750J, 850J

Crawler Dozer
Operation and Test

TECHNICAL MANUAL
750J, 850J Crawler Dozers
07JAN06 (ENGLISH)

For complete service information also see:

750J, 850J Crawler Dozer Repair . . . . . . . . . TM2261
750J, 850J Crawler Dozer Operator’s
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OMT202117
Alternators and Starting Motors . . . . . . . . . . CTM77
POWERTECH 4.5L and 6.8L Diesel
Engines Base Engine . . . . . . . . . . . . . . . . . . CTM104
POWERTECH 4.5L and 6.8L Diesel
Engines Level 12 Electronic Fuel System
with DE10 Pump . . . . . . . . . . . . . . . . . . . . . . CTM331
POWERTECH 8.1L Diesel Engines Base
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM86
POWERTECH 8.1L Diesel Engines Level 9
Electronic Fuel System with High Pressure
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . CTM255
Super Caddy Oil Cleanup Procedure . . . . . . CTM310
120 Series Hydraulic Cylinders . . . . . . . . . . TM-H120A
125 Series Hydraulic Cylinders . . . . . . . . . . TM-H125A
Service ADVISOR System Computer
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . T133991
Undercarriage Appraisal Manual . . . . . . . . . SP326
Specifications Manual . . . . . . . . . . . . . . . . . . SP458
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
 Introduction
Foreword

This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine problems quickly.

TX,750C,YY977 –19–06APR95–1/1

TM2260 (07JAN06) 750J, 850J Crawler

010706
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

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

OVERALL, how would you rate the quality of this publication? (Check one)

Poor Fair Good Very Good Excellent

1 2 3 4 5 6 7 8 9 10

Company Name:

Technician Name:

Address:

Phone:

Fax No.:

Dealer Acct. No.:

THANK YOU!

TX,TM,FAX –19–03JUL01–1/1

TM2260 (07JAN06) 750J, 850J Crawler

010706
PN=3
 Introduction

TM2260 (07JAN06) 750J, 850J Crawler

010706
PN=4
 Contents
9000
SECTION 9000—General Information
Group 01—Safety

SECTION 9005—Operational Checkout Procedure

Group 10—Operational Checkout Procedure
9005

SECTION 9010—Engine
Group 05—Theory of Operation
Group 15—Diagnostic Information
Group 25—Tests
9010
SECTION 9015—Electrical System
Group 05—System Information
Group 10—System Diagrams
Group 15—Sub-System Diagnostics
Group 20—References
9015

SECTION 9025—Hydraulics
Group 05—Theory
Group 15—Diagnostic Information
Group 25—Tests
9025
SECTION 9026—Hydrostatic System
Group 05—Theory of Operation
Group 15—Diagnostic Information
Group 25—Tests
9026
SECTION 9031—Heating and Air Conditioning
Group 05—Theory of Operation
Group 15—Diagnostic Information
Group 25—Tests

9031

INDX

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  2006
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2005

TM2260 (07JAN06) i 750J, 850J Crawler

010706
PN=1
 Contents

9000

9005

9010

9015

9025

9026

9031

INDX

TM2260 (07JAN06) ii 750J, 850J Crawler

010706
PN=2
 9000

Section 9000
General Information
Contents

Page

Group 01—Safety . . . . . . . . . . . . . . . . . . . .9000-01-1

TM2260 (07JAN06) 9000-1 750J, 850J Crawler

010706
PN=1
 Contents

9000

TM2260 (07JAN06) 9000-2 750J, 850J Crawler

010706
PN=2
 Group 01
Safety
9000
Recognize Safety Information 01
1

This is the safety alert symbol. When you see this

–UN–28AUG00
symbol on your machine or in this manual, be alert
for the potential of personal injury.

Follow the precautions and safe operating practices

T133555
highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.

–19–28AUG00
On your 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

T133588
labels.

TX03679,00016CC –19–21AUG00–1/1

Follow Safety Instructions

Read the safety messages in this manual and on the

–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include

T133556
the current safety signs. Replacement safety signs are
available from your John Deere dealer.

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 –19–12AUG03–1/1

TM2260 (07JAN06) 9000-01-1 750J, 850J Crawler

010706
PN=9
 Safety

9000
01 Operate Only If Qualified
2

Do not operate this machine unless you have read the machine functions with the machine in an open area
operator’s manual carefully and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Familiarize yourself with the job site and your your work situation and your work site.
surroundings before operating. Try all controls and

TX03679,00016FA –19–07OCT05–1/1

Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.

Wear close fitting clothing and safety equipment

appropriate to the job.

–UN–23AUG88
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

TS206
uncomfortable loud noises.

TX03679,00016D0 –19–30OCT00–1/1

Avoid Unauthorized Machine Modifications

Modifications of this machine, or addition of Always contact an authorized dealer before making
unapproved products or attachments, may affect machine modifications that change the intended use,
machine stability or reliability, and may create a hazard weight or balance of the machine, or that alter
for the operator or others near the machine. The machine controls, performance or reliability.
installer of any modification which may affect the
electronic controls of this machine is responsible for
establishing that the modification does not adversely
affect the machine or its performance.

TX03679,00016B7 –19–12AUG03–1/1

TM2260 (07JAN06) 9000-01-2 750J, 850J Crawler

010706
PN=10
 Safety

9000
Inspect Machine 01
3

Inspect machine carefully each day by walking around it

before starting.

Keep all guards and shields in good condition and

–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.

T6607AQ
TX03679,0001734 –19–20OCT05–1/1

Stay Clear Of Moving Parts

–UN–12SEP01
Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.

T133592
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.

TX03679,00016D2 –19–30OCT00–1/1

Avoid High-Pressure Fluids

This machine uses a high-pressure hydraulic system.

Escaping fluid under pressure can penetrate the skin

–UN–31OCT00
causing serious injury.

Never search for leaks with your hands. Protect hands.

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

T133509
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.

If hydraulic fluid penetrates your skin, see a doctor

immediately. Injected fluid must be removed
surgically within hours or gangrene may result.
–UN–20SEP00

Contact a knowledgeable medical source or the Deere &

Company Medical Department in Moline, Illinois, U.S.A.
T133840

TX03679,00016D3 –19–30OCT00–1/1

TM2260 (07JAN06) 9000-01-3 750J, 850J Crawler

010706
PN=11
 Safety

9000
01 Beware Of Exhaust Fumes
4

Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

–UN–24AUG00
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring

T133546
outside air into the area.

TX03679,00016D4 –19–14SEP00–1/1

Prevent Fires

–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.

T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.

–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil

T133553
spills. Examine electrical wiring and connectors frequently
for damage.

Keep A Fire Extinguisher Available: Always keep a

multi-purpose fire extinguisher on or near the machine.

–UN–07SEP00
Know how to use extinguisher properly.

T133554

TX03679,00016F5 –19–25SEP00–1/1

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.

Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
–UN–23AUG88

Do not charge a frozen battery; it may explode. Warm

battery to 16°C (60°F).
TS204

TX03679,000174A –19–14SEP00–1/1

TM2260 (07JAN06) 9000-01-4 750J, 850J Crawler

010706
PN=12
 Safety

9000
Handle Chemical Products Safely 01
5

Exposure to hazardous chemicals can cause serious

–UN–25AUG00
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.

T133580
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. 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.

TX03679,00016D7 –19–07OCT05–1/1

Dispose Of Waste Properly

Improper disposal of waste can threaten the environment.

–UN–25AUG00
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

T133567
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.

If uncertain about the safe disposal of waste, contact your

local environmental or recycling center or your authorized
dealer for more information.

TX03679,0001733 –19–17APR01–1/1

Prepare For Emergencies

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88

hospital, and fire department near your telephone.

TS291

TX03679,000174B –19–14SEP00–1/1

TM2260 (07JAN06) 9000-01-5 750J, 850J Crawler

010706
PN=13
 Safety

9000
01 Add Cab Guarding For Special Uses
6

Special work situations or machine attachments may

expose the operator to intruding or flying objects. Using
this machine in a forestry application or woods
environment, or with attachments such as a winch,

–UN–05MAR01
requires added guarding to protect the operator.

Forestry protection packages or special screens should be

installed when working in areas where logs or branches

T139005
may strike the operator. A rear screen should always be
used with a winch to protect against a snapping cable.
Contact your authorized dealer for information on
protective guarding before operating in any hazardous
environment.

TX03768,0000B77 –19–06MAR01–1/1

Use Steps And Handholds Correctly

Prevent falls by facing the machine when you get on and

–UN–30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.

Use extra care when mud, snow, or moisture present

T133468
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.

TX03679,00016F2 –19–14SEP00–1/1

Start Only From Operator’s Seat

–UN–07SEP00
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.
T133715

Never attempt to start engine from the ground. Do not

attempt to start engine by shorting across the starter
solenoid terminals.

TX03679,0001799 –19–01NOV05–1/1

TM2260 (07JAN06) 9000-01-6 750J, 850J Crawler

010706
PN=14
 Safety

9000
Use And Maintain Seat Belt 01
7

Use seat belt when operating machine. Remember to

–19–14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.

T133716
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.

The complete seat belt assembly should be replaced

every three years, regardless of appearance.

TX03679,00016DD –19–17OCT00–1/1

Prevent Unintended Machine Movement (LOCKED)

UP POSITION
Always move the park lock lever to the “up” (locked)
position before leaving the operator’s seat for any
reason.

–19–31JAN05
Be careful not to accidentally actuate controls when (UNLOCKED)
co-workers are present. Engage park lock and lower work DOWN POSITION
equipment to the ground during work interruptions. Stop
the engine before allowing anyone to approach the

T207688
machine. Follow these same precautions before standing
up, leaving the operator’s seat, or exiting the machine.

TX03768,0000B72 –19–01MAY01–1/1

TM2260 (07JAN06) 9000-01-7 750J, 850J Crawler

010706
PN=15
 Safety

9000
01 Avoid Work Site Hazards
8

Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all
underground utilities before working below ground level.

–UN–05MAR01
Avoid or correct hazardous work situations. Avoid
operating near structures or objects that could fall onto the
machine. Clear away debris that could move unexpectedly
if run over.

T139002
Keep bystanders clear at all times. Use barricades or a
signal person to keep vehicles and pedestrians away.
Always keep signal person in view. Instruct co-workers
and bystanders not to approach the machine while it is
operating.

Operate only on solid footing Use extra care when

operating on stockpiles or near banks or excavations that

–UN–05MAR01
may cave in and cause machine to tip or fall. Never allow
the machine on a floor or structure until you are sure it will
support the weight.

T139003
Avoid contact with overhead electrical wires. Stay
clear of 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.

TX03768,0000B76 –19–06MAR01–1/1

Keep Riders Off Machine

Only allow operator on machine.

Riders are subject to injury. They may fall from machine,

be caught between machine parts, or be struck by foreign
–UN–22FEB01

objects.

Riders may obstruct operator’s view or impair his ability to

operate machine safely.
T137580

TX03768,0000B73 –19–05FEB01–1/1

TM2260 (07JAN06) 9000-01-8 750J, 850J Crawler

010706
PN=16
 Safety

9000
Avoid Backover Accidents 01
9

Before moving machine, be sure all persons are clear

of the machine path. Turn around and look directly for
best visibility. Use mirror to assist in checking behind the
machine. Keep windows and mirror clean and in good

–UN–22FEB01
repair.

Be certain backup warning alarm is working properly.

T138441
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.

TX03768,0000B69 –19–01MAY01–1/1

Avoid Machine Tip Over

Use seat belt at all times.

–19–14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.

T133716
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and secured 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.

–UN–22FEB01
Be careful on slopes. Use extra care on soft, rocky or
frozen ground because machine may slip sideways in
these conditions. When traveling up or down steep slopes,

T138416
keep the bucket or blade on uphill side and just above
ground level.

Ensure solid footing. Use extra care when operating on

stockpile materials, or near banks or excavations that may
cave-in and cause machine to tip or fall.
–UN–22FEB01
T138415

TX03768,0000B6B –19–29JAN01–1/1

TM2260 (07JAN06) 9000-01-9 750J, 850J Crawler

010706
PN=17
 Safety

9000
01 Add And Operate Attachments Safely
10

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 –19–07OCT05–1/1

Park And Prepare For Service Safely

Warn others of service work. Always park and prepare

your machine for service or repair properly.

• Park machine on a level surface and lower blade and

–19–14DEC01
attachments to the ground.
• Place park lock lever in “up” (locked) position. Stop
engine and remove key.
• Attach a “Do Not Operate” tag in an obvious place in

T133332
the operator’s station.

Securely support machine or attachment before working

under it.

• Do not support machine with blade or 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
devices that may slip out of place.
–UN–23AUG88

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

TX03768,0000B6A –19–29JAN01–1/1

TM2260 (07JAN06) 9000-01-10 750J, 850J Crawler

010706
PN=18
 Safety

9000
Service Cooling System Safely 01
11

Explosive release of fluids from pressurized cooling

system can cause serious burns.

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

–UN–23AUG88
to relieve pressure before removing completely.

TS281
DX,RCAP –19–04JUN90–1/1

Remove Paint Before Welding or Heating

Hazardous fumes can be generated when paint is heated

by welding or using a torch. Dust from sanding or grinding

–UN–24AUG00
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

T133546
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.

Work outside or in a well-ventilated area. Dispose of

waste, paint and solvents properly.

TX03679,0001732 –19–06SEP00–1/1

TM2260 (07JAN06) 9000-01-11 750J, 850J Crawler

010706
PN=19
 Safety

9000
01 Make Welding Repairs Safely
12

NOTE: To avoid machine damage, disable electrical

–UN–31AUG00
power before welding. Turn off main battery
switch or disconnect positive battery cable.
Separate harness connectors to engine and
machine microprocessors.

T133547
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.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.

TX03679,00016D5 –19–02OCT00–1/1

Drive Metal Pins Safely

–UN–14SEP00
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.

T133738
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.

TX03679,0001745 –19–25SEP00–1/1

TM2260 (07JAN06) 9000-01-12 750J, 850J Crawler

010706
PN=20
 Section 9005
Operational Checkout Procedure
Contents 9005

Page

Group 10—Operational Checkout Procedure

Operational Checkout . . . . . . . . . . . . . . . . . .9005-10-1
Engine Off Checks . . . . . . . . . . . . . . . . . . . .9005-10-1
Engine On Checks . . . . . . . . . . . . . . . . . . . .9005-10-8

TM2260 (07JAN06) 9005-1 750J, 850J Crawler

010706
PN=1
 Contents

9005

TM2260 (07JAN06) 9005-2 750J, 850J Crawler

010706
PN=2
 Group 10
Operational Checkout Procedure
Operational Checkout

Use this procedure to make a quick check of machine adequate space to operate machine. Some checks
operation by doing a walk around inspection and may require varied surfaces.
performing specific checks from operator’s seat.
9005
No special tools are necessary to perform the 10
Complete visual checks (oil levels, oil condition, checkout. 1
external leaks, loose hardware, linkage, wiring, etc.)
before performing checkout. If no problem is found, go to next check. If problem is
indicated, an additional check or repair procedure will
Most checks will require machine systems to be at be suggested.
normal operating temperatures and a level area with

HG31779,00000D1 –19–03SEP02–1/1

1 Engine Off Checks

– – –1/1

TM2260 (07JAN06) 9005-10-1 750J, 850J Crawler

010706
PN=23
 Operational Checkout Procedure

Diagnostic Trouble Code Always check for diagnostic trouble codes and correct them before performing the YES: Check complete.
(DTC) Check operational checkout.
NO: See Diagnostic
Check Diagnostic Trouble Codes (DTCs). Diagnostic Trouble Codes can be displayed Trouble Codes (DTCs)
using SERVICE ADVISOR system or monitor on machine. Quick Reference List.
(Group 9015-20.)
9005
Display diagnostic trouble codes using SERVICE ADVISOR system:
10
2
1. Establish a live connection to machine.
2. Select Diagnostic Trouble Codes icon under Readings tab.

Display diagnostic trouble codes using machine monitor:

View codes on the Active Codes screen and Stored Codes screen. Press NEXT to
scroll through the codes if more than one exists. See CAN Monitor Unit (CMU) Circuit
Theory of Operation. (Group 9015-15.)

Record any DTCs that appears.

Press and hold the MENU button on the CAN Monitor Unit (CMU) for 5 seconds to
enter the service menu.

Press SELECT to enter the codes menu.

Press NEXT until Clear Codes is highlighted and press SELECT.

Press SELECT to clear DTCs.

If any DTCs remain, fix before continuing with checks. See Diagnostic Trouble Codes
(DTCs) Quick Reference List for more information. (Group 9015-20.)

Are all DTCs checked and cleared?

SERVICE ADVISOR is a trademark of Deere & Company – – –1/1

Radiator Cap, Coolant YES: Check complete.

Level, Coolant Condition CAUTION: Explosive release of fluids from pressurized cooling system
Checks can cause serious burns. DO NOT remove radiator cap unless engine is NO: If vacuum release
cool. Then turn cap slowly to the stop. Release all pressure before you valve is plugged or spring
remove cap. corroded, replace radiator
cap.
Open radiator cap.
NO: If coolant is rusty,
FEEL: The radiator cap must have a stop position and must be pushed down to turn oily, or foamy, drain, flush
when removing. and replace coolant. See
Draining the Cooling
LOOK: Does radiator cap have a good seal and gasket? The seal must move freely System. (Operator’s
and the spring must not be corroded. Manual.)

Inspect coolant level and coolant condition. NO: If radiator is low and
coolant tank has coolant
LOOK: Is coolant clean and not oily, foamy, or rusty? in it, check for leak on
recovery hose.

– – –1/1

TM2260 (07JAN06) 9005-10-2 750J, 850J Crawler

010706
PN=24
 Operational Checkout Procedure

Start Aid Check Open right front engine service door. YES: Check complete.

Check position of canister. NO: Adjust fitting so dot

is in correct position.
Inspect plastic line from bottom of starting aid to air intake manifold. Replace plastic line if
kinks are present.
9005
Press and release starting aid button down to operate starting aid.
10
3
LOOK: There must NOT be any kinks or breaks in line and ends must be installed
securely.

Check for dot on ether starting aid nozzle in air intake manifold.

LOOK: Is dot at 12 o’clock position on the fitting of air intake manifold?

– – –1/1

Final Fuel Filter Checks YES: Check complete.

25
NO: Clean or replace fuel
filter. See Replace
Primary and Final Fuel
Filters—750J or see
Replace Primary and
Final Fuel Filters—850J.
(Operator’s Manual.)

17
15 16
T206264 –UN–10JAN05

15—Final Fuel Filter

16—Water Separator
17—Fuel Supply Pump
25—Final Fuel Filter Bleed Screw

Open drain valve on bottom of final fuel filter (15) to drain sediment.
Slowly open bleed screw (25) on fuel filter and operate hand primer on fuel supply
pump (17).

LOOK: Does fuel come out of bleed screw when hand primer is operated?

Tighten fuel filter bleed screw and again operate hand primer on fuel supply pump.

FEEL: Is resistance felt when fuel is being pumped?

– – –1/1

Water Separator Check Loosen drain knob on bottom of water separator and drain fuel for several seconds or YES: Check complete.
until water and sediment are removed.
NO: No flow, clean or
Tighten drain knob. replace valve.

LOOK: Does fuel flow from drain tube?

– – –1/1

TM2260 (07JAN06) 9005-10-3 750J, 850J Crawler

010706
PN=25
 Operational Checkout Procedure

Grouser Wear, Bent Inspect for worn grousers, bent track shoes and loose shoe hardware. YES: If shoe hardware is
Track Shoe, and Loose loose, remove shoe and
Hardware Checks Hardware must be tight. clean joint before
tightening. If worn or
NOTE: Excessive grouser wear weakens track shoes and may result in track shoes bent, replace.
bending.
9005
NO: Check complete.
10
LOOK: Are grouser bars worn excessively? Are track shoes bent?
4

– – –1/1

Track Sag, Roller and Measure track sag at longest span of unsupported track. YES: Check complete.
Idler Leakage Checks
Inspect rollers and front idler. NO: Adjust track sag.
See Adjust Track Sag.
LOOK: Is track sag between 45—57 mm (1-3/4 — 2-1/4 (Operator’s Manual.)
in.)?
NO: Repair or replace
LOOK: Are rollers and idlers free of oil seepage? roller or idler.
T119010 –UN–14DEC98

– – –1/1

Battery Disconnect NOTE: Battery disconnect switch is located inside of the YES: Check battery
Switch Check right rear service door. disconnect switch.

Turn battery disconnect switch OFF. NO: Continue check.

Turn key switch on.

LOOK: Do indicator lights illuminate?

T118722B –UN–01DEC98

Turn battery disconnect switch ON. YES: Check complete.

Turn key switch on, but do not start engine. NO: Check battery
disconnect switch.
LOOK: Do indicator lights illuminate?

– – –1/1

TM2260 (07JAN06) 9005-10-4 750J, 850J Crawler

010706
PN=26
 Operational Checkout Procedure

Fuel Cap Remove fuel cap. YES: Replace fuel cap

and open vent.
NOTE: Air "hiss" from tank is normal when cap is
removed. NO: Check complete.

T118247C –UN–24NOV98 Inspect fuel cap seal.

9005
10
LOOK: Is seal on fuel cap damaged and vents closed?
5

– – –1/1

Cab Door and Window Open and close door and windows. Inspect seals. YES: Check complete.
Seals Check
LOOK: Do door and windows contact seals evenly? NO: Adjust door and
windows to close against
LOOK: Are seals in position and in good condition? seals properly. Replace
seals as necessary.
LOOK: Are latches aligned with strikers?

FEEL/LOOK: Are the door and window latches and door hold-open-latches easy to
operate?

– – –1/1

Horn Check With key off, push horn button. YES: Check complete.

LISTEN: Does horn work with key off? NO: Check horn circuit.

– – –1/1

Seat Control Checks Does seat raise and lower easily? YES: Check complete.

Does seat angle change easily? NO: Inspect linkage and

repair. See Adjusting
Does lever move easily to unlock seat support? Seat. (Operator’s
Manual.)
Does seat move forward and rearward easily?

Does lever lock seat support in position when released?

Does seat back tilt forward and rearward easily?

Does lever unlock and lock easily to hold seat back in position?

– – –1/1

TM2260 (07JAN06) 9005-10-5 750J, 850J Crawler

010706
PN=27
 Operational Checkout Procedure

Reverse Warning Alarm Key switch on, engine off. YES: Check complete.
Check
Put park lock lever down position. NO: Check for voltage at
backup alarm. If no
Move transmission control lever to reverse. voltage is present,
calibrate machine.
9005
LISTEN: Does reverse warning alarm sound in reverse?
10
6

– – –1/1

Front/Rear Wiper and YES: Check complete.

Washer Motor Check—If
Equipped NO: Check fuse. Washer
fluid may be empty.

T199302A –UN–15APR04

1—Left/Right Wiper Rocker Switch

2—Front/Rear Wiper Rocker Switch

Key switch on.

Push rocker switch (2) to first detent, middle position.

Push rocker switch all the way in and hold.

LOOK: Do both front/rear wipers and washer pumps operate?

– – –1/1

TM2260 (07JAN06) 9005-10-6 750J, 850J Crawler

010706
PN=28
 Operational Checkout Procedure

Left/Right Wiper and YES: Check complete.

Washer Motor Check—If
Equipped NO: Check fuse.

9005
10
7

T199302A –UN–15APR04

1—Left/Right Wiper Rocker Switch

2—Front/Rear Wiper Rocker Switch

Key switch on.

Push rocker switch (1) to first detent, middle position.

Push rocker switch all the way in and hold.

LOOK: Do both left/right wiper and washer pumps operate?

– – –1/1

Heater Blower Motor YES: Check complete.

Check—If Equipped
NO: Check fuse. Replace
if necessary.

NO: Check wiring

harness.

T199304A –UN–16APR04

1—Air Conditioning Switch

2—Blower Switch
3—Temperature Control
4—Air Duct (8 used)

Engine off. Key switch on.

Turn blower switch (2) to position (1, 2, 3 and 4).

FEEL: Does air exit all ducts from roof?

– – –1/1

TM2260 (07JAN06) 9005-10-7 750J, 850J Crawler

010706
PN=29
 Operational Checkout Procedure

Battery Check Key off. YES: Check complete.

Press SELECT button and hold until battery volts are displayed. NO: See CAN Monitor
Unit (CMU) Circuit Theory
LOOK: Do battery volts read a minimum of 24 volts? of Operation. (Group
9015-15.) Check voltage
9005
on each battery before
10
recharging.
8
If one battery will not hold
a charge, replace both
batteries.

– – –1/1

Monitor Check Key switch on. YES: Check complete.

Observe monitor and note changes for first 3 seconds (bulbs, indicators and gauges). NO: Check CMU ignition
power 5 A fuse. See
LOOK/LISTEN: Do all lights come on and does alarm sound? Fuse and Relay
Specifications. (Group
Does the LCD display show John Deere and the model number? 9015-10.)

Do all the gauge indicators point to approximately 12 o’clock position?

Is backlighting of gauges on?

After four seconds observe changes in monitor.

LOOK: Do gauge indicators change from 12 o’clock to normal readings?

– – –1/1

2 Engine On Checks

– – –1/1

TM2260 (07JAN06) 9005-10-8 750J, 850J Crawler

010706
PN=30
 Operational Checkout Procedure

Pilot Controller Lock Run machine at idle. YES: Check complete.

Check
Press pilot control switch to the locked position to lock NO: Check pilot enable
the pilot controls. switch and circuit. See
Diagnose Hydraulic
Hold control lever in blade raise position. System Malfunctions.
9005
(Group 9025-15.)
10
Press pilot control switch to the unlocked position to
9
T194312 –UN–11SEP03 unlock the pilot controls.

LOOK: Does blade raise when pilot controls are

unlocked?

Press pilot control switch to the locked position to lock

the pilot controls and observe blade.

LOOK: Does blade stop when controls are locked?

Unlock pilot controls and check all hydraulic functions.

• Blade lift up/down

• Blade angle left/right
• Blade tilt

LOOK: Do all equipped hydraulic functions operate

correctly?

– – –1/1

Blade Float Check Raise front of crawler off ground with blade. YES: Check complete.

Push hydraulic control lever into float detent. NO: Check blade detent
coil and pilot control
LOOK: Does front of crawler lower to ground? enable circuit. See
System Functional
FEEL: Does hydraulic control lever stay in float detent position? Schematic and Section
Legend. (Group 9015-10.)

– – –1/1

TM2260 (07JAN06) 9005-10-9 750J, 850J Crawler

010706
PN=31
 Operational Checkout Procedure

Pilot Controller Check A—Blade Tilt Right YES: Continue check.

B—Blade Lift
C—Blade Tilt Left NO: Remove and inspect
D—Blade Down hydraulic control lever.
E—Blade Float
9005
LOOK/FEEL: Lever must move to all positions easily and
10
return to neutral when released.
10
T8404AC –UN–14FEB95
NOTE: Hydraulic control lever will not return to neutral
when moved to blade float position (E), lever must be
manually pulled from float position.

Run engine at slow idle. YES: Check complete.

Slowly move hydraulic control lever to all positions except blade float (E) and release. NO: If functions hesitate
or do not operate
LOOK/FEEL: Control lever must move to all positions easily and return to neutral when smoothly, see Diagnose
released. Hydraulic function must operate smoothly without hesitation. Hydraulic System
Malfunctions. (Group
LOOK: A=Tilt Right, B=Blade Raise, C=Tilt Left, D=Blade Lower, E=Float. 9025-15.)

– – –1/1

Transmission Speed Start engine. YES: Check complete.

Check
Check transmission speed. Transmission speed should be defaulted to 1.6. NO: Calibrate machine.

LOOK: Is transmission speed defaulted to 1.6?

Increase transmission speed to 3.0.

LOOK: Does transmission speed increase to 3.0?

– – –1/1

Quick-Drop Valve Check Engine at fast idle. YES: Check complete.

(Outside Dozers Only)
Record time to lower blade to ground from maximum height. NO: See Quick-Drop
Valve Operation. (Group
NOTE: Quick-Drop is activated when control lever is in float position or when lever is 9025-05.)
at the end of power down position.

LOOK: Maximum times:

• Float down Quick-Drop activated—1.0 sec.

Raise blade after blade has been lowered with Quick Drop valve.

LOOK: Blade must raise immediately.

– – –1/1

TM2260 (07JAN06) 9005-10-10 750J, 850J Crawler

010706
PN=32
 Operational Checkout Procedure

Slow and Fast Idle Check Run at slow and fast idle and record rpm reading on monitor. YES: Check complete.

LOOK: Are slow and fast idle displayed correctly on monitor? NO: Check monitor
inputs. See CAN Monitor
Engine—Specification Unit (CMU) Circuit Theory
Slow Idle—Speed ....................................................................................... 880—910 rpm of Operation. (Group
9005
Fast Idle—Speed .................................................................................... 2255—2285 rpm 9015-15.)
10
11

– – –1/1

Air Conditioner Check— YES: Check complete.

If Equipped
NO: See Diagnose Air
Conditioning System
Malfunctions. (Group
9031-15.)

T199304A –UN–16APR04

1—Air Conditioning Switch

2—Blower Switch
3—Heater Temperature Control
4—Air Duct (8 used)

Start engine and run at fast idle.

Turn air conditioner switch (1) to on position. On position is up (Snow Flake). Position
down is not used for this test.

Turn blower switch (2) to 4th position.

Wait for any warm air in duct system to dissipate.

FEEL: Is air from ducts cool?

– – –1/1

Alternator Check Key switch on. YES: Check and

recharge batteries.
Start engine.
NO: Check complete.
LOOK: Is ENGINE ALT VOLTS indicator light on?

– – –1/1

TM2260 (07JAN06) 9005-10-11 750J, 850J Crawler

010706
PN=33
 Operational Checkout Procedure

Air Restriction Indicator YES: Clean or replace air

Check ENGINE cleaner elements.

AIR NO: Check complete.

FILTER
9005
10
12

T206395 –UN–21DEC04
Air Restriction Indicator Light

Start engine.
LOOK: Does indicator light come on?

– – –1/1

Transmission Control YES: Check complete.

Lever Check CAUTION: Prevent possible injury from machine movement. Make sure
there is adequate room and be aware of bystanders. NO: Test transmission
control lever sensor.
Engine speed at 1500 rpm. Transmission speed to 2.0. Make several shifts from
neutral to forward, neutral to reverse and then forward to reverse.

Specification
Engine—Speed .................................................................................................. 1500 rpm

LOOK: Does machine shift smoothly?

LOOK: Does machine operate in forward and reverse?

NOTE: Transmission control lever shift rate can be set to operator preference. Low has
a slower reaction time and high has a quicker reaction time. See Transmission Control
Unit (TCU) Circuit Theory of Operation to change transmission rates. (Group 9015-15.)

– – –1/1

TM2260 (07JAN06) 9005-10-12 750J, 850J Crawler

010706
PN=34
 Operational Checkout Procedure

Decelerator/Brake Pedal Start engine. YES: Check complete.

and Park Brake Check
NO: See Transmission
CAUTION: Pushing on decel/brake pedal will stop machine abruptly. Control Unit (TCU) Circuit
Theory of Operation.
Park lock lever down. (Group 9015-15.)
9005
Operate machine slowly in forward. Fully depress decel/brake pedal and then release. 10
13
LOOK: Machine must stop when pedal is depressed and must move when pedal is
released.

Depress decel/brake pedal until spring resistance is felt.

Adjust engine speed to fast idle.

Transmission speed to 3.0.

Transmission control lever in forward position.

Release decel/brake pedal.

LOOK: Does machine accelerate smoothly to maximum speed?

NOTE: Decel/brake response time can be set to operator preference.

– – –1/1

Park Brake Valve Hydrostatic oil must be at operating temperature 66°C (150°F). View in monitor. YES: Isolate park brakes,
Leakage Check brake valve to locate
Adjust engine speed control to slow idle with park lock lever up. leakage.

LOOK: Observe charge pressure reading on monitor display. YES: Tracks move in
neutral. Inspect park
LOOK: Pressure should drop as park lock lever is moved down, then return to original brake valve. See Park
value. Brake Valve Operation.
(Group 9026-05.) Perform
Fully depress decel/brake pedal. Park Brake Test. (Group
9026-25.)
LOOK: Pressure should drop as decel/brake pedal is released, then return to original
value. NO: Check complete.

LOOK: Do tracks creep or move?

– – –1/1

TM2260 (07JAN06) 9005-10-13 750J, 850J Crawler

010706
PN=35
 Operational Checkout Procedure

Reverse Fan Check (If Press the reverse fan switch to turn on manual mode YES: Check complete.
Equipped) (reverse engine fan indicator light illuminated).
NO: Verify that function is
NOTE: Reverse fan function cannot be operated twice enabled in CAN Monitor
within one minute. Wait one minute before attempting to Unit (CMU) machine
reverse fan direction again. Reverse fan will not operate configuration. See
9005
until transmission control lever is out of forward position. Controller Area Network
10
(CAN) Theory of
14
T194319 –UN–11SEP03 LISTEN/LOOK: Does fan reverse direction and operate Operation. (Group
at full speed for 15 seconds? 9015-15.) See Hydraulic
Fan Drive Operation.
Fan will change directions and operate at normal speed. (Group 9026-05.)

– – –1/1

Cycle Time Check Use the CAN Monitor Unit (CMU) or SERVICE ADVISOR application to read engine YES: Check complete.
rpm and hydraulic oil temperature.
NO: Check hydraulic
Specification pump. See Hydraulic
Hydraulic Oil—Temperature ............................................................................... 57—66°C Pump Flow Test. (Group
135—150°F 9025-25.)

Specification
Engine—Speed ................................................................................................... Fast Idle

Blade Raise—Specification
750J OSD—Cycle Time ................................................................................. 2.8 seconds
750J PAT—Cycle Time .................................................................................. 2.9 seconds
850J OSD—Cycle Time ................................................................................. 2.6 seconds
850J PAT—Cycle Time .................................................................................. 2.3 seconds

Blade Power Down—Specification

750J OSD—Cycle Time ................................................................................. 2.2 seconds
750J PAT—Cycle Time .................................................................................. 1.8 seconds
850J OSD—Cycle Time ................................................................................. 2.0 seconds
850J PAT—Cycle Time .................................................................................. 1.6 seconds

Blade Tilt Left—Specification

750J OSD—Cycle Time ................................................................................. 1.0 seconds
750J PAT—Cycle Time .................................................................................. 1.4 seconds
850J OSD—Cycle Time ................................................................................. 0.8 seconds
850J PAT—Cycle Time .................................................................................. 1.1 seconds

Blade Tilt Right—Specification

750J OSD—Cycle Time ................................................................................. 1.0 seconds
750J PAT—Cycle Time .................................................................................. 1.4 seconds
850J OSD—Cycle Time ................................................................................. 0.9 seconds
850J PAT—Cycle Time .................................................................................. 1.2 seconds

Blade Angle Left—Specification

750J PAT—Cycle Time .................................................................................. 4.0 seconds
850J PAT—Cycle Time .................................................................................. 3.8 seconds

Blade Angle Right—Specification

750J PAT—Cycle Time .................................................................................. 4.1 seconds
850J PAT—Cycle Time .................................................................................. 4.0 seconds

Are cycle times faster than specification?

SERVICE ADVISOR is a trademark of Deere & Company – – –1/1

TM2260 (07JAN06) 9005-10-14 750J, 850J Crawler

010706
PN=36
 Operational Checkout Procedure

Tracking and Maximum IMPORTANT: Track sag must be at specification and machine must be driven on YES: Check complete.
Speed Check a level surface for all tracking checks.
NO: Calibrate machine.
Transmission speed at 3.0, transmission control lever in forward position. Depress See Mistrack/Indexes—
decel/brake pedal and adjust engine speed to fast idle.. Flowchart and See
Machine Will Not Reach
9005
LOOK: Machine speed should increase as engine rpm increases. Tracking should be Full Speed—Flowchart.
10
straight at all speeds. (Group 9026-15.)
15
Repeat check in reverse.

– – –1/1

TM2260 (07JAN06) 9005-10-15 750J, 850J Crawler

010706
PN=37
 Operational Checkout Procedure

9005
10
16

TM2260 (07JAN06) 9005-10-16 750J, 850J Crawler

010706
PN=38
 Section 9010
Engine
Contents

Page

Group 05—Theory of Operation

POWERTECH 6.8L (6068) and 8.1L 9010
(6081) John Deere Engines . . . . . . . . . . . .9010-05-1

Group 15—Diagnostic Information

Diagnose Engine Malfunctions . . . . . . . . . . .9010-15-1
Engine Cooling System Component
Location. . . . . . . . . . . . . . . . . . . . . . . . . . .9010-15-4
Engine Fuel System Component Location. . .9010-15-8
Engine Intake and Exhaust Component
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9010-15-12

Group 25—Tests
Intake Manifold Pressure Test—
Turbocharger Boost . . . . . . . . . . . . . . . . . .9010-25-1
Fuel Supply Pump Pressure Test . . . . . . . . .9010-25-2

TM2260 (07JAN06) 9010-1 750J, 850J Crawler

010706
PN=1
 Contents

9010

TM2260 (07JAN06) 9010-2 750J, 850J Crawler

010706
PN=2
 Group 05
Theory of Operation
POWERTECH 6.8L (6068) and 8.1L (6081)
John Deere Engines

For additional information on John Deere engines and

components, see the following Component Technical
Manuals.

• PowerTech 4.5L and 6.8L Diesel Engines Base Engine.

(CTM104.)
• PowerTech 8.1L Diesel Engines Base Engine. (CTM86.)
• PowerTech 4.5L and 6.8L Diesel Engines Level 12 9010
05
Electronic Fuel System with DE10 Pump. (CTM331.)
1
• PowerTech 8.1L Diesel Engines Level 9 Electronic Fuel
System with Denso HPCR. (CTM255.)
• Alternators and Starting Motors. (CTM77.)

POWERTECH is a trademark of Deere & Company BR81691,000006C –19–13OCT04–1/1

TM2260 (07JAN06) 9010-05-1 750J, 850J Crawler

010706
PN=41
 Theory of Operation

9010
05
2

TM2260 (07JAN06) 9010-05-2 750J, 850J Crawler

010706
PN=42
 Group 15
Diagnostic Information
Diagnose Engine Malfunctions

Symptom Problem Solution

Engine Cranks/Won’t Start Engine Problem For 6.8L engines, see E1 - Engine
Cranks/Won’t Start in Section 4,
Group 150 of CTM331.

For 8.1L engines with a Level 9

ECU, see E1 - Engine Cranks/Won’t
Start in Section 4, Group 150 of 9010
CTM255. 15
1

Engine Misfires/Runs Irregularly Engine Problem For 6.8L engines, see E2 - Engine
Misfires/Runs Irregularly in Section
4, Group 150 of CTM331.

For 8.1L engines with a Level 9

ECU, see E2 - Engine Misfires/Runs
Irregularly in Section 4, Group 150 of
CTM255.

Engine Does Not Develop Full Engine Problem For 6.8L engines, see E3 - Engine
Power Does Not Develop Full Power in
Section 4, Group 150 of CTM331.

For 8.1L engines with a Level 9

ECU, see E3 - Engine Does Not
Develop Full Power in Section 4,
Group 150 of CTM255.

Engine Emits Excessive White Engine Problem For 6.8L engines, see E4 - Engine
Exhaust Smoke Emits Excessive White Exhaust
Smoke in Section 4, Group 150 of
CTM331.

For 8.1L engines with a Level 9

ECU, see E4 - Engine Emits
Excessive White Exhaust Smoke in
Section 4, Group 150 of CTM255.

Continued on next page TX,9010,DS6700 –19–12OCT04–1/3

TM2260 (07JAN06) 9010-15-1 750J, 850J Crawler

010706
PN=43
 Diagnostic Information

Symptom Problem Solution

Engine Emits Excessive Black Or Engine Problem For 6.8L engines, see E5 - Engine
Gray Smoke Emits Excessive Black or Gray
Smoke in Section 4, Group 150 of
CTM331.

For 8.1L engines with a Level 9

ECU, see E5 - Engine Emits
Excessive Black Or Gray Exhaust
9010 Smoke in Section 4, Group 150 of
15 CTM255.
2

Engine Will Not Crank Engine Problem For 6.8L engines, see E6 - Engine
Will Not Crank in Section 4, Group
150 of CTM331.

For 8.1L engines with a Level 9

ECU, see E6 - Engine Will Not
Crank in Section 4, Group 150 of
CTM255.

Engine Idles Poorly Engine Problem For 6.8L engines, see E7 - Engine
Idles Poorly in Section 4, Group 150
of CTM331.

For 8.1L engines with a Level 9

ECU, see E7 - Engine Idles Poorly
in Section 4, Group 150 of CTM255.

Abnormal Engine Noise Engine Problem For 6.8L engines, see E8 - Abnormal
Engine Noise in Section 4, Group
150 of CTM331.

For 8.1L engines with a Level 9

ECU, see E8 - Abnormal Engine
Noise in Section 4, Group 150 of
CTM255.

Excessive Fuel Consumption Engine Problem For 6.8L engines, see F2 -

Excessive Fuel Consumption in
Section 4, Group 150 of CTM331.

For 8.1L engines with a Level 9

ECU, see F2 - Excessive Fuel
Consumption in Section 4, Group
150 of CTM255.

Continued on next page TX,9010,DS6700 –19–12OCT04–2/3

TM2260 (07JAN06) 9010-15-2 750J, 850J Crawler

010706
PN=44
 Diagnostic Information

Symptom Problem Solution

Fuel in Oil Engine Problem For 6.8L engines, see F3 - Fuel in

Oil in Section 4, Group 150 of
CTM331

For 8.1L engines with a Level 9

ECU, see F3 - Fuel in Oil in Section
4, Group 150 of CTM255.

9010
15
TX,9010,DS6700 –19–12OCT04–3/3 3

TM2260 (07JAN06) 9010-15-3 750J, 850J Crawler

010706
PN=45
 Diagnostic Information

Engine Cooling System Component Location

20

21

9010
15
4

19
22

18

–UN–08NOV04
T204062

T204062
750J—Engine Cooling System (6.8L)
Continued on next page BR81691,0000069 –19–12OCT04–1/4

TM2260 (07JAN06) 9010-15-4 750J, 850J Crawler

010706
PN=46
 Diagnostic Information

8—Charge Air Cooler 19—Fan 21—Coolant Overfill Tank 22—Radiator

18—Fan Shroud 20—Hydrostatic Oil Cooler

Continued on next page BR81691,0000069 –19–12OCT04–2/4

9010
15
5

TM2260 (07JAN06) 9010-15-5 750J, 850J Crawler

010706
PN=47
 Diagnostic Information

20
21

9010
15 22
6
8

19

18

–UN–08NOV04
T204136

T204136
850J—Engine Cooling System (8.1L)

Continued on next page BR81691,0000069 –19–12OCT04–3/4

TM2260 (07JAN06) 9010-15-6 750J, 850J Crawler

010706
PN=48
 Diagnostic Information

8—Charge Air Cooler 19—Fan 21—Coolant Overfill Tank 22—Radiator

18—Fan Shroud 20—Oil Cooler

BR81691,0000069 –19–12OCT04–4/4

9010
15
7

TM2260 (07JAN06) 9010-15-7 750J, 850J Crawler

010706
PN=49
 Diagnostic Information

Engine Fuel System Component Location

9010
15
8

14

10

13
11

13

14

12

11
15
–UN–16DEC04

17
16
T204061

T204061
750J—Engine Fuel System (6.8L)
Continued on next page BR81691,000006A –19–12OCT04–1/4

TM2260 (07JAN06) 9010-15-8 750J, 850J Crawler

010706
PN=50
 Diagnostic Information

9—Fuel Injection Nozzle 12—Fuel Level Sensor 15—Final Fuel Filter 17—Fuel Supply Pump
10—Fuel Injection Pump 13—Fuel Tank 16—Primary Fuel Filter/Water
11—Fuel Leak-Off Line 14—Fuel Supply Line Separator

Continued on next page BR81691,000006A –19–12OCT04–2/4

9010
15
9

TM2260 (07JAN06) 9010-15-9 750J, 850J Crawler

010706
PN=51
 Diagnostic Information

9010
15
10

13

14

12

11

15

16

17
24
–UN–16DEC04
T204137

T204137
850J—Engine Fuel System (8.1L)

Continued on next page BR81691,000006A –19–12OCT04–3/4

TM2260 (07JAN06) 9010-15-10 750J, 850J Crawler

010706
PN=52
 Diagnostic Information

11—Fuel Leak-Off Line 14—Fuel Supply Line 16—Primary Fuel Filter/Water 17—Fuel Supply Pump
12—Fuel Level Sensor 15—Final Fuel Filter Separator 24—High Pressure Fuel Pump
13—Fuel Tank

BR81691,000006A –19–12OCT04–4/4

9010
15
11

TM2260 (07JAN06) 9010-15-11 750J, 850J Crawler

010706
PN=53
 Diagnostic Information

Engine Intake and Exhaust Component Location

T204054 –UN–09NOV04

23

6
6
7

4
8 5
4
5
2

T204054
750J—Engine Intake and Exhaust System (6.8L)
BR81691,000006B –19–12OCT04–1/4

TM2260 (07JAN06) 9010-15-12 750J, 850J Crawler

010706
PN=54
 Diagnostic Information

2—Intake Manifold 4—Turbocharger Compressor 6—Air Filter Housing 8—Charge Air Cooler
3—Exhaust Manifold 5—Turbocharger Turbine 7—Muffler 23—Optional Precleaner

Continued on next page BR81691,000006B –19–12OCT04–2/4

9010
15
13

TM2260 (07JAN06) 9010-15-13 750J, 850J Crawler

010706
PN=55
 Diagnostic Information

23

9010
15
14

7
6

–UN–17DEC04

8
2
T204135

T204135
850J—Engine Intake and Exhaust System (8.1L)

Continued on next page BR81691,000006B –19–12OCT04–3/4

TM2260 (07JAN06) 9010-15-14 750J, 850J Crawler

010706
PN=56
 Diagnostic Information

2—Intake Manifold 4—Turbocharger Compressor 6—Air Filter Housing 8—Charge Air Cooler
3—Exhaust Manifold 5—Turbocharger Turbine 7—Muffler 23—Optional Precleaner

BR81691,000006B –19–12OCT04–4/4

9010
15
15

TM2260 (07JAN06) 9010-15-15 750J, 850J Crawler

010706
PN=57
 Diagnostic Information

9010
15
16

TM2260 (07JAN06) 9010-15-16 750J, 850J Crawler

010706
PN=58
 Group 25
Tests
Intake Manifold Pressure Test—Turbocharger Boost

SPECIFICATIONS 4. Perform Cab or ROPS Remove and Install. (Group

Engine Coolant Temperature 72—92°C 1800.)
160—200°F
Rated Engine Speed 2100 rpm 5. Disconnect brake hose from brake valve port B. (B
750J Intake Manifold (Using 48—69 kPa marking is cast in housing of brake valve.)
No. 2 Diesel Fuel) Pressure 0.48—0.69 bar
7—10 psi 6. Plug and cap hose and fitting.
850J Intake Manifold (Using 96—117 kPa
No. 2 Diesel Fuel) Pressure 0.96—1.17 bar 7. Return cab to operational position. 9010
14—17 psi 25
1
8. Connect boost pressure gauge to start aid hole in
SERVICE EQUIPMENT AND TOOLS intake manifold.
JT03092 Pressure Gauge
9. Start engine and warm to operating temperature.
IMPORTANT: Reduce boost pressure
specifications by 7% if No. 1 fuel is Specification
used. Engine Coolant Temperature—
Temperature ......................................................................... 72—92°C
160—200°F
NOTE: Machines are shipped from the factory with
No. 1 fuel. 10. Move FNR lever forward with speed in 1.0
position. Run engine at fast idle. Slowly increase
New engines will not develop specified boost speed to obtain rated engine speed. Lug machine
pressure. Test after 50 hours of operation. for 15 seconds and record boost pressure reading.
Intake Manifold Pressure Test—Turbocharger Repeat procedure to verify reading.
Boost is a general indicator of engine
performance. Specification
Rated Engine—Speed .......................................................... 2100 rpm
NOTE: If machine is not equipped with rear-mounted
equipment, do steps 1—3. Specification
750J Intake Manifold (Using
No. 2 Diesel Fuel)—Pressure........................................... 48—69 kPa
1. Remove rear hydrostatic motor access cover. 0.48—0.69 bar
7—10 psi
2. Disconnect brake line at left final drive housing 850J Intake Manifold (Using
tee-fitting. No. 2 Diesel Fuel)—Pressure......................................... 96—117 kPa
0.96—1.17 bar
14—17 psi
3. Cap and plug all openings.
Repeat procedure to verify reading.
NOTE: If machine is equipped with rear-mounted
equipment, do steps 4—7.
11. If boost pressure is too low, see Diagnose Engine
Malfunctions. (Group 9010-15.)

TX,9025,BS474 –19–12OCT04–1/1

TM2260 (07JAN06) 9010-25-1 750J, 850J Crawler

010706
PN=59
 Tests

Fuel Supply Pump Pressure Test

SPECIFICATIONS
Engine Speed Slow idle
750J Fuel Pressure 15—30 kPa
0.15—0.3 bar
2—4 psi
850J Fuel Pressure 200—207 kPa
2.0—2.1 bar
29—30 psi
9010
25 ESSENTIAL TOOLS
2 JT05487 750J—Fitting
JT03083 850J—Fitting

SERVICE EQUIPMENT AND TOOLS

JT03092 Pressure Gauge 0—200 kPa (0—2 bar) (0—30 psi)

Continued on next page TX,9010,DS6708 –19–12OCT04–1/2

TM2260 (07JAN06) 9010-25-2 750J, 850J Crawler

010706
PN=60
 Tests

1. Connect fitting and gauge to fuel filter base auxiliary

outlet port (A).

2. Run engine at test specification.

Specification

–UN–22APR97
Engine—Speed ............................................................................ Slow idle

Record fuel pressure.

Specification

T108450
9010
750J Fuel—Pressure ............................................................... 15—30 kPa
25
0.15—0.3 bar
750J Shown 3
2—4 psi
850J Fuel—Pressure ........................................................... 200—207 kPa
2.0—2.1 bar A—Auxiliary Outlet Port
29—30 psi

3. If fuel pressure is low, check for:

• Partially closed fuel tank shutoff valve.

• Pinched or kinked fuel lines.
• Injection pump overflow valve stuck open.
• Fuel transfer pump malfunctioning.

4. To help isolate the cause of low pressure, connect a

hose to transfer pump inlet and put the other end into
a container of fuel. Repeat test. If fuel pressure
increases to normal, the malfunction is between the
tank and fuel transfer pump. If pressure is still low, the
malfunction is in the fuel transfer pump or injection
pump overflow valve.

5. If fuel pressure is high, check for:

• Plugged fuel filters.

• Restricted fuel return hose or leak-off lines.

TX,9010,DS6708 –19–12OCT04–2/2

TM2260 (07JAN06) 9010-25-3 750J, 850J Crawler

010706
PN=61
 Tests

9010
25
4

TM2260 (07JAN06) 9010-25-4 750J, 850J Crawler

010706
PN=62
 Section 9015
Electrical System
Contents

Page Page

Group 05—System Information CAN Monitor Unit (CMU) Circuit Theory of

Electrical Diagram Information. . . . . . . . . . . .9015-05-2 Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-21

Group 10—System Diagrams Group 20—References

Fuse and Relay Specifications . . . . . . . . . . .9015-10-2 Diagnostic Trouble Codes (DTCs) Quick
System Functional Schematic, Wiring Reference List . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Diagram, and Component Location CAN Monitor Unit (CMU) Diagnostic 9015
Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-4 Trouble Codes . . . . . . . . . . . . . . . . . . . . . .9015-20-9
System Functional Schematic and Schematic Engine Control Unit (ECU) Diagnostic
Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-9 Trouble Codes—750J . . . . . . . . . . . . . . .9015-20-12
Operator’s Station Harness (W7) Component Engine Control Unit (ECU) Diagnostic
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-24 Trouble Codes—850J . . . . . . . . . . . . . . .9015-20-16
Operator’s Station Harness (W7) Wiring Transmission Control Unit (TCU) Diagnostic
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-26 Trouble Codes . . . . . . . . . . . . . . . . . . . . .9015-20-24
Canopy Roof Harness (W8) Component Alternator Test Procedure . . . . . . . . . . . . . .9015-20-80
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-32 Electrical Component Specifications . . . . . .9015-20-82
Transmission Control Unit (TCU)
Canopy Roof Harness (W8) Wiring
Calibration . . . . . . . . . . . . . . . . . . . . . . . .9015-20-89
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-34
Wire Harness Test . . . . . . . . . . . . . . . . . . .9015-20-90
Cab Roof Harness (W9) Component
Decelerator/Brake Pedal Adjustment . . . . . .9015-20-91
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-36
Engine Speed Control Switch Remove
Cab Roof Harness (W9) Wiring Diagram. . .9015-10-38
and Install . . . . . . . . . . . . . . . . . . . . . . . .9015-20-92
Engine Harness (W10) Component
Rotary Sensor Remove and Install . . . . . . .9015-20-93
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-40
Transmission Control Lever (TCL)
Engine Harness (W10) Wiring Diagram. . . .9015-10-44
Adjustment. . . . . . . . . . . . . . . . . . . . . . . .9015-20-94
Transmission Harness (W11) Component
Replace WEATHER PACKConnector . . . .9015-20-97
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-50
Install WEATHER PACKContact. . . . . . . .9015-20-98
Transmission Harness (W11) Wiring Replace DEUTSCH Connectors . . . . . . . .9015-20-99
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-52 Replace DEUTSCH Rectangular or
Air Conditioning Harness (W14) Component Triangular Connectors . . . . . . . . . . . . . . 9015-20-100
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-60 Install DEUTSCH Contact. . . . . . . . . . . . 9015-20-101
Air Conditioning Harness (W14) Wiring Replace CINCH Connectors . . . . . . . . . . 9015-20-102
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-62 Install CINCH Contact . . . . . . . . . . . . . . 9015-20-104
Radio Harness (W15) Component Replace (Pull Type) Metri-Pack
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-64 Connectors . . . . . . . . . . . . . . . . . . . . . . 9015-20-105
Radio Harness (W15) Wiring Diagram. . . . .9015-10-66 Replace (Push Type) Metri-Pack
Connectors . . . . . . . . . . . . . . . . . . . . . . 9015-20-106
Group 15—Sub-System Diagnostics
Starting and Charging Circuit Theory of
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-1
Controller Area Network (CAN) Theory of
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-3
Engine Control Unit (ECU) Circuit Theory of
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-5
Transmission Control Unit (TCU) Circuit
Theory of Operation. . . . . . . . . . . . . . . . .9015-15-10

TM2260 (07JAN06) 9015-1 750J, 850J Crawler

010706
PN=1
 Contents

9015

TM2260 (07JAN06) 9015-2 750J, 850J Crawler

010706
PN=2
 Group 05
System Information

9015
05
1

TM2260 (07JAN06) 9015-05-1 750J, 850J Crawler

010706
PN=65
 System Information

Electrical Diagram Information

9015
05
2

–UN–29FEB00
T128818

Continued on next page MF82180,00001AF –19–14JAN04–1/6

TM2260 (07JAN06) 9015-05-2 750J, 850J Crawler

010706
PN=66
 System Information

1—Continuity Chart 4—Wire Identification 7—Section Number 10—Component Schematic

2—Power Wires 5—Ground Wires 8—Component Name Symbol
3—Routing Location 6—Circuit Name 9—Component Identification
Information Number

NOTE: All System Functional Schematics, Circuit Each electrical component is shown by a schematic
Schematics, and Wiring Diagrams are shown symbol (10), the component name (8), and a
with key switch in the off position. component identification number (9). A component
identification number and name will remain the same
System Functional Schematic Diagram throughout the Operation and Test Technical Manual.
This will allow for easy cross-referencing of all
The System Functional Schematic is made up of electrical drawings (Schematics, Wiring Diagrams, and
sections which contain one or more Subsystem Component Location). A continuity chart (1) is included
Functional Schematics laid out side by side in a logical for each multi-terminal switch.
sequence of related functions. Each subsystem is a
major group of components like starting components or Routing location information (3) is presented to let the
charging components. Each section of the System reader know when a wire is connected to a component 9015
Functional Schematic is assigned a number (7) and a in another section. TO and FROM statements identify 05
name (6) that reflects a group of components. The when power is going “To” or coming “From” a 3
System Functional Schematic is formatted with power component in a different location. The section and
supply wires (2) shown across the top of the drawing component number are given in parenthesis at the
and ground wires (5) across the bottom. The bottom of the statement. In the example, power is
schematic contains no harness or connector going to component F15 Horn Fuse, in section SE15.
information.

Continued on next page MF82180,00001AF –19–14JAN04–2/6

TM2260 (07JAN06) 9015-05-3 750J, 850J Crawler

010706
PN=67
 System Information

9015
05
4

–UN–30OCT03
T195714

Continued on next page MF82180,00001AF –19–14JAN04–3/6

TM2260 (07JAN06) 9015-05-4 750J, 850J Crawler

010706
PN=68
 System Information

1—Component Identification 4—Wire Harness 7—Wire End #1 Termination 9—Wire Color

Number 5—Wire Number Location 10—Wire End #2 Termination
2—Connector 6—Wire Splice 8—Wire Number Location
3—Connector End View

Wiring Diagram A wire legend is provided for each harness. A

component identification number is listed in the “END
Each harness on the machine is drawn showing #1” column (7) to indicate the termination location of
connectors, wires, and splices. A “W” component one end of a wire. In the center, the wire number (8)
identification number identifies harnesses. (W6, Etc.) and wire color (9) are listed. A component identification
The harness is drawn showing spatial arrangement of number in the “END #2” column (10) identifies the
components and branches. opposite end of the wire.

A component identification or connector number (1) Component Location Diagram

identifies each component. The harness branch (4) is
terminated by a top or side view of the connector (2). If The Component Location Diagram is a pictorial view
more than one wire is supplied to the connector, a by harness showing location of all electrical 9015
harness side connector end view (3) is provided. Each components, connectors, harness main ground 05
wire number is labeled for the appropriate pin. If only locations and harness band and clamp location. Each 5
one wire is supplied to the connector, the wire number component will be identified by the same identification
(5) is indicated. letter/number and description used in the System
Functional Schematic Diagram.
An “X” component identification number of 100 or
higher identifies splices (6). Each splice lists side A
wires and side B wires to differentiate the side of the
harness that the wires come from.

Continued on next page MF82180,00001AF –19–14JAN04–4/6

TM2260 (07JAN06) 9015-05-5 750J, 850J Crawler

010706
PN=69
 System Information
T128823 –UN–03MAR00

Continued on next page MF82180,00001AF –19–14JAN04–5/6

TM2260 (07JAN06) 9015-05-6 750J, 850J Crawler

010706
PN=70
 System Information

1—Battery 24—Sensor 46—Resistor 62—Momentary Switch

2—Wire Splice 25—Sensor with Normally 47—Variable Resistor Normally Open
3—Fuse Open Switch 48—Multi-Pin Connector 63—Momentary Switch
4—Circuit Breaker 26—Speed Sensor 49—Single-Pin Connector Normally Closed
5—Fusible Link 27—Rotary Sensor 50—Connector 64—Toggle Switch Normally
6—Power Outlet 28—Single Element Bulb 51—4-Pin Relay Open
7—Alternator 29—Dual Element Bulb 52—5-Pin Relay 65—Toggle Switch Normally
8—Air Conditioner 30—Electrically Operated 53—5-Pin Relay With Internal Closed
Compressor hydraulic Valve Suppression Diode 66—2 Way Toggle Switch
9—Compressor 31—Solenoid Normally Open 54—5-Pin Relay With Internal Normally Open
10—Liquid Pump 32—Solenoid Normally Closed Suppression Resistor 67—2 Way Toggle Switch
11—Antenna 33—Starter Motor 55—Key Switch Normally Closed
12—Diode 34—Starter Motor 56—Temperature Switch 68—Manual Switch Operation
13—Zener Diode 35—DC Motor Normally Open 69—Push Switch Operation
14—Capacitor 36—DC Stepping Motor 57—Temperature Switch 70—Pull Switch Operation
15—Magnet 37—Wiper Motor Normally Closed 71—Turn Switch Operation
16—Flasher 38—Blower Motor 58—Pressure Switch Normally 72—Toggle Switch Operation
17—Buzzer 39—Servo Motor Open 73—Pedal Switch Operation
18—Horn 40—Speedometer 59—Pressure Switch Normally 74—Key Switch Operation
19—Alarm 41—Tachometer Closed 75—Detent Switch Operation 9015
20—Clock 42—Temperature Gauge 60—Liquid Level Switch 76—Temperature Sensor 05
21—Internal Ground 43—Liquid Level Gauge Normally Open 77—Solar Sensor 7
22—Single Point Ground 44—Gauge 61—Liquid Level Switch 78—Pressure Sensor
23—External Ground 45—Hourmeter Normally Closed 79—Liquid Level Sensor

Electrical Schematic Symbols

MF82180,00001AF –19–14JAN04–6/6

TM2260 (07JAN06) 9015-05-7 750J, 850J Crawler

010706
PN=71
 System Information

9015
05
8

TM2260 (07JAN06) 9015-05-8 750J, 850J Crawler

010706
PN=72
 Group 10
System Diagrams

9015
10
1

TM2260 (07JAN06) 9015-10-1 750J, 850J Crawler

010706
PN=73
 System Diagrams

Fuse and Relay Specifications

F8 F18
F1 F21

F22
K1 K5
F23

CB1 F11
K6
CB2

F2 K4 F24
9015
10
2
K2 F12 K7

F3 F13 F25

F4 F14 F26

F5
F15 K8

K3
F
16 V1

F17 F27
F19
F6 F9 F28

–UN–30SEP04
F7 F29

F10 F20
T203636

T203636
Vehicle Electrical Center (VEC)

Continued on next page MF82180,000001E –19–01SEP04–1/2

TM2260 (07JAN06) 9015-10-2 750J, 850J Crawler

010706
PN=74
 System Diagrams

F1—Condenser Fan Motor 2 10 F11—Winch Switch/Solenoids F23—Standard Powerport 10 A F31—Standard Worklight 15 A

A Fuse 5 A Fuse Fuse Circuit Breaker (Marked
F2—Condenser Fan Motor 1 10 F12—Heater Blower 10 A Fuse F24—Air Conditioning CB2)
A Fuse F13—Start Aid 15 A Fuse Compressor Clutch 5 A K1—Condenser Fan 2 Relay
F3—Service ADVISOR Power 5 F14—Airseat 10 A Fuse Fuse K2—Condenser Fan 1 Relay
A Fuse F15—Switch LED (Backlight) F25—Start Relay 10 A Fuse K3—Optional 10 A Convertor
F4—CMU Power 5 A Fuse Circuit 5 A Fuse F26—ECU Ignition Power 5 A Relay
F5—Alternator Excitation 5 A F16—Optional Powerport 10 A Fuse K4—Auxiliary Worklight Relay
Fuse Fuse F27—Spare 10 A Fuse K5—Wiper Relay
F6—TCU Power 10 A Fuse F17—Spare 10 A Fuse F28—CMU Battery Power 5 A K6—Standard Worklight Relay
F7—Autoblade 10 A Fuse F18—Heater Valve 5 A Fuse Fuse K7—Air Conditioning
F8—Dome Light 5 A Fuse F19—Horn 5 A Fuse F29—ECU Battery Power 10 A Compressor Clutch Relay
F9—Pilot Enable Ignition F20—Radio Memory 5 A Fuse Fuse K8—Horn Relay
Power 5 A Fuse F21—Front/Rear Wiper Motor F30—Auxiliary Worklight 20 A V1—Alternator Excitation 3 A
F10—Under-Seat Heater 15 A 10 A Fuse Circuit Breaker (Marked Diode
Fuse F22—Right/Left Wiper Motor CB1)
10 A Fuse

IMPORTANT: Install fuse with correct amperage • K10—Accessory Relay 1 (SE4, W7) 9015
rating to prevent electrical system • K11—Accessory Relay 2 (SE4, W7) 10
damage from overload. • V2—Starter Solenoid 5 A Diode (SE1, W10 (750J), 3
W10 (850J))
The Vehicle Electrical Center (VEC) is located in the • V3—Start Relay 1 A Diode (SE2, W10 (750J), W10
operator’s station. See Operator’s Station Harness (850J))
(W7) Component Location. (Group 9015-10.) • V4—Air Conditioning Compressor Clutch 5 A Diode
(SE3, W10 (750J), W10 (850J))
NOTE: The following items are located outside of the • V5—Door Wiper Diode (SE26, W9)
VEC: • V6—Front Wiper Diode (SE25, W9)
• V7—Rear Wiper Diode (SE25, W7)
• K9—Start Relay (SE2, W10 (750J), W10 (850J))

MF82180,000001E –19–01SEP04–2/2

TM2260 (07JAN06) 9015-10-3 750J, 850J Crawler

010706
PN=75
 System Diagrams

System Functional Schematic, Wiring Diagram, and Component Location Legend

NOTE: A1—Transmission Controller (SE5, W6) • B15—Camshaft Position Sensor (850J only) (SE36,
W10 (850J))
• A1 indicates component identification • B16—Ambient Air Temperature Sensor (SE33,
number. SE35, W10 (750J), W10 (850J))
• Transmission Controller indicates component • B17—Engine Oil Pressure Sensor (SE33, SE35,
name. W10 (750J), W10 (850J))
• SE5 indicates section number of SYSTEM • B18—Water-in-Fuel Sensor (SE33, SE35, W10
FUNCTIONAL SCHEMATIC where (750J), W10 (850J))
component is located. • B19—Fuel Level Sensor (SE23, W18)
• W6 indicates HARNESS WIRING DIAGRAM • B20—Hydraulic Oil Temperature Sensor (SE24,
and HARNESS COMPONENT LOCATION W11)
drawings where component is located. • B21—Transmission Oil Temperature Sensor (SE23,
W11)
• A1—Transmission Control Unit (TCU) (SE15, W7) • B22—Air Filter Restriction Switch (SE24, W10
9015
10 • A2—Engine Control Unit (ECU) (SE34, SE36, W10 (750J), W10 (850J))
4 (750J), W10 (850J)) • B23—Hydraulic Oil Filter Restriction Switch (SE24,
• A3—CAN Monitor Unit (CMU) (SE23, W7) W11)
• A5—Radio (12 V) (SE28, W15) • B24—Hydraulic Fan Oil Filter Restriction Switch
• A6—Vehicle Electrical Center (VEC) (SE4, SE6, (SE23, W11)
SE7, SE8, SE9, W7, W9) • B25—Hydrostatic Charge Oil Filter Restriction
• B1—Decelerator Sensor (SE13, W7) Switch (SE24, W11)
• B2—Motor Speed Sensor Left (SE13, W11) • B26—Winch Oil Pressure Switch (SE24)
• B3—Motor Speed Sensor Right (SE13, W11) • B27—Air Conditioning Freeze Switch (SE21, W14)
• B4—Hydrostatic Charge Pressure Sensor (SE12, • B28—Air Conditioning High Pressure Switch (SE21,
W11) W17)
• B5—Hydrostatic Pressure Sensor Right (SE12, • B29—Air Conditioning Low Pressure Switch (SE21,
W11) W14)
• B6—Hydrostatic Pressure Sensor Left (SE12, W11) • B30—Right Speaker (SE28, W15)
• B7—Pump Pressure Control Pilot (PCP) Rear • B31—Left Speaker (SE28, W15)
(SE16, W10 (750J), W10 (850J)) • B32—FNR Sensor (SE14, W7)
• B8—Pump Pressure Control Pilot (PCP) Front • B33—Steer Sensor (SE14, W7)
(SE16, W10 (750J), W10 (850J)) • B34—Transmission Speed Control Switch (SE14,
• B9—Quick-Drop Pressure Switch (SE19, W11) W7)
• B10—Fuel Rail Pressure Sensor (850J only) (SE36, • B35—Brake Pressure Sensor (SE12, W11)
W10 (850J)) • E1—Dome Light (SE32, W9)
• B11—Fuel Temperature Sensor (SE33, SE35, W10 • E2—Standard Work Light Left Grill (SE30, W10
(750J), W10 (850J)) (750J), W10 (850J))
• B12—Engine Coolant Temperature Sensor (SE33, • E3—Standard Work Light Right Grill (SE30, W10
SE35, W10 (750J), W10 (850J)) (750J), W10 (850J))
• B13—Manifold Air Temperature Sensor (SE33, • E4—Auxiliary Work Light Left Rear (SE31, W8, W9)
SE35, W10 (750J), W10 (850J)) • E5—Standard Work Light Right Rear (SE30, W8,
• B14—Crankshaft Position Sensor (SE34, SE36, W9)
W10 (750J), W10 (850J)) • E6—Auxiliary Work Light Left Front (SE31, W8, W9)

Continued on next page MF82180,000001F –19–06OCT05–1/5

TM2260 (07JAN06) 9015-10-4 750J, 850J Crawler

010706
PN=76
 System Diagrams

• E7—Auxiliary Work Light Right Front (SE31, W8, • G2—Jump Start Terminal (SE1, W10 (750J), W10
W9) (850J))
• E9—Auxiliary Work Light Right Rear (SE31, W8, • G3—Alternator (SE2, W10 (750J), W10 (850J))
W9) • H1—Horn (SE3, W10 (750J), W10 (850J))
• F1—Condenser Fan Motor 2 10 A Fuse (VEC) • H2—Monitor Alarm (SE23, W7)
(SE6) • H3—Backup Alarm (SE15, W18)
• F2—Condenser Fan Motor 1 10 A Fuse (VEC) • H4—Warmup Indicator Light (SE34, SE37, W7)
(SE7) • K1—Condenser Fan 2 Relay (VEC) (SE7)
• F3—Service ADVISOR Power 5 A Fuse (VEC) • K2—Condenser Fan 1 Relay (VEC) (SE7)
(SE8) • K3—Optional 10 A Converter Relay (VEC) (SE9)
• F4—CMU Power 5 A Fuse (VEC) (SE9) • K4—Auxiliary Worklight Relay (VEC) (SE5)
• F5—Alternator Excitation 5 A Fuse (VEC) (SE8) • K5—Wiper Relay (VEC) (SE6)
• F6—TCU Power 10 A Fuse (VEC) (SE7) • K6—Standard Worklight Relay (VEC) (SE5)
• F7—Autoblade 10 A Fuse (VEC) (SE8) • K7—Air Conditioning Compressor Clutch Relay
• F8—Dome Light 5 A Fuse (VEC) (SE6) (VEC) (SE6)
• F9—Pilot Enable Ignition Power 5 A Fuse (VEC) • K8—Horn Relay (VEC) (SE9)
9015
(SE8) • K9—Start Relay (SE2, W10 (750J), W10 (850J)) 10
• F10—Under-Seat Heater 15 A Fuse (VEC) (SE7) • K10—Accessory Relay 1 (SE4, W7) 5
• F11—Winch Switch/Solenoids 5 A Fuse (VEC) • K11—Accessory Relay 2 (SE4, W7)
(SE5) • M1—Starter Motor (SE1, W10 (750J), W10 (850J))
• F12—Heater Blower 10 A Fuse (VEC) (SE5) • M2—Heater Valve Motor (SE20, W11)
• F13—Start Aid 15 A Fuse (VEC) (SE9) • M3—Heater Blower Motor (SE20, W14)
• F14—Airseat 10 A Fuse (VEC) (SE9) • M4—Condenser Fan Motor (SE21, W17)
• F15—Switch LED (Backlight) Circuit 5 A Fuse (VEC) • M5—Condenser Fan Motor (SE21, W17)
(SE8) • M6—Wiper Motor Front (SE25, W9)
• F16—Optional Powerport 10 A Fuse (VEC) (SE9) • M7—Wiper Motor Left Door (SE26, W9)
• F17—Spare 10 A Fuse (VEC) (SE7) • M8—Wiper Motor Right Door (SE25, W9)
• F18—Heater Valve 5 A Fuse (VEC) (SE6) • M9—Washer Motor Front/Rear (SE25, W11)
• F19—Horn 5 A Fuse (VEC) (SE9) • M10—Washer Motor Left/Right (SE26, W11)
• F20—Radio Memory 5 A Fuse (VEC) (SE8) • M11—Wiper Motor Rear (SE25, W12)
• F21—Front/Rear Wiper Motor 10 A Fuse (VEC) • M12—Under-Seat Heater Blower Motor (SE26, W13)
(SE6) • M13—Air Seat Motor (SE32, W7)
• F22—Right/Left Wiper Motor 10 A Fuse (VEC) (SE6) • R1—CAN Termination Resistor (SE22, W7)
• F23—Standard Powerport 10 A Fuse (VEC) (SE5) • R2—CAN Termination Resistor (SE22, W10 (750J),
• F24—Air Conditioning Compressor Clutch 5 A Fuse W10 (850J))
(VEC) (SE6) • R3—Heater Valve Resistor (SE20, W14)
• F25—Start Relay 10 A Fuse (VEC) (SE9) • R4—Cab Heater Blower Resistor (SE20, W14)
• F26—ECU Ignition Power 5 A Fuse (VEC) (SE9) • R5—Under-Seat Heater Blower Resistor (SE26,
• F27—Spare 10 A Fuse (VEC) (SE8) W13)
• F28—CMU Battery Power 5 A Fuse (VEC) (SE8) • S1—Key Switch (SE1, W7)
• F29—ECU Battery Power 10 A Fuse (VEC) (SE8) • S2—Battery Disconnect Switch (SE1)
• F30—Auxiliary Worklight 20 A Circuit Breaker (CB1) • S4—Blade Angle Switch (SE12, W7)
(VEC) (SE5) • S5—Horn Switch (SE14, W7)
• F31—Standard Worklight 15 A Circuit Breaker (CB2) • S7—Decelerator Mode Switch (SE11, W7)
(VEC) (SE5) • S8—Pilot Control Enable Switch (SE19, W7)
• G1—Batteries (SE1) • S9—Heater Temperature Control Switch (SE20, W9)

Continued on next page MF82180,000001F –19–06OCT05–2/5

TM2260 (07JAN06) 9015-10-5 750J, 850J Crawler

010706
PN=77
 System Diagrams

• S10—Heater Blower Switch (SE20, W9) • W16—Standard Fan Drive Harness (W10 (750J),
• S11—Air Conditioning On/Off Switch (SE21, W9) W10 (850J))
• S12—Front/Rear Door Wiper Motor Switch (SE25, • W17—Condenser Harness (W14)
W9) • W18—Fuel Tank Harness
• S13—Left/Right Door Wiper Motor Switch (SE25, • W19—Electronic Injector Harness
W9) • W20—Optional Power Converter Harness
• S14—Dome Light Switch (SE32, W9) • X1—TCU Connector (SE15, W7)
• S15—Under-Seat Heater Blower Switch (SE26, W7) • X2—TCU Connector (SE15, W7)
• S16—Standard Work Light Switch (SE30, W7) • X3—ECU 30-Pin Connector (L-Y) (850J only) (SE36,
• S17—Auxiliary Work Light Switch (SE30, W7) W10 (850J))
• S18—Park Lock Lever Switch (SE2, W7) • X4—CMU 16-Pin Connector (SE23, W7)
• S19—Start Aid Switch (SE3, W7) • X5—CMU 14-Pin Connector (SE23, W7)
• S20—Neutral Start Switch (SE14, W7) • X6—Bussed +5V Sensor Connector (SE11, W7)
• S22—Engine Speed Control Switch (SE11, W7) • X7—Bussed Ground Sensor Connector (SE11, W7)
• S23—Fan Reversing Switch (SE24, W7) • X8—Service ADVISOR Connector (SE22, W7)
• S25—Air Seat Switch (SE32, W7) • X9—Standard 12 V Power Outlet (SE27, W7)
9015
10 • U2—Standard 12 V Power Converter (SE27, W11) • X10—ECU 30-Pin Connector (A-K) (SE34, SE36,
6 • U3—Optional 12 V Power Converter (SE29, W20) W10 (750J), W10 (850J))
• V1—Alternator Excitation 3 A Diode (VEC) (SE8, • X11—Cab Roof Harness-to-Air Conditioning Harness
W10 (750J), W10 (850J)) Connector (W9, W14)
• V2—Starter Solenoid 5 A Diode (SE1, W10 (750J), • X12—Cab Harness-to-Rear Wiper Harness
W10 (850J)) Connector (W7, W12, SE25)
• V3—Start Relay 1 A Diode (SE2, W10 (750J), W10 • X13—Operator’s Station Harness-to-Roof Harness
(850J)) Connector (W7, W8, W9)
• V4—Air Conditioning Compressor Clutch 5 A Diode • X16—Operator’s Station Harness-to-Transmission
(SE3, W10 (750J), W10 (850J)) Harness Connector 1 (W7, W11)
• V5—Door Wiper Diode (SE26, W9) • X17—Operator’s Station Harness-to-Transmission
• V6—Front Wiper Diode (SE25, W9) Harness Connector 2 (W7, W11)
• V7—Rear Wiper Diode (SE25, W7) • X18—Operator’s Station Harness-to-Transmission
• W1—Radio Antenna (SE28, W15) Harness Connector 3 (W7, W11)
• W2—Ground to Cab Right Rear (W8, W9) • X19—Engine Harness-to-Transmission Harness
• W3—Ground to Frame Under Cab (W11) Connector (W10 (750J), W10 (850J), W11)
• W4—Ground to Cab Left Rear (W7) • X20—Optional 12 V Power Converter Connector
• W5—HIC Valve Ground (W11) (SE29, W11, W20)
• W6—Ground to Engine on Starter Motor (W10 • X21—Transmission Harness-to-Fuel Tank Harness
(750J), W10 (850J)) Connector (W11, W18)
• W7—Operator’s Station Harness • X22—Cab/Canopy Harness-to-Under-Seat Harness
• W8—Canopy Roof Harness Connector (SE26, W7, W13)
• W9—Cab Roof Harness • X23—Engine Harness-to-Electronic Injector Harness
• W10 (750J)—Engine Harness Connector (850J Only) (W10 (850J), W19)
• W10 (850J)—Engine Harness • X24—Optional 12 V Power Outlet (SE29, W7)
• W11—Transmission Harness • X25—Spare Connector Roof (SE10, W9)
• W12—Rear Wiper Harness • X26—Spare Connector Right Console (SE10, W7)
• W13—Under-Seat Heater Harness • X27—Spare Connector Front Console (SE10, W7)
• W14—Air Conditioning Harness • X28—Engine Harness-to-Standard Fan Drive
• W15—Radio Harness Harness Connector (SE17, W10 (750J), W10 (850J))

Continued on next page MF82180,000001F –19–06OCT05–3/5

TM2260 (07JAN06) 9015-10-6 750J, 850J Crawler

010706
PN=78
 System Diagrams

• X29—Automatic Diagnostic Connector (SE23, W7) • X120—G03 BLK Splice 1 (W7)

• X30—Operator’s Station Harness-to-Transmission • X121—B01 RED Splice (W7)
Harness Connector 4 (W7, W11) • X122—L06 BRN Splice (W7)
• X31—VEC 8-Pin Connector (Gray) (SE5, W7) • X123—G03 BLK Splice 2 (W7)
• X32—VEC 8-Pin Connector (Red) (SE5, W7) • X124—P28 RED Splice (W7)
• X33—VEC 8-Pin Connector (Black) (SE6, W9) • X125—G02 BLK Splice (W7)
• X34—VEC 8-Pin Connector (Orange) (SE6, W9) • X126—P03 RED Splice (W7)
• X35—VEC 8-Pin Connector (Blue) (SE7, W7) • X127—R13 BLK Splice 2 (W7)
• X36—VEC 8-Pin Connector (Green) (SE8, W7) • X128—M12 YEL Splice 2 (W7)
• X37—VEC 8-Pin Connector (Brown) (SE9, W7) • X129—M13 LGRN Splice 2 (W7)
• X38—VEC 2-Pin Connector (Gray) (SE4, W7) • X130—P09 RED Splice (W9)
• X39—VEC 2-Pin Connector (Black) (SE4, W7) • X131—G04 BLK Splice 1 (W8, W9)
• X40—Operator’s Station-to-Cab Roof Harness • X132—G04 BLK Splice 2 (W9)
Connector (W7, W9) • X133—L05 BRN Splice (W8, W9)
• X41—Cab Roof Harness-to-Radio Harness • X134—G09 BLK Splice (W7)
Connector (SE28, W9, W15) • X135—T10 BLU Splice (W7)
9015
• X42—Optional 12 V Terminal Block (SE29, W20) • X136—R06 BLK Splice (W7) 10
• X49—Battery Power Connector (SE1, W11) • X137—P14 RED Splice (W20) 7
• X51—Air Conditioner Harness-to-Condenser • Y1—Start Aid Solenoid (SE3, W10 (750J), W10
Harness Connector (W14, W17) (850J))
• X52—TCU Programming Connector (SE15, W7) • Y2—Park Brake Solenoid 1 (SE16, W11)
• X100—T24 BLU Splice (W11) • Y3—Motor Shift Solenoid Left (SE17, W11)
• X101—G05 BLK Splice (W11) • Y4—Motor Shift Solenoid Right (SE17, W11)
• X102—R12 BLK Splice (W7, W11) • Y5A—Hydraulic Fan Proportional Relief Solenoid
• X103—G10 BLK Splice (W11) (Standard) (SE17, W16)
• X104—G11 BLK Splice (W10 (750J), W10 (850J)) • Y5—Hydraulic Fan Proportional Relief Solenoid
• X105—H02 GRN Splice (W10 (750J), W10 (850J)) (With Reversing Option) (SE17, W10 (750J), W10
• X106—Shield Ground Splice (W10 (750J), W10 (850J))
(850J)) • Y6—Hydraulic Fan Reversing Solenoid (SE17, W10
• X107—R15 BLK Splice (W10 (750J), W10 (850J)) (750J), W10 (850J))
• X108—G12 BLK Splice (W10 (750J), W10 (850J)) • Y7—Blade Angle Solenoid Left (Top) (SE18, W11)
• X109—R13 BLK Splice 1 (W7, W10 (750J), W10 • Y8—Blade Angle Solenoid Right (Bottom) (SE18,
(850J)) W11)
• X110—M13 LGRN Splice 1 (W7, W10 (750J), W10 • Y9—Quick-Drop Solenoid (SE19, W10 (750J), W10
(850J)) (850J))
• X111—M12 YEL Splice 1 (W7, W10 (750J), W10 • Y10—Pilot Control Enable Solenoid (SE19, W11)
(850J)) • Y11—Blade Detent Coil (SE19, W7)
• X112—L02 BRN Splice (W7, W10 (750J), W10 • Y12—High Pressure Fuel Pump Solenoid 1 (850J
(850J)) only) (SE37, W10 (850J))
• X113—P30 RED Splice (W10 (850J)) • Y13—High Pressure Fuel Pump Solenoid 2 (850J
• X114—R14 BLK Splice (W10 (850J)) only) (SE37, W10 (850J))
• X115—E19 WHT Splice (W10 (850J)) • Y14—Hydrostatic Oil Cooler Bypass Solenoid
• X116—P31 RED Splice (W7) (SE18, W11)
• X117—E05 WHT Splice (W7) • Y15—Park Brake Solenoid 2 (SE16, W11)
• X118—G07 BLK Splice (W7) • Y16—Air Conditioning Compressor Clutch Solenoid
• X119—P18 RED Splice (W7, W9) (SE3, W10 (750J), W10 (850J))

Continued on next page MF82180,000001F –19–06OCT05–4/5

TM2260 (07JAN06) 9015-10-7 750J, 850J Crawler

010706
PN=79
 System Diagrams

• Y17—Hydrostatic Oil Reservoir Bypass Solenoid • Y22—Electronic Injector (Cylinder 2) (SE37, W19)
(SE18, W11) • Y23—Electronic Injector (Cylinder 3) (SE37, W19)
• Y18—Injection Pump Solenoid (750J only) (SE34, • Y24—Electronic Injector (Cylinder 4) (SE37, W19)
W10 (750J)) • Y25—Electronic Injector (Cylinder 5) (SE37, W19)
• Y21—Electronic Injector (Cylinder 1) (SE37, W19) • Y26—Electronic Injector (Cylinder 6) (SE37, W19)

MF82180,000001F –19–06OCT05–5/5

9015
10
8

TM2260 (07JAN06) 9015-10-8 750J, 850J Crawler

010706
PN=80
 System Diagrams

System Functional Schematic and Schematic Legend

T216035 –19–17OCT05

System Functional Schematic (SE1, SE2, SE3)

MF82180,0000020 –19–13OCT05–1/14

TM2260 (07JAN06) 9015-10-9 750J, 850J Crawler

010706
PN=81
 System Diagrams
T206668 –19–31JAN05

System Functional Schematic (SE4, SE5, SE6)

MF82180,0000020 –19–13OCT05–2/14

TM2260 (07JAN06) 9015-10-10 750J, 850J Crawler

010706
PN=82
 System Diagrams
T206669 –19–31JAN05

System Functional Schematic (SE7, SE8, SE9)

MF82180,0000020 –19–13OCT05–3/14

TM2260 (07JAN06) 9015-10-11 750J, 850J Crawler

010706
PN=83
 System Diagrams
T206670 –19–07JAN05

System Functional Schematic (SE10, SE11, SE12)

MF82180,0000020 –19–13OCT05–4/14

TM2260 (07JAN06) 9015-10-12 750J, 850J Crawler

010706
PN=84
 System Diagrams
T206671 –19–07JAN05

System Functional Schematic (SE13, SE14, SE15)

MF82180,0000020 –19–13OCT05–5/14

TM2260 (07JAN06) 9015-10-13 750J, 850J Crawler

010706
PN=85
 System Diagrams
T206672 –19–07JAN05

System Functional Schematic (SE16, SE17, SE18)

MF82180,0000020 –19–13OCT05–6/14

TM2260 (07JAN06) 9015-10-14 750J, 850J Crawler

010706
PN=86
 System Diagrams
T206673 –19–07JAN05

System Functional Schematic (SE19, SE20, SE21)

MF82180,0000020 –19–13OCT05–7/14

TM2260 (07JAN06) 9015-10-15 750J, 850J Crawler

010706
PN=87
 System Diagrams
T206674 –19–07JAN05

System Functional Schematic (SE22, SE23, SE24)

MF82180,0000020 –19–13OCT05–8/14

TM2260 (07JAN06) 9015-10-16 750J, 850J Crawler

010706
PN=88
 System Diagrams
T206675 –19–07JAN05

System Functional Schematic (SE25, SE26, SE27)

MF82180,0000020 –19–13OCT05–9/14

TM2260 (07JAN06) 9015-10-17 750J, 850J Crawler

010706
PN=89
 System Diagrams
T206676 –19–07JAN05

System Functional Schematic (SE28, SE29, SE30)

MF82180,0000020 –19–13OCT05–10/14

TM2260 (07JAN06) 9015-10-18 750J, 850J Crawler

010706
PN=90
 System Diagrams
T206677 –19–07JAN05

System Functional Schematic (SE31, SE32, SE33)

MF82180,0000020 –19–13OCT05–11/14

TM2260 (07JAN06) 9015-10-19 750J, 850J Crawler

010706
PN=91
 System Diagrams
T206678 –19–07JAN05

System Functional Schematic (SE34, SE35)

MF82180,0000020 –19–13OCT05–12/14

TM2260 (07JAN06) 9015-10-20 750J, 850J Crawler

010706
PN=92
 System Diagrams
T206679 –19–07JAN05

System Functional Schematic (SE36, SE37)

• SE1—Battery, Ignition Power Circuit (24 V System) • SE2—Alternator and Start Circuits
MF82180,0000020 –19–13OCT05–13/14

TM2260 (07JAN06) 9015-10-21 750J, 850J Crawler

010706
PN=93
 System Diagrams

• SE3—Start Aid, Horn, and A/C Compressor Circuit • SE23—CAN Monitor Unit (CMU) Circuit
• SE4—Accessory Circuit • SE24—CAN Monitor Unit (CMU) Circuit
• SE5—Vehicle Electrical Center Circuit • SE25—Wiper and Washer Circuits
• SE6—Vehicle Electrical Center Circuit • SE26—Wiper, Washer, and Under-Seat Heater
• SE7—Vehicle Electrical Center Circuit Circuits
• SE8—Vehicle Electrical Center Circuit • SE27—Standard 12 V Power Converter Circuit
• SE9—Vehicle Electrical Center Circuit • SE28—Radio Circuit
• SE10—Spare Connector Circuit • SE29—Optional 12 V Power Convertor Circuit
• SE11—Transmission Control Unit (TCU) Circuit • SE30—Standard Work Light Circuit
• SE12—Transmission Control Unit (TCU) Circuit • SE31—Auxiliary Light Circuit
• SE13—Transmission Control Unit (TCU) Circuit • SE32—Dome Light and Air Seat Circuit
• SE14—Transmission Control Unit (TCU) Circuit • SE33—Engine Control Unit (ECU) Input Circuit
• SE15—Transmission Control Unit (TCU) Circuit (750J)
• SE16—Transmission Control Unit (TCU) Circuit • SE34—Engine Control Unit (ECU) Circuit (750J)
• SE17—Transmission Control Unit (TCU) Circuit • SE35—Engine Control Unit (ECU) Input Circuit
• SE18—Transmission Control Unit (TCU) Circuit (850J)
9015
10 • SE19—Pilot Enable and Quick Drop Circuit • SE36—Engine Control Unit (ECU) Circuit (850J)
22 • SE20—Air Conditioning and Heater Circuit • SE37—Engine Control Unit (ECU) Output Circuit
• SE21—Air Conditioning and Heater Circuit (850J)
• SE22—Service ADVISOR Connector Circuit

MF82180,0000020 –19–13OCT05–14/14

TM2260 (07JAN06) 9015-10-22 750J, 850J Crawler

010706
PN=94
 System Diagrams

9015
10
23

TM2260 (07JAN06) 9015-10-23 750J, 850J Crawler

010706
PN=95
 System Diagrams

Operator’s Station Harness (W7) Component Location

T203312 –UN–14JAN05

X5
X7
X4

X2
X6
X1
R1 X52

S15 S4
S16 S5
S22
Y11 X12
S17
A6 H4
S1 M11
S19 A3
X26 B34
S7
S23
X27

X17

X18
X16
S8 A1
X30 H2
X24
V7 X9
X22
S25
W4
X13
X40 X32 B1

X8
X39
S18 X31
B33 X37
X38 X36

K10
S20 X35
B32 K11
T203312
Operator’s Station Harness (W7) Component Location
MF82180,0000021 –19–01SEP04–1/2

TM2260 (07JAN06) 9015-10-24 750J, 850J Crawler

010706
PN=96
 System Diagrams

A1—Transmission Control Unit S15—Under-Seat Heater X9—Standard 12 V Power X30—Operator’s Station

(TCU) Blower Switch Outlet Harness-to-Transmission
A3—CAN Monitor Unit (CMU) S16—Standard Work Light X12—Cab Harness-to-Rear Harness Connector 4
A6—Vehicle Electrical Center Switch Wiper Harness X31—VEC 8-Pin Connector
(VEC) S17—Auxiliary Work Light Connector (Gray)
B1—Decelerator Sensor Switch X13—Operator’s Station X32—VEC 8-Pin Connector
B32—FNR Sensor S18—Park Lock Lever Switch Harness-to-Roof Harness (Red)
B33—Steer Sensor S19—Start Aid Switch Connector X35—VEC 8-Pin Connector
B34—Transmission Speed S20—Neutral Start Switch X16—Operator’s Station (Blue)
Control Sensor S22—Engine Speed Control Harness-to-Transmission X36—VEC 8-Pin Connector
H2—Monitor Alarm Switch Harness Connector 1 (Green)
H4—Warmup Indicator Light S23—Fan Reversing Switch X17—Operator’s Station X37—VEC 8-Pin Connector
K10—Accessory Relay 1 S25—Air Seat Switch Harness-to-Transmission (Brown)
K11—Accessory Relay 2 V7—Rear Wiper Diode Harness Connector 2 X38—VEC 2-Pin Connector
M11—Wiper Motor Rear W4—Ground to Cab Left Rear X18—Operator’s Station (Gray)
R1—CAN Termination Resistor X1—TCU Connector Harness-to-Transmission X39—VEC 2-Pin Connector
R3—Under-Seat Heater Blower X2—TCU Connector Harness Connector 3 (Black)
Resistor X4—CMU 16-Pin Connector X22—Cab/Canopy X40—Operator’s
R5—CAN Termination Resistor X5—CMU 14-Pin Connector Harness-to-Under-Seat Station-to-Cab Roof
S1—Key Switch X6—Bussed +5V Sensor Harness Connector Harness Connector 9015
S4—Blade Angle Switch Connector X24—Optional 12 V Power X52—TCU Programming 10
S5—Horn Switch X7—Bussed Ground Sensor Outlet Connector 25
S7—Decelerator Mode Switch Connector X26—Spare Connector Right Y11—Blade Detent Coil
S8—Pilot Control Enable X8—Service ADVISOR Console
Switch Connector X27—Spare Connector Front
Console

MF82180,0000021 –19–01SEP04–2/2

TM2260 (07JAN06) 9015-10-25 750J, 850J Crawler

010706
PN=97
 System Diagrams

Operator’s Station Harness (W7) Wiring Diagram

T206598 –UN–05JAN05

Operator’s Station Harness (W7) Wire Legend

MF82180,0000022 –19–01SEP04–1/5

TM2260 (07JAN06) 9015-10-26 750J, 850J Crawler

010706
PN=98
 System Diagrams

9015
10
27

TM2260 (07JAN06) 9015-10-27 750J, 850J Crawler

010706
PN=99
 System Diagrams
T206599 –UN–05JAN05

Operator’s Station Harness (W7) Wiring Diagram (1 of 2)

MF82180,0000022 –19–01SEP04–2/5

TM2260 (07JAN06) 9015-10-28 750J, 850J Crawler

010706
PN=100
 System Diagrams

B32—FNR Sensor V7—Rear Wiper Diode X22—Cab/Canopy X38—VEC 2-Pin Connector

B33—Steer Sensor W4—Ground to Cab Left Rear Harness-to-Under-Seat (Gray)
B34—Transmission Speed X8—Service ADVISOR Harness Connector X39—VEC 2-Pin Connector
Control Sensor Connector X24—Optional 12 V Power (Black)
H4—Warmup Indicator Light X9—Standard 12 V Power Outlet X40—Operator’s
K10—Accessory Relay 1 Outlet X26—Spare Connector Right Station-to-Cab Roof
K11—Accessory Relay 2 X12—Cab Harness-to-Rear Console Harness Connector
M11—Wiper Motor Rear Wiper Harness X30—Operator’s Station X112—L02 BRN Splice
R3—Under-Seat Heater Blower Connector Harness-to-Transmission X116—P31 RED Splice
Resistor X13—Operator’s Station Harness Connector 4 X117—E05 WHT Splice
R5—CAN Termination Resistor Harness-to-Roof Harness X31—VEC 8-Pin Connector X118—G07 BLK Splice
S4—Blade Angle Switch Connector (Gray) X119—P18 RED Splice
S5—Horn Switch X16—Operator’s Station X32—VEC 8-Pin Connector X120—G03 BLK Splice 1
S8—Pilot Control Enable Harness-to-Transmission (Red) X121—B01 RED Splice
Switch Harness Connector 1 X35—VEC 8-Pin Connector X122—L06 BRN Splice
S18—Park Lock Lever Switch X17—Operator’s Station (Blue) X123—G03 BLK Splice 2
S20—Neutral Start Switch Harness-to-Transmission X36—VEC 8-Pin Connector X124—P28 RED Splice
S22—Engine Speed Control Harness Connector 2 (Green) Y11—Blade Detent Coil
Switch X18—Operator’s Station X37—VEC 8-Pin Connector
S25—Air Seat Switch Harness-to-Transmission (Brown) 9015
Harness Connector 3 10
29

Continued on next page MF82180,0000022 –19–01SEP04–3/5

TM2260 (07JAN06) 9015-10-29 750J, 850J Crawler

010706
PN=101
 System Diagrams
T206600 –UN–05JAN05

Operator’s Station Harness (W7) Wiring Diagram (2 of 2)

Continued on next page MF82180,0000022 –19–01SEP04–4/5

TM2260 (07JAN06) 9015-10-30 750J, 850J Crawler

010706
PN=102
 System Diagrams

B1—Decelerator Sensor S17—Auxiliary Work Light X7—Bussed Ground Sensor X110—M13 LGRN Splice 1
H2—Monitor Alarm Switch Connector X111—M12 YEL Splice 1
M11—Wiper Motor Rear S19—Start Aid Switch X22—Cab/Canopy X125—G02 BLK Splice
R1—CAN Termination Resistor S23—Fan Reversing Switch Harness-to-Under-Seat X126—P03 RED Splice
R3—Under-Seat Heater Blower S25—Air Seat Switch Harness Connector X127—R13 BLK Splice 2
Resistor X1—TCU Connector X27—Spare Connector Front X128—M12 YEL Splice 2
R5—CAN Termination Resistor X2—TCU Connector Console X129—M13 LGRN Splice 2
S1—Key Switch X4—CMU 16-Pin Connector X52—TCU Programming X134—G09 BLK Splice
S7—Decelerator Mode Switch X5—CMU 14-Pin Connector Connector X135—T10 BLU Splice
S15—Under-Seat Heater X6—Bussed +5V Sensor X102—R12 BLK Splice X136—R06 BLK Splice
Blower Switch Connector X109—R13 BLK Splice 1
S16—Standard Work Light
Switch

9015
10
31

MF82180,0000022 –19–01SEP04–5/5

TM2260 (07JAN06) 9015-10-31 750J, 850J Crawler

010706
PN=103
 System Diagrams

Canopy Roof Harness (W8) Component Location

E6

E4

E7
9015
10
32

E5
E9

X13
W2
–UN–15OCT04
T203316

T203316
Canopy Roof Harness (W8) Component Location
Continued on next page MF82180,0000023 –19–01SEP04–1/2

TM2260 (07JAN06) 9015-10-32 750J, 850J Crawler

010706
PN=104
 System Diagrams

E4—Auxiliary Work Light Left E6—Auxiliary Work Light Left E9—Auxiliary Work Light Right W2—Ground to Cab Right
Rear Front Rear Rear
E5—Standard Work Light E7—Auxiliary Work Light Right X13—Operator’s Station
Right Rear Front Harness-to-Roof Harness
Connector

MF82180,0000023 –19–01SEP04–2/2

9015
10
33

TM2260 (07JAN06) 9015-10-33 750J, 850J Crawler

010706
PN=105
 System Diagrams

Canopy Roof Harness (W8) Wiring Diagram

T206443 –UN–05JAN05

Canopy Roof Harness (W8) Wiring Diagram

MF82180,0000024 –19–01SEP04–1/2

TM2260 (07JAN06) 9015-10-34 750J, 850J Crawler

010706
PN=106
 System Diagrams

E4—Auxiliary Work Light Left E7—Auxiliary Work Light Right X13—Operator’s Station X133—L05 BRN Splice
Rear Front Harness-to-Roof Harness W2—Ground to Cab Right
E5—Standard Work Light E9—Auxiliary Work Light Right Connector Rear
Right Rear Rear X131—G04 BLK Splice 1
E6—Auxiliary Work Light Left
Front

MF82180,0000024 –19–01SEP04–2/2

9015
10
35

TM2260 (07JAN06) 9015-10-35 750J, 850J Crawler

010706
PN=107
 System Diagrams

Cab Roof Harness (W9) Component Location

E6

E1
S14
S13 S12
E4 V6
X41
E5 S11
9015 X11 S10
10 V5
36

S9 X25
E9
E7
M6

M7

X13
X40 X34
A6

M8
W2
X33

–UN–07JAN05
T202966

T202966
Cab Roof Harness (W9) Component Location
Continued on next page MF82180,0000025 –19–01SEP04–1/2

TM2260 (07JAN06) 9015-10-36 750J, 850J Crawler

010706
PN=108
 System Diagrams

A6—Vehicle Electrical Center M6—Wiper Motor Front S14—Dome Light Switch X25—Spare Connector Roof
(VEC) M7—Wiper Motor Left Door V5—Door Wiper Diode X33—VEC 8-Pin Connector
E1—Dome Light M8—Wiper Motor Right Door V6—Front Wiper Diode (Black)
E4—Auxiliary Work Light Left S9—Heater Temperature W2—Ground to Cab Right X34—VEC 8-Pin Connector
Rear Control Switch Rear (Orange)
E5—Standard Work Light S10—Heater Blower Switch X11—Cab Roof Harness-to-Air X40—Operator’s
Right Rear S11—Air Conditioning On/Off Conditioning Harness Station-to-Cab Roof
E6—Auxiliary Work Light Left Switch Connector Harness Connector
Front S12—Front/Rear Door Wiper X13—Operator’s Station X41—Cab Roof
E7—Auxiliary Work Light Right Motor Switch Harness-to-Roof Harness Harness-to-Radio
Front S13—Left/Right Door Wiper Connector Harness Connector
E9—Auxiliary Work Light Right Motor Switch
Rear

9015
10
37

MF82180,0000025 –19–01SEP04–2/2

TM2260 (07JAN06) 9015-10-37 750J, 850J Crawler

010706
PN=109
 System Diagrams

Cab Roof Harness (W9) Wiring Diagram

T206442 –UN–05JAN05

Cab Roof Harness (W9) Wiring Diagram

MF82180,0000026 –19–01SEP04–1/2

TM2260 (07JAN06) 9015-10-38 750J, 850J Crawler

010706
PN=110
 System Diagrams

E1—Dome Light M7—Wiper Motor Left Door V5—Door Wiper Diode X34—VEC 8-Pin Connector
E4—Auxiliary Work Light Left M8—Wiper Motor Right Door V6—Front Wiper Diode (Orange)
Rear S9—Heater Temperature W2—Ground to Cab Right X40—Operator’s
E5—Standard Work Light Control Switch Rear Station-to-Cab Roof
Right Rear S10—Heater Blower Switch X11—Cab Roof Harness-to-Air Harness Connector
E6—Auxiliary Work Light Left S11—Air Conditioning On/Off Conditioning Harness X41—Cab Roof
Front Switch Connector Harness-to-Radio
E7—Auxiliary Work Light Right S12—Front/Rear Door Wiper X13—Operator’s Station Harness Connector
Front Motor Switch Harness-to-Roof Harness X131—G04 BLK Splice 1
E9—Auxiliary Work Light Right S13—Left/Right Door Wiper Connector X132—G04 BLK Splice 2
Rear Motor Switch X25—Spare Connector Roof X133—L05 BRN Splice
M6—Wiper Motor Front S14—Dome Light Switch X33—VEC 8-Pin Connector
(Black)

9015
10
39

MF82180,0000026 –19–01SEP04–2/2

TM2260 (07JAN06) 9015-10-39 750J, 850J Crawler

010706
PN=111
 System Diagrams

Engine Harness (W10) Component Location

T202563 –UN–14JAN05

E3

E2
X28 A2
X10 B16
Y9
B22

W16
H1 G3

Y1 B13

V4
R2

Y5A B12

Y16 X19
K9
B18
V3
B14 V2
B11 Y18 B17
B8
Y5
M1 B7
G2

Y6

T202563
Engine Harness (W10) Component Location (750J shown with optional pre-cleaner)
MF82180,0000027 –19–01SEP04–1/4

TM2260 (07JAN06) 9015-10-40 750J, 850J Crawler

010706
PN=112
 System Diagrams

A2—Engine Control Unit (ECU) B17—Engine Oil Pressure V2—Starter Solenoid 5 A Y1—Start Aid Solenoid
B7—Pump Pressure Control Sensor Diode Y5—Hydraulic Fan
Pilot (PCP) Rear B18—Water-in-Fuel Sensor V3—Start Relay 1 A Diode Proportional Relief
B8—Pump Pressure Control B22—Air Filter Restriction V4—Air Conditioning Solenoid (With Reversing
Pilot (PCP) Front Switch Compressor Clutch 5 A Option)
B11—Fuel Temperature E2—Standard Work Light Left Diode Y5A—Hydraulic Fan
Sensor Grill W16—Standard Fan Drive Proportional Relief
B12—Engine Coolant E3—Standard Work Light Harness Solenoid (Standard)
Temperature Sensor Right Grill X10—ECU Connector (A-K) Y6—Hydraulic Fan Reversing
B13—Manifold Air G2—Jump Start Terminal X19—Engine Solenoid
Temperature Sensor G3—Alternator Harness-to-Transmission Y9—Quick-Drop Solenoid
B14—Crankshaft Position H1—Horn Harness Connector Y16—Air Conditioning
Sensor K9—Start Relay X28—Engine Compressor Clutch
B16—Ambient Air Temperature M1—Starter Motor Harness-to-Standard Fan Solenoid
Sensor R2—CAN Termination Resistor Drive Harness Connector Y18—Injection Pump Solenoid

750J If the machine is not equipped with the

optional pre-cleaner, the ambient air
NOTE: The engine harness is shown with optional temperature sensor will be mounted on the air 9015
equipment. Both the standard fan drive and cleaner bracket. 10
41
the optional reversing fan drive options are
shown. The machine will only be equipped
with one hydraulic fan proportional relief
solenoid.

Continued on next page MF82180,0000027 –19–01SEP04–2/4

TM2260 (07JAN06) 9015-10-41 750J, 850J Crawler

010706
PN=113
 System Diagrams
T202564 –UN–01OCT04

E3

E2

X28 Y9
B16

B22

A2
W16

H1

R2
B12

X23 Y13
Y1
X3 X10
Y5A B15
Y16 B13
X19
B11 Y12
B10

V2
Y5
B8
V3 G3

V4 K9 B7
Y6 B17
B14 B18
M1
G2

T202564
Engine Harness (W10) Component Location (850J shown with optional pre-cleaner)

Continued on next page MF82180,0000027 –19–01SEP04–3/4

TM2260 (07JAN06) 9015-10-42 750J, 850J Crawler

010706
PN=114
 System Diagrams

A2—Engine Control Unit (ECU) B17—Engine Oil Pressure V4—Air Conditioning Y5—Hydraulic Fan
B7—Pump Pressure Control Sensor Compressor Clutch 5 A Proportional Relief
Pilot (PCP) Rear B18—Water-in-Fuel Sensor Diode Solenoid (With Reversing
B8—Pump Pressure Control B22—Air Filter Restriction W16—Standard Fan Drive Option)
Pilot (PCP) Front Switch Harness Y5A—Hydraulic Fan
B10—Fuel Rail Pressure E2—Standard Work Light Left X3—ECU Connector (L-Y) Proportional Relief
Sensor Grill X10—ECU Connector (A-K) Solenoid (Standard)
B11—Fuel Temperature E3—Standard Work Light X19—Engine Y6—Hydraulic Fan Reversing
Sensor Right Grill Harness-to-Transmission Solenoid
B12—Engine Coolant G2—Jump Start Terminal Harness Connector Y9—Quick-Drop Solenoid
Temperature Sensor G3—Alternator X23—Engine Y12—High Pressure Fuel
B13—Manifold Air H1—Horn Harness-to-Electronic Pump Solenoid 1
Temperature Sensor K9—Start Relay Injector Harness Y13—High Pressure Fuel
B14—Crankshaft Position M1—Starter Motor Connector Pump Solenoid 2
Sensor R2—CAN Termination Resistor X28—Engine Y16—Air Conditioning
B15—Camshaft Position V2—Starter Solenoid 5 A Harness-to-Standard Fan Compressor Clutch
Sensor Diode Drive Harness Connector Solenoid
B16—Ambient Air Temperature V3—Start Relay 1 A Diode Y1—Start Aid Solenoid
Sensor
9015
10
850J If the machine is not equipped with the 43
optional pre-cleaner, the ambient air
NOTE: The engine harness is shown with optional temperature sensor will be mounted on the air
equipment. Both the standard fan drive and cleaner bracket.
the optional reversing fan drive options are
shown. The machine will only be equipped
with one hydraulic fan proportional relief
solenoid.

MF82180,0000027 –19–01SEP04–4/4

TM2260 (07JAN06) 9015-10-43 750J, 850J Crawler

010706
PN=115
 System Diagrams

Engine Harness (W10) Wiring Diagram

T216036 –UN–17OCT05

Engine Harness (W10) Wiring Diagram (750J)

MF82180,0000028 –19–13OCT05–1/5

TM2260 (07JAN06) 9015-10-44 750J, 850J Crawler

010706
PN=116
 System Diagrams

B7—Pump Pressure Control B22—Air Filter Restriction W16—Standard Fan Drive X112—L02 BRN Splice
Pilot (PCP) Rear Switch Harness Y1—Start Aid Solenoid
B8—Pump Pressure Control E2—Standard Work Light Left X10—ECU Connector (A-K) Y5—Hydraulic Fan
Pilot (PCP) Front Grill X19—Engine Proportional Relief
B11—Fuel Temperature E3—Standard Work Light Harness-to-Transmission Solenoid (With Reversing
Sensor Right Grill Harness Connector Option)
B12—Engine Coolant G2—Jump Start Terminal X28—Engine Y5A—Hydraulic Fan
Temperature Sensor G3—Alternator Harness-to-Standard Fan Proportional Relief
B13—Manifold Air H1—Horn Drive Harness Connector Solenoid (Standard)
Temperature Sensor K9—Start Relay X104—G11 BLK Splice Y6—Hydraulic Fan Reversing
B14—Crankshaft Position M1—Starter Motor X105—H02 GRN Splice Solenoid
Sensor R2—CAN Termination Resistor X106—Shield Ground Splice Y9—Quick-Drop Solenoid
B16—Ambient Air Temperature V2—Starter Solenoid 5 A X107—R15 BLK Splice Y16—Air Conditioning
Sensor Diode X108—G12 BLK Splice Compressor Clutch
B17—Engine Oil Pressure V3—Start Relay 1 A Diode X109—R13 BLK Splice 1 Solenoid
Sensor V4—Air Conditioning X110—M13 LGRN Splice 1 Y18—Injection Pump Solenoid
B18—Water-in-Fuel Sensor Compressor Clutch 5 A X111—M12 YEL Splice 1
Diode

9015
750J 10
45

Continued on next page MF82180,0000028 –19–13OCT05–2/5

TM2260 (07JAN06) 9015-10-45 750J, 850J Crawler

010706
PN=117
 System Diagrams

9015
10
46

–UN–17OCT05
T216037

Engine Harness (W10) Wire Legend (850J)

850J
Continued on next page MF82180,0000028 –19–13OCT05–3/5

TM2260 (07JAN06) 9015-10-46 750J, 850J Crawler

010706
PN=118
 System Diagrams

9015
10
47

TM2260 (07JAN06) 9015-10-47 750J, 850J Crawler

010706
PN=119
 System Diagrams
T216038 –UN–17OCT05

Engine Harness (W10) Wiring Diagram (850J)

Continued on next page MF82180,0000028 –19–13OCT05–4/5

TM2260 (07JAN06) 9015-10-48 750J, 850J Crawler

010706
PN=120
 System Diagrams

B7—Pump Pressure Control E2—Standard Work Light Left X19—Engine X114—R14 BLK Splice
Pilot (PCP) Rear Grill Harness-to-Transmission X115—E19 WHT Splice
B8—Pump Pressure Control E3—Standard Work Light Harness Connector Y1—Start Aid Solenoid
Pilot (PCP) Front Right Grill X23—Engine Y5—Hydraulic Fan
B11—Fuel Temperature G2—Jump Start Terminal Harness-to-Electronic Proportional Relief
Sensor G3—Alternator Injector Harness Solenoid (With Reversing
B12—Engine Coolant H1—Horn Connector Option)
Temperature Sensor K9—Start Relay X28—Engine Y5A—Hydraulic Fan
B13—Manifold Air M1—Starter Motor Harness-to-Standard Fan Proportional Relief
Temperature Sensor R2—CAN Termination Resistor Drive Harness Connector Solenoid (Standard)
B14—Crankshaft Position V2—Starter Solenoid 5 A X104—G11 BLK Splice Y6—Hydraulic Fan Reversing
Sensor Diode X105—H02 GRN Splice Solenoid
B15—Camshaft Position V3—Start Relay 1 A Diode X106—Shield Ground Splice Y9—Quick-Drop Solenoid
Sensor V4—Air Conditioning X107—R15 BLK Splice Y12—High Pressure Fuel
B16—Ambient Air Temperature Compressor Clutch 5 A X108—G12 BLK Splice Pump Solenoid 1
Sensor Diode X109—R13 BLK Splice 1 Y13—High Pressure Fuel
B17—Engine Oil Pressure W16—Standard Fan Drive X110—M13 LGRN Splice 1 Pump Solenoid 2
Sensor Harness X111—M12 YEL Splice 1 Y16—Air Conditioning
B18—Water-in-Fuel Sensor X3—ECU Connector (L-Y) X112—L02 BRN Splice Compressor Clutch
B22—Air Filter Restriction X10—ECU Connector (A-K) X113—P30 RED Splice Solenoid 9015
Switch 10
49

MF82180,0000028 –19–13OCT05–5/5

TM2260 (07JAN06) 9015-10-49 750J, 850J Crawler

010706
PN=121
 System Diagrams

Transmission Harness (W11) Component Location

T202939 –UN–07JAN05

M2

X16

Y7 Y7 Y10 X17
B23 B25
U2
U3 X18

W20 X30

B20

X42 Y8 X21
X20 H3 B6
W20
B19 B5
B21 B4
M9
Y15 Y17
B35 X29
B34 W18 M10

X19 X49
W3

B3
Y14 B9
Y2 Y3
B2

Y4

B3

Y4

Y3

B2
T202939
Transmission Harness (W11) Component Location
MF82180,00001AA –19–14JAN04–1/2

TM2260 (07JAN06) 9015-10-50 750J, 850J Crawler

010706
PN=122
 System Diagrams

B2—Motor Speed Sensor Left B34—Transmission Speed X17—Operator’s Station X42—Optional 12 V Terminal
B3—Motor Speed Sensor Control Switch Harness-to-Transmission Block
Right B35—Hydrostatic Pump Case harness Connector 2 X49—Battery Power Connector
B4—Hydrostatic Charge Pressure Sensor X18—Operator’s Station Y2—Park Brake Solenoid 1
Pressure Sensor H3—Backup Alarm Harness-to-Transmission Y3—Motor Shift Solenoid Left
B5—Hydrostatic Pressure M2—Heater Valve Motor harness Connector 3 Y4—Motor Shift Solenoid
Sensor Right M9—Washer Motor Front/Rear X19—Engine Right
B6—Hydrostatic Pressure M10—Washer Motor Left/Right Harness-to-Transmission Y7—Blade Angle Solenoid Left
Sensor Left U2—Standard 12 V Power Harness Connector (top)
B9—Quick-Drop Pressure Converter X20—Optional 12 V Power Y8—Blade Angle Solenoid
Switch U3—Optional 12 V Power Converter Connector Right (bottom)
B19—Fuel Level Sensor Converter X21—Transmission Y10—Pilot Control Enable
B20—Hydraulic Oil W3—Ground to Frame Under Harness-to-Fuel Tank Solenoid
Temperature Sensor Cab Harness Connector Y14—Hydrostatic Oil Cooler
B21—Transmission Oil W18—Fuel Tank Harness Harness Bypass Solenoid
Temperature Sensor W20—Optional Power X29—Automatic Diagnostic Y15—Park Brake Solenoid 2
B23—Hydraulic Oil Filter Converter Harness Connector Y17—Hydrostatic Oil Reservoir
Restriction Switch X16—Operator’s Station X30—Operator’s Station Bypass Solenoid
B25—Hydraulic Fan Oil Filter Harness-to-Transmission Harness-to-Transmission
Restriction Switch harness Connector 1 Harness Connector 4 9015
10
51

MF82180,00001AA –19–14JAN04–2/2

TM2260 (07JAN06) 9015-10-51 750J, 850J Crawler

010706
PN=123
 System Diagrams

Transmission Harness (W11) Wiring Diagram

9015
10
52

–UN–17OCT05
T216039

Transmission Harness (W11) Wire Legend

Continued on next page MF82180,00001A9 –19–13OCT05–1/7

TM2260 (07JAN06) 9015-10-52 750J, 850J Crawler

010706
PN=124
 System Diagrams

9015
10
53

TM2260 (07JAN06) 9015-10-53 750J, 850J Crawler

010706
PN=125
 System Diagrams
TX1001637 –UN–21DEC05

Transmission Harness (W11) Wiring Diagram

Continued on next page MF82180,00001A9 –19–13OCT05–2/7

TM2260 (07JAN06) 9015-10-54 750J, 850J Crawler

010706
PN=126
 System Diagrams

B2—Motor Speed Sensor Left B34—Transmission Speed X18—Operator’s Station X103—G10 BLK Splice
B3—Motor Speed Sensor Control Switch Harness-to-Transmission Y2—Park Brake Solenoid 1
Right B35—Hydrostatic Pump Case harness Connector 3 Y3—Motor Shift Solenoid Left
B4—Hydrostatic Charge Pressure Sensor X19—Engine Y4—Motor Shift Solenoid
Pressure Sensor M2—Heater Valve Motor Harness-to-Transmission Right
B5—Hydrostatic Pressure M9—Washer Motor Front/Rear Harness Connector Y7—Blade Angle Solenoid Left
Sensor Right M10—Washer Motor Left/Right X20—Optional 12 V Power (top)
B6—Hydrostatic Pressure U2—Standard 12 V Power Converter Connector Y8—Blade Angle Solenoid
Sensor Left Converter X29—Automatic Diagnostic Right (bottom)
B9—Quick-Drop Pressure W3—Ground to Frame Under Connector Y10—Pilot Control Enable
Switch Cab X30—Operator’s Station Solenoid
B20—Hydraulic Oil X16—Operator’s Station Harness-to-Transmission Y14—Hydrostatic Oil Reservoir
Temperature Sensor Harness-to-Transmission Harness Connector 4 Bypass Solenoid
B21—Transmission Oil harness Connector 1 X49—Battery Power Connector Y15—Park Brake Solenoid 2
Temperature Sensor X17—Operator’s Station X100—T24 BLU Splice Y17—Hydrostatic Oil Cooler
B23—Hydraulic Oil Filter Harness-to-Transmission X101—G05 BLK Splice Bypass Solenoid
Restriction Switch harness Connector 2 X102—R12 BLK Splice
B25—Hydraulic Fan Oil Filter
Restriction Switch
9015
10
55

Continued on next page MF82180,00001A9 –19–13OCT05–3/7

TM2260 (07JAN06) 9015-10-55 750J, 850J Crawler

010706
PN=127
 System Diagrams

9015
10
56

–UN–05JAN05
T206603

Fuel Tank Harness (W18) Wiring Diagram

Continued on next page MF82180,00001A9 –19–13OCT05–4/7

TM2260 (07JAN06) 9015-10-56 750J, 850J Crawler

010706
PN=128
 System Diagrams

B19—Fuel Level Sensor H3—Backup Alarm X21—Transmission

Harness-to-Fuel Tank
Harness Connector
Harness

Continued on next page MF82180,00001A9 –19–13OCT05–5/7

9015
10
57

TM2260 (07JAN06) 9015-10-57 750J, 850J Crawler

010706
PN=129
 System Diagrams

9015
10
58

–UN–05JAN05
T206604

Optional Power Converter Harness (W20) Wiring Diagram

Continued on next page MF82180,00001A9 –19–13OCT05–6/7

TM2260 (07JAN06) 9015-10-58 750J, 850J Crawler

010706
PN=130
 System Diagrams

U3—Standard 12 V Power X20—Optional 12 V Power X42—Optional 12 V Terminal X137—P14 RED Splice

Converter Converter Connector Block

MF82180,00001A9 –19–13OCT05–7/7

9015
10
59

TM2260 (07JAN06) 9015-10-59 750J, 850J Crawler

010706
PN=131
 System Diagrams

Air Conditioning Harness (W14) Component Location

M3
9015
10
60

B27

R4

B29

M4

B28

M5

X11
W17
–UN–23SEP04

X51
T203319

T203319
Air Conditioning Harness (W12) Component Location
Continued on next page MF82180,00001AE –19–14JAN04–1/2

TM2260 (07JAN06) 9015-10-60 750J, 850J Crawler

010706
PN=132
 System Diagrams

B27—Air Conditioning Freeze M3—Heater Blower Motor W17—Condenser Harness X51—Air Conditioning
Switch M4—Condenser Fan Motor X11—Cab Roof Harness-to-Air Harness-to-Condenser
B28—Air Conditioning High M5—Condenser Fan Motor Conditioning Harness Harness Connector
Pressure Switch R4—Cab Heater Blower Connector
B29—Air Conditioning Low Resistor
Pressure Switch

MF82180,00001AE –19–14JAN04–2/2

9015
10
61

TM2260 (07JAN06) 9015-10-61 750J, 850J Crawler

010706
PN=133
 System Diagrams

Air Conditioning Harness (W14) Wiring Diagram

T203320 –UN–27SEP04

Air Conditioning Harness (W12) Wiring Harness

MF82180,00001AD –19–14JAN04–1/2

TM2260 (07JAN06) 9015-10-62 750J, 850J Crawler

010706
PN=134
 System Diagrams

B27—Air Conditioning Freeze M3—Heater Blower Motor W17—Condenser Harness X51—Air Conditioning
Switch M4—Condenser Fan Motor X11—Cab Roof Harness-to-Air Harness-to-Condenser
B28—Air Conditioning High M5—Condenser Fan Motor Conditioning Harness Harness Connector
Pressure Switch R4—Cab Heater Blower Connector
B29—Air Conditioning Low Resistor
Pressure Switch

MF82180,00001AD –19–14JAN04–2/2

9015
10
63

TM2260 (07JAN06) 9015-10-63 750J, 850J Crawler

010706
PN=135
 System Diagrams

Radio Harness (W15) Component Location

W1

B31

9015
10 B30
64
A5

X41

–UN–23SEP04
T203317

T203317
Radio Harness (W13) Component Location
Continued on next page MF82180,00001DE –19–24MAY04–1/2

TM2260 (07JAN06) 9015-10-64 750J, 850J Crawler

010706
PN=136
 System Diagrams

A5—Radio (12 V) B31—Left Speaker W1—Radio Antenna X41—Cab Roof

B30—Right Speaker Harness-to-Radio
Harness Connector

MF82180,00001DE –19–24MAY04–2/2

9015
10
65

TM2260 (07JAN06) 9015-10-65 750J, 850J Crawler

010706
PN=137
 System Diagrams

Radio Harness (W15) Wiring Diagram

9015
10
66

–UN–14JAN05
T203318

Radio Harness (W13) Wiring Diagram

Continued on next page CED,TX14826,10546 –19–26OCT99–1/2

TM2260 (07JAN06) 9015-10-66 750J, 850J Crawler

010706
PN=138
 System Diagrams

A5—Radio (12 V) B30—Right Speaker B31—Left Speaker X41—Cab/Canopy

Harness-to-Radio
Harness Connector

CED,TX14826,10546 –19–26OCT99–2/2

9015
10
67

TM2260 (07JAN06) 9015-10-67 750J, 850J Crawler

010706
PN=139
 System Diagrams

9015
10
68

TM2260 (07JAN06) 9015-10-68 750J, 850J Crawler

010706
PN=140
 Group 15
Sub-System Diagnostics
Starting and Charging Circuit Theory of Operation
T204499 –19–19NOV04

Starting and Charging Circuit Theory of Operation

MF82180,000002B –19–01SEP04–1/2

TM2260 (07JAN06) 9015-15-1 750J, 850J Crawler

010706
PN=141
 Sub-System Diagnostics

Starting and Power Circuit lever switch (S2) will apply ground to start relay pin
C2, energizing the relay. Battery power is applied to
Battery power is supplied to the starter motor (M1), the starter motor solenoid, engaging the starter motor.
key switch (S1), alternator (G3), start relay (K1), The start relay 1 A diode (V2) protects the start
inline fuse connector (X49) and other components circuit from voltage spikes when the start relay
using battery power. Power can be disconnected by de-energizes.
the manual battery disconnect (S2). When the key
switch is placed in the accessory position, power is As the starter motor cranks the engine, the crankshaft
applied from the key switch ACC terminal to position sensor (B6) produces a pulsed signal to
accessory relay 1 (K10) and accessory relay 2 inform the Engine Control Unit (ECU) (A2) that the
(K11). These two relays are energized and supply crankshaft is turning. The ECU controls the fuel
battery power to the accessory circuits within the system, starting the engine. For more information on
Vehicle Electrical Center (VEC) (A6). the ECU, see Engine Control Unit (ECU) Circuit
Theory of Operation. (Group 9015-20.)
When the key switch (S1) is placed in the on position,
power is applied from the key switch ACC terminal (as Charging Circuit
9015
15 explained above) and the IGN terminal to VEC pin 6A.
2 The VEC supplies ignition power to CMU power 5 A When the key switch (S1) is in the on position,
fuse (F4), TCU power 10 A fuse (F6), dome light 5 ignition power is applied through alternator excitation
A fuse (F8), start aid 15A fuse (F13), and ECU 5 A fuse (F5) and alternator excitation 3 A diode
ignition power 5 A fuse (F26). (V1) to alternator terminals W and D+. When the
engine is running and alternator is producing power,
When the key switch (S1) is placed in the start the alternator charges the batteries and provides
position, power is applied from the ST terminal to start power to the battery and ignition power circuits. See
relay 10 A fuse (F25). Power is supplied from start Alternator Test Procedure for more information. (Group
relay 10 A fuse to start relay (K9) pin C1. If the park 9015-20.)
lock lever is in the PARK position (up), park lock

MF82180,000002B –19–01SEP04–2/2

TM2260 (07JAN06) 9015-15-2 750J, 850J Crawler

010706
PN=142
 Sub-System Diagnostics

Controller Area Network (CAN) Theory of Operation

T204316 –19–19NOV04

Controller Area Network (CAN) Theory of Operation

MF82180,000002C –19–01SEP04–1/2

TM2260 (07JAN06) 9015-15-3 750J, 850J Crawler

010706
PN=143
 Sub-System Diagnostics

This machine utilizes a Controller Area Network (CAN) interference caused by many electrical sources. The
on which devices communicate. The Transmission devices on the CAN are connected via three wires
Control Unit (TCU) (A1), Engine Control Unit (ECU) weaved together called a twisted triple. The twisted
(A2), and CAN Monitor Unit (CMU) (A3) are all triple consists of a high voltage signal wire, a low
connected to the CAN. Operations and functions of voltage signal wire, and a ground wire. This method
these individual devices are covered separately. reduces interference and helps the devices
communicate with minimal errors.
• See Transmission Control Unit (TCU) Circuit Theory
of Operation. (Group 9015-10.) There are a few more components connected to the
• See Engine Control Unit (ECU) Circuit Theory of CAN. CAN termination resistor R1 and CAN
Operation. (Group 9015-10.) termination resistor R2 are 120 ohm resistors which
• See CAN Monitor Unit (CMU) Circuit Theory of are connected on opposite ends of the bus to avoid
Operation. (Group 9015-10.) signal errors. The Service ADVISOR Connector (X3)
is provided for machine diagnostic purposes. See
The devices on the CAN are communicating at a high Service ADVISOR System Computer Connection for
frequency, which makes the network susceptible to more information on connecting to a J-Series crawler.
9015
15
4

MF82180,000002C –19–01SEP04–2/2

TM2260 (07JAN06) 9015-15-4 750J, 850J Crawler

010706
PN=144
 Sub-System Diagnostics

Engine Control Unit (ECU) Circuit Theory of Operation

T204188 –19–19NOV04

Engine Control Unit (ECU) Circuit Theory of Operation (750J)

MF82180,000002D –19–01SEP04–1/5

TM2260 (07JAN06) 9015-15-5 750J, 850J Crawler

010706
PN=145
 Sub-System Diagnostics
T204190 –19–19NOV04

Engine Control Unit (ECU) Circuit Theory of Operation (850J)

MF82180,000002D –19–01SEP04–2/5

TM2260 (07JAN06) 9015-15-6 750J, 850J Crawler

010706
PN=146
 Sub-System Diagnostics

The Engine Control Unit (ECU) (A2) uses the Engine Coolant Temperature Sensor
information received by its sensors to determine the
correct amount of fuel and injection timing based on The engine coolant temperature sensor (B12) is a
load, temperatures, and operator input. Some of the variable resistance temperature sensor. The resistance
data calculated by the ECU is broadcast across CAN is sensed at pins B1 (X2) and D3 (P2). The ECU
to other controllers. The ECU also detects faults in the broadcasts the engine coolant temperature across the
sensors or abnormal operating conditions. CAN to the CMU. The CMU displays the temperature
on the engine coolant temperature gauge. The engine
NOTE: The following theory references pins on two coolant temperature is also used by the TCU in
different level ECUs. For inputs and outputs calculating proportional fan speed. See Transmission
common to both fuel systems, the pins for the Control Unit (TCU) Circuit Theory of Operation for
Level 12 controller (750J) will be listed first more information on the proportional fan circuit. (Group
followed by the Level 9 controller (850J) pins 9015-15.) For more information on the engine coolant
listed in parentheses. temperature sensor, see Electrical Component
Specifications. (Group 9015-20.)
The ECU receives battery power at pin K1 (B1 and
9015
B2) from ECU battery power 10 A fuse (F29). The The engine coolant temperature can cause engine fuel 15
warmup indicator light (H4) and ECU receive ignition derate conditions. If the engine coolant temperature 7
power from ECU ignition power 5 A fuse (F26). reaches 230°F (110°C), the ECU will derate fuel by 2%
per minute up to 20%. If the coolant temperature
Crankshaft Position Sensor reaches 239°F (115°C), the ECU will derate fuel by
20% per minute up to 40%. If the coolant temperature
The crankshaft position sensor (B14) is an inductive drops below the derate threshold temperatures, the
pickup located at the front of the engine. The signal is ECU will recover fuel delivery by the same rate until
produced by teeth on a timing gear and is sensed by power is fully restored.
the ECU at pins D2 (W1) and B2 (W2). The ECU uses
this signal to determine when the number one cylinder Manifold Air Temperature (MAT) Sensor
is at top dead center. The ECU also uses this signal to
calculate engine speed. For more information on the The Manifold Air Temperature (MAT) sensor (B13)
crankshaft position sensor, see Electrical Component is a variable resistance temperature sensor. The
Specifications. (Group 9015-20.) resistance is sensed at pins D1 (Y2) and D3 (N3). The
ECU uses the manifold air temperature to adjust fuel
Camshaft Position Sensor—850J delivery and derate the engine when the temperature
becomes too high. The ECU broadcasts the MAT
The camshaft position sensor (B15) is an inductive across the CAN to the CMU and TCU. The MAT is
pickup located in the high pressure fuel pump. The used by the TCU in calculating proportional fan speed.
signal is produced by notches on the auxiliary gear of See Transmission Control Unit (TCU) Circuit Theory of
the high pressure fuel pump and is sensed by the ECU Operation for more information on the proportional fan
at pins X1 and W3. The ECU uses this signal to circuit. (Group 9015-15.) For more information on the
determine which cylinder is approaching top dead MAT sensor, see Electrical Component Specifications.
center. For more information on the camshaft position (Group 9015-20.)
sensor, see Electrical Component Specifications.
(Group 9015-20.)

Continued on next page MF82180,000002D –19–01SEP04–3/5

TM2260 (07JAN06) 9015-15-7 750J, 850J Crawler

010706
PN=147
 Sub-System Diagnostics

The manifold air temperature can cause an engine fuel sensed at pins C3 (X3) and D3 (P2). The ECU
derate condition if it reaches 190°F (88°C). The ECU broadcasts the fuel temperature across the CAN to the
will derate fuel 2% per minute up to 20%. If the CMU. For more information on the fuel temperature
manifold air temperature falls below the derate sensor, see Electrical Component Specifications.
temperature, the ECU will recovery fuel delivery 2% (Group 9015-20.)
per minute until power is fully restored.
Engine Oil Pressure Sensor
Water In Fuel (WIF) Sensor
The engine oil pressure sensor (B23) is a variable
The Water In Fuel (WIF) Sensor (B48) is a variable resistance pressure sensor. Power is applied to the
resistance sensor. The WIF sensor measures the sensor from ECU pin E2 (P1) and resistance is sensed
amount of resistance of the fluid in the water separator at pins F3 (T2) and D3 (P2). The ECU uses the engine
bowl. Since water is a better conductor of electricity oil pressure sensor to monitor the oil pressure and
than fuel is, if water is present in the separator bowl, apply derate conditions when needed. The ECU
the ECU senses a resistance drop between pins F2 broadcasts the engine oil pressure across the CAN to
(Y3) and D3 (N3). For more information on the WIF the CMU. For more information on the engine oil
9015
15 sensor, see Electrical Component Specifications. pressure sensor, see Electrical Component
8 (Group 9015-20.) Specifications. (Group 9015-20.)

The water in fuel sensor can cause an engine fuel The engine oil pressure can cause an engine fuel
delivery derate if water is sensed in the fuel. If the delivery derate if the pressure falls below the first
ECU senses too low of resistance, the ECU will derate threshold pressure. The ECU will derate the fuel
fuel delivery by 40% per minute. Once the problem is delivery by 20% per minute up to 40% if the pressure
corrected, fuel delivery will be recovered to full power. falls below the first threshold pressure. If the pressure
falls below the second threshold pressure, the ECU
Fuel Rail Pressure Sensor—850J will derate fuel delivery by 40% per minute up to 60%.
If the oil pressure increases past the first threshold
The fuel rail pressure sensor (B10) is a variable pressure, the ECU will recover fuel delivery by 20%
resistance pressure sensor. The ECU supplies the per minute until full power is reached.
sensor 5 volts at pin R3 and resistance is sensed at
pins P3 and R1. The ECU uses the fuel rail pressure Injection Pump Solenoid—750J
to monitor the fuel system pressure and apply derate
conditions when needed. For more information on the Located on the end of the injection pump, the
fuel rail pressure sensor, see Electrical Component injection pump solenoid (Y18) controls the
Specifications. (Group 9015-20.) movement of the pump control valve. This controls the
timing and quantity of fuel delivered to the engine. The
The fuel rail pressure sensor can cause an engine fuel ECU applies an electrical signal from pins A3 and K2
delivery derate if a problem in the harness wiring or to the solenoid. When the ECU supplies no current to
sensor occurs. If the ECU senses a value that is out of the solenoid, the valve does not move. Thus, the
valid range, the ECU will derate fuel delivery by 50%. injection pump delivers no fuel. When the ECU
Once the problem is corrected, fuel delivery will be supplies current to the solenoid, the pump control
recovered to full power. valve closes off the high injection chamber, which
allows the fuel in the chamber to reach injection
Fuel Temperature Sensor pressure. The quantity of fuel is determined by the
ECU based on the sensor inputs.
The fuel temperature sensor (B11) is a variable
resistance temperature sensor. The resistance is

Continued on next page MF82180,000002D –19–01SEP04–4/5

TM2260 (07JAN06) 9015-15-8 750J, 850J Crawler

010706
PN=148
 Sub-System Diagnostics

High Pressure Fuel Pump Solenoids—850J See Pump Control Valves (PCVs) for more
information. (CTM255.)
The high pressure fuel pump solenoids (Y12, Y13)
are located on the high pressure fuel pump. The ECU Electronic Injectors—850J
applies a common voltage at pin J1 to the solenoids
and controls the ground signals at pins K2 and K3 to The ECU controls the injection timing and the amount
regulate delivery of fuel to the high pressure common of fuel injected by energizing and de-energizing the
rail (HPCR). When the solenoids are energized, fuel is electronic injectors (Y21—Y26). For more information
allowed to discharge from the fuel outlet on the high on the electronic injectors, see Electronic Injector (EI)
pressure fuel pump to the HPCR. Operation. (CTM255.)

MF82180,000002D –19–01SEP04–5/5

9015
15
9

TM2260 (07JAN06) 9015-15-9 750J, 850J Crawler

010706
PN=149
 Sub-System Diagnostics

Transmission Control Unit (TCU) Circuit Theory of Operation

T204493 –19–07JAN05

Transmission Control Unit (TCU) Circuit Theory of Operation (Inputs)

MF82180,000002E –19–06OCT05–1/11

TM2260 (07JAN06) 9015-15-10 750J, 850J Crawler

010706
PN=150
 Sub-System Diagnostics
T204494 –19–07JAN05

Transmission Control Unit (TCU) Circuit Theory of Operation (Feedback)

MF82180,000002E –19–06OCT05–2/11

TM2260 (07JAN06) 9015-15-11 750J, 850J Crawler

010706
PN=151
 Sub-System Diagnostics
T204495 –19–19NOV04

Transmission Control Unit (TCU) Circuit Theory of Operation (Outputs)

MF82180,000002E –19–06OCT05–3/11

TM2260 (07JAN06) 9015-15-12 750J, 850J Crawler

010706
PN=152
 Sub-System Diagnostics

Ignition power is supplied to the TCU through the The bussed 5 V sensor connector receives 5 volt
TCU/MDU relay (K8). When the key switch is in the sensor supply from TCU pin 3 on connector X1 and
on or start position, the key switch supplies accessory distributes it to various sensors. The bussed ground
power to TCU/MDU relay pin 86, energizing the relay. sensor connector provides ground it receives from
Ignition power is then supplied through TCU 10 A fuse TCU pin 22 on connector X1 to various sensors.
(F5) to TCU pin F1 on TCU 18-pin connector (X2).
If this sensor causes a DTC, the forward and reverse
When the engine is started, the TCU keeps the functions will be disabled.
transmission in neutral, regardless of the Transmission
Control Lever (TCL) position. If the TCL is not in Neutral Start Switch (S20)
neutral, the TCU requires the TCL be placed in neutral
first before forward or reverse can be selected. The neutral start switch (S20) is located in the TCL.
When the TCL is in the neutral position, the neutral
The TCU monitors the neutral start switch (S3) at pin start switch is closed and applies ground to TCU pin
E2 on connector X2 and park lock lever switch (S20) 14 on connector X1. TCU pin 14 on connector X1
at pins E2 on TCU 30-pin connector (X1) and B3 on loses ground when the TCL is moved into either the
9015
connector X2 for starting purposes. For more forward or reverse position. 15
information on the starting circuit, see Starting and 13
Charging Circuit Theory of Operation. (Group If this sensor causes a DTC, the forward and reverse
9015-15.) functions will be disabled.

The TCU communicates with the Engine Control Unit Steer Sensor (B33)
(ECU) (A2) and CAN Monitor Unit (CMU) (A3) over
the Controller Area Network (CAN). The TCU The steer sensor (B33) is located on a rotating shaft
broadcasts certain conditions to the MDU, including if on the TCL. The steer sensor is a rotary sensor
a TCU Diagnostic Trouble Code (DTC) is active to without contacts which receives 5 volt power from the
activate the DTC indicator light. The MDU broadcasts bussed 5 V sensor connector (X6) and reference
the transmission oil temperature for transmission ground from bussed ground sensor connector (X7).
protection. For more information on CAN When the TCL is moved left or right, the rotating shaft
communication, see Controller Area Network (CAN) turns a keyed slot on the sensor and the sensor
Theory of Operation. (Group 9015-15.) applies a varied resistance to TCU pin 24 on
connector X1. The resistance of this sensor at certain
FNR Sensor (B32) TCL positions is stored in the TCU during calibration.

The FNR sensor (B32) is located on a rotating shaft The bussed 5 V sensor connector receives 5 volt
on the TCL. The FNR sensor is a rotary sensor without sensor supply from TCU pin 3 on connector X1 and
contacts which receives 5 volt power from the bussed distributes it to various sensors. The bussed ground
5 V sensor connector (X6) and reference ground sensor connector provides ground it receives from
from bussed ground sensor connector (X7). When TCU pin 22 on connector X1 to various sensors.
the TCL is moved into forward or reverse, the rotating
shaft turns a keyed slot on the sensor and the sensor If this sensor causes a DTC, the steer functions will be
applies a varied resistance to TCU pin 23 on disabled and the maximum machine speed will be
connector X1. The resistance of this sensor at certain limited to 4.1 km/h (2.52 mph).
TCL positions is stored in the TCU during calibration.

Continued on next page MF82180,000002E –19–06OCT05–4/11

TM2260 (07JAN06) 9015-15-13 750J, 850J Crawler

010706
PN=153
 Sub-System Diagnostics

Decelerator Sensor (B1) Transmission Speed Control Switch (B34)

The decelerator sensor (B1) is located on a rotating The transmission speed control switch (B34)
shaft on the decelerator pedal. The decelerator sensor increases and decreases ground speed. The
is a rotary sensor without contacts which receives 5 transmission speed control switch receives 5 volt
volt power from the bussed 5 V sensor connector power from the bussed 5 V sensor connector (X6)
(X6) and reference ground from bussed ground and reference ground from bussed ground sensor
sensor connector (X7). When the decelerator pedal is connector (X7). When neither the up or down buttons
pressed down, the rotating shaft turns a keyed slot on are pressed, the transmission speed control switch
the sensor and the sensor applies a varied resistance applies a voltage to TCU pin 17 on connector X1.
to TCU pin 18 on connector X1. The resistance of this When either the up or down buttons are pressed, a
sensor at certain decelerator positions (including brake different voltage is applied to the TCU. The values of
positions) is stored in the TCU during calibration. the up, down, and null voltages are stored in the TCU
during calibration.
The bussed 5 V sensor connector receives 5 volt
sensor supply from TCU pin 3 on connector X1 and When either the up or down buttons are pressed, the
9015
15 distributes it to various sensors. The bussed ground TCU broadcasts the transmission speed over CAN to
14 sensor connector provides ground it receives from the CAN Monitor Unit (CMU). The CMU displays the
TCU pin 22 on connector X1 to various sensors. transmission speed in the display window.

If this sensor causes a DTC, the maximum machine The bussed 5 V sensor connector receives 5 volt
speed will be limited to creep. If this sensor causes a sensor supply from TCU pin 3 on connector X1 and
calibration code, the TCU default values will be used distributes it to various sensors. The bussed ground
for this sensor. sensor connector provides ground it receives from
TCU pin 22 on connector X1 to various sensors.
Decelerator Mode Switch (S7)
If this sensor causes a DTC, the maximum machine
The decelerator mode switch (S7) is a two position speed will be limited to 4.1 km/h (5.52 mph).
rocker switch that changes the function of the
decelerator pedal. When the switch is in the engine Blade Angle Operation (PAT Machines)
position, ground is applied from pin 2 to TCU pin 10 on
connector X1. When the decelerator is pressed down The blade angle switch (S4) angles the blade on
in this mode, engine speed will be decreased and Power Angle Tilt (PAT) machines. The blade angle
effectively decrease ground speed. switch receives 5 volt power from the bussed 5 V
sensor connector (X6) and reference ground from
When the switch is placed in the transmission position, bussed ground sensor connector (X7). When
ground is removed from TCU pin 10 on connector. The neither the left or right buttons are pressed, the blade
TCU sees an open circuit and broadcasts the angle switch applies a voltage to TCU pin 19 on
decelerator mode switch state over CAN to the CAN connector X1. When either the left or right buttons are
Monitor Unit (CMU). The CMU will illuminate the no pressed, a different voltage is applied to the TCU. The
engine decel indicator light. When the decelerator is values of the left, right, and null voltages are stored in
pressed down in the transmission mode, transmission the TCU during calibration.
speed will decrease but engine speed will remain
constant.

Continued on next page MF82180,000002E –19–06OCT05–5/11

TM2260 (07JAN06) 9015-15-14 750J, 850J Crawler

010706
PN=154
 Sub-System Diagnostics

The bussed 5 V sensor connector receives 5 volt 20 on connector X1. For more information on the
sensor supply from TCU pin 3 on connector X1 and motor speed sensors, see Electrical Component
distributes it to various sensors. The bussed ground Specifications. (Group 9015-20.)
sensor connector provides ground it receives from
TCU pin 22 on connector X1 to various sensors. The bussed 5 V sensor connector receives 5 volt
sensor supply from TCU pin 3 on connector X1 and
When the left button is pressed, the TCU interprets the distributes it to various sensors. The bussed ground
voltage as being a blade angle left command and sensor connector provides ground it receives from
applies voltage from pin 24 on connector X2 to the TCU pin 22 on connector X1 to various sensors.
blade angle solenoid left (top) (Y7). The blade angle
solenoid left (top) will energize and shift the valve If one of these sensors causes a DTC, the tracker
spool and allow pilot oil to pass to the left blade angle function will be disabled and mistracking will occur.
pilot inlet on the angle section of the hydraulic control
valve. Hydrostatic Charge Pressure Sensor (B4)

When the right button is pressed, the TCU interprets The hydrostatic charge pressure sensor (B4)
9015
the voltage as being a blade angle right command and provides the TCU with a variable resistance based on 15
applies voltage from pin 20 on connector X2 to the charge pressure. The charge pressure sensor receives 15
blade angle solenoid right (bottom) (Y8). The blade 5 volt power from the bussed 5 V sensor connector
angle solenoid right (bottom) will energize and shift the (X6) and reference ground from bussed ground
valve spool and allow pilot oil to pass to the right blade sensor connector (X7). The TCU senses resistance
angle pilot inlet on the angle section of the hydraulic at pin 1 on connector X1. The charge pressure can be
control valve. read on the CAN Monitor Unit (CMU). For more
information on the charge pressure sensor, see
If the blade angle switch causes a DTC, both right and Electrical Component Specifications. (Group 9015-20.)
left blade angle functions will be disabled. If either
blade angle solenoid causes a DTC, the corresponding The bussed 5 V sensor connector receives 5 volt
direction will be disabled. sensor supply from TCU pin 3 on connector X1 and
distributes it to various sensors. The bussed ground
For more information on the blade angle operation, sensor connector provides ground it receives from
see Blade Angle Operation. (Group 9025-05.) TCU pin 22 on connector X1 to various sensors.

Motor Speed Sensor (B2 and B3) If the charge pressure drops below 1310 kPa (13.1
bar) (190 psi) for more than 10 seconds while the
Motor speed sensor right (B3) and motor speed engine is running, machine speed will ramp down and
sensor left (B2) are feed back devices used by the the machine will stop. Forward and reverse functions
TCU to determine actual track speed. The sensors will be disabled and the engine speed will be limited to
enable the TCU to control tracking, allowing the slow idle. Once the fault is fixed, the key switch must
machine to move in the desired motion. The TCU be cycled to clear the code.
monitors track speeds and slows the faster track to
match the slower track. Each sensor receives 5 volt If the charge pressure exceeds 3447 kPa (34.5 bar)
power from the bussed 5 V sensor connector (X6) (500 psi) and the transmission oil temperature is above
and reference ground from bussed ground sensor 32°C (90°F) or if the charge pressure exceeds 5170
connector (X7). Motor speed sensor right applies a kPa (51.7 bar) (750 psi) at any temperature, engine
pulsed signal at TCU pin 21 on connector X1. Motor speed will be limited to 1200 rpm. Once the fault is
speed sensor left applies a pulsed signal at TCU pin fixed, the key switch must be cycled to clear the code.

Continued on next page MF82180,000002E –19–06OCT05–6/11

TM2260 (07JAN06) 9015-15-15 750J, 850J Crawler

010706
PN=155
 Sub-System Diagnostics

Brake Pressure Sensor (B35) Hydrostatic Pressure Sensor Left (B6)

The brake pressure sensor (B35) provides the TCU The hydrostatic pressure sensor left (B6) provides
with a variable resistance based on brake pressure. the TCU with a variable resistance based on the left
The brake pressure sensor receives 5 volt power from hydrostatic system pressure. The left hydrostatic
the bussed 5 V sensor connector (X6) and reference pressure sensor receives 5 volt power from the
ground from bussed ground sensor connector (X7). bussed 5 V sensor connector (X6) and reference
The TCU senses resistance at pin 16 on connector X1. ground from bussed ground sensor connector (X7).
The brake pressure can be read on the CAN Monitor The TCU senses resistance at pin 2 on connector X1.
Unit (CMU). For more information on the brake The system pressure can be read on the CAN Monitor
pressure sensor, see Electrical Component Unit (CMU). For more information on the hydrostatic
Specifications. (Group 9015-20.) pressure sensor, see Electrical Component
Specifications. (Group 9015-20.)
The bussed 5 V sensor connector receives 5 volt
sensor supply from TCU pin 3 on connector X1 and The bussed 5 V sensor connector receives 5 volt
distributes it to various sensors. The bussed ground sensor supply from TCU pin 3 on connector X1 and
9015
15 sensor connector provides ground it receives from distributes it to various sensors. The bussed ground
16 TCU pin 22 on connector X1 to various sensors. sensor connector provides ground it receives from
TCU pin 22 on connector X1 to various sensors.
If the brake pressure exceeds 345 kPa (3.5 bar) (50
psi) when park brake is engaged and engine is Pump Pressure Control Pilot (PCP) (B7 and B8)
running, or if brake pressure falls below 1379 kPa (14
bar) (200psi) when park brake is disengaged and Pump Pressure Control Pilot (PCP) rear (B7) and
engine is running a DTC becomes active and pump Pressure Control Pilot (PCP) front (B8) are
maximum machine speed will be limited to creep. TCU output devices that control the displacement of
Once either of these faults is fixed, the key switch the rear and front pumps, respectively. When the TCU
must be cycled to clear the code. receives input from the input sensors, the TCU applies
positive or negative voltage to the PCPs to control
Hydrostatic Pressure Sensor Right (B5) machine movement through moving electromagnetic
valves and creating differential control pressures,
The hydrostatic pressure sensor right (B5) provides varying pump displacement. For forward movement,
the TCU with a variable resistance based on the right the TCU will increase voltage to increase pump
hydrostatic system pressure. The right hydrostatic displacement and decrease voltage to decrease pump
pressure sensor receives 5 volt power from the displacement. For reverse movement, the TCU will
bussed 5 V sensor connector (X6) and reference increase negative voltage (i.e. -3.5 V to -4.0 V) to
ground from bussed ground sensor connector (X7). increase pump displacement and decrease negative
The TCU senses resistance at pin 15 on connector X1. voltage (i.e. -3.5 V to -3.0 V) to decrease pump
The system pressure can be read on the CAN Monitor displacement. The TCU also applies the voltage to the
Unit (CMU). For more information on the hydrostatic rear PCP proportional to the front PCP in steering and
pressure sensor, see Electrical Component counter-rotation commands. For more information on
Specifications. (Group 9015-20.) PCP operations, see Pump Pressure Control Pilot
(PCP) Operation. (Group 9026-05.)
The bussed 5 V sensor connector receives 5 volt
sensor supply from TCU pin 3 on connector X1 and If one of these component causes a DTC, either the
distributes it to various sensors. The bussed ground forward or reverse functions will be disabled.
sensor connector provides ground it receives from
TCU pin 22 on connector X1 to various sensors.

Continued on next page MF82180,000002E –19–06OCT05–7/11

TM2260 (07JAN06) 9015-15-16 750J, 850J Crawler

010706
PN=156
 Sub-System Diagnostics

Motor Shift Solenoids (Y3 and Y4) If these solenoids cause a DTC, the forward and
reverse functions will be disabled.
The TCU applies a frequency-varied signal to the
motor shift solenoid left (Y3) and motor shift Proportional Fan
solenoid right (Y4) to control the displacement of the
hydrostatic motors. As transmission speed increases, The proportional fan controls the cooling capacity of
the TCU applies a higher frequency signal to the motor the cooling package by varying the speed of the fan.
shift solenoids to reduce the motor displacement. The The TCU automatically controls the speed of the fan
solenoids movement along with the motor by monitoring engine coolant temperature,
displacement control valve (MDCV) to control motor transmission oil temperature, ambient air temperature,
displacement. The TCU will also reduce voltage to manifold air temperature, and hydraulic oil temperature
Pump Pressure Control Pilot (PCP) rear (B7) and (if equipped with hydraulic oil cooler). The hydrostatic
pump Pressure Control Pilot (PCP) front (B8) as oil temperature sensor (B21) and hydraulic oil
motor displacement decreases for a smooth temperature sensor (B20) are hard-wired to the CMU
acceleration. For more information on the motor shift and broadcast across CAN to the TCU. The engine
solenoids in motor operation, see Hydrostatic Motor coolant temperature sensor (B12), manifold air
9015
Operation. (Group 9026-05.) For more information on temperature sensor (B13), and ambient air 15
the solenoids, see Electrical Component temperature sensor (B16) are hard-wired to the 17
Specifications. (Group 9015-20.) Engine Control Unit (ECU) (A2) and broadcaster
across CAN to the TCU.
If one of these components causes a DTC, the
maximum machine speed will be limited to 4.06 km/h NOTE: Hydraulic oil temperature is only used to
(2.52 mph). calculate fan speed if machine is equipped
with a hydraulic oil cooler. If machine is
Park Brake Solenoids (Y2 and Y15) equipped with a hydraulic oil cooler, the option
must be set in the CAN Monitor Unit (CMU).
Park brake solenoid 1 (Y2) and park brake solenoid See CAN Monitor Unit (CMU) Circuit Theory of
2 (Y15) control the charge pressure which releases the Operation for more information. (Group
park brake. When the engine is running and the park 9015-15.)
lock lever is placed in the off (down) position, the park
lock lever switch (S20) applies ground to TCU pin 11 The TCU applies a varied voltage from pin 14 on
on connector X1. If the decelerator is not fully connector X2 to the hydraulic fan proportional relief
depressed to the brake stop, the TCU will apply power solenoid (Y5 or Y5A). The voltage applied to the
from pin 15 on connector X2 to the park brake solenoid is inversely proportional to the fan speed; as
solenoids, energizing both solenoids. Charge pressure more voltage is applied to the solenoid, more oil
oil will then be allowed to release the park brake. The bypasses the fan motor, slowing the fan speed down.
park brake solenoid will be de-energized if the engine As the voltage decreases towards 0 V, less oil is
quits running, the park lock lever is raised, or if the bypassing the fan motor and the fan will accelerate
decelerator pedal is pressed into the brake range. For towards full speed.
more information on the park brake, see Park Brake
Valve Operation. (Group 9026-05.)

Continued on next page MF82180,000002E –19–06OCT05–8/11

TM2260 (07JAN06) 9015-15-17 750J, 850J Crawler

010706
PN=157
 Sub-System Diagnostics

NOTE: The TCU can also receive a hydraulic corresponding temperature, linear to the points
proportional fan speed command from the listed.
CMU for testing purposes. See CAN Monitor
Unit (CMU) Circuit Theory of Operation for Multiplier Manifold Air Temperature
more information. (Group 9015-15.) 0.0 50°C
122°F
The TCU uses certain reference values for determining 0.5 55°C
fan speed. The first set of values the TCU interprets is 131°F
the hydraulic oil temperature, engine coolant 1.0 60°C
temperature, and the transmission oil temperature. The 140°F
TCU assigns a solenoid current based on the highest
fluid temperature. If the highest temperature is below Multiplier Manifold Air
Temperature-Ambient Air
70°C (158°F), the TCU will assign a solenoid current
Temperature
value of 650 mA (minimum speed). If the highest
0.0 21°C
temperature is above 100°C (212°F), the TCU will
70°F
assign a current value of 0 mA (maximum speed). If
9015 0.5 28°C
15 the highest temperature falls within those two points,
82.4°F
18 the TCU will assign a current value in linear
1.0 35°C
relationship between to those two points.
95°F
Proportional Relief Solenoid Temperature
Current If the manifold air temperature is 60°C (140°F) or
650 mA 70°C higher, the fan will operate at 100% of the rated speed
158°F based on fluid and differential air temperature. See
0 mA 100°C Hydraulic Fan Drive Operation for more information.
212°F (Group 9026-05.)

Once the TCU determines a solenoid current based on Hydraulic Fan Reversing Solenoid (Y6) (Optional)
fluid temperatures, the TCU applies two multipliers to
this value. The first is proportional to the manifold air The reverse fan function reverses the fan direction to
temperature and the second is proportional to the purge the cooling system of debris. The reverse fan
manifold air temperature minus the ambient air function can be operated in manual and automatic
temperature. The three values are multiplied together mode. Automatic mode is the default and will
and the TCU applies the calculated current to the automatically reverse directions unless manual mode
hydraulic fan proportional relief valve solenoid. is activated. The frequency at which the fan will
reverse is adjustable in the CAN Monitor Unit (CMU).
NOTE: Only three points are shown for simplicity. See CAN Monitor Unit (CMU) Circuit Theory of
Multipliers exist at 0.1 increments and have a Operationfor more information. (Group 9015-15.)

Continued on next page MF82180,000002E –19–06OCT05–9/11

TM2260 (07JAN06) 9015-15-18 750J, 850J Crawler

010706
PN=158
 Sub-System Diagnostics

Manual mode is activated by pressing the fan the TCU applies power from pin 5 on connector X2,
reversing switch (S23) into the momentary position. the hydrostatic oil cooler bypass solenoid energizes
In the momentary position, ground will be applied to and oil bypasses the cooler. This functionality is
CMU pin N on connector X5. The CMU then lights the utilized during warmup and when the oil cooler
reverse fan indicator light and broadcasts this becomes plugged. When the TCU removes power
message over CAN to the TCU. Once the manual from pin 5 on connector X2, the solenoid de-energizes
reverse cycle is complete, the reverse fan indicator and allows oil to flow to the oil cooler. The TCU is
light will become unlit and the function will return to dependant on the oil temperature measured by the
automatic mode. hydrostatic oil temperature sensor (B21), which is
hard-wired to the CMU and broadcast across CAN to
When the internal timer in the TCU reaches full count the TCU, to control the hydrostatic oil cooler bypass
or if manual mode is selected and the FNR lever is in solenoid. For more information on the hydrostatic oil
neutral or reverse positions, the TCU will begin the cooler bypass, see Oil Cooler and Reservoir Bypass
reversing sequence. The reversing function works in Operation. (Group 9026-05.)
conjunction with the proportional fan solenoid. The
FLC ramps up the proportional fan solenoid current to If this solenoid causes a DTC, hydrostatic oil will
9015
slow the fan down to minimum fan speed always flow through the oil cooler. 15
(approximately 500 rpm). Once the fan speed is at a 19
minimum, the TCU will apply power from pin 13 on Hydrostatic Oil Reservoir Bypass Solenoid (Y17)
connector X2 to the hydraulic fan reversing solenoid
(Y6), reversing the fan drive direction. Once power is Hydrostatic oil reservoir bypass solenoid (Y17) is a
applied to the reverse fan solenoid, the TCU will ramp variable solenoid which controls the case drain oil flow
down the current applied to the hydraulic fan to the hydrostatic oil reservoir. The TCU controls the
proportional relief solenoid (Y5) until maximum fan hydrostatic oil reservoir bypass solenoid by supplying
speed (approximately 1900 rpm) is reached. The TCU power from pin 16 on connector X2. This solenoid
will operate the fan at maximum speed for 15 seconds works along with the hydrostatic oil cooler bypass
then ramp up the hydraulic fan proportional relief solenoid (Y14) to control hydrostatic oil temperature.
solenoid current until the fan is at minimum speed. For more information on the hydrostatic oil cooler
Once the fan is slowed down to minimum speed, the bypass, see Oil Cooler and Reservoir Bypass
TCU will remove power from the hydraulic fan Operation. (Group 9026-05.)
reversing solenoid then ramp hydraulic fan proportional
relief solenoid current down to the normal current for If this solenoid causes a DTC, case drain oil pressure
the normal operating fan speed. will rise and overcome the internal spring force of the
solenoid and drain to tank.
The reverse fan sequence cannot be activated again
for one minute after it was completed. If the reverse Back-Up Alarm (H6)
fan was in automatic mode prior to manual mode
being activated, the timer is stopped then started again When reverse direction is selected, the TCU will apply
after the reverse fan sequence is completed. See Fan power from TCU pin 19 on connector X2 to the
Drive Theory for more information. (Group 9025-05.) backup alarm (H3), causing it to sound.

Hydrostatic Oil Cooler Bypass Solenoid (Y14)

Hydrostatic oil cooler bypass solenoid (Y14)

controls the oil flow to the hydrostatic oil cooler. When

Continued on next page MF82180,000002E –19–06OCT05–10/11

TM2260 (07JAN06) 9015-15-19 750J, 850J Crawler

010706
PN=159
 Sub-System Diagnostics

Engine Speed Control either direction, it applies a variable voltage to TCU pin
14 on connector X1. The TCU matches the given
The TCU receives the desired engine speed voltage with the values recorded during calibration and
commands and broadcasts the throttle command over accordingly broadcasts the engine speed command as
CAN to the Engine Control Unit (ECU) (A2). The a percentage.
ECU responds by increasing or decreasing engine
speed. The ECU broadcasts the engine speed from If machine is started and the TCU does not measure
the crankshaft position sensor (B14) and the slow idle, the engine speed control sensor must be
requested throttle command back to the TCU for rotated to slow idle before the engine speed can be
antistall purposes. If the load on the engine is too increased.
great and the engine begins to pull down, the TCU will
decrease pump displacement to prevent the engine The bussed 5 V sensor connector receives 5 volt
from stalling. The TCU uses the engine speed to sensor supply from TCU pin 3 on connector X1 and
determine the pump speeds. For more information on distributes it to various sensors. The bussed ground
the ECU, see Engine Control Unit (ECU) Circuit sensor connector provides ground it receives from
Theory of Operation. (Group 9015-15.) TCU pin 22 on connector X1 to various sensors.
9015
15
20 The engine speed control switch (S22) is a If this sensor causes a DTC, engine speed will be
potentiometer which receives 5 volt power from the limited to slow idle and machine speed will be limited
bussed 5 V sensor connector (X6) and reference to creep. If this sensor causes a calibration code, the
ground from bussed ground sensor connector (X7). TCU default values will be used for this sensor.
When the engine speed control sensor is turned in

MF82180,000002E –19–06OCT05–11/11

TM2260 (07JAN06) 9015-15-20 750J, 850J Crawler

010706
PN=160
 Sub-System Diagnostics

CAN Monitor Unit (CMU) Circuit Theory of Operation

T204272 –19–19NOV04

CAN Monitor Unit (CMU) Circuit Theory of Operation

MF82180,000002F –19–01SEP04–1/40

TM2260 (07JAN06) 9015-15-21 750J, 850J Crawler

010706
PN=161
 Sub-System Diagnostics

The CAN Monitor Unit (CMU) (A3) receives battery illuminate the hydraulic fan oil filter restriction indicator
power from the CMU battery power 5 A fuse (F28). light.
The CMU receives ignition power from the CMU
ignition power 5 A fuse (F4). Hydrostatic Oil Charge Filter Restriction Switch
(B25)
Fuel Level Sensor (B19)
The hydrostatic oil charge filter restriction switch
The fuel level sensor (B19) is a float arm type (B25) is a normally open switch that closes once the
sensor. As the fuel level falls, the float arm moves with hydrostatic oil charge filter becomes restricted. Ground
the fuel level and turns a rheostat. The resistance is is applied to pin J on connector X5. The CMU will then
sensed by the CMU at pins F and N. The CMU then illuminate the hydrostatic oil charge filter restriction
converts this resistance into a gauge position. indicator light.

Monitor Alarm (H2) Hydraulic Oil Temperature Sensor (B20)

The monitor alarm (H2) is sounded during monitor The hydraulic oil temperature sensor (B20) provides
9015
15 self test, during certain monitor selections, and when the CMU with a variable resistance based on hydraulic
22 the stop light is illuminated. The CMU provides power oil temperature. The CMU senses resistance at pin K
at pin M on connector X4 and ground at pin D on on connector X5. The CMU converts the sensed
connector X4. resistance into a gauge position. The hydraulic oil
temperature is broadcast over CAN to the TCU for
Reversing Fan calculation of proportional fan speed (if equipped with
optional oil cooler). For more information on the
When the fan reversing switch (S23) is pressed into hydraulic oil temperature sensor, see Electrical
its momentary position, ground is applied at pin N on Component Specifications. (Group 9015-20.)
connector X5. The CMU will broadcast the manual
reverse fan command over CAN to the TCU, which will Hydrostatic Oil Temperature Sensor (B21)
carry out the command. Other settings are available in
the CMU menu structure for test purposes, these The hydrostatic oil temperature sensor (B21)
commands are also broadcast over CAN to the TCU provides the CMU with a variable resistance based on
for execution. hydrostatic oil temperature. The CMU senses
resistance at pin A on connector X5. The CMU
Hydraulic Oil Filter Restriction Switch (B23) converts the sensed resistance into a gauge position.
The hydrostatic oil temperature is broadcast over CAN
The hydraulic oil filter restriction switch (B23) is a to the TCU for calculation of proportional fan speed.
normally open switch that closes once the hydraulic oil For more information on the hydrostatic oil temperature
filter becomes restricted. Ground is applied to pin F on sensor sensor, see Electrical Component
connector X5. The CMU will then illuminate the Specifications. (Group 9015-20.)
hydraulic oil filter restriction indicator light.
Air Filter Restriction Switch (B22)
Hydraulic Fan Oil Filter Restriction Switch (B24)
The air filter restriction switch (B22) is a normally
The hydraulic fan oil filter restriction switch (B24) open switch that closes once the engine air filter
is a normally open switch that closes once the becomes restricted. Ground is applied to pin E on
hydraulic fan oil filter becomes restricted. Ground is connector X5. The CMU will then illuminate the engine
applied to pin G on connector X5. The CMU will then air filter restriction indicator light.

Continued on next page MF82180,000002F –19–01SEP04–2/40

TM2260 (07JAN06) 9015-15-22 750J, 850J Crawler

010706
PN=162
 Sub-System Diagnostics

Winch Oil Pressure Switch (B26) The CMU has a menu-based information structure. To
reach the main menu, press the MENU button. Press
The winch oil pressure switch (B26) is a normally BACK to go back one screen, press NEXT to scroll
open switch that closes once the winch oil pressure down the menu, and press SELECT to select the
becomes too low. Ground is applied to pin H on highlighted item. Selecting an item on the main menu
connector X5. The CMU will then illuminate the winch will bring up the appropriate submenu. Each submenu
oil pressure indicator light. in this referenced with a two number reference (X-X).
The first number references the main menu item
With the key switch in the off position, the SELECT number and the second number references the
button can be pressed to “wake up” the monitor. As submenu item number. These instructions will work for
long as the SELECT button is pressed, the monitor will all submenus unless noted.
display machine hours, battery voltage, and fuel level.
The service menu allows access to addition items not
The center of the CMU is a liquid crystal display (LCD) available in the normal menu system. These items are
which shows machine information. The home screen marked with a footnote. To enter the service menu,
contains FNR position, transmission speed, engine press the MENU button and hold it down for 5
9015
speed, hourmeter, battery voltage, and charge seconds. 15
pressure. To cycle between hourmeter, charge 23
pressure and battery voltage, press the NEXT button.

MF82180,000002F –19–01SEP04–3/40

CMU Main Menu

1. Codes (1)
2. Machine Settings (2) Main Menu 1/6
3.
4.
Diagnostics (3)
Monitor Settings (4)
1-Codes
5. Calibration1 (5) 2-Machine Settings
6. TCU Diagnostics1 (6)
3-Diagnostics
4-Monitor Settings
–19–28JAN05
5-Calibration
6-TCU Diagnostics
T205939

1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–4/40

TM2260 (07JAN06) 9015-15-23 750J, 850J Crawler

010706
PN=163
 Sub-System Diagnostics

Codes (1)

Codes 1/3
1-Active Codes
2-Stored Codes

–19–10NOV03
3-Clear Codes

T196108
MF82180,000002F –19–01SEP04–5/40

1. Active Codes (1-1)

9015 This menu displays the diagnostic trouble codes
15
24
(DTCs) that are currently active on the machine. A
detailed description of the code, the source controller
Active Codes 1/3
(the controller which is reporting a problem), and the Right Turn Lts
SPN.FMI number. Press NEXT to display the next
High Current

–19–30SEP03
code or BACK to get to (1). Press SELECT to view
more information about the DTC. The next screen will
show information on what to check to fix the code. FLC 2370.6

T193355
MF82180,000002F –19–01SEP04–6/40

2. Stored Codes (1-2)

This menu displays the DTCs that are stored in
memory. A detailed description of the code, the source
controller (the controller which is reporting a problem),
Stored Codes 2/3
and the SPN.FMI number. Press NEXT to display the CAN Comm
next code or BACK to get to (1). Press SELECT to
Lost for TCU

–19–08OCT03
view more information about the DTC. The next screen
will show the number of occurrences, when the code
first and last appeared and the sensor reading at that CMU 2003.9
time. Press SELECT to view information on what to
T193356
check to fix the code.
3. Clear Codes1 (1-3)
This menu will clear all stored DTCs on the machine.
Press SELECT to clear the codes or BACK to get back
to (1).
Stored Codes 2/3
Occurrences: 7
–19–23SEP03

First: Last:
118.0 hrs 119.5 hrs
T195058

1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–7/40

TM2260 (07JAN06) 9015-15-24 750J, 850J Crawler

010706
PN=164
 Sub-System Diagnostics

Machine Settings (2)

Machine Settings 1/5

1-Job Timer
2-Track Info
3-Controller Info
4-Trans Settings

–19–28JAN05
5-Reversing Fan
6-Auxiliary Cooler

T205940
9015
15
25

MF82180,000002F –19–01SEP04–8/40

1. Job Timer (2-1)

This menu controls a continually running job timer.
Press SELECT reset the job timer or press BACK to
get back to (2).
Job Timer
SELECT to Reset

–19–05AUG03
BACK to Exit

0.0 hours

T193360
MF82180,000002F –19–01SEP04–9/40

2. Track Info (2-1)

This menu displays track information calculated by the Track Info 1/5
TCU.
• Display All—All track information will be displayed.
1-Display All
• Forward Distance—The distance the machine has 2-Forward Distance
traveled in forward direction is displayed.
3-Reverse Distance
–19–09SEP04

• Reverse Distance—The distance the machine has

traveled in reverse direction is displayed. 4-Forward Hours
• Forward Hours—The hours the machine has spent
traveling in forward direction is displayed. 5-Reverse Hours
T202433

• Forward Distance—The hours the machine has

spent traveling in reverse direction is displayed.

Continued on next page MF82180,000002F –19–01SEP04–10/40

TM2260 (07JAN06) 9015-15-25 750J, 850J Crawler

010706
PN=165
 Sub-System Diagnostics

3. Controller Info (2-3)

This menu displays the machine ID, hardware part Controller Info 1/8
numbers, and software version numbers for various 1-Display All
devices on the machine.
• Display All—All controller information will be 2-CMU Software
displayed.
• CMU Software Number—The CMU software version
3-CMU SW Version
number will be displayed. 4-TCU Software
• CMU SW Version Number—The machine ID number
5-ECU Software

–19–28JAN05
will be displayed.
• TCU Software Number—The TCU software build 6-CMU Software
number will be displayed.
• ECU Software Number—The ECU software version 7-TCU Software

T202434
number will be displayed. 8-ECU Software
• CMU Hardware Number—The CMU hardware part
number will be displayed.
9015
15 • TCU Hardware Number—The TCU hardware part
26 number will be displayed.
• ECU Hardware Number—The ECU hardware part
number will be displayed.

Continued on next page MF82180,000002F –19–01SEP04–11/40

TM2260 (07JAN06) 9015-15-26 750J, 850J Crawler

010706
PN=166
 Sub-System Diagnostics

4. Trans Settings (2-4)

This menu contains settings that affect transmission
function and performance. Trans Settings 1/9
• Aggressiveness—Transmission aggressiveness can 1-Aggresiveness
be set to low, medium, or high.
• Decel Response—Decelerator response can be set 2-Decel Response
to low, medium, or high. 3-FNR Shift Rate
• FNR Shift Rate—FNR shift rate can be set to low,
medium, or high. 4-Steer Rate
• Steer Rate—Steer rate can be set to low, medium,
or high.
5-Steer Modulation
• Steer Modulation—Steer modulation can be set to 6-FWD Track Speed
low, medium, or high.
7-Rev Track Speed

–19–28JAN05
• Fwd Track Speed1—Forward track speed can be set
to low, medium, or high. 8-Reverse Ratio
• Rev Track Speed1—Reverse track speed can be set
to low, medium, or high. 9-Transmission Settings 9015

T205941
15
• Reverse Ratio—The reverse ratio can be set to 80%, 27
100%, 115%, or 130%.
• Transmission Settings1—All settings can be return to
factory settings.

1
Only Available in the Service Menu
MF82180,000002F –19–01SEP04–12/40

5. Reversing Fan (2-5)

The interval between reverse cycles for the hydraulic
fan can be set in this menu.
• Off—Turns the reversing function off. Reversing Fan 1/4
• 0.5 hours—Fan will reverse every half hour when
machine is in neutral or reverse. Off
• 1.0 hours (default)—Fan will reverse every hour 0.5 hours
when machine is in neutral or reverse.
–19–16DEC04

• 1.5 hours—Fan will reverse every hour and a half 1.0 hours
when machine is in neutral or reverse.
1.5 hours
T205942

Continued on next page MF82180,000002F –19–01SEP04–13/40

TM2260 (07JAN06) 9015-15-27 750J, 850J Crawler

010706
PN=167
 Sub-System Diagnostics

6. Auxiliary Cooler1 (2-6)

The auxiliary oil cooler option is set here.
• Off—Proportional fan speed will not compensate for
hydraulic oil temperature. Auxiliary Cooler 1/2
• On—Proportional fan speed will be calculated with
hydraulic oil temperature as a variable. Off
On

–19–16DEC04
T205943
9015
15
28
1
Only Available in the Service Menu
MF82180,000002F –19–01SEP04–14/40

Diagnostics (3)

Diagnostics 1/2
1-Live Values

–19–16DEC04
2-Calibrated Vals

T205951
MF82180,000002F –19–01SEP04–15/40

1. Live Values (3-1)

This menu displays the live values that the controllers Live Values 1/8
see. 1-Temperatures
2-Pressures
3-Speed
4-Input Voltages
5-Output Current
–19–09SEP04

6-Switch State
7-Performance
T202447

8-System Status

Continued on next page MF82180,000002F –19–01SEP04–16/40

TM2260 (07JAN06) 9015-15-28 750J, 850J Crawler

010706
PN=168
 Sub-System Diagnostics

• Temperatures—Displays values for transmission oil,

hydraulic oil , engine coolant, fuel, and manifold air Temperatures 1/7
temperatures. 1-Display All
2-Transmission
3-Hydraulic
4-Coolant
5-Fuel

–19–02FEB05
6-Manifold Air
7-Ambient Air

T202449
9015
15
29

MF82180,000002F –19–01SEP04–17/40

• Pressures—Displays values for transmission charge,

left track system, right track system, engine oil, and Pressures 1/7
engine fuel rail pressures. 1-Display All
NOTE: Engine fuel rail pressure only available on 850J. 2-Trans Charge
3-Left Track Sys
4-Right Track Sys
5-Engine Oil

–19–05JAN05
6-Engine Rail
7-Trans Case

T202450
Continued on next page MF82180,000002F –19–01SEP04–18/40

TM2260 (07JAN06) 9015-15-29 750J, 850J Crawler

010706
PN=169
 Sub-System Diagnostics

• Speeds—Displays values for engine, left motor, right

motor, crankshaft, and camshaft speeds. Speeds 1/6
1-Display All
NOTE: Camshaft speed only available on 850J.
2-Engine
3-Left Motor
4-Right Motor
5-Crankshaft

–19–09SEP04
6-Camshaft

T202464
9015
15
30

Continued on next page MF82180,000002F –19–01SEP04–19/40

TM2260 (07JAN06) 9015-15-30 750J, 850J Crawler

010706
PN=170
 Sub-System Diagnostics

• Input Voltages1—Displays voltages for all input

sensors as well as system voltages. Input Voltages
Speed Button 2.228
Steer 2.482
FNR 2.492
Decel 1.441
Trans Temp 3.276
Trans Charge 0.488
L. Trk Pressure 0.493
R. Trk Pressure 0.503 9015
15
Hydraulic Temp 3.272 31

Fuel Level 2.724

Battery 24.7
Engine Throttle 2.776
ECU Switched 24.82
ECU Unswitched 24.48
Oil Pressure 0.001
Coolant Temp 3.272
Manifold Temp 3.272
Ambient Air 0.00
Fuel Temp 3.272
Blade Ang Btn 2.218
Case Pressure 0.503
Diag Sensor 1 0.000
Diag Sensor 2 0.000
Diag Sensor 3 0.000
Diag Sensor 4 0.000
–19–28JAN05
T205956

1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–20/40

TM2260 (07JAN06) 9015-15-31 750J, 850J Crawler

010706
PN=171
 Sub-System Diagnostics

• Output Currents, Output States, Resistance (ohms)1—

Displays output currents for solenoids and PCPs, output
states for solenoids and alarms, and resistance of PCPs
and solenoids. Output Currents
Left Pump PCP 0.00
Right Pump PCP 0.00
Left Motor 0.00
Right Motor 0.00
Oil Cooler Byp 0.00%
Fan Drive 64.93
9015 Blade Left 0.0
15
32 Blade Right 0.0
Output States
Brake Solenoid Off
Backup Alarm Off
Display Buzzer Off
Fan Rev. Solenoid On
Resistance (ohms)
Left Pump PCP 200
Right Pump PCP 200
Left Motor 200
Right Motor 200
Fan Drive 314
–19–28JAN05
T205957

1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–21/40

TM2260 (07JAN06) 9015-15-32 750J, 850J Crawler

010706
PN=172
 Sub-System Diagnostics

• Switch State1—Displays interpreted switch states as the

controllers see them.
Switch State
Neutral On
Park Lock Park Off
Park Lock Run On
T. Charge Fltr Off
T. Return Fltr Off
Eng Air Filter Off
Hyd Oil Filter Off
9015
Winch Oil Pres Off 15
33
Decouple Off
Water in Fuel Off

–19–16DEC04
Fan Reverse Off

T205958
1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–22/40

TM2260 (07JAN06) 9015-15-33 750J, 850J Crawler

010706
PN=173
 Sub-System Diagnostics

• Performance1—Displays engine and transmission

performance variables. Performance
Trans Speed Set 2.0
Antistall Percent 4
Tracker Error 0 RPM
Tracker Comp 0 RPM
Rev Ratio % 100
Throttle Percent 0.0
Load at RPM 0
9015 Fuel Rate 0.0G/hr
15
34 Engine Hours 62.1
Fuel Derate % 16
Torque ID 1
TCU Motor OvrSpd 100
TCU Press OvrRide 100

–19–28JAN05
T205959
1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–23/40

TM2260 (07JAN06) 9015-15-34 750J, 850J Crawler

010706
PN=174
 Sub-System Diagnostics

• System Status1—Displays transmission control systems

status.
System Status
Forward Status On
Reverse Status On
Steering Status On
Tracker Status On
Antistall Status On
Full Speed Status On

–19–16DEC04
9015
15
35

T205960
1
Only Available in the Service Menu
MF82180,000002F –19–01SEP04–24/40

2. Calibrated Vals1 (3-2)

This menu displays the input and output values
recorded during calibration. Calibrated Vals 1/3
1-Inputs

–19–16DEC04
2-Outputs

T205961
1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–25/40

TM2260 (07JAN06) 9015-15-35 750J, 850J Crawler

010706
PN=175
 Sub-System Diagnostics

• Inputs1—Displays sensor input voltages recorded during

calibration.
Cal Input (volts)
Right Steer 1.739
Left Steer 3.220
Right Counter 1.568
Left Counter 3.382
FNR Forward 3.499
FNR Fwd Switch 2.649
FNR Rev Switch 2.355
9015
15
FNR Reverse 1.500
36
Decel Up 1.500
Decel Brk Pt. 3.431
Decel Down 3.885
Throttle Low 0.747
Throttle High 0.000
Speed Btn UP 0.923
Speed Btn N 2.228
Speed Btn DN 3.025
Blade Ang Rt 3.064
Blade Ang N 2.218

–19–17DEC04
Blade Ang Lt 0.918

T205962
1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–26/40

TM2260 (07JAN06) 9015-15-36 750J, 850J Crawler

010706
PN=176
 Sub-System Diagnostics

• Outputs1—Displays output current values recorded

during calibration.
Cal Output (mA)
L. Fwd Threshhold 18.6
R. Fwd Threshhold 18.1
L. Rev Threshhold 9.0
R. Rev Threshhold 10.9
L. Fwd Max Pump 80
R. Fwd Max Pump 80
L. Rev Max Pump 80
9015
R. Rev Max Pump 80 15
37
L. Thresh Motor 240.0
R. Thresh Motor 240.0

–19–16DEC04
L. Max Motor 460.0
R. Max Motor 460.0

T205963
1
Only Available in the Service Menu
MF82180,000002F –19–01SEP04–27/40

Monitor Settings (4)

Monitor Settings 1/6

1-Units
2-Backlighting
3-LCD Contrast
4-Monitor Config
–19–16DEC04
5-Language
6-Hide Main Menu
T205952

Continued on next page MF82180,000002F –19–01SEP04–28/40

TM2260 (07JAN06) 9015-15-37 750J, 850J Crawler

010706
PN=177
 Sub-System Diagnostics

1. Units (4-1)
This menu sets the units for all functions of the CMU.
Press SELECT to select the desired mode.
• English—All units will be English standard units.
Units 1/2
• Metric—All units will be metric units. English

–19–05AUG03
Metric

T193395
MF82180,000002F –19–01SEP04–29/40

2. Backlighting (4-2)
9015 This menu sets the amount of backlighting for the
15
38
CMU. The backlighting can be adjusted in increments
of 1 from 1 (no light) to 10 (brightest). Press BACK to
Backlighting
decrement the value, press NEXT to increment the BACK to decrease
value, and press SELECT to store the current value.
NEXT to increase

–19–15OCT03
Once SELECT is pressed, the CMU will confirm that
the value is stored. To exit this menu, press MENU to
return to the main menu. SELECT to store
10

T193397
MF82180,000002F –19–01SEP04–30/40

3. LCD Contrast (4-3)

This menu sets the amount of contrast for the CMU
LCD. The contrast can be adjusted in increments of 1
from 1 (lightest) to 10 (darkest). Press BACK to
LCD Contrast
decrement the value, press NEXT to increment the BACK to decrease
value, and press SELECT to store the current value.
NEXT to increase

–19–22SEP03
Once SELECT is pressed, the CMU will confirm that
the value is stored. To exit this menu, press MENU to
return to the main menu. SELECT to store
9 T193398

MF82180,000002F –19–01SEP04–31/40

4. Monitor Config (4-4)

This menu displays the type and performance level of
the machine. These items are populated by the Engine
Control Unit installed on the machine.
Monitor Config
Type: Large J Crawler
Perf. Level: 750J
–19–21JAN05
T206594

Continued on next page MF82180,000002F –19–01SEP04–32/40

TM2260 (07JAN06) 9015-15-38 750J, 850J Crawler

010706
PN=178
 Sub-System Diagnostics

5. Language1 (4-5)
This menu sets the language for all functions of the
CMU. Press SELECT to select the desired language.
• English—The menu language will be set to English. Language 1/3
• Spanish—The menu language will be set to Spanish. English
• French—The menu language will be set to French.

–19–01OCT03
Spanish
French

T194687
1
Only Available in the Service Menu
MF82180,000002F –19–01SEP04–33/40

6. Hide Main Menu1 (4-6)

This menu sets the display mode for the main menu. 9015
Press SELECT to select the desired mode.
• Hide Main Menu—The main menu will not be
Hide Main Menu 1/2 15
39
available. The service menu will have to be entered Hide Main Menu
to access any menus.

–19–05AUG03
• Show Main Menu—The main menu will be available Show Main Menu
when the MENU button is pressed.

T193396
1
Only Available in the Service Menu
MF82180,000002F –19–01SEP04–34/40

Calibrate TCU (5)1

This menu performs the transmission calibration

procedure. Press SELECT to start the procedure. The
CMU broadcasts the request across CAN to the TCU and
Calibrate TCU
the TCU will initiate the procedure. For more information Press SELECT to begin calibrating
on this procedure, See Transmission Control Unit (TCU) the transmission...
Calibration. (Group 9020-20.)
–19–16DEC04
T205964

1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–35/40

TM2260 (07JAN06) 9015-15-39 750J, 850J Crawler

010706
PN=179
 Sub-System Diagnostics

TCU Diagnostics (6)1

TCU Diagnostics 1/2

1-Settings

–19–16DEC04
2-Procedures

T205965
1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–36/40

9015
15
40

TM2260 (07JAN06) 9015-15-40 750J, 850J Crawler

010706
PN=180
 Sub-System Diagnostics

1. Settings1
• Tracker Ctrl—This function maintains straight
tracking by slowing down the faster track so both
tracks travel at the same speed.
Settings 1/8
Off—The tracker function will be disabled for 1-Tracker Ctrl
troubleshooting. This setting will reset to normal
when the keyswitch is cycled. 2-Antistall Ctrl
• Antistall Ctrl—This function maintains target engine 3-Motor Soln
speed by reducing the transmission demand when
there is a high load on the engine to prevent stalling. 4-Brake Ctrl
Off—The antistall function will be disabled for
troubleshooting. This setting will reset to normal
5-Tank Byp Ctrl
when the keyswitch is cycled. 6-Cool Byp Ctrl

–19–16DEC04
• Motor Soln—This function forces the motor shift
solenoids on or off. 7-Fan Valve
On—The right and left motor shift solenoids are 8-Fan Rev 9015
turned on for troubleshooting. This setting will reset

T205966
15
to normal when the keyswitch is cycled. 41
Off—The right and left motor shift solenoids are
turned off for troubleshooting. This setting will reset
to normal when the keyswitch is cycled.
• Brake Ctrl—This function controls the park brake
solenoids.
Test—The park brake will be forced on with the park
brake lever in the run position to allow for the
transmission to drive against the brakes. This setting
will reset to normal when the keyswitch is cycled.
Tow—The park brake will be forced off to allow the
machine to be towed. This setting will reset to
normal when the keyswitch is cycled.
• Tank Byp Ctrl—This function controls the hydrostatic
oil reservoir bypass solenoid.
Off—The hydrostatic oil reservoir bypass solenoid is
de-energized for troubleshooting. This setting will
reset to normal when the keyswitch is cycled.
On—The hydrostatic oil reservoir bypass solenoid is
energized for troubleshooting. This setting will reset
to normal when the keyswitch is cycled.
• Cool Byp Ctrl—This function controls the hydrostatic
oil cooler bypass solenoid.
Off—The hydrostatic oil cooler bypass solenoid is
de-energized for troubleshooting. This setting will
reset to normal when the keyswitch is cycled.

1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–37/40

TM2260 (07JAN06) 9015-15-41 750J, 850J Crawler

010706
PN=181
 Sub-System Diagnostics

On—The hydrostatic oil cooler bypass solenoid is

energized for troubleshooting. This setting will reset to
normal when the keyswitch is cycled.

• Fan Valve Set—This function controls the hydraulic

fan proportional relief solenoid.
Maximum—For troubleshooting, the hydraulic fan
proportional relief solenoid is supplied minimum
current for maximum fan speed. This setting will
reset to normal when the keyswitch is cycled.
70%—For troubleshooting, the hydraulic fan
proportional relief solenoid is supplied medium
current for 70% fan speed. This setting will reset to
normal when the keyswitch is cycled.
Minimum—For troubleshooting, the hydraulic fan
proportional relief solenoid is supplied maximum
9015
15 current for minimum fan speed. This setting will reset
42 to normal when the keyswitch is cycled.
• Fan Rev (if equipped)—This function controls the
hydraulic fan reversing solenoid.
On—The hydraulic fan is forced in the reverse
direction for troubleshooting. This setting will reset to
normal when the keyswitch is cycled.
Off—The hydraulic fan reverse function is forced off
for troubleshooting. This setting will reset to normal
when the keyswitch is cycled.

MF82180,000002F –19–01SEP04–38/40

2. Procedures1
After pressing select, procedures available for the
machine will be listed. Procedures
TCU Diagnostic
Procedures mode,
–UN–14JAN05

press SELECT to
continue...
T207032

1
Only Available in the Service Menu
Continued on next page MF82180,000002F –19–01SEP04–39/40

TM2260 (07JAN06) 9015-15-42 750J, 850J Crawler

010706
PN=182
 Sub-System Diagnostics

• Efficiency and Relief Valve Test—This function displays

information required to perform diagnostic tests. System
pressure and pump PCP current supply for the right and Eff and Relief
left sides are shown in their respective column. Charge Sys psi 0 0
pressure and pump case pressure are also shown.
Pump mA 0.0 0.0

–UN–14JAN05
eng 0 rpm
charge 0.0 psi
case 0.0 psi

T207033
MF82180,000002F –19–01SEP04–40/40

9015
15
43

TM2260 (07JAN06) 9015-15-43 750J, 850J Crawler

010706
PN=183
 Sub-System Diagnostics

9015
15
44

TM2260 (07JAN06) 9015-15-44 750J, 850J Crawler

010706
PN=184
 Group 20
References
Diagnostic Trouble Codes (DTCs) Quick
Reference List

The diagnostic trouble code number is indicated by an

(SPN) Suspect Parameter Number and a (FMI) Failure
Mode Indicator number. (91.03) 91 is the SPN number
and 03 is the FMI number.

Use SERVICE ADVISOR system or see Stored Codes

in the Display Menu to view stored diagnostic trouble
codes.

Transmission Control Unit (TCU) Diagnostic Trouble

Codes

NOTE: For more information See Transmission Control 9015

Unit (TCU) Diagnostic Trouble Codes. 20
1
• 70.00—Park Lock Lever Inputs both On
• 70.01—Park Lock Lever Inputs both Off
• 91.00—Throttle Sensor Input Greater Than Maximum
Calibration Value
• 91.01—Throttle Sensor Input Less Than Minimum
Calibration Value
• 91.03—Throttle Sensor Short to Power
• 91.04—Throttle Sensor Open or Short
• 91.15—Throttle Sensor Minimum Calibration Value Too
High
• 91.16—Throttle Sensor Maximum Calibration Value Too
High
• 91.17—Throttle Sensor Minimum Calibration Value Too
Low
• 91.18—Throttle Sensor Maximum Calibration Value Too
Low
• 116.00—Brake Pressure High
• 116.01—Brake Pressure Low
• 116.03—Brake Pressure Short to Power
• 116.04—Brake Pressure Open or Short
• 158.03—TCU System Volts Too High
• 158.04—TCU System Volts Too Low
• 177.00—Transmission Over Temp
• 190.09—CAN Communication Error No Engine Speed
• 190.19—CAN Communication Error Invalid Engine
Speed

SERVICE ADVISOR is a trademark of Deere & Company Continued on next page MF82180,0000033 –19–06OCT05–1/8

TM2260 (07JAN06) 9015-20-1 750J, 850J Crawler

010706
PN=185
 References

• 521.00—Decel Sensor Input Greater Than Maximum

Calibration Value
• 521.01—Decel Sensor Input Less Than Minimum
Calibration Value
• 521.03—Decel Sensor Short to Power
• 521.04—Decel Sensor Open or Short
• 521.05—Decel Sensor Brake Calibration Value Too Low
• 521.06—Decel Sensor Brake Calibration Value Too
High
• 521.15—Decel Sensor Minimum Calibration Value Too
High
• 521.16—Decel Sensor Maximum Calibration Value Too
Low
• 521.17—Decel Sensor Minimum Calibration Value Too
Low
• 521.18—Decel Sensor Maximum Calibration Value Too
9015
20 Low
2 • 581.00—Speed Buttons Input Greater Than Maximum
Calibration Value
• 581.01—Speed Buttons Input Less Than Minimum
Calibration Value
• 581.03—Speed Buttons Short to Power
• 581.04—Speed Buttons Open or Short
• 581.15—Speed Buttons Minimum Calibration Value Too
High
• 581.16—Speed Buttons Maximum Calibration Value
Too High
• 581.17—Speed Buttons Minimum Calibration Value Too
Low
• 581.18—Speed Buttons Maximum Calibration Value
Too Low
• 604.03—FNR Neutral Switch Open Circuit
• 604.04—FNR Neutral Switch Short Circuit
• 604.15—FNR Neutral Switch Minimum Calibration
Value Too High
• 604.16—FNR Neutral Switch Maximum Calibration
Value Too High
• 604.17—FNR Neutral Switch Minimum Calibration
Value Too Low
• 604.18—FNR Neutral Switch Maximum Calibration
Value Too Low
• 619.05—Brake Solenoid No Response
• 620.03—ECU 5V Supply Short To Power
• 620.04—ECU 5V Supply Open or Short
• 907.03—Left Speed Sensor Short to Power
• 907.04—Left Speed Sensor Short

Continued on next page MF82180,0000033 –19–06OCT05–2/8

TM2260 (07JAN06) 9015-20-2 750J, 850J Crawler

010706
PN=186
 References

• 907.07—Left Speed Sensor No Response

• 907.12—Left Speed Sensor Open
• 908.03—Right Speed Sensor Short to Power
• 908.04—Right Speed Sensor Short
• 908.07—Right Speed Sensor No Response
• 908.12—Right Speed Sensor Open
• 977.05—Fan Reverse Solenoid No Response
• 1071.05—Fan Drive Solenoid Open Circuit
• 1071.06—Fan Drive Solenoid Short Circuit
• 2660.00—Steer Sensor Input Greater Than Maximum
Calibration Value
• 2660.01—Steer Sensor Input Less Than Minimum
Calibration Value
• 2660.03—Steer Sensor Short to Power
• 2660.04—Steer Sensor Open or Short
• 2660.15—Steer Sensor Minimum Calibration Value Too
9015
High 20
• 2660.16—Steer Sensor Maximum Calibration Value Too 3
Low
• 2660.17—Steer Sensor Minimum Calibration Value Too
Low
• 2660.18—Steer Sensor Maximum Calibration Value Too
Low
• 2661.00—FNR Sensor Input Greater Than Maximum
Calibration Value
• 2661.01—FNR Sensor Input Less Than Minimum
Calibration Value
• 2661.03—FNR Sensor Short to Power
• 2661.04—FNR Sensor Open or Short
• 2661.15—FNR Sensor Minimum Calibration Value Too
High
• 2661.16—FNR Sensor Maximum Calibration Value Too
Low
• 2661.17—FNR Sensor Minimum Calibration Value Too
Low
• 2661.18—FNR Sensor Maximum Calibration Value Too
Low
• 522439.05—Tank Bypass Solenoid Open Circuit
• 522440.05—Blade Left Solenoid Open Circuit
• 522440.06—Blade Left Solenoid Short Circuit
• 522441.05—Blade Right Solenoid Open Circuit
• 522441.06—Blade Right Solenoid Short Circuit
• 522442.00—Blade Buttons Input Greater Than
Maximum Calibration Value
• 522442.01—Blade Buttons Input Less Than Minimum
Calibration Value

Continued on next page MF82180,0000033 –19–06OCT05–3/8

TM2260 (07JAN06) 9015-20-3 750J, 850J Crawler

010706
PN=187
 References

• 522442.03—Blade Buttons Short to Power

• 522442.04—Blade Buttons Open or Short
• 522442.15—Blade Buttons Minimum Calibration Value
Too High
• 522442.16—Blade Buttons Maximum Calibration Value
Too High
• 522442.17—Blade Buttons Minimum Calibration Value
Too Low
• 522442.18—Blade Buttons Maximum Calibration Value
Too Low
• 522444.00—Charge Pressure High
• 522444.01—Charge Pressure Low
• 522444.03—Charge Pressure Short to Power
• 522444.04—Charge Pressure Open or Short
• 522447.05—Right Forward Pump Coil Open
• 522447.06—Right Forward Pump Coil Short
9015
20 • 522447.15—Right Forward Pump Threshold Calibration
4 Value Too High
• 522447.16—Right Forward Pump Max Speed
Calibration Value Too High
• 522447.17—Right Forward Pump Threshold Calibration
Value Too Low
• 522447.18—Right Forward Pump Max Speed
Calibration Value Too Low
• 522448.05—Right Reverse Pump Coil Open
• 522448.06—Right Reverse Pump Coil Short
• 522448.15—Right Reverse Pump Threshold Calibration
Value Too High
• 522448.15—Right Reverse Pump Max Speed
Calibration Value Too High
• 522448.16—Right Reverse Pump Max Speed
Calibration Value Too Low
• 522448.17—Right Reverse Pump Thresh Calibration
Value Too Low
• 522448.18—Right Reverse Pump Max Speed
Calibration Value Too Low
• 522449.05—Left Forward Pump Coil Open
• 522449.06—Left Forward Pump Coil Short
• 522449.15—Left Forward Pump Threshold Calibration
Value Too High
• 522449.16—Left Forward Pump Max Speed Calibration
Value Too Low
• 522449.17—Left Forward Pump Threshold Calibration
Value Too Low
• 522449.18—Left Forward Pump Max Speed Calibration
Value Too Low

Continued on next page MF82180,0000033 –19–06OCT05–4/8

TM2260 (07JAN06) 9015-20-4 750J, 850J Crawler

010706
PN=188
 References

• 522450.05—Left Reverse Pump Coil Open

• 522450.06—Left Reverse Pump Coil Short
• 522450.15—Left Reverse Pump Threshold Calibration
Value Too High
• 522450.15—Left Reverse Pump Max Speed Calibration
Value Too High
• 522450.16—Left Reverse Pump Max Speed Calibration
Value Too Low
• 522450.17—Left Reverse Pump Threshold Calibration
Value Too Low
• 522450.18—Left Reverse Pump Max Speed Calibration
Value Too Low
• 522451.05—Cooler Bypass Solenoid No Response
• 523108.13—TCU Not Calibrated High Speed Not Done
• 523108.14—TCU Not Calibrated Sensor/Pump/Motor
• 523436.07—TCU Watchdog Timer Exceeded
9015
• 523577.05—Left Motor Solenoid Open Circuit 20
• 523577.06—Left Motor Solenoid Short Circuit 5
• 523577.16—Left Motor Maximum Calibration Value Too
High
• 523577.18—Left Motor Maximum Calibration Value Too
Low
• 523578.05—Right Motor Solenoid Open Circuit
• 523578.06—Right Motor Solenoid Short Circuit
• 523578.16—Right Motor Maximum Calibration Value
Too High
• 523578.18—Right Motor Maximum Calibration Value
Too Low

Engine Control Unit (ECU) Diagnostic Trouble Codes

NOTE: For more information See Engine Control Unit

(ECU) Diagnostic Trouble Codes—750J or see
Engine Control Unit (ECU) Diagnostic Trouble
Codes—850J.

• 91.09—CAN Throttle Missing from TCU

• 91.14—CAN Throttle Invalid from TCU
• 94.03—Rail Pressure Short To Power
• 94.04—Rail Pressure Open or Short
• 94.10—Rail Pressure Abnormal Rate of Change
• 94.17—Fuel Pressure Too Low
• 97.03—Water in Fuel Sensor Open or Short
• 97.04—Water in Fuel Short to Ground
• 97.31—Water in Fuel
• 100.01—Engine Oil Pressure Low

Continued on next page MF82180,0000033 –19–06OCT05–5/8

TM2260 (07JAN06) 9015-20-5 750J, 850J Crawler

010706
PN=189
 References

• 100.03—Engine Oil Pressure Short To Power

• 100.04—Engine Oil Pressure Open or Short
• 100.16—Faulty Oil Pressure Sensor, Open Sensor
Ground
• 105.03—Manifold Air Temperature Sensor Open or
Short
• 105.04—Manifold Air Temperature Sensor Short To
Ground
• 105.16—Manifold Air Temperature Too High
• 110.00—Engine Coolant Temperature Too High
• 110.03—Engine Coolant Temperature Sensor Open or
Short
• 110.04—Engine Coolant Temperature Sensor Short To
Ground
• 110.16—Engine Coolant Temperature High
• 158.17—ECU Ignition Power Not at 0 Volts
9015
20 • 171.03—Ambient Air Temperature Sensor Open or
6 Short
• 171.04—Ambient Air Temperature Sensor Short to
Ground
• 174.03—Fuel Temperature Open or Short
• 174.04—Fuel Temperature Short To Ground
• 174.16—Fuel Temperature High
• 611.03—Injector Wiring Short To Power
• 611.04—Injector Wiring Short To Ground
• 620.03—Sensor Supply Voltage Short To Power
• 620.04—Sensor Supply Voltage Short To Ground
• 627.01—Injector Current is Incorrect
• 629.13—ECU Failure
• 636.02—Camshaft Position Sensor Out of Sync
• 636.08—Camshaft Position Sensor Signal Not Present
• 636.10—Camshaft Position Sensor Fault
• 637.02—Crankshaft Position Sensor Out of Sync
• 637.07—Crankshaft or Camshaft Out of Sync
• 637.08—Crankshaft Position Sensor Signal Not Present
• 637.10—Crankshaft Position Sensor Fault
• 639.13—CAN Network Wiring Fault
• 651.05—Cylinder #1 Injector Open Circuit
• 651.06—Cylinder #1 Injector Short Circuit
• 651.07—Cylinder #1 Injector Fault
• 652.05—Cylinder #2 Injector Open Circuit
• 652.06—Cylinder #2 Injector Short Circuit
• 652.07—Cylinder #2 Injector Fault
• 653.05—Cylinder #3 Injector Open Circuit
• 653.06—Cylinder #3 Injector Short Circuit
• 653.07—Cylinder #3 Injector Fault

Continued on next page MF82180,0000033 –19–06OCT05–6/8

TM2260 (07JAN06) 9015-20-6 750J, 850J Crawler

010706
PN=190
 References

• 654.05—Cylinder #4 Injector Open Circuit

• 654.06—Cylinder #4 Injector Short Circuit
• 654.07—Cylinder #4 Injector Fault
• 655.05—Cylinder #5 Injector Open Circuit
• 655.06—Cylinder #5 Injector Short Circuit
• 655.07—Cylinder #5 Injector Fault
• 656.05—Cylinder #6 Injector Open Circuit
• 656.06—Cylinder #6 Injector Short Circuit
• 656.07—Cylinder #6 Injector Fault
• 1076.00—Fuel Injection Pump Solenoid Adaptive
Closure High
• 1076.01—Fuel Injection Pump Solenoid Adaptive
Closure Low
• 1076.03—Fuel Injection Pump Solenoid Overcurrent
• 1076.05—Fuel Injection Pump Solenoid Open Circuit
• 1076.06—Fuel Injection Pump Solenoid Fall Current
9015
Short 20
• 1076.07—Fuel Injection Pump Solenoid Composite 7
Closure Failure
• 1076.10—Fuel Injection Pump Solenoid Fall Current
Slow
• 1076.13—Fuel Injection Pump Solenoid Current Decay
Time Fault
• 1080.03—Rail Pressure Sensor Supply Short to Power
• 1080.04—Rail Pressure Sensor Supply Short To
Ground
• 1347.05—Fuel Pump Solenoid 1 Open Circuit
• 1347.07—Fuel System Failure
• 1347.10—Fuel Pump Solenoid 1 Failure
• 1348.05—Fuel Pump Solenoid 2 Open Circuit
• 1348.10—Fuel Pump Solenoid 2 Failure
• 1568.02—Invalid Torque Request from TCU
• 1569.31—Engine Derate Active
• 2000.06—Fuel Pump Solenoid Fall Time Long
• 2000.13—ECU/Monitor Configuration Mismatch

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

NOTE: For more information See CAN Monitor Unit

(CMU) Diagnostic Trouble Codes.

• 96.03—Fuel Level Sensor Open or Short

• 96.04—Fuel Level Sensor Short to Ground
• 107.03—Engine Air Filter Restriction Indicator Switch
Short to Power
• 107.04—Engine Air Filter Restricted

Continued on next page MF82180,0000033 –19–06OCT05–7/8

TM2260 (07JAN06) 9015-20-7 750J, 850J Crawler

010706
PN=191
 References

• 177.03—Transmission Oil Temperature Sensor Short to

Power
• 177.04—Transmission Oil Temperature Sensor Short to
Ground
• 609.09—CAN Communication Error, No TCU Message
• 1638.00—Hydraulic Oil Temperature High
• 1638.03—Hydraulic Oil Temperature Short to Power
• 1638.04—Hydraulic Oil Temperature Short to Ground
• 1713.31—Hydraulic Oil Filter Restricted
• 1857.03—Winch Oil Pressure Sensor Short to Power
• 1857.04—Winch Oil Pressure Low
• 2000.09—CAN Communication Error, No ECU
Configuration
• 524227.31—Transmission Oil Filter Restricted

9015
20
8

MF82180,0000033 –19–06OCT05–8/8

TM2260 (07JAN06) 9015-20-8 750J, 850J Crawler

010706
PN=192
 References

CAN Monitor Unit (CMU) Diagnostic Trouble

Codes

The Diagnostic Trouble Code number is indicated by a

Suspect Parameter Number (SPN) and a Failure Mode
Indicator (FMI) number. 2000.09 2000 is the SPN number
and 09 is the FMI number.

Use SERVICE ADVISOR system or see Stored Codes

in the Display Menu to view stored diagnostic trouble
codes.

Symptom Problem Solution

96.03 Fuel Level Sensor open or short Check wires Y01 YEL and R10 BLK.
See CAN Monitor Unit (CMU) Circuit 9015
Theory of Operation. (Group 20
9015-15.) 9

Check fuel level sensor (B19). See

Electrical Component Specifications.
(Group 9015-20.)

96.04 Fuel Level Sensor short to ground Check wires Y01 YEL for short to
ground. See CAN Monitor Unit
(CMU) Circuit Theory of Operation.
(Group 9015-15.)

Check fuel level sensor (B19). See

Electrical Component Specifications.
(Group 9015-20.)

107.03 Engine Air Filter Restriction Switch Check wire N01 YEL for a short to
short to power power.

Check wire G12 BLK at sensor for

proper ground

107.04 Engine air filter restricted Check engine air filter for restriction.
Operator’s Manual.

Check Engine Air Filter Restriction

Switch (B22). See Electrical
Component Specifications. (Group
9015-20.)

SERVICE ADVISOR is a trademark of Deere & Company Continued on next page MF82180,0000030 –19–01SEP04–1/3

TM2260 (07JAN06) 9015-20-9 750J, 850J Crawler

010706
PN=193
 References

Symptom Problem Solution

177.03 Transmission oil temperature sensor Check wire X01 YEL for a short to
short to power power.

Check wire R12 BLK at sensor for

proper ground.

Check Hydrostatic Oil

Temperature Sensor (B21). See
Electrical Component Specifications.
(Group 9015-20.)

177.04 Transmission oil temperature sensor Check wire X01 YEL for a short to
short to ground ground.
9015
20 Check Hydrostatic Oil
10 Temperature Sensor (B21). See
Electrical Component Specifications.
(Group 9015-20.)

609.09 CAN communication error, no status Check CAN wires M12 YEL and
message received from TCU M13 LTGRN for an open or short.
See Controller Area Network (CAN)
Theory of Operation. (Group
9015-10.)

1638.00 Hydraulic oil temperature high See Diagnose Hydraulic System

Malfunctions. (Group 9025-15.)

1638.03 Hydraulic oil temperature sensor Check wire X02 YEL for short to
open or short to power power.

Check wire R12 BLK at sensor for

proper ground.

Check Hydraulic Oil Temperature

Sensor (B20). See Electrical
Component Specifications. (Group
9015-20.)

1638.04 Hydraulic oil temperature sensor Check wire X02 YEL for a short to
short to ground ground.

Check wire R12 BLK at sensor for

proper ground.

Continued on next page MF82180,0000030 –19–01SEP04–2/3

TM2260 (07JAN06) 9015-20-10 750J, 850J Crawler

010706
PN=194
 References

Symptom Problem Solution

Check Hydraulic Oil Temperature

Sensor (B20). See Electrical
Component Specifications. (Group
9015-20.)

1713.31 Hydraulic oil filter restricted Check hydraulic oil filter for
restriction. Operator’s Manual.

Check Hydraulic Oil Filter

Restriction Switch (B23). See
Electrical Component Specifications.
(Group 9015-20.)

1857.03 Winch oil pressure switch short to Check wire N04 YEL for a short to
9015
power power. 20
11
Check wire G00 BLK at sensor for
proper ground

1857.04 Winch oil pressure low

2000.09 CAN communication error, no Check CAN wires M12 YEL and
configuration message received from M13 LTGRN for an open or short.
ECU See Controller Area Network (CAN)
Circuit Theory of Operation. (Group
9015-10.)

524227.31 Transmission oil filter restricted Check hydrostatic charge oil filter for
restriction. Operator’s Manual.

Check Hydrostatic Charge Oil

Filter Restriction Switch (B25).
See Electrical Component
Specifications. (Group 9015-20.)

MF82180,0000030 –19–01SEP04–3/3

TM2260 (07JAN06) 9015-20-11 750J, 850J Crawler

010706
PN=195
 References

Engine Control Unit (ECU) Diagnostic

Trouble Codes—750J

The diagnostic trouble code number is indicated by a

Suspect Parameter Number (SPN) and a Failure Mode
Indicator (FMI) number. 91.03 91 is the SPN number and
03 is the FMI number.

Use SERVICE ADVISOR system or see Stored Codes

in the Display Menu to view stored diagnostic trouble
codes.

Symptom Problem Solution

91.09 CAN communication error, throttle See T7 - CAN Throttle Invalid

9015 message missing from TCU Diagnostic Procedure in Section 04,
20 Group 160 of CTM331.
12
91.14 CAN communication error, throttle See 000091.14 - Throttle Voltage
message invalid from TCU Out of Range in Section 04, Group
160 of CTM331.

97.03 Water in Fuel Sensor Signal Voltage See 000097.03 Water In Fuel Signal
High Voltage High Diagnostic Procedure
in Section 04, Group 160 of CTM
220.

97.04 Water in Fuel Sensor Signal Voltage See 000097.04 Water In Fuel Signal
Low Voltage Low Diagnostic Procedure in
Section 04, Group 160 of CTM 220.

97.31 Water in Fuel Detected See 000097.16 Water In Fuel

Detected Diagnostic Procedure in
Section 04, Group 160 of CTM 220.

100.01 Engine Oil Pressure Sensor See 000100.01 Engine Oil Pressure
Extremely Low Extremely Low Diagnostic Procedure
in Section 04, Group 160 of
CTM331.

100.03 Engine Oil Pressure Sensor Input See 000100.03 Engine Oil Pressure
Voltage Low Input Voltage High Diagnostic
Procedure in Section 04, Group 160
of CTM331.

SERVICE ADVISOR is a trademark of Deere & Company Continued on next page MF82180,0000041 –19–06OCT05–1/4

TM2260 (07JAN06) 9015-20-12 750J, 850J Crawler

010706
PN=196
 References

Symptom Problem Solution

100.04 Engine Oil Pressure Sensor Input See 000100.04 Engine Oil Pressure
Voltage Low Input Voltage Low Diagnostic
Procedure in Section 04, Group 160
of CTM331.

100.16 Engine Oil Pressure Sensor Open Check engine oil pressure sensor
Ground B17 wires. See Engine Control Unit
(ECU) Circuit Theory of Operation.
(Group 9015-15.)

105.03 Manifold Air Temperature Sensor See 000105.03 Manifold Air

Input Voltage High Temperature Input Voltage High
Diagnostic Procedure in Section 04,
Group 160 of CTM331.
9015
20
105.04 Manifold Air Temperature Sensor See 000105.04 Manifold Air 13
Input Voltage Low Temperature Input Voltage Low
Diagnostic Procedure in Section 04,
Group 160 of CTM331.

105.16 Manifold Air Temperature Moderately See 000105.16 Manifold Air

High Temperature Moderately High
Diagnostic Procedure in Section 04,
Group 160 of CTM331.

110.00 Engine Coolant Temperature High See 000110.00 Engine Coolant

Most Severe Temperature High Most Severe
Diagnostic Procedure in Section 04,
Group 160 of CTM331.

110.03 Engine Coolant Temperature Sensor See 000110.03 Engine Coolant

Input Voltage High Temperature Input Voltage High
Diagnostic Procedure in Section 04,
Group 160 of CTM331.

110.04 Engine Coolant Temperature Sensor See 000110.04 Engine Coolant

Input Voltage Low Temperature Input Voltage Low
Diagnostic Procedure in Section 04,
Group 160 of CTM331.

110.16 Engine Coolant Temperature High See 000110.16 Engine Coolant

Moderately Severe Temperature High Moderately
Severe Diagnostic Procedure in
Section 04, Group 160 of CTM331.

Continued on next page MF82180,0000041 –19–06OCT05–2/4

TM2260 (07JAN06) 9015-20-13 750J, 850J Crawler

010706
PN=197
 References

Symptom Problem Solution

158.17 ECU Power Down Error See 000158.17 ECU Power Down
Error Diagnostic Procedure in
Section 04, Group 160 of CTM331.

174.03 Fuel Temperature Sensor Input See 000174.03 Fuel Temperature

Voltage High Input Voltage High Diagnostic
Procedure in Section 04, Group 160
of CTM331.

174.04 Fuel Temperature Sensor Input See 000174.04 Fuel Temperature

Voltage Low Input Voltage Low Diagnostic
Procedure in Section 04, Group 160
of CTM331.
9015
20 174.16 Fuel Temperature High Moderately See 000174.16 Fuel Temperature
14 Severe High Moderately Severe Diagnostic
Procedure in Section 04, Group 160
of CTM331.

620.03 ECU Sensor Supply Voltage Short to See 000620.03 Sensor Supply 2
Power Voltage High Diagnostic Procedure
in Section 04, Group 160 of
CTM331.

620.04 ECU Sensor Supply Voltage Short to See 000620.04 Sensor Supply 2
Ground Voltage Low Diagnostic Procedure in
Section 04, Group 160 of CTM331.

629.13 ECU Failure See 000629.13 ECU Error

Diagnostic Procedure in Section 04,
Group 160 of CTM331.

637.02 Crank Position Sensor Input Noise See 000637.02 Crank Position Input
Noise Diagnostic Procedure in
Section 04, Group 160 of CTM331.

637.10 Crank Position Sensor Input Pattern See 000637.10 Crank Position Input
Error Pattern Error Diagnostic Procedure
in Section 04, Group 160 of
CTM331.

1076.00 Fuel Pump Solenoid Adaptive See 001076.00 Pump Control Valve
Closure High Closure Too Long Diagnostic
Procedure in Section 04, Group 160
of CTM331.

Continued on next page MF82180,0000041 –19–06OCT05–3/4

TM2260 (07JAN06) 9015-20-14 750J, 850J Crawler

010706
PN=198
 References

Symptom Problem Solution

1076.01 Fuel Pump Solenoid Adaptive See 001076.01 Pump Control Valve
Closure Low Closure Too Short Diagnostic
Procedure in Section 04, Group 160
of CTM331.

1076.03 Fuel Pump Solenoid Low Side See 001076.03 Pump Solenoid
Overcurrent Current High Diagnostic Procedure
in Section 04, Group 160 of
CTM331.

1076.05 Fuel Pump Solenoid Open Circuit See 001076.05 Pump Solenoid
Circuit Open Diagnostic Procedure in
Section 04, Group 160 of CTM331.
9015
1076.06 Fuel Pump Solenoid Current Fall See 001076.06 Pump Solenoid 20
Current Short Circuit Severely Shorted Diagnostic 15
Procedure in Section 04, Group 160
of CTM331.

1076.07 Composite Closure Detection Failure See 001076.07 Pump Control Valve
Closure Not Detected Diagnostic
Procedure in Section 04, Group 160
of CTM331.

1076.10 Injector Current Fall Time Slow See 001076.10 Pump Solenoid
Circuit Moderately Shorted
Diagnostic Procedure in Section 04,
Group 160 of CTM331.

1076.13 Current Decay Time Fault See 001076.13 Pump Current Decay
Time Invalid Diagnostic Procedure in
Section 04, Group 160 of CTM331.

1568.02 Torque Curve Selection Invalid From See 001568.02 - Torque Curve
TCU Selection Invalid in Section 04,
Group 160 of CTM331.

1569.31 Fuel Derate See 001569.31 Fuel Derate in

Section 04, Group 160 of CTM331.

2000.06 Fuel Injection Pump Fuel Control See 002000.06 — Internal ECU
Valve Current Fall Time Long Failure in Section 04, Group 160 of
CTM331.

2000.13 ECU/Monitor Mismatch See 002000.13 Security Violation in

Section 04, Group 160 of CTM 255.

MF82180,0000041 –19–06OCT05–4/4

TM2260 (07JAN06) 9015-20-15 750J, 850J Crawler

010706
PN=199
 References

Engine Control Unit (ECU) Diagnostic

Trouble Codes—850J

The diagnostic trouble code number is indicated by a

Suspect Parameter Number (SPN) and a Failure Mode
Indicator (FMI) number. 91.03 91 is the SPN number and
03 is the FMI number.

Use SERVICE ADVISOR system or see Stored Codes

in the Display Menu to view stored diagnostic trouble
codes.

Symptom Problem Solution

91.09 CAN Communication Error, Throttle See 000091.09 — Throttle Invalid in

9015 Message Missing From TCU Section 04, Group 160 of CTM255.
20
16 91.14 CAN Communication Error, Throttle See 000091.14 — Throttle Voltage
Message Invalid From TCU Out of Range in Section 04, Group
160 of CTM255.

94.03 Fuel Rail Pressure Sensor Input See 000094.03 Fuel Rail Pressure
Voltage High Input Voltage High Diagnostic
Procedure in Section 04, Group 160
of CTM255.

94.04 Fuel Rail Pressure Sensor Input See 000094.03 Fuel Rail Pressure
Voltage Low Input Voltage Low Diagnostic
Procedure in Section 04, Group 160
of CTM255.

94.10 Fuel Rail Pressure Abnormal Rate of See 000094.10 Fuel Rail Pressure
Change Loss Detected Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

94.17 Fuel Rail Pressure Not Developed See 000094.17 Fuel Rail Pressure
During Cranking Not Developed Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

97.03 Water in Fuel Sensor Signal Voltage See 000097.03 Water In Fuel Signal
High Voltage High Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

SERVICE ADVISOR is a trademark of Deere & Company Continued on next page MF82180,0000042 –19–06OCT05–1/8

TM2260 (07JAN06) 9015-20-16 750J, 850J Crawler

010706
PN=200
 References

Symptom Problem Solution

97.04 Water in Fuel Sensor Signal Voltage See 000097.04 Water In Fuel Signal
Low Voltage Low Diagnostic Procedure in
Section 04, Group 160 of CTM255.

97.31 Water in Fuel Detected See 000097.31 Water In Fuel

Detected Diagnostic Procedure in
Section 04, Group 160 of CTM255.

100.01 Engine Oil Pressure Extremely Low See 000100.01 Engine Oil Extremely
Low Diagnostic Procedure in Section
04, Group 160 of CTM255.

100.03 Engine Oil Pressure Sensor Input See 000100.03 Engine Oil Pressure
Voltage High Input Voltage High Diagnostic
9015
Procedure in Section 04, Group 160 20
of CTM255. 17

100.04 Engine Oil Pressure Sensor Input See 000100.04 Engine Oil Pressure
Voltage Low Input Voltage Low Diagnostic
Procedure in Section 04, Group 160
of CTM255.

100.16 Engine Oil Pressure Sensor Open Check engine oil pressure sensor
Ground B17 wires. See Engine Control Unit
(ECU) Circuit Theory of Operation.
(Group 9015-15.)

105.03 Manifold Air Temperature Sensor See 000105.03 Manifold Air

Input Voltage High Temperature Input Voltage High
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

105.04 Manifold Air Temperature Sensor See 000105.04 Manifold Air

Input Voltage Low Temperature Input Voltage Low
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

105.16 Manifold Air Temperature Moderately See 000105.16 Manifold Air

High Temperature Moderately High
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

Continued on next page MF82180,0000042 –19–06OCT05–2/8

TM2260 (07JAN06) 9015-20-17 750J, 850J Crawler

010706
PN=201
 References

Symptom Problem Solution

110.00 Engine Coolant Temperature See 000110.00 Engine Coolant

Extremely High Temperature High Most Severe
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

110.03 Engine Coolant Temperature Sensor See 000110.03 Engine Coolant

Input Voltage High Temperature Input Voltage High
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

110.04 Engine Coolant Temperature Sensor See 000110.04 Engine Coolant

Input Voltage Low Temperature Input Voltage Low
Diagnostic Procedure in Section 04,
Group 160 of CTM255.
9015
20
18 110.16 Engine Coolant Temperature See 000110.16 Engine Coolant
Moderately High Temperature High Moderately
Severe Diagnostic Procedure in
Section 04, Group 160 of CTM255.

158.17 ECU Power Down Error See 000158.17 ECU Power Down
Error Diagnostic Procedure in
Section 04, Group 160 of CTM255.

171.03 Ambient Air Temperature Sensor Check ambient air temperature

Input Voltage High sensor. See Electrical Component
Specifications. (Group 9015-20.)

Check engine harness wiring for

open and short circuits. See Engine
Control Unit (ECU) Circuit Theory of
Operation. (Group 9015-15.)

171.04 Ambient Air Temperature Sensor Check ambient air temperature

Input Voltage Low sensor. See Electrical Component
Specifications. (Group 9015-20.)

Check engine harness wiring for

open and short circuits. See Engine
Control Unit (ECU) Circuit Theory of
Operation. (Group 9015-15.)

Continued on next page MF82180,0000042 –19–06OCT05–3/8

TM2260 (07JAN06) 9015-20-18 750J, 850J Crawler

010706
PN=202
 References

Symptom Problem Solution

174.03 Fuel Temperature Sensor Input See 000174.03 Fuel Temperature

Voltage High Input Voltage High Diagnostic
Procedure in Section 04, Group 160
of CTM255.

174.04 Fuel Temperature Sensor Input See 000174.04 Fuel Temperature

Voltage Low Input Voltage Low Diagnostic
Procedure in Section 04, Group 160
of CTM255.

174.16 Fuel Temperature High Moderately See 000174.16 Fuel Temperature

Severe High Moderately Severe Diagnostic
Procedure in Section 04, Group 160
of CTM255.
9015
20
611.03 Electronic Injector Wiring Shorted To See 000611.03 Electronic Injector 19
Power Source Wiring Shorted To Power Source
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

611.04 Electronic Injector Wiring Shorted To See 000611.04 Electronic Injector

Ground Wiring Shorted To Ground
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

620.03 ECU Sensor Supply Voltage High See 000620.03 Sensor Supply 1
Voltage High Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

620.04 ECU Sensor Supply Voltage Low See 000620.04 Sensor Supply 1
Voltage Low Diagnostic Procedure in
Section 04, Group 160 of CTM255.

627.01 Electronic Injector Supply Voltage See 000627.01 Electronic Injector

Problem Supply Voltage Problem Diagnostic
Procedure in Section 04, Group 160
of CTM255.

629.13 ECU Failure See 000629.13 ECU Error in Section

04, Group 160 of CTM255.

Continued on next page MF82180,0000042 –19–06OCT05–4/8

TM2260 (07JAN06) 9015-20-19 750J, 850J Crawler

010706
PN=203
 References

Symptom Problem Solution

636.02 Camshaft Position Sensor Input See 000636.02 Pump Position

Noise Sensor Input Noise Diagnostic
Procedure in Section 04, Group 160
of CTM255.

636.08 Camshaft Position Sensor Input See 000636.08 Pump Position

Missing Sensor Input Missing Diagnostic
Procedure in Section 04, Group 160
of CTM255.

636.10 Pump Position Sensor Input Pattern See 000636.10 Pump Position
Error Sensor Input Pattern Error
Diagnostic Procedure in Section 04,
Group 160 of CTM255.
9015
20
20 637.02 Crank Position Input Noise See 000636.02 Crank Position Input
Noise Diagnostic Procedure in
Section 04, Group 160 of CTM255.

637.07 Crank Position/Pump Position Timing See 000637.07 Crank Position/Pump

Moderately Out of Sync Position Timing Moderately Out Of
Sync Diagnostic Procedure in
Section 04, Group 160 of CTM255.

637.08 Crank Position Input Missing See 000637.08 Crank Position Input
Missing Diagnostic Procedure in
Section 04, Group 160 of CTM255.

637.10 Crank Position Input Pattern Error See 000637.10 Crank Position Input
Pattern Error Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

639.13 CAN Network Wiring Fault See 000639.13 CAN Bus Error
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

651.05 Cylinder #1 EI Circuit Open See 000651.05 Cylinder #1 EI

Circuit Open Diagnostic Procedure in
Section 04, Group 160 of CTM255.

651.06 Cylinder #1 EI Circuit Shorted See 000651.06 Cylinder #1 EI

Circuit Shorted Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

Continued on next page MF82180,0000042 –19–06OCT05–5/8

TM2260 (07JAN06) 9015-20-20 750J, 850J Crawler

010706
PN=204
 References

Symptom Problem Solution

651.07 Cylinder #1 EI Fuel Delivery Failure See 000651.07 Cylinder #1 EI Fuel

Delivery Failure Diagnostic
Procedure in Section 04, Group 160
of CTM255.

652.05 Cylinder #2 EI Circuit Open See 000652.05 Cylinder #2 EI

Circuit Open Diagnostic Procedure in
Section 04, Group 160 of CTM255.

652.06 Cylinder #2 EI Circuit Shorted See 000652.06 Cylinder #2 EI

Circuit Shorted Diagnostic Procedure
in Section 04, Group 160 of
CTM255.
9015
652.07 Cylinder #2 EI Fuel Delivery Failure See 000652.07 Cylinder #2 EI Fuel 20
Delivery Failure Diagnostic 21
Procedure in Section 04, Group 160
of CTM255.

653.05 Cylinder #3 EI Circuit Open See 000653.05 Cylinder #3 EI

Circuit Open Diagnostic Procedure in
Section 04, Group 160 of CTM255.

653.06 Cylinder #3 EI Circuit Shorted See 000653.06 Cylinder #3 EI

Circuit Shorted Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

653.07 Cylinder #3 EI Fuel Delivery Failure See 000653.07 Cylinder #3 EI Fuel

Delivery Failure Diagnostic
Procedure in Section 04, Group 160
of CTM255.

654.05 Cylinder #4 EI Circuit Open See 000654.05 Cylinder #4 EI

Circuit Open Diagnostic Procedure in
Section 04, Group 160 of CTM255.

654.06 Cylinder #4 EI Circuit Shorted See 000654.06 Cylinder #4 EI

Circuit Shorted Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

Continued on next page MF82180,0000042 –19–06OCT05–6/8

TM2260 (07JAN06) 9015-20-21 750J, 850J Crawler

010706
PN=205
 References

Symptom Problem Solution

654.07 Cylinder #4 EI Fuel Delivery Failure See 000654.07 Cylinder #4 EI Fuel

Delivery Failure Diagnostic
Procedure in Section 04, Group 160
of CTM255.

655.05 Cylinder #5 EI Circuit Open See 000655.05 Cylinder #5 EI

Circuit Open Diagnostic Procedure in
Section 04, Group 160 of CTM255.

655.06 Cylinder #5 EI Circuit Shorted See 000655.06 Cylinder #5 EI

Circuit Shorted Diagnostic Procedure
in Section 04, Group 160 of
CTM255.
9015
20 655.07 Cylinder #5 EI Fuel Delivery Failure See 000655.07 Cylinder #5 EI Fuel
22 Delivery Failure Diagnostic
Procedure in Section 04, Group 160
of CTM255.

656.05 Cylinder #6 EI Circuit Open See 000656.05 Cylinder #6 EI

Circuit Open Diagnostic Procedure in
Section 04, Group 160 of CTM255.

656.06 Cylinder #6 EI Circuit Shorted See 000656.06 Cylinder #6 EI

Circuit Shorted Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

656.07 Cylinder #6 EI Fuel Delivery Failure See 000656.07 Cylinder #6 EI Fuel

Delivery Failure Diagnostic
Procedure in Section 04, Group 160
of CTM255.

1080.03 Fuel Rail Pressure Sensor Supply See 001080.03 Fuel Rail Pressure
Voltage High Sensor Supply Voltage High
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

1080.04 Fuel Rail Pressure Sensor Supply See 001080.04 Fuel Rail Pressure
Voltage Low Sensor Supply Voltage Low
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

Continued on next page MF82180,0000042 –19–06OCT05–7/8

TM2260 (07JAN06) 9015-20-22 750J, 850J Crawler

010706
PN=206
 References

Symptom Problem Solution

1347.05 Pump Control Valve #1 Is Open, See 001347.05 Pump Control Valve
Shorted to Ground, or Overloaded #1 Error Diagnostic Procedure in
Section 04, Group 160 of CTM255.

1347.07 Fuel Rail Pressure Incorrect See 001347.07 Fuel Rail Pressure
Control Error Diagnostic Procedure
in Section 04, Group 160 of
CTM255.

1347.10 Pump Control Valve #1 Fault See 001347.10 Pump Control Valve
#1 Fuel Flow Not Detected
Diagnostic Procedure in Section 04,
Group 160 of CTM255.
9015
1348.05 Pump Control Valve #2 Is Open, See 001348.05 Pump Control Valve 20
Shorted to Ground, or Overloaded #2 Error Diagnostic Procedure in 23
Section 04, Group 160 of CTM255.

1348.10 Pump Control Valve #2 Fault See 001348.10 Pump Control Valve
#2 Fuel Flow Not Detected
Diagnostic Procedure in Section 04,
Group 160 of CTM255.

1568.02 Torque Curve Selection Invalid From See 001568.02 Torque Curve
TCU Selection Invalid in Section 04,
Group 160 of CTM255.

1569.31 Fuel Derate See 001569.31 Fuel Derate in

Section 04, Group 160 of CTM255.

2000.13 ECU/Monitor Mismatch See 002000.13 Security Violation in

Section 04, Group 160 of CTM 255.

MF82180,0000042 –19–06OCT05–8/8

TM2260 (07JAN06) 9015-20-23 750J, 850J Crawler

010706
PN=207
 References

Transmission Control Unit (TCU) Diagnostic

Trouble Codes

The diagnostic trouble code number is indicated by an

(SPN) Suspect Parameter Number and a (FMI) Failure
Mode Indicator number. (522421.02) 522421 is the SPN
number and 02 is the FMI number.

Use SERVICE ADVISOR system or see Stored Codes

in the Display Menu to view stored diagnostic trouble
codes.

Symptom Problem Solution

70.00 Both Park Lock Lever inputs are on Check T16 BLU and E05 WHT wires
9015 in the operator’s station harness for
20 opens and shorts.
24
Check Park Lock Lever Switch
(S20) for continuity between pins A
and C in the park position, and
continuity between pins A and B in
the run position. Replace switch if
failed.

70.01 Both Park Lock Lever inputs are off Check T16 BLU and E05 WHT wires
in the operator’s station harness for
opens and shorts.

Check Park Lock Lever Switch

(S20) for continuity between pins A
and C in the park position, and
continuity between pins A and B in
the run position. Replace switch if
failed.

91.00 Engine Speed Control Switch input Enter service menu on CMU and go
is greater than stored maximum to 3-Diagnostics, 1-Live Values,
calibrated value 4-Input Voltages. Press NEXT
twice. Record Engine Throttle with
engine speed control switch (S22)
at fast idle position. If reading is
within 2.54—3.58 V, calibrate the
TCU. See Transmission Control Unit
(TCU) Calibration. (Group 9015-15.)

SERVICE ADVISOR is a trademark of Deere & Company Continued on next page MF82180,0000031 –19–28NOV05–1/56

TM2260 (07JAN06) 9015-20-24 750J, 850J Crawler

010706
PN=208
 References

Symptom Problem Solution

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015-20.)

Check T15 BLU, E02 WHT, and R08

BLK wires in the operator’s station
harness for opens and shorts.

91.01 Engine Speed Control Switch input Enter service menu on CMU and go
is less than stored minimum to 3-Diagnostics, 1-Live Values,
calibrated value 4-Input Voltages. Press NEXT
twice. Record Engine Throttle with
engine speed control switch (S22)
9015
at slow idle position. If reading is 20
within 0.44—1.07 V, calibrate the 25
TCU. See Transmission Control Unit
(TCU) Calibration. (Group 9015-15.)

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015-20.)

Check T15 BLU, E02 WHT, and R08

BLK wires in the operator’s station
harness for opens and shorts.

91.03 Engine Speed Control Switch input Disconnect engine speed control
voltage high switch (S22). Turn key switch on
and check T15 BLU wire for 4.75—
5.25 V. If voltage is out of range,
check for a short-to-power.

Check R08 BLK wire for continuity to

Bussed Ground Sensor Connector
(X7). Repair wire if no continuity is
measured.

Continued on next page MF82180,0000031 –19–28NOV05–2/56

TM2260 (07JAN06) 9015-20-25 750J, 850J Crawler

010706
PN=209
 References

Symptom Problem Solution

Connect engine speed control

switch (S22) and enter service
menu on CMU and go to
3-Diagnostics, 1-Live Values,
4-Input Voltages. Press NEXT
twice. Move engine speed control
switch and verify that the Engine
Throttle voltage changes. If voltage
doesn’t change, check E02 WHT
wire for open and short circuits.

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015
20 9015-20.)
26
91.04 Engine Speed Control Switch input Disconnect engine speed control
voltage low switch (S22). Turn key switch on
and check T15 BLU wire for 4.75—
5.25 V. If voltage is out of range,
check for a short-to-ground.

Check R08 BLK wire for continuity to

Bussed Ground Sensor Connector
(X7). Repair wire if no continuity is
measured.

Connect engine speed control

switch (S22) and enter service
menu on CMU and go to
3-Diagnostics, 1-Live Values,
4-Input Voltages. Press NEXT
twice. Move engine speed control
switch and verify that the Engine
Throttle voltage changes. If voltage
doesn’t change, check E02 WHT
wire for open and short circuits.

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–3/56

TM2260 (07JAN06) 9015-20-26 750J, 850J Crawler

010706
PN=210
 References

Symptom Problem Solution

91.15 Engine Speed Control Switch Enter service menu on CMU and go
minimum calibration value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Press NEXT
twice. Record Engine Throttle with
engine speed control switch (S22)
at slow idle position. If reading is
within 0.44—1.07 V, calibrate the
TCU. See Transmission Control Unit
(TCU) Calibration. (Group 9015-15.)

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015-20.)
9015
20
91.16 Engine Speed Control Switch Enter service menu on CMU and go 27
maximum calibration value is too to 3-Diagnostics, 1-Live Values,
high 4-Input Voltages. Press NEXT
twice. Record Engine Throttle with
engine speed control switch (S22)
at fast idle position. If reading is
within 2.53—3.59 V, calibrate the
TCU. See Transmission Control Unit
(TCU) Calibration. (Group 9015-15.)

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015-20.)

91.17 Engine Speed Control Switch Enter service menu on CMU and go
minimum calibration value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Press NEXT
twice. Record Engine Throttle with
engine speed control switch (S22)
at slow idle position. If reading is
within 0.44—1.07 V, calibrate the
TCU. See Transmission Control Unit
(TCU) Calibration. (Group 9015-15.)

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–4/56

TM2260 (07JAN06) 9015-20-27 750J, 850J Crawler

010706
PN=211
 References

Symptom Problem Solution

91.18 Engine Speed Control Switch Enter service menu on CMU and go
maximum calibration value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Press NEXT
twice. Record Engine Throttle with
engine speed control switch (S22)
at fast idle position. If reading is
within 2.53—3.59 V, calibrate the
TCU. See Transmission Control Unit
(TCU) Calibration. (Group 9015-15.)

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015-20.)
9015
20
28 116.00 Brake Pressure is too high Perform Park Brake Test (Group
9026-25)

116.01 Brake Pressure is too low Perform Park Brake Test (Group
9026-25)

116.03 Brake Pressure Sensor input voltage With key switch off, disconnect
is too high brake pressure sensor (B35).
Connect (JDG1933) 3-pin test
harness. Connect (JT07237-1)
single-pin test harness to red and
black wire connectors on 3-pin test
harness and multimeter. Turn key
switch on. Check for 4.75—5.25 V. If
voltage is out of range, check T12
BLU and R07 BLK wires for open
circuits and shorts-to-ground.

Connect single-pin test harness to

white and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
0.27—4.81 V. If voltage is out of
range, check T09 BLU wire for a
short-to-power.

Replace brake pressure sensor

(B35).

Continued on next page MF82180,0000031 –19–28NOV05–5/56

TM2260 (07JAN06) 9015-20-28 750J, 850J Crawler

010706
PN=212
 References

Symptom Problem Solution

116.04 Brake Pressure Sensor input voltage With key switch off, disconnect
is too low brake pressure sensor (B35).
Connect (JDG1933) 3-pin test
harness. Connect (JT07237-1)
single-pin test harness to red and
black wire connectors on 3-pin test
harness and multimeter. Turn key
switch on. Check for 4.75—5.25 V. If
voltage is out of range, check T12
BLU and R07 BLK wires for open
circuits and shorts-to-ground.

Connect single-pin test harness to

white and black wire connectors on
9015
3-pin test harness and multimeter. 20
Turn key switch on. Check for 29
0.27—4.81 V. If voltage is out of
range, check T09 BLU wire for a
short-to-power.

Replace brake pressure sensor

(B35).

158.03 TCU system voltage too high See Alternator Test Procedure.
(Group 9015-20.)

Check batteries. See Handling,

Checking And Servicing Batteries
Carefully and Check Battery
Electrolyte Level and Terminals.
(Operator’s Manual.)

158.04 TCU system voltage too low See Alternator Test Procedure.
(Group 9015-20.)

Check batteries. See Handling,

Checking And Servicing Batteries
Carefully and Check Battery
Electrolyte Level and Terminals.
(Operator’s Manual.)

177.00 Transmission temperature too high See Overheating - Flow Chart.

(Group 9026-15.)

Continued on next page MF82180,0000031 –19–28NOV05–6/56

TM2260 (07JAN06) 9015-20-29 750J, 850J Crawler

010706
PN=213
 References

Symptom Problem Solution

190.09 CAN communication error, no engine View engine speed on CMU with
speed message received from ECU engine running. If speed is correct,
check M12 YEL and M13 LGRN
wires in operator’s station harness,
transmission harness, and engine
harness for open and short circuits.

Check ECU DTCs. See Engine

Control Unit (ECU) Diagnostic
Trouble Codes. (Group 9015-20.)

190.19 CAN communication error, invalid View engine speed on CMU with
engine speed message received engine running. If speed is correct,
from ECU check M12 YEL and M13 LGRN
9015
20 wires in operator’s station harness,
30 transmission harness, and engine
harness for open and short circuits.

Check ECU DTCs. See Engine

Control Unit (ECU) Diagnostic
Trouble Codes. (Group 9015-20.)

521.00 Decelerator Sensor input is greater Enter service menu on CMU and go
than stored maximum calibrated to 3-Diagnostics, 1-Live Values,
value 4-Input Voltages. Record Decel
voltage with decel pedal down to first
stop. If the reading is within 3.25—
3.75 V, calibrate the TCU. See
Transmission Control Unit (TCU)
Calibration. (Group 9015-20.)

Adjust decelerator sensor (B1).

See Decelerator/Brake Pedal
Adjustment. (Group 9015-20.)

Remove the decelerator sensor

(B1) and verify the shaft is turning.
Replace sensor if necessary.

Continued on next page MF82180,0000031 –19–28NOV05–7/56

TM2260 (07JAN06) 9015-20-30 750J, 850J Crawler

010706
PN=214
 References

Symptom Problem Solution

521.01 Decelerator Sensor input is less than Enter service menu on CMU and go
stored minimum calibrated value to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Record Decel
voltage with decel pedal up. If the
reading is within 1.25—1.75 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust decelerator sensor (B1).

See Decelerator/Brake Pedal
Adjustment. (Group 9015-20.)

Remove the decelerator sensor

9015
(B1) and verify the shaft is turning. 20
Replace sensor if necessary. 31

521.03 Decelerator Sensor input voltage is With key switch off, disconnect
too high decelerator sensor (B1). Connect
(JDG1933) 3-pin test harness.
Connect (JT07237-1) single-pin test
harness to red and black wire
connectors on 3-pin test harness
and multimeter. Turn key switch on.
Check for 4.75—5.25 V. If voltage is
out of range, check T02 BLU and
R02 BLK wires for open circuits and
shorts-to-ground.

Connect single-pin test harness to

white and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
0.05—4.95 V. If voltage is out of
range, check T03 BLU wire for a
short-to-power.

Connect decelerator sensor (B1)

and enter service menu on CMU and
go to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Press pedal down
and release to verify that the voltage
changes. If voltage doesn’t change,
check T03 BLU wire for open and
short circuits.

Continued on next page MF82180,0000031 –19–28NOV05–8/56

TM2260 (07JAN06) 9015-20-31 750J, 850J Crawler

010706
PN=215
 References

Symptom Problem Solution

Replace decelerator sensor (B1).

521.04 Decelerator Sensor input voltage is With key switch off, disconnect
too low decelerator sensor (B1). Connect
(JDG1933) 3-pin test harness.
Connect (JT07237-1) single-pin test
harness to red and black wire
connectors on 3-pin test harness
and multimeter. Turn key switch on.
Check for 4.75—5.25 V. If voltage is
out of range, check T02 BLU and
R02 BLK wires for open circuits and
shorts-to-ground.
9015
20 Connect single-pin test harness to
32 white and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
0.05—4.95 V. If voltage is out of
range, check T03 BLU wire for a
short-to-power.

Connect decelerator sensor (B1)

and enter service menu on CMU and
go to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Press pedal down
and release to verify that the voltage
changes. If voltage doesn’t change,
check T03 BLU wire for open and
short circuits.

Replace decelerator sensor (B1).

521.05 Decelerator Sensor brake calibration Enter service menu on CMU and go
value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Record Decel
voltage with decel pedal in brake
position. If the reading is within
3.79—3.99 V, calibrate the TCU.
See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

Adjust decelerator sensor (B1).

See Decelerator/Brake Pedal
Adjustment. (Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–9/56

TM2260 (07JAN06) 9015-20-32 750J, 850J Crawler

010706
PN=216
 References

Symptom Problem Solution

Remove the decelerator sensor

(B1) and verify the shaft is turning.
Replace sensor if necessary.

521.06 Decelerator Sensor brake calibration Enter service menu on CMU and go
value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Record Decel
voltage with decel in brake position.
If the reading is within 3.79—3.99 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust decelerator sensor (B1).

9015
See Decelerator/Brake Pedal 20
Adjustment. (Group 9015-20.) 33

Remove the decelerator sensor

(B1) and verify the shaft is turning.
Replace sensor if necessary.

521.15 Decelerator Sensor minimum Enter service menu on CMU and go

calibration value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Record Decel
reading voltage with decel pedal up.
If the reading is within 1.25—1.75 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust decelerator sensor (B1).

See Decelerator/Brake Pedal
Adjustment. (Group 9015-20.)

Remove the decelerator sensor

(B1) and verify the shaft is turning.
Replace sensor if necessary.

Continued on next page MF82180,0000031 –19–28NOV05–10/56

TM2260 (07JAN06) 9015-20-33 750J, 850J Crawler

010706
PN=217
 References

Symptom Problem Solution

521.16 Decelerator Sensor maximum Enter service menu on CMU and go

calibration value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Record Decel
voltage with decel pedal down. If the
reading is within 3.25—3.75 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust decelerator sensor (B1).

See Decelerator/Brake Pedal
Adjustment. (Group 9015-20.)

Remove the decelerator sensor

9015
20 (B1) and verify the shaft is turning.
34 Replace sensor if necessary.

521.17 Decelerator Sensor minimum Enter service menu on CMU and go

calibration value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Record Decel
voltage with decel pedal up. If the
reading is within 1.25—1.75 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust decelerator sensor (B1).

See Decelerator/Brake Pedal
Adjustment. (Group 9015-20.)

Remove the decelerator sensor

(B1) and verify the shaft is turning.
Replace sensor if necessary.

521.18 Decelerator Sensor maximum Enter service menu on CMU and go

calibration value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Record Decel
voltage with decel pedal down. If the
reading is within 3.25—3.75 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–11/56

TM2260 (07JAN06) 9015-20-34 750J, 850J Crawler

010706
PN=218
 References

Symptom Problem Solution

Adjust decelerator sensor (B1).

See Decelerator/Brake Pedal
Adjustment. (Group 9015-20.)

Remove the decelerator sensor

(B1) and verify the shaft is turning.
Replace sensor if necessary.

581.00 Transmission Speed Control Switch Enter service menu on CMU and go
input is greater than stored to 3-Diagnostics, 1-Live Values,
maximum calibrated value 4-Input Voltages. Access Speed
Button reading. Increase and
decrease the speed using the
transmission speed control buttons
9015
and note the reading on the CMU. If 20
readings are within 0.50—3.50 V, 35
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

With key switch off, disconnect

harness from transmission speed
control sensor (B4). Connect
(JT07239-3) 3-pin test harness
between sensor and harness.
Connect (JT07237-1) single-pin test
harness to white and black wire
connectors on 3 pin test harness
and multimeter. Record resistance
with no buttons pressed and with
each button pressed. See Electrical
Component Specifications. (Group
9015-20.) Replace sensor as
necessary.

Check R21 BLK wire for an open

circuit.

Continued on next page MF82180,0000031 –19–28NOV05–12/56

TM2260 (07JAN06) 9015-20-35 750J, 850J Crawler

010706
PN=219
 References

Symptom Problem Solution

581.01 Transmission Speed Control Switch Enter service menu on CMU and go
input is less than stored minimum to 3-Diagnostics, 1-Live Values,
calibrated value 4-Input Voltages. Access Speed
Button reading. Increase and
decrease the speed using the
transmission speed control buttons
and note the reading on the CMU. If
readings are within 0.50—3.50 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

With key switch off, disconnect

harness from transmission speed
9015
20 control sensor (B4). Connect
36 (JT07239-3) 3-pin test harness
between sensor and harness.
Connect (JT07237-1) single-pin test
harness to white and black wire
connectors on 3 pin test harness
and multimeter. Record resistance
with no buttons pressed and with
each button pressed. See Electrical
Component Specifications. (Group
9015-20.) Replace sensor as
necessary.

Check T30 BLU and T33 BLU wires

for open circuits and
shorts-to-ground.

581.03 Transmission Speed Control Switch Enter service menu on CMU and go
input voltage is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Speed
Button reading. Increase and
decrease the speed using the
transmission speed control buttons
and note the reading on the CMU. If
readings are within 0.50—3.50 V,
check T30 BLU, T33 BLU, and R21
BLK wires for intermittent open and
short circuits.

Continued on next page MF82180,0000031 –19–28NOV05–13/56

TM2260 (07JAN06) 9015-20-36 750J, 850J Crawler

010706
PN=220
 References

Symptom Problem Solution

With key switch off, disconnect

harness from transmission speed
control sensor (B4). Connect
(JT07239-3) 3-pin test harness
between sensor and harness.
Connect (JT07237-1) single-pin test
harness to white and black wire
connectors on 3 pin test harness
and multimeter. Record resistance
with no buttons pressed and with
each button pressed. See Electrical
Component Specifications. (Group
9015-20.) Replace sensor as
necessary.
9015
20
Check T33 BLU wire for a 37
short-to-power.

Check R21 BLK wire for open circuit.

581.04 Transmission Speed Control Switch Enter service menu on CMU and go
input voltage is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Speed
Button reading. Increase and
decrease the speed using the
transmission speed control buttons
and note the reading on the CMU. If
readings are within 0.50—3.50 V,
check T30 BLU, T33 BLU, and R21
BLK wires for intermittent open and
short circuits.

Continued on next page MF82180,0000031 –19–28NOV05–14/56

TM2260 (07JAN06) 9015-20-37 750J, 850J Crawler

010706
PN=221
 References

Symptom Problem Solution

With key switch off, disconnect

harness from transmission speed
control sensor (B4). Connect
(JT07239-3) 3-pin test harness
between sensor and harness.
Connect (JT07237-1) single-pin test
harness to white and black wire
connectors on 3 pin test harness
and multimeter. Record resistance
with no buttons pressed and with
each button pressed. See Electrical
Component Specifications. (Group
9015-20.) Replace sensor as
necessary.
9015
20
38 Check T30 BLU and T33 BLU wires
for open circuits and
shorts-to-ground.

581.15 Transmission Speed Control Switch Enter service menu on CMU and go
minimum calibration value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Speed
Button reading. Increase and
decrease the speed using the
transmission speed control buttons
and note the reading on the CMU. If
readings are within 0.50—1.22 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–15/56

TM2260 (07JAN06) 9015-20-38 750J, 850J Crawler

010706
PN=222
 References

Symptom Problem Solution

With key switch off, disconnect

harness from transmission speed
control sensor (B4). Connect
(JT07239-3) 3-pin test harness
between sensor and harness.
Connect (JT07237-1) single-pin test
harness to white and black wire
connectors on 3 pin test harness
and multimeter. Record resistance
with no buttons pressed and with
each button pressed. See Electrical
Component Specifications. (Group
9015-20.) Replace sensor as
necessary.
9015
20
Check T33 BLU wire for a 39
short-to-power.

Check R21 BLK wire for an open

circuit.

581.16 Transmission Speed Control Switch Enter service menu on CMU and go
maximum calibration value is too to 3-Diagnostics, 1-Live Values,
high 4-Input Voltages. Access Speed
Button reading. Increase and
decrease the speed using the
transmission speed control buttons
and note the reading on the CMU. If
readings are within 2.66—3.50 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–16/56

TM2260 (07JAN06) 9015-20-39 750J, 850J Crawler

010706
PN=223
 References

Symptom Problem Solution

With key switch off, disconnect

harness from transmission speed
control sensor (B4). Connect
(JT07239-3) 3-pin test harness
between sensor and harness.
Connect (JT07237-1) single-pin test
harness to white and black wire
connectors on 3 pin test harness
and multimeter. Record resistance
with no buttons pressed and with
each button pressed. See Electrical
Component Specifications. (Group
9015-20.) Replace sensor as
necessary.
9015
20
40 Check T33 BLU wire for a
short-to-power.

Check R21 BLK wire for an open

circuit.

581.17 Transmission Speed Control Switch Enter service menu on CMU and go
minimum calibration value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Speed
Button reading. Increase and
decrease the speed using the
transmission speed control buttons
and note the reading on the CMU. If
readings are within 0.50—1.22 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–17/56

TM2260 (07JAN06) 9015-20-40 750J, 850J Crawler

010706
PN=224
 References

Symptom Problem Solution

With key switch off, disconnect

harness from transmission speed
control sensor (B4). Connect
(JT07239-3) 3-pin test harness
between sensor and harness.
Connect (JT07237-1) single-pin test
harness to white and black wire
connectors on 3 pin test harness
and multimeter. Record resistance
with no buttons pressed and with
each button pressed. See Electrical
Component Specifications. (Group
9015-20.) Replace sensor as
necessary.
9015
20
Check T30 BLU and T33 BLU wires 41
for open circuits and
shorts-to-ground.

581.18 Transmission Speed Control Switch Enter service menu on CMU and go
maximum calibration value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Speed
Button reading. Increase and
decrease the speed using the
transmission speed control buttons
and note the reading on the CMU. If
readings are within 2.66—3.50 V,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–18/56

TM2260 (07JAN06) 9015-20-41 750J, 850J Crawler

010706
PN=225
 References

Symptom Problem Solution

With key switch off, disconnect

harness from transmission speed
control sensor (B4). Connect
(JT07239-3) 3-pin test harness
between sensor and harness.
Connect (JT07237-1) single-pin test
harness to white and black wire
connectors on 3 pin test harness
and multimeter. Record resistance
with no buttons pressed and with
each button pressed. See Electrical
Component Specifications. (Group
9015-20.) Replace sensor as
necessary.
9015
20
42 Check T30 BLU and T33 BLU wires
for open circuits and
shorts-to-ground.

604.3 Neutral Start Switch input open If DTC 2661.03 or 2661.04 exists, fix
circuit that code first and it may eliminate
this code also.

Disconnect neutral start switch

(S20). Check pins A and B for a
short-to-ground. Replace switch if
shorted.

Move FNR lever to all positions

while checking for continuity
between pins A and B. Continuity
should be measured only in neutral
position. Replace switch as
necessary.

Check T34 BLU wire for an open

circuit.

604.04 Neutral Start Switch input short If DTC 2661.03 or 266.04 exists, fix
circuit that code first and it may eliminate
this code also.

Continued on next page MF82180,0000031 –19–28NOV05–19/56

TM2260 (07JAN06) 9015-20-42 750J, 850J Crawler

010706
PN=226
 References

Symptom Problem Solution

Disconnect neutral start switch

(S20). Check pins A and B for a
short-to-ground. Replace switch if
shorted.

Move FNR lever to all positions

while checking for continuity
between pins A and B. Continuity
should be measured only in neutral
position. Replace switch as
necessary.

Check T34 BLU wire for

short-to-ground.
9015
20
604.15 Neutral Start Switch minimum If DTC 2661.15 exists, fix that code 43
calibration value is too high first and it may eliminate this code
also.

Disconnect neutral start switch

(S20). Check pins A and B for a
short-to-ground. Replace switch if
shorted.

Move FNR lever to all positions

while checking for continuity
between pins A and B. Continuity
should be measured only in neutral
position. Replace switch as
necessary.

Adjust FNR sensor (B2) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)

604.16 Neutral Start Switch maximum If DTC 2661.16 exists, fix that code
calibration value is too high first and it may eliminate this code
also.

Disconnect neutral start switch

(S20). Check pins A and B for a
short-to-ground. Replace switch if
shorted.

Continued on next page MF82180,0000031 –19–28NOV05–20/56

TM2260 (07JAN06) 9015-20-43 750J, 850J Crawler

010706
PN=227
 References

Symptom Problem Solution

Move FNR lever to all positions

while checking for continuity
between pins A and B. Continuity
should be measured only in neutral
position. Replace switch as
necessary.

Adjust FNR sensor (B2) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)

604.17 Neutral Start Switch minimum If DTC 2661.17 exists, fix that code
calibration value is too low first and it may eliminate this code
also.
9015
20
44 Disconnect neutral start switch
(S20). Check pins A and B for a
short-to-ground. Replace switch if
shorted.

Move FNR lever to all positions

while checking for continuity
between pins A and B. Continuity
should be measured only in neutral
position. Replace switch as
necessary.

Adjust FNR sensor (B2) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)

604.18 Neutral Start Switch maximum If DTC 2661.18 exists, fix that code
calibration value is too low first and it may eliminate this code
also.

Disconnect neutral start switch

(S20). Check pins A and B for a
short-to-ground. Replace switch if
shorted.

Continued on next page MF82180,0000031 –19–28NOV05–21/56

TM2260 (07JAN06) 9015-20-44 750J, 850J Crawler

010706
PN=228
 References

Symptom Problem Solution

Move FNR lever to all positions

while checking for continuity
between pins A and B. Continuity
should be measured only in neutral
position. Replace switch as
necessary.

Adjust FNR sensor (B2) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)

619.05 Brake Solenoid is not responding Check T24 BLU wire and G10 BLK
wires for open and short circuits.
9015
Check park brake solenoids (Y2 20
and Y15) . See Electrical 45
Component Specifications. (Group
9015-20.)

With engine running, move park lock

lever into the run position and note
park brake indicator light. If light
goes out, check T24 BLU and G10
BLK wires for intermittent open and
short circuits.

Replace TCU.

620.03 TCU 5 V supply voltage too high Check FNR sensor (B32) wire T01
(blue) for a short-to-power.

Check decelerator sensor (B1) wire

T02 BLU for a short-to-power.

Check steer sensor (B33) wire T29

BLU for a short-to-power.

Check transmission speed control

sensor (B34) wire T30 BLU for a
short-to-power.

Check engine speed control

switch (S22) wire T15 BLU for a
short-to-power.

Continued on next page MF82180,0000031 –19–28NOV05–22/56

TM2260 (07JAN06) 9015-20-45 750J, 850J Crawler

010706
PN=229
 References

Symptom Problem Solution

Check motor speed sensor left

(B2) wire T04 BLU for a
short-to-power.

Check motor speed sensor right

(B3) wire T06 BLU for a
short-to-power.

Check hydrostatic pump case

pressure sensor (B35) wire T12
BLU for a short-to-power.

Check hydrostatic charge

pressure sensor (B4) wire T08 BLU
9015
20 for a short-to-power.
46
Check blade angle switch (S4) wire
T14 BLU for a short-to-power.

Check FNR sensor (B32). See

Electrical Component Specifications.
(Group 9015-20.)

Check decelerator sensor (B1).

See Electrical Component
Specifications. (Group 9015-20.)

Check steer sensor (B33). See

Electrical Component Specifications.
(Group 9015-20.)

Check transmission speed control

sensor (B34). See Electrical
Component Specifications. (Group
9015-20.)

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015-20.)

Check motor speed sensor left

(B2). See Electrical Component
Specifications. (Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–23/56

TM2260 (07JAN06) 9015-20-46 750J, 850J Crawler

010706
PN=230
 References

Symptom Problem Solution

Check motor speed sensor right

(B3). See Electrical Component
Specifications. (Group 9015-20.)

Check hydrostatic pump case

pressure sensor (B35). See
Electrical Component Specifications.
(Group 9015-20.)

Check hydrostatic charge

pressure sensor (B4). See
Electrical Component Specifications.
(Group 9015-20.)
9015
Check blade angle switch (S4). 20
See Electrical Component 47
Specifications. (Group 9015-20.)

Replace Transmission Control Unit

(TCU) (A4).

620.04 TCU 5 V supply voltage too low Check FNR sensor (B32) wire T01
(blue) for an open circuit or
short-to-ground.

Check decelerator sensor (B1) wire

T02 BLU for an open circuit or
short-to-ground.

Check steer sensor (B33) wire T29

BLU for an open circuit or
short-to-ground.

Check transmission speed control

sensor (B34) wire T30 BLU for an
open circuit or short-to-ground.

Check engine speed control

switch (S22) wire T15 BLU for an
open circuit or short-to-ground.

Check motor speed sensor left

(B2) wire T04 BLU for an open
circuit or short-to-ground.

Continued on next page MF82180,0000031 –19–28NOV05–24/56

TM2260 (07JAN06) 9015-20-47 750J, 850J Crawler

010706
PN=231
 References

Symptom Problem Solution

Check motor speed sensor right

(B3) wire T06 BLU for an open
circuit or short-to-ground.

Check hydrostatic pump case

pressure sensor (B35) wire T12
BLU for an open circuit or
short-to-ground.

Check hydrostatic charge

pressure sensor (B4) wire T08 BLU
for an open circuit or
short-to-ground.
9015
20 Check blade angle switch (S4) wire
48 T14 BLU for an open circuit or
short-to-ground.

Check FNR sensor (B32). See

Electrical Component Specifications.
(Group 9015-20.)

Check decelerator sensor (B1).

See Electrical Component
Specifications. (Group 9015-20.)

Check steer sensor (B33). See

Electrical Component Specifications.
(Group 9015-20.)

Check transmission speed control

sensor (B34). See Electrical
Component Specifications. (Group
9015-20.)

Check engine speed control

switch (S22). See Electrical
Component Specifications. (Group
9015-20.)

Check motor speed sensor left

(B2). See Electrical Component
Specifications. (Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–25/56

TM2260 (07JAN06) 9015-20-48 750J, 850J Crawler

010706
PN=232
 References

Symptom Problem Solution

Check motor speed sensor right

(B3). See Electrical Component
Specifications. (Group 9015-20.)

Check hydrostatic pump case

pressure sensor (B35). See
Electrical Component Specifications.
(Group 9015-20.)

Check hydrostatic charge

pressure sensor (B4). See
Electrical Component Specifications.
(Group 9015-20.)
9015
Check blade angle switch (S4). 20
See Electrical Component 49
Specifications. (Group 9015-20.)

Replace Transmission Control Unit

(TCU) (A4).

907.03 Motor Speed Sensor Left input too Disconnect motor speed sensor
high left (B2) and connect JDG1933
3-pin test harness. Connect
JT07237-1 single-pin test harness to
the red and black wires of the 3-pin
test harness. Turn key switch on and
check for 4.75—5.25 V. If voltage is
out of range, check T04 BLU and
R03 BLK for an open or short circuit.

Connect JT07237-1 single-pin test

harness to the white and black wires
of the 3-pin test harness. Check for
0.11—1.10 V or 3.90—4.85 V. If
voltage is out of range, check T05
BLU for a short-to-power.

Check sensor. See Electrical

Component Specifications. (Group
9015-20.) Replace motor speed
sensor left (B2) as necessary.

Continued on next page MF82180,0000031 –19–28NOV05–26/56

TM2260 (07JAN06) 9015-20-49 750J, 850J Crawler

010706
PN=233
 References

Symptom Problem Solution

907.04 Motor Speed Sensor Left input too Disconnect motor speed sensor
low left (B2) and connect JDG1933
3-pin test harness. Connect
JT07237-1 single-pin test harness to
the red and black wires of the 3-pin
test harness. Turn key switch on and
check for 4.75—5.25 V. If voltage is
out of range, check T04 BLU and
R03 BLK for an open or short circuit.

Connect JT07237-1 single-pin test

harness to the white and black wires
of the 3-pin test harness. Check for
0.11—1.10 V or 3.90—4.85 V. If
9015
20 voltage is out of range, check T05
50 BLU for an open circuit or
short-to-ground.

Check sensor. See Electrical

Component Specifications. (Group
9015-20.) Replace motor speed
sensor left (B2) as necessary.

907.07 Motor Speed Sensor Left is not Disconnect motor speed sensor
responding left (B2) and connect JDG1933
3-pin test harness. Connect
JT07237-1 single-pin test harness to
the red and black wires of the 3-pin
test harness. Turn key switch on and
check for 4.75—5.25 V. If voltage is
out of range, check T04 BLU and
R03 BLK for an open or short circuit.

Connect JT07237-1 single-pin test

harness to the white and black wires
of the 3-pin test harness. Check for
0.11—1.10 V or 3.90—4.85 V. If
voltage is out of range, check T05
BLU for an open or short circuit.

Check sensor. See Electrical

Component Specifications. (Group
9015-20.) Replace motor speed
sensor left (B2) as necessary.

Continued on next page MF82180,0000031 –19–28NOV05–27/56

TM2260 (07JAN06) 9015-20-50 750J, 850J Crawler

010706
PN=234
 References

Symptom Problem Solution

907.12 Motor Speed Sensor Left input at 2.5 Disconnect motor speed sensor
V left (B2) and connect JDG1933
3-pin test harness. Connect
JT07237-1 single-pin test harness to
the red and black wires of the 3-pin
test harness. Turn key switch on and
check for 4.75—5.25 V. If voltage is
out of range, check T04 BLU and
R03 BLK for an open or short circuit.

Connect JT07237-1 single-pin test

harness to the white and black wires
of the 3-pin test harness. Check for
0.11—1.10 V or 3.90—4.85 V. If
9015
voltage is out of range, check T05 20
BLU for an open or short circuit. 51

Check sensor. See Electrical

Component Specifications. (Group
9015-20.) Replace motor speed
sensor left (B2) as necessary.

908.03 Motor Speed Sensor Right input too Disconnect motor speed sensor
high right (B3) and connect JDG1933
3-pin test harness. Connect
JT07237-1 single-pin test harness to
the red and black wires of the 3-pin
test harness. Turn key switch on and
check for 4.75—5.25 V. If voltage is
out of range, check T06 BLU and
R04 BLK for an open or short circuit.

Connect JT07237-1 single-pin test

harness to the white and black wires
of the 3-pin test harness. Check for
0.11—1.10 V or 3.90—4.85 V. If
voltage is out of range, check T07
BLU for a short-to-power.

Check sensor. See Electrical

Component Specifications. (Group
9015-20.) Replace motor speed
sensor right (B3) as necessary.

Continued on next page MF82180,0000031 –19–28NOV05–28/56

TM2260 (07JAN06) 9015-20-51 750J, 850J Crawler

010706
PN=235
 References

Symptom Problem Solution

908.04 Motor Speed Sensor Right input too Disconnect motor speed sensor
low right (B3) and connect JDG1933
3-pin test harness. Connect
JT07237-1 single-pin test harness to
the red and black wires of the 3-pin
test harness. Turn key switch on and
check for 4.75—5.25 V. If voltage is
out of range, check T06 BLU and
R04 BLK for an open or short circuit.

Connect JT07237-1 single-pin test

harness to the white and black wires
of the 3-pin test harness. Check for
0.11—1.10 V or 3.90—4.85 V. If
9015
20 voltage is out of range, check T07
52 BLU for an open circuit or
short-to-ground.

Check sensor. See Electrical

Component Specifications. (Group
9015-20.) Replace motor speed
sensor right (B3) as necessary.

908.07 Motor Speed Sensor Right is not Disconnect motor speed sensor
responding right (B3) and connect JDG1933
3-pin test harness. Connect
JT07237-1 single-pin test harness to
the red and black wires of the 3-pin
test harness. Turn key switch on and
check for 4.75—5.25 V. If voltage is
out of range, check T06 BLU and
R04 BLK for an open or short circuit.

Connect JT07237-1 single-pin test

harness to the white and black wires
of the 3-pin test harness. Check for
0.11—1.10 V or 3.90—4.85 V. If
voltage is out of range, check T07
BLU for an open or short circuit.

Check sensor. See Electrical

Component Specifications. (Group
9015-20.) Replace motor speed
sensor right (B3) as necessary.

Continued on next page MF82180,0000031 –19–28NOV05–29/56

TM2260 (07JAN06) 9015-20-52 750J, 850J Crawler

010706
PN=236
 References

Symptom Problem Solution

908.12 Motor Speed Sensor Right input at Disconnect motor speed sensor
2.5 V right (B3) and connect JDG1933
3-pin test harness. Connect
JT07237-1 single-pin test harness to
the red and black wires of the 3-pin
test harness. Turn key switch on and
check for 4.75—5.25 V. If voltage is
out of range, check T06 BLU and
R04 BLK for an open or short circuit.

Connect JT07237-1 single-pin test

harness to the white and black wires
of the 3-pin test harness. Check for
0.11—1.10 V or 3.90—4.85 V. If
9015
voltage is out of range, check T07 20
BLU for an open or short circuit. 53

Check sensor. See Electrical

Component Specifications. (Group
9015-20.) Replace motor speed
sensor right (B3) as necessary.

977.05 Hydraulic Fan Reversing Solenoid is Check H03 GRN wire and G11 BLK
not responding wires for open and short circuits.

Check hydraulic fan reversing

solenoid (Y6). See Electrical
Component Specifications. (Group
9015-20.)

With engine running, press the fan

reversing switch (S23) and note
fan reversing indicator light. If light
goes out, check H03 GRN and G11
BLK wires for intermittent open and
short circuits.

Replace TCU.

1071.05 Hydraulic Fan Proportional Relief Using JDG1886 2-pin test harness
Solenoid open circuit and JT07237-1 single-pin test
harness, check H02 GRN and G11
BLK wires for open circuits.

Continued on next page MF82180,0000031 –19–28NOV05–30/56

TM2260 (07JAN06) 9015-20-53 750J, 850J Crawler

010706
PN=237
 References

Symptom Problem Solution

Check hydraulic fan proportional

relief solenoid (Y5 or Y5A). See
Electrical Component Specifications.
(Group 9015-20.)

1071.06 Hydraulic Fan Proportional Relief Using JDG1886 2-pin test harness
Solenoid short circuit and JT07237-1 single-pin test
harness, check H02 GRN and G11
BLK wires for short circuits.

Check hydraulic fan proportional

relief solenoid (Y5 or Y5A). See
Electrical Component Specifications.
(Group 9015-20.)
9015
20
54 2660.00 Steer Sensor input is greater than Enter service menu on CMU and go
stored maximum calibrated value to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Record Steer
voltage in left steer and left
counter-rotate positions. Voltage
should be within 3.06—3.48 V for left
steer and 3.22—3.60 V for left
counter-rotate. If the readings are
within specifications, calibrate the
TCU. See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

Adjust steer sensor (B33) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)

Remove the steer sensor (B33) and

verify the shaft is turning. Replace
sensor if necessary.

Continued on next page MF82180,0000031 –19–28NOV05–31/56

TM2260 (07JAN06) 9015-20-54 750J, 850J Crawler

010706
PN=238
 References

Symptom Problem Solution

2660.01 Steer Sensor input is less than Enter service menu on CMU and go
stored minimum calibrated value to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Record Steer
voltage in right steer and right
counter-rotate positions. Voltage
should be within 1.52—1.94 V for
right steer and 1.40—1.78 V for right
counter-rotate. If the readings are
within specifications, calibrate the
TCU. See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

Adjust steer sensor (B33) linkage.

See Transmission Control Lever
9015
(TCL) Adjustment. (Group 9015-20.) 20
55
Remove the steer sensor (B33) and
verify the shaft is turning. Replace
sensor if necessary.

2660.03 Steer Sensor input open circuit With key switch off, disconnect steer
sensor (B33). Connect (JDG1933)
3-pin test harness. Connect
(JT07237-1) single-pin test harness
to red and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
4.75—5.25 V. If voltage is out of
range, check T29 BLU and R23 BLK
wires for open circuits and
shorts-to-ground.

Connect single-pin test harness to

white and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
0.05—4.95 V. If voltage is out of
range, check T32 BLU wire for a
short-to-power.

Continued on next page MF82180,0000031 –19–28NOV05–32/56

TM2260 (07JAN06) 9015-20-55 750J, 850J Crawler

010706
PN=239
 References

Symptom Problem Solution

Connect steer sensor (B33) and

enter service menu on CMU and go
to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Note Steer
voltage in right and left steer
positions. If voltage doesn’t change,
check T32 BLU wire for open and
short circuits.

Replace steer sensor (B33).

2660.04 Steer Sensor input short circuit With key switch off, disconnect steer
sensor (B33). Connect (JDG1933)
3-pin test harness. Connect
9015
20 (JT07237-1) single-pin test harness
56 to red and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
4.75—5.25 V. If voltage is out of
range, check T29 BLU and R23 BLK
wires for open circuits and
shorts-to-ground.

Connect single-pin test harness to

white and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
0.05—4.95 V. If voltage is out of
range, check T32 BLU wire for a
short-to-power.

Connect steer sensor (B33) and

enter service menu on CMU and go
to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Note Steer
voltage in right and left steer
positions. If voltage doesn’t change,
check T32 BLU wire for open and
short circuits.

Replace steer sensor (B33).

Continued on next page MF82180,0000031 –19–28NOV05–33/56

TM2260 (07JAN06) 9015-20-56 750J, 850J Crawler

010706
PN=240
 References

Symptom Problem Solution

2660.15 Steer Sensor minimum calibration Enter service menu on CMU and go
value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Steer
reading. Record voltage in right steer
and right counter-rotate positions.
Voltage should be within 1.52—1.94
V for right steer and 1.40—1.78 V
for right counter-rotate. If the
readings are within specifications,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust steer sensor (B33). See

9015
Transmission Control Lever (TCL) 20
Adjustment. (Group 9015-20.) 57

Remove the steer sensor (B33) and

verify the shaft is turning. Replace
sensor if necessary.

2660.16 Steer Sensor maximum calibration Enter service menu on CMU and go
value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Steer
reading. Record voltage in left steer
and left counter-rotate positions.
Voltage should be within 3.06—3.48
V for left steer and 3.22—3.60 V for
left counter-rotate. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust steer sensor (B33). See

Transmission Control Lever (TCL)
Adjustment. (Group 9015-20.)

Remove the steer sensor (B33) and

verify the shaft is turning. Replace
sensor if necessary.

Continued on next page MF82180,0000031 –19–28NOV05–34/56

TM2260 (07JAN06) 9015-20-57 750J, 850J Crawler

010706
PN=241
 References

Symptom Problem Solution

2660.17 Steer Sensor minimum calibration Enter service menu on CMU and go
value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Steer
reading. Record voltage in right steer
and right counter-rotate positions.
Voltage should be within 1.52—1.94
V for right steer and 1.40—1.78 V
for right counter-rotate. If the
readings are within specifications,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust steer sensor (B33). See

9015
20 Transmission Control Lever (TCL)
58 Adjustment. (Group 9015-20.)

Remove the steer sensor (B33) and

verify the shaft is turning. Replace
sensor if necessary.

2660.18 Steer Sensor maximum calibration Enter service menu on CMU and go
value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Steer
reading. Record voltage in left steer
and left counter-rotate positions.
Voltage should be within 3.06—3.48
V for left steer and 3.22—3.60 V for
left counter-rotate. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust steer sensor (B33). See

Transmission Control Lever (TCL)
Adjustment. (Group 9015-20.)

Remove the steer sensor (B33) and

verify the shaft is turning. Replace
sensor if necessary.

Continued on next page MF82180,0000031 –19–28NOV05–35/56

TM2260 (07JAN06) 9015-20-58 750J, 850J Crawler

010706
PN=242
 References

Symptom Problem Solution

2661.00 FNR Sensor input is greater than Enter service menu on CMU and go
stored maximum calibrated value to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access FNR
reading. Record voltage in reverse
and neutral positions. Subtract the
reverse reading from the neutral
reading. If the reading is within
0.667—1.408 V, calibrate the TCU.
See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

Adjust FNR sensor (B32) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)
9015
20
Remove the FNR sensor (B32) and 59
verify the shaft is turning. Replace
sensor if necessary.

2661.01 FNR Sensor input is less than stored Enter service menu on CMU and go
minimum calibrated value to 3-Diagnostics, 1-Live Values,
4-Input Voltages. FNR reading.
Record voltage in forward and
neutral positions. Subtract the
forward reading from the neutral
reading. If the reading is within
0.667—1.408 V, calibrate the TCU.
See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

Adjust FNR sensor (B32) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)

Remove the FNR sensor (B32) and

verify the shaft is turning. Replace
sensor if necessary.

Continued on next page MF82180,0000031 –19–28NOV05–36/56

TM2260 (07JAN06) 9015-20-59 750J, 850J Crawler

010706
PN=243
 References

Symptom Problem Solution

2661.03 FNR Sensor input open circuit With key switch off, disconnect FNR
sensor (B32). Connect (JDG1933)
3-pin test harness. Connect
(JT07237-1) single-pin test harness
to red and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
4.75—5.25 V. If voltage is out of
range, check T29 BLU and R23 BLK
wires for open circuits and
shorts-to-ground.

Connect single-pin test harness to

white and black wire connectors on
9015
20 3-pin test harness and multimeter.
60 Turn key switch on. Check for
0.05—4.95 V. If voltage is out of
range, check T32 BLU wire for a
short-to-power.

Connect FNR sensor (B32) and

enter service menu on CMU and go
to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Note FNR voltage
in forward and reverse positions. If
voltage doesn’t change, check T31
BLU wire for open and short circuits.

Replace FNR sensor (B32).

Continued on next page MF82180,0000031 –19–28NOV05–37/56

TM2260 (07JAN06) 9015-20-60 750J, 850J Crawler

010706
PN=244
 References

Symptom Problem Solution

2661.04 FNR Sensor input short circuit With key switch off, disconnect steer
sensor (B33). Connect (JDG1933)
3-pin test harness. Connect
(JT07237-1) single-pin test harness
to red and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
4.75—5.25 V. If voltage is out of
range, check T29 BLU and R23 BLK
wires for open circuits and
shorts-to-ground.

Connect single-pin test harness to

white and black wire connectors on
9015
3-pin test harness and multimeter. 20
Turn key switch on. Check for 61
0.05—4.95 V. If voltage is out of
range, check T31 BLU wire for a
short-to-power.

Connect FNR sensor (B32) and

enter service menu on CMU and go
to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Note FNR voltage
in forward and reverse positions. If
voltage doesn’t change, check T31
BLU wire for open and short circuits.

Replace FNR sensor (B32).

2661.15 FNR Sensor minimum calibration Enter service menu on CMU and go
value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access FNR
reading. Record voltage in neutral
and reverse positions. If the reverse
reading is within 0.667—1.408 V
less than the neutral reading,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust FNR sensor (B32) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–38/56

TM2260 (07JAN06) 9015-20-61 750J, 850J Crawler

010706
PN=245
 References

Symptom Problem Solution

Remove the FNR sensor (B32) and

verify the shaft is turning. Replace
sensor if necessary.

2661.16 FNR Sensor maximum calibration Enter service menu on CMU and go
value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access FNR
reading. Record voltage in neutral
and forward positions. If the forward
reading is within 0.667—1.408 V
more than the neutral reading,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)
9015
20
62 Adjust FNR sensor (B32) linkage.
See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)

Remove the FNR sensor (B32) and

verify the shaft is turning. Replace
sensor if necessary.

2661.17 FNR Sensor minimum calibration Enter service menu on CMU and go
value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access FNR
reading. Record voltage in neutral
and reverse positions. If the reverse
reading is within 0.667—1.408 V
less than the neutral reading,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust FNR sensor (B32) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)

Remove the FNR sensor (B32) and

verify the shaft is turning. Replace
sensor if necessary.

Continued on next page MF82180,0000031 –19–28NOV05–39/56

TM2260 (07JAN06) 9015-20-62 750J, 850J Crawler

010706
PN=246
 References

Symptom Problem Solution

2661.18 FNR Sensor maximum calibration Enter service menu on CMU and go
value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access FNR
reading. Record voltage in neutral
and forward positions. If the forward
reading is within 0.667—1.408 V
more than the neutral reading,
calibrate the TCU. See Transmission
Control Unit (TCU) Calibration.
(Group 9015-20.)

Adjust FNR sensor (B32) linkage.

See Transmission Control Lever
(TCL) Adjustment. (Group 9015-20.)
9015
20
Remove the FNR sensor (B32) and 63
verify the shaft is turning. Replace
sensor if necessary.

522439.05 Hydrostatic Oil Reservoir Bypass Check T27 BLU wire and G09 BLK
Solenoid no response for open circuits.

Check hydrostatic oil reservoir

bypass solenoid (Y14). See
Electrical Component Specifications.
(Group 9015-20.)

Replace TCU.

522440.05 Blade Angle Solenoid Left (Top) Check H05 GRN wire and G09 BLK
open circuit for open circuits.

Check blade angle solenoid left

(top) (Y7). See Electrical
Component Specifications. (Group
9015-20.)

With engine running, press blade

angle switch to angle blade to the
left. If blade moves, check H05 BLU
wire and G09 BLK wires for
intermittent open circuits.

Replace TCU.

Continued on next page MF82180,0000031 –19–28NOV05–40/56

TM2260 (07JAN06) 9015-20-63 750J, 850J Crawler

010706
PN=247
 References

Symptom Problem Solution

522440.06 Blade Angle Solenoid Left (Top) Check H05 GRN wire and G09 BLK
short circuit for short circuits.

Check blade angle solenoid left

(top) (Y7). See Electrical
Component Specifications. (Group
9015-20.)

With engine running, press blade

angle switch to angle blade to the
left. If blade moves, check H05 GRN
wire and G09 BLK wires for
intermittent open circuits.
9015
20 Replace TCU.
64
522441.05 Blade Angle Solenoid Right (Bottom) Check H04 GRN wire and G09 BLK
open circuit for open circuits.

Check blade angle solenoid right

(bottom) (Y8). See Electrical
Component Specifications. (Group
9015-20.)

With engine running, press blade

angle switch to angle blade to the
left. If blade moves, check H04 BLU
wire and G09 BLK wires for
intermittent open circuits.

Replace TCU.

522441.06 Blade Angle Solenoid Right (Bottom) Check H04 GRN wire and G09 BLK
short circuit for short circuits.

Check blade angle solenoid right

(bottom) (Y8). See Electrical
Component Specifications. (Group
9015-20.)

With engine running, press blade

angle switch to angle blade to the
left. If blade moves, check H04 GRN
wire and G09 BLK wires for
intermittent open circuits.

Continued on next page MF82180,0000031 –19–28NOV05–41/56

TM2260 (07JAN06) 9015-20-64 750J, 850J Crawler

010706
PN=248
 References

Symptom Problem Solution

Replace TCU.

522442.00 Blade Angle Switch input is greater With engine running, enter service
than stored maximum calibrated menu on CMU and go to
value 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Blade
Ang Btn reading. Angle blade to the
left and right and note the reading
on the CMU. If readings are within
0.50—3.50 V, calibrate the TCU.
See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

With key switch off, disconnect

9015
harness from blade angle switch 20
(S4). Connect (JT07239-3) 3-pin test 65
harness between sensor and
harness. Connect (JT07237-1)
single-pin test harness to white and
black wire connectors on 3 pin test
harness and multimeter. Record
resistance with no buttons pressed
and with each button pressed. See
Electrical Component Specifications.
(Group 9015-20.) Replace sensor as
necessary.

Check R09 BLK wire for an open

circuit.

522442.01 Blade Angle Switch input is less than Enter service menu on CMU and go
stored minimum calibrated value to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Blade
Ang Btn reading. Angle blade to the
left and right and note the reading
on the CMU. If readings are within
0.50—3.50 V, calibrate the TCU.
See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–42/56

TM2260 (07JAN06) 9015-20-65 750J, 850J Crawler

010706
PN=249
 References

Symptom Problem Solution

With key switch off, disconnect

harness from blade angle switch
(S4). Connect (JT07239-3) 3-pin test
harness between sensor and
harness. Connect (JT07237-1)
single-pin test harness to white and
black wire connectors on 3 pin test
harness and multimeter. Record
resistance with no buttons pressed
and with each button pressed. See
Electrical Component Specifications.
(Group 9015-20.) Replace sensor as
necessary.
9015
20 Check T14 BLU and H01 GRN wires
66 for open circuits and
shorts-to-ground.

522442.03 Blade Angle Switch input voltage is Enter service menu on CMU and go
too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Blade
Ang Btn reading. Angle blade to the
left and right and note the reading
on the CMU. If readings are within
0.50—3.50 V, check T14 BLU, H01
GRN, and R09 BLK wires for
intermittent open and short circuits.

With key switch off, disconnect

harness from blade angle switch
(S4). Connect (JT07239-3) 3-pin test
harness between sensor and
harness. Connect (JT07237-1)
single-pin test harness to white and
black wire connectors on 3 pin test
harness and multimeter. Record
resistance with no buttons pressed
and with each button pressed. See
Electrical Component Specifications.
(Group 9015-20.) Replace sensor as
necessary.

Check H01 GRN wire for a

short-to-power.

Continued on next page MF82180,0000031 –19–28NOV05–43/56

TM2260 (07JAN06) 9015-20-66 750J, 850J Crawler

010706
PN=250
 References

Symptom Problem Solution

Check R09 BLK wire for open circuit.

522442.04 Blade Angle Switch input voltage is Enter service menu on CMU and go
too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Blade
Ang Btn reading. Angle blade to the
left and right and note the reading
on the CMU. If readings are within
0.50—3.50 V, check T14 BLU, H01
GRN, and R09 BLK wires for
intermittent open and short circuits.

With key switch off, disconnect

harness from blade angle switch
9015
(S4). Connect (JT07239-3) 3-pin test 20
harness between sensor and 67
harness. Connect (JT07237-1)
single-pin test harness to white and
black wire connectors on 3 pin test
harness and multimeter. Record
resistance with no buttons pressed
and with each button pressed. See
Electrical Component Specifications.
(Group 9015-20.) Replace sensor as
necessary.

Check T14 BLU and H01 GRN wires

for open circuits and
shorts-to-ground.

522442.15 Blade Angle Switch minimum Enter service menu on CMU and go
calibration value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Blade
Ang Btn reading. Angle blade to the
left and right and note the reading
on the CMU. If readings are within
0.50—1.22 V, calibrate the TCU.
See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–44/56

TM2260 (07JAN06) 9015-20-67 750J, 850J Crawler

010706
PN=251
 References

Symptom Problem Solution

With key switch off, disconnect

harness from blade angle switch
(S4). Connect (JT07239-3) 3-pin test
harness between sensor and
harness. Connect (JT07237-1)
single-pin test harness to white and
black wire connectors on 3 pin test
harness and multimeter. Record
resistance with no buttons pressed
and with each button pressed. See
Electrical Component Specifications.
(Group 9015-20.) Replace sensor as
necessary.
9015
20 Check H01 GRN wire for a
68 short-to-power.

Check R09 BLK wire for an open

circuit.

522442.16 Blade Angle Switch maximum Enter service menu on CMU and go
calibration value is too high to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Blade
Ang Btn reading. Angle blade to the
left and right and note the reading
on the CMU. If readings are within
2.66—3.50 V, calibrate the TCU.
See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

With key switch off, disconnect

harness from blade angle switch
(S4). Connect (JT07239-3) 3-pin test
harness between sensor and
harness. Connect (JT07237-1)
single-pin test harness to white and
black wire connectors on 3 pin test
harness and multimeter. Record
resistance with no buttons pressed
and with each button pressed. See
Electrical Component Specifications.
(Group 9015-20.) Replace sensor as
necessary.

Continued on next page MF82180,0000031 –19–28NOV05–45/56

TM2260 (07JAN06) 9015-20-68 750J, 850J Crawler

010706
PN=252
 References

Symptom Problem Solution

Check H01 GRN wire for a

short-to-power.

Check R09 BLK wire for an open

circuit.

522442.17 Blade Angle Switch minimum Enter service menu on CMU and go
calibration value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Blade
Ang Btn reading. Angle blade to the
left and right and note the reading
on the CMU. If readings are within
0.50—1.22 V, calibrate the TCU.
See Transmission Control Unit
9015
(TCU) Calibration. (Group 9015-20.) 20
69
With key switch off, disconnect
harness from blade angle switch
(S4). Connect (JT07239-3) 3-pin test
harness between sensor and
harness. Connect (JT07237-1)
single-pin test harness to white and
black wire connectors on 3 pin test
harness and multimeter. Record
resistance with no buttons pressed
and with each button pressed. See
Electrical Component Specifications.
(Group 9015-20.) Replace sensor as
necessary.

Check T14 BLU and H01 GRN wires

for open circuits and
shorts-to-ground.

522442.18 Blade Angle Switch maximum Enter service menu on CMU and go
calibration value is too low to 3-Diagnostics, 1-Live Values,
4-Input Voltages. Access Blade
Ang Btn reading. Angle blade to the
left and right and note the reading
on the CMU. If readings are within
2.66—3.50 V, calibrate the TCU.
See Transmission Control Unit
(TCU) Calibration. (Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–46/56

TM2260 (07JAN06) 9015-20-69 750J, 850J Crawler

010706
PN=253
 References

Symptom Problem Solution

With key switch off, disconnect

harness from blade angle switch
(S4). Connect (JT07239-3) 3-pin test
harness between sensor and
harness. Connect (JT07237-1)
single-pin test harness to white and
black wire connectors on 3 pin test
harness and multimeter. Record
resistance with no buttons pressed
and with each button pressed. See
Electrical Component Specifications.
(Group 9015-20.) Replace sensor as
necessary.
9015
20 Check T14 BLU and H01 GRN wires
70 for open circuits and
shorts-to-ground.

522444.00 Hydrostatic Charge Pressure is too Perform Perform Neutral Charge

high Relief and Operating Charge Relief
Pressure Test. (Group 9026-25.)

522444.01 Hydrostatic Charge Pressure is too See Low Charge Pressure - Flow
low Chart. (Group 9026-15.)

522444.03 Hydrostatic Charge Pressure Sensor With key switch on, press next on
input voltage is too high CMU to read charge pressure on
CMU display. Start engine. If TCU
reading changes with pressure
change, check T08 BLU, T09 BLU,
and R05 BLK wires for intermittent
open and short circuits.

Continued on next page MF82180,0000031 –19–28NOV05–47/56

TM2260 (07JAN06) 9015-20-70 750J, 850J Crawler

010706
PN=254
 References

Symptom Problem Solution

With key switch off, disconnect

hydrostatic charge pressure
sensor (B4). Connect (JDG1933)
3-pin test harness. Connect
(JT07237-1) single-pin test harness
to red and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
4.75—5.25 V. If voltage is out of
range, check T08 BLU and R05 BLK
wires for open circuits and
shorts-to-ground.

Connect single-pin test harness to

9015
white and black wire connectors on 20
3-pin test harness and multimeter. 71
Turn key switch on. Check for
0.27—4.81 V. If voltage is out of
range, check T09 BLU wire for a
short-to-power.

Replace hydrostatic charge

pressure sensor (B4).

522444.04 Hydrostatic Charge Pressure Sensor With key switch on, press next on
input voltage is too low CMU to read charge pressure on
CMU display. Start engine. If TCU
reading changes with pressure
change, check T08 BLU, T09 BLU,
and R05 BLK wires for intermittent
open and short circuits.

Continued on next page MF82180,0000031 –19–28NOV05–48/56

TM2260 (07JAN06) 9015-20-71 750J, 850J Crawler

010706
PN=255
 References

Symptom Problem Solution

With key switch off, disconnect

hydrostatic charge pressure
sensor (B4). Connect (JDG1933)
3-pin test harness. Connect
(JT07237-1) single-pin test harness
to red and black wire connectors on
3-pin test harness and multimeter.
Turn key switch on. Check for
4.75—5.25 V. If voltage is out of
range, check T08 BLU and R05 BLK
wires for open circuits and
shorts-to-ground.

Connect single-pin test harness to

9015
20 white and black wire connectors on
72 3-pin test harness and multimeter.
Turn key switch on. Check for
0.27—4.81 V. If voltage is out of
range, check T09 BLU wire for an
open circuit or short-to-ground.

Replace hydrostatic charge

pressure sensor (B4).

522447.05 Pump Pressure Control Pilot (PCP) Operate machine in reverse

Front coil open circuit in forward direction. If machine moves, check
direction T22 BLU and T23 BLU wires for an
intermittent open circuit.

Check pump Pressure Control

Pilot (PCP) front (B8). See
Electrical Component Specifications.
(Group 9015-20.)

Connect only the TCU to the

diagnostic test box JT07349. Check
for continuity to ground on pin X2-7
to X2-8. If continuity is measured,
replace TCU.

Check for resistance across pins

X2-7 to X2-8. If approximately 2
mega ohms is not measured,
replace TCU.

Continued on next page MF82180,0000031 –19–28NOV05–49/56

TM2260 (07JAN06) 9015-20-72 750J, 850J Crawler

010706
PN=256
 References

Symptom Problem Solution

522447.06 Pump Pressure Control Pilot (PCP) Operate machine in reverse

Front coil short circuit in forward direction. If machine moves, check
direction T22 BLU and T23 BLU wires for an
intermittent short-to-ground.

Check pump Pressure Control

Pilot (PCP) front (B8). See
Electrical Component Specifications.
(Group 9015-20.)

Check for continuity to ground on pin

X2-7 and pin X2-8. If continuity is
measured, replace TCU.
9015
Check for resistance across pins 20
X2-7 to X2-8. If approximately 2 73
mega ohms is not measured,
replace TCU.

522447.15 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Front calibration threshold current Flowchart. (Group 9026-15.)
too high in forward direction

522447.16 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Front calibration current too low at Flowchart. (Group 9026-15.)
maximum speed in forward direction

522447.17 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Front calibration threshold current Flowchart. (Group 9026-15.)
too low in forward direction

522447.18 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Front calibration current too low at Flowchart. (Group 9026-15.)
maximum speed in forward direction

522448.05 Pump Pressure Control Pilot (PCP) Operate machine in forward

Front coil open circuit in reverse direction. If machine moves, check
direction T22 BLU and T23 BLU wires for an
intermittent open circuit.

Check pump Pressure Control

Pilot (PCP) front (B8). See
Electrical Component Specifications.
(Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–50/56

TM2260 (07JAN06) 9015-20-73 750J, 850J Crawler

010706
PN=257
 References

Symptom Problem Solution

Connect only the TCU to the

diagnostic test box JT07349. Check
for continuity to ground on pin X2-7
and pin X2-8. If continuity is
measured, replace TCU.

Check for resistance across pins

X2-7 and pin X2-8. If approximately
2 mega ohms is not measured,
replace TCU.

522448.06 Pump Pressure Control Pilot (PCP) Operate machine in reverse

Front coil short circuit in reverse direction. If machine moves, check
direction T22 BLU and T23 BLU wires for an
9015
20 intermittent short-to-ground.
74
Check pump Pressure Control
Pilot (PCP) front (B8). See
Electrical Component Specifications.
(Group 9015-20.)

Connect only the TCU to the

diagnostic test box JT07349. Check
for continuity to ground on pin X2-7
and pin X2-8. If continuity is
measured, replace TCU.

Check for resistance across pins

X2-7 and pin X2-8. If approximately
2 mega ohms is not measured,
replace TCU.

522448.15 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Front calibration threshold current Flowchart. (Group 9026-15.)
too high in reverse direction

522448.16 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Front calibration current too high at Flowchart. (Group 9026-15.)
maximum speed in reverse direction

522448.17 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Front calibration threshold current Flowchart. (Group 9026-15.)
too low in reverse direction

Continued on next page MF82180,0000031 –19–28NOV05–51/56

TM2260 (07JAN06) 9015-20-74 750J, 850J Crawler

010706
PN=258
 References

Symptom Problem Solution

522448.18 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Front calibration current too low at Flowchart. (Group 9026-15.)
maximum speed in reverse direction

522449.05 Pump Pressure Control Pilot (PCP) Operate machine in forward

Rear coil open circuit in reverse direction. If machine moves, check
direction T20 BLU and T21 BLU wires for an
intermittent open circuit.

Check pump Pressure Control

Pilot (PCP) rear (B7). See Electrical
Component Specifications. (Group
9015-20.)
9015
Connect only the TCU to the 20
diagnostic test box JT07349. Check 75
for continuity to ground on pin X2-9
and pin X2-17. If continuity is
measured, replace TCU.

Check for resistance across pins

X2-7 and pin X2-8. If approximately
2 mega ohms is not measured,
replace TCU.

522449.06 Pump Pressure Control Pilot (PCP) Operate machine in reverse

Rear coil short circuit in reverse direction. If machine moves, check
direction T20 BLU and T21 BLU wires for an
intermittent short-to-ground.

Check pump Pressure Control

Pilot (PCP) rear (B7). See Electrical
Component Specifications. (Group
9015-20.)

Connect only the TCU to the

diagnostic test box JT07349. Check
for continuity to ground on pin X2-9
and pin X2-17. If continuity is
measured, replace TCU.

Check for resistance across pins

X2-9 and pin X2-17. If approximately
2 mega ohms is not measured,
replace TCU.

Continued on next page MF82180,0000031 –19–28NOV05–52/56

TM2260 (07JAN06) 9015-20-75 750J, 850J Crawler

010706
PN=259
 References

Symptom Problem Solution

522449.15 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Rear calibration threshold current too Flowchart. (Group 9026-15.)
high in reverse direction

522449.16 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Rear calibration current too low at Flowchart. (Group 9026-15.)
maximum speed in reverse direction

522449.17 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Rear calibration threshold current too Flowchart. (Group 9026-15.)
low in reverse direction

522449.18 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Rear calibration current too low at Flowchart. (Group 9026-15.)
9015
20 maximum speed in reverse direction
76
522450.05 Pump Pressure Control Pilot (PCP) Operate machine in reverse
Rear coil open circuit in forward direction. If machine moves, check
direction T20 BLU and T21 BLU wires for an
intermittent open circuit.

Check pump Pressure Control

Pilot (PCP) rear (B7). See Electrical
Component Specifications. (Group
9015-20.)

Connect only the TCU to the

diagnostic test box JT07349. Check
for continuity to ground on pin X2-9
and pin X2-17. If continuity is
measured, replace TCU.

Check for resistance across pins

X2-9 and pin X2-17. If approximately
2 mega ohms is not measured,
replace TCU.

522450.06 Pump Pressure Control Pilot (PCP) Operate machine in reverse

Rear coil short circuit in forward direction. If machine moves, check
direction T20 BLU and T21 BLU wires for an
intermittent short-to-ground.

Continued on next page MF82180,0000031 –19–28NOV05–53/56

TM2260 (07JAN06) 9015-20-76 750J, 850J Crawler

010706
PN=260
 References

Symptom Problem Solution

Check pump Pressure Control

Pilot (PCP) rear (B7). See Electrical
Component Specifications. (Group
9015-20.)

Connect only the TCU to the

diagnostic test box JT07349. Check
for continuity to ground on pin X2-9
and pin X2-17. If continuity is
measured, replace TCU.

Check for resistance across pins

X2-9 and pin X2-17. If approximately
2 mega ohms is not measured,
9015
replace TCU. 20
77
522450.15 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Rear calibration threshold current too Flowchart. (Group 9026-15.)
high in forward direction

522450.16 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Rear calibration current too high at Flowchart. (Group 9026-15.)
maximum speed in forward direction

522450.17 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Rear calibration threshold current too Flowchart. (Group 9026-15.)
low in forward direction

522450.18 Pump Pressure Control Pilot (PCP) See TCU Calibration Problems—
Rear calibration current too low at Flowchart. (Group 9026-15.)
maximum speed in forward direction

522451.05 Hydrostatic Oil Cooler Bypass Check T35 BLU wire and G09 BLK
Solenoid no response for open and short circuits.

Check hydrostatic oil cooler

bypass solenoid (Y17). See
Electrical Component Specifications.
(Group 9015-20.)

Replace TCU.

523108.13 TCU not calibrated, high speed Calibrate the TCU. See
calibration is not completed Transmission Control Unit (TCU)
Calibration. (Group 9015-20.)

Continued on next page MF82180,0000031 –19–28NOV05–54/56

TM2260 (07JAN06) 9015-20-77 750J, 850J Crawler

010706
PN=261
 References

Symptom Problem Solution

523108.14 TCU not calibrated, threshold and Calibrate the TCU. See
sensor calibration is not completed Transmission Control Unit (TCU)
Calibration. (Group 9015-20.)

523436.07 TCU watchdog timer exceeded Cycle power. If code is still active,
replace TCU.

523577.05 Motor Shift Solenoid Left open circuit Disconnect motor shift solenoid
left (Y3) and motor shift solenoid
right (Y4). Connect right side
harness to left motor shift solenoid
and connect left side harness to right
motor shift solenoid. Start machine
and move tracks. If 523577.05 goes
9015
20 away, solenoid is good. If 523578.05
78 appears, solenoid should be
replaced.

Using JDG1886 2-pin test harness

and JT07237-1 single-pin test
harness, check T26 BLU and G09
BLK wires for open and short
circuits.

523577.06 Motor Shift Solenoid Left short circuit Disconnect motor shift solenoid
left (Y3) and motor shift solenoid
right (Y3). Connect right side
harness to left motor shift solenoid
and connect left side harness to right
motor shift solenoid. Start machine
and move tracks. If 523577.06 goes
away, solenoid is good. If 523578.05
appears, solenoid should be
replaced.

Using JDG1886 2-pin test harness

and JT07237-1 single-pin test
harness, check T26 BLU and G09
BLK wires for open and short
circuits.

523577.16 Motor Solenoid Left maximum See TCU Calibration Problems—

calibration current too high Flowchart. (Group 9026-15.)

Continued on next page MF82180,0000031 –19–28NOV05–55/56

TM2260 (07JAN06) 9015-20-78 750J, 850J Crawler

010706
PN=262
 References

Symptom Problem Solution

523577.18 Motor Solenoid Left maximum See TCU Calibration Problems—

calibration current too low Flowchart. (Group 9026-15.)

523578.05 Motor Solenoid Right open circuit Disconnect motor shift solenoid
left (Y3) and motor shift solenoid
right (Y4). Connect right side
harness to left motor shift solenoid
and connect left side harness to right
motor shift solenoid. Start machine
and move tracks. If 523578.05 goes
away, solenoid is good. If 523577.05
appears, solenoid should be
replaced.
9015
Using JDG1886 2-pin test harness 20
and JT07237-1 single-pin test 79
harness, check T25 BLU and G09
BLK wires for open circuits.

523578.06 Motor Solenoid Right short circuit Disconnect motor shift solenoid
left (Y3) and motor shift solenoid
right (Y4). Connect right side
harness to left motor shift solenoid
and connect left side harness to right
motor shift solenoid. Start machine
and move tracks. If 523578.05 goes
away, solenoid is good. If 523577.05
appears, solenoid should be
replaced.

Using JDG1886 2-pin test harness

and JT07237-1 single-pin test
harness, check T25 BLU and G09
BLK wires for short circuits.

523578.16 Motor Solenoid Right maximum See TCU Calibration Problems—

calibration current too high Flowchart. (Group 9026-15.)

523578.18 Motor Solenoid Right maximum See TCU Calibration Problems—

calibration current too low Flowchart. (Group 9026-15.)

MF82180,0000031 –19–28NOV05–56/56

TM2260 (07JAN06) 9015-20-79 750J, 850J Crawler

010706
PN=263
 References

Alternator Test Procedure

9015
20
80

–19–14SEP92
T7751GM
12 V System 4. With engine running, check AC voltage between
terminal W (if equipped) and ground. Voltage
1. With engine running at slow idle, check DC voltage should be 6—7 VAC.
between terminal D+ and ground. Voltage should
be 13.5 VDC or greater1. 5. Repeat above steps with lights on to load the
alternator.
2. With engine running at fast idle, check DC voltage
between terminal B+ and ground. Voltage should 6. If alternator fails to produce specified voltage after
be 13.5 VDC or greater1. testing, check for worn out brushes in the
regulator/brush assembly. Replace brush/regulator
3. If voltage from previous steps is below 13.5 VDC1, assembly if necessary. See Alternators and Starting
check excitation by placing a jumper wire between Motors for specific test and repair procedures.
terminals D+ and B+ with the engine running. If (CTM77.) If alternator still fails, replace it. If
output at terminals B+ and D+ rise to 13.5 VDC or alternator tests OK, check indicator light circuit.
greater, check for an open diode, wiring problem or
blown fuse in the alternator excitation circuit (wire to
D+ terminal).

1
Note: For 12 V systems with maintenance free batteries, D+ and B+
voltage should be 14.1 VDC or greater.
Continued on next page MF82180,00001DC –19–18MAY04–1/2

TM2260 (07JAN06) 9015-20-80 750J, 850J Crawler

010706
PN=264
 References

24 V System 4. With engine running, check AC voltage between

terminal W (if equipped) and ground. Voltage
1. With engine running at slow idle, check DC voltage should be 12—14 VAC.
between terminal D+ and ground. Voltage should
be 27.5 VDC or greater2. 5. Repeat above steps with lights on to load the
alternator.
2. With engine running at fast idle, check DC voltage
between terminal B+ and ground. Voltage should 6. If alternator fails to produce specified voltage after
be 27.5 VDC or greater2. testing, check for worn out brushes in the
regulator/brush assembly. Replace brush/regulator
3. If voltage from previous steps is below 27.5 VDC2, assembly if necessary. See Alternators and Starting
check excitation by placing a jumper wire between Motors for specific test and repair procedures.
terminals D+ and B+ with the engine running. If (CTM77.) If alternator still fails, replace it. If
output at terminals B+ and D+ rise to 27.5 VDC or alternator tests OK, check indicator light circuit.
greater, check for an open diode, wiring problem or
blown fuse in the alternator excitation circuit (wire to
9015
D+ terminal). 20
81

2
Note: For 24 V systems with maintenance free batteries, D+ and B+
voltage should be 28.2 VDC or greater.
MF82180,00001DC –19–18MAY04–2/2

TM2260 (07JAN06) 9015-20-81 750J, 850J Crawler

010706
PN=265
 References

Electrical Component Specifications

Item Measurement Specification

B1—Decelerator Sensor Calibration Limits 1.25—1.75 V at High Decel Position

3.25—3.75 V at Low Decel Position
3.79—3.99 V at Brake Position

B2—Motor Speed Sensor Left Output Signal Voltage (High) 4.0—14.5 V

Output Signal Voltage (Low) 0.0—0.9 V

B3—Motor Speed Sensor Right Output Signal Voltage (High) 4.0—14.5 V

Output Signal Voltage (Low) 0.0—0.9 V

B4—Hydrostatic Charge Pressure Operating Pressure 0—5171 kPa

Sensor 0—51.7 bar
9015
20 0—750 psi
82
B5—Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa
Right 0—689.5 bar
0—10 000 psi

B6—Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa

Left 0—689.5 bar
0—10 000 psi

B7—Pump Pressure Control Pilot Resistance 20.7—25.3 ohms

(PCP) Rear Amperage 56—80 mA

B8—Pump Pressure Control Pilot Resistance 20.7—25.3 ohms

(PCP) Front Amperage 56—80 mA

B9—Quick-Drop Pressure Switch Closing pressure 2758—3103 kPa

27.5—31 bar
400—450 psi
Opening pressure 2034—2379 kPa
20.3—23.8 bar
295—345 psi

B10—Fuel Rail Pressure Sensor Operating pressure 0—180 MPa

0—1800 bar
0—26 100 psi

Continued on next page MF82180,00001C3 –19–06OCT05–1/7

TM2260 (07JAN06) 9015-20-82 750J, 850J Crawler

010706
PN=266
 References

Item Measurement Specification

B11—Fuel Temperature Sensor Resistance 90—108 kohms at -40°C (-40°F)

26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)

B12—Engine Coolant Temperature Resistance 120.6—147.4 ohms at 60°C (140°F)

Sensor 46.8—56.3 ohms at 90°C (194°F)
34.6—42.35 ohms at 100°C (212°F)
9015
B13—Manifold Air Temperature Resistance 90—108 kohms at -40°C (-40°F) 20
Sensor 26—31 kohms at -20°C (-4°F) 83
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)

B14—Crankshaft Position Sensor Resistance 2.7—3.3 kohms

B15—Camshaft Position Sensor Resistance 2.7—3.3 kohms

B16—Ambient Air Temperature Resistance 90—108 kohms at -40°C (-40°F)

Sensor 26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)

B17—Engine Oil Pressure Sensor Operating pressure 0—2660 kPa

0—26.6 bar
0—385 psi

B18—Water-in-Fuel Sensor Resistance 209—231 kohms

Continued on next page MF82180,00001C3 –19–06OCT05–2/7

TM2260 (07JAN06) 9015-20-83 750J, 850J Crawler

010706
PN=267
 References

Item Measurement Specification

B19—Fuel Level Sensor Resistance 168—192 ohms at 100% Fill (Full)

129.5—150.5 ohms at 75% Fill
96—114 ohms at 50% Fill
67.5—82.5 ohms at 25% Fill
4—16 ohms at 0% Fill (Empty)

B20—Hydraulic Oil Temperature Resistance 90—108 kohms at -40°C (-40°F)

Sensor 26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
9015
20 97—105 ohms at 120°C (248°F)
84
B21—Transmission Oil Temperature Resistance 90—108 kohms at -40°C (-40°F)
Sensor 26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)

B22—Engine Air Filter Restriction Closing pressure 4.98—7.48 kPa

Switch 1.47—2.2 in. of Hg
20—30 in. of H2O

B23—Hydraulic Oil Filter Restriction Closing pressure 248—303 kPa

Switch 2.5—3 bar
36—44 psi

B24—Hydraulic Fan Oil Filter Opening pressure 248—303 kPa

Restriction Switch 2.5—3 bar
36—44 psi

B25—Hydrostatic Charge Oil Filter Opening pressure 248—303 kPa

Restriction Switch 2.5—3 bar
36—44 psi

Continued on next page MF82180,00001C3 –19–06OCT05–3/7

TM2260 (07JAN06) 9015-20-84 750J, 850J Crawler

010706
PN=268
 References

Item Measurement Specification

B26—Winch Oil Pressure Switch Opening pressure 1310—1448 kPa

13.1—14.5 bar
190—210 psi
Closing pressure 1034—1172 kPa
10.3—11.7 bar
150—170 psi

B27—Air Conditioning Freeze Switch Opening temperature (decreasing) -1.4°C

29.5°F
Closing temperature (increasing) 2.2°C
36°F

B28—Air Conditioning High Pressure Opening pressure 2620—2896 kPa

Switch 26.2—29 bar
9015
380—420 psi 20
Closing pressure 1379—2068 kPa 85
13.8—20.7 bar
200—300 psi

B29—Air Conditioning Low Pressure Opening pressure (low) 137.9—227.5 kPa

Switch 1.38—2.28 bar
20—33 psi
Closing pressure (low) 158.6—255.1 kPa
1.58—2.55 bar
23—37 psi

B32—FNR Sensor Calibration Limits 2.37—2.63 V at Neutral Position

3.09—3.95 V at Forward Position
1.05—1.91 V at Reverse Position

B33—Steer Sensor Calibration Limits 2.3—2.7 V at Neutral Position

1.52—1.94 V at Right Steer Position
1.40—1.78 V at Right Counter
Rotate Position
3.06—3.48 V at Left Steer Position
3.22—3.60 V at Left Counter Rotate
Position

B34—Transmission Speed Control Calibration Limits 0.50—1.22 V w/ Up button pressed

Sensor 2.66—3.50 V w/ Down button
pressed

B35—Brake Pressure Sensor Operating Pressure 0—5171 kPa

0—51.7 bar
0—750 psi

Continued on next page MF82180,00001C3 –19–06OCT05–4/7

TM2260 (07JAN06) 9015-20-85 750J, 850J Crawler

010706
PN=269
 References

Item Measurement Specification

R1—CAN Termination Resistor Resistance 120 ohms

R2—CAN Termination Resistor Resistance 120 ohms

R4—Cab Heater Blower Resistor Low Speed Resistance (X12 pins 2 2.2—2.7 ohms
and 6)
Medium Low Speed Resistance (X12 1.3—1.9 ohms
pins 3 and 6)
Medium Speed Resistance (X12 pins 0.5—0.9 ohms
5 and 6)

R5—Under-Seat Heater Blower Low speed resistance (wires A15 1.2 ohms
Resistor and A18)
Medium speed resistance (wires A16 0.6 ohms
9015
20 and A18)
86 High speed resistance (wires A17 0.4 ohms
and A18)

S4—Blade Angle Switch Calibration Limits 0.50—1.22 V w/ Right button

pressed
2.66—3.50 V w/ Left button pressed

S9—Heater Temperature Control Resistance between pins A and B 0 kohms at maximum hot
Switch 5 kohms at maximum cold
Resistance Between Pins A and C 5 kohms

S22—Engine Speed Control Sensor Resistance between pins A and B 280—420 ohms Minimum Value
4.28—6.42 kohms Maximum Value
Resistance Between Pins A and C 4—6 kohms
Calibration Limits 0.44—1.07 V at Slow Idle
2.53—3.59 V at Fast Idle

Y2—Park Brake Solenoid 1 Resistance 17.3—19.5 ohms at -40°C (-40°F)

19.0—21.5 ohms at -20°C (-4°F)
20.8—23.5 ohms at 0°C (32°F)
22.7—25.6 ohms at 20°C (68°F)
24.4—27.6 ohms at 40°C (104°F)

Y3—Motor Shift Solenoid Left Resistance 21.3 ohms at 20°C (68°F)

Y4—Motor Shift Solenoid Right Resistance 21.3 ohms at 20°C (68°F)

Continued on next page MF82180,00001C3 –19–06OCT05–5/7

TM2260 (07JAN06) 9015-20-86 750J, 850J Crawler

010706
PN=270
 References

Item Measurement Specification

Y5(A)—Hydraulic Fan Proportional Resistance 17.3—19.5 ohms at -40°C (-40°F)

Relief Solenoid 19.0—21.5 ohms at -20°C (-4°F)
20.8—23.5 ohms at 0°C (32°F)
22.7—25.6 ohms at 20°C (68°F)
24.4—27.6 ohms at 40°C (104°F)

Y6—Hydraulic Fan Reversing Resistance 24.2—27.3 ohms at -40°C (-40°F)

Solenoid 26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

Y7—Blade Angle Solenoid Left (Top) Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
9015
29.2—33.0 ohms at 0°C (32°F) 20
31.8—35.8 ohms at 20°C (68°F) 87
34.2—38.6 ohms at 40°C (104°F)

Y8—Blade Angle Solenoid Right Resistance 24.2—27.3 ohms at -40°C (-40°F)

(Bottom) 26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

Y9—Quick-Drop Solenoid Resistance 24.2—27.3 ohms at -40°C (-40°F)

26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

Y10—Pilot Control Enable Solenoid Resistance 20.5—23.1 ohms at -40°C (-40°F)

22.6—25.5 ohms at -20°C (-4°F)
24.7—27.8 ohms at 0°C (32°F)
26.8—30.2 ohms at 20°C (68°F)
28.9—32.6 ohms at 40°C (104°F)

Y11—Blade Detent Coil Resistance 110—120 ohms

Y14—Hydrostatic Oil Cooler Bypass Resistance 20.5—23.1 ohms at -40°C (-40°F)

Solenoid 22.6—25.5 ohms at -20°C (-4°F)
24.7—27.8 ohms at 0°C (32°F)
26.8—30.2 ohms at 20°C (68°F)
28.9—32.6 ohms at 40°C (104°F)

Continued on next page MF82180,00001C3 –19–06OCT05–6/7

TM2260 (07JAN06) 9015-20-87 750J, 850J Crawler

010706
PN=271
 References

Item Measurement Specification

Y15—Park Bake Solenoid 2 Resistance 17.3—19.5 ohms at -40°C (-40°F)

19.0—21.5 ohms at -20°C (-4°F)
20.8—23.5 ohms at 0°C (32°F)
22.7—25.6 ohms at 20°C (68°F)
24.4—27.6 ohms at 40°C (104°F)

Y16—Air Conditioning Compressor Resistance 3.5—6 ohms

Clutch Solenoid

Y17—Hydrostatic Oil Reservoir Resistance 24.2—27.3 ohms at -40°C (-40°F)

Bypass Solenoid 26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)
9015
20
88

MF82180,00001C3 –19–06OCT05–7/7

TM2260 (07JAN06) 9015-20-88 750J, 850J Crawler

010706
PN=272
 References

Transmission Control Unit (TCU) Calibration

IMPORTANT: Prior to running this procedure, clear

tracks of excessive mud and verify Calibrate TCU
track tension is within specification. Press SELECT to begin calibrating
See Check Track Sag. (Operator’s
the transmission...
Manual.)

–UN–
NOTE: Do this procedure on level ground with enough
room to accelerate to full speed for approximately

T205964
46—61 m (150—200 ft.), or with machine off
ground supported by blocks.
Transmission Control Unit (TCU) Calibration
NOTE: If diagnostic trouble code 158.3, 158.4, 620.3 or
620.4 is displayed, do not calibrate, See
Transmission Control Unit (TCU) Diagnostic
9015
Trouble Codes. (Group 9015-20.) 20
89
IMPORTANT: Recalibrate whenever transmission
components are adjusted or replaced.

A pump null adjustment must be made

before calibration following pump
repair. See Pump Displacement Control
Valve (PDCV) Neutral (Null) Adjustment.
(Group 9026-25.)

1. Record diagnostic trouble codes and the number of

occurrences and clear all stored diagnostic trouble
codes before calibration. See Transmission Control
Unit (TCU) Diagnostic Trouble Codes. (Group
9015-20.)

2. Verify park lock lever is in the up position (Park). Turn

engine speed control switch to the low idle position.
Verify transmission control lever is in neutral.

3. Start engine.

4. Warm machine to normal operating temperature. Press

SELECT on the CAN Monitor Unit (CMU) until charge
pressure is displayed. If charge pressure is low, see
High/Low Charge Pressure - Flow Chart. (Group
9026-25.)

Continued on next page MF82180,000003E –19–05JAN05–1/2

TM2260 (07JAN06) 9015-20-89 750J, 850J Crawler

010706
PN=273
 References

5. Press and hold the MENU button on the CMU for 5

seconds until the monitor alarm beeps and Service
Mode is briefly displayed on the screen.

6. Press NEXT 4 times until Calibration is highlighted

and then press SELECT.

7. Press SELECT again to start the calibration procedure.

Follow the commands displayed on the CMU. If any
problems occur during the calibration period and the
calibration procedure ends prematurely, check
diagnostic trouble codes. See Transmission Control
Unit (TCU) Diagnostic Trouble Codes. (Group
9015-20.)

9015
20
90

MF82180,000003E –19–05JAN05–2/2

Wire Harness Test

IMPORTANT: When testing wire harnesses, it is

necessary to place spare mating
terminals into the terminal sockets of
the connectors that are to be tested and
apply test leads to those terminals
instead of the terminal sockets.
Inserting test leads into terminal
sockets of harness connectors can
damage the terminal socket and/or
connector, causing unnecessary
problems in the electrical system.

–UN–14JAN05
1—Test Lead
2—Spare Mating Terminal

T207090A

Proper Wire Harness Test (Deutsch connectors shown)

MF82180,000003F –19–14JAN05–1/1

TM2260 (07JAN06) 9015-20-90 750J, 850J Crawler

010706
PN=274
 References

Decelerator/Brake Pedal Adjustment 2 1

1. Disconnect harness from decelerator sensor (B1) (1)

and connect JT07329-3 test harness between sensor
and harness. Connect JT07237-1 test harness to the
white and black leads of the JT07329-3 test harness.

–UN–13APR04
2. Turn key switch on measure the sensor DC voltage on
a multimeter. Adjust high position stop (2) until reading
is within specification.

T198884
Specification 4 3
High Position—Voltage .................................................... 1.40—1.55 Volts
1—Decelerator Sensor
3. Press the decel pedal down until the low position stop 2—High Position Stop
is met. Adjust low position stop (3) until reading is 3—Low Position Stop
within specification. 4—Brake Position Stop 9015
20
91
Specification
Low Position—Voltage ..................................................... 3.40—3.60 Volts

4. Press the decel pedal down to the brake stop. Adjust

brake position stop (4) until reading is within
specification.

Specification
Brake Position—Voltage................................................... 3.79—3.99 Volts

MF82180,00001DF –19–24MAY04–1/1

TM2260 (07JAN06) 9015-20-91 750J, 850J Crawler

010706
PN=275
 References

Engine Speed Control Switch Remove and

Install 1

1—Knob 2
2—Push Nut
3—Stop Tab 5
4—Nut (2.71 N•m [24 lb-in.])
5—Stop Plate
6—Potentiometer
6 3
4

–UN–16DEC04
9015
20
92

T205069
Engine Speed Control Switch Remove and Install

MF82180,000003D –19–22DEC04–1/1

TM2260 (07JAN06) 9015-20-92 750J, 850J Crawler

010706
PN=276
 References

Rotary Sensor Remove and Install

1
1. To ease removal and installation, remove the
Transmission Control Lever (TCL) or decelerator 2
assembly. See Transmission Control Lever (TCL)
Remove and Install (Group 0315.) or

–UN–19APR04
2. Remove the two cap screws and sensor. Replace as 3
necessary.

T199285
3. Install O-ring (3) if needed.

4. Position sensor (2) at about a 4 o’clock position to Rotary Sensor Remove and Install (Steer Sensor shown)
install sensor on keyed shaft (1). 1—Shaft
2—Sensor
5. Twist sensor to line up sensor with mounting holes. 3—O-Ring
9015
20
6. Install cap screws and tighten to specification. 93

Specification
Rotary Sensor Mounting Cap
Screws—Torque ............................................................................... 5 N•m
48 lb-in.

7. Install the TCL or decelerator assembly.

MF82180,00001D5 –19–29NOV05–1/1

TM2260 (07JAN06) 9015-20-93 750J, 850J Crawler

010706
PN=277
 References

Transmission Control Lever (TCL)

Adjustment

This procedure is used to adjust the steer sensor linkage

and FNR sensor linkage to provide the correct voltage for
the rotary sensors.

1. Key switch on, engine off.

2. Access service mode by holding MENU button for 5

seconds.

3. Select Diagnostics

4. Live Values
9015
20 5. Input Voltages
94
6. Steer voltage in neutral position must be 2.39—2.60 V.

7. FNR voltage in neutral position must be 2.25—2.76 V.

8. If voltages are not to specification, remove SLC

assembly from machine.

Continued on next page CED,OUTX466,1293 –19–07OCT05–1/3

TM2260 (07JAN06) 9015-20-94 750J, 850J Crawler

010706
PN=278
 References

Steer Linkage Adjustment

1. Install JT07329-1 test harness (1) to machine harness

and to steer sensor (2).

2. Loosen lock nut (3) from ball joint. Turn rod assembly
(4) while monitoring steer voltage on monitor. Adjust to
specification and tighten lock nut.

3. Move steer lever to right steer position. Do not go into

counter-rotate. Voltage must be 1.52—1.94 V.

4. Move steer lever to right counter-rotate position.

Voltage must be 1.40—1.78 V.

5. Move steer lever to left steer position. Do not go into

9015
counter-rotate. Voltage must be 3.06—3.48 V. 20
95
6. Move steer lever to left counter-rotate position. Voltage
must be 3.22—3.60 V.

–UN–09DEC98
7. If voltage is not to specification, calibrate machine and
recheck voltage. If voltage is still not to specification,
replace sensor.

T118886B
8. If no voltage can be recorded, see Transmission
Control Unit (TCU) Circuit Theory of Operation. (Group
9015-15.) 1—JT07329-1 Test Harness
2—Steer Sensor
9. Route all wiring harnesses back to their original 3—Lock Nut
4—Rod Assembly
location and replace all tie bands that were removed.
5—FNR Sensor

NOTE: Recalibrate whenever control linkages are

adjusted or replaced.

Continued on next page CED,OUTX466,1293 –19–07OCT05–2/3

TM2260 (07JAN06) 9015-20-95 750J, 850J Crawler

010706
PN=279
 References

FNR Linkage Adjustment

1. Install JT07329-1 test harness to FNR sensor.

2. Remove nut (7) and ball joint (8). Loosen lock nut (6)
and adjust to specification.

3. Move FNR lever to forward position. Voltage must be

3.13—3.88 V.

4. Move FNR lever to reverse position. Voltage must be

1.06—1.80 V.

5. If voltage cannot be adjusted to specification, verify

sensor is installed correctly. See Rotary Sensor
Remove and Install. (Group 9015-20.)
9015
20
96 6. If no voltage can be recorded, see Transmission
Control Unit (TCU) Circuit Theory of Operation. (Group
9015-15.)

–UN–09DEC98
7. Route all wiring harnesses back to their original
location and replace all tie bands that were removed.

T118887B
NOTE: Recalibrate whenever control linkages are
adjusted or replaced.

6—Lock Nut
7—Nut
8—Ball Joint

CED,OUTX466,1293 –19–07OCT05–3/3

TM2260 (07JAN06) 9015-20-96 750J, 850J Crawler

010706
PN=280
 References

Replace WEATHER PACKConnector

IMPORTANT: Identify wire color locations with

connector terminal letters.

–UN–23AUG88
1. Open connector body.

2. Insert JDG364 Extraction Tool over terminal contact in

connector body.

TS0128
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.
9015
20
97

WEATHER PACK is a trademark of Packard Electric. DX,ECONN,O –19–03NOV94–1/2

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.

–UN–23AUG88
4. Push contact into new connector body until fully
seated.

TS0130
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.

DX,ECONN,O –19–03NOV94–2/2

TM2260 (07JAN06) 9015-20-97 750J, 850J Crawler

010706
PN=281
 References

Install WEATHER PACKContact

NOTE: Cable seals are color coded for three sizes of

wire:

• Green - 18 to 20 gauge wire

–UN–23AUG88
• Gray - 14 to 16 gauge wire
• Blue - 10 to 12 gauge wire

1. Slip correct size cable seal on wire.

TS0136
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: a) #15 for 14 to 16 gauge wire b)
9015
20 #19 for 18 to 20 gauge wire
98
3. Put proper size contact on wire and crimp in place with

–UN–02NOV94
a "W" type crimp, using JDG783 Terminal Applicator.

TS1623
WEATHER PACK is a trademark of Packard Electric. DX,ECONN,AA –19–04JUN90–1/2

IMPORTANT: Proper contact installation for "sleeve"

(A) and "pin” (B) is shown.

4. Secure cable seal to contact as shown, using JDG783

Terminal Applicator.

–UN–02DEC88
TS0139

DX,ECONN,AA –19–04JUN90–2/2

TM2260 (07JAN06) 9015-20-98 750J, 850J Crawler

010706
PN=282
 References

Replace DEUTSCH Connectors

1. Select correct size extractor tool for size of wire to be

removed:

• JDG361 Extractor Tool for 12 to 14 gauge wire.

–UN–23AUG88
• JDG362 Extractor Tool for 16 to 18 gauge wire.
• JDG363 Extractor Tool for 20 gauge wire.

2. Start correct size extractor tool over wire at handle (A).

TS0124
3. Slide extractor tool rearward along wire until tool tip
snaps onto wire.

IMPORTANT: Do NOT twist tool when inserting in

connector.
9015
20
4. Slide extractor tool along wire into connector body until 99

–UN–23AUG88
it is positioned over terminal contact.

5. Pull wire out of connector body, using extractor tool.

TS120
DEUTSCH is a trademark of the Deutsch Co. DX,ECONN,J –19–03NOV94–1/2

IMPORTANT: Install contact in proper location using

correct size grommet.

6. Push contact straight into connector body until positive

stop is felt.

–UN–23AUG88
7. Pull on wire slightly to be certain contact is locked in
place.

8. Transfer remaining wires to correct terminal in new

TS122
connector.

DX,ECONN,J –19–03NOV94–2/2

TM2260 (07JAN06) 9015-20-99 750J, 850J Crawler

010706
PN=283
 References

Replace DEUTSCH Rectangular or

Triangular Connectors

NOTE: Connector shown is the female half or a 4-pin

square connector. Other similar styles of Deutsch
connectors can be serviced using the same

–UN–01MAY00
procedure.

1. Pull connector (1) apart. Inspect and clean connector

seal and contacts.

T130688B
2. Remove locking wedge (2) from connector using hook
on JDG1383 service tool.
1—Connector
2—Locking Wedge

9015
20
,100

DEUTSCH is a trademark of Deutsch Co. CED,TX17994,305 –19–09JUN05–1/2

3. Release primary locking latch (3) next to the pin to be

removed using screwdriver on JDG1383 service tool.

4. Gently pull wire out from back of connector.

5. Replace connector contact as necessary. (See Install

–UN–01MAY00
Connector Contact procedure.)

6. Install wire terminal back into connector until it clicks

into place.

T130689B
NOTE: Locking wedge in 2-pin connector is not
symmetrical. Position latch shoulder next to
terminals.

7. Install locking wedge until it snaps into place.

3—Primary Locking Latches –UN–01MAY00

T130690B

CED,TX17994,305 –19–09JUN05–2/2

TM2260 (07JAN06) 9015-20-100 750J, 850J Crawler

010706
PN=284
 References

Install DEUTSCH Contact

1. Strip 6 mm (1/4 in.) insulation from wire.

2. Adjust selector (A) on JDG360 Crimper for correct wire

size.

–UN–23AUG88
3. Loosen lock nut (B) and turn adjusting screw (C) in
until it stops.

TS117
DEUTSCH is a trademark of the Deutsch Co. DX,ECONN,W –19–04JUN90–1/4

IMPORTANT: Select proper size contact "sleeve" or

"pin" to fit connector body. 9015
20
4. Insert contact (A) and turn adjusting screw (D) until ,101
contact is flush with cover (B).

–UN–23AUG88
5. Tighten lock nut (C).

TS0134
DX,ECONN,W –19–04JUN90–2/4

IMPORTANT: Contact must remain centered between

indentors while crimping.

6. Insert wire in contact and crimp until handle touches

stop.

–UN–23AUG88
7. Release handle and remove contact.

TS118
DX,ECONN,W –19–04JUN90–3/4

IMPORTANT: If all wire strands are not crimped into

contact, cut off wire at contact and
repeat contact installation procedures.

NOTE: Readjust crimping tool for each crimping

procedure.
–UN–23AUG88

8. Inspect contact to be certain all wires are in crimped

barrel.
TS0135

DX,ECONN,W –19–04JUN90–4/4

TM2260 (07JAN06) 9015-20-101 750J, 850J Crawler

010706
PN=285
 References

Replace CINCH Connectors

1. Remove extraction tool (1) from the loading side of

connector.

2. Insert blade of extraction tool into locking tabs (2) of

secondary lock (3). Rotate tool away from the
connector to pry one side of the secondary lock out of
the locked position. Repeat this step for the other
locking tab.

NOTE: After unlocking one side of the secondary lock, a

screw driver or similar device may need to be
used to hold it in the unlocked position while

–UN–29JUN00
unlocking the second locking tab.
9015
20 1—Extraction Tool
,102 2—Secondary Lock Locking Tabs

T132105B
3—Secondary Lock

CINCH is a trademark of the Cinch Co. CED,TX17994,319 –19–09JUN00–1/3

3. Remove secondary lock (3).

3—Secondary Lock

–UN–29JUN00
T132301B

Continued on next page CED,TX17994,319 –19–09JUN00–2/3

TM2260 (07JAN06) 9015-20-102 750J, 850J Crawler

010706
PN=286
 References

4. Insert pointed side of extraction tool into the contact

cavity so that the flat side of tool faces secondary lock
cavity (4). This will release the primary contact locking
tab.

5. Gently pull wire out of the connector.

–UN–29JUN00
6. Repair/Replace terminals as necessary using
procedure in this group. (See Install CINCH Contact.)

T132107B
7. Insert contact and wire into connector until it clicks.

8. Install secondary lock.

9015
20
,103

CED,TX17994,319 –19–09JUN00–3/3

TM2260 (07JAN06) 9015-20-103 750J, 850J Crawler

010706
PN=287
 References

Install CINCH Contact

9015
20
,104

–UN–14FEB01
T138057
A—Top of Tool D—Wire F—Junior Timer Slot I—Wire Tab
B—Contact Support E—Micro Timer Slot G—Contact J—Insulation Tab
C—Locator

1. Hold JDG708 crimping tool so that the tool is facing 3. Hold the contact in position and squeeze the tool
you as shown (left side of graphic). Squeeze tool handles together until ratchet engages sufficiently to
handles together and allow them to open fully. hold the contact in position. Do NOT deform wire
and insulation tabs (I and J).
IMPORTANT: Make sure that both sides of the
insulation barrel are started evenly 4. Insert stripped wire into contact insulation and wire
into the crimping section. Do NOT tabs until it is butted against locator (C).
attempt to crimp an improperly
positioned contact. 5. Hold the wire in place. Squeeze tool handles
together until ratchet releases. Allow tool handles to
2. Position the contact so that the mating end of the open and remove crimped contact.
contact (G) is on the locator side of the tool (C).
Wire and insulation tabs (I and J) should point to 6. Install contact into connector. See Replace CINCH
top of tool (A). Butt wire tab (I) against the movable Connectors.(Go to procedure in this group.)
locator (C).

CINCH is a trademark of the Cinch Co. CED,TX17994,330 –19–29JUN00–1/1

TM2260 (07JAN06) 9015-20-104 750J, 850J Crawler

010706
PN=288
 References

Replace (Pull Type) Metri-Pack Connectors

Disconnect the Metri-Pack1 connector (A). Remove tie

bands and tape.

Insert a “T” pin (B) 6.4 mm (1/4 in.) into connector body

–UN–26APR89
socket (C).

NOTE: Use JDG7772 Terminal Extraction Tool or “T” pin

to remove terminals.

RW16933
Angle “T” pin so pin tip slides close to the plastic socket
edge pushing terminal locking tab (D) inward.

Remove “T” pin and push terminal (E) out of socket.

9015
Remove terminal, cut strip and crimp wire through 20
connector. ,105

–UN–26APR89
Check to make sure locking tab on new terminal is in
outward position, then pull on wire until terminal locks in
connector body socket.

RW16934
NOTE: Terminal will seat only one way. If terminal does
not pull into the connector body socket, check to
make sure terminal is aligned correctly.

A—Connector
B—“T” Pin
C—Body Socket
D—Locking Tab
E—Push Terminal

–UN–26APR89
RW16935

1
Metri-Pack is a trademark of Packard Electric

2
Included in JT07195A Electrical Repair Kit

CED,OUO1032,1347 –19–09JUN05–1/1

TM2260 (07JAN06) 9015-20-105 750J, 850J Crawler

010706
PN=289
 References

Replace (Push Type) Metri-Pack

Connectors

Disconnect the Metri-Pack1 connector. Remove the tie

bands and tape.

–UN–29JUN92
Remove the connector lock (A), and mark wire colors for
identification.

Identify wire color locations with connector terminal letters.

RW21325
Insert JDG776 or JDG7772 Terminal Extraction Tool (B)
into connector body socket (C) pushing the terminal
A—Connector Lock
locking tab inward.
B—Extraction Tool JDG777
C—Connector Body Socket
9015 NOTE: Use JDG776 Extraction Tool with 56, 280 and 630 D—Terminal
20 series METRI-PACK terminals. Use JDG777 E—Locking Tab
,106 Extraction Tool with 150 series METRI-PACK
terminals.

Remove extraction tool and pull terminal (D) out of the

socket.

Replace terminal. Make sure locking tab (E) on the new

terminal is in the outward position.

Push terminal into connector body socket until terminal

locks.

1
Metri-Pack is a trademark of Packard Electric

2
Included in JT07195A Electrical Repair Kit

CED,OUO1032,1348 –19–09JUN05–1/1

TM2260 (07JAN06) 9015-20-106 750J, 850J Crawler

010706
PN=290
 Section 9025
Hydraulics
Contents

Page

Group 05—Theory
Hydraulic System Operation . . . . . . . . . . . . .9025-05-1
Hydraulic Pump Operation . . . . . . . . . . . . . .9025-05-2
Hydraulic Control Valve Operation. . . . . . . . .9025-05-5
Load Sense Circuit Operation . . . . . . . . . . . .9025-05-6
Load Sense Isolator Operation . . . . . . . . . . .9025-05-7
Circuit Relief Valve with Anticavitation
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-8
Hydraulic System Relief Valve Operation . . .9025-05-9
Hydraulic Oil Filter Manifold Operation . . . .9025-05-10
Blade Angle Operation . . . . . . . . . . . . . . . .9025-05-12
Ripper Operation. . . . . . . . . . . . . . . . . . . . .9025-05-16
Quick-Drop Valve Operation . . . . . . . . . . . .9025-05-20 9025

Group 15—Diagnostic Information

Hydraulic System Schematic . . . . . . . . . . . . .9025-15-2
Main Hydraulic Component Location . . . . . .9025-15-14
Ripper Ready Hydraulic Component
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-16
Winch Ready Hydraulic Component
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-18
Diagnose Hydraulic System
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9025-15-19

Group 25—Tests
JT02156A Digital Pressure/Temperature
Analyzer Installation. . . . . . . . . . . . . . . . . .9025-25-1
JDG1770 Ultra Clean Hand Launcher . . . . .9025-25-1
Hydraulic Oil Cleanup Procedure . . . . . . . . .9025-25-2
Hydraulic System Relief Valve Test. . . . . . . .9025-25-2
Circuit Relief Valve Test . . . . . . . . . . . . . . . .9025-25-4
Pump Load Sense Differential and System
Pressure Test and Adjustment. . . . . . . . . .9025-25-5
Lift and Tilt Cylinder Function Drift Test . . . .9025-25-7
Hydraulic Cylinder Drift Test . . . . . . . . . . . .9025-25-10
Cylinder Leakage Test . . . . . . . . . . . . . . . .9025-25-11
Pressure Reducing Valve Pressure Test and
Adjustment. . . . . . . . . . . . . . . . . . . . . . . .9025-25-13
Blade Down Accumulator Hydraulic
Discharge . . . . . . . . . . . . . . . . . . . . . . . .9025-25-15
Blade Down Accumulator Precharge
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-16
Hydraulic Pump Flow Test . . . . . . . . . . . . .9025-25-17
Hydraulic Pump Case Drain Test . . . . . . . .9025-25-20

TM2260 (07JAN06) 9025-1 750J, 850J Crawler

010706
PN=1
 Contents

9025

TM2260 (07JAN06) 9025-2 750J, 850J Crawler

010706
PN=2
 Group 05
Theory
Hydraulic System Operation

NOTE: See Hydraulic System Schematic. (Group pressure will be equal to the highest work port
9025-15.) pressure sensed in the system plus the load sense
differential pressure.
All hydraulic functions are incorporated into one
system utilizing a single axial piston pump. The entire hydraulic system is protected from pressure
spikes by the system relief valve, located in the inlet
This machine has a closed-center, load sensing section of the control valve. On Power Angle Tilt (PAT)
hydraulic system. A variable displacement, axial piston machines, circuit relief valves protect the blade angle
pump supplies oil to hydraulic functions. circuit. On Outside Dozers (OSD), a circuit relief valve
protects the blade lift circuit.
Upon initial startup, the hydraulic pump reaches low
standby pressure until a function is activated. Standby Return oil flows through the return line into the filter to
pressure oil is equally supplied to the control valve the reservoir. The return filter has a bypass valve and
inlet section and the pressure reducing valve. Standby a filter restriction indicator switch.
pressure oil is converted to load sense (LS) pressure
oil when a function is activated and valve spool shifted. The load sensing hydraulic system on this machine
improves fuel economy and reduces heat buildup by
Pump will go into stroke and deliver highest workport not wasting horsepower on unused excessive pump
pressure required from an activated function when LS output.
signal is received from that function. Total pump 9025
05
1

BR81691,0000064 –19–10SEP04–1/1

TM2260 (07JAN06) 9025-05-1 750J, 850J Crawler

010706
PN=293
 Theory

Hydraulic Pump Operation

109

200

201
129

199
131
129
9025
05
2

130

132
131

–UN–20NOV04
104
T202385

T202385
Hydraulic Pump Component Location

104—Hydraulic Pump 130—Hydraulic 199—Hydraulic Pump Case 201—Pressure Reducing

109—Pressure Reducing Valve Reservoir-to-Hydraulic Drain Hose Valve-to-Hydraulic
129—Control Pump Inlet Hose 200—Control Reservoir Return Hose
Valve-to-Pressure 131—Load Sense Hose Valve-to-Hydraulic Filter
Reducing Valve Hose 132—Hydraulic Hose
Pump-to-Control Valve
Inlet Hose

Continued on next page BR81691,0000009 –19–06JAN05–1/3

TM2260 (07JAN06) 9025-05-2 750J, 850J Crawler

010706
PN=294
 Theory

170 171 172

169

176
175
177
174 173

–UN–22OCT04
181 9025
178 05
3
179 180

T204409
T204409
Hydraulic Pump Cross Section

The hydraulic pump is an axial piston variable

132
displacement pump. The pump is mounted to and driven 104
by the rear hydrostatic pump. The hydraulic system is a
closed-center load sensing system. Load sense (LS)
pressure is always equal to the highest work port pressure
created by an activated function. 180

131
104—Hydraulic Pump
131—Load Sense Isolator-to-Hydraulic Pump
132—Hydraulic Pump-to-Control Valve Inlet
169—Pump Drive Shaft
170—Rotating Group
181
171—Bias Piston
172—Bias Piston Spring
173
173—Displacement Piston 171
–UN–13APR05

174—Swashplate
175—Roller Bearing
176—Cutoff Spring
177—High Pressure Cutoff Adjustment Screw
178—Load Sense Differential Pressure Adjustment
T210372

Screw
179—Load Sense Spring
180—Load Sense Spool Hydraulic Pump Schematic
181—High Pressure Cutoff Spool

Continued on next page BR81691,0000009 –19–06JAN05–2/3

TM2260 (07JAN06) 9025-05-3 750J, 850J Crawler

010706
PN=295
 Theory

When a function is activated, a LS signal is sent to the

pump control valve. This pressure in addition to spring
force cause LS spool (180) to shift making a connection
between the displacement piston and case return. This
connection vents displacement piston oil to return allowing
the displacement piston to shift as the bias spring and
piston force the pump onto stroke. The pump will come
onto stroke until demanded pressure settings are
achieved.

The pump has two pistons, bias piston (171) and

displacement piston (173). With engine off, spring force
acting on bias piston holds the pump at maximum
displacement. As the engine is started, transmission
begins to rotate turning pump drive shaft (169). Pump
outlet pressure acts against the head end of load sense
spool (180) and high pressure cutoff spool (181). When
pump outlet pressure is great enough to overcome the LS
spring (179) and cutoff spring (176) pressure, the spools
shift making a connection to the displacement piston (173)
and allowing oil into displacement piston (173). The
9025 displacement piston then shifts to rotate swashplate (174)
05 to minimum displacement, allowing a small amount of
4
displacement for internal leakage. This condition is known
as low pressure standby.

BR81691,0000009 –19–06JAN05–3/3

TM2260 (07JAN06) 9025-05-4 750J, 850J Crawler

010706
PN=296
 Theory

Hydraulic Control Valve Operation

The control valve inlet valve section contains the system

relief valve. See Hydraulic System Relief Valve Operation
(Group 9025-05.) The blade lift valve is a four-position,
five-way, spool-type valve containing a load check valve.
The valve spool is returned to neutral by a centering
spring in the spool end cap. When a function is activated,
oil flows from the parallel passage, past the load check,
spool, and out the workport to the cylinders. Return oil
from the cylinders flows into the other workport, past the
spool, into the return passage, and out of the control valve
to the hydraulic reservoir. When the spool is moved to the
blade float position, both workports are open to the return
passage, allowing oil to flow in and out both ends of the
cylinders. The blade float function uses an
electromagnetic detent. When the hydraulic control lever
is moved forward to the float position, a plate connected
to the control lever is held downward by the
electromagnet with enough force to hold the control lever
in the float position, but it can be manually disengaged by
pulling back on the hydraulic control lever. When the 9025
hydraulic control lever is in float position it sends full pilot 05
5
pressure to the lift spool.

The blade tilt valve is a three-position, five-way valve. The

blade angle valve is a three-position, five-way valve that
contains two circuit relief valves with anticavitation check
valves. See Circuit Relief Valve with Anticavitation
Operation. Both the blade tilt and blade angle valves
contain a load check valve. The valve spools are returned
to neutral by a centering spring in the spool end cap.
When a function is activated, oil flows from the parallel
passage, past the load check, spool, and out the workport
to the cylinder. Return oil from the cylinder flows into the
other workport, past the spool, into the return oil passage,
and out the control valve to the hydraulic reservoir. The
spools have grooves that meter oil through the valve to
allow for smooth starts and stops.

TX,9025,BS429 –19–29OCT04–1/1

TM2260 (07JAN06) 9025-05-5 750J, 850J Crawler

010706
PN=297
 Theory

Load Sense Circuit Operation

Load Sense (LS) hydraulic systems provide flow on

demand. When the valve spools are all in neutral
positions, then the hydraulic pump is in neutral as well.
When the hydraulic pump is in neutral, it outputs
differential standby pressure. See Pump Load Sense
Differential and Standby Pressure Test and Adjustment.
(Group 9025-25.)

Each hydraulic function has a LS shuttle check valve. The

purpose of the LS shuttle is to compare LS signals from
each function and direct the highest work port pressure to
the LS isolator valve, located in the outlet section of the
control valve, to the hydraulic pump. See Load Sense
Isolator Operation. (Group 9025-05.) When the hydraulic
pump senses work port pressure, it goes onto stroke
producing the highest work port pressure needed plus
differential standby pressure.

The LS circuit port is located on the outlet section of the

9025 control valve. This port allows additional hydraulic
05 functions, such as a winch, to be added into the LS
6
circuit. This is accomplished by adding a LS shuttle valve
in the LS circuit. See Hydraulic System Schematic. (Group
9025-15.)

BR81691,000000F –19–27JAN05–1/1

TM2260 (07JAN06) 9025-05-6 750J, 850J Crawler

010706
PN=298
 Theory

Load Sense Isolator Operation

161
167 168 164 165

160 162 163

160

163 162

9025
05
7
155 164
161 165
156

159 166

–UN–21JAN05
T204271
T204271
Load Sense Isolator

155—Low Pressure Oil 161—Supply from Pump 163—Return Passage 166—Orifice

156—Load Sense Pressure Oil 162—Load Sense Output (to 164—Damping Orifice 167—Spring
159—Return Oil compensators and pump 165—Pilot Passage 168—Spool
160—Input from Valve Load load sense input)
Sensing Network

The load sense (LS) isolator senses the control valve’s through port (162). The pump provides its own
highest bridge pressure which indicates the greatest constant source of oil through the isolator to keep the
load at a work port. The isolator then shifts to allow an hose between the load sense output port of the control
equal pressure to flow to the pump load sense control valve and the port on the load sense control valve
valve. When all control valve spools are in neutral, the filled with oil. When load sense pressure changes, the
highest work port pressure at isolator input (160) is new pressure is transmitted to the load sense port
equal to return pressure. Pump output pressure is without the need to first fill the hose with oil, and
transmitted to LS isolator through port (161) and out performance lag is eliminated.

TX,9025,RR7541 –19–08NOV96–1/1

TM2260 (07JAN06) 9025-05-7 750J, 850J Crawler

010706
PN=299
 Theory

Circuit Relief Valve with Anticavitation Operation

189 190 196 191 194

195

–UN–10NOV04
188
156

T204503
9025 197 192 193 159
05 T204503
8 Circuit Relief with Anitcavitation

156—Pressure Oil 189—Main Poppet 192—Main Spring 195—Orifice

159—Return Oil 190—Anticavitation Poppet 193—Pilot Poppet 196—Cavity
188—Piston 191—Anticavitation Spring 194—Pilot Spring 197—Relief Body

The relief valve is used in the blade angle, lift, and through orifice (195) into cavity (196) past pilot poppet
ripper lift circuits. The relief is a pilot operated, screw (193) to tank through a path between relief body (197)
adjustable, with anticavitation operation. and anticavitation poppet (190). The pressure drop
through orifice (195) causes a pressure difference
The relief valve setting is controlled by the pilot spring across piston (188) and it moves against main spring
(194) holding the pilot poppet (193) on its seat. The (192) until it rests on pilot poppet (193). This
setting is adjustable. Loosening lock nut and screwing movement shuts off orifice (195) and further reduces
adjustment cap in will increase pressure setting. the pressure in cavity (196). When the pressure
difference is large enough to overcome the differential
In normal operation, pressure oil less than relief valve area effect holding the main poppet (189) on its seat
setting flows though orifice (195) in piston (188) into and oil is allowed to flow from the work port to the
cavity (196) behind the anticavitation poppet (190) and return port.
main relief valve poppet (189). This oil pressure and
the springs hold the main poppet (189) and During anticavitation operation, the pressure in the
anticavitation poppet (190) closed because the work port and cavity (196) is less than the pressure in
effective areas of the poppets on the cavity side is the return port. This pressure difference overcomes the
greater than the work port side. differential area effect holding the anticavitation poppet
(190) on it’s seat and oil is allowed to flow from return
In relief operation, pressure oil overcomes the pilot port to work port to prevent cavitation.
poppet (193) and oil flows from the pressurized port

TX03768,0000B03 –19–25OCT05–1/1

TM2260 (07JAN06) 9025-05-8 750J, 850J Crawler

010706
PN=300
 Theory

Hydraulic System Relief Valve Operation

198

9025

–UN–10NOV04
05
156 9

159

T204514
T204514
System Relief Valve Operation

156—Pressure Oil 159—Return Oil 198—Main Poppet

This metal-to-metal seal relief is used on the inlet of In relief operation, pressure oil overcomes main poppet
the load sensing control valve. (198) and oil flows from the pressurized port to tank.

This relief valve is direct acting, screw adjustable, and

does not have anticavitation operation.

The pressure set point is adjustable by turning the

adjustment screw at the end of the relief. Turning the
screw in increases the pressure setting.

BT40170,0000040 –19–27OCT04–1/1

TM2260 (07JAN06) 9025-05-9 750J, 850J Crawler

010706
PN=301
 Theory

Hydraulic Oil Filter Manifold Operation

114

107

106

9025
05
10

134

–UN–23SEP04
T202635

T202635
Hydraulic Oil Filter Manifold Operation

106—Oil Filter Element 107—Oil Filter Head 114—Hydraulic Reservoir 134—Control Valve-to-Filter
Head Inlet Hose

Continued on next page BR81691,0000066 –19–27OCT04–1/2

TM2260 (07JAN06) 9025-05-10 750J, 850J Crawler

010706
PN=302
 Theory

–UN–13SEP04
9025
05
11

T203022
106—Oil Filter Element 142—Diagnostic Port 144—Outlet Port 145—Hydraulic Oil Filter
141—Oil Filter Restriction 143—Inlet Port Bypass Valve
Indicator Switch

The hydraulic oil filter manifold contains the hydraulic cause the filter element to have a structural failure.
oil filter element (106), hydraulic oil filter restriction High pressure drop conditions can occur from cold
indicator switch (141) and hydraulic oil filter bypass start high viscosity oil, contamination build up in the
valve (145). Hydraulic oil enters through the inlet port filter element, or high flow surge conditions. The
(143) elbow fitting. Oil is directed into the head bypass valve will open under these conditions allowing
assembly toward the filter bypass valve where it flows some fluid to bypass the filter element. Fluid flowing
into the spin-on filter assembly. Oil continues to flow through the bypass is not filtered.
through the filter element from an outside-to-inside
path. Oil then flows back into the filter head and There is a filter restriction indicator switch (141) that
through the outlet port fitting (144) to the reservoir. monitors pressure drop across the filter element. If the
pressure drop attains the setting of the electrical
Diagnostic port (142) can be used to collect oil indicator it will activate a light on the monitor warning
samples or to obtain pressure readings on the the machine operator that the spin-on filter needs to be
upstream side of the filter element. serviced. The filter restriction indicator switch is set at
a point just lower than the bypass valve setting
Filter bypass valve (145) function is used to protect the allowing the operator time to change the spin-on filter
filter element from excessive pressure drop and from prior to the bypass valve opening due to contamination
pressure differential between the clean side and dirty build up in the filter element.
side of the filter element. High pressure drop can

BR81691,0000066 –19–27OCT04–2/2

TM2260 (07JAN06) 9025-05-11 750J, 850J Crawler

010706
PN=303
 Theory

Blade Angle Operation

T202384 –UN–07OCT04

118

117

109
108

121
122 122
122

102
121

105

121
102 104

T202384
Blade Angle Operation
BR81691,0000065 –19–10SEP04–1/4

TM2260 (07JAN06) 9025-05-12 750J, 850J Crawler

010706
PN=304
 Theory

102—Angle Cylinder (2 used) 109—Pressure Reducing Valve 121—Control Valve-to-Rod End 122—Control Valve-to-Head
104—Hydraulic Pump 117—Hydraulic Control Lever of Right Angle Cylinder End of Right Angle
105—Hydraulic Control Valve 118—Blade Angle Switch and Head End of Left Cylinder and Rod End of
108—Angle Solenoid Valve Angle Cylinder Hose Left Angle Cylinder Hose

The blade angle circuit contains two proportional located on the hydraulic control lever. When the blade
solenoid valves (108), a valve section, two circuit relief angle switch is pressed, a signal is sent to the
valves, and two cylinders (102). transmission control unit (TCU), where it is interpreted
and sent to the blade angle solenoid valves. The blade
Pilot oil is sent from the pressure reducing valve (109), angle solenoid valves will shift allowing pilot oil to the
to the blade angle solenoid valves. The solenoid blade angle valve section shifting the spool.
valves are controlled by the blade angle switch (118)

Continued on next page BR81691,0000065 –19–10SEP04–2/4

9025
05
13

TM2260 (07JAN06) 9025-05-13 750J, 850J Crawler

010706
PN=305
 Theory

–UN–13SEP04
9025
05
14

T203015
135—Solenoid Coil 1 137—Port 1 139—Port 3 140—Port 4
136—Solenoid Coil 2 138—Port 2

The blade angle solenoid valve is a 4-way, 3-position, (135) is energized, flow is allowed from port 3 (139) to
spool type, screw-in hydraulic cartridge valve. When port 4 (140), and from port 2 (138) to port 1 (137).
de-energized, the cartridge blocks flow to port 3 (139), When coil 2 (136) is energized, flow is allowed from
while allowing flow from port 2 (138) to port 1 (137), port 3 (139) to port 2 (138) and from port 4 (140) to
and from port 4 (140) to port 1 (137). When coil 1 port 1 (137).

Continued on next page BR81691,0000065 –19–10SEP04–3/4

TM2260 (07JAN06) 9025-05-14 750J, 850J Crawler

010706
PN=306
 Theory

ANGLE
3 1 108 SOLENOID
VALVE

ANGLE
2 4 CYLINDERS
102

120
CIRCUIT
RELIEFS

9025
05
15

155

156

–19–14OCT04
157
149
BLADE 158
ANGLE
SECTION 159 T203834

T203834
Blade Angle Section Schematic

102—Angle Cylinder (2 used) 149—Blade Angle Section 156—Load Pressure Sense Oil 158—Trapped Oil
108—Angle Solenoid Valve 155—Low Pressure Oil 157—Regulated Pressure Oil 159—Return Oil
120—Circuit Relief (2 used)

The blade angle valve section is a three-position, to neutral by centering springs in the spool end caps.
four-way, spool type valve containing a load check. There is one circuit relief for each angle direction,
Pilot oil shifts the valve spool sending pressure oil to protecting the system from excessive pressure.
the blade angle cylinders. The valve spool is returned

BR81691,0000065 –19–10SEP04–4/4

TM2260 (07JAN06) 9025-05-15 750J, 850J Crawler

010706
PN=307
 Theory

Ripper Operation
T215999 –UN–19OCT05

119

107

105
107

T215999
Ripper Operation
MS12501,0000011 –19–27OCT05–1/4

TM2260 (07JAN06) 9025-05-16 750J, 850J Crawler

010706
PN=308
 Theory

105—Hydraulic Control Valve 107—Ripper Cylinder (2 Used) 119—Auxiliary Pilot Controller

The ripper circuit contains a valve section, one circuit to the hydraulic control valve (105) allowing pilot oil to
relief valve, and two cylinders (107). the ripper lift valve section shifting the spool.

When the auxiliary pilot controller (119) is pushed or

pulled, pilot oil is sent from the auxiliary pilot controller,

Continued on next page MS12501,0000011 –19–27OCT05–2/4

9025
05
17

TM2260 (07JAN06) 9025-05-17 750J, 850J Crawler

010706
PN=309
 Theory

RIPPER LIFT
107 CYLINDER

119

9025
05
18
154

155

146 RIPPER LIFT 156

–19–27OCT05

SECTION
158

159
T216778

T216778
Ripper Section Schematic

Continued on next page MS12501,0000011 –19–27OCT05–3/4

TM2260 (07JAN06) 9025-05-18 750J, 850J Crawler

010706
PN=310
 Theory

107—Ripper Cylinders (2 used) 154—Anticavitation Valve 156—Load Pressure Sense Oil 158—Trapped Oil
119—Circuit Relief 155—Low Pressure Oil 157—Regulated Pressure Oil 159—Return Oil
146—Ripper Section

The ripper valve section (146) is a three-position, to neutral by centering springs in the spool end caps.
four-way, spool type valve containing a load check. There is one circuit relief (119) used on the rod end
Pilot oil shifts the valve spool sending pressure oil to side of the ripper cylinders, protecting the system from
the ripper cylinders (107). The valve spool is returned excessive pressure.

MS12501,0000011 –19–27OCT05–4/4

9025
05
19

TM2260 (07JAN06) 9025-05-19 750J, 850J Crawler

010706
PN=311
 Theory

Quick-Drop Valve Operation

T203418 –UN–29OCT04

103

103

115

105

104

T203418
Quick-Drop Valve
TX,9025,BS442 –19–18OCT04–1/2

TM2260 (07JAN06) 9025-05-20 750J, 850J Crawler

010706
PN=312
 Theory

103—Lift Cylinder (2 used) 104—Hydraulic Pump 105—Control Valve 115—Quick-Drop Valve

The quick-drop valve (115) allows the operator to hydraulic control valve is not activated and the
lower the blade to the ground very quickly. The high quick-drop spool is in its normal spring biased position.
speed blade drop allows for shedding of material from In this mode the quick-drop valve is nothing more than
the mold board. The quick-drop valve also serves as a tee fitting, connected to the hydraulic control valve,
an anticavitation device. In quick-drop mode, return oil that splits the flow to the two lift cylinders.
from the rod end of the lift cylinders is allowed to fill
the head end of the lift cylinders instead of returning to When raising the blade, oil is directed from the blade
the reservoir. The cylinder velocity when the blade is lift section of the control valve to the quick-drop valve.
falling is much faster than the pump can provide flow From the quick-drop valve oil is directed to the rod end
for, so the head end of the cylinder will cavitate. of both lift cylinders.
Dumping rod end oil into the head end helps eliminate
this void. During blade float, oil is directed from the control valve
through the quick-drop valve to the head end of both
The quick-drop valve is connected to the system lift cylinders. The solenoid valve shifts, blocking pilot oil
between the blade lift cylinders and the hydraulic to the pilot valve. Oil from the rod end of both lift
control valve. The quick-drop valve operation is cylinders is directed to the quick-drop valve where oil
controlled by an electric switch activated by the applied pressure to the top of the pilot valve which
position of the valve spool in the hydraulic control overcomes the spring force, shifting the spool. With the
valve. spool shifted, oil flows through the pilot valve and back
out of the quick-drop valve to the head end of the lift 9025
During normal lift and lower operation of the dozer cylinders. 05
blade, the quick-drop solenoid actuation switch in the 21

TX,9025,BS442 –19–18OCT04–2/2

TM2260 (07JAN06) 9025-05-21 750J, 850J Crawler

010706
PN=313
 Theory

9025
05
22

TM2260 (07JAN06) 9025-05-22 750J, 850J Crawler

010706
PN=314
 Group 15
Diagnostic Information

9025
15
1

TM2260 (07JAN06) 9025-15-1 750J, 850J Crawler

010706
PN=315
 Diagnostic Information

Hydraulic System Schematic

T202520 –19–31JAN05

ANGLE
3 1 108 SOLENOID
VALVE
LIFT
CYLINDERS
P 103 TILT ANGLE
CYLINDER CYLINDERS
2 4
101
102
T

T PREG

109
PRESSURE
REDUCING 120 120
VALVE 105
CONTROL
VALVE
T

154
154
LOAD LS
SENSE 211 CIRCUIT
T ISOLATOR PORT

LS 116
SHUTTLE 152
PREG
PUMP
TEST 203
HYDRAULIC 151 PORT
PUMP
SYSTEM
104 117 PILOT RELIEF
CONTROLLER
P VALVE

LS 147 148 149

146 150
BLADE BLADE BLADE
INLET LIFT TILT ANGLE OUTLET LOAD
SECTION SECTION SECTION SECTION SECTION SENSE 202
TEST
PORT

157 REGULATED
PRESSURE OIL
155 LOW PRESSURE OIL 158 TRAPPED OIL

114 106 HYDRAULIC FILTER 156 LOAD SENSE PRESSURE OIL 159 RETURN OIL
T202520
Hydraulic Schematic Power Angle Tilt (PAT)—Neutral
BR81691,0000067 –19–06OCT05–1/12

TM2260 (07JAN06) 9025-15-2 750J, 850J Crawler

010706
PN=316
 Diagnostic Information

101—Tilt Cylinder 116—Load Sense Isolator 150—Outlet Valve Section 156—Load Sense Pressure Oil
102—Angle Cylinder (2 used) 117—Pilot Controller 151—Hydraulic System Relief 157—Regulated Pressure Oil
103—Lift Cylinder (2 used) 120—Blade Angle Circuit Valve 158—Trapped Oil
104—Hydraulic Pump Relief Valve (2 used) 152—Load Sense (LS) Shuttle 159—Return Oil
105—Control Valve 146—Inlet Valve Section Valve (3 used) 202—Load Sense Test Port
106—Hydraulic Filter 147—Blade Lift Valve Section 154—Anticavitation Valve (2 203—Pump Test Port
108—Angle Solenoid Valve 148—Blade Tilt Valve Section used) 211—LS Circuit Port
109—Pressure Reducing Valve 149—Blade Angle Valve 155—Low Pressure Oil
114—Hydraulic Reservoir Section

Continued on next page BR81691,0000067 –19–06OCT05–2/12

9025
15
3

TM2260 (07JAN06) 9025-15-3 750J, 850J Crawler

010706
PN=317
 Diagnostic Information
T203133 –19–31JAN05

LIFT
CYLINDERS 155 LOW
103 PRESSURE OIL
156 LOAD SENSE
PRESSURE OIL
109
P
157 REGULATED
PRESSURE PRESSURE OIL
REDUCING
VALVE 158 TRAPPED OIL
T
159 RETURN OIL
115 QUICK-DROP
VALVE
PREG

101 TILT
CYLINDER

120 120
146 147 148 150
INLET BLADE BLADE OUTLET
SECTION LIFT TILT SECTION
SECTION SECTION

105
CONTROL 154 154
VALVE
211
LS
CIRCUIT
PORT
HYDRAULIC
PUMP
104 117 PILOT LOAD
CONTROLLER LS SENSE
SHUTTLE 152 ISOLATOR
PUMP
116 TEST
PORT
203
151
SYSTEM
RELIEF
VALVE

LOAD
SENSE 202
TEST
PORT

114 106 HYDRAULIC FILTER

T203133
Hydraulic Schematic Outside Dozer (OSD)—Neutral

Continued on next page BR81691,0000067 –19–06OCT05–3/12

TM2260 (07JAN06) 9025-15-4 750J, 850J Crawler

010706
PN=318
 Diagnostic Information

101—Tilt Cylinder 116—Load Sense Isolator 151—Hydraulic System Relief 156—Load Sense Pressure Oil
103—Lift Cylinder (2 used) 117—Pilot Controller Valve 157—Regulated Pressure Oil
104—Hydraulic Pump 120—Blade Lift Circuit Relief 152—Load Sense (LS) Shuttle 158—Trapped Oil
105—Control Valve Valve (2 used) Valve (2 used) 159—Return Oil
106—Hydraulic Filter 146—Inlet Valve Section 154—Anticavitation Valve (2 202—Load Sense Test Port
109—Pressure Reducing Valve 147—Blade Lift Valve Section used) 203—Pump Test Port
114—Hydraulic Reservoir 148—Blade Tilt Valve Section 155—Low Pressure Oil 211—LS Circuit Port
115—Quick-Drop Valve 150—Outlet Valve Section

Continued on next page BR81691,0000067 –19–06OCT05–4/12

9025
15
5

TM2260 (07JAN06) 9025-15-5 750J, 850J Crawler

010706
PN=319
 Diagnostic Information
T207347 –19–31JAN05

ANGLE
3 1 108 SOLENOID
VALVE
LIFT
CYLINDERS
P 103 TILT
CYLINDER
2 4
101
102 ANGLE
T CYLINDERS

T PREG

109
AUXILIARY
PILOT PRESSURE
CONTROLLER REDUCING 120 120
VALVE 105
210
CONTROL 152 LS
CIRCUIT
VALVE PORT
T

154
154
LOAD
SENSE
ISOLATOR 152 LS
SHUTTLE
T

LS 116
SHUTTLE 152
PREG
PUMP
TEST 203
HYDRAULIC 151 PORT
PUMP
SYSTEM
104 117 PILOT RELIEF
CONTROLLER
P VALVE
155 LOW PRESSURE OIL

156 LOAD SENSE PRESSURE OIL

LS 147 148 149
146 150
157 REGULATED PRESSURE OIL BLADE BLADE BLADE
INLET LIFT TILT ANGLE OUTLET LOAD
SECTION SECTION SECTION SECTION SECTION SENSE 202
158 TRAPPED OIL TEST
PORT
159 RETURN OIL
209

106 HYDRAULIC
BYPASS 207
FILTER VALVE
HYDRAULIC
114 OIL COOLER 208

T207347
Hydraulic Schematic Power Angle Tilt (PAT) with Winch—Neutral

Continued on next page BR81691,0000067 –19–06OCT05–5/12

TM2260 (07JAN06) 9025-15-6 750J, 850J Crawler

010706
PN=320
 Diagnostic Information

101—Tilt Cylinder 117—Pilot Controller 152—Load Sense (LS) Shuttle 202—Load Sense Test Port
102—Angle Cylinder (2 used) 120—Blade Angle Circuit Valve (4 used) 203—Pump Test Port
103—Lift Cylinder (2 used) Relief Valve (2 used) 154—Anticavitation Valve (2 207—Bypass Valve
104—Hydraulic Pump 146—Inlet Valve Section used) 208—Hydraulic Oil Cooler
105—Control Valve 147—Blade Lift Valve Section 155—Low Pressure Oil 209—Winch Valve (for
106—Hydraulic Filter 148—Blade Tilt Valve Section 156—Load Sense Pressure Oil reference only)
108—Angle Solenoid Valve 149—Blade Angle Valve 157—Regulated Pressure Oil 210—Auxiliary Pilot Controller
109—Pressure Reducing Valve Section 158—Trapped Oil 211—LS Circuit Port
114—Hydraulic Reservoir 150—Outlet Valve Section 159—Return Oil
116—Load Sense Isolator 151—Hydraulic System Relief
Valve

Continued on next page BR81691,0000067 –19–06OCT05–6/12

9025
15
7

TM2260 (07JAN06) 9025-15-7 750J, 850J Crawler

010706
PN=321
 Diagnostic Information
T207428 –19–31JAN05

LIFT
CYLINDERS
103

109
P
PRESSURE
REDUCING
VALVE
T

QUICK
115 DROP
PREG VALVE

AUXILIARY
PILOT 101 TILT
CONTROLLER CYLINDER

210
120 120
147 148
146 150
BLADE BLADE
INLET LIFT TILT OUTLET
SECTION SECTION SECTION SECTION

105 211 LS
CIRCUIT
CONTROL 154 154 PORT
VALVE

152 LS
SHUTTLE
HYDRAULIC
PUMP
104 117 PILOT LOAD
CONTROLLER LS SENSE
155 LOW SHUTTLE 152 ISOLATOR
PRESSURE OIL PUMP
116 203 TEST
156 LOAD SENSE PORT
PRESSURE OIL
157 REGULATED
151
PRESSURE OIL
SYSTEM
158 TRAPPED OIL RELIEF LOAD SENSE
VALVE
202 TEST PORT
159 RETURN OIL 209

207 BYPASS
VALVE
HYDRAULIC
OIL COOLER 208
114 106 HYDRAULIC FILTER
T207428
Hydraulic Schematic Outside Dozer (OSD) with Winch—Neutral

Continued on next page BR81691,0000067 –19–06OCT05–7/12

TM2260 (07JAN06) 9025-15-8 750J, 850J Crawler

010706
PN=322
 Diagnostic Information

101—Tilt Cylinder 117—Pilot Controller 152—Load Sense (LS) Shuttle 202—Load Sense Test Port
103—Lift Cylinder (2 used) 120—Blade Lift Circuit Relief Valve (3 used) 203—Pump Test Port
104—Hydraulic Pump Valve (2 used) 154—Anticavitation Valve (2 207—Bypass Valve
105—Control Valve 146—Inlet Valve Section used) 208—Hydraulic Oil Cooler
106—Hydraulic Filter 147—Blade Lift Valve Section 155—Low Pressure Oil 209—Winch Valve (for
109—Pressure Reducing Valve 148—Blade Tilt Valve Section 156—Load Sense Pressure Oil reference only)
114—Hydraulic Reservoir 150—Outlet Valve Section 157—Regulated Pressure Oil 210—Auxiliary Pilot Controller
115—Quick-Drop Valve 151—Hydraulic System Relief 158—Trapped Oil 211—LS Circuit Port
116—Load Sense Isolator Valve 159—Return Oil

Continued on next page BR81691,0000067 –19–06OCT05–8/12

9025
15
9

TM2260 (07JAN06) 9025-15-9 750J, 850J Crawler

010706
PN=323
 Diagnostic Information
T215737 –19–10OCT05

ANGLE
3 1 108 SOLENOID
VALVE
RIPPER LIFT LIFT
CYLINDERS CYLINDERS
P
107 103 TILT ANGLE
CYLINDER CYLINDERS
2 4
101
T
102
PRESSURE
REDUCING
VALVE T PREG
109

CONTROL 105 120 120

VALVE 119
AUXILIARY
PILOT
CONTROLLER
T
210
154 154
154
LOAD LS
SENSE 211 CIRCUIT
T
ISOLATOR PORT

LS 116
SHUTTLE 152
PREG
PUMP
TEST 203
HYDRAULIC 151 PORT
PUMP
SYSTEM
104 117 PILOT RELIEF
CONTROLLER
P VALVE

145 146 147 148

LS 149
INLET RIPPER BLADE 150
SECTION BLADE BLADE
LIFT LIFT TILT ANGLE OUTLET LOAD
SECTION SECTION SECTION SECTION SECTION SENSE 202
TEST
PORT

157 REGULATED
PRESSURE OIL
155 LOW PRESSURE OIL 158 TRAPPED OIL

114 106 HYDRAULIC FILTER 156 LOAD SENSE PRESSURE OIL 159 RETURN OIL
T215737
Hydraulic Schematic Power Angle Tilt (PAT) with Ripper--Neutral

Continued on next page BR81691,0000067 –19–06OCT05–9/12

TM2260 (07JAN06) 9025-15-10 750J, 850J Crawler

010706
PN=324
 Diagnostic Information

101—Tilt Cylinder 114—Hydraulic Reservoir 148—Blade Tilt Valve Section 155—Low Pressure Oil
102—Angle Cylinder (2 used) 116—Load Sense Isolator 149—Blade Angle Valve 156—Load Sense Pressure Oil
103—Lift Cylinder (2 used) 117—Pilot Controller Section 157—Regulated Pressure Oil
104—Hydraulic Pump 119—Ripper Lift Circuit Relief 150—Outlet Valve Section 158—Trapped Oil
105—Control Valve Valve 151—Hydraulic System Relief 159—Return Oil
106—Hydraulic Filter 120—Blade Angle Circuit Valve 202—Load Sense Test Port
107—Ripper Lift Cylinders (2 Relief Valve (2 used) 152—Load Sense (LS) Shuttle 203—Pump Test Port
used) 145—Inlet Valve Section Valve (4 used) 211—LS Circuit Port
108—Angle Solenoid Valve 146—Ripper Lift Valve Section 154—Anticavitation Valve (3
109—Pressure Reducing Valve 147—Blade Lift Valve Section used)

Continued on next page BR81691,0000067 –19–06OCT05–10/12

9025
15
11

TM2260 (07JAN06) 9025-15-11 750J, 850J Crawler

010706
PN=325
 Diagnostic Information
T215738 –19–11OCT05

RIPPER LIFT
CYLINDERS 155 LOW
PRESSURE OIL
107
156 LOAD SENSE
PRESSURE OIL
109
P 103 103
LIFT LIFT 157 REGULATED
PRESSURE PRESSURE OIL
REDUCING CYLINDER CYLINDER
VALVE 158 TRAPPED OIL
T
159 RETURN OIL
115 QUICK-DROP
VALVE
PREG

101 TILT
AUXILIARY CONTROL CYLINDER
PILOT VALVE 105
CONTROLLER
210 119 120 120
145 146 147 148 150
INLET RIPPER BLADE BLADE OUTLET
SECTION LIFT LIFT TILT SECTION
SECTION SECTION SECTION

154 154 154

211
LS
CIRCUIT
PORT
HYDRAULIC
PUMP 117 PILOT
CONTROLLER LOAD
104 SENSE
LS
SHUTTLE 152 ISOLATOR
PUMP
116 TEST
PORT
203
151
SYSTEM
RELIEF
VALVE
LOAD
SENSE 202
TEST
PORT

114 106 HYDRAULIC FILTER

T215738
Hydraulic Schematic Outside Dozer (OSD) with Ripper—Neutral

Continued on next page BR81691,0000067 –19–06OCT05–11/12

TM2260 (07JAN06) 9025-15-12 750J, 850J Crawler

010706
PN=326
 Diagnostic Information

101—Tilt Cylinder 115—Quick-Drop Valve 147—Blade Lift Valve Section 155—Low Pressure Oil
103—Lift Cylinder (2 used) 116—Load Sense Isolator 148—Blade Tilt Valve Section 156—Load Sense Pressure Oil
104—Hydraulic Pump 117—Pilot Controller 150—Outlet Valve Section 157—Regulated Pressure Oil
105—Control Valve 119—Ripper Lift Circuit Relief 151—Hydraulic System Relief 158—Trapped Oil
106—Hydraulic Filter Valve Valve 159—Return Oil
107—Ripper Lift Cylinders (2 120—Blade Lift Circuit Relief 152—Load Sense (LS) Shuttle 202—Load Sense Test Port
used) Valve (2 used) Valve (3 used) 203—Pump Test Port
109—Pressure Reducing Valve 145—Inlet Valve Section 154—Anticavitation Valve (3 211—LS Circuit Port
114—Hydraulic Reservoir 146—Ripper Lift Valve Section used)

BR81691,0000067 –19–06OCT05–12/12

9025
15
13

TM2260 (07JAN06) 9025-15-13 750J, 850J Crawler

010706
PN=327
 Diagnostic Information

Main Hydraulic Component Location

T202636 –UN–01NOV04

118
114

117

109
108
103
106
105
101

102 103

104

102

T202636
Main Hydraulic Component Location
BR81691,0000068 –19–08OCT04–1/2

TM2260 (07JAN06) 9025-15-14 750J, 850J Crawler

010706
PN=328
 Diagnostic Information

101—Tilt Cylinder 104—Hydraulic Pump 108—Angle Solenoid Valve 117—Hydraulic Control Lever
102—Angle Cylinder (2 used) 105—Hydraulic Control Valve 109—Pressure Reducing Valve 118—Blade Angle Switch
103—Lift Cylinder (2 used) 106—Hydraulic Filter 114—Hydraulic Reservoir

BR81691,0000068 –19–08OCT04–2/2

9025
15
15

TM2260 (07JAN06) 9025-15-15 750J, 850J Crawler

010706
PN=329
 Diagnostic Information

Ripper Ready Hydraulic Component Location

T215999 –UN–19OCT05

119

107

105
107

T215999
Ripper Ready Hydraulic Component Location
MS12501,000000C –19–27OCT05–1/2

TM2260 (07JAN06) 9025-15-16 750J, 850J Crawler

010706
PN=330
 Diagnostic Information

105—Hydraulic Control Valve 107—Ripper Cylinder (2 Used) 119—Auxiliary Pilot Controller

MS12501,000000C –19–27OCT05–2/2

9025
15
17

TM2260 (07JAN06) 9025-15-17 750J, 850J Crawler

010706
PN=331
 Diagnostic Information

Winch Ready Hydraulic Component Location

T207370 –UN–26JAN05

210

207

208

106
109

105

T207370
Winch Ready Hydraulic Component Location
BR81691,0000010 –19–27JAN05–1/2

TM2260 (07JAN06) 9025-15-18 750J, 850J Crawler

010706
PN=332
 Diagnostic Information

105—Control Valve 109—Pressure Reducing Valve 208—Hydraulic Oil Cooler 210—Auxiliary Pilot Controller
106—Hydraulic Filter 207—Bypass Valve

BR81691,0000010 –19–27JAN05–2/2

Diagnose Hydraulic System Malfunctions

Symptom Problem Solution

No Hydraulic Functions Pilot enable switch off Turn switch on.

Pilot enable switch failed Perform pilot controller lock check.

See Operational Checkout. (Group
9005-10.)

Stuck open relief valve Replace relief valve.

Improper pilot pressure Pressure Reducing Valve Pressure

Test and Adjustment. (Group
9025-25.) 9025
15
19

Continued on next page TX,15,SS3744 –19–16NOV04–1/6

TM2260 (07JAN06) 9025-15-19 750J, 850J Crawler

010706
PN=333
 Diagnostic Information

Symptom Problem Solution

Slow Hydraulic Functions Cold oil Warmup hydraulic oil.

Slow engine speed See Diagnose Engine Malfunctions.

(Group 9010-15).

Suction line air leak Check for foamy oil. See Check
Hydraulic Oil Level. (Operator’s
Manual.)

Low oil supply Add recommended oil. See

Transmission, Hydraulic, and Hand
Pump Reservoir Oil. (Operator’s
Manual.)

Wrong oil viscosity Use recommended oil. See

Transmission, Hydraulic, and Hand
Pump Reservoir Oil. (Operator’s
Manual.)

9025 Relief valve Perform Hydraulic System Relief

15 Valve Test or Circuit Relief Valve
20
Test. (Group 9025-25.)

Oil leaking past cylinders or control Perform Lift and Tilt Cylinder
valve Function Drift Test. (Group 9025-25.)

Pump regulator out of adjustment Perform Pump Load Sense

Differential and Standby Pressure
Test and Adjustment. (Group
9025-25).

Blocked or damaged line Inspect lines.

Faulty or misadjusted pressure Perform Pressure Reducing Valve

reducing valve Pressure Test and Adjustment.
(Group 9025-25.)

Faulty pilot control valve Perform Pressure Reducing Valve

Pressure Test and Adjustment.
(Group 9025-25.)

Binding loader control valve spool Inspect valve.

Continued on next page TX,15,SS3744 –19–16NOV04–2/6

TM2260 (07JAN06) 9025-15-20 750J, 850J Crawler

010706
PN=334
 Diagnostic Information

Symptom Problem Solution

Noisy Hydraulic Pump Low oil supply or wrong viscosity Fill reservoir with recommended oil.
See Transmission, Hydraulic, and
Hand Pump Reservoir Oil.
(Operator’s Manual.)

Plugged or pinched suction line Clean or replace line.

Air in oil Check for foamy oil. Tighten

connections. Replace O-rings and/or
lines. See Check Hydraulic Oil Level.
(Operator’s Manual.)

Loose or missing hydraulic line Tighten or replace clamps.

clamps

Hydraulic lines in contact with frame Inspect and repair.

Worn or damaged pump Perform Hydraulic Pump Flow Test.

(Group 9025-25.)
9025
Blade Float Function Does Not Low pilot control pressure Perform Pressure Reducing Valve 15
21
Work Pressure Test and Adjustment.
(Group 9025-25.)

Faulty detent in pilot controller See System Functional Schematic

and Section Legend. (Group
9015-10.)

Faulty pilot control valve Perform Pressure Reducing Valve

Pressure Test and Adjustment.
(Group 9025-25.)

Loader control valve spool binding in See Hydraulic Pump Disassemble

bore and Assemble. (Group 3260.)

Continued on next page TX,15,SS3744 –19–16NOV04–3/6

TM2260 (07JAN06) 9025-15-21 750J, 850J Crawler

010706
PN=335
 Diagnostic Information

Symptom Problem Solution

One Hydraulic Function Does Not Faulty pilot control valve Perform Pressure Reducing Valve
Work Pressure Test and Adjustment.
(Group 9025-25.)

Stuck open circuit relief valve See Hydraulic System Relief Valve
Disassemble and Assemble. (Group
3260.)

Anticavitation valve open Inspect and repair valve.

Oil leaking past cylinder packings See Cylinder Leakage Test. (Group
9025-25.)

Blockage in oil lines or valve Inspect lines for damage. Disconnect

and inspect lines for internal
blockage.

Control valve spool stuck in bore See Hydraulic Pump Disassemble

and Assemble. (Group 3260.)
9025
15 Low Hydraulic Power Low relief valve setting Perform Hydraulic System Relief
22
Valve Test. (Group 9025-25.)

Pump control adjustment Perform Pump Load Sense

Differential and Standby Pressure
Test and Adjustment. (Group
9025-25.)

Low circuit relief valve setting Perform Hydraulic System Relief

Valve Test or Circuit Relief Valve
Test. (Group 9025-25.)

Faulty or misadjusted pressure Perform Pressure Reducing Valve

reducing valve Pressure Test and Adjustment.
(Group 9025-25.)

Leaking relief valve Remove and inspect valve.

Worn hydraulic pump Perform Hydraulic Pump Flow Test.

(Group 9025-25.)

Faulty pilot control valve Perform Pressure Reducing Valve

Pressure Test and Adjustment.
(Group 9025-25.)

Continued on next page TX,15,SS3744 –19–16NOV04–4/6

TM2260 (07JAN06) 9025-15-22 750J, 850J Crawler

010706
PN=336
 Diagnostic Information

Symptom Problem Solution

Function Drifts Down Leaking cylinders Cap off blade lift cylinder to isolate if
leakage is in cylinder or in circuit
before doing Cylinder Leakage Test.
(Group 9025-25.)

Leaking seals in circuit relief valve or Inspect relief valve seals.

valve stuck open

Pressure Reducing Valve See Pressure Reducing Valve

Pressure Test and Adjustment.
(Group 9025-25.)

Leaking control valve See Control Valve Disassemble and

Assemble. (Group 3260.)

Oil Overheats Low oil viscosity in hot weather Add recommended oil. See
Transmission, Hydraulic, and Hand
Pump Reservoir Oil. (Operator’s
Manual.)
9025
Incorrect relief or circuit relief valve Perform Hydraulic System Relief 15
23
setting Valve Test or Circuit Relief Valve
Test. (Group 9025-25.)

Restriction in oil lines or loader valve Inspect for restriction in oil lines.

Leaking relief valve Remove and inspect valve and

seals.

Worn hydraulic pump (internal Perform Hydraulic Pump Flow Test.

leakage) (Group 9025-25.)

Continued on next page TX,15,SS3744 –19–16NOV04–5/6

TM2260 (07JAN06) 9025-15-23 750J, 850J Crawler

010706
PN=337
 Diagnostic Information

Symptom Problem Solution

Hydraulic Oil Foams Low oil level Add recommended oil. See Check
Hydraulic Oil Level. (Operator’s
Manual.)

Wrong oil Add recommended oil. See

Transmission, Hydraulic, and Hand
Pump Reservoir Oil. (Operator’s
Manual.)

Water in oil Change oil. See Change Hydraulic

System Oil and Replace Filter.
(Operator’s Manual.)

Loose or faulty suction lines (air leak Tighten or install new lines.
in system)

TX,15,SS3744 –19–16NOV04–6/6

9025
15
24

TM2260 (07JAN06) 9025-15-24 750J, 850J Crawler

010706
PN=338
 Group 25
Tests
JT02156A Digital Pressure/Temperature
Analyzer Installation
SERVICE EQUIPMENT AND TOOLS
JT02156A Digital Pressure/Temperature Analyzer
JT02159 20 ft Cable with Couplers

–UN–25AUG95
JT02161 500 psi Transducer
JT02162 5000 psi Transducer
JT05969 Thermo-Coupler

T8543AI
312883 Carry Case
JT02160 10 000 psi Transducer (Optional, Order Separately)
JT07148-2 Flow Block
A—Digital Pressure/Temperature Analyzer
B—3400 kPa (35 bar) (500 psi) Transducer
Use the digital pressure/temperature analyzer (A), and —34 000 kPa (350 bar) (5000 psi) Transducer
transducers (B) in place of analog gauges and a separate —70 000 kPa (700 bar) (10 000 psi) Transducer
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
9025
for one second to set the true zero point. 25
1
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.

MF82180,0000047 –19–28JAN05–1/1

JDG1770 Ultra Clean Hand Launcher

Use the Ultra Clean Hand Launcher Kit to help eliminate

contamination in hydraulic systems. All newly installed
hose and tube assemblies should be cleaned using this
tool.

Ultra Clean is a trademark of Ultra Clean Technologies Corp. BR81691,000000E –19–18JAN05–1/1

TM2260 (07JAN06) 9025-25-1 750J, 850J Crawler

010706
PN=339
 Tests

Hydraulic Oil Cleanup Procedure

A hydraulic oil cleanup procedure must be done prior to

starting machine after a component has been repaired or
replaced. The use of attachments increases the need to
monitor and filter oil to a safe contamination level. See
750J and 850J Crawler Dozer General Oil Cleanup
Procedure. (CTM310—Super Caddy Oil Cleanup
Procedure.)

TE14778,0000087 –19–25JAN05–1/1

Hydraulic System Relief Valve Test

SPECIFICATIONS
750J and 850J System Relief 28 269—28 786 kPa
Valve Pressure 282.7—287.9 bar
4100—4175 psi

9025 SERVICE EQUIPMENT AND TOOLS

25
JT07192 Electric/Hydraulic Pump
2
Gauge (0—35 000 kPa) (0—350 bar) (0—5000 psi)

1. Relieve hydraulic system pressure.

2. Tilt cab.

Continued on next page TX,9025,BS445 –19–28FEB95–1/2

TM2260 (07JAN06) 9025-25-2 750J, 850J Crawler

010706
PN=340
 Tests

NOTE: Hydraulic system relief valve (151) is located in

the control valve inlet section.
151
3. Disconnect and cap hydraulic pump-to-control valve
inlet hose (132).

4. Connect JT07192 Electric/Hydraulic Pump pressure

hose to control valve inlet section.

5. Start pump to pressurize valve inlet. Record relief valve

pressure setting.

6. Adjust system relief valve to specification or replace.

To adjust pressure setting, loosen nut on system relief
132
valve. Turn adjusting hex screw in to increase pressure
or out to decrease pressure.

Specification
750J and 850J System Relief
Valve—Pressure ........................................................ 28 269—28 786 kPa
282.7—287.9 bar

–UN–05JAN05
4100—4175 psi
104 9025
25
104—Hydraulic Pump 3
132—Hydraulic Pump-to-Control Valve Inlet Hose

T206639
151—Hydraulic System Relief Valve

Hydraulic System Relief Valve

TX,9025,BS445 –19–28FEB95–2/2

TM2260 (07JAN06) 9025-25-3 750J, 850J Crawler

010706
PN=341
 Tests

Circuit Relief Valve Test

SERVICE EQUIPMENT AND TOOLS 4. Connect JT07192 Electric/Hydraulic Pump pressure

JT07192 Electric/Hydraulic Pump hose to work port that hose disconnected from.
Gauge (0—35 000 kPa) (0—350 bar) (0—5000 psi)
JT02156A Digital Pressure/Temperature Analyzer 5. Start pump to pressurize valve inlet. Record circuit
relief valve pressure setting.
SPECIFICATIONS
6. Adjust circuit relief valve to specification or replace.
750J Angle Cylinder Circuit 26 200—26 717 kPa
Relief Valve Pressure 262—267 bar
To adjust setting, loosen nut on circuit relief valve.
3800—3875 psi Turn adjusting hex screw in to increase pressure or
850J Angle Cylinder Circuit 32 405—32 922 kPa
out to decrease pressure.
Relief Valve Pressure 324—329 bar
4700—4775 psi Specification
750J Angle Cylinder Circuit
750J and 850J Lift Rod End 27 579—28 096 kPa Relief Valve—Pressure....................................... 26 200—26 717 kPa
Cylinder Circuit Relief Valve 276—281 bar 262—267 bar
Pressure 4000—4075 psi
3800—3875 psi
750J and 850J Lift Head End 15 513—16 030 kPa 850J Angle Cylinder Circuit
Cylinder Circuit Relief Pressure 155—160 bar Relief Valve—Pressure....................................... 32 405—32 922 kPa
2250—2325 psi 324—329 bar
750J and 850J Ripper Lift Rod 38 610 kPa 4700—4775 psi

9025 End Cylinder Circuit Relief 386 bar

Valve Pressure 5600 psi Specification
25
750J and 850J Lift Rod End
4
Cylinder Circuit Relief Valve—
1. Relieve hydraulic system pressure. Pressure.............................................................. 27 579—28 096 kPa
276—281 bar
2. Tilt cab. 4000—4075 psi
750J and 850J Lift Head End
Cylinder Circuit Relief Valve—
NOTE: Power Angle Tilt (PAT) machines have circuit Pressure.............................................................. 15 513—16 030 kPa
relief valves on the blade angle valve section. 155—160 bar
Outside Dozers (OSD) have circuit relief 2250—2325 psi
valves on the blade lift valve section.
Specification
3. Disconnect and cap work port hose of circuit relief 750J and 850J Ripper Lift Rod
End Cylinder Circuit Relief
valve to be tested. Valve—Pressure ................................................................ 38 610 kPa
386 bar
5600 psi

TX,9025,BS449 –19–25OCT05–1/1

TM2260 (07JAN06) 9025-25-4 750J, 850J Crawler

010706
PN=342
 Tests

Pump Load Sense Differential and System

Pressure Test and Adjustment
SPECIFICATIONS
Hydraulic Oil Temperature 60—71°C
140—160°F
Hydraulic System Pressure 24 993—26 372 kPa
250—264 bar
3625—3825 psi
Engine Speed Slow Idle
750J Load Sense Differential 1620—1827 kPa
Pressure 16.2—18.3 bar
235—265 psi
850J Load Sense Differential 1793—2000 kPa
Pressure 17.9—20 bar
260—290 psi

SERVICE EQUIPMENT AND TOOLS

JTO2156A Digital Pressure Analyzer
JT02162 Transducer 34 000 kPa (350 bar) (5000 psi)

The purpose of this test is to adjust pump load sense 9025

25
differential and system pressure.
5

BR81691,0000002 –19–18OCT05–1/3

1. Install JTO2156A Digital Pressure Analyzer with

transducers to the hydraulic test ports (202 and 203).

2. Remove hydraulic pump control valve caps.

3. Warm hydraulic oil to specification.

–UN–27DEC04
Specification
Hydraulic Oil—Temperature ........................................................ 60—71°C
140—160°F

T206452A
202—Load Sense Test Port
203—Pump Pressure Test Port Hydraulic Test Ports
204—JTO2156A Digital Pressure Analyzer

Continued on next page BR81691,0000002 –19–18OCT05–2/3

TM2260 (07JAN06) 9025-25-5 750J, 850J Crawler

010706
PN=343
 Tests

4. With engine at slow idle, while holding blade tilt

function over relief, adjust high pressure cutoff
adjustment screw (177) to specification.

Specification
Hydraulic System—Pressure..................................... 24 993—26 372 kPa

–UN–27DEC04
250—264 bar
3625—3825 psi

Specification
Engine—Speed ............................................................................ Slow Idle

T206453A
5. With engine at fast idle, while slowly tilting the blade,
adjust load sense differential pressure (178) to Hydraulic Pump Control Valve
specification.
177—High Pressure Cutoff Adjustment Screw
(system pressure)
Specification 178—Load Sense Differential Pressure
750J Load Sense Differential— Adjustment Screw
Pressure .......................................................................... 1620—1827 kPa
16.2—18.3 bar
235—265 psi

Specification
9025 850J Load Sense Differential—
25 Pressure .......................................................................... 1793—2000 kPa
6 17.9—20 bar
260—290 psi

6. Tighten lock nuts and install control valve caps.

BR81691,0000002 –19–18OCT05–3/3

TM2260 (07JAN06) 9025-25-6 750J, 850J Crawler

010706
PN=344
 Tests

Lift and Tilt Cylinder Function Drift Test

SPECIFICATIONS
Hydraulic Oil Temperature 60—72°C
140—160°F
Lift Cylinder Rod Drift Maximum 4 mm/min
0.16 in./min
Tilt Cylinder Rod Drift Maximum 2 mm/min
0.08 in./min
Lift Cylinder Rod Drift Maximum 4 mm/min
0.16 in./min
Tilt Cylinder Rod Drift Maximum 2 mm/min
0.08 in./min

SERVICE EQUIPMENT AND TOOLS

Tape and Ruler

9025
25
7

Continued on next page TX,9025,BS457 –19–28FEB95–1/3

TM2260 (07JAN06) 9025-25-7 750J, 850J Crawler

010706
PN=345
 Tests

CAUTION: Relieve pressure in circuit prior to

disconnecting hydraulic lines.

NOTE: Cylinder rod movement is an indication of cylinder

drift. Drift can be caused by leakage in cylinder
packing, cylinder bypass valve poppets, circuit

–UN–23AUG88
relief valve, control valve, or quick-drop valve.
Cylinders are tested for both blade raise and
blade lower rod movement.

X9811
1. Warm hydraulic oil to specification.

Specification
Hydraulic Oil—Temperature ........................................................ 60—72°C
140—160°F

2. Raise blade approximately two feet from ground. Place

control valve in neutral.

–UN–26MAY89
3. Stop engine.

9025 4. Measure movement of lift and tilt cylinder rod for five
25 minutes. Divide measured rod movement by five to

T6222AM
8
determine drift per minute.

Specification
Lift Cylinder Rod Maximum—Drift .............................................. 4 mm/min
0.16 in./min
Tilt Cylinder Rod Maximum—Drift .............................................. 2 mm/min
0.08 in./min

5. Start machine. Lower blade to ground.

6. Raise front of machine off ground 2—3 inches. Place

control valve in neutral.

7. Stop engine.

8. Measure movement of lift and tilt cylinder rod for five

minutes. Divide measured rod movement by five to
determine drift per minute.

Specification
Lift Cylinder Rod Maximum—Drift .............................................. 4 mm/min
0.16 in./min
Tilt Cylinder Rod Maximum—Drift .............................................. 2 mm/min
0.08 in./min

Continued on next page TX,9025,BS457 –19–28FEB95–2/3

TM2260 (07JAN06) 9025-25-8 750J, 850J Crawler

010706
PN=346
 Tests

9. If cylinders drift in rod extend function only, perform

Cylinder Leakage Test. (Group 9025-25.)

10. If cylinder drifts in both directions, leakage could be in

the control valve.

TX,9025,BS457 –19–28FEB95–3/3

9025
25
9

TM2260 (07JAN06) 9025-25-9 750J, 850J Crawler

010706
PN=347
 Tests

Hydraulic Cylinder Drift Test

9025
25
10

–19–16OCT98
T117807

TX,9025,BS456 –19–30NOV04–1/1

TM2260 (07JAN06) 9025-25-10 750J, 850J Crawler

010706
PN=348
 Tests

Cylinder Leakage Test

SPECIFICATIONS
Oil Temperature 60—72°C
140—160°F
Approximate Engine Speed 1000 rpm
Cylinder Leakage Test Maximum 5 mL/min
Allowable Flow 1/6 oz/min

Continued on next page CED,TX03768,2287 –19–08MAR04–1/3

9025
25
11

TM2260 (07JAN06) 9025-25-11 750J, 850J Crawler

010706
PN=349
 Tests

1. Heat hydraulic oil to specification.

Specification
Oil Temperature—Temperature .................................................. 60—72°C
140—160°F

2. Fully extend rod on cylinder to be checked. Turn

–UN–23AUG88
engine off.

CAUTION: Escaping fluid under pressure can

X9811
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Keep hands and body
away from pinholes and nozzles which eject
fluids under high pressure. Use a piece of
cardboard or paper to search for leaks. Do not
use you hand.

–UN–26OCT88
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
9025 doctor familiar with this type of injury or
25 gangrene may result.

T6222AL
12

3. Remove hose from rod end of cylinder. Position a

beaker under rod end port.

4. Plug hose that was disconnected from rod end of

cylinder.

5. Start and run engine at specification.

Specification
Approximate Engine—Speed ...................................................... 1000 rpm

6. Activate rod extend function and record leakage from

rod end of cylinder for one minute.

Specification
Cylinder Leakage Test—
Maximum Allowable Flow ............................................................ 5 mL/min
1/6 oz/min

If leakage is in one direction, but not both directions,

disassemble cylinder and inspect bypass valve poppet.

If leakage in a cylinder is in both directions, disassemble

cylinder and repair seals and packing.

Continued on next page CED,TX03768,2287 –19–08MAR04–2/3

TM2260 (07JAN06) 9025-25-12 750J, 850J Crawler

010706
PN=350
 Tests

If no cylinder leakage in either direction is found, the

problem is in the control valve or quick-drop valve if
equipped. Check relief valve for contamination and O-ring
leakage. Disassemble control valve and check for spool or
bore scoring. Test quick-drop valve drift.

CED,TX03768,2287 –19–08MAR04–3/3

Pressure Reducing Valve Pressure Test and

Adjustment
SPECIFICATIONS
Hydraulic Oil Temperature 57—66°C
135—150°F
Engine Speed Slow Idle
9025
Pressure Reducing Valve 4137—4826 kPa 25
Pressure 41.4—48.3 bar 13
600—700 psi

SERVICE EQUIPMENT AND TOOLS

JTO2156A Digital Pressure Analyzer
JTO2162 34 000 kPa (350 bar) (5000 psi) Transducer

The purpose of this test is to determine the pressure

setting of the Pressure Reducing Valve (PRV). The PRV
regulates pressure to the pilot control systems.

This procedure is used to test and adjust regulated

pressure in the pilot control system.

1. Warm hydraulic oil to specification.

Specification
Hydraulic Oil—Temperature ........................................................ 57—66°C
135—150°F

2. Relieve all hydraulic system pressure by cycling

hydraulic functions with key in on position.

Continued on next page BR81691,0000006 –19–17DEC04–1/2

TM2260 (07JAN06) 9025-25-13 750J, 850J Crawler

010706
PN=351
 Tests

3. Install JTO2156A Digital Pressure Analyzer with

pressure transducers to PRV test port (206).

4. Start engine and hold a blade function over relief at

slow idle. Record pressure reading. Pressure should
be within specification.

–UN–27DEC04
Specification
Engine—Speed ............................................................................ Slow Idle

T206458A
Specification
Pressure Reducing Valve—
Pressure .......................................................................... 4137—4826 kPa
41.4—48.3 bar Pressure Reducing Valve
600—700 psi
204—JTO2156A Digital Pressure Analyzer
205—Pressure Reducing Adjustment Screw
5. If pressure is not within specification, remove spool 206—Pressure Reducing Valve Test Port
end cap and adjust pressure. While holding a blade
function over relief at slow idle, turn pressure reducing
adjustment screw (205) in to increase pressure and out
to decrease pressure .

9025
25
14

BR81691,0000006 –19–17DEC04–2/2

TM2260 (07JAN06) 9025-25-14 750J, 850J Crawler

010706
PN=352
 Tests

Blade Down Accumulator Hydraulic

Discharge

The purpose of this procedure is to ensure that no

hydraulic pressure remains in accumulator prior to
charging accumulator.

CAUTION: Prevent possible injury from high

pressure fluid. Discharge accumulator before
servicing any hydraulic components. Hydraulic
oil in accumulator can be stored at pressures
equal to or above system relief pressures.

1. Warm hydraulic oil to specification.

Specification
Hydraulic Oil—Temperature ........................................................ 60—71°C
140—160°F

2. Lower blade to ground and stop engine.

3. Install JT02156A Digital Pressure Analyzer with 9025

25
pressure transducers to Pressure Reducing Valve
15
(PRV) test port.

4. Turn key switch to on position. Without starting engine

and pilot enable switch in unlocked position, cycle
hydraulic control lever in all directions.

5. Hold hydraulic control lever in forward position until

digital pressure analyzer reads zero. All hydraulic
accumulator pressure has been discharged.

BR81691,0000008 –19–28DEC04–1/1

TM2260 (07JAN06) 9025-25-15 750J, 850J Crawler

010706
PN=353
 Tests

Blade Down Accumulator Precharge Test

SPECIFICATIONS
Hydraulic Oil Temperature 57—66°C
135—150°F
Pressure Reducing Valve 4137—4826 kPa
Pressure 41.4—48.3 bar
600—700 psi
Blade Down Accumulator 1034—1241 kPa
Precharge Pressure 10.3—12.4 bar
150—180 psi

SERVICE EQUIPMENT AND TOOLS

JTO2156A Digital Pressure Analyzer
JTO2162 34 000 kPa (350 bar) (5000 psi) Transducer

The purpose of this test is to determine blade down

accumulator precharge pressure.

1. Warm hydraulic oil to specification.

9025 Specification
25 Hydraulic Oil—Temperature ........................................................ 57—66°C
16 135—150°F

2. Install JTO2156A Digital Pressure Analyzer with

pressure transducer to Pressure Reducing Valve (PRV)
test port.

3. Start engine and record PRV pressure. Pressure

should be within specification.

Specification
Pressure Reducing Valve
(PRV)—Pressure ............................................................. 4137—4826 kPa
41.4—48.3 bar
600—700 psi

If pressure is not within specification, see Pressure

Reducing Valve Pressure Test and Adjustment. (Group
9025-25.)

4. Stop engine with blade on ground.

5. Turn key switch to on position.

Continued on next page BR81691,0000007 –19–17DEC04–1/2

TM2260 (07JAN06) 9025-25-16 750J, 850J Crawler

010706
PN=354
 Tests

NOTE: Blade down accumulator pressure will drop slowly

when cycling lever. The last pressure seen before
pressure drop of 345 kPa (3.4 bar) (50 psi), is the
blade down accumulator precharge pressure.
Accumulator precharge pressure must be within
specification.

6. Record pressure while slowly cycling hydraulic control

lever to blade up and down positions.

Specification
Blade Down Accumulator
Precharge—Pressure ...................................................... 1034—1241 kPa
10.3—12.4 bar
150—180 psi

BR81691,0000007 –19–17DEC04–2/2

9025
Hydraulic Pump Flow Test 25
17
SPECIFICATIONS
Engine Speed 2200 rpm
Hydraulic Oil Temperature 60—72°C
140—160°F
Hydraulic Oil Pressure 13 700 kPa
137 bar
2000 psi
New, 750J (63cc) Minimum Flow 128.7 L/min
34.0 gpm
New, 850J (74cc) Minimum Flow 166.6 L/min
44.0 gpm
New, 750J—850J (100cc) 200.6 L/min
Minimum Flow 53.0 gpm
Used, 750J (63cc) Minimum Flow 103.0 L/min
27.2 gpm
Used, 850J (74cc) Minimum Flow 125.7 L/min
33.2 gpm
Used, 750J—850J (100cc) 160.5 L/min
Minimum Flow 42.4 gpm

SERVICE EQUIPMENT AND TOOLS

JT07148 Flow Meter

Continued on next page TX,9025,BS451 –19–28FEB95–1/3

TM2260 (07JAN06) 9025-25-17 750J, 850J Crawler

010706
PN=355
 Tests

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Keep hands and body
away from pinholes and nozzles which eject

–UN–23AUG88
fluids under high pressure. Use a piece of
cardboard or paper to search for leaks. Do not
use your hand.

X9811
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result.

1. Relieve hydraulic system pressure.

2. Tilt cab.

3. Pull vacuum on hydraulic reservoir.

9025
25
18

Continued on next page TX,9025,BS451 –19–28FEB95–2/3

TM2260 (07JAN06) 9025-25-18 750J, 850J Crawler

010706
PN=356
 Tests

4. Disconnect hydraulic pump-to-control valve inlet hose

(132).

5. Disconnect load sense hose (131) (hydraulic

pump-to-control valve) from control valve outlet section.

–UN–03JAN05
6. Connect hoses (131 and 132) from hydraulic pump to
tee fitting (167) before flow meter (168), as shown.

7. Connect flow meter to control valve inlet.

T206566A
8. Open flow meter loading valve.
Hydraulic Flow Test
9. Start engine and run at specification.
131—Load Sense Hose
132—Hydraulic Pump-to-Control Valve Inlet Hose
Specification 166—Flow Meter-to-Control Valve
Engine—Speed ........................................................................... 2200 rpm 167—Tee Fitting
168—Flow Meter
10. Slowly close flow meter loading valve to obtain
specified temperature and pressure.

Specification
9025
Hydraulic Oil—Temperature ........................................................ 60—72°C
25
140—160°F
19
Hydraulic Oil—Pressure ........................................................... 13 700 kPa
137 bar
2000 psi

11. Record pump flow reading.

Specification
New, 750J (63cc)—Minimum
Flow ......................................................................................... 128.7 L/min
34.0 gpm
New, 850J (74cc)—Minimum
Flow ......................................................................................... 166.6 L/min
44.0 gpm
New, 750J—850J (100cc)—
Minimum Flow ......................................................................... 200.6 L/min
53.0 gpm
Used, 750J (63cc)—Minimum
Flow ......................................................................................... 103.0 L/min
27.2 gpm
Used, 850J (74cc)—Minimum
Flow ......................................................................................... 125.7 L/min
33.2 gpm
Used, 750J—850J (100cc)—
Minimum Flow ......................................................................... 160.5 L/min
42.4 gpm

TX,9025,BS451 –19–28FEB95–3/3

TM2260 (07JAN06) 9025-25-19 750J, 850J Crawler

010706
PN=357
 Tests

Hydraulic Pump Case Drain Test

SPECIFICATIONS
Hydraulic Oil Temperature 60—71°C
140—160°F
Engine Speed 2200 rpm
New, 750J (63cc) and 850J 7.9 L/min
(74cc) Hydraulic Pump Case 2.10 gpm
Drain Maximum Leakage
New, 750J—850J (100cc) 10.4 L/min
Hydraulic Pump Case Drain 2.75 gpm
Maximum Leakage
Used, 750J (63cc) and 850J 9.5 L/min
(74cc) Hydraulic Pump Case 2.52 gpm
Drain Maximum Leakage
Used, 750J—850J (100cc) 12.5 L/min
Hydraulic Pump Case Drain 3.3 gpm
Maximum Leakage

SERVICE EQUIPMENT AND TOOLS

JT07148 Flow Meter

9025
25 The purpose of this test is to determine efficiency of the
20 pump rotating group by measuring amount of case drain
with pump at maximum pressure. This test will help isolate
a pump performance problem to either the rotating group
or pump control. Perform this test before removing or
replacing pump.

1. Warm hydraulic oil to specification.

Specification
Hydraulic Oil—Temperature ........................................................ 60—71°C
140—160°F

2. Pull vacuum on hydraulic reservoir.

Continued on next page BR81691,000000A –19–06JAN05–1/2

TM2260 (07JAN06) 9025-25-20 750J, 850J Crawler

010706
PN=358
 Tests

3. Disconnect pump case drain hose (199) from top of

pump (104).

IMPORTANT: Non-adjustable flow meter is the best

tool for this test. If using adjustable
flow meter, flow meter control valve
must be open at all times. Serious
hydraulic pump damage may result if
pump back pressure is increased.

4. Connect a non-adjustable flow meter to pump case

199
drain port with a test hose.

5. Connect flow meter outlet to hydraulic hose (199)

–UN–07JAN05
which was previously removed from pump case drain 130
port.

6. Remove vacuum from hydraulic reservoir.

T206793
104
7. Start and run engine at specification.
Hydraulic Pump Case Drain
Specification 9025
Engine—Speed ........................................................................... 2200 rpm 104—Hydraulic Pump 25
130—Hydraulic Reservoir-to-Hydraulic Pump Inlet 21
Hose
8. Hold blade lift function over relief and record flow.
199—Hydraulic Pump Case Drain Hose
Case drain flow must be within specification.

Specification
New, 750J (63cc) and 850J
(74cc) Hydraulic Pump Case
Drain—Maximum Leakage .......................................................... 7.9 L/min
2.10 gpm
New, 750J—850J (100cc)
Hydraulic Pump Case Drain—
Maximum Leakage .................................................................... 10.4 L/min
2.75 gpm
Used, 750J (63cc) and 850J
(74cc) Hydraulic Pump Case
Drain—Maximum Leakage .......................................................... 9.5 L/min
2.52 gpm
Used, 750J—850J (100cc)
Hydraulic Pump Case Drain—
Maximum Leakage .................................................................... 12.5 L/min
3.3 gpm

BR81691,000000A –19–06JAN05–2/2

TM2260 (07JAN06) 9025-25-21 750J, 850J Crawler

010706
PN=359
 Tests

9025
25
22

TM2260 (07JAN06) 9025-25-22 750J, 850J Crawler

010706
PN=360
 Section 9026
Hydrostatic System
Contents

Page Page

Group 05—Theory of Operation Group 25—Tests

Hydrostatic System . . . . . . . . . . . . . . . . . . . .9026-05-1 JT02156A Digital Pressure/Temperature
Transmission Control Circuit Operation Analyzer Installation. . . . . . . . . . . . . . . . . .9026-25-1
(Flow Chart). . . . . . . . . . . . . . . . . . . . . . . .9026-05-3 JDG1770 Ultra Clean Hand Launcher . . . . .9026-25-1
Charge Pump Operation . . . . . . . . . . . . . . . .9026-05-4 Transmission Oil Warm-Up Procedure . . . . .9026-25-2
Hydrostatic Charge Oil Filter Operation . . . . .9026-05-5 Releasing Park Brake to Tow the
Neutral Charge Relief Valve Operation . . . . .9026-05-6 Machine. . . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-5
Multi-Function Valve Operation . . . . . . . . . . .9026-05-7 Hydrostatic Pump and Motor Initial Start-Up
Hydraulic Integrated Circuit (HIC) Valve Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-8
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9026-05-9 Hydrostatic Pump Flushing Procedure. . . . .9026-25-10
Park Brake Valve Operation . . . . . . . . . . . .9026-05-11 Hydraulic Oil Cleanup Procedure . . . . . . . .9026-25-11
Oil Cooler and Reservoir Bypass Pressure Control Pilot (PCP) Manual
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9026-05-12 Override Test. . . . . . . . . . . . . . . . . . . . . .9026-25-12
Pump Pressure Control Pilot (PCP) Pressure Control Pilot (PCP) Test . . . . . . . .9026-25-14
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9026-05-14 Pressure Control Pilot (PCP) Internal
Pump Displacement Control Valve (PDCV) Adjustment. . . . . . . . . . . . . . . . . . . . . . . .9026-25-18
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9026-05-16 Multi-Function Relief Valve Test . . . . . . . . .9026-25-22
Hydrostatic Pump Operation . . . . . . . . . . . .9026-05-18 Transmission Efficiency Test . . . . . . . . . . . .9026-25-27 9026
Flushing Valve and Operating Charge Relief Neutral Charge Relief and Operating
Valve Operation . . . . . . . . . . . . . . . . . . . .9026-05-19 Charge Relief Pressure Test . . . . . . . . . .9026-25-31
Hydrostatic Motor Operation . . . . . . . . . . . .9026-05-21 Pump Displacement Control Valve (PDCV)
Hydraulic Fan Drive Operation . . . . . . . . . .9026-05-23 Neutral (Null) Adjustment . . . . . . . . . . . . .9026-25-36
Hydraulic Fan Return Filter Operation . . . . .9026-05-26 Pump Servo Pressure Test . . . . . . . . . . . . .9026-25-39
Motor Displacement Control Valve (MDCV)
Adjustment. . . . . . . . . . . . . . . . . . . . . . . .9026-25-43
Group 15—Diagnostic Information Hydrostatic Motor Min./Max. Angle Servo
Overheating—Flowchart . . . . . . . . . . . . . . . .9026-15-1 Piston Pressure Test . . . . . . . . . . . . . . . .9026-25-46
Low Charge Pressure—Flowchart . . . . . . . . .9026-15-2 Charge Pump Flow Test . . . . . . . . . . . . . . .9026-25-50
Mistrack/Indexes—Flowchart . . . . . . . . . . . . .9026-15-3 Hydrostatic Oil Cooler Bypass Test . . . . . . .9026-25-52
Machine Will Not Reach Full Speed— Hydrostatic Oil Reservoir Bypass Test . . . .9026-25-57
Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . .9026-15-4 Park Brake Test . . . . . . . . . . . . . . . . . . . . .9026-25-61
Low Power—Flowchart . . . . . . . . . . . . . . . . .9026-15-5 Park Brake Relief Valve Test . . . . . . . . . . .9026-25-67
Engine Starts But One Or Both Tracks Cab Tilt Relief Valve Test . . . . . . . . . . . . . .9026-25-68
Will Not Move—Flowchart . . . . . . . . . . . . .9026-15-6 Hand Pump Bleed Procedure . . . . . . . . . . .9026-25-68
TCU Calibration Problems—Flowchart . . . . .9026-15-7 Fan Pump Pressure Test . . . . . . . . . . . . . .9026-25-69
Hydrostatic System Component Location . . .9026-15-8 Fan Pump Flow Test . . . . . . . . . . . . . . . . . .9026-25-71
Park Brake System Component Fan Motor Speed Test . . . . . . . . . . . . . . . .9026-25-73
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9026-15-10 Fan Motor Case Drain Test . . . . . . . . . . . . .9026-25-75
Hydrostatic System Schematic—Neutral
(Park Brake On). . . . . . . . . . . . . . . . . . . .9026-15-12
Hydrostatic System Diagram—Neutral (Park
Brake On) . . . . . . . . . . . . . . . . . . . . . . . .9026-15-14
Hydrostatic System Diagram—Reverse (Slow
Speed). . . . . . . . . . . . . . . . . . . . . . . . . . .9026-15-16
Hydrostatic System Diagram—Forward (Fast
Speed). . . . . . . . . . . . . . . . . . . . . . . . . . .9026-15-18

TM2260 (07JAN06) 9026-1 750J, 850J Crawler

010706
PN=1
 Contents

9026

TM2260 (07JAN06) 9026-2 750J, 850J Crawler

010706
PN=2
 Group 05
Theory of Operation
Hydrostatic System

The transmission consists of an automatic, dual-path,

hydrostatic drive with a load sensing feature that
automatically adjusts speed and power to match changing
load conditions. An electronic controller governs
transmission control. Each individually controlled track is
powered by a variable displacement axial piston pump
and a variable displacement bent axis motor combination.
Travel speeds (forward and reverse) are controlled by a
rocker switch on the Transmission Control Lever (TCL).
Independently selectable reverse speed ratios of 80%,
100%, 115% or 130% of forward ground speed are
selected through the monitor. A decelerator pedal controls
ground speed down to a complete stop.

The pumps are mounted directly to the engine in a

tandem configuration and are designed for through torque
capability. This means the main hydraulic pump and winch
can be driven from the back of the tandem hydrostatic
pump. High pressure hoses transmit pump flow to the
motors. The variable displacement bent axis motors are
mounted directly to the final drives.

Transmission control can be divided into three groups:

inputs, outputs and feedbacks.
9026
The operator sends inputs into the Transmission Control 05
Unit (TCU) from the steering sensor, FNR sensor, 1
transmission speed control switch, decelerator sensor,
decelerator mode switch, and engine speed control
sensor.

The TCU sends a current signal to the Pressure Control

Pilot (PCP) on each pump. The PCP is a servo valve
which produces a hydraulic pressure differential relative to
the amount of current. The pressure differential is sent to
the Pump Displacement Control Valve (PDCV) on the
pump. This shifts the servo piston causing the angle of
the swash plate to increase or decrease, controlling the
amount of displacement produced by the axial pistons.

Continued on next page TE14778,000007D –19–04AUG05–1/2

TM2260 (07JAN06) 9026-05-1 750J, 850J Crawler

010706
PN=363
 Theory of Operation

The TCU also sends a current signal to energize the

motor shift solenoid on the motor. The motor is normally
held at its maximum displacement (slower speed, greater
torque). Energizing the solenoid will cause the servo
piston to shift causing the angle of the swash plate to
decrease. As the swash plate angle decreases the
displacement decreases (faster speed, less torque).

The left and right motor speed sensors provide feedback

to the TCU for tracking. The Engine Control Unit (ECU)
provides engine speed feedback to the TCU for antistall
control. The TCU compares operator input commands and
feedback from the sensors to regulate output accordingly

TE14778,000007D –19–04AUG05–2/2

9026
05
2

TM2260 (07JAN06) 9026-05-2 750J, 850J Crawler

010706
PN=364
 Theory of Operation

Transmission Control Circuit Operation (Flow Chart)

B5 B2 S22 B4 B1 S7
STEER FNR ENGINE TRANSMISSION DECELERATOR DECELERATOR
SENSOR SENSOR SPEED CONTROL SPEED CONTROL SENSOR MODE
SWITCH SWITCH SWITCH

OPERATOR INPUT
COMMANDS A3 CAN
POWER IN 24V DC MONITOR UNIT (CMU)

(TRACKING FEEDBACK) A1 TRANSMISSION (TRACKING FEEDBACK)

CONTROL UNIT (TCU)

CURRENT CURRENT B8
B7
PUMP PUMP
PRESSURE TO LEFT TO RIGHT PRESSURE
CONTROL TRACK TRACK CONTROL
PILOT (PCP) THROTTLE ANTI- PILOT
REAR COMMAND STALL (PCP) FRONT

VOLTAGE VOLTAGE
A2 ENGINE
DIFFERENTIAL CONTROL UNIT (ECU) DIFFERENTIAL
CONTROL CONTROL 9026
PRESSURE FUEL DELIVERY PRESSURE 05
COMMAND 3

Y3 Y4
MOTOR REAR PUMP MOTOR
SHIFT DISPLACEMENT FRONT PUMP SHIFT
ENGINE DISPLACEMENT
SOLENOID CONTROL SOLENOID
LEFT VALVE CONTROL RIGHT
(PDCV) VALVE
HP (PDCV)

CHARGE CHARGE
PRESSURE FRONT PRESSURE
CONTROL PUMP CONTROL
PRESSURE CLOSED LOOP PRESSURE
PRESSURE
HP

REAR
CLOSED LOOP PUMP
LEFT PRESSURE RIGHT
MOTOR MOTOR
B2 B3
RPM MOTOR SPEED MOTOR SPEED RPM
SENSOR SENSOR
–UN–10JAN05

LEFT RIGHT

(TRACKING FEEDBACK) (TRACKING FEEDBACK)

T205066

T205066
Transmission Control Circuit (Flow Chart)
TE14778,000004A –19–13OCT04–1/1

TM2260 (07JAN06) 9026-05-3 750J, 850J Crawler

010706
PN=365
 Theory of Operation

Charge Pump Operation

–UN–30JAN04
1 3

T197492
9026 T197492
05
4
1—To Hydrostatic Charge Oil 2—From Reservoir 3—Return Oil 4—Charge Oil
Filter

The charge pump is an integral part of each After passing through the filter, charge oil is routed to
hydrostatic pump. The charge pump is a gerotor type the park brake solenoid 1, hydrostatic oil cooler bypass
pump and is driven directly at engine speed. Each solenoid, and neutral charge relief valve that regulates
pump has a separate suction line from the reservoir. charge pressure and protects the charge pumps.
Charge pressure oil from each pump is sent through These components are also located in the HIC valve.
separate hoses to the Hydraulic Integrated Circuit
(HIC) valve. There it is combined and sent to a single Charge oil is also routed to the multi-function valves,
filter located on the bottom of the HIC valve and control circuit for each hydrostatic pump.

TE14778,000004B –19–13OCT04–1/1

TM2260 (07JAN06) 9026-05-4 750J, 850J Crawler

010706
PN=366
 Theory of Operation

Hydrostatic Charge Oil Filter Operation 3 39

3
The hydrostatic charge oil filter (18) removes
contaminants from the hydrostatic oil. The Hydraulic
16
Integrated Circuit (HIC) valve (39) contains the hydrostatic CHG_IN
charge oil filter bypass valve (16) and restriction switch 18
73 2

–UN–04JAN05
(17). The filter element is located on the bottom of the CHG_IN
HIC valve.
17
Under normal operation, charge pressure oil enters the

T206402
HIC valve at the two CHG_IN ports (73), flows through the
filter element, up through the filter canister and out the
two HIC valve CHG_OUT ports to the multi-function
valves and control circuits for each hydrostatic pump and 2—To Multi-Function Valves and Control Circuits
motor (2). 3—Diagnostic Test Port
16—Hydrostatic Charge Oil Filter Bypass Valve
17—Hydrostatic Charge Oil Filter Restriction
If the pressure differential between the inlet and outlet Switch
increases past a set level due to cold oil or partially 18—Hydrostatic Charge Oil Filter
restricted filter element, inlet pressure in the HIC valve 39—Hydraulic Integrated Circuit (HIC) valve
increases, moving the restriction switch piston against 73—Charge Pressure Lines (charge pump to HIC
valve ports CHG_IN)
spring force and outlet pressure. The piston contacts the
terminal, completing a circuit that causes the charge filter
restriction indicator light to illuminate.

As the filter element becomes plugged, the pressure

differential between the inlet and outlet increases. Inlet
pressure is sensed on one side of the bypass valve that
9026
opens against spring force and outlet pressure. The oil 05
then bypasses the filter while the restriction indicator light 5
illuminates.

It is normal for the restriction indicator light to be

illuminated when operating the machine with cold oil. If
the restriction indicator light is still illuminated after the oil
reaches operating temperature, the filter is being
bypassed and the filter element should be replaced.
Extended operation in the bypass mode could cause
damage to the hydrostatic system.

For more Charge Oil Filter information, see Hydraulic

Integrated Circuit (HIC) Valve Operation. (Group 9026-05.)

For Charge Oil Filter circuit information, see Hydrostatic

System Schematic—Neutral (Park Brake On). (Group
9026-15.)

TE14778,0000056 –19–04AUG05–1/1

TM2260 (07JAN06) 9026-05-5 750J, 850J Crawler

010706
PN=367
 Theory of Operation

Neutral Charge Relief Valve Operation

8
2

1
3
4
6

93

–UN–17DEC04
98

T206124
9026
T206124
05
6 Neutral Charge Relief Valve

1—Neutral Charge Relief Valve 4—Main Poppet 7—From Hydrostatic Charge 93—Charge Oil
2—Pilot Valve 5—Adjusting Screw Oil Filter 98—Return Oil
3—Main Poppet Orifice 6—Edge Filter 8—To Hydrostatic Pump
Cases

The neutral charge relief valve is a screw-in, causing it to move off its seat. In this condition there is
cartridge-style, pilot operated (two stage), spool-type oil flow through the main poppet orifice (3), through the
hydraulic relief valve. It is located in the Hydraulic unseated pilot valve, and out of the relief valve to both
Integrated Circuit (HIC) valve and is used to regulate pump cases (8). The oil flow through the orifice causes
hydrostatic charge oil pressure. a pressure drop across the main poppet (4) moving it
off it’s seat. This allows charge pressure oil to flow
While the machine is in neutral, charge pressure (7) on past the main poppet and out of the relief valve to both
the pilot valve (2) overcomes the spring force on it pump cases (8).

TE14778,0000071 –19–04AUG05–1/1

TM2260 (07JAN06) 9026-05-6 750J, 850J Crawler

010706
PN=368
 Theory of Operation

Multi-Function Valve Operation

2 3

–UN–30JAN04
6
7

T197495
T197495 5 4
Multi-Function Valve - Make-Up operation

1—High Pressure Relief Valve 3—Pressure Limiter Poppet 5—Pressure Limiter Poppet 6—Charge Oil
Poppet 4—Spring Seat Seat 7—Return Oil
2—Check Valve Poppet

The multi-function valves are located in the pump end The check valve also senses closed-loop pressure. 9026
05
cap. There are two multi-function valves for each Any time the closed-loop pressure is less than charge 7
pump. The valves are in the closed-loop circuit. They pressure the check valve moves the high pressure
sense closed-loop pressure. Two functions performed relief valve poppet (1) off its seat and there is charge
by each valve include closed-loop charge and high flow into the closed loop. This keeps the closed loop
pressure relief. filled with charge oil under all normal operating
conditions. This function is similar to that of an
Closed-Loop Charge As soon as there is charge anticavitation valve in a hydraulic system.
pressure, it is sensed at the check valve poppet (2).

Continued on next page TE14778,0000050 –19–13OCT04–1/2

TM2260 (07JAN06) 9026-05-7 750J, 850J Crawler

010706
PN=369
 Theory of Operation

2 3

6
7

–UN–30JAN04
8
9

T197496
T197496 5 4

Multi-Function Valve - High Pressure Relief Operation

1—High Pressure Relief Valve 3—Pressure Limiter Poppet 6—High Pressure Oil 8—Charge Oil
Poppet 4—Spring Seat 7—Reduced High Pressure Oil 9—Return Oil
2—Check Valve Poppet 5—Pressure Limiter Poppet
Seat

High Pressure Relief During normal operation of the oil flow through the high pressure relief valve poppet
9026 machine, the pressure limiter poppet (3) senses orifice (1), the unseated limiter poppet (3), and out of
05
closed-loop pressure and is held against its seat by the housing to pump case. The oil flow through the
8
spring force through the spring seat (4). orifice causes a pressure drop across the high
pressure relief moving it off the valve seat. This allows
Relief operation occurs when the closed-loop pressure closed-loop high pressure oil to flow past the poppet
on the limiter poppet overcomes the spring force on it and into the charge circuit.
causing it to move off its seat. In this condition there is

TE14778,0000050 –19–13OCT04–2/2

TM2260 (07JAN06) 9026-05-8 750J, 850J Crawler

010706
PN=370
 Theory of Operation

Hydraulic Integrated Circuit (HIC) Valve Operation

51

10 52

16 8 24
13
20 39

12

17

19

–UN–22AUG05
18 14 11 22

T213602
9 23 21
T213602 2 9026
05
Hydraulic Integrated Circuit (HIC) Valve 9

2—Ball Shuttle Valve 13—Hydrostatic Oil Reservoir 19—Neutral Charge Relief 24—Hand Pump Cab Tilt Relief
8—Hydrostatic Oil Bypass Solenoid Valve Valve
Temperature Sensor 14—Hydrostatic Oil Reservoir 20—Hand Pump Park Brake 39—Hydraulic Integrated
9—Park Brake Solenoid 1 Bypass Valve Relief Valve Circuit (HIC) Valve
10—Park Brake Solenoid 2 16—Hydrostatic Charge Oil 21—Hand Pump 51—Park Brake Pressure
11—Hydrostatic Oil Cooler Filter Bypass Valve 22—Hand Pump Selector Valve Sensor
Bypass Solenoid 17—Hydrostatic Charge Oil 1 52—Hydrostatic Charge
12—Hydrostatic Oil Cooler Filter Restriction Switch 23—Hand Pump Selector Valve Pressure Sensor
Bypass Valve 18—Hydrostatic Charge Oil 2
Filter

The Hydraulic Integrated Circuit (HIC) valve (39) is • Hydrostatic Charge Oil Filter Bypass Valve (16)
located inside the left rear access door next to the
hydrostatic reservoir. The HIC valve contains For information on the charge oil circuit, see Charge
components for four different hydraulic circuits. Pump Operation. (Group 9026-05.) Also, see
Hydrostatic Charge Oil Filter Operation. (Group
First, it contains the components for the hydrostatic 9026-05.)
charge oil circuit:
Second, it contains components for the hydrostatic oil
• Hydrostatic Charge Oil Filter (18) cooling circuit:
• Neutral Charge Relief Valve (19)
• Hydrostatic Charge Pressure Sensor (52) • Hydrostatic Oil Cooler Bypass Solenoid (11)
• Hydrostatic Charge Oil Filter Restriction Switch (17) • Hydrostatic Oil Cooler Bypass Valve (12)

Continued on next page TE14778,000005A –19–22AUG05–1/2

TM2260 (07JAN06) 9026-05-9 750J, 850J Crawler

010706
PN=371
 Theory of Operation

• Hydrostatic Oil Reservoir Bypass Solenoid (13) Fourth, it contains components for the hydraulic hand
• Hydrostatic Oil Reservoir Bypass Valve (14) pump circuit:
• Hydrostatic Oil Temperature Sensor (8)
• Hand Pump (21)
For information on the hydrostatic oil cooling circuit, • Hand Pump Selector Valve 1 (22)
see Oil Cooler and Reservoir Bypass Operation. • Hand Pump Selector Valve 2 (23)
(Group 9026-05.) • Hand Pump Park Brake Relief Valve (20)
• Hand Pump Cab Tilt Relief Valve (24)
Third, it contains components for the park brake circuit: • Ball Shuttle Valve (2)

• Park Brake Solenoid 1 (9) For information on hand pump operation, see the
• Park Brake Solenoid 2 (10) Operators Manual.
• Park Brake Pressure Sensor (51)
For more HIC valve information see Hydrostatic
For information on the park brake circuit, see Park System Schematic—Neutral (Park Brake On). (Group
Brake Valve Operation. (Group 9026-05.) 9026-15.)

TE14778,000005A –19–22AUG05–2/2

9026
05
10

TM2260 (07JAN06) 9026-05-10 750J, 850J Crawler

010706
PN=372
 Theory of Operation

Park Brake Valve Operation

66

27 27
BRK 13

16 9 10
39

18
CHG_IN
73 61
CHG_IN

–UN–04OCT04
17
T
60

T203005
T203005 40
Park Brake Valves - Brake On

2—Ball Shuttle Valve 18—Hydrostatic Charge Oil 60—Return Line (HIC valve T 73—Charge Pressure Lines
9—Park Brake Solenoid 1 Filter port to hydrostatic (charge pump to HIC valve
10—Park Brake Solenoid 1 27—Brake Piston (2 used) reservoir) ports CHG_IN)
16—Hydrostatic Charge Oil 39—Hydrostatic Integrated 61—To hand pump circuit
9026
Filter Bypass Valve Circuit (HIC) Valve 66—Charge Pressure Line (HIC
05
17—Hydrostatic Charge Oil 40—Hydrostatic Reservoir valve BRK port to final
11
Filter Restriction Switch drives)

The multiple wet disk park brakes are located in the pressure oil flow to the cavity behind the piston
final drives. The park brakes are spring applied and compressing the springs. This allows the friction disks
hydraulically released. When the park lock lever is in to rotate with the final drive gear and the machine is
the DOWN position or the decelerator pedal is fully free to move.
depressed or the machine is shut off, spring force
applies the park brakes. When the park lock lever is in When the park brake is applied or the machine is shut
the UP position and pressure on the decelerator pedal off, the park brake solenoids are de-energized. Park
is removed, the park brake is released. Brake Solenoid 1 blocks oil from the charge pump.
Park Brake Solenoid 2 opens the piston cavity to
The separator plates are held stationary with the brake return. The springs force the piston towards the final
housing. The friction disks are splined to the final drive drive compressing the pressure plates against the
gear. Two park brake solenoid valves are located in friction disks. This locks the final drive gear to the
the Hydraulic Integrated Circuit (HIC) valve, Park brake housing to apply the brake.
Brake Solenoid 1 and Park Brake Solenoid 2.
For park brake component location see Park Brake
When the park brake is released, the park brake System Component Location. (Group 9026-15.)
solenoids are energized. Park Brake Solenoid 2
closes, blocking return flow to the hydrostatic reservoir. To manually release the park brake see Releasing
Park Brake Solenoid 1 opens, allowing charge Park Brake to Tow the Machine. (Group 9026-25.)

TE14778,0000058 –19–04AUG05–1/1

TM2260 (07JAN06) 9026-05-11 750J, 850J Crawler

010706
PN=373
 Theory of Operation

Oil Cooler and Reservoir Bypass Operation

39
93

13

6 11
68
CSE_IN

TO_CLR_BOT

12
14
25 7 8 9 10 11 T
8

–UN–16DEC04
40

T203809
9026 T203809
05
12 Oil Cooler and Reservoir Bypass Operation

8—Hydrostatic Oil 13—Hydrostatic Oil Reservoir 39—Hydraulic Integrated 93—Charge Oil

Temperature Sensor Bypass Solenoid Circuit (HIC) Valve
11—Hydrostatic Oil Cooler 14—Hydrostatic Oil Reservoir 40—Hydrostatic Reservoir
Bypass Solenoid Bypass Valve 68—Case Drain Line
12—Hydrostatic Oil Cooler 25—Hydrostatic Oil Cooler (hydrostatic pumps and
Bypass Valve motors to HIC valve
CSE_IN port)

The oil cooler and reservoir bypass system is This system provides a means of quickly warming up
comprised of the Hydrostatic Oil Cooler Bypass the transmission oil after machine start-up by
Solenoid (11), Hydrostatic Oil Cooler Bypass Valve preventing transmission oil from entering the cooler
(12), Hydrostatic Oil Reservoir Bypass Solenoid (13), until oil temperature has reached specification. It also
Hydrostatic Oil Reservoir Bypass Valve (14), routes cooling flow from the pump and motor cases
Hydrostatic Oil Cooler (25), and Hydrostatic Reservoir directly to the reservoir in case the oil cooler becomes
(40). The solenoids and valves are located in the plugged.
Hydraulic Integrated Circuit (HIC) Valve (39).

The Hydrostatic Oil Temperature Sensor (8) is located

in Test Port 7 on the HIC valve. It sends transmission
oil temperature to an indicator on the monitor.

Continued on next page TE14778,0000070 –19–10DEC04–1/2

TM2260 (07JAN06) 9026-05-12 750J, 850J Crawler

010706
PN=374
 Theory of Operation

At startup, Oil Cooler Bypass Solenoid (11) is As case oil temperature rises further, Oil Reservoir
energized, allowing charge pressure oil (93) to flow to Bypass Solenoid starts de-energizing. Pressure starts
the Oil Cooler Bypass Valve (12). This causes the rising ahead of the solenoid which causes the Oil
valve to shift, blocking case drain oil to the Oil Cooler Reservoir Bypass Valve to start closing. Less oil is
(25). Oil Reservoir Bypass Solenoid (13) is also now directed to the reservoir and more oil is directed
energized, allowing previously trapped oil to drain to to the oil cooler.
the reservoir. This creates a pressure drop causing
case drain oil to shift Oil Reservoir Bypass Valve (14) If the oil cooler becomes plugged, pressure overcomes
allowing full case drain oil flow to the reservoir. the relief spring on the Oil Reservoir Bypass Solenoid
and the valve opens. Case drain oil flows directly to
As case drain oil temperature rises, Oil Cooler Bypass the reservoir, protecting the case seals and oil cooler
Solenoid de-energizes, blocking charge pressure oil to from excessive pressure buildup.
Oil Cooler Bypass Valve. This causes a pressure drop
and allows case drain oil to shift the cooler bypass
valve. Oil flow is now divided between the oil cooler
and reservoir.

TE14778,0000070 –19–10DEC04–2/2

9026
05
13

TM2260 (07JAN06) 9026-05-13 750J, 850J Crawler

010706
PN=375
 Theory of Operation

Pump Pressure Control Pilot (PCP) Operation

–UN–30JAN04
7
8

T197498
T197498
9026
05
14 Pressure Control Pilot (PCP) - Neutral

1—Torque Motor 3—Orifice 5—Flapper Valve 7—Low Pressure Control Oil

2—Coil 4—Nozzle 6—Charge Pressure Oil 8—Return Oil

There are two identical pressure control pilots (PCP’s), pressure drop when the system is at null. With the
one for each pump. The basic function of each PCP is flapper at null there is equal charge pressure oil (6)
to take a current signal from the transmission controller flow and both output pressures are equal.
and convert it to a differential control pressure which is
sent to each pump displacement control valve to When the machine is in neutral, no current signal is
regulate swash angles. sent to the torque motor. The centering springs hold
the flapper in a null (centered) position. Charge
The major components of the PCP are the torque pressure oil is equal through both upstream orifices
motor (1) and the flapper valve (5). The coil (2) and through each nozzle. With equal flow and
establishes a magnetic force to position the flapper pressure drop the two output pressures are exactly the
valve. One coil is used for forward and reverse. The same and the pressure differential is zero. In this
flapper is centered between two nozzles (4). Centering condition the pump swash angle will be zero and the
springs help keep the flapper at null. Upstream from motor will be at maximum swash angle.
each nozzle is an orifice (3) which provides a nominal

Continued on next page TE14778,000004C –19–13OCT04–1/2

TM2260 (07JAN06) 9026-05-14 750J, 850J Crawler

010706
PN=376
 Theory of Operation

When the machine is in forward, the transmission direction compared to forward. Thus the magnetic field
controller will send a positive current signal to the coil in the pump PCP is in the opposite direction which
in the pump PCP’s. The coil produces a magnetic field cause the flapper to move toward the opposite nozzle
in a given direction which in turn causes the flapper to orifice.
move accordingly. The flapper restricts oil flow through
one nozzle and opens the other. This produces a There is a manual mode which is controlled by a small
higher pressure at the restricted nozzle and a lower external lever on the PCP. The lever is connected to
pressure at the unrestricted nozzle. Thus an output the flapper valve. The lever can be moved in both
pressure differential is produced. This in turn will cause directions which causes the flapper valve to move the
the pump displacement control valve to increase the same as with a current signal. This will manually
pump swash angle and increase machine speed. override the transmission controller current signal.

For reverse operation, the transmission controller

sends a negative current signal in the opposite

TE14778,000004C –19–13OCT04–2/2

9026
05
15

TM2260 (07JAN06) 9026-05-15 750J, 850J Crawler

010706
PN=377
 Theory of Operation

Pump Displacement Control Valve (PDCV) Operation

2
1

6
4
9

–UN–30JAN04
10
8
11
7

T197499
T197499
9026
05
16 Pump Displacement Control Valve (PDCV) - Neutral

1—Null Adjustment Screw 4—To Reservoir 7—To Pump Servo 10—Low Pressure Control Oil
2—Control Pressure From 5—Charge Pressure Inlet 8—To Pump Servo 11—Return Oil
Pressure Control Pilot 6—Control Pressure From 9—Charge Pressure Oil
(PCP) Pressure Control Pilot
3—Connects To Pump (PCP)
Swashplate Feedback
Linkage

The major components in the Pump Displacement blocked at the spool center and both output ports are
Control Valve (PDCV) are the valve spool with connected to case (4).
centering spring, feedback linkage (3) to the pump
swash plate, and a null adjusting screw (1). In forward, a given differential control pressure will shift
the spool against the centering spring. Charge oil is
The PDCV is supplied with charge pressure (5) and a now directed to the servo piston that swashes the
differential control pressure (2 and 6) from the pump in forward. As the swash plate moves, the
Pressure Control Pilot (PCP). It produces a servo feedback linkage causes a movement on the centering
pressure at two output ports (7 and 8) which directs spring opposite to that of the differential control
the pump servo piston. pressure. The spool moves back toward neutral to a
point where a given servo pressure is maintained to
In a neutral condition with zero differential control the servo piston. This provides control of the pump
pressure, the valve spool is centered by the feedback swash plate relative to differential control pressure.
linkage and the centering spring. Charge pressure is

Continued on next page TE14778,000004D –19–27AUG04–1/2

TM2260 (07JAN06) 9026-05-16 750J, 850J Crawler

010706
PN=378
 Theory of Operation

In reverse the PCP produces a differential control adjustment is made so that with no current signal to
pressure of the opposite polarity, the spool is moved in the PCP the valve spool is exactly centered. Charge
the opposite direction and charge oil is directed to the pressure is blocked and both output ports are
opposite servo piston. Thus the pump is swashed for connected to case.
reverse operation.

The null adjust screw through the feedback linkage

adjusts the centering position of the spool. The

TE14778,000004D –19–27AUG04–2/2

9026
05
17

TM2260 (07JAN06) 9026-05-17 750J, 850J Crawler

010706
PN=379
 Theory of Operation

Hydrostatic Pump Operation

2
1
3

4
6

–UN–30JAN04
7
5

T197500
T197500
9026
05
18 Hydrostatic Pump - Neutral

1—Swash Plate 3—Piston 5—From Neutral Charge Relief 6—Charge Pressure Oil
2—Case Drain 4—Servo Piston Valve 7—Return Oil

Two pumps are mounted directly to the engine in a the end cap. The front pump is connected to the right
tandem configuration and are designed for through motor by pressure hoses. In the same manner the rear
torque capability. This means the main hydraulic pump pump is connected to the left motor.
and the winch can be driven from the back of the
tandem pump. Both pump rotating groups turn at engine speed. In
neutral the swash plate is at zero and there is no axial
Each pump consists of a nine piston rotating group of movement of the pistons and no pump flow. In forward
the parallel axial piston/slipper design, a tiltable cradle the transmission controller sends an current signal to
swash plate that controls pump flow and direction and the pressure control pilot (PCP) which sends a
a integral geroter type charge pump mounted on the differential control pressure to the pump displacement
pump drive shaft. A hydraulic displacement control control valve (PDCV). The PDCV sends a controlled
valve directs swash plate angle through a double servo charge pressure to one of the servo pistons. As the
piston assembly and a pressure control pilot (PCP) piston is moved the swash plate which is connected to
which controls the hydraulic displacement control it also moves. Now with a given amount of swash plate
valve. The output of the PCP is controlled by a angle, there will be a given amount of axial movement
milliamp current signal from the transmission controller. of pistons and a given amount of pump flow.
In addition each pump has two multi-function valves in

Continued on next page TE14778,000004F –19–13OCT04–1/2

TM2260 (07JAN06) 9026-05-18 750J, 850J Crawler

010706
PN=380
 Theory of Operation

In reverse the transmission controller sends a current will be switched from one side of the closed loop to the
signal of opposite polarity to the PCP. In turn then all other side. The pump is protected from high pressure
the control signals and movements are reversed. With by two multi-function valves, one for each direction.
the swash plate movement reversed the pump output
TE14778,000004F –19–13OCT04–2/2

Flushing Valve and Operating Charge Relief Valve Operation

2 3

9026
05
19

–UN–04FEB04
5
6

T197501
4 4
T197501
Flushing Valve and Operating Charge Relief Valve - Neutral

1—Flushing Valve 3—To Motor Case 5—Charge Pressure Oil 6—Return Oil
2—Operating Charge Relief 4—From Closed Loop
Valve

The flushing valve (1) and the operating charge relief In neutral with equal pressure on both sides of the
valve (2) are a part of the closed loop and are used to closed loop (4), the springs center the flushing valve
cool both the oil and the hydraulic components of the spool. In the centered position operating charge
closed loop circuit. pressure relief valve is not connected to the closed
loop. The closed loop pressure is controlled by the
The flushing valve (shuttle valve) is a spring balanced neutral charge pressure relief valve.
spool that senses pressure on both sides of the closed
loop. The operating charge pressure relief valve is of
the direct acting, orificed, poppet type design.

Continued on next page TE14778,0000051 –19–13OCT04–1/2

TM2260 (07JAN06) 9026-05-19 750J, 850J Crawler

010706
PN=381
 Theory of Operation

In forward, one side of the closed loop will be at a valves. To make up for this loss, cool filtered oil from
higher pressure than the other. The flushing valve the charge circuit will enter the low side of the closed
senses this and shifts away from the high pressure. In loop through the multi-function valve. Thus there is
this position the lower pressure side of the closed loop constant flow of clean cool oil into the closed loop
is connected to the operating charge relief valve. Its when in forward.
setting is lower than the neutral charge pressure relief
valve. With this pressure difference relationship and In reverse, the closed loop pressures switch from one
with pressure oil taking the path of least resistance, side to the other, the flushing valve shifts to the
there will be oil flow through the operating charge opposite side and the low side pressure is again
pressure relief valve. In this condition, oil on the low connected to the operating charge pressure relief
pressure side of the closed loop will be lost through valve. As in forward the hot oil in the closed loop is
the flushing and operating charge pressure relief routed out and clean oil is directed in.

TE14778,0000051 –19–13OCT04–2/2

9026
05
20

TM2260 (07JAN06) 9026-05-20 750J, 850J Crawler

010706
PN=382
 Theory of Operation

Hydrostatic Motor Operation

9
5

10 3

11

12 9026
05
21
13

–UN–28DEC04
2
1 14
8 15

T205062
T205062
Hydrostatic Motor Operation - Reverse (Slow Speed)

1—Servo Piston 5—Rotating Group 10—Closed Loop High 12—Case Drain Oil
2—Feedback Pin 7—Motor Shift Solenoid Pressure 13—High Pressure Oil
3—Motor Displacement 8—Control Spring Adjusting 11—Closed Loop Charge 14—Charge Oil
Control Valve (MDCV) Screw Pressure 15—Return Oil
4—Ball Shuttle 9—Motor Speed Sensor

The synchronizing shaft with spherical rollers cylinder block. The ball end of each piston runs in a
synchronizes the rotation of the output shaft and the socket bushing pressed into the output shaft. No other
cylinder block. The ball end of each piston runs in a parts are used to connect the pistons to the shaft.
socket bushing pressed into the output shaft. No other
parts are used to connect the pistons to the shaft. The motor displacement unit consists of a servo piston
(1), a Motor Displacement Control Valve (MDCV) (3)
The synchronizing shaft with spherical rollers assembly and a direct acting variable solenoid control
synchronizes the rotation of the output shaft and the (7).

Continued on next page TE14778,000006F –19–16NOV04–1/2

TM2260 (07JAN06) 9026-05-21 750J, 850J Crawler

010706
PN=383
 Theory of Operation

The servo piston is connected to the cylinder block (5) MDCV. The MDCV is spring biased so that the small
with the feedback pin (2). The servo piston positions applied force will not move it. The ball shuttle now
the cylinder block between maximum and minimum directs the high pressure (10) side of the closed loop
angle. A spacer connected to the piston provides a to the MDCV. Since it has not moved from the
stop for minimum angle. previous neutral operation position, high pressure from
the closed loop continues to hold the servo piston at
In forward or reverse operation, the Transmission maximum angle.
Control Unit (TCU) sends a current signal to the motor
shift solenoid which directly acts (applies a force) on Forward or Reverse (High Speed)
the MDCV. The MDCV sends a controlled closed loop
pressure to the servo piston. As the TCU gets input commands for increased speed,
the current signal to the motor solenoids increases. In
Neutral Operation turn, the solenoid applied force increases. As applied
force increases, the MDCV starts moving against
With the Transmission Control Lever (TCL) in neutral, spring force. At this point, pressure to the servo piston
the TCU sends zero control signal current to the motor is blocked, the low speed (maximum angle) side is
shift solenoid, which in turn applies no force to the connected to return and high pressure from the closed
MDCV. The ball shuttle sends closed loop pressure, loop is directed to the high speed (minimum angle)
charge pressure when in neutral, to the MDCV. With side of the piston. The piston movement starts
no force applied to the MDCV, it directs charge de-swashing the motor and increases the feedback
pressure to low speed end of the servo piston. Since spring force on the displacement valve. The
the opposite end of the piston is connected to return, displacement valve now goes to a "hold" position when
the piston moves to the low speed, maximum angle the solenoid applied force is equal to the opposing
position. Therefore, when the TCL is moved out of spring force and maintains the motor at a given
neutral, the motor always starts turning at low speed, displacement angle. Thus, the transmission controller
maximum torque. with a given current signal out to the motor solenoid
has positional control of the motor displacement angle
9026
05 Forward or Reverse (Low Speed)
22
The TCU sends a low current signal to the motor shift
solenoid which in turn sends an applied force to the

TE14778,000006F –19–16NOV04–2/2

TM2260 (07JAN06) 9026-05-22 750J, 850J Crawler

010706
PN=384
 Theory of Operation

Hydraulic Fan Drive Operation

NOTE: Fan reversing valve is a factory option. Not all

machines may be equipped with reversing option.

The hydraulic fan drive system consists of:

• Gear type pump

• Gear type motor
• Fan reversing valve
• Fan directional valve
• Fan proportional solenoid
• Fan reversing solenoid
• Fan oil filter

Continued on next page TE14778,000007E –19–13JAN05–1/3

9026
05
23

TM2260 (07JAN06) 9026-05-23 750J, 850J Crawler

010706
PN=385
 Theory of Operation

49

58 42

59
48

54 46
41
50 45 57
54
44
56
59 43

–UN–13JAN05
56 57
96
98

T202967
55
T202967
Hydraulic Fan Drive Component Location (750J Shown)
9026
05
24

41 54

43
56
55

44 42
45
48
47
PUMP A
TANK
B 59
47 57
50

46
58
–UN–28DEC04

40
49
96
T202928

98
T202928
Hydraulic Fan Drive Schematic
Continued on next page TE14778,000007E –19–13JAN05–2/3

TM2260 (07JAN06) 9026-05-24 750J, 850J Crawler

010706
PN=386
 Theory of Operation

39—Hydraulic Integrated 46—Hydraulic Fan 55—High Pressure Line 58—Return Line (hydraulic fan
Circuit (HIC) Valve Proportional Solenoid (hydraulic fan pump to reversing valve to
40—Hydrostatic Reservoir 47—Hydraulic Fan Check hydraulic fan reversing hydraulic fan oil filter)
41—Hydraulic Fan Pump Valve (3 used) valve) 59—Case Drain Line (hydraulic
42—Hydraulic Fan Motor 48—Hydraulic Fan Oil Filter 56—Forward Pressure Line fan motor to hydraulic fan
43—Hydraulic Fan Reversing Bypass Valve (hydraulic fan reversing oil filter)
Valve 49—Hydraulic Fan Oil Filter valve through bulkhead to 96—High Pressure Oil
44—Hydraulic Fan Reversing Restriction Switch hydraulic fan motor) 98—Return Oil
Solenoid 50—Hydraulic Fan Oil Filter 57—Reverse Pressure Line
45—Hydraulic Fan Directional 54—Suction Line (hydrostatic (hydraulic fan reversing
Valve reservoir through valve through bulkhead to
bulkhead to hydraulic fan hydraulic fan motor)
pump)

Normal Operation ejecting trapped foreign material. When the reversing

solenoid (44) is energized, oil flows through the
Fan pump (41) is powered by a gear on the front of reversing solenoid and shifts position of the directional
the engine. Pump output is directed to the fan valve. This sends oil flow to the outlet port of the fan
reversing valve (43) inlet. Oil flows to the reversing motor, reversing the direction of the fan.
solenoid (44), through the directional valve (45), and
on to fan motor (42) inlet. Oil also flows past check Fan reversal can be set in the CMU to automatically
valves (47) to proportional solenoid (46). This solenoid reverse direction every 0.5 hour, 1 hour, or 1.5 hour.
is used to control fan speed by electronic control of the Fan reversal can also be started manually by pushing
proportional relief valve. the Fan Reversing Switch on the side of the monitor.
The monitor contains a fan reversal indicator light to
Proportional fan speed is controlled by the alert the operator when a fan reversal is set to occur.
Transmission Control Unit (TCU) based upon machine The indicator also lights when the operator pushes the
fluid and air temperatures. Fan speed may be Fan Reversing Switch. The indicator light goes off
manually set to Minimum, 70%, Maximum, or Normal once the reversal cycle is complete. Note: Fan reverse
9026
in the CAN Monitor Unit (CMU). With fan speed set at operation will only initiate if the machine is in Neutral
05
Minimum, proportional solenoid (46) allows a large or Reverse. Fan reversal will fully finish its cycle if the 25
amount of oil from fan pump (41) to return to reservoir machine is shifted to Forward.
(40). As fan speed setting increases to Maximum,
proportional solenoid allows less oil to return to For access to fan speed settings, see CAN Monitor
reservoir and more oil to flow to fan motor (42). An Unit (CMU) Circuit Theory of Operation. (Group
electrical malfunction will default fan speed to 9015-15.)
Maximum to avoid overheating.
For more electrical fan drive information, see
Reverse Operation Transmission Control Unit (TCU) Circuit Theory of
Operation. (Group 9015-15.)
The fan reverse function allows the fan to reverse
direction, blowing air through the heat exchanger and

TE14778,000007E –19–13JAN05–3/3

TM2260 (07JAN06) 9026-05-25 750J, 850J Crawler

010706
PN=387
 Theory of Operation

Hydraulic Fan Return Filter Operation

84

90 82

83

59 48
59
58

90
58 50

–UN–26NOV04
40
49

T205038
9026
T205038
05
26

A
72
49 89
82 75 84

75 90

72

48
58
–UN–29NOV04

50
SECTION A
T205039

A 98
T205039

Continued on next page TE14778,0000059 –19–13OCT04–1/2

TM2260 (07JAN06) 9026-05-26 750J, 850J Crawler

010706
PN=388
 Theory of Operation

40—Hydrostatic Reservoir 59—Case Drain Line (hydraulic 82—Hydraulic Fan Oil Filter 89—Switch Spring
48—Hydraulic Fan Oil Filter fan motor to hydraulic fan Main Inlet 90—To Hydrostatic Reservoir
Bypass Valve oil filter) 83—Hydraulic Fan Oil Filter 98—Return Oil
49—Hydraulic Fan Oil Filter 72—Hydraulic Fan Oil Filter Auxilliary Inlet
Restriction Switch Bypass Valve Piston 84—Hydraulic Fan Oil Filter
50—Hydraulic Fan Oil Filter 75—Hydraulic Fan Oil Filter Outlet
58—Return Line (hydraulic fan Restriction Switch
reversing valve to Terminal
hydraulic fan oil filter)

The hydraulic fan oil filter (50) is located inside the left hydraulic fan oil filter restriction indicator light to
rear access door. It is mounted on the hydrostatic illuminate.
reservoir (40) and removes contaminants from the
hydrostatic oil system. The filter housing contains a As the filter element becomes plugged, the pressure
bypass valve (48) and filter restriction switch (49). differential between the inlet and outlet increases. High
inlet pressure (96) is sensed on inlet side of the
Under normal operation, return oil (58) flows from the bypass valve that opens against spring force and
hydraulic fan reversing valve into the main inlet (82). outlet pressure. The oil then bypasses the filter while
Case drain oil (59) flows from the hydraulic fan motor the restriction indicator light illuminates.
into the auxiliary inlet (83). This combined return oil
(98) then flows through the hydraulic fan oil filter (50), It is normal for the restriction indicator light to be
through the outlet (84), and into hydrostatic reservoir illuminated when operating the machine with cold oil. If
(40). the restriction indicator light is still illuminated after the
oil reaches operating temperature, the filter is being
If the pressure differential between the inlet and outlet bypassed and the filter element should be replaced.
increases past a set level due to cold oil or partially Extended operation in the bypass mode could cause
restricted filter element, inlet pressure increases (95), damage to the hydrostatic system.
moving the restriction switch piston (72) against spring
force and outlet pressure. The piston contacts the For complete circuit theory see Hydraulic Fan Drive 9026
terminal (73), completing a circuit that causes the Operation. (9026-05.) 05
27

TE14778,0000059 –19–13OCT04–2/2

TM2260 (07JAN06) 9026-05-27 750J, 850J Crawler

010706
PN=389
 Theory of Operation

9026
05
28

TM2260 (07JAN06) 9026-05-28 750J, 850J Crawler

010706
PN=390
 Group 15
Diagnostic Information
Overheating—Flowchart

Check oil level

Check components
that would reduce
air flow

OVERHEATING (TRANSMISSION ONLY)

External debris in YES Operate reversing fan
cooler? (if equipped)
NO
YES Install sand shield in
Damaged Fins?
NO abrasive conditions

Install temperature YES YES Perform Fan Motor NO Correct fan system
gauge in HIC Valve Is fan installed
correctly? Reference Speed Test. OK?
Test Port 8. Verify
temperature reading. photo in fan speed YES
OK? test or decal on fan.
NO Verify motor at max angle
NO Turn tracker off
Correct fan system Turn motor solenoids off
Repair or replace Set/maintain 2100 engine rpm
sensor or wiring Set speed to 1.8
With tracker off, note YES Read motor rpm's NO
if mistrack severe 750J approx = 1370 rpm
and which is fast 850J approx = 1140 rpm
side. Motor rpm's over spec? 9026
15
1

Turn Motor solenoids Perform oil cooler

off in CMU. Install JD YES Perform
and tank bypass Efficiency
Repair wiring NO test harness. Verify 0 tests. OK? test. OK?
or TCU voltage at motor
solenoid connector. NO NO
OK?
Correct oil Correct cause
cooler or tank of inefficiency
bypass valves in pumps and
YES motors
Perform Motor
Repair or NO Displacement Control
adjust Valve (MDCV)
Adjustment. OK?
YES

Perform Hydrostatic
Repair or NO Motor Min./Max.
adjust Angle Servo Piston
Pressure Test. OK?
YES
–19–12SEP05

Repair motor, looking

for swashplate not
returning to max
T214093

angle stop
T214093
Overheating—Flowchart
TE14778,000007F –19–06OCT05–1/1

TM2260 (07JAN06) 9026-15-1 750J, 850J Crawler

010706
PN=391
 Diagnostic Information

Low Charge Pressure—Flowchart

See TM. YES

Are Diagnostic Trouble
Take Codes displayed
appropriate
action NO

Check oil level

LOW CHARGE PRESSURE
Perform Charge
Pump Flow Test NO Are dozer blade hydraulic
for front and rear functions ok?
HST pumps
YES

Does charge YES Perform valve

Inspect
coupler YES Low flow pressure drop and portion of Park
between stay low when Brake Test
rear pump brakes are released
HST pumps only? in N
NO NO
Inspect YES
engine Low flow
from both Set brakes to Test Mode in
coupler CMU.
pumps?
Operate against brakes in 4 NO Charge YES Inspect /
conditions: replace Loop
Fwd with left stop track steer low only
for one Flushing Valve
Fwd with right stop track steer in motor on this
Rev with left stop track steer direction
9026 and on side
Rev with right stop track steer
15 Was charge pressure low for all one side?
2 4 conditions? NO
YES

Check sensor NO Compare charge pressure

wiring and reading with guage
replace sensor installed in HIC Valve test
port 2. Equal?
Repair charge
YES Perform pump or pumps
Charge as indicated
Pump
Perform Neutral Replace Flow Test
and Operating Neutral
Charge Pressure Charge YES
Test Relief
Valve and
Seal as
necessary NO Repair pumps
Done YES Note position of charge set Perform or motors as
screw and count turns. efficiency neccessary
Adjust neutral charge relief test. OK?
valve. Can specified
pressure be obtained by NO YES
adjusting setscrew?
–19–12SEP05

Remove Neutral Charge

NO Relief Valve. Inspect,
verify that it's closed, and
Return setscrew to requires force against
original position spring to open.
T214106

and setting Valve and Seals OK

T214106
Low Charge Pressure—Flowchart
TE14778,0000080 –19–06OCT05–1/1

TM2260 (07JAN06) 9026-15-2 750J, 850J Crawler

010706
PN=392
 Diagnostic Information

Mistrack/Indexes—Flowchart

See TM. Take YES Are Diagnostic Trouble

MISTRACK OR INDEX
appropriate Codes displayed?
action NO
Adjust NO Track tension ok?
tracks
YES
Record existing calibrated
values from CMU:
Pump thresh mA Perform Motor
Pump max mA Repair or
Displacement Control NO adjust motor
Motor max mA Valve (MDCV) control
Note: Adjustment. OK?
If calibration Calibrate TCU YES
fails, "menu" Record pump and motor
resets factory mA on monitor while Perform Motor
default values to Repair or
calibrating Min./Max. Angle Servo NO adjust motor
keep customer Piston Pressure Test.
running. control
OK?
Go to TCU YES
YES
Calibration Diagnostic Trouble
Problems- Codes generated? Repair motor, looking for swashplate
Flowchart angle function incorrect.
NO
Compare new and old Was more than one
calibration values for condition not ok?
large changes.
YES
9026
15
Go to Low Perform Neutral Charge Swap front and rear pump PDCV's 3
Charge NO Relief and Operating and inspect/replace control screens
Pressure- Charge Relief Pressure under PDCV's.
Flowchart Test. OK? Mistrack and efficiency ok?
YES NO
Test both motor
speed sensors YES Turn off tracker in CMU. Does mistrack and inefficency NO
per TM Did mistrack improve? problem move with PDCV?
NO YES
Turn motor solenoid off Isolate pump(s)
in CMU. Did mistrack YES
and/or motor(s)
improve? and repair
Perform Displacement Repair or replace
Control Valve (PDCV) NO
PDCV
Neutral (NUll) Do efficiency/relief test. Check 4
Adjustment conditions: Calibrate TCU
Fwd with left stop track steer after repairs
Fwd with right stop track steer and recheck for
Perform Pressure Rev with left stop track steer Diagnostic
Control Pilot YES Rev with right stop track steer Trouble codes.
(PCP) Test OK?
–19–12SEP05

NO Switch Multi-
NO Function valves.
Was only one condition Inspect/replace If problem moves
not ok? loop flushing repair or replace
YES valve in motor on Multi-Function
T214101

this side valve

T214101
Mistrack or Index Flowchart
TE14778,0000081 –19–06OCT05–1/1

TM2260 (07JAN06) 9026-15-3 750J, 850J Crawler

010706
PN=393
 Diagnostic Information

Machine Will Not Reach Full Speed—Flowchart

See TM. Take YES Are Diagnostic Trouble

appropriate Codes displayed
action NO

See Electrical NO Set engine

Component speed switch
Specifications to fast idle. MACHINE WILL NOT REACH FULL SPEED
(Group 9015-20) 2255-2285
rpm showing
on CMU?
YES
Calibrate

Go to Low NO Set transmission

Power- speed to 3.0. Engine
Flowchart speed in transport at
least 2100 rpm?
YES

Verify intended Compare rate setting with motor rpm values:

reverse ratio Turn off tracker on (CMU)
setting in CMU Set/maintain engine 2100 rpm
Hold transmission speed high
Read motor rpm on CMU
Verify intended rate 750J 850J
9026 setting on CMU for Max Rate Motor Rate Motor
15 Fwd and Rev speeds rpm rpm
4 Low 2600 Low 2350
Med 3130 Med 2820
Go to Mistrack/ High 3540 High 3200
YES Turn off tracker through
Indexes- CMU. Does unit
Flowchart mistrack substantially?
NO

Go to Low NO Perform Neutral Charge

Charge Relief and Operating
Pressure- Charge Relief Pressure
Flowchart Test. OK?

Go to TCU Calibration
Problems-Flowchart

YES
Note:
–19–12SEP05

If calibration YES
fails, "menu" Calibrate TCU.
resets factory Record pump and Diagnostic Trouble NO Done
default values to motor ma on monitor Codes generated?
while calibrating
T214102

keep customer
T214102 running.
Machine Will Not Reach Full Speed—Flowchart
TE14778,0000082 –19–06OCT05–1/1

TM2260 (07JAN06) 9026-15-4 750J, 850J Crawler

010706
PN=394
 Diagnostic Information

Low Power—Flowchart
T207108 –19–01FEB05

See TM. Take YES Are Diagnostic Trouble

Load test engine power
appropriate Codes displayed Record forward left and forward right pump threshold mA from CMU. LOW POWER
action NO Calculate Load mA per below table:
Load mA Load mA
Adjust NO Check track Model Left Right
tension OK? 750J 54+threshold=
YES 750J LGP 59+threshold=
850J 47+threshold=
Go to Low NO Perform Neutral Charge Relief 850J LGP 51+threshold=
Charge and Operating Charge Relief Start engine
Pressure- Pressure Test. OK? Set Decelerator mode switch to transmission mode.
Flowchart YES Set engine speed to fast idle.
In CMU set:
Go to Mistrack/ Brake rate setting to Test
Indexes- YES Turn off tracker through Fan speed to Maximum
CMU. Does unit
Flowchart mistrack substantially? Antistall to Off
In CMU select EFF and Relief screen
NO
YES
Perform Efficiency/Relief test. Check 4 conditions:
Fwd with left stop track steer Park lever up, Decel down, TCL in Forward.
Fwd with right stop track steer Steer right stop track
Rev with left stop track steer Slowly raise decel pedal to Load mA.
Rev with right stop track steer At approximate load mA is engine rpm > 1700?
All efficiencies ok? Repeat with opposite steer and load mA.
At approximate load mA is engine rpm > 1700?
Inspect/replace NO
YES NO
loop flushing
valve in motor YES Was efficiency or relief Perform Manifold
low in one direction on
on this side one side only? Pressure Test-
Turbocharger
NO Boost. OK?
Switch Multi- Record existing calibrated YES
Function valves. If values from CMU:
problem moves Pump threshold mA Check engine
repair or replace Pump max mA Perform Park Brake Test. fuel and air
Multi-Function Valve Motor max mA Verify brake valves are
functioning and no
Note: binding or drag from NO
If calibration discs or final drive OK?
fails, "menu" Calibrate TCU. YES
resets factory Record pump and Repair brake
default values to motor mA on monitor Verify motor swash plate valves or final
keep customer while calibrating is reaching max angle drive or brake
running. discs as needed

YES Diagnostic Trouble Perform Motor NO Repair or

Codes generated? Displacement Control adjust
NO Valve (MDCV)
Go to TCU Calibration Adjustment. OK?
Problems-Flowchart Compare new and old YES
calibration values for large
changes and keep in mind Perform Hydrostatic NO Repair or
while further investigating. Motor Min./Max. Angle adjust
Servo Piston Pressure
Calibrate TCU Test. OK?
Isolate efficiency after repairs YES
problem to pump(s) and recheck for
and/or motor(s) and Diagnostic All systems normal. Machine
repair Trouble Codes. may be too heavy.
T207108
Low Power—Flowchart
TE14778,0000083 –19–14JAN05–1/1

TM2260 (07JAN06) 9026-15-5 750J, 850J Crawler

010706
PN=395
 Diagnostic Information

Engine Starts But One Or Both Tracks Will Not Move—Flowchart

See TM. Take

appropriate YES Are Diagnostic Trouble ENGINE STARTS, BUT ONE OR
action Codes displayed BOTH TRACKS WILL NOT MOVE
NO

Adjust/repair NO
--Cycle park brake lever.
park lever Does monitor cycle from "P" to "N"?
switch --Cycle TCL
Does monitor cycle from "N" to "F" or
"R"?
YES

Go to Low NO Perform Neutral Charge

Charge Relief and Operating
Pressure- Charge Relief Pressure
Flowchart Test. OK?
YES

Perform Multi-Function YES NO

Repair brakes
Relief Valve Test. OK? Perform Park
Brake Test OK? and/or valves
NO
YES
Check for YES Check motor speed on
mechanical CMU. Have motor Final drive or
failure of final speed but no track brake binding
drive or motor movement?
9026 NO
15
6
Activitate pump manual NO Does system pressure YES
overrides. Does track build in circuit while
move now? activating
YES NO
YES
Wiring ok? Install test harness Adjust or replace
JDG1932 as described in YES Done
YES Multi-Function Relief
pump servo test. Activate Valve. OK?
switch to FWD and REV.
Replace TCU Does track move now? NO
NO
Perform Pressure Disassemble
Control Pilot (PCP ) More than PDCV and
Test. What is 2 turns check for worn
differential pressure? feed back link
More than 1/2
More than but less than
15 psi 2 turns
More than 5 Perform Pump 1/2 Turn
and less than Displacement or Less
15 psi Control Valve

–19–20JAN05
(PDCV) Neutral
Less than (Null) Adjustment.
5 psi Replace PCP
Count turns for 50 Disassemble
Adjust PCP psi between pump and
forward and relevel swash

T207107
reverse. plate Calibrate TCU
T207107
Engine Starts But One Or Both Tracks Will Not Move—Flowchart
TE14778,0000084 –19–14JAN05–1/1

TM2260 (07JAN06) 9026-15-6 750J, 850J Crawler

010706
PN=396
 Diagnostic Information

TCU Calibration Problems—Flowchart

T214104 –19–13SEP05

Will unit go into YES Will unit pass YES Will unit pass pump YES Will unit pass pump YES Will unit pass motor YES
calibration? sensor portion of threshold portion of max portion of max portion of DONE TCU CALIBRATION PROBLEMS
NO calibration? calibration? calibration? calibration?
NO NO NO Max Motor cal mA low <400 mA NO Max Motor cal mA low <700 mA
Monitor powered and working:
Refer to group NO Normal start-up display? 523578.18 Right Track 523578.16 Right Track
9015-15 of TM CMU "Menu" switches work? 523577.18 Left Track 523577.16 Left Track
Engine rpm displayed?
YES Max Pump cal mA low <51 mA Max Pump cal mA high >83 mA Turn off tracker. Note NO
See TM. Take YES Are diagnostic 522450.18 Left Track Fwd 522450.16 Left Track Fwd Adjust tracks Track Tension ok?
Refer to group YES Are Diagnostic if mistrack is severe
appropriate trouble codes 522447.18 Right Track Fwd 522447.16 Right Track Fwd and which side is slow. YES
9015-20 of TM. Take Trouble Codes action displayed? 522449.18 Left Track Rev 522449.16 Left Track Rev
appropriate action displayed NO Engine speed of 2100 rpm
NO 522448.18 Right Track Rev 522448.16 Right Track Rev Repair engine
NO minimum maintained for no
Actuate sensor where load transport?
Monitor: calibration stops. Read YES
Refer to group NO Displays "N" - park lever down? NO
9015-15 of TM voltage on monitor Turn off tracker. Note Track Tension ok? Adjust tracks NO
Displays "P" - park lever up? diagnostics. Adjust, Reset max Are max speed rate
if mistrack severe and YES
YES check wiring, replace as which side is slow. speed rates settings set correctly?
neccessary to make Engine speed of 2100 rpm NO YES
Repair engine YES
Check wiring voltage outputs conform minimum maintained for no NO
and TCU with calibration voltage Perform Motor High/Low
load transport? Displacement Control NO Perform Neutral Charge Relief
requirements. Charge
YES Valve (MDCV) Adjustment Pressure- and Operating Charge Relief
Repair or Pressure Test. OK?
OK? adjust Flowchart
Are max speed rate NO Reset max
YES YES
settings set correctly? speed rates
YES Repair or NO Perform Motor Turn off tracker. Note
Pump threshold mA low <6 mA Pump threshold mA high >25 mA if mistrack is severe
522450.17 Left Track Fwd 522450.15 Left Track Fwd High/Low adjust Min./Max. Angle Servo
Perform Neutral Charge Relief NO Piston Pressure Test. and which side is slow.
522447.17 Right Track Fwd 522447.15 Right Track Fwd Charge
522449.17 Left Track Rev 522449.15 Left Track Rev YES and Operating Charge Relief Pressure- OK? YES
522448.17 Right Track Rev 522448.15 Right Track Rev Pressure Test. OK? Flowchart YES Perform Efficiency/Relief test. Check 4 conditions:
NO Fwd with left stop track steer
Perform Motor Repair or Repair motor, looking Fwd with right stop track steer
Displacement Control adjust Turn off tracker. Note
if mistrack is severe for swashplate not Rev with left stop track steer
Repair or replace NO Is motor rpm YES Go to Engine Starts But Valve (MDCV) Adjustment returning to max angle
Cycle PCP manual motor speed and which side is slow. Rev with right stop track steer
overides to flush displayed on CMU One Or Both Tracks Will OK? stop
sensors or wiring when tracks are Not Move-Flowchart Switch Multi-
contaminant YES Function valves.
moving? Perform Efficiency/Relief test. Check 4 conditions: If problem Adjust or NO Do motor NO Was efficiency or relief low in one
Fwd with left stop track steer moves, repair or repair motor solenoid direction and on one side only?
Fwd with right stop track steer replace Multi- solenoid test OK?
Perform Pressure Disassemble Rev with left stop track steer Function Valve YES
Perform Hydrostatic NO Repair or Rev with right stop track steer YES
Control Pilot (PCP) Test. More than PDCV and
What is differential 2 turns check for worn Motor Min./Max. Angle adjust YES
pressure? feed back link Servo Piston Pressure
Inspect / replace loop
Test. OK? Was efficiency or relief low in one YES flushing valve in motor Inspect / replace
More than 1/2 YES direction and on one side only? on this side NO Do motor Loop Flushing
More than but less than Repair or
adjust servo piston Valve in motor
15 psi 2 turns YES on this side
More than 5 Perform Pump 1/2 turn test OK?
psi but less Displacement or Less Repair motor, looking Verify low efficiency reading not due to faulty pump control:
for swashplate not YES
than 15 psi Control Valve -Perform Pressure Control Pilot (PCP) Test
(PDCV) Neutral returning to max angle -Perform Pump Displacement Control Valve (PCDV) Neutral
Less than (Null) Adjustment. stop (Null) Adjustment
5 psi Replace PCP -Remove PDCV's. Inspect replace screens Switch Multi-
Count turns for 50 Disassemble Verify low efficiency reading not due to faulty pump control Function valves.
Adjust PCP psi between pump and Repair or
replace pump(s) Isolate pumps(s) -Perform Pressure Control Pilot (PCP) Test If problem
forward and relevel swash Repair or and/or motor(s) -Perform Pump Displacement Control Valve (PCDV) Neutral moves repair or
reverse. plate Calibrate TCU and or motor(s)
Isolate pumps(s) replace pump(s) (Null) Adjustment replace Multi-
and/or motor(s) and or motor(s) -Remove PDCV's inspect replace screens Function Valve
T214104
TCU Calibration Problems—Flowchart
TE14778,0000085 –19–07OCT05–1/1

TM2260 (07JAN06) 9026-15-7 750J, 850J Crawler

010706
PN=397
 Diagnostic Information

Hydrostatic System Component Location

T203810 –UN–05JAN05

19

85

86

70 74 87
69
67
70 88
39

73

28 88
18 85
65
28

68
70
68
76
5
1 81
35 87
68 1
80
86
6

35
78
71 77
79
4
38
37
69

T203810
Hydrostatic System Component Location
TE14778,000006D –19–02NOV04–1/2

TM2260 (07JAN06) 9026-15-8 750J, 850J Crawler

010706
PN=398
 Diagnostic Information

1—Motor Shift Solenoid 39—Hydraulic Integrated 70—Return Line (top of 77—Reverse Pressure Line
4—Operating Charge Pressure Circuit (HIC) Valve hydrostatic oil cooler (left motor)
Relief Valve 65—Suction Line (hydrostatic through bulkhead to 78—Forward Pressure Line
5—Hydrostatic Motor Left reservoir to hydrostatic hydrostatic reservoir) (right motor)
6—Hydrostatic Motor Right charge pumps) 71—Minimum Displacement 79—Reverse Pressure Line
18—Hydrostatic Charge Oil 67—Case Flushing Line (HIC Limiter (right motor)
Filter valve P_CSE_OUT port to 73—Charge Pressure Line 80—Motor Speed Sensor Left
19—Neutral Charge Relief bottom of hydrostatic (charge pump to HIC valve 81—Motor Speed Sensor Right
Valve pump cases) port CHG_IN) 85—Left Forward (LF)
28—Multi-Function Valve 68—Case Drain Line 74—Charge Pressure Line (HIC 86—Left Reverse (LR)
35—Pressure Control Pilot (hydrostatic pumps and valve CHG_OUT port to 87—Right Reverse (RR)
(PCP) Valve motors to HIC valve hydrostatic pumps) 88—Right Forward (RF)
37—Hydrostatic Pump Front CSE_IN port) 76—Forward Pressure Line
(Right Track) 69—Return Line (HIC valve (left motor)
38—Hydrostatic Pump Front TO_CLR_BOT port to
(Left Track) bottom of hydrostatic oil
cooler)

TE14778,000006D –19–02NOV04–2/2

9026
15
9

TM2260 (07JAN06) 9026-15-9 750J, 850J Crawler

010706
PN=399
 Diagnostic Information

Park Brake System Component Location

10

9
39 19

60

73

9026
15
10

36
65
66 36

63

93
–UN–01OCT04

98

64
T203006

T203006
Park Brake System Component Location (Park Brake Released)
Continued on next page TE14778,0000086 –19–24JAN05–1/2

TM2260 (07JAN06) 9026-15-10 750J, 850J Crawler

010706
PN=400
 Diagnostic Information

9—Park Brake Solenoid 1 60—Return Line (HIC valve T 66—Charge Pressure Line (HIC 93—Charge Pressure Oil
10—Park Brake Solenoid 2 port to hydrostatic valve BRK port to final 98—Return Oil
19—Neutral Charge Relief reservoir) drives)
Valve 63—Final Drive Left 73—Charge Pressure Line
36—Charge Pump 64—Final Drive Right (charge pump to HIC valve
39—Hydraulic Integrated 65—Suction Line (hydrostatic port CHG_IN)
Circuit (HIC) Valve reservoir to hydrostatic
charge pumps)

TE14778,0000086 –19–24JAN05–2/2

9026
15
11

TM2260 (07JAN06) 9026-15-11 750J, 850J Crawler

010706
PN=401
 Diagnostic Information

Hydrostatic System Schematic—Neutral (Park Brake On)

T214088 –19–12SEP05

51

CHG_OUT

CHG_OUT
92 52

CAB_DN
OPEARTING
4 CHARGE 26
RELIEF 3 2 1 BRK 13 CAB_UP
VALVE CAB TILT
PARK BRAKE PARK BRAKE CYLINDER
B M2 M1 A B M2 M1 A SOLENOID 1 10 SOLENOID 2
3
M2 9 22
38 HYDROSTATIC 16
PUMP REAR
B REV (LEFT TRACK) CHG_IN
23
2 CHG_IN
18 2
L2 HYDRO-
29 29 4 STATIC 17 19
A FWD CHARGE 21
28 NEUTRAL 20 24
OIL FILTER HAND
MULTI- 30 P_CSE_OUT CHARGE
FUNCTION 30 CHARGE 28 RELIEF PUMP HP_IN
M1
34 VALVE PUMP VALVE
36
7 36
5 S1 S1 11 13
HYDRO- M5
STATIC HYDROSTATIC HYDROSTATIC
1 OIL COOLER OIL
MOTOR
LEFT MOTOR BYPASS RESERVOIR
SHIFT 31 31 6 SOLENOID BYPASS
SOLENOID S2 S2 SOLENOID
PUMP 32 32 32 32 CSE_IN
M3 M4 DISPLACEMENT 33 33
CONTROL TO_CLR_BOT
27 BRAKE VALVE (PDCV) 39
PISTON HYDRAULIC
12
32 32 14 INTEGRATED
14 CIRCUIT (HIC)
OPEARTING VALVE
X1 X1 25
4 CHARGE
RELIEF X2 X2 HYDROSTATIC 7 8 9 10 11 T 12
VALVE OIL COOLER 8
3
M2 15 35 15 35
B REV PRESSURE 41
CONTROL HYDRAULIC
PILOT (PCP) 30
FAN PUMP 50 HYDRAULIC
2
FAN OIL FILTER
L2 45
30 44
47 48
A FWD
28 28 29
42 HYDRAULIC
M1 93 CHARGE OIL FAN MOTOR
53 37 29 L1 L1
HYDROSTATIC 94 LOW PRESSURE OIL
6
7 PUMP FRONT 47
HYDRO- (RIGHT TRACK) S S 96 HIGH PRESSURE OIL
STATIC M5
MOTOR 49
RIGHT 1 98 RETURN OIL
46 43 HYDRAULIC FAN
99 TRAPPED OIL REVERSING VALVE
M3 M4

27 BRAKE
PISTON 40
T214088
Hydrostatic System Schematic—Neutral (Park Brake On)
TE14778,000006C –19–06OCT05–1/2

TM2260 (07JAN06) 9026-15-12 750J, 850J Crawler

010706
PN=402
 Diagnostic Information

1—Motor Shift Solenoid 18—Hydrostatic Charge Oil 33—Pump Displacement 47—Hydraulic Fan Check
2—Ball Shuttle Valve Filter Control Valve (PDCV) Valve
3—Flushing Valve 19—Neutral Charge Relief 34—Left Forward (LF) 48—Hydraulic Fan Oil Filter
4—Operating Charge Pressure Valve Pressure Sensor Bypass Valve
Relief Valve 20—Hand Pump Park Brake 35—Pressure Control Pilot 49—Hydraulic Fan Oil Filter
5—Hydrostatic Motor Left Relief Valve (PCP) Valve Restriction Switch
6—Hydrostatic Motor Right 21—Hand Pump 36—Charge Pump 50—Hydraulic Fan Oil Filter
7—Motor Servo Piston 22—Hand Pump Selector Valve 37—Hydrostatic Pump Front 51—Hydrostatic Pump Case
8—Hydrostatic Oil 1 (Right Track) Pressure Sensor
Temperature Sensor 23—Hand Pump Selector Valve 38—Hydrostatic Pump Front 52—Hydrostatic Charge
9—Park Brake Solenoid 1 2 (Left Track) Pressure Sensor
10—Park Brake Solenoid 2 24—Hand Pump Cab Tilt Relief 39—Hydraulic Integrated 53—Right Forward (RF)
11—Hydrostatic Oil Cooler Valve Circuit (HIC) Valve Pressure Sensor
Bypass Solenoid 25—Hydrostatic Oil Cooler 40—Hydrostatic Reservoir 92—Quick Coupler
12—Hydrostatic Oil Cooler 26—Cab Tilt Cylinder 41—Hydraulic Fan Pump 93—Charge Oil
Bypass Valve 27—Brake Piston 42—Hydraulic Fan Motor 94—Low Pressure Oil
13—Hydrostatic Oil Reservoir 28—Multi-Function Valve 43—Hydraulic Fan Reversing 95—Not Used
Bypass Solenoid 29—Multi-Function Check Valve 96—High Pressure Oil
14—Hydrostatic Oil Reservoir Valve 44—Hydraulic Fan Reversing 97—Not Used
Bypass Valve 30—Multi-Function Relief Solenoid 98—Return Oil
16—Hydrostatic Charge Oil Valve 45—Hydraulic Fan Directional 99—Trapped Oil
Filter Bypass Valve 31—Pump Servo Piston Valve
17—Hydrostatic Charge Oil 32—Screen 46—Hydraulic Fan
Filter Restriction Switch Proportional Solenoid

TE14778,000006C –19–06OCT05–2/2
9026
15
13

TM2260 (07JAN06) 9026-15-13 750J, 850J Crawler

010706
PN=403
 Diagnostic Information

Hydrostatic System Diagram—Neutral (Park Brake On)

T204520 –UN–26JAN05

12 14
35
13

33

11 25
31
40

32
3

1 81

32
2

19
28 18
37

36

32

6
10 9

93
94
98 66 61

T204520

Hydrostatic System Diagram - Neutral (Park Brake On)

TE14778,0000079 –19–13JAN05–1/2

TM2260 (07JAN06) 9026-15-14 750J, 850J Crawler

010706
PN=404
 Diagnostic Information

1—Motor Shift Solenoid 12—Hydrostatic Oil Cooler 25—Hydrostatic Oil Cooler 40—Hydrostatic Reservoir
2—Ball Shuttle Valve Bypass Valve 28—Multi-Function Valve 61—To Hand Pump Circuit
3—Flushing Valve 13—Hydrostatic Oil Reservoir 31—Pump Servo Piston 66—Charge Pressure Line (HIC
4—Operating Charge Pressure Bypass Solenoid 32—Screen valve BRK port to final
Relief Valve 14—Hydrostatic Oil Reservoir 33—Pump Displacement drives)
6—Hydrostatic Motor Bypass Valve Control Valve (PDCV) 81—Motor Speed Sensor
9—Park Brake Solenoid 1 18—Hydrostatic Charge Oil 35—Pressure Control Pilot 93—Charge Oil
10—Park Brake Solenoid 2 Filter (PCP) Valve 94—Low Pressure Oil
11—Hydrostatic Oil Cooler 19—Neutral Charge Relief 36—Charge Pump 98—Return Oil
Bypass Solenoid Valve 37—Hydrostatic Pump

TE14778,0000079 –19–13JAN05–2/2

9026
15
15

TM2260 (07JAN06) 9026-15-15 750J, 850J Crawler

010706
PN=405
 Diagnostic Information

Hydrostatic System Diagram—Reverse (Slow Speed)

T206119 –UN–26JAN05

12 14
35
13

33

11 25

31
40

1
32
3

81
6
32 2

19
28 18 91
37

36

32

10 9

93
94
98 66 61

T206119

Hydrostatic System Diagram - Reverse (Slow Speed)

TE14778,000007A –19–13JAN05–1/2

TM2260 (07JAN06) 9026-15-16 750J, 850J Crawler

010706
PN=406
 Diagnostic Information

1—Motor Shift Solenoid 12—Hydrostatic Oil Cooler 25—Hydrostatic Oil Cooler 40—Hydrostatic Reservoir
2—Ball Shuttle Valve Bypass Valve 28—Multi-Function Valve 61—To Hand Pump Circuit
3—Flushing Valve 13—Hydrostatic Oil Reservoir 31—Pump Servo Piston 66—Charge Pressure Line (HIC
4—Operating Charge Pressure Bypass Solenoid 32—Screen valve BRK port to final
Relief Valve 14—Hydrostatic Oil Reservoir 33—Pump Displacement drives)
6—Hydrostatic Motor Bypass Valve Control Valve (PDCV) 81—Motor Speed Sensor
9—Park Brake Solenoid 1 18—Hydrostatic Charge Oil 35—Pressure Control Pilot 93—Charge Oil
10—Park Brake Solenoid 2 Filter (PCP) Valve 94—Low Pressure Oil
11—Hydrostatic Oil Cooler 19—Neutral Charge Relief 36—Charge Pump 98—Return Oil
Bypass Solenoid Valve 37—Hydrostatic Pump

TE14778,000007A –19–13JAN05–2/2

9026
15
17

TM2260 (07JAN06) 9026-15-17 750J, 850J Crawler

010706
PN=407
 Diagnostic Information

Hydrostatic System Diagram—Forward (Fast Speed)

T206120 –UN–26JAN05

12 14
35
13

33

11 25
31
40

1
32
3

81
6
32
2

19
18 91
28
37

36

32

10 9

93
94
98 66 61

T206120

Hydrostatic System Diagram - Forward (Fast Speed)

TE14778,000007B –19–13JAN05–1/2

TM2260 (07JAN06) 9026-15-18 750J, 850J Crawler

010706
PN=408
 Diagnostic Information

1—Motor Shift Solenoid 12—Hydrostatic Oil Cooler 25—Hydrostatic Oil Cooler 40—Hydrostatic Reservoir
2—Ball Shuttle Valve Bypass Valve 28—Multi-Function Valve 61—To Hand Pump Circuit
3—Flushing Valve 13—Hydrostatic Oil Reservoir 31—Pump Servo Piston 66—Charge Pressure Line (HIC
4—Operating Charge Pressure Bypass Solenoid 32—Screen valve BRK port to final
Relief Valve 14—Hydrostatic Oil Reservoir 33—Pump Displacement drives)
6—Hydrostatic Motor Bypass Valve Control Valve (PDCV) 81—Motor Speed Sensor
9—Park Brake Solenoid 1 18—Hydrostatic Charge Oil 35—Pressure Control Pilot 93—Charge Oil
10—Park Brake Solenoid 2 Filter (PCP) Valve 94—Low Pressure Oil
11—Hydrostatic Oil Cooler 19—Neutral Charge Relief 36—Charge Pump 98—Return Oil
Bypass Solenoid Valve 37—Hydrostatic Pump

TE14778,000007B –19–13JAN05–2/2

9026
15
19

TM2260 (07JAN06) 9026-15-19 750J, 850J Crawler

010706
PN=409
 Diagnostic Information

9026
15
20

TM2260 (07JAN06) 9026-15-20 750J, 850J Crawler

010706
PN=410
 Group 25
Tests
JT02156A Digital Pressure/Temperature
Analyzer Installation
SERVICE EQUIPMENT AND TOOLS
JT02156A Digital Pressure/Temperature Analyzer
JT02159 20 ft Cable with Couplers

–UN–25AUG95
JT02161 500 psi Transducer
JT02162 5000 psi Transducer
JT05969 Thermocoupler

T8543AI
312883 Carry Case
JT02160 10 000 psi Transducer (Optional, Order Separately)
JT07148-2 Flow Block
A—Digital Pressure/Temperature Analyzer
B—3400 kPa (35 bar) (500 psi) Transducer
Use the digital pressure/temperature analyzer (A), and —34 000 kPa (350 bar) (5000 psi) Transducer
transducers (B) in place of analog gauges and a separate —70 000 kPa (700 bar) (10 000 psi) Transducer
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.

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.
9026
25
1

MF82180,0000048 –19–28JAN05–1/1

JDG1770 Ultra Clean Hand Launcher

Use the Ultra Clean Hand Launcher Kit to help eliminate

contamination in hydraulic systems. All newly installed
hose and tube assemblies should be cleaned using this
tool.

Ultra Clean is a trademark of Ultra Clean Technologies Corp. MF82180,0000045 –19–28JAN05–1/1

TM2260 (07JAN06) 9026-25-1 750J, 850J Crawler

010706
PN=411
 Tests

Transmission Oil Warm-Up Procedure

SPECIFICATIONS SERVICE EQUIPMENT AND TOOLS

Speed-In-Grip (SIG) Position 3.0 D01182AA 20-Ton Floor Stand
Fast Idle Speed 2255—2285 rpm JDG10013 750J/850J Floor Stand Kit
Transmission Oil Temperature 57—66°C
135—150°F Follow this procedure to heat hydrostatic oil to a
specified temperature.

Continued on next page TE14778,000005B –19–19AUG05–1/4

9026
25
2

TM2260 (07JAN06) 9026-25-2 750J, 850J Crawler

010706
PN=412
 Tests

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks must be clear of tools and
objects before rotating.

1. Raise machine off the ground and support with 20-Ton

Floor Stands. Lower blade to ground. Tracks must be
free to rotate in either direction.

–UN–04DEC04
2. Start engine.

3. Set hydrostatic transmission Speed-In-Grip (SIG) to

specification.

T205099A
Specification
Speed-In-Grip (SIG)—Position .............................................................. 3.0
750J/850J Floor Stand Kit

NOTE: The TEST setting is located in the service menu. 1—20-Ton Floor Stand (4 used)
To enter the service menu, press the MENU 2—Floor Stand Adapter (2 used)
button and hold it down for 5 seconds. 3—Floor Stand Rod
4—Washer (2 used)
5—Cap Screw (2 used)
4. Set brake control setting to TEST.

a. Access Service Menu on monitor.

b. Select TCU Diagnostics. 9026

25
c. Select Settings. 3

d. Select Brake Ctrl.

e. Select Test.

NOTE: Do not leave machine in brake Test setting during

normal operation.

5. Set monitor display setting to Transmission

Temperature.

a. Access Menu on monitor.

b. Select Diagnostics.

c. Select Live Values.

d. Select Temperatures.

Continued on next page TE14778,000005B –19–19AUG05–2/4

TM2260 (07JAN06) 9026-25-3 750J, 850J Crawler

010706
PN=413
 Tests

e. Select Transmission.

6. Set engine speed to specification.

Specification
Fast Idle—Speed ............................................................. 2255—2285 rpm

7. Set Decelerator Mode Switch to transmission mode.

8. Heating oil:

a. Push decel pedal to floor.

b. Put park lock lever in UP position.

c. Put Transmission Control Lever (TCL) in forward.

d. Slowly release decel pedal.

e. Heat oil for 15 seconds while reading transmission

temperature on monitor.

f. Push decel pedal to floor.

9. Set hydrostatic transmission Speed-In-Grip (SIG) to

specification.
9026
25 Specification
4 Speed-In-Grip (SIG)—Position .............................................................. 1.4

10. Circulating oil:

a. Push decel pedal to floor.

b. Put park lock lever in DOWN position.

c. Put TCL in forward.

d. Release decel and cycle TCL in forward and

reverse for a total of 15 seconds.

e. Push decel pedal to floor.

11. Alternate heating and circulating cycles until

transmission oil temperature reaches specification.

Continued on next page TE14778,000005B –19–19AUG05–3/4

TM2260 (07JAN06) 9026-25-4 750J, 850J Crawler

010706
PN=414
 Tests

Specification
Transmission Oil—Temperature.................................................. 57—66°C
135—150°F

12. Turn machine OFF to reset brake to normal setting.

TE14778,000005B –19–19AUG05–4/4

Releasing Park Brake to Tow the Machine

This procedure is used to release park brake for towing

the machine.

Continued on next page TE14778,0000067 –19–06OCT05–1/4

9026
25
5

TM2260 (07JAN06) 9026-25-5 750J, 850J Crawler

010706
PN=415
 Tests

IMPORTANT: DO NOT tow machine faster than 2.4

km/h (1.5 mph) or extensive machine
damage may result.

NOTE: Multi-function valves can be turned out using a 1

1/4 in. socket and a flexible head ratchet. Engine
does not have to be running to tow machine.

NOTE: The top multi-function valves are in the forward

side of the closed loop circuit and must be
loosened to tow the machine in reverse. Likewise,
the bottom multi-function valves are in the reverse
side of the closed loop circuit and must be
loosened to tow the machine in forward.

Towing Machine With Engine OFF

1. Tilt cab or ROPS up. See Cab or ROPS Tilting

Procedure. (Operators Manual.)

–UN–26AUG02
2. TO TOW MACHINE FORWARD both front and rear
pump bottom multi-function relief valves MUST be
turned out (counterclockwise) 1/2 to 1 turn and blade
must be raised off the ground. (If engine will crank but

T158857B
will not start, blade can be raised by cranking engine
while holding blade raise function on control valve.)
9026 Multi-function Valves
25 TO TOW MACHINE IN REVERSE both front and rear
6 pump top multi-function valves MUST be turned out 1—Multi-function Valve
(counterclockwise) 1/2 to 1 turn.

3. Tilt cab down.

4. Turn key switch ON.

5. Put park lock lever in DOWN position and transmission

control lever (TCL) in NEUTRAL.

NOTE: TOW will allow the machine to be towed without

automatically applying the brakes (hill hold
disabled).

The TOW setting is located in the service menu.

To enter the service menu, press the MENU
button and hold it down for 5 seconds.

6. Set brake control setting to Tow.

Continued on next page TE14778,0000067 –19–06OCT05–2/4

TM2260 (07JAN06) 9026-25-6 750J, 850J Crawler

010706
PN=416
 Tests

a. Access Service Menu on monitor.

b. Select TCU Diagnostics.

c. Select Settings.

d. Select Brake Ctrl Set.

e. Select Tow.

7. Display brake pressure on monitor.

a. Select Diagnostics.

b. Select Live Values.

c. Select Pressures.

d. Select Brake Pressure.

8. Pull and turn the RED knob on HIC valve to the

extended [out] (tow) position.

9. Use pump handle and apply pressure to release

brakes.

NOTE: There’s a relief valve for the park brake in the HIC
9026
valve. You will hear oil flow through relief and feel 25
increased pressure on handle when brakes are 7
totally released.

10. Verify that the brake pressure is above specification.

Specification
Brake Release Pressure—
Pressure ...................................................................................... 2070 kPa
21 bar
300 psi

NOTE: Brake pressure does not exceed specification,

refer to Park Brake Relief Valve Test.

11. Tow machine.

Towing Machine With Engine ON

1. Tilt cab up. See Cab or ROPS Tilting Procedure.

(Operators Manual.)

Continued on next page TE14778,0000067 –19–06OCT05–3/4

TM2260 (07JAN06) 9026-25-7 750J, 850J Crawler

010706
PN=417
 Tests

2. TO TOW MACHINE FORWARD both front and rear

pump bottom multi-function relief valves MUST be
turned out (counterclockwise) 1/2 to 1 turn and blade
must be raised off the ground. (If engine will crank but
will not start, blade can be raised by cranking engine
while holding blade raise function on control valve.)

TO TOW MACHINE IN REVERSE both front and rear

pump top multi-function valves MUST be turned out
(counterclockwise) 1/2 to 1 turn.

3. Tilt cab down.

4. Start engine.

5. Put park lock lever in DOWN position and transmission

control lever (TCL) in NEUTRAL.

6. Tow machine.

TE14778,0000067 –19–06OCT05–4/4
9026
25
8
Hydrostatic Pump and Motor Initial Start-Up
Procedure
SPECIFICATIONS
Transmission Charge Pressure 345 kPa
3.45 bar
50 psi

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit

This procedure is used to bleed air from the hydrostatic

circuit after a major component repair.

Continued on next page TE14778,0000031 –19–06OCT05–1/2

TM2260 (07JAN06) 9026-25-8 750J, 850J Crawler

010706
PN=418
 Tests

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks MUST be clear of tools and
objects before rotating.

1. Raise machine off the ground and support with 20-Ton

Floor Stands. Lower blade to ground. Tracks MUST be
free to rotate in either direction.

–UN–04DEC04
2. Fill reservoir with specified oil. See Check
Transmission Oil Level. (Operators Manual.) Leave
reservoir cap OFF.

T205099A
3. Disconnect engine harness from crankshaft position
sensor.
750J/850J Floor Stand Kit
4. Set monitor display to CHARGE.
1—20-Ton Floor Stand (4 used)
2—Floor Stand Adapter (2 used)
IMPORTANT: Never operate starting motor more than
3—Floor Stand Rod
30 seconds. Allow at least 2 minutes for 4—Washer (2 used)
cooling and battery recovery before 5—Cap Screw (2 used)
operating again. Overheating, caused
by excessive operation, will seriously
damage starting motor.

5. Crank engine in 30 second intervals until transmission 9026

charge pressure reaches specification. 25
9
Specification
Transmission Charge—Pressure .................................................. 345 kPa
3.45 bar
50 psi

6. Reconnect engine harness onto crankshaft position

sensor.

7. Start engine and leave at low idle for one minute.

Operate machine at low speed in forward and reverse
cycles through counter-rotate for several minutes. This
will flush the displacement control valve areas.

8. Recheck reservoir oil level and install cap.

TE14778,0000031 –19–06OCT05–2/2

TM2260 (07JAN06) 9026-25-9 750J, 850J Crawler

010706
PN=419
 Tests

Hydrostatic Pump Flushing Procedure

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit
38H1004 90° Fitting (2 used)
38H1160 Fitting (4 used)
Parker 1JS43-6-6 Fitting 9/16 ORB (4 used)
Parker #601-6 Hose 2134 mm (7 ft) (4 used)

This procedure is used whenever major repair has been

done to the hydrostatic circuit.

TE14778,0000088 –19–26JAN05–1/3

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks MUST be clear of tools and
objects before rotating.
9026
25
10 1. Raise machine off the ground and support with 20-Ton
Floor Stands. Lower blade to ground. Tracks MUST be
free to rotate in either direction.

–UN–04DEC04
1—20-Ton Floor Stand (4 used)
2—Floor Stand Adapter (2 used)
3—Floor Stand Rod
4—Washer (2 used)

T205099A
5—Cap Screw (2 used)

750J/850J Floor Stand Kit

Continued on next page TE14778,0000088 –19–26JAN05–2/3

TM2260 (07JAN06) 9026-25-10 750J, 850J Crawler

010706
PN=420
 Tests

NOTE: Test ports (1) MUST be closed to shift

displacement control valve and allow flow from
servos (2).

2. Install test hoses and fittings into ports (1) on both

pump displacement control valves. Route opposite end

–UN–16DEC04
of hoses back to reservoir.

3. Start engine. Leave engine speed at slow idle.

T206311A
CAUTION: Tracks will rotate when FNR is
moved to forward or reverse. Hydrostatic Pump Test Ports

NOTE: Operate machine in 20 second intervals allowing 1—Pump Displacement Control Valve (PDCV) Test
sufficient time for cooling. Ports
2—Pump Servo Test Port Ports
3—Pump Pressure Control Pilot (PCP) Connector
4. Put transmission speed control to midrange. Cycle
Transmission Control Lever (TCL) from forward left
counter rotate through right counter rotate positions.
This will flush the displacement control valve areas.

Continue cycling machine at slow idle for several

minutes. Increase engine speed to 1500 rpm and
continue cycling TCL to actuate transmission pumps
for approximately 10 minutes.

5. Repeat procedure using servo test ports (2). 9026

25
11

TE14778,0000088 –19–26JAN05–3/3

Hydraulic Oil Cleanup Procedure

A hydraulic oil cleanup procedure must be done prior to

starting machine after a component has been repaired or
replaced. The use of attachments increases the need to
monitor and filter oil to a safe contamination level. See
750J and 850J Crawler Dozer General Oil Cleanup
Procedure. (CTM310—Super Caddy Oil Cleanup
Procedure.)

MF82180,0000046 –19–28JAN05–1/1

TM2260 (07JAN06) 9026-25-11 750J, 850J Crawler

010706
PN=421
 Tests

Pressure Control Pilot (PCP) Manual

Override Test
SPECIFICATIONS
Slow Idle Speed 880—910 rpm

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit

This procedure will help isolate between electrical and

hydraulic problems. Moving the manual override lever
produces a hydraulic differential pressure signal to the
pump displacement control valve (PDCV). If operation is
normal, pressure will be produced in the closed loop and
tracks will rotate.

Continued on next page TE14778,0000077 –19–12AUG05–1/3

9026
25
12

TM2260 (07JAN06) 9026-25-12 750J, 850J Crawler

010706
PN=422
 Tests

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks MUST be clear of tools and
objects before rotating.

1. Raise machine off the ground and support with 20-Ton

Floor Stands. Lower blade to ground. Tracks MUST be
free to rotate in either direction.

–UN–04DEC04
2. Tilt cab or ROPS to midway position. Install operator’s
station tilt cylinder lock. See Cab or ROPS Tilting
Procedure. (Operators Manual.)

T205099A
3. Start engine and run at slow idle. Access Motor Speed
Check SERVICE ADVISOR system template.
750J/850J Floor Stand Kit
Specification
Slow Idle—Speed ................................................................ 880—910 rpm 1—20-Ton Floor Stand (4 used)
2—Floor Stand Adapter (2 used)
NOTE: In order to allow manual override in neutral, the 3—Floor Stand Rod
4—Washer (2 used)
brake rate setting must be set to TEST. In Normal
5—Cap Screw (2 used)
mode the brakes will engage after three seconds.

NOTE: The TEST setting is located in the service menu.

To enter the service menu, press the MENU
button and hold it down for 5 seconds. 9026
25
4. Set brake rate setting to TEST. 13

a. Access Service Menu on monitor.

b. Select TCU Diagnostics.

c. Select Settings.

d. Select Brake Ctrl.

e. Select Test.

NOTE: Do not leave machine in brake Test setting during

normal operation.

5. Put park lock lever in DOWN position.

Continued on next page TE14778,0000077 –19–12AUG05–2/3

TM2260 (07JAN06) 9026-25-13 750J, 850J Crawler

010706
PN=423
 Tests

CAUTION: Tracks will rotate when PCP manual

override lever is moved.

6. Momentarily move the PCP manual override lever (1)

in each direction. The tracks will rotate as the lever is
moved in each direction. This indicates normal

–UN–10MAR95
hydraulic operation in the closed-loop system.

7. Set brake rate setting to Normal.

T8437AI
1—Pump PCP Manual Override Lever

TE14778,0000077 –19–12AUG05–3/3

Pressure Control Pilot (PCP) Test

SPECIFICATIONS
Transmission Oil Temperature 57—66°C
135—150°F
9026 Neutral PCP Differential Pressure 34 kPa
25 0.34 bar
14 0—5 psi
Fast Idle Speed 2255—2285 rpm
Transmission Speed-In-Grip (SIG) 1.0
Position
Input Current-to-Control Pressure 1 mA/6.89 kPa
1 mA/0.069 bar
1 mA/1 psi

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit
XPD361 Quick Coupler (9/16-20UN M ORB) (2 used)
JT03448 Test Hose (2 used)
JT05753 Hydrostatic Test Switch Box
JT02156A Digital Pressure/Temperature Analyzer
JT02161 350 kPa (35 bar) (500 PSI) Transducer

This procedure will test pump PCP’s in neutral and also in

operational mode.

Continued on next page TE14778,0000065 –19–12AUG05–1/5

TM2260 (07JAN06) 9026-25-14 750J, 850J Crawler

010706
PN=424
 Tests

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks MUST be clear of tools and
objects before rotating.

1. Raise machine off the ground and support with 20-Ton

Floor Stands. Lower blade to ground. Tracks MUST be
free to rotate in either direction.

–UN–04DEC04
2. Tilt cab or ROPS up. See Cab or ROPS Tilting
Procedure. (Operators Manual.)

1—20-Ton Floor Stand (4 used)

T205099A
2—Floor Stand Adapter (2 used)
3—Floor Stand Rod
4—Washer (2 used) 750J/850J Floor Stand Kit
5—Cap Screw (2 used)

Continued on next page TE14778,0000065 –19–12AUG05–2/5

9026
25
15

TM2260 (07JAN06) 9026-25-15 750J, 850J Crawler

010706
PN=425
 Tests

3. Install fittings and test hoses in ports (1).

NOTE: A switching valve and gauge or some type of

differential pressure gauge or reader must be
used to obtain an accurate differential pressure
reading. Two separate pressure gauges cannot be

–UN–16DEC04
used.

4. Connect switching valve, digital pressure/temperature

analyzer and transducer or a gauge.

T206311A
5. Lower cab or ROPS to normal operating position.
Hydrostatic Pump Test Ports
6. Start engine and heat hydrostatic oil to specified
1—Pump Displacement Control Valve (PDCV) Test
temperature. See Transmission Oil Warm-Up Ports
Procedure. (Group 9026-25.) 2—Pump Servo Test Port Ports
3—Pump Pressure Control Pilot (PCP) Connector
Specification
Transmission Oil—Temperature.................................................. 57—66°C
135—150°F

7. Check neutral PCP differential pressure.

Specification
Neutral PCP Differential—
Pressure .......................................................................................... 34 kPa
0.34 bar
0—5 psi
9026
25
If neutral PCP differential pressure is greater than
16
specification but less than 103 kPa (1.03 bar) (15 psi),
PCP must be adjusted. See Pressure Control Pilot (PCP)
Internal Adjustment. (9026-25.)

If differential pressure is over 103 kPa (1.03 bar) (15 psi),

PCP must be replaced

8. Set transmission Speed-In-Grip (SIG) to specification.

Specification
Transmission Speed-In-Grip
(SIG)—Position ...................................................................................... 1.0

NOTE: Output currents are located in the service menu.

To enter the service menu, press the MENU
button and hold it down for 5 seconds.

9. Access the Output Info menu.

a. Access Service Menu on monitor.

Continued on next page TE14778,0000065 –19–12AUG05–3/5

TM2260 (07JAN06) 9026-25-16 750J, 850J Crawler

010706
PN=426
 Tests

b. Select Diagnostics.

c. Select Live Values.

d. Select Output Info.

10. Set Decelerator Mode Switch to transmission mode.

11. Record Left Pump PCP and Right Pump PCP mA

values.

12. Depress decelerator pedal to floor.

13. Set engine speed control to specification.

Specification
Fast Idle—Speed ............................................................. 2255—2285 rpm

CAUTION: Tracks will rotate when Transmission

Control Lever (TCL) is moved to forward or
reverse.

14. Move Transmission Control Lever (TCL) to forward.

Slowly release decelerator pedal. Carefully monitor
the mA as the decelerator is released. The reading
will suddenly go from 0 to some low reading (e.g.,
15.9 mA). This is the threshold or initial reading. 9026
25
15. With the decelerator fully released, slowly increase 17
SIG to maximum speed position to continue
increasing the mA.

16. Record the milliamp and differential readings as

follows:

Control Milliamp Control Pressure 1 Control Pressure 2 Differential

Forward Reverse Forward Reverse Forward Reverse
Neutral Reading 0
Initial Reading
35
50
75
Maximum Reading

17. Repeat the procedure for reverse.

18. Analyze test results as follows:

Continued on next page TE14778,0000065 –19–12AUG05–4/5

TM2260 (07JAN06) 9026-25-17 750J, 850J Crawler

010706
PN=427
 Tests

The initial reading when coming out of neutral is the

threshold of movement value (point tracks begin to
move). The relationship between control milliamps
and differential control pressure is approximately 7
kPa (0.07 bar) (1 psi) differential OUT of the Pressure
Control Pilot (PCP) for each milliamp IN. The
operation of the PCP can be considered acceptable if
pressure reading is reasonably close to the theoretical
value and linear to the milliamp values.

Specification
Input Current-to-Control—
Pressure ............................................................................. 1 mA/6.89 kPa
1 mA/0.069 bar
1 mA/1 psi

TE14778,0000065 –19–12AUG05–5/5

Pressure Control Pilot (PCP) Internal

Adjustment
SPECIFICATIONS
Transmission Oil Temperature 57—66°C
9026 135—150°F
25
Differential Pressure 34.5 kPa
18
0.34 bar
0—5 psi

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit
XPD361 Quick Coupler (9/16-20UN M ORB) (2 used)
JT03448 Test Hose (2 used)
JT05753 Hydrostatic Test Switch Box
JT02156A Digital Pressure/Temperature Analyzer
JT02161 350 kPa (35 bar) (500 PSI) Transducer
3/32 Hex Key Wrench

The purpose of this test is to adjust the internal flapper

valve in the pressure control pilot (PCP).

Continued on next page TE14778,0000064 –19–06OCT05–1/4

TM2260 (07JAN06) 9026-25-18 750J, 850J Crawler

010706
PN=428
 Tests

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks MUST be clear of tools and
objects before rotating.

1. Raise machine off the ground and support with 20-Ton

Floor Stands. Lower blade to ground. Tracks MUST be
free to rotate in either direction.

–UN–04DEC04
2. Tilt cab or ROPS up. See Cab or ROPS Tilting
Procedure. (Operators Manual.)

1—20-Ton Floor Stand (4 used)

T205099A
2—Floor Stand Adapter (2 used)
3—Floor Stand Rod
4—Washer (2 used) 750J/850J Floor Stand Kit
5—Cap Screw (2 used)

Continued on next page TE14778,0000064 –19–06OCT05–2/4

9026
25
19

TM2260 (07JAN06) 9026-25-19 750J, 850J Crawler

010706
PN=429
 Tests

3. Thoroughly clean area around PCP and pump

displacement control valve (PDCV) test ports.

4. Install fittings and test hoses in ports (1).

NOTE: A switching valve and gauge or some type of

–UN–16DEC04
differential pressure gauge or reader must be
used to obtain an accurate differential pressure
reading. Two separate pressure gauges cannot be
used.

T206311A
5. Connect switching valve, digital pressure/temperature
analyzer and transducer or a gauge. Hydrostatic Pump Test Ports

1—Pump Displacement Control Valve (PDCV) Test

6. Return cab or ROPS to operating position. Ports
2—Pump Servo Test Port Ports
7. Start engine and heat hydrostatic oil to normal 3—Pump Pressure Control Pilot (PCP) Connector
operating temperature. See Transmission Oil Warm-Up
Procedure. (Group 9026-25.)

Specification
Transmission Oil—Temperature.................................................. 57—66°C
135—150°F

8. Disconnect PCP wire connector (3).

9. With park lock lever in UP position, record differential

9026 pressure.
25
20
10. Differential pressure meets spec, do not complete
steps 11,12,13,16.

Continued on next page TE14778,0000064 –19–06OCT05–3/4

TM2260 (07JAN06) 9026-25-20 750J, 850J Crawler

010706
PN=430
 Tests

IMPORTANT: The coil and flapper valve area of the

PCP MUST be kept clean for proper
operation. Always use clean wrenches
and keep entire area clear of any dirt.

NOTE: Some silicone oil will leak from port when screw is

–UN–20NOV98
removed.

11. Remove slotted screw (4) with O-ring on side of PCP.

T118613A
12. Adjust internal allen screw as necessary to get
differential pressure to specification.

Specification 4—Slotted Screw

Differential—Pressure................................................................... 34.5 kPa
0.34 bar
0—5 psi

IMPORTANT: DO NOT overtighten PCP screw (4).

13. Install screw (4) by hand until O-ring contacts

housing. Turn screw an additional 1/8 turn.

14. Remove test equipment and connect wire lead to

PCP.

15. Route all wiring harnesses back to their original

location and replace all tie bands that were removed. 9026
25
16. Calibrate machine. See Transmission Control Unit 21
(TCU) Calibration. (Group 9015-20.)

TE14778,0000064 –19–06OCT05–4/4

TM2260 (07JAN06) 9026-25-21 750J, 850J Crawler

010706
PN=431
 Tests

Multi-Function Relief Valve Test

SPECIFICATIONS
Transmission Oil Temperature 57—66°C
135—150°F
Fast Idle Speed 2255—2285 rpm
Transmission Speed-In-Grip (SIG) 1.0
Position
Multi-Function Relief Valve 44 128—46 884 kPa
Pressure 441—468 bar
6400—6800 psi
Lock Nut Torque 16.3 N•m
144 lb-in.

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit

Continued on next page TE14778,000005C –19–24AUG05–1/5

9026
25
22

TM2260 (07JAN06) 9026-25-22 750J, 850J Crawler

010706
PN=432
 Tests

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

–UN–15DEC04
CAUTION: Pressure spikes in the transmission
closed loop can approach 68 950 kPa (690 bar)
(10 000 psi). Use hoses and fittings rated for

T206277A
these pressures when checking transmission
system pressures.
Closed Loop Test Ports
IMPORTANT: Carefully monitor transmission
1—Left Forward (LF)
temperature during this test. 2—Left Reverse (LR)
Temperature will rise very quickly when 3—Right Reverse (RR)
operating in an over-relief condition. Do 4—Right Forward (RF)
not exceed 71°C (160°F).

1. If testing reverse relief settings, transducers will need

to be moved to test ports (2 and 3). Each test port
senses closed-loop pressure.

2. Start engine and heat oil to specification. See

Transmission Oil Warm-Up Procedure. (Group
9026-25.)
9026
Specification
25
Transmission Oil—Temperature.................................................. 57—66°C
23
135—150°F

NOTE: The TEST setting is located in the service menu.

To enter the service menu, press the MENU
button and hold it down for 5 seconds.

3. Set brake rate setting to TEST.

a. Access Service Menu on monitor.

b. Select TCU Diagnostics.

c. Select Settings.

d. Select Brake Ctrl.

e. Select Test.

Continued on next page TE14778,000005C –19–24AUG05–2/5

TM2260 (07JAN06) 9026-25-23 750J, 850J Crawler

010706
PN=433
 Tests

NOTE: Do not leave machine in brake Test setting during

normal operation.

4. Set Decelerator Mode Switch to transmission mode.

5. Depress decel pedal to floor and set engine speed to

specification.

Specification
Fast Idle—Speed ............................................................. 2255—2285 rpm

6. With park lock lever in UP (locked) position, set

transmission Speed-In-Grip (SIG) to specification.

Specification
Transmission Speed-In-Grip
(SIG)—Position ...................................................................................... 1.0

NOTE: Output currents and pressures are located in the

service menu. To enter the service menu, press
the MENU button and hold it down for 5 seconds.

7. Access the Efficiency and Relief menu.

a. Access Service Menu on monitor.

b. Select TCU Diagnostics.

9026
25 c. Select Procedures.
24

Continued on next page TE14778,000005C –19–24AUG05–3/5

TM2260 (07JAN06) 9026-25-24 750J, 850J Crawler

010706
PN=434
 Tests

NOTE: If high pressure reading is erratic (very unstable),

rotate tracks slightly to reposition motor speed
ring and sensor. Repeat test. If pressures remain
erratic, turn tracker (Trkr) off in TCU and perform
test. Service codes will be recorded when motor
speed sensor is disconnected and MUST be
cleared when completed.

8. Put Transmission Control Lever (TCL) in forward and

hold steering lever to stop track on opposite side.
System pressure should rise as the engine speed is
slowly increased and then levels out. The point at
which the pressure levels out is the relief valve setting.
In order to obtain an accurate gauge reading, it is
important not to flood the relief valve with excessive oil
flow. Therefore, do not continue increasing engine
speed after pressure levels out. If the relief setting
cannot be reached at fast idle, then slowly increase
transmission speed until pressure levels out.

Specification
Multi-Function Relief Valve—
Pressure .................................................................... 44 128—46 884 kPa
441—468 bar
6400—6800 psi

9. Repeat this procedure in reverse and record the relief

setting. 9026
25
25

Continued on next page TE14778,000005C –19–24AUG05–4/5

TM2260 (07JAN06) 9026-25-25 750J, 850J Crawler

010706
PN=435
 Tests

NOTE: The top multi-function valve on each pump senses

pressure in forward and the bottom valve in
reverse.

10. If multi-function valve settings are not to specification,

adjust by loosening the outer lock nut (1) and turning
the allen screw in to increase pressure or out to
decrease pressure (1/2 turn equals approximately
7000 kPa, 70 bar, 1000 psi). Tighten lock nut to
specification.

Specification
Lock Nut—Torque ....................................................................... 16.3 N•m
144 lb-in.

1—Outer Lock Nut

–UN–26AUG02
T158857B
TE14778,000005C –19–24AUG05–5/5
9026
25
26

TM2260 (07JAN06) 9026-25-26 750J, 850J Crawler

010706
PN=436
 Tests

Transmission Efficiency Test

SPECIFICATIONS
Transmission Oil Temperature 57—66°C
135—150°F
Transmission Speed-In-Grip (SIG) 1.0
Position
Fast Idle Speed 2255—2285 rpm
Amperage 0—15 mA above Good
threshold
Amperage 15—20 mA above Marginal
threshold
Amperage Over 20 mA above Bad
threshold

The purpose of this test is to determine the amount of

transmission internal leakage in the closed-loop
components. This is accomplished by determining the
amount of oil the transmission pump must deliver to
maintain a specified system pressure in the closed loop.
This pressure is below the relief valve setting. Therefore,
the amount of pump flow indicates the amount of internal
leakage in the closed loop. The transmission controller
sends a current signal to the Pressure Control Pilot (PCP)
on each pump. The PCP produces a hydraulic pressure
differential to the servo piston relative to the amount of
current. By monitoring the current signal being sent to the 9026
PCP, the amount of leakage in the closed loop can be 25
determined. A small current signal to maintain system 27
pressure means there is very little leakage. A large
current signal reading means higher internal leakage.

Continued on next page TE14778,000005F –19–07OCT05–1/5

TM2260 (07JAN06) 9026-25-27 750J, 850J Crawler

010706
PN=437
 Tests

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

–UN–15DEC04
CAUTION: Pressure spikes in the transmission
closed loop can approach 68 950 kPa (690 bar)
(10 000 psi). Use hoses and fittings rated for

T206277A
these pressures when checking transmission
system pressures.
Closed Loop Test Ports
IMPORTANT: Carefully monitor transmission
1—Left Forward (LF)
temperature during this test. 2—Left Reverse (LR)
Temperature will rise very quickly when 3—Right Reverse (RR)
operating in an over-relief condition. Do 4—Right Forward (RF)
not exceed 71°C (160°F).

1. Move transducers to test ports (1 and 4) to check the

relief settings in forward. Use test ports (2 and 3) to
check the relief settings in reverse. Each test port
senses closed-loop pressure.

2. Start engine and heat transmission oil to specification.

See Transmission Oil Warm-Up Procedure. (Group
9026-25.)
9026
25
28 Specification
Transmission Oil—Temperature.................................................. 57—66°C
135—150°F

3. With park lock lever in UP position, set transmission

Speed-In-Grip (SIG) to specification.

Specification
Transmission Speed-In-Grip
(SIG)—Position ...................................................................................... 1.0

NOTE: The TEST setting is located in the service menu.

To enter the service menu, press the MENU
button and hold it down for 5 seconds.

4. Set brake rate setting to TEST.

a. Access Service Menu on monitor.

b. Select TCU Diagnostics.

Continued on next page TE14778,000005F –19–07OCT05–2/5

TM2260 (07JAN06) 9026-25-28 750J, 850J Crawler

010706
PN=438
 Tests

c. Select Settings.

d. Select Brake Ctrl Set.

e. Select Test.

NOTE: Do not leave machine in brake Test setting during

normal operation.

NOTE: Output currents and pressures are located in the

service menu. To enter the service menu, press
the MENU button and hold it down for 5 seconds.

5. Access the Efficiency and Relief menu.

a. Access Service Menu on monitor.

b. Select TCU Diagnostics.

c. Select Procedures.

6. Set Decelerator Mode Switch to transmission mode.

7. Fully depress decelerator pedal, park lock lever in up

position.

8. Set engine speed to specification.

9026
25
Specification 29
Fast Idle—Speed ............................................................. 2255—2285 rpm

9. Move Transmission Control Lever (TCL) to forward and

hold steering lever to stop track on opposite side.
System pressure will increase rapidly to maximum
value. this value must be at minimum specification. If
not Perform Multi-Function Relief Valve Test (Group
9026-25)

Specification
Multi-Function Relief Valve—
Pressure .................................................................... 44 128—46 884 kPa
441—468 bar
6400—6800 psi

Continued on next page TE14778,000005F –19–07OCT05–3/5

TM2260 (07JAN06) 9026-25-29 750J, 850J Crawler

010706
PN=439
 Tests

NOTE: If high pressure reading is erratic (very unstable),

rotate tracks slightly to reposition motor speed
ring and sensor. If pressures remain erratic, turn
tracker (Trkr) off in TCU and perform test.

10. SLOWLY release the decelerator pedal until SYS PSI

reads 6895 kPa (68.9 bar) (1000 psi). Record Pump
mA.

11. Continue releasing decelerator pedal until SYS PSI

reads 34 474 kPa (345 bar) (5000 psi). Record Pump
mA.

12. Move Transmission Control Lever (TCL) to neutral.

Return engine speed to slow idle.

13. Subtract mA reading at 1000 psi from mA reading at

5000 psi. Refer to interpretation chart to determine
closed-loop condition.

Specification
Amperage—0—11 mA above
1000 psi reading ................................................................................ Good
Amperage—11—16 mA above
1000 psi reading ........................................................................... Marginal
Amperage—Over 16 mA above
1000 psi reading ................................................................................... Bad

9026
14. Repeat procedure for other track in forward.
25
30
15. Move transducers to Left Reverse (LR ) test port (2)
and Right Reverse (RR) test port (3) to check reverse
efficiency settings.

16. If any of the four readings are not within spec,

continue to step 17.

NOTE: The hydrostatic pump does not have test ports to

record closed loop pressure. By setting mA the
same as first part of test, we can now monitor
engine rpm to isolate if leakage is in pump or
motor.

17. Remove the high pressure hoses from pump. Cap

and plug open lines and ports.

18. Run test as before and set to the same mA reading at

5000 psi on monitor. Record engine RPM.

Continued on next page TE14778,000005F –19–07OCT05–4/5

TM2260 (07JAN06) 9026-25-30 750J, 850J Crawler

010706
PN=440
 Tests

If engine RPM decreases, internal leakage is

indicated in the motor. If engine RPM stays the same,
leakage is indicated in the pump.

19. Change test connections and repeat test procedure

for opposite side.

TE14778,000005F –19–07OCT05–5/5

Neutral Charge Relief and Operating Charge

Relief Pressure Test
SPECIFICATIONS
Transmission Oil Temperature 57—66°C
135—150°F
Engine Speed 1780—1820 rpm
Neutral Delta
750J Pressure 2482—2620 kPa
24.8—26.2 bar
360—380 psi
850J Pressure 2689—2827 kPa
26.9—28.3 bar 9026
390—410 psi 25
31
Minimum Operating Delta
750J Pressure 2275 kPa
22.8 bar
330 psi
850J Pressure 2482 kPa
24.8 bar
360 psi

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit

Continued on next page TE14778,000003B –19–06OCT05–1/5

TM2260 (07JAN06) 9026-25-31 750J, 850J Crawler

010706
PN=441
 Tests

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks MUST be clear of tools and
objects before rotating.

1. Raise machine off the ground and support with floor

stands. Lower blade to ground. Tracks MUST be free
to rotate in either direction.

–UN–04DEC04
1—20-Ton Floor Stand (4 used)
2—Floor Stand Adapter (2 used)
3—Floor Stand Rod
4—Washer (2 used)

T205099A
5—Cap Screw (2 used)

Continued on next page TE14778,000003B –19–06OCT05–2/5

9026
25
32

TM2260 (07JAN06) 9026-25-32 750J, 850J Crawler

010706
PN=442
 Tests

51

10 52

16 8 24
13
20 39

12

17

19

53

–UN–21SEP05
9 21
2 14 11
18 22

T214791
23
T214791
9026
Hydraulic Integrated Circuit (HIC) Valve
25
33
2—Ball Shuttle Valve 14—Hydrostatic Oil Reservoir 20—Hand Pump Park Brake 39—Hydraulic Integrated
8—Hydrostatic Oil Bypass Valve Relief Valve Circuit (HIC) Valve
Temperature Sensor 16—Hydrostatic Charge Oil 21—Hand Pump 51—Park Brake Pressure
9—Park Brake Solenoid 1 Filter Bypass Valve 22—Hand Pump Selector Valve Sensor
10—Park Brake Solenoid 2 17—Hydrostatic Charge Oil 1 52—Hydrostatic Charge
11—Hydrostatic Oil Cooler Filter Restriction Switch 23—Hand Pump Selector Valve Pressure Sensor
Bypass Solenoid 18—Hydrostatic Charge Oil 2 53—Port 4
12—Hydrostatic Oil Cooler Filter 24—Hand Pump Cab Tilt Relief
Bypass Valve 19—Neutral Charge Relief Valve
13—Hydrostatic Oil Reservoir Valve
Bypass Solenoid

2. Disconnect brake pressure sensor (51) connector. 9026-25.)

3. Move brake pressure sensor to port 4 (53) on Specification

outbound face of hydraulic integrated circuit (HIC) Transmission Oil—Temperature ........................................... 57—66°C
135—150°F
valve.
6. Put park lock lever UP and the transmission control
4. Reconnect brake pressure sensor connector.
lever (TCL) in neutral.
5. Heat transmission oil to specification. See
7. Start engine.
Transmission Oil Warm-Up Procedure. (Group

Continued on next page TE14778,000003B –19–06OCT05–3/5

TM2260 (07JAN06) 9026-25-33 750J, 850J Crawler

010706
PN=443
 Tests

NOTE: Output currents and pressures are located in 10. Record delta pressure.
the service menu. To enter the service menu,
press the MENU button and hold it down for 5 Neutral Delta—Specification
seconds. 750J—Pressure ........................................................ 2482—2620 kPa
24.8—26.2 bar
360—380 psi
8. Access the Efficiency and Relief menu. 850J—Pressure ........................................................ 2689—2827 kPa
26.9—28.3 bar
a. Access Service Menu on monitor. 390—410 psi

b. Select TCU Diagnostics. 11. If delta pressure is low. Remove valve and inspect
seals. Replace if necessary.
c. Select Procedures.

9. Set engine speed to specification.

Specification
Engine—Speed ......................................................... 1780—1820 rpm

Continued on next page TE14778,000003B –19–06OCT05–4/5

9026
25
34

TM2260 (07JAN06) 9026-25-34 750J, 850J Crawler

010706
PN=444
 Tests

NOTE: The neutral charge relief valve (1) is located on

front of hydraulic integrated circuit (HIC) valve.

12. If delta pressure is not within specification, adjust

pressure by turning screw IN or OUT. One turn
equals approximately 579 kPa (5.79 bar) (84 psi).

–UN–15DEC04
13. Move park lock lever to DOWN position.

T206279A
CAUTION: Tracks will rotate when Transmission
Control Lever (TCL) is moved to forward or
reverse.
1—Neutral Charge Relief Valve
IMPORTANT: If operating charge pressure drops
below 1310 kPa (13.1 bar) (190 psi)
brakes will start to engage. Adjust
neutral charge pressure to the high end
of specification.

14. Move TCL into forward or reverse. Record delta

pressure. Delta pressure MUST drop approximately
207 kPa (2.07 bar) (30 psi) as TCL is moved to
forward or reverse. Delta pressure MUST NOT drop
below specification.

Minimum Operating Delta—Specification

750J—Pressure ........................................................................... 2275 kPa 9026
22.8 bar 25
330 psi 35
850J—Pressure ........................................................................... 2482 kPa
24.8 bar
360 psi

15. Disconnect brake pressure sensor (51) connector.

16. Move brake pressure sensor back to original location

on the HIC valve.

17. Reconnect brake pressure sensor connector.

18. Clear diagnostic trouble codes that were generated

during test.

TE14778,000003B –19–06OCT05–5/5

TM2260 (07JAN06) 9026-25-35 750J, 850J Crawler

010706
PN=445
 Tests

Pump Displacement Control Valve (PDCV)

Neutral (Null) Adjustment
SPECIFICATIONS
Transmission Oil Temperature 57—66°C
135—150°F
Slow Idle Speed 880—910 rpm
Adjusting Screw Pressure 138 kPa
1.38 bar
20 psi
Neutral Adjustment Midway in Neutral Band

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit
JT05598 Gauge

This procedure will adjust the hydrostatic pump neutral

between forward and reverse. Repeat procedure for left
and right track.

Diagnostic Trouble Codes will be recorded during this test

and must be cleared when completed.

9026
25
36

Continued on next page TE14778,000005D –19–12AUG05–1/5

TM2260 (07JAN06) 9026-25-36 750J, 850J Crawler

010706
PN=446
 Tests

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks MUST be clear of tools and
objects before rotating.

1. Raise machine off the ground and support with 20-Ton

Floor Stands. Lower blade to ground. Tracks MUST be
free to rotate in either direction.

–UN–04DEC04
2. Tilt cab or ROPS to midway position. Install operator’s
station tilt cylinder lock. See Cab or ROPS Tilting
Procedure. (Operators Manual.)

T205099A
1—20-Ton Floor Stand (4 used)
2—Floor Stand Adapter (2 used)
3—Floor Stand Rod 750J/850J Floor Stand Kit
4—Washer (2 used)
5—Cap Screw (2 used)

TE14778,000005D –19–12AUG05–2/5
9026
25
37
3. Install test gauge in one of the servo tests ports (2).

4. Heat transmission oil to normal operating temperature.

See Transmission Oil Warm-Up Procedure. (Group
9026-25.)

–UN–16DEC04
Specification
Transmission Oil—Temperature.................................................. 57—66°C
135—150°F

T206311A
5. Turn machine OFF and disconnect front and rear
Pump Pressure Control Pilot (PCP) (3) harness
connectors. Hydrostatic Pump Test Ports

6. Start machine and set engine speed to specification. 1—Pump Displacement Control Valve (PDCV) Test
Ports
Specification 2—Pump Servo Test Port Ports
Slow Idle—Speed ................................................................ 880—910 rpm 3—Pump Pressure Control Pilot (PCP) Connector

7. Ensure that park lock lever is in the UP (locked)

position.

Continued on next page TE14778,000005D –19–12AUG05–3/5

TM2260 (07JAN06) 9026-25-37 750J, 850J Crawler

010706
PN=447
 Tests

8. Loosen lock nut (4) on the pump neutral adjustment

screw on the Pump Displacement Control Valve
(PDCV).

9. Slowly turn adjusting screw, noting direction of turn,

until gauge reads correct specification.

Specification
Adjusting Screw—Pressure ........................................................... 138 kPa
1.38 bar
20 psi

10. Turn machine OFF and move gauge to opposite

servo test port.

11. Start machine and set engine speed to specification.

12. Ensure that park lock lever is in the UP (locked)

position.

13. Slowly turn the screw in the opposite direction,

–UN–15DEC98
counting the number of turns until gauge reads
correct specification.

Specification

T118976B
Adjusting Screw—Pressure .......................................................... 138 kPa
1.38 bar
20 psi
9026
25 4—Null Adjusting Screw Lock Nut
14. Turn the screw to a point halfway (1/2 the total
38
number turns) and tighten locking nut.

Specification
Neutral—Adjustment............................................. Midway in Neutral Band

Continued on next page TE14778,000005D –19–12AUG05–4/5

TM2260 (07JAN06) 9026-25-38 750J, 850J Crawler

010706
PN=448
 Tests

NOTE: If total number of turns is 1/2 turn or less,

disassemble pump and level swash plate again.
See Hydrostatic Pumps Disassemble. (Group
0360.)

If total number of turns is more than 2 turns,

disassemble pump displacement control valve and
check for a worn feedback link. See Pump
Displacement Control Valve (PDCV) Disassemble
and Assemble. (Group 0360.)

If total number of turns is more than 1/2 but less

than 2 turns, continue with next step.

15. Repeat procedure on the other pump.

16. Disconnect test equipment and return cab or ROPS to

operating position.

17. Calibrate Transmission Controller. See Transmission

Control Unit (TCU) Calibration. (Group 9015-20.)

TE14778,000005D –19–12AUG05–5/5
9026
25
39
Pump Servo Pressure Test

SPECIFICATIONS
Fast Idle Speed 2255—2285 rpm
Speed-In-Grip (SIG) Position 3.0

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit
XPD361 Quick Coupler
JT02156A Digital Pressure/Temperature Analyzer
JT02161 3446 kPa (35 bar) (500 psi) Transducer
JDG1932 Motor Flushing Test Harness

The purpose of this test is to check proper operation of

the pump servo control circuit and pump displacement
control valve (PDCV).

Diagnostic Trouble Codes will be recorded during this test

and must be cleared when completed.

Continued on next page TE14778,0000037 –19–07OCT05–1/5

TM2260 (07JAN06) 9026-25-39 750J, 850J Crawler

010706
PN=449
 Tests

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks MUST be clear of tools and
objects before rotating.

1. Raise machine off the ground and support with 20-Ton

Floor Stands. Lower blade to ground. Tracks MUST be
free to rotate in either direction.

–UN–04DEC04
2. Tilt cab or ROPS up. See Cab or ROPS Tilting
Procedure. (Operators Manual.)

1—20-Ton Floor Stand (4 used)

T205099A
2—Floor Stand Adapter (2 used)
3—Floor Stand Rod
4—Washer (2 used) 750J/850J Floor Stand Kit
5—Cap Screw (2 used)

Continued on next page TE14778,0000037 –19–07OCT05–2/5

9026
25
40

TM2260 (07JAN06) 9026-25-40 750J, 850J Crawler

010706
PN=450
 Tests

3. Install quick couplers in servo test ports (2). Connect

digital pressure/temperature analyzer and transducer or
a gauge.

4. Return cab or ROPS to operating position.

–UN–16DEC04
5. Set monitor display to CHARGE (transmission charge
pressure).

6. Start engine and check that forward and reverse

T206311A
pressures on both pumps are equal, and less than
charge pressure in neutral.
Hydrostatic Pump Test Ports
If pressures are not OK, check neutral (null)
1—Pump Displacement Control Valve (PDCV) Test
adjustment or go to Mistrack/Indexes flow chart. See Ports
Pump Displacement Control Valve (PDCV) Neutral 2—Pump Servo Test Port Ports
(Null) Adjustment. (Group 9026-25.) See 3—Pump Pressure Control Pilot (PCP) Connector
Mistrack/Indexes—Flowchart. (9026-15.)

7. Set engine speed control to specification.

Specification
Fast Idle—Speed ............................................................. 2255—2285 rpm

8. Set transmission Speed-In-Grip (SIG) to specification.

Specification
Speed-In-Grip (SIG)—Position .............................................................. 3.0 9026
25
9. Set Decelerator Mode Switch to transmission mode. 41

CAUTION: Tracks will rotate when FNR is

moved to forward or reverse.

a. Push decel pedal to floor.

b. Put park lock lever in DOWN position.

c. Put FNR lever in forward.

d. Slowly release decel pedal.

e. Record forward servo pressure and charge

pressure.

10. Repeat test using reverse servo pressure and charge

pressure.

Continued on next page TE14778,0000037 –19–07OCT05–3/5

TM2260 (07JAN06) 9026-25-41 750J, 850J Crawler

010706
PN=451
 Tests

Servo pressures must be approximately equal and will

be less than charge pressure. If servo pressures are
not approximately equal, a problem exists in the
pump displacement control valve (PDCV) such that
the PDCV cannot fully activate or a leak in the servo
is indicated.

If servo pressure is equal to charge pressure, a

mechanical problem is indicated in the pump or pump
servo. Remove displacement control valve and
inspect pump servo or repair pump. See Pump
Displacement Control Valve (PDCV) Disassemble and
Assemble. (Group 0360.)

If pressures are still not OK, see Mistrack/Indexes—

Flowchart. (9026-15.)

NOTE: During normal operation, the transmission

controller regulates the mA to the PCP which will
not allow the swash plate to contact the
mechanical stop. When the JDG1932 test harness
is installed, 5 volts are supplied directly to the
PCP forcing the swash plate to the mechanical
stops.

NOTE: It may be necessary to use JDG1886 test harness

for additional length when connecting JDG1932
9026
25 test harness to machine.
42
11. Install JDG1932 test harness with switch between
pump PCP and left or right motor speed sensor.

NOTE: The TEST setting is located in the service menu.

To enter the service menu, press the MENU
button and hold it down for 5 seconds.

12. Set brake control setting to TEST.

a. Access Service Menu on monitor.

b. Select TCU Diagnostics.

c. Select Settings.

d. Select Brake Ctrl.

e. Select Test.

Continued on next page TE14778,0000037 –19–07OCT05–4/5

TM2260 (07JAN06) 9026-25-42 750J, 850J Crawler

010706
PN=452
 Tests

NOTE: Do not leave machine in brake Test setting during

normal operation.

13. Repeat servo pressure test using switch to activate

track in forward and reverse. Servo pressure must
now equal charge pressure.

14. Clear any diagnostic trouble codes that may have

appeared during procedure. See Diagnostic Trouble
Codes (DTCs) Quick Reference List. (Group
9015-20.)

15. Turn machine OFF to reset brake to normal mode.

TE14778,0000037 –19–07OCT05–5/5

Motor Displacement Control Valve (MDCV)

Adjustment
SPECIFICATIONS
Transmission Oil Temperature 57—66°C
135—150°F 9026
25
Speed-In-Grip (SIG) Position 1.6
43
Transmission Control Unit (TCU) 238—242 mA
Amperage

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit
XPD361 Quick Coupler (9/16-20UN M ORB)
JT02156A Digital Pressure/Temperature Analyzer
JT02162 35 000 kPa (350 bar) (5000 PSI) Transducer

This procedure is used to establish the point where the

hydrostatic circuit goes from pump phase to motor phase.

Continued on next page TE14778,000006B –19–06OCT05–1/5

TM2260 (07JAN06) 9026-25-43 750J, 850J Crawler

010706
PN=453
 Tests

NOTE: Do this procedure for front pump and right motor

or rear pump and left motor.

Both front and rear pump null adjustment MUST

be accurate (and machine recalibrated , if it was
adjusted) before doing this threshold adjustment.

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or

–UN–04DEC04
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

CAUTION: Prevent possible injury from

T205099A
unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
750J/850J Floor Stand Kit
Stands. Tracks MUST be clear of tools and
objects before rotating. 1—20-Ton Floor Stand (4 used)
2—Floor Stand Adapter (2 used)
1. Raise machine off the ground and support with 20-Ton 3—Floor Stand Rod
Floor Stands. Lower blade to ground. Tracks MUST be 4—Washer (2 used)
5—Cap Screw (2 used)
free to rotate in either direction.

9026
25
44

Continued on next page TE14778,000006B –19–06OCT05–2/5

TM2260 (07JAN06) 9026-25-44 750J, 850J Crawler

010706
PN=454
 Tests

NOTE: Test port (2) on each motor senses pressure to

the max. angle control piston. Test port (1) on
each motor senses min. angle control pressure.

2. Install quick couplers in servo test ports (1 and 2).

Connect digital pressure/temperature analyzer and

–UN–04DEC04
transducer or a gauge.

3. Start engine and heat hydrostatic oil to specified

temperature. See Transmission Oil Warm-Up

T205134A
Procedure. (Group 9026-25.)

Specification
Transmission Oil—Temperature.................................................. 57—66°C
135—150°F

4. With park lock lever in UP (locked) position, set

transmission Speed-In-Grip (SIG) to specification.

–UN–04DEC04
Specification
Speed-In-Grip (SIG)—Position .............................................................. 1.6

5. Access the Output Info menu.

T205135A
a. Access Main Menu on monitor.

b. Select Diagnostics.
1—Min. Angle Servo Piston Pressure Test Port
2—Max. Angle Servo Piston Pressure Test Port 9026
c. Select Live Values. 25
45
d. Select Output Info.

6. Record Left Motor and Right Motor mA values.

7. Set Decelerator Mode Switch to transmission mode.

CAUTION: Tracks will rotate when FNR is

moved out of neutral.

a. Push decel pedal to floor.

b. Put park lock lever in DOWN position.

c. Put FNR lever in forward.

d. Slowly release decel pedal.

e. Slowly increase engine RPM until amperage

reaches specification.

Continued on next page TE14778,000006B –19–06OCT05–3/5

TM2260 (07JAN06) 9026-25-45 750J, 850J Crawler

010706
PN=455
 Tests

Specification
Transmission Control Unit
(TCU)—Amperage ................................................................ 238—242 mA

TE14778,000006B –19–06OCT05–4/5

8. Loosen lock nut and adjust motor displacement control

valve (MDCV) (3) until max servo pressure begins to
drop (turning the screw OUT will cause the motor
servo pressure to drop sooner). This sudden drop in
motor servo pressure indicates that the motor is
starting to de-swash (increase speed).

–UN–04DEC04
9. Repeat procedure on other side.

10. Calibrate machine. See Transmission Control Unit

T205765A
(TCU) Calibration.. (Group 9015-20.)

Threshold Adjusting Screw

3—Threshold Control Spring Adjusting Screw

TE14778,000006B –19–06OCT05–5/5
9026
25
46
Hydrostatic Motor Min./Max. Angle Servo
Piston Pressure Test
SPECIFICATIONS
Transmission Oil Temperature 57—66°C
135—150°F
Speed-In-Grip (SIG) Position 1.0
Fast Idle Speed 2255—2285 rpm

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand
JDG10013 750J/850J Floor Stand Kit
XPD361 Quick Coupler (9/16-20UN M ORB)
JT02156A Digital Pressure/Temperature Analyzer
JT02162 35 000 kPa (350 bar) (5000 PSI) Transducer

The purpose of this test is to verify that the motor shift

solenoid has shifted allowing control pressure to the servo
piston, swashing the motor to minimum or maximum
displacement.

Continued on next page TE14778,0000038 –19–10MAY04–1/4

TM2260 (07JAN06) 9026-25-46 750J, 850J Crawler

010706
PN=456
 Tests

IMPORTANT: Carefully monitor transmission

temperature during this test.
Temperature will rise very quickly when
operating in an over-relief condition. Do
not exceed 71°C (160°).

CAUTION: Prevent possible injury from

unexpected track movement. Raise the machine
off the ground and support with 20-Ton Floor
Stands. Tracks MUST be clear of tools and

–UN–04DEC04
objects before rotating.

1. Raise machine off the ground and support with 20-Ton

Floor Stands. Lower blade to ground. Tracks MUST be

T205099A
free to rotate in either direction.

1—20-Ton Floor Stand (4 used) 750J/850J Floor Stand Kit

2—Floor Stand Adapter (2 used)
3—Floor Stand Rod
4—Washer (2 used)
5—Cap Screw (2 used)

Continued on next page TE14778,0000038 –19–10MAY04–2/4

9026
25
47

TM2260 (07JAN06) 9026-25-47 750J, 850J Crawler

010706
PN=457
 Tests

NOTE: Test port (2) on each motor senses pressure to

the max. angle control piston. Test port (1) on
each motor senses min. angle control pressure.

2. Install quick couplers in servo test ports (1 and 2).

Connect digital pressure/temperature analyzer and

–UN–04DEC04
transducer or a gauge.

3. Heat oil to specification. See Transmission Oil

Warm-Up Procedure. (Group 9026-25.)

T205134A
Specification
Transmission Oil—Temperature.................................................. 57—66°C
135—150°F

4. Set transmission Speed-In-Grip (SIG) to specification.

Specification
Speed-In-Grip (SIG)—Position .............................................................. 1.0

–UN–04DEC04
5. Set Decelerator Mode Switch to transmission mode.

6. Push decel pedal to floor.

T205135A
7. Set engine speed to specification.

Specification
Fast Idle—Speed ............................................................. 2255—2285 rpm 1—Min. Angle Servo Piston Pressure Test Port
9026 2—Max. Angle Servo Piston Pressure Test Port
25
48 8. Put park lock lever in DOWN position.

9. Put Transmission Control Lever (TCL) in forward and

slowly release decel pedal.

CAUTION: Tracks will rotate when FNR is

moved out of neutral.

10. Slowly increase transmission speed to maximum.

11. Compare test port pressures to table. Track speeds

MUST increase evenly.

Continued on next page TE14778,0000038 –19–10MAY04–3/4

TM2260 (07JAN06) 9026-25-48 750J, 850J Crawler

010706
PN=458
 Tests

Min. Angle Test Port Max. Angle Test Port

Neutral Return Pressure Charge Pressure
Slow Speed (1.0) Return Pressure Reduced
Closed-Loop
Pressure
Fast Speed (3.0) Reduced Reduced
Closed-Loop Closed-Loop
Pressure Pressure

TE14778,0000038 –19–10MAY04–4/4

9026
25
49

TM2260 (07JAN06) 9026-25-49 750J, 850J Crawler

010706
PN=459
 Tests

Charge Pump Flow Test

SPECIFICATIONS
Transmission Oil Temperature 57—66°C
135—150°F
Engine Speed 1800 rpm
750J
Typical Single Flow Rate 45—53 L/min(f)
12—14 gpm
Minimum Single Flow Rate 43.5 L/min(f)
11.5 gpm
850J
Typical Single Flow Rate 61—68 L/min(f)
16—18 gpm
Minimum Single Flow Rate 57 L/min(f)
15 gpm
750J
Typical Combined Flow Rate 98—106 L/min(f)
26—28 gpm
Minimum Combined Flow Rate 87 L/min(f)
23 gpm
850J
Typical Combined Flow Rate 129—136 L/min(f)
34—36 gpm
Minimum Combined Flow Rate 114 L/min(f)
30 gpm
9026
25
SERVICE EQUIPMENT AND TOOLS
50
JT07148 Digital Hydraulic Tester
JT03448 Test Hose (2 used)

This procedure is used to determine hydrostatic pump

flow and to isolate front and rear pump flow, if necessary.
Charge pressures MUST be to specification. See Neutral
Charge Relief and Operating Charge Relief Pressure Test.
(Group 9026-25.)

1. Single Charge Pump Flow

Tilt cab or ROPS up. See Cab or ROPS Tilting

Procedure. (Operators Manual.)

Continued on next page CED,OUTX466,1291 –19–29OCT04–1/3

TM2260 (07JAN06) 9026-25-50 750J, 850J Crawler

010706
PN=460
 Tests

IMPORTANT: Flow control valve on flow meter MUST

be fully open. Damage to charge pumps
will result if valve is not fully open.

2. Connect flow meter in line between front hydrostatic

charge pump (right track) pressure hose (1) and

–UN–04JAN05
Hydraulic Integrated Circuit (HIC) valve (3). Flow
control valve must be OPEN.

3. Lower cab or ROPS to normal operating position.

T206596A
4. Heat oil to specification. See Transmission Oil
Warm-Up Procedure. (Group 9026-25.)
1—Front Hydrostatic Charge Pump Pressure Hose
Specification 2—Rear Hydrostatic Charge Pump Pressure Hose
Transmission Oil—Temperature.................................................. 57—66°C 3—Hydraulic Integrated Circuit (HIC) Valve
135—150°F

5. With park lock lever UP, run engine at specified RPM.

Record flow meter reading. If charge pump flow is
below specification, the complete hydrostatic pump
assembly must be removed to replace or repair charge
pump.

Specification
Engine—Speed ........................................................................... 1800 rpm

750J—Specification
9026
Typical Single—Flow Rate ................................................ 45—53 L/min(f)
25
12—14 gpm
51
Minimum Single—Flow Rate .................................................. 43.5 L/min(f)
11.5 gpm

850J—Specification
Typical Single—Flow Rate ................................................ 61—68 L/min(f)
16—18 gpm
Minimum Single—Flow Rate ..................................................... 57 L/min(f)
15 gpm

6. Repeat procedure for testing flow from rear hydrostatic

charge pump (left track).

7. Remove test equipment.

8. Combined Charge Pump Flow

Add front and rear pump flows together to determine

combined flow.

Continued on next page CED,OUTX466,1291 –19–29OCT04–2/3

TM2260 (07JAN06) 9026-25-51 750J, 850J Crawler

010706
PN=461
 Tests

750J—Specification
Typical Combined—Flow Rate ........................................ 98—106 L/min(f)
26—28 gpm
Minimum Combined—Flow Rate............................................... 87 L/min(f)
23 gpm

850J—Specification
Typical Combined—Flow Rate ...................................... 129—136 L/min(f)
34—36 gpm
Minimum Combined—Flow Rate............................................. 114 L/min(f)
30 gpm

CED,OUTX466,1291 –19–29OCT04–3/3

Hydrostatic Oil Cooler Bypass Test

SPECIFICATIONS
Fast Idle Speed 2255—2285 rpm
Hydrostatic Oil Cooler Bypass 23.5—33.5 ohms
Solenoid Coil Resistance at 20°C
(68°F)
Hydrostatic Oil Cooler Bypass 24 V
Solenoid Voltage
Oil Cooler Inlet (Bypass OFF) 414—552 kPa
Pressure 4.14—5.52 bar
60—80 psi

9026 Oil Cooler Bypass Valve Torque 88—102 N•m

25 65—75 lb ft
52
ESSENTIAL TOOLS
JDG1886 Test Harness
JT07237-1 Single Pin Test Harness

SERVICE EQUIPMENT AND TOOLS

XPD341 Quick Coupler (7/16-20UN M ORB)
JT02156A Digital Pressure/Temperature Analyzer
JT02162 34 000 kPa (350 bar) (5000 PSI) Transducer
Multimeter

The purpose of this test is to determine if the cooler

bypass solenoid and valves are opening and closing.

Diagnostic Trouble Codes will be recorded during this test

and must be cleared when completed.

Continued on next page TE14778,000005E –19–22AUG05–1/5

TM2260 (07JAN06) 9026-25-52 750J, 850J Crawler

010706
PN=462
 Tests

NOTE: Before performing diagnostic procedures, check

diagnostic trouble codes and stored diagnostic 2 1
trouble codes. See Diagnostic Trouble Codes
(DTCs) Quick Reference List. (Group 9015-20.)
See CAN Monitor Unit (CMU) Circuit Theory of
Operation. (Group 9015-15.)

–UN–10JAN05
1. Heat transmission oil to operating temperature. See
Transmission Oil Warm-Up Procedure. (Group
9026-25) 12

T206645
11 39
2. Oil Cooler Bypass Solenoid Test

a. Install quick coupler in test port 6 (1) on top of 1—Test Port 6

hydraulic integrated circuit (HIC) valve. Connect 2—Test Port 14
11—Hydrostatic Oil Cooler Bypass Solenoid
digital pressure/temperature analyzer and
12—Hydrostatic Oil Cooler Bypass Valve
transducer or a gauge. 39—Hydraulic Integrated Circuit (HIC) Valve

b. Start engine.

NOTE: The Cooler Bypass Control setting is located in

the service menu. To enter the service menu,
press the MENU button and hold it down for 5
seconds.

c. Set cooler bypass control to OFF.

9026
• Access Service Menu on monitor. 25
• Select TCU Diagnostics. 53
• Select Settings.
• Select Cooler Byp Ctrl.
• Select Off.

d. Set engine speed to specification.

Specification
Fast Idle—Speed ............................................................. 2255—2285 rpm

e. Record pressures in test port 6:

• With cooler bypass control turned OFF, pressure

should be at zero.
• Set cooler bypass control to ON.
• Set monitor display to CHARGE (transmission
charge pressure).

Continued on next page TE14778,000005E –19–22AUG05–2/5

TM2260 (07JAN06) 9026-25-53 750J, 850J Crawler

010706
PN=463
 Tests

• With cooler bypass control turned ON, pressure

should equal Neutral Charge pressure.
• If either of these conditions is not true, test
Hydrostatic Oil Cooler Bypass Solenoid.

1. Disconnect harness to Hydrostatic Oil Cooler

Bypass Solenoid.
2. Connect test harness JDG1886 to Hydrostatic
Oil Cooler Bypass Solenoid (11) only. Do not
connect other connector to transmission harness.
3. Connect Multimeter using JT07237-1 Single Pin
Test Harness.

NOTE: Machine wire harness must be disconnected for

correct measurement.

4. Measure resistance of solenoid coil.

Specification
Hydrostatic Oil Cooler Bypass
Solenoid Coil—Resistance at
20°C (68°F) ..................................................................... 23.5—33.5 ohms

If resistance is not to specification, remove and replace

Hydrostatic Oil Cooler Bypass Solenoid.

5. Disconnect test harness from solenoid and

9026 connect to machine harness.
25 6. Turn key switch to ON.
54 7. Set cooler bypass control to ON. Measure DC
voltage at harness. Voltage should be zero.
8. Set cooler bypass control to OFF. Measure DC
voltage at harness. If voltage is not to
specification, check wiring.

Specification
Hydrostatic Oil Cooler Bypass
Solenoid—Voltage ............................................................................... 24 V

9. Record pressure in test port 6. If pressure is not

zero, remove Oil Cooler Bypass Solenoid Valve.
10. Inspect O-rings and movement of spool, if spool
does not move freely replace valve or O-rings.

3. Oil Cooler Bypass Valve Test

Continued on next page TE14778,000005E –19–22AUG05–3/5

TM2260 (07JAN06) 9026-25-54 750J, 850J Crawler

010706
PN=464
 Tests

a. Install quick coupler in test port 14 (2) on top of

hydraulic integrated circuit (HIC) valve. Connect
digital pressure/temperature analyzer and
transducer or a gauge.

b. Unplug Hydrostatic Oil Reservoir Bypass Solenoid

Connector.

c. Start engine.

d. Set engine speed to specification.

Specification
Fast Idle—Speed ............................................................. 2255—2285 rpm

e. Set cooler bypass control to ON.

• Access Service Menu on monitor.

• Select TCU Diagnostics.
• Select Settings.
• Select Cooler Byp Ctrl.
• Select On.

f. Record pressure in test port 14. If pressure is not

zero, remove Oil Cooler Bypass Valve. Inspect
O-rings and movement of spool. Spool should move 9026
25
freely. If necessary, replace valve or O-rings.
55

g. Set cooler bypass control to OFF.

h. Record pressure in test port 14. If pressure is not to

specification, remove Oil Cooler Bypass Valve.
Inspect O-rings and movement of spool. Spool
should move freely. If necessary, replace valve or
O-rings.

Specification
Oil Cooler Inlet (Bypass OFF)—
Pressure .............................................................................. 414—552 kPa
4.14—5.52 bar
60—80 psi

Continued on next page TE14778,000005E –19–22AUG05–4/5

TM2260 (07JAN06) 9026-25-55 750J, 850J Crawler

010706
PN=465
 Tests

Install valve and tighten to specification.

Specification
Oil Cooler Bypass Valve—Torque ........................................ 88—102 N•m
65—75 lb ft

i. Clear any diagnostic trouble codes that may have

appeared during procedure. See Diagnostic Trouble
Codes (DTCs) Quick Reference List. (Group
9015-20.)

TE14778,000005E –19–22AUG05–5/5

9026
25
56

TM2260 (07JAN06) 9026-25-56 750J, 850J Crawler

010706
PN=466
 Tests

Hydrostatic Oil Reservoir Bypass Test

SPECIFICATIONS
Fast Idle Speed 2255—2360 rpm
Hydrostatic Oil Reservoir Bypass Solenoid
Case Return (Bypass ON) 69—172 kPa
Pressure 0.69—1.72 bar
10—25 psi
Case Return (Bypass ON) 12 V
Voltage
Case Return (Bypass OFF) 345—172 kPa
Pressure 3.45—1.72 bar
50—80 psi
Case Return (Bypass OFF) 0V
Voltage
Hydrostatic Oil Cooler Reservoir 27.75—39.75 ohms
Solenoid Coil Resistance at 20°C
(68°F)
Hydrostatic Oil Reservoir Bypass Valve
Case Return (Bypass ON) 241—345 kPa
Pressure 2.41—3.45 bar
35—50 psi
Case Return (Bypass ON) 12 V
Voltage
Case Return (Bypass OFF) 414—621 kPa
Pressure 4.14—6.21 bar
60—90 psi
Case Return (Bypass OFF) 0V 9026
Voltage 25
57

ESSENTIAL TOOLS
JDG10006 2-Pin Test Harness
JT07237-1 Single Pin Test Harness

SERVICE EQUIPMENT AND TOOLS

XPD341 Quick Coupler (7/16-20UN M ORB)
JT02156A Digital Pressure/Temperature Analyzer
JT02162 34 000 kPa (350 bar) (5000 PSI) Transducer
Multimeter

The purpose of this test is to determine if the reservoir

bypass valves are opening and closing.

Diagnostic Trouble Codes will be recorded during this test

and must be cleared when completed.

Continued on next page TE14778,0000073 –19–05AUG05–1/5

TM2260 (07JAN06) 9026-25-57 750J, 850J Crawler

010706
PN=467
 Tests

NOTE: Before performing diagnostic procedures, check 13 2

diagnostic trouble codes and stored diagnostic 1
39
trouble codes. See Diagnostic Trouble Codes
(DTCs) Quick Reference List. (Group 9015-20.)
See CAN Monitor Unit (CMU) Circuit Theory of
Operation. (Group 9015-15.)

–UN–11JAN05
1. Heat transmission oil to operating temperature. See
Transmission Oil Warm-Up Procedure. (Group
9026-25)

T206680
14
2. Hydrostatic Oil Reservoir Bypass Solenoid Test

a. Install quick coupler in test port 11 (1) on top of 1—Test Port 11

hydraulic integrated circuit (HIC) valve. Connect 2—Test Port 8
13—Hydrostatic Oil Reservoir Bypass Solenoid
digital pressure/temperature analyzer and
14—Hydrostatic Oil Reservoir Bypass Valve
transducer or a gauge. 39—Hydraulic Integrated Circuit (HIC) Valve

b. Connect test harness JDG10006 between

Hydrostatic Oil Reservoir Bypass Solenoid and
transmission harness.

c. Connect Multimeter using JT07237-1 harness.

d. Start engine.

e. Set engine speed to specification.

9026
25
58 Specification
Fast Idle—Speed ............................................................. 2255—2360 rpm

NOTE: The Cooler Bypass Control and Tank Bypass

Control settings are located in the service menu.
To enter the service menu, press the MENU
button and hold it down for 5 seconds.

f. Set cooler bypass control to ON (Cooler Closed).

• Access Service Menu on monitor.

• Select TCU Diagnostics.
• Select Settings.
• Select Cool Byp Ctrl.
• Select Off.

g. Set tank bypass control to ON (Tank Open).

Continued on next page TE14778,0000073 –19–05AUG05–2/5

TM2260 (07JAN06) 9026-25-58 750J, 850J Crawler

010706
PN=468
 Tests

• Access Service Menu on monitor.

• Select TCU Diagnostics.
• Select Settings.
• Select Tank Byp Ctrl.
• Select ON.

h. Record pressure in test port 11. Record DC voltage.

Set tank bypass control to OFF (Tank Closed).
Record pressure and voltage.

Hydrostatic Oil Reservoir Bypass Solenoid —Specification

Case Return (Bypass ON)—
Pressure ................................................................................ 69—172 kPa
0.69—1.72 bar
10—25 psi
Voltage................................................................................................. 12 V
Case Return (Bypass OFF)—
Pressure .............................................................................. 345—172 kPa
3.45—1.72 bar
50—80 psi
Voltage................................................................................................... 0 V

If pressure or voltage is not to specification, test

Hydrostatic Oil Reservoir Bypass Solenoid Coil (13).

NOTE: Machine wire harness must be disconnected for 9026

correct measurement. 25
59
1. Disconnect test harness JDG1886 from
transmission harness.
2. Measure resistance of solenoid coil.

Specification
Hydrostatic Oil Cooler Reservoir
Solenoid Coil—Resistance at
20°C (68°F) ................................................................. 27.75—39.75 ohms

If resistance is not to specification, remove and replace

Hydrostatic Oil Reservoir Bypass Solenoid Coil.

3. If pressure is still not to specification, remove

Hydrostatic Oil Reservoir Bypass Solenoid Valve.
Inspect O-rings and movement of spool. Spool
should move freely. If necessary, replace valve
or O-rings.
a. Turn key switch to ON.

Continued on next page TE14778,0000073 –19–05AUG05–3/5

TM2260 (07JAN06) 9026-25-59 750J, 850J Crawler

010706
PN=469
 Tests

b. Have someone cycle tank bypass control ON

and OFF.
c. If solenoid is working correctly, you should
feel the solenoid vibrate in your hand.

3. Hydrostatic Oil Reservoir Bypass Valve Test

a. Install quick coupler in test port 8 (2) on top of

hydraulic integrated circuit (HIC) valve. Connect
digital pressure/temperature analyzer and
transducer or a gauge.

b. Connect JDG1886 Test Harness between

Hydrostatic Oil Reservoir Bypass Solenoid and
transmission harness.

c. Connect Multimeter using JT07237-1 Single Pin

Test Harness.

d. Start engine.

e. Set engine speed to specification.

Specification
Fast Idle—Speed ............................................................. 2255—2360 rpm

9026
25
f. Set cooler bypass control to ON (Cooler Closed).
60

g. Set tank bypass control to ON (Tank Open).

h. Record pressure in test port 8. Record DC voltage.

Set tank bypass control to OFF (Tank Closed).
Record pressure and voltage.

Hydrostatic Oil Reservoir Bypass Valve —Specification

Case Return (Bypass ON)—
Pressure .............................................................................. 241—345 kPa
2.41—3.45 bar
35—50 psi
Voltage................................................................................................. 12 V
Case Return (Bypass OFF)—
Pressure .............................................................................. 414—621 kPa
4.14—6.21 bar
60—90 psi
Voltage................................................................................................... 0 V

Continued on next page TE14778,0000073 –19–05AUG05–4/5

TM2260 (07JAN06) 9026-25-60 750J, 850J Crawler

010706
PN=470
 Tests

1. If pressures are not changing according to

specification, remove Oil Reservoir Bypass
Valve. Inspect O-rings and movement of spool.
Spool should compress spring when pushed. If
necessary, replace valve or O-rings.

TE14778,0000073 –19–05AUG05–5/5

Park Brake Test

SPECIFICATIONS
Park Brake Solenoid Coil 22.5—34.5 ohms
Resistance at 20°C (68°F)
Park Brake Solenoid Coil Nut 6.8—9.5 N•m
Torque 5—7 lb ft
Park Brake Voltage 24 V
Park Brake Solenoid 1 Torque 34—36.7 N•m
25—27 lb ft
Park Brake Solenoid 2 Torque 44.9—50.3 N•m
33—37 lb ft
Fast Idle Speed 2255—2285 rpm 9026
25
Speed-In-Grip (SIG) Position 1.6
61
Multi-Function Relief Valve 44 128—46 884 kPa
Pressure 441—468 bar
6400—6800 psi

ESSENTIAL TOOLS
JDG1886 Test Harness
JT07237-1 Single Pin Test Harness

SERVICE EQUIPMENT AND TOOLS

XPD341 Quick Coupler (7/16-20UN M ORB)
JT02156A Digital Pressure/Temperature Analyzer
JT02162 34 000 kPa (350 bar) (5000 PSI) Transducer
Multimeter

The purpose of this test is to determine if the brake

solenoids and valves are working and if the brake disks
are applying and releasing.

Diagnostic Trouble Codes will be recorded during this test

and must be cleared when completed.

Continued on next page TE14778,0000072 –19–26OCT05–1/6

TM2260 (07JAN06) 9026-25-61 750J, 850J Crawler

010706
PN=471
 Tests

NOTE: Before performing diagnostic procedures:

• Check diagnostic trouble codes and stored

diagnostic trouble codes. See Diagnostic
Trouble Codes (DTCs) Quick Reference List.
(Group 9015-20.) See CAN Monitor Unit (CMU)
Circuit Theory of Operation. (Group 9015-15.)
• Turn key switch to ON position. Cycle park lock
lever while checking for corresponding N or P
on monitor. If N or P is not displayed See
Transmission Control Unit (TCU) Circuit Theory
of Operation. (Group 9015-15.)

1. Brake Operation Test:

Continued on next page TE14778,0000072 –19–26OCT05–2/6

9026
25
62

TM2260 (07JAN06) 9026-25-62 750J, 850J Crawler

010706
PN=472
 Tests

a. Start engine.
10 1
39
b. Display Brake Pressure on Monitor.

• Select Diagnostics
• Select Live Values
•

–UN–11JAN05
Select Pressures
• Select Brake Pressure

c. With park lock lever in UP position, record brake

T206646
pressure. Pressure should be zero. 9 2
Move park lock lever to DOWN position. Pressure
should equal Neutral Charge pressure. 1—Brake Pressure Sensor
2—Ball Shuttle Valve
9—Park Brake Solenoid 1
If either of these conditions is not true, test Park
10—Park Brake Solenoid 2
Brake Solenoids 1 and 2 (9 and 10). 39—Hydraulic Integrated Circuit (HIC) Valve

1. Disconnect harness to Park Brake Solenoid 1.

2. Connect JDG1886 Test Harness to Park Brake
Solenoid 1 only. Do not connect other connector
to transmission harness.
3. Connect Multimeter using JT07237-1 Single Pin
Test Harness.

NOTE: Machine wire harness must be disconnected for

correct measurement.
9026
25
4. Measure resistance of solenoid coil. 63

Specification
Park Brake Solenoid Coil—
Resistance at 20°C (68°F) .............................................. 22.5—34.5 ohms

If resistance is not to specification, remove and replace

coil. Tighten nut on coil to specification.

Specification
Park Brake Solenoid Coil Nut—
Torque ................................................................................... 6.8—9.5 N•m
5—7 lb ft

5. Disconnect test harness from solenoid and

connect to machine harness.
6. Turn key switch ON. Measure DC voltage at
harness. Voltage should be zero.

Continued on next page TE14778,0000072 –19–26OCT05–3/6

TM2260 (07JAN06) 9026-25-63 750J, 850J Crawler

010706
PN=473
 Tests

7. Place park lock lever in DOWN position.

Measure DC voltage at harness. If voltage is not
to specification, check wiring.

Specification
Park Brake—Voltage ........................................................................... 24 V

8. Perform same test on Park Brake Solenoid 2

(10).
9. If pressure is still not zero, remove and inspect
Park Brake Solenoids 1 and 2. Replace if
necessary.
a. Remove solenoid from Hydraulic Integrated
Circuit (HIC) valve.
b. Connect solenoid to transmission harness.
c. Turn key switch to ON.
d. While holding solenoid in your hand, have
someone cycle park lock lever to UP and
DOWN position.
e. If solenoid piston is moving freely, you should
feel and hear an audible click.

Tighten solenoids to specification.

Park Brake Solenoids—Specification

9026 Park Brake Solenoid 1—Torque .......................................... 34—36.7 N•m
25 25—27 lb ft
64 Park Brake Solenoid 2—Torque ....................................... 44.9—50.3 N•m
33—37 lb ft

10. If pressure is still not zero, inspect Ball Shuttle

Valve (2). Replace if necessary.

2. Heat transmission oil to operating temperature. See

Transmission Oil Warm-Up Procedure. (Group
9026-25)

3. Park Brake Slipping Test:

a. Start engine.

Continued on next page TE14778,0000072 –19–26OCT05–4/6

TM2260 (07JAN06) 9026-25-64 750J, 850J Crawler

010706
PN=474
 Tests

NOTE: The TEST setting is located in the service menu.

To enter the service menu, press the MENU
button and hold it down for 5 seconds.

b. Set brake control setting to TEST.

• Access Service Menu on monitor.

• Select TCU Diagnostics.
• Select Settings.
• Select Brake Ctrl.
• Select Test.

NOTE: Do not leave machine in brake Test setting during

normal operation.

c. Set engine speed to specification.

Specification
Fast Idle—Speed ............................................................. 2255—2285 rpm

d. Push decel pedal to floor.

e. Put park lock lever in UP position.

f. Set Decelerator Mode Switch to transmission mode.

9026
25
g. Set hydrostatic transmission Speed-In-Grip (SIG) to
65
specification.

Specification
Speed-In-Grip (SIG)—Position .............................................................. 1.6

NOTE: The Autodiagnostics setting is located in the

service menu. To enter the service menu, press
the MENU button and hold it down for 5 seconds.

h. Set TCU Diagnostics setting to Autodiagnostics.

• Access Service Menu on monitor.

• Select TCU Diagnostics.
• Select Procedures.
• Select Autodiagnostics.

i. Put Transmission Control Lever (TCL) in forward.

Continued on next page TE14778,0000072 –19–26OCT05–5/6

TM2260 (07JAN06) 9026-25-65 750J, 850J Crawler

010706
PN=475
 Tests

j. Slowly release decel pedal.

NOTE: There is a feature built in to the brake test mode

that allows you to remain out of neutral for 13
seconds, after which, the TCU will kick out to
neutral. Then you have to shift the trans lever to
neutral and leave it there for 13 more seconds
before going back in range. Then the cycle starts
again

k. When in the brake test mode, if motion is detected

by either motor speed sensor, the TCU will default
to neutral and closed loop pressure will go to near
zero (charge). This happens so quickly that you do
not see track movement. If you can build to full
relief pressure in brake test mode the brakes held. If
full relief pressure drops to near zero the brakes
have slipped. See Park Brake Remove and Install.
(Group 1100.)

Specification
Multi-Function Relief Valve—
Pressure .................................................................... 44 128—46 884 kPa
441—468 bar
6400—6800 psi

9026
25 l. Turn machine OFF to reset brake to normal
66 operation setting.

4. Clear any diagnostic trouble codes that may have

appeared during procedure. See Diagnostic Trouble
Codes (DTCs) Quick Reference List. (Group 9015-20.)

TE14778,0000072 –19–26OCT05–6/6

TM2260 (07JAN06) 9026-25-66 750J, 850J Crawler

010706
PN=476
 Tests

Park Brake Relief Valve Test

SPECIFICATIONS
Park Brake Relief Valve Pressure 2275—2551 kPa
22.75—25.51 bar
330—370 psi

SERVICE EQUIPMENT AND TOOLS

XPD341 Quick Coupler
JT02156A Digital Pressure/Temperature Analyzer
JT02161 3446 kPa (35 bar) (500 PSI) Transducer

This procedure will check hand pump relief valve setting.

TE14778,0000078 –19–07OCT05–1/2

IMPORTANT: Incorrect relief setting could cause

damage to brake seals when brakes are
manually released.

1. Position hand pump selector lever (RED) OUT.

9026

–UN–04JAN05
2. Insert handle in hand pump (2) and begin stroking 25
67
pump. During initial operation, monitor will indicate
pressure required to release brakes. When brake
pistons bottom, pressure will rise rapidly to the setting

T206573A
of hand pump park brake relief valve.

Specification
Park Brake Relief Valve— 1— Brake Pressure Sensor
Pressure .......................................................................... 2275—2551 kPa 2—Hand Pump
22.75—25.51 bar
330—370 psi

If relief pressure is not within specification, adjust

pressure by turning screw IN or OUT.

TE14778,0000078 –19–07OCT05–2/2

TM2260 (07JAN06) 9026-25-67 750J, 850J Crawler

010706
PN=477
 Tests

Cab Tilt Relief Valve Test

SPECIFICATIONS
Cab Tilt Relief Valve Pressure 10 000—21 374 kPa
200—214 bar
2900—3100 psi

This procedure will check hand pump relief valve setting.

KV70328,0000001 –19–26SEP05–1/2

IMPORTANT: Incorrect relief setting could cause

damage to cylinder when cab is tilted.

1. Install quick coupler in Test Port 12 (1). Connect

JT02156A Digital Pressure/Temperature Analyzer and
JT02162 5000 PSI Transducer.

–UN–21SEP05
2. Position hand pump selector lever (RED) IN

3. Insert handle in hand pump (2) and begin stroking

T214859A
pump. When cylinder is bottomed out, pressure will
rise rapidly to the setting of hand pump cab tilt relief
valve. Cab Tilt Relief Valve Test
9026
25
1— Brake Pressure Sensor
68 Specification
2—Hand Pump
Cab Tilt Relief Valve—Pressure................................ 10 000—21 374 kPa
3—Hand Pump Selector Lever (Black)
200—214 bar
4—Hand Pump Selector Lever (Red)
2900—3100 psi

If relief pressure is not within specification, adjust

pressure by removing cap on end of valve and turning
adjustment screw IN or OUT.

KV70328,0000001 –19–26SEP05–2/2

Hand Pump Bleed Procedure

Follow this procedure to bleed air from the hand

pump/cab tilt cylinder circuit.
Continued on next page TE14778,000006E –19–16NOV04–1/2

TM2260 (07JAN06) 9026-25-68 750J, 850J Crawler

010706
PN=478
 Tests

IMPORTANT: For satisfactory operation of the cab tilt

cylinder it is essential that all air be
bled from the system. Therefore, any
time air is induced into the system, the
bleed procedure MUST be performed.

–UN–04JAN05
1. Remove Test Port 12 (1) plug.

2. Operate Hand Pump (2) until all air is out of system.

T206573A
3. Install and tighten Test Port 12 plug.

1—Test Port 12
2—Hand Pump

TE14778,000006E –19–16NOV04–2/2

Fan Pump Pressure Test

The purpose of this test is to determine fan pump accessing Settings under TCU Diagnostics in
outlet pressure. Pressure not within specification can the CAN Monitor Unit (CMU). See CAN
indicate excessive wear on internal components. Monitor Unit (CMU) Circuit Theory of
Operation. (Group 9015-15.) 9026
SPECIFICATIONS 25
69
Fan Pump Pressure 17 582—18 961 kPa This test checks hydraulic fan pump output pressure. If
176—190 bar digital hand held tachometer JT05719 is available,
2550—2750 psi perform Fan Motor Speed Test in this group in place of
this test.
SERVICE EQUIPMENT AND TOOLS
JT02156A Digital Pressure and Temperature Analyzer

NOTE: Deactivate proportional fan drive before

performing test. Set fan speed to Maximum by

Continued on next page TE14778,0000060 –19–14OCT04–1/2

TM2260 (07JAN06) 9026-25-69 750J, 850J Crawler

010706
PN=479
 Tests

1. Make test connections as shown using existing pump

outlet hose (3). Pump is located on left side rear of
engine.

2. Perform Transmission Oil Warm-Up Procedure. (Group

9026-25).

–UN–20NOV04
3. Install JT02156A Digital Pressure Analyzer with 34 474
kPa (344.738 bar) (5000 psi) pressure transducers to
quick coupler (2). Perform JT02156A Digital

T205157A
Pressure/Temperature Analyzer Installation . (Group
9026-25.)
Fan Pump Pressure Test (750J Fan Pump shown)
NOTE: The Fan Valve Set setting is located in the service 1—Fan Pump
menu. To enter the service menu, press the 2—Quick Coupler
MENU button and hold it down for 5 seconds. 3—Pump Outlet Hose

4. Set fan speed to Maximum.

a. Access Service Menu on monitor.

b. Select TCU Diagnostics.

c. Select Settings.

d. Select Fan Valve Set.

9026
25 e. Select Maximum.
70
5. Operate engine at fast idle and record pressure.
Pressure must be within specification.

Specification
Fan Pump—Pressure ................................................ 17 582—18 961 kPa
176—190 bar
2550—2750 psi

6. If fan pump pressure is not within specification:

• Perform Fan Pump Flow Test. (Group 9026-25.)

• Inspect proportional fan solenoid for contamination or
seal leakage. Replace if necessary.

7. After performing this test, cycle key switch to restart

engine. This will activate proportional fan drive.

TE14778,0000060 –19–14OCT04–2/2

TM2260 (07JAN06) 9026-25-70 750J, 850J Crawler

010706
PN=480
 Tests

Fan Pump Flow Test

SPECIFICATIONS
Fast Idle Speed 2330—2360 rpm
Fan Pump Pressure 17 926 kPa
179 bar
2600 psi
New Fan Pump Flow (Minimum) 54.1 L/min
14.3 gpm
Used Fan Pump Flow (Minimum) 51.9 L/min
13.7 gpm

SERVICE EQUIPMENT AND TOOLS

JT07148 Digital Hydraulic Tester
JT03448 Test Hose (2 used)

The purpose of this test is to determine fan pump flow.

Flow not within specification can indicate excessive wear
on internal components.

Perform this test only if Fan Pump Pressure Test or Fan

Motor Speed Test procedures have failed to meet
specification.

9026
25
71

Continued on next page TE14778,0000062 –19–14OCT04–1/3

TM2260 (07JAN06) 9026-25-71 750J, 850J Crawler

010706
PN=481
 Tests

49

58 42

59
48

54 46
41
50 45 57
54
44
56
59 43

–UN–13JAN05
56 57
96
98

T202967
55
T202967
Hydraulic Fan Drive (750J Shown)
9026
25 40—Hydrostatic Reservoir 47—Hydraulic Fan Check 55—High Pressure Line 58—Return Line (hydraulic fan
72 41—Hydraulic Fan Pump Valve (3 used) (hydraulic fan pump to reversing valve to
42—Hydraulic Fan Motor 48—Hydraulic Fan Oil Filter hydraulic fan reversing hydraulic fan oil filter)
43—Hydraulic Fan Reversing Bypass Valve valve) 59—Case Drain Line (hydraulic
Valve 49—Hydraulic Fan Oil Filter 56—Forward Pressure Line fan motor to hydraulic fan
44—Hydraulic Fan Reversing Restriction Switch (hydraulic fan reversing oil filter)
Solenoid 50—Hydraulic Fan Oil Filter valve through bulkhead to 96—High Pressure Oil
45—Hydraulic Fan Directional 54—Suction Line (hydrostatic hydraulic fan motor) 98—Return Oil
Valve reservoir through 57—Reverse Pressure Line
46—Hydraulic Fan bulkhead to hydraulic fan (hydraulic fan reversing
Proportional Solenoid pump) valve through bulkhead to
hydraulic fan motor)

IMPORTANT: Flow control valve on flow meter NOTE: The Fan Valve Set setting is located in the
MUST be fully open. Damage to service menu. To enter the service menu,
charge pumps will result if valve is press the MENU button and hold it down for 5
not fully open. seconds.

1. Disconnect hose (55) from fan drive pump and 3. Set fan speed to Maximum.
install to flow meter. Assemble test hose from flow
meter to fan pump outlet. Flow control valve must a. Access Service Menu on monitor.
be OPEN.
b. Select TCU Diagnostics.
2. Perform Transmission Oil Warm-Up Procedure in
this group. c. Select Settings.

Continued on next page TE14778,0000062 –19–14OCT04–2/3

TM2260 (07JAN06) 9026-25-72 750J, 850J Crawler

010706
PN=482
 Tests

d. Select Fan Valve Set. Pump Flow Rate—Specification

New Fan—Pump Flow
(Minimum) ........................................................................... 54.1 L/min
e. Select Maximum. 14.3 gpm
Used Fan—Pump Flow
4. Set engine speed to specification. (Minimum) ........................................................................... 51.9 L/min
13.7 gpm
Specification
Fast Idle—Speed ...................................................... 2330—2360 rpm 6. If fan pump flow is not within specification, remove
and inspect fan pump. Replace if necessary.
5. Record pump flow. Pump flow must be within
specification. 7. After performing this test, cycle key switch to restart
engine. This will activate proportional fan drive.
Specification
Fan Pump—Pressure ........................................................ 17 926 kPa
179 bar
2600 psi

TE14778,0000062 –19–14OCT04–3/3

Fan Motor Speed Test

The purpose of this test is to determine fan motor SERVICE EQUIPMENT AND TOOLS
speed. Motor speed not within specification can JT05709 Reflective Tape
indicate improper fan pump flow or excessive wear on JT05719 Handheld Digital Tachometer
internal components. 9026
25
SPECIFICATIONS 73

750J
Fan Motor Minimum Speed at 1700 rpm
100% setting
850J
Fan Motor Minimum Speed at 1450 rpm
100% setting

Continued on next page TE14778,0000063 –19–14OCT04–1/2

TM2260 (07JAN06) 9026-25-73 750J, 850J Crawler

010706
PN=483
 Tests

NOTE: This test requires two people to complete. One

operates machine while other obtains reading
from digital handheld tachometer.

1. Place piece of Reflective Tape (1) on fan hub.

–UN–21JAN05
NOTE: The Fan Valve Set setting is located in the service
menu. To enter the service menu, press the
MENU button and hold it down for 5 seconds.

T207357A
2. Set fan speed to Maximum.

a. Access Service Menu on monitor.

1—JT05709 Reflective Tape
b. Select TCU Diagnostics.

c. Select Settings.

d. Select Fan Valve Set.

e. Select Maximum.

3. Perform Transmission Oil Warm-Up Procedure. (Group

9026-25.)

4. Operate engine at fast idle and record rpm using digital

hand held tachometer JT05719. Motor RPM must be
9026
25 within specification.
74
750J—Specification
Fan Motor—Minimum Speed at
100% setting ................................................................................ 1700 rpm

850J—Specification
Fan Motor—Minimum Speed at
100% setting ................................................................................ 1450 rpm

5. If fan motor rpm is not within specification:

• Perform Fan Pump Flow Test. (Group 9026-25.)

• Inspect proportional fan solenoid for contamination or
seal leakage. Replace if necessary.
• Inspect fan motor. Repair or replace if necessary.

TE14778,0000063 –19–14OCT04–2/2

TM2260 (07JAN06) 9026-25-74 750J, 850J Crawler

010706
PN=484
 Tests

Fan Motor Case Drain Test

SPECIFICATIONS
Transmission Oil Temperature 57—66°C
135—150°F
Fan Motor Case Drain Leakage 1.2 L/min
(maximum per minute) 0.317 gpm

SERVICE EQUIPMENT AND TOOLS

38H1415 (—6 F ORFS) Cap
Calibrated Container

The purpose of this test is to determine if case drain

leakage is within specification. Accelerated case drain can
indicate excessive wear on internal components.

1. Heat transmission oil to specification. See

Transmission Oil Warm-Up Procedure. (Group
9026-25.)

Specification
Transmission Oil—Temperature.................................................. 57—66°C
135—150°F

2. Stop the engine.

9026
25
75

TE14778,0000061 –19–14OCT04–1/2

3. Disconnect Case Drain Line (1) from hydraulic fan oil

filter head. Cap opening. Put line in a calibrated
container (2).

4. Operate engine at slow idle and fast idle. Record case

drain flow. Case drain flow must be within specification.
–UN–13JAN05

Specification
Fan Motor Case Drain—Leakage
(maximum per minute) ................................................................ 1.2 L/min
T207021A

0.317 gpm

5. If case drain flow not within specification, replace

motor. Fan motor is not serviceable.
1—Case Drain Line (hydraulic fan motor to
hydraulic fan oil filter)
2—Calibrated Container

TE14778,0000061 –19–14OCT04–2/2

TM2260 (07JAN06) 9026-25-75 750J, 850J Crawler

010706
PN=485
 Tests

9026
25
76

TM2260 (07JAN06) 9026-25-76 750J, 850J Crawler

010706
PN=486
 Section 9031
Heating and Air Conditioning
Contents

Page

Group 05—Theory of Operation

Air Conditioning System Cycle Of
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-1

Group 15—Diagnostic Information

Diagnose Air Conditioning System
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9031-15-1
Diagnose Heater System Malfunctions . . . . .9031-15-4

Group 25—Tests
Proper Refrigerant Handling . . . . . . . . . . . . .9031-25-1
R134a Refrigerant Cautions . . . . . . . . . . . . .9031-25-1
R134a Oil Charge Capacity. . . . . . . . . . . . . .9031-25-2
R134a Refrigerant Charge Capacity . . . . . . .9031-25-2
Refrigerant Hoses And Tubing Inspection . . .9031-25-2
R134a Air Conditioning System Test . . . . . . .9031-25-3
Operating Pressure Diagnostic Chart . . . . . .9031-25-5
Air Conditioner Low Pressure Switch Test. . .9031-25-8
Air Conditioner High Pressure Switch
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-10
Freeze Control Switch Test . . . . . . . . . . . . .9031-25-11
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .9031-25-12

9031

TM2260 (07JAN06) 9031-1 750J, 850J Crawler

010706
PN=1
 Contents

9031

TM2260 (07JAN06) 9031-2 750J, 850J Crawler

010706
PN=2
 Group 05
Theory of Operation
Air Conditioning System Cycle Of Operation

2
1

5 4

7
8
6
9

–UN–20JUN01
10
11
9031

T142307
05
T142307 1

1—Evaporator Core 4—Circulation Blower Motor 7—High Pressure Liquid 10—Low Pressure Gas
2—Compressor 5—Expansion Valve 8—High Pressure Gas 11—Air Flow
3—Condenser Core 6—Receiver-Dryer 9—Low Pressure Liquid

The compressor is belt driven and engaged by an temperature of refrigerant to rise higher than that of
electromagnetic clutch. The air conditioning circuit outside air.
automatically controls compressor engagement or
disengagement when system is in operation. See High pressure gas leaves compressor and flows
System Functional Schematic and Schematic Legend. through condenser where heat is removed and
(Group 9015-10.) transferred to outside air being drawn through
condenser core by fan. Cooling refrigerant causes it to
Compressor draws low pressure gas from evaporator condense and refrigerant leaves condenser as high
and compresses it into high pressure gas. This causes pressure liquid.

Continued on next page MF82180,00001D8 –19–03MAY04–1/2

TM2260 (07JAN06) 9031-05-1 750J, 850J Crawler

010706
PN=489
 Theory of Operation

High pressure liquid flows into receiver-dryer where A freeze control switch senses temperature of
moisture and contaminants (acid, solids, etc.) are evaporator coil through a capillary tube. This prevents
removed. Receiver-dryer may contain a color moisture the evaporator from becoming cold enough to freeze
indicator. (Blue) indicates no moisture is present. moisture that condenses on evaporator coil.
(Pink) indicates moisture is present. Should moisture Condensed moisture is drained away through drain
be combined with refrigerant, hydrofluoric and tubes connected to drain pan under evaporator.
hydrochloric acids are formed. These acids are very
corrosive to metal surfaces and leakage will eventually System pressure is monitored by high and low
develop. Receiver-dryer also stores refrigerant allowing pressure switch, located on high pressure side of
a longer period of time before additional refrigerant is expansion valve. If pressure becomes too high or too
needed. Refrigerant hoses allow a small amount of low the switch opens and stops compressor,
refrigerant to migrate through their walls. interrupting the cycle.

Refrigerant flows from receiver-dryer through Accumulator is located between evaporator and
expansion valve to evaporator. Expansion valve compressor in low pressure gas hose to retain a
senses refrigerant temperature and pressure to quantity of oil to protect compressor from a dry start
modulate refrigerant flow. Expansion valve changes after long periods of not being used.
refrigerant to low pressure liquid entering evaporator.
Actual cooling and drying of cab air takes place at See Air Conditioning Harness (W14) Component
evaporator. Heat absorbed by evaporator and Location (Group 9015-10) for location of machine
transferred to refrigerant causes refrigerant to vaporize heater and air conditioning components.
into low pressure gas. Low pressure gas is drawn from
evaporator by compressor and cycle is repeated.

9031
05
MF82180,00001D8 –19–03MAY04–2/2
2

TM2260 (07JAN06) 9031-05-2 750J, 850J Crawler

010706
PN=490
 Group 15
Diagnostic Information
Diagnose Air Conditioning System
Malfunctions
Symptom Problem Solution

Air Conditioning System Does Heater Blower 10 A Fuse (F12) Replace fuse. See Fuse and Relay
Not Operate Specifications. (Group 9015-10.)

Heater Blower Switch (S10) Check blower switch. See Cab Roof
Harness (W9) Component Location.
(Group 9015-10.)

Cab Heater Blower Resistor (R4) Check blower speed resistor. See
Electrical Component Specifications.
(Group 9015-20.)

Heater Blower Motor (M3) Check blower motor. See Air

Conditioning Harness (W14)
Component Location. (Group
9015-10.)

Accessory Relay #2 (K11) Check relay. See Fuse and Relay

Specifications. (Group 9015-10.)

Air Conditioning On/Off Switch (S11) Check air conditioning on/off switch.
See Cab Roof Harness (W9)
Component Location. (Group
9015-10.)

Air Conditioning Freeze Switch (B27) Check freeze switch. Perform Freeze
Control Switch Test. (Group
9031-25.)
9031
15
Air Conditioning High Pressure Check air conditioning high pressure
1
Switch (B28) switch. Perform Air Conditioner High
Pressure Switch Test. (Group
9031-25.)

Air Conditioning Low Pressure Check air conditioning low pressure

Switch (B29) switch. Perform Air Conditioner Low
Pressure Switch Test. (Group
9031-25.)

Air Conditioning Compressor Clutch Check air conditioning compressor

(Y16) clutch. See Engine Harness (W10)
Component Location. (Group
9015-10.)

Continued on next page MF82180,00001D6 –19–03MAY04–1/3

TM2260 (07JAN06) 9031-15-1 750J, 850J Crawler

010706
PN=491
 Diagnostic Information

Symptom Problem Solution

Air Conditioning Compressor Clutch Check air conditioning compressor

5 A Diode (V4) clutch diode. See Engine Harness
(W10) Component Location. (Group
9015-10.)

Wiring harness Check air conditioning and cab roof

harnesses for short-circuits and/or
open-circuits. See Cab Roof
Harness (W9) Wiring Diagram and
see Air Conditioning Harness (W14)
Wiring Diagram. (Group 9015-10.)

Air Conditioner Does Not Cool Fresh air filter clogged Clean or replace filter
Interior of Cab

Condenser fins clogged with debris Clean condenser fins

Recirculating air filter clogged Clean or replace filter

Refrigerant hose kinked, pinched or Re-route or re-index hoses, replace

collapsed kinked or collapsed hoses

Heater or evaporator core fins Clean heater or evaporator core fins

clogged with dirt or dust

Blower motor failed or operating too Check cab blower motor and
slowly resistor. See Air Conditioning
Harness (W14) Component Location
and See Electrical Component
Specifications. (Group 9015-10.)
9031
15 Compressor belt slipping or failed Inspect and/or replace belt. See
2
Check Alternator Belt Tension.
(Operator’s Manual.)

Warm outside air leaking into cab Inspect, repair or replace door and
window seals

Condenser Fan Motor 1 Relay (K2) Check relay. See Fuse and Relay
Specifications. (Group 9015-10.)

Condenser Fan Motor 2 Relay (K1) Check relay. See Fuse and Relay
Specifications. (Group 9015-10.)

Condenser Fan Motor 1 10 A Fuse Check fuse. See Fuse and Relay
(F2) Specifications. (Group 9015-10.)

Continued on next page MF82180,00001D6 –19–03MAY04–2/3

TM2260 (07JAN06) 9031-15-2 750J, 850J Crawler

010706
PN=492
 Diagnostic Information

Symptom Problem Solution

Condenser Fan Motor 2 10 A Fuse Check fuse. See Fuse and Relay
(F1) Specifications. (Group 9015-10.)

Heater valve remaining open Check heater valve motor (M2) for
proper operation.

System refrigerant (R134a) charge Inspect system for leaks, then

low recharge. See Charge R134a
System. (Group 1830.)

Evaporator fins frosting or freezing Thermostat switch capillary tube not

positioned correctly in evaporator
core

Air Conditioner Runs Constantly, Air Conditioning Thermostat Switch Reposition capillary tube in
Too Cold capillary tube not positioned in evaporator core
evaporator properly

Compressor clutch engaged Perform Freeze Control Switch Test.

constantly (Group 9031-25.)

Interior Windows Continue To Fresh air filter clogged Clean or replace filter
Fog

Air Conditioning system off Turn air conditioning on/off switch

on.

9031
15
MF82180,00001D6 –19–03MAY04–3/3
3

TM2260 (07JAN06) 9031-15-3 750J, 850J Crawler

010706
PN=493
 Diagnostic Information

Diagnose Heater System Malfunctions

Symptom Problem Solution

Heater System Does Not Operate Under-Seat Heater 10 A Fuse (F10) Replace fuse. See Fuse and Relay
Specifications. (Group 9015-10.)

Heater Blower 10 A Fuse (F12) Replace fuse. See Fuse and Relay
Specifications. (Group 9015-10.)

Under-Seat Heater Blower Switch Check blower switch. See Operator’s

(S15) Station Harness (W7) Component
Location. (Group 9015-10.)

Heater Blower Switch (S10) Check blower switch. See Cab Roof
Harness (W9) Component Location.
(Group 9015-10.)

Accessory Relay #1 (K10) Check relay. See Fuse and Relay

Specifications. (Group 9015-10.)

Accessory Relay #2 (K11) Check relay. See Fuse and Relay

Specifications. (Group 9015-10.)

Wiring harness Check air conditioning, operator’s

station and cab roof wiring
harnesses for short-circuits and/or
open-circuits. See Operator’s Station
Harness (W7) Wiring Diagram, see
Cab Roof Harness (W9) Wiring
Diagram, and see Air Conditioning
Harness (W14) Wiring Diagram.
9031 (Group 9015-10.)
15
4

Continued on next page MF82180,00001D7 –19–03MAY04–1/2

TM2260 (07JAN06) 9031-15-4 750J, 850J Crawler

010706
PN=494
 Diagnostic Information

Symptom Problem Solution

Heater Does Not Warm Interior Fresh air filter clogged Clean or replace filter.
Of Cab

Recirculating air filter clogged Clean or replace filter.

Heater hose kinked, pinched or Re-route or re-index hoses, replace

collapsed collapsed hoses.

Heater core fins clogged with dirt or Clean heater fins.

dust

Blower motor failed or operating too Check cab blower motor and
slowly resistor. See Operator’s Station
Harness (W7) Component Location
or see Air Conditioning Harness
(W8) Component Location for
location. (Group 9015-10.) See
Electrical Component Specifications.
(Group 9015-20.)

Heater Valve 5 A Fuse (F18) Check fuse. See Fuse and Relay
Specifications. (Group 9015-10.)

Heater valve remaining closed Check heater valve for proper

operation.

Interior Windows Continue To Fresh air filter clogged Clean or replace filter.
Fog

Air Conditioning system off Turn air conditioning on/off switch

on. 9031
15
5

MF82180,00001D7 –19–03MAY04–2/2

TM2260 (07JAN06) 9031-15-5 750J, 850J Crawler

010706
PN=495
 Diagnostic Information

9031
15
6

TM2260 (07JAN06) 9031-15-6 750J, 850J Crawler

010706
PN=496
 Group 25
Tests
Proper Refrigerant Handling

The U.S. Environmental Protection Agency prohibits

discharge of any refrigerant into the atmosphere, and
requires that refrigerant be recovered using the approved
recovery equipment.

IMPORTANT: Use correct refrigerant recovery,

recycling and charging stations. Do not
use refrigerant, hoses, fittings,
components or refrigerant oils intended
for use with R12 refrigerant.

Recovery, recycling and charging stations for R12 and

R134a refrigerants must not be interchanged. Systems
containing R12 refrigerant use a different oil than systems
using R134a. Certain seals are not compatible with both
types of refrigerants.

MODTX9031QQ2009 –19–06MAY04–1/1

R134a Refrigerant Cautions

SPECIFICATIONS Do not heat refrigerant over 52°C (125°F) in a

Maximum Amount To Heat 52°C closed container. Heated refrigerant will 9031
Refrigerant In Closed Container 125°F develop high pressure which can burst the 25
Temperature
container. 1

Specification
CAUTION: Do not allow liquid refrigerant to Maximum Amount To Heat
contact eyes or skin. Liquid refrigerant will Refrigerant In Closed
freeze eyes or skin on contact. Wear Container—Temperature ............................................................. 52°C
goggles, gloves and protective clothing. 125°F

If liquid refrigerant contacts eyes or skin, do Keep refrigerant containers away from heat sources.
not rub the area. Splash large amounts of Store refrigerant in a cool place.
cool water on affected area. Go to a
physician or hospital immediately for Do not handle damp refrigerant container with your
treatment. bare hands. Skin may freeze to container. Wear
gloves.
Do not allow refrigerant to contact open
flames or very hot surfaces such as electric If skin freezes to container, pour cool water over
welding arc, electric heating element and container to free the skin. Go to a physician or hospital
lighted smoking materials. immediately for treatment.

TX,9031,JC1705 –19–06MAY04–1/1

TM2260 (07JAN06) 9031-25-1 750J, 850J Crawler

010706
PN=497
 Tests

R134a Oil Charge Capacity

Item Measurement Specification

System (Total) Capacity 232.2 mL

7.85 fl oz

Compressor (Precharge) Capacity 229.8 mL

7.77 fl oz

TX14826,000009E –19–21AUG03–1/1

R134a Refrigerant Charge Capacity

Item Measurement Specification

Refrigerant Charge (Portable Charge Capacity 1.59 kg

Station) 3.5 lb

Item Measurement Specification

Refrigerant Charge (Automated Capacity 1.47 kg

Charge Station) 3.25 lb

TX14826,000009F –19–31AUG04–1/1

Refrigerant Hoses And Tubing Inspection

When a component is disconnected from the system, hose and tube connections. Dip O-rings in correct
9031 special care should be given to inspecting hoses and viscosity oil before assembling.
25 tubing for moisture, grease, dirt, rust, or other foreign
2 material. If such contamination is present in hoses, IMPORTANT: Hose used for air conditioning
tubing, or fittings and cannot be removed by cleaning, systems contains special barriers in
then replace parts. its walls to prevent migration of
refrigerant gas.
Fittings that have grease or dirt on them should be
wiped clean with a cloth dampened with alcohol. Do not use hydraulic hoses as
Chlorinated solvents (such as trichloroethylene) are replacement hoses in the air
contaminants, and must not be used for cleaning. conditioning system. Use only
certified hose meeting SAE J51B
To assist in making leak proof joints, use a small requirements.
amount of clean correct viscosity refrigerant oil on all

MODTX9031QQ1882 –19–06MAY04–1/1

TM2260 (07JAN06) 9031-25-2 750J, 850J Crawler

010706
PN=498
 Tests

R134a Air Conditioning System Test

SPECIFICATIONS
Cab Position Open
Engine rpm 2000 rpm
Temperature Control Switch Maximum
Position
Blower Speed High
Run Unit Time At least 5 minutes

ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station

Temperature/Pressure Chart (624J)

Ambient Temperature Air Duct Temperature Low Pressure Gauge High Pressure Gauge
21.1—26.7°C (70—80°F) 8°C (47°F) 68.9—93.1 kPa (0.69—0.93 bar) 1110—1386 kPa (11.1—12.9 bar)
(10—13 psi) (161—210 psi)
26.7—29.4°C (80—85°F) 10.6°C (51°F) 93.1—100 kPa (0.93—1 bar) 1358—1476 kPa (13.6—14.8 bar)
(13.5—14.5 psi) (197—214 psi)
29.4—32.2°C (85—90°F) 11.1°C (52°F) 96.1—103.4 kPa (0.96—1.03 bar) 1427—1586 kPa (14.3—15.9 bar)
(14—15 psi) (207—230 psi)
32.2—37.8°C (90—100°F) 13.3°C (56°F) 100—131 kPa (1—1.31 bar) (14.5— 1538—2013 kPa (15.4—20.13 bar)
19 psi) (223—292 psi)
37.8—43.3°C (100—110°F) 16.9°C (62.5°F) 135.8—168.9 kPa (1.36—1.69 bar) 1868—2275 kPa (18.7—22.8 bar)
(19.7—24.5 psi) (271—330 psi)
43.3—48.9°C (110—120°F) 22.5°C (72.5°F) 171.7—217.9 kPa (1.72—2.18 bar) 2275—2723 kPa (22.8—27.2 bar)
(24.9—31.6 psi) (330-395 psi)
48.9—54.4°C (120—130°F) 28°C (82.5°F) 217.9—268.9 kPa (2.18—2.69 bar) 2654—3103kPa (25.5—31.0 bar)
(31.6—39 psi) (385—450 psi)

NOTE: JTO2046 and JTO2050 Recovery and Charging

Stations can be substituted for the JTO2045 9031
station. 25
3

IMPORTANT: Use correct refrigerant recovery,

recycling and charging stations. DO
NOT use refrigerant, hoses, fittings,
components or refrigerant oils intended
for R12 refrigerant.

1. Connect refrigerant recovery, recycling and charging

station. See R134a Refrigerant Recovery, Recycling
And Charging Station Installation Procedure. (Group
1830.)

2. Close both low and high pressure valves on refrigerant

recovery, recycling and charging station.

Continued on next page TX,9031,JC1706 –19–12NOV96–1/3

TM2260 (07JAN06) 9031-25-3 750J, 850J Crawler

010706
PN=499
 Tests

3. Open cab doors and windows. Disconnect hydraulic

fan proportional relief solenoid (Y5) and hydraulic fan
reversing solenoid (Y6).

Specification
Cab—Position .................................................................................... Open

TX,9031,JC1706 –19–12NOV96–2/3

4. Start engine and run at rated engine speed.

Specification
Engine—Speed ........................................................................... 2000 rpm

5. Turn temperature control switch to the maximum

cooling position.

Specification
Temperature Control Switch—
Position .......................................................................... Maximum Cooling

6. Turn blower switch to high speed.

Specification
Blower—Speed .................................................................................... High

7. Check sight glass in receiver-dryer to condenser line.

9031 8. Run unit for at least 5 minutes.

25
4
Specification

–UN–06DEC93
Run Unit—Time ............................................................. At least 5 minutes

9. Measure air temperature at condenser air inlet and at

air ducts in air conditioning unit.
T8118AG

10. Compare air duct temperature reading to the

temperatures shown in the specifications.
A—High Pressure Hose Charge Port Cap
B—Red Hose (High Pressure)
11. Observe low-side pressure (C) and high-side pressure C—Blue Hose (Low Pressure)
(B) on gauges. D—High Pressure Relief Valve
E—Refrigerant Recovery/Recycling and Charging
12. Compare pressure readings to the pressure shown in System
specifications. See Operating Pressure Diagnostic
Chart. (Group 9031-25.)

TX,9031,JC1706 –19–12NOV96–3/3

TM2260 (07JAN06) 9031-25-4 750J, 850J Crawler

010706
PN=500
 Tests

Operating Pressure Diagnostic Chart

NOTE: Inspection of the sight glass will not give proper

indicators of air conditioning concerns on R134a
systems.

OPERATING PRESSURE DIAGNOSTIC CHART

Low Side Pressure High Side Pressure Problem Solution
Low Low or Normal Loss of refrigerant. Leak in system. Do leak test. Add refrigerant. Normal
migration through hoses. Add refrigerant.
Low Low or Normal Loss of refrigerant. Leak in system. Do leak test. Repair leak. Add refrigerant
in this group.
Low Low or Normal Loss of refrigerant. Normal migration through hoses. Add refrigerant in this
group
Low Low or Normal Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
1. Between compressor temperature change. Remove refrigerant by recovery
and condenser. method. Inspect and clean each component.
2. Inside condenser.
3. Between condenser and
receiver-dryer.
4. Inside receiver-dryer.
Low Low or Normal Blower motor running too Check for motor shaft binding or defective electrical
slow. connections.
Low Low or Normal Evaporator core dirty or air Clean evaporator and straighten fins.
flow through evaporator
restricted.
Low Low or Normal Expansion valve Replace expansion valve.
malfunction.
Low Low or Normal Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
1. Between receiver-dryer temperature change. Remove refrigerant by recovery
and expansion valve. method. Inspect and clean each component.
2. Between expansion
valve and evaporator.
3. Between evaporator and
compressor. 9031
25
Low Low or Normal Moisture in system. Remove refrigerant using recovery method, evacuate and 5
charge the system. See Recover R134a SystemSee
Evacuate R134a System See Charge R134a System.
(Group 1830.)
Low High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
1. Between compressor temperature change. Remove refrigerant by recovery
and condenser. method. Inspect and clean each component.
2. Inside condenser.
3. Between condenser and
receiver-dryer.
4. Inside receiver-dryer.
5. Between receiver-dryer
and expansion valve.
Normal Normal Heater valve not closing. Close heater shutoff valve on engine block or clamp heater
hoses shut

Continued on next page CED,OUTX466,1346 –19–28SEP98–1/3

TM2260 (07JAN06) 9031-25-5 750J, 850J Crawler

010706
PN=501
 Tests

OPERATING PRESSURE DIAGNOSTIC CHART

Low Side Pressure High Side Pressure Problem Solution
Normal Normal Expansion valve Replace expansion valve.
malfunction.
Normal Normal Moisture in system Remove refrigerant using recovery method, evacuate and
(intermittent cooling below charge the system. See Recover R134a System. See
27°C [80°F] ambient). Evacuate R134a System. See Charge R134a System.
(Group 1830.)
Normal Normal Loss of refrigerant. Leak in system. Do leak test. Repair leak. Add refrigerant.
Normal Normal Loss of refrigerant Normal migration through hoses. Add refrigerant in this
group.
Normal Normal Air is system. Remove refrigerant using recovery method, evacuate and
charge the system. See Recover R134a System. See
Evacuate R134a System. See Charge R134a System.
(Group 1830.)
Normal High Restricted air flow through Inspect for debris. Straighten fins.
condenser or radiator.
Normal High Overcharge of refrigerant. Start engine and run at fast idle. Operate air conditioner at
maximum cooling. Remove refrigerant from low-side of
system using recovery operation until bubbles appear in
sight glass. Add 0.7 kg (1.5 lb) of refrigerant through
low-side valve.
Normal High Expansion valve Replace expansion valve.
malfunction.
Normal High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
1. Between compressor temperature change. Remove refrigerant by recovery
and condenser. method. Inspect and clean each component.
2. Inside condenser.
3. Between condenser and
receiver-dryer.
4. Inside receiver-dryer.
Normal High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
1. Between compressor temperature change. Remove refrigerant by recovery
and condenser. method. Inspect and clean each component.
9031 2. Inside condenser.
25 3. Between condenser and
6 receiver-dryer.
4. Inside receiver-dryer.
High Low Compressor belt loose. Tighten belt.
High Low Compressor clutch slipping. Check for battery voltage at compressor clutch with clutch
engaged. Clean electrical connections or replace relay.
High Low Compressor clutch slipping. Inspect and repair clutch.
High Low Compressor failure. Test compressor efficiency. (Group 1830.)
High Normal Expansion valve Replace expansion valve.
malfunction.
High High Restricted air flow through Inspect for debris. Straighten fins.
condenser or radiator.
High High Expansion valve Replace expansion valve.
malfunction.

Continued on next page CED,OUTX466,1346 –19–28SEP98–2/3

TM2260 (07JAN06) 9031-25-6 750J, 850J Crawler

010706
PN=502
 Tests

OPERATING PRESSURE DIAGNOSTIC CHART

Low Side Pressure High Side Pressure Problem Solution
High High Overcharge of refrigerant. Start engine and run at fast idle. Operate air conditioner at
maximum cooling. Remove refrigerant from low-side of
system using refrigerant recovery method until bubbles
appear in sight glass. Add 0.7 kg (1.5 lb) of refrigerant
through low-side valve.
High High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
temperature change. Remove refrigerant by recovery
method. Inspect and clean each component.
High High Air in system. Remove refrigerant using recovery method, evacuate and
charge the system. See Recover R134a System.See
Evacuate R134a System. See Charge R134a System.
(Group 1830.)
High High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
1. Between compressor temperature change. Remove refrigerant by recovery
and condenser. method. Inspect and clean each component.
2. Inside condenser.
3. Between condenser and
receiver-dryer.
4. Inside receiver-dryer.

CED,OUTX466,1346 –19–28SEP98–3/3

9031
25
7

TM2260 (07JAN06) 9031-25-7 750J, 850J Crawler

010706
PN=503
 Tests

Air Conditioner Low Pressure Switch Test

SPECIFICATIONS
Low Pressure Switch Opens 138—208 kPa
(Normally Open) Decreasing 1.38—2.08 bar
Pressure 20—30 psi

–UN–06MAR95
Low Pressure Switch Closes 310—380 kPa
(Normally Open) Increasing 3.1—3.8 bar
Pressure 45—55 psi

T8426AD
SERVICE EQUIPMENT AND TOOLS
JT05791 Multimeter

NOTE: Low pressure switch is normally open when

removed from machine. When installed the switch
becomes closed because of normal system
pressure.

1. Turn key switch on but do not start engine. Turn

blower switch on. Turn temperature control switch to
the maximum cooling position.

2. Disconnect and connect low pressure switch at

harness connector. Compressor clutch must engage
and disengage (click).

NOTE: The line that attaches the low pressure switch has
a valve to prevent discharging the air conditioning
system when switch is removed.

3. Disconnect harness from switch and remove switch

from line. Connect low pressure switch to harness.
9031
25 Compressor clutch must not engage (click).
8
4. The actual pressure setting of switch can be checked
by connecting it to a regulated pressure source such
as dry nitrogen.

Specification
Low Pressure Switch Opens
(Normally Open)—Decreasing
Pressure .............................................................................. 138—208 kPa
1.38—2.08 bar
20—30 psi
Low Pressure Switch Closes
(Normally Open)—Increasing
Pressure .............................................................................. 310—380 kPa
3.1—3.8 bar
45—55 psi

Continued on next page CED,OUTX466,1348 –19–03MAY04–1/2

TM2260 (07JAN06) 9031-25-8 750J, 850J Crawler

010706
PN=504
 Tests

5. Switch must not have continuity between terminals until

pressure increases to switch closing pressure
specification. Slowly release pressure. Switch must
have continuity until pressure decreases to switch
opening pressure specification.

CED,OUTX466,1348 –19–03MAY04–2/2

9031
25
9

TM2260 (07JAN06) 9031-25-9 750J, 850J Crawler

010706
PN=505
 Tests

Air Conditioner High Pressure Switch Test

SPECIFICATIONS
High Pressure Switch Opens 2622—2898 kPa
(Normally Closed) Increasing 2.62—2.90 bar
Pressure 380—420 psi

–UN–06MAR95
High Pressure Switch Closes 1172—1448 kPa
(Normally Closed) Decreasing 1.172—1.448 bar
Pressure 170—210 psi

T8426AE
SERVICE EQUIPMENT AND TOOLS
Multimeter
D18018KD Air Conditioning Gauge Set

NOTE: The line that attaches the high pressure switch

has a valve installed to prevent discharging the air
conditioning system when switch is removed. The
high pressure switch is normally closed when
removed from the machine. It does not open
when installed in the air conditioning system until
pressure exceeds specification.

1. Remove high pressure switch.

2. Connect a regulated pressure source, such as dry

nitrogen to high pressure switch.

3. Switch must have continuity between terminals until

pressure increases to switch opening pressure
specification.

Specification
9031 High Pressure Switch Opens
25 (Normally Closed)—Increasing
10 Pressure .......................................................................... 2622—2898 kPa
2.62—2.90 bar
380—420 psi
High Pressure Switch Closes
(Normally Closed)—Decreasing
Pressure ......................................................................... 1172—1448 kPa
1.172—1.448 bar
170—210 psi

4. Slowly release pressure. Switch must not have

continuity until pressure decreases to switch closing
pressure specification.

Continued on next page CED,OUTX466,1349 –19–03MAY04–1/2

TM2260 (07JAN06) 9031-25-10 750J, 850J Crawler

010706
PN=506
 Tests

5. The switch can also be checked when installed in air

conditioning system, however, pressure is slow to
increase to test specification.

Connect an air conditioning gauge set to service

fittings at compressor. Cover condenser with paper or
plastic to stop air flow. Operate air conditioner on
maximum cooling. Note high-side pressure when high
pressure switch opens and then closes.

CED,OUTX466,1349 –19–03MAY04–2/2

Freeze Control Switch Test

SPECIFICATIONS
Freeze Control Switch (Normally -1.4—0.28°C
Closed) Opens As Temperature 29.5—32.5°F
Drops Opening Temperature

–UN–13NOV90
Freeze Control Switch (Normally 1.38—3.06°C
Closed) Closes as Temperature 34.5—37.5°F
rises Closing Temperature

• Remove freeze control switch from evaporator.

T7199EZ
• Connect ohmmeter to switch terminals. Switch must be
closed at room temperature.
• Put switch into a freezer (temperature must be below
-0.56 ± 0.84°C [31 ± 1.5°F]). Switch must open, and
continuity must not be read.

Specification
Freeze Control Switch (Normally 9031
Closed) Opens As Temperature 25
Drops—Opening Temperature .............................................. -1.4—0.28°C 11
29.5—32.5°F

• Remove switch from freezer. Put sensing tube into a

glass of warm water. Switch must close, and continuity
must be read.

Specification
Freeze Control Switch (Normally
Closed) Closes As Temperature
Rises—Closing Temperature ................................................ 1.38—3.06°C
34.5—37.5°F

• If switch does not open and close during testing, install

new switch.

TX18076,0000016 –19–14NOV00–1/1

TM2260 (07JAN06) 9031-25-11 750J, 850J Crawler

010706
PN=507
 Tests

Leak Testing

SPECIFICATIONS • If a leak detector is used, move the leak detector

Move Leak Detector Speed 25 mm per second probe under the hoses and around the connections
1 in. per second at a rate of 25 mm (1 in.) per second.

• Inspect all lines, fittings, and components for oily or Specification

dusty spots. When refrigerant leaks from the system, Move Leak Detector—Speed ................................ 25 mm per second
1 in. per second
a small amount of oil is carried out with it.
• A soap and water solution can be sprayed on the
• Some refrigerant manufacturers add dye to
components in the system to form bubbles at the
refrigerant to aid in leak detection.
source of the leak.

MODTX9031QQ1881 –19–19AUG94–1/1

9031
25
12

TM2260 (07JAN06) 9031-25-12 750J, 850J Crawler

010706
PN=508
 Index
Page Page

A Blade down accumulator precharge

Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-16
Adjustment Blade float
Motor displacement control valve (MDCV) Operational check . . . . . . . . . . . . . . . . . .9005-10-9
akjustment . . . . . . . . . . . . . . . . . . . . .9026-25-43 Bleed procedure
Adjustments Hand pump bleed procedure. . . . . . . . .9026-25-68
Brake pedal to brake valve linkage Brake
adjustment. . . . . . . . . . . . . . . . . . . . .9015-20-91 Brake pedal to brake valve linkage
Pressure control pilot (PCP) internal adjustment adjustment. . . . . . . . . . . . . . . . . . . . .9015-20-91
test . . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-18 Park brake test . . . . . . . . . . . . . . . . . . .9026-25-61
Pump displacement control valve (PDCV) neutral Releasing park brake to tow the
(null) adjustment . . . . . . . . . . . . . . . .9026-25-36 machine. . . . . . . . . . . . . . . . . . . . . . . .9026-25-5
Transmission Control Lever (TCL) Brake pedal
adjustment. . . . . . . . . . . . . . . . . . . . .9015-20-94 Operational check . . . . . . . . . . . . . . . . .9005-10-13
Air conditioner
Operational check . . . . . . . . . . . . . . . . .9005-10-11
Air conditioning
Diagnose malfunctions . . . . . . . . . . . . . .9031-15-1
C
Freeze control switch test . . . . . . . . . . .9031-25-11
Hoses and tubing inspection . . . . . . . . . .9031-25-2 Cab door
Leak testing . . . . . . . . . . . . . . . . . . . . .9031-25-12 Operational check . . . . . . . . . . . . . . . . . .9005-10-5
Refrigerant cycle . . . . . . . . . . . . . . . . . . .9031-05-1 Calibration
Refrigerant handling . . . . . . . . . . . . . . . .9031-25-1 Transmission Control Unit (TCU) . . . . .9015-20-89
Refrigerant R134a caution . . . . . . . . . . .9031-25-1 CAN Monitor Unit (CMU)
R134a oil charge capacity. . . . . . . . . . . .9031-25-2 Diagnostic Trouble Codes (DTCs). . . . . .9015-20-9
R134a Refrigerant charge capacity . . . . .9031-25-2 Theory of operation. . . . . . . . . . . . . . . .9015-15-21
System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-3 Charge oil filter
Air restriction indicator Hydrostatic charge oil filter operation . . .9026-05-5
Operational check . . . . . . . . . . . . . . . . .9005-10-12 Charge Pump
Alternator Charge pump operation . . . . . . . . . . . . .9026-05-4
Operational check . . . . . . . . . . . . . . . . .9005-10-11 Charging circuit
Test procedure . . . . . . . . . . . . . . . . . . .9015-20-80 Theory of operation. . . . . . . . . . . . . . . . .9015-15-1
Angle Chemical Products
Blade operation. . . . . . . . . . . . . . . . . . .9025-05-12 Handling . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-5
Attachments Cinch connector
Adding Safely . . . . . . . . . . . . . . . . . . . .9000-01-10 Install contact . . . . . . . . . . . . . . . . . . . 9015-20-104
Operating Safely . . . . . . . . . . . . . . . . . .9000-01-10 Cinch connectors Indx
Replace Connector . . . . . . . . . . . . . . . 9015-20-102 1
Circuit relief valve operation . . . . . . . . . . . .9025-05-8
Circuit relief valve test . . . . . . . . . . . . . . . .9025-25-4
Component location
B Air conditioning harness (W14) . . . . . . .9015-10-60
Cab roof harness (W9) . . . . . . . . . . . . .9015-10-36
Battery Canopy roof harness (W8) . . . . . . . . . .9015-10-32
Explosions, prevent. . . . . . . . . . . . . . . . .9000-01-4 Engine harness (W10) . . . . . . . . . . . . .9015-10-40
Operational check . . . . . . . . . . . . . . . . . .9005-10-8 Hydrostatic system component
Battery disconnect switch location . . . . . . . . . . . . . . . . . . . . . . . .9026-15-8
Operational check . . . . . . . . . . . . . . . . . .9005-10-4 Information . . . . . . . . . . . . . . . . . . . . . . .9015-05-2
Blade angle Operator’s station harness (W7) . . . . . .9015-10-24
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-12 Park brake system component
Blade angle operation. . . . . . . . . . . . . . . .9025-05-12 location . . . . . . . . . . . . . . . . . . . . . . .9026-15-10
Blade down accumulator hydraulic Radio harness (W15) . . . . . . . . . . . . . .9015-10-64
discharge . . . . . . . . . . . . . . . . . . . . . . .9025-25-15 Transmission harness (W11). . . . . . . . .9015-10-50

TM2260 (07JAN06) Index-1 750J, 850J Crawler

010706
PN=1
 Index

Page Page

Controller Area Network (CAN) Engine on checks

Theory of operation. . . . . . . . . . . . . . . . .9015-15-3 Operational checkout . . . . . . . . . . . . . . .9005-10-8
Controls Engine speed control
Transmission Control Lever (TCL) Remove and install . . . . . . . . . . . . . . . .9015-20-92
adjustment. . . . . . . . . . . . . . . . . . . . .9015-20-94 Equipment, Protective
Coolant condition Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-2
Operatonal check . . . . . . . . . . . . . . . . . .9005-10-2
Cooler
Hydrostatic oil cooler bypass test . . . . .9026-25-52
Oil cooler and reservoir bypass F
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-12
Cycle time
Operational check . . . . . . . . . . . . . . . . .9005-10-14 Fan
Cylinder drift test procedure . . . . . . . . . . .9025-25-10 Fan motor case drain test . . . . . . . . . . .9026-25-75
Cylinder leakage test . . . . . . . . . . . . . . . .9025-25-11 Fan motor speed test . . . . . . . . . . . . . .9026-25-73
Fan pump flow test . . . . . . . . . . . . . . . .9026-25-71
Fan pump pressure test . . . . . . . . . . . .9026-25-69
Hydraulic fan drive operation. . . . . . . . .9026-05-23
D Hydraulic fan return filter operation . . . .9026-05-26
Filter
Decelerator sensor Hydrostatic charge oil filter operation . . .9026-05-5
Remove and install . . . . . . . . . . . . . . . .9015-20-93 Final fuel filter
Decelerator/brake pedal Operational check . . . . . . . . . . . . . . . . . .9005-10-3
Operational check . . . . . . . . . . . . . . . . .9005-10-13 Fires, prevent . . . . . . . . . . . . . . . . . . . . . . .9000-01-4
Diagnose malfunction Flow chart
Hydraulic system. . . . . . . . . . . . . . . . . .9025-15-19 Transmission control circuit operation (flow
Diagnostic chart, pressure . . . . . . . . . . . . .9031-25-5 chart). . . . . . . . . . . . . . . . . . . . . . . . . .9026-05-3
Diagnostic Touble Codes (DTCs) Flowcharts
CAN Monitor Unit (CMU). . . . . . . . . . . . .9015-20-9 Engine starts but one or both tracks will not
Engine Control Unit (ECU) . . . . . . . . . 9015-20-12, move-flowchart . . . . . . . . . . . . . . . . . .9026-15-6
9015-20-16 Low charge pressure-flowchart . . . . . . . .9026-15-2
Quick reference list . . . . . . . . . . . . . . . . .9015-20-1 Low Power-flowchart. . . . . . . . . . . . . . . .9026-15-5
Transmission Control Unit (TCU) . . . . .9015-20-24 Machine will not reach full
Diagrams speed-flowchart . . . . . . . . . . . . . . . . . .9026-15-4
System functional schematic . . . . . . . . . .9015-10-9 Mistrack/Indexes-flowchart . . . . . . . . . . .9026-15-3
Digital pressure/temperature analyzer Overheating-flowchart . . . . . . . . . . . . . . .9026-15-1
Installation. . . . . . . . . . . . . . .9025-25-1, 9026-25-1 TCU Diagnostic problems-flowchart . . . .9026-15-7
Indx
2 Fluids, high pressure
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-3
E Flushing procedure
Hydraulic oil cleanup procedure . . . . . . 9025-25-2,
Electrical 9026-25-11
Component specifications . . . . . . . . . . .9015-20-82 Hydrostatic pump flushing procedure . .9026-25-10
Schematic, wiring diagram, and component Flushing valve
location information . . . . . . . . . . . . . . .9015-05-2 Flushing valve and operating charge relief valve
Emergencies operation . . . . . . . . . . . . . . . . . . . . . .9026-05-19
Prepare for . . . . . . . . . . . . . . . . . . . . . . .9000-01-5 FNR sensor
Engine Control Unit (ECU) Remove and install . . . . . . . . . . . . . . . .9015-20-93
Diagnostic Trouble Codes (DTCs). . . . 9015-20-12, Fuel cap
9015-20-16 Operational check . . . . . . . . . . . . . . . . . .9005-10-5
Theory of operation. . . . . . . . . . . . . . . . .9015-15-5 Fuel supply pump pressure test . . . . . . . . .9010-25-2
Engine off checks Fumes, exhaust
Operational check . . . . . . . . . . . . . . . . . .9005-10-1 Beware . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-4

TM2260 (07JAN06) Index-2 750J, 850J Crawler

010706
PN=2
 Index

Page Page

Fuse Hydraulic pump flow

Location . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-17
Specifications . . . . . . . . . . . . . . . . . . . . .9015-10-2 Hydraulic pump operation. . . . . . . . . . . . . .9025-05-2
Hydraulic system
Malfunctions . . . . . . . . . . . . . . . . . . . . .9025-15-19
Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-1
G
Hydraulic system operation . . . . . . . . . . . .9025-05-1
Hydraulic system relief valve operation. . . .9025-05-9
Grouser wear
Hydraulic system relief valve test . . . . . . . .9025-25-2
Operational check . . . . . . . . . . . . . . . . . .9005-10-4
Hydraulic system schematic
Schematic, hydraulic system . . . . . . . . . .9025-15-2
Hydrostatic motor
H Hydrostatic motor operation . . . . . . . . .9026-05-21
Hydrostatic pump operation . . . . . . . . .9026-05-18
Hand pump bleed procedure . . . . . . . . . .9026-25-68 Hydrostatic system
Handholds Brake pedal to brake valve linkage
Use correctly. . . . . . . . . . . . . . . . . . . . . .9000-01-6 adjustment. . . . . . . . . . . . . . . . . . . . .9015-20-91
Harness Charge pump flow test . . . . . . . . . . . . .9026-25-50
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-90 Hydrostatic System
Heater blower motor Charge pump operation . . . . . . . . . . . . .9026-05-4
Operational check . . . . . . . . . . . . . . . . . .9005-10-7 Hydrostatic system
Heater system Engine starts but one or both tracks will not
Diagnose malfunctions . . . . . . . . . . . . . .9031-15-4 move-flowchart . . . . . . . . . . . . . . . . . .9026-15-6
HIC valve Flushing valve and operating charge relief valve
Hydraulic intregrated circuit (HIC) valve operation . . . . . . . . . . . . . . . . . . . . . .9026-05-19
operation . . . . . . . . . . . . . . . . . . . . . . .9026-05-9 Hydraulic fan drive operation. . . . . . . . .9026-05-23
Horn Hydraulic fan return filter operation . . . .9026-05-26
Operational check . . . . . . . . . . . . . . . . . .9005-10-5 Hydraulic oil cleanup procedure . . . . . . 9025-25-2,
Hydraulic 9026-25-11
Component location . . . . . 9025-15-14, 9025-15-16 Hydrostatic System
Fan motor case drain test . . . . . . . . . . .9026-25-75 Hydrostatic charge oil filter operation . . .9026-05-5
Fan motor speed test . . . . . . . . . . . . . .9026-25-73 Hydrostatic system
Fan pump flow test . . . . . . . . . . . . . . . .9026-25-71 Hydrostatic motor min./max. angle control piston
Fan pump pressure test . . . . . . . . . . . .9026-25-69 pressure test . . . . . . . . . . . . . . . . . . .9026-25-46
Hydraulic Component Location . . . . . . . . 9025-15-14, Hydrostatic motor operation . . . . . . . . .9026-05-21
9025-15-16 Hydrostatic oil cooler bypass test . . . . .9026-25-52
Hydraulic control valve Hydrostatic Oil Reservoir bypass Indx
Cross section . . . . . . . . . . . . . . . . . . . . .9025-05-5 test . . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-57 3
Hydraulic control valve operation . . . . . . . .9025-05-5 Hydrostatic pump and motor initial start-up
Hydraulic Discharge . . . . . . . . . . . . . . . . .9025-25-15 procedure . . . . . . . . . . . . . . . . . . . . . .9026-25-8
Hydraulic fan Hydrostatic pump flushing procedure . .9026-25-10
Hydraulic fan drive operation. . . . . . . . .9026-05-23 Hydrostatic pump operation . . . . . . . . .9026-05-18
Hydraulic fan return filter operation . . . .9026-05-26 Hydrostatic schematic - neutral (park brake
Hydraulic intregrated circuit (HIC) valve on). . . . . . . . . . . . . . . . . . . . . . . . . . .9026-15-12
Hydraulic intregrated circuit (HIC) valve Hydrostatic system component
operation . . . . . . . . . . . . . . . . . . . . . . .9026-05-9 location . . . . . . . . . . . . . . . . . . . . . . . .9026-15-8
Hydraulic oil filter manifold Hydrostatic system diagram - forward (fast
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-10 speed) . . . . . . . . . . . . . . . . . . . . . . . .9026-15-18
Hydraulic oil filter manifold operation . . . .9025-05-10 Hydrostatic system diagram - neutral (park brake
Hydraulic pump on). . . . . . . . . . . . . . . . . . . . . . . . . . .9026-15-14
Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-2 Hydrostatic system diagram - reverse (slow
Hydraulic pump case drain speed) . . . . . . . . . . . . . . . . . . . . . . . .9026-15-16
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-20 JDG1770 Ultra clean hand launcher . . . .9026-25-1

TM2260 (07JAN06) Index-3 750J, 850J Crawler

010706
PN=3
 Index

Page Page

Low charge pressure-flowchart . . . . . . . .9026-15-2 J

Low Power-flowchart. . . . . . . . . . . . . . . .9026-15-5
Machine will not reach full JT02156A digital pressure/temperature analyzer
speed-flowchart . . . . . . . . . . . . . . . . . .9026-15-4 Installation. . . . . . . . . . . . . . .9025-25-1, 9026-25-1
Mistrack/Indexes-flowchart . . . . . . . . . . .9026-15-3
Multi-function relief valve test . . . . . . . .9026-25-22
Multi-function valve operation . . . . . . . . .9026-05-7 L
Neutral charge relief pressure test . . . .9026-25-31
Neutral charge relief valve operation. . . .9026-05-6 Legend
Oil cooler and reservoir bypass Component location . . . . . . . . . . . . . . . .9015-10-4
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-12 System Functional Schematic . . . . . . . . .9015-10-4
Operating charge relief pressure test . .9026-25-31 Wiring diagram . . . . . . . . . . . . . . . . . . . .9015-10-4
Overheating-flowchart . . . . . . . . . . . . . . .9026-15-1 Lift cylinder function drift
Park brake system component Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-7
location . . . . . . . . . . . . . . . . . . . . . . .9026-15-10 Lift Operation . . . . . . . . . . . . . . . . . . . . . .9025-05-16
Park brake test . . . . . . . . . . . . . . . . . . .9026-25-61 Load Sense
Park brake valve operation . . . . . . . . . .9026-05-11 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-5
Pressure control pilot (PCP) internal adjustment Load sense isolator
test . . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-18 Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-7
Pressure control pilot (PCP) manual override Load sense isolator operation. . . . . . . . . . .9025-05-7
test . . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-12
Pressure control pilot (PCP) test . . . . . .9026-25-14
Pump displacement control valve (PDCV) neutral M
(null) adjustment . . . . . . . . . . . . . . . .9026-25-36
Pump displacement control valve (PDCV) Machine modifications
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-16 Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-2
Pump pressure control pilot (PCP) Machine, inspect . . . . . . . . . . . . . . . . . . . .9000-01-3
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-14 Main
Pump servo pressure test . . . . . . . . . . .9026-25-39 hydraulic system . . . . . . . . . . . . . . . . . . .9025-05-1
Releasing park brake to tow the Monitor
machine. . . . . . . . . . . . . . . . . . . . . . . .9026-25-5 Operational check . . . . . . . . . . . . . . . . . .9005-10-8
TCU Diagnostic problems-flowchart . . . .9026-15-7 Motor
Theory of operation. . . . . . . . . . . . . . . . .9026-05-1 Fan motor case drain test . . . . . . . . . . .9026-25-75
Hydrostatic System Fan motor speed test . . . . . . . . . . . . . .9026-25-73
Transmission control circuit operation (flow Hydrostatic motor min./max. angle control piston
pressure test . . . . . . . . . . . . . . . . . . .9026-25-46
Indx chart). . . . . . . . . . . . . . . . . . . . . . . . . .9026-05-3
Hydrostatic motor operation . . . . . . . . .9026-05-21
4 Hydrostatic system
Hydrostatic pump and motor initial start-up
Transmission Control Lever (TCL)
procedure . . . . . . . . . . . . 9026-25-8, 9026-25-10
adjustment. . . . . . . . . . . . . . . . . . . . .9015-20-94
Motor displacement control valve (MDCV)
Transmission efficiency test . . . . . . . . .9026-25-27
adjustment. . . . . . . . . . . . . . . . . . . . .9026-25-43
Transmission Oil Warm-up Procedure. . .9026-25-2 Motor displacement control valve (MDCV)
Hydrotatic System Adjustment . . . . . . . . . . . . . . . . . . . . . .9026-25-43
Hydraulic intregrated circuit (HIC) valve Multi-function valve
operation . . . . . . . . . . . . . . . . . . . . . . .9026-05-9 Multi-function valve operation . . . . . . . . .9026-05-7

O
I
Oil
Intake manifold pressure test-turbocharger boost Hydraulic oil cleanup procedure . . . . . . 9025-25-2,
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-1 9026-25-11

TM2260 (07JAN06) Index-4 750J, 850J Crawler

010706
PN=4
 Index

Page Page

Oil cooler Hydrostatic pump and motor initial start-up

Hydrostatic oil cooler bypass test . . . . .9026-25-52 procedure . . . . . . . . . . . . . . . . . . . . . .9026-25-8
Oil Cooler Hydrostatic pump flushing procedure . .9026-25-10
Oil cooler and reservoir bypass Hydrostatic pump theory of
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-12 operation . . . . . . . . . . . . . . . . . . . . . .9026-05-18
Oil filter Pump servo pressure test . . . . . . . . . . .9026-25-39
Hydrostatic charge oil filter operation . . .9026-05-5 Pump displacement control valve
Operating charge relief valve Pump displacement control valve (PDCV)
Flushing valve and operating charge relief valve operation . . . . . . . . . . . . . . . . . . . . . .9026-05-16
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-19 Pump load sense differential and system pressure
Operation Test
Hydraulic control valve . . . . . . . . . . . . . .9025-05-5 Adjustment . . . . . . . . . . . . . . . . . . . . .9025-25-5
Hydraulic system relief valve. . . . . . . . . .9025-05-9 Pump pressure control pilot
Operation Qualification . . . . . . . . . . . . . . . .9000-01-2 Pump pressure control pilot (PCP)
Operational checkout . . . . . . . . . . . . . . . . .9005-10-1 operation . . . . . . . . . . . . . . . . . . . . . .9026-05-14
Operator’s Seat
Starting . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-6
Q

Quick-drop valve
P Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-20
Quick-Drop valve
Park brake Operational check . . . . . . . . . . . . . . . . .9005-10-10
Operational check . . . . . . . . . . . . . . . . .9005-10-13 Quick-drop valve operation . . . . . . . . . . . .9025-05-20
Park Brake
Park brake test . . . . . . . . . . . . . . . . . . .9026-25-61
Park brake valve R
Park brake valve operation . . . . . . . . . .9026-05-11
Park brake valve leakage Radiator cap
Operational check . . . . . . . . . . . . . . . . .9005-10-13 Operational check . . . . . . . . . . . . . . . . . .9005-10-2
Parts, moving Relief valve
Stay clear . . . . . . . . . . . . . . . . . . . . . . . .9000-01-3 Flushing valve and operating charge relief valve
PCP operation . . . . . . . . . . . . . . . . . . . . . .9026-05-19
Pump pressure control pilot (PCP) Neutral charge relief valve operation. . . .9026-05-6
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-14 Relief valve, anti-cavitation
PDCV Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-8
Indx
Hydrostatic pump displacement control valve Reservoir 5
(PDCV) operation . . . . . . . . . . . . . . .9026-05-16 Hydrostatic oil reservoir bypass test . . .9026-25-57
Pilot controller Oil cooler and reservoir bypass
Operational check . . . . . . . . . . . . . . . . .9005-10-10 operation . . . . . . . . . . . . . . . . . . . . . .9026-05-12
Pilot controller lock Reverse fan
Operational check . . . . . . . . . . . . . . . . . .9005-10-9 Operational check . . . . . . . . . . . . . . . . .9005-10-14
Pressure diagnostic chart . . . . . . . . . . . . . .9031-25-5 Reverse warning alarm
Pressure reducing valve pressure Operational check . . . . . . . . . . . . . . . . . .9005-10-6
Test Ripper Operation
Adjustment . . . . . . . . . . . . . . . . . . . .9025-25-13 Ripper . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-16
Pump
Charge pump flow test . . . . . . . . . . . . .9026-25-50
Charge pump operation . . . . . . . . . . . . .9026-05-4 S
Fan pump flow test . . . . . . . . . . . . . . . .9026-25-71
Fan pump pressure test . . . . . . . . . . . .9026-25-69 Safety
Hand pump bleed procedure. . . . . . . . .9026-25-68 Add cab guarding for special uses . . . . .9000-01-6

TM2260 (07JAN06) Index-5 750J, 850J Crawler

010706
PN=5
 Index

Page Page

Avoid backover accidents . . . . . . . . . . . .9000-01-9 Circuit relief valve . . . . . . . . . . . . . . . . . .9025-25-4

Avoid machine tip over . . . . . . . . . . . . . .9000-01-9 Fan motor case drain test . . . . . . . . . . .9026-25-75
Avoid work site hazards . . . . . . . . . . . . .9000-01-8 Fan motor speed test . . . . . . . . . . . . . .9026-25-73
Drive metal pins safely . . . . . . . . . . . . .9000-01-12 Fan pump flow test . . . . . . . . . . . . . . . .9026-25-71
Information, recognize. . . . . . . . . . . . . . .9000-01-1 Fan pump pressure test . . . . . . . . . . . .9026-25-69
Instructions, follow . . . . . . . . . . . . . . . . .9000-01-1 Fuel transfer pump pressure . . . . . . . . . .9010-25-2
Keep riders off machine . . . . . . . . . . . . .9000-01-8 Hand pump bleed procedure. . . . . . . . .9026-25-68
Make welding repairs safely . . . . . . . . .9000-01-12 Hydraulic system relief valve. . . . . . . . . .9025-25-2
Park and preapre for service safely. . . .9000-01-10 Tow disconnect relief valve test . . . . . .9026-25-67
Prevent unintended machine Test, cylinder drift . . . . . . . . . . . . . . . . . . .9025-25-10
movement . . . . . . . . . . . . . . . . . . . . . .9000-01-7 Test, cylinder leakage. . . . . . . . . . . . . . . .9025-25-11
Schematic Tests
Hydrostatic schematic - neutral (park brake Charge pump flow test . . . . . . . . . . . . .9026-25-50
on). . . . . . . . . . . . . . . . . . . . . . . . . . .9026-15-12 Digital pressure/temperature analyzer
Information . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 installation . . . . . . . . . . . . . . . . . . . . . .9026-25-1
Seat belt Hydraulic oil cleanup procedure . . . . . . 9025-25-2,
Use and maintain . . . . . . . . . . . . . . . . . .9000-01-7 9026-25-11
Seat control Hydrostatic motor min./max. angle control piston
Operational check . . . . . . . . . . . . . . . . . .9005-10-5 pressure test . . . . . . . . . . . . . . . . . . .9026-25-46
Servo Hydrostatic oil cooler bypass test . . . . .9026-25-52
Pump servo pressure test . . . . . . . . . . .9026-25-39 Hydrostatic oil reservoir bypass test . . .9026-25-57
Slow and fast idle Hydrostatic pump and motor initial start-up
Operational check . . . . . . . . . . . . . . . . .9005-10-11 procedure . . . . . . . . . . . . . . . . . . . . . .9026-25-8
Specifications Hydrostatic pump flushing procedure . .9026-25-10
Electrical components . . . . . . . . . . . . . .9015-20-82 JDG1770 Ultra clean hand launcher . . . .9026-25-1
Start aid Motor displacement control valve (MDCV)
Operational check . . . . . . . . . . . . . . . . . .9005-10-3 adjustment. . . . . . . . . . . . . . . . . . . . .9026-25-43
Start-up procedure Multi-function relief valve test . . . . . . . .9026-25-22
Hydrostatic pump and motor initial start-up Neutral charge relief pressure test . . . .9026-25-31
procedure . . . . . . . . . . . . . . . . . . . . . .9026-25-8 Operating charge relief pressure test . .9026-25-31
Starting circuit Park brake test . . . . . . . . . . . . . . . . . . .9026-25-61
Theory of operation. . . . . . . . . . . . . . . . .9015-15-1 Pressure control pilot (PCP) internal adjustment
Starting machine test . . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-18
Operator’s seat . . . . . . . . . . . . . . . . . . . .9000-01-6 Pressure control pilot (PCP) manual override
Steer sensor test . . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-12
Remove and install . . . . . . . . . . . . . . . .9015-20-93 Pressure control pilot (PCP) test . . . . . .9026-25-14
Indx Steps Pump displacement control valve (PDCV) neutral
6 Use correctly. . . . . . . . . . . . . . . . . . . . . .9000-01-6 (null) adjustment . . . . . . . . . . . . . . . .9026-25-36
System functional schematic Pump servo pressure test . . . . . . . . . . .9026-25-39
Information . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 Releasing park brake to tow the
machine. . . . . . . . . . . . . . . . . . . . . . . .9026-25-5
Transmission efficiency test . . . . . . . . .9026-25-27
Transmission Oil Warm-up Procedure. . .9026-25-2
T Theory of operation
CAN Monitor Unit (CMU). . . . . . . . . . . .9015-15-21
Tank Charge pump operation . . . . . . . . . . . . .9026-05-4
Hydrostatic oil reservoir bypass test . . .9026-25-57 Charging circuit . . . . . . . . . . . . . . . . . . . .9015-15-1
Oil cooler and reservoir bypass Controller Area Network (CAN) . . . . . . . .9015-15-3
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-12 Engine Control Unit (ECU) . . . . . . . . . . .9015-15-5
Test Flushing valve and operating charge relief valve
A/C High pressure switch . . . . . . . . . . .9031-25-10 operation . . . . . . . . . . . . . . . . . . . . . .9026-05-19
A/C Low pressure switch. . . . . . . . . . . . .9031-25-8 Hydraulic fan drive operation. . . . . . . . .9026-05-23
Cab tilt relief valve test . . . . . . . . . . . . .9026-25-68 Hydraulic fan return filter operation . . . .9026-05-26

TM2260 (07JAN06) Index-6 750J, 850J Crawler

010706
PN=6
 Index

Page Page

Hydraulic intregrated circuit (HIC) valve Circuit relief, anti-cavitation . . . . . . . . . . .9025-05-8

operation . . . . . . . . . . . . . . . . . . . . . . .9026-05-9 Hydraulic intregrated circuit (HIC) valve
Hydrostatic charge oil filter operation . . .9026-05-5 operation . . . . . . . . . . . . . . . . . . . . . . .9026-05-9
Hydrostatic motor operation . . . . . . . . .9026-05-21 Hydrostatic flushing valve and operating charge
Hydrostatic pump operation . . . . . . . . .9026-05-18 relief valve operation . . . . . . . . . . . . .9026-05-19
Hydrostatic system . . . . . . . . . . . . . . . . .9026-05-1 Hydrostatic motor min./max. angle control piston
Multi-function valve operation . . . . . . . . .9026-05-7 pressure test . . . . . . . . . . . . . . . . . . .9026-25-46
Neutral charge relief valve operation. . . .9026-05-6 Hydrostatic pump displacement control valve
Oil cooler and reservoir bypass (PDCV) operation . . . . . . . . . . . . . . .9026-05-16
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-12 Motor displacement control valve (MDCV)
Park brake valve operation . . . . . . . . . .9026-05-11 adjustment. . . . . . . . . . . . . . . . . . . . .9026-25-43
Pump displacement control valve (PDCV) Multi-function relief valve test . . . . . . . .9026-25-22
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-16 Multi-function valve operation . . . . . . . . .9026-05-7
Pump pressure control pilot (PCP) Neutral charge relief pressure test . . . .9026-25-31
operation . . . . . . . . . . . . . . . . . . . . . .9026-05-14 Neutral charge relief valve operation. . . .9026-05-6
Starting circuit . . . . . . . . . . . . . . . . . . . . .9015-15-1 Operating charge relief pressure test . .9026-25-31
Transmission control circuit operation (flow Park brake test . . . . . . . . . . . . . . . . . . .9026-25-61
chart). . . . . . . . . . . . . . . . . . . . . . . . . .9026-05-3 Park brake valve operation . . . . . . . . . .9026-05-11
Transmission Control Unit (TCU) . . . . .9015-15-10 Pressure control pilot (PCP) internal adjustment
Throttle control test . . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-18
Remove and install . . . . . . . . . . . . . . . .9015-20-92 Pressure control pilot (PCP) manual override
Towing test . . . . . . . . . . . . . . . . . . . . . . . . . .9026-25-12
Releasing park brake to tow the Pressure control pilot (PCP) test . . . . . .9026-25-14
machine. . . . . . . . . . . . . . . . . . . . . . . .9026-25-5 Pump displacement control valve (PDCV) neutral
Track idler leakage (null) adjustment . . . . . . . . . . . . . . . .9026-25-36
Operational check . . . . . . . . . . . . . . . . . .9005-10-4 Pump pressure control pilot (PCP)
Track roller operation . . . . . . . . . . . . . . . . . . . . . .9026-05-14
Operational check . . . . . . . . . . . . . . . . . .9005-10-4 Tow disconnect relief valve test . . . . . .9026-25-67
Track sag
Operational check . . . . . . . . . . . . . . . . . .9005-10-4
Track shoe
Operational check . . . . . . . . . . . . . . . . . .9005-10-4 W
Tracking and maximum speed
Operational check . . . . . . . . . . . . . . . . .9005-10-15 Washer motor, front and rear
Transmission Operational check . . . . . . . . . . . . . . . . . .9005-10-6
Transmission control circuit operation (flow Washer motor, left and right
chart). . . . . . . . . . . . . . . . . . . . . . . . . .9026-05-3 Operational check . . . . . . . . . . . . . . . . . .9005-10-7 Indx
Transmission efficiency test . . . . . . . . .9026-25-27 Waste 7
Transmission control lever Dispose of properly . . . . . . . . . . . . . . . . .9000-01-5
Operational check . . . . . . . . . . . . . . . . .9005-10-12 Water separator
Transmission Control Unit (TCU) Operational check . . . . . . . . . . . . . . . . . .9005-10-3
Calibration. . . . . . . . . . . . . . . . . . . . . . .9015-20-89 Window seal
Diagnostic Trouble Codes (DTCs). . . . .9015-20-24 Operational check . . . . . . . . . . . . . . . . . .9005-10-5
Theory of operation. . . . . . . . . . . . . . . .9015-15-10 Wiper, front and rear
Transmission speed Operational check . . . . . . . . . . . . . . . . . .9005-10-6
Operational check . . . . . . . . . . . . . . . . .9005-10-10 Wiper, left and right
Turbocharger boost, intake manifold Operational check . . . . . . . . . . . . . . . . . .9005-10-7
test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-1 Wire harness
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-90
V Wiring diagram
Air conditioning harness (W14) . . . . . . .9015-10-62
Valve Cab roof harness (W9) . . . . . . . . . . . . .9015-10-38
Cab tilt relief valve test . . . . . . . . . . . . .9026-25-68 Canopy roof harness (W8) . . . . . . . . . .9015-10-34

TM2260 (07JAN06) Index-7 750J, 850J Crawler

010706
PN=7
 Index

Page

Engine harness (W10) . . . . . . . . . . . . .9015-10-44

Information . . . . . . . . . . . . . . . . . . . . . . .9015-05-2
Operator’s station harness (W7) . . . . . .9015-10-26
Radio harness (W15) . . . . . . . . . . . . . .9015-10-66
Transmission harness (W11). . . . . . . . .9015-10-52

Indx
8

TM2260 (07JAN06) Index-8 750J, 850J Crawler

010706
PN=8