tm1610 - 410e backhoe loader operation and

test
Technical Manual

Main Sections

Foreword

HELP!! HELP!! HELP!! HELP!!

General Information

Safety Information

General Specifications

Torque Values

Fuels and Lubricants

Operational Checkout
Procedure

Operational Checkout Procedure

ENGINE

Theory of Operation

Diagnostic Information

Adjustments
 Tests

Electrical System

System Information

System Diagrams

Sub-System Diagnostics

References

Power Train

Theory of Operation

System Diagnostic Information

Adjustments

Tests

Hydraulic System

Theory of Operation

Diagnostic Information

Adjustments

Tests

Heating And Air Conditioning

Theory Of Operation

System Operational Checks

Diagnostic Information
Adjustments

Test
 Table of Contents

tm1610 - 410e backhoe loader operation and

test

Table of Contents
Foreword

HELP!! HELP!! HELP!! HELP!!

Section 9000: General Information

Group 01: Safety Information

Handle Fluids Safely-Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

4
 Table of Contents
Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 02: General Specifications

410E Backhoe Loader Dimensions

410E Backhoe Loader Specifications

Other Information-410E Backhoe Loader

410E Backhoe Loader Weight

410E Backhoe and Loader Buckets

410E Backhoe Loader Drain and Refill Capacities

410E Backhoe Loader Lifting Capacities-Standard Dipperstick

410E Backhoe Loader Lifting Capacities-Extendible Dipperstick

(Retracted)

410E Backhoe Loader Lifting Capacities-Extendible Dipperstick

(Extended)

Group 03: Torque Values

Hardware Torque Specifications

ROPS Torque Specifications

5
 Table of Contents
Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

O-Ring Groove Connections

Check Oil Lines And Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Flat Face O-Ring Seal Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Group 04: Fuels and Lubricants

Diesel Fuel

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Do Not Use Galvanized Containers

Fuel Tank

Diesel Engine Oil

Transmission, Rear Axle and Mechanical Front Wheel Drive Oil

Hydraulic Oil

Diesel Engine Coolant

Grease

Grease For Extendible Dipperstick

Alternative and Synthetic Lubricants

Lubricant Storage

6
 Table of Contents
Mixing of Lubricants

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout Procedure

Section 9010: ENGINE

Group 05: Theory of Operation

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

Engine-Sectional View

General Engine Description

Group 15: Diagnostic Information

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

Make Visual Inspection of Engine and Supporting Systems

Diagnose Engine Malfunctions

Group 20: Adjustments

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

JT05801 Clamp-On Electronic Tachometer Installation

Adjust Speed Control Lever Tension

Slow and Fast Idle

Engine Speed Control Linkage

Group 25: Tests

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

JT05801 Clamp-On Electronic Tachometer Installation

7
 Table of Contents
JT05800 Digital Thermometer Installation

Air Intake System Leakage Test

Radiator Air Flow Test

Turbocharger Boost Pressure-Engine Performance Test

Injection Pump Timing

Fuel Line Leakage Test

Section 9015: Electrical System

Group 05: System Information

Visually Inspect Electrical System

Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Multimeter

Seven Step Electrical Test Procedure

System Functional Schematic Information

Reading a System Functional Schematic

Reading a Component Location Diagram

Electrical Schematic Symbols

Group 10: System Diagrams

Component Identification Table

Fuse (Blade-Type) Color Codes

8
 Table of Contents
Fuse Specifications

Wiring and Schematic Diagrams Legend

System Functional Schematic Section Legend

System Functional Schematic

Cab Roof Harness (W5) Component Location

Cab Roof Harness (W5) Connectors, Wire and Pin Location

Cab Side Console Harness (W6) Component Location

Cab Side Console Harness (W6) Connectors, Wire and Pin Location

Front Console Harness (W7) Component Location

Front Console Harness (W7) Component Location (With Optional Power

Shift)

Front Console Harness (W7) Connectors, Wire and Pin Location

Engine Harness (W8) Component Location

Engine Harness (W8) Component Location (With Optional Power Shift)

Engine Harness (W8) Connectors, Wire and Pin Location

Blower Harness (W10) Component Location

Blower Harness (W10) Connectors, Wire and Pin Location

Radio Harness (W12) Component Location

Radio Harness (W12) Connectors, Wire and Pin Location

Air Conditioning Compressor Harness (W11) Component Location

Air Conditioning Compressor Harness (W11) Connectors, Wire and Pin

Location

Selective Flow Valve Harness (W15) Component Location

Selective Flow Valve Harness (W15) Connectors, Wire and Pin Location

9
 Table of Contents
Ride Control Harness (W17) Component Location

Ride Control Harness (W17) Connectors, Wire and Pin Location

Pin Disconnect Harness (W18) Component Location

Pin Disconnect Harness (W18) Connectors, Wire and Pin Location

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory Of Operation

Power Circuit Schematic

Sub-System Diagnostics/Power Circuit

Start Circuit Operational Information

Start Circuit Theory of Operation

Start Circuit Schematic

Sub-System Diagnostics/Start Circuit

Charging Circuit Operational Information

Charging Circuit Theory of Operation

Charge Circuit Schematic

Sub-System Diagnostics/Charging Circuit

Differential Lock Circuit Operational Information

Differential Lock Circuit Theory of Operation

Differential Lock Circuit Schematic

Sub-System Diagnostics/Differential Lock Circuit

MFWD Circuit Operational Information

MFWD Circuit Theory of Operation

10
 Table of Contents
MFWD Circuit Schematic

Sub-System Diagnostics/MFWD Circuit

Display Monitor Circuit Operational Information

Display Monitor Circuit Theory Of Operation

Display Monitor Circuit Schematic

Sub-System Diagnostics/Display Monitor

Indicator Circuit Specifications

Indicator Circuit Operational Information

Indicator Circuit Theory of Operation

Indicator Circuit Schematic

Sub-System Diagnostics/Indicator Circuit

Park Brake/FNR Circuit Operational Information

Park Brake/FNR Circuit Specifications

Park Brake/Neutral Disconnect Circuit (Manual Shift) Theory Of Operation

Park Brake/FNR Circuit (Manual Shift) Schematic

Park Brake/FNR Circuit (Power Shift) Theory of Operation

Park Brake/FNR Circuit (Power Shift) Schematic

Sub-System Diagnostics/Park Brake/FNR Circuit

Ride Control Circuit Operational Information

Ride Control Circuit Theory of Operation

Ride Control Circuit Schematic

Sub-System Diagnostics/Ride Control Circuit

Selective Flow Valve Circuit Operational Information

11
 Table of Contents
Selective Flow Valve Circuit Theory of Operation

Selective Flow Valve Circuit Schematic

Sub-System Diagnostics/Selective Flow Valve Circuit

Pin Disconnect Circuit Operational Information

Pin Disconnect Circuit Theory of Operation

Pin Disconnect Circuit Schematic

Sub-System Diagnostics/Pin Disconnect Circuit

Group 20: References

Alternators and Starting Motors-Use CTM77

JT05801 Clamp-On Electronic Tachometer Installation

Battery Operation

Battery Specifications

Diagnose Battery Malfunctions

Check Battery Electrolyte Level and Terminals

Using Booster Batteries-12 Volt System

Alternator Operation-65 Amp Bosch and 95 Amp Bosch

Alternator Operation-65 Amp Bosch and 95 Amp Bosch (Continued)

Tachometer Calibration (S.N. -852337)

Tachometer Calibration (S.N. 852338- )

Section 9020: Power Train

Group 05: Theory of Operation

Forward, Reverse, Low Range Forward and Third Speed Clutch Pack
Operation

12
 Table of Contents
Power Shift High Range Forward, First Speed and Second Speed Clutch
Packs

Manual Shift Power Train Overview

Torque Converter Operation

Manual Shift Synchronizer Operation

Transmission Pump Operation

Transmission Filter Operation

Manual Shift Transmission Operation-First Gear Forward

Manual Shift Transmission Operation-Third Gear Reverse

Power Shift Power Train Overview

Power Shift Transmission Gear Flow

Mechanical Front Wheel Drive (MFWD) Operation

Manual Shift Transmission Control Valve Operation

Manual Shift Transmission Control Circuit-Neutral With Park Brake Off

Manual Shift Transmission Control Circuit-Forward

Manual Shift Transmission Control Circuit-Reverse

Power Shift Transmission Clutch Engagement And Solenoids Activated

Power Shift Transmission Control Circuit-Neutral With Park Brake Off

Power Shift Transmission Control Valve and Shift Valve Operation-Neutral

Power Shift Transmission Control Circuit-First Forward

Power Shift Transmission Control Valve and Shift Valve-First Forward

Power Shift Transmission Control Circuit-High Range (Fourth) Forward

Power Shift Transmission Control Valve and Shift Valve-High Range

(Fourth) Forward

13
 Table of Contents
Power Shift Transmission Control Circuit-First Reverse

Power Shift Transmission Control Valve and Shift Valve-First Reverse

Manual Shift Modulation Valve Operation

Power Shift Modulation Valve Operation

Differential Operation

Differential Lock Operation

John Deere Brake Valve Operation

Service Brake Operation

MICO Power Boost Brake Valve-Neutral Position

MICO Power Boost Brake Valve-Both Pedals Applied Position

MICO Power Boost Brake Valve-One Pedal Applied Position

MICO Power Boost Brake Valve-Both Pedals Applied, Engine Off Position

Park Brake Operation

MFWD Differential Operation-Unequal Traction

MFWD Differential Operation-Equal Traction-If Equipped

Group 15: System Diagnostic Information

Diagnose Manual Shift Power Train Malfunction

Diagnose Power Shift Power Train Malfunction

Diagnose MFWD Malfunction

Diagnose Rear Axle Malfunction

Hydraulic Circuit Symbols

Group 20: Adjustments

Adjust Brake Pedals and Equalizing Valves

14
 Table of Contents
Bleeding Brakes

Checking and Adjusting Toe-In

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Transmission Oil Warm-Up Procedure

Manual Shift Transmission Overall Test Connections, Ports, and

Locations

Power Shift Transmission Overall Test Connections, Ports, and Locations

Torque Converter Stall Speed Test

Converter-In Relief Valve Test

Brake Valve Leakage Test

Park Brake Release Pressure Test

System Pressure Test

Manual Shift Forward and Reverse Clutch Pressure Test

Power Shift Low Range Forward, High Range Forward, Reverse and
Speed Clutch Pressure Test

Reducing Valve Pressure Test

Modulation Valve Pressure Test

Differential Lock Pressure Test

MFWD Pressure Test-If Equipped

Cooler In and Cooler Out Pressure Test

Solenoid Circuit Leakage Test

Pump Flow Test

15
 Table of Contents

Section 9025: Hydraulic System

Group 05: Theory of Operation

Backhoe Hydraulic System

Hydraulic Component Location

Hydraulic System Schematic-Neutral

Hydraulic System Schematic-Multiple Functions Activated

Hydraulic System Schematic-Neutral with Power Boost MICO Brake Valve

Hydraulic System Schematic-Multiple Functions Activated with Power

Boost MICO Brake Valve

Hydrualic Component Location-Power Boost MICO Brake Valve Circuit-

Both Pedals Applied

Load Sense Isolator

Load Sense With All Functions in Neutral

Load Sense With One Function Activated

Load Sense With Multiple Functions Activated

Load Sense With Multiple Functions Activated (One Function Stalled)

Hydraulic Pump-Neutral Operation

Hydraulic Pump-Full Stroke

Hydraulic Pump Controls-Neutral

Hydraulic Pump Controls-Function Metering

Hydraulic Pump Controls-Full Flow

Hydraulic Pump Controls-Flow Limited (High Pressure)

Hydraulic Filter Operation

Steering-No Steering

16
 Table of Contents
Steering

Secondary Steering

Ride Control Hydraulic Component Location Circuit-Off

Ride Control Valve Operation “OFF” Position-Continued

Ride Control Hydraulic Component Location Circuit-On Position

Ride Control Valve Operation “ON” Position-Continued

Circuit Relief Valve without Anti-Cavitation-Loader and Backhoe

Circuit Relief Valve with Anti-Cavitation-Loader and Backhoe-Continued

Circuit Relief Valve with Anti-Cavitation-Loader and Backhoe (Continued)

Backhoe Auxiliary Flow Control Circuit Relief Valve

Stabilizer Valve Operation

Backhoe Inlet Section with Swing Section Activated

Backhoe Auxiliary Flow Valve-Solenoid Energized

Backhoe Swing Section-Swing Right Position

Backhoe Boom Section-Boom Raise Position

Backhoe Bucket Section-Bucket Curl Position

Backhoe Crowd Section-Crowd In Position

Backhoe Auxiliary Section-Neutral

Backhoe Endcap Outlet Section

Loader Inlet Endcap Section with Bucket Section Activated

Loader Bucket Section-Bucket Rollback Position

Loader Boom Section-Boom Raise Position

Loader Auxiliary Section-Load Position

17
 Table of Contents
Loader Endcap Outlet Section

Group 15: Diagnostic Information

Use These Seven Basic Steps to Diagnose and Test the Hydraulic System

Make a Pretest Inspection and an Operation Check of the Machine

Hydraulic System Pretest

Diagnose Steering System Malfunctions

Diagnose Hydraulic System Problems

Group 20: Adjustments

Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch

Adjustment

Loader Control Valve Linkage Adjustment

Backhoe Valve Linkage Adjustment

Stabilizer Valve Linkage Adjustment

Group 25: Tests

Pre-Test Diagnostics

Diagnostics Flow Charts

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Hydraulic Oil Warm-Up Procedure

Pump Load Sense Differential Pressure Test

Pump Flow Test

Backhoe Load Sense and Loader Load Sense Relief Stall Pressure Test

Steering Load Sense Relief Valve Stall Pressure Test

18
 Table of Contents
Flow Limiter Test

Hydraulic Oil Cooler Restriction Test

Circuit Relief Valve Test with Remote Pump

Charging the Ride Control Accumulator

Charging the Ride Control Accumulator-Procedure “A” (14.2 in.

accumulator)

Charging the Ride Control Accumulator-Procedure “B” (17.2 in.

accumulator)

Ride Control Accumulator Discharge Procedure

Steering System Leakage Test

Steering Cylinder Leakage Test

Hydraulic Cylinder Drift Test Procedure

Function Drift Test

Cylinder Leakage Test

Stabilizer Valve Lockout Leakage Test

Cycle Time Specifications-410E

Section 9031: Heating And Air Conditioning

Group 05: Theory Of Operation

Proper Refrigerant Handling

R134A Refrigerant Cautions

Refrigerant Theory Of Operation

Air Conditioning Circuit Operational Information

Air Conditioning Circuit Theory Of Operation

Air Conditioning Circuit Schematic

19
 Table of Contents
Blower Circuit Operational Information

Blower Circuit Theory Of Operation

Blower Circuit Schematic

Receiver/Dryer Operation

Expansion Valve Operation

Compressor Relief Valve Operation

Temperature Control

Group 10: System Operational Checks

Air Conditioning Operational Checks

Group 15: Diagnostic Information

Diagnose Air Conditioning Electrical Malfunctions

Air Conditioning Component Location

Group 20: Adjustments

Special or Essential Tools

Service Equipment and Tools

Other Materials

Proper Refrigerant Handling

R134A Refrigerant Cautions

R134A Compressor Oil Charge Check

R134A Compressor Oil Removal

R134A Component Oil Charge

R134A Refrigerant Recovery, Recycling And Charging Station Installation

Procedure

20
 Table of Contents
Recover R134A System

Evacuate R134A System

Charge R134A System

Group 25: Test

Special or Essential Tools

Service Equipment and Tools

Proper Refrigerant Handling

R134A Refrigerant Cautions

R134A Air Conditioning System Test

Pressure Diagnostic Chart

Low Pressure Switch Test

High Pressure Switch Test

A/C Freeze Control Switch

Leak Testing

Refrigerant Hoses And Tubing Inspection

21
 Foreword

Foreword

This manual is written for an experienced technician. Essential tools required in

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

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

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

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

Information is organized in groups for the various components requiring service

instruction. At the beginning of each group are summary listings of all applicable
essential tools, service equipment and tools, other materials needed to do the job,
service parts kits, specifications, wear tolerances, and torque values.

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

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

1. Section 9000:

To include any specifications, oil capacity and safety updates.

2. Section 9005:

To include miscellaneous updates.

3. Section 9010:

To include miscellaneous updates.

4. Section 9015:

To include serial number for tachometer, updates for selective flow control
valve harness, timer relay updates, and miscellaneous updates.
22
 Foreword
5. Section 9020:

To add keys and legend to foldout pages and control valves in theory of
operation section. To add miscellaneous updates.

6. Section 9025:

To update cycle times, change ride control accumulator specifications and

miscellaneous updates.

7. Section 9031:

To update miscellaneous nomenclature.

TX,INTR,MB52-19-1997/09/12

23
 HELP!! HELP!! HELP!! HELP!!

HELP!! HELP!! HELP!! HELP!!

We need your help to continually improve our technical publications. Please FAX or
mail your comments, ideas and improvements.

-: Send To Address

SEND TO: John Deere Dubuque Works

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

FAX NUMBER: 319-589-5800

-: Ideas, Comments

Ideas, Comments (Please State Page Number):

-: Rating Scale

OVERALL, how would you rate the quality of "ALL" Installation Instructions provided to
you? (Check one)

Poor Fair Good Very Good Excellent

1 2 3 4 5 6 7 8 9 10

-: Return Address

Company Name

24
 HELP!! HELP!! HELP!! HELP!!

Address

Phone

FAX No.

Dealer Acct. No.

THANK YOU!

TX,II,FAX-19-1996/12/05

25
 Handle Fluids Safely-Avoid Fires

Handle Fluids Safely-Avoid Fires

TS227-UN: Avoid Fires

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture
pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

DX,FLAME-19-1998/09/29

26
 Handle Fluids Safely-Avoid Fires

Handle Fluids Safely-Avoid Fires

TS227-UN: Avoid Fires

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture
pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

DX,FLAME-19-1998/09/29

27
 Handle Fluids Safely-Avoid Fires

Handle Fluids Safely-Avoid Fires

TS227-UN: Avoid Fires

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture
pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

DX,FLAME-19-1998/09/29

28
 Prevent Battery Explosions

Prevent Battery Explosions

TS204-UN: Battery Explosions

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

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

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

DX,SPARKS-19-1993/03/03

29
 Prepare for Emergencies

Prepare for Emergencies

TS291-UN: First Aid Kit

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

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

DX,FIRE2-19-1993/03/03

30
 Prevent Acid Burns

Prevent Acid Burns

TS203-UN: Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
31
 Prevent Acid Burns

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15-30 minutes. Get medical attention
immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3. Get medical attention immediately.

DX,POISON-19-1993/04/21

32
 Handle Chemical Products Safely

Handle Chemical Products Safely

TS1132-UN: Material Safety Data Sheet

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous
chemicals used with John Deere equipment include such items as lubricants, coolants,
paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products:
physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you
will know exactly what the risks are and how to do the job safely. Then follow
procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere
equipment.)

DX,MSDS,NA-19-1993/03/03

33
 Avoid High-Pressure Fluids

Avoid High-Pressure Fluids

X9811-UN: High-Pressure Fluids

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

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure
fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information
is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

DX,FLUID-19-1993/03/03

34
 Park Machine Safely

Park Machine Safely

TS230-UN: Remove the Key

Before working on the machine:

Lower all equipment to the ground.

Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.

DX,PARK-19-1990/06/04

35
 Support Machine Properly

Support Machine Properly

TS229-UN: Support Properly

Always lower the attachment or implement to the ground before you work on the
machine. If you must work on a lifted machine or attachment, securely support the
machine or attachment. If left in a raised position, hydraulically supported devices can
settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble
under continuous load. Do not work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.

When implements or attachments are used with a tractor, always follow safety
precautions listed in the implement operator's manual.

DX,LOWER-19-1999/02/17

36
 Wear Protective Clothing

Wear Protective Clothing

TS206-UN: Protective Clothing

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

Operating equipment safely requires the full attention of the operator. Do not wear radio
or music headphones while operating machine.

DX,WEAR2-19-1993/03/03

37
 Work in Clean Area

Work in Clean Area

T6642EJ-UN: Clean Work Area

Before starting a job:

Clean work area and machine.

Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt shortcuts.

DX,CLEAN-19-1990/06/04

38
 Service Machines Safely

Service Machines Safely

TS228-UN: Moving Parts

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace
when you work near machine tools or moving parts. If these items were to get caught,
severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving
parts.

DX,LOOSE-19-1990/06/04

39
 Work In Ventilated Area

Work In Ventilated Area

TS220-UN: Engine Exhaust Fumes

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine
in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe
extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into
the area

DX,AIR-19-1999/02/17

40
 Illuminate Work Area Safely

Illuminate Work Area Safely

TS223-UN: Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a portable safety light for working
inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot
filament of an accidentally broken bulb can ignite spilled fuel or oil.

DX,LIGHT-19-1990/06/04

41
 Replace Safety Signs

Replace Safety Signs

TS201-UN: Safety Signs

Replace missing or damaged safety signs. See the machine operator’s manual for
correct safety sign placement.

DX,SIGNS1-19-1990/06/04

42
 Use Proper Lifting Equipment

Use Proper Lifting Equipment

TS226-UN: Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the

manual.

DX,LIFT-19-1990/06/04

43
 Remove Paint Before Welding or Heating

Remove Paint Before Welding or Heating

TS220-UN: Toxic Fumes

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or

using a torch.

Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.

Remove paint before welding or heating:

If you sand or grind paint, avoid breathing the dust. Wear an approved
respirator.
If you use solvent or paint stripper, remove stripper with soap and water before
welding. Remove solvent or paint stripper containers and other flammable
material from area. Allow fumes to disperse at least 15 minutes before welding
or heating.

DX,PAINT-19-1993/03/03

44
 Avoid Heating Near Pressurized Fluid Lines

Avoid Heating Near Pressurized Fluid Lines

TS953-UN: Flammable Spray

Flammable spray can be generated by heating near pressurized fluid lines, resulting in
severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a
torch near pressurized fluid lines or other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate flame area.

DX,TORCH-19-1993/03/03

45
 Keep ROPS Installed Properly

Keep ROPS Installed Properly

TS212-UN: Roll Over Protective Structure

Make certain all parts are reinstalled correctly if the roll over protective structure
(ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper
torque.

The protection offered by ROPS will be impaired if ROPS is subjected to structural

damage, is involved in an overturn incident, or is in any way altered by welding,
bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.

DX,ROPS3-19-1993/03/03

46
 Service Tires Safely

Service Tires Safely

TS211-UN: Explosive Tire and Rim Parts

Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to
perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the
recommended pressure. Never weld or heat a wheel and tire assembly. The heat can
cause an increase in air pressure resulting in a tire explosion. Welding can structurally
weaken or deform the wheel.

47
 Service Tires Safely

When inflating tires, use a clip-on chuck and extension hose long enough to allow you
to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if
available.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and
nuts.

DX,RIM-19-1990/08/24

48
 Practice Safe Maintenance

Practice Safe Maintenance

TS218-UN: Keep Area Clean

Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and
clothing from power-driven parts. Disengage all power and operate controls to relieve
pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow
machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately.
49
 Practice Safe Maintenance
Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making

adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing

electrical system components or welding on machine.

DX,SERV-19-1999/02/17

50
 Use Proper Tools

Use Proper Tools

TS779-UN: Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety
hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid bodily injury caused by slipping
wrenches.

Use only service parts meeting John Deere specifications.

DX,REPAIR-19-1999/02/17

51
 Dispose of Waste Properly

Dispose of Waste Properly

TS1133-UN: Recycle Waste

Improperly disposing of waste can threaten the environment and ecology. Potentially
harmful waste used with John Deere equipment include such items as oil, fuel, coolant,
brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers
that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere.
Government regulations may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental
or recycling center, or from your John Deere dealer.

DX,DRAIN-19-1993/03/03

52
 Live With Safety

Live With Safety

TS231-19: Safety Systems

Before returning machine to customer, make sure machine is functioning properly,

especially the safety systems. Install all guards and shields.

DX,LIVE-19-1992/09/25

53
 410E Backhoe Loader Dimensions

410E Backhoe Loader Dimensions

T115805-UN: 410E Backhoe Loader Dimensions

NOTE:

Specifications and design subject to change without notice. Whenever

applicable, specifications are in accordance with SAE Standards unless
otherwise noted, these specifications are based on a standard machine
with 19.5L-24, 8PR, R4 rear tires; 11L-16, 12PR, F3 front tires; 0.86 m
3

(1.12 cu yd) loader bucket; 610 mm (24 in.) backhoe bucket;

ROPS/FOPS; full fuel tank and 79 kg (175 lb) operator.

54
410E Backhoe Loader Dimensions

55
 410E Backhoe Loader Dimensions

Item MeasurementSpecification
A-Loading Height, Truck Loading Position
Backhoe w/o Ext. Dipperstick Height 3.81 m (12 ft 6 in.)
Backhoe w/Ext. Dipperstick Retracted Height 3.86 m (12 ft 8 in.)
Backhoe w/Ext. Dipperstick Extended Height 4.72 m (15 ft 6 in.)
B-Reach from Center of Swing Mast
Backhoe w/o Ext. Dipperstick Distance 5.99 m (19 ft 8 in.)
Backhoe w/Ext. Dipperstick Retracted Distance 6.07 m (19 ft 11 in.)
Backhoe w/Ext. Dipperstick Extended Distance 7.21 m (23 ft 8 in.)
C-Reach From center of Rear Axle
Backhoe w/o Ext. Dipperstick Distance 7.11 m (23 ft 4 in.)
Backhoe w/Ext. Dipperstick Retracted Distance 7.19 m (23 ft 7 in.)
Backhoe w/Ext. Dipperstick Extended Distance 8.33 m (27 ft 4 in.)
D-Maximum Digging Depth
Backhoe w/o Ext. Dipperstick Depth 4.83 m (15 ft 10 in.)
Backhoe w/Ext. Dipperstick Retracted Depth 4.90 m (16 ft 1 in.)
Backhoe w/Ext. Dipperstick Extended Depth 6.10 m (20 ft 0 in.)
E-Digging Depth (SAE)-610 mm (2 ft) Flat Bottom
Backhoe w/o Ext. Dipperstick Distance 4.78 m (15 ft 8 in.)
Backhoe w/Ext. Dipperstick Retracted Distance 4.85 m (15 ft 11 in.)
Backhoe w/Ext. Dipperstick Extended Distance 6.07 m (19 ft 11 in.)
F-Digging Depth (SAE)-2440 mm (8 ft) Flat Bottom
Backhoe w/o Ext. Dipperstick Distance 4.45 m (14 ft 7 in.)
Backhoe w/Ext. Dipperstick Retracted Distance 4.55 m (14 ft 11 in.)
Backhoe w/Ext. Dipperstick Extended Distance 5.82 m (19 ft 1 in.)
G-Ground Clearance Minimum
Backhoe w/o Ext. Dipperstick Clearance 356 mm (14 in.)
Backhoe w/Ext. Dipperstick Retracted Clearance 356 mm (14 in.)
Backhoe w/Ext. Dipperstick Extended Clearance 356 mm (14 in.)
H-Bucket Rotation
Backhoe w/o Ext. Dipperstick Rotation 190°
Backhoe w/Ext. Dipperstick Retracted Rotation 190°
Backhoe w/Ext. Dipperstick Extended Rotation 190°
I-Transport Height
Backhoe Height 3.94 m (12 ft 11 in.)
J-Overall Length, Transport
Backhoe Length 7.29 m (23 ft 11 in.)
K-Stabilizer Width, Transport
Backhoe Width 2.18 m (7 ft 2 in.)
L-Stabilizer Spread, Operating

56
 410E Backhoe Loader Dimensions
Item MeasurementSpecification
Backhoe Width 3.10 m (10 ft 2 in.)
M-Overall Width, Stabilizer Spread (Less Loader Bucket)
Backhoe Width 3.53 m (11 ft 7 in.)
N-Width Over Tires
Backhoe Width 2.18 m (7 ft 2 in.)
O-Height to Cab/ROPS Top
Backhoe Height 2.82 m (9 ft 3 in.)
P-Front Wheel to Loader Dig Position
Backhoe Distance 2.10 m (6 ft 11 in.)
Q-Wheelbase
Backhoe Length 2.10 m (6 ft 10 in.)
R-Maximum Height to Loader Bucket Hinge Pin
Heavy Duty Long Lip 0.86 m (1.12 yd ) Height 3.35 m (11 ft 0 in.)
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Height 3.35 m (11 ft 0 in.)
3 3

Multipurpose 0.76 m (1.00 yd ) Height 3.35 m (11 ft 0 in.)

3 3

S-Dump Clearance, Loader Bucket at 45°

Heavy Duty Long Lip 0.86 m (1.12 yd ) Clearance 2.69 m (8 ft 10 in.)
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Clearance 2.67 m (8 ft 9 in.)

3 3

Multipurpose 0.76 m (1.00 yd ) Clearance 2.64 m (8 ft 8 in.)

3 3

T-Maximum Loader Bucket Dump Angle

Heavy Duty Long Lip 0.86 m (1.12 yd ) Angle 45°
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Angle 45°

3 3

Multipurpose 0.76 m (1.00 yd ) Angle 45°

3 3

U-Reach at Full Height, Loader Bucket at 45°

Heavy Duty Long Lip 0.86 m (1.12 yd ) Distance 762 mm (30.0 in.)
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Distance 787 mm (31.0 in.)
3 3

Multipurpose 0.76 m (1.00 yd ) Distance 818 mm (32.2 in.)

3 3

V-Loader Bucket Rollback at Ground Level

Heavy Duty Long Lip 0.86 m (1.12 yd ) Angle 40°
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Angle 40°

3 3

Multipurpose 0.76 m (1.00 yd ) Angle 40°

3 3

W-Dig Below Ground-Loader Bucket Level

Heavy Duty Long Lip 0.86 m (1.12 yd ) Depth 170 mm (6.7 in.)
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Depth 157 mm (6.2 in.)
3 3

Multipurpose 0.76 m (1.00 yd ) Depth 150 mm (5.9 in.)

3 3

Digging Force, Bucket Cylinder

Backhoe w/o Ext. Dipperstick Force 65.8 kN (14,801 lb)
Backhoe w/Ext. Dipperstick Retracted Force 66.7 kN (15,010 lb)
Backhoe w/Ext. Dipperstick Extended Force 66.7 kN (15,010 lb)

57
 410E Backhoe Loader Dimensions
Item MeasurementSpecification
Digging Force, Crowd Cylinder
Backhoe w/o Ext. Dipperstick Force 38.9 kN (8741 lb)
Backhoe w/Ext. Dipperstick Retracted Force 37.6 kN (8446 lb)
Backhoe w/Ext. Dipperstick Extended Force 26.6 kN (5980 lb)
Swing Arc
Backhoe w/o Ext. Dipperstick Rotation 180°
Backhoe w/Ext. Dipperstick Retracted Rotation 180°
Backhoe w/Ext. Dipperstick Extended Rotation 180°
Bucket Rotation
Backhoe w/o Ext. Dipperstick Rotation 190°
Backhoe w/Ext. Dipperstick Retracted Rotation 190°
Backhoe w/Ext. Dipperstick Extended Rotation 190°
Stabilizer Angle Rearward
Backhoe w/o Ext. Dipperstick Angle 18°
Backhoe w/Ext. Dipperstick Retracted Angle 18°
Backhoe w/Ext. Dipperstick Extended Angle 18°

TX,110,BD2412-19-1998/06/10

58
 410E Backhoe Loader Dimensions

410E Backhoe Loader Dimensions

T115805-UN: 410E Backhoe Loader Dimensions

NOTE:

Specifications and design subject to change without notice. Whenever

applicable, specifications are in accordance with SAE Standards unless
otherwise noted, these specifications are based on a standard machine
with 19.5L-24, 8PR, R4 rear tires; 11L-16, 12PR, F3 front tires; 0.86 m
3

(1.12 cu yd) loader bucket; 610 mm (24 in.) backhoe bucket;

ROPS/FOPS; full fuel tank and 79 kg (175 lb) operator.

59
410E Backhoe Loader Dimensions

60
 410E Backhoe Loader Dimensions

Item MeasurementSpecification
A-Loading Height, Truck Loading Position
Backhoe w/o Ext. Dipperstick Height 3.81 m (12 ft 6 in.)
Backhoe w/Ext. Dipperstick Retracted Height 3.86 m (12 ft 8 in.)
Backhoe w/Ext. Dipperstick Extended Height 4.72 m (15 ft 6 in.)
B-Reach from Center of Swing Mast
Backhoe w/o Ext. Dipperstick Distance 5.99 m (19 ft 8 in.)
Backhoe w/Ext. Dipperstick Retracted Distance 6.07 m (19 ft 11 in.)
Backhoe w/Ext. Dipperstick Extended Distance 7.21 m (23 ft 8 in.)
C-Reach From center of Rear Axle
Backhoe w/o Ext. Dipperstick Distance 7.11 m (23 ft 4 in.)
Backhoe w/Ext. Dipperstick Retracted Distance 7.19 m (23 ft 7 in.)
Backhoe w/Ext. Dipperstick Extended Distance 8.33 m (27 ft 4 in.)
D-Maximum Digging Depth
Backhoe w/o Ext. Dipperstick Depth 4.83 m (15 ft 10 in.)
Backhoe w/Ext. Dipperstick Retracted Depth 4.90 m (16 ft 1 in.)
Backhoe w/Ext. Dipperstick Extended Depth 6.10 m (20 ft 0 in.)
E-Digging Depth (SAE)-610 mm (2 ft) Flat Bottom
Backhoe w/o Ext. Dipperstick Distance 4.78 m (15 ft 8 in.)
Backhoe w/Ext. Dipperstick Retracted Distance 4.85 m (15 ft 11 in.)
Backhoe w/Ext. Dipperstick Extended Distance 6.07 m (19 ft 11 in.)
F-Digging Depth (SAE)-2440 mm (8 ft) Flat Bottom
Backhoe w/o Ext. Dipperstick Distance 4.45 m (14 ft 7 in.)
Backhoe w/Ext. Dipperstick Retracted Distance 4.55 m (14 ft 11 in.)
Backhoe w/Ext. Dipperstick Extended Distance 5.82 m (19 ft 1 in.)
G-Ground Clearance Minimum
Backhoe w/o Ext. Dipperstick Clearance 356 mm (14 in.)
Backhoe w/Ext. Dipperstick Retracted Clearance 356 mm (14 in.)
Backhoe w/Ext. Dipperstick Extended Clearance 356 mm (14 in.)
H-Bucket Rotation
Backhoe w/o Ext. Dipperstick Rotation 190°
Backhoe w/Ext. Dipperstick Retracted Rotation 190°
Backhoe w/Ext. Dipperstick Extended Rotation 190°
I-Transport Height
Backhoe Height 3.94 m (12 ft 11 in.)
J-Overall Length, Transport
Backhoe Length 7.29 m (23 ft 11 in.)
K-Stabilizer Width, Transport
Backhoe Width 2.18 m (7 ft 2 in.)
L-Stabilizer Spread, Operating

61
 410E Backhoe Loader Dimensions
Item MeasurementSpecification
Backhoe Width 3.10 m (10 ft 2 in.)
M-Overall Width, Stabilizer Spread (Less Loader Bucket)
Backhoe Width 3.53 m (11 ft 7 in.)
N-Width Over Tires
Backhoe Width 2.18 m (7 ft 2 in.)
O-Height to Cab/ROPS Top
Backhoe Height 2.82 m (9 ft 3 in.)
P-Front Wheel to Loader Dig Position
Backhoe Distance 2.10 m (6 ft 11 in.)
Q-Wheelbase
Backhoe Length 2.10 m (6 ft 10 in.)
R-Maximum Height to Loader Bucket Hinge Pin
Heavy Duty Long Lip 0.86 m (1.12 yd ) Height 3.35 m (11 ft 0 in.)
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Height 3.35 m (11 ft 0 in.)
3 3

Multipurpose 0.76 m (1.00 yd ) Height 3.35 m (11 ft 0 in.)

3 3

S-Dump Clearance, Loader Bucket at 45°

Heavy Duty Long Lip 0.86 m (1.12 yd ) Clearance 2.69 m (8 ft 10 in.)
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Clearance 2.67 m (8 ft 9 in.)

3 3

Multipurpose 0.76 m (1.00 yd ) Clearance 2.64 m (8 ft 8 in.)

3 3

T-Maximum Loader Bucket Dump Angle

Heavy Duty Long Lip 0.86 m (1.12 yd ) Angle 45°
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Angle 45°

3 3

Multipurpose 0.76 m (1.00 yd ) Angle 45°

3 3

U-Reach at Full Height, Loader Bucket at 45°

Heavy Duty Long Lip 0.86 m (1.12 yd ) Distance 762 mm (30.0 in.)
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Distance 787 mm (31.0 in.)
3 3

Multipurpose 0.76 m (1.00 yd ) Distance 818 mm (32.2 in.)

3 3

V-Loader Bucket Rollback at Ground Level

Heavy Duty Long Lip 0.86 m (1.12 yd ) Angle 40°
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Angle 40°

3 3

Multipurpose 0.76 m (1.00 yd ) Angle 40°

3 3

W-Dig Below Ground-Loader Bucket Level

Heavy Duty Long Lip 0.86 m (1.12 yd ) Depth 170 mm (6.7 in.)
3 3

Heavy Duty Long Lip 1.0 m (1.30 yd ) Depth 157 mm (6.2 in.)
3 3

Multipurpose 0.76 m (1.00 yd ) Depth 150 mm (5.9 in.)

3 3

Digging Force, Bucket Cylinder

Backhoe w/o Ext. Dipperstick Force 65.8 kN (14,801 lb)
Backhoe w/Ext. Dipperstick Retracted Force 66.7 kN (15,010 lb)
Backhoe w/Ext. Dipperstick Extended Force 66.7 kN (15,010 lb)

62
 410E Backhoe Loader Dimensions
Item MeasurementSpecification
Digging Force, Crowd Cylinder
Backhoe w/o Ext. Dipperstick Force 38.9 kN (8741 lb)
Backhoe w/Ext. Dipperstick Retracted Force 37.6 kN (8446 lb)
Backhoe w/Ext. Dipperstick Extended Force 26.6 kN (5980 lb)
Swing Arc
Backhoe w/o Ext. Dipperstick Rotation 180°
Backhoe w/Ext. Dipperstick Retracted Rotation 180°
Backhoe w/Ext. Dipperstick Extended Rotation 180°
Bucket Rotation
Backhoe w/o Ext. Dipperstick Rotation 190°
Backhoe w/Ext. Dipperstick Retracted Rotation 190°
Backhoe w/Ext. Dipperstick Extended Rotation 190°
Stabilizer Angle Rearward
Backhoe w/o Ext. Dipperstick Angle 18°
Backhoe w/Ext. Dipperstick Retracted Angle 18°
Backhoe w/Ext. Dipperstick Extended Angle 18°

TX,110,BD2412-19-1998/06/10

63
 410E Backhoe Loader Specifications
410E Backhoe Loader Specifications

Item MeasurementSpecification Item MeasurementSpecification Item MeasurementSpecification Item MeasurementSpecification

Engine-John Deere 4045T Forward Travel Speeds [ With Reverse Travel Speeds [ With Forward Travel Speeds [ With
Rated Power Power SAE gross 73 standard 19.5L-24 rear tires.] with standard 19.5L-24 rear tires.] with standard 19.5L-24 rear tires.] with
@ 2200 rpm kW (98 hp) Manual Transmission Manual Transmission Powershift Transmission
Rated Power Power SAE net 67 Gear Speed 5.8 km/h (3.6 Gear Speed 6.4 km/h (4.0 Gear Speed 5.8 km/h (3.6
@ 2200 rpm kW (90 hp) 1 mph) 1 mph) 1 mph)
Cylinders Quantity 4 Gear Speed 9.5 km/h (5.9 Gear Speed 10.6 km/h Gear Speed 9.5 km/h (5.9
Displacement Volume 4.52 L (276 2 mph) 2 (6.6 mph) 2 mph)
in. )
3
Gear Speed 23.2 km/h Gear Speed 25.9 km/h Gear Speed 23.2 km/h
Engine Torque 34% 3 (14.4 mph) 3 (16.1 mph) 3 (14.4 mph)
Torque Rise Gear Speed 39.3 km/h Gear Speed 43.8 km/h Gear Speed 39.3 km/h
Maximum Torque 389 N·m (287 4 (24.4 mph) 4 (27.2 mph) 4 (24.4 mph)
Engine Net lb-ft)
Torque
Electrical Voltage 12-volt
System
Alternator Amperage 65 amps
Alternator Amperage 95 amps
with Cab

NOTE:

With powershift transmission, third and fourth gear speeds are the same in reverse.

64
 410E Backhoe Loader Specifications
Item Measurement Specification Item MeasurementSpecification Item MeasurementSpecification
Reverse Travel Speeds [ With standard 19.5L-24 rear tires.] Steering: Hydrostatic Power Hydraulic System: Closed Center
with Powershift Transmission Non- Radius 3.56 m (11 ft Main Pressure 25 000 kPa
Gear 1 Speed 6.4 km/h (4.0 mph) Powered 8 in.) Pressure (3625 psi)
Gear 2 Speed 10.6 km/h (6.0 mph) Axle Curb Relief
Gear 3 Speed 25.9 km/h (16.1 mph) Turning Setting
Gear 4 Speed 43.8 km/h (27.2 mph) Radius- Flow @ Flow Rate 159 L/min.
Brakes 2200 (42 gpm)
Applied rpm,
Non- Radius 4.04 m (13 ft Backhoe
Powered 3 in.) Flow @ Flow Rate 159 L/min.
Axle Curb 2200 (42 gpm)
Turning rpm,
Radius- Loader
Without
Brakes
Non- Radius 9.65 m (31 ft
Powered 8 in.)
Axle
Bucket
Clearance
Circle-
Brakes
Applied
Non- Radius 10.59 m (34 ft
Powered 10 in.)
Axle
Bucket
Clearance
Circle-
Without
Brakes
Non- Quantity 2.3-3.0 turns
Powered
Axle
Steering
Wheel
Turns-
Stop to
Stop
Powered Radius 3.56 m (11 ft
Axle 8 in.)
(MFWD)
Curb
Turning
Radius-
Brakes
Applied
Powered Radius 4.04 m (13 ft
Axle 3 in.)
(MFWD)
Curb
Turning
Radius-
Without
Brakes
Powered Radius 9.65 m (31 ft
Axle 8 in.)
Bucket
Clearance
Circle-
Brakes
Applied
Powered Radius 10.59 m (34 ft
Axle 9 in.)
Bucket
Clearance
Circle-
Without
Brakes

65
410E Backhoe Loader Specifications
Item MeasurementSpecification

Non- Quantity 2.5 turns

Powered
Axle
Steering
Wheel
TX,115,BG331-19-1997/09/30
Turns-
Stop to
Stop

66
 Other Information-410E Backhoe Loader

Other Information-410E Backhoe Loader

1. Hydraulic system:

Axial piston pump

10 micron replaceable element return oil filter

2. Final drives:

Heavy-duty inboard mounted planetary

Evenly distributes axle shock loads over three oil cooled gears

3. Brakes:

Hydraulic wet disk

Mounted inboard
Self-adjusting
Self-equalizing

4. Park brake:

Independent system
Spring applied
Hydraulically released
Controlled by an electric switch on the side console

5. Transmission:

4-speed helical gear

Synchronized collar shift transmission with hydraulic reverser
Torque converter 280 mm (11 in.) with 2.12:1 stall ratio

6. Lubrication:

Pressure system with spin-on filter

Air cleaner
Dual stage dry, with element and precleaner

7. Tires:

67
 Other Information-410E Backhoe Loader
Front w/o MFWD-14.5/75-16.1, 10PR F3
Front w/o MFWD-11L-16, 12PR F3
Front with MFWD-12.5/80, 10PR
Rear w/o MFWD-19.5L-24, 10PR R4
Rear w/o MFWD-21L-24, 10PR R4
Rear with MFWD-19.5L-24, 10PR R4
Rear with MFWD-21L-24, 10PR R4

8. Operator Control:

Backhoe w/o Ext. Dipperstick

Two Levers
Backhoe w/Ext. Dipperstick Retracted
Right Foot Treadle
Backhoe w/Ext. Dipperstick Retracted
Right Foot Treadle

CED,OUO1032,1006-19-1998/06/09

68
 410E Backhoe Loader Weight

410E Backhoe Loader Weight

Item MeasurementSpecification
Transporting
SAE Operating Weight with ROPS Weight 5806 kg (12,800 lb)
Cab Added Weight 263 kg (580 lb)
MFWD with Tires Added Weight 168 kg (370 lb)
Extendible Dipperstick Weight 200 kg (440 lb)
Optional Front Counterweight Weight 181 kg (400 lb)
Optional Front Counterweight Weight 295 kg (650 lb)

TX,110,BD2420-19-1996/12/06

69
 410E Backhoe and Loader Buckets

410E Backhoe and Loader Buckets

Width Heaped Capacity Weight

Loader: mm (In.) m
3
(Cu Yd) kg lb
Heavy duty long lip 2340 (92) 1.00 (1.30) 476 (1050)
2340 (92) 1.15 (1.50) 540 (1190)

Multipurpose 2340 (92) 0.96 (1.25) 703 (1550)

Width Heaped Capacity Weight

Backhoe: mm (In.) m
3
(Cu Ft) kg (lb)
Standard duty 610 (24) 0.21 (7.5) 159 (350)

Heavy duty with lift loops 305 (12) 0.09 (3.3) 134 (295)

457 (18) 0.14 (5.1) 152 (335)

610 (24) 0.21 (7.5) 181 (400)

762 (30) 0.25 (8.8) 191 (420)

914 (36) 0.35 (12.5) 231 (510)

Extra Heavy Duty 457 (18) 0.14 (5.1) 164 (362)

610 (24) 0.21 (7.5) 193 (425)

610 (24) 0.25 (8.8) 206 (455)

762 (30) 0.28 (10.0) 215 (475)

Ditch cleaning 914 (36) 0.35 (12.5) 231 (510)

TX,110,BD2212-19-1998/06/15

70
 410E Backhoe Loader Drain and Refill Capacities

410E Backhoe Loader Drain and Refill Capacities

Item MeasurementSpecification
Engine Coolant Capacity 16 L (17 qt)
Engine Oil (including filter) Capacity 12.8 L (13.5 qt)
Torque Converter and Transmission System Capacity 14 L (15 qt)
Rear Axle (S.N. -851673) Capacity 13 L (14 qt)
Rear Axle (S.N. 851674-) Capacity 16 L (17 qt)
MFWD Front Axle Housing Capacity 6.5 L (7 qt)
MFWD Front Wheel Planetary Housing (each) Capacity 1 L (1.1 qt)
Fuel Tank Capacity 136 L (36 gal)
Hydraulic System Reservoir Capacity 37 L (39 qt)

TX,115,BG332-19-1999/11/01

71
 410E Backhoe Loader Lifting Capacities-Standard Dipperstick

410E Backhoe Loader Lifting Capacities-Standard Dipperstick

T105558-19: Lift Capacity, Backhoe with Standard Dipperstick

Based on SAE J31 (Except with Loader Bucket on Ground)
Lifting capacity ratings are made with bucket hinge pin, loader bucket and stabilizers on
firm, level ground. Lift capacities are hydraulically limited. Lifting capacities are 87
percent of the maximum lift over any point on the swing arc and do not exceed 75
percent of the tipping load. Angle between boom and ground is 65 degrees. Machine is
equipped with 610 mm (24 in.) standard bucket, standard or extendible dipperstick, and
standard equipment.

NOTE:

Loader bucket on ground significantly

72 improves side stability, therefore
 410E Backhoe Loader Lifting Capacities-Standard Dipperstick
Loader bucket on ground significantly improves side stability, therefore
improving lift capacity to the side. Lift capacity over the rear is not
affected.

TX,110,BD2416-19-1996/12/06

73
 410E Backhoe Loader Lifting Capacities-Extendible Dipperstick (Retracted)

410E Backhoe Loader Lifting Capacities-Extendible Dipperstick

(Retracted)

T105559-19: Lift Capacity, Backhoe with Extendible Dipperstick, Retracted

Based on SAE J31 (Except with Loader Bucket on Ground)

TX,110,BD2417-19-1996/12/06

74
 410E Backhoe Loader Lifting Capacities-Extendible Dipperstick (Extended)

410E Backhoe Loader Lifting Capacities-Extendible Dipperstick

(Extended)

T105560-19: Lift Capacity, Backhoe with Extendible Dipperstick, Retracted

Based on SAE J31 (Except with Loader Bucket on Ground)

TX,110,BD2418-19-1996/12/06

75
 Hardware Torque Specifications

Hardware Torque Specifications

Check cap screws and nuts to be sure they are tight. If hardware is loose, tighten to
torque shown on the following charts unless a special torque is specified.

TX,03,SS3508-19-1994/08/01

76
 Hardware Torque Specifications

Hardware Torque Specifications

Check cap screws and nuts to be sure they are tight. If hardware is loose, tighten to
torque shown on the following charts unless a special torque is specified.

TX,03,SS3508-19-1994/08/01

77
 ROPS Torque Specifications

ROPS Torque Specifications

TS176-UN: Keep ROPS Installed Properly

CAUTION:
Make certain all parts are reinstalled correctly if the roll-over
protective structure (ROPS) is loosened or removed for any
reason. Tighten mounting bolts to proper torque.

The protection offered by ROPS will be impaired if ROPS is

subjected to structural damage, is involved in an overturn
incident, or is in any way altered. A damaged ROPS should be
replaced, not reused.

When installation of equipment on a machine necessitates loosening or removing

ROPS, mounting bolts must be tightened to specification.

Item MeasurementSpecification
ROPS Mounting Bolts Torque 420 ± 84 N·m (310 ± 62 lb-ft)

TX,03,SS3509-19-1999/12/07

78
 Metric Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

TS1657-19: Metric Torque Values

DX,TORQ2-19-1994/07/20

79
 Additional Metric Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

T6873AA-UN: T-Bolt

T6873AB-UN: H-Bolt

T6873AC-UN: M-Bolt

CAUTION:
Use only metric tools on metric hardware. Other tools may not fit
properly. They may slip and cause injury.

80
 Additional Metric Cap Screw Torque Values

Check tightness of cap screws periodically. Torque values listed are for general use
only. Do not use these values if a different torque value or tightening procedure is listed
for a specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts
with identical grade.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners
are used, these should only be tightened to the strength of the original.

Make sure fastener threads are clean and you properly start thread engagement. This
will prevent them from failing when tightening.

Tighten cap screws having lock nuts to approximately 50 percent of amount shown in
chart.

-: Metric Cap Screw Torque Values

[METRIC CAP SCREW TORQUE VALUES Torque tolerance is ±10%.]

T-Bolt H-Bolt M-Bolt
Nominal Dia N·m lb-ft N·m lb-ft N·m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15

12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159

24 931 687 686 506 274 202

27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687

TX,03,SS3511-19-1994/08/01

81
 Unified Inch Bolt and Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

TS1656-19: Inch Torque Values

TX,03,SS3512-19-1994/07/20

82
 O-Ring Groove Connections

O-Ring Groove Connections

T127838-UN: Face Seal Groves

LEGEND:
1 - O-Ring
2 - Half Dovetail Groove
3 - Fitting
4 - Standard Groove

Face seal grooves (2 and 4) on fittings (3) should be identified before the O-ring (1) is
installed into the fitting (use a O-ring pick to feel for the dovetail edge). Applying
petroleum jelly on an O-ring to install it in a Standard Groove is appropriate. However,
do not use petroleum jelly or grease on an O-ring to install it into a Half Dovetail Groove

83
 O-Ring Groove Connections
(Captive O-ring Groove). If petroeium jelly is used in a Half Dovetail groove, the jelly
could push the O-ring out of the groove before the fitting is tighten.

CED,TX03768,2691-19-2000/02/01

84
 Check Oil Lines And Fittings

Check Oil Lines And Fittings

X9811-UN: Escaping Fluid Under Pressure

CAUTION:
Escaping fluid under pressure can penetrate the skin causing
serious injury. Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with a piece of
cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected

into the skin must be surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with this type of injury
may call the Deere & Company Medical Department in Moline,
Illinois, or other knowledgeable medical source.

Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all
clamps are in position and tight. Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace immediately.

Tubing with dents may cause the oil to overheat. If you find tubing with dents, install
new tubing immediately.

IMPORTANT:

Tighten fittings as specified in torque chart.

85
 Check Oil Lines And Fittings

When you tighten connections, use two wrenches to prevent bending or breaking tubing
and fittings.

TX,9000,RB19-19-1997/10/30

86
 Service Recommendations for O-Ring Boss Fittings

Service Recommendations for O-Ring Boss Fittings

Straight Fitting

T6243AE-UN: Straight Fitting

1. Inspect O-ring boss seat for dirt or defects.

2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to
protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove
tape.

3. Tighten fitting to torque value shown on chart.

Angle Fitting

87
 Service Recommendations for O-Ring Boss Fittings
T6520AB-UN: Angle Fitting

1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of
fitting.

2. Turn fitting into threaded boss until back-up washer contacts face of boss.

3. Turn fitting head-end counterclockwise to proper index (maximum of one turn).

4. NOTE:

Do not allow hoses to twist when tightening fittings.

Hold fitting head-end with a wrench and tighten locknut and back-up washer to
proper torque value.

-: Straight Fitting or Special Nut Torque Chart

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N·m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18

3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160

NOTE:

Torque tolerance is ± 10%.

88
Service Recommendations for O-Ring Boss Fittings
TX,03,SS3514-19-1996/05/ 2

89
 Service Recommendations for Flat Face O-Ring Seal Fittings

Service Recommendations for Flat Face O-Ring Seal Fittings

T6243AD-UN: Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces. They must be free of dirt or defects.

2. Inspect the O-ring. It must be free of damage or defects.

3. Lubricate O-rings and install into groove using petroleum jelly to hold in place.

4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not
displaced during assembly.

5. Index angle fittings and tighten by hand pressing joint together to insure O-ring
remains in place.

6. Tighten fitting or nut to torque value shown on the chart per dash size
stamped on the fitting. Do not allow hoses to twist when tightening fittings.

-: Flat Face O-Ring Seal Fitting Torque

FLAT FACE O-RING SEAL FITTING TORQUE

Nominal Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. Dash Size in. N·m lb-ft N·m lb-ft

6.35 0.250 -4 9/16-18 16 12 5.0 3.5

9.52 0.375 -6 11/16-16 24 18 9.0 6.5
12.70 0.500 -8 13/16-16 50 37 17.0 12.5

90
 Service Recommendations for Flat Face O-Ring Seal Fittings

FLAT FACE O-RING SEAL FITTING TORQUE

Nominal Tube O.D. Thread Size Swivel Nut Bulkhead Nut

mm in. Dash Size in. N·m lb-ft N·m lb-ft

15.88 0.625 -10 1-14 69 51 17.0 12.5
19.05 0.750 -12 1 3/16-12 102 75 17.0 12.5
22.22 0.875 -14 1 3/16-12 102 75 17.0 12.5

25.40 1.000 -16 1 7/16-12 142 105 17.0 12.5

31.75 1.250 -20 1 11/16-12 190 140 17.0 12.5
38.10 1.500 -24 2-12 217 160 17.0 12.5

NOTE:

Torque tolerance is +15 -20%.

TX,03,SS3515-19-1994/08/01

91
 Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations for Metric Series Four Bolt Flange Fitting

T6890BB-UN: Metric Series Four Bolt Flange Fitting

LEGEND:
A - Sealing Surface
B - Split Flange
C - Pinched O-Ring
D - Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness

causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be
polished out, replace component.

2. Install the correct O-ring (and backup washer if required) into groove using
petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B) halves. Make sure split is
centrally located and perpendicular to the port. Hand tighten cap screws to
hold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line in center of flange and install four
cap screws. Flange must be centrally located on port. Hand tighten cap
screws to hold flange in place. Do not pinch O-ring.

5. After components are properly positioned and cap screws are hand tightened,
tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten
two remaining cap screws. Tighten all cap screws as specified in the chart
below.

DO NOT use air wrenches. DO NOT tighten one cap screw fully before
tightening the others. DO NOT over tighten.

-: Torque Chart

92
Service Recommendations for Metric Series Four Bolt Flange Fitting

[TORQUE CHARTTolerance ± 10%. The torques given are enough for

the given size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures. ]

[ThreadMetric standard thread. ] N·m lb-ft

M6 12 9
M8 30 22

M10 57 42
M12 95 70
M14 157 116
M16 217 160

M18 334 246

M20 421 318

TX,03,SS3516-19-1994/08/01

93
 Service Recommendations For Inch Series Four Bolt Flange Fittings

Service Recommendations For Inch Series Four Bolt Flange Fittings

T6890BB-UN: Flange Fittings

LEGEND:
A - Sealing Surface
B - Split Flange
C - Pinched O-Ring
D - Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness

causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be
polished out, replace component.

2. Install O-ring (and backup washer if required) into groove using petroleum jelly
to hold it in place.

3. Split flange: Loosely assemble split flange (B) halves. Make sure split is
centrally located and perpendicular to port. Hand tighten cap screws to hold
parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line in center of flange and install cap
screws. Flange must be centrally located on port. Hand tighten cap screws to
hold flange in place. Do not pinch O-ring.

5. Tighten one cap screw, then tighten the diagonally opposite cap screw.
Tighten two remaining cap screws. Tighten all cap screws as specified in the
chart below.

DO NOT use air wrenches. DO NOT tighten one cap screw fully before
tightening the others. DO NOT over tighten.

-: Four Bolt Flange Fittings Torque

94
 Service Recommendations For Inch Series Four Bolt Flange Fittings

TORQUE CHART
N·m lb-ft

Nominal Flange Size Cap Screw Size Min Max Min Max
1/2 5/16-18 UNC 20 31 15 23
3/4 3/8-16 UNC 28 54 21 40

1 3/8-16 UNC 37 54 27 40
1-1/4 7/16-14 UNC 47 85 35 63
1-1/2 1/2-13 UNC 62 131 46 97

2 1/2-13 UNC 73 131 54 97

2-1/2 1/2-13 UNC 107 131 79 97
3 5/8-11 UNC 158 264 117 195
3-1/2 5/8-11 UNC 158 264 117 195

4 5/8-11 UNC 158 264 117 195

5 5/8-11 UNC 158 264 117 195

TX,03,SS3517-19-1994/08/01

95
 Diesel Fuel

Diesel Fuel

Consult your local fuel distributor for properties of the diesel fuel available in your area.

In general, diesel fuels are blended to satisfy the low temperature requirements of the
geographical area in which they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 are recommended.

In all cases, the fuel shall meet the following properties:

Cetane number of 40 minimum. Cetane number greater than 50 is preferred,

especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5,000 ft).

Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud
Point at least 5°C (9°F) below the expected low temperature.

Fuel lubricity should pass a minimum of 3100 gram load level as measured by the
BOCLE scuffing test.

Sulfur content:

Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is
preferred.
If diesel fuel with sulfur content greater than 0.5% sulfur content is used,
reduce the service interval for engine oil and filter by 50%.
DO NOT use diesel fuel with sulfur content greater than 1.0%.

Bio-diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent
specification.

DO NOT mix used engine oil or any other type of lubricant with diesel fuel.

DX,FUEL1-19-1999/02/17

96
 Diesel Fuel

Diesel Fuel

Consult your local fuel distributor for properties of the diesel fuel available in your area.

In general, diesel fuels are blended to satisfy the low temperature requirements of the
geographical area in which they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 are recommended.

In all cases, the fuel shall meet the following properties:

Cetane number of 40 minimum. Cetane number greater than 50 is preferred,

especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5,000 ft).

Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud
Point at least 5°C (9°F) below the expected low temperature.

Fuel lubricity should pass a minimum of 3100 gram load level as measured by the
BOCLE scuffing test.

Sulfur content:

Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is
preferred.
If diesel fuel with sulfur content greater than 0.5% sulfur content is used,
reduce the service interval for engine oil and filter by 50%.
DO NOT use diesel fuel with sulfur content greater than 1.0%.

Bio-diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent
specification.

DO NOT mix used engine oil or any other type of lubricant with diesel fuel.

DX,FUEL1-19-1999/02/17

97
 Low Sulfur Diesel Fuel Conditioner

Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations for engines used off-highway. This fuel
will not require any additives to provide good performance and engine reliability.
However, many local fuel distributors will not carry both low and regular sulfur diesel
fuels.

If the local fuel distributor will supply only low sulfur fuel, order and use John Deere
PREMIUM DIESEL FUEL CONDITIONER. It provides lubricating properties along with
other useful benefits, such as cetane improver, anti-oxidant, fuel stabilizer, corrosion
inhibitor and others. John Deere PREMIUM DIESEL FUEL CONDITIONER is
specifically for use with low sulfur fuels. Nearly all other diesel fuel conditioners only
improve cold weather flow and stabilizer long-term fuel storage. They do not contain the
lubrication additives needed by rotary fuel injection pumps.

TX,45,BG344-19-1997/09/30

98
 Diesel Fuel Storage

Diesel Fuel Storage

Proper fuel storage is critically important. Use clean storage and transfer tanks.
Periodically drain water and sediment from bottom of tank. Store fuel in a convenient
place away from buildings.

IMPORTANT:

DO NOT store diesel fuel in galvanized containers. Diesel fuel

stored in galvanized containers reacts with zinc coating on
container to form zinc flakes. If fuel contains water, a zinc gel will
also form. The gel and flakes will quickly plug fuel filters, damage
injection nozzles and injection pump.

DO NOT use brass-coated containers for fuel storage. Brass is an

alloy of copper and zinc.

Store diesel fuel in plastic, aluminum, and steel containers specially coated for diesel
fuel storage.

Avoid storing fuel over long periods of time. If fuel is stored for more than a month prior
to use, or there is a slow turnover in fuel tank or supply tank, add a fuel conditioner
such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to
stabilize the fuel and prevent water condensation. John Deere PREMIUM DIESEL
FUEL CONDITIONER is available in winter and summer formulas. Fuel conditioner also
reduces fuel gelling and controls wax separation during cold weather.

Consult your John Deere engine distributor or servicing dealer for recommendations
and local availability. Always follow manufacturer’s directions on label.

TX,45,BG288-19-1997/01/08

99
 Do Not Use Galvanized Containers

Do Not Use Galvanized Containers

IMPORTANT:

Diesel fuel stored in galvanized containers reacts with zinc

coating on the container to form flakes. If fuel contains water, a
zinc gel will also form. The gel and flakes will quickly plug fuel
filters and damage fuel injectors and pumps.

DO NOT USE a galvanized container to store diesel fuel.

Store fuel in:

plastic containers.
aluminum containers.
specially coated steel containers made for diesel fuel.

DO NOT USE brass-coated containers: brass is an alloy of copper and zinc.

MX,FLBT,C-19-1990/06/04

100
 Fuel Tank

Fuel Tank

TS185-UN: No Smoking While Fueling

CAUTION:
Handle fuel carefully. If the engine is hot or running, DO NOT fill
fuel tank. DO NOT smoke while you fill fuel tank or work on fuel
system.

To avoid condensation, fill the fuel tank at the end of each day’s operation. Shut off
engine before filling.

Item MeasurementSpecification
Fuel Tank Capacity 136 L (36 gal)

TX,45,BD2125-19-1998/05/06

101
 Diesel Engine Oil

Diesel Engine Oil

TS1661-UN: Diesel Engine Oil

Use oil viscosity based on the expected air temperature range during the period
between oil changes.

The following oil is preferred:

John Deere PLUS-50 ®

The following oil is also recommended:

John Deere TORQ-GARD SUPREME®

Other oils may be used if they meet one or more of the following:

API Service Classification CG-4

API Service Classification CF-4
ACEA Specification E3
ACEA Specification E2

102
 Diesel Engine Oil

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval by
50%.

Extended service intervals may apply when John Deere preferred engine oils are used.
Consult your John Deere dealer for more information.

DX,ENOIL-19-1997/10/10

103
 Transmission, Rear Axle and Mechanical Front Wheel Drive Oil

Transmission, Rear Axle and Mechanical Front Wheel Drive Oil

T103849-19: Transmission, Axles, and MFWD Oil Chart

Depending on the expected air temperature range between oil changes, use oil
viscosity shown on the chart above.

JOHN DEERE HY-GARD® TRANSMISSION AND HYDRAULIC OIL IS

RECOMMENDED because it is specifically formulated to minimize brake chatter, and to
provide maximum protection against mechanical wear.

You may also use oils which meet minimum John Deere standards, or other oils
meeting John Deere Standard JDM J20C and J20D.

Oils meeting MIL-L-46167A may be used as arctic oil.

TX,45,BG293-19-1997/01/09

104
 Hydraulic Oil

Hydraulic Oil

T103848-19: Hydraulic Oil Chart

Depending on the expected air temperature range between oil changes, use oil
viscosity shown on the chart above.

JOHN DEERE HY-GARD® TRANSMISSION AND HYDRAULIC OIL IS

RECOMMENDED because it is specifically formulated to minimize brake chatter, and to
provide maximum protection against mechanical wear.

You may also use oils which meet minimum John Deere standards, or other oils
meeting John Deere Standard JDM J20C and J20D.

Oils meeting MIL-L-46167A may be used as arctic oil.

TX,45,BD2127-19-1996/10/07

105
 Diesel Engine Coolant

Diesel Engine Coolant

The engine cooling system is filled to provide year-round protection against corrosion
and cylinder liner pitting, and winter freeze protection to -37°C (-34°F).

The following engine coolant is preferred for service:

John Deere COOL-GARD Prediluted Coolant

The following engine coolant is also recommended:

John Deere COOL-GARD Coolant Concentrate in a 40 to 60% mixture of

concentrate with quality water.

Other low silicate ethylene glycol base coolants for heavy-duty engines may be used if
they meet one of the following specifications:

ASTM D5345 (prediluted coolant)

ASTM D4985 (coolant concentrate) in a 40 to 60% mixture of concentrate with
quality water

Coolants meeting these specifications require use of supplemental coolant additives,

formulated for heavy-duty diesel engines, for protection against corrosion and cylinder
liner erosion and pitting.

A 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -
37°C (-34°F). If protection at lower temperatures is required, consult your John Deere
dealer for recommendations.

Water quality is important to the performance of the cooling system. Distilled, deionized,
or demineralized water is recommended for mixing with ethylene glycol base engine
coolant concentrate.

IMPORTANT:

Do not use cooling system sealing additives or antifreeze that

contains sealing additives.

Coolant Drain Intervals

Drain the factory fill engine coolant, flush the cooling system, and refill with new coolant
after the first 3 years or 3000 hours of operation. Subsequent drain intervals are
determined by the coolant used for service. At each interval, drain the coolant, flush the
cooling system, and refill with new coolant.
106
 Diesel Engine Coolant

When John Deere COOL-GARD is used, the drain interval may be extended to 5 years
or 5000 hours of operation, provided that the coolant is tested annually AND additives
are replenished, as needed, by adding a supplemental coolant additive.

If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of
operation.

DX,COOL3-19-1999/02/05

107
 Grease

Grease

TS1667-UN: Grease

Use grease based on NLGI consistency numbers and the expected air temperature
range during the service interval.

The following greases are preferred:

John Deere SD POLYUREA GREASE

The following greases are also recommended:

John Deere HD MOLY GREASE

John Deere HD LITHIUM COMPLEX GREASE
John Deere HD WATER RESISTANT GREASE
John Deere GREASE-GARD

Other greases may be used if they meet the following:

NLGI Performance Classification GC-LB

108
 Grease

IMPORTANT:

Some types of grease thickener are not compatible with others.

DX,GREA1-19-1999/07/07

109
 Grease For Extendible Dipperstick

Grease For Extendible Dipperstick

SAE Multipurpose Grease with Extreme Pressure (EP) performance and containing 3 to
5 per cent molybdenum disulfide (preferred).

EX,45,BG153-19-1996/12/18

110
 Alternative and Synthetic Lubricants

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require lubricant recommendations

different from those printed in this manual.

Some John Deere brand coolants and lubricants may not be available in your location.

Consult your John Deere dealer to obtain information and recommendations.

Synthetic lubricants may be used if they meet the performance requirements as shown
in this manual.

The temperature limits and service intervals shown in this manual apply to both
conventional and synthetic oils.

Re-refined base stock products may be used if the finished lubricant meets the
performance requirements.

DX,ALTER-19-1996/03/18

111
 Lubricant Storage

Lubricant Storage

Your equipment can operate at top efficiency only when clean lubricants are used.

Use clean containers to handle all lubricants.

Whenever possible, store lubricants and containers in an area protected from dust,
moisture, and other contamination. Store containers on their side to avoid water and dirt
accumulation.

Make certain that all containers are properly marked to identify their contents.

Properly dispose of all old containers and any residual lubricant they may contain.

DX,LUBST-19-1996/03/18

112
 Mixing of Lubricants

Mixing of Lubricants

In general, avoid mixing different brands or types of oil. Oil manufacturers blend
additives in their oils to meet certain specifications and performance requirements.

Mixing different oils can interfere with the proper functioning of these additives and
degrade lubricant performance.

Consult your John Deere dealer to obtain specific information and recommendations.

DX,LUBMIX-19-1996/03/18

113
 Operational Checkout Procedure

Operational Checkout Procedure

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

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

The information obtained after completing the operational checkout will allow you or
your authorized dealer to pinpoint a specific test or repair needed to restore the
machine to specifications.

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

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

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

1 Gauge and Indicator Check With Engine Off

Launch Close Expand List Collapse List

1A Monitor Indicator Lights and Alarm Checks

Action:

114
 Operational Checkout Procedure
T103007-UN: Monitor Indicator Lights and Alarm

Turn key switch to BULB CHECK position and hold.

LOOK: Are all monitor indicator lights on? Is STOP light ON and does alarm
sound?

NOTE:

Starting motor MUST NOT operate.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check monitor/gauge fuse. Go to Group 9015-15, Display Monitor Checks. If
motor starts and bulb check position is OK, key switch is failed or there is a short in
wiring. Go to Group 9015-15, Start Circuit.

2 FNR, Neutral Start Circuit and Reverse Warning Alarm Checks

Launch Close Expand List Collapse List

2A FNR Switch Check

Action:

T7447AH-UN: FNR Switch

Engine off.

115
 Operational Checkout Procedure

Move FNR lever to forward (F), reverse (R), then neutral (N) position.

FEEL: Observe and feel forward, neutral and reverse detents.

Turn key switch to ON position. Move FNR lever into forward and reverse.

LISTEN: Did you hear a "click" from the side console neutral start relay as FNR
lever was moved?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If no "click", inspect neutral start relay. Go to Group 9015-15, Start Circuit.

2B Neutral Start Check

Action:

Move FNR lever to forward (F) position and turn key switch to start position.

Move FNR lever to reverse (R) position and turn key switch to start position.

LISTEN: Did starting motor operate?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Group 9015-15, Start Circuit.

2C Start Circuit Check

Action:

116
 Operational Checkout Procedure

T7447AH-UN: Start Circuit

Move FNR lever to neutral (N) position and turn key switch to START position.

Observe and listen to monitor as engine is cranking.

LISTEN: Did starting motor operate?

LISTEN: Did alarm sound?

LOOK: During engine cranking, were all indicator lights ON? Is STOP indicator
ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If engine turns but does not start, check fuel shut-off/start aid/reverse alarm fuse. If
starting motor does not operate check start fuse. Go to Group 9015-15, Start
Circuit. If indicator lights are NOT ON, check monitor/gauge fuse. Go to Group
9015-15, Display Monitor Checks.

2D Reverse Warning Alarm Check

Action:

117
 Operational Checkout Procedure

T7447AI-UN: Reverse Warning Alarm

Key switch ON.

Move FNR lever to reverse (R) position.

LISTEN: Does reverse warning alarm sound?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
See Reverse Alarm Circuit. Go to Group 9015-10.

3 Park Brake, Charge Indicator Light, Tachometer/Hour Meter

Circuit and Engine Speed Control Linkage Checks
Launch Close Expand List Collapse List

3A Park Brake Indicator Check

Action:

118
 Operational Checkout Procedure

T7447AG-UN: Park Brake Indicator

T103007-UN: Indicators

IMPORTANT:

If engine oil pressure indicator light stays ON, STOP ENGINE

IMMEDIATELY, check oil level.

Engage park brake.

Put FNR lever in neutral (N) and start the engine.

Put FNR lever in forward (F) position.

LOOK: Is STOP indicator ON? Does alarm sound? Is park brake and seat belt light
ON? Are all other indicator lights out?

Release park brake.

LOOK/LISTEN: Is park brake indicator and STOP light out? Alarm WILL NOT
sound.

Record of Actual Results:

119
 Operational Checkout Procedure

Result:
YES:
Go to next check.
NO:
If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY
and check oil level. Go to Group 9010-15, Engine Low Oil Pressure. If alternator
indicator light is ON, increase engine speed to 1200 rpm and alternator light MUST
go out. Go to Group 9015-15, Charge Circuit Checks. If no park brake light,
inspect wiring connector at switch on park brake linkage. Go to Group 9015-15,
Park Brake Circuit.

3B Seat Position Sensor Check

Action:

Engine speed at low idle.

Item MeasurementSpecification
Seat Position Sensor Check Engine Speed Low idle

Lower all equipment to ground.

Release park brake.

Transmission gear shift lever in neutral, FNR in forward or reverse.

Operators seat in the backhoe position.

LISTEN: Does alarm sound and is STOP indicator ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to indicator circuit in Group 9015-15.

120
 Operational Checkout Procedure

3C Tachometer/
Hourmeter Circuit Check

Action:

T7447AH-UN: Tachometer/Hourmeter Circuit

IMPORTANT:

If engine low oil pressure indicator light stays ON, STOP

ENGINE IMMEDIATELY and check oil level.

Engage park brake.

Put FNR lever in neutral and start the engine.

LOOK/LISTEN: Is hourmeter indicator rotating? Does tachometer (if equipped)

indicate rpm?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If park brake indicator light is not ON, go to Group 9015-15, Park Brake Circuit. If
no hour meter or tachometer movement, go to Group 9015-10, Gauge and Hour
Meter Circuit.

3D Engine Speed Control Lever Linkage Check

121
 Operational Checkout Procedure

Action:

T102991-UN: Engine Speed Control Lever Linkage

Engage park brake.

Put FNR lever in neutral and start engine.

Note rpm on tachometer (if equipped).

Move speed control lever to fast idle position.

LOOK: Does tachometer read 900 + 25 - 0 rpm (slow idle) or 2400 + 25 - 0 rpm
(fast idle)?

Item MeasurementSpecification
Slow Idle Speed 900 + 25 - 0 rpm
Fast Idle Speed 2400 + 25 - 0 rpm

LOOK: Does speed control lever remain at selected position?

Record of Actual Results:

Result:
NO:
Tighten friction lock. Go to Group 9010-20. Check engine speed. Go to Group
9010-20.
YES:
Go to next check.

3E Engine Speed Control Pedal Linkage Check

122
 Operational Checkout Procedure

Action:

T7394BF-UN: Engine Speed Control Pedal Linkage

Depress speed control pedal

LISTEN: Does engine speed stay the same as with speed control lever in fast idle
position?

Record of Actual Results:

Result:
YES:
Yes: Go to next check.
NO:
Adjust Speed Control Linkage. Go to Group 9010-20.

4 Brake System Checks

Launch Close Expand List Collapse List

4A Pedal Stop Check

Action:

123
 Operational Checkout Procedure

T7394BG-UN: Brake System

Lift left and right brake pedals.

LOOK: Are brake pedals against pedal stop?

NOTE:

This ensures that brake check valves are opened and brakes
released.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust brake pedal stops. Go to Group 9020-20.

4B Brake System Leakage Check

Action:

124
 Operational Checkout Procedure

T7367AM-UN: Brake System Leakage

Depress and hold left brake pedal, then right brake pedal using approximately 267
N (60 lb. force).

LOOK: Brake pedal must NOT feel spongy (caused by air in system). Does pedal
settle more than 25 mm (1.0 in.) per minute?

Item MeasurementSpecification
Brake Leakage Pedal settles more than 25 mm (1.0 in.) per minute with
System 267 N (60 lb. force) applied

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Bleed brake system. Go to Group 9020-20.

4C Brake Drag/Park Brake Check

Action:

125
 Operational Checkout Procedure

T6171AL-UN: Brake Drag/Park Brake Check

Position machine on a gradual slope with front of machine downhill.

Lift bucket so it clears ground.

Shift FNR lever to neutral, differential lock control up, disengage park brake and
release service brakes.

Let machine coast freely for several feet. Apply park brake.

LOOK: Did machine stop?

Release park brake.

LOOK: Did machine move or coast freely?

NOTE:

If machine does not move freely on slope, drive the machine for
five minutes. Feel axle housing area to locate which brake is
dragging.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Group 9020-25, Brake Valve Leakage Test or Park Brake Release Pressure
Test.

126
 Operational Checkout Procedure

4D Park Brake Function Check

Action:

Start machine, move throttle to 1200 rpm.

Leave park brake ON.

Put FNR lever in forward position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever to reverse position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever back to neutral position.

Move throttle back to slow idle and shut the machine off.

LOOK: The machine MUST NOT move in any gear.

LOOK: STOP light and Park Brake indicators MUST be lit.

LOOK: Hazard light MUST be flashing.

LISTEN: An audible beeping alarm MUST be heard.

LISTEN: With the FNR In the reverse position, the reverse audible alarm MUST be
heard.

Record of Actual Results:

Result:
YES:
If the machine moves in any gear, see your authorized dealer.
YES:
If the indicators do not work, see your authorized dealer.
NO:

127
 Operational Checkout Procedure
Go to next check.

4E Park Brake Function Check

Action:

Start machine, move throttle to 1200 rpm.

Leave park brake ON.

Put FNR lever in forward position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever to reverse position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever back to neutral position.

Move throttle back to slow idle and shut the machine off.

LOOK: The machine MUST NOT move in any gear.

LOOK: STOP light and Park Brake indicators MUST be lit.

LOOK: Hazard light MUST be flashing.

LISTEN: An audible beeping alarm MUST be heard.

LISTEN: With the FNR In the reverse position, the reverse audible alarm MUST be
heard.

Record of Actual Results:

Result:
YES:
If the machine moves in any gear, see your authorized dealer.
YES:
If the indicators do not work, see your authorized dealer.

128
 Operational Checkout Procedure

NO:
Go to next check.

5 Steering System Checks

Launch Close Expand List Collapse List

5A Steering Check

Action:

Raise loader bucket above ground level.

Raise rear of machine off ground using stabilizers.

Operate engine at approximately 1000 rpm.

Item Measurement Specification

Steering Check Approximate Engine Speed 1000 rpm

Turn steering wheel from full left to full right several times.

LOOK: Did front wheels move smoothly in both directions?

LOOK: When steering wheel was stopped, did front wheels stop moving?

NOTE:

Internal leakage or a sticking steering valve spool can cause

wheels to continue to move after steering wheel is stopped.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Group 9025-15, Steering Valve Does Not Return to Neutral.

129
 Operational Checkout Procedure

5B Steering System Leakage Check

Action:

NOTE:

Hydraulic oil must be at operating temperature.

Run engine at slow idle.

Item Measurement Specification

Steering System Leakage Engine Speed Slow idle
Check
Hydraulic Oil Operating
Temperature temperature
Turn steering wheel until wheels are in maximum right turn position. Continue
turning steering wheel, using approximately 11.3 N·m (100 lb-in.) force while
counting steering wheel rpm.
Item MeasurementSpecification
Steering Wheel Torque 11.3 N·m (100 lb-in.)

Repeat leakage check turning steering wheel to the left.

LOOK: Did steering wheel turn 5 rpm or less to the left or right?

Item Measurement Specification

Steering System Maximum Leakage 5 rpm
This represents acceptable steering wheel movement during normal operation.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If steering wheel turns more than 5 rpm, verify whether valve or cylinder is leaking.
Go to Group 9025-25, Steering System Leakage Test.

130
 Operational Checkout Procedure

5C Steering Load Sense Check

Action:

Operate engine at slow idle.

Turn steering wheel to stop left and right. Note effort required to turn wheel.

Turn wheel to stop and apply constant pressure.

LOOK/FEEL: Does wheel stop at both axle stops and require normal steering
wheel effort?

LOOK/LISTEN: Does tachometer (if equipped) momentarily decrease in rpm or

does engine rpm momentarily decrease when steering wheel is held against stop?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Steers hard and no decrease in engine rpm. Go to Group 9025-25, Steering Load
Sense Relief Valve Stall Pressure Test.

6 Transmission Neutral Disconnect Circuit Check

Launch Close Expand List Collapse List

6A Neutral Disconnect Circuit Check

Action:

CAUTION:
Machine will move forward as FNR lever is moved.

Start engine, set idle speed at approximately 1500 rpm.

131
 Operational Checkout Procedure

Item Measurement Specification

Neutral Disconnect Circuit Check Approximate Engine Idle Speed 1500 rpm

Put transmission in fourth gear.

Release park brake.

Shift FNR lever to forward (F) position.

LISTEN: When FNR lever is shifted to forward (F) position, can a noticeable drop
in engine speed should be heard?

Press button on gear shift lever (manual shift only) or loader control lever
individually and note sound of engine.

LISTEN: Does engine rpm increase when the neutral solenoid switches are
depressed?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check switch. Go to Group 9015-15, Park Brake/Neutral Disconnect Circuit.

7 Driving Checks
Launch Close Expand List Collapse List

7A Transmission Shift Noise Check

Action:

IMPORTANT:

Press button on gear shift lever when shifting gears (manual

shift only).

132
 Operational Checkout Procedure

Run engine at approximately 1500 rpm with FNR lever in forward (F) position.

Item Measurement Specification

Transmission Noise Approximate Engine 1500 rpm with FNR lever in forward
Check Speed (F) position

Shift transmission into each gear and drive for a short distance.

LISTEN: Can excessive gear noise be heard when shifting between gears?

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Go to Group 9020-15, Excessive Power Train Noise or Excessive Gear Clash
When Shifting for manual or power shift transmission.

7B Differential Lock Check

Action:

T6295AD-UN: Differential Lock

Raise machine off ground with stabilizers and loader bucket.

Unlock brake pedals. Turn MFWD switch OFF (if equipped).

Operate machine at approximately 1500 rpm in 1st forward.

133
 Operational Checkout Procedure

Item Measurement Specification

Differential Lock Check Approximate Engine Speed 1500 rpm in 1st forward

Depress differential lock control.

Apply one brake pedal.

LOOK: Both wheels must stop.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check differential lock switch and solenoid. Go to Group 9015-10. Go to Group
9020-25, Differential Lock Pressure Test.

7C Differential Gear and Pinion Check

Action:

Shift transmission to first gear and operate engine at approximately 1500 rpm.

Item Measurement Specification

Differential Gear and Pinion Approximate Engine 1500 rpm in 1st
Check Speed gear

Move FNR lever to forward (F) position.

Steer machine in a maximum left turn and depress left brake pedal to stop the left
wheel.

Steer machine in a maximum right turn and depress right brake pedal to stop the
right wheel.

LISTEN: Can excessive gear noise be heard in the differential or pinion gear area?

Record of Actual Results:

134
 Operational Checkout Procedure

Result:
NO:
Go to next check.
YES:
Go to Group 9020-15, Diagnose Rear Axle Malfunctions.

7D Front Wheel Alignment (Toe-In) Check

Action:

T6264AI-UN: Front Wheel Alignment (Toe-In)

Drive machine in fourth gear forward on a surface with loose material.

LOOK: Is material from behind front wheels thrown excessively inward or

outward?

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
If material is thrown, excessive tire wear will result. Go to Group 9020-20, Adjust
Toe-In.

7E Engine and Torque Converter Check (Without MFWD)

135
 Operational Checkout Procedure

Action:

T6171AM-UN: Engine and Torque Converter (Without MFWD)

Position machine with loader bucket at ground level against dirt bank or
immovable object.

Shift transmission into first gear.

Move FNR lever to forward (F) position.

Engage differential lock.

Increase engine speed to fast idle.

LOOK: Do rear wheels stall?

NOTE:

This test will give a general indication of engine, transmission and

torque converter performance.

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
If the wheels can be easily stalled, go to Group 9020-15, Power Train-Machine
Lacks Power or Moves Slow.

136
 Operational Checkout Procedure

7F Transmission Hydraulic System Check

Action:

Run engine at approximately 1500 rpm.

Item Measurement Specification

Transmission Hydraulic System Check Approximate Engine Speed 1500 rpm

Shift transmission into third gear.

Move FNR lever to forward (F) position.

Make several shifts from third forward to third reverse. Start counting the number
of seconds when FNR lever is moved to opposite direction.

LOOK: Has machine changed direction in three seconds?

NOTE:

If bad in one direction ONLY, check direction pack.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check torque converter or modulation valve. Go to Group 9020-25.

8 Ride Control Operational Checks (If Equipped)

Launch Close Expand List Collapse List

8A Electrical Checks

Action:

Turn key switch on (do not start engine).

137
 Operational Checkout Procedure

Turn ride control switch on.

LOOK: Does ride control switch light turn on?

Turn ride control switch off.

LOOK: Does ride control switch light turn off?

Turn ride control switch on.

Turn key switch off.

LOOK: Does ride control switch light turn off?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check and replace ride control switch light.
IF OK:
Check wiring.

8B Hydraulic Checks

NOTE:

Make sure park brake is off during hydraulic checks.

Action:

Start tractor and set throttle about 1000 - 1500 rpm.

Turn ride control on.

Try to lift front end of tractor off ground using loader boom lever.

Release loader boom lever.

138
 Operational Checkout Procedure
LOOK/FEEL: Will front end of tractor lift off of ground and hold?

Record of Actual Results:

Result:
NO:
Continue check.
YES:
Check ride control hydraulics.
Action:

Turn ride control off.

Try to lift front end of tractor off ground using loader boom lever.

Release loader boom lever.

LOOK/FEEL: Will front end of tractor lift off of ground and hold?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check ride control hydraulics.

8C Ride Control Check

CAUTION:
Boom will jump upward during this check. Make sure area
around bucket is clear.

Action:

Start engine.
139
 Operational Checkout Procedure
Start engine.

Push Ride Control Switch to OFF position.

Raise boom to maximum height and hold control lever over relief for 2 seconds.

Lower boom and bucket to ground and stop engine. Put boom control lever in
neutral.

Turn key switch on. Turn ride control switch on.

Does boom jump up?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check accumulator charge.

9 Mechanical Front Wheel Drive (MFWD) Driving Check

Launch Close Expand List Collapse List

9A MFWD Switch Check

Action:

T102991-UN: MFWD Switch

Engage MFWD.

LOOK: Does MFWD light in display monitor come ON when switch is moved?
140
 Operational Checkout Procedure

Disengage MFWD.

LOOK: Is MFWD light in display monitor OFF with MFWD disengaged?

NOTE:

Indicator light in MFWD switch will remain ON while MFWD is

engaged. If MFWD is turned OFF while operating, light will go out
but MFWD could stay on until load on drive train is released.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check electrical circuit. Go Group 9015-10, MFWD circuit. Go to Group 9020-25,
MFWD Pressure Test.

9B MFWD Differential Check

Action:

Start engine and run at low idle.

Item MeasurementSpecification
MFWD Differential Check Engine Speed Low idle

Raise machine off ground with stabilizers and loader.

Release park brake.

Shift transmission to first gear and put FNR in forward.

Engage MFWD.

Lower front wheels to just contact ground.

LOOK: Do both front wheels turn?

141
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If at least one front wheel does not turn with MFWD applied, go to group 9020-25
MFWD pressure test. Check electrical circuit, go to Group 9015-10 MFWD circuit.

9C Engine and Torque Converter Check (With MFWD)

Action:

T6171AN-UN: Engine and Torque Converter (With MFWD)

With loader bucket level and cutting edge at the centerline of front wheels, put
machine against a dirt bank or immovable object.

Engage MFWD and differential lock.

Shift transaxle to first forward.

Increase engine speed to fast idle

LOOK: Do both rear wheels and both front wheels turn?

Record of Actual Results:

Result:

142
 Operational Checkout Procedure

YES:
Go to next check.
NO:
If all wheels stop, a torque converter or transmission control valve problem is
indicated. If the front wheels stop, MFWD problem is indicated. Go to Group 9020-
15, Machine Lacks Power or Moves Slow.

9D MFWD Gear and Pinion Check

Action:

Drive machine at transport speed with MFWD engaged, then disengaged.

LISTEN: Does MFWD “whine” when disengaged.

NOTE:

It is normal for MFWD to “whine” when engaged.

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
If MFWD whines, check oil levels and fill to correct levels. Go to Diagnose MFWD
Malfunctions in Group 9020-15.

10 Hydraulic System Checks

Launch Close Expand List Collapse List

10A Hydraulic Pump Performance Check

Action:

NOTE:

If hydraulic oil is not at operating temperature, heat oil to 38-52° C

(100-125°F).
143
 Operational Checkout Procedure

Put backhoe bucket in fully extended position.

Run engine at high idle.

Item Measurement Specification

Hydraulic Pump Performance Engine Speed High idle
Check
Hydraulic Oil 38-52° C (100-
Temperature 125°F)

FNR in neutral.

Park brake ON.

Measure cycle time to fully curl backhoe bucket.

LOOK: Does bucket curl in 4 seconds or less?

Item Measurement Specification

Backhoe Bucket Fully Curled Maximum Cycle Time 4 seconds

NOTE:

Take the average cycle time for at least three cycles. This time will
give a general indication of main hydraulic pump performance.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If cycle time slow, go to 9025-15, Slow Hydraulic Functions.

10B Flow Limiter Check

Action:

144
 Operational Checkout Procedure

NOTE:

If hydraulic oil is not at operating temperature, heat oil to 38-52° C

(100-125°F).

NOTE:

This check indicates a nominal flow limiter setting for machines

doing both loader and backhoe operations.

Park brake ON.

FNR in neutral.

Engine speed at high idle.

Item Measurement Specification

Flow Limiter Check Engine Speed High idle
Hydraulic Oil Temperature 38-52° C (100-125°F)

Put backhoe bucket in dump position.

Record cycle time to extend dipperstick while holding backhoe bucket dump over
relief.

LOOK: Does dipperstick extend in 3.5-4?

Item MeasurementSpecification
Extend Dipperstick (Backhoe Bucket Dump Held Cycle Time 3.5-4 seconds
Over Relief)

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Do Flow Limiter Test in group 9025-25.

145
 Operational Checkout Procedure

10C Cylinder Cushion Check

Action:

Raise wheels off ground with stabilizers.

Boom MUST be lowered from the transport position.

Run engine at high idle.

Item MeasurementSpecification
Cylinder Cushion Check Engine Speed High idle
Activate backhoe swing left and right.

Note sound and speed as cylinders near end of their stroke.

LOOK: Does speed of cylinder rod decrease near the end of its stroke?

LISTEN: Can hydraulic oil be heard flowing through orifice as cylinder rod nears
the end of its stroke?

Repeat check using backhoe boom raise functions.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Remove and repair cylinder cushion. Go to repair manual.

10D Stabilizer Cylinder and Valve Check

Action:

Operate machine at approximately 1500 rpm.

Item Measurement Specification

Stabilizer Cylinder and Valve Check Approximate Engine Speed 1500 rpm

146
 Operational Checkout Procedure

Position loader bucket above ground.

Lower each stabilizer cylinder and raise rear of machine off ground.

LOOK/FEEL: Do cylinders extend smoothly and hold machine up?

Retract each stabilizer cylinder.

LOOK/FEEL: Do cylinders retract smoothly and remain retracted?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Cylinders drift up or down. Inspect lock outs. Go to repair manual. Cylinders drift
down rapidly. Go to Group 9025-25, Cylinder Leakage Test.

10E Backhoe and Loader Function Drift Check

Action:

T7374CI-UN: Backhoe and Loader Function Drift

NOTE:

Feel backhoe cylinders. Cylinder must be warm to touch (38-52°C

[100-125°F]). If cylinders are not warm, heat oil to specifications.

With backhoe fully extended, put backhoe bucket at a 45° angle to ground. Lower
boom until bucket cutting edge is 50 mm (2.0 in.) off the ground.
147
 Operational Checkout Procedure

Position loader bucket same distance off ground as backhoe bucket.

Run engine at slow idle and observe bucket cutting edge.

Item Measurement Specification

Backhoe and Loader Engine Speed Slow idle
Function Drift Check
Hydraulic Oil 38-52°C (100-125°F) (Cylinders
Temperature warm to touch)

LOOK: Do cutting edges touch ground within one minute?

Item MeasurementSpecification
Backhoe and Loader Function Drift 50 mm (2.0 in.) in one minute

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Verify which function is drifting. Go to Group 9025-25, Drift Test.

10F Hydraulic Control Valve Lift Check Test

Action:

NOTE:

Husco valves have one lift check for both work ports, and
therefore only need to be checked in one direction.

Raise loader bucket 1 m (3.0 ft.) off the ground with the bucket level.

Position backhoe at maximum reach with bucket in dump position, 1 m (3.0 ft.) off
the ground.

Stop the engine.

148
 Operational Checkout Procedure

Activate each function one at a time.

Loader boom raise

Loader bucket rollback
Backhoe boom up
Dipperstick extend
Backhoe bucket dump

LOOK: Do functions move when the control lever is activated?

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Inspect control valve lift check. Go to repair manual. Do cylinder leakage test, go
to group 9025-25.

10G Loader Boom Float Check

Action:

Put loader bucket at maximum height position with bucket dumped.

Run engine at approximately 1500 rpm.

Item Measurement Specification

Loader Boom Float Check Approximate Engine Speed 1500 rpm

Move the loader control lever forward into boom float detent position, and at the
same time into bucket rollback detent position. Remove hand from control lever.

LOOK: Does loader control lever remain in the boom float detent position?

Record of Actual Results:

Result:

149
 Operational Checkout Procedure

YES:
Go to next check.
NO:
If it jumps out of detent, check detent spring and detent balls. Go to repair manual.

10H Loader Return-to-Dig Check

Action:

T6171AT-UN: Loader Return-to-Dig Switch

T7374CH-UN: Bucket Indicator Pointer

Put loader bucket at maximum height position with bucket dumped.

Run engine at approximately 2000 rpm.

Item Measurement Specification

Loader Return-to-Dig Check Approximate Engine Speed 2000 rpm

Move the loader control lever forward into boom float detent position, and at the
same time into bucket rollback detent position. Remove hand from control lever.

LOOK: Does the loader control lever disengage from the bucket rollback detent
when the bucket is level.

150
 Operational Checkout Procedure
LOOK: When the bucket is at ground level, bucket must be level and the bucket
indicator pointer must be aligned with mark on the boom pivot.

NOTE:

When return-to-dig is used with loader boom in full up position, the

bucket leveling linkage will move the bucket control valve out of
return-to-dig position before bucket is actually level.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust switch until it is activated in cam. Go to Group 9025-20, Loader Bucket
Self-Leveling Indicator Linkage and Return-to-Dig Switch Adjustment.

10I Bucket Leveling Linkage Check

Action:

T7374CJ-UN: Bucket Leveling Linkage

NOTE:

The loader bucket leveling feature functions during the boom raise
cycle only. When bucket is lowered, the operator can manually
level the bucket or use the return-to-dig.

151
 Operational Checkout Procedure

Put loader bucket in the rollback position with the boom near ground level.

Raise the loader and at the same time hold the control lever in the bucket rollback
position.

Observe bucket and loader control lever as the loader raises.

LOOK/FEEL: Does loader control lever move into the bucket dump position and
the bucket dump function slowly activate? When the loader control lever moves to
activate the bucket dump function, does the bucket position remain stationary the
remainder of the loader boom raise cycle?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust switch until it is activated in cam. Go to Group 9025-20, Loader Bucket
Self-Leveling Indicator Linkage and Return-to-Dig Switch Adjustment.

11 Check Operation Of Accessories (Engine Stopped)

Launch Close Expand List Collapse List

11A Front Light Switch Check

Action:

Turn key switch to ON position.

Push front light rocker switch to middle position.

LOOK: Are two front lights, two red tail lights and gauge lights ON?

Push front light rocker switch in completely.

LOOK: Are four front lights (if equipped), two red tail lights and gauge lights ON?

Record of Actual Results:

152
 Operational Checkout Procedure

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Front Work and Drive
Light Circuit.

11B Rear Light Switch Check

Action:

Turn key switch to ON position.

Push side console rear light rocker switch in.

LOOK: Are rear lights ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Front Work and Drive
Light Circuit .

11C Turn Signal Check

Action:

Turn key switch to ON position.

Push right side of turn signal rocker switch down.

LOOK: Are right front and rear amber lights flashing? Does right indicator light on
top of steering column flash?

153
 Operational Checkout Procedure

Push left side of turn signal rocker switch down.

LOOK: Are left front and rear amber lights flashing? Does left indicator light on top
of steering column flash?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuses and wiring. Go to Group 9015-10, Turn Signal, Flasher and Brake
Light Circuit.

11D Brake Light Switch Check

Action:

Key switch in the ON position.

Depress and hold left brake pedal, then right brake pedal.

LOOK: Rear brake lights must come ON when either pedal is depressed with key
switch in ON position.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Turn Signal, Flasher
and Brake Light Circuit.

11E Warning Light Check

Action:

Key switch ON.

154
 Operational Checkout Procedure
Key switch ON.

Push bottom of warning light rocker switch in.

LOOK: Are both front and rear amber lights ON? Are both turn signal indicators
and light in warning light rocker switch flashing?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuses and wiring. Go to Group 9015-10, Turn Signal, Flasher and Brake
Light Circuit.

11F Horn Check

Action:

Turn key switch to ON position.

Push horn button

LISTEN: Did horn sound?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuses and wiring. Go to Group 9015-10, Horn Circuit.

12 Cab Component Checks

Launch Close Expand List Collapse List

155
 Operational Checkout Procedure

12A Seat Linkage Check

Action:

T103194-UN: Seat Linkage

Lift lever (1).

Move seat forward and rearward and release lever.

LOOK: Does lever move freely and lock seat in desired position?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Repair linkage. Go to repair manual.

12B Seat Height Adjustment Check

Action:

T103194-UN: Seat Height Adjustment

156
 Operational Checkout Procedure

Turn knob (3) to raise or lower seat to desired position.

LOOK: Does seat move up or down and remain in desired position?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to repair manual.

12C Seat Swivel Linkage Check

Action:

T103194-UN: Seat Swivel Linkage

Lift lever (2) up.

Move seat from loader to backhoe position and engage latch.

LOOK: Does seat latch move freely and hold seat in desired position?

FEEL: Does lever move freely and hold seat in loader and backhoe positions?

Record of Actual Results:

Result:
YES:
Go to next check.

157
 Operational Checkout Procedure

NO:
Lubricate or repair linkage. Go to repair manual.

12D Seat Back Linkage Check

Action:

T103194-UN: Seat Back Linkage

Lift lever (4) up.

Position seat back as desired and engage latch.

FEEL: Does lever move freely and hold seat in desired positions?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Lubricate or repair linkage. Go to repair manual.

12E Left Cab Door Latch and Opener Check

Action:

Unlatch door.

Observe door as it opens.

Pull door closed and latch it.

158
 Operational Checkout Procedure
FEEL: Does cab door latch work freely?

LOOK: Will door cylinder push door open?

LOOK: Does cab door contact door stop bumper before door cylinder bottoms?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust cab door. Go to repair manual.

12F Right Door Latch and Opener Check (If Equipped)

Action:

Unlatch door and pull door open.

Close and latch door.

FEEL: Does cab door latch work freely?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust door. Go repair manual.

12G Rear Window Latch and Opener Checks

Action:

Squeeze latches on both sides of middle rear window. Lower window to rubber
bumpers.

159
 Operational Checkout Procedure
Push latch releases on upper rear window.

Observe window as it opens.

Push window up and into window catches and note fit.

Observe cylinders while closing window. Raise middle window and push into
latches.

LOOK: Do window latches and hinges move freely?

LOOK: Will the gas-filled cylinders slowly assist raising the window to open
position?

NOTE:

Cylinders must not be at end of travel when closing window.

LOOK: Do window catches hold and not bow the window in the up position?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check for obstructions. Go to repair manual.

12H Side Window Checks

Action:

160
 Operational Checkout Procedure
T6171DF-UN: Side Window

Open left and right rear side window.

Fasten rear window against front window.

LOOK: Does sleeve on rear window align with knob on front window?

LOOK/FEEL: Do hinges move freely? Are locking latches equally loaded when
closed?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust windows. Go to repair manual.

12I Blower Motor Check

Action:

T101677-UN: Blower Motor

Engine OFF key switch ON.

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

FEEL/LISTEN: Does blower fan have four speeds?

Does air exit from ducts?

161
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check wiring harness. See Group 9015-10, Blower Circuit.

12J Heater

Action:

T101678-UN: Heater

Start engine and run at fast idle.

Item MeasurementSpecification
Heater Check Engine Speed Fast idle

Wait two minutes.

Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to
high speed.

FEEL: Is air from ducts warm?

Record of Actual Results:

Result:

162
 Operational Checkout Procedure

YES:
Go to next check.
NO:
See to Group 9015-10, Blower Circuit.

12K Air Conditioner (If Equipped)

Action:

T101679-UN: Air Conditioner

Start engine and run at fast idle.

Item MeasurementSpecification
Air Conditioner Check Engine Speed Fast idle

Turn air conditioner switch (A) to ON position.

Turn blower switch (B) to high speed.

Wait for any warm air in duct system to be exhausted.

FEEL: Is air from ducts cool?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Heating and Air Conditioning, Group 9031-10. See Charging the System in

163
 Operational Checkout Procedure
Group 9031-20.

12L Rear Windshield Wiper Check

Action:

Turn key to ON position.

Push rear wiper rocker switch to first detent, middle position.

Push rear wiper rocker switch all the way in.

Push rear wiper switch to OFF position.

LOOK: Rear wiper must operate and have two speeds.

LOOK: Wipers must return to park position.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse. Check rear wiper. Go to Group 9015-10, Wiper/Washer Circuit.

12M Front Windshield Wiper Check

Action:

Turn key switch to ON position.

Push front wiper rocker switch to first detent, middle position.

Push front wiper switch all the way in.

Push front wiper switch to OFF position.

LOOK: Do both front wipers operate and have two speeds?

LOOK: Do wipers return to the park position?

164
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse. Check front wiper. Go to Group 9015-10, Wiper/Washer Circuit.

12N Front Windshield Washer Check

Action:

Turn key switch to ON position.

Push windshield washer rocker switch in.

LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF
position.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fluid level, and fluid lines for blockage. Check wiring. Go to Group 9015-10,
Wiper/Washer Circuit.

12O Cab Dome Light Check

Action:

Turn key switch to ON position.

Push dome light switch to ON position.

LOOK: Does lights come ON?

165
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Dome Light Circuit.

13 Miscellaneous Checks
Launch Close Expand List Collapse List

13A Vandal Protection Check

Action:

Lock cab door(s) using ignition key.

FEEL: Does lock operate freely and key not stick in lock?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Lubricate or repair lock. Go to repair manual.

13B Check Periodic Maintenance Decal

Action:

Check periodic maintenance decal on inside of hood access door.

LOOK: Is periodic maintenance decal legible?

Record of Actual Results:

166
 Operational Checkout Procedure

Result:
YES:
Go to next check.
NO:
Replace decal. Go to John Deere Dealer for part.

13C Backhoe Transport Pin Check

Action:

Raise boom into transport position.

Remove swing lock pin from holder in rear corner of cab and install through top
and bottom holes of swing frame and through main frame.

LOOK: Does swing lock pin install freely?

Record of Actual Results:

Result:
YES:
Operational Checkout completed.
NO:
Repair or replace swing lock pin. Check pin bore for burrs or obstruction.

TX,9005,YY2135-19-1996/08/08

167
 Operational Checkout Procedure

Operational Checkout Procedure

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

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

The information obtained after completing the operational checkout will allow you or
your authorized dealer to pinpoint a specific test or repair needed to restore the
machine to specifications.

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

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

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

1 Gauge and Indicator Check With Engine Off

Launch Close Expand List Collapse List

1A Monitor Indicator Lights and Alarm Checks

Action:

168
 Operational Checkout Procedure
T103007-UN: Monitor Indicator Lights and Alarm

Turn key switch to BULB CHECK position and hold.

LOOK: Are all monitor indicator lights on? Is STOP light ON and does alarm
sound?

NOTE:

Starting motor MUST NOT operate.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check monitor/gauge fuse. Go to Group 9015-15, Display Monitor Checks. If
motor starts and bulb check position is OK, key switch is failed or there is a short in
wiring. Go to Group 9015-15, Start Circuit.

2 FNR, Neutral Start Circuit and Reverse Warning Alarm Checks

Launch Close Expand List Collapse List

2A FNR Switch Check

Action:

T7447AH-UN: FNR Switch

Engine off.

169
 Operational Checkout Procedure

Move FNR lever to forward (F), reverse (R), then neutral (N) position.

FEEL: Observe and feel forward, neutral and reverse detents.

Turn key switch to ON position. Move FNR lever into forward and reverse.

LISTEN: Did you hear a "click" from the side console neutral start relay as FNR
lever was moved?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If no "click", inspect neutral start relay. Go to Group 9015-15, Start Circuit.

2B Neutral Start Check

Action:

Move FNR lever to forward (F) position and turn key switch to start position.

Move FNR lever to reverse (R) position and turn key switch to start position.

LISTEN: Did starting motor operate?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Group 9015-15, Start Circuit.

2C Start Circuit Check

Action:

170
 Operational Checkout Procedure

T7447AH-UN: Start Circuit

Move FNR lever to neutral (N) position and turn key switch to START position.

Observe and listen to monitor as engine is cranking.

LISTEN: Did starting motor operate?

LISTEN: Did alarm sound?

LOOK: During engine cranking, were all indicator lights ON? Is STOP indicator
ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If engine turns but does not start, check fuel shut-off/start aid/reverse alarm fuse. If
starting motor does not operate check start fuse. Go to Group 9015-15, Start
Circuit. If indicator lights are NOT ON, check monitor/gauge fuse. Go to Group
9015-15, Display Monitor Checks.

2D Reverse Warning Alarm Check

Action:

171
 Operational Checkout Procedure

T7447AI-UN: Reverse Warning Alarm

Key switch ON.

Move FNR lever to reverse (R) position.

LISTEN: Does reverse warning alarm sound?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
See Reverse Alarm Circuit. Go to Group 9015-10.

3 Park Brake, Charge Indicator Light, Tachometer/Hour Meter

Circuit and Engine Speed Control Linkage Checks
Launch Close Expand List Collapse List

3A Park Brake Indicator Check

Action:

172
 Operational Checkout Procedure

T7447AG-UN: Park Brake Indicator

T103007-UN: Indicators

IMPORTANT:

If engine oil pressure indicator light stays ON, STOP ENGINE

IMMEDIATELY, check oil level.

Engage park brake.

Put FNR lever in neutral (N) and start the engine.

Put FNR lever in forward (F) position.

LOOK: Is STOP indicator ON? Does alarm sound? Is park brake and seat belt light
ON? Are all other indicator lights out?

Release park brake.

LOOK/LISTEN: Is park brake indicator and STOP light out? Alarm WILL NOT
sound.

Record of Actual Results:

173
 Operational Checkout Procedure

Result:
YES:
Go to next check.
NO:
If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY
and check oil level. Go to Group 9010-15, Engine Low Oil Pressure. If alternator
indicator light is ON, increase engine speed to 1200 rpm and alternator light MUST
go out. Go to Group 9015-15, Charge Circuit Checks. If no park brake light,
inspect wiring connector at switch on park brake linkage. Go to Group 9015-15,
Park Brake Circuit.

3B Seat Position Sensor Check

Action:

Engine speed at low idle.

Item MeasurementSpecification
Seat Position Sensor Check Engine Speed Low idle

Lower all equipment to ground.

Release park brake.

Transmission gear shift lever in neutral, FNR in forward or reverse.

Operators seat in the backhoe position.

LISTEN: Does alarm sound and is STOP indicator ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to indicator circuit in Group 9015-15.

174
 Operational Checkout Procedure

3C Tachometer/
Hourmeter Circuit Check

Action:

T7447AH-UN: Tachometer/Hourmeter Circuit

IMPORTANT:

If engine low oil pressure indicator light stays ON, STOP

ENGINE IMMEDIATELY and check oil level.

Engage park brake.

Put FNR lever in neutral and start the engine.

LOOK/LISTEN: Is hourmeter indicator rotating? Does tachometer (if equipped)

indicate rpm?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If park brake indicator light is not ON, go to Group 9015-15, Park Brake Circuit. If
no hour meter or tachometer movement, go to Group 9015-10, Gauge and Hour
Meter Circuit.

3D Engine Speed Control Lever Linkage Check

175
 Operational Checkout Procedure

Action:

T102991-UN: Engine Speed Control Lever Linkage

Engage park brake.

Put FNR lever in neutral and start engine.

Note rpm on tachometer (if equipped).

Move speed control lever to fast idle position.

LOOK: Does tachometer read 900 + 25 - 0 rpm (slow idle) or 2400 + 25 - 0 rpm
(fast idle)?

Item MeasurementSpecification
Slow Idle Speed 900 + 25 - 0 rpm
Fast Idle Speed 2400 + 25 - 0 rpm

LOOK: Does speed control lever remain at selected position?

Record of Actual Results:

Result:
NO:
Tighten friction lock. Go to Group 9010-20. Check engine speed. Go to Group
9010-20.
YES:
Go to next check.

3E Engine Speed Control Pedal Linkage Check

176
 Operational Checkout Procedure

Action:

T7394BF-UN: Engine Speed Control Pedal Linkage

Depress speed control pedal

LISTEN: Does engine speed stay the same as with speed control lever in fast idle
position?

Record of Actual Results:

Result:
YES:
Yes: Go to next check.
NO:
Adjust Speed Control Linkage. Go to Group 9010-20.

4 Brake System Checks

Launch Close Expand List Collapse List

4A Pedal Stop Check

Action:

177
 Operational Checkout Procedure

T7394BG-UN: Brake System

Lift left and right brake pedals.

LOOK: Are brake pedals against pedal stop?

NOTE:

This ensures that brake check valves are opened and brakes
released.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust brake pedal stops. Go to Group 9020-20.

4B Brake System Leakage Check

Action:

178
 Operational Checkout Procedure

T7367AM-UN: Brake System Leakage

Depress and hold left brake pedal, then right brake pedal using approximately 267
N (60 lb. force).

LOOK: Brake pedal must NOT feel spongy (caused by air in system). Does pedal
settle more than 25 mm (1.0 in.) per minute?

Item MeasurementSpecification
Brake Leakage Pedal settles more than 25 mm (1.0 in.) per minute with
System 267 N (60 lb. force) applied

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Bleed brake system. Go to Group 9020-20.

4C Brake Drag/Park Brake Check

Action:

179
 Operational Checkout Procedure

T6171AL-UN: Brake Drag/Park Brake Check

Position machine on a gradual slope with front of machine downhill.

Lift bucket so it clears ground.

Shift FNR lever to neutral, differential lock control up, disengage park brake and
release service brakes.

Let machine coast freely for several feet. Apply park brake.

LOOK: Did machine stop?

Release park brake.

LOOK: Did machine move or coast freely?

NOTE:

If machine does not move freely on slope, drive the machine for
five minutes. Feel axle housing area to locate which brake is
dragging.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Group 9020-25, Brake Valve Leakage Test or Park Brake Release Pressure
Test.

180
 Operational Checkout Procedure

4D Park Brake Function Check

Action:

Start machine, move throttle to 1200 rpm.

Leave park brake ON.

Put FNR lever in forward position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever to reverse position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever back to neutral position.

Move throttle back to slow idle and shut the machine off.

LOOK: The machine MUST NOT move in any gear.

LOOK: STOP light and Park Brake indicators MUST be lit.

LOOK: Hazard light MUST be flashing.

LISTEN: An audible beeping alarm MUST be heard.

LISTEN: With the FNR In the reverse position, the reverse audible alarm MUST be
heard.

Record of Actual Results:

Result:
YES:
If the machine moves in any gear, see your authorized dealer.
YES:
If the indicators do not work, see your authorized dealer.
NO:

181
 Operational Checkout Procedure
Go to next check.

4E Park Brake Function Check

Action:

Start machine, move throttle to 1200 rpm.

Leave park brake ON.

Put FNR lever in forward position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever to reverse position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever back to neutral position.

Move throttle back to slow idle and shut the machine off.

LOOK: The machine MUST NOT move in any gear.

LOOK: STOP light and Park Brake indicators MUST be lit.

LOOK: Hazard light MUST be flashing.

LISTEN: An audible beeping alarm MUST be heard.

LISTEN: With the FNR In the reverse position, the reverse audible alarm MUST be
heard.

Record of Actual Results:

Result:
YES:
If the machine moves in any gear, see your authorized dealer.
YES:
If the indicators do not work, see your authorized dealer.

182
 Operational Checkout Procedure

NO:
Go to next check.

5 Steering System Checks

Launch Close Expand List Collapse List

5A Steering Check

Action:

Raise loader bucket above ground level.

Raise rear of machine off ground using stabilizers.

Operate engine at approximately 1000 rpm.

Item Measurement Specification

Steering Check Approximate Engine Speed 1000 rpm

Turn steering wheel from full left to full right several times.

LOOK: Did front wheels move smoothly in both directions?

LOOK: When steering wheel was stopped, did front wheels stop moving?

NOTE:

Internal leakage or a sticking steering valve spool can cause

wheels to continue to move after steering wheel is stopped.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Group 9025-15, Steering Valve Does Not Return to Neutral.

183
 Operational Checkout Procedure

5B Steering System Leakage Check

Action:

NOTE:

Hydraulic oil must be at operating temperature.

Run engine at slow idle.

Item Measurement Specification

Steering System Leakage Engine Speed Slow idle
Check
Hydraulic Oil Operating
Temperature temperature
Turn steering wheel until wheels are in maximum right turn position. Continue
turning steering wheel, using approximately 11.3 N·m (100 lb-in.) force while
counting steering wheel rpm.
Item MeasurementSpecification
Steering Wheel Torque 11.3 N·m (100 lb-in.)

Repeat leakage check turning steering wheel to the left.

LOOK: Did steering wheel turn 5 rpm or less to the left or right?

Item Measurement Specification

Steering System Maximum Leakage 5 rpm
This represents acceptable steering wheel movement during normal operation.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If steering wheel turns more than 5 rpm, verify whether valve or cylinder is leaking.
Go to Group 9025-25, Steering System Leakage Test.

184
 Operational Checkout Procedure

5C Steering Load Sense Check

Action:

Operate engine at slow idle.

Turn steering wheel to stop left and right. Note effort required to turn wheel.

Turn wheel to stop and apply constant pressure.

LOOK/FEEL: Does wheel stop at both axle stops and require normal steering
wheel effort?

LOOK/LISTEN: Does tachometer (if equipped) momentarily decrease in rpm or

does engine rpm momentarily decrease when steering wheel is held against stop?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Steers hard and no decrease in engine rpm. Go to Group 9025-25, Steering Load
Sense Relief Valve Stall Pressure Test.

6 Transmission Neutral Disconnect Circuit Check

Launch Close Expand List Collapse List

6A Neutral Disconnect Circuit Check

Action:

CAUTION:
Machine will move forward as FNR lever is moved.

Start engine, set idle speed at approximately 1500 rpm.

185
 Operational Checkout Procedure

Item Measurement Specification

Neutral Disconnect Circuit Check Approximate Engine Idle Speed 1500 rpm

Put transmission in fourth gear.

Release park brake.

Shift FNR lever to forward (F) position.

LISTEN: When FNR lever is shifted to forward (F) position, can a noticeable drop
in engine speed should be heard?

Press button on gear shift lever (manual shift only) or loader control lever
individually and note sound of engine.

LISTEN: Does engine rpm increase when the neutral solenoid switches are
depressed?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check switch. Go to Group 9015-15, Park Brake/Neutral Disconnect Circuit.

7 Driving Checks
Launch Close Expand List Collapse List

7A Transmission Shift Noise Check

Action:

IMPORTANT:

Press button on gear shift lever when shifting gears (manual

shift only).

186
 Operational Checkout Procedure

Run engine at approximately 1500 rpm with FNR lever in forward (F) position.

Item Measurement Specification

Transmission Noise Approximate Engine 1500 rpm with FNR lever in forward
Check Speed (F) position

Shift transmission into each gear and drive for a short distance.

LISTEN: Can excessive gear noise be heard when shifting between gears?

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Go to Group 9020-15, Excessive Power Train Noise or Excessive Gear Clash
When Shifting for manual or power shift transmission.

7B Differential Lock Check

Action:

T6295AD-UN: Differential Lock

Raise machine off ground with stabilizers and loader bucket.

Unlock brake pedals. Turn MFWD switch OFF (if equipped).

Operate machine at approximately 1500 rpm in 1st forward.

187
 Operational Checkout Procedure

Item Measurement Specification

Differential Lock Check Approximate Engine Speed 1500 rpm in 1st forward

Depress differential lock control.

Apply one brake pedal.

LOOK: Both wheels must stop.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check differential lock switch and solenoid. Go to Group 9015-10. Go to Group
9020-25, Differential Lock Pressure Test.

7C Differential Gear and Pinion Check

Action:

Shift transmission to first gear and operate engine at approximately 1500 rpm.

Item Measurement Specification

Differential Gear and Pinion Approximate Engine 1500 rpm in 1st
Check Speed gear

Move FNR lever to forward (F) position.

Steer machine in a maximum left turn and depress left brake pedal to stop the left
wheel.

Steer machine in a maximum right turn and depress right brake pedal to stop the
right wheel.

LISTEN: Can excessive gear noise be heard in the differential or pinion gear area?

Record of Actual Results:

188
 Operational Checkout Procedure

Result:
NO:
Go to next check.
YES:
Go to Group 9020-15, Diagnose Rear Axle Malfunctions.

7D Front Wheel Alignment (Toe-In) Check

Action:

T6264AI-UN: Front Wheel Alignment (Toe-In)

Drive machine in fourth gear forward on a surface with loose material.

LOOK: Is material from behind front wheels thrown excessively inward or

outward?

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
If material is thrown, excessive tire wear will result. Go to Group 9020-20, Adjust
Toe-In.

7E Engine and Torque Converter Check (Without MFWD)

189
 Operational Checkout Procedure

Action:

T6171AM-UN: Engine and Torque Converter (Without MFWD)

Position machine with loader bucket at ground level against dirt bank or
immovable object.

Shift transmission into first gear.

Move FNR lever to forward (F) position.

Engage differential lock.

Increase engine speed to fast idle.

LOOK: Do rear wheels stall?

NOTE:

This test will give a general indication of engine, transmission and

torque converter performance.

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
If the wheels can be easily stalled, go to Group 9020-15, Power Train-Machine
Lacks Power or Moves Slow.

190
 Operational Checkout Procedure

7F Transmission Hydraulic System Check

Action:

Run engine at approximately 1500 rpm.

Item Measurement Specification

Transmission Hydraulic System Check Approximate Engine Speed 1500 rpm

Shift transmission into third gear.

Move FNR lever to forward (F) position.

Make several shifts from third forward to third reverse. Start counting the number
of seconds when FNR lever is moved to opposite direction.

LOOK: Has machine changed direction in three seconds?

NOTE:

If bad in one direction ONLY, check direction pack.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check torque converter or modulation valve. Go to Group 9020-25.

8 Ride Control Operational Checks (If Equipped)

Launch Close Expand List Collapse List

8A Electrical Checks

Action:

Turn key switch on (do not start engine).

191
 Operational Checkout Procedure

Turn ride control switch on.

LOOK: Does ride control switch light turn on?

Turn ride control switch off.

LOOK: Does ride control switch light turn off?

Turn ride control switch on.

Turn key switch off.

LOOK: Does ride control switch light turn off?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check and replace ride control switch light.
IF OK:
Check wiring.

8B Hydraulic Checks

NOTE:

Make sure park brake is off during hydraulic checks.

Action:

Start tractor and set throttle about 1000 - 1500 rpm.

Turn ride control on.

Try to lift front end of tractor off ground using loader boom lever.

Release loader boom lever.

192
 Operational Checkout Procedure
LOOK/FEEL: Will front end of tractor lift off of ground and hold?

Record of Actual Results:

Result:
NO:
Continue check.
YES:
Check ride control hydraulics.
Action:

Turn ride control off.

Try to lift front end of tractor off ground using loader boom lever.

Release loader boom lever.

LOOK/FEEL: Will front end of tractor lift off of ground and hold?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check ride control hydraulics.

8C Ride Control Check

CAUTION:
Boom will jump upward during this check. Make sure area
around bucket is clear.

Action:

Start engine.
193
 Operational Checkout Procedure
Start engine.

Push Ride Control Switch to OFF position.

Raise boom to maximum height and hold control lever over relief for 2 seconds.

Lower boom and bucket to ground and stop engine. Put boom control lever in
neutral.

Turn key switch on. Turn ride control switch on.

Does boom jump up?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check accumulator charge.

9 Mechanical Front Wheel Drive (MFWD) Driving Check

Launch Close Expand List Collapse List

9A MFWD Switch Check

Action:

T102991-UN: MFWD Switch

Engage MFWD.

LOOK: Does MFWD light in display monitor come ON when switch is moved?
194
 Operational Checkout Procedure

Disengage MFWD.

LOOK: Is MFWD light in display monitor OFF with MFWD disengaged?

NOTE:

Indicator light in MFWD switch will remain ON while MFWD is

engaged. If MFWD is turned OFF while operating, light will go out
but MFWD could stay on until load on drive train is released.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check electrical circuit. Go Group 9015-10, MFWD circuit. Go to Group 9020-25,
MFWD Pressure Test.

9B MFWD Differential Check

Action:

Start engine and run at low idle.

Item MeasurementSpecification
MFWD Differential Check Engine Speed Low idle

Raise machine off ground with stabilizers and loader.

Release park brake.

Shift transmission to first gear and put FNR in forward.

Engage MFWD.

Lower front wheels to just contact ground.

LOOK: Do both front wheels turn?

195
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If at least one front wheel does not turn with MFWD applied, go to group 9020-25
MFWD pressure test. Check electrical circuit, go to Group 9015-10 MFWD circuit.

9C Engine and Torque Converter Check (With MFWD)

Action:

T6171AN-UN: Engine and Torque Converter (With MFWD)

With loader bucket level and cutting edge at the centerline of front wheels, put
machine against a dirt bank or immovable object.

Engage MFWD and differential lock.

Shift transaxle to first forward.

Increase engine speed to fast idle

LOOK: Do both rear wheels and both front wheels turn?

Record of Actual Results:

Result:

196
 Operational Checkout Procedure

YES:
Go to next check.
NO:
If all wheels stop, a torque converter or transmission control valve problem is
indicated. If the front wheels stop, MFWD problem is indicated. Go to Group 9020-
15, Machine Lacks Power or Moves Slow.

9D MFWD Gear and Pinion Check

Action:

Drive machine at transport speed with MFWD engaged, then disengaged.

LISTEN: Does MFWD “whine” when disengaged.

NOTE:

It is normal for MFWD to “whine” when engaged.

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
If MFWD whines, check oil levels and fill to correct levels. Go to Diagnose MFWD
Malfunctions in Group 9020-15.

10 Hydraulic System Checks

Launch Close Expand List Collapse List

10A Hydraulic Pump Performance Check

Action:

NOTE:

If hydraulic oil is not at operating temperature, heat oil to 38-52° C

(100-125°F).
197
 Operational Checkout Procedure

Put backhoe bucket in fully extended position.

Run engine at high idle.

Item Measurement Specification

Hydraulic Pump Performance Engine Speed High idle
Check
Hydraulic Oil 38-52° C (100-
Temperature 125°F)

FNR in neutral.

Park brake ON.

Measure cycle time to fully curl backhoe bucket.

LOOK: Does bucket curl in 4 seconds or less?

Item Measurement Specification

Backhoe Bucket Fully Curled Maximum Cycle Time 4 seconds

NOTE:

Take the average cycle time for at least three cycles. This time will
give a general indication of main hydraulic pump performance.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If cycle time slow, go to 9025-15, Slow Hydraulic Functions.

10B Flow Limiter Check

Action:

198
 Operational Checkout Procedure

NOTE:

If hydraulic oil is not at operating temperature, heat oil to 38-52° C

(100-125°F).

NOTE:

This check indicates a nominal flow limiter setting for machines

doing both loader and backhoe operations.

Park brake ON.

FNR in neutral.

Engine speed at high idle.

Item Measurement Specification

Flow Limiter Check Engine Speed High idle
Hydraulic Oil Temperature 38-52° C (100-125°F)

Put backhoe bucket in dump position.

Record cycle time to extend dipperstick while holding backhoe bucket dump over
relief.

LOOK: Does dipperstick extend in 3.5-4?

Item MeasurementSpecification
Extend Dipperstick (Backhoe Bucket Dump Held Cycle Time 3.5-4 seconds
Over Relief)

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Do Flow Limiter Test in group 9025-25.

199
 Operational Checkout Procedure

10C Cylinder Cushion Check

Action:

Raise wheels off ground with stabilizers.

Boom MUST be lowered from the transport position.

Run engine at high idle.

Item MeasurementSpecification
Cylinder Cushion Check Engine Speed High idle
Activate backhoe swing left and right.

Note sound and speed as cylinders near end of their stroke.

LOOK: Does speed of cylinder rod decrease near the end of its stroke?

LISTEN: Can hydraulic oil be heard flowing through orifice as cylinder rod nears
the end of its stroke?

Repeat check using backhoe boom raise functions.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Remove and repair cylinder cushion. Go to repair manual.

10D Stabilizer Cylinder and Valve Check

Action:

Operate machine at approximately 1500 rpm.

Item Measurement Specification

Stabilizer Cylinder and Valve Check Approximate Engine Speed 1500 rpm

200
 Operational Checkout Procedure

Position loader bucket above ground.

Lower each stabilizer cylinder and raise rear of machine off ground.

LOOK/FEEL: Do cylinders extend smoothly and hold machine up?

Retract each stabilizer cylinder.

LOOK/FEEL: Do cylinders retract smoothly and remain retracted?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Cylinders drift up or down. Inspect lock outs. Go to repair manual. Cylinders drift
down rapidly. Go to Group 9025-25, Cylinder Leakage Test.

10E Backhoe and Loader Function Drift Check

Action:

T7374CI-UN: Backhoe and Loader Function Drift

NOTE:

Feel backhoe cylinders. Cylinder must be warm to touch (38-52°C

[100-125°F]). If cylinders are not warm, heat oil to specifications.

With backhoe fully extended, put backhoe bucket at a 45° angle to ground. Lower
boom until bucket cutting edge is 50 mm (2.0 in.) off the ground.
201
 Operational Checkout Procedure

Position loader bucket same distance off ground as backhoe bucket.

Run engine at slow idle and observe bucket cutting edge.

Item Measurement Specification

Backhoe and Loader Engine Speed Slow idle
Function Drift Check
Hydraulic Oil 38-52°C (100-125°F) (Cylinders
Temperature warm to touch)

LOOK: Do cutting edges touch ground within one minute?

Item MeasurementSpecification
Backhoe and Loader Function Drift 50 mm (2.0 in.) in one minute

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Verify which function is drifting. Go to Group 9025-25, Drift Test.

10F Hydraulic Control Valve Lift Check Test

Action:

NOTE:

Husco valves have one lift check for both work ports, and
therefore only need to be checked in one direction.

Raise loader bucket 1 m (3.0 ft.) off the ground with the bucket level.

Position backhoe at maximum reach with bucket in dump position, 1 m (3.0 ft.) off
the ground.

Stop the engine.

202
 Operational Checkout Procedure

Activate each function one at a time.

Loader boom raise

Loader bucket rollback
Backhoe boom up
Dipperstick extend
Backhoe bucket dump

LOOK: Do functions move when the control lever is activated?

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Inspect control valve lift check. Go to repair manual. Do cylinder leakage test, go
to group 9025-25.

10G Loader Boom Float Check

Action:

Put loader bucket at maximum height position with bucket dumped.

Run engine at approximately 1500 rpm.

Item Measurement Specification

Loader Boom Float Check Approximate Engine Speed 1500 rpm

Move the loader control lever forward into boom float detent position, and at the
same time into bucket rollback detent position. Remove hand from control lever.

LOOK: Does loader control lever remain in the boom float detent position?

Record of Actual Results:

Result:

203
 Operational Checkout Procedure

YES:
Go to next check.
NO:
If it jumps out of detent, check detent spring and detent balls. Go to repair manual.

10H Loader Return-to-Dig Check

Action:

T6171AT-UN: Loader Return-to-Dig Switch

T7374CH-UN: Bucket Indicator Pointer

Put loader bucket at maximum height position with bucket dumped.

Run engine at approximately 2000 rpm.

Item Measurement Specification

Loader Return-to-Dig Check Approximate Engine Speed 2000 rpm

Move the loader control lever forward into boom float detent position, and at the
same time into bucket rollback detent position. Remove hand from control lever.

LOOK: Does the loader control lever disengage from the bucket rollback detent
when the bucket is level.

204
 Operational Checkout Procedure
LOOK: When the bucket is at ground level, bucket must be level and the bucket
indicator pointer must be aligned with mark on the boom pivot.

NOTE:

When return-to-dig is used with loader boom in full up position, the

bucket leveling linkage will move the bucket control valve out of
return-to-dig position before bucket is actually level.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust switch until it is activated in cam. Go to Group 9025-20, Loader Bucket
Self-Leveling Indicator Linkage and Return-to-Dig Switch Adjustment.

10I Bucket Leveling Linkage Check

Action:

T7374CJ-UN: Bucket Leveling Linkage

NOTE:

The loader bucket leveling feature functions during the boom raise
cycle only. When bucket is lowered, the operator can manually
level the bucket or use the return-to-dig.

205
 Operational Checkout Procedure

Put loader bucket in the rollback position with the boom near ground level.

Raise the loader and at the same time hold the control lever in the bucket rollback
position.

Observe bucket and loader control lever as the loader raises.

LOOK/FEEL: Does loader control lever move into the bucket dump position and
the bucket dump function slowly activate? When the loader control lever moves to
activate the bucket dump function, does the bucket position remain stationary the
remainder of the loader boom raise cycle?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust switch until it is activated in cam. Go to Group 9025-20, Loader Bucket
Self-Leveling Indicator Linkage and Return-to-Dig Switch Adjustment.

11 Check Operation Of Accessories (Engine Stopped)

Launch Close Expand List Collapse List

11A Front Light Switch Check

Action:

Turn key switch to ON position.

Push front light rocker switch to middle position.

LOOK: Are two front lights, two red tail lights and gauge lights ON?

Push front light rocker switch in completely.

LOOK: Are four front lights (if equipped), two red tail lights and gauge lights ON?

Record of Actual Results:

206
 Operational Checkout Procedure

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Front Work and Drive
Light Circuit.

11B Rear Light Switch Check

Action:

Turn key switch to ON position.

Push side console rear light rocker switch in.

LOOK: Are rear lights ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Front Work and Drive
Light Circuit .

11C Turn Signal Check

Action:

Turn key switch to ON position.

Push right side of turn signal rocker switch down.

LOOK: Are right front and rear amber lights flashing? Does right indicator light on
top of steering column flash?

207
 Operational Checkout Procedure

Push left side of turn signal rocker switch down.

LOOK: Are left front and rear amber lights flashing? Does left indicator light on top
of steering column flash?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuses and wiring. Go to Group 9015-10, Turn Signal, Flasher and Brake
Light Circuit.

11D Brake Light Switch Check

Action:

Key switch in the ON position.

Depress and hold left brake pedal, then right brake pedal.

LOOK: Rear brake lights must come ON when either pedal is depressed with key
switch in ON position.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Turn Signal, Flasher
and Brake Light Circuit.

11E Warning Light Check

Action:

Key switch ON.

208
 Operational Checkout Procedure
Key switch ON.

Push bottom of warning light rocker switch in.

LOOK: Are both front and rear amber lights ON? Are both turn signal indicators
and light in warning light rocker switch flashing?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuses and wiring. Go to Group 9015-10, Turn Signal, Flasher and Brake
Light Circuit.

11F Horn Check

Action:

Turn key switch to ON position.

Push horn button

LISTEN: Did horn sound?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuses and wiring. Go to Group 9015-10, Horn Circuit.

12 Cab Component Checks

Launch Close Expand List Collapse List

209
 Operational Checkout Procedure

12A Seat Linkage Check

Action:

T103194-UN: Seat Linkage

Lift lever (1).

Move seat forward and rearward and release lever.

LOOK: Does lever move freely and lock seat in desired position?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Repair linkage. Go to repair manual.

12B Seat Height Adjustment Check

Action:

T103194-UN: Seat Height Adjustment

210
 Operational Checkout Procedure

Turn knob (3) to raise or lower seat to desired position.

LOOK: Does seat move up or down and remain in desired position?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to repair manual.

12C Seat Swivel Linkage Check

Action:

T103194-UN: Seat Swivel Linkage

Lift lever (2) up.

Move seat from loader to backhoe position and engage latch.

LOOK: Does seat latch move freely and hold seat in desired position?

FEEL: Does lever move freely and hold seat in loader and backhoe positions?

Record of Actual Results:

Result:
YES:
Go to next check.

211
 Operational Checkout Procedure

NO:
Lubricate or repair linkage. Go to repair manual.

12D Seat Back Linkage Check

Action:

T103194-UN: Seat Back Linkage

Lift lever (4) up.

Position seat back as desired and engage latch.

FEEL: Does lever move freely and hold seat in desired positions?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Lubricate or repair linkage. Go to repair manual.

12E Left Cab Door Latch and Opener Check

Action:

Unlatch door.

Observe door as it opens.

Pull door closed and latch it.

212
 Operational Checkout Procedure
FEEL: Does cab door latch work freely?

LOOK: Will door cylinder push door open?

LOOK: Does cab door contact door stop bumper before door cylinder bottoms?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust cab door. Go to repair manual.

12F Right Door Latch and Opener Check (If Equipped)

Action:

Unlatch door and pull door open.

Close and latch door.

FEEL: Does cab door latch work freely?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust door. Go repair manual.

12G Rear Window Latch and Opener Checks

Action:

Squeeze latches on both sides of middle rear window. Lower window to rubber
bumpers.

213
 Operational Checkout Procedure
Push latch releases on upper rear window.

Observe window as it opens.

Push window up and into window catches and note fit.

Observe cylinders while closing window. Raise middle window and push into
latches.

LOOK: Do window latches and hinges move freely?

LOOK: Will the gas-filled cylinders slowly assist raising the window to open
position?

NOTE:

Cylinders must not be at end of travel when closing window.

LOOK: Do window catches hold and not bow the window in the up position?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check for obstructions. Go to repair manual.

12H Side Window Checks

Action:

214
 Operational Checkout Procedure
T6171DF-UN: Side Window

Open left and right rear side window.

Fasten rear window against front window.

LOOK: Does sleeve on rear window align with knob on front window?

LOOK/FEEL: Do hinges move freely? Are locking latches equally loaded when
closed?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust windows. Go to repair manual.

12I Blower Motor Check

Action:

T101677-UN: Blower Motor

Engine OFF key switch ON.

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

FEEL/LISTEN: Does blower fan have four speeds?

Does air exit from ducts?

215
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check wiring harness. See Group 9015-10, Blower Circuit.

12J Heater

Action:

T101678-UN: Heater

Start engine and run at fast idle.

Item MeasurementSpecification
Heater Check Engine Speed Fast idle

Wait two minutes.

Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to
high speed.

FEEL: Is air from ducts warm?

Record of Actual Results:

Result:

216
 Operational Checkout Procedure

YES:
Go to next check.
NO:
See to Group 9015-10, Blower Circuit.

12K Air Conditioner (If Equipped)

Action:

T101679-UN: Air Conditioner

Start engine and run at fast idle.

Item MeasurementSpecification
Air Conditioner Check Engine Speed Fast idle

Turn air conditioner switch (A) to ON position.

Turn blower switch (B) to high speed.

Wait for any warm air in duct system to be exhausted.

FEEL: Is air from ducts cool?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Heating and Air Conditioning, Group 9031-10. See Charging the System in

217
 Operational Checkout Procedure
Group 9031-20.

12L Rear Windshield Wiper Check

Action:

Turn key to ON position.

Push rear wiper rocker switch to first detent, middle position.

Push rear wiper rocker switch all the way in.

Push rear wiper switch to OFF position.

LOOK: Rear wiper must operate and have two speeds.

LOOK: Wipers must return to park position.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse. Check rear wiper. Go to Group 9015-10, Wiper/Washer Circuit.

12M Front Windshield Wiper Check

Action:

Turn key switch to ON position.

Push front wiper rocker switch to first detent, middle position.

Push front wiper switch all the way in.

Push front wiper switch to OFF position.

LOOK: Do both front wipers operate and have two speeds?

LOOK: Do wipers return to the park position?

218
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse. Check front wiper. Go to Group 9015-10, Wiper/Washer Circuit.

12N Front Windshield Washer Check

Action:

Turn key switch to ON position.

Push windshield washer rocker switch in.

LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF
position.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fluid level, and fluid lines for blockage. Check wiring. Go to Group 9015-10,
Wiper/Washer Circuit.

12O Cab Dome Light Check

Action:

Turn key switch to ON position.

Push dome light switch to ON position.

LOOK: Does lights come ON?

219
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Dome Light Circuit.

13 Miscellaneous Checks
Launch Close Expand List Collapse List

13A Vandal Protection Check

Action:

Lock cab door(s) using ignition key.

FEEL: Does lock operate freely and key not stick in lock?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Lubricate or repair lock. Go to repair manual.

13B Check Periodic Maintenance Decal

Action:

Check periodic maintenance decal on inside of hood access door.

LOOK: Is periodic maintenance decal legible?

Record of Actual Results:

220
 Operational Checkout Procedure

Result:
YES:
Go to next check.
NO:
Replace decal. Go to John Deere Dealer for part.

13C Backhoe Transport Pin Check

Action:

Raise boom into transport position.

Remove swing lock pin from holder in rear corner of cab and install through top
and bottom holes of swing frame and through main frame.

LOOK: Does swing lock pin install freely?

Record of Actual Results:

Result:
YES:
Operational Checkout completed.
NO:
Repair or replace swing lock pin. Check pin bore for burrs or obstruction.

TX,9005,YY2135-19-1996/08/08

221
 Operational Checkout Procedure

Operational Checkout Procedure

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

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

The information obtained after completing the operational checkout will allow you or
your authorized dealer to pinpoint a specific test or repair needed to restore the
machine to specifications.

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

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

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

1 Gauge and Indicator Check With Engine Off

Launch Close Expand List Collapse List

1A Monitor Indicator Lights and Alarm Checks

Action:

222
 Operational Checkout Procedure
T103007-UN: Monitor Indicator Lights and Alarm

Turn key switch to BULB CHECK position and hold.

LOOK: Are all monitor indicator lights on? Is STOP light ON and does alarm
sound?

NOTE:

Starting motor MUST NOT operate.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check monitor/gauge fuse. Go to Group 9015-15, Display Monitor Checks. If
motor starts and bulb check position is OK, key switch is failed or there is a short in
wiring. Go to Group 9015-15, Start Circuit.

2 FNR, Neutral Start Circuit and Reverse Warning Alarm Checks

Launch Close Expand List Collapse List

2A FNR Switch Check

Action:

T7447AH-UN: FNR Switch

Engine off.

223
 Operational Checkout Procedure

Move FNR lever to forward (F), reverse (R), then neutral (N) position.

FEEL: Observe and feel forward, neutral and reverse detents.

Turn key switch to ON position. Move FNR lever into forward and reverse.

LISTEN: Did you hear a "click" from the side console neutral start relay as FNR
lever was moved?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If no "click", inspect neutral start relay. Go to Group 9015-15, Start Circuit.

2B Neutral Start Check

Action:

Move FNR lever to forward (F) position and turn key switch to start position.

Move FNR lever to reverse (R) position and turn key switch to start position.

LISTEN: Did starting motor operate?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Group 9015-15, Start Circuit.

2C Start Circuit Check

Action:

224
 Operational Checkout Procedure

T7447AH-UN: Start Circuit

Move FNR lever to neutral (N) position and turn key switch to START position.

Observe and listen to monitor as engine is cranking.

LISTEN: Did starting motor operate?

LISTEN: Did alarm sound?

LOOK: During engine cranking, were all indicator lights ON? Is STOP indicator
ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If engine turns but does not start, check fuel shut-off/start aid/reverse alarm fuse. If
starting motor does not operate check start fuse. Go to Group 9015-15, Start
Circuit. If indicator lights are NOT ON, check monitor/gauge fuse. Go to Group
9015-15, Display Monitor Checks.

2D Reverse Warning Alarm Check

Action:

225
 Operational Checkout Procedure

T7447AI-UN: Reverse Warning Alarm

Key switch ON.

Move FNR lever to reverse (R) position.

LISTEN: Does reverse warning alarm sound?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
See Reverse Alarm Circuit. Go to Group 9015-10.

3 Park Brake, Charge Indicator Light, Tachometer/Hour Meter

Circuit and Engine Speed Control Linkage Checks
Launch Close Expand List Collapse List

3A Park Brake Indicator Check

Action:

226
 Operational Checkout Procedure

T7447AG-UN: Park Brake Indicator

T103007-UN: Indicators

IMPORTANT:

If engine oil pressure indicator light stays ON, STOP ENGINE

IMMEDIATELY, check oil level.

Engage park brake.

Put FNR lever in neutral (N) and start the engine.

Put FNR lever in forward (F) position.

LOOK: Is STOP indicator ON? Does alarm sound? Is park brake and seat belt light
ON? Are all other indicator lights out?

Release park brake.

LOOK/LISTEN: Is park brake indicator and STOP light out? Alarm WILL NOT
sound.

Record of Actual Results:

227
 Operational Checkout Procedure

Result:
YES:
Go to next check.
NO:
If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY
and check oil level. Go to Group 9010-15, Engine Low Oil Pressure. If alternator
indicator light is ON, increase engine speed to 1200 rpm and alternator light MUST
go out. Go to Group 9015-15, Charge Circuit Checks. If no park brake light,
inspect wiring connector at switch on park brake linkage. Go to Group 9015-15,
Park Brake Circuit.

3B Seat Position Sensor Check

Action:

Engine speed at low idle.

Item MeasurementSpecification
Seat Position Sensor Check Engine Speed Low idle

Lower all equipment to ground.

Release park brake.

Transmission gear shift lever in neutral, FNR in forward or reverse.

Operators seat in the backhoe position.

LISTEN: Does alarm sound and is STOP indicator ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to indicator circuit in Group 9015-15.

228
 Operational Checkout Procedure

3C Tachometer/
Hourmeter Circuit Check

Action:

T7447AH-UN: Tachometer/Hourmeter Circuit

IMPORTANT:

If engine low oil pressure indicator light stays ON, STOP

ENGINE IMMEDIATELY and check oil level.

Engage park brake.

Put FNR lever in neutral and start the engine.

LOOK/LISTEN: Is hourmeter indicator rotating? Does tachometer (if equipped)

indicate rpm?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If park brake indicator light is not ON, go to Group 9015-15, Park Brake Circuit. If
no hour meter or tachometer movement, go to Group 9015-10, Gauge and Hour
Meter Circuit.

3D Engine Speed Control Lever Linkage Check

229
 Operational Checkout Procedure

Action:

T102991-UN: Engine Speed Control Lever Linkage

Engage park brake.

Put FNR lever in neutral and start engine.

Note rpm on tachometer (if equipped).

Move speed control lever to fast idle position.

LOOK: Does tachometer read 900 + 25 - 0 rpm (slow idle) or 2400 + 25 - 0 rpm
(fast idle)?

Item MeasurementSpecification
Slow Idle Speed 900 + 25 - 0 rpm
Fast Idle Speed 2400 + 25 - 0 rpm

LOOK: Does speed control lever remain at selected position?

Record of Actual Results:

Result:
NO:
Tighten friction lock. Go to Group 9010-20. Check engine speed. Go to Group
9010-20.
YES:
Go to next check.

3E Engine Speed Control Pedal Linkage Check

230
 Operational Checkout Procedure

Action:

T7394BF-UN: Engine Speed Control Pedal Linkage

Depress speed control pedal

LISTEN: Does engine speed stay the same as with speed control lever in fast idle
position?

Record of Actual Results:

Result:
YES:
Yes: Go to next check.
NO:
Adjust Speed Control Linkage. Go to Group 9010-20.

4 Brake System Checks

Launch Close Expand List Collapse List

4A Pedal Stop Check

Action:

231
 Operational Checkout Procedure

T7394BG-UN: Brake System

Lift left and right brake pedals.

LOOK: Are brake pedals against pedal stop?

NOTE:

This ensures that brake check valves are opened and brakes
released.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust brake pedal stops. Go to Group 9020-20.

4B Brake System Leakage Check

Action:

232
 Operational Checkout Procedure

T7367AM-UN: Brake System Leakage

Depress and hold left brake pedal, then right brake pedal using approximately 267
N (60 lb. force).

LOOK: Brake pedal must NOT feel spongy (caused by air in system). Does pedal
settle more than 25 mm (1.0 in.) per minute?

Item MeasurementSpecification
Brake Leakage Pedal settles more than 25 mm (1.0 in.) per minute with
System 267 N (60 lb. force) applied

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Bleed brake system. Go to Group 9020-20.

4C Brake Drag/Park Brake Check

Action:

233
 Operational Checkout Procedure

T6171AL-UN: Brake Drag/Park Brake Check

Position machine on a gradual slope with front of machine downhill.

Lift bucket so it clears ground.

Shift FNR lever to neutral, differential lock control up, disengage park brake and
release service brakes.

Let machine coast freely for several feet. Apply park brake.

LOOK: Did machine stop?

Release park brake.

LOOK: Did machine move or coast freely?

NOTE:

If machine does not move freely on slope, drive the machine for
five minutes. Feel axle housing area to locate which brake is
dragging.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Group 9020-25, Brake Valve Leakage Test or Park Brake Release Pressure
Test.

234
 Operational Checkout Procedure

4D Park Brake Function Check

Action:

Start machine, move throttle to 1200 rpm.

Leave park brake ON.

Put FNR lever in forward position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever to reverse position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever back to neutral position.

Move throttle back to slow idle and shut the machine off.

LOOK: The machine MUST NOT move in any gear.

LOOK: STOP light and Park Brake indicators MUST be lit.

LOOK: Hazard light MUST be flashing.

LISTEN: An audible beeping alarm MUST be heard.

LISTEN: With the FNR In the reverse position, the reverse audible alarm MUST be
heard.

Record of Actual Results:

Result:
YES:
If the machine moves in any gear, see your authorized dealer.
YES:
If the indicators do not work, see your authorized dealer.
NO:

235
 Operational Checkout Procedure
Go to next check.

4E Park Brake Function Check

Action:

Start machine, move throttle to 1200 rpm.

Leave park brake ON.

Put FNR lever in forward position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever to reverse position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds
in each gear.

Move FNR lever back to neutral position.

Move throttle back to slow idle and shut the machine off.

LOOK: The machine MUST NOT move in any gear.

LOOK: STOP light and Park Brake indicators MUST be lit.

LOOK: Hazard light MUST be flashing.

LISTEN: An audible beeping alarm MUST be heard.

LISTEN: With the FNR In the reverse position, the reverse audible alarm MUST be
heard.

Record of Actual Results:

Result:
YES:
If the machine moves in any gear, see your authorized dealer.
YES:
If the indicators do not work, see your authorized dealer.

236
 Operational Checkout Procedure

NO:
Go to next check.

5 Steering System Checks

Launch Close Expand List Collapse List

5A Steering Check

Action:

Raise loader bucket above ground level.

Raise rear of machine off ground using stabilizers.

Operate engine at approximately 1000 rpm.

Item Measurement Specification

Steering Check Approximate Engine Speed 1000 rpm

Turn steering wheel from full left to full right several times.

LOOK: Did front wheels move smoothly in both directions?

LOOK: When steering wheel was stopped, did front wheels stop moving?

NOTE:

Internal leakage or a sticking steering valve spool can cause

wheels to continue to move after steering wheel is stopped.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Group 9025-15, Steering Valve Does Not Return to Neutral.

237
 Operational Checkout Procedure

5B Steering System Leakage Check

Action:

NOTE:

Hydraulic oil must be at operating temperature.

Run engine at slow idle.

Item Measurement Specification

Steering System Leakage Engine Speed Slow idle
Check
Hydraulic Oil Operating
Temperature temperature
Turn steering wheel until wheels are in maximum right turn position. Continue
turning steering wheel, using approximately 11.3 N·m (100 lb-in.) force while
counting steering wheel rpm.
Item MeasurementSpecification
Steering Wheel Torque 11.3 N·m (100 lb-in.)

Repeat leakage check turning steering wheel to the left.

LOOK: Did steering wheel turn 5 rpm or less to the left or right?

Item Measurement Specification

Steering System Maximum Leakage 5 rpm
This represents acceptable steering wheel movement during normal operation.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If steering wheel turns more than 5 rpm, verify whether valve or cylinder is leaking.
Go to Group 9025-25, Steering System Leakage Test.

238
 Operational Checkout Procedure

5C Steering Load Sense Check

Action:

Operate engine at slow idle.

Turn steering wheel to stop left and right. Note effort required to turn wheel.

Turn wheel to stop and apply constant pressure.

LOOK/FEEL: Does wheel stop at both axle stops and require normal steering
wheel effort?

LOOK/LISTEN: Does tachometer (if equipped) momentarily decrease in rpm or

does engine rpm momentarily decrease when steering wheel is held against stop?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Steers hard and no decrease in engine rpm. Go to Group 9025-25, Steering Load
Sense Relief Valve Stall Pressure Test.

6 Transmission Neutral Disconnect Circuit Check

Launch Close Expand List Collapse List

6A Neutral Disconnect Circuit Check

Action:

CAUTION:
Machine will move forward as FNR lever is moved.

Start engine, set idle speed at approximately 1500 rpm.

239
 Operational Checkout Procedure

Item Measurement Specification

Neutral Disconnect Circuit Check Approximate Engine Idle Speed 1500 rpm

Put transmission in fourth gear.

Release park brake.

Shift FNR lever to forward (F) position.

LISTEN: When FNR lever is shifted to forward (F) position, can a noticeable drop
in engine speed should be heard?

Press button on gear shift lever (manual shift only) or loader control lever
individually and note sound of engine.

LISTEN: Does engine rpm increase when the neutral solenoid switches are
depressed?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check switch. Go to Group 9015-15, Park Brake/Neutral Disconnect Circuit.

7 Driving Checks
Launch Close Expand List Collapse List

7A Transmission Shift Noise Check

Action:

IMPORTANT:

Press button on gear shift lever when shifting gears (manual

shift only).

240
 Operational Checkout Procedure

Run engine at approximately 1500 rpm with FNR lever in forward (F) position.

Item Measurement Specification

Transmission Noise Approximate Engine 1500 rpm with FNR lever in forward
Check Speed (F) position

Shift transmission into each gear and drive for a short distance.

LISTEN: Can excessive gear noise be heard when shifting between gears?

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Go to Group 9020-15, Excessive Power Train Noise or Excessive Gear Clash
When Shifting for manual or power shift transmission.

7B Differential Lock Check

Action:

T6295AD-UN: Differential Lock

Raise machine off ground with stabilizers and loader bucket.

Unlock brake pedals. Turn MFWD switch OFF (if equipped).

Operate machine at approximately 1500 rpm in 1st forward.

241
 Operational Checkout Procedure

Item Measurement Specification

Differential Lock Check Approximate Engine Speed 1500 rpm in 1st forward

Depress differential lock control.

Apply one brake pedal.

LOOK: Both wheels must stop.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check differential lock switch and solenoid. Go to Group 9015-10. Go to Group
9020-25, Differential Lock Pressure Test.

7C Differential Gear and Pinion Check

Action:

Shift transmission to first gear and operate engine at approximately 1500 rpm.

Item Measurement Specification

Differential Gear and Pinion Approximate Engine 1500 rpm in 1st
Check Speed gear

Move FNR lever to forward (F) position.

Steer machine in a maximum left turn and depress left brake pedal to stop the left
wheel.

Steer machine in a maximum right turn and depress right brake pedal to stop the
right wheel.

LISTEN: Can excessive gear noise be heard in the differential or pinion gear area?

Record of Actual Results:

242
 Operational Checkout Procedure

Result:
NO:
Go to next check.
YES:
Go to Group 9020-15, Diagnose Rear Axle Malfunctions.

7D Front Wheel Alignment (Toe-In) Check

Action:

T6264AI-UN: Front Wheel Alignment (Toe-In)

Drive machine in fourth gear forward on a surface with loose material.

LOOK: Is material from behind front wheels thrown excessively inward or

outward?

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
If material is thrown, excessive tire wear will result. Go to Group 9020-20, Adjust
Toe-In.

7E Engine and Torque Converter Check (Without MFWD)

243
 Operational Checkout Procedure

Action:

T6171AM-UN: Engine and Torque Converter (Without MFWD)

Position machine with loader bucket at ground level against dirt bank or
immovable object.

Shift transmission into first gear.

Move FNR lever to forward (F) position.

Engage differential lock.

Increase engine speed to fast idle.

LOOK: Do rear wheels stall?

NOTE:

This test will give a general indication of engine, transmission and

torque converter performance.

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
If the wheels can be easily stalled, go to Group 9020-15, Power Train-Machine
Lacks Power or Moves Slow.

244
 Operational Checkout Procedure

7F Transmission Hydraulic System Check

Action:

Run engine at approximately 1500 rpm.

Item Measurement Specification

Transmission Hydraulic System Check Approximate Engine Speed 1500 rpm

Shift transmission into third gear.

Move FNR lever to forward (F) position.

Make several shifts from third forward to third reverse. Start counting the number
of seconds when FNR lever is moved to opposite direction.

LOOK: Has machine changed direction in three seconds?

NOTE:

If bad in one direction ONLY, check direction pack.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check torque converter or modulation valve. Go to Group 9020-25.

8 Ride Control Operational Checks (If Equipped)

Launch Close Expand List Collapse List

8A Electrical Checks

Action:

Turn key switch on (do not start engine).

245
 Operational Checkout Procedure

Turn ride control switch on.

LOOK: Does ride control switch light turn on?

Turn ride control switch off.

LOOK: Does ride control switch light turn off?

Turn ride control switch on.

Turn key switch off.

LOOK: Does ride control switch light turn off?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check and replace ride control switch light.
IF OK:
Check wiring.

8B Hydraulic Checks

NOTE:

Make sure park brake is off during hydraulic checks.

Action:

Start tractor and set throttle about 1000 - 1500 rpm.

Turn ride control on.

Try to lift front end of tractor off ground using loader boom lever.

Release loader boom lever.

246
 Operational Checkout Procedure
LOOK/FEEL: Will front end of tractor lift off of ground and hold?

Record of Actual Results:

Result:
NO:
Continue check.
YES:
Check ride control hydraulics.
Action:

Turn ride control off.

Try to lift front end of tractor off ground using loader boom lever.

Release loader boom lever.

LOOK/FEEL: Will front end of tractor lift off of ground and hold?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check ride control hydraulics.

8C Ride Control Check

CAUTION:
Boom will jump upward during this check. Make sure area
around bucket is clear.

Action:

Start engine.
247
 Operational Checkout Procedure
Start engine.

Push Ride Control Switch to OFF position.

Raise boom to maximum height and hold control lever over relief for 2 seconds.

Lower boom and bucket to ground and stop engine. Put boom control lever in
neutral.

Turn key switch on. Turn ride control switch on.

Does boom jump up?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check accumulator charge.

9 Mechanical Front Wheel Drive (MFWD) Driving Check

Launch Close Expand List Collapse List

9A MFWD Switch Check

Action:

T102991-UN: MFWD Switch

Engage MFWD.

LOOK: Does MFWD light in display monitor come ON when switch is moved?
248
 Operational Checkout Procedure

Disengage MFWD.

LOOK: Is MFWD light in display monitor OFF with MFWD disengaged?

NOTE:

Indicator light in MFWD switch will remain ON while MFWD is

engaged. If MFWD is turned OFF while operating, light will go out
but MFWD could stay on until load on drive train is released.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check electrical circuit. Go Group 9015-10, MFWD circuit. Go to Group 9020-25,
MFWD Pressure Test.

9B MFWD Differential Check

Action:

Start engine and run at low idle.

Item MeasurementSpecification
MFWD Differential Check Engine Speed Low idle

Raise machine off ground with stabilizers and loader.

Release park brake.

Shift transmission to first gear and put FNR in forward.

Engage MFWD.

Lower front wheels to just contact ground.

LOOK: Do both front wheels turn?

249
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If at least one front wheel does not turn with MFWD applied, go to group 9020-25
MFWD pressure test. Check electrical circuit, go to Group 9015-10 MFWD circuit.

9C Engine and Torque Converter Check (With MFWD)

Action:

T6171AN-UN: Engine and Torque Converter (With MFWD)

With loader bucket level and cutting edge at the centerline of front wheels, put
machine against a dirt bank or immovable object.

Engage MFWD and differential lock.

Shift transaxle to first forward.

Increase engine speed to fast idle

LOOK: Do both rear wheels and both front wheels turn?

Record of Actual Results:

Result:

250
 Operational Checkout Procedure

YES:
Go to next check.
NO:
If all wheels stop, a torque converter or transmission control valve problem is
indicated. If the front wheels stop, MFWD problem is indicated. Go to Group 9020-
15, Machine Lacks Power or Moves Slow.

9D MFWD Gear and Pinion Check

Action:

Drive machine at transport speed with MFWD engaged, then disengaged.

LISTEN: Does MFWD “whine” when disengaged.

NOTE:

It is normal for MFWD to “whine” when engaged.

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
If MFWD whines, check oil levels and fill to correct levels. Go to Diagnose MFWD
Malfunctions in Group 9020-15.

10 Hydraulic System Checks

Launch Close Expand List Collapse List

10A Hydraulic Pump Performance Check

Action:

NOTE:

If hydraulic oil is not at operating temperature, heat oil to 38-52° C

(100-125°F).
251
 Operational Checkout Procedure

Put backhoe bucket in fully extended position.

Run engine at high idle.

Item Measurement Specification

Hydraulic Pump Performance Engine Speed High idle
Check
Hydraulic Oil 38-52° C (100-
Temperature 125°F)

FNR in neutral.

Park brake ON.

Measure cycle time to fully curl backhoe bucket.

LOOK: Does bucket curl in 4 seconds or less?

Item Measurement Specification

Backhoe Bucket Fully Curled Maximum Cycle Time 4 seconds

NOTE:

Take the average cycle time for at least three cycles. This time will
give a general indication of main hydraulic pump performance.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
If cycle time slow, go to 9025-15, Slow Hydraulic Functions.

10B Flow Limiter Check

Action:

252
 Operational Checkout Procedure

NOTE:

If hydraulic oil is not at operating temperature, heat oil to 38-52° C

(100-125°F).

NOTE:

This check indicates a nominal flow limiter setting for machines

doing both loader and backhoe operations.

Park brake ON.

FNR in neutral.

Engine speed at high idle.

Item Measurement Specification

Flow Limiter Check Engine Speed High idle
Hydraulic Oil Temperature 38-52° C (100-125°F)

Put backhoe bucket in dump position.

Record cycle time to extend dipperstick while holding backhoe bucket dump over
relief.

LOOK: Does dipperstick extend in 3.5-4?

Item MeasurementSpecification
Extend Dipperstick (Backhoe Bucket Dump Held Cycle Time 3.5-4 seconds
Over Relief)

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Do Flow Limiter Test in group 9025-25.

253
 Operational Checkout Procedure

10C Cylinder Cushion Check

Action:

Raise wheels off ground with stabilizers.

Boom MUST be lowered from the transport position.

Run engine at high idle.

Item MeasurementSpecification
Cylinder Cushion Check Engine Speed High idle
Activate backhoe swing left and right.

Note sound and speed as cylinders near end of their stroke.

LOOK: Does speed of cylinder rod decrease near the end of its stroke?

LISTEN: Can hydraulic oil be heard flowing through orifice as cylinder rod nears
the end of its stroke?

Repeat check using backhoe boom raise functions.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Remove and repair cylinder cushion. Go to repair manual.

10D Stabilizer Cylinder and Valve Check

Action:

Operate machine at approximately 1500 rpm.

Item Measurement Specification

Stabilizer Cylinder and Valve Check Approximate Engine Speed 1500 rpm

254
 Operational Checkout Procedure

Position loader bucket above ground.

Lower each stabilizer cylinder and raise rear of machine off ground.

LOOK/FEEL: Do cylinders extend smoothly and hold machine up?

Retract each stabilizer cylinder.

LOOK/FEEL: Do cylinders retract smoothly and remain retracted?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Cylinders drift up or down. Inspect lock outs. Go to repair manual. Cylinders drift
down rapidly. Go to Group 9025-25, Cylinder Leakage Test.

10E Backhoe and Loader Function Drift Check

Action:

T7374CI-UN: Backhoe and Loader Function Drift

NOTE:

Feel backhoe cylinders. Cylinder must be warm to touch (38-52°C

[100-125°F]). If cylinders are not warm, heat oil to specifications.

With backhoe fully extended, put backhoe bucket at a 45° angle to ground. Lower
boom until bucket cutting edge is 50 mm (2.0 in.) off the ground.
255
 Operational Checkout Procedure

Position loader bucket same distance off ground as backhoe bucket.

Run engine at slow idle and observe bucket cutting edge.

Item Measurement Specification

Backhoe and Loader Engine Speed Slow idle
Function Drift Check
Hydraulic Oil 38-52°C (100-125°F) (Cylinders
Temperature warm to touch)

LOOK: Do cutting edges touch ground within one minute?

Item MeasurementSpecification
Backhoe and Loader Function Drift 50 mm (2.0 in.) in one minute

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Verify which function is drifting. Go to Group 9025-25, Drift Test.

10F Hydraulic Control Valve Lift Check Test

Action:

NOTE:

Husco valves have one lift check for both work ports, and
therefore only need to be checked in one direction.

Raise loader bucket 1 m (3.0 ft.) off the ground with the bucket level.

Position backhoe at maximum reach with bucket in dump position, 1 m (3.0 ft.) off
the ground.

Stop the engine.

256
 Operational Checkout Procedure

Activate each function one at a time.

Loader boom raise

Loader bucket rollback
Backhoe boom up
Dipperstick extend
Backhoe bucket dump

LOOK: Do functions move when the control lever is activated?

Record of Actual Results:

Result:
NO:
Go to next check.
YES:
Inspect control valve lift check. Go to repair manual. Do cylinder leakage test, go
to group 9025-25.

10G Loader Boom Float Check

Action:

Put loader bucket at maximum height position with bucket dumped.

Run engine at approximately 1500 rpm.

Item Measurement Specification

Loader Boom Float Check Approximate Engine Speed 1500 rpm

Move the loader control lever forward into boom float detent position, and at the
same time into bucket rollback detent position. Remove hand from control lever.

LOOK: Does loader control lever remain in the boom float detent position?

Record of Actual Results:

Result:

257
 Operational Checkout Procedure

YES:
Go to next check.
NO:
If it jumps out of detent, check detent spring and detent balls. Go to repair manual.

10H Loader Return-to-Dig Check

Action:

T6171AT-UN: Loader Return-to-Dig Switch

T7374CH-UN: Bucket Indicator Pointer

Put loader bucket at maximum height position with bucket dumped.

Run engine at approximately 2000 rpm.

Item Measurement Specification

Loader Return-to-Dig Check Approximate Engine Speed 2000 rpm

Move the loader control lever forward into boom float detent position, and at the
same time into bucket rollback detent position. Remove hand from control lever.

LOOK: Does the loader control lever disengage from the bucket rollback detent
when the bucket is level.

258
 Operational Checkout Procedure
LOOK: When the bucket is at ground level, bucket must be level and the bucket
indicator pointer must be aligned with mark on the boom pivot.

NOTE:

When return-to-dig is used with loader boom in full up position, the

bucket leveling linkage will move the bucket control valve out of
return-to-dig position before bucket is actually level.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust switch until it is activated in cam. Go to Group 9025-20, Loader Bucket
Self-Leveling Indicator Linkage and Return-to-Dig Switch Adjustment.

10I Bucket Leveling Linkage Check

Action:

T7374CJ-UN: Bucket Leveling Linkage

NOTE:

The loader bucket leveling feature functions during the boom raise
cycle only. When bucket is lowered, the operator can manually
level the bucket or use the return-to-dig.

259
 Operational Checkout Procedure

Put loader bucket in the rollback position with the boom near ground level.

Raise the loader and at the same time hold the control lever in the bucket rollback
position.

Observe bucket and loader control lever as the loader raises.

LOOK/FEEL: Does loader control lever move into the bucket dump position and
the bucket dump function slowly activate? When the loader control lever moves to
activate the bucket dump function, does the bucket position remain stationary the
remainder of the loader boom raise cycle?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust switch until it is activated in cam. Go to Group 9025-20, Loader Bucket
Self-Leveling Indicator Linkage and Return-to-Dig Switch Adjustment.

11 Check Operation Of Accessories (Engine Stopped)

Launch Close Expand List Collapse List

11A Front Light Switch Check

Action:

Turn key switch to ON position.

Push front light rocker switch to middle position.

LOOK: Are two front lights, two red tail lights and gauge lights ON?

Push front light rocker switch in completely.

LOOK: Are four front lights (if equipped), two red tail lights and gauge lights ON?

Record of Actual Results:

260
 Operational Checkout Procedure

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Front Work and Drive
Light Circuit.

11B Rear Light Switch Check

Action:

Turn key switch to ON position.

Push side console rear light rocker switch in.

LOOK: Are rear lights ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Front Work and Drive
Light Circuit .

11C Turn Signal Check

Action:

Turn key switch to ON position.

Push right side of turn signal rocker switch down.

LOOK: Are right front and rear amber lights flashing? Does right indicator light on
top of steering column flash?

261
 Operational Checkout Procedure

Push left side of turn signal rocker switch down.

LOOK: Are left front and rear amber lights flashing? Does left indicator light on top
of steering column flash?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuses and wiring. Go to Group 9015-10, Turn Signal, Flasher and Brake
Light Circuit.

11D Brake Light Switch Check

Action:

Key switch in the ON position.

Depress and hold left brake pedal, then right brake pedal.

LOOK: Rear brake lights must come ON when either pedal is depressed with key
switch in ON position.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Turn Signal, Flasher
and Brake Light Circuit.

11E Warning Light Check

Action:

Key switch ON.

262
 Operational Checkout Procedure
Key switch ON.

Push bottom of warning light rocker switch in.

LOOK: Are both front and rear amber lights ON? Are both turn signal indicators
and light in warning light rocker switch flashing?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuses and wiring. Go to Group 9015-10, Turn Signal, Flasher and Brake
Light Circuit.

11F Horn Check

Action:

Turn key switch to ON position.

Push horn button

LISTEN: Did horn sound?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuses and wiring. Go to Group 9015-10, Horn Circuit.

12 Cab Component Checks

Launch Close Expand List Collapse List

263
 Operational Checkout Procedure

12A Seat Linkage Check

Action:

T103194-UN: Seat Linkage

Lift lever (1).

Move seat forward and rearward and release lever.

LOOK: Does lever move freely and lock seat in desired position?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Repair linkage. Go to repair manual.

12B Seat Height Adjustment Check

Action:

T103194-UN: Seat Height Adjustment

264
 Operational Checkout Procedure

Turn knob (3) to raise or lower seat to desired position.

LOOK: Does seat move up or down and remain in desired position?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to repair manual.

12C Seat Swivel Linkage Check

Action:

T103194-UN: Seat Swivel Linkage

Lift lever (2) up.

Move seat from loader to backhoe position and engage latch.

LOOK: Does seat latch move freely and hold seat in desired position?

FEEL: Does lever move freely and hold seat in loader and backhoe positions?

Record of Actual Results:

Result:
YES:
Go to next check.

265
 Operational Checkout Procedure

NO:
Lubricate or repair linkage. Go to repair manual.

12D Seat Back Linkage Check

Action:

T103194-UN: Seat Back Linkage

Lift lever (4) up.

Position seat back as desired and engage latch.

FEEL: Does lever move freely and hold seat in desired positions?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Lubricate or repair linkage. Go to repair manual.

12E Left Cab Door Latch and Opener Check

Action:

Unlatch door.

Observe door as it opens.

Pull door closed and latch it.

266
 Operational Checkout Procedure
FEEL: Does cab door latch work freely?

LOOK: Will door cylinder push door open?

LOOK: Does cab door contact door stop bumper before door cylinder bottoms?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust cab door. Go to repair manual.

12F Right Door Latch and Opener Check (If Equipped)

Action:

Unlatch door and pull door open.

Close and latch door.

FEEL: Does cab door latch work freely?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust door. Go repair manual.

12G Rear Window Latch and Opener Checks

Action:

Squeeze latches on both sides of middle rear window. Lower window to rubber
bumpers.

267
 Operational Checkout Procedure
Push latch releases on upper rear window.

Observe window as it opens.

Push window up and into window catches and note fit.

Observe cylinders while closing window. Raise middle window and push into
latches.

LOOK: Do window latches and hinges move freely?

LOOK: Will the gas-filled cylinders slowly assist raising the window to open
position?

NOTE:

Cylinders must not be at end of travel when closing window.

LOOK: Do window catches hold and not bow the window in the up position?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check for obstructions. Go to repair manual.

12H Side Window Checks

Action:

268
 Operational Checkout Procedure
T6171DF-UN: Side Window

Open left and right rear side window.

Fasten rear window against front window.

LOOK: Does sleeve on rear window align with knob on front window?

LOOK/FEEL: Do hinges move freely? Are locking latches equally loaded when
closed?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Adjust windows. Go to repair manual.

12I Blower Motor Check

Action:

T101677-UN: Blower Motor

Engine OFF key switch ON.

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

FEEL/LISTEN: Does blower fan have four speeds?

Does air exit from ducts?

269
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check wiring harness. See Group 9015-10, Blower Circuit.

12J Heater

Action:

T101678-UN: Heater

Start engine and run at fast idle.

Item MeasurementSpecification
Heater Check Engine Speed Fast idle

Wait two minutes.

Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to
high speed.

FEEL: Is air from ducts warm?

Record of Actual Results:

Result:

270
 Operational Checkout Procedure

YES:
Go to next check.
NO:
See to Group 9015-10, Blower Circuit.

12K Air Conditioner (If Equipped)

Action:

T101679-UN: Air Conditioner

Start engine and run at fast idle.

Item MeasurementSpecification
Air Conditioner Check Engine Speed Fast idle

Turn air conditioner switch (A) to ON position.

Turn blower switch (B) to high speed.

Wait for any warm air in duct system to be exhausted.

FEEL: Is air from ducts cool?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Go to Heating and Air Conditioning, Group 9031-10. See Charging the System in

271
 Operational Checkout Procedure
Group 9031-20.

12L Rear Windshield Wiper Check

Action:

Turn key to ON position.

Push rear wiper rocker switch to first detent, middle position.

Push rear wiper rocker switch all the way in.

Push rear wiper switch to OFF position.

LOOK: Rear wiper must operate and have two speeds.

LOOK: Wipers must return to park position.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse. Check rear wiper. Go to Group 9015-10, Wiper/Washer Circuit.

12M Front Windshield Wiper Check

Action:

Turn key switch to ON position.

Push front wiper rocker switch to first detent, middle position.

Push front wiper switch all the way in.

Push front wiper switch to OFF position.

LOOK: Do both front wipers operate and have two speeds?

LOOK: Do wipers return to the park position?

272
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse. Check front wiper. Go to Group 9015-10, Wiper/Washer Circuit.

12N Front Windshield Washer Check

Action:

Turn key switch to ON position.

Push windshield washer rocker switch in.

LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF
position.

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fluid level, and fluid lines for blockage. Check wiring. Go to Group 9015-10,
Wiper/Washer Circuit.

12O Cab Dome Light Check

Action:

Turn key switch to ON position.

Push dome light switch to ON position.

LOOK: Does lights come ON?

273
 Operational Checkout Procedure

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check fuse and bulbs. Check wiring. Go to Group 9015-10, Dome Light Circuit.

13 Miscellaneous Checks
Launch Close Expand List Collapse List

13A Vandal Protection Check

Action:

Lock cab door(s) using ignition key.

FEEL: Does lock operate freely and key not stick in lock?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Lubricate or repair lock. Go to repair manual.

13B Check Periodic Maintenance Decal

Action:

Check periodic maintenance decal on inside of hood access door.

LOOK: Is periodic maintenance decal legible?

Record of Actual Results:

274
 Operational Checkout Procedure

Result:
YES:
Go to next check.
NO:
Replace decal. Go to John Deere Dealer for part.

13C Backhoe Transport Pin Check

Action:

Raise boom into transport position.

Remove swing lock pin from holder in rear corner of cab and install through top
and bottom holes of swing frame and through main frame.

LOOK: Does swing lock pin install freely?

Record of Actual Results:

Result:
YES:
Operational Checkout completed.
NO:
Repair or replace swing lock pin. Check pin bore for burrs or obstruction.

TX,9005,YY2135-19-1996/08/08

275
 PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

M44215-UN: Component Technical Manual

For additional engine information, the component technical manual (CTM) is also
required.

Use the CTM in conjunction with this machine manual.

TX,05,SS3179-19-1996/08/05

276
 PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

M44215-UN: Component Technical Manual

For additional engine information, the component technical manual (CTM) is also
required.

Use the CTM in conjunction with this machine manual.

TX,05,SS3179-19-1996/08/05

277
 PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

M44215-UN: Component Technical Manual

For additional engine information, the component technical manual (CTM) is also
required.

Use the CTM in conjunction with this machine manual.

TX,05,SS3179-19-1996/08/05

278
 Engine-Sectional View

Engine-Sectional View

T102831-UN: Sectional View of Engine

LEGEND:
A - Rocker Arm Shaft
B - Cylinder Head
C - Push Rod
D - Cam Follower
E - camshaft
F - Cylinder Block
G - Crankshaft
H - Crankshaft Counterweight
I - Oil Pan
J - Balancer Shafts
K - Connecting Rod
L - Liner Packing Rings

279
 Engine-Sectional View
M - Cylinder Liner
N - Piston
O - Piston Pin
P - Piston Rings
Q - Valve
R - Fuel Injection Nozzle
S - Valve Spring
T - Rocker Arm

TX,05,SS3181-19-1996/08/05

280
 General Engine Description

General Engine Description

Engines are vertical, in-line, valve-in-head, 4-cycle (stroke) diesel engines.

Direct fuel injection is provided by a rotary-type injection pump and 9.5 mm injection
nozzles mounted in cylinder head. The camshaft gear-driven injection pump is timed to
the crankshaft by the timing gear train.

Some engines are equipped with a turbocharger. The turbocharger uses energy from
exhaust gases to compress intake air and force it into the combustion chamber.

The cylinder block is a one-piece casting. The block is available in structural and non-
structural configurations.

The camshaft is timed to the crankshaft through the timing gear train. The camshaft
rotates in honed bores in the cylinder block. All engines use a bushing in No. 1
camshaft bore. The camshaft lobes determine the duration and lift of each valve.

Intake and exhaust valves are operated by camshaft followers, push rods and rocker
arm assembly. Valve seat inserts in cylinder head are used for intake and exhaust
valves.

The crankshaft is a one-piece, heat treated, nodular-iron or steel forging which operates
in replaceable two-piece main bearings. Crankshafts are dynamically balanced and are
machined with undercut and rolled fillets. Two-piece main thrust bearing inserts are
used to control crankshaft endplay.

Cylinder liners are “wet” sleeve type and are individually replaceable. O-rings seals are
used at the lower connection between cylinder block and liners.

Pistons are made of high-grade cast aluminum alloy with internal ribbing. The shirt is
cam ground to allow for expansion during operation. The piston crown has a cut-out
combustion bowl with a truncated cone center. All piston rings are located above the
piston pin. Two compression rings and one oil control ring are used. The top
compression ring is a keystone shaped ring located close to the top of the piston for
improved engine performance.

The hardened, fully-floating piston pins are held in place by snap rings. Spray jets
(piston cooling orifices) in cylinder block spray pressurized oil on the underside of the
piston to lubricate piston pins and cool pistons.

The forged steel connecting rods have replaceable pin bushing and bearing inserts.
Some connecting rods have a tapered pin-end while others have a straight pin end.

281
 General Engine Description

The engine is equipped with a gear driven oil pump and full-flow oil filter. The oil filter
has an internal bypass valve which opens if the filter element becomes restricted.
Engines are equipped with an oil cooler mounted on the right side of the cylinder block.
The engine is equipped with a pressure regulator valve to relieve excessive pressure
build-up in the main oil gallery, and a bypass valve to prevent oil starvation if the oil
cooler and filter become plugged.

Balancer shafts are used on four-cylinder engines to reduce vibration. The two shafts
rotate on bushings in cylinder block and are counter-rotating at twice engine speed.

The engine has a pressurized cooling system, consisting of radiator, water pump, multi-
blade fan, and one or two thermostats.

TX,05,SS3180-19-1998/06/09

282
 PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

M44215-UN: Component Technical Manual

For additional engine information, the component technical manual (CTM) is also
required.

Use the CTM in conjunction with this machine manual.

TX,05,SS3179-19-1996/08/05

283
 PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

M44215-UN: Component Technical Manual

For additional engine information, the component technical manual (CTM) is also
required.

Use the CTM in conjunction with this machine manual.

TX,05,SS3179-19-1996/08/05

284
 Make Visual Inspection of Engine and Supporting Systems

Make Visual Inspection of Engine and Supporting Systems

1. Inspect for coolant leaks at:

Radiator
Water pump
Hoses
Coolant manifold
Thermostat cover

Check for proper coolant level in radiator. Look at coolant for evidence of oil
and/or debris.

2. Inspect for oil leaks around the oil pan, drain plug, oil filter, and clutch housing
at drain hole.

3. Inspect hoses to see if they are hard, cracked, soft, or swelled. Replace as
necessary.

4. Inspect radiator for bent fins, kinks, dents, cracked side frames, seams and
tubes. Check radiator mounts for loose hardware.

5. Check fan to ensure it has been installed correctly.

6. Inspect fan blades. They must be straight and not striking the radiator core or
shroud. Bent blades reduce the efficiency of the fan and make the fan out of
balance. An out of balance condition can add additional load to the fan support
and bearings.

7. Inspect fan belt and belt tensioner. Belt must not be too tight, too loose, or
cracked. Check to see if belt pulleys are worn excessively (if belts run against
bore of groove) and that the pulleys are in proper alignment. Tensioner must
turn freely and smoothly. Tensioner must hold constant pressure on belt.

A belt which is too tight puts extra load on the bearings and shortens the life of
the bearings as well as the belts. A belt which is too loose allows slippage and
reduces fan and alternator speed, causes excess belt wear. Belt slippage can
lead to overheating of the cooling and/or hydraulic system, and undercharged
batteries.

The condition of the belts and their tension must be checked periodically.

8. Inspect fuel tank:

285
 Make Visual Inspection of Engine and Supporting Systems

1. Inspect the tank mounting hardware to ensure they are in position

and tight.

2. Inspect fuel tank for cracks and leakage.

3. Inspect fuel tank outlet strainer and water trap for accumulated
debris by shining a flashlight through the filler neck toward bottom
right corner of fuel tank.

9. Inspect fuel transfer pump. See if there is fuel leaking from inlet and outlet
connections.

10. Inspect fuel filter for water in base of filter. Look for fuel leaking from inlet and
outlet connections.

Check for debris and air in filters. Drain or bleed filters if necessary. Replace
filters as required.

11. CAUTION:
Escaping fluid under pressure can penetrate the skin
causing serious injury. Relieve pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Keep hands and
body away from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard or paper
to search for leaks. DO NOT use your hand.

If ANY fluid is injected into the skin, it must be surgically

removed within a few hours by a doctor familiar with this
type injury or gangrene may result.

Inspect injection pump and nozzles.

Check fuel inlet and outlet connections and injection line connections. If any of
the lines are twisted, kinked, or broken, repair or replace as necessary. Check
injection line clamps to ensure they are in position and tight.

12. Inspect speed control linkage.

Check for free movement. Be sure the injection pump lever contacts the fast
idle stop on the injection pump.

286
 Make Visual Inspection of Engine and Supporting Systems

13. Inspect air cleaner elements for debris, filter condition and air restriction
indicator to ensure indicator isn’t in red.

Check all air intake system connections to be sure they are tight. Clean or
replace filters when indicator shows red or when there is excessive smoke or
loss of power.

14. Check muffler for any signs of leakage or areas that have rusted through.
Exhaust leaks can result in a fire in the engine compartment.

15. Check for debris on exhaust manifold.

TX,15,SS3183-19-1996/08/09

287
 Diagnose Engine Malfunctions

Diagnose Engine Malfunctions

NOTE:

Diagnostic charts are arranged from most probable and simplest to

verify, to least likely and more difficult to verify. Remember the following
steps when diagnosing a problem:

Step 1. Operational Checkout Procedure (See Group 9005-10).

Step 2. Adjustments and/or Tests (See Group 9010-20 and/or 9010-

25).

288
Diagnose Engine Malfunctions

289
 Diagnose Engine Malfunctions

Symptom Problem Solution

Engine Will Fuel tank empty Check fuel quantity

Not Start Or
Starts Hard

Fuel tank vent plugged Remove cap and listen for sound of air
entering tank. Replace cap.

No electrical power to Turn key switch to "On". Must hear click at

injection pump solenoid injection pump. Replace fuse. Repair wiring.

Water in fuel or water Drain water from fuel tank. Inspect fuel filter
frozen in fuel line. for water. Change filter.

Debris in fuel or wrong Check fuel tank outlet strainer for type of
grade of fuel fuel debris. Check bottom of fuel tank for
debris. Clean tank. Add fuel. Check grade
of fuel. Add correct fuel. See Diesel Fuel in
Group 9000-04 or CTM207.

Air leak on suction side of Check for bubbles in fuel filter and tighten
fuel system connections. Inspect fuel lines for damage.

Fuel transfer pump Check engine oil for fuel dilution. Replace
diaphragm leaking fuel pump.

Slow cranking speed Check battery and connections. Incorrect

engine oil (Cold weather).

Restricted air filter Check air filter restriction indicator and air
filters. Clean.

290
 Diagnose Engine Malfunctions
Symptom Problem Solution

Stuck injection pump Tap injection pump housing (lightly) if

metering valve. engine now starts. Replace metering valve.
See your authorized injection pump service
center.

Faulty electric shut-off Test shut-off solenoid. See 9015-15.

Inspect solenoid wiring and linkage.

Improper injection pump Check pump timing. See Lucas and

timing Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

Injection pump Remove and test pump. See Remove

Stanadyne Model DB2 and DB4 Injection
Pump CTM207.

Injection nozzle(s) Remove and test nozzles. See Test Fuel

Injection Nozzles in CTM207.

Worn compression rings Check compression. See Test Engine

or low compression Compression Pressure in CTM104.

Blown head gasket Route radiator overflow into container of

fluid and check for bubbles. Bubbles
indicate head gasket linkage. See Check for
Head Gasket Failures in CTM104.

Engine Air in fuel Inspect filter for evidence of air in fuel.

Surges Or Tighten connections and bleed fuel system.
Stalls
Frequently

Fuel tank vent plugged Remove cap and listen for sound of air
entering tank. Replace cap.

291
 Diagnose Engine Malfunctions
Symptom Problem Solution

Debris in fuel or wrong Check fuel tank outlet strainer for debris.
grade of fuel Check bottom of fuel tank for debris. Clean
tank. Add fuel. Check grade of fuel. See
Diesel Fuel Group 9000-04 or CTM207.

Water in fuel Drain fuel tank and inspect filter element for
water. Replace filters.

Fuel filter plugged Replace filter.

Return line from injection Route return line at the pump into a
pump to tank restricted separate container. If engine now operates
normally, check return line to tank for
restriction. Replace.

Fuel injection pump out of Check pump timing. See Lucas and
time Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

Check return oil fitting on Remove, inspect and clean. Determine

top of injection pump source of debris. See your authorized
control cover plugged. injection pump service center.

Injection pump metering Remove pump top cover and inspect.

valve sticking Replace metering valve. See your
authorized injection pump service center.

Engine overheating Test cooling system. See CTM104.

Fuel transfer pump Test transfer pump pressure. See Measure

Fuel Supply Pump Pressure in CTM207.

292
 Diagnose Engine Malfunctions
Symptom Problem Solution

Fuel injection pump Remove fuel injection pump. See Remove

Stanadyne Model DB2 and DB4 Injection
Pump CTM207. Test pump. See your
authorized injection pump service center.

Injection nozzles(s) Remove and test nozzles. See Test Fuel

Injection Nozzles in CTM207.

Improper valve clearance See Check and Adjust Valve Clearance in

CTM104.

Valve sticking or burned Check compression. See Test Engine

Compression Pressure in CTM104.

Worn or broken Route radiator overflow hose into a

compression rings or container of fluid and check for bubbles.
cylinder head gasket Bubbles indicate head gasket leakage. See
leaking Check for Head Gasket Failures in
CTM104. Check compression. See Test
Engine Compression Pressure in CTM104.

Engine Air in fuel Check for evidence of air in filter. Tighten

Misses connections and bleed fuel system.

Debris in fuel or wrong Check fuel tank for water. Check fuel tank
grade of fuel strainer and fuel filter for debris. Clean.
Check grade of fuel. See Diesel Fuel Group
9000-04 or CTM207.

Idle speeds out of Test slow idle speeds. See CTM104.

adjustment (too low)

293
 Diagnose Engine Malfunctions
Symptom Problem Solution

Fuel injection pump out of Check pump timing. See Lucas and
time Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

Fuel transfer pump Test transfer pump pressure. See Measure

Fuel Supply Pump Pressure in CTM207.

Injection pump governor Inspect. Repair. See Remove Stanadyne

faulty or metering valve Model DB2 and DB4 Injection Pump
sticking CTM207. See your authorized injection
pump service center.

Engine overheating Verify engine temperature. See CTM104.

Test thermostat. Replace. See CTM104.

Incorrect valve clearance See Check and Adjust Valve Clearance in

CTM104.

Bent push rods Inspect. Replace.

Cylinder head gasket Route radiator overflow hose into container

leaking of fluid and check for bubbles. Bubbles
indicate head gasket leakage. See Check
for Head Gasket Failures in CTM104.

Valve sticking or burned Check compression. See Test Engine

Compression Pressure in CTM104.

Worn or broken Check compression. See Test Engine

compression rings Compression Pressure in CTM104.

Fuel injection pump Remove and test fuel injection pump. See
Remove Stanadyne Model DB2 and DB4
Injection Pump CTM207.

294
 Diagnose Engine Malfunctions
Symptom Problem Solution

Injection nozzles(s) Remove and test nozzles. See Test Fuel

plugged Injection Nozzles in CTM207.

Engine Does Fuel tank outlet strainer Check fuel tank for water or debris. Remove
Not Develop plugged and clean.
Power

Fuel filter plugged Replace fuel filter.

Wrong grade of fuel Drain and add correct fuel. See Diesel Fuel
Group 9000-04 or CTM207.

Air system restricted Check air filter restriction and air filters.
Clean.

Incorrect high idle speed Adjust linkage. Check high idle speed. See
(too low) or linkage out CTM207.
adjustment.

Incorrect engine or Check pump timing. See Lucas and

injection pump timing Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

Incorrect valve clearance See Check and Adjust Valve Clearance in

CTM104.

Injection pump return fuel Route return line at the pump into a
tube or fittings are separate container. If engine now operates
restricted normal, check return line for restriction.
Replace.

Fuel transfer pump Test transfer pump pressure. See Measure

malfunction Fuel Supply Pump Pressure in CTM207.

295
 Diagnose Engine Malfunctions
Symptom Problem Solution

Fuel line restricted Route an external fuel source to fuel

transfer pump. If engine operation is normal
clean fuel line.

Excess drag in brake Check axle and park brake drag. See
system Operational Checkout Procedure 9005-10.

Excess drag in transaxle Test drag. See Operational Checkout

Procedure 9005-10.

Muffler restricted Operate without muffler. If engine operation

is now normal, replace muffler.

Injection pump delivery or Remove pump and test. See Remove

governor faulty Stanadyne Model DB2 and DB4 Injection
Pump CTM207. See your authorized
injection pump service center.

Injection nozzle(s) Remove and test nozzles. See Test Fuel

Injection Nozzles in CTM207.

Low compression Check compression. See Test Engine

Compression Pressure in CTM104.

Worn camshaft See Measure Valve Lift in CTM104.

Engine Emits Restricted air filter Check air filter restriction and air filters.
Excessive Clean or replace.
Black or Gray
Exhaust
Smoke

296
 Diagnose Engine Malfunctions
Symptom Problem Solution

Incorrect grade of fuel Drain and add correct fuel. See Diesel Fuel
Group 9000-04 or CTM207.

Incorrect injection pump Check pump timing. See Lucas and

timing Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

Excessive fuel delivery Remove fuel injection pump. See Remove

Stanadyne Model DB2 and DB4 Injection
Pump CTM207. See your authorized
injection pump service center.

Injection nozzle(s) Remove and test nozzles. See Test Fuel

Injection Nozzles in CTM207.

Turbocharger not Repair. See CTM104

functioning.

Engine Emits Cranking speed too slow Check batteries and connections.
Excessive
Blue or White
Smoke

Incorrect grade of fuel Drain and add correct fuel. See Diesel Fuel
Group 9000-04 or CTM207.

Engine running too cold Check thermostat operation. Replace.

Injection pump out of time Check pump timing. See Lucas and
Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

297
 Diagnose Engine Malfunctions
Symptom Problem Solution

Injection nozzle(s) Remove and test nozzles. See Test Fuel

Injection Nozzles in CTM207.

Low compression Check compression. See Test Engine

Compression Pressure in CTM104.

Excessive wear in liners Disassemble, inspect, repair.

and/or piston rings stuck

Slow Wrong grade of fuel Drain and add correct fuel. See Diesel Fuel
Acceleration Group 9000-04 or CTM207.

Injection nozzle(s) Remove and test nozzles. See Test Fuel

Injection Nozzles in CTM207.

Fuel injection pump Remove and test fuel injection. See

Remove Stanadyne Model DB2 and DB4
Injection Pump CTM207.

Detonation Low engine oil level. Add oil.

(Excess
Engine
Knock)

Stuck cold weather Repair.

starting aid

Incorrect injection pump Check pump timing. See Lucas and

timing. Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

Low coolant temperature. Remove and check thermostat. See

CTM104.

298
 Diagnose Engine Malfunctions
Symptom Problem Solution

Abnormal Low or incorrect engine Add correct oil to proper level.

Engine Noise oil (too thin).

Loose or worn hydraulic Inspect. Repair.

pump drive coupling

Engine oil diluted with fuel Inspect engine oil. Determine cause of fuel
dilution.

Incorrect fuel injection Check pump timing. See Lucas and

pump timing Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

Excessive valve See Check and Adjust Valve Clearance in

clearance CTM104.

Bent push rods Inspect. Replace.

Worn rocker arm shafts Replace.

Loose connecting rod Inspect, tighten connecting rod cap screws.

caps See CTM104.

Loose main bearing caps Inspect, tighten main bearing cap screws.
See CTM104.

Worn main bearings Replace bearings. See CTM104.

Worn connecting rod Replace bearings. See CTM104.

bearings

Incorrect cam timing Check engine timing. Repair.

299
 Diagnose Engine Malfunctions
Symptom Problem Solution

Scored piston Inspect. Replace.

Worn piston pin bushings Inspect. Replace pins and bushings. See
and pins CTM104.

Low Oil Low oil level Add oil to proper level. Inspect engine oil.
Pressure (Oil
Pressure
Light On-Red
"Stop"
Flashing)

Wrong viscosity oil/oil Change oil. Check injection pump shaft

diluted with diesel fuel seals and transfer pump diaphragm. See
Remove Stanadyne Model DB2 and DB4
Injection Pump CTM207.

Oil pressure switch or Check engine oil pressure. See CTM104.

indicator Test switch and indicator. See 9015-15.

Oil pressure regulating Test or replace. See CTM104.

valve

Plugged or broken oil Inspect. Clean.

pump intake screen

Loose oil pump drive gear Inspect. Repair. See CTM104.

Worn oil pump gear or Remove, inspect and repair. See CTM104.
housing

300
 Diagnose Engine Malfunctions
Symptom Problem Solution

Excessive main bearing, See CTM104.

connecting rod or balance
shaft clearance

Cracked cylinder block Replace cylinder block. See Engine

Disassembly Sequence in CTM104. Inspect
piston cooling jets.

Leakage at internal oil Check all possible internal leakage paths.

passage. Repair.

Engine Low coolant level Fill cooling system and check for leaks.
Overheats
(Engine
Coolant
Indicator
Light On and
Red "Stop"
Flashing)

Low engine oil level Add oil.

Loose or broken fan belt. Inspect belt tensioner or replace belt. See
CTM104.

Engine overloaded, Reduce load.

operating in wrong gear

Fan on backwards Check for correct fan installation. See

CTM104.

Radiator dirty or plugged Check air flow. See Group 9010-25. Clean
radiator. See CTM104.

301
 Diagnose Engine Malfunctions
Symptom Problem Solution

Radiator shroud missing, Inspect. Repair or replace.

damaged or baffles
missing

Improper fuel Drain and add correct fuel. See Diesel Fuel
Group 9000-04 or CTM207.

Radiator cap Replace cap.

Faulty temperature Test, repair or replace. See 9015-15.

sender

Incorrect injection pump Check pump timing. See Lucas and

timing Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

Excessive axle drag Check axle drag. See Operational Checkout

Procedure 9005-10.

Excessive brake drag Check brake drag. See Operational

Checkout Procedure 9005-10.

Faulty thermostat (Struck Inspect thermostat. Replace. See CTM104.

closed)

Thermostat missing, Replace thermostats. Flush cooling system.

cooling system coated See CTM104.
with lime deposits

Water pump Remove, inspect and repair. See CTM104.

302
 Diagnose Engine Malfunctions
Symptom Problem Solution

Excessive fuel delivery Remove. Check for proper fuel delivery,

adjust. See CTM104.

Scored piston Replace piston. See CTM104.

Engine Runs Thermostat (stuck open) Replace. See CTM104.

Cold

Oil in Coolant Leaking cylinder head See Check for Head Gasket Failures in
or Coolant in gasket CTM104.
Oil

Leaking cylinder liner Replace packings. CTM104.

packing

Cracked cylinder liner Replace liner. CTM104.

Oil cooler Replace cooler. CTM104.

Cracked cylinder block See Engine Disassembly Sequence in

CTM104.

Excessive Air system restricted Check filter restriction indicator and air
Fuel filters. Replace.
Consumption

Leakage in fuel system Inspect. Repair.

Incorrect grade of fuel Refill with correct fuel. See Diesel Fuel
Group 9000-04 or CTM207.

303
 Diagnose Engine Malfunctions
Symptom Problem Solution

Operator holding Return control levers to neutral position.

hydraulics over relief.

High system relief valve Test system relief valve pressure. See
setting 9025-25

Incorrect injection pump Check pump timing. See Lucas and

timing Stanadyne Rotary Fuel Injection Pump
Timing in CTM207.

Faulty injection nozzle(s) Remove and test nozzles. See Test Fuel
Injection Nozzles in CTM207.

Turbocharger Bearings not lubricated Insufficient oil pressure. Check for restricted
Excessively turbocharger oil line.
Noisy or
Vibrates

Worn bearings Replace. See CTM104.

Air leak in engine, intake Inspect and repair. See CTM104.

or exhaust manifold

Improper clearance Remove exhaust elbow and air inlet hose.

between turbine wheel Inspect and repair. See CTM104.
and turbine housing

Broken blades on turbine Remove exhaust elbow and air inlet hose.
Inspect and repair. See CTM104.

304
 Diagnose Engine Malfunctions
Symptom Problem Solution

Oil Dripping Damaged or worn Inspect compressor and turbine wheel for
from bearings and/or worn damaged blades. Check for proper engine
Turbocharger seals service intervals or dirt entering engine. See
Adapter CTM104.

Excessive crankcase Check for plugged oil drain line. Clean.

pressure

Turbocharger oil return Remove line. Inspect and clean.

line carbon buildup where
line passes exhaust
manifold.

Excessive Carbon build-up behind Inspect and clean. See CTM104.

Drag in turbine wheel caused by
Turbocharger combustion deposits
Rotating
Members

Dirt build-up behind Inspect and repair. See CTM104.

compressor wheel caused
by air intake leaks

Bearing seizure or dirty or Check for plugged air filters. See CTM104.
worn bearings caused by
excessive temperature,
unbalanced wheel, dirty
oil, oil starvation, or
insufficient lubrication

TX,15,SS3184-19-1998/07/09

305
 PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

M44215-UN: Component Technical Manual

For additional engine information, the component technical manual (CTM) is also
required.

Use the CTM in conjunction with this machine manual.

TX,05,SS3179-19-1996/08/05

306
 PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

M44215-UN: Component Technical Manual

For additional engine information, the component technical manual (CTM) is also
required.

Use the CTM in conjunction with this machine manual.

TX,05,SS3179-19-1996/08/05

307
 JT05801 Clamp-On Electronic Tachometer Installation

JT05801 Clamp-On Electronic Tachometer Installation

T6813AG-UN: JT05801

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Tachometer
A-Clamp-On Transducer. Remove paint using emery cloth and connect to a straight
section of injection line within 100 mm (4 in.) of pump. Finger tighten only. DO NOT
overtighten.

B-Black Clip (-). Connect to main frame.

C-Red Clip (+). Connect to transducer.

D-Tachometer Readout. Install cable.

TX,25,SS3151-19-1996/06/17

308
 Adjust Speed Control Lever Tension

Adjust Speed Control Lever Tension

T8219CA-UN: Lever Nut

-: Specifications

SPECIFICATIONS

Lever Nut Torque 62-71 N (14-16 lb force)

Tighten nut (A) until 62-71 N (14-16 lb force) is required to move lever using a spring
scale.

Item MeasurementSpecification
Lever NutTorque 62-71 N (14-16 lb force)

TX,20,SS3186-19-1996/08/12

309
 Slow and Fast Idle

Slow and Fast Idle

T103088-UN: Slow and Fast Idle Screws

LEGEND:
A - Slow Idle Adjusting Screw
B - Speed Control Rod Pin
C - Fast Idle Adjusting Screw

-: Specifications

SPECIFICATIONS

Slow Idle Speed 900 + 25 - 0 rpm

Fast Idle Speed 2375 + 25 - 0 rpm

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer
Sealing Wire Pliers

1. Run engine until it is at normal operating temperature.

2. Install tachometer. See procedure in this group.

3. CAUTION:
Take care to avoid rotating fan blades while making
injection pump adjustments.

310
 Slow and Fast Idle

Remove pin (B) and disconnect speed control rod from fuel injection pump
lever.

4. Start engine.

5. Hold injection pump lever forward (toward radiator). Check to make sure slow
idle is to specification.

Item MeasurementSpecification
Slow Idle Speed 900 + 25 - 0 rpm

6. If slow idle is not correct:

1. Check air cleaner elements.

2. Remove sealing wire.

3. Loosen slow idle screw lock. Turn screw (A) clockwise to increase
speed and counterclockwise to decrease engine speed. Tighten lock
nut.

7. Hold injection pump lever rearward (away from radiator). Check to make sure
fast idle is to specification.

Item MeasurementSpecification
Fast Idle Speed 2375 + 25 - 0 rpm

8. If fast idle is not correct:

1. Remove sealing wire.

2. Loosen lock nut and turn screw (C) counterclockwise to increase rpm
or clockwise to decrease rpm.

3. Tighten lock nut and install a new sealing wire using a seal wire
pliers.

9. Connect rod.

TX,20,SS3188-19-1998/06/23

311
 Engine Speed Control Linkage

Engine Speed Control Linkage

T103046-UN: Measure Injection Pump Lever Override

-: Specifications

SPECIFICATIONS

Injection Pump Lever Override 2-8 mm (0.08-0.32 in.)

Speed Control Lever Rear Position Minimum Override 0.5 mm (0.02 in.)
High Idle Minimum Override 2 mm (0.08 in.)

1. Move speed control lever to extreme forward position.

2. Measure injection pump lever override. Override must be 2-8 mm (0.08-0.32

in.).

Item MeasurementSpecification
Injection Pump LeverOverride 2-8 mm (0.08-0.32 in.)

3. Adjust yoke on speed control rod to provide override.

4. Move speed control lever to rear most position and check override. Override
must be at least 0.5 mm (0.02 in.) minimum.

Item Measurement Specification

Speed Control Lever Rear Position Minimum Override 0.5 mm (0.02 in.)

5. Recheck high idle for a minimum of 2 mm (0.08 in.) override.

312
 Engine Speed Control Linkage

Item Measurement Specification

High Idle Minimum Override 2 mm (0.08 in.)

6. Remove reservoir cowling to adjust foot control pedal.

7.

T7387AB-UN: Engine Speed Control Linkage

Disconnect swivel (A) from rod (B). Adjust vertical rod (C) length to allow foot
control pedal to stop on floor with hand lever in the extreme forward position.

TX,20,SS3187-19-1996/08/12

313
 PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

M44215-UN: Component Technical Manual

For additional engine information, the component technical manual (CTM) is also
required.

Use the CTM in conjunction with this machine manual.

TX,05,SS3179-19-1996/08/05

314
 PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

PowerTech 4.5 L (4045) John Deere Engine-Use CTM104

M44215-UN: Component Technical Manual

For additional engine information, the component technical manual (CTM) is also
required.

Use the CTM in conjunction with this machine manual.

TX,05,SS3179-19-1996/08/05

315
 JT05801 Clamp-On Electronic Tachometer Installation

JT05801 Clamp-On Electronic Tachometer Installation

T6813AG-UN: JT05801 Clamp-On Electronic Tachometer

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT05801 Electronic Tachometer Contains of:

A-Clamp-On Transducer. Remove paint using emery cloth and connect to a straight
section of injection line within 100 mm (4 in.) of pump. Finger tighten only. DO NOT
overtighten.

B-Black Clip (-). Connect to main frame.

C-Red Clip (+). Connect to transducer.

D-Tachometer Readout. Install cable.

TX,25,SS3189-19-1996/08/12

316
 JT05800 Digital Thermometer Installation

JT05800 Digital Thermometer Installation

T6808CE-UN: JT05800 Digital Thermometer

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT05800 Digital Thermometer Consists of:

A-Temperature Probe

B-Cable
C-Digital Thermometer

TX,25,SS3190-19-1996/08/12

317
 Air Intake System Leakage Test

Air Intake System Leakage Test

T5906AP-UN: Plastic Bag Over Safety Element

T103547-UN: JDG51 Adapter

-: Specifications

SPECIFICATIONS
Air Intake System Pressure 13.8-20.7 kPa (0.13-0.21 bar) (2-3 psi)

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JDG51 Adapter
Air Regulator With Gauge

IMPORTANT:

Anytime the air intake system is opened it must be tested for leaks
before the machine is returned to service.

318
 Air Intake System Leakage Test

1. Remove air cleaner cover and main filter element.

2. Put a plastic bag over safety element and install main element and cover.

3. Remove plug or either start aid from air intake tube and install adapter (A).

4. Connect air pressure regulator to adapter using hose and fitting.

5. CAUTION:
Plastic bag can be sucked into engine if engine is started
when trying to close valves.

Pressurize air intake system to specifications.

Item MeasurementSpecification
Air Intake System Pressure 13.8-20.7 kPa (0.13-0.21 bar) (2-3 psi)
If system cannot be pressurized, turn engine slightly to close valves. Check
plastic bag.

6. Spray soap solution over all connections from the air cleaner to the
turbocharger or air inlet to check for leaks. Repair all leaks.

TX,25,SS3194-19-1996/08/12

319
 Radiator Air Flow Test

Radiator Air Flow Test

T6080AH-UN: Air Flow Meter To Digital Thermometer

-: Specifications

SPECIFICATIONS

Engine Speed 2375 + 25 - 0 rpm

Voltage Reading (typical) Voltage 4.85 volts

-: Essential Tools

320
 Radiator Air Flow Test

ESSENTIAL TOOLS
JT05529 Air Flow Meter

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Tachometer
Multimeter

1. Apply parking brake, put transmission in neutral and lower equipment to the
ground. Stop engine.

2. Install tachometer. (See procedure in this group.)

3. Check that all sheet metal is in place. Close side shields.

4. Divide the surface of the grille into 16 equal squares.

5. Start engine and run at specified speed.

Item MeasurementSpecification
Engine Speed 2375 + 25 - 0 rpm

6. Connect air flow meter to digital multimeter. Turn switch on multimeter to 20

volts A.C.

7. Place air flow meter in contact with grille. Arrow on meter must point in
direction of air flow (away from machine).

8. Record voltage reading for each area.

9. Combined total of air flow test readings must be approximately at

specifications.

Item MeasurementSpecification
Voltage Reading (typical) Voltage 4.85 volts
If readings are less than specifications remove oil cooler and clean external
surfaces of both oil cooler and radiator. Install oil cooler and repeat test. If
reading is still low, check for correct fan installation. Be sure sheet metal is in
place.

NOTE:
321
 Radiator Air Flow Test
Air flow readings minus 20% is a number used as a guideline
to determine when a partially plugged radiator and or cooler
core may cause overheating.

T6500AK-19: JT05529 Airflow Meter Test Record

322
 Radiator Air Flow Test

T95955-UN: Record Air Flow In Each Square

Divide the surface of the grille into 16 equal squares.
Park brake ON.
Transmission in Neutral and side shields closed.
Divide the surface of the grille into 16 equal squares.
Start engine.
Perform AIR FLOW TEST at fast idle. Observe correct air flow direction and
place air flow meter in direct contract with grille.
Record air flow in each square.
Combine total of air flow test readings must be approximately at
specifications.

TX,9010,SS4105-19-1996/09/06

323
 Turbocharger Boost Pressure-Engine Performance Test

Turbocharger Boost Pressure-Engine Performance Test

T103239-UN: Plug

-: Specifications

SPECIFICATIONS

Engine Temperature 82° ± 10°C (180° ± 20F)

(Normal Operating
Temperature)

Engine Rated Speed 2200 rpm

Turbocharger Boost Pressure-Engine Boost 55-69 kPa (0.55-0.69 bar) (8-10
Pressure (Using No. 2 Fuel with Engine Broke-In psi)

-: Essential Tools

ESSENTIAL TOOLS

JT07248 Turbocharger Boost Test Kit

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

30 psi Gauge

Electronic Tachometer
Digital Thermometer

IMPORTANT:

On power shift transmissions ONLY, never operate machine

324
 Turbocharger Boost Pressure-Engine Performance Test
equipped with MFWD with front wheels (axle) on the ground, rear
wheels (axle) off the ground and transmission in fourth gear
forward. Damage to the MFWD will occur.

NOTE:

Reduce the boost specifications by 7% if using No. 1 fuel.

1. Remove plug (A) and install adapter and gauge.

2. Install tachometer and thermometer. (See procedure in this group.)

3. Lower stabilizers and use loader to raise wheels off ground and disengage
MFWD if equipped.

4. Park brake OFF.

5. Put transmission in 3rd gear and FNR lever in forward.

6. Run engine at normal operating temperature.

Item MeasurementSpecification
Engine Temperature 82° ± 10°C (180° ± 20F) (Normal Operating
Temperature)

7. Run engine at fast idle (2375 + 25 - 0 rpm). Apply service brakes to load
engine and hold at 2200 rpm. Read pressure gauge.

Item MeasurementSpecification
Engine Rated Speed 2200 rpm

8. Record highest boost pressure at rated rpm.

Item Measurement Specification

Turbocharger Boost Boost Pressure (Using No. 2 55-69 kPa (0.55-0.69
Pressure-Engine Fuel with Engine Broke-In bar) (8-10 psi)

9. Repeat test several times.

10. If boost pressure is too high, remove and test fuel injection pump for high fuel
delivery.

325
 Turbocharger Boost Pressure-Engine Performance Test

11. If boost pressure is too low, check for the following:

Restricted air filter elements.

Restricted fuel filter elements.
Incorrect fast idle adjustment.
Incorrect injection pump timing.
Exhaust manifold leaks.
Intake manifold leaks.
Faulty fuel transfer pump.
Low compression pressure.
Faulty fuel injection nozzle.
Carbon build-up in turbocharger.
Turbocharger compressor or turbine wheel rubbing housing.
Low fuel injection pump fuel delivery, remove and test fuel injection
pump for low fuel delivery.

TX,25,SS3197-19-1998/06/23

326
 Injection Pump Timing

Injection Pump Timing

RG6293-UN: Injection Pump Timing

LEGEND:
A - Front Plate
B - Pump Flange

-: Specifications

SPECIFICATIONS

Engine Model 4045

Net hp (kW) 90 hp (67 kW
Engine Rated Speed 2200 rpm

Engine Dynamic Timing (BTDC) 6.5 + 0 - 1

-: Essential Tools

ESSENTIAL TOOLS
JT07158 TIME TRAC® Kit

IMPORTANT:

On power shift transmissions ONLY, never operate machine

equipped with MFWD with front wheels (axle) on the ground, rear
wheels (axle) off the ground and transmission in fourth gear
forward. Damage to the MFWD will occur.

327
 Injection Pump Timing

The JT07158 timing kit electronically indicates start of injection with respect to piston
top dead center, and allows setting injection pump timing to provide optimum power,
smoke and exhaust emissions.

Timing engines with this tool improves consistency between engines and helps to
control cylinder firing pressures which can be a factor in head gasket failures as well as
improve overall engine efficiencies.

1. Install JT07158 TIME TRAC® . See CTM104.

2. Raise machine off the ground with stabilizers and loader. Put transmission in
third forward.

3. Operate machine at WOT. Slowly depress service brakes until engine is at

2200 rpm.

Item MeasurementSpecification
Engine Rated Speed 2200 rpm

4. Record dynamic timing.

Item Measurement Specification

Engine Dynamic Timing (BTDC) 6.5 + 0 - 1

5. If timing is not to specification, follow procedure in CTM207.

TX,9010,SS3222-19-1996/08/20

328
 Fuel Line Leakage Test

Fuel Line Leakage Test

Connections may allow air to enter the fuel system without allowing fuel to leak out.
Follow this procedure to find air leaks in the system.

Disconnect fuel supply and fuel return lines at fuel tank.

Drain all fuel from system, including fuel transfer pump, fuel injection pump, and fuel
filter(s).

Close end of fuel return line using a plug, cap, or a short length of hose, plug, and
clamps.

CAUTION:
Never exceed 103 kPa (1 bar) (15 psi) to prevent damage to fuel
system components.

Item MeasurementSpecification
Prevent Damage To Fuel Pressure Never exceed 103 kPa (1
System bar) (15 psi)

Pressurize the system to 69 kPa (0.7 bar) (10 psi) at the fuel supply line using a
regulated pressure air source.

Item MeasurementSpecification
Fuel System Pressurize To 69 kPa (0.7 bar) (10 psi)

Apply liquid soap and water solution to all joints and connections in the fuel system and
inspect for leaks.

Repair any leaks.

Connect supply and return lines and prime system.

Start machine and let run for approximately 10 minutes.

NOTE:

For engines with an in-line fuel injection pump, an internal leak path
may allow air to enter the fuel system. If an internal pump leak is
suspected, remove the pump and have a pressure test performed by

329
 Fuel Line Leakage Test
an authorized repair station.

TX,25,SS3209-19-1996/08/16

330
 Visually Inspect Electrical System

Visually Inspect Electrical System

Make the following visual electrical inspection prior to starting the tractor after receiving
customer complaint:

1. Look for bare wires that could ground a component or short across to another
component.

2. Look for missing or worn conduit. This could indicate a wire problem.

3. Look for loose or broken connectors and wires.

4. Inspect batteries for:

Corroded terminals
Loose terminals or battery posts
Dirty condition
Damp condition
Cracked case
Proper electrolyte level

5. Check alternator belt tension.

6. After machine has been shut down for five minutes inspect for overheated
parts. They will often smell like burned insulation. Put your hand on the
alternator. Heat in these parts when the unit has not been operated for some
time is a sure clue to charging circuit problems.

7. If your visual inspection does not indicate the possible malfunction, but your
inspection does indicate that the machine can be run, turn the key switch to
the IGN position. Try out the accessory circuits, indicator lights, gauge lights.
How does each of these components work? Look for sparks or smoke which
might indicate shorts.

8. Start machine. Check all gauges for good operation and check to see if
system is charging or discharging.

9. In general, look for anything unusual.

Many electrical failures cannot be detected even if the machine is started.

Therefore, a systematic and complete inspection of the electrical system is
necessary.

331
Visually Inspect Electrical System
TX,9015,QQ6730-19-1995/05/01

332
 Visually Inspect Electrical System

Visually Inspect Electrical System

Make the following visual electrical inspection prior to starting the tractor after receiving
customer complaint:

1. Look for bare wires that could ground a component or short across to another
component.

2. Look for missing or worn conduit. This could indicate a wire problem.

3. Look for loose or broken connectors and wires.

4. Inspect batteries for:

Corroded terminals
Loose terminals or battery posts
Dirty condition
Damp condition
Cracked case
Proper electrolyte level

5. Check alternator belt tension.

6. After machine has been shut down for five minutes inspect for overheated
parts. They will often smell like burned insulation. Put your hand on the
alternator. Heat in these parts when the unit has not been operated for some
time is a sure clue to charging circuit problems.

7. If your visual inspection does not indicate the possible malfunction, but your
inspection does indicate that the machine can be run, turn the key switch to
the IGN position. Try out the accessory circuits, indicator lights, gauge lights.
How does each of these components work? Look for sparks or smoke which
might indicate shorts.

8. Start machine. Check all gauges for good operation and check to see if
system is charging or discharging.

9. In general, look for anything unusual.

Many electrical failures cannot be detected even if the machine is started.

Therefore, a systematic and complete inspection of the electrical system is
necessary.

333
Visually Inspect Electrical System
TX,9015,QQ6730-19-1995/05/01

334
 Visually Inspect Electrical System

Visually Inspect Electrical System

Make the following visual electrical inspection prior to starting the tractor after receiving
customer complaint:

1. Look for bare wires that could ground a component or short across to another
component.

2. Look for missing or worn conduit. This could indicate a wire problem.

3. Look for loose or broken connectors and wires.

4. Inspect batteries for:

Corroded terminals
Loose terminals or battery posts
Dirty condition
Damp condition
Cracked case
Proper electrolyte level

5. Check alternator belt tension.

6. After machine has been shut down for five minutes inspect for overheated
parts. They will often smell like burned insulation. Put your hand on the
alternator. Heat in these parts when the unit has not been operated for some
time is a sure clue to charging circuit problems.

7. If your visual inspection does not indicate the possible malfunction, but your
inspection does indicate that the machine can be run, turn the key switch to
the IGN position. Try out the accessory circuits, indicator lights, gauge lights.
How does each of these components work? Look for sparks or smoke which
might indicate shorts.

8. Start machine. Check all gauges for good operation and check to see if
system is charging or discharging.

9. In general, look for anything unusual.

Many electrical failures cannot be detected even if the machine is started.

Therefore, a systematic and complete inspection of the electrical system is
necessary.

335
Visually Inspect Electrical System
TX,9015,QQ6730-19-1995/05/01

336
 Malfunctions

Malfunctions

T7713AD-19: Basic Electrical Circuit

LEGEND:
A - Battery
B - Fuse
C - Switch
D - Light
E - Ground

1. There are four common circuit malfunctions.

High-Resistance Circuit
Open Circuit
Grounded Circuit
Shorted Circuit

2. Three sections in a simple circuit where these malfunctions can occur;

Before the controlling switch (C).

Between the controlling switch and before the component, light (D).
After the component.

Component malfunctions can easily be confused with circuit malfunctions.

337
 Malfunctions
Therefore, care must be exercised when isolating the cause of a problem.

Example: Light does not operate or is dim when switch is turned ON, until
switch connector is disconnected and reconnected.

Reason: High resistance caused by a dirty switch connector, caused a voltage

drop which prevented the proper amount of current from flowing to the light.

TX,9015,QQ6731-19-1994/02/07

338
 High Resistance Circuit

High Resistance Circuit

T7713AG-19: High Resistance Circuit

LEGEND:
A - Battery
B - Fuse
C - Switch
D - Switch Terminal
E - High Resistance
F - Harness Connector
G - Light Terminal
H - Light
I - Ground

A high resistance circuit can result in slow, dim or no component operation.

Examples: Loose, corroded, dirty or oily terminals. Wire size too small. Strands broken
inside the wire. Poor ground connection to frame.

To locate the cause of high resistance:

With switch (C) ON, check for battery voltage between switch and ground (I) at an
easily accessible location, like harness connector (F).

If less than battery voltage is measured, check again closer to switch.

339
 High Resistance Circuit

If battery voltage is measured, check closer to ground to locate point of voltage drop.
The example shows high resistance (E) between switch and harness connector.

Repair circuit as required. In the example, strands were broken inside the wire, replace
that section of wire.

Repeat check-out procedure after repair.

TX,9015,QQ6732-19-1995/05/01

340
 Open Circuit

Open Circuit

T7713AF-19: Open Circuit

LEGEND:
A - Battery
B - Fuse
C - Switch
D - Switch Terminal
E - Harness Connector
F - Open Circuit
G - Light Terminal
H - Light
I - Ground

An open circuit will result in no components operating. Fuse may or may not be blown.

Example: Broken wire, disconnected component terminal, pins inside a connector not
making contact, blown fuse, open circuit breaker, failed switch or component, or a
disconnected ground wire.

To locate an open circuit:

Check fuse. If blown, replace and operate circuit. If fuse blows a second time, continue
check.

341
 Open Circuit

With switch (C) ON check for battery voltage at switch terminal (D).

If no voltage is measured, check switch, fuse and wiring to battery.

If battery voltage is measured, check for voltage closer to ground at harness connector
(E).

If no voltage is measured, wire may be broken between switch and connector.

If battery voltage is measured, inspect connector pins. If pins are OK check for voltage
at light terminal (G).

In the example, zero voltage will be measured at light terminal, indicating a broken wire
between harness connector and light terminal.

If battery voltage had been measured, the next check for voltage would be at ground
connection (I).

Normal measured voltage at a ground connection should be 0.0 to 0.5 volts.

Item Measurement Specification

Ground Connection Normal Voltage 0.0-0.5 volts

If battery voltage is measured, poor connection to frame or broken wire is indicated.

When problem is located, repair as needed then repeat last check.

TX,9015,QQ6733-19-1995/05/01

342
 Grounded Circuit

Grounded Circuit

T7713AE-19: Grounded Circuit

LEGEND:
A - Battery
B - Fuse
C - Fuse Terminal
D - Switch
E - Switch Terminal
F - Harness Connector
G - Harness Connector
H - Grounded Circuit
I - Light (Component) Terminal
J - Light
K - Ground

If no component operates, the fuse is blown and replacement fuses blow immediately or
the circuit breaker is open and reopens when reset, a grounded circuit exists. (Example:
power wire contacting frame or other metal component). A wire may be pinched or
insulation may be worn from a wire.

To isolate the location of a grounded circuit:

If circuit is grounded between battery and fuse, wire will be burned and circuit will be
open, fuse will not be blown.
343
 Grounded Circuit

If fuse is blown, remove fuse from circuit, disconnect circuit near its center, such as
harness connector (F), turn switch (D) ON, check for continuity to ground at harness
connector (F). This will check harness from harness connector to fuse.

If continuity to ground is measured, there is a pinched or bare wire between fuse (C)
and harness connector (F).

If continuity to ground does not exist, disconnect ground (K) from frame. Measure
continuity to ground at harness connector (G). This checks harness from harness
connector to ground terminal. In the example continuity to ground will exist because
circuit is grounded (wire is pinched) at (H).

If continuity exists, disconnect circuit at light terminal (I) and measure continuity to
ground on light terminal. This checks harness from light to ground terminal. In the
example continuity will not exist, indicating a grounded circuit between the light and
harness connector (G).

Repeat check-out procedure after repair.

TX,9015,QQ6734-19-1995/05/01

344
 Shorted Circuit

Shorted Circuit

T7713AH-19: Shorted Circuit

LEGEND:
A - Battery
B - Fuse
C - Fuse
D - Switch
E - Switch Terminal
F - Switch
G - Harness Connector
H - Shorted Circuit
I - Harness Connector
J - Light
K - Light Terminal
L - Light
M - Ground
N - Ground

A shorted circuit causes components in separate circuits to operate when a switch in

either circuit is turned ON. (Example: two harnesses rubbing together until insulation is
worn through allowing bare wires to touch). Components can also become shorted.
However, shorted components will usually blow the fuse.

345
 Shorted Circuit

To locate a shorted circuit:

Turn Switch (F) ON then OFF, turn switch (D) ON then OFF, both lights (J and L) will be
ON when either switch (D or F) is ON.

Turn switch (F) ON. Both lights (J and L) will be ON, only light (L) should be ON.

Disconnect wire from switch of component that should not be ON. In the example,
disconnect wire from terminal (E) at switch (D). Light (J) remains ON.

Disconnect circuit at convenient places like harness connectors (G), (I) and light
terminal (K) until light (J) goes OFF.

The short circuit will be between the last two places the circuit was disconnected. In the
example, it is between harness connectors (G and I). Light (J) will go OFF when
harness connector (I) is disconnected. Inspect harness between connectors (G and I).

Repair or replace wires and harnesses as needed. Install tie bands and clamps on
harnesses as required to prevent future failures.

Repeat check-out procedure after repair.

TX,9015,QQ6735-19-1995/05/01

346
 Multimeter

Multimeter

T8074AA-19: Multimeter
LEGEND:
A - Display
B - Voltage AC (Alternating Current)
C - Voltage DC (Direct Current)
D - Resistance
E - Diode Test/Continuity
F - Current AC (Alternating Current)
G - Current DC (Direct Current)
H - Voltage, Resistance, Diode/Continuity (Red Lead Input)

347
 Multimeter
I - Ground (Black Lead Input)
J - Current/Amps (Red Lead Input)

The multimeter is an autoranging digital display that allows very accurate readings to be
taken.

TX,9015,QQ6736-19-1996/03/20

348
 Seven Step Electrical Test Procedure

Seven Step Electrical Test Procedure

T7719AA-19: Circuit Breakers

LEGEND:
A - Battery Ground
B - Battery
C - Battery Side Of Fuse Or Circuit Breaker
D - Fuse Or Circuit Breaker
E - Component Side Of Fuse Or Circuit Breaker
F - Switch
G - Battery Side Of Component Terminal
H - Light (Component)
I - Ground Side Of Component Terminal
J - Component Ground

-: Seven Step Procedure-Steps 1 and 2

Step 1-Switch ON
Check battery side of circuit breaker (C) for battery Battery voltage normal. Go to
voltage Step 2.
Low voltage, repair high
resistance.

Open circuit from battery.

349
 Seven Step Electrical Test Procedure

Step 2-Switch OFF

Check component side of circuit breaker for battery Battery voltage normal. Go to
voltage Step 4.
Low voltage, repair high
resistance.
No voltage. Go to Step 3.

-: Seven Step Procedure-Steps 3 through 7

Step 3-Switch OFF

Check component side of circuit breaker for Continuity to ground. Repair grounded
continuity to ground circuit at or before switch.
No continuity to ground, replace circuit
breaker.
Step 4-Switch ON

Check component side of circuit breaker for Battery voltage normal. Go to Step 6.
battery voltage
Low voltage, repair high resistance.
No voltage. Go to Step 5.
Step 5

Disconnect wire at battery side of component Battery voltage, repair component.

(G). Switch ON. Check wire at (G) for battery
voltage
No voltage, repair grounded or open
circuit at or after switch.
Step 6-Switch ON

Check lead to component at (G) for battery Battery voltage normal. Go to Step 7.
voltage
Low voltage, repair high resistance in
circuit between fuse and component.
No voltage, repair high resistance or
open circuit between fuse and
component.
Step 7-Switch ON

350
 Seven Step Electrical Test Procedure

Check ground wire of component at (I) for No voltage, good continuity to ground.
voltage

Repair component.
Voltage, poor continuity to ground.
Repair high resistance or open ground
circuit.

TX,9015,QQ6737-19-1995/05/01

351
 System Functional Schematic Information

System Functional Schematic Information

System Functional Schematic Diagram

The System Functional Schematic is a schematic diagram of the complete machine. All
harnesses are identified by letter/number designation and description (W1 Engine
Harness, W2 Dash Harness, etc.). Each wire is identified by number and/or color (G01
BLK, R02 Red, RED/WHT, BLU/GRN, etc.). All components are identified by
letter/number designation, description and are represented by a schematic symbol.
Component letter/number designation, (K1 Start Relay, S1 Key Switch, B9 Horn, etc.)
will indicate that component throughout the manual. The System Functional Schematic
Diagram is divided into Sections. Each section contains one or more electrical circuits.
Each section is indicated by a number and circuit (SE1 CHARGING CIRCUIT, SE2
STARTING CIRCUIT, etc.).

NOTE:

All System Functional Schematics are shown with key switch in the off
position.

TX,9015,QQ6738-19-1996/03/20

352
 Reading a System Functional Schematic

Reading a System Functional Schematic

T7502CE-19: System Functional Schematic

LEGEND:
A - Power Wires
B - Continuity Chart
C - Component Schematic Symbol
D - Component Identification Code
E - Component Name
F - Ground Wires
G - Circuit Name
H - Section Number

The System Functional Schematic is made up of sections which contain one or more
Subsystem Functional Schematic laid out side by side in a logical sequence of related
functions. Each Subsystem is a major group of components like starting components or
charging components (H). Sections are named to reflect that group of components (G).
The System Functional Schematic is formatted with power supply wires (A) shown
across the top of the drawing and ground wires (F) across the bottom. The diagram
contains no harness or connector information.

Each electrical component is shown by a schematic symbol (C), the component name
(E), and a component identification code (D). A continuity chart (B) is included for each
multi-terminal switch.

353
 Reading a System Functional Schematic

The same names and identification letter codes are used on all machine drawings, the
System Functional Schematic, System Wiring and Harness Diagram, and the System
Component Location Drawing. Components and connectors can easily be cross-
referenced from one drawing to another. See Group -10 for Component Identification
Legend.

TX,9015,QQ6739-19-1994/04/12

354
 Reading a Component Location Diagram

Reading a Component Location Diagram

T102966-19: Component Location Diagram

LEGEND:
A - Component Identification Number
B - Component Name
C - End View of Connector
D - Mating Connector “X” Identification Number
E - Harness Component Identification Number
F - Name of Harness

355
 Reading a Component Location Diagram
G - Diagram View of Connector
H - Terminal Number
I - Wire Number and Color
J - Routing Destination(s) of Wire

NOTE:

The same names and identification numbers are used on all machine
schematic and harness electrical drawings throughout the operation
and test technical manual, so components can easily be cross-
referenced from one drawing to another.

The component location by harness drawing is a pictorial representation that shows

harness routing, component location and mating harness connector information.

The location of each component that is connected to the harness is shown and
identified by its alpha-numeric identification number.

Each connector that joins one harness to another is identified by an “X” component
identification number and a name. An end view of the connector is shown. Also, a
diagram view of the connector shows connector terminal number, wire number and
color and destination of each wire.

For example, X18 connector connects the Cab Work Light Harness to the Load Center
Harness. Terminal 5 of the connector contains L02 Brn Wire, which routes to E20 Left
Front Work Light, E22 Left Rear Work Light, and E23 Right Rear Work Light.

Each wiring harness component location is followed by individual component connector

drawings. These drawings show an end view and a diagram view of each connector in
the harness that connects to a component.

356
 Reading a Component Location Diagram

T102978-19: Individual Component Connector Drawing

In the preceding example, to see the location of L02 Brn Wire in connectors for E20,
E22, and E23 Work Lights, the connection would reference the “Connectors for Cab
Work Light Harness” on the page following the component location drawing. This
drawing shows the end view of the wiring harness connector for each component. In the
case of L02 Brown wire, it is located in Terminal A for all three work lights.

TX,9015,RB30-19-1997/11/06

357
 Electrical Schematic Symbols

Electrical Schematic Symbols

T7719BA-19: Electrical Schematic Symbols

358
 Electrical Schematic Symbols

T7719BB-19: Electrical Schematic Symbols

359
 Electrical Schematic Symbols

T8295BI-19: Electrical Schematic Symbols

TX,9015,QQ6741-19-1993/10/26

360
 Component Identification Table

Component Identification Table

Each component (electrical device) and main connector will have and identification
letter assigned to it. A number is added to the letter to separate and indicate the total
components within that letter group.

-: Component Identification-Letters A-R

Identification
Letter Type Examples

A System, Control units, trigger boxes, two-way radios, logic

subassembly, module, FNR logic module
parts group
B Transducer for Speed sensors, pressure sensors, pressure switches
conversion of horns, sensors, pickups, limit-value sensors, pulse
non-electrical generators, loudspeakers, inductive pickups, probes,
variables to air-flow sensors, oil-pressure switches, temperature
electrical and sensors, ignition-voltage pickups
vice versa
C Condenser, Condensers and capacitors, general
capacitor

D Binary device, Digital devices, integrated circuits, pulse counters,

memory magnetic tape recorders

E Various devices Heating devices, air conditioners, light, headlights,

and equipment spark plugs, ignition distributors
F Protection device Release mechanisms, polarity protection devices,
fuses, current protection circuits
G Power supply, Batteries, generators, alternators, charging units
generator

H Monitor, alarm, Audible alarms, indicator lights, turn-signal lights,

signalling device brake lights, alarms, warning lights, buzzers
K Relay Battery relays, turn-signal relays, solenoid switches,
starting relays, warning flashers
L Inductor Choke coils, windings

M Motor Blower motors, fan motors, starter motors

N Regulator, Regulators (electronic or electromechanical), voltage
amplifier stabilizers

361
 Component Identification Table

Identification
Letter Type Examples
P Measuring Ammeter, diagnostic connectors, tachometers, fuel
instrument gauge, pressure gauges, measuring points, test
points, speedometers

R Resistor Flame glow plugs, sheathed-element flame glow

plugs, glow plugs, heating resistors, NTC resistors,
PTC resistors, potentiometers, regulating resistors

-: Component Identification-Letters S-Z

Identification
Letter Type Examples
S Switch Switches and push-buttons, general key switch, light
switch, horn switch, flasher switch
T Transformer Ignition coil, ignition transformer
U Modulator, DC transformers
converter

V Semiconductor, Transistors, diodes, electron tubes, rectifiers,

electron tubes semiconductors, thyristors, zener diodes
W Transmission Antennas, shielding components, shielded conductors,
path, cable harnesses, conductors, ground conductors
conductor,
antenna
X Terminal, plug, Terminal studs, electrical connections, connectors
plug and electrical line couplers, line connectors, sockets, plugs,
socket terminals, plug-and-socket connections
connection

Y Electrically Permanent magnets, (solenoid-operated) injection

actuated valves, electromagnetic clutches and brakes, air valves,
mechanical fuel pumps, solenoids, switching valves, start valves,
device locking systems
Z Electrical filter Interference suppression filters

TX,9015,QQ6742-19-1996/05/20

362
 Component Identification Table

Component Identification Table

Each component (electrical device) and main connector will have and identification
letter assigned to it. A number is added to the letter to separate and indicate the total
components within that letter group.

-: Component Identification-Letters A-R

Identification
Letter Type Examples

A System, Control units, trigger boxes, two-way radios, logic

subassembly, module, FNR logic module
parts group
B Transducer for Speed sensors, pressure sensors, pressure switches
conversion of horns, sensors, pickups, limit-value sensors, pulse
non-electrical generators, loudspeakers, inductive pickups, probes,
variables to air-flow sensors, oil-pressure switches, temperature
electrical and sensors, ignition-voltage pickups
vice versa
C Condenser, Condensers and capacitors, general
capacitor

D Binary device, Digital devices, integrated circuits, pulse counters,

memory magnetic tape recorders

E Various devices Heating devices, air conditioners, light, headlights,

and equipment spark plugs, ignition distributors
F Protection device Release mechanisms, polarity protection devices,
fuses, current protection circuits
G Power supply, Batteries, generators, alternators, charging units
generator

H Monitor, alarm, Audible alarms, indicator lights, turn-signal lights,

signalling device brake lights, alarms, warning lights, buzzers
K Relay Battery relays, turn-signal relays, solenoid switches,
starting relays, warning flashers
L Inductor Choke coils, windings

M Motor Blower motors, fan motors, starter motors

N Regulator, Regulators (electronic or electromechanical), voltage
amplifier stabilizers

363
 Component Identification Table

Identification
Letter Type Examples
P Measuring Ammeter, diagnostic connectors, tachometers, fuel
instrument gauge, pressure gauges, measuring points, test
points, speedometers

R Resistor Flame glow plugs, sheathed-element flame glow

plugs, glow plugs, heating resistors, NTC resistors,
PTC resistors, potentiometers, regulating resistors

-: Component Identification-Letters S-Z

Identification
Letter Type Examples
S Switch Switches and push-buttons, general key switch, light
switch, horn switch, flasher switch
T Transformer Ignition coil, ignition transformer
U Modulator, DC transformers
converter

V Semiconductor, Transistors, diodes, electron tubes, rectifiers,

electron tubes semiconductors, thyristors, zener diodes
W Transmission Antennas, shielding components, shielded conductors,
path, cable harnesses, conductors, ground conductors
conductor,
antenna
X Terminal, plug, Terminal studs, electrical connections, connectors
plug and electrical line couplers, line connectors, sockets, plugs,
socket terminals, plug-and-socket connections
connection

Y Electrically Permanent magnets, (solenoid-operated) injection

actuated valves, electromagnetic clutches and brakes, air valves,
mechanical fuel pumps, solenoids, switching valves, start valves,
device locking systems
Z Electrical filter Interference suppression filters

TX,9015,QQ6742-19-1996/05/20

364
 Fuse (Blade-Type) Color Codes

Fuse (Blade-Type) Color Codes

-: Fuse Color Codes

Amperage Rating Color

1 Black
3 Violet

4 Pink
5 Tan
7-1/2 Brown
10 Red

15 Light Blue

20 Yellow

25 Natural (White)
30 Light Green

TX,9015,QQ6743-19-1992/09/28

365
 Fuse Specifications

Fuse Specifications

T100712-19: Fuse Locations

LEGEND:
F1 - 7.5 Amp MFWD/Alternator/Diff. Lock Fuse
F2 - 15 Amp Fuel/Start Aid and Reverse Alarm Fuse
F3 - 5 Amp Dome Light/Radio Fuse
F4 - 5 Amp Radio Fuse (Unswitched Power)
F5 - 15 Amp Wiper Fuse
F6 - 30 Amp Heater/AC Fuse
F7 - 15 Amp Rear Light Fuse
F8 - 25 Amp Front Light/Tail Light Fuse
F9 - 10 Amp FNR/Park Brake Fuse
F10 - 20 Amp Turn/Stop/Flash and Horn Fuse
F11 - Not Used
F12 - Not Used
F13 - 10 Amp RTD/Beacon and Pump cutout Fuse
F14 - 10 Amp Monitor/Gauge Fuse
F15 - 10 Auxiliary Fuse
F16 - 10 Amp Start Fuse
K3 - Hydraulic Pump Relay (Not Used)
K4 - Reverse Alarm Relay
K5 - Park Brake Relay

366
 Fuse Specifications
K6 - Neutral Relay
K7 - Timer Relay (Behind the console)
S21 - Flasher

IMPORTANT:

Install fuse with correct amperage rating to prevent electrical

system damage from overload.

The fuse block is located on the side console inside an access cover.

TX,9015,QQ6744-19-1999/12/10

367
 Wiring and Schematic Diagrams Legend

Wiring and Schematic Diagrams Legend

NOTE:

A2-Radio (SE3, W12).

A2 indicates component identification number.

Radio indicates component name.
SE3 indicates section number of SYSTEM FUNCTIONAL
SCHEMATIC where component is located.
W12 indicates HARNESS WIRING DIAGRAM and HARNESS
COMPONENT LOCATION drawings where component is
located.

A2-Radio (SE3, W12)

A3-Auxiliary Flow Controller (W15)
B1-Backup Warning Alarm (SE5,W8)
B2-Hydraulic Oil Temperature Switch (SE15,W8)
B3-Horn (SE12,W8)
B4-Fuel Sender (SE15,W8)
B5-Engine Coolant Temp. Switch (SE17,W8)
B6-Engine Oil Pressure Switch (SE17,W8)
B7-Air Filter Restriction Switch (SE17,W8)
B8-Converter Temperature Switch (SE17,W8)
B9-Hydraulic Filter Switch (SE17,W8)
B10-Park Brake Pressure Switch (SE15)
B11-Brake Light Switches (SE13,W6)
B12-Not Used
B13-Radio Speaker (W12)
B14-Radio Speaker (W13)
E1-Dome Light (SE3, W5)
E2-Not Used
E3-Left Front Work Light (SE8,W5)
E4-Right Front Work Light (SE8,W5)
E5-Left Rear Work Light (SE8,W5)
E6-Right Rear Work Light (SE8,W5)
E7-Left Front Drive Light (SE8,W5)
E8-Right Front Drive Light (SE8,W5)
E9-Left Tail Light (SE8,W5)
E10-Right Tail Light (SE8,W5)
E11-Left Brake Light (SE13,W5)
E12-Right Brake Light (SE13,W5)
E13-Beacon Light (SE14,W5)

368
 Wiring and Schematic Diagrams Legend
E14-Fuel Gauge Light (SE15,W8)
E15- Not Used
E16-Tachometer Lights (S.N. 852338- ) (SE14)
F1-MFWD/ALT/Diff. Lock Fuse (SE2,W6)
F2-Fuel Shutoff/Start Aid/Reverse Alarm Fuse (SE5,W6)
F3-Dome Light/Radio Fuse (SE3,W6)
F4-Radio Fuse (Unswitched Power) (SE3,W6)
F5-Windshield Wiper/Washer Fuse (SE6,W6)
F6-Heater Circuit Breaker (SE5,W6)
F7-Rear Work Light Fuse (SE7,W6)
F8-Front Work Light/Tail Light Fuse (SE8,W6)
F9-FNR/Park Brake Fuse (SE9,W6)
F10-Turn/Stop/Horn Fuse (SE12,W6)
F11-Not Used
F12-Not Used
F13-Return-To-Dig/Beacon Fuse (SE14,W6)
F14-Monitor Fuse (SE15,W6)
F15-Auxiliary Fuse
F16-Start Fuse (SE11,W6)
F17-Fuse Block (W6)
F18-Flow Control Fuse Block (W15)
F19-Auxiliary Fuse (SE19, W15)
G1-Battery (SE1,W8)
G2-Alternator (SE1,W8)
H1-Not Used
H2-Left Front Turn Light (SE13,W5)
H3-Left Rear Turn Light (SE13,W5)
H4-Right Front Turn Light (SE13,W5)
H5-Right Rear Turn Light (SE13,W5)
H6-Not Used
H7-Not Used
H8-Display Monitor (SE16,W6)
H9-Not Used
H10-Not Used
H11-Display Monitor Alarm (SE17, W6)
K1-Start Relay (SE1,W8)
K2-Accessory Relay (SE1,W6)
K3-Pump Unloading Valve Relay (SE10,W6) (Not Used)
K4-Backup Alarm Relay (SE4,W6 )
K5-Park Brake Latching Relay (SE9,W6)
K6-Neutral Start Relay (SE9,W6)
K7-Timer Relay (Power Shift Only) (SE10, W7)
M1-Starter Motor (SE1,W8)
M2-Rear Wiper Motor (SE6,W5)

369
 Wiring and Schematic Diagrams Legend
M3-Left Hand Door Wiper Motor (SE6,W5)
M4-Right Hand Door Wiper Motor (SE6,W5)
M5-Washer Motor (SE6,W8)
M6-Heater Blower Motor (SE5,W6)
M7-Air Adjust Seat Motor (SE6, W10)
P1-Fuel Gauge (SE15,W6)
P2-Tachometer (SE15,W6)
P3-Hour Meter (SE15,W6)
R1-Heater Motor Resistor (SE5,W6)
S1-Key Switch (SE2,W6)
S2-MFWD Switch (SE2,W6)
S3-Diff. Lock Switch (SE2,W6)
S4-Start Aid Switch (SE5,W6)
S5-Front Wiper Switch (SE6,W7)
S6-Rear Wiper Switch (SE6,W6)
S7-Windshield Washer Switch (SE6,W6)
S8-Blower Switch (SE5,W6)
S9-Front Light Switch (SE8,W7)
S10-Rear Light Switch (SE7,W6)
S11-FNR Switch (SE9,W7)
S12-Park Brake Dash Switch (SE9,W6)
S13-Loader Lever Switch (SE8,W6)
S14-Gear Shift Lever Switch (SE8,W6)
S15-Horn Switch (SE12,W6)
S16-Turn Signal Switch (SE13,W7)
S17-4-Way Flasher Switch (SE13,W7)
S18-Beacon Switch (Optional) (SE14,W6)
S19-Seat Position Sensor (SE15,W6)
S20-Return-To-Dig Switch (SE14,W8)
S21-Flasher (SE13,W6)
S22-Heater Temperature Switch (W6)
S23-Low Pressure Switch (W11)
S24-High Pressure Switch (W11)
S25-A/C Switch (If Equipped) (W6)
S26-A/C Freeze Switch (W10)
S27-Dome Light Switch (SE3,W5)
S28-Selective Flow Valve Switch (SE18, W15)
S29-Foot Switch (SE18, W15)
SE30-Ride Control Switch (SE17, W17)
S31-Pin Disconnect Switch (SE19, W18)
S32-Air Adjust Seat Switch (SE6, W10)
V1-MFWD Solenoid Diode (SE2,W8)
V2-Park Brake Solenoid Diode (SE9,W8)
V3-Reverse Solenoid Diode (SE9,W8)

370
 Wiring and Schematic Diagrams Legend
V4-Forward Solenoid Diode (SE9,W8)
V5-Neutral Disconnect Solenoid Diode (SE10, W8)
V6-4-Way Flasher Switch Diode (SE13,W7)
V7-4-Way Flasher Switch Diode (SE13,W7)
V8-Start Solenoid Diode (SE1,W4)
V9-Alternator Diode (SE1,W8)
V10-Diff. Lock Diode (SE2,W)
V11-Park Brake Relay Diode (SE9,W6) (SN-778669)
V12-Speed Solenoid (1) Diode (Power Shift only) (SE10, W8)
V13-Speed Solenoid (2) Diode (Power Shift only) (SE10, W8)
V14-Speed Solenoid (3) Diode (Power Shift only) (SE10, W8)
V15-Ride Control Diode (SE17, W17)
V16-Not Used
V17-Pin Disconnect Diode (SE19, W18)
V18-Low Range Solenoid Diode (Power Shift only) (SE10, W8)
V19-Timer Relay Diode (Power Shift only) (SE10, W7)
V20-Timer Relay Diode (Power Shift only) (SE10, W7)
V21-Tachometer Isolation Diode (SE15,W6) (S.N. 852338- )
W1-Machine Frame Ground Right Side Of Flywheel Housing (SE1,W8)
W2-Ground To Cab Frame (SE14,W5)
W3-Ground At Cab Floor (SE1,W8)
W4-Engine Ground Strap (W8)
W5-Cab Roof Harness (W5)
W6-Cab Side Console Harness (W6)
W7-Front Console Harness (W7)
W8-Engine Harness (W8)
W9-Not Used
W10-Blower Harness (W10)
W11-A/C Compressor Harness (W11)
W12-Radio Harness (W12)
W13-Radio Antenna (W12)
W14-Ground to A/C Compressor (W8)
W15-Selective Flow Valve Harness (W15)
W16-Selective Flow Valve Harness Ground Connector (W15)
W17-Ride Control Harness (W17)
W18-Pin Disconnect Harness (W18)
W19-Pin Disconnect Harness Ground Connector (W18)
W20-Ride Control Harness Ground Connector (W17)
X1-Side Console Harness To Roof Harness Connectors (W5,W6)
X2-Side Console Harness To Roof Harness Connectors (W5,W6)
X3-Side Console Harness To Roof Harness Connectors (W5,W6)
X4-Display Monitor Alarm Connector (SE15,W6)
X5-Seat Position Sensor Connector
X6-Blower Switch Connector (W10)

371
 Wiring and Schematic Diagrams Legend
X7-Display Monitor Connectors (W6)
X8-Horn Switch Connector (W6)
X9-Rear Light Switch Connector (W6)
X10-Rear Wiper Switch Connector (W6)
X11-Beacon Switch Connector (W6)
X12-MFWD Switch Connector (W6)
X13-Park Brake Switch Connector (W6)
X14-Start Aid Switch Connector (W6)
X15-Fuel Gauge Connector (W6)
X16-Key Switch Connector (W6)
X17-Accessory Relay Connectors
X18-Tachometer Connectors (S.N. 852338- )
X19-Not Used
X20-Side Console To Engine Harness (W6,W8)
X21-Side Console To Engine Harness (W6,W8)
X22-Side Console To Engine Harness (W6,W8)
X23-Side Console To Engine Harness (W6,W8)
X24-Side Console To Engine Harness (W6,W8)
X25-Side To Front Console Connectors (W6,W7)
X26-FNR Switch Connector (W7)
X27-Turn Signal Switch Connector (W7)
X28-Beacon Light Connector (W5)
X29-Roof Harness to Radio Harness Connector (W5,W12)
X30-Spliced G40 To G10,G30 (Inside Side Console Harness) (W6)
X31-Forward/Reverse Solenoid Connector (W8)
X32-Clutch Disconnect Solenoid Connector (W8)
X33-Connectors For A/C Switch (W6)
X34-Engine Harness To A/C Compressor Harness Connector (W8,W11)
X35-Side Console Harness To Blower Harness Connectors (W8,W10)
X36-A/C Freeze Switch Connector (W10)
X37-Not Used
X38-A/C Switch Connector (W6)
X39-Radio Harness To Radio Connector (W12)
X40-Flow Control Harness to Auxiliary Resistor Connector (S.N. -843176)
X41-Hour Meter Connector (SE14,W6)
X42-Auxiliary Harness Connector (W15)
X43-Auxiliary Flow Control Switch Connector (W15)
X44-Auxiliary Power Connector (W15)
X45-Diagnostic Connector (W15) (not used)
X46-Controller Harness Connector (W15)
X47-Controller Harness 18-pin Connector (W15)
X48-Controller Harness 30-pin Connector (W15)
X49-Auxiliary Flow Control Foot Switch Connector (W15)
X50-Auxiliary Flow Control Solenoid Single Pin Connectors (S.N. -843176),

372
 Wiring and Schematic Diagrams Legend
Auxiliary Flow Control Solenoid Two Pin Connector (S.N. 843177- )(W15)
X51-Side Console Harness to Ride Control Harness Connector (W6, W17)
X52-Ride Control Harness to Ride Control Engine Harness Connector (W17)
X53-Engine Harness to Auxiliary Gauge Harness Connector (W8)
X54-Engine Harness to Transmission Control Valve Connector (W8)
X55-Side Console Harness to Air Adjust Seat Harness Connector (ROPS
Machines Only) (W6)
X56-Blower Harness to Air Adjust Seat Harness Connector (Cab Machines
Only) (W10)
X57-Engine Harness to Transmission Control Valve Connector (W8)
X58-Side Console Harness Auxiliary Connector (W6)
Y1-MFWD Solenoid (SE2,W8)
Y2-Start Aid Solenoid (SE5,W8)
Y3-Fuel Shutoff Solenoid (SE5,W8)
Y4-Park Brake Solenoid (SE9,W8)
Y5-Reverse/Solenoid (SE9,W8)
Y6-Forward/Solenoid (SE9,W8)
Y7-Neutral Disconnect Solenoid (SE9,W8)
Y8-Diff. Lock Solenoid (SE1,W8)
Y9-Return-To-Dig Solenoid (SE14,W8)
Y10-A/C Compressor (W11)
Y11-Pump Unloading Valve Solenoid (SE10,W8)
Y12-Speed Solenoid (1) (Power Shift only) (SE10, W8)
Y13-Speed Solenoid (2) (Power Shift only) (SE10, W8)
Y14-Speed Solenoid (3) (Power Shift only) (SE10, W8)
Y15-Ride Control Solenoid (SE17, W17)
Y16-Selective Flow Valve Solenoid (SE18, W15)
Y17-Pin Disconnect Solenoid (SE19, W18)
Y18-Low Range Solenoid (Power Shift only) (SE10, W8)

TX,9015,QQ6745-19-2000/01/18

373
 System Functional Schematic Section Legend

System Functional Schematic Section Legend

NOTE:

SE1-Battery/Ignition, Power, Charging and Start Circuit (12 Volt

System)

SE1 indicates section number of system functional schematic

where circuit is located.
Battery/Ignition, Power, Charging and Start Circuit (12 Volt
System) indicates circuit name.

SE1-Battery/Ignition, Power, Charging and Start Circuit (12 Volt System)

SE2-Differential Lock Circuit
SE3-MFWD Circuit
SE4-Dome Light and Radio Circuit
SE5-Start Aid, Fuel Shut Off and Reverse Alarm Circuit
SE6-Blower Circuit
SE7-Wiper and Washer Circuit
SE8-Rear Work Light Circuit
SE9-Front Work and Drive Light Circuit
SE10-FNR/Park Brake Circuit
SE-FNR/Park Brake Circuit (With Optional Power Shift)
SE11-Horn Circuit
SE12-Turn Signal, Flasher and Brake Light Circuit
SE13-Beacon and RTD Circuit
SE14-Gauge and Hour Meter Circuit
SE15-Monitor Circuit
SE16-Indicator Circuit
SE17-Ride Control Circuit
SE18-Selective Flow Valve Circuit
SE19-Pin Disconnect Circuit

TX,9015,QQ6746-19-1998/07/21

374
 System Functional Schematic

System Functional Schematic

T126722-19: Charging, Start, Differential Lock, MFWD Circuits

T126723-19: Dome Light, Start Aid, Blower Circuit

T126724-19: Wiper, Washer, Work Light, Drive Light Circuits

375
 System Functional Schematic

T126725-19: FNR/Park Brake Circuit

T126726-19: FNR/Park Brake Circuit (With Optional Power Shift)

T126727-19: Horn, Turn Signal, Flasher, Brake, Return-to-Dig Circuits

376
 System Functional Schematic

T126728-19: Gauge and Hour Meter, Display Monitor, and Indicator Circuits

T126729-19: Ride Control, Selective Flow Valve, Pin Disconnect Circuits

TX,9015,QQ6747-19-1999/12/15

377
 Cab Roof Harness (W5) Component Location

Cab Roof Harness (W5) Component Location

T100583-19: Cab Roof Harness Component Location

TX,9015,QQ6748-19-1999/12/15

378
 Cab Roof Harness (W5) Connectors, Wire and Pin Location

Cab Roof Harness (W5) Connectors, Wire and Pin Location

T101266-19: Connectors for Cab Roof Harness

379
 Cab Roof Harness (W5) Connectors, Wire and Pin Location

T101396-19: Connectors for Cab Roof Harness

TX,9015,QQ6749-19-1996/05/20

380
 Cab Side Console Harness (W6) Component Location

Cab Side Console Harness (W6) Component Location

T126757-19: Cab Side Console Harness Components

T126759-19: Cab Side Console Harness

T114518-19: Cab Side Console Harness (With Optional Powershift)

TX,9015,QQ6750-19-1999/12/13

381
 Cab Side Console Harness (W6) Connectors, Wire and Pin Location

Cab Side Console Harness (W6) Connectors, Wire and Pin Location

T126763-19: Connectors for Cab Side Console Harness

382
 Cab Side Console Harness (W6) Connectors, Wire and Pin Location

T115813-19: Connectors for Cab Side Console Harness

383
 Cab Side Console Harness (W6) Connectors, Wire and Pin Location

T115818-19: Connectors for Cab Side Console Harness

384
 Cab Side Console Harness (W6) Connectors, Wire and Pin Location

T126826-19: Connectors for Cab Side Console Harness

385
 Cab Side Console Harness (W6) Connectors, Wire and Pin Location

T115923-19: Connectors for Cab Side Console Harness

TX,9015,QQ6751-19-1999/12/15

386
 Front Console Harness (W7) Component Location

Front Console Harness (W7) Component Location

T100586-19: Front Console Harness Components

TX,9015,QQ6752-19-1998/07/21

387
 Front Console Harness (W7) Component Location (With Optional Power Shift)

Front Console Harness (W7) Component Location (With Optional

Power Shift)

T126766-19: Front Console Harness Component Location (With Optional Power Shift)

CED,TX17864,100-19-1999/12/15

388
 Front Console Harness (W7) Connectors, Wire and Pin Location

Front Console Harness (W7) Connectors, Wire and Pin Location

T101267-19: Connectors for Front Console Harness

389
 Front Console Harness (W7) Connectors, Wire and Pin Location

T126767-19: Connectors for Front Console Harness (With Optional Power Shift)

TX,9015,QQ6753-19-1999/12/15

390
 Engine Harness (W8) Component Location

Engine Harness (W8) Component Location

T115796-19: Engine Harness Component Location

TX,9015,QQ6754-19-1998/07/21

391
 Engine Harness (W8) Component Location (With Optional Power Shift)

Engine Harness (W8) Component Location (With Optional Power

Shift)

T114520-19: Engine Harness Component Location (With Optional Power Shift)

CED,TX17864,103-19-1998/07/21

392
 Engine Harness (W8) Connectors, Wire and Pin Location

Engine Harness (W8) Connectors, Wire and Pin Location

T126769-19: Engine Harness Connector Views

393
 Engine Harness (W8) Connectors, Wire and Pin Location

T115798-19: Engine Harness Connector Views

394
 Engine Harness (W8) Connectors, Wire and Pin Location

T115799-19: Engine Harness Connector Views

395
 Engine Harness (W8) Connectors, Wire and Pin Location

T126770-19: Engine Harness Connector Views

TX,9015,QQ6755-19-1999/12/15

396
 Blower Harness (W10) Component Location

Blower Harness (W10) Component Location

T116040-19: Blower Harness Component Location

TX,9015,QQ6756-19-1998/07/21

397
 Blower Harness (W10) Connectors, Wire and Pin Location

Blower Harness (W10) Connectors, Wire and Pin Location

T101392-19: Connectors for Blower Harness

398
 Blower Harness (W10) Connectors, Wire and Pin Location

T116079-19: Connectors for Blower Harness

TX,9015,QQ6757-19-1998/07/21

399
 Radio Harness (W12) Component Location

Radio Harness (W12) Component Location

T100589-19: Radio Harness Component Location

TX,9015,QQ6758-19-1996/03/20

400
 Radio Harness (W12) Connectors, Wire and Pin Location

Radio Harness (W12) Connectors, Wire and Pin Location

T101356-19: Connectors for Radio Harness

TX,9015,QQ6759-19-1996/05/21

401
 Air Conditioning Compressor Harness (W11) Component Location

Air Conditioning Compressor Harness (W11) Component Location

T116041-19: AC Compressor Harness Components

TX,9015,QQ6760-19-1998/07/21

402
 Air Conditioning Compressor Harness (W11) Connectors, Wire and Pin Location

Air Conditioning Compressor Harness (W11) Connectors, Wire and

Pin Location

T101360-19: Connectors for AC Compressor Harness

TX,9015,QQ6761-19-1998/07/21

403
 Selective Flow Valve Harness (W15) Component Location

Selective Flow Valve Harness (W15) Component Location

T111749-19: Flow Control Harness Components

TX,9015,RB15-19-1998/07/21

404
 Selective Flow Valve Harness (W15) Connectors, Wire and Pin Location

Selective Flow Valve Harness (W15) Connectors, Wire and Pin

Location

T126832-19: Flow Control Harness Components

405
 Selective Flow Valve Harness (W15) Connectors, Wire and Pin Location

T126833-19: Flow Control Harness Components

406
 Selective Flow Valve Harness (W15) Connectors, Wire and Pin Location

T126831-19: Flow Control Harness Components

CED,TX17864,111-19-1999/12/16

407
 Ride Control Harness (W17) Component Location

Ride Control Harness (W17) Component Location

T116113-19: Ride Control Component Location

CED,TX17864,104-19-1998/06/29

408
 Ride Control Harness (W17) Connectors, Wire and Pin Location

Ride Control Harness (W17) Connectors, Wire and Pin Location

T116114-19: Connectors for Ride Control Harness

CED,TX17864,105-19-1998/06/29

409
 Pin Disconnect Harness (W18) Component Location

Pin Disconnect Harness (W18) Component Location

T116110-19: Pin Disconnect Harness Component Location

CED,TX17864,106-19-1998/06/29

410
 Pin Disconnect Harness (W18) Connectors, Wire and Pin Location

Pin Disconnect Harness (W18) Connectors, Wire and Pin Location

T116112-19: Connectors for Pin Disconnect Harness

CED,TX17864,107-19-1998/06/29

411
 Power Circuit Operational Information

Power Circuit Operational Information

The following conditions must exist for power circuit to function:

Voltage must be present at these distribution points for other circuits to operate.

BAT terminal of key switch

Terminal 30 of accessory relay
Start relay
B+ terminal of alternator
Starter motor
Radio fuse

TX,9015,QQ6762-19-1996/06/06

412
 Power Circuit Operational Information

Power Circuit Operational Information

The following conditions must exist for power circuit to function:

Voltage must be present at these distribution points for other circuits to operate.

BAT terminal of key switch

Terminal 30 of accessory relay
Start relay
B+ terminal of alternator
Starter motor
Radio fuse

TX,9015,QQ6762-19-1996/06/06

413
 Power Circuit Theory Of Operation

Power Circuit Theory Of Operation

The power circuit includes battery and main current paths to primary distribution points.

With key switch OFF, power from battery goes to key switch, accessory relay, start
relay, alternator, starter motor and unswitched radio fuse.

When key switch is moved from OFF position, power continues through IGN and ST
terminals to main fuse block. ACC terminal power goes to accessory relay, energizing
relay sending power to the main fuse block.

The key switch “G” terminal is a ground terminal only in “Bulb Check” and “Start”
positions.

NOTE:

For component identification code description, see Wiring and

Schematic Diagrams Legend, Group 9015-10.

TX,9015,QQ6763-19-1996/06/06

414
 Power Circuit Schematic

Power Circuit Schematic

T100796-19: Power Circuit Schematic

TX,9015,QQ6764-19-1996/06/06

415
 Sub-System Diagnostics/Power Circuit

Sub-System Diagnostics/Power Circuit

Power Circuit Diagnostic Procedures

Launch Close Expand List Collapse List

1 Battery State of Charge

Action:

CAUTION:
Engine may crank during this check.

Move light switch to ON position.

Do Work lights go out or get very dim while cranking engine?

Record of Actual Results:

Result:
YES:
Clean battery cable terminals. Repeat test.

If lights still get dim, test battery.

NO:
Battery charge is good. Go to next check.

2 Starter Motor

Action:

416
 Sub-System Diagnostics/Power Circuit

T7199BK-19: Starter Motor

Key switch OFF.

With harness connected, check voltage at terminal of starter with red cable.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check wiring harness between battery and starter.

3 Alternator

Action:

T7828AA-19: Alternator

417
 Sub-System Diagnostics/Power Circuit

Key switch OFF.

With harness connected, check voltage at B+ terminal of alternator

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check wiring harness between battery and alternator

4 Start Relay

Action:

T7199BM-19: Start Relay

Key switch OFF.

With harness connected, check voltage at terminal with BO3 red wire.

Are 12 volts measured?

Record of Actual Results:

Result:

418
 Sub-System Diagnostics/Power Circuit

YES:
Go to next check.
NO:
Check wiring harness between battery and start relay.

5 Key Switch Check

Action:

T7199BO-UN: Key Switch OFF

Key switch OFF.

Disconnect harness from switch.

Check voltage on B11 red wire at BAT terminal of key switch.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness between battery and key switch.
Action:

419
 Sub-System Diagnostics/Power Circuit

T7199BO-UN: Key Switch at START

Switch disconnected from harness.

Turn key switch to START position.

Check for continuity between BAT and IGN terminals and BAT and ST terminals.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace key switch.
Action:

T7199BO-UN: Key Switch ON

Switch disconnected from harness.

420
 Sub-System Diagnostics/Power Circuit

Key switch ON.

Check for continuity between BAT and ACC terminal.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Replace key switch.

6 Accessory Relay

Action:

T7199BN-UN: Accessory Relay

Key switch OFF.

With harness connected, check voltage at large terminal with B11 red wire.

Are 12 volts measured?

Record of Actual Results:

Result:

421
 Sub-System Diagnostics/Power Circuit

YES:
Go to next step in this check.
NO:
Check wiring harness between battery and accessory relay.
Action:

T7199BN-UN: Accessory Relay

Key switch ON.

With harness connected, check voltage at small terminal with B14 red wire.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness between battery and accessary relay.
Action:

422
 Sub-System Diagnostics/Power Circuit
T7199BN-UN: Accessory Relay

Disconnect harness from relay.

Connect battery voltage to small terminal. Ground mounting bracket.

Does relay click?

Measure continuity between the two large terminals.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Relay is good.
NO:
Replace accessory relay.

TX,9015,QQ6765-19-1996/06/06

423
 Start Circuit Operational Information

Start Circuit Operational Information

The following conditions must exist for start circuit to function:

FNR lever in neutral

Key switch in START position

TX,9015,QQ6766-19-1996/06/06

424
 Start Circuit Theory of Operation

Start Circuit Theory of Operation

The start circuit converts the electrical energy from the battery to mechanical energy by
the starter. A heavy current draw takes place in the starter.

With key switch OFF, power flows from battery to starter motor terminal, start relay
spade terminal, accessory relay, and key switch BAT terminal.

With key in ON or IGN, power flows from IGN terminal through FNR/park brake fuse, to
FNR switch. With the FNR in neutral power flows to the neutral start relay terminal 86,
energizing relay.

With key switch in START, power flows from ST terminal through start fuse, neutral
start relay, to the start relay closing the relay. With relay closed, power flows from
starter motor through BO3 red wire to start relay, through EO2 white wire to starting
motor solenoid “S terminal”, closing solenoid contacts. With solenoid contacts closed,
power flows from battery to the starter windings.

NOTE:

For component identification code description, see Wiring and

Schematic Diagrams Legend , Group 9015-10.

TX,9015,QQ6767-19-1996/06/06

425
 Start Circuit Schematic

Start Circuit Schematic

T100797-19: Start Circuit Schematic

TX,9015,QQ6768-19-1996/06/06

426
 Sub-System Diagnostics/Start Circuit

Sub-System Diagnostics/Start Circuit

Start Circuit Diagnostic Procedures

Launch Close Expand List Collapse List

1 Key Switch Check

Action:

T7199BO-UN: Key Switch at START

Switch disconnected from harness.

Turn key switch to START position.

Check for continuity between BAT and IGN terminals and BAT and ST terminals.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace key switch.

2 FNR Lever

Action:

427
 Sub-System Diagnostics/Start Circuit

T115867-19: FNR Lever

Key switch ON. FNR lever in neutral

With harness connected, check voltage at terminals with P24 red wire and T12
blue wire.

Are 12 volts measured at each terminal?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness.
Action:

428
 Sub-System Diagnostics/Start Circuit

T115868-19: FNR Lever

Key switch ON.

With harness connected, and FNR lever moved to forward, check voltage at
terminal with T11 blue wire.

Move FNR lever to reverse, check voltage at T13 blue wire.

Are 12 volts measured at each terminal?

Record of Actual Results:

Result:
YES:
FNR lever is good. Go to next check.
NO:
Replace FNR lever.

3 Neutral Start Relay

429
 Sub-System Diagnostics/Start Circuit

Action:

T7287BH-UN: Neutral Start Relay

Key switch OFF.

Disconnect harness from relay.

Connect battery voltage to terminal #85.

Does relay click?

Measure continuity between terminals #30 and #87.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Relay is good. Check wiring harness.
NO:
Replace neutral start relay.

4 Start Relay

Action:

430
 Sub-System Diagnostics/Start Circuit

T7287BK-19: Start Relay

Key switch OFF.

Disconnect harness from relay.

Connect battery voltage to one of the small blade terminals and ground the other.
Does relay click?

Measure continuity between two large terminals. Is continuity measured?

Record of Actual Results:

Result:
YES:
Relay is good.
NO:
Replace start relay.

5 Starter Solenoid Check

Action:

431
 Sub-System Diagnostics/Start Circuit

T6534BI-UN: Starter Solenoid

CAUTION:
Starter will crank engine if metal strap is NOT disconnected
from starter motor.

Disconnect metal strap from starter motor terminal.

Connect battery voltage to solenoid small terminal.

Ground metal strap from solenoid with heavy gauge wire.

Does solenoid “click”?

Remove jumper wires.

Record of Actual Results:

Result:
YES:
Solenoid is OK. Check starter motor.
NO:
Replace starter solenoid.

6 Starter Motor

Action:

T6534BJ-UN: Starter Motor

432
 Sub-System Diagnostics/Start Circuit

CAUTION:
Starter will crank engine if metal strap is NOT disconnected
from starter motor.

Disconnect metal strap from starter motor large terminal.

Connect a heavy gauge jumper wire from battery positive cable to starter motor
terminal.

Connect a heavy gauge jumper wire from battery positive cable to starter motor
terminal.

Does starter motor turn, but NOT crank engine?

Record of Actual Results:

Result:
YES:
Starter motor is good. Check wiring harness.
NO:
Repair or replace starter motor.

TX,9015,QQ6769-19-1998/07/21

433
 Charging Circuit Operational Information

Charging Circuit Operational Information

The following conditions must exist for charging circuit to function:

Key switch in ON position

Engine running

TX,9015,QQ6770-19-1996/06/06

434
 Charging Circuit Theory of Operation

Charging Circuit Theory of Operation

65 or 95 AMP Bosch Alternator: The alternator (B+) terminal is connected to battery

voltage at all times.

The alternator terminal (D+) gets power from ACC terminal of the key switch by
energizing the accessory relay, closing relay contacts and sending power to
MFWD/Alternator/Diff. Lock fuse.

With key switch ON and engine running, power flows from terminal (W) of alternator to
display monitor, ground is removed and indicator light goes out.

When key is on but engine is not running or if alternator fails, a ground is supplied to the
display monitor and indicator lights come on.

NOTE:

For component identification code description, see Wiring and

Schematic Diagrams Legend, Group 9015-10.

TX,9015,QQ6771-19-1996/06/06

435
 Charge Circuit Schematic

Charge Circuit Schematic

T100798-19: Charge Circuit Schematic

TX,9015,QQ6772-19-1996/06/06

436
 Sub-System Diagnostics/Charging Circuit

Sub-System Diagnostics/Charging Circuit

Charging Circuit Diagnostic Procedures

Launch Close Expand List Collapse List

1 Alternator Output

Action:

T6569AZ-UN: Alternator Output

Key switch OFF.

Measure and record battery voltage.

Start and run engine at 1500 rpm, and check battery voltage.

Item MeasurementSpecification
Alternator Output Check Engine Speed 1500 rpm

Does battery voltage increase?

Record of Actual Results:

Result:
YES:
Alternator is good. Check wiring harness. Check battery.
NO:
Check alternator.

2 Alternator
437
 Sub-System Diagnostics/Charging Circuit

Action:

T7835AT-19: Alternator

Key switch ON. Engine running. Park brake ON.

Using a multimeter, check for DC voltage at terminals (D+) and (B+).

Is 14 DC volts measured?

Using a multimeter, check for AC voltage at terminal (W).

Is 7.63 AC volts measured?

Record of Actual Results:

Result:
YES:
Alternator is good.
NO:
Alternator is failed. Repair or replace.

438
 Sub-System Diagnostics/Charging Circuit

3 Alternator Diode Test

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

T7961AA-UN: Alternator Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:

439
 Sub-System Diagnostics/Charging Circuit
If continuity is measured in one check and not the other, diode is OK.

4 Key Switch Check

Action:

T7199BO-UN: Key Switch OFF

Key switch OFF.

Disconnect harness from switch.

Check voltage on B11 red wire at BAT terminal of key switch.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness between battery and key switch.
Action:

440
 Sub-System Diagnostics/Charging Circuit

T7199BO-UN: Key Switch at START

Switch disconnected from harness.

Turn key switch to START position.

Check for continuity between BAT and IGN terminals and BAT and ST terminals.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace key switch.
Action:

T7199BO-UN: Key Switch ON

Switch disconnected from harness.

441
 Sub-System Diagnostics/Charging Circuit

Key switch ON.

Check for continuity between BAT and ACC terminal.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Replace key switch.

5 Accessory Relay

Action:

T7199BN-UN: Accessory Relay

Key switch OFF.

With harness connected, check voltage at large terminal with B11 red wire.

Are 12 volts measured?

Record of Actual Results:

Result:

442
 Sub-System Diagnostics/Charging Circuit

YES:
Go to next step in this check.
NO:
Check wiring harness between battery and accessory relay.
Action:

T7199BN-UN: Accessory Relay

Key switch ON.

With harness connected, check voltage at small terminal with B14 red wire.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness between battery and accessary relay.
Action:

443
 Sub-System Diagnostics/Charging Circuit
T7199BN-UN: Accessory Relay

Disconnect harness from relay.

Connect battery voltage to small terminal. Ground mounting bracket.

Does relay click?

Measure continuity between the two large terminals.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Relay is good.
NO:
Replace accessory relay.

TX,9015,QQ6773-19-2000/01/28

444
 Differential Lock Circuit Operational Information

Differential Lock Circuit Operational Information

The following conditions must exist for differential lock to function.

Key switch in ON position.

Engine running
Differential lock switch held down.

CED,TX17864,86-19-2000/01/28

445
 Differential Lock Circuit Theory of Operation

Differential Lock Circuit Theory of Operation

Power flows from the MFWD/Alternator/Differential lock fuse (F1) to the differential lock
switch (S3). The differential lock switch is normally open. When the operator depresses
the differential lock switch, power continues to flow to the differential lock solenoid (Y8)
and energize the solenoid.

When the operator releases the switch, the switch opens and the differential solenoid is
de-energized. The differential lock diode (V11) prevents voltage spikes from arching
across the terminals of the switch when the switch is released.

CED,TX17864,87-19-1998/06/12

446
 Differential Lock Circuit Schematic

Differential Lock Circuit Schematic

447
 Differential Lock Circuit Schematic

T115838-19: Differential Lock Circuit Schematic

CED,TX17864,88-19-1998/06/12

448
 Sub-System Diagnostics/Differential Lock Circuit

Sub-System Diagnostics/Differential Lock Circuit

Differential Lock Circuit Diagnostic Procedures

Launch Close Expand List Collapse List

1 Differential Lock Switch

Action:

T115875-19: Differential Lock Switch

Disconnect harness from switch.

Connect multimeter to switch terminals.

Depress differential lock switch.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace switch.
Action:

449
 Sub-System Diagnostics/Differential Lock Circuit

T115875-19: Differential Lock Switch

Release Switch.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Replace switch.
NO:
Go to next check.

2 Differential Lock Solenoid

Action:

T126771-19: Differential Lock Solenoid

Key switch ON.

Differential lock switch depressed and held.

450
 Sub-System Diagnostics/Differential Lock Circuit

Disconnect harness from solenoid.

Measure voltage at terminals in harness.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Repair or replace solenoid.
NO:
Repair harness. (See Group -10.)

3 Differential Lock Diode

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

T7961AA-UN: Differential Lock Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

451
 Sub-System Diagnostics/Differential Lock Circuit

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

CED,TX17864,89-19-1999/12/15

452
 MFWD Circuit Operational Information

MFWD Circuit Operational Information

The following conditions must exist for MFWD to function.

Key switch in ON position.

Engine running.
MFWD switch on.

CED,OUTX782,527-19-1999/06/30

453
 MFWD Circuit Theory of Operation

MFWD Circuit Theory of Operation

NOTE:

The MFWD is spring applied, hydraulically released. See Mechanical

Front Wheel Drive (MFWD) Operation in Group 9020-05.

Power flows from the MFWD/Alternator/Differential lock fuse (F1) to the MFWD switch
(S2). When MFWD switch is in disengaged position, power continues to flow to the
MFWD solenoid (Y1) and energize the solenoid.

When switch is in engaged position, the switch opens and the MFWD solenoid is de-
energized. The MFWD diode (V10) prevents voltage spikes from arching across the
terminals of the switch.

CED,OUTX782,529-19-2002/05/02

454
 MFWD Circuit Schematic

MFWD Circuit Schematic

455
MFWD Circuit Schematic

456
 MFWD Circuit Schematic

T115840-19: MFWD Circuit Schematic

CED,OUTX782,531-19-1999/06/30

457
 Sub-System Diagnostics/MFWD Circuit

Sub-System Diagnostics/MFWD Circuit

MFWD Circuit Diagnostic Procedures

Launch Close Expand List Collapse List

1 MFWD Switch

Action:

T100731-UN: MFWD Switch

Disconnect harness from switch.

MFWD switch OFF.

Check for continuity between terminals 2B and 1.

Is continuity measured?

MFWD switch ON.

Check for continuity between terminals 2B and 3.

Is continuity measured?

458
 Sub-System Diagnostics/MFWD Circuit

Record of Actual Results:

Result:
YES:
MFWD switch is good. Check wiring harness.
NO:
Replace MFWD switch.

2 MFWD Solenoid

Action:

T126771-19: MFWD Solenoid

Key switch ON.

MFWD switch OFF.

Disconnect harness from solenoid.

Measure voltage at terminals in harness.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Repair or replace solenoid.

459
 Sub-System Diagnostics/MFWD Circuit

NO:
Repair harness. (See Group -10.)

3 MFWD Diode

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

T7961AA-UN: MFWD Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.

460
 Sub-System Diagnostics/MFWD Circuit

NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

CED,OUTX782,533-19-2000/01/28

461
 Display Monitor Circuit Operational Information

Display Monitor Circuit Operational Information

The following condition must exist for display module to function.

The key switch must be in the “ON” position so failures will be indicated.

TX,9015,QQ6774-19-1996/06/06

462
 Display Monitor Circuit Theory Of Operation

Display Monitor Circuit Theory Of Operation

Power is supplied to the display monitor through the 10 AMP Monitor/Gauge fuse.

Each display indicator will be colored either (RED) or (YELLOW) to indicate the severity
of the situation. Red is a high level warning and the yellow is a low level warning. When
the “RED” high level warning is indicated, the operator will see a (RED COLORED
INDICATOR), (RED STOP INDICATOR) and (AUDIBLE ALARM). When the “YELLOW”
low level warning is indicated, the operator will see only the (YELLOW COLORED
INDICATOR). On “Low Level” warnings the operation of the machine can continue but
the problem should be investigated and solved. On “High Level” warnings except
“Engine Coolant Temperature Indicator” the operation of the machine should be
stopped immediately and problem corrected,

CONDITION: High Level Warning Indicators (RED) “STOP”

Red Stop Indicator:

Park Brake Indicator:
Engine Oil Pressure Indicator:
Engine Coolant Temperature Indicator: DO NOT stop engine when engine
coolant temperature indicator comes on, or temperature will rise further.
Reduce load and run engine at slow idle for several minutes, stop engine and
service machine.

CONDITION: Low Level Warning Indicators (YELLOW) “SERVICE”

Air Filter Restriction Indicator:

Charging System Indicator:
Converter Oil Temperature Indicator:
Hydraulic Oil Filter Indicator:
Hydraulic Oil Temperature Indicator:

CONDITION: Seat Belt Indicator (WHITE)

The seat belt indicator will be back-lighted “White” when ever the key switch is
on and park brake is applied.

CONDITION: MFWD Indicator (GREEN)

MFWD indicator will be back-lighted “Green” when switch is on.

CONDITION: Beacon Indicator (GREEN)

Beacon indicator will be back-lighted “Green” when switch is on.

463
Display Monitor Circuit Theory Of Operation
TX,9015,QQ6775-19-1996/06/06

464
 Display Monitor Circuit Schematic

Display Monitor Circuit Schematic

T100799-19: Display Monitor Circuit Schematic

TX,9015,QQ6776-19-1996/06/06

465
 Sub-System Diagnostics/Display Monitor

Sub-System Diagnostics/Display Monitor

Display Monitor Diagnostic Procedures

Launch Close Expand List Collapse List

1 Fuse

Action:

Remove fuse cover.

Check 10 amp monitor/gauge fuse.

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace fuse
NO:
Go to next check.

2 Key Switch Check

Action:

T7199BO-UN: Key Switch OFF

Key switch OFF.

466
 Sub-System Diagnostics/Display Monitor

Disconnect harness from switch.

Check voltage on B11 red wire at BAT terminal of key switch.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness between battery and key switch.
Action:

T7199BO-UN: Key Switch at START

Switch disconnected from harness.

Turn key switch to START position.

Check for continuity between BAT and IGN terminals and BAT and ST terminals.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
467
 Sub-System Diagnostics/Display Monitor

NO:
Replace key switch.
Action:

T7199BO-UN: Key Switch ON

Switch disconnected from harness.

Key switch ON.

Check for continuity between BAT and ACC terminal.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Replace key switch.

3 Display Monitor

Action:

468
 Sub-System Diagnostics/Display Monitor

T102886-19: P21 Red Wire Location

Unplug 12 pin harness connector from display monitor.

Key switch to ON position.

Check for voltage on P21 red wire

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness
Action:

469
 Sub-System Diagnostics/Display Monitor

T102887-19: R31 Black Wire Location

Unplug 8 pin harness connector from display monitor.

Key switch to OFF position.

Check for continuity between R31 black wire and ground.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Check connector pins in connector.
IF OK:
Go to indicator circuit and check indicators.
IF OK:
Replace display monitor.
NO:
Check wiring harness.

470
Sub-System Diagnostics/Display Monitor

TX,9015,QQ6777-19-1996/06/06

471
 Indicator Circuit Specifications
Indicator Circuit Specifications

Item MeasurementSpecification Item MeasurementSpecification Item MeasurementSpecification Item Measurement

Engine Closing 115.6°C Engine Opening 37-72 kPa Air Filter Closing 4.98-7.48 kPa Converter Closing
Coolant Temperature (240°F) Oil Pressure (0.4-0.7 bar) Restriction Vacuum Vacuum (20- Oil Temperature
Temperature Pressure (5.5-10.5 psi) Switch 30 in. H 2O) Temperature
Switch Switch (Normally Switch
(Normally (Normally Open) (Normally
Open) Closed) Open)

TX,9015,QQ6778-19-1998/07/21

472
 Indicator Circuit Operational Information

Indicator Circuit Operational Information

The indicator circuit has “Two” modes of operation.

Bulb check mode

Failure mode

The following conditions must exist for indicator circuit to function in bulb check mode:

Key switch moved between “ON” and “START” position for bulb check.

The following conditions must exist for indicator circuit to function in a failure mode:

Engine must be running for a failure to be indicated on display monitor. An indicator

switch or alternator senses a failure and supplies a high or low level warning to display
monitor.

TX,9015,QQ6779-19-1996/06/06

473
 Indicator Circuit Theory of Operation

Indicator Circuit Theory of Operation

Indicator switches to the display monitor are:

B10-Park Brake Pressure Switch: (Stop)

B6-Engine Oil Pressure Switch: (Stop)
B5-Engine Coolant Temperature Switch: (Stop)
B7-Air Filter Restriction Switch: (Service)
B8-Converter Oil Temperature Switch: (Service)
B9-Hydraulic Filter Restriction Switch: (Service)
B2-Hydraulic Oil Temperature Switch (Service)
G2-Alternator: (Service)

The following indicators will be displayed on display monitor when a signal from a High
Level Warning Indicator switch is activated:

Red Colored Indicator

Red Stop Indicator
Audible Alarm

The following indicator will be displayed on display monitor when a signal from a Low
Level Warning Indicator switch is activated or the signal from the alternator disappears.

Yellow Colored Indicator

On Mode

Key switch is moved to “ON” position. The park brake, seat belt, engine oil pressure,
charging system light and stop warning light will be on.

Bulb Check Mode

Key switch is moved between “ON” and “START” position to activate bulb check mode.
All high and low level indicator lights will activate and audible alarm will sound. The seat
belt (White) indicator will be on.

High or Low Level Warning Mode

During normal operation the indicator lights are turned on when an indicator switch or
the alternator provides a signal to the display monitor indicating a “STOP” High Level
Warning or “SERVICE” Low Level Warning indicator.

Seat Position Sensor

474
 Indicator Circuit Theory of Operation

The seat position sensor is located in the operators seat base. When the seat is moved
to operate backhoe functions the sensor is closed. When the sensor is closed (seat
moved to operate backhoe functions) A signal is sent to the display monitor. When the
FNR lever is moved into forward or reverse position during backhoe operation the
display monitor is activated turning on the audible alarm and the red “STOP” indicator
light.

TX,9015,QQ6780-19-1996/10/02

475
 Indicator Circuit Schematic

Indicator Circuit Schematic

T100800-19: Indicator Circuit Schematic

TX,9015,QQ6781-19-1996/10/02

476
 Sub-System Diagnostics/Indicator Circuit

Sub-System Diagnostics/Indicator Circuit

Indicator Circuit Diagnostic Procedures

This circuit is powered by the monitor fuse, and hazard/monitor fuse.

Launch Close Expand List Collapse List

1 Engine Coolant Temperature Indicator Switch

Action:

T7199CG-19: Engine Coolant Temperature Indicator

Disconnect X36 yellow wire from switch and ground to frame.

Without starting engine, turn key switch to BULB CHECK, then release to ON.

Is engine coolant indicator light on?

Record of Actual Results:

Result:
YES:
Replace switch.
NO:
Switch is good. Go to next check.

2 Engine Oil Pressure Switch

Action:

477
 Sub-System Diagnostics/Indicator Circuit

T7199DZ-19: Engine Oil Pressure

Disconnect N34 yellow wire from switch and ground to frame.

Without starting engine, turn key switch to BULB CHECK, then release to ON.

Is engine oil pressure indicator light on?

Record of Actual Results:

Result:
YES:
Replace switch.
NO:
Switch is good. Go to next check.

3 Engine Alternator Indicator Circuit

Action:

Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to
M39 purple wire.

Without starting engine, turn key switch to BULB CHECK, then release to ON.

Is alternator indicator light off?

Remove voltage from M39 purple wire.

Is alternator indicator light on?

478
 Sub-System Diagnostics/Indicator Circuit

Record of Actual Results:

Result:
YES:
Circuit is good. Repair or replace alternator.
NO:
Go to next check.

4 Engine Air Filter Restriction Switch

Action:

T7199CI-19: Engine Air Filter Restriction Switch

Disconnect M40 purple wire from switch and ground to frame.

Without starting engine, turn key switch to BULB CHECK, then release to ON?

Is air filter restriction indicator light on?

Record of Actual Results:

Result:
YES:
Replace switch.
NO:
Switch is good. Go to next check.

479
 Sub-System Diagnostics/Indicator Circuit

5 Converter Oil Temperature Switch

Action:

T7199CJ-19: Converter Oil Temperature Switch

Disconnect X38 yellow wire from switch and ground to frame.

Without starting engine, turn key to BULB CHECK, then release to ON.

Is converter oil temperature light on?

Record of Actual Results:

Result:
YES:
Replace switch.
NO:
Switch is good. Go to next check.

6 Hydraulic Filter Restriction Indicator Switch

Action:

480
 Sub-System Diagnostics/Indicator Circuit

T7199CK-19: Hydraulic Filter Restriction Indicator Switch

Disconnect F39 yellow wire from switch and ground to frame.

Without starting engine, turn key switch to BULB CHECK, then release to ON.

Is hydraulic filter restriction indicator light on?

Record of Actual Results:

Result:
YES:
Replace switch.
NO:
Switch is good. Go to next check.

7 Hydraulic Oil Temperature Switch

Action:

T115835-19: Hydraulic Oil Temperature Switch

481
 Sub-System Diagnostics/Indicator Circuit

Disconnect X41 yellow wire from switch and ground to frame.

Without starting engine, turn key switch to BULB CHECK, then release to ON.

Is hydraulic oil temperature indicator light on?

Record of Actual Results:

Result:
YES:
Replace switch.
NO:
Switch is good. Go to next check.

8 Seat Position Sensor

Action:

T102968-19: Seat Position Sensor

Key switch OFF.

Seat in loader function position.

NOTE:

Seat position sensor is located in the operators seat base.

Check for continuity between terminals with M1 purple wire and G10 black wire

Is continuity “NOT” measured?

482
 Sub-System Diagnostics/Indicator Circuit

Move seat into backhoe function position

Check for continuity between terminals with M1 purple wire and G10 black wire

Is continuity measured:

Record of Actual Results:

Result:
YES:
Seat position sensor is good. Check wiring harness.
NO:
Replace seat position sensor.

TX,9015,QQ6782-19-1996/10/02

483
 Park Brake/FNR Circuit Operational Information

Park Brake/FNR Circuit Operational Information

The following condition or conditions must exist for park brake/FNR circuit to function:

Key switch OFF

Park brake dash switch in ON position with machine running
Machine Mechanically Shut Down

TX,9015,QQ6784-19-1998/07/21

484
 Park Brake/FNR Circuit Specifications

Park Brake/FNR Circuit Specifications

Item MeasurementSpecification
Park Brake Pressure Switch Opening 1103 ± 110 kPa (11.3 ± 1.10 bar)
(Normally Closed) Pressure (160 ± 16 psi)
Closing 896 ± 89.6 kPa (8.96 ± 0.896 bar)
Pressure (130 ± 13 psi)

TX,9015,QQ6783-19-1998/07/21

485
 Park Brake/Neutral Disconnect Circuit (Manual Shift) Theory Of Operation

Park Brake/Neutral Disconnect Circuit (Manual Shift) Theory Of

Operation

The Park Brake/FNR Circuit consists of FNR/park brake fuse, park brake dash switch,
park brake latching relay, FNR switch, loader lever switch, gear shift lever switch, park
brake solenoid, neutral disconnect solenoid, starter motor, neutral start relay, pump
unloading valve relay and park brake pressure switch.

The park brake is spring applied and hydraulically released.

NOTE:

The park brake applies automatically when machine is mechanically

shut down or when key switch is turned off. Park brake dash switch
must be cycled first to applied position (ON), then to released position
(OFF) before park brake can be released when engine is running.

Park brake cannot be hydraulically released if FNR/Park Brake Fuse is blown.

Key ON:
Park Brake Dash Switch in On Position:
FNR Lever in Neutral:

Power flows from terminal 3 to terminal 2B of park brake dash switch and then to park
brake latching relay terminal 85, energizing relay K5 causing it to latch terminals 30 and
87. Ground is supplied to the park brake latching relay through the “S” terminal of
starter motor. Power is disconnected from park brake solenoid, and neutral disconnect
solenoid de-energizing solenoids. With the engine not running hydraulic pressure is not
present, this putts the reverser in neutral applying the park brake. When the park brake
is applied the park brake pressure switch closes providing a ground for the park brake
indicator light in the display monitor to come on.

Key ON:
Park Brake Dash Switch In ON position:
FNR Lever Shifted Out of Neutral:

With the park brake dash switch ON, and FNR lever shifted out of neutral, a signal is
sent to the display monitor. With engine not running the park brake is spring applied and
park brake pressure switch is closed, causing park brake indicator light on display
monitor to come on and alarm to sound.

Key ON:
Engine Running:

486
 Park Brake/Neutral Disconnect Circuit (Manual Shift) Theory Of Operation

With engine running and is then mechanically shut down, the park brake latching relay
is de-energized, removing power from terminal 2B on park brake dash switch. This, in
turn, de-energizes the park brake solenoid and neutral disconnect solenoid. Engine is
not running, so hydraulic pressure goes to zero, which puts the reverser in neutral and
park brake is applied. When the park brake is applied, the park brake pressure switch
closes providing a ground for the park brake indicator light in the display monitor to
come on.

TX,9015,QQ6785-19-1998/07/21

487
 Park Brake/FNR Circuit (Manual Shift) Schematic

Park Brake/FNR Circuit (Manual Shift) Schematic

T115983-19: Park Brake/FNR Circuit

TX,9015,QQ6786-19-1998/07/21

488
 Park Brake/FNR Circuit (Power Shift) Theory of Operation

Park Brake/FNR Circuit (Power Shift) Theory of Operation

The Park Brake/FNR circuit controls the park brake and transmission.

The park brake is spring applied and hydraulically released.

NOTE:

The park brake applies automatically when machine is mechanically

shut down or when key switch is turned off. Park brake dash switch
must be cycled first to applied position (ON), then to released position
(OFF) before park brake can be released when engine is running.

Park brake cannot be hydraulically released if FNR/Park Brake Fuse is blown.

Key ON:
Park Brake Dash Switch in On Position:
FNR Lever in Neutral:

Power flows from terminal 3 to terminal 2B of park brake dash switch (S12) and then to
park brake latching relay terminal 85, energizing the park brake latching relay (K5)
causing it to latch terminals 30 and 87. Ground is supplied to the park brake latching
relay through the “S” terminal of starter motor. Power is disconnected from park brake
solenoid (Y4), and timer relay (K7).

With the FNR switch (S11) in neutral, power flows from the FNR switch to the display
monitor (H8). Combine this with the park brake pressure switch being closed and
providing a ground for the park brake indicator light, the park brake indicator light in the
display monitor glows signaling that the park brake is applied.

Key ON:
Engine Running:
Park Brake Dash Switch In ON position:
FNR Lever Shifted Out of Neutral:

With the park brake dash switch ON, and FNR lever shifted out of neutral, the signal
from the FNR lever to the display monitor disappears. With the park brake switch on,
the park brake pressure switch is closed sending a ground signal to the display monitor.
With the ground signal present from the park brake pressure switch without the power
signal from the FNR switch, the park brake indicator light on display monitor glows and
the alarm sounds. The red stop light will also blink on and off.

The machine is unable to move because the park brake dash switch is NOT sending

489
 Park Brake/FNR Circuit (Power Shift) Theory of Operation
voltage to the timer relay, thus all of the speed solenoids are de-energized.

Machine started with park brake switch in OFF position:

When the machine is started with the park brake dash switch in the OFF position the
park brake latching relay is unlatched or open. When the park brake latching relay is
open the park brake dash switch does receive voltage to terminal 2B. If the FNR switch
is placed out of neutral the display monitor alarm will sound and the stop light will flash.
This occurs because the park brake solenoid is not energized, thus the park brake
pressure switch is closed and sending a ground signal to the display monitor.

To enable the machine to operate, place the park dash switch in the ON position. This
allows power to flow to terminal 85 of the park brake latching relay causing the relay to
close. With the relay closed, power can now flow from terminal 87 of the park brake
latching relay to terminal 2B of the park brake switch.

Key ON:
Engine Running:
Park Brake Switch OFF:

With the park brake dash switch in the OFF position, voltage is sent to both the timer
relay and the park brake solenoid.

The park brake solenoid is now energized and sending pressurized oil to the park brake
to release it. This also opens the park brake pressure switch, thus the ground signal to
the display monitor is removed and the park brake indicator light goes out.

Key ON:
Engine Running:
Park Brake Switch OFF:
FNR Switch in Forward or Reverse:

With the park brake dash switch in the OFF position, voltage is sent to both the timer
relay (K7) terminal 2 and the park brake solenoid.

The park brake solenoid is now energized and sending pressurized oil to the park brake
to release it. This also opens the park brake pressure switch, thus the ground signal to
the display monitor is removed and the park brake indicator light goes out.

Power flows through the loader lever switch (S13) to the FNR switch (S11). With FNR
switch in either forward or reverse power flows to the timer relay terminal 7. This signal
closes the timer relay allowing power to flow from the park brake dash switch through
the timer relay to the FNR switch. Depending on FNR switch position, the proper
direction and speed solenoids in the transmission are energized.

490
 Park Brake/FNR Circuit (Power Shift) Theory of Operation

NOTE:

If the signal to the timer relay terminal 7 disappears for more than one
second, the timer relay will open.

CED,TX17864,101-19-1998/06/22

491
 Park Brake/FNR Circuit (Power Shift) Schematic

Park Brake/FNR Circuit (Power Shift) Schematic

T126773-19: Park Brake/FNR Circuit (Power Shift) Schematic

CED,TX17864,102-19-1999/12/15

492
 Sub-System Diagnostics/Park Brake/FNR Circuit

Sub-System Diagnostics/Park Brake/FNR Circuit

Park Brake/Neutral Disconnect Circuit Diagnostic Procedures

Launch Close Expand List Collapse List

1 Park Brake Switch “Dash”

Action:

T100731-UN: Park Brake Switch “Dash”

Disconnect harness from park brake switch.

Park brake switch OFF.

Check for continuity between terminals 2A and 1.

Is continuity measured?

Park brake switch ON.

Check for continuity between terminals 2B and 3.

Is continuity measured?

493
 Sub-System Diagnostics/Park Brake/FNR Circuit

Record of Actual Results:

Result:
YES:
Park brake switch is good. Check wiring harness.
NO:
Replace park brake switch.

2 Forward Solenoid Check (Manual Shift)

Action:

T101725-19: Forward Solenoid

Remove fuse block cover.

Remove FNR/park brake fuse.

Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and
black lead into (COM.) terminal.

494
 Sub-System Diagnostics/Park Brake/FNR Circuit

Key switch ON and engine OFF.

Place probe ends of multimeter at locations (A and B) in fuse block.

Park brake switch “ON” applied.

Move FNR into forward position.

Is (.52-.65) amps measured?

NOTE:

The current value measurement is controlled by the number of

components that are connected within the circuit.

Record of Actual Results:

Result:
YES:
Forward solenoid electrically is good. See Group 9020-25 Power Train Test.
NO:
Check wiring harnesses. See Group 9015-10.

3 Reverse Solenoid Check (Manual Shift)

Action:

495
 Sub-System Diagnostics/Park Brake/FNR Circuit

T101725-19: Reverse Solenoid

Remove fuse block cover.

Remove FNR/park brake fuse.

Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and
black lead into (COM.) terminal.

Key switch ON and engine OFF.

Place probe ends of multimeter at locations (A and B) in fuse block.

Park brake switch “ON” applied.

Move FNR into reverse position.

Is (.70-.82) amps measured?

NOTE:

The current value measurement is controlled by the number of

components that are connected within the circuit.

496
 Sub-System Diagnostics/Park Brake/FNR Circuit

Record of Actual Results:

Result:
YES:
Reverse solenoid electrically is good. See Group 9020-25 Power Train Test.
NO:
Check wiring harnesses. See Group 9015-10.

4 Neutral Solenoid Check (Manual Shift)

Action:

T101725-19: Neutral Solenoid

Remove fuse block cover.

Remove FNR/park brake fuse.

Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and
black lead into (COM.) terminal.

497
 Sub-System Diagnostics/Park Brake/FNR Circuit

FNR lever in neutral position.

Key switch ON and engine OFF.

Place probe ends of multimeter at locations (A and B) in fuse block.

Cycle Park brake switch “ON” and then to “OFF” position. Approximately 2.40 amp
value will display.

Push the loader lever disconnect button.

Does the amp value drop to 0.4 amps?

Record of Actual Results:

Result:
YES:
Neutral solenoid electrically is good. See Group 9020-25 Power Train Test.
NO:
Check wiring harnesses. See Group 9015-10.

5 Transmission Solenoids Check (Power Shift)

Action:

498
 Sub-System Diagnostics/Park Brake/FNR Circuit

T101725-19: Transmission Solenoids

Remove fuse block cover.

Remove FNR/park brake fuse.

Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and
black lead into (COM.) terminal.

Place probe ends of multimeter at locations (A and B) in fuse block.

Key switch ON and engine OFF.

Park brake switch “OFF”. Approximately 1.9 amp value will display.

NOTE:

If 1.9 amp value is not displayed, cycle park brake on then off
again.

FNR lever in forward position.

499
 Sub-System Diagnostics/Park Brake/FNR Circuit

NOTE:

Each solenoid in the transmission draws approximately 0.5 amps.

If measured amperage value is approximately 0.5 amps less than
specification, a problem with one solenoid is indicated.

Does the amp value match the following specifications for each speed?

Item Measurement Specification

FNR Current 1st Speed Forward Amperage 3.12 ± 0.1 amps
2nd Speed Forward Amperage 3.12 ± 0.1 amps
3rd Speed Forward Amperage 3.12 ± 0.1 amps
4th Speed Forward Amperage 2.8 ± 0.1 amps

FNR lever in reverse position.

Does the amp value match the following specifications for each speed?

Item Measurement Specification

FNR Current 1st Speed Reverse Amperage 3.22 ± 0.1 amps
2nd Speed Reverse Amperage 3.22 ± 0.1 amps
3rd Speed Reverse Amperage 3.22 ± 0.1 amps

NOTE:

The current value measurement is controlled by the number of

components that are connected within the circuit.

Record of Actual Results:

Result:
YES:
Transmission solenoids are electrically good. See Group 9020-25 Power Train
Test.
NO:
Check wiring harness or transmission solenoids.

500
 Sub-System Diagnostics/Park Brake/FNR Circuit

6 Park Brake Solenoid Check (Manual Shift)

Action:

T101725-19: Park Brake Solenoid

Remove fuse block cover.

Remove FNR/park brake fuse.

Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and
black lead into (COM.) terminal.

FNR lever in neutral position.

Key switch ON and engine OFF.

Place probe ends of multimeter at locations (A and B) in fuse block.

Park brake switch “ON”. Approximately 0.45 amp value will display.

Move park brake switch to “OFF” position.

Does the amp value increase by approximately 2.0 amps?

501
 Sub-System Diagnostics/Park Brake/FNR Circuit

Record of Actual Results:

Result:
YES:
Park brake solenoid electrically is good. See Group 9020-25 Power Train Test.
NO:
Check wiring harnesses. See Group 9015-10.

7 Park Brake Solenoid Check (Power Shift)

Action:

T101725-19: Park Brake Solenoid

Remove fuse block cover.

Remove FNR/park brake fuse.

Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and
black lead into (COM.) terminal.

502
 Sub-System Diagnostics/Park Brake/FNR Circuit

FNR lever in neutral position.

Key switch ON and engine OFF.

Place probe ends of multimeter at locations (A and B) in fuse block.

Park brake switch “ON”. Approximately 0.45 amp value will display.

Move park brake switch to “OFF” position.

Does the amp value increase by approximately 1.5 amps?

Record of Actual Results:

Result:
YES:
Park brake solenoid electrically is good. See Group 9020-25 Power Train Test.
NO:
Check wiring harnesses. See Group 9015-10.

8 Loader Lever Switch

Action:

T7199CU-19: Loader Lever Switch

Disconnect harness from loader lever switch

Check for continuity between terminals with J27 tan wire and T53 blue wire.

Is continuity measured?

503
 Sub-System Diagnostics/Park Brake/FNR Circuit

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace loader lever switch.
Action:

T7199CU-19: Loader Lever Switch

Disconnect harness from loader lever switch

Depress loader lever switch and check for continuity between terminals with J27
tan wire and T53 blue wire.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Replace loader lever switch.
NO:
Loader lever switch is good. Check wiring harness.

9 Gear Shift Lever Switch (Manual Shift)

504
 Sub-System Diagnostics/Park Brake/FNR Circuit

Action:

T7199CV-19: Gear Shift Lever Switch

Disconnect harness from gear shift lever switch.

Check for continuity between terminals with T53 blue wire and T52 blue wire.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace gear shift lever switch.
Action:

T7199CV-19: Gear Shift Lever Switch

Disconnect harness from gear shift lever switch.

505
 Sub-System Diagnostics/Park Brake/FNR Circuit

Depress gear shift lever switch and check for continuity between terminals with
T53 blue wire and T52 blue wire.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Replace gear shift lever switch.
NO:
Gear shift lever switch is good. Check wiring harness.

10 Park Brake Latching Relay

Action:

T7287BH-UN: Park Brake Latching Relay

Key switch OFF.

Disconnect harness from relay.

Connect battery voltage to terminal #86. Ground terminal #85.

Does relay click?

Measure continuity between terminals #30 and #87.

Is continuity measured?

Record of Actual Results:

506
 Sub-System Diagnostics/Park Brake/FNR Circuit

Result:
YES:
Relay is good. Check wiring harness.
NO:
Replace relay.

11 Timer Relay Check (Power Shift)

Action:

T126811-UN: Timer Relay Test

Disconnect timer relay from front console harness.

Connect a 12 power supply and ground to the timer relay as shown.

Check for continuity across terminals 5 and 6 of timer relay.

Is continuity measured?

Record of Actual Results:

507
 Sub-System Diagnostics/Park Brake/FNR Circuit

Result:
YES:
Go to next check.
NO:
Replace timer relay.

12 Park Brake Pressure Switch

Action:

T7199EE-UN: Park Brake Pressure Switch

Disconnect harness from switch.

Measure continuity between terminals A and B on connector end of switch.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Switch is good. Check wiring harness.
NO:
Replace switch.

13 FNR Lever (Manual Shift)

508
 Sub-System Diagnostics/Park Brake/FNR Circuit

Action:

T115867-19: FNR Lever

Disconnect FNR switch from harness.

Connect a 12 volt power supply to FNR lever as shown.

Place FNR lever in neutral.

Check voltage at terminal D as shown.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness.

509
 Sub-System Diagnostics/Park Brake/FNR Circuit

Action:

T115868-19: FNR Lever

Disconnect FNR switch from harness.

Connect a 12 volt power supply to FNR lever as shown.

Place FNR lever in forward.

Check voltage at terminal C as shown.

Are 12 volts measured?

Place FNR lever in reverse.

Check voltage at terminal B.

Are 12 volts measured?

Record of Actual Results:

510
 Sub-System Diagnostics/Park Brake/FNR Circuit

Result:
YES:
FNR lever is good. Go to next check.
NO:
Replace FNR lever.

14 FNR Lever Check (Power Shift)

Action:

T114633-19: FNR Lever (Power Shift)

Disconnect FNR lever from harness.

Connect a 12 volt power supply to FNR lever as shown.

Place FNR lever in neutral.

Are 12 volts measured at only terminal D of four pin connector?

Place FNR lever in reverse.

Are 12 volts measured at only terminal B of four pin connector?

Place FNR lever in forward.

Are 12 volts measured at only terminal C of four pin connector?

Record of Actual Results:

511
 Sub-System Diagnostics/Park Brake/FNR Circuit

Result:
YES:
Continue with check
NO:
Replace FNR lever.
Action:

T114633-19: FNR Lever (Power Shift)

Disconnect FNR lever from harness.

Connect a 12 volt power supply to FNR lever as shown.

Place FNR lever in first speed forward.

Are 12 volts measured at only terminals A, C, and D of six pin connector?

Place FNR lever in second speed forward.

Are 12 volts measured at only terminals A, B, and C of six pin connector?

Place FNR lever in third speed forward.

Are 12 volts measured at only terminals B, C, and D of six pin connector?

Place FNR lever in fourth speed forward.

512
 Sub-System Diagnostics/Park Brake/FNR Circuit

Are 12 volts measured at only terminals B and D of six pin connector?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Replace FNR lever.

15 Park Brake Relay Diode

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

T7961AA-UN: Park Brake Relay Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

Reverse probes

Is continuity measured?

513
 Sub-System Diagnostics/Park Brake/FNR Circuit

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

16 Park Brake Solenoid Diode

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

T7961AA-UN: Park Brake Solenoid Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

Reverse probes

514
 Sub-System Diagnostics/Park Brake/FNR Circuit

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

17 Reverse Solenoid Diode

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

T7961AA-UN: Reverse Solenoid Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

515
 Sub-System Diagnostics/Park Brake/FNR Circuit

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

18 Forward Solenoid Diode

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

T7961AA-UN: Forward Solenoid Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

516
 Sub-System Diagnostics/Park Brake/FNR Circuit

Is continuity measured?

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

19 Neutral Disconnect Solenoid Diode (Manual Shift)

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

T7961AA-UN: Neutral Disconnect Solenoid Diode

Remove diode from connector.

517
 Sub-System Diagnostics/Park Brake/FNR Circuit

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

20 Low Range Solenoid Diode (Power Shift)

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

T7961AA-UN: Low Range Solenoid Diode

518
 Sub-System Diagnostics/Park Brake/FNR Circuit

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

21 Speed Solenoid Diodes (Power Shift)

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

519
 Sub-System Diagnostics/Park Brake/FNR Circuit
T7961AA-UN: Speed Solenoid Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

TX,9015,QQ6787-19-2000/01/28

520
 Ride Control Circuit Operational Information

Ride Control Circuit Operational Information

The following conditions must exist for the ride control circuit to function.

Key switch ON
Ride control switch ON

CED,OUTX782,528-19-1999/06/30

521
 Ride Control Circuit Theory of Operation

Ride Control Circuit Theory of Operation

Power flow from the auxiliary fuse (F15) to the ride control switch (S30).

When the ride control switch is switched on, power flows to both the ride control
solenoid (Y15), energizing the solenoid, and to the light in the ride control switch
causing it to illuminate alerting the operator that the ride control system is on.

When the switch is switched off and the circuit is broken the ride control diode (V15)
allows the current to dissipate.

CED,OUTX782,530-19-1999/06/30

522
 Ride Control Circuit Schematic

Ride Control Circuit Schematic

T115841-19: Ride Control Circuit Schematic

CED,OUTX782,532-19-1999/06/30

523
 Sub-System Diagnostics/Ride Control Circuit

Sub-System Diagnostics/Ride Control Circuit

Ride Control Circuit Diagnostic Procedures

Launch Close Expand List Collapse List

1 Fuse Check

Action:

Remove fuse cover.

Check 10 amp auxiliary fuse.

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace fuse.
NO:
Go to next check.

2 Ride Control Switch Check

Action:

524
 Sub-System Diagnostics/Ride Control Circuit

T100731-UN: Ride Control Switch

Unplug harness from ride control switch.

Key switch to ON position.

Check for voltage in receptacle 2B (P30 RED wire) of switch connector.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness.
Action:

525
 Sub-System Diagnostics/Ride Control Circuit

T100731-UN: Ride Control Switch

Unplug harness from ride control switch.

Switch ride control switch ON.

Check for continuity between terminals 2B and 1.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Replace switch.

3 Ride Control Solenoid Check

526
 Sub-System Diagnostics/Ride Control Circuit

Action:

T116136-19: Ride Control Solenoid Connector

Disconnect harness from solenoid.

Key switch and ride control switch ON.

Measure voltage at harness connector.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Replace solenoid.
NO:
Check wire harness.

4 Ride Control Solenoid Diode Check

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

527
 Sub-System Diagnostics/Ride Control Circuit

T7961AA-UN: Ride Control Solenoid Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

CED,OUTX782,534-19-2000/01/28

528
 Selective Flow Valve Circuit Operational Information

Selective Flow Valve Circuit Operational Information

The following conditions must exist for the selective flow valve circuit to function.

NOTE:

The selective flow valve circuit has two different modes of operation. It
can be either continuously on or momentarily on using the foot switch.
This selected using the two different positions on the switch in the dash.

Key switch ON
Selective flow valve switch in either foot ON or continuous ON.
Foot switch held ON if selective flow valve switch is in foot ON position.

CED,TX17864,90-19-1998/06/12

529
 Selective Flow Valve Circuit Theory of Operation

Selective Flow Valve Circuit Theory of Operation

Power flows from the auxiliary fuse (F15) to both the selective flow valve fuse block
(F18) and the selective flow valve switch (S28).

The selective flow valve fuse block controls the flow rate out of the selective flow valve
depending on the position of the fuse in the fuse block. If the fuse is placed in the 30
gpm position, power flows through the V02 PNK wire to the selective flow valve
controller (A3). If the fuse is placed in the 22 gpm position, power flows through the V01
PNK wire to the selective flow valve controller. If the fuse is placed in the 9 gpm
position, no power flows to the controller.

The selective flow valve switch has three positions; off, foot on, and continuous on.

With the selective flow valve switch in the foot on position, power flows to the selective
flow valve controller and to the foot switch (S29). When the foot switch is depressed,
power flows to the selective flow valve switch to illuminate the light in the switch and
also to selective flow valve controller.

With the selective flow valve switch in the continuous on position, power immediately
flows to the selective flow valve controller and bypasses the foot switch.

The selective flow valve controller requires power at three terminals (E1, E2, F2) before
the selective flow valve solenoid will be energized.

CED,TX17864,91-19-1998/06/12

530
 Selective Flow Valve Circuit Schematic

Selective Flow Valve Circuit Schematic

T115842-19: Selective Flow Valve Circuit

CED,TX17864,92-19-1998/06/12

531
 Sub-System Diagnostics/Selective Flow Valve Circuit

Sub-System Diagnostics/Selective Flow Valve Circuit

Selective Flow Valve Diagnostic Procedures

Launch Close Expand List Collapse List

1 Fuse Check

Action:

Remove fuse cover.

Check 10 amp auxiliary fuse.

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace fuse.
NO:
Go to next check.

2 Selective Flow Valve Switch Check

Action:

532
 Sub-System Diagnostics/Selective Flow Valve Circuit

T100731-UN: Selective Flow Valve Switch

Disconnect harness from selective flow valve switch.

Selective Flow Valve Switch to foot on position.

Check for continuity between terminals 5B and 3 of switch.

Is continuity measured?

Selective Flow Valve Switch to continuous on position.

Check for continuity between terminals 5B and 6 of switch.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next check.

533
 Sub-System Diagnostics/Selective Flow Valve Circuit

NO:
If switch fails any of the above continuity checks, replace switch.

3 Foot Switch Check

Action:

T116147-19: Foot Switch Connector

Disconnect foot switch from harness.

Depress foot switch.

Check for continuity at connector.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Replace foot switch.

4 Selective Flow Valve Fuse Block Fuse Check

Action:

Remove fuse cover.

534
 Sub-System Diagnostics/Selective Flow Valve Circuit

Check fuse (F18) in selective flow valve fuse block.

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace fuse.
NO:
Go to next check.

5 Selective Flow Hydraulic Operational Check

Action:

Turn hydraulic switch to OFF position and start engine.

Record of Actual Results:

Result:

LOOK: Does attachment operate?

YES:
Check electrical connections, attachment should not operate.
NO:
Go to next check.

Action:

Depress foot switch. Release foot switch. Attachment and light should not operate.

Record of Actual Results:

535
 Sub-System Diagnostics/Selective Flow Valve Circuit

Result:

LOOK: Did attachment operate?

LOOK: Did switch light turn ON?

YES:
Check electrical connections, attachment and light should not operate.
NO:
Go to next check.

Action:

Place switch in FOOT ON position. Does attachment operate and does switch light
come ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check electrical connections, attachment and light should operate.

Action:

With switch in CONT ON position, shut engine off. Leave switch in CONT ON
position and restart engine. Does attachment operate and does switch light come
ON.

Record of Actual Results:

536
 Sub-System Diagnostics/Selective Flow Valve Circuit

Result:
YES:
Go to next check.
NO:
Check electrical connections, attachment and light should not operate.

Action:

Cycle switch to OFF position and then to CONT ON position. Does attachment
operate and is switch ON?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Check electrical connections, attachment and light should not operate.

10 Selective Flow Valve Solenoid Check

Action:

Disconnect selective flow valve harness under cab.

Measure resistance across selective flow valve solenoid by placing multi meter
probes in end of harness coming from valve.

Do resistance meet specification?

Item Measurement Specification

Selective Flow Valve Solenoid Resistance (at 20°C (68°F) 4.93 ± 0.2 ohms

Record of Actual Results:

537
 Sub-System Diagnostics/Selective Flow Valve Circuit

Result:
YES:
Check all wiring harnesses. If harness are OK replace controller.
NO:
Replace solenoid.

CED,TX17864,93-19-1998/06/12

538
 Pin Disconnect Circuit Operational Information

Pin Disconnect Circuit Operational Information

The following conditions must exist for the pin disconnect circuit to function.

Key switch ON
Pin disconnect switch held in the unlocked position

CED,TX17864,94-19-1998/06/12

539
 Pin Disconnect Circuit Theory of Operation

Pin Disconnect Circuit Theory of Operation

Power flow from the auxiliary fuse (F15) to the pin disconnect switch (S31).

The pin disconnect switch is a spring loaded momentary style switch. The switch must
be held in the unlocked position to allow power to flow through the switch. If the switch
is released it will return to the locked position by itself.

When the pin disconnect switch is held in the unlocked position on, power flows to the
pin disconnect solenoid (Y17), energizing the solenoid.

When the switch is released and the circuit is broken, the pin disconnect diode (V17)
allows the current to dissipate.

CED,TX17864,95-19-1998/06/12

540
 Pin Disconnect Circuit Schematic

Pin Disconnect Circuit Schematic

T115843-19: Pin Disconnect Circuit

541
Pin Disconnect Circuit Schematic
CED,TX17864,96-19-1998/06/12

542
 Sub-System Diagnostics/Pin Disconnect Circuit

Sub-System Diagnostics/Pin Disconnect Circuit

Pin Disconnect Circuit Diagnostic Procedures

Launch Close Expand List Collapse List

1 Fuse Check

Action:

Remove fuse cover.

Check 10 amp auxiliary fuse.

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace fuse.
NO:
Go to next check.

2 Pin Disconnect Switch Check

Action:

543
 Sub-System Diagnostics/Pin Disconnect Circuit

T116137-19: Pin Disconnect Switch

Unplug harness from pin disconnect switch.

Key switch to ON position.

Check for voltage in receptacle A (P01 RED wire) of switch connector.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wiring harness.
Action:

544
 Sub-System Diagnostics/Pin Disconnect Circuit

T116137-19: Pin Disconnect Switch

Unplug harness from pin disconnect switch.

Hold pin disconnect switch in the unlocked position.

Check for continuity between terminals A and B.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Replace switch.

3 Pin Disconnect Solenoid Check

Action:

545
 Sub-System Diagnostics/Pin Disconnect Circuit

T116138-UN: Pin Disconnect Solenoid

Disconnect harness from solenoid.

Key switch ON.

Pin disconnect switch held in the unlocked position.

Measure voltage at harness connector.

Are 12 volts measured?

Record of Actual Results:

Result:
YES:
Replace solenoid.
NO:
Check wire harness.

4 Pin Disconnect Solenoid Diode Check

NOTE:

A diode can fail in two modes, either shorted or open. Continuity will
be measured in one direction only in a serviceable diode.

Action:

546
 Sub-System Diagnostics/Pin Disconnect Circuit

T7961AA-UN: Pin Disconnect Solenoid Diode

Remove diode from connector.

Using a multimeter, turn to diode test and connect probes to diode terminals.

Is continuity measured?

Reverse probes

Is continuity measured?

Record of Actual Results:

Result:
YES:
If continuity is measured in both checks, diode has failed in a shorted mode.
Replace.
NO:
If continuity is NOT measured in either check diode has failed in an open mode.
Replace.
NO:
If continuity is measured in one check and not the other, diode is OK.

CED,TX17864,97-19-2000/01/28

547
 Alternators and Starting Motors-Use CTM77

Alternators and Starting Motors-Use CTM77

TS225-UN: Component Technical Manual

For additional information, the component technical manual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

TX,9015,QQ6788-19-1996/05/21

548
 Alternators and Starting Motors-Use CTM77

Alternators and Starting Motors-Use CTM77

TS225-UN: Component Technical Manual

For additional information, the component technical manual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

TX,9015,QQ6788-19-1996/05/21

549
 JT05801 Clamp-On Electronic Tachometer Installation

JT05801 Clamp-On Electronic Tachometer Installation

T6813AG-UN: JT05801

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Tachometer
A-Clamp-On Transducer. Remove paint using emery cloth and connect to a straight
section of injection line within 100 mm (4 in.) of pump. Finger tighten only. DO NOT
overtighten.

B-Black Clip (-). Connect to main frame.

C-Red Clip (+). Connect to transducer.

D-Tachometer Readout. Install cable.

TX,9015,QQ6789-19-1996/05/21

550
 Battery Operation

Battery Operation

A battery is a device for converting chemical energy to electrical energy. It is not a

storage tank for electricity, but stores electrical energy in chemical form.

Because of the constant chemical to electrical change (self-discharge, discharge, or

charge), the battery has a limited life. Proper care (cleaning, adding water, charging) will
extend the life of the battery.

The battery is made up of positive plates, negative plates, separators, plate straps, and
chemical solution (electrolyte). The electrolyte is a solution of sulfuric acid and water.
Sulfuric acid is not lost during overcharging; therefore, if the liquid solution is low, only
water should be added.

In a fully charged battery, the positive plate is lead peroxide (PBQ2), the negative plate
is "spongy" lead (Pb), and the electrolyte solution is about 1.270 times heavier than
water.

Item Measurement Specification

Fully Charged Battery Electrolyte Specific Gravity 1.270
The amount that the solution is heavier than water is called specific gravity.

All batteries will self discharge at a rate of .001 specific gravity point per 24 hour period
at a constant 85 °F.

Item Measurement Specification

Battery Self-Discharge .001 specific gravity point per 24 hour period at a constant
Rate 85°F
The discharge rate increases as temperature increases and decreases as temperature
decreases. If the machine is not used for a period of time, the batteries must be
maintained or stored in a cool place.

Wipe batteries with a damp cloth. If terminals are corroded, use a stiff brush and wash
with an ammonia solution. After washing, flush battery and compartment with clear
water. Keep caps in place when cleaning and charging.

Batteries should be maintained at an open circuit voltage of 12.50 volts or greater.

Item Measurement Specification

Battery Minimum Open Circuit Voltage 12.50 volts
To determine open circuit voltage do the following:

1. Turn master disconnect switch to ON position.

551
 Battery Operation

2. For machines that have not been run during the past ten hours, go to Step 4.

3. For machines that have been run in the past ten hours, remove surface
charge. Turn key switch to START, turn on 3 or 4 work lights and leave them
on for 3 to 5 minutes. Turn key switch OFF, then wait two minutes. (If machine
does not have lights, turn key switch to START position for at least 5 minutes,
then turn off.)

4. Measure voltage at alternator by placing the negative lead of a multimeter to

case of alternator and the positive lead to the sense terminal of the alternator.

Item MeasurementSpecification
100% Charged Stabilized Open Circuit Voltage 12.5 volts or more
75% Charged Stabilized Open Circuit Voltage 12.4
50% Charged Stabilized Open Circuit Voltage 12.2
25% Charged Stabilized Open Circuit Voltage 12.0
0% Charged Stabilized Open Circuit Voltage 11.7 or less

TX,9015,QQ6790-19-1996/05/21

552
 Battery Specifications

Battery Specifications

Item Measurement Specification

Battery Volts 12 Volts
Cold Cranking Power 750 amps-18°C (0°F)
Reserve Capacity 150 minutes at 25 amps
BCI Group Size 31
Fully Charged Electrolyte Specific Gravity 1.265-1.280

TX,9015,QQ6791-19-1996/05/21

553
 Diagnose Battery Malfunctions

Diagnose Battery Malfunctions

554
Diagnose Battery Malfunctions

555
 Diagnose Battery Malfunctions

Symptom Problem Solution

Battery Using Shorted battery cell Check battery state of charge. (See
Too Much Procedure for Testing Batteries. )
Water

High ambient temperature Add distilled water.

Cracked battery case Check battery hold down clamps.

Replace battery.

Regulator Do Alternator Output Check. (See

Charging Circuit Operational Checks. )

Cracked Battery hold down clamp too Install new battery. Install hold down
Battery Case tight, too loose or missing clamps correctly.

Frozen battery Keep electrolyte at correct level and

battery fully charged during cold
weather.

Low Battery Low water level See Battery Using Too Much Water and
Output Cracked Battery Case symptoms.

Dirty or wet battery top, Clean battery top. Recharge battery.

causing discharge

Corroded or loose battery Clean and tighten cable end clamps.

cable ends Recharge battery.

Broken or loose battery Wiggle posts by hand. If posts are loose

posts or will turn, replace battery.

556
 Diagnose Battery Malfunctions
Symptom Problem Solution

Loose fan/alternator belt or Inspect belt or pulley. Adjust or replace

worn pulleys as necessary.

TX,9015,QQ6792-19-1996/05/21

557
 Check Battery Electrolyte Level and Terminals

Check Battery Electrolyte Level and Terminals

TS203-UN: Prevent Acid Burns

1. CAUTION:
Battery gas can explode. Keep sparks and flames away
from batteries. Use a flashlight to check battery
electrolyte level.

Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.

558
 Check Battery Electrolyte Level and Terminals
Always remove grounded (-) battery clamp first and
replace it last.

Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.

Avoid the hazard by:

Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is
added.
Avoiding spilling or dripping electrolyte
Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.

If acid is swallowed:

1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.

Remove hold-down clamps.

2. Remove battery covers.

3. IMPORTANT:

During freezing weather, batteries must be charged after

water is added to prevent battery freezing. Charge battery
using a battery charger or by running the engine.

559
 Check Battery Electrolyte Level and Terminals

T6996DB-UN: Single Level Fill Tube Application

T6996DA-UN: Dual Level Fill Tube Application

LEGEND:
A - Battery Post
B - Fill Tube
C - Electrolyte Level Range

Fill each cell to within specified range with distilled water. DO NOT overfill.

TX,9015,RB21-19-1997/10/30

560
 Using Booster Batteries-12 Volt System

Using Booster Batteries-12 Volt System

T6508AE1-UN: Single Battery Application

561
 Using Booster Batteries-12 Volt System

T6713AI1-UN: Two Battery Application

LEGEND:
A - Machine Battery(s)
B - Booster Battery(s)

Before boost starting, machine must be properly shut down and secured to prevent
unexpected machine movement when engine starts.

CAUTION:
An explosive gas is produced while batteries are in use or being
charged. Keep flames or sparks away from the battery area. Make
sure the batteries are charged in a well ventilated area.
562
 Using Booster Batteries-12 Volt System
Always remove grounded (-) battery clamp first and replace it last.

IMPORTANT:

The machine electrical system is a 12-volt negative (-) ground. Use

only 12-volt booster batteries.

1. Connect one end of the positive cable to the positive terminal of the machine
batteries and the other end to the positive terminal of the booster batteries.

2. Connect one end of the negative cable to the negative terminal of the booster
batteries. Then connect other end of the negative cable to the machine frame
as far away from the machine batteries as possible.

3. Start engine.

4. Immediately after starting engine, disconnect end of the negative cable from
the machine frame and disconnect the other end of the negative cable from
the negative terminal of the booster batteries.

5. Disconnect positive cable from booster batteries and machine batteries.

TX,25,BD2079-19-1996/10/07

563
 Alternator Operation-65 Amp Bosch and 95 Amp Bosch

Alternator Operation-65 Amp Bosch and 95 Amp Bosch

T8301AL-19: Alternator
LEGEND:
A - Alternator
B - Internal Ground
C - Negative Diodes
D - Exciter Diodes
E - Stator Windings
F - Positive Diodes
G - D+ Terminal
H - B+ Terminal
I - W Terminal
J - Excitation Winding
K - Regulator
L - External Ground Terminal
M - Rotor
N - Alternator Diode
O - Battery
P - Key Switch
Q - Display Monitor
R - Brushes
S - Sense Circuit

564
 Alternator Operation-65 Amp Bosch and 95 Amp Bosch
T - Noise Filter

TX,9015,QQ6795-19-1996/05/21

565
 Alternator Operation-65 Amp Bosch and 95 Amp Bosch (Continued)

Alternator Operation-65 Amp Bosch and 95 Amp Bosch (Continued)

The Bosch alternator has three basic stages for proper operation. The operating
principles are as follows.

Pre-Excitation Stage

When key switch (P) is turned to ON position, battery power flows to (G) terminal D+ on
alternator, excitation winding (J), through regulator (K) and to internal ground (B).

Excitation Stage

During alternator start (as the engine speeds up from 0 to idle) current supplied by the
external alternator diode to the field coil of the rotor produces a magnetic field which
induces current in the three-phase winding of the stator (E). The alternator reaches cut-
in RPM when the induced current is large enough to produce voltage equal to the
battery voltage plus 1.0 volt. At this time, some current from the stator is rectified by the
exciter diodes (D) (producing battery voltage at the D+ terminal (G) and is supplied to
the carbon brushes and slip rings of the excitation winding (J), strengthening the
magnetic field in the excitation winding. This in turn will increase the stator voltage. This
will occur continuously until the alternator (A) is fully excited and the alternator regulated
voltage is reached.

Normal Operation

The alternating current induced in the stator winding (E) is rectified by the positive and
negative diodes (F and C) and delivered to the battery and current consuming
accessories. The currents in the stator winding (E) are constantly changing magnitude
and direction. However, current flowing to the battery and accessories always maintains
the same direction. This is because no matter what position the rotor (M) is in, all the
diodes are simultaneously involved in the process of rectification. The regulator (K)
measures the B+ voltage (H) and compares it to an internal reference. When the B+
voltage (H) starts to rise above the reference voltage the regulator (K) switches off the
field current. When the B+ voltage (H) starts to fall below the reference voltage the
regulator (K) switches on the field current. The regulator (K) switches the field ON and
OFF several thousand times a second in response to the current load placed on the
alternator output and the engine RPM.

When the alternator is operating, the W terminal voltage out put is (7 to 8 volts) (AC).
This voltage is supplied to the display monitor and tachometer or hour meter. Current
available from the alternator is dependent on engine RPM. Depending on pulley ratios.

CED,OUTX782,535-19-1999/06/30

566
 Tachometer Calibration (S.N. -852337)

Tachometer Calibration (S.N. -852337)

T7545BQ-UN: Adjusting Screw

1. Remove heater control knob, blower speed knob and four side console panel
screws to remove panel.

2. Verify engine speed using tachometer. See Tachometer Installation in this

group.

3. Adjust screw (B) to adjust machine tachometer to high idle speed.

TX,9015,QQ6797-19-1998/07/21

567
 Tachometer Calibration (S.N. 852338- )

Tachometer Calibration (S.N. 852338- )

1.

T114085-UN: Calibration Button

T114688B-UN: Tachometer Calibration

568
 Tachometer Calibration (S.N. 852338- )

T114523-19: Calibration
LEGEND:
C - Tachometer
E - Calibration Button

Remove side console panel.

2. Verify engine speed using tachometer. See Tachometer Installation in this

group.

3. NOTE:

Calibration of tachometer should be performed at an engine

speed near 2000 rpm.

Cut and remove plastic covering from calibration button (E) on back of
tachometer (C).

569
 Tachometer Calibration (S.N. 852338- )

4. Press and hold in calibration button as you turn on ignition and start engine.
Hold button until “ ADJUST ” is displayed on LCD readout. When it does,
release calibration button.

5. Press calibration button once, and “ UP ” will be displayed on LCD readout for
upward calibration of pointer. Press calibration button again, and “ DN ” will be
displayed for downward calibration of pointer.

6. NOTE:

If pointer is moved past upper limit of calibration range, LCD

display will flash and pointer can only be adjusted downward.
If pointer is moved past lower calibration limit, LCD display will
also flash and pointer can only be adjusted upward.

When either “ UP ” or “ DN ” is showing, press button again and hold it in to

move pointer. If button is held in for just a short time, pointer will move slowly
either upwards or downwards, depending on which mode is selected. Holding
button in for a longer period of time makes pointer move faster.

7. When pointer is in desired position, release calibration button and wait. If no

further adjustments are made within one minute, tachometer will perform self-
test and revert back to normal operating mode.

8. After calibration is complete, cover hole for calibration button (E) with a small
amount of non-corrosive Form-in-Place Gasket sealer.

CED,TX17864,110-19-1998/07/21

570
 Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation

Forward, Reverse, Low Range Forward and Third Speed Clutch Pack
Operation

T113896-19: Manual Shift Clutch Pack Shown

LEGEND:
A - Disk (as required between manual shift and power shift)
B - Clutch Drum
C - Separator Plate (as required between manual shift and power shift)
D - Pressure Oil
E - Hub
F - End Plate
G - Piston
H - Spring Disks
I - Lubrication Oil
J - Clutch Pack

NOTE:

This operation covers the manual shift forward and reverse clutch
packs and the power shift low range forward, reverse and third speed
clutch packs. The function of the packs are the same, but the quantity
on the disks and separator plates will be different between clutch
packs.

571
 Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation

When the FNR lever is placed in forward or reverse and the shift lever (manual shift) is
placed in a gear, pressure oil (D) from the control valve forces the clutch piston (G) to
compress the plates (C) and disks (A). The plates are splined to the clutch drum (B) and
the disks are splined to hub (E) locking them together. The input drive shaft is splined to
the hub on the manual shift forward and reverse packs and on the power shift the input
drive shaft gear is splined to the low range forward, reverse, and high range forward
(4th) gear. All gears are constantly meshed and supported by antifriction bearings. The
bearings and clutches are lubricated with cooled lubrication oil (I). Spring disks (H) push
back the piston (G) when the clutch pack (J) is disengaged, thus releasing the multi-disk
clutch.

CED,TX03399,4248-19-1998/06/23

572
 Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation

Forward, Reverse, Low Range Forward and Third Speed Clutch Pack
Operation

T113896-19: Manual Shift Clutch Pack Shown

LEGEND:
A - Disk (as required between manual shift and power shift)
B - Clutch Drum
C - Separator Plate (as required between manual shift and power shift)
D - Pressure Oil
E - Hub
F - End Plate
G - Piston
H - Spring Disks
I - Lubrication Oil
J - Clutch Pack

NOTE:

This operation covers the manual shift forward and reverse clutch
packs and the power shift low range forward, reverse and third speed
clutch packs. The function of the packs are the same, but the quantity
on the disks and separator plates will be different between clutch
packs.

573
 Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation

When the FNR lever is placed in forward or reverse and the shift lever (manual shift) is
placed in a gear, pressure oil (D) from the control valve forces the clutch piston (G) to
compress the plates (C) and disks (A). The plates are splined to the clutch drum (B) and
the disks are splined to hub (E) locking them together. The input drive shaft is splined to
the hub on the manual shift forward and reverse packs and on the power shift the input
drive shaft gear is splined to the low range forward, reverse, and high range forward
(4th) gear. All gears are constantly meshed and supported by antifriction bearings. The
bearings and clutches are lubricated with cooled lubrication oil (I). Spring disks (H) push
back the piston (G) when the clutch pack (J) is disengaged, thus releasing the multi-disk
clutch.

CED,TX03399,4248-19-1998/06/23

574
 Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation

Forward, Reverse, Low Range Forward and Third Speed Clutch Pack
Operation

T113896-19: Manual Shift Clutch Pack Shown

LEGEND:
A - Disk (as required between manual shift and power shift)
B - Clutch Drum
C - Separator Plate (as required between manual shift and power shift)
D - Pressure Oil
E - Hub
F - End Plate
G - Piston
H - Spring Disks
I - Lubrication Oil
J - Clutch Pack

NOTE:

This operation covers the manual shift forward and reverse clutch
packs and the power shift low range forward, reverse and third speed
clutch packs. The function of the packs are the same, but the quantity
on the disks and separator plates will be different between clutch
packs.

575
 Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation

When the FNR lever is placed in forward or reverse and the shift lever (manual shift) is
placed in a gear, pressure oil (D) from the control valve forces the clutch piston (G) to
compress the plates (C) and disks (A). The plates are splined to the clutch drum (B) and
the disks are splined to hub (E) locking them together. The input drive shaft is splined to
the hub on the manual shift forward and reverse packs and on the power shift the input
drive shaft gear is splined to the low range forward, reverse, and high range forward
(4th) gear. All gears are constantly meshed and supported by antifriction bearings. The
bearings and clutches are lubricated with cooled lubrication oil (I). Spring disks (H) push
back the piston (G) when the clutch pack (J) is disengaged, thus releasing the multi-disk
clutch.

CED,TX03399,4248-19-1998/06/23

576
 Power Shift High Range Forward, First Speed and Second Speed Clutch Packs

Power Shift High Range Forward, First Speed and Second Speed
Clutch Packs

T115656-19: High Range Forward Clutch Pack Shown

LEGEND:
A - Separator Plate (as required per clutch packs
B - Disk (as required per clutch pack)
C - Clutch Drum
D - Roller Bearings
E - Tapered Bearing
F - Pressure Oil
G - Hub
H - End Plate
I - Piston
J - Spring
K - Tapered Bearing
L - Lubrication Oil
M - Clutch Pack

NOTE:

This operation covers the power shift high range forward, first and
second speed clutch packs. The function of the packs are the same,
but the quantity on the disks and separator plates will be different

577
 Power Shift High Range Forward, First Speed and Second Speed Clutch Packs
between packs.

When the FNR lever is placed in forward or reverse, pressure oil (F) from the control
valve forces the clutch piston (I) to compress the plates (A) and disks (B). The plates
are splined to the clutch drum (C) and the disks are splined to hub (G) locking them
together. The drive shaft gear is splined to the low range forward, reverse, and high
range forward (4th) gear. All gears are constantly meshed and supported by antifriction
bearings. The bearings and clutches are lubricated with cooled lubrication oil (L). Spring
disks (J) push back the piston (I) when the clutch pack (M) is disengaged, thus
releasing the multi-disk clutch.

CED,TX03399,4234-19-1998/05/29

578
 Manual Shift Power Train Overview

Manual Shift Power Train Overview

T113897-19: Transmission Overview

LEGEND:
A - Torque Converter
B - Reverse Clutch Pack
C - Transmission Pump
D - Gear Shift Lever
E - Rear Output Shaft
F - Synchronizer 3rd and 4th

579
 Manual Shift Power Train Overview
G - Synchronizer 1st and 2nd
H - MFWD Output Shaft
I - Idler Shaft
J - Intermediate Shaft
K - Forward Clutch Pack
L - Pump Drive Shaft
M - Transmission

The power train elements consist of a torque converter, reverser, four speed fully
synchronized manual transmission, an optional MFWD, and a separate rear axle with
service brakes, park brake and differential lock.

The transmission is a forward, neutral, reverse countershaft design with multi-disk

clutches that receive input from a torque converter (A). Machine direction is controlled
by engagement of the forward clutch pack (K) or the reverse clutch pack (B). A four
speed manual transmission is composed of an intermediate shaft (J) and rear output
shaft (E), each with a synchronizer (F and G). The synchronizers for 1st and 2nd speed
(G) are located on the rear output shaft and the 3rd and 4th speed (F) on the
intermediate shaft. The synchronizers are controlled by a mechanical gearshift lever
(D).

The transmission may also have an optional front output shaft (H) for mechanical front
wheel drive (MFWD) which is spring applied and hydraulically released.

The transmission pump (C) is a gear type pump. The transmission pump is driven at
engine speed through the impeller drive from the torque converter.

The optional MFWD front axle is a self applied limited slip design. It consists of a
differential with outboard planetary final drives.

The rear axle is an inboard planetary design with internal wet multi-disk service brakes
that are self adjusting. Pressure oil for the service brakes is supplied by a foot operated
brake valve. The park brake is a wet multi-disk design which is spring applied and
hydraulically released. The differential lock is a sliding sleeve design, which is
hydraulically engaged and spring released.

CED,TX03399,4198-19-1998/03/02

580
 Torque Converter Operation

Torque Converter Operation

T101172-19: Torque Converter

LEGEND:
1 - Turbine
2 - Impeller
3 - Stator Shaft
4 - Input Shaft
5 - Shaft Seal
6 - Drain Plug
7 - Turbine Shaft
8 - Pump Drive Shaft
9 - Free-Wheel Clutch
10 - Stator
11 - Torque Converter

The three main parts of the torque converter include the impeller, turbine and stator.

The impeller (2) is driven by the engine. As it rotates, centrifugal force throws oil out of
the impeller against the blades of the turbine (1). This forces the turbine to rotate in the
same direction as the impeller.

The turbine (1) is connected to the turbine shaft (7) which provides input to the
transmission gear train. Pump drive shaft (8) is driven by the engine directly and at
engine speed. The pump drive shaft provides input to the transmission pump and the

581
 Torque Converter Operation
hydraulic system pump.

As the oil leaves the turbine, it is redirected by the stator (10) back into the impeller
which increases the torque converter performance.

Oil leaving the turbine enters the stator (10). The stator is curved so that the oil flow
changes direction. Oil leaving the stator is moving in the same direction as the impeller.
This adds to the force of the oil entering the impeller. The turbine will be rotating at a
slower speed than the impeller, but it will produce a higher torque. It is this increased
force developed by the stator that makes a converter able to multiply torque. Under light
load the speed of the turbine will increase until it equals impeller speed. The free-wheel
clutch (9) unlocks, allowing the stator to free-wheel or rotate with the turbine and
impeller as a unit. Input speed and torque are equal to output speed and torque when
the stator is free-wheeling. The transmission pump is constantly pumping oil through
the converter. The converter multiplies the torque and at the same time, the heat
created in the converter is eliminated through the circulation of oil from converter to
cooler and back to sump.

TX,05,SS3120-19-1998/06/22

582
 Manual Shift Synchronizer Operation

Manual Shift Synchronizer Operation

T101275-19: Synchronizer
LEGEND:
A - Synchronizer Collar
B - Shift Fork
C - Fourth Speed Drive Gear
D - Synchronizer Ring
E - Needle Bearing
F - Hub

583
 Manual Shift Synchronizer Operation
G - Snap Ring
H - Intermediate Shaft
I - Third Speed Drive Gear
J - Spring
K - Synchronizer Ring
L - Synchronizer Detent (Pressure Piece)
M - Third Gear Engaged
N - Synchronizer

The components of the synchronizer are the hub (F), collar (A), synchronizer ring (D
and K), spring (J) and synchronizer detent (pressure piece) (L).

The hub (F) is splined to the intermediate shaft (H). The synchronizer collar (A) is
splined to the hub. Three of the splines in the hub are omitted and a synchronizer
detent (L) is inserted between the hub and the collar. Springs (J) push the detents (L)
out against the collar.

The synchronizer detents extend into slots in the synchronizer collar. The hub, collar,
synchronizer detent, and synchronizer rings always rotate as an assembly with the
shaft.

With the synchronizer in neutral, the synchronizer rings do not contact either drive gear.
Since the gears are not splined to the shaft, they are free to rotate at different speeds.

When a shift to third gear is made, the first step is synchronizing the speed of
intermediate drive shaft (H) and third speed drive gear (I). As the collar (A) moves
across the hub, the synchronizer detents move down and force the synchronizer ring (K)
against the tapered portion of third speed gear. The synchronizer rings will accelerate
until the speed of the transmission drive shaft matches the speed of the third speed
drive gear.

After the gear and the shaft have been synchronized, the collar slides over the teeth of
the synchronizer ring and the gear to allow smooth engagement of third gear (M).

CED,TX03399,4210-19-1998/06/22

584
 Transmission Pump Operation

Transmission Pump Operation

T101251-UN: Transmission Pump

LEGEND:
1 - Angle Disk
2 - Washer
3 - O-Ring (2 used)
4 - Cap Screw (4 used)
5 - Pump Housing
6 - O-Ring
7 - Needle Bearing
8 - Stop Sleeve

585
 Transmission Pump Operation

T101252-UN: Pump Gears

The transmission uses a high capacity fixed displacement gear-type pump to provide
constant flow for the transmission hydraulic system. Pump flow is proportional to engine
speed.

The input shaft to the pump is driven by the engine. The pump gears rotate inside of the
pump housing. As the gears rotate, oil is trapped between the gear teeth and the pump
housing which forces oil to move from the pump inlet around the gears to the pump
outlet.

TX,05,SS3124-19-1998/06/22

586
 Transmission Filter Operation

Transmission Filter Operation

T101250-19: Transmission Filter

LEGEND:
A - Filter
B - Spring
C - Bypass Valve
D - To Transmission Circuit
E - From Transmission Pump

NOTE:

Filter housing removed to show element and bypass valve.

The transmission filter is a spin on replaceable element. If the filter (A) becomes
obstructed, a bypass valve (C) opens to maintain flow to the transmission control
system.

Oil from the transmission pump enters from outside of the filter element. The filter
element traps contaminants as the oil passes through it. Filtered oil flows up through the
middle of the element to the transmission control system.

If the filter element becomes obstructed or during extremely cold conditions, the
pressure difference across the filter element exceeds the set value of the bypass spring
(B), causing the bypass valve (C) to unseat. This unseated valve allows unfiltered oil to

587
 Transmission Filter Operation
pass through the filter housing. Bypass operation for extended periods of time is not
recommended.

TX,05,SS3125-19-1998/06/22

588
 Manual Shift Transmission Operation-First Gear Forward

Manual Shift Transmission Operation-First Gear Forward

T113898-19: First Gear-Forward

LEGEND:
A - Torque Converter
B - Input Drive Shaft
C - Gear Shift Lever
D - Forward Clutch Hub
E - Plates and Disks
F - Intermediate Shaft

589
 Manual Shift Transmission Operation-First Gear Forward
G - Synchronizer
H - Rear Output Shaft
I - Idler Shaft
J - MFWD Output Shaft
K - First Gear
L - Intermediate Gear
M - Piston
N - Forward Clutch Gear
O - Forward Clutch Shaft
P - First Speed-Forward

With the transmission in first speed forward (P), the torque converter (A) supplies torque
to the input drive shaft gear (B) which meshes with the input gear on the forward clutch
hub (D).

System pressure oil, from the transmission control valve, is routed through a drilled
passage in the forward clutch shaft (O). This causes the piston (M) to move
compressing the plates and disks (E) causing the clutch to rotate as a unit. The forward
clutch gear (N) meshes with the intermediate gear (L) and shaft (F).

As the shift is made in first gear the synchronizer collar is moved to the left. The first
gear (K) and rear output shaft (H) are in mesh to the intermediate shaft (F). The idler
shaft (I) is in mesh with the rear output shaft (H) and the MFWD output shaft (J) is in
mesh with the idler shaft (I) and turns at a constant speed with the rear output shaft.
This transfers torque to the rear output shaft and the MFWD shaft if engaged.

CED,TX03399,4200-19-1998/06/22

590
 Manual Shift Transmission Operation-Third Gear Reverse

Manual Shift Transmission Operation-Third Gear Reverse

T113899-19: Third Gear-Reverse

LEGEND:
A - Torque Converter
B - Reverse Clutch Pack
C - Plates and Disks
D - Reverse Clutch Hub
E - Input Drive Shaft
F - Gear Shift Lever

591
 Manual Shift Transmission Operation-Third Gear Reverse
G - Intermediate Shaft
H - Synchronizer
I - Rear Output Shaft
J - Idler Shaft
K - MFWD Output Shaft
L - Third Gear
M - Forward Clutch Gear
N - Reverse Clutch Gear
O - Piston
P - Reverse Clutch Shaft
Q - Third Speed-Reverse

With the transmission in third speed reverse (Q), the torque converter (A) supplies
torque to the input drive shaft gear (E) which meshes with the input gear on the reverse
clutch hub (D).

System pressure oil, from the transmission control valve, is routed through a drilled
passage in the reverse clutch shaft (P). This causes the piston (O) to move
compressing the plates and disks (C) causing the clutch to rotate as a unit. The reverse
clutch gear (N) meshes with the forward clutch gear (M) which acts as a countershaft
and reverses the direction of input to the intermediate shaft (G).

As the shift is made in third gear the synchronizer collar is moved to the left. The third
gear (L) and rear output shaft (I) are locked to the intermediate shaft (G). The idler shaft
(J) is in mesh with the rear output shaft (I) and the MFWD shaft (K) is in mesh with the
idler shaft (J) and turns at a constant speed with the rear output shaft (I). This transfers
torque to the rear output shaft (I) and the MFWD shaft if engaged.

CED,TX03399,4201-19-1998/06/22

592
 Power Shift Power Train Overview

Power Shift Power Train Overview

T115039-19: Transmission Overview

LEGEND:
A - Torque Converter
B - High Range (4th) Forward Clutch
C - Transmission Pump
D - Reverse Clutch
E - Low Range Forward Clutch
F - Third Speed Clutch

593
 Power Shift Power Train Overview
G - Second Speed Clutch
H - MFWD
I - First Speed Clutch
J - Pump Drive Shaft
K - Transmission

A single stage torque converter drives a hydraulically engaged four speeds forward and
three speeds reverse countershaft type power shift transmission.

Six clutch packs provide four forward and three reverse speeds. Two clutch packs have
to be engaged for movement. One directional clutch pack, either low-range forward,
high-range forward or reverse and one speed range clutch pack either 1st, 2nd or 3rd.

The transmission may also have an optional front output shaft (H) for mechanical front
wheel drive (MFWD) which is spring applied and hydraulically released.

The transmission pump (C) is a gear type pump. The transmission pump is driven at
engine speed through the impeller drive from the torque converter.

The optional MFWD front axle is a self applied limited slip design. It consists of a
differential with outboard planetary final drives.

The rear axle is an inboard planetary design with internal wet multi-disk service brakes
that are self adjusting. Pressure oil for the service brakes is supplied by a foot operated
brake valve. The park brake is a wet multi-disk design which is spring applied and
hydraulically released. The differential lock is a sliding sleeve design, which is
hydraulically engaged and spring released.

CED,TX03399,4205-19-1998/03/03

594
 Power Shift Transmission Gear Flow

Power Shift Transmission Gear Flow

T115189-19: Power Shift Transmission Gear Flow

LEGEND:
A - 4th Forward (High Range)
B - Reverse
C - Low Range Forward
D - 1st Speed
E - MFWD Output
F - 3rd Speed (Rear Output)

595
 Power Shift Transmission Gear Flow
G - 2nd Speed

The torque converter supplies torque to the drive gear which is in constant mesh with
the low-range forward, reverse and high range forward clutch hubs.

The low-range forward clutch, reverse, high range forward and second speed clutch
outer gears are in mesh. As are the first speed hub gear and third speed clutch outer
gear.

With MFWD (if equipped) the first speed hub is in mesh with the MFWD output gear.

As a example, with the transmission in second speed forward, the low range forward
clutch (C) and the second speed clutch (G) are engaged. The torque converter supplies
torque to the drive gear which meshes with the gear on the low-range forward clutch.
Power flow continues through the reverse (B) and high range forward clutch (A) output
gears to the second speed (G) output gear which drives the third speed clutch (F) rear
axle output which is in mesh with first speed clutch (D) hub which is in mesh with the
MFWD (E) (if equipped) output gear.

CED,TX03399,4206-19-1998/03/03

596
 Mechanical Front Wheel Drive (MFWD) Operation

Mechanical Front Wheel Drive (MFWD) Operation

T114902-19: MFWD System-On

LEGEND:
A - Sliding Sleeve
B - MFWD Solenoid Valve
C - From Transmission Pump
D - Drive Gear
E - Backing Plate
F - Front Output Shaft

597
 Mechanical Front Wheel Drive (MFWD) Operation
G - Spring
H - Manual Shift MFWD-ON (Engaged)
I - Sliding Sleeve
J - MFWD Solenoid Valve
K - From Transmission Pump
L - Drive Gear
M - Backing Plate
N - Front Output Shaft
O - Spring
P - System Pressure
Q - Return Pressure
R - Power Shift MFWD-On (Engaged)

The MFWD is powered by transmission.

The MFWD is spring applied, hydraulically released. When the MFWD switch is “ON”,
spring (G or O) force holds the sliding sleeve (A or I) in mesh with the drive gear (D or
L). The drive gear is connected to the front output shaft (F or N) and transmits power to
the front axle.

The disengagement of the MFWD is controlled by an electric solenoid located on the

transmission. When energized, with MFWD switch in the “OFF” position, transmission
pressure oil (P) is routed through the MFWD sliding sleeve (A or I). Pressure pushes
the sleeve back against the spring (G or O) and backing plate (E or M). The drive gear
(D or L) and front output shaft (F or N) are disengaged.

CED,TX03399,4226-19-1998/04/15

598
 Manual Shift Transmission Control Valve Operation

Manual Shift Transmission Control Valve Operation

T127723-19: Transmission Control Valve-Neutral

LEGEND:
1 - Main Frame Harness
2 - Forward Solenoid
3 - Neutral Solenoid
4 - Reverse Solenoid
5 - Converter Relief Valve
6 - Pressure Regulating Valve

599
 Manual Shift Transmission Control Valve Operation
7 - Modulation Valve
8 - Modulation Piston
9 - Orifice
10 - Forward or Reverse Shift Valve
11 - Neutral Shift Valve
12 - Pressure Reducing Valve
13 - System Pressure
14 - Medium Pressure
15 - Low Pressure
16 - Return Pressure
17 - Transmission Control Valve-Neutral
18 - From Pump
19 - To Solenoids
20 - To Torque Converter

The transmission control valve regulates the hydraulic oil pressures and controls
circuits required for operation of the transmission. Electrical signals from the FNR lever
and park brake switch are used to energize the solenoids which direct oil to move the
shift valves and engage the directional clutches.

The transmission control valve contains the pressure regulating valve (6), converter
relief valve (5), modulation piston (8), modulation valve (7), shift valves (forward or
reverse) (10), neutral shift valve (11), pressure reducing valve (12), forward, neutral,
and reverse solenoids (2, 3, and 4).

The pressure regulating valve (6) is a spring loaded spool valve with shims, which
regulates main system pressure. Excess oil from the circuit is directed to the torque
converter.

The converter relief valve (5) controls the maximum pressure to the torque converter.

The modulation valve (7) is a spring loaded spool which controls the rate of clutch
engagement during a shift.

The pressure reducing valve (12) supplies reduced pressure oil to the solenoid valves
(forward, neutral, reverse).

The forward/reverse shift valve (10) is a spring loaded spool valve which engages the
directional clutches. The neutral shift valve (11) is a spring loaded spool valve which
also must be shifted to allow pressure oil to be directed to the selected directional
clutch. The forward or reverse shift valve solenoids (2 or 4) are activated by the FNR
lever. The neutral solenoid (3) is controlled by the park brake switch and must be

600
 Manual Shift Transmission Control Valve Operation
energized before forward or reverse clutches can be engaged. The loader and shift
lever disconnect switches also control the neutral solenoid.

CED,TX03399,4249-19-2000/01/28

601
 Manual Shift Transmission Control Circuit-Neutral With Park Brake Off

Manual Shift Transmission Control Circuit-Neutral With Park Brake

Off

T127862-19: Manual Shift Transmission Control Circuit-Neutral

LEGEND:
1 - Transmission Control Valve
2 - Forward Clutch
3 - Reverse Clutch
4 - Differential Lock
5 - MFWD (Mechanical Front Wheel Drive)
6 - Park Brake
7 - Park Brake Solenoid Valve
8 - Screen In All Solenoids
9 - MFWD Solenoid Valve
10 - Differential Solenoid Valve
11 - Forward Solenoid Valve
12 - Forward/Reverse Shift Valve
13 - Neutral Shift Valve
14 - Neutral Solenoid Valve
15 - Reverse Solenoid Valve
16 - Orifice In Modulation Spool
17 - Modulation Valve
18 - Orifice in Valve Housing

602
 Manual Shift Transmission Control Circuit-Neutral With Park Brake Off
19 - Modulation Piston
20 - Pressure Reducing Valve
21 - Orifice In Intermediate Plate
22 - Pressure Regulating Valve
23 - Torque Converter
24 - Converter Relief Valve
25 - Transmission Oil Cooler
26 - Orifice In Transmission Front Housing
27 - Filter And Bypass
28 - Transmission Pump
29 - Sump
30 - System Pressure
31 - Medium Pressure
32 - Low Pressure
33 - Lube Pressure
34 - Return Pressure
35 - Manual Shift Transmission Control Circuit-Neutral with Park Brake Off

T129429-UN: Manual Shift Transmission Control Circuit-Neutral with Park Brake Off-
With Power Boost MICO Brake Valve
LEGEND:
1 - Transmission Control Valve
2 - Forward Clutch
3 - Reverse Clutch

603
 Manual Shift Transmission Control Circuit-Neutral With Park Brake Off
4 - Differential Lock
5 - MFWD (Mechanical Front Wheel Drive)
6 - Park Brake
7 - Park Brake Solenoid Valve
8 - Screen In All Solenoids
9 - MFWD Solenoid Valve
10 - Differential Solenoid Valve
11 - Forward Solenoid Valve
12 - Forward/Reverse Shift Valve
13 - Neutral Shift Valve
14 - Neutral Solenoid Valve
15 - Reverse Solenoid Valve
16 - Orifice In Modulation Spool
17 - Modulation Valve
18 - Orifice in Valve Housing
19 - Modulation Piston
20 - Pressure Reducing Valve
21 - Orifice In Intermediate Plate
22 - Pressure Regulating Valve
23 - Torque Converter
24 - Converter Relief Valve
25 - Transmission Oil Cooler
26 - Orifice In Transmission Front Housing
27 - Filter And Bypass
28 - Transmission Pump
29 - Sump
30 - Power Boost Brake Valve
31 - Oil From Hydraualic Oil Cooler Return
32 - System Pressure
33 - Medium Pressure
34 - Low Pressure
35 - Lube Pressure
36 - Return Pressure
37 - Manual Shift Transmission Control Circuit-Neutral with Park Brake Off-With Power Boost
MICO Brake Valve

Flow from the transmission charge pump (28) passes through the filter to the pressure
regulating valve (22), reducing valve (20), differential lock solenoid valve (10), MFWD

604
 Manual Shift Transmission Control Circuit-Neutral With Park Brake Off
solenoid valve (9), and the park brake solenoid valve (7). The pressure regulating valve
regulates system pressure and directs high pressure oil to the modulation valve.

When pressure exceeds the pressure regulating valve setting the valve opens. Low
pressure oil (32) then flows through the torque converter (23). Converter flow is excess
oil from the pressure regulating valve. A torque converter relief valve (24) protects the
circuit by dumping to tank when pressure exceeds the setting. The oil is then routed to
the oil cooler (25). A portion of the oil returning from the cooler provides lubrication to
the clutches, and the remaining oil goes to sump.

The pressure reducing valve (20) supplies medium pressure oil to the solenoid valves
(neutral, reverse and forward). In neutral, with park brake OFF, the forward and reverse
solenoids (11 and 15) are de-energized (open), and medium pressure oil is not directed
to the forward/reverse shift valve (12). The neutral solenoid valve (14) is energized
(closed) and medium pressure oil is routed to the end of the neutral shift valve. The
reducing valve controls the pressure by dumping oil to tank when pressure exceeds its
setting.

In neutral, pressure oil flows to the modulation valve (17) through an orifice. Flow to the
modulation valve is reduced by the orifice.

Forward and reverse clutch packs (2 and 3) dump to sump when in neutral or park
brake is ON.

CED,TX03399,4202-19-2000/04/14

605
 Manual Shift Transmission Control Circuit-Forward

Manual Shift Transmission Control Circuit-Forward

T127863-19: Transmission Control Circuit-Forward

LEGEND:
1 - Transmission Control Valve
2 - Forward Clutch
3 - Reverse Clutch
4 - Differential Lock
5 - MFWD (Mechanical Front Wheel Drive)
6 - Park Brake
7 - Park Brake Solenoid Valve
8 - Screen In All Solenoids
9 - MFWD Solenoid Valve
10 - Differential Solenoid Valve
11 - Forward Solenoid Valve
12 - Forward/Reverse Shift Valve
13 - Neutral Shift Valve
14 - Neutral Solenoid Valve
15 - Reverse Solenoid Valve
16 - Orifice In Modulation Spool
17 - Modulation Valve
18 - Orifice in Valve Housing
19 - Modulation Piston

606
 Manual Shift Transmission Control Circuit-Forward
20 - Pressure Reducing Valve
21 - Orifice In Intermediate Plate
22 - Pressure Regulating Valve
23 - Torque Converter
24 - Converter Relief Valve
25 - Transmission Oil Cooler
26 - Orifice In Transmission Front Housing
27 - Filter And Bypass
28 - Transmission Pump
29 - Sump
30 - System Pressure
31 - Medium Pressure
32 - Low Pressure
33 - Lube Pressure
34 - Return Pressure
35 - Manual Shift Transmission Control Circuit-Forward

T129430-UN: Manual Shift Transmission Control Circuit-Forward-With Power Boost

MICO Brake Valve
LEGEND:
1 - Transmission Control Valve
2 - Forward Clutch
3 - Reverse Clutch
4 - Differential Lock

607
 Manual Shift Transmission Control Circuit-Forward
5 - MFWD (Mechanical Front Wheel Drive)
6 - Park Brake
7 - Park Brake Solenoid Valve
8 - Screen In All Solenoids
9 - MFWD Solenoid Valve
10 - Differential Solenoid Valve
11 - Forward Solenoid Valve
12 - Forward/Reverse Shift Valve
13 - Neutral Shift Valve
14 - Neutral Solenoid Valve
15 - Reverse Solenoid Valve
16 - Orifice In Modulation Spool
17 - Modulation Valve
18 - Orifice in Valve Housing
19 - Modulation Piston
20 - Pressure Reducing Valve
21 - Orifice In Intermediate Plate
22 - Pressure Regulating Valve
23 - Torque Converter
24 - Converter Relief Valve
25 - Transmission Oil Cooler
26 - Orifice In Transmission Front Housing
27 - Filter And Bypass
28 - Transmission Pump
29 - Sump
30 - Power Boost Brake Valve
31 - Oil From Hydraulic Oil Cooler Return
32 - System Pressure
33 - Medium Pressure
34 - Low Pressure
35 - Lube Pressure
36 - Return Pressure
37 - Manual Shift Transmission Control Circuit-Forward-With Power Boost MICO Brake Valve

During forward operation, forward and neutral solenoid valves (11 and 14) are
energized. The neutral solenoid valve (14) routes pressure oil (31) to the neutral shift
valve (13) and moves the spool down. The energized forward solenoid (11) routes
pressure oil to the forward/reverse shift valve (12) moving the spool up. Shifting of the
forward/reverse spool allows oil to flow from the modulation valve (17) to fill the forward
608
 Manual Shift Transmission Control Circuit-Forward
clutch pack (2) and compress the clutch plates. Shifting of the forward/reverse spool
also blocks the flow of oil downstream of the orifice in valve housing (18) from returning
to tank and allows the pressure in the modulation valve to build. As pressure builds, the
balance between orifice size and spring load in the modulation valve controls the rate of
shift and pushes the modulation piston down. The downward force from the modulation
piston pushes on the modulation springs which drive the modulation spool down to the
fully open position. In the fully open position, high pressure oil from the pressure
regulating valve (22) keeps the forward clutch engaged.

CED,TX03399,4209-19-2000/04/14

609
 Manual Shift Transmission Control Circuit-Reverse

Manual Shift Transmission Control Circuit-Reverse

T127866-19: Transmission Control Circuit-Reverse

LEGEND:
1 - Transmission Control Valve
2 - Forward Clutch
3 - Reverse Clutch
4 - Differential Lock
5 - MFWD (Mechanical Front Wheel Drive)
6 - Park Brake
7 - Park Brake Solenoid Valve
8 - Screen In All Solenoids
9 - MFWD Solenoid Valve
10 - Differential Solenoid Valve
11 - Forward Solenoid Valve
12 - Forward/Reverse Shift Valve
13 - Neutral Shift Valve
14 - Neutral Solenoid Valve
15 - Reverse Solenoid Valve
16 - Orifice In Modulation Spool
17 - Modulation Valve
18 - Orifice in Valve Housing
19 - Modulation Piston

610
 Manual Shift Transmission Control Circuit-Reverse
20 - Pressure Reducing Valve
21 - Orifice In Intermediate Plate
22 - Pressure Regulating Valve
23 - Torque Converter
24 - Converter Relief Valve
25 - Transmission Oil Cooler
26 - Orifice In Transmission Front Housing
27 - Filter And Bypass
28 - Transmission Pump
29 - Sump
30 - System Pressure
31 - Medium Pressure
32 - Low Pressure
33 - Lube Pressure
34 - Return Pressure
35 - Manual Shift Transmission Control Circuit-Reverse

T129431-UN: Manual Shift Transmission Control Circuit-Reverse-With Power Boost

MICO Brake Valve
LEGEND:
1 - Transmission Control Valve
2 - Forward Clutch
3 - Reverse Clutch
4 - Differential Lock

611
 Manual Shift Transmission Control Circuit-Reverse
5 - MFWD (Mechanical Front Wheel Drive)
6 - Park Brake
7 - Park Brake Solenoid Valve
8 - Screen In All Solenoids
9 - MFWD Solenoid Valve
10 - Differential Solenoid Valve
11 - Forward Solenoid Valve
12 - Forward/Reverse Shift Valve
13 - Neutral Shift Valve
14 - Neutral Solenoid Valve
15 - Reverse Solenoid Valve
16 - Orifice In Modulation Spool
17 - Modulation Valve
18 - Orifice in Valve Housing
19 - Modulation Piston
20 - Pressure Reducing Valve
21 - Orifice In Intermediate Plate
22 - Pressure Regulating Valve
23 - Torque Converter
24 - Converter Relief Valve
25 - Transmission Oil Cooler
26 - Orifice In Transmission Front Housing
27 - Filter And Bypass
28 - Transmission Pump
29 - Sump
30 - Power Boost Brake Valve
31 - Oil From Hydraulic Oil Cooler Return
32 - System Pressure
33 - Medium Pressure
34 - Low Pressure
35 - Lube Pressure
36 - Return Pressure
37 - Manual Shift Transmission Control Circuit-Reverse-With Power Boost MICO Brake Valve

During reverse operation, solenoid valves reverse (15) and neutral (14) are energized.
The neutral solenoid valve (14) routes pressure oil (31) to the neutral shift valve (13)
and moves the spool down. The energized reverse solenoid (15) routes pressure oil to
the forward/reverse shift valve (12) moving the spool down. Shifting of the
forward/reverse spool allows oil to flow from the modulation valve (17) to fill the reverse
612
 Manual Shift Transmission Control Circuit-Reverse
clutch pack (3) and compress the clutch plates. Shifting of the forward/reverse spool
also blocks the flow of oil downstream of the orifice in valve housing (18) from returning
to tank and allows the pressure in the modulation valve to build. As pressure builds, the
balance between orifice size and spring load in the modulation valve controls the rate of
shift and pushes the modulation piston down. The downward force from the modulation
piston pushes on the modulation springs which drive the modulation spool down to the
fully open position. In the fully open position, high pressure oil from the pressure
regulating valve (22) keeps the reverse clutch engaged

CED,TX03399,4212-19-2000/04/14

613
 Power Shift Transmission Clutch Engagement And Solenoids Activated

Power Shift Transmission Clutch Engagement And Solenoids

Activated

-: Transmission Clutch Engagement

Transmission Clutch Engagement

Low and High Range Forward and Reverse Pack Engaged Speed Pack Engaged
Lo-Range Forward Hi-Range Forward Reverse 1st 2nd 3rd

N
F1 X X
F2 X X

F3 X X
F4 X X

R1 X X

R2 X X
R3 X X

-: Solenoids Activated

Solenoids Activated

Low Range, Forward, & Reverse Speed Solenoid

Gear Selection
Solenoid Energized Energized
Forward Low Range Reverse 1 2 3
Neutral

1st Forward X X X X
2nd Forward X X X X
3rd Forward X X X X

4th Forward (High X X

X
Range)
1st Reverse X X X X
2nd Reverse X X X X

3rd Reverse X X X X

CED,TX03399,4223-19-1998/03/24

614
 Power Shift Transmission Control Circuit-Neutral With Park Brake Off

Power Shift Transmission Control Circuit-Neutral With Park Brake Off

T127885-19: Transmission Control Circuit-Neutral

LEGEND:
1 - 1st Speed Clutch
2 - 2nd Speed Clutch
3 - 3rd Speed Clutch
4 - Transmission Speed Shift Valve
5 - Transmission Control Valve
6 - Low Range Forward Clutch
7 - High Range Forward Clutch
8 - Reverse Clutch
9 - Differential Lock
10 - MFWD (Mechanical Front Wheel Drive)
11 - Park Brake
12 - Park Brake Solenoid Valve
13 - Screen In All Solenoids
14 - MFWD Solenoid Valve
15 - Differential Solenoid Valve
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve

615
 Power Shift Transmission Control Circuit-Neutral With Park Brake Off
25 - Reverse Solenoid Valve
26 - Sequence Valve
27 - Orifice In Modulation Spool
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice in Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
33 - Orifice In Modulation Piston
34 - Orifice In Intermediate Plate
35 - Orifice in Duct Plate
36 - Pressure Regulating Valve
37 - Torque Converter
38 - Converter Relief Valve
39 - Transmission Oil Cooler
40 - Filter and Bypass
41 - Transmission Pump
42 - Sump
43 - System Pressure
44 - Medium Pressure
45 - Low Pressure
46 - Lube Pressure
47 - Return Pressure
48 - Power Shift Transmission Control Circuit-Neutral With Park Brake OFF

T129427-UN: Power Shift Transmission Control Circuit-Neutral With Park Brake OFF-
With Power Boost MICO Brake Valve
LEGEND:
1 - 1st Speed Clutch
616
 Power Shift Transmission Control Circuit-Neutral With Park Brake Off
2 - 2nd Speed Clutch
3 - 3rd Speed Clutch
4 - Transmission Speed Shift Valve
5 - Transmission Control Valve
6 - Low Range Forward Clutch
7 - High Range Forward Clutch
8 - Reverse Clutch
9 - Differential Lock
10 - MFWD (Mechanical Front Wheel Drive)
11 - Park Brake
12 - Park Brake Solenoid Valve
13 - Screen In All Solenoids
14 - MFWD Solenoid Valve
15 - Differential Solenoid Valve
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve
25 - Reverse Solenoid Valve
26 - Sequence Valve
27 - Orifice In Modulation Spool
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice in Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
33 - Orifice In Modulation Piston
34 - Orifice In Intermediate Plate
35 - Orifice in Duct Plate
36 - Pressure Regulating Valve
37 - Torque Converter
38 - Converter Relief Valve
39 - Transmission Oil Cooler
617
 Power Shift Transmission Control Circuit-Neutral With Park Brake Off
40 - Filter and Bypass
41 - Transmission Pump
42 - Sump
43 - Power Boost MICO Brake Valve
44 - Oil From Hydraulic Oil Cooler Return
45 - System Pressure
46 - Medium Pressure
47 - Low Pressure
48 - Lube Pressure
49 - Return Pressure
50 - Power Shift Transmission Control Circuit-Neutral With Park Brake OFF-With Power
Boost MICO Brake Valve

NOTE:

Transmission control valve (5) and transmission speed shift valve (4)
components are shown in detail on the "Power Shift Transmission
Control Valve and Shift Valve Operation-Neutral in this group. Keys and
nomenclature will match where applicable.

The transmission control valve regulates the hydraulic oil pressures and controls
circuits required for operation of the transmission. Electrical signals from the FNR lever
and park brake switch are used to energize the solenoids which direct oil to move the
shift valves and engage the appropriate selected clutches.

The transmission control valve contains the main frame harness which connects to the
transmission control valve, forward solenoid valve (16), low range solenoid valve (24),
reverse solenoid valve (25), converter relief valve (38), pressure regulating valve (36),
modulation valve (31), modulation piston (29), forward/reverse shift valve (28), low
range shift valve (17), and the pressure reducing valve (32). The transmission speed
shift valve contains the speed solenoid valves 1, 2 and 3 (23, 22 and 21) and speed
shift valves 1, 2 and 3 (20, 19 and 18).

The converter relief valve (38) controls the maximum pressure to the torque converter.
The pressure regulating valve (36) is a spring loaded spool valve with shims. It
regulates main system pressure. Excess oil from the circuit is directed to the torque
converter through this valve. The modulation valve (31) is a spring loaded spool which
controls the rate of clutch engagement during a shift. Within the valve is the modulation
piston (29).

When a gear is selected the speed solenoid valves (21, 22, or 23) are energized in
combinations of two which shift two of the speed shift valves (18, 19, or 20). The shift
618
 Power Shift Transmission Control Circuit-Neutral With Park Brake Off
valves direct system pressure oil to one of the speed clutches 1st, 2nd or 3rd.

The forward/reverse shift valve (28), is a spring loaded spool valve which routes system
pressure oil to the low range shift valve (17). The low range shift valve (17), is a spring
loaded spool valve which routes system oil to the low range (6), high range forward (7),
and reverse clutches (8). The forward and reverse solenoid valves, (16) and (25), are
activated by the FNR lever. Each directs medium pressure oil to the forward/reverse
shift valve (28). The low range solenoid valve (24), directs medium pressure oil to the
low range shift valve (17). The low range solenoid valve is controlled by the gear
selection on the FNR lever.

The pressure reducing valve (32) supplies medium pressure oil to the speed, forward,
reverse and low range solenoid valves.

Flow from the transmission charge pump (41) passes through the filter to the pressure
regulating valve (36). The pressure regulating valve regulates system pressure and
directs high pressure oil to the reducing valve (32), differential solenoid valve (15),
MFWD solenoid valve (14) and the park brake solenoid valve (12).

When pressure exceeds the pressure regulating valve setting the valve opens. Low
pressure oil then flows through the torque converter (37). Converter flow is excess oil
from the pressure regulating valve. A torque converter relief valve (38) protects the
circuit by dumping to tank when pressure exceeds the setting. The oil is then routed to
the oil cooler (39). The oil returning from the cooler provides lubrication to the clutches.

In neutral, with park brake OFF, the forward and reverse solenoids (16 and 25) are de-
energized (open), medium pressure oil is not directed to the forward/reverse shift valve
(28). The low range solenoid valve is de-energized (open) and no pressure oil is routed
to the end of the low range shift valve (17). In neutral all speed clutch packs also dump
to sump and all speed clutch solenoids are de-energized. The reducing valve (32)
controls the pressure by dumping oil to tank when pressure exceeds its setting.

CED,TX03399,4214-19-2000/04/14

619
 Power Shift Transmission Control Valve and Shift Valve Operation-Neutral

Power Shift Transmission Control Valve and Shift Valve Operation-

Neutral

T127893-19: Control Valve and Shift Valve-Neutral

LEGEND:
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1

620
 Power Shift Transmission Control Valve and Shift Valve Operation-Neutral
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve
25 - Reverse Solenoid Valve
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice In Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
36 - Pressure Regulating Valve
38 - Converter Relief Valve
43 - System Pressure Oil
44 - Medium Pressure Oil
45 - Low Pressure Oil
47 - Return Oil
49 - Transmission Control Valve And Shift Valve-Neutral

For theory see Power Shift Transmission Control Circuit-Neutral With Park Brake Off in
this group. Keys and nomenclature will match where applicable.

CED,TX03399,5911-19-2000/01/28

621
 Power Shift Transmission Control Circuit-First Forward

Power Shift Transmission Control Circuit-First Forward

T127890-19: Power Shift Transmission Control Circuit-First Forward

LEGEND:
1 - 1st Speed Clutch
2 - 2nd Speed Clutch
3 - 3rd Speed Clutch
4 - Transmission Speed Shift Valve
5 - Transmission Control Valve
6 - Low Range Forward Clutch
7 - High Range Forward Clutch
8 - Reverse Clutch
9 - Differential Lock
10 - MFWD (Mechanical Front Wheel Drive)
11 - Park Brake
12 - Park Brake Solenoid Valve
13 - Screen In All Solenoids
14 - MFWD Solenoid Valve
15 - Differential Solenoid Valve
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve

622
 Power Shift Transmission Control Circuit-First Forward
25 - Reverse Solenoid Valve
26 - Sequence Valve
27 - Orifice In Modulation Spool
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice in Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
33 - Orifice In Modulation Piston
34 - Orifice In Intermediate Plate
35 - Orifice in Duct Plate
36 - Pressure Regulating Valve
37 - Torque Converter
38 - Converter Relief Valve
39 - Transmission Oil Cooler
40 - Filter and Bypass
41 - Transmission Pump
42 - Sump
43 - System Pressure
44 - Medium Pressure
45 - Low Pressure
46 - Lube Pressure
47 - Return Pressure
48 - Power Shift Transmission Control Circuit-First Forward

T129432-UN: Power Shift Transmission Control Circuit-First Forward-With Power

Boost MICO Brake Valve
LEGEND:
1 - 1st Speed Clutch
623
 Power Shift Transmission Control Circuit-First Forward
2 - 2nd Speed Clutch
3 - 3rd Speed Clutch
4 - Transmission Speed Shift Valve
5 - Transmission Control Valve
6 - Low Range Forward Clutch
7 - High Range Forward Clutch
8 - Reverse Clutch
9 - Differential Lock
10 - MFWD (Mechanical Front Wheel Drive)
11 - Park Brake
12 - Park Brake Solenoid Valve
13 - Screen In All Solenoids
14 - MFWD Solenoid Valve
15 - Differential Solenoid Valve
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve
25 - Reverse Solenoid Valve
26 - Sequence Valve
27 - Orifice In Modulation Spool
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice in Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
33 - Orifice In Modulation Piston
34 - Orifice In Intermediate Plate
35 - Orifice in Duct Plate
36 - Pressure Regulating Valve
37 - Torque Converter
38 - Converter Relief Valve
39 - Transmission Oil Cooler
624
 Power Shift Transmission Control Circuit-First Forward
40 - Filter and Bypass
41 - Transmission Pump
42 - Sump
43 - Power Boost Brake Valve
44 - Oil From Hydraulic Oil Cooler Return
45 - System Pressure
46 - Medium Pressure
47 - Low Pressure
48 - Lube Pressure
49 - Return Pressure
50 - Power Shift Transmission Control Circuit-First Forward-With Power Boost MICO Brake
Valve

NOTE:

Transmission control valve (5) and transmission speed shift valve (4)
components are shown in detail on the "Power Shift Transmission
Control Valve and Shift Valve Operation-First Forward in this group.
Keys and nomenclature will match where applicable.

NOTE:

Refer to Power Shift Transmission Control Circuit-Neutral for pressure

reducing, converter relief and pressure regulating valve theory of
operation.

During 1st gear forward operation the forward solenoid valve (16), low range solenoid
valve (24), speed solenoid valve 2 (22), and speed solenoid valve 3 (21) are energized.
The energized low range solenoid valve routes medium pressure oil to the low range
shift valve (17) and moves the spool down. The energized forward solenoid valve (16)
routes medium pressure oil to the forward/reverse shift valve (28) moving its spool up.
The energized speed solenoids 2 and 3 (22 and 21) route medium pressure oil to the
shift valves 2 and 3 (19 and 18) moving the spools down. Shifting of the speed shift
spools allows oil to flow from the regulating valve (36) through the orifice in duct plate
(replenishing orifice) (35) to fill the 1st speed clutch pack (1) and compress the clutch
plates. Shifting of the forward/reverse spool (28) and the low range shift spool (17)
allows oil to flow from the modulation valve (31) to fill the low range forward clutch pack
(6) and compress the clutch plates. Shifting of the forward/reverse spool also blocks the
flow of oil downstream of the orifice (30) in valve housing from returning to tank and
allows the pressure in the modulation valve to build. As pressure builds, the balance
between orifice size and spring load in the modulation valve controls the rate of shift
625
 Power Shift Transmission Control Circuit-First Forward
and pushes the modulation piston down.

The sequence valve (26) insures that the speed clutch fills and engages before the
direction clutch by allowing oil to flow from the modulation valve (31) to the speed clutch
circuit downstream of the orifice in duct plate (replenishing orifice) (35) when the
pressure in the speed clutch circuit is lower than the pressure in the direction clutch
circuit. The downward force from the modulation piston (29) pushes on the modulation
springs which drive the modulation spool down to the fully open position. In the fully
open position, high pressure oil from the pressure regulating valve (36) keeps the
speed and direction clutches engaged.

CED,TX03399,4215-19-2000/04/14

626
 Power Shift Transmission Control Valve and Shift Valve-First Forward

Power Shift Transmission Control Valve and Shift Valve-First

Forward

T127897-19: Control Valve and Shift Valve-First Forward

LEGEND:
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1

627
 Power Shift Transmission Control Valve and Shift Valve-First Forward
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve
25 - Reverse Solenoid Valve
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice In Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
36 - Pressure Regulating Valve
38 - Converter Relief Valve
43 - System Pressure Oil
44 - Medium Pressure Oil
47 - Return Oil
49 - Transmission Control Valve And Shift Valve-First Forward

For theory see Power Shift Transmission Control Circuit-First Forward in this group.
Keys and nomenclature will match where applicable.

CED,TX03399,5912-19-2000/01/28

628
 Power Shift Transmission Control Circuit-High Range (Fourth) Forward

Power Shift Transmission Control Circuit-High Range (Fourth)

Forward

T127900-19: Transmission Control Circuit-Fourth Forward

LEGEND:
1 - 1st Speed Clutch
2 - 2nd Speed Clutch
3 - 3rd Speed Clutch
4 - Transmission Speed Shift Valve
5 - Transmission Control Valve
6 - Low Range Forward Clutch
7 - High Range Forward Clutch
8 - Reverse Clutch
9 - Differential Lock
10 - MFWD (Mechanical Front Wheel Drive)
11 - Park Brake
12 - Park Brake Solenoid Valve
13 - Screen In All Solenoids
14 - MFWD Solenoid Valve
15 - Differential Solenoid Valve
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1

629
 Power Shift Transmission Control Circuit-High Range (Fourth) Forward
24 - Low Range Solenoid Valve
25 - Reverse Solenoid Valve
26 - Sequence Valve
27 - Orifice In Modulation Spool
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice in Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
33 - Orifice In Modulation Piston
34 - Orifice In Intermediate Plate
35 - Orifice in Duct Plate
36 - Pressure Regulating Valve
37 - Torque Converter
38 - Converter Relief Valve
39 - Transmission Oil Cooler
40 - Filter and Bypass
41 - Transmission Pump
42 - Sump
43 - System Pressure
44 - Medium Pressure
45 - Low Pressure
46 - Lube Pressure
47 - Return Pressure
48 - Power Shift Transmission Control Circuit-Fourth Forward

T129428-UN: Power Shift Transmission Control Circuit-Fourth Forward-With Power

Boost MICO Brake Valve

630
 Power Shift Transmission Control Circuit-High Range (Fourth) Forward
LEGEND:
1 - 1st Speed Clutch
2 - 2nd Speed Clutch
3 - 3rd Speed Clutch
4 - Transmission Speed Shift Valve
5 - Transmission Control Valve
6 - Low Range Forward Clutch
7 - High Range Forward Clutch
8 - Reverse Clutch
9 - Differential Lock
10 - MFWD (Mechanical Front Wheel Drive)
11 - Park Brake
12 - Park Brake Solenoid Valve
13 - Screen In All Solenoids
14 - MFWD Solenoid Valve
15 - Differential Solenoid Valve
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve
25 - Reverse Solenoid Valve
26 - Sequence Valve
27 - Orifice In Modulation Spool
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice in Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
33 - Orifice In Modulation Piston
34 - Orifice In Intermediate Plate
35 - Orifice in Duct Plate
36 - Pressure Regulating Valve
37 - Torque Converter

631
 Power Shift Transmission Control Circuit-High Range (Fourth) Forward
38 - Converter Relief Valve
39 - Transmission Oil Cooler
40 - Filter and Bypass
41 - Transmission Pump
42 - Sump
43 - Power Boost Brake Valve
44 - Oil From Hydraulic Oil Cooler Retrun
45 - System Pressure
46 - Medium Pressure
47 - Low Pressure
48 - Lube Pressure
49 - Return Pressure
50 - Power Shift Transmission Control Circuit-Fourth Forward-With Power Boost MICO Brake
Valve

NOTE:

Transmission control valve (5) and transmission speed shift valve (4)
components are shown in detail on the "Power Shift Transmission
Control Valve and Shift Valve Operation-High Range (Fourth) Forward
in this group. Keys and nomenclature will match where applicable.

NOTE:

Refer to Power Shift Transmission Control Circuit-Neutral for pressure

reducing, converter relief and pressure regulating valve theory of
operation.

During 4th gear forward operation the forward solenoid valve (16), speed solenoid valve
1 (23), and speed solenoid valve 3 (21) are energized. Both the low range shift valve
(17) and the forward/reverse shift valve (28) are in the up position. The energized speed
solenoids 1 and 3 (23 and 21) routes oil to the shift valves 1 and 3 (20 and 18) moving
the spools down. Pressure oil is routed through the shift valves to the 3rd speed clutch
(3). Shifting of the speed shift spools allows oil to flow from the regulating valve (36)
through the orifice in duct plate (replenishing orifice) (35) to fill the 3rd speed clutch
pack and compress the clutch plates. Shifting of the forward/reverse spool (28) allows
oil to flow from the modulation valve (31) to fill the high range forward clutch pack (7)
and compress the clutch plates. Shifting of the forward/reverse spool also blocks the
flow of oil downstream of the orifice (30) in valve housing from returning to tank and
allows the pressure in the modulation valve to build. As pressure builds, the balance

632
 Power Shift Transmission Control Circuit-High Range (Fourth) Forward
between orifice size and spring load in the modulation valve controls the rate of shift
and pushes the modulation piston (29) down.

The sequence valve (26) insures that the speed clutch fills and engages before the
direction clutch by allowing oil to flow from the modulation valve (31) to the speed clutch
circuit downstream of the orifice in duct plate (replenishing orifice) (35) when the
pressure in the speed clutch circuit is lower than the pressure in the direction clutch
circuit. The downward force from the modulation piston (29) pushes on the modulation
springs which drive the modulation spool down to the fully open position. In the fully
open position, high pressure oil from the pressure regulating valve (36) keeps the
speed and direction clutches engaged.

CED,TX03399,4216-19-2000/04/14

633
 Power Shift Transmission Control Valve and Shift Valve-High Range (Fourth) Forward

Power Shift Transmission Control Valve and Shift Valve-High Range

(Fourth) Forward

T127901-19: Control Valve and Shift Valve-Fourth Forward

LEGEND:
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1

634
 Power Shift Transmission Control Valve and Shift Valve-High Range (Fourth) Forward
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve
25 - Reverse Solenoid Valve
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice In Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
36 - Pressure Regulating Valve
38 - Converter Relief Valve
43 - System Pressure Oil
44 - Medium Pressure Oil
47 - Return Oil
49 - Transmission Control Valve And Shift Valve-Fourth Forward

For theory see Power Shift Transmission Control Circuit-High Range (Fourth) Forward
in this group. Keys and nomenclature will match where applicable.

CED,TX03399,5913-19-2000/01/28

635
 Power Shift Transmission Control Circuit-First Reverse

Power Shift Transmission Control Circuit-First Reverse

T127902-19: Transmission Control Circuit-First Reverse

LEGEND:
1 - 1st Speed Clutch
2 - 2nd Speed Clutch
3 - 3rd Speed Clutch
4 - Transmission Speed Shift Valve
5 - Transmission Control Valve
6 - Low Range Forward Clutch
7 - High Range Forward Clutch
8 - Reverse Clutch
9 - Differential Lock
10 - MFWD (Mechanical Front Wheel Drive)
11 - Park Brake
12 - Park Brake Solenoid Valve
13 - Screen In All Solenoids
14 - MFWD Solenoid Valve
15 - Differential Solenoid Valve
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve

636
 Power Shift Transmission Control Circuit-First Reverse
25 - Reverse Solenoid Valve
26 - Sequence Valve
27 - Orifice In Modulation Spool
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice in Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
33 - Orifice In Modulation Piston
34 - Orifice In Intermediate Plate
35 - Orifice in Duct Plate
36 - Pressure Regulating Valve
37 - Torque Converter
38 - Converter Relief Valve
39 - Transmission Oil Cooler
40 - Filter and Bypass
41 - Transmission Pump
42 - Sump
43 - System Pressure
44 - Medium Pressure
45 - Low Pressure
46 - Lube Pressure
47 - Return Pressure
48 - Power Shift Transmission Control Circuit-First Reverse

T129409-UN: Power Shift Transmission Control Circuit-First Reverse-With Power Boost

MICO Brake Valve
LEGEND:
1 - 1st Speed Clutch
637
 Power Shift Transmission Control Circuit-First Reverse
2 - 2nd Speed Clutch
3 - 3rd Speed Clutch
4 - Transmission Speed Shift Valve
5 - Transmission Control Valve
6 - Low Range Forward Clutch
7 - High Range Forward Clutch
8 - Reverse Clutch
9 - Differential Lock
10 - MFWD (Mechanical Front Wheel Drive)
11 - Park Brake
12 - Park Brake Solenoid Valve
13 - Screen In All Solenoids
14 - MFWD Solenoid Valve
15 - Differential Solenoid Valve
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve
25 - Reverse Solenoid Valve
26 - Sequence Valve
27 - Orifice In Modulation Spool
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice in Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
33 - Orifice In Modulation Piston
34 - Orifice In Intermediate Plate
35 - Orifice in Duct Plate
36 - Pressure Regulating Valve
37 - Torque Converter
38 - Converter Relief Valve
39 - Transmission Oil Cooler
638
 Power Shift Transmission Control Circuit-First Reverse
40 - Filter and Bypass
41 - Transmission Pump
42 - Sump
43 - Power Boost MICO Brake Valve
44 - Oil From Hydraulic Oil Cooler Return
45 - System Pressure
46 - Medium Pressure
47 - Low Pressure
48 - Lube Pressure
49 - Return Pressure
50 - Power Shift Transmission Control Circuit-First Reverse-With Power Boost MICO Brake
Valve

NOTE:

Transmission control valve (5) and transmission speed shift valve (4)
components are shown in detail on the "Power Shift Transmission
Control Valve and Shift Valve Operation-First Reverse in this group.
Keys and nomenclature will match where applicable.

NOTE:

Refer to Power Shift Transmission Control Circuit-Neutral for pressure

reducing, converter relief and pressure regulating valve theory of
operation.

During 1st gear reverse operation the reverse solenoid valve (25), low range solenoid
valve (24), speed solenoid valve 2 (22), and speed solenoid valve 3 (21) are energized.
The energized reverse solenoid valve (25) routes pressure oil to the forward/reverse
shift valve (28) moving its spool down. The energized low range solenoid valve (24)
routes pressure oil to the low range shift valve (17), shifting it down. The energized
speed solenoids 2 and 3 (22 and 21) routes oil to the shift valves 2 and 3 (19 and 18)
moving the spools down. Pressure oil is routed through the shift valves to the lst. speed
clutch (1). Shifting of the speed shift spools allows oil to flow from the regulating valve
(36) through the orifice in duct plate (replenishing orifice) (35) to fill the 1st speed clutch
pack and compress the clutch plates. Shifting of the forward/reverse spool (28) and the
low range shift spool (17) allows oil to flow from the modulation valve (31) to fill the
reverse clutch pack (8) and compress the clutch plates. Shifting of the forward/reverse
spool also blocks the flow of oil downstream of the orifice (30) in valve housing from
returning to tank and allows the pressure in the modulation valve (31) to build. As
pressure builds, the balance between orifice size and spring load in the modulation
639
 Power Shift Transmission Control Circuit-First Reverse
valve controls the rate of shift and pushes the modulation piston down.

The sequence valve (26) insures that the speed clutch fills and engages before the
direction clutch by allowing oil to flow from the modulation valve to the speed clutch
circuit downstream of the orifice in duct plate (replenishing orifice) (36) when the
pressure in the speed clutch circuit is lower than the pressure in the direction clutch
circuit. The downward force from the modulation piston (29) pushes on the modulation
springs which drive the modulation spool down to the fully open position. In the fully
open position, high pressure oil from the pressure regulating valve (36) keeps the
speed and direction clutches engaged.

CED,TX03399,4217-19-2000/04/14

640
 Power Shift Transmission Control Valve and Shift Valve-First Reverse

Power Shift Transmission Control Valve and Shift Valve-First

Reverse

T127903-19: Transmission Control Valve and Shift Valve-First Reverse

LEGEND:
16 - Forward Solenoid Valve
17 - Low Range Shift Valve
18 - Speed Shift Valve 3
19 - Speed Shift Valve 2
20 - Speed Shift Valve 1

641
 Power Shift Transmission Control Valve and Shift Valve-First Reverse
21 - Speed Solenoid Valve 3
22 - Speed Solenoid Valve 2
23 - Speed Solenoid Valve 1
24 - Low Range Solenoid Valve
25 - Reverse Solenoid Valve
28 - Forward/Reverse Shift Valve
29 - Modulation Piston
30 - Orifice In Valve Housing
31 - Modulation Valve
32 - Pressure Reducing Valve
36 - Pressure Regulating Valve
38 - Converter Relief Valve
43 - System Pressure Oil
44 - Medium Pressure Oil
47 - Return Oil
49 - Transmission Control Valve And Shift Valve-First Reverse

For theory see Power Shift Transmission Control Circuit-First Reverse in this group.
Keys and nomenclature will match where applicable.

CED,TX03399,5914-19-2000/01/28

642
 Manual Shift Modulation Valve Operation

Manual Shift Modulation Valve Operation

T115940-19: Modulation Valve

LEGEND:
A - Neutral
B - Start of Fill
C - Modulation
D - Engagement
E - Orifice In Valve Spool
F - Orifice In Valve Housing

643
 Manual Shift Modulation Valve Operation
G - Piston
H - Outer Spring
I - Inner Spring
J - Modulation Spool
K - System Pressure
L - Medium Pressure
M - Low Pressure
N - Return Pressure
O - Modulation Valve

Rate of shift from neutral into forward or reverse is controlled by movement of the
modulation valve and modulation piston during a shift. By regulating the amount of oil
flow being sent to engage the direction pack, the time required is extended to assure a
smooth shift.

When the machine is in neutral (A), system pressure oil (K) bleeds by the edge of the
modulation spool (J). This oil (M) (low pressure) flows through orifice (F) and that
passage is open to return. Low pressure oil (M) also flows through the orifice (E) to the
bottom side of the modulation spool (J). This oil applies sufficient force on the spring to
hold the valve on the edge of pressure port opening.

Forward and reverse clutch packs are also open to sump when in neutral.

The start of fill (B) mode begins when a shift to forward or reverse occurs. Shifting of the
forward/reverse spool allows oil to flow from the modulation valve to the neutral shift
valve and fill the clutch pack. Shifting of the forward/reverse spool also blocks the flow
of oil downstream of the orifice (F) from returning to tank and allows the pressure in the
modulation valve to build. The clutch pack fills rapidly at the low pressure level.

Modulation mode (C) begins as pressure in the clutch pack begins to rise (L). The
pressure is also being sensed through orifice (F). Pressure on the back side of orifice
(F) is building to low pressure (M). This pressure starts moving the piston (G), springs
(H and I) and modulation spool (J) down. There are two small orifices toward the top of
the piston (G) (not shown). The orifices allow return oil to dump to sump during the start
of fill and half way through modulation mode. This helps control the rate of shift. The
orifices in the piston close off as the piston moves down. An equalization of spring and
pressure forces on the modulation valve regulates the rate of clutch engagement during
modulation.

When the final engagement mode (D) is reached, the modulation spool (J) is in the fully
open position, and the two small orifices (not shown) in the modulation piston (G) are
closed off. With the spool in the fully open position, high pressure oil from the pressure
regulating valve maintains the downward force on the modulation piston and keeps the
644
 Manual Shift Modulation Valve Operation
clutch engaged until the next shift.

Cycling the forward/reverse spool or the neutral shift spool allows the high pressure oil
in the engaged clutch and between the orifice (F) and the top of the modulation piston to
vent to tank. The resulting loss in pressure allows the modulation valve to reset to begin
the next shift sequence.

CED,TX03399,4254-19-1998/06/23

645
 Power Shift Modulation Valve Operation

Power Shift Modulation Valve Operation

T114787-19: Modulation Valve

LEGEND:
A - Neutral
B - Start of Fill
C - Modulation
D - Engagement
E - Orifice
F - Orifice (in Valve Housing)

646
 Power Shift Modulation Valve Operation
G - Piston
H - Outer Spring
I - Inner Spring
J - Sequence Valve
K - Orifice In Duct Plate (Replenishing Orifice)
L - Modulation Spool
M - Orifice (2 used)
N - System Pressure
O - Medium High Pressure
P - Medium Pressure
Q - Low Pressure
R - Return Pressure
S - Modulation Valve

Rate of shift is controlled by movement of the modulation valve and modulation piston
during a shift. By regulating the amount of oil flow being sent to engage the direction
pack, the time required is extended to assure a smooth shift.

When the machine is in neutral (A), system pressure oil (N), bleeds by the edge of the
modulation spool (L). This oil (Q) (low pressure) flows through orifice (F), which is open
to return. Low pressure oil (Q), also flows through orifice (E) to the bottom side of the
modulation spool (L). This oil applies sufficient force on the spring to hold the valve on
the edge of pressure port opening.

All direction and speed clutch packs are also open to sump when the FNR is in neutral.

The start of fill mode (B), begins when a shift occurs. Shifting of the speed shift spools
allows oil to flow from the regulating valve through the orifice (K) to fill the speed clutch
pack. Shifting of the forward/reverse spool allows oil to flow from the modulation valve
and will fill the direction clutch pack. Shifting of the forward/reverse spool also blocks
the flow of oil downstream of the orifice (F) from returning to tank and allows the
pressure in the modulation valve to build. Both direction and speed clutch packs fill
rapidly at the low pressure level.

Modulation mode (C), begins as pressure in the clutch pack begins to rise (P). The
pressure is also being sensed through orifice (F). Pressure on the back side of orifice
(F) is building to low pressure (Q). This pressure starts moving the modulation piston
(G), springs (H and I) and modulation spool (L), down. There are two small orifices (M)
located near the top of the piston (G). These orifices allow return oil to dump to sump
during start of fill and half way through modulation mode. This helps control the rate of
shift. The orifices in the piston close off as the piston moves down. An equalization of
spring and pressure forces on the modulation valve regulates the rate of clutch

647
 Power Shift Modulation Valve Operation
engagement during modulation.

The orifice in duct plate (replenishing orifice) (K), supplies oil from the pressure
regulating valve to the speed shift valves. The sequence valve (J) supplies oil from the
modulation valve to the speed shift valves also, but only when the oil downstream of the
orifice in duct plate (replenishing orifice) (K) is below the modulation pressure filling the
direction clutch pack. This insures that the speed clutch fills and engages before the
direction clutch.

When the final engagement mode (D) is reached, the modulation spool (L) is in the fully
open position, and the two small orifices (M) in the modulation piston (G) are closed off.
With the spool in the fully open position, high pressure oil from the pressure regulating
valve maintains the downward force on the modulation piston and keeps the clutches
engaged until the next shift.

Cycling the forward/reverse spool allows the high pressure oil in the engaged clutch
and between the orifice (F) and the top of the modulation piston to vent to tank. The
resulting loss in pressure allows the modulation valve to reset to begin the next shift
sequence.

CED,TX03399,4225-19-1998/03/27

648
 Differential Operation

Differential Operation

T101246-19: Differential
LEGEND:
A - Final Drive Ring Gear
B - Differential Housing
C - Differential Ring Gear
D - Bevel Pinion Shaft (2 used)
E - Bevel Pinion (4 used)
F - Input Pinion Shaft

649
 Differential Operation
G - Side Gear
H - Sun Pinion Shaft
I - Planet Pinion Carrier
J - Output Shaft
K - Differential

The differential allows independent rotation of the axles when the machine is steered.
The final drive planetaries are attached to the axles. Their purpose is to reduce speed
and increase torque through gear reduction. The input pinion shaft to differential ring
gear also provides a reduction in speed and an increase to torque.

Input torque from the drive shaft rotates the input bevel pinion shaft (F) which meshes
with the differential ring gear (C), causing it to turn. The ring gear is fastened to the
differential housing (B) which drives the bevel pinion shafts (D) and bevel pinions (E).
The bevel pinions located on the bevel pinion shaft are in mesh with the side gears (G)
which spline to the sun pinion shaft (H).

The sun pinion shaft meshes with the planet pinion carrier assembly (I) which rotates
around the inside of the stationary planetary final drive ring gear (A). Torque is
transferred into the output shaft (J) causing it to rotate at a reduced speed but with
greater torque.

As the machine is steered, the inside wheel slows down in relation to the outside wheel.
This causes the side gear, attached to the inside wheel’s axle, to slow down. The
rotating differential housing and bevel pinion shafts allow the differential bevel pinions to
rotate around the slow moving side gear; this allows the opposite side gear to rotate at
a faster speed. This rotation causes the outside wheel’s axle to rotate faster than the
inside axle which prevents tire scuffing.

TX,05,SS3139-19-1998/06/23

650
 Differential Lock Operation

Differential Lock Operation

T101241-19: Differential Lock

LEGEND:
A - Side Gear
B - Differential Housing
C - Bearing
D - Brake Housing
E - Piston
F - Differential Solenoid Valve
G - Sliding Gear
H - From Transmission Pump
I - Spring
J - System Pressure
K - Return Pressure
L - Differential Lock

When the operator has the differential lock foot control switch in the "OFF" position, the
spring force (I) moves the sliding gear (G) and piston (E) back releasing the differential
651
 Differential Lock Operation
lock. The return oil returns through the same port as when the switch is in the "ON"
position.

When the operator pushes the differential lock foot control switch to the "ON" position,
the switch energizes the differential lock solenoid on the transmission. When the
differential lock solenoid (F) is energized, pressure oil flows to the inlet and through the
cross-drilled passages to the piston (E). The pressurized oil moves the piston (E)
against the sliding gear locking the sliding gear with side gear (A) of the differential,
causing both axles to rotate at the same speed.

TX,05,SS3130-19-1998/07/23

652
 John Deere Brake Valve Operation

John Deere Brake Valve Operation

T101247-19: Brake Valve

LEGEND:
A - High Pressure
B - Return Oil
C - Return Port
D - Check Valve
E - Right Brake Pedal
F - Left Brake Pedal
G - Equalizing Valve
H - Piston (2 used)
I - Brake Bleed Screw (2 used)
J - Brake Disk and Plates (3 used)

653
 John Deere Brake Valve Operation
K - Brake Pressure Plate (2 used)
L - Inlet to Brake Piston
M - Inlet Port
N - Brake Valve

The brake system is hydraulic with no mechanical connection between the brake valve
and the brake pressure plates. The brake valve reservoir is filled with return oil from the
hydraulic system.

The brake valve is activated by two brake pedals that allow individual or simultaneous
operation of brake pressure plates that are located in the brake housing of each axle.

When the brakes are engaged, the brake pressure plate applies force on the brake disk
and plates which are connected to the final drive pinion shaft.

TX,05,SS3131-19-2000/03/14

654
 Service Brake Operation

Service Brake Operation

T101300-19: Service Brake

LEGEND:
A - Disk (3 used)
B - Plate (4 used)
C - Piston
D - From Brake Valve
E - Brake Housing
F - Adjusting Screw
G - Hub
H - Sun Gear Shaft
I - Service Brake

The rear axle assembly uses wet multi-disk brakes which are self-adjusting to
compensate for wear. The disks are splined to the sun gear shaft and the plates are
splined to the rear axle housing.
655
 Service Brake Operation

When the service brakes are applied, the pressure oil from the brake valve (D), forces
the brake piston (C) against the brake plates (B) and disks (A) which stops rotation of
the sun gear shaft (H). When the brakes are released the return oil flows back out the
same port to the brake valve.

TX,05,SS3133-19-1996/05/16

656
 MICO Power Boost Brake Valve-Neutral Position

MICO Power Boost Brake Valve-Neutral Position

T129233-UN:
LEGEND:
1 - Push Rod (Brake Pedal)
2 - Check Ball
3 - Land
4 - Inlet Port
5 - Spring
6 - Spring
7 - Seal
8 - Piston
9 - Valve Assembly
10 - Hydraulic Reservoir Port
11 - Spring
12 - Brake Port
13 - Spool
14 - Brake Port
15 - Spring
16 - Hydraulic Reservoir Port

657
 MICO Power Boost Brake Valve-Neutral Position
17 - Valve Assembly
18 - Piston
19 - Seal
20 - Spring
21 - Spring
22 - Inlet port
23 - Land
24 - Check Ball
25 - Push Rod (Brake Pedal)
26 - Transmission Reservoir Port
27 - Pressure Free Oil
28 - Low Pressure Oil
29 - Neutral Position-Engine On

Oil from the transmission enter ports (4 and 22) separately. This oil flows thru land
areas (3 and 23), thru the center of pistons (8 and 18) and on to the transmission
reservoir port (26).

The two halves of the master cylinder reservoir are open to one another. Hydraulic oil
enters the master cylinder reservoir at port (10) and exits at port (16). A small flow of oil
thru these ports keeps the master cylinder reservoir full.

In the neutral position, pistons (8 and 18) are fully retracted and valve assemblies (9
and 17) are open. The brake system is at reservoir pressure thru brake ports (12 and
14).

The pedals are held in the neutral position by spring (5 and 6) and springs (20 and 21).

CED,TX03768,2711-19-2000/03/14

658
 MICO Power Boost Brake Valve-Both Pedals Applied Position

MICO Power Boost Brake Valve-Both Pedals Applied Position

T129234-UN:
LEGEND:
1 - Push Rod (Brake Pedal)
2 - Check Ball
3 - Land
4 - Inlet Port
5 - Spring
6 - Spring
7 - Seal
8 - Piston
9 - Valve Assembly
10 - Hydraulic Reservoir Port
11 - Spring
12 - Brake Port
13 - Spool
14 - Brake Port
15 - Spring
16 - Hydraulic Reservoir Port

659
 MICO Power Boost Brake Valve-Both Pedals Applied Position
17 - Valve Assembly
18 - Piston
19 - Seal
20 - Spring
21 - Spring
22 - Inlet port
23 - Land
24 - Check Ball
25 - Push Rod (Brake Pedal)
26 - Transmission Reservoir Port
27 - Pressure Free Oil
28 - Low Pressure Oil
29 - Medium Pressure Oil
30 - High Pressure Oil
31 - Both Pedals Applied-Engine On

Oil from the transmission enters ports (4 and 22) separately and drains to transmission
reservoir port (26). Both pedals are depressed forcing springs (5 and 21) to compress.
Oil flowing thru land areas (3 and 23) becomes restricted. Oil flow moves to close check
balls (2 and 24). Restricted oil flow and lands (3 and 23) causes pressure to act against
the large diameter of pistons (8 and 18). Pistons (8 and 18) move to compress springs
(6 and 20). As more push rod displacement occurs, valve assemblies (9 and 17) close,
stopping brake system oil from moving to reservoir or atmosphere pressure. Additional
movement of the push rods and pistons (8 and 18) forces brake system oil to the brakes
causing brakes to fill thru ports (12 and 14).

Spool (13) moves against either spring (11 or 15) to perform an equalization function by
compensating for differences between right and left brake pack fill volumes.

After the brakes are filled, higher brake pressure is developed by the inlet oil pressure
being modulated at lands (3 and 23). causing piston (8 and 18) to generate a higher
pressure at the brake ports. Brake pedal modulated feel is determined by the hydraulic
areas of push rods (1 and 25) and modulated pressure at lands (3 and 23).

Maximum boosted brake pressure is limited by the inlet oil pressure at ports (4 and 22).
Additional pedal effort can cause higher brake pressure and is dependent only by the
amount of pedal force applied.

CED,TX03768,2712-19-2000/03/14

660
 MICO Power Boost Brake Valve-One Pedal Applied Position

MICO Power Boost Brake Valve-One Pedal Applied Position

T129235-UN:
LEGEND:
1 - Push Rod (Brake Pedal)
2 - Check Ball
3 - Land
4 - Inlet Port
5 - Spring
6 - Spring
7 - Seal
8 - Piston
9 - Valve Assembly
10 - Hydraulic Reservoir Port
11 - Spring
12 - Brake Port
13 - Spool
14 - Brake Port
15 - Spring
16 - Hydraulic Reservoir Port

661
 MICO Power Boost Brake Valve-One Pedal Applied Position
17 - Valve Assembly
18 - Piston
19 - Seal
20 - Spring
21 - Spring
22 - Inlet port
23 - Land
24 - Check Ball
25 - Push Rod (Brake Pedal)
26 - Transmission Reservoir Port
27 - Pressure Free Oil
28 - Low Pressure Oil
29 - Medium Pressure Oil
30 - High Pressure Oil
31 - One Pedal Applied-Engine On

When only one pedal is applied, the opposite side brake remains at reservoir pressure.
The effort required on one pedal is one half that of the effort when apply both pedals to
obtain the same brake pressure.

CED,TX03768,2713-19-2000/03/14

662
 MICO Power Boost Brake Valve-Both Pedals Applied, Engine Off Position

MICO Power Boost Brake Valve-Both Pedals Applied, Engine Off

Position

T129236-UN:
LEGEND:
1 - Push Rod (Brake Pedal)
2 - Check Ball
3 - Land
4 - Inlet Port
5 - Spring
6 - Spring
7 - Seal
8 - Piston
9 - Valve Assembly
10 - Hydraulic Reservoir Port
11 - Spring
12 - Brake Port
13 - Spool
14 - Brake Port
15 - Spring
663
 MICO Power Boost Brake Valve-Both Pedals Applied, Engine Off Position
16 - Hydraulic Reservoir Port
17 - Valve Assembly
18 - Piston
19 - Seal
20 - Spring
21 - Spring
22 - Inlet port
23 - Land
24 - Check Ball
25 - Push Rod (Brake Pedal)
26 - Transmission Reservoir Port
27 - Pressure Free Oil
28 - High Pressure Oil
29 - Both Pedals Applied-Engine Off

When the engine is not running, one or both brakes can be actuated manually. When
push rods (1 and 25) are displaced by the pedals, springs (5 and 21) compress until
lands (3 and 23) are mechanically closed. Additional push rod displacement forces
pistons (8 and 18) to move. Valve assemblies (9 and 17) close, stopping oil from gong
to the hydraulic reservoir. More push rod travel fills the brakes and pressure is
developed to provide pedal force. The amount of pressure to the brakes depends on
how hard the pedals are pushed. When the pedals return to the neutral position, valve
assemblies (9 and 17) open and return brakes to reservoir pressure.

CED,TX03768,2714-19-2000/03/14

664
 Park Brake Operation

Park Brake Operation

T101244-19: Park Brake-On

LEGEND:
A - Spring Plate
B - Spring Washer
C - Towing Cap Screw
D - Disk (3 used)
E - Plate (2 used)
F - Piston
G - From Transmission Pump
H - Park Brake Solenoid Valve
I - System Pressure
J - Return Pressure

665
 Park Brake Operation
K - Park Brake-ON

The park brake is spring applied and hydraulically released. When the park brake is
applied (ON) or machine is shut-off, spring force applies the park brake. The spring
washer (B) forces the piston (F) against brake disks (D) and plates (E) on the axle input
shaft.

When park brake switch is cycled to the OFF position, the switch energizes the park
brake solenoid (H) on the transmission. The solenoid routes transmission system
pressure oil (I) to the park brake piston (F). The piston moves against the spring washer
(B) and releases the disks and plates (D and E). Two manual operated cap screws (C)
release the park brake for emergency towing.

TX,05,SS3134-19-1996/05/16

666
 MFWD Differential Operation-Unequal Traction

MFWD Differential Operation-Unequal Traction

T6058AL-UN: MFWD Differential-Unequal Traction

LEGEND:
A - Tire With Most Traction
B - Drive Shaft
C - R.H. Drive Gear
D - L.H. Drive Gear
E - Pinion Gears
F - Differential Housing
G - Clutch Disks
H - Clutch Plate
I - Power Flow
J - Rotation Direction

As available traction changes, tire with better traction (A) can use move power. Self-
limiting differential action begins to occur.

When one wheel begins to slip more than the other, wheel with better traction hold its
drive shaft (B) and drive gear (C) from rotating. Wheel with less traction provides less
resistance against its drive gear (D).

Pinion gears (E) continue to be driven by rotating differential housing (F). These pinion

667
 MFWD Differential Operation-Unequal Traction
gears push against bevel drive gears as before. Angle of gear teeth tries to force
meshed gears apart. On the side with more traction, pinion gears begin to "walk" around
drive gear and push against restraining force transmitted from tire. Drive gear is
wedged outward and compresses a clutch pack with disks (G) splined to axle and plates
(H) tanged to housing. Disks begin to slip less against plates as compressing force
increases. As the pack slippage decreases driveshaft begins to receive driving force
through the differential housing.

Since the tire with less traction is exerting less force trying to keep its axle from turning,
the bevel gear does not force the drive gear outward and its clutch pack increases its
slip. Less drive force is being transmitted to this drive shaft. As long as the difference in
traction between tires remains the same, the clutch pack on the side with less traction
will continue to slip more than pack for other side.

With MFWD engaged, differential works to automatically balance driving power to

available traction.

TX,05,SS3140-19-2000/01/26

668
 MFWD Differential Operation-Equal Traction-If Equipped

MFWD Differential Operation-Equal Traction-If Equipped

T6058AM-UN: MFWD Differential Operation-Equal

LEGEND:
A - Differential Drive Shaft
B - Ring Gear
C - Differential Housing
D - Pinions
E - Bevel Drive Gears
F - Drive Shafts
G - Power Flow
H - Rotation Direction

Differential unit has self-applied, limited slip feature. When engaged under slippery field
conditions, this system automatically applies correct amount of torque to match traction
available to each tire.

With MFWD engaged, when tractor is moving in a straight line and each tire has equal
traction, equal power is supplied to left and right axle. No differential action occurs.

Power flows into axle housing through differential drive shaft (A), turning ring gear (B)
and attached differential housing (C). When both wheels have equal traction, pinions
(D) remain stationary within rotating housing. Pinions turn bevel drive gears (E) and
drive shafts (F) splined to drive gears.
669
MFWD Differential Operation-Equal Traction-If Equipped

TX,05,SS3141-19-2000/01/26

670
 Diagnose Manual Shift Power Train Malfunction

Diagnose Manual Shift Power Train Malfunction

NOTE:

Diagnose malfunction charts are arranged from most probable and

simplest to verify. Remember the following steps when troubleshooting
a problem:

Step 1. Operational Checkout Procedure (See Group 9005-10.)

Step 2. Diagnose Malfunctions Charts (See Group 9020-15.)

Step 3. Adjustments and/or Tests (See Group 9020-20 and/or 9020-

25.)

671
Diagnose Manual Shift Power Train Malfunction

672
 Diagnose Manual Shift Power Train Malfunction

Symptom Problem Solution

Machine Will Low oil level in Add oil to correct level. See Group 9000-04.
Not Move in transmission
Forward or
Reverse

Brakes Dragging Adjust Brake Pedals and Equalizing Valves. See

Group 9020-20. Check brake valve and repair.
See repair manual, Group 1060.

Park brake not Check park brake solenoid. See Group 9015-10.
releasing

Neutral disconnect Check switch. See Group 9015-15.

not disengaging

Leaking clutch Do Forward and Reverse Pressure Test in Group

piston O-ring 9020-25. See repair manual, Group 0350.

Piston in clutch Check System Pressure, Forward and Reverse

pack stuck Clutch Pressure. See Group 9020-25. If OK,
mechanical problem is indicated. See repair
manual, Group 0350.

Piston ball does not Do Forward and Reverse Clutch Pressure Test.
seat See Group 9020-25.

Torque Converter Inspect and repair. See repair manual, Group

Flexplate broken 0350 for Removal and Installation. See Group
0651 for Disassemble and Assemble.

Worn or slipping Check system pressure. See Group 9020-25.

forward/reverse
clutch disks

673
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Incorrect shim Do Modulation Pressure Test. See Group 9020-

under modulation 25. Repair, and adjust. See Group 0360.
piston.

Restricted Do Modulation Valve Pressure Test in Group

modulation orifice 9020-25. Remove orifice and check for
contamination and/or plugged. See repair manual,
Group 0360.

Stuck spool in Remove and inspect control valve spools. See

control valve repair manual, Group 0360.

Low or no system Check system pressure. See Group 9020-25.

pressure

Low torque Do Torque Converter Stall Speed Test. See Group

converter oil 9020-25
flow/pressure

Clutch shaft sealing Do Forward or Reverse Pressure Test. See Group

rings leaking 9020-25

Synchronizer worn Repair transmission synchronizers. See repair

manual, Group 0350.

FNR solenoids not See 9015-15. Check solenoids for leakage. See
working group 9020-25.

Converter drive Replace converter. See repair manual, Group

splines worn or not 0651.
engaged in pump
drive shaft

674
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Pump gears seized Replace pump assembly, inspect and replace

pump drive parts as necessary. See repair
manual, Group 0360.

Mechanical failure Inspect transmission and repair. See repair

in transmission manual, Group 0350.

Transmission Repair or replace parts as necessary. See repair

shifter forks and/or manual, Group 0350.
shaft broken

Broken drive shafts Inspect drive shafts and universal joints for
external damage. See repair manual, Group 0325.

Broken ring or If drive shafts rotate with transmission in gear but

pinion gear machine does not move a differential failure is
indicated. Repair. See Rear Axle, Group 0250.

Transmission Low oil level Add oil. See Group 9000-04.

Slippage

Wrong oil grade Change oil. See Group 9000-04

Restricted Do Modulation Valve Pressure Test in Group

modulation orifice 9020-25. Remove orifice and check for
contamination and/or plugged. See repair manual,
Group 0360.

Leaking clutch Do Forward and Reverse Pressure Test in Group

piston O-ring 9020-25. See repair manual, Group 0350.

Piston ball does not Do Forward and Reverse Clutch Pressure Test.
seat See Group 9020-25. See repair manual, Group
0350.

675
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Clutch shaft sealing Do Forward or Reverse Pressure Test. See Group

rings leaking 9020-25. See repair manual, Group 0350.

Worn or slipping Check system pressure or circuit pressure. See

forward/reverse Group 9020-25. See repair manual, Group 0350.
clutch disks

Leak in Remove valve and inspect gaskets. See repair

transmission control manual, Group 0360.
valve or gaskets

Low torque Do Torque Converter Stall Speed Test. See Group

converter oil 9020-25.
flow/pressure

Low transmission Do Transmission Pump Flow Test. See Group

pump flow due to 9020-25. See repair manual, Group 0360.
worn pump

Weak or broken Do Transmission System Pressure Test. See

pressure regulating Group 9020-25. See repair manual, Group 0360.
valve spring

Machine Warped disks and Check transmission. See Repair, Group 0350.
“Creeps” with plates in
FNR in transmission
Neutral

Piston in clutch Check System Pressure and Forward and

pack stuck Reverse Clutch pressure. See Group 9020-25.
See repair manual, Group 0350.

676
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Ball pressed in end Check Forward or Reverse Clutch Pressure. See

of clutch shafts Group 9020-25. See repair manual, Group 0350.
(lube passage)
came out

Clutch ball stuck Do Forward and Reverse Pressure Test. See

shut Group 9020-25

Internal leakage in Do Pump Flow Test. See Group 9020-25.

control valve

Solenoids stuck Check solenoids. See Group 9015-15.

Machine Oil level is low Add oil to correct level. See Group 9000-04.
Lacks Power
or Moves
Slow

Wrong oil, aerated Change oil. See Group 9000-04.

oil

Brake dragging Check for excessive heat in brake area of axle

housing after operating machine. See repair
manual, Group 0250.

Park brake Repair park brake in rear axle. See repair manual,
dragging, piston Group 0250.
stuck

Engine fast idle Check fast idle adjustment. See Group 9020-20.
speed set too low

677
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Low pressure in Do Transmission System Pressure Test. See

transmission Group 9020-25.
system

Restricted Do Modulation Valve Pressure Test in Group

modulation orifice 9020-25. Remove orifice and check for
contamination and /or plugged. See repair
manual, Group 0360.

Leaking clutch Do Forward and Reverse Pressure Test in Group

piston O-ring 9020-25. See repair manual, Group 0350.

Piston ball does not Do Forward and Reverse Clutch Pressure Test.
seat See Group 9020-25

Clutch pack slipping Do Transmission System Pressure Test. See

Group 9020-25.

Clutch pack Repair clutch pack. See repair manual, Group

dragging, disks 0350.
warped

Clutch shaft sealing Do Forward or Reverse Pressure Test. See Group

ring leaking 9020-25

Clutch ball stuck Do Forward and Reverse Pressure Test. See

shut Group 9020-25.

Internal leakage in Do Pump Flow Test. See Group 9020-25.

control valve

Failed torque Do Torque Converter Stall Speed Test. See Group

converter 9020-25.

678
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Wrong torque Do Torque Converter Stall Test in Group 9020-25.

converter Check number of torque converter through access
hole under machine (either 247002 or 4168-028-
211).

Low engine power Do Engine Performance Test. See Group 9010-

25.

Mechanical failure Inspect. See repair manual, Group 0250 or 0350.

in transmission or
axle

Transmission Low or high oil level Add oil or drain. See Group 9000-04.
Shifts Too (aeration of oil)
Slow

Wrong oil Change oil. See Group 9000-04.

Pressure regulating Do Reducing Valve Pressure Test. See Group

valve setting 9020-25.
incorrect

Clutch pack slipping Do System Pressure Test. See Group 9020-25.

Repair. See repair manual, Group 0350.

Control valve Do Pump Flow Test. See Group 9020-25 Repair.

leaking internally

Control valve Do Modulation Valve Pressure Test in Group

modulation piston 9020-25. Repair. See repair manual, Group 0360.
not shim properly

679
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Modulation piston Do Modulation Valve Pressure Test. See Group

spring broken 9020-25. Remove control valve cover and inspect
modulation piston and spring. See repair manual,
Group 0360.

Restricted oil Do Forward and Reverse Pressure Test. See

passage to clutch Group 9020-25.
pack

Transmission pump Do Pump Flow Test and System Pressure Test.

malfunction See Group 9020-25.

Transmission pump Repair transmission. See repair manual, Group

oil pickup blocked 0360.

Transmission Modulation valve Do Modulation Valve Pressure Test. See Group

Shifts Too blocked 9020-25.
Fast

Modulation valve Do Modulation Valve Pressure Test in Group

piston stuck or 9020-25. Remove control valve cover and inspect
spring broken modulation piston and spring. Repair, see Group
0360.

Modulation orifice Do Modulation Pressure Test. See Group 9020-

out of place or 25. See repair manual, Group 0360.
missing

Transmission Oil level too high or Check oil level and correct. See Group 9000-04.
Overheats too low

Transmission Check switch. See Group 9015-15

Temperature
Indicator light is on

680
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Incorrect type of oil Drain and replace oil. See Group 9000-04.

Clutch pack Repair transmission. See Group 0350.

dragging, worn
disks

Torque converter Do Torque Converter Stall Speed Test. See Group

malfunction 9020-25. See repair manual, Group 0350.

Torque converter Use neutral disconnect switch in machine

stalled excessively operations to reduce stall.

Operating in too Operate one gear lower. See Operator’s Manual.

high a gear

Oil cooler air flow Inspect and clean exterior of cooler. Do Air Flow
restricted Test. See Group 9010-25.

Missing baffles, Inspect and check belt. See Group 9010-20.

damaged fan Check baffles and repair. See repair manual,
shrouds or loose Group 0510.
fan belt

Oil cooler restricted Flush Cooling System. See CTM104.

internally

Converter flow Do Converter In/Out Pressure Test. See Group

blocked by pump 9020-25.
stop

Oil flow to or from Do Cooler-In/Out Pressure Test. See Group 9020-

cooler restricted 25.

681
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Converter-in relief Remove valve, inspect and repair. See Repair,

valve stuck open or Group 0360.
broken spring

Low transmission Do Pump Flow Test. See Group 9020-25.

pump flow

Transmission Inspect transmission and repair. See Repair

mechanical manual, Group 0350.
malfunction

Engine Over-fueled Remove fuel injection pump. See your authorized

Injection Pump Service Center

Excessive Engine low idle too Check engine slow idle speed. See Group 9010-
Power Train slow 20.
Noise

Oil level low Fill to correct oil level. See Group 9000-04.

Worn or damaged Check transmission filter for metal particles.

parts in Repair as necessary. See repair manual, Groups
transmission or axle 0250 and 0350.

Worn universal Inspect universal joints or drive shaft. See repair

joints on drive shaft manual, Group 0325.

Misalignment of Check position of components. Be sure they are

power train setting on mounts correctly.
components

No oil in lube circuit Do Converter Relief Valve Pressure Test. See

Group 9020-25.

682
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Hydraulic lines in Inspect all hydraulic lines and repair. See

contact with power Hydraulic Component Location in Group 9025-05.
train components

Assembly Isolate where noise is coming from. Adjust. Repair.

adjustments or Check mounts.
setting made
incorrectly

Excessive Attempt to shift too See Operator’s Manual for instructions.

Gear Clash fast
When Shifting

Shifting without Depress neutral disconnect when shifting. See

using neutral Operator’s Manual.
disconnect

Shifters worn or Inspect and replace as necessary. See repair

broken manual, Group 0315.

Synchronizer Repair transmission synchronizers. See repair

malfunction manual, Group 0350.

Park Brake Park brake solenoid Test solenoid. See Group 9015-15.
Pressure not working
Light Comes
On

Park brake piston Do Park Brake Release Pressure Test. See Group
leak 9020-25.
TX,15,SS3144-19-2000/01/28

Park brake hose Do Park Brake Release Pressure Test. See Group
leaking 9020-25. Inspect and repair leak.

683
 Diagnose Manual Shift Power Train Malfunction

Diagnose Manual Shift Power Train Malfunction

NOTE:

Diagnose malfunction charts are arranged from most probable and

simplest to verify. Remember the following steps when troubleshooting
a problem:

Step 1. Operational Checkout Procedure (See Group 9005-10.)

Step 2. Diagnose Malfunctions Charts (See Group 9020-15.)

Step 3. Adjustments and/or Tests (See Group 9020-20 and/or 9020-

25.)

684
Diagnose Manual Shift Power Train Malfunction

685
 Diagnose Manual Shift Power Train Malfunction

Symptom Problem Solution

Machine Will Low oil level in Add oil to correct level. See Group 9000-04.
Not Move in transmission
Forward or
Reverse

Brakes Dragging Adjust Brake Pedals and Equalizing Valves. See

Group 9020-20. Check brake valve and repair.
See repair manual, Group 1060.

Park brake not Check park brake solenoid. See Group 9015-10.
releasing

Neutral disconnect Check switch. See Group 9015-15.

not disengaging

Leaking clutch Do Forward and Reverse Pressure Test in Group

piston O-ring 9020-25. See repair manual, Group 0350.

Piston in clutch Check System Pressure, Forward and Reverse

pack stuck Clutch Pressure. See Group 9020-25. If OK,
mechanical problem is indicated. See repair
manual, Group 0350.

Piston ball does not Do Forward and Reverse Clutch Pressure Test.
seat See Group 9020-25.

Torque Converter Inspect and repair. See repair manual, Group

Flexplate broken 0350 for Removal and Installation. See Group
0651 for Disassemble and Assemble.

Worn or slipping Check system pressure. See Group 9020-25.

forward/reverse
clutch disks

686
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Incorrect shim Do Modulation Pressure Test. See Group 9020-

under modulation 25. Repair, and adjust. See Group 0360.
piston.

Restricted Do Modulation Valve Pressure Test in Group

modulation orifice 9020-25. Remove orifice and check for
contamination and/or plugged. See repair manual,
Group 0360.

Stuck spool in Remove and inspect control valve spools. See

control valve repair manual, Group 0360.

Low or no system Check system pressure. See Group 9020-25.

pressure

Low torque Do Torque Converter Stall Speed Test. See Group

converter oil 9020-25
flow/pressure

Clutch shaft sealing Do Forward or Reverse Pressure Test. See Group

rings leaking 9020-25

Synchronizer worn Repair transmission synchronizers. See repair

manual, Group 0350.

FNR solenoids not See 9015-15. Check solenoids for leakage. See
working group 9020-25.

Converter drive Replace converter. See repair manual, Group

splines worn or not 0651.
engaged in pump
drive shaft

687
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Pump gears seized Replace pump assembly, inspect and replace

pump drive parts as necessary. See repair
manual, Group 0360.

Mechanical failure Inspect transmission and repair. See repair

in transmission manual, Group 0350.

Transmission Repair or replace parts as necessary. See repair

shifter forks and/or manual, Group 0350.
shaft broken

Broken drive shafts Inspect drive shafts and universal joints for
external damage. See repair manual, Group 0325.

Broken ring or If drive shafts rotate with transmission in gear but

pinion gear machine does not move a differential failure is
indicated. Repair. See Rear Axle, Group 0250.

Transmission Low oil level Add oil. See Group 9000-04.

Slippage

Wrong oil grade Change oil. See Group 9000-04

Restricted Do Modulation Valve Pressure Test in Group

modulation orifice 9020-25. Remove orifice and check for
contamination and/or plugged. See repair manual,
Group 0360.

Leaking clutch Do Forward and Reverse Pressure Test in Group

piston O-ring 9020-25. See repair manual, Group 0350.

Piston ball does not Do Forward and Reverse Clutch Pressure Test.
seat See Group 9020-25. See repair manual, Group
0350.

688
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Clutch shaft sealing Do Forward or Reverse Pressure Test. See Group

rings leaking 9020-25. See repair manual, Group 0350.

Worn or slipping Check system pressure or circuit pressure. See

forward/reverse Group 9020-25. See repair manual, Group 0350.
clutch disks

Leak in Remove valve and inspect gaskets. See repair

transmission control manual, Group 0360.
valve or gaskets

Low torque Do Torque Converter Stall Speed Test. See Group

converter oil 9020-25.
flow/pressure

Low transmission Do Transmission Pump Flow Test. See Group

pump flow due to 9020-25. See repair manual, Group 0360.
worn pump

Weak or broken Do Transmission System Pressure Test. See

pressure regulating Group 9020-25. See repair manual, Group 0360.
valve spring

Machine Warped disks and Check transmission. See Repair, Group 0350.
“Creeps” with plates in
FNR in transmission
Neutral

Piston in clutch Check System Pressure and Forward and

pack stuck Reverse Clutch pressure. See Group 9020-25.
See repair manual, Group 0350.

689
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Ball pressed in end Check Forward or Reverse Clutch Pressure. See

of clutch shafts Group 9020-25. See repair manual, Group 0350.
(lube passage)
came out

Clutch ball stuck Do Forward and Reverse Pressure Test. See

shut Group 9020-25

Internal leakage in Do Pump Flow Test. See Group 9020-25.

control valve

Solenoids stuck Check solenoids. See Group 9015-15.

Machine Oil level is low Add oil to correct level. See Group 9000-04.
Lacks Power
or Moves
Slow

Wrong oil, aerated Change oil. See Group 9000-04.

oil

Brake dragging Check for excessive heat in brake area of axle

housing after operating machine. See repair
manual, Group 0250.

Park brake Repair park brake in rear axle. See repair manual,
dragging, piston Group 0250.
stuck

Engine fast idle Check fast idle adjustment. See Group 9020-20.
speed set too low

690
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Low pressure in Do Transmission System Pressure Test. See

transmission Group 9020-25.
system

Restricted Do Modulation Valve Pressure Test in Group

modulation orifice 9020-25. Remove orifice and check for
contamination and /or plugged. See repair
manual, Group 0360.

Leaking clutch Do Forward and Reverse Pressure Test in Group

piston O-ring 9020-25. See repair manual, Group 0350.

Piston ball does not Do Forward and Reverse Clutch Pressure Test.
seat See Group 9020-25

Clutch pack slipping Do Transmission System Pressure Test. See

Group 9020-25.

Clutch pack Repair clutch pack. See repair manual, Group

dragging, disks 0350.
warped

Clutch shaft sealing Do Forward or Reverse Pressure Test. See Group

ring leaking 9020-25

Clutch ball stuck Do Forward and Reverse Pressure Test. See

shut Group 9020-25.

Internal leakage in Do Pump Flow Test. See Group 9020-25.

control valve

Failed torque Do Torque Converter Stall Speed Test. See Group

converter 9020-25.

691
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Wrong torque Do Torque Converter Stall Test in Group 9020-25.

converter Check number of torque converter through access
hole under machine (either 247002 or 4168-028-
211).

Low engine power Do Engine Performance Test. See Group 9010-

25.

Mechanical failure Inspect. See repair manual, Group 0250 or 0350.

in transmission or
axle

Transmission Low or high oil level Add oil or drain. See Group 9000-04.
Shifts Too (aeration of oil)
Slow

Wrong oil Change oil. See Group 9000-04.

Pressure regulating Do Reducing Valve Pressure Test. See Group

valve setting 9020-25.
incorrect

Clutch pack slipping Do System Pressure Test. See Group 9020-25.

Repair. See repair manual, Group 0350.

Control valve Do Pump Flow Test. See Group 9020-25 Repair.

leaking internally

Control valve Do Modulation Valve Pressure Test in Group

modulation piston 9020-25. Repair. See repair manual, Group 0360.
not shim properly

692
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Modulation piston Do Modulation Valve Pressure Test. See Group

spring broken 9020-25. Remove control valve cover and inspect
modulation piston and spring. See repair manual,
Group 0360.

Restricted oil Do Forward and Reverse Pressure Test. See

passage to clutch Group 9020-25.
pack

Transmission pump Do Pump Flow Test and System Pressure Test.

malfunction See Group 9020-25.

Transmission pump Repair transmission. See repair manual, Group

oil pickup blocked 0360.

Transmission Modulation valve Do Modulation Valve Pressure Test. See Group

Shifts Too blocked 9020-25.
Fast

Modulation valve Do Modulation Valve Pressure Test in Group

piston stuck or 9020-25. Remove control valve cover and inspect
spring broken modulation piston and spring. Repair, see Group
0360.

Modulation orifice Do Modulation Pressure Test. See Group 9020-

out of place or 25. See repair manual, Group 0360.
missing

Transmission Oil level too high or Check oil level and correct. See Group 9000-04.
Overheats too low

Transmission Check switch. See Group 9015-15

Temperature
Indicator light is on

693
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Incorrect type of oil Drain and replace oil. See Group 9000-04.

Clutch pack Repair transmission. See Group 0350.

dragging, worn
disks

Torque converter Do Torque Converter Stall Speed Test. See Group

malfunction 9020-25. See repair manual, Group 0350.

Torque converter Use neutral disconnect switch in machine

stalled excessively operations to reduce stall.

Operating in too Operate one gear lower. See Operator’s Manual.

high a gear

Oil cooler air flow Inspect and clean exterior of cooler. Do Air Flow
restricted Test. See Group 9010-25.

Missing baffles, Inspect and check belt. See Group 9010-20.

damaged fan Check baffles and repair. See repair manual,
shrouds or loose Group 0510.
fan belt

Oil cooler restricted Flush Cooling System. See CTM104.

internally

Converter flow Do Converter In/Out Pressure Test. See Group

blocked by pump 9020-25.
stop

Oil flow to or from Do Cooler-In/Out Pressure Test. See Group 9020-

cooler restricted 25.

694
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Converter-in relief Remove valve, inspect and repair. See Repair,

valve stuck open or Group 0360.
broken spring

Low transmission Do Pump Flow Test. See Group 9020-25.

pump flow

Transmission Inspect transmission and repair. See Repair

mechanical manual, Group 0350.
malfunction

Engine Over-fueled Remove fuel injection pump. See your authorized

Injection Pump Service Center

Excessive Engine low idle too Check engine slow idle speed. See Group 9010-
Power Train slow 20.
Noise

Oil level low Fill to correct oil level. See Group 9000-04.

Worn or damaged Check transmission filter for metal particles.

parts in Repair as necessary. See repair manual, Groups
transmission or axle 0250 and 0350.

Worn universal Inspect universal joints or drive shaft. See repair

joints on drive shaft manual, Group 0325.

Misalignment of Check position of components. Be sure they are

power train setting on mounts correctly.
components

No oil in lube circuit Do Converter Relief Valve Pressure Test. See

Group 9020-25.

695
 Diagnose Manual Shift Power Train Malfunction
Symptom Problem Solution

Hydraulic lines in Inspect all hydraulic lines and repair. See

contact with power Hydraulic Component Location in Group 9025-05.
train components

Assembly Isolate where noise is coming from. Adjust. Repair.

adjustments or Check mounts.
setting made
incorrectly

Excessive Attempt to shift too See Operator’s Manual for instructions.

Gear Clash fast
When Shifting

Shifting without Depress neutral disconnect when shifting. See

using neutral Operator’s Manual.
disconnect

Shifters worn or Inspect and replace as necessary. See repair

broken manual, Group 0315.

Synchronizer Repair transmission synchronizers. See repair

malfunction manual, Group 0350.

Park Brake Park brake solenoid Test solenoid. See Group 9015-15.
Pressure not working
Light Comes
On

Park brake piston Do Park Brake Release Pressure Test. See Group
leak 9020-25.
TX,15,SS3144-19-2000/01/28

Park brake hose Do Park Brake Release Pressure Test. See Group
leaking 9020-25. Inspect and repair leak.

696
 Diagnose Power Shift Power Train Malfunction

Diagnose Power Shift Power Train Malfunction

697
Diagnose Power Shift Power Train Malfunction

698
 Diagnose Power Shift Power Train Malfunction

Symptom Problem Solution

Machine Will Not Low oil level in Add oil to correct level. See Group 9000-04.
Move in Low transmission, park
Range Forward, brake will not
High Range (4th) release and light
or Reverse on console is ON.

Service brakes Adjust brake pedals and equalizing valves. See

dragging Group 9020-20. Check brake valve and repair.
See repair manual, Group 1060.

If light in console Check console light and /or pressure switch.

OFF and park See Group 9015-15. Check park brake disks
brake not releasing and separator plates. See repair in Group 0250.

Proper solenoids Test solenoids. See Group 9015-15.

not energized

Low or no system Check system pressure. See Group 9020-25.

pressure

Leaking clutch Do Low Range Forward, High Range Forward,

piston O-ring Reverse and Speed Clutch Pressure Test or
Modulation Pressure Test in Group 9020-25.
See repair manual, Group 0350.

Piston in clutch Check system pressure. Do Low Range

pack stuck Forward, High Range Forward, Reverse and
Speed Clutch Pressure Test. See Group 9020-
25 If OK, mechanical problem is indicated. See
repair manual, Group 0350.

Piston ball does Do Low Range Forward, High Range Forward,

not seat Reverse and Speed Clutch Pressure Test or
Modulation Pressure Test. See Group 9020-25

699
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Torque Converter Inspect and repair. See repair manual, Group

Flexplate broken 0350 for Removal and Installation. See Group
0651 for Disassemble and Assemble.

Worn or slipping Check system pressure. See Group 9020-25.

low range forward,
high range forward
reverse, or speed
clutch disks

Incorrect shim Do Modulation Pressure Test. See Group 9020-

under modulation 25. Repair and adjust. See Group 0360.
piston

Restricted Do Modulation Valve Pressure Test in Group

modulation orifice 9020-25. Remove orifice and check for
contamination and/or plugged. See repair
manual Group 0360.

Stuck spool in Do Clutch Pressure Tests in Group 9020-25.

control valve Remove and inspect control valve spools. See
repair manual, Group 0360.

Clutch malfunction Do Torque Converter Stall Speed Test. See

in torque converter Group 9020-25.

Low torque Do Cooler In and Out Pressure Test. See

converter oil Group 9020-25.
flow/pressure

Charge pump stop Remove and repair charge pump. See repair
sleeve out of manual, Group 0360.
location

700
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Clutch shaft Do Low Range Forward, High Range Forward,

sealing rings Reverse and Speed Clutch Pressure Test or
leaking Modulation Pressure Test. See Group 9020-25.

Converter drive Replace converter. See repair manual, Group

splines worn or not 0651.
engaged in pump
drive shaft

Pump gears seized Replace pump assembly. Inspect and replace

pump drive parts as necessary. See repair
manual, Group 0360.

Mechanical failure Inspect transmission and repair. See repair

in transmission manual, Group 0350.

Broken drive shafts Inspect drive shafts, universal joints, and pump
or pump drive shaft drive shaft for external or internal damage. See
repair manual, Group 0325 or 0360.

Broken ring or If drive shafts rotate with transmission in gear

pinion gear but machine does not move a differential failure
is indicated. Repair. See Rear Axle, Group
0250.

Machine Will Not Leakage in speed Do Low Range Forward, High Range Forward,
Move in One clutch Reverse and Speed Clutch Pressure Test.
Gear

Proper solenoids Check solenoids. See Group 9015-15.

not working

701
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Worn or slipping in Do Low Range Forward, High Range Forward,

one clutch pack Reverse and Speed Clutch Pressure Test. See
Group 9020-25.

Transmission Low oil level and Add oil. See Group 9000-04.
Slippage park indicator light
ON

Wrong oil grade Change oil. See Group 9000-04.

Restricted Do Modulation Valve Pressure Test in Group

modulation orifice 9020-25. Remove orifice and check for
contamination and/or plugged. See repair
manual, Group 0360.

Leaking clutch Do Low Range Forward, High Range Forward,

piston O-ring Reverse and Speed Clutch Pressure Test or
Modulation Pressure Test in Group 9020-25.
See repair manual, Group 0350.

Piston ball does Do Low Range Forward, High Range Forward,

not seat Reverse and Speed Clutch Pressure Test. See
Group 9020-25. See repair manual, Group
0350.

Clutch shaft Do Low Range Forward, High Range Forward,

sealing rings Reverse and Speed Clutch Pressure Test or
leaking. Modulation Pressure Test. See Group 9020-25.
See repair manual, Group 0350.

Worn or slipping Do individual clutch pressure tests. See Group

clutch disks 9020-25. Check system pressure or circuit
pressure. See Group 9020-25. See repair
manual, Group 0350.

702
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Leak in Do Clutch Pressure Test. See Group 9020-25.

transmission Remove valve and inspect gaskets. See repair
control valve, shift manual, Group 0360.
valve or gaskets

Low torque Do Cooler In and Cooler Out Pressure Test.

converter oil See Group 9020-25.
flow/pressure

Low transmission Do Transmission Pump Flow Test. See Group

pump flow due to 9020-25. See repair manual, Group 0360.
worn pump

Weak or broken Do Transmission System Pressure Test. See

pressure regulating Group 9020-25. See repair manual, Group
valve spring 0360.

Weak or broken Do Modulation Pressure Test. See Group 9020-

modulation valve 25. See repair manual, Group 0360.
spring

Machine Warped disks and Check transmission. See repair manual, Group
“Creeps” with plates in 0350.
FNR in Neutral transmission

Piston in clutch Check System Pressure and Low Range

pack stuck. Forward, High Range Forward, Reverse and
Speed Clutch Pressure. See Group 9020-25.
See repair manual, Group 0350.

Ball pressed in end Check Low Range Forward, High Range

of clutch shafts Forward, Reverse and Speed Clutch Pressure.
(lube passage) See Group 9020-25. See repair manual, Group
came out 0350.

703
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Clutch ball stuck Do Low Range Forward, High Range Forward,

shut Reverse and Speed Clutch Pressure Test. See
Group 9020-25

Internal leakage in Do Pump Flow Test. See Group 9020-25.

control valve

Solenoids stuck Check solenoids. See Group 9015-15.

Machine Lacks Oil level is low and Add oil to correct level. See Group 9000-04
Power or Moves park brake
Slow indicator light is ON

Wrong oil, aerated Change oil. See Group 9000-4.

oil

Service Brake Check for excessive heat in brake area of axle

dragging housing after operating machine. See repair
manual, Group 0250.

Park brake Repair park brake in rear axle. See repair

dragging, piston manual, Group 0250.
stuck

Engine fast idle Check fast idle adjustment. See Group 9010-
speed set too low 20.

Low pressure in Do Transmission System Pressure Test. See

transmission Group 9020-25.
system

704
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Restricted Do Modulation Valve Pressure Test in Group

modulation orifice 9020-25. Remove orifice and check for
contamination and/or plugged. See repair
manual, Group 0360.

Leaking clutch Do Low Range Forward, High Range Forward,

piston O-ring Reverse and Speed Clutch Pressure Test or
Modulation Pressure Test in Group 9020-25.
See repair manual, Group 0350.

Piston ball does Do Low Range Forward, High Range Forward,

not seat Reverse and Speed Clutch Pressure Test. See
Group 9020-25.

Clutch pack Do Transmission System Pressure Test. See

slipping Group 9020-25.

Clutch pack Repair clutch pack. See repair manual, Group

dragging, disks 0350.
warped

Clutch shaft Do Low Range Forward, High Range Forward,

sealing ring leaking Reverse and Speed Clutch Pressure Test or
Modulation Pressure Test. See Group 9020-25.

Clutch ball stuck Do Low Range Forward, High Range Forward,

shut Reverse and Speed Clutch Pressure Test. See
Group 9020-25

Internal leakage in Do Pump Flow Test. See Group 9020-25.

control valve

Failed torque Do Torque Converter Stall Speed Test. See

converter Group 9020-25.

705
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Low torque Do Torque Converter Stall Speed Test. See

converter oil Group 9020-25.
flow/pressure

Wrong torque Do Torque Converter Stall Test in Group 9020-

converter 25. Check number of torque converter through
access hole under machine (either 247002 or
4168-028-211).

Low engine power Do Engine Performance Test. See Group 9010-

25.

Mechanical failure Inspect. See repair manual, Group 0250 or

in transmission or 0350.
axle

Transmission Low or high oil Add oil or drain. See Group 9000-04
Shifts Too Slow level (aeration of
oil)

Wrong oil Change oil. See Group 9000-04.

Pressure reducing Do Reducing Valve Pressure Test. See Group

valve setting 9020-25.
incorrect

Pressure regulating Do System Pressure Test. See Group 9020-25.

valve setting
incorrect

Clutch pack Do System Pressure Test. See Group 9020-25.

slipping Repair. See repair manual, Group 0350

706
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Control valve Do Pump Flow Test. See Group 9020-25

leaking internally Repair.

Control valve Do Modulation Valve Pressure Test in Group

modulation piston 9020-25. Repair. See repair manual, Group
not shimmed 0360.
properly

Restricted Do Modulation Pressure Test. See Group 9020-

modulation orifice 25.

Modulation piston Do Modulation Valve Pressure Test. See Group

spring broken 9020-25. Remove control valve cover and
inspect modulation piston and spring. See
repair manual, Group 0360.

Restricted oil Do Low Range Forward, High Range Forward,

passage to clutch Reverse and Speed Clutch Pressure Test. See
pack Group 9020-25.

Transmission Do Pump Flow Test and System Pressure Test.

pump malfunction See Group 9020-25.

Transmission Repair transmission. See repair manual, Group

pump oil pickup 0350.
blocked

Transmission Modulation piston Do Modulation Valve Pressure Test. See Group

Shifts Too Fast orifice blocked 9020-25. Repair, see Group 0360.

Modulation valve Do Modulation Valve Pressure Test in Group

piston stuck 9020-25. Remove control valve cover and
inspect modulation piston and spring. Repair,
see Group 0360.

707
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Modulation orifice Do Modulation Pressure Test. See Group 9020-

out of place or 25. See repair manual, Group 0360.
missing

Modulation orifice Do Modulation Pressure Test. See Group 9020-

oversized 25. See repair manual, Group 0360.

Transmission Oil level too high or Check oil level and correct. See Group 9000-
Overheats too low 04.

Incorrect type of oil Drain and replace oil. See Group 9000-04.

Temperature Check sensor, see Group 9015-15.

sensor malfunction

Clutch pack Repair transmission. See Group 0350.

dragging, worn
disks

Torque converter Do Torque Converter Stall Speed Test. See

malfunction Group 9020-25. See repair manual, Group
0350.

Torque converter Use neutral disconnect switch in machine

stalled excessively operations to reduce stall.

Operating in too Operate one gear lower. See Operator’s

high a gear Manual.

Oil cooler air flow Inspect and clean exterior of cooler. Do Air
restricted Flow Test. See Group 9010-25.

708
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Missing baffles, Inspect and check belt. See Group 9010-20.

damaged fan Check baffles and repair. See repair manual,
shrouds or loose Group 0510.
fan belt

Oil cooler restricted Do Cooler In and Out Pressure Test. See

internally Group 9020-25. Flush cooling system. See
CTM104.

Converter flow Do Converter In/Out Pressure Test. See Group

blocked by pump 9020-25
stop sleeve.

Oil flow to or from Do Cooler-In/Out Pressure Test. See Group

cooler restricted 9020-25.

Converter-In relief Do Converter-In Relief Valve Test in Group

valve stuck open or 9020-25. Remove valve, inspect and repair.
broken spring See repair manual, Group 0360.

Low transmission Do Pump Flow Test. See Group 9020-25.

pump flow

Transmission Inspect transmission and repair. See Repair,

mechanical Group 0350.
malfunction

Engine over-fueled Remove fuel injection pump. See your

authorized Injection Pump Service Center.

Excessive Power Engine low idle too Check engine slow idle speed. See Group
Train Noise slow 9010-20.

Oil level low Fill to correct oil level. See Group 9000-04.

709
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Worn or damaged Check transmission filter for metal particles.

parts in Repair as necessary. See repair manual,
transmission or Groups 0250 and 0350.
axle

Worn universal Inspect universal joints or drive shaft. See

joints on drive repair manual, Group 0325.
shaft

Misalignment of Check position of components. Be sure they

power train are setting on mounts correctly.
components

No oil in lube Do Cooler In and Out Pressure Test. See

circuit Group 9020-25. Do Converter Relief Valve
Pressure Test. See Group 9020-25.

Hydraulic lines in Inspect all hydraulic lines and repair. See

contact with power Hydraulic Component Location in Group 9025-
train components 05.

Assembly Isolate where noise is coming from. Adjust.

adjustments or Repair. Check mounts.
setting made
incorrectly

Excessive Gear Rate of shift too Do Modulation Pressure Test in Group 9020-
Clash When fast 25.
Shifting

Worn Gears Inspect transmission. See repair manual, Group

0350.

710
 Diagnose Power Shift Power Train Malfunction
Symptom Problem Solution

Park Brake Transmission oil Add oil. See Group 9000-04.

Pressure Light level too low
Comes On

Park brake Test solenoid. See Group 9015-15.

solenoid not
working

Park brake piston Do Park Brake Release Pressure Test. See

leak Group 9020-25. Inspect and repair. See repair
manual, Group 0250.

Park brake hose Do Park Brake Release Pressure Test. See

leaking Group 9020-25. Inspect and repair leak.

CED,TX03399,4235-19-1998/06/04

711
 Diagnose MFWD Malfunction

Diagnose MFWD Malfunction

NOTE:

See CTM4509 for repair for MFWD axle.

712
 Diagnose MFWD Malfunction

Symptom Problem Solution

No Power to Solenoid not actuated Check electrical connection. Inspect

MFWD solenoid. See Group 9015-10.

Drive shaft failure Inspect and repair. See repair

manual, Group 0325.

Failed MFWD output shaft Inspect and repair. See repair

spline manual, Group 0350.

Failed axle shaft in MFWD Inspect and repair. See repair

manual, Group 0240.

Failed ring gear or pinion in Inspect and repair. See repair

front axle. manual, Group 0240.

Failed MFWD gear train Inspect and repair. See repair

components in transmission manual, Group 0350.

No Power to One Wheel U-Joint failure Inspect and repair. See repair
Wheel of MFWD manual, Group 0240.

Failed outboard planetary Inspect and repair. See repair

manual, Group 0240.

Failed axle shaft in MFWD Inspect and repair. See repair

manual, Group 0240

Failed limited-slip in MFWD Inspect and repair. See repair

manual, Group 0240.

713
Diagnose MFWD Malfunction
TX,15,MA17-19-1998/07/23

714
 Diagnose Rear Axle Malfunction

Diagnose Rear Axle Malfunction

715
Diagnose Rear Axle Malfunction

716
 Diagnose Rear Axle Malfunction

Symptom Problem Solution

No Malfunction in With engine stopped and key switch turned to

Differential electrical circuit to accessory, activate differential lock and listen for a
Lock solenoid click from solenoid valve.
Operation
Do Differential Lock Operational Checks. See
Group 9015-15.

Stuck differential With engine stopped and key switch turned to

lock solenoid valve accessory, activate differential lock and listen for a
click from solenoid valve. Remove and inspect
valve. See repair manual, Group 0360.

Excessive leakage Do Differential Lock Pressure Test. See Group

in differential lock 9020-25. Check rear axle oil level. See Group
piston seals 9000-04

Stuck differential Do Differential Lock Pressure Test. See Group

lock piston 9020-25. Disassemble, inspect, repair. See repair
manual, Group 0250.

Excessive wear on Disassemble, inspect, repair. See repair manual,

differential lock Group 0250.
engaging gears

Differential Excessive leakage Do Differential Lock Pressure Test. See Group

Lock Slips or differential lock 9020-25.
Chatters piston seals
When
Engaged

Failed seals on Remove and inspect seals. See repair manual,

differential lock Group 0360.
solenoid valve

717
 Diagnose Rear Axle Malfunction
Symptom Problem Solution

Stuck differential Disassemble, inspect and repair. See repair

lock piston manual, Group 0250.

Excessive wear of Disassemble, inspect, and repair. See repair

differential lock manual, Group 0250.
engaging gears

Differential Stuck foot switch Inspect. See electrical, Group 9015-15.

Lock Will Not
Release

Malfunction in With engine stopped and key switch on, activate

electrical circuit differential lock and listen for a click from solenoid
valve. See Differential Lock Circuit, Group 9015-15.

Stuck differential With engine stopped and key switch on, activate
lock solenoid valve differential lock and listen for a click from solenoid
valve. Remove and inspect valve. See repair
manual, Group 0360.

Stuck differential Do Differential Lock Pressure Test. See Group

lock piston 9020-25. Disassemble, inspect, repair. See repair
manual, Group 0250.

Stuck differential Disassemble, inspect, repair. See repair manual,

lock engaging Group 0250.
gears or clutch

Oil level low in Add oil to correct level. See Group 9000-04. Check
transmission axle for overfill.

Rear Axle Differential lock Do Differential Lock Pressure Test. See Group
Overfilled piston seals 9020-25. Inspect, repair. See repair manual, Group
With Oil leaking 0250.

718
 Diagnose Rear Axle Malfunction
Symptom Problem Solution

Service brake Do Brake Valve Leakage Test. See Group 9020-25.

piston seals Inspect and repair. See repair manual, Group 0250.
leaking

Park brake piston Do Park Brake Release Pressure Test. See Group
seals leaking 9020-25. Inspect and repair. See repair manual,
Group 0250.

Poor Service Low oil level Check oil level and fill. See Group 9000-04.
Brakes

Air in brake valve Bleed brakes. See Group 9020-20.

or lines or piston

Brake valve leaks Do Brake Valve Leakage Test. See Group 9020-25.

Brake piston seals Inspect and repair. See repair manual, Group 0250.
leak

Brake disks worn Inspect disks through axle brake inspection hole.
excessively Disassemble, inspect and repair. See repair
manual, Group 0250.

Restriction in Remove lines and components and inspect.

brake circuit

Service Brake pedal not Inspect brake pedal linkage. Repair/Adjust. See
Brakes Will returning to full up Group 1060.
Not Release position or not
adjusted properly

Brake valve Remove, disassemble and inspect. Repair brake

malfunction valve. See repair manual, Group 1060.

719
 Diagnose Rear Axle Malfunction
Symptom Problem Solution

Warped brake Disassemble, inspect and repair. See repair

disks manual, Group 0250.

Stuck brake piston Remove and inspect. See Repair, Group 0250.

No free travel on Disassemble and inspect, check specifications. See

brake adjusters repair manual, Group 0250.

Service Air in brake Bleed brakes. See Group 9020-20.

Brakes system
Chatter or
Noisy

Wrong oil in rear Drain and refill with correct oil. See Group 9000-04.
axle

Disks worn Disassemble, inspect and repair. See repair

excessively manual, Group 0250.

Brake Valve Do Brake Valve Leakage Test. See Group 9020-25.

leakage Repair.

Park Brake Worn parts Inspect and replace. See repair manual, Group
Will Not Hold 0250.

Park brake piston Do Park Brake Release Pressure Test. See Group
stuck 9020-25.

Park brake Do System and Park Brake Release Pressure Test.

manually released See Group 9020-25

720
 Diagnose Rear Axle Malfunction
Symptom Problem Solution

Park brake Check solenoid. See Group 9015-15. Repair.

solenoid plugged

Park Brake Park brake hose Inspect and repair all leaks.
Will Not leaking
Release

Low hydraulic Do Park Brake Release Pressure Test. See Group

pressure oil to 9020-25
park brake

Park Brake Check solenoid. See Group 9015-15.

Solenoid not
working

Park brake piston Remove and inspect. See Repair, Group 0250.
stuck

Park Brake piston Do Park Brake Pressure Test. See Group 9020-25.
seals leaking Inspect and repair. See Group 0250.
TX,15,MA18-19-2000/01/28

721
 Hydraulic Circuit Symbols

Hydraulic Circuit Symbols

TS700-19: Hydraulic Circuit Symbols

TX,9020,SS3253-19-1996/08/30

722
 Adjust Brake Pedals and Equalizing Valves

Adjust Brake Pedals and Equalizing Valves

1. Remove brake valve from machine. (See repair manual.)

2. Clamp brake valve level in bench vise.

3.

T7407AU-UN: Caps
Install caps (A). Fill brake valve reservoir with oil.

4. IMPORTANT:

DO NOT allow pedal to return abruptly before the stop

screws are adjusted. Check valves could be damaged if
stop screws are not properly adjusted.

T7407AT-UN: Purging Air

Remove left cap and hold finger over end to stop oil flow. Slowly pump left
pedal until air is purged. Install cap and repeat procedure on other side. Refill
reservoir.

723
 Adjust Brake Pedals and Equalizing Valves
5.

T7407AS-UN: Brake Pedal Cap Screws

Adjust right-hand brake pedal cap screw (B) so brake piston is fully extended
from the housing and brake pedal arm is tight against the piston.

6. Apply a minimum of 44.5 N (10 lb) force to the left-hand brake pedal.

Item MeasurementSpecification
Left-Hand Brake Pedal Force 44.5 N (10 lb) Minimum
If the pedal starts to settle, turn right-hand cap screw (B) out
(counterclockwise) until the settling stops. Turn the right-hand cap screw (B)
an additional 1/3 turn (two wrench flats) out (counterclockwise).
Item MeasurementSpecification
Right- Torque Turn If pedal starts to settle, turn cap screw out
Hand (counterclockwise) until settling stops. Turn the right-
Cap hand cap screw an additional 1/3 turn (two wrench
Screw flats) out (counterclockwise)

7. Adjust left-hand brake pedal cap screw (A) so brake piston is fully extended
from the housing and brake pedal arm is tight against the piston.

8. Apply a minimum of 44.5 N (10 lb) force to right-hand brake pedal.

Item MeasurementSpecification
Right-Hand Brake Pedal Force 44.5 N (10 lb) Minimum
If pedal starts to settle, turn the left-hand cap screw (A) out (counterclockwise)
until settling stops. Turn the left-hand cap screw (A) an additional 1/3 turn (two
wrench flats) out (counterclockwise).
Item MeasurementSpecification
Left- Torque Turn If pedal starts to settle, turn cap screw out
Hand (counterclockwise) until settling stops. Turn left-hand
Cap cap screw an additional 1/3 turn (two wrench flats) out
Screw (counterclockwise)

724
 Adjust Brake Pedals and Equalizing Valves

9. After both pedals have been adjusted, align pedals by turning cap screws for
the highest pedal, a maximum of 1/6 turn (one wrench flat) out
(counterclockwise). Lock both stop screws.

Item MeasurementSpecification
Pedal Torque Turn Turn cap screws for the highest pedal, a maximum
Alignment of 1/6 turn (one wrench flat) out (counterclockwise).

10.

T7407AU-UN: Cap Locations

Remove cap (A). A steady stream of oil must flow to indicate that check valve
is in "open" position with pedals up. Depress pedal up to 13 mm (0.5 in.) and
flow must stop which indicates that check valve is in "closed" position and
sealing.
Item Measurement Specification
Check Valve Closes Brake Pedal Before 13 mm (0.5 in.) (flow must
at Travel stop)

11. Slowly release pedal; pedal must return to stop screw by return spring force
alone. Install cap. Repeat for other side. Fill reservoir.

NOTE:

If oil does not flow, readjust valve stop screws. If flow does not
stop with pedal depressed, inspect or replace check valve.

12. Depress one brake pedal. Brake pedal must be solid within first 19 mm (0.75
in.) of pedal travel.

725
 Adjust Brake Pedals and Equalizing Valves

Item MeasurementSpecification
Brake PedalTravel Solid within first 19 mm (0.75 in.)
Repeat for other pedal.

NOTE:

Excessive pedal travel indicates air in brake valve; repeat step 4.

TX,20,SS3171-19-1998/07/22

726
 Adjust Brake Pedals and Equalizing Valves

Adjust Brake Pedals and Equalizing Valves

1. Remove brake valve from machine. (See repair manual.)

2. Clamp brake valve level in bench vise.

3.

T7407AU-UN: Caps
Install caps (A). Fill brake valve reservoir with oil.

4. IMPORTANT:

DO NOT allow pedal to return abruptly before the stop

screws are adjusted. Check valves could be damaged if
stop screws are not properly adjusted.

T7407AT-UN: Purging Air

Remove left cap and hold finger over end to stop oil flow. Slowly pump left
pedal until air is purged. Install cap and repeat procedure on other side. Refill
reservoir.

727
 Adjust Brake Pedals and Equalizing Valves
5.

T7407AS-UN: Brake Pedal Cap Screws

Adjust right-hand brake pedal cap screw (B) so brake piston is fully extended
from the housing and brake pedal arm is tight against the piston.

6. Apply a minimum of 44.5 N (10 lb) force to the left-hand brake pedal.

Item MeasurementSpecification
Left-Hand Brake Pedal Force 44.5 N (10 lb) Minimum
If the pedal starts to settle, turn right-hand cap screw (B) out
(counterclockwise) until the settling stops. Turn the right-hand cap screw (B)
an additional 1/3 turn (two wrench flats) out (counterclockwise).
Item MeasurementSpecification
Right- Torque Turn If pedal starts to settle, turn cap screw out
Hand (counterclockwise) until settling stops. Turn the right-
Cap hand cap screw an additional 1/3 turn (two wrench
Screw flats) out (counterclockwise)

7. Adjust left-hand brake pedal cap screw (A) so brake piston is fully extended
from the housing and brake pedal arm is tight against the piston.

8. Apply a minimum of 44.5 N (10 lb) force to right-hand brake pedal.

Item MeasurementSpecification
Right-Hand Brake Pedal Force 44.5 N (10 lb) Minimum
If pedal starts to settle, turn the left-hand cap screw (A) out (counterclockwise)
until settling stops. Turn the left-hand cap screw (A) an additional 1/3 turn (two
wrench flats) out (counterclockwise).
Item MeasurementSpecification
Left- Torque Turn If pedal starts to settle, turn cap screw out
Hand (counterclockwise) until settling stops. Turn left-hand
Cap cap screw an additional 1/3 turn (two wrench flats) out
Screw (counterclockwise)

728
 Adjust Brake Pedals and Equalizing Valves

9. After both pedals have been adjusted, align pedals by turning cap screws for
the highest pedal, a maximum of 1/6 turn (one wrench flat) out
(counterclockwise). Lock both stop screws.

Item MeasurementSpecification
Pedal Torque Turn Turn cap screws for the highest pedal, a maximum
Alignment of 1/6 turn (one wrench flat) out (counterclockwise).

10.

T7407AU-UN: Cap Locations

Remove cap (A). A steady stream of oil must flow to indicate that check valve
is in "open" position with pedals up. Depress pedal up to 13 mm (0.5 in.) and
flow must stop which indicates that check valve is in "closed" position and
sealing.
Item Measurement Specification
Check Valve Closes Brake Pedal Before 13 mm (0.5 in.) (flow must
at Travel stop)

11. Slowly release pedal; pedal must return to stop screw by return spring force
alone. Install cap. Repeat for other side. Fill reservoir.

NOTE:

If oil does not flow, readjust valve stop screws. If flow does not
stop with pedal depressed, inspect or replace check valve.

12. Depress one brake pedal. Brake pedal must be solid within first 19 mm (0.75
in.) of pedal travel.

729
 Adjust Brake Pedals and Equalizing Valves

Item MeasurementSpecification
Brake PedalTravel Solid within first 19 mm (0.75 in.)
Repeat for other pedal.

NOTE:

Excessive pedal travel indicates air in brake valve; repeat step 4.

TX,20,SS3171-19-1998/07/22

730
 Bleeding Brakes

Bleeding Brakes

T6838AE-UN: Pedal Travel Measurement

-: Specifications

SPECIFICATIONS

Engine Speed 1500 rpm

Brake Pedal Travel Firm within 133 mm (5.25 in.) after 10 second wait cycle

NOTE:

Air will "gravity bleed" from brake system through brake valve without
use of bleed screws. Brake lines must be inclined toward brake valve.

Low ambient temperature or aeration of oil will slow bleed process.

This procedure will require two technicians.

1. Leave ON park brake. Bleed brakes one pedal at a time.

2. Run engine at 1500 rpm and cycle a hydraulic function such as backhoe
bucket.

Item MeasurementSpecification
Engine Speed 1500 rpm

3. Open service brake bleed screws on rear axle.

731
 Bleeding Brakes
3. Open service brake bleed screws on rear axle.

4. Pump the brake pedal slowly until air free oil comes out of service brakes rear
axle bleed screws.

5. Close bleed screw.

6. Release brake pedal completely and wait a minimum of 10 seconds.

7. CAUTION:
Do not operate machine if pedal travel exceeds 133 mm
(5.25 in.) while applying 267 N (60 lb) force. Operating
machine with excessive brake travel could cause brakes
not to stop machine on first application.

Repeat step 4 through 5 until a firm pedal is obtained within 133 mm (5.25 in.)
of pedal travel after a 10 second wait cycle.

Item MeasurementSpecification
Brake Travel Firm within 133 mm (5.25 in.) after 10 second wait
Pedal cycle

8. As brakes continue to self-bleed, pedal firmness should improve.

9. If unable to obtain firm brake pedal, inspect lines and connections for leakage.
If no external leaks, test axle. Do Service Brake Leakage Test in Group 9020-
25. Repair, see repair manual.

TX,20,SS3172-19-1998/06/25

732
 Checking and Adjusting Toe-In

Checking and Adjusting Toe-In

T6159AC-UN: Hub Height Measurement

T6157AF-UN: Toe-In Measurement

733
 Checking and Adjusting Toe-In
T6162AT-UN: Non-MFWD

T103499-UN: MFWD
LEGEND:
A - Center of Hub
B - Front of Tire
C - Rear of Tire
D - Tie Rod Tube
E - Tie Rod Clamp
F - Nuts
G - Rod End

1. Measure distance from ground to center of hub (A) and make a mark on front
(B) and rear (C) of each front tire in center of tread.

2. Measure distance between front marks (B).

3. Measure distance between rear marks (C).

4. The distance between front marks must be less than distance between rear
marks by the following amount.

Item Measurement Specification

Toe-In Standard Axle Distance between (B) 6 ± 3 mm (1/4 ± 1/8
Measurement and (C) in.)
MFWD Axle Distance between (B) 3 ± 3 mm (1/8 ± 1/8
and (C) in.)

Machines Without Mechanical Front Wheel Drive:

1. To adjust toe-in, loosen both tie rod clamps (E) and turn tie rod tube (D).

2. Turn clamps so that cap screws are toward rear of machine and tipped down
approximately 45°.

734
 Checking and Adjusting Toe-In

3. Tighten clamp cap screws to specification.

Item MeasurementSpecification
Toe-In Tie Rod Clamp Cap Screws Torque 95 ± 14 N·m (70 ± 10 lb-ft)

Machines With Mechanical Front Wheel Drive:

1. To adjust toe-in, loosen nuts (F).

2. Turn rod end (G) to get proper toe-in.

3. Adjust toe-in equally on both tie rods.

4. Tighten nuts to specification.

Item MeasurementSpecification
Toe-In Tie Rod Nuts Torque 50 N·m (35 lb-ft)

TX,90,BD2189-19-1999/11/19

735
 JT05801 Clamp-On Electronic Tachometer Installation

JT05801 Clamp-On Electronic Tachometer Installation

T6813AG-UN: JT05801

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Tachometer
A-Clamp-On Transducer. Remove paint using emery cloth and connect to a straight
section of injection line within 100 mm (4 in.) of pump. Finger tighten only. DO NOT
overtighten.

B-Black Clip (-). Connect to main frame.

C-Red Clip (+). Connect to transducer.

D-Tachometer Readout. Install cable.

TX,25,SS3151-19-1996/06/17

736
 JT05801 Clamp-On Electronic Tachometer Installation

JT05801 Clamp-On Electronic Tachometer Installation

T6813AG-UN: JT05801

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Tachometer
A-Clamp-On Transducer. Remove paint using emery cloth and connect to a straight
section of injection line within 100 mm (4 in.) of pump. Finger tighten only. DO NOT
overtighten.

B-Black Clip (-). Connect to main frame.

C-Red Clip (+). Connect to transducer.

D-Tachometer Readout. Install cable.

TX,25,SS3151-19-1996/06/17

737
 JT05800 Digital Thermometer Installation

JT05800 Digital Thermometer Installation

T6808CE-UN: JT05800

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

A-Temperature Probe
B-Cable

C-Digital Thermometer

NOTE:

Cooler In and Cooler Out lines can be switched depending on

installation.

For transmission testing, run machine for two minutes. Use a temperature probe and
determine which line is the hottest and install temperature probe on metal part of line for
cooler IN or feel both cooler hoses and start machine, whichever one pressurizes first is
cooler inlet. On Torque Converter Stall, Converter-In Relief Pressure Test, and Cooler
In and Out Pressure Test, install digital thermometer probe into sump using dipstick
tube.

TX,25,SS3152-19-1998/06/23

738
 Transmission Oil Warm-Up Procedure

Transmission Oil Warm-Up Procedure

T7446AF-UN: Gear Selector and FNR Levers

-: Specifications

SPECIFICATIONS

Engine Speed Slow Idle (900 + 25 - 0 rpm) and Fast Idle (2375 + 25 - 0 rpm)

IMPORTANT:

On power shift transmissions ONLY, never operate machine

equipped with MFWD with front wheels (axle) on the ground, rear
wheels (axle) off the ground and transmission in fourth gear
forward. Damage to the MFWD will occur.

NOTE:

Have test equipment installed before warm-up. Cooling system is highly

efficient and may require blocking air flow around the transmission
cooling system to control temperature.

1. Raise machine off ground using loader and stabilizers.

2. Put transmission in third gear (A) for manual shift or move lever (B) to 3rd
speed for power shift. Park brake OFF.

3. IMPORTANT:

Do not stall converter for longer than 20 seconds or

serious converter damage could result.

739
 Transmission Oil Warm-Up Procedure

Cycle from slow idle (900 + 25 - 0 rpm) to fast idle (2375 + 25 - 0 rpm) with
service brakes engaged. Approximately 10 seconds in high idle and 5
seconds in low idle until desired temperature is reached.

Item MeasurementSpecification
Engine Speed Slow Idle (900 + 25 - 0 rpm) and Fast Idle (2375 + 25 -
0 rpm)

NOTE:

To cool machine, shift to neutral and run at fast idle.

Temperature should drop approximately 1° every 5 seconds.

CED,TX03399,4231-19-1999/12/09

740
 Manual Shift Transmission Overall Test Connections, Ports, and Locations

Manual Shift Transmission Overall Test Connections, Ports, and

Locations

T101411-19: Test Connections and Locations

LEGEND:
A - MFWD Solenoid
B - Park Brake Solenoid
C - Differential Lock Solenoid
D - Park Brake Pressure Port
E - Differential Lock Pressure Port
F - Transmission Control Valve
G - Gearshift Lever
H - Oil Drain
I - Model Identification Plate
J - Output Flange-to-Rear Axle
K - Filter
L - Transmission Pump
M - Rear of Transmission
N - MFWD Pressure Test Port
O - Reverse Clutch Pressure Test Port
P - Forward Clutch Pressure Test Port
Q - Converter-In Relief Valve Pressure Port
R - System Pressure Test Port

741
 Manual Shift Transmission Overall Test Connections, Ports, and Locations
S - Modulation Valve Pressure Test Port
T - Reducing Valve Pressure Test Port
U - Transmission Control Valve

CED,TX03399,4264-19-1998/07/22

742
 Power Shift Transmission Overall Test Connections, Ports, and Locations

Power Shift Transmission Overall Test Connections, Ports, and

Locations

T113993-19: Transmission Overall Test Connections and Ports

LEGEND:
A - Differential Lock Solenoid
B - Park Brake Pressure Port
C - Differential Lock Pressure Port
D - Transmission Control Valve
E - Transmission Speed Shift Valve
F - Oil Drain
G - Model Identification Plate
H - Filter
I - Transmission Pump
J - MFWD Solenoid
K - MFWD Test Port
L - Park Brake Solenoid
M - Low Range Forward Clutch Pressure Test Port
N - Converter-In Relief Valve Pressure Port
O - Modulation Valve Pressure Test Port
P - System Pressure Test Port

743
 Power Shift Transmission Overall Test Connections, Ports, and Locations
Q - Third Speed Clutch Pressure Test Port
R - Second Speed Clutch Pressure Test Port
S - First Speed Clutch Pressure Test Port
T - High Range Forward Clutch Pressure Test Port
U - Reverse Clutch Pressure Test Port
V - Reducing Valve Pressure Test Port
W - Output Flange to Rear Axle
X - Rear of Transmission
Y - Control Valve
Z - Speed Shift Valve

CED,TX03399,4230-19-1998/05/08

744
 Torque Converter Stall Speed Test

Torque Converter Stall Speed Test

-: Specifications

SPECIFICATIONS

Transmission/Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed High idle

Torque Converter Stall Speed 1900-2050 rpm

Combined Torque Converter/Hydraulic Engine Stall Speed 1250-1550 rpm

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer
Digital Thermometer

NOTE:

Before doing either of the following procedures, Pump Load Sense

Differential Pressure Test and Loader and Backhoe Load Sense Relief
Tests, must be performed and adjustments made as needed. See
Group 9025-25.

1. Torque Converter Stall: Install electronic tachometer. (See procedure in this

group.)

2. Install digital thermometer probe into the transmission and hydraulic sump
through the dipstick tube.

3. Heat oil to specifications.

Item MeasurementSpecification
Transmission/Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
See Transmission Warm-Up Procedure in this Group and Hydraulic Warm-Up
Procedure in Group 9025-25.

4. IMPORTANT:

Converter should NOT be stalled longer than 20 seconds

or serious converter damage may result. Return FNR

745
 Torque Converter Stall Speed Test
lever to neutral position for 10 seconds before doing next
stall test.

With machine off the ground, put transmission in third gear.

5. Apply and hold service brakes during test.

6. Cycle from low idle to high idle with service brakes engaged. The highest
stabilized speed measured is converter stall speed.

Item MeasurementSpecification
Engine Speed Low and High idle
Torque Converter Stall Speed 1900-2050 rpm

IMPORTANT:

Minimum engine speed listed is for an engine that is

broken-in and using No. 2 fuel.

7. NOTE:

Combined stall is done by stalling torque converter, holding

loader bucket dump over relief and raising loader boom at the
same time.

NOTE:

Specifications of combined stall are nominal for machines that

have not been altered to bias the hydraulic system toward
increased backhoe performance.

Combined Torque Converter Stall: Stall converter as described above and

hold loader bucket dump over relief, raise loader boom at the same time.

Item MeasurementSpecification
Transmission/Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
Observe tachometer reading while boom is raising.
Item MeasurementSpecification
Combined Torque Converter/Hydraulic Engine Stall Speed 1250-1550 rpm

746
 Torque Converter Stall Speed Test

8. If converter stall speed is low, check for:

Low engine output. See Group 9010-25.

Incorrect torque converter. Check part number through inspection
hole in bottom of transmission housing, number should be either
247002 or 4168-028-211.
Failed freewheel clutch in torque converter.

9. If converter stall speed is too high, check for:

Incorrect oil temperature.

Low oil level.
Incorrect oil in machine.
Restricted suction screen. See repair manual.
Incorrect torque converter. Check part number through inspection
hole in bottom of transmission housing, number should be either
247002 or 4168-028-211.
Engine over fueled. See Group 9010-25.
Converter failed.
Failed transmission clutch pack.
Low system (pump) pressure in transmission.

TX,25,SS3154-19-1998/07/22

747
 Converter-In Relief Valve Test

Converter-In Relief Valve Test

T101750-UN: Valve Test Port

-: Specifications

SPECIFICATIONS
Oil Temperature at Sump 65 ± 5°C (150 ± 10°F)

Engine Speed 2375 + 25 - 0 rpm

Converter-in Relief Valve Pressure 800 + 200 kPa (8 + 2 bar) (116 + 29 psi)

-: Essential Tools

748
 Converter-In Relief Valve Test

ESSENTIAL TOOLS

AT202955 (Parker No. PD357) Diagnostic Coupler

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Gauge 0-2000 kPa (0-20 bar) (0-300 psi)

1. Remove floor panel in cab or ROPS.

2. Install adapter and gauge in port (A).

3. Install digital thermometer probe into sump using dipstick tube. Warm
transmission oil, see procedure in this group.

Item Measurement Specification

Oil Temperature at Sump 65 ± 5°C (150 ± 10°F)

4. Put FNR lever in neutral.

5. IMPORTANT:

DO NOT exceed 1000 kPa (10 bar) (145 psi) or converter

damage could result.

Slowly increase rpm until maximum pressure is reached on gauge.

Item MeasurementSpecification
Engine Speed 2375 + 25 - 0
Converter-In Relief Pressure 800 + 200 kPa (8 + 2 bar) (116 + 29
Valve psi)

6. If maximum pressure is reached at low idle, check for a plugged cooler. Back
flush using an oil caddy or replace cooler.

7. If pressure is too high, remove relief valve. Disassemble, clean and inspect
valve.

8. If pressure is low, check for weak or broken spring and scored or sticking
valve.

749
 Converter-In Relief Valve Test

9. Install and check relief valve after repair.

TX,25,SS3155-19-1998/05/15

750
 Brake Valve Leakage Test

Brake Valve Leakage Test

T102934-UN: Brake Valve Leakage

LEGEND:
A - Fitting
B - Tee
C - Gauge

-: Specifications

SPECIFICATIONS
Brake Valve Leakage Pressure drops more than 100 psi in 30 seconds with
brake pedal applied
Brake Pedals Released 0
Pressure

-: Essential Tools

751
 Brake Valve Leakage Test

ESSENTIAL TOOLS

A-JT03455 (7/16 M JIC x -4 F ORFS) Fitting

B-38H1029 (-4 M x -4 F x -4 M ORFS) (Parker No. 4R6LO-S) Tee

38H1352 (-4 ORFS) Nut (2 Used)

38H1138 (-4 ORFS) Plug (2 Used)

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

(C) Gauge 0-6895 kPa (0-69 bar) (0-1000 psi)

1. Heat oil. See Hydraulic Oil Warm-up in Group 9025-25.

2. Stop engine.

3. Push left and right brake pedal individually. If either pedal settles, leakage is
indicated in final drive brake piston or brake valve reservoir.

4. Disconnect brake line and clamp. Tee gauge (C) at brake valve line of pedal
that settled.

5. Push brake pedal down and block in place to set gauge at 500 psi starting
point.

6. Monitor gauge. If pressure drops more than 100 psi in 30 seconds, excessive
leakage is indicated.

Item MeasurementSpecification
Brake Leakage Pressure drops more than 100 psi in 30 seconds
Valve with brake pedal applied

NOTE:

When pedals are release pressure should be zero.

7. To isolate leakage, disconnect line going to axle.

Item MeasurementSpecification
Brake Pedals Released Pressure 0

752
 Brake Valve Leakage Test

8. If leakage continues, replace check valve.

9. No pressure drop indicates leakage at piston seals in axle housing. See

Repair, Group 0250.

TX,25,SS3156-19-1998/05/15

753
 Park Brake Release Pressure Test

Park Brake Release Pressure Test

T101901-UN: Test Connections

LEGEND:
A - Quick Coupler
B - Adapter
C - Park Brake-to-Transmission Line
D - Tee

-: Specifications

SPECIFICATIONS
Oil Temperature 65 ± 5°C (150 ± 10°F)

754
 Park Brake Release Pressure Test

SPECIFICATIONS
Engine Speed 1500 ± 25 rpm

Park Brake Release Pressure 1600 + 400 kPa (16 + 4 bar) (232 + 58 psi)
Park Brake Applied Pressure 0

-: Essential Tools

ESSENTIAL TOOLS
D-38H1032 (-10 M x -10 F x -10 M ORFS) (Parker No. 10R6IO-S) Tee
B-JT03458 (7/16 -20 M JIC x 1-14 F ORFS -10) Adapter
A-PD34BTX Quick Coupler

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer
Digital Thermometer
Gauge 0-3500 kPa (0-35 bar) (0-500 psi)

1. Remove floor panel in cab or ROPS.

2. Install tachometer and thermometer. (See procedures in this group.)

3. Make test connections.

4. Heat oil to specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Transmission Oil Warm-up Procedure in this group.)

5. Increase rpm to specification and record pressure reading with park brake
OFF, FNR in neutral , MFWD engaged (if equipped) and differential lock
disengaged.

Item Measurement Specification

Engine Speed 1500 ± 25 rpm
Park Brake Release Pressure 1600 + 400 kPa (16 + 4 bar) (232 + 58 psi)

755
 Park Brake Release Pressure Test
With park brake switch ON pressure should be zero.
Item MeasurementSpecification
Park Brake Applied Pressure 0

6. If park brake pressure is not to specification, do System Pressure Test. (See

procedure in this group.) If system pressure is OK, but park brake pressure is
low, it indicates leakage in park brake circuit. Check axle oil level. See Section
9000, Group 4. If oil level is high park brake piston seals may be leaking. If
axle oil level is OK, but park brake pressure is low, leakage is indicated in
transmission control valve, park brake solenoid or gasket.

TX,25,SS3157-19-1998/07/22

756
 System Pressure Test

System Pressure Test

T101892-UN: Test Port Location

-: Specifications

SPECIFICATIONS
Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed 1500 ± 25 rpm

System Pressure 1600 + 300 kPa (16 + 3 bar) (232 +
44 psi)

757
 System Pressure Test

SPECIFICATIONS
Each 1.00 mm (0.039 in.) Shim Changes 115 kPa (1.15 bar) (16.68 psi)
Pressure

-: Essential Tools

ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer
Digital Thermometer
Gauge 0-3500 kPa (0-35 bar) (0-500 psi)

1. Install Electronic Tachometer and Digital Thermometer, see procedures in this

group.

2. Remove floor panel in cab or ROPS.

3. Make test connections in port (A).

4. Heat oil to specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
See Transmission Oil Warm-up Procedure in this group.

5. With FNR lever in neutral and gear shift lever (manual shift) in neutral.
Operate machine to specifications and record pressure.

Item MeasurementSpecification
Engine Speed 1500 ± 25 rpm
System Pressure 1600 + 300 kPa (16 + 3 bar) (232 + 44 psi)

6. If pressure is too low, run test at 80° C (176° F) if pressure is still low check
pressure regulating valve, repair or shim adjust. A 1.00 mm (0.039 in.) shim is
equal to 115 kPa (1.15 bar) (16.68 psi) (see Pressure Regulating Valve
Adjustment in repair manual).

758
 System Pressure Test

Item MeasurementSpecification
Each 1.00 mm (0.039 in.) Shim Pressure 115 kPa (1.15 bar)
Changes (16.68 psi)

If adjustment does not raise pressure, do Transmission Pump Flow Test see
procedure in this group.

7. If pressure is too high redo test using 80° C (176° F) temperature. If pressure
is still to high check pressure regulating valve, repair or shim adjust.

Item MeasurementSpecification
Each 1.00 mm (0.039 in.) Shim Pressure 115 kPa (1.15 bar)
Changes (16.68 psi)
Make sure test was performed at correct specifications.

CED,TX03399,4265-19-1998/07/22

759
 Manual Shift Forward and Reverse Clutch Pressure Test

Manual Shift Forward and Reverse Clutch Pressure Test

T101895-UN: Forward Clutch Test Port

760
 Manual Shift Forward and Reverse Clutch Pressure Test

T101896-UN: Reverse Clutch Test Port

-: Specifications

SPECIFICATIONS
Oil Temperature 65 ± 5°C (150 ± 10°F)
Engine Speed 1500 ± 25 rpm

Forward or Reverse Pressure 1600 + 300 kPa (16 + 3 bar) (232 + 44

psi)
Neutral Disconnect De-Activated 0
Pressure

761
 Manual Shift Forward and Reverse Clutch Pressure Test
-: Essential Tools

ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer
Digital Thermometer
Gauge 0-3500 kPa (0-35 bar) (0-500 psi)

1. Install tachometer and thermometer. (See procedure in this group.)

2. Remove floor panel in cab or ROPS.

3. Make test connections in port (A) forward or (B) reverse.

4. Heat oil to specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Transmission Oil Warm-Up procedure in this group.)

5. NOTE:

Forward and reverse pressures should be the same.

Gear shift lever in neutral and park brake OFF and FNR lever in forward or
reverse, record pressure gauge readings.

Item MeasurementSpecification
Engine Speed 1500 ± 25 rpm
Forward or Pressure 1600 + 300 kPa (16 + 3 bar) (232 + 44
Reverse psi)

6. Low pressure in one direction indicates leakage in that pack or solenoid. Low
pressure in both directions indicates low system pressure. (Do System
Pressure Test in this group.)

7. With FNR lever in neutral, a slight pressure recorded in either the forward or
762
 Manual Shift Forward and Reverse Clutch Pressure Test
reverse test port could indicate that the ball in the clutch shaft came out (lube
passage) or a problem with the control valve. Repair clutch pack, see Group
0350. Repair control valve, see Group 0360.

NOTE:

When neutral disconnect is de-activated pressure should be

zero.

Item MeasurementSpecification
Neutral Disconnect De-Activated Pressure 0

CED,TX03399,4232-19-1998/05/15

763
Power Shift Low Range Forward, High Range Forward, Reverse and Speed Clutch Pressure Test

Power Shift Low Range Forward, High Range Forward, Reverse and
Speed Clutch Pressure Test

T115471-UN: Clutch Pack Pressure Test Ports

LEGEND:
A - Low Range Forward Clutch Pressure Test Port
B - Reverse Clutch Pressure Test Port
C - High Range Forward Clutch Pressure Test Port
D - First Speed Clutch Pressure Test Port
E - Second Speed Clutch Pressure Test Port
F - Third Speed Clutch Pressure Test Port

-: Specifications

764
Power Shift Low Range Forward, High Range Forward, Reverse and Speed Clutch Pressure Test

SPECIFICATIONS
Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed 1500 ± 25 rpm

Forward or Reverse Pressure 1600 + 300 kPa (16 + 3 bar) (232 + 44
psi)
Neutral Disconnect De-Activated 0
Pressure

-: Essential Tools

ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer
Digital Thermometer

Gauge 0-3500 kPa (0-35 bar) (0-500 psi)

1. Install tachometer and thermometer. (See procedure in this group.)

2. Remove floor panel in cab or ROPS.

3. Make test connection in appropriate port (A, B, C, D, E or F).

4. Heat oil to specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Transmission Oil Warm-Up Procedure in this group.)

5. NOTE:

All clutch pressures should be the same.

Machine off ground. Engine speed at specifications and park brake OFF and
FNR lever in forward or reverse, record pressure in all speed ranges.

765
Power Shift Low Range Forward, High Range Forward, Reverse and Speed Clutch Pressure Test

Item MeasurementSpecification
Engine Speed 1500 ± 25 rpm
Forward or Pressure 1600 + 300 kPa (16 + 3 bar) (232 + 44
Reverse psi)

6. Low pressure in one direction indicates a leakage in that pack or solenoid.

Low pressure in both directions indicates a leakage in the speed clutch or low
system pressure. (Do System Pressure Test in this group.)

7. With FNR lever in neutral, a slight pressure recorded in either the forward or
reverse test port could indicate that the ball in the clutch shaft came out (lube
passage) or a problem in control valve. Repair clutch pack, see Group 0350.
Repair control valve, see Group 0360.

8. With FNR lever in neutral, pressure recorded in the speed clutch test ports
could indicate a problem with the time delay relay. See Group 9015-15.

NOTE:

When neutral disconnect is de-activated, pressure should be

zero.

Item MeasurementSpecification
Neutral Disconnect De- Pressure 0
Activated

CED,TX03399,4233-19-1998/05/15

766
 Reducing Valve Pressure Test

Reducing Valve Pressure Test

T101897-UN: Test Port Location

-: Specifications

SPECIFICATIONS
Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed 1500 ± 25 rpm

Reducing Valve Pressure 850-1050 kPa (8.5-10.5 bar) (123-152 psi)

-: Essential Tools

767
 Reducing Valve Pressure Test

ESSENTIAL TOOLS

AT202955 (Parker No. PD357) Diagnostic Coupler

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer

Digital Thermometer
Gauge 0-2000 kPa (0-20 bar) (0-300 psi)

1. Install Electronic Tachometer and Digital Thermometer , see procedure in this

group

2. Remove floor panel in cab or ROPS.

3. Make test connections in port (A).

4. Heat oil to specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
See Transmission Oil Warm-up Procedure in this group.

5. With FNR lever in neutral and gear shift lever (manual shift) in neutral.
Operate machine to specifications and record pressure.

Item MeasurementSpecification
Engine Speed 1500 ± 25 rpm
Reducing Valve Pressure 850-1050 kPa (8.5-10.5 bar) (123-152 psi)

6. If reducing valve pressure is not to specification do System Pressure Test in

this group. If system pressure is OK, but reducing valve pressure is low, it
indicates a leak in the circuit. See repair Group 0360.

7. If pressure is too high check reducing valve for sticky spool or binding. See
repair manual, Group 0360. Make sure test was performed at correct
specifications.

CED,TX03399,4266-19-1998/07/22

768
 Modulation Valve Pressure Test

Modulation Valve Pressure Test

T101898-UN: Test Port Location

-: Specifications

SPECIFICATIONS
Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed 1500 ± 25 rpm

Neutral Pressure 270-300 kPa (2.7-3 bar) (39-44 psi)
Engine Speed 1500 ± 25 rpm

769
 Modulation Valve Pressure Test

SPECIFICATIONS
System Modulated 1600 + 300 kPa (16 + 3 bar) (232 + 44 psi)
(Final) Pressure

Modulation Phase 300-1200 kPa (3-12 bar) (44-174 psi)

Pressure
Modulation Valve Neutral into gear 0-1600 kPa (0-16 bar) (0-232 psi) in 2
Pressure Test Shift seconds and from Forward/Reverse or Reverse/Forward into
Time a gear 1.7 seconds Maximum
Each 1.00 mm 42 kPa (0.42 bar) (6.09 psi)
(0.039 in.) Shim
Changes Pressure

-: Essential Tools

ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler (Power Shift Only)
Parker No. 4M10C80MX (7/16-20 37° x M10 x 1) Elbow (Manual Shift Only)
Parker No. PD348 Diagnostic Coupler (Manual Shift Only)

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer
Digital Thermometer
Gauge 0-3500 kPa (0-35 bar) (0-500 psi)

1. Install tachometer and thermometer . (See procedure in this group.)

2. Remove floor panel in cab or ROPS.

3. Make test connections in port (A).

4. Heat oil to specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Transmission Oil Warm-Up Procedure in this group.)

770
 Modulation Valve Pressure Test

5. FNR lever in neutral, record pressure reading.

Item MeasurementSpecification
Engine Speed 1500 ± 25 rpm
Neutral Pressure 270-300 kPa (2.7-3 bar) (39-44 psi)

6. NOTE:

Forward and reverse pressures should be the same.

Machine off the ground. FNR lever in forward or reverse, record pressure
gauge readings.

Item MeasurementSpecification
Engine Speed 1500 ± 25 rpm
System Modulated Pressure 1600 + 300 kPa (16 + 3 bar) (232 +
(Final) 44 psi)
Modulation Phase Pressure 300-1200 kPa (3-12 bar) (44-174 psi)

7. If total shift time from 0-1600 kPa (0-16 bar) (0-232 psi) takes more than
specifications while doing this test, it indicates a problem in the modulation
valve.

Item MeasurementSpecification
Modulation Shift Time Neutral into gear 0-1600 kPa (0-16 bar) (0-232
Valve psi) in 2 seconds and from Forward/Reverse or
Pressure Reverse/Forward into a gear 1.7 seconds
Test Maximum

8. If shift is slow (long modulation time only), and neutral pressure is between
270-300 kPa (2.7-3 bar) (39-44 psi) orifice in modulation circuit is restricted. If
shift is hard or neutral pressure is high, orifice is oversized, loose or missing. If
shift is long (hesitation or long fill time) or neutral pressure is low, spring is
weak, orifice is plugged. A shim 1 mm (0.039 in.) is equal to 42 kPa (0.42 bar)
(6.09 psi), see repair manual for modulation shim adjustment if modulation
shift is not acceptable. See Group 0360. Clean orifice, see Group 0360.

Item MeasurementSpecification
Each 1.00 mm (0.039 in.) Shim Pressure 42 kPa (0.42 bar) (6.09
Changes psi)

771
Modulation Valve Pressure Test
TX,25,SS3170-19-1999/12/10

772
 Differential Lock Pressure Test

Differential Lock Pressure Test

T101983-UN: Test Connections

LEGEND:
A - Tee
B - Quick Coupler
C - Adapter
D - Transmission-to-Differential Lock Rear Axle Hose

-: Specifications

SPECIFICATIONS

Oil Temperature 65 ± 5°C (150 ± 10°F)

773
 Differential Lock Pressure Test

SPECIFICATIONS
Engine Speed 1500 ± 25 rpm
Differential Lock Pressure 1600 + 400 kPa (16 + 4 bar) (232 + 58 psi)

-: Essential Tools

ESSENTIAL TOOLS

38H1022 (1/4 M x 1/4 F x 1/4 M) (Parker No. 4R6LO-S) Tee

PD34BTX Quick Coupler
JT03455 (7/16 -20 M JIC x 9/16 -18 x -4 F ORFS) Adapter

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer
Digital Thermometer
Gauge 0-3500 kPa (0-35 bar) (0-500 psi)

1. Install tachometer and thermometer. (See procedure in this group.)

2. Remove floor panel in cab or ROPS.

3. Make test connections.

4. Heat oil to specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Transmission Oil Warm-Up Procedure in this group.)

5. MFWD and park brake engaged.

6. Increase rpm to specification and record pressure reading with differential lock
pedal switch pressed down.

Item MeasurementSpecification
Engine Speed 1500 ± 25 rpm
Differential Lock Pressure 1600 + 400 kPa (16 + 4 bar) (232 + 58 psi)

NOTE:
774
 Differential Lock Pressure Test
NOTE:

When differential lock pedal switch is released pressure

should be zero.

7. If differential pressure is not to specification, do System Pressure Test. (See

procedure in this group). If system pressure is OK, but differential lock
pressure is low, it indicates a leak in the circuit. See repair.

Check axle oil level. See Section 9000. Group 4. If oil level is high, seals may
be leaking. If axle oil level is OK, but differential lock pressure is low leakage is
indicated in transmission control valve, differential lock solenoid or gasket.

TX,25,SS3165-19-1998/07/22

775
 MFWD Pressure Test-If Equipped

MFWD Pressure Test-If Equipped

T101916-UN: MFWD Pressure

-: Specifications

SPECIFICATIONS
Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed 1500 rpm

MFWD Pressure 1600 + 400 kPa (16 + 4 bar) (232 + 58 psi)

-: Essential Tools

776
 MFWD Pressure Test-If Equipped

ESSENTIAL TOOLS

(M10 x 1.0 ORB) (Parker No. PD357) Quick Coupler

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer

Digital Thermometer
Gauge 0-3500 kPa (0-35 bar) (0-500 psi)

1. Install tachometer and thermometer. (See procedure in this group.)

2. Remove floor panel in cab or ROPS.

3. Make test connections in port (A).

4. Heat oil to specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Transmission Oil Warm-Up Procedure in this group.)

5. Increase rpm to specifications and record pressure reading with MFWD switch
OFF, park brake engaged and differential lock disengaged.

Item MeasurementSpecification
Engine Speed 1500 rpm
MFWD Pressure 1600 + 400 kPa (16 + 4 bar) (232 + 58 psi)

NOTE:

When MFWD switch is ON pressure should be zero.

6. If pressure is low, check System Pressure. See procedure in this group. If low,
leakage in MFWD circuit is indicated . Possible locations include the delivery
tube (inside case), the MFWD piston seal, the transmission control valve
gasket, or the MFWD solenoid.

TX,25,SS3166-19-2000/01/28

777
 Cooler In and Cooler Out Pressure Test

Cooler In and Cooler Out Pressure Test

T115564-19: High Ambient Cooler

778
 Cooler In and Cooler Out Pressure Test

T115565-UN: Standard Cooler

-: Specifications

SPECIFICATIONS

Oil Temperature at Sump 65 ± 5° C (150 ± 10° F)

Engine Speed 1500 ± 25 rpm
Standard Cooler
Cooler In Pressure 317 ± 35 kPa (3.17 ± 0.35 bar) (39 ± 5
psi)

Cooler Out Pressure 152 ± 35 kPa (1.52 ± 0.35 bar) (24 ± 5

psi)

779
 Cooler In and Cooler Out Pressure Test

SPECIFICATIONS
Normal Cooler Pressure Difference 165 ± 35 kPa(1.65 ± 0.35 bar) (15 ± 5
(Drop) psi)

Normal Cooler Flow 38 ± 1 L/min (10 ± 0.264 gpm)

Minimum Cooler Flow 25 ±1 L/min (6.6 ± 0.264 gpm)
High Ambient Cooler

Cooler In Pressure 207 ± 35 kPa (2.07 ± 0.35 bar) (30 ± 5

psi)
Cooler Out Pressure 124 ± 35 kPa (1.24 ± 0.35 bar) (18 ± 5
psi)
Normal Cooler Pressure Difference 83 ± 35 kPa (0.83 ±0.35 bar) (12 ± 5 psi)
(Drop)

Normal Cooler Flow 42 ± 1 L/min (11 ± 0.264 gpm)

Minimum Cooler Flow 25 ± 1 L/min (6.6 ± 0.264 gpm)

-: Essential Tools

ESSENTIAL TOOLS

(C) (1/2 M NPT x 3/4) Barb Fitting (4 Used)

(D) (1/2 M NPT x 1/2 F NPT) Elbow 90°
(F) XPD343 Quick Coupler

(G) JT03105 (1/2 M NPT x 1/4 F NPT) Connector

(H) JT03348 (1/2 F NPT x 1/2 F NPT x 1/2 F NPT) Tee

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer
Digital Thermometer

Gauge 0-2000 kPa (0-20 bar) (0-300 psi) (2 Used)

(E) Flowmeter

(A) Hose Piece 3/4 in., cut to length required

(B) Hose Piece 3/4 in., cut to length required

780
 Cooler In and Cooler Out Pressure Test

NOTE:

High ambient cooler shown with test connections. Same test

connections are also used for the standard cooler. Make test
connection to standard cooler at location key (I).

1. Install Electronic Tachometer , see procedure in this group.

2. Install digital thermometer probe into sump using dipstick tube.

3. Make test connections to high ambient cooler or standard cooler.

4. Heat oil to specifications.

Item Measurement Specification

Oil Temperature at Sump 65 ± 5° C (150 ± 10° F)
See Transmission Oil Warm-up Procedure in this group.

5. With FNR lever in neutral and gear shift lever (manual shift only) in neutral.
Operate machine to specifications and record pressure and flow.

781
 Cooler In and Cooler Out Pressure Test

Item Measurement Specification

Engine Speed 1500 ± 25 rpm
Standard Cooler
Standard Cooler-Cooler Pressure 317 ± 35 kPa (3.17 ± 0.35 bar)
In (39 ± 5 psi)
Standard Cooler-Cooler Pressure 152 ± 35 kPa (1.52 ± 0.35 bar)
Out (24 ± 5 psi)
Standard Cooler-Normal Pressure 165 ± 35 kPa (1.65 ± 0.35 bar)
Cooler Difference (Drop) (15 ± 5 psi)
Standard Cooler-Normal Flow 38 ± 1 L/min (10 ± 0.264 gpm)
Cooler
Standard Cooler- Flow 25 ± 1 L/min (6.6 ± 0.264 gpm)
Minimum Cooler
High Ambient Cooler
High Ambient Cooler- Pressure 207 ± 35 kPa (2.07 ± 0.35 bar)
Cooler In (30 ± 5 psi)
High Ambient Cooler- Pressure 124 ± 35 kPa (1.24 ± 0.35 bar)
Cooler Out (18 ± 5 psi)
High Ambient Cooler- Pressure 83 ± 35 kPa (0.83 ± 0.35 bar)
Normal Cooler Difference (Drop) (12 ± 5 psi)
High Ambient Cooler- Flow 42 ± 1 L/min (11 ± 0.264 gpm)
Normal Cooler
High Ambient-Minimum Flow 25 ± 1 L/min (6.6 ± 0.264 gpm)
Cooler

6. If cooler restriction is high, inspect cooler hoses and cooler for damage. If no
damage found, clean cooler using oil caddy.

7. If cooler pressures are low, see Solenoid Circuit Leakage Test in this group.

8. Check cooler pressures in all shifts. If pressure is low, FNR solenoid or pump
problems are indicated. Pump stop sleeve may be blocking flow to torque
converter or torque converter may be plugged. Do Torque Converter Stall in
this group.

CED,TX03399,4267-19-1998/07/22

782
 Solenoid Circuit Leakage Test

Solenoid Circuit Leakage Test

NOTE:

Do Cooler In and Cooler Out Pressure Test in conjunction with this

test.

-: Specifications

SPECIFICATIONS
Oil Temperature at Sump 65° C (150° F )
Engine Speed 900 + 25 - 0 rpm

If cooler pressures are low from the Cooler In and Cooler Out Pressure Test do the
following test.

1. Install test equipment, see Cooler In and Cooler Out Pressure Test in this
group.

2. Heat oil to specification. See procedure in this group.

Item Measurement Specification

Oil Temperature at Sump 65° C (150° F )

3. Machine off the ground. FNR lever in neutral and gear shift lever (manual shift
only) in neutral, operate machine to specifications. Record pressures and
flows in forward, high range forward (power shift only) reverse, neutral, speed
clutches (power shift only), MFWD, differential lock and park brake.

Item MeasurementSpecification
Engine Speed 900 + 25 - 0 rpm
There should be a momentary fluctuation in pressure/flow if circuit is normal. If
pressure and cooler pressure in and out and flow remains down, this indicates
a leakage in that circuit. See 9015-15 to check solenoids.

CED,TX03399,4268-19-1998/07/22

783
 Pump Flow Test

Pump Flow Test

T102857-UN: Test Connections-Manual Shift Shown

-: Specifications

SPECIFICATIONS

Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed 1500 ± 25 rpm
New Pump Flow 42 L/min (11.2 gpm)

Used Pump Flow 36 L/min (9.5 gpm)

-: Essential Tools

784
 Pump Flow Test

ESSENTIAL TOOLS
A-JDG596 Filter Adapter

JDG596A1 Spacer and Sealing Washer Kit

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

B-Flowmeter
Electronic Tachometer
Digital Thermometer

1. IMPORTANT:

On early machines use the washers and spacer to make

filter adapter fit. This will keep filter from leaking. On later
machines just use the filter adapter.

Make test connections. When installing filter adapter use a washer on both
sides of spacer on early machines.

2. Install electronic tachometer and digital thermometer. (See procedure in this

group.)

3. IMPORTANT:

Before starting engine, check that flowmeter loading

valve is open. Pump can be damaged if engine is started
with loading valve closed.

Heat oil to specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Transmission Oil Warm-up Procedure in this group.)

4. Run engine at test specification.

785
 Pump Flow Test

Item MeasurementSpecification
Engine Speed 1500 ± 25 rpm
Measure flow.
Item MeasurementSpecification
PumpFlow 42 L/min (11.2 gpm)

5. Low transmission pump flow can be caused by:

Low oil level in transmission

Cold transmission oil
Plugged intake tube
Air leak in pump suction tube
Pump mounting cap screws loose
Worn transmission pump

TX,25,SS3207-19-1998/07/22

786
 Backhoe Hydraulic System

Backhoe Hydraulic System

The hydraulic system is a closed center, load sensing system. A variable displacement,
axial piston pump (6) supplies oil for the hydraulic system. Flow from the pump is
supplied to the inlet section of the backhoe control valve (1) and then is sent to the
stabilizer valve (5). Pump supply oil is also routed from the backhoe inlet section to the
loader control valve (22) and also to the steering valve (12). The steering valve will
always receive pump supply oil through steering pressure regulating valve (13).

The pump will adjust to the highest work port pressure sensed through the isolator
valves (27 and 19) and then through the load sense shuttle check valve (23). Pump
pressure will be 275 psi higher than the highest pressure sensed at anytime.

Item Measurement Specification

Load Sense Differential Pressure 275 psi
The pump will only supply the amount of oil required by a work port function or a
combination of work port functions. The backhoe system pressure is regulated by a
backhoe load sense relief valve (30) located in the inlet section of the backhoe stack.
The loader system pressure is regulated by a loader load sense relief valve (18) in the
loader valve inlet section. The hydraulic system is protected from extreme oil pressure
by a system relief valve (3) located in the outlet section of the backhoe valve. Load
sensing improves fuel economy and reduces heat build-up because horsepower is not
wasted on excessive pump flow that is not being used.

Return oil flows through the anti-cavitation function check valve (7) into the filter (8) and
then flows through both the cooler flow check valve (9) and the cooler (14), and on to
the reservoir. The return filter uses a spin-on filter element which attaches to a filter
housing. The return filter has a by-pass valve with a pressure switch to indicate when
the filter is restricted. The oil cooler is an air-to-oil heat exchanger. Oil is provided off
the cooler return circuit through an orifice to the service brake valve reservoir (11).

TX,9025,RR7523-19-1996/10/10

787
 Backhoe Hydraulic System

Backhoe Hydraulic System

The hydraulic system is a closed center, load sensing system. A variable displacement,
axial piston pump (6) supplies oil for the hydraulic system. Flow from the pump is
supplied to the inlet section of the backhoe control valve (1) and then is sent to the
stabilizer valve (5). Pump supply oil is also routed from the backhoe inlet section to the
loader control valve (22) and also to the steering valve (12). The steering valve will
always receive pump supply oil through steering pressure regulating valve (13).

The pump will adjust to the highest work port pressure sensed through the isolator
valves (27 and 19) and then through the load sense shuttle check valve (23). Pump
pressure will be 275 psi higher than the highest pressure sensed at anytime.

Item Measurement Specification

Load Sense Differential Pressure 275 psi
The pump will only supply the amount of oil required by a work port function or a
combination of work port functions. The backhoe system pressure is regulated by a
backhoe load sense relief valve (30) located in the inlet section of the backhoe stack.
The loader system pressure is regulated by a loader load sense relief valve (18) in the
loader valve inlet section. The hydraulic system is protected from extreme oil pressure
by a system relief valve (3) located in the outlet section of the backhoe valve. Load
sensing improves fuel economy and reduces heat build-up because horsepower is not
wasted on excessive pump flow that is not being used.

Return oil flows through the anti-cavitation function check valve (7) into the filter (8) and
then flows through both the cooler flow check valve (9) and the cooler (14), and on to
the reservoir. The return filter uses a spin-on filter element which attaches to a filter
housing. The return filter has a by-pass valve with a pressure switch to indicate when
the filter is restricted. The oil cooler is an air-to-oil heat exchanger. Oil is provided off
the cooler return circuit through an orifice to the service brake valve reservoir (11).

TX,9025,RR7523-19-1996/10/10

788
 Backhoe Hydraulic System

Backhoe Hydraulic System

The hydraulic system is a closed center, load sensing system. A variable displacement,
axial piston pump (6) supplies oil for the hydraulic system. Flow from the pump is
supplied to the inlet section of the backhoe control valve (1) and then is sent to the
stabilizer valve (5). Pump supply oil is also routed from the backhoe inlet section to the
loader control valve (22) and also to the steering valve (12). The steering valve will
always receive pump supply oil through steering pressure regulating valve (13).

The pump will adjust to the highest work port pressure sensed through the isolator
valves (27 and 19) and then through the load sense shuttle check valve (23). Pump
pressure will be 275 psi higher than the highest pressure sensed at anytime.

Item Measurement Specification

Load Sense Differential Pressure 275 psi
The pump will only supply the amount of oil required by a work port function or a
combination of work port functions. The backhoe system pressure is regulated by a
backhoe load sense relief valve (30) located in the inlet section of the backhoe stack.
The loader system pressure is regulated by a loader load sense relief valve (18) in the
loader valve inlet section. The hydraulic system is protected from extreme oil pressure
by a system relief valve (3) located in the outlet section of the backhoe valve. Load
sensing improves fuel economy and reduces heat build-up because horsepower is not
wasted on excessive pump flow that is not being used.

Return oil flows through the anti-cavitation function check valve (7) into the filter (8) and
then flows through both the cooler flow check valve (9) and the cooler (14), and on to
the reservoir. The return filter uses a spin-on filter element which attaches to a filter
housing. The return filter has a by-pass valve with a pressure switch to indicate when
the filter is restricted. The oil cooler is an air-to-oil heat exchanger. Oil is provided off
the cooler return circuit through an orifice to the service brake valve reservoir (11).

TX,9025,RR7523-19-1996/10/10

789
 Hydraulic Component Location

Hydraulic Component Location

T100889-19: Backhoe
LEGEND:
32 - Bucket Cylinder
33 - Extendible Dipperstick Cylinder
34 - Crowd Cylinder
35 - Boom Cylinder from Auxiliary Pump
36 - To Stabilizer Valve
37 - To Steering Valve

790
 Hydraulic Component Location
38 - To Loader Control Valve
39 - From Pump to Backhoe Valve
40 - To Load Sense Shuttle Valve
41 - To Auxiliary Function
42 - To Right Swing Cylinder
43 - To Left Swing Cylinder
44 - Backhoe Hydraulic-Component Location

T132707-19: Main Hydraulic System Component Location

LEGEND:
1 - Backhoe Valve
2 - Stabilizer Load Sense Orifice Tee
3 - System Relief Valve
4 - Right Stabilizer Cylinder
5 - Stabilizer Valve
6 - Hydraulic Oil Pump
7 - Anti-Cavitation Function Check Valve
8 - Hydraulic Oil Filter
9 - Cooler Flow Check Valve
10 - Hydraulic Oil Reservoir
11 - Brake Valve
12 - Steering Valve
13 - Steering Pressure Regulating Valve
14 - Hydraulic Oil Cooler
15 - Bucket Cylinder
16 - Front Axle
17 - Transmission
18 - Loader Load Sense Relief Valve

791
 Hydraulic Component Location
19 - Isolator Valve
20 - Right Loader Cylinder
21 - Load Sense Line
22 - Loader Valve
23 - Load Sense Shuttle Check Valve
24 - Rear Axle
25 - Steering Pressure Hose (Special Attenuator)
26 - Main Hydraulic Component Location (Neutral)
27 - Isolator Valve
28 - Left Stabilizer Cylinder
29 - Left Swing Cylinder
30 - Backhoe Load Sense Relief Valve
31 - Right Swing Cylinder
32 - Bucket Cylinder
33 - Extendible Dipperstick Cylinder
34 - Crowd Cylinder
35 - Boom Cylinder
36 - To Stabilizer Valve
37 - To Steering Valve
38 - To Loader Control Valve
39 - From Pump to Backhoe Valve
40 - To Load Sense Shuttle Valve
41 - To Auxiliary Function
42 - To Right Swing Cylinder
43 - To Left Swing Cylinder
44 - Backhoe Hydraulic-Component Location
45 - Attenuator (Cab Machines only)(S.N.xxxx-)

CED,TX03768,2674-19-1999/11/19

792
 Hydraulic System Schematic-Neutral

Hydraulic System Schematic-Neutral

T132709-19: Hydraulic Schematic-Neutral

TX,9025,RR7524-19-1996/10/10

793
 Hydraulic System Schematic-Multiple Functions Activated

Hydraulic System Schematic-Multiple Functions Activated

T132708-19: Hydraulic Schematic-Multiple Functions Activated

TX,9025,RB16-19-1997/10/30

794
 Hydraulic System Schematic-Neutral with Power Boost MICO Brake Valve

Hydraulic System Schematic-Neutral with Power Boost MICO Brake

Valve

T129443-UN:

CED,TX03768,2727-19-2000/04/13

795
Hydraulic System Schematic-Multiple Functions Activated with Power Boost MICO Brake Valve

Hydraulic System Schematic-Multiple Functions Activated with

Power Boost MICO Brake Valve

T129450-UN:

CED,TX03768,2728-19-2000/04/13

796
 Hydrualic Component Location-Power Boost MICO Brake Valve Circuit- Both Pedals Applied

Hydrualic Component Location-Power Boost MICO Brake Valve

Circuit- Both Pedals Applied

T129552-UN: MICO Brake Valve Circuit

LEGEND:
1 - Axle
2 - MICO Brake Valve
3 - Hydraulic Reservoir
4 - Radiator
5 - Transmission
6 - Hydraulic Pump
7 - Oil Cooler
8 - Pressure Free Oil
9 - Low Pressure Oil
10 - Medium Pressure Oil
11 - High Pressure Oil
12 - Power Boost MICO Brake Valve-Both Pedals Applied

CED,TX03768,2726-19-2000/04/13

797
 Load Sense Isolator

Load Sense Isolator

T109416-19: Load Sense Isolator-Neutral Position

LEGEND:
A - Input from Valve Load Sensing Network
B - Supply from Pump
C - Load Sense Output (to compensators and pump load sense input)
D - Return Passage
E - Damping Orifice

798
 Load Sense Isolator
F - Pilot Passage
G - Orifice
H - Return Pressure
I - Load Sense Pressure
J - Pump Pressure
K - Load Sense Isolator-Metering

The load sense isolators are used to sense the loader or backhoe valve’s highest
bridge pressure, representing the highest load at a work port. It then sends an equal
pressure to the pump’s load sense port.

When all of the control valve spools are in neutral, the highest work port pressure at the
input (A) of the isolator is equal to return pressure. Pump output pressure is transmitted
into port (B) of the isolator and out port (C). This pressure, also sensed at the end of the
spool through the damping orifice (E) and pilot passage (F) tends to push the spool
toward the inlet chamber (to the left). As the spool moves in that direction, the flow path
created by the connection of pump port (B) to load sense output port (C) begins to be
choked off by the spool land and metering occurs. This will tend to limit the pressure in
the load sense output port (C) to some equalized value. Since the spring force is light,
the pump load sense port sees zero pressure and therefore the pump puts out pressure
equal to the load sense differential setting. The existing return passage pressure will
increase pump outlet pressure by the same value.

If one of the control valve spools is moved in order to move a load, the work port
pressure is sensed at the input port (A) of the isolator. That pressure will now become
the equalized pressure and will therefore be output at passage (C) to the pump load
sense port. The pump will then output port (C) pressure plus the load sense differential
pressure.

As a result, the pump load sense port sees the highest work port pressure, but the oil in
the load sensing shuttle system does not leave the valve assembly. It is stopped at the
isolator input (A), which is located at the inlet section of the valve assembly. The pump
provides it’s own constant source of oil, through the isolator, to keep the hose between
the load sense output port of the valve and the load sense port of the pump filled with
oil. When load sense pressure changes, the new pressure is transmitted to the load
sense port without the need to first fill the hose with oil, and load dipping is eliminated.

A load sense relief valve is present downstream of orifice (G), it’s poppet will unseat
when load sense pressure at (C) exceeds the relief’s pressure setting. The orifice (G) is
added in the inlet housing to limit the flow through the load sense relief valve.

TX,9025,RR7541-19-1996/11/08

799
 Load Sense With All Functions in Neutral

Load Sense With All Functions in Neutral

T109410-19: Load Sense With All Functions in Neutral

LEGEND:
A - Load Sense Isolator
B - Load Sense Relief Valve
C - Compensator
D - Load Sense Shuttle Check
E - Compensator Lock
F - Load Sense Shuttle Connection

800
 Load Sense With All Functions in Neutral
G - Load Sense-to-Pump Connection
H - Load Sense-to-Compensator Connection
I - Load Sense Port
J - Load Sense to Pump Port
K - Main Spool
L - Exhaust (Tank) Passage
M - Pump Passages
N - Compensator Feeder Passage
O - Bridge Passage
P - Pump
Q - Load Sense Orifice
R - Work Port
S - Work Port
T - Outlet Housing
U - Main Relief
V - Return Oil
W - Load Sense Oil
X - Trapped Oil
Y - Low Standby Pressure
Z - Load Sense with All Functions in Neutral

The backhoe and loader control valves are closed center, load sensing, sectional
valves with individual section compensation. The compensators located between
sections divide pump flow to control multiple functions. Flow from each function remains
constant regardless of pressure requirement until pump capacity is exceeded. When
flow demand does exceed pump capacity, all functions will continue to operate at
reduced flows.

To illustrate how the valve works within the pressure compensated load sensing
system, consider this sequence of events:

1. Valve in neutral.
2. Operate boom raise function requiring 500 psi.
3. While raising the boom, dump the bucket requiring 1000 psi.
4. Boom stalls at maximum height with bucket still dumping.

With all valve spools (K) in neutral, the pump (P) has no load sense pressure signal.
The load sense passages (F) within the valve are connected internally to the return
circuit. Return circuit pressure, however, can vary between 0 and 150 psi during
operation. This means with a load sense differential pressure of 275 psi, pump outlet
pressure with the valve spools in neutral can vary between 275 and 425 psi. The load

801
 Load Sense With All Functions in Neutral
sense differential pressure is always a constant 275 psi.

Item Measurement Specification

Load Sense Differential Pressure 275 psi

TX,9025,RR7547-19-1996/11/22

802
 Load Sense With One Function Activated

Load Sense With One Function Activated

T111786-19: Load Sense With One Function Activated

LEGEND:
A - Load Sense Isolator
B - Load Sense Relief Valve
C - Compensator
D - Load Sense Shuttle Check
E - Compensator Lock
F - Load Sense Shuttle Connection

803
 Load Sense With One Function Activated
G - Load Sense-to-Pump Connection
H - Load Sense-to-Compensator Connection
I - Load Sense Port
J - Load Sense to Pump Port
K - Main Spool
L - Exhaust (Tank) Passage
M - Pump Passages
N - Compensator Feeder Passage
O - Bridge Passage
P - Pump
Q - Load Sense Orifice
R - Work Port
S - Work Port
T - Outlet Housing
U - Main Relief
V - System Pressure Oil
W - Load Pressure
X - Load Sense Oil
Y - Return Oil
Z - Trapped Oil
AA - Load Sense with One Function Activated

When the boom spool is moved in, several connections are made within the valve
section; the bridge passage (O) load sense internal bleed is shutoff, work port (S) is
connected to the return passage (L) through the spool notches, the pump passage (M)
is connected to the compensator feeder passage (N) through spool notches and the
bridge passage (O) is connected to work port (R) through spool notches.

With the above connections made, the 500 psi work port pressure is sensed at the
isolator through the load sense shuttle check (D). The isolator then sends the 500 psi
signal through passage (G) to the pump’s load sense port. The pump adds 275 psi load
sense differential pressure to the 500 psi signal pressure and outputs 775 psi.

Item Measurement Specification

Load Sense Differential Pressure 275 psi
This pressure is seen in all valve sections at the pump passages (M).

As the pressure in the compensator feeder passage (N) increases slightly over 500 psi
(the compensator bias spring force is light), the compensator spool (C) moves allowing
oil flow into the bridge (O) and then past the spool notches to work port (R). The flow to

804
 Load Sense With One Function Activated
the work port is determined by the 275 psi differential pressure across the spool
notches between the pump output passage (M) and the feeder passage (N).

Item Measurement Specification

Load Sense Differential Pressure 275 psi

TX,9025,RR7569-19-1996/12/16

805
 Load Sense With Multiple Functions Activated

Load Sense With Multiple Functions Activated

T109412-19: Load Sense With Multi-Functions Activated

LEGEND:
A - Load Sense Isolator
B - Load Sense Relief Valve
C - Compensator
D - Load Sense Shuttle Check
E - Compensator Lock
F - Load Sense Shuttle Connection

806
 Load Sense With Multiple Functions Activated
G - Load Sense-to-Pump Connection
H - Load Sense-to-Compensator Connection
I - Load Sense Port
J - Load Sense to Pump Port
K - Main Spool
L - Exhaust (tank) Passage
M - Pump Passages
N - Compensator Feeder Passage
O - Bridge Passage
P - Pump
Q - Load Sense Orifice
R - Work Port
S - Work Port
T - Outlet Housing
U - Main Relief
V - System Pressure Oil
W - Highest Load Pressure
X - Lowest Load Pressure
Y - Load Sense Oil
Z - Return Oil
AA - Trapped Oil
BB - Load Sense with Multiple Functions Activated

When the bucket spool is moved out, the connections made within the valve section are
the same as for the boom section previously discussed, except that work port (R) is
connected to return passage (L) and bridge passage (O) is connected to workport (S).

The pressure required is now 1000 psi at workport (S) of the bucket section. This
pressure is sent through the load sense shuttle check (D). Since this pressure is higher
than the 500 psi required in the boom section, the shuttle check (D) in the bucket
section moves to block the 500 psi signal allowing the 1000 psi signal to the isolator and
then to the pump’s load sense port. The pump adds 275 psi load sense differential to
the 1000 psi signal pressure and outputs 1275 psi.

Item Measurement Specification

Load Sense Differential Pressure 275 psi
Again this pressure is seen at the pump passages (M).

The compensator (C) in the boom section must now react to the increase in load sense
pressure (to 1000 psi) since this pressure is on the load sense side of the compensator

807
 Load Sense With Multiple Functions Activated
(C) and the pressure in the bridge (O) is still 500 psi. The pressure in the compensator
feeder passage (N) must build to slightly over 1000 psi to overcome the load sense
pressure. This allows flow to the bridge (O) of the boom section through the
compensator (C). At this time there is still 500 psi in the bridge (O), but the compensator
feeder passage (N) is at 1000 psi, and the pump passage (M) is at 1275 psi. Note that
the differential pressure of 275 psi still exists across the spool notches between the
pump output passage (M) and the feeder passage (N).

Item Measurement Specification

Load Sense Differential Pressure 275 psi
Therefore, even though the pump output pressure required increases from 775 psi to
1275 psi, the flow to the boom workport remains the same.
TX,9025,RR7570-19-1996/12/16

808
 Load Sense With Multiple Functions Activated (One Function Stalled)

Load Sense With Multiple Functions Activated (One Function Stalled)

T111785-19: Load Sense With Multiple Functions Activated

LEGEND:
A - Load Sense Isolator
B - Load Sense Relief Valve
C - Compensator
D - Load Sense Shuttle Check
E - Compensator Lock
F - Load Sense Shuttle Connection

809
 Load Sense With Multiple Functions Activated (One Function Stalled)
G - Load Sense-to-Pump Connection
H - Load Sense-to-Compensator Connection
I - Load Sense Port
J - Load Sense to Pump Port
K - Main Spool
L - Exhaust (tank) Passage
M - Pump Passages
N - Compensator Feeder Passage
O - Bridge Passage
P - Pump
Q - Load Sense Orifice
R - Workport
S - Work Port
T - Outlet Housing
U - Main Relief
V - System Pressure Oil
W - Highest Load Pressure
X - Lowest Load Pressure
Y - Load Sense Oil
Z - Return Oil
AA - Trapped Oil
BB - Load Sense with Multiple Functions Activated and One Function Stalled

When the boom stalls at maximum height, the load sense relief (B) unseats limiting load
sense pressure to 3350 psi. All compensators and the pump’s load sense port sense
this pressure and the pump will output 3625 psi. The bucket function will continue to
operate, but the speed will be reduced as the flow limiter engages.

TX,9025,RR7571-19-1996/12/16

810
 Hydraulic Pump-Neutral Operation

Hydraulic Pump-Neutral Operation

T105504-19: Pump in Neutral

LEGEND:
A - Outlet Port
B - Pump Inlet Port
C - Suction
D - Pump Piston
E - Control Pin
F - Drive Shaft
G - Swash Plate
H - Pressure
I - Low Pressure
J - Pump-Neutral

The main hydraulic pump is an axial piston, variable displacement pump. The pump
mounts to the machine’s transmission auxiliary drive case and the pump’s drive shaft
(F) splines into the external pump drive. The drive shaft is supported by a ball bearing
on the spline end and a bearing sleeve in the valve plate’s end cap.

Neutral position results when the pump control centers the swash plate (G) with its

811
 Hydraulic Pump-Neutral Operation
control pin (E). The swash plate angle is now zero and swash plate face is now parallel
to cylinder face. Therefore, no inward or outward motion of the pump pistons (D) exists
as piston shoes rotate around the swash plate face. The lack of inward and outward
motion results in no fluid being displaced from the piston bores (A and B) to the
crescents (A and B) in the valve plate and therefore no delivery from the pump ports.

TX,9025,RR7554-19-1996/12/03

812
 Hydraulic Pump-Full Stroke

Hydraulic Pump-Full Stroke

T105505-19: Pump-Full Stroke

LEGEND:
A - Pump Inlet
B - Pump Outlet
C - Suction
D - Piston
E - Control Pin
F - Drive Shaft
G - Swash Plate
H - Pump Suction Inlet
I - High Pressure
J - Low Pressure
K - Pump-Full Stroke

With the engine running, and full stroke is required, the drive shaft drives the splined
cylinder block which contains the pumping pistons (D). When the cylinder is rotated, the
pistons move in and out of their bores as the shoes “ride” against the angled swash
plate (G). The angled swash plate rides on two journal bearings and is moved by a
control pin (E) that moves with the pump control’s control piston.

813
 Hydraulic Pump-Full Stroke

As the cylinder rotates, the individual piston bores are connected, alternately, to suction
ports (B) and pressure ports (A) in valve plate. While connected to the suction port,
each piston moves outward, drawing fluid into its bore until its’s outermost stroke is
reached. As the cylinder continues to rotate, each piston moves across the angled
swash plate face. Thus, each piston is forced inward. Each piston displaces fluid out the
pressure port until it’s innermost stroke is reached. At this point, the piston bore passes
from the suction port again and the operating cycle is repeated.

TX,9025,YY2137-19-1996/12/19

814
 Hydraulic Pump Controls-Neutral

Hydraulic Pump Controls-Neutral

T105467-19: Hydraulic Pump-Neutral

LEGEND:
A - Bias Piston Spring
B - Bias Piston
C - Control Pin-to-Swash Plate in Pump
D - Control Piston
E - Pin From Flow Limiter-to-Control Piston
F - Flow Limiter

815
 Hydraulic Pump Controls-Neutral
G - Poppet
H - Load Sense Line (Port)
I - Load Sense Valve
J - Orifice
K - Control Displacement Valve
L - From Pump Outlet
M - Hydraulic Pump Function Metering
N - System Pressure Oil
O - Load Sense Pressure Oil
P - Control Pressure Oil
Q - Bias Pressure Oil
R - Return Oil

The hydraulic system is a closed center load-sensing system. The pump senses both
pressure and flow needs, and also senses hydraulic power. When none of the hydraulic
circuits are being used the pump is at low pressure standby.

The pump has three control valves, load sense valve (I), displacement control valve (K),
and flow limiter valve (F).

Pump outlet pressure is maintained at about 1865-1965 kPa (19-20 bar) (275-
285 psi) above load sense pressure.
Item MeasurementSpecification
Hydraulic Pump Pressure 1865-1965 kPa (19-20 bar) (275-285 psi)
Outlet above load sense pressure

The pump has two control pistons, bias piston (B) and control piston (D). Bias piston (B)
and bias spring (A) causes the swashplate to increase pump stroke. Control pressure
oil (O) acting on the control piston (D) causes the swashplate to decrease the pump
stroke.

With all control valve sections in neutral, load sensing pressure from the valves is equal
to return oil pressure.

Before cranking the engine, bias piston spring (A) holds control piston (D) and pump
swashplate at maximum angle. As the pump begins to turn, causing oil to flow,
pressure builds in the pump outlet passage (L) because the closed center valves are
closed.

Pump outlet pressure (L) will increase until the signal pressure oil that flows through
orifice (J) opens the load sense valve spool (I) against the spring force, allowing signal
oil to flow to return. This allows pump outlet pressure acting on the displacement control

816
 Hydraulic Pump Controls-Neutral
valve spool (K) to move it to the left.

The displacement control valve spool (K) moves to the left until the bias pressure (P) oil
can flow to return oil (Q) passage and pump outlet pressure oil can flow to control
piston (D) passage.

Pump outlet pressure acting on the control piston (D) causes the swashplate to
destroke the pump to near zero flow condition or standby mode, by overcoming the bias
piston spring (A).

In neutral, pump outlet pressure (N) (low pressure standby pressure), should be 1900-
2930 kPa (19-29.3 bar) (275-425 psi) (differential pressure plus 0-1034 kPa {0-10 bar}
{0-150 psi} return pressure).

Item MeasurementSpecification
Pump Low Standby 1900-2930 kPa (19-29.3 bar) (275-425 psi) (differential
Pressure Pressure pressure plus 0-1034 kPa {0-10 bar} {0-150 psi} return
pressure)

In standby mode the load sense valve spool (I) continues to meter signal oil during
neutral operation to maintain standby pressure.

TX,9025,RR7526-19-1996/10/10

817
 Hydraulic Pump Controls-Function Metering

Hydraulic Pump Controls-Function Metering

T105590-19: Hydraulic Pump-Function Metering

LEGEND:
A - Bias Piston Spring
B - Bias Piston
C - Control Pin-to-Swash Plate in Pump
D - Control Piston
E - Pin From Flow Limiter-to-Control Piston
F - Flow Limiter

818
 Hydraulic Pump Controls-Function Metering
G - Poppet
H - Load Sense Line (Port)
I - Load Sense Valve
J - Orifice
K - Control Displacement Valve
L - From Pump Outlet
M - Hydraulic Pump Function Metering
N - System Pressure Oil
O - Load Sense Pressure Oil
P - Control Pressure Oil
Q - Bias Pressure Oil
R - Return Oil

In the function metering mode, as the control lever is moved to change cylinder velocity,
load sense Pressurer is connected with the load sense circuit through load sense port
(H) on the load sense valve (I). Load sense pressure is equal to the highest work port
pressure created by the cylinder and is variable, dependent on the cylinder load.

If the demand for flow or pressure in the circuit increases, raising the load sense
pressure (O), load sense pressure and spring force acting on the load sense valve
spool (I) cause the spool to move, closing the valve. With the load sense spool closed,
pressure builds on the left side of the displacement control valve (K) shifting it to the
right, allowing control pressure oil (P) on the large end of the control piston (D) to drain
to return and pump outlet pressure (L) oil to flow through the center of the displacement
control valve (K) to the bias piston passage. This pressure plus the bias piston spring
(A) force moves the control piston to the right, increasing pump stroke. Pump outlet
pressure will increase until it is maintained at about 1900 kPa (19 bar) (275 psi) higher
than load sense pressure.

Item MeasurementSpecification
Hydraulic Pump Pressure Approximately 1900 kPa (19 bar) (275 psi) above
Outlet load sense pressure

If the demand for flow or pressure in the circuit decreases, reducing the load sense
pressure (O), load sense pressure and spring force acting on the load sense valve
spool (I), cause the spool to move, opening the valve. With the load sense spool
opened, pressure is reduced on the left side of the displacement control valve (K),
shifting it to the left, allowing bias pressure oil to drain to return and pump outlet
pressure (L) oil to flow to the large end of the control piston (D). This pressure moves
the control piston to the left, decreasing pump stroke. Once the lower flow requirements
are met, the displacement control valve (K) moves right to the metering position. The
pump displacement is then maintained to provide the lower pressure required.

819
 Hydraulic Pump Controls-Function Metering

When the control valves are returned to neutral, the pump will go to low pressure
standby.

TX,9025,SS3471-19-1996/12/10

820
 Hydraulic Pump Controls-Full Flow

Hydraulic Pump Controls-Full Flow

T105589-19: Hydraulic Pump-Full Flow

LEGEND:
A - Bias Piston Spring
B - Bias Piston
C - Control Pin-to-Swash Plate in Pump
D - Control Piston
E - Pin From Flow Limiter-to-Control Piston
F - Flow Limiter

821
 Hydraulic Pump Controls-Full Flow
G - Poppet
H - Load Sense Line (Port)
I - Load Sense Valve
J - Orifice
K - Pressure compensator Valve
L - From Pump Outlet
M - Pump
N - System Pressure Oil
O - Return Oil
P - Hydraulic Pump-Full Flow (Low-Medium Pressure)

If several functions are engaged at the same time, to require full flow, the pump
displacement will increase with flow demand until full displacement is achieved.

The load sense signal will be the highest work port pressure sensed. The sensed
pressure is routed to the load sense valve (I) spring area.

As the increased oil flow demand occurs at low to medium pressures, the pressure
difference between pump outlet and load sense is reduced, causing the load sense
valve (I) to close. With the load sense spool closed, pressure builds on the left side of
the displacement control valve (K) shifting it to the right, allowing control pressure oil (P)
on the large end of the control piston (D) to drain to return and pump outlet pressure (L)
oil to flow through the center of the displacement control valve (K) to the bias piston
passage. This pressure, plus the bias piston spring (A) force moves the bias piston (B)
to the right, increasing pump stroke until maximum displacement is achieved.

TX,9025,SS3472-19-1996/12/10

822
 Hydraulic Pump Controls-Flow Limited (High Pressure)

Hydraulic Pump Controls-Flow Limited (High Pressure)

T105468-19: Hydraulic Pump-Flow Limiter

LEGEND:
A - Bias Piston Spring
B - Bias Piston
C - Control Pin-to-Swash Plate in Pump
D - Control Piston
E - Pin From Flow Limiter-to-Control Piston
F - Flow Limiter

823
 Hydraulic Pump Controls-Flow Limited (High Pressure)
G - Poppet
H - Load Sense Line (Port)
I - Load Sense Valve
J - Orifice
K - Pressure Compensator Valve
L - From Pump Outlet
M - Pump
N - System Pressure Oil
O - Control Pressure Oil
P - Bias Pressure Oil
Q - Return Oil
R - Hydraulic Pump-Flow Limiter (High Pressure)

As hydraulic system pressure increases during high load applications, the flow limiter
(F) senses pump displacement swash and system pressure from the pump outlet to
limit the maximum engine speed pulldown.

The flow limiter maintains the pump displacement in relation to pump outlet pressure.
As system pressure increases, less pump displacement is available.

As hydraulic system pressure is increased to above the flow limiter setting, the pump
outlet pressure is sensed through the orifice in the center of the displacement control
valve (K) and the pressure opens the flow limiter poppet (G), allowing oil to flow to
return. This causes a pressure drop through the orifice and lowers the signal to the left
side of the displacement control valve (K).

The lower signal oil pressure causes the displacement control valve to shift to the left,
allowing bias pressure oil to drain to return and the pump outlet pressure (L) oil to flow
to the large end of the control piston (D). This pressure moves the control piston to the
left, decreasing pump stroke. The control pin (E) from the control piston to flow limiter
also moves to the left, increasing spring force on the poppet (G).

As the poppet (G) displacement control valve closes, pressure increases on the left side
of the displacement control valve (K), allowing the spool to shift to the right, maintaining
a constant pump displacement setting.

If the system pressure is again increased, the flow limiter poppet (G) will again open and
cause the pump displacement to decrease until flow limiter setting is reached.

As the system pressure is lowered below the flow limiter setting, the flow limiter poppet
(G) is closed, stopping signal oil flow to return.

824
Hydraulic Pump Controls-Flow Limited (High Pressure)
TX,9025,SS3473-19-1996/12/10

825
 Hydraulic Filter Operation

Hydraulic Filter Operation

T101460-19: Return Filter

LEGEND:
A - Inlet Port
B - Filter Housing
C - Piston
D - Spring
F - Spring
G - Valve
H - Terminal
I - Filter Element
J - To Cooler and Reservoir
K - Outlet Port to Reservoir
L - Restricted Flow
M - Semi-Restricted Flow
N - Return Flow
O - Return Filter
P - Filter Restriction Switch

826
 Hydraulic Filter Operation

The hydraulic return filter removes contaminants from the hydraulic system oil. The filter
housing contains a bypass valve (G) and a filter restriction switch (P).

Under normal operation, return flow from the loader valve, stabilizer valve and backhoe
valve enters the inlet (A), flows through the filter element (I), through the filter canister
and out the outlet (K) to reservoir, or to cooler and then to reservoir (J).

If the pressure differential between the inlet and outlet increases past a set level due to
cold oil or a partially restricted filter element, pressure drop across the filter in the
housing (B) increases, moving the piston (C) down against spring (D) force and outlet
pressure. The piston contacts the terminal (H), completing a circuit which causes the
filter restriction indicator light to glow.

As the filter element becomes plugged, the pressure differential between the inlet and
outlet increases. Inlet pressure is sensed on one side of the valve (G) which opens
against spring (F) force and outlet pressure. The return oil then bypasses the filter. This
bypass valve differential pressure setting is slightly higher than the indicator light
switch, therefore, the indicator light will always glow just before oil begins to bypass the
filter element.

Under normal operation, the restriction indicator light will glow when operating the
hydraulic functions with cold oil. If the restriction indicator light continues to glow after
the oil reaches operating temperature, the return filter is being bypassed. Extended
operation in the bypass mode will cause damage to the hydraulic system.

TX,9025,RR7516-19-1996/09/30

827
 Steering-No Steering

Steering-No Steering

T105008-19: Steering-No Steering

LEGEND:
A - Pump Pressure
B - Orifice
C - Spring
D - To Steering Port
E - Signal From Steering
F - Port “T”

828
 Steering-No Steering
G - Port “L”
H - Port “R”
I - Port “P”
J - Steering Unit
K - Load Sense Passage
L - Load Sense Spring
M - Load Sense Relief Valve
N - Load Sense Relief Adjusting Screw
O - Pump Pressure Oil
P - Return Oil
Q - Trapped Oil
R - Load Sense Oil
S - No Steering

The steering valve is essentially a closed-center type valve. The steering valve and
pressure regulating valve provide a smooth pressure compensated steering system.

When steering valve is in neutral, there is no oil flowing through it except neutral
leakage. Neutral leakage is used for lubrication and cooling the steering valve.

TX,9025,RR7527-19-1996/11/05

829
 Steering

Steering

T105007-19: Steering
LEGEND:
A - Pump Pressure
B - Orifice
C - Spring
D - To Steering Port
E - Signal From Steering
F - Port “T”

830
 Steering
G - Port “L”
H - Port “R”
I - Port “P”
J - Steering Unit
K - Load Sense Passage
L - Load Sense Spring
M - Load Sense Relief Valve
N - Load Sense Relief Adjusting Screw
O - Pump Pressure Oil
P - Return Oil
Q - Load Sense Oil
R - Steering

The steering control valve has a pressure regulating valve bolted to its port face. The
pressure regulating valve in conjunction with the load sense relief valve regulates flow
and pressure to the steering control valve.

A constant pressure drop is established across the orifice (B) in the pressure regulating
valve by means of a spring (C) in the regulating valve which will bias the spool for
steering. The pressure caused by the spring is equal to the pressure drop across the
orifice in the pressure regulating valve which produces a constant flow through the
steering control valve. The pressure caused by the spring is referred to as the control
pressure.

When the operator speeds up the steering, the pressure drop across the orifice is
reduced. The spool in the pressure regulating valve must shift to provide more flow for
the steering until the pressure drop across the orifice is equal to the control pressure.
The pressure regulating valve with a given spring will supply a predetermined amount of
flow to the steering control unit as the control orifice is varied.

As the steering wheel is turned, the spool is turned by means of its direct connection to
the steering shaft. This movement aligns the spool passages with the sleeve ports and
pressure oil begins to flow in the valve.

The oil flows through the sleeve, into spool passages, and back out of the sleeve into
the valve housing. The passages in the housing direct oil to one side of the gerotor
moving the gerotor gear. As the gear is rotated, it performs the following functions:

1. It forces oil out of the gerotor into outlet passages in the housing, back through
the sleeve and spool, and out the work port.

2. The oil is directed to the rod end of the steering cylinder. Return oil from the

831
 Steering
cylinder is forced back through the valve and out to the reservoir.

3. The rotation of the gerotor gear also turns the gerotor drive which is connected
to and turns the valve sleeve.

TX,9025,YY2136-19-1996/12/19

832
 Secondary Steering

Secondary Steering

T80790-UN: Oil Flow for Secondary Steering

LEGEND:
1 - Pressure Oil
2 - Suction Oil
3 - Return Oil
4 - Trapped Oil

833
 Secondary Steering
5 - Gerotor Gear Assembly
6 - Check Valve
7 - Pin
8 - Control Spool
9 - Port “T”
10 - Port “L”
11 - Port “R”
12 - Port “P”

If there is no power to supply pressure oil to the steering valve, the machine can be
turned manually. When the steering wheel is turned, the spool will come into contact
with the pin (7). The pin then will provide a direct mechanical connection to the gerotor
gear assembly (5). As the gerotor is turned, it pumps oil to the steering cylinder. Return
oil form the cylinder is drawn through a check valve (6) between port “P” (12) and port
“T” (9) to provide oil for the secondary manual steering operation. Make up oil is drawn
from the hydraulic reservoir through return line of the steering valve.

TX,9025,RR7548-19-1996/11/23

834
 Ride Control Hydraulic Component Location Circuit-Off

Ride Control Hydraulic Component Location Circuit-Off

T126022-19: Ride Control Hydraulic Circuit-Off

LEGEND:
A - Pressure Oil
B - Trapped Oil
C - Return Oil
D - Accumulator
E - Reservoir
F - To Reservoir

835
 Ride Control Hydraulic Component Location Circuit-Off
G - To Boom Cylinder Rod End
H - To Boom Cylinder Head End
I - Solenoid
J - Ride Control Valve
K - To Boom Cylinder Rod End
L - To Boom Cylinder Head End
M - Right Side Frame
N - Ride Control Hydraulic Circuit
O - Orifice
P - Ride Control Hydraulic Circuit-OFF

In this operation, the machine is in normal operation with the boom being raised and
lowered. In this position, the solenoid (I) and valve (J) are deactivated and the boom
cylinder rod end (K and G) are disconnected from the reservoir (E). The boom cylinder
head end (L and H) are still connected to the accumulator (D) through ride control valve
internal orifice. The orifice maintains the accumulator oil pressure closely to boom
cylinder head end oil pressure. This allows activation of the ride control without boom
sag.

CED,TX03543,2275-19-1998/07/17

836
 Ride Control Valve Operation “OFF” Position-Continued

Ride Control Valve Operation “OFF” Position-Continued

T126021-19:

837
 Ride Control Valve Operation “OFF” Position-Continued

T116556-19: Ride Control Hydraulic Circuit-OFF

LEGEND:
A - Pressure Oil
B - Trapped Oil
C - Return Oil
D - Accumulator
E - Reservoir
F - To Reservoir
G - To Boom Cylinder Rod End
H - To Boom Cylinder Head End

838
 Ride Control Valve Operation “OFF” Position-Continued
I - Solenoid
J - Ride Control Valve
K - To Boom Cylinder Rod End
L - To Boom Cylinder Head End
M - Right Side Frame
N - Ride Control Hydraulic Circuit
O - Orifice
P - Ride Control Hydraulic Circuit-OFF

CED,TX03768,8499-19-1999/11/19

839
 Ride Control Hydraulic Component Location Circuit-On Position

Ride Control Hydraulic Component Location Circuit-On Position

T126021-19: Ride Control Component Location-ON

LEGEND:
A - Pressure Oil
B - Trapped Oil
C - Return Oil
D - Accumulator
E - Reservoir
F - To Reservoir

840
 Ride Control Hydraulic Component Location Circuit-On Position
G - To Boom Cylinder Rod End
H - To Boom Cylinder Head End
I - Solenoid
J - Ride Control Valve
K - To Boom Cylinder Rod End
L - To Boom Cylinder Head End
M - Right Side Frame
N - Ride Control Hydraulic Circuit
O - Orifice
P - Ride Control Hydraulic Circuit-OFF

In this operation, there is no loader boom operation and the machine is in transport
position. In the “ON” position, the solenoid (I) and valve (J) are activated. Pressure
spikes from the boom cylinder head end (L and H) flow into the accumulator (D). The
boom cylinder rod end (K and G) is open to return (F). Oil is free to flow in and out of the
rod end, therefore the boom cannot be powered down while ride control is ON. Ride
control can be engaged during bucket loading, but may be turned OFF if more rigid
operation is desired.

CED,TX03543,2276-19-1999/11/24

841
 Ride Control Valve Operation “ON” Position-Continued

Ride Control Valve Operation “ON” Position-Continued

T116295-19: Ride Control Hydraulic Circuit-ON

LEGEND:
A - Pressure Oil
B - Trapped Oil
C - Return Oil
D - Accumulator
E - Reservoir
F - To Reservoir

842
 Ride Control Valve Operation “ON” Position-Continued
G - To Boom Cylinder Rod End
H - To Boom Cylinder Head End
I - Solenoid
J - Ride Control Valve
K - To Boom Cylinder Rod End
L - To Boom Cylinder Head End
M - Right Side Frame
N - Ride Control Hydraulic Circuit
O - Orifice
P - Ride Control Hydraulic Circuit-ON

CED,TX03768,8500-19-1998/06/22

843
 Circuit Relief Valve without Anti-Cavitation-Loader and Backhoe

Circuit Relief Valve without Anti-Cavitation-Loader and Backhoe

T101165-19: Circuit Relief Valve without Anti-Cavitation

LEGEND:
A - Main Poppet
B - Pressure Oil
C - Return Oil
D - Circuit Relief Valve without Anti-Cavitation

Used on backhoe control valve boom raise, bucket dump, crowd out, and load sense
relief valve. Also used on loader control valve bucket rollback, load sense, and boom
raise. The relief is direct acting, screw adjustable, and does not have anti-cavitation
operation.

The pressure set point is adjustable by turning the adjustment screw at the end of the
relief. Turning screw IN increases pressure setting.

In relief operation, pressure oil overcomes main poppet (A) and oil flows from the
pressurized port to tank.

TX,9025,RR7290-19-1999/11/19

844
 Circuit Relief Valve with Anti-Cavitation-Loader and Backhoe-Continued

Circuit Relief Valve with Anti-Cavitation-Loader and Backhoe-

Continued

T7742AE-19: Circuit Relief Valve with Anti-Cavitation

LEGEND:
A - Orifice
B - Relief Poppet
C - Cavity
D - Pressure Oil
E - Return Oil
F - Anti-Cavitation Poppet

The relief valve is used on the backhoe control valve sections: swing, boom lower,
crowd in, and system relief. Also used on the loader control valve auxiliary section. The
relief is direct acting and has anti-cavitation operation except as a system relief valve.

In normal operation, pressure oil less than relief valve setting flows through orifice (A)
into cavity (C) behind relief valve poppet. Pressure oil and spring in cavity hold the anti-
cavitation poppet closed because effective area on this side is greater than on work
port side.

In relief operation, pressure oil overcomes relief poppet (B) pressure setting and opens
a path to return.

During anti-cavitation operation, the pressure in the work port is less than pressure in
the return port. The pressure difference pushes the anti-cavitation poppet (F) off its seat
845
 Circuit Relief Valve with Anti-Cavitation-Loader and Backhoe-Continued
allowing oil to flow from return port to work port to prevent cavitation.

The circuit relief is not adjustable.

TX,9025,RB22-19-1999/11/24

846
 Circuit Relief Valve with Anti-Cavitation-Loader and Backhoe (Continued)

Circuit Relief Valve with Anti-Cavitation-Loader and Backhoe

(Continued)

T101164-19: Circuit Relief Valve with Anti-Cavitation

LEGEND:
A - Piston
B - Main Poppet
C - Anti-Cavitation Poppet
D - Anti-Cavitation Spring
E - Main Spring
F - Pilot Poppet
G - Pilot Spring
H - Orifice
I - Cavity
J - Relief Body
K - Pressure Oil
L - Return Oil
M - Loader Circuit Relief Valve with Anti-Cavitation

The relief valve is used on the backhoe control valve bucket curl and the loader control
valve bucket dump. The relief is a pilot operated, screw adjustable, with anti-cavitation
operation.

The relief valve setting is controlled by the spring load (G) holding the pilot poppet (F)

847
 Circuit Relief Valve with Anti-Cavitation-Loader and Backhoe (Continued)
on its seat. The setting is adjustable. Loosen lock nut and screw adjustment cap IN to
increase pressure setting.

In normal operation, pressure oil less than relief valve setting flows though orifice (H) in
piston (A) into cavity (I) behind the anti-cavitation poppet (C) and main relief valve
poppet (B). This oil pressure and the springs hold the main poppet (B) and anti-
cavitation poppet (C) closed because the effective areas of the poppets on the cavity
side is greater than the work port side.

In relief operation, pressure oil overcomes pilot poppet (F) and oil flows from the
pressurized port through orifice (H) into cavity (I) past pilot poppet (F) to tank through a
path between relief body (J) and anti-cavitation poppet (C). The pressure drop through
orifice (H) causes a pressure difference across piston (A) and it moves against main
spring (E) until it rests on pilot poppet (F). This movement shuts off orifice (H) and
further reduces the pressure in cavity (I). When the pressure difference is large enough
to overcome the differential area effect holding the main poppet (B) on its seat and oil is
allowed to flow from the work port to the return port.

During anti-cavitation operation, the pressure in the work port and cavity (I) is less than
the pressure in the return port. This pressure difference overcomes the differential area
effect holding the anti-cavitation poppet (C) on it’s seat and oil is allowed to flow from
return port to work port to prevent cavitation.

TX,9025,RR7555-19-1996/12/03

848
 Backhoe Auxiliary Flow Control Circuit Relief Valve

Backhoe Auxiliary Flow Control Circuit Relief Valve

T105523-19: Circuit Relief Valve

LEGEND:
A - Piston
B - Main Poppet
C - Anti-Cavitation Poppet
D - Anti-Cavitation Spring
E - Main Spring
F - Poppet Pilot
G - Pilot Spring
H - Orifice
I - Oil Cavity
J - Relief Body
K - Pressure Oil
L - Return Oil
M - Circuit Relief Valve

The relief is pilot operated and screw adjustable.

The relief valve setting is controlled by the spring load (G) holding the pilot poppet (F)
on its seat. This setting is adjustable by turning the adjustment screw at the end of the
relief.

849
 Backhoe Auxiliary Flow Control Circuit Relief Valve

In normal operation, pressure oil less than relief valve setting flows through orifice (H) in
piston (A) into cavity (I) behind the anti-cavitation poppet (C) and main relief valve
poppet (B). This oil pressure and the springs hold the main poppet (B) and anti-
cavitation poppet (C) closed because the effective areas of the poppets on the cavity
side is greater than the work port side.

In relief operation, pressure oil overcomes pilot poppet (F) and oil flows from the
pressurized port through orifice (H) into cavity (I) past pilot poppet (F) to tank through a
path between relief body (J) and anti-cavitation poppet (C). The pressure drop through
orifice (H) causes a pressure difference across piston (A) and it moves against main
spring (E) until it rests on pilot poppet (F). This movement shuts off orifice (H) and
further reduces the pressure in cavity (I). When the pressure difference is large enough
to overcome the differential area effect holding the main poppet (B) on it’s seat and oil is
allowed to flow from the work port to return port.

TX,9025,RR7557-19-1996/12/03

850
 Stabilizer Valve Operation

Stabilizer Valve Operation

T109396-19: Stabilizer Valve-Lower

LEGEND:
A - Pressure Oil
B - Return Oil
C - Stabilizer Valve-Lower
D - Return Passage
E - Pressure Passage
F - Connecting Passage
G - Power Passage
H - Poppet
I - Thermal Relief Valve
J - Work Port

The stabilizer valve is a two-spool, unibody valve containing two lockout poppets (H)
and one thermal relief valve (I) for each circuit.

When the valve is activated to lower a stabilizer, inlet oil (A) acts on the lockout plunger
and lockout poppet (H). The inlet oil pushes the poppet off its seat and flows through
work port (J) to head of cylinder. At the same time, the lockout plunger is pushed
against the other poppet, opening the return flow (B) from the cylinder to the return
passage (J). The load sense port also senses the load pressure and feeds it back to the
pump load sense port.

851
 Stabilizer Valve Operation

The lockout poppets are used to prevent cylinder drift while the valve is in neutral. The
poppets trap oil in both rod and head ends of the stabilizer.

When the stabilizer is in the full down position, high temperatures can be generated by
the forces working against the stabilizer. Regardless of pressure, the lockout plunger
will not push the poppet off its seat allowing the stabilizer to raise.

The thermal relief valve is used to release high pressures in the rod end of cylinder due
to high temperatures

TX,9025,RR7546-19-1996/11/14

852
 Backhoe Inlet Section with Swing Section Activated

Backhoe Inlet Section with Swing Section Activated

T109415-19: Backhoe Inlet Section with Swing Section Activated

LEGEND:
A - Isolator
B - Load Sense Relief Valve
C - Pump Load Sense Port
D - Inlet Pressure Oil
E - High Pressure Oil
F - Return Pressure Oil
G - Auxiliary Pilot Oil-Optional
H - Inlet Section

853
 Backhoe Inlet Section with Swing Section Activated
I - Trapped Oil

The inlet section of the backhoe valve provides a means of connecting the valve to the
pump. The pump output is connected to the valve’s inlet pressure port (D). The load
sense port (C) connects to the pump’s load sense port.

The isolator valve assembly (A) is used to supply a signal equal to the highest work port
pressure to the pump load sense port without allowing load sense oil to exit the valve.

A direct acting load sense relief valve (B) limits the maximum load sense pressure
signal sent to the pump, which limits the pump pressure sent to the hydraulic system.

The auxiliary pilot oil passage (G) is present in the inlet section if the spool section next
to the inlet section is the electro-hydraulic auxiliary section. This passage supplies
pressure to the spool section’s actuator, which reduces the pressure for use as a pilot
signal to shift the spool. An O-ring is installed in the inlet section around the pilot supply
port for sealing between the inlet section and spool section.

TX,9025,RR7549-19-2000/02/08

854
 Backhoe Auxiliary Flow Valve-Solenoid Energized

Backhoe Auxiliary Flow Valve-Solenoid Energized

T109414-19: Engine Running Solenoid Energized

LEGEND:
A - Electro-Hydraulic Pilot Actuator
B - Circuit Relief without Anti-Cavitation
C - Work Port
D - Compensator
E - Inlet Pressure Passage
F - Port Plug

855
 Backhoe Auxiliary Flow Valve-Solenoid Energized
G - Bridge Bleed Orifice
H - Return Spring
J - Pilot Pressure
K - Load Sense Logic Check Shuttle
L - High Pressure Oil
M - Pilot Pressure Oil
N - Low Pressure Oil
O - Backhoe Auxiliary Valve-Solenoid Energized

The auxiliary section is a two-position, two-way, closed-center, spool-type valve. The

section contains a solenoid pilot actuator (A) which is used to proportionally shift the
main spool. The spool was designed to deliver three distinct flows (9, 22, and 30 GPM)
at three corresponding current inputs. The current is set by moving a fuse in the fuse
box to one of three positions. To set preferred flow refer to decal on rear of fuse block
access cover. When setting the flow, both the ignition and auxiliary flow switches must
be turned OFF. The section includes a circuit relief valve without anti-cavitation (B).

The valve section contains a bleed orifice (G) to bleed the section’s load sense signal to
tank when the spool is in neutral.

When current is supplied to the actuator (A), pilot pressure (J) is metered to the end of
the main spool, causing it to shift against the return spring (H). Oil flows from the inlet
passage (E), past the spool and compensator (D), out the work port to the cylinder.
Return oil from the attachment is directed back to the hydraulic reservoir through the
auxiliary return port of the backhoe valve.

TX,9025,RR7532-19-2000/02/08

856
 Backhoe Swing Section-Swing Right Position

Backhoe Swing Section-Swing Right Position

T109409-19: Backhoe Swing Section-Swing Right Position

LEGEND:
A - Return Passage
B - Circuit Relief with Anti-cavitation
C - Swing Left Work Port
D - Compensator
E - Inlet Pressure Passage
F - Swing Right Work Port

857
 Backhoe Swing Section-Swing Right Position
G - Bridge Bleed Orifice
H - Load Sense Logic Check Shuttle
I - High Pressure Oil
J - Return Pressure Oil
K - Backhoe Swing Section-Swing Right Position

The swing section is a three-position, four-way, closed-center, spool-type valve. The

valve contains two circuit relief valves with anti-cavitation (B).

The valve section contains a bleed orifice (G) to bleed the section’s load sense signal to
the return passage when the spool is in neutral.

When the spool is moved to activate a function, oil flows from the inlet passage (E),
past the spool and compensator (D), out the work port to the cylinders. Return oil from
the cylinders flows into the other work port, past the spool, into the return passage (A),
then out of the control valve to the system reservoir.

TX,9025,RR7533-19-1996/11/08

858
 Backhoe Boom Section-Boom Raise Position

Backhoe Boom Section-Boom Raise Position

T109408-19: Backhoe Boom Section-Boom Raise Position

LEGEND:
A - Return Passage
B - Circuit Relief with Anti-cavitation
C - Boom Lower Work Port
D - Compensator
E - Inlet Pressure Passage
F - Boom Raise Work Port

859
 Backhoe Boom Section-Boom Raise Position
G - Bridge Bleed Orifice
H - Circuit Relief without Anti-Cavitation
I - Anti-Drift Check
J - Orifice
K - Work Port Passage
L - Vent Passage
M - Load Sense Logic Check Shuttle
N - High Pressure Oil
O - Low Pressure Oil
P - Backhoe Boom Section-Boom Raise Position

The boom valve is three-position, four-way, closed-center, spool-type valve section. The
section contains a circuit relief valve (H) in the boom raise circuit and a circuit relief with
anti-cavitation (B) in the boom lower work port.

The valve section contains a bleed orifice (G) to bleed the section’s load sense signal to
return passage when the spool is in neutral.

When the spool is moved to activate a function, oil flows from the inlet passage (E),
past the spool and compensator (D), out the work port to the cylinders. Return oil from
the cylinders flows into the other work port, past the spool, into the return passage (A),
then out of the control valve to the system reservoir.

An anti-drift check valve (I) is provide significantly to reduce oil leakage back into the
boom raise work port (F). With the valve in neutral, the check (I) is spring loaded to the
closed position. Pressure in the boom raise work port (F) enters orifice (J) and is
passed to the spring side of the check. Pressure in the work port (K) falls due to oil
leakage past the spool to the return passage (A). The higher work port pressure on the
spring side of the check forces the check securely into the seat forming a seal. The
spring side of the check may be vented to the return passage through a vent passage
(L). This passage is open and closed depending on the position on the main spool. With
the main spool in neutral or boom raise position the vent passage (L) is blocked. When
the main spool is moved to the boom lower position the vent passage (L) is opened to
the return passage (A). Oil flows from the work port (F) through orifice (J) in the check
(I), though the vent passage (L) to the return passage (A). Pressure drop across the
orifice (J) causes the pressure on the spring side of the check to drop lower than the
pressure in work port (F). This pressure imbalance causes the check (I) to open
allowing flow to main spool.

TX,9025,RR7534-19-1996/11/08

860
 Backhoe Bucket Section-Bucket Curl Position

Backhoe Bucket Section-Bucket Curl Position

T109407-19: Backhoe Bucket Section-Bucket Curl

LEGEND:
A - Return Passage
B - Circuit Relief with Anti-Cavitation
C - Bucket Load Work Port
D - Compensator
E - Inlet Pressure Passage
F - Bucket Dump Work Port
861
 Backhoe Bucket Section-Bucket Curl Position
G - Bridge Bleed Orifice
H - Load Sense Logic Check Shuttle
I - High Pressure Oil
J - Return Pressure Oil
K - Circuit Relief without Anti-Cavitation

The bucket valve is three-position, four-way, closed-center, spool-type valve section.

The section contains a circuit relief valve with anti-cavitation (B) in the bucket load
circuit and circuit relief valve (K) in the bucket dump circuit.

The valve section contains a bleed orifice (G) to bleed the section’s load sense signal to
the return passage when the spool is in neutral.

When the spool is moved to activate a function, oil flows from the inlet passage (E),
past the spool and compensator (D), out the work port to the cylinders. Return oil from
the cylinders flows into the other work port, past the spool, into the return passage (A),
then out of the control valve to the system reservoir.

TX,9025,RR7535-19-2000/02/08

862
 Backhoe Crowd Section-Crowd In Position

Backhoe Crowd Section-Crowd In Position

T109406-19: Backhoe Crowd Section-Crowd In Position

LEGEND:
A - Return Passage
B - Circuit Relief with Anti-Cavitation
C - Crowd Out Work Port
D - Compensator
E - Inlet Pressure Passage
F - Crowd In Work Port

863
 Backhoe Crowd Section-Crowd In Position
G - Bridge Bleed Orifice
H - Circuit Relief without Anti-Cavitation
I - Anti-Drift
J - Orifice
K - Work Port Passage
L - Vent Passage
M - Load Sense Logic Check Shuttle
N - Pump Oil
O - Return Pressure Oil

The crowd valve is a three-position, four-way, closed-center, spool-type valve section.

The section contains a circuit relief valve (H) in the crowd out circuit and a circuit relief
with anti-cavitation (B) in the crowd in circuit

The valve section contains a bleed orifice (G) to bleed the section’s load sense signal to
the return passage when the spool is neutral.

When the spool is moved to activate a function, oil flows from the inlet passage (E),
past the spool and compensator (D), out the work port to the cylinders. Return oil from
the cylinders flows into the other work port, past the spool, into the return passage (A),
then out of the control valve to the system reservoir.

An anti-drift check valve (I) is provided to significantly reduce oil leakage back into the
crowd out work port (C). With the valve in neutral, the check (I) is spring loaded to the
closed position. Pressure in the work port (F) enters orifice (J) and is passed to the
spring side of the check. Pressure in the work port passage (K) falls due to oil leakage
past the spool to the return passage (A). The higher work port pressure on the spring
side of the check forces the check securely into the seat forming a seal. The spring side
of the check may be vented to the return passage (A) through a vent passage (L). This
passage is open and closed depending on the position of the main spool. With the main
spool in neutral or the crowd out position the vent passage (L) is blocked. When the
main spool is moved to the crowd in position the vent passage (L) is opened to the
return passage (A). Oil flows from the work port (F) through orifice (J) in the check (I),
through the vent passage (L) to the return passage (A). Pressure drop across the orifice
(J) causes the pressure on the spring side of the check to drop lower than the pressure
in work port (F). This pressure imbalance causes the check (I) to open allowing flow to
the main spool.

TX,9025,RR7536-19-2000/02/08

864
 Backhoe Auxiliary Section-Neutral

Backhoe Auxiliary Section-Neutral

T109405-19: Backhoe Auxiliary Section-Neutral

LEGEND:
A - Return Passage
B - Relief Valve Port Shutoff Plug
C - Head End Work Port
D - Compensator
E - Inlet Pressure Passage
F - Rod End Work Port

865
 Backhoe Auxiliary Section-Neutral
G - Bridge Bleed Orifice
H - Load Sense Logic Check Shuttle
I - High Pressure Oil
J - Return Pressure Oil
K - Relief Valve with Anti-Cavitation
L - Trapped Oil
M - Loader Auxiliary Section-Neutral Position

The backhoe auxiliary valve section is a three-position, four-way, closed-center, spool-

type valve section. The section contains a circuit relief valve with anti-cavitation (K) in
the head end work port.

The valve section contains a bleed orifice (G) to bleed the section’s load sense signal to
the return passage when the spool is in neutral.

When the spool is moved to activate a function, oil flows from the inlet passage (E),
past the spool and compensator (D), out the work port to the cylinders. Return oil form
the cylinders flows into the other work port, past the spool, into return passage (A), then
out of the control valve to the system reservoir.

The auxiliary valve is normally used to control extendible buckets.

CED,TX03768,2675-19-1999/11/19

866
 Backhoe Endcap Outlet Section

Backhoe Endcap Outlet Section

T109404-19: Backhoe Endcap Outlet Section

LEGEND:
A - Return Ports
C - Load Sense Input Port
D - System Relief Valve
E - High Pressure Oil
F - Return Pressure Oil

867
 Backhoe Endcap Outlet Section

The outlet section provides a means to connect the valve to the hydraulic reservoir via
the return ports (A). The load sense input port allows a load sense signal to be input
from the stabilizer valve. This signal is compared to the work port pressures in this valve
and the highest pressure is sent to the pump’s load sense port. The outlet section
includes a system relief valve (D) which is used to relieve pressure spikes in the pump
output passage.

The system relief valve also protects the system in case the pump would fail to destroke
with all valves in neutral.

TX,9025,RR7550-19-2000/02/08

868
 Loader Inlet Endcap Section with Bucket Section Activated

Loader Inlet Endcap Section with Bucket Section Activated

T109403-19: Loader Inlet Endcap Section with Bucket Section Activated

LEGEND:
A - Isolator
B - Load Sense Relief Valve
D - Inlet Pressure Oil
E - High Pressure Oil
F - Return Pressure Oil
H - Loader Inlet Section

869
 Loader Inlet Endcap Section with Bucket Section Activated

The inlet section of the loader valve provides a means of connecting the valve to the
pump. The pump output is connected to the valve’s inlet pressure port (D).

The isolator valve assembly (A) is used to supply a signal equal to the highest work port
pressure to the pump load sense port without allowing load sense oil to exit the valve.

A direct acting load sense relief valve (B) limits the maximum load sense pressure
signal sent to the pump, which limits the pump pressure sent to the hydraulic system.

TX,9025,RR7551-19-1996/11/23

870
 Loader Bucket Section-Bucket Rollback Position

Loader Bucket Section-Bucket Rollback Position

T109402-19: Loader Bucket-Bucket Rollback Position

LEGEND:
A - Return Passage
B - Circuit Relief without Anti-Cavitation
C - Bucket Load Work Port
D - Compensator
E - Inlet Pressure Passage
F - Bucket Dump Work Port

871
 Loader Bucket Section-Bucket Rollback Position
G - Bridge Bleed Orifice
H - Load Sense Logic Check Shuttle
I - High Pressure Oil
J - Return Pressure Oil
K - Circuit Relief with Anti-Cavitation
L - Return-to-Dig Electromagnet
M - Loader Bucket Section-Rollback Position

The bucket valve is a three-position, four-way, closed-center, spool-type valve section.

The section contains a circuit relief valve with anti-cavitation (K) in the bucket dump
circuit and circuit relief valve (B) in the bucket load circuit.

The valve section contains a bleed orifice (G) to bleed the section’s load sense signal to
the return passage when the spool is in neutral.

When the spool is moved to activate a function, oil flows from the inlet passage (E),
past the spool and compensator (D), out the work port to the cylinders. Return oil from
the cylinders flows into the other work port, past the spool, into the return passage (A),
then out of the control valve to the system reservoir.

The valve is equipped with a return-to-dig spool positioner. When loader control lever is
moved to the bucket rollback position, a plate fastened to the end of valve spool
contacts an electromagnet. If the bucket is in dump position, the return-to-dig switch is
closed which energizes the electromagnet and holds the spool in the load position.
When the bucket rolls back to the dig position, the self-leveling linkage opens the
return-to-dig switch, which de-energizes the electromagnet allowing the spool centering
spring to move the spool to neutral.

TX,9025,RR7538-19-1996/11/08

872
 Loader Boom Section-Boom Raise Position

Loader Boom Section-Boom Raise Position

T109401-19: Loader Boom Section-Boom Raise Position

LEGEND:
A - Return Passage
B - Circuit Relief without Anti-Cavitation
C - Boom Raise Work Port
D - Compensator
E - Inlet Pressure Passage
F - Boom Lower Work Port

873
 Loader Boom Section-Boom Raise Position
G - Bridge Bleed Orifice
H - Load Sense Logic Check Shuttle
I - High Pressure Oil
J - Return Pressure Oil
K - Anti-Cavitation Check Valve
L - Detent Spool Positioner
M - Loader Boom Section-Boom Raise Position

The boom valve is a four-position, four-way, closed-center, spool-type valve section.

The section contains a circuit relief valve (B) in the boom raise circuit and anti-cavitation
check valve (K) in the boom lower circuit.

The valve section contains a bleed orifice (G) to bleed the section’s load sense signal to
the return passage when the spool is in neutral.

When the spool is moved to activate a function, oil flows from the inlet passage (E),
past the spool and compensator (D), out the work port to the cylinders. Return oil from
the cylinders flows into the other work port, past the spool, into return passage (A), then
out of the control valve to the system reservoir.

When the spool is moved to the boom float detent position (two positions out from
neutral), both work ports (C and F) are open to return passage (A) allowing oil to flow in
and out both ends of the cylinders.

TX,9025,RR7539-19-1996/11/08

874
 Loader Auxiliary Section-Load Position

Loader Auxiliary Section-Load Position

T109400-19: Loader Auxiliary Section-Load Position

LEGEND:
A - Return Passage
B - Relief Port Shutoff Plug
C - extendable Out Work Port
D - Compensator
E - Inlet Pressure Passage
F - extendable In Work Port

875
 Loader Auxiliary Section-Load Position
G - Bridge Bleed Orifice
H - Relief Port Shutoff Plug
I - Anti-Drift Check Valve
J - Orifice
K - Work Port Passage
L - Vent Passage
M - Load Sense Logic Check Shuttle
N - High Pressure Oil
O - Low Pressure Oil
P - Loader Auxiliary Section-Load Position

The auxiliary valve is a three-position, four-way, closed-center, spool-type valve section.

The section contains shutoff plugs in place of relief valves in both work ports.

The valve section contains a bleed orifice (G) to bleed the section’s load sense signal to
the return passage when the spool is in neutral.

When the spool is moved to activate a function, oil flows from the inlet passage (E),
past the spool and compensator (D), out the work port to the cylinders. Return oil from
the cylinders flows into the other work port, past the spool, into the return passage (A),
then out of the control valve to the system reservoir.

An anti-drift check valve (I) is provided to significantly reduce oil leakage back into the
extendable in work port (F). With the valve in neutral, the check (I) is spring loaded to
the closed position. Pressure in the extendable in work port (F) enters orifice (J) and is
passed to the spring side of the check. Pressure in the work port passage (K) falls due
to oil leakage past the spool to the return passage (A). The higher work port pressure
on the spring side of the check forces the check securely into the seat forming a seal.
The spring side of the check may be vented to the return passage (A) through a vent
passage (L). This passage is open and closed depending on the position of the main
spool. With the main spool in neutral or the boom raise position the vent passage (L) is
blocked. When the main spool is moved to the lower position the vent passage (L) is
opened to the return passage (A). Oil flows from the work port (F) through orifice (J) in
the check (I), through the vent passage (L) to the return passage (A). Pressure drop
across the orifice (J) causes the pressure on the spring side of the check to drop lower
than the pressure in work port (F). This pressure imbalance causes the check (I) to
open allowing flow to the main spool.

CED,TX03768,2676-19-1999/11/19

876
 Loader Endcap Outlet Section

Loader Endcap Outlet Section

T109399-19: Loader Endcap Outlet Section

LEGEND:
A - Return Port
B - Pump Load Sense Port
C - Load Sense Input Port
D - Plug
E - High Pressure Oil
F - Return Pressure Oil

877
 Loader Endcap Outlet Section
G - Loader Outlet Section

The outlet section provides a means to connect the valve to the hydraulic reservoir via
the return ports (A). The load sense port (B) connects to the pump’s load sense port.
The load sense input port (C) allows a load sense signal to be input from the steering
valve. This signal is compared to the work port pressures in this valve and the highest
pressure is sent to the pump’s controller.

TX,9025,RR7552-19-1996/11/23

878
 Use These Seven Basic Steps to Diagnose and Test the Hydraulic System

Use These Seven Basic Steps to Diagnose and Test the Hydraulic
System

1. KNOW THE SYSTEM. Study the information on the system and component
operation given in the front part of Section 9025. Learn the basic principles of
hydraulics by reading the Fundamentals of Service manual on hydraulics.

2. ASK THE OPERATOR. The operator can tell you how the machine performed
when it started to fail; what was unusual about it. Try to find out if any do-it-
yourself service has been performed. Ask about how the machine was
operated and when it was serviced.

3. OPERATE THE MACHINE. Are the gauge indications normal? How is the
performance? Do the controls feel normal? Do you smell or hear anything
unusual.

4. INSPECT THE MACHINE. Use your eyes, ears, and nose to find signs of
trouble. Check the level and condition of the hydraulic oil. Is the oil dirty; are
the filters plugged? Are the hydraulic oil lines hotter than normal; covered with
dirt; paint peeled off from heat; dented or collapsed; show signs of leakage?

5. LIST THE POSSIBLE CAUSES. What unusual conditions did you find when
the machine was inspected? What are the possible causes? Are there other
possibilities? Remember, one failure often leads to another.

NOTE:

You can use the Hydraulic System Pretest Check Sheet to list
the possible causes.

6. REACH A CONCLUSION. Decide which possible causes are the most likely
and the easiest to verify. Use the Diagnose Malfunctions section of Group
9025 to help you.

7. TEST YOUR CONCLUSION. Do individual component tests to verify your

conclusion before you repair or replace any components.

TX,9025,RR7304-19-1996/06/10

879
 Use These Seven Basic Steps to Diagnose and Test the Hydraulic System

Use These Seven Basic Steps to Diagnose and Test the Hydraulic
System

1. KNOW THE SYSTEM. Study the information on the system and component
operation given in the front part of Section 9025. Learn the basic principles of
hydraulics by reading the Fundamentals of Service manual on hydraulics.

2. ASK THE OPERATOR. The operator can tell you how the machine performed
when it started to fail; what was unusual about it. Try to find out if any do-it-
yourself service has been performed. Ask about how the machine was
operated and when it was serviced.

3. OPERATE THE MACHINE. Are the gauge indications normal? How is the
performance? Do the controls feel normal? Do you smell or hear anything
unusual.

4. INSPECT THE MACHINE. Use your eyes, ears, and nose to find signs of
trouble. Check the level and condition of the hydraulic oil. Is the oil dirty; are
the filters plugged? Are the hydraulic oil lines hotter than normal; covered with
dirt; paint peeled off from heat; dented or collapsed; show signs of leakage?

5. LIST THE POSSIBLE CAUSES. What unusual conditions did you find when
the machine was inspected? What are the possible causes? Are there other
possibilities? Remember, one failure often leads to another.

NOTE:

You can use the Hydraulic System Pretest Check Sheet to list
the possible causes.

6. REACH A CONCLUSION. Decide which possible causes are the most likely
and the easiest to verify. Use the Diagnose Malfunctions section of Group
9025 to help you.

7. TEST YOUR CONCLUSION. Do individual component tests to verify your

conclusion before you repair or replace any components.

TX,9025,RR7304-19-1996/06/10

880
 Make a Pretest Inspection and an Operation Check of the Machine

Make a Pretest Inspection and an Operation Check of the Machine

1. Write the pretest inspection and operation check information on the Hydraulic
System Pretest Check Sheet (Form M-5107 is available from Deere and
Company, Distribution Service Center).

2. Go to Diagnose Malfunctions to determine the cause of the customer

complaint. If necessary, do tests of individual component to verify the
malfunction.

3. Repair or replace the faulty component.

TX,9025,RR7305-19-1996/06/10

881
 Hydraulic System Pretest

Hydraulic System Pretest

1. Clean machine as needed.

2. Perform all inspections.

3. Correct any problems.

4. Perform Operational Checks:

Hydraulic Oil:
Correct Oil
Correct Level
Bubbles in Oil
Control Valve(s):
Bent Linkage
Proper Linkage Adjustment
Filters: Hydraulic, Transmission:
Ruptured
Plugged
Metal Particles
Packing Particles
Install New Filter
Oil Cooler:
Clean of Dirt and Debris
Fan or Shroud Damaged
Belt Tension and Condition
Leaking Lines or Cooler
Hydraulic System:
Bent or Damaged Lines
External Oil Lines
Cylinder Rod(s) Bent
Blown Seals and Fittings

TX,9025,RR7306-19-1996/08/09

882
 Diagnose Steering System Malfunctions

Diagnose Steering System Malfunctions

NOTE:

Diagnostic charts are arranged from most probable and simplest to

verify, to least likely more difficult to verify. Remember the following
steps when diagnosing a problem:

Step 1. Operational Check Out Procedure

Step 2. Diagnostic Charts
Step 3. Adjustments and/or Tests

883
Diagnose Steering System Malfunctions

884
 Diagnose Steering System Malfunctions

Symptom Problem Solution

Slow or Hard Steering Air in system. Check oil level.

Check suction hose

clamps.

Steering lines or load Check and replace.

sensing "LS" lines damaged
(bent).

Shaft in steering wheel Check for bent steering

column binding. column.

Internal leakage in system. Do Steering System

Leakage Check. (See
Group 9025-10.)

Hydraulic pump (low Do Steering Load

pressure). Sense Valve Test. (See
Group 9025-25.)

Steering pressure Inspect and Repair.

regulating valve spool.

Excessive Steering Wheel Steering cylinder leakage. Do Steering System

Turns to Steer Machine Leakage Check. (See
Group 9025-10.)

Excessive wear in steering Do Steering System

valve. Leakage Check. (See
Group 9025-10.)

885
 Diagnose Steering System Malfunctions
Symptom Problem Solution

Erratic ("Spongy") Steering Air in system. Check oil level.

Check suction hose

clamps.

Steering Wheel "Locks" Up Debris in gerotor section. Disassemble and

inspect. Flush.

Broken drive shaft to Replace.

gerotor pin.

Low hydraulic flow. Check system pressure

and flow.

Poor Centering of Steering Binding or misalignment in Inspect column and

Wheel (Wheels Continue to steering column or splined spline to steering valve
Move After Steering Wheel is connection. connection. Repair.
Stopped)

Steering Wheel Oscillates or Parts misassembled Disassemble, inspect

Turns by Itself After Starting (steering valve improperly and reassemble.
Machine timed)

Line connected to wrong Inspect and connect

ports. correctly.

Wander-Vehicle Will Not Stay in Air in the system due to low Inspect and correct.
a Straight Line level of oil, cavitating pump,
leaky fitting, pinched hose.

Worn mechanical linkage. Repair or replace. See

Repair Manual.

886
 Diagnose Steering System Malfunctions
Symptom Problem Solution

Bending of linkage or Repair or replace. See

cylinder rod. Repair Manual.

Loose steering cylinder Repair or replace. See

piston. Repair Manual.

Severe wear in steering Replace the steering

control unit. control unit.

Erratic Steering Loose cylinder piston. Replace cylinder.

Sticking pressure regulating Replace.

valve spool

Steering Valve Does Not Return Broken centering springs Inspect steering valve.
to Neutral See Technical Repair
manual.

Damaged steering valve Inspect steering valve.

sleeve See Technical Repair
manual TM1611.

No Response When Steering Low or no oil Check reservoir oil

Wheel Is Turned level.

External leakage Check for leakage.

Repair as necessary.

Steering valve leakage Do Steering System

Leakage Test. See
Group 9025-25.

887
 Diagnose Steering System Malfunctions
Symptom Problem Solution

Steering cylinder leakage Test steering valve or

cylinder for leakage.
See Group 9025-25.

Steering column shaft Replace.

broken.

Splines on shaft Check and repair.

disengaged from steering
valve.

Worn main pump Do Pump Flow Test.

See 9025-25.

Steering lines broken Repair.

Machine Turns in Opposite Steering cylinder lines not Connect steering

Direction connected properly cylinder lines to
opposite ports.

Excessive Vibration of Steering Misalignment of steering Put steering valve

Wheel valve geroter geroter in alignment.
See Technical Repair
manual.

Machine Turns When Steering Steering valve leakage Do Steering System

Valve Is in Neutral Leakage Test. See
Group 9025-25.

Misalignment of steering See Technical Repair

column to steering valve. manual to repair.

888
 Diagnose Steering System Malfunctions
Symptom Problem Solution

Steering Wheel Kickback Check valve leakage Inspect check valve in

"P" port of steering
TX,9025,SS3536-19-1996/12/13
valve. See repair
manual.

889
 Diagnose Hydraulic System Problems

Diagnose Hydraulic System Problems

890
Diagnose Hydraulic System Problems

891
 Diagnose Hydraulic System Problems

Symptom Problem Solution

Reservoir Drains When Oil cooler return Remove, inspect and repair. See
Changing Hydraulic Filter tube vent hole in Technical Repair manual.
reservoir may be
plugged

Vent tube broken Remove and repair or replace. See

off inside reservoir Technical Repair manual.

Cooler flow check Inspect and repair.

valve stuck open

No Hydraulics Low oil level Add oil to correct level.

Failed pump drive Replace. See Technical Repair

shaft manual.

Pump problem Remove hydraulic filter and

inspect. If filter contains excessive
amounts of metal material,
remove, and inspect pump. See
Technical Repair manual.

Load sense shuttle Remove and inspect. See repair

check valve manual.

Obstruction in oil Inspect for pinched lines or stuck

lines or valves valve spools. See Technical
Repair manual.

Low Loader Hydraulic Power Incorrect loader Check relief setting at the loader
load sense relief valve. Do Loader Load Sense
pressure setting. Relief Valve Pressure Test, see
Group 9025-25.

892
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Incorrect flow Do Flow Limiter Test in Group

limiter setting 9025-25.

Low Backhoe Hydraulic Incorrect backhoe Do Load Sense and System Relief
Power load sense relief Tests, see Group 9025-25.
setting

Incorrect flow Do Flow Limiter Test, see Group

limiter setting 9025-25.

Low Hydraulic Power Hydraulic oil Incorrect oil, drain and refill.
aerated Suction hose has air leak. Inspect
and tighten. See repair manual.

Leakage within Check circuit for leakage. Do

work circuit Cylinder Leakage Test in Group
9025-25 and Circuit Relief Valve
Test with Remote Pump in Group
9025-25.

Low oil level Check oil levels.

Incorrect flow Do Flow Limiter Test in Group

limiter setting 9025-25.

Incorrect relief Check load sense and system

pressure setting reliefs. Do Loader Load Sense
Relief, and Backhoe Load Sense
Relief and System Relief Valve
Pressure Tests . See Group 9025-
25.

893
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Slow Steering Hydraulics Pressure Test operation. Do Steering Load

Regulating Valve Sense Relief Valve Test in Group
9025-25.

Worn steering Inspect and repair.

valve

Steering valve Test Steering System for leakage.

leakage See Group 9025-25.

Steering cylinder Do Steering Cylinder Leakage

leakage Test. See Group 9025-25.

Steering linkage Inspect and repair. See Technical

Repair Manual.

No Steering Hydraulics Pressure Inspect and repair. See Technical

(Loader Hydraulics OK) Regulating Valve Repair Manual.

Worn steering Do Steering Load Sense Valve

pressure regulating Pressure Test. See Group 9025-
valve 25.

Obstruction in Inspect and repair.

steering load sense
hose

Machine Transport Speed Is Engine or See Section 9020-15, Machine

Slow transmission Lacks Power/Moves Slow
problem
See Section 9010-10, Engine
Speed and Performance
Operational Check.

894
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Engine Pulls Down Relief pressure Do Loader Load Sense Relief

Excessively During Loader setting too high Valve Pressure Test , see Group
Operation 9025-25.

Engine not Check engine performance. Do

operating to Engine Performance Operational
specifications. Checks in Group 9005

Pump flow limiter Do Flow Limiter Test. See Group

set too high 9025-25.

Engine Pulls Down Relief pressure Do Backhoe Load Sense Relief

Excessively During Backhoe setting too high Pressure Test, see Group 9025-25
Operation

Pump Flow limiter Do Flow Limiter Test, see Group

setting too high 9025-25.

Slow Backhoe Hydraulics- Control Valve worn. Do Function Drift Tests in Group
Loader OK 9025-25.

Also see Slow Hydraulic

Functions . Higher hydraulic
demand by backhoe can
make a system problem
appear to be isolated to
backhoe.

Backhoe valve Remove and inspect. See repair

isolator stuck manual.

Load sense relief Do Backhoe Load Sense Relief

set too low Valve Pressure Test. See Group
9025-25.

895
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Flow limiter setting Do Flow Limiter Test. see Group

too low 9025-25.

Slow Loader Hydraulics- Control Valve worn. Do Function Drift Tests in Group
Backhoe OK 9025-25.

Loader valve Remove and inspect. See repair

isolator stuck manual.

Load sense relief Do Loader Load Sense Relief

set too low Valve Pressure Test. See Group
9025-25.

Flow limiter setting Do Flow Limiter Test, see Group

too low 9025-25.

Slow Hydraulic Functions Low pump flow Do Pump Performance Test. See
9025-25.

Relief valve leaking Do Loader Load Sense Relief, and

Backhoe Load Sense Relief and
System Relief Valve Tests . See
9025-25.

Isolator valve stuck Remove and inspect. See repair

manual.

Low oil level Add oil to correct level.

Engine rpm too low Increase rpm or check engine

speed. See Group 9010-20.

896
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Hydraulic oil Incorrect oil, drain and refill.

aerated. Suction hose has air leak. Inspect
and tighten. See Technical Repair
manual.

Low load sense Do Pump Load Sense Differential

differential Pressure Test, see Group 9025-
pressure 25.

Hose or line Inspect and tighten fittings.

leakage

Loader or Backhoe Operates Control Valve Do Function Drift Test. See Group
Slowly in One Function section problem. 9025-25.

Control lever and Inspect lever and linkage. Adjust to

linkage out of get equal valve spool travel in
adjustment. each direction. See Group 9025-
20.

Circuit Relief valve Remove, inspect and repair

or plug leakage in sealing rings on relief valve or
control valve. plug. See Technical Repair
manual.

Do Circuit Relief Valve Test with

Remote Pump. See Group 9025-
25.

Compensator spool Remove and inspect. See repair

stuck manual.

Hydraulic cylinder Do Cylinder Leakage Test. See

leakage Group 9025-25.

897
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Bent or restricted Inspect and repair. See Technical

line Repair manual.

Hydraulic control Do Valve Leakage Test. See

valve not operating Group 9025-25. Remove, inspect
properly and repair. See Technical Repair
manual.

Bent cylinder rod. Remove and inspect. See

Technical Repair manual.

No Loader or Backhoe Control lever and Inspect lever and linkage. Adjust to
Power in One Function linkage out of get equal valve spool travel in
adjustment each direction.

Circuit relief valve Remove, inspect, and repair

or plug leakage in sealing rings on relief valve or
control valve plug. See repair manual.

Do Circuit Relief Valve Test with

Remote Pump. See Group 9025-
25.

Do Function Drift Test. See Group

9025-25.

Bent or restricted Inspect and repair.

line

Hydraulic control Remove, inspect and repair. See

valve not operating Technical Repair manual.
properly

Compensator stuck Remove and repair. See repair

manual.

898
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Low Hydraulic Power (Low Low oil level Add oil to correct level.
Hydraulic Pressure) (aeration of oil)

Load sense shuttle Remove and inspect. See repair

check valve stuck manual.

Hydraulic oil Incorrect oil, drain and refill.

aerated Suction hose has air leak. Inspect
and tighten. See repair manual.

Incorrect relief Do Loader Load Sense, Backhoe

valve setting Load Sense and System Relief
Valve Tests. See Group 9025-25,
adjust. Repair or replace. See
repair manual.

Leakage within Feel components for heat. Do

work circuit Cylinder Drift Test. See Group
9025-25.

Excessive leakage Do Leakage Test. See Group

in hydraulic system 9025-25.

Hydraulic Function Makes Low oil level Add oil to correct level.
"Chattering" Noise

Hydraulic oil Incorrect oil, drain and refill.

aerated Suction hose has air leak. Inspect
and tighten. See repair manual.

Worn or wrong Inspect, remove and repair. See

circuit relief valve Circuit Relief Valve in Group 9025-
installed in 25.
backhoe valve.

899
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Functions Drift Oil leaking past Do System Operational Checkout

valve port drift test to pinpoint cylinder or
valve leakage. See Group 9005-
10.

Oil leaking past Do Function Drift test to pinpoint

cylinders or valve. cylinder or valve leakage. See
Group 9025-25.

Anti-drift check Remove and inspect. Repair as

valve not necessary.
functioning

Control Valve Lever Sticks Control valve lever Inspect and adjust linkage. See
or Works Hard linkage binding Group 9025-20. Inspect valve
spools. See repair manual.

Hydraulic system Test component leakage. See

overheating Group 9025-25.

Check hydraulic oil temperature

sender. See Group 9015-10

Return spring Inspect and adjust. See Technical

rubbing on spring Repair manual.
cap

Broken return Remove and replace. See

spring Technical Repair manual.

Contamination in Remove and clean. See Technical

control valve Repair manual. Locate source of
contamination. Repair and clean
oil in system.

900
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Scored valve bore See Technical Repair manual.

or bent spool

Hydraulic Oil Overheats Excessive load Reduce load.

Operator holding Return levers to neutral when not

hydraulic system in use.
over relief

Oil levels too low in Check levels and add oil. Use
reservoir. recommended oil. See
TMS16109000 Section.

Using low viscosity Use recommended oil. See

oil in hot weather TMS16109000 Section.

Hydraulic cooling Clean radiator and coolers. Do

system restricted. Hydraulic Cooler Restriction Test.
See 9025-25.

Temperature Check hydraulic oil temperature

sender not working sender. See Group 9015-10

Incorrect relief Do Loader Load Sense Relief,

valve pressure Backhoe Load Sense Relief and
System Relief Valve Tests. See
Group 9025-25.

Excessive leakage Do Leakage Tests. See Group

in the hydraulic 9025-25.
system

Foaming Oil Oil level too low or Check oil level. Adjust to full mark
too high on sight gauge.

901
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Incorrect type of oil Drain and replace. See Operator’s

Manual.

Air leak on suction Locate and repair leak. See

side of pump Technical Repair manual.

Oil maintenance See Operator’s Manual.

not performed.

Hydraulic Pump Leaking Cap screws that Tighten to specification or replace

hold pump together seals and gaskets. See repair
are loose manual.

Worn shaft seal Replace seal. See repair manual.

Hydraulic oil Determine cause of overheating,

overheating see Hydraulics Oil Overheats in
this Group.

Excessive Pump Noise Low oil level Add oil to correct level.

Hydraulic filter by- Replace filter. Inspect, clean, and

pass valve repair. See Technical Repair
chattering manual.

Worn pump drive Inspect and repair. See Technical

Repair manual.

Oil lines in contact Inspect, repair or replace. See

with operators repair manual.
station (Worn cab,
transmission, or
canopy rubber
isolators)

902
 Diagnose Hydraulic System Problems
Symptom Problem Solution

Pump attaching Retighten to specification. See

hardware loose Technical Repair manual.

Leakage in Do Leakage Tests. See Group

hydraulic circuit 9025-25.

TX,9025,RR7542-19-1996/11/08

903
 Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment

Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig

Switch Adjustment

-: Specifications

SPECIFICATIONS
Guard and Stop-to-Bell Crank Gap 1 mm (0.04 in.)
Top of Bell Crank Pin-to-Bottom of Actuator Tang Gap 152 mm (6 in.)

1.

T102233-UN: Loader Bucket Self-Leveling Linkage

904
Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment

T102231-UN: Loader Bucket Self-Leveling Linkage

LEGEND:
A - 1 mm (0.04 in.) gap
B - Guard/Stop
C - Bell Crank-Neutral Position
D - Rod Jam Nut and Yoke
E - 152 mm (6 in.) gap
F - Bell Crank Pin
G - Actuator Tang
H - Sensor Tube Jam Nut and Yoke
I - Bucket Dump
J - Bucket Rollback

Position bucket flat on ground. Turn engine off.

2. Remove cover that covers linkage and reinstall cap screw.

3. Hold bucket lever in roll-back position.

4. Measure gap (A) between guard and stop (B) and bell crank (C). Gap should
be 1 mm (0.04 in.).

Item MeasurementSpecification
Guard and Stop-to-Bell Crank Gap 1 mm (0.04 in.)

5. If gap is not to specification, adjust rod jam nut and yoke (D) to obtain correct
gap.

905
Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment

Item MeasurementSpecification
Guard and Stop-to-Bell Crank Gap 1 mm (0.04 in.)

Allow bucket lever to return to neutral position.

6. Measure gap (E) between top of bell crank pin (F) and bottom of actuator tang
(G). Gap should be 152 mm (6 in.).

Item MeasurementSpecification
Top of Bell Crank Pin-to-Bottom of Actuator Gap 152 mm (6
Tang in.)

7. If gap is not to specification, adjust sensor tube jam nut and yoke (H) to
correct length.

Item MeasurementSpecification
Top of Bell Crank Pin-to-Bottom of Actuator Gap 152 mm (6
Tang in.)

8.

T87154-UN: Loader Bucket Self-Leveling Linkage

LEGEND:
A - Cap Screw
B - Roller
C - Area on Cam

Loosen cap screw (A) and move return-to-dig switch so roller (B) is touching
area (C) on the cam.
906
Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment

9. Move switch toward cam until a "click" is heard.

10. Move switch away from cam until a "click" is heard.

11. Tighten cap screw without moving switch.

12. While watching clearance between cam and switch, turn bucket level pointer
back and forth to be sure cam does not hit switch bracket.

13. NOTE:

Be sure that switch arm and roller does not bottom on switch
housing.

If cam touches bracket or switch arm, and roller bottoms on switch housing,
reposition switch. (See steps 8-12.)

14. Install cover.

15. When self-leveling mechanism is adjusted correctly, bucket position will be

approximately level or slightly forward with the ground.

T6161AA-UN: Loader Bucket Self-Leveling Linkage

16. Check bucket level indicator to leveling decal. For operator’s preference, the
decal may be moved to align with the bucket pointer.

907
Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment
TX,9025,RR7308-19-1996/08/19

908
 Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment

Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig

Switch Adjustment

-: Specifications

SPECIFICATIONS
Guard and Stop-to-Bell Crank Gap 1 mm (0.04 in.)
Top of Bell Crank Pin-to-Bottom of Actuator Tang Gap 152 mm (6 in.)

1.

T102233-UN: Loader Bucket Self-Leveling Linkage

909
Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment

T102231-UN: Loader Bucket Self-Leveling Linkage

LEGEND:
A - 1 mm (0.04 in.) gap
B - Guard/Stop
C - Bell Crank-Neutral Position
D - Rod Jam Nut and Yoke
E - 152 mm (6 in.) gap
F - Bell Crank Pin
G - Actuator Tang
H - Sensor Tube Jam Nut and Yoke
I - Bucket Dump
J - Bucket Rollback

Position bucket flat on ground. Turn engine off.

2. Remove cover that covers linkage and reinstall cap screw.

3. Hold bucket lever in roll-back position.

4. Measure gap (A) between guard and stop (B) and bell crank (C). Gap should
be 1 mm (0.04 in.).

Item MeasurementSpecification
Guard and Stop-to-Bell Crank Gap 1 mm (0.04 in.)

5. If gap is not to specification, adjust rod jam nut and yoke (D) to obtain correct
gap.

910
Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment

Item MeasurementSpecification
Guard and Stop-to-Bell Crank Gap 1 mm (0.04 in.)

Allow bucket lever to return to neutral position.

6. Measure gap (E) between top of bell crank pin (F) and bottom of actuator tang
(G). Gap should be 152 mm (6 in.).

Item MeasurementSpecification
Top of Bell Crank Pin-to-Bottom of Actuator Gap 152 mm (6
Tang in.)

7. If gap is not to specification, adjust sensor tube jam nut and yoke (H) to
correct length.

Item MeasurementSpecification
Top of Bell Crank Pin-to-Bottom of Actuator Gap 152 mm (6
Tang in.)

8.

T87154-UN: Loader Bucket Self-Leveling Linkage

LEGEND:
A - Cap Screw
B - Roller
C - Area on Cam

Loosen cap screw (A) and move return-to-dig switch so roller (B) is touching
area (C) on the cam.
911
Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment

9. Move switch toward cam until a "click" is heard.

10. Move switch away from cam until a "click" is heard.

11. Tighten cap screw without moving switch.

12. While watching clearance between cam and switch, turn bucket level pointer
back and forth to be sure cam does not hit switch bracket.

13. NOTE:

Be sure that switch arm and roller does not bottom on switch
housing.

If cam touches bracket or switch arm, and roller bottoms on switch housing,
reposition switch. (See steps 8-12.)

14. Install cover.

15. When self-leveling mechanism is adjusted correctly, bucket position will be

approximately level or slightly forward with the ground.

T6161AA-UN: Loader Bucket Self-Leveling Linkage

16. Check bucket level indicator to leveling decal. For operator’s preference, the
decal may be moved to align with the bucket pointer.

912
Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig Switch Adjustment
TX,9025,RR7308-19-1996/08/19

913
 Loader Control Valve Linkage Adjustment

Loader Control Valve Linkage Adjustment

-: Specifications

SPECIFICATIONS

Right Side of Loader Knob-to-Masking Tape Distance 250 mm (10 in.)

Front of Loader Knob-to-Masking Tape Distance 130 mm (5.25 in.)

NOTE:

Levers must be positioned correctly to allow full travel and proper

operation of loader valves. Cab and other components have been
removed in some photographs for clarity.

1. Put loader control valve spools in neutral position.

2.

T7407AN-UN: Loader Control Valve Linkage Adjustment-Earlier Machines

914
 Loader Control Valve Linkage Adjustment
T121805B-UN: Loader Control Valve Linkage Adjustment-Later Machines
Adjust rods (A) so tabs (B) on bell crank are horizontal.

3. Put a piece of masking tape from right front to right rear ROPS posts on inside
surface at loader knob height.

4.

T7407AO-UN: Loader Control Valve Linkage Adjustment

Distance (C) from right side of knob to tape should be 250 mm (10 in.).
Item MeasurementSpecification
Right Side of Loader Knob-to-Masking Tape Distance 250 mm (10 in.)

5. Put a piece of masking tape from left front to right front ROPS posts on inside
surface at loader knob height.

6. Distance (D) from front of loader knob to tape should be 130 mm (5.25 in.).

Item MeasurementSpecification
Front of Loader Knob-to-Masking Tape Distance 130 mm (5.25 in.)

7.

915
 Loader Control Valve Linkage Adjustment
T7407AP-UN: Adjusting Rods
The distances in steps 4 and 6 can be obtained by adjusting rods (E).

NOTE:

T7407AQ-UN: Pivot
Pivot (F) must remain in slot when holding the loader lever in the roll-
back position.

TX,9025,RR7309-19-2000/02/17

916
 Backhoe Valve Linkage Adjustment

Backhoe Valve Linkage Adjustment

-: Specifications

SPECIFICATIONS

Backhoe Lever Knob Edge-to-Masking Tape Distance 140 mm (5.5 in.)

Backhoe Lever Knob-to-Knob Distance 260 mm (10.25 in.)

NOTE:

Levers must be positioned correctly to allow full travel and proper

operation of backhoe valves. Cab and other components have been
removed in some photographs for clarity.

1. Put backhoe valve spools in neutral position.

2. Put a piece of masking tape across the rear ROPS posts on inside surface at
backhoe lever knob height.

3.

T7407AJ-UN: Distance From Edge of Knobs to Tape

Measure from edge of knobs to tape. Distance (B) should be 140 mm (5.5 in.).
Item MeasurementSpecification
Backhoe Lever Knob Edge-to-Masking Tape Distance 140 mm (5.5 in.)
Knobs should be 260 mm (10.25 in.) apart.
Item MeasurementSpecification
Backhoe Lever Knob-to-Knob Distance 260 mm (10.25 in.)

TX,9025,RR7310-19-1999/11/24

917
 Stabilizer Valve Linkage Adjustment

Stabilizer Valve Linkage Adjustment

NOTE:

Levers must be positioned correctly to allow full travel and proper

operation of stabilizer valves. Cab and other components have been
removed in some photographs for clarity.

1. Put stabilizer valve spools in neutral position.

2.

T8187AL-UN: Linkage Rods and Tabs

Adjust linkage rods (A) so that tabs (B) are vertical.

3. Put masking tape across left and right rear ROPS posts on inside surface at
stabilizer knob height.

4.

T7407AL-UN: Distance from Edge to Knob and Knob to Tape

918
 Stabilizer Valve Linkage Adjustment

T7407AM-UN: Adjusting Rods

Measure the distance (C) from edge of right stabilizer knob to tape. It should
be 260 mm (10.25 in.).
Item MeasurementSpecification
Edge of Right Stabilizer Knob-to-Masking Distance 260 mm (10.25
Tape in.)
Measure the distance (D) from edge of left stabilizer knob to tape. It should be
295 mm (11.6 in.).
Item MeasurementSpecification
Edge of Left Stabilizer Knob-to-Masking Distance 295 mm (11.6
Tape in.)
Adjust rods (E) as necessary.

TX,9025,RR7312-19-1996/06/10

919
 Pre-Test Diagnostics

Pre-Test Diagnostics

Check for external oil leaks: i.e. fittings, hoses, and valves.
Check for valve spool return-to-neutral that might be caused from: i.e. spool
sticking, linkage binding, detent mechanism, self-leveling adjustment,
vibration, control valve tie-rod torque.
Hydraulic reservoir oil level and the viscosity/condition of hydraulic oil.
Transmission oil level and the viscosity/condition of engine oil.
Radiator and oil cooler fins are clean and free of debris.
Hydraulic System: Check for leaks, missing or loose clamps, kinked hoses
and lines, and hoses or lines that rub against each other or other parts.
Boom, Bucket, Sheet Metal: Check for bent, broken, loose, or missing parts.
Hardware: Check for loose or missing parts.
Protective Devices: Check that guards, shields, and covers are in place and in
good condition.

CED,TX03768,2673-19-1999/11/18

920
 Pre-Test Diagnostics

Pre-Test Diagnostics

Check for external oil leaks: i.e. fittings, hoses, and valves.
Check for valve spool return-to-neutral that might be caused from: i.e. spool
sticking, linkage binding, detent mechanism, self-leveling adjustment,
vibration, control valve tie-rod torque.
Hydraulic reservoir oil level and the viscosity/condition of hydraulic oil.
Transmission oil level and the viscosity/condition of engine oil.
Radiator and oil cooler fins are clean and free of debris.
Hydraulic System: Check for leaks, missing or loose clamps, kinked hoses
and lines, and hoses or lines that rub against each other or other parts.
Boom, Bucket, Sheet Metal: Check for bent, broken, loose, or missing parts.
Hardware: Check for loose or missing parts.
Protective Devices: Check that guards, shields, and covers are in place and in
good condition.

CED,TX03768,2673-19-1999/11/18

921
 Diagnostics Flow Charts

Diagnostics Flow Charts

T121126-19: Hydraulic System Noise/vibration Problem

922
 Diagnostics Flow Charts

T121148-19: Hydraulic Function Droop Problem

923
 Diagnostics Flow Charts

T121147-19: Hydraulic Control Valve Sticking Problem

924
 Diagnostics Flow Charts

T121125-19: Hydraulic Function Drift Problem

925
 Diagnostics Flow Charts

T121146-19: Hydraulic Function Drift (Steering) Problem

926
 Diagnostics Flow Charts

T121146-19: Hydraulic Function Drift (Steering) Problem

CED,TX03768,2672-19-1999/11/18

927
T125994-19: Low Hydraulic Power

CED,TX03768,2683-19-1999/12/10

928
 JT05801 Clamp-On Electronic Tachometer Installation

JT05801 Clamp-On Electronic Tachometer Installation

T6813AG-UN: JT05801

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Tachometer
A-Clamp-On Transducer. Remove paint with emery cloth and connect to a straight
section of injection line within 100 mm (4 in.) of pump. Finger tighten only. DO NOT
overtighten.

B-Black Clip (-). Connect to main frame.

C-Red Clip (+). Connect to transducer.

D-Tachometer Readout. Install cable.

TX,9025,RR7313-19-1995/08/10

929
 JT05800 Digital Thermometer Installation

JT05800 Digital Thermometer Installation

T6808CE-UN: JT05800

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer
A-Temperature Probe

B-Cable
C-Digital Thermometer

TX,9025,RR7314-19-1995/02/28

930
 Hydraulic Oil Warm-Up Procedure

Hydraulic Oil Warm-Up Procedure

-: Specifications

SPECIFICATIONS

Engine Speed Fast idle

Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)

-: Essential Tools

ESSENTIAL TOOLS

JT03111 (9/16 -18 M ORB x 7/16 -20 M JIC) Connector

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer

1. Install temperature probe in reservoir.

2. Put FNR and transmission gear shift lever in neutral and engage park brake.

3. Start engine and run at fast idle.

Item MeasurementSpecification
Engine Speed Fast idle

4. Lower loader bucket to the ground.

5. Place backhoe in transport position and apply boom lock. Stall the boom down
circuit by pushing the boom down lever fully for one minute, then cycle
function to reduce localized over-heating in control valve and to equalize
temperature in circuits being tested. Repeat cycle until oil, after cycling, is at
test specifications.

Item MeasurementSpecification
Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)

TX,9025,RR7558-19-1996/12/07

931
 Pump Load Sense Differential Pressure Test

Pump Load Sense Differential Pressure Test

T104871-UN: Pump Load Sense Differential Pressure

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed Slow idle (900 + 25 - 0 rpm)
Pump Load Sense Differential Pressure Setting 1930 ± 34 kPa (19 ± 0.5 bar)
(280 ±5 psi)

One Full Turn of Load Sense Differential Pressure Approximately 30 psi

Screw Changes Pressure

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Method I - JT02156A Digital Pressure and Temperature Analyzer or Equivalent

Digital Thermometer
Digital Tachometer

932
 Pump Load Sense Differential Pressure Test

SERVICE EQUIPMENT AND TOOLS

Method II - Gauge 0-3450 kPa (0-35 bar) (0-500 psi)

The purpose of this test is to check the pump load sense differential pressure setting.
This test should be performed when the pump performance is in doubt.

1. Method I Operate all hydraulic control valves to relieve pressure in the

hydraulic system.

2. Install digital pressure transducers or equivalent to pump outlet coupler (A)

and load sense coupler (B). Install temperature analyzer coupler to reservoir.

3. Warm oil to specification.

Item MeasurementSpecification
Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)

4. Set digital pressure analyzer to 500 psi delta.

5. IMPORTANT:

Do not operate hydraulic control levers during this test.

Run engine at low idle.

Item MeasurementSpecification
Engine Speed Slow idle (900 + 25 - 0 rpm)

6. Record pressure.

Item Measurement Specification

Pump Load Differential Pressure 1930 ± 34 kPa (19 ± 0.5 bar) (280
Sense Setting ±5 psi)
Stop engine.

7. If adjustment is necessary turn load sense differential pressure screw (C) IN

(clockwise) to raise pressure and OUT (counterclockwise) to lower pressure.
One turn equals approximately 30 psi.

933
 Pump Load Sense Differential Pressure Test

Item MeasurementSpecification
One Full Turn of Load Sense Differential Pressure Approximately
Pressure Screw Changes 30 psi

8. Repeat step 5 and 6 until pressure is at specification.

Item Measurement Specification

Pump Load Differential Pressure 1930 ± 34 kPa (19 ± 0.5 bar) (280
Sense Setting ±5 psi)

1.

T104871-UN: Pump Outlet Coupler

Method II: Operate all hydraulic control valves to relieve pressure in the
hydraulic system.

2. Install temperature probe in reservoir.

3. Connect gauge to pump outlet coupler (A).

4. Install tachometer.
934
 Pump Load Sense Differential Pressure Test

5. Warm oil to specifications.

Item MeasurementSpecification
Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up procedure in this group.)

6. IMPORTANT:

DO NOT cap or plug load sense line or port.

Shut engine off and disconnect load sense line (D) at pump. Place line in
bucket without being capped. Also, do not plug load sense port at pump.

7. CAUTION:
To prevent injury from spraying hot oil, do not operate
hydraulic control levers during this test.

Start engine and run at slow idle.

Item MeasurementSpecification
Engine Speed Slow idle (900 + 25 - 0 rpm)
Do not operate hydraulic control levers during this test. Record pressure.
Item Measurement Specification
Pump Load Differential Pressure 1930 ± 34 kPa (19 ± 0.5 bar) (280
Sense Setting ±5 psi)

8. Engine off. Adjust the pump load sense pressure by turning screw (C) in to
raise pressure and out to lower pressure. (Each full turn is approximately 30
psi.)

Item MeasurementSpecification
One Full Turn of Load Sense Differential Pressure Approximately
Pressure Screw Changes 30 psi

9. Repeat step 7 and 8 until pressure is to specification.

935
 Pump Load Sense Differential Pressure Test

Item Measurement Specification

Pump Load Differential Pressure 1930 ± 34 kPa (19 ± 0.5 bar) (280
Sense Setting ±5 psi)

TX,9025,SS3533-19-1996/12/10

936
 Pump Flow Test

Pump Flow Test

T104864-UN: Test Connections

LEGEND:
A - Bucket Cylinder Rod End Hose
B - Flowmeter
C - Bucket Head End Hose

-: Specifications

SPECIFICATIONS
Oil Temperature 49 ± 5°C (120 ± 10°F)

Engine Speed 2200 rpm

Flowmeter Pressure 13 700 ± 70 kPa (137 ± 0.7 bar) (2000 ± 100 psi)
New Pump Flow 151 L/min (40 gpm)

Used Pump Minimum Flow 129 L/min (34 gpm)

937
 Pump Flow Test
-: Essential Tools

ESSENTIAL TOOLS
JT05688 (1-1/16 -12 M 37° x -8 F ORFS) Adapter (2 Used)
38H1279* (-8 M x -8 M ORFS) Union

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Flowmeter
Digital Thermometer
Electronic Tachometer

1. Do Pump Load Sense Differential Pressure Test, see procedure in this group.

2. Do Backhoe Load Sense and Loader Load Sense Relief Stall Pressure Test,
see procedure in this group.

3. Put FNR and transmission control levers in neutral and engage park brake.

4. Stop engine. Operate all hydraulic control valves to release pressure in the
hydraulic system.

5. Connect hose and flowmeter (B) with analyzer to bucket cylinder rod end hose
(A) and head end hose (C).

6. Open flowmeter. Install digital thermometer sensor in reservoir. Install

electronic tachometer, see procedure in this group.

7. Warm oil to specification.

Item MeasurementSpecification
Oil Temperature 49 ± 5°C (120 ± 10°F)
(See Hydraulic Oil Warm-up Procedure in this group.)

8. Run engine to specified temperature and engine rpm.

Item MeasurementSpecification
Engine Speed 2200 rpm
Oil Temperature 49 ± 5°C (120 ± 10°F)

9. Slowly apply 13,700 ± 70 kPa (137 ± 0.7 bar) (2000 ± 10 psi) to pump and
938
 Pump Flow Test
9. Slowly apply 13,700 ± 70 kPa (137 ± 0.7 bar) (2000 ± 10 psi) to pump and
record pump flow.

Item Measurement Specification

Flowmeter Pressure 13 700 ± 70 kPa (137 ± 0.7 bar) (2000 ± 100 psi)
New Pump Flow 151 L/min (40 gpm)
Used Pump Minimum Flow 129 L/min (34 gpm)

TX,9025,SS3537-19-1996/08/22

939
 Backhoe Load Sense and Loader Load Sense Relief Stall Pressure Test

Backhoe Load Sense and Loader Load Sense Relief Stall Pressure
Test

T105642-UN: Adjusting Screw

940
 Backhoe Load Sense and Loader Load Sense Relief Stall Pressure Test

T104872-UN: Pump Outlet Coupler

-: Specifications

SPECIFICATIONS
Engine Speed WOT
Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
Backhoe Load Sense Relief Stall Pressure 25683 ± 689 kPa (257 ±7 bar) (3725
Setting ±100 psi)
Loader Load Sense Relief Stall Pressure 25683 ± 689 kPa (257 ±7 bar) (3725
Setting ±100 psi)

-: Essential Tools

ESSENTIAL TOOLS
JT03111 (9/16 -18 M ORB x 7/16 -20 M JIC) Connector

941
 Backhoe Load Sense and Loader Load Sense Relief Stall Pressure Test
-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer
Gauge 0-35 000 kPa (0-350 bar) (0-5000 psi)

NOTE:

Before performing these two tests, the Pump Load Sense Differential
Pressure Test must be done and adjusted if necessary. (See procedure
in this Section).

Both the backhoe and loader control valves have a load sense relief valve. The load
sense relief valves are adjusted to set stall pressures.

1. Backhoe Load Sense Relief Stall Pressure Test:

Do Pump Load Sense Differential Pressure Test , see procedure in this group.

2. Operate all hydraulic control valves to relieve pressure in the hydraulic

system.

3. Install temperature probe in reservoir.

4. Connect gauge to pump outlet coupler (1).

5. Warm oil to specifications.

Item MeasurementSpecification
Engine Speed WOT
Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up procedure in this group.)

6. Raise the backhoe boom fully to transport position and hold over relief to stall
the circuit. Record the backhoe load sense relief stall pressure setting from
the gauge.

Item Measurement Specification

Backhoe Load Relief Stall Pressure 25683 ± 689 kPa (257 ±7 bar) (3725
Sense Setting ±100 psi)

7. To adjust the backhoe load sense relief valve, turn adjusting screw (A).
942
7. ToBackhoe Load
adjust the Sense and
backhoe Loader
load senseLoad Sense
relief Relief
valve, turn Stall Pressure
adjusting Test(A).
screw

NOTE:

One gauge can be used if necessary.

1.

T104872-UN: Pump Outlet Coupler

943
 Backhoe Load Sense and Loader Load Sense Relief Stall Pressure Test

T105643-UN: Adjusting Screw and Gauge

Loader Load Sense Relief Stall Pressure Test:

Do Pump Load Sense Differential Pressure Test, see procedure in this group.

2. Operate all hydraulic control valves to relieve pressure in the hydraulic

system.

3. Install temperature probe in reservoir.

4. Connect gauge to pump outlet coupler (1).

5. Warm oil to specifications.

Item MeasurementSpecification
Engine Speed WOT
Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up procedure in this group.)

6. Loader bucket fully dumped and held over relief at ground level. Record the
944
 Backhoe Load Sense and Loader Load Sense Relief Stall Pressure Test
6. Loader bucket fully dumped and held over relief at ground level. Record the
loader load sense relief stall pressure setting from the gauge (C).

Item Measurement Specification

Loader Load Relief Stall Pressure 25683 ± 689 kPa (257 ±7 bar) (3725
Sense Setting ±100 psi)

7. To adjust the load sense relief valve, turn adjusting screw (B).

TX,9025,RR7545-19-2001/11/09

945
 Steering Load Sense Relief Valve Stall Pressure Test

Steering Load Sense Relief Valve Stall Pressure Test

T104872-UN: Pump Outlet Coupler

946
 Steering Load Sense Relief Valve Stall Pressure Test

T104869-UN: Steering Load Sense Relief Valve

-: Specifications

SPECIFICATIONS

Engine Speed Fast idle

Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
Steering Load Sense Relief Valve Stall 20891 ± 689 kPa (209 ± 7 bar) (3030
Pressure Setting ±100 psi)

One Turn IN of Hex Screw Increases Approximately 1000 psi

Pressure

-: Essential Tools

ESSENTIAL TOOLS
JT03111 (9/16 -18 M ORB x 7/16 -20 M JIC) Connector

-: Service Equipment and Tools

947
 Steering Load Sense Relief Valve Stall Pressure Test

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer

Gauge 0-35 000 kPa (0-350 bar) (0-5000 psi)

The purpose of this test is to check the setting of the steering load sense relief valve.
The steering load sense relief valve is adjusted to set stall pressure.

1. Do Pump Load Sense Differential Pressure Test, see procedure in this group.

2. Operate all hydraulic control valves to relieve pressure in the hydraulic

system.

3. Install temperature probe in reservoir.

4. Connect gauge to pump outlet coupler (1).

5. Install tachometer.

Item MeasurementSpecification
Engine Speed WOT

6. Warm oil to specifications.

Item MeasurementSpecification
Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up procedure in this group.)

7. Turn the steering wheel either left or right and hold against stop.

8. Read gauge and record value.

Item Measurement Specification

Steering Load Sense Stall Pressure 20891 ± 689 kPa (209 ± 7 bar)
Relief Valve Setting (3030 ±100 psi)

9. To adjust the steering load sense relief valve, turn hex screw (A), (One turn IN
increases pressure approximately 1000 psi).

Item MeasurementSpecification
One Turn IN of Hex Screw Increases Pressure Approximately 1000 psi

948
 Steering Load Sense Relief Valve Stall Pressure Test

NOTE:

The adjustment of the steering valve load sense relief can

only be done when the steering valve is removed from the
machine. (See Technical Repair Manual.)

TX,9025,RR7567-19-2001/11/09

949
 Flow Limiter Test

Flow Limiter Test

-: Specifications

SPECIFICATIONS

Transmission and Hydraulic Oil Temperature 65 ± 5°C (150 ±

10°F)
Engine Speed Fast idle (2400 + 25 -
0 rpm)
Engine RPM 1250-1450 rpm*

One Full Turn IN of Flow Limiter Screw Decreases Engine Approximately 50

RPM rpm
One Full Turn IN of Flow Limiter Screw Increases Approximately 5 hp
Horsepower to Hydraulic Pump

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Electronic Tachometer

Digital Thermometer

The purpose of this test is to adjust the maximum power that can be used by the
hydraulic pump.

NOTE:

Increasing the power level to the hydraulic pump can result in additional
engine pulldown during certain loader operations.

NOTE:

Before doing the following procedure, Pump Load Sense Differential

Pressure Test and Backhoe Load Sense and Loader Load Sense
Relief Stall Pressure Tests, must be performed and adjustments made
as needed (see Group 9025-25). Also do the Torque Converter Stall
Speed Test (see Group 9020-25).

1. Install electronic tachometer. (See procedure in this group.)

950
 Flow Limiter Test

2. Install digital thermometer probe into the transmission and hydraulic reservoir
through the dipstick tube.

3. Heat oil to specifications.

Item MeasurementSpecification
Transmission and Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
See Transmission Warm-Up Procedure in Group 9020-25 and Hydraulic
Warm-Up Procedure in this Group.

4. Lower stabilizers to raise wheels off ground.

5. IMPORTANT:

Converter should NOT be stalled longer than 20 seconds

or serious converter damage may result. Return FNR
lever to neutral position for 10 seconds before doing next
stall test.

Put transmission in fourth gear.

6.

951
 Flow Limiter Test

T104870-UN: Flow Limiter Screw

Apply and hold service brakes during test.

7. Move FNR lever to forward position.

8. Run engine at fast idle with speed control lever.

Item MeasurementSpecification
Engine Speed Fast idle (2400 + 25 - 0 rpm)

9. IMPORTANT:

Minimum engine speed listed is for an engine that is

broken-in and using No. 2 fuel.

Loader bucket fully dumped and held over relief at ground level. Record
tachometer reading while raising loader boom to maximum height.

10. Record rpm.

Item MeasurementSpecification
Engine RPM 1250-1450 rpm*
This rpm is the dependent on the flow limiter setting.

11. Adjust Flow Limiter:

Turning the flow limiter screw (A) IN (clockwise) one full turn will decrease the
engine rpm measured during the above test approximately 50 rpm and provide
approximately five more horsepower to the hydraulic pump.

Item Measurement Specification

One Full Turn IN of Flow Decreases Engine RPM Approximately
Limiter Screw 50 rpm
Increases Horsepower to Approximately 5
Hydraulic Pump hp

TX,9025,RB23-19-1997/10/31

952
 Hydraulic Oil Cooler Restriction Test

Hydraulic Oil Cooler Restriction Test

T102207-UN: Hydraulic Oil Cooler

LEGEND:
A - Hydraulic Analyzer
B - Tee Fittings (2 used)
C - Oil Cooler

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 65 ± 5°C (120 ± 10°F)

Engine Speed Low idle

Flowmeter Flow 28.4 L/min. (7.5 gpm)

Hydraulic Oil Cooler Maximum Differential Pressure 207 kPa (2.1 bar) (30 psi)

-: Essential Tools

ESSENTIAL TOOLS

3/4 M NPT x 5/8 Barb Barb Fitting

JT03012 (1-1/16 F 37° SW x 3/4 F NPT) Fitting
JT03048 (1-1/16 M ORB x 1-1/16 M 37°) Fitting

JT03348 (1/2 F NPT) Tee (2 Used)

953
 Hydraulic Oil Cooler Restriction Test

ESSENTIAL TOOLS

JT03213 (5/8 I.D. Hose x 1/2 M NPT) Adapter (6 Used)

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Hydraulic Analyzer

Gauge 0-345 kPa (0-3.5 bar) (0-50 psi)

Flowmeter with Temperature Gauge

1. Make test connection.

2. Open flowmeter. Heat oil to test specification.

Item MeasurementSpecification
Hydraulic Oil Temperature 65 ± 5°C (120 ± 10°F)
(See Hydraulic Oil Warm-Up Procedures in this group.)

3. Meter backhoe bucket dump at low idle to obtain specified cooler flow.

Item MeasurementSpecification
Engine Speed Low idle
Flowmeter Flow 28.4 L/min. (7.5 gpm)

4. Read pressure gauges at inlet and outlet of cooler. Difference in gauge

reading is pressure drop in cooler.

Item Measurement Specification

Hydraulic Oil Cooler Maximum Differential 207 kPa (2.1 bar) (30 psi)
Pressure

TX,9025,RR7320-19-1996/08/12

954
 Circuit Relief Valve Test with Remote Pump

Circuit Relief Valve Test with Remote Pump

-: Specifications

SPECIFICATIONS

Hydraulic Source Maximum Flow Rate 7.5 L/min (2 gpm)

Oil Temperature 40 ± 6°C (104 ±10°F)

Set Tolerance Pressure +1380 -0 kPa (+13.8 -0 bar) (+200 -0

psi)

Loader Circuits
Auxiliary Extend Pressure (non-adjustable) 26200 kPa (262 bar) (3800 psi)

Bucket Curl Pressure (screw adjustable) 31715 kPa (317 bar) (4600 psi)
Bucket Dump Pressure (screw adjustable) 31715 kPa (317 bar) (4600 psi)

Boom Up Pressure (screw adjustable) 34473 kPa (344 bar) (5000 psi)

Backhoe Circuits
Crowd Out Pressure (screw adjustable) 32800 kPa (327 bar) (4750 psi)

Crowd In Pressure (non-adjustable) 26200 kPa (276 bar) (3800 psi)

Bucket Curl Pressure (screw adjustable) 31700 kPa (317 bar) (4600 psi)
Bucket Dump Pressure (screw adjustable) 31700 kPa (317 bar) (4600 psi)

Boom Raise Pressure (screw adjustable) 34500 kPa (345 bar) (5000 psi)
Boom Down Pressure (non-adjustable) 14800 kPa (148 bar) (2150 psi)

Swing Left Pressure (non-adjustable) 28900 kPa (290 bar) (4200 psi)
Swing Right Pressure (non-adjustable) 28900 kPa (290 bar) (4200 psi)
System Relief Valve Pressure (non- 27600 kPa (276 bar) (4000 psi)
adjustable)

-: Essential Tools

ESSENTIAL TOOLS
JT07192 Electric/Hydraulic Pump
38H1355 (-10 ORFS) Nut

38H1470 (-10 F x -6 M ORFS) Reducer

38H1356 (-12 ORFS) Nut

955
 Circuit Relief Valve Test with Remote Pump

ESSENTIAL TOOLS
38H1473 (-12 F x -6 M ORFS) Reducer

38H1358 (-16 F x -8 M ORFS) Nut

38H1475 (-16 F x -8 M ORFS) Reducer

38H1481 (-8 F x -6 M ORFS) Reducer

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer

Gauge 0-48 260 kPa (0-482 bar) (0-7000 psi)

IMPORTANT:

Relief valve is flow sensitive. A flow rate greater than 7.5 L/min (2
gpm) will flood the valve causing an inaccurate pressure reading.
A hydraulic source must be used that will provide a continuous
flow to get an accurate reading.

1. Operate hydraulic functions to relieve pressure.

Item Measurement Specification

Hydraulic Source Maximum Flow Rate 7.5 L/min (2 gpm)

2. CAUTION:
To avoid injury from escaping fluid under pressure, stop
engine and relieve the pressure in the system before
disconnecting or connecting hydraulic or other lines.
Tighten all connections before applying pressure.

Place container (C) under hoses to catch any oil leakage.

Item MeasurementSpecification
Oil Temperature 40 ± 6°C (104 ±10°F)

956
 Circuit Relief Valve Test with Remote Pump

T102189-UN: Container Used to Catch Oil Leakage

3. Connect remote pump pressure hose (A) to circuit inlet hoses and cap all
other ends of hose during this test.

4. Start remote pump to pressurize valve inlet.

NOTE:

Take reading when pressure on gauge starts to decrease.

The point at which pressure decreases is the opening
pressure of the relief valve.

5. Adjust or replace as required.

1. System Relief Test: Remove system relief valve from backhoe endcap outlet
section.

957
 Circuit Relief Valve Test with Remote Pump

2. Remove upper work port circuit relief valve from swing section of backhoe
control valve and install the system relief valve.

3. Start pump to pressurize circuit and record reading from gauge.

Item MeasurementSpecification
Pump Set TolerancePressure +1380 -0 kPa (+13.8 -0 bar) (+200 -0 psi)
System relief valve is not adjustable, replace if not to specification.

TX,9025,RB17-19-1999/12/08

958
 Charging the Ride Control Accumulator

Charging the Ride Control Accumulator

CAUTION:

X9811-UN: Escaping Fluid

Hydraulic oil may escape at pressure high enough to penetrate
skin from components in the Ride Control solenoid circuit if
components are removed without discharging this accumulator.
Hydraulic oil in accumulator can be stored at pressures equal to
or above system relief pressures. Escaping fluid under pressure
can penetrate the skin causing serious injury. Avoid the hazard by
relieving pressure before disconnecting hydraulic or other lines.
Tighten all connections before applying pressure. Search for
leaks with a piece of cardboard. Protect hands and body from
high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected

into the skin must be surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with this type of injury
should reference a knowledgeable medical source. Such
information is available from Deere & Company Medical
Department in Moline, Illinois, U.S.A.

959
 Charging the Ride Control Accumulator

Item Measurement Specification

Oil Temperature 40°C (104°F)
Ride Control Accumulator Pre-charge Pressure (310E, 2482 ± 241 kPa (25
Charge-17.2 in. accumulator 310SE, 315SE Machines) ± 2.4 bar) (360 ± 35
canister length psi)
Ride Control Accumulator Pre-charge Pressure (410E 3447 ± 241 kPa (35
Charge-17.2 in accumulator Machine) ± 2.4 bar) (500 ± 35
canister length psi)
Ride Control Accumulator Pre-charge Pressure (310E, 2930 ± 241 kPa (29
Charge-14.2 in. accumulator 310SE, 315SE and 410E ± 2.4 bar) (425 ± 35
canister length Machines) psi)

Gas
Cock.......JT01735
Charge
Accumulator

Two different length accumulators have been used in production and field installed ride
control kits. The nitrogen charge pressure is different for the two accumulators;
measure the length of the accumulator to determine the proper charge. If the
accumulator length is 14.2 in., use procedure “A”. If the length is 17.2 in., use procedure
“B”.

CED,TX03768,8501-19-2000/03/08

960
 Charging the Ride Control Accumulator-Procedure “A” (14.2 in. accumulator)

Charging the Ride Control Accumulator-Procedure “A” (14.2 in.

accumulator)

1.

T128981-UN:

T128982-UN:
LEGEND:
A - Top Nut
B - Bottom Nut

IMPORTANT:

Charge accumulator using only dry nitrogen. Dry

nitrogen does not mix with oil and is non-combustible. It
961
 Charging the Ride Control Accumulator-Procedure “A” (14.2 in. accumulator)
will not cause oxidation or condensation inside
accumulator and is not harmful to piston seal. DO NOT
use air or any combustible gas as these can cause
oxidation and condensation. Oxidation and condensation
are harmful to piston seal and accumulator.

If accumulator is to be charged on machine and has some nitrogen pressure

left, turn key to ON position. Move ride control switch to OFF then back to ON.
Move control lever to float position to drain oil from accumulator.

2. Loosen hose fitting on bottom of ride control accumulator to release any

trapped oil pressure. Leave fitting loose until after charge pressure process is
complete.

3. Remove cover and cap from top of accumulator.

4. Turn handle on gas cock fully counterclockwise. Attach gas cock, hose, and
regulator to accumulator.

5. CAUTION:
Loosen only the top nut (A). The bottom nut (B) is
actually the accumulator gas valve fitting. Do Not loosen
bottom fitting. Loose fitting under pressure can cause
injury.

Loosen top nut (A) (counterclockwise) 2 1/2 turns to open gas valve in
accumulator. (Resistance may be felt at approximately 1 1/2 turns.)

6. Slowly open regulator valve to pressurize accumulator to specification 2930

kPa (29 bar )(425 psi).

7. Ttighten nut (A) clockwise until snug to close gas valve.

8. Shut-off the gas pressure from the nitrogen tank.

9. Slowly loosen the connector at the pressure regulator valve to release

pressure from the hose.

10. Remove the gas cock from the accumulator and install cap.

962
 Charging the Ride Control Accumulator-Procedure “A” (14.2 in. accumulator)

11. Tighten hydraulic hose fitting on bottom of accumulator.

CED,TX03768,2708-19-2000/03/13

963
 Charging the Ride Control Accumulator-Procedure “B” (17.2 in. accumulator)

Charging the Ride Control Accumulator-Procedure “B” (17.2 in.

accumulator)

The following procedure should be used for charging accumulator that is already
installed on the machine. See specifications above to charge accumulator that needs a
precharge before it is installed on the machine.

1.

T115658B-UN:
To determine proper nitrogen charge pressure for the machine, install a gage
into the head end of the loader cylinder.

2. Raise the loader 3 to 4 ft. off the ground. Note the head end pressure required
to support the loader. (The accumulator charge pressure should be 50 psi
below this pressure.)

3. If accumulator is to be charged on machine and has some nitrogen pressure

left, turn key to ON position. Move ride control switch to OFF then back to ON.
Move control lever to float position to drain oil from accumulator.

4. Loosen hose fitting on bottom of ride control accumulator to release any

trapped oil pressure. Leave fitting loose until after charge pressure process is
complete.

5. Remove cover and cap from the top of accumulator.

6. Turn handle on gas cock fully counterclockwise. Attach gas cock, hose, and
regulator to accumulator.

964
 Charging the Ride Control Accumulator-Procedure “B” (17.2 in. accumulator)
7.

T128981-UN:

T128982-UN:
LEGEND:
A - Top Nut
B - Bottom Nut

CAUTION:
Loosen only the top nut (A). The bottom nut (B) is
actually the accumulator gas valve fitting. Do Not loosen
bottom fitting. Loose fitting under pressure can cause
injury.

965
 Charging the Ride Control Accumulator-Procedure “B” (17.2 in. accumulator)

Loosen top nut (A) counterclockwise 2 1/2 turns to open gas valve in
accumulator. (Resistance may be felt in approximately 1 1/2 turns.)

8. Slowly open the regulator valve to pressurize accumulator to 345 kPa (3.5 bar
)(50 psi) below head end psi measured earlier.

9. Tighten nut (A) clockwise until snug to close gas valve.

10. Shut-off the gas pressure from the nitrogen tank.

11. Slowly loosen the connector at the pressure regulator valve to release
pressure from the hose.

12. Remove the gas cock from the accumulator and install cap.

13. Tighten hydraulic hose fitting on bottom of accumulator.

CED,TX03768,2709-19-2000/03/13

966
 Ride Control Accumulator Discharge Procedure

Ride Control Accumulator Discharge Procedure

1. CAUTION:
Prevent possible injury from unexpected boom or bucket
movement when equipped with ride control. Ride control
accumulator energy must be discharged when working
on hydraulic components. Turn key switch to ON position
and move the loader control lever into the float position.

Position loader bucket approximately 30 cm (1 ft) off the ground.

2. Make sure area around bucket is clear and move ride control switch to OFF
position.

3. Turn key switch to ON position, but do not start engine. Move ride control
switch to ON position.

4. Move loader control lever to float position. Bucket should lower to ground.

CED,OUTX466,955-19-1998/04/16

967
 Steering System Leakage Test

Steering System Leakage Test

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed Low idle

Steering Wheel Torque 11.3 N·m (100 lb-in.)

Steering Wheel Leakage 5 to 7 rpm for hot oil

-: Essential Tools

ESSENTIAL TOOLS

38H1145 [PlugThese ORFS fittings should be ordered through normal service parts
channels.] (2 Used)
38H1352 [NutThese ORFS fittings should be ordered through normal service parts
channels.] (2 Used)

38H1138 [PlugThese ORFS fittings should be ordered through normal service parts
channels.] (2 Used)

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer

1.

T93024-UN: Turn Steering Wheel Clockwise/Counterclockwise

Install digital thermometer probe in reservoir.

2. Heat hydraulic oil to specifications.

968
 Steering System Leakage Test

Item MeasurementSpecification
Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)

(See procedure in this group.)

3. Put FNR lever in neutral and engage park brake.

4. Remove steering wheel emblem.

5. Bend locking tab away from steering wheel nut.

6. Run the engine at low idle.

Item MeasurementSpecification
Engine Speed Low idle

7. Turn the steering wheel clockwise at a constant torque of 11.3 N·m (100 lb-in.)
with wheels in the maximum right position.

Item MeasurementSpecification
Steering Wheel Torque 11.3 N·m (100 lb-in.)
Count the rpm.

8. Turn the steering wheel counterclockwise at a constant torque of 11.3 N·m

(100 lb-in.) with wheels in the maximum left turn position.

Item MeasurementSpecification
Steering Wheel Torque 11.3 N·m (100 lb-in.)
Count the rpm.

9. If the steering wheel can be turned faster than 7 rpm in either direction,
excessive leakage is indicated.

Item MeasurementSpecification
Steering Wheel Leakage 5 to 7 rpm for hot oil
Go to steps 12-16 to isolate steering valve or cylinder leakage.

10. If the steering wheel cannot be turned faster than 7 rpm in both directions, the
steering valve and cylinder are good. Stop the test here.

11. Stop the engine.

969
 Steering System Leakage Test

12. CAUTION:

X9811-UN: Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin
causing serious injury. Avoid the hazard by relieving
pressure before disconnecting hydraulic or other lines.
Tighten all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands and
body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
with this type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.

Operate all hydraulic control valves to release pressure in system.

970
 Steering System Leakage Test
13.

T6076AM-UN: Axle Without MFWD Shown

Disconnect hydraulic lines from steering cylinder and install caps (B) and
plugs (A).

14. Start the engine and run at low idle.

Item MeasurementSpecification
Engine Speed Low idle

15. Turn steering wheel counterclockwise and then clockwise at a constant torque
of 11.3 N·m (100 lb-in.). Count the rpm.

Item MeasurementSpecification
Steering Wheel Torque 11.3 N·m (100 lb-in.)

16. If steering wheel can be turned faster than 7 rpm in either direction, steering
valve is leaking excessively.

Item MeasurementSpecification
Steering Wheel Leakage 5 to 7 rpm for hot oil

971
 Steering System Leakage Test
If the rpm is less than 7, do Steering Cylinder Leakage Test in this section.

TX,9025,RR7322-19-1996/08/12

972
 Steering Cylinder Leakage Test

Steering Cylinder Leakage Test

-: Specifications

SPECIFICATIONS

Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed Low idle

Steering Cylinder Leakage 5 ml/min (1/6 oz/min)

-: Essential Tools

ESSENTIAL TOOLS
38H1145 [PlugThese ORFS fittings should be ordered through normal service parts
channels.]

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer

1. Install digital thermometer probe in reservoir.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)

2. Put FNR lever in neutral and engage park brake.

3. Start engine. Turn the steering wheel to left turn stop to extend cylinder rod.
Stop engine. Move steering wheel back and forth to relieve hydraulic pressure.

973
 Steering Cylinder Leakage Test
4.

T6076AL-UN: Axle Without MFWD Shown

Remove rod end hose and plug (A) and recover excess oil from cylinder.
Place a beaker under cylinder port. Remove rod end hose and plug (A).

5. Start engine and hold steering wheel in full left turn with constant pressure for
one minute.

Item MeasurementSpecification
Engine Speed Low idle
Stop engine.

6. Measure oil collected and connect hose.

Item MeasurementSpecification
Steering Cylinder Leakage 5 ml/min (1/6 oz/min)

TX,9025,RB18-19-1997/10/30

974
 Hydraulic Cylinder Drift Test Procedure

Hydraulic Cylinder Drift Test Procedure

T103936-19: Cylinder Drift Test Procedure

TX,9025,RR7336-19-1996/09/20

975
 Function Drift Test

Function Drift Test

-: Specifications

SPECIFICATIONS

Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed Low idle

Backhoe Function Max Allowable Drift 50 mm/min (2.00 in/min)

BH Boom Cylinder, (Std. Dipper) Max Allowable Drift 5 mm/min (0.20 in/min)
BH Crowd Cylinder, (Std. Dipper) Max Allowable Drift 6 mm/min (0.25 in/min)
BH Bucket Cylinder Max Allowable Drift 3 mm/min (0.12 in/min)

Swing Cylinder Max Allowable Drift 150 mm/min (6.00 in/min)

Loader Function Max Allowable Drift 50 mm/min (2.00 in/min)

Loader Boom and Bucket Drift 3 mm/min (0.12 in/min)

Ext. Dipper Cylinder Max Allowable Drift 6 mm/min (0.25 in/min)

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer

NOTE:

The following tests are used to check leakage past the cylinder piston
seals and through the main control valve spool and reliefs. Weighting
the machine is not required to perform these tests. On extendable
dipperstick machines fully retract dipperstick for all testing.

1. Install digital thermometer probe in reservoir. Warm hydraulic oil to

specifications.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.)

2. Put FNR lever in neutral and engage park brake.

976
 Function Drift Test

Function Drift

3. Position backhoe bucket side cutters at 45° angle to ground and lower boom
until bucket cutting edge is 50 mm (2.00 in.) off ground.

4.

T102956-UN: Level Loader/Backhoe Bucket

Position loader bucket cutting edge approximately 2 inches off ground.

5. NOTE:

If bucket cutting edges touch the ground within one minute,

excessive leakage is indicated in the cylinders or control
valve. Position machine as shown, with the bucket pivot pin
one meter (36 in.) off ground.

Run engine at slow idle and observe bucket cutting edges for one minute.

Item Measurement Specification

Engine Speed Low idle
Backhoe Function Max Allowable Drift 50 mm/min (2.00 in/min)

977
 Function Drift Test
6.

T6222AM-UN: Backhoe Cylinder Drift

Position the crowd cylinder with rod 20-50 mm (0.75-2.00 in.) extended from
the fully retracted position.

7. Position the bucket cylinder with rod 20-50 mm (0.75-2.00 in) retracted from
the fully extended position.

8. Measure movement of boom, crowd, and bucket cylinder rods for five minutes.
Divide measured rod drift by five to determine drift per minute.

Item Measurement Specification

BH Boom Cylinder, (Std. Dipper) Max Allowable Drift 5 mm/min (0.20 in/min)
BH Crowd Cylinder, (Std. Dipper) Max Allowable Drift 6 mm/min (0.25 in/min)
BH Bucket Cylinder Max Allowable Drift 3 mm/min (0.12 in/min)

978
 Function Drift Test
9.

T102957-UN: Measure Swing Drift

To measure swing drift tilt machine by fully extending right hand stabilizer.
Fully extend dipperstick and bucket straight behind following centerline of
machine, so bucket is approximately 300 mm (12 in.) off ground. Boom should
be parallel to ground. Position left hand stabilizer 75 mm (3 in.) off ground.

10. Measure swing drift from side of bucket, to vertical rod placed in ground next
to bucket, for five minutes. Divide measured drift by five to determine drift per
minute.

Item Measurement Specification

Swing Cylinder Max Allowable Drift 150 mm/min (6.00 in/min)

11. Measure swing drift in opposite direction by reversing stabilizer positions and
vertical rod.

979
 Function Drift Test
12.

T6222AM-UN: Loader Cylinder Drift

Position the machine as shown with the loader bucket cutting edge one meter
(36 in.) above ground, with bucket level.

13. Measure movement of boom and bucket cylinders for five minutes. Divide
measured rod drift by five to determine drift per minute.

Item Measurement Specification

Loader Function Max Allowable Drift 50 mm/min (2.00 in/min)
Loader Boom and Bucket Drift 3 mm/min (0.12 in/min)

Extendible Dipperstick Cylinder Drift

14. Machine in transport position. Curl backhoe bucket. Remove extendable

dipperstick locking pin. Measure drift from end of dipperstick housing to
ground for five minutes. Divide measured drift by five to determine drift per
minute.

Item Measurement Specification

Ext. Dipper Cylinder Max Allowable Drift 6 mm/min (0.25 in/min)

TX,9025,RB42-19-1997/11/19

980
 Cylinder Leakage Test

Cylinder Leakage Test

T6222AL-UN: Cylinder Rod

-: Specifications

SPECIFICATIONS

Oil Temperature 65 ± 5°C (150 ± 10°F)

Engine Speed Low idle

Cylinder Leakage 5 ml/min (1/6 oz/min)

-: Essential Tools

ESSENTIAL TOOLS

38H1353 [NutThese ORFS fittings should be ordered through normal service parts
channels. ]
38H1139 [PlugThese ORFS fittings should be ordered through normal service parts
channels. ]
38H1354 [NutThese ORFS fittings should be ordered through normal service parts
channels. ]

38H1140 [PlugThese ORFS fittings should be ordered through normal service parts
channels. ]
38H1146 [PlugThese ORFS fittings should be ordered through normal service parts
channels. ]

981
 Cylinder Leakage Test

ESSENTIAL TOOLS
38H1147 [PlugThese ORFS fittings should be ordered through normal service parts
channels. ]

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer

1. Install digital thermometer probe in reservoir.

Item MeasurementSpecification
Oil Temperature 65 ± 5°C (150 ± 10°F)

2. Put FNR lever in neutral and engage park brake.

3. Start engine. Fully extend cylinder rod. Stop engine. Activate a hydraulic
function to relieve pressure in the system.

4. Remove rod end hose and plug hose. Use a measuring beaker, after oil stops
dripping, to catch oil. This can also be done at control valve, which would
require capping control valve port and putting hose end into measuring beaker
after oil stops dripping.

5. Start engine and actuate cylinder extend function for one minute.

Item MeasurementSpecification
Engine Speed Low idle

6. Stop engine. Measure oil collected and connect hose.

Item MeasurementSpecification
Cylinder Leakage 5 ml/min (1/6 oz/min)

7. Repair as necessary. (See repair manual.)

8. Repeat procedure to test each cylinder.

TX,9025,RR7326-19-1994/07/21

982
 Stabilizer Valve Lockout Leakage Test

Stabilizer Valve Lockout Leakage Test

T6222AN-UN: Cylinder Rod

-: Specifications

SPECIFICATIONS

Engine Speed Low idle

Oil Temperature 65 ± 5°C (150 ± 10°F)

Rod Travel Max. Distance 0.15 mm/min (.006 in/min)

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Digital Thermometer
Dial Indicator

1. Install digital thermometer probe in reservoir. Heat hydraulic oil to test

specifications.

Item MeasurementSpecification
Engine Speed Low idle
Oil Temperature 65 ± 5°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.)

2. Lower stabilizers to lift machine off ground. Check for cylinder rod movement

983
 Stabilizer Valve Lockout Leakage Test
with dial indicator.

Item MeasurementSpecification
Rod Travel Max. Distance 0.15 mm/min (.006 in/min)

NOTE:

The stabilizer valve has lockouts to prevent cylinder drift up or

down. If cylinder rod drift is above specification, remove the
lockout and check for scratches on the seat and poppet.
Replace if required. Check that the lockout plunger which
slides between the two lockouts is not sticking. Also check for
contamination in the thermal relief poppet seat and cylinder
packing.

TX,9025,RR7517-19-1996/10/02

984
 Cycle Time Specifications-410E

Cycle Time Specifications-410E

INDIVIDUAL CIRCUIT CYCLE TIME SPECIFICATIONS

Oil temperature: 65 ± 5°C (150 ± 10°F)

Engine speed: Fast idle
Function Operating Conditions Maximum Cycle
Time in
Seconds

Loader boom raise Bucket flat on ground to full height (includes 4.9
bucket self-leveling)
Loader boom lower 2.8

Loader bucket Bucket just clears ground 2.3

dump
Loader bucket Bucket just clears ground 2.3
rollback

Backhoe boom Backhoe at maximum reach with bucket teeth on 2.7

raise ground up to cylinder cushion
Backhoe boom Backhoe at maximum reach. Transport position to 2.9
lower bucket teeth on ground

Crowd in Boom in transport position 3.6

Crowd out 3.4

Backhoe bucket 2.1

dump

Backhoe bucket 3.0

curl
Backhoe swing Boom raised to cushion, bucket curled, 4.1
dipperstick parallel to ground. Time cycle to
cylinder cushion

Right stabilizer Full up to ground level 2.8

down
Left stabilizer down Full up to ground level 1.9
Stabilizer up left Ground level to full up 2.4
and right

985
 Cycle Time Specifications-410E

INDIVIDUAL CIRCUIT CYCLE TIME SPECIFICATIONS

Extendible 3.2
dipperstick extend
and retract

TURNS
Steering right to left Turns 2.3 to 3
Steering left to right Turns 2.3 to 3

Steering right to left Turns 2.3 to 3

(MFWD)
Steering left to right Turns 2.3 to 3
(MFWD)

TX,9025,SS3534-19-2000/02/02

986
 Proper Refrigerant Handling

Proper Refrigerant Handling

The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into
the atmosphere, and requires that refrigerant be recovered using the approved recovery
equipment.

IMPORTANT:

To meet government standards relating to the use of refrigerants,

R134a is used in the air conditioning system. Because it does not
contain chlorine, R134a is not detrimental to the ozone in the
atmosphere. However, it is illegal to discharge any refrigerant into
the atmosphere. It must be recovered using the appropriate
recovery stations.

Use correct refrigerant recovery, recycling and charging stations.

DO NOT mix refrigerants, hoses, fittings, components or
refrigerant oils.

Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT
be interchanged. Systems containing R12 refrigerant use a different oil than systems
using R134a. Certain seals are not compatible with both types of refrigerants.

TX,9031,QQ6676-19-1996/08/05

987
 Proper Refrigerant Handling

Proper Refrigerant Handling

The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into
the atmosphere, and requires that refrigerant be recovered using the approved recovery
equipment.

IMPORTANT:

To meet government standards relating to the use of refrigerants,

R134a is used in the air conditioning system. Because it does not
contain chlorine, R134a is not detrimental to the ozone in the
atmosphere. However, it is illegal to discharge any refrigerant into
the atmosphere. It must be recovered using the appropriate
recovery stations.

Use correct refrigerant recovery, recycling and charging stations.

DO NOT mix refrigerants, hoses, fittings, components or
refrigerant oils.

Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT
be interchanged. Systems containing R12 refrigerant use a different oil than systems
using R134a. Certain seals are not compatible with both types of refrigerants.

TX,9031,QQ6676-19-1996/08/05

988
 Proper Refrigerant Handling

Proper Refrigerant Handling

The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into
the atmosphere, and requires that refrigerant be recovered using the approved recovery
equipment.

IMPORTANT:

To meet government standards relating to the use of refrigerants,

R134a is used in the air conditioning system. Because it does not
contain chlorine, R134a is not detrimental to the ozone in the
atmosphere. However, it is illegal to discharge any refrigerant into
the atmosphere. It must be recovered using the appropriate
recovery stations.

Use correct refrigerant recovery, recycling and charging stations.

DO NOT mix refrigerants, hoses, fittings, components or
refrigerant oils.

Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT
be interchanged. Systems containing R12 refrigerant use a different oil than systems
using R134a. Certain seals are not compatible with both types of refrigerants.

TX,9031,QQ6676-19-1996/08/05

989
 R134A Refrigerant Cautions

R134A Refrigerant Cautions

CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid
refrigerant will freeze eyes or skin on contact. Wear goggles,
gloves and protective clothing.

If liquid refrigerant contacts eyes or skin, DO NOT rub the area.

Splash large amounts of COOL water on affected area. Go to a
physician or hospital immediately for treatment.

DO NOT allow refrigerant to contact open flames or very hot

surfaces such as electric welding arc, electric heating element
and lighted smoking materials.

DO NOT heat refrigerant over 52°C (125°F) in a closed container.

Heated refrigerant will develop high pressure which can burst the
container.

Keep refrigerant containers away from heat sources. Store

refrigerant in a cool place.

DO NOT handle damp refrigerant container with your bare hands.

Skin may freeze to container. Wear gloves.

If skin freezes to container, pour COOL water over container to

free the skin. Go to a physician or hospital immediately for
treatment.

(R12 ONLY) Refrigerant exposed to high temperature forms

phosgene gas. Inhaling toxic phosgene gas may result in serious
illness or death. Phosgene gas has an odor like new mown hay or
green corn. If you inhale phosgene gas, go to a physician or
hospital immediately for treatment.

TX,9031,QQ6677-19-1996/06/11

990
 Refrigerant Theory Of Operation

Refrigerant Theory Of Operation

T126716-19: Refrigerant Theory of Operation

LEGEND:
A - Compressor
B - Low Pressure Switch
C - High Pressure Switch
D - High Pressure Gas
E - Condenser
F - Engine Fan
G - High Pressure Liquid
H - Receiver Dryer
I - Expansion Valve
J - Low Pressure Liquid
K - Evaporator
L - Blowers
M - A/C Freeze Switch
N - Low Pressure Gas

The compressor (A) draws low pressure gas (N) from the evaporator (K) and
compresses it into high pressure gas (D). Increasing the pressure of the refrigerant
causes its boiling point to rise to a temperature higher than the outside air temperature.

High pressure gas (D) leaves the compressor (A) and passes through two switches (B

991
 Refrigerant Theory Of Operation
and C). These switches monitor refrigerant pressure. Should the pressure become too
great or too small, either the high or low pressure switch will open and stop the
compressor, interrupting the cycle.

As the high pressure gas flows through the condenser (E), the engine fan (F) draws air
through the condenser core which cools the refrigerant. Cooling the refrigerant causes it
to condense and it leaves the condenser (E) as a high pressure liquid (G). The high
pressure liquid flows into the receiver-dryer (H) where moisture and contaminants are
removed.

The refrigerant flows from the receiver-dryer (H) to the expansion valve (I). The
expansion valve (I) is a variable orifice used to cause a pressure and temperature drop
in the refrigerant causing refrigerant to vaporize. The expansion valve (I) is one of the
dividing lines between the high side and low side of the air conditioning system. At this
point in the system, the high pressure/high temperature liquid is sprayed into the
evaporator (K) where it changes and becomes a gas.

The expansion valve diaphragm is activated by sensing temperature and pressure

within the valve body. The internal bulb senses the evaporator outlet or discharge
temperature and pressure of refrigerant as it passes through the valve back to the low
pressure or suction side of the compressor. (See Expansion Valve Operation in this
group for additional information on theory of operation.)

If too much refrigerant is flowing into evaporator, the liquid refrigerant will still be
evaporating as it leaves the evaporator, causing a low temperature at the evaporator
outlet. The low temperature causes the expansion valve variable orifice to decrease in
size, restricting refrigerant flow. If the evaporator outlet temperature is too warm, the
orifice will increase in size, allowing more refrigerant into evaporator.

If evaporator (K) temperature becomes too low, the A/C freeze switch (M) will interrupt
current flow to the compressor clutch coil, stopping system operation until the
temperature becomes normal, between 31° and 40°.

TX,9031,QQ6678-19-2000/02/02

992
 Air Conditioning Circuit Operational Information

Air Conditioning Circuit Operational Information

The following conditions must exist for air conditioning circuit to function:

Key switch ON
Machine running
Air conditioning switch turned ON.
Blower switch turned to position 1, 2, 3 or 4.

TX,9031,QQ6679-19-1996/10/07

993
 Air Conditioning Circuit Theory Of Operation

Air Conditioning Circuit Theory Of Operation

Power from 30 amp heater fuse flows through P16 red and 518 red wires to blower
switch. With blower switch turned to 1, 2, or 3 position, power flows to blower resistor
and then to heater blower motor. With blower switch turned to position 4 the resistor is
bypassed and blower motor is in max speed.

Power also flows from blower switch, through white wire to A/C freeze switch, through
black/white and A16 orange wire to air conditioning switch.

With air conditioning switch turned ON, power flows through A17 orange wire to the low
pressure switch. With low pressure switch closed, power flows through A18 green wire
to high pressure switch. With high pressure switch closed power flows through A19
green wire to the coil terminal of the compressor coil to energize the compressor clutch.

Low Pressure Switch

The low pressure switch will open if the air conditioning system loses its refrigerant
charge. The switch opens to stop current flow to the compressor which prevents
compressor engagement. The low pressure switch is located near the compressor in
high pressure line.

High Pressure Switch

The high pressure switch protects the system from high pressure. If a malfunction or
line restriction causes the high pressure to increase above the setting of the switch, the
switch will open to stop current flow to the compressor clutch. The high pressure switch
is located near the compressor in the high pressure line.

A/C Freeze Switch

The A/C freeze switch is used to sense the temperature in the evaporator core. When
the temperature drops, the A/C freeze switch opens, shutting the compressor off. When
the temperature in the evaporator core raises, the A/C freeze switch closes sending
voltage to the compressor.

The A/C freeze switch receives power from the blower switch when blower switch is
turned to each position.

NOTE:

For component identification code description, see Wiring and

Schematic Diagrams Legend, Group 9015-10.

994
Air Conditioning Circuit Theory Of Operation
TX,9031,QQ6680-19-1999/12/10

995
 Air Conditioning Circuit Schematic

Air Conditioning Circuit Schematic

T126713-19: Air Conditioning Circuit Schematic

TX,9031,QQ6681-19-1999/12/10

996
 Blower Circuit Operational Information

Blower Circuit Operational Information

The following conditions must exist for blower circuit to function:

Key switch in ON or ACC position

Blower switch turned ON

TX,9031,QQ6682-19-1996/06/11

997
 Blower Circuit Theory Of Operation

Blower Circuit Theory Of Operation

Power from heater circuit breaker goes to blower switch. With blower switch in positions
1, 2, or 3 power is sent to blower resistor reducing blower motor speed. With blower
switch in position 4 the resister is bypassed and blower motor will run in max speed.

NOTE:

For component identification code description, see Wiring and

Schematic Diagrams Legend, Group 9015-10.

TX,9031,QQ6683-19-1996/06/11

998
 Blower Circuit Schematic

Blower Circuit Schematic

T126714-19: Blower Circuit Schematic

TX,9031,QQ6684-19-1999/12/10

999
 Receiver/Dryer Operation

Receiver/Dryer Operation

T8104AE-UN: Receiver/Dryer

1000
 Receiver/Dryer Operation

T8104AF-UN: Moisture Indicator

LEGEND:
A - Inlet Port
B - Sight Glass
C - Outlet Port
D - Pickup Tube
E - Filter
F - Desiccant
G - Strainer
H - Spring
I - Receiver/Dryer
J - Wet/Dry Indicator

The receiver/dryer is a reservoir to store excess liquid refrigerant in the system. Excess
refrigerant is required for two reasons:

Outside air temperature and humidity have an effect on the minimum quantity of
refrigerant required in the system for the air conditioner to operate at maximum
efficiency. The higher the temperature and humidity, the more refrigerant required in the
system. More refrigerant is required due to the expansion valve opening farther allowing
more refrigerant into the low pressure side of the system.

Refrigerant hoses allow a small amount of refrigerant to migrate through their walls.
Extra refrigerant stored in the system allows for a longer period of time before additional
refrigerant is needed.

The receiver/dryer also contains two filters (E) and desiccant (F) between the filters. The

1001
 Receiver/Dryer Operation
filters remove solid materials which could be generated by a compressor failure, debris
left in the system due to improper service procedures, or particles caused by corrosion
of metal parts due to moisture and acids in the system (also caused by improper service
procedures).

Desiccant is used to absorb moisture. If too much moisture gets into the system, the
desiccant may not be able to absorb it all. When moisture is combined with refrigerant
oil, a sludge is formed. This sludge does not permit moving parts to be adequately
lubricated. When moisture is combined with refrigerant, hydrofluoric and hydrochloric
acids are formed. These acids are very corrosive to metal surfaces and leakage will
eventually develop. If the air conditioning system is left open for a period of time or if the
plugs are removed from the receiver/dryer, the desiccant will also absorb moisture from
the air. The receiver/dryer contains a color moisture indicator. (Blue) indicates dryer is
dry. (Pink) indicates moisture in the desiccant. Evacuating the system will not remove
moisture from the desiccant. You must replace the receiver/dryer.

A sight glass is installed in the receiver/dryer outlet port. If the refrigerant level is low, a
steady stream of gas bubbles will be present in the liquid flowing from the
receiver/dryer. These gas bubbles can be seen in the sight glass and are an indication
that the system needs charging. However, bubbles may be present when the
compressor clutch first engages but must disappear after a few seconds. If the sight
glass is clear, the system either has a sufficient charge or is completely discharged.

TX,9031,QQ6685-19-1996/06/11

1002
 Expansion Valve Operation

Expansion Valve Operation

T7828AY-19: Expansion Valve Operation

LEGEND:
A - Valve Diaphragm
B - Sealed Sensing Bulb
C - Outlet to Compressor
D - Operating Pin
E - Inlet Flow
F - Metering Orifice
G - Valve Spring
H - Ball Seat
I - Outlet to Evaporator
J - Discharge from Evaporator
K - Internal Equalization Passage

The expansion valve is used to regulate the amount of refrigerant flowing into the
evaporator. At this point in the system, the high pressure/high temperature liquid is
sprayed into the evaporator where it changes state and becomes a gas.

The valve diaphragm (A) is activated by sensing temperature and pressure within the
valve body. The sealed sensing bulb (B) senses the evaporator outlet (I) or discharge
temperature and pressure of the refrigerant as it passes through the valve back to the
low pressure or suction side of the compressor.

1003
 Expansion Valve Operation

The metering orifice (F) and ball seat area (H) in the expansion valve is relatively small.
The rapidly expanding refrigerant passing through this area can cause any moisture in
the system to freeze at this point and block refrigerant flow. Other contaminants in the
system can also cause a valve to malfunction. If expansion valve malfunctions, it must
be replaced. Expansion valve is not repairable.

TX,9031,QQ6686-19-1996/06/11

1004
 Compressor Relief Valve Operation

Compressor Relief Valve Operation

The compressor relief valve is a direct acting pressure limiting valve. If a malfunction in
the system occurs that would cause high pressure, such as a restricted line, the valve
will open near 4137 kPa (41.4 bar) (600 psi) and remain open until pressure drops to
below the valve setting.

Item MeasurementSpecification
Compressor Relief ValvePressure 4137 kPa (41.4 bar) (600 psi)

If the relief valve opens, a loud popping noise will be heard. Some oil may also be lost
from the system. Correct any condition that would cause the valve to open.

TX,9031,QQ6687-19-1996/06/11

1005
 Temperature Control

Temperature Control

Temperature control is adjusted by the position of the heater temperature switch in the
cab. This switch is mechanically connected to the water valve at the base of the heater
core. Turning the heater temperature switch towards maximum and/or towards off
opens and closes the water valve controlling engine coolant flow through the heater
core, thus controlling the temperature inside the cab.

In certain conditions when the air conditioning switch is turned on and the blower switch
is in low position, the cab temperature may still be too cool. It may be necessary to
blend heat with cooling to get a comfortable cab temperature.

TX,9031,QQ6688-19-1996/06/11

1006
 Air Conditioning Operational Checks

Air Conditioning Operational Checks

This procedure is designed so the mechanic can make a quick check of the system
using a minimum amount of diagnostic equipment. If you need additional information,
read Theory of Operation (Group 9031-05).

The engine or other major components must be at operating temperature for some
checks.

Locate system check in the left column and read completely, following this sequence
from left to right. Read each check completely before performing.

At the end of each check, if no problem is found, that check is complete. When a
problem is indicated, additional checks or repair information will be given. TM Group or
CTM number required for repair will be given. If verification is needed, you will be given
next best source of information:

Group: 10 (System Operational Checks)

Group: 15 (Diagnostic Information)

Group: 20 (Adjustments)

Group: 25 (Tests)

CTM (Component Technical Manual)

1 Visual Inspection Of Components

Launch Close Expand List Collapse List

1A Check All Lines And Hoses

Action:

Engine OFF.

Inspect all lines and hoses.

Are lines and hoses straight, NOT kinked or worn from rubbing on other machine
parts or "weather checked"?

Are hose and line connections clean NOT showing signs of leakage, such as oil or
dust accumulation at fittings?

1007
 Air Conditioning Operational Checks

All hose and line clamps must be in place and tight. Clamps must have rubber
inserts or cushions in place to prevent clamps from crushing or wearing into hoses
or lines?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Reposition hoses or lines and tighten or replace clamps. Tighten fittings or replace
O-rings in fittings. Replace hoses or lines as required.

1B Condenser Check

Action:

Engine OFF.

Inspect condenser cores.

Is condenser core free of dirt or debris?

Does condenser show signs of leakage, dust accumulation or oily areas?

Are condenser fins straight, not bent or damaged?

Inspect engine fan.

Are fan blades in good condition, not worn, bent, broken or missing?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Clean, repair or replace condenser core. Replace engine fan.

1008
 Air Conditioning Operational Checks

1C Evaporator Core Check

Action:

Engine OFF.

Inspect core.

Are fins straight?

Is evaporator core free of dirt and debris?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Repair, replace or clean evaporator.

1D A/C Freeze Switch Sensing Tube Check

Action:

Engine OFF.

Inspect A/C freeze switch sensing tube.

Is sensing tube straight, NOT kinked or broken?

Is sensing tube inserted into evaporator core and secured in place?

Record of Actual Results:

Result:
YES:
Check complete.

1009
 Air Conditioning Operational Checks

NO:
If sensing tube is kinked, replace A/C freeze switch.
NO:
If tube is positioned in evaporator incorrectly, re-route.

1E Air Conditioner Compressor Check

Action:

Engine OFF.

Inspect compressor.

Is compressor drive belt tight? Is belt in good condition? Is belt tightening strap
straight?

Is compressor belt pulley in good condition (NOT grooved)?

Are compressor to bracket and bracket to engine mounting cap screws tight?

Is compressor pulley aligned with engine pulley?

Are electrical connections to compressor clutch clean and tight? Is wiring to

compressor in good condition?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Repair or replace components as required.

1F Cab Door And Window Seals Check

Action:

Open and close door and windows. Inspect seals.

Do door and windows contact seals evenly?

1010
 Air Conditioning Operational Checks

Are seals in position and in good condition?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Adjust door and windows to close against seals properly. Replace seals as
necessary.

2 System Operating Checks

Launch Close Expand List Collapse List

2A Blower Motor Check

Action:

T101677-UN: Blower Motor Check

Engine OFF. Key switch ON.

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

Does fan have four speeds?

Does air exit from ducts?

Record of Actual Results:

1011
 Air Conditioning Operational Checks

Result:
YES:
Check complete.
NO:
See Circuit Checks in Group 9031-10. Check wiring harness.

2B Heater Check

Action:

T101678-UN: Heater

Start engine and allow to warm several minutes.

Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to
high speed.

Does warm air exit from ducts?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Circuit Checks in Group 9031-10. Check wiring harness.

2C Air Conditioner (If Equipped) Check

Action:

1012
 Air Conditioning Operational Checks

T101679-UN: Air Conditioner Switch

Start engine and run at fast idle.

Turn air conditioner switch (A) to ON position.

Turn blower switch (B) to high speed.

Wait for any warm air in duct system to dissipate.

Is air from ducts cool?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Blower/Air Conditioning Circuit Checks in Group 9031-10. See Charging the
system in Group 9031-20.

2D Compressor Clutch Check

Action:

Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner switch ON.

Does compressor clutch "click" as switch is pushed?

Record of Actual Results:

1013
 Air Conditioning Operational Checks

Result:
YES:
Check complete.
NO:
Replace compressor clutch.

3 System Performance Checks

Launch Close Expand List Collapse List

3A Expansion Valve Check

Action:

Is expansion valve outlet line free of frost?

Is insulating tape wound tightly around outlet line and is tape in good condition?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Go to Expansion Valve Operation in Group 9031-05.

3B Evaporator Check

Action:

Remove seat and heater/blower cover.

Is ice forming on evaporator core?

Is fan motor failing or fan blades damaged?

Is clutch cycle sensing tube properly positioned?

1014
 Air Conditioning Operational Checks

Is heater temperature balance control misadjusted or damaged?

Is evaporator drain tubes plugged?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Go to Clutch Cycle Switch Bench Test in Group 9031-25.

4 Blower/Air Conditioning Circuit Checks

Launch Close Expand List Collapse List

4A Blower Switch Check

Action:

T101680-UN: Blower Switch

1015
 Air Conditioning Operational Checks

Disconnect harness from blower switch.

Using a multimeter check for continuity.

Move blower switch to position 1, 2, 3, and 4 checking terminals B and 1, B and 2,

B and 3, B and 4.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Blower switch is good. Go to next check.
NO:
Replace blower switch.

4B Blower Resister Check

Action:

1016
 Air Conditioning Operational Checks
T102849-UN: Blower Resister

Measure ohms between terminals 4 and 2.

Does ohmmeter read 1.0 ohms?

Record of Actual Results:

Result:
YES:
Resistor is good. Check wiring harness.
NO:
Replace resistor

4C Heater/Blower Motor Check

Action:

T7199CM-UN: Heater/Blower Motor

Disconnect harness from heater blower motor.

Connect 12 volts to heater blower motor, and ground motor.

Does heater blower motor operate?

Record of Actual Results:

Result:
YES:
1017
 Air Conditioning Operational Checks
Heater blower motor is good. Check wiring harness.
NO:
Replace heater blower motor.

4D A/C Freeze Switch Check

Action:

T7835AV-19: A/C Freeze Switch

With A/C freeze switch at room temperature.

Disconnect harness from switch.

Measure continuity across switch terminals.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Do A/C Freeze Switch Test. See Group 9031-25. If switch is OK, check wiring
harness.
NO:
Switch has failed. Replace switch.

4E Air Conditioning Switch Check

Action:

1018
 Air Conditioning Operational Checks

T100731-UN: Air Conditioning Switch

Disconnect harness from air conditioning switch.

A/C switch OFF, and measure for continuity between terminals 2A and 1.

Is continuity measured?

Turn switch ON, and measure for continuity between terminals 2B and 3.

Is continuity measured?

Record of Actual Results:

Result:
YES:
A/C switch is good. Check wiring harness.
NO:
Replace A/C switch.

1019
 Air Conditioning Operational Checks

4F Air Conditioner Low Pressure Switch Check

Action:

T101619-19: Air Conditioner Low Pressure Switch

Disconnect harness from switch.

Check for continuity between terminals. Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace switch.
Action:

Remove switch from system. (The line that attaches the low pressure switch has a
valve to prevent discharging the air conditioning system when switch is removed.)

Measure for continuity across switch terminals.

Does ohmmeter read open?

Record of Actual Results:

Result:

1020
 Air Conditioning Operational Checks

YES:
Switch is good. Check wiring harness.
NO:
Go to Low Pressure Switch Test, Group 9031-25.

4G Air Conditioner High Pressure Switch Check

Action:

T101618-19: Air Conditioner High Pressure Switch

Disconnect harness from switch.

Measure continuity across outer switch terminals.

Does ohmmeter read continuity?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace switch.
Action:

Remove switch from system. (The line that attaches the high pressure switch has
a valve to prevent discharging the air conditioning system when switch is
removed.)

Measure continuity across switch terminals.

1021
 Air Conditioning Operational Checks

Does ohmmeter read continuity?

Record of Actual Results:

Result:
YES:
Switch is good. Check wiring harness.
NO:
System pressure is too high. Go to Air Conditioning Pressure Diagnostic Chart,
Group 9031-25.

4H Air Conditioning Compressor Clutch Coil Check

Action:

T6534CV-UN: Air Conditioning Compressor Clutch Coil

Disconnect harness from clutch.

Connect battery voltage to clutch terminal that has orange wire. Ground black wire
terminal.

Does clutch "click"?

Record of Actual Results:

Result:
YES:
A/C compressor clutch coil is good. Check wiring harness.

1022
 Air Conditioning Operational Checks

NO:
Replace clutch coil.

TX,9031,QQ6689-19-2000/02/02

1023
 Air Conditioning Operational Checks

Air Conditioning Operational Checks

This procedure is designed so the mechanic can make a quick check of the system
using a minimum amount of diagnostic equipment. If you need additional information,
read Theory of Operation (Group 9031-05).

The engine or other major components must be at operating temperature for some
checks.

Locate system check in the left column and read completely, following this sequence
from left to right. Read each check completely before performing.

At the end of each check, if no problem is found, that check is complete. When a
problem is indicated, additional checks or repair information will be given. TM Group or
CTM number required for repair will be given. If verification is needed, you will be given
next best source of information:

Group: 10 (System Operational Checks)

Group: 15 (Diagnostic Information)

Group: 20 (Adjustments)

Group: 25 (Tests)

CTM (Component Technical Manual)

1 Visual Inspection Of Components

Launch Close Expand List Collapse List

1A Check All Lines And Hoses

Action:

Engine OFF.

Inspect all lines and hoses.

Are lines and hoses straight, NOT kinked or worn from rubbing on other machine
parts or "weather checked"?

Are hose and line connections clean NOT showing signs of leakage, such as oil or
dust accumulation at fittings?

1024
 Air Conditioning Operational Checks

All hose and line clamps must be in place and tight. Clamps must have rubber
inserts or cushions in place to prevent clamps from crushing or wearing into hoses
or lines?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Reposition hoses or lines and tighten or replace clamps. Tighten fittings or replace
O-rings in fittings. Replace hoses or lines as required.

1B Condenser Check

Action:

Engine OFF.

Inspect condenser cores.

Is condenser core free of dirt or debris?

Does condenser show signs of leakage, dust accumulation or oily areas?

Are condenser fins straight, not bent or damaged?

Inspect engine fan.

Are fan blades in good condition, not worn, bent, broken or missing?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Clean, repair or replace condenser core. Replace engine fan.

1025
 Air Conditioning Operational Checks

1C Evaporator Core Check

Action:

Engine OFF.

Inspect core.

Are fins straight?

Is evaporator core free of dirt and debris?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Repair, replace or clean evaporator.

1D A/C Freeze Switch Sensing Tube Check

Action:

Engine OFF.

Inspect A/C freeze switch sensing tube.

Is sensing tube straight, NOT kinked or broken?

Is sensing tube inserted into evaporator core and secured in place?

Record of Actual Results:

Result:
YES:
Check complete.

1026
 Air Conditioning Operational Checks

NO:
If sensing tube is kinked, replace A/C freeze switch.
NO:
If tube is positioned in evaporator incorrectly, re-route.

1E Air Conditioner Compressor Check

Action:

Engine OFF.

Inspect compressor.

Is compressor drive belt tight? Is belt in good condition? Is belt tightening strap
straight?

Is compressor belt pulley in good condition (NOT grooved)?

Are compressor to bracket and bracket to engine mounting cap screws tight?

Is compressor pulley aligned with engine pulley?

Are electrical connections to compressor clutch clean and tight? Is wiring to

compressor in good condition?

Record of Actual Results:

Result:
YES:
Go to next check.
NO:
Repair or replace components as required.

1F Cab Door And Window Seals Check

Action:

Open and close door and windows. Inspect seals.

Do door and windows contact seals evenly?

1027
 Air Conditioning Operational Checks

Are seals in position and in good condition?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Adjust door and windows to close against seals properly. Replace seals as
necessary.

2 System Operating Checks

Launch Close Expand List Collapse List

2A Blower Motor Check

Action:

T101677-UN: Blower Motor Check

Engine OFF. Key switch ON.

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

Does fan have four speeds?

Does air exit from ducts?

Record of Actual Results:

1028
 Air Conditioning Operational Checks

Result:
YES:
Check complete.
NO:
See Circuit Checks in Group 9031-10. Check wiring harness.

2B Heater Check

Action:

T101678-UN: Heater

Start engine and allow to warm several minutes.

Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to
high speed.

Does warm air exit from ducts?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Circuit Checks in Group 9031-10. Check wiring harness.

2C Air Conditioner (If Equipped) Check

Action:

1029
 Air Conditioning Operational Checks

T101679-UN: Air Conditioner Switch

Start engine and run at fast idle.

Turn air conditioner switch (A) to ON position.

Turn blower switch (B) to high speed.

Wait for any warm air in duct system to dissipate.

Is air from ducts cool?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Blower/Air Conditioning Circuit Checks in Group 9031-10. See Charging the
system in Group 9031-20.

2D Compressor Clutch Check

Action:

Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner switch ON.

Does compressor clutch "click" as switch is pushed?

Record of Actual Results:

1030
 Air Conditioning Operational Checks

Result:
YES:
Check complete.
NO:
Replace compressor clutch.

3 System Performance Checks

Launch Close Expand List Collapse List

3A Expansion Valve Check

Action:

Is expansion valve outlet line free of frost?

Is insulating tape wound tightly around outlet line and is tape in good condition?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Go to Expansion Valve Operation in Group 9031-05.

3B Evaporator Check

Action:

Remove seat and heater/blower cover.

Is ice forming on evaporator core?

Is fan motor failing or fan blades damaged?

Is clutch cycle sensing tube properly positioned?

1031
 Air Conditioning Operational Checks

Is heater temperature balance control misadjusted or damaged?

Is evaporator drain tubes plugged?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Go to Clutch Cycle Switch Bench Test in Group 9031-25.

4 Blower/Air Conditioning Circuit Checks

Launch Close Expand List Collapse List

4A Blower Switch Check

Action:

T101680-UN: Blower Switch

1032
 Air Conditioning Operational Checks

Disconnect harness from blower switch.

Using a multimeter check for continuity.

Move blower switch to position 1, 2, 3, and 4 checking terminals B and 1, B and 2,

B and 3, B and 4.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Blower switch is good. Go to next check.
NO:
Replace blower switch.

4B Blower Resister Check

Action:

1033
 Air Conditioning Operational Checks
T102849-UN: Blower Resister

Measure ohms between terminals 4 and 2.

Does ohmmeter read 1.0 ohms?

Record of Actual Results:

Result:
YES:
Resistor is good. Check wiring harness.
NO:
Replace resistor

4C Heater/Blower Motor Check

Action:

T7199CM-UN: Heater/Blower Motor

Disconnect harness from heater blower motor.

Connect 12 volts to heater blower motor, and ground motor.

Does heater blower motor operate?

Record of Actual Results:

Result:
YES:
1034
 Air Conditioning Operational Checks
Heater blower motor is good. Check wiring harness.
NO:
Replace heater blower motor.

4D A/C Freeze Switch Check

Action:

T7835AV-19: A/C Freeze Switch

With A/C freeze switch at room temperature.

Disconnect harness from switch.

Measure continuity across switch terminals.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Do A/C Freeze Switch Test. See Group 9031-25. If switch is OK, check wiring
harness.
NO:
Switch has failed. Replace switch.

4E Air Conditioning Switch Check

Action:

1035
 Air Conditioning Operational Checks

T100731-UN: Air Conditioning Switch

Disconnect harness from air conditioning switch.

A/C switch OFF, and measure for continuity between terminals 2A and 1.

Is continuity measured?

Turn switch ON, and measure for continuity between terminals 2B and 3.

Is continuity measured?

Record of Actual Results:

Result:
YES:
A/C switch is good. Check wiring harness.
NO:
Replace A/C switch.

1036
 Air Conditioning Operational Checks

4F Air Conditioner Low Pressure Switch Check

Action:

T101619-19: Air Conditioner Low Pressure Switch

Disconnect harness from switch.

Check for continuity between terminals. Is continuity measured?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace switch.
Action:

Remove switch from system. (The line that attaches the low pressure switch has a
valve to prevent discharging the air conditioning system when switch is removed.)

Measure for continuity across switch terminals.

Does ohmmeter read open?

Record of Actual Results:

Result:

1037
 Air Conditioning Operational Checks

YES:
Switch is good. Check wiring harness.
NO:
Go to Low Pressure Switch Test, Group 9031-25.

4G Air Conditioner High Pressure Switch Check

Action:

T101618-19: Air Conditioner High Pressure Switch

Disconnect harness from switch.

Measure continuity across outer switch terminals.

Does ohmmeter read continuity?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace switch.
Action:

Remove switch from system. (The line that attaches the high pressure switch has
a valve to prevent discharging the air conditioning system when switch is
removed.)

Measure continuity across switch terminals.

1038
 Air Conditioning Operational Checks

Does ohmmeter read continuity?

Record of Actual Results:

Result:
YES:
Switch is good. Check wiring harness.
NO:
System pressure is too high. Go to Air Conditioning Pressure Diagnostic Chart,
Group 9031-25.

4H Air Conditioning Compressor Clutch Coil Check

Action:

T6534CV-UN: Air Conditioning Compressor Clutch Coil

Disconnect harness from clutch.

Connect battery voltage to clutch terminal that has orange wire. Ground black wire
terminal.

Does clutch "click"?

Record of Actual Results:

Result:
YES:
A/C compressor clutch coil is good. Check wiring harness.

1039
 Air Conditioning Operational Checks

NO:
Replace clutch coil.

TX,9031,QQ6689-19-2000/02/02

1040
 Diagnose Air Conditioning Electrical Malfunctions

Diagnose Air Conditioning Electrical Malfunctions

NOTE:

Diagnostic charts are arranged from most probable and simplest to

verify, to least likely more difficult to verify. Remember the following
steps when diagnosing a problem:

Step 1. Operational Check Out Procedure

Step 2. Diagnostic Charts
Step 3. Adjustments and/or Tests

1041
Diagnose Air Conditioning Electrical Malfunctions

1042
 Diagnose Air Conditioning Electrical Malfunctions

Symptom Problem Solution

Air Conditioning System Circuit Breaker Replace circuit breaker.

Does Not Operate

Blower Switch See Blower/Air Conditioning Circuit

Checks , Group 9031-10.

Blower See Blower/Air Conditioning Circuit

Resistor Checks , Group 9031-10.

Heater/Blower See Blower/Air Conditioning Circuit

Motor Checks, Group 9031-10.

A/C Freeze See Blower/Air Conditioning Circuit

Switch Checks, Group 9031-10.

Air See Blower/Air Conditioning Circuit

Conditioning Checks, Group 9031-10.
Switch

Low Pressure See Blower/Air Conditioning Circuit

Switch Checks, Group 9031-10.

High Pressure See Blower/Air Conditioning Circuit

Switch Checks, Group 9031-10.

Compressor See Blower/Air Conditioning Circuit

Clutch Coil Checks, Group 9031-10.

Wiring Harness Check wiring harness. See Group 9015-

10.

1043
Diagnose Air Conditioning Electrical Malfunctions

TX,9031,QQ6690-19-1996/06/12

1044
 Diagnose Air Conditioning Electrical Malfunctions

Diagnose Air Conditioning Electrical Malfunctions

NOTE:

Diagnostic charts are arranged from most probable and simplest to

verify, to least likely more difficult to verify. Remember the following
steps when diagnosing a problem:

Step 1. Operational Check Out Procedure

Step 2. Diagnostic Charts
Step 3. Adjustments and/or Tests

1045
Diagnose Air Conditioning Electrical Malfunctions

1046
 Diagnose Air Conditioning Electrical Malfunctions

Symptom Problem Solution

Air Conditioning System Circuit Breaker Replace circuit breaker.

Does Not Operate

Blower Switch See Blower/Air Conditioning Circuit

Checks , Group 9031-10.

Blower See Blower/Air Conditioning Circuit

Resistor Checks , Group 9031-10.

Heater/Blower See Blower/Air Conditioning Circuit

Motor Checks, Group 9031-10.

A/C Freeze See Blower/Air Conditioning Circuit

Switch Checks, Group 9031-10.

Air See Blower/Air Conditioning Circuit

Conditioning Checks, Group 9031-10.
Switch

Low Pressure See Blower/Air Conditioning Circuit

Switch Checks, Group 9031-10.

High Pressure See Blower/Air Conditioning Circuit

Switch Checks, Group 9031-10.

Compressor See Blower/Air Conditioning Circuit

Clutch Coil Checks, Group 9031-10.

Wiring Harness Check wiring harness. See Group 9015-

10.

1047
Diagnose Air Conditioning Electrical Malfunctions

TX,9031,QQ6690-19-1996/06/12

1048
 Air Conditioning Component Location

Air Conditioning Component Location

T116041-19: Air Conditioning Compressor Harness - Component Location

LEGEND:
1 - Condenser
2 - High Pressure Switch (S24)
3 - Low Pressure Switch (S23)
4 - A/C Compressor Harness (W11)
5 - Engine Harness (W8)
6 - Expansion Valve
7 - Cab Floor Ground (W3)
8 - Blower Switch Connector (X6)
9 - Blower Harness To Side Console Harness Connector (X35)
10 - Blower Switch (S8)
11 - Heater Temp. Switch (S22)
12 - Blower Harness (W10)
13 - Blower Harness To Side Console Harness Connector (X5)
14 - Seat Position Sensor (S19)
15 - Blower Harness To Air Adjust Seat Harness Connector (X56)
16 - Blower Resister (R1)
17 - Heater Blower Motor (M6)
18 - A/C Freeze Switch (S26)
19 - Evaporator

1049
 Air Conditioning Component Location
20 - Line To Water Pump
21 - Line To Engine Block
22 - Receiver Dryer
23 - Compressor (Y10)
24 - High Pressure Service Port

NOTE:

For electrical call-outs in parenthesis, see Wiring and Schematic

Diagrams Legend in Group 9015-10.

CED,OUTX466,1107-19-1998/07/20

1050
 Special or Essential Tools

Special or Essential Tools

NOTE:

Order tools according to information given in the U.S. SERVICEGARD

™ Catalog or in the European Microfiche Tool Catalog (MTC).

Charging Station.......JT02046 [Used with

JT02050 Recovery and Recycling Station.
JT02045 Recovery, Recycling, and
Charging Station can be substituted for
JT02046 and JT02050.]
Servicing air conditioning system using
R134a refrigerant.

RW21595-UN: JT02046

Recovery and Recycling

Station.......JT02050 [Used with JT02046
Charging Station. JT02045 Recovery,
Recycling, and Charging Station can be
substituted for JT02046 and JT02050.]
Servicing air conditioning system using
R134a refrigerant.

RW21613-UN: JT02050

Schrader Valve Tool.......JT02130

To replace Schrader valve in compressor
manifold on R134a A/C Systems.

T8389AF-UN: JT02130

TX,9031,QQ6692-19-1998/06/15

1051
 Special or Essential Tools

Special or Essential Tools

NOTE:

Order tools according to information given in the U.S. SERVICEGARD

™ Catalog or in the European Microfiche Tool Catalog (MTC).

Charging Station.......JT02046 [Used with

JT02050 Recovery and Recycling Station.
JT02045 Recovery, Recycling, and
Charging Station can be substituted for
JT02046 and JT02050.]
Servicing air conditioning system using
R134a refrigerant.

RW21595-UN: JT02046

Recovery and Recycling

Station.......JT02050 [Used with JT02046
Charging Station. JT02045 Recovery,
Recycling, and Charging Station can be
substituted for JT02046 and JT02050.]
Servicing air conditioning system using
R134a refrigerant.

RW21613-UN: JT02050

Schrader Valve Tool.......JT02130

To replace Schrader valve in compressor
manifold on R134a A/C Systems.

T8389AF-UN: JT02130

TX,9031,QQ6692-19-1998/06/15

1052
 Service Equipment and Tools

Service Equipment and Tools

NOTE:

Order tools from the U.S. SERVICEGARD ™ Catalog or from the

European Microfiche Tool Catalog (MTC). Some tools may be available
from a local supplier.

Air
Conditioning
Fitting Belt
Kit.......JT02098 Tension
Used with Air Conditioning Gauge
Electronic Leak JT02075 to Flusher.......JT02075 To check
Detector.......JT02081 flush R134a air To flush R134a air compressor
Detect refrigerant conditioning conditioning belt
leaks. systems. systems. tension.

TX,9031,QQ6693-19-1996/11/11

1053
 Other Materials

Other Materials

Number Name Use

TY16134 (U.S.) R134A Flushing Flush R134A air conditioning system.

Solvent

TY15949 (12 oz) R134A Refrigerant Charge R134A air conditioning system.
(U.S.)

TY15950 (15 lb) (U.S.) R134A Refrigerant Charge R134A air conditioning system.

TY15951 (30 lb) (U.S.) R134A Refrigerant Charge R134A air conditioning system.

TY22025 (8.5 oz) R134A Compressor Oil Lubricate R134A air conditioning
(U.S.) system.

TX,9031,QQ6694-19-1996/04/23

1054
 Proper Refrigerant Handling

Proper Refrigerant Handling

The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into
the atmosphere, and requires that refrigerant be recovered using the approved recovery
equipment.

IMPORTANT:

To meet government standards relating to the use of refrigerants,

R134a is used in the air conditioning system. Because it does not
contain chlorine, R134a is not detrimental to the ozone in the
atmosphere. However, it is illegal to discharge any refrigerant into
the atmosphere. It must be recovered using the appropriate
recovery stations.

Use correct refrigerant recovery, recycling and charging stations.

DO NOT mix refrigerants, hoses, fittings, components or
refrigerant oils.

Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT
be interchanged. Systems containing R12 refrigerant use a different oil than systems
using R134a. Certain seals are not compatible with both types of refrigerants.

TX,9031,QQ6695-19-1996/06/12

1055
 R134A Refrigerant Cautions

R134A Refrigerant Cautions

CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid
refrigerant will freeze eyes or skin on contact. Wear goggles,
gloves and protective clothing.

If liquid refrigerant contacts eyes or skin, DO NOT rub the area.

Splash large amounts of COOL water on affected area. Go to a
physician or hospital immediately for treatment.

DO NOT allow refrigerant to contact open flames or very hot

surfaces such as electric welding arc, electric heating element
and lighted smoking materials.

DO NOT heat refrigerant over 52°C (125°F) in a closed container.

Heated refrigerant will develop high pressure which can burst the
container.

Keep refrigerant containers away from heat sources. Store

refrigerant in a cool place.

DO NOT handle damp refrigerant container with your bare hands.

Skin may freeze to container. Wear gloves.

If skin freezes to container, pour COOL water over container to

free the skin. Go to a physician or hospital immediately for
treatment.

(R12 ONLY) Refrigerant exposed to high temperature forms

phosgene gas. Inhaling toxic phosgene gas may result in serious
illness or death. Phosgene gas has an odor like new mown hay or
green corn. If you inhale phosgene gas, go to a physician or
hospital immediately for treatment.

TX,9031,QQ6696-19-1996/06/12

1056
 R134A Compressor Oil Charge Check

R134A Compressor Oil Charge Check

Remove compressor if R134a leakage was detected and repaired. See Remove and
Install Compressor in Repair Manual.

Drain oil from the compressor and record the amount. See Compressor Oil Removal
procedure in this group.

NOTE:

Drain oil and save if this is a new compressor.

If the oil drained from a compressor removed from operation is very black or the amount
of oil is less than 6 mL (0.2 fl oz), perform the following:

Item MeasurementSpecification
Oil Volume Less than 6 mL (0.2 fl oz)

1. Remove and discard the receiver-dryer.

2. Remove, clean, but do not disassemble the valve.

3. Flush the complete system with TY16134 air conditioning flushing solvent.

4. If the compressor is serviceable, pour flushing solvent in the manifold ports

and internally wash out the old oil.

5. Install a new receiver-dryer.

6. Install required amount of TY22025 refrigerant oil in the compressor. (See

R134a Component Oil Charge in this group.)

7. Connect all components, evacuate and charge the system.

TX,9031,QQ6697-19-1996/06/12

1057
 R134A Compressor Oil Removal

R134A Compressor Oil Removal

1. Remove compressor from machine. See Remove and Install Compressor in

Repair Manual.

2. Remove inlet/outlet manifold from compressor, and clutch dust cover.

3. Drain oil into graduated container while rotating compressor shaft.

4. Record measured oil and discard oil properly.

5. Install new oil. See R134a Component Oil Charge in this Group.

6. Install compressor. See Remove and Install Compressor in Repair Manual.

TX,9031,QQ6698-19-1996/06/12

1058
 R134A Component Oil Charge

R134A Component Oil Charge

CAUTION:
All new compressors are charged with a mixture of nitrogen,
R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety
goggles and discharge the compressor slowly to avoid possible
injury.

Compressors can be divided into three categories when determining the correct oil
charge for the system.

New compressor from parts depot

Used compressor removed from operation
Compressor internally washed with flushing solvent

Determining the amount of system oil charge prior to installation of compressor on a

machine.

1. When the complete system, lines, and components are flushed, add the
correct amount of oil as described.

New compressor from parts depot contains quantity of new oil, 230 ±
20 mL (7.7 ± .7 fl oz). System requires an additional amount of new
oil, 80 mL (2.7 fl oz).
Item MeasurementSpecification
New Volume 230 ± 20 mL (7.8 ± 0.7 fl oz) New
Compressor Oil
System Volume Additional 80 mL (2.7 fl oz) New Oil
Used compressor removed from operation, oil drained, and flushed
requires 310 ± 20 mL (10.5 ± .7 fl oz) of new oil.
Item MeasurementSpecification
Used Volume 310 ± 20 mL (10.5 ± 0.7 fl oz) New
Compressor Oil

2. If the complete system was not flushed, add the correct amount of oil for the
compressor plus amount of oil for each component that was serviced.

New compressor from parts depot, drain and return 45 mL (1.5 fl oz)
of oil to the compressor. (See Compressor Oil Removal procedure in

1059
 R134A Component Oil Charge
this group.)
Item MeasurementSpecification
New Volume Drain and return 45 mL (1.5 fl oz)
Compressor Oil

Used compressor removed from operation and oil drained, (See

Compressor Oil Removal procedure in this group.) Add 45 mL (1.5 fl
oz) of new oil.
Item MeasurementSpecification
Oil, Used Compressor Installation, Volume Add 45 mL
Complete System Not Flushed, Oil (1.5 fl oz)
Drained
Used compressor removed from operation, oil drained, and flushed
add 60 mL (2.0 fl oz) of new oil.
Item MeasurementSpecification
Oil, Used Compressor Installation, Volume Add 60 mL
Complete System Not Flushed, Oil (2.0 fl oz)
Drained, Flushed

NOTE:

Components listed below which have been removed, drained or

flushed, require the removal of the compressor to determine the correct
oil charge. Use the following chart as a guide for adding oil to
components:

Item MeasurementSpecification
Evaporator Oil Charge 130 mL (4.4 fl oz)
Condenser Oil Charge 65 mL (2.2 fl oz)
Receiver-Dryer Oil Charge 30 mL (1.0 fl oz)
Hoses Oil Charge 60 mL (2.0 fl oz)

NOTE:

Hoses = 3 mL per 30 cm (0.1 fl oz per ft).

Item MeasurementSpecification
Hoses Oil Charge 3 mL per 30 cm (0.1 fl oz per ft)
Approximate total length equals 600 cm (20 ft).

If any section of hose is removed and flushed or replaced, measure the length of hose
1060
 R134A Component Oil Charge
and use the formula to determine the correct amount of oil to be added.

CAUTION:
DO NOT leave the system or R134a compressor oil containers
open. This oil easily absorbs moisture. DO NOT spill R134a
compressor oil on acrylic or ABS plastic. This oil will deteriorate
these materials rapidly. Identify R134a oil containers and
measures to eliminate accidental mixing of different oils.

TX,9031,QQ6699-19-1996/06/12

1061
 R134A Refrigerant Recovery, Recycling And Charging Station Installation Procedure

R134A Refrigerant Recovery, Recycling And Charging Station

Installation Procedure

T101551-UN: AC Compressor And Recovery Station

LEGEND:
A - Low Pressure Test Port
B - High Pressure Relief Valve
C - Low Pressure Hose
D - Low Pressure Switch
E - High Pressure Switch
F - High Pressure Quick-Disconnect
G - Blue Hose

1062
 R134A Refrigerant Recovery, Recycling And Charging Station Installation Procedure
H - High Pressure Hose
I - Red Hose
J - Refrigerant Recovery/Recycling and Charging Station

-: Essential Tools

ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station [ JT02046
and JT02050 recovery and charging stations can be substituted for the JT02045
station.]

CAUTION:
Do not remove high pressure relief valve (B). Air conditioning
system will discharge rapidly causing possible injury.

IMPORTANT:

Use correct refrigerant recovery, recycling and charging stations.

DO NOT mix refrigerant, hoses, fittings, components or refrigerant
oils.

1. Close both high and low pressure valves on refrigerant recovery, recycling
and charging station (J).

2. Remove cap from low pressure test port (A).

3. Connect low pressure blue hose (G) from refrigerant recovery, recycling and
charging station (J) to low pressure test port (A) on compressor.

4. Connect high pressure red hose (I) to high pressure quick disconnect (F).

5. Follow the manufacturer’s instructions when using the refrigerant recovery,

recycling and charging station.

TX,9031,QQ6700-19-1996/06/12

1063
 Recover R134A System

Recover R134A System

T101551-UN: AC Compressor And Recovery Station

LEGEND:
A - Low Pressure Test Port
B - High Pressure Relief Valve
C - Low Pressure Hose
D - Low Pressure Switch
E - High Pressure Switch
F - High Pressure Quick-Disconnect
G - Blue Hose
H - High Pressure Hose

1064
 Recover R134A System
I - Red Hose
J - Refrigerant Recovery/Recycling and Charging Station

-: Essential Tools

ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station [ JT02046
and JT02050 recovery and charging stations can be substituted for the JT02045
station.]

CAUTION:
Do not remove high pressure relief valve (B). Air conditioning
system will discharge rapidly causing possible injury.

IMPORTANT:

Use correct refrigerant recovery, recycling and charging stations.

DO NOT mix refrigerant, hoses, fittings, components or refrigerant
oils.

NOTE:

Run the air conditioning system for three minutes to help in the
recovery process. Turn air conditioning system off before proceeding
with recovery steps.

1. Connect refrigerant recovery, recycling and charging station. (See installation

procedure in this group.)

2. Follow the manufacturer’s instructions when using the refrigerant recovery,

recycling and charging station.

TX,9031,QQ6701-19-1996/06/12

1065
 Evacuate R134A System

Evacuate R134A System

T101551-UN: AC Compressor And Recovery Station

LEGEND:
A - Low Pressure Test Port
B - High Pressure Relief Valve
C - Low Pressure Hose
D - Low Pressure Switch
E - High Pressure Switch
F - High Pressure Quick-Disconnect
G - Blue Hose
H - High Pressure Hose

1066
 Evacuate R134A System
I - Red Hose
J - Refrigerant Recovery/Recycling and Charging station

-: Essential Tools

ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station [ JT02046
and JT02050 recovery and charging stations can be substituted for the JT02045
station.]

CAUTION:
Do not remove high pressure relief valve (B). Air conditioning
system will discharge rapidly causing possible injury.

IMPORTANT:

Use correct refrigerant recovery, recycling and charging stations.

DO NOT mix refrigerant, hoses, fittings, components or refrigerant
oils.

Do not run compressor while evacuating.

1. Connect refrigerant recovery, recycling and charging station. (See installation

procedure in this group.)

2. Open low and high pressure valves on refrigerant recovery, recycling and
charging station.

3. Follow the manufacturer’s instructions and evacuate the system.

4. NOTE:

The vacuum specifications listed are for sea level conditions.

Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar)
(29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

Evacuate system until low pressure gauge registers 98 kPa (980 mbar) (29 in.
Hg) vacuum.

1067
 Evacuate R134A System

If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be obtained in 15 minutes,
test the system for leaks. (See Leak Testing, 9031-25). Correct any leaks.

Item MeasurementSpecification
Vacuum Pressure at 98 kPa (980 mbar) (29 in. Hg)
Sea Level
Pressure Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa
Above Sea (980 mbar) (29 in. Hg) for each 300 m (1000 ft)
Level elevation

5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side
valves. Turn vacuum pump off.

Item Measurement Specification

Vacuum Pressure at Sea Level 98 kPa (980 mbar) (29 in. Hg)

6. If the vacuum decreases more than 3.4 kPa (34 mbar) (1 in. Hg) in 5 minutes,
there is a leak in the system.

Item MeasurementSpecification
Vacuum Pressure Subtract 3.4 kPa (34 mbar) (1 in. Hg) (1 in. Hg) from
Above Sea 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000
Level ft) elevation

7. Repair leak.

8. Start to evacuate.

9. Open low-side and high-side valves.

10. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum
is reached.

Item Measurement Specification

Vacuum Pressure at Sea Level 98 kPa (980 mbar) (29 in. Hg)

11. Close low-side and high-side valves. Stop evacuation.

12. Charge the system. (See procedure in this group.)

TX,9031,QQ6702-19-1996/06/12

1068
 Charge R134A System

Charge R134A System

T101551-UN: AC Compressor And Recovery Station

LEGEND:
A - Low Pressure Test Port
B - High Pressure Relief Valve
C - Low Pressure Hose
D - Low Pressure Switch
E - High Pressure Switch
F - High Pressure Quick-Disconnect
G - Blue Hose
H - High Pressure Hose

1069
 Charge R134A System
I - Red Hose
J - Refrigerant Recovery/Recycling and Charging Station

-: Essential Tools

ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station [ JT02046
and JT02050 recovery and charging stations can be substituted for the JT02045
station.]

CAUTION:
Do not remove high pressure relief valve (B). Air conditioning
system will discharge rapidly causing possible injury.

IMPORTANT:

Use correct refrigerant recovery, recycling and charging stations.

DO NOT mix refrigerant, hoses, fittings, components or refrigerant
oils.

1. Connect JT02047 R134a refrigerant recovery, recycling and charging station.

(See installation procedure in this group.)

2. Evacuate the system. (See Evacuate Air Conditioning System, this group.)

3. NOTE:

Before beginning to charge air conditioning system, the

following conditions must exist: Engine STOPPED, the pump
must be capable of pulling at least 28.6 in. Hg vacuum (sea
level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980
mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above
sea level.

1070
 Charge R134A System

Item MeasurementSpecification
Vacuum Pressure at 98 kPa (980 mbar) (29 in. Hg)
Sea Level
Pressure Subtract 3.4 kPa (34 mbar) (1 in. Hg)
Above Sea from 98 kPa (980 mbar) (29 in. Hg)
Level for each 300 m (1000 ft) elevation

Follow the manufacturer’s instructions and charge the system.

4. Add refrigerant until system is charged with 2.04 Kg (4.50 lbs).

Item Measurement Specification

R134a System Refrigerant Charge 2.04 Kg (4.50 lbs)

5. Do air conditioner checks and tests in Groups 9031-10 and 9031-25.

TX,9031,QQ6703-19-1996/06/12

1071
 Special or Essential Tools

Special or Essential Tools

NOTE:

Order tools according to information given in the U.S. SERVICEGARD

™ Catalog or in the European Microfiche Tool Catalog (MTC).

Charging Station.......JT02046 [Used with

JT02050 Recovery and Recycling Station.
JT02045 Recovery, Recycling, and
Charging Station can be substituted for
JT02046 and JT02050.]
Servicing air conditioning system using
R134a refrigerant.

RW21595-UN: JT02046

Recovery and Recycling

Station.......JT02050 [Used with JT02046
Charging Station. JT02045 Recovery,
Recycling, and Charging Station can be
substituted for JT02046 and JT02050.]
Servicing air conditioning system using
R134a refrigerant.

RW21613-UN: JT02050

Schrader Valve Tool.......JT02130

To replace Schrader valve in compressor
manifold on R134a A/C Systems and to
replace Schrader valve in ports where high
and low pressure switches are located in
R134a A/C Systems.

T8389AF-UN: JT02130

1072
 Special or Essential Tools

Air Conditioning Test Equipment

Kit.......D18018KD
Used to test air conditioning.

T7541AD-UN: D18018KD

Straight Connector.......JT02148
Used to test air conditioning high and low
pressure switches.

T105533-UN: JT02148

TX,9031,QQ6705-19-1998/06/15

1073
 Special or Essential Tools

Special or Essential Tools

NOTE:

Order tools according to information given in the U.S. SERVICEGARD

™ Catalog or in the European Microfiche Tool Catalog (MTC).

Charging Station.......JT02046 [Used with

JT02050 Recovery and Recycling Station.
JT02045 Recovery, Recycling, and
Charging Station can be substituted for
JT02046 and JT02050.]
Servicing air conditioning system using
R134a refrigerant.

RW21595-UN: JT02046

Recovery and Recycling

Station.......JT02050 [Used with JT02046
Charging Station. JT02045 Recovery,
Recycling, and Charging Station can be
substituted for JT02046 and JT02050.]
Servicing air conditioning system using
R134a refrigerant.

RW21613-UN: JT02050

Schrader Valve Tool.......JT02130

To replace Schrader valve in compressor
manifold on R134a A/C Systems and to
replace Schrader valve in ports where high
and low pressure switches are located in
R134a A/C Systems.

T8389AF-UN: JT02130

1074
 Special or Essential Tools

Air Conditioning Test Equipment

Kit.......D18018KD
Used to test air conditioning.

T7541AD-UN: D18018KD

Straight Connector.......JT02148
Used to test air conditioning high and low
pressure switches.

T105533-UN: JT02148

TX,9031,QQ6705-19-1998/06/15

1075
 Service Equipment and Tools
Service Equipment and Tools

NOTE:

Order tools from the U.S. SERVICEGARD ™ Catalog or from the European
Microfiche Tool Catalog (MTC). Some tools may be available from a local
supplier.

Air
Conditioning
Fitting
Air Kit.......JT02098 Volt-Ohm-
Manifold Pressure Conditioning Used with Amp
Gauge Electronic Leak Service Fitting JT02075 to Multimeter
Assembly.......JT02051 Detector.......JT02081 Kit.......JT05419 flush R134a air To test
Test air conditioning Detect refrigerant Connect test conditioning thermostat
system. leaks. equipment. systems. switch.

TX,9031,QQ6706-19-1996/11/12

1076
 Proper Refrigerant Handling

Proper Refrigerant Handling

The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into
the atmosphere, and requires that refrigerant be recovered using the approved recovery
equipment.

IMPORTANT:

To meet government standards relating to the use of refrigerants,

R134a is used in the air conditioning system. Because it does not
contain chlorine, R134a is not detrimental to the ozone in the
atmosphere. However, it is illegal to discharge any refrigerant into
the atmosphere. It must be recovered using the appropriate
recovery stations.

Use correct refrigerant recovery, recycling and charging stations.

DO NOT mix refrigerants, hoses, fittings, components or
refrigerant oils.

Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT
be interchanged. Systems containing R12 refrigerant use a different oil than systems
using R134a. Certain seals are not compatible with both types of refrigerants.

TX,9031,QQ6707-19-1996/08/13

1077
 R134A Refrigerant Cautions

R134A Refrigerant Cautions

CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid
refrigerant will freeze eyes or skin on contact. Wear goggles,
gloves and protective clothing.

If liquid refrigerant contacts eyes or skin, DO NOT rub the area.

Splash large amounts of COOL water on affected area. Go to a
physician or hospital immediately for treatment.

DO NOT allow refrigerant to contact open flames or very hot

surfaces such as electric welding arc, electric heating element
and lighted smoking materials.

DO NOT heat refrigerant over 52°C (125°F) in a closed container.

Heated refrigerant will develop high pressure which can burst the
container.

Keep refrigerant containers away from heat sources. Store

refrigerant in a cool place.

DO NOT handle damp refrigerant container with your bare hands.

Skin may freeze to container. Wear gloves.

If skin freezes to container, pour COOL water over container to

free the skin. Go to a physician or hospital immediately for
treatment.

(R12 ONLY) Refrigerant exposed to high temperature forms

phosgene gas. Inhaling toxic phosgene gas may result in serious
illness or death. Phosgene gas has an odor like new mown hay or
green corn. If you inhale phosgene gas, go to a physician or
hospital immediately for treatment.

TX,9031,QQ6708-19-1996/08/13

1078
 R134A Air Conditioning System Test

R134A Air Conditioning System Test

Item MeasurementSpecification
Engine Speed RPM 2200 rpm
Blower Speed Maximum
Air Conditioning Cooling Temperature Maximum

-: R134A Air Conditioning System Test Temperature and Pressure Chart

Ambient
Temperature Maximum Louver
(F) Temperature (F) Suction Pressure Discharge Pressure

16-21°C (60- 7.3°C (45°F) 41-89 kPa (0.41-0.89 655-1172 kPa (6.55-11.72
70°F) bar) (6-13 psi) bar) (95-170 psi)

21-27°C (70- 10°C (50°F) 55-103 kPa (0.55-1.03 792-1516 kPa (7.92-15.16
80°F) bar) (8-15 psi) bar) (115-220 psi)

27-32°C (80- 13°C (55°F) 68-124 kPa (0.68-1.24 1172-1792 kPa (11.72-
90°F) bar) (10-18 psi) 17.92 bar) (170-260 psi)
32-38°C (90- 16°C (60°F) 82-137 kPa (0.82-1.37 1482-2068 kPa (14.82-
100°F) bar) (12-20 psi) 20.68 bar) (215-300 psi)

38-43°C (100- 19°C (65°F) 103-151 kPa (1.03- 1172-2275 kPa (11.72-
110°F) 1.51 bar) (15-22 psi) 22.75 bar) (260-330 psi)

-: Essential Tools

ESSENTIAL TOOLS

JT02045 R134a Refrigerant Recovery, Recycling and Charging Station [ JT02046

and JT02050 recovery and charging stations can be substituted for the JT02045
station.]

IMPORTANT:

Use correct refrigerant recovery, recycling and charging stations.

DO NOT use refrigerant, hoses, fittings, components or refrigerant
oils intended for R12 refrigerant.

1. Connect refrigerant recovery, recycling and charging station. (See installation

1079
 R134A Air Conditioning System Test
procedure in this group.)

2. Close both low and high pressure valves on refrigerant recovery, recycling
and charging station.

3. Open cab doors and windows.

4.

T101551-UN: AC Compressor And Recovery Station

LEGEND:
A - Low Pressure Test Port
B - High Pressure Relief Valve

1080
 R134A Air Conditioning System Test
C - Low Pressure Hose
D - Low Pressure Switch
E - High Pressure Switch
F - High Pressure Quick-Disconnect
G - Blue Hose
H - High Pressure Hose
I - Red Hose
J - Refrigerant Recovery/Recycling and Charging Station

Connect low pressure blue hose (G) from refrigerant recovery, recycling and
charging station (J) to low pressure test port (A) on compressor.

5. Connect high pressure red hose (I) to high pressure quick-disconnect (F) on
compressor.

6. Follow the manufacturer’s instructions when using the refrigerant recovery,

recycling and charging station.

7. Start engine and run at rated engine speed.

8. Turn temperature control switch to the maximum cooling position.

9. Turn blower switch to high speed.

10. Check sight glass in receiver-dryer.

11. Run unit for at least 5 minutes.

12. Measure air temperature at condenser air inlet and at air ducts in air
conditioning unit.

13. Compare air duct temperature reading to the temperatures shown in the
specifications.

14. Observe low and high pressure gauges on refrigerant recovery, recycling and
charging station.

15. Compare pressure readings to the pressure shown in specifications.

Use the Operating Pressure Diagnostic Chart in this group to diagnose the
malfunction.

TX,9031,QQ6709-19-1996/10/01

1081
 Pressure Diagnostic Chart

Pressure Diagnostic Chart

T6609AB-19: Pressure Diagnostic Chart

TX,9031,QQ6710-19-1996/08/13

1082
 Low Pressure Switch Test

Low Pressure Switch Test

Item MeasurementSpecification
Switch Test (Normally Open) Opens on Pressure 173 ± 35 kPa (1.73 ± 0.3 bar)
Decreasing (25 ± 53 psi)
Switch Test (Normally Open) Closes on Pressure 345 ± 35 kPa (3.45 ± 0.3 bar)
Increasing (50 ± 5 psi)

-: Essential Tools

ESSENTIAL TOOLS
JT02148 Straight Connector For Testing Switches

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Multimeter

NOTE:

Low pressure switch is normally open when removed from machine.

When installed the switch becomes closed because of normal system
pressure.

1. Turn key switch ON but DO NOT start engine. Turn blower switch ON. Turn
temperature control switch to the maximum cooling position.

2. Disconnect and connect low pressure switch at harness connector.

Compressor clutch must engage and disengage (click).

3. NOTE:

The line that attaches the low pressure switch has a valve to
prevent discharging the air conditioning system when switch is
removed.

Disconnect harness from switch and remove switch from line. Connect low
pressure switch to harness.

Compressor clutch must not engage (click).

1083
 Low Pressure Switch Test

4. The actual pressure setting of switch can be checked by connecting it to a

pressure source such as a regulated air supply or hydraulic hand pump.

5.

T8426AD-UN: Low Pressure Switch

Switch must not have continuity between terminals (A and C) until pressure
increases to switch closing pressure specification. Slowly release pressure.
Switch must have continuity until pressure decreases to switch opening
pressure specification.

TX,9031,QQ6711-19-1996/08/13

1084
 High Pressure Switch Test

High Pressure Switch Test

Item MeasurementSpecification
Switch Test (Normally Closed) Opens Pressure 2760 ± 138 kPa (27.6 ± 1.38
on Increasing bar) (400 ± 20 psi)
Switch Test (Normally Closed) Closes Pressure 1310 ± 138 kPa (13.11 ± 1.38
on Decreasing bar) (190 ± 20 psi)

-: Essential Tools

ESSENTIAL TOOLS
JT02148 Straight Connector For Testing Switch

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Multimeter

NOTE:

The line that attaches the high pressure switch has a valve installed to
prevent discharging the air conditioning system when switch is
removed. The high pressure switch is normally closed when removed
from the machine. It does not open when installed in the A/C system
until pressure exceeds specification.

1. Remove high pressure switch.

2. Connect a portable pressure source, such as a hydraulic hand pump, to high

pressure switch.

1085
 High Pressure Switch Test
3.

T8426AE-UN: High Pressure Switch

Switch must have continuity between terminals (A and C) until pressure
increases to switch opening pressure specification.

4. Slowly release pressure. Switch must not have continuity until pressure
decreases to switch closing pressure specification.

5. The switch can also be checked when installed in air conditioning system,
however, pressure is slow to increase to test specification.

Connect an air conditioning gauge set to service fittings at compressor. Cover

condenser with paper or plastic to stop air flow. Operate air conditioner on
maximum cooling. Note high-side pressure when high pressure switch opens
and then closes.

TX,9031,QQ6712-19-1996/08/13

1086
 A/C Freeze Control Switch

A/C Freeze Control Switch

Item Measurement Specification

A/C Control Switch (Normally Closed) Opens as Temperature Drops -0.5°C (31°F)
A/C Control Switch (Normally Closed) Closes as Temperature Rises 4°C (39°F)

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Multimeter

1. Remove A/C freeze switch from evaporator.

2. Connect ohmmeter to switch terminals. Switch must be closed at room

temperature.

3. Put switch into a freezer (assure freezer temperature is below -0.5°C (31°F).
Switch must open, and continuity must not be read.

4. Remove switch from freezer. Put sensing tube into a glass of warm water.
Switch must close, and continuity must be read.

5. If switch does not open and close during testing, install new switch.

TX,9031,QQ6713-19-1996/08/13

1087
 Leak Testing

Leak Testing

1. Inspect all lines, fittings, and components for oily or dusty spots. When
refrigerant leaks from the system, a small amount of oil is carried out with it.

2. A soap and water solution can be sprayed on the components in the system to
form bubbles at the source of the leak.

3. If a leak detector is used, move the leak detector probe under the hoses and
around the connections at a rate of 25 mm (1 in.) per second.

4. Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.

TX,9031,QQ6714-19-1996/08/13

1088
 Refrigerant Hoses And Tubing Inspection

Refrigerant Hoses And Tubing Inspection

When a component is disconnected from the system, special care should be given to
inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign material. If
such contamination is present in hoses, tubing, or fittings and cannot be removed by
cleaning, then replace parts.

Fittings that have grease or dirt on them should be wiped clean with a cloth dampened
with alcohol. Chlorinated solvents (such as trichloroethylene) are contaminants, and
must not be used for cleaning.

To assist in making leak-proof joints, use a small amount of clean correct viscosity
refrigerant oil on all hose and tube connections. Dip O-rings in correct viscosity oil
before assembling.

IMPORTANT:

Hose used for air conditioning systems contains special barriers

in its walls to prevent migration of refrigerant gas.

DO NOT use hydraulic hoses as replacement hoses in the air

conditioning system. Use ONLY certified hose meeting SAE J51B
requirements.

TX,9031,QQ6715-19-1996/08/13

1089