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710D Backhoe Technical Manual TM1537 PDF
710D Backhoe Technical Manual TM1537 PDF
710D Backhoe Technical Manual TM1537 PDF
TECHNICAL MANUAL
710D Backhoe Loader
Operation and Test
TM1537 26FEB02 (ENGLISH)
!TM1537__26FEB02!
1200 Series Axle . . . . . . . . . . . . . . . . . . . . . . CTM43
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. See DB1990 Service Publications Catalog to order a
Essential tools required in performing certain service complete Technical Manual (TM) or a Technical
work are identified in this manual and are Manual Section (TMS). A complete Operation and Test
recommended for use. manual includes the following sections:
2. 9005
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
Section 9005 Operational Checkout Procedure
the potential for personal injury.
3. 9010
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
Section 9010 Engine
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
4. 9015
Information is organized in groups for the various
Section 9015 Electrical System
components requiring service instruction. At the
beginning of each group are summary listings of all
5. 9020
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Section 9020 Power Train
specifications, wear tolerances, and torque values.
6. 9025
Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
Section 9025 Hydraulic System
the vital information needed for diagnosis, analysis,
testing, and repair.
7. 9031
Fundamental service information is available from
Section 9031 Heating and Air Conditioning
other sources covering basic theory of operation,
fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.
TX,710D00 1925FEB021/1
PN=2
Introduction
1. Section 9000:
To include any specifications, oil capacity and safety
concerns for new rear axle, transmission, charge
pump, park brake, and service brake valve.
2. Section 9005:
To add operational checks for new transmission, park
brake, differential lock, and service brake valve.
3. Section 9010:
To include miscellaneous updates and update serial
numbers.
4. Section 9015:
To include information for new engine, front console,
and side console harnesses. To add new tachometer
and low brake pressure warning system.
5. Section 9020:
To add information for new transmission and rear axle.
For machines (S.N. 872257 ), information on the
park brake and differential lock will now be provided in
this section.
6. Section 9025:
To make required changes because of new charge
pump located on the rear of the transmission. To
change plumbing and schematics required by the
removal of the park brake/differential lock valve. To
add information on the new service brake valve.
7. Section 9031:
To improve format and add information on new side
console harness.
8. ..
CED,TX03399,4247 1912JUN981/1
PN=3
Introduction
PN=4
Introduction
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
Company Name
Address
Phone
FAX No.
Dealer Acct. No.
THANK YOU!
TX,HELP,153715 1916SEP961/1
PN=5
Introduction
PN=6
Contents
9000
SECTION 9000General Information Group 20Adjustments
Group 01Safety Information Group 25Test
Group 02General Specifications
Group 03Torque Values
Group 04Fuels and Lubricants
9005
SECTION 9010Engine
Group 05Theory of Operation 9010
Group 15System Diagnostic Information
Group 20Adjustments
Group 25Tests
PN=1
Contents
9000
9005
9010
9015
9020
9025
9031
INDX
PN=2
9000
Section 9000
General Information
Contents
Page Page
PN=1
Contents
9000
PN=2
Group 01
Safety Information
9000
Handle Fluids SafelyAvoid Fires 01
1
UN23AUG88
Make sure machine is clean of trash, grease, and debris.
TS227
spontaneously.
DX,FLAME 1929SEP981/1
UN23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16C (60F).
TS204
DX,SPARKS 1903MAR931/1
DX,FIRE2 1903MAR931/1
PN=11
Safety Information
9000
01 Prevent Acid Burns
2
UN23AUG88
If acid is swallowed:
TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.
DX,POISON 1921APR931/1
PN=12
Safety Information
9000
Handle Chemical Products Safely 01
3
UN26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
TS1132
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.
DX,MSDS,NA 1903MAR931/1
UN23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
and body from high pressure fluids.
DX,FLUID 1903MAR931/1
PN=13
Safety Information
9000
01 Park Machine Safely
4
UN24MAY89
Hang a "DO NOT OPERATE" tag in operator station.
TS230
DX,PARK 1904JUN901/1
UN23AUG88
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.
TS229
Follow recommended procedures in this manual.
DX,LOWER 1917FEB991/1
DX,WEAR2 1903MAR931/1
PN=14
Safety Information
9000
Work in Clean Area 01
5
UN18OCT88
Have the right parts on hand.
Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN 1904JUN901/1
UN23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228
DX,LOOSE 1904JUN901/1
UN23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR 1917FEB991/1
DX,LIGHT 1904JUN901/1
PN=15
Safety Information
9000
01 Replace Safety Signs
6
UN23AUG88
TS201
DX,SIGNS1 1904JUN901/1
UN23AUG88
TS226
DX,LIFT 1904JUN901/1
UN23AUG88
Do all work outside or in a well ventilated area. Dispose of
paint and solvent properly.
DX,PAINT 1903MAR931/1
PN=16
Safety Information
9000
Avoid Heating Near Pressurized Fluid Lines 01
7
UN15MAY90
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH 1903MAR931/1
UN23AUG88
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
TS212
replaced, not reused.
DX,ROPS3 1903MAR931/1
PN=17
Safety Information
9000
01 Service Tires Safely
8
UN23AUG88
TS211
DX,RIM 1924AUG901/1
UN23AUG88
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as TS220
DX,DUST 1915MAR911/1
PN=18
Safety Information
9000
Practice Safe Maintenance 01
9
UN23AUG88
or welding on machine.
TS218
welding on machine.
DX,SERV 1917FEB991/1
wrenches.
DX,REPAIR 1917FEB991/1
PN=19
Safety Information
9000
01 Dispose of Waste Properly
10
UN26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.
DX,DRAIN 1903MAR931/1
1907OCT88
TS231
DX,LIVE 1925SEP921/1
PN=20
Group 02
General Specifications
9000
02
1
PN=21
General Specifications
9000
02 710D Backhoe Loader Specifications
2
NOTE: Specifications and design subject to change tires; 14.5/7516.1, 10PR, F3 front tires with UN19OCT88
T6245AF1
without notice. Wherever applicable, 75 percent CaCl2 fill; 1.15 m3(1.5 cu yd) loader
specifications are in accordance with ICED bucket; 610 mm (24 in.) backhoe bucket;
and SAE Standards. Except where otherwise ROPS/FOPS; full fuel tank and 79 kg (175 lb)
noted, these specifications are based on a operator.
standard machine with 21L-24, 16PR, R4 rear
TX,115,RR2655 1919AUG991/1
PN=22
General Specifications
9000
710D Backhoe Loader Dimensions 02
3
Extendible Dipperstick
Backhoe Standard Retracted Extended
ALoading height, truck loading position 4.03 m (13 ft 3 in.) 3.98 m (13 ft 1 in.) 4.65 m (15 ft 3 in.)
BReach from center of swing mast 6.90 m (22 ft 8 in.) 6.90 m (22 ft 8 in.) 8.31 m (27 ft 3 in.)
CReach from center of rear axle 8.15 m (26 ft 9 in.) 8.15 m (26 ft 9 in.) 9.56 m (31 ft 4 in.)
DDigging depth (SAE):
(1) 610 mm (2 ft) flat bottom 5.53 m (18 ft 2 in.) 5.51 m (18 ft 1 in.) 7.03 m (23 ft 1 in.)
(2) 2440 mm (8 ft) flat bottom 5.26 m (17 ft 3 in.) 5.24 m (17 ft 2 in.) 6.82 m (22 ft 4 in.)
EMaximum digging depth 5.55 m (18 ft 2 in.) 5.52 m (18 ft 1 in.) 7.04 m (23 ft 1 in.)
FGround clearance, minimum 356 mm (14 in.) 356 mm (14 in.) 356 mm (14 in.)
GBucket rotation 152/162 152/162 152/162
HTransport height 4.21 m (13 ft 10 in.) 4.31 m (13 ft 11 in.) 4.31 m (13 ft 11 in.)
JOverall length, transport 8.13 m (26 ft 8 in.) 8.13 m (26 ft 8 in.) 8.13 m (26 ft 8 in.)
KStabilizer widthtransport 2.44 m (8 ft 0 in.) 2.44 m (8 ft 0 in.) 2.44 m (8 ft 0 in.)
LStabilizer spreadoperating 3.48 m (11 ft 5 in.) 3.48 m (11 ft 5 in.) 3.48 m (11 ft 5 in.)
MOverall width (less loader bucket) 2235 mm (88 in.) 2235 mm (88 in.) 2235 mm (88 in.)
Digging force, bucket cylinder (power dig position) 57.5 kN (12,940 lb force) 57.5 kN (12,940 lb force) 57.5 kN (12,940 lb force)
Digging force, crowd cylinder 42.7 kN (9600 lb force) 42.7 kN (9600 lb force) 29.8 kN (6700 lb force)
Loader with 1.24 m3 (1.62 yd3 ) Loader with 1.0 m3 (1.375 yd3 ) Bucket
Bucket and MFWD
NWheelbase 2.29 m (90.5 in.) 2.29 m (90.5 in.)
ODig below groundbucket level 147 mm (5.8 in.) 152 mm (6.0 in.)
PRollback at ground level 40 40
QDump clearance, bucket at 40 2.80 m (9 ft 6 in.) 2.80 m (9 ft 6 in.)
RMaximum height to bucket hinge pin 3.57 m (11 ft 8 in.) 3.61 m (11 ft 10 in.)
SMaximum bucket dump angle 40 40
TReach at full height, bucket at 40 851 mm (33.5 in.) 836 mm (32.9 in.)
TX,115,RR2626 1919AUG991/1
PN=23
General Specifications
9000
02 710D Backhoe Loader Engine Specifications
4
(S.N. 830204)
Cylinders Quantity 6
Fan Suction
CED,OUO1032,1216 1919AUG991/1
PN=24
General Specifications
9000
710D Backhoe Loader Engine Specifications 02
5
(S.N. 830205 )
Cylinders Quantity 6
PN=25
General Specifications
9000
02 710D Backhoe Loader Specifications (S.N. 872328)
6
PN=26
General Specifications
9000
Item Measurement Specification 02
7
Steering
Flow @ 15 170 kPa (151 bar) Flow Rate 201 L/min (53 gpm)
(2200 psi)
Charge Pump Flow @ Fast Idle Flow Rate 64 L/min (17 gpm)
(Minimum)
TX,9000,BG785 1919AUG992/2
PN=27
General Specifications
9000
02 710D Backhoe Loader Specifications (S.N. 872329 )
8
PN=28
General Specifications
9000
Item Measurement Specification 02
9
Steering
PN=29
General Specifications
9000
02 Item Measurement Specification
10
Flow @ 15 170 kPa (151 bar) Flow Rate 201 L/min (53 gpm)
(2200 psi)
Charge Pump Flow @ Fast Idle Flow Rate 90 L/min (24 gpm)
(Minimum)
CED,TX03679,3599 1919AUG993/3
PN=30
General Specifications
9000
710D Backhoe LoaderOther Information 02
11
Final Drives:
Brakes:
Tires:
Regular
Axle
PN=31
General Specifications
9000
02 Front: 14.5/75 x 16.1, 10PR, F3
12
Rear: 21L x 28, 14PR, R4
Front: 16.5L x 16.1, 10PR, I-1
Rear: 21L x 28, 14PR, R4
MFWD
Operating Weights:
Loader buckets:
CED,TX03679,3601 1919AUG992/2
PN=32
General Specifications
9000
710D Backhoe Buckets 02
13
Width mm (in.) Heaped Capacity m3 (cu yd)
Loader 2337 (92) 1.24 (1.62)
2438 (96) 1.34 (1.75)
Backhoe 457 (18) 0.22 (0.29)
610 (24) 0.31 (0.41)
762 (30) 0.42 (0.55)
914 (36) 0.53 (0.69)
TX,115,RR2628 1919AUG991/1
TX,9000,BG788 1919AUG991/1
PN=33
General Specifications
9000
02 710D Backhoe Loader Lifting Capacities
14
UN06OCT92
T7840AS
Lift Capacity, Backhoe with Standard Dipperstick. Based on SAE J31. Rated lift capacities are in kg (lb). Lift
capacities are hydraulically limited.
Lifting capacity ratings are made with bucket hinge pin, Angle between boom and ground is 65. Machine is
loader bucket and stabilizers on firm, level ground. Lift equipped with 610 mm (24 in.) standard bucket,
capacities are hydraulically limited. Lifting capacities standard or extendible dipperstick and standard
are 87% of the maximum lift over any point on the equipment.
swing arc and do not exceed 75% of the tipping load.
PN=34
General Specifications
9000
02
15
UN26OCT92
T7840AU
Lift Capacity, Backhoe with 1.52 m (5 ft) Extendible Dipperstick, Retracted. Based on SAE J31. Rated lift capacities
are in kg (lb). Lift capacities are hydraulically limited.
NOTE: Loader bucket on ground significantly improves to the side. Lift capacity over the rear is not
side stability, therefore improving lift capacity affected.
PN=35
General Specifications
9000
02
16
UN06OCT92
T7840AT
Lift Capacity, Backhoe with 1.52 m (5 ft) Extendible Dipperstick, Extended. Based on SAE J31. Rated lift capacities
are in kg (lb). Lift capacities are hydraulically limited.
TX,115,RR2660 1919AUG993/3
PN=36
Group 03
Torque Values
9000
Hardware Torque Specifications 03
1
TX,90,FF1225 1915MAR931/1
14.5/75 x 16.1, 10PR, F3 Pressure 276 kPa (2.8 bar) (40 psi)
15 x 19.5, 8PR (w/MFWD only) Pressure 276 kPa (2.8 bar) (40 psi)
16.5 L x 16.1, 10PR, I-1 Pressure 276 kPa (2.8 bar) (40 psi)
20.5 x 25, 12PR, R4 Pressure 241 kPa (2.4 bar) (35 psi)
TX,55,RR2589 1902OCT981/1
PN=37
Torque Values
9000
03 ROPS Torque Specifications
2
UN23AUG88
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or
TS176
is in any way altered. A damaged ROPS should
be replaced, not reused.
CED,OUTX782,583 1918AUG991/1
PN=38
Torque Values
9000
Checking Wheel Fastener Torque 03
3
Specification
Front Standard AxleTorque ................ 230 + 35 -46 Nm (170 + 26 -34
UN18OCT88
ft-lb)
Front MFWD AxleTorque .................... 407 + 60 -80 Nm (300 + 45 -60
ft-lb)
Rear AxleTorque ................................. 575 + 170 -115 Nm (425 + 125
-85 ft-lb)
T6000AU
UN14MAR94
T8196AY
TX,90,RR2625 1919AUG991/1
PN=39
Torque Values
9000
03 Unified Inch Bolt and Cap Screw Torque Values
4
1902APR97
TS1656
DX,TORQ1 1920JUL941/1
PN=40
Torque Values
9000
Metric Bolt and Cap Screw Torque Values 03
5
1902APR97
TS1657
DX,TORQ2 1920JUL941/1
PN=41
Torque Values
9000
03 Additional Metric Cap Screw Torque Values
6
UN18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
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.
UN18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
UN18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
Continued on next page 04T,90,M170 1901AUG941/2
PN=42
Torque Values
9000
METRIC CAP SCREW TORQUE VALUESa 03
7
Nominal
Dia T-Bolt H-Bolt M-Bolt
Nm lb-ft Nm lb-ft Nm 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
a
Torque tolerance is 10%.
04T,90,M170 1901AUG942/2
PN=43
Torque Values
9000
03 Check Oil Lines And Fittings
8
UN23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
X9811
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.
TX,90,DH1559 1901AUG941/1
PN=44
Torque Values
9000
Service Recommendations for 37 Flare and 03
9
30 Cone Seat Connectors
UN18OCT88
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6234AC
3. Align tube with fitting before attempting to start nut.
T82,BHMA,EL 1919MAR961/1
PN=45
Torque Values
9000
03 Service Recommendations for O-Ring Boss
10
Fittings
Straight Fitting
UN18OCT88
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.
T6243AE
3. Tighten fitting to torque value shown on chart.
PN=46
Torque Values
9000
Angle Fitting 03
11
UN18OCT88
contacts face of boss.
T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.
04T,90,K66 1919MAR962/2
PN=47
Torque Values
9000
03 Service Recommendations for Flat Face
12
O-Ring Seal Fittings
UN18OCT88
2. Inspect the O-ring. It must be free of damage or
defects.
T6243AD
petroleum jelly to hold in place.
04T,90,K67 1901AUG941/1
PN=48
Torque Values
9000
Service Recommendations For Inch Series Four Bolt Flange Fittings 03
13
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
TX,9000,BG380 1914JAN971/1
PN=49
Torque Values
9000
03 Service Recommendations for Metric Series Four Bolt Flange Fitting
14
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Threadb Nm lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42
M12 95 70
4. Single piece flange (D): Place hydraulic line in
center of flange and install four cap screws. Flange M14 157 116
must be centrally located on port. Hand tighten cap M16 217 160
screws to hold flange in place. Do not pinch O-ring. M18 334 246
M20 421 318
5. After components are properly positioned and cap a
Tolerance 10%. The torques given are enough for the given
screws are hand tightened, tighten one cap screw, 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.
b
Metric standard thread.
04T,90,K175 1905JAN961/1
PN=50
Group 04
Fuels and Lubricants
9000
Fuel Specifications 04
1
Use ONLY clean, high-quality fuel. For maximum filter life, sediment and water should not
be more than 0.10 percent.
Use Grade No. 2-D fuel above 40F (4C).
The cetane number should be 40 minimum. If you
Use Grade No. 1-D fuel below 40F (4C). operate your machine where air temperatures are
normally low or where altitudes are high, you may
Use Grade No. 1-D fuel for all air temperatures at need fuel with a higher cetane number.
altitudes above 1 500 m (5000 ft).
Cloud PointFor cold weather operation, cloud point
IMPORTANT: If fuel sulfur content exceeds 0.5 should be -12C (10F) below lowest normal air
percent, the engine oil drain interval temperature.
must be reduced by 50 percent (to
125 hours).
TX,9000,BG789 1904MAR971/1
Diesel Fuel
Consult your local fuel distributor for properties of the Fuel lubricity should pass a minimum of 3100 gram
diesel fuel available in your area. load level as measured by the BOCLE scuffing test.
In general, diesel fuels are blended to satisfy the low Sulfur content:
temperature requirements of the geographical area in
which they are marketed. Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
Diesel fuels specified to EN 590 or ASTM D975 are If diesel fuel with sulfur content greater than 0.5%
recommended. sulfur content is used, reduce the service interval for
engine oil and filter by 50%.
In all cases, the fuel shall meet the following DO NOT use diesel fuel with sulfur content greater
properties: than 1.0%.
Cetane number of 40 minimum. Cetane number Bio-diesel fuels may be used ONLY if the fuel
greater than 50 is preferred, especially for properties meet DIN 51606 or equivalent specification.
temperatures below -20C (-4F) or elevations above
1500 m (5,000 ft). DO NOT mix used engine oil or any other type of
lubricant with diesel fuel.
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature.
DX,FUEL1 1917FEB991/1
PN=51
Fuels and Lubricants
9000
04 Do Not Use Galvanized Containers
2
MX,FLBT,C 1904JUN901/1
Fuel Tank
TX,45,DH1588 1905FEB991/1
PN=52
Fuels and Lubricants
9000
Diesel Engine Oil 04
3
1922MAY96
T101239
Use oil viscosity based on the expected air John Deere TORQ-GARD SUPREME
temperature range during the period between oil
changes. Other oils may be used if they meet one or more of
the following:
The following oil is preferred:
API Service Classification CG-4
John Deere PLUS-50
Multi-viscosity diesel engine oils are preferred.
If John Deere PLUS-50 engine oil and a John Deere
oil filter are used, the service interval for oil and filter If diesel fuel with sulfur content greater than 0.5% is
changes may be extended by 50 hours. used, reduce the service interval by 50%.
PN=53
Fuels and Lubricants
9000
04 Transmission Oil, Hydraulic System Oil and Differential Oil
4
1910MAY96
T100663
Use oil viscosity based on the expected air John Deere Standard JDM J20C
temperature range during the period between oil John Deere Standard JDM J20D
changes.
Use the following oil when a biodegradable fluid is
The following oils are preferred: required:
1
BIO-HY-GARD meets or exceeds the minimum biodegradability of
80% within 21 days according to CEC-L-33T-82 test method.
2
BIO-HY-GARD should not be mixed with mineral oils because this
reduces the biodegradability and makes proper oil recycling
impossible.
TX,45,JC1864 1919AUG991/1
PN=54
Fuels and Lubricants
9000
Mechanical Front Wheel Drive Oil 04
5
1905JAN89
T6247AB
Depending on the expected air temperature range John Deere API GL-5 Gear Oil
between oil changes, use oil viscosity shown on the Oils meeting API Service GL-5 (MIL-L-2105B or
chart above. MIL-2105C)
The following oils are recommended: Oil meeting MIl-L-10324A may be used as arctic oil.
T82,45,C11 1915MAR931/1
PN=55
Fuels and Lubricants
9000
04 Grease
6
1927MAR95
T8358AI
Use grease based on NLGI consistency numbers and John Deere HIGH TEMPERATURE EP GREASE
the expected air temperature range during the service John Deere GREASE-GARD
interval.
Other greases may be used if they meet one of the
The following greases are preferred: following:
TX,45,DH1576 1921JAN921/1
PN=56
Fuels and Lubricants
9000
Alternative and Synthetic Lubricants 04
7
DX,ALTER 1918MAR961/1
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet information and recommendations.
certain specifications and performance requirements.
DX,LUBMIX 1918MAR961/1
PN=57
Fuels and Lubricants
9000
04 Diesel Engine Coolant
8
The engine cooling system is filled to provide protection at lower temperatures is required, consult
year-round protection against corrosion and cylinder your John Deere dealer for recommendations.
liner pitting, and winter freeze protection to -37C
(-34F). Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
The following engine coolant is preferred for service: water is recommended for mixing with ethylene glycol
base engine coolant concentrate.
John Deere COOL-GARD Prediluted Coolant
IMPORTANT: Do not use cooling system sealing
The following engine coolant is also recommended: additives or antifreeze that contains
sealing additives.
John Deere COOL-GARD Coolant Concentrate in a
40 to 60% mixture of concentrate with quality water. Coolant Drain Intervals
Other low silicate ethylene glycol base coolants for Drain the factory fill engine coolant, flush the cooling
heavy-duty engines may be used if they meet one of system, and refill with new coolant after the first 3
the following specifications: years or 3000 hours of operation. Subsequent drain
intervals are determined by the coolant used for
ASTM D5345 (prediluted coolant) service. At each interval, drain the coolant, flush the
ASTM D4985 (coolant concentrate) in a 40 to 60% cooling system, and refill with new coolant.
mixture of concentrate with quality water
When John Deere COOL-GARD is used, the drain
Coolants meeting these specifications require use of interval may be extended to 5 years or 5000 hours of
supplemental coolant additives, formulated for operation, provided that the coolant is tested annually
heavy-duty diesel engines, for protection against AND additives are replenished, as needed, by adding
corrosion and cylinder liner erosion and pitting. a supplemental coolant additive.
A 50% mixture of ethylene glycol engine coolant in If COOL-GARD is not used, the drain interval is
water provides freeze protection to -37C (-34F). If reduced to 2 years or 2000 hours of operation.
DX,COOL3 1905FEB991/1
PN=58
Section 9005
Operational Checkout Procedure
Contents 9005
Page
PN=1
Contents
9005
PN=2
Group 10
Operational Checkout Procedure
Operational Checkout Procedure
Use this procedure to check all systems and functions Operational Checkout Record Sheet and record the
on the machine. results of each check on this sheet.
9005
This checkout procedure is designed so technician can At the end of each check, if no problem is found (OK:), 10
make a quick check of the operation of machine while you will instructed to GO TO NEXT CHECK. If problem 1
sitting in operators seat. (NOT OK:) is indicated, you will be given repair
required or CTM number. If verification is needed, you
A location will be required which is level, has adequate will be given next best source of information after GO
space to complete the driving checks and to work TO:
machine. The engine, power train and hydraulic oil
must be at operating temperature. Group 10 (System Operational Checks)
Complete the necessary visual checks (oil levels, oil Group 15 (System Diagnostic Information)
condition, external leaks, loose hardware, loose
linkage) prior to doing the checkout procedure. Group 20 (Adjustments)
TX,D300,DS1984 1906APR951/1
UN07SEP88
M44215
CED,TX03679,5015 1905FEB991/1
CED,TX03679,5016 1905FEB991/1
PN=61
Operational Checkout Procedure
UN07SEP88
2 Use the CTM in conjunction with this machine manual.
M44215
CED,TX03679,5017 1905FEB991/1
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
CED,TX03679,5019 1905FEB991/1
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
CED,TX03679,5016 1905FEB991/1
CED,TX03679,5018 1905FEB991/1
PN=62
Operational Checkout Procedure
UN07SEP88
Use the CTM in conjunction with this machine manual. 3
M44215
CED,TX03679,5014 1905FEB991/1
1/1
LOOK: Front wheel drive indicator light (if equipped) must be ON.
PN=63
Operational Checkout Procedure
1/1
Turn key switch to BULB CHECK position. NOT OK: If motor starts
and bulb check position is
OK, key switch failed or
LOOK: On machines S.N. 872256 all monitor indicators and SERVICE REQUIRED
INDICATOR light must be on, STOP must flash and alarm must "BEEP". On machines there is a short in the
S.N. 872257 all monitor indicators , SERVICE REQUIRED INDICATOR light and wiring. Go to Section
STOP must be on, and alarm must "BEEP". 9015 Key Switch Test.
1/1
PN=64
Operational Checkout Procedure
1/1
PN=65
Operational Checkout Procedure
9005
10
6
T7447AG UN04JAN91 T7447AI UN04JAN91 T7447AH UN04JAN91
LOOK: FNR/range lever must align with neutral position to quadrant when in neutral
(center) detent position.
LOOK: Does pointer on range handle line up wtih correct gear number on FNR/range
handle?
1/1
Move FNR/range lever to reverse position and turn key to START position.
LISTEN: Reverse warning alarm must sound when FNR/range lever is in reverse
position.
1/1
1/1
PN=66
Operational Checkout Procedure
Park Brake Indicator and IMPORTANT: If engine low oil pressure indicator light stays ON, stop engine OK: Go to next step in
Tachometer/Hour Meter immediately and check oil level. this check.
Circuit Check
NOT OK: If engine low oil
pressure indicator light
stays on, stop engine
9005
immediately and check oil
10
level. Go to Group
7
9010-Diagnose Engine
Malfunctions, Low Oil
Pressure.
T7447AH UN04JAN91 T7394BH UN10DEC90
(S.N. 872256) NOT OK: If alternator
indicator light is on,
increase engine speed to
1200 rpm and alternator
light must go out. Go to
Section 9015 Charging
Circuit Checks.
LOOK: On units S.N. 872256 park brake indicator and STOP indicator lights must be
on and flashing, all other lights must go out. On units S.N. 872257 park brake
indicator and STOP indicator lights must be on, all other lights must go out. Alarm
must "BEEP".
1/2
PN=67
Operational Checkout Procedure
NOTE: Hour meter turns very slowly (one tenth hour every six minutes). OK: Go to next check.
T103007 UN30OCT98
(S.N. 872257)
LOOK: Park brake indicator and STOP light must go out. Alarm must stop "BEEPING".
19 2/2
PN=68
Operational Checkout Procedure
(S.N. 830204)
(S.N. 830205)
1/1
Engine Speed Control Depress speed control pedal. OK: Go to next check.
Pedal Linkage Check
LISTEN: Engine speed must be the same as with speed NOT OK: Adjust Speed
control lever in fast idle position. Control Linkage Override.
Go to Group 9010-20
Engine Speed Control
Linkage.
T6171AF UN09DEC88
1/1
PN=69
Operational Checkout Procedure
Start Aid Check (If Operate engine at slow idle. OK: Go to next check.
Equipped)
Push start aid button once. NOT OK: Check can
contents by shaking.
LISTEN: Engine speed must increase then return to slow idle.
NOT OK: Check fuse. Go
9005
to Section 9015Start
10
Aid Check.
10
1/1
1/1
T6171AH UN09DEC88
After machine has moved for 3 seconds, depress and
hold left brake pedal.
1/1
1/1
PN=70
Operational Checkout Procedure
Service Brake Retraction Park machine on inclined surface. OK: Go to next check.
Check Lock service brakes together.
NOT OK: Do Service
Park brake OFF. Brake and Pedal
Adjustment, Group
Shift FNR/range lever to neutral. 9025-20.
9005
10
Release service brakes. NOT OK: Do Service
11
Brake Valve Test, Group
T6171AI UN09DEC88
LOOK: Does front of machine pull to the side when 9025-25.
service brakes are released?
1/1
Service Brake Pressure NOTE: Axles and hydraulic oil must be at operating temperature. OK: Go to next check.
Indicator And Brake
Accumulator Precharge NOT OK: If fewer than 7
(S.N 872257) brake pedal applications
are required to turn brake
pressure indicator ON,
accumulator charge
pressure may be low. Go
to Brake Accumulator
T103007 UN30OCT98
Precharge Test in Group
T6171AH UN09DEC88
9025-25.
1/1
FEEL: (SN 872256) Pedals must have approximately 6 NOT OK: Adjust brake
mm (0.25 in.) free-travel above the rest position. light switches to get
free-travel. For (S.N.
(SN 872257 ) Pedals must have no free-travel above 872256) go to Repair
the rest position. Manual. For (SN
872257 ) go to Service
T6171AG UN09DEC88
Brake Valve and Pedal
Adjustment in Group
9020.25 .
1/1
PN=71
Operational Checkout Procedure
Brake System Leakage Start engine and run for 10 seconds. OK: Go to next check.
Check
Unlock brake pedals. NOT OK: Excessive
leakage in brake system.
Run engine at slow idle. Depress and hold right brake Go to Group 9025-25
pedal. Brake Valve Leakage
9005
Test.
10
Release brake pedal.
12
NOT OK: Inspect horn,
T6171AH UN09DEC88
LISTEN/LOOK: Engine speed will not decrease as pedal brake, light fuse.
is depressed.
OK: Go to Section
LISTEN: There must NOT be any noticeable engine 9015Lighting Circuit.
speed change when pedal is released or depressed.
1/1
Brake Pedal Latch Check Latch the brake pedals together. OK: Go to next check.
Kick each brake pedal three times. NOT OK: Repair latch.
T6171AI UN09DEC88
1/1
PN=72
Operational Checkout Procedure
T103007 UN30OCT98
(S.N. 872257)
Disengage MFWD (if equipped). Raise loader bucket to transport height, stabilizers
fully up, and backhoe off the ground.
Operate engine at 1000 rpm and drive approximately 7 m (20 ft) before moving the
park brake switch to the "ON" position.
LOOK: On machines with S.N. 872256, park brake switch light (B) will be ON. On
machines with S.N. 872257, park brake indicator in monitor will be on.
1/1
PN=73
Operational Checkout Procedure
1/1
1/1
Steering System Operate engine at approximately 1000 rpm. OK: Go to next check.
Operational Check
Turn steering wheel from full left to full right several times. NOT OK: Check
hydraulic oil level.
LOOK: Front wheels must move smoothly in both directions.
NOT OK: Check Steering
LOOK: When steering wheel is stopped, front wheels must stop moving. System Leakage. Go to
Group 9025-25.
NOTE: Internal leakage or sticking steering valve spool can cause wheels to continue
to move after steering wheel is stopped.
1/1
Steering System Leakage NOTE: Hydraulic oil must be at operating temperature for this test. OK: Go to next check.
Check
Run engine at approximately 1000 rpm. Turn steering wheel until wheels are against NOT OK: Go to Steering
stop. Continue turning steering wheel, using approximately 11.3 Nm (100 lb-in.) force. System Leakage Test in
Group 9025-25.
Repeat leakage check turning steering wheel to the left.
NOT OK: Repair steering
LOOK: Steering wheel should turn approximately 5 rpm, left or right. cylinder. Go to Repair
Manual.
NOTE: Use good judgment. Excessive steering wheel rpm does not mean steering
performance will be affected. NOT OK: Repair steering
valve. Go to Repair
Manual.
1/1
PN=74
Operational Checkout Procedure
Steering Priority Valve Operate engine at slow idle. OK: Go to next check.
Check
Turn steering wheel left to right and note effort needed NOT OK: If steering
to turn wheel. wheel effort is more or
wheel will not turn as
Operate the loader raise function and turn steering wheel hydraulic function is
9005
at the same time. Note effort needed to turn the steering activated, a problem is
10
wheel. indicated in steering
15
priority valve. Go to
T6295AC UN19OCT88
FEEL: Effort to turn steering wheel must NOT increase Steering Valve Pressure
when turning the wheel while a hydraulic function is check.
activated.
1/1
Steering Priority Valve Put front wheels on dirt or gravel. OK: Go to next check.
Pressure Check
Raise rear of machine so tires are just off ground using NOT OK: If front wheels
stabilizers. do not turn in either
direction, pressure setting
Operate engine at approximately 1000 rpm. is too low. Go to Group
9025-25 Priority Valve
Starting with front wheels in the straight ahead position, Test.
T6295AC UN19OCT88
turn steering wheel to the left and right while raising
loader.
LOOK: Wheels must turn to the left and to the right while
loader is being raised.
1/1
1/1
1/1
PN=75
Operational Checkout Procedure
9005 1/1
10
16
Transmission Warm-Up OK: Go to next check.
Procedure CAUTION: Machine will try to move forward during this procedure. Use
service brakes plus park brake to hold machine stationary. NOT OK: Repeat
warm-up procedure.
IMPORTANT: Transmission oil must be at correct level and operating
temperature.
Start engine.
1/1
PN=76
Operational Checkout Procedure
Transmission Shift Position machine on hard level surface. OK: Go to next check.
Check
Run engine at approximately 1500 rpm. NOT OK: No
corresponding change in
Shift transmission into all of the 4 forward and 2 reverse speeds, driving a short speed of machine or
distance in each speed. wrong speed when a shift
9005
is made may be caused
10
FEEL: FNR/range lever must move freely into each speed. On machines with S.N. by a stuck shift spool in
17
872256, there must be 4 forward and 2 reverse speeds. On machines with S.N. transmission control
872257, there must be 4 forward and 3 reverse speeds. valve, or a failed O-ring
on solenoid valve. Go to
LOOK: The FNR/range lever must stop at each detent. Repair Manual.
LISTEN: Excessive gear and transmission noise must not be heard in any gear. NOT OK: Excessive
engine pull-down when
NOTE: When shifting to 3rd and 4th, it is normal for torque converter to slip but shift is made may be
machine must not stop. caused by "drag" in
transmission clutch or
brake element. Go to
Brake Drag Check in this
section.
1/1
Front Wheel (Toe-In) Drive machine in 4th forward on a surface with loose OK: Go to the next
Alignment Check material such as gravel. check.
LOOK: Material behind front tires must not be thrown NOT OK: If material is
excessively inward or outward. thrown, excessive tire
wear will result. Go to
Group 9020-20Adjust
Toe-In.
T6264AI UN22OCT91
1/1
PN=77
Operational Checkout Procedure
Engine and Position machine with loader bucket at ground level against a dirt bank or immovable OK: Go to next check.
Transmission Check object.
NOT OK: If engine stalls,
Shift transmission into 1st gear. check if fuel supply
shut-off is closed. Check
Apply differential lock. for restricted fuel or air
9005
filters. Go to Group
10
Move FNR/range lever to forward position. Increase engine speed to fast idle. 9010-10 Engine Power
18
Check.
LOOK: Engine must NOT stall.
NOT OK: If the wheels
LOOK: Rear wheels must NOT stall. can be easily stalled, go
to Group 9020-10 Engine
NOTE: This test will give a general indication of engine and transmission performance. and Transmission Check.
If loader bucket is positioned above the centerline of front axle and ground conditions
are soft, the engine can be stalled due to the weight transferred to rear wheels and
tractive conditions. The preceding situations should not be confused with low engine
power.
1/1
MFWD OFF.
PN=78
Operational Checkout Procedure
MFWD OFF.
T6264AM UN19OCT88
Operate machine in all speeds forward and reverse.
MFWD OFF.
PN=79
Operational Checkout Procedure
MFWD OFF.
T6264AM UN19OCT88
Operate machine in all speeds forward and reverse.
MFWD OFF.
PN=80
Operational Checkout Procedure
MFWD OFF.
T6264AM UN19OCT88
Operate machine in all speeds forward and reverse.
1/1
Transmission Shift Raise rear of machine off ground using stabilizers. OK: Go to next check.
Modulation Check
MFWD OFF. NOT OK: Go to group
9020-15B, Diagnose
Park Brake OFF. Power Train Malfunctions.
T6264AM UN19OCT88
Shift machine from neutral to 1st forward.
1/1
PN=81
Operational Checkout Procedure
B3, C2 Accumulator Perform this check on dirt or loose gravel surface. OK: Go to next check.
Check (S.N. 872256)
Operate machine at approximately 1500 rpm in 1st gear NOT OK: Too aggressive
forward. shifts or "clunk" sound.
Check accumulator
Shift to 2nd gear and observe rear tires. piston. Go to Repair
9005
Manual.
10
LOOK: Rear wheels must not spin (lose traction) as
22
machine comes up to speed. NOT OK: Slow shifts,
T6908BF UN07APR89
check oil level. Replace
FEEL: Unit must not "jerk" aggressively during this shift. transmission or inspect
suction screen. Go to
NOTE: A "clunk" sound will be heard if shift is too Repair Manual.
aggressive.
1/1
C1, B1, B2 Accumulator Operate machine on hard surface such as compacted OK: Go to next check.
Check (S.N. 872256) clay or road.
NOT OK: Slow shifts can
Operate machine at approximately 1500 rpm in 2nd be caused by low oil level
forward. or restricted filter. Repair
as required. Do
Make several forward to reverse shifts. Count the Transmission Drag
number of seconds (one thousand oneone thousand Checks in this group.
T6908BF UN07APR89
two, etc.) required for machine to change direction and
get up to speed. NOT OK: Too fast shifts
or "clunk" sound. Inspect
LOOK/FEEL: Machine must change direction within 1-1/2 accumulator piston. Go to
seconds and be up to speed in 3 seconds. Repair Manual.
1/1
PN=82
Operational Checkout Procedure
NOTE: If wheels turn, apply service brakes until wheels stop and note change in rpm
on tachometer.
If depressing brake pedal causes rpm to drop enough that difference can be seen on
tachometer (15 rpm), it indicates warped disks in that pack. Lube oil does not affect
these "drag" checks because they are done at operating temperature and at slow idle.
If "drag" is caused by lube oil within the transmission clutches and brakes, "drag" will
increase when oil is cold. When engine speed is increased to 1500 rpm or higher,
"drag" is reduced because lube relief valve opens and returns excessive cold oil to
sump. It is normal for wheels to "creep" with cold oil as engine speed is increased but
to stop moving at speeds above 2000 rpm. If "drag" is caused by warped clutch or
brake disks or plates, "drag" will be seen at any oil temperature and will increase
proportionally as engine speed is increased.
1/1
C2 Clutch, B3 Brake Raise wheels off ground with stabilizers and loader OK: Go to next check.
Drag Check (S.N. bucket.
872256) NOT OK: Engine speed
Release park brake. drops, C2 is dragging.
Repair transmission, go
Shift transmission to 1st forward. to Repair Manual.
Adjust engine speed to 1000 rpm per tachometer. NOT OK: Engine speed
T6295AD UN19OCT88
increases, B3 is dragging.
Shift transmission to 2nd forward. Repair transmission, go
to Repair Manual.
LOOK: Wheels must increase in speed but engine rpm
must return to 1000 rpm.
1/1
PN=83
Operational Checkout Procedure
Differential Lock Check Raise wheels off ground with stabilizers and loader OK: Go to next check.
bucket.
NOT OK: If one wheel
Unlock brake pedals. Turn MFWD switch (if equipped) stops, on machines with
off. S.N. 872256, go to
Differential Lock Pressure
9005
Operate machine at approximately 1500 rpm in 1st Test in Group 9025-25.
10
forward. On machines with S.N.
24
872257, go to
T6295AD UN19OCT88
Depress differential lock pedal or switch. Differential Lock Pressure
Test in Group 9020-25.
Apply one brake pedal until engine rpm drops.
NOT OK: If engine rpm is
LOOK/FEEL: Both wheels must turn at same speed. reduced and stays down
while only differential lock
Release differential lock pedal or switch. is depressed, excessive
leakage is indicated. For
LOOK: Pedal or switch must return to up position and machines with S.N.
engine speed must return to 1500 rpm. 872256 go to Differential
Lock Leakage Test in
Release brake pedal and move transmission control Group 9025-25. For
levers to neutral. machines with S.N.
872257 go to
Reduce engine speed to slow idle. Differential Lock Leakage
Test in Group 9020-25.
Depress differential lock pedal or switch and note engine
rpm change.
1/1
Differential Gear and NOTE: Hold the wheel being braked stationary during OK: Go to next check.
Pinion Noise Check this check or brake chatter could be confused with
differential gear noise. NOT OK: If wheels do
not turn at same speed,
Raise wheels off ground with stabilizers and loader brake drag is indicated.
bucket. Go to Brake Drag Check
in Group 9025-10.
Operate engine at approximately 1500 rpm in 1st gear
T6295AD UN19OCT88
forward. NOT OK: Excessive
noise. Check differential
LOOK: Both wheels must turn at same speed. oil level. Inspect pinion
assembly, go to CTM43
Depress right brake pedal until wheel stops. Observe left for machines S.N.
wheel. 872256. On machines
with S.N. 872257, see
LOOK: Wheel being braked must stop and opposite Group 0200 in the Repair
wheel must increase in speed. Manual.
1/1
PN=84
Operational Checkout Procedure
1/1 9005
10
25
MFWD Clutch Drag Raise machine off ground with stabilizers and loader OK: Go to next check.
Check bucket.
NOT OK: If light is on,
Shift transmission to 2nd gear and FNR/range lever to check fuse. Go to Group
forward position. 9020-25 MFWD Clutch
Pressure Test.
Run engine speed at 1000 rpm.
NOT OK: If rear wheels
T6264AM UN19OCT88
Check that MFWD control is disengaged (switch up/light stop, MFWD control valve
off). problem or clutch "drag"
is indicated. Repeat
Lower front wheels to ground and raise bucket above check using 1st gear.
ground.
NOT OK: If front wheels
LOOK: MFWD indicator light must be off. turn, or rear wheels stall,
MFWD solenoid valve
LOOK: Front wheels may turn while wheels are off problem is indicated. Go
ground but must stop when lowered to ground. Rear to Group 9020-25 MFWD
wheels must continue to turn. Clutch Pressure Test.
1/1
PN=85
Operational Checkout Procedure
T118248 UN03NOV98
(S.N. 872257)
Turn steering wheel for a full left or right turn and observe the front tires.
LOOK: Observe how the front tires attempt to slide sideways (side load) and the
amount of tire scuffing. MFWD indicator lights must be on.
LOOK: Tire side loading and scuffing must stop when MFWD is disengaged.
NOTE: If tires attempt to slide sideways and tire scuffing is seen with MFWD applied,
limited-slip differential is working and power is being transmitted to MFWD.
1/1
MFWD Gear and Pinion Drive machine at transport speed with MFWD applied, then disengaged. OK: Go to next check.
Noise Check
LISTEN: MFWD must NOT "whine" when disengaged. NOT OK: If MFWD
"whines", check oil levels
and fill to specification.
1/1
PN=86
Operational Checkout Procedure
1/1 9005
10
27
Hydraulic Pump OK: Go to next check.
Performance Check
NOT OK: If boom down
relief does not load
engine, check main pump
stand-by pressure. Go to
Group 9025-25.
T6295AH UN19OCT88
NOT OK: Go to Group
9025-25, Backhoe Relief
NOTE: If hydraulic oil is not at operating temperature, heat hydraulic oil until loader Valve Test.
and backhoe cylinders feel warm to touch using following procedure:
NOT OK: If cycle times
Cover front of radiator to stop air flow. are slow, check hydraulic
charge system. Go to
Activate backhoe boom down function and run engine at 2000 rpm. Group 9025-25 Surge
Relief Pressure Test and
NOTE: Activating boom down may load engine, boom down relief valve is set too high Charge Pressure Test.
or hydraulic pump stand-by pressure too low.
NOT OK: Go to Group
Operate all functions periodically to distribute heated oil to all cylinders. 9025-25 Hydraulic Pump
Flow Test.
Lower stabilizers.
Put backhoe at maximum reach with bucket fully dumped at ground level.
Measure cycle time by simulating loading the bucket, retracting the dipperstick and
raising the boom to the boom cylinder cushion. Do not time boom cylinder through
cushion.
NOTE: Take the average cycle time for at least three complete cycles. This average
cycle time will give a general indication of hydraulic pump performance.
1/1
PN=87
Operational Checkout Procedure
Hydraulic System Charge Raise machine with stabilizers until wheels are 150 mm OK: Go to next check.
and Return System (6.0 in.) off ground.
Check NOT OK: Check charge
Fully extend dipperstick, putting bucket in loaded position pump pressure. Test
and lower boom until dipperstick is 45 to the ground. hydraulic charge system.
Go to Group 9025-25
9005
Slowly retract dipperstick. Bucket must clear ground. Surge Relief Pressure
10
Test.
28
Fully extend dipperstick.
T118265 UN05NOV98
NOT OK: Check charge
Run engine at 1200 rpm. pump flow. Go to Group
9025-25 Charge Pump
Retract dipperstick while holding control valve fully open. Flow Test.
1/1
Hydraulic Control Valve Raise loader until bucket is 1 m (3 ft) off ground with the bucket level. OK: Go to next check.
Lift Check Test
Position backhoe at maximum reach with bottom of bucket level with ground, 1 m (3 ft) NOT OK: If a function
off ground. cylinder moves, problem
could be a leak in
Stop the engine. cylinder in lift check.
Inspect and repair lift
Activate each function one at a time: check. Go to Repair
Manual.
Loader boom raise
Loader bucket rollback
Backhoe boom up
Dipperstick extend
Backhoe bucket dump
LOOK: These functions must NOT move when the control lever is activated.
NOTE: It is normal for a function to jump upward but must not lower.
1/1
PN=88
Operational Checkout Procedure
Backhoe Circuit Leakage Put backhoe in transport position and set boom and OK: Go to next step in
Checks swing lock. this check.
Boom up
Bucket load
Dipperstick retract
Extendible dipperstick retract (if equipped)
Boom down
Swing left, then right
1/2
PN=89
Operational Checkout Procedure
19 2/2
LISTEN: When functions are activated, engine rpm must NOT decrease.
NOTE: Leakage return passages are used in boom valve. When boom cylinders are
retracted and valve is "metered", rpm will decrease and leakage within circuit will be
apparent. This is normal.
1/1
PN=90
Operational Checkout Procedure
Cylinder Cushion Check Run engine at slow idle. OK: Go to next check.
LISTEN: Note sound and speed as cylinders near the end of their stroke.
LOOK: Speed of cylinder rod must decrease near the end of its stroke.
LISTEN: Must hear oil flowing through orifice as cylinder rod nears the end of its
stroke.
1/1
Backhoe and Loader FEEL: Backhoe cylinder must be warm to touch 38 OK: Go to next check.
Function Drift Check 52C (100125F). If cylinders are not warm, heat
hydraulic oil. NOT OK: Use good
judgment in determining if
Raise machine off ground with stabilizers. the amount of drift is
objectionable for the type
Position backhoe bucket at a 45 angle to the ground. of operation that the
Lower boom until bucket cutting edge is 50 mm (2.0 in.) machine is performing.
T6171AQ UN25MAY89
off ground.
NOT OK: Isolate which
Position loader bucket at the same angle and distance function is leaking. Go to
from ground as backhoe bucket. Group 9025-25, Cylinder
Drift Test.
Run engine at slow idle and observe bucket cutting
edges.
1/1
PN=91
Operational Checkout Procedure
Loader Boom Float and Put loader at maximum height position with bucket OK: Go to next step in
Return-to-Dig Check dumped. this check.
LOOK: Loader control lever must disengage from the OK: Go to next step in
bucket rollback detent when the bucket is level. this check.
LOOK: When the bucket is at ground level, bucket must OK: Go to next check.
be level and the bucket indicator pointer must be aligned
with mark on the boom pivot. NOT OK: Adjust linkage
as necessary. Go to
NOTE: When return-to-dig is used with loader boom in Group 9025-20 Loader
full up position, the bucket leveling linkage will move the Bucket Level Indicator
bucket control valve out of return-to-dig position before and Return-to-Dig
bucket is actually level. Adjustment.
T7374CH UN04OCT90
1/1
Bucket Leveling Linkage NOTE: The loader bucket leveling feature functions during the boom raise cycle only. OK: Go to next check.
Check
Put bucket in the rollback position with the boom near NOT OK: Adjust linkage
the ground level. on the loader control
valve. Go to Group
Raise the loader and at the same time, hold the control 9025-20. Loader Bucket
lever in the bucket rollback position. Level Indicator and
Return-to-Dig Adjustment.
Observe bucket and loader control lever as the loader
rises.
T7374CJ UN05OCT90
LOOK/FEEL: Loader control lever must move into the
bucket dump position and the bucket dump function
must slowly activate. When the loader control lever
moves to activate the bucket dump function, the bucket
position must remain stationary the remainder of the
loader boom raise cycle.
1/1
PN=92
Operational Checkout Procedure
1/1 9005
10
33
All Lines and Hoses Engine OFF. OK: Check complete.
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?
1/1
1/1
Are fan blades in good condition, not worn, bent, broken or missing?
1/1
PN=93
Operational Checkout Procedure
Evaporator Check Remove seat and heater/blower cover. OK: Check complete.
1/1
1/1
Is sensing tube inserted into evaporator core and secured in place? NOT OK: If tube is
positioned in evaporator
incorrectly, re-route.
1/1
Expansion Valve Check Is expansion valve outlet line free of frost? OK: Check complete.
Is insulating tape wound tightly around outlet line and is tape in good condition? NOT OK: Go to
Expansion Valve
Operation in Group
9031-05.
1/1
Cab Door and Window Open and close door and windows. Inspect seals. OK: Check complete.
Seals Check
Do door and windows contact seals evenly? NOT OK: Adjust door and
windows to close against
Are seals in position and in good condition? seals properly. Replace
seals as necessary.
1/1
PN=94
Operational Checkout Procedure
Engine OFF.
1/1
T7835AW 1930SEP92
Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high
speed.
1/1
PN=95
Operational Checkout Procedure
Wait several minutes for any warm air in duct system to escape.
1/1
T101677 UN28JUN96
1/1
PN=96
Operational Checkout Procedure
Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high
speed.
1/1
1/1
Compressor Clutch Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner switch ON. OK: Check complete.
Check
Does compressor clutch "click" as switch is pushed? NOT OK: Replace
compressor clutch.
1/1
1/1
PN=97
Operational Checkout Procedure
LOOK: The vacuum release valve (center of cap rubber seal) must move freely and
holes must not be plugged.
1/1
Hose and Water Pump Inspect all radiator and heater hoses and water pump for cracks or leaks. OK: Check complete.
Check
LOOK: Radiator hoses must not be brittle or show signs of leaks. NOT OK: Replace
defective hoses, tighten
Check all hose clamps. clamps as necessary.
LOOK: All hose clamps must be tight. NOT OK: Repair water
pump. Go to Engine
Squeeze lower radiator hose. CTM.
1/1
Radiator Bubble Check Fill radiator to proper level. OK: Check complete.
1/1
PN=98
Operational Checkout Procedure
Fan and Fan Shroud Inspect fan and shroud clearance. OK: Check complete.
Check
inspect fan blades for damages. NOT OK: If fan blades
have any bends, replace
Check fan belts for wear. fan. If fan has nicks,
locate interference and
9005
LOOK: Fan blades must not have any nicks or bends. repair. See Repair
10
Manual.
39
LOOK: Make sure there is no oil or grease on fan belt or
pulleys. NOT OK: Replace fan
belt. Go to Repair
LOOK: Inside surface of fan belt must not have any Manual.
cracks or contact bottom of pulley groove.
NOT OK: If fan is
NOTE: If the fan blade has been installed backwards installed backward,
about 50% of its capacity is lost. remove and install
correctly. Go to Repair
LOOK: Cupped portion of fan blades must be away from Manual.
radiator.
T6171CB UN25MAY89
1/1
1/1
LOOK: If can is missing, lower portion of holder must be upside down to seal opening
in upper holder.
Inspect plastic line from top of starting aid to air intake manifold.
LOOK: There must NOT be any kinks or breaks in line and ends must be installed
securely.
Check for arrow on either starting aid nozzle in air intake manifold.
LOOK: Arrow must be pointed AGAINST air flow of air intake manifold.
1/1
PN=99
Operational Checkout Procedure
T105143 UN10JAN97
AClamp
BEther Aid Can
CBase
DCap
Check to be sure ether aid can (B) is tight and clamp (A)
T6488GE UN23AUG93
is tight
1/1
PN=100
Operational Checkout Procedure
Exhaust Smoke Check NOTE: Engine must be at operating temperature before performing this check. OK: Check complete.
1/1
1/1
NOTE: If oil level is high, check for fuel in oil. Drain a small quantity of oil and check
for anti-freeze. If oil level is low check for oil leaks or oil seal problems in engine.
Remove dipstick and check condition of oil. Clean oil from dipstick with finger and
thumb.
LOOK: Oil must NOT be milky, grainy or contain fuel oil or anti-freeze.
1/1
1/1
PN=101
Operational Checkout Procedure
Engine Fuel System Engine off, speed control lever at fast idle position. OK: Check complete.
Inspection Checks
Inspect fuel drain, cap strainer and inside fuel tank (with flashlight). NOT OK: If air "hissing"
from tank or enters tank
Operate pump primer by hand. when cap is removed,
replace fuel cap.
9005
Inspect all fuel lines, line clamps and speed control linkage stop.
10
NOT OK: If excessive
42
Inside of fuel tank must NOT contain any foreign matter. debris is found in the
bottom of the fuel line,
LOOK: No fuel leakage must be noted at any of the fuel line connections. The injection observe flow. If flow is
line rubber clamps must be in position and NO wiring banded to the injection lines. restricted, clean tank.
1/1
1/1
Increase engine speed to fast idle with speed control pedal and record rpm.
1/1
PN=102
Operational Checkout Procedure
Engine Power Check NOTE: Engine and transmission must be at operating temperature using No. 2 fuel. OK: Check complete.
(S.N. 872256)
Start engine. NOT OK: RPM too low.
Inspect air and fuel filters.
Hold service brake.
NOT OK: Above 2000
9005
Put transmission in fourth gear. rpm, inspect transmission.
10
Go to Group 9020-10.
43
Operate engine at fast idle.
1/1
Engine Power Check NOTE: Engine and transmission must be at operating temperature using No. 2 fuel. OK: Check complete.
(S.N. 872257 )
Start engine. NOT OK: RPM too low.
Inspect air and fuel filters.
Hold service brake.
NOT OK: Above 2100
Put transmission in fourth gear. rpm, inspect transmission.
Go to Group 9020-10.
Operate engine at fast idle.
1/1
PN=103
Operational Checkout Procedure
1/1
Engine Blow-By Check Run engine at fast idle and check blow-by tube. OK: Check complete.
LOOK: Fumes should be barely visible at the blow-by tube at fast idle with no load. NOT OK: If blow-by is
excessive, see Engine
NOTE: Excessive blow-by indicates that piston rings and cylinder liners do not seal off CTM.
the combustion chamber. This is a comparative check that requires some experience
to determine excessive blow-by.
1/1
Loose or Worn Engine Run engine at slow idle. OK: Check complete.
Parts
Depress brake pedals. NOT OK: Go to Abnormal
Engine Noise in this
Shift to first forward. section.
1/1
1/1
PN=104
Operational Checkout Procedure
Front Light Switch Turn key switch to ON position. OK: Go to next check.
Push front light rocker switch to middle position. NOT OK: Check fuse and
bulbs.
LOOK: Two front lights, two red tail lights and gauge lights must come on.
OK: Check switch. Go to
9005
Push front light rocker switch in completely. Group 9015-15, Drive and
10
Work Light Circuit.
45
LOOK: All four front lights, two red tail lights and gauge lights must come on.
1/1
Rear Light Switch Check Turn key switch to ON position. OK: Go to next check.
Push side console rear light rocker switch in. NOT OK: Check fuse and
bulbs.
LOOK: Rear light(s) must come on.
OK: Check switch. Go to
Section 9015, Drive and
Work Light Circuit.
1/1
Turn Signal Check Turn key switch to ON position. OK: Go to next check.
Push down right side of turn signal switch. NOT OK: Check fuses
and wiring. Go to Sub
LOOK: Right front and right rear amber lights must flash. Right indicator light on top of System
steering column must flash. Left front and left rear amber lights, and left indicator light Diagnostics/Indicator
on top of steering column will stay completely lit. Circuit, Section 9015-15.
LOOK: Left front and left rear amber lights must flash. Left indicator light on top of
steering column must flash. Right front and right rear amber lights, and right indicator
light on top of steering column will stay completely lit.
1/1
Push bottom of warning light rocker switch in. NOT OK: Check fuses
and bulbs.
LOOK: Both front and rear amber lights must come ON. Both turn signal indicators and
light in warning light rocker switch must flash. OK: Check 4-way flasher
switch. Go to Section
9015, Brake Light Circuit.
1/1
PN=105
Operational Checkout Procedure
Horn Circuit Check Turn key switch to ON position. OK: Go to next check.
1/1
Start Aid Check (If Operate engine at slow idle. OK: Go to next check.
Equipped)
Push start aid button once. NOT OK: Check can
contents by shaking or
LISTEN: Engine speed must increase then return to slow idle. weight.
IF OK: Go to Section
9015, Start Aid Circuit.
1/1
1/1
Left Cab Door Latch and Unlatch door. OK: Go to next check.
Opener Check
Observe door as it opens. NOT OK: Adjust cab
door. Go to repair
Pull door closed and latch it. manual.
LOOK: Cab door must contact door stop bumper before door cylinder bottoms.
1/1
Right Cab Door Latch Unlatch door and pull door open. OK: Go to next check.
and Opener Check
Close and latch door. NOT OK: Adjust door. Go
to repair manual.
FEEL: Cab door latch must work freely.
1/1
PN=106
Operational Checkout Procedure
Rear Window Latch and Squeeze latches on both sides of middle rear window. Lower window to rubber OK: Go to next check.
Opener Checks bumpers.
NOT OK: Check for
Push latch releases on upper rear window. obstructions. Go to repair
manual.
Observe window as it opens.
9005
10
Push window up and into window catches and note fit.
47
Observe cylinders while closing window. Raise middle window and push into latches.
LOOK: The gas-filled cylinders must slowly assist raising the window to open position.
Cylinders must not be at end of travel when closing window.
LOOK: The window catches must hold and not bow the window in the up position.
1/1
Side Window Checks Open left and right rear side window. OK: Go to next check.
1/1
1/1
PN=107
Operational Checkout Procedure
Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high
speed.
1/1
T7860AB UN06OCT92
1/1
Push rear wiper rocker switch all the way in. OK: Check rear wiper.
Go to Section 9015,
LOOK: Rear wiper must operate and have two speeds. Wiper/Washer Circuit.
1/1
PN=108
Operational Checkout Procedure
Front Windshield Wiper Turn key switch to ON position. OK: Go to next check.
Check
Push front wiper rocker switch to first detent, middle position. NOT OK: Check fuse.
Push front wiper switch all the way in. OK: Check front wiper.
Go to Section 9015,
9005
LOOK: Both front wipers must operate and have two speeds. Wiper/Washer Circuit.
10
49
LOOK: Wipers must return to park position.
1/1
Front Windshield Washer Turn key switch to ON position. OK: Go to next check.
Check
Push windshield washer rocker switch in. NOT OK: Check fluid
level, and fluid lines for
LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF blockage.
position.
NOT OK: Check wiring.
Go to Section 9015,
Wiper/Washer Circuit.
1/1
Cab Dome Light and Turn key switch to ON position. OK: Go to next check.
Swivel Light Check
Push dome light switch to ON position. NOT OK: Check fuse and
bulbs.
Push swivel light switch to ON position (S.N. 872256).
NOT OK: Check wiring.
LOOK: Lights must come ON. Go to Group 9015-15,
Dome Light Circuit.
1/1
Seat Linkage Check Move lever (A) to the right. OK: Go to next check.
(S.N. 830204)
Move seat forward and rearward and release lever. NOT OK: Repair linkage.
Go to repair manual.
LOOK: Lever must move freely and lock seat in desired
position.
T7394BD UN29NOV90
1/1
PN=109
Operational Checkout Procedure
Height Adjustable Seat Pull lever (C) up and at the same time remove your OK: Go to next check.
Check (If Equipped) weight from the seat.
(S.N. 830204) NOT OK: Lubricate seat
Raise seat several positions and engage latch. pedestal. Go to repair
manual.
LOOK: Seat must rise upward and must remain in
9005
desired latched position.
10
50
T7394BD UN29NOV90
1/1
Seat Swivel Linkage Pull lever (B) up. OK: Go to next check.
Check (S.N. 830204)
Move seat from loader to backhoe position and engage NOT OK: Lubricate or
latch. repair linkage. Go to
repair manual.
LOOK: Seat latch must move freely and hold seat at the
desired position.
T7394BD UN29NOV90
FEEL: Lever must move freely and hold seat in loader
and backhoe positions.
1/1
Seat Linkage Check (S.N. Lift lever (1). OK: Go to next check.
830205 )
Move seat forward and rearward and release lever. NOT OK: Repair linkage.
Go to repair manual.
LOOK: Does lever move freely and lock seat in desired
position?
T103194 UN20AUG96
1/1
Seat Height Adjustment Turn knob (3) to raise or lower seat to desired position. OK: Go to next check.
Check (S.N. 830205 )
LOOK: Does seat move up or down and remain in NOT OK: Go to repair
desired position? manual.
T103194 UN20AUG96
1/1
PN=110
Operational Checkout Procedure
Seat Swivel Linkage Lift lever (2) up. OK: Go to next check.
Check (S.N. 830205 )
Move seat from loader to backhoe position and engage NOT OK: Lubricate or
latch. repair linkage. Go to
repair manual.
LOOK: Does seat latch move freely and hold seat in
9005
desired position?
10
51
T103194 UN20AUG96
FEEL: Does lever move freely and hold seat in loader
and backhoe positions?
1/1
Seat Back Linkage Lift lever (4) up. OK: Go to next check.
Check (S.N. 830205 )
Position seat back as desired and engage lever. NOT OK: Lubricate or
repair linkage. Go to
FEEL: Does lever move freely and hold seat in desired repair manual.
positions?
T103194 UN20AUG96
1/1
Miscellaneous Check
1/1
Vandal Protection Check Lock right side service access doors and cab doors using the ignition key. OK: Go to next check.
FEEL: All locks must operate freely and key must not stick in locks. NOT OK: Lubricate or
repair lock as necessary.
1/1
Check Periodic Check the periodic maintenance label located inside of OK: Go to next check.
Maintenance Label the hood access door.
NOT OK: Replace decal.
LOOK: Periodic maintenance label decal must be legible.
T6171DG UN09DEC88
1/1
PN=111
Operational Checkout Procedure
T7860AC UN06OCT92
LOOK/FEEL: Boom and swing lock pin must freely enter hooks (B) and fit at bottom of
slot in hooks. Lever must enter locked position and remain locked.
1/1
PN=112
Section 9010
Engine
Contents
Page
Group 20Adjustments
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
JT05800 Digital Thermometer Installation . . .9010-20-1
Slow and Fast Idle Adjustment
(S.N. 830204). . . . . . . . . . . . . . . . . . . . .9010-20-2
(S.N. 830305 ) . . . . . . . . . . . . . . . . . . . .9010-20-4
Adjust Engine Speed Control Linkage
(S.N. 830204). . . . . . . . . . . . . . . . . . . . .9010-20-5
(S.N. 830205). . . . . . . . . . . . . . . . . . . . .9010-20-6
Adjust Speed Control Lever Tension . . . . . . .9010-20-7
Group 25Tests
Cooling System Test . . . . . . . . . . . . . . . . . . .9010-25-1
Radiator Air Flow Test. . . . . . . . . . . . . . . . . .9010-25-2
JT05529 Air Flowmeter Test Record . . . . . . .9010-25-3
Engine Performance Using Turbocharger
Boost Pressure Test . . . . . . . . . . . . . . . . .9010-25-4
Air Intake System Leakage Test . . . . . . . . . .9010-25-6
Fuel Line Leakage Test. . . . . . . . . . . . . . . . .9010-25-7
PN=1
Contents
9010
PN=2
Group 05
Theory of Operation
General Engine Description
John Deere engines are vertical-in-line, valve in head, insert is used on Dubuque engines. A five-piece
4-cycle (stroke) diesel engines. bearing insert normally is installed on Saran engines.
The five-piece bearing has high thrust load capability.
Direct fuel injection is provided by a distributor-type
fuel injection pump and 9.5 mm injection nozzles The five-piece thrust bearings must be installed as a
mounted in cylinder head. The pump is driven by an set. They may be retro-fitted to Dubuque engines1 at
intermediate gear in the timing gear train meshing with service repair if so desired. Should a crankshaft be
the crankshaft gear. found to have developed excessive end play, an
oversized thrust bearing plate set is available through 9010
Some engines are equipped with a turbocharger. service parts. Thrust bearing side plates are available 05
1
Operated by exhaust gases, the turbocharger in standard size or 0.007 in. oversize.
compresses intake air from air cleaner and routes it to
the combustion chamber. Cylinder liners are "wet" (surrounded by coolant) and
are individually replaceable. O-rings are used to seal
The cylinder block is made from a one-piece casting. the connection between cylinder block and liners.
The rugged, cast iron block may be structural or
non-structural. Pistons are made of cast high-grade aluminum alloy
with internal ribbing. The skirt is cam ground to allow
The camshaft is driven by an intermediate gear in the for expansion when heated during operation. The
timing gear train which meshes with the crankshaft piston crown has a cut-out swivel cup with a truncated
gear. Camshaft rotates in honed machined bores in cone in the center. Two compression rings and one oil
cylinder block; no bushings are used. The camshaft control ring are used. The top compression ring is a
lobes determine the time and rate of opening of each keystone type ring. All piston rings are located above
valve and actuates the fuel transfer pump. the piston pin. The top ring has been moved closer to
the top of the piston for improved engine performance
Intake and exhaust valves are operated by cam attributable to increased air availability during
followers, push rods and rocker arm assembly. Valve combustion and reduced heat losses in the top ring
seat inserts in cylinder head are used for intake and land.
exhaust valves.
The hardened piston pins are fully-floating and held in
The crankshaft is a one-piece, heat treated, nodular position by means of snap rings. Spray jets (piston
iron or steel forging which operates in replaceable cooling orifices) in cylinder block direct pressure oil to
two-piece main bearings. lubricate piston pins and cool pistons.
Two different types of crankshaft main thrust bearing Connecting rods are of forged steel and have
inserts are used to control end-play, depending on the replaceable bushing and bearing inserts.
producing factory. Normally a two-piece thrust bearing
1
Main (thrust) bearing web undercut in block and or bearing cap
MUST be 113.8 mm (4.48 in.) in order to accept five-piece thrust
bearings.
Continued on next page TX,901005,BR181 1924JUN941/2
PN=115
Theory of Operation
The engine is supplied with lubricating oil by a gear Balancer shafts are used on some four-cylinder
pump driven by the crankshaft. The lubricating oil engines to reduce vibration. The two shafts operate on
passes through a full-flow oil filter in the main oil bushings in cylinder block and are counter-rotating at
gallery of cylinder block. To ensure engine lubrication, twice the engine speed.
the oil filter is provided with a by-pass valve which
opens when the filter element is restricted. On most The engine has a pressurized cooling system,
engines, engine oil is cooled by means of an oil cooler consisting of radiator, water pump, multi-blade fan and
mounted externally on the cylinder block. Engine oil one or two thermostats.
passes through the oil cooler before flowing to the oil
filter. A by-pass valve located between oil pump and
9010 main gallery relieves any pressure build-up in this
05 area.
2
TX,901005,BR181 1924JUN942/2
EngineSectional View
1Rocker Arm Shaft 6Cylinder Block 11Liner Packing Rings 16Valve
2Cylinder Head 7Crankshaft 12Cylinder Liner 17Fuel Injection Nozzle
3Push Rod 8Crankshaft Counterweight 13Piston 18Valve Spring
4Cam Follower 9Oil Pan 14Piston Ring 19Rocker Arm
5Cam Shaft 10Connecting Rod 15Piston Rings
PN=116
Theory of Operation
9010
05
3
UN01JUN89
T6030AS
T59,9010,335 1909MAR932/2
PN=117
Theory of Operation
UN18NOV89
T6543AB
10T,9010,K181 1909MAR931/1
CED,TX17864,241 1907OCT981/1
PN=118
Theory of Operation
The fan drive (A), driven by one fan belt from the engine
crankshaft (B), is self-adjustable. The fan belt tension
adjuster (C) automatically adjusts the belt to the correct
tension.
9010
05
5
UN01MAR93
T7950AH
TX,710D,DS4687 1909MAR931/1
PN=119
Theory of Operation
9010
05
6
PN=120
Group 15
System Diagnostic Information
6059 John Deere Engine (S.N. 830204)
Use CTM8
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
9010
15
TX,9010,BG802 1905MAR971/1 1
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
TX,9010,BG803 1905MAR971/1
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
POWERTECH is a trademark of Deere & Company. TX,9010,BG792 1905MAR971/1
TX,9010,BG791 1905MAR971/1
PN=121
System Diagnostic Information
UN17JAN89
TS225
9010
15
2 09T,2160,K5 1912MAY941/1
PN=122
System Diagnostic Information
1. Inspect for coolant leaks at: well as the belts. A belt which is too loose allows
slippage and reduces fan and alternator speed,
Radiator causing excess belt wear. Belt slippage can lead to
Water pump overheating of the cooling and/or hydraulic system,
Hoses and undercharged batteries.
Coolant manifold
Thermostat cover The condition of the belts and their tension must be
checked periodically. Adjust belt tension. See
Check for proper coolant level in radiator. Look at Adjust Fan Belt Tension, Group 0510. 9010
coolant for evidence of oil and/or debris. 15
3
8. Inspect fuel tank:
2. Inspect for oil leaks around the oil pan, drain plug,
oil filter, and clutch housing at drain hole. a. Inspect the tank mounting hardware to ensure
they are in position and tight.
3. Inspect hoses to see if they are hard, cracked, soft,
or swelled. Replace as necessary. b. Inspect fuel tank for cracks and leakage.
4. Inspect radiator for bent fins, kinks, dents, cracked c. Inspect fuel tank outlet strainer and water trap
side frames, seams and tubes. Check radiator for accumulated debris by shining a flashlight
mounts for loose hardware. through the filler neck toward bottom right corner
of fuel tank.
5. Check fan to ensure it has been installed correctly.
See Cooling System Inspection, in this section. 9. Inspect fuel transfer pump. See if there is fuel
leaking from inlet and outlet connections.
6. Inspect fan blades. They must be straight and not
striking the radiator core or shroud. Bent blades 10. Inspect fuel filter for water in base of filter. Look
reduce the efficiency of the fan and make the fan for fuel leaking from inlet and outlet connections.
out of balance. An out of balance condition can add
additional load to the water pump bearings. Check Check for debris and air in filters. Drain or bleed
water pump bearings by moving fan and note filters if necessary. Replace filters as required.
looseness of bearings.
11. Inspect injection pump and nozzles.
7. Inspect fan belts. They must not be too tight, too
loose, or cracked. Check to see if belt pulleys are Check fuel inlet and outlet connections and
worn excessively (if belts run against bore of injection line connections. If any of the lines are
groove) and that the pulleys are in proper twisted, kinked, or broken, repair or replace as
alignment. necessary. Check injection line clamps to ensure
they are in position and tight.
A belt which is too tight puts extra load on the
bearings and shortens the life of the bearings as
PN=123
System Diagnostic Information
TX,9010,YY509 1902JUN932/2
PN=124
System Diagnostic Information
Engine Cranks but Will Not Start Fuel tank empty. Check fuel level.
or Starts Hard
Water in fuel or water frozen in fuel Thaw and drain water from fuel tank.
lines. Water frozen in fuel filter. Thaw ice in fuel lines and drain.
Install new fuel filter.
Fuel shut-off solenoid not opening Turn key switch on. Solenoid
shut-off valve. "clicks". Check voltage at solenoid if
voltage is present. Check fuse and
wiring if voltage is not present.
Fuel tank cap vent plugged. Loosen cap, listen for air entering
tank suddenly. Replace cap.
Wrong grade fuel for low ambient Fuel "jelled" in tank or lines. Warm
temperature. machine. Drain fuel system. Change
fuel filter. Refill with proper fuel.
Air entering suction side of fuel Check for bubbles in fuel filter.
system. Tighten connections. Inspect lines
for damage.
Stuck injection pump metering valve. Lightly tap injection pump housing. If
engine now starts, repair. (See
Engine CTM.)
PN=125
System Diagnostic Information
Air filter elements restricted with dirt, Clean or replace filter elements.
snow or water. Check air filter indicator switch.
Engine Cranks Slow Wrong weight oil for low ambient Drain and refill with proper weight
temperature. oil. Change oil filter.
Poor or dirty connections at batteries Clean battery posts and cable ends.
or starter. Reinstall cables. Clean connections
at start relay and starter.
Hydraulic pump destroke valve Turn steering wheel back and forth
stuck. while cranking engine. If cranking
speed is normal, check stroke
control valve. (See CTM7.)
Engine Surges or Stalls Air entering suction side of fuel Check fuel filter for air bubbles.
Frequently system. Tighten fittings and connections.
Inspect lines for damage.
PN=126
System Diagnostic Information
Fuel tank cap vent plugged. Remove cap, listen for air entering
tank suddenly. Replace cap.
Fuel "jelled" due to low ambient Drain fuel system. Refill with proper
temperatures. grade fuel. Replace fuel filter. 9010
15
7
Fuel filter plugged. Replace filter. Check for debris in
fuel system.
Return line from injection pump to Check line for kinks or damage.
tank restricted. Check line for debris. Clean with
compressed air.
Fuel injection pump out of time. Check injection pump timing. (See
Engine CTM.)
PN=127
System Diagnostic Information
Engine Missing, Erratic Air entering suction side of fuel Check fuel filter for air bubbles.
Operation Or Poor Slow Speed system. Tighten fittings. Inspect lines for
Operation damage.
Water or debris in fuel. Drain water from fuel tank. Drain and
flush fuel tank to remove debris.
Fuel tank cap vent plugged. Remove cap. Listen for air entering
9010 tank suddenly. Replace cap.
15
8
Return line from injection pump to Inspect lines for kinks or damage.
tank restricted. Use compressed air to clear debris.
Engine Missing, Erratic Fuel injection pump out of time. Time injection pump. (See Engine
CTM.)
Slow idle speed set too low. Check for bent, worn or loose control
linkage. Repair as needed. Adjust
linkage and reset slow idle speed.
(See procedures in this section.)
PN=128
System Diagnostic Information
Water in fuel or wrong grade of fuel. Drain water from fuel tank or drain
and refill with proper fuel.
Fast idle speed too low. Adjust. Check for worn or damaged
linkage. Check and adjust fast idle.
(See procedure in this section.)
Fuel line restriction or injection pump Clear restriction with compressed air.
line restricted. Replace line.
PN=129
System Diagnostic Information
Worn camshaft or incorrect camshaft Check valve lift. (See Engine CTM.)
timing.
Engine Emits Excessive Black or Restricted air filter element. Incorrect Check. Clean or replace elements.
Gray Exhaust Smoke grade of fuel. Drain and refill.
Air leak between turbo and manifold. Test air intake system for leaks.
(See test procedure in this section.)
PN=130
System Diagnostic Information
Engine Emits Excessive Blue or Cranking speed too slow. Check batteries and connections.
White Exhaust Smoke
Detonation (Excessive Engine Stuck starting aid solenoid or switch. Repair or replace solenoid or switch.
Knock)
Improper fuel (gasoline mixed with Drain and refill fuel tank. Replace
diesel fuel). fuel filter.
Abnormal Engine Noise (Rattle, Low engine oil level. Fill to correct level.
Knock or Squeal)
Too light weight engine oil for high Drain and refill with correct weight
ambient temperatures. oil.
Fuel in engine oil. Drain and refill with proper oil. Check
fuel system to find leakage.
PN=131
System Diagnostic Information
Worn piston pin bushings and pins. Replace pins and bushings. (See
Engine CTM.)
Low Engine Oil Pressure (Oil Low oil level. Check oil level. Fill to correct level.
Pressure Indicator Light On, Red Check for leaks. Repair leaks.
STOP Light ON and Alarm
Pulsing)
Using low viscosity winter oil in Drain and fill with summer weight oil.
summer.
Oil diluted with fuel. Drain and fill with proper weight oil.
Check fuel system for leakage.
Repair.
Faulty oil pressure control valve. Repair valve. (See Engine CTM.)
Plugged oil pump intake screen. Inspect. Clean. (See Engine CTM.)
PN=132
System Diagnostic Information
Loose oil pump drive gear or worn Inspect and repair. (See Engine
pump housing. CTM.)
Engine Overheats Low coolant level. Fill to correct level and check for
leaks.
PN=133
System Diagnostic Information
Oil In Coolant Or Coolant In Oil Leaking cylinder head gasket or liner Repair. (See Engine CTM.)
packings. Cracked cylinder or block.
Excessive Fuel Consumption Air system restricted. Clean or replace filter elements.
Check filter restriction indicator
switch. (See Section 9015, Indicator
Circuit.)
PN=134
System Diagnostic Information
Fan Belt Slips Belt slipping because of insufficient Inspect adjuster. Replace belt.
tension.
9010
Belt subjected to substance that has Replace belt and clean pulleys. 15
15
reduced friction.
Mismatch of belt and pulley groove Clean rust or other buildup from
widths. pulleys.
Turbocharger Excessively Noisy Bearings not lubricated. Insufficient oil pressure. Check for
or Vibrates restricted turbocharger oil line.
Air leak in engine, intake or exhaust Inspect, repair. (See test procedure
manifold. in this section.)
Improper clearance between turbine Remove exhaust elbow and air inlet
wheel and turbine housing. hose and inspect, repair. (See
Engine CTM.)
Oil Dripping from Turbocharger Damaged or worn bearings and/or Inspect compressor and turbine
Adapter worn seals. wheel for damaged blades.
PN=135
System Diagnostic Information
Excessive Drag in Turbocharger Carbon build-up behind turbine Inspect and clean.
Rotating Member wheel caused by combustion
deposits.
10T,9010,K81 1909MAR9312/12
PN=136
Group 20
Adjustments
JT05801 Clamp-On Electronic Tachometer
Installation
SERVICE EQUIPMENT AND TOOLS
Tachometer
AClamp-On Transducer. Remove paint with emery cloth and
UN28FEB89
connect to a straight section of injection line within 100 mm (4 in.) of
pump. Finger tighten onlyDO NOT overtighten.
BBlack Clip (). Connect to main frame.
CRed Clip (+). Connect to transducer.
T6813AG
9010
DTachometer Readout. Install cable. 20
1
10T,9010,K182 1910AUG951/1
UN28FEB89
BCable
CDigital Thermometer
T6808CE
902525,AA4 1928FEB951/1
PN=137
Adjustments
UN18OCT88
SERVICE EQUIPMENT AND TOOLS
Electronic Tachometer
T6023AD
9010 Sealing Wire Pliers
20
2 1. Run engine at normal operating temperature. (S.N. 830204)
4. Start engine.
Specification
Engine SpeedSlow Idle .................................................... 850 50 rpm
Specification
Engine SpeedFast Idle ................................................... 2375 50 rpm
PN=138
Adjustments
9010
20
CED,TX17864,245 1922OCT982/2 3
PN=139
Adjustments
UN13DEC96
Installation procedure in this group.)
T105637
9010
20
4. Start engine.
4 (S.N. 830205 )
5. Hold injection pump lever forward (toward radiator). ALever Stop Screw
Check to make sure slow idle is to specification. BSpeed Control Rod
CFast Idle Adjusting Screw
Specification DSealing Wire
Engine SpeedSlow Idle .................................................... 900 25 rpm ESlow Idle Adjusting Screw
Specification
Engine SpeedFast Idle ................................................... 2375 25 rpm
CED,TX17864,246 1922OCT981/1
PN=140
Adjustments
UN18OCT88
1. Move speed control pedal to full fast idle position.
T6030AU
Override must be to specification. 9010
20
5
Specification
Injection Pump LeverOverride
(Fast Idle) .............................................................. 36 mm (1/81/4 in.)
TX,9010,BG794 1905MAR971/2
UN29MAR90
5. Move pump lever by hand until override is within
specifications.
6. Turn yoke until holes align and connect yoke (D) and
T6030AV
lever. Tighten nut (E).
DYoke
ENut
TX,9010,BG794 1905MAR972/2
PN=141
Adjustments
UN13DEC96
2. Measure injection pump lever override. Override is
9010 measured at the top edge of the short lever (B) to the
20
edge of the long lever (B). Override must be to
6
specification.
T105635
Specification
Injection Pump Lever Override
Override ............................................................. 36 mm (0.120.24 in.)
UN30OCT98
minimum.
T118064B
6. Open access door on reservoir cowling to adjust foot
control pedal.
PN=142
Adjustments
ASwivel
BRod (Speed Control Pedal)
CVertical Rod
9010
20
7
UN13DEC96
T105636
TX,9010,BG796 1905MAR972/2
Specification
UN11MAY94
Speed Control Lever Tension
Force .............................................................. 6271 N (1416 lb force)
T8219CA
(S.N. 830205 ) Shown
TX,9010,BG797 1901APR971/1
PN=143
Adjustments
9010
20
8
PN=144
Group 25
Tests
Cooling System Test
SPECIFICATIONS
Cooling System Test Pressure 70 kPa (0.7 bar) (10 psi)
Radiator Cap Opening Pressure 82.7110 kPa (0.821.02 bar)
(1215 psi)
UN27OCT88
SERVICE EQUIPMENT AND TOOLS
DO5104ST Cooling System Pressure Pump
T5903AA
9010
1. Check cooling system for leaks using a DO5104ST
25
cooling system pressure pump. 1
Specification
Cooling System TestPressure ........................ 70 kPa (0.7 bar) (10 psi)
Specification
Radiator Cap OpeningPressure........... 82.7110 kPa (0.821.02 bar)
(1215 psi)
10T,9010,K96 1909MAR931/1
PN=145
Tests
SPECIFICATIONS
Radiator Air Flow Test Engine Fast idle
Speed
Typical Test Voltage Reading 3.00 volts
ESSENTIAL TOOLS
JT05529 Air Flowmeter
UN01NOV88
4. Divide grille into 16 equal squares.
T6080AH
6. Start and run engine at fast idle.
Specification
Radiator Air Flow TestEngine
Speed ........................................................................................... Fast idle
Specification
Typical TestVoltage Reading ................................................... 3.00 volts
1025,DS4253 1909MAR931/1
PN=146
Tests
PRE-TEST INSPECTION
CUSTOMER NAME:
CUSTOMER ADDRESS:
DATE:
MACHINE MODEL NO.
SERIAL NO.
9010
SERV SERV 25
OK REQD OK REQD 3
Coolant Level
Belt Tension Correct Fan Installation (Sucker
Fan)
Radiator Fin Condition Radiator Cap
Fan Tip & Shroud Condition
TX,1025,DS4254 1909MAR931/2
1.
3. Start engine.
UN13NOV92
T7886AE
TX,1025,DS4254 1909MAR932/2
PN=147
Tests
UN23AUG88
Engine Using No. 1 Diesel Fuel 5165.5 kPa (0.510.65 bar)
Minimum Turbocharger Boost (7.59.5 psi)
Pressure at 2200 rpm With
Muffler Installed
X9811
9010 Engine Using No. 2 Diesel Fuel 5569 kPa (550.69 bar) 810
25 Minimum Turbocharger Boost psi)
4 Pressure at 2200 rpm With
Muffler Installed
UN12NOV92
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
T7886AF
hydraulic or other lines. Tighten all connections
before applying pressure. Keep hands and body
away from pinholes and nozzles which eject S.N. 830204
fluids under high pressure. Use a piece of
cardboard or paper to search for leaks. Do not
use your hand.
UN09JAN97
may result.
T105842
2. Raise wheels off ground with stabilizer and bucket.
S.N. 830205
Specification
TransmissionTemperature ............................. 65 4C (130F 10F)
EngineTemperature ........................................ At operating temperature
PN=148
Tests
Specification
Engine Using No. 1 Diesel Fuel
Minimum Turbocharger Boost
9010
Pressure at 2200 rpm With
25
Muffler Installed ......................................... 5165.5 kPa (0.510.65 bar)
5
(7.59.5 psi)
Engine Using No. 2 Diesel Fuel
Minimum Turbocharger Boost
Pressure at 2200 rpm With
Muffler Installed .................................... 5569 kPa (550.69 bar) 810
psi)
TX,9010,BG798 1905MAR972/2
PN=149
Tests
SPECIFICATIONS
Air Intake System Regulated 13.820.7 kPa (0.130.21 bar)
Pressure (23 psi)
UN25OCT88
SERVICE EQUIPMENT AND TOOLS
JDG51 Air Regulator With Gauge
T92026
9010 it must be tested for leaks before the
25
machine is returned to service.
6
UN25OCT88
adapter (A).
T92027
CAUTION: Plastic bag can be sucked into S.N. 830204
engine if engine is started when trying to close
valves.
Specification
Air Intake SystemRegulated
Pressure ................................................. 13.820.7 kPa (0.130.21 bar)
UN09JAN97
(23 psi)
T105843
6. Spray soap solution over all connections from the air S.N. 830205
cleaner to the turbocharger or air inlet to check for
leaks. Repair all leaks.
TX,9010,BG799 1905MAR971/1
PN=150
Tests
10T,9010,C145 1909MAR931/1
PN=151
Tests
9010
25
8
PN=152
Section 9015
Electrical System
Contents
Page Page
Page Page
PN=2
Contents
Page Page
PN=3
Contents
Page Page
PN=4
Contents
Page Page
PN=5
Contents
Page
Group 20References
Alternators and Starting MotorsUse
CTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Battery Operation . . . . . . . . . . . . . . . . . . . . .9015-20-2
Battery Specifications . . . . . . . . . . . . . . . . . .9015-20-3
Diagnose Battery Malfunctions . . . . . . . . . . .9015-20-4
Check Battery Electrolyte Level and
Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-5
Procedure for Testing Batteries . . . . . . . . . . .9015-20-7
Using Booster Batteries12 Volt System . . .9015-20-8
Alternator Operation
9015 78 Amp DELCO REMY (Serial No.
787513) . . . . . . . . . . . . . . . . . . . . . . . .9015-20-10
95 Amp BOSCH (Serial No. 787514
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-12
95 Amp BOSCH . . . . . . . . . . . . . . . . . . .9015-20-13
Monitor Test in Machine . . . . . . . . . . . . . . .9015-20-14
Logic Module Test in Machine (S.N.
815415) . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-15
Logic Module Bench Test (S.N.
815415) . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-17
Tachometer Calibration
(S.N. 872256). . . . . . . . . . . . . . . . . . . .9015-20-18
(S.N. 872257 ) . . . . . . . . . . . . . . . . . . .9015-20-19
PN=6
Group 05
System Information
Visually Inspect Electrical System
Corroded terminals
9015
Loose terminals or battery posts 05
Dirty condition 1
Damp condition
Cracked case
Proper electrolyte level
CED,OUTX466,1353 1903FEB991/1
PN=155
System Information
Circuit Malfunctions
9015
05
2
1919DEC97
T112479
ABattery CSwitch DLight EGround
BFuse
AG,tx13067,2 1903FEB991/1
PN=156
System Information
9015
05
3
1917DEC97
T112473
ABattery CSwitch ELight FGround
BFuse DHigh Resistance
PN=157
System Information
9015
05
4
1917DEC97
T112476
ABattery CSwitch ELight FGround
BFuse DOpen
PN=158
System Information
9015
05
5
1917DEC97
T112477
ABattery CSwitch ELight FGround
BFuse DGrounded Circuit
A Grounded Circuit (shorted circuit) has a power wire provides continuity to the battery ground terminal
with its insulation rubbed through contacting the (shorted to ground).
machine frame causing a grounded circuit (D). This
PN=159
System Information
9015
05
6
1922DEC97
T112583
ABattery ECircuit Ground ISensor Signal Wire Shorted KController
BFuse F1 FController Ground To Ground LFuse F2
CSwitch GSensor JSensor Voltage Wire
DLight HSensor Ground Wire Shorted To Ground
Shorted To Ground
A sensor circuit shorted to ground has one or more wire (H) shorted to machine ground or a grounded
sensor wires, voltage wire (J), signal wire (I) or ground wire.
PN=160
System Information
9015
05
7
1922DEC97
T112584
ABattery ESensor Signal Wire GLight KController Ground
BFuse F1 Shorted to Power HCircuit Ground LFuse F2
CSwitch FSensor Ground Wire ISensor MBattery Ground
DSensor Voltage Wire Shorted to Power JController
Shorted to Power
AG,tx13067,4 1903FEB995/5
PN=161
System Information
9015
05
8
1903FEB99
T120026
ABattery CSwitch DLoad (Light) EGround
BFuse
In a simple electrical circuit malfunctions only occur at 3. After the load (D).
three locations:
Failed components can be diagnosed as circuit
1. Before the controlling switch (C). malfunctions. Isolate malfunctions to determine the
2. Between controlling switch (C) and load (D). cause of failure.
CED,TX13067,1 1903FEB991/1
PN=162
System Information
9015
05
9
1903FEB99
T120025
ABattery DSwitch Terminal GOpen JLoad (Light)
BFuse EResistance HConnector KGround
CSwitch FConnector IComponent Terminal
PN=163
System Information
3. If voltage is zero, the malfunction is between the 4. If voltage is normal, the malfunction is between
point of measurement and the battery. Continue point of measurement and circuit ground. Continue
measuring voltage toward the battery until normal measuring voltage toward circuit ground until zero
voltage is found. Malfunction is between last two voltage is found. Malfunction is between last two
points of measurement. points of measurement.
9015
05
10
PN=164
System Information
9015
05
11
1917DEC97
T112481
AFuse (Power Side) DSwitch Terminal FGrounded Circuit HLoad (Light)
BFuse (Circuit Side) EWire Terminal GComponent Terminal IGround
CSwitch
PN=165
System Information
9015
05
12
1919DEC97
T112482
PN=166
System Information
PN=167
System Information
9015
05
14
1922DEC97
T112583
ABattery ECircuit Ground ISensor Signal Wire Shorted KController
BFuse F1 FController Ground To Ground LFuse F2
CSwitch GSensor JSensor Voltage Wire
DLight HSensor Ground Wire Shorted To Ground
Shorted To Ground
Sensor Circuit Shorted to Ground: 3. If a sensor voltage wire shorts to a machine ground
wire (J), a Service Code may be generated. The
1. If a sensor circuit ground wire shorts to a machine monitor indicator for the sensor may illuminate.
ground wire (H), a service code probably wont be
generated. Sensor operation may be normal.
2. If a sensor signal wire shorts to a machine ground
wire (I), a Short to Ground service code may be
generated.
CED,TX13067,2 1903FEB996/6
PN=168
System Information
Multimeter
ADisplay
BVoltage AC (Alternating Current)
CVoltage DC (Direct Current)
DResistance
EDiode Test/Continuity
FCurrent AC (Alternating Current)
GCurrent DC (Direct Current)
HVoltage, Resistance, Diode/Continuity (Red Lead
Input)
IGround (Black Lead Input)
JCurrent/Amps (Red Lead Input)
9015
05
15
1903SEP93
T8074AA
TX,9015,MM2916A 1920MAR961/1
PN=169
System Information
9015
05
16
1905MAR92
T7719AA
ABattery Ground DFuse Or Circuit Breaker GBattery Side Of IGround Side Of Component
BBattery EComponent Side Of Fuse Component Terminal Terminal
CBattery Side Of Fuse Or Or Circuit Breaker HLight (Component) JComponent Ground
Circuit Breaker FSwitch
Step 1Switch ON
Check battery side of circuit breaker (C) for battery voltage Battery voltage normal. Go to Step 2.
Low voltage, repair high resistance.
Open circuit from battery.
Step 2Switch OFF
Check component side of circuit breaker for battery voltage Battery voltage normal. Go to Step 4.
Low voltage, repair high resistance.
No voltage. Go to Step 3.
PN=170
System Information
TX,9015,MM2917B 1901MAY952/2
PN=171
System Information
UN27FEB90
Wiring DiagramIf Provided
T85958
color, wire destination, harness connectors, and schematic
symbols for each electrical component connected to that
harness. Harnesses are identified by the same
letter/number designation and description used in the
System Functional Schematic Diagram (W1 Engine
Harness, W2 Dash Harness, Etc.). Each component
schematic symbol will be identified by the same
letter/number designation used in the System Functional
Schematic Diagram. Harness connectors will be identified
by a letter/number designation and description (X1 CAB
HARNESS TO ENGINE HARNESS CONNECTOR, X3
DASH HARNESS TO HEATER BLOWER HARNESS
CONNECTOR, Etc.).
PN=172
System Information
CED,OUTX466,1361 1903FEB992/2
PN=173
System Information
9015
05
20
1929MAY91
T7502CE
APower Wires DComponent Identification EComponent Name GCircuit Name
BContinuity Chart Code FGround Wires HSection Number
CComponent Schematic
Symbol
The System Functional Schematic is made up of component identification code (D). A continuity chart
sections which contain one or more Subsystem (B) is included for each multi-terminal switch.
Functional Schematic laid out side by side in a logical
sequence of related functions. Each Subsystem is a The same names and identification letter codes are
major group of components like starting components or used on all machine drawings, the System Functional
charging components (H). Sections are named to Schematic, System Wiring and Harness Diagram, and
reflect that group of components (G). The System the System Component Location Drawing.
Functional Schematic is formatted with power supply Components and connectors can easily be
wires (A) shown across the top of the drawing and cross-referenced from one drawing to another. See
ground wires (F) across the bottom. The diagram Group -10 for Component Identification Legend.
contains no harness or connector information.
TX,9015,MM2919B 1912APR941/1
PN=174
System Information
9015
05
21
1910AUG95
T8534AC
AHarness Connector DComponent Connector GHarness Identification JWire Number And/Or Color
Letter/Number EWire Number And/Or Color Letter/Number And KHarness Connector Pin
Identification FComponent(s) Identification Description Number Or Letter
BComponent Letter/Number Number/Letter Wire Is HWiring Harness
Identification Routed To IComponent(s) Identification
CComponent Connector Pin Number/Letter Wire Is
Number Or Letter Routed To
Each harness on the machine is drawn showing Main harness connectors (A) are identified by a
components, connectors, and wires. Harnesses (G) letter/number designation and description (X2 PARK
are identified by a letter/number designation and BRAKE HARNESS TO DASH HARNESS
description (W3 PARK BRAKE HARNESS, Etc.). CONNECTOR, Etc.). Harness connector description
indicates which harnesses connect together.
Each component (B) is represented by a schematic Connector pin numbers or letters (K) are indicated as
symbol and is identified by the same letter/number they are marked on the connector. Wires attached to
designation and description used in the System each connector pin are identified by number and/or
Functional Schematic. Components with integral color designation (J). Component identification
connectors (D) have pin number/letters indicated (C). number/letter (I) indicates destination of each wire.
Wires from harness to components are identified by
letter/number designation (E). Component identification Harness, harness connector, and component
letter/number (F) indicates component wire is routed identification letter/numbers and description are the
to. same as used on the System Functional Schematic.
CED,OUTX466,1363 1915OCT981/1
PN=175
System Information
9015
05
22
1909FEB98
T113251
PN=176
System Information
AComponent Identification DMating Connector X FName of Harness IWire Number and Color
Number Identification Number GDiagram View of JRouting Destination(s) of
BComponent Name EHarness Component Connector Wire
CEnd View of Connector Identification Number HTerminal Numbers
NOTE: The same names and identification numbers Each connector that joins one harness to another is
are used on all machine schematic and identified by an X component identification number
harness electrical drawings throughout the and a name. An end view of the connector is shown.
Operation and Test Technical Manual so Also, a diagram view of the connector shows
components can easily be cross-referenced connector terminal number, wire number and color and
from one drawing to another. destination of each wire.
The component location by harness drawing is a For example, X18 connector connects the Cab Work
pictorial representation that shows harness routing, Light Harness to the Load Center Harness. Terminal 5
component location and mating harness connector of the connector contains L02 Brn Wire, which routes
information. to E20 Left Front Work Light, E21 Right Front Work
Light, E22 Left Rear Work Light, and E23 Right Rear 9015
The location of each component that is connected to Work Light. 05
the harness is shown and identified by its 23
alpha-numeric identification number.
TX,9015,MM2920B 1927MAY982/2
PN=177
System Information
9015
05
24
1905SEP97
T102978
PN=178
System Information
Each wiring harness component location is followed by Work Lights, the connection would reference the
individual component connector drawings. These Connectors for Cab Work Light Harness on the page
drawings show an end view and a diagram view of following the component location drawing. This
each connector in the harness that connects to a drawing shows the end view of the wiring harness
component. connector for each component. In the case of L02
Brown wire, it is located in Terminal A for all three
In the preceding example, to see the location of L02 work lights.
Brn Wire in connectors for E20, E21, E22, and E23
CED,TX17864,1018 1903FEB992/2
9015
05
25
PN=179
System Information
9015
05
26
1903FEB99
T120028
PN=180
System Information
9015
05
27
1903FEB99
T120029
PN=181
System Information
9015
05
28
1903FEB99
T120030
PN=182
System Information
9015
05
29
1922MAR99
T120031
TX,9015,MM2921 1926OCT934/4
PN=183
System Information
9015
05
30
PN=184
Group 10A
System Diagrams (S.N. 872256)
Component Identification Table
Identification
Letter Type Examples
A System, subassembly, parts group Control units, trigger boxes, two-way radios, logic module, FNR
logic module
B Transducer for conversion of non-electrical Speed sensors, pressure sensors, pressure switches horns,
variables to electrical and vice versa sensors, pickups, limit-value sensors, pulse generators,
loudspeakers, inductive pickups, probes, air-flow sensors,
oil-pressure switches, temperature sensors, ignition-voltage pickups
C Condenser, capacitor Condensers and capacitors, general
D Binary device, memory Digital devices, integrated circuits, pulse counters, magnetic tape 9015
recorders 10A
1
E Various devices and equipment Heating devices, air conditioners, light, headlights, spark plugs,
ignition distributors
F Protection device Release mechanisms, polarity protection devices, fuses, current
protection circuits
G Power supply, generator Batteries, generators, alternators, charging units
H Monitor, alarm, signalling device Audible alarms, indicator lights, turn-signal lights, brake lights,
alarms, warning lights, buzzers
K Relay Battery relays, turn-signal relays, solenoid switches, starting relays,
warning flashers
L Inductor Choke coils, coils, windings
M Motor Blower motors, fan motors, starter motors
N Regulator, amplifier Regulators (electronic or electromechanical), voltage stabilizers
P Measuring instrument Ammeter, diagnostic connectors, tachometers, fuel 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
PN=185
System Diagrams (S.N. 872256)
Identification
Letter Type Examples
S Switch Switches and pushbuttons, general key switch, light switch, horn
switch, flasher switch
T Transformer Ignition coil, ignition transformer
U Modulator, converter DC transformers
V Semiconductor, electron tubes Transistors, diodes, electron tubes, rectifiers, semiconductors,
thyristors, zener diodes
W Transmission path, conductor, antenna Antennas, shielding components, shielded conductors, cable
harnesses, conductors, ground conductors
X Terminal, plug, plug and socket connection Terminal studs, electrical connections, connectors electrical line
couplers, line connectors, sockets, plugs, terminals, plug-and-socket
connections
Y Electrically actuated mechanical device Permanent magnets, (solenoid-operated) injection valves,
electromagnetic clutches and brakes, air valves, fuel pumps,
solenoids, switching valves, start valves, locking systems
9015
Z Electrical filter Interference suppression filters
10A
2
TX,901505,QQ381 1916SEP922/2
TX,9015,QQ6743 1928SEP921/1
PN=186
System Diagrams (S.N. 872256)
9015
10A
3
1923SEP92
T7812AF
F17.5 Amp MFWD/ F630 Amp Heater/AC Circuit F117.5 Amp Left Turn Fuse F1610 Amp Start Fuse
Alternator/Diff Lock Fuse Breaker F127.5 Amp Right Turn Fuse K3Park Light Relay
F215 Amp Fuel/Ether Aid F715 Amp Rear Light/ Tail F1310 Amp RTD/Beacon K4Reverse Alarm Relay
and Reverse Alarm Fuse Light fuse Fuse K5Park Brake Relay
F35 Amp Dome Light/Radio F825 Amp Front Light Fuse F145 Amp Monitor/Gauge K6Neutral Relay
fuse F910 Amp FNR/Park Brake Fuse K7Alternator Sense Relay
F45 Amp Radio Fuse Fuse F1515 Amp Hazard/Monitor S21Flasher
(Unswitched Power) F1020 Amp Turn/Stop and Fuse (Unswitched
F515 Amp Wiper Fuse Horn Fuse Power)
IMPORTANT: Install fuse with correct amperage The fuse block is located on the side console inside an
rating to prevent electrical system access cover.
damage from overload.
TX,9015,QQ1700 1912MAR931/1
PN=187
System Diagrams (S.N. 872256)
NOTE: A1Shift Controller (SE10, W7) E6Right Rear Work Light (SE8,W5)
E7Left Front Drive Light (SE8,W5)
A1 indicates component identification E8Right Front Drive Light (SE8,W5)
number. E9Left Tail Light (SE8,W5)
Shift Controller indicates component name. E10Right Tail Light (SE8,W5)
SE10 indicates section number of SYSTEM E11Left Brake Light (SE13,W5)
FUNCTIONAL SCHEMATIC where E12Right Brake Light (SE13,W5)
component is located. E13Beacon Light (SE14,W5)
W7 indicates HARNESS WIRING DIAGRAM E14Fuel Gauge Light (SE15,W8)
and HARNESS COMPONENT LOCATION E15Seat Belt Light (SE9,W6)
drawings where component is located. F1MFWD/ALT/Diff Lock Fuse (SE2,W6)
F2Fuel Shutoff/Start Aid/Reverse Alarm Fuse
V1MFWD Solenoid Diode (SE2,W8) (SE5,W6)
F3Dome Light Fuse (SE3,W6)
9015
10A V1 indicates component identification F4Radio Fuse (Unswitched Power) (SE3,W6)
4 number. F5Windshield Wiper/Washer Fuse (SE4,W6)
MFWD Solenoid Diode indicates component F6Heater Circuit Breaker (SE6,W6)
name. F7Rear Work Light Fuse (SE7,W6))
SE1 indicates section number of SYSTEM F8Front Work Light Fuse (SE8,W6)
FUNCTIONAL SCHEMATIC where F9FNR/Park Brake Fuse (SE9,W6)
component is located. F10Turn/Stop/Horn Fuse (SE12,W6)
W8 indicates HARNESS WIRING DIAGRAM F11Left Turn Light Fuse (SE13,W6)
and HARNESS COMPONENT LOCATION F12Right Turn Light Fuse (SE13,W6)
drawings where component is located. F13Return-To-Dig/Beacon Fuse (SE14,W6)
F14Monitor Fuse (SE15,W6)
A1Shift Controller (SE10,W7) F15Hazard/Monitor Fuse (Unswitched Power)
A2Radio (W12) (SE16,W6)
B1Reverse Warning Alarm (SE5,W8) F16Start Fuse (SE11,W6)
B2Park Brake Sensing Switch (SE9,W8) F17Fuse Block (W6)
B3Horn (SE12,W8) G1Battery (SE1,W8)
B4Fuel Sender (SE15,W8) G2Alternator (SE1,W8)
B5Engine Coolant Temperature Switch (SE17,W8) H1Left Indicator Turn Light (SE13,W7)
B6Engine Oil Pressure Switch (SE17,W8) H2Left Front Turn Light (SE13,W5)
B7Air Filter Restriction Switch (SE17,W8) H3Left Rear Turn Light (SE13,W5)
B8Transmission Temperature Switch (SE17,W8) H4Right Front Turn Light (SE13,W5)
B9Hydraulic Filter Restriction Switch (SE17,W8) H5Right Rear Turn Light (SE13,W5)
B10Radio Speaker (W12) H6Right Indicator Turn Light (SE13,W7)
B11Brake Light Switches (SE13,W6) H7Logic Module (S.N. 815415) (SE16,W6)
B12Radio Speaker (W12) H8Display Module (SE16,W6)
E1Dome Light (SE3,W5) H9Red Warning Light (SE17,W6)
E2Swivel Light (SE3,W5) H10Yellow Warning Light (SE17,W6)
E3Left Front Work Light (SE8,W5) H11Alarm (SE17,W6)
E4Right Front Work Light (SE8,W5) K1Start Relay (SE1,W8)
E5Left Rear Work Light (SE8,W5) K2Accessory Relay (SE1,W6)
PN=188
System Diagrams (S.N. 872256)
PN=189
System Diagrams (S.N. 872256)
X9Rear Light Switch Connector (W6) X37Seat Belt Light Connector (W6)
X10Rear Wiper Switch Connector (W6) X38A.C. Switch Connector (W6)
X11Beacon Switch Connector (W6) X41Hour Meter or Auxiliary Valve Connector
X12MFWD Switch Connector (W6) (W14)
X13Park Brake Switch Connector (W6) X41AAuxiliary Valve Harness Connector (W14)
X14Start Aid Switch Connector (W6) X42Auxiliary Valve Harness Connector (W14)
X15Fuel Gauge Connector (W6) X43Splice (Inside Harness) (S.N. 825658 )
X16Key Switch Connector (W6) X44Splice (Inside Harness) (S.N. 825658 )
X17Logic Module 4-Pin Connector (W6) X45Splice (Inside Harness) (S.N. 825658 )
X18Logic Module 6-Pin Connector (W6) X46Splice (Inside Harness) (S.N. 825658 )
X19Logic Module 4-Pin Connector (W6) X47Splice (Inside Harness) (S.N. 825658 )
X20Logic Module 6-Pin Connector (W6) X48Splice (Inside Harness) (S.N. 825658 )
X21Side Console To Engine Harness Connectors X49Splice (Inside Harness) (S.N. 825658 )
(W6,W8) X50Splice (Inside Harness) (S.N. 825658 )
X22Side Console To Engine Harness Connectors X51Splice (Inside Harness) (S.N. 825658 )
(W6,W8) X52Splice (Inside Harness) (S.N. 825658 )
9015
10A X23Floor Harness To Engine Harness Connectors X53Splice (Inside Harness) (S.N. 825658 )
6 (W6,W8) X54Splice (Inside Harness) (S.N. 825658 )
X24Side Console To Front Console Harness X55Splice (Inside Harness) (S.N. 825658 )
Connectors (W6,W7) X56Seat Switch Connector (S.N. 825658 ) (W6)
X25Side Console To Front Console Harness Y1MFWD Solenoid (SE2,W8)
Connectors (W6,W7) Y2Start Aid Solenoid (SE5,W8)
X26FNR/Range Switch Connectors (W7) Y3Fuel Shutoff Solenoid (SE5,W8)
X27Turn Signal Switch Connector (W7) Y4Park Brake Solenoid (SE9,W8)
X28Beacon Light Connector (W5) Y5Reverse/Solenoid (SE10,W9)
X29Roof Harness to Radio Harness Connector Y6Forward/Solenoid (SE10,W9)
(W5,W12) Y7Neutral Disconnect Solenoid (SE11,W9)
X30Splice (Inside Harness) (W6) Y8Hydraulic Pump Destroke Solenoid (SE 11,W8)
X31Forward Solenoid Connector (W8) Y9Return-To-Dig Solenoid (SE14,W8)
X32Clutch Disconnect Solenoid Connector (W8) Y10Air Conditioning Compressor (W11)
X33Connector for Air Conditioning Switch (W8) Y11Differential Lock Solenoid (SE2,W8)
X34Engine Harness To A/C Compressor Harness Y12C1/B2 Solenoid (SE10,W9)
Connector (W8,W11) Y13C2/B3 Solenoid (SE10,W9)
X35Side Console Harness To Blower Harness Y14Park Brake Solenoid (SE9,W8)
Connectors (W8,W10) Y15Auxiliary Valve Solenoid
X36Air Conditioning Clutch Cycle Switch
Connectors (W10)
TX,9015,QQ3270 1910MAR973/3
PN=190
System Diagrams (S.N. 872256)
TX,9015,QQ1703 1912MAR931/1
PN=191
System Diagrams (S.N. 872256)
TX,9015,QQ3257 1910MAR971/6
PN=192
System Diagrams (S.N. 872256)
T8542AG 1925APR97
TX,9015,QQ3257 1910MAR972/6
PN=193
System Diagrams (S.N. 872256)
T8542AH 1925APR97
TX,9015,QQ3257 1910MAR973/6
PN=194
System Diagrams (S.N. 872256)
T8542AI 1925APR97
TX,9015,QQ3257 1910MAR974/6
PN=195
System Diagrams (S.N. 872256)
T8542AJ 1925APR97
TX,9015,QQ3257 1910MAR975/6
PN=196
System Diagrams (S.N. 872256)
T8542AK 1925APR97
TX,9015,QQ3257 1910MAR976/6
PN=197
System Diagrams (S.N. 872256)
P13A RED
SWITCH ORG
P14C RED 2 6 1 5
ON
T16 OFF
ON 5 S7 II I O
P14A
RED
P13E RED BLU Y11
P13 OFF
P25 RED
P15A RED
ST RED I O WINDSHIELD
P13C DIFF.
B11B RED
RED
WASHER
LOCK P14G RED
K2 OFF 6 9 SWITCH
ON
V10 SOLENOID 4 8 3 7
G ACCESSORY M5
I O DIFF. 1
P13
RED
RELAY WASHER
B15 RED
LOCK P14 RED
B11 RED MOTOR A66 ORG
SOLENOID P15 RED
S2
M39C PUR
DIODE A65 ORG
A17 ORG
MFWD 8 10 A68 ORG
G10L BLK G10M BLK
B11C RED
SWITCH TO A2 RADIO ON 1 5 P14 RED
G05 BLK
G05 BLK
W55
BLU
RED CABLE (IF EQUIPPED) OFF
II I O
P15 RED
G1 M
M31 PUR
BATTERIES TO NEUTRAL
G20 BLK
WIRES A68 AND
E1
A69 ORG
P13B TAN
V1 W55
A63 ORG
START RELAY
P14 RED
A64 ORG
A66 ORG
A62 ORG
A65 ORG
A69 (SHOWN AS
A61 ORG
P14 RED
A68 ORG
V9
P14 RED
M39
PUR
B11 RED G2 WIPER
B03 RED
RED
YEL
YEL
E23 WHT
GRN
RED
BLU
P13C
TAN
ALTERNATOR
G01 BLK
SWITCH
BLU
- E02 WHT E2
GRN
RED
YEL
BLU
W D+ SWIVEL
W3 K1 S LIGHT
BRN
GROUND START G
Y1 M2 M M
S27 M3 M4
BRN
NOT MFWD
AT CAB RELAY USED DOME REAR L.H. R.H. M
FLOOR SOLENOID WIPER
B+ S3 LIGHT DOOR DOOR
S28
E02 WHT
M MFWD SWITCH MOTOR WIPER WIPER
M1 B11 RED SWIVEL
BLK CABLE
STARTER INDICATOR MOTOR MOTOR
G10A BLK
LIGHT
G01 BLK
MOTOR SWITCH
E02 WHT
TO PARK SWITCH
G20 BLK
G20 BLK
G20 BLK
G20 BLK
G20 BLK
BRAKE
G30 BLK
G01 BLK
LATCHING RELAY
G01
BLK SE9, K5 G20 BLK
G02 BLK G02 BLK G20 BLK G20 BLK G20 BLK
G10A BLK G10 BLK G10 BLK
G40 BLK G40 BLK G40 BLK
G01 BLK G01 BLK G01 BLK
W1 SE1 POWER, CHARGING AND START CIRCUIT SE2 MFWD AND DIFFERENTIAL LOCK CIRCUIT SE3 DOME LIGHT AND RADIO CIRCUIT SE4 WIPER AND WASHER CIRCUIT
MACHINE FRAME/ENGINE
BLOCK GROUND LEFT SIDE SYSTEM FUNCTIONAL SCHEMATIC (1 OF 5)
T117118 CONTINUED ON NEXT PAGE
CED,TX17864,148 1909SEP981/1
PN=198
System Diagrams (S.N. 872256)
F2 P24C RED
F6 F8
FUEL SHUTOFF/ F7
B12C
RED
HEATER
START AID/REVERSE REAR WORK FRONT WORK
CIRCUIT F9
ALARM FUSE LIGHT FUSE LIGHT FUSE
BREAKER FNR/PARK
BRAKE FUSE
P16 RED
OFF L43 BRN M32A PUR
P17A RED
R
L42 BRN
2C
P1 ED
1 S8 L42 BRN
ON 1 ON S12 J27A TAN
2 1 6 8
BLOWER OFF OFF
II I O
PARK BRAKE J27A TAN
3 SWITCH I O E4
4
SWITCH (DASH) M32B PUR
S4 RIGHT
P12A RED
L42 BRN
P18A RED
E3
P24B RED
1
START YEL
S10 LEFT ON 1 7 2 8 10
518 RED
AID 5 3 2 OFF
REAR S9 V15 I O
SWITCH 2
BLU LIGHT PARK WARNING
B FRONT P18B RED FRONT
T13C BLU 518 RED SWITCH LIGHT LIGHT DIODE
M32A PUR
WORK
P18C RED
K4 3 LIGHTS SWITCH
PUR 5 6 9
G20 BLK
L43 BRN L43 BRN
P12B RED
L41A BRN
REVERSE
G20 BLK
J20B TAN
ALARM 4 L43 BRN J20A TAN
ORG
M01B
PUR
YEL
Y2
L43 BRN
REAR
E25 WHT
L41
BRN
START
L43 BRN
E5 E6
L43 BRN
PUR
WORK
P24F
RED
J27A TAN
J27A TAN
BLU
TAIL
G20 BLK
SOLENOID
M01A
PUR
ORG
BLOWER
M32C PUR
BELT
J20A TAN
B1 1 E7 E8
RESISTOR 85 87A 87
L43 BRN
3 K3 LIGHT
T12 BLU
P12 RED
WARNING ORG TO
M62 PUR
FRONT LIGHT
ALARM S31 SHIFT
G10G BLK
Z36D
RELAY
G20
BLK
G20
BLK
DRIVE
G20 BLK
G20 BLK
M6 SEAT CONTROLLER
ORG
LIGHTS SWITCH SE10, A1
HEATER
K6
B2
G10P BLK
G10R BLK
G10V BLK
BLOWER
G20
BLK
G01 BLK
TO W3 PARK TO
MOTOR TO TO
NEUTRAL GROUND M TO K7 BRAKE PARK
G20 BLK G20 BLK G20 BLK TO H9 TO NEUTRAL PARK
Y3 BRAKE
G20 BLK
START TO FNR/RANGE AT CAB ALTERNATOR SENSING START
FUEL RED STOP BRAKE
RELAY SWITCH FLOOR RELAY ALTERNATOR SWITCH LATCHING
RELAY SOLENOIDS
G01
BLK
G10P BLK
SHUTOFF SE10, S11 LIGHT RELAY RELAY
G01 BLK
SE11, K6 BLK
SE14, K7 SE11, K6 SE9, Y4, Y14
SOLENOID SE15, H9 SE14, K7 SE9, K5
G20 BLK ROOF HARNESS GROUND G20 BLK G20 BLK
G10A BLK SIDE CONSOLE HARNESS GROUND G10A BLK G10A BLK
G40 BLK G40 BLK G40 BLK
G01 BLK ENGINE HARNESS GROUND G01 BLK G01 BLK
SE5 START AID, FUEL SHUTOFF AND REVERSE ALARM CIRCUIT SE6 BLOWER CIRCUIT SE7 REAR WORK LIGHT CIRCUIT SE8 FRONT WORK AND DRIVING LIGHTS CIRCUIT SE9 PARK BRAKE CIRCUIT
T117119 SYSTEM FUNCTIONAL SCHEMATIC (2 OF 5) CONTINUED ON NEXT PAGE
CED,TX17864,149 1909SEP981/1
PN=199
System Diagrams (S.N. 872256)
FNR SWITCH RANGE SWITCH N C2-B3 FWD C1-B2 REV N C2-B3 FWD C1-B2 REV GROUND CIRCUIT
WIRE WIRE RANGE 1ST FORWARD 2ND NEUTRAL (WIRE COLOR) G01 BLKENGINE HARNESS
COLOR FOR NEU REV COLOR 1 2 3 4 2ND FORWARD SOLENOIDS 3RD NEUTRAL SOLENOIDS G10 BLKSIDE CONSOLE HARNESS
DENOTES CONNECTIONS F YEL BLU 3RD FORWARD ENERGIZED 4TH NEUTRAL ENERGIZED G20 BLKROOF HARNESS
TO POWER (P24 RED) N GRY GRN 4TH FORWARD 1ST REVERSE G30 BLKFRONT CONSOLE HARNESS
R PNK BLK 1ST NEUTRAL 2ND-4TH REVERSE G40 BLKENGINE HARNESS TO SIDE CONSOLE HARNESS
B11B RED B11B RED
B12D RED B12D RED
E22 WHT E22 WHT
R31 BLK R31 BLK
B11D RED B11D RED
M39 PUR M39 PUR
B15 RED B15 RED
P24C RED RED
P24A RED P24A RED
T11 BLU
T12 BLU T12 BLU
T13 BLU F16
K5 D C B A START
PARK BRAKE S11 FUSE
LATCHING FNR/RANGE
P24C RED
RELAY GRN
SWITCH A1
GRY D RED
RED
RED SHIFT
86 30 PNK C RED
GRN
FNR CONTROLLER
RED
GRN
GRN
YEL B RED
N
R F R N F RED A RED GRN
J25 TAN
85 87A 87 E23
J20C WHT
TAN 86 30
87A
K6 86 30
D
V11 GRN NEUTRAL
85 87
PARK BLU C RED
RANGE TIME START
E22A WHT
J20A TAN
RELAY A 87A 85 87A 87
T12A BLU
DIODE 85 87
T13 BLU
E2B WHT
86 30 86 30
87A 87A
E23 WHT
85 87 85 87
RED
S13
NEUTRAL E23 WHT
GRN SWITCH
GRN
GRN A B C D
T11 BLU
T13 BLU
E23 WHT
Y8
J27 TAN
Y4 Y14 V3 T13 T11 J27 TAN HYDRAULIC
J27 TAN
G10E BLK
J27 TAN
T52 BLU
J20A TAN
E2B WHT
V2 BRAKE SOLENOID BLU
BLU Y12 ALARM
PARK SOLE- SOLE- DIODE SOLENOID V12 SOLENOID
J27 TAN
Y6 Y7
T15 BLU
G04
BLK
SOLENOID DISCONNECT
G30 BLK
DIODE SOLENOID BRAKE DIODE SOLENOID DISCONNECT
V13 SOLENOID
TO PARK G04 G01 SWITCH G01
SOLENOID
G04 BLK TO STARTER G01 C2/B3
BRAKE BLK BLK G01 BLK DIODE G01
MOTOR TO PARK BLK (DASH) TO LEFT SOLENOID
BLK BLK
G01 BLK
G01 BLK
G01 BLK
G01 BLK
G01 BLK
SE5, K4
G01 BLK
G01 BLK
SE9 PARK BRAKE CIRCUIT SE10 FNR/RANGE CONTROL CIRCUIT SE11 NEUTRAL DISCONNECT CIRCUIT
T117120 CONTINUED ON NEXT PAGE
SYSTEM FUNCTIONAL SCHEMATIC (3 OF 5)
CED,TX17864,150 1909SEP981/1
PN=200
System Diagrams (S.N. 872256)
GROUND CIRCUIT
TERMINALS (WIRE COLOR) G01 BLKENGINE HARNESS
TURN POSITION 5 6 3 7 OFF 4-WAY G10 BLKSIDE CONSOLE HARNESS
SIGNAL OFF ON FLASH BEACON OFF 9 G20 BLKROOF HARNESS
SWITCH LEFT 8 6 2 5 1 3 10 SWITCH SWITCH ON G30 BLKFRONT CONSOLE HARNESS
RIGHT 10 5 1
G40 BLKENGINE HARNESS TO SIDE CONSOLE HARNESS
B11B RED B11B RED B11B RED
B12D RED B12D RED
R31 BLK R31 BLK
B11D RED B11D RED
M39 PUR M39 PUR M39 PUR
B15 RED B15 RED
P19E RED P23A RED
F10 F13
TURN/STOP/ F11 F12 RETURN-TO-DIG/
HORN FUSE LEFT TURN RIGHT TURN BEACON FUSE
ON 2 8 3 LIGHT FUSE
S17 OFF
LIGHT FUSE
P19A
RED
P19E RED 4-WAY I O
M07 PUR
6 1 10
5
B11 S16 G30 BLK
P20A RED
BRAKE TURN
LIGHT SIGNAL SWITCH V7
L50 BRN
V6
M08 PUR
L49 BRN
4-WAY P20C RED
L50 BRN
SWITCHES 4-WAY
FLASHER L45B BRN
L48A BRN
L47A BRN
M47D PUR
L46B BRN FLASHER
7 3
M48D PUR
SWITCH
P19B RED
S15 R OFF L SWITCH L45A BRN
M47 PUR
HORN I O II DIODE DIODE
M47 PUR ON 10
M48 PUR
1
P20C RED
L46A BRN
H6 I O S20
RIGHT TURN
P20B RED
L47A BRN
L50 BRN
L46 BRN
L46 BRN
E12 H3 H2 S18
E11 RIGHT L49A BRN H5 H4 BEACON
LEFT REAR FRONT REAR FRONT SWITCH
H01 GRN
LEFT
E13
M48 PUR
TURN RIGHT
A67 ORG
+
BRAKE + LIGHTS TURN BEACON
LIGHTS
H1 LIGHT Y9
LIGHTS
G20
BLK
G30 BLK
G30 BLK
G LEFT TURN
G20
BLK
G20 BLK
RETURN-
G20 BLK
INDICATOR
B3 G20 BLK
TO-DIG
LIGHT G20 BLK G20 BLK
HORN SOLENOID
G20 BLK
S21
G30
BLK
G20 BLK
FLASHER
G20 BLK
G10H BLK
G30 BLK FRONT CONSOLE HARNESS GROUND G30 BLK G30 BLK
G10D BLK
G10E BLK
G30 BLK
G01 BLK
TO SHIFT CONTROLLER
W2
G30E BLK
GROUND TO
SE10, A1
G40 BLK G40A BLK SIDE CONSOLE HARNESS GROUND G40A BLK
CAB FRAME G10A BLK G10A BLK
G20 BLK
G40A BLK G10A BLK G10A BLK
G40 BLK
G01 BLK G01 BLK G01 BLK
SE12 HORN CIRCUIT SE13 TURN SIGNAL, FLASHER AND BRAKE LIGHT CIRCUIT SE14 BEACON AND RETURN-TO-DIG CIRCUIT
CED,TX17864,151 1909SEP981/1
1584 X 628
TM1537 (26FEB02) 9015-10A-17 710D Backhoe Loader
022602
PN=201
System Diagrams (S.N. 872256)
GROUND CIRCUIT
(WIRE COLOR) G01 BLKENGINE HARNESS
G10 BLKSIDE CONSOLE HARNESS
G20 BLKROOF HARNESS
G30 BLKFRONT CONSOLE HARNESS
B11B RED G40 BLKENGINE HARNESS TO SIDE CONSOLE HARNESS
B12D RED
R31 BLK R31 BLK
B11D RED
M39 PUR M39B PUR
B11A
RED
P23A RED
F14 F15
P21E RED MONITOR TACH./
FUSE HMTR.
P21D RED P21F RED
M39A PUR
FUSE P23A
P1 RED
FUEL H9
GAUGE RED
+ P21D RED P21D RED STOP
R31 BLK
LIGHT
P23
RED
E14 Z36B GRY
P21A
RED
G10K BLK GS
FUEL P21B RED
P21B RED
VALVE HARNESS Z37 GRY
METER ENG. ENG. ENG. ENG. CONVTR. HYD. ALARM
CONNECTOR COOLANT OIL ALT. AIR OIL OIL
H10
Y33 YEL
G10J BLK
TEMP. PRESS. VOLTS FILTER TEMP. FILTER
Z36A
GRY
h YELLOW
- +
1 A P21H RED
WARNING
H8 2 B LIGHT
3 C
M37C
PUR
G10B BLK
G10C BLK
DISPLAY 4 D
BLK 5 E P21B RED
B4 M37C PUR MODULE 6 F
FUEL
M37D + SIG
SENDER
M37D PUR
PUR 11 F
n
G10C BLK P23 RED 12 E
13 D
14 C
15 B
P2 M37A PUR 16 A
TACHOMETER/
M39B PUR
M39A
PUR
K7 M37B PUR
X36
YEL
B5
Z36B GRY
HOUR METER
(OPTIONAL) ALTERNATOR ENGINE
RELAY 86 30 7 A B7 COOLANT
8 B
X38 YEL
AIR FILTER
N34 YEL
M39A PUR 10 D
TEMPERATURE
87A SEAT RESTRICTION SWITCH
TO K3 G10R
M40 PUR
85 87 SWITCH SWITCH B9
BLK
PARK LIGHT
G10B BLK
SE9, S31 HYDRAULIC
G10J BLK
TO B8
G01 BLK
RELAY G10T BLK B6
SE8 K3 PARK CONVERTER FILTER
P23 RED ENGINE OIL
RESTRICTION
G01 BLK
SE13 GAUGE AND HOUR METER CIRCUIT SE14 DISPLAY MODULE AND LOGIC MODULE CIRCUIT SE15 INDICATOR CIRCUIT
CED,TX17864,152 1909SEP981/1
PN=202
System Diagrams (S.N. 872256)
E1 E2 M2
DOME SWIVEL REAR
LIGHT LIGHT WIPER MOTOR E6 M4 H4 E8 E4
GRY
R.H. R.H. DOOR R.H. R.H. R.H.
REAR WIPER MOTOR FRONT FRONT FRONT X2
E10 H5 E12 WORK TURN DRIVE WORK ROOF HARNESS
R.H. R.H. R.H. LIGHT LIGHT LIGHT LIGHT TO SIDE CONSOLE
REAR REAR BRAKE HARNESS CONNECTOR
M
TAIL TURN LIGHT
LIGHT LIGHT X29 P25 RED B
M E1, X29 P15 RED A
RED
BLU
YEL
BRN
GRN
RED
BRN
YEL
BLU
* WIRES A68 AND A69
G20 BLK
G20 BLK
P15 RED
(SHOWN AS DASHED
LINES) ARE USED FOR
(S.N. 816286) X3
ROOF HARNESS
TO SIDE CONSOLE
S27 S28 HARNESS CONNECTOR
G20 BLK
DOME SWIVEL M4 * A69 ORG H
A66 ORG
P14 RED
A63 ORG
A65 ORG
G20 BLK
G20 BLK
G20 BLK
L42 BRN
A64 ORG
G20 BLK
L43 BRN
G20 BLK
L47 BRN
L41 BRN
G20 BLK
G20 BLK
L47 BRN
P14 RED
LIGHT LIGHT
* A69 ORG
M3 * A68 ORG G
SWITCH SWITCH
L47 BRN
L46 BRN
G20 BLK
G20 BLK
L43 BRN
M2 A66 ORG F
M2 A65 ORG E
E6
W2
X3
X3
X1
W2
H4
E4
W2
X3
X3
X3
X1
E8
W2
X1
M4
X1
X2
W2
X1
M2
X1
X1
H4
X1
H5
M4 A64 ORG D
W2
X3
X3
X3
X1
X1
H2
X1
X1
W2
W2
W2
E3
X1
X2
X2
W2
X1
W2
X1
X1
W2
H3
X1
E7
E5
M4 A63 ORG C
M3 A62 ORG B
E10, H5
E11
E12, M4
E7, H2
E9, H3
H4, E13
X29, M3
S28, M2
M3 A61 ORG A
X1
L46 BRN
G20 BLK
A61 ORG
L41 BRN
G20 BLK
L48 BRN
L48 BRN
G20 BLK
L48 BRN
G20 BLK
A62 ORG
L43 BRN
G20 BLK
L43 BRN
L45 BRN
G20 BLK
L42 BRN
G20 BLK
G20 BLK
G20 BLK
P14 RED
P15 RED
L43 BRN
G20 BLK
P25 RED
ROOF HARNESS
*A68 ORG
G20 BLK
TO SIDE CONSOLE
HARNESS CONNECTOR
M3 P14 RED H
M2, M4
E6, E5 L41 BRN G
H2, H3 L48 BRN F
A B C D X29 L43 BRN E
E7, E9, E10, E8
RED
YEL
BLU
GRN
TX,9015,QQ1704 1912MAR931/1
PN=203
System Diagrams (S.N. 872256)
TX,9015,QQ1705 1912MAR931/1
PN=204
System Diagrams (S.N. 872256)
TX,9015,QQ3265 1910MAR971/1
PN=205
System Diagrams (S.N. 872256)
TX,9015,BG976 1901APR971/1
PN=206
System Diagrams (S.N. 872256)
TX,9015,BD2726 1910MAR971/1
PN=207
System Diagrams (S.N. 872256)
TX,9015,BG977 1901APR971/1
PN=208
System Diagrams (S.N. 872256)
S18 S6
S25 BEACON REAR X10
SWITCH WIPER S10 REAR WIPER F4
AC SWITCH S2 REAR LIGHT F2
(OPTIONAL) (OPTIONAL) SWITCH X12 SWITCH CONNECTOR F14 FUEL/ETHER/ RADIO F12
MFWD SWITCH F15
SWITCH MFWD MONITOR/ BK. ALARM HAZARD RTURN
S15 X37 SWITCH X11 X9 GAUGES F11
SEAT BELT REAR LIGHT MONITOR
E15 HORN CONNECTOR BEACON LTURN
SEAT LIGHT CONNECTOR SWITCH SWITCH V11 F9
SWITCH PARK BRAKE FNR/PARK
BELT X38 CONNECTOR CONNECTOR
P2 X13 RELAY DIODE F13
LIGHT AC SWITCH RTD/BEACON/PUMP
TACHOMETER PARK BRAKE CONNECTOR X8 F16
S12 SWITCH HORN SWITCH START F10
PARK
H8 CONNECTOR CONNECTOR P2 S21 TURN/STOP/HORN
-
+
DISPLAY TACHOMETER
BRAKE FLASHER F8
+
MONITOR
-
SWITCH RELAY FRONT LIGHTS/
S22
HEATER TEMP. TAIL LIGHTS
S4 X14 K7
SWITCH START AID
START AID ALTERNATOR F7
SWITCH CONNECTOR K5 REAR LIGHTS
SWITCH F3
S8 V8 PARK
BRAKE DOME/ F6
P1 BLOWER LOGIC MODULE/ K3 HEATER/AC
PARK RELAY RADIO
FUEL GAUGE SWITCH DISPLAY MODULE
S1 SEE BLOWER HARNESS DIODE LIGHT F5
KEY
K6 WIPER
(W10) K4 NEUTRAL F1
SWITCH S13 BACKUP RELAY
NEUTRAL
H10 MFWD/ALT
YELLOW ALARM
X19 DISCONNECT DIFF. LOCK
WARNING RELAY
LOGIC MODULE F SWITCH
K2 G LIGHT
4 PIN CONNECTOR X1 H E
ACCESSORY ROTATED 180
(S.N. 815415) SIDE CONSOLE X15
RELAY
HARNESS TO FUEL GAUGE
ROOF HARNESS CONNECTOR X7
X20 D DISPLAY
LOGIC MODULE H7 CONNECTOR A B C X16 MODULE
6 PIN CONNECTOR LOGIC KEY SWITCH CONNECTORS
(S.N. 815415) MODULE F G CONNECTOR H9
(S.N. 815415) X3 E H RED STOP
SIDE CONSOLE LIGHT
HARNESS TO
ROOF HARNESS
K2
A ACCESSORY
CONNECTOR D C B X17 RELAY
LOGIC MODULE
4 PIN CONNECTOR X18
X2 (S.N. 815415) LOGIC MODULE
SIDE CONSOLE B A 6 PIN CONNECTOR
HARNESS TO (S.N. 815415)
ROOF HARNESS
CONNECTOR
TX,9015,BG972 1919AUG991/1
PN=209
System Diagrams (S.N. 872256)
TX,9015,BG978 1919AUG991/1
PN=210
System Diagrams (S.N. 872256)
X41
P2 HOUR METER OR
F14 TACHOMETER AUXILIARY
S1 ACC
FUEL HOUR METER VALVE HARNESS
X2 KEY OFF
ON CONNECTOR
GAUGE BLK
SIDE CONSOLE SWITCH BULB CHECK
START LIGHT
HARNESS TO ACC H11
E15 n
ROOF HARNESS X44 SIG
SEAT BELT +
DISPLAY
CONNECTOR SPLICE MODULE
(INSIDE HARNESS) LIGHT
B P25 RED F4 IGN ALARM
S4
A P15A RED F3 START S15 H10
G10K BLK
P21E RED
AID HORN YELLOW
P21D RED
ST WARNING
SWITCH SWITCH
P1 LIGHT
+
B14 RED
G
X3 FUEL
G10C BLK
G
G10B BLK
P21B RED
G10C BLK
M37D PUR
M37D PUR
M37C PUR
B11B RED
GAUGE
M39A PUR
SIDE CONSOLE
HARNESS TO
ROOF HARNESS
B12A RED
P21A RED
CONNECTOR
M32A PUR
Z36C GRY
R31A BLK
M32C PUR
P24F RED
A67 ORG
H A69 ORG X25
B12B RED
B12B RED
B12C RED
B12D RED
E25 WHT
G10J BLK
G A68 ORG
Y33 YEL
X25
P21J RED
P19B RED
G10L BLK
E22 WHT
P21D RED
P12A RED
P12B RED
P21B RED
Z37 GRY
P21C RED
F A66 ORG S6
E A65 ORG S6
S1
F9
F14
S12
X43
X48
H8
F16
F2
X44
K2
X25
X22
V12
S12
X48
X23
F14
F2
X21
H10
X23
X46
X51
X48
X45
X47
H8
F14
H9
X3
X3
S1
K2
K3
F9
K7
H8
X41
S13
E15
K5
H9
H8
P1
H11
E15
X30
X50
F15
E15
X25
X52
X22
X22
X24
X22
X49
B A62 ORG X25
A A61 ORG X25
X1
SIDE CONSOLE
T53 BLU
T52 BLU
HARNESS TO
ROOF HARNESS
B11C RED
B11B RED
M37A PUR
M37B PUR
M37C PUR
B11A RED
W55 BLU
A66 ORG
P13D
RED
J27 TAN
M31 PUR
M32A PUR
M01B PUR
P20B BLK
L45A BRN
A65 ORG
OFF
M32C PUR
H P14G RED X52 6 9
G10H BLK
S12 ON
J27A TAN
P21F RED
P21H RED
P21D RED
P21J RED
B I 0
J20A TAN
G L41A BRN S10 A
P14B RED
PARK
F L48A BRN F11 BRAKE
M32B PUR
P24B RED
P24F RED
GRN
E L43A BRN X25 SWITCH 8 10
D L45A BRN S18 ON
RED
ON 1 10 1 5
OFF OFF
C L47A BRN F12 ON I 0 II I 0
OFF 1 7 2 8 10
B L46A BRN B11 X43 X45 S2 V15
I 0
L45B
BRN
J20B TAN
DISCONNECT S18 S6 DIODE
SWITCH BEACON REAR
P24E
RED
SWITCH WIPER
SWITCH
T107052
TX,9015,BD2727 1910MAR971/1
PN=211
T107051
F14
P21C RED
H49
X47
LIGHT
Z36B GRY
K3
Z36D GRY
RED WARNING
X46
P21F RED
H8
Z36A GRY
H9
Z36B GRY
6
5
4
3
2
1
16
15
14
13
12
11
X47
H8
8 B
7 A
A
B
E
H11
10 D
9 C
F
C
D
E
B
A
D
C
Z36C GRY
SPLICE
X21
DISPLAY
MODULE
F39 YEL
X21
X38 YEL
X23
M40 PUR
Z36A GRY
(INSIDE HARNESS)
K7, H7, P2
M37B PUR
K3
Z36A GRY
X30 H10
G10A BLK Z37 GRY
S1
S21 R31A BLK
G10D BLK
X21
P1 N34 YEL
G10J BLK
X21
X36 YEL
K2
G10M BLK
F14, P2
X48
P21H RED
X41
G10B BLK
SPLICE
F1
S18 P13A RED
G10H BLK
X49
X23
S1 P13B RED
G10L BLK
SPLICE
S2
P13C RED
(INSIDE HARNESS)
S19
P13E RED
X23
P20C RED
(INSIDE HARNESS)
S18
P20B RED
X50
F13
P20A RED
SPLICE
X57
K7 M39B PUR
SPLICE
P2
M39A PUR
X21
M39 PUR
(INSIDE HARNESS)
(INSIDE HARNESS)
K7
X1 G10V BLK
P14G RED
X25
S31
P14C RED
SEAT
S6 K3
X52
SWITCH
F5
P14A RED
X44
B12C RED
P12C RED
S12
P24B RED
X48
(INSIDE HARNESS)
G10D BLK
X25
L49A BRN
X25
L50 BRN
X1
L41A BRN S1
E22 WHT
I
X57
M39B PUR
ON
O
OFF
X45
M37A PUR
F7 P24C RED
P17A RED
1
5
G10R BLK
L49A BRN
S10
REAR
LIGHT
P24C RED
E22A WHT
SWITCH
M39B PUR
L50 BRN
G10R BLK
M37A PUR
G10R BLK
G10E BLK
S31
G10V BLK
H9
S1 Z36D GRY
B14 RED
T12A BLU
S31
ALT
M01A PUR
V12
K7
X30
K3
PARK LT
WHT
E22A
X43
B11C RED P12C RED
X23
F17 M62 PUR
B15 RED
X21
FLSHR
T13C BLU
K4
S21
B15 RED
BLK
BACKUP ALM
BLK
G10P
G10E
G10G
BLK
P24B RED
X23
E22 WHT
E23 WHT
B12C RED
P23 RED
NEUTL
K6
X25
T12 BLU
K2
J20C TAN
P12C RED
T107051
RELAY
X25
F16
J24A RED
S12 START
J20A TAN
K5
PARK BRK
P24C RED
ACCESSORY
F9
V11 FNR/PARK
J25 TAN
1911APR97
TM1537 (26FEB02)
P13A RED
F1
F14
X35
X2
P15A RED
F2
P12C RED
F3
A16 ORG X33
DOME/ FUEL/ETHER
RADIO BK. ALM.
X52
P14A RED
F5
CONNECTOR
F15
HARNESS TO
WIPER TACH/
P12A RED
B11D RED
SIDE CONSOLE
H MOTOR
X35
B12A RED
P16 RED
F4
F6
BLOWER HARNESS
HEATER/ RADIO
P23A RED
AC
S10
X35 P17A RED
F7
A16 ORG P25 RED
REAR LTS
X33
X53 B11A RED
P18A RED
F8
X22
A17 ORG
FRONT LTS/
SWITCH
TAIL LTS
X54
P19A RED
F10
F12
TURN/STOP/ R TURN
HORN
X50
P20A RED
F13
F11
CONNECTOR FOR
AIR CONDITIONING
RTD/BCON L TURN
9015-10A-28
F17
X21
FUSE
E2B WHT
K2
BLOCK
System Diagrams (S.N. 872256)
K5 B15 RED
V11
J25 TAN
X25
M48D PUR
X1
L48A BRN
X25
M47D PUR
PARK BRAKE
X1
RELAY DIODE
L47A BRN
X2
P25 RED
TX,9015,BG979
B12A RED
P2
P21A RED
X44
B12D RED
1901APR971/1
PN=212
System Diagrams (S.N. 872256)
X23
SIDE CONSOLE HARNESS TO
ENGINE HARNESS CONNECTOR X25
S4 P12B RED 1 SIDE CONSOLE HARNESS
TO FRONT CONSOLE
K6 E23 WHT 2 HARNESS CONNECTOR
P1 Y33 YEL 3
X3 A61 ORG 1
B11 X49 P13B RED 4
BRAKE LIGHT X3 A62 ORG 2
SWITCH K4 M62 PUR 5
X3 A63 ORG 3
P19F RED
X50 P20C RED 6
X3 A64 ORG 4
S12 J27 TAN 7
X22 A71 ORG 5
H8 M40 PUR 8
X52 P14C RED 6
F12 M47D PUR 7
X3 A69 ORG 8
X53 X53 X22
SPLICE L46B BRN SPLICE F15 P23A RED 9
SIDE CONSOLE HARNESS
(INSIDE HARNESS) (INSIDE HARNESS) TO ENGINE HARNESS CONNECTOR X54 P19E RED 10
S2 M31 PUR 1 S21 L50 BRN 11
S2 W55 BLU 2 S21 L49A BRN 12
X33 A17 ORG 3 F11 M48D PUR 13
X25 A71 ORG 4 X30 G30E BLK 14
X4 T14 BLU 5 X21 T11 BLU 15
L46A BRN
P19D RED
X4 T15 BLU 6 X55 T13 BLU 16
S15 A67 ORG 7 K5 P24A RED 17
S12 J27A TAN 18
P18B RED
P18A RED
P18C RED
T13 BLU
T13A BLU
T13C BLU
S13 T52 BLU 8
X3 A68 ORG 19
X21 X53 P18B RED 20
SIDE CONSOLE HARNESS TO
X54
X1
X21
K4
F8
X25
X25
X25
ENGINE HARNESS CONNECTOR X1 L43A BRN 21
K2 B11 RED 1 X53 P18C RED 22
X21
X21
X25
X48
X49
S15
B11
F10
X25
X30 G40A BLK 2 X1 L42A BRN 23
X25 T11 BLU 3 K6 T12 BLU 24
V11 E2B WHT 4
X55 T13A BLU 5
H8 F39 YEL 6 X24
G30E BLK
G40A BLK
G10A BLK
S4 E25 WHT 7 SIDE CONSOLE HARNESS
TO FRONT CONSOLE
H8 X38 YEL 8 HARNESS CONNECTOR
P19A RED
P19E RED
P19B RED
P19D RED
T16 BLU
P13E RED
X51 M39 PUR 9 S13 T53 BLU A
H8 N34 YEL 10
X22 T14 BLU B
S12 M32B PUR 11
C
12
X22 T15 BLU D
H8 X36 YEL 13
X30 E
X54 S19 S19 T16 BLU 14
SPLICE
(INSIDE HARNESS) SPLICE DIFFERENTIAL
(INSIDE HARNESS) LOCK SHIFT
T107053
TX,9015,BG980 1901APR971/1
PN=213
System Diagrams (S.N. 872256)
X2 B A
SIDE CONSOLE
HARNESS TO
ROOF HARNESS X56
CONNECTOR SEAT
SWITCH
CONNECTOR
(ROPS)
TX,9015,BG970 1925MAR971/1
PN=214
System Diagrams (S.N. 872256)
X25
SIDE CONSOLE HARNESS TO FRONT X24 B11
CONSOLE HARNESS CONNECTOR SIDE CONSOLE HARNESS TO FRONT BRAKE
CONSOLE HARNESS CONNECTOR S31
LIGHT SEAT
B SWITCHES SWITCH
1 2 3 4 5 6 A
7 8 9 10 11 12
C E
13 14 15 16 17 18
D
19 20 21 22 23 24
X21
SIDE CONSOLE HARNESS
TO ENGINE HARNESS
CONNECTOR
13 14 2 3
4
12
11 5
6
10
7
9 1 8
X22 3 2
SIDE 4 1
CONSOLE
HARNESS TO S19
ENGINE DIFF. LOCK
HARNESS SWITCH
CONNECTOR 5 7 8
6
3 2
4 1
5 6 7 8 X23
SIDE CONSOLE HARNESS
TO ENGINE HARNESS
CONNECTOR CAB SIDE CONSOLE COMPONENT LOCATION
T107603
TX,9015,BG981 1901APR971/1
PN=215
System Diagrams (S.N. 872256)
TX,9015,QQ1708 1906OCT931/1
PN=216
System Diagrams (S.N. 872256)
TX,9015,QQ1709 1912MAR931/1
PN=217
System Diagrams (S.N. 872256)
V9 X23
ALTERNATOR S20 ENGINE HARNESS
DIODE RETURN- TO SIDE CONSOLE
P13C TAN Y8 M1 Y3
TO-DIG HARNESS CONNECTOR
M39 PUR
Y2 B7 HYDRAULIC SWITCH STARTER FUEL Y3 P12 RED 1
RED
START AIR FILTER PUMP K1 MOTOR B5 SHUTOFF
K1 E23 WHT 2
GRN
AID RESTRICTION B3 DESTROKE START ENGINE SOLENOID
G2 SOLENOID SWITCH HORN SOLENOID RELAY Y9 B6 COOLANT B4 Y33 YEL 3
A B RETURN-
ALTERNATOR ENGINE OIL TEMPERATURE G2 P13 RED 4
TO-DIG PRESSURE SWITCH
W D+ SOLENOID B1 M62 PUR 5
G X34 SWITCH
S20 P20 RED 6
RED CABLE
P13B TAN
ENGINE HARNESS
M06 PUR
B+
TO A/C COMPRESSOR V2 J27 TAN 7
HARNESS CONNECTOR M B7 M40 PUR 8
A
B11 RED
A B C D B
+ + X22
ENGINE HARNESS TO SIDE
CONSOLE HARNESS
CONNECTOR
S3 M31 PUR 1
E02 WHT
N34 YEL
X36 YEL
P12 RED
E02 WHT
-
V1 W55 BLU 2
G01 BLK
P13 RED
B11 RED
G01 BLK
M39 PUR
H01 GRN
G1
B11 RED
A17 ORG
B11 RED
G02 BLK
G01 BLK
G01 BLK
M40 PUR
A67 ORG
G01 BLK
E23 WHT
E02 WHT
B03 RED
P20 RED
H01 GRN
B03 RED
B11 RED
E27 WHT
E23 WHT
G01 BLK
E23 WHT
X34 A17 ORG 3
(S.N. XXXXXX- )
BATTERIES
M5 A71 ORG 4
X21
X23
W1
K1
X23
Y9
W1
S20
X21
M1
X22
X23
W1
W1
Y8
W1
G2
K1
X23
X22
W1
M1
X23
K1
X21
X21
X23
X21
W1
X22
W1
V1
X22
X23
W1
G2
X21
Y14, Y4
X23
W11
V2, Y14 M1
W1
W1
X4
X22
X21
X22
X21
X21
W1
X23
Y1
W1
X21
W1
Y4, V2
V10
Y11
X21
W1
X4
X32
W1
W1
X4
W1
X4
X4
X22
X21
W1
W1
B3 A67 ORG 7
V5 T52 BLU 8
V5
V13
V4
V12
V3
W1
G01 BLK
G01 BLK
X21
J27 TAN
J27 TAN
T16 BLU
B6, Y9, B7
ENGINE HARNESS TO SIDE
T13 BLU
J27 TAN
J27 TAN
G01 BLK
M32 PUR
M62 PUR
W55 BLU
W55 BLU
G01 BLK
G01 BLK
T16 BLU
T16 BLU
T15 BLU
T15 BLU
G01 BLK
T52 BLU
T52 BLU
T13 BLU
A71 ORG
X38 YEL
W55 BLU
G01 BLK
F39 YEL
G01 BLK
Y33 YEL
G01 BLK
G01 BLK
T14 BLU
T14 BLU
G01 BLK
T11 BLU
T11 BLU
G01 BLK
G01 BLK
G01 BLK
G01 BLK
M31 PUR
Y8, B2, B1
V1, Y1, S3, Y2
Y7, V5, V3
V4, Y5, Y6
B4, B12, Y4
CONSOLE HARNESS
CONNECTOR
B
T52 BLU
T15 BLU
T11 BLU
T14 BLU
T13 BLU
G01 BLK
M1 B11 RED 1
B
B W1 G40 BLK 2
M
G02 BLK
G05 BLK
G40 BLK
G01 BLK
G05 BLK
V4 T11 BLU 3
G05 BLK
M1 E02 WHT 4
RED
A
B
C
D
E
F
A B
V3 T13 BLU 5
G04 BLK
G04 BLK
G04 BLK
G05 BLK
B X4 M5 B9 F39 YEL 6
ENGINE HARNESS WASHER
A Y2 E25 WHT 7
TO TRANSMISSION V13 V4 V3 MOTOR
B4 W3 A SOLENOID HARNESS C2/B3 B8 X38 YEL 8
GROUND V12 FORWARD V5 REVERSE
G03 BLK
FUEL A A CONNECTOR G2 M39 PUR 9
AT CAB SOLENOID C1/B2 SOLENOID NEUTRAL DIODE
SENDER DIODE
FLOOR SOLENOID DIODE DISCONNECT B8 B6 N34 YEL 10
DIODE SOLENOID TRANSMISSION B2 M32 PUR 11
B2 B1 V1 V2 V10 DIODE TEMPERATURE
REVERSE PARK BLK
DIFF. LOCK SWITCH 12
PARK MFWD
WARNING B9 W1 BRAKE SOLENOID B5 X36 YEL 13
BRAKE SOLENOID BLK BLK Y11
ALARM Y1 HYDRAULIC
S3 MACHINE SOLENOID DIODE
SENSING DIODE Y4 Y14 DIFF. LOCK V10 T16 BLU 14
MFWD MFWD FILTER FRAME/ENGINE DIODE
SWITCH PARK BRAKE PARK BRAKE SOLENOID
SOLENOID INDICATOR RESTRICTION BLOCK GROUND/
T108132 SWITCH SWITCH LEFT SIDE SOLENOID SOLENOID
TX,9015,BG973 1925MAR971/1
PN=218
System Diagrams (S.N. 872256)
TX,9015,QQ1711 1912MAR931/1
PN=219
System Diagrams (S.N. 872256)
TX,9015,QQ1712 1912MAR931/1
PN=220
System Diagrams (S.N. 872256)
TX,9015,QQ1713 1912MAR931/1
TX,9015,QQ1714 1910MAR971/1
PN=222
System Diagrams (S.N. 872256)
TX,9015,QQ1722 1910MAR971/1
W3
GROUND AT
R1 CAB FLOOR
BLOWER X6
RESISTOR BLOWER SWITCH
4 CONNECTOR
X36
1
AIR CONDITIONING R1 YEL 1
3
CLUTCH CYCLE
2
SWITCH CONNECTORS
R1 BLU 2 OFF
200 BLK
ORG
1
S8
2
3
BLOWER
4
SWITCH
522 WHT
PUR
BLU
YEL
517 DK BLU
1
X6, M6
M6
X6
X6
X35
X6
R1 ORG 4 2
M6
W3
B
3
M7, R1, X6
4
X36 PUR 3
BLK
X35 518 RED B
ORG
M6 X35
HEATER BLOWER HARNESS TO
BLOWER M SIDE CONSOLE HARNESS
MOTOR CONNECTOR
52C BLK/WHT
X6 WHT
T107545
TX,9015,BD2729 1910MAR971/1
PN=224
System Diagrams (S.N. 872256)
S22
HEATER TEMP.
SWITCH
S8
BLOWER SWITCH
X6
BLOWER SWITCH
CONNECTOR
X35
BLOWER HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
W3
GROUND AT
CAB FLOOR
W10
BLOWER
HARNESS
R1
BLOWER
RESISTOR
M6
HEATER
BLOWER
BLOWER HARNESS COMPONENT LOCATION MOTOR
T106845
TX,9015,BG971 1925MAR971/1
TX,9015,QQ1715 1910MAR971/1
PN=226
System Diagrams (S.N. 872256)
TX,9015,QQ1724 1910MAR971/1
F5
30 AMP HEATER/A.C.
BLOWER SWITCH S25 CIRCUIT BREAKER
CONNECTOR AIR CONDITIONING S22
SWITCH HEATER TEMPERATURE
SWITCH
YEL 1
BLU 2
PUR 3
ORG 4
RED B
BLOWER HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
S8
BLK / W C BLOWER
SWITCH
RED B
R1
S23 BLOWER
LOW PRESSURE RESISTOR
SWITCH
CONDENSOR
S24
HIGH PRESSURE M7
SWITCH HEATER BLOWER
MOTOR
S26
AC FREEZE
SWITCH
Y10
COMPRESSOR
TX,9015,BD2731 1910MAR971/1
PN=228
System Diagrams (S.N. 872256)
TX,9015,QQ1760 1912MAR931/1
TX,9015,QQ1761 1912MAR931/1
PN=230
System Diagrams (S.N. 872256)
TX,9015,QQ3272 1907SEP951/1
TX,9015,QQ3273 1907SEP951/1
PN=232
Group 10B
System Diagrams (S.N. 872257 )
Component Identification Table
Identification
Letter Type Examples
A System, subassembly, parts group Control units, trigger boxes, two-way radios, logic module, FNR
logic module
B Transducer for conversion of non-electrical Speed sensors, pressure sensors, pressure switches horns,
variables to electrical and vice versa sensors, pickups, limit-value sensors, pulse generators,
loudspeakers, inductive pickups, probes, air-flow sensors,
oil-pressure switches, temperature sensors, ignition-voltage pickups
C Condenser, capacitor Condensers and capacitors, general
D Binary device, memory Digital devices, integrated circuits, pulse counters, magnetic tape 9015
recorders 10B
1
E Various devices and equipment Heating devices, air conditioners, light, headlights, spark plugs,
ignition distributors
F Protection device Release mechanisms, polarity protection devices, fuses, current
protection circuits
G Power supply, generator Batteries, generators, alternators, charging units
H Monitor, alarm, signalling device Audible alarms, indicator lights, turn-signal lights, brake lights,
alarms, warning lights, buzzers
K Relay Battery relays, turn-signal relays, solenoid switches, starting relays,
warning flashers
L Inductor Choke coils, coils, windings
M Motor Blower motors, fan motors, starter motors
N Regulator, amplifier Regulators (electronic or electromechanical), voltage stabilizers
P Measuring instrument Ammeter, diagnostic connectors, tachometers, fuel 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
PN=233
System Diagrams (S.N. 872257 )
Identification
Letter Type Examples
S Switch Switches and pushbuttons, general key switch, light switch, horn
switch, flasher switch
T Transformer Ignition coil, ignition transformer
U Modulator, converter DC transformers
V Semiconductor, electron tubes Transistors, diodes, electron tubes, rectifiers, semiconductors,
thyristors, zener diodes
W Transmission path, conductor, antenna Antennas, shielding components, shielded conductors, cable
harnesses, conductors, ground conductors
X Terminal, plug, plug and socket connection Terminal studs, electrical connections, connectors electrical line
couplers, line connectors, sockets, plugs, terminals, plug-and-socket
connections
Y Electrically actuated mechanical device Permanent magnets, (solenoid-operated) injection valves,
electromagnetic clutches and brakes, air valves, fuel pumps,
solenoids, switching valves, start valves, locking systems
9015
Z Electrical filter Interference suppression filters
10B
2
TX,901505,QQ381 1916SEP922/2
TX,9015,QQ6743 1928SEP921/1
PN=234
System Diagrams (S.N. 872257 )
9015
10B
3
1928MAY96
T100712
F17.5 Amp F515 Amp Wiper Fuse F11Not Used K3Hydraulic Pump Relay
MFWD/Alternator/Diff. F630 Amp Heater/AC/Air F12Not Used (Not Used)
Lock Fuse Seat Fuse F1310 Amp RTD/Beacon and K4Reverse Alarm Relay
F215 Amp Fuel/Start Aid and F715 Amp Rear Light Fuse Pump Cutout Fuse K5Park Brake Relay
Reverse Alarm Fuse F825 Amp Front Light/Tail F1410 Amp Monitor/Gauge K6Neutral Relay
F35 Amp Dome Light/Radio Light Fuse Fuse K7Alternator Sense Relay
Fuse F910 Amp FNR/Park Brake F1510 Auxiliary Fuse S21Flasher
F45 Amp Radio Fuse Fuse F1610 Amp Start Fuse
(Unswitched Power) F1020 Amp Turn/Stop/Flash
and Horn Fuse
IMPORTANT: Install fuse with correct amperage The fuse block is located on the side console inside an
rating to prevent electrical system access cover.
damage from overload.
CED,TX17864,121 1921AUG981/1
PN=235
System Diagrams (S.N. 872257 )
NOTE: A2Radio (SE4, W12). E8R. H. Front Drive Light (SE9, W5)
E9L. H. Rear Tail Light (SE9, W5)
A2 indicates component identification E10R. H. Rear Tail Light (SE9, W5)
number. E11L. H. Brake Light (SE12, W5)
Radio indicates component name. E12R. H. Brake Light (SE12, W5)
SE4 indicates section number of SYSTEM E13Beacon Light (SE13, W5)
FUNCTIONAL SCHEMATIC where E14Fuel Gauge Light (SE14, W6)
component is located. E16Tachometer Lights (SE14, W6)
W12 indicates HARNESS WIRING F1MFWD/ Alt. Diff Lock Fuse (SE3, W6)
DIAGRAM and HARNESS COMPONENT F2Fuel/Either/Backup Alarm Fuse (SE5, W6)
LOCATION drawings where component is F3Dome/Radio Fuse (SE4, W6)
located. F4Radio Fuse (SE4, W6)
F5Wiper Fuse (SE7, W6)
A2Radio (SE4, W12) F6A/C-HTR/Air Seat Fuse (SE6, W6)
9015
10B B1 Backup Warning Alarm (SE5, W8) F7Rear Lights Fuse (SE8, W6)
4 B2Hydraulic Oil Temperature Switch (SE15, W8) F8Front Lights/Tail Lights Fuse (SE9, W6)
B3Horn (SE12, W8) F9FNR/Park Brake Fuse (SE10, W6)
B4Fuel Sender (SE15, W8) F10Turn/Stop/Flasher/Horn Fuse (SE12, W6)
B5Engine Coolant Temperature Switch (SE16, F13RTD/Beacon/Pump Fuse (SE13, W6)
W8) F14Monitor Gauges Fuse (SE14, W6)
B6Engine Oil Pressure Switch (SE16, W8) F15Auxiliary Fuse (SE1, W6)
B7Air Filter Restriction Switch (SE16, W8) F16Start Fuse (SE1, W6)
B8Converter Oil Temperature Switch (SE16, W8) F17Fuse Block (, W6)
B9Hydraulic Filter Restriction Indicator Switch G1Battery (SE1, W8)
(SE16, W8) G2Alternator (SE1, W8)
B10Park Brake Pressure Switch (SE16, W8) H2L. H. Front Turn Light (SE12, W5)
B11Brake Light Switches (SE12, W6) H3L. H. Rear Turn Light (SE12, W5)
B13Radio Speaker (SE4, W12) H4R. H. Front Turn Light (SE9, W5)
B14Radio Speaker (SE4, W12) H5R. H. Rear Turn Light (SE12, W5)
B15Engine Coolant Temperature Sender (If H8Display Monitor (SE15, W6)
Equipped) (SE16, ) H11Monitor Alarm (SE15, W6)
B16Hydraulic Oil Temperature Sender (If K1Starter Relay (SE1, W8)
Equipped) (SE16, ) K2Accessory Relay (SE1, W6)
B17Brake Pressure Switch (SE16, W6) K3Pump Cutout Relay (Not Used) (SE10, W6)
B18Brake Pressure Switch (SE16, W6) K4Backup Alarm Relay (SE5, W6)
B19A/C Freeze Switch (SE6, W10) K5Park Brake Relay (SE10, W6)
B20Low Pressure Switch (SE6, W11) K6Neutral Start Relay (SE10, W6)
B21High Pressure Switch (SE6, W11) K7Timer Relay (SE10, W7)
E1Dome Light (SE4, W5) K8Selective Flow Valve Relay (SE18, W15)
E3L. H. Front Work Light (SE9, W5) M1Starter Motor (SE1, W8)
E4R. H. Front Work Light (SE9, W5) M2Rear Wiper Motor (SE7, W5)
E5L. H. Rear Work Light (SE8, W5) M3L. H. Door Wiper Motor (SE7, W5)
E6R. H. Rear Work Light (SE8, W5) M4R. H. Door Wiper Motor (SE7, W5)
E7L. H. Front Drive Light (SE9, W5) M5Washer Motor (SE6, W8)
PN=236
System Diagrams (S.N. 872257 )
M6Blower Motor (SE6, W10) V10Differential Lock Solenoid Diode (SE2, W8)
M7Air Adjust Seat Motor (SE6, ) V11Park Brake Relay Diode (SE10, W6)
P1Fuel Gauge (SE14, W6) V12Speed Solenoid (1) Diode (SE10, W8)
P2Tachometer/Hourmeter (Optional) (SE14, W6) V13Speed Solenoid (2) Diode (SE10, W8)
P3Hour Meter (SE14, W6) V14Speed Solenoid (3) Diode (SE10, W8)
P4Voltage Gauge (Optional) (SE14, W6) V16Selective Flow Valve Diode (SE18, W15)
P5Engine Coolant Temperature Gauge (Optional) V18Low Range Solenoid Diode (SE10, W8)
(SE14, W6) V19Timer Relay Diode (SE10, W7)
P6Transmission Temperature Gauge (Optional) V20Timer Relay Diode (SE10, W7)
(SE14, W6) W1Machine Frame Ground (SE1, W8)
R1Blower Resistor (SE6, W10) W2Ground to Cab Frame (SE13, W5)
S1Key Switch (SE1, W6) W3Ground to Cab Floor (SE1, W8)
S2 MFWD Switch (SE3, W6) W4Engine Ground Strap (, W8)
S3Differential Lock Switch (SE2, W6) W5Cab Roof Harness (, W5)
S4Start Aid Switch (SE5, W6) W6Side Console Harness (, W6)
S5Front Windshield Wiper Switch (SE7, W7) W7Front Console Harness (, W7)
9015
S6Rear Wiper Switch (SE7, W6) W8Engine Harness (, W8) 10B
S7Windshield Washer Switch (SE7, W7) W10Blower Harness (, W10) 5
S8Blower Switch (SE6, W10) W11Air Conditioning Compressor Harness (, W11)
S9Front Light Switch (SE9, W7) W12Radio Harness (, W12)
S10Rear Light Switch (SE8, W6) W13Antenna (, W12)
S11FNR/Range Switch (SE10, W7) W15Selective Flow Valve Harness (, W15)
S12Park Brake Dash Switch (SE10, W6) W16Selective Flow Valve Ground Connector
S13Loader Lever Switch (SE10, W6) (SE18, W15)
S15Horn Switch (SE11, W6) X1Roof Harness to Side Console Harness
S16Turn Signal Switch (SE12, W7) Connector (, W5, W6)
S174-Way Flasher Switch (SE12, W7) X2Roof Harness to Side Console Harness
S18Beacon Switch (Optional) (SE13, W6) Connector (, W5, W6)
S19Seat Position Sensor (SE16, W6) X3Roof Harness to Side Console Harness
S19Seat Position Sensor (SE16, W10) Connector (, W5, W6)
S20Return-to-Dig Switch (SE14, W8) X5 Side Console Harness to Blower Harness
S21Flasher (SE12, W6) Connector (Cab Only) (, W6, W10)
S22Heater Temperature Switch (, W10) X20Side Console Harness to Engine Harness
S25Air Conditioning Switch (Optional) (SE6, W6) Connector (, W6, W8)
S27Dome Light Switch (SE4, W5) X21Side Console Harness to Engine Harness
S28Selective Flow Valve Switch (SE18, W15) Connector (, W6, W8)
S29Foot Switch (SE18, W15) X22Side Console Harness to Engine Harness
S32Air Adjust Seat Switch (SE6, ) Connector (, W6, W8)
V1MFWD Solenoid Diode (SE3, W8) X23Side Console Harness to Engine Harness
V2Park Brake Solenoid Diode (SE10, W8) Connector (, W6, W8)
V3Reverse Solenoid Diode (SE10, W8) X24Side Console Harness to Engine Harness
V4Forward Solenoid Diode (SE10, W8) Connector (, W6, W8)
V64-Way Flasher Switch Diode (SE12, W7) X25Side Console Harness to Front Console
V74-Way Flasher Switch Diode (SE12, W7) Harness Connector (, W6, W7)
V8Starter Solenoid Diode (SE1, W8) X29Roof Harness to Radio Harness Connector (,
V9Alternator Diode (SE1, W8) W5, W12)
PN=237
System Diagrams (S.N. 872257 )
X30Splice (Inside Side Console Harness) (, W6) X59Engine Harness to AC Compressor Harness
X34Engine Harness to AC Compressor Harness Connector (, W8, W11)
Connector (, W8, W11) X60Splice (Inside Blower Harness) (, W10)
X35Side Console Harness to Blower Harness Y1MFWD Solenoid (SE3, W8)
Connector (Cab Only) (, W6 W10) Y2Start Aid Solenoid (SE5, W8)
X46Selective Flow Valve Harness to Foot Switch Y3Fuel Shutoff Solenoid (SE5, W8)
Harness Connector (, W15) Y4Park Brake Solenoid (SE9, W8)
X48Selective Flow Valve Harness to Valve Y5Reverse Solenoid (SE10, W8)
Solenoid Harness Connector (, W15) Y6Forward Solenoid (SE10, W8)
X53Engine Harness to Auxiliary Gauge Harness (, Y8Differential Lock Solenoid (SE2, W8)
W8) Y9Return-to-Dig Solenoid (SE14, W8)
X54Engine Harness to Transmission Control Valve Y10A/C Compressor Clutch (SE6, W11)
Connector (, W8) Y12Speed Solenoid (1) (SE10, W8)
X55Side Console Harness to Air Adjust Seat Y13Speed Solenoid (2) (SE10, W8)
Harness Connector (ROPS Only) (, W6) Y14Speed Solenoid (3) (SE10, W8)
X56Blower Harness to Air Adjust Seat Harness Y16Selective Flow Valve Solenoid (SE18, W15)
9015
10B (Cab Only) (, W10) Y18Low Range Solenoid (SE10, W8)
6 X57Engine Harness to Transmission Control Valve Y19Hydraulic Pump Destroke Solenoid (SE10,
Connector (, W8) W8)
X58Side Console Harness Auxiliary Power
Connector (SE1, W6, W15)
CED,TX17864,122 1921AUG983/3
PN=238
System Diagrams (S.N. 872257 )
CED,TX17864,123 1921AUG981/1
PN=239
System Diagrams (S.N. 872257 )
CED,TX17864,124 1921AUG981/7
PN=240
System Diagrams (S.N. 872257 )
T116836 1908OCT98
CED,TX17864,124 1921AUG982/7
PN=241
System Diagrams (S.N. 872257 )
T117529 1908OCT98
CED,TX17864,124 1921AUG983/7
PN=242
System Diagrams (S.N. 872257 )
T117085 1908OCT98
CED,TX17864,124 1921AUG984/7
PN=243
System Diagrams (S.N. 872257 )
T117360 1908OCT98
CED,TX17864,124 1921AUG985/7
PN=244
System Diagrams (S.N. 872257 )
T116992 1908OCT98
CED,TX17864,124 1921AUG986/7
PN=245
System Diagrams (S.N. 872257 )
9015
10B
14
T117392 1908OCT98
CED,TX17864,124 1921AUG987/7
PN=246
System Diagrams (S.N. 872257 )
E1 M2 E10 H5 E12
DOME REAR R.H. R.H. R.H.
LIGHT WIPER MOTOR REAR REAR BRAKE E6 M4 H4 E8 E4
TAIL TURN LIGHT R.H. R.H. DOOR R.H. R.H. R.H.
LIGHT LIGHT REAR WIPER MOTOR FRONT FRONT FRONT X2
WORK TURN DRIVE WORK ROOF HARNESS
LIGHT LIGHT LIGHT LIGHT TO SIDE CONSOLE
HARNESS CONNECTOR
M
X29 P25 RED B
M E1, X29 P15 RED A
RED
BLU
YEL
BRN
RED
YEL
BLU
G20 BLK
X3
S27 ROOF HARNESS
DOME TO SIDE CONSOLE
LIGHT HARNESS CONNECTOR
SWITCH
H
A66 ORG
P14 RED
G20 BLK
L42 BRN
A65 ORG
G20 BLK
A63 ORG
G20 BLK
A64 ORG
G20 BLK
L43 BRN
L41 BRN
G20 BLK
L47 BRN
P14 RED
L47 BRN
L46 BRN
G20 BLK
L43 BRN
G
G20 BLK
P15 RED
M2 A66 ORG F
M2 A65 ORG E
W2
X3
X3
X1, M3, M4
W2
H4, X1
X1, E11
W2
W2
X3
X3
X1, M2, M3
W2
X1, E9, E10,
X29, E7
W2
X1, E3
X2
X29
W2
X1, E5
X1, H5
W2
W2
X3
X3
W2
W2
X2
W2
W2
X1
W2
W2
W2
M4 A63 ORG C
H2, X1
H3, X1
X2, E1
X1, E6
X1, E4
X1, E12
M3 A62 ORG B
E9,E10,
X1, E7, E8
E10, X29,
X1, E8, E9
X1, M4, M2
E7,E8
X1, E10, X29
E3, E5
E10, H5
E11, E8
E4, E6
E12, M4
E7, H2
E9, H3
H4, E13
X29, M3
S27, M2
M3 A61 ORG A
X1
L46 BRN
G20 BLK
L41 BRN
G20 BLK
L48 BRN
L48 BRN
G20 BLK
A61 ORG
A62 ORG
L43 BRN
G20 BLK
L43 BRN
L45 BRN
G20 BLK
L42 BRN
G20 BLK
G20 BLK
P14 RED
P15 RED
L43 BRN
G20 BLK
P25 RED
ROOF HARNESS
G20 BLK
TO SIDE CONSOLE
HARNESS CONNECTOR
M3 P14 RED H
M2, M4
E6, E5 L41 BRN G
H2, H3 L48 BRN F
A B C D X29 L43 BRN E
E7, E9, E10, E8
RED
YEL
BLU
CED,TX17864,137 1921AUG981/1
PN=247
System Diagrams (S.N. 872257 )
H5/E12/E10
R.H. REAR
TURN/BRAKE/TAIL LIGHT
E6
R.H. REAR
WORK LIGHT
H3/E11/E9
L.H. REAR
S27 TURN/BRAKE/TAIL LIGHT
DOME X28
H4 LIGHT
R.H. FRONT BEACON
SWITCH LIGHT E5 X1
TURN LIGHT
CONNECTOR L.H. REAR ROOF HARNESS
E1 WORK LIGHT TO SIDE CONSOLE
DOME HARNESS CONNECTOR
LIGHT M2
E8 REAR WIPER M3 P14 RED H
R.H. FRONT MOTOR X29 M2,M4
DRIVE ROOF HARNESS
TO RADIO E6,E5 L41 BRN G
LIGHT
HARNESS H2,H3 L48 BRN F
A B C D CONNECTOR X29 L43 BRN E
E7,E9,E10,E8
E4 E13 L45 BRN D
R.H. FRONT H G F E
H4,H5 L47 BRN C
WORK LIGHT X1 E11,E12 L46 BRN B
W2 ROOF HARNESS
GROUND TO SIDE E4,E3 L42 BRN A
H2 TO CAB CONSOLE
L.H. FRONT FRAME HARNESS
TURN LIGHT CONNECTOR
X3
M4 ROOF HARNESS
R.H. DOOR A B C D TO SIDE CONSOLE
WIPER HARNESS CONNECTOR
MOTOR M4 A69 ORG H
E F G H
X3 M3 A68 ORG G
ROOF HARNESS M2 A66 ORG F
TO SIDE M2 A65 ORG E
CONSOLE M4 A64 ORG D
E3 HARNESS M4 A63 ORG C
L.H. FRONT CONNECTOR
D C B M3 A62 ORG B
WORK A
LIGHT M3 A61 ORG A
A B X2 X2
ROOF HARNESS ROOF HARNESS
TO SIDE TO SIDE CONSOLE
M3 CONSOLE HARNESS CONNECTOR
E7 L.H. DOOR HARNESS X29 P25 RED B
L.H. FRONT WIPER MOTOR
DRIVE LIGHT CONNECTOR E1,X29 P15 RED A
TX,9015,QQ6748 1920MAR961/1
PN=248
System Diagrams (S.N. 872257 )
Cab Roof Harness (W5) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
17
1908AUG96
T101266
PN=249
System Diagrams (S.N. 872257 )
9015
10B
18
1908AUG96
T101396
TX,9015,QQ6749 1920MAY962/2
PN=250
System Diagrams (S.N. 872257 )
CED,TX17864,143 1924AUG981/3
PN=251
System Diagrams (S.N. 872257 )
T117078 1910SEP98
CED,TX17864,143 1924AUG982/3
PN=252
System Diagrams (S.N. 872257 )
T116949 1910SEP98
CED,TX17864,143 1924AUG983/3
PN=253
System Diagrams (S.N. 872257 )
X20 S19
X24 SIDE CONSOLE HARNESS SEAT POSITION
SIDE CONSOLE HARNESS TO ENGINE HARNESS SENSOR
TO ENGINE HARNESS CONNECTOR 31 20
30 8 21 B11 (ROPS ONLY)
CONNECTOR X30 G40 BLK 19 9
18 2 10
BRAKE
M1 B11 RED X20 29 7 3 22 LIGHT X55
SIDE CONSOLE HARNESS 17 1 11 SWITCH SIDE CONSOLE
TO ENGINE HARNESS 28 6 4 23 HARNESS TO
X21 16 5 12 X25 B18
CONNECTOR 15 13 BRAKE AIR ADJUST
SIDE CONSOLE HARNESS 27 14 24 SIDE CONSOLE SEAT HARNESS
TO ENGINE HARNESS 26 25 PRESSURE
HARNESS TO FRONT SWITCH CONNECTOR
X25 CONNECTOR CONSOLE HARNESS (ROPS ONLY)
SIDE CONSOLE HARNESS H8 X36 YEL 1 X24 CONNECTOR
TO FRONT CONSOLE H8 N34 YEL 2 SIDE CONSOLE HARNESS
CONNECTOR H8 X38 YEL 3 TO ENGINE HARNESS
X3 A61 ORG 1 H8 F39 YEL 4 CONNECTOR B17
X3 A62 ORG 2 H8 M40 PUR 5 BRAKE
X3 A63 ORG 3 P2,H8 M39 PUR 6 7 8 9 10 11 12 PRESSURE
X3 A64 ORG 4 SWITCH
P1 Y33 YEL 7
X22 A71 ORG 5 NOT USED Y1 YEL 8
F5,S6,X1 P14 RED 6 NOT USED Y2 YEL 9
F12 L47 BRN 7 NOT USED K1 BLU 10
8 S15 A67 ORG 11
9 V14 M62 PUR 12
B11,F10,S15 P19 RED 10 6 5 4 3 2 1
11 X23 X21
S21 L49 BRN 12 SIDE CONSOLE HARNESS SIDE CONSOLE HARNESS
TO ENGINE HARNESS TO ENGINE HARNESS
F11 L48 BRN 13 CONNECTOR
X30 G30 BLK 14 CONNECTOR
K6 E23 WHT 1
X21 T11 BLU 15 S4 P12 RED 2 7 8 9 10 11 12
S4 E25 WHT 3
16 S2,F1 P13 RED 4
F9 P24 RED 17 S14 T53 BLU 5
18 S2 W55 BLU 6
19 S12 J27 TAN 7
F8 P18 RED 20 E15 M32 PUR 8
X1 L43 BRN 21 X25 T11 BLU 9 6 5 4 3 2 1
F8 P18 RED 22 X25 T13 BLU 10
X1 L42 BRN 23 V11 E02 WHT 11 X23
K6 T12 BLU 24 SIDE CONSOLE HARNESS
Y8 W02 BLU 12 TO ENGINE HARNESS
25 CONNECTOR
26 X22 S3
27 SIDE CONSOLE HARNESS 5 4 DIFF.
28 TO ENGINE HARNESS LOCK
CONNECTOR 6 3 SWITCH
29
1
30
H8 X41 YEL 2
31 7 2
3
F13 P20 RED 4 8 1
5
X22
X38 A17 ORG 6 SIDE CONSOLE HARNESS
X25 A71 ORG 7 TO ENGINE HARNESS
T116951 8 CONNECTOR SIDE CONSOLE HARNESS COMPONENT LOCATION
CED,TX17864,125 1921AUG981/2
PN=254
System Diagrams (S.N. 872257 )
T116952 1914OCT98
CED,TX17864,125 1921AUG982/2
PN=255
System Diagrams (S.N. 872257 )
Side Console Harness (W6) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
24
T116958 1910SEP98
PN=256
System Diagrams (S.N. 872257 )
9015
10B
25
1910SEP98
T116959
PN=257
System Diagrams (S.N. 872257 )
9015
10B
26
1910SEP98
T116960
PN=258
System Diagrams (S.N. 872257 )
9015
10B
27
1910SEP98
T116961
CED,TX17864,126 1921AUG984/4
PN=259
System Diagrams (S.N. 872257 )
CED,TX17864,138 1921AUG981/1
PN=260
System Diagrams (S.N. 872257 )
CED,TX17864,136 1921AUG981/1
Front Console Harness (W7) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
30
T116908 1910SEP98
PN=262
System Diagrams (S.N. 872257 )
9015
10B
31
1910SEP98
T116909
CED,TX17864,127 1921AUG982/2
PN=263
System Diagrams (S.N. 872257 )
CED,TX17864,139 1921AUG981/2
PN=264
System Diagrams (S.N. 872257 )
T116815 1910SEP98
CED,TX17864,139 1921AUG982/2
PN=265
System Diagrams (S.N. 872257 )
G1 S20 Y9
BATTERIES RETURN-TO-DIG RETURN-TO-DIG
SWITCH SOLENOID
M5 V13
WASHER W1 SPEED
MOTOR MACHINE W1 G40 BLK
FRAME SOLENOID (2) X20
GROUND DIODE ENGINE HARNESS
B3 V12 TO SIDE CONSOLE
HORN SPEED
SOLENOID (1) HARNESS CONNECTOR
K1 DIODE
START
RELAY X54
Y2 ENGINE HARNESS TO M1,G2 B11 RED
START TRANSMISSION CONTROL X24
ENGINE HARNESS
AID VALVE CONNECTOR TO SIDE CONSOLE
SOLENOID B10
PARK BRAKE HARNESS CONNECTOR
B7 PRESSURE SWITCH
B5 X36 YEL 1
AIR FILTER 7 8 9 10 11 12 B6 N34 YEL 2
RESTRICTION V14
SPEED B8 X38 YEL 3
SWITCH
SOLENOID (3) B9 F39 YEL 4
V9 DIODE B7 M40 PUR 5
ALTERNATOR G2 M39 PUR 6
DIODE S4 Y33 YEL 7
NOT USED Y1 YEL 8
X53 6 5 4 3 2 1 NOT USED Y2 YEL 9
ENGINE HARNESS
TO AUXILIARY X21 NOT USED K1 BLU 10
GAUGE HARNESS ENGINE HARNESS B3 A67 ORG 11
TO SIDE CONSOLE B1 M62 PUR 12
B9 HARNESS CONNECTOR
HYDRAULIC
B1
BACKUP 7 8 9 10 11 12 K1 E23 WHT 1
FILTER WARNING
RESTRICTION Y3 P12 RED 2
ALARM Y2 E25 WHT 3
SWITCH
Y19 V3 Y9 P13BRED 4
HYDRAULIC REVERSE
SOLENOID 5
PUMP DESTROKE Y1,V1 W55 BLU 6
SOLENOID W3 DIODE
GROUND TO Y4,V2 J27 TAN 7
V4
CAB FLOOR FORWARD B10 M32 PUR 8
6 5 4 3 2 1 X54,V4 T11 BLU 9
SOLENOID
Y8 DIODE X23 X54,V3 T13 BLU 10
B8 DIFF. ENGINE HARNESS
CONVERTER LOCK M1,V8,K1,Y19 E02 WHT 11
G2 TO SIDE CONSOLE Y8,V10 W02 BLU 12
ALTERNATOR OIL SOLENOID HARNESS CONNECTOR
V8 TEMP. Y4
START PARK BRAKE
SOLENOID 5 4
SOLENOID
DIODE X57 6 3 V13,X57 T18 BLU 1
B5 ENGINE HARNESS Y1
TO TRANSMISSION MFWD 2
ENGINE COOLANT SOLENOID V2
X59 TEMP. SWITCH CONTROL VALVE V14,X57 T19 BLU 3
ENGINE HARNESS PARK BRAKE V1 7 2
M1 CONNECTOR SOLENOID V10 V18 S20 P20 RED 4
TO AC COMPRESSOR B4 MFWD DIFF.
HARNESS CONNECTOR STARTER FUEL DIODE SOLENOID LOW RANGE 8 1 V18,X54 T16 BLU 5
X34 B6 MOTOR LOCK SOLENOID X34 A17 ORG 6
Y3 SENDER DIODE DIODE X22
ENGINE HARNESS TO ENGINE OIL W4 DIODE ENGINE HARNESS M5 A71 ORG 7
FUEL PRESSURE SWITCH
AC COMPRESSOR HARNESS SHUTOFF GROUND TO SIDE CONSOLE V12,X57 T17 BLU 8
T116817 CONNECTOR SOLENOID STRAP ENGINE HARNESS COMPONENT LOCATION HARNESS CONNECTOR
CED,TX17864,129 1921AUG981/1
PN=266
System Diagrams (S.N. 872257 )
Engine Harness (W8) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
35
1910SEP98
T116911
PN=267
System Diagrams (S.N. 872257 )
9015
10B
36
1910SEP98
T116912
PN=268
System Diagrams (S.N. 872257 )
9015
10B
37
T116913 1910SEP98
CED,TX17864,130 1921AUG983/3
CED,TX17864,147 1925AUG981/1
PN=270
System Diagrams (S.N. 872257 )
CED,TX17864,131 1921AUG981/1
Blower Harness (W10) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
40
1915OCT98
T116924
TX,9015,QQ6757 1921JUL981/1
PN=272
System Diagrams (S.N. 872257 )
9015
10B
41
1908OCT98
T116838
CED,TX17864,140 1921AUG981/1
PN=273
System Diagrams (S.N. 872257 )
9015
10B
42
1908OCT98
T116925
CED,TX17864,132 1921AUG981/1
PN=274
System Diagrams (S.N. 872257 )
Air Conditioning Compressor Harness (W11) Connectors, Wire and Pin Location (S.N.
872257 )
9015
10B
43
1915OCT98
T116926
CED,TX17864,133 1921AUG981/1
PN=275
System Diagrams (S.N. 872257 )
9015
10B
44
1910SEP98
T116854
CED,TX17864,141 1921AUG981/1
PN=276
System Diagrams (S.N. 872257 )
TX,9015,QQ6758 1920MAR961/1
Radio Harness (W12) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
46
T101356 1908AUG96
TX,9015,QQ6759 1921MAY961/1
PN=278
System Diagrams (S.N. 872257 )
9015
10B
47
1910SEP98
T116865
CED,TX17864,142 1921AUG981/1
PN=279
System Diagrams (S.N. 872257 )
9015
10B
48
1910SEP98
T116866
CED,TX17864,134 1921AUG981/1
PN=280
System Diagrams (S.N. 872257 )
Selective Flow Valve Harness (W15) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
49
1910SEP98
T116931
CED,TX17864,135 1921AUG981/1
PN=281
System Diagrams (S.N. 872257 )
9015
10B
50
PN=282
Group 15A
Sub-System Diagnostics (S.N. 872256)
Power Circuit Operational Information
(S.N. 872256)
TX,9015,QQ1725 1912MAR931/1
TX,9015,QQ1726 1912MAR931/1
PN=283
Sub-System Diagnostics (S.N. 872256)
S1 ACC
OFF
B12 RED
B11 RED
START AID/ FUSE
REVERSE ALARM UNSWITCHED
FUSE RADIO FUSE
9015
15A IGN
2
B11 RED
E22 WHT
B11 RED
F9 F15
UNSWITCHED
ST FNR/PARK
HAZARD
BRAKE FUSE
G10 BLK
K2 MONITOR
ACCESSORY FUSE
G
B11 RED
RELAY
B15
G10 RED
BLK B14 RED
G1 F1
BATTERIES MFWD/
B11 RED
RED CABLE
+ ALT
DIFF F3 F6
TO NEUTRAL LOCK F8
START RELAY DOME/ HEATER/
FUSE FRONT
E23 WHT
F7 F10
G10 BLK
RELAY F5
BLK
E02 WHT
MACHINE FRAME/ENGINE W D+ F13
BLOCK GROUND/LEFT SIDE RETURN-TO-DIG/
G
BEACON FUSE
1916SEP98
G01 BLK
W1
G10
B+
BLK
G40
BLK
G40 BLK G2
G02 BLK ALTERNATOR
T117133
T117133
CED,TX17864,153 1910SEP981/1
PN=284
Sub-System Diagnostics (S.N. 872256)
S1 ACC
OFF
B12B RED
B11D RED
KEY ON B12A RED
BULB CHECK
SWITCH
B12C RED
START
F2 F16
ACC
BAT B14 FUEL SHUTOFF/ START
B11A RED
RED
START AID/ F4
FUSE UNSWITCHED
REVERSE ALARM
FUSE RADIO FUSE
9015
IGN 15A
B11B RED
3
E22 WHT
B11 RED
F9 F15
UNSWITCHED
ST FNR/PARK
HAZARD
BRAKE FUSE
G10 BLK
K2 MONITOR
ACCESSORY FUSE
G
B11C RED
RELAY
B15
G10L RED
BLK B14 RED
G1 F1
BATTERIES MFWD/
B11 RED
RED CABLE
+ ALT
DIFF F3 F6
TO NEUTRAL LOCK F8
DOME/ HEATER/
START RELAY FUSE FRONT
RADIO FUSE
E23 WHT
SE11, K6 CIRCUIT
B11 RED BREAKER WORK/
B03 RED LIGHT
E02 WHT FUSE
K1
START S
CABLE
F5 F7 F10
G10 BLK
RELAY
BLK
E02 WHT
MACHINE FRAME/ENGINE W D+ F13
BLOCK GROUND/LEFT SIDE RETURN-TO-DIG/
G
BEACON FUSE
1916SEP98
G01 BLK
W1
G10
B+
BLK
G40
BLK
G40 BLK G2
G02 BLK ALTERNATOR
T117134
T117134
CED,TX17864,154 1910SEP981/1
PN=285
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,158 1910SEP981/1
1/1
1/1
T7199BK 1917SEP90
1/1
T7828AA 1923SEP92
1/1
PN=286
Sub-System Diagnostics (S.N. 872256)
With harness connected, check voltage at terminal with NO: Check wiring
BO3 red wire. harness between battery
and start relay.
Are 12 volts measured?
T7199BM 1917SEP90
1/1
T7199BO UN17SEP90
Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next step in
this check.
Remove FNR/park brake fuse.
NO: Replace key switch
Remove start fuse.
T7199BO UN17SEP90
With harness connected, check voltage at IGN and ST
terminals.
With harness connected, check voltage at ACC terminal NO: Replace key switch.
of key switch.
T7199BO UN17SEP90
1/1
PN=287
Sub-System Diagnostics (S.N. 872256)
T7199BN UN16AUG90
9015
15A T7199BN UN16AUG90
6
1/1
PN=288
Sub-System Diagnostics (S.N. 872256)
9015
15A
7
PN=289
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ1732 1912MAR931/1
TX,9015,QQ1729 1912MAR931/1
PN=290
Sub-System Diagnostics (S.N. 872256)
ACC
BAT
E22 WHT
D
BLU C 9015
2 3 4 GRN B 15A
IGN 1
A 9
RANGE
B12 RED
B11B RED
ST
F9 D B C A
G FNR/PARK A1
RED
T12 BLU
86 30
G1 87A
B11 RED
BATTERIES 85 87
TIME
E22 WHT
K2 DELAY 30
G10 BLK
86
+ CIRCUIT
87A
ACCESSORY 85 87
RELAY
RED
CABLE 86 30
86 30
E23 WHT 87A
87A
E02
T12 BLU
85 87 85 87
WHT
BLK CABLE
B03 RED
E23 WHT
86 30 K6 F16
K1 M NEUTRAL
START 87A START
START
RELAY 85 87 FUSE
M1 RELAY
STARTER E22A WHT
MOTOR
G01
BLK
T117135
CED,TX17864,155 1910SEP981/1
PN=291
Sub-System Diagnostics (S.N. 872256)
ACC
BAT
E22 WHT
D
BLU C
9015
2 3 4 GRN B
15A IGN 1
10 A
RANGE
B12B
RED
B11B RED
B12C
RED
ST P24B
RED P24A RED
F9 D B C A
G FNR/PARK A1
RED
T12 BLU
CONTROLLER
B11C RED
86 30
G1 87A
B11 RED
BATTERIES 85 87
TIME
E22 WHT
K2 DELAY 30
G10 BLK
86
+ CIRCUIT
87A
ACCESSORY 85 87
RELAY
RED
CABLE 86 30
86 30
E23 WHT 87A
87A
E02
T12 BLU
85 87 85 87
WHT
BLK CABLE
B03 RED
E23 WHT
86 30 K6 F16
K1 M NEUTRAL
START 87A START
START
RELAY 85 87 FUSE
M1 RELAY
STARTER E22A WHT
MOTOR
G01
BLK
T117136
CED,TX17864,156 1910SEP981/1
PN=292
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,157 1910SEP981/1
1/1
Key Switch Check Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next check.
9015
Remove FNR/park brake fuse. NO: Replace key switch.
15A
11
Remove start fuse.
T7199BO UN17SEP90
With harness connected, check voltage at IGN and ST
terminals.
1/1
PN=293
Sub-System Diagnostics (S.N. 872256)
9015
15A T7828AC UN09MAR93
12
Key switch ON. FNR/range lever in neutral
With harness connected, check voltage at terminals with red wire and gray wire.
T7828AD UN09MAR93
With harness connected, and FNR/range lever moved to forward, check voltage at
terminal with yellow wire.
1/1
PN=294
Sub-System Diagnostics (S.N. 872256)
1/1
1/1
1/1
1/1
PN=295
Sub-System Diagnostics (S.N. 872256)
Disconnect metal strap from starter motor large terminal. NO: Repair or replace
starter motor.
Connect a heavy gauge jumper wire from battery
positive cable to starter motor terminal.
T6534BJ UN07JAN97
1/1
TX,9015,QQ1827 1912MAR931/1
PN=296
Sub-System Diagnostics (S.N. 872256)
With key switch ON and engine running, power flows from 9015
terminal (W) of alternator to alternator relay, energizing it. 15A
Terminals 30 and 87 are connected, and indicator light 15
goes out.
TX,9015,QQ1375 1912MAR931/1
PN=297
Sub-System Diagnostics (S.N. 872256)
ENGINE ALT
VOLTS
ST H8 1
2
A
B
DISPLAY 3
4
C
D
E
MODULE 5
6 F
G
K2 11
12
F
E
G10 ACCESSORY 13
14
D
C
G10
BLK RELAY 15 B
B11 RED
DIFF
P13
B11
RED
METER
M39
G1
BLK CABLE
PUR
S
P13B
BATTERIES
BRN
30
86
PUR
M39
M1 NOT
V9 87A
STARTER USED
ALTERNATOR 85 87
MOTOR M
DIODE
P13C
G10
D+ TAN
W BLK
RED
G40
B11
G10 BLK
G10
1916SEP98
T117137
CED,TX17864,159 1910SEP981/1
PN=298
Sub-System Diagnostics (S.N. 872256)
BAT ACC
6 F
B11 RED
ST
11 F
12 E
13 D
14 C
G 15 B
16 A
7 A
8 B
B11 RED 9 C
10 D
G10 BLK
M37 PUR
G10
BLK
M37 PUR
B14 RED
TO P3
B11 RED
HOUR
M37 PUR
F1 METER
MFWD/ALT
G10 BLK
FUSE
B15 RED
CABLE
B11 RED
RED
F15
RED
B11 RED
P13
S
HAZARD/
MONITOR FUSE
G1 M39 PUR
CABLE
BATTERIES M1 86 30
BLK
P13B
PUR
BRN
M39
STARTER
M MOTOR B11 RED 87A
G40 P13C
W D+ 85 87
BLK TAN
G G10 BLK
G10 G2
G10 BLK
T117138
CED,TX17864,161 1910SEP981/1
PN=299
Sub-System Diagnostics (S.N. 872256)
ACC GROUNDCIRCUIT
OFF (WIRE COLOR) G01 BLKENGINE HARNESS
ON G10 BLKSIDE CONSOLE HARNESS
BULB CHECK KEY G20 BLKROOF HARNESS
START SWITCH G30 BLKFRONT CONSOLE HARNESS
BAT IGN ACC ST G BODY G40 BLKENGINE HARNESS TO SIDE
CONSOLE HARNESS
B11B RED
ACC
S1 OFF
ON
KEY BULB CHECK
SWITCH START
ENGINE ALT VOLTS
BAT ACC
1 A
9015 H8 2 B
3 C
15A DISPLAY 4 D
MODULE 5 E
18 IGN 6 F
11 F
12 E
B14 RED
13 D
B11B RED
14 C
ST 15 B
16 A
7 A
8 B
9 C
G D
10
M37B PUR
B11 RED
M37C PUR
G10 BLK
B11C RED TO P3
G10
BLK
HOUR
METER
B14 RED
M37A PUR
B11A RED
F1
MFWD/ALT
G10 BLK
FUSE
B15 RED
CABLE
F15
RED
P13A
RED
B11 RED
HAZARD/
S
MONITOR FUSE
G1 M39 PUR
CABLE
BATTERIES M1 86 30
BLK
P138
PUR
BRN
M39
STARTER
M MOTOR B11 RED 87A
G40 P13C
W D+ 85 87
BLK TAN
G G10T BLK
G10 G2
G10 BLK
K7
TO ENGINE GROUND STRAP ALTERNATOR
RELAY
T117139
T117139
CED,TX17864,162 1910SEP981/1
PN=300
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,163 1910SEP981/1
1/1
1/1
Alternator Key switch ON. Engine running. Park brake ON. YES: Alternator is good.
Is 14 DC volts measured?
T7835AT 1923SEP92
1/1
PN=301
Sub-System Diagnostics (S.N. 872256)
Alternator Relay IMPORTANT: Relay is a six volt relay. Do not apply YES: Relay is good.
more than 6 volts when testing. Check wiring harness.
1/1
T7199BO UN17SEP90
Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next step in
this check.
Remove FNR/park brake fuse.
NO: Replace key switch
Remove start fuse.
T7199BO UN17SEP90
With harness connected, check voltage at IGN and ST
terminals.
With harness connected, check voltage at ACC terminal NO: Replace key switch.
of key switch.
T7199BO UN17SEP90
1/1
PN=302
Sub-System Diagnostics (S.N. 872256)
T7199BN UN16AUG90
9015
T7199BN UN16AUG90 15A
21
1/1
TX,9015,QQ3185 1910MAR971/1
PN=303
Sub-System Diagnostics (S.N. 872256)
Display Module and Logic Module Circuit Theory of Operation (S.N. 815415) With Logic
Module
Key Switch OFF The logic module stops current flow to the display
monitor.
Power is supplied to the logic module through the
Hazard/Monitor Unswitched fuse to pin A of logic Failure Occurs
module (6 pin connector).
The indicator switch (sensor) closes, grounding an
Key Switch ON indicator light and also the logic module. The logic
module supplies power to all bulbs in the display
Power is supplied to the logic module through the module, the secondary failure indicator light, primary
Monitor Switched fuse. No power is supplied from the indicator light, and alarm. The logic module then
logic module to the display module since the logic connects either the red light and alarm or the yellow
module has not been "armed." light to ground, turning them ON.
9015
15A Key Switch in BULB CHECK or START If the key switch is momentarily turned OFF and back
22 ON while the engine is running, power from the
The key switch connects all indicator lights in the alternator indicator terminal will keep the logic module
display module to ground when the key switch is in the activated.
BULB CHECK or START positions. The key switch
also grounds the logic module, signaling the logic NOTE: For component identification code description,
module to supply power to all bulbs in the display see Wiring and Schematic Diagrams Legend,
module, the primary and secondary indicators and the Group 9015-10.
alarm, turning them ON. Turning the key switch to
BULB CHECK or START also "arms" the logic module
so failures will be indicated.
TX,9015,DY663 1910MAR971/1
TX,9015,QQ3187 1910MAR971/1
PN=304
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ3188 1910MAR971/1
PN=305
Sub-System Diagnostics (S.N. 872256)
TX,9015,BD2733 1907MAR971/1
PN=306
Sub-System Diagnostics (S.N. 872256)
P23 RED
A B Z36 GRY
B C Z36 GRY
C D Z33 GRY
Z34 GRY
D E
IGN Z37 GRY
F
H11
M37 PUR H10 ALARM
Z36 GRY
YELLOW
Z32 GRY
WARNING
ST
R31 BLK LIGHT
Z33 GRY
Z34 GRY
G10 BLK
G
R31 BLK Z32 GRY
R31 BLK
86 30 1 A
2 B
3 C
87A
M39 PUR
4 D
G10 BLK
5 E
85 6 F
M37 PUR
87
G10 BLK
TO G2 K7 P23 RED 11 F
ALTER- ALTERNATOR H8 12
13
E
D
14 C
NATOR RELAY DISPLAY 15 B
MODULE 16 A
M37 PUR
G10 BLK
1916SEP98
7 A
G10 BLK G40 BLK G40 BLK 8 B
9 C
W1 MACHINE FRAME/ENGINE 10 D
T117140
CED,TX17864,164 1910SEP981/1
PN=307
Sub-System Diagnostics (S.N. 872256)
P21 RED
F14
S1 MONITOR F15
KEY FUSE UNSWITCHED
9015 SWITCH HAZARD/MONITOR
ACC
15A OFF
FUSE P21 RED
26 ON
H9
BULB CHECK
START RED
WARNING
ACC
BAT LIGHT
P23 RED
B12 RED
Z36 GRY
Z36 GRY
P21 RED
Z36 GRY
Z37 GRY
IGN
H10 H11
YELLOW ALARM
WARNING
LIGHT
P21 RED P21 RED
ST
V8 Z37 GRY
M38 PUR TO K3
G Z36 GRY
R31 BLK R31 BLK
86 30 1 A
M39 PUR
2 B
G10 BLK
3 C
87A 4 D
5 E
85 6 F
M37 PUR
87
G10 BLK
11 F
TO G2 P23 RED 12 E
ALTER- K7 H8 13
14
D
C
NATOR DISPLAY 15 B
M37 PUR
ALTERNATOR 16 A
RELAY MODULE 7 A
8 B
9 C
G10 BLK G40 BLK G40 BLK 10 D
W1 MACHINE FRAME/ENGINE
1916SEP98
T117141
CED,TX17864,164 1910SEP981/1
PN=308
Sub-System Diagnostics (S.N. 872256)
FUEL GAUGE
DISPLAY
B11A RED
LIGHT
MODULE RELAY
F14 DIODE 86 30
F15
TO P1
MONITOR 9015
S1 TACH/ 15A
KEY FUSE
HMTR TO E15 SEAT 27
SWITCH
P21B RED
FUSE
M01A PUR
ACC BELT LIGHT
OFF M32A PUR 85 87A 87
ON G10R BLK
BULB CHECK
START
TO K6 NEUTRAL G10P BLK
START RELAY
ACC P21D RED
BAT
P21F RED
B12 RED
P23 RED
H9
RED
SEAT WARNING
IGN
Z36P GRY
SWITCH LIGHT
Z36B GRY
Z36C GRY
P21J RED
G10R BLK
Z37 GRY
Z36 GRY
H11
G10V BLK
ST H10
YELLOW ALARM
WARNING
P21H RED
G LIGHT
R31 BLK
P21C RED P21B RED
Z37 GRY
Z36 GRY
G10L
BLK
R31 BLK
ENG ALT VOLTS
M37A PUR
1 A
2 B
86 30 3 C
4 D
5 E
87A
M39B PUR
6 F
G10A BLK
85
87
M37B PUR
G10T BLK 11 F
12 E
TO G2
G10R BLK H8 13
14
D
C
ALTER-
P23 RED DISPLAY 15 B
ALTERNATOR MODULE 16 A
NATOR K7 RELAY 7 A
M37B PUR
8 B
1916SEP98
G10A G40A 9 C
G40 BLK
BLK BLK 10 D
W1 MACHINE FRAME/ENGINE
BLOCK GROUND/LEFT SIDE
T117142
T117142
CED,TX17864,164 1910SEP981/1
PN=309
Sub-System Diagnostics (S.N. 872256)
TX,901515,QQ363 1910MAR971/1
CED,TX17864,165 1910SEP981/1
This circuit is powered by the monitor fuse, and the hazard/monitor unswitched fuse.
1/1
Is fuse blown?
T7199BR 1916AUG90
1/1
PN=310
Sub-System Diagnostics (S.N. 872256)
TX,9015,BG982 1901APR971/1
TX,901515,QQ534 1907DEC901/1
PN=311
Sub-System Diagnostics (S.N. 872256)
Failure Mode:
TX,9015,QQ3189 1910MAR971/1
PN=312
Sub-System Diagnostics (S.N. 872256)
Failure Mode:
TX,9015,QQ3190 1910MAR971/1
PN=313
Sub-System Diagnostics (S.N. 872256)
Failure Mode:
TX,9015,BD2735 1910MAR971/1
PN=314
Sub-System Diagnostics (S.N. 872256)
G10 BLK
P23 RED
M37 PUR MONITOR
ENG ENG ENG ENG CONVTR HYD FUSE
COOLANT OIL ALT AIR OIL OIL
R31 BLK
TEMP PRESS VOLTS FILTER TEMP FILTER
GRY
Z32
1 A
2 B X36 YEL
V8 3
4
C
D
5 E
6 F Z32
GRY
N34 YEL
11 F
M38 PUR
H8
12
13
E
D B5
DISPLAY
14
15
C
B
ENGINE
MODULE
16 A COOLANT
7 A TEMPERATURE
TO K3
8
9
B
C
SWITCH
10 D
PARK M37 PUR M37 PUR
P23 RED
X38 YEL
LIGHT F15
RELAY UNSWITCHED B6
M37 PUR
MONITOR PRESSURE
M39 PUR M39 PUR FUSE SWITCH
K7
F39 YEL
86 30
M39 PUR
P23 RED
ALTERNATOR 87A
RELAY 85
87 B8
G10 BLK CONVERTER
P23 RED OIL
W D+
B7 M40 PUR TEMPERATURE
AIR FILTER SWITCH
G RESTRICTION
B9
HYDRAULIC G01 BLK
SWITCH
1916SEP98
B+ FILTER
G02
BLK
RESTRICTION W1
G2 SWITCH MACHINE FRAME/
ALTERNATOR G01 BLK ENGINE BLOCK
G02 BLK GROUND/LEFT SIDE
T117143
T117143
CED,TX17864,166 1910SEP981/1
PN=315
Sub-System Diagnostics (S.N. 872256)
GROUND CIRCUIT
F14 (WIRE COLOR) G01 BLKENGINE HARNESS
MONITOR G10 BLKSIDE CONSOLE HARNESS
FUSE P21 RED
G20 BLKROOF HARNESS
H9 G30 BLKFRONT CONSOLE HARNESS
RED WARNING G40 BLKENGINE HARNESS TO SIDE
P21 RED LIGHT
Z36 GRY
Z36 GRY H11
P21 RED ALARM
Z37 GRY
GROUND FROM S1
H10 KEY SWITCH
YELLOW WARNING
LIGHT TERMINAL
P21 RED
9015
Z36 GRY
15A
34 ENG ENG ENG ENG CONVTR
Z36 GRY
P21 RED
Z37 GRY
R31 BLK
COOLANT OIL ALT AIR OIL HYD
TEMP PRESS VOLTS FILTER TEMP OIL
FILTER
1 A
2 B X36 YEL
3 C
V8 4
5
D
E
6 F Z36 GRY
DISPLAY
MODULE
N34 YEL
DIODE 11 F
M38 PUR
12
13
E
D B5
H8 14
15
C
B
ENGINE
DISPLAY 16 A COOLANT
MODULE 7 A TEMPERATURE
X38 YEL
8 B
TO K3 9 C SWITCH
10 D
PARK M37 PUR
LIGHT
RELAY F15
M37 PUR
UNSWITCHED
HAZARD/
M40 PUR
F39 YEL
MONITOR
M39 PUR
FUSE B6
30
ENGINE OIL
K7 86
PRESSURE
M39 PUR
RELAY 85
87
SWITCH
ALTERNATOR G01 BLK
G02 BLK MACHINE FRAME/
ENGINE BLOCK
GROUND/LEFT SIDE
T117144
T117144
OUO1048,00003E0 1908SEP001/1
PN=316
Sub-System Diagnostics (S.N. 872256)
9015
Z36 GRY 15A
ENGINE ENGINE ENGINE ENGINE CONVERT HYDRAULIC 35
COOLANT OIL ALT. AIR OIL. OIL
Z37 GRY
H8
P21 RED
Z36 GRY
R31 BLK
TEMP. PRES. VOLTS FILTER TEMP. FILTER
DISPLAY
MODULE 1 A
2 B X36 YEL
3 C
TO S12 4 D
5 E
PARK 6 F Z36 GRY B5
BRAKE ENGINE
SWITCH COOLANT
(DASH) 11 F
TEMP.
12 E SWITCH
V8
N34 YEL
K3 13 D
DISPLAY PARK LIGHT 14 C
M32 PUR
15 B
MODULE RELAY 16 A (S.N. XXXXXX)
DIODE 7 A
T12 BLU
8 B
TO K6 9 C
10 D
86 30 NEUTRAL START
(S.N. XXXXXX )
X38 YEL
M37 PUR
S31 RELAY F15
SEAT
G01 BLK
UNSWITCHED
PUR
M37
SWITCH W2 HAZARD/ B6
F39 YEL
85 87A 87
GROUND TO MONITOR ENGINE OIL
G10 BLK
CAB FRAME FUSE PRESSURE
M39 PUR 86 30 SWITCH
M40 PUR
K7
P23 RED
M39 PUR
ALTERNATOR 85 87
87A
B8
RELAY CONVERTER
B7 G10 BLK G10 BLK
OIL TEMP.
P23 RED
W D
+ AIR FILTER M40 PUR SWITCH
G
RESTRICTION B9 G01
BLK
B+ SWITCH HYDRAULIC FILTER W1
MACHINE FRAME/
1916SEP98
T117145
OUO1048,00003E1 1908SEP001/1
PN=317
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,168 1910SEP981/1
1/1
Engine Coolant Disconnect X36 yellow wire from switch and ground to YES: Replace switch.
Temperature Indicator frame.
9015
Switch (S.N. 825657) NO: Switch is good. Go
15A
Without starting engine, turn key switch to BULB to next check.
36
CHECK, then release to ON.
T7199CG 1916AUG90
1/1
Engine Coolant Disconnect X36 yellow wire from switch and ground to YES: Replace switch.
Temperature Indicator frame.
Switch (S.N. 825658 ) NO: Switch is good. Go
Without starting engine, turn key switch to BULB to next check.
CHECK, then release to ON.
T107548 1925MAR97
1/1
Engine Coolant Disconnect connector from display module. YES: Indicator light is
Temperature Indicator good. Check wiring
Light Connect 12 volts to pin terminal 1 for Z33 gray wire. harness.
Ground pin terminal 2 for X36 yellow wire to machine
frame. NO: Check display
module. Replace bulb or
Is engine coolant temperature indicator light on? module.
T6877AB UN18OCT88
1/1
PN=318
Sub-System Diagnostics (S.N. 872256)
Engine Oil Pressure Disconnect N34 yellow wire from switch and ground to YES: Replace switch.
Switch frame.
NO: Switch is good. Go
Without starting engine, turn key switch to BULB to next check.
CHECK, then release to ON.
T7199DZ 1926SEP90
1/1
Engine Oil Pressure Disconnect connector from display module. YES: Indicator light is
Indicator Light good. Check wiring
9015
Connect 12 volts to pin terminal 1 for Z33 gray wire. harness.
15A
Ground pin terminal 3 for N34 yellow wire to machine
37
frame. NO: Check display
module. Replace bulb or
Is engine oil pressure indicator light on? module.
T6877AC UN18OCT88
1/1
Engine Alternator Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39 YES: Circuit is good.
Indicator Circuit purple wire. Repair or replace
alternator.
Without starting engine, turn key switch to BULB CHECK, then release to ON.
NO: Go to next check.
Is alternator indicator light off?
1/1
Alternator Relay IMPORTANT: Relay is a six volt relay. Do not apply YES: Relay is good.
more than 6 volts when testing. Check wiring harness.
T7596AQ 1903OCT91
Connect battery voltage to terminal #86. Ground terminal
#85. Does relay click?
1/1
PN=319
Sub-System Diagnostics (S.N. 872256)
Engine Alternator Disconnect middle connector on display module. YES: Indicator light is
Indicator Light good. Check wiring
Ground pin terminal 13 for M37 purple wire to machine harness.
frame.
NO: Check display
Without starting engine, turn key switch to BULB module. Replace bulb or
CHECK, then release to ON. module.
1/1
Engine Air Filter Disconnect M40 purple wire from switch and ground to YES: Replace switch.
Restriction Switch frame.
9015
NO: Switch is good. Go
15A
Without starting engine, turn key switch to BULB to next check.
38
CHECK, then release to ON?
T7199CI 1917SEP90
1/1
Engine Air Filter Disconnect middle connector of display module. YES: Indicator light is
Restriction Indicator good. Check wiring
Light Ground pin terminal 14 for M40 purple wire to machine harness.
frame.
NO: Check display
Without starting engine, turn key switch to BULB module. Replace bulb or
CHECK, then release to ON. module.
T6877AG UN18OCT88
Is air restriction indicator light on?
1/1
Converter Oil Disconnect X38 yellow wire from switch and ground to YES: Replace switch.
Temperature Switch frame.
NO: Switch is good. Go
Without starting engine, turn key to BULB CHECK, then to next check.
release to ON.
T7199CJ 1917SEP90
1/1
PN=320
Sub-System Diagnostics (S.N. 872256)
Converter Oil Disconnect middle connector from display module. YES: Indicator light is
Temperature Light good. Check wiring
Ground pin terminal 15 for X38 yellow wire from switch harness.
and ground to frame.
NO: Check display
Without starting engine, turn key to BULB CHECK, then module. Replace bulb or
release to ON. module.
1/1
Hydraulic Filter Disconnect F39 yellow wire from switch and ground to YES: Replace switch.
Restriction Indicator frame.
9015
Switch NO: Switch is good. Go
15A
Without starting engine, turn key switch to BULB to next check.
39
CHECK, then release to ON.
T7199CK 1917SEP90
1/1
Hydraulic Filter Disconnect middle connector on display module. YES: Indicator light is
Restriction Indicator good. Check wiring
Light Ground pin terminal 16 for F39 yellow wire to machine harness.
frame.
NO: Check display
Without starting engine, turn key switch to BULB module. Replace bulb or
CHECK, then release to ON. module.
T7199BT 1916AUG90
Is hydraulic filter restriction indicator light on?
1/1
Specification
MFWD Indicator Switch (Normally
Closed)Opening Pressure............................ 3772 KPa (0.40.7 bar)
(5.510.5 psi)
TX,9015,BG983 1901APR971/1
PN=321
Sub-System Diagnostics (S.N. 872256)
TX,901515,QQ811 1919NOV901/1
TX,9015,QQ1744 1912MAR931/1
PN=322
Sub-System Diagnostics (S.N. 872256)
9015
15A
41
1923SEP92
T7828AG
TX,9015,QQ1830 1912MAR931/1
PN=323
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1019 1904FEB991/1
1/1
MFWD Switch Disconnect harness from MFWD switch. YES: Switch is good. Go
to next check.
9015
With MFWD switch OFF, measure continuity between
15A
terminals 6 and 8. NO: Replace MFWD
42
switch.
Is continuity measured?
1/1
MFWD Pressure Disconnect M31 purple wire from switch and ground to YES: Replace switch.
Indicator Switch frame.
NO: Switch is good.
Without starting engine, turn key switch to BULB Check wiring harness.
CHECK, then release to ON.
T7835AS 1923SEP92
1/1
MFWD Solenoid Disconnect harness from MFWD solenoid. YES: Solenoid is good.
Check wiring harness.
Connect battery voltage to solenoid terminal (B) of
connector and ground terminal (A) of connector. NO: Replace solenoid.
T7828AZ 1923SEP92
1/1
PN=324
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ1745 1912MAR931/1
TX,9015,QQ1746 1912MAR931/1
PN=325
Sub-System Diagnostics (S.N. 872256)
9015
15A
44
1923SEP92
T7828AH
TX,9015,QQ1747 1912MAR931/1
PN=326
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1020 1904FEB991/1
1/1
Differential Lock Switch Disconnect harness from differential lock switch. YES: Switch is good. Go
to next check.
9015
With differential lock switch pressed, measure continuity
15A
between terminals A and B of connector. NO: Replace Differential
45
lock switch.
Is continuity measured?
T7828AI 1923SEP92
1/1
Differential Lock Disconnect harness from differential lock solenoid. YES: Solenoid is good.
Solenoid Check wiring harness.
Connect ground to terminal (A) of connector on solenoid.
Apply voltage to terminal (B) of connector on solenoid. NO: Replace differential
lock solenoid.
Is continuity measured?
T7828AZ 1923SEP92
1/1
TX,9015,BG984 1901APR971/1
PN=327
Sub-System Diagnostics (S.N. 872256)
9015
15A
46
TX,9015,QQ1751 1912MAR931/1
PN=328
Sub-System Diagnostics (S.N. 872256)
9015
15A
47
1923SEP92
T7828AJ
TX,9015,QQ1752 1912MAR931/1
PN=329
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1022 1904FEB991/1
1/1
Start Aid Switch Disconnect harness from start aid switch. YES: Start aid switch is
good. Go to next check.
9015
With start aid button pushed, check for continuity
15A
between terminals with P12 red wire and E25 white wire. NO: Replace start aid
48
switch.
Is continuity measured?
T7199BW 1916AUG90
1/1
Start Aid Solenoid NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into YES: Start aid solenoid is
engine. good. Check wiring
harness.
Key switch OFF.
NO: Replace start aid
Disconnect harness from solenoid. solenoid.
1/1
TX,9015,BG985 1901APR971/1
PN=330
Sub-System Diagnostics (S.N. 872256)
9015
15A
49
TX,9015,BG986 1901APR971/1
PN=331
Sub-System Diagnostics (S.N. 872256)
9015
15A
50
1912DEC90
T7418AZ
TX,901515,QQ825 1912MAR931/1
PN=332
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1023 1904FEB991/1
1/1
Injection Pump Fuel Connect battery voltage to solenoid P12 red wire YES: Solenoid is good.
Shut-Off Solenoid terminal. Check wiring harness.
9015
15A
Does solenoid "click"? NO: Replace fuel shut-off
51
solenoid.
Remove voltage from terminal.
1/1
PN=333
Sub-System Diagnostics (S.N. 872256)
Key switch ON
FNR lever must be in reverse position
TX,9015,QQ1815 1912MAR931/1
TX,9015,BG987 1901APR971/1
PN=334
Sub-System Diagnostics (S.N. 872256)
9015
15A
53
1916SEP93
T8077AF
TX,9015,QQ1756 1906OCT931/1
PN=335
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1024 1904FEB991/1
1/1
9015
15A
54
PN=336
Sub-System Diagnostics (S.N. 872256)
9015
T8077AO 1916SEP93 15A
55
Key switch ON. Harness connected.
T8077AP 1916SEP93
1/1
PN=337
Sub-System Diagnostics (S.N. 872256)
9015
15A T7828AC UN09MAR93
56
Key switch ON. Harness connected. FNR in reverse.
1/1
1/1
Reverse Alarm Disconnect harness from reverse alarm. YES: Reverse alarm is
good. Check wiring
Connect battery voltage to reverse warning alarm harness.
positive (+) terminal.
NO: Replace reverse
Connect jumper wire from reverse warning alarm alarm.
negative (-) terminal to ground.
T7199BZ UN16AUG90
Does reverse alarm sound?
1/1
PN=338
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ1816 1912MAR931/1
TX,9015,QQ1762 1912MAR931/1
PN=339
Sub-System Diagnostics (S.N. 872256)
9015
15A
58
1923SEP92
T7828AP
TX,9015,QQ1763 1912MAR931/1
PN=340
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1025 1904FEB991/1
1/1
Dome Light and Swivel Disconnect harness from switch. YES: Switch is good.
Light Switch Check wiring harness
9015
Turn dome light/swivel light switch ON.
15A
NO: Replace switch.
59
Using a multimeter check continuity at switch terminals
for dome and swivel light switch.
1/1
Dome and Swivel Light Disconnect harness from light. YES: Light is good.
Check wiring harness.
Connect battery voltage to light terminal. Ground light
housing. NO: Replace bulbs or
dome/swivel lights.
Does light come on?
T6534DZ UN19OCT88
1/1
PN=341
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ1769 1912MAR931/1
TX,9015,QQ1770 1931AUG951/1
PN=342
Sub-System Diagnostics (S.N. 872256)
9015
15A
61
1923SEP92
T7828AS
TX,9015,BG988 1901APR971/1
PN=343
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1026 1904FEB991/1
This circuit is powered by the unswitched radio fuse and the dome light fuse.
1/1
T7828AT 1923SEP92
Measure 12 volts at wire terminals L43 brown, P25 red and P15 red.
1/1
Radio Speaker Disconnect harness from radio speaker. YES: Replace radio.
T7828AU 1923SEP92
1/1
PN=344
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ1817 1912MAR931/1
Front wipers on HIGH, power flows through terminal 3 Rear wiper in LOW position, power flows from rear
and out terminal 1 to left hand door wiper motor. wiper switch terminal 5 through A65 orange wire to
Power also flows through terminal 4 and out terminal 2 rear wiper motor.
to right hand door wiper motor.
Rear wiper in PARK position, power flows through P14
Front wipers on LOW, power flows through terminal 3 red to rear wiper motor deactivating a switch in rear
and out terminal 5 to left hand door wiper motor. wiper motor putting wiper in park position.
Power also flows through terminal 4 and out terminal 6
to right hand door wiper motor. Washer: Power flows from 15 amp wiper/washer fuse
to terminal 5 of washer switch. With washer switch
Front wiper in PARK position, power flows through P14 pushed in power flows from terminal 1 to washer
red wire to right hand door wiper motor, through A69 motor, activating pump.
orange wire to terminal 8 of front wiper switch, out
terminal 6 of front wiper switch through A63 orange NOTE: For component identification code description,
wire to right hand door wiper motor and to ground by see Wiring and Schematic Diagrams Legend,
G20 black wire. Power also flows through P14 red wire Group 9015-10.
to left hand door wiper motor, through A68 orange wire
to terminal 7 of front wiper switch, out terminal 5
through A61 orange wire to left hand door wiper motor
and to ground by G20 black wire.
TX,9015,QQ1764 1912MAR931/1
PN=345
Sub-System Diagnostics (S.N. 872256)
9015
15A
64
1923APR97
T7828AQ
TX,9015,QQ1765 1912MAR931/1
PN=346
Sub-System Diagnostics (S.N. 872256)
Sub-System Diagnostics/Wiper/Washer
Circuit (S.N. 872256)
CED,TX17864,1027 1904FEB991/1
1/1
Front Wiper Switch Wiper switch ON. YES: Front wiper switch
is good. Go to next
9015
Disconnect harness from front wiper switch. check.
15A
65
Measure for continuity between terminals 2 and 4, 6 and NO: Replace front wiper
8, 1 and 3, and 5 and 7. switch.
Is continuity measured?
T7199CA UN02OCT90
1/1
Wiper Motor LH Door Disconnect harness from wiper motor. YES: Go to next check.
and RH DoorLow
Speed Connect battery voltage to terminal with red wire and NO: Replace wiper motor.
yellow wire. Ground terminal with black wire.
1/1
Wiper Motor LH Door Disconnect harness from wiper motor. YES: Wiper motor is
and RH DoorHigh good. Check wiring
Speed Connect battery voltage to terminal with blue wire and harness.
yellow wire. Ground terminal with black wire.
NO: Replace wiper motor.
Does motor run in HIGH speed?
1/1
PN=347
Sub-System Diagnostics (S.N. 872256)
Rear Wiper Switch Wiper switch ON. YES: Rear wiper switch is
good. Go to next check.
Disconnect harness from rear wiper switch.
NO: Replace rear wiper
Using a multimeter measure for continuity between switch.
terminals 1 and 3, and 5 and 7.
Is continuity measured?
T7199CC UN02OCT90
1/1
Rear Wiper MotorLow Disconnect harness from wiper motor. YES: Go to next check.
Speed
9015
Connect battery voltage to terminal with red wire and NO: Replace wiper motor.
15A
yellow wire. Ground terminal with black wire.
66
Does motor run in LOW speed?
1/1
Rear Wiper MotorHigh Disconnect harness from wiper motor. YES: Wiper motor is
Speed good. Check wiring
Connect battery voltage to terminal with blue wire and harness.
yellow wire. Ground terminal with black wire.
NO: Replace wiper motor.
Does motor run in HIGH speed?
1/1
Is continuity measured?
T7199CE UN02OCT90
1/1
PN=348
Sub-System Diagnostics (S.N. 872256)
Windshield Washer Disconnect harness from washer motor. YES: Washer motor is
Motor good. Check wiring
Connect battery voltage to terminal with S71 orange harness.
wire. Ground motor.
NO: Replace washer
Does motor run and operate the pump? motor.
T7199CF 1916AUG90
1/1
9015
15A
67
PN=349
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ1818 1917JUN941/1
TX,9015,QQ1766 1910MAR971/1
PN=350
Sub-System Diagnostics (S.N. 872256)
9015
15A
69
1930SEP92
T7857AD
TX,9015,BG989 1902APR971/1
PN=351
Sub-System Diagnostics (S.N. 872256)
TX,9015,BD2734 1907MAR971/1
9015
15A
70
PN=352
Sub-System Diagnostics (S.N. 872256)
9015
15A
71
1922APR97
T101441
TX,901515,QQ809 1910MAR971/1
PN=353
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1028 1904FEB991/1
1/1
Blower Switch (S.N. Disconnect harness from blower switch. YES: Blower switch is
816286) good.
9015
Use a multimeter and check for continuity.
15A
NO: Replace blower
72
Move blower switch to LOW, MEDIUM and HIGH switch.
checking terminals B and L, B and M, and B and H.
Is continuity measured?
T7199CL UN17SEP90
1/1
T109254 1924APR97
1/1
PN=354
Sub-System Diagnostics (S.N. 872256)
Blower Resistor (S.N. Measure ohms between terminals 3 and 1. YES: Resistor is good.
816286) Check wiring harness.
Does ohmmeter read 1.0 ohms.
NO: Replace resistor.
Measure ohms between terminals 3 and 2)
T6534CR UN19OCT88
1/1
Blower Resistor (S.N. Measure ohms between terminals 4 and 2. YES: Resistor is good.
816287 ) Check wiring harness.
9015
Does ohmmeter read 1.0 ohms?
15A
NO: Replace resistor.
73
T102849 UN06AUG96
1/1
Heater Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
motor is good. Check
Connect 12 volts to heater blower motor, and ground wiring harness.
motor.
NO: Replace heater
Does heater blower motor operate? blower motor.
T7199CM UN16AUG90
1/1
PN=355
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ1820 1912MAR931/1
Rear work lights, power flows from rear work light fuse to
terminal 1 of rear light switch.
With rear light switch in the first position, power flows from
terminal 5 of rear light switch to make rear work lights
come on.
TX,9015,QQ1767 1912MAR931/1
PN=356
Sub-System Diagnostics (S.N. 872256)
9015
15A
75
1923SEP92
T7828AR
TX,9015,QQ1768 1912MAR931/1
PN=357
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1029 1904FEB991/1
This circuit is powered by the front work and drive light fuse, and the rear work light fuse.
1/1
Front Light Switch Disconnect harness from front light switch. YES: Front light switch is
good. Check wiring
9015
Light switch ON. harness.
15A
76
Measure for continuity between terminals 3 and 1, and 2 NO: Replace switch.
and 8.
Is continuity measured?
T7199CN UN16AUG90
1/1
Rear Light Switch Disconnect harness from rear light switch. YES: Rear light switch is
good. Check wiring
Light switch ON. harness.
Is continuity measured?
T7199CO UN16AUG90
1/1
Work/Drive Light Disconnect harness from work/drive light. YES: Work light is good.
Check wiring harness.
Connect 12 volts to blue wire and ground black wire.
NO: Replace bulb. If bulb
Does light come ON? is good replace light.
T7199CP UN17SEP90
1/1
PN=358
Sub-System Diagnostics (S.N. 872256)
Tail Light Disconnect harness from turn/tail/brake light. YES: Tail light is good.
Check wiring harness.
Connect 12 volts to terminal marked TAIL, and ground
terminal marked GROUND. NO: Replace bulb. If bulb
is good replace light.
Does tail light come on?
T7199CQ 1902OCT90
1/1
TX,9015,QQ1785 1912MAR931/1
TX,9015,QQ1776 1912MAR931/1
PN=359
Sub-System Diagnostics (S.N. 872256)
The Park Brake/Neutral Disconnect Circuit consists of When the park brake is applied (ON position) the park
FNR/park brake fuse, park brake dash switch, park brake sensing switch closes providing a ground for the
brake latching relay, FNR/range switch, shift controller, park brake dash switch light and seat belt light. Power
park brake solenoids, neutral disconnect switch, is removed from park brake solenoids and neutral
neutral disconnect solenoid, park light relay, park disconnect solenoid de-energizing solenoids.
brake sensing switch and seat belt light.
Key ON:
NOTE: The park brake applies automatically when Park Brake Dash Switch in ON position.
machine is mechanically shut down or when FNR Lever Shifted Out of Neutral:
key switch is turned off. Park brake dash
switch must be cycled first to applied position With the park brake dash switch ON, and the FNR
(ON), then to released position (OFF) before lever shifted out of neutral the park light relay K3 is
park brake can be released when engine is de-energized connecting terminals 30 and 87A causing
running. red light and alarm to come ON.
9015
15A
78 Key OFF: Key ON:
Engine running.
Park brake cannot be hydraulically released if there is
a blown fuse or key switch is OFF. With machine mechanically shut down, ground from
the starter motor (S) terminal is removed from terminal
Key ON: 86 of park brake latching relay de-energizing relay.
Park Brake Dash Switch in ON Position. Terminals 30 and 87A are connected removing power
FNR Lever in Neutral: from terminals 6 and 8 of park brake dash switch,
de-energizing park brake solenoids and neutral
Power flows from terminal 1 to terminal 6 of park brake disconnect solenoid. Park brake is applied.
dash switch and then to park brake latching relay
terminal 85, energizing relay K5 causing it to latch NOTE: For component identification code description,
terminals 30 and 87. Ground is supplied to the park see Wiring and Schematic Diagrams Legend,
brake latching relay terminal 86 from the (S) terminal Group 9015-10.
of starter motor.
TX,9015,QQ1775 1912MAR931/1
PN=360
Sub-System Diagnostics (S.N. 872256)
J27 TAN
P24 RED BRAKE T12 BLU
T12 BLU
RELAY
S12 DIODE
85 87A 87
86 30 86 30
PARK BRAKE
E02 WHT 9015
SWITCH (DASH) 15A
M32 PUR 85 87A 87 79
85 87A 87
1 7 2 10
P24 RED
8
P24 RED
ON
OFF G01 BLU TO H7
Z32 GRY
M38 PUR LOGIC
M3 2 PUR
1 0
MODULE
Z32 GRY
TO H8
J2 0 TAN
J20 TAN
D C B A A1
P24 RED GRN SHIFT
J27 TAN
P24 RED GRN CONTROLLER
E02 WHT
E15 S
86 30
SEAT BELT B
M32 PUR
87A
LIGHT
M1 85 87
STARTER TIME
RED
86 30
M MOTOR DELAY
CIRCUIT 87A
85 87
RED
PUR
M32
GRY D
FNR 86 30 86 30
C
N
R F R N F 87A 87A
B
B2 RED A 85 87 85 87
G01 BLK
CED,TX17864,169 1910SEP981/1
PN=361
Sub-System Diagnostics (S.N. 872256)
J2 7 TAN
P24 RED BRAKE T12 BLU T12
RELAY BLU
S12 DIODE
85 87A 87
86 30 86 30
9015 PARK BRAKE
E02 WHT
15A SWITCH
80 M32 PUR
85 87A 87 87
85 87A
1 7 2 8 10
P24 RED
P24 RED
ON
OFF G01 BLU
TO H7
M38 PUR RED WARNING
1 0
M32 PUR
MODULE
T12 BLU
5 6 9 P24 RED
J20 TAN
D C B A A1
P24 RED GRN
SHIFT
J27 TAN
P24 RED GRN
CONTROLLER
E02 WHT
E15 S
86 30
SEAT BELT B
M32 PUR
87A
LIGHT
M1 85 87
STARTER TIME
RED
86 30
M MOTOR DELAY
CIRCUIT 87A
85 87
RED
TAN
M32
GRY D
FNR 86 30 86 30
C
N
R F R N F 87A 87A
B
B2 RED A 85 87 85 87
G01 BLK
PARK
G01
BLK
CED,TX03610,131 1919MAR991/1
PN=362
Sub-System Diagnostics (S.N. 872256)
J27 TAN
P24C RED BRAKE T12A BLU
RELAY M0IB T12
S12 DIODE
85 87A 87 PUR BLU
PARK BRAKE 86 30 9015
E2B WHT 86 30
SWITCH 15A
M32A PUR 81
P24B RED
P24A RED
ON 1 7 2 8 10
85 87A 87
85 87A 87
OFF
G10R BLK
1 0 TO H9 RED
M32 PUR
M0IA
PUR WARNING
Z36D GRY LIGHT
J20B TAN
J2 7 TAN
GRN
P24F RED W2 GRN
CONTROLLER
E02 WHT GROUND
E15 TO CAB
S
SEAT BELT B FRAME 86 30
M32C PUR
87A
LIGHT
M1 85 87
STARTER
RED
TIME 86 30
M MOTOR DELAY
CIRCUIT 87A
RED
85 87
PUR
M32
GRY D
FNR 86 30 86 30
C
N
R F R N F 87A 87A
B
B2 RED A 85 87 85 87
G10 BLK
SWITCH G01
T53 BLU
J27
TAN
BLK
J27 TAN
S13 NEUTRAL T52
BLU
V2 J27 TAN
1916SEP98
CED,TX03610,132 1919MAR991/1
PN=363
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ3282 1910MAR971/1
1/1
Park Brake Switch Disconnect harness from park brake switch. YES: Park brake switch is
Dash good. Check wiring
9015
Park brake switch OFF. harness.
15A
82
Check for continuity between terminals 5 and 7, and 6 NO: Replace park brake
and 8. switch.
Is continuity measured?
T7199CS UN16AUG90
Park brake switch ON.
Is continuity measured?
1/1
Is continuity measured?
1/1
PN=364
Sub-System Diagnostics (S.N. 872256)
1/1
Is continuity measured?
1/1
T7835AC 1923SEP92
Is continuity measured?
1/1
PN=365
Sub-System Diagnostics (S.N. 872256)
NOTE: Seat position sensor is located in the operators NO: Replace seat
seat base. position sensor.
Is continuity measured?
9015
15A
84
1/1
T8077AJ 1916SEP93
Is continuity measured?
1/1
PN=366
Sub-System Diagnostics (S.N. 872256)
9015
T7828AC UN09MAR93 15A
85
Key switch ON. FNR/range lever in neutral
With harness connected, check voltage at terminals with red wire and gray wire.
T7828AD UN09MAR93
With harness connected, and FNR/range lever moved to forward, check voltage at
terminal with yellow wire.
1/1
PN=367
Sub-System Diagnostics (S.N. 872256)
Neutral Disconnect Disconnect harness from neutral disconnect switch. YES: Switch is good.
Switch Check wiring harness.
Check for continuity between terminals with T52 blue
wire and T53 blue wire. NO: Replace neutral
disconnect switch.
Is continuity measured?
1/1
1/1
Key switch ON
Power to FNR/park brake fuse
Power to Shift Controller
FNR/range switch in NEUTRAL position to allow for
engine starting
TX,9015,DY666 1916AUG961/1
PN=368
Sub-System Diagnostics (S.N. 872256)
The following chart shows the solenoids that are 2ND Neutral:
energized to obtain the transmission speeds.
With FNR/range switch in 2nd neutral the C2/B3
SOLENOIDS ENERGIZED solenoid is energized. Power is removed from blue and
N C2-B3 FWD C1-B2 REV red wire from range switch and shift controller,
1st Forward X X de-energizing relay in shift controller sending power to
2nd Forward X X X
C2-B3 solenoid through green and T15 blue wire
energizing solenoid.
3rd Forward X X X
4th Forward X X X X 3RD Neutral:
1st Neutral
2nd Neutral X With FNR/range switch in 3rd neutral the C1/B2
3rd Neutral X solenoid is energized. Power from the range switch is
4th Neutral X X
routed through green and red wire to shift controller,
out shift controller through green and T14 blue wire to
1st Reverse X X
C1/B2 solenoid, energizing solenoid.
2nd4th X X X
Reverse
1ST Neutral:
PN=369
Sub-System Diagnostics (S.N. 872256)
With FNR/range switch in 4th neutral the C2/B3 and With FNR/range switch in fourth forward, the forward
C1/B2 solenoids are both energized. Power from the solenoid, neutral disconnect solenoid and C2-B3
range switch is routed through green and red wire to solenoid and C1-B2 solenoid are energized. Power
shift controller, out shift controller through green and from range switch is routed through green and red wire
T14 blue wire to C1/B2 solenoid. Power is also routed to shift controller, out shift controller through green and
through blue and red wire to shift controller, out shift T14 blue wire to C1/B2 solenoid. Power is also routed
controller through green and T15 blue wire to C2/B3 through blue and red wire to shift controller, out shift
solenoid, energizing solenoid. controller through green and T15 blue wire to C2/B3
solenoid, energizing solenoid.
1ST Forward
1ST Reverse
With FNR/range switch in first forward the forward
solenoid and neutral disconnect solenoid are With FNR/range switch in first reverse, the neutral
energized. Power from the FNR/range switch is routed disconnect solenoid and reverse solenoid are
9015
15A through yellow and blue wire to shift controller, out energized. Power from FNR switch is routed through
88 controller through green and T11 blue wire to forward pink and red wire to shift controller, out shift controller
solenoid, energizing solenoid. Power is routed through through T13 blue wire. T13 blue wire sends power to
J27 tan wire to terminal 30 and 87 of relay in shift reverse alarm relay, activating alarm and sending
controller sending power to neutral disconnect power to reverse solenoid, energizing solenoid. Power
solenoid, energizing solenoid. Power is sent from is sent from range switch through blue and red wire to
range switch through blue and red wire to shift shift controller energizing relay in shift controller,
controller energizing relay in shift controller, removing removing power on green and T15 blue wire to C2-B3
power on green and T15 blue wire to C2-B3 solenoid. solenoid, de-energizing solenoid.
With FNR/range switch in second forward, the forward With FNR/range switch in second reverse, the neutral
solenoid, neutral disconnect solenoid and C2-B3 disconnect solenoid, reverse solenoid and C2-B3
solenoid are energized. Power from range switch is solenoid are energized. Power is routed through pink
removed from blue and red wire to shift controller and red wire from FNR switch to shift controller, out
de-energizing relay in shift controller supplying power shift controller through T13 blue wire. T13 blue wire
to C2-B3 solenoid through green and T15 blue wire sends power to reverse solenoid, energizing solenoid.
energizing solenoid. Power from range switch is removed from blue and red
wire to shift controller de-energizing relay in shift
3RD Forward controller, supplying power to C2-B3 solenoid through
green and T15 blue wire.
With FNR/range switch in third forward, the forward
solenoid, neutral disconnect solenoid and C1-B2 In 3RD and 4TH position of range selector switch for
solenoid are energized. Power from range switch is reverse, the shift controller continues to supply power
routed through green and red wire to shift controller, through green wire and T15 blue wire to C2-B3
out shift controller through green and T14 blue wire to solenoid, energizing solenoid.
C1-B2 solenoid, energizing solenoid.
TX,9015,QQ1799 1912MAR932/2
PN=370
Sub-System Diagnostics (S.N. 872256)
9015
15A
89
1916SEP93
T8077AH
TX,9015,QQ1797 1906OCT931/1
PN=371
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1030 1904FEB991/1
1/1
T8077AI UN14SEP93
Touch neutral, C2-B3, forward and C1-B2 solenoid with
metal object (Screwdriver).
1/1
PN=372
Sub-System Diagnostics (S.N. 872256)
9015
T7835AM UN09MAR93 15A
91
T7835AN UN09MAR93
Is continuity measured?
Range selector in 3rd, check continuity between pin A at female connector and pin B
at male connector.
Range selector in 1st, check continuity between pin A at female connector and pin C
at male connector.
Range selector in 4th, check continuity between pin A at female connector with pin B
and C at male connector.
Is continuity measured?
1/1
PN=373
Sub-System Diagnostics (S.N. 872256)
Shift Controller
Emergency Bypass
Operation
9015
15A T8095AB 1901OCT93
92
NOTE: Use this procedure for diagnostic testing only. Do not operate machine for
extended periods with out shift controller.
T8090AF 1930SEP93
NOTE: With shift controller out of the circuit the machine will operate in speeds other
than indicated on FNR/range lever.
1/2
PN=374
Sub-System Diagnostics (S.N. 872256)
9015
15A
93
T8077AJ 1916SEP93
Is continuity measured?
1/4
PN=375
Sub-System Diagnostics (S.N. 872256)
9015
15A T8077AK 1916SEP93
94
Set multimeter on diode test.
19 2/4
PN=376
Sub-System Diagnostics (S.N. 872256)
9015
T8077AL 1916SEP93 15A
95
Set multimeter on diode test.
Apply 12 volts on pin C of connector 2 and ground pin A of connector 5. Check value
between pin C of connector 4 and pin B of connector 1.
T8077AM 1916SEP93
Apply 12 volts on pin B of connector 2 and ground pin A of connector 5. Check value
between pin C of connector 4 and pin C of connector 1.
19 3/4
PN=377
Sub-System Diagnostics (S.N. 872256)
9015
15A T8077AN 1916SEP93
96
Set multimeter on diode test.
19 4/4
Neutral Disconnect Disconnect harness from neutral disconnect switch. YES: Switch is good.
Switch Check wiring harness.
Check for continuity between terminals with T52 blue
wire and T53 blue wire. NO: Replace neutral
disconnect switch.
Is continuity measured?
1/1
PN=378
Sub-System Diagnostics (S.N. 872256)
9015
15A
97
PN=379
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ1821 1912MAR931/1
TX,9015,QQ1786 1912MAR931/1
PN=380
Sub-System Diagnostics (S.N. 872256)
9015
15A
99
1923SEP92
T7835AE
TX,9015,QQ1787 1912MAR931/1
PN=381
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1031 1904FEB991/1
1/1
Horn Switch Disconnect harness from horn switch. YES: Horn switch is
good.
9015
Push horn switch and measure for continuity.
15A
NO: Replace horn switch.
,100
Is continuity measured?
T7199CY UN16AUG90
1/1
1/1
Turn Signal, Flasher and Brake Light Circuit Operational Information (S.N. 872256)
The following conditions must exist for turn signal, Key switch in ON position
flasher and brake light circuit to function:
TX,9015,QQ1822 1912MAR931/1
PN=382
Sub-System Diagnostics (S.N. 872256)
Turn Signal:
4-Way Flasher:
PN=383
Sub-System Diagnostics (S.N. 872256)
Brake Light:
9015
15A
,102
TX,9015,DY667 1916AUG962/2
PN=384
Sub-System Diagnostics (S.N. 872256)
Turn Signal, Flasher and Brake Light Circuit Schematic (S.N. 872256)
9015
15A
,103
1923SEP92
T7835AF
TX,9015,QQ1789 1912MAR931/1
PN=385
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1032 1905FEB991/1
This circuit is powered by the turn/stop/horn fuse, left turn fuse and right turn fuse.
1/1
4-Way Flasher Switch Disconnect harness from 4-way flasher switch. YES: 4-way flasher
switch is good. Check
9015
With 4-way flasher switch OFF, check for continuity wiring harness.
15A
between terminals 6 and 8.
,104
NO: Replace 4-way
Is continuity measured? flasher switch.
Is continuity measured?
1/1
1/1
PN=386
Sub-System Diagnostics (S.N. 872256)
Turn Signal Switch Disconnect harness from turn signal switch. YES: Turn signal switch
is good. Go to next
With turn signal switch turned right, check for continuity check.
between connector terminals 5 and 7, and 6 and 3.
NO: Replace turn signal
Is continuity measured? switch.
Is continuity measured?
9015
T7199DB UN01OCT90 15A
,105
1/1
Brake Light Disconnect harness from turn/tail/brake light. YES: Brake light is good.
Check wiring harness.
Connect 12 volts to terminal marked STOP, and ground
terminal marked GROUND. NO: Replace bulb. If bulb
is good replace light.
Does brake light function?
T7199DS 1902OCT90
1/1
Turn Signal Light Disconnect harness from turn/tail/brake light. YES: Turn signal light is
good. Check wiring
Connect 12 volts to terminal marked DIRECTIONAL, and harness.
ground terminal marked GROUND.
NO: Replace bulb. If bulb
Does turn signal light function? is good replace light.
T7199DT 1902OCT90
1/1
PN=387
Sub-System Diagnostics (S.N. 872256)
Left/Right Indicator Light Disconnect harness from indicator light. YES: Indicator light is
good. Check wiring
Connect battery voltage to purple wire and ground black harness.
wire.
NO: Check bulb, if good
Does indicator light function? replace indicator light.
T7199DC 1916AUG90
1/1
Brake Light Switch Disconnect harness from brake light switch. YES: Replace switch.
9015
Check for continuity between the two terminals. NO: Go next step in this
15A
check.
,106
Is continuity measured?
T7199DD UN16AUG90
Disconnect harness from brake light switch. YES: Brake light switch is
good. Check wiring
With brake light switch pushed (closed), check for harness.
continuity between the two terminals.
NO: Replace switch.
Is continuity measured?
T7199DD UN16AUG90
1/1
TX,9015,QQ1823 1912MAR931/1
PN=388
Sub-System Diagnostics (S.N. 872256)
9015
15A
,107
TX,9015,QQ1791 1912MAR931/1
PN=389
Sub-System Diagnostics (S.N. 872256)
9015
15A
,108
1923SEP92
T7835AG
TX,9015,QQ1792 1912MAR931/1
PN=390
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1033 1905FEB991/1
1/1
Beacon Switch Disconnect harness from beacon switch. YES: Beacon switch is
good. Go to next check.
9015
Beacon switch ON.
15A
NO: Replace beacon
,109
Check for continuity between terminals 1 and 5. switch.
Is continuity measured?
T7199DE UN02OCT90
1/1
T7199DF UN16AUG90
1/1
Key switch ON
Engine running
TX,9015,QQ1824 1912MAR931/1
PN=391
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ1793 1912MAR931/1
PN=392
Sub-System Diagnostics (S.N. 872256)
9015
15A
,111
1923SEP92
T7835AH
TX,9015,QQ1794 1912MAR931/1
PN=393
Sub-System Diagnostics (S.N. 872256)
Sub-System Diagnostics/Return-to-Dig
Circuit (S.N. 872256)
CED,TX17864,1034 1905FEB991/1
1/1
T7199DG UN17SEP90
Check for continuity between common terminal and open NO: Replace return-to-dig
terminal. switch.
Is continuity measured?
T7199DG UN17SEP90
1/1
PN=394
Sub-System Diagnostics (S.N. 872256)
1/1
TX,9015,QQ1825 1931AUG951/1
TX,901515,QQ600 1931AUG951/1
PN=395
Sub-System Diagnostics (S.N. 872256)
Fuel Gauge:
Tachometer/Hour Meter:
TX,9015,DY668 1916AUG961/1
PN=396
Sub-System Diagnostics (S.N. 872256)
9015
15A
,115
1923SEP92
T7835AI
TX,9015,QQ1796 1912MAR931/1
PN=397
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1035 1905FEB991/1
1/1
Fuel Gauge NOTE: Be sure some fuel is in tank. YES: Fuel gauge is good.
Go to next check.
9015
Key switch ON. Engine OFF.
15A
NO: Replace fuel gauge.
,116
Disconnect harness from fuel gauge.
1/1
Fuel Gauge Sender Key switch ON. Engine OFF. YES: Replace sender.
Disconnect wire Y33 yellow from center of sender. NO: Fuel gauge sender is
good. Check wiring
Does gauge read EMPTY? harness to sender.
T6431AJ UN19OCT88
Attach a jumper wire from center screw to ground.
1/1
PN=398
Sub-System Diagnostics (S.N. 872256)
9015
T7199DJ 1902OCT90 15A
,117
Using a voltmeter, check voltage on terminal (SIG) M39 YES: Tachometer is bad,
purple wire. replace tachometer/hour
meter.
Are 7.63 volts (AC) measured?
NO: Check wiring
harness.
T7199DK 1917SEP90
1/1
Alternator Relay IMPORTANT: Relay is a six volt relay. Do not apply YES: Relay is good.
more than 6 volts when testing. Check wiring harness.
T7596AQ 1903OCT91
Measure continuity between terminals #30 and #87. Is
continuity measured?
1/1
PN=399
Sub-System Diagnostics (S.N. 872256)
TX,9015,QQ2581 1912APR941/1
TX,9015,QQ2582 1912APR941/1
PN=400
Sub-System Diagnostics (S.N. 872256)
9015
15A
,119
1929AUG95
T8544AL
TX,9015,BD2754 1918APR971/1
PN=401
Sub-System Diagnostics (S.N. 872256)
CED,TX17864,1036 1905FEB991/1
1/1
1/1
Auxiliary Valve Switch Disconnect harness from auxiliary valve switch. YES: Auxiliary valve
switch is good. Check
Move auxiliary valve switch to FOOT ON. wiring harness.
Measure for continuity between terminals 3 and 5, 3 and NO: Replace auxiliary
6. valve switch.
Is continuity measured?
T8173BN UN20FEB94
Measure for continuity between terminals 3 and 1, 3 and
2.
Is continuity measured?
1/1
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
PN=402
Sub-System Diagnostics (S.N. 872256)
Auxiliary Valve Foot Disconnect harness from auxiliary valve foot switch. YES: Auxiliary valve foot
Switch switch is good. Check
Foot switch pressed. wiring harness.
Is continuity measured?
9015
T8173BP UN20FEB94 15A
,121
1/1
PN=403
Sub-System Diagnostics (S.N. 872256)
Auxiliary Valve Solenoid Key switch ON. Auxiliary valve switch to CONTINUOUS YES: Continue on.
ON. Harness wires connected.
NO: Check ground
Check battery voltage at (A). connection at (B). Check
wiring harness.
Is battery voltage measured?
Is continuity measured?
9015
15A T8176AF UN20FEB94
,122
Is continuity measured?
T8176AF UN20FEB94
1/1
PN=404
Group 15B
Sub-System Diagnostics (S.N. 872257 )
Power Circuit Operational Information (S.N.
872257 )
TX,9015,QQ6762 1906JUN961/1
TX,9015,QQ6763 1906JUN961/1
PN=405
Sub-System Diagnostics (S.N. 872257 )
9015
15B
2
1910SEP96
T100796
TX,9015,QQ6764 1906JUN961/1
PN=406
Sub-System Diagnostics (S.N. 872257 )
TX,9015,QQ6765 1906JUN961/1
1/1
1/1
T7199BK 1917SEP90
1/1
T7828AA 1923SEP92
1/1
PN=407
Sub-System Diagnostics (S.N. 872257 )
With harness connected, check voltage at terminal with NO: Check wiring
BO3 red wire. harness between battery
and start relay.
Are 12 volts measured?
T7199BM 1917SEP90
1/1
Is continuity measured?
T7199BO UN17SEP90
Is continuity measured?
T7199BO UN17SEP90
1/1
PN=408
Sub-System Diagnostics (S.N. 872257 )
T7199BN UN16AUG90
9015
T7199BN UN16AUG90 15B
5
1/1
CED,TX17864,171 1911SEP981/1
PN=409
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,172 1911SEP981/1
PN=410
Sub-System Diagnostics (S.N. 872257 )
9015
15B
7
1918SEP98
T117158
CED,TX17864,170 1910SEP981/1
PN=411
Sub-System Diagnostics (S.N. 872257 )
TX,9015,QQ6769 1921JUL981/1
This circuit is powered by the FNR/park brake fuse and the start fuse.
1/1
Key Switch Check Switch disconnected from harness. YES: Go to next step in
this check.
9015
Turn key switch to START position.
15B
NO: Replace key switch.
8
Check for continuity between BAT and IGN terminals
and BAT and ST terminals.
Is continuity measured?
T7199BO UN17SEP90
1/1
T114633 1921JUL98
PN=412
Sub-System Diagnostics (S.N. 872257 )
Is continuity measured?
1/1
1/1
T6534BI UN19OCT88
Ground metal strap from solenoid with heavy gauge
wire.
1/1
PN=413
Sub-System Diagnostics (S.N. 872257 )
1/1
1/1
TX,9015,QQ6770 1906JUN961/1
PN=414
Sub-System Diagnostics (S.N. 872257 )
TX,9015,QQ6771 1906JUN961/1
PN=415
Sub-System Diagnostics (S.N. 872257 )
9015
15B
12
1903NOV97
T100798
TX,9015,QQ6772 1906JUN961/1
PN=416
Sub-System Diagnostics (S.N. 872257 )
TX,9015,QQ6773 1904AUG981/1
1/1
Specification
T6569AZ UN23AUG93
Alternator Output
CheckEngine Speed....................................... 1500 rpm
1/1
Alternator Key switch ON. Engine running. Park brake ON. YES: Alternator is good.
Is 14 DC volts measured?
T7835AT 1923SEP92
1/1
PN=417
Sub-System Diagnostics (S.N. 872257 )
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
Is continuity measured?
T7199BO UN17SEP90
Is continuity measured?
T7199BO UN17SEP90
1/1
PN=418
Sub-System Diagnostics (S.N. 872257 )
T7199BN UN16AUG90
9015
T7199BN UN16AUG90 15B
15
1/1
CED,TX17864,86 1912JUN981/1
PN=419
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,87 1912JUN981/1
PN=420
Sub-System Diagnostics (S.N. 872257 )
9015
15B
17
1919JUN98
T115838
CED,TX17864,88 1912JUN981/1
PN=421
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,89 1912JUN981/1
1/1
Differential Lock Switch Disconnect harness from switch. YES: Go to next step in
this check.
9015
Connect multimeter to switch terminals.
15B
NO: Replace switch.
18
Depress differential lock switch.
Is continuity measured?
T115875 1919JUN98
T115875 1919JUN98
1/1
1/1
PN=422
Sub-System Diagnostics (S.N. 872257 )
NO: If continuity is
measure in one check
and not the other, diode
is OK.
9015
15B
19
1/1
CED,TX17864,86 1912JUN981/1
CED,TX17864,87 1912JUN981/1
PN=423
Sub-System Diagnostics (S.N. 872257 )
9015
15B
20
1919JUN98
T115840
OUO1048,00003E3 1913SEP001/1
CED,TX17864,89 1912JUN981/1
1/1
PN=424
Sub-System Diagnostics (S.N. 872257 )
9015
T100731 UN28MAY96 15B
21
Disconnect harness from switch.
Is continuity measured?
Is continuity measured?
1/1
1/1
PN=425
Sub-System Diagnostics (S.N. 872257 )
NO: If continuity is
measure in one check
and not the other, diode
is OK.
9015
15B
22
1/1
CED,TX17864,181 1915SEP981/1
CED,TX17864,182 1915SEP981/1
PN=426
Sub-System Diagnostics (S.N. 872257 )
9015
15B
23
1918SEP98
T117203
CED,TX17864,183 1915SEP981/1
PN=427
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,184 1915SEP981/1
This circuit is powered by the unswitched radio fuse, dome light/radio fuse, and the front work/tail light fuse.
1/1
Front Light Switch Disconnect harness from front light switch. YES: Front light switch is
good. Go to next check.
Light switch ON.
NO: Replace switch.
Measure for continuity between terminals 3 and 1, and 2
and 8.
Is continuity measured?
T7199CN UN16AUG90
1/1
T117205 1918SEP98
1/1
PN=428
Sub-System Diagnostics (S.N. 872257 )
Radio Speaker Disconnect harness from radio speaker. YES: Replace radio.
T7828AU 1923SEP92
1/1
CED,TX17864,185 1915SEP981/1
CED,TX17864,186 1915SEP981/1
PN=429
Sub-System Diagnostics (S.N. 872257 )
9015
15B
26
1918SEP98
T117204
CED,TX17864,187 1915SEP981/1
PN=430
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,188 1915SEP981/1
1/1
Dome Light Switch and Disconnect dome light assembly from harness. YES: Replace dome light
Dome Light Key switch ON or ACC position. assembly.
T117254 1918SEP98
1/1
TX,9015,BG984 1901APR971/1
PN=431
Sub-System Diagnostics (S.N. 872257 )
9015
15B
28
TX,9015,QQ1751 1912MAR931/1
PN=432
Sub-System Diagnostics (S.N. 872257 )
9015
15B
29
1923SEP92
T7828AJ
TX,9015,QQ1752 1912MAR931/1
PN=433
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,243 1908OCT981/1
1/1
Start Aid Switch Disconnect harness from start aid switch. YES: Start aid switch is
good. Go to next check.
9015
With start aid button pushed, check for continuity
15B
between terminals with P12 red wire and E25 white wire. NO: Replace start aid
30
switch.
Is continuity measured?
T7199BW 1916AUG90
1/1
Start Aid Solenoid NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into YES: Start aid solenoid is
engine. good. Check wiring
harness.
Key switch OFF.
NO: Replace start aid
Disconnect harness from solenoid. solenoid.
1/1
TX,9015,BG985 1901APR971/1
PN=434
Sub-System Diagnostics (S.N. 872257 )
9015
15B
31
TX,9015,BG986 1901APR971/1
PN=435
Sub-System Diagnostics (S.N. 872257 )
9015
15B
32
1912DEC90
T7418AZ
TX,901515,QQ825 1912MAR931/1
PN=436
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,242 1908OCT981/1
1/1
Injection Pump Fuel Connect battery voltage to solenoid P12 red wire YES: Solenoid is good.
Shut-Off Solenoid terminal. Check wiring harness.
9015
15B
Does solenoid "click"? NO: Replace fuel shut-off
33
solenoid.
Remove voltage from terminal.
1/1
Key switch ON
FNR lever must be in reverse position
TX,9015,QQ1815 1912MAR931/1
PN=437
Sub-System Diagnostics (S.N. 872257 )
9015
15B
34
CED,TX17864,180 1915SEP981/1
PN=438
Sub-System Diagnostics (S.N. 872257 )
9015
15B
35
1918SEP98
T117206
CED,TX17864,189 1916SEP981/1
PN=439
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,191 1916SEP981/1
1/1
Loader Lever Switch Disconnect harness from loader lever switch YES: Go to next step in
this check.
Check for continuity between terminals with J27 tan wire
and T53 blue wire. NO: Replace loader lever
switch.
Is continuity measured?
T7199CU 1902OCT90
T7199CU 1902OCT90
1/1
PN=440
Sub-System Diagnostics (S.N. 872257 )
T114633 1921JUL98
PN=441
Sub-System Diagnostics (S.N. 872257 )
T114633 1921JUL98
19 2/2
1/1
PN=442
Sub-System Diagnostics (S.N. 872257 )
Reverse Alarm Disconnect harness from reverse alarm. YES: Reverse alarm is
good. Check wiring
Connect battery voltage to reverse warning alarm harness.
positive (+) terminal.
NO: Replace reverse
Connect jumper wire from reverse warning alarm alarm.
negative (-) terminal to ground.
1/1
CED,TX17864,195 1916SEP981/1
Power flows through the heater fuse to the air adjust seat
switch. When the switch is depressed and held, power
continues to flow to the air adjust seat motor causing the
motor to operate.
CED,TX17864,196 1916SEP981/1
PN=443
Sub-System Diagnostics (S.N. 872257 )
9015
15B
40
1918SEP98
T117256
CED,TX17864,192 1916SEP981/1
PN=444
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,197 1917SEP981/1
1/1
1/1
Air Adjust Seat Switch Disconnect switch from harness. YES: Go to next check.
Is continuity measured?
T117271 1918SEP98
1/1
Air Adjust Seat Motor Disconnect harness from motor. YES: An open circuit is
indicated. Check wiring
Connect motor to 12 volts and ground as shown. harnesses.
T117270 1918SEP98
1/1
PN=445
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,198 1917SEP981/1
CED,TX17864,199 1917SEP981/1
PN=446
Sub-System Diagnostics (S.N. 872257 )
9015
15B
43
1918SEP98
T117257
CED,TX17864,193 1916SEP981/1
PN=447
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,200 1917SEP981/1
1/1
1/1
Blower Switch Disconnect harness from blower switch. YES: Blower switch is
good. Go to next check.
Using a multimeter check for continuity.
NO: Replace blower
Move blower switch to position, 1, 2, 3, and 4 checking switch.
terminals B and 1, B and 2, B and 3, B and 4)
T117277 1918SEP98
1/1
Blower Resistor Measure ohms between terminals 4 and 2. YES: Resistor is good.
Check wiring harness.
Does ohmmeter read approximately 0.9 ohms?
NO: Replace resistor.
T102849 UN06AUG96
1/1
PN=448
Sub-System Diagnostics (S.N. 872257 )
Heater Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
motor is good. Check
Connect 12 volts to heater blower motor, and ground wiring harness.
motor.
NO: Replace heater
Does heater blower motor operate? blower motor.
T7199CM UN16AUG90
1/1
Specification
Air Conditioning High Pressure
Switch (normally closed)
Opening Pressure .................................. 2760 138 kPa (27.6 1.4 bar)
(400.3 20 psi)
Closing Pressure .................................... 1310 138 kPa (13.1 1.4 bar)
(190 20 psi)
Specification
Air Conditioning Low Pressure
Switch (normally open)Closing
Pressure ................................................... 345 35 kPa (3.45 0.35 bar)
(50 5.1 psi)
Opening Pressure .................................... 173 35 kPa (1.73 0.35 bar)
(25.1 5.1 psi)
CED,TX17864,205 1917SEP981/1
CED,TX17864,202 1917SEP981/1
PN=449
Sub-System Diagnostics (S.N. 872257 )
Power flows through the heater fuse to the blower High Pressure Switch
switch. The blower switch has five different positions,
off and four speeds. With the switch in speeds 1, 2, The high pressure switch protects the system from
and 3 power is sent to the blower resistor. The blower high pressure. If a malfunction or line restriction
resistor has three different resistance values causing causes the high pressure to increase above the setting
the fan to have different speeds. With the blower of the switch, the switch will open to stop current flow
switch on the speed 4, power is sent directly to the to the compressor clutch. The high pressure switch is
blower motor and bypasses the blower resistor. This located near the compressor in the high pressure line.
causes the fan to be at the highest speed.
Freeze Protection Switch
When the blower switch is in any of the four ON
speeds, power also flows through the normally closed The freeze protection switch is used to sense the
freeze control switch and to the A/C on/off switch. temperature in the evaporator core. When the
When the A/C on/off switch is switched on power temperature drops, the freeze protection switch opens,
9015
15B continues to flow through the normally closed high and stopping power flow to the compressor. When the
46 low pressure switches to the A/C compressor engaging temperature in the evaporator core raises, the freeze
the compressor clutch. protection switch closes allowing power to continue to
flow to the compressor.
Low Pressure Switch
The freeze protection switch receives power from the
The low pressure switch will open if the air blower switch when the blower switch is in any of the
conditioning system loses its refrigerant charge. The four ON speeds.
switch opens to stop current flow to the compressor
which prevents compressor engagement. The low
pressure switch is located near the compressor in the
high pressure line.
CED,TX17864,203 1917SEP981/1
PN=450
Sub-System Diagnostics (S.N. 872257 )
9015
15B
47
1918SEP98
T117258
CED,TX17864,194 1916SEP981/1
PN=451
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,206 1917SEP981/1
1/1
1/1
Blower Switch Disconnect harness from blower switch. YES: Blower switch is
good. Go to next check.
Using a multimeter check for continuity.
NO: Replace blower
Move blower switch to position, 1, 2, 3, and 4 checking switch.
terminals B and 1, B and 2, B and 3, B and 4)
T117277 1918SEP98
1/1
Blower Resistor Measure ohms between terminals 4 and 2. YES: Resistor is good.
Check wiring harness.
Does ohmmeter read 0.9 ohms?
NO: Replace resistor
T102849 UN06AUG96
1/1
PN=452
Sub-System Diagnostics (S.N. 872257 )
Heater/Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
Check motor is good. Check
Connect 12 volts to heater blower motor, and ground wiring harness.
motor.
NO: Replace heater
Does heater blower motor operate? blower motor.
T7199CM UN16AUG90
1/1
A/C Freeze Switch With A/C freeze switch at room temperature. YES: Do A/C Freeze
Switch Test. See Group
9015
Disconnect harness from switch. 9031-25. If switch is OK,
15B
check wiring harness.
49
Measure continuity across switch terminals.
NO: Switch has failed.
Is continuity measured? Replace switch.
T7835AV 1924SEP92
1/1
Air Conditioning Switch Disconnect harness from air conditioning switch. YES: A/C switch is good.
(S.N. 816286) Check wiring harness.
Place switch in snowflake or A/C position, and measure
for continuity between terminals 2B and 1. NO: Replace A/C switch.
Is continuity measured?
Is continuity measured?
1/1
PN=453
Sub-System Diagnostics (S.N. 872257 )
Air Conditioner Low Disconnect harness from switch. YES: Continue with this
Pressure Switch Check check.
Check for continuity between terminals. Is continuity
measured? NO: Replace switch.
T101619 1913JUN96
Remove switch from system. (The line that attaches the low pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness.
9015
15B
50
1/1
Air Conditioner High Disconnect harness from switch. YES: Continue with this
Pressure Switch Check check.
Measure continuity across outer switch terminals.
NO: Switch may be bad,
Does ohmmeter read continuity? or system pressure is too
high. Continue with this
check to verify switch
operation.
T101618 1913JUN96
Remove switch from system. (The line that attaches the high pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness and
system pressure. Go to
Measure continuity across switch terminals. Air Conditioning Pressure
Diagnostic Chart, Group
Does ohmmeter read continuity? 9031-25.
1/1
T6534CV UN19OCT88
1/1
PN=454
Sub-System Diagnostics (S.N. 872257 )
TX,9015,QQ1817 1912MAR931/1
Front Wiper
The front wiper switch has both a high and low position.
With the switch on low, power flows from terminals 2A
and 5A to both the left and right front wiper motors
causing the motors to run on low speed. With the switch
on high, power flows from terminals 6 and 3 to both the
left and right front wiper motors causing the motors to run
on high speed.
Rear Wiper
The rear wiper switch has both a high and low position.
With the switch on low, power flows from terminal 2A to
the rear wiper motor causing the motor to run on low
speed. With the switch on high, power flows from terminal
6 to the rear wiper motor causing the motor to run on high
speed.
Washer
CED,TX17864,207 1918SEP981/1
PN=455
Sub-System Diagnostics (S.N. 872257 )
9015
15B
52
1908OCT98
T116925
CED,TX17864,209 1918SEP981/1
PN=456
Sub-System Diagnostics (S.N. 872257 )
Sub-System Diagnostics/Wiper/Washer
Circuit (S.N. 872257 )
CED,TX17864,210 1918SEP981/1
1/1
T100731 UN28MAY96
1/1
PN=457
Sub-System Diagnostics (S.N. 872257 )
Front Right Wiper Motor Connect an external ground to the eyelet on the end of YES: Wiper motor is
the G20 BLK wire. good. Check wiring
harnesses.
Connect 12 volts to the L terminal.
NO: Replace wiper motor.
Does wiper run on low speed?
9015
15B
54
1/1
Front Left Wiper Motor Connect an external ground to the eyelet on the end of YES: Wiper motor is
the G20 BLK wire. good. Check wiring
harnesses.
Connect 12 volts to the L terminal.
NO: Replace wiper motor.
Does wiper run on low speed?
1/1
PN=458
Sub-System Diagnostics (S.N. 872257 )
9015
T100731 UN28MAY96 15B
55
Disconnect harness from switch.
Is continuity measured?
Is continuity measured?
1/1
Rear Wiper Motor Disconnect harness from wiper motor wire lead. YES: Wiper motor is
good. Check wiring
Connect battery voltage to terminal with BLU/RED wire. harnesses.
Ground terminal with black wire.
NO: Replace wiper motor.
Does wiper motor run at low speed?
1/1
PN=459
Sub-System Diagnostics (S.N. 872257 )
9015
15B T100731 UN28MAY96
56
Disconnect harness from switch.
Is continuity measured?
1/1
Washer Motor Disconnect harness from washer motor. YES: An open circuit is
indicated. Check wiring
Connect battery voltage to motor A71 ORG terminal of harnesses.
motor. Ground other terminal to machine frame.
NO: Replace motor.
Does washer motor run?
T7349DJ UN27AUG90
1/1
CED,TX17864,211 1921SEP981/1
PN=460
Sub-System Diagnostics (S.N. 872257 )
Power flows through the rear work light fuse to the rear
light switch. With the rear light switch in the ON position,
power continues to flow to the left and right rear work
lights causing the lights to light.
CED,TX17864,212 1921SEP981/1
9015
15B
57
PN=461
Sub-System Diagnostics (S.N. 872257 )
9015
15B
58
1908OCT98
T117299
CED,TX17864,213 1921SEP981/1
PN=462
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,214 1921SEP981/1
1/1
1/1
T100731 UN28MAY96
Is continuity measured?
1/1
PN=463
Sub-System Diagnostics (S.N. 872257 )
Rear Work Lights Disconnect harness from rear work light. YES: Work light is good.
Check wiring harness.
Connect 12 volts to blue wire and ground black wire.
NO: Replace bulb. If bulb
Does light come ON? is good replace light.
T7199CP UN17SEP90
1/1
CED,TX17864,215 1921SEP981/1
CED,TX17864,216 1921SEP981/1
PN=464
Sub-System Diagnostics (S.N. 872257 )
9015
15B
61
1908OCT98
T117300
CED,TX17864,217 1921SEP981/1
PN=465
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,218 1921SEP981/1
1/1
1/1
T100731 UN28MAY96
Is continuity measured?
Is continuity measured?
1/1
PN=466
Sub-System Diagnostics (S.N. 872257 )
Work/Drive Lights Disconnect harness from work/drive light. YES: Work light is good.
Check wiring harness.
Connect 12 volts to blue wire and ground black wire.
NO: Replace bulb. If bulb
Does light come ON? is good replace light.
T7199CP UN17SEP90
1/1
Tail Light Disconnect harness from turn/tail/brake light. YES: Tail light is good.
Check wiring harness.
9015
Connect 12 volts to terminal marked TAIL, and ground
15B
terminal marked GROUND. NO: Replace bulb. If bulb
63
is good replace light.
Does tail light come on?
T7199CQ 1902OCT90
1/1
TX,9015,QQ6784 1921JUL981/1
TX,9015,QQ6783 1921JUL981/1
PN=467
Sub-System Diagnostics (S.N. 872257 )
The Park Brake/FNR circuit controls the park brake the display monitor disappears. With the park brake
and transmission. switch on, the park brake pressure switch is closed
sending a ground signal to the display monitor. With
The park brake is spring applied and hydraulically the ground signal present from the park brake
released. pressure switch without the power signal from the FNR
switch, the park brake indicator light on display monitor
NOTE: The park brake applies automatically when glows and the alarm sounds. The red stop light will
machine is mechanically shut down or when also blink on and off.
key switch is turned off. Park brake dash
switch must be cycled first to applied position The machine is unable to move because the park
(ON), then to released position (OFF) before brake dash switch is NOT sending voltage to the timer
park brake can be released when engine is relay, thus all of the speed solenoids are de-energized.
running.
Machine started with park brake switch in OFF
9015
15B Park brake cannot be hydraulically released if position:
64 FNR/Park Brake Fuse is blown.
When the machine is started with the park brake dash
Key ON: switch in the OFF position the park brake latching
Park Brake Dash Switch in On Position: relay is unlatched or open. When the park brake
FNR Lever in Neutral: latching relay is open, the park brake dash switch does
not receive voltage to terminal 2B. If the FNR switch is
Power flows from terminal 3 to terminal 2B of park placed out of neutral the display monitor alarm will
brake dash switch (S12) and then to park brake sound and the stop light will flash. This occurs
latching relay terminal 85, energizing the park brake because the park brake solenoid is not energized, thus
latching relay (K5) causing it to latch terminals 30 and the park brake pressure switch is closed and sending
87. Ground is supplied to the park brake latching relay a ground signal to the display monitor.
through the S terminal of starter motor. Power is
disconnected from park brake solenoid (Y4), and timer To enable the machine to operate, place the park dash
relay (K7). switch in the ON position. This allows power to flow to
terminal 85 of the park brake latching relay causing the
With the FNR switch (S11) in neutral, power flows from relay to close. With the relay closed, power can now
the FNR switch to the display monitor (H8). Combine flow from terminal 87 of the park brake latching relay
this with the park brake pressure switch being closed to terminal 2B of the park brake switch.
and providing a ground for the park brake indicator
light, the park brake indicator light in the display Key ON:
monitor glows signaling that the park brake is applied. Engine Running:
Park Brake Switch OFF:
Key ON:
Engine Running: With the park brake dash switch in the OFF position,
Park Brake Dash Switch In ON position: voltage is sent to both the timer relay and the park
FNR Lever Shifted Out of Neutral: brake solenoid.
With the park brake dash switch ON, and FNR lever
shifted out of neutral, the signal from the FNR lever to
PN=468
Sub-System Diagnostics (S.N. 872257 )
The park brake solenoid is now energized and sending opens the park brake pressure switch, thus the ground
pressurized oil to the park brake to release it. This also signal to the display monitor is removed and the park
opens the park brake pressure switch, thus the ground brake indicator light goes out.
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
Key ON: forward or reverse power flows to the timer relay
Engine Running: terminal 7. This signal closes the timer relay allowing
Park Brake Switch OFF: power to flow from the park brake dash switch through
FNR Switch in Forward or Reverse: the timer relay to the FNR switch. Depending on FNR
switch position, the proper direction and speed
With the park brake dash switch in the OFF position, solenoids in the transmission are energized.
voltage is sent to both the timer relay (K7) terminal 2
and the park brake solenoid. NOTE: If the signal to the timer relay terminal 7
disappears for more than one second, the
The park brake solenoid is now energized and sending timer relay will open.
9015
pressurized oil to the park brake to release it. This also 15B
65
Solenoids Energized
Solenoid Y5 Y6 Y18 Y12 Y13 Y14
1st Forward X X X X
2nd Forward X X X X
3rd Forward X X X X
4th Forward X X X
1st Reverse X X X X
2nd Reverse X X X X
3rd Reverse X X X X
Neutral
CED,TX17864,177 1915SEP982/2
PN=469
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,178 1915SEP981/1
PN=470
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,179 1915SEP981/1
This circuit is powered by the FNR/park brake fuse and the start fuse.
1/1
T100731 UN28MAY96
Is continuity measured?
Is continuity measured?
1/1
PN=471
Sub-System Diagnostics (S.N. 872257 )
Transmission Solenoids
Check
9015
15B T101725 1912SEP96
68
Remove fuse block cover.
Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and black
lead into (COM.) terminal.
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.
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.
NOTE: The following specifications are at a voltage of 12.4 volts. Voltage should be
approximately 12.4 volts when current measurements are taken.
Does the amp value match the following specifications for each speed?
Specification
FNR Current1st Speed Forward
Amperage ................................................................................................ 3.38 0.1 amps
2nd Speed Forward Amperage ............................................................... 3.38 0.1 amps
3rd Speed Forward Amperage ................................................................ 3.38 0.1 amps
4th Speed Forward Amperage ................................................................ 3.00 0.1 amps
Does the amp value match the following specifications for each speed?
Specification
FNR Current1st Speed Reverse
Amperage .................................................................................................. 3.5 0.1 amps
2nd Speed Reverse Amperage................................................................. 3.5 0.1 amps
3rd Speed Reverse Amperage ................................................................. 3.5 0.1 amps
1/2
PN=472
Sub-System Diagnostics (S.N. 872257 )
NOTE: The current value measurement is controlled by the number of components YES: Transmission
that are connected within the circuit. solenoids are electrically
good. See Group 9020-25
Power Train Test.
19 2/2
T101725 1912SEP96
Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and black
lead into (COM.) terminal.
Park brake switch ON. Approximately 0.45 amp value will display.
PN=473
Sub-System Diagnostics (S.N. 872257 )
Loader Lever Switch Disconnect harness from loader lever switch YES: Go to next step in
this check.
Check for continuity between terminals with J27 tan wire
and T53 blue wire. NO: Replace loader lever
switch.
Is continuity measured?
T7199CU 1902OCT90
9015
15B T7199CU 1902OCT90
70
1/1
Is continuity measured?
1/1
PN=474
Sub-System Diagnostics (S.N. 872257 )
9015
T114654 1921JUL98 15B
71
Disconnect timer relay from front console harness.
Is continuity measured?
1/1
Park Brake Pressure Disconnect harness from switch. YES: Replace switch.
Switch
Measure continuity between terminals A and B on NO: Switch is good.
connector end of switch. Check wiring harness.
Is continuity measured?
T7199EE UN02OCT90
1/1
PN=475
Sub-System Diagnostics (S.N. 872257 )
T114633 1921JUL98
PN=476
Sub-System Diagnostics (S.N. 872257 )
T114633 1921JUL98
19 2/2
Park Brake Relay Diode Remove diode from connector. YES: If continuity is
measured in both checks,
Connect an ohmmeter to diode terminals. diode has failed in a
shorted mode. Replace.
Is continuity measured?
NO: If continuity is NOT
Reverse ohmmeter probes. measured in either check
diode has failed in an
T7961AA UN10MAR93
Is continuity measured? open mode. Replace.
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
PN=477
Sub-System Diagnostics (S.N. 872257 )
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
PN=478
Sub-System Diagnostics (S.N. 872257 )
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
TX,9015,QQ1821 1912MAR931/1
TX,9015,QQ1786 1912MAR931/1
PN=479
Sub-System Diagnostics (S.N. 872257 )
9015
15B
76
1923SEP92
T7835AE
CED,TX17864,220 1922SEP981/1
PN=480
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,219 1922SEP981/1
1/1
Horn Switch Disconnect harness from horn switch. YES: Horn switch is
good.
9015
Push horn switch and measure for continuity.
15B
NO: Replace horn switch.
77
Is continuity measured?
T7199CY UN16AUG90
1/1
1/1
CED,TX17864,234 1924SEP981/1
PN=481
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,221 1922SEP981/1
Turn Signal, Flasher, and Brake Light Circuit Theory Of Operation (S.N. 872257 )
9015
15B Power flows through the 20 amp Turn/Stop/Flash/Horn left, flashing power flows out terminal 5B and to the left
78 fuse to the flasher, 4-way flasher switch, and brake front and left rear turn light. The 4-way flasher switch
light switch. diode prevents the flashing power to flow to the right
turn lights.
4-Way Flasher
When the turn signal switch is used in combination
When the 4-way flasher switch is switched on, current with the 4-way flasher switch switched ON, the turn
is allowed to flow through the flasher and causes it to signal switch receives continuous power from the
alternate on and off or flash. This flashing power flows 4-way flasher switch and flows to terminals 1 and 6 of
in terminal 2B of the 4-way flasher switch and out the turn signal switch. The 4-way flasher switch also
terminal 3 to the 4-way flasher switch diodes. The sends flashing power to all four turn lights causing
flashing power continues to flow through the diodes to them to blink. When the turn signal switch is switched
the front and rear turn lights causing them to blink. to the right, continuous power flows from terminal 6 to
terminal 5B of the turn signal switch and on to the left
Turn Signal turn lights. This causes the left turn lights to glow
continuously. The 4-way flasher switch diode prevents
The turn signal switch can function two different ways. the right turn lights from glowing continuously and
The first is to have only the turn signal switch on by allows them to remain blinking. When the turn signal
itself, or it can work in combination with the 4-way switch is switched to the left, continuous power flows
flasher switch. from terminal 1 to terminal 2B of the turn signal switch
and on to the right turn lights. This causes the right
When the turn signal switch is on by itself, current is turn lights to glow continuously. The 4-way flasher
allowed to flow through the flasher and causes it to switch diode prevents the left turn lights from glowing
alternate on and off or flash. This flashing power flows continuously and allows them to remain blinking.
into terminals 3 and 4 of the turn signal switch. When
the turn signal switch is switched to the right, flashing Brake Light
power flows out terminal 2B and to the right front and
right rear turn light. The 4-way flasher switch diode When the brake pedals are depressed, pressurized oil
prevents the flashing power to flow to the left turn causes the brake light switch to close sending power
lights. When the turn signal switch is switched to the to the brake lights and lighting the lights.
CED,TX17864,222 1922SEP981/1
PN=482
Sub-System Diagnostics (S.N. 872257 )
Turn Signal, Flasher, and Brake Light Circuit Schematic (S.N. 872257 )
T117361 1908OCT98
CED,TX17864,223 1922SEP981/1
CED,TX17864,224 1922SEP981/1
1/1
1/1
Brake Light Switch Disconnect harness from brake light switch. YES: Replace switch.
Check for continuity between the two terminals. NO: Go next step in this
check.
Is continuity measured?
T7199DD UN16AUG90
Disconnect harness from brake light switch. YES: Brake light switch is
good. Check wiring
Key switch ON, engine running. harness.
Depress brake pedal and check for continuity between NO: Replace switch.
the two terminals.
Is continuity measured?
T7199DD UN16AUG90
1/1
Brake Light Disconnect harness from turn/tail/brake light. YES: Brake light is good.
Check wiring harness.
Connect 12 volts to terminal marked STOP, and ground
terminal marked GROUND. NO: Replace bulb. If bulb
is good replace light.
Does brake light function?
T7199DS 1902OCT90
1/1
PN=484
Sub-System Diagnostics (S.N. 872257 )
Is 12 volts measured?
1/1
T100731 UN28MAY96
Is continuity measured?
Is continuity measured?
1/1
PN=485
Sub-System Diagnostics (S.N. 872257 )
9015
15B T100731 UN28MAY96
82
Disconnect harness from switch.
Is continuity measured?
Is continuity measured?
1/2
PN=486
Sub-System Diagnostics (S.N. 872257 )
9015
T100731 UN28MAY96 15B
83
Disconnect harness from switch.
Is continuity measured?
Is continuity measured?
19 2/2
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
PN=487
Sub-System Diagnostics (S.N. 872257 )
Turn Signal Light Disconnect harness from turn/tail/brake light. YES: Turn signal light is
good. Check wiring
Connect 12 volts to terminal marked DIRECTIONAL, and harness.
ground terminal marked GROUND.
NO: Replace bulb. If bulb
Does turn signal light function? is good replace light.
T7199DT 1902OCT90
1/1
CED,TX17864,225 1924SEP981/1
CED,TX17864,226 1924SEP981/1
PN=488
Sub-System Diagnostics (S.N. 872257 )
9015
15B
85
1928OCT98
T117389
CED,TX17864,227 1924SEP981/1
PN=489
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,228 1924SEP981/1
1/1
1/1
T100731 UN28MAY96
Is continuity measured?
1/1
PN=490
Sub-System Diagnostics (S.N. 872257 )
T7199DF UN16AUG90
1/1
Key switch ON
Engine running
CED,TX17864,233 1924SEP981/1
CED,TX17864,232 1924SEP981/1
PN=491
Sub-System Diagnostics (S.N. 872257 )
9015
15B
88
1923SEP92
T7835AH
CED,TX17864,231 1924SEP981/1
PN=492
Sub-System Diagnostics (S.N. 872257 )
Sub-System Diagnostics/Return-to-Dig
Circuit (S.N. 872257 )
CED,TX17864,230 1924SEP981/1
1/1
1/1
PN=493
Sub-System Diagnostics (S.N. 872257 )
9015
15B T7199DG UN17SEP90
90
Check for continuity between common terminal and open NO: Replace return-to-dig
terminal. switch.
Is continuity measured?
T7199DG UN17SEP90
1/1
T7199DH 1917SEP90
Does control lever stay in return-to-dig detent position
until voltage is removed, and then return to neutral?
1/1
PN=494
Sub-System Diagnostics (S.N. 872257 )
Specification
Transmission Temperature
SenderResistance at 60C
(140F) ................................................................................ 221 26 ohms
Resistance at 90C (194F)
83 8 ohms
Resistance at 120C (248F) ........................................... 36.5 2.7 ohms
Specification
Engine Coolant Temperature
9015
SenderResistance at 60C
15B
(140F) ................................................................................ 221 26 ohms
91
Resistance at 90C (194F)
83 8 ohms
Resistance at 120C (248F) ........................................... 36.5 2.7 ohms
CED,TX17864,235 1924SEP981/1
TX,901515,QQ600 1931AUG951/1
PN=495
Sub-System Diagnostics (S.N. 872257 )
Fuel Gauge:
Tachometer/Hour Meter:
CED,TX17864,236 1924SEP981/1
PN=496
Sub-System Diagnostics (S.N. 872257 )
9015
15B
93
1908OCT98
T117535
CED,TX17864,237 1924SEP981/1
PN=497
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,238 1924SEP981/1
1/1
Fuel Gauge NOTE: Be sure some fuel is in tank. YES: Fuel gauge is good.
Go to next check.
9015
Key switch ON. Engine OFF.
15B
NO: Replace fuel gauge.
94
Disconnect harness from fuel gauge.
1/1
Fuel Gauge Sender Key switch ON. Engine OFF. YES: Fuel gauge sender
is good. Check wiring
Disconnect wire Y33 yellow from center of sender. harness to sender.
T6431AJ UN19OCT88
Attach a jumper wire from center screw to ground.
1/1
PN=498
Sub-System Diagnostics (S.N. 872257 )
Measure voltage.
Measure voltage.
1/1
Measure voltage.
1/1
PN=499
Sub-System Diagnostics (S.N. 872257 )
9015
15B
96
T105163 1919NOV96
Disconnect Y33 YEL and G10 BLK wires from gauge cluster.
1/4
PN=500
Sub-System Diagnostics (S.N. 872257 )
9015
15B
97
T105163 1919NOV96
Disconnect Y01 YEL and G10 BLK wires from gauge cluster.
19 2/4
PN=501
Sub-System Diagnostics (S.N. 872257 )
YES: Transmission
temperature gauge is
good. Continue with
check.
9015
15B
98
T105163 1919NOV96
Disconnect Y02 YEL and G10 BLK wires from gauge cluster.
19 3/4
PN=502
Sub-System Diagnostics (S.N. 872257 )
9015
15B
99
T105163 1919NOV96
Disconnect P21 RED and G10 BLK wires from gauge cluster.
19 4/4
Engine Coolant Key switch ON. Engine OFF. YES: Replace sender.
Temperature Sender
(Optional) Disconnect wire Y01 YEL from engine coolant sender. NO: Sender is good.
Check wiring harness to
Does engine coolant temperature gauge read COLD? sender.
T117613 1908OCT98
Does engine coolant temperature gauge read HOT?
1/1
PN=503
Sub-System Diagnostics (S.N. 872257 )
1/1
TX,9015,QQ6774 1906JUN961/1
PN=504
Sub-System Diagnostics (S.N. 872257 )
UN22OCT98
T118037
APark Brake Indicator FTransmission Oil IBrake Pressure Indicator MMechanical Front Wheel
BSeat Belt Indicator Temperature Indicator JAlternator Voltage Indicator Drive Indicator (If 9015
CSTOP-Engine Indicator GHydraulic Oil Filter KAir Filter Restriction Equipped) 15B
DEngine Coolant Restriction Indicator Indicator ,101
Temperature Indicator HNot Used LBeacon Indicator (If
EEngine Oil Pressure Equipped)
Indicator
Power is supplied to the display monitor through the indicator comes on, or temperature will rise further.
10 AMP Monitor/Gauge fuse. Reduce load and run engine at slow idle for several
minutes, stop engine and service machine.
Each display indicator will be colored either (RED) or Brake Pressure Indicator
(YELLOW) to indicate the severity of the situation. Red
is a high level warning and the yellow is a low level CONDITION: Low Level Warning Indicators (YELLOW)
warning. When the RED high level warning is SERVICE
indicated, the operator will see a (RED COLORED
INDICATOR), (RED STOP INDICATOR) and Air Filter Restriction Indicator:
(AUDIBLE ALARM). When the YELLOW low level Charging System Indicator:
warning is indicated, the operator will see only the Converter Oil Temperature Indicator:
(YELLOW COLORED INDICATOR). On Low Level Hydraulic Oil Filter Indicator:
warnings the operation of the machine can continue Hydraulic Oil Temperature Indicator:
but the problem should be investigated and solved. On
High Level warnings except Engine Coolant CONDITION: Seat Belt Indicator (WHITE)
Temperature Indicator the operation of the machine
should be stopped immediately and problem corrected, The seat belt indicator will be back-lighted White
when ever the key switch is on and park brake is
CONDITION: High Level Warning Indicators (RED) applied.
STOP
CONDITION: MFWD Indicator (GREEN)
Red Stop Indicator:
Park Brake Indicator: MFWD indicator will be back-lighted Green when
Engine Oil Pressure Indicator: switch is on.
Engine Coolant Temperature Indicator: DO NOT
stop engine when engine coolant temperature CONDITION: Beacon Indicator (GREEN)
PN=505
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,173 1911SEP982/2
9015
15B
,102
PN=506
Sub-System Diagnostics (S.N. 872257 )
9015
15B
,103
1918SEP98
T117170
CED,TX17864,174 1911SEP981/1
PN=507
Sub-System Diagnostics (S.N. 872257 )
TX,9015,QQ6777 1906JUN961/1
1/1
1/1
Is continuity measured?
T7199BO UN17SEP90
Is continuity measured?
T7199BO UN17SEP90
1/1
PN=508
Sub-System Diagnostics (S.N. 872257 )
9015
T102886 1908AUG96 15B
,105
Unplug 12 pin harness connector from display monitor.
IF OK: Go to indicator
circuit and check
indicators.
T102887 1908AUG96
Is continuity measured?
1/1
PN=509
Sub-System Diagnostics (S.N. 872257 )
Specification
Engine Oil Pressure Switch
(Normally Closed)Opening
Pressure ........................................................... 3772 kPa (0.40.7 bar)
(5.510.5 psi)
Specification
Air Filter Restriction Switch
(Normally Open)Closing
Vacuum.................................................. 4.987.48 kPa Vacuum (2030
9015
in. H2O)
15B
,106
Specification
Converter Oil Temperature Switch
(Normally Open)Closing
Temperature ............................................. 114C122C (238F252F)
Specification
Hydraulic Filter Restriction Switch
(Normally Open)Closing
Pressure ......................................................... 344 kPa (3.45 bar) (50 psi)
Specification
Brake Pressure Switches
(Normally Open)Closing
Pressure ............................................... 7584 690 kPa (75.84 6.9 bar)
(1100 100 psi)
CED,TX17864,175 1914SEP981/1
PN=510
Sub-System Diagnostics (S.N. 872257 )
TX,9015,QQ6779 1906JUN961/1
PN=511
Sub-System Diagnostics (S.N. 872257 )
B17 Brake Pressure Switch: (Stop) Key switch is moved between ON and START
B18 Brake Pressure Switch: (Stop) position to activate bulb check mode. All high and low
B10Park Brake Pressure Switch: (Stop) level indicator lights will activate and audible alarm will
B6Engine Oil Pressure Switch: (Stop) sound. The seat belt (White) indicator will be on.
B5Engine Coolant Temperature Switch: (Stop)
B7Air Filter Restriction Switch: (Service) High or Low Level Warning Mode
B8Converter Oil Temperature Switch: (Service)
B9Hydraulic Filter Restriction Switch: (Service) During normal operation the indicator lights are turned
B2Hydraulic Oil Temperature Switch (Service) on when an indicator switch or the alternator provides
G2Alternator: (Service) a signal to the display monitor indicating a STOP
High Level Warning or SERVICE Low Level Warning
The following indicators will be displayed on display indicator.
9015
15B monitor when a signal from a High Level Warning
,108 Indicator switch is activated: Seat Position Sensor
Red Colored Indicator The seat position sensor is located in the operators
Red Stop Indicator seat base. When the seat is moved to operate
Audible Alarm backhoe functions the sensor is closed. When the
sensor is closed (seat moved to operate backhoe
The following indicator will be displayed on display functions) A signal is sent to the display monitor. When
monitor when a signal from a Low Level Warning the FNR lever is moved into forward or reverse
Indicator switch is activated or the signal from the position during backhoe operation the display monitor
alternator disappears. is activated turning on the audible alarm and the red
STOP indicator light.
Yellow Colored Indicator
On Mode
CED,TX17864,176 1914SEP981/1
PN=512
Sub-System Diagnostics (S.N. 872257 )
9015
15B
,109
1918SEP98
T117193
TX,9015,QQ6781 1902OCT961/1
PN=513
Sub-System Diagnostics (S.N. 872257 )
TX,9015,QQ6782 1902OCT961/1
1/1
Engine Coolant Disconnect X36 yellow wire from switch and ground to YES: Replace switch.
Temperature Indicator frame.
9015
Switch NO: Switch is good. Go
15B
Without starting engine, turn key switch to BULB to next check.
,110
CHECK, then release to ON.
T7199CG 1916AUG90
1/1
Engine Oil Pressure Disconnect N34 yellow wire from switch and ground to YES: Replace switch.
Switch frame.
NO: Switch is good. Go
Without starting engine, turn key switch to BULB to next check.
CHECK, then release to ON.
T7199DZ 1926SEP90
1/1
Engine Alternator Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39 YES: Circuit is good.
Indicator Circuit purple wire. Repair or replace
alternator.
Without starting engine, turn key switch to BULB CHECK, then release to ON.
NO: Go to next check.
Is alternator indicator light off?
1/1
PN=514
Sub-System Diagnostics (S.N. 872257 )
Engine Air Filter Disconnect M40 purple wire from switch and ground to YES: Replace switch.
Restriction Switch frame.
NO: Switch is good. Go
Without starting engine, turn key switch to BULB to next check.
CHECK, then release to ON?
T7199CI 1917SEP90
1/1
Converter Oil Disconnect X38 yellow wire from switch and ground to YES: Replace switch.
Temperature Switch frame.
9015
NO: Switch is good. Go
15B
Without starting engine, turn key to BULB CHECK, then to next check.
,111
release to ON.
T7199CJ 1917SEP90
1/1
Hydraulic Filter Disconnect F39 yellow wire from switch and ground to YES: Replace switch.
Restriction Indicator frame.
Switch NO: Switch is good. Go
Without starting engine, turn key switch to BULB to next check.
CHECK, then release to ON.
T7199CK 1917SEP90
1/1
PN=515
Sub-System Diagnostics (S.N. 872257 )
Brake Pressure Switches Disconnect left brake pressure switch from harness. YES: Replace Switch
Install jumper wire into harness connector as shown. NO: Switch is good.
Continue with check.
Without starting engine, turn key switch to BULB
CHECK, then release to ON.
Disconnect right brake pressure switch from harness. YES: Replace Switch
Install jumper wire into harness connector as shown.
NO: Switch is good. An
Without starting engine, turn key switch to BULB open circuit in harnesses
CHECK, then release to ON. is indicated. Check
harnesses. Go to next
Is indicator light off? check.
9015
15B T117194 1918SEP98
,112
1/1
NOTE: Seat position sensor is located in the operators NO: Replace seat
seat base. position sensor.
Is continuity measured:
1/1
PN=516
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,119 1931JUL981/1
PN=517
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,116 1931JUL981/1
PN=518
Sub-System Diagnostics (S.N. 872257 )
9015
15B
,115
1931JUL98
T116668
CED,TX17864,117 1931JUL981/1
PN=519
Sub-System Diagnostics (S.N. 872257 )
CED,TX17864,118 1931JUL981/1
1/1
1/1
PN=520
Sub-System Diagnostics (S.N. 872257 )
9015
T100731 UN28MAY96 15B
,117
Disconnect harness from selective flow valve switch.
Is Continuity measured?
Is continuity measured?
Is continuity measured?
1/1
Foot Switch Check Disconnect foot switch from harness. YES: Go to next check.
Is continuity measured?
T116147 1927JUL98
1/1
PN=521
Sub-System Diagnostics (S.N. 872257 )
1/1
9015
15B
,118
PN=522
Group 20
References
Alternators and Starting MotorsUse CTM77
UN17JAN89
TS225
TX,9010,SS2208 1901SEP941/1
Tachometer
AClamp-On Tachometer.
UN28FEB89
Remove paint with emery cloth and connect to a straight section of
injection line within 100 mm (4 in.) of pump. Finger tighten onlyDO
NOT over tighten.
BBlack Clip (-). Connect to main frame.
T6813AG
CRed Clip (+). Connect to transducer.
DTachometer Readout. Install cable.
10T,9010,K182 1910AUG951/1
PN=523
References
Battery Operation
A battery is a device for converting chemical energy to Batteries should be maintained at an open circuit
electrical energy. It is not a storage tank for electricity, voltage of 12.50 volts or greater. To determine open
but stores electrical energy in chemical form. circuit voltage do the following:
Because of the constant chemical to electrical change 1. Turn master disconnect switch to ON position.
(self-discharge, discharge, or charge), the battery has
a limited life. Proper care (cleaning, adding water, 2. For machines that have not been run during the
charging) will extend the life of the battery. past ten hours, go to Step 4.
The battery is made up of positive plates, negative 3. For machines that have been run in the past ten
plates, separators, plate straps, and chemical solution hours, remove surface charge. Turn key switch to
(electrolyte). The electrolyte is a solution of sulfuric START, turn on 3 or 4 work lights and leave them
acid and water. Sulfuric acid is not lost during on for 3 to 5 minutes. Turn key switch OFF, then
overcharging; therefore, if the liquid solution is low, wait two minutes. (If machine does not have lights,
9015
20 only water should be added. turn key switch to START position for at least 5
2 minutes, then turn off.)
In a fully charged battery, the positive plate is lead
peroxide (PBQ2), the negative plate is "spongy" lead 4. Measure voltage at alternator by placing the
(Pb), and the electrolyte solution is about 1.270 times negative lead of a multimeter to case of alternator
heavier than water. The amount that the solution is and the positive lead to the sense terminal of the
heavier than water is called specific gravity. alternator.
All batteries will self discharge at a rate of .001 specific STABILIZED OPEN
gravity point per 24 hour period at a constant 85 F. CIRCUIT VOLTAGE PERCENT CHARGED
The discharge rate increases as temperature increases 12.5 Volts or More 100%
and decreases as temperature decreases. If the 12.4 75%
machine is not used for a period of time, the batteries 12.2 50%
must be maintained or stored in a cool place. 12.0 25%
11.7 or less 0%
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.
TX,9015,MM1631 1910AUG951/1
PN=524
References
Battery Specifications
Specification
BatteryVoltage............................................................................ 12 Volts
Cold Cranking Power ......................................... 625 amps at -18C (0F)
Reserve Capacity ................................................ 160 minutes at 25 amps
BCI Group Size ...................................................................................... 31
Fully Charged Electrolyte Specific
Gravity ................................................................................... 1.2651.280
TX,9015,BG993 1902APR971/1
9015
20
3
PN=525
References
Battery Using Too Much Water Shorted battery cell Check battery state of charge. (See
Procedure for Testing Batteries.)
Low Battery Output Low water level See Battery Using Too Much Water
and Cracked Battery Case
symptoms.
Dirty or wet battery top, causing Clean battery top. Recharge battery.
discharge
Corroded or loose battery cable Clean and tighten cable end clamps.
ends Recharge battery.
TX,901505,QQ365 1910AUG951/1
PN=526
References
9015
20
5
UN23AUG88
TS203
UN10FEB89
T6996DB
Single Level Fill Tube Application
UN10FEB89
T6996DA
PN=527
References
If acid is swallowed:
PN=528
References
TX,9015,QQ1696 1901SEP953/3
Hydrometer Test If one battery fails load test, replace both batteries.
TX,9015,DY669 1916AUG961/1
PN=529
References
9015
20
8
UN24OCT91
UN24OCT91
T6508AE1
T6713AI1
Single Battery Application Two Battery Application
Before boost starting, machine must be properly shut IMPORTANT: The machine electrical system is a
down and secured to prevent unexpected machine 12 volt negative (-) ground. Use only
movement when engine starts. 12 volt booster batteries.
TX,901505,QQ364 1901SEP951/1
PN=530
References
9015
20
9
PN=531
References
9015
20
10
1903OCT91
T7596AR
AAlternator EAlternator Relay ITerminal 1 MStator
BBattery FBAT terminal JRegulator NRectifier
CKey Switch GR Terminal KDiode Trio ODiode
DIndicator Light HTerminal 2 LRotor (Field)
The alternator is a 12 volt system. The operating The regulator (J) acts like a switch for the rotor (L). A
principles are as follows: wire runs from BAT terminal (F) to terminal 2 (H). If the
regulator (J) senses a low battery voltage, rotor is
When key switch (C) is turned ON, voltage is applied switched on. Field current increases and alternator
to terminal 1 (I) of the alternator. The regulator (J) output increases.
switches the rotor (L) ON or OFF.
When high battery voltage is sensed by the regulator
Once the engine reaches alternator cut in RPM, the rotor is switched off, reducing current output from
alternating output current is produced in the stator (M) stator. This on and off occurs many times a second.
windings. This alternating current is changed to direct The voltage regulator is temperature compensated to
current by the rectifier (N) diodes. Voltage is available provide a slightly higher voltage at low temperature to
at BAT (F) terminal. The current is used to charge the charge the battery.
battery (B) and supply electrical current to the machine
electrical system. Once alternator is charging, field
current is supplied by the diode trio. Diode (O) protects
the diode trio from external loads.
PN=532
References
When the alternator is operating, the R terminal and removing the ground for the alternator indicator
voltage is approximately 7.8 volts AC. This voltage is light (D) in the display module, turning off the
supplied to the alternator relay, energizing the relay alternator indicator light.
TX,9015,QQ1926 1910AUG952/2
9015
20
11
PN=533
References
9015
20
12
1923SEP92
T7812AZ
AAlternator GD+ Terminal LExternal Ground Terminal QAlternator Relay
BInternal Ground HB+ Terminal MRotor RIndicator Light
CNegative Diodes IW Terminal NAlternator Diode SBrushes
DExciter Diodes JExcitation Winding OBattery TSense Circuit
EStator Windings KRegulator PKey Switch UNoise Filter
FPositive Diodes
TX,9015,QQ1927 1910AUG951/1
PN=534
References
The 95 AMP Bosch alternator has three basic stages and F) and delivered to the battery and current
for proper operation. The operating principles are as consuming accessories. The currents in the stator
follows. winding (E) are constantly changing magnitude and
direction. However, current flowing to the battery and
Pre-Excitation Stage: accessories always maintains the same direction. This
is because no matter what position the rotor (M) is in,
When key switch (P) is turned to ON position, battery all the diodes are simultaneously involved in the
power flows to (G) terminal D+ on alternator, excitation process of rectification. The regulator (K) measures the
winding (J), through regulator (K) and to internal B+ voltage (H) and compares it to an internal
ground (B). reference. When the B+ voltage (H) starts to rise
above the reference voltage the regulator (K) switches
Excitation Stage: off the field current. When the B+ voltage (H) starts to
fall below the reference voltage the regulator (K)
During alternator start (as the engine speeds up from 0 switches on the field current. The regulator (K)
9015
to idle) current supplied by the external alternator switches the field ON and OFF several thousand times 20
diode to the field coil of the rotor produces a magnetic a second in response to the current load placed on the 13
field which induces current in the three-phase winding alternator output and the engine RPM.
of the stator (E). The alternator reaches cut-in RPM
when the induced current is large enough to produce When the alternator is operating, the W terminal
voltage equal to the battery voltage plus 1.0 volt. At voltage is (7 to 8) volts (AC). This voltage is supplied
this time, some current from the stator is rectified by to the alternator relay, energizing the relay and
the exciter diodes (D) (producing battery voltage at the removing the ground for the alternator indicator light
D+ terminal (G)) and is supplied to the carbon brushes (Q) in the display module, turning off the alternator
and slip rings of the excitation winding (J), indicator light.
strengthening the magnetic field in the excitation
winding. This in turn will increase the stator voltage. Current available from the alternator is dependent on
This will occur continuously until the alternator (A) is engine RPM. Depending on pulley ratios, little or no
fully excited and the alternator regulated voltage is current is available below abut 700 RPM. Full rated
reached. current is not available below about 1500 RPM.
Normal Operation:
TX,9015,DY670 1916AUG961/1
PN=535
References
1. Turn key switch to "Bulb Check" position. All sending unit switches that are closed and sending a
indicator and warning lights and the buzzer must ground signal for a primary (red light) failure
come on. If none of the lights come on, check the indication.
"monitor" fuse. If one or two lights fail to light,
replace the bulb. 4. Turn key switch to "bulb check" momentarily and
back to "on". After 2-3 seconds, the alternator
2. Return key switch to "ON" position from "bulb indicator light and the yellow warning light should
check". Hold just momentarily in "bulb check". If come on. There may be additional indicator lights
held too long, the logic modules with time delay will on, depending on which secondary (yellow light)
have no delay. With machines that have time delay failure sending unit switches are closed.
logic modules, after 2-3 seconds the engine oil
pressure and engine alternator volts indicator lights 5. If the warning lights do not come on, with (S.N
and the red warning light and buzzer should come 815415) the next step is to isolate the logic module
on. With no time delay the lights and buzzer will from the display module and the machine wiring
9015
20 come on immediately. On some machines and sending units. See Logic Module Test In
14 additional indicator lights may come on, depending Machine, and Logic Module Bench Test in this
on sending unit switches being closed and sending group.
a ground signal to the monitor.
TX,9015,QQ3203 1910MAR971/1
PN=536
References
5. With pin "F" grounded, red STOP light and alarm must 9015
come on. 20
15
If logic module does not work when grounding pins
"D", "E" and "F", check logic module wiring by
UN03NOV88
continuing with step 6. If wiring is OK, replace logic
module.
T6883BE
Continued on next page TX,9015,QQ3201 1910MAR971/2
PN=537
References
UN09FEB94
Continuity ChecksKey Switch OFF
A of 4-Pin to C of 4-Pin
A of 4-Pin to D of 6-Pin
T8174AM
B of 4-Pin to Ground
D of 4-Pin to Ground
B of 6-Pin to Alternator Relay NO Terminal
E of 6-Pin to Ground (With key in BULB CHECK
position only)
F of 6-Pin to Ground
TX,9015,QQ3201 1910MAR972/2
PN=538
References
9015
20
17
UN28FEB94
UN28FEB94
T8188AM
T8188AN
IMPORTANT: DO NOT allow wires to touch one does, remove wire from pin E and go to next step.
another after being connected to If light does not come on, replace module.
logic module.
5. Connect wire (E) to pin B in small connector. Light
1. Connect wires (A and B) from positive (+) battery must come on. If it does, remove wire (E) from pin
post to pins A and C in large connector. B and go to next step. If light does not come on,
replace module.
2. Connect wire (C) from negative battery post to pin
F in large connector. 6. Remove the indicator light lead from pin D in large
connector and connect to pin C in small connector.
3. Using a 12V indicator light with two wire leads, Connect wire (D) to pin D in small connector. Light
connect one lead to pin D in large connector, and must pulse on and off. If it does not, replace
one lead to pin A in small connector. module.
TX,9015,QQ3202 1910MAR971/1
PN=539
References
UN27JUN91
Tachometer Installation in this group.
T7545BQ
TX,9015,QQ1798 1931AUG951/1
9015
20
18
PN=540
References
UN09APR98
(E) on back of tachometer (C).
T114085
displayed on LCD readout. When it does, release
9015
calibration button. 20
19
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.
UN02APR98
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
T114688B
and pointer can only be adjusted upward.
CED,TX17864,110 1921JUL981/1
PN=541
References
9015
20
20
PN=542
Section 9020
Power Train
Contents
Page Page
PN=1
Contents
Page Page
PN=2
Group 05A
Theory of Operation (S.N. 872256)
Transmission (S.N. 872256)
Input/Output Sections
PN=545
Theory of Operation (S.N. 872256)
SOLENOIDS ENERGIZED
- N C2-B3 FWD C1-B2 REV
1st Forward X X
2nd Forward X X X
3rd Forward X X X
4th Forward X X X X
1st Neutral
2nd Neutral X
3rd Neutral X
4th Neutral X X
1st Reverse X X
9020
05A 2nd4th X X X
2 Reverse
PN=546
Theory of Operation (S.N. 872256)
TX,9020,BG381 1914JAN973/3
9020
05A
3
PN=547
Theory of Operation (S.N. 872256)
F IMPELLER G TURBINE
PUMP
HOUSING E
SEAL D
TRANSMISSION
INPUT
CONVERTER-IN C
H SHAFT
9020
05A
4
TO COOLER B
AND LUBE I CONVERTER-OUT
J STATOR
PUMP A
DRIVE
GEAR
K CONVERTER-IN
PRESSURE
L CONVERTER-OUT
1915JAN98
PRESSURE
M LUBE
PRESSURE
T7601AB
PN=548
Theory of Operation (S.N. 872256)
The single turbine torque converter is located inside stationary stator. The stator blades are curved so the
the front of the transmission housing. A drive plate is oil flow changes direction and exits the stator moving
mounted to the torque converter housing. The outer in the same direction as the impeller.
edge of the drive plate is attached to the engine
flywheel. The turbine rotates at a slower speed than the
impeller, but with more torque. The increased force
There are three main parts to the torque converter. developed by the stator makes the torque converter
able to multiply torque.
Impeller (F)
Turbine (G) During light load applications, the turbine speed
Stator (J) becomes equal to the impeller speed. The free wheel
clutch will unlock allowing the stator to rotate with the
The impeller is driven by the engine and drives the turbine and impeller. Input speed and torque from the
transmission oil pump drive gear (A). As it rotates, engine is equal to the output speed and torque of the
centrifugal force throws oil out of the impeller against converter when the stator is freewheeling.
the blades of the turbine. This forces the turbine to
rotate in the same direction as the impeller. The There are no serviceable parts inside the torque
9020
turbine is connected to the transmission input shaft converter. If it is defective, replace the entire
05A
(H). assembly. 5
10T,9020,J196 1903MAR932/2
PN=549
Theory of Operation (S.N. 872256)
SECOND
SUN GEAR
C2 CLUTCH E
FIRST
D SUN GEAR
F
REDUCTION
FROM GEAR SHAFT
CONTROL C
VALVE
B
9020
05A
C2
6
G
POWER FROM
B1 C1
TORQUE
H CONVERTER
INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT
I PRESSURE OIL
SHAFT
J RETURN OIL
K POWER FLOW - NEUTRAL
1915JAN98
T6885AA
TXC6885AA
PN=550
Theory of Operation (S.N. 872256)
In neutral, power from the engine is transmitted engaged, no power is transmitted to the output section
through the torque converter (G) to the transmission of the transmission. In neutral, engagement oil is
input shaft (H). The transmission input shaft is splined routed from the transmission control valve (B) to the
to the C1 clutch hub and the second planetary sun C2 clutch (D). With no power coming from the input
gear (E). The first planetary sun gear (F) is machined section of the transmission, the reduction gear shaft
in the input shaft. These parts rotate at engine speed. (C) and the output shaft (A) do not rotate.
Since neither B1 or B2 brakes or C1 clutch are
10T,9020,J198 1903MAR932/2
9020
05A
7
PN=551
Theory of Operation (S.N. 872256)
THIRD
SUN GEAR
FOURTH F
SUN GEAR
D C2 CLUTCH G B2 BRAKE
E
H B2 RING GEAR
I SECOND
REDUCTION C SUN GEAR
GEAR SHAFT
FROM
CONTROL
VALVE
B
9020
05A
8
C2
J
POWER FROM
B1 C1
TORQUE
CONVERTER
K INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT L PRESSURE OIL
SHAFT
M RETURN OIL
TXC7601AC
PN=552
Theory of Operation (S.N. 872256)
AOutput Shaft EFourth Sun Gear ISecond Sun Gear LPressure Oil
BFrom Control Valve FThird Sun Gear JPower from Torque MReturn Oil
CReduction Gear Shaft GB2 Brake Converter NPower Flow-First Forward
DC2 Clutch HB2 Ring Gear KInput Shaft
When the transmission control lever is shifted to first sun gear (I). The second sun gear forces the planet
forward, transmission control oil is sent to the B2 pinion gears to orbit around the B2 ring gear rotating
Brake (under drive) (G) and the C2 Clutch (direct the planetary carrier in the same direction as the input
drive) (D). shaft, but at a slower speed.
The B2 ring gear (H) is clamped to the transmission The planetary carrier transmits power to the output
housing. planetary set. When C2 is engaged, both the third and
fourth sun gears are locked to the reduction gear shaft
The C2 clutch drum is locked to the C2 clutch hub. and provide direct drive out of the transmission at the
This ties the fourth sun gear (E) to the reduction gear same speed as the carrier.
shaft (C).
The reduction gear shaft transmits engine power
Engine power (J) flows through the torque converter to through the output shaft (A) to the differential.
the input shaft (K) and the compound planetary second
9020
05A
9
10T,9020,J200 1922OCT912/2
PN=553
Theory of Operation (S.N. 872256)
B3 BRAKE
D FOURTH F THIRD
SUN GEAR SUN GEAR
E
B3 RING GEAR G B2 BRAKE
C H B2 RING GEAR
REDUCTION
GEAR SHAFT
B
9020
05A
10 C2
I
POWER FROM
B1 C1
TORQUE
J CONVERTER
INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT
SHAFT K PRESSURE OIL
L RETURN OIL
M POWER FLOW - SECOND FORWARD
1915JAN98
T6885AG
TXC6885AG
PN=554
Theory of Operation (S.N. 872256)
AOutput Shaft EFourth Sun Gear IPower from Torque LReturn Oil
BReduction Gear Shaft FThird Sun Gear Converter MPower Flow-Second
CB3 Ring Gear GB2 Brake JInput Shaft Forward
DB3 Brake HB2 Ring Gear KPressure Oil
When the transmission control lever is shifted to second gear forces the planet pinion gears to orbit the
second forward, transmission control oil is sent to the B2 ring gear rotating the planetary carrier in the same
B2 Brake (under drive, G) and the B3 Brake (over direction as the input shaft, but at a slower speed.
drive, D).
The planetary carrier transmits power to the output
The B2 ring gear (H) is clamped to the transmission planetary set. Since the B3 brake (D) is engaged, the
housing. fourth sun gear (E) is stationary. The output planet
pinions are forced to orbit the fourth sun gear. This
The B3 ring gear (C), which is located on the external causes the third sun gear (F) and reduction gear shaft
diameter of the C2 clutch drum, is also clamped to the (B) to rotate in the same direction as the planetary
transmission case. This ties the fourth planetary sun carrier, but at a faster speed.
gear (E) to the transmission case.
Power from the reduction gear shaft is sent through
Engine power (I) flows through the torque converter to the output shaft (A) to the differential.
the input shaft (J) and the second sun gear. The
9020
05A
11
10T,9020,J202 1922OCT912/2
PN=555
Theory of Operation (S.N. 872256)
FOURTH F THIRD
SUN GEAR SUN GEAR
C2 CLUTCH D E
G C1 CLUTCH
REDUCTION C
GEAR SHAFT
FROM
CONTROL
VALVE
B
9020
05A
12
C2
H
POWER FROM
B1
TORQUE
C1
CONVERTER
I
B3 B1 C1 B2
INPUT
SHAFT
A
OUTPUT
SHAFT J PRESSURE OIL
B FROM CONTROL VALVE K RETURN OIL
TXC7601AD
PN=556
Theory of Operation (S.N. 872256)
AOutput Shaft EFourth Sun Gear HPower from Torque JPressure Oil
BFrom Control Valve FThird Sun Gear Converter KReturn Oil
CReduction Gear Shaft GC1 Clutch IInput Shaft LPower Flow-Third Forward
DC2 Clutch
When the transmission control lever is moved to third Engine power (H) flows through the torque converter to
forward, transmission control oil (B) is sent to the C1 the input shaft and planetary carrier. The carrier
Clutch (direct drive, G) and the C2 Clutch (direct drive, rotates at the same speed as the input shaft.
D).
The planetary carrier transmits power to the output
The C1 clutch drum is locked to the C1 clutch hub. planetary set. With C2 clutch engaged, both the third
This clamps the input shaft (I) to the planetary carrier and fourth sun gears are locked to the reduction gear
and causes it to rotate at the same speed as the input shaft and provide direct drive out of the transmission at
shaft. the same speed as the input shaft.
The C2 clutch drum is locked to the C2 clutch hub. The reduction gear shaft transmits engine power
This ties the fourth sun gear (E) to the reduction gear through the output shaft (A) to the differential.
shaft (C).
9020
05A
13
10T,9020,J204 1922OCT912/2
PN=557
Theory of Operation (S.N. 872256)
D B3 BRAKE F THIRD
FOURTH SUN GEAR
SUN GEAR
B3 RING GEAR C E
G C1 CLUTCH
REDUCTION B
GEAR SHAFT
9020
05A
14
C2
H
POWER FROM
B1 C1
TORQUE
CONVERTER
I INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT J PRESSURE OIL
SHAFT
K RETURN OIL
TXC6885AD
PN=558
Theory of Operation (S.N. 872256)
When the transmission control lever is shifted to fourth The planetary carrier transmits power to the output
forward, transmission control oil is sent to the C1 planetary set. Since the B3 brake is engaged, the
Clutch (direct drive, G) and B3 Brake (over drive, D). fourth sun gear is stationary. The output planet pinions
are forced to orbit the fourth sun gear. This causes the
The C1 clutch drum is locked to the C1 clutch hub. third sun gear (F) and reduction gear shaft (B) to
This clamps the input shaft (I) to the planetary carrier rotate in the same direction as the planetary carrier,
and causes it to rotate at the same speed as the input but at a faster speed.
shaft.
Power from the reduction gear shaft is sent through
The B3 ring gear which is located on the external the output shaft (A) to the differential.
diameter of the C2 clutch drum is clamped to the
transmission case. This ties the fourth planetary sun
gear (E) to the transmission case.
10T,9020,J206 1922OCT912/2
PN=559
Theory of Operation (S.N. 872256)
THIRD
SUN GEAR
FOURTH F
SUN GEAR
C2 CLUTCH D G B1 BRAKE
E
H B1 RING GEAR
I FIRST
REDUCTION C SUN GEAR
GEAR SHAFT
FROM
CONTROL
VALVE
B
9020
05A
16
C2
J
POWER FROM
B1
TORQUE
C1
CONVERTER
K
B3 B1 C1 B2
INPUT
SHAFT
A
OUTPUT
L PRESSURE OIL
SHAFT
B FROM CONTROL VALVE M RETURN OIL
TXC7601AE
PN=560
Theory of Operation (S.N. 872256)
AOutput Shaft EFourth Sun Gear IFirst Sun Gear LPressure Oil
BFrom Control Valve FThird Sun Gear JPower from Torque MReturn Oil
CReduction Gear Shaft GB1 Brake Converter NPower Flow-First Reverse
DC2 Clutch HB1 Ring Gear KInput Shaft
When the transmission control lever is shifted to first sun gear and the B1 ring gear. This causes the
reverse, transmission control (B) oil is sent to the B1 planetary carrier to rotate in the opposite direction of
Brake (reverse, G) and the C2 Clutch (direct drive, D). the input shaft. Carrier rotates 15 percent faster
making reverse speeds 15 percent faster than
The B1 ring gear (H) is clamped to the transmission corresponding forward speeds.
case.
The planetary carrier transmits power to the output
The C2 clutch drum is locked to the C2 clutch hub. planetary set. When C2 is engaged, both the third and
This ties the fourth sun gear (E) to the reduction gear fourth sun gears are locked together and provide direct
shaft (C). drive out of the transmission at the same speed as the
carrier.
Engine power (J) flows through the torque converter to
the input shaft and its first sun gear (I). Since the B1 The reduction gear shaft transmits engine power
ring gear is locked to the transmission case, the first through the output shaft (A) to the differential in the
sun gear forces the planet pinion gears to orbit the B1 reverse direction of the converter input.
ring gear.
9020
There are two sets of planet pinion gears in the first
05A
planetary assembly. They are in mesh with the first 17
10T,9020,J208 1922OCT912/2
PN=561
Theory of Operation (S.N. 872256)
F THIRD
SUN GEAR
D B3 BRAKE
G B1 BRAKE
REDUCTION B
GEAR SHAFT
9020
05A
18
C2
J
POWER FROM
B1 C1
TORQUE
CONVERTER
K INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT L PRESSURE OIL
SHAFT M RETURN OIL
TXC6885AF
PN=562
Theory of Operation (S.N. 872256)
AOutput Shaft EFourth Sun Gear IPower from Torque MReturn Oil
BReduction Gear Shaft FThird Sun Gear Converter NPower Flow-Second
CB3 Ring Gear GB1 Brake KInput Shaft Reverse
DB3 Brake HB1 Ring Gear LPressure Oil
When the transmission is shifted into second reverse, the B1 ring gear. This causes the planetary carrier to
transmission control oil is sent to the B1 Brake rotate in the opposite direction of the input shaft.
(reverse, G) and the B3 Brake (over drive, D). Carrier rotates 15 percent faster making reverse
speeds 15 percent faster than corresponding forward
The B1 ring gear (H) is clamped to the transmission speeds.
case.
The planetary carrier transmits power to the output
The B3 ring gear (C), which is located on the external planetary set. Since the B3 brake is engaged, the
diameter of the C2 clutch drum, is also clamped to the fourth sun gear is stationary. The output planet pinions
transmission case. This ties the fourth planetary sun are forced to orbit the fourth sun gear. This causes the
gear (E) to the transmission case. third sun gear (F) and reduction gear shaft (B) to
rotate in the same direction as the planetary carrier
Engine power (J) flows through the torque converter to (reverse), but at a faster speed.
the input shaft and its first sun gear (I). Since the B1
ring gear is locked to the transmission case, the first The reduction gear shaft transmits engine power
sun gear forces the planet pinion gears to orbit the B1 through the output shaft (A) to the differential in the
ring gear. reverse direction of the converter input.
9020
05A
There are two sets of planet gears in the first planetary 19
assembly. They are in mesh with the first sun gear and
10T,9020,J210 1922OCT912/2
PN=563
Theory of Operation (S.N. 872256)
PRESSURE G
H
REGULATING
VALVE
I
E
F
D REDUCED
FLOW
C
FROM
TRANSMISSION
FILTER TO
G CONVERTER - IN
F
9020
05A
20
TO
RESERVOIR
C FROM LUBE
CIRCUIT
H
CONVERTER - IN
RELIEF VALVE
I
B
LUBE
RELIEF
EXCESS VALVE
LUBE A
PRESSURE
EXCESS
CONVERTER - IN
PRESSURE
J
K CONTROL PRESSURE
L CONVERTER - IN PRESSURE
M LUBE PRESSURE
1915JAN98
N RETURN
TXC7849AL
PN=564
Theory of Operation (S.N. 872256)
AExcess Lube Pressure FFrom Transmission Filter JExcess Converter-In MLube Pressure
BLube Relief Valve GTo Converter-In Pressure NReturn
CTo Reservoir HFrom Lube Circuit KControl Pressure OPressure Regulating Valve
DReduced Flow IConverter-In Relief Valve LConverter-In Pressure Housing
EPressure Regulating Valve
The pressure regulating valve housing contains the subsequently, the oil cooler. Excess converter-in oil
pressure regulating valve (E), the lube relief valve (B) pressure (J) due to cold oil or a restriction in the oil
and the converter-in/cooler relief valve (I). cooler will push the valve poppet down opening a
passage for oil to flow to the lube circuit (H).
The pressure regulating valve is used to set the
pressure for the transmission control circuit. Oil from The lube relief valve is used to set the maximum
the transmission filter (F) acts on the top of the valve pressure in the lube circuit. Excess lube pressure (A)
poppet. The control pressure is determined by the pushes the valve spool down opening a passage from
valve spring and shims. During normal operation, the the lube circuit to the reservoir (C).
valve allows excess pump flow to go to the torque
converter-in circuit (G). When there is reduced flow The spring side of the three relief valves are open to
from the transmission pump (D) like during a shift, the the reservoir to prevent a hydraulic lock of the valve
valve moves up and blocks oil flow to the converter-in spool. The lube relief and the converter-in relief valves
circuit. are not adjustable. If pressure settings are low, replace
the spring.
The converter-in/cooler relief valve is used to control
the pressure of oil going to the torque converter and, 9020
05A
21
10T,9020,J214 1903MAR932/2
PN=565
Theory of Operation (S.N. 872256)
G H
9020
05A
22
E F
D I
E
F
A
B
C
G H
1929JAN97
I
T6300AG
T6300AG
AHigh Pressure Oil DRestricted Filter FTo Lube HTo Control Circuit
BMedium Pressure Oil EFilter Relief Valve GFrom Transmission Pump IFilter Element
CLow Pressure Oil
The transmission filter (I) is a 10 micron full-flow filter. poppet. When the filter becomes restricted (D), the
It is protected by a pressure differential type relief filter inlet oil pressure increases and the outlet oil
valve (E). Oil flow from the transmission pump (G) pressure decreases. When the pressure differential
flows through the filter to transmission control circuit exceeds the spring force of the poppet spring, the
(H). Oil from the pump acts on the end of the relief relief valve opens the routes the unfiltered oil to the
valve. Filtered oil acts on the spring side of the relief lube circuit (F).
10T,9020,J216 1903MAR931/1
PN=566
Theory of Operation (S.N. 872256)
F SOLENOID
COIL
E PLUNGER
D TO
RETURN
C BALL G PRESSURE OIL 9020
1915JAN98
05A
B FROM PRESSURE H RETURN OIL
23
REGULATING VALVE
A ENERGIZED I DE-ENERGIZED
T7864AN
TXC7864AN J SOLENOID VALVE OPERATION
The neutral solenoid is used to disengage the When the operator releases the neutral disconnect
transmission during normal operation. When the switch, he energizes (A) the neutral solenoid. The coil
solenoid is de-energized (I), the plunger (E) is in the draws the plunger up and opens the passage from the
down position. In this position, pressure oil from the pressure regulating valve to the neutral spool and FNR
pressure regulating valve (B) is blocked at the neutral spool.
solenoid.
10T,9020,J219 1904MAR931/1
PN=567
Theory of Operation (S.N. 872256)
C1 FNR
B1 SPOOL
B2 J
B3 C1, B1, B2
ACCUMULATOR C2, B3
H SHIFT K C1, B2
SPOOL SHIFT SPOOL
C2, B3 I
ACCUMULATOR
C2 G
SOLENOID
L
9020 F
05A NEUTRAL
24 SPOOL C1, B2
FROM OIL REV
COOLER TRANSMISSION FWD
D LUBRICATION C2, B3
E
PRESSURE
NEU REGULATING
VALVE
HOUSING
M
FILTER C
RELIEF
VALVE
N
TO TORQUE
CONVERTER
AND OIL
COOLER
O CONVERTER-IN
B TRANSMISSION RELIEF VALVE
FILTER R TRANSMISSION P LUBE RELIEF
PUMP VALVE
S CONTROL PRESSURE Q PRESSURE
REGULATING
T CONVERTER PRESSURE VALVE
1915JAN98
A SUCTION
SCREEN U LUBE PRESSURE
V RETURN
T7870BE
PN=568
Theory of Operation (S.N. 872256)
ASuction Screen HC1,B1,B2 Accumulator NTo Torque Converter and SControl Pressure
BTransmission Filter IC2,B3 Shift Spool Oil Cooler TConverter Pressure
CFilter Relief Valve JFNR Spool OConverter-In Relief Valve ULube Pressure
DFrom Oil Cooler KC1,B2 Shift Spool PLube Relief Valve VReturn
ETransmission Lubrication LSolenoid QPressure Regulating Valve WTransmission Hydraulic
FNeutral Spool MPressure Regulating Valve RTransmission Pump Circuit-1st Neutral
GC2,B3 Accumulator Housing
PN=569
Theory of Operation (S.N. 872256)
Spring force closes the neutral spool and blocks oil spool which is being held down by spring force. Oil
flow to the FNR spool. Oil flow is routed from the flow through the shift spool in this position results in
accumulator housing back through the C2,B3 shift the engagement of only the C2 clutch.
TX,9020,BG383 1914JAN973/3
9020
05A
26
PN=570
Theory of Operation (S.N. 872256)
9020
05A
27
PN=571
Theory of Operation (S.N. 872256)
C1 FNR
B1 SPOOL
B2 D
B3
C1, B1, B2
ACCUMULATOR C2, B3
C SHIFT E C1, B2
SPOOL SHIFT SPOOL
C2, B3 I
ACCUMULATOR
C2 B
SOLENOID
F
9020
05A
28
C1, B2
REV
FWD
A C2, B3
NEUTRAL
SPOOL NEU
1915JAN98
G CONTROL PRESSURE
H RETURN
T7840BE
TXC7840BE I TRANSMISSION HYDRAULIC CIRCUIT-1ST FORWARD
When the FNR lever is moved from the neutral the spool moves up against the spring, pressure oil
position, the neutral solenoid is energized and control from the neutral spool is allowed to flow through the
oil is allowed to flow to the neutral spool. When the FNR spool to the C1,B2 shift spool.
neutral spool is moved against the spring, main
pressure from the B1,B2,C1 accumulator is available Since the C1,B2 solenoid is not energized, pressure oil
to the FNR spool for clutch or brake engagement. flows through to engage B2 brake.
TX,9020,YY745 1904MAR931/1
PN=572
Theory of Operation (S.N. 872256)
B1 C1 FNR
SPOOL
B2
E
B3
C1, B1, B2
ACCUMULATOR C2, B3
C SHIFT F C1, B2
SPOOL SHIFT SPOOL
C2, B3 D
ACCUMULATOR
C2
B
SOLENOID
G
9020
05A
29
C1, B2
REV
A FWD
NEUTRAL C2, B3
SPOOL
NEU
1915JAN98
H CONTROL PRESSURE
I RETURN
T7840BD
TXC7840BD J TRANSMISSION HYDRAULIC CIRCUIT-2ND REVERSE
When the FNR lever is moved from neutral position, the spool moves down against the spring, pressure oil
the neutral solenoid is energized and control oil is from the neutral spool is allowed to flow through the
allowed to flow to the neutral spool. When the neutral FNR spool to engage B1 brake.
spool is moved against the spring, main pressure from
the B1,B2,C1 accumulator is available to the FNR The C2,B3 solenoid is also energized which routes
spool for clutch or brake engagement. control oil to the bottom of C2,B3 shift spool. When the
spool moves up against the spring, main pressure from
In 2nd reverse, the reverse solenoid is energized and the C2,B3 accumulator is allowed to flow to engage B3
control oil is routed to the top of the FNR spool. When brake.
TX,9020,YY746 1904MAR931/1
PN=573
Theory of Operation (S.N. 872256)
Differential drive gear supplies power to MFWD driver Drive shaft powers sun gear of wheel hub planetary.
shaft then to front MFWD drive gear set. MFWD idler Sun gear rotates fixed planetary gears which turn outer
gear shaft directs power to clutch through MFWD ring. The planetary system reduces drive shaft output
clutch drive gear. speed and increases torque at front tires.
When control valve is engaged, valve prevents flow of Wheel drive gear is meshed with outer ring. Outer ring
clutch control oil to clutch. Springs force clutch disk is meshed to wheel hub.
pack together and power is transmitted forward by
U-jointed drive shaft to front axle differential drive When MFWD control valve is disengaged, valve
shaft. Shaft drive gear and ring gear mesh turning directs pressure oil to release the MFWD clutch.
limited-slip differential unit.
TX,9020,BG382 1914JAN971/1
9020
05A
30
PN=574
Theory of Operation (S.N. 872256)
9020
05A
31
UN19OCT88
T6771AH
ATire with Most Traction DLH Drive Gear GClutch Disks IPower Flow
BDrive Shaft EPinion Gears HClutch Plate JRotation Direction
CRH Drive Gear FDifferential Housing
As available traction changes, tire with better traction drive gear (C) from rotating. Wheel with less traction
(A) can use more power. Self-limiting differential action provides less resistance against its drive gear (D).
begins to occur.
PN=575
Theory of Operation (S.N. 872256)
Pinion gears (E) continue to be driven by rotating Since the tire with less traction is exerting less force
differential housing (F). These pinion gears push trying to keep its axle from turning, the bevel gear
against bevel drive gears as before. Angle of gear force is not being transmitted to this drive shaft. As
teeth tries to force meshed gears apart. On the side long as the difference in traction between tires remains
with more traction, pinion gears begin to walk around the same, the clutch pack on the side with less traction
drive gear and push against restraining force will continue to slip more than the clutch pack on the
transmitted from tire. Drive gear is wedged outward other side.
and compresses a clutch pack with disks (G) splined
to axle and plates (H) tanged to housing. Disks begin With MFWD engaged, differential works to
to slip less against plates as compressing force automatically balance driving power to available
increases. As the pack slippage decreases drive shaft traction.
begins to receive driving force through the differential
housing.
TX,05,SS3140 1910SEP982/2
9020
05A
32
PN=576
Theory of Operation (S.N. 872256)
9020
05A
33
UN19OCT88
T6771AG
ADifferential Drives Shaft CDifferential Housing EBevel Drive Gears GPower Flow
BRing Gear DPinions FDrive Shafts HRotation Direction
Differential unit has self-applied, limited slip feature. With MFWD engaged, when tractor is moving in a
When engaged under slippery field conditions, this straight line and each wheel has equal traction, equal
system automatically applies correct amount of torque power is supplied to left and right axle. No differential
to match traction available to each wheel. action occurs.
PN=577
Theory of Operation (S.N. 872256)
Power flows into axle housing through differential drive pinions (D) remain stationary within rotating housing.
shaft (A), turning ring gear (B) and attached differential Pinions turn bevel drive gears (E) and drive shafts (F)
housing (C). When both wheels have equal traction, splined to drive gears.
TX,05,SS3141 1910SEP982/2
9020
05A
34
PN=578
Theory of Operation (S.N. 872256)
OIL TORQUE
COOLER CONVERTER
B3-C2 B1-B2-C1
ACCUMULATOR ACCUMULATOR
FNR
SPOOL
C1, B2
C2, B3 SHIFT
SHIFT SPOOL
SPOOL
TRANSMISSION
LUBRICATION NEUTRAL
FILTER RELIEF SPOOL
VALVE
TRANSMISSION
PUMP
TRANSMISSION MFWD
FILTER SOLENOID
[ENGAGED]
SUCTION
SCREEN CONTROL PRESSURE
CONVERTER-IN PRESSURE C1 C2 B1 B2 B3
LUBE PRESSURE
RETURN TRANSMISSION HYDRAULIC SCHEMATIC - 2ND NEUTRAL
TXC7840BA
TX,9020,BG386 1914JAN971/1
9020
05A
36
PN=580
Theory of Operation (S.N. 872256)
OIL TORQUE
COOLER CONVERTER
B3-C2
ACCUMULATOR
TRANSMISSION
LUBRICATION
FILTER RELIEF
VALVE
TRANSMISSION
PUMP
TRANSMISSION MFWD
FILTER SOLENOID
[ENGAGED]
SUCTION
SCREEN CONTROL PRESSURE
CONVERTER-IN PRESSURE
LUBE PRESSURE
RETURN TRANSMISSION HYDRAUL
TXC7840BA
TX,9020,BG386 1914JAN971/1
B1-B2-C1
ACCUMULATOR
FNR
SPOOL
C1, B2
C2, B3 SHIFT
SHIFT SPOOL
SPOOL
NEUTRAL
SPOOL
C1 C2 B1 B2 B3
/1
der
22602
579
Page 9020-05A-35 B
Group 05B
Theory of Operation (S.N. 872257 )
Power Train Conponents (S.N.872257 )
NOTE: For (S.N. 872257 ) The operation and test A single stage torque converter drives a hydraulically
procedures for the park brake and differential engaged four speed forward, three speed reverse,
lock are found in Section 9020. Service brakes countershaft type power shift transmission.
are found in Section 9025.
A multiple wet disk park brake is located in the rear
The power train uses a ZF (4WG984 speed forward axle. It is spring applied and hydraulic released. The
& 3 speed reverse) reversing powershift transmission park brake switch on the side console controls a
with hydrodynamic torque converter. Optional MFWD solenoid located in the transmission duct plate to
axle is a ZF (APL355E). Rear Axle is ZF (AP-2085) activate the park brake.
with multiple disk hydraulically activated differential and
wet multiple disk brakes. Park Brake is integral with The transmission outputs through universal joints and
the rear axle housing. two drive shaft assemblies. The front axle may be
equipped with either a standard axle or optional
The power train consists of the following components: MFWD limited slip self-locking differential axle.
Torque converter The rear axle is equipped with the differential lock.
Transmission
Rear drive shafts The torque converter is a fluid coupling between the
MFWD (Optional) engine and the powershift transmission. It uses oil
Park brake (in rear axle) flow, rather than a dry clutch disk, to transmit engine 9020
Front and rear axles power to the rest of the power train. 05B
1
TX,05,SS3678 1913FEB971/1
PN=581
Theory of Operation (S.N. 872257 )
9020
1904MAR98
05B
2
T101172
1Turbine 4Input Shaft 7Turbine Shaft 10Stator
2Impeller 5Shaft Seal 8Pump Drive Shaft 11Torque Converter
3Stator Shaft 6Drain Plug 9Free-wheel Clutch
The three main parts of the torque converter include Pump drive shaft (8) is driven by the engine directly
the impeller, turbine and stator. and at engine speed. The pump drive shaft provides
input to the transmission pump and the hydraulic
The impeller (2) is driven by the engine. As it rotates, system pump.
centrifugal force throws oil out of the impeller against
the blades of the turbine (1). This forces the turbine to As the oil leaves the turbine, it is redirected by the
rotate in the same direction as the impeller. stator (10) back into the impeller which increases the
torque converter performance.
The turbine (1) is connected to the turbine shaft (7)
which provides input to the transmission gear train.
PN=582
Theory of Operation (S.N. 872257 )
Oil leaving the turbine enters the stator (10). The stator torque are equal to output speed and torque when the
is curved so that the oil flow changes direction. Oil stator is free-wheeling. The transmission pump is
leaving the stator is moving in the same direction as constantly pumping oil through the converter. The
the impeller. This adds to the force of the oil entering converter multiplies the torque and at the same time,
the impeller. The turbine will be rotating at a slower the heat created in the converter is eliminated through
speed than the impeller, but it will produce a higher the circulation of oil from converter to cooler and back
torque. It is this increased force developed by the to sump.
stator that makes a converter able to multiply torque.
Under light load the speed of the turbine will increase There are no serviceable parts inside the torque
until it equals impeller speed. The free-wheel clutch (9) converter. If it is defective, replace the entire
unlocks, allowing the stator to free-wheel or rotate with assembly.
the turbine and impeller as a unit. Input speed and
TX,05,SS3120 1909SEP982/2
9020
05B
3
PN=583
Theory of Operation (S.N. 872257 )
9020
05B
UN12JUL96
4
T101251
1Angle Disk 3O-Ring (2 used) 5Pump Housing 7Needle Bearing
2Washer 4Cap Screw (4 used) 6O-Ring 8Stop Sleeve
TX,05,SS3124 1922JUN981/2
TX,05,SS3124 1922JUN982/2
PN=584
Theory of Operation (S.N. 872257 )
9020
05B
1912JUL96
5
T101250
AFilter CBypass Valve DTo Transmission Circuit EFrom Transmission Pump
BSpring
NOTE: Filter housing removed to show element and through the middle of the element to the transmission
bypass valve. control system.
The transmission filter is a spin on replaceable If the filter element becomes obstructed or during
element. If the filter (A) becomes obstructed, a bypass extremely cold conditions, the pressure difference
valve (C) opens to maintain flow to the transmission across the filter element exceeds the set value of the
control system. bypass spring (B), causing the bypass valve (C) to
unseat. This unseated valve allows unfiltered oil to
Oil from the transmission pump enters from outside of pass through the filter housing. Bypass operation for
the filter element. The filter element traps contaminants extended periods of time is not recommended.
as the oil passes through it. Filtered oil flows up
TX,05,SS3125 1922JUN981/1
PN=585
Theory of Operation (S.N. 872257 )
C
D
H
C TO C G
LUBE F
9020
05B
6
FROM
D D
COOLER
SEAT B
H SPRING
VALVE A
FROM
E E
CONVERTER
I BYPASS J COOLING
THERMOSTAT G
F TO
1920JAN98
F
COOLER
K LUBE/CONVERTER-OUT FLOW
L TO COOLER (VALVE CLOSED)
T7799BX
PN=586
Theory of Operation (S.N. 872257 )
The thermal bypass valve is used to maintain the enters passage (E) and flows through the valve (A) to
transmission oil temperature at a level which provides lube (C).
optimum torque converter performance and lubrication
to transmission. At higher temperatures, the thermostat (G) begins to
open, allowing flow out of passage (F) to the
The valve contains a standard automotive-type transmission oil cooler. The thermostat will go to the
thermostat element connected to a hollow valve spool. full open position, forcing the valve closed against the
seat (B). The spring loaded seat will act as a relief
The valve is designed to bypass the transmission oil valve in the event cooler flow is blocked.
cooler at low temperatures. Converter outlet flow
TX,9020,ME437 1928AUG962/2
9020
05B
7
PN=587
Theory of Operation (S.N. 872257 )
Power Shift High Range Forward, First Speed and Second Speed Clutch Packs (S.N.
872257 )
9020
05B
8
1904SEP98
T117074
ASeparator Plate (as CClutch Drum GHub KTapered Bearing
required per clutch pack) DRoller Bearing HEnd Plate LLubrication Oil
BDisk (as required per ETapered Bearing IPiston MClutch Pack
clutch pack) FPressure Oil JSpring
NOTE: This operation covers the power shift high plates are splined to the clutch drum (C) and the disks
range forward, first and second speed clutch are splined to hub (G) locking them together. The drive
packs. The function of the packs are the same, shaft gear is splined to the low range forward, reverse,
but the quantity on the disks and separator and high range forward (4th) gear. All gears are
plates will be different between packs. constantly meshed and supported by antifriction
bearings. The bearings and clutches are lubricated
When the FNR lever is placed in forward or reverse, with cooled lubrication oil (L). Spring disks (J) push
pressure oil (F) from the control valve forces the clutch back the piston (I) when the clutch pack (M) is
piston (I) to compress the plates (A) and disks (B). The disengaged, thus releasing the multi-disk clutch.
CED,TX03399,4234 1929MAY981/1
PN=588
Theory of Operation (S.N. 872257 )
9020
05B
9
PN=589
Theory of Operation (S.N. 872257 )
TRANSMISSION
PUMP C
TORQUE A
CONVERTER
PUMP
DRIVE J
SHAFT
REVERSE
9020
D
CLUTCH
05B
10
LOW
RANGE
E
FORWARD
CLUTCH
FIRST
SPEED I
CLUTCH
THIRD
F SPEED
CLUTCH
MFWD H
SECOND
G SPEED
CLUTCH
1901FEB99
T117096
T117096 K TRANSMISSION
PN=590
Theory of Operation (S.N. 872257 )
ATorque Converter CTransmission Pump FThird Speed Clutch IFirst Speed Clutch
BHigh Range (4th) Forward DReverse Clutch GSecond Speed Clutch JPump Drive Shaft
Clutch ELow Range Forward Clutch HMFWD KTransmission
A single stage torque converter drives a hydraulically The optional MFWD front axle is a self applied limited
engaged four speeds forward and three speeds slip design. It consists of a differential with outboard
reverse countershaft type power shift transmission. planetary final drives.
Six clutch packs provide four forward and three The rear axle is an inboard planetary design with
reverse speeds. Two clutch packs have to be engaged internal wet multi-disk service brakes that are self
for movement. One directional clutch pack, either adjusting. Pressure oil for the service brakes is
low-range forward, high-range forward or reverse and supplied by a full power operated brake valve. The
one speed range clutch pack either 1st, 2nd or 3rd. park brake is a wet multi-disk design which is spring
applied and hydraulically released. The differential lock
The transmission may also have an optional front is a lever activated multi-disk clutch design, which is
output shaft (H) for mechanical front wheel drive hydraulically engaged and spring released.
(MFWD) which is spring applied and hydraulically
released.
CED,TX03399,4205 1903MAR982/2
PN=591
Theory of Operation (S.N. 872257 )
4th FORWARD
(HIGH RANGE) A B REVERSE A B
C LOW RANGE C
2nd SPEED G FORWARD G
F D 1st SPEED F D
3rd SPEED
(REAR OUTPUT)
E MFWD E
OUTPUT
9020 A B A B
05B
12
C C
G G
F D D
F
E E
A B A B A B
C C C
G G G
F D D F D
F
1902JUN98
E E E
T115189
T115189
PN=592
Theory of Operation (S.N. 872257 )
A4th Forward (High Range) CLow Range Forward EMFWD Output G2nd Speed
BReverse D1st Speed F3rd Speed (Rear Output)
The torque converter supplies torque to the drive gear As a example, with the transmission in second speed
which is in constant mesh with the low-range forward, forward, the low range forward clutch (C) and the
reverse and high range forward clutch hubs. second speed clutch (G) are engaged. The torque
converter supplies torque to the drive gear which
The low-range forward clutch, reverse, high range meshes with the gear on the low-range forward clutch.
forward and second speed clutch outer gears are in Power flow continues through the reverse (B) and high
mesh. As are the first speed hub gear and third speed range forward clutch (A) output gears to the second
clutch outer gear. speed (G) output gear which drives the third speed
clutch (F) rear axle output which is in mesh with first
With MFWD (if equipped) the first speed hub is in speed clutch (D) hub which is in mesh with the MFWD
mesh with the MFWD output gear. (E) (if equipped) output gear.
CED,TX03399,4206 1903MAR982/2
9020
05B
13
PN=593
Theory of Operation (S.N. 872257 )
Solenoids Activated
Gear Selection Low Range, Forward, & Reverse Solenoid Energized Speed Solenoid Energized
Forward Low Range Reverse 1 2 3
9020
Neutral
05B
14 1st Forward X X X X
2nd Forward X X X X
3rd Forward X X X X
4th Forward (High Range) X X X
1st Reverse X X X X
2nd Reverse X X X X
3rd Reverse X X X X
CED,TX03399,4223 1924MAR981/1
PN=594
Theory of Operation (S.N. 872257 )
9020
05B
15
PN=595
Theory of Operation (S.N. 872257 )
HIGH RANGE
FORWARD CLUTCH
1ST SPEED
CLUTCH LOW RANGE DIFFERENTIAL LOCK MFWD PARK
FORWARD REVERSE BRAKE
TRANSMISSION CLUTCH CLUTCH
2ND SPEED CONTROL VALVE
CLUTCH
LOW RANGE P
3RD SPEED TRANSMISSION SPEED SHIFT VALVE
CLUTCH SHIFT VALVE
SPEED SHIFT
VALVE L FORWARD/REVERSE
3 SHIFT VALVE
O
SPEED SHIFT
VALVE SEQUENCE
K VALVE ORIFICE IN
2 VALVE HOUSING
LOW N
RANGE R DIFFERENTIAL
FORWARD MFWD PARK BRAKE
SPEED SOLENOID REVERSE SOLENOID SOLENOID SOLENOID SOLENOID
SHIFT VALVE SOLENOID VALVE VALVE VALVE VALVE
VALVE C VALVE
1 J B
D
ORIFICE IN
MODULATION SCREEN
MODULATION IN ALL
SPOOL VALVE G
SPEED SPEED SPEED PRESSURE SOLENOIDS
SOLENOID SOLENOID SOLENOID REDUCING
VALVE VALVE VALVE ORIFICE ORIFICE IN VALVE Q
3 M 2 I 1 H IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
LOW RANGE, FORWARD, & REVERSE SPEED PLATE
GEAR SOLENOID ENERGIZED SOLENOID ENERGIZED CONVERTER
SELECTION FORWARD LOW RANGE REVERSE 1 2 3 RELIEF
NEUTRAL VALVE
COOLER TORQUE E
1ST FORWARD X X X X RELIEF CONVERTER
2ND FORWARD X X X X BYPASS
VALVE SYSTEM PRESSURE
3RD FORWARD X X X X FILTER
AND MEDIUM PRESSURE
HIGH RANGE THERMAL TRANSMISSION BYPASS
X X X RELIEF OIL COOLER LOW PRESSURE
(4TH FORWARD)
BYPASS
1ST REVERSE X X X X VALVE LUBE PRESSURE
TRANSMISSION
2ND REVERSE TO PUMP
X X X X LUBE RETURN PRESSURE
3RD REVERSE X X X X
T117376 TRANSMISSION CONTROL CIRCUIT NEUTRAL SUMP
CED,TX03399,4214 1906MAR981/1
PN=596
2ND SPEED
CLUTCH
SPEED SHIFT
VALVE L
3
SPEED SHIFT
VALVE
2 K
LOW
RANGE
SPEED SOLENO
SHIFT VALVE
VALVE C
1 J
Page 9020-05B-16 A
Power Shift
T117376 1901FEB99
HIGH RANGE
FORWARD CLUTCH
LOW RANGE P
SHIFT VALVE
FORWARD/REVERSE
SHIFT VALVE
O
SEQUENCE
VALVE ORIFICE IN
VALVE HOUSING
LOW N
RANGE R
FORWARD
SOLENOID REVERSE SOLENOID
VALVE SOLENOID VALVE
C VALVE
B
D
ORIFICE IN
MODULATION MODULATION
SPOOL VALVE G
PRESSUR
REDUCIN
ORIFICE ORIFICE IN VALVE
IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
TORQUE E
CONVERTER
FILTER
AND
TRANSMISSION BYPASS
OIL COOLER
TRANSMISSION
TO PUMP
LUBE
TM1537 (26FEB0
Page 9020-05B-16 B
Theory of Operation (S.N. 872257 )
SCREEN
IN ALL
ESSURE SOLENOIDS
DUCING
ALVE Q
SYSTEM PRESSURE
MEDIUM PRESSURE
LOW PRESSURE
LUBE PRESSURE
RETURN PRESSURE
CED,TX03399,4214 1906MAR981/1
NOTE: Keys and story on control valve in the circuit is a spring loaded spool valve which routes system oil
correspond to the control valve on next page. to the low range, high range forward, and reverse
clutches. The forward and reverse solenoid valves, (B)
The transmission control valve regulates the hydraulic and (D), are activated by the FNR lever. Each directs
oil pressures and controls circuits required for medium pressure oil to the forward/reverse shift valve
operation of the transmission. Electrical signals from (O). The low range solenoid valve (C), directs medium
the FNR lever and park brake switch are used to pressure oil to the low range shift valve (P). The low
energize the solenoids which direct oil to move the range solenoid valve is controlled by the gear selection
shift valves and engage the appropriate selected on the FNR lever.
clutches.
The pressure reducing valve (Q) supplies medium
The transmission control valve contains the main pressure oil to the speed, forward, reverse and low
frame harness (A), forward solenoid valve (B), low range solenoid valves.
range solenoid valve (C), reverse solenoid valve (D),
converter relief valve (E), pressure regulating valve (F), Flow from the transmission charge pump passes
modulation valve (G), modulation piston (N), through the filter to the pressure regulating valve. The
forward/reverse shift valve (O), low range shift valve pressure regulating valve regulates system pressure
(P), and the pressure reducing valve (Q). The and directs high pressure oil to the reducing valve,
transmission speed shift valve contains the speed differential solenoid valve, MFWD solenoid valve and
solenoid valves 1, 2 and 3 (H, I and M) and speed the park brake solenoid valve. 9020
shift valves 1, 2 and 3 (J, K and L). 05B
17
When pressure exceeds the pressure regulating valve
The converter relief valve (E) controls the maximum setting the valve opens. Low pressure oil then flows
pressure to the torque converter. The pressure through the torque converter. Converter flow is excess
regulating valve (F) is a spring loaded spool valve with oil from the pressure regulating valve. A torque
shims. It regulates main system pressure. Excess oil converter relief valve protects the circuit by dumping to
from the circuit is directed to the torque converter tank when pressure exceeds the setting. The oil is
through this valve. The modulation valve (G) is a then routed to the oil cooler. The oil returning from the
spring loaded spool which controls the rate of clutch cooler provides lubrication to the clutches.
engagement during a shift. Within the valve is the
modulation piston (N). In neutral, with park brake OFF, the forward and
reverse solenoids are de-energized (open), medium
When a gear is selected the speed solenoid valves (H, pressure oil is not directed to the forward/reverse shift
I, or M) are energized in combinations of two which valve. The low range solenoid valve is de-energized
shift two of the speed shift valves (J, K, or L). The shift (open) and no pressure oil is routed to the end of the
valves direct system pressure oil to one of the speed low range shift valve. In neutral all speed clutch packs
clutches 1st, 2nd or 3rd. also dump to sump and all speed clutch solenoids are
de-energized. The reducing valve controls the pressure
The forward/reverse shift valve (O), is a spring loaded by dumping oil to tank when pressure exceeds its
spool valve which routes system pressure oil to the setting.
low range shift valve (P). The low range shift valve (P),
CED,TX03399,4218 1906MAR981/1
PN=597
Theory of Operation (S.N. 872257 )
Power Shift Transmission Control Valve and Shift Valve OperationNeutral (S.N.
872257 )
D REVERSE
SOLENOID
E
CONVERTER
RELIEF
A MAIN VALVE
FRAME
HARNESS
9020 Q
05B F
18 PRESSURE
REDUCING PRESSURE
VALVE REGULATING
VALVE
P
LOW RANGE
SHIFT VALVE R
ORIFICE N
O
G
FORWARD MODULATION
OR REVERSE PISTON MODULATION
SHIFT VALVE VALVE
H
SPEED
SOLENOID
VALVE 1
M I
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2
SHIFT
VALVE 3
K SPEED
W TRANSMISSION CONTROL VALVE SHIFT
T114881
VALVE 2
T114881 AND SHIFT VALVE - NEUTRAL
Continued on next page CED,TX03399,4224 1927MAR981/2
PN=598
Theory of Operation (S.N. 872257 )
AMain Frame Harness HSpeed Solenoid Valve 1 OForward/Reverse Shift TMedium Pressure Oil
BForward Solenoid Valve ISpeed Solenoid Valve 2 Valve ULow Pressure Oil
CLow Range Solenoid Valve JSpeed Shift Valve 1 PLow Range Shift Valve VReturn Oil
DReverse Solenoid Valve KSpeed Shift Valve 2 QPressure Reducing Valve WTransmission Control
EConverter Relief Valve LSpeed Shift Valve 3 ROrifice (In Valve Housing) Valve And Shift Valve
FPressure Regulating Valve MSpeed Solenoid Valve 3 SSystem Pressure Oil Neutral
GModulation Valve NModulation Piston
CED,TX03399,4224 1927MAR982/2
9020
05B
19
PN=599
Theory of Operation (S.N. 872257 )
HIGH RANGE
FORWARD CLUTCH
1ST SPEED
CLUTCH LOW RANGE DIFFERENTIAL LOCK MFWD PARK
FORWARD REVERSE BRAKE
TRANSMISSION CLUTCH CLUTCH
2ND SPEED CONTROL VALVE
CLUTCH
LOW RANGE
3RD SPEED TRANSMISSION SPEED SHIFT VALVE
CLUTCH SHIFT VALVE P
SPEED SHIFT
VALVE L FORWARD/REVERSE
3 SHIFT VALVE
O
SEQUENCE
SPEED SHIFT VALVE
VALVE ORIFICE IN
2 K PARK BRAKE
VALVE HOUSING SOLENOID
LOW N
RANGE R DIFFERENTIAL VALVE
FORWARD MFWD
SPEED SOLENOID REVERSE SOLENOID SOLENOID SOLENOID
SHIFT VALVE SOLENOID VALVE VALVE VALVE
VALVE C VALVE
1 J B
D
ORIFICE IN
MODULATION MODULATION
SPOOL SCREEN
SPEED SPEED SPEED VALVE G PRESSURE IN ALL
SOLENOID SOLENOID REDUCING SOLENOIDS
VALVE VALVE VALVE ORIFICE ORIFICE IN VALVE Q
3 M 2 I 1 H IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
LOW RANGE, FORWARD, & REVERSE SPEED PLATE
GEAR SOLENOID ENERGIZED SOLENOID ENERGIZED CONVERTER
SELECTION FORWARD LOW RANGE REVERSE 1 2 3 RELIEF
NEUTRAL VALVE
COOLER TORQUE E
1ST FORWARD X X X X RELIEF CONVERTER
2ND FORWARD X X X X BYPASS
VALVE SYSTEM PRESSURE
3RD FORWARD X X X X FILTER
AND MEDIUM PRESSURE
HIGH RANGE THERMAL TRANSMISSION BYPASS
X X X RELIEF OIL COOLER LOW PRESSURE
(4TH FORWARD)
BYPASS
1ST REVERSE X X X X VALVE LUBE PRESSURE
TRANSMISSION
2ND REVERSE TO PUMP
X X X X LUBE RETURN PRESSURE
3RD REVERSE X X X X
T117377 TRANSMISSION CONTROL CIRCUIT FIRST FORWARD SUMP
CED,TX03399,4215 1906MAR981/1
PN=600
2ND SPEED
CLUTCH
SPEED SHIFT
VALVE L
3
SPEED SHIFT
VALVE
2 K
LOW
RANGE
SPEED SOLENO
SHIFT VALVE
VALVE C
1 J
Page 9020-05B-20 A
Power Shift
T117377 1901FEB99
HIGH RANGE
FORWARD CLUTCH
LOW RANGE
SHIFT VALVE
P
FORWARD/REVERSE
SHIFT VALVE
O
SEQUENCE
VALVE
ORIFICE IN
VALVE HOUSING
LOW N
RANGE R
FORWARD
SOLENOID REVERSE SOLENOID
VALVE SOLENOID VALVE
C VALVE
B
D
ORIFICE IN
MODULATION MODULATION
SPOOL VALVE G PRESSUR
REDUCIN
ORIFICE ORIFICE IN VALVE
IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
TORQUE E
CONVERTER
FILTER
AND
TRANSMISSION BYPASS
OIL COOLER
TRANSMISSION
TO PUMP
LUBE
TM1537 (26FEB0
Page 9020-05B-20 B
Theory of Operation (S.N. 872257 )
PARK BRAKE
SOLENOID
DIFFERENTIAL VALVE
MFWD
SOLENOID SOLENOID
VALVE VALVE
SCREEN
ESSURE IN ALL
DUCING SOLENOIDS
ALVE Q
SYSTEM PRESSURE
MEDIUM PRESSURE
LOW PRESSURE
LUBE PRESSURE
RETURN PRESSURE
CED,TX03399,4215 1906MAR981/1
NOTE: Keys and story on control valve in the circuit and the low range shift spool allows oil to flow from the
correspond to the control valve on next page. modulation valve to fill the low range forward clutch
pack and compress the clutch plates. Shifting of the
The relief valves are the same pressure oil as forward/reverse spool also blocks the flow of oil
shown in the neutral story. Refer to neutral downstream of the orifice (R) in valve housing from
story for pressure reducing, converter relief returning to tank and allows the pressure in the
and pressure regulating valve. modulation valve to build. As pressure builds, the
balance between orifice size and spring load in the
During 1st gear forward operation the forward solenoid modulation valve controls the rate of shift and pushes
valve (B), low range solenoid valve (C), speed the modulation piston down.
solenoid valve 2 (I), and speed solenoid valve 3 (M)
are energized. The energized low range solenoid valve The sequence valve insures that the speed clutch fills
routes medium pressure oil to the low range shift valve and engages before the direction clutch by allowing oil
(P) and moves the spool down. The energized forward to flow from the modulation valve to the speed clutch
solenoid valve (B) routes medium pressure oil to the circuit downstream of the orifice in duct plate
forward/reverse shift valve (O) moving its spool up. (replenishing orifice) when the pressure in the speed
The energized speed solenoids 2 and 3 (I and M) clutch circuit is lower than the pressure in the direction
route medium pressure oil to the shift valves 2 and 3 clutch circuit. The downward force from the modulation
(K and L) moving the spools down. Shifting of the piston pushes on the modulation springs which drive
speed shift spools allows oil to flow from the regulating the modulation spool down to the fully open position. 9020
valve through the orifice in duct plate (replenishing In the fully open position, high pressure oil form the 05B
21
orifice) to fill the 1st speed clutch pack and compress pressure regulating valve keeps the speed and
the clutch plates. Shifting of the forward/reverse spool direction clutches engaged.
CED,TX03399,4219 1906MAR981/1
PN=601
Theory of Operation (S.N. 872257 )
Power Shift Transmission Control Valve and Shift ValveFirst Forward (S.N. 872257 )
D REVERSE
SOLENOID
E
CONVERTER
RELIEF
A MAIN VALVE
FRAME
HARNESS
Q
9020 F
PRESSURE
05B REDUCING PRESSURE
22
VALVE REGULATING
VALVE
P
LOW RANGE
SHIFT VALVE R
O ORIFICE N
G
FORWARD MODULATION
OR REVERSE PISTON MODULATION
SHIFT VALVE VALVE
H
SPEED
SOLENOID
VALVE 1
M I
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2
SHIFT
VALVE 3
K SPEED
V TRANSMISSION CONTROL VALVE SHIFT
T114882
VALVE 2
T114882 AND SHIFT VALVE - FIRST FORWARD
PN=602
Theory of Operation (S.N. 872257 )
AMain Frame Harness HSpeed Solenoid Valve 1 NModulation Piston SSystem Pressure Oil
BForward Solenoid Valve ISpeed Solenoid Valve 2 OForward/Reverse Shift TMedium Pressure Oil
CLow Range Solenoid Valve JSpeed Shift Valve 1 Valve UReturn Pressure Oil
DReverse Solenoid Valve KSpeed Shift Valve 2 PLow Range Shift Valve VTransmission Control
EConverter Relief Valve LSpeed Shift Valve 3 QPressure Reducing Valve Valve and Shift Valve
FPressure Regulating Valve MSpeed Solenoid Valve 3 ROrifice (In Valve Housing) First Forward
GModulation Valve
CED,TX03399,4227 1922APR982/2
9020
05B
23
PN=603
Theory of Operation (S.N. 872257 )
Power Shift Transmission Control CircuitHigh Range (Fourth) Forward (S.N. 872257 )
T117378 1901FEB99
HIGH RANGE
FORWARD CLUTCH
1ST SPEED
CLUTCH LOW RANGE DIFFERENTIAL LOCK MFWD PARK
FORWARD REVERSE BRAKE
TRANSMISSION CLUTCH CLUTCH
2ND SPEED CONTROL VALVE
CLUTCH
LOW RANGE P
3RD SPEED TRANSMISSION SPEED SHIFT VALVE
CLUTCH SHIFT VALVE
SPEED SHIFT
VALVE L FORWARD/REVERSE
3 SHIFT VALVE
O
SPEED SHIFT
VALVE SEQUENCE
K VALVE ORIFICE IN PARK BRAKE
2 VALVE HOUSING
LOW N SOLENOID
RANGE R DIFFERENTIAL VALVE
FORWARD MFWD
SOLENOID REVERSE SOLENOID SOLENOID SOLENOID
VALVE SOLENOID VALVE VALVE VALVE
SPEED C VALVE
B
SHIFT D
VALVE ORIFICE IN
1 J MODULATION
SPOOL MODULATION SCREEN
SPEED SPEED SPEED VALVE G PRESSURE IN ALL
SOLENOID SOLENOID SOLENOID REDUCING SOLENOIDS
VALVE VALVE VALVE ORIFICE ORIFICE IN VALVE Q
3 M 2 I 1 H IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
LOW RANGE, FORWARD, & REVERSE SPEED PLATE
GEAR SOLENOID ENERGIZED SOLENOID ENERGIZED CONVERTER
SELECTION FORWARD LOW RANGE REVERSE 1 2 3 RELIEF
NEUTRAL VALVE
COOLER TORQUE E
1ST FORWARD X X X X RELIEF CONVERTER
2ND FORWARD X X X X BYPASS
VALVE SYSTEM PRESSURE
3RD FORWARD X X X X FILTER
AND MEDIUM PRESSURE
HIGH RANGE THERMAL TRANSMISSION BYPASS
X X X RELIEF OIL COOLER LOW PRESSURE
(4TH FORWARD)
BYPASS
1ST REVERSE X X X X VALVE LUBE PRESSURE
TRANSMISSION
2ND REVERSE TO PUMP
X X X X LUBE RETURN PRESSURE
3RD REVERSE X X X X
T117378 TRANSMISSION CONTROL CIRCUIT FOURTH FORWARD SUMP
CED,TX03399,4216 1906MAR981/1
PN=604
2ND SPEED
CLUTCH
SPEED SHIFT
VALVE L
3
SPEED SHIFT
VALVE
2 K
LOW
RANGE
SOLENO
VALVE
SPEED C
SHIFT
VALVE
1 J
SPEED SPEED SPEED
SOLENOID SOLENOID SOLENOID
VALVE VALVE VALVE
3 M 2 I 1 H
Page 9020-05B-24 A
Power Shift
T117378 1901FEB99
HIGH RANGE
FORWARD CLUTCH
LOW RANGE P
SHIFT VALVE
FORWARD/REVERSE
SHIFT VALVE
O
SEQUENCE
VALVE ORIFICE IN
VALVE HOUSING
LOW N
RANGE R
FORWARD
SOLENOID REVERSE SOLENOID
VALVE SOLENOID VALVE
C VALVE
B
D
ORIFICE IN
MODULATION
SPOOL MODULATION
VALVE G PRESSUR
REDUCIN
ORIFICE ORIFICE IN VALVE
IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
TORQUE E
CONVERTER
FILTER
AND
TRANSMISSION BYPASS
OIL COOLER
TRANSMISSION
TO PUMP
LUBE
TM1537 (26FEB0
Page 9020-05B-24 B
Theory of Operation (S.N. 872257 )
PARK BRAKE
SOLENOID
DIFFERENTIAL VALVE
MFWD
SOLENOID SOLENOID
VALVE VALVE
SCREEN
ESSURE IN ALL
DUCING SOLENOIDS
ALVE Q
SYSTEM PRESSURE
MEDIUM PRESSURE
LOW PRESSURE
LUBE PRESSURE
RETURN PRESSURE
CED,TX03399,4216 1906MAR981/1
NOTE: Keys and story on control valve in the circuit clutch pack and compress the clutch plates. Shifting of
correspond to the control valve on next page. the forward/reverse spool also blocks the flow of oil
downstream of the orifice (R) in valve housing from
The relief valves are the same pressure oil as returning to tank and allows the pressure in the
shown in the neutral story. Refer to neutral modulation valve to build. As pressure builds, the
story for pressure reducing, converter relief balance between orifice size and spring load in the
and pressure regulating valve. modulation valve controls the rate of shift and pushes
the modulation piston down.
During 4th gear forward operation the forward solenoid
valve (B), speed solenoid valve 1 (H), and speed The sequence valve insures that the speed clutch fills
solenoid valve 3 (M) are energized. Both the low range and engages before the direction clutch by allowing oil
shift valve (P) and the forward/reverse shift valve (O) to flow from the modulation valve to the speed clutch
are in the up position. The energized speed solenoids circuit downstream of the orifice in duct plate
1 and 3 (H and M) route medium pressure oil to the (replenishing orifice) when the pressure in the speed
shift valves 1 and 3 (J and L) moving the spools down. clutch circuit is lower than the pressure in the direction
Pressure oil is routed through the shift valves to the clutch circuit. The downward force from the modulation
3rd speed clutch. Shifting of the speed shift spools piston pushes on the modulation springs which drive
allows oil to flow from the regulating valve through the the modulation spool down to the fully open position.
orifice in duct plate (replenishing orifice) to fill the 3rd In the fully open position, high pressure oil form the 9020
05B
speed clutch pack and compress the clutch plates. pressure regulating valve keeps the speed and
25
Shifting of the forward/reverse spool allows oil to flow direction clutches engaged.
from the modulation valve to fill the high range forward
CED,TX03399,4222 1913MAR981/1
PN=605
Theory of Operation (S.N. 872257 )
Power Shift Transmission Control Valve and Shift ValveHigh Range (Fourth) Forward
(S.N. 872257 )
D REVERSE
SOLENOID
E
CONVERTER
RELIEF
A MAIN VALVE
FRAME
HARNESS
9020 Q
05B F
26 PRESSURE
REDUCING PRESSURE
VALVE REGULATING
VALVE
P
LOW RANGE
SHIFT VALVE R
ORIFICE N
G
O MODULATION
PISTON MODULATION
FORWARD VALVE
OR REVERSE
SHIFT VALVE H
SPEED
SOLENOID
VALVE 1
M I
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2
L
SPEED
1926JUN98
SHIFT
VALVE 3
K SPEED
V TRANSMISSION CONTROL VALVE SHIFT
T114883
VALVE 2
T114883 AND SHIFT VALVE - FOURTH FORWARD
Continued on next page CED,TX03399,4228 1922APR981/2
PN=606
Theory of Operation (S.N. 872257 )
AMain Frame Harness HSpeed Solenoid Valve 1 OForward/Reverse Shift TMedium Pressure Oil
BForward Solenoid Valve ISpeed Solenoid Valve 2 Valve UReturn Pressure Oil
CLow Range Solenoid Valve JSpeed Shift Valve 1 PLow Range Shift Valve VTransmission Control
DReverse Solenoid Valve KSpeed Shift Valve 2 QPressure Reducing Valve Valve and Shift Valve
EConverter Relief Valve LSpeed Shift Valve 3 ROrifice (In Valve Housing) High Range (Fourth)
FPressure Regulating Valve MSpeed Solenoid Valve 3 SSystem Pressure Oil Forward
GModulation Valve NModulation Piston
CED,TX03399,4228 1922APR982/2
9020
05B
27
PN=607
Theory of Operation (S.N. 872257 )
HIGH RANGE
FORWARD CLUTCH
1ST SPEED
CLUTCH LOW RANGE DIFFERENTIAL LOCK MFWD PARK
FORWARD REVERSE BRAKE
TRANSMISSION CLUTCH CLUTCH
2ND SPEED CONTROL VALVE
CLUTCH
LOW RANGE
3RD SPEED TRANSMISSION SPEED SHIFT VALVE
CLUTCH SHIFT VALVE P
SPEED SHIFT
VALVE L FORWARD/REVERSE
3 SHIFT VALVE
O
SEQUENCE
SPEED SHIFT VALVE
VALVE ORIFICE IN
2 K PARK BRAKE
VALVE HOUSING SOLENOID
LOW N
RANGE R DIFFERENTIAL VALVE
FORWARD MFWD
SPEED SOLENOID SOLENOID SOLENOID SOLENOID
SHIFT VALVE REVERSE VALVE
SOLENOID VALVE VALVE
VALVE C
1 J VALVE B
D ORIFICE IN
MODULATION MODULATION
SPOOL SCREEN
SPEED SPEED SPEED VALVE G PRESSURE IN ALL
SOLENOID SOLENOID SOLENOID REDUCING SOLENOIDS
VALVE VALVE VALVE ORIFICE ORIFICE IN VALVE Q
3 M 2 I 1 H IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
LOW RANGE, FORWARD, & REVERSE SPEED PLATE
GEAR SOLENOID ENERGIZED SOLENOID ENERGIZED CONVERTER
SELECTION FORWARD LOW RANGE REVERSE 1 2 3 RELIEF
NEUTRAL VALVE
COOLER TORQUE E
1ST FORWARD X X X X RELIEF CONVERTER
2ND FORWARD X X X X BYPASS
VALVE SYSTEM PRESSURE
3RD FORWARD X X X X FILTER
AND MEDIUM PRESSURE
HIGH RANGE THERMAL TRANSMISSION BYPASS
X X X RELIEF OIL COOLER LOW PRESSURE
(4TH FORWARD)
BYPASS
1ST REVERSE X X X X VALVE LUBE PRESSURE
TRANSMISSION
2ND REVERSE TO PUMP
X X X X LUBE RETURN PRESSURE
3RD REVERSE X X X X
T117379 TRANSMISSION CONTROL CIRCUIT FIRST REVERSE SUMP
CED,TX03399,4217 1906MAR981/1
PN=608
2ND SPEED
CLUTCH
SPEED SHIFT
VALVE L
3
SPEED SHIFT
VALVE
2 K
LOW
RANGE
SPEED SOLENO
SHIFT VALVE
VALVE C
1 J
Page 9020-05B-28 A
Power Shift
T117379 1901FEB99
HIGH RANGE
FORWARD CLUTCH
LOW RANGE
SHIFT VALVE
P
FORWARD/REVERSE
SHIFT VALVE
O
SEQUENCE
VALVE
ORIFICE IN
VALVE HOUSING
LOW N
RANGE R
FORWARD
SOLENOID SOLENOID
VALVE REVERSE
SOLENOID VALVE
C VALVE B
D ORIFICE IN
MODULATION MODULATION
SPOOL VALVE G PRESSUR
REDUCIN
ORIFICE ORIFICE IN VALVE
IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
TORQUE E
CONVERTER
FILTER
AND
TRANSMISSION BYPASS
OIL COOLER
TRANSMISSION
TO PUMP
LUBE
TM1537 (26FEB0
Page 9020-05B-28 B
Theory of Operation (S.N. 872257 )
PARK BRAKE
SOLENOID
DIFFERENTIAL VALVE
MFWD
SOLENOID SOLENOID
VALVE VALVE
SCREEN
ESSURE IN ALL
DUCING SOLENOIDS
ALVE Q
SYSTEM PRESSURE
MEDIUM PRESSURE
LOW PRESSURE
LUBE PRESSURE
RETURN PRESSURE
CED,TX03399,4217 1906MAR981/1
NOTE: Keys and story on control valve in the circuit low range shift spool allows oil to flow from the
correspond to the control valve on next page. modulation valve to fill the reverse clutch pack and
compress the clutch plates. Shifting of the
The relief valves are the same pressure oil as forward/reverse spool also blocks the flow of oil
shown in the neutral story. Refer to neutral downstream of the orifice (R) in valve housing from
story for pressure reducing, converter relief returning to tank and allows the pressure in the
and pressure regulating valve. modulation valve to build. As pressure builds, the
balance between orifice size and spring load in the
During 1st gear reverse operation the reverse solenoid modulation valve controls the rate of shift and pushes
valve (D), low range solenoid valve (C), speed the modulation piston down.
solenoid valve 2 (I), and speed solenoid valve 3 (M)
are energized. The energized reverse solenoid valve The sequence valve insures that the speed clutch fills
routes medium pressure oil to the forward/reverse shift and engages before the direction clutch by allowing oil
valve (O) moving its spool down. The energized low to flow from the modulation valve to the speed clutch
range solenoid valve routes medium pressure oil to the circuit downstream of the orifice in duct plate
low range shift valve (P) moving its spool down. The (replenishing orifice) when the pressure in the speed
energized speed solenoids 2 and 3 (I and M) route clutch circuit is lower than the pressure in the direction
medium pressure oil to the shift valves 2 and 3 (K and clutch circuit. The downward force from the modulation
L) moving the spools down. Shifting of the speed shift piston pushes on the modulation springs which drive
spools allows oil to flow from the regulating valve the modulation spool down to the fully open position. 9020
through the orifice in duct plate (replenishing orifice) to In the fully open position, high pressure oil form the 05B
29
fill the 1st speed clutch pack and compress the clutch pressure regulating valve keeps the speed and
plates. Shifting of the forward/reverse spool and the direction clutches engaged.
CED,TX03399,4221 1913MAR981/1
PN=609
Theory of Operation (S.N. 872257 )
Power Shift Transmission Control Valve and Shift ValveFirst Reverse (S.N. 872257 )
D REVERSE
SOLENOID
E
CONVERTER
RELIEF
A MAIN VALVE
FRAME
HARNESS
Q
9020 F
PRESSURE
05B REDUCING PRESSURE
30 VALVE REGULATING
VALVE
P
LOW RANGE
SHIFT VALVE R
ORIFICE N
O
G
FORWARD MODULATION
OR REVERSE PISTON MODULATION
SHIFT VALVE VALVE
H
SPEED
SOLENOID
VALVE 1
M I
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2
SHIFT
VALVE 3
K SPEED
V TRANSMISSION CONTROL VALVE SHIFT
T114884
VALVE 2
T114884 AND SHIFT VALVE - FIRST REVERSE
PN=610
Theory of Operation (S.N. 872257 )
AMain Frame Harness HSpeed Solenoid Valve 1 NModulation Piston SSystem Pressure Oil
BForward Solenoid Valve ISpeed Solenoid Valve 2 OForward/Reverse Shift TMedium Pressure Oil
CLow Range Solenoid Valve JSpeed Shift Valve 1 Valve UReturn Pressure Oil
DReverse Solenoid Valve KSpeed Shift Valve 2 PLow Range Shift Valve VTransmission Control
EConverter Relief Valve LSpeed Shift Valve 3 QPressure Reducing Valve Valve and Shift Valve
FPressure Regulating Valve MSpeed Solenoid Valve 3 ROrifice (In Valve Housing) First Reverse
GModulation Valve
CED,TX03399,4229 1922APR982/2
9020
05B
31
PN=611
Theory of Operation (S.N. 872257 )
M ORIFICES
J SEQUENCE
VALVE B C D
E
ORIFICE
M6 M6
K ORIFICE
A
NEUTRAL L MODULATION
SPOOL
9020 B C D
05B START OF FILL MODULATION ENGAGEMENT
32
N SYSTEM PRESSURE
O MEDIUM HIGH PRESSURE
1926JUN98
P MEDIUM PRESSURE
Q LOW PRESSURE
R RETURN PRESSURE
T114787
PN=612
Theory of Operation (S.N. 872257 )
ANeutral FOrifice (In Valve Housing) KOrifice In Duct Plate OMedium High Pressure
BStart of Fill GPiston (Replenishing Orifice) PMedium Pressure
CModulation HOuter Spring LModulation Spool QLow Pressure
DEngagement IInner Spring MOrifice (2 used) RReturn Pressure
EOrifice JSequence Valve NSystem Pressure SModulation Valve
Rate of shift is controlled by movement of the springs (H and I) and modulation spool (L), down.
modulation valve and modulation piston during a shift. There are two small orifices (M) located near the top of
By regulating the amount of oil flow being sent to the piston (G). These orifices allow return oil to dump
engage the direction pack, the time required is to sump during start of fill and half way through
extended to assure a smooth shift. modulation mode. This helps control the rate of shift.
The orifices in the piston close off as the piston moves
When the machine is in neutral (A), system pressure down. An equalization of spring and pressure force on
oil (N), bleeds by the edge of the modulation spool (L). the modulation valve regulates the rate of clutch
This oil (Q) (low pressure) flows through orifice (F), engagement during modulation.
which is open to return. Low pressure oil (Q), also
flows through orifice (E) to the bottom side of the The orifice in duct plate (replenishing orifice) (K),
modulation spool (L). This oil applies sufficient force on supplies oil from the pressure regulating valve to the
the spring to hold the valve on the edge of pressure speed shift valves. The sequence valve (J) supplies oil
port opening. from the modulation valve to the speed shift valves
also, but only when the oil downstream of the orifice in
All direction and speed clutch packs are also open to duct plate (replenishing orifice) (K) is below the
sump when the FNR is in neutral. modulation pressure filling the direction clutch pack. 9020
05B
This insures that the speed clutch fills and engages
33
The start of fill mode (B), begins when a shift occurs. before the direction clutch.
Shifting of the speed shift spools allows oil to flow from
the regulating valve through the orifice (K) to fill the When the final engagement mode (D) is reached, the
speed clutch pack. Shifting of the forward/reverse modulation spool (L) is in the fully open position, and
spool allows oil to flow from the modulation valve and the two small orifices (M) in the modulation piston (G)
will fill the direction clutch pack. Shifting of the are closed off. With the spool in the fully open position,
forward/reverse spool also blocks the flow of oil high pressure oil from the pressure regulating valve
downstream of the orifice (F) from returning to tank maintains the downward force on the modulation
and allows the pressure in the modulation valve to piston and keeps the clutches engaged until the next
build. Both direction and speed clutch packs fill rapidly shift.
at the low pressure level.
Cycling the forward/reverse spool allows the high
Modulation mode (C), begins as pressure in the clutch pressure oil in the engaged clutch and between the
pack begins to rise (P). The pressure is also being orifice (F) and the top of the modulation piston to vent
sensed through orifice (F). Pressure on the back side to tank. The resulting loss in pressure allows the
of orifice (F) is building to low pressure (Q). This modulation valve to reset to begin the next shift
pressure starts moving the modulation piston (G), sequence.
CED,TX03399,4225 1927MAR982/2
PN=613
Theory of Operation (S.N. 872257 )
9020
05B
34
AFinal Drive Ring Gear DBevel Pinion Shaft (2 used) GSide Gear JOutput Shaft 1902FEB99
T117161
The differential allows independent rotation of the reduction. The input pinion shaft to differential ring
axles when the machine is steered. The final drive gear also provides a reduction in speed and an
planetaries are attached to the axles. Their purpose is increase to torque.
to reduce speed and increase torque through gear
PN=614
Theory of Operation (S.N. 872257 )
Input torque from the drive shaft rotates the input bevel Torque is transferred into the output shaft (J) causing it
pinion shaft (F) which meshes with the differential ring to rotate at a reduced speed but with greater torque.
gear (C), causing it to turn. The ring gear is fastened
to the differential housing (B) which drives the bevel As the machine is steered, the inside wheel slows
pinion shafts (D) and bevel pinions (E). The bevel down in relation to the outside wheel. This causes the
pinions located on the bevel pinion shaft are in mesh side gear, attached to the inside wheels axle, to slow
with the side gears (G) which spline to the sun pinion down. The rotating differential housing and bevel
shaft (H). pinion shafts allow the differential bevel pinions to
rotate around the slow moving side gear; this allows
The sun pinion shaft meshes with the planet pinion the opposite side gear to rotate at a faster speed. This
carrier assembly (I) which rotates around the inside of rotation causes the outside wheels axle to rotate
the stationary planetary final drive ring gear (A). faster than the inside axle which prevents tire scuffing.
TX,05,SS3139 1923JUN982/2
9020
05B
35
PN=615
Theory of Operation (S.N. 872257 )
E BEARING
F SNAP RING
SIDE A B DIFFERENTIAL C LEVER D CAGE
GEAR HOUSING G SEAL
H BRAKE
HOUSING
DIFFERENTIAL
SOLENOID
VALVE
I
9020
05B J SEAL
36
K NEEDLE
BEARING
L PISTON
FROM M
TRANSMISSION
PUMP
1902FEB99
P CLUTCH O SPRING N SLIDING
Q SYSTEM PRESSURE SLEEVE
PACK
R RETURN PRESSURE
S DIFFERENTIAL LOCK
T117099
T117099
When the operator has the differential lock foot control piston (L) back releasing the differential lock. The
switch in the "OFF" position (unapplied), the spring return oil returns through the same port as when the
force (O) moves the sliding sleeve (N), lever (C) and switch is in the "ON" position.
PN=616
Theory of Operation (S.N. 872257 )
When the operator pushes the differential lock foot the cross-drilled passages to the piston (L). The
control switch to the "ON" position, the switch pressurized oil moves the piston against the sliding
energizes the differential lock solenoid (I) on the sleeve and lever to lock up the clutch pack (P) with
transmission. When the differential lock solenoid is side gear (A) of the differential, causing both axles to
energized, pressure oil flows to the inlet and through rotate at the same speed.
TX,05,SS3130 1923JUL982/2
9020
05B
37
PN=617
Theory of Operation (S.N. 872257 )
9020
05B
38
A INNER
SPRING
F PISTON
B OUTER
H SPRING
PARK BRAKE
SOLENOID
VALVE
G DISK E
FROM
TRANSMISSION D PLATE
PUMP
C TOWING
CAP SCREW
I SYSTEM PRESSURE
J RETURN PRESSURE
1902FEB99
T117163
PN=618
Theory of Operation (S.N. 872257 )
The park brake is spring applied and hydraulically the transmission. The solenoid routes transmission
released. When the park brake is applied (ON) or system pressure oil (I) to the park brake piston (F).
machine is shut-off, spring force applies the park The piston moves against the springs (A&B) and
brake. The springs (A&B) force the piston (F) against releases the disks and plates (D and E). Two manual
brake disks (D) and plates (E) on the axle input shaft. operated cap screws (C) release the park brake for
emergency towing.
When park brake switch is cycled to the OFF position,
the switch energizes the park brake solenoid (H) on
TX,05,SS3134 1916MAY962/2
9020
05B
39
PN=619
Theory of Operation (S.N. 872257 )
ACTUATION DRIVE
PIN GEAR
SPRING F
D
B PISTON
C PLATES
AND DISKS
FRONT E
OUTPUT
SHAFT
A
G
MFWD
SOLENOID
VALVE
H
FROM
TRANSMISSION
9020 PUMP
05B
40
RETAINER RETAINER
J SPRING
I
G
MFWD
SOLENOID
VALVE
H
FROM
TRANSMISSION
K END PUMP
PLATE
1928OCT98
T117105
P MFWD CLUTCH ASSEMBLY (DISENGAGED)
Continued on next page CED,TX03399,4226 1915APR981/2
PN=620
Theory of Operation (S.N. 872257 )
AFront Output Shaft EPlates and Disks IRetainer Spring MReturn Oil
BSpring FDrive Gear JRetainer NLubricatin Oil
CPiston GSolenoiod Valve KEnd Plate OMFWDOn (Engaged)
DActuation Pin HFrom Transmission Pump LSystem Pressure PMFWDOn (Disengaged)
The MFWD is spring applied, hydraulically released. When energized, with MFWD switch in the OFF
When the MFWD switch is ON, spring (B) force locks position, transmission pressure oil (H) is routed to
the clutch pack disk and plates with drive gear (F). The piston (C). Pressure pushes the piston against the
drive gear is connected to the front output shaft (A) spring (B) and releases actuation pin (D) from end
and transmits power to the front axle drive shaft. plate (K). The drive gear (F) and front output shaft (A)
are now disengaged.
The disengagement of the MFWD is controlled by an
electric solenoid (G) located on the transmission.
CED,TX03399,4226 1915APR982/2
9020
05B
41
PN=621
Theory of Operation (S.N. 872257 )
9020
05B
42
UN24MAY89
T6058AM
ADifferential Driveshaft CDifferential Housing EBevel Drive Gears GPower Flow
BRing Gear DPinions FDrive Shafts HRotation Direction
Differential unit in MFWD axle has self-applied, Power flows into axle housing through differential drive
limited-slip feature. When MFWD is engaged under shaft (A), turning ring gear (B) and attached differential
slippery field conditions, this system automatically housing (C). When both wheels have equal traction,
applies correct amount of torque to match traction pinions (D) remain stationary within rotating housing.
available to each wheel. Pinions turn bevel drive gears (E) and drive shafts (F)
splined to drive gears.
With MFWD engaged, when tractor is moving in a
straight line and each wheel has equal traction, equal
power is supplied to left and right axle. No differential
action occurs.
TX,9020,BG384 1914JAN971/1
PN=622
Theory of Operation (S.N. 872257 )
9020
05B
43
PN=623
Theory of Operation (S.N. 872257 )
9020
05B
44
UN24MAY89
T6058AL
ATire With Most Traction DL.H. Drive Gear GClutch Disks IPower Flow
BDrive Shaft EPinion Gears HClutch Plate JRotation Direction
CR.H. Drive Gear FDifferential Housing
As available traction changes, tire with better traction and compresses a clutch pack with disks (G) splined
(A) can use move power. Self-limiting differential action to axle and plates (H) tanged to housing. Disks begin
begins to occur. to slip less against plates as compressing force
increases. As the pack slippage decreases driveshaft
When one wheel begins to slip more than the other, begins to receive driving force through the differential
wheel with better traction hold its drive shaft (B) and housing.
drive gear (C) from rotating. Wheel with less traction
provides less resistance against its drive gear (D). Since the tire with less traction is exerting less force
trying to keep its axle from turning, the bevel gear
Pinion gears (E) continue to be driven by rotating does not force the drive gear outward and its clutch
differential housing (F). These pinion gears push pack increases its slip. Less drive force is being
against bevel drive gears as before. Angle of gear transmitted to this drive shaft. As long as the
teeth tries to force meshed gears apart. On the side difference in traction between tires remains the same,
with more traction, pinion gears begin to "walk" around the clutch pack on the side with less traction will
drive gear and push against restraining force continue to slip more than pack for other side.
transmitted from tire. Drive gear is wedged outward
PN=624
Theory of Operation (S.N. 872257 )
TX,9020,BG385 1914JAN972/2
9020
05B
45
PN=625
Theory of Operation (S.N. 872257 )
9020
05B
46
PN=626
Group 15A
System Diagnostic Information (S.N. 872256)
John Deere Inboard Planetary AxlesUse
CTM43 (S.N. 872256)
UN07SEP88
Use the CTM in conjunction with this machine manual.
M44215
TX,CTM18 1909NOV921/1
9020
15A
1
PN=627
System Diagnostic Information (S.N. 872256)
Transmission Slippage (Low Low oil level Check and add oil.
Pressure)
Filter bypass valve stuck open Remove filter housing and inspect
valve. (See Repair Manual, Group
0360.)
Transmission Shifts Too Slow Low oil level (aeration of oil) Check and add oil.
PN=628
System Diagnostic Information (S.N. 872256)
Oil passages restricted between Remove control valve and inspect oil
control valve and clutch or brake passages. See Transmission Oil
Passage Identification in this group.
Transmission Shifts Too Fast System pressure too high Do Transmission System Pressure
Test. (See Group 9020-25.)
Clutch or brake piston not returning Do Transmission Drag Check. (See 9020
properly or warped disks and plates Group 9005-10.) 15A
3
Oil Leakage From Torque Transmission overfilled with oil Check oil level. (See Group
Converter Housing 9000-04.)
Erratic Shifts (Wrong Gears or Shift valve stuck Do Control System Pressure Test.
No Gear Change When Gearshift (See Group 9020-25.) Remove and
Lever is Moved) inspect valve.
PN=629
System Diagnostic Information (S.N. 872256)
Machine Will Not Move In Any Neutral disconnect solenoid Do Transmission Neutral Disconnect
Gear (No Load Put On Engine Solenoid Check. (See Group
When Shifted Into Gear) 9005-10.)
Machine Will Not Move (Load Put Transmission Inspect transmission suction screen
On Engine Or Engine Stalls for metal particles.
When Shifted Into Gear)
Machine Creeps In Neutral (Load Transmission overfilled with oil Check oil level.
Put On Engine When Brakes Are
Applied)
Transmission Hydraulic System Transmission overfilled with oil Check oil level.
Overheats (Slow Hydraulic
Functions And Transmission
Slippage May Also Occur)
Air flow through oil cooler or radiator Do Radiator Air Flow Test. (See
restricted Group 9010.) Clean oil cooler and
radiator.
PN=630
System Diagnostic Information (S.N. 872256)
Cooler relief valve stuck open or Remove and inspect cooler relief
spring broken valve. (See Repair Manual, Group
0360.)
Loss of 3rd and 4th Forward C1 element, C1 circuit leakage, or Do Transmission Pump Flow Test.
broken sealing rings on reduction (See Group 9020-25.)
gear shaft
Loss of 1st and 2nd Forward B2 element or B2 circuit leakage Do Transmission Control Circuit
Pressure Test. (See Group
9020-25.)
Loss of 1st and 2nd Reverse B1 element or B1 circuit leakage Do Transmission Control Circuit
Pressure Test. (See Group 9020
9020-25.) 15A
5
Loss of 2nd, 4th Forward and B3 element or B3 circuit leakage Do Transmission Control Circuit
2nd Reverse Pressure Test. (See Group
9020-25.)
Loss of 1st, 3rd Forward and C2 element, C2 circuit leakage, or Do Transmission Control Circuit
Reverse broken sealing rings on reduction Pressure Test. (See Group
gear shaft 9020-25.)
Lube Pressure Low, Control Lube relief valve stuck open or Inspect lube relief valve and spring.
Pressure and Charge Pressure spring broken
Normal
Lube Pressure Low, Control Excessive wear in bushings in Remove transmission filter and
Pressure Normal, And Charge transmission suction screen to inspect for metal
Pressure Low particles in filter and bottom of
transmission case.
Excessive Transmission Noise Engine slow idle too low Check engine slow idle speed. (See
(Under Load or No Load) Group 9010-20.)
PN=631
System Diagnostic Information (S.N. 872256)
Differential Overfilled With Oil Brake piston seals leaking Remove front differential check plug.
Actuate brake and observe leakage
from check plug. Repair. (See
CTM43.)
9020 Excessive Differential or Axle Low oil level in differential Remove drain plug and inspect for
15A Noise metal particles in differential case.
6
Disassemble and determine cause.
Gear mesh pattern between ring and Remove pinion gear housing and
pinion gear incorrect inspect ring and pinion gear. (See
CTM43.)
PN=632
System Diagnostic Information (S.N. 872256)
Oil Seeping From Outer Axle Excessive axle end play Check axle end play. (See CTM43.)
Seal
No Power To Either MFWD Wheel MFWD valve solenoid stuck Remove and inspect solenoid.
Drive shaft universal joints or drive Inspect and repair. (See Repair
output shaft Manual, Group 0240.)
9020
Gear in MFWD transfer case Raise all wheels off ground with 15A
7
engine running. Engage MFWD
drive. If MFWD shaft does not turn.
(See Repair Manual, Group 0350.)
Inspect MFWD transfer gears.
No Power To One MFWD Wheel Wheel constant velocity joint Inspect and repair. (See Repair
Manual, Group 0240.)
PN=633
System Diagnostic Information (S.N. 872256)
No Power To One Wheel (Under Limited-slip in MFWD Raise rear tires off ground. Turn
Load) steering wheel for a full left or right
turn. Set engine at approximately
1200 rpm and engage MFWD. If
only one wheel spins, repair
limited-slip in MFWD. (See Repair
Manual, Group 0240.)
MFWD Whines or Makes Low oil level Check MFWD oil level. Add oil as
Excessive Noises necessary.
10T,9020,J234 1903MAR937/7
Three Valves
DFrom Filter Relief Valve to Lubrication Circuit
EFrom Regulating Valve to Transmission Control Circuit
T6917AN
PN=634
System Diagnostic Information (S.N. 872256)
UN22MAR90
UN22MAR90
T6921AC
T6921AB
Transmission Filter Oil Passages
AFrom Filter to BFrom Filter Relief Valve to CFrom Transmission Pump DOil Filter Housing
Transmission Control Lubrication Circuit to Filter ETransmission Housing
Circuit
10T,9020,J242 1930OCT912/3
9020
15A
9
UN22MAR90
T6917AJ
Oil Pump and Transmission Oil Passages
UN22MAR90
T6917AK
AConvertor-Out To Oil BFrom Pump To Filter DFrom Regulating Valve To EFrom Oil Cooler To
Cooler CFrom Reservoir To Pump Convertor-In Lubrication Circuit
10T,9020,J242 1930OCT913/3
PN=635
System Diagnostic Information (S.N. 872256)
9020
15A
10
PN=636
Group 15B
System Diagnostic Information (S.N. 872257 )
Diagnose Power Shift Power Train
Malfunction (S.N. 872257 )
Symptom Problem Solution
Machine Will Not Move in Low Low oil level in transmission, park Add oil to correct level. See Group
Range Forward, High Range (4th) brake will not release and light on 9000-04.
or Reverse console is ON.
If light in console OFF and park Check console light and /or pressure
brake not releasing switch. See Group 9015-15. Check
park brake disks and separator
plates. See repair in Group 0250.
Piston ball does not seat Do Low Range Forward, High Range
Forward, Reverse and Speed Clutch
Pressure Test or Modulation
Pressure Test. See Group 9020-25
PN=637
System Diagnostic Information (S.N. 872257 )
Worn or slipping low range forward, Check system pressure. See Group
high range forward reverse, or speed 9020-25.
clutch disks
Clutch shaft sealing rings leaking Do Low Range Forward, High Range
Forward, Reverse and Speed Clutch
Pressure Test or Modulation
Pressure Test. See Group 9020-25.
Broken drive shafts or pump drive Inspect drive shafts, universal joints,
shaft and pump drive shaft for external or
internal damage. See repair manual,
Group 0325 or 0360.
PN=638
System Diagnostic Information (S.N. 872257 )
Machine Will Not Move In One Leakage in speed clutch Do Low Range Forward, High Range
Gear Forward, Reverse and Speed Clutch
Pressure Test.
Worn or slipping in one clutch pack Do Low Range Forward, High Range
Forward, Reverse and Speed Clutch
Pressure Test. See Group 9020-25.
Transmission Slippage Low oil level and park indicator light Add oil. See Group 9000-04.
ON
9020
Wrong oil grade Change oil. See Group 9000-04. 15B
3
Piston ball does not seat Do Low Range Forward, High Range
Forward, Reverse and Speed Clutch
Pressure Test. See Group 9020-25.
See repair manual, Group 0350.
Clutch shaft sealing rings leaking. Do Low Range Forward, High Range
Forward, Reverse and Speed Clutch
Pressure Test or Modulation
Pressure Test. See Group 9020-25.
See repair manual, Group 0350.
PN=639
System Diagnostic Information (S.N. 872257 )
Machine Creeps with FNR in Warped disks and plates in Check transmission. See repair
Neutral transmission manual, Group 0350.
Ball pressed in end of clutch shafts Check Low Range Forward, High
(lube passage) came out Range Forward, Reverse and Speed
Clutch Pressure. See Group
9020-25. See repair manual, Group
0350.
PN=640
System Diagnostic Information (S.N. 872257 )
Machine Lacks Power or Moves Oil level is low and park brake Add oil to correct level. See Group
Slow indicator light is ON 9000-04
Park brake dragging, piston stuck Repair park brake in rear axle. See
repair manual, Group 0250.
Engine fast idle speed set too low Check fast idle adjustment. See 9020
Group 9010-20. 15B
5
Piston ball does not seat Do Low Range Forward, High Range
Forward, Reverse and Speed Clutch
Pressure Test. See Group 9020-25.
Clutch pack dragging, disks warped Repair clutch pack. See repair
manual, Group 0350.
PN=641
System Diagnostic Information (S.N. 872257 )
Clutch shaft sealing ring leaking Do Low Range Forward, High Range
Forward, Reverse and Speed Clutch
Pressure Test or Modulation
Pressure Test. See Group 9020-25.
Transmission Shifts Too Slow Low or high oil level (aeration of oil) Add oil or drain. See Group 9000-04
PN=642
System Diagnostic Information (S.N. 872257 )
Restricted oil passage to clutch pack Do Low Range Forward, High Range
Forward, Reverse and Speed Clutch
Pressure Test. See Group 9020-25.
Transmission Shifts Too Fast Modulation piston orifice blocked Do Modulation Valve Pressure Test.
See Group 9020-25. Repair, see
Group 0360.
Transmission Overheats Oil level too high or too low Check oil level and correct. See
Group 9000-04.
PN=643
System Diagnostic Information (S.N. 872257 )
Oil cooler air flow restricted Inspect and clean exterior of cooler.
Do Air Flow Test. See Group
9010-25.
9020 Missing baffles, damaged fan Inspect and check belt. See Group
15B shrouds or loose fan belt 9010-20. Check baffles and repair.
8
See repair manual, Group 0510.
PN=644
System Diagnostic Information (S.N. 872257 )
Excessive Power Train Noise Engine low idle too slow Check engine slow idle speed. See
Group 9010-20.
Hydraulic lines in contact with power Inspect all hydraulic lines and repair.
train components See Hydraulic Component Location
in Group 9025-05.
Excessive Gear Clash When Rate of shift too fast Do Modulation Pressure Test in
Shifting Group 9020-25.
Park Brake Pressure Light Transmission oil level too low Add oil. See Group 9000-04.
Comes On
Park brake solenoid not working Test solenoid. See Group 9015-15.
PN=645
System Diagnostic Information (S.N. 872257 )
CED,TX03399,4235 1904JUN9810/10
Failed MFWD output shaft spline Inspect and repair. See repair
manual, Group 0350.
Failed ring gear or pinion in front Inspect and repair. See repair
axle. manual, Group 0240.
Failed MFWD gear train components Inspect and repair. See repair
in transmission manual, Group 0350.
No Power to One Wheel of MFWD Wheel U-Joint failure Inspect and repair. See repair
manual, Group 0240.
TX,15,MA17 1923JUL981/1
PN=646
System Diagnostic Information (S.N. 872257 )
No Differential Lock Operation Malfunction in electrical circuit to With engine stopped and key switch
solenoid turned to accessory, activate
differential lock and listen for a click
from solenoid valve.
Stuck differential lock solenoid valve With engine stopped and key switch
turned to accessory, activate
differential lock and listen for a click
from solenoid valve. Remove and
inspect valve. See repair manual,
Group 0360.
Differential Lock Slips or Excessive leakage differential lock Do Differential Lock Pressure Test.
Chatters When Engaged piston seals See Group 9020-25.
Differential Lock Will Not Release Stuck foot switch Inspect. See electrical, Group
9015-10.
PN=647
System Diagnostic Information (S.N. 872257 )
Stuck differential lock solenoid valve With engine stopped and key switch
on, activate differential lock and
listen for a click from solenoid valve.
Remove and inspect valve. See
repair manual, Group 0360.
Rear Axle Overfilled With Oil Differential lock piston seals leaking Do Differential Lock Pressure Test.
See Group 9020-25. Inspect, repair.
See repair manual, Group 0250.
Service brake piston seals leaking Do Brake Valve Leakage Test. See
Group 9025-25. Inspect and repair.
See repair manual, Group 0250.
Poor Service Brakes Low oil level Check oil level and fill. See Group
9000-04.
Air in brake valve or lines or piston Bleed brakes. See Group 9025-20.
PN=648
System Diagnostic Information (S.N. 872257 )
Service Brakes Will Not Release Brake pedal not returning to full up Inspect brake pedal linkage.
position or not adjusted properly Repair/Adjust. See Group 1060.
Service Brakes Chatter or Noisy Air in brake system Bleed brakes. See Group 9025-20.
Wrong oil in rear axle Drain and refill with correct oil. See
Group 9000-04.
Park Brake Will Not Hold Worn parts Inspect and replace. See repair
manual, Group 0250.
PN=649
System Diagnostic Information (S.N. 872257 )
Park Brake Will Not Release Park brake hose leaking Inspect and repair all leaks.
Park Brake Solenoid not working Check solenoid. See Group 9015-15.
Park Brake piston seals leaking Do Park Brake Pressure Test. See
Group 9020-25. Inspect and repair.
See Group 0250.
TX,15,MA18 1923JUL984/4
9020
15B
14
PN=650
System Diagnostic Information (S.N. 872257 )
9020
15B
15
1928SEP89
TS700
TX,9020,SS3253 1930AUG961/1
PN=651
System Diagnostic Information (S.N. 872257 )
9020
15B
16
PN=652
Group 20
Adjustments
Check and Adjust Toe-In
UN02NOV88
2. Measure distance between front marks (B) and rear
marks (C).
T6382JW
DRIVE (MFWD):
UN02NOV88
Tighten clamp cap screws to 95 14 Nm (70 10
lb-ft).
9020
MACHINES WITH MECHANICAL FRONT WHEEL 20
T6162AT
1
DRIVE (MFWD):
UN02NOV88
Install nut (F), tighten to 220 Nm (162 lb-ft) and install
cotter pin. Tighten nuts (H).
T5983AF2
ACenter of Hub
BFront of Tire
CRear of Tire
DTie Rod Tube
FNut
GCotter Pin
HNut
10T,9020,J220 1903MAR931/1
PN=653
Adjustments
9020
20
2
PN=654
Group 25A
Tests (S.N. 872256)
JT05801 Clamp-On Electronic Tachometer
Installation (S.N. 872256)
SERVICE EQUIPMENT AND TOOLS
Tachometer
AClamp-on Transducer. Remove paint with emery cloth and
UN28FEB89
connect to a straight section of injection line within 100 mm (4 in.) of
pump. Finger tighten only. DO NOT overtighten.
BBlack Clip (-). Connect to main frame.
CRed Clip (+). Connect to transducer.
T6813AG
DTachometer Readout. Install cable.
10T,9010,K182 1910AUG951/1
9020
JT05800 Digital Thermometer Installation 25A
(S.N. 872256) 1
UN28FEB89
Wrap with shop towel.
BCable
CDigital Thermometer
T6808CE
TX,9020,BG388 1914JAN971/1
PN=655
Tests (S.N. 872256)
UN23SEP92
9020
25A
2
T7840BB
TX,9020,BG389 1914JAN971/1
PN=656
Tests (S.N. 872256)
9020
25A
3
PN=657
Tests (S.N. 872256)
ESSENTIAL TOOLS
JT38070 Diagnostic Destroke Wire Harness
UN23SEP92
9020 Group 9025-25).
25A
4 3. Hold service brakes on.
T7840BB
4. Operate engine at fast idle.
PN=658
Tests (S.N. 872256)
Specification
Minimum Engine Speed With
Pump DestrokedTorque
Converter Stall Speed ..................................................... 18002000 rpm
Specification
OilTemperature ................................................... 65 5C (150 10F)
TX,9020,BG390 1914JAN972/2
PN=659
Tests (S.N. 872256)
ESSENTIAL TOOLS
JT05490 (3/8-24 M ORB x 7/16 M 37) Adapter
JT01608 (7/16-20 F 37 x 1/8) Nipple Quick Coupler Adapter
9020
25A The pressure regulating valve setting and leakage in C-2
6 clutch is checked using this test.
PN=660
Tests (S.N. 872256)
Specification
OilTemperature ..................................................... 40 4C (104 7F)
Specification
EngineSpeed .................................................................. 1500 25 rpm
UN23SEP92
If low pressure is NOT caused by leakage in C2 clutch
9020
circuit, adjust pressure regulating valve. One shim will
25A
change pressure approximately 70 kPa (0.7 bar) (10 psi). 7
T7840BC
Specification
One Shim ChangesPressure .......................... 70 kPa (0.7 bar) (10 psi)
Specification
TransmissionPressure ........................ 1240 35 kPa (12.4 0.35 bar)
(180 5 psi)
TX,9020,YY714 1903MAR932/2
PN=661
Tests (S.N. 872256)
ESSENTIAL TOOLS
JDG419 Pump Adapter
JT03059 (1-1/16-12 M 37 x 1-1/16-12 F 37) 90 Elbow (2 used)
JT03048 (1-1/16-12 M 37 x 1-1/16-12 M ORB) Adapter (2 used)
JT05490 (3/8-24 M ORB x 7/16-20 M 37) Adapter
JT01608 (7/16-20 F 37 x 1/8) Nipple Quick Coupler Adapter
PN=662
Tests (S.N. 872256)
Specification
TestPressure ....................................... 1240 35 kPa (12.4 0.35 bar)
(180 5 psi)
UN27MAR90
9020
Specification
25A
OilTemperature ................................................... 65 5C (150 10F)
9
T6327AA
7. Adjust engine speed to specifications. Put FNR lever in
neutral. Record flow rate.
TX,9020,BG391 1914JAN972/2
PN=663
Tests (S.N. 872256)
ESSENTIAL TOOLS
JT05496 (7/16-20 M 37 x 1-1/16-12 M ORB) AAdapter
9020
25A
10
PN=664
Tests (S.N. 872256)
Specification
Converter-In/Cooler Relief
Pressure ............................................... 793 70 kPa (7.9 0.7 bar) (115
10 psi)
Specification
OilTemperature ..................................................... 40 4C (104 7F)
UN23SEP92
5. Start engine, operate at approximately 1500 rpm (1/2
speed) and record pressure. 9020
25A
Specification 11
EngineSpeed ................................................... Approximately 1500 rpm
T7845AC
6. Compare reading to specification. If required, adjust
relief to specification with shims. Each shim will change
pressure approximately 35 kPa (0.35 bar) (5 psi).
Specification
Each Shim ChangesPressure......................... 35 kPa (0.35 bar) (5 psi)
TX,9020,BG392 1914JAN972/2
PN=665
Tests (S.N. 872256)
ESSENTIAL TOOLS
JT05490 (7/16 M 37 x 3/8-24 M ORB) AAdapter
9020
25A
12
PN=666
Tests (S.N. 872256)
UN23SEP92
2. Start engine and heat oil to specification. (See
procedure in this group.)
Specification
T7847AC
OilTemperature .......................................... Approximately 40C (104F)
Specification
EngineSpeed ............................................................................ Slow idle
Specification
B2 Switch DownTransmission
Pressure .................................................................... 0 kPa (0 bar) (0 psi)
Specification
B2 Switch UpTransmission
Pressure ................................................. 1206 70 kPa (12.1 0.70 bar)
(175 10 psi)
TX,9020,YY716 1903MAR932/2
PN=667
Tests (S.N. 872256)
ESSENTIAL TOOLS
JT05487 (1/8 M NPT x 7/10-20 M 37) BAdapter
9020
25A
14
PN=668
Tests (S.N. 872256)
UN07APR89
3. Heat transmission oil to test specifications. See
procedure in this group.
Specification
T6910AW
OilTemperature ..................................................... 40 4C (104 7F)
Specification
EngineSpeed .................................................................. 1500 15 rpm
Specification 9020
Engaged MFWD Clutch 25A
Pressure .................................................................... 0 kPa (0 bar) (0 psi) 15
Specification
Disengaged MFWD Clutch
Pressure ................................................... 1210 70 kPa (12.1 .70 bar)
(175 10 psi)
TX,9020,BG393 1914JAN972/2
PN=669
Tests (S.N. 872256)
ESSENTIAL TOOLS
JT03111 (9/16-18M 37 x 7/16-20 F 37) DAdapter
JT05496 (7/16-20 M 37 x 1-1/16-12 M ORB) AAdapter
PN=670
Tests (S.N. 872256)
UN23SEP92
1. Install electronic tachometer and digital thermometer.
(See procedure in this group.)
T7849AC
Specification
LubePressure Difference .................... Must vary proportionally in same
direction as Converter-In/Cooler
Pressure
Specification
Converter-In/CoolerMaximum
Pressure Difference ............................................ 70 kPa (0.7 bar) (10 psi)
9020
25A
CAUTION: Rear wheels will turn. If machine is 17
equipped with mechanical front wheel drive,
front wheels will also turn during this test.
Machine must be supported by shop stands so
that wheels are free to turn or machine could
move during test.
Specification
EngineSpeed .................................................................... 1000 3 rpm
Specification
OilTemperature ................................................... 65 7C (150 10F)
PN=671
Tests (S.N. 872256)
TX,9020,BG394 1914JAN973/3
PN=672
Tests (S.N. 872256)
9020
25A
19
PN=673
Tests (S.N. 872256)
Step 1
Step 2
9020
Any change is caused by B2 brake circuit, piston rings or
25A
20 O-rings. It is normal for cooler pressure to drop 730 kPa
(0.070.30 bar) (14 psi) when the second circuit is
pressurized.
Step 3
Step 4
PN=674
Tests (S.N. 872256)
Step 5
Step 6
TX,9020,DY658 1915AUG962/2
9020
25A
21
PN=675
Tests (S.N. 872256)
ESSENTIAL TOOLS
203654 (7/16-20 M37 x 1/2 M NPT) GConnector
JT03348 (1/2 F NPT) HTee (2 used)
JT03212 (1/2 I.D. Hose x 1/2 M NPT) IAdapter (6 used)
JT03070 (1/2 F NPT 1-1/6-12 F 37 SW) JCoupler (2 used)
PN=676
Tests (S.N. 872256)
Specification
OilFlow .................................................................... 30.4 L/min. (8 gpm)
Specification
Gauge DifferenceMaximum
Pressure Drop .................................................... 70 kPa (0.7 bar) (10 psi)
UN29SEP92
AHydraulic Analyzer
BGauge1000 kPa
CGauge Port
DCooler-In
T7851AD
ECooler-Out
FSwitch Box
GConnector
HTee
IAdapter
JCoupler
KFlowmeter
TX,9020,YY721 1903MAR932/2
PN=677
Tests (S.N. 872256)
ESSENTIAL TOOLS
JT03111 (9/16-18 M ORB x 7/16-20 M 37) Adapter
JT01608 (7/16-20 F 37 x 1/8) Nipple Quick Coupler Adapter
9020
25A
24
PN=678
Tests (S.N. 872256)
UN23SEP92
Specification
OilTemperature ..................................................... 40 4C (104 7F)
T7852AB
4. Slowly increase engine speed from slow idle until lube
pressure stops increasing (relief valve opens). Record
pressure.
Specification
EngineSpeed ..................................... Variable (Slow idle to relief valve
opening)
Specification
Lube ReliefPressure ........................... 276 70 kPa (2.8 0.7 bar) (40
10 psi)
TX,9020,BG395 1914JAN972/2
PN=679
Tests (S.N. 872256)
Control Circuit Test Using Seven Gauge Method (Modified) (S.N. 872256)
ESSENTIAL TOOLS
JT03111 (7/16 M 37 x 9/16 M ORB) Adapter
AT53713 (3/4-16 M ORB x 9/16-18 M JIC x 1/8 -27 NPTF)a 90
Elbow
R39832 (1/8-27 F NPFT x 1/8-27 M 37)a Adapter
JT05401 Power Shift Transmission Test Kit
a
These fittings can be ordered through normal service parts
channels.
9020
25A
26
PN=680
Tests (S.N. 872256)
UN29SEP92
9020
25A
27
T7852AC
AJT05490 Adapter (C2) CJT05490 Adapter (B1) EJT05490 Adapter (B2) GJT03111 Adapter (Lube)
BJT05490 Adapter (B3) DJT05490 Adapter (C1) FJT05490 Adapter (Pressure) HGauge Kit
PN=681
Tests (S.N. 872256)
4. Heat oil to 65 5C (150 10F). (See procedure Shift machine into each gear and adjust engine
in this group.) Operate machine in 4th forward to speed to test specification. Record pressure reading
warm-up transmission components. of each gauge.
Specification Specification
OilTemperature ............................................ 65 5C (150 10F) EngineSpeed .............................................................. 1500 5 rpm
5. Run engine at slow idle. Engage MFWD if If pressure difference is excessive, leakage is indicated
equipped. in that element or circuit.
TX,9020,BG396 1914JAN973/3
9020
25A
Complete Transmission System Test (S.N. 872256)
28
SPECIFICATIONS ESSENTIAL TOOLS
Converter-in/Cooler Minimum 30.2 L/min (8 gpm) JT03111 (7/16 M 37 x 9/16 M ORB) Adapter
Flow at Fast Idle JT05490 (7/16 M 37 x 3/8-24 ORB) Adapter 6 used)
Converter-in/Cooler Maximum 3.0 L/min (0.8 gpm)
JT03212 (1/2 I.D. Hose x 1/2 M NPT) Adapter (2 used)
Flow Difference Between Gears
JT03070 (1/2 F NPT x 1-1/16-12 F 37) Adapter (2 used)
New Pump (with Cooler Relief 38 L/min (10 gpm)
Blocked) Flow
SERVICE EQUIPMENT AND TOOLS
Used Pump (with Cooler Relief 34 L/min (9 gpm)
Blocked) Flow JT05081 Electronic Tachometer
Converter-in/Cooler Relief 793 70 kPa (7.9 0.7 bar) JT05800 Digital Thermometer
Pressure (115 10 psi) JT05401 Powershift Transmission Test Kit
Lube Pressure 276 70 kPa (2.8 0.7 bar) Gauge 02000 kPa (020 bar) (03000 psi) (7 used)a
(40 10 psi)
Flowmeter
Transmission System Pressure 1210 70 kPa (12.1 0.7
bar) (175 10 psi) 1/2 in. I.D. Hose 4 ft. Long
Difference Between System and 70 kPa (0.7 bar) (10 psi) 9.5 mm (0.38 in.) x 92 mm (3.62 in.) Pin
Circuit Maximum Pressure 10 Ton Shop Stands ( 2 required4 with MFWD)
a
Neutral Disconnect Switch Down 0 kPa (0 bar) (0 psi) These items are part of JT05401 Powershift Transmission Test
Pressure Kit.
Neutral Disconnect Switch Up 1210 70 kPa (12.1 0.7
Pressure bar) (175 10 psi)
PN=682
Tests (S.N. 872256)
UN29SEP92
9020
25A
29
T7852AD
AJT05490 Adapter (C2) DJT05490 Adapter (C1) GJT03111 Adapter (Lube) JJT03070 Adapter
BJT05490 Adapter (B3) EJT05490 Adapter (B2) HJT05401 Gauge Kit KFlowmeter
CJT05490 Adapter (B1) FJT05490 Adapter (P) IJT03212 Adapter
This test checks the overall performance of during test. After test, use this data with Specifications
transmission hydraulic system. Use a copy of and Analysis to make diagnosis.
Transmission Test Checkout Sheet to record data
PN=683
Tests (S.N. 872256)
Specification
Converter-in/CoolerMinimum
UN31JAN90
Flow at Fast Idle .......................................................... 30.2 L/min (8 gpm)
Maximum Flow Difference
Between Gears ........................................................... 3.0 L/min (0.8 gpm)
New Pump (with Cooler Relief
T94644
Blocked)Flow............................................................. 38 L/min (10 gpm)
Used Pump (with Cooler Relief
Blocked)Flow............................................................... 34 L/min (9 gpm)
Converter-in/Cooler Relief
Pressure ............................................... 793 70 kPa (7.9 0.7 bar) (115
10 psi)
LubePressure ...................................... 276 70 kPa (2.8 0.7 bar) (40
10 psi)
Transmission SystemPressure ............. 1210 70 kPa (12.1 0.7 bar)
(175 10 psi)
Difference Between System and
CircuitMaximum Pressure ............................... 70 kPa (0.7 bar) (10 psi)
Neutral Disconnect Switch
9020 DownPressure........................................................ 0 kPa (0 bar) (0 psi)
25A Neutral Disconnect Switch Up
30 Pressure ................................................... 1210 70 kPa (12.1 0.7 bar)
(175 10 psi)
PN=684
Tests (S.N. 872256)
TX,9020,BG397 1914JAN974/4
9020
25A
31
PN=685
Tests (S.N. 872256)
NOTE: To get accurate test data, keep temperature flow and pressure, lube pressure, and C2 circuit
and rpm at specifications. pressure.
Step 1 Step 7
System Pressure Check: Run engine at 1500 15 MFWD circuit leakage check (If equipped): Disengage
rpm. Record reading on gauge from point F. MFWD switch (light off). Run engine at 1500 3 rpm.
Record cooler flow and pressures.
Step 2
Step 8
Neutral Disconnect Solenoid Check: Put transmission
in 1st forward. Run engine at 1500 15 rpm. Observe Direction Spool Leakage Check: Put FNR lever in
B2 pressure gauge. Depress neutral disconnect switch forward. Engage MFWD (light on) if equipped. Run
and record reading. engine at 1500 3 rpm. Record cooler flow.
Step 3 Step 9
Lube Relief Pressure Check: Run engine at slow idle. B1 Leakage Check: Put transmission in 1st reverse.
Slowly increase engine speed until lube pressure stops Run engine at 1500 3 rpm. Record cooler flow.
9020 increasing. Record reading for lube pressure.
25A Step 10
32
Step 4
B2 Brake Leakage Check: Put transmission in 1st
Cooler (converter-in) relief valve check: Close forward. Run engine at 1500 3 rpm. Record cooler
flowmeter. Put transmission in 1st neutral. Run engine flow.
at 1500 5 rpm. Record reading from pressure gauge
in flowmeter. Open flowmeter. Step 11
Block oil cooler relief valve: Stop engine. Open C1 Leakage Check: Put transmission in 3rd forward.
flowmeter. Install pin behind cooler relief valve to hold Run engine at 1500 3 rpm. Record cooler flow.
valve closed. Leave pin installed for remainder of test.
Step 13
NOTE: Flowmeter must be open for remainder of test.
Stop engine, remove pin from cooler relief valve and
Step 6 install spring. For oil cooler and accumulator check,
heat oil to 65 6C (150 10F).
Transmission pump check, C2 leakage check and
establish base cooler flow for steps 7 through 12: Put 1. Put FNR lever in 1st neutral. Increase engine speed
FNR lever in 1st neutral. Engage MFWD (light on) if to fast idle. Record cooler flow.
equipped. Run engine at 1500 3 rpm. Record cooler
PN=686
Tests (S.N. 872256)
2. B1,B2,C1 accumulator check: Run engine at 1500 3. C2,B3 accumulator check: Observe gauge in B3
15 rpm. Observe gauge in B2 test port. Put FNR in test port. Put FNR in 1st forward then wait 5
1st reverse then wait 5 seconds. Shift FNR lever to seconds. Shift into 2nd forward. Compare
1st forward. Compare observations to gauge observations to gauge illustration at B3 test port.
illustration at B2 test port.
TX,9020,BG398 1914JAN972/2
9020
25A
33
PN=687
Tests (S.N. 872256)
Cooler Lube
Step Gear Engine RPM Cooler Flow Pressure Pressure Test Port Temperature
1 N-1-U 1500 15 P Start
2 F-1-U 1500 15 B2
F-1-D 1500 15 B2
3 N-1-U Variable
4 N-1-U 1500 15 With flow meter closed.
5 Stop engine, install pin in cooler relief and open flow meter.
6 MFWD (if equipped)
N-1-U 1500 3 C2
7 N-1-U 1500 3 C2
CLUTCH/BRAKE ENGAGEMENT
1st Forward B2 C2
2nd Forward B2 B3
3rd Forward C1 C2
4th Forward C1 B3
1st Neutral C2
2nd Neutral B3
3rd Neutral C2
4th Neutral B3
1st Reverse B1 C2
2nd4th Reverse B1 B3
TX,9020,BG399 1914JAN971/1
PN=688
Tests (S.N. 872256)
9020
25A
35
PN=689
Tests (S.N. 872256)
PN=690
Tests (S.N. 872256)
NOTE: If leakage is excessive, check shift valve The actual time required to charge the accumulator
gaskets before removing clutch or brake is difficult to measure. The charging time is
packs. important to the service life of the transmission and
can be a help in diagnosing transmission problems.
Step 10 Proper accumulator operation can be determined by
operating the tractor as follows and observing the
Subtract cooler flow measured in step 10 from cooler gauge as the specified shifts are made.
flow measured in step 6 to determine B2 circuit
leakage. Maximum allowable leakage is 3.0 L/min (0.8 As the shift is made from 1st reverse to 1st forward for
gpm). front accumulator on B2 gauge or 1st forward to 2nd
forward for rear accumulator on B3 gauge and count
Step 11 one thousand and one, one thousand and two. The
gauge must be up to system pressure by the count
Compare cooler flow measured in step 11 to cooler one thousand and one. Compare your pressure gauge
flow measured in step 6 to determine B3 circuit readings to the following gauge illustrations as the
leakage. They should be approximately equal. It is specified shift is made.
normal for flow to increase slightly, if it increases more
than 2.0 L/min (0.6 gpm), C2 leakage is excessive. If The first gauge indicator movement on the illustrations
cooler flow decreases more than 2.0 L/min (0.6 gpm), indicated the point at which the accumulator piston has
B3 leakage is excessive. moved to discharge condition.
TX,9020,BG400 1914JAN972/2
PN=691
Tests (S.N. 872256)
(S.N. 872256)
TX,9020,BG401 1914JAN971/4
UN28OCT91
T7639AA
TX,9020,BG401 1914JAN972/4
9020
25A Shift transmission from first forward to second forward
38 with accumulator charging for 0.30.5 seconds. Pressure
must be 275 70 kPa (2.7 0.7 bar) (40 10 psi).
UN28OCT91
T7639AB
TX,9020,BG401 1914JAN973/4
UN28OCT91
T7639AC
TX,9020,BG401 1914JAN974/4
PN=692
Tests (S.N. 872256)
UN28OCT91
T7639AA
10T,9020,M145 1903MAR931/3
UN28OCT91
9020
25A
39
T7639AB
10T,9020,M145 1903MAR932/3
UN28OCT91
T7639AC
10T,9020,M145 1903MAR933/3
PN=693
Tests (S.N. 872256)
TX,9020,BG402 1914JAN971/1
1/1
C1 Clutch, B1, B2 Brake Raise wheels off ground with stabilizers and loader OK: Go to next test.
Drag Test bucket.
NOT OK: If wheels
Release park brake. continue to move but at a
slower speed, B2 is
Shift transmission to 2nd forward. dragging.
1/1
C2 Clutch, B3 Brake Raise wheels off ground with stabilizers and loader OK: Check completed.
Drag Test bucket.
NOT OK: Engine speed
Release park brake. drops, C2 is dragging.
Repair transmission. Go
Shift transmission to 1st forward. to Repair Manual, Group
0350.
Adjust engine speed to 1000 rpm.
T6295AD UN19OCT88
NOT OK: Engine speed
Shift transmission to 2nd forward. increases, B3 is dragging.
Repair transmission. Go
LOOK: Wheels must increase in speed but engine rpm to Repair Manual, Group
must return to 1000 rpm. 0350.
1/1
PN=694
Group 25B
Tests (S.N. 872257 )
JT05801 Clamp-On Electronic Tachometer
Installation (S.N. 872257 )
SERVICE EQUIPMENT AND TOOLS
Tachometer
AClamp-On Transducer. Remove paint using emery cloth and
UN28FEB89
connect to a straight section of injection line within 100 mm (4 in.) of
pump. Finger tighten only. DO NOT overtighten.
BBlack Clip (-). Connect to main frame.
CRed Clip (+). Connect to transducer.
T6813AG
DTachometer Readout. Install cable.
TX,25,SS3151 1917JUN961/1
9020
JT05800 Digital Thermometer Installation 25B
(S.N. 872257 ) 1
UN28FEB89
CDigital Thermometer
T6808CE
depending on installation.
TX,25,SS3152 1923JUN981/1
PN=695
Tests (S.N. 872257 )
UN23SEP92
9020 2. Put transmission in third gear (A). Park brake OFF.
25B
2
IMPORTANT: Do not stall converter for longer than 20
T7840BB
seconds or serious converter damage
could result.
Specification
EngineSpeed ................................... Low Idle (900 25 rpm) and High
Idle (2375 25 rpm)
CED,TX03399,4231 1915MAY981/1
PN=696
Tests (S.N. 872257 )
Power Shift Transmission Overall Test Connections, Ports, and Locations (S.N. 872257
)
9020
25B
3
1918MAY98
T113993
ADifferential Lock Solenoid HFilter PSystem Pressure Test Port UReverse Clutch Pressure
BPark Brake Pressure Port ITransmission Pump QThird Speed Clutch Test Port
CDifferential Lock Pressure JMFWD Solenoid Pressure Test Port VReducing Valve Pressure
Port KMFWD Test Port RSecond Speed Clutch Test Port
DTransmission Control LPark Brake Solenoid Pressure Test Port WOutput Flange to Rear
Valve MLow Range Forward Clutch SFirst Speed Clutch Axle
ETransmission Speed Shift Pressure Test Port Pressure Test Port XRear of Transmission
Valve NConverter-In Relief Valve THigh Range Forward Clutch YControl Valve
FOil Drain Pressure Port Pressure Test Port ZSpeed Shift Valve
GModel Identification Plate OModulation Valve Pressure
Test Port
CED,TX03399,4230 1908MAY981/1
PN=697
Tests (S.N. 872257 )
2. Install digital thermometer probe into the Low engine output. See Group 9010-25.
transmission sump through the dipstick tube. Incorrect torque converter. Check part number
through inspection hole in bottom of transmission
9020
25B 3. Install hydraulic pump destroke tool. See procedure housing, number should be 4168-028-219).
4 in Group 9025-25. Failed freewheel clutch in torque converter.
4. Heat oil to specifications. 9. If converter stall speed is too high, check for:
TX,25,SS3154 1922JUL981/1
PN=698
Tests (S.N. 872257 )
9020
25B
5
PN=699
Tests (S.N. 872257 )
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler
UN12JUL96
9020
25B 3. Install digital thermometer probe into sump using
6 dipstick tube. Warm transmission oil, see procedure in
this group.
T101750
Specification
OilTemperature at Sump .................................... 65 5C (150 10F)
Specification
EngineSpeed ......................................................................... 2375 25
Converter-In Relief Valve (SN
895999)Pressure............................... 800 + 200 kPa (8 + 2 bar) (116 +
29 psi)
Converter-In Relief Valve (SN
896000)Pressure ............................... 9001150 kPa (9 11.5 bar)
(130167 psi)
PN=700
Tests (S.N. 872257 )
TX,25,SS3155 1917APR012/2
9020
25B
7
PN=701
Tests (S.N. 872257 )
ESSENTIAL TOOLS
D38H1032 (10 M x 10 F x 10 M ORFS) (Parker No.
10R6IO-S) Tee
BJT03458 (7/16 20 M JIC x 1-14 F ORFS 10) Adapter
APD34BTX Quick Coupler
UN06AUG96
Gauge 03500 kPa (035 bar) (0500 psi)
9020
25B
8 1. Remove floor panel in cab or ROPS.
T101901
2. Install tachometer and thermometer. (See procedure in
this group.)
AQuick Coupler
3. Make test connections. BAdapter
CPark Brake-to-Transmission Line
4. Heat oil to specifications. DTee
Specification
OilTemperature ................................................... 65 5C (150 10F)
Specification
EngineSpeed .................................................................. 1500 25 rpm
Park BrakeRelease Pressure .......... 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
Specification
Park Brake AppliedPressure ................................................................ 0
PN=702
Tests (S.N. 872257 )
TX,25,SS3157 1922JUL982/2
9020
25B
9
PN=703
Tests (S.N. 872257 )
SPECIFICATIONS
Oil Temperature 65 5C (150 10F)
Engine Speed 1500 25 rpm
System Pressure 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Each 1.00 mm (0.039 in.) Shim 115 kPa (1.15 bar) (16.68 psi)
Changes Pressure
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler
UN12JUL96
9020
25B 2. Remove floor panel in cab or ROPS.
10
T101892
3. Make test connections in port (A).
Specification
OilTemperature ................................................... 65 5C (150 10F)
Specification
EngineSpeed .................................................................. 1500 25 rpm
SystemPressure ............................... 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
PN=704
Tests (S.N. 872257 )
Specification
Each 1.00 mm (0.039 in.) Shim
ChangesPressure .................................. 115 kPa (1.15 bar) (16.68 psi)
Specification
Each 1.00 mm (0.039 in.) Shim
ChangesPressure .................................. 115 kPa (1.15 bar) (16.68 psi)
CED,TX03399,4265 1922JUL982/2
9020
25B
11
PN=705
Tests (S.N. 872257 )
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler
UN21MAY98
9020
1. Install tachometer and thermometer. (See procedure in
25B
12 this group.)
T115471
2. Remove floor panel in cab or ROPS.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Forward or ReversePressure........... 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
PN=706
Tests (S.N. 872257 )
Specification
Neutral Disconnect
De-ActivatedPressure ........................................................................... 0
9020
25B
13
CED,TX03399,4233 1915MAY982/2
PN=707
Tests (S.N. 872257 )
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler
UN22AUG96
9020 2. Remove floor panel in cab or ROPS.
25B
14
3. Make test connections in port (A).
T101897
4. Heat oil to specifications.
Specification
OilTemperature ................................................... 65 5C (150 10F)
Specification
EngineSpeed .................................................................. 1500 25 rpm
Reducing ValvePressure ...................... 8501050 kPa (8.510.5 bar)
(123152 psi)
CED,TX03399,4266 1922JUL981/1
PN=708
Tests (S.N. 872257 )
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler
UN12JUL96
9020
SERVICE EQUIPMENT AND TOOLS 25B
15
Electronic Tachometer
T101898
Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)
Specification
OilTemperature ................................................... 65 5C (150 10F)
Specification
EngineSpeed .................................................................. 1500 25 rpm
NeutralPressure ......................................... 270300 kPa (2.73 bar)
(3944 psi)
PN=709
Tests (S.N. 872257 )
Specification
EngineSpeed .................................................................. 1500 25 rpm
System Modulated (Final)
Pressure .............................................. 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Modulation PhasePressure ......................... 3001200 kPa (312 bar)
(44174 psi)
Specification
Modulation Valve Pressure
TestShift Time ........................................ Neutral into gear 01600 kPa
(016 bar) (0232 psi) in 2
seconds and from
9020 Forward/Reverse or
25B Reverse/Forward into a gear 1.7
16 seconds Maximum
Specification
Each 1.00 mm (0.039 in.) Shim
ChangesPressure ...................................... 42 kPa (0.42 bar) (6.09 psi)
TX,25,SS3170 1922JUL982/2
PN=710
Tests (S.N. 872257 )
9020
25B
17
PN=711
Tests (S.N. 872257 )
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
UN16JUL96
1. Install tachometer and thermometer. (See procedure in
9020
25B this group.)
18
2. Remove floor panel in cab or ROPS.
T101983
3. Make test connections.
ATee
4. Heat oil to specifications. BQuick Coupler
CAdapter
Specification DTransmission-to-Differential Lock Rear Axle
OilTemperature ................................................... 65 5C (150 10F) Hose
Specification
EngineSpeed .................................................................. 1500 25 rpm
Differential LockPressure ................. 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
PN=712
Tests (S.N. 872257 )
TX,25,SS3165 1922JUL982/2
9020
25B
19
PN=713
Tests (S.N. 872257 )
SPECIFICATIONS
Oil Temperature 65 5C (150 10F)
Engine Speed 1500 rpm
MFWD Pressure 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
ESSENTIAL TOOLS
(M10 x 1.0 ORB) (Parker No. PD357) Quick Coupler
UN12JUL96
9020
25B 3. Make test connections in port (A).
20
T101916
4. Heat oil to specifications.
Specification
OilTemperature ................................................... 65 5C (150 10F)
Specification
EngineSpeed ........................................................................... 1500 rpm
MFWDPressure................................ 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
TX,25,SS3166 1922JUL981/1
PN=714
Tests (S.N. 872257 )
9020
25B
21
PN=715
Tests (S.N. 872257 )
9020
25B
22
UN30OCT98
T118098
A3/4 in Barb Tee B3/4 in Test Hose CGauge DFlowmeter
PN=716
Tests (S.N. 872257 )
5. With FNR lever in neutral. Operate machine to 7. If cooler pressures are low, see Solenoid Circuit
specifications and record pressure and flow. Leakage Test in this group.
9020
25B
23
CED,TX03399,4267 1922JUL982/2
PN=717
Tests (S.N. 872257 )
9020
25B
24
UN23OCT98
T117559
ATest Hose
PN=718
Tests (S.N. 872257 )
TX,9020,ME475 1926JUN982/2
9020
25B
25
PN=719
Tests (S.N. 872257 )
Transmission Oil Cooler Thermal Bypass Valve Pressure Test (S.N. 872257 )
9020
25B
26
UN23OCT98
T117560
A3/4 in. Barb Tee B3/4 in. Test Hose C3/4 in. Barb Plug
PN=720
Tests (S.N. 872257 )
9020
9. Record differential pressure and compare to
25B
specification. 27
TX,9020,ME476 1917JUL982/2
PN=721
Tests (S.N. 872257 )
Specification
OilTemperature at Sump ............................................... 80 C (176 F )
Specification
EngineSpeed ............................................................... 900 + 25 - 0 rpm
CED,TX03399,4268 1922JUL981/1
PN=722
Tests (S.N. 872257 )
9020
25B
29
PN=723
Tests (S.N. 872257 )
ESSENTIAL TOOLS
AJDG596 Filter Adapter
JDG596A1 Spacer and Sealing Washer Kit
UN03FEB99
9020 spacer to make filter adapter fit. This
25B will keep filter from leaking. On later
30 machines just use the filter adapter.
T119993
1. Make test connections. When installing filter adapter
use a washer on both sides of spacer on early
machines.
Specification
OilTemperature ................................................... 65 5C (150 10F)
Specification
EngineSpeed .................................................................. 1500 25 rpm
PN=724
Tests (S.N. 872257 )
Measure flow.
Specification
PumpFlow .............................................................. 42 L/min (11.2 gpm)
TX,25,SS3207 1922JUL982/2
9020
25B
31
PN=725
Tests (S.N. 872257 )
9020
25B
32
PN=726
Section 9025
Hydraulic System
Contents
Page Page
PN=1
Contents
Page Page
Service Brake Inspection (S.N. 872328) . .9025-20-5 Service Brake Valve Work Port Pressure
Service Brake Inspection (S.N. 872329 Test (S.N. 872329 ) . . . . . . . . . . . . . . .9025-25-62
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-6 Brake Accumulator Precharge Pressure Test
Service Brake Valve And Pedal (S.N. 872328) . . . . . . . . . . . . . . . . . . .9025-25-64
Adjustment (S.N. 872329 ) . . . . . . . . . . .9025-20-8 Brake Accumulator Precharge Pressure
Backhoe Valve Linkage Adjustment . . . . . .9025-20-10 Test (S.N. 872329 ) . . . . . . . . . . . . . . .9025-25-66
Loader Control Valve Linkage
Adjustment. . . . . . . . . . . . . . . . . . . . . . . .9025-20-10
Stabilizer Valve Linkage Adjustment . . . . . .9025-20-12
Group 25Tests
John Deere Radial Piston PumpUse
CTM7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
JT05800 Digital Thermometer Installation . . .9025-25-1
Hydraulic Oil Warm-Up Procedure. . . . . . . . .9025-25-2
Manual Destroke Installation Procedure . . . .9025-25-3
Diagnostic Destroke Wire Harness Installation
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-4
Charge Pressure Test . . . . . . . . . . . . . . . . . .9025-25-5
Charge Pump Flow (S.N. 872256) . . . . . . .9025-25-6
Charge Pump Flow (S.N. 872329 ) . . . . . .9025-25-8
Surge Relief Valve Pressure Test . . . . . . . . .9025-25-9
9025 Main Pump Standby Pressure Test . . . . . . .9025-25-10
Main Pump Flow Test . . . . . . . . . . . . . . . . .9025-25-12
Priority Valve Test . . . . . . . . . . . . . . . . . . . .9025-25-14
Priority Valve "LS" Port Flow Test . . . . . . . .9025-25-16
Hydraulic Oil Cooler Restriction Test. . . . . .9025-25-18
Steering Valve Neutral Drift Test . . . . . . . . .9025-25-20
Cylinder Drift Test . . . . . . . . . . . . . . . . . . . .9025-25-21
Steering System Leakage Test . . . . . . . . . .9025-25-22
Steering Cylinder Leakage Test . . . . . . . . .9025-25-26
Cylinder Leakage Test . . . . . . . . . . . . . . . .9025-25-28
Hydraulic Component Leakage Test . . . . . .9025-25-29
Circuit Relief Valve Test with Flow
RegulatorTest Cylinder Method
Gresen. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-36
Circuit Relief Valve TestRemote Pump
Method . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-43
Cycle Time Test . . . . . . . . . . . . . . . . . . . . .9025-25-48
Cycle Time Test Continued . . . . . . . . . . . . .9025-25-49
Flowmeter Calibration Procedure . . . . . . . .9025-25-50
Differential Lock Pressure Reducing Valve
Test (S.N. 872256). . . . . . . . . . . . . . . .9025-25-52
Park Brake Circuit Pressure Test (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-54
Park Brake Thermal Relief Valve Test (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-56
Service Brake Valve Pressure Test (S.N.
872328) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-58
Service Brake Valve Pressure Test (S.N.
872329 ). . . . . . . . . . . . . . . . . . . . . . . .9025-25-60
9025
05
1
PN=729
Theory of Operation
UN19FEB97
T105415
9025
(Serial No. 830204)
05
2
UN19FEB97
T106263
ABackhoe Control Valve EHydraulic Reservoir IMain Hydraulic Pump MPark Brake/Differential
BStabilizer Control Valve FBrake Accumulator JSurge Relief Valve Lock Valve
CBrake Valve GCharge Pump KLoader Control Valve NHydraulic Filter
DSteering Valve HHydraulic Oil Cooler LPriority Valve ORear Differential
This is a closed-center hydraulic system. Oil flows from brake/differential lock valve is routed to the priority
the hydraulic reservoir to the charge pump (G). Charge valve (L) and brake valve (C). Oil flows past the
oil flows to inlet of hydraulic filter (N). Return oil from priority valve spool to the non-priority circuit (loader
all hydraulic functions except steering, brakes and function). When pressure drops below setting of valve,
differential lock also flows to filter inlet to form charge flow to the loader circuit is restricted to supply priority
circuit flow. A surge relief check valve (J) is used to oil to the steering circuit.
maintain charge pressure and protect oil cooler from
excess pressure by releasing excess oil to the Charge circuit flow not required by the main hydraulic
hydraulic reservoir (E). pump flows to the hydraulic oil cooler (H). Oil cooler,
main hydraulic pump seal drain, steering valve, brake
Oil flows from the filter to main hydraulic pump (I) inlet. valve, and differential lock and park brake valve return
Oil flows from the main pump to the park oil flow directly to hydraulic reservoir.
brake/differential lock valve (M). Oil from the park
TX,9025,BG216 1902JAN972/2
9025
05
3
PN=731
Theory of Operation
UN23OCT98
T117454
9025
05
ABackhoe Control Valve HHydraulic Reservoir OSteering Cylinder TPriority Valve
4
BStabilizer Control Valve ISurge Relief Valve PAttenuator Hose UCharge Pump
CBrake System Filter JTransmission Oil Cooler QThermal Relief Bypass VHydraulic Filter
DRight Stabilizer Cylinder KHydraulic Oil Cooler Valve WRight Swing Cylinder
ESteering Valve LLeft Loader Boom Cylinder RRight Loader Boom XLeft Swing Cylinder
FBrake Valve MLoader Bucket Cylinder Cylinder YLeft Stabilizer Cylinder
GBrake Accumulator (2 NMain Hydraulic Pump SLoader Control Valve
used)
The hydraulic system is a closed-center system. Oil (T). Oil flows to the priority valve spool to the
flows from the hydraulic reservoir to the charge pump non-priority circuit (loader function). When pressure
(U). Charge oil flows to inlet of hydraulic filter (V). drops below setting of valve, flow to the loader circuit
Return oil from all hydraulic functions except steering, is restricted to supply priority oil to the steering circuit.
brakes, transmission and differential lock flows to filter
inlet to form charge circuit flow. A surge relief check Charge circuit flow not required by the main hydraulic
valve (I) is located in the reservoir return line from the pump flows to the hydraulic oil cooler (H). Oil cooler,
filter base in the bottom of the reservoir. It is used to main hydraulic pump seal drain, steering valve, brake
maintain charge pressure and protect oil cooler from valve, and differential lock and park brake valve return
excess pressure by releasing excess oil to the oil flow directly to hydraulic reservoir.
hydraulic reservoir (H).
CED,TX03610,135 1919MAR991/1
HYDRAULIC OIL
COOLER
CROWD
T LS P
HYDRAULIC
FILTER
BOOM LOADER
VALVE
CED,TX03768,8484 1924APR981/1
PN=733
HYDRAULIC OIL
COOLER
CROWD
T LS P
HYDRAULIC
FILTER
BUCKET
PRIORITY
VALVE
PARK BRAKE/ ACCUMULATOR
DIFF. LOCK VALVE
MAIN HYDRAULIC
PRIORITY PUMP
VALVE
LOADER CHARGE
BOOM PUMP
VALVE
CED,TX03768,8485 1924APR981/1
PN=734
BACKHOE
BACKHOE CONTROL VALVE VALVE STABI
VALVE
OUTLET END CAP
AUXILIARY
CROWD
HYDRAULIC
FILTER
PARK BRAKE
DIFF. LOCK V
BOOM
LOADER CO
BOOM
SWING
STABILIZER VALVE
SYSTEM
RELIEF
VALVE
INLET END CAP
T119027
CED,TX03768,8484 1924APR981/1
CHARGE PUMP
HYDRAULIC OIL
COOLER
LOADER
VALVE
PRESSURE
REDUCING
PARK VALVE
BRAKE
RELIEF SOLENOIDS
VALVE
DIFF.
LOCK
SOLENOID
PARK BRAKE PARK
DIFF. BRAKE
LOCK SWITCH
THERMAL
710D HYDRAULIC SCHEMATIC RELIEF VALVE
/1
der
22602
733
Page 9025-05-5 B
STEERING VALVE BRAKE VALVE
L R
T LS P
PRIORITY
VALVE
ACCUMULATOR
RESERVOIR
TRAPPED OIL
FILTER BYPASS RETURN OIL
VALVE
HYDRAULIC
OIL COOLER
Page 9025-05-5 C
BACKHOE
BACKHOE CONTROL VALVE VALVE STABILIZER
VALVE BRAKE
OUTLET END CAP VALVE
AUXILIARY
CROWD
HYDRAULIC
FILTER
BUCKET
PARK BRAKE/
DIFF. LOCK VALVE
PRIORITY
VALVE
BOOM
SWING
STABILIZER VALVE
SYSTEM
RELIEF
VALVE
INLET END CAP
T119026
Page 9025-05-6 A
Hydraulic Sc
T119026 1917DEC98
STEERIN
STEERING
KE VALVE ACCUMULATOR
RESERVOIR L
E
SURGE RELIEF VALVE
HYDRAULIC OIL
COOLER
PR
VA
ACCUMULATOR
MAIN HYDRAULIC
PUMP
LOADER CHARGE
VALVE PUMP
ALVE
BUCKET AUXILIARY
DIFF.
LOCK
SOLENOID
PARK BRAKE PARK
DIFF. BRAKE
LOCK SWITCH
THERMAL
710D HYDRAULIC SCHEMATIC RELIEF VALVE
(GRESEN BACKHOE VALVE)
TM1537 (26FEB0
Page 9025-05-6 B
Theory of Operation
L R
T LS P
PRIORITY
VALVE
OR
RESERVOIR
TRAPPED OIL
FILTER BYPASS RETURN OIL
VALVE
HYDRAULIC
OIL COOLER
CED,TX03768,8485 1924APR981/1
T LS P
CROWD
HYDRAULIC
FILTER
BUCKET
PRIORITY
VALVE
PARK BRAKE/ ACCUMULATOR
DIFF. LOCK VALVE
MAIN HYDRAULIC
BOOM PRIORITY PUMP
VALVE
LOADER CHARGE
VALVE PUMP
CED,TX03768,8486 1924APR981/1
PN=735
LEFT B A A B
STABILIZER LEFT I I
CYLINDER SWING
BUCKET CYLINDER HYDRAULIC P C C P
RIGHT FILTER
SWING
CYLINDER CHARGE BUCKET
PUMP CYLINDER BRAKE BRAKE BRAKE
PRIORITY
BOOM PRESSURE LIGHT PRESSURE
VALVE
SWITCH SWITCH SWITCH
TRANSMISSION
LOADER MAIN HYDRAULIC
VALVE TRANSMISSION STEERING OIL PUMP
HYDRAULIC RIGHT ATTENUATOR
CYLINDER
FILTER LOADER HOSE
CYLINDER
SWING
RESERVOIR
BOOM BUCKET AUXILIARY STEERING VALVE
L R
MAIN HYDRAULIC PUMP HYDRAULIC HIGH PRESSURE OIL
AUXILLIARY STABILIZER VALVE FILTER
(ATTACHMENT) ATTENUATOR MEDIUM PRESSURE OIL
HOSE
PRIORITY CHARGE PRESSURE OIL
VALVE SURGE
RELIEF CHARGE TRAPPED OIL
VALVE PUMP
LUBRICATION OIL
SYSTEM
RELIEF T LS P RETURN OIL
INLET END CAP VALVE
FILTER BYPASS
VALVE
HYDRAULIC
OIL COOLER
T116994
710D HYDRAULIC SCHEMATIC
Hydraulic Schematic
CED,TX04577,769 1928SEP981/1
PN=736
BACKHOE
VALVE STABILIZER
VALVE
BACKHOE CONTROL VALVE
AUXILIARY
CROWD
HYDRAULIC
FILTER
BUCKET
PARK BRAKE/
DIFF. LOCK VALVE
BOOM PRIORITY
VALVE
SYSTEM
RELIEF
INLET END CAP VALVE
T119025
CED,TX03768,8486 1924APR981/1
HYDRAULIC OIL
COOLER
ACCU
VE
MAIN HYDRAULIC
ORITY PUMP
VE
LOADER CHARGE
VALVE PUMP
ER CONTROL VALVE
OM BUCKET AUXILIARY
PRESSURE
REDUCING
PARK VALVE
BRAKE
RELIEF SOLENOIDS
VALVE
DIFF.
LOCK
SOLENOID
PARK BRAKE PARK
DIFF. BRAKE
LOCK SWITCH
THERMAL
710D HYDRAULIC SCHEMATIC RELIEF VALVE
(HUSCO BACKHOE VALVE)
/1
der
22602
735
Page 9025-05-7 B
STEERING VALVE BRAKE VALVE
L R
T LS P
PRIORITY
VALVE
ACCUMULATOR
RESERVOIR
TRAPPED OIL
FILTER BYPASS RETURN OIL
VALVE
HYDRAULIC
OIL COOLER
Page 9025-05-7 C
EXTENDIBLE RIGHT
DIPPERSTICK CROWD BACKHOE
CYLINDER VALVE STABILIZE
CYLINDER CYLINDER
BACKHOE CONTROL VALVE
STABILIZ
VALVE
AUXILIARY
BUCKET
CYLINDER
CROWD BOOM
CYLINDER
LEFT
STABILIZER LEFT
CYLINDER SWING
BUCKET CYLINDER HYDRAULIC
RIGHT FILTER
SWING
CYLINDER CHARGE
PUMP
PRIORITY
BOOM VALVE
LOADER
VALVE
SWING
BOOM BU
SYSTEM
RELIEF
INLET END CAP VALVE
T116994
Page 9025-05-8 A
Hydraulic S
T116994 1913NOV98
HT STEERING BRAKE
BILIZER BRAKE
VALVE VALVE ACCUMULATORS
INDER SURGE RELIEF
ABILIZER BRAKE HYDRAULIC OIL VALVE
LVE SYSTEM RESERVOIR
FILTER TRANSMISSION
OIL COOLER HYDRAULIC
OIL COOLER
THERMAL
RELIEF
BYPASS
VALVE
LEFT LOADER
CYLINDER ACCUMU
BUCKET
CYLINDER
RITY
VE
TRANSMISSION
OADER MAIN HYDRAULIC
ALVE TRANSMISSION STEERING OIL PUMP
HYDRAULIC RIGHT ATTENUATOR
CYLINDER
FILTER LOADER HOSE
CYLINDER
L R
MAIN HYDRA
ATTE
HOS
PRIORITY
VALVE
T LS P
TM1537 (26FEB
Page 9025-05-8 B
Theory of Operation
BRAKE VALVE
CUMULATOR ACCUMULATOR
B A A B
I I
P C C P
RESERVOIR
RETURN OIL
FILTER BYPASS
VALVE
HYDRAULIC
OIL COOLER
Hydraulic Schematic
CED,TX04577,769 1928SEP981/1
H
E G
F
D L
1915JAN98
A
B K
C
T6895AD
TXC6895AD
9025
05
9
ACharge Pressure DCharge Pump GLoader Control Valve JAuxiliary Valve
BReturn Oil (Low Pressure) EMain Hydraulic Pump HStabilizer Control Valve KHydraulic Filter
CReturn Oil (Pressure Free) FHydraulic Oil Cooler IBackhoe Control Valve LHydraulic Reservoir
The charge pump (D) (SN 830204) is located on left Charge pump is a low pressure, constant displacement
side of engine above injection pump. It is belt driven gear pump. Charge oil is drawn from hydraulic
off the engine crankshaft pulley and belt tension is reservoir (L) and pumped into return line ahead of
adjustable. hydraulic filter to supply main hydraulic pump (E).
The charge pump (SN 830205 872256) is located on When main hydraulic pump is at standby, charge oil
the right side of the engine beneath the alternator. It is (A) flows through oil cooler (F) and is returned to
driven by the right camshaft gear through the auxiliary hydraulic reservoir. Excess charge flow is returned to
drive assembly. reservoir through surge relief check valve. The surge
relief check valve is located in reservoir return line
The charge pump (S.N. 872329 ) is mounted on the from filter base and limits charge pressure to a
rear of the transmission. The pump is driven by the maximum of 827 kPa (120 psi).
transmission input shaft at engine speed.
TX,9025,BG217 1902JAN971/1
PN=737
Theory of Operation
K
J
N
L
O
U
A
M
H
F G
D
B
9025
05
10 E
1915JAN98
Q
R C
T6902AA
S
TXC6902AA
The 3000 Series radial piston pump is a variable double bank pump is essentially two single bank
displacement pump. Single and double bank versions pumps sharing a common drive shaft and control
operate the same to provide high pressure oil flow. A valve.
Inlet oil (R) enters through inlet ports (A) in the inlet oil in the outlet gallery closes the discharge valve (C).
housing (T). A common inlet gallery in the housing All discharge valves share a common outlet gallery in
provides oil to eight inlet valves (G) in pump housing the pump housing (S). An orifice (I) is located between
(S). Pistons (D) radially surround an eccentric cam. the crankcase and the inlet gallery. Any oil leakage
The pistons ride on the cam bearing race (F). A spring past the pistons is routed through the orifice (I) to the
behind each piston hold it against the bearing race. As inlet gallery. This flow allows for cooling and
pump shaft (E) rotates, a low pressure cavity develops lubrication. Pressure compensation pumps (both older
in the piston spring area during downward stroke of style non-utilized and newer style unitized designs) are
piston. This low pressure allows inlet valve (G) to open designed to provide "on demand" discharge pressure
filling the piston cavity with oil. Inlet valves close at the oil (P) regardless of flow requirements. As demand for
end of intake stroke of pistons. High pressure oil is oil decreases, system pressure increases. Pressure
developed as bearing race pushes pistons outward. compensator valve (L) then routes system oil into
crankcase (H). Increased pressure in the crankcase
As pressure increases, the discharge valve (C) opens overcomes piston spring pressure and holds pistons
allowing discharge pressure oil (P) to pass into the (D) away from race (F), thereby destroking the pump.
outlet gallery. At the end of stroke, discharge pressure
27T,9025,M65 1924MAR932/2
9025
05
11
PN=739
Theory of Operation
B P
P
G
E G B N
C
E
I F
J
H K
9025
L
05
12
1915JAN98
TXC6902AB
D O
T6902AB
APressure Compensator ECrankcase Relief Valve KCrankcase Pressure Oil OPlug (or Optional Manual
Adjusting Screw FExternal Control Valve LInlet Pressure Oil Destroke or Electric
BPressure Compensator GSpring MPressure Compensator Solenoid)
Spring(s) HShuttle Valve Valve in 1st Position PValve Housing
CSpring Guide ISpring NPressure Compensator
DPressure Compensator JDischarge Pressure Oil Valve in 2nd Position
Valve
The 3000 Series unitized designed pump provides a pressure increases moving pressure compensator
bolt-on control valve. The pressure compensator valve valve (D) toward spring (B).
(D) controls the flow of oil in the pump. Valve
movement is controlled by discharge pressure oil (J) The valve continues to move to position (N) dumping
on one end of the valve and by inlet pressure oil (L) discharge pressure oil (J) into the crankcase,
and force from spring (B) on the other end. Discharge increasing crankcase pressure. Crankcase pressure
pressure can be increased or deceased by changing overcomes the combined spring force on the pump
the force on spring (B) using the pressure pistons. Pistons are then held away from the pump
compensator adjusting screw (A). Shuttle valve (H) is shaft bearing race and the pump is DESTROKED.
used in conjunction with either a manual destroke
screw or an electric destroke solenoid in place of plug The pump goes into QUICK DESTROKE when there is
(O). Valve (H) moves against crankcase relief valve a sudden drop in demand for oil flow, creating a
(E) and spring (G) allowing discharge pressure oil to sudden increase in discharge pressure oil. Discharge
be dumped into crankcase and inlet destroking the pressure oil increases greatly allowing the crankcase
pump. relief valve (E) to move against the spring (G). This
allows crankcase pressure oil (K) to dump into inlet
Pump is in FULL STROKE when pressure pressure oil (L). This limits high pressure spikes
compensator valve (D) is in the position (M) shown caused by discharge pressure oil being too rapidly
above. As demand for oil decreases, discharge routed into crankcase cavity.
27T,9025,M67 1915OCT912/2
9025
05
13
PN=741
Theory of Operation
A
INLET P
I
C
J
G BYPASS
INLET VALVE
HOUSING
A A
B PISTON K G
P C NORMAL OPERATION
SPRING
D
SPRING F
H TERMINAL
L RESTRICTED FLOW
9025
05 I ELEMENT INDICATOR LIGHT
J
14 ON AND BYPASS OIL
1910SEP98
TO
RESERVOIR M SEMI-RESTRICTED
K K FLOW INDICATOR
OUTLET LIGHT ON
T101460
T101460 O RETURN FILTER N RETURN FLOW
The hydraulic return filter removes contaminants from (B) increases, moving the piston (C) down against
the hydraulic system oil. The filter housing contains a spring (D) force and outlet pressure. The piston
bypass valve and a filter restriction switch. contacts the terminal (H), completing a circuit which
causes the filter restriction indicator light to glow.
Under normal operation, return flow from the backhoe
loader and priority valve enters the inlet (A), flows As the filter element becomes plugged, the pressure
through the filter element (I), up through the filter differential between the inlet and outlet increases. Inlet
canister and out the outlet (K) or to the reservoir (J). pressure is sensed on one side of the valve (G) which
opens against spring (F) force and outlet pressure.
If the pressure differential between the inlet and outlet The return oil then bypasses the filter while the
increases past a set level due to cold oil or partially restriction indicator lights glow.
restricted filter element, inlet pressure in the housing
Under normal operation, the restriction indicator light return filter is being bypassed. Extended operation in
will glow when operating the hydraulic functions with the bypass mode will cause damage to the hydraulic
cold oil. If the restriction indicator light continues to system.
glow after the oil reaches operating temperature, the
27T,9025,M69 1924MAR932/2
9025
05
15
PN=743
Theory of Operation
D P PORT A D
E
SPOOL
LAND C
NOTCHES E SPOOL
B F
H
G
LS PORT B
SPRING A
ORIFICE H
J SYSTEM PRESSURE
LOADER I K STEERING CIRCUIT
VALVE G F PRESSURE
ACTUATED EF PORT CF PORT L RETURN PRESSURE
1915JAN98
T7833AG
9025 TXC7833AG M PRIORITY VALVE NEUTRAL
05
16
ASpring ESpool HOrifice KSteering Circuit Pressure
B"LS" Port F"CF" Port, To Steering ILoader Valve Actuated LReturn Pressure
CSpool Land Notches Valve JSystem Pressure MPriority Valve-Neutral
D"P" Port, Inlet G"EF" Port, To Loader Valve
The priority valve (M) is a pressure control valve that causes the priority valve spool to shift left against the
maintains priority pressure to the closed-center spring and open the "EF" port. As long as the steering
steering valve. With the engine running and the valve is in neutral, just enough pressure to the steering
steering valve in neutral, flow to the steering valve is valve is maintained to keep the priority valve spool
not required and all flow through the priority valve is shifted to the left.
directed out the "EF" port (G) to the loader control
valve. The operating pressure in the loader circuit does not
affect the operation of the priority valve. With a loader
With the engine off, the spool (E) is pushed to the right function activated the priority valve will not shift until
by the spring (A). The passage to the "CF" port (F) is the unit is steered.
open.
Flow through the priority valve spool passes through
When the machine is first started, all pump flow is the orifice (H) and into the "LS" port (B) flowing
routed to the steering valve which, if not being through the steering valve "LS" passage which is
operated, blocks the flow. This causes pump pressure routed to return when the steering valve is in neutral.
to increase. Steering inlet pressure is supplied through This provides a warm-up circuit to prevent binding of
the pilot orifice to the right end of the spool. This the steering valve due to temperature extremes.
D P PORT H E
D
SPOOL
LAND B
NOTCHES E SPOOL
A F
C
G
LS PORT A
SPRING H
ORIFICE C
J HIGH PRESSURE
FULL K MEDIUM PRESSURE
STEER I
RATE G F
EF PORT CF PORT
1915JAN98
L PRIORITY VALVE STEERING ACTIVATED
T7833AH
TXC7833AH LOADER VALVE IN NEUTRAL
9025
A"LS" Port ESpool HSpring LPriority ValveSteering
05
BSpool Land Notches F"CF" Port, To Steering IFull Steer Rate ActivatedLoader Valve in
17
COrifice Valve JHigh Pressure Neutral
D"P" Port, Inlet G"EF" Port, To Loader Valve KMedium Pressure
When steering the machine, load-sensing pressure conditions. During normal conditions, oil is metered
from the steering valve flows through the orificed "LS" into the load sensing circuit through an orifice in the
port (A) in the priority valve. Load sensing pressure steering valve. When steering is at the full steer rate
plus spring (H) force moves the spool (E) to the right (I), the spool shifts to the full right position, directing all
against the pilot pressure on the right end of the spool. flow to the steering valve. At fast idle, the steering
This restricts flow through the "EF" port (G) while the system will not use all of the pump flow. Therefore, the
"CF" port (F) is open to the steering valve. excess oil flows to the loader control valve.
The load sensing circuit is a control circuit that routes The load sensing circuit receives the majority of its
steering work port pressure oil to the spring side of the flow from the load sensing orifice in the steering valve.
priority valve spool to sense the pressure that is Some flow is also supplied from the "CF" port through
required to steer the machine under various load orifice (C) in the priority valve spool.
PN=745
Theory of Operation
E PORT
E B
SPRING D
PLUG C
SPOOL F SPOOL
LAND B
A G
NOTCHES
H
LS PORT A
I HIGH PRESSURE
J MEDIUM PRESSURE
H G
1915JAN98
EF PORT CF PORT
T7833AI
TXC7833AI BOTTOMED AND LOADER ACTIVATED
9025
A"LS" Port E"P" Port, Inlet H"EF" Port, To Loader Valve KPriority ValveSteering
05
BSpool Land Notches FSpool IHigh Pressure Cylinder Bottomed, Loader
18
CPlug G"CF" Port, To Steering JMedium Pressure Activated
DSpring Valve
With steering turned fully against stop, maximum into loader valve for boom and bucket operation from
steering system pressure (I) is created, which is pump EF port. Priority flow and pressure is still given to the
standby pressure. The spool (F) is shifted to the right steering valve through the CF port (G).
as shown. Notches on spool land (B) allow limited flow
TX,902505,BS152 1903MAR933/3
UN07APR98
HOutlet Port
A
B H
T94230
T94230
TX,902505,BS209 1903MAR931/1
PN=747
Theory of Operation
1904JAN99
T119238
9025
05
20
AInlet Check Valve COutlet EBrake Circuit Pressure GBrake Accumulator
BPiston DInlet FPrecharge Pressure
NOTE: Brake accumulators are not repairable and are If pump flow stops, the inlet check valve will close
serviced as a complete unit. against inlet fitting which is machined to provide a
check valve seat, keeping the accumulator charged.
The brake system uses two accumulators. They are The accumulator will remain pressurized until the
used to store pressurized oil for reserve brake brakes are applied. The volume of the accumulator will
application. The top of the accumulator is charged with allow several brake applications in the event of a loss
dry nitrogen gas valve. When the hydraulic system of brake pump flow.
pressure exceeds the charge pressure, oil flows
through the inlet (D) and inlet check valve (A). The
piston (B) moves upward until gas pressure is equal to
hydraulic circuit pressure.
TX,9025,ME327 1928AUG961/1
9025
05
21
PN=749
Theory of Operation
A NEUTRAL
B STEERING
CYLINDER
D GEROTOR
LOAD SENSE
PORT TO
PRIORITY
VALVE
C
J SPOOL I SLEEVE
9025
05
22
E INLET CHECK
H RETURN VALVE
RETURN H
K STEERING
SHAFT F FROM PRIORITY
VALVE
L R
D G MANUAL STEER
CHECK VALVE
G
H
E
L SYSTEM PRESSURE OIL
C
1915JAN98
F
M WORK PRESSURE OIL
T LS P
N TRAPPED OIL
O RETURN PRESURE OIL
T7849AB
The steering valve (P) is a closed center valve that the sleeve, until the sleeve stops the flow to the
consists of a rotary spool (J) inside a sleeve (I) within gerotor. At this point, the valve is back in the neutral
a housing. When steering wheel is not moving, the position and will remain there until the steering wheel
valve is in the neutral (A) position. In neutral, the spool is moved again.
and sleeve are aligned so that oil flow through the
valve is blocked. The steering cylinder (B) is held The steering valve has a variable steering rate which
stationary by trapped oil (N) in the left and right is proportional to the speed the steering wheel is
workports. rotated. A variable orifice bypasses oil around the
gerotor. Turning the steering wheel slowly takes
When the steering valve is turned to the right or left, approximately six turns (variable orifice small)
the spool rotates relative to the sleeve, and opens stop-to-stop versus three turns (variable orifice large)
passages which allows pressure oil from priority valve when turning the steering wheel quickly.
oil (F) to flow through the spool and sleeve assembly.
Work pressure oil (M) flows to gerotor (D) causing the An inlet check valve (E) prevents oil from returning
gerotor gear to rotate. Oil flow from the gerotor flows through the steering unit, when pressure on the
back into the valve where it is directed out the right or cylinder side is greater than on the inlet side. This
left workport to the respective ends of the steering prevents steering wheel kickback.
cylinder.
If there is no power to supply pressure oil (L) to the
Return oil (O) flows back in through the right or left steering valve, the unit can be steered manually. If no
workport through the spool and sleeve assembly to pressure oil is available, there is a direct mechanical
return circuit (H). The load-sensing orifice is located connection through the drive shaft to the gerotor gear 9025
between the sleeve and the gerotor. This orifice feeds assembly (D). As the gerotor is turned it pumps oil to 05
the load-sensing circuit between the steering valve and the steering cylinder. Return oil from the cylinder is 23
the priority valve through the LS-port (C). drawn through a check valve (G) between inlet and
outlet ports to provide oil for manual steering
When the rotation of the steering wheel shaft (K) operation. Thus the unit can be steered manually until
stops, the gerotor (D) gear continues to move, turning the unit is brought to a stop.
TX,902505,BS155 1903MAR932/2
PN=751
Theory of Operation
E
N
H I
D G
9025 A
05 L
24 B
UN06MAR97
C
K
J
T6298BF
T6298BF
When the circuit relief valve is closed (E), oil from work faster than oil can flow though orifice causing pressure
port (M) flows through orifice (L) into the area behind oil (B) to decrease. Then high pressure oil pushes the
poppet (K). With pressure equal on both sides of poppet off its seat releasing oil through return port (G)
poppet, spring force holds poppet (K) closed and stops to return passage of valve.
flow through return port (G).
During anti-cavitation operation (F) the pressure in
During relief operation (D) when pressure in the circuit return port is greater than pressure in work port. The
increases above relief valve setting, high pressure oil difference in pressure pushes collar (H) against snap
(A) pushes pilot valve (J) off its seat. Low pressure oil ring (N) pulling the poppet off its seat. Oil then flows
(B) behind the poppet flows out return passage (I) from return port into work port to prevent cavitation.
TX,9025,BG218 1902JAN971/1
E F
D D
C
A
J
B G
I H
N C
9025
05
25
UN20FEB97
I
L K
G J D H
T6298BM
T6298BM
AHigh Pressure Oil DReturn Passage HInlet Passage KBucket Dump Position
BCharge Pressure Oil EBucket Dump Work Port ILift Check LCheck Valve
(Return to Charge Circuit) FBucket Rollback Work Port JCircuit Relief Valve With MBucket Cylinder
CReturn-To-Dig GCircuit Relief Valve Anti-Cavitation NBucket Rollback Position
Electromagnet
The bucket valve is a three-position, four-way, When bucket dump function is activated and pressure
spool-type valve. It contains a lift check (J) and two in circuit is less than charge pressure, oil flows from
circuit relief valves. Relief valve (K) also contains an return passage (E) past anti-cavitation valve (K) to the
anti-cavitation valve. bucket dump circuit (F).
PN=753
Theory of Operation
F G
E E
D
A
K
B
H
C
UN20FEB97
J I
T6298BN
T6298BN
The valve is equipped with a return-to-dig. When rollback position. When the bucket rolls back to the dig
loader control lever is moved to the bucket rollback position, a mechanical linkage opens the return-to-dig
position, a plate fastened to end of valve spool, switch, which de-energizes electromagnet (D) letting
contacts an electromagnet (D). If the bucket is in dump the spool centering spring move the spool to neutral
position, the return-to-dig switch is closed which position.
energizes the electromagnet and holds spool in the
TX,902505,BS228 1903MAR932/2
9025
05
27
PN=755
Theory of Operation
D E
F F
L I
A
B
K J
C
N
P
9025
05
28
UN20FEB97
L
M O Q
N
F J
T6298BG
T6298BG
AHigh Pressure Oil EBoom Lower Work Port JInlet Passage NBoom Cylinders
BTrapped Oil FReturn Passage KLift Check OBoom Float Position
CCharge Pressure Oil GLeakage Return Passage LAnti-Cavitation Valve PBoom Lower Position
(Return to Charge Circuit) HBoom Spool MCap With Detent QBoom Raise Position
DBoom Raise Work Port ICircuit Plug
The boom valve (SN812257) is a four-position, causing function drift. Leakage flows from the inlet
four-way spool type valve. The spool (H) has grooves passage, through the leakage return passage, into the
in both ends to meter oil through the valve to prevent return passage (F), then out of control valve to charge
abrupt starts and stops. The boom valve contains a lift circuit.
check (K) and an anti-cavitation valve (L).
Valve spool can be metered to restrict oil flow to the
A leakage return passage (G) is used to prevent cylinder.
leakage from the inlet passage to boom raise circuit
When spool (H) is moved to activate a function, oil Return oil from the cylinders flows into the other work
flows from functional inlet passage (J), past lift check port, past the spool, into the return passage (F), then
(K) and spool (H), out the work port to the cylinders. out of control valve to charge circuit.
9025
05
29
PN=757
Theory of Operation
D E
F
F
G
H
M
A
L I
B
C K J
P Q N
9025
UN06MAR97
05
30
I L M O K
N
F J
T105845
T105845
AHigh Pressure Oil EBoom Lower Work Port JInlet Passage NBoom Cylinders
BTrapped Oil FReturn Passage KLift Check OBoom Float Position
CCharge Pressure Oil GLeakage Return Passage LAnti-Cavitation Valve PBoom Lower Position
(Return to Charge Circuit) HBoom Spool MCap With Detent QBoom Raise Position
DBoom Raise Work Port IBoom Head Circuit Relief
Valve
The boom valve for (SN 812258 ) uses a relief valve causing function drift. Leakage flows from the inlet
in the head end circuit. The spool (H) has grooves in passage, through the leakage return passage, into the
both ends to meter oil through the valve to prevent return passage (F), then out of control valve to charge
abrupt starts and stops. The boom valve contains a lift circuit.
check (K) and an anti-cavitation valve (L).
Valve spool can be metered to restrict oil flow to the
A leakage return passage (G) is used to prevent cylinder.
leakage from the inlet passage to boom raise circuit
When spool (H) is moved to activate a function, oil The relief valve (I) protects the head end of the boom
flows from functional inlet passage (J), past lift check circuit for pressures exceeding the relief valve setting.
(K) and spool (H), 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 (F), then
out of control valve to charge circuit.
TX,9025,BG219 1902JAN974/5
D E
C F F
G
9025
05
31
N M
L H
UN20FEB97
B
K J I
T6298BH
T6298BH
AHigh Pressure Oil EBoom Lower Work Port HRelief Valve (SN 812258 ) LPlug with Anti-Cavitation
BCharge Pressure Oil FReturn Passage IInlet Passage MDetent Balls (4 used)
(Return To Charge Circuit) GSpool JLift Check NDetent Spring
CDetent Housing HCircuit Plug (SN 812257) KFloat Oil Passage (Compressed)
DBoom Raise Work Port
The boom float function operates the same for all are open to return passage (F) connected by float
710D machines. When spool (G) is moved to the passage (K) allowing oil to flow in and out both ends of
boom float (detent) position, both work ports (D and E) cylinders.
TX,9025,BG219 1902JAN975/5
PN=759
Theory of Operation
CENTERING
SPRING
B
A
E
C H
G PLUG
1915JAN98
A J CHARGE PRESSURE
RELIEF VALVE H OIL
PRESSURE PASSAGE K TRAPPED OIL
T7419BC
TXC7419BC M LOADER AUXILIARY VALVE NEUTRAL
9025
05
32 Valve Shown in Neutral Position
The loader auxiliary valve is a three position, four-way, The relief valve is in the cylinder head end circuit. The
spool-type valve. It contains a lift check (E), relief valve auxiliary valve is used to control clam buckets or other
(A) and a plug (G). front-mounted hydraulic functions.
B
C A
1915JAN98
G CHARGE PRESSURE
LIFT CHECK B A PRESSURE OIL
PASSAGE
T7419BB
TXC7419BB H LOADER AUXILIARY VALVE EXTEND
When the auxiliary valve is moved to the extend through rod end work port (D) to return passage. Oil in
position, oil flows from pressure passage (A) by lift the return passage is sent to main hydraulic filter
check (B) out head end work port (E) to cylinder head where it combines with other return oil and becomes
end. Oil from rod end of cylinder flows back to valve charge oil for main pump.
TX,902505,BR122 1924MAR932/2
PN=761
Theory of Operation
J K
L
D
I
O
9025
A
H
05 B
34
C
UN06MAR97
G
M
F N P
T88947
T88947
When the circuit relief valve is closed (F), oil from work through orifice causing pressure to decrease. Then
port (I) flows through orifice (N) into the area behind high pressure oil pushes the poppet off its seat
poppet (H). With pressure equal on both sides of releasing oil through return port (G) to return passage
poppet, spring force holds poppet (H) closed and stops of valve.
flow through return port (G).
During anti-cavitation operation (E), the pressure in
During relief operation (D) when high pressure oil (A) return port is greater than pressure in work port. The
in the head end work port circuit increases above relief difference in pressure pushes collar (J) against snap
valve setting, high pressure oil pushes pilot valve (L) ring (K) pulling the poppet off its seat. Oil then flows
off its seat. Low pressure oil (B) behind the poppet from return port into work port to prevent cavitation.
flows out return passage (M) faster than oil can flow
27T,9025,M78 1924MAR931/1
I RETURN PASSAGE F
ANTI-CAVITATION
POPPET F
C CAVITY
H
WORK
PORT
9025
05
A 35
1903JUN98
ORIFICE B RELIEF D PRESSURE OIL
POPPET
E CHARGE PRESSURE OIL
T115031
T115031 G CIRCUIT RELIEF VALVE WITH ANTI-CAVITATION
The relief is direct acting, non adjustable and has pressure oil overcomes relief poppet (B) pressure
anti-cavitation operation. In normal operation, pressure setting and opens a path to return passage of valve (I).
oil less than relief valve setting flows through orifice During anti-cavitation operation, the pressure in the
(A) into cavity (C) behind relief valve poppet. Pressure work port (H) is less than pressure in return passage
oil and spring in cavity hold the anti-cavitation poppet (I). The pressure difference pushes the anti-cavitation
(F) closed because effective area on the spring side is poppet (F) off the seat allowing oil to flow from the
greater than on work port side (H). In relief operation, return passage to work port to prevent cavitation.
CED,TX03768,8487 1924APR981/1
PN=763
Theory of Operation
D
MAIN POPPET
A
E
9025
05 WORK PORT F RETURN PASSAGE
36
1903JUN98
B HIGH PRESSURE OIL
C CHARGE PRESSURE OIL
T115029
T115029 D CIRCUIT RELIEF VALVE WITHOUT ANTI-CAVITATION
The relief is direct acting, screw adjustable and does overcomes main poppet (A) pressure setting and oil
not have anti-cavitation operation. The pressure set flows from the pressurized work port (E) to return
point is adjustable by turning the adjustment screw at passage of valve (F).
the end of the relief. In relief operation, pressure oil
CED,TX03768,8488 1924APR981/1
9025
05
37
PN=765
Theory of Operation
I C
F G
R S Q C
SPOOL N
T115025
O BACKHOE SWING SECTION-SWING LEFT POSITION
AHigh Pressure Oil FInlet Passage LInlet Metering PSwing Cylinders (2 used)
BCharge Pressure Oil GReturn Oil MBridge Bleed Passage QSwing Right
CCircuit Relief Valve with HBridge Passage NSpool RSwing Left
Anti-cavitation (2 used) ILift Check OBackhoe Swing SNeutral Position
DSwing Left Work Port JReturn metering Section-Swing Left
ESwing Right Work Port KBridge Metering Position
The swing section is a three-position, four-way, closed activate a function, oil flows from the inlet passage (F),
center, spool-type valve. The valve contains two circuit through holes in spool and inlet metering notches (L)
relief valves with anti-cavitation (C) and a lift check (I). and lift check (I), into the bridge passage (H), past
The valve section contains a bridge bleed (M) to bleed bridge metering notches (K) and out work port (D or E)
bridge passage (H) to the return passage (G) when to the cylinders (P). Return oil from the cylinders flows
spool (N) is in the neutral position (S) to prevent inlet into the other work port, through holes in spool and
pressure (F) from leaking to either work port (D or E) return metering notches (J), into the return passage
causing function drift. When the spool is moved to (G), then out of the control valve to the charge circuit.
CED,TX03768,8493 1927APR982/2
9025
05
39
PN=767
Theory of Operation
J C
H
G R S Q D
BUCKET DUMP
BUCKET CURL F E WORK PORT
WORK PORT J LIFT
I BRIDGE
PASSAGE CHECK
9025 CIRCUIT RELIEF
CIRCUIT RELIEF
05 WITHOUT ANTI-
D WITH ANTI- CAVITATION
40 CAVITATION
C
SPOOL O
K RETURN METERING
RETURN H L BRIDGE METERING
PASSAGE
L T BRIDGE BLEED PASSAGE
M INLET G INLET
K BRIDGE METERING
METERING PRESSURE
RETURN
METERING
1903JUN98
A High Pressure Oil EBucket Dump Workport KReturn metering QBucket Dump
BCharge Pressure Oil FBucket Curl Workport LBridge Metering RBucket Curl
CCircuit Relief Valve without GInlet Pressure MInlet Metering SNeutral Position
Anti-cavitation HReturn Oil NBridge Bleed Passage TBucket Cylinder
DCircuit Relief Valve with IBridge Passage OSpool
Anti-cavitation JLift Check PBackhoe Bucket
Section-Bucket Curl
Position
The bucket section is a three-position, four-way, closed causing function drift. When the spool is moved to
center, spool-type valve. The valve contains one circuit activate a function, oil flows from the inlet passage (G),
relief valve with anti-cavitation (D) in the bucket-curl through holes in spool and inlet metering notches (M)
position, one circuit relief valve without anti-cavitation and lift check (J), into the bridge passage (I), past
(C) in the bucket-dump position and a lift check (I). bridge metering notches (L) and out work port (E or F)
The valve section contains a bridge bleed (N) to bleed to the cylinder (T). Return oil from the cylinder flows
bridge passage (I) to the return passage (H) when into the other work port, through return metering
spool (O) is in the neutral position (S) to prevent inlet notches (K), into the return passage (H), then out of
pressure (G) from leaking to either work port (E or F) the control valve to the charge circuit.
CED,TX03768,8491 1927APR982/2
9025
05
41
PN=769
Theory of Operation
K D
H S T R I E
BOOM LOWER
WORK PORT F LIFT G BOOM RAISE
K WORK PORT
J BRIDGE CHECK
PASSAGE
CIRCUIT RELIEF
CIRCUIT RELIEF
9025 WITH ANTI-
05
E WITH ANTI- CAVITATION
42
CAVITATION
D
SPOOL P
AHigh Pressure Oil FBoom Lower Workport LReturn metering RBoom Raise
BCharge Pressure Oil GBoom Raise Workport MInlet Metering SBoom Lower
CTrapped Oil HInlet Pressure NBridge Metering TNeutral Position
DCircuit Relief Valve without IReturn Oil OBridge Bleed Passage UBoom Cylinder
Anti-cavitation JBridge Passage PSpool
ECircuit Relief Valve with KLift Check QBackhoe Boom
Anti-cavitation Section-Boom Neutral
Position
The boom section is a three-position, four-way, closed causing function drift. When the spool is moved to
center, spool-type valve. The valve contains one circuit activate a function, oil flows from the inlet passage (H),
relief valve with anti-cavitation (E) in the boom-lower through holes in spool and inlet metering notches (M)
position, one circuit relief valve without anti-cavitation and lift check (K), into the bridge passage (J), past
(D) in the boom-raise position and a lift check (K). The bridge metering notches (N) and out work port (F or G)
valve section contains a bridge bleed (O) to bleed to the cylinder (U). Return oil from the cylinder flows
bridge passage (J) to the return passage (I) when into the other work port, through return metering
spool (P) is in the neutral position (T) to prevent inlet notches (L), into the return passage (I), then out of the
pressure (H) from leaking to either work port (F or G) control valve to the charge circuit.
CED,TX03768,8489 1927APR982/2
9025
05
43
PN=771
Theory of Operation
J C
G R T Q H D
SPOOL O
PRESSURE
A HIGH PRESSURE OIL
B CHARGE PRESSURE OIL
T115027
AHigh Pressure Oil ECrowd Out Workport KReturn metering QCrowd Out
BCharge Pressure Oil FCrowd In Workport LBridge Metering RCrowd In
CCircuit Relief Valve with GInlet Pressure MInlet Metering SCrowd Cylinder
Anti-cavitation HReturn Oil NBridge Bleed Passage TNeutral Position
DCircuit Relief Valve without IBridge Passage OSpool
Anti-cavitation JLift Check PBackhoe Crowd
Section-Crowd In Position
The crowd section is a three-position, four-way, closed causing function drift. When the spool is moved to
center, spool-type valve. The valve contains one circuit activate a function, oil flows from the inlet passage (G),
relief valve with anti-cavitation (C) in the crowd-in through holes in spool and inlet metering notches (M)
position, one circuit relief valve without anti-cavitation and lift check (J), into the bridge passage (I), past
(D) in the crowd-out position and a lift check (I). The bridge metering notches (L) and out work port (E or F)
valve section contains a bridge bleed (N) to bleed to the cylinder (S). Return oil from the cylinders flows
bridge passage (I) to the return passage (H) when into the other work port, through return metering
spool (O) is in the neutral position (T) to prevent inlet notches (K), into the return passage (H), then out of
pressure (G) from leaking to either work port (E or F) the control valve to the charge circuit.
CED,TX03768,8490 1927APR982/2
9025
05
45
PN=773
Theory of Operation
F G
R S Q
SPOOL N
J RETURN METERING
RETURN G
PASSAGE K BRIDGE METERING
The auxiliary section is a three-position, four-way, and lift check (I), into the bridge passage (H), past
closed center, spool-type valve. The valve contains bridge metering notches (K) and out work port (D or E)
two shut-off plugs (C) in place of relief valves and a lift to the cylinder (P). Return oil from the cylinder flows
check (I). Shut-off plugs may be replaced with circuit into the other work port, through return metering
relief valves appropriate to attachment being installed. notches (J), into the return passage (G), then out of
The valve section contains a bridge bleed (M) to bleed the control valve to the charge circuit. Two auxiliary
bridge passage (H) to the return passage (G) when valve sections can be added to the backhoe valve for
spool (N) is in the neutral position (S) to prevent inlet a total of six sections. Both are the same in design
pressure (F) from leaking to either work port (D or E) and operation. The fifth section is normally used for
causing function drift. When the spool is moved to extendible dipper operation. The sixth section can be
activate a function, oil flows from the inlet passage (F), used to operate accessory hydraulic equipment.
through holes in spool and inlet metering notches (L)
CED,TX03768,8494 1927APR982/2
9025
05
47
PN=775
Theory of Operation
RELIEF
CARTRIDGE C SPRING D THREE POSITION
B ORIFICE
1915JAN98
CARTRIDGE
I RETURN PRESSURE OIL
TXC7864AC
T7864AC
9025
05
48
ASolenoid Cartridge DThree Position Orifice GHigh Pressure Oil JSolenoid Controlled
BRelief Cartridge EOil Passage HReduced Pressure Oil Auxiliary Valve Operation
CSpring FSpool IReturn Pressure Oil
The Auxiliary Hydraulic Valve is a flow control valve The reduced pressure (H) that results from oil passing
that is mounted on the RH rear side of the backhoe through the three position orifice to the regulated port
valve mounting plate. Operation of the valve is is routed through passage (E) past the energized
controlled by an electrical solenoid. A pressure solenoid cartridge (A) to the spring (C) end of spool
compensated, variable volume flow rate is provided to (F). Main pressure oil "in" flows through the radial
meet specific attachment requirements. holes to the opposite end of the spool. Consequently
the position of the spool is maintained in a balanced
High pressure oil (G) flow is routed to the auxiliary position to provide the "regulated" flow rate that was
valve, which is connected to the main hydraulic system selected.
at the inlet to the backhoe valve. When the console
mounted control switch is moved to the "on" position, The relief cartridge (B) protects the regulated circuit by
electrical current is provided to the foot pedal. Pressing dumping excess pressure oil at the spring (C) end of
the foot pedal energizes solenoid cartridge (A) and oil the spool (F) to tank. Reduced pressure assisting the
flow "in" is diverted at a controlled rate past the spool spring causes the spool to shift toward the spring and
(F) and three position orifice (D) to the regulated port the flow of oil that is being routed to the regulated
for operation of the accessory attachment. circuit is decreased.
The regulated flow can be turned off by de-energizing (G) forces the spool to move against the spring which
the solenoid cartridge (A). This allows oil in the spring blocks oil flow through the valve.
chamber to be released to tank and pressure inlet oil
TX,902505,BS184 1903MAR932/2
9025
05
49
PN=777
Theory of Operation
M METERING
RETURN K GROOVES
PASSAGE
AUXILIARY I J SPOOL M
METERING O
PASSAGE
PASSAGES
1915JAN98
B CHARGE PRESSURE OIL
D K D C N
F
T8381BB
9025 TXC8381BB P VALVE IN SWING RIGHT POSITION
05
50 Valve in Swing Right Position
AHigh Pressure Oil ESwing Right Work Port JSpool NSwing Left
BCharge Pressure Oil FLift Check KReturn passage OMetering Passages
(Return To Charge Circuit) GSwing Left Work Port LSwing Cylinders (2 used) PBackhoe Swing
CSwing Right HFunctional Inlet Passage MMetering Grooves Valve-Swing Right Position
DCircuit Relief Valve with IAuxiliary Passage
Anti-cavitation Valve (2
used)
The swing valve is a three-position, four-way When the spool is moved to activate a function, oil
spool-type valve. The valve contains two circuit relief flows from the functional inlet passage (H), past the lift
valves with anti-cavitation (D). check (F) and spool (J), out the work port to the
cylinders. Return oil from the cylinders flows into the
The spool (J) has grooves on both ends to meter oil other work port, past the spool, into the return passage
flow through the valve to prevent abrupt starts and (K), then out of control valve to charge circuit.
stops. The return oil metering grooves (M) are longer
to give more control of function speed.
TX,902505,BS157 1920DEC941/1
9025
05
51
PN=779
Theory of Operation
E H
G
F
D I
J Q P Q K J
L
D
A
9025 M
B
UN07FEB97
05
52 C P
I N O
T88938
T88938
G
AHigh Pressure Oil FFunctional Inlet Passage JReturn Passage NBoom Down
BCharge Pressure Oil GLift Check KSpool OBoom Cylinder
CTrapped Oil HBoom Lower Work Port LAuxiliary Passage PMetering Grooves
DCircuit Relief Valve ICircuit Relief Valve with MBoom Up QPressure Seal Passage
EBoom Raise Work Port Anti-Cavitation Valve
The spool (K) has grooves on both ends to "meter" oil Pressure seal passages (Q) are used to prevent
flow through valve to prevent abrupt starts and stops. leakage from the boom raise circuit to return passage
The boom down return oil metering grooves (P) are (J) causing function drift. Oil flows from the inlet
longer to give more control of boom down speed. passage, through pressure seal passage to the land
between boom raise work port (E) passage and return
The boom valve is a three-position, four-way passage to form a high pressure seal between land
spool-type valve. The valve contains a lift check (G), a and housing.
circuit relief valve (D) in boom rise circuit, and a circuit
relief valve with anti-cavitation valve (I) in boom lower
circuit.
When the spool is moved to activate a function, oil cylinder. Return oil from the cylinder flows into the
flows from the functional inlet passage (F), past the lift other work port, past the spool, into the return passage
check (G) and spool (K), out the work port to the (J), then out of control valve to charge circuit.
27T,9025,M74 1906APR942/2
AUXILIARY K RETURN
I
PASSAGE SPOOL J PASSAGE
N
9025
05
A HIGH PRESSURE OIL
53
1915JAN98
B CHARGE PRESSURE OIL M
C TRAPPED OIL O D L G
T8381BA
TXC8381BA
P BACKHOE BUCKET VALVE - LOAD POSITION
AHigh Pressure Oil EBucket Dump Work Port JSpool OCircuit Relief Valve with
BCharge Pressure Oil FFunctional Inlet Passage KAuxiliary Passage Anti-cavitation
(Return to Charge Circuit) GLift Check LBucket Dump PBackhoe Bucket
CTrapped Oil HBucket Load Work Port MBucket Load Valve-Load Position
DCircuit Relief Valve IReturn Passage NBucket Cylinder
The backhoe bucket valve is a three-position, four-way When the spool (J) is moved to activate a function, oil
spool-type valve. The valve contains a circuit relief flows from the functional inlet passage (F), past the lift
valve with anti-cavitation valve (O) in the bucket load check (G) and spool out the work port to the cylinder.
circuit and circuit relief valve (D) in the bucket dump Return oil from the cylinder flows into the other work
circuit. port, past the spool, into the return passage (I), then
out of control valve to charge circuit.
The spool (J) has grooves on both ends to meter oil
flow through the valve to prevent abrupt starts and
stops.
TX,902505,BS156 1920DEC941/1
PN=781
Theory of Operation
E H
G
F
D I
K J
J L
O
A
9025 M
B
UN07FEB97
05
54 C
D N
I G
T88940
T88940
AHigh Pressure Oil ECrowd-In Work Port ICircuit Relief Valve MCrowd-In
BCharge Pressure Oil FFunctional Inlet Passage JReturn Passage NCrowd-Out
(Return to Charge Circuit) GLift Check KSpool OCrowd Cylinder
CTrapped Oil HCrowd-Out Work Port LAuxiliary Passage
DCircuit Relief With
Anti-Cavitation Valve
The backhoe crowd valve is a three-position, four-way When the spool is moved to activate a function, oil
spool-type valve. The valve contains a circuit relief flows from the functional inlet passage (F) past the lift
valve with anti-cavitation valve (D) in the crowd-in check (G) and spool (K), out the work port to the
circuit and circuit relief valve (I) in the crowd-out circuit. cylinder. Return oil from the cylinder flows into the
other work port, past the spool, into the return passage
The spool (K) has grooves on both ends to meter oil (J), then out of control valve to charge circuit.
flow through the valve to prevent abrupt starts and
stops.
27T,9025,M75 1906APR941/1
A D C
RETURN
PASSAGE
A
A RETURN
PASSAGE
1915JAN98
F HIGH PRESSURE OIL
T7419BM
G CHARGE PRESSURE
TXC7419BM
H BACKHOE AUXILIARY VALVE EXTEND 9025
OIL
05
55
AReturn Passage CLift Check EHead End Work Port GCharge Pressure Oil
BRod End Work Port DPressure Passage FHigh Pressure Oil
The auxiliary valve is a three-position, four-way port (B), past the spool into the return passage (A),
spool-type valve. The valve has two plugs and no then out of the valve to charge circuit.
reliefs. Plugs may be replaced with reliefs appropriate
to attachment being installed. Two auxiliary valve sections can be added to the
backhoe valve for a total of six sections. Both are the
When the spool is moved to extend position, oil flows same in design and operation. The fifth section is
from the pressure passage (D) past the lift check (C) normally used for extendable dipper operation. The
and spool, out the head end work port to the cylinder. sixth section can be used to operate accessory
Return oil from the cylinder flows into the rod end work hydraulic equipment.
TX,902505,BS158 1903MAR931/1
PN=783
Theory of Operation
G E G F
D F
D
A
H B
1910SEP98
H
J J
T7348AD
9025 TXC7348AD C STABILIZER VALVE - LOWER
05
56
APressure Oil DReturn Passage GPower Passage IThermal Relief Valve
BReturn Oil ENeutral Passage HPoppet JWork Passage
CStabilizer Valve-Lower FConnecting Passage
The stabilizer valve is a two-spool, unibody valve The thermal relief valve is used to release high
containing two lockout poppets (H) and one thermal pressures in the rod end of cylinder due to high
relief valve (I) for each circuit. temperatures changes.
When the valve is activated to lower a stabilizer, inlet When the stabilizer is in the full down position, high
oil (A) acts on the lockout plunger and lockout poppet temperatures can be generated by the forces working
(H). The inlet oil pushes the poppet off its seat and against the stabilizer. If the forces get too high, the
flows through work port (J) to head of cylinder. At the lockout plunger would not push the poppet off its seat
same time, the lockout plunger is pushed against the to raise the stabilizer.
other poppet, opening the return flow (B) from the
cylinder to the return passage (J).
TX,902505,BR125 1924MAR931/1
A
B
1915JAN98
T7879AD
TXC7879AD
9025
05
57
ABrake Disk CBacking Plate DAnnular Brake Piston EOil From Brake Valve
BFinal Drive Sun Pinion
Brake piston (A), backing plate (C), and disk (B) are (not shown). Anti-rotation pin prevents rotation of
located on each side of the transmission case final backing plate. Annular brake piston (D) seats against
drive. axle housing and is held in place by anti-rotation pins.
Force applied to a brake pedal unseats the appropriate When brakes are applied, oil pressure in annular
brake valve sending pressure oil (E), in proportion to passage forces piston out. Brake disk is squeezing
force applied, to the connected brake pistons. The against backing plate which stops rotation of disk and
right brake pedal operates the brake on the right-hand sun pinion.
side and the left brake pedal operates the left side.
Locking the pedals together provides simultaneous When force is removed, oil flows from annular pistons
braking on both sides. back through the brake valve and returns to the
hydraulic reservoir.
Brake disk (A) is tanged to final drive sun pinion (B).
Backing plate (C) seats against final drive ring gear
TX,902505,BS197 1903MAR931/1
PN=785
Theory of Operation
21
5
3
RWC20537
20
4
2
1
23
24
18
12
14
9025
13
05
12
22
58
19
9
22
17
11
13
13
8 15
16
10
6
UN20AUG98
7
16
RWC20537
1Pressure Oil Inlet 8Prefill Chamber 14Brake Chamber 20Bleed Orifice (LS)
2Inlet Check Valve 9Equalizing Passage 15Pin 21Check Ball (LS)
3Piston (LS) 10Pressure/Return Passage 16Relief Valve Ball 22To Right And Left Brake
4Capped Port (LS) 11Make-Up Check Valve 17Spool Valve Pistons
5Shuttle Valve (LS) 12Orificed Check Valve 18Return To Sump 23Pressure Oil
6Orifice Ring 13Annular Pressure Passage 19Equalizing Valve Land 24Return (Pressure Free) Oil
7Brake Piston
NOTE: The brake valve has a load sense (LS) feature Brake chamber (14) is connected to sump by passage
which is not used for this machine. Load sense (10). Oil in prefill chamber (8) returns to sump by
port (4) is closed using a cap. passing through drilled holes in forward land of brake
piston (7) and between orifice ring (6) and second land
Pressure oil (1) from main hydraulic pump opens inlet of piston.
check valve (2) to reach annular passage (13). Inlet
check valve is only required during manual braking. Orificed equalizing valve lands (19) are closed trapping
oil in equalizing passage (9).
With brake piston and spool in released position,
annular pressure passage (13) is closed to brake
chamber (14).
PN=787
Theory of Operation
23 PRESSURE OIL
24 RETURN OIL
18
22
1
20
2
21
3
13
12
9025 11
14
05
5
60
9
16
19
6
8
1915JAN98
TXC7879AE
T7879AE
Brake Released
TX,902505,BS198 1920DEC943/3
9025
05
61
PN=789
Theory of Operation
21
3
4
23 20
24 1 2
25
18
9025 14
05 22
62 12
12
9
13 19
22
17
11
15
13 8
13
16
UN11JUL00
6 10
RWC20540
7
16
NOTE: The brake valve has a load sense (LS) feature oil flows through spool valve, opens check valve (12)
which is not used for this machine. Load sense and is routed to annular brake piston at rear axle.
port (4) is closed using a cap.
Oil pressure on pin (15) unseats relief valve ball (16)
When brake pedal is depressed, piston (7) and spool providing passage to sump for oil trapped in prefill
valve (17) moves right closing off return at passage chamber.
(10). Equalizing valve land (19) opens to equalizing
passage (9). When both pedals are depressed, When pedal release begins, passage (10) closes to
equalization of pressure in chambers (14) occurs annular pressure passage (13) and orifice ring (6)
through passage (9). moves against forward land of piston, this opens prefill
chamber to sump (18). Brake chamber pressure (14)
Additional pedal travel aligns passage (10) in spool bleeds past shuttle valve (5), check ball (21) and bleed
valve with pressure oil annular passage (13). Pressure orifice (20) to sump.
PN=791
Theory of Operation
23 PRESSURE OIL
24 RETURN OIL
18
22
1
20
2
21
13
12
9025
05
64 11
14
16
17
9
19
6
8
1915JAN98
TXC7879AF
7
T7879AF
Brake Engaging
TX,902505,BS200 1920DEC943/3
9025
05
65
PN=793
Theory of Operation
21
5
3
RWC20539
20
4
2
1
23
24
18
12
9025
14
05
13
66
12
22
19
9
22
17
11
13
8 15
13
16
10
6
UN20AUG98
RWC20539
16
7
1Pressure Oil Inlet 8Prefill Chamber 14Brake Chamber 20Bleed Orifice (LS)
2Inlet Check Valve 9Equalizing Passage 15Pin 21Check Ball (LS)
3Piston (LS 10Pressure/Return Passage 16Relief Valve Ball 22To Right And Left Brake
4Capped Port (LS) 11Make-Up Check Valve 17Spool Valve Pistons
5Shuttle Valve (LS) 12Orificed Check Valve 18Return To Sump 23Pressure Oil
6Orifice Ring 13Annular Pressure Passage 19Equalizing Valve Land 24Return (Pressure Free) Oil
7Brake Piston
NOTE: The brake valve has a load sense (LS) feature When pedal is depressed, piston (7) and spool (17)
which is not used for this machine. Load sense move forward. Orifice ring (6) seats to rear closing
port (4) is closed using a cap. return passage. Oil trapped in pre-fill chamber (8)
forces make-up check valve (11) forward against
When main pump pressure is unavailable for braking, spring pressure. Oil from prefill chamber flows past
inlet check valve (2) prevents loss of oil from brake check valve (12) to differential to take up free play
circuit. between brake piston, disk and backing plate.
PN=795
Theory of Operation
23 PRESSURE OIL
24 RETURN OIL
18
22
1
20
2
21
3
13
9025
12
05
68
11
14
16
19
6
8
1915JAN98
TXC7879AG
7
T7879AG
Manual BrakingPrefill
TX,902505,BS202 1920DEC943/3
9025
05
69
PN=797
Theory of Operation
21
RWC20541
3
20
4
2
1
23
24
18
12
9025
14
05
70
13
22
12
19
9
22
17
11
13
8 15
13
16
6
UN20AUG98
10
16
RWC20541
7
1Pressure Oil Inlet 8Prefill Chamber 14Brake Chamber 20Bleed Orifice (LS)
2Inlet Check Valve 9Equalizing Passage 15Pin 21Check Ball (LS)
3Piston (LS) 10Pressure/Return Passage 16Relief Valve Ball 22To Right And Left Brake
4Capped Port (LS) 11Make-Up Check Valve 17Spool Valve Pistons
5Shuttle Valve (LS) 12Orificed Check Valve 18Return To Sump 23Pressure Oil
6Orifice Ring 13Annular Pressure Passage 19Equalizing Valve Land 24Return (Pressure Free) Oil
7Brake Piston
NOTE: The brake valve has a load sense (LS) feature If operator is unable to press pedal hard enough to
which is not used for this machine. Load sense reach relief valve setting, relief of prefill chamber is
port (4) is closed using a cap. accomplished as oil bleeds through end gap of orifice
ring (6). Pedal effort is transferred to smaller diameter
When pressure in prefill chamber (8) reaches relief of spool.
valve setting, ball (16) is unseated reducing pressure
in prefill chamber. As pressure drops in prefill When pedal is released, orifice ring seats against
chamber, make-up check valve (11) is seated by forward piston land opening sump passage to pre-fill
spring and oil pressure. As pedal moves further, chamber. Relief valve ball (16) reseats. Oil is drawn
pressure increases in brake chamber (14), sensing pin past orifice ring into prefill chamber from return line as
(15) fully opens valve ball (16) relieving pressure in piston retracts. Smaller orificed check valve (12) slows
prefill chamber to sump. return of oil from rear axle to allow pumping action to
fill chambers.
Further pedal travel now works against smaller
diameter of spool (17) producing higher pressure
required to apply brakes.
9025
05
71
PN=799
Theory of Operation
23 PRESSURE OIL
24 PRESSURE OIL
18
22
1
20
2
21
13
12
9025
05
11
72
14
16
9
19
6
8
1915JAN98
7
TXC7879AH
T7879AH
Manual BrakingEngaging
TX,902505,BS204 1920DEC943/3
9025
05
73
PN=801
Theory of Operation
9025
05
74
1904FEB99
T117162
ADisk (4 used) DFrom Brake Valve FAdjusting Screw HSun Gear Shaft
BPlate (4 used) EBrake Housing GHub IService Brake
CPiston
The rear axle assembly uses wet multi-disk brakes against the brake plates (B) and disks (A) which stops
which are self-adjusting to compensate for wear. The rotation of the sun gear shaft (H). When the brakes are
disks are splined to the sun gear shaft and the plates released the return oil flows back out the same port to
are splined to the rear axle housing. the brake valve.
TX,05,SS3133 1916MAY962/2
9025
05
75
PN=803
Theory of Operation
The brake system is hydraulic with no mechanical Two accumulators provide pressure oil for secondary
connection between the brake valve and the brake braking. A pressure switch will alert operator with light
pressure plates. It consist of two accumulators which and audible warning if pressure is below specification.
are sourced from system pressure oil from the
stabilizer valve. The brake valve is a full power valve When the brakes are engaged, the brake piston
with equalization. applies force on the brake disks and plates which are
connected to the final drive pinion shaft.
The brake valve is activated by two brake pedals that
allow individual or simultaneous operation of brake
pressure pistons that are located in the brake housing
of each axle.
TX,05,SS3131 1923JUL981/1
9025
05
76
9025
05
77
PN=805
Theory of Operation
12 19
14 17
9
8 22
8
UN07JAN99
11 16
20
13 10 15 21 18
T118962
T118962
9025
05
78
13 14 15 16 17 18
12 19
11 20
10 21
9
8 22
7
23
6
5 24
4 25
3 26
2 27
1 28
1911JAN99
T118980
LEFT 31 BRAKES RELEASED RIGHT
Continued on next page CED,TX03610,138 1919MAR991/2
Oil pressure from the accumulators enters pressure moving through the valve. All other internal chambers
ports (11 & 20). Pressure switches connected to ports and brake ports (9 & 22) are connected to the
(13 & 18) sense pressure in each accumulator through reservoir via the tank port (8). The pedals are held in
the valve. Spools (12 & 19) block oil pressure from the neutral position by springs (7 & 23).
CED,TX03610,138 1919MAR992/2
9025
05
79
PN=807
Theory of Operation
12 19
14 17
9
22
8 8
UN16DEC98
11 16
20
13 10 15 21 18
T118979
T118979
9025
05
80
13 14 15 16 17 18
12 19
11 20
10 21
9
8 22
7
23
6
5 24
4 25
3 26
2 27
1911JAN99
1 28
29 HIGH PRESSURE OIL
30 LOW PRESSURE OIL
T118981
T118981
LEFT 32 BRAKES ENGAGED RIGHT 31 RETURN OIL
Continued on next page CED,TX03610,139 1919MAR991/2
Oil under pressure from accumulators enters pressure (21) closes and shuttle ball (16) moves to close off the
ports (11 & 20). Both pedals are depressed forcing lower right side pressure. The higher pressure from the
spools (12 & 19) to move through springs (1 & 4) and left spool (12) moves through orifice (17) to increase
(25 & 28) respectively. When the spools travel a short the right brake pressure to equal that of the left brake.
distance, the brake ports (9 & 22) become blocked to The maximum pressure that can be reached in the
tank and are then pressurized by oil moving through brakes is limited by the force of springs (1 & 28)
spools (12 & 19), through check balls (10 & 21), again regardless of higher accumulator pressures or pedal
through spools (12 & 19) and to brake ports (9 & 22). force. The maximum brake pressures are set by shims
Pressure modulation to each brake is regulated by (3 & 26) on retainers (2 & 27). The brake light switch
springs (25 & 28) for the right brake and (1 & 4) for the is connected to port (15) and will see the higher
left brake. If the right side spool (19) is regulating modulated brake pressure of either side.
pressure lower than the left side spool (12), check ball
CED,TX03610,139 1919MAR992/2
9025
05
81
PN=809
Theory of Operation
12 19
14 17
9
22
8 8
UN16DEC98
11 16
20
13 10 15 21 18
T118978
T118978
9025
05
82
13 14 15 16 17 18
12 19
11 20
10 21
9
8 22
7
23
6
5 24
4 25
3 26
2 27
1 28
1911JAN99
T118982 RIGHT
(RIGHT ONLY) 31 RETURN OIL
LEFT
Continued on next page CED,TX04577,834 1918DEC981/2
Oil under pressure from the accumulators enters check ball (21), again through spool (19) and to the
pressure ports (11 & 20). The right pedal is depressed right brake port (22). Brake pressure is blocked from
forcing spool (19) to move through springs (28 & 25). entering the left brake by check ball (10), shuttle ball
Spool (12) remains in the neutral position blocking (16), and spool (12). Pressure modulation is regulated
accumulator pressure from moving through the valve by springs (25 & 28). The maximum pressure to the
and the left brake port (9) remains at tank pressure. right brake is limited by the force of spring (28)
When spool (19) travels a short distance, the right regardless of higher accumulator pressures or pedal
brake port (22) becomes blocked to tank and is force. The brake light switch connected to port (15) will
pressurized with oil moving through spool (19), through see the right brake pressure.
CED,TX04577,834 1918DEC982/2
9025
05
83
PN=811
Theory of Operation
L PARK BRAKE
DIFFERENTIAL
LOCK VALVE
DUST B SEALS
A
SEAL
C PISTON
9025
05
84
D ADJUSTING
SCREW
J F COVER
PADS
I G
H
SHAFT SNAP RING
SPRING
WASHERS M RETURN PRESSURE OIL
1915JAN98
ADust Seal ELock Nut JPark Brake Pads MReturn Pressure Oil
BSeals FCover KPark Brake Disc NHigh Pressure Oil
CPiston GSnap Ring LPark Brake/Differential OEngagement Pressure Oil
DParking Brake Adjusting HSpring Washers Lock Valve PParking Brake
Screw IShaft
NOTE: For (S.N. 872329 ) see Section 9020 for and the return of oil to reservoir is blocked. This
operation and test procedures for the park causes the piston to move against the spring washers
brake. (H) which releases the force on the shaft (I) and the
park brake pads (J). As the pressure on the pads is
The parking brake (P) is spring applied and hydraulic released, the parking brake disc (K) is free to turn and
released. When the operator actuates the park brake the machine can move.
switch to the "on" position or shuts the machine off,
spring washers (H) force the piston (C) against the To release the parking brake following machine
shaft (I). This force causes the park brake pads (J) to shut-down with the switch in the off position, the switch
be compressed against the parking brake disc (K) must be cycled from "off" to "on" then back to "off"
which is attached to the axle input shaft. When the after the engine is started.
park brake is applied, engagement of the brake pads
with the brake disc prevents machine movement. If required, the parking brake can be manually
released to allow movement of the machine if the
When the operator moves the parking brake switch to engine cannot be started. Remove cover (F), loosen
the "off" position with the engine running, two lock nut (E) and turn out parking brake adjustment
solenoids that are located on the park brake/differential screw (D) until brake disc is released by the brake
lock valve (L) are energized simultaneously. Main pads. The adjusting screw must be turned back in to
hydraulic pressure oil (N) is routed to the piston (C) allow the parking brake to engage.
9025
05
85
TX,902505,BS185 1920DEC942/2
PN=813
Theory of Operation
F OIL SEAL
J
PRESSURE
REDUCING VALVE
1915JAN98
A HIGH PRESSURE OIL
SEALING
G RINGS B ENGAGEMENT PRESSURE OIL
C RETURN OIL
T8381BD
9025
TXC8381BD L DIFFERENTIAL LOCK OPERATION
05
86
AHigh Pressure Oil EOil Seal HCapture System Return JPressure Reducing Valve
BEngagement Pressure Oil FOil Seal IPark Brake/Differential Lock KDifferential Lock Solenoid
CReturn Oil GSealing Rings Valve LDifferential Lock Operation
DDifferential Lock Piston
NOTE: For (S.N. 872329 ) see Section 9020 for Engagement of the differential lock occurs when the
operation and test procedures for the differential lock solenoid is energized. Oil is allowed to
differential lock. flow past the energized valve and engagement
pressure (B) is routed between internal sealing rings
The hydraulic differential lock is supplied with high (G) to move the differential lock piston (D).
pressure oil (A) by the main hydraulic system. A
pressure reducing valve (J) and a differential lock Oil that seeps past the sealing rings is contained by
solenoid valve (K) are located on the park the outer oil seals (E) and (F), and is return oil (C) that
brake/differential lock valve (I) to control oil pressure is routed to reservoir through the capture system
and flow required for engagement. return passage (H).
When the differential lock is not engaged, oil flow to Refer to CTM43 for additional details on differential
the differential lock piston (D) is blocked and the lock and axle assembly.
passage to the piston is open to return. Normal
differential action occurs when the differential lock is
not activated.
TX,902505,BS186 1920DEC941/1
9025
05
87
PN=815
Theory of Operation
D E
C B G
H
I
N O
P
L M
K
W
R Q
ADifferential Lock Solenoid FP2 Port LPark Brake Work Port SHigh Pressure Oil
Valve GPark Brake Solenoid MDifferential Lock Test Port TReduced Pressure Oil
BPark Brake Solenoid Valve-Normally Closed NRelief Valve UReturn Oil
Valve-Normally Open HPressure Reducing Valve OOrifice VPark Brake/Differential
CP3 Port IReturn To Drain PCheck Valve Lock Valve
DP1 Port JDifferential Lock Work Port QPark Brake WThermal Relief Valve
EService Brakes Work Port KPark Brake Pressure RDifferential Lock
Sensing Switch
NOTE: For (S.N. 872329 ) see Section 9020 for park brake. Since the "normally open" park brake
operation and test procedures for the solenoid valve (B) is energized at the same time and
differential lock and park brake. becomes "closed", oil is prevented from returning to
reservoir and pressure increases to release the park
The park brake/differential lock valve is mounted on brake.
the right frame member below the cab and receives oil
directly from the main hydraulic pump at P3 port A thermal relief valve (W) is located in the park brake
(SN830204) or at P1 port (SN 830205 ). pressure port (L). The relief valve prevents excessive
Solenoid valves control the internal flow of oil that pressure build-up from thermal expansion in the park
operates the park brake and differential lock functions. brake circuit.
Incoming oil is routed to the park brake solenoid valve Park brake pressure is sensed at a switch (K) which
(G) that is normally closed when de-energized and the de-activates a light on the control panel when the
park brake is "on". Therefore oil is prevented from brake is "off". Relief valve (N) is in the park brake
flowing to the park brake. circuit to protect against excessive pressure build-up
on trapped oil due to heat and expansion.
Another park brake solenoid valve (B) is normally
"open" when de-energized, which allows oil within the By energizing the differential lock solenoid valve (A)
park brake to return to reservoir. This results in the reduced pressure oil (T) is allowed to flow to the rear
spring applied, hydraulic release park brake becoming axle for differential lock engagement. When 9025
05
engaged to prevent the machine from moving. disengaged return oil flows back through the
89
de-energized solenoid and is routed to reservoir.
When the park brake switch is moved to the "off"
position with the engine running, the normally closed High pressure oil is (S) provided the service brakes
park brake solenoid valve (G) is energized and from the inlet galley through the service brake work
becomes "open". This allows pressure oil to flow port (E).
through an orifice (O) and a check valve (P) to the
TX,902505,BS187 1920DEC942/2
PN=817
Theory of Operation
9025
05
90
Excessive Steering Wheel Turns Steering cylinder leakage. Do Steering System Leakage Check.
to Steer Machine (See Group 9025-10.)
Erratic ("Spongy") Steering Air in system. Check oil level. Check for cavitation
in charge system.
Steering Wheel "Locks" Up Debris in gerotor section. Disassemble and inspect. Flush.
PN=819
Diagnostic Information
Steering Wheel Turns Freely But Steering column shaft broken. Replace.
No Wheel Movement
No oil in steering valve. Can happen Verify and repair the cause of no oil.
when starting machine after a repair. Operate valve to purge air from
system.
Poor Centering of Steering Wheel High back pressure in return line. Remove line, inspect. Replace.
(Wheels Continue to Move After
Steering Wheel is Stopped)
Steering Wheel Oscillates Or Parts assembled wrong (steering Disassemble, inspect and
Turns By Itself After Starting valve improperly timed) reassemble.
Machine
WanderVehicle Will Not Stay in Air in the system due to low level of Inspect and correct.
a Straight Line. oil, cavitating pump, leaky fitting,
pinched hose.
Severe wear in steering control unit. Replace the steering control unit.
DriftVehicle Veers Slowly in Worn or damaged steering linkage. Replace linkage and align front end
One Direction (toe-in).
"Spongy" or Soft Steering. Low fluid level. Add fluid and check for leaks.
Steered Wheels Turn in Wrong Lines connected to wrong cylinder Inspect and reconnect correctly.
Direction When Operator ports.
Activates Steering Wheel.
Steering Wheel Kicks at Start of Inlet check valve in steering valve Check and repair.
9025
Steering. stuck open. 15
3
T60,9025,C148 1924MAY933/3
PN=821
Diagnostic Information
Charge pump belt. (SN 830204) Inspect and replace. See Repair
Manual.
Slow Hydraulics (Low Pump Hydraulic filter restricted. Inspect and replace filter. See
Output) Repair Manual.
9025 Priority valve stuck or orifice in spool Check hydraulic functions. If only
15 plugged. loader is affected, problem is priority
4 valve.
Surge relief valve stuck open. Remove and inspect surge relief
valve. See Repair Manual.
System Relief valve too low. Do System relief Valve Test. (See
Group 9025-25.)
Stroke control valve seat, spring, or Inspect valve. See Repair Manual.
packing.
Crankcase relief valve stuck closed. Inspect valve. See Repair Manual.
Main pump discharge valve worn. Do Cycle Time Test. (See Group
Inlet valve broken or leaking. Worn 9025-25.)
pistons.
Low Hydraulic Power (Low Low oil level (aeration of oil) Add oil. (See Group 9000-04.)
Hydraulic Pressure)
Stroke control valve setting too low. Do Main Pump Standby Pressure
Test. (See Group 9025-25.)
Low charge flow due to filter relief Do Charge Pump Pressure Check
valve stuck or setting too low, or and Transmission Pump Flow Test
restriction in filter base or lines. Group. (See Group 9025-25.)
Hydraulic Function (Or Pump) Low oil level (pump cavitation). Check and add oil. (See Group
Makes "Chatter" Noise 9000-04.)
PN=823
Diagnostic Information
Pump cavitation during combined full This is normal in full cycle operation
cycle crowd and bucket curl. of both functions. Function not used
in actual digging operation.
Wrong circuit relief valve (without Inspect relief valves. See Repair
anti-cavitation valve) installed in Manual.
backhoe valve.
Excessive Pump Noise Low oil level. Add oil. (See Group 9000-04.)
Charge pump belt slipping. (SN Inspect and repair. See Repair
830204) Manual.
Stroke control valve seat, spring or Inspect valve. See Repair Manual.
packing.
9025
Pump pistons sticking. Inspect pistons. See Repair Manual. 15
7
Outlet valve broken. Inspect valve. See Repair Manual.
Hydraulic System Overheats Reservoir overfilled with oil. Check oil level. (See Group
9000-04.)
Charge pump belt slipping. (SN Inspect and repair. See Repair
830204) Manual.
PN=825
Diagnostic Information
Oil cooler and radiator air flow Do Air Flow Test. (See Group
restricted. 9010-25.)
Wrong oil (viscosity too low) Verify type of oil. Change oil. (See
Group 9000-04.)
Incorrect circuit relief valve, low relief Do Circuit Relief Valve Pressure
valve setting, or broken spring in Test. (See Group 9025-25.)
relief valve.
710D,DS4165 1903MAR936/6
9025
15
9
PN=827
Diagnostic Information
Poor or No Brakes (steering and Air in system. Check for damaged O-ring or lines.
hydraulic system operation
normal)
Brakes Will Not Release Or Drag Brake valve sticking. Remove, inspect and repair. See
Repair Manual. (Spool valve and
housing are matched.)
Work port orifice plugged. (S.N. Remove, inspect, clean. See Repair
872256) Manual.
Manual Brakes Do Not Build Inlet check valve leaking. Replace. See Repair Manual.
Pressure (S.N. 872329)
With Pedals Locked Together Equalization orifice plugged. Remove spool valve, clean and
Machine Does Not Stop in replace.
Straight Line
Brakes Dragging (S.N. 872328 ) Improper Adjustment Do Service Brake Valve and Pedal
Adjustment. (See Group 9025.25)
Brake Single Pedal Drift (S.N. Leaking shuttle valve check in brake Inspect and Repair. See Repair
872328 ) valve. Manual
T60,9025,C198 1903MAR932/2
9025
15
11
PN=829
Diagnostic Information
No Differential Lock Operation Differential lock pressure regulating Do Differential Lock Pressure
valve stuck open or spring broken. Regulating Valve Test See Group
(S.N. 872256) 9025-25. Remove and inspect
regulating valve.
Differential Lock Chatters When Excessive differential lock sealing Do Park Brake/Differential Lock
Engaged ring leakage Valve Leakage For (S.N. 872329)
see Group 9025-25. For (S.N.
872256 ) see 9020-25
Differential lock regulating valve seal Remove and inspect seals. (See
Repair Manual, Group 1160.)
PN=831
Diagnostic Information
Differential Lock Chatters When Warped differential lock disks and Disassemble, inspect, and repair.
Disengaged plates For (S.N. 872256) see CTM43.
For (S.N. 872329 ) see Repair
Manual Section 02.)
Differential Overfilled With Oil Differential lock pressure oil leaking Remove differential check plugs and
at piston seals, capture seals, or check leakage with differential lock
around differential bearing cup engaged.
Brake disk and/or brake shoes worn Disassemble, inspect, repair. (See
Repair Manual, Group 1111.)
Thermal relief valve will not open. Replace. See Repair Manual.
Park Brake Disk Overheats Incorrect park brake adjusting screw Adjust park brake. (See Group
torque. 9025-20.)
Thermal relief valve will not close. Replace. See Repair Manual.
Park Brake Will Not Apply Incorrect park brake adjusting screw Adjust park brake. See Group
torque. For (S.N. 872329) 9025-25.
Thermal relief valve will not open. Replace. See Repair Manual.
TX,902515,BS206 1920DEC944/4
9025
15
15
PN=833
Diagnostic Information
9025
15
16
UN06OCT92
Belt Strand (without Air 311 N (70 lb force)
Conditioning) Tension (Used)
Belt Strand (with Air Conditioning) 623800 N (140180 lb force)
Tension (New)
T7861AF
Belt Strand (with Air Conditioning) 356512 N (80115 lb force)
Tension (Used)
Specification
Belt Strand (without Air
Conditioning)Tension (New) ................................... 445 N (100 lb force)
Belt Strand (without Air
Conditioning)Tension (Used) .................................... 311 N (70 lb force) 9025
Belt Strand (with Air 20
Conditioning)Tension (New) ............... 623800 N (140180 lb force) 1
Belt Strand (with Air
Conditioning)Tension (Used) ................ 356512 N (80115 lb force)
TX,9025,DS4173 1903MAR931/1
PN=835
Adjustments
1915OCT92
3. Measure gap (A) between guard and stop (B) and bell
crank (C). Gap should be 1 mm (0.04 in.).
T7864AE
4. If gap is not to specification, adjust rod jam nut and
yoke (D) to obtain correct gap. Allow bucket lever to
return to neutral position.
5. Measure gap (E) between top of bell crank pin (F) and
top of actuator tang (G). Gap should be 130 mm (5.1
in.).
1915OCT92
T7864AD
UN09NOV88
10. Tighten cap screw without moving switch.
T87154
12. While watching clearance between cam and switch,
turn command pointer back and forth to be sure cam ACap Screw
does not hit switch bracket. BRoller
CArea on Cam
NOTE: Be sure that switch arm and roller does not
bottom on switch housing.
TX,9025,DS4174 1903MAR932/2
9025
20
3
PN=837
Adjustments
1914SEP92
T7799CW
9025
20
4
ADust Seal ELock Nut HSpring Washers KParking Brake Disk
BSeals FCover IShaft LCap Screw
CPiston GSnap Ring JPark Brake Pads
DParking Brake Adjusting
Screw
1. Park machine on level surface. NOTE: If this is the initial installation of new park
brake pads, install the four mounting screws
2. Lower bucket to ground. but do not tighten them.
Specification
CAUTION: Prevent possible injury from Brake Pad Assembly
unexpected machine movement. Never rely Minimum Thickness .................................................. 9 mm (0.354 in.)
on loader bucket to keep machine from Pad-to-Disk Running
moving. Machine can unexpectedly roll, Maximum Clearance ............................................ 4.76 mm (0.187 in.)
Pad-to-Disk RunningMinimum
resulting in death or serious injury. Always Clearance............................................................... 0.5 mm (0.020 in.)
block wheels to hold machine when working
on park brake. 5. Remove three park brake adjustment cover cap
screws (L) and cover (F). Loosen lock nut (E).
3. Stop engine. This will engage park brake.
6. Tighten park brake adjustment screw (D) to 100 8. Turn park brake adjustment screw counterclockwise
Nm (75 lb-ft). 1/2 turn (180).
7. If a new brake assembly is being installed, tighten 9. Hold adjusting screw (D) and tighten lock nut (E).
brake assembly mounting cap screws to 70 Nm
(50 lb-ft). 10. Install cover and tighten cap screws (L).
TX,9025,DS4176 1903MAR932/2
Specification
UN13DEC90
Service Brake Inspection
Thickness (New) ......................................................... 7.57 mm (0.298 in.)
RW18679
on facing material are no longer visible. (See Repair
Manual.)
9025
ABrake Inspection Port 20
5
TX,2520,DS4307 1903MAR931/1
PN=839
Adjustments
UN01OCT98
external inspection ports (A).
Specification
Service Brake Inspection
T117539
Thickness (New) ......................................................... 7.24 mm (0.285 in.)
2. Remove axle housing and replace brakes if oil grooves External Inspection Ports
(B) on facing material are no longer visible. (See
Repair Manual.)
9025
20
6
UN03DEC93
T8137AC
9025
20
7
PN=841
Adjustments
Specification
UN04JAN99
Brake Pedal Leveling
AdjustmentClearance ............................. 2022 mm (.07870.866 in.)
AStop Screw
T118050
BJam Nut
CLeveling Adjustment Dimension
DLock Bar Pedal Leveling Adjustment
9025
20
8
2.
UN28OCT98
3. Disengage locking bar in brake pedal. Depress right
pedal 31.8 mm (1.25 in.) and measure distance (D)
using a straight edge or ruler. Measure from edge of
one pedal to other pedal as shown. Note pressure
T118051B
reading on gauge when pedal has been depressed
down one inch travel dimension (D).
Specification
Brake Valve Pressure Setting
Pressure ............................................................ 689 kPa (7 bar) (100 psi)
Brake Pedal Linkage
AdjustmentDistance .................................................. 31.8 mm (1.25 in.)
UN02FEB99
to obtain correct pressure setting.
5. Scribe a line (B) on jam nut (C) and push rod (A) for
ease of adjustment
T118819
6. Loosen jam nut on push rod. Adjust as required being
Brake Pedal Linkage Adjustment
careful not to tear boot. Note, one flat on jam nut
equals approximately 25 psi. Tighten jam nut to APush Rod 9025
specification. BScribe Line 20
CJam Nut 9
Specification DPedal Travel (Pressure Setting Positon)
Jam NutTorque ............................................................ 45 Nm (33 lb-ft)
CED,TX04577,768 1921SEP982/2
PN=843
Adjustments
UN15OCT92
Cab and other components have been removed in
some photographs for clarity.
T7861AD
1. Put backhoe valve spools in neutral position.
UN30OCT90
Distance should be 190 mm (7.5 in.).
T7407AJ
5. Measure from edge of knobs to tape. Distance (B)
should be 140 mm (5.5 in.). Knobs should be 250 mm
(9.8 in.) apart.
9025
20
10
TX,9025,DS4178 1903MAR931/1
ARod
BTab
UN14NOV90
5. Put a piece of masking tape from left front to right front
ROPS posts on inside surface at loader knob height.
T7407AO
6. Distance (C) from front of knob to tape should be 130
mm (5.1 in.).
UN30OCT90
C130 mm (5.1 in.)
D250 mm (9.8 in.)
EAdjusting Rod
FPivot
T7407AP
9025
20
11
UN30OCT90
T7407AQ
TX,9025,BG231 1906JAN972/2
PN=845
Adjustments
UN30OCT90
some photographs for clarity.
T7407AK
2. Adjust linkage rods (A) to position tabs (B) vertically.
UN30OCT90
necessary.
ALinkage Rods
BTab
T7407AL
C260 mm (10.2 in.)
D295 mm (11.6 in.)
9025
20
12
UN30OCT90
T7407AM
TX,9025,DS4180 1903MAR931/1
UN17JAN89
TS225
09T,2160,K5 1912MAY941/1
UN28FEB89
connect to a straight section of injection line within 100 mm (4 in.) of
pump. Finger tighten only. DO NOT overtighten.
BBlack Clip (-). Connect to main frame.
CRed Clip (+). Connect to transducer.
T6813AG
DTachometer Readout. Install cable.
9025
25
1
10T,9010,K182 1910AUG951/1
BCable
CDigital Thermometer
T6808CE
902525,AA4 1928FEB951/1
PN=847
Tests
UN23AUG88
penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
X9811
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
UN17SEP92
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.
T7839AA
2. Disconnect boom cylinder rod end hose (A) from
control valve, and boom cylinder head end hose (B)
from boom cylinder.
9025
25 3. Connect boom cylinder rod end hose (A) to cylinder
2
head end port and boom cylinder head end hose (B) to
control valve.
TX,902525,BS159 1903MAR931/1
ESSENTIAL TOOLS
a
RE25493 Manual Destroke Assembly
a
Order from John Deere parts system.
27T,9025,M100 1916OCT911/2
2. Remove grille.
UN20MAR90
assembly.
T6900AG
9025
25
3
UN20MAR90
T6900AH
27T,9025,M100 1916OCT912/2
PN=849
Tests
AGround Clamp
BPower Cable
CInjection Pump
DSwitch Box
EConnector
FMain Hydraulic Pump
UN26OCT88
T6900AI
27T,9025,M101 1916OCT911/1
9025
25
4
PN=850
Tests
SPECIFICATIONS
Oil Temperature 66 4C (150 7F)
Engine Speed WOT
Charge Minimum Pressure 827 138 kPa (8 1.4 bar) (120
UN26SEP91
20 psi)
ESSENTIAL TOOLS
JT05494 (7/16-20 M 37 x 3/4-16 ORB) AAdapter
T7615AF
JT05490 (7/16-20 M 37 x 3/8-24 M ORB) BAdapter
UN26OCT88
(See procedure in this group.)
T6900AF
3. Heat hydraulic oil to test specifications. (See procedure
in this group.)
9025
Specification 25
OilTemperature ..................................................... 66 4C (150 7F) 5
Specification
EngineSpeed .................................................................................. WOT
ChargeMinimum Pressure ................... 827 138 kPa (8 1.4 bar) (120
20 psi)
TX,902525,BS160 1908NOV011/1
PN=851
Tests
ESSENTIAL TOOLS
JT05690 (1-1/16-12 M 37 x -12 F ORFS) AAdapter
UN26OCT88
damage to charge pump.
T6900AM
4. Apply park brake. Start engine and warm oil to
specification (see procedure in this group or use
9025
25 flowmeter).
6
Specification
OilTemperature ..................................................... 40 4C (104 7F)
Specification
EngineSpeed ............................................................................ Fast idle
ChargeMinimum Flow ............................................. 102 L/min (27 gpm)
TX,902525,BS161 1903MAR931/1
9025
25
7
PN=853
Tests
UN23OCT98
T117960
9025
25
8
AUnion
IMPORTANT: Flowmeter must be open to prevent Do Surge Relief Valve Pressure Test in this
damage to charge pump. group.
CED,TX03610,140 1919MAR991/1
SPECIFICATIONS
Oil Temperature 40 4C (104 7F)
Engine Speed Fast Idle
Surge Relief Pressure 827 140 kPa (8.2 1.4 bar)
UN12NOV92
(120 20 psi)
ESSENTIAL TOOLS
JT05494 (7/16-20 M 37 x 3/4-16 ORB) AAdapter
T7888AA
SERVICE EQUIPMENT AND TOOLS
BHose
CGauge 02000 kPa (020 bar) (0300 psi)
Digital Thermometer
DVice Grips
Specification
OilTemperature ..................................................... 40 4C (104 7F)
9025
1. Apply park brake.
25
9
2. Install gauge (C) and digital thermometer.
UN26OCT88
pressure. (Surge relief is not adjustable or repairable,
see group 2160 to replace.)
Specification
T6900AN
EngineSpeed ............................................................................ Fast idle
Surge ReliefPressure .............................. 827 140 kPa (8.2 1.4 bar)
(120 20 psi)
AAdapter
BHose
CGauge
DCooler Hose
ESurge Relief Valve
TX,902525,BS162 1903MAR931/1
PN=855
Tests
UN07FEB90
(2550 50 psi)
ESSENTIAL TOOLS
JT05490 (7/16-20 M37 x 3/8-24 M ORB) AConnector
T93021
202850 (7/16-20 F 37 x 1/8) BNipple Adapter
JT05491 (7/16-20 M 37 x 14 M x 1.5 M ORB) EConnector
UN26OCT88
DGauge 034 500 kPa (0345 bar) (05000 psi)
T6900AO
AConnector
BAdapter
CHose
DGauge
9025 EConnector
25 FAdjusting Screw
10
UN23AUG88
1. Operate all hydraulic control valves to release pressure
in the hydraulic system. Install electronic tachometer
and digital thermometer. (See procedure in this group.)
X9811
2. Connect hose and gauge to main pump or backhoe
valve. Heat oil to specifications. (See procedure in this
group.)
Specification
OilTemperature ..................................................... 40 4C (104 7F)
Specification
EngineSpeed .................................................................. 2000 25 rpm
StandbyPressure............................... 17 580 350 kPa (176 3.5 bar)
(2550 50 psi)
TX,9025,BR526 1903MAR932/2
PN=857
Tests
UN23AUG88
connections before applying pressure.
SPECIFICATIONS
Oil Temperature 65 5C (150 + 10F)
X9811
Engine Speed 2000 10 rpm
Oil Pressure 13 790 69 kPa (138 0.7 bar)
(2000 10 psi)
Acceptable Minimum Flow 170 L/min (45 gpm)
710D Oil Pressure 15 170 kPa (151.7 bar) (2200 psi)
710D Oil Pressure 15 860 kPa (158.6 bar) (2300 psi)
710D Oil Pressure 16 550 kPa (165.5 bar) (2400 psi)
Standby Oil Pressure 17 580 kPa (175.8 bar) (2550 psi)
ESSENTIAL TOOLS
JT15073 (1-1/16 Male JIC x 1-5/16-12 Male ORB) Connector
Specification
OilTemperature ................................................... 65 5C (150 + 10F)
Specification
EngineSpeed .................................................................. 2000 10 rpm
UN25MAY89
Subtract recorded flow rates from rate recorded at 13 790
kPa (138 bar) (2000 psi) during first part of test.
Specification
T6264AH
OilPressure ......................................... 13 790 69 kPa (138 0.7 bar)
(2000 10 psi)
9025
Flow rate should not decrease by more than 7.5 L/min AJT15073 Connector (2 used) 25
(2.0 gpm) until pump pressure is within 2069 kPa (207 BHose (2 used) 13
bar) (300 psi) of standby pressure, then decrease sharply CFlowmeter
as pump destrokes. DLoading Valve
EBackhoe Valve
Specification
AcceptableMinimum Flow ....................................... 170 L/min (45 gpm)
TX,9025,BR527 1903MAR932/2
PN=859
Tests
SPECIFICATIONS
Oil Temperature 40 4 C (104 10F)
Engine Speed High Idle
Steering Against Stops Pressure 17 581 345 kPa (175 3.5 bar)
UN14SEP92
(2550 50 psi)
Steering in Neutral Pressure 2068 kPa (20 Bar) (300 psi)
Steering Against Stops and 17 581 345 kPa (175 3.5 bar)
(2550 50 psi)
T7845AA
Loader Boom Raising Pressure
ESSENTIAL TOOLS
-8 ORFS (Parker No. 8R6LOS) Swivel Run Tee
PN=860
Tests
UN23AUG88
1.
X9811
2. Start engine and heat hydraulic oil to specifications.
(See procedure in this group.)
Specification
OilTemperature .................................................. 40 4 C (104 10F)
Specification
EngineSpeed ............................................................................ High Idle
Steering Against Stops
Pressure .............................................. 17 581 345 kPa (175 3.5 bar)
(2550 50 psi)
Steering in NeutralPressure....................... 2068 kPa (20 Bar) (300 psi)
Steering Against Stops and
9025
Loader Boom RaisingPressure ......... 17 581 345 kPa (175 3.5 bar)
25
(2550 50 psi)
15
TX,902525,BS165 1903MAR932/2
PN=861
Tests
UN23AUG88
connections before applying pressure.
SPECIFICATIONS
Oil Temperature 40 6C (100 10F)
X9811
Engine Speed Slow Idle
"LS" Port Flow 700 100 mL/min (.18 .03
gpm)
ESSENTIAL TOOLS
38H1414 (-4 F ORFS) (Parker No. FNL-S) Cap
UN17SEP92
JT05801 Electronic Tachometer
JT05800 Digital Thermometer
Measuring Container
T7849AA
Stop Watch
Specification
OilTemperature ................................................... 40 6C (100 10F)
Specification
EngineSpeed ............................................................................ Slow Idle
Specification
"LS" PortFlow ............................................ 700 100 mL/min (.18 .03
gpm)
TX,902525,BS167 1903MAR931/1
9025
25
17
PN=863
Tests
ESSENTIAL TOOLS
203654 (7/16-20 M 37 x 1/2 M NPT) GConnector
JT03348 (1/2 F NPT) HTee (2 used)
JT03212 (1/2 I.D. Hose x 1/2 M NPT) IAdapter (6 used)
JT03070 (1/2 F NPT 1-1/6-12 F 37 SW) JCoupler (2 used)
UN07APR89
AHydraulic Analyzer
BGauge 01000 kPa
CGauge Port
DCooler-In
ECooler-Out
T6908BG
FSwitch Unit
GFitting
HTee
IBarb Fitting
JFitting
KFlowmeter
Specification
OilTemperature ................................................... 65 4C (150 10F)
Specification
EngineSpeed ........................................................................... 2000 rpm
OilFlow .................................................................. 68.1 L/min. (18 gpm)
Specification
Gauge DifferenceMaximum
Pressure Drop .................................................. 586 kPa (5.8 bar) (85 psi)
Gauge DifferenceMinimum
Pressure Drop .................................................. 517 kPa (5.1 bar) (75 psi)
TX,902525,BS169 1903MAR932/2
PN=865
Tests
Specification
OilTemperature ................................. 40 10C (100 20F) (cylinders
warm to touch)
UN25MAY89
Position wheels straight ahead, measure and record
steering cylinder rod length sticking out of cylinder.
T6076AN
at fast idle.
TX,902525,BR119 1906APR941/1
SPECIFICATIONS
Oil Temperature 40 10C (104 20F) (cylinders
warm to touch)
Engine Speed Low Idle
UN26MAY89
Cylinder Maximum Drift 7 mm/min (0.28 in./min)
T6222AM
Specification
OilTemperature ................................. 40 10C (104 20F) (cylinders
warm to touch)
UN26OCT88
using machine weight. Measure and record cylinder
rod extension.
T6222AN
cylinder rod in one minute. Record measurement.
Specification
EngineSpeed ............................................................................. Low Idle
9025
5. Compare to specification. 25
21
Specification
CylinderMaximum Drift...................................... 7 mm/min (0.28 in./min)
T60,9025,1073 1924MAR931/1
PN=867
Tests
UN26OCT88
Steering System Maximum 5 rpm
Leakage
ESSENTIAL TOOLS
T93024
38H1145 (4 ORFS) Plug (2 used)
38H1352 (4 ORFS) Nut (2 used)
38H1138 (4 ORFS) Plug (2 used)
Specification
OilTemperature ................................................... 65 5C (150 10F)
Specification
EngineSpeed ............................................................................. Low Idle
Specification
Steering WheelTorque ........................................... 11.3 Nm (100 lb-in.)
Specification
Steering WheelTorque ........................................... 11.3 Nm (100 lb-in.)
Specification
Steering SystemMaximum
Leakage ............................................................................................. 5 rpm
PN=869
Tests
UN23AUG88
13. Disconnect hydraulic lines from steering cylinder and
install caps (B) and plugs (A).
X9811
15. Turn steering wheel counterclockwise and then
clockwise at a constant torque of 11.3 Nm (100
lb-in.). Count the rpm.
UN25MAY89
9025
25
24
T6076AM
Two Wheel Drive Axle Shown
TX,902525,BS170 1924MAY933/3
9025
25
25
PN=871
Tests
ESSENTIAL TOOLS
38H 1145 (4 ORFS) APluga
a
These ORFS fittings should be ordered through normal service
channels.
Specification
EngineSpeed ............................................................................. Low Idle
Steering CylinderLeakage..................................... 5 ml/min (1/6 oz/min)
9025
25
26
4. Remove rod end hose and plug (A). Put beaker under
cylinder port after oil stops dripping.
Specification
OilTemperature ................................................... 65 5C (150 10F)
UN25MAY89
T6076AL
Axle Without MFWD Shown
T60,9025,1065 1921JUL942/2
9025
25
27
PN=873
Tests
UN26OCT88
ESSENTIAL TOOLS
38H1353 (-6 ORFS) Nut
T6222AL
38H1139 (-6 ORFS) Plug
38H1354 (-8 ORFS) Nut
38H1140 (-8 ORFS) Plug
38H1146 (-6 ORFS) Plug
38H1147 (-8 ORFS) Plug
Specification
OilTemperature ................................................... 65 5C (150 10F)
T60,9025,1068 1921JUL941/1
SPECIFICATIONS
Oil Temperature 40 4C (104 7F)
Engine Speed 1000 10 rpm
Steering Valve Return Line 900 mL/min (30 oz/min)
Maximum Leakage
Main Hydraulic Pump Seal 2 mL/min 0.07 oz/min
Maximum Leakage
Loader Valve-2 Section Maximum 220 mL/min (7 oz/min)
Leakage
Loader Valve-3 Section Maximum 320 mL/min (11 oz/min)
Leakage
Loader Valve Work Port 31 mL/min (1 oz/min)
Maximum Leakage
Backhoe Valve-4 Section 1000 mL/min (34 oz/min)
Maximum Leakage
Backhoe Valve-5 Section 1050 mL/min (36 oz/min)
Maximum Leakage
Backhoe Valve-6 Section 1100 mL/min (38 oz/min)
Maximum Leakage
Backhoe Valve Work Port 60 mL/min (2 oz/min)
Maximum Leakage
Stabilizer Valve Maximum Spool 500 mL/min (17 oz/min)
Leakage
Stabilizer Valve Maximum 0.15 mm/min (.006 in/min)
Cylinder Drift 9025
(SN872328)Brake Valve 50 mL/min (1.7 oz/min) 25
Maximum Leakage (Both pedals 29
Applied)
Diff. Lock/Park Brake Valve 160 mL/min (6 oz/min)
Maximum Leakage
Differential Lock Capture Circuit 1.9 L/min (0.5 gpm)
Maximum Leakage
Park Brake Thermal Relief Valve 10 mL/min (0.34 oz/min)
Maximum Leakage
PN=875
Tests
Specification
OilTemperature ..................................................... 40 4C (104 7F)
TX,902525,BS172 1903MAR932/12
UN23AUG88
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
4.
X9811
Disconnect return lines for hydraulic components, one
9025
at a time, to check for leakage. Install cap on fitting.
25
30
5. Place beaker under component to be tested.
Specification
EngineSpeed .................................................................. 1000 10 rpm
Specification
Steering Valve Return Line
Maximum Leakage ............................................... 900 mL/min (30 oz/min)
UN25SEP92
T7855AI
TX,902525,BS172 1903MAR934/12
9025
25
31
If leakage is excessive, check main hydraulic pump shaft
for excessive end play.
Specification
Main Hydraulic Pump Seal
Maximum Leakage .................................................. 2 mL/min 0.07 oz/min
UN25SEP92
ANo. 4 Plug (In reservoir)
BPump Seal Drain Hose
T7855AE
Continued on next page TX,902525,BS172 1903MAR935/12
PN=877
Tests
UN25SEP92
port leakage test using beaker to collect oil.
Specification
Loader Valve-2 Section
T7855AH
Maximum Leakage ................................................. 220 mL/min (7 oz/min)
Loader Valve-3 Section
Maximum Leakage ............................................... 320 mL/min (11 oz/min)
Loader Valve Work Port
Maximum Leakage ................................................... 31 mL/min (1 oz/min)
TX,902525,BS172 1903MAR936/12
UN07JAN91
25 Specification
32 Backhoe Valve-4 Section
Maximum Leakage ............................................. 1000 mL/min (34 oz/min)
Backhoe Valve-5 Section
Maximum Leakage ............................................. 1050 mL/min (36 oz/min)
T7440BN
Backhoe Valve-6 Section
Maximum Leakage ............................................. 1100 mL/min (38 oz/min)
Backhoe Valve Work Port
Maximum Leakage ................................................... 60 mL/min (2 oz/min)
UN07JAN91
slides between the two lockouts . If the lockout
plunger spool is stuck it can hold a lockout open.
Specification
T7440BO
Stabilizer ValveMaximum Spool
Leakage ................................................................ 500 mL/min (17 oz/min)
Maximum Cylinder Drift .................................... 0.15 mm/min (.006 in/min)
UN26OCT88
T6222AN
TX,902525,BS172 1903MAR938/12
9025
25
33
Specification
Brake ValveMaximum Leakage
(Both pedals Unapplied) ........................................ 50 mL/min (1.7 oz/min)
UN25SEP92
T7855AJ
(SN 802550) & (SN 872329)
PN=879
Tests
Specification
Diff. Lock/Park Brake Valve
Maximum Leakage ................................................. 160 mL/min (6 oz/min)
UN25SEP92
ADifferential Lock and Park Brake Valve Return
Line
BNo. 6 Plug (In Reservoir)
T7855AG
TX,902525,BS172 1903MAR9310/12
Specification
Differential Lock Capture Circuit
Maximum Leakage ..................................................... 1.9 L/min (0.5 gpm)
UN25SEP92
T7855AF
Continued on next page TX,902525,BS172 1903MAR9311/12
9025
25
34
PN=880
Tests
1. Block wheels.
Specification
Park Brake Thermal Relief
ValveMaximum Leakage.................................. 10 mL/min (0.34 oz/min)
UN04DEC94
4. Change position of tee fitting so relief valve outlet is
down.
T8373BC
5. Put beaker under relief valve. Operate engine for 1
minute at slow idle and measure leakage at relief
valve.
9025
AThermal Relief Valve Return Hose 25
6. Connect hose and engage park brake. BThermal Relief Valve 35
TX,902525,BS172 1903MAR9312/12
PN=881
Tests
ESSENTIAL TOOLS
38H1030 (-6 F ORFS) a Tee
38H1031 (-8 ORFS) a Tee
38H1033 (-12 ORFS) a Tee
38H1002 (-16 ORFS) a Tee
AH120121 a Test Cylinder (Cancelled)
AH93323 (Replaces AH120121) a Test Cylinder
(-6 ORFS x 3/8 M NPT) Adapter
(3/8 M NPT x 3/8 F NPT) 90 Elbow
(9/1618 M ORB x 3/8 F NPT) Adapter
AT81867 Check Valve
(1/4 M NPT x 9/16-18 F 37) Adapter
NA Quick Coupler
(1/8 M NPT x 1/4 F NPT) Nipple
(1/4 M NPT x 1/4 F NPT 90) Elbow
(1/4 M NPT x 1/4 F NPT x 1/4 F NPT) Tee
38H1146 (-6 ORFS)a Plug
38H1147 (-8 ORFS)a Plug
38H1149 (-12 ORFS)a Plug
38H1150 (-16 ORFS) a Plug
38H1415 (-6 ORFS) a Cap (2 used)
JT03408 Hydraulic Flow Regulator
a
These ORFS fittings and parts should be ordered through normal
service parts channels. 9025
25
SERVICE EQUIPMENT AND TOOLS 37
PN=883
Tests
Specification
UN07JAN91
Test Cylinder Rod EndFlow ..................................... 3.78 L/min (1 gpm)
T7440BC
AAuxiliary Plug
BCrowd Out Relief
CBucket Curl Relief w/ anti-cavitation
DBoom Lower Relief w/ anti-cavitation
ESwing Left Relief w/ anti-cavitation
FSwing Right Relief w/ anti-cavitation
GBoom Raise Relief
HBucket Dump Relief
ICrowd In Relief w/ anti-cavitation
UN07JAN91
JAuxiliary Plug
KSystem Relief
LAuxiliary Retract Plug
MPlug (SN 812257)
MBoom Raise Relief (SN 812258 )
T7440BD
NBucket Curl Relief
OBucket Dump Relief
PAnti-Cavitation Valve
QAuxiliary Extend Relief
9025
25
38
UN26OCT88
1. Lower stabilizer to ground.
T6725AB
DCylinder
IAdapter
JJT03408 Hydraulic Flow Regulator
KElbow
LAdapter
MCheck Valve
NAdapter
OQuick Coupler
PNipple
Q90 Elbow
RTee
SAdapter
PN=885
Tests
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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.
UN20MAR90
2. Operate hydraulic control valves to relieve pressure in
the hydraulic system.
T6900AL
(27.5 bar) (400 psi) gauge to return side of backhoe
valve.
PN=886
Tests
1921MAR89
T6773AN
9025
ARod End Hose-To-Tee CGauge EStabilizer Hose (Rod End) G38H1415 Cap (2 used) 25
BTee DCylinder FStabilizer Hose (Head End) 41
PN=887
Tests
710D Backhoe CircuitsSpecification Bucket DumpPressure ........................ 31 000 kPa (310 bar) (4500
Crowd OutPressure............................. 24 000 kPa (240 bar) (3480 psi)
psi) Boom Raise (SN 812258 )
Bucket CurlPressure ........................... 22 000 kPa (220 bar) (3200 Pressure.................................................. 31 000 kPa (310 bar) (4500
psi) psi)
Boom DownPressure .......................... 14 000 kPa (140 bar) (2030
psi) Specification
Swing LeftPressure ............................. 19 000 kPa (190 bar) (2750 System ReliefPressure........................ 20 300 kPa (203 bar) (2950
psi) psi)
Crowd InPressure ............................... 19 000 kPa (190 bar) (2750
psi)
Bucket DumpPressure ........................ 24 000 kPa (240 bar) (3480
11. Retract cylinder rod for next test cycle. Repeat
psi) steps 8 and 9 if required.
Boom RaisePressure .......................... 27 600 kPa (276 bar) (4500
psi) 12. Move tee (B) to next relief valve port to be tested.
Swing RightPressure........................... 19 000 kPa (190 bar) (2750 Repeat steps 7 through 11.
psi)
Loader CircuitsSpecification
IMPORTANT: To prevent structural damage of
Auxiliary ExtendPressure .................... 20 600 kPa (206 bar) (3000 machine, do not adjust relief valves
psi) above specifications.
Bucket CurlPressure ........................... 31 000 kPa (310 bar) (4500
psi) 13. Adjust or replace reliefs as required.
TX,902525,BS181 1903MAR937/7
9025
25
42
PN=888
Tests
SPECIFICATIONS
Relief Valve Oil Tolerance +1380 -0 kPa (+13.8 -0 bar)
Pressure (+200 -0 psi)
System Relief Pressure 20 300 kPa (203 bar) (2950 psi)
Oil Temperature 40 6C (104 10F)
710D Backhoe CircuitsGresen 9025
Crowd Out Pressure 24 000 kPa (240 bar) (3480 psi) 25
43
Bucket Curl Pressure 22 000 kPa (220 bar) (3200 psi)
Boom Down Pressure 14 000 kPa (140 bar) (2030 psi)
Swing Left Pressure 19 000 kPa (190 bar) (2750 psi)
Crowd In Pressure 19 000 kPa (190 bar) (2750 psi)
Bucket Dump Pressure 24 000 kPa (240 bar) (3480 psi)
Boom Raise Pressure 27 600 kPa (276 bar) (4500 psi)
Swing Right Pressure 19 000 kPa (190 bar) (2750 psi)
Loader Circuits
Auxiliary Extend Pressure 20 600 kPa (206 bar) (3000 psi)
Bcuket Curl Pressure 31 000 kPa (310 bar) (4500 psi)
Bucket Dump Pressure 31 000 kPa (310 bar) (4500 psi)
Boom Raise (SN 812258 ) 31 000 kPa (310 bar) (4500 psi)
Pressure
PN=889
Tests
TX,9025,BD2746 1904APR972/6
AAuxiliary Plug
BCrowd Out Relief
CBucket Curl Relief w/ anti-cavitation
DBoom Lower Relief w/ anti-cavitation
9025 ESwing Left Relief w/ anti-cavitation
UN07JAN91
25 FSwing Right Relief w/ anti-cavitation
44 GBoom Raise Relief
HBucket Dump Relief
ICrowd In Relief w/ anti-cavitation
JAuxiliary Plug
T7440BC
KSystem Relief
LAuxiliary Retract Plug
MPlug (SN 812257)
Relief Valve TestGresen
MBoom Raise Relief (SN 812258 )
NBucket Curl Relief
OBucket Dump Relief
PAnti-Cavitation Valve
QAuxiliary Extend Relief
UN07JAN91
T7440BD
Specification
Relief Valve Oil Tolerance
Pressure ........................................................ +1380 -0 kPa (+13.8 -0 bar)
(+200 -0 psi)
710D Backhoe CircuitsSpecification
Crowd OutPressure ............................ 24 000 kPa (240 bar) (3480 psi)
Bucket CurlPressure ........................... 22 000 kPa (220 bar) (3200 psi)
Boom DownPressure .......................... 14 000 kPa (140 bar) (2030 psi)
Swing LeftPressure ............................. 19 000 kPa (190 bar) (2750 psi)
Crowd InPressure ............................... 19 000 kPa (190 bar) (2750 psi)
Bucket DumpPressure ........................ 24 000 kPa (240 bar) (3480 psi)
Boom RaisePressure .......................... 27 600 kPa (276 bar) (4500 psi)
Swing RightPressure .......................... 19 000 kPa (190 bar) (2750 psi)
Loader CircuitsSpecification
Auxiliary ExtendPressure .................... 20 600 kPa (206 bar) (3000 psi)
Bucket CurlPressure ........................... 31 000 kPa (310 bar) (4500 psi)
Bucket DumpPressure ........................ 31 000 kPa (310 bar) (4500 psi)
Boom Raise (SN 812258 )
Pressure ................................................. 31 000 kPa (310 bar) (4500 psi)
UN29MAY98
Specification
System ReliefPressure ....................... 20 300 kPa (203 bar) (2950 psi)
T114667
AAuxiliary Plug (4 used)
BCrowd Out Circuit Relief
CBucket Curl Circuit Relief W/Anti-Cavitation
DBoom Lower Circuit Relief W/Anti-Cavitation Backhoe Valve--Husco
9025
ESwing Left Circuit Relief W/Anti-Cavitation 25
FSwing Right Circuit Relief W/Anti-Cavitation 45
GBoom Raise Circuit Relief
HBucket Dump Circuit Relief
ICrowd In Circuit Relief W/Anti-Cavitation
JSystem Relief
PN=891
Tests
UN23AUG88
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
1.
Specification
OilTemperature ................................................... 40 6C (104 10F)
9025
25
46
PN=892
Tests
UN08APR97
T108839
9025
ACap BTest Pump CPressure Gauge 25
47
3. Disconnect pressure line at cylinder inlet port of NOTE: Take reading when pressure on gauge starts
relief valve to be tested. Install cap (A) on cylinder to decrease. The point at which pressure
port. decreases is the opening pressure of the relief
valve.
4. Connect test pump (B) pressure hose to inlet hose
of relief valve to be tested. Install gauge (C) on test 6. Adjust or replace reliefs as required.
pump.
TX,9025,BD2746 1904APR976/6
PN=893
Tests
Specification
EngineSpeed ............................................................................ Fast Idle
OilTemperature ................................................... 65 5C (150 10F)
TX,9025,BR539 1916OCT911/1
TX,9025,BD2740 1917MAR971/1
PN=895
Tests
UN23AUG88
Flowmeter Radial Piston Pump
38114 L/min (1030 gpm) 49 cc (3 cu in.)
76228 L/min (2060 gpm) 100 cc (6 cu in.)
X9811
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.
L/min (gpm) rpm L/min (gpm) rpm L/min (gpm) rpm L/min (gpm) rpm
100 cc (6 cu. in.) Pump Specs
76 20 811 114 (30) 1216 151 (40) 1621 189 (50) 2026
80 (21) 851 117 (31) 1256 155 (41) 1661 193 (51) 2066
83 (22) 892 121 (32) 1297 159 (42) 1702 197 (52) 2107
87 (23) 932 125 (33) 1337 163 (43) 1742 201 (53) 2147
91 (24) 973 129 (34) 1378 167 (44) 1783 204 (54) 2188
95 (25) 1013 132 (35) 1418 170 (45) 1823 208 (55) 2228
98 (26) 1054 136 (36) 1459 174 (46) 1864 212 (56) 2269
102 (27) 1094 140 (37) 1499 178 (47) 1904 216 (57) 2309
106 (28) 1135 144 (38) 1540 182 (48) 1945 220 (58) 2350
110 (29) 1175 148 (39) 1580 185 (49) 1985 223 (59) 2390
227 (60) 2431
49 cc (3 cu. in.) Pump Specs
38 (10) 811 57 (15) 1216 76 (20) 1621 95 (25) 2026
42 (11) 892 61 (16) 1297 80 (21) 1702 98 (26) 2107
45 (12) 973 64 (17) 1378 83 (22) 1783 102 (27) 2188
49 (13) 1054 68 (18) 1459 87 (23) 1864 106 (28) 2269
53 (14) 1135 72 (19) 1540 91 (24) 1945 110 (29) 2350
114 (30) 2431
65 cc (4 cu in.) Pump Specs
53 (14) 851 79 (21) 1277 106 (28) 1702 132 (35) 2127
57 (15) 911 83 (22) 1337 110 (29) 1763 136 (36) 2188
61 (16) 972 87 (23) 1398 114 (30) 1823 140 (37) 2250 9025
25
64 (17) 1033 91 (24) 1459 117 (31) 1884 144 (38) 2310 51
68 (18) 1094 95 (25) 1520 121 (32) 1945 148 (39) 2370
72 (19) 1155 98 (26) 1580 125 (33) 2006 151 (40) 2431
76 (20) 1215 102 (27) 1641 129 (34) 2067
27T,9025,M124 1916OCT912/2
PN=897
Tests
UN23AUG88
SPECIFICATIONS
Oil Temperature 40 4C (104 7F)
Engine Speed Slow Idle
Differential Lock Pressure 36544482 kPa (3644 bar)
X9811
(550650 psi)
ESSENTIAL TOOLS
(1/2 M ORB x 7/16 M 37) (Parker No. 5-4-0503) Adapter
Specification
OilTemperature ..................................................... 40 4C (104 7F)
3. Start engine.
Specification
EngineSpeed ............................................................................ Slow Idle
Specification
Differential LockPressure ........................ 36544482 kPa (3644 bar)
(550650 psi)
1905OCT92
position. If valve can be adjusted in "off" position
leakage is in differential lock assembly. To test
differential lock solenoid see group 9015-15.
T7861AA
A"Reg Test" Port
BPressure Reducing Valve
9025
25
53
TX,902525,BS189 1903MAR932/2
PN=899
Tests
UN23AUG88
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
X9811
connections before applying pressure.
SPECIFICATIONS
Oil Temperature 40 4C (104 7F)
Engine Speed Fast Idle
Park Brake Pressure 17 23022750 kPa (172228
bar) (25003300 psi)
ESSENTIAL TOOLS
(-4 ORFS) (Parker No. -4 R6LO-S) Swivel Run Tee
Specification
OilTemperature ..................................................... 40 4C (104 7F)
Specification
EngineSpeed ............................................................................ Fast Idle
Park BrakePressure .............................. 17 23022750 kPa (172228
bar) (25003300 psi)
1905OCT92
pump standby pressure (See Test in this Group).
Check park brake assembly for external leakage, or
adjust park brake relief valve if standby is to
T7861AB
specification. To test park brake solenoids see group
9015-15.
9025
APark Brake Work Port 25
BRelief Valve 55
TX,902525,BS190 1920DEC942/2
PN=901
Tests
UN23AUG88
SERVICE EQUIPMENT AND TOOLS
D01019AA Hydraulic Hand Pump with Gauge (from D01047AA 17-1/2
and 30 Ton Puller Set)
X9811
JT15068 (3/8 F NPT x 9/16 F ORB) BCoupler
UN04DEC94
If pressure is not within specification, replace thermal
relief valve.
T8373BE
TX902525,BD1663 1920DEC941/1
9025
25
57
PN=903
Tests
UN23AUG88
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
SPECIFICATIONS
X9811
Engine Speed Slow Idle
Oil Temperature 49 2.5C (120 5F)
Brake-Engine On- LH or RH 47757 kPa (47.5 bar) (690 70
Minimum Pressure psi)
Brake-Engine Off-Manual Mode, 5 515 kPa (55 bar) (800 psi)
LH or RH Minimum Pressure
Differential, LH to RH, Engine On 1000 kPa (10 bar) (145 psi)
Maximum Pressure
ESSENTIAL TOOLS
JT05487 (1/8 M NPT x 7/16 M 37) Fitting
9025 1. Engine off, park brake on, FNR neutral. Remove brake
25 light pressure switches from LH and RH brake outlet
58 lines.
Specification
EngineSpeed ............................................................................ Slow Idle
OilTemperature .................................................. 49 2.5C (120 5F)
Brake-Engine On- LH or RH
Minimum Pressure................................... 17 47757 kPa (47.5 bar) (690
70 psi)
Brake-Engine Off-Manual Mode,
LH or RHMinimum Pressure..................... 5 515 kPa (55 bar) (800 psi)
Differential, LH to RH, Engine
OnMaximum Pressure ............................... 1000 kPa (10 bar) (145 psi)
UN16OCT92
do not build pressure" for causes.
T7869CA
pressure.
TX,902525,BS192 1903MAR932/2
PN=905
Tests
UN23AUG88
Brake-Engine On- LH or RH 10 000 kPa 345 kP (100 3.5
Minimum Pressure bar) (1450 50 psi)
ESSENTIAL TOOLS
X9811
JT05494 ( 7/1628 M 37 x 3/416 M ORB) Connector
JT05483 ( 7/1620 M 37 x 7/1620 F 37 Deg.) Elbow (90 Degree
Swivel)
UN23OCT98
9025 pumping one pedal 20 times while depressing the
25 other pedal with tractor running at slow idle.
60 Repeat for the opposite pedal.
T118039
1. Engine off, park brake on, FNR neutral. Remove brake
light pressure switch and adapter fitting from port in
brake housing.
AConnector
2. Install connector (A), elbow (B) and gauge (C). BElbow
CGauge
Specification
EngineSpeed ............................................................................ Slow Idle
OilTemperature .................................................. 49 2.5C (120 5F)
Brake-Engine On- LH or RH
Minimum Pressure.................................. 10 000 kPa 345 kP (100 3.5
bar) (1450 50 psi)
OUO1048,00003DE 1908SEP002/2
9025
25
61
PN=907
Tests
ESSENTIAL TOOLS
38h1030 (6M x 6M x 6 F ORFS) Tee (Running)
JT03456 (7/16-20 M JIC x 6 F ORFS) Adapter
UN16DEC98
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
T119057
connections before applying pressure.
9025 1. Engine off, park brake on, FNR neutral. Remove floor
25 plate in cab floor.
62
Specification
Brake Work PortPressure ...................................... 0 kPa (0 bar) (0 psi)
CED,TX04577,833 1917DEC982/2
9025
25
63
PN=909
Tests
UN23AUG88
(1230 44 psi)
ESSENTIAL TOOLS
JT03083 (7/16 Male JIC x 1/2 ORB Male) Adapter
X9811
SERVICE EQUIPMENT AND TOOLS
Gauge 034 500 kPa (0345 bar) (05000 psi)
Digital Thermometer
Electronic Tachometer
UN12NOV92
3. Heat hydraulic oil to specification. (See procedure in
this group.)
T7888AB
Specification
OilTemperature ..................................................... 40 4C (104 7F)
TX,902525,BS207 1903MAR932/2
PN=911
Tests
UN23AUG88
bar) (500 50 psi)
ESSENTIAL TOOLS
JT05494 ( 7/1628 M 37 x 3/416 M ORB) Connector
X9811
JT05483 ( 7/1620 M 37 x 7/1620 F 37 Deg.) Elbow (90 Degree
Swivel)
Specification
OilTemperature ..................................................... 40 4C (104 7F)
Specification
Accumulator Precharge
Pressure ..................................................... 3 447 345 kPa (34.5 3.45
bar) (500 50 psi)
PN=913
Tests
OUO1048,00003DF 1908SEP003/3
9025
25
68
Page Page
PN=1
Contents
9031
PN=2
Group 05
Theory of Operation
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits It must be recovered using the
discharge of any refrigerant into the atmosphere, and appropriate recovery stations.
requires that refrigerant be recovered using the
approved recovery equipment. Use correct refrigerant recovery,
recycling and charging stations. DO
IMPORTANT: To meet government standards NOT mix refrigerants, hoses, fittings,
relating to the use of refrigerants, components or refrigerant oils.
R134a is used in the air conditioning
system. Because it does not contain Recovery, recycling and charging stations for R12 and
chlorine, R134a is not detrimental to R134a refrigerants MUST NOT be interchanged.
the ozone in the atmosphere. Systems containing R12 refrigerant use a different oil
However, it is illegal to discharge than systems using R134a. Certain seals are not
any refrigerant into the atmosphere. compatible with both types of refrigerants.
TX,9031,QQ5732 1905AUG961/1
TX,9031,QQ5733 1911JUN961/1
PN=917
Theory of Operation
1904MAR97
T106841
ACompressor ECondenser IExpansion Valve LBlowers
BLow Pressure Switch FEngine Fan JLow Pressure Liquid MA/C Freeze Switch
CHigh Pressure Switch GHigh Pressure Liquid KEvaporator NLow Pressure Gas
9031 DHigh Pressure Gas HReceiver Dryer
05
2 The compressor (A) draws low pressure gas (N) from the refrigerant causes it to condense and it leaves the
the evaporator (K) and compresses it into high condenser (E) as a high pressure liquid (G). The high
pressure gas (D). Increasing the pressure of the pressure liquid flows into the receiver-dryer (H) where
refrigerant causes its boiling point to rise to a moisture and contaminants are removed.
temperature higher than the outside air temperature.
The refrigerant flows from the receiver-dryer (H) to the
High pressure gas (D) leaves the compressor (A) and expansion valve (I). The expansion valve (I) is a
passes through two switches (B and C). These variable orifice used to cause a pressure and
switches monitor refrigerant pressure. Should the temperature drop in the refrigerant causing refrigerant
pressure become too great or too small, either the high to vaporize. The expansion valve (I) is one of the
or low pressure switch will open and stop the dividing lines between the high side and low side of
compressor, interrupting the cycle. the air conditioning system. At this point in the system,
the high pressure/high temperature liquid is sprayed
As the high pressure gas flows through the condenser into the evaporator (K) where it changes and becomes
(E), the engine fan (F) draws air through the a gas.
condenser core which cools the refrigerant. Cooling
PN=918
Theory of Operation
The expansion valve diaphragm is activated by evaporator outlet. The low temperature causes the
sensing temperature and pressure within the valve expansion valve variable orifice to decrease in size,
body. The internal bulb senses the evaporator outlet or restricting refrigerant flow. If the evaporator outlet
discharge temperature and pressure of refrigerant as it temperature is too warm, the orifice will increase in
passes through the valve back to the low pressure or size, allowing more refrigerant into evaporator.
suction side of the compressor. (See Expansion Valve
Operation in this group for additional information on If evaporator (K) temperature becomes too low, the
theory of operation.) A/C freeze switch (M) will interrupt current flow to the
compressor clutch coil, stopping system operation until
If too much refrigerant is flowing into evaporator, the the temperature becomes normal, between 31 and
liquid refrigerant will still be evaporating as it leaves 40.
the evaporator, causing a low temperature at the
TX,9031,BG643 1929JAN972/2
Key switch ON
Machine running
Air conditioning switch turned ON
Blower switch turned to low, medium or high
9031
05
TX,9031,QQ5735 1911JUN961/1
3
PN=919
Theory of Operation
Power from 30 amp heater fuse flows through P16 red High Pressure Switch
and 518 red wires to blower switch. With blower switch
turned to low, medium or high position, power flows to The high pressure switch protects the system from
blower resistor and then to heater blower motors. high pressure. If a malfunction or line restriction
causes the high pressure to increase above the setting
Power also flows from C terminal of blower switch, of the switch, the switch will open to stop current flow
through 522 white wire to freeze control switch, to the compressor clutch. The high pressure switch is
through 517 dark blue wire to air conditioning switch. located near the compressor in the high pressure line.
With air conditioning switch turned ON, power flows A/C Freeze Switch
through A17 orange wire to the lower pressure switch.
With low pressure switch closed, power flows through The A/C freeze switch is used to sense the
A18 green wire to high pressure switch. With high temperature in the evaporator core. When the
pressure switch closed power flows through A19 green temperature drops, the clutch cycle switch opens,
wire to the coil terminal of the compressor coil to shutting the compressor off. When the temperature in
energize the compressor clutch. the evaporator core raises, the A/C freeze switch
closes sending voltage to the compressor.
Low Pressure Switch
The A/C freeze switch receives power from the blower
The low pressure switch will open if the air switch when blower switch is turned to low, medium or
conditioning system loses its refrigerant charge. The high position.
switch opens to stop current flow to the compressor
which prevents compressor engagement. The low NOTE: For component identification code description
pressure switch is located near the compressor in high see Wiring and Schematic Diagrams Legend,
pressure line. Group 9015-10.
9031
05
TX,9031,BG784 1904MAR971/1
4
PN=920
Theory of Operation
9031
05
5
1924SEP92
T7835AU
TX,9031,BG647 1929JAN971/1
PN=921
Theory of Operation
Power from 30 amp heater fuse flows through P16 red High Pressure Switch
and 518 red wires to blower switch. With blower switch
turned to 1, 2, or 3 position, power flows to blower The high pressure switch protects the system from
resistor and then to heater blower motor. With blower high pressure. If a malfunction or line restriction
switch turned to position 4 the resistor is bypassed and causes the high pressure to increase above the setting
blower motor is in max speed. of the switch, the switch will open to stop current flow
to the compressor clutch. The high pressure switch is
Power also flows from blower switch, through white located near the compressor in the high pressure line.
wire to A/C freeze switch, through black/white and A16
orange wire to air conditioning switch. A/C Freeze Switch
With air conditioning switch turned ON, power flows The A/C freeze switch is used to sense the
through A17 orange wire to the low pressure switch. temperature in the evaporator core. When the
With low pressure switch closed, power flows through temperature drops, the A/C freeze switch opens,
A18 green wire to high pressure switch. With high shutting the compressor off. When the temperature in
pressure switch closed power flows through A19 green the evaporator core raises, the A/C freeze switch
wire to the coil terminal of the compressor coil to closes sending voltage to the compressor.
energize the compressor clutch.
The A/C freeze switch receives power from the blower
Low Pressure Switch switch when blower switch is turned to low, medium or
high position.
The low pressure switch will open if the air
conditioning system loses its refrigerant charge. The NOTE: For component identification code description,
switch opens to stop current flow to the compressor see Wiring and Schematic Diagrams Legend,
which prevents compressor engagement. The low Group 9015-10.
pressure switch is located near the compressor in high
pressure line.
9031
05
TX,9031,BG645 1929JAN971/1
6
PN=922
Theory of Operation
9031
05
7
1931MAY96
T101444
TX,9031,BG648 1929JAN971/1
PN=923
Theory of Operation
Power flows through the heater fuse to the blower High Pressure Switch
switch. The blower switch has five different positions,
off and four speeds. With the switch in speeds 1, 2, The high pressure switch protects the system from
and 3 power is sent to the blower resistor. The blower high pressure. If a malfunction or line restriction
resistor has three different resistance values causing causes the high pressure to increase above the setting
the fan to have different speeds. With the blower of the switch, the switch will open to stop current flow
switch on the speed 4, power is sent directly to the to the compressor clutch. The high pressure switch is
blower motor and bypasses the blower resistor. This located near the compressor in the high pressure line.
causes the fan to be at the highest speed.
Freeze Protection Switch
When the blower switch is in any of the four ON
speeds, power also flows through the normally closed The freeze protection switch is used to sense the
freeze control switch and to the A/C on/off switch. temperature in the evaporator core. When the
When the A/C on/off switch is switched on power temperature drops, the freeze protection switch opens,
continues to flow through the normally closed high and stopping power flow to the compressor. When the
low pressure switches to the A/C compressor engaging temperature in the evaporator core raises, the freeze
the compressor clutch. protection switch closes allowing power to continue to
flow to the compressor.
Low Pressure Switch
The freeze protection switch receives power from the
The low pressure switch will open if the air blower switch when the blower switch is in any of the
conditioning system loses its refrigerant charge. The four ON speeds.
switch opens to stop current flow to the compressor
which prevents compressor engagement. The low
pressure switch is located near the compressor in the
high pressure line.
9031
05
CED,TX17864,203 1917SEP981/1
8
PN=924
Theory of Operation
9031
05
9
1918SEP98
T117258
CED,TX17864,194 1916SEP981/1
PN=925
Theory of Operation
TX,9031,BG649 1929JAN971/1
TX,9031,BG650 1902OCT981/1
PN=926
Theory of Operation
9031
05
11
1930SEP92
T7857AD
TX,9031,BG651 1929JAN971/1
PN=927
Theory of Operation
TX,9031,BG652 1929JAN971/1
9031
05
12
PN=928
Theory of Operation
9031
05
13
1922APR97
T101441
TX,9031,BG653 1929JAN971/1
PN=929
Theory of Operation
Receiver/Dryer Operation
UN19OCT93
The receiver/dryer also contains two filters (E) and
desiccant (F) between the filters. The filters remove solid
materials which could be generated by a compressor
failure, debris left in the system due to improper service
T8104AE
procedures, or particles caused by corrosion of metal
parts due to moisture and acids in the system (also
caused by improper service procedures).
UN10JAN94
14
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
T8104AF
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 AInlet Port
moisture in the desiccant. Evacuating the system will not BSight Glass
remove moisture from the desiccant. You must replace COutlet Port
the receiver/dryer. DPickup Tube
EFilter
FDesiccant
GStrainer
HSpring
IReceiver/Dryer
JWet/Dry Indicator
PN=930
Theory of Operation
TX,9031,QQ5741 1911JUN962/2
9031
05
15
PN=931
Theory of Operation
1924SEP92
T7828AY
AValve Diaphragm DOperating Pin GValve Spring JDischarge from Evaporator
BSealed Sensing Bulb EInlet Flow HBall Seat KInternal Equalization
COutlet to Compressor FMetering Orifice IOutlet to Evaporator Passage
9031
05 The expansion valve is used to regulate the amount of The metering orifice (F) and ball seat area (H) in the
16 refrigerant flowing into the evaporator. At this point in expansion valve is relatively small. The rapidly
the system, the high pressure/high temperature liquid expanding refrigerant passing through this area can
is sprayed into the evaporator where it changes state cause any moisture in the system to freeze at this
and becomes a gas. point and block refrigerant flow. Other contaminants in
the system can also cause a valve to malfunction. If
The valve diaphragm (A) is activated by sensing expansion valve malfunctions, it must be replaced.
temperature and pressure within the valve body. The Expansion valve is not repairable.
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.
TX,9031,QQ5742 1911JUN961/1
PN=932
Theory of Operation
The compressor relief valve is a direct acting pressure If the relief valve opens, a loud popping noise will be
limiting valve. If a malfunction in the system occurs heard. Some oil may also be lost from the system.
that would cause high pressure, such as a restricted Correct any condition that would cause the valve to
line, the valve will open near 4137 kPa (41.4 bar) (600 open.
psi) and remain open until pressure drops to below the
valve setting.
TX,9031,QQ5743 1911JUN961/1
Temperature Control
9031
05
TX,9031,QQ5744 1911JUN961/1
17
PN=933
Theory of Operation
9031
05
18
PN=934
Group 15
Diagnostic Information
Diagnose Air Conditioning Electrical
Malfunctions
Air Conditioning System Does Circuit Breaker (S.N. 816286) or Replace circuit breaker or fuse.
Not Operate Fuse (S.N. 816287 )
TX,9031,QQ5746 1912JUN961/1
PN=935
Diagnostic Information
S25
AIR CONDITIONING P
SWITCH F6
A 30 AMP HEATER/A.C.
CIRCUIT BREAKER
HIGH PRESSURE
QUICK DISCONNECT S26
N CLUTCH
CYCLE O
S23 SWITCH S22
LOW PRESSURE M B HEATER TEMP.
SWITCH SWITCH
S24
HIGH PRESSURE L S8
SWITCH C BLOWER
SWITCH
Y10
COMPRESSOR K
D EXPANSION
VALVE
CONDENSOR J
M7
E HEATER BLOWER
MOTOR
M6
F HEATER BLOWER
MOTOR
R1
G BLOWER
RESISTOR
H
EVAPORATOR
I
RECEIVER
DRYER
TX,9031,BG656 1930JAN971/2
PN=936
Diagnostic Information
AAir Conditioning Switch DExpansion Valve IClutch Cycle Switch (S26) NLow Pressure Switch (S23)
(S25) EHeater Blower Motor (M7) JReceiver Dryer OHigh Pressure Quick
BBlower Switch (S8) FHeater Blower Motor (M6) KCondenser Disconnect
CHeater Temperature Switch GBlower Resistor (R1) LCompressor (Y10) PHeater/A.C. Circuit Breaker
(S22) HEvaporator MHigh Pressure Switch
(S24)
TX,9031,BG656 1930JAN972/2
9031
15
3
PN=937
Diagnostic Information
F6
BLOWER SWITCH A 30 AMP HEATER/A.C.
CONNECTOR R CIRCUIT BREAKER
S25 S22
YEL 1 AIR CONDITIONING S B HEATER TEMPERATURE
SWITCH SWITCH
BLU 2
PUR 3 S8
ORG 4 C BLOWER
SWITCH
RED B
BLOWER HARNESS Q
TO SIDE CONSOLE
HARNESS CONNECTOR D EVAPORATOR
BLK / W C
RED B
EXPANSION
E VALVE
S23
LOW PRESSURE
S24 SWITCH P R1
HIGH PRESSURE O F BLOWER
SWITCH RESISTOR
CONDENSOR N M6
G HEATER BLOWER
MOTOR
S26
H AC FREEZE
SWITCH
HIGH PRESSURE M
CHARGE PORT
LINE
J TO
ENGINE I LINE TO
BLOCK WATER PUMP
RECEIVER
K
DRYER
L
Y10
COMPRESSOR
TX,9031,BG655 1930JAN971/2
PN=938
Diagnostic Information
A30 Amp Heater/A.C. Circuit FBlower Resistor (R1) LCompressor (Y10) RBlower Switch Connector
Breaker (F6) GHeater Blower Motor (M6) MHigh Pressure Charge Port SAir Conditioning Switch
BHeater Temp. Switch (S22) HA/C Freeze Switch (S26) NCondenser (S25)
CBlower Switch (S8) ILine To Water Pump OHigh Pressure Switch (S24)
DEvaporator JLine To Engine Block PLow Pressure Switch (S23)
EExpansion Valve KReceiver Dryer QBlower Harness To Side
Console Harness
Connector
TX,9031,BG655 1930JAN972/2
9031
15
5
PN=939
Diagnostic Information
CED,TX17864,147 1925AUG981/1
PN=940
Diagnostic Information
9031
15
7
T116838 1908OCT98
CED,TX17864,140 1921AUG981/1
CED,OUTX466,1107 1920JUL981/2
PN=942
Diagnostic Information
1Condenser 10Blower Switch (S8) 16Blower Resister (R1) 23A/C Compressor Harness
2High Pressure Switch (S24) 11Heater Temp. Switch (S22) 17Heater Blower Motor (M6) to Engine Harness
3Low Pressure Switch (S23) 12Blower Harness (W10) 18A/C Freeze Switch (S26) Connector (X59)
4A/C Compressor Harness 13Blower Harness To Side 19Evaporator 24A/C Compressor Harness
(W11) Console Harness 20Line To Water Pump to Engine Harness
5Not Used Connector (X5) 21Line To Engine Block Connector (X34)
6Expansion Valve 14Seat Position Sensor 22Receiver Dryer 25Compressor (Y10)
7Cab Floor Ground (W3) (S19)
8Not Used 15Blower Harness To Air
9Blower Harness To Side Adjust Seat Harness
Console Harness Connector (X56)
Connector (X35)
CED,OUTX466,1107 1920JUL982/2
This procedure is designed so the mechanic can make additional checks or repair information will be given.
a quick check of the system using a minimum amount T.M. Group or CTM number required for repair will be
of diagnostic equipment. If you need additional given. If verification is needed, you will be given next
information, read Theory of Operation (Group best source of information:
9031-05).
Group: 10 (System Operational Checks)
The engine or other major components must be at
operating temperature for some checks. Group: 15 (Diagnostic Information)
Locate system check in the left column and read Group: 20 (Adjustments)
completely, following this sequence from left to right.
Read each check completely before performing. Group: 25 (Tests)
At the end of each check, if no problem is found, that CTM (Component Technical Manual)
check is complete. When a problem is indicated,
9031
15
9
TX,9031,BG654 1902OCT981/1
1/1
PN=943
Diagnostic Information
Blower Switch (S.N. Disconnect harness from blower switch. YES: Blower switch is
816286) good. Go to next check.
Using a multimeter check for continuity.
NO: Replace blower
Move blower switch to LOW, MEDIUM and HIGH switch.
checking terminals B to L and C, B to M and C and B to
H and C.
Is continuity measured?
T7199CL UN17SEP90
1/1
Blower Resister (S.N. Measure resistance between terminals 3 and 1. YES: Resistor is good.
816286) Check wiring harness.
Does ohmmeter read 1.0 ohms?
NO: Replace resistor
Measure ohms between terminals 3 and 2.
T6534CR UN19OCT88
1/1
Blower Switch (S.N. Disconnect harness from blower switch. YES: Blower switch is
816287 ) good. Go to next check.
Using a multimeter check for continuity.
NO: Replace blower
9031 Move blower switch to position 1, 2, 3, and 4 checking switch.
15 terminals B and 1, B and 2, B and 3, B and 4.
10
Is continuity measured?
T117277 1918SEP98
1/1
PN=944
Diagnostic Information
Blower Resister (S.N. Measure ohms between terminals 4 and 2. YES: Resistor is good.
816287 ) Check wiring harness.
Does ohmmeter read 1.0 ohms?
NO: Replace resistor
T102849 UN06AUG96
1/1
Heater/Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
Check motor is good. Check
Connect 12 volts to heater blower motor, and ground wiring harness.
motor.
NO: Replace heater
Does heater blower motor operate? blower motor.
T7199CM UN16AUG90
9031
15
1/1
11
A/C Freeze Switch With A/C freeze switch at room temperature. YES: Do A/C Freeze
Switch Test. See Group
Disconnect harness from switch. 9031-25. If Switch is OK.
Check wiring harness.
Measure continuity across switch terminals.
NO: Switch has failed.
Is continuity measured? Replace switch.
T7835AV 1924SEP92
1/1
PN=945
Diagnostic Information
Air Conditioning Switch Disconnect harness from air conditioning switch. YES: A/C switch is good.
(S.N. 816286) Check wiring harness.
Place switch in snowflake or A/C position, and measure
for continuity between terminals 2B and 1. NO: Replace A/C switch.
Is continuity measured?
Is continuity measured?
1/1
T100731 UN28MAY96
9031
Disconnect harness from air conditioning switch.
15
12
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?
1/1
PN=946
Diagnostic Information
Air Conditioner Low Disconnect harness from switch. YES: Continue with this
Pressure Switch Check check.
Check for continuity between terminals. Is continuity
measured? NO: Replace switch.
T101619 1913JUN96
Remove switch from system. (The line that attaches the low pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness.
1/1
Air Conditioner High Disconnect harness from switch. YES: Continue with this
Pressure Switch Check check.
Measure continuity across outer switch terminals.
NO: Switch may be bad,
Does ohmmeter read continuity? or system pressure is too
high. Continue with this
check to verify switch
operation.
T101618 1913JUN96
Remove switch from system. (The line that attaches the high pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness and
system pressure. Go to 9031
Measure continuity across switch terminals. Air Conditioning Pressure 15
Diagnostic Chart, Group 13
Does ohmmeter read continuity? 9031-25.
1/1
T6534CV UN19OCT88
1/1
PN=947
Diagnostic Information
9031
15
14
PN=948
Group 20
Adjustments
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits It must be recovered using the
discharge of any refrigerant into the atmosphere, and appropriate recovery stations.
requires that refrigerant be recovered using the
approved recovery equipment. Use correct refrigerant recovery,
recycling and charging stations. DO
IMPORTANT: To meet government standards NOT mix refrigerants, hoses, fittings,
relating to the use of refrigerants, components or refrigerant oils.
R134a is used in the air conditioning
system. Because it does not contain Recovery, recycling and charging stations for R12 and
chlorine, R134a is not detrimental to R134a refrigerants MUST NOT be interchanged.
the ozone in the atmosphere. Systems containing R12 refrigerant use a different oil
However, it is illegal to discharge than systems using R134a. Certain seals are not
any refrigerant into the atmosphere. compatible with both types of refrigerants.
TX,9031,QQ5748 1912JUN961/1
TX,9031,QQ5749 1912JUN961/1
PN=949
Adjustments
Remove compressor if R134a leakage was detected 3. Flush the complete system with TY16134 air
and repaired. See Remove and install Compressor in conditioning flushing solvent.
Repair Manual.
4. If the compressor is serviceable, pour flushing
Drain oil from the compressor and record the amount. solvent in the manifold ports and internally wash out
See Compressor Oil Removal procedure in this group. the old oil.
NOTE: Drain oil and save if this is a new compressor. 5. Install a new receiver-dryer.
If the oil drained from a compressor removed from 6. Install required amount of TY22025 refrigerant oil in
operation is very black or the amount of oil is less than the compressor. (See R134a Component Oil
6 mL (0.2 fl oz), perform the following: Charge in this group.)
1. Remove and discard the receiver-dryer. 7. Connect all components, evacuate and charge the
system.
2. Remove, clean, but do not disassemble the valve.
TX,9031,QQ5750 1912JUN961/1
TX,9031,QQ5751 1912JUN961/1
PN=950
Adjustments
1. When the complete system, lines, and components Receiver-Dryer 30 mL (1.0 fl oz)
were flushed add the correct amount of oil as Hoses 60 mL (2.0 fl oz)
described.
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft).
New compressor from parts depot contains the Approximate total length equals 600 cm (20 ft).
amount of new oil of 230 20 mL (7.7 0.7 fl
oz). System requires an additional amount of new If any section of hose is removed and flushed or
oil of 118 mL (4.0 fl oz) of new oil. replaced, measure the length of hose and use the
Used compressor removed from operation, oil formula to determine the correct amount of oil to be
drained, and flushed requires 348 20 mL (11.6 added.
0.7 fl oz) of new oil.
CAUTION: DO NOT leave the system or
2. When the complete system was not flushed add the
R134a compressor oil containers open. This
correct amount of oil for the compressor plus
oil easily absorbs moisture. DO NOT spill 9031
amount of oil for each component that was 20
R134a compressor oil on acrylic or ABS
serviced. 3
plastic. This oil will deteriorate these
materials rapidly. Identify R134a oil
New compressor from parts depot, drain and
containers and measures to eliminate
return 63 mL (2.1 fl oz) of oil to the compressor.
accidental mixing of different oils.
(See Compressor Oil Removal procedure in this
group.)
TX,9031,BG804 1906MAR971/1
PN=951
Adjustments
UN10SEP96
1. Close both high and low pressure valves on refrigerant
recovery, recycling and charging station (J).
T101551
3. Connect low pressure blue hose (G) from refrigerant
recovery, recycling and charging station (J) to low
pressure test port (A) on compressor. ALow Pressure Test Port
BHigh Pressure Relief Valve
4. Connect high pressure red hose (I) to high pressure CLow Pressure Hose
DLow Pressure Switch
quick disconnect (F). EHigh Pressure Switch
FHigh Pressure Quick-Disconnect
9031 5. Follow the manufactures instructions when using the GBlue Hose
20 refrigerant recovery, recycling and charging station. HHigh Pressure Hose
4 IRed Hose
JRefrigerant Recovery/Recycling and Charging
Station
TX,9031,QQ5753 1912JUN961/1
PN=952
Adjustments
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station
UN10SEP96
conditioning system off before proceeding with
recovery steps.
T101551
1. Connect refrigerant recovery, recycling and charging
station. (See installation procedure in this group.)
2. Follow the manufactures instructions when using the ALow Pressure Test Port
refrigerant recovery, recycling and charging station. BHigh Pressure Relief Valve
CLow Pressure Hose
DLow Pressure Switch
EHigh Pressure Switch
FHigh Pressure Quick-Disconnect
GBlue Hose 9031
HHigh Pressure Hose 20
IRed Hose 5
JRefrigerant Recovery/Recycling and Charging
Station
TX,9031,QQ5754 1912JUN961/1
PN=953
Adjustments
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station
UN10SEP96
1. Connect refrigerant recovery, recycling and charging
station. (See installation procedure in this group.)
T101551
2. Open low and high pressure valves on refrigerant
recovery, recycling and charging station.
ALow Pressure Test Port
3. Follow the manufactures instructions and evacuate the BHigh Pressure Relief Valve
system. CLow Pressure Hose
DLow Pressure Switch
EHigh Pressure Switch
NOTE: The vacuum specifications listed are for sea level FHigh Pressure Quick-Disconnect
9031 conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) GBlue Hose
20 from 98 kPa (980 mbar) (29 in. Hg) for each 300 HHigh Pressure Hose
6 m (1000 ft) elevation above sea level. IRed Hose
JRefrigerant Recovery/Recycling and Charging
station
4. Evacuate system until low pressure gauge registers 98
kPa (980 mbar) (29 in. Hg) vacuum.
PN=954
Adjustments
7. Repair leak.
8. Start to evacuate.
TX,9031,QQ5755 1912JUN962/2
9031
20
7
PN=955
Adjustments
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station
UN10SEP96
group.)
T101551
System, this group.)
TX,9031,BG805 1906MAR971/1
PN=956
Adjustments
SERVICE EQUIPMENT AND TOOLS 2. Belt must deflect 19 mm (0.75 in.) at 400 N (90 lb
Belt Tension Gauge force). If not, allow belt to cool for 810 minutes.
IMPORTANT: Never over tighten belt. Over IMPORTANT: Force to adjust belt must be applied
tightening may cause belt cord to front of compressor housing only
damage and excessive load on to prevent damage to compressor.
bearings.
3. Loosen compressor mounting cap screws. Apply
1. Run engine for five minutes. Stop the engine, then force to front of compressor housing to tighten belt.
immediately check tension using a belt tension Tighten cap screws.
gauge. Measure strand tension or deflection at a
point halfway between pulleys. 4. Repeat Steps 1 and 2 to check belts.
TX,9031,BG806 1906MAR971/1
9031
20
9
PN=957
Adjustments
9031
20
10
PN=958
Group 25
Test
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits It must be recovered using the
discharge of any refrigerant into the atmosphere, and appropriate recovery stations.
requires that refrigerant be recovered using the
approved recovery equipment. Use correct refrigerant recovery,
recycling and charging stations. DO
IMPORTANT: To meet government standards NOT mix refrigerants, hoses, fittings,
relating to the use of refrigerants, components or refrigerant oils.
R134a is used in the air conditioning
system. Because it does not contain Recovery, recycling and charging stations for R12 and
chlorine, R134a is not detrimental to R134a refrigerants MUST NOT be interchanged.
the ozone in the atmosphere. Systems containing R12 refrigerant use a different oil
However, it is illegal to discharge than systems using R134a. Certain seals are not
any refrigerant into the atmosphere. compatible with both types of refrigerants.
TX,9031,QQ5758 1913AUG961/1
TX,9031,QQ5759 1913AUG961/1
PN=959
Test
SPECIFICATIONS
Engine Speed 2200 rpm
Air Conditioning Cooling Maximum
Blower Speed Maximum
Maximum Louver
Ambient Temperature (F) Temperature (F) Suction Pressure Discharge Pressure
1621C (6070F) 7.3C (45F) 4189 kPa (0.410.89 bar) 6551172 kPa (6.5511.72 bar)
(613 psi) (95170 psi)
2127C (7080F) 10C (50F) 55103 kPa (0.551.03 bar) 7921516 kPa (7.9215.16 bar)
(815 psi) (115220 psi)
2732C (8090F) 13C (55F) 68124 kPa (0.681.24 bar) 11721792 kPa (11.7217.92 bar)
(1018 psi) (170260 psi)
3238C (90100F) 16C (60F) 82137 kPa (0.821.37 bar) 14822068 kPa (14.8220.68 bar)
(1220 psi) (215300 psi)
3843C (100110F) 19C (65F) 103151 kPa (1.031.51 bar) 11722275 kPa (11.7222.75 bar)
(1522 psi) (260330 psi)
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station
PN=960
Test
Specification
EngineSpeed ........................................................................... 2200 rpm
Specification
Air ConditioningCooling ........................................................... Maximum
UN10SEP96
9. Turn blower switch to high speed.
Specification
BlowerSpeed ............................................................................ Maximum
T101551
10. Check sight glass in receiver-dryer.
11. Run unit for at least 5 minutes. ALow Pressure Test Port
BHigh Pressure Relief Valve
CLow Pressure Hose
12. Measure air temperature at condenser air inlet and at DLow Pressure Switch
air ducts in air conditioning unit. EHigh Pressure Switch
FHigh Pressure Quick-Disconnect
13. Compare air duct temperature reading to the GBlue Hose 9031
temperatures shown in the specifications. HHigh Pressure Hose 25
IRed Hose 3
JRefrigerant Recovery/Recycling and Charging
14. Observe low and high pressure gauges on refrigerant Station
recovery, recycling and charging station.
TX,9031,BG657 1930JAN972/2
PN=961
Test
9031
25
4
1928FEB89
T6609AB
TX,9031,QQ5761 1913AUG961/1
PN=962
Test
SPECIFICATIONS
Low Pressure Switch (Normally 276 20 kPa (2.76 0.2 bar) (40
Open) Closes on Increasing 3 psi)
UN08NOV88
Pressure
Low Pressure Switch (Normally 220 20 kPa (2.2 0.2 bar) (32
Open) Opens on Decreasing 3 psi)
Pressure
T88001
SERVICE EQUIPMENT AND TOOLS
Volt-Ohm-Amp Meter
Specification
Low Pressure Switch (Normally
Open)Closes on Increasing
Pressure ............................................... 276 20 kPa (2.76 0.2 bar) (40
3 psi)
PN=963
Test
Specification
Low Pressure Switch (Normally
Open)Opens on Decreasing
Pressure ................................................. 220 20 kPa (2.2 0.2 bar) (32
3 psi)
TX,9031,BG659 1930JAN972/2
9031
25
6
PN=964
Test
9031
25
7
PN=965
Test
SPECIFICATIONS
Low Pressure Switch (Normally 173 35 kPa (1.73 0.3 bar) (25
Open) Opens on Decreasing 53 psi)
Pressure
Low Pressure Switch (Normally 345 35 kPa (3.45 0.3 bar) (50
Open) Closes on Increasing 5 psi)
Pressure
NOTE: The line that attaches the low pressure switch has
a valve to prevent discharging the air conditioning
system when switch is removed.
PN=966
Test
Specification
Low Pressure Switch (Normally
Open)Opens on Decreasing
UN04MAR97
Pressure ............................................... 173 35 kPa (1.73 0.3 bar) (25
53 psi)
T106843
until pressure decreases to switch opening pressure
specification.
Specification
Low Pressure Switch (Normally
Open)Closes on Increasing
Pressure ............................................... 345 35 kPa (3.45 0.3 bar) (50
5 psi)
TX,9031,BG658 1930JAN972/2
9031
25
9
PN=967
Test
SPECIFICATIONS
High Pressure Switch (Normally 2410 100 kPa (24.1 1 bar)
Closed) Opens on Increasing (350 15 psi)
UN08NOV88
Pressure
High Pressure Switch (Normally 1390 100 kPa (13.91 1 bar)
Closed) Closes on Decreasing (220 15 psi)
Pressure
T88002
SERVICE EQUIPMENT AND TOOLS
Volt-Ohm-Amp Meter
Air Conditioning Gauge Set
Specification
High Pressure Switch (Normally
Closed)Opens on Increasing
Pressure .................................................... 2410 100 kPa (24.1 1 bar)
(350 15 psi)
Specification
High Pressure Switch (Normally
Closed)Closes on Decreasing
Pressure .................................................. 1390 100 kPa (13.91 1 bar)
(220 15 psi)
PN=968
Test
TX,9031,BG660 1930JAN972/2
9031
25
11
PN=969
Test
SPECIFICATIONS
High Pressure Switch (Normally 2760 138 kPa (27.6 1.38
Closed) Opens on Increasing bar) (400 20 psi)
Pressure
High Pressure Switch (Normally 1310 138 kPa (13.11 1.38
Closed) Closes on Decreasing bar) (190 20 psi)
Pressure
9031
25
Continued on next page TX,9031,BG661 1930JAN971/2
12
PN=970
Test
Specification
High Pressure Switch (Normally
Closed)Opens on Increasing
UN04MAR97
Pressure ............................................... 2760 138 kPa (27.6 1.38 bar)
(400 20 psi)
T106842
continuity until pressure decreases to switch closing
pressure specification.
Specification
High Pressure Switch (Normally
Closed)Closes on Decreasing
Pressure ..................................................... 1310 138 kPa (13.11 1.38
bar) (190 20 psi)
9031
25
TX,9031,BG661 1930JAN972/2
13
PN=971
Test
SPECIFICATIONS
A/C Freeze Control Switch -0.5C (31F)
(Normally Closed) Opens as
Temperature Drops
A/C Freeze Control Switch 4C (39F)
(Normally Closed) Closes as
Temperature Rises
Specification
A/C Freeze Control Switch
(Normally Closed)Opens as
Temperature Drops ............................................................... -0.5C (31F)
Specification
A/C Freeze Control Switch
9031 (Normally Closed)Closes as
25 Temperature Rises .................................................................... 4C (39F)
14
5. If switch does not open and close during testing, install
new switch.
TX,9031,QQ5764 1913AUG961/1
PN=972
Test
Leak Testing
1. Inspect all lines, fittings, and components for oily or 3. If a leak detector is used, move the leak detector
dusty spots. When refrigerant leaks from the probe under the hoses and around the connections
system, a small amount of oil is carried out with it. at a rate of 25 mm (1 in.) per second.
2. A soap and water solution can be sprayed on the 4. Some refrigerant manufacturers add dye to
components in the system to form bubbles at the refrigerant to aid in leak detection.
source of the leak.
TX,9031,QQ5765 1913AUG961/1
When a component is disconnected from the system, hose and tube connections. Dip O-rings in correct
special care should be given to inspecting hoses and viscosity oil before assembling.
tubing for moisture, grease, dirt, rust, or other foreign
material. If such contamination is present in hoses, IMPORTANT: Hose used for air conditioning
tubing, or fittings and cannot be removed by cleaning, systems contains special barriers in
then replace parts. its walls to prevent migration of
refrigerant gas.
Fittings that have grease or dirt on them should be
wiped clean with a cloth dampened with alcohol. DO NOT use hydraulic hoses as
Chlorinated solvents (such as trichloroethylene) are replacement hoses in the air
contaminants, and must not be used for cleaning. conditioning system. Use ONLY
certified hose meeting SAE J51B
To assist in making leak-proof joints, use a small requirements.
amount of clean correct viscosity refrigerant oil on all
9031
25
TX,9031,QQ5766 1913AUG961/1
15
PN=973
Test
9031
25
16
PN=974
Index
Page Page
PN=1
Index
Page Page
PN=2
Index
Page Page
Page Page
PN=4
Index
Page Page
PN=5
Index
Page Page
Page Page
PN=7
Index
Page Page
PN=8
Index
Page Page
PN=9
Index
Page Page
Power shift high range forward clutch (S.N.872257 Operational Information (S.N. 872257
) ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-22
Pressure test. . . . . . . . . . . . . . . . . . . 9020-25B-12 Schematic (S.N. 872256). . . . . . . . 9015-15A-61
Power shift low range forward clutch (S.N.872257 ) Schematic (S.N. 872257 ) . . . . . . . 9015-15B-23
Pressure Test . . . . . . . . . . . . . . . . . . 9020-25B-12 Sub-System Diagnostics (S.N.
Power shift modulation valve (S.N.872257 ) 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-62
Operation . . . . . . . . . . . . . . . . . . . . . 9020-05B-32 Sub-System Diagnostics (S.N. 872257
Power shift power train (S.N.872257 ) ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-24
Diagnose malfunctions . . . . . . . . . . . . 9020-15B-1 Radio harness (W12)
Overview. . . . . . . . . . . . . . . . . . . . . . 9020-05B-10 Component location (S.N.
Power shift speed clutch (S.N.872257 ) -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-46
Pressure test. . . . . . . . . . . . . . . . . . . 9020-25B-12 Component location (S.N. 872257-
Power Shift Transmission Control Circuit (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-45
872257 ) Connectors, wire and pin location (S.N.
First Forward. . . . . . . . . . . . . . . . . . . 9020-05B-20 872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-46
First Reverse . . . . . . . . . . . . . . . . . . 9020-05B-28 Wiring diagram (S.N. -872256) . . . . . 9015-10A-45
High range (fourth) forward . . . . . . . . 9020-05B-24 Wiring diagram (S.N. 872257- ). . . . . 9015-10B-44
Neutral . . . . . . . . . . . . . . . . . . . . . . . 9020-05B-16 Rear Work Light Circuit
Power shift transmission control circuit Operational Information (S.N. 872257
(S.N.872257 ) ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-56
First forward . . . . . . . . . . . . . . . . . . . 9020-05B-20 Sub-System Diagnostics (S.N. 872257
First Reverse . . . . . . . . . . . . . . . . . . 9020-05B-28 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-59
Fourth forward . . . . . . . . . . . . . . . . . 9020-05B-24 Theory Of Operation (S.N. 872257
Neutral . . . . . . . . . . . . . . . . . . . . . . . 9020-05B-16 ). . . . . . . . . . . . . . . . 9015-15B-57, 9015-15B-58
Power shift transmission control valve and shift valve Receiver/dryer
(S.N.872257 ) Operation . . . . . . . . . . . . . . . . . . . . . . .9031-05-14
Operation-first forward. . . . . . . . . . . . 9020-05B-22
Reducing valve presssure (S.N.872257 )
Operation-first reverse. . . . . . . . . . . . 9020-05B-30
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-14
Operation-neutral . . . . . . . . . . . . . . . 9020-05B-18
Refrigerant A/C
Power shift transmission (S.N.872257 )
Theory of operation. . . . . . . . . . . . . . . . .9031-05-2
Control valve operation-fourth
Refrigerant, A/C
forward . . . . . . . . . . . . . . . . . . . . . 9020-05B-26
Cautions . . . . . . . 9031-05-1, 9031-20-1, 9031-25-1
Gear flow . . . . . . . . . . . . . . . . . . . . . 9020-05B-12
Handling . . . . . . . 9031-05-1, 9031-20-1, 9031-25-1
Power train overview (S.N.872257 )
Recovery. . . . . . . . . . . . . . . . . . . . . . . . .9031-20-5
Power shift . . . . . . . . . . . . . . . . . . . . 9020-05B-10
Recovery/recycling/charging . . . . . . . . . .9031-20-4
Pressure Compensator Operation . . . . . .9025-05-12
Pressure regulating valve (S.N. Return to dig adjustment . . . . . . . . . . . . . .9025-20-2
Indx
872256) . . . . . . . . . . . . . . . . . . . . . . 9020-05A-20 Return-to-Dig Circuit
10
Priority valve Operational Information (S.N.
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-16 872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-109
Priority valve LS port flow test . . . . . . . . .9025-25-16 Operational Information (S.N. 872257
Priority valve test . . . . . . . . . . . . . . . . . . .9025-25-14 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-87
Pump, Charge . . . . . . . . . . . . . . . . . . . . . .9025-05-9 Schematic (S.N. 872256). . . . . . . .9015-15A-111
Pump, transmission (S.N.872257 ) Schematic (S.N. 872257 ) . . . . . . . 9015-15B-88
Operation . . . . . . . . . . . . . . . . . . . . . . 9020-05B-4 Sub-System Diagnostics (S.N.
872256) . . . . . . . . . 9015-15A-112, 9015-15B-89
Theory of Operation (S.N.
872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-110
R Theory of Operation (S.N. 872257
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-87
Radio circuit Reverse Alarm Circuit
Operational Information (S.N. Operational Information (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-60 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-52
PN=10
Index
Page Page
PN=11
Index
Page Page
PN=12
Index
Page Page
PN=13
Index
Page Page
PN=14