2)(W3) R13 — Glow Plug (SE2)(W3) R14 — Glow Plug (SE2)(W3) R15 — Glow Plug (50C ZTS Only)(SE2)(W3)

• S1 — Key Switch (SE1)(W2) • S2 — Horn Switch (SE5)(W2) • S3 — Dome Light Switch (SE7)(W5) • S4 — Heater Blower Motor Switch (SE7)(W10) • S6 — Drive and Boom Work Light Switch (SE4)(W2) • S8 — Propel Speed Switch (SE5)(W2) • S9 — Windshield Wiper and Washer Switch (SE8)(W5) • S10 — Propel Alarm Cancel Switch (SE9)(W11) • S21 — Left Pilot Shut-Off Switch (SE4)(W2) • W1 — Main Harness • W2 — Floor Harness • W3 — Engine Harness • W4 — Antenna • W5 — Cab Harness • W6 — Main Harness Ground • W7 — Battery to Frame Ground • W8 — Engine to Frame Ground • W11 — Propel Alarm Harness • W12 — Propel Alarm Cancel Switch Harness • X1 — Main Harness to Floor Harness 11 Pin Connector (W1, W2)

• X2 — Engine Harness to Floor Harness 8 Pin Connector (W2, W3)

• X3 — Floor Harness to Monitor Controller and Display Harness 12 Pin Connector (SE3)(W2)

• X4 — Floor Harness to Cab Harness 10 Pin Connector (SE6)(W2, W5)

• X5 — Floor Harness to Engine Harness 4 Pin Connector (W2, W3)

• X6 — Engine Harness to Main Harness 1 Pin Connector (W1, W3)

• X7 — Engine Harness to Fuel Transfer Pump 2 Pin Connector (W3)

• X8 — Engine Harness to Fuel Shut-Off Solenoid 3 Pin Connector (W3)

• X9 — Engine Harness to Alternator 3 Pin Connector (W3)

• X10 — Main Harness to Floor Harness 1 Pin Connector (W1, W2)

• X11 — Main Harness to Battery 2 Pin Connector (W1) • X12 — Main Harness to Pilot Shut-Off Solenoid (W1) • X13 — Main Harness to Propel Speed Change Solenoid (W1)

• X14 — Main Harness to Alternator Fusible Link 2 Pin Connector (W1)

• X15 — Main Harness to Battery Power Fusible Link 2 Pin Connector (W1)

• X16 — SATE 3 Pin Connector (Not Used)(SE8)(W2, W5) • X17 — Floor Harness to Heater Harness 2 Pin Connector (SE7)(W2, W5)

• X18 — Starter Protection Controller to Floor Harness 4 Pin Connector (W2)

• X19 — Glow Plug Timer to Floor Harness 6 Pin Connector (W2)

• X20 — Glow Plug Relay to Floor Harness 2 Pin Connector (W2)

• X21 — Floor Harness to Left Pilot Control Shut-Off Switch 2 Pin Connector (W2)

Continued on next page

TM2052 (17JUL18)

9015-10-2

CED,OUOE011,1 -19-15NOV99-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=92

System Diagrams

• X22 — Floor Harness to Right Pilot Control Shut-Off

• X31 — Air Conditioner Harness 3 Pin Connector

•

• X32 — Fuse Block (W2) • X33 — Propel Alarm Harness to Propel Alarm Cancel

• • • • •

Switch Jumper 2 Pin Connector (SE4)(W2) X23 — Main Harness to Fuel Level Sender 3 Pin Connector (W1) X24 — PAT Connector (Not Used)(SE8)(W2) X25 — Floor Harness to Propel Alarm Harness Connector (W2, W11) X26 — 12V Power Outlet Connector (W2) X29 — Floor Harness to Auto Idle 1 Pin Connector (SE4)(W2) X30 — Floor Harness to Auto Idle 1 Pin Connector (SE4)(W2)

(SE6)(W5)

Switch Harness Connector (SE9)(W11)

• X34 — Radio to Cab Harness Connector (SE7)(W5) • X35 — Radio Harness to Right Speaker Connector (SE7)(W5)

• Y6 — Propel Speed Solenoid (SE5)(W1) • Y7 — Fuel Shut-Off Solenoid (SE2)(W3) • Y8 — Pilot Control Shut-Off Solenoid (SE4)(W1) • Y14 — Fuel Transfer Pump (SE1)(W3) CED,OUOE011,1 -19-15NOV99-2/2

TM2052 (17JUL18)

9015-10-3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=93

System Diagrams

TM2052 (17JUL18)

9015-10-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=94

System Diagrams

System Functional Schematic T215314 —19—04OCT05

CED,OUOE003,1508 -19-05OCT05-1/3

Continued on next page

TM2052 (17JUL18)

9015-10-5

27C ZTS and 35C ZTS Operation & Tests 071718 PN=95

System Diagrams

T215315 —19—04OCT05

CED,OUOE003,1508 -19-05OCT05-2/3

Continued on next page

TM2052 (17JUL18)

9015-10-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=96

System Diagrams

T215316 —19—04OCT05

CED,OUOE003,1508 -19-05OCT05-3/3

TM2052 (17JUL18)

9015-10-7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=97

System Diagrams

TM2052 (17JUL18)

9015-10-8

27C ZTS and 35C ZTS Operation & Tests 071718 PN=98

System Diagrams

Main Harness (W1) Component Location T155001 —UN—21JUN02

E12

Y8 X13

Y6 X12

X10 E2 X1

B25 W6 X14 X15

S8

F22 F21 X11

X23

X6 R5 T155001

TX18160,0000077 -19-24APR02-1/2

Continued on next page

TM2052 (17JUL18)

9015-10-9

27C ZTS and 35C ZTS Operation & Tests 071718 PN=99

System Diagrams

TM2052 (17JUL18)

9015-10-10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=100

System Diagrams B25— Horn E2— Drive Light E12— Boom Work Light R5—Fuel Level Sender S8— Propel Speed Switch W6—Main Harness Ground X1— Main Harness to Floor Harness 11 Pin Connector

X6— Engine Harness to Main X13— Main Harness to Propel X23— Main Harness to Fuel Level Harness 1 Pin Connector Speed Change Solenoid Sender 3 Pin Connector X10— Main Harness to Floor X14— Main Harness to Alternator Y6— Propel Speed Solenoid Harness 1 Pin Connector Fusible Link 2 Pin Y8— Pilot Control Shut-Off X11— Main Harness to Battery 2 Connector Solenoid Pin Connector X15— Main Harness to Battery X12— Main Harness to Pilot Power Fusible Link 2 Pin Control Shut-Off Solenoid Connector TX18160,0000077 -19-24APR02-2/2

TM2052 (17JUL18)

9015-10-11

27C ZTS and 35C ZTS Operation & Tests 071718 PN=101

System Diagrams

T155009 —UN—30MAY02

Main Harness (W1) Wiring Diagram

Continued on next page

TM2052 (17JUL18)

9015-10-12

TX18160,0000078 -19-24APR02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=102

System Diagrams B25— Horn E2— Drive Light E12— Boom Work Light F21— Battery Power 45 Amp Fusible Link F22— Alternator 45 Amp Fusible Link G1—Battery R5—Fuel Level Sender S8— Propel Speed Switch W6—Main Harness Ground

W8—Engine to Frame Ground X1— Main Harness to Floor Harness 11 Pin Connector X6— Engine Harness to Main Harness 1 Pin Connector X10— Main Harness to Floor Harness 1 Pin Connector X11— Main Harness to Battery 2 Pin Connector

Trace wires through the following mating connectors and machine harnesses:

• X1—See Floor Harness (W2) Wiring Diagram. (Group 9015-10)

X12— Main Harness to Pilot X23— Main Harness to Fuel Level Control Shut-Off Solenoid Sender 3 Pin Connector X13— Main Harness to Propel Y6— Propel Speed Solenoid Speed Change Solenoid Y8— Pilot Control Shut-Off X14— Main Harness to Alternator Solenoid Fusible Link 2 Pin Connector X15— Main Harness to Battery Power Fusible Link 2 Pin Connector

• X6—See Engine Harness (W3) Wiring Diagram. (Group 9015-10)

• X10—See Floor Harness (W2) Wiring Diagram. (Group 9015-10)

TX18160,0000078 -19-24APR02-2/2

TM2052 (17JUL18)

9015-10-13

27C ZTS and 35C ZTS Operation & Tests 071718 PN=103

System Diagrams

TM2052 (17JUL18)

9015-10-14

27C ZTS and 35C ZTS Operation & Tests 071718 PN=104

System Diagrams

Floor Harness (W2) Component Location T155046 —UN—30MAY02

S2

S1

X22 X32 A5

K29

G4

X26 K12 B10

S21

X19

K3

X3 X21

X20

K5 A8

X30 X29

X18

X4 X10 X1 X2 X5 X25 X16 X24

X17

T155046

TX18160,0000079 -19-24APR02-1/2

Continued on next page

TM2052 (17JUL18)

9015-10-15

27C ZTS and 35C ZTS Operation & Tests 071718 PN=105

System Diagrams

TM2052 (17JUL18)

9015-10-16

27C ZTS and 35C ZTS Operation & Tests 071718 PN=106

System Diagrams

A5—Monitor Controller and Display A8—Starter Protection Controller B10— Glow Plug Timer G4—12V Power Outlet K3—Drive and Boom Work Light Relay K5—Horn Relay K12— Starter Relay K29— Glow Plug Relay S1— Key Switch S2— Horn Switch S21— Left Pilot Control Shut-Off Switch X1— Main Harness to Floor Harness 11 Pin Connector

X2— Engine Harness to Floor Harness 8 Pin Connector X3— Floor Harness to Monitor Controller and Display Harness 12 Pin Connector X4— Floor Harness to Cab Harness 10 Pin Connector X5— Floor Harness to Engine Harness 4 Pin Connector X10— Main Harness to Floor Harness 1 Pin Connector X16— SATE 3 Pin Connector (Not Used) X17— Floor Harness to Heater Harness 2 Pin Connector

X18— Starter Protection Controller to Floor Harness 4 Pin Connector X19— Glow Plug Timer to Floor Harness 6 Pin Connector X20— Glow Plug Relay to Floor Harness 2 Pin Connector X21— Floor Harness to Left Pilot Control Shut-Off Switch 2 Pin Connector X22— Floor Harness to Right Pilot Control Shut-Off Jumper 2 Pin Connector X24— PAT Connector (Not Used)

X25— Floor Harness to Propel Alarm Harness Connector X26— 12V Power Outlet Connector X29— Floor Harness to Auto Idle Harness 1 Pin Connector (Not Used) X30— Floor Harness to Auto Idle Harness 1 Pin Connector (Not Used) X32— Fuse Block

TX18160,0000079 -19-24APR02-2/2

TM2052 (17JUL18)

9015-10-17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=107

System Diagrams

TM2052 (17JUL18)

9015-10-18

27C ZTS and 35C ZTS Operation & Tests 071718 PN=108

System Diagrams

Floor Harness (W2) Wiring Diagram T155006 —UN—30MAY02

TX18160,000007A -19-24APR02-1/2

Continued on next page

TM2052 (17JUL18)

9015-10-19

27C ZTS and 35C ZTS Operation & Tests 071718 PN=109

System Diagrams

TM2052 (17JUL18)

9015-10-20

27C ZTS and 35C ZTS Operation & Tests 071718 PN=110

System Diagrams

A5—Monitor Controller and Display A8—Starter Protection Controller B10— Glow Plug Timer E4— Monitor Controller and Display Backlight F1— Pilot Shut-Off 5 Amp Fuse F2— Drive and Boom Work Light 20 Amp Fuse F3— Horn 10 Amp Fuse F4— 12V Power Outlet 10 Amp Fuse F5— Engine Power 10 Amp Fuse F6— Heater and Wiper 15 Amp Fuse F7— Not Used F8— Fuel Pump 5 Amp Fuse F9— Propel Alarm 5 Amp Fuse F10— Monitor Controller and Display 5 Amp Fuse

F11— Back-Up Power 5 Amp Fuse F12— Auto Idle 5 Amp Fuse (Not Used) F13— Radio 5 Amp Fuse (Field Option) G4—12V Power Outlet H8—Monitor Controller and Display Alarm H9—Glow Plug Indicator H17— Engine Oil Pressure Indicator H18— Alternator Indicator K3—Drive and Boom Work Light Relay K5—Horn Relay K12— Starter Relay K29— Glow Plug Relay S1— Key Switch S2— Horn Switch S6— Drive and Boom Work Light Switch S21— Left Pilot Control Shut-Off Switch

Trace wires through the following mating connectors and machine harnesses:

• X1—See Main Harness (W1) Wiring Diagram. (Group • •

9015-10) X2—See Engine Harness (W3) Wiring Diagram. (Group 9015-10) X4—See Cab Harness (W5) Wiring Diagram. (Group 9015-10)

X1— Main Harness to Floor Harness 11 Pin Connector X2— Engine Harness to Floor Harness 8 Pin Connector X3— Floor Harness to Monitor Controller and Display Harness 12 Pin Connector X4— Floor Harness to Cab Harness 10 Pin Connector X5— Floor Harness to Engine Harness 4 Pin Connector X10— Main Harness to Floor Harness 1 Pin Connector X16— SATE 3 Pin Connector (Not Used) X17— Floor Harness to Heater Harness 2 Pin Connector

X21— Floor Harness to Left Pilot Control Shut-Off Switch 2 Pin Connector X22— Floor Harness to Right Pilot Control Shut-Off Jumper 2 Pin Connector X24— PAT Connector (Not Used) X25— Floor Harness to Propel Alarm Harness Connector X29— Floor Harness to Auto Idle Harness 1 Pin Connector (Not Used) X30— Floor Harness to Auto Idle Harness 1 Pin Connector (Not Used)

• X5—See Engine Harness (W3) Wiring Diagram. (Group 9015-10)

• X10—See Main Harness (W1) Wiring Diagram. (Group 9015-10)

• X17—See Heater Harness (W10) Wiring Diagram.

(Group 9015-10)

TX18160,000007A -19-24APR02-2/2

TM2052 (17JUL18)

9015-10-21

27C ZTS and 35C ZTS Operation & Tests 071718 PN=111

System Diagrams

Engine Harness (W3) Component Location

B46

B53 B9

X2 R12

X5

R13 R14

X6

G3 X9 M1

Y7 X8

B4

Y14

T155011 —UN—21JUN02

X7

T155011

Continued on next page

TM2052 (17JUL18)

9015-10-22

TX18160,000007B -19-24APR02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=112

System Diagrams B4—Engine Oil Pressure Switch B9—Coolant Temperature Gauge Sensor B46— Coolant Overheat Switch B53— Glow Timer Engine Coolant Sensor G3—Alternator

M1—Starter R12— Glow Plug R13— Glow Plug R14— Glow Plug X2— Engine Harness to Floor Harness 8 Pin Connector X5— Floor Harness to Engine Harness 4 Pin Connector

X6— Engine Harness to Main Harness 1 Pin Connector X7— Engine Harness to Fuel Transfer Pump 2 Pin Connector X8— Engine Harness to Fuel Shut-Off Solenoid 3 Pin Connector

X9— Engine Harness to Alternator 3 Pin Connector Y7— Fuel Shut-Off Solenoid Y14— Fuel Transfer Pump

TX18160,000007B -19-24APR02-2/2

TM2052 (17JUL18)

9015-10-23

27C ZTS and 35C ZTS Operation & Tests 071718 PN=113

System Diagrams

T155008 —UN—28AUG02

Engine Harness (W3) Wiring Diagram

Continued on next page

TM2052 (17JUL18)

9015-10-24

TX18160,000007C -19-24APR02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=114

System Diagrams B4—Engine Oil Pressure Switch B9—Coolant Temperature Gauge Sensor B46— Coolant Overheat Switch B53— Glow Timer Engine Coolant Sensor G3—Alternator M1—Starter

X6— Engine Harness to Main R12— Glow Plug Harness 1 Pin Connector R13— Glow Plug X7— Engine Harness to Fuel R14— Glow Plug Transfer Pump 2 Pin R15— Glow Plug (50C ZTS Only) Connector X2— Engine Harness to Floor X8— Engine Harness to Fuel Harness 8 Pin Connector Shut-Off Solenoid 3 Pin X5— Floor Harness to Engine Connector Harness 4 Pin Connector

Trace wires through the following mating connectors and machine harnesses:

• X2—See Floor Harness (W2) Wiring Diagram. (Group 9015-10)

X9— Engine Harness to Alternator 3 Pin Connector Y7— Fuel Shut-Off Solenoid Y14— Fuel Transfer Pump

• X5—See Floor Harness (W2) Wiring Diagram. (Group 9015-10)

• X6—See Main Harness (W1) Wiring Diagram. (Group 9015-10)

TX18160,000007C -19-24APR02-2/2

TM2052 (17JUL18)

9015-10-25

27C ZTS and 35C ZTS Operation & Tests 071718 PN=115

System Diagrams

TM2052 (17JUL18)

9015-10-26

27C ZTS and 35C ZTS Operation & Tests 071718 PN=116

System Diagrams

Cab Harness (W5) Component Location T155316 —UN—30MAY02

X35 E3 B24 F27 S3

W4

X34 F19

M3

X4 M4 S9

X31

T155316

TX18160,000007D -19-24APR02-1/2

Continued on next page

TM2052 (17JUL18)

9015-10-27

27C ZTS and 35C ZTS Operation & Tests 071718 PN=117

System Diagrams

TM2052 (17JUL18)

9015-10-28

27C ZTS and 35C ZTS Operation & Tests 071718 PN=118

System Diagrams

B24— Left Speaker E3— Cab Dome Light F19— Radio 5 Amp In-Line Fuse (Field Option) F27— Radio Backup Inline 1 Amp Fuse (Field Option)

M3—Windshield Wiper Motor M4—Windshield Washer Motor S3— Dome Light Switch S9— Windshield Wiper and Washer Switch

W4—Antenna X35— Radio Harness to Right X4— Floor Harness to Cab Speaker Connector Harness 10 Pin Connector X31— Air Conditioner Harness 3 Pin Connector X34— Radio to Cab Harness Connector TX18160,000007D -19-24APR02-2/2

TM2052 (17JUL18)

9015-10-29

27C ZTS and 35C ZTS Operation & Tests 071718 PN=119

System Diagrams

T155007 —UN—30MAY02

Cab Harness (W5) Wiring Diagram

Continued on next page

TM2052 (17JUL18)

9015-10-30

TX18160,000007E -19-24APR02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=120

System Diagrams B24— Left Speaker E3— Cab Dome Light F19— Radio 5 Amp In-Line Fuse (Field Option) F27— Radio Backup Inline 1 Amp Fuse (Field Option)

M3—Windshield Wiper Motor M4—Windshield Washer Motor S3— Dome Light Switch S9— Windshield Wiper and Washer Switch

Trace wires through the following mating connectors and machine harnesses:

X35— Radio Harness to Right X4— Floor Harness to Cab Speaker Connector Harness 10 Pin Connector X31— Air Conditioner Harness 3 Pin Connector X34— Radio to Cab Harness Connector

• X4—See Floor Harness (W2) Wiring Diagram. (Group 9015-10)

TX18160,000007E -19-24APR02-2/2

TM2052 (17JUL18)

9015-10-31

27C ZTS and 35C ZTS Operation & Tests 071718 PN=121

System Diagrams

T155004 —UN—30MAY02

Heater Harness (W10) Wiring Diagram

M5—Heater Blower Motor X17— Floor Harness to Heater S4— Heater Blower Motor Switch Harness 2 Pin Connector Continued on next page

TM2052 (17JUL18)

9015-10-32

TX18160,0000086 -19-24APR02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=122

System Diagrams Trace wires through the following mating connectors and machine harnesses:

• X17—See Floor Harness (W2) Wiring Diagram. (Group 9015-10)

TX18160,0000086 -19-24APR02-2/2

TM2052 (17JUL18)

9015-10-33

27C ZTS and 35C ZTS Operation & Tests 071718 PN=123

System Diagrams

TM2052 (17JUL18)

9015-10-34

27C ZTS and 35C ZTS Operation & Tests 071718 PN=124

System Diagrams

Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12) Component Location T155220 —UN—30MAY02

A10

S10

W12

B16 B15 W11 X33

X25

H3

T155220

LD30992,00001A7 -19-30MAY02-1/2

Continued on next page

TM2052 (17JUL18)

9015-10-35

27C ZTS and 35C ZTS Operation & Tests 071718 PN=125

System Diagrams

TM2052 (17JUL18)

9015-10-36

27C ZTS and 35C ZTS Operation & Tests 071718 PN=126

System Diagrams

A10— Propel Alarm Controller B15— Left Propel Pressure Sensor B16— Right Propel Pressure Sensor

H3—Propel Alarm S10— Propel Alarm Cancel Switch W11— Propel Alarm Harness W12—Propel Alarm Cancel Switch Harness

X25— Floor Harness to Propel Alarm Harness Connector X33— Propel Alarm Harness to Propel Alarm Cancel Switch Harness Connector LD30992,00001A7 -19-30MAY02-2/2

TM2052 (17JUL18)

9015-10-37

27C ZTS and 35C ZTS Operation & Tests 071718 PN=127

System Diagrams

TM2052 (17JUL18)

9015-10-38

27C ZTS and 35C ZTS Operation & Tests 071718 PN=128

System Diagrams

Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12) Wire Diagram T155317 —UN—30MAY02

LD30992,00001A8 -19-30MAY02-1/2

Continued on next page

TM2052 (17JUL18)

9015-10-39

27C ZTS and 35C ZTS Operation & Tests 071718 PN=129

System Diagrams

TM2052 (17JUL18)

9015-10-40

27C ZTS and 35C ZTS Operation & Tests 071718 PN=130

System Diagrams

A10— Propel Alarm Controller B15— Left Propel Pressure Sensor B16— Right Propel Pressure Sensor

H3—Propel Alarm X33— Propel Alarm Harness S10— Propel Alarm Cancel to Propel Alarm Cancel Switch Switch Harness Connector X25— Floor Harness to Propel Alarm Harness Connector LD30992,00001A8 -19-30MAY02-2/2

TM2052 (17JUL18)

9015-10-41

27C ZTS and 35C ZTS Operation & Tests 071718 PN=131

System Diagrams

TM2052 (17JUL18)

9015-10-42

27C ZTS and 35C ZTS Operation & Tests 071718 PN=132

Group 15

Sub-System Diagnostics Starting and Charging Circuit Theory of Operation T155457 —19—03JUN02

CED,OUOE003,1510 -19-29NOV99-1/2

Continued on next page

TM2052 (17JUL18)

9015-15-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=133

Sub-System Diagnostics

TM2052 (17JUL18)

9015-15-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=134

Sub-System Diagnostics

A5—Monitor Controller and Display A8—Starter Protection Controller B10— Glow Plug Timer B53— Glow Timer Engine Coolant Sensor F5— Engine Power 10 Amp Fuse F8— Fuel Pump 5 Amp Fuse

F10— Monitor Controller and Display 5 Amp Fuse F21— Battery Power 45 Amp Fusible Link F22— Alternator 45 Amp Fusible Link G1—Battery G3—Alternator H9—Glow Plug Indicator

X3— Floor Harness to Monitor K12— Starter Relay Controller and Display K29— Glow Plug Relay Harness 12 Pin Connector M1—Starter Y7— Fuel Shut-Off Solenoid R12— Glow Plug Y14— Fuel Transfer Pump R13— Glow Plug R14— Glow Plug R15— Glow Plug (50C ZTS Only) S1— Key Switch W6—Main Harness Ground W7—Battery To Frame Ground

Starting Circuit Theory of Operation When the key switch (S1) is turned to the ON position, battery voltage is routed to the fuel transfer pump (Y14), pin 3 of fuel shut-off solenoid (Y7), glow plug relay (K29), and glow plug timer (B10). The voltage to pin 3 of the fuel shut-off solenoid will not cause the solenoid to open. This voltage will hold the solenoid open once it is opened by a signal at pin 2. When the glow plug timer receives the voltage signal, it grounds pins 2 and 5, turning on the glow plug indicator (H9) and activating the glow plug relay. The length of time that pins 2 and 5 remain grounded depends on the signal that the glow plug timer receives from the glow timer engine coolant sensor (B53). When the engine is cold, the glow plugs and glow plug indicator will stay on for approximately five seconds. When the engine is warm, the glow plugs and glow plug indicator will turn on, but will turn back off after less than a second.

When the key switch is turned to the START position, battery voltage is routed to the same components as in the ON position as well as to pin 1 of the glow plug timer, pin 2 of the fuel shut-off solenoid, and through the starter relay (K12) to the starter (M1). The glow plug timer activates the glow plug indicator and the glow plugs any time the key switch is in the start position. The starter motor rotates and cranks the engine. Once the engine is started, a signal from the L terminal of the alternator (G3) is sent to the starter protection controller (A8). This causes pin 4 of the starter protection controller to be routed to ground and

activates the starter relay so that the starter motor cannot be activated when the engine is running. The voltage at pin 2 of the fuel shut-off solenoid causes the solenoid to activate so that fuel can be delivered to the engine.

The voltage at pin 3 will hold the solenoid in the activated position once the key switch is returned to the ON position.

Charging Circuit Theory of Operation When the engine is running, the alternator provides power to all machine circuits and charges the battery.

When the key switch is ON and the engine is not running, the voltage at terminal L is 0 and current flows from the battery indicator lamp on the meter panel through terminal L, lighting the alternator voltage indicator light (H18).

When the key switch is ON and the engine is running, the voltage at alternator terminal L is equal to or greater than the battery voltage. This results in no current flow through the monitor controller and display (A5) and terminal L of alternator (G3), causing alternator voltage indicator light (H18) to go out.

If the alternator fails while the engine is running, causing the voltage at terminal L to drop below the battery voltage, current will flow through the alternator voltage indicator light (H18), illuminating the light. The lower the voltage at terminal L, the greater the current flow through the alternator voltage indicator light (H18), and the brighter the light will illuminate.

CED,OUOE003,1510 -19-29NOV99-2/2

Monitor Controller Circuit Theory of Operation Continued on next page

TM2052 (17JUL18)

9015-15-3

CED,OUOE003,1957 -19-29NOV99-1/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=135

Sub-System Diagnostics

TM2052 (17JUL18)

9015-15-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=136

Sub-System Diagnostics

T155462 —19—03JUN02

CED,OUOE003,1957 -19-29NOV99-2/3

Continued on next page

TM2052 (17JUL18)

9015-15-5

27C ZTS and 35C ZTS Operation & Tests 071718 PN=137

Sub-System Diagnostics

TM2052 (17JUL18)

9015-15-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=138

Sub-System Diagnostics

A5—Monitor Controller and Display B4—Engine Oil Pressure Switch B9—Coolant Temperature Gauge Sensor B10— Glow Plug Timer B46— Coolant Overheat Sensor E2— Drive Light E4— Monitor Controller and Display Backlight E12— Boom Work Light

F2— Drive and Boom Work Light 20 Amp Fuse F10— Monitor Controller and Display 5 Amp Fuse F11— Backup Power 5 Amp Fuse F21— Battery Power 45 Amp Fusible Link G1—Battery H8—Monitor Controller and Display Alarm H9—Glow Plug Indicator

The monitor controller and display (A5) receives signals from the engine coolant overheat switch (B46), engine oil pressure switch (B4), fuel level sender (R5), glow plug timer (B10), alternator (G3), and coolant temperature gauge sensor (B9). The controller takes this information and turns on warning lights, activates alarms, or actuates the gauges. The monitor controller and display activates the monitor controller and display alarm (H8) when the coolant overheat switch closes, the engine oil pressure switch opens, or the fuel level gets low.

The monitor controller and display is powered by the monitor controller and display 5 amp fuse (F10) and the back-up power 5 amp fuse (F11). Both fuses must be intact for the monitor controller and display to function, however, the indicator lights will function without the back-up power 5 amp fuse.

H17— Engine Oil Pressure X4— Floor Harness to Cab Indicator Harness 10 Pin Connector H18— Alternator Indicator X30— Floor Harness to Auto-Idle K3—Drive and Boom Work Light Harness 1 Pin Connector Relay X34— Radio to Cab Harness R5—Fuel Level Sender Connector S1— Key Switch S6— Drive and Boom Work Light Switch W6—Main Harness Ground W7—Battery to Frame Ground X3— Floor Harness to Monitor Controller and Display Harness 12 Pin Connector

The drive and boom work light switch (S6), when pressed, sends a ground signal to the monitor controller and display which in turn sends a ground path to the drive and boom work light relay (K3) and to the monitor controller and display backlight (E4), turning the backlight on. The drive and boom work light relay is then activated, providing power to the drive light (E2), boom work light (E12), and the radio to cab harness connector (X34).

The glow plug indicator (H9) illuminates when the glow plug timer (B10) opens a ground path to the indicator lamp during the preheating of the glow plugs (R12, R13, R14, R15)

CED,OUOE003,1957 -19-29NOV99-3/3

TM2052 (17JUL18)

9015-15-7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=139

Sub-System Diagnostics

T155464 —19—03JUN02

Pilot Control Shut-Off Circuit Theory of Operation

Continued on next page

TM2052 (17JUL18)

9015-15-8

TX18160,000009F -19-31MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=140

Sub-System Diagnostics F1— Pilot Control Shut-Off 5 Amp S1— Key Switch W7—Battery To Frame Ground Fuse S21— Left Pilot Control Shut-Off X22— Floor Harness to Right F21— Battery Power 45 Amp Switch Pilot Control Shut-Off Fusible Link W6—Main Harness Ground Switch 2 Pin Connector G1—Battery

The pilot control shut-off circuit consists of the pilot control shut-off solenoid valve (Y8), and pilot control shut-off switch (S21).

The pilot control shut-off switch is designed to shut off hydraulic pilot pressure to all pilot controllers. This prevents accidental machine movement when operator enters and exits the machine.

When the engine is running and left armrest is down, the pilot control shut-off switch (S21) is enabled (closed).

This completes ground circuit to pilot control shut-off solenoid (Y8), allowing hydraulic pilot pressure to all pilot controllers.

Y8— Pilot Control Shut-Off Solenoid

If the pilot control shut-off switch (S10) or the harness fail, the emergency pilot control shut-off 2 pin connector (X36) can be used to restore temporary power to the pilot control shut-off solenoid (Y8) to return the machine to a safe position. With the emergency pilot control shut-off 2 pin connector (X36) in place of the main harness to propel speed change connector (X13), the propel speed switch (S8) provides the ground path to the pilot control shut-off solenoid (Y8). The pilot control shut-off solenoid (Y8) will only stay activate as long as the propel speed switch (S8) is pressed.

TX18160,000009F -19-31MAY02-2/2

TM2052 (17JUL18)

9015-15-9

27C ZTS and 35C ZTS Operation & Tests 071718 PN=141

Sub-System Diagnostics

T155463 —19—03JUN02

Propel Alarm Circuit Theory of Operation

Continued on next page

TM2052 (17JUL18)

9015-15-10

CED,OUOE003,2502 -19-29NOV99-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=142

Sub-System Diagnostics A10— Propel Alarm Controller B15— Left Propel Pressure Sensor B16— Right Propel Pressure Sensor

F9— Propel Alarm 5 Amp Fuse F21— Battery Power 45 Amp Fusible Link G1—Battery H3—Propel Alarm

The propel alarm circuit consists of a left and right propel pressure sensors (B15 and B16), propel alarm controller (A10), propel alarm (H3), and a propel alarm cancel switch (S10).

The circuit is designed to warn bystanders of machine movement by signaling with an audible alarm any time the propel levers are moved.

When the propel levers are moved, propel pressure sensor (B15) left or (B16) right sense pilot pressure and send a signal to the propel alarm controller (A10). The

S1— Key Switch S10— Propel Alarm Cancel Switch W6—Main Harness Ground W7—Battery to Frame Ground

X33— Propel Alarm Harness to Propel Alarm Cancel Switch Harness 3 Pin Connector

propel alarm controller then completes ground from the propel alarm (H3), activating the alarm.

When pressed, the propel alarm cancel switch (S10) applies ground to pin 7 of the propel alarm controller (A10). The propel alarm cancel switch (S10) must be pressed and released in order to cancel the alarm. The propel alarm controller (A10) is reset when the control levers are returned to the neutral position. The propel alarm cancel switch (S10) must be pressed and released again to cancel the alarm.

CED,OUOE003,2502 -19-29NOV99-2/2

TM2052 (17JUL18)

9015-15-11

27C ZTS and 35C ZTS Operation & Tests 071718 PN=143

Sub-System Diagnostics

TM2052 (17JUL18)

9015-15-12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=144

Group 20

References Fuse Test

if fuses have failed. If certain circuits or components operate, fuses are considered to be OK.

Some symptoms may indicate an expensive component failure, when in fact a fuse has failed. Machine functions can be performed without test equipment to determine

For location of fuses See Fuse Specifications. (Group 9015-10.)

Fuse Test Fuse

Test

Results of Fuse Failure

F1—Pilot Control Shut-off 5 Amp (Marked PILOT-SHUT OFF)

Start Engine.

Operate hydraulic function.

If hydraulics operate, fuse is OK.

Pilot functions will not work.

F2—Drive and Boom Work Light 20 Amp (Marked LIGHT)

Turn key ON. Turn light switch ON. If drive and boom lights operate, fuse is OK.

Drive and boom work lights will not operate.

F3—Horn 10 Amp Fuse (Marked HORN TRAVEL MODE)

Turn key switch ON. Push horn switch. If horn operates, fuse is OK.

Horn will not operate.

F4—12V Power Outlet 10 Amp (Marked ACC)

Check fuse with multimeter.

12V power outlet will not operate.

F5—Engine Power 10 Amp (Marked ENG)

Turn key switch ON. If glow plug indicator lights for bulb check, fuse is OK.

Glow plug timer and starter protection controller will not operate.

F6—Heater and Wiper 15 Amp (Marked COOLER WIPER)

Heater blower motor and windshield wiper will Turn key switch ON. Turn heater blower motor ON, or turn windshield not operate. wiper ON. If heater blower motor or windshield wiper operates, fuse is OK.

F7—Not Used 20 Amp (Marked COOLER HEATER) F8—Fuel Pump 5 Amp (Marked PUMP)

Check fuse with multimeter.

Engine may not operate.

F9—Propel Alarm 5 Amp (Marked PAT. TRAVEL)

Start engine.

Operate propel function.

If alarm sounds, fuse is OK.

Propel alarm will not operate.

F10—Monitor Controller and Display 5 Amp (Marked MONITOR)

Turn key switch ON. If indicator lights and monitor display are on, fuse is OK.

Monitor controller and display will not operate.

F11—Back Up Power 5 Amp (Marked BACK UP)

Turn key switch ON. If monitor display is on, fuse is OK.

Monitor display will not operate.

F13—Radio (field option) 5 Amp (Marked RADIO)

Turn key switch ON. Turn radio ON. If radio operates fuse is OK.

Radio will not operate.

F19—Radio (field option) inline 5 Amp

Turn key switch ON. Turn radio ON. If radio operates fuse is OK

Radio will not operate.

F21—Fusible Link 45 Amp

If engine starts, fuse is OK

Engine will not start.

F22—Fusible Link 45 Amp

Check fuse with multimeter.

Glow plugs will not operate and battery will not charge.

F27—Radio backup (field option) inline 1 Amp

Check fuse with multimeter.

Radio presets will be lost.

F12—Not Used 5 Amp (Marked AI)

TX13067,0000192 -19-25FEB02-1/1

T158554 —UN—15AUG02

Relay Test For location of relays see Floor Harness (W2) Component Location. (Group 9015-10.)

1. Connect multimeter to terminals 3 and 4.

About 0.0—0.4 ohms must be measured. If not, relay has failed.

2. Connect multimeter to terminals 3 and 5, then 4 and 5.

Multimeter must read open in both connections. If not, relay has failed.

3. Connect 12 volts to terminal 1, ground terminal 2.

Connect multimeter to terminals 3 and 5.

Multimeter must read continuity. If not, relay has failed.

TX13067,000015A -19-27NOV01-1/1

TM2052 (17JUL18)

9015-20-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=145

References

Pressure Sensor Test Pressure Sensor Resistance Test Item

Measurement

Specification

Left Propel Pressure Sensor (B15)

Resistance

5k—15k ohms (Terminals 1—2) 30k—50k ohms (Terminals 2—3)

Right Propel Pressure Sensor (B16)

Resistance

5k—15k ohms (Terminals 1—2) 30k—50k ohms (Terminals 2—3)

1. A suspect pressure sensor can be checked by switching positions with a known good sensor. If the problem follows the suspect pressure sensor, it has failed.

If the problem remains, the harness has failed.

2. To check a pressure sensor using a multimeter, remove it from the machine.

3. For location of pressure sensors see Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12) Component Location. (Group 9015-10.)

4. Measure resistance as indicated. Resistance may vary from one sensor to another.

Pressure Sensor Voltage Test

Item

Measurement

Specification

Left Propel Pressure Sensor (B15)

Voltage

4.5—5.5 volts

Right Propel Pressure Sensor (B16)

Voltage

4.5—5.5 volts

1. Lack of voltage to pressure sensors will generate service codes. Disconnect harness connector from a pressure sensor.

2. With key switch ON, measure voltage between terminals 1 and 3 of pressure sensor harness connector.

TX13067,0000193 -19-08MAR02-1/1

Solenoid Test Item

Measurement

Specification

Propel Speed Solenoid (Y6)

Resistance

10—15 ohms

Pilot Shut-Off Solenoid (Y8)

Resistance

10—15 ohms

1. A suspect solenoid can be checked by switching positions with a known good solenoid. If the problem follows the suspect solenoid, it has failed.

If the problem remains, the harness has failed.

3. For location of solenoids see Main Harness (W1) Component Location. (Group 9015-10.)

4. Measure resistance as indicated. Resistance may vary from one solenoid to another.

2. To check a solenoid using an multimeter, remove it from the machine.

TX13067,0000194 -19-08MAR02-1/1

TM2052 (17JUL18)

9015-20-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=146

References

Temperature Sensor Test Item

Measurement

Specification

Resistance

450—550 Ω at 21 °C (70 °F) approximate 1600—1700 Ω at 0 °C (32 °F) approximate

Temperature Sensor Test Coolant Temperature Gauge Sensor (B9)

Glow Timer Engine Coolant Sensor Resistance (B53)

1. To check a temperature sensor using an multimeter, remove it from the machine.

1800—1900 Ω at 21 °C (70 °F) approximate 5200—5400 Ω at 0 °C (32 °F) approximate 3. For location of temperature sensors See Engine Harness (W3) Component Location. (Group 9015-10.)

2. Measure resistance as indicated. Resistance may vary from one sensor to another.

TX13067,000017B -19-08MAR02-1/1

Electrical Component Checks The following checks can be used to test electrical components in all machine circuits.

TX13067,0000162 -19-27NOV01-1/12

• 1

Component Checks

Continued on next page

TM2052 (17JUL18)

9015-20-3

TX13067,0000162 -19-27NOV01-2/12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=147

References Key Switch Check

T124133 —UN—17SEP99

Disconnect battery ground cable.

Turn key to ON position.

Is continuity measured between terminals:

• (B) and (ACC)?

• (B) and (R2)?

YES: Go to next step in this check.

• (B) and (BR)?

NO: Key switch has failed.

Replace key switch.

T124132 —UN—17SEP99

Turn key to START position.

Is continuity measured between terminals:

• (B) and (ACC)?

• (B) and (R1)?

• (B) and (C)?

• (B) and (BR)?

YES: Key switch is OK. NO: Key switch has failed.

Replace key switch.

Continued on next page

TM2052 (17JUL18)

9015-20-4

TX13067,0000162 -19-27NOV01-3/12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=148

References Starter (M1) Solenoid Check

T155834 —UN—12JUN02

CAUTION: Starter will crank engine if metal strap is NOT disconnected from motor.

Disconnect metal strap from solenoid terminal.

Connect battery voltage to solenoid small terminal.

YES: Solenoid is OK. Check wiring harness.

See Engine Harness (W3) Component Location and See Engine Harness (W3) Wiring Diagram. (Group 9015-10.)

Does solenoid click?

NO: Repair or replace starter solenoid. See Engine Harness (W3) Component Location.

(Group 9015-10.)

TX13067,0000162 -19-27NOV01-4/12

Starter (M1) Motor Check

T155838 —UN—12JUN02

Connect a heavy gauge wire from battery positive cable to starter motor terminal.

YES: Starter motor is OK. Check wiring harness.

See Engine Harness (W3) Component Location and See Engine Harness (W3) Wiring Diagram. (Group 9015-10.)

Does starter motor turn, but NOT crank engine?

NO: Repair or replace starter. See Engine Harness (W3) Component Location. (Group 9015-10.)

Continued on next page

TM2052 (17JUL18)

9015-20-5

TX13067,0000162 -19-27NOV01-5/12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=149

References Battery Voltage Check

T123529 —UN—17SEP99

Measure battery voltage by connecting a multimeter to (-) negative battery terminal grounded to frame and (+) positive battery terminal connected to machine harness.

YES: Batteries are OK. .

Is 12 to 13 volts measured?

NO: Batteries are undercharged. Charge batteries.

TX13067,0000162 -19-27NOV01-6/12

Fusible Link Check

T125432 —UN—18NOV99

Press locking tab on side of fusible link and lift from holder.

Connect a multimeter to terminals inside fusible link.

YES: Fusible link is OK. Check wiring harness.

See Main Harness (W1) Component Location and See Main Harness (W1) Wiring Diagram. (Group 9015-10.)

Does multimeter read continuity?

NO: Fusible link has failed. Replace. See Main Harness (W1) Component Location. (Group 9015-10.)

Continued on next page

TM2052 (17JUL18)

9015-20-6

TX13067,0000162 -19-27NOV01-7/12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=150

References Alternator Output Check

T123529 —UN—17SEP99

Key switch OFF. With multimeter connected from battery (+) terminal to vehicle ground, measure and record battery voltage. 12 - 13 volts is normal.

Start and run engine at slow idle, and check battery voltage.

YES: Alternator is OK.

Does battery voltage increase?

NO: Repair or replace alternator.

TX13067,0000162 -19-27NOV01-8/12

Propel Alarm Check

T125863 —UN—22NOV99

Engine OFF Disconnect harness from propel alarm.

Apply battery voltage to (RED) wire terminal of propel alarm and ground (BLK) wire terminal.

YES: Alarm is OK. Harness may have failed. See Propel Alarm Harness (W11) and Propel Alarm Cancel Switch Harness (W12) Component Location to check harness.

(Group 9015-10.)

Does alarm sound?

NO: Alarm has failed.

Replace.

TX13067,0000162 -19-27NOV01-9/12

Monitor Controller and Display Alarm Check

Key OFF. Disconnect harness connector from coolant overheat switch (B46).

Connect a jumper wire between terminals in harness connector.

Key ON.

YES: Alarm and harness are OK.

Does monitor controller and display alarm sound?

NO: Monitor controller and display or harness has failed. Repair or replace.

See Monitor Controller and Display (A5) Remove and Install. (Group 9015-20.)

Continued on next page

TM2052 (17JUL18)

9015-20-7

TX13067,0000162 -19-27NOV01-10/12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=151

References Fuel Shut-Off Solenoid Check

T155723B —UN—21JUN02

1— Pin 1 2— Pin 2 3— Pin 3 4— Fuel Shut-Off Solenoid Ground pin 1.

Apply 12 V to pin 2. Does solenoid click?

YES: Go to next step in this check.

Remove 12 V from pin 2. Does solenoid click?

NO: Solenoid has failed.

Replace.

Ground pin 1.

Apply 12 V to pins 2 and 3.

Remove 12 V from pin 2. Does solenoid click?

YES: Solenoid has failed.

Replace.

NOTE: Voltage at pin 3 will not activate the solenoid, but will hold the solenoid in the activated position once the solenoid is activated by voltage at pin 2.

NO: Go to next check.

Continued on next page

TM2052 (17JUL18)

9015-20-8

TX13067,0000162 -19-27NOV01-11/12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=152

References Windshield Wiper and Washer Switch Check

T156118B —UN—20JUN02

1— Pin 2— Pin 3— Pin 5— Pin 6— Pin

1 2 3 5 6

Remove windshield wiper and washer switch.

Connect multimeter to pins 5 and 6.

Is continuity measured when switch is in the wiper OFF position?

Is continuity measured when switch is in the wiper OFF and washer ON position?

Connect multimeter to pins 1 and 6.

Is continuity measured when switch is in the wiper ON position?

Is continuity measured when switch is in the wiper ON and Washer ON position?

Connect multimeter to pins 2 and 3.

Is continuity measured when switch is in the wiper OFF and washer ON position?

YES: Windshield wiper and washer switch is OK.

Is continuity measured when switch is in the wiper ON and washer ON position?

NO: Windshield wiper and washer switch has failed.

Replace.

TX13067,0000162 -19-27NOV01-12/12

TM2052 (17JUL18)

9015-20-9

27C ZTS and 35C ZTS Operation & Tests 071718 PN=153

References

Battery Remove and Install

1. Remove parts (1—3).

3— Left Side Access Panel

T156340B —UN—20JUN02

1— Cap Screw (9 Used) 2— Step

TS204 —UN—15APR13

CAUTION: Prevent personal injury from exploding battery. Keep sparks and flames away from battery.

TX13067,0000163 -19-27NOV01-1/2

2. Remove parts (4—10).

3. Remove batteries. Replace as needed.

4. Check cables and terminals for wear or corrosion.

Make sure new batteries are fully charged. See Battery Voltage Check. (Group 9015-20)

4— Negative Battery Cable 5— Positive Battery Cable 6— Bracket 7— Alternator Fusible Link (F22)

8— Battery Fusible Link (F21) 9— Washer 10— Hex Nut (2 Used)

T156339B —UN—20JUN02

5. Install batteries.

TX13067,0000163 -19-27NOV01-2/2

TM2052 (17JUL18)

9015-20-10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=154

References

Propel Alarm Cancel Switch Remove and Install 1. Disconnect battery ground (-) cable.

2. Remove screws (1) and (2).

3. Remove console bottom cover.

2— Screw

T156337B —UN—20JUN02

T156336B —UN—20JUN02

1— Screw (2 Used)

Continued on next page

TM2052 (17JUL18)

9015-20-11

TX13067,0000164 -19-27NOV01-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=155

References

4. Push propel alarm cancel switch up and out of console.

5. Remove propel alarm cancel switch (3).

6. Replace switch as necessary.

3— Propel Alarm Cancel Switch

T156338B —UN—20JUN02

7. Install switch.

4— Key Switch

TX13067,0000164 -19-27NOV01-2/2

TM2052 (17JUL18)

9015-20-12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=156

References

Key Switch Remove and Install 1. Disconnect battery ground (-) cable.

2. Remove screws (1) and (2).

2— Screw

T156337B —UN—20JUN02

T156336B —UN—20JUN02

1— Screw (2 Used)

Continued on next page

TM2052 (17JUL18)

9015-20-13

TX13067,0000165 -19-27NOV01-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=157

References

3. Remove key switch cover (3).

4. Remove key switch.

5. Replace key switch as necessary.

T156381B —UN—20JUN02

6. Install key switch.

3— Key Switch Cover

TX13067,0000165 -19-27NOV01-2/2

TM2052 (17JUL18)

9015-20-14

27C ZTS and 35C ZTS Operation & Tests 071718 PN=158

References

Monitor Controller and Display (A5) Remove and Install 1. Remove screws (1) and (2).

2. Remove console bottom cover.

2— Screw (2 Used)

T156332B —UN—20JUN02

T156331B —UN—20JUN02

1— Screw (2 Used)

Continued on next page

TM2052 (17JUL18)

9015-20-15

TX13067,000016A -19-27NOV01-1/4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=159

References

3. Remove screws (3) and plates (4).

4— Plate (2 Used)

T156333B —UN—20JUN02

3— Screw (4 Used)

TX13067,000016A -19-27NOV01-2/4

4. Remove cap screws (5) and arm rest.

5. Disconnect harness from monitor controller display from back side of monitor.

T156334B —UN—20JUN02

5— Cap Screw (2 Used)

TX13067,000016A -19-27NOV01-3/4

6. Remove screws (6).

7. Remove monitor controller and display.

8. Repair or replace as necessary.

T156335B —UN—20JUN02

9. Install monitor controller and display.

6— Screw (4 Used)

TX13067,000016A -19-27NOV01-4/4

TM2052 (17JUL18)

9015-20-16

27C ZTS and 35C ZTS Operation & Tests 071718 PN=160

References

Glow Plug Timer Remove and Install

1— Cap Screw (2 Used) 2— Cap Screw (3 Used)

3— Toolbox And Operator's Manual Compartment Door 4— Side Cover

T156341B —UN—20JUN02

1. Remove parts (1—4).

TX18160,00000A0 -19-07JUN02-1/3

2. Remove cap screws (5) 3. Cap screw (6) may be loosened for clearance to remove relay panel.

6— Cap Screw

T156342B —UN—20JUN02

5— Cap Screw (3 Used)

Continued on next page

TM2052 (17JUL18)

9015-20-17

TX18160,00000A0 -19-07JUN02-2/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=161

References

4. Remove screws (7).

5. Remove glow plug timer.

6. Replace glow plug timer as necessary.

7. Install glow plug timer.

11— Glow Plug Timer (B10) 12— Starter Relay (K12) 13— Boom and Work Light Relay (K3) T156343B —UN—20JUN02

7— Screw (2 Used) 8— Horn Relay (K5) 9— Glow Plug Relay (K29) 10— Starter Protection Controller (A8)

TX18160,00000A0 -19-07JUN02-3/3

Disconnect Tab Retainer Connectors

T7535AE —UN—22MAY91

IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to controllers or other components may result.

Disconnect connectors only when instructed during a test or check.

DO NOT pull on wires to disconnect connector or damage to wires or connector may result. Grasp both halves of the connector to pull connector apart.

1. Push retainer tab (A).

2. While holding tab in, grasp other half of connector and pull connector halves apart.

A—Retainer Tab

3. To connect, push connector halves together until retainer “clicks”.

TX13067,000016B -19-27NOV01-1/1

TM2052 (17JUL18)

9015-20-18

27C ZTS and 35C ZTS Operation & Tests 071718 PN=162

References

Disconnect Spring Wire Clip Connectors 1. Remove wire clip from connector.

Grasp connector; move connector halves from side-to-side as they're being pulled apart. Do not pull on wiring leads.

T8197AO —UN—14MAR94

2. To reconnect, install wire clip on connector half, push connector halves together until wire retainer “clicks” over tabs.

TX13067,000016C -19-27NOV01-1/1

Replace DEUTSCH™ Connectors

• JDG361 Extractor Tool11 for 12 to 14 gauge wire.

• JDG362 Extractor Tool1 for 16 to 18 gauge wire.

• JDG363 Extractor Tool for 20 gauge wire.

2. Start correct size extractor tool over wire at handle (A).

3. Slide extractor tool rearward along wire until tool tip snaps onto wire.

TS0124 —UN—23AUG88

1. Select correct size extractor tool for size of wire to be removed:

IMPORTANT: Do NOT twist tool when inserting in connector.

4. Slide extractor tool along wire into connector body until it is positioned over terminal contact.

TS120 —UN—23AUG88

5. Pull wire out of connector body, using extractor tool.

A—Extractor Tool Handle

DEUTSCH is a trademark of the Deutsch Co. 1

Included in JDG359 DEUTSCH Electrical Repair Kit. Continued on next page

TM2052 (17JUL18)

9015-20-19

TX13067,000016D -19-27NOV01-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=163

References

IMPORTANT: Install contact in proper location using correct size grommet.

6. Push contact straight into connector body until positive stop is felt.

TS122 —UN—23AUG88

7. Pull on wire slightly to be certain contact is locked in place.

8. Transfer remaining wires to correct terminal in new connector.

TX13067,000016D -19-27NOV01-2/2

Install DEUTSCH™ Contacts 1. Strip 6 mm (1/4 in.) insulation from wire.

2. Adjust selector (A) on JDG360 Crimper1 for correct wire size.

A—Crimper Selector B—Lock Nut

TS117 —UN—23AUG88

3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops.

C—Adjusting Screw

DEUTSCH is a trademark of the Deutsch Co. 1

Included in JDG359 Deutsch Electrical Repair Kit. TX13067,000016E -19-27NOV01-1/4

IMPORTANT: Select proper size contact “sleeve” or “pin” to fit connector body.

4. Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B).

A—Contact B—Cover

TS0134 —UN—23AUG88

5. Tighten lock nut (C).

C—Lock Nut D—Adjusting Screw

Continued on next page

TM2052 (17JUL18)

9015-20-20

TX13067,000016E -19-27NOV01-2/4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=164

References

IMPORTANT: Contact must remain centered between indentors while crimping.

6. Insert wire in contact and crimp until handle touches stop.

TS118 —UN—23AUG88

7. Release handle and remove contact.

TX13067,000016E -19-27NOV01-3/4

IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures.

TS0135 —UN—23AUG88

NOTE: Readjust crimping tool for each crimping procedure.

8. Inspect contact to be certain all wires are in crimped barrel.

TX13067,000016E -19-27NOV01-4/4

Replace WEATHER PACK™ Connector IMPORTANT: Identify wire color locations with connector terminal letters.

TS0128 —UN—23AUG88

1. Open connector body.

2. Insert JDG364 Extraction Tool1 over terminal contact in connector body.

3. Hold extractor tool fully seated and pull wire from connector body.

NOTE: If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal contact from connector.

WEATHER PACK is a trademark of Packard Electric.

1

Included in JT07195A Electrical Repair Kit. Continued on next page

TM2052 (17JUL18)

9015-20-21

TX13067,000016F -19-27NOV01-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=165

References

IMPORTANT: Carefully spread contact lances to assure good seating on connector body.

NOTE: Connector bodies are “keyed” for proper contact mating. Be sure contacts are in proper alignment.

TS0130 —UN—23AUG88

4. Push contact into new connector body until fully seated.

5. Pull on wire slightly to be certain contact is locked in place.

6. Transfer remaining wires to correct terminal in new connector.

7. Close connector body.

TX13067,000016F -19-27NOV01-2/2

Install WEATHER PACK™ Contacts NOTE: Cable seals are color coded for three sizes of wire:

TS0136 —UN—23AUG88

• Green - 18 to 20 gauge wire • Gray - 14 to 16 gauge wire • Blue - 10 to 12 gauge wire 1. Slip correct size cable seal on wire.

2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.

NOTE: Contacts have numbered identification for two sizes of wire:

Correct Size Cable

• #15 for 14 to 16 gauge wire • #19 for 18 to 20 gauge wire TS1623 —UN—02NOV94

3. Put proper size contact on wire and crimp in place with a “W” type crimp, using JDG783 Crimping Tool.

Strip Insulation WEATHER PACK is a trademark of Packard Electric.

Continued on next page

TM2052 (17JUL18)

9015-20-22

TX13067,0000170 -19-27NOV01-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=166

References

IMPORTANT: Proper contact installation for “sleeve” (A) and “pin” (B) is shown.

A—Sleeve

TS0139 —UN—02DEC88

4. Secure cable seal to contact as shown, using JDG783 Crimping Tool.

B—Pin

Contact Installation TX13067,0000170 -19-27NOV01-2/2

Remove Connector Body from Blade Terminals

2. Be sure to bend locking tang back to its original position (B) before installing connector body.

A—Locking Tang (Depressed Position)

B—Locking Tang (Original Position)

RW4218 —UN—23AUG88

1. Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off.

TX13067,0000171 -19-27NOV01-1/1

TM2052 (17JUL18)

9015-20-23

27C ZTS and 35C ZTS Operation & Tests 071718 PN=167

References

TM2052 (17JUL18)

9015-20-24

27C ZTS and 35C ZTS Operation & Tests 071718 PN=168

Contents

Section 9020 Power Train

Page

Group 05—Theory of Operation Track Adjuster and Recoil Spring ..............9020-05-1 Propel Gearbox .........................................9020-05-2 Group 15—Diagnostic Information Diagnose Malfunctions Undercarriage Components ..................9020-15-1 Swing Bearing Measure Wear.......................................9020-15-3

TM2052 (17JUL18)

9020-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=1

Contents

TM2052 (17JUL18)

9020-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=2

Group 05

Theory of Operation

T121975 —19—17SEP99

Track Adjuster and Recoil Spring Operation

1— Track Frame 2— Fitting 3— Nut 4— Spring

5— Seal 6— Piston 7— Idler 8— Yoke

9— Cylinder Barrel 10— Grease 11— Adapter

The track adjuster (12) is supported by the track frame (1).

Shock loads on the track and front idler (7) are absorbed by the recoil spring (4).

To tighten the track, pump grease (10) into fitting (2) to force the piston (6) out. As it presses against the yoke

12— Track Adjuster

(8), the track becomes tighter. Loosen adapter (11), NOT the fitting (2) to release grease to loosen track. Grease will escape through a small passage that is concealed by nut (3).

CED,OUOE003,1894 -19-26AUG99-1/1

TM2052 (17JUL18)

9020-05-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=171

Theory of Operation

T154931 —UN—16MAY02

Propel Gearbox Operation

Propel Gearbox—27C ZTS 1— First Planet Gear 2— Ring Gear 3— Second Planet Carrier 4— Second Planet Gear

5— Input Shaft 6— Drum 7— Sprocket 8— Metal Face Seal 9— Propel Motor

10— Ball Bearing 11— Second Planet Sun Gear 12— First Planet Carrier

Continued on next page

TM2052 (17JUL18)

9020-05-2

13— First Planet Sun Gear 14— Thrust Plug 15— Cover

TX19495,0000079 -19-15MAY02-1/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=172

T154930 —UN—16MAY02

Theory of Operation

Propel Gearbox—35C ZTS 1— First Planet Gear 2— Ring Gear 3— Second Planet Carrier 4— Second Planet Gear

10— Ball Bearing 11— Second Planet Sun Gear 12— First Planet Carrier

5— Input Shaft 6— Drum 7— Sprocket 8— Metal Face Seal 9— Propel Motor

The propel gearbox is a double reduction planetary drive.

The gearboxes are interchangeable from the right to the left side of machine. The propel motor (9) is connected to and turns the gearbox input shaft (5) through a spline

connection. The function of the propel gearbox is to convert fast rotary speed and low torque from the propel motor to a slow rotary speed and high torque to rotate the sprocket (7).

Continued on next page

TM2052 (17JUL18)

13— First Planet Sun Gear 14— Thrust Plug 15— Cover

9020-05-3

TX19495,0000079 -19-15MAY02-2/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=173

Theory of Operation

Rotary motion is transferred from the input shaft (5) to the sprocket (7) by the two planetary gear sets that mesh with the ring gear (2). As the input shaft turns, it turns the first planet gears (1) against the ring gear causing the first planet carrier (12) to rotate. The first planet carrier turns the second planet sun gear (11) through a spline connection. The second planet sun gear is in mesh with and turns the second planet gears (4) in the second planet

carrier (3). The second planet carrier is fixed to the propel motor housing and does not rotate so the rotation of the second planet gears is transferred to and turns the ring gear. The ring gear (2), drum (6) and sprocket (7) all turn as a unit driving the track chain to move the machine.

A replaceable thrust plug (14) is used in the cover (15) to keep the floating input shaft in position.

TX19495,0000079 -19-15MAY02-3/3

TM2052 (17JUL18)

9020-05-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=174

Group 15

Diagnostic Information Diagnose Undercarriage Components Malfunctions NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely and most difficult to verify.

Symptom

Problem

Solution

Noisy or Loose Track Chain

Incorrect track tension adjustment

Perform Check and Adjust Track Sag. (Operator's Manual.)

Track shoe loose

Perform Track Shoe Remove and Install. (Group 0130.)

Grease leaking from track adjuster seals, grease fitting, or valve

Perform Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.)

Material packing in sprocket

Material filling sprocket teeth can cause sprocket tooth to bushing impact. Perform Check and Adjust Track Sag. (Operator's Manual.)

Track sag less than specification

Perform Check and Adjust Track Sag. (Operator's Manual.)

Frequent Track Sag Adjustment Required

Grease leaking from track adjuster seals, grease fitting, or valve

Perform Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.)

Excessive Oil Leakage From Front Idlers, Track, And Carrier Rollers

Loose plug, worn or damaged O-ring or metal faced seal

Perform Front Idler Repair. (Group 0130.)

Tight Track Chain

Perform Track Roller Repair. (Group 0130.)

Perform Track Carrier Roller Repair.

(Group 0130.)

Bent Track Shoes

Excessive grouser wear

Measure grouser height. See SP326 Undercarriage Appraisal Manual.

Perform Track Shoe Remove and Install to replace track shoes. (Group 0130.)

"Popping" Of Track

Loose track shoes

Perform Track Shoe Remove and Install. (Group 0130.)

Excessive high speed operation on rough and rocky terrain

Slow propel speed on rough and rocky terrain.

High propel loads in reverse

High propel loads in reverse can cause the recoil spring to retract allowing sprocket to slip in chain.

Continued on next page

TM2052 (17JUL18)

9020-15-1

TX08227,00001F4 -19-14MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=175

Diagnostic Information Symptom

Cracked Track Link

Chipped Link Rails

Problem

Solution

Material packed in sprocket

Material filling sprocket teeth can cause sprocket tooth to bushing impact. Perform Check and Adjust Track Sag. (Operator's Manual.)

Excessive high speed operation on rough and rocky terrain

Slow propel speed on rough and rocky terrain.

Track shoes too wide for ground conditions

Use the narrowest shoes possible for required flotation. See SP326 Undercarriage Appraisal Manual.

Repeated high impacts with roller Perform Check and Adjust Track Sag. tread on flanges caused by a loose or (Operator's Manual.) “snaky� track, or using shoes that are too wide Check track pitch. See SP326 Undercarriage Appraisal Manual.

Use the narrowest shoes possible for required flotation. See SP326 Undercarriage Appraisal Manual.

Individual Undercarriage Component Wear

Some wear is normal

Measure components to determine if they can be rebuilt using weld.

See SP326 Undercarriage Appraisal Manual.

TX08227,00001F4 -19-14MAY02-2/2

TM2052 (17JUL18)

9020-15-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=176

Diagnostic Information

Measure Swing Bearing Wear SPECIFICATIONS Swing Bearing Outer Race to Inner Race Play

0.3 mm (0.012 in.) or less new

SERVICE EQUIPMENT AND TOOLS D17526CI Dial Indicator D17525CI Magnetic Base with Adjustable Arm

CAUTION: Stay clear of moving parts.

Position dial indicator so it can be seen while operator can see you.

NOTE: Two people are needed to do the measurement.

One to operate the machine and one to take the readings.

Check that bearing is lubricated with the specified grease. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease.

(Group 9000-04.)

Check that bearing rotation is smooth and without noise.

T7886AI —UN—23NOV92

1. Check that swing bearing to upperstructure and undercarriage cap screws are tight. See Swing Bearing Remove and Install. (Group 4350.)

2. Install the dial indicator with needle point contacting bottom face of swing bearing outer race.

3. Move boom and arm to position shown with bucket off the ground.

4. Turn dial indicator to zero.

5. Lower boom to raise front idlers off the ground approximately 500 mm (20 in.)

6. Record dial indicator reading.

If reading is more than maximum allowable, check for steel ball and spacer wear. See Swing Bearing Remove and Install. (Group 4350.)

T7886AJ —UN—23NOV92

Swing Bearing—Specification Outer Race to Inner Race—Play .............................................0.3 mm (0.012 in.) or less new

CED,OUOE003,1959 -19-14MAY02-1/1

TM2052 (17JUL18)

9020-15-3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=177

Diagnostic Information

TM2052 (17JUL18)

9020-15-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=178

Section 9025 Hydraulic System Contents Page Page

Group 05—Theory of Operation Hydraulic System Diagram ........................9025-05-1 Pilot System Diagram and Operation ........9025-05-3 Pilot Pump 27CZTS.................................................9025-05-4 Pilot Filter Operation.................................. 9025-05-4 Solenoid Valve Manifold Operation............................................... 9025-05-5 Pilot Controller ...........................................9025-05-7 Propel Pilot Controller................................9025-05-8 Blade, Boom Swing, and Auxiliary Pilot Controller Operation ...................... 9025-05-9 Hydraulic Pump 1 and 2 ...............................................9025-05-10 Hydraulic Pump P3 and Pilot Pump 35C ZTS..............................................9025-05-15 Pilot Controller Operation of Control Valve............... 902505-16 Control Valve System Relief Valve ............................9025-05-22 Circuit Relief Valve ..............................9025-05-23 Boom Swing Make-Up Check Valve ...9025-05-23 Flow Combiner Valve ..........................9025-05-24 Auxiliary Flow Combiner Valve............9025-05-24 Boom Reduced Leakage Valve ...........9025-05-25 Arm Regenerative Valve Operation .........9025-05-26 Swing Gearbox 27C ZTS..............................................9025-05-27 35C ZTS..............................................9025-05-28 Swing Motor.............................................9025-05-29 Swing Motor Crossover Relief Valve .......9025-05-30 Swing Motor Make-Up Check Valve ........9025-05-31 Swing Motor Park Brake..........................9025-05-32 Rotary Manifold .......................................9025-05-34 Propel Motor and Brake Valve Housing...9025-05-36 Propel Motor Speed Circuit .....................9025-05-41 Blade Hydraulic System ..........................9025-05-42 One Way/Two Way Valve ........................9025-05-43 Hydraulic Cylinder ...................................9025-05-44 Hydraulic System Circuit Symbols...........9025-05-45 Hydraulic System Schematics .................9025-05-46 Group 15—Diagnostic Information Diagnose Malfunctions Hydraulic System ..................................9025-15-1 Pilot Circuit ............................................9025-15-3 Dig Circuit..............................................9025-15-5 Swing Circuit .........................................9025-15-7 Propel System.......................................9025-15-9 Pilot Controller to Pattern Conversion Valve Line Connection ..................................9025-15-13 Blade Hydraulic System

Component Location ...........................9025-15-14 Propel Hydraulic System Line Connection ..................................9025-15-17 Main Hydraulic System Line Connection ..................................9025-15-21 Group 25—Tests JT05801 Clamp-On Electronic Tachometer Installation .............................................9025-25-1 JT05800 Digital Thermometer Installation................ 902525-1 JT02156A Digital Pressure/Temperature Analyzer... 902525-2 Hydraulic System Warm-Up Procedure .............................................. 9025-25-3 Cylinder Drift Test—Boom, Arm, Bucket, and Blade—27C ZTS ............... 9025-25-4 Cylinder Drift Test—Boom, Arm, Bucket, and Blade—35C ZTS ............... 9025-25-5 Pilot Pressure Regulating Valve Test and Adjustment—27C ZTS........................................................ 9025-25-6 Pilot Pressure Regulating Valve Test and Adjustment—35C ZTS........................................................ 9025-25-7 Control Valve Spool Pilot Actuating Pressure Test......................................... 9025-25-8 Hydraulic Pump 1, 2, and 3 System Relief Valve Test and Adjustment—27C ZTS........................... 9025-25-9 Hydraulic Pump 1, 2, and 3 System Relief Valve Test and Adjustment—35C ZTS......................... 9025-25-11 Circuit Relief Valve Test and Adjustment—27C ZTS......................... 9025-25-13 Circuit Relief Valve Test and Adjustment—35C ZTS......................... 9025-25-15 Swing Motor Crossover Relief Valve Test and Adjustment—27C ZTS...................................................... 9025-25-17 Swing Motor Crossover Relief Valve Test and Adjustment—35C ZTS...................................................... 9025-25-18 Hydraulic Pump 1 and 2 Regulator Test and Adjustment—Engine Pulldown .............................................. 9025-25-20 Hydraulic Pump 1 and 2 Flow Test—27C ZTS .................................... 9025-25-21 Hydraulic Pump 1 and 2 Flow Test—35C ZTS .................................... 9025-25-22

Continued on next page

TM2052 (17JUL18)

9025-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=1

Contents

Page

Hydraulic Pump 3 Flow Test—27C ZTS...................................................... 9025-25-23 Hydraulic Pump 3 Flow Test—35C ZTS...................................................... 9025-25-24 Swing Motor Leakage Test ...................... 9025-25-25 Propel Motor Leakage Test—27C ZTS...................................................... 9025-25-26 Propel Motor Leakage Test—35C ZTS...................................................... 9025-25-27

TM2052 (17JUL18)

9025-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=2

Group 05

Theory of Operation Hydraulic System Diagram and Operation 60 14

72

59

71

15

19

57 A 22 24 26 30 33 39

11

17

A

40 43 48

16

A

18

12

5 1

2

3

9

8 A

4

B

61

C D 62

69

T155014

T155014 —UN—12JUN02

70

Hydraulic System Diagram

Continued on next page

TM2052 (17JUL18)

9025-05-1

FR91424,0000001 -19-29MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=181

Theory of Operation 1— Hydraulic Pump 1 2— Hydraulic Pump 2 3— Hydraulic Pump 3 4— Pilot Pump 5— Pilot Filter 8— Propel Speed Solenoid Valve 9— Pilot Control Shut-Off Solenoid Valve 11— Oil Cooler 12— Hydraulic Oil Tank 14— Left Pilot Controller

15— Right Pilot Controller 16— Propel Pilot Controller 17— Blade Pilot Controller 18— Boom Swing Pilot Controller 19— Pilot Controller Pattern Conversion Valve 22— Blade Valve Spool 24— Swing Valve Spool 26— Boom Swing Valve Spool

The main hydraulic system is an open-center hydraulic system.

The hydraulic pump housing contains four pumps; hydraulic pump 1 (1), hydraulic pump 2 (2), hydraulic pump 3 (3), and pilot pump (4). The hydraulic pump is fastened to the engine flywheel housing and driven at engine speed through a flex coupling. The hydraulic pump contains two different types, a variable displacement, axial piston pump (1 and 2) and a gear pump (3). They supply high pressure oil to the control valve. The axial piston pump has a dual delivery port design allowing it to function as two pumps. The pilot pump supplies oil to the pilot circuit. See Pilot System Diagram and Operation for information on the pilot circuit. (Group 9025-05.)

Hydraulic oil flows from the hydraulic oil tank (12) through a suction screen to the hydraulic pumps. The hydraulic

30— Auxiliary Valve Spool 33— Arm Valve Spool 39— Right Propel Valve Spool 40— Left Propel Valve Spool 43— Boom Valve Spool 48— Bucket Valve Spool 57— Swing Motor and Gearbox 59— Bucket Cylinder 60— Boom Cylinder 61— Blade Cylinder

62— Left Propel Motor 69— Right Propel Motor 70— Rotary Manifold 71— Arm Cylinder 72— Boom Swing Cylinder A—To Control Valve Work Port Pilot Caps B—Supply Oil C—Pilot Oil D—Return or Pressure Free Oil

oil tank is pressurized to create a head of oil to ensure oil flows from the tank, through the suction line, and into the pumps. Hydraulic pumps 1, 2, and 3 deliver supply oil to the control valve. Supply oil is routed to motors (57, 62, and 69) and cylinders (59, 60, 61, 71, and 72) by valve spools (22, 24, 26, 30, 33, 39, 40, 43, and 48) of their respective valve section.

Return oil from the motors and cylinders is routed into the return passages in the control valve by the valve spools.

From the return passages, return oil flows out of the control valve through the oil cooler (11) to the hydraulic oil tank (12). An oil cooler bypass valve opens to route return oil around the oil cooler and directly into the hydraulic oil tank when resistance is high because the oil is cold (high viscosity), there is a surge of return oil, or the oil cooler becomes plugged.

FR91424,0000001 -19-29MAY02-2/2

TM2052 (17JUL18)

9025-05-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=182

Theory of Operation

Pilot System Diagram and Operation R

P

T

16 3

P

T

A

1

2

4

B R

4

D

P

T

E

2

1

3

F

C

R

H G

14

1

2

I

15 60

62

J

R T

57

F

K

P

L

R T

P

18

1

2

M Q

4

69 17

46

G

3

I

K

N

D

P

1

2

O A

P N 21

H

E

J

L

8

C

O

P4

5

P3

B

M

P2 P1

9 12 4 T155085 —UN—12JUN02

Q

R

T155085 Pilot System Diagram (Excavator Pattern Shown)

Continued on next page

TM2052 (17JUL18)

9025-05-3

FR91424,0000002 -19-30MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=183

Theory of Operation 4— Pilot Pump 5— Pilot Filter 8— Propel Speed Solenoid Valve 9— Pilot Control Shut-Off Solenoid Valve 12— Hydraulic Oil Tank 14— Left Pilot Controller 15— Right Pilot Controller 16— Propel Pilot Controller

17— Blade Pilot Controller 18— Boom Swing Pilot Controller 21— Flow Combiner Valve 46— Boom Reduced Leakage Valve 57— Swing Motor 60— Boom Cylinder 62— Left Propel Motor 69— Right Propel Motor

Pilot system is used to operate control circuits for control valve spools, swing park release, propel speed change valves, flow combiner valve (21), and boom reduced leakage valve (46).

See the following for the operation of pilot components:

• See Pilot Pump Operation—27C ZTS (Group 9025-05.)

• See Hydraulic Pump 3 and Pilot Pump Operation—35C

A—Swing Left B—Swing Right C—Arm Out D—Arm In E—Boom Up F— Boom Down G—Bucket Dump H—Bucket Curl I— Left Propel Forward J— Left Propel Reverse K—Right Propel Reverse L— Right Propel Forward

M—Blade Lower N—Blade Raise O—Boom Swing Right P—Boom Swing Left Q—Return to Hydraulic Oil Tank R—Return to Hydraulic Oil Tank

• See Pilot Controller Operation (Group 9025-05.)

• See Blade, Boom Swing, and Auxiliary Controller Operation (Group 9025-05.)

• See Propel Pilot Controller Operation (Group 9025-05.)

• See Control Valve Operation (Group 9025-05.)

• See Flow Combiner Valve Operation (Group 9025-05.)

• See Boom Reduced Leakage Valve Operation (Group 9025-05.)

ZTS (Group 9025-05.)

• See Swing Motor Park Brake Release Circuit Operation

9025-05.)

• See Hydraulic System Schematics (Group 9025-05.)

(Group 9025-05.)

• See Solenoid Valve Manifold Operation (Group

FR91424,0000002 -19-30MAY02-2/2

Pilot Pump Operation—27C ZTS

T125017 —19—17NOV99

The purpose of the pilot pump is to supply pilot pressure for the operation of the control valves. This pressure is directed to the control valves through the operation of the pilot controllers.

T121868 —19—17SEP99

The inner rotor is splined to an engine driven input shaft.

This shaft rotates the inner rotor which in turn rotates the outer rotor. The rotational center of the outer rotor is eccentric to rotation of the input shaft. As the rotors are turned, hydraulic oil is drawn into the suction side or space between rotors, then discharged when aligned with the delivery port.

TX19495,000007C -19-16MAY02-1/1

Pilot Filter Operation Pilot filter bypass valve senses differential pressure between inlet side and outlet side of filter element. During normal operation, bypass valve is held closed by spring and oil flows through filter element to pilot pressure

regulating valve. If filter element becomes plugged, pressure on inlet side increases forcing bypass valve open. Pilot oil now bypasses filter element and unfiltered oil flows to pilot pressure regulating valve spool.

TX19495,0000084 -19-31MAY02-1/1

TM2052 (17JUL18)

9025-05-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=184

Theory of Operation

Solenoid Valve Manifold Operation The solenoid valve manifold contains the propel speed solenoid valve (8), pilot control shut-off solenoid valve (9), and pilot pressure regulating valve (7). This assembly is mounted on a bracket located at the right side of the machine, under the hydraulic oil tank access cover.

B—To Pilot Controllers and Swing Park Brake C—To Hydraulic Oil Tank D—To Propel Motors (Propel Speed Change Valves)

T155108 —UN—23MAY02

7— Pilot Pressure Regulating Valve 8— Propel Speed Solenoid Valve 9— Pilot Control Shut-Off Solenoid Valve A—From Pilot Pump

FR91424,0000003 -19-31MAY02-1/4

Pilot Control Shut-Off Solenoid Valve The pilot control shut-off solenoid valve is switched ON/OFF by the position of the pilot control shut-off lever (1).

T155109 —UN—22MAY02

When the pilot control shut-off lever is in the LOCK position (armrest up), the pilot shut-off switch (2) is OFF. By this action, the pilot control shut-off solenoid valve is de-energized so that pilot pressure is blocked by the solenoid valve spool; pressure oil is not delivered to the pilot controllers.

When the pilot control shut-off lever is in the UNLOCK position (armrest down), the pilot shut-off switch is ON. By this action, the pilot control shut-off solenoid valve is energized so pilot pressure is supplied to the pilot controllers and the swing motor park brake through the solenoid valve spool.

Pilot Control Shut-Off Lever and Pilot Shut-Off Switch.

1— Pilot Control Shut-Off Lever 2— Pilot Shut-Off Switch

3— Armrest 4— Pilot Controller Continued on next page

TM2052 (17JUL18)

9025-05-5

FR91424,0000003 -19-31MAY02-2/4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=185

Theory of Operation Propel Speed Solenoid Valve The propel speed is controlled by the propel speed switch (1) that is actuated by a pedal.

When the pedal is pressed, the propel speed switch is ON. By this action, the propel speed solenoid valve is energized so that pilot pressure is delivered through the solenoid valve spool to the propel speed change valves in the propel motors .

T155110 —UN—22MAY02

When the pedal is in the slow speed position (not being depressed), the propel speed switch is OFF. By this action, the propel speed solenoid valve is de-energized so that pilot pressure is blocked by the solenoid valve spool; pilot oil is not being applied to the propel speed change valves in the propel motors.

Propel Speed Switch 1— Propel Speed Switch FR91424,0000003 -19-31MAY02-3/4

Pilot Pressure Regulating Valve The pilot pressure regulating valve prevents pressure in the circuit from exceeding a preset pressure. When the pressure in the pilot circuit increases to the pressure setting of spring (C), the poppet (B) moves to relieve hydraulic oil pressure through the poppet hole. The oil then passes into the return passage of the solenoid valve manifold back to the hydraulic oil tank.

C—Spring D—To Hydraulic Oil Tank

T155185 —UN—23MAY02

7— Pilot Pressure Regulating Valve A—From Pilot Pump B—Poppet

Pilot Pressure Regulating Valve FR91424,0000003 -19-31MAY02-4/4

TM2052 (17JUL18)

9025-05-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=186

Theory of Operation

Pilot Controller Operation

1 1

2 6 3 7 4 5 6 10

11

12

7 13 8

15

11 14

T143081 —UN—02FEB11

12

16 9

10

T143081 Metering and Full Stroke 1— Control Lever 2— Plunger 3— Spring Guide 4— Balance Spring 5— Return Spring 6— Orifice

7— Spool 8— Hole 9— Housing 10— Work Port 1, 2, 3, or 4 To Control Valve Pilot Caps

The pilot controllers regulate the pilot oil (15) pressure to shift the control valve spools to actuate the dig functions.

See Control Valve Operation for control valve operation.

(Group 9025-05.)

Each controller contains four valves. The ports (10, 11, and 12) in housing (9) are identified by numbers and letters next to each port. The valves are pressure reducing valves controlled by the movement of the control lever (1) and plunger (2).

Moving the control lever to actuate a function pushes the plunger and spring guide (3) against the balance spring (4) which moves the spool (7) down. During the initial movement (14) there is a deadband area (13) where the return oil (16) flow through the holes (8) to port T is blocked before pilot oil can flow from port P through the spool to the work port and out to the control valve pilot caps (10). Pilot oil pressure also flows through the orifice (6) to the top of the spool to dampen the upward

13— Deadband Area 11— Port P From Pilot Control 14— Initial Movement Shut-Off Solenoid Valve 12— Port T To Hydraulic Oil Tank 15— Pilot Oil 16— Return Oil

movement of spool. Pilot oil pressure increases until the pressure is equal to the force of the balance spring.

The balance spring pushes the spool up until the oil flow through the holes is blocked in the deadband area.

With the oil flow blocked, the control valve spool is held stationary until the control lever is again actuated.

When the control lever is actuated to full stroke, the plunger contacts the spool pushing it down until the plunger contacts a shoulder in the housing. Oil pressure to the control valve pilot caps is now approximately equal to pilot system pressure.

When the control lever is returned to neutral, the spool is pulled up by the return spring (5) and pushes the plunger up. The return springs hold the control lever in the center position. With the spool up, the passage to the control valve pilot cap is open to port T and pilot oil from port P is blocked.

TX08227,000000A -19-31MAY02-1/1

TM2052 (17JUL18)

9025-05-7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=187

Theory of Operation

Propel Pilot Controller Operation 1 1 2

6

3

12

11

9

12

4 5 9

6 7

10

8

T155283 —UN—03JUN02

11 13 14

T155283

12 Propel Pilot Controller—Metering and Full Stroke

1— Cam 2— Plunger 3— Plunger Spring Guide 4— Plunger Spring 5— Spool Spring Guide

6— Spool 7— Return Spring 8— Balance Spring 9— Port T to Hydraulic Oil Tank

One pilot controller is used to control the propel functions.

The controller contains four valve assemblies, one for each direction of travel for each track.

The pilot controller consists of the cam (1), plunger (2), plunger spring guide (3), plunger spring (4), spool spring guide (5), spool (6), return spring (7), and balance spring (8).

In neutral, the spool is pushed up by the return spring blocking pilot oil at port P from the pilot control shut-off valve (11). With the spool up, hole (10) connects the work port to control valve propel spool pilot cap (12) to port T to hydraulic oil tank (9) by the passage through the spool.

When the pedal or lever is pushed to move the machine, the cam pushes the plunger and spool spring guide down

10— Hole 11— Port P from Pilot Control Shut-Off Valve 12— Work Port to Control Valve Propel Spool Pilot Cap

13— Pilot Oil 14— Return Oil

against the return spring and balance spring. The balance spring pushes the spool down. As the spool is pushed down the passage from the control valve propel spool pilot cap to the hydraulic oil tank is closed and then is opened to the pilot oil from pilot control shut-off valve. When the pilot oil pressure to the control valve propel spool pilot cap is equal to the force applied by the balance spring the spool moves up trapping the oil to the pilot cap.

When the pedal or lever moves the cam to full stroke, the plunger compresses plunger spring (4) and return spring (7) allowing the plunger to push directly on the spool. The plunger holds the spool down so the passage through spool remains open to pilot oil. Oil pressure to the control valve propel spool pilot cap now equals pilot oil pressure.

FR91424,0000004 -19-03JUN02-1/1

TM2052 (17JUL18)

9025-05-8

27C ZTS and 35C ZTS Operation & Tests 071718 PN=188

Theory of Operation

Blade, Boom Swing, and Auxiliary Pilot Controller Operation 1 1 2

6

10

3

9

7

10

4 5

7

6 8

T155284 —UN—05JUN02

9 11 12

T155284

10 Boom and Auxiliary Pilot Controller—Metering and Full Stroke

1— Cam 2— Plunger 3— Spring Guide 4— Balance Spring 5— Return Spring

6— Spool 7— Port T to Hydraulic Oil Tank 8— Hole 9— Port P from Pilot Control Shut-Off Solenoid Valve

10— Work Port to Control Valve Propel Spool Pilot Cap 11— Pilot Oil

12— Return Oil

The pilot controller consists of the cam (1), plunger (2), spring guide (3), balance spring (4), return spring (5), and spool (6).

down so the passage through spool remains open to pilot oil. Oil pressure to the control valve propel spool pilot cap now equals pilot oil pressure.

In neutral, the spool blocks pilot oil at port P from the pilot control shut-off valve (9). With the spool in the neutral position, hole (8) connects the work port to control valve propel spool pilot cap (10) to port T to hydraulic oil tank (7) by the passage through the spool.

Blade Controller Operation

When the pedal or lever is pushed to activate a function, the cam pushes the plunger down against the spring guide. The spring guide compresses the balance spring and return spring. The return spring pushes the spool down. As the spool is pushed down the passage from the control valve propel spool pilot cap to the hydraulic oil tank is closed and then is opened to the pilot oil from pilot control shut-off valve. When the pilot oil pressure to the control valve propel spool pilot cap is equal to the force applied by the balance spring the spool moves up trapping the oil to the pilot cap.

The blade controller is operated by a lever located to the right of the operator's seat. When the lever is pulled back, pilot oil is routed to the control valve blade valve spool blade raise pilot cap. When the lever is pushed forward, pilot oil is routed to the control valve blade valve spool blade lower pilot cap. When the lever is released, it returns to the neutral (center) position.

Boom Swing Controller Operation

When the pedal or lever moves the cam to full stroke, the plunger pushes down on the spring guide compressing balance spring and return spring allowing the plunger to push directly on the spool. The plunger holds the spool

The boom swing controller is operated by a pedal located on the right side of the cab floor. When the pedal is rocked to the left, pilot oil is routed to the control valve boom swing spool swing left pilot cap. When the pedal is rocked to the right, pilot oil is routed to the control valve boom swing spool swing right pilot cap. When the pedal is released, it returns to the neutral (center) position.

Auxiliary Controller Operation

Continued on next page

TM2052 (17JUL18)

9025-05-9

FR91424,0000005 -19-03JUN02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=189

Theory of Operation

The auxiliary controller is used for any add on accessories such as an auger, pile driver, etc. The controller is operated by a pedal located on the left side of the cab floor. The operation of the rocking of the pedal is

determined by the accessory attached. The auxiliary control valve works in conjunction with the one way/two way valve. See One Way/Two Way Valve Operation for more information. (Group 9025-05.)

FR91424,0000005 -19-03JUN02-2/2

T125019 —19—18NOV99

Hydraulic Pump 1 and 2 Operation

T125052 —19—17NOV99

Hydraulic Pump 1 and 2—35C ZTS

Hydraulic Pump 1 and 2—27C ZTS Continued on next page

TM2052 (17JUL18)

9025-05-10

CED,OUOE011,27 -19-16MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=190

Theory of Operation

The hydraulic pump is driven at engine speed. It consists of four pumps: 1, 2, 3 and pilot pump. The hydraulic pump contains two different types, a variable displacement, axial piston pump (1 and 2) and a gear pump (3). They supply high pressure oil to the control valve. The axial piston pump has a dual delivery port design. This allows it to function as two pumps.

The hydraulic pump shaft is splined to the cylinder block and pistons are inserted in the cylinder block.

Suction/delivery ports are alternately placed on the inside and outside of the cylinder block. Also, there are delivery ports on each side (inside and outside) of the valve plate (there is only one suction port). The dual outlet port design allows one pump to function like two pumps having equal oil displacement.

T121929 —19—17SEP99

The engine rotation drives the shaft directly and rotates the cylinder block and pistons together. The pistons slide on the thrust plate and reciprocate in the cylinder block by the tilt of the swash plate.

Pump Suction/Delivery Ports

CED,OUOE011,27 -19-16MAY02-2/2

TM2052 (17JUL18)

9025-05-11

27C ZTS and 35C ZTS Operation & Tests 071718 PN=191

Theory of Operation

T156112 —UN—18JUN02

Hydraulic Pump Regulator Operation—27C ZTS

Pump Delivery Flow Rate Operation—27C ZTS 1— Hydraulic Pump 1 and 2 2— Hydraulic Pump 3 3— Pilot Pump

4— Supply Pressure from Hydraulic Pump 3 5— Pump Flow Rate Control Piston

To prevent the load of hydraulic pumps 1, 2, and 3 (1 and 2) from exceeding the engine torque, the pumps self-regulate delivery flow rate.

When the discharged pressure from hydraulic pumps 1 and 2 increases, the pump pistons (6) apply a force to the swash plate (8) against the swash plate angle regulating spring (9) force. If the piston force exceeds the spring force, the swash plate decreases the angle at pivot pin (7), causing hydraulic pumps 1 and 2 to reduce flow.

The supply pressure from hydraulic pump 3 (2) is applied to the pump flow rate control piston (5) through a passage in the housing. The control piston is held against swash plate by a spring.

6— Piston 7— Pivot Pin 8— Swash Plate 9— Swash Plate Angle Regulating Springs

When the supply pressure from hydraulic pump 3 increases, the control piston pushes the swash plate against the spring force. If the control piston force exceeds the spring force, the swash plate decreases the angle at the pivot pin, causing hydraulic pumps 1 and 2 to reduce flow.

Consequently, the delivery flow rate of hydraulic pumps 1 and 2 varies depending on changes in load from hydraulic pump 3 so that the total load from the three pumps does not exceed the engine output torque.

CED,OUOE011,29 -19-17MAY02-1/1

TM2052 (17JUL18)

9025-05-12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=192

Theory of Operation

T155991 —UN—18JUN02

Hydraulic Pump Regulator Operation—35C ZTS

Pump Delivery Flow Rate Operation—35C ZTS 1— Hydraulic Pump 1 and 2 2— Hydraulic Pump 3

3— Pilot Pump 5— Piston 4— Swash Plate Angle Regulating 6— Swash Plate Spring 7— Pivot Pin 8— Pump Flow Rate Control Piston

To prevent the load of hydraulic pumps 1, 2, and 3 (1 and 2) from exceeding the engine torque, the pumps self-regulate delivery flow rate.

When the discharged pressure from hydraulic pumps 1 and 2 increases, the pump pistons (5) apply a force to the swash plate (6) against the swash plate angle regulating spring (4) force. If the piston force exceeds the spring force, the swash plate decreases the angle at pivot pin (7), causing hydraulic pumps 1 and 2 to reduce flow.

The supply pressure from hydraulic pump 3 (2) is applied to the pump flow rate control piston (8) through a passage in the housing. The control piston is held against swash plate by a spring.

When the supply pressure from the hydraulic pump 3 increases, the control piston pushes the swash plate against the swash plate angle spring force. If the control piston force exceeds the spring force, the swash plate decreases the angle at the pivot pin, causing hydraulic pumps 1 and 2 to reduce flow.

Consequently, the delivery flow rate of hydraulic pumps 1 and 2 varies depending on changes in load from hydraulic pump 3 so that the total load from the three pumps does not exceed the engine output torque.

CED,OUOE003,5512 -19-17MAY02-1/1

TM2052 (17JUL18)

9025-05-13

27C ZTS and 35C ZTS Operation & Tests 071718 PN=193

Theory of Operation

Hydraulic Pump 3 Operation—27C ZTS Hydraulic pump 3 is a gear pump. The drive gear is mounted on the shaft engaging the driven gear.

Engine rotation drives the shaft directly and rotates along with the drive gear.

T121931 —19—17SEP99

T125053 —19—17NOV99

When the drive gear rotates, the driven gear also rotates.

Hydraulic oil from the suction port fills the spaces between the gears, then flows along the inner surfaces of the housing and discharges through the delivery port.

TX19495,000007D -19-16MAY02-1/1

TM2052 (17JUL18)

9025-05-14

27C ZTS and 35C ZTS Operation & Tests 071718 PN=194

Theory of Operation

The purpose of the pilot pump is to supply pilot pressure for the operation of the control valves. This pressure is directed to the control valves through the operation of the pilot controllers.

Hydraulic pump 3 is a gear pump. The drive gear is mounted on the shaft engaging the driven gear.

Engine rotation drives the shaft directly and rotates along with the drive gear.

T125018 —19—18NOV99

Hydraulic Pump 3 and Pilot Pump Operation—35C ZTS

T121931 —19—17SEP99

When the drive gear rotates, the driven gear also rotates.

Hydraulic oil from the suction port fills the spaces between the gears, then flows along the inner surfaces of the housing and discharges through the delivery port.

TX19495,000007B -19-16MAY02-1/1

TM2052 (17JUL18)

9025-05-15

27C ZTS and 35C ZTS Operation & Tests 071718 PN=195

Theory of Operation

Control Valve Operation The control valve is an assembly consisting of twelve valve sections, nine of which are function control valves.

The remaining three sections are for flow combining and relief valve functions. The function control valves are open center and each section controls flow rate and direction for its own hydraulic circuit. Valve spools are controlled by pilot pressure. All valve spools are accessible by removal of a plug or pilot cap.

Individual circuits are protected by circuit relief valves (35, 36, 44, 45, 49, 50, 76, and 77). System relief valves (20) are used to govern supply pressures from hydraulic pumps 1, 2, and 3.

See Hydraulic System Schematics for Control Valve Schematic. (Group 9025-05.)

Continued on next page

TM2052 (17JUL18)

9025-05-16

FR91424,0000007 -19-04JUN02-1/7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=196

Theory of Operation

Control Valve Component Identification

P1

P3

A

P2

B

C

D

E

F

G

H

I

J

K

L

74 76 35 20

20 46 47 49

36 20 45 44

T155812

50

T155812 —UN—10JUN02

77

Control Valve Components

Continued on next page

TM2052 (17JUL18)

9025-05-17

FR91424,0000007 -19-04JUN02-2/7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=197

Theory of Operation A—Flow Combiner Valve Section (Hydraulic Pump 3 System Relief Valve Section) B—Blade Valve Section C—Swing Valve Section D—Boom Swing Valve Section E—Auxiliary Flow Combiner Valve Section F— Auxiliary Valve Section G—Arm Valve Section H—Right Propel Valve Section

I— Hydraulic Pump 1 and 2 System Relief Valve Section J— Left Propel Valve Section K—Boom Valve Section L— Bucket Valve Section 20— System Relief Valve (3 used) 35— Arm Out Circuit Relief and Anti-Cavitation Valve 36— Arm In Circuit Relief and Anti-Cavitation Valve

44— Boom Down Circuit Relief and Anti-Cavitation Valve 45— Boom Up Circuit Relief and Anti-Cavitation Valve 46— Boom Reduced Leakage Valve 47— Boom Reduced Leakage Valve Check Valve 49— Bucket Curl Circuit Relief and Anti-Cavitation Valve 50— Bucket Dump Circuit Relief and Anti-Cavitation Valve

74— Boom Swing Make-Up Check Valve 76— Auxiliary Circuit Relief and Anti-Cavitation Valve 77— Auxiliary Circuit Relief and Anti-Cavitation Valve

FR91424,0000007 -19-04JUN02-3/7

Control Valve Pressure and Return Line Identification

2 3 4 5 1

6 23

9

7 22

8

10 11

21

12 13

20 19 18 17 16 15

T156456 —UN—27JUN02

14

T156456 Control Valve Pressure and Return Line Identification 1 — From Hydraulic Pump 2— To Hydraulic Oil Tank 3— To Rotary Manifold Port F (Blade Raise) 4— To Swing Motor Port A 5— To Boom Swing Cylinder Head End 6— To Swing Motor Port M 7— To Auxiliary Attachment Manifold Rear Bottom Port

8— To Arm Cylinder Rod End 9— To Rotary Manifold Port A (Right Propel Reverse) 10— From Hydraulic Pump 1 11— To Rotary Manifold Port D (Left Propel Forward) 12— To Boom Cylinder Head End 13— To Bucket Cylinder Head End

14— To Bucket Cylinder Rod End 15— To Boom Cylinder Rod End 16— To Rotary Manifold Port C (Left Propel Reverse) 17— From Hydraulic Pump 2 18— To Rotary Manifold Port B (Right Propel Forward) 19— To Arm Cylinder Head End

Continued on next page

TM2052 (17JUL18)

9025-05-18

20— To One Way/Two Way Valve Top Port 21— To Blade Swing Cylinder Rod End 22— To Swing Motor Port B 23— To Rotary Manifold Port E (Blade Lower)

FR91424,0000007 -19-04JUN02-4/7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=198

Theory of Operation Control Valve Pilot Pressure Line Identification

2A

U

5A

5B

8B

PILOT

1

A CONTROLLER

2

B

PATTERN CONVERSION VALVE

3

C

4

D

8A

1B

1A

4B

4A

7A

7B

9A

9B

3B

3A

6A

6B

PILOT LINE BULKHEAD

2B

1A

2A

3B

4B

5B

6B

7B

8B

9B

3A

4A

5A

6A

7A

8A

9A

U

T156488

D1

S2

NOTE: PILOT LINES ARE ROUTED FROM THE CONTROL VALVE TO THE BULKHEAD AS LABELED, EXCEPT THOSE ROUTED AS SHOWN HERE

T156488 —19—15AUG02

2B

1B

Control Valve Pilot Pressure Line Identification

Continued on next page

TM2052 (17JUL18)

9025-05-19

FR91424,0000007 -19-04JUN02-5/7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=199

Theory of Operation 1A—Bucket Curl 2A—Boom Up D1—To Hydraulic Oil Tank 3A—Left Propel Forward 4A—Right Propel Reverse 5A—Arm Out

6A—Auxiliary Function Supply 7A—Boom Swing Right 8A—Swing Left 9A—Blade Raise 1B—Bucket Dump 2B—Boom Down

3B—Left Propel Reverse 4B—Right Propel Forward 5B—Arm In 6B—Auxiliary Function Return 7B—Boom Swing Left Continued on next page

TM2052 (17JUL18)

9025-05-20

8B—Swing Right 9B—Blade Lower S2— Flow Combiner U—Boom Reduced Leakage Valve (Boom Lower) FR91424,0000007 -19-04JUN02-6/7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=200

Theory of Operation Control Valve Neutral and Parallel Passage Operation

62

69

71

61

57 60

72

59 70

A

46

28

21 20

A 20

49

50 45

44

35 36

74

B

2

B

1

12 11 3

C D

T156615

T156615 —UN—02JUL02

4 10

Control Valve Neutral and Parallel Passages

FR91424,0000007 -19-04JUN02-7/7

TM2052 (17JUL18)

9025-05-21

27C ZTS and 35C ZTS Operation & Tests 071718 PN=201

Theory of Operation A—Neutral Passage B—Parallel Passage C—Supply Oil D—Return Oil 1— Hydraulic Pump 1 2— Hydraulic Pump 2 3— Hydraulic Pump 3 4— Pilot Pump 10— Oil Cooler Bypass Valve 11— Oil Cooler 12— Hydraulic Oil Tank 20— System Relief Valve (3 used)

21— Flow Combiner Valve 28— Auxiliary Flow Combiner Valve 35— Arm Out Circuit Relief and Anti-Cavitation Valve 36— Arm In Circuit Relief and Anti-Cavitation Valve 44— Boom Down Circuit Relief and Anti-Cavitation Valve

Supply oil (C) from hydraulic pumps 1, 2, and 3 flows to the control valve respectively. When the spools are in neutral (all pilot controllers in neutral) the supply oil returns to the hydraulic oil tank (12) through the neutral passage (A).

When a pilot controller is operated the corresponding spool valve is shifted by pilot oil and the supply oil from the pump is directed to the function, either a motor or cylinder, actuating that function.

When a combined operation of propel and front attachment is performed, the flow combiner valve (21) is

45— Boom Up Circuit Relief and Anti-Cavitation Valve 46— Boom Reduced Leakage Valve 49— Bucket Curl Circuit Relief and Anti-Cavitation Valve 50— Bucket Dump Circuit Relief and Anti-Cavitation Valve 57— Swing Motor and Gearbox

59— Bucket Cylinder 60— Boom Cylinder 61— Blade Cylinder 62— Left Propel Motor 69— Right Propel Motor 70— Rotary Manifold 71— Arm Cylinder 72— Boom Swing Cylinder

shifted by pilot oil and supply oil from hydraulic pump 3 is routed into the parallel passage (B) providing the needed oil to perform combined functions.

The supply oil pressure from the pumps is controlled by system relief valves (20). The system relief valves prevent the pressure in the system from exceeding the set pressure when operating functions. The pressure in a functional circuit is controlled by circuit relief valves to prevent the pressure from exceeding the set pressure at the spool.

FR91424,0000007 -19-04JUN02-8/7

System Relief Valve Operation

T125077 —19—18NOV99

There are three system relief valves used on the main control valve. Each relief valve governs a series of functions. One governs the blade, swing and boom swing, another the auxiliary, propel-right, and arm. The last governs the bucket, boom and propel-left.

The system relief valves prevent pressures in the main circuit from exceeding set pressures.

The pressure on port HP acts on pilot poppet (8) through orifice (2) in main poppet (1) and orifice (4) in seat (5).

When the pressure in port HP exceeds the set pressure, pilot poppet (8) opens to release a small quantity of pressure oil to port LP via passage (6) of seat (5).

At this time, the pressure difference between port HP and spring chamber (9) occurs, caused by orifice (2). By this pressure difference, main poppet (1) opens when it becomes greater than spring (3) force, to relieve the pressure oil from port HP to port LP.

1— Main Poppet 2— Orifice 3— Spring 4— Orifice 5— Seat

6— Passage 7— Spring 8— Pilot Poppet 9— Spring Chamber

CED,OUOE011,77 -19-15MAY02-1/1

TM2052 (17JUL18)

9025-05-22

27C ZTS and 35C ZTS Operation & Tests 071718 PN=202

Theory of Operation

Circuit Relief Valve Operation

T154998 —UN—19JUN02

The circuit relief valve has two operations; one is the relief operation which prevents the pressure in the actuator circuit from exceeding the set pressure, and the other is the make-up operation which prevents cavitation. The circuit relief valve is provided in boom, arm and bucket circuits.

Relief Operation When the pressure in the actuator circuit rises, pressure oil is relieved to the hydraulic oil tank.

The pressure on port HP acts on pilot poppet (4) via passage (8) in piston (9).

When the pressure on port HP exceeds the set pressure, pilot poppet (4) opens. Then, the pressure oil can flow to port LP via passage (6) in seat (3).

At this time, the pressure difference between port HP and spring chamber (7) occurs, caused by orifice (8).

By this pressure difference, main poppet (1) opens when it becomes greater than spring (2) force, to relieve the pressure oil from HP to port LP. Make-Up Operation When actuator speed increases faster than the pressure used to actuate it, the circuit relief valve supplies hydraulic oil from the hydraulic oil tank into the actuator circuit to prevent cavitation.

Circuit Relief and Anti-Cavitation Valve 1— Main Poppet 2— Spring 3— Seat 4— Pilot Poppet 5— Spring 6— Passage

7— Spring Chamber 8— Orifice 9— Piston 10— Sleeve 11— Spring

Oil pressure in port HP becomes less than return oil pressure in port LP. The higher pressure of return oil acts on face of main poppet (1) and sleeve (10) to overcome spring (11) force. Return oil flows from port LP into port HP preventing cavitation.

TX19495,000007F -19-17MAY02-1/1

Boom Swing Make-Up Check Valve Operation The make-up check valve is used to prevent cavitation in the boom swing circuit.

The pressure on port HP acts on the spring chamber through the poppet passage, so the pressure on port HP and spring chamber becomes equal. When the pressure on port HP is higher, the closing force (Pressure in Spring Chamber x Pressurized Area S2) becomes greater than the opening force of the poppet (Port HP x Pressurized Area S1), the poppet closes.

When the pressure on port HP is lower than the pressure on port LP (pressure on port HP is almost zero), the closing force of the poppet is only the spring force. When

T121977 —19—17SEP99

When the boom swing function is operated downward on a slope, the boom is accelerated by its own weight and moves quicker than the supply oil flow to the boom swing cylinder. Therefore, cavitation can occur in the circuit.

the opening force of poppet (Pressure on Port LP x [Pressurized Area S2—S1]) becomes greater than the closing force (Spring Force), the poppet opens to supply hydraulic oil to port HP. Thereby, cavitation at the port HP side is prevented.

TX19495,0000080 -19-17MAY02-1/1

TM2052 (17JUL18)

9025-05-23

27C ZTS and 35C ZTS Operation & Tests 071718 PN=203

Theory of Operation

Flow Combiner Valve Operation 3

1

2

T155118 —UN—23MAY02

5

4 T155118 Flow Combiner Valve 1— To Bucket and Boom Valve Spools

2— To Arm and Auxiliary Valve Spools

When propel (right), propel (left), boom, arm, or bucket function is operated, the valve spool in the control valve blocks the pilot signal circuit. Therefore, the pressure in the pilot signal circuit increases, shifting the flow combiner valve spool.

When the flow combiner valve spool is shifted, pressure oil from hydraulic pump 3 is routed through passages in the flow combiner valve to the bucket, boom, arm and auxiliary valve spools. Pressure oil to the bucket

3— Pressure Oil From Hydraulic Pump 3

4— Valve Spool 5— Pilot Oil

and boom valve spools is routed through passage (1).

Pressure oil to the arm and auxiliary valve spools is routed through passage (2).

Hydraulic pumps 1 and 2 provide pressure oil to the left and right propel valve spools. Hydraulic pump 3 provides pressure oil to the blade, swing, and boom swing valve spools through a separate circuit, bypassing the flow combiner valve.

TX19495,0000081 -19-21MAY02-1/1

Auxiliary Flow Combiner Valve Operation Hydraulic pumps 2 and 3 provide pressure oil to the auxiliary valve spool. When using an attachment that does not require much oil flow, the auxiliary flow combiner

valve is shifted by pilot oil. When shifted, pressure oil from hydraulic pump 3 is not supplied to the auxiliary valve spool.

TX19495,0000083 -19-24MAY02-1/1

TM2052 (17JUL18)

9025-05-24

27C ZTS and 35C ZTS Operation & Tests 071718 PN=204

Theory of Operation

T155104 —UN—22MAY02

Boom Reduced Leakage Valve Operation

Boom Reduced Leakage Valve 1— Boom Cylinder 2— Pilot Pressure Signal 3— Piston

4— To Hydraulic Oil Tank 5— Pilot Valve Spool 6— Boom Valve Spool

7— Spring 8— Passage 9— Check Valve Poppet 10— To Boom Valve Lower Work Port

(5). The check valve poppet is held closed against the seat in control valve housing.

The boom reduced leakage valve is used in the boom head end circuit. The function of the reduced leakage valve is to reduce cylinder drift by stopping leakage from the boom cylinder (1) back through the control valve.

When the boom valve is in neutral, the pressure generated in the boom cylinder head end by the load on the cylinder is applied to the spring (7) side of check valve poppet (9) through a control valve passage (8) and pilot valve spool

Actuating the boom up function applies supply oil pressure against the check valve. The supply oil pressure increases until it pushes the check valve poppet open against the pressure applied to the check valve. Supply oil flows to the head end of boom cylinder raising the boom.

Continued on next page

TM2052 (17JUL18)

9025-05-25

CED,TX08227,3277 -19-20MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=205

Theory of Operation

Actuating the boom down function sends a pilot pressure signal to the bottom pilot caps and to the boom reduced leakage valve piston (3). The pilot pressure signal to the bottom pilot cap shifts the boom spool up routing supply oil to the boom cylinder rod end. At the same time the pilot pressure signal shifts the piston in the boom reduced leakage valve. The piston pushes the pilot valve spool (5) against its spring opening a passage through the spool for

oil to flow from the check valve spring (7) chamber out of the drain port to the hydraulic oil tank (4). The return oil pressure from the boom cylinder head end pushes the check valve poppet off its seat opening a passage for oil to flow to the return passage. The check valve poppet is pushed off its seat because the OD of the upper land at the head end of the poppet is slightly larger than the lower land.

CED,TX08227,3277 -19-20MAY02-2/2

Arm Regenerative Valve Operation 4

T155080 —UN—23MAY02

1

2 3 5 T155080 Arm Regenerative Valve 1— Cylinder Rod Side 2— Passage

3— Arm Regenerative Valve

4— Cylinder Bottom Side 5— Arm Valve Spool

The arm regenerative valve controls return oil flow from arm cylinder rod side when arm is rolled in to regulate arm acceleration. This prevents cavitation and also improves control.

opens a poppet in the arm regenerative valve (3) so that the return oil can flow into the cylinder bottom side (4) together with pressure oil from the pump, compensating for the insufficient oil flow into the arm cylinder bottom side.

When the arm is rolled in with the bucket raised off the ground, the arm cylinder is pulled due to the arm and bucket weight. Therefore, the arm cylinder is extended at a faster speed than oil can be supplied from the pump, reducing the pressure in the cylinder bottom side lower than in the rod side pressure. Then, the return oil from the arm cylinder rod side (1) flows through a passage (2) and

During excavation, when the pressure in the arm cylinder bottom side increases more than in the rod side, the high pressure in the bottom side acts on the poppet, keeping the poppet closed. Accordingly, the return oil from the arm cylinder rod side flows back to the hydraulic oil tank without flowing to the bottom side.

CED,OUOE011,39 -19-22MAY02-1/1

TM2052 (17JUL18)

9025-05-26

27C ZTS and 35C ZTS Operation & Tests 071718 PN=206

Theory of Operation

T125212 —19—17NOV99

Swing Gearbox Operation—27C ZTS

The swing reduction gear is a one-stage planetary-gear reduction type.

The swing motor rotation force is transmitted to the sun gear via the shaft.

The rotation of the sun gear is reduced by the planetary gear and the ring gear. This in turn rotates the output shaft via the holder.

The output shaft rotates in two roller bearings. The output shaft and bearings are retained in the housing by a nut.

The lower bearing is isolated from the oil in the gearbox by an oil seal. The cavity for the lower bearing is filled with grease at assembly.

CED,OUOE011,40 -19-16MAY02-1/1

TM2052 (17JUL18)

9025-05-27

27C ZTS and 35C ZTS Operation & Tests 071718 PN=207

Theory of Operation

T156023 —UN—18JUN02

Swing Gearbox Operation—35C ZTS

1— First Stage Sun Gear 2— First Stage Carrier 3— First Stage Planet Gear

4— Second Stage Planet Gear 5— Second Stage Carrier

The swing gearbox is a two-stage planetary type gearbox.

The swing motor is mounted on the swing gearbox housing and encloses the top of gearbox housing. The ring gear (6) is part of the gearbox housing. The first stage planet gears (3) rotate around needle bearings on the shafts in the first stage carrier (2). The second stage planet gears (4) and bushings rotate on the shafts in the second stage carrier (5). The output shaft (8) is in mesh with the swing gear. Swing motor rotational speed is reduced and output torque is increased by the two-stage planetary gear set to turn the upperstructure.

The swing motor output shaft (9) drives the first stage sun gear (1) turning the first stage planet gears against the

6— Ring Gear 7— Second Stage Sun Gear 8— Shaft 9— Swing Motor Output Shaft

stationary ring gear. Rotary power is transmitted through the shafts to the first stage carrier. The first stage carrier turns, transmitting rotary power to the second stage sun gear (7). The second stage sun gear turns the second stage planet gears against the stationary ring gear. Then, rotary power is transmitted through the shafts to the second stage carrier which turns the output shaft.

The output shaft rotates in two roller bearings. The output shaft and bearings are retained in the housing by a nut.

The lower bearing is isolated from the oil in the gearbox by an oil seal. The cavity for the lower bearing is filled with grease at assembly.

CED,OUOE011,83 -19-16MAY02-1/1

TM2052 (17JUL18)

9025-05-28

27C ZTS and 35C ZTS Operation & Tests 071718 PN=208

Theory of Operation

T158727 —UN—27AUG02

Swing Motor Operation

Swing Motor 1— Holder 2— Retainer 3— Pin 4— Disk Plate 5— Collar 6— O-Ring 7— O-Ring 8— Socket Bolt

9— Spring Seat 10— Valve Plate 11— Spring 12— Cover 13— Retaining Ring 14— Washer 15— Bearing

16— Shaft 17— Pin 18— Disk Spring 19— Pin 20— Cylinder Block 21— Brake Piston 22— O-Ring

The swing motor is a fixed-displacement, axial piston motor.

The motor consists of the cylinder block (20) and shaft (16), pistons and slippers, valve plate (10), disk plate (4), brake piston (21), and cover (12). The cover contains the crossover relief valves, anti-cavitation valves, and work ports.

The cylinder block and output shaft are one assembly.

Each piston is connected to a slipper by a ball joint. The slippers slide on the inclined swash plate (26) forcing the cylinder block to turn when pressure oil is applied to the pistons. Retainer (2) holds the slippers on the swash plate and the retainer itself is held against the slippers by the ball guide. The pistons in the valve plate hold the valve plate against the cylinder block and the cylinder block and output shaft against the ball guide. The valve plate is held stationary by dowel pins in the cover.

Oil from swing control valve is routed through the work ports and valve plate to the pistons.

23— O-Ring 24— Plunger 25— Housing 26— Swash Plate 27— Bearing

inclined swash plate. The slippers slide down the inclined swash plate causing the cylinder block and output shaft to turn. Swing speed varies depending on the amount of supply oil delivered by the pump through the control valve.

During the second half of motor's revolution, low pressure oil is discharged as pistons slide back up the inclined swash plate. To reverse rotation, oil flow is reversed. A small amount of supply oil flows through the center of each piston to ball joint and to face of slipper for lubrication.

The swing park brake is spring applied and hydraulically released. The disk plate (4) is connected by splines to rotate with the cylinder block. When the pilot control shut-off switch is off, pilot oil is blocked from the park brake piston by the pilot control shut off solenoid valve.

The brake springs squeeze the plate and disk together to prevent the upperstructure from swinging. The park brake is released when the pilot control shut off switch is on and the pilot control shut off solenoid is energized.

In operation, high pressure supply oil enters the cylinder block bores through ports forcing pistons down against the CED,OUOE011,42 -19-23AUG02-1/1

TM2052 (17JUL18)

9025-05-29

27C ZTS and 35C ZTS Operation & Tests 071718 PN=209

Theory of Operation

Swing Motor Crossover Relief Valve Operation 2— Crossover Relief Valve (2 used)

T125214 —19—17NOV99

1— Swing Motor Cover

T158713 —19—27AUG02

Crossover Relief Valve—Location In Cover

Crossover Relief Valve Continued on next page

TM2052 (17JUL18)

9025-05-30

CED,OUOE011,43 -19-16MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=210

Theory of Operation

There are two crossover relief valves (2) located in the swing motor cover (1).

T122040 —19—17SEP99

The relief valves function to reduce shocks developed when starting or stopping swing movement (shockless) and to protect the circuit from overloading (relief).

When the pressure in the circuit increases, the pressure oil enters the piston chamber via orifice in poppet and housing to move the piston. The pressure in the spring chamber is kept low during the movement of the piston.

Therefore, when the pressure on port HP exceeds the spring set force, the poppet opens to relieve hydraulic oil.

When the piston moves to the stroke end, pressure in the spring chamber becomes equal to the pressure on port HP. As a result, the relief set force overcomes the normal pressure, so the poppet closes.

Relief Valve—Shockless Operation

When the pressure in the circuit exceeds the relief set pressure, the force acting on the poppet (Pressurized Area [S1—S2] x Pressure on Port HP) exceeds the spring force, causing the poppet to open and allow hydraulic oil to be relieved.

T122041 —19—17SEP99

When operating the swing suddenly in the reverse direction, pressure will be routed to the opposite side (port LP, in this case) of the piston to return the piston to its original position.

Relief Valve—Relief Operation CED,OUOE011,43 -19-16MAY02-2/2

Swing Motor Make-Up Check Valve Operation There are two make-up check valves (2) located in swing motor cover (1).

The make-up check valve prevents cavitation in the circuit.

To prevent cavitation when oil pressure in the circuit is lower than pressure at port M (hydraulic oil tank pressure), the poppet opens, drawing hydraulic oil into the circuit so that the pump oil flow rate is replenished.

1— Swing Motor Cover

2— Make-Up Check Valve (2 used)

T125215 —19—19NOV99

When the upperstructure swings downward on a slope, the upperstructure is accelerated by its own weight and moves quicker than the swing motor drive speed developed by the pump oil flow rate. Therefore, cavitation can occur in the circuit.

TX19495,000007E -19-16MAY02-1/1

TM2052 (17JUL18)

9025-05-31

27C ZTS and 35C ZTS Operation & Tests 071718 PN=211

Theory of Operation

Swing Motor Park Brake Release Circuit Operation The park brake is a wet type, single disk, negative type brake. A negative type brake is spring applied and hydraulically released. The park brake is released only when the brake release pressure oil is routed into the brake piston chamber.

When the pilot control shut-off lever is in the UNLOCKED position, the pilot shut-off switch is ON. By this action, the pilot shut-off solenoid valve is energized, so that the brake release pressure (pilot pressure) is guided to the brake piston chamber to push the brake piston upward, allowing the brake piston and the disk plate contact to free, which releases the brake.

Brake Applied When the pilot control shut-off lever is in the LOCKED position, the pilot shut-off switch is OFF. By this action, the pilot shut-off solenoid valve is de-energized, so that the brake release pressure (pilot pressure) is not guided to the brake piston chamber. The brake release pressure oil in the brake piston chamber flows back to the hydraulic oil tank via the pilot shut-off solenoid valve.

T125220 —19—19NOV99

Brake Released

T125221 —19—01DEC99

Accordingly, by the spring, the brake piston gradually moves downward, allowing the brake piston to slowly come in contact with the disk plate to apply the swing brake.

CED,OUOE011,45 -19-19AUG02-1/1

TM2052 (17JUL18)

9025-05-32

27C ZTS and 35C ZTS Operation & Tests 071718 PN=212

Theory of Operation

TM2052 (17JUL18)

9025-05-33

27C ZTS and 35C ZTS Operation & Tests 071718 PN=213

Theory of Operation

T122060 —19—17SEP99

Rotary Manifold Operation

8— To Right Propel Motor—Forward 9— To Left Propel Motor—Forward 10— Inner Spindle

1— To Blade Cylinder—Lower 4— To Hydraulic Oil Tank 2— To Blade Cylinder—Raise 5— Body 3— To Propel Speed Changeover 6— To Right Propel Valve Motor—Reverse 7— To Left Propel Motor—Reverse

The rotary manifold is a 360° rotary joint. It allows oil to flow to and from the propel motors (12) and blade cylinder (13) without twisting hoses when the upperstructure is rotated.

The inner spindle (10) is connected to the undercarriage and the body (5) is connected to the upperstructure. The body rotates around the spindle during swing operation.

Continued on next page

TM2052 (17JUL18)

11— Oil Seal 12— Propel Motor (2 used) 13— Blade Cylinder

9025-05-34

CED,OUOE011,5097 -19-17MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=214

Theory of Operation

Oil flows into and through the body to passages in the spindle, and then out of the spindle to the propel motors and the blade cylinder. Oil seal (11) prevents oil from

leaking between the spindle and body into adjacent passages.

CED,OUOE011,5097 -19-17MAY02-2/2

TM2052 (17JUL18)

9025-05-35

27C ZTS and 35C ZTS Operation & Tests 071718 PN=215

Theory of Operation

T155248 —UN—29MAY02

Propel Motor and Brake Valve Housing Operation

Propel Motor and Brake Valve Housing—27C ZTS

The propel motor (5) is a swash plate design, two-speed, axial piston motor that includes the brake valve housing (6), propel park brake (8), and propel motor speed change valve. The counterbalance valve, crossover relief valves, and check valves are integral components of the brake valve housing.

T125223 —UN—18NOV99

Supply oil flows through the valve plate (7) to half of the pistons (3) in the cylinder block (4). The supply oil forces the pistons against the swash plate (9). The piston slippers slide down the angle face of the swash plate causing the cylinder block and drive shaft (1) to rotate. The drive shaft rotation is transferred to the propel gearbox driving the machine. As the cylinder block and drive shaft turn, half of the pistons are being forced against the swash plate while the remaining pistons in the other half of the cylinder block are being pushed back into bores by the angle of the swash plate to discharge oil to return.

Forward or reverse travel direction is determined by which half of the valve plate ports and pistons are pressurized by supply oil from the control valve. Swash plate position determines the propel speed of machine actuated by control piston (2).

Propel Motor and Brake Valve Housing—35C ZTS 1— Drive Shaft 2— Control Piston (2 used) 3— Piston and Slipper (9 used) 4— Cylinder Block 5— Propel Motor

Continued on next page

TM2052 (17JUL18)

9025-05-36

6— Brake Valve Housing 7— Valve Plate 8— Park Brake 9— Swash Plate

TX19495,0000082 -19-23MAY02-1/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=216

Theory of Operation

T125256 —19—17NOV99

Counterbalance Valve

T125257 —19—23NOV99

Brake Valve Housing—27C ZTS

Brake Valve Housing—35C ZTS

Continued on next page

TM2052 (17JUL18)

9025-05-37

TX19495,0000082 -19-23MAY02-2/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=217

Theory of Operation The counterbalance valve has two functions; one is to start and stop the propel smoothly and the other is to prevent the machine from running away while descending slopes.

Propel Operation—When pressure oil from the control valve is supplied to port P1, the pressure oil flows to motor port AM through the inside of the spool of counterbalance valve and opens the check valve. On the other hand, the return oil from motor port BM is blocked by the check valve and spool. Thereby, the pressure on port P1 side increases gradually. The pressure on port P1 enters into the spring chamber through an orifice which moves the spool to the right by the pressure at the end surface of the spool. As a result, the spool notch opens, so port BM and port P2 connect, and the propel motor rotates.

Down Hill Operation—When the machine propels down a slope, the propel motors are forcibly driven by the machine weight so that the motor draws oil like a pump.

The pressure oil in port P1 is drawn into the propel motor so the pressure on port P1 decreases. Thereby, the spool returns to the left and returning oil from port BM to port P2 is restricted, slowing the motor.

Propel Speed Change Valve The propel speed change valve is switched by pressure oil from the propel speed solenoid valve. It switches the propel speed by moving the control piston. See Propel Motor Speed Circuit Operation. (Group 9025-05.)

Continued on next page

TM2052 (17JUL18)

9025-05-38

TX19495,0000082 -19-23MAY02-3/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=218

Theory of Operation

T124020 —19—17SEP99

Park Brake

The propel park brake is a wet type, multi-disk, negative type brake. A negative type brake is spring applied and hydraulically released. The plates are connected to the propel motor housing by teeth and splines and remain stationary with the housing. The disks are connected to the cylinder block by teeth and splines and rotate with the cylinder block.

Park Brake Released—Actuating the propel function sends supply oil to the propel motors. A small amount of the supply oil is routed to the piston chamber by the counterbalance valve. When the supply oil pressure overcomes the spring force, the park brake piston is pushed against the spring. The contact pressure between the plates and disks is reduced so the propel motor can rotate.

blocked at the control valve. The counterbalance valve returns to its neutral position opening a passage for oil in the brake chamber to flow out of the brake chamber. The spring, pushing against the park brake piston, forces the oil in the piston chamber to flow through the counterbalance valve and into the drain circuit and then back to the hydraulic oil tank. As the piston moves, the opening for oil to flow from the piston chamber becomes less causing a restriction. The delay caused by the oil flowing through the restriction is enough to slow the engagement of the park brake to ensure it is only fully applied after the machine has stopped. The spring pushes the park brake piston against the plates and disks squeezing them together creating enough friction to hold the machine.

Park Brake Applied—When the propel function is returned to neutral, supply oil to the propel motor is Continued on next page

TM2052 (17JUL18)

9025-05-39

TX19495,0000082 -19-23MAY02-4/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=219

Theory of Operation

T155224 —UN—29MAY02

Anti-Cavitation Valve—35C ZTS

T155225 —UN—29MAY02

Anti-Cavitation Valve—When Propelling

Anti-Cavitation Valve—When Propelling Is Stopped Continued on next page

TM2052 (17JUL18)

9025-05-40

TX19495,0000082 -19-23MAY02-5/6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=220

Theory of Operation 1— Passage 2— Passage 3— Passage

4— Poppet 5— Poppet 6— Port 7— Port

8— Counterbalance Valve 9— Port

The anti-cavitation valve reduces cavitation in the propel motor when the propel motor is stopped.

NOTE: The anti-cavitation valve does not operate during normal propel operation.

When propelling—Pressure oil from port (6) flows to port (9) through the counterbalance valve (8). At the same time, pressure oil flows to the back of poppet (5) through passage (1). Accordingly, passage (1) to passage (3) is closed and the return oil from port (10) flows to port (7) through the counterbalance valve.

10— Port 11— Orifice

When propelling is stopped—As pressure oil from port (6) decreases, the counterbalance valve returns to the neutral position. Propel inertia forces causes the propel motor to draw oil like a pump. Accordingly, the pressure in port (10) increases and pressure in port (9) decreases.

High pressure oil in passage (3) forces poppet (5) downward. The return oil from port (10) flows into port (9) through passages (3 and 1). Oil flow continues until orifice (11) in the counterbalance valve (8) closes completely.

TX19495,0000082 -19-23MAY02-6/6

Propel Motor Speed Circuit Operation There are two surfaces on the swash plate; surface (1) and surface (2). Surface (1) makes contact with the housing at slow speed and surface (2) makes contact with the housing at fast speed.

Two balls are located off the center line on the swash plate so they can roll freely.

Slow Speed Operation

T155135 —UN—22MAY02

When the propel is in slow speed, the pressure oil from the propel speed solenoid valve is not supplied to the propel speed change valve. Surface (1) of the swash plate makes contact with the housing by the oil pressure acting on the piston and the spring force in the cylinder block.

As a result, the angle of the swash plate increases which makes the stroke of the piston longer. The motor capacity increases, causing the propel motor to rotate in slow speed.

1— Slow Speed 2— Fast Speed 3— Swash Plate

4— Piston 5— Cylinder Block

Propel Motor—Slow Speed

Continued on next page

TM2052 (17JUL18)

9025-05-41

CED,OUOE011,5098 -19-22MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=221

Theory of Operation Fast Speed Operation When the propel is in fast speed, the pressure oil from the propel speed solenoid valve is supplied to the propel speed change valve. The propel speed change valve switches to supply the pressure oil to the control piston.

The swash plate is pushed by the control piston which makes surface (2) contact with the housing.

As a result, the angle of the swash plate decreases which makes the stroke of the piston shorter. The motor capacity decreases, causing the propel motor to rotate in fast speed.

T155136 —UN—22MAY02

When Engine Stops When the engine stops, pressure oil applied to the control piston returns to the hydraulic oil tank through the propel speed change valve. Surface (1) of the swash plate then makes contact with the housing by the spring force in the cylinder block.

As a result, the propel motor is in slow speed position whenever the engine is started.

1— Slow Speed 2— Fast Speed 3— Swash Plate 4— Piston

Propel Motor—Fast Speed

5— Cylinder Block 6— Control Piston 7— From Propel Speed Change Valve CED,OUOE011,5098 -19-22MAY02-2/2

T155286 —UN—31MAY02

Blade Circuit Operation

Blade Control Valve 1— Valve Spool

2— Lift Check Valve

3— Work Port (2 used)

The blade control valve is a three-position, open-center type valve. The valve spool (1) is pilot actuated through the use of a lever. A lift check valve (2) is also incorporated. The work ports (3) are connected to the blade cylinder through the rotary manifold.

Supply oil for the blade circuit is from hydraulic pump 3.

CED,OUOE011,49 -19-28MAY02-1/1

TM2052 (17JUL18)

9025-05-42

27C ZTS and 35C ZTS Operation & Tests 071718 PN=222

Theory of Operation

T155281 —UN—29MAY02

One Way/Two Way Valve Operation

One Way/Two Way Valve 1— One Way/Two Way Valve 2— Auxiliary Control Valve

3— To Hydraulic Oil Tank 4— One Way Valve Operation

The one way/two way valve is used with the auxiliary control valve to operate front attachments. When turned,

5— Two Way Valve Operation

it selects either single or double work port usage. See illustration for valve positions for each operation.

Continued on next page

TM2052 (17JUL18)

9025-05-43

CED,OUOE003,1940 -19-24MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=223

Theory of Operation

One Way Operation

Two Way Operation

When auxiliary pedal is rocked to the left, work port pressure is directed to front attachment to operate. Return oil then passes through the valve to the hydraulic oil tank.

No action is accomplished when pedal is rocked to the right as pressure is stopped at valve.

When auxiliary pedal is rocked either left or right, work port pressure is directed to front attachment to operate two modes of use. For example, up-down, in-out, left-right.

Return oil then passes through the control valve to the hydraulic oil tank.

CED,OUOE003,1940 -19-24MAY02-2/2

T122090 —UN—17SEP99

Hydraulic Cylinder Operation

1— Piston Rod 2— Wiper Ring 3— Nut

7— Piston 8— O-Ring 9— Backup Ring

4— O-Ring 5— Cylinder Barrel 6— Cushion

All cylinders are similar in design. The boom cylinder is illustrated. A large nut (3) acts as a rod guide and retains piston rod (1) from over extension in cylinder barrel (5).

It houses a wiper ring (2), O-ring (4), and bushing (11).

The cylinder barrel houses O-rings (8), backup rings (9), and retainer (10). Some cylinders provide a cushion (6) to

10— Retainer 11— Bushing

provide cushioning action during cylinder full extension.

Incoming pressure for extension moves piston (7). As the piston nears the end of its stroke, the cushion enters a bore in the rod guide. The remaining return oil ahead of piston flows through a clearance between cushion and rod guide.

CED,OUOE011,5104 -19-22JUL99-1/1

TM2052 (17JUL18)

9025-05-44

27C ZTS and 35C ZTS Operation & Tests 071718 PN=224

Theory of Operation

TS700 —19—28SEP89

Hydraulic System Circuit Symbols

TX,15,GG2166 -19-17NOV97-1/1

TM2052 (17JUL18)

9025-05-45

27C ZTS and 35C ZTS Operation & Tests 071718 PN=225

Theory of Operation

Hydraulic System Schematics Continued on next page

TM2052 (17JUL18)

9025-05-46

TX18160,0000090 -19-17JUN02-1/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=226

Theory of Operation

T154907 —19—27AUG02

BUCKET CYLINDER 59

ARM CYLINDER 71

BOOM CYLINDER 60

BOOM SWING CYLINDER 72

FROM HYDRAULIC PUMP 2 N TO LEFT FROM TO RIGHT PROPEL HYDRAULIC PROPEL MOTOR PUMP 1 MOTOR C I D

B1

A1

A2

B2

B3

A3

P1

AI

P2

A4

BLADE CYLINDER 61

FROM SOLENOID VALVE MANIFOLD K

TO SWING MOTOR AND GEARBOX G

B4

A5

B5

A6

B6

B7

A7

B8

A8

B9

A9

FROM HYDRAULIC PUMP 3 M

S2

46 48 43

33

40

30

28

26

24

22

21

47 20

34

31 23

T1 51

20 52

29

38

42 41 20

39

32 74

35

45

25

37

44

49

27

P3

36 50

T3

S1

T2

J TO OIL COOLER BYPASS VALVE

L TO SWING MOTOR AND GEARBOX

O TO HYDRAULIC OIL TANK

T154907 Control Valve Schematic Continued on next page

TM2052 (17JUL18)

9025-05-47

27C ZTS and 35C ZTS Operation & Tests 071718 PN=227

TX18160,0000090 -19-17JUN02-2/17

Theory of Operation

TM2052 (17JUL18)

9025-05-48

27C ZTS and 35C ZTS Operation & Tests 071718 PN=228

Theory of Operation

20— System Relief Valve (3 used) 21— Flow Combiner Valve 22— Blade Valve Spool 23— Blade Lift Check 24— Swing Valve Spool 25— Swing Lift Check 26— Boom Swing Valve Spool 27— Boom Swing Lift Check 28— Auxiliary Flow Combiner Valve 29— Auxiliary Flow Combiner Valve Check Valve 30— Auxiliary Valve Spool 31— Auxiliary Lift Check 32— Auxiliary Check Valve and Orifice 33— Arm Valve Spool

34— Arm Regenerative Valve 35— Arm Out Circuit Relief and Anti-Cavitation Valve 36— Arm In Circuit Relief and Anti-Cavitation Valve 37— Arm Check Valve 38— Arm Lift Check 39— Right Propel Valve Spool 40— Left Propel Valve Spool 41— Left Propel Lift Check 42— Boom Lift Check 43— Boom Valve Spool 44— Boom Down Circuit Relief and Anti-Cavitation Valve 45— Boom Up Circuit Relief and Anti-Cavitation Valve

46— Boom Reduced Leakage Valve 47— Boom Reduced Leakage Valve Check Valve 48— Bucket Valve Spool 49— Bucket Curl Circuit Relief and Anti-Cavitation Valve 50— Bucket Dump Circuit Relief and Anti-Cavitation Valve 51— Bucket Lift Check 52— Bucket Check Valve and Orifice 74— Boom Swing Make-Up Check Valve A—To Bucket Cylinder B—To Boom Cylinder C—To Left Propel Motor D—To Right Propel Motor

Continued on next page

TM2052 (17JUL18)

9025-05-49

E—To Arm Cylinder F— To Boom Swing Cylinder G—To Swing Motor and Gearbox H—To Blade Cylinder I— From Hydraulic Pump 1 J— To Oil Cooler Bypass Valve K—From Solenoid Valve Manifold L— To Swing Motor and Gearbox M—From Hydraulic Pump 3 N—From Hydraulic Pump 2 O—To Hydraulic Oil Tank

TX18160,0000090 -19-17JUN02-3/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=229

Theory of Operation

14 LEFT PILOT CONTROLLER

3

P

T

1

A

2

15 RIGHT PILOT CONTROLLER

4

B C

4

T

2

E

D

P

P

F

1

3

G

H

T

16 PROPEL PILOT CONTROLLER 1

2

I

3

J

4

K

L

Q T

P

T

P

17 BLADE PILOT CONTROLLER 1

2

M

1

N T S

O

2

18 BOOM SWING PILOT CONTROLLER

P

V U

19 PILOT CONTROLLER PATTERN CONVERSION VALVE BACKHOE

EXCAVATOR D

T154908

C

F E

T154908 —19—19JUL02

R

Pilot Controller Schematic

Continued on next page

TM2052 (17JUL18)

9025-05-50

TX18160,0000090 -19-17JUN02-4/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=230

Theory of Operation 14— Left Pilot Controller 15— Right Pilot Controller 16— Propel Pilot Controller 17— Blade Pilot Controller 18— Boom Swing Pilot Controller 26— Pilot Controller Pattern Conversion Valve

A—Swing Left B—Swing Right C—Arm Out D—Arm In E—Boom Up F— Boom Down G—Bucket Dump H—Bucket Curl I— Left Propel Forward J— Left Propel Reverse K—Right Propel Reverse

L— Right Propel Forward T— To Arm Valve Spool (Arm In) M—Blade Lower U—To Boom Valve Spool (Boom N—Blade Raise Up) O—Boom Swing Right V—To Boom Valve Spool (Boom P—Boom Swing Left Down) Q—From Solenoid Valve Manifold R—To Hydraulic Oil Tank S—To Arm Valve Spool (Arm Out)

Continued on next page

TM2052 (17JUL18)

9025-05-51

TX18160,0000090 -19-17JUN02-5/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=231

Theory of Operation

TM2052 (17JUL18)

9025-05-52

27C ZTS and 35C ZTS Operation & Tests 071718 PN=232

Theory of Operation

T154909 —19—27AUG02

TO SWING MOTOR AND GEARBOX D

TO BLADE PILOT CONTROLLER F

TO PROPEL SPEED CHANGE VALVE C

PILOT OIL RETURN K

PILOT CONTROL 9 SHUT-OFF SOLENOID VALVE

HYDRAULIC 12 OIL TANK

PROPEL SPEED SOLENOID VALVE 8 A

B

TO CONTROL VALVE G HYDRAULIC 2 PUMP 2

TO CONTROL VALVE FLOW COMBINER VALVE CIRCUIT E

RETURN 13 FILTER AND BYPASS VALVE

A4

PILOT FILTER 5

G

I FROM PILOT CONTROLLERS

SOLENOID 75 VALVE MANIFOLD

PILOT 7 PRESSURE REGULATING VALVE

A3

A2

A1

HYDRAULIC PUMP 1 1

P

FROM OIL CONTROL COOLER 11 VALVE A

TO CONTROL VALVE B

TO CONTROL H VALVE

PILOT 4 PUMP

PILOT 6 FILTER BYPASS VALVE

PUMP FLOW RATE CONTROL 73 PISTON

S1

3 HYDRAULIC PUMP 3

J FROM CONTROL VALVE

OIL 10 COOLER BYPASS VALVE

T154909 Hydraulic Pump, Solenoid Valve Manifold, and Hydraulic Oil Tank Schematic—27C ZTS Continued on next page

TM2052 (17JUL18)

9025-05-53

27C ZTS and 35C ZTS Operation & Tests 071718 PN=233

TX18160,0000090 -19-17JUN02-6/17

Theory of Operation

TM2052 (17JUL18)

9025-05-54

27C ZTS and 35C ZTS Operation & Tests 071718 PN=234

Theory of Operation 1— Hydraulic Pump 1 2— Hydraulic Pump 2 3— Hydraulic Pump 3 4— Pilot Pump 5— Pilot Filter 6— Pilot Filter Bypass Valve 7— Pilot Pressure Regulating Valve 8— Propel Speed Solenoid Valve

9— Pilot Control Shut-Off Solenoid Valve 10— Oil Cooler Bypass Valve 11— Oil Cooler 12— Hydraulic Oil Tank 13— Return Filter and Bypass Valve 73— Pump Flow Rate Control Piston

A—From Control Valve B—To Control Valve C—To Propel Speed Change Valve D—To Swing Motor and Gearbox E—To Control Valve Flow Combiner Valve Circuit F— To Blade Pilot Controller Continued on next page

TM2052 (17JUL18)

9025-05-55

G—To Control Valve H—To Control Valve I— From Pilot Controllers J— From Control Valve

TX18160,0000090 -19-17JUN02-7/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=235

Theory of Operation

TM2052 (17JUL18)

9025-05-56

27C ZTS and 35C ZTS Operation & Tests 071718 PN=236

Theory of Operation

T154918 —19—27AUG02

TO SWING MOTOR AND GEARBOX D

TO BLADE PILOT CONTROLLER F

TO PROPEL SPEED CHANGE VALVE C

PILOT OIL RETURN K

PILOT CONTROL 9 SHUT-OFF SOLENOID VALVE

HYDRAULIC 12 OIL TANK

PROPEL SPEED SOLENOID VALVE 8 A

B

TO CONTROL VALVE G HYDRAULIC 2 PUMP 2

TO CONTROL VALVE FLOW COMBINER VALVE CIRCUIT E

RETURN 13 FILTER AND BYPASS VALVE

P3

P2

P1

HYDRAULIC PUMP 1 1

P

FROM OIL CONTROL COOLER 11 VALVE A

J FROM CONTROL VALVE

P4

PILOT FILTER 5

G

TO CONTROL VALVE B

TO CONTROL H VALVE

I FROM PILOT CONTROLLERS

SOLENOID 75 VALVE MANIFOLD

PILOT 7 PRESSURE REGULATING VALVE

PILOT 6 FILTER BYPASS VALVE

PUMP 73 FLOW RATE CONTROL PISTON

S1

PILOT 4 PUMP

3 HYDRAULIC PUMP 3

OIL 10 COOLER BYPASS VALVE

T154918 Hydraulic Pump, Solenoid Valve Manifold, and Hydraulic Oil Tank Schematic—35C ZTS Continued on next page

TM2052 (17JUL18)

9025-05-57

27C ZTS and 35C ZTS Operation & Tests 071718 PN=237

TX18160,0000090 -19-17JUN02-8/17

Theory of Operation

TM2052 (17JUL18)

9025-05-58

27C ZTS and 35C ZTS Operation & Tests 071718 PN=238

Theory of Operation 1— Hydraulic Pump 1 2— Hydraulic Pump 2 3— Hydraulic Pump 3 4— Pilot Pump 5— Pilot Filter 6— Pilot Filter Bypass Valve 7— Pilot Pressure Regulating Valve 8— Propel Speed Solenoid Valve

9— Pilot Control Shut-Off Solenoid Valve 10— Oil Cooler Bypass Valve 11— Oil Cooler 12— Hydraulic Oil Tank 13— Return Filter and Bypass Valve 73— Pump Flow Rate Control Piston

A—From Control Valve B—To Control Valve C—To Propel Speed Change Valve D—To Swing Motor and Gearbox E—To Control Valve Flow Combiner Valve Circuit F— To Blade Pilot Controller Continued on next page

TM2052 (17JUL18)

9025-05-59

G—To Control Valve H—To Control Valve I— From Pilot Controllers J— From Control Valve

TX18160,0000090 -19-17JUN02-9/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=239

Theory of Operation

LEFT PROPEL MOTOR 62

SWASH PLATE PISTON 63

RIGHT PROPEL MOTOR 69

FAST SPEED ORIFICE 64

DR

68 SHUTTLE VALVE

DR

68 67 PP

67 PROPEL SPEED CHANGE VALVE

63

PP

66 COUNTERBALANCE VALVE A

66

B

B

65 COUNTERBALANCE VALVE ORIFICE

A

65

70 ROTARY MANIFOLD

FROM LEFT PROPEL VALVE SPOOL B A TO HYDRAULIC OIL TANK

T154910

D FROM PROPEL SPEED SOLENOID VALVE

FROM RIGHT PROPEL VALVE SPOOL

T154910 —19—18JUN02

C

Propel Motor Schematic—27C ZTS

Continued on next page

TM2052 (17JUL18)

9025-05-60

TX18160,0000090 -19-17JUN02-10/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=240

Theory of Operation 62— Left Propel Motor 63— Swash Plate Piston 64— Fast Speed Orifice 65— Counterbalance Valve Orifice

66— Counterbalance Valve 67— Propel Speed Change Valve 68— Shuttle Valve 69— Right Propel Motor

70— Rotary Manifold D—From Propel Speed Solenoid A—To Hydraulic Oil Tank Valve B—From Left Propel Valve Spool C—From Right Propel Valve Spool

Continued on next page

TM2052 (17JUL18)

9025-05-61

TX18160,0000090 -19-17JUN02-11/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=241

Theory of Operation

LEFT PROPEL MOTOR 62

SWASH PLATE PISTON 63

63

T1

T1

64

FAST SPEED ORIFICE 64 Ps

Ps

67 PROPEL SPEED CHANGE VALVE

66 COUNTERBALANCE VALVE P2

RIGHT PROPEL MOTOR 69

68 ANTICAVITATION VALVE

67

66

65

P1

P1

65 COUNTERBALANCE VALVE ORIFICE

68

P2

70 ROTARY MANIFOLD

FROM LEFT PROPEL VALVE SPOOL B

C

TO HYDRAULIC OIL TANK

D FROM PROPEL SPEED SOLENOID VALVE

T154919

FROM RIGHT PROPEL VALVE SPOOL T154919 —19—18JUN02

A

Propel Motor Schematic—35C ZTS

Continued on next page

TM2052 (17JUL18)

9025-05-62

TX18160,0000090 -19-17JUN02-12/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=242

Theory of Operation 62— Left Propel Motor 63— Swash Plate Piston (2 used per motor) 64— Fast Speed Orifice 65— Counterbalance Valve Orifice

66— Counterbalance Valve 67— Propel Speed Change Valve 68— Anti-Cavitation Valve 69— Right Propel Motor

70— Rotary Manifold D—From Propel Speed Solenoid A—To Hydraulic Oil Tank Valve B—From Left Propel Valve Spool C—From Right Propel Valve Spool

Continued on next page

TM2052 (17JUL18)

9025-05-63

TX18160,0000090 -19-17JUN02-13/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=243

Theory of Operation

SWING PARK BRAKE 56

DB

E

TO HYDRAULIC OIL TANK

54 CROSSOVER RELIEF ORIFICE

55 SWING CROSSOVER RELIEF VALVE WITH CUSHION

A FROM PILOT CONTROL SHUT-OFF SOLENOID VALVE

B

M

B FROM SWING VALVE SPOOL

A

C

D FROM SWING VALVE SPOOL

TO HYDRAULIC OIL TANK

53 MAKE-UP CHECK VALVE

T154911

T154911 —19—21MAY02

PG

58 ORIFICE (RETURN LINE)

Swing Motor Schematic—27C ZTS

Continued on next page

TM2052 (17JUL18)

9025-05-64

TX18160,0000090 -19-17JUN02-14/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=244

Theory of Operation 53— Make-Up Check Valve 54— Crossover Relief Orifice 55— Swing Crossover Relief Valve with Cushion

56— Swing Park Brake 58— Orifice (Return Line) A—Pilot Control Shut-Off Solenoid Valve

B—From Swing Valve Spool C—To Hydraulic Oil Tank D—From Swing Valve Spool Continued on next page

TM2052 (17JUL18)

9025-05-65

E—To Hydraulic Oil Tank

TX18160,0000090 -19-17JUN02-15/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=245

Theory of Operation

SWING PARK BRAKE 56

DB

E

TO HYDRAULIC OIL TANK

54 CROSSOVER RELIEF ORIFICE

55 SWING CROSSOVER RELIEF VALVE WITH CUSHION

A FROM PILOT CONTROL SHUT-OFF SOLENOID VALVE

B

M

B FROM SWING VALVE SPOOL

A

C

D FROM SWING VALVE SPOOL

TO HYDRAULIC OIL TANK

53 MAKE-UP CHECK VALVE

T154920

T154920 —19—21MAY02

PG

58 ORIFICE (RETURN LINE)

Swing Motor Schematic—35C ZTS

Continued on next page

TM2052 (17JUL18)

9025-05-66

TX18160,0000090 -19-17JUN02-16/17

27C ZTS and 35C ZTS Operation & Tests 071718 PN=246

Theory of Operation 53— Make-Up Check Valve 54— Crossover Relief Orifice 55— Swing Crossover Relief Valve with Cushion

56— Swing Park Brake 58— Orifice (Return Line) A—Pilot Control Shut-Off Solenoid Valve

B—From Swing Valve Spool C—To Hydraulic Oil Tank D—From Swing Valve Spool

E—To Hydraulic Oil Tank

TX18160,0000090 -19-17JUN02-17/17

TM2052 (17JUL18)

9025-05-67

27C ZTS and 35C ZTS Operation & Tests 071718 PN=247

Theory of Operation

TM2052 (17JUL18)

9025-05-68

27C ZTS and 35C ZTS Operation & Tests 071718 PN=248

Group 15

Diagnostic Information Diagnose Hydraulic System Malfunctions NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely and most difficult to verify.

Symptom

Problem

Solution

All Hydraulic Functions Slow

Low oil level

Check oil level in hydraulic oil tank.

Cold hydraulic oil

Heat hydraulic oil. Perform Hydraulic System Warm-Up Procedure. (Group 9025-25.)

Oil viscosity too heavy

Use the recommended oil. See Hydraulic Oil. (Operator's Manual.)

Slow engine speed

Check engine speeds. See Engine Speed Check. (Group 9010-25.)

Air leak in pump suction line

Check for air bubbles in oil. Tighten clamps and check hoses.

Pilot circuit malfunction

See Diagnose Pilot Circuit Malfunctions. (Group 9025-15.)

Restricted pump suction screen

Clean pump suction screen. See Change Hydraulic Oil, Clean Suction Screen. (Operator's Manual.)

Worn pumps

Check pump flow rate. Perform Hydraulic Pump 1 and 2 Flow Test.

(Group 9025-25.) Perform Hydraulic Pump 3 Flow Test. (Group 9025-25.)

System relief valve setting too low or malfunctioning

Check system relief valve setting.

Perform Pump 1, 2, and 3 System Relief Valve Test and Adjustment.

(Group 9025-25.)

Low pilot oil pressure

Check pilot pressure regulating valve.

Perform Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

Low oil level

Check oil level in hydraulic oil tank.

Plugged oil cooler

Test air flow through oil cooler.

Perform Radiator Air Flow Test.

(Group 9010-25.)

Oil viscosity too light

Use the recommended oil. See Hydraulic Oil. (Operator's Manual.)

Return filter plugged

Replace filter. See Hydraulic Oil Tank Remove and Install. (Group 3360.)

Hydraulic Oil Overheats

Continued on next page

TM2052 (17JUL18)

9025-15-1

CED,OUOE011,55 -19-10DEC12-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=249

Diagnostic Information Symptom

Problem

Solution

System relief valve malfunction

Test system relief valve. Perform Pump 1, 2, and 3 System Relief Valve Test and Adjustment. (Group 9025-25.)

Oil cooler bypass valve stuck open

Repair or replace bypass valve.

See Hydraulic Oil Tank Remove and Install. (Group 3360.)

Fan belt slipping

Check for worn belt. Check tension adjuster. See Fan Belt Repair. (Group 0510.)

Pump stuck at maximum displacement Perform Hydraulic Pump 1 and 2 Flow Test. (Group 9025-25.)

No Hydraulic Functions (Pilot Pressure Actuated)

Poor Combined Operation

No oil

Check oil level in hydraulic oil tank.

Pilot control shut-off switch in left armrest Pilot control shut-off switch jumper connector in right armrest

Check pilot shut-off switch.

Pilot control shut-off solenoid valve

Check pilot control shut-off solenoid valve. See Solenoid Test. (Group 9015-20.) Repair or replace pilot control shut-off solenoid valve. See Solenoid Valve Maniflod Repair.

(Group 3360.)

Pump drive failure

Check pump drive coupling. See Hydraulic Pump Remove and Install.

(Group 3360.)

Restricted pump suction screen

Clean pump suction screen. See Change Hydraulic Oil, Clean Suction Screen. (Operator's Manual.)

Pilot controller

Check pilot pressure at control valve.

Perform Control Valve Spool Pilot Actuating Pressure Test. (Group 9025-25.)

Pilot pressure regulating valve

Check pilot pressure regulating valve pressure setting. Perform Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

Check valves in control valve

Inspect valves. See Control Valve Remove and Install. (Group 3360.)

Check that connector is in place and jumper wire is not broken.

CED,OUOE011,55 -19-10DEC12-2/2

TM2052 (17JUL18)

9025-15-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=250

Diagnostic Information

Diagnose Pilot Circuit Malfunctions NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely and most difficult to verify.

Symptom

Problem

Solution

All Functions Cannot be Operated

Pilot pressure regulating valve stuck open

Check pilot pressure regulating valve.

Perform Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.) Inspect pilot pressure regulating valve. See Solenoid Valve Maniflod Repair. (Group 3360.)

Pilot pump failure

Remove and inspect pilot pump. See Hydraulic Pump Remove and Install.

(Group 3360.)

Pilot control shut-off switch in left armrest Pilot control shut-off switch jumper connector in right armrest

Check pilot shut-off switch.

Pilot control shut-off solenoid valve

Check pilot control shut-off solenoid valve. See Solenoid Test. (Group 9015-20.) Repair or replace pilot control shut-off solenoid valve. See Solenoid Valve Manifold Repair.

(Group 3360.)

Control valve spool stuck

Manually move spool to check for sticking. See Control Valve Remove and Install. (Group 3360.)

Pilot controller

Check for sticking spool. See Pilot Controller Repair. (Group 3360.)

Pilot cap

Inspect for leakage at pilot cap. See Control Valve Remove and Install.

(Group 3360.)

Pilot controller or hoses to function that cannot be operated

Check pilot controller or pilot controller hoses. See Pilot Controller Repair (Group 3360.)

Pilot filter plugged

Replace pilot filter.

Low pilot system pressure

Check pilot pressure regulating valve pressure setting. Perform Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

Function Does Not Stop When Control Lever Released

Some Functions Cannot be Operated, All Others Are Normal

All Functions Slow

Continued on next page

TM2052 (17JUL18)

9025-15-3

Check that connector is in place and jumper wire is not broken.

CED,OUOE011,56 -19-10DEC12-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=251

Diagnostic Information Symptom

Problem

Solution

Function Moves In Opposite Direction

Pilot control hoses connected incorrectly at pilot controller, pattern conversion valve, or control valve

Check installation of hoses. See Pilot Controller to Pattern Conversion Valve Line Connection. (Group 9025-15.)

See Control Valve Line Identification.

(Group 9025-15.) See Main Hydraulic System Component Location. (Group 9025-15.)

Arm And Boom Functions Do Not Operate Or Do Not Operate As Expected

Pilot controller pattern conversion valve

Check position of pilot controller pattern conversion valve. See Control Lever Pattern Conversion. (Operator's Manual.)

CED,OUOE011,56 -19-10DEC12-2/2

TM2052 (17JUL18)

9025-15-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=252

Diagnostic Information

Diagnose Dig Circuit Malfunctions NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely and most difficult to verify.

Symptom

Problem

Solution

All Dig Functions Slow or No Power Hydraulic system malfunction

Some Dig Functions Slow (Not All)

Load Drifts Down When Control Valve Is In Neutral Position

Pilot circuit malfunction

See Diagnose Pilot Circuit Malfunctions. (Group 9025-15.)

Hydraulic pump malfunction

Check pump flow rate. Perform Hydraulic Pump 1 and 2 Flow Test.

(Group 9025-25.) Perform Hydraulic Pump 3 Flow Test. (Group 9025-25.)

Pilot circuit malfunction

See Diagnose Pilot Circuit Malfunctions. (Group 9025-15.)

Control valve leakage

Check dig functions for drift. Perform Cylinder Drift Test-Boom, Arm, Bucket, and Blade. (Group 9025-25.)

Specific system relief valve stuck

Test system relief valve. Perform Pump 1, 2, and 3 System Relief Valve Test and Adjustment. (Group 9025-25.)

Cylinder leakage

Test cylinder for leakage. Perform Cylinder Drift Test-Boom, Arm, Bucket, and Blade. (Group 9025-25.)

Specific circuit relief valve stuck

Test circuit relief valves. Perform Circuit Relief Valve Test and Adjustment. (Group 9025-25.)

Cylinder leakage

Test cylinder for leakage. Perform Cylinder Drift Test-Boom, Arm, Bucket, and Blade. (Group 9025-25.)

Specific circuit relief valve stuck

Test circuit relief valves. Perform Circuit Relief Valve Test and Adjustment. (Group 9025-25.)

Boom reduced leakage valve for boom down inoperative

Inspect boom reduced leakage valve.

See Control Valve Remove and Install.

(Group 3360.)

Control valve leakage

Inspect control valve. See Control Valve Remove and Install. (Group 3360.)

Continued on next page

TM2052 (17JUL18)

See Diagnose Hydraulic System Malfunctions. (Group 9025-15.)

9025-15-5

CED,OUOE003,1901 -19-29MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=253

Diagnostic Information Symptom

Problem

Solution

Load Falls When Control Valve is Actuated to Raise Load With Engine Running At Slow Idle

Lift check valve leakage

Inspect lift check valve. See Control Valve Remove and Install. (Group 3360.)

Function Moves In Opposite Direction

Pilot control hoses connected Check installation of hoses. See incorrectly at pilot controller or control Control Valve Line Identification. valve (Group 9025-15.) See Main Hydraulic System Component Location. (Group 9025-15.)

Blade Function Slow or Inoperative Rotary manifold leakage

Auxiliary Function Inoperative

Inspect rotary manifold. See Rotary Manifold Remove and Install. (Group 0260.)

Damaged hoses to blade cylinder

Inspect and repair hoses.

One way/Two way valve

Check for proper position according to attachment used.

CED,OUOE003,1901 -19-29MAY02-2/2

TM2052 (17JUL18)

9025-15-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=254

Diagnostic Information

Diagnose Swing Circuit Malfunctions NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely and most difficult to verify.

Symptom

Problem

Solution

Swing Speed Slow In Both Directions

Low pilot system pressure

If all other functions are slow. See Diagnose Pilot Circuit Malfunctions.

(Group 9025-15.)

Swing motor crossover relief valve leakage

Test swing motor crossover relief valve pressure. Perform Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.)

Swing valve leakage

Inspect swing valve. See Control Valve Remove and Install. (Group 3360.)

Swing motor leakage

Test swing motor for leakage. Perform Swing Motor Leakage Test. (Group 9025-25.)

Swing park brake not releasing

See Swing Motor and Park Brake Remove and Install. (Group 4360.)

Worn pump

Check pump flow rate. Perform Hydraulic Pump 3 Flow Test. (Group 9025-25.)

Pilot circuit malfunction

See Diagnose Pilot Circuit Malfunctions. (Group 9025-15.)

Swing motor crossover relief valve malfunction

Test swing motor crossover relief valves. Perform Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.)

Swing park brake not holding

Inspect swing park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.)

Swing motor crossover relief valve leakage

Test swing motor crossover relief valves. Perform Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.)

Swing motor leakage

Test swing motor for leakage. Perform Swing Motor Leakage Test. (Group 9025-25.)

Pilot circuit malfunction

See Diagnose Pilot Circuit Malfunctions. (Group 9025-15.)

Swing Speed Slow or Does Not Operate In One Direction

Upperstructure Drift With Swing Valve In Neutral

Swing Function Does Not Operate

Continued on next page

TM2052 (17JUL18)

9025-15-7

CED,OUOE003,1902 -19-29MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=255

Diagnostic Information Symptom

Problem

Solution

Swing park brake malfunction

See Swing Motor and Park Brake Remove and Install. (Group 4360.)

Mechanical failure of swing motor or gearbox.

Repair or replace swing motor or gearbox. See Swing Motor and Park Brake Remove and Install. (Group 4360.) See Swing Gearbox Remove and Install. (Group 4350.)

CED,OUOE003,1902 -19-29MAY02-2/2

TM2052 (17JUL18)

9025-15-8

27C ZTS and 35C ZTS Operation & Tests 071718 PN=256

Diagnostic Information

Diagnose Propel System Malfunctions NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely and most difficult to verify.

Symptom

Problem

Solution

Propel Park Brakes Do Not Apply

Oil not released from piston cavity

Check for leakage from propel motor drain hose. Perform Propel Motor Leakage Test. (Group 9025-25.)

Propel park brake piston and brake pack

Repair or replace park brake. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Pilot circuit malfunction

See Diagnose Pilot Circuit Malfunctions. (Group 9025-15.)

Propel motor crossover relief valve

Inspect propel motor crossover relief valve. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Counterbalance valve spool stuck

Inspect counterbalance and crossover relief valve. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Rotary manifold leakage

Inspect rotary manifold. See Rotary Manifold Remove and Install. (Group 0260.)

Pilot circuit malfunction

See Diagnose Pilot Circuit Malfunctions. (Group 9025-15.)

Propel motor crossover relief valve malfunction

Inspect propel motor crossover relief valve. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Propel pilot controller malfunction

Inspect propel pilot controller. See Propel Pilot Controller Repair. (Group 3360.)

Counterbalance valve spool stuck

Inspect counterbalance and crossover relief valve. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Track Will Not Move In One Direction

Track Will Not Move In Either Directions

Continued on next page

TM2052 (17JUL18)

9025-15-9

CED,OUOE011,57 -19-30MAY02-1/4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=257

Diagnostic Information Symptom

Excavator Mistracks at All Speeds in Both Directions

Slow Propel Speed or Low Power

Problem

Solution

Mechanical failure of propel motor or gearbox.

Repair or replace propel motor or gearbox. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.) See Propel Gearbox Remove and Install—27C ZTS and 35C ZTS. (Group 0250.)

Rotary manifold leakage

Inspect rotary manifold. See Rotary Manifold Remove and Install. (Group 0260.)

Track sag adjustment

Adjust track sag. See Adjusting Track Sag. (Operator's Manual.)

Propel pilot controller malfunction

Inspect propel pilot controller. See Propel Pilot Controller Repair. (Group 3360.)

Propel motor crossover relief valve malfunction

Inspect propel motor crossover relief valve. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Leakage in motor

Check tracking while descending a hill.

If tracking is within specification when descending a hill, but not when on the level or going up hill, motor leakage is indicated. Perform Propel Motor Leakage Test. (Group 9025-25.)

Flow combiner valve malfunction

Check flow combiner valve operation.

See Control Valve Remove and Install.

(Group 3360.)

Rotary manifold leakage

See Rotary Manifold Remove and Install. (Group 0260.)

Track sag adjustment

Adjust track sag. See Adjusting Track Sag. (Operator's Manual.)

Propel motor crossover relief valve malfunction

Inspect propel motor crossover relief valve. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Propel park brake not releasing

Inspect propel park brake. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Continued on next page

TM2052 (17JUL18)

9025-15-10

CED,OUOE011,57 -19-30MAY02-2/4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=258

Diagnostic Information Symptom

Combined Propel and Dig Functions Slow or No Power

Propel Is “Jerky”

Problem

Solution

Propel motor

Check propel motor for leakage.

Perform Propel Motor Leakage Test.

(Group 9025-25.)

Rotary manifold leakage

Inspect rotary manifold. See Rotary Manifold Remove and Install. (Group 0260.)

Low pump flow

Check pump flow rate. Perform Hydraulic Pump 1 and 2 Flow Test.

(Group 9025-25.) Check propel cycle times.

Engine performance low

Check engine performance. Perform Engine Compression Pressure Test.

(Group 9010-25.)

Flow combiner valve malfunction

Check flow combiner valve operation.

See Control Valve Remove and Install.

(Group 3360.)

Check valves

Inspect check valve operation. See Control Valve Remove and Install.

(Group 3360.)

Track sag too tight or too loose

Adjust track sag. See Adjusting Track Sag. (Operator's Manual.)

No oil or low oil level in rollers

Fill with recommended oil. See Hydraulic Oil. (Operator's Manual.)

Propel park brake leakage

Inspect propel park brake piston.

See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Mechanical failure in propel motor or gearbox

Repair or replace propel motor or gearbox. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.) See Propel Gearbox Remove and Install—27C ZTS and 35C ZTS. (Group 0250.)

Deformed track frame

Repair or replace components.

Continued on next page

TM2052 (17JUL18)

9025-15-11

CED,OUOE011,57 -19-30MAY02-3/4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=259

Diagnostic Information Symptom

Problem

Solution

Excavator Will Not Hold Back and Counterbalance valve spool stuck Park Brakes Engage and Disengage When Traveling Down an Incline

Inspect counterbalance and crossover relief valve. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

Excavator Will Not Turn Smoothly In Counterbalance valve spool stuck One Direction or Park Brake Grabs

Inspect counterbalance and crossover relief valve. See Propel Motor Disassemble and Assemble—27C ZTS and See Propel Motor Disassemble and Assemble—35C ZTS. (Group 0260.)

CED,OUOE011,57 -19-30MAY02-4/4

TM2052 (17JUL18)

9025-15-12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=260

Diagnostic Information

Pilot Controller to Pattern Conversion Valve Line Connection 15 14

P

T 1

4 3

T

P

4

1

3

2 2

19

L E F T

EXCAVATOR PATTERN

BACKHOE PATTERN

BOOM RAISE

ARM IN

BUCKET OUT

BUCKET OUT

BOOM LOWER

ARM OUT

BUCKET IN

BUCKET IN

1

SWING LEFT

SWING LEFT

2

ARM - OUT

BOOM LOWER

3

SWING RIGHT

SWING RIGHT

4

ARM - IN

BOOM RAISE

A

B

B

A

C

D

D

C

T155916

A

B D

C

T155916 —19—12JUN02

PILOT CONTROLLER PORT 1 R I 2 G 3 H 4 T

PATTERN PATTERN CONVERSION CONVERSION VALVE VALVE PORT PORT EXCAVATOR BACKHOE PATTERN PATTERN

Excavator Pattern Shown

Continued on next page

TM2052 (17JUL18)

9025-15-13

TX19495,0000087 -19-11JUN02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=261

Diagnostic Information P—Port T— Port 1— Port 2— Port

P T 1 2

3— Port 3 4— Port 4 14— Left Pilot Controller

15— Right Pilot Controller 19— Pilot Controller Pattern Conversion Valve TX19495,0000087 -19-11JUN02-2/2

Blade Hydraulic System Component Location Continued on next page

TM2052 (17JUL18)

9025-15-14

TX19495,0000085 -19-04JUN02-1/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=262

Diagnostic Information

T155704 —UN—28AUG02

5

2 75

17

12

1 3

4

22

61

T155704

TX19495,0000085 -19-04JUN02-2/3

Continued on next page

TM2052 (17JUL18)

9025-15-15

27C ZTS and 35C ZTS Operation & Tests 071718 PN=263

Diagnostic Information

TM2052 (17JUL18)

9025-15-16

27C ZTS and 35C ZTS Operation & Tests 071718 PN=264

Diagnostic Information 1— Hydraulic Pump 1 2— Hydraulic Pump 2 3— Hydraulic Pump 3

4— Pilot Pump 5— Pilot Filter 12— Hydraulic Oil Tank 17— Blade Pilot Controller

22— Blade Valve Spool 61— Blade Cylinder 70— Rotary Manifold

75— Solenoid Valve Manifold

TX19495,0000085 -19-04JUN02-3/3

Propel Hydraulic System Line Connection Continued on next page

TM2052 (17JUL18)

9025-15-17

CED,OUOE011,148 -19-04JUN02-1/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=265

Diagnostic Information

TM2052 (17JUL18)

9025-15-18

27C ZTS and 35C ZTS Operation & Tests 071718 PN=266

Diagnostic Information

T155727 —UN—28AUG02

12

5 1 70

4

2

39

40 75

16

69

62

T155727 CED,OUOE011,148 -19-04JUN02-2/3

Continued on next page

TM2052 (17JUL18)

9025-15-19

27C ZTS and 35C ZTS Operation & Tests 071718 PN=267

Diagnostic Information

TM2052 (17JUL18)

9025-15-20

27C ZTS and 35C ZTS Operation & Tests 071718 PN=268

Diagnostic Information 1— Hydraulic Pump 1 2— Hydraulic Pump 2 4— Pilot Pump 5— Pilot Filter

12— Hydraulic Oil Tank 16— Propel Pilot Controller 39— Right Propel Valve Spool

40— Left Propel Valve Spool 62— Left Propel Motor 69— Right Propel Motor

70— Rotary Manifold 75— Solenoid Valve Manifold

CED,OUOE011,148 -19-04JUN02-3/3

Main Hydraulic System Line Connection Continued on next page

TM2052 (17JUL18)

9025-15-21

TX19495,0000086 -19-10JUN02-1/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=269

Diagnostic Information

TM2052 (17JUL18)

9025-15-22

27C ZTS and 35C ZTS Operation & Tests 071718 PN=270

Diagnostic Information

T155871 —UN—28AUG02

11 12

79 5 1

3 70 4 2 71

57

78

59

75

60

69

61

72

62

T155871

TX19495,0000086 -19-10JUN02-2/3

Continued on next page

TM2052 (17JUL18)

9025-15-23

27C ZTS and 35C ZTS Operation & Tests 071718 PN=271

Diagnostic Information

TM2052 (17JUL18)

9025-15-24

27C ZTS and 35C ZTS Operation & Tests 071718 PN=272

Diagnostic Information 1— Hydraulic Pump 1 2— Hydraulic Pump 2 3— Hydraulic Pump 3 4— Pilot Pump 5— Pilot Filter 11— Oil Cooler

12— Hydraulic Oil Tank 57— Swing Motor and Gearbox 59— Bucket Cylinder 60— Boom Cylinder 61— Blade Cylinder

62— Left Propel Motor 69— Right Propel Motor 70— Rotary Manifold 71— Arm Cylinder 72— Boom Swing Cylinder

75— Solenoid Valve Manifold 78— Main Control Valve 79— One Way/Two Way Valve

TX19495,0000086 -19-10JUN02-3/3

TM2052 (17JUL18)

9025-15-25

27C ZTS and 35C ZTS Operation & Tests 071718 PN=273

Diagnostic Information

TM2052 (17JUL18)

9025-15-26

27C ZTS and 35C ZTS Operation & Tests 071718 PN=274

Group 25

Tests JT05801 Clamp-On Electronic Tachometer Installation SERVICE EQUIPMENT AND TOOLS

T6813AG —UN—28FEB89

JT05801 Clamp-On Electronic Tachometer

1. Before installing clamp-on electronic tachometer, remove the paint from a straight section of injection line within 100 mm (4 in.) of No. 1 injection nozzle.

Use emery cloth to remove the paint.

2. Install the clamp-on transducer (A). Tighten finger tight only—DO NOT overtighten.

3. Connect the red clip (+) (C) to the clamp-on transducer.

4. Connect the black clip (-) (B) to a ground connection such as the head of a cap screw or other metal part on engine.

A—Clamp-On Transducer B—Black Clip (—)

C—Red Clip (+) D—Digital Readout Unit

5. Start the engine. Check for a reading on the digital readout unit (D).

CED,TX08227,2879 -19-11NOV97-1/1

JT05800 Digital Thermometer Installation SERVICE EQUIPMENT AND TOOLS

1. Fasten temperature probe (A) to a bare metal hydraulic line using a tie band.

2. Wrap temperature probe and line with a shop towel.

A—Temperature Probe B—Cable

C—JT05800 Digital Thermometer

T6808CE —UN—28FEB89

JT05800 Digital Thermometer

CED,TX08227,2895 -19-19NOV97-1/1

TM2052 (17JUL18)

9025-25-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=275

Tests

JT02156A Digital Pressure/Temperature Analyzer Installation SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure/Temperature Analyzer T8543AI —UN—25AUG95

JT02158 Digital Pressure/Temperature Analyzer JT02159 20 ft Cable with Couplers JT02161 500 psi Transducer JT02162 5000 psi Transducer JT05969 Thermo-Coupler 312883 Carry Case JT02160 10,000 psi Transducer (Optional, Order Separately)

Use the digital pressure/temperature analyzer (A), and transducers (B) in place of analog gauges and a separate temperature reader.

Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is warmed and no pressure applied, push sensor zero button for one second to set the true zero point.

A—Digital Pressure/Tempera- 34 000 kPa (350 bar) (5000 psi) ture Analyzer Transducer B—3 400 kPa (35 bar) (500 psi) 70 000 kPa (700 bar) (10,000 psi Transducer Transducer

When using for different pressures, turn selector to OFF for two seconds and then to the pressure range. Readings are inaccurate if proper range for transducer is not used.

CED,TX08227,2896 -19-02JUL01-1/1

TM2052 (17JUL18)

9025-25-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=276

Tests

Hydraulic System Warm-Up Procedure 2. Clear the area of all bystanders to allow for machine movement.

SPECIFICATIONS Hydraulic System Hydraulic Oil Temperature

45—55 °C (110—130 °F)

3. Start engine. Do not accelerate engine rapidly during warm up. Run engine at 1/2 speed for approximately 5 minutes before operating any functions. Do not run engine at fast or slow idle.

SERVICE EQUIPMENT AND TOOLS JT05800 Digital Thermometer

IMPORTANT: If machine temperature is below -18°C (0°F), start procedure with engine running at 1/2 speed. Failure to do this could cause pump cavitation. Once oil temperature is above -18°C (0°F) the engine speed can be increased to fast idle.

Below -18°C (0°F) an extended warm-up period may be necessary. Hydraulic function will move slowly and lubrication of parts may not be adequate with cold oil.

Do not attempt normal machine operation until hydraulic functions move at or close to normal cycle times.

Operate functions slowly and avoid sudden movements until engine and hydraulic oils are thoroughly warmed.

Operate a function by moving it a short distance in each direction. Continue operating the function increasing the distance traveled in each cycle until full stroke is reached.

For faster warm-up, restrict air flow through oil cooler using cardboard or other similar material. Use correct viscosity oil to minimize warm-up period. Go to Hydraulic Oil. (Operator's Manual) 1. Perform JT05800 Digital Thermometer Installation.

(See procedure in this group.)

CAUTION: Avoid possible serious injury from machine movement during warm-up procedure.

Clear the area of all bystanders before doing the warm-up procedure.

4. Slowly turn upperstructure so boom is to the side.

CAUTION: Avoid possible serious injury from machine sliding backwards. Keep angle between boom and arm at 90—110° 5. Keeping the angle between boom and arm at 90—110°, lower boom to raise one track off the ground.

6. Operate propel function for approximately 5 minutes.

7. Once oil temperature is above -18°C (0°F), increase engine speed to fast idle.

IMPORTANT: Holding a function over relief for more than 10 seconds can cause damage from hot spots in the control valve.

8. Operate the propel function (side with track off the ground). Also operate the bucket curl function over relief for 10 seconds and then stop for 5 seconds.

Repeat the cycle until oil is heated to specifications.

9. Stop periodically and operate all hydraulic functions to distribute the heated oil.

10. Continue procedure until oil temperature is within specifications.

Hydraulic System—Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F) CED,TX08227,3305 -19-22NOV99-1/1

TM2052 (17JUL18)

9025-25-3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=277

Tests

Cylinder Drift Test—Boom, Arm, Bucket, and Blade—27C ZTS SPECIFICATIONS Hydraulic Oil Temperature

45—55 °C (110—130 °F)

Bucket Load Weight

120 kg (265 lb) approximate

Arm Cylinder Length

50 mm (2.00 in.) approximate extension

Bucket Cylinder Length

50 mm (2.00 in.) approximate retraction

Boom Cylinder Height

Bucket pivot pin at the same height as boom-to-main frame pin

Blade Height

Top of Stroke

Engine Speed

0 rpm

Boom Cylinder Drift

5 mm (3/16 in.) maximum allowable for 5 minutes

Arm Cylinder Drift

8 mm (5/16 in.) maximum allowable for 5 minutes

Bucket Cylinder Drift

5 mm (3/16 in.) maximum allowable for 5 minutes

Blade Cylinder Drift

5 mm (3/16 in.) maximum allowable for 5 minutes with blade raised

Bottom of Bucket-to-Ground Drift

70 mm (2 3/4 in.) maximum allowable for 5 minutes

Blade Cylinder Drift

10 mm (3/8 in.) maximum allowable for 5 minutes with blade lowered

T124278 —UN—17SEP99

Cylinder Drift Test—27C ZTS

Specification Bucket Cylinder—Length............................... 50 mm (2.00 in.) approximate retraction

6. Position the boom cylinder so bucket pivot pin is at the same height as the boom-to-main frame pin.

Specification Boom Cylinder—Height............................... Bucket pivot pin at the same height as boom-to-main frame pin

7. Raise blade to top of stroke.

Specification Blade—Height..................................................................... Top of Stroke

8. Stop the engine.

ESSENTIAL TOOLS

Specification Engine—Speed............................................................................... 0 rpm

JT05800 Digital Thermometer Tape Measure

9. After 5 minutes, measure the amount of movement for boom, arm, bucket, and blade cylinders and from bottom of bucket to the ground.

Procedure is used to check the leakage past the cylinder piston seals, control valve spools, circuit relief valves, boom reduced leakage valve, and arm reduced leakage valve.

1. Perform JT05800 Digital Thermometer Installation.

(See procedure in this group.)

2. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

3. Fill the bucket to get the specified bucket load with the standard arm and bucket.

Specification Bucket Load—Weight.................................. 120 kg (265 lb) approximate

4. Position arm cylinder so rod is extended the specified length from full retraction.

Specification Arm Cylinder—Length...............50 mm (2.00 in.) approximate extension

5. Position bucket cylinder so rod is retracted the specified length from full extension.

Specification Boom Cylinder—Drift........................................................ 5 mm (3/16 in.) maximum allowable for 5 minutes Arm Cylinder—Drift.......................................................... 8 mm (5/16 in.) maximum allowable for 5 minutes Bucket Cylinder—Drift...................................................... 5 mm (3/16 in.) maximum allowable for 5 minutes Blade Cylinder—Drift....................... 5 mm (3/16 in.) maximum allowable for 5 minutes with blade raised Bottom of Bucket-toGround—Drift................................................................ 70 mm (2 3/4 in.) maximum allowable for 5 minutes

10. Start engine.

11. Lower blade completely to lift front of machine off ground.

12. Stop engine.

13. After 5 minutes, measure the amount of movement for blade cylinder.

Specification Blade Cylinder—Drift....................... 10 mm (3/8 in.) maximum allowable for 5 minutes with blade lowered

Continued on next page

TM2052 (17JUL18)

9025-25-4

CED,OUOE011,144 -19-22NOV99-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=278

Tests

Cylinder Drift Test—Boom, Arm, Bucket, and Blade—35C ZTS SPECIFICATIONS Cylinder Drift Test—35C ZTS 45—55 °C (110—130 °F)

Bucket Load Weight

165 kg (364 lb) approximate

Arm Cylinder Length

50 mm (2.00 in.) approximate extension

Bucket Cylinder Length

50 mm (2.00 in.) approximate retraction

Boom Cylinder Height

Bucket pivot pin at the same height as boom-to-main frame pin

Blade Height

Top of Stroke

Engine Speed

0 rpm

Boom Cylinder Drift

5 mm (3/16 in.) maximum allowable for 5 minutes

Arm Cylinder Drift

8 mm (5/16 in.) maximum allowable for 5 minutes

Bucket Cylinder Drift

5 mm (3/16 in.) maximum allowable for 5 minutes

Blade Cylinder Drift

3 mm (1/8 in.) maximum allowable for 5 minutes with blade raised

Bottom of Bucket-to-Ground Drift

100 mm (3 15/16 in.) maximum allowable for 5 minutes

7. Raise blade to specified height.

Blade Cylinder Drift

15 mm (9/16 in.) maximum allowable for 5 minutes with blade lowered

Specification Blade—Height......................................................................Top of stroke

T124278 —UN—17SEP99

Hydraulic Oil Temperature

Specification Bucket Cylinder—Length............................... 50 mm (2.00 in.) approximate retraction

6. Position the boom cylinder so bucket pivot pin is at the same height as the boom-to-main frame pin.

Specification Boom Cylinder—Height............................... Bucket pivot pin at the same height as boom-to-main frame pin

8. Stop the engine.

ESSENTIAL TOOLS

Specification Engine—Speed............................................................................... 0 rpm

JT05800 Digital Thermometer Tape Measure

9. After 5 minutes, measure the amount of movement for boom, arm, bucket, and blade cylinders and from bottom of bucket to the ground.

Procedure is used to check the leakage past the cylinder piston seals, control valve spools, circuit relief valves, boom reduced leakage valve, and arm reduced leakage valve.

1. Do JT05800 Digital Thermometer Installation. (See procedure in this group.)

2. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

3. Fill the bucket to get the specified bucket load with the standard arm and bucket.

Specification Bucket Load—Weight.................................. 165 kg (364 lb) approximate

4. Position arm cylinder so rod is extended the specified length from full retraction.

Specification Arm Cylinder—Length...............50 mm (2.00 in.) approximate extension

5. Position bucket cylinder so rod is retracted the specified length from full extension.

Specification Boom Cylinder—Drift........................................................ 5 mm (3/16 in.) maximum allowable for 5 minutes Arm Cylinder—Drift.......................................................... 8 mm (5/16 in.) maximum allowable for 5 minutes Bucket Cylinder—Drift...................................................... 5 mm (3/16 in.) maximum allowable for 5 minutes Blade Cylinder—Drift......................... 3 mm (1/8 in.) maximum allowable for 5 minutes with blade raised Bottom of Bucket-toGround—Drift.......................................................... 100 mm (3 15/16 in.) maximum allowable for 5 minutes

10. Start engine.

11. Lower blade completely to lift front of machine off ground.

12. Stop engine.

13. After 5 minutes, measure the amount of movement for blade cylinder.

Specification Blade Cylinder—Drift..................... 15 mm (9/16 in.) maximum allowable for 5 minutes with blade lowered

Continued on next page

TM2052 (17JUL18)

9025-25-5

TX18160,000009E -19-20MAY02-1/2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=279

Tests

Pilot Pressure Regulating Valve Test and Adjustment—27C ZTS SPECIFICATIONS Hydraulic Oil Temperature

45—55 °C (110—130 °F)

Engine Speed

Fast Idle

Pilot Pressure Regulating Valve Pressure

3920— 4900 kPa (39.2—49.0 bar) (570—711 psi) at fast idle

Nut-to-Pilot Pressure Regulating Valve Housing Torque

25 N·m (18 lb-ft)

T155909B —UN—11JUN02

Pilot Pressure Regulating Valve—27C ZTS

ESSENTIAL TOOLS JT03523 Test Kit JT03523-13 (3/8 BSPP) Swivel Run Tee

1— Gauge 2— 45° Elbow Fitting 3— Tee

JT03523-4 (7/16 M 37° x 3/8 MBSPP) Adapter XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler

4— Hose 5— Adapter 6— 90° Elbow Fitting

SERVICE EQUIPMENT AND TOOLS

and male quick coupler. Connect the digital pressure/temperature analyzer and transducer or a gauge (1).

JT02156A Digital Pressure/Temperature Analyzer JT02161 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 7000 kPa (70 bar) (1000 psi)

4. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

17 mm Combination Wrench 5 mm Hex Key Wrench

Purpose of test is to ensure there is enough pilot pressure to operate all the pilot system functions and to adjust the pressure as necessary.

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

5. Run machine at specifications.

1. Stop the engine.

2. Loosen cap to release the air pressure in hydraulic oil tank.

3. Disconnect pilot pressure hose (4) at elbow fitting (2). Install tee (3), adapter (5), elbow fitting (6)

Specification Engine—Speed.......................................................................... Fast Idle

6. Record pressure reading for pilot pressure regulating valve.

CED,OUOE011,134 -19-22NOV99-1/2

7. As necessary, loosen nut (2) on pilot pressure regulating valve. Turn adjusting screw (1) in to increase pressure or out to decrease pressure.

Specification Pilot Pressure Regulating Valve—Pressure........................................3920— 4900 kPa (39.2—49.0 bar) (570—711 psi) at fast idle

Specification Nut-to-Pilot Pressure Regulating Valve Housing—Torque............................................................ 25 N·m (18 lb-ft) 1— Adjusting Screw

2— Nut

T125611 —UN—18NOV99

8. Tighten nut (2).

CED,OUOE011,134 -19-22NOV99-2/2

TM2052 (17JUL18)

9025-25-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=280

Tests

Pilot Pressure Regulating Valve Test and Adjustment—35C ZTS SPECIFICATIONS Hydraulic Oil Temperature

45—55 °C (110—130 °F)

Engine Speed

Fast Idle

Pilot Pressure Regulating Valve Pressure

3920— 4900 kPa (39.2—49.0 bar) (570—711 psi) at fast idle

Nut-to-Pilot Pressure Regulating Valve Housing Torque

25 N·m (18 lb-ft)

T155873B —UN—11JUN02

Pilot Pressure Regulating Valve—35C ZTS

ESSENTIAL TOOLS JT03523 Test Kit JT03523-13 (3/8 BSPP) Swivel Run Tee

1— Hose 2— Tee 3— Elbow Fitting

JT03523-4 (7/16 M 37° x 3/8 MBSPP) Adapter JT05483 (7/16 37°) 90° Elbow Fitting

4— Gauge 5— Adapter

XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler

Connect the digital pressure/temperature analyzer and transducer or a gauge (4).

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure/Temperature Analyzer

4. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

JT02161 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 7000 kPa (70 bar) (1000 psi) 17 mm Combination Wrench

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

5 mm Hex Key Wrench

Purpose of test is to ensure there is enough pilot pressure to operate all the pilot system functions and to adjust the pressure as necessary.

1. Stop the engine.

2. Loosen cap to release the air pressure in hydraulic oil tank.

5. Run machine at specifications.

Specification Engine—Speed.......................................................................... Fast Idle

6. Record pressure reading for pilot pressure regulating valve.

3. Disconnect pilot pressure hose (1) at elbow fitting (3).

Install tee (2), adapter (5), and male quick coupler.

TX18160,00000A1 -19-11JUN02-1/2

7. As necessary, loosen nut (2) on pilot pressure regulating valve. Turn adjusting screw (1) in to increase pressure or out to decrease pressure.

Specification Pilot Pressure Regulating Valve—Pressure........................................3920— 4900 kPa (39.2—49.0 bar) (570—711 psi) at fast idle

Specification Nut-to-Pilot Pressure Regulating Valve Housing—Torque............................................................ 25 N·m (18 lb-ft) 1— Adjusting Screw

2— Nut

T125611 —UN—18NOV99

8. Tighten nut (2).

TX18160,00000A1 -19-11JUN02-2/2

TM2052 (17JUL18)

9025-25-7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=281

Tests

Control Valve Spool Pilot Actuating Pressure Test

1

SPECIFICATIONS Control Valve Spool Pilot Actuating Pressure Test 45—55 °C (110—130 °F)

Engine Speed Control Lever Position

Fast Idle

Pilot Actuation Pressure

3920— 4900 kPa (39.2—49.0 bar) (570—711 psi) at fast idle

T155982 —UN—18JUN02

2

Hydraulic Oil Temperature

3 5

ESSENTIAL TOOLS

4

JT03523 Test Kit JT03523-12 (1/4 BSPP) Swivel Run Tee JT03523-4 (7/16 M 37° x 1/4 MBSPP) Adapter

1— Gauge 2— Adapter 3— Pilot Cap Fitting

XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler

4— Tee 5— Pilot Line

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure/Temperature Analyzer Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

JT02161 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 7000 kPa (70 bar) (1000 psi)

Procedure is used to check that there is enough pilot pressure oil to the pilot cap to completely shift the valve spools when pilot controllers are actuated.

CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine.

5. Start and run engine at specification.

Specification Engine Speed Control Lever—Position.......................................................................... Fast Idle

NOTE: Spool actuation pressure can be checked for each function by installing the tee and gauge in that pilot line and then actuating that function.

1. Stop the engine.

2. Loosen cap to release the air pressure in hydraulic oil tank.

NOTE: Spool actuating pressure can be checked for each function by installing the hose, tee, and gauge in place of that pilot line and then actuating that function.

3. Disconnect pilot line (5) at pilot cap fitting (3). Install tee (4), adapter (2), and male quick coupler. Install the digital pressure and temperature analyzer and transducer or a gauge (1).

6. Actuate the function being checked to full stroke.

If valve spool actuation pressure is not to specification, perform Pilot Pressure Regulating Valve Test and Adjustment. (See procedure in this group.)

Specification Pilot Actuation—Pressure...........................................................3920— 4900 kPa (39.2—49.0 bar) (570—711 psi) at fast idle

4. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

If pilot system pressure is still not to specification, check pilot filter for restrictions, pilot pressure at the pilot control shut-off solenoid valve, and pilot controllers.

CED,OUOE011,135 -19-22NOV99-1/1

TM2052 (17JUL18)

9025-25-8

27C ZTS and 35C ZTS Operation & Tests 071718 PN=282

Tests

Hydraulic Pump 1, 2, and 3 System Relief Valve Test and Adjustment—27C ZTS SPECIFICATIONS Hydraulic Oil Temperature

45—55 °C (110—130 °F)

Engine Speed

Fast Idle

Hydraulic Pump 1, 2, and 3 System Relief Valve Pressure

20 600—22 600 kPa (206—226 bar) (2990—3280 psi)

Per 1/4 Turn of Adjusting Screw Change Pressure

4450 kPa (45 bar) (650 psi) approximate

17 mm Nut Torque

29 N·m (22 lb-ft)

T156021B —UN—12JUN02

Hydraulic Pumps 1, 2, and 3 System Relief Valve—27C ZTS

System Relief Valve Test Connections (35C ZTS Shown)

ESSENTIAL TOOLS JT03360 (7/16 M 37° x 1/4 MBSPT) Adapter

1— Quick Connector 2— Adapter 3— Tee Fitting 4— Line

XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler 6 mm Hex Wrench SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure/Temperature Analyzer JT02161 Transducer 35 000 kPa (350 bar) (5000 psi)

5— Hydraulic Pump 1 Delivery Port 6— Hydraulic Pump 2 Delivery Port 7— Hydraulic Pump 3 Delivery Port 8— Gauge

Gauge 35 000 kPa (350 bar) (5000 psi) 60 mm (2-3/8 in.) OD Pin or Length of Round Bar Stock (2 used) 17 mm Combination Wrench

The system relief valves are used to limit the maximum pressure in the hydraulic system. The purpose of test is to check and adjust system relief valves to specification to protect components from damage caused by excessive pressure.

3. Install adapters (2) and male quick couplers (1) to pump fittings (3). Connect the digital pressure/temperature analyzer and transducers or gauges (8).

4. Raise and lower boom to pressurize hydraulic oil tank.

5. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

NOTE: Installation for 35C ZTS is shown. 27C ZTS is similar.

1. Stop the engine.

2. Loosen hydraulic oil tank cap to release the air pressure in hydraulic oil tank.

CED,OUOE011,136 -19-22NOV99-1/4

6. Install pins or round bar stock (1) between the sprockets and track frame to stall propel motors.

Specification Engine—Speed.......................................................................... Fast Idle

8. Slowly actuate the left propel to load hydraulic pump 1, right propel to load hydraulic pump 2 or blade to load hydraulic pump 3. Record the pressure readings.

1— Pin or Round Bar Stock

Continued on next page

TM2052 (17JUL18)

9025-25-9

T123253 —UN—17SEP99

7. Run machine at specification.

CED,OUOE011,136 -19-22NOV99-2/4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=283

Tests

9. Adjust the system relief valves (9—11) pressure setting as needed.

10

11

9— Hydraulic Pump 1 System Relief Valve 10— Hydraulic Pump 2 System Relief Valve

T156024 —UN—18JUN02

Specification Hydraulic Pump 1, 2, and 3 System Relief Valve—Pressure...................................................... 20 600—22 600 kPa (206—226 bar) (2990—3280 psi) 11— Hydraulic Pump 3 System Relief Valve

9

CED,OUOE011,136 -19-22NOV99-3/4

10. Loosen the 17 mm nut (12).

11. Turn adjusting screw (13) in to increase pressure or turn adjusting screw out to decrease pressure to get specified pressure for propel function.

T156102 —UN—18JUN02

Specification Per 1/4 Turn of Adjusting Screw Change—Pressure...................4450 kPa (45 bar) (650 psi) approximate

12. Hold adjusting screw and tighten 17 mm nut.

Specification 17 mm Nut—Torque....................................................... 29 N·m (22 lb-ft)

13. Check the pressure setting again.

14. Remove the pins or round bar stock between sprockets and track frame.

12— Nut

13— Adjusting Screw

CED,OUOE011,136 -19-22NOV99-4/4

TM2052 (17JUL18)

9025-25-10

27C ZTS and 35C ZTS Operation & Tests 071718 PN=284

Tests

Hydraulic Pump 1, 2, and 3 System Relief Valve Test and Adjustment—35C ZTS SPECIFICATIONS Hydraulic Oil Temperature

45—55 °C (110—130 °F)

Engine Speed

Fast Idle

Hydraulic Pump 1, 2, and 3 System Relief Valve Pressure

24 500—26 500 kPa (245—265 bar) (3550—3845 psi)

Per 1/4 Turn of Adjusting Screw Change Pressure

4450 kPa (45 bar) (650 psi) approximate

17 mm Nut Torque

29 N·m (22 lb-ft)

T156021B —UN—12JUN02

Hydraulic Pumps 1, 2, and 3 System Relief Valve—35C ZTS

System Relief Valve Test Connections

ESSENTIAL TOOLS JT03360 (7/16 M 37° x 1/4 MBSPT) Adapter

1— Quick Connector 2— Adapter 3— Tee Fitting 4— Line

XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler 6 mm Hex Wrench SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure/Temperature Analyzer JT02161 Transducer 35 000 kPa (350 bar) (5000 psi)

5— Hydraulic Pump 1 Delivery Port 6— Hydraulic Pump 2 Delivery Port 7— Hydraulic Pump 3 Delivery Port 8— Gauge

Gauge 35 000 kPa (350 bar) (5000 psi) 60 mm (2-3/8 in.) OD Pin or Length of Round Bar Stock (2 used) 17 mm Combination Wrench

The system relief valves are used to limit the maximum pressure in the hydraulic system. The purpose of test is to check and adjust system relief valves to specification to protect components from damage caused by excessive pressure.

3. Install adapters (2) and male quick couplers (1) to pump fittings (3). Connect the digital pressure/temperature analyzer and transducers or gauges (8).

4. Raise and lower boom to pressurize hydraulic oil tank.

5. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

1. Stop the engine.

2. Loosen hydraulic oil tank cap to release the air pressure in hydraulic oil tank.

TX18160,00000A2 -19-12JUN02-1/4

6. Install pins or round bar stock (1) between the sprockets and track frame to stall propel motors.

Specification Engine—Speed.......................................................................... Fast Idle

8. Slowly actuate the left propel to load hydraulic pump 1, right propel to load hydraulic pump 2 or blade to load hydraulic pump 3. Record the pressure readings.

1— Pin or Round Bar Stock

Continued on next page

TM2052 (17JUL18)

9025-25-11

T123253 —UN—17SEP99

7. Run machine at specification.

TX18160,00000A2 -19-12JUN02-2/4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=285

Tests

9. Adjust the system relief valves (9—11) pressure setting as needed.

10

11

9— Hydraulic Pump 1 System Relief Valve 10— Hydraulic Pump 2 System Relief Valve

T156024 —UN—18JUN02

Specification Hydraulic Pump 1, 2, and 3 System Relief Valve—Pressure...................................................... 24 500—26 500 kPa (245—265 bar) (3550—3845 psi) 11— Hydraulic Pump 3 System Relief Valve

9

TX18160,00000A2 -19-12JUN02-3/4

10. Loosen the 17 mm nut (12).

11. Turn adjusting screw (13) in to increase pressure or turn adjusting screw out to decrease pressure to get specified pressure for propel function.

T156102 —UN—18JUN02

Specification Per 1/4 Turn of Adjusting Screw Change—Pressure...................4450 kPa (45 bar) (650 psi) approximate

12. Hold adjusting screw and tighten 17 mm nut.

Specification 17 mm Nut—Torque....................................................... 29 N·m (22 lb-ft)

13. Check the pressure setting again.

14. Remove the pins or round bar stock between sprockets and track frame.

12— Nut

13— Adjusting Screw

TX18160,00000A2 -19-12JUN02-4/4

TM2052 (17JUL18)

9025-25-12

27C ZTS and 35C ZTS Operation & Tests 071718 PN=286

Tests

Circuit Relief Valve Test and Adjustment—27C ZTS SPECIFICATIONS 45-55°C (110-130°F)

Engine Speed

Slow idle

Bucket Curl Pressure

22 500—24 500 kPa (225—245 bar) (3260—3555 psi)

Bucket Dump Pressure

22 500—24 500 kPa (225—245 bar) (3260—3555 psi)

Arm In Pressure

22 500—24 500 kPa (225—245 bar) (3260—3555 psi)

Arm Out Pressure

22 500—24 500 kPa (225—245 bar) (3260—3555 psi)

Boom Up Pressure

22 500—24 500 kPa (225—245 bar) (3260—3555 psi)

Boom Down Pressure

22 500—24 500 kPa (225—245 bar) (3260—3555 psi)

Circuit Relief Valve Pressure Change

7 100 kPa (71 bar) (1030 psi) approximate per 1/4 turn

T156113B —UN—11JUL02

Hydraulic Oil Temperature

Circuit Relief Valve Test Connections (35C ZTS Shown) 1— Gauge 2— Male Quick Coupler 3— Adapter 4— Tee Fitting

5— Line 6— Hydraulic Pump 1 Discharge Port 7— Hydraulic Pump 2 Discharge Port

ESSENTIAL TOOLS JT03360 (7/16 M 37° x 1/4 MBSPT) Adapter

2. Perform JT05801 Clamp-On Electronic Tachometer Installation. (Group 9025-25)

XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler

3. Loosen cap to release the air pressure in hydraulic oil tank.

SERVICE EQUIPMENT AND TOOLS JT05801 Clamp-On Electronic Tachometer JT02156A Digital Pressure/Temperature Analyzer

4. Install adapters (3) and male quick coupler (2) to hydraulic pump delivery fitting (4). Connect the digital pressure/temperature analyzer and transducers or gauges (1).

JT02161 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 35 000 kPa (350 bar) (5000 psi) 17 mm Combination Wrench 6 mm Hex Key Wrench

The purpose of circuit relief valves is to relieve high pressure spikes caused by external forces when functions are in neutral. The valves are checked and adjusted to specification to protect components from damage.

5. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

Specification Hydraulic Oil—Temperature.................................................... 45-55°C (110-130°F)

1. Stop the engine.

Continued on next page

TM2052 (17JUL18)

9025-25-13

CED,OUOE011,138 -19-22NOV99-1/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=287

Tests

13 12 11 10

9

8

T156136 —UN—18JUN02

NOTE: The pressure setting for circuit relief valves is higher than the system relief valves (10 and 15). The system relief valves must be adjusted to a higher pressure setting to check the circuit relief valve pressure settings.

6. Turn system relief valve adjusting screw in 1/4 turn to increase the system pressure setting.

7. Run machine at specification.

Specification Engine—Speed..........................................................................Slow idle

8. Actuate the function over relief for circuit relief valve being checked. Record pressure reading.

Specification Bucket Curl—Pressure............................................ 22 500—24 500 kPa (225—245 bar) (3260—3555 psi) Bucket Dump—Pressure......................................................................... 22 500—24 500 kPa (225—245 bar) (3260—3555 psi) Arm In—Pressure.................................................... 22 500—24 500 kPa (225—245 bar) (3260—3555 psi) Arm Out—Pressure................................................. 22 500—24 500 kPa (225—245 bar) (3260—3555 psi) Boom Up—Pressure............................................... 22 500—24 500 kPa (225—245 bar) (3260—3555 psi)

14

15

16

8— Auxiliary Circuit Relief Valve 9— Arm In Circuit Relief Valve 10— Hydraulic Pump 2 System Relief Valve 11— Boom Up Circuit Relief Valve 12— Boom Down Circuit Relief Valve

17

13— Bucket Dump Circuit Relief Valve 14— Bucket Curl Circuit Relief Valve 15— Hydraulic Pump 1 System Relief Valve 16— Arm Out Circuit Relief Valve 17— Auxiliary Circuit Relief Valve

Boom Down—Pressure........................................... 22 500—24 500 kPa (225—245 bar) (3260—3555 psi) CED,OUOE011,138 -19-22NOV99-2/3

NOTE: Auxiliary circuit relief valves should be adjusted to the manufacturer's specifications for the attachment being used.

T156137 —UN—19JUN02

9. Adjust the circuit relief valve as needed. Loosen nut (18). Turn adjusting screw (19) IN to increase pressure setting: turn adjusting screw OUT to decrease pressure setting.

Specification Circuit Relief Valve—Pressure Change....................................................................... 7 100 kPa (71 bar) (1030 psi) approximate per 1/4 turn

10. Hold adjusting screw and tighten nut.

18— Nut

19— Adjusting Screw

11. Check pressures again.

12. Perform Hydraulic Pump 1, 2, and 3 System Relief Valve Test and Adjustment. (Group 9025-25) CED,OUOE011,138 -19-22NOV99-3/3

TM2052 (17JUL18)

9025-25-14

27C ZTS and 35C ZTS Operation & Tests 071718 PN=288

Tests

Circuit Relief Valve Test and Adjustment—35C ZTS SPECIFICATIONS 45-55°C (110-130°F)

Engine Speed

Slow idle

Bucket Curl Pressure

26 500—28 500 kPa (265—285 bar) (3845—4135 psi)

Bucket Dump Pressure

26 500—28 500 kPa (265—285 bar) (3845—4135 psi)

Arm In Pressure

26 500—28 500 kPa (265—285 bar) (3845—4135 psi)

Arm Out Pressure

26 500—28 500 kPa (265—285 bar) (3845—4135 psi)

Boom Up Pressure

26 500—28 500 kPa (265—285 bar) (3845—4135 psi)

Boom Down Pressure

26 500—28 500 kPa (265—285 bar) (3845—4135 psi)

Circuit Relief Valve Pressure Change

7 100 kPa (71 bar) (1030 psi) approximate per 1/4 turn

T156113B —UN—11JUL02

Hydraulic Oil Temperature

1— Gauge 2— Male Quick Coupler 3— Adapter 4— Tee Fitting

ESSENTIAL TOOLS

5— Line 6— Hydraulic Pump 1 Discharge Port 7— Hydraulic Pump 2 Discharge Port

2. Perform JT05801 Clamp-On Electronic Tachometer Installation. (Group 9025-25)

JT03360 (7/16 M 37° x 1/4 MBSPT) Adapter XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler

3. Loosen cap to release the air pressure in hydraulic oil tank.

SERVICE EQUIPMENT AND TOOLS JT05801 Clamp-On Electronic Tachometer

4. Install adapters (3) and male quick coupler (2) to hydraulic pump delivery fitting (4). Connect the digital pressure/temperature analyzer and transducers or gauges (1).

JT02156A Digital Pressure/Temperature Analyzer JT02161 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 35 000 kPa (350 bar) (5000 psi) 17 mm Combination Wrench

5. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

6 mm Hex Key Wrench

The purpose of circuit relief valves is to relieve high pressure spikes caused by external forces when functions are in neutral. The valves are checked and adjusted to specification to protect components from damage.

Specification Hydraulic Oil—Temperature.................................................... 45-55°C (110-130°F)

1. Stop the engine.

Continued on next page

TM2052 (17JUL18)

9025-25-15

TX18160,00000A3 -19-20JUN02-1/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=289

Tests

13 12 11 10

9

8

T156136 —UN—18JUN02

NOTE: The pressure setting for circuit relief valves is higher than the system relief valves (10 and 15). The system relief valves must be adjusted to a higher pressure setting to check the circuit relief valve pressure settings.

6. Turn system relief valve adjusting screw in 1/4 turn to increase the system pressure setting.

7. Run machine at specification.

Specification Engine—Speed..........................................................................Slow idle

8. Actuate the function over relief for circuit relief valve being checked. Record pressure reading.

Specification Bucket Curl—Pressure............................................ 26 500—28 500 kPa (265—285 bar) (3845—4135 psi) Bucket Dump—Pressure......................................................................... 26 500—28 500 kPa (265—285 bar) (3845—4135 psi) Arm In—Pressure.................................................... 26 500—28 500 kPa (265—285 bar) (3845—4135 psi) Arm Out—Pressure................................................. 26 500—28 500 kPa (265—285 bar) (3845—4135 psi) Boom Up—Pressure............................................... 26 500—28 500 kPa (265—285 bar) (3845—4135 psi)

14

15

16

8— Auxiliary Circuit Relief Valve 9— Arm In Circuit Relief Valve 10— Hydraulic Pump 2 System Relief Valve 11— Boom Up Circuit Relief Valve 12— Boom Down Circuit Relief Valve

17

13— Bucket Dump Circuit Relief Valve 14— Bucket Curl Circuit Relief Valve 15— Hydraulic Pump 1 System Relief Valve 16— Arm Out Circuit Relief Valve 17— Auxiliary Circuit Relief Valve

Boom Down—Pressure........................................... 26 500—28 500 kPa (265—285 bar) (3845—4135 psi) TX18160,00000A3 -19-20JUN02-2/3

NOTE: Auxiliary circuit relief valves should be adjusted to the manufacturer's specifications for the attachment being used.

T156137 —UN—19JUN02

9. Adjust the circuit relief valve as needed. Loosen nut (18). Turn adjusting screw (19) IN to increase pressure setting: turn adjusting screw OUT to decrease pressure setting.

Specification Circuit Relief Valve—Pressure Change....................................................................... 7 100 kPa (71 bar) (1030 psi) approximate per 1/4 turn

10. Hold adjusting screw and tighten nut.

18— Nut

19— Adjusting Screw

11. Check pressures again.

12. Perform Hydraulic Pump 1, 2, and 3 System Relief Valve Test and Adjustment-35C ZTS. (Group 9025-25) TX18160,00000A3 -19-20JUN02-3/3

TM2052 (17JUL18)

9025-25-16

27C ZTS and 35C ZTS Operation & Tests 071718 PN=290

Tests

Swing Motor Crossover Relief Valve Test and Adjustment—27C ZTS SPECIFICATIONS Swing Motor Crossover Relief Valve—27C ZTS 45—55°C (110—130°F)

Engine Speed

Slow Idle

Swing Crossover Relief Valve Pressure

18 600—20 600 kPa (186—206 bar) (2700—2990 psi)

T156484B —UN—11JUL02

Hydraulic Oil Temperature

ESSENTIAL TOOLS JT03360 Adapter XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler

Swing Motor Crossover Relief Valve Test Connections (35C ZTS Shown)

SERVICE EQUIPMENT AND TOOLS JT05800 Digital Thermometer

1— Gauge 2— Quick Coupler

JT02156A Digital Pressure/Temperature Analyzer

3— Adapter

JT02161 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 35 000 kPa (350 bar) (5000 psi)

4. Raise and lower boom to pressurize hydraulic oil tank.

17 mm Combination Wrench 4 mm Hex Wrench

The purpose of swing crossover relief valves is to limit pressure in the swing circuit, to relieve high pressure spikes caused by starting and stopping the swing function and to relieve pressure spikes caused by external forces when functions are in neutral . The valves are checked and adjusted to specification to protect components from damage.

1. Stop the engine.

5. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

Specification Hydraulic Oil—Temperature............................................... 45—55°C (110—130°F)

6. Run machine at specifications.

Specification Engine—Speed..........................................................................Slow Idle

7. Operate the swing function at stall.

2. Loosen cap to release the air pressure in hydraulic oil tank.

8. Record the pressure reading.

3. Install adapter (3) and male quick coupler (2).

Connect the digital pressure/temperature analyzer and transducer or gauge (1).

Repeat procedure for the opposite direction. Record the pressure reading.

CED,OUOE011,139 -19-22NOV99-1/3

9. Adjust the right and left swing crossover relief valves (1 or 2) as needed.

Specification Swing Crossover Relief Valve—Pressure...................................................... 18 600—20 600 kPa (186—206 bar) (2700—2990 psi) 2— Left Swing Crossover Relief Valve T126056 —UN—19NOV99

1— Right Swing Crossover Relief Valve

Continued on next page

TM2052 (17JUL18)

9025-25-17

CED,OUOE011,139 -19-22NOV99-2/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=291

Tests

10. Loosen nut (3). Turn adjusting screw (4) in to increase pressure setting; turn screw out to decrease pressure setting.

3— Nut

T126057 —UN—19NOV99

Hold adjusting screw and tighten nut.

4— Adjusting Screw

CED,OUOE011,139 -19-22NOV99-3/3

Swing Motor Crossover Relief Valve Test and Adjustment—35C ZTS SPECIFICATIONS Hydraulic Oil Temperature

45—55°C (110—130°F)

Engine Speed

Slow Idle

Swing Crossover Relief Valve Pressure

15 200—17 200 kPa (152—172 bar) (2205—2495 psi)

T156484B —UN—11JUL02

Swing Motor Crossover Relief Valve—35C ZTS

ESSENTIAL TOOLS JT03360 Adapter XPD34BTX (1/8 x 7/16-20 F 37°) Male Quick Coupler SERVICE EQUIPMENT AND TOOLS

1— Gauge 2— Quick Coupler

JT05800 Digital Thermometer

3— Adapter

JT02156A Digital Pressure/Temperature Analyzer JT02161 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 35 000 kPa (350 bar) (5000 psi)

4. Raise and lower boom to pressurize hydraulic oil tank.

17 mm Combination Wrench

5. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

4 mm Hex Wrench

The purpose of swing crossover relief valves is to limit pressure in the swing circuit, to relieve high pressure spikes caused by starting and stopping the swing function and to relieve pressure spikes caused by external forces when functions are in neutral . The valves are checked and adjusted to specification to protect components from damage.

Specification Hydraulic Oil—Temperature............................................... 45—55°C (110—130°F)

1. Stop the engine.

7. Operate the swing function at stall.

2. Loosen cap to release the air pressure in hydraulic oil tank.

8. Record the pressure reading.

6. Run machine at specifications.

Specification Engine—Speed..........................................................................Slow Idle

3. Install adapter (3) and male quick coupler (2).

Connect the digital pressure/temperature analyzer and transducer or gauge (1).

Repeat procedure for the opposite direction. Record the pressure reading.

Continued on next page

TM2052 (17JUL18)

9025-25-18

TX18160,00000A4 -19-24JUN02-1/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=292

Tests

9. Adjust the right and left swing crossover relief valves (1 or 2) as needed.

Specification Swing Crossover Relief Valve—Pressure...................................................... 15 200—17 200 kPa (152—172 bar) (2205—2495 psi) 2— Left Swing Crossover Relief Valve T126056 —UN—19NOV99

1— Right Swing Crossover Relief Valve

TX18160,00000A4 -19-24JUN02-2/3

10. Loosen nut (3). Turn adjusting screw (4) in to increase pressure setting; turn screw out to decrease pressure setting.

3— Nut

T126057 —UN—19NOV99

Hold adjusting screw and tighten nut.

4— Adjusting Screw

TX18160,00000A4 -19-24JUN02-3/3

TM2052 (17JUL18)

9025-25-19

27C ZTS and 35C ZTS Operation & Tests 071718 PN=293

Tests

Hydraulic Pump 1 and 2 Regulator Test and Adjustment—Engine Pulldown 45-55°C (110-130°F)

Engine Speed

fast idle

Engine Speed

2410—2510 rpm with three pumps loaded

Engine Pulldown Speed

6—10 rpm per 1/4 turn of adjusting screw change

T156599B —UN—11JUL02

SPECIFICATIONS Hydraulic Oil Temperature

SERVICE EQUIPMENT AND TOOLS JT05801 Clamp-On Electronic Tachometer Load Adjusting Screw - 27C ZTS Shown

13 mm Combination Wrench 4 mm Hex Key Wrench

2— Nut

1— Screw

IMPORTANT: In this procedure the hydraulic pump is adjusted using the flow rate adjusting screw to load the engine to rated speed so all available engine horsepower is used. Prior to performing this adjustment, proper engine performance with number two diesel fuel must be verified. The fast idle speed with no load must be adjusted to specifications.

NOTE: The adjustment to load the engine to rated speed is made at the factory and does not require regular adjustment. Adjustment may be required after hydraulic pump repair.

Specification Engine—Speed............................................................................fast idle

6. Actuate boom up, arm in, and boom swing at stall.

7. Record the engine speed.

Specification Engine—Speed..................... 2410—2510 rpm with three pumps loaded

If engine speed is not to specification, adjust the flow rate adjusting screw to get the specified pulldown.

8. Loosen the nut (2).

1. Stop the engine.

Turn the load adjusting screw (1) in to decrease engine speed or out to increase engine speed.

2. Perform JT05801 Clamp-On Electronic Tachometer Installation. (Group 9025-25) 3. Perform Hydraulic System Warm-Up Procedure. (See procedure in this group.)

Specification Hydraulic Oil—Temperature.................................................... 45-55°C (110-130°F)

4. Perform Engine Speed Check. (Group 9010-25)

Specification Engine Pulldown—Speed.............................................................. 6—10 rpm per 1/4 turn of adjusting screw change

9. Check the engine speed again.

5. Run the machine at specifications.

CED,OUOE011,140 -19-22NOV99-1/1

TM2052 (17JUL18)

9025-25-20

27C ZTS and 35C ZTS Operation & Tests 071718 PN=294

Tests

Hydraulic Pump 1 and 2 Flow Test—27C ZTS SPECIFICATIONS Hydraulic Oil Temperature

45—55 °C (110—130 °F)

Engine Speed

2400 rpm (approximate)

Hydraulic Pump Flow Rate

27 L/min (7.3 gpm) at 13 790 kPa (2000 psi) (typical new)

Hydraulic Pump Flow Rate

22 L/min (5.8 gpm) at 13 790 kPa (2000 psi) minimum acceptable

Hydraulic Pump Flow Rate

26 L/min (6.9 gpm) at 20 680 kPa (3000 psi) (typical new)

Hydraulic Pump Flow Rate

21 L/min (5.5 gpm) at 20 680 kPa (3000 psi) minimum acceptable

T157023B —UN—03JUL02

Hydraulic Pump 1 and 2 Flow Test—27C ZTS

1— Reader 2— Digital Tachometer

ESSENTIAL TOOLS Parker number MB5315-8-8 Fitting

3— Flow Block

JT03523 Compact Excavator Fitting Kit JT03523-14 Metric Adapter Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

SERVICE EQUIPMENT AND TOOLS JT05801 Clamp-On Electronic Tachometer

Test is used to determine hydraulic pump condition and should be performed only if a comparison of actual machine cycle times to specified cycle times indicates low pump flow.

1. Stop the engine.

2. Perform JT05801 Clamp-On Electronic Tachometer Installation. (Group 9025 25) 3. Loosen cap to release the air pressure in hydraulic oil tank.

4. Remove tee fitting from hydraulic pump 1 or hydraulic pump 2 discharge port.

5. Install a flow meter to hydraulic pump 1 or hydraulic pump 2.

7. Operate the machine at specification.

Specification Engine—Speed..................................................2400 rpm (approximate)

8. Close flow meter loading valve to obtain the specified pressure. Record pump flow at each pressure.

Specification Hydraulic Pump 1 or 2—Flow Rate..................................................... 27 L/min (7.3 gpm) at 13 790 kPa (2000 psi) (typical new) 22 L/min (5.8 gpm) at 13 790 kPa (2000 psi) minimum acceptable 26 L/min (6.9 gpm) at 20 680 kPa (3000 psi) (typical new) 21 L/min (5.5 gpm) at 20 680 kPa (3000 psi) minimum acceptable

6. Perform Hydraulic System Warm-Up Procedure.

(Group 9025-25)

If pump flow is low, repair or replace pump.

CED,OUOE011,141 -19-22NOV99-1/1

TM2052 (17JUL18)

9025-25-21

27C ZTS and 35C ZTS Operation & Tests 071718 PN=295

Tests

Hydraulic Pump 1 and 2 Flow Test—35C ZTS SPECIFICATIONS Hydraulic Oil Temperature

45—55 °C (110—130 °F)

Engine Speed

2400 rpm T157023B —UN—03JUL02

Hydraulic Pump 1 and 2 Flow Rate 31 L/min (8.2 gpm) at 13 790 kPa (2000 psi) (typical new) Hydraulic Pump 1 and 2 Flow Rate 25 L/min (6.6 gpm) at 13 790 kPa (2000 psi) minimum acceptable Hydraulic Pump 1 and 2 Flow Rate 24 L/min (6.4 gpm) at 20 680 kPa (3000 psi) (typical new) Hydraulic Pump 1 and 2 Flow Rate 20 L/min (5.2 gpm) at 20 680 kPa (3000 psi) minimum acceptable Hydraulic Pump 1 or 2 Flow Test Connections—27C ZTS Shown ESSENTIAL TOOLS Parker number MB5315-8-8 Fitting

1— Reader 2— Digital Tachometer

JT03523 Compact Excavator Fitting Kit

3— Flow Block

JT03523-14 Metric Adapter SERVICE EQUIPMENT AND TOOLS JT05801 Clamp-On Electronic Tachometer

Test is used to determine hydraulic pump condition and should be performed only if a comparison of actual machine cycle times to specified cycle times indicates low pump flow.

1. Stop the engine.

2. Perform JT05801 Clamp-On Electronic Tachometer Installation. (Group 9025 25) 3. Loosen cap to release the air pressure in hydraulic oil tank.

4. Remove tee fitting from hydraulic pump 1 or hydraulic pump 2 discharge port.

5. Install a flow meter to hydraulic pump 1 or hydraulic pump 2.

6. Perform Hydraulic System Warm-Up Procedure.

(Group 9025-25)

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

7. Operate the machine at specification.

Specification Engine—Speed......................................................................... 2400 rpm

8. Close flow meter loading valve to obtain the specified pressure. Record pump flow at each pressure.

Specification Hydraulic Pump 1 and 2—Flow Rate..................................................... 31 L/min (8.2 gpm) at 13 790 kPa (2000 psi) (typical new) 25 L/min (6.6 gpm) at 13 790 kPa (2000 psi) minimum acceptable 24 L/min (6.4 gpm) at 20 680 kPa (3000 psi) (typical new) 20 L/min (5.2 gpm) at 20 680 kPa (3000 psi) minimum acceptable

If pump flow is low, repair or replace pump.

TX18160,00000A5 -19-27JUN02-1/1

TM2052 (17JUL18)

9025-25-22

27C ZTS and 35C ZTS Operation & Tests 071718 PN=296

Tests

Hydraulic Pump 3 Flow Test—27C ZTS 45—55 °C (110—130 °F)

Engine Speed

2400 rpm approximate

Hydraulic Pump 3 Flow Rate

15 L/min (4.0 gpm) at 13 790 kPa (2000 psi) (typical new)

Hydraulic Pump 3 Flow Rate

12 L/min (3.2 gpm) at 13 790 kPa (2000 psi) minimum acceptable

Hydraulic Pump 3 Flow Rate

14 L/min (3.8 gpm) at 20 680 kPa (3000 psi) (typical new)

Hydraulic Pump 3 Flow Rate

11 L/min (3.0 gpm) at 20 680 kPa (3000 psi) minimum acceptable

T157201B —UN—09JUL02

SPECIFICATIONS Hydraulic Oil Temperature

Hydraulic Pump Test Connections—35C ZTS Shown ESSENTIAL TOOLS Parker number MB5315-8-8 Fitting

1— Flow Meter 2— Flow Block

Parker number M9600-8-6 Fitting

3— Digital Tachometer 4— Hydraulic Pump 3

SERVICE EQUIPMENT AND TOOLS JT05801 Clamp-On Electronic Tachometer

7. Run machine at specification.

JT05800 Digital Thermometer

Test will determine the condition of the gear pump. The pump is driven at engine speed.

1. Stop the engine.

2. Loosen cap to release the air pressure in hydraulic oil tank.

3. Remove tee fitting from hydraulic pump 3 discharge port.

4. Install a flow meter to hydraulic pump 3.

5. Perform JT05801 Clamp-On Electronic Tachometer Installation. (Group 9025-25) 6. Perform Hydraulic System Warm-Up Procedure.

(Group 9025-25)

Specification Engine—Speed.................................................... 2400 rpm approximate

8. Close flow meter loading valve to increase hydraulic pump 3 pressure to test specification. Record flow meter reading.

Specification Hydraulic Pump 3—Flow Rate................................................................... 15 L/min (4.0 gpm) at 13 790 kPa (2000 psi) (typical new) 12 L/min (3.2 gpm) at 13 790 kPa (2000 psi) minimum acceptable 14 L/min (3.8 gpm) at 20 680 kPa (3000 psi) (typical new) 11 L/min (3.0 gpm) at 20 680 kPa (3000 psi) minimum acceptable

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

If flow is low, check inlet hose to hydraulic pump for restriction. If there is no restriction, replace gear pump.

CED,OUOE011,142 -19-22NOV99-1/1

TM2052 (17JUL18)

9025-25-23

27C ZTS and 35C ZTS Operation & Tests 071718 PN=297

Tests

Hydraulic Pump 3 Flow Test—35C ZTS 45—55 °C (110—130 °F)

Engine Speed

2400 rpm approximate

Hydraulic Pump 3 Flow Rate

34 L/min (9.1 gpm) at 13 790 kPa (2000 psi) (typical new)

Hydraulic Pump 3 Flow Rate

28 L/min (7.3 gpm) at 13 790 kPa (2000 psi) minimum acceptable

Hydraulic Pump 3 Flow Rate

34 L/min (9 gpm) at 20 680 kPa (3000 psi) (typical new)

Hydraulic Pump 3 Flow Rate

27 L/min (7.2 gpm) at 20 680 kPa (3000 psi) minimum acceptable

T157201B —UN—09JUL02

SPECIFICATIONS Hydraulic Oil Temperature

ESSENTIAL TOOLS 1— Flow Meter 2— Flow Block

Parker number MB5315-8-8 Fitting Parker number M9600-8-6 Fitting

3— Digital Tachometer 4— Hydraulic Pump 3

SERVICE EQUIPMENT AND TOOLS JT05801 Clamp-On Electronic Tachometer

7. Run machine at specification.

JT05800 Digital Thermometer

Test will determine the condition of the gear pump. The pump is driven at engine speed.

1. Stop the engine.

2. Loosen cap to release the air pressure in hydraulic oil tank.

3. Remove tee fitting from hydraulic pump 3 discharge port.

4. Install a flow meter to hydraulic pump 3.

5. Perform JT05801 Clamp-On Electronic Tachometer Installation. (Group 9025-25) 6. Perform Hydraulic System Warm-Up Procedure.

(Group 9025-25)

Specification Engine—Speed.................................................... 2400 rpm approximate

8. Close flow meter loading valve to increase hydraulic pump 3 pressure to test specification. Record flow meter reading.

Specification Hydraulic Pump 3—Flow Rate................................................................... 34 L/min (9.1 gpm) at 13 790 kPa (2000 psi) (typical new) 28 L/min (7.3 gpm) at 13 790 kPa (2000 psi) minimum acceptable 34 L/min (9 gpm) at 20 680 kPa (3000 psi) (typical new) 27 L/min (7.2 gpm) at 20 680 kPa (3000 psi) minimum acceptable

Specification

If flow is low, check inlet hose to pump for restriction.

If there is no restriction, replace pump.

Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F) TX18160,00000A6 -19-27JUN02-1/1

TM2052 (17JUL18)

9025-25-24

27C ZTS and 35C ZTS Operation & Tests 071718 PN=298

Tests

Swing Motor Leakage Test SPECIFICATIONS Swing Motor Leakage Test Hydraulic Oil Temperature

45—55 °C (110—130 °F)

Engine Speed

Fast Idle

Swing Motor While Swinging Leakage

0.5 or less L/min (0.13 or less gpm)

ESSENTIAL TOOLS JT03523 Compact Excavator Fitting Kit SERVICE EQUIPMENT AND TOOLS

1

Calibrated Container JT05800 Digital Thermometer

Purpose of test is to check the efficiency of swing motor.

Leakage can occur between the cylinder block and valve plate, and the slippers and swash plate when parts are worn or damaged.

T157286 —UN—16JUL02

1. Loosen cap to release the air pressure in hydraulic oil tank.

2. Disconnect drain hose from swing motor port (1).

Install a plug into hose.

Install a test hose onto swing motor drain port. Place opposite end of drain hose in a calibrated container.

CAUTION: To avoid personnel injury, clear area of all bystanders before doing test. Slowly swing through one complete revolution to ensure that the area is clear of objects before doing test.

3. Perform Hydraulic System Warm-Up Procedure.

(Group 9025-25) Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

4. Operate the machine at specifications.

Specification Engine—Speed.......................................................................... Fast Idle

CAUTION: To avoid personnel injury, clear area of all bystanders before doing test. Slowly swing through one complete revolution to ensure that the area is clear of objects before doing test.

1— Drain Port

5. Curl bucket, extend arm, and position boom so that bucket pivot pin is at the same height as the boom to frame pin.

6. Fully actuate swing for one minute. Start measurement once full swing speed is reached.

7. Compare amount of leakage to specifications.

Specification Swing Motor While Swinging—Leakage.........................0.5 or less L/min (0.13 or less gpm)

If leakage is greater than the maximum specified, see Swing Motor and Park Brake Remove and Install.

(Group 4360) 8. Remove test hose. Connect drain hose to swing motor.

CED,OUOE011,145 -19-22NOV99-1/1

TM2052 (17JUL18)

9025-25-25

27C ZTS and 35C ZTS Operation & Tests 071718 PN=299

Tests

Propel Motor Leakage Test—27C ZTS SPECIFICATIONS 45—55 °C (110—130 °F)

Engine Speed

Fast Idle

Propel Motor Leakage

0.7 L/min (0.18 gpm) maximum while propelling in slow speed with track raised

Propel Motor Leakage

0.7 L/min (0.18 gpm) maximum while propelling in fast speed with track raised T124284 —UN—17SEP99

Hydraulic Oil Temperature

ESSENTIAL TOOLS JT03523 Compact Excavator Fitting Kit SERVICE EQUIPMENT AND TOOLS Calibrated Container

1. Perform Hydraulic System Warm-Up Procedure.

(Group 9025-25) 1— Drain Hose

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

2. Stop the engine.

3. Loosen cap to release the air pressure in hydraulic oil tank.

4. Disconnect the drain hose (1) at propel motor and cap.

Install a test hose to propel motor drain port. Place opposite end of test hose in a calibrated container.

5. Raise track off the ground for side being checked.

6. Run machine at specifications.

7. For propel motor being checked, actuate propel forward function at full speed for one minute. Record amount of leakage. Repeat procedure for reverse.

8. Compare amount of leakage to specifications. If leakage is more than specification, repair or replace motor.

Specification Propel Motor—Leakage................ 0.7 L/min (0.18 gpm) maximum while propelling in slow speed with track raised Propel Motor—Leakage................ 0.7 L/min (0.18 gpm) maximum while propelling in fast speed with track raised

Specification Engine—Speed.......................................................................... Fast Idle CED,OUOE011,146 -19-22NOV99-1/1

TM2052 (17JUL18)

9025-25-26

27C ZTS and 35C ZTS Operation & Tests 071718 PN=300

Tests

Propel Motor Leakage Test—35C ZTS SPECIFICATIONS 45—55 °C (110—130 °F)

Engine Speed

Fast Idle

Propel Motor Leakage

0.2 L/min (0.18 gpm) maximum while propelling in slow speed with track raised

Propel Motor Leakage

0.3 L/min (0.18 gpm) maximum while propelling in fast speed with track raised T124284 —UN—17SEP99

Hydraulic Oil Temperature

ESSENTIAL TOOLS JT03523 Compact Excavator Fitting Kit SERVICE EQUIPMENT AND TOOLS Calibrated Container

1. Perform Hydraulic System Warm-Up Procedure.

(Group 9025-25) 1— Drain Hose

Specification Hydraulic Oil—Temperature............................................. 45—55 °C (110—130 °F)

2. Stop the engine.

3. Loosen cap to release the air pressure in hydraulic oil tank.

4. Disconnect the drain hose (1) at propel motor and cap.

Install a test hose to propel motor drain port. Place opposite end of test hose in a calibrated container.

5. Raise track off the ground for side being checked.

6. Run machine at specifications.

7. For propel motor being checked, actuate propel forward function at full speed for one minute. Record amount of leakage. Repeat procedure for reverse.

8. Compare amount of leakage to specifications. If leakage is more than specification, repair or replace motor.

Specification Propel Motor—Leakage................ 0.2 L/min (0.18 gpm) maximum while propelling in slow speed with track raised Propel Motor—Leakage................ 0.3 L/min (0.18 gpm) maximum while propelling in fast speed with track raised

Specification Engine—Speed.......................................................................... Fast Idle TX18160,00000A7 -19-03JUL02-1/1

TM2052 (17JUL18)

9025-25-27

27C ZTS and 35C ZTS Operation & Tests 071718 PN=301

Tests

TM2052 (17JUL18)

9025-25-28

27C ZTS and 35C ZTS Operation & Tests 071718 PN=302

Contents

Section 9031 Heater

Page

Group 05—Theory of Operation Heater System Theory of Operation..........9031-05-1 Group 15—Diagnostic Information Heater System Malfunctions......................9031-15-1 Heater Component Location......................9031-15-1 Group 25—Tests Heater System Checks.............................. 9031-25-1 Visual Inspection of Components .....................................................9031-25-1

TM2052 (17JUL18)

9031-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=1

Contents

TM2052 (17JUL18)

9031-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=2

Group 05

Theory of Operation Heater System Engine coolant is forced through the heater system by the engine water pump. The coolant passes through the heater core then back to the engine coolant system.

As the time that the engine has been operating increases, the coolant absorbs heat from the engine and the coolant increases in temperature. This heat is then transferred into the cab through the heater core. The blower fan moves air across the fins of the heater core, increasing the amount of heat transferred to the cab. The flow of coolant is controlled by the heater valve.

The speed of the blower fan is controlled by the blower speed switch. The H position applies voltage across the blower motor to run it at HIGH speed. The L position applies voltage across a resistor and the blower motor, which reduces the amount of current applied to the blower motor. This setting runs the blower motor at LOW speed.

The O position removes voltage from the blower motor, turning the blower motor off. See System Functional Schematic section SE7 for heater schematic.

OUT1738,000001C -19-18JUN02-1/1

TM2052 (17JUL18)

9031-05-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=305

Theory of Operation

TM2052 (17JUL18)

9031-05-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=306

Group 15

Diagnostic Information Diagnose Heater System Malfunction NOTE: Perform Heater System Checks prior to diagnosis and component tests. (Group 9031-25.) These conditions may affect diagnostic and test results.

Symptom

Problem

Solution

Heater System Does Not Operate

Air conditioner and heater 15 amp fuse (F7)

Replace fuse. See Fuse Specifications. (Group 9015-10.)

Wiring harness

Check Heater Harness wiring.

See Heater Harness (W10) Wiring Diagram. (Group 9015-10.)

Check Floor Harness wiring. See Floor Harness (W2) Wiring Diagram.

(Group 9015-10.)

Heater Does Not Warm Interior of Cab

Heater blower motor switch failed

Replace heater blower motor switch.

See Heater Component Location Diagram. (Group 9031-15.)

Heater hose kinked, pinched or collapsed

Re-route or re-index hoses. Replace collapsed hoses. See Heater Component Location Diagram.

(Group 9031-15.)

Heater core plugged

Clean heater core fins. See Heater Component Location Diagram.

(Group 9031-15.)

Heater fan motor failed or operating too slowly

Check fan motor.

Heater valve is closed

Open heater valve. See Heater Component Location Diagram.

(Group 9031-15.)

See Heater Component Location Diagram. (Group 9031-15.)

OUT1738,000001D -19-18JUN02-1/1

Heater Component Location Diagram Continued on next page

TM2052 (17JUL18)

9031-15-1

OUT1738,000001F -19-18JUN02-1/3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=307

Diagnostic Information

TM2052 (17JUL18)

9031-15-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=308

Diagnostic Information

T156397 —UN—21JUN02

5

7

2 1

6

4

3

T156397

OUT1738,000001F -19-18JUN02-2/3

Continued on next page

TM2052 (17JUL18)

9031-15-3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=309

Diagnostic Information

TM2052 (17JUL18)

9031-15-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=310

Diagnostic Information

1— Heater Core 2— Low Speed Resistor 3— Floor Harness to Heater Harness 2 Pin Connector (X17)

4— Heater Blower Motor (M5) 5— Heater Blower Motor Switch (S4)

6— Heater Assembly 7— Heater Valve

OUT1738,000001F -19-18JUN02-3/3

TM2052 (17JUL18)

9031-15-5

27C ZTS and 35C ZTS Operation & Tests 071718 PN=311

Diagnostic Information

TM2052 (17JUL18)

9031-15-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=312

Group 25

Tests Heater System Checks OUT1738,000001E -19-18JUN02-1/5

• 1

Visual Inspection of Components

OUT1738,000001E -19-18JUN02-2/5

Lines and Hoses Check

1. Inspect all hoses. See Heater Component Location Diagram. (Group 9031-15.)

2. Are all hoses straight, NOT kinked or worn from rubbing on other machine parts or "weather checked"?

3. Are hose connections clean, NOT showing signs of leakage, such as oil or dust accumulation at fittings?

YES: Check complete. Go on to next check.

4. All hose clamps must be in place and tight. Clamps must have rubber inserts or cushions in place to prevent clamps from crushing or wearing into hoses or lines.

NO: Reposition hoses and tighten or replace clamps.

Tighten fittings. Replace hoses as required. See Heater Component Location Diagram. (Group 9031-15.)

OUT1738,000001E -19-18JUN02-3/5

Heater Core Check

1. Inspect core. See Heater Component Location Diagram. (Group 9031-15.)

2. Are fins straight?

3. Is core free of dirt and debris?

YES: Check complete. Go on to next check.

4. Are heater core drain tubes free of obstructions?

NO: Repair or clean heater core and drain tubes.

OUT1738,000001E -19-18JUN02-4/5

Cab Door and Window Seals Check

1. Open and close door and windows. Inspect seals.

2. Do door and windows contact seals evenly?

YES: Checks complete.

3. Are seals in position and in good condition?

NO: Adjust door and windows to close against seals properly. Replace seals as necessary. See Windowpane and Molding Repair. (Group 1810.)

OUT1738,000001E -19-18JUN02-5/5

TM2052 (17JUL18)

9031-25-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=313

Tests

TM2052 (17JUL18)

9031-25-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=314

Index Page Page

A Adjuster Track, operation ............................................. 9020-05-1 Air conditioning Cab door and Window seal check ................. 9031-25-1 Lines and hoses -visual inspection ................ 9031-25-1 Air flow Radiator ......................................................... 9010-25-8 Air intake system Leakage test .................................................. 9010-25-7 Alternator output Check............................................................. 9015-20-7 Arm Cylinder drift 27C ZTS ..................................................... 9025-25-4 35C ZTS ..................................................... 9025-25-5 Arm regenerative valve Operation ..................................................... 9025-05-26 Attachments Adding safely ................................................. 9000-01-8 Operating safely............................................. 9000-01-8 Auxiliary flow combiner valve Operation ..................................................... 9025-05-24 Auxiliary pilot controller Operation ....................................................... 9025-05-9

B Backhoe pattern Pilot controller to pattern conversion valve........................................................... 9025-15-13 Battery Remove and install ...................................... 9015-20-10 Battery explosions Prevent........................................................... 9000-01-4 Battery voltage Check............................................................. 9015-20-6 Bearing Swing, measure wear .................................... 9020-15-3 Blade circuit Operation ..................................................... 9025-05-42 Blade function Operational checks ...................................... 9005-10-21 Blade hydraulic system Component location ..................................... 9025-15-14 Blade pilot controller Operation ....................................................... 9025-05-9 Blade terminals from connector body Remove........................................................ 9015-20-23 Boom Cylinder drift 27C ZTS ..................................................... 9025-25-4 35C ZTS ..................................................... 9025-25-5 Boom reduced leakage valve Operation ..................................................... 9025-05-25

Boom swing make-up check valve Operation ..................................................... 9025-05-23 Boom swing pilot controller Operation ....................................................... 9025-05-9 Brake valve housing Operation ..................................................... 9025-05-36 Bucket Cylinder drift 27C ZTS ..................................................... 9025-25-4 35C ZTS ..................................................... 9025-25-5

C Cab guarding ..................................................... 9000-01-2 Cab harness (W5) Component location ..................................... 9015-10-27 Wiring diagram............................................. 9015-10-30 Charging circuit Theory of operation........................................ 9015-15-1 Chemical products Safe handling ................................................. 9000-01-4 Circuit relief valve Operation ..................................................... 9025-05-23 Test and adjustment 27C ZTS ................................................... 9025-25-13 35C ZTS ................................................... 9025-25-15 Circuit symbols Hydraulic system.......................................... 9025-05-45 Component checks Electrical ........................................................ 9015-20-3 Electrical diagnostic procedures .................... 9015-20-3 Component location Blade hydraulic system ................................ 9025-15-14 Cab harness (W5)........................................ 9015-10-27 Engine............................................................ 9010-05-1 Engine harness (W3) ................................... 9015-10-22 Floor harness (W2) ...................................... 9015-10-15 Information ..................................................... 9015-05-1 Main harness (W1)......................................... 9015-10-9 Propel alarm harness (W11) and propel alarm cancel switch harness (W12) ......................................................... 9015-10-35 Component location drawing Legend ........................................................... 9015-10-2 Connector body from blade terminals Remove........................................................ 9015-20-23 Connector, DEUTSCH Replace........................................................ 9015-20-19 Connector, WEATHER PACK Replace........................................................ 9015-20-21 Contacts, DEUTSCH Install............................................................ 9015-20-20 Contacts, WEATHER PACK Install............................................................ 9015-20-22 Control cable, engine speed Adjustment ..................................................... 9010-25-2 Continued on next page

TM2052 (17JUL18)

Index-1

27C ZTS and 35C ZTS Operation & Tests 071718 PN=1

Index

Page

Page

Control valve Component identification ............................. 9025-05-16 Neutral and parallel passage operation ................................9025-05-16, 9025-05-21 Operation ..................................................... 9025-05-16 Pilot pressure line identification ................... 9025-05-16 Pressure and return line identification ............................................................. 9025-05-16 Schematic .................................................... 9025-05-46 Spool pilot actuation pressure........................ 9025-25-8 System relief valve test and adjustment 27C ZTS ..................................................... 9025-25-9 35C ZTS ................................................... 9025-25-11 Control valve lift Operational checks ...................................... 9005-10-16 Coolant temperature gauge sensor test ................................................................... 9015-20-3 Cooling system Theory of operation........................................ 9010-05-2 Crossover relief valve, swing motor Test and adjustment 27C ZTS ................................................... 9025-25-17 35C ZTS ................................................... 9025-25-18 Cycle times, 27C ZTS Operational checks ...................................... 9005-10-22 Cycle times, 35C ZTS Operational checks ...................................... 9005-10-24 Cylinder drift Boom, arm, and bucket 27C ZTS ..................................................... 9025-25-4 35C ZTS ..................................................... 9025-25-5 Cylinder head Check for head gasket failures .................... 9010-25-12 Cylinder, hydraulic Operation ..................................................... 9025-05-44

Driving metal pins ............................................ 9000-01-10

D DEUTSCH Connector Replace........................................................ 9015-20-19 DEUTSCH Contacts Install............................................................ 9015-20-20 Diagnose malfunction Engine............................................................ 9010-15-1 Undercarriage component ............................. 9020-15-1 Diagnose malfunctions Dig circuit ....................................................... 9025-15-5 Hydraulic system............................................ 9025-15-1 Pilot circuit...................................................... 9025-15-3 Propel system ................................................ 9025-15-9 Swing circuit................................................... 9025-15-7 Dig circuit Diagnose malfunctions................................... 9025-15-5 Dig function drift Operational checks ...................................... 9005-10-15 Digital pressure/temperature analyzer Installation...................................................... 9025-25-2 Digital thermometer installation ......................... 9025-25-1

E Electrical Component checks ........................................ 9015-20-3 Component location drawing legend .......................................................... 9015-10-2 Fuse specifications ........................................ 9015-10-1 Schematic, wiring diagram, and component location information ................... 9015-05-1 Spring wire retainer connector ..................... 9015-20-19 System functional schematic ......................... 9015-10-5 Tab retainer connector ................................. 9015-20-18 Electrical checks Alternator output ............................................ 9015-20-7 Battery voltage ............................................... 9015-20-6 Fuel shut-off solenoid..................................... 9015-20-8 Fusible link ..................................................... 9015-20-6 Key switch...................................................... 9015-20-4 Monitor controller and display alarm ............................................................ 9015-20-7 Propel alarm................................................... 9015-20-7 Starter (M1) motor.......................................... 9015-20-5 Starter (M1) solenoid check ........................... 9015-20-5 Electrical diagnostic procedures Component checks ........................................ 9015-20-3 Electronic tachometer installation........901025-1, 9025-25-1 Emergency preparation ..................................... 9000-01-5 Engine Component location ....................................... 9010-05-1 Diagnose malfunctions................................... 9010-15-1 Engine compression pressure test .................. 9010-25-10 Engine harness (W3) Component location ..................................... 9015-10-22 Wiring diagram............................................. 9015-10-24 Engine lubrication system Theory of operation........................................ 9010-05-3 Engine oil pressure test ................................... 9010-25-11 Engine speed Check............................................................. 9010-25-1 Control cable adjustment ............................... 9010-25-2 Engine speed control cable Adjustment ..................................................... 9010-25-2 Engine valve lash (clearance) Check and adjust ........................................... 9010-25-6 Excavator pattern Pilot controller to pattern conversion valve........................................................... 9025-15-13 Exhaust fumes................................................... 9000-01-3 Explosion Battery............................................................ 9000-01-4

Continued on next page

TM2052 (17JUL18)

Index-2

27C ZTS and 35C ZTS Operation & Tests 071718 PN=2

Index

Page

Page

F Fan belt Adjust tension ................................................ 9010-25-5 Filter, pilot Operation ....................................................... 9025-05-4 Fire prevention................................................... 9000-01-4 Floor harness (W2) Component location ..................................... 9015-10-15 Wiring diagram............................................. 9015-10-19 Flow combiner valve Operation ..................................................... 9025-05-24 Flow Test Hydraulic Pump 1 and 2 27C ZTS ................................................... 9025-25-21 35C ZTS ................................................... 9025-25-22 Hydraulic Pump 3 27C ZTS ................................................... 9025-25-23 Fuel injection nozzle Check and adjust ........................................... 9010-25-3 Theory of operation........................................ 9010-05-4 Fuel injection pump Theory of operation........................................ 9010-05-4 Fuel injection pump timing Check and adjust ........................................... 9010-25-4 Fuel shut-off solenoid Check............................................................. 9015-20-8 Fuse Specification................................................... 9015-10-1 Test ................................................................ 9015-20-1 Fusible link Check............................................................. 9015-20-6

G Gearbox Propel, operation............................................ 9020-05-2 Gearbox, swing Operation 27C ZTS ................................................... 9025-05-27 35C ZTS ................................................... 9025-05-28 Glow plug Operational checks ........................................ 9005-10-2 Glow plug timer Remove and install ...................................... 9015-20-17 Glow timer engine coolant temperature sensor test ....................................................... 9015-20-3

Heater controls Operational checks ........................................ 9005-10-8 Heater harness (W10) Wiring diagram............................................. 9015-10-32 Heater system Diagnose malfunctions................................... 9031-15-1 Heater System Coolant cycle ................................................. 9031-05-1 Heater system diagnostic procedures Visual inspection of components ................... 9031-25-1 High-pressure oils Avoid .............................................................. 9000-01-3 Horn circuit Operational checks ........................................ 9005-10-6 Hydraulic cylinder Operation ..................................................... 9025-05-44 Hydraulic oil tank Schematic .................................................... 9025-05-46 Hydraulic oil tank pressurization Operational checks ...................................... 9005-10-11 Hydraulic pump Regulator operation 27C ZTS ................................................... 9025-05-12 35C ZTS ................................................... 9025-05-13 Schematic .................................................... 9025-05-46 Hydraulic pump 1 and 2 Flow test 27C ZTS ................................................... 9025-25-21 35C ZTS ................................................... 9025-25-22 Operation ..................................................... 9025-05-10 Regulator test and adjustment ..................... 9025-25-20 Hydraulic pump 1, 2, and 3 System relief valve test and adjustment 27C ZTS ..................................................... 9025-25-9 35C ZTS ................................................... 9025-25-11 Hydraulic pump 3 Flow test 35C ZTS ................................................... 9025-25-24 Operation 27C ZTS ................................................... 9025-05-14 35C ZTS ................................................... 9025-05-15 Hydraulic Pump 3 Flow test 27C ZTS ................................................... 9025-25-23 Hydraulic system Circuit symbols............................................. 9025-05-45 Diagnose malfunctions................................... 9025-15-1 Diagram ......................................................... 9025-05-1 Warm-up procedure ....................................... 9025-25-3

H

I

Handhold use .................................................... 9000-01-5 Handling chemicals ........................................... 9000-01-4 Head gasket failure check ............................... 9010-25-12 Heater Component location diagram ......................... 9031-15-1 Heater core check.......................................... 9031-25-1 System checks............................................... 9031-25-1

Inspect machine ................................................ 9000-01-2

Continued on next page

TM2052 (17JUL18)

Index-3

27C ZTS and 35C ZTS Operation & Tests 071718 PN=3

Index

Page

Page

J JT02156A digital pressure/temperature analyzer Installation...................................................... 9025-25-2 JT05800 digital thermometer installation........................................................ 9025-25-1

K Key switch Check............................................................. 9015-20-4 Remove and install ...................................... 9015-20-13

L Leakage Air intake system test..................................... 9010-25-7 Leakage test Propel motor 27C ZTS ................................................... 9025-25-26 Propel motor-35C ZTS................................. 9025-25-27 Swing motor ................................................. 9025-25-25 Lifting objects Special care ................................................... 9000-01-8 Light circuit Operational checks ........................................ 9005-10-3 Line connection Main hydraulic system ................................. 9025-15-21 Pilot controller to pattern conversion valve........................................................... 9025-15-13 Propel hydraulic system............................... 9025-15-17

M Machine inspection............................................ 9000-01-2 Machine movement Unintended..................................................... 9000-01-6 Machine tip over Avoiding ......................................................... 9000-01-8 Main harness (W1) Component location ....................................... 9015-10-9 Wiring diagram............................................. 9015-10-12 Main hydraulic system Line connection............................................ 9025-15-21 Malfunction Engine, diagnose ........................................... 9010-15-1 Manifold, soleoid valve Schematic .................................................... 9025-05-46 Metal pins ........................................................ 9000-01-10 Monitor and gauges, engine off Operational checks ........................................ 9005-10-1 Monitor and gauges, engine on Operational checks ........................................ 9005-10-7 Monitor controller and display (A5) Remove and install ...................................... 9015-20-15

Monitor controller and display alarm check.............................................................. 9015-20-7 Monitor controller circuit Theory of operation........................................ 9015-15-3 Motor Leakage test, propel-35C ZTS..................... 9025-25-27 Propel, operation.......................................... 9025-05-36 Propel, schematic ........................................ 9025-05-46 Swing crossover relief valve test and adjustment 27C ZTS ................................................... 9025-25-17 35C ZTS ................................................... 9025-25-18 Swing, leakage test...................................... 9025-25-25 Swing, operation .......................................... 9025-05-29 Swing, schematic ......................................... 9025-05-46 Motor, propel Leakage test 27C ZTS ................................................... 9025-25-26 Moving parts Safety............................................................. 9000-01-3 Servicing ........................................................ 9000-01-3

N Nozzle, fuel injection Check and adjust ........................................... 9010-25-3

O One way/two way valve Operation ..................................................... 9025-05-43 Operation qualification....................................... 9000-01-1 Operational checkout......................................... 9005-10-1 Operator station, engine on ........................... 9005-10-6 Operator station, key switch on, engine off ................................................................. 9005-10-1 Operational checks Blade function .............................................. 9005-10-21 Control valve lift ........................................... 9005-10-16 Cycle times, 27C ZTS .................................. 9005-10-22 Cycle times, 35C ZTS .................................. 9005-10-24 Dig function drift ........................................... 9005-10-15 Glow plug ....................................................... 9005-10-2 Heater controls............................................... 9005-10-8 Horn circuit..................................................... 9005-10-6 Hydraulic oil tank pressurization .................. 9005-10-11 Light circuit..................................................... 9005-10-3 Monitor and gauges, engine off ..................... 9005-10-1 Monitor and gauges, engine on ..................... 9005-10-7 Pilot control shut-off switch ............................ 9005-10-9 Pilot controller pattern, ISO excavator pattern ........................................................ 9005-10-13 Pilot controller pattern, SAE backhoe pattern ........................................................ 9005-10-12 Propel alarm................................................. 9005-10-10 Propel alarm cancel switch .......................... 9005-10-11 Propel lever and pedal operation ................... 9005-10-2 Continued on next page

TM2052 (17JUL18)

Index-4

27C ZTS and 35C ZTS Operation & Tests 071718 PN=4

Index

Page

Page

Propel speed change ................................... 9005-10-20 Propel system tracking................................. 9005-10-17 Propel system tracking while operating a dig function................................................. 9005-10-19 Swing dynamic brake................................... 9005-10-14 Windshield washer circuit, cab....................... 9005-10-5 Windshield wiper circuit, cab.......................... 9005-10-4 Operator station, engine on Operational checkout ..................................... 9005-10-6 Operator station, key switch on, engine off Operational checkout ..................................... 9005-10-1

Remove and install ...................................... 9015-20-11 Propel alarm cancel switch harness (W12), propel alarm harness (W11) Component location ..................................... 9015-10-35 Propel alarm cancel switch harness (W12), propel alarm harness (W11) Wiring diagram............................................. 9015-10-39 Propel alarm circuit Theory of operation...................................... 9015-15-10 Propel alarm harness (W11) and propel alarm cancel switch harness (W12) Component location ..................................... 9015-10-35 Wiring diagram............................................. 9015-10-39 Propel gearbox Operation ....................................................... 9020-05-2 Propel hydraulic system Line connection............................................ 9025-15-17 Propel lever and pedal operation Operational checks ........................................ 9005-10-2 Propel motor Leakage test 27C ZTS ................................................... 9025-25-26 Leakage test-35C ZTS................................. 9025-25-27 Operation ..................................................... 9025-05-36 Schematic .................................................... 9025-05-46 Propel motor speed circuit Operation ..................................................... 9025-05-41 Propel pilot controller Operation ....................................................... 9025-05-8 Propel speed change Operational checks ...................................... 9005-10-20 Propel speed solenoid valve Operation ....................................................... 9025-05-5 Propel system Diagnose malfunctions................................... 9025-15-9 Propel system tracking Operational checks ...................................... 9005-10-17 Propel system tracking while operating a dig function Operational checks ...................................... 9005-10-19 Protective equipment......................................... 9000-01-2 Pump, hydraulic Regulator, operation 27C ZTS ................................................... 9025-05-12 35C ZTS ................................................... 9025-05-13 Pump, hydraulic 1 and 2 Flow test 27C ZTS ................................................... 9025-25-21 35C ZTS ................................................... 9025-25-22 Operation ..................................................... 9025-05-10 Regulator test and adjustment ..................... 9025-25-20 Pump, hydraulic 1, 2, and 3 System relief valve test and adjustment 27C ZTS ..................................................... 9025-25-9 35C ZTS ................................................... 9025-25-11 Pump, hydraulic 3 Flow test 27C ZTS ................................................... 9025-25-23

P Pilot circuit Diagnose malfunctions................................... 9025-15-3 Pilot control shut-off circuit Theory of operation........................................ 9015-15-8 Pilot control shut-off solenoid valve Operation ....................................................... 9025-05-5 Pilot control shut-off switch Operational checks ........................................ 9005-10-9 Pilot control shutoff lever ................................... 9000-01-6 Pilot controller Operation ....................................................... 9025-05-7 Auxiliary...................................................... 9025-05-9 Blade .......................................................... 9025-05-9 Boom swing................................................ 9025-05-9 Propel ......................................................... 9025-05-8 Schematic .................................................... 9025-05-46 Pilot controller pattern, ISO excavator pattern Operational checks ...................................... 9005-10-13 Pilot controller pattern, SAE backhoe pattern Operational checks ...................................... 9005-10-12 Pilot controller to pattern conversion valve Backhoe pattern........................................... 9025-15-13 Excavator pattern......................................... 9025-15-13 Line connection............................................ 9025-15-13 Pilot filter Operation ....................................................... 9025-05-4 Pilot pressure regulating valve Operation ....................................................... 9025-05-5 Test and adjustment 27C ZTS ..................................................... 9025-25-6 35C ZTS ..................................................... 9025-25-7 Pilot pump Operation 27C ZTS ..................................................... 9025-05-4 35C ZTS ................................................... 9025-05-15 Pilot system Diagram and operation .................................. 9025-05-3 Pressure sensor test.......................................... 9015-20-2 Propel alarm Check............................................................. 9015-20-7 Operational checks ...................................... 9005-10-10 Propel alarm cancel switch Operational checks ...................................... 9005-10-11

Continued on next page

TM2052 (17JUL18)

Index-5

27C ZTS and 35C ZTS Operation & Tests 071718 PN=5

Index

Page

Page

35C ZTS ................................................... 9025-25-24 Operation 27C ZTS ................................................... 9025-05-14 35C ZTS ................................................... 9025-05-15 Pump, pilot Operation 27C ZTS ..................................................... 9025-05-4 35C ZTS ................................................... 9025-05-15

Servicing machine safely................................... 9000-01-9 Solenoid test...................................................... 9015-20-2 Solenoid valve manifold Schematic .................................................... 9025-05-46 Specification Fuse ............................................................... 9015-10-1 Spool Pilot actuation pressure, control valve............................................................. 9025-25-8 Starter (M1) motor Check............................................................. 9015-20-5 Starter (M1) solenoid Check............................................................. 9015-20-5 Starting circuit Theory of operation........................................ 9015-15-1 Steps use........................................................... 9000-01-5 Swing bearing Measure wear ................................................ 9020-15-3 Swing circuit Diagnose malfunctions................................... 9025-15-7 Swing crossover relief valve Operation ..................................................... 9025-05-30 Swing dynamic brake Operational checks ...................................... 9005-10-14 Swing gearbox Operation 27C ZTS ................................................... 9025-05-27 35C ZTS ................................................... 9025-05-28 Swing motor Leakage test ................................................ 9025-25-25 Operation ..................................................... 9025-05-29 Schematic .................................................... 9025-05-46 Swing motor crossover relief valve Operation ..................................................... 9025-05-30 Test and adjustment 27C ZTS ................................................... 9025-25-17 35C ZTS ................................................... 9025-25-18 Swing motor make-up check valve Operation ..................................................... 9025-05-31 Swing motor park brake Operation ..................................................... 9025-05-32 System checks Heater ............................................................ 9031-25-1 System functional schematic ............................. 9015-10-5 Information ..................................................... 9015-05-1 System relief valve Hydraulic pumps 1, 2, and 3 test and adjustment 27C ZTS ..................................................... 9025-25-9 35C ZTS ................................................... 9025-25-11 Operation ..................................................... 9025-05-22

R Radiator Air flow test .................................................... 9010-25-8 Recoil spring Operation ....................................................... 9020-05-1 Reduced leakage valve, boom Operation ..................................................... 9025-05-25 Regulator, hydraulic pump Operation 27C ZTS ................................................... 9025-05-12 35C ZTS ................................................... 9025-05-13 Relay test........................................................... 9015-20-1 Remove and install Battery.......................................................... 9015-20-10 Glow plug timer ............................................ 9015-20-17 Key switch.................................................... 9015-20-13 Monitor controller and display (A5) .............. 9015-20-15 Propel alarm cancel switch .......................... 9015-20-11 Riding machine.................................................. 9000-01-7 Rotary manifold Operation ..................................................... 9025-05-34

S Safety Operator's seat .............................................. 9000-01-5 Safety equipment............................................... 9000-01-2 Safety information Recognizing ................................................... 9000-01-1 Safety instructions ............................................. 9000-01-1 Safety symbols .................................................. 9000-01-1 Schematic Control valve ................................................ 9025-05-46 Hydraulic oil tank.......................................... 9025-05-46 Hydraulic pump ............................................ 9025-05-46 Information ..................................................... 9015-05-1 Pilot controller .............................................. 9025-05-46 Propel motor ................................................ 9025-05-46 Solenoid valve manifold ............................... 9025-05-46 Swing motor ................................................. 9025-05-46 System functional........................................... 9015-10-5 Seat belt Use and maintenance .................................... 9000-01-6 Sensor test Coolant temperature gauge ........................... 9015-20-3 Glow timer engine coolant ............................. 9015-20-3 Pressure......................................................... 9015-20-2

T Tachometer Electronic, installation ..................9010-25-1, 9025-25-1 Test Coolant temperature gauge sensor ............... 9015-20-3 Continued on next page

TM2052 (17JUL18)

Index-6

27C ZTS and 35C ZTS Operation & Tests 071718 PN=6

Index

Page

Page

Fuse ............................................................... 9015-20-1 Glow timer engine coolant temperature sensor .......................................................... 9015-20-3 Pressure sensor............................................. 9015-20-2 Relay.............................................................. 9015-20-1 Solenoid ......................................................... 9015-20-2 Theory of operation Cooling system .............................................. 9010-05-2 Engine lubrication system .............................. 9010-05-3 Fuel injection nozle ........................................ 9010-05-4 Fuel injection pump........................................ 9010-05-4 Monitor controller circuit................................. 9015-15-3 Pilot control shut-off circuit............................. 9015-15-8 Propel alarm circuit ...................................... 9015-15-10 Starting and charging circuit .......................... 9015-15-1 Thermometer installation, digital........................ 9025-25-1 Timing, injection pump Check and adjust ........................................... 9010-25-4 Tip over Avoiding ......................................................... 9000-01-8 Track Adjuster operation.......................................... 9020-05-1 Track adjuster Operation ....................................................... 9020-05-1

35C ZTS ..................................................... 9025-25-7 Pilot pressure regulating, operation ............................................................... 9025-05-5 propel speed change, operation .................. 9025-05-41 Propel speed change, operation .................. 9025-05-36 Propel speed solenoid, operation .................. 9025-05-5 Spool pilot actuation pressure test................. 9025-25-8 Swing motor crossover relief, operation .................................................... 9025-05-30 Swing motor crossover relief, test and adjustment 27C ZTS ................................................... 9025-25-17 35C ZTS ................................................... 9025-25-18 Swing motor make-up check, operation .................................................... 9025-05-31 Swing motor park brake, operation .............. 9025-05-32 System relief, hydraulic pumps 1, 2, and 3, test and adjustment 27C ZTS ..................................................... 9025-25-9 35C ZTS ................................................... 9025-25-11 System relief, operation ............................... 9025-05-22 Valve lash, engine Check and adjust ........................................... 9010-25-6 Visual inspection of components Heater system diagnostic procedures ............................................................ 9031-25-1

U

W

Undercarriage component Diagnose malfunction .................................... 9020-15-1

V Valve Anti-cavitation, operation 35C ZTS ................................................... 9025-05-36 Auxiliary flow combiner, operation ............... 9025-05-24 Blade circuit, operation ................................ 9025-05-42 Boom reduced leakage, operation ............... 9025-05-25 Boom swing make-up check, operation .................................................... 9025-05-23 Circuit relief, operation ................................. 9025-05-23 Circuit relief, test and adjustment 27C ZTS ................................................... 9025-25-13 35C ZTS ................................................... 9025-25-15 Control, neutral and parallel passage operation .................................................... 9025-05-21 Control, schematic ....................................... 9025-05-46 Counterbalance, operation........................... 9025-05-36 Flow combiner, operation............................. 9025-05-24 One way/two way, operation ........................ 9025-05-43 Park brake, operation................................... 9025-05-36 Pilot control shut-off solenoid, operation ...................................................... 9025-05-5 Pilot pressure regulating test and adjustment 27C ZTS ..................................................... 9025-25-6

TM2052 (17JUL18)

Warm-up procedure Hydraulic system............................................ 9025-25-3 Waste disposal .................................................. 9000-01-5 WEATHER PACK Connector Replace........................................................ 9015-20-21 WEATHER PACK Contacts Install............................................................ 9015-20-22 Welding repairs................................................ 9000-01-10 Windshield washer circuit, cab Operational checks ........................................ 9005-10-5 Windshield wiper circuit, cab Operational checks ........................................ 9005-10-4 Wire markings.................................................... 9015-10-1 Wiring diagram Cab harness (W5)........................................ 9015-10-30 Engine harness (W3) ................................... 9015-10-24 Floor harness (W2) ...................................... 9015-10-19 Heater harness (W10).................................. 9015-10-32 Information ..................................................... 9015-05-1 Main harness (W1)....................................... 9015-10-12 Propel alarm harness (W11) and propel alarm cancel switch harness (W12) ......................................................... 9015-10-39

Index-7

27C ZTS and 35C ZTS Operation & Tests 071718 PN=7

Index

TM2052 (17JUL18)

Index-8

27C ZTS and 35C ZTS Operation & Tests 071718 PN=8