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Worldwide Construction And Forestry Division 35D Technical Manual

Operation and tests
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Table of Contents

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Operation and Tests
For complete service information also see:
35D and 50D Excavator Repair...........................
35D and 50D Excavator Operator's Manual ......
Alternators and Starting Motors ........................
Super Caddy Oil Cleanup Procedure.................
Undercarriage Appraisal Manual .......................
Specifications Manual.........................................
35D and 50D
Excavator
TECHNICAL MANUAL
35D and 50D
Excavator
Operation and Tests
TM2263 09JUL14
TM2264
OMT209413
CTM77
CTM310
SP326VOL1
SP458VOL2
Worldwide Construction
And Forestry Division
(ENGLISH)
LITHO IN U.S.A.

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Table of Contents
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Summary of Contents for Worldwide Construction And Forestry Division 35D

  • Page 1 Operation and Tests TM2263 09JUL14 (ENGLISH) For complete service information also see: 35D and 50D Excavator Repair......TM2264 35D and 50D Excavator Operator's Manual ..OMT209413 Alternators and Starting Motors ......CTM77 Super Caddy Oil Cleanup Procedure....CTM310 Undercarriage Appraisal Manual .......
  • Page 2 Operation and tests sections help you of troubleshooting, general maintenance, and basic type identify the majority of routine failures quickly. of failures and their causes. DX,TMIFC -19-15APR14-1/1 TM2263 (09JUL14) 35D and 50D Operation & Tests 070914 PN=2...
  • Page 3 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 FAX NUMBER: 1-563-589-5800 (USA) Publication Number: Page Number: Ideas, Comments: Name: Phone: Email Address: THANK YOU! TX,TM,FAX -19-03JUL01-1/1 TM2263 (09JUL14) 35D and 50D Operation & Tests 070914 PN=3...
  • Page 4 Introduction TM2263 (09JUL14) 35D and 50D Operation & Tests 070914 PN=4...

  • Page 5: Group 01-Safety

    The right is reserved to make changes at any time without notice. COPYRIGHT © 2014 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ® Manual Previous Editions Copyright © 2009, 2010, 2011, 2012, 2013 TM2263 (09JUL14) 35D and 50D Operation & Tests 070914 PN=1...
  • Page 6 Contents TM2263 (09JUL14) 35D and 50D Operation & Tests 070914 PN=2...

  • Page 7: Table Of Contents

    Park and Prepare for Service Safely........... 9000-01-10 Service Cooling System Safely ....9000-01-10 Remove Paint Before Welding or Heating ..........9000-01-11 Make Welding Repairs Safely ....9000-01-11 Drive Metal Pins Safely ......9000-01-11 TM2263 (09JUL14) 9000-1 35D and 50D Operation & Tests 070914 PN=1...
  • Page 8 Contents TM2263 (09JUL14) 9000-2 35D and 50D Operation & Tests 070914 PN=2...

  • Page 9: Recognize Safety Information

    Know and observe all safety rules that may apply to every supervised training and instruction. work situation and work site. Operator should be familiar with the job site and surroundings before operating. Try all controls and TX,QUALIFIED -19-18JAN11-1/1 TM2263 (09JUL14) 9000-01-1 35D and 50D Operation & Tests 070914 PN=9...

  • Page 10: Wear Protective Equipment

    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. TX,MOVING,PARTS -19-20JAN11-1/1 TM2263 (09JUL14) 9000-01-2 35D and 50D Operation & Tests 070914 PN=10...

  • Page 11: Avoid High-Pressure Fluids

    Injected oil must be removed surgically within hours or gangrene could result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A. TX,HPOILS -19-20JAN11-1/1 TM2263 (09JUL14) 9000-01-3 35D and 50D Operation & Tests 070914 PN=11...

  • Page 12: Work In Ventilated Area

    Examine electrical wiring and connectors frequently for damage. Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly. T133554 —UN—07SEP00 TX,PREVENT,FIRE -19-20JAN11-1/1 TM2263 (09JUL14) 9000-01-4 35D and 50D Operation & Tests 070914 PN=12...

  • Page 13: Prevent Battery Explosions

    Inquire on the proper way to recycle or dispose of waste recover and recycle used air conditioning refrigerants. from your local environmental or recycling center, or from your John Deere dealer. DX,DRAIN -19-03MAR93-1/1 TM2263 (09JUL14) 9000-01-5 35D and 50D Operation & Tests 070914 PN=13...

  • Page 14: Prepare For Emergencies

    Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine. TX,STEPS -19-09FEB11-1/1 TM2263 (09JUL14) 9000-01-6 35D and 50D Operation & Tests 070914 PN=14...

  • Page 15: Start Only From Operator's Seat

    Always lower work equipment to the ground and pull pilot shutoff lever to locked (UP) position before standing up or leaving the operator's seat. Stop engine before exiting. VD76477,000036D -19-19APR11-1/1 TM2263 (09JUL14) 9000-01-7 35D and 50D Operation & Tests 070914 PN=15...

  • Page 16: Avoid Work Site Hazards

    Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator’s view or impair his ability to operate machine safely. TX14740,0001E7A -19-19MAR02-1/1 TM2263 (09JUL14) 9000-01-8 35D and 50D Operation & Tests 070914 PN=16...

  • Page 17: Avoid Backover Accidents

    Check ROPS for cracks or physical damage. bending, drilling, or cutting. If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again. TX,ROPS -19-20JAN11-1/1 TM2263 (09JUL14) 9000-01-9 35D and 50D Operation & Tests 070914 PN=17...

  • Page 18: Add And Operate Attachments Safely

    Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. DX,RCAP -19-04JUN90-1/1 TM2263 (09JUL14) 9000-01-10 35D and 50D Operation & Tests 070914 PN=18...

  • Page 19: Remove Paint Before Welding Or Heating

    Hammering hardened metal parts such as pins and bucket teeth could dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping. TX,PINS -19-20JAN11-1/1 TM2263 (09JUL14) 9000-01-11 35D and 50D Operation & Tests 070914 PN=19...
  • Page 20 Safety TM2263 (09JUL14) 9000-01-12 35D and 50D Operation & Tests 070914 PN=20...

  • Page 21: Operation

    Operational Checkout Procedure Contents Page Group 10—Operational Checkout Procedure Operational Checkout........ 9005-10-1 Ignition OFF, Engine OFF Checks ..........9005-10-1 Ignition ON, Engine OFF Checks ..........9005-10-2 Ignition ON, Engine ON Checks ....9005-10-6 TM2263 (09JUL14) 9005-1 35D and 50D Operation & Tests 070914 PN=1...
  • Page 22 Contents TM2263 (09JUL14) 9005-2 35D and 50D Operation & Tests 070914 PN=2...

  • Page 23: Operational Checkout

    FEEL/LOOK: Does each lever return to neutral at the same time when released? NO: Repair or replace pilot controller. See Pilot Control Valve Remove and Install. (Group 3360.) Continued on next page TZ24494,0000F46 -19-24OCT13-4/32 TM2263 (09JUL14) 9005-10-1 35D and 50D Operation & Tests 070914 PN=23...

  • Page 24: Ignition On, Engine Off Checks

    F9). See Fuse Specifications. (Group 9015-10.) Check and replace any malfunctioning bulb. See Monitor Controller Remove and Install. (Group 9015-20.) Continued on next page TZ24494,0000F46 -19-24OCT13-6/32 TM2263 (09JUL14) 9005-10-2 35D and 50D Operation & Tests 070914 PN=24...
  • Page 25 Wiring Diagram. (Group 9015-10.) See Boom Work Light Harness (W14) Wiring Diagram. (Group 9015-10.) See ROPS Work Light Harness (W15) Wiring Diagram. (Group 9015-10.) Continued on next page TZ24494,0000F46 -19-24OCT13-7/32 TM2263 (09JUL14) 9005-10-3 35D and 50D Operation & Tests 070914 PN=25...
  • Page 26 See System Functional Schematic. (Group 9015-10.) See Cab Harness (W13) Wiring Diagram. (Group 9015-10.) See Heating and A/C Control Harness (W11) Wiring Diagram. (Group 9015-10.) Continued on next page TZ24494,0000F46 -19-24OCT13-8/32 TM2263 (09JUL14) 9005-10-4 35D and 50D Operation & Tests 070914 PN=26...
  • Page 27 See System Functional Schematic. (Group 9015-10.) See Cab Harness (W13) Wiring Diagram. (Group 9015-10.) See Heating and A/C Control Harness (W11) Wiring Diagram. (Group 9015-10.) Continued on next page TZ24494,0000F46 -19-24OCT13-9/32 TM2263 (09JUL14) 9005-10-5 35D and 50D Operation & Tests 070914 PN=27...

  • Page 28: Ignition On, Engine On Checks

    If fuse is good, check wires and connections between fuse and monitor controller. See Platform Harness (W9) Wiring Diagram. (Group 9015-10.) TZ24494,0000F46 -19-24OCT13-10/32 Ignition ON, Engine ON Checks Continued on next page TZ24494,0000F46 -19-24OCT13-11/32 TM2263 (09JUL14) 9005-10-6 35D and 50D Operation & Tests 070914 PN=28...
  • Page 29 See Inspect Fan Belt, Check and Adjust Tension. (Operator's Manual.) If belt tension OK, test alternator output. See Alternator Test. (Group 9015-20.) Continued on next page TZ24494,0000F46 -19-24OCT13-12/32 TM2263 (09JUL14) 9005-10-7 35D and 50D Operation & Tests 070914 PN=29...
  • Page 30 Heater and Air Conditioning Circuit Check—If Equipped TX1095460 —UN—09AUG11 35D (S.N. —260000) and 50D (S.N. —270000) Console Shown 1— Upper Vent and Defrost Button 2— Upper and Lower Vents and Defrost Button 3— Lower Vent Button 4— Blower Speed—Increase Button 5—...
  • Page 31 Check wiring and connections: See Cab Harness (W13) Wiring Diagram. (Group 9015-10.) See Heating and A/C Control Harness (W11) Wiring Diagram. (Group 9015-10.) Continued on next page TZ24494,0000F46 -19-24OCT13-14/32 TM2263 (09JUL14) 9005-10-9 35D and 50D Operation & Tests 070914 PN=31...
  • Page 32 NO: Go to next step in this check. TX1095468 —UN—01SEP11 1— Pilot Control Shutoff Lever Move pilot control shutoff lever (1) to UNLOCKED (lowered) position. Continued on next page TZ24494,0000F46 -19-24OCT13-15/32 TM2263 (09JUL14) 9005-10-10 35D and 50D Operation & Tests 070914 PN=32...
  • Page 33 See Platform Harness (W9) Wiring Diagram and see Main Harness (W8) Wiring Diagram—35D or see Main Harness (W8) Wiring Diagram—50D. (Group 9015-10.) Continued on next page TZ24494,0000F46 -19-24OCT13-17/32 TM2263 (09JUL14) 9005-10-11 35D and 50D Operation & Tests 070914 PN=33...
  • Page 34 If the filler cap does not seal correctly, the hydraulic pumps could cavitate and damage the pumps. Continued on next page TZ24494,0000F46 -19-24OCT13-18/32 TM2263 (09JUL14) 9005-10-12 35D and 50D Operation & Tests 070914 PN=34...
  • Page 35 NO: Check pilot controller pattern conversion valve position. Check line connections. See Pilot Control Valve to Pattern Selector Valve Line Connection. (Group 9025-15.) Continued on next page TZ24494,0000F46 -19-24OCT13-19/32 TM2263 (09JUL14) 9005-10-13 35D and 50D Operation & Tests 070914 PN=35...
  • Page 36 NO: Check pilot controller pattern conversion valve position. Check line connections. See Pilot Control Valve to Pattern Selector Valve Line Connection. (Group 9025-15.) Continued on next page TZ24494,0000F46 -19-24OCT13-20/32 TM2263 (09JUL14) 9005-10-14 35D and 50D Operation & Tests 070914 PN=36...

  • Page 37: Adjustment-35D

    See Control Valve Disassemble and Assemble—35D and 50D (S.N. —274999) or see Control Valve Disassemble and Assemble—50D (S.N. 275000— ). (Group 3360.) Continued on next page TZ24494,0000F46 -19-24OCT13-21/32 TM2263 (09JUL14) 9005-10-15 35D and 50D Operation & Tests 070914 PN=37...

  • Page 38: Reduced Leakage Valve

    Repair boom cylinder. See Boom Cylinder Disassemble and Assemble. (Group 3360.) LOOK: Does bucket drift. down to ground within 1 minute? NO: Check complete. Continued on next page TZ24494,0000F46 -19-24OCT13-22/32 TM2263 (09JUL14) 9005-10-16 35D and 50D Operation & Tests 070914 PN=38...
  • Page 39 LOOK: Do functions move in opposite direction as control levers are moved, then NO: Check complete. change direction as levers are moved further? Continued on next page TZ24494,0000F46 -19-24OCT13-23/32 TM2263 (09JUL14) 9005-10-17 35D and 50D Operation & Tests 070914 PN=39...
  • Page 40 Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8). Measure and record greatest distance of mistrack (5) between inside edge of track print and test line. Repeat procedure in reverse travel. Continued on next page TZ24494,0000F46 -19-24OCT13-24/32 TM2263 (09JUL14) 9005-10-18 35D and 50D Operation & Tests 070914 PN=40...
  • Page 41 Control Valve Disassemble and Assemble—50D (S.N. 275000— ). (Group 3360.) LOOK: Does machine mistrack excessively when the arm is extended? NO: Check complete. Continued on next page TZ24494,0000F46 -19-24OCT13-26/32 TM2263 (09JUL14) 9005-10-19 35D and 50D Operation & Tests 070914 PN=41...
  • Page 42 Also see Travel Speed Control and Alarm Circuit Theory of Operation. (Group 9015-15.) Repair solenoid valve, if necessary. See Solenoid Valve Manifold Repair. (Group 3360.) Continued on next page TZ24494,0000F46 -19-24OCT13-27/32 TM2263 (09JUL14) 9005-10-20 35D and 50D Operation & Tests 070914 PN=42...
  • Page 43 Schematic. (Group 9015-20.) Blade Angle Control Harness (W18) Component Location—If Equipped. (Group 9015-20.) Blade Angle Control Harness (W18) Wiring Diagram—If Equipped. (Group 9015-20.) Continued on next page TZ24494,0000F46 -19-24OCT13-28/32 TM2263 (09JUL14) 9005-10-21 35D and 50D Operation & Tests 070914 PN=43...
  • Page 44 Running Start—Cycle Time (S.N. —264999)..................17.9—20.9 seconds Swing Left or Right, 3 Revolutions from a Running Start—Cycle Time (S.N. 265000—)..................18.5—21.5 seconds Continued on next page TZ24494,0000F46 -19-24OCT13-29/32 TM2263 (09JUL14) 9005-10-22 35D and 50D Operation & Tests 070914 PN=44...
  • Page 45 NO: Check engine speed. See Engine Speed Check. (Group 9010-25.) Check pump flow. See Hydraulic Pump 1 and 2 Flow Test—35D. (Group 9025-25.) Continued on next page TZ24494,0000F46 -19-24OCT13-30/32 TM2263 (09JUL14) 9005-10-23 35D and 50D Operation & Tests 070914 PN=45...
  • Page 46 Running Start—Cycle Time (S.N. —274999)..................17.8—20.8 seconds Swing Left or Right, 3 Revolutions from a Running Start—Cycle Time (S.N. 275000—)..................18.5—21.5 seconds Continued on next page TZ24494,0000F46 -19-24OCT13-31/32 TM2263 (09JUL14) 9005-10-24 35D and 50D Operation & Tests 070914 PN=46...
  • Page 47 21.8—24.8 seconds with steel track LOOK: Does machine perform within specifications? NO: Check engine speed. See Engine Speed Check. (Group 9010-25.) Check pump flow. See Hydraulic Pump Flow Test—50D. (Group 9025-25.) TZ24494,0000F46 -19-24OCT13-32/32 TM2263 (09JUL14) 9005-10-25 35D and 50D Operation & Tests 070914 PN=47...
  • Page 48 Operational Checkout Procedure TM2263 (09JUL14) 9005-10-26 35D and 50D Operation & Tests 070914 PN=48...
  • Page 49 Bleed fuel system ........9010-25-21 Coolant in Oil or Oil in Coolant Diagnostics Procedure ......9010-15-11 Low Engine Oil Pressure ......9010-15-11 Low Engine Oil Pressure Diagnostics Procedure..........9010-15-11 High Engine Oil Pressure ......9010-15-12 TM2263 (09JUL14) 9010-1 35D and 50D Operation & Tests 070914 PN=1...

  • Page 50: Engine Component Location

    Group 05 Theory of Operation Engine Component Location Continued on next page OUO1030,0000019 -19-07DEC04-1/2 TM2263 (09JUL14) 9010-05-1 35D and 50D Operation & Tests 070914 PN=50...
  • Page 51 A overheat switch is used to send a signal to a warning light on the instrument panel. OUO1030,000001A -19-07DEC04-1/1 TM2263 (09JUL14) 9010-05-2 35D and 50D Operation & Tests 070914 PN=51...

  • Page 52: Engine Lubrication System

    Pressure oil is also supplied to the cylinder head, rocker shaft and rocker arms. Pressurized oil is directed to the oil filter. The filter element is equipped with an integral bypass valve. When OUO1030,000001B -19-07DEC04-1/1 TM2263 (09JUL14) 9010-05-3 35D and 50D Operation & Tests 070914 PN=52...

  • Page 53: Engine Fuel System Operation

    C—Feed Pump G—Return Fuel D—Fuel Filter Any air in the fuel system is bled out with return fuel to the fuel tank. Continued on next page OUO1030,0000018 -19-26MAY10-1/2 TM2263 (09JUL14) 9010-05-4 35D and 50D Operation & Tests 070914 PN=53...
  • Page 54 When the fuel pressure reaches specified pressure, fuel tank. it overcomes the nozzle spring (I) tension. The nozzle valve (G) retracts into the nozzle body (F) and fuel is injected into the engine. OUO1030,0000018 -19-26MAY10-2/2 TM2263 (09JUL14) 9010-05-5 35D and 50D Operation & Tests 070914 PN=54...

  • Page 55: Yanmar 3 And 4-Cylinder Engine Troubleshooting Manual

    For diagnosing engine malfunctions, see the appropriate Troubleshooting Manual observable symptom in this group. For more information regarding the 3TNV88 and 4TNV88 Yanmar diesel The 35D excavator uses one of the following 3TNV88 engines, see the following manuals: 3-cylinder Yanmar diesel engines: •...

  • Page 56: Engine Misfires Or Runs Irregularly

    Irregular running means that abnormal vibrations, abnormal running, and black smoke are observed during acceleration at full load conditions. Continued on next page OUO1010,0000B7C -19-28JAN09-2/9 TM2263 (09JUL14) 9010-15-2 35D and 50D Operation & Tests 070914 PN=56...
  • Page 57 Are the fuel injection nozzles working properly? See Fuel Injection Nozzle Test. (Group YES: Go to Engine Check 9010-25.) Compression Pressure Test. NO: Repair or replace injector as necessary. Continued on next page OUO1010,0000B7C -19-28JAN09-6/9 TM2263 (09JUL14) 9010-15-3 35D and 50D Operation & Tests 070914 PN=57...

  • Page 58: Engine Does Not Develop Full Power Diagnostic Procedure

    Does engine coolant temperature exceed 108°C (226°F)? YES: Examine and repair Temperature Check cause of overheating. Repair or replace parts as necessary. NO: Go to Air Intake Check. Continued on next page OUO1010,0000B7D -19-28JAN09-4/11 TM2263 (09JUL14) 9010-15-4 35D and 50D Operation & Tests 070914 PN=58...
  • Page 59 Are the fuel injectors working properly? See Fuel Injection Nozzle Test. (Group YES: Go to Mechanical Check 9010-25.) Engine Check. NO: Repair or replace injector as necessary. Continued on next page OUO1010,0000B7D -19-28JAN09-9/11 TM2263 (09JUL14) 9010-15-5 35D and 50D Operation & Tests 070914 PN=59...

  • Page 60: Engine Overheats

    YES: Clean or replace filter elements. See Cleaning Air Cleaner Element. (Operator's Manual.) Is air filter restricted or dirty? NO: Go to Air Intake Check. Continued on next page OUO1010,0000B7E -19-10FEB09-4/7 TM2263 (09JUL14) 9010-15-6 35D and 50D Operation & Tests 070914 PN=60...

  • Page 61: System Failure Indicator Light Flashes In Half Second Intervals

    (A3) malfunction. Replace auto-idle controller. See Platform Harness (W9) Component Location. (Group 9015-10.) Is voltage between 2.0 and 4.0 volts? NO: Go to Continuity Check. Continued on next page MB00333,000019E -19-10MAY13-4/5 TM2263 (09JUL14) 9010-15-7 35D and 50D Operation & Tests 070914 PN=61...

  • Page 62: System Failure Indicator Light Flashes In One Second Intervals

    Is voltage between 0.8 and 4.2 volts? NO: Engine speed control potentiometer (R2) malfunction. Replace engine speed control potentiometer. See Platform Harness (W9) Component Location. (Group 9015-10.) Continued on next page MB00333,000019F -19-09MAY13-4/5 TM2263 (09JUL14) 9010-15-8 35D and 50D Operation & Tests 070914 PN=62...

  • Page 63: System Failure Indicator Light Stays On

    (A3) malfunction. Replace auto-idle controller. See Platform Harness (W9) Component Location. (Group 9015-10.) Is voltage between 0.8 and 4.2 volts? NO: Go to Continuity Check. Continued on next page MB00333,00001A0 -19-09MAY13-4/5 TM2263 (09JUL14) 9010-15-9 35D and 50D Operation & Tests 070914 PN=63...

  • Page 64: Auto-Idle Does Not Work

    See System Functional Schematic and Section Legend. (Group 9015-10.) OUO1010,0000B7F -19-10FEB09-4/4 Coolant Temperature Too Low OUO1010,0000B80 -19-28JAN09-1/4 Coolant Temperature Too Low Diagnostics Procedure Continued on next page OUO1010,0000B80 -19-28JAN09-2/4 TM2263 (09JUL14) 9010-15-10 35D and 50D Operation & Tests 070914 PN=64...

  • Page 65: Coolant In Oil Or Oil In Coolant Diagnostics Procedure

    Are either components cracked? NO: Refer to Yanmar Troubleshooting manual. OUO1010,0000B81 -19-28JAN09-4/4 Low Engine Oil Pressure OUO1010,0000B82 -19-28JAN09-1/6 Low Engine Oil Pressure Diagnostics Procedure Continued on next page OUO1010,0000B82 -19-28JAN09-2/6 TM2263 (09JUL14) 9010-15-11 35D and 50D Operation & Tests 070914 PN=65...

  • Page 66: High Engine Oil Pressure

    Was problem found? NO: Refer to Yanmar Service Manual Industrial Engines for additional information. OUO1010,0000B82 -19-28JAN09-6/6 High Engine Oil Pressure Continued on next page OUO1010,0000B83 -19-28JAN09-1/6 TM2263 (09JUL14) 9010-15-12 35D and 50D Operation & Tests 070914 PN=66...

  • Page 67: High Engine Oil Pressure Diagnostics Procedure

    NO: Refer to Yanmar Service Manual Industrial Engines for additional information. OUO1010,0000B83 -19-28JAN09-6/6 Engine Uses Too Much Oil OUO1010,0000B84 -19-28JAN09-1/7 Engine Uses Too Much Oil Diagnostics Continued on next page OUO1010,0000B84 -19-28JAN09-2/7 TM2263 (09JUL14) 9010-15-13 35D and 50D Operation & Tests 070914 PN=67...
  • Page 68 Check valve guides and valve stems for wear. YES: Refer to Yanmar Service Manual Industrial Engines for additional information. Are mechanical parts of engine within specification? NO: Repair or replace parts as necessary. OUO1010,0000B84 -19-28JAN09-7/7 TM2263 (09JUL14) 9010-15-14 35D and 50D Operation & Tests 070914 PN=68...

  • Page 69: Engine Uses Too Much Fuel

    YES: Go to Engine Valve 9010-25.) Lash (Clearance) Check and Adjust. Is compression within specification? NO: Repair or replace parts as necessary and test again. Continued on next page OUO1010,0000B85 -19-28JAN09-7/9 TM2263 (09JUL14) 9010-15-15 35D and 50D Operation & Tests 070914 PN=69...

  • Page 70: Engine Emits Excessive White Exhaust Smoke

    Are the fuel injection nozzles working properly? See Fuel Injection Nozzle Check. YES: Go to Compression (Group 9010-25.) Check. NO: Repair or replace injector as necessary. Continued on next page OUO1010,0000B86 -19-10FEB09-4/7 TM2263 (09JUL14) 9010-15-16 35D and 50D Operation & Tests 070914 PN=70...

  • Page 71: Engine Emits Excessive Black Or Gray Exhaust Smoke

    3. Check for dirty or restricted air filter. YES: Reduce load on engine. Repair or replace parts as necessary. Was the problem found? NO: Go to Air Intake Check. Continued on next page OUO1010,0000B87 -19-28JAN09-3/9 TM2263 (09JUL14) 9010-15-17 35D and 50D Operation & Tests 070914 PN=71...
  • Page 72 Valves. See Engine Valve Lash (Clearance) Check and Adjustment. (Group 9010-25.) YES: Go to Fuel Injection Pump Timing Check. Are mechanical parts of engine within specification? NO: Repair or replace parts as necessary and test again. Continued on next page OUO1010,0000B87 -19-28JAN09-8/9 TM2263 (09JUL14) 9010-15-18 35D and 50D Operation & Tests 070914 PN=72...

  • Page 73: Fuel In Oil

    Inspect front seal on fuel injection pump. YES: Repair or replace parts as necessary. Is seal damaged or worn? NO: Refer to Yanmar Service Manual Industrial Engines for additional information. OUO1010,0000B88 -19-28JAN09-3/3 TM2263 (09JUL14) 9010-15-19 35D and 50D Operation & Tests 070914 PN=73...
  • Page 74 Diagnostic Information TM2263 (09JUL14) 9010-15-20 35D and 50D Operation & Tests 070914 PN=74...

  • Page 75: Jt05801 Clamp-On Electronic Tachometer Installation

    3. Turn engine speed control dial from slow idle to fast Adjust as necessary. idle. Confirm that fuel injection pump governor lever contacts fast idle stop. 4. Start engine and warm to operating temperature. TZ24494,0000F45 -19-24APR13-1/1 TM2263 (09JUL14) 9010-25-1 35D and 50D Operation & Tests 070914 PN=75...

  • Page 76: Engine Speed Control Cable Adjustment

    If excessive tension is felt on cable, turn cable nut (1) 1/2 to 1 turn counterclockwise to decrease cable 10. Turn the key switch OFF. tension. Tighten cable nut (2) to secure cable. OUO1030,000000C -19-23NOV04-1/1 TM2263 (09JUL14) 9010-25-2 35D and 50D Operation & Tests 070914 PN=76...

  • Page 77: Fuel Injection Nozzle Check

    BEFORE checking and to determine the pumping rate required for proper chatter and spray pattern. Otherwise, these characteristics may be affected. Continued on next page OUO1030,000000D -19-12DEC05-1/4 TM2263 (09JUL14) 9010-25-3 35D and 50D Operation & Tests 070914 PN=77...
  • Page 78 Injection Nozzle Pattern—Pressure........... 21 600—22 600 kPa 216—226 bar 3133—3278 psi A—Proper Spray Angle B—Correct Injection Angle Correct (Top) and Poor (Bottom) Spray Pattern Continued on next page OUO1030,000000D -19-12DEC05-3/4 TM2263 (09JUL14) 9010-25-4 35D and 50D Operation & Tests 070914 PN=78...
  • Page 79 Inspect valve seating surface. Replace nozzle assembly if necessary. 3. Watch for leakage from nozzle spray orifice. Leakage time should be a minimum of 5 seconds. OUO1030,000000D -19-12DEC05-4/4 TM2263 (09JUL14) 9010-25-5 35D and 50D Operation & Tests 070914 PN=79...

  • Page 80: Fuel Transfer Pump Pressuretest

    OUO1030,0000010 -19-29NOV04-1/1 Fan Belt Tension Adjustment See Inspect Fan Belt, Check and Adjust Tension. (Operator's Manual.) OUO1030,00000D6 -19-11MAR05-1/1 TM2263 (09JUL14) 9010-25-6 35D and 50D Operation & Tests 070914 PN=80...

  • Page 81: Engine Valve Lash (Clearance) Check And Adjustment

    5. Remove rocker arm cover from engine. See Rocker 6— Cap Screw (4 used) 7— Frame Cover Arm Cover Remove and Install. (Group 0400.) Continued on next page OUO1030,0000017 -19-18JUN14-1/8 TM2263 (09JUL14) 9010-25-7 35D and 50D Operation & Tests 070914 PN=81...
  • Page 82 10— Flywheel 9— Timing Mark Groove (2 shown) Flywheel Housing Timing Inspection Port (shown with plug removed) Three Cylinder Engine Flywheel Timing Marks Continued on next page OUO1030,0000017 -19-18JUN14-2/8 TM2263 (09JUL14) 9010-25-8 35D and 50D Operation & Tests 070914 PN=82...
  • Page 83 11. Measure engine valve lash after adjustment has been positions No. 3 cylinder at overlap. made. Compare measurement to specification and adjust as necessary. Continued on next page OUO1030,0000017 -19-18JUN14-3/8 TM2263 (09JUL14) 9010-25-9 35D and 50D Operation & Tests 070914 PN=83...
  • Page 84 19. Install frame cover and cap screws. 22. Connect negative (-) battery cable. 20. Install counterweight. See Counterweight Remove and Install—35D. (Group 1749.) Continued on next page OUO1030,0000017 -19-18JUN14-4/8 TM2263 (09JUL14) 9010-25-10 35D and 50D Operation & Tests 070914 PN=84...
  • Page 85 12— Frame Bracket Arm Cover Remove and Install. (Group 0400.) 9— Air Intake Baffle Clamp 13— Air Cleaner Assembly 10— Cap Screw (4 used) Continued on next page OUO1030,0000017 -19-18JUN14-5/8 TM2263 (09JUL14) 9010-25-11 35D and 50D Operation & Tests 070914 PN=85...
  • Page 86 16— Flywheel 15— Timing Mark Groove (2 shown) Flywheel Housing Timing Inspection Port (shown with plug removed) Four Cylinder Engine Flywheel Timing Mark Continued on next page OUO1030,0000017 -19-18JUN14-6/8 TM2263 (09JUL14) 9010-25-12 35D and 50D Operation & Tests 070914 PN=86...
  • Page 87 TDC mark on the flywheel. made. Compare measurement to specification and This positions No. 1 cylinder at overlap. adjust as necessary. Continued on next page OUO1030,0000017 -19-18JUN14-7/8 TM2263 (09JUL14) 9010-25-13 35D and 50D Operation & Tests 070914 PN=87...
  • Page 88 22. Install hose and tighten air intake baffle clamp. 23. Install top frame bracket and cap screws (7). 24. Install counterweight. See Counterweight Remove and Install—50D. (Group 1749.) OUO1030,0000017 -19-18JUN14-8/8 TM2263 (09JUL14) 9010-25-14 35D and 50D Operation & Tests 070914 PN=88...

  • Page 89: Air Intake System Leakage

    10. Remove plastic bag from filter element. 9. Spray soap solution over all connections from the air cleaner to air intake manifold. Check for leaks. Repair all leaks. OUO1030,0000013 -19-20DEC05-1/1 TM2263 (09JUL14) 9010-25-15 35D and 50D Operation & Tests 070914 PN=89...

  • Page 90: Cooling System Pressure Test

    3. Remove the cap from gauge, turn it 180°, and retest 2. Pressurize cap to the following specification. cap. This will verify that the first measurement was accurate. OUO1030,0000016 -19-06DEC04-1/1 TM2263 (09JUL14) 9010-25-16 35D and 50D Operation & Tests 070914 PN=90...

  • Page 91: Engine Thermostat Test

    If thermostat does not open according to specifications, 185°F replace. Thermostat Opening (Minimum at Full If closing action is not smooth and slow, replace Open)—Height................8 mm thermostat. 0.31 in. OUO1030,0000014 -19-20DEC05-1/1 TM2263 (09JUL14) 9010-25-17 35D and 50D Operation & Tests 070914 PN=91...

  • Page 92: Engine Compression Pressure Test

    7. Crank engine for 10—15 seconds with starter. Ensure check for leaking valves, valve seats or cylinder head minimum cranking speed is met. gasket. 8. Record pressure reading for each cylinder. OUO1030,0000011 -19-30NOV04-1/1 TM2263 (09JUL14) 9010-25-18 35D and 50D Operation & Tests 070914 PN=92...

  • Page 93: Engine Oil Pressure

    JT03115 gauge (1) from universal pressure test kit. Engine Oil Pressure at Fast Idle—Pressure ..............296 kPa 5. Start engine and run at specification. 2.96 bar 43 psi Specification Engine—Speed................Slow Idle OUO1030,0000012 -19-02DEC04-1/1 TM2263 (09JUL14) 9010-25-19 35D and 50D Operation & Tests 070914 PN=93...

  • Page 94: Head Gasket Failure Check

    Low coolant flow • Coolant in cylinder • Loss of cab heating (air lock) • Coolant in crankcase oil • Low coolant level Continued on next page OUO1030,000001D -19-13DEC04-1/2 TM2263 (09JUL14) 9010-25-20 35D and 50D Operation & Tests 070914 PN=94...

  • Page 95: Bleed Fuel System

    Excessive liner standout OUO1030,000001D -19-13DEC04-2/2 Bleed Fuel System 2. Do not start engine. 1. Turn the key switch ON for 10—15 seconds to engage automatic fuel bleeding. OUO1030,000001C -19-10DEC04-1/1 TM2263 (09JUL14) 9010-25-21 35D and 50D Operation & Tests 070914 PN=95...
  • Page 96 Tests TM2263 (09JUL14) 9010-25-22 35D and 50D Operation & Tests 070914 PN=96...

  • Page 97: Electrical Component

    Boom Work Light Harness (W14) Electrical Component Wiring Diagram........9015-10-214 Specifications ........9015-20-2 ROPS Work Light Harness (W15) Alternator Test ........... 9015-20-4 Component Location ......9015-10-216 Relay Test..........9015-20-5 Continued on next page TM2263 (09JUL14) 9015-1 35D and 50D Operation & Tests 070914 PN=1...
  • Page 98 Contact ..........9015-20-24 Replace CINCH™ Connectors ....9015-20-25 Install CINCH™ Contact......9015-20-26 Repair 32 and 48 Way CINCH™ Connectors .......... 9015-20-27 Remove Connector Body from Blade Terminals ........9015-20-29 TM2263 (09JUL14) 9015-2 35D and 50D Operation & Tests 070914 PN=2...

  • Page 99: Electrical Diagram Information

    Red/Wht would be a primarily Red wire, Yel—Yellow with a Wht stripe. A wire identified as Wht/Red would be a primarily Wht wire with a Red stripe. Continued on next page OUO1010,00006CA -19-03DEC04-1/6 TM2263 (09JUL14) 9015-05-1 35D and 50D Operation & Tests 070914 PN=99...
  • Page 100 System Information System Functional Schematic Diagram Continued on next page OUO1010,00006CA -19-03DEC04-2/6 TM2263 (09JUL14) 9015-05-2 35D and 50D Operation & Tests 070914 PN=100...
  • Page 101 In the example, power is going TO component F15 Horn symbol (10), the component name (8), and a component Fuse, in section SE15. identification number (9). A component identification Continued on next page OUO1010,00006CA -19-03DEC04-3/6 TM2263 (09JUL14) 9015-05-3 35D and 50D Operation & Tests 070914 PN=101...
  • Page 102 System Information Wiring Diagram Continued on next page OUO1010,00006CA -19-03DEC04-4/6 TM2263 (09JUL14) 9015-05-4 35D and 50D Operation & Tests 070914 PN=102...
  • Page 103 (6) as description used in the System Functional Schematic marked on the connector. Wires attached to each Diagram. Continued on next page OUO1010,00006CA -19-03DEC04-5/6 TM2263 (09JUL14) 9015-05-5 35D and 50D Operation & Tests 070914 PN=103...
  • Page 104 System Information TM2263 (09JUL14) 9015-05-6 35D and 50D Operation & Tests 070914 PN=104...
  • Page 105 System Information Electrical Schematic Symbols T143000 —UN—21JUN01 OUO1010,00006CA -19-03DEC04-6/6 TM2263 (09JUL14) 9015-05-7 35D and 50D Operation & Tests 070914 PN=105...
  • Page 106 System Information TM2263 (09JUL14) 9015-05-8 35D and 50D Operation & Tests 070914 PN=106...

  • Page 107: Color Codes (Blade-Type)

    28— Single Element Bulb 29— Dual Element Bulb OUO1010,00006CA -19-03DEC04-7/6 Fuse (Blade-Type) Color Codes Amperage Rating Color Black Violet Pink 7-1/2 Brown Light Blue Yellow Natural (White) Light Green CED,TX14826,12562 -19-12JUN00-1/1 TM2263 (09JUL14) 9015-05-9 35D and 50D Operation & Tests 070914 PN=107...
  • Page 108 System Information TM2263 (09JUL14) 9015-05-10 35D and 50D Operation & Tests 070914 PN=108...

  • Page 109: Fuse Specifications

    Group 10 System Diagrams Fuse Specifications Fuse Block—35D (S.N. —260000), 50D (S.N. —270000) Fuse Block—35D (S.N. 260001— ), 50D (S.N. 270001— ) IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload. NOTE: The main 65-amp fuse (F11) is located next to the battery.

  • Page 110: System Functional Schematic, Wiring Diagrams, And Component Locations Master Legend

    F14—Blade Angle Left 10-Amp Fuse (SE17) (W18) W9 is the identification number of the COMPONENT • LOCATION AND HARNESS CONNECTOR ) G1—Battery (SE1) (W6 & W7-35D) or (W6 & W7 - 50D) • WITH WIRE AND PIN LOCATION) drawings G2—Alternator (SE2) (W8-50D) or (W10) for the component.
  • Page 111 • • X1—Main Harness-to-Battery Power Connector (W6 & X24—Blower Motor 2-Pin Connector (W11) • W7-35D) or (W6 & W7 - 50D), (W8-35D) or (W8-50D) X25—Fresh Air Vent Actuator 7-Pin Connector (W11) Continued on next page OUO1010,00016CA -19-19AUG11-2/4 TM2263 (09JUL14) 9015-10-3 35D and 50D Operation &...
  • Page 112 (W10). • Harness-to-Wiper Motor Harness Connector (W13) X78—Platform Harness-to-Key Switch Harness 7-Pin • X35—Fuse Block (W9) connector [35D (S.N. 265000— )] [50D (S.N. 275000— • X36—Starter Interlock Relay 2-Pin Connector (W9) )] (W9) • • X37—Starter Interlock Relay 6-Pin Connector (W9) X79—12-Volt Power Outlet (SE11) (W9)
  • Page 113 System Diagrams • Y15—Auxiliary Function Solenoid 2 [35D (S.N. 265000— )] [50D (S.N. 275000— )] (SE18) (W19) OUO1010,00016CA -19-19AUG11-4/4 TM2263 (09JUL14) 9015-10-5 35D and 50D Operation & Tests 070914 PN=113...
  • Page 114 System Diagrams TM2263 (09JUL14) 9015-10-6 35D and 50D Operation & Tests 070914 PN=114...

  • Page 115: System Functional Schematic

    System Diagrams System Functional Schematic 35D (S.N. —260000) 50D (S.N. —270000) TX1090847 —UN—10JUN11 System Functional Schematic (SE1—SE3) 35D (S.N. —260000) 50D (S.N. —270000) OUO1010,00016CB -19-09MAY13-1/24 Continued on next page TM2263 (09JUL14) 9015-10-7 35D and 50D Operation & Tests 070914 PN=115...
  • Page 116 System Diagrams TM2263 (09JUL14) 9015-10-8 35D and 50D Operation & Tests 070914 PN=116...
  • Page 117 Alternator Excite, Fuel Relay Strap Shutoff Hold-In Coil, Fuel M1—Starter Motor X2— Main Harness-to-Engine Pump, Travel Alarm 10-Amp R1—Intake Air Preheater Harness 12-Pin Connector Fuse Continued on next page OUO1010,00016CB -19-09MAY13-2/24 TM2263 (09JUL14) 9015-10-9 35D and 50D Operation & Tests 070914 PN=117...
  • Page 118 System Diagrams TM2263 (09JUL14) 9015-10-10 35D and 50D Operation & Tests 070914 PN=118...
  • Page 119 System Diagrams TX1090848 —UN—16JUN11 System Functional Schematic (SE4—SE6) 35D (S.N. —260000) 50D (S.N. —270000) OUO1010,00016CB -19-09MAY13-3/24 Continued on next page TM2263 (09JUL14) 9015-10-11 35D and 50D Operation & Tests 070914 PN=119...
  • Page 120 System Diagrams TM2263 (09JUL14) 9015-10-12 35D and 50D Operation & Tests 070914 PN=120...
  • Page 121 Switch, Travel Alarm X14— Auxiliary Switched Power Switch Controller, Auxiliary Flow 1-Pin Connector B4—Engine Oil Pressure Switch Selector 20-Amp Fuse X15— Auxiliary Ground 1-Pin Connector Continued on next page OUO1010,00016CB -19-09MAY13-4/24 TM2263 (09JUL14) 9015-10-13 35D and 50D Operation & Tests 070914 PN=121...
  • Page 122 System Diagrams TM2263 (09JUL14) 9015-10-14 35D and 50D Operation & Tests 070914 PN=122...
  • Page 123 SE7 AUTO-IDLE CIRCUIT SE8 AUTO-IDLE CIRCUIT CONTINUED SE9 PILOT CONTROL SHUTOFF CIRCUIT 35D AND 50D SYSTEM FUNCTIONAL SCHEMATIC (3 OF 6) TX1135357 System Functional Schematic (SE7—SE9) 35D (S.N. —260000) 50D (S.N. —270000) OUO1010,00016CB -19-09MAY13-5/24 Continued on next page TM2263 (09JUL14) 9015-10-15 35D and 50D Operation &...
  • Page 124 System Diagrams TM2263 (09JUL14) 9015-10-16 35D and 50D Operation & Tests 070914 PN=124...
  • Page 125 K4—Platform Tilt Pilot Control R2—Engine Speed Control X9— Interlock Switch JDG1928 Lockout Relay Potentiometer Connector R3—Actuator Feedback X11— Pilot Shutoff 1-Pin Potentiometer Connector Continued on next page OUO1010,00016CB -19-09MAY13-6/24 TM2263 (09JUL14) 9015-10-17 35D and 50D Operation & Tests 070914 PN=125...
  • Page 126 System Diagrams TM2263 (09JUL14) 9015-10-18 35D and 50D Operation & Tests 070914 PN=126...
  • Page 127 System Diagrams TX1092630 —UN—06JUN11 System Functional Schematic (SE10—SE12) 35D (S.N. —260000) 50D (S.N. —270000) OUO1010,00016CB -19-09MAY13-7/24 Continued on next page TM2263 (09JUL14) 9015-10-19 35D and 50D Operation & Tests 070914 PN=127...
  • Page 128 System Diagrams TM2263 (09JUL14) 9015-10-20 35D and 50D Operation & Tests 070914 PN=128...
  • Page 129 S10— Wiper Motor and Washer E4— Cab Work Light M3—Wiper Motor Switch F4— Auto-Idle, 12-Volt Power S11— Wiper Motor Disconnect Outlet 10-Amp Fuse Switch Continued on next page OUO1010,00016CB -19-09MAY13-8/24 TM2263 (09JUL14) 9015-10-21 35D and 50D Operation & Tests 070914 PN=129...
  • Page 130 System Diagrams TM2263 (09JUL14) 9015-10-22 35D and 50D Operation & Tests 070914 PN=130...
  • Page 131 System Diagrams TX1093047 —UN—07JUN11 System Functional Schematic (SE13— SE15) 35D (S.N. —260000) 50D (S.N. —270000) OUO1010,00016CB -19-09MAY13-9/24 Continued on next page TM2263 (09JUL14) 9015-10-23 35D and 50D Operation & Tests 070914 PN=131...
  • Page 132 System Diagrams TM2263 (09JUL14) 9015-10-24 35D and 50D Operation & Tests 070914 PN=132...
  • Page 133 E5— Heating and Air Compressor Clutch Relay Conditioner (A/C) Conditioning Unit Controller 18-Pin Connector X21— Heating and Air Conditioner (A/C) Controller 30-Pin Connector Continued on next page OUO1010,00016CB -19-09MAY13-10/24 TM2263 (09JUL14) 9015-10-25 35D and 50D Operation & Tests 070914 PN=133...
  • Page 134 System Diagrams TM2263 (09JUL14) 9015-10-26 35D and 50D Operation & Tests 070914 PN=134...
  • Page 135 SE16 AUXILIARY FLOW SELECTOR CIRCUIT (OPTIONAL) SE17 BLADE ANGLE CONTROL CIRCUIT (IF EQUIPPED) 35D AND 50D SYSTEM FUNCTIONAL SCHEMATIC (6 OF 6) TX1127729 System Functional Schematic (SE16 and SE17) 35D (S.N. —260000) 50D (S.N. —270000) OUO1010,00016CB -19-09MAY13-11/24 Continued on next page TM2263 (09JUL14) 9015-10-27 35D and 50D Operation &...
  • Page 136 System Diagrams TM2263 (09JUL14) 9015-10-28 35D and 50D Operation & Tests 070914 PN=136...
  • Page 137 Connector 1-Pin Connector Solenoid S13— Blade Angle Right Switch X14D— Auxiliary Control Harness X15D— Auxiliary Control Harness (power-out) 1-Pin (ground-out) 1-Pin Connector Connector Continued on next page OUO1010,00016CB -19-09MAY13-12/24 TM2263 (09JUL14) 9015-10-29 35D and 50D Operation & Tests 070914 PN=137...
  • Page 138 System Diagrams TM2263 (09JUL14) 9015-10-30 35D and 50D Operation & Tests 070914 PN=138...
  • Page 139 System Diagrams 35D (S.N. 260001— ) 50D (S.N. 270001— ) TX1090850 —UN—10JUN11 System Functional Schematic (SE1—SE3) 35D (S.N. 260001— ) 50D (S.N. 270001— ) OUO1010,00016CB -19-09MAY13-13/24 Continued on next page TM2263 (09JUL14) 9015-10-31 35D and 50D Operation & Tests 070914...
  • Page 140 System Diagrams TM2263 (09JUL14) 9015-10-32 35D and 50D Operation & Tests 070914 PN=140...
  • Page 141 Shutoff Hold-In Coil, Fuel K3—Fuel Shutoff Pull-In Coil W2—Main Harness Ground Pump, Travel Alarm 10-Amp Relay W3—Platform Harness Ground Fuse K11— Glow Plug Relay M1—Starter Motor Continued on next page OUO1010,00016CB -19-09MAY13-14/24 TM2263 (09JUL14) 9015-10-33 35D and 50D Operation & Tests 070914 PN=141...
  • Page 142 System Diagrams TM2263 (09JUL14) 9015-10-34 35D and 50D Operation & Tests 070914 PN=142...
  • Page 143 System Diagrams TX1090849 —UN—20JUN11 System Functional Schematic (SE4—SE6) 35D (S.N. 260001— ) 50D (S.N. 270001— ) OUO1010,00016CB -19-09MAY13-15/24 Continued on next page TM2263 (09JUL14) 9015-10-35 35D and 50D Operation & Tests 070914 PN=143...
  • Page 144 System Diagrams TM2263 (09JUL14) 9015-10-36 35D and 50D Operation & Tests 070914 PN=144...
  • Page 145 Display 20-Pin Connector B4—Engine Oil Pressure Switch H2—Travel Alarm [35D (S.N. —264999)] B7—Travel Speed Pressure S3— Travel Speed Selector [50D (S.N. —274999)] Sensor Switch Continued on next page OUO1010,00016CB -19-09MAY13-16/24 TM2263 (09JUL14) 9015-10-37 35D and 50D Operation & Tests 070914 PN=145...
  • Page 146 System Diagrams TM2263 (09JUL14) 9015-10-38 35D and 50D Operation & Tests 070914 PN=146...
  • Page 147 System Diagrams TX1090851 —UN—16JUN11 System Functional Schematic (SE7—SE9) 35D (S.N. 260001— ) 50D (S.N. 270001— ) OUO1010,00016CB -19-09MAY13-17/24 Continued on next page TM2263 (09JUL14) 9015-10-39 35D and 50D Operation & Tests 070914 PN=147...
  • Page 148 System Diagrams TM2263 (09JUL14) 9015-10-40 35D and 50D Operation & Tests 070914 PN=148...
  • Page 149 R2—Engine Speed Control S14— Auto-Idle Switch Y4— Pilot Control Shutoff Lockout Relay Potentiometer [35D (S.N. 265000— )] Solenoid R3—Actuator Feedback [50D (S.N. 275000— )] Potentiometer Continued on next page OUO1010,00016CB -19-09MAY13-18/24 TM2263 (09JUL14) 9015-10-41 35D and 50D Operation & Tests 070914 PN=149...
  • Page 150 System Diagrams TM2263 (09JUL14) 9015-10-42 35D and 50D Operation & Tests 070914 PN=150...
  • Page 151 System Diagrams TX1090854 —UN—24MAY11 System Functional Schematic (SE10—SE12) 35D (S.N. 260001— ) 50D (S.N. 270001— ) OUO1010,00016CB -19-09MAY13-19/24 Continued on next page TM2263 (09JUL14) 9015-10-43 35D and 50D Operation & Tests 070914 PN=151...
  • Page 152 System Diagrams TM2263 (09JUL14) 9015-10-44 35D and 50D Operation & Tests 070914 PN=152...
  • Page 153 S7— Horn Switch [50D (S.N. 275000— )] F5— Work Lights 20A Fuse S8— Work Lights Switch X13— Platform Harness-to- Heating and A/C Control Harness Connector Continued on next page OUO1010,00016CB -19-09MAY13-20/24 TM2263 (09JUL14) 9015-10-45 35D and 50D Operation & Tests 070914 PN=153...
  • Page 154 System Diagrams TM2263 (09JUL14) 9015-10-46 35D and 50D Operation & Tests 070914 PN=154...
  • Page 155 System Diagrams TX1090862 —UN—20MAY11 System Functional Schematic (SE13— SE15) 35D (S.N. 260001— ) 50D (S.N. 270001— ) OUO1010,00016CB -19-09MAY13-21/24 Continued on next page TM2263 (09JUL14) 9015-10-47 35D and 50D Operation & Tests 070914 PN=155...
  • Page 156 System Diagrams TM2263 (09JUL14) 9015-10-48 35D and 50D Operation & Tests 070914 PN=156...
  • Page 157 X13— Platform Harness-to- Y7— Air Conditioner Torque E5— Heating and Air Control Relay Heating and A/C Control Control Solenoid Conditioning Unit Harness Connector Continued on next page OUO1010,00016CB -19-09MAY13-22/24 TM2263 (09JUL14) 9015-10-49 35D and 50D Operation & Tests 070914 PN=157...
  • Page 158 System Diagrams TM2263 (09JUL14) 9015-10-50 35D and 50D Operation & Tests 070914 PN=158...
  • Page 159 System Diagrams TX1090869 —UN—08JUL11 System Functional Schematic (SE16—SE18) 35D (S.N. 260001— ) 50D (S.N. 270001— ) OUO1010,00016CB -19-09MAY13-23/24 Continued on next page TM2263 (09JUL14) 9015-10-51 35D and 50D Operation & Tests 070914 PN=159...
  • Page 160 System Diagrams TM2263 (09JUL14) 9015-10-52 35D and 50D Operation & Tests 070914 PN=160...
  • Page 161 S12— Blade Angle Left Switch X14C— Auxiliary Flow Selector Connector S13— Blade Angle Right Switch Switched Power In Y5— Auxiliary Flow Selector Connector Solenoid [35D (S.N. —264999)] [50D (S.N. —274999)] OUO1010,00016CB -19-09MAY13-24/24 TM2263 (09JUL14) 9015-10-53 35D and 50D Operation & Tests 070914 PN=161...

  • Page 162: Battery And Power Cable (W6 And W7) Component Location-35D

    System Diagrams Battery and Power Cable (W6 and W7) Component Location—35D T205709 Battery and Power Cable (W6 and W7) Component Location—35D Continued on next page OUO1010,00006CC -19-03DEC04-1/2 TM2263 (09JUL14) 9015-10-54 35D and 50D Operation & Tests 070914 PN=162...
  • Page 163 System Diagrams G1—Battery W5—Engine-to-Frame Ground W7—Battery Ground (-) Cable M1—Starter Motor Strap X1— Main Harness-to-Battery W1—Battery-to-Frame Ground W6—Battery Positive (+) Cable Power Connector OUO1010,00006CC -19-03DEC04-2/2 TM2263 (09JUL14) 9015-10-55 35D and 50D Operation & Tests 070914 PN=163...

  • Page 164: Battery And Power Cable (W6 And W7) Component Location-50D

    System Diagrams Battery and Power Cable (W6 and W7) Component Location—50D T205710 Battery and Power Cable (W6 and W7) Component Location—50D Continued on next page OUO1010,00006CD -19-03DEC04-1/2 TM2263 (09JUL14) 9015-10-56 35D and 50D Operation & Tests 070914 PN=164...
  • Page 165 System Diagrams G1—Battery W5—Engine-to-Frame Ground W7—Battery Ground (-) Cable M1—Starter Motor Strap X1— Main Harness-to-Battery W1—Battery-to-Frame Ground W6—Battery Positive (+) Cable Power Connector OUO1010,00006CD -19-03DEC04-2/2 TM2263 (09JUL14) 9015-10-57 35D and 50D Operation & Tests 070914 PN=165...

  • Page 166: Main Harness (W8) Component Location-35D

    System Diagrams Main Harness (W8) Component Location—35D 35D (S.N. —264999) M2/R3 TX1091937 Main Harness (W8) Component Location—35D (S.N. —264999) Continued on next page OUO1010,00016CE -19-19AUG11-1/4 TM2263 (09JUL14) 9015-10-58 35D and 50D Operation & Tests 070914 PN=166...
  • Page 167 Work Light Harness Potentiometer Harness 4-Pin Connector (power) 1-Pin Connector NOTE: For 35D (S.N. —264999), travel speed solenoid to platform harness (W9). See Platform Harness (Y3) and pilot control shutoff solenoid (Y4) (W9) Component Location. (Group 9015-10.) connect to main harness (W8).
  • Page 168 System Diagrams 35D (S.N. 265000— ) TX1091938 Main Harness (W8) Component Location—35D (S.N. 265000— ) Continued on next page OUO1010,00016CE -19-19AUG11-3/4 TM2263 (09JUL14) 9015-10-60 35D and 50D Operation & Tests 070914 PN=168...
  • Page 169 X38— Main Harness-to-Boom (ground) 1-Pin Connector K11— Glow Plug Relay Harness Connector Work Light Harness W2—Main Harness Ground X3— Main Harness-to-Platform (power) 1-Pin Connector W8—Main Harness Harness 4-Pin Connector OUO1010,00016CE -19-19AUG11-4/4 TM2263 (09JUL14) 9015-10-61 35D and 50D Operation & Tests 070914 PN=169...
  • Page 170 System Diagrams TM2263 (09JUL14) 9015-10-62 35D and 50D Operation & Tests 070914 PN=170...

  • Page 171: Main Harness (W8) Wiring Diagram-35D

    X1 (1) (SHT 1) (SHT 2) BLK/RED X5 (12) F11 (2) (SHT 1) TX1092360 Main Harness (W8) Wiring Diagram—35D (S.N. —260000) (1 of 2) OUO1010,00016DC -19-27FEB12-1/10 Continued on next page TM2263 (09JUL14) 9015-10-63 35D and 50D Operation & Tests 070914 PN=171...
  • Page 172 System Diagrams TM2263 (09JUL14) 9015-10-64 35D and 50D Operation & Tests 070914 PN=172...
  • Page 173 Y3— Travel Speed Solenoid X1— Main Harness-to-Battery X39— Main Harness-to-Boom Y4— Pilot Control Shutoff Power Connector Work Light Harness Solenoid (ground) 1-Pin Connector Continued on next page OUO1010,00016DC -19-27FEB12-2/10 TM2263 (09JUL14) 9015-10-65 35D and 50D Operation & Tests 070914 PN=173...
  • Page 174 System Diagrams TM2263 (09JUL14) 9015-10-66 35D and 50D Operation & Tests 070914 PN=174...
  • Page 175 X2 (10) (SHT 1) GRN/WHT X5 (9) (SHT 2) X5 (10) (SHT 2) TX1092361 Main Harness (W8) Wiring Diagram—35D (S.N. —260000) (2 of 2) OUO1010,00016DC -19-27FEB12-3/10 Continued on next page TM2263 (09JUL14) 9015-10-67 35D and 50D Operation & Tests 070914 PN=175...
  • Page 176 System Diagrams TM2263 (09JUL14) 9015-10-68 35D and 50D Operation & Tests 070914 PN=176...
  • Page 177 X6— Main Harness-to-Auto-Idle Actuator Harness 4-Pin Connector Pressure Sensor Harness R3—Actuator Feedback X4— Main Harness-to-Platform Connector Potentiometer Harness 6-Pin Connector X67— 8 GRN/RED Circuit Splice Continued on next page OUO1010,00016DC -19-27FEB12-4/10 TM2263 (09JUL14) 9015-10-69 35D and 50D Operation & Tests 070914 PN=177...
  • Page 178 System Diagrams TM2263 (09JUL14) 9015-10-70 35D and 50D Operation & Tests 070914 PN=178...
  • Page 179 (SHT 2) BLK/RED X5 (12) (SHT 2) 5 WHT F11 (2) (SHT 1) TX1109167 Main Harness (W8) Wiring Diagram—35D (S.N. 260001—264999) (1 of 2) OUO1010,00016DC -19-27FEB12-5/10 Continued on next page TM2263 (09JUL14) 9015-10-71 35D and 50D Operation & Tests 070914...
  • Page 180 System Diagrams TM2263 (09JUL14) 9015-10-72 35D and 50D Operation & Tests 070914 PN=180...
  • Page 181 K11— Glow Plug Relay 4-Pin X38— Main Harness-to-Boom Harness Connector Work Light Harness X65— WHT Circuit Splice W2—Main Harness Ground (power) 1-Pin Connector Continued on next page OUO1010,00016DC -19-27FEB12-6/10 TM2263 (09JUL14) 9015-10-73 35D and 50D Operation & Tests 070914 PN=181...
  • Page 182 System Diagrams TM2263 (09JUL14) 9015-10-74 35D and 50D Operation & Tests 070914 PN=182...
  • Page 183 X2 (1) (SHT 1) GRN/WHT X5 (9) (SHT 2) X5 (10) (SHT 2) TX1092363 Main Harness (W8) Wiring Diagram—35D (S.N. 260001—264999) (2 of 2) OUO1010,00016DC -19-27FEB12-7/10 Continued on next page TM2263 (09JUL14) 9015-10-75 35D and 50D Operation & Tests 070914 PN=183...
  • Page 184 System Diagrams TM2263 (09JUL14) 9015-10-76 35D and 50D Operation & Tests 070914 PN=184...
  • Page 185 X6— Main Harness-to-Auto-Idle Actuator Harness 4-Pin Connector Pressure Sensor Harness R3—Actuator Feedback X4— Main Harness-to-Platform Connector Potentiometer Harness 6-Pin Connector X67— 8 GRN/RED Circuit Splice Continued on next page OUO1010,00016DC -19-27FEB12-8/10 TM2263 (09JUL14) 9015-10-77 35D and 50D Operation & Tests 070914 PN=185...
  • Page 186 System Diagrams TM2263 (09JUL14) 9015-10-78 35D and 50D Operation & Tests 070914 PN=186...
  • Page 187 X65 (1) GRN/RED X5 (10) X1 (1) BLK/RED X5 (11) 5 WHT F11 (2) TX1092364 Main Harness (W8) Wiring Diagram—35D (S.N. 265000— ) OUO1010,00016DC -19-27FEB12-9/10 Continued on next page TM2263 (09JUL14) 9015-10-79 35D and 50D Operation & Tests 070914 PN=187...
  • Page 188 System Diagrams TM2263 (09JUL14) 9015-10-80 35D and 50D Operation & Tests 070914 PN=188...
  • Page 189 Harness 4-Pin Connector X39— Main Harness-to-Boom Connector X5— Main Harness-to-Platform Work Light Harness W2—Main Harness Ground Harness 12-Pin Connector (ground) 1-Pin Connector X1— Main Harness-to-Battery Power Connector OUO1010,00016DC -19-27FEB12-10/10 TM2263 (09JUL14) 9015-10-81 35D and 50D Operation & Tests 070914 PN=189...
  • Page 190 System Diagrams TM2263 (09JUL14) 9015-10-82 35D and 50D Operation & Tests 070914 PN=190...

  • Page 191: Main Harness (W8) Component Location-50D

    System Diagrams Main Harness (W8) Component Location—50D 50D (S.N. —270000) TX1054347 —UN—15JAN09 M2/R3 TX1054347 Main Harness (W8) Component Location—50D (S.N. —270000) OUO1010,00016CF -19-19AUG11-1/6 Continued on next page TM2263 (09JUL14) 9015-10-83 35D and 50D Operation & Tests 070914 PN=191...
  • Page 192 System Diagrams TM2263 (09JUL14) 9015-10-84 35D and 50D Operation & Tests 070914 PN=192...
  • Page 193 (power) 1-Pin Connector W2—Main Harness Ground X4— Main Harness-to-Platform X39— Main Harness-to-Boom W8—Main Harness Harness 6-Pin Connector Work Light Harness (ground) 1-Pin Connector Continued on next page OUO1010,00016CF -19-19AUG11-2/6 TM2263 (09JUL14) 9015-10-85 35D and 50D Operation & Tests 070914 PN=193...
  • Page 194 System Diagrams TM2263 (09JUL14) 9015-10-86 35D and 50D Operation & Tests 070914 PN=194...
  • Page 195 System Diagrams 50D (S.N. 270001—274999) TX1091939 —UN—12MAY11 M2/R3 TX1091939 Main Harness (W8) Component Location—50D (S.N. 270001—274999) OUO1010,00016CF -19-19AUG11-3/6 Continued on next page TM2263 (09JUL14) 9015-10-87 35D and 50D Operation & Tests 070914 PN=195...
  • Page 196 System Diagrams TM2263 (09JUL14) 9015-10-88 35D and 50D Operation & Tests 070914 PN=196...
  • Page 197 (W9) Component Location. (Group 9015-10.) connect to main harness (W8). For 50D (S.N. 275000— ), travel speed solenoid (Y3) and pilot control shutoff solenoid (Y4) connect Continued on next page OUO1010,00016CF -19-19AUG11-4/6 TM2263 (09JUL14) 9015-10-89 35D and 50D Operation & Tests 070914 PN=197...
  • Page 198 System Diagrams TM2263 (09JUL14) 9015-10-90 35D and 50D Operation & Tests 070914 PN=198...
  • Page 199 System Diagrams 50D (S.N. 275000— ) TX1091940 —UN—12MAY11 TX1091940 Main Harness (W8) Component Location—50D (S.N. 275000— ) OUO1010,00016CF -19-19AUG11-5/6 Continued on next page TM2263 (09JUL14) 9015-10-91 35D and 50D Operation & Tests 070914 PN=199...
  • Page 200 System Diagrams TM2263 (09JUL14) 9015-10-92 35D and 50D Operation & Tests 070914 PN=200...
  • Page 201 B4—Engine Oil Pressure Switch W8—Main Harness Work Light Harness Y1— Fuel Pump F11— Main 65-Amp Fuse X1— Main Harness-to-Battery (power) 1-Pin Connector Y2— Fuel Shutoff Solenoid G2—Alternator Power Connector OUO1010,00016CF -19-19AUG11-6/6 TM2263 (09JUL14) 9015-10-93 35D and 50D Operation & Tests 070914 PN=201...
  • Page 202 System Diagrams TM2263 (09JUL14) 9015-10-94 35D and 50D Operation & Tests 070914 PN=202...

  • Page 203: Main Harness (W8) Wiring Diagram-50D

    5 WHT F11 (2) BLU/BLK X2 (9) (SHT 1) X2 (10) (SHT 1) TX1092555 Main Harness (W8) Wiring Diagram—50D (S.N. —270000) (1 of 2) OUO1010,00016D8 -19-19AUG11-1/12 Continued on next page TM2263 (09JUL14) 9015-10-95 35D and 50D Operation & Tests 070914 PN=203...
  • Page 204 System Diagrams TM2263 (09JUL14) 9015-10-96 35D and 50D Operation & Tests 070914 PN=204...
  • Page 205 X38— Main Harness-to-Boom X66— 901 BLK Circuit Splice X2— Main Harness-to-Engine Work Light Harness X67— 8 GRN/RED Circuit Splice Harness Connector (power) 1-Pin Connector Continued on next page OUO1010,00016D8 -19-19AUG11-2/12 TM2263 (09JUL14) 9015-10-97 35D and 50D Operation & Tests 070914 PN=205...
  • Page 206 (SHT 1) — GRN/WHT X5 (9) (SHT 1) X5 (10) (SHT 1) TX1092556 Main Harness (W8) Wiring Diagram—50D (S.N. —270000) (2 of 2) Continued on next page OUO1010,00016D8 -19-19AUG11-3/12 TM2263 (09JUL14) 9015-10-98 35D and 50D Operation & Tests 070914 PN=206...
  • Page 207 X69— 76 BLK/BLU Circuit Splice B6—Auto-Idle Pressure Sensor Potentiometer Pressure Sensor Harness M2—Engine Speed Control W8A—Auto-Idle Pressure Sensor Connector Actuator Harness X68— 75 RED/BLU Circuit Splice Continued on next page OUO1010,00016D8 -19-19AUG11-4/12 TM2263 (09JUL14) 9015-10-99 35D and 50D Operation & Tests 070914 PN=207...
  • Page 208 System Diagrams TM2263 (09JUL14) 9015-10-100 35D and 50D Operation & Tests 070914 PN=208...
  • Page 209 (SHT 2) GRN/RED X67 (3) (SHT 1) BLK/RED X5 (12) (SHT 2) TX1092233 Main Harness (W8) Wiring Diagram—50D (S.N. 270001—274999) (1 of 2) OUO1010,00016D8 -19-19AUG11-5/12 Continued on next page TM2263 (09JUL14) 9015-10-101 35D and 50D Operation & Tests 070914 PN=209...
  • Page 210 System Diagrams TM2263 (09JUL14) 9015-10-102 35D and 50D Operation & Tests 070914 PN=210...
  • Page 211 X1— Main Harness-to-Battery X75— 17 RED Circuit Splice F11— Main 65-Amp Fuse Power Connector X38— Main Harness-to-Boom Work Light Harness (power) 1-Pin Connector Continued on next page OUO1010,00016D8 -19-19AUG11-6/12 TM2263 (09JUL14) 9015-10-103 35D and 50D Operation & Tests 070914 PN=211...
  • Page 212 System Diagrams TM2263 (09JUL14) 9015-10-104 35D and 50D Operation & Tests 070914 PN=212...
  • Page 213 X5 (10) (SHT 2) BLU/BLK G2 (3)(L) (SHT 1) B2 (1) (SHT 1) TX1092234 Main Harness (W8) Wiring Diagram—50D (S.N. 270001—274999) (2 of 2) OUO1010,00016D8 -19-19AUG11-7/12 Continued on next page TM2263 (09JUL14) 9015-10-105 35D and 50D Operation & Tests 070914 PN=213...
  • Page 214 System Diagrams TM2263 (09JUL14) 9015-10-106 35D and 50D Operation & Tests 070914 PN=214...
  • Page 215 Harness 4-Pin Connector Pressure Sensor Harness Solenoid R3—Actuator Feedback X4— Main Harness-to-Platform Connector Potentiometer Harness 6-Pin Connector X68— 75 RED/BLU Circuit Splice W2—Main Harness Ground Continued on next page OUO1010,00016D8 -19-19AUG11-8/12 TM2263 (09JUL14) 9015-10-107 35D and 50D Operation & Tests 070914 PN=215...
  • Page 216 System Diagrams TM2263 (09JUL14) 9015-10-108 35D and 50D Operation & Tests 070914 PN=216...
  • Page 217 X5 (5) GRN/RED X5 (10) (SHT 1) BLK/RED X5 (11) (SHT 2) TX1092235 Main Harness (W8) Wiring Diagram—50D (S.N. 275000— ) (1 of 2) OUO1010,00016D8 -19-19AUG11-9/12 Continued on next page TM2263 (09JUL14) 9015-10-109 35D and 50D Operation & Tests 070914 PN=217...
  • Page 218 System Diagrams TM2263 (09JUL14) 9015-10-110 35D and 50D Operation & Tests 070914 PN=218...
  • Page 219 Y1— Fuel Pump B3—Engine Coolant Overtemp K11— Glow Plug Relay 4-Pin X75— 17 RED Circuit Splice Y2— Fuel Shutoff Solenoid Switch Connector M1—Starter Motor Continued on next page OUO1010,00016D8 -19-19AUG11-10/12 TM2263 (09JUL14) 9015-10-111 35D and 50D Operation & Tests 070914 PN=219...
  • Page 220 System Diagrams TM2263 (09JUL14) 9015-10-112 35D and 50D Operation & Tests 070914 PN=220...
  • Page 221 GRN/RED H2 (1) (SHT 1) BLK/RED H2 (2) (SHT 1) — TX1092236 Main Harness (W8) Wiring Diagram—50D (S.N. 275000— ) (2 of 2) OUO1010,00016D8 -19-19AUG11-11/12 Continued on next page TM2263 (09JUL14) 9015-10-113 35D and 50D Operation & Tests 070914 PN=221...
  • Page 222 System Diagrams TM2263 (09JUL14) 9015-10-114 35D and 50D Operation & Tests 070914 PN=222...
  • Page 223 Harness 12-Pin Connector Work Light Harness X3— Main Harness-to-Platform X38— Main Harness-to-Boom (ground) 1-Pin Connector Harness 4-Pin Connector Work Light Harness X65— 6 RED Circuit Splice (power) 1-Pin Connector OUO1010,00016D8 -19-19AUG11-12/12 TM2263 (09JUL14) 9015-10-115 35D and 50D Operation & Tests 070914 PN=223...
  • Page 224 System Diagrams TM2263 (09JUL14) 9015-10-116 35D and 50D Operation & Tests 070914 PN=224...

  • Page 225: Platform Harness (W9) Component Location

    Platform Harness (W9) Component Location 35D (S.N. —264999) 50D (S.N. —274999) TX1091941 —UN—12MAY11 K1 K5 A4 R2 S1 TX1091941 Platform Harness (W9) Component Location—35D (S.N. —264999) 50D (S.N. —274999) OUO1010,00016D0 -19-28JUN11-1/6 Continued on next page TM2263 (09JUL14) 9015-10-117 35D and 50D Operation & Tests...
  • Page 226 System Diagrams TM2263 (09JUL14) 9015-10-118 35D and 50D Operation & Tests 070914 PN=226...
  • Page 227 K14— Work Lights Relay [35D Harness 12-Pin Connector Heating and A/C Control (S.N. 260001— )] [50D (S.N. Harness Connector 270001— )] R2—Engine Speed Control Potentiometer Continued on next page OUO1010,00016D0 -19-28JUN11-2/6 TM2263 (09JUL14) 9015-10-119 35D and 50D Operation & Tests 070914 PN=227...
  • Page 228 System Diagrams TM2263 (09JUL14) 9015-10-120 35D and 50D Operation & Tests 070914 PN=228...
  • Page 229 System Diagrams 35D (S.N. 265000— ) TX1091942 —UN—12MAY11 K1 K5 A4 R2 S1 M2/R3 TX1091942 Platform Harness (W9) Component Location—35D (S.N. 265000— ) OUO1010,00016D0 -19-28JUN11-3/6 Continued on next page TM2263 (09JUL14) 9015-10-121 35D and 50D Operation & Tests 070914 PN=229...
  • Page 230 System Diagrams TM2263 (09JUL14) 9015-10-122 35D and 50D Operation & Tests 070914 PN=230...
  • Page 231 W3—Platform Harness Ground K5—Horn Relay W9—Platform Harness K14— Work Lights Relay NOTE: For 35D (S.N. 265000— ), travel speed solenoid to main harness (W8). See Main Harness (W8) (Y3) and pilot control shutoff solenoid (Y4) Component Location—35D. (Group 9015-10.) connect to platform harness (W9).
  • Page 232 System Diagrams TM2263 (09JUL14) 9015-10-124 35D and 50D Operation & Tests 070914 PN=232...
  • Page 233 System Diagrams 50D (S.N. 275000— ) TX1091943 —UN—12MAY11 K1 K5 A4 R2 S1 M2/R3 TX1091943 Platform Harness (W9) Component Location—50D (S.N. 275000— ) OUO1010,00016D0 -19-28JUN11-5/6 Continued on next page TM2263 (09JUL14) 9015-10-125 35D and 50D Operation & Tests 070914 PN=233...
  • Page 234 System Diagrams TM2263 (09JUL14) 9015-10-126 35D and 50D Operation & Tests 070914 PN=234...
  • Page 235 (Y3) and pilot control shutoff solenoid (Y4) Component Location—50D. (Group 9015-10.) connect to platform harness (W9). For 50D (S.N. —274999), travel speed solenoid (Y3) and pilot control shutoff solenoid (Y4) connect OUO1010,00016D0 -19-28JUN11-6/6 TM2263 (09JUL14) 9015-10-127 35D and 50D Operation & Tests 070914 PN=235...
  • Page 236 System Diagrams TM2263 (09JUL14) 9015-10-128 35D and 50D Operation & Tests 070914 PN=236...

  • Page 237: Platform Harness (W9) Wiring Diagram

    (SHT 3) X56 (1) (SHT 1) X56 (2) (SHT 1) TX1092227 Platform Harness (W9) Wiring Diagram 35D (S.N. —260000) 50D (S.N. —270000) (1 of 3) OUO1010,00016D5 -19-27FEB12-1/20 Continued on next page TM2263 (09JUL14) 9015-10-129 35D and 50D Operation & Tests...
  • Page 238 System Diagrams TM2263 (09JUL14) 9015-10-130 35D and 50D Operation & Tests 070914 PN=238...
  • Page 239 X7— Platform Harness-to-ROPS X57— 912 BLK Circuit Splice Lockout Switch Work Light Harness (power) X58— RED/BLK Circuit Splice W3—Platform Harness Ground 1-Pin Connector Continued on next page OUO1010,00016D5 -19-27FEB12-2/20 TM2263 (09JUL14) 9015-10-131 35D and 50D Operation & Tests 070914 PN=239...
  • Page 240 System Diagrams TM2263 (09JUL14) 9015-10-132 35D and 50D Operation & Tests 070914 PN=240...
  • Page 241 (SHT 1) NOT USED NOT USED X35 (21) (SHT 3) TX1092228 Platform Harness (W9) Wiring Diagram 35D (S.N. —260000) 50D (S.N. —270000) (2 of 3) OUO1010,00016D5 -19-27FEB12-3/20 Continued on next page TM2263 (09JUL14) 9015-10-133 35D and 50D Operation & Tests...
  • Page 242 System Diagrams TM2263 (09JUL14) 9015-10-134 35D and 50D Operation & Tests 070914 PN=242...
  • Page 243 R2—Engine Speed Control S4— Travel Alarm Cancel Switch X17— Monitor Controller and Potentiometer S7— Horn Switch Display 16-Pin Connector S8— Work Light Switch (M2) Continued on next page OUO1010,00016D5 -19-27FEB12-4/20 TM2263 (09JUL14) 9015-10-135 35D and 50D Operation & Tests 070914 PN=243...
  • Page 244 System Diagrams TM2263 (09JUL14) 9015-10-136 35D and 50D Operation & Tests 070914 PN=244...
  • Page 245 (SHT 3) BLU/YEL X51 (3) (SHT 3) NOT USED TX1092229 Platform Harness (W9) Wiring Diagram 35D (S.N. —260000) 50D (S.N. —270000) (3 of 3) OUO1010,00016D5 -19-27FEB12-5/20 Continued on next page TM2263 (09JUL14) 9015-10-137 35D and 50D Operation & Tests 070914...
  • Page 246 System Diagrams TM2263 (09JUL14) 9015-10-138 35D and 50D Operation & Tests 070914 PN=246...
  • Page 247 (S.N. 244953—270000)] X90— 6 RED Circuit Splice Lockout Relay [35D (S.N. —234983)] [50D X30— Horn Relay 1-Pin (S.N. —244952)] Connector Continued on next page OUO1010,00016D5 -19-27FEB12-6/20 TM2263 (09JUL14) 9015-10-139 35D and 50D Operation & Tests 070914 PN=247...
  • Page 248 System Diagrams TM2263 (09JUL14) 9015-10-140 35D and 50D Operation & Tests 070914 PN=248...
  • Page 249 (SHT 3) X56 (1) (SHT 1) X56 (2) (SHT 1) TX1109164 Platform Harness (W9) Wiring Diagram 35D (S.N. 260001—264999) 50D (S.N. 270001—274999) (1 of 3) OUO1010,00016D5 -19-27FEB12-7/20 Continued on next page TM2263 (09JUL14) 9015-10-141 35D and 50D Operation & Tests...
  • Page 250 System Diagrams TM2263 (09JUL14) 9015-10-142 35D and 50D Operation & Tests 070914 PN=250...
  • Page 251 X7— Platform Harness-to-ROPS X57— 912 BLK Circuit Splice Lockout Switch Work Light Harness (power) X58— RED/BLK Circuit Splice W3—Platform Harness Ground 1-Pin Connector Continued on next page OUO1010,00016D5 -19-27FEB12-8/20 TM2263 (09JUL14) 9015-10-143 35D and 50D Operation & Tests 070914 PN=251...
  • Page 252 System Diagrams TM2263 (09JUL14) 9015-10-144 35D and 50D Operation & Tests 070914 PN=252...
  • Page 253 (SHT 1) NOT USED NOT USED X35 (21) (SHT 3) TX1109165 Platform Harness (W9) Wiring Diagram 35D (S.N. 260001—264999) 50D (S.N. 270001—274999) (2 of 3) OUO1010,00016D5 -19-27FEB12-9/20 Continued on next page TM2263 (09JUL14) 9015-10-145 35D and 50D Operation & Tests...
  • Page 254 System Diagrams TM2263 (09JUL14) 9015-10-146 35D and 50D Operation & Tests 070914 PN=254...
  • Page 255 R2—Engine Speed Control S4— Travel Alarm Cancel Switch X17— Monitor Controller and Potentiometer S7— Horn Switch Display 16-Pin Connector S8— Work Light Switch (M2) Continued on next page OUO1010,00016D5 -19-27FEB12-10/20 TM2263 (09JUL14) 9015-10-147 35D and 50D Operation & Tests 070914 PN=255...
  • Page 256 System Diagrams TM2263 (09JUL14) 9015-10-148 35D and 50D Operation & Tests 070914 PN=256...
  • Page 257 (SHT 3) BLU/YEL X51 (3) (SHT 3) NOT USED TX1109166 Platform Harness (W9) Wiring Diagram 35D (S.N. 260001—264999) 50D (S.N. 270001—274999) (3 of 3) OUO1010,00016D5 -19-27FEB12-11/20 Continued on next page TM2263 (09JUL14) 9015-10-149 35D and 50D Operation & Tests 070914...
  • Page 258 System Diagrams TM2263 (09JUL14) 9015-10-150 35D and 50D Operation & Tests 070914 PN=258...
  • Page 259 K4—Platform Tilt Pilot Control source for auxiliary (S.N. 270001—274999)] Lockout Relay harnesses [35D (S.N. X30— Horn Relay 1-Pin 260001—264999)] [50D Connector (S.N. 270001—274999)] X35— Fuse Block Continued on next page OUO1010,00016D5 -19-27FEB12-12/20 TM2263 (09JUL14) 9015-10-151 35D and 50D Operation & Tests 070914 PN=259...
  • Page 260 System Diagrams TM2263 (09JUL14) 9015-10-152 35D and 50D Operation & Tests 070914 PN=260...
  • Page 261 A3 (9) (SHT 3) RED/BLU X80 (6) (SHT 3) TX1092144 Platform Harness (W9) Wiring Diagram 35D (S.N. 265000— ) 50D (S.N. 275000— ) (1 of 4) OUO1010,00016D5 -19-27FEB12-13/20 Continued on next page TM2263 (09JUL14) 9015-10-153 35D and 50D Operation & Tests...
  • Page 262 System Diagrams TM2263 (09JUL14) 9015-10-154 35D and 50D Operation & Tests 070914 PN=262...
  • Page 263 R3—Actuator Feedback X7— Platform Harness-to-ROPS X59— RED/YEL Circuit Splice Potentiometer Work Light Harness (power) S2— Safety Start, Pilot Control 1-Pin Connector Shutoff Switch Continued on next page OUO1010,00016D5 -19-27FEB12-14/20 TM2263 (09JUL14) 9015-10-155 35D and 50D Operation & Tests 070914 PN=263...
  • Page 264 System Diagrams TM2263 (09JUL14) 9015-10-156 35D and 50D Operation & Tests 070914 PN=264...
  • Page 265 A2 (16) (SHT 2) X5 (7) (SHT 2) TX1092145 Platform Harness (W9) Wiring Diagram 35D (S.N. 265000— ) 50D (S.N. 275000— ) (2 of 4) OUO1010,00016D5 -19-27FEB12-15/20 Continued on next page TM2263 (09JUL14) 9015-10-157 35D and 50D Operation & Tests...
  • Page 266 System Diagrams TM2263 (09JUL14) 9015-10-158 35D and 50D Operation & Tests 070914 PN=266...
  • Page 267 X79— 12-Volt Power Outlet Display S3— Travel Speed Selector X61— 920 BLK Circuit Splice H1—Buzzer Switch X62— GRN/RED Circuit Splice S4— Travel Alarm Cancel Switch Continued on next page OUO1010,00016D5 -19-27FEB12-16/20 TM2263 (09JUL14) 9015-10-159 35D and 50D Operation & Tests 070914 PN=267...
  • Page 268 System Diagrams TM2263 (09JUL14) 9015-10-160 35D and 50D Operation & Tests 070914 PN=268...
  • Page 269 X5 (11) (SHT 1) X57 (5) (SHT 1) TX1092146 Platform Harness (W9) Wiring Diagram 35D (S.N. 265000— ) 50D (S.N. 275000— ) (3 of 4) OUO1010,00016D5 -19-27FEB12-17/20 Continued on next page TM2263 (09JUL14) 9015-10-161 35D and 50D Operation & Tests...
  • Page 270 System Diagrams TM2263 (09JUL14) 9015-10-162 35D and 50D Operation & Tests 070914 PN=270...
  • Page 271 X91— 205 Circuit Splice A4—Travel Alarm Controller Heating and A/C Control Connector X92— 21 BLU/YEL Circuit Splice Harness Connector X30— Horn Relay 1-Pin Connector Continued on next page OUO1010,00016D5 -19-27FEB12-18/20 TM2263 (09JUL14) 9015-10-163 35D and 50D Operation & Tests 070914 PN=271...
  • Page 272 System Diagrams TM2263 (09JUL14) 9015-10-164 35D and 50D Operation & Tests 070914 PN=272...
  • Page 273 X80 (19) (SHT 3) TX1092147 — A1 (2) (SHT 4) Platform Harness (W9) Wiring Diagram 35D (S.N. 265000— ) 50D (S.N. 275000— ) (4 of 4) OUO1010,00016D5 -19-27FEB12-19/20 Continued on next page TM2263 (09JUL14) 9015-10-165 35D and 50D Operation & Tests...
  • Page 274 System Diagrams TM2263 (09JUL14) 9015-10-166 35D and 50D Operation & Tests 070914 PN=274...
  • Page 275 X36— Starter Interlock Relay X90— Unswitched Power RED K1—Safety Start Relay Lockout Relay 2-Pin Connector Circuit Splice K2—Starter Relay K5—Horn Relay X37— Starter Interlock Relay 6-Pin Connector OUO1010,00016D5 -19-27FEB12-20/20 TM2263 (09JUL14) 9015-10-167 35D and 50D Operation & Tests 070914 PN=275...

  • Page 276: Engine Harness (W10) Component Location

    System Diagrams Engine Harness (W10) Component Location 35D (S.N. —260000), 50D (S.N. —270000) T205714 Engine Harness (W10) Component Location—35D (S.N. —260000) 50D (S.N. —270000) Continued on next page OUO1010,00016D1 -19-24MAY11-1/4 TM2263 (09JUL14) 9015-10-168 35D and 50D Operation & Tests 070914...
  • Page 277 Gauge Sensor G2—Alternator W10—Engine Harness Y2— Fuel Shutoff Solenoid B3—Engine Coolant Overtemp M1—Starter Motor X2— Main Harness-to-Engine Switch R1—Intake Air Preheater Harness Connector Continued on next page OUO1010,00016D1 -19-24MAY11-2/4 TM2263 (09JUL14) 9015-10-169 35D and 50D Operation & Tests 070914 PN=277...
  • Page 278 System Diagrams 35D (S.N. 260001— ) TX1091944 Engine Harness (W10) Component Location—35D (S.N. 260001— ) Continued on next page OUO1010,00016D1 -19-24MAY11-3/4 TM2263 (09JUL14) 9015-10-170 35D and 50D Operation & Tests 070914 PN=278...
  • Page 279 X76— Glow Plug Power 1-Pin Connector 50D (S.N. 270001— ) NOTE: For location of engine electrical components on 50D (S.N. 270001— ) machines, see Main Harness (W8) Component Location—50D. (Group 9015-10.) OUO1010,00016D1 -19-24MAY11-4/4 TM2263 (09JUL14) 9015-10-171 35D and 50D Operation & Tests 070914 PN=279...
  • Page 280 System Diagrams TM2263 (09JUL14) 9015-10-172 35D and 50D Operation & Tests 070914 PN=280...

  • Page 281: Engine Harness (W10) Wiring Diagram

    System Diagrams Engine Harness (W10) Wiring Diagram 35D (S.N. —260000) 50D (S.N. —270000) T206017 —UN—21DEC04 Engine Harness (W10) Wiring Diagram 35D (S.N. —260000) 50D (S.N. —270000) OUO1010,00016DA -19-06JUN11-1/4 Continued on next page TM2263 (09JUL14) 9015-10-173 35D and 50D Operation & Tests...
  • Page 282 System Diagrams TM2263 (09JUL14) 9015-10-174 35D and 50D Operation & Tests 070914 PN=282...
  • Page 283 Y2— Fuel Shutoff Solenoid B3—Engine Coolant Over M1—Starter Motor Harness Connector Temperature Switch R1—Intake Air Preheater X41— Start Circuit Splice in Engine Harness Continued on next page OUO1010,00016DA -19-06JUN11-2/4 TM2263 (09JUL14) 9015-10-175 35D and 50D Operation & Tests 070914 PN=283...
  • Page 284 System Diagrams TM2263 (09JUL14) 9015-10-176 35D and 50D Operation & Tests 070914 PN=284...
  • Page 285 System Diagrams 35D (S.N. 260001— ) TX1080737 —UN—14SEP10 Engine Harness (W10) Wiring Diagram 35D (S.N. 260001— ) OUO1010,00016DA -19-06JUN11-3/4 Continued on next page TM2263 (09JUL14) 9015-10-177 35D and 50D Operation & Tests 070914 PN=285...
  • Page 286 System Diagrams TM2263 (09JUL14) 9015-10-178 35D and 50D Operation & Tests 070914 PN=286...
  • Page 287 Main Harness (W8) Wiring Diagram—50D NOTE: For wiring diagram of engine harness for 50D (S.N. 275000— ). (Group 9015-10.) (S.N. 270001— ) machines, see Main Harness OUO1010,00016DA -19-06JUN11-4/4 TM2263 (09JUL14) 9015-10-179 35D and 50D Operation & Tests 070914 PN=287...
  • Page 288 System Diagrams TM2263 (09JUL14) 9015-10-180 35D and 50D Operation & Tests 070914 PN=288...

  • Page 289: Heating And A/C Control Harness (W11) Component Location

    System Diagrams Heating and A/C Control Harness (W11) Component Location T205715 —UN—17DEC04 W11A T205715 Heating and A/C Control Harness (W11) Component Location OUO1010,00016E1 -19-29JUN11-1/2 Continued on next page TM2263 (09JUL14) 9015-10-181 35D and 50D Operation & Tests 070914 PN=289...
  • Page 290 System Diagrams TM2263 (09JUL14) 9015-10-182 35D and 50D Operation & Tests 070914 PN=290...
  • Page 291 Connector Connector NOTE: The heating and A/C controller (A5) is used only For 35D (S.N. 260001— ) and 50D (S.N. 270001— on 35D (S.N. —260000) and 50D (S.N. —270000). ), the heating and A/C controller circuity is inside the heating and A/C console (A6).
  • Page 292 System Diagrams TM2263 (09JUL14) 9015-10-184 35D and 50D Operation & Tests 070914 PN=292...

  • Page 293: Heating And A/C Control Harness (W11) Wiring Diagram

    Heating and A/C Control Harness (W11) Wiring Diagram 35D (S.N. —260000) 50D (S.N. —270000) T206018 —UN—03JAN05 Heating and A/C Control Harness (W11) Wiring Diagram 35D (S.N. —260000) 50D (S.N. —270000) (1 of 3) OUO1010,00016DF -19-19AUG11-1/9 Continued on next page TM2263 (09JUL14) 9015-10-185 35D and 50D Operation &...
  • Page 294 System Diagrams TM2263 (09JUL14) 9015-10-186 35D and 50D Operation & Tests 070914 PN=294...
  • Page 295 S10— Wiper Motor and Washer Control Harness-to-A/C X28— Heating and A/C Control Switch Compressor Harness Harness-to-A/C Torque W11A—A/C Torque Control Connector Control Solenoid Harness Solenoid Harness Connector Continued on next page OUO1010,00016DF -19-19AUG11-2/9 TM2263 (09JUL14) 9015-10-187 35D and 50D Operation & Tests 070914 PN=295...
  • Page 296 System Diagrams TM2263 (09JUL14) 9015-10-188 35D and 50D Operation & Tests 070914 PN=296...
  • Page 297 System Diagrams T206262 —UN—21DEC04 Heating and A/C Control Harness (W11) Wiring Diagram 35D (S.N. —260000) 50D (S.N. —270000) (2 of 3) OUO1010,00016DF -19-19AUG11-3/9 Continued on next page TM2263 (09JUL14) 9015-10-189 35D and 50D Operation & Tests 070914 PN=297...
  • Page 298 System Diagrams TM2263 (09JUL14) 9015-10-190 35D and 50D Operation & Tests 070914 PN=298...
  • Page 299 X24— Blower Motor 2-Pin V2— Heating and A/C Diode X18B— Radio Power 1-Pin X21— Heating and A/C Controller Connector Connector (male) (A5) 30-Pin Connector Continued on next page OUO1010,00016DF -19-19AUG11-4/9 TM2263 (09JUL14) 9015-10-191 35D and 50D Operation & Tests 070914 PN=299...
  • Page 300 System Diagrams Heating and A/C Control Harness (W11) Wiring Diagram 35D (S.N. —260000) 50D (S.N. —270000) (3 of 3) 2— Continued on Sheet 2 of 3 K7—Blower Relay—Medium K10— A/C Compressor Clutch K6—Blower Relay—Low K8—Blower Relay—High Relay Continued on next page...
  • Page 301 System Diagrams 35D (S.N. 260001— ) 50D (S.N. 270001— ) TX1092497 —UN—23MAY11 Heating and A/C Control Harness (W11) Wiring Diagram 35D (S.N. 260001— ) 50D (S.N. 270001— ) (1 of 2) OUO1010,00016DF -19-19AUG11-6/9 Continued on next page TM2263 (09JUL14) 9015-10-193 35D and 50D Operation &...
  • Page 302 System Diagrams TM2263 (09JUL14) 9015-10-194 35D and 50D Operation & Tests 070914 PN=302...
  • Page 303 X28— Heating and A/C Control Harness-to-Cab Harness X25— Fresh Air Vent Actuator Harness-to-A/C Torque 2-Pin Connector 7-Pin Connector Control Solenoid Harness 2-Pin Connector Continued on next page OUO1010,00016DF -19-19AUG11-7/9 TM2263 (09JUL14) 9015-10-195 35D and 50D Operation & Tests 070914 PN=303...
  • Page 304 System Diagrams TM2263 (09JUL14) 9015-10-196 35D and 50D Operation & Tests 070914 PN=304...
  • Page 305 System Diagrams TX1092498 —UN—23MAY11 Heating and A/C Control Harness (W11) Wiring Diagram 35D (S.N. 260001— ) 50D (S.N. 270001— ) (2 of 2) OUO1010,00016DF -19-19AUG11-8/9 Continued on next page TM2263 (09JUL14) 9015-10-197 35D and 50D Operation & Tests 070914 PN=305...
  • Page 306 System Diagrams TM2263 (09JUL14) 9015-10-198 35D and 50D Operation & Tests 070914 PN=306...
  • Page 307 X18A— Radio Power 1-Pin X23— Thermistor 2-Pin X102— 24 RED/BLK Circuit Relay Connector (female) Connector Splice X18B— Radio Power 1-Pin X24— Blower Motor 2-Pin Connector (male) Connector OUO1010,00016DF -19-19AUG11-9/9 TM2263 (09JUL14) 9015-10-199 35D and 50D Operation & Tests 070914 PN=307...

  • Page 308: A/C Compressor Harness (W12) Component Location

    System Diagrams A/C Compressor Harness (W12) Component Location T205716 A/C Compressor Harness (W12) Component Location Continued on next page OUO1072,0000D88 -19-07DEC04-1/2 TM2263 (09JUL14) 9015-10-200 35D and 50D Operation & Tests 070914 PN=308...
  • Page 309 System Diagrams B10— A/C High/Low Pressure X26— Heating and A/C Y6— A/C Compressor Clutch Switch Control Harness-to-A/C W12—A/C Compressor Harness Compressor Harness Connector OUO1072,0000D88 -19-07DEC04-2/2 TM2263 (09JUL14) 9015-10-201 35D and 50D Operation & Tests 070914 PN=309...

  • Page 310: A/C Compressor Harness (W12) Wiring Diagram

    System Diagrams A/C Compressor Harness (W12) Wiring Diagram A/C Compressor Harness (W12) Wiring Diagram Continued on next page OUO1072,0000D89 -19-07DEC04-1/2 TM2263 (09JUL14) 9015-10-202 35D and 50D Operation & Tests 070914 PN=310...
  • Page 311 System Diagrams B10— A/C High/Low Pressure X26— Heating and A/C Y6— A/C Compressor Clutch Switch Control Harness-to-A/C Compressor Harness Connector OUO1072,0000D89 -19-07DEC04-2/2 TM2263 (09JUL14) 9015-10-203 35D and 50D Operation & Tests 070914 PN=311...
  • Page 312 System Diagrams TM2263 (09JUL14) 9015-10-204 35D and 50D Operation & Tests 070914 PN=312...

  • Page 313: Cab Harness (W13) Component Location

    System Diagrams Cab Harness (W13) Component Location TX1054353 —UN—15JAN09 W13A TX1054353 Cab Harness (W13) Component Location OUO1010,0000B28 -19-06JUN11-1/2 Continued on next page TM2263 (09JUL14) 9015-10-205 35D and 50D Operation & Tests 070914 PN=313...
  • Page 314 System Diagrams TM2263 (09JUL14) 9015-10-206 35D and 50D Operation & Tests 070914 PN=314...
  • Page 315 E4— Cab Work Light X27— Heating and A/C Control Harness Connector M3—Wiper Motor Harness-to-Cab Harness X46— Auxiliary Work Light S11— Wiper Motor Disconnect Connector (power) 1-Pin Connector Switch OUO1010,0000B28 -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-207 35D and 50D Operation & Tests 070914 PN=315...
  • Page 316 System Diagrams TM2263 (09JUL14) 9015-10-208 35D and 50D Operation & Tests 070914 PN=316...

  • Page 317: Cab Harness (W13) Wiring Diagram

    System Diagrams Cab Harness (W13) Wiring Diagram TX1054354 —UN—16JAN09 Cab Harness (W13) Wiring Diagram OUO1010,0000B29 -19-06JUN11-1/2 Continued on next page TM2263 (09JUL14) 9015-10-209 35D and 50D Operation & Tests 070914 PN=317...
  • Page 318 System Diagrams TM2263 (09JUL14) 9015-10-210 35D and 50D Operation & Tests 070914 PN=318...
  • Page 319 M3—Wiper Motor X29— Radio Connector X52— Light Circuit Splice S11— Wiper Motor Disconnect X34— Heating and A/C Control X53— Wiper Motor Ground Splice Switch Harness-to-Wiper Motor Harness Connector OUO1010,0000B29 -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-211 35D and 50D Operation & Tests 070914 PN=319...

  • Page 320: Boom Work Light Harness (W14) Component Location

    System Diagrams Boom Work Light Harness (W14) Component Location TX1054355 Boom Work Light Harness (W14) Component Location Continued on next page OUO1010,0000B2A -19-06JUN11-1/2 TM2263 (09JUL14) 9015-10-212 35D and 50D Operation & Tests 070914 PN=320...
  • Page 321 System Diagrams E2— Boom Work Light X38— Main Harness-to-Boom X39— Main Harness-to-Boom W14—Boom Work Light Harness Work Light (power) 1-Pin Work Light (ground) 1-Pin Connector Connector OUO1010,0000B2A -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-213 35D and 50D Operation & Tests 070914 PN=321...

  • Page 322: Boom Work Light Harness (W14) Wiring Diagram

    System Diagrams Boom Work Light Harness (W14) Wiring Diagram Boom Work Light Harness (W14) Wiring Diagram Continued on next page OUO1010,0000B2B -19-06JUN11-1/2 TM2263 (09JUL14) 9015-10-214 35D and 50D Operation & Tests 070914 PN=322...
  • Page 323 System Diagrams E2— Boom Work Light X39— Main Harness-to-Boom X38— Main Harness-to-Boom Work Light (ground) 1-Pin Work Light (power) 1-Pin Connector Connector OUO1010,0000B2B -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-215 35D and 50D Operation & Tests 070914 PN=323...

  • Page 324: Rops Work Light Harness (W15) Component Location

    System Diagrams ROPS Work Light Harness (W15) Component Location TX1054357 ROPS Work Light Harness (W15) Component Location Continued on next page OUO1010,0000B2C -19-06JUN11-1/2 TM2263 (09JUL14) 9015-10-216 35D and 50D Operation & Tests 070914 PN=324...
  • Page 325 System Diagrams E1— ROPS Work Light X7— Platform Harness-to-ROPS X8— Platform Harness-to-ROPS W15—ROPS Work Light Harness Work Light Harness (power) Work Light Harness 1-Pin Connector (ground) 1-Pin Connector OUO1010,0000B2C -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-217 35D and 50D Operation & Tests 070914 PN=325...

  • Page 326: Rops Work Light Harness (W15) Wiring Diagram

    System Diagrams ROPS Work Light Harness (W15) Wiring Diagram ROPS Work Light Harness (W15) Wiring Diagram Continued on next page OUO1010,0000B2D -19-06JUN11-1/2 TM2263 (09JUL14) 9015-10-218 35D and 50D Operation & Tests 070914 PN=326...
  • Page 327 System Diagrams E1— ROPS Work Light X8— Platform Harness-to-ROPS X7— Platform Harness-to-ROPS Work Light Harness Work Light Harness (power) (ground) 1-Pin Connector 1-Pin Connector OUO1010,0000B2D -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-219 35D and 50D Operation & Tests 070914 PN=327...

  • Page 328: Auxiliary Flow Selector Harness (W16) Component Location-35D

    System Diagrams Auxiliary Flow Selector Harness (W16) Component Location—35D X15A X14A X15B X14B W16A TX1054359 Auxiliary Flow Selector Harness (W16) Component Location—35D Continued on next page OUO1010,0000B2E -19-06JUN11-1/2 TM2263 (09JUL14) 9015-10-220 35D and 50D Operation & Tests 070914 PN=328...
  • Page 329 Solenoid Harness Connector Harness-to-Auxiliary Flow X14A— Auxiliary Flow Selector X15B— Auxiliary Flow Selector Selector Solenoid Harness Harness (power-in) 1-Pin Harness (ground-out) (ground) 1-Pin Connector Connector 1-Pin Connector OUO1010,0000B2E -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-221 35D and 50D Operation & Tests 070914 PN=329...
  • Page 330 System Diagrams TM2263 (09JUL14) 9015-10-222 35D and 50D Operation & Tests 070914 PN=330...

  • Page 331: Auxiliary Flow Selector Harness (W16) Wiring Diagram-35D

    System Diagrams Auxiliary Flow Selector Harness (W16) Wiring Diagram—35D TX1054360 —UN—16JAN09 Auxiliary Flow Selector Harness (W16) Wiring Diagram—35D OUO1010,0000B2F -19-06JUN11-1/2 Continued on next page TM2263 (09JUL14) 9015-10-223 35D and 50D Operation & Tests 070914 PN=331...
  • Page 332 System Diagrams TM2263 (09JUL14) 9015-10-224 35D and 50D Operation & Tests 070914 PN=332...
  • Page 333 W16B—Auxiliary Flow Selector X15B— Auxiliary Flow Selector Selector Solenoid Harness Ground Harness (S.N. Harness (ground-out) (ground) 1-Pin Connector —234983) 1-Pin Connector X14A— Auxiliary Flow Selector Harness (power-in) 1-Pin Connector OUO1010,0000B2F -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-225 35D and 50D Operation & Tests 070914 PN=333...

  • Page 334: Auxiliary Flow Selector Harness (W16) Component Location-50D

    System Diagrams Auxiliary Flow Selector Harness (W16) Component Location—50D X14A X15A X15B X14B TX1054362 Auxiliary Flow Selector Harness (W16) Component Location—50D Continued on next page OUO1010,0000B30 -19-06JUN11-1/2 TM2263 (09JUL14) 9015-10-226 35D and 50D Operation & Tests 070914 PN=334...
  • Page 335 W16—Auxiliary Flow Selector 1-Pin Connector 1-Pin Connector Harness X15A— Auxiliary Flow Selector Y5— Auxiliary Flow Selector X14A— Auxiliary Flow Selector Harness (ground-in) 1-Pin Solenoid Harness (power-in) 1-Pin Connector Connector OUO1010,0000B30 -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-227 35D and 50D Operation & Tests 070914 PN=335...

  • Page 336: Auxiliary Flow Selector Harness (W16) Wiring Diagram-50D

    System Diagrams Auxiliary Flow Selector Harness (W16) Wiring Diagram—50D Auxiliary Flow Selector Harness (W16) Wiring Diagram—50D Continued on next page OUO1010,0000B31 -19-06JUN11-1/2 TM2263 (09JUL14) 9015-10-228 35D and 50D Operation & Tests 070914 PN=336...
  • Page 337 Y5— Auxiliary Flow Selector —244952) X15A— Auxiliary Flow Selector Solenoid X12— Spare 4-Pin Connector Harness (ground-in) 1-Pin [used as ground source Connector for auxiliary harnesses (S.N. —244952)] OUO1010,0000B31 -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-229 35D and 50D Operation & Tests 070914 PN=337...

  • Page 338: Blade Angle Control Harness (W18) Component Location-If Equipped

    System Diagrams Blade Angle Control Harness (W18) Component Location—If Equipped X15D X14D X14C W18A X15C TX1092693 Blade Angle Control Harness (W18) Component Location—If Equipped Continued on next page OUO1010,00016E2 -19-06JUN11-1/2 TM2263 (09JUL14) 9015-10-230 35D and 50D Operation & Tests 070914 PN=338...
  • Page 339 1-Pin Connector X45— Blade Angle Control Harness X15D— Blade Angle Control Harness-to-Blade Angle W18A—Blade Angle Solenoid Harness (ground-out) Switches (S12 and S13) Harness 1-Pin Connector Ground 1-Pin Connector OUO1010,00016E2 -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-231 35D and 50D Operation & Tests 070914 PN=339...
  • Page 340 System Diagrams TM2263 (09JUL14) 9015-10-232 35D and 50D Operation & Tests 070914 PN=340...

  • Page 341: Blade Angle Control Harness (W18) Wiring Diagram-If Equipped

    System Diagrams Blade Angle Control Harness (W18) Wiring Diagram—If Equipped TX1092694 —UN—06JUN11 Blade Angle Control Harness (W18) Wiring Diagram—If Equipped OUO1010,00016E3 -19-06JUN11-1/2 Continued on next page TM2263 (09JUL14) 9015-10-233 35D and 50D Operation & Tests 070914 PN=341...
  • Page 342 System Diagrams TM2263 (09JUL14) 9015-10-234 35D and 50D Operation & Tests 070914 PN=342...
  • Page 343 X14C— Blade Angle Control Connector X72— Blade Angle BLK Ground Harness (power-in) 1-Pin X44— Blade Angle Control Circuit Splice Connector Harness-to-Blade Angle Right Switch (S13) 1-Pin Connector OUO1010,00016E3 -19-06JUN11-2/2 TM2263 (09JUL14) 9015-10-235 35D and 50D Operation & Tests 070914 PN=343...

  • Page 344: Auxiliary Function Control Harness (W19) Component Location

    (A7) X15A X14A X15B X14B TX1092598 Auxiliary Function Control Harness (W19) Component Location—35D (S.N. 265000— ) 50D (S.N. 275000— ) A7—Auxliary Function Controller X14A— Auxiliary Control X15B— Auxiliary Control Harness Y15— Auxliary Function S15— Auxliary Function Trigger Harness (power-in) 1-Pin...
  • Page 345 System Diagrams TM2263 (09JUL14) 9015-10-237 35D and 50D Operation & Tests 070914 PN=345...

  • Page 346: Auxiliary Function Control Harness (W19) Wiring Diagram

    System Diagrams Auxiliary Function Control Harness (W19) Wiring Diagram Auxiliary Function Control Harness (W19) Wiring Diagram—35D (S.N. 265000— ) 50D (S.N. 275000— ) Continued on next page OUO1010,00016D4 -19-19JUL11-1/2 TM2263 (09JUL14) 9015-10-238 35D and 50D Operation & Tests 070914 PN=346...
  • Page 347 X15B— Auxiliary Control Harness X84— RED/YEL Circuit Splice Solenoid 2 X14B— Auxiliary Control Harness (ground-out) 1-Pin X85— BLK Circuit Splice (power-out) 1-Pin Connector (male) X86— BLU/BLK Circuit Splice Connector (female) OUO1010,00016D4 -19-19JUL11-2/2 TM2263 (09JUL14) 9015-10-239 35D and 50D Operation & Tests 070914 PN=347...
  • Page 348 System Diagrams TM2263 (09JUL14) 9015-10-240 35D and 50D Operation & Tests 070914 PN=348...

  • Page 349: Starting Circuit Theory Of Operation

    Group 15 Sub-System Diagnostics Starting Circuit Theory of Operation TX1092800 —UN—10JUN11 Starting Circuit Schematic—35D (S.N. —260000) 50D (S.N. —270000) OUO1010,00016EA -19-24JUN11-1/4 Continued on next page TM2263 (09JUL14) 9015-15-1 35D and 50D Operation & Tests 070914 PN=349...
  • Page 350 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-2 35D and 50D Operation & Tests 070914 PN=350...
  • Page 351 F10— Safety Start Relay 5-Amp S2— Safety Start, Pilot Control Harness 12-Pin Connector Fuse Shutoff Switch X3— Main Harness-to-Platform W1—Battery-to-Frame Ground Harness 4-Pin Connector Continued on next page OUO1010,00016EA -19-24JUN11-2/4 TM2263 (09JUL14) 9015-15-3 35D and 50D Operation & Tests 070914 PN=351...
  • Page 352 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-4 35D and 50D Operation & Tests 070914 PN=352...
  • Page 353 Sub-System Diagnostics TX1092802 —UN—10JUN11 Starting Circuit Schematic—35D (S.N. 260001— ) 50D (S.N. 270001— ) OUO1010,00016EA -19-24JUN11-3/4 Continued on next page TM2263 (09JUL14) 9015-15-5 35D and 50D Operation & Tests 070914 PN=353...
  • Page 354 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-6 35D and 50D Operation & Tests 070914 PN=354...
  • Page 355 C of the key switch will not activate. flows through fuse (F10), across the normally closed contacts of the safety start relay, to pin 3 on the starter interlock relay. OUO1010,00016EA -19-24JUN11-4/4 TM2263 (09JUL14) 9015-15-7 35D and 50D Operation & Tests 070914 PN=355...

  • Page 356: Charging Circuit Theory Of Operation

    Sub-System Diagnostics Charging Circuit Theory of Operation 35D (S.N. —264999) 50D (S.N. —274999) Charging Circuit Schematic—35D (S.N. —264999) 50D (S.N. —274999) Continued on next page OUO1010,00016EB -19-19AUG11-1/4 TM2263 (09JUL14) 9015-15-8 35D and 50D Operation & Tests 070914 PN=356...
  • Page 357 When the key switch is ON and the engine is running, the voltage output at pin L of the alternator is equal to or Continued on next page OUO1010,00016EB -19-19AUG11-2/4 TM2263 (09JUL14) 9015-15-9 35D and 50D Operation & Tests 070914 PN=357...
  • Page 358 Sub-System Diagnostics 35D (S.N. 265000— ) 50D (S.N. 275000— ) Charging Circuit Schematic—35D (S.N. 265000— ) 50D (S.N. 275000— ) Continued on next page OUO1010,00016EB -19-19AUG11-3/4 TM2263 (09JUL14) 9015-15-10 35D and 50D Operation & Tests 070914 PN=358...
  • Page 359 When the key switch is in the ON position and the engine is running, the voltage output at pin L of the alternator is OUO1010,00016EB -19-19AUG11-4/4 TM2263 (09JUL14) 9015-15-11 35D and 50D Operation & Tests 070914 PN=359...

  • Page 360: Fuel Shutoff Circuit Theory Of Operation

    Sub-System Diagnostics Fuel Shutoff Circuit Theory of Operation Fuel Shutoff Circuit Schematic Continued on next page OUO1010,00016EC -19-24JUN11-1/2 TM2263 (09JUL14) 9015-15-12 35D and 50D Operation & Tests 070914 PN=360...
  • Page 361 1 second. With the fuel shutoff pull-in coil relay energized, current flows through fuse (F1), to the pull-in OUO1010,00016EC -19-24JUN11-2/2 TM2263 (09JUL14) 9015-15-13 35D and 50D Operation & Tests 070914 PN=361...
  • Page 362 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-14 35D and 50D Operation & Tests 070914 PN=362...

  • Page 363: Engine Speed Control Circuit Theory Of Operation

    Sub-System Diagnostics Engine Speed Control Circuit Theory of Operation TX1092997 —UN—08JUN11 Engine Speed Control Circuit Schematic—35D (S.N. —264999) 50D (S.N. —274999) OUO1010,00016E5 -19-09MAY13-1/5 Continued on next page TM2263 (09JUL14) 9015-15-15 35D and 50D Operation & Tests 070914 PN=363...
  • Page 364 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-16 35D and 50D Operation & Tests 070914 PN=364...
  • Page 365 Harness 12-Pin Connector B6—Auto-Idle Pressure Sensor Potentiometer X16— Monitor Controller and F4— Auto-Idle, 12-Volt Power R3—Actuator Feedback Display 20-Pin Connector Outlet 10-Amp Fuse Potentiometer Continued on next page OUO1010,00016E5 -19-09MAY13-2/5 TM2263 (09JUL14) 9015-15-17 35D and 50D Operation & Tests 070914 PN=365...
  • Page 366 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-18 35D and 50D Operation & Tests 070914 PN=366...
  • Page 367 Sub-System Diagnostics TX1092998 —UN—08JUN11 Engine Speed Control Circuit Schematic—35D (S.N. 265000— ) 50D (S.N. 275000— ) OUO1010,00016E5 -19-09MAY13-3/5 Continued on next page TM2263 (09JUL14) 9015-15-19 35D and 50D Operation & Tests 070914 PN=367...
  • Page 368 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-20 35D and 50D Operation & Tests 070914 PN=368...
  • Page 369 X17, causing the auto-idle indicator to come on. If the voltage from actuator feedback potentiometer (R3) For 35D (S.N. 265000— ) 50D (S.N. 275000— ): When does not equal the percentage of position as determined auto-idle switch (S14) is moved to the ON position, a...
  • Page 370 2.5—5.0 volts to pin 9 of the auto-idle controller. by the engine speed control potentiometer. When the auto-idle controller detects more than 2.5 volts OUO1010,00016E5 -19-09MAY13-5/5 TM2263 (09JUL14) 9015-15-22 35D and 50D Operation & Tests 070914 PN=370...

  • Page 371: Monitor Controller Circuit Theory Of Operation

    Sub-System Diagnostics Monitor Controller Circuit Theory of Operation 35D (S.N. —264999) 50D (S.N. —274999) TX1092995 —UN—24JUN11 Monitor Controller Circuit Schematic—35D (S.N. —264999) 50D (S.N. —274999) OUO1010,00016E6 -19-28MAY14-1/5 Continued on next page TM2263 (09JUL14) 9015-15-23 35D and 50D Operation & Tests...
  • Page 372 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-24 35D and 50D Operation & Tests 070914 PN=372...
  • Page 373 (Group 9015-15.) come on, the first segment on the fuel gauge will flash, and the buzzer (H1) will activate. If the wiring between the Continued on next page OUO1010,00016E6 -19-28MAY14-2/5 TM2263 (09JUL14) 9015-15-25 35D and 50D Operation & Tests 070914 PN=373...
  • Page 374 START positions, current flows to pin 12 of monitor 15 seconds, indicating to the operator to start the engine. controller connector (X16), causing the preheat indicator Continued on next page OUO1010,00016E6 -19-28MAY14-3/5 TM2263 (09JUL14) 9015-15-26 35D and 50D Operation & Tests 070914 PN=374...
  • Page 375 Sub-System Diagnostics 35D (S.N. 265000— ) 50D (S.N. 275000— ) TX1092996 —UN—24JUN11 Monitor Controller Circuit Schematic—35D (S.N. 265000— ) 50D (S.N. 275000— ) OUO1010,00016E6 -19-28MAY14-4/5 Continued on next page TM2263 (09JUL14) 9015-15-27 35D and 50D Operation & Tests 070914 PN=375...
  • Page 376 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-28 35D and 50D Operation & Tests 070914 PN=376...
  • Page 377 20. The monitor controller 15 seconds, indicating to the operator to start the engine. processes the signal and activates the appropriate OUO1010,00016E6 -19-28MAY14-5/5 TM2263 (09JUL14) 9015-15-29 35D and 50D Operation & Tests 070914 PN=377...

  • Page 378: Pilot Control Shutoff Circuit Theory Of Operation

    Sub-System Diagnostics Pilot Control Shutoff Circuit Theory of Operation Pilot Shutoff Circuit Schematic Continued on next page OUO1010,00016ED -19-08JUN11-1/2 TM2263 (09JUL14) 9015-15-30 35D and 50D Operation & Tests 070914 PN=378...
  • Page 379 UP position. For more information on the start circuit, see Starting Circuit Theory of Operation. (Group 9015-15.) OUO1010,00016ED -19-08JUN11-2/2 TM2263 (09JUL14) 9015-15-31 35D and 50D Operation & Tests 070914 PN=379...

  • Page 380: Travel Speed Control And Alarm Circuit Theory Of Operation

    Sub-System Diagnostics Travel Speed Control and Alarm Circuit Theory of Operation Travel Speed Control Circuit Schematic—35D (S.N. —264999) 50D (S.N. —274999) Continued on next page OUO1010,00016E7 -19-07JUL11-1/4 TM2263 (09JUL14) 9015-15-32 35D and 50D Operation & Tests 070914 PN=380...
  • Page 381 F8— Travel Speed Selector H2—Travel Alarm X4— Main Harness-to-Platform Switch, Travel Alarm S3— Travel Speed Selector Harness 6-Pin Connector Controller, Auxiliary 20-Amp Switch Fuse Continued on next page OUO1010,00016E7 -19-07JUL11-2/4 TM2263 (09JUL14) 9015-15-33 35D and 50D Operation & Tests 070914 PN=381...
  • Page 382 Sub-System Diagnostics Travel Speed Control Circuit Schematic—35D (S.N. 265000— ) 50D (S.N. 275000— ) Continued on next page OUO1010,00016E7 -19-07JUL11-3/4 TM2263 (09JUL14) 9015-15-34 35D and 50D Operation & Tests 070914 PN=382...
  • Page 383 NEUTRAL position so that when the travel 35D (S.N. 265000— ) 50D (S.N. 275000— ): When the levers are moved to the FORWARD or REVERSE travel travel speed selector switch is in the HIGH position, the positions, the travel alarm will activate again.
  • Page 384 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-36 35D and 50D Operation & Tests 070914 PN=384...

  • Page 385: Heating And Air Conditioning Control Circuit Theory Of Operation

    Sub-System Diagnostics Heating and Air Conditioning Control Circuit Theory of Operation 35D (S.N. —260000) 50D (S.N. —270000) TX1092706 —UN—27MAY11 Heating and Air Conditioning Control Circuit Schematic—35D (S.N. —260000) 50D (S.N. —270000) OUO1010,00016E8 -19-19AUG11-1/6 Continued on next page TM2263 (09JUL14) 9015-15-37 35D and 50D Operation &...
  • Page 386 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-38 35D and 50D Operation & Tests 070914 PN=386...
  • Page 387 A/C controller provides a ground closes the valve. to blower relay medium (K7), energizing the relay. With the blower relay medium energized, a ground is provided Continued on next page OUO1010,00016E8 -19-19AUG11-2/6 TM2263 (09JUL14) 9015-15-39 35D and 50D Operation & Tests 070914 PN=387...
  • Page 388 If so, the heating and A/C controller provides a ground [pin (Group 9025-05.) 13 of connector (X21)] to the coil of A/C compressor clutch Continued on next page OUO1010,00016E8 -19-19AUG11-3/6 TM2263 (09JUL14) 9015-15-40 35D and 50D Operation & Tests 070914 PN=388...
  • Page 389 Sub-System Diagnostics 35D (S.N. 260001— ) 50D (S.N. 270001— ) TX1092707 —UN—10JUN11 Heating and Air Conditioning Control Circuit Schematic—35D (S.N. 260001— ) 50D (S.N. 270001— ) OUO1010,00016E8 -19-19AUG11-4/6 Continued on next page TM2263 (09JUL14) 9015-15-41 35D and 50D Operation & Tests...
  • Page 390 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-42 35D and 50D Operation & Tests 070914 PN=390...
  • Page 391 The ground circuit goes through one fixed resistor, then connects to the blower motor at pin 2 of connector (X24), activating the blower motor in medium speed. Continued on next page OUO1010,00016E8 -19-19AUG11-5/6 TM2263 (09JUL14) 9015-15-43 35D and 50D Operation & Tests 070914 PN=391...
  • Page 392 (F7) flows to the A/C compressor clutch (Y6), activating the clutch. At the same time the heating and air conditioner console activates the A/C compressor clutch, it also provides a OUO1010,00016E8 -19-19AUG11-6/6 TM2263 (09JUL14) 9015-15-44 35D and 50D Operation & Tests 070914 PN=392...

  • Page 393: Preheating Circuit Theory Of Operation

    Sub-System Diagnostics Preheating Circuit Theory of Operation 35D (S.N. —260000) 50D (S.N. —270000) Intake Air Preheat Circuit Schematic—35D (S.N. —260000) 50D (S.N. —270000) A2—Monitor Controller and S1— Key Switch X2— Main Harness-to-Engine X16— Monitor Controller and Harness 12-Pin Connector Display W1—Battery-to-Frame Ground...
  • Page 394 (X16) on the monitor controller and display bearing on length of time heater is energized. (A2), causing the engine preheat indicator to come on Continued on next page OUO1010,00016EE -19-12MAR14-2/4 TM2263 (09JUL14) 9015-15-46 35D and 50D Operation & Tests 070914 PN=394...
  • Page 395 Sub-System Diagnostics 35D (S.N. 260001— ) 50D (S.N. 270001— ) TX1092756 —UN—10JUN11 Glow Plugs Preheat Circuit Schematic—35D (S.N. 260001— ) 50D (S.N. 270001— ) OUO1010,00016EE -19-12MAR14-3/4 Continued on next page TM2263 (09JUL14) 9015-15-47 35D and 50D Operation & Tests 070914...
  • Page 396 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-48 35D and 50D Operation & Tests 070914 PN=396...
  • Page 397 (F11), across the contacts of the glow plug relay, then For [35D (S.N. 265000— )] [50D (S.N. 275000— )] to glow plugs (R4—R7). machines, current from pin R1 of the key switch also flows NOTE: 35D machines use glow plugs (R4—R6).

  • Page 398: Auxiliary Function Control Lever Circuit Theory Of Operation

    Sub-System Diagnostics Auxiliary Function Control Lever Circuit Theory of Operation Auxiliary Function Control Circuit Schematic Continued on next page OUO1010,00016FD -19-19AUG11-1/2 TM2263 (09JUL14) 9015-15-50 35D and 50D Operation & Tests 070914 PN=398...
  • Page 399 For hydraulic operation, see Auxiliary Auxiliary Function Proportional Control (S16)—The Function Control Valve Operation. (Group 9025-05.) auxiliary function proportional control, located on the right OUO1010,00016FD -19-19AUG11-2/2 TM2263 (09JUL14) 9015-15-51 35D and 50D Operation & Tests 070914 PN=399...
  • Page 400 Sub-System Diagnostics TM2263 (09JUL14) 9015-15-52 35D and 50D Operation & Tests 070914 PN=400...

  • Page 401: Alternator And Starting Motors

    Group 20 References Alternator and Starting Motors For more information on the alternator and starting motor, see Alternators and Starting Motors. (CTM77.) OUO1010,00006D8 -19-29NOV05-1/1 TM2263 (09JUL14) 9015-20-1 35D and 50D Operation & Tests 070914 PN=401...

  • Page 402: Electrical Component Specifications

    Voltage 2.1 volts (approximate) @ slow idle Feedback Potentiometer position 3.9 volts (approximate) @ fast idle position Y3—Travel Speed Solenoid Resistance 10—15 ohms Continued on next page OUO1010,0000B3B -19-21JAN09-1/2 TM2263 (09JUL14) 9015-20-2 35D and 50D Operation & Tests 070914 PN=402...
  • Page 403 References Item Measurement Specification Y4—Pilot Shutoff Solenoid Resistance 10—15 ohms OUO1010,0000B3B -19-21JAN09-2/2 TM2263 (09JUL14) 9015-20-3 35D and 50D Operation & Tests 070914 PN=403...

  • Page 404: Alternator Test

    Replace brush/regulator 5. Repeat above steps with lights on to load the alternator. Continued on next page LD30992,0000002 -19-19OCT11-1/2 TM2263 (09JUL14) 9015-20-4 35D and 50D Operation & Tests 070914 PN=404...

  • Page 405: Relay Test

    JDG1478 Digital Multimeter For location of relays: • Platform Harness (W9) Component Location. (Group 9015-10.) • Main Harness (W8) Component Location—35D or Main Harness (W8) Component Location—50D. (Group 9015-10.) • Heating and A/C Control Harness (W11) Component Location. (Group 9015-10.)

  • Page 406: Pressure Sensor Test

    • 30—50 kilo-ohms (pins 2 - 3) For sensor (B6) on 35D (S.N. —264999), see Main Harness (W8) Wiring Diagram—35D. (Group For location of auto-idle pressure sensor (B6) on 35D 9015-10.) (S.N. —264999), see Main Harness (W8) Component • For sensor (B6) on 50D (S.N. —274999), see Location—35D.

  • Page 407: Solenoid Test

    248° F For machine location of Engine Coolant Temperature Gauge Sensor (B2) and Engine Coolant Temperature Switch (B3) see Main Harness (W8) Component Location—35D or see Main Harness (W8) Component Location—50D. (Group 9015-10.) OUO1010,0000B4F -19-06FEB09-1/1 Fuel Shutoff Circuit Test Continued on next page...
  • Page 408 (A1) and fuel shutoff pull-in coil relay (K3). See Platform Harness (W9) Wiring Diagram. (Group 9015-10.) Is system voltage measured? NO: Replace timer. Continued on next page OUO1010,0001708 -19-27JUN11-5/7 TM2263 (09JUL14) 9015-20-8 35D and 50D Operation & Tests 070914 PN=408...
  • Page 409 NO: Check wires 8 GRN/RED and 9 YEL/RED between fuel shutoff solenoid (Y2) and fuse F9 (X35). For 35D (all) and 50D (S.N. —270000), see Engine Harness (W10) Wiring Diagram . (Group 9015-10.) For 50D (S.N. 270001— ), see Main Harness (W8) Wiring Diagram—50D.
  • Page 410 Is system voltage measured? NO: Check wire 17 WHT between fuel shutoff solenoid (Y2) and fuel shutoff pull-in coil relay (K3). For 35D (all) and 50D (S.N. —270000), see Engine Harness (W10) Wiring Diagram . (Group 9015-10.) For 50D (S.N. 270001—...

  • Page 411: Electrical Component Checks

    Check harness wiring and connections. See Platform Harness (W9) Wiring Diagram. (Group 9015-10.) LOOK: Is continuity indicated between designated terminals? NO: Replace key switch. Continued on next page OUO1010,0001709 -19-18JUL11-3/8 TM2263 (09JUL14) 9015-20-11 35D and 50D Operation & Tests 070914 PN=411...
  • Page 412 Diagram—35D or see Main Harness (W8) Wiring Diagram—50D. (Group 9015-10.) LOOK: Does the multimeter indicate continuity? NO: Replace fuse. See Fuse Specifications. (Group 9015-10.) Continued on next page OUO1010,0001709 -19-18JUL11-5/8 TM2263 (09JUL14) 9015-20-12 35D and 50D Operation & Tests 070914 PN=412...
  • Page 413 LISTEN: Does the multimeter beep? NO: If multimeter does not beep in either check, diode has failed in an open mode. Replace diode. Continued on next page OUO1010,0001709 -19-18JUL11-6/8 TM2263 (09JUL14) 9015-20-13 35D and 50D Operation & Tests 070914 PN=413...
  • Page 414 LOOK: Does travel alarm activate? NO: Replace travel alarm. For information on travel alarm circuit, see Travel Speed Control and Alarm Circuit Theory of Operation. (Group 9015-15.) Continued on next page OUO1010,0001709 -19-18JUL11-7/8 TM2263 (09JUL14) 9015-20-14 35D and 50D Operation & Tests 070914 PN=414...
  • Page 415 Platform Harness (W9) Wiring Diagram. (Group 9015-10.) LOOK: Does monitor buzzer activate? NO: Replace monitor buzzer. See Monitor Controller Remove and Install. (Group 9015-20.) OUO1010,0001709 -19-18JUL11-8/8 TM2263 (09JUL14) 9015-20-15 35D and 50D Operation & Tests 070914 PN=415...

  • Page 416: Monitor Controller Remove And Install

    3— Cap Screw (2 used) Monitor Connectors (2 8— Monitor Buzzer (H3) used) 10— Monitor Bracket Monitor Controller 35D (S.N. —264999), 50D (S.N. —274999) Shown Continued on next page OUO1010,000170A -19-29JUN11-2/3 TM2263 (09JUL14) 9015-20-16 35D and 50D Operation & Tests...

  • Page 417: Disconnect Tab Retainer Connectors

    4— Screw (5 used) Monitor Connectors (2 8— Monitor Buzzer (H1) used) 10— Monitor Bracket Monitor Controller 35D (S.N. —264999), 50D (S.N. —274999) Shown OUO1010,000170A -19-29JUN11-3/3 Disconnect Tab Retainer Connectors IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to controllers or other components may result.

  • Page 418: Disconnecting Spring Wire Clip Connectors

    6. Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position. Metri-Pack is a trademark of Delphi Connection Systems CS33148,0002A92 -19-08JUL08-1/1 TM2263 (09JUL14) 9015-20-18 35D and 50D Operation & Tests 070914 PN=418...

  • Page 419: Replace Metri-Pack® Connectors

    7. Use a small screwdriver (B) to move tab (A) inward to the first detent position; the tab will “click” and lock the wires in the connector body. A—Tab B—Screwdriver CS33148,0002A93 -19-08JUL08-3/3 TM2263 (09JUL14) 9015-20-19 35D and 50D Operation & Tests 070914 PN=419...

  • Page 420: Replace Deutsch® Circular Connectors

    6. Push contact straight into connector body until positive stop is felt. 7. Pull on wire and verify contact is locked in place. CS33148,0002A8A -19-08JUL08-2/2 TM2263 (09JUL14) 9015-20-20 35D and 50D Operation & Tests 070914 PN=420...

  • Page 421: Replace Deutsch® Rectangular Or Triangular Connectors

    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 CS33148,0002A94 -19-08JUL08-2/2 TM2263 (09JUL14) 9015-20-21 35D and 50D Operation & Tests 070914 PN=421...

  • Page 422: Install Deutsch® Contact

    IMPORTANT: Contact must remain centered between indenters while crimping. 6. Insert wire in contact and crimp until handle touches stop. 7. Release handle and remove contact. Continued on next page CS33148,0002A8B -19-08JUL08-3/4 TM2263 (09JUL14) 9015-20-22 35D and 50D Operation & Tests 070914 PN=422...

  • Page 423: Replace Weather Pack® Connector

    6. Pull on wire slightly to be certain contact is locked in place. 7. Transfer remaining wires to correct terminal in new connector. 8. Close connector body. CS33148,0002A8C -19-08JUL08-2/2 TM2263 (09JUL14) 9015-20-23 35D and 50D Operation & Tests 070914 PN=423...

  • Page 424: Install Weather Pack® Contact

    NOTE: Proper contact installation for sleeve (A) and pin (B) is shown. 4. Fasten cable seal to contact using JDG783 Packard Crimping Tool. A—Sleeve B—Pin Contact Installation CS33148,0002A8D -19-08JUL08-2/2 TM2263 (09JUL14) 9015-20-24 35D and 50D Operation & Tests 070914 PN=424...

  • Page 425: Replace Cinch™ Connectors

    6. Replace terminals as necessary. See Install CINCH™ Contact. (Group 9015-20.) 7. Insert contact and wire into connector until it clicks. 8. Install secondary lock. 1— Extraction Tool 4— Cavity CS33148,0002A8E -19-08JUL08-3/3 TM2263 (09JUL14) 9015-20-25 35D and 50D Operation & Tests 070914 PN=425...

  • Page 426: Install Cinch™ Contact

    (A). Push wire tab (I) against the movable Connectors. (Group 9015-20.) locator (C). AMP is a trademark of Tyco Electronics CINCH is a trademark of the Cinch Co. CS33148,0002A8F -19-24JUN08-1/1 TM2263 (09JUL14) 9015-20-26 35D and 50D Operation & Tests 070914 PN=426...

  • Page 427: Repair 32 And 48 Way Cinch™ Connectors

    C—Cover Locks B—Locking Cam D—Cover TF44157,0001444 -19-13JUL10-1/4 4. Pull terminal lock (A) out until it stops. Do not force its removal. A—Terminal Lock Continued on next page TF44157,0001444 -19-13JUL10-2/4 TM2263 (09JUL14) 9015-20-27 35D and 50D Operation & Tests 070914 PN=427...
  • Page 428 (D) to unlock terminal. 6. Pull wire and terminal (E) from connector body. A—20 Gauge Holes D—Terminal Hole B—16 and 18 Gauge Holes E—Terminal C—Holes Continued on next page TF44157,0001444 -19-13JUL10-3/4 TM2263 (09JUL14) 9015-20-28 35D and 50D Operation & Tests 070914 PN=428...

  • Page 429: Remove Connector Body From Blade Terminals

    1. Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off. 2. Be sure to bend locking tang back to its original position (B) before installing connector body. DX,ECONN,V1 -19-02NOV94-1/1 TM2263 (09JUL14) 9015-20-29 35D and 50D Operation & Tests 070914 PN=429...
  • Page 430 References TM2263 (09JUL14) 9015-20-30 35D and 50D Operation & Tests 070914 PN=430...

  • Page 431: Diagnose Malfunctions

    Contents Page Group 05—Theory of Operation Track Adjuster and Recoil Spring ....9020-05-1 Travel Gearbox Operation ......9020-05-2 Group 15—Diagnostic Information Diagnose Malfunctions Undercarriage Components ....9020-15-1 Swing Bearing Measure Wear........9020-15-4 TM2263 (09JUL14) 9020-1 35D and 50D Operation & Tests 070914 PN=1...
  • Page 432 Contents TM2263 (09JUL14) 9020-2 35D and 50D Operation & Tests 070914 PN=2...
  • Page 433 To tighten the track, pump grease (15) into fitting (2) to force the piston (11) out. As it presses against the yoke OUO1030,0000006 -19-12NOV04-1/1 TM2263 (09JUL14) 9020-05-1 35D and 50D Operation & Tests 070914 PN=433...
  • Page 434 Theory of Operation Travel Gearbox Operation Travel Gearbox 35D and Travel Gearbox 50D (S.N. —274999) 1— First Planet Gear 5— Input Shaft 10— Ball Bearing 13— First Planet Sun Gear 2— Ring Gear 6— Drum 11— Second Planet Sun Gear 14—...
  • Page 435 (2). As the input shaft turns, it turns keep the floating input shaft in position. the first planet gears (1) against the ring gear causing the AA95137,0001D7D -19-23FEB09-2/2 TM2263 (09JUL14) 9020-05-3 35D and 50D Operation & Tests 070914 PN=435...
  • Page 436 Theory of Operation TM2263 (09JUL14) 9020-05-4 35D and 50D Operation & Tests 070914 PN=436...
  • Page 437 Idlers, Track, and Carrier Rollers or metal faced seal Remove and Install. (Group 0130.) Perform Track Roller Repair. (Group 0130.) Perform Track Carrier Roller Repair. (Group 0130.) Continued on next page AA95137,0001CBE -19-10FEB09-1/3 TM2263 (09JUL14) 9020-15-1 35D and 50D Operation & Tests 070914 PN=437...
  • Page 438 Symptom Problem Solution Bent Track Shoes Excessive grouser wear Measure grouser height: For 35D, see 27ZTS, 27C ZTS, 35ZTS, and 35C ZTS Grouser Height—Steel Track. (SP326 Undercarriage Appraisal Manual.) For 50D, see 50ZTS and 50C ZTS Grouser Height—Steel Track. (SP326 Undercarriage Appraisal Manual.)
  • Page 439 Diagnostic Information Symptom Problem Solution Check track chain pitch: For 35D, see 27ZTS, 27C ZTS, 35ZTS, and 35C ZTS Chain Pitch—101.5 mm (3.99 in.). (SP326 Undercarriage Appraisal Manual.) For 50D, see 50ZTS and 50C ZTS Chain Pitch—135 mm (5.31 in.).

  • Page 440: Swing Bearing

    Diagnostic Information Measure Swing Bearing Wear SPECIFICATIONS 2. Check that swing bearing is lubricated with the Swing Bearing—35D Play (normal) 0.62 mm specified grease. See Grease. (Operator's Manual.) 0.024 in. 3. Check that swing bearing rotation is smooth and Swing Bearing—35D Play 1.5 mm...
  • Page 441 9. If reading is more than maximum allowable, check for mum allowable)................1.5 mm wear to balls, spacers, and race bearings. See Swing 0.059 in. Bearing Remove and Install. (Group 4350.) OUO1030,0000004 -19-26MAR13-2/2 TM2263 (09JUL14) 9020-15-5 35D and 50D Operation & Tests 070914 PN=441...
  • Page 442 Diagnostic Information TM2263 (09JUL14) 9020-15-6 35D and 50D Operation & Tests 070914 PN=442...

  • Page 443: Operation

    Group 15—Diagnostic Information Auxiliary Function Control Valve Diagnostic Procedure ........ 9025-15-1 Operation..........9025-05-49 Diagnose Malfunctions Pressure Compensator Hydraulic System ........9025-15-2 Operation—50D........9025-05-51 Pilot Circuit ..........9025-15-5 Continued on next page TM2263 (09JUL14) 9025-1 35D and 50D Operation & Tests 070914 PN=1...
  • Page 444 Adjustment—50D ........ 9025-25-15 Control Valve Differential Reducing Valve Test and Adjustment—50D ........ 9025-25-17 Circuit Relief Valve Test and Adjustment—35D ........ 9025-25-19 Circuit Relief Valve Test and Adjustment—50D ........ 9025-25-21 TM2263 (09JUL14) 9025-2 35D and 50D Operation & Tests 070914 PN=2...

  • Page 445: Hydraulic System Diagram-35D

    Group 05 Theory of Operation Hydraulic System Diagram—35D TX1053002 Hydraulic System Diagram Continued on next page OUO1020,00018E5 -19-20JAN09-1/2 TM2263 (09JUL14) 9025-05-1 35D and 50D Operation & Tests 070914 PN=445...

  • Page 446: Hydraulic System Diagram-50D

    The hydraulic oil tank is pressurized to create a head of oil to ensure oil OUO1020,00018E5 -19-20JAN09-2/2 Hydraulic System Diagram—50D Continued on next page OUO1020,00018E6 -19-28JAN09-1/3 TM2263 (09JUL14) 9025-05-2 35D and 50D Operation & Tests 070914 PN=446...
  • Page 447 TX1053032 —UN—30JAN09 A M B A3 B3 A4 B4 A5 B5 A7 B7 A8 B8 A9 B9 A10 B10 Plmax TX1053032 Hydraulic System Diagram OUO1020,00018E6 -19-28JAN09-2/3 Continued on next page TM2263 (09JUL14) 9025-05-3 35D and 50D Operation & Tests 070914 PN=447...
  • Page 448 Theory of Operation TM2263 (09JUL14) 9025-05-4 35D and 50D Operation & Tests 070914 PN=448...

  • Page 449: Pilot System Diagram-35D

    41, 47, 49, 54, 56, 113, and 114). the pilot control shutoff lever is in the unlocked (armrest OUO1020,00018E6 -19-28JAN09-3/3 Pilot System Diagram—35D Continued on next page NM00125,000088F -19-19JUL11-1/3 TM2263 (09JUL14) 9025-05-5 35D and 50D Operation & Tests 070914 PN=449...
  • Page 450 Theory of Operation TM2263 (09JUL14) 9025-05-6 35D and 50D Operation & Tests 070914 PN=450...
  • Page 451 Theory of Operation TX1094546 —UN—19JUL11 P2 P1 TX1094546 Pilot System Diagram—35D (excavator pattern shown) NM00125,000088F -19-19JUL11-2/3 Continued on next page TM2263 (09JUL14) 9025-05-7 35D and 50D Operation & Tests 070914 PN=451...
  • Page 452 Theory of Operation TM2263 (09JUL14) 9025-05-8 35D and 50D Operation & Tests 070914 PN=452...
  • Page 453 See the following for the operation of pilot components: (Group 9025-05.) • See Swing Motor Park Brake Release Circuit Operation • See Hydraulic Pump 3 and Pilot Pump Operation—35D (Group 9025-05.) (Group 9025-05.) • See Hydraulic System Schematics—35D (Group •...

  • Page 454: Pilot System Diagram-50D

    Theory of Operation Pilot System Diagram—50D TX1094098 Pilot System Diagram Continued on next page NM00125,000088B -19-12JUL11-1/2 TM2263 (09JUL14) 9025-05-10 35D and 50D Operation & Tests 070914 PN=454...
  • Page 455 See Pilot Control Valve Operation. (Group 9025-05.) • See Auxiliary Function Control Valve Operation. (Group • See Blade, Swing Boom, and Auxiliary Pilot Control 9025-05.) Valve Operation. (Group 9025-05.) NM00125,000088B -19-12JUL11-2/2 TM2263 (09JUL14) 9025-05-11 35D and 50D Operation & Tests 070914 PN=455...

  • Page 456: Pilot Pump Operation

    During oil flows to pilot pressure regulating valve spool. normal operation, bypass valve is held closed by spring and oil flows through filter element to pilot pressure OUO1030,0000063 -19-21DEC04-1/1 TM2263 (09JUL14) 9025-05-12 35D and 50D Operation & Tests 070914 PN=456...

  • Page 457: Solenoid Valve Manifold Operation

    1— Pilot Control Shutoff Lever 3— Armrest Pilot Control Shutoff Lever and Pilot Shutoff Switch 4— Pilot Control Valve 2— Pilot Shutoff Switch Continued on next page OUO1020,00018E9 -19-28JAN09-2/4 TM2263 (09JUL14) 9025-05-13 35D and 50D Operation & Tests 070914 PN=457...
  • Page 458 7— Pilot Pressure Regulating C—Spring Valve D—To Hydraulic Oil Tank A—From Pilot Pump B—Poppet Pilot Pressure Regulating Valve OUO1020,00018E9 -19-28JAN09-4/4 TM2263 (09JUL14) 9025-05-14 35D and 50D Operation & Tests 070914 PN=458...

  • Page 459: Pilot Flow Rate Sensing Manifold Operation-50D

    (11), and variable metering orifice (12). The pilot flow rate sensing manifold is located in the pilot circuit between the pilot pump and the solenoid valve Continued on next page PK80954,000093A -19-22DEC04-1/3 TM2263 (09JUL14) 9025-05-15 35D and 50D Operation & Tests 070914 PN=459...
  • Page 460 (B), variable metering orifice (12), variable metering valve metering orifice. spool (F), and piston (I). The differential pressure across Continued on next page PK80954,000093A -19-22DEC04-2/3 TM2263 (09JUL14) 9025-05-16 35D and 50D Operation & Tests 070914 PN=460...
  • Page 461 PGR at PGR port (D). When pressure value. PPHI force increases more then the spring force of spring (E), the variable metering valve spool is shifted to the PK80954,000093A -19-22DEC04-3/3 TM2263 (09JUL14) 9025-05-17 35D and 50D Operation & Tests 070914 PN=461...

  • Page 462: Pilot Control Valve Operation

    For control valve operation, see Control Valve The balance spring pushes the spool up until the oil Operation—35D or see Control Valve Operation—50D. flow through the holes is blocked in the deadband area. (Group 9025-05.) With the oil flow blocked, the control valve spool is held stationary until the control lever is again actuated.

  • Page 463: Travel Pilot Control Valve Operation

    Oil pressure to the control valve travel spool pilot cap When the pedal or lever is pushed to move the machine, now equals pilot oil pressure. the cam pushes the plunger and spool spring guide down OUO1020,00018EB -19-16JAN09-1/1 TM2263 (09JUL14) 9025-05-19 35D and 50D Operation & Tests 070914 PN=463...

  • Page 464: Blade, Swing Boom, And Auxiliary Pilot Control Valve Operation

    (center) position. When the pedal or lever moves the cam to full stroke, the plunger pushes down on the spring guide, compressing Continued on next page NM00125,0000883 -19-14JUL11-1/2 TM2263 (09JUL14) 9025-05-20 35D and 50D Operation & Tests 070914 PN=464...

  • Page 465: Hydraulic Pump 1 And 2 Operation-35D

    Theory of Operation Auxiliary Control Valve Operation 35D (S.N. —264999) Auxiliary Function Controller 35D (S.N. 26500— ) 50D 50D (S.N. —274999) The auxiliary control valve is used (S.N. 275000— ) The auxiliary function controller is used for any add-on accessories, such as an auger, pile driver, to control pilot oil to the auxiliary spool.
  • Page 466 1— Delivery Port (Inside) 6— Suction/Delivery Port 3— Suction Port (Inside) (Inside) 4— Suction Port (Outside) 7— Suction/Delivery Port 5— Cylinder Block (Outside) 8— Delivery Port (Outside) PK80954,000093B -19-22DEC04-2/2 TM2263 (09JUL14) 9025-05-22 35D and 50D Operation & Tests 070914 PN=466...

  • Page 467: Hydraulic Pump Regulator Operation-35D

    3 increases, the pump 3 torque control air conditioning system. The A/C control piston is only in piston pushes the swash plate against the swash plate pumps on air conditioned units. PK80954,000093C -19-22DEC04-1/1 TM2263 (09JUL14) 9025-05-23 35D and 50D Operation & Tests 070914 PN=467...

  • Page 468: Hydraulic Pump 3 And Pilot Pump Operation-35D

    5— Shaft 2— Piston 6— Pilot Oil Port (Air 3— Cylinder Block Conditioning Only) 4— Swash Plate 7— A/C Torque Control Piston (Air Conditioning Only) Hydraulic Pump OUO1030,0000061 -19-20DEC04-1/1 TM2263 (09JUL14) 9025-05-24 35D and 50D Operation & Tests 070914 PN=468...

  • Page 469: Hydraulic Pump Regulator Operation-50D

    When these pressures become system is operating. equal, the hydraulic pump swash plate stops tilting. Continued on next page OUO1030,0000062 -19-20DEC04-1/2 TM2263 (09JUL14) 9025-05-25 35D and 50D Operation & Tests 070914 PN=469...
  • Page 470 When pressure PLS is greater than pressure PGR, actuator load has decreased. Delivery flow rate from the hydraulic pump is reduced. 1— Spool 3— Spring Pump Delivery Flow Rate Valve 2— Sleeve OUO1030,0000062 -19-20DEC04-2/2 TM2263 (09JUL14) 9025-05-26 35D and 50D Operation & Tests 070914 PN=470...

  • Page 471: A/C Torque Control Solenoid Valve Operation

    1— Spool 4— Spring 2— Port P 5— Port A 3— Port T A/C Torque Control Solenoid Valve Cross-Section OUO1020,000148B -19-19DEC04-1/1 TM2263 (09JUL14) 9025-05-27 35D and 50D Operation & Tests 070914 PN=471...

  • Page 472: Control Valve Operation-35D

    Theory of Operation Control Valve Operation—35D 46 47 T206293 Control Valve Component Identification Continued on next page OUO1020,00018EE -19-28JAN09-1/7 TM2263 (09JUL14) 9025-05-28 35D and 50D Operation & Tests 070914 PN=472...
  • Page 473 1, 2, and 3. center and each section controls flow rate and direction for its own hydraulic circuit. Valve spools are controlled by See Hydraulic System Schematics—35D for Control Valve pilot pressure. All valve spools are accessible by removal Schematic. (Group 9025-05.) of a plug or pilot cap.
  • Page 474 Head End B (right travel forward) Attachment Manifold 13— Port B1 to Bucket Cylinder 19— Port B5 to Arm Cylinder Head End Head End Continued on next page OUO1020,00018EE -19-28JAN09-3/7 TM2263 (09JUL14) 9025-05-30 35D and 50D Operation & Tests 070914 PN=474...
  • Page 475 NOTE: PILOT LINES ARE ROUTED FROM THE CONTROL VALVE TO THE BULKHEAD AS LABELED, EXCEPT THOSE ROUTED AS SHOWN HERE T206297 Control Valve Pilot Pressure Line Identification Continued on next page OUO1020,00018EE -19-28JAN09-4/7 TM2263 (09JUL14) 9025-05-31 35D and 50D Operation & Tests 070914 PN=475...
  • Page 476 1B—Bucket Dump 8B—Swing Right 5A—Arm Out 2B—Boom Down 9B—Blade Lower 6A—Auxiliary Function Supply 3B—Left Travel Reverse D1—To Hydraulic Oil Tank 4B—Right Travel Forward Continued on next page OUO1020,00018EE -19-28JAN09-5/7 TM2263 (09JUL14) 9025-05-32 35D and 50D Operation & Tests 070914 PN=476...
  • Page 477 Theory of Operation 35 36 T206296 Control Valve Neutral and Parallel Passages Continued on next page OUO1020,00018EE -19-28JAN09-6/7 TM2263 (09JUL14) 9025-05-33 35D and 50D Operation & Tests 070914 PN=477...
  • Page 478 (35, 36, 44, 45, 49, and 50) to prevent the pressure from When a combined operation of travel and front attachment exceeding the set pressure at the spool. is performed, the flow combiner valve (21) is shifted by OUO1020,00018EE -19-28JAN09-7/7 TM2263 (09JUL14) 9025-05-34 35D and 50D Operation & Tests 070914 PN=478...

  • Page 479: Control Valve Operation-50D

    Theory of Operation Control Valve Operation—50D Control Valve Sections Control Valve Relief Valves Continued on next page OUO1020,00018F9 -19-28JAN09-1/4 TM2263 (09JUL14) 9025-05-35 35D and 50D Operation & Tests 070914 PN=479...
  • Page 480 See System Relief Valve See Hydraulic System Schematics—50D for Control Valve Operation for more information. (Group 9025-05.) Schematic. (Group 9025-05) Continued on next page OUO1020,00018F9 -19-28JAN09-2/4 TM2263 (09JUL14) 9025-05-36 35D and 50D Operation & Tests 070914 PN=480...
  • Page 481 Theory of Operation Control Valve Port Designations Control Valve Pilot Port Designations Continued on next page OUO1020,00018F9 -19-28JAN09-3/4 TM2263 (09JUL14) 9025-05-37 35D and 50D Operation & Tests 070914 PN=481...

  • Page 482: System Relief Valve Operation

    9— Spring Chamber pressure difference, main poppet opens when it becomes 5— Seat greater than spring (3) force, to relieve the pressure oil from port HP to port LP. OUO1020,00018EF -19-28JAN09-1/1 TM2263 (09JUL14) 9025-05-38 35D and 50D Operation & Tests 070914 PN=482...

  • Page 483: Circuit Relief Valve Operation

    OUO1020,00018F1 -19-05JAN09-1/1 TM2263 (09JUL14) 9025-05-39 35D and 50D Operation & Tests 070914 PN=483...

  • Page 484: Swing Boom Make-Up Check Valve Operation

    LP, the closing force of the poppet is only the cavitation at the port HP side. spring force. When the opening force of the poppet OUO1020,00018F2 -19-28JAN09-1/1 TM2263 (09JUL14) 9025-05-40 35D and 50D Operation & Tests 070914 PN=484...

  • Page 485: Unload Valve Operation-50D

    T (7) to pump pressure P1. The opening to along with the force from spring (13) on the left side of port T varies in proportion to the spool stroke. OUO1020,00018F3 -19-20JAN09-1/1 TM2263 (09JUL14) 9025-05-41 35D and 50D Operation & Tests 070914 PN=485...

  • Page 486: Control Valve Differential Reducing Valve Operation-50D

    (9), is routed into chamber C (3) and acts against area S3 port (13). (6), moving the spool to the left. OUO1020,00018F4 -19-20JAN09-1/1 TM2263 (09JUL14) 9025-05-42 35D and 50D Operation & Tests 070914 PN=486...

  • Page 487: Flow Combiner Valve Operation-35D

    Pressure oil to the bucket OUO1020,00018F5 -19-20JAN09-1/1 TM2263 (09JUL14) 9025-05-43 35D and 50D Operation & Tests 070914 PN=487...

  • Page 488: Auxiliary Flow Combiner Valve Operation-35D

    Auxiliary Flow Selector Solenoid Valve valve spool (1) is shifted by pilot oil from the auxiliary Operation (If Equipped)—35D. (Group 9025-05.) OUO1020,00018F6 -19-20JAN09-1/1 TM2263 (09JUL14) 9025-05-44 35D and 50D Operation & Tests 070914 PN=488...

  • Page 489: Auxiliary Flow Selector Solenoid Valve Operation (If Equipped)-35D

    Theory of Operation Auxiliary Flow Selector Solenoid Valve Operation (If Equipped)—35D T206379 Auxiliary Flow Selector Solenoid Valve in Low Flow Position 1— Auxiliary Spool Valve 3— Auxiliary Flow Combiner 5— Pump 1 2— Lines to Attachment Valve 6— Pump 3 4—...

  • Page 490: Auxiliary Flow Selector Solenoid Valve Operation (If Equipped)-50D

    2— Solenoid Valve Spool Spool 3— Port T 6— Port A 4— Spring Chamber 7— Pilot Oil 8— Return Oil T206380 Solenoid De-Energized Continued on next page OUO1020,00018F8 -19-21JAN09-1/3 TM2263 (09JUL14) 9025-05-46 35D and 50D Operation & Tests 070914 PN=490...
  • Page 491 2— Solenoid Valve Spool Spool 3— Port T 6— Port A 4— Spring Chamber 7— Pilot Oil 8— Return Oil T206381 Solenoid Energized Continued on next page OUO1020,00018F8 -19-21JAN09-2/3 TM2263 (09JUL14) 9025-05-47 35D and 50D Operation & Tests 070914 PN=491...
  • Page 492 2— Solenoid Valve Spool Spool 3— Port T 6— Port A 4— Spring Chamber 7— Pilot Oil 8— Return Oil T206382 Reduced Pilot Pressure to Auxiliary Spool Valve OUO1020,00018F8 -19-21JAN09-3/3 TM2263 (09JUL14) 9025-05-48 35D and 50D Operation & Tests 070914 PN=492...

  • Page 493: Auxiliary Function Control Valve Operation

    A trigger as a breaker. switch and a proportional control function, located on the right auxiliary function control lever, are used by the Continued on next page OUO1010,00016FE -19-24JUN11-1/2 TM2263 (09JUL14) 9025-05-49 35D and 50D Operation & Tests 070914 PN=493...
  • Page 494 2 de-energized, the auxiliary spool returns function solenoid valve 1 routes pilot oil to one side of the to center, trapping the oil in the actuator. OUO1010,00016FE -19-24JUN11-2/2 TM2263 (09JUL14) 9025-05-50 35D and 50D Operation & Tests 070914 PN=494...

  • Page 495: Pressure Compensator Operation-50D

    (6) in spool (7). Pressure oil P1 acts against area S3 (4) and piston (3) pushing the spool to the left. OUO1020,0001485 -19-16DEC04-1/1 TM2263 (09JUL14) 9025-05-51 35D and 50D Operation & Tests 070914 PN=495...

  • Page 496: Boom Reduced Leakage Valve Operation-35D

    (7) side of check valve poppet (9) the head end of boom cylinder raising the boom. through a control valve passage (8) and pilot valve spool Continued on next page OUO1020,0001483 -19-16DEC04-1/2 TM2263 (09JUL14) 9025-05-52 35D and 50D Operation & Tests 070914 PN=496...

  • Page 497: Boom Reduced Leakage Valve Operation-50D

    At this time, pressure on the bottom side circuit acts on the spring chamber (1) through an orifice (2) in the poppet Continued on next page OUO1020,0001484 -19-16DEC04-1/3 TM2263 (09JUL14) 9025-05-53 35D and 50D Operation & Tests 070914 PN=497...
  • Page 498 (6) pushes the poppet (3) open, so cylinder (8). Continued on next page OUO1020,0001484 -19-16DEC04-2/3 TM2263 (09JUL14) 9025-05-54 35D and 50D Operation & Tests 070914 PN=498...
  • Page 499 (8) acts on the ball from the orifice (2) in the poppet (3). to flow to the hydraulic oil tank. When ball opens, return oil flows to the hydraulic oil tank. OUO1020,0001484 -19-16DEC04-3/3 TM2263 (09JUL14) 9025-05-55 35D and 50D Operation & Tests 070914 PN=499...

  • Page 500: Arm Regenerative Valve Operation-35D

    Then, the return oil from the without flowing to the bottom side. arm cylinder rod side (1) flows through a passage (2) and PK80954,0000947 -19-22DEC04-1/1 TM2263 (09JUL14) 9025-05-56 35D and 50D Operation & Tests 070914 PN=500...

  • Page 501: Swing Gearbox Operation

    The cavity for the lower bearing is filled with grease at assembly. The swing motor output shaft (9) drives the first stage sun gear (1) turning the first stage planet gears against the TX19495,0000088 -19-16DEC04-1/1 TM2263 (09JUL14) 9025-05-57 35D and 50D Operation & Tests 070914 PN=501...

  • Page 502: Swing Motor Operation

    In operation, high pressure supply oil enters the cylinder block bores through ports forcing pistons down against the CED,OUOE011,42 -19-16DEC04-1/1 TM2263 (09JUL14) 9025-05-58 35D and 50D Operation & Tests 070914 PN=502...

  • Page 503: Swing Motor Crossover Relief Valve Operation

    Theory of Operation Swing Motor Crossover Relief Valve Operation 1— Swing Motor Cover 2— Crossover Relief Valve (2 used) Continued on next page CED,OUOE011,43 -19-16DEC04-1/2 TM2263 (09JUL14) 9025-05-59 35D and 50D Operation & Tests 070914 PN=503...

  • Page 504: Swing Motor Make-Up Check Valve Operation

    M (hydraulic oil tank pressure), the poppet opens, drawing hydraulic oil into the circuit. 1— Swing Motor Cover 2— Make-Up Check Valve (2 used) TX19495,000007E -19-16DEC04-1/1 TM2263 (09JUL14) 9025-05-60 35D and 50D Operation & Tests 070914 PN=504...

  • Page 505: Swing Motor Park Brake Release Circuit Operation

    Accordingly, by the spring, the brake piston gradually moves downward, allowing the brake piston to slowly come in contact with the disc plate to apply the swing brake. CED,OUOE011,45 -19-16DEC04-1/1 TM2263 (09JUL14) 9025-05-61 35D and 50D Operation & Tests 070914 PN=505...

  • Page 506: Center Joint Operation

    The inner spindle (10) is connected to the undercarriage and the body (5) is connected to the upperstructure. The body rotates around the spindle during swing operation. OUO1020,00018FA -19-13JAN09-1/1 TM2263 (09JUL14) 9025-05-62 35D and 50D Operation & Tests 070914 PN=506...

  • Page 507: Center Joint Operation-If Equipped With Angle Blade

    The center joint inner spindle (10) is connected to the undercarriage, and the center joint body (5) is connected to the upperstructure. The center joint body rotates around the center joint spindle during swing operation. OUO1020,00018FF -19-20JAN09-1/1 TM2263 (09JUL14) 9025-05-63 35D and 50D Operation & Tests 070914 PN=507...

  • Page 508: Travel Motor And Brake Valve Housing Operation-35D And 50D (S.n. -274999)

    Theory of Operation Travel Motor and Brake Valve Housing Operation—35D and 50D (S.N. —274999) Travel Motor and Brake Valve Housing—35D The travel motor (5) is a two-speed, axial piston motor that includes the brake valve housing (6), travel park brake (8), and travel motor speed change valve.
  • Page 509 Counterbalance Valve—has two functions; one is to start and stop the travel smoothly and the other is to prevent the machine from running away while descending slopes. Continued on next page OUO1020,000193C -19-23FEB09-2/6 TM2263 (09JUL14) 9025-05-65 35D and 50D Operation & Tests 070914 PN=509...
  • Page 510 As a result, speed by moving the control piston. See Travel Motor the spool notch opens, so port BM and port P2 connect, Speed Circuit Operation—35D and 50D (S.N. —274999). and the travel motor rotates. (Group 9025-05.)
  • Page 511 Park Brake Applied—when the travel function is returned to neutral, supply oil to the travel motor is blocked at the Continued on next page OUO1020,000193C -19-23FEB09-4/6 TM2263 (09JUL14) 9025-05-67 35D and 50D Operation & Tests 070914 PN=511...
  • Page 512 Theory of Operation Anticavitation Valve Traveling—50D (S.N. —274999) Anticavitation Valve Traveling Stopped—50D (S.N. —274999) Continued on next page OUO1020,000193C -19-23FEB09-5/6 TM2263 (09JUL14) 9025-05-68 35D and 50D Operation & Tests 070914 PN=512...
  • Page 513 (3 and 1). Oil flow continues until orifice closed and the return oil from port (10) flows to port (7) (11) in the counterbalance valve (8) closes completely. through the counterbalance valve. OUO1020,000193C -19-23FEB09-6/6 TM2263 (09JUL14) 9025-05-69 35D and 50D Operation & Tests 070914 PN=513...

  • Page 514: Travel Motor And Brake Valve Housing Operation-50D (S.n. 275000- )

    Theory of Operation Travel Motor and Brake Valve Housing Operation—50D (S.N. 275000— ) TX1040518 Travel Motor Schematic Continued on next page OUO1020,0001939 -19-23FEB09-1/7 TM2263 (09JUL14) 9025-05-70 35D and 50D Operation & Tests 070914 PN=514...
  • Page 515 The supply oil forces the pistons determines the travel speed of machine actuated by against the swash plate. The piston slippers (4) slide swash plate control piston (144). Continued on next page OUO1020,0001939 -19-23FEB09-3/7 TM2263 (09JUL14) 9025-05-71 35D and 50D Operation & Tests 070914 PN=515...
  • Page 516 As a result, the spool notch (11) opens. Port M2 and port P2 are connected and the travel motor rotates. Continued on next page OUO1020,0001939 -19-23FEB09-4/7 TM2263 (09JUL14) 9025-05-72 35D and 50D Operation & Tests 070914 PN=516...
  • Page 517 Continued on next page OUO1020,0001939 -19-23FEB09-5/7 TM2263 (09JUL14) 9025-05-73 35D and 50D Operation & Tests 070914 PN=517...
  • Page 518 P2 (25) through the counterbalance valve. When Traveling—pressure oil from port P1 (24) flows to port M1 (37) through the counterbalance valve (147). At Continued on next page OUO1020,0001939 -19-23FEB09-6/7 TM2263 (09JUL14) 9025-05-74 35D and 50D Operation & Tests 070914 PN=518...
  • Page 519 Passage A (28) is connected of cavitation in the motor when travel is stopped. to port M1 and the pressure becomes low. Pressure oil OUO1020,0001939 -19-23FEB09-7/7 TM2263 (09JUL14) 9025-05-75 35D and 50D Operation & Tests 070914 PN=519...

  • Page 520: Travel Motor Speed Circuit Operation-35D And 50D (S.n. -274999)

    1— Slow Speed Surface 5— Cylinder Block 2— Fast Speed Surface 6— Control Piston 3— Swash Plate 7— From Travel Speed Change Travel Motor—Fast Speed 4— Piston Valve OUO1020,000193B -19-20FEB09-2/2 TM2263 (09JUL14) 9025-05-76 35D and 50D Operation & Tests 070914 PN=520...

  • Page 521: Travel Motor Speed Circuit Operation-50D (S.n. 275000- )

    M2 (4)] of the travel mode selector solenoid valve slow speed. (5) are blocked by the spool. Continued on next page OUO1020,000193A -19-20FEB09-1/3 TM2263 (09JUL14) 9025-05-77 35D and 50D Operation & Tests 070914 PN=521...
  • Page 522 Theory of Operation Travel Speed—Fast Speed Continued on next page OUO1020,000193A -19-20FEB09-2/3 TM2263 (09JUL14) 9025-05-78 35D and 50D Operation & Tests 070914 PN=522...

  • Page 523: Blade Circuit Operation-35D

    A lift check valve (2) is also incorporated. The work ports (3) are connected to the blade cylinder through the center joint. OUO1020,0001901 -19-13JAN09-1/1 TM2263 (09JUL14) 9025-05-79 35D and 50D Operation & Tests 070914 PN=523...

  • Page 524: Blade Circuit Operation-50D

    (82). The work ports are connected to the pilot actuated by the lever actuated pilot control valve. The blade cylinder through the center joint. blade control valve is equipped with a shuttle valve (78), OUO1020,0001902 -19-13JAN09-1/1 TM2263 (09JUL14) 9025-05-80 35D and 50D Operation & Tests 070914 PN=524...

  • Page 525: Angle Blade Circuit Operation-If Equipped

    The angle blade control are connected to the angle blade cylinder through the valve is equipped with a shuttle valve (112), circuit relief center joint. OUO1020,0001900 -19-28JAN09-1/1 TM2263 (09JUL14) 9025-05-81 35D and 50D Operation & Tests 070914 PN=525...

  • Page 526: Angle Blade Solenoid Valve Operation-If Equipped

    2— Inlet Port 5— Angle Left Port to Control 3— Angle Left Solenoid Valve Valve Spool 6— Angle Right Port to Control Valve Spool Angle Blade Solenoid Valve OUO1020,0001903 -19-20JAN09-1/1 TM2263 (09JUL14) 9025-05-82 35D and 50D Operation & Tests 070914 PN=526...

  • Page 527: Auxiliary Selector Valve Operation-If Equipped

    Theory of Operation Auxiliary Selector Valve Operation—If Equipped Auxiliary Selector Valve 35D (S.N. —264999) 50D (S.N. —274999) 1— Auxiliary Selector Valve 3— To Hydraulic Oil Tank 5— Double Work Port Operation 2— Auxiliary Control Valve 4— Single Work Port Operation The auxiliary selector valve is used with the auxiliary it selects either single or double work port usage.

  • Page 528: Hydraulic Cylinder Operation

    The cylinder barrel houses O-rings (8), backup rings (9), flows through a clearance between cushion and rod guide. and retainer (10). Some cylinders provide a cushion (6) to CED,OUOE011,5104 -19-14DEC04-1/1 TM2263 (09JUL14) 9025-05-84 35D and 50D Operation & Tests 070914 PN=528...

  • Page 529: Hydraulic Oil Return Filter Operation

    A bypass valve (2) is located at the top of the filter. The valve opens to protect the filter element against pressure CED,OUOE011,5105 -19-26MAY10-1/1 TM2263 (09JUL14) 9025-05-85 35D and 50D Operation & Tests 070914 PN=529...

  • Page 530: Hydraulic System Circuit Symbols

    Theory of Operation Hydraulic System Circuit Symbols TX,15,GG2166 -19-17NOV97-1/1 TM2263 (09JUL14) 9025-05-86 35D and 50D Operation & Tests 070914 PN=530...

  • Page 531: Hydraulic System Schematics-35D

    Theory of Operation Hydraulic System Schematics—35D Continued on next page NM00125,0000888 -19-23AUG11-1/12 TM2263 (09JUL14) 9025-05-87 35D and 50D Operation & Tests 070914 PN=531...
  • Page 532 Theory of Operation TM2263 (09JUL14) 9025-05-88 35D and 50D Operation & Tests 070914 PN=532...
  • Page 533 PRESSURE AUXILIARY REGULATING SELECTOR VALVE VALVE COOLER BYPASS FROM VALVE CONTROL VALVE TX1078132 Hydraulic Pump, Solenoid Valve Manifold, and Hydraulic Oil Tank Schematic—35D NM00125,0000888 -19-23AUG11-2/12 Continued on next page TM2263 (09JUL14) 9025-05-89 35D and 50D Operation & Tests 070914 PN=533...
  • Page 534 Theory of Operation TM2263 (09JUL14) 9025-05-90 35D and 50D Operation & Tests 070914 PN=534...
  • Page 535 J— From Control Valve P—From Boom Reduced Leakage Valve A—From Control Valve K—Pilot Oil Return Valve 10— Oil Cooler Bypass Valve B—To Control Valve Continued on next page NM00125,0000888 -19-23AUG11-3/12 TM2263 (09JUL14) 9025-05-91 35D and 50D Operation & Tests 070914 PN=535...
  • Page 536 PILOT CONTROL CONTROL VALVE VALVE AUXILIARY ANGLE CONTROL PILOT BLADE LEVER CONTROL PILOT PATTERN VALVE CONTROL SELECTOR VALVE TX1094097 Pilot Control Valve Schematic—35D Continued on next page NM00125,0000888 -19-23AUG11-4/12 TM2263 (09JUL14) 9025-05-92 35D and 50D Operation & Tests 070914 PN=536...
  • Page 537 M—Blade Lower (if equipped) Solenoid Valve 1 (S.N. N—Blade Raise 265000— ) O—Swing Boom Left P—Swing Boom Right Q—From Pilot Control Shutoff Solenoid Valve Continued on next page NM00125,0000888 -19-23AUG11-5/12 TM2263 (09JUL14) 9025-05-93 35D and 50D Operation & Tests 070914 PN=537...
  • Page 538 Theory of Operation TM2263 (09JUL14) 9025-05-94 35D and 50D Operation & Tests 070914 PN=538...
  • Page 539 PUMP 3 GEARBOX AI P2 42 41 TO OIL COOLER FROM SOLENOID TO OIL VALVE SWING COOLER MANIFOLD MOTOR GEARBOX TX1078133 Control Valve Schematic—35D NM00125,0000888 -19-23AUG11-6/12 Continued on next page TM2263 (09JUL14) 9025-05-95 35D and 50D Operation & Tests 070914 PN=539...
  • Page 540 Theory of Operation TM2263 (09JUL14) 9025-05-96 35D and 50D Operation & Tests 070914 PN=540...
  • Page 541 Anticavitation Valve 35— Arm Out Circuit Relief and and Anticavitation Valve 83— System Relief Valve (pump Anticavitation Valve 84— System Relief Valve (pump Continued on next page NM00125,0000888 -19-23AUG11-7/12 TM2263 (09JUL14) 9025-05-97 35D and 50D Operation & Tests 070914 PN=541...
  • Page 542 CENTER LEFT JOINT TRAVEL VALVE SPOOL FROM RIGHT FROM TRAVEL HYDRAULIC TRAVEL VALVE OIL TANK SPOOL SPEED SOLENOID TX1078134 VALVE Travel Motor Schematic—35D Continued on next page NM00125,0000888 -19-23AUG11-8/12 TM2263 (09JUL14) 9025-05-98 35D and 50D Operation & Tests 070914 PN=542...
  • Page 543 64— Fast Speed Orifice 68— Shuttle Valve B—From Left Travel Valve Spool 65— Counterbalance Valve 69— Right Travel Motor C—From Right Travel Valve Spool Orifice Continued on next page NM00125,0000888 -19-23AUG11-9/12 TM2263 (09JUL14) 9025-05-99 35D and 50D Operation & Tests 070914 PN=543...
  • Page 544 FROM FROM SWING PILOT SWING HYDRAULIC VALVE CONTROL VALVE OIL TANK SPOOL SHUT-OFF SPOOL SOLENOID VALVE MAKE-UP CHECK VALVE TX1078116 Swing Motor Schematic—35D Continued on next page NM00125,0000888 -19-23AUG11-10/12 TM2263 (09JUL14) 9025-05-100 35D and 50D Operation & Tests 070914 PN=544...

  • Page 545: Hydraulic System Schematics-50D

    Solenoid Valve Valve D—To Pump Control Piston 86— A/C Torque Control Solenoid B—To Return Manifold E—To Return Manifold Valve NM00125,0000888 -19-23AUG11-12/12 Hydraulic System Schematics—50D Continued on next page NM00125,0000887 -19-12JUL11-1/12 TM2263 (09JUL14) 9025-05-101 35D and 50D Operation & Tests 070914 PN=545...
  • Page 546 Theory of Operation TM2263 (09JUL14) 9025-05-102 35D and 50D Operation & Tests 070914 PN=546...

  • Page 547: Return Filter

    CONTROL PISTON PISTON A/C TORQUE COOLER CONTROL PISTON (OPTIONAL) TX1078137 Hydraulic Pump, Pilot Flow Rate Sensing, Solenoid Manifold and Angle Blade Solenoid Schematic—50D NM00125,0000887 -19-12JUL11-2/12 Continued on next page TM2263 (09JUL14) 9025-05-103 35D and 50D Operation & Tests 070914 PN=547...
  • Page 548 Theory of Operation TM2263 (09JUL14) 9025-05-104 35D and 50D Operation & Tests 070914 PN=548...
  • Page 549 H—To Travel Speed Change Valve 10— Differential Reducing Valve (if equipped) 11— Variable Metering Valve 111— Hydraulic Oil Tank Relief 12— Orifice Valve and Breather Continued on next page NM00125,0000887 -19-12JUL11-3/12 TM2263 (09JUL14) 9025-05-105 35D and 50D Operation & Tests 070914 PN=549...
  • Page 550 PILOT CONTROL CONTROL VALVE VALVE AUXILIARY ANGLE CONTROL PILOT BLADE LEVER CONTROL PILOT PATTERN VALVE CONTROL SELECTOR VALVE TX1094097 Pilot Control Valve Schematic—50D Continued on next page NM00125,0000887 -19-12JUL11-4/12 TM2263 (09JUL14) 9025-05-106 35D and 50D Operation & Tests 070914 PN=550...
  • Page 551 Z— To Auxiliary Flow Selector J— Right Travel Forward Solenoid Valve (if equipped) K—Left Travel Reverse L— Left Travel Forward M—Blade Lower N—Blade Raise O—Swing Boom Left Continued on next page NM00125,0000887 -19-12JUL11-5/12 TM2263 (09JUL14) 9025-05-107 35D and 50D Operation & Tests 070914 PN=551...
  • Page 552 Theory of Operation TM2263 (09JUL14) 9025-05-108 35D and 50D Operation & Tests 070914 PN=552...

  • Page 553: Swing Boom

    A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10 Plmax RETURN CHECK VALVE HYDRAULIC HYDRAULIC PUMP COOLER TX1078138 Control Valve Schematic—50D NM00125,0000887 -19-12JUL11-6/12 Continued on next page TM2263 (09JUL14) 9025-05-109 35D and 50D Operation & Tests 070914 PN=553...
  • Page 554 Theory of Operation TM2263 (09JUL14) 9025-05-110 35D and 50D Operation & Tests 070914 PN=554...
  • Page 555 64— Pressure Compensator 92— Left Travel Motor 42— Boom Spool (swing boom) 100— Right Travel Motor 43— Shuttle Valve (boom) 44— Pressure Compensator (boom) Continued on next page NM00125,0000887 -19-12JUL11-7/12 TM2263 (09JUL14) 9025-05-111 35D and 50D Operation & Tests 070914 PN=555...
  • Page 556 FROM VALVE JOINT LEFT TRAVEL VALVE SPOOL FROM RIGHT TRAVEL RETURN VALVE MANIFOLD FROM SPOOL TRAVEL SPEED SOLENOID VALVE TX1078139 Travel Motor Schematic—50D Continued on next page NM00125,0000887 -19-12JUL11-8/12 TM2263 (09JUL14) 9025-05-112 35D and 50D Operation & Tests 070914 PN=556...
  • Page 557 A—From Left Travel Valve Spool Valve 95— Travel Speed Control Valve 98— Anticavitation Valve B—From Right Travel Valve Spool 99— Travel Brake Piston Continued on next page NM00125,0000887 -19-12JUL11-9/12 TM2263 (09JUL14) 9025-05-113 35D and 50D Operation & Tests 070914 PN=557...
  • Page 558 FROM FROM FROM SWING PILOT SWING CONTROL VALVE CONTROL VALVE VALVE SPOOL SHUTOFF SPOOL SOLENOID VALVE MAKE-UP CHECK VALVE TX1078140 Swing Motor Schematic—50D Continued on next page NM00125,0000887 -19-12JUL11-10/12 TM2263 (09JUL14) 9025-05-114 35D and 50D Operation & Tests 070914 PN=558...
  • Page 559 E—To Return Manifold Solenoid Valve Valve Line Valve Line F— From Pilot Line 109— A/C Torque Control B—To Return Manifold Line D—To A/C Torque Control Piston Solenoid Valve NM00125,0000887 -19-12JUL11-12/12 TM2263 (09JUL14) 9025-05-115 35D and 50D Operation & Tests 070914 PN=559...
  • Page 560 Theory of Operation TM2263 (09JUL14) 9025-05-116 35D and 50D Operation & Tests 070914 PN=560...

  • Page 561: Diagnostic Procedure

    Make a plan for appropriate repair to avoid other 3. Inspect the machine. malfunctions. Check all daily maintenance points. See Check Engine Oil Level. (Operator's Manual.) Check batteries, fuses, fusible link, and electrical connections. CED,OUOE003,1960 -19-06FEB09-1/1 TM2263 (09JUL14) 9025-15-1 35D and 50D Operation & Tests 070914 PN=561...

  • Page 562: Pilot Circuit

    Cleaning Suction Screen. (Operator's Manual.) Worn pumps Check pump flow rate. See Hydraulic Pump 1 and 2 Flow Test—35D or perform Hydraulic Pump 3 Flow Test—35D or perform Hydraulic Pump Flow Test—50D. (Group 9025-25.) System relief valve setting too low or Check system relief valve setting.
  • Page 563 Adjustment—50D. (Group 9025-25.) Oil cooler bypass valve stuck open Repair or replace bypass valve. See Hydraulic Oil Tank Remove and Install—35D or see Hydraulic Oil Tank Remove and Install—50D. (Group 3360.) Fan belt slipping Check for worn belt. Check tension adjuster.
  • Page 564 Perform Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.) Check valves in control valve Inspect valves. See Control Valve Remove and Install. (Group 3360.) OUO1020,000148D -19-23FEB09-3/3 TM2263 (09JUL14) 9025-15-4 35D and 50D Operation & Tests 070914 PN=564...
  • Page 565 System Relief Valve Test and Adjustment—50D. (Group 9025-25.) Unload valve malfunction (50D only) Inspect unload valve. Perform Unload Valve Test and Adjustment—50D. (Group 9025-25.) Continued on next page OUO1020,000148E -19-10FEB09-1/2 TM2263 (09JUL14) 9025-15-5 35D and 50D Operation & Tests 070914 PN=565...
  • Page 566 Pilot controller pattern conversion Check position of pilot controller Operate Or Do Not Operate As valve pattern conversion valve. See Control Expected Lever Pattern Conversion. (Operator's Manual.) OUO1020,000148E -19-10FEB09-2/2 TM2263 (09JUL14) 9025-15-6 35D and 50D Operation & Tests 070914 PN=566...
  • Page 567 Check for sticking spool. See Control Valve Disassemble and Assemble—35D and 50D (S.N. —274999) or see Control Valve Disassemble and Assemble—50D (S.N. 275000— ). (Group 3360.) Continued on next page OUO1020,000148F -19-24FEB09-1/2 TM2263 (09JUL14) 9025-15-7 35D and 50D Operation & Tests 070914 PN=567...
  • Page 568 —274999) or see Control Valve Disassemble and Assemble—50D (S.N. 275000— ). (Group 3360.) Auxiliary Function Inoperative One way/Two way valve Check for proper position according to attachment used. OUO1020,000148F -19-24FEB09-2/2 TM2263 (09JUL14) 9025-15-8 35D and 50D Operation & Tests 070914 PN=568...
  • Page 569 Perform Swing Motor Crossover Relief Valve Test and Adjustment—35D or perform Swing Motor Crossover Relief Valve Test and Adjustment—50D. (Group 9025-25.) Continued on next page OUO1020,0001490 -19-24FEB09-1/2 TM2263 (09JUL14) 9025-15-9 35D and 50D Operation & Tests 070914 PN=569...
  • Page 570 Control valve spool stuck Check for sticking spool. See Control Valve Disassemble and Assemble—35D and 50D (S.N. —274999) or see Control Valve Disassemble and Assemble—50D (S.N. 275000— ). (Group 3360.) OUO1020,0001490 -19-24FEB09-2/2 TM2263 (09JUL14) 9025-15-10 35D and 50D Operation & Tests 070914 PN=570...

  • Page 571: Diagnose Travel System Malfunctions

    (S.N. 275000— ). (Group 0260.) Travel pilot control valve malfunction Inspect travel pilot control valve. See Travel Pilot Controller Remove and Install. (Group 3360.) Continued on next page OUO1020,0001906 -19-24FEB09-1/4 TM2263 (09JUL14) 9025-15-11 35D and 50D Operation & Tests 070914 PN=571...

  • Page 572: Leakage Test

    See Center Joint Disassemble and Assemble. (Group 0260.) Slow Travel Speed or Low Power Track sag adjustment Adjust track sag. See Adjusting Track Sag. (Operator's Manual.) Continued on next page OUO1020,0001906 -19-24FEB09-2/4 TM2263 (09JUL14) 9025-15-12 35D and 50D Operation & Tests 070914 PN=572...
  • Page 573 See Control Valve Disassemble and Assemble—35D and 50D (S.N. —274999) or see Control Valve Disassemble and Assemble—50D (S.N. 275000— ). (Group 3360.) Continued on next page OUO1020,0001906 -19-24FEB09-3/4 TM2263 (09JUL14) 9025-15-13 35D and 50D Operation & Tests 070914 PN=573...

  • Page 574: Major Component Location-35D

    Disassemble and Assemble—35D and 50D (S.N. —274999) or see Travel Motor Disassemble and Assemble—50D (S.N. 275000— ). (Group 0260.) OUO1020,0001906 -19-24FEB09-4/4 Major Component Location—35D Continued on next page NM00125,000088D -19-16AUG11-1/3 TM2263 (09JUL14) 9025-15-14 35D and 50D Operation & Tests 070914 PN=574...
  • Page 575 Diagnostic Information TX1094532 —UN—14JUL11 TX1094532 Major Component Location-35D NM00125,000088D -19-16AUG11-2/3 Continued on next page TM2263 (09JUL14) 9025-15-15 35D and 50D Operation & Tests 070914 PN=575...
  • Page 576 Diagnostic Information TM2263 (09JUL14) 9025-15-16 35D and 50D Operation & Tests 070914 PN=576...

  • Page 577: Main Hydraulic Pilot System Line Identification-35D

    Component Location. (Group 9015-10.) For more information regarding angle blade solenoid valve (119) component location, see NM00125,000088D -19-16AUG11-3/3 Main Hydraulic Pilot System Line Identification—35D Continued on next page OUO1020,0001908 -19-28JAN09-1/3 TM2263 (09JUL14) 9025-15-17 35D and 50D Operation & Tests 070914 PN=577...
  • Page 578 Diagnostic Information TM2263 (09JUL14) 9025-15-18 35D and 50D Operation & Tests 070914 PN=578...
  • Page 579 Diagnostic Information T205438 —UN—27DEC04 T205438 OUO1020,0001908 -19-28JAN09-2/3 Continued on next page TM2263 (09JUL14) 9025-15-19 35D and 50D Operation & Tests 070914 PN=579...
  • Page 580 Diagnostic Information TM2263 (09JUL14) 9025-15-20 35D and 50D Operation & Tests 070914 PN=580...

  • Page 581: Main Hydraulic Working System Line Identification-35D

    57— Swing Motor and Gearbox 88— Tank Manifold (platform) 15— Right Pilot Control Valve 78— Auxiliary Pilot Control Valve OUO1020,0001908 -19-28JAN09-3/3 Main Hydraulic Working System Line Identification—35D Continued on next page OUO1020,0001909 -19-15JAN09-1/3 TM2263 (09JUL14) 9025-15-21 35D and 50D Operation & Tests 070914 PN=581...
  • Page 582 Diagnostic Information TM2263 (09JUL14) 9025-15-22 35D and 50D Operation & Tests 070914 PN=582...
  • Page 583 Diagnostic Information T205440 —UN—27DEC04 30 33 T205440 OUO1020,0001909 -19-15JAN09-2/3 Continued on next page TM2263 (09JUL14) 9025-15-23 35D and 50D Operation & Tests 070914 PN=583...
  • Page 584 Diagnostic Information TM2263 (09JUL14) 9025-15-24 35D and 50D Operation & Tests 070914 PN=584...

  • Page 585: Blade Hydraulic System Line

    30— Auxiliary Valve Spool 60— Boom Cylinder 12— Hydraulic Oil Tank 33— Arm Valve Spool 71— Arm Cylinder OUO1020,0001909 -19-15JAN09-3/3 Blade Hydraulic System Line Identification—35D Continued on next page OUO1020,000146A -19-28JAN09-1/3 TM2263 (09JUL14) 9025-15-25 35D and 50D Operation & Tests 070914 PN=585...
  • Page 586 Diagnostic Information TM2263 (09JUL14) 9025-15-26 35D and 50D Operation & Tests 070914 PN=586...
  • Page 587 Diagnostic Information T205442 —UN—27DEC04 T205442 OUO1020,000146A -19-28JAN09-2/3 Continued on next page TM2263 (09JUL14) 9025-15-27 35D and 50D Operation & Tests 070914 PN=587...
  • Page 588 Diagnostic Information TM2263 (09JUL14) 9025-15-28 35D and 50D Operation & Tests 070914 PN=588...

  • Page 589: Travel Hydraulic System Line Identification-35D

    90— Pressure Manifold 9— Pilot Control Shutoff Solenoid 17— Blade Pilot Controller 88— Tank Manifold (platform) Valve OUO1020,000146A -19-28JAN09-3/3 Travel Hydraulic System Line Identification—35D Continued on next page OUO1020,000190A -19-11FEB09-1/3 TM2263 (09JUL14) 9025-15-29 35D and 50D Operation & Tests 070914 PN=589...
  • Page 590 Diagnostic Information TM2263 (09JUL14) 9025-15-30 35D and 50D Operation & Tests 070914 PN=590...
  • Page 591 Diagnostic Information T205443 —UN—27DEC04 T205443 OUO1020,000190A -19-11FEB09-2/3 Continued on next page TM2263 (09JUL14) 9025-15-31 35D and 50D Operation & Tests 070914 PN=591...
  • Page 592 Diagnostic Information TM2263 (09JUL14) 9025-15-32 35D and 50D Operation & Tests 070914 PN=592...
  • Page 593 40— Left Travel Valve Spool 75— Solenoid Valve Manifold 8— Travel Speed Solenoid Valve 57— Swing Motor and Gearbox 88— Tank Manifold (platform) 9— Pilot Control Shutoff Solenoid Valve OUO1020,000190A -19-11FEB09-3/3 TM2263 (09JUL14) 9025-15-33 35D and 50D Operation & Tests 070914 PN=593...

  • Page 594: Pilot Control Valve To Pattern Selector Valve Line Connection

    Excavator Pattern Shown 14— Left Pilot Control Valve 16— Excavator Pattern 18— Pilot Control Valve Pattern 15— Right Pilot Control Valve 17— Backhoe Pattern Selector Continued on next page OUO1020,000190B -19-29JAN09-1/2 TM2263 (09JUL14) 9025-15-34 35D and 50D Operation & Tests 070914 PN=594...

  • Page 595: Major Component Location-50D

    2—B Arm Out 2—D Boom Down 3—C Boom Up 3—A Arm In 4—B 4—D Boom Down Arm Out OUO1020,000190B -19-29JAN09-2/2 Major Component Location—50D Continued on next page NM00125,000088E -19-14JUL11-1/3 TM2263 (09JUL14) 9025-15-35 35D and 50D Operation & Tests 070914 PN=595...
  • Page 596 Diagnostic Information TM2263 (09JUL14) 9025-15-36 35D and 50D Operation & Tests 070914 PN=596...
  • Page 597 Diagnostic Information TX1094533 —UN—14JUL11 TX1094533 Component Locations—50D NM00125,000088E -19-14JUL11-2/3 Continued on next page TM2263 (09JUL14) 9025-15-37 35D and 50D Operation & Tests 070914 PN=597...
  • Page 598 Diagnostic Information TM2263 (09JUL14) 9025-15-38 35D and 50D Operation & Tests 070914 PN=598...

  • Page 599: Main Hydraulic Pilot System Line Identification-50D

    Auxiliary Function Control Harness (W19) function control valve (120) component location, Component Location. (Group 9015-10.) NM00125,000088E -19-14JUL11-3/3 Main Hydraulic Pilot System Line Identification—50D Continued on next page OUO1020,000190D -19-28JAN09-1/3 TM2263 (09JUL14) 9025-15-39 35D and 50D Operation & Tests 070914 PN=599...
  • Page 600 Diagnostic Information TM2263 (09JUL14) 9025-15-40 35D and 50D Operation & Tests 070914 PN=600...
  • Page 601 Diagnostic Information TX1054652 —UN—30JAN09 TX1054652 Main Hydraulic Pilot System Line Identification—50D OUO1020,000190D -19-28JAN09-2/3 Continued on next page TM2263 (09JUL14) 9025-15-41 35D and 50D Operation & Tests 070914 PN=601...
  • Page 602 Diagnostic Information TM2263 (09JUL14) 9025-15-42 35D and 50D Operation & Tests 070914 PN=602...

  • Page 603: Main Hydraulic Working System Line Identification-50D

    119— Angle Blade Solenoid 24— Swing Boom Pilot Control 106— Auxiliary Pilot Control Valve (optional) Valve Valve OUO1020,000190D -19-28JAN09-3/3 Main Hydraulic Working System Line Identification—50D Continued on next page OUO1020,000190E -19-16JAN09-1/3 TM2263 (09JUL14) 9025-15-43 35D and 50D Operation & Tests 070914 PN=603...
  • Page 604 Diagnostic Information TM2263 (09JUL14) 9025-15-44 35D and 50D Operation & Tests 070914 PN=604...
  • Page 605 Diagnostic Information T205983 —UN—27DEC04 T205983 OUO1020,000190E -19-16JAN09-2/3 Continued on next page TM2263 (09JUL14) 9025-15-45 35D and 50D Operation & Tests 070914 PN=605...
  • Page 606 Diagnostic Information TM2263 (09JUL14) 9025-15-46 35D and 50D Operation & Tests 070914 PN=606...

  • Page 607: Blade Hydraulic System Line Identification-50D

    89— Boom Cylinder 105— Auxiliary Selector Valve 36— Swing Valve Spool 65— Quick Couplers 90— Arm Cylinder OUO1020,000190E -19-16JAN09-3/3 Blade Hydraulic System Line Identification—50D Continued on next page OUO1020,000190F -19-29JAN09-1/3 TM2263 (09JUL14) 9025-15-47 35D and 50D Operation & Tests 070914 PN=607...
  • Page 608 Diagnostic Information TM2263 (09JUL14) 9025-15-48 35D and 50D Operation & Tests 070914 PN=608...
  • Page 609 Diagnostic Information TX1055173 —UN—30JAN09 TX1055173 Blade Hydraulic System Line Identification—50D OUO1020,000190F -19-29JAN09-2/3 Continued on next page TM2263 (09JUL14) 9025-15-49 35D and 50D Operation & Tests 070914 PN=609...
  • Page 610 Diagnostic Information TM2263 (09JUL14) 9025-15-50 35D and 50D Operation & Tests 070914 PN=610...

  • Page 611: Angle Blade Hydraulic System Line Identification-If Equipped

    Manifold 80— Blade Valve Spool (upperstructure) 13— Solenoid Valve Manifold 112— Return Manifold (platform) OUO1020,000190F -19-29JAN09-3/3 Angle Blade Hydraulic System Line Identification—If Equipped Continued on next page NM00125,0000890 -19-13JUL11-1/3 TM2263 (09JUL14) 9025-15-51 35D and 50D Operation & Tests 070914 PN=611...
  • Page 612 Diagnostic Information TM2263 (09JUL14) 9025-15-52 35D and 50D Operation & Tests 070914 PN=612...
  • Page 613 Diagnostic Information TX1054709 —UN—30JAN09 TX1054709 Angle Blade Hydraulic System Line Identification NM00125,0000890 -19-13JUL11-2/3 Continued on next page TM2263 (09JUL14) 9025-15-53 35D and 50D Operation & Tests 070914 PN=613...
  • Page 614 Diagnostic Information TM2263 (09JUL14) 9025-15-54 35D and 50D Operation & Tests 070914 PN=614...

  • Page 615: Travel Hydraulic System Line Identification-50D

    115— Angle Blade Spool 13— Solenoid Valve Manifold 104— Control Valve 15— Pilot Control Shutoff Solenoid Valve NM00125,0000890 -19-13JUL11-3/3 Travel Hydraulic System Line Identification—50D Continued on next page OUO1020,0001910 -19-11FEB09-1/3 TM2263 (09JUL14) 9025-15-55 35D and 50D Operation & Tests 070914 PN=615...
  • Page 616 Diagnostic Information TM2263 (09JUL14) 9025-15-56 35D and 50D Operation & Tests 070914 PN=616...
  • Page 617 Diagnostic Information T205984 —UN—27DEC04 T205984 OUO1020,0001910 -19-11FEB09-2/3 Continued on next page TM2263 (09JUL14) 9025-15-57 35D and 50D Operation & Tests 070914 PN=617...
  • Page 618 Diagnostic Information TM2263 (09JUL14) 9025-15-58 35D and 50D Operation & Tests 070914 PN=618...
  • Page 619 70— Right Travel Valve Spool 104— Control Valve Manifold 75— Left Travel Valve Spool 107— Return Manifold 13— Solenoid Valve Manifold (upperstructure) 15— Pilot Control Shutoff Solenoid Valve OUO1020,0001910 -19-11FEB09-3/3 TM2263 (09JUL14) 9025-15-59 35D and 50D Operation & Tests 070914 PN=619...
  • Page 620 Diagnostic Information TM2263 (09JUL14) 9025-15-60 35D and 50D Operation & Tests 070914 PN=620...

  • Page 621: Jt05800 Digital Thermometer Installation

    When using for different pressures, turn selector to OFF for two seconds and then to the pressure range. Readings are inaccurate if proper range for transducer is not used. CED,TX08227,2896 -19-02JUL01-1/1 TM2263 (09JUL14) 9025-25-1 35D and 50D Operation & Tests 070914 PN=621...

  • Page 622: Hydraulic System Warm-Up Procedure

    CAUTION: Avoid possible serious injury from Hydraulic System—Specification machine movement during warm-up procedure. Hydraulic Clear the area of all bystanders before doing Oil—Temperature..............45—55 °C the warm-up procedure. 110—130 °F CED,TX08227,3305 -19-21DEC05-1/1 TM2263 (09JUL14) 9025-25-2 35D and 50D Operation & Tests 070914 PN=622...

  • Page 623: Cylinder Drift Test-Boom, Arm, Bucket, And Blade

    2. Perform Hydraulic System Warm-Up Procedure. (Group 9025-25.) 7. Raise blade to specified height. Specification Specification Hydraulic Blade—Height..............Top of stroke Oil—Temperature..............45—55 °C 8. Stop engine. 110—130 °F Continued on next page OUO1020,0001D89 -19-01JUL11-1/2 TM2263 (09JUL14) 9025-25-3 35D and 50D Operation & Tests 070914 PN=623...
  • Page 624 Allowable for 5 Minutes Blade Cylinder Maximum with Blade Lowered Allowable for 5 Minutes (lifting machine)—Drift..............15 mm with Blade Raised—Drift..............3 mm 0.59 in. 0.12 in. OUO1020,0001D89 -19-01JUL11-2/2 TM2263 (09JUL14) 9025-25-4 35D and 50D Operation & Tests 070914 PN=624...

  • Page 625: Pilot Pressure Regulating Valve Test And Adjustment

    Hydraulic pressure as necessary. Oil—Temperature..............45—55 °C 110—130 °F NOTE: 50D shown, procedure for 35D is the same. 5. Run machine at specifications with auto-idle switch off. 1. Stop the engine. Specification 2. Loosen cap to release the air pressure in hydraulic Engine—Speed................
  • Page 626 Idle—50D—Pressure........... 6100— 7100 kPa 61.0—71.0 bar 885—1030 psi 8. Tighten nut (1). 50D Shown Specification Nut-to-Pilot Pressure 1— Nut 2— Adjusting Screw Regulating Valve Housing—Torque ................25 N·m 18 lb-ft OUO1030,0000009 -19-16NOV04-2/2 TM2263 (09JUL14) 9025-25-6 35D and 50D Operation & Tests 070914 PN=626...

  • Page 627: Control Valve Spool Pilot Actuating Pressure Test

    Engine Speed Control Lever—Position................Fast Idle NOTE: 35D shown, procedure for 50D is the same. NOTE: Spool actuation pressure can be checked for each function by installing the tee and gauge in that CAUTION: Machine will move during this pilot line and then actuating that function.

  • Page 628: Hydraulic Pump 1, 2, And 3 System Relief Valve Test And Adjustment-35D

    3. Install digital pressure/temperature analyzer and transducers or gauges to hydraulic pump test ports (2—4) using adapters (1). Continued on next page OUO1020,0001466 -19-06FEB09-1/3 TM2263 (09JUL14) 9025-25-8 35D and 50D Operation & Tests 070914 PN=628...
  • Page 629 650 psi 11. Hold adjusting screw and tighten nut to specification. Specification Relief Valve Nut—Torque..................29 N·m 9— Nut 8— Adjusting Screw 22 lb-ft 12. Check pressure setting. OUO1020,0001466 -19-06FEB09-3/3 TM2263 (09JUL14) 9025-25-9 35D and 50D Operation & Tests 070914 PN=629...

  • Page 630: System Relief Valve Test And Adjustment-50D (S.n. -274999)

    Tighten cap. 3. Install digital pressure/temperature analyzer and transducer or gauge to hydraulic pump test port (2) using adapter (1). Continued on next page OUO1020,0001467 -19-13FEB12-1/2 TM2263 (09JUL14) 9025-25-10 35D and 50D Operation & Tests 070914 PN=630...
  • Page 631 319 psi 10. Hold adjusting screw and tighten nut. 3— System Relief Valve 5— Adjusting Screw 4— Nut Specification Nut—Torque..................37 N·m 27 lb-ft 11. Check the pressure setting. OUO1020,0001467 -19-13FEB12-2/2 TM2263 (09JUL14) 9025-25-11 35D and 50D Operation & Tests 070914 PN=631...

  • Page 632: System Relief Valve Test And Adjustment-50D (S.n. 275000- )

    Tighten cap. 3. Install JT02156A Digital Pressure/Temperature Analyzer and JT02162 Transducer or gauge to hydraulic pump test port (2) using adapter (1). Continued on next page AS20895,00008DB -19-12JUN12-1/2 TM2263 (09JUL14) 9025-25-12 35D and 50D Operation & Tests 070914 PN=632...
  • Page 633 13. Check the pressure setting. 9. Loosen lock nut (4). 14. Remove test equipment. 10. Turn adjustment nut (5) in to increase pressure or out to decrease pressure to specification. AS20895,00008DB -19-12JUN12-2/2 TM2263 (09JUL14) 9025-25-13 35D and 50D Operation & Tests 070914 PN=633...

  • Page 634: Pilot Flow Rate Sensing Manifold Test And Adjustment-50D

    11. Run machine at specification. flow rate sensing manifold. Specification 1. Perform Hydraulic Pump 1, 2, and 3 System Relief Engine—Speed................Slow Idle Valve Test and Adjustment—35D or perform System 12. Record pressure reading. Relief Valve Test and Adjustment—50D. (Group 9025-25.) Specification Differential 2.

  • Page 635: Unload Valve Test And Adjustment-50D

    Tighten cap. 1. Perform Hydraulic Pump 1, 2, and 3 System Relief 7. Install digital pressure/temperature analyzer and Valve Test and Adjustment—35D or perform System transducer or gauge to hydraulic pump test port (2) Relief Valve Test and Adjustment—50D. (Group 9025-25.)
  • Page 636 13. Hold adjusting screw and tighten nut. 14. Check pressure setting. 15. Perform Control Valve Differential Reducing Valve Test and Adjustment—50D. (Group 9025-25.) 3— Nut 5— Unload Valve 4— Adjusting Screw OUO1020,000146E -19-06FEB09-2/2 TM2263 (09JUL14) 9025-25-16 35D and 50D Operation & Tests 070914 PN=636...

  • Page 637: Control Valve Differential Reducing Valve Test And Adjustment-50D

    Specification Hydraulic 1. Perform Hydraulic Pump 1, 2, and 3 System Relief Oil—Temperature..............45—55 °C Valve Test and Adjustment—35D or perform System 110—130 °F Relief Valve Test and Adjustment—50D. (Group 9025-25.) 8. Run machine at specification with auto-idle switch OFF.
  • Page 638 12. Hold adjusting screw and tighten nut. 13. Check pressure setting. 3— Control Valve Differential 5— Nut Reducing Valve 4— Adjusting Screw OUO1020,000146F -19-06FEB09-2/2 TM2263 (09JUL14) 9025-25-18 35D and 50D Operation & Tests 070914 PN=638...

  • Page 639: Circuit Relief Valve Test And Adjustment-35D

    Gauge 35 000 kPa (350 bar) (5000 psi) The purpose of circuit relief valves is to relieve high pressure spikes caused by external forces when functions Continued on next page TX18160,00000A3 -19-06FEB09-1/3 TM2263 (09JUL14) 9025-25-19 35D and 50D Operation & Tests 070914 PN=639...
  • Page 640 10. Hold adjusting screw and tighten nut. 11. Check pressure setting. 14— Nut 15— Adjusting Screw 12. Perform Hydraulic Pump 1, 2, and 3 System Relief Valve Test and Adjustment—35D. (Group 9025-25.) TX18160,00000A3 -19-06FEB09-3/3 TM2263 (09JUL14) 9025-25-20 35D and 50D Operation & Tests...

  • Page 641: Circuit Relief Valve Test And Adjustment-50D

    JT02156A Digital Pressure/Temperature Analyzer 110—130 °F JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 35 000 kPa (350 bar) (5000 psi) Continued on next page OUO1020,000191B -19-21JAN09-1/3 TM2263 (09JUL14) 9025-25-21 35D and 50D Operation & Tests 070914 PN=641...
  • Page 642 392 psi 10. Hold adjusting screw and tighten nut. 11. Check pressure setting. 12— Nut 13— Adjusting Screw 12. Perform System Relief Valve Test and Adjustment—50D. (Group 9025-25.) OUO1020,000191B -19-21JAN09-3/3 TM2263 (09JUL14) 9025-25-22 35D and 50D Operation & Tests 070914 PN=642...

  • Page 643: Swing Motor Crossover Relief Valve Test And Adjustment-35D

    Swing Crossover Relief Valve—Pressure ............17 400—19 400 kPa 174—194 bar 2524—2814 psi 3— Right Swing Crossover 4— Left Swing Crossover Relief Relief Valve Valve Continued on next page OUO1020,0001471 -19-03DEC04-2/3 TM2263 (09JUL14) 9025-25-23 35D and 50D Operation & Tests 070914 PN=643...

  • Page 644: Swing Motor Crossover Relief Valve Test And Adjustment-50D

    7. Repeat procedure for the opposite direction. Record 3. Install digital pressure/temperature analyzer and the pressure reading. transducer or gauge to hydraulic pump test port (2) using adapter (1). Continued on next page OUO1020,0001472 -19-06FEB09-1/3 TM2263 (09JUL14) 9025-25-24 35D and 50D Operation & Tests 070914 PN=644...
  • Page 645 Relief Valve Change Per 1/4 Turn Approximate—Pressure............2450 kPa 24.5 bar 360 psi 10. Hold adjusting screw and tighten nut. 11. Check pressure setting. 5— Nut 6— Adjusting Screw OUO1020,0001472 -19-06FEB09-3/3 TM2263 (09JUL14) 9025-25-25 35D and 50D Operation & Tests 070914 PN=645...

  • Page 646: Hydraulic Pump 1 And 2 Regulator Test And Adjustment-Engine Pulldown-35D

    12. Check engine speed setting. 6. Actuate bucket at relief. 13. Simultaneously actuate bucket, arm, and blade at 7. Record engine speed. relief. Engine should not stall with three pumps loaded. OUO1030,00000D9 -19-05FEB13-1/1 TM2263 (09JUL14) 9025-25-26 35D and 50D Operation & Tests 070914 PN=646...

  • Page 647: Hydraulic Pump Regulator Test And Adjustment-Engine Pulldown-50D

    Specification 4. Run machine at specification with auto-idle switch OFF. Adjustment Screw Nut—Torque..................12 N·m Specification 96 lb-in. Engine—Fast Idle 10. Check engine speed setting. Speed................2600—2700 rpm OUO1030,00000D8 -19-10JUL07-1/1 TM2263 (09JUL14) 9025-25-27 35D and 50D Operation & Tests 070914 PN=647...

  • Page 648: Hydraulic Pump 1 And 2 Flow Test

    8. Perform Hydraulic System Warm-Up Procedure. 4.5 gpm (Group 9025-25.) If pump flow is not within specification, repair or replace Specification pump. See Hydraulic Pump Remove and Install—35D Hydraulic and see Hydraulic Pump Disassemble—35D. (Group Oil—Temperature..............45—55 °C 3360.) 110—130 °F...

  • Page 649: Hydraulic Pump 3 Flow Test-35D

    (S.N. 265000— ) Specification Hydraulic Pump 3 at Hydraulic 20 615 kPa (2990 psi) Oil—Temperature..............45—55 °C New—Flow Rate..............34.8 L/min 110—130 °F 10.1 gpm Continued on next page OUO1020,0001477 -19-10SEP10-1/2 TM2263 (09JUL14) 9025-25-29 35D and 50D Operation & Tests 070914 PN=649...

  • Page 650: Hydraulic Pump Flow Test-50D

    Tests and see Hydraulic Pump Disassemble—35D. (Group If pump flow is not within specification, repair or replace 3360.) pump. See Hydraulic Pump Remove and Install—35D OUO1020,0001477 -19-10SEP10-2/2 Hydraulic Pump Flow Test—50D SPECIFICATIONS Hydraulic Oil Temperature 45—55 °C 110—130 °F Engine Speed 2500—2550 rpm...
  • Page 651 Tests TM2263 (09JUL14) 9025-25-31 35D and 50D Operation & Tests 070914 PN=651...

  • Page 652: Swing Motor Leakage Test

    Tests Swing Motor Leakage Test TX1042286 Swing Motor Continued on next page CED,OUOE011,145 -19-16JUL10-1/2 TM2263 (09JUL14) 9025-25-32 35D and 50D Operation & Tests 070914 PN=652...
  • Page 653 Swing Motor and Park Brake Remove and Install. (Group 4360.) 5. Disconnect make-up hose (2) and close openings with caps and plugs. 12. Remove test line. Connect drain line to swing motor. CED,OUOE011,145 -19-16JUL10-2/2 TM2263 (09JUL14) 9025-25-33 35D and 50D Operation & Tests 070914 PN=653...

  • Page 654: Travel Motor Leakage Test

    7. For travel motor being checked, actuate travel forward Track Raised—50D function at full speed for 1 minute. Record amount of Maximum—Leakage..............0.3 L/min leakage. Repeat procedure for reverse. 0.08 gpm OUO1020,0001913 -19-28JAN09-1/1 TM2263 (09JUL14) 9025-25-34 35D and 50D Operation & Tests 070914 PN=654...

  • Page 655: Refrigerant Cautions And Proper

    Visual Inspection Of Compo- nents .............9031-25-1 Refrigerant Leak Test ........ 9031-25-3 Air Conditioner Compressor Clutch Test ............9031-25-3 R134a Air Conditioning System Test ............9031-25-4 Operating Pressure Diagnostic Chart............9031-25-5 TM2263 (09JUL14) 9031-1 35D and 50D Operation & Tests 070914 PN=1...
  • Page 656 Contents TM2263 (09JUL14) 9031-2 35D and 50D Operation & Tests 070914 PN=2...

  • Page 657: Air Conditioning System Cycle Of Operation

    (acid, solids, etc.) are from evaporator by compressor and cycle is repeated. removed. Receiver-dryer contains a color moisture indicator. (Blue) indicates no moisture is present. (Pink) Continued on next page LD30992,0000083 -19-04AUG03-1/2 TM2263 (09JUL14) 9031-05-1 35D and 50D Operation & Tests 070914 PN=657...
  • Page 658 Condensed moisture is drained away through drain tubes becomes too high or too low the switch opens and stops connected to drain pan under evaporator. compressor, interrupting the cycle. LD30992,0000083 -19-04AUG03-2/2 TM2263 (09JUL14) 9031-05-2 35D and 50D Operation & Tests 070914 PN=658...

  • Page 659: Diagnose Air Conditioning System Malfunctions

    Blower motor failed or operating too Replace blower motor. See Heating slowly and Air Conditioning Unit Remove and Install. (Group 1830.) Continued on next page OUO1072,0000D94 -19-06FEB09-1/2 TM2263 (09JUL14) 9031-15-1 35D and 50D Operation & Tests 070914 PN=659...
  • Page 660 Fresh/recirculating air filter clogged Clean or replace filter. See Cleaning Heating and Air Conditioning Filter Screens—If Equipped. (Operator's Manual.) Air conditioning system off Turn AC switch to ON position. OUO1072,0000D94 -19-06FEB09-2/2 TM2263 (09JUL14) 9031-15-2 35D and 50D Operation & Tests 070914 PN=660...

  • Page 661: Diagnose Heater System Malfunctions

    Screens—If Equipped. (Operator's Manual.) Heating and Air Conditioning Unit (E5) Replace Heating and Air Conditioning Unit. See Heating and Air Conditioning Unit Remove and Install. (Group 1830.) OUO1072,0000D97 -19-06FEB09-1/1 TM2263 (09JUL14) 9031-15-3 35D and 50D Operation & Tests 070914 PN=661...

  • Page 662: Air Conditioner And Heater Component Location

    Air Conditioner and Heater Component Location (1 of 2) 1— Air Conditioner Compressor 3— High Pressure Service Port 5— High/Low Pressure Switch 2— Low Pressure Service Port 4— Condenser 6— Receiver-Dryer Continued on next page OUO1072,0000D98 -19-09DEC04-1/2 TM2263 (09JUL14) 9031-15-4 35D and 50D Operation & Tests 070914 PN=662...
  • Page 663 Diagnostic Information T206111 Air Conditioner and Heater Component Location (2 of 2) 1— Air Vent Door Actuator 2— Heater Control Valve Actuator 3— Heating and Air Conditioning Unit OUO1072,0000D98 -19-09DEC04-2/2 TM2263 (09JUL14) 9031-15-5 35D and 50D Operation & Tests 070914 PN=663...
  • Page 664 Diagnostic Information TM2263 (09JUL14) 9031-15-6 35D and 50D Operation & Tests 070914 PN=664...

  • Page 665: Refrigerant Cautions And Proper Handling

    Checks NOTE: Perform Visual Inspection of Components (Group 9031-25.) check prior to diagnostics OUO1072,0000D96 -19-09DEC04-1/9 • Visual Inspection Of Components Continued on next page OUO1072,0000D96 -19-09DEC04-2/9 TM2263 (09JUL14) 9031-25-1 35D and 50D Operation & Tests 070914 PN=665...

  • Page 666: Inspect

    LOOK/FEEL: Is condensation drain tube attached and in good condition, NOT kinked, NO: Clean and straighten damaged, or clogged? fins if necessary. Note any components that will require repair or replacement. Continued on next page OUO1072,0000D96 -19-09DEC04-7/9 TM2263 (09JUL14) 9031-25-2 35D and 50D Operation & Tests 070914 PN=666...

  • Page 667: Refrigerant Leak Test

    5. If air conditioner compressor clutch “clicks” and engages, check wiring harness and A/C high/low pressure switch. See Heating and A/C Control 1— A/C Compressor Clutch Harness (W11) Wiring Diagram (Group 9015-10). Wire Connector OUO1072,0000D95 -19-09DEC04-1/1 TM2263 (09JUL14) 9031-25-3 35D and 50D Operation & Tests 070914 PN=667...

  • Page 668: R134A Air Conditioning System Test

    117—172 kPa 2241—2723 kPa 110°F 1.2—1.7 bar 22—27 bar 17—25 psi 325—395 psi 16. If measurements do not meet specifications, see Operating Pressure Diagnostic Chart. (Group 9031-25.) OUO1030,00000D7 -19-20DEC05-1/1 TM2263 (09JUL14) 9031-25-4 35D and 50D Operation & Tests 070914 PN=668...

  • Page 669: Operating Pressure Diagnostic Chart

    Cool Warm Warm Warm Stuck Open Lack of Normal (No Normal Occasional Warm to Hot Warm Warm Warm Slightly Cool Refrigerant Drop) Bubbles and Air in System LD30992,00000AA -19-16SEP03-1/1 TM2263 (09JUL14) 9031-25-5 35D and 50D Operation & Tests 070914 PN=669...
  • Page 670 Tests TM2263 (09JUL14) 9031-25-6 35D and 50D Operation & Tests 070914 PN=670...
  • Page 671 Operational checks ........9031-25-1 Avoiding ............9000-01-9 System operation ........... 9031-05-1 Battery and power cables (W6 & W7) System test, R134a........9031-25-4 Component location - 35D ......9015-10-54 Torque control solenoid valve, Component location - 50D ......9015-10-56 operation ............ 9025-05-27 Battery voltage Air intake system Check............
  • Page 672 Heating and A/C control harness Cylinder head (W11)............9015-10-181 Head gasket failure Check......9010-25-20 Information ............. 9015-05-1 Main harness (W8) - 35D......9015-10-58 Main harness (W8) - 50D......9015-10-83 Major-35D ............ 9025-15-14 Major-50D ............ 9025-15-35 Diagnose malfunction Platform harness (W9) ....... 9015-10-117 Undercarriage component ......
  • Page 673 Fan belt 35D (SN —260000) 50D (SN Adjust tension ..........9010-25-6 —270000) ............ 9015-10-7 Filter 35D (SN 260001— ) 50D (SN 270001— Hydraulic oil return, operation ...... 9025-05-85 ) ..............9015-10-31 Piolt operation ..........9025-05-12 Electronic tachometer installation...... 9010-25-1 Fire prevention........... 9000-01-4...
  • Page 674 Hydraulic pump 3 Theory of operation - 35D (S.N. -260000) Operation-35D ..........9025-05-24 50D (S.N. -270000) ........9015-15-37 Hydraulic system Theory of operation - 35D (S.N. 260001- ) Circuit symbols..........9025-05-86 50D (S.N. 270001- ) ........9015-15-41 Diagnose malfunctions........9025-15-2 Horn circuit Diagram-35D..........
  • Page 675 Index Page Page Main system functional schematics 35D (SN —260000) 50D (SN —270000) ............ 9015-10-7 35D (SN 260001— ) 50D (SN 270001— Leakage ) ..............9015-10-31 Air intake system test........9010-25-15 Major component Leakage test Location-35D..........9025-15-14 Swing motor ..........9025-25-32 Location-50D..........
  • Page 676 Hydraulic pump-50D ........9025-05-25 Preheat circuit Theory of operation - 35D (S.N. -260000) 50D (S.N. -270000) ........9015-15-45 Theory of operation - 35D (S.N. 260001- ) Parts, moving 50D (S.N. 270001- ) ........9015-15-47 Stay clear ............9000-01-2 Pressure compensator Pilot Operation-50D ..........
  • Page 677 Electrical - 35D (SN —260000) 50D (SN handling ............9031-25-1 —270000) ............ 9015-10-7 Refrigerant leak test .......... 9031-25-3 Electrical - 35D (SN 260001— ) 50D (SN Regulator 270001— ) ..........9015-10-31 Hydraulic pump 1 and 2, test and Hydraulic system-35D........9025-05-87 adjustment-35D..........
  • Page 678 -270000)............. 9015-15-37 Operational checks ........9005-10-18 Heating and air conditioning control circuit Travel system tracking while operating a dig - 35D (S.N. 260001- ) 50D (S.N. 270001- function ) ..............9015-15-41 Operational checks ........9005-10-19 Monitor controller circuit 35D (S.N.
  • Page 679 Engine harness (W10) 35D (S.N. Swing motor crossover relief, test and —260000) 50D (S.N. —270000)....9015-10-173 adjustment-35D.......... 9025-25-23 Engine harness (W10) 35D (S.N. 260001— ) ..........9015-10-177 Continued on next page Index-9 TM2263 (09JUL14) 35D and 50D Operation & Tests 070914 PN=9...
  • Page 680 Main harness (W8) - 35D (S.N. ROPS work light harness (W15) ....9015-10-218 260001—264999) ........9015-10-71 Work site hazards Main harness (W8) - 35D (S.N. 265000— Avoid .............. 9000-01-8 ) ..............9015-10-79 Main harness (W8) - 50D (S.N. —270000) ..........9015-10-95 Main harness (W8) - 50D (S.N.
  • Page 681 Index Index-11 TM2263 (09JUL14) 35D and 50D Operation & Tests 070914 PN=11...
  • Page 682 Index Index-12 TM2263 (09JUL14) 35D and 50D Operation & Tests 070914 PN=12...

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