Worldwide Construction And Forestry Division 27C ZTS User manual

27CZTSand35CZTS
Excavator
OperationandTests
TECHNICALMANUAL
27CZTSand35CZTSExcavator
OperationandTests
TM205217JUL18(ENGLISH)
WorldwideConstruction
AndForestryDivision
PRINTEDINU.S.A.

Introduction
DX,TMIFC-19-15APR14-1/1
Foreword
Thismanualiswrittenforanexperiencedtechnician.
Essentialtoolsrequiredinperformingcertainservicework
areidentifiedinthismanualandarerecommendedforuse.
Livewithsafety:Readthesafetymessagesinthe
introductionofthismanualandthecautionspresented
throughoutthetextofthemanual.
Thisisthesafety-alertsymbol.Whenyouseethis
symbolonthemachineorinthismanual,bealerttothe
potentialforpersonalinjury.
Technicalmanualsaredividedintwoparts:repairand
operationandtests.Repairsectionstellhowtorepair
thecomponents.Operationandtestssectionshelpyou
identifythemajorityofroutinefailuresquickly.
Informationisorganizedingroupsforthevarious
componentsrequiringserviceinstruction.Atthe
beginningofeachgrouparesummarylistingsofall
applicableessentialtools,serviceequipmentandtools,
othermaterialsneededtodothejob,servicepartskits,
specifications,weartolerances,andtorquevalues.
TechnicalManualsareconciseguidesforspecific
machines.Theyareon-the-jobguidescontainingonlythe
vitalinformationneededfordiagnosis,analysis,testing,
andrepair.
Fundamentalserviceinformationisavailablefromother
sourcescoveringbasictheoryofoperation,fundamentals
oftroubleshooting,generalmaintenance,andbasictype
offailuresandtheircauses.
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Introduction
TX,TM,FAX-19-03JUL01-1/1
TechnicalInformationFeedbackForm
Weneedyourhelptocontinuallyimproveourtechnical
publications.PleasecopythispageandFAXormailyour
comments,ideasandimprovements.
SENDTO:JohnDeereDubuqueWorks
18600SouthJohnDeereRoad
Attn:Publications,Dept.324
Dubuque,IA52004-0538
USA
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Introduction
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Contents
Section9000—GeneralInformation
Group01—Safety
Section9005—OperationalCheckout
Procedure
Group10—OperationalCheckoutProcedure
Section9010—Engine
Group05—TheoryofOperation
Group15—DiagnosticInformation
Group25—Tests
Section9015—ElectricalSystem
Group05—SystemInformation
Group10—SystemDiagrams
Group15—Sub-SystemDiagnostics
Group20—References
Section9020—PowerTrain
Group05—TheoryofOperation
Group15—DiagnosticInformation
Section9025—HydraulicSystem
Group05—TheoryofOperation
Group15—DiagnosticInformation
Group25—Tests
Section9031—Heater
Group05—TheoryofOperation
Group15—DiagnosticInformation
Group25—Tests
OriginalInstructions.Allinformation,illustrationsandspecificationsinthis
manualarebasedonthelatestinformationavailableatthetimeofpublication.
Therightisreservedtomakechangesatanytimewithoutnotice.
COPYRIGHT©2018
DEERE&COMPANY
Moline,Illinois
Allrightsreserved.
AJohnDeereILLUSTRUCTION™Manual
PreviousEditions
Copyright©2002,2006,2012,2014
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Contents
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Section9000
GeneralInformation
Contents
Page
Group01—Safety
RecognizeSafetyInformation...................9000-01-1
FollowSafetyInstructions..........................9000-01-1
OperateOnlyIfQualified...........................9000-01-1
WearProtectiveEquipment.......................9000-01-2
AvoidUnauthorizedMachine
Modifications..........................................9000-01-2
AddCabGuardingforSpecial
Uses......................................................9000-01-2
InspectMachine........................................9000-01-2
StayClearofMovingParts........................9000-01-3
AvoidHigh-PressureOils..........................9000-01-3
BewareofExhaustFumes........................9000-01-3
PreventFires.............................................9000-01-4
PreventBatteryExplosions.......................9000-01-4
HandleChemicalProductsSafely..............9000-01-4
DisposeofWasteProperly........................9000-01-5
PrepareforEmergencies...........................9000-01-5
UseStepsandHandholds
Correctly................................................9000-01-5
StartOnlyFromOperator'sSeat...............9000-01-5
UseandMaintainSeatBelt.......................9000-01-6
PreventUnintendedMachine
Movement..............................................9000-01-6
AvoidWorkSiteHazards...........................9000-01-6
KeepRidersOffMachine..........................9000-01-7
AvoidBackoverAccidents.........................9000-01-7
AvoidMachineTipOver............................9000-01-8
UseSpecialCareWhenLifting
Objects..................................................9000-01-8
AddandOperateAttachments
Safely.....................................................9000-01-8
ParkandPrepareforService
Safely.....................................................9000-01-9
ServiceCoolingSystemSafely.................9000-01-9
RemovePaintBeforeWeldingOr
Heating..................................................9000-01-9
MakeWeldingRepairsSafely.................9000-01-10
DriveMetalPinsSafely...........................9000-01-10
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Contents
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Group01
Safety
TX03679,00016CC-19-03JAN07-1/1
TX03679,00016F9-19-03JAN07-1/1
TX03679,00016FA-19-03JAN07-1/1
RecognizeSafetyInformation
Thisisthesafetyalertsymbol.Whenthissymbolis
noticedonthemachineorinthismanual,bealertfor
thepotentialofpersonalinjury.
Followtheprecautionsandsafeoperatingpractices
highlightedbythissymbol.
Asignalword—DANGER,WARNING,orCAUTION—
isusedwiththesafetyalertsymbol.DANGERidentifies
themostserioushazards.
Onthemachine,DANGERsignsareredincolor,
WARNINGsignsareorange,andCAUTIONsignsare
yellow.DANGERandWARNINGsignsarelocatednear
specifichazards.GeneralprecautionsareonCAUTION
labels.
T133555—UN—15APR13T133588—19—28AUG00
FollowSafetyInstructions
Readthesafetymessagesinthismanualandonthe
machine.Followthesewarningsandinstructionscarefully.
Reviewthemfrequently.
Besurealloperatorsofthismachineunderstandevery
safetymessage.Replaceoperator'smanualandsafety
labelsimmediatelyifmissingordamaged.
T133556—UN—24AUG00
OperateOnlyIfQualified
Donotoperatethismachineunlesstheoperator'smanual
hasbeenreadcarefully,andyouhavebeenqualifiedby
supervisedtrainingandinstruction.
Operatorshouldbefamiliarwiththejobsiteand
surroundingsbeforeoperating.Tryallcontrolsand
machinefunctionswiththemachineinanopenarea
beforestartingtowork.
Knowandobserveallsafetyrulesthatmayapplytoevery
worksituationandworksite.
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Safety
TX03679,00016D0-19-03JAN07-1/1
TX03679,00016B7-19-30OCT00-1/1
TX03679,00016CE-19-03JAN07-1/1
TX03679,0001734-19-17DEC14-1/1
WearProtectiveEquipment
Guardagainstinjuryfromflyingpiecesofmetalordebris;
weargogglesorsafetyglasses.
Wearclosefittingclothingandsafetyequipment
appropriatetothejob.
Prolongedexposuretoloudnoisecancauseimpairment
orlossofhearing.Wearsuitablehearingprotectionsuch
asearmuffsorearplugstoprotectagainstobjectionable
oruncomfortableloudnoises.
TS206—UN—15APR13
AvoidUnauthorizedMachineModifications
Modificationsofthismachine,oradditionofunapproved
productsorattachments,mayaffectmachinestabilityor
reliability,andmaycreateahazardfortheoperatoror
othersnearthemachine.
Alwayscontactanauthorizeddealerbeforemaking
machinemodificationsthatchangetheintendeduse,
weightorbalanceofthemachine,orthataltermachine
controls,performanceorreliability.
AddCabGuardingforSpecialUses
Specialworksituationsormachineattachmentsmay
createanenvironmentwithfallingorflyingobjects.
Workingnearanoverheadbank,doingdemolitionwork,
usingahydraulichammer,orworkinginawoodedarea,
forexample,mayrequireaddedguardingtoprotectthe
operator.
FOPS(fallingobjectprotectivestructures)andspecial
screensorguardingshouldbeinstalledwhenfallingor
flyingobjectsmayenterordamagethemachine.Contact
yourauthorizeddealerforinformationondevicesintended
toprovideprotectioninspecialworksituations.
T133733—UN—15SEP00
InspectMachine
Inspectmachinecarefullyeachdaybywalkingaroundit
beforestarting.
InspectandCleanthePolycarbonateWindows.See
InspectandCleanPolycarbonateWindows.(Section4-1.)
Keepallguardsandshieldsingoodconditionandproperly
installed.Fixdamageandreplacewornorbrokenparts
immediately.Payspecialattentiontohydraulichosesand
electricalwiring.
T6607AQ—UN—15APR13
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Safety
TX03679,00016D2-19-03JAN07-1/1
TX03679,00016D3-19-03NOV08-1/1
TX03679,00016D4-19-03NOV08-1/1
StayClearofMovingParts
Entanglementsinmovingpartscancauseseriousinjury.
Stopenginebeforeexamining,adjustingormaintaining
anypartofmachinewithmovingparts.
Keepguardsandshieldsinplace.Replaceanyguard
orshieldthathasbeenremovedforaccessassoonas
serviceorrepairiscomplete.
T133592—UN—15APR13
AvoidHigh-PressureOils
Thismachineusesahigh-pressurehydraulicsystem.
Escapingoilunderpressurecanpenetratetheskin
causingseriousinjury.
Neversearchforleakswithyourhands.Protecthands.
Useapieceofcardboardtofindlocationofescapingoil.
Stopengineandrelievepressurebeforedisconnecting
linesorworkingonhydraulicsystem.
Ifhydraulicoilpenetratesyourskin,seeadoctor
immediately.Injectedoilmustberemovedsurgically
withinhoursorgangrenemayresult.Contacta
knowledgeablemedicalsourceortheDeere&Company
MedicalDepartmentinMoline,Illinois,U.S.A.
T133509—UN—15APR13T133840—UN—20SEP00
BewareofExhaustFumes
Preventasphyxiation.Engineexhaustfumescancause
sicknessordeath.
Ifyoumustoperateinanenclosedspace,provide
adequateventilation.Useanexhaustpipeextensionto
removetheexhaustfumesoropendoorsandwindowsto
bringoutsideairintothearea.
T133546—UN—24AUG00
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Safety
TX03679,00016F5-19-03NOV08-1/1
TX03679,000174A-19-03NOV08-1/1
TX03679,00016D7-19-31JAN07-1/1
PreventFires
HandleFuelSafely:Storeflammablefluidsawayfrom
firehazards.Neverrefuelmachinewhilesmokingorwhen
nearsparksorflame.
CleanMachineRegularly:Keeptrash,debris,grease
andoilfromaccumulatinginenginecompartment,around
fuellines,hydrauliclines,exhaustcomponents,and
electricalwiring.Neverstoreoilyragsorflammable
materialsinsideamachinecompartment.
MaintainHosesandWiring:Replacehydraulichoses
immediatelyiftheybegintoleak,andcleanupanyoil
spills.Examineelectricalwiringandconnectorsfrequently
fordamage.
KeepAFireExtinguisherAvailable:Alwayskeepa
multipurposefireextinguisheronornearthemachine.
Knowhowtouseextinguisherproperly.
T133552—UN—15APR13
T133553—UN—07SEP00
T133554—UN—07SEP00
PreventBatteryExplosions
Batterygascanexplode.Keepsparks,lightedmatches,
andopenflameawayfromthetopofbattery.
Nevercheckbatterychargebyplacingametalobject
acrosstheposts.Useavoltmeterorhydrometer.
Donotchargeafrozenbattery;itmayexplode.Warm
batteryto16°C(60°F).
TS204—UN—15APR13
HandleChemicalProductsSafely
Exposuretohazardouschemicalscancauseserious
injury.Undercertainconditions,lubricants,coolants,
paintsandadhesivesusedwiththismachinemaybe
hazardous.
Ifuncertainaboutsafehandlingoruseofthesechemical
products,contactyourauthorizeddealerforaMaterial
SafetyDataSheet(MSDS).TheMSDSdescribesphysical
andhealthhazards,safeuseprocedures,andemergency
responsetechniquesforchemicalsubstances.Follow
MSDSrecommendationstohandlechemicalproducts
safely.
T133580—UN—25AUG00
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Safety
TX03679,0001733-19-03JAN07-1/1
TX03679,000174B-19-03JAN07-1/1
TX03679,00016F2-19-24APR13-1/1
TX03679,0001799-19-22APR10-1/1
DisposeofWasteProperly
Improperdisposalofwastecanthreatentheenvironment.
Fuel,oils,coolants,filtersandbatteriesusedwiththis
machinemaybeharmfulifnotdisposedofproperly.
Neverpourwasteontotheground,downadrain,orinto
anywatersource.
Airconditioningrefrigerantscandamagetheatmosphere.
Governmentregulationsmayrequireusingacertified
servicecentertorecoverandrecycleusedrefrigerants.
Ifuncertainaboutthesafedisposalofwaste,contactyour
localenvironmentalorrecyclingcenteroryourauthorized
dealerformoreinformation.
T133567—UN—25AUG00
PrepareforEmergencies
Bepreparedifanemergencyoccursorafirestarts.
Keepafirstaidkitandfireextinguisherhandy.
Keepemergencynumbersfordoctors,ambulanceservice,
hospital,andfiredepartmentnearyourtelephone.
TS291—UN—15APR13
UseStepsandHandholdsCorrectly
Preventfallsbyfacingthemachinewhengettingonand
off.Maintain3-pointcontactwithstepsandhandrails.
Neverusemachinecontrolsashandholds.
Useextracarewhenmud,snow,ormoisturepresent
slipperyconditions.Keepstepscleanandfreeofgrease
oroil.Neverjumpwhenexitingmachine.Nevermountor
dismountamovingmachine.
T133468—UN—15APR13
StartOnlyFromOperator'sSeat
Avoidunexpectedmachinemovement.Startengineonly
whilesittinginoperator'sseat.Ensureallcontrolsand
workingtoolsareinproperpositionforaparkedmachine.
Neverattempttostartenginefromtheground.Donot
attempttostartenginebyshortingacrossthestarter
solenoidterminals.
T133715—UN—15APR13
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Safety
TX03679,00016DD-19-03NOV08-1/1
TX03679,0001746-19-24JAN07-1/1
TX14740,0001E9F-19-30JUN10-1/1
UseandMaintainSeatBelt
Useseatbeltwhenoperatingmachine.Rememberto
fastenseatbeltwhenloadingandunloadingfromtrucks
andduringotheruses.
Examineseatbeltfrequently.Besurewebbingisnot
cutortorn.Replaceseatbeltimmediatelyifanypartis
damagedordoesnotfunctionproperly.
Thecompleteseatbeltassemblyshouldbereplaced
every3years,regardlessofappearance.
T133716—19—17APR13
PreventUnintendedMachineMovement
Becarefulnottoaccidentallyactuatecontrolleverswhen
co-workersarepresent.Pullpilotcontrolshutoffleverto
lockedpositionduringworkinterruptions.Pullpilotcontrol
shutofflevertolockedpositionandstopenginebefore
allowinganyonetoapproachmachine.
Alwayslowerworkequipmenttothegroundandpullpilot
controlshutofflevertolockedpositionbeforestandingup
orleavingtheoperator'sseat.Stopenginebeforeexiting.
T133863—UN—20SEP00
AvoidWorkSiteHazards
Avoidcontactwithgaslines,buriedcablesandwater
lines.Callutilitylinelocationservicestoidentifyall
undergroundutilitiesbeforeyoudig.
Prepareworksiteproperly.Avoidoperatingnear
structuresorobjectsthatcouldfallontothemachine.Clear
awaydebristhatcouldmoveunexpectedlyifrunover.
Avoidboomorarmcontactwithoverheadobstacles
oroverheadelectricallines.Nevermoveanypartof
machineorloadcloserthan3m(10ft)plustwicetheline
insulatorlengthtooverheadwires.
Keepbystandersclearatalltimes.Keepbystanders
awayfromraisedbooms,attachments,andunsupported
loads.Avoidswingingorraisingbooms,attachments,or
loadsoverornearpersonnel.Usebarricadesorasignal
persontokeepvehiclesandpedestriansaway.Usea
signalpersonifmovingmachineincongestedareasor
wherevisibilityisrestricted.Alwayskeepsignalpersonin
view.Coordinatehandsignalsbeforestartingmachine.
Operateonlyonsolidfootingwithstrengthsufficientto
supportmachine.Whenworkingclosetoanexcavation,
positiontravelmotorsawayfromthehole.
Reducemachinespeedwhenoperatingwithtoolonor
neargroundwhenobstaclesmaybehidden(e.g.,during
snowremovalorclearingmud,dirt,etc.).Athighspeeds
hittingobstacles(rocks,unevenconcreteormanholes)
cancauseasuddenstop.Alwayswearyourseatbelt.
T153094—UN—01APR02T153096—UN—01APR02T153097—UN—01APR02
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Safety
TX14740,0001E7A-19-19MAR02-1/1
TX14740,0001E7B-19-19MAR02-1/1
KeepRidersOffMachine
Onlyallowoperatoronmachine.
Ridersaresubjecttoinjury.Theymayfallfrommachine,
becaughtbetweenmachineparts,orbestruckbyforeign
objects.
Ridersmayobstructoperator’svieworimpairhisability
tooperatemachinesafely.
T120807—UN—14APR99
AvoidBackoverAccidents
Beforemovingmachine,besureallpersonsareclear
ofbothtravelandswingpaths.Turnaroundandlook
directlyforbestvisibility.Usemirrorstoassistinchecking
allaroundmachine.Keepwindowsandmirrorsclean,
adjusted,andingoodrepair.
Becertaintravelalarmisworkingproperly.
Useasignalpersonwhenbackingifviewisobstructed
orwheninclosequarters.Keepsignalpersoninviewat
alltimes.Useprearrangedhandsignalstocommunicate.
T120806—UN—14APR99
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Safety
TX03679,00016DF-19-30JUN16-1/1
TX03679,00016E1-19-08JUL15-1/1
TX03679,00016F0-19-12FEB07-1/1
AvoidMachineTipOver
Useseatbeltatalltimes.
Donotjumpifthemachinetips.Operatorwillbeunlikely
tojumpclearandthemachinemaycrushtheoperator.
Loadandunloadfromtrucksortrailerscarefully.Be
suretruckiswideenoughandonafirmlevelsurface.
Useloadingrampsandattachthemproperlytotruckbed.
Avoidtruckswithsteelbedsbecausetracksslipmore
easilyonsteel.
Becarefulonslopes.Useextracareonsoft,rocky
orfrozenground.Machinemayslipsidewaysinthese
conditions.Whentravelingupordownslopes,keepthe
bucketonuphillsideandjustabovegroundlevel.
Becarefulwithheavyloads.Usingoversizebucketsor
liftingheavyobjectsreducesmachinestability.Extending
aheavyloadorswingingitoversideofundercarriage
maycausemachinetotip.
Ensuresolidfooting.Useextracarewhenoperating
nearbanksorexcavationsthatmaycave-inandcause
machinetotiporfall.
T133716—19—17APR13
UseSeatBelt
T133545—UN—15SEP00
UnloadingMachine
T133803—UN—27SEP00
DoNotJump
UseSpecialCareWhenLiftingObjects
Neverusethismachinetoliftpeople.
Neverliftaloadaboveanotherperson.Keepbystanders
clearofallareaswherealoadmightfallifitbreaksfree.
Donotleavetheseatwhenthereisaraisedload.
Donotexceedliftcapacitylimitspostedonmachineand
inthismanual.Extendingheavyloadstoofarorswinging
overundercarriagesidemaycausemachinetotipover.
Useproperriggingtoattachandstabilizeloads.Besure
slingsorchainshaveadequatecapacityandareingood
T133839—UN—27SEP00
UseSpecialCareWhenLiftingObjects
condition.Usetetherlinestoguideloadsandprearranged
handsignalstocommunicatewithco-workers.
AddandOperateAttachmentsSafely
Alwaysverifycompatibilityofattachmentsbycontacting
yourauthorizeddealer.Addingunapprovedattachments
mayaffectmachinestabilityorreliabilityandmaycreatea
hazardforothersnearthemachine.
Ensurethataqualifiedpersonisinvolvedinattachment
installation.Addguardstomachineifoperatorprotection
isrequiredorrecommended.Verifythatallconnections
aresecureandattachmentrespondsproperlytocontrols.
Carefullyreadattachmentmanualandfollowall
instructionsandwarnings.Inanareafreeofbystanders
andobstructions,carefullyoperateattachmenttolearnits
characteristicsandrangeofmotion.
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Safety
TX03679,00016E9-19-03JAN07-1/1
DX,RCAP-19-04JUN90-1/1
TX03679,0001732-19-06SEP00-1/1
ParkandPrepareforServiceSafely
Warnothersofservicework.Alwaysparkandprepare
yourmachineforserviceorrepairproperly.
•Parkmachineonalevelsurfaceandlowerequipment
andattachmentstotheground.
•Placepilotshutoffleverin“lock”position.Stopengine
andremovekey.
•Attacha“DoNotOperate”taginanobviousplacein
theoperator'sstation.
Securelysupportmachineorattachmentbeforeworking
underit.
•Donotsupportmachinewithboom,arm,orother
hydraulicallyactuatedattachments.
•Donotsupportmachinewithcinderblocksorwooden
piecesthatmaycrumbleorcrush.
•Donotsupportmachinewithasinglejackorother
devicesthatmayslipoutofplace.
Understandserviceproceduresbeforebeginningrepairs.
Keepserviceareacleananddry.Usetwopeople
whenevertheenginemustberunningforservicework.
T133332—19—17APR13TS229—UN—23AUG88
ServiceCoolingSystemSafely
Explosivereleaseoffluidsfrompressurizedcooling
systemcancauseseriousburns.
Shutoffengine.Onlyremovefillercapwhencoolenough
totouchwithbarehands.Slowlyloosencaptofirststop
torelievepressurebeforeremovingcompletely.
TS281—UN—15APR13
RemovePaintBeforeWeldingOrHeating
Hazardousfumescanbegeneratedwhenpaintisheated
byweldingorusingatorch.Dustfromsandingorgrinding
paintcanalsobehazardous.
Removepainttoatleast76mm(3in.)fromareato
beheated.Wearanapprovedrespiratorwhensanding
orgrindingpaint.Ifasolventorpaintstripperisused,
washareawithsoapandwater.Removesolventorpaint
strippercontainersfromworkareaandallowfumesto
disperseatleast15minutesbeforeweldingorheating.
Workoutsideorinawell-ventilatedarea.Disposeof
waste,paintandsolventsproperly.
T133546—UN—24AUG00
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Safety
TX03679,00016D5-19-25APR08-1/1
TX03679,0001745-19-03JAN07-1/1
MakeWeldingRepairsSafely
IMPORTANT:Disableelectricalpowerbefore
welding.Turnoffmainbatteryswitch
ordisconnectpositivebatterycable.
Separateharnessconnectorstoengineand
vehiclemicroprocessors.
Avoidweldingorheatingnearpressurizedfluidlines.
Flammablespraymayresultandcausesevereburnsif
pressurizedlinesfailasaresultofheating.Donotletheat
gobeyondworkareatonearbypressurizedlines.
Removepaintproperly.Donotinhalepaintdustorfumes.
Useaqualifiedweldingtechnicianforstructuralrepairs.
T133547—UN—15APR13
Makesurethereisgoodventilation.Weareyeprotection
andprotectiveequipmentwhenwelding.
DriveMetalPinsSafely
Alwayswearprotectivegogglesorsafetyglassesand
otherprotectiveequipmentbeforestrikinghardened
parts.Hammeringhardenedmetalpartssuchaspinsand
bucketteethmaydislodgechipsathighvelocity.
Useasofthammerorabrassbarbetweenhammerand
objecttopreventchipping.
T133738—UN—15APR13
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Section9005
OperationalCheckoutProcedure
Contents
Page
Group10—OperationalCheckoutProcedure
OperationalCheckout................................9005-10-1
OperatorStationChecks—KeySwitch
On,EngineOff......................................9005-10-1
OperationalChecks—Engine
On.........................................................9005-10-6
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