John Deere 410G Operation Test Manual TM1881 Service Manual 690 Páginas

Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC –19–29SEP98–1/1
TM1881 (15MAR04) 410G Backhoe Loader

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Introduction
Technical Information Feedback Form
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P.O. Box 538
Attn: Publications Supervisor, Dept. 303
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TX,II,FAX –19–10JUL01–1/1

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Introduction

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Contents
9000
SECTION 9000—General Information
Group 01—Safety Information
SECTION 9005—Operational Checkout Procedure

Group 10—Operational Checkout Procedure
9005
SECTION 9010—Engine
Group 05—Theory of Operation
Group 15—Diagnostic Information
Group 20—Adjustments
Group 25—Tests 9010
SECTION 9015—Electrical System

Group 05—System Information
Group 10—System Diagrams
Group 15—Sub-System Diagnostics
9015
Group 20—References
SECTION 9020—Power Train

Group 15—System Diagnostic Information
Group 20—Adjustments 9020
Group 25—Tests
SECTION 9025—Hydraulic System

9025
Group 25—Tests
SECTION 9031—Heating and Air Conditioning

Group 15—Diagnostic Information 9031
Group 25—Test
INDX
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT  2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2000, 2001, 2002, 2003
TM1881 (15MAR04) i 410G Backhoe Loader

031504
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Contents
9000
9005
9010
9015
9020
9025
9031
INDX
TM1881 (15MAR04) ii 410G Backhoe Loader

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9000
Section 9000
General Information
Contents
Page
Group 01—Safety Information

Safety Features. . . . . . . . . . . . . . . . . . . . . . .9000-01-1
Recognize Safety Information . . . . . . . . . . . .9000-01-2
Follow Safety Instructions . . . . . . . . . . . . . . .9000-01-2
Operate Only If Qualified. . . . . . . . . . . . . . . .9000-01-3
Wear Protective Equipment . . . . . . . . . . . . . .9000-01-3
Avoid Unauthorized Machine
Modifications . . . . . . . . . . . . . . . . . . . . . . .9000-01-3
Inspect Machine . . . . . . . . . . . . . . . . . . . . . .9000-01-4
Stay Clear Of Moving Parts. . . . . . . . . . . . . .9000-01-4
Avoid High-Pressure Fluids . . . . . . . . . . . . . .9000-01-4
Beware Of Exhaust Fumes . . . . . . . . . . . . . .9000-01-5
Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . .9000-01-5
Prevent Battery Explosions . . . . . . . . . . . . . .9000-01-5
Handle Chemical Products Safely . . . . . . . . .9000-01-6
Dispose Of Waste Properly . . . . . . . . . . . . . .9000-01-6
Prepare For Emergencies . . . . . . . . . . . . . . .9000-01-6
Use Steps And Handholds Correctly . . . . . . .9000-01-7
Start Only From Operator’s Seat . . . . . . . . . .9000-01-7
Use And Maintain Seat Belt . . . . . . . . . . . . .9000-01-7
Prevent Unintended Machine Movement . . . .9000-01-8
Prevent Unintended Machine Movement—
For Machines With Pilot Controls. . . . . . . .9000-01-8
Avoid Work Site Hazards . . . . . . . . . . . . . . .9000-01-9
Keep Riders Off Machine . . . . . . . . . . . . . . .9000-01-9
Avoid Backover Accidents . . . . . . . . . . . . . .9000-01-10
Avoid Machine Tipover . . . . . . . . . . . . . . . .9000-01-10
Add And Operate Attachments Safely . . . . .9000-01-11
Use Special Care When Operating . . . . . . .9000-01-11
Operating Or Traveling On Public Roads . .9000-01-12
Inspect and Maintain ROPS . . . . . . . . . . . .9000-01-12
Park And Prepare For Service Safely . . . . .9000-01-13
Service Cooling System Safely . . . . . . . . . .9000-01-13
Remove Paint Before Welding or
Heating . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-14
Make Welding Repairs Safely . . . . . . . . . . .9000-01-14
Drive Metal Pins Safely . . . . . . . . . . . . . . . .9000-01-15
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . .9000-01-16
TM1881 (15MAR04) 9000-1 410G Backhoe Loader

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Contents
9000

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Group 01
Safety Information
9000
Safety Features 01
1
2 3
1
17 5
16
6
13
4
15
12 7 8
14 10 9
–UN–05SEP01
11
T145296
T145296
Please remember, the operator is the key to 9. Bypass Start Protection. Shielding over the starter
preventing accidents. solenoid helps prevent dangerous bypass starting.
10. Ground-Level Fueling, Daily Service Checks.
1. Headlights/Taillights. Two front halogen Ground-level fueling feature eliminates the need to
driving/work lights and two rear halogen work lights. climb on the machine to fuel it.
2. Signal/Warning Lights. Roof mounted turning 11. Steps. Wide, skid-resistant steps provide excellent
signal lights and warning lights for on-road use. footing for getting in/out of operator’s station.
3. ROPS Protection. Certified rollover protection 12. Independent Parking/Secondary Brake.
structure surrounds the operator. Integral roof Independent, electrically controlled, parking brake
provides overhead protection. electrically engages when the engine is stopped.
4. Seat Position Switch. An audio/visual warning 13. Neutral Start. Prevents the engine from being
alerts operator when FNR is in forward/ reverse and started unless FNR control is in neutral.
the seat turned toward the backhoe position. 14. Back-Up Alarm. Alerts bystanders when the
5. Interior Rearview Mirror. Offers the operator a machine is shifted into reverse.
view of activity behind him. 15. Seat Belt Retractors. Seatbelt retractors help
6. Handholds. Large and conveniently placed, make it keep belts clean and convenient to use.
easy to enter or exit the operator’s station. 16. Exceptional Visibility. Views to either side and
7. Loader Boom Service Lock. Provided for working front or rear working tools are unrestricted.
on or around this machine with the boom raised. 17. Operator Manual Holder. A sealed manual holder
8. Engine Fan Guard. A secondary engine fan guard keeps manual clean and dry.
inside engine compartment encloses rotating fan
blades.
TX03768,0000B8D –19–07SEP01–1/1
TM1881 (15MAR04) 9000-01-1 410G Backhoe Loader

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Safety Information
9000
01 Recognize Safety Information
2
This is the safety alert symbol. When you see this
–UN–28AUG00
symbol on your machine or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
T133555
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.
–19–28AUG00
On your machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
T133588
labels.
TX03679,00016CC –19–21AUG00–1/1
Follow Safety Instructions
Read the safety messages in this manual and on the
–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
T133556
the current safety signs. Replacement safety signs are
available from your authorized John Deere dealer.
Be sure all operators of this machine understand every

safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.
TX03679,00016F9 –19–28JAN03–1/1

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Safety Information
9000
Operate Only If Qualified 01
3
Do not operate this machine unless you have read the machine functions with the machine in an open area
operator’s manual carefully and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Familiarize yourself with the job site and your your work situation and your work site.
surroundings before operating. Try all controls and
TX03679,00016FA –19–30OCT00–1/1
Wear Protective Equipment
Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.
Wear close fitting clothing and safety equipment

appropriate to the job.
–UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
TS206
uncomfortable loud noises.
TX03679,00016D0 –19–30OCT00–1/1
Avoid Unauthorized Machine Modifications
Modifications of this machine, or addition of Always contact an authorized dealer before making
unapproved products or attachments, may affect machine modifications that change the intended use,
machine stability or reliability, and may create a hazard weight or balance of the machine, or that alter
for the operator or others near the machine. machine controls, performance or reliability.
TX03679,00016B7 –19–17APR01–1/1

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Safety Information
9000
01 Inspect Machine
4
Inspect machine carefully each day by walking around it

before starting.
Keep all guards and shields in good condition and
–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
T6607AQ
TX03679,0001734 –19–25SEP00–1/1
Stay Clear Of Moving Parts
–UN–12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
T133592
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.
TX03679,00016D2 –19–30OCT00–1/1
Avoid High-Pressure Fluids
This machine uses a high-pressure hydraulic system.

Escaping fluid under pressure can penetrate the skin
–UN–31OCT00
causing serious injury.
Never search for leaks with your hands. Protect hands.

Use a piece of cardboard to find location of escaping fluid.
T133509
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic fluid penetrates your skin, see a doctor

immediately. Injected fluid must be removed
surgically within hours or gangrene may result.
–UN–20SEP00
Contact a knowledgeable medical source or the Deere &

Company Medical Department in Moline, Illinois, U.S.A.
T133840
TX03679,00016D3 –19–30OCT00–1/1

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Safety Information
9000
Beware Of Exhaust Fumes 01
5
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
–UN–24AUG00
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
T133546
outside air into the area.
TX03679,00016D4 –19–14SEP00–1/1
Prevent Fires
–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.
–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
T133553
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a

multi-purpose fire extinguisher on or near the machine.
–UN–07SEP00
Know how to use extinguisher properly.
T133554
TX03679,00016F5 –19–25SEP00–1/1
Prevent Battery Explosions
Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm

battery to 16°C (60°F).
TS204
TX03679,000174A –19–14SEP00–1/1

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Safety Information
9000
01 Handle Chemical Products Safely
6
Exposure to hazardous chemicals can cause serious
–UN–25AUG00
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
T133580
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
TX03679,00016D7 –19–05AUG02–1/1
Dispose Of Waste Properly
Improper disposal of waste can threaten the environment.
–UN–25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
T133567
any water source.
Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your

local environmental or recycling center or your authorized
dealer for more information.
TX03679,0001733 –19–17APR01–1/1
Prepare For Emergencies
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
TX03679,000174B –19–14SEP00–1/1

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Safety Information
9000
Use Steps And Handholds Correctly 01
7
Prevent falls by facing the machine when you get on and
–UN–30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
T133468
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,00016F2 –19–14SEP00–1/1
Start Only From Operator’s Seat
–UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.
T133715
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,0001799 –19–02MAY01–1/1
Use And Maintain Seat Belt
Use seat belt when operating machine. Remember to
–19–14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.
T133716
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced

every three years, regardless of appearance.
TX03679,00016DD –19–17OCT00–1/1

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Safety Information
9000
01 Prevent Unintended Machine Movement
8
ON PARK BRAKE OFF
Always set the park lock brake switch to the “ON”
position before leaving the operator’s seat for any
reason.
–19–26OCT01
Be careful not to accidentally actuate steering, travel or
Always set parking brake
other controls. Engage park brake and lower work before leaving seat.
equipment to the ground during work interruptions. Stop After startup, cycle park
the engine before allowing anyone to approach the brake switch ON/OFF to
T147434
machine. Follow proper parking procedures before leaving release park brake.
the operator’s station.
TX03768,0000B8A –19–26OCT01–1/1
Prevent Unintended Machine Movement—For

Machines With Pilot Controls
Be careful not to accidentally actuate control levers when

co-workers are present. Always lock hydraulics on
backhoe during work interruptions. Lock hydraulics before
–UN–21JAN03
allowing anyone to approach machine.
T164252
HG31779,00001D2 –19–23JAN03–1/1

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Safety Information
9000
Avoid Work Site Hazards 01
9
Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all
underground utilities before you dig.
–UN–01NOV01
Prepare work site properly. Avoid operating near
structures or objects that could fall onto the machine.
Clear away debris that could move unexpectedly if run
over.
T147554
Avoid boom or attachment contact with overhead
obstacles or overhead electrical lines. Never move any
part of machine or load closer than 3 m (10 ft) plus twice
the line insulator length to overhead wires.
Keep bystanders clear at all times. Use barricades or a

signal person to keep vehicles and pedestrians away. Use
a signal person if moving machine in congested areas or
–UN–13DEC01
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to
T147555
support machine. Be especially alert working near
embankments or excavations.
Avoid working under over-hanging embankments or

stockpiles that could collapse on machine.
TX03768,0000BAA –19–21DEC01–1/1
Keep Riders Off Machine
Only allow the operator on the machine. Keep riders off.
Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off of the
–UN–06DEC01
machine. Riders also obstruct the operator’s view resulting

in the machine being operated in an unsafe manner.
T148715
TX03768,0000BAF –19–21NOV01–1/1

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Safety Information
9000
01 Avoid Backover Accidents
10
Before moving machine, be sure all persons are clear

of the machine travel path. Turn around and look
–UN–06SEP01
directly for best visibility. Use mirror to assist in checking
behind the machine. Keep windows and mirror clean and
in good repair.
T145317
Be certain back-up warning alarm is working properly.
Use a signal person when backing if view is

obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
TX03768,0000B8B –19–06SEP01–1/1
Avoid Machine Tipover
Use seat belt at all times.
Do not jump if the machine tips. You will be unlikely to

jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be

sure truck is wide enough and secured on a firm level
surface. Use loading ramps and attach them properly to
truck bed.
Be careful on slopes. Use extra care on soft, rocky or

frozen ground because machine may slip sideways in
these conditions.
Ensure solid footing. Use extra care when operating on

stockpile materials, or near banks or excavations that may
cave-in and cause machine to tip or fall.
–19–26OCT01
T147495
TX03768,0000BA3 –19–26OCT01–1/1

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Safety Information
9000
Add And Operate Attachments Safely 01
11
Always verify compatibility of attachments by contacting

your authorized dealer. Adding unapproved attachments
may affect machine stability or reliability, and may create
a hazard for others near the machine.
Ensure that a qualified person is involved in attachment

installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections
are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all

instructions and warnings. In an area free of bystanders
and obstructions, carefully operate attachment to learn its
characteristics and range of motion.
TX03679,00016F0 –19–14SEP00–1/1
Use Special Care When Operating
Never use the loader to lift people. Do not allow anyone

to ride in the bucket or use the bucket as a work platform.
Operate carefully with raised loads. Raising the load
–UN–05DEC01
reduces machine stability, especially on side slopes on
soft terrain. Drive and turn slowly with a raised load.
Ensure that objects in the bucket are secure. Do not
T148749
attempt to lift or carry objects that are too big or too long
to fit inside the bucket unless secured with an adequate
chain or other device. Keep bystanders away from raised
loads.
Be careful when lifting objects. Never attempt to lift

objects too heavy for your machine. Assure machine
stability and hydraulic capability with a test lift before
attempting other maneuvers. Use an adequate chain or –UN–26OCT01
sling and proper rigging techniques to attach and stabilize
loads.
Never lift an object above or near another person.

T147438
TX03768,0000B70 –19–21DEC01–1/1

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Safety Information
9000
01 Operating Or Traveling On Public Roads
12
Machines that work near vehicle traffic or travel slower

than normal highway speeds must have proper lighting
–UN–22MAY01
and markings to assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle

(SMV) emblems, or other devices and use as required to
T141891
make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.
TX03679,00017C8 –19–14JUN01–1/1
Inspect and Maintain ROPS
A damaged roll-over protective structure (ROPS) To maintain the ROPS:

should be replaced, not reused.
• Replace missing hardware using correct grade
The protection offered by ROPS will be impaired if hardware.
ROPS is subjected to structural damage, is involved in • Check hardware torque.
an overturn incident, or is in any way altered by • Check isolation mounts for damage, looseness or
welding, bending, drilling, or cutting. wear; replace them if necessary.
• Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason,
inspect it carefully before operating the machine again.
TX03679,000179F –19–20APR01–1/1

031504
PN=20
Safety Information
9000
Park And Prepare For Service Safely 01
13
Warn others of service work. Always park and prepare

your machine for service or repair properly.
• Park machine on a level surface and lower equipment
–19–14DEC01
to the ground.
• Engage park brake.
• Stop engine and remove key.
• Attach a “Do Not Operate” tag in an obvious place in
T133332
the operator’s station.
Securely support machine or attachment before working

under it.
• Do not support machine with any hydraulically actuated

tools or attachments.
• Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
• Do not support machine with a single jack or other
–UN–23AUG88
devices that may slip out of place.
• Always install boom lock before working on or around
this machine with the loader boom raised.
TS229
Understand service procedures before beginning repairs.
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TX03679,0001809 –19–18SEP01–1/1
Service Cooling System Safely
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
to relieve pressure before removing completely.

TS281
DX,RCAP –19–04JUN90–1/1

031504
PN=21
Safety Information
9000
01 Remove Paint Before Welding or Heating
14
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
–UN–23AUG88
Remove paint before heating:
• Remove paint a minimum of 101 mm (4 in.) from area

to be affected by heating. If paint cannot be removed,
TS220
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1
Make Welding Repairs Safely
NOTE: Disable electrical power before welding. Turn off

–UN–31AUG00
main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and
vehicle microprocessors.
T133547
Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
TX03679,00016D5 –19–02OCT00–1/1

031504
PN=22
Safety Information
9000
Drive Metal Pins Safely 01
15
–UN–14SEP00
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
T133738
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
TX03679,0001745 –19–25SEP00–1/1

031504
PN=23
Safety Information
9000
01 Safety Signs
16
–19–28JAN03
T164249
Continued on next page HG31779,00001C6 –19–21JAN03–1/2

031504
PN=24
Safety Information
9000
01
17
–19–21JAN03
T164250
HG31779,00001C6 –19–21JAN03–2/2

031504
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Safety Information
9000
01
18

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Section 9005
Operational Checkout Procedure
Contents 9005
Page
Group 10—Operational Checkout Procedure

Operational Checkout Procedure. . . . . . . . . .9005-10-1
Gauge and Indicator Check With Engine
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-1
FNR, Neutral Start Circuit and Reverse
Warning Alarm Checks . . . . . . . . . . . . . . .9005-10-2
Park Brake, Charge Indicator Light,
Tachometer/Hour Meter Circuit and
Engine Speed Control Linkage Checks . . .9005-10-3
Brake System Checks . . . . . . . . . . . . . . . . . .9005-10-6
Steering System Checks . . . . . . . . . . . . . . . .9005-10-8
Transmission Neutral Disconnect Circuit
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-9
Driving Checks . . . . . . . . . . . . . . . . . . . . . .9005-10-10
Ride Control Operational Checks (If
Equipped) . . . . . . . . . . . . . . . . . . . . . . . .9005-10-12
Mechanical Front Wheel Drive (MFWD)
Driving Check (If Equipped) . . . . . . . . . . .9005-10-14
Hydraulic System Checks . . . . . . . . . . . . . .9005-10-15
Check Operation Of Accessories (Engine
Stopped) . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-19
Cab Component Checks . . . . . . . . . . . . . . .9005-10-20
Pilot Control System Checks . . . . . . . . . . . .9005-10-25

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Contents
9005

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Group 10
This procedure is designed so a technician can make sequence from left to right. Read each check
a quick check of the operation of machine while sitting completely before performing.
in operator’s seat.
9005
At the end of each check, if check works correctly then 10
Checks should be followed in order from the beginning you will be instructed to go to next check. If problem 1
to end. exists, you will be given repair required and group
location 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:
space to complete the driving checks and to operate
the machine. Group 10 (System Operational Checks)
The engine, transmission and hydraulic systems must Group 15 (Diagnostic Information)
be at operating temperature when performing checks.
Group 20 (Adjustments)
Complete the necessary visual checks (oil levels, oil
condition, external leaks, loose hardware, loose Group 25 (Tests)
linkage, etc.) prior to doing the checkout.
CTM (Component Technical Manual)
No special tools or gauges are needed. Always start in
the left column and read completely, following this
TX,9005,YY2037 –19–08AUG96–1/1
Gauge and Indicator Check With Engine Off
– – –1/1
Monitor Indicator Lights YES: Go to next check.

and Alarm Checks
NO: Check monitor/gauge
fuse. See Fuse
Specifications. (Go to
Group 9015-10). If motor
starts and bulb check
position is OK, key switch
T134624 –UN–19OCT00
is failed or there is a
short in wiring. See Start
Turn key switch to ON position and hold. Circuit Schematic. (Go to
Group 9015-15).
LOOK: Are all monitor indicator lights on? Is STOP light ON and does alarm sound?
NOTE: Starting motor MUST NOT operate.
– – –1/1

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FNR, Neutral Start Circuit and Reverse Warning Alarm Checks
9005 – – –1/1
10
2
FNR Switch Check Engine off. YES: Go to next check.
Move FNR lever to forward (F), reverse (R), then neutral NO: If no "click", inspect
(N) position. neutral start relay. See
Start Circuit Schematic.
FEEL: Observe and feel forward, neutral and reverse (Go to Group 9015-15).
detents.
T7447AH –UN–04JAN91
Turn key switch to ON position. Move FNR lever into
forward and reverse.
LISTEN: Did you hear a "click" from the front console

neutral start relay when the key switch was turned ON?
– – –1/1
Neutral Start Check Move FNR lever to forward (F) position and turn key switch to start position. YES: Go to next check.
Move FNR lever to reverse (R) position and turn key switch to start position. NO: Check starting
circuit. See Start Circuit
LISTEN: Did starting motor operate? Schematic. (Go to Group
9015-15).
– – –1/1
Start Circuit Check Move FNR lever to neutral (N) position and turn key YES: Go to next check.
switch to START position.
NO: If engine turns but
Observe and listen to monitor as engine is cranking. does not start, check fuel
shut-off/start aid/reverse
LISTEN: Did starting motor operate? alarm fuse. If starting
motor does not operate
LISTEN: Did alarm sound? check start fuse. If
indicator lights are NOT
LOOK: During engine cranking, were all indicator lights ON, check monitor/gauge
ON? Is STOP indicator ON? fuse. See Fuse
Specifications. (Go to
Group 9015-10).
– – –1/1
Reverse Warning Alarm Key switch ON. YES: Go to next check.

Check
Move FNR lever to reverse (R) position. NO: Check reverse
warning alarm. See
LISTEN: Does reverse warning alarm sound? System Functional
Schematic SE10 Back-Up
Alarm Circuit. (Go to
Group 9015-10).
T7447AI –UN–04JAN91
– – –1/1

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Park Brake, Charge Indicator Light, Tachometer/Hour Meter Circuit and Engine Speed Control Linkage
Checks
– – –1/1 9005
10
3
Park Brake Indicator YES: Go to next check.
Check
NO: If engine low oil
pressure indicator light
stays ON, STOP ENGINE
IMMEDIATELY and check
oil level. If alternator
indicator light is ON,
T7447AG –UN–04JAN91 T134624 –UN–19OCT00
increase engine speed to
1200 rpm and alternator
IMPORTANT: If engine oil pressure indicator light stays ON, STOP ENGINE light MUST go out. Go to
IMMEDIATELY, check oil level. Group 9015-15, .
Engage park brake.
Put FNR lever in neutral (N) and start the engine.
Put FNR lever in forward (F) position.
LOOK: Is STOP indicator ON? Does alarm sound? Are all other indicator lights out?
Release park brake.
LOOK/LISTEN: Is park brake indicator and STOP light out? Alarm will not sound.
– – –1/1

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Seat Position Switch Engine speed at low idle. YES: Continue with
Check check.
Lower all equipment to ground.
NOTE: This check should NO: Check Indicator
be performed on level Operators seat in backhoe position. Circuit (SE22). See
ground. Display Monitor/Indicator
9005
Release park brake. Circuit in System
10
Functional Schematic.
4
FNR in forward or reverse. (Group 9015-15.)
LISTEN: Does monitor alarm sound and is STOP indicator on?
The following two checks are for machines with pilot controls.
Operators seat in backhoe position. YES: Continue with

check.
NOTE: Pilot control towers should be in stored position for ease of rotating seat.
NO: Check pilot control
Enable pilot controls (switch in unlock position). circuit (SE31). See
System Functional
Activate a function and rotate seat towards loader position. Schematic (S.N.
913484— ). (Group
LOOK: Does backhoe function stop after seat has been rotated at least 15° out of 9015-15.)
backhoe position?
NO: Check Indicator
Circuit (SE22). See
Display Monitor/Indicator
Circuit in System
(Group 9015-15.)
Rotate operators seat to loader position. YES: Go to next check.
Enable pilot controls. NO: Check pilot control

circuit (SE31). See Pilot
Release park brake. Control Circuit in System
FNR in forward or reverse. (Group 9015-15.)
LOOK/LISTEN: Does monitor alarm sound and does monitor display HOE On? NO: Check Indicator
Circuit (SE22). See
Display Monitor/Indicator
Circuit in System
(Group 9015-15.)
NO: Check pilot control

hydraulic circuit. Perform
Pilot Control Pressure
Test. (Group 9025-25.)
– – –1/1

031504
PN=32
Tachometer/Hourmeter YES: Go to next check.

Circuit Check
NO: If park brake
indicator light is not ON
check schematic. See
Park Brake/FNR Circuit
9005
Schematic. (Go to Group
10
9015-15). If no hour
5
meter or tachometer
movement, check display
monitor. See Display
Monitor/Indicator Circuit
Schematic.
A
SELECT
n/min
T131866
T131866 –UN–22JUN00
IMPORTANT: If engine low oil pressure indicator light stays ON, STOP ENGINE
IMMEDIATELY and check oil level.
Engage park brake.
Put FNR lever in neutral and start the engine.
LOOK/LISTEN: Is hourmeter indicator changing? Does tachometer indicate rpm?
– – –1/1

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Engine Speed Control NO: Tighten threaded

Lever Linkage Check part of cable. See Engine
Speed Control Linkage
Adjustment. (Go to Group
9010-20).
9005
YES: Go to next check.
10
6
T134640 –UN–19OCT00
Engage park brake.
Put FNR lever in neutral and start engine.
Note rpm on tachometer.
Move speed control lever to fast idle position.
LOOK: Does tachometer read 900 + 25 — 0 rpm (slow idle) or 2400 + 25 — 0 rpm
(fast idle)?
Specification
Slow Idle—Speed ................................................................................ 900 + 25 — 0 rpm
Fast Idle—Speed ............................................................................... 2400 + 25 — 0 rpm
LOOK: Does speed control lever remain at selected position?
– – –1/1
Engine Speed Control Depress speed control pedal YES: Yes: Go to next
Pedal Linkage Check check.
LISTEN: Does engine speed stay the same as with
speed control lever in fast idle position? NO: Adjust Speed Control
Linkage. See Engine
Speed Control Linkage
Adjustment. (Go to Group
9010-20).
T7394BF –UN–06JAN92
– – –1/1
Brake System Checks
– – –1/1

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Brake Pedal Stop Check Lift left and right brake pedals individually. YES: Go to next check.
LOOK: Is there a minimal amount of travel before cap NO: Adjust brake pedal
screws contact stop? stops. Go to Adjust Brake
Pedals. (Group 9020-20.)
NOTE: Gap between pedal stop screws and plate should
9005
be 0.127—0.381 mm (0.005—0.015 in.).
10
7
T134625 –UN–19OCT00
This travel ensures that brake check valves are opened
and brakes are released.
– – –1/1
Brake System Leakage Depress and hold left brake pedal, then right brake pedal NO: Go to next check.
Check using approximately 267 N (60 lb. force).
YES: Bleed brake
LOOK: Brake pedal must NOT feel spongy (caused by system. See Bleeding
air in system). Does pedal settle more than 25 mm (1.0 Brakes. (Go to Group
in.) per minute? 9020-20).
Specification
Brake System—Maximum
T134626 –UN–19OCT00
Leakage ............................................. 25 mm (1.0 in.) per
minute with approximately
267 N (60 lb. force)
applied
– – –1/1
Brake Drag/Park Brake Position machine on a gradual slope with front of YES: Go to next check.
Check machine downhill.
NO: Check for brake
Lift bucket so it clears ground. valve leakage. See Brake
Valve Leakage Test. See
Shift FNR lever to neutral, differential lock control up, Park Brake Release
disengage park brake and release service brakes. Pressure Test. (Go to
Group 9020-25).
T6171AL –UN–09DEC88
Let machine coast freely for several feet. Apply park
brake.
LOOK: Did machine stop?
Release park brake.
LOOK: Did machine move or coast freely?
NOTE: If machine does not move freely on slope, drive

the machine for five minutes. Feel axle housing area to
locate which brake is dragging.
– – –1/1

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Park Brake Function Start machine, move throttle to 1200 rpm. YES: If the machine
Check moves in any gear, see
Leave park brake ON. your authorized dealer.
Put FNR lever in forward position. YES: If the indicators do

not work, see your
9005
Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds in authorized dealer.
10
each gear.
8
NO: Go to next check.
Move FNR lever to reverse position.
Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds in
each gear.
Move FNR lever back to neutral position.
Move throttle back to slow idle and shut the machine off.
LOOK: The machine MUST NOT move in any gear.
LOOK: Park Brake indicators MUST be lit.
LOOK: Stop light MUST be flashing.
LISTEN: An audible beeping alarm MUST be heard.
LISTEN: With the FNR In the reverse position, the reverse audible alarm MUST be
heard.
– – –1/1
Steering System Checks
– – –1/1
Steering Check Raise loader bucket above ground level. YES: Go to next check.
Raise rear of machine off ground using stabilizers. NO: Steering Valve Does
Not Return to Neutral.
Operate engine at approximately 1000 rpm. See Diagnose Steering
System Malfunctions. (Go
Specification to Group 9025-15).
Steering Check—Approximate Engine
Speed ................................................................................................................. 1000 rpm
Turn steering wheel from full left to full right several times.
LOOK: Did front wheels move smoothly in both directions?
LOOK: When steering wheel was stopped, did front wheels stop moving?
NOTE: Internal leakage or a sticking steering valve spool can cause wheels to
continue to move after steering wheel is stopped.
– – –1/1

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Steering System Leakage NOTE: Hydraulic oil must be at operating temperature. YES: Go to next check.
Check
Run engine at slow idle. NO: If steering wheel
turns with same effort
Specification after tires stop moving,
Steering System Leakage Check— verify whether valve or
9005
Engine Speed ...................................................................................................... Slow idle cylinder is leaking.
10
Hydraulic Oil—Temperature .......................................................... Operating temperature
9
Specification
Turn
Steering
steering
System—Maximum
wheel until wheels
Leakage
are in.....................................................................
maximum right turn position (against stop)Force and
then continue turning steering wheel.
See Steering System
Repeat leakage check turning steering wheel to the left. Leakage Test. (Go to
Group 9025-25).
LOOK: Did steering wheel turn with much greater effort to the left or right after the
wheels stop moving?
– – –1/1
Steering Priority Valve Operate engine at slow idle. YES: Go to next check.
Check
Specification NO: Steers hard and no
Steering Priority Valve Check—Engine decrease in engine rpm.
Speed .................................................................................................................. Slow idle See Steering, No
Steering. (Go to Group
Turn steering wheel to stop left and right. Note effort required to turn wheel. 9025-25).
Turn wheel to stop and apply constant pressure.
LOOK/FEEL: Does wheel stop at both axle stops and require normal steering wheel
effort?
LOOK/LISTEN: Does tachometer (if equipped) decrease in rpm or does engine rpm
decrease when steering wheel is held against stop?
– – –1/1
Transmission Neutral Disconnect Circuit Check
– – –1/1

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Neutral Disconnect YES: Go to next check.

Circuit Check CAUTION: Machine will move forward as FNR lever is moved.
NO: Check S21 Loader
Start engine, set idle speed at approximately 1500 rpm. Lever switch. See Park
Brake/FNR Circuit
Specification Schematic. (Go to Group
9005 Neutral Disconnect Circuit Check— 9015-15).
10 Approximate Engine Idle Speed ........................................................................ 1500 rpm
10
Put transmission in fourth gear.
Release park brake.
Shift FNR lever to forward (F) position.
LISTEN: When FNR lever is shifted to forward (F) position, can a noticeable drop in
engine speed should be heard?
Press button on loader control lever (power shift) and note sound of engine.
LISTEN: Does engine rpm increase when the neutral solenoid switches are
depressed?
– – –1/1
Driving Checks
– – –1/1
Transmission Noise IMPORTANT: Press button on gear shift lever when shifting gears (manual shift NO: Go to next check.
Check only).
YES: Go to Group
Run engine at approximately 1500 rpm with FNR lever in forward (F) position. 9020-15, Excessive
power train noise or
Specification excessive gear clash
Transmission Noise Check— when shifting for manual
Approximate Engine Speed ............................... 1500 rpm with FNR lever in forward (F) shift or power shift.
position
Shift transmission into each gear and drive for a short distance.
LISTEN: Can excessive gear noise be heard when shifting between gears?
– – –1/1

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Differential Lock Check Raise wheels off ground with stabilizers and loader YES: Go to next check.
bucket.
NO: Check differential
Unlock brake pedals. Turn MFWD switch OFF (if lock switch and solenoid.
equipped). See Differential Lock
Pressure test. (Go to
9005
Operate machine at approximately 1500 rpm in 1st Group 9020-25).
10
forward.
11
T6295AD –UN–19OCT88
Specification
Differential Lock Check—
Approximate Engine
Speed .......................................... 1500 rpm in 1st forward
Depress differential lock control.
Apply one brake pedal.
LOOK: Both wheels must stop.
– – –1/1
Differential Gear and Shift transmission to first gear and operate engine at approximately 1500 rpm. NO: Go to next check.
Pinion Check
Specification YES: Check rear axle.
Differential Gear and Pinion Check— See Diagnose Rear Axle
Approximate Engine Speed ............................................................ 1500 rpm in 1st gear Malfunctions. (Go to
Group 9020-15).
Move FNR lever to forward (F) position.
Steer machine in a maximum left turn and depress left brake pedal to stop the left
wheel.
Steer machine in a maximum right turn and depress right brake pedal to stop the right
wheel.
LISTEN: Can excessive gear noise be heard in the differential or pinion gear area?
– – –1/1
Front Wheel Alignment Drive machine in fourth gear forward on a surface with NO: Go to next check.
(Toe-In) Check loose material.
YES: If material is
LOOK: Is material from behind front wheels thrown thrown, excessive tire
excessively inward or outward? wear will result. See
Checking and Adjusting
Toe-In. (Go to Group
9020-20).
T6264AI –UN–22OCT91
– – –1/1

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Engine and Torque Position machine with loader bucket at ground level NO: Go to next check.
Converter Check against dirt bank or immovable object.
(Without MFWD) YES: If the wheels can
Shift transmission into first gear. be easily stalled, check
rear axle malfunction.
Move FNR lever to forward (F) position. See Diagnose Rear Axle
9005
Malfunction. (Go to Group
10
Engage differential lock. 9020-15).
12
T6171AM –UN–09DEC88
Increase engine speed to fast idle.
LOOK: Do rear wheels stall?
NOTE: This test will give a general indication of engine,

transmission and torque converter performance.
– – –1/1
Transmission Hydraulic Run engine at approximately 1500 rpm. YES: Go to next check.
System Check
Specification NO: Check torque
Transmission Hydraulic System Check— converter. See Torque
Approximate Engine Speed ............................................................................... 1500 rpm Converter Stall Speed
Test. (Go to Group
Shift transmission into third gear. 9020-25).
Move FNR lever to forward (F) position.
Make several shifts from third forward to third reverse. Start counting the number of
seconds when FNR lever is moved to opposite direction.
LOOK: Is shift from one direction to the other completed in three seconds.
NOTE: If bad in one direction ONLY, check direction pack.
– – –1/1
Ride Control Operational Checks (If Equipped)
– – –1/1

031504
PN=40
Electrical Checks Turn key switch on (do not start engine). YES: Go to next check.
Turn ride control switch on. NO: Check and replace

ride control switch light.
LOOK: Does ride control switch light turn on?
IF OK: Check wiring. See
9005
Turn ride control switch off. Ride Control Circuit
10
13
LOOK: Does ride control switch light turn off? 9015-15).
Turn ride control switch on.
Turn key switch off.
LOOK: Does ride control switch light turn off?
– – –1/1
Hydraulic Checks Start tractor and set throttle about 1000 - 1500 rpm. NO: Continue check.
NOTE: Make sure park Turn ride control on. YES: Check ride control
brake is off during hydraulics.
hydraulic checks. Try to lift front end of tractor off ground using loader boom lever.
Release loader boom lever.
LOOK/FEEL: Will front end of tractor lift off of ground and hold?
Turn ride control off. YES: Go to next check.
Try to lift front end of tractor off ground using loader boom lever. NO: Check ride control
hydraulics. See Ride
Release loader boom lever. Control Hydraulic Circuit.
(Go to Group 9025-05).
LOOK/FEEL: Will front end of tractor lift off of ground and hold?
– – –1/1
Ride Control System Run engine at high idle. YES: Go to next check.
Check
Push ride control switch to on position. NO: Check accumulator
charge. See Ride Control
Raise boom to maximum height. Accumulator Check and
Charge. (Group 9025-20.)
Power boom down half-way to ground.
Stop suddenly by releasing loader control lever.
LOOK: Is boom cushioned when loader control valve is released?
– – –1/1

031504
PN=41
Mechanical Front Wheel Drive (MFWD) Driving Check (If Equipped)
9005 – – –1/1
10
14
MFWD Switch Check YES: Go to next check.
NO: Check electrical

circuit. See MFWD Circuit
9015-15). See MFWD
Pressure Test. (Go to
Group 9020-25).
T131717B –UN–15JUN00
Turn key switch to ON.
Push switch and engage MFWD.
LOOK: Does MFWD light (B) display in switch come ON when switch is pressed?
Push switch to disengage MFWD.
LOOK: Is MFWD light in switch OFF with MFWD disengaged?
NOTE: Indicator light in MFWD switch will remain ON while MFWD is engaged. If
MFWD is turned OFF while operating, light will go out but MFWD could stay on until
load on drive train is released.
– – –1/1
MFWD Differential Check Start engine and run at low idle. YES: Go to next check.
Specification NO: If at least one front

MFWD Differential Check—Engine wheel does not turn with
Speed ................................................................................................................... Low idle MFWD applied, check
circuit schematic.See
Raise machine off ground with stabilizers and loader. MFWD Circuit Schematic.
Release park brake. See MFWD Pressure
Test. (Go to Group
Shift transmission to first gear and put FNR in forward. 9020-25).
Engage MFWD.
Lower front wheels to just contact ground.
LOOK: Does at least one front wheel turn?
– – –1/1

031504
PN=42
Engine and Torque With loader bucket level and cutting edge at the YES: Go to next check.
Converter Check (With centerline of front wheels, put machine against a dirt
MFWD) bank or immovable object. NO: If all wheels stop, a
torque converter or
Engage MFWD and differential lock. transmission control valve
problem is indicated. If
9005
Shift transmission to first forward. the front wheels stop,
10
MFWD problem is
15
Increase engine speed to fast idle indicated. See MFWD
T6171AN –UN–09DEC88
Pressure Test. (Go to
LOOK: Do both rear wheels and both front wheels turn? Group 9020-25).
– – –1/1
MFWD Gear and Pinion Drive machine at transport speed with MFWD engaged, then disengaged. NO: Go to next check.
Check
LISTEN: Does MFWD “whine” when disengaged. YES: If MFWD whines,
check oil levels and fill to
NOTE: It is normal for MFWD to “whine” when engaged. correct levels.
– – –1/1
Hydraulic System Checks
– – –1/1
Hydraulic Pump NOTE: If hydraulic oil is not at operating temperature, heat oil to 38—52° C (100— YES: Go to next check.
Performance Check 125°F).
NO: If cycle time is slow,
Put loader bucket flat on ground. check hydraulic functions.
See Hydraulic System
Specification Pretest. (Go to Group
Hydraulic Oil—Temperature ....................................................... 38—52° C (100—125°F) 9025-15).
Transmission in neutral, FNR in Forward.
Run engine at slow idle.
Specification
Main Hydraulic Pump Performance
Check—Engine Speed ........................................................................................ Slow idle
Measure cycle time of loader raise to maximum height (including bucket leveling).
LOOK: Does loader raise to maximum height in 15 seconds or less?
Specification
Loader Raise to Maximum Height
(Including Bucket Leveling)—Maximum
Cycle Time ...................................................................................................... 15 seconds
NOTE: Take the average cycle time for at least three cycles. This time will give a
general indication of main hydraulic pump performance.
– – –1/1

031504
PN=43
Cylinder Cushion Check Raise wheels off ground with stabilizers. YES: Go to next check.
Boom MUST be lowered from the transport position. NO: Remove and repair
cylinder cushion. Go to
Run engine at high idle. repair manual.
9005
Specification
10
Cylinder Cushion Check—Engine Speed ........................................................... High idle
16
Activate backhoe swing left and right.
Note sound and speed as cylinders near end of their stroke.
LOOK: Does speed of cylinder rod decrease near the end of its stroke?
LISTEN: Can hydraulic oil be heard flowing through orifice as cylinder rod nears the
end of its stroke?
Repeat check using backhoe boom raise function.
NOTE: Crowd cylinder does not have cylinder cushion.
– – –1/1
Stabilizer Cylinder and Operate machine at approximately 1500 rpm. YES: Go to next check.
Valve Check
Specification NO: Cylinders drift up or
Stabilizer Cylinder and Valve Check— down. See Cylinder
Approximate Engine Speed ............................................................................... 1500 rpm Leakage Test. (Go to
Group 9025-25).
Position loader bucket above ground.
Lower each stabilizer cylinder and raise rear of machine off ground.
LOOK/FEEL: Do cylinders extend smoothly and hold machine up?
Retract each stabilizer cylinder.
LOOK/FEEL: Do cylinders retract smoothly and remain up?
– – –1/1

031504
PN=44
Backhoe and Loader NOTE: Feel backhoe cylinders. Cylinder must be warm NO: Go to next check.
Function Drift Check to touch (38—52°C [100—125°F). If cylinders are not
warm, heat oil to specifications. YES: Verify which
function is drifting. See
With backhoe fully extended, put backhoe bucket at a Function Drift Test. (Go to
45° angle to ground. Group 9025-25).
9005
10
Specification
17
Hydraulic Oil—
T7374CI –UN–04OCT90
Temperature................................ 38—52°C (100—125°F)
(Cylinders warm to touch)
Lower boom until bucket cutting edge is 50 mm (2.0 in.)

off the ground.
Position loader bucket same distance off ground as

backhoe bucket.
Run engine at slow idle and observe bucket cutting

edge.
Specification
Backhoe and Loader
Function Drift Check—
Engine Speed ..................................................... Slow idle
LOOK: Do cutting edges touch ground within one

minute?
Specification
Backhoe and Loader
Function—Maximum Drift ............. 50 mm (2.0 in.) in one
minute
– – –1/1
Hydraulic Control Valve NOTE: Husco valves have one lift check for both work ports, and therefore only need NO: Go to next check.
Lift Check Test to be checked in one direction.
YES: Check cylinder
Raise loader bucket 1 m (3.0 ft.) off the ground with the bucket level. leakage. See Cylinder
Leakage Test. (Go to
Position backhoe at maximum reach with bucket in dump position, 1 m (3.0 ft.) off the group 9025-25).
ground.
Stop the engine.
Activate each function one at a time.
• Loader boom raise

• Loader bucket rollback
• Backhoe boom up
• Dipperstick extend
• Backhoe bucket dump
LOOK: Do functions move when the control lever is activated?
– – –1/1

031504
PN=45
Loader Boom Float Put loader bucket at maximum height position with bucket dumped. YES: Go to next check.
Check
Run engine at approximately 1500 rpm. NO: If it jumps out of
detent, check detent
Specification spring and detent balls.
Loader Boom Float Check—Approximate Go to repair manual.
9005
Engine Speed ..................................................................................................... 1500 rpm
10
18
Move the loader control lever forward into boom float detent position, and at the same
time into bucket rollback detent position. Remove hand from control lever.
LOOK: Does loader control lever remain in the boom float detent position?
– – –1/1
Loader Return-to-Dig YES: Go to next check.

Check
NO: Adjust switch until
activated in cam. See
Adjusting Loader Bucket
Self-Leveling Linkage and
Return-to-Dig Switch.
(Group 9025-20.)
T7374CH –UN–04OCT90 T164529B –UN–24JAN03
Early Machines Later Machines
Run engine at approximately 1500 rpm.

Position loader and bucket 2 m (6.0 ft) above ground level with bucket in full dump
position.
Move the loader control lever into bucket rollback detent position. Remove hand from
control lever.
LOOK: Does loader control lever disengage from bucket rollback detent when bucket
indicator pointer is aligned with mark (1) on boom pivot?
LOOK: When bucket is at ground level, bucket must be level and bucket indicator
pointer must be aligned with mark (1) on the boom pivot.
– – –1/1
Bucket Leveling Linkage NOTE: The loader bucket leveling feature functions YES: Go to next check.
Check during the boom raise cycle only. When bucket is
lowered, the operator can manually level the bucket or NO: Adjust switch until it
use the return-to-dig. is activated in cam. See
Loader Bucket
Put loader bucket in the rollback position with the boom Self-Leveling Indicator
near ground level. Linkage and
Return-to-Dig Switch
T7374CJ –UN–05OCT90
Raise the loader and at the same time hold the control Adjustment. (Go to Group
lever in the bucket rollback position. 9025-20).
Observe bucket and loader control lever as the loader

raises.
LOOK/FEEL: Does loader control lever move into the

bucket dump position and the bucket dump function
slowly activate? When the loader control lever moves to
activate the bucket dump function, does the bucket
position remain stationary the remainder of the loader
boom raise cycle?
– – –1/1

031504
PN=46
Check Operation Of Accessories (Engine Stopped)
– – –1/1 9005
10
19
Front Light Switch Check Turn key switch to ON position. YES: Go to next check.
Push front light rocker switch to middle position. NO: Check fuse and
bulbs. Check wiring. See
LOOK: Are two front lights, two red tail lights and gauge lights ON? System Functional
Schematic Front Work
Push front light rocker switch in completely. and Drive Light Circuit.
LOOK: Are four front lights (if equipped), two red tail lights and gauge lights ON?
– – –1/1
Rear Light Switch Check Turn key switch to ON position. YES: Go to next check.
Push side console rear light rocker switch in. NO: Check fuse and
LOOK: Are rear lights ON? System Functional
Schematic SE15 Front
Work and Drive Light
Circuit. (Go to Group
9015-10).
– – –1/1
Turn Signal Check Turn key switch to ON position. YES: Go to next check.
Push right side of turn signal rocker switch down. NO: Check fuse and
LOOK: Are right front and rear amber lights flashing? Does right indicator light on top System Functional
of steering column flash? Schematic SE19 Flasher
And Turn Signal Light
Push left side of turn signal rocker switch down. Circuit. (Go to Group
9015-10).
LOOK: Are left front and rear amber lights flashing? Does left indicator light on top of
steering column flash?
– – –1/1

031504
PN=47
Brake Light Switch Key switch in the ON position. YES: Go to next check.
Check
Depress and hold left brake pedal, then right brake pedal. NO: Check fuse and
LOOK: Rear brake light must come ON when either pedal is depressed with key switch System Functional
in ON position. Schematic SE19 Flasher
9005
10
20
9015-10).
– – –1/1
Warning Light Check Key switch ON. YES: Go to next check.
Push bottom of warning light rocker switch in. NO: Check fuse and
LOOK: Are both front and rear amber lights ON? Are both turn signal indicators and System Functional
light in warning light rocker switch flashing? Schematic SE19 Flasher
9015-10).
– – –1/1
Horn Check Turn key switch to ON position. YES: Go to next check.
Push horn button NO: Check fuse and

bulbs. Check wiring.See
LISTEN: Did horn sound? System Functional
Schematic SE18 Horn
9015-10).
– – –1/1
Cab Component Checks
– – –1/1

031504
PN=48
Seat Linkage Check Lift lever (1). YES: Go to next check.
Move seat forward and rearward and release lever. NO: Repair linkage. Go to
repair manual.
LOOK: Does lever move freely and lock seat in desired
position?
9005
10
21
T103194 –UN–20AUG96
– – –1/1
Seat Height Adjustment Turn knob (3) to raise or lower seat to desired position. YES: Go to next check.
Check
LOOK: Does seat move up or down and remain in NO: Go to repair manual.
desired position?
T103194 –UN–20AUG96
– – –1/1
Seat Swivel Linkage Lift lever (2) up. YES: Go to next check.
Check
Move seat from loader to backhoe position and engage NO: Lubricate or repair
latch. linkage. Go to repair
manual.
LOOK: Does seat latch move freely and hold seat in
desired position?
T103194 –UN–20AUG96
FEEL: Does lever move freely and hold seat in loader
and backhoe positions?
– – –1/1
Seat Back Linkage Lift lever (4) up. YES: Go to next check.
Check
Position seat back as desired and engage latch. NO: Lubricate or repair
linkage. Go to repair
FEEL: Does lever move freely and hold seat in desired manual.
positions?
T103194 –UN–20AUG96
– – –1/1

031504
PN=49
Left Cab Door Latch and Unlatch door. YES: Go to next check.
Opener Check
Observe door as it opens. NO: Adjust cab door. Go
to repair manual.
Pull door closed and latch it.
9005
FEEL: Does cab door latch work freely?
10
22
LOOK: Will door cylinder push door open?
LOOK: Does cab door contact door stop bumper before door cylinder bottoms?
– – –1/1
Right Door Latch and Unlatch door and pull door open. YES: Go to next check.
Opener Check (If
Equipped) Close and latch door. NO: Adjust door. Go
repair manual.
FEEL: Does cab door latch work freely?
– – –1/1
Rear Windows Latch and YES: Go to next check.

Opener Checks CAUTION: Prevent unexpected machine movement. Pilot controls must
be disabled when opening or closing rear windows. NO: Check for
obstructions. Go to repair
Squeeze latches on both sides of upper rear window. Lower window to rubber manual.
bumpers.
Observe window as it opens.
Push window up and into window catches and note fit.
Squeeze latches on both sides of middle rear window. Raise window to catches.
LOOK: Do window latched
LOOK: Do window catches hold and not bow the windows in the up and down
position?
– – –1/1
Side Window Checks Open front and rear side windows. YES: Go to next check.
Fasten rear window against front window. NO: Adjust windows. Go

to repair manual.
Fasten front window against rear window
Fasten windows with latches
T6171DF –UN–09DEC88
LOOK/FEEL: Do hinges move freely? Are locking latches
equally loaded when closed?
– – –1/1

031504
PN=50
Blower Motor Check YES: Go to next check.
NO: Check fuse and

bulbs. See System
Functional Schematic
SE11 Blower Circuit. (Go
9005
to Group 9015-10).
10
23
T134376B –UN–07OCT00
Engine OFF key switch ON.
Turn blower switch (3) to detent positions.
FEEL/LISTEN: Does blower fan have four speeds?
Does air exit from ducts?

– – –1/1
Heater YES: Go to next check.
NO: Check fuse and

bulbs. See System
SE11 Blower Circuit. (Go
to Group 9015-10).
T134376B –UN–07OCT00
Start engine and run at fast idle.
Specification
Heater Check—Engine Speed ............................................................................ Fast idle
Wait two minutes.
Turn heater temperature switch (1) ON. Turn temperature switch (2) to maximum heat.
Turn blower switch (3) to high speed.
FEEL: Is air from ducts warm?
– – –1/1

031504
PN=51
Air Conditioner (If YES: Go to next check.

Equipped)
NO: Check the
malfunctions list. See
Diagnose Air Conditioning
Electrical Malfunctions.
9005
Go to Group 9031-15.
10
24
T134376B –UN–07OCT00
Start engine and run at fast idle.
Specification
Air Conditioner Check—Engine Speed ............................................................... Fast idle
Turn air conditioner switch (1) to ON position turn knob (2) to a high cold setting.
Turn blower switch (3) to high speed.
Wait for any warm air in duct system to be exhausted.
FEEL: Is air from ducts cool?
– – –1/1
Rear Windshield Wiper Turn key to ON position. YES: Go to next check.

Check
Push rear wiper rocker switch to ON position. NO: Check fuse. Check
rear wiper. See System
Push rear wiper rocker switch all the way in. Functional Schematic
SE13 Wiper And Washer
Push rear wiper switch to OFF position. Circuit. (Go to Group
9015-10).
LOOK: Rear wiper must operate.
LOOK: Wipers must return to park position.
– – –1/1
Front Windshield Wiper Turn key switch to ON position. YES: Go to next check.
Check
Push front wiper rocker switch to first detent, middle position. NO: Check fuse. Check
rear wiper. See System
Push front wiper switch all the way in. Functional Schematic
SE13 Wiper And Washer
Push front wiper switch to OFF position. Circuit. (Go to Group
9015-10).
LOOK: Does wiper operate and have two speeds?
LOOK: Do wipers return to the park position?
– – –1/1

031504
PN=52
Front Windshield Washer Turn key switch to ON position. YES: Go to next check.
Check
Push windshield washer rocker switch in. NO: Check fluid level,
and fluid lines for
LOOK: Fluid must spray on front window. Rocker switch must return to OFF position. blockage. Check wiring.
See System Functional
9005
Schematic SE13 Wiper
10
And Washer Circuit. (Go
25
to Group 9015-10).
– – –1/1
Cab Dome Light Check Turn key switch to ON position. YES: Go to next check.
Push dome light switch to ON position. NO: Check fuse and

LOOK: Does lights come ON? System Functional
Schematic SE6 Dome
Light Circuit. (Go to
Group 9015-10).
– – –1/1
Pilot Control System Checks
– – –1/1
Pilot Control Tower Move pilot control towers into operating position. YES: Go to next check.
Operating/Stored
Position Check Release towers. NO: Inspect and repair
pilot control towers. See
LOOK/FEEL: Do towers stay in operating position? Pilot Control Tower
Repair (S.N. 913484— ).
Move pilot control towers into stored position. (Group 3315.)
LOOK/FEEL: Do towers stay in stored position?
– – –1/1

031504
PN=53
Pilot Control Run engine at 1500 rpm. NO: Continue with check.
Enable/Disable Switch
Check Raise machine off ground with stabilizers and loader bucket. YES: Check pilot control
Disable pilot controls and move control levers. Control Circuit in System
9005
LOOK: Do activated functions move? (Group 9015-15.)
10
26
Enable pilot controls and move control levers. YES: Go to next check.
LOOK: Do activated functions move? NO: Check pilot control

Control Circuit in System
(Group 9015-15.)
– – –1/1
Pilot Control Pattern Enable pilot controls. YES: Continue with

Select Switch Check check.
Select backhoe from the two position pattern select switch.
NO: Check pattern select
Activate left and right pilot control levers forward and backward. circuit (SE32). See
System Functional
LOOK: Does backhoe boom move when left pilot control lever is activated? Schematic (S.N. —
913483) or see System
Does backhoe crowd move when right pilot control lever is activated? Functional Schematic
(S.N. 913484— ). (Group
9015-15.)
Select excavator from the two position pattern select switch. YES: Go to next check.
Activate left and right pilot control levers forward and backward. NO: Check pattern select
circuit (SE32). See
LOOK: Does backhoe crowd move when left pilot control lever is activated? Pattern Select Circuit in
System Functional
Does backhoe boom move when right pilot control lever is activated? Schematic. (Group
9015-15.)
– – –1/1
Pilot Control Valve Enable pilot controls. YES: Go to next check.

Check
Move pilot control levers in all directions. NO: If pilot control levers
bind during travel or do
FEEL/LOOK: Do levers move freely in all directions? not return to neutral
position, inspect and
FEEL/LOOK: Do levers spring back to neutral when released? repair pilot control valves.
See Pilot Control Valve
Repair (S.N. 913484— ).
(Group 3315.)
– – –1/1

031504
PN=54
Pilot Control Run engine at 1500 rpm. YES: Go to next check.

Accumulator Check
Operators seat in backhoe position. NO: Check pilot control
Enable pilot controls. Control Circuit in System
9005
Disengage boom from boom lock. (Group 9015-15.)
10
27
Hold boom up function over relief for ten seconds.
Turn engine off, and turn key switch to on.
NOTE: Pilot control enable switch must be cycled after key switch is turned back into
on position.
Cycle pilot enable switch to enable position.
Activate boom down function.
LOOK: Does boom lower when boom down function is activated?
– – –1/1

031504
PN=55
9005
10
28

031504
PN=56
Section 9010
Engine
Contents
Page

POWERTECH 4.5L (4045) and 6.8L 9010
(6068) John Deere Engines . . . . . . . . . . . .9010-05-1
Engine—Sectional View . . . . . . . . . . . . . . . .9010-05-2
General Engine Description. . . . . . . . . . . . . .9010-05-3

POWERTECH 4.5L (4045) and 6.8L
Make Visual Inspection of Engine and
Supporting Systems. . . . . . . . . . . . . . . . . .9010-15-2
Diagnose Engine Malfunctions . . . . . . . . . . .9010-15-4
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
Adjust Speed Control Lever Tension . . . . . . .9010-20-2
Engine Speed Control Linkage
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .9010-20-4
Slow and Fast Idle . . . . . . . . . . . . . . . . . . . .9010-20-8
Group 25—Tests
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-1
JT05800 Digital Thermometer Installation . . .9010-25-1
Air Intake System Leakage Test . . . . . . . . . .9010-25-2
Radiator Air Flow Test. . . . . . . . . . . . . . . . . .9010-25-4
Turbocharger Boost Pressure—Engine
Performance Test . . . . . . . . . . . . . . . . . . .9010-25-8
Injection Pump Timing. . . . . . . . . . . . . . . . .9010-25-10
Fuel Line Leakage Test. . . . . . . . . . . . . . . .9010-25-11

031504
PN=1
Contents
9010

031504
PN=2
Group 05
Theory of Operation
POWERTECH 4.5L (4045) and 6.8L (6068)
John Deere Engines
For additional engine information on John Deere engines

and components, see the following component technical
manuals (CTM).
–UN–07SEP88
• See POWERTECH 4.5L (4045) and 6.8L (6068) Diesel
Engines Base Engine (CTM104).
M44215
Engines Mechanical Fuel Systems (CTM207). 9010
05
1
OUO1010,0000660 –19–18FEB04–1/1

031504
PN=59
Theory of Operation
Engine—Sectional View
9010
05
2
–UN–06AUG96
T102831
A—Rocker Arm Shaft F—Cylinder Block K—Connecting Rod P—Piston Rings

B—Cylinder Head G—Crankshaft L—Liner Packing Rings Q—Valve
C—Push Rod H—Crankshaft Counterweight M—Cylinder Liner R—Fuel Injection Nozzle
D—Cam Follower I—Oil Pan N—Piston S—Valve Spring
E—camshaft J—Balancer Shafts O—Piston Pin T—Rocker Arm
TX,05,SS3181 –19–05AUG96–1/1

031504
PN=60
Theory of Operation
General Engine Description
Engines are vertical, in-line, valve-in-head, 4-cycle Pistons are made of high-grade cast aluminum alloy
(stroke) diesel engines. with internal ribbing. The shirt is cam ground to allow
for expansion during operation. The piston crown has
Direct fuel injection is provided by a rotary-type a cut-out combustion bowl with a truncated cone
injection pump and 9.5 mm injection nozzles mounted center. All piston rings are located above the piston
in cylinder head. The camshaft gear-driven injection pin. Two compression rings and one oil control ring are
pump is timed to the crankshaft by the timing gear used. The top compression ring is a keystone shaped
train. ring located close to the top of the piston for improved
engine performance. 9010
Some engines are equipped with a turbocharger. The 05
3
turbocharger uses energy from exhaust gases to The hardened, fully-floating piston pins are held in
compress intake air and force it into the combustion place by snap rings. Spray jets (piston cooling orifices)
chamber. in cylinder block spray pressurized oil on the underside
of the piston to lubricate piston pins and cool pistons.
The cylinder block is a one-piece casting. The block is
available in structural and non-structural configurations. The forged steel connecting rods have replaceable pin
bushing and bearing inserts. Some connecting rods
The camshaft is timed to the crankshaft through the have a tapered pin-end while others have a straight
timing gear train. The camshaft rotates in honed bores pin end.
in the cylinder block. All engines use a bushing in No.
1 camshaft bore. The camshaft lobes determine the The engine is equipped with a gear driven oil pump
duration and lift of each valve. and full-flow oil filter. The oil filter has an internal
bypass valve which opens if the filter element
Intake and exhaust valves are operated by camshaft becomes restricted. Engines are equipped with an oil
followers, push rods and rocker arm assembly. Valve cooler mounted on the right side of the cylinder block.
seat inserts in cylinder head are used for intake and The engine is equipped with a pressure regulator valve
exhaust valves. to relieve excessive pressure build-up in the main oil
gallery, and a bypass valve to prevent oil starvation if
The crankshaft is a one-piece, heat treated, the oil cooler and filter become plugged.
nodular-iron or steel forging which operates in
replaceable two-piece main bearings. Crankshafts are Balancer shafts are used on four-cylinder engines to
dynamically balanced and are machined with undercut reduce vibration. The two shafts rotate on bushings in
and rolled fillets. Two-piece main thrust bearing inserts cylinder block and are counter-rotating at twice engine
are used to control crankshaft endplay. speed.
Cylinder liners are “wet” sleeve type and are The engine has a pressurized cooling system,
individually replaceable. O-rings seals are used at the consisting of radiator, water pump, multi-blade fan, and
lower connection between cylinder block and liners. one or two thermostats.
TX,05,SS3180 –19–08JUN98–1/1

031504
PN=61
Theory of Operation
9010
05
4

031504
PN=62
Group 15
Diagnostic Information
POWERTECH 4.5L (4045) and 6.8L (6068)
John Deere Engines

manuals (CTM).
–UN–07SEP88
M44215
15
1
OUO1010,0000660 –19–18FEB04–1/1

031504
PN=63
Make Visual Inspection of Engine and Supporting Systems
1. Inspect for coolant leaks at: The condition of the belts and their tension must be
checked periodically.
• Radiator
• Water pump 8. Inspect fuel tank:
• Hoses
• Coolant manifold a. Inspect the tank mounting hardware to ensure
• Thermostat cover they are in position and tight.
9010 Check for proper coolant level in radiator. Look at b. Inspect fuel tank for cracks and leakage.
15 coolant for evidence of oil and/or debris.
2
c. Inspect fuel tank outlet strainer and water trap
2. Inspect for oil leaks around the oil pan, drain plug, for accumulated debris by shining a flashlight
oil filter, and clutch housing at drain hole. through the filler neck toward bottom right corner
of fuel tank.
3. Inspect hoses to see if they are hard, cracked, soft,
or swelled. Replace as necessary. 9. Inspect fuel transfer pump. See if there is fuel
leaking from inlet and outlet connections.
4. Inspect radiator for bent fins, kinks, dents, cracked
side frames, seams and tubes. Check radiator 10. Inspect fuel filter for water in base of filter. Look
mounts for loose hardware. for fuel leaking from inlet and outlet connections.
5. Check fan to ensure it has been installed correctly. Check for debris and air in filters. Drain or bleed
filters if necessary. Replace filters as required.
6. Inspect fan blades. They must be straight and not
striking the radiator core or shroud. Bent blades
CAUTION: Escaping fluid under pressure
reduce the efficiency of the fan and make the fan
can penetrate the skin causing serious
out of balance. An out of balance condition can add
injury. Relieve pressure before
additional load to fan support and bearing.
disconnecting hydraulic or other lines.
Tighten all connections before applying
7. Inspect fan belt and belt tensioner. Belt must not be
pressure. Keep hands and body away from
too tight, too loose, or cracked. Check to see if belt
pinholes and nozzles which eject fluids
pulleys are worn excessively (if belts run against
under high pressure. Use a piece of
bore of groove) and that the pulleys are in proper
cardboard or paper to search for leaks. DO
alignment. Tensioner must turn freely and smoothly.
NOT use your hand.
Tensioner must hold constant pressure on belt.
If ANY fluid is injected into the skin, it must
A belt which is too tight puts extra load on the
be surgically removed within a few hours by
bearings and shortens the life of the bearings as
a doctor familiar with this type injury or
well as the belts. A belt which is too loose allows
gangrene may result.
slippage and reduces fan and alternator speed,
causes excess belt wear. Belt slippage can lead to
11. Inspect injection pump and nozzles.
overheating of the cooling and/or hydraulic system,
and undercharged batteries.
Continued on next page TX,15,SS3183 –19–09AUG96–1/2

031504
PN=64
Check fuel inlet and outlet connections and Check all air intake system connections to be sure
injection line connections. If any of the lines are they are tight. Clean or replace filters when
twisted, kinked, or broken, repair or replace as indicator shows red or when there is excessive
necessary. Check injection line clamps to ensure smoke or loss of power.
they are in position and tight.
14. Check muffler for any signs of leakage or areas
12. Inspect speed control linkage. that have rusted through. Exhaust leaks can result
in a fire in the engine compartment.
Check for free movement. Be sure the injection
pump lever contacts the fast idle stop on the 15. Check for debris on exhaust manifold.
injection pump. 9010
15
3
13. Inspect air cleaner elements for debris, filter
condition and air restriction indicator to ensure
indicator isn’t in red.
TX,15,SS3183 –19–09AUG96–2/2

031504
PN=65
Diagnose Engine Malfunctions
NOTE: Diagnostic charts are arranged from most

probable and simplest to verify, to least likely and
more difficult to verify. Remember the following
steps when diagnosing a problem:
Step 1. Operational Checkout Procedure (See

Group 9005-10).
9010 Step 2. Adjustments and/or Tests (See Group

15 9010-20 and/or 9010-25).
4
Symptom Problem Solution
Engine Will Not Start Or Starts Fuel tank empty Check fuel quantity
Hard
Fuel tank vent plugged Remove cap and listen for sound of
air entering tank. Replace cap.
No electrical power to injection pump Turn key switch to "On". Must hear
solenoid click at injection pump. Replace
fuse. Repair wiring.
Water in fuel or water frozen in fuel Drain water from fuel tank. Inspect
line. fuel filter for water. Change filter.
Debris in fuel or wrong grade of fuel Check fuel tank outlet strainer for
type of fuel debris. Check bottom of
fuel tank for debris. Clean tank. Add
fuel. Check grade of fuel. Add
correct fuel. See Fuel Tank. In
Group 4-6.
Air leak on suction side of fuel Check for bubbles in fuel filter and
system tighten connections. Inspect fuel
lines for damage.
Fuel transfer pump diaphragm Check engine oil for fuel dilution.
leaking Replace fuel pump.
Slow cranking speed Check battery and connections.

Incorrect engine oil (Cold weather).
Restricted air filter Check air filter restriction indicator

and air filters. Clean.
Continued on next page TX,15,SS3184 –19–09JUL98–1/11

031504
PN=66
Stuck injection pump metering valve. Tap injection pump housing (lightly)
if engine now starts. Replace
metering valve. See your authorized
injection pump service center.
Faulty electric shut-off Test shut-off solenoid in Group

9015-10. See System Functional
Schematic (2 of 9). Inspect solenoid
wiring and linkage. 9010
15
5
Improper injection pump timing Check timing. See CTM104.
Injection pump Remove and test pump. See

CTM104.
Injection nozzle(s) Remove and test nozzles. See

CTM104.
Worn compression rings or low Check compression. Repair. See

compression CTM104.
Blown head gasket Remove. Route radiator overflow

into container of fluid and check for
bubbles. Bubbles indicate head
gasket linkage. See CTM104.
Engine Surges Or Stalls Air in fuel Inspect filter for evidence of air in
Frequently fuel. Tighten connections and bleed
fuel system.
Fuel tank vent plugged Remove cap and listen for sound of
air entering tank. Replace cap.
Debris in fuel or wrong grade of fuel Check fuel tank outlet strainer for
debris. Check bottom of fuel tank for
debris. Clean tank. Add fuel. See
Fuel Tank.Check grade of fuel in
operator’s manual.
Water in fuel Drain fuel tank and inspect filter

element for water. Replace filters.
Fuel filter plugged Replace filter.

031504
PN=67
Return line from injection pump to Route return line at the pump into a
tank restricted separate container. If engine now
operates normally, check return line
to tank for restriction. Replace.
Fuel injection pump out of time Time injection pump. See CTM104.
Check return oil fitting on top of Remove, inspect and clean.

9010 injection pump control cover Determine source of debris. See
15 plugged. your authorized injection pump
6
service center.
Injection pump metering valve Remove pump top cover and

sticking inspect. Replace metering valve.
See your authorized injection pump
service center.
Engine overheating Test cooling system. See CTM104.
Fuel transfer pump Test transfer pump pressure. See

CTM104.
Fuel injection pump Remove fuel injection pump. See

CTM104. Test pump. See your
authorized injection pump service
center.
Injection nozzle(s) Remove and test nozzle(s). See

CTM104.
Improper valve clearance Check and adjust valve clearance.

See CTM104.
Valve sticking or burned Do compression pressure test. See

CTM104.
Worn or broken compression rings Route radiator overflow hose into a

or cylinder head gasket leaking container of fluid and check. Check
for bubbles. Bubbles indicate head
gasket leakage. See CTM104. Do
compression pressure test. See
CTM104.
Engine Misses Air in fuel Check for evidence of air in filter.

Tighten connections and bleed fuel
system.

031504
PN=68
Debris in fuel or wrong grade of fuel Check fuel tank for water. Check fuel
tank strainer and fuel filter for debris.
Clean. Check grade of fuel.
Idle speeds out of adjustment (too Test slow idle speeds. See CTM104.
low)
Fuel injection pump out of time Time injection pump. See CTM104.
9010
Fuel transfer pump Test fuel system pressure. See 15
7
CTM104.
Injection pump governor faulty or Inspect. Repair. See your authorized

metering valve sticking injection pump service center.
Engine overheating Verify engine temperature. See

CTM104. Test thermostat. Replace.
See CTM104.
Incorrect valve clearance Check and adjust valve clearance.

See CTM104.
Bent push rods Inspect. Replace.
Cylinder head gasket leaking Route radiator overflow hose into

container of fluid and check for
bubbles. Bubbles indicate head
gasket leakage. See CTM104.
Valve sticking or burned Do compression pressure test. See

CTM104.
Worn or broken compression rings Do compression pressure test. See

CTM104.
Fuel injection pump Remove and test fuel injection

pump. See CTM104.
Injection nozzles(s) plugged Remove and test nozzles. See

CTM104.
Engine Does Not Develop Power Fuel tank outlet strainer plugged Check fuel tank for water or debris.
Remove and clean.
Fuel filter plugged Replace fuel filter.

031504
PN=69
Wrong grade of fuel Drain and add correct fuel.
Air system restricted Check air filter restriction and air

filters. Clean.
Incorrect high idle speed (too low) or Adjust linkage. See Engine Speed
linkage out adjustment. Control Linkage Adjustment. In this
Group. Check high idle speed. See
9010 Slow and Fast Idle. In this Group.
15
8
Incorrect engine or injection pump Check. Adjust timing. See CTM104.
timing
Incorrect valve clearance Adjust valve clearance. See

CTM104.
Injection pump return fuel tube or Route return line at the pump into a
fittings are restricted separate container. If engine now
operates normal, check return line
for restriction. Replace.
Fuel transfer pump malfunction Test fuel transfer pump pressure.

See CTM104.
Fuel line restricted Route an external fuel source to fuel

transfer pump. If engine operation is
normal clean fuel line.
Excess drag in brake system Check park brake drag. See Brake
System Checks. In Group 9005-10.
Excess drag in axle Test drag. See Brake System

Checks. In Group 9005-10.
Muffler restricted Operate without muffler. If engine

operation is now normal, replace
muffler.
Injection pump delivery or governor Remove pump and test. See your
faulty authorized injection pump service
center.

CTM104.

031504
PN=70
Low compression Do compression pressure test. See

CTM104.
Worn camshaft Do valve clearance check. Replace.

See CTM104.
Engine Emits Excessive Black or Restricted air filter Check air filter restriction and air
Gray Exhaust Smoke filters. Clean or replace.
9010
Incorrect grade of fuel Drain and add correct fuel. 15
9
Incorrect injection pump timing Time injection pump. See CTM104.
Excessive fuel delivery Remove fuel injection pump. See

your authorized injection pump
service center.

CTM104
Turbocharger not functioning. Repair. See CTM104
Engine Emits Excessive Blue or Cranking speed too slow Check batteries and connections.
White Smoke
Incorrect grade of fuel Drain and add correct fuel.
Engine running too cold Check thermostat operation.

Replace.
Injection pump out of time Time injection pump. See CTM104.
Injection nozzle(s) Remove and test nozzle(s).
Low compression Do compression test. See CTM104.
Excessive wear in liners and/or Disassemble, inspect, repair.

piston rings stuck
Slow Acceleration Wrong grade of fuel Drain and add correct fuel.
Injection nozzle(s) Remove and test nozzle(s).
Fuel injection pump Remove and test fuel injection.
Detonation (Excess Engine Low engine oil level. Add oil.

Knock)

031504
PN=71
Stuck cold weather starting aid Repair.
Incorrect injection pump timing. Time injection pump. See CTM104.
Low coolant temperature. Remove and check thermostat. See

CTM104.
Abnormal Engine Noise Low or incorrect engine oil (too thin). Add correct oil to proper level.
9010
15 Loose or worn hydraulic pump drive Inspect. Repair.
10
coupling
Engine oil diluted with fuel Inspect engine oil. Determine cause
of fuel dilution.
Incorrect fuel injection pump timing Time injection pump. See CTM104.
Excessive valve clearance Adjust valve clearance. See

CTM104.
Bent push rods Inspect. Replace.
Worn rocker arm shafts Replace.
Loose connecting rod caps Inspect, tighten connecting rod cap

screws. See CTM104.
Loose main bearing caps Inspect, tighten main bearing cap

screws. See CTM104.
Worn main bearings Replace bearings. See CTM104.
Worn connecting rod bearings Replace bearings. See CTM104.
Incorrect cam timing Check engine timing. Repair.
Scored piston Inspect. Replace.
Worn piston pin bushings and pins Inspect. Replace pins and bushings.
See CTM104.
Low Oil Pressure (Oil Pressure Low oil level Add oil to proper level. Inspect
Light on—Red "Stop" Flashing) engine oil.
Wrong viscosity oil/oil diluted with Change oil. Check injection pump
diesel fuel shaft seals and transfer pump
diaphragm. See CTM104.

031504
PN=72
Oil pressure switch or indicator Check engine oil pressure switch.

See Display Monitor/Indicator Circuit
Schematic. In Group 9015-15.
Oil pressure regulating valve Test or replace. See CTM104.
Plugged or broken oil pump intake Inspect. Clean.

screen
9010
Loose oil pump drive gear Inspect. Repair. See CTM104. 15
11
Worn oil pump gear or housing Remove, inspect and repair. See
CTM104.
Excessive main bearing, connecting See CTM104.

rod or balance shaft clearance
Cracked cylinder block Replace cylinder block. See

CTM104. Inspect piston cooling jets.
Leakage at internal oil passage. Check all possible internal leakage

paths. Repair.
Engine Overheats (Engine Low coolant level Fill cooling system and check for
Coolant Indicator Light On and leaks.
Red "Stop" Flashing)
Low engine oil level Add oil.
Loose or broken fan belt. Inspect belt tensioner or replace belt.

See CTM104.
Engine overloaded, operating in Reduce load.

wrong gear
Fan on backwards Check for correct fan installation.

See CTM104.
Radiator dirty or plugged Check air flow. See Radiator Air

Flow Test. In Group 9010—25.
Clean radiator. See CTM104.
Radiator shroud missing, damaged Inspect. Repair or replace.

or baffles missing
Improper fuel Drain and add correct fuel.

031504
PN=73
Radiator cap Replace cap.
Faulty temperature sender Test, repair or replace converter oil

temperature senderSee Display
Monitor/indicator Circuit Schematic..
n Group 9015-15.

9010
15 Excessive axle drag Check axle drag. See Brake System
12
Checks. In Group 9005-10
Operational Checkout Procedure.
Excessive brake drag Check Brake drag. See Brake

System Checks. In Group 9005-10.
Faulty thermostat (Struck closed) Inspect thermostat. Replace. See

CTM104.
Thermostat missing, cooling system Replace thermostats Flush cooling

coated with lime deposits system. See CTM104.
Water pump Remove, inspect and repair. See

CTM104.
Excessive fuel delivery Remove. Check for proper fuel

delivery, adjust. See CTM104.
Scored piston Replace piston. See CTM104.
Engine Runs Cold Thermostat (stuck open) Replace. See CTM104.
Oil in Coolant Or Coolant in Oil Leaking cylinder head gasket Replace gasket. CTM104.
Leaking cylinder liner packing Replace packings. CTM104.
Cracked cylinder liner Replace liner. See CTM104.
Oil cooler Replace oil cooler. See CTM104
Cracked cylinder block Replace block. See CTM104.
Excessive Fuel Consumption Air system restricted Check filter restriction indicator and
air filters. Replace
Leakage in fuel system Inspect. Repair.

031504
PN=74
Incorrect grade of fuel Refill with correct fuel. See Fuel

tank. in operator’s manual.
Operator holding hydraulics over Return control levers to neutral

relief. position.
High system relief valve setting Test system relief valve pressure.
See Loader System Relief Pressure
Test. In Group 9025-25 9010
15
13
Faulty injection nozzle(s) Test nozzle(s). Repair. See

CTM104.
Turbocharger Excessively Noisy Bearings not lubricated Insufficient oil pressure. Check for
or Vibrates restricted turbocharger oil line.
Worn bearings Replace. See CTM104.
Air leak in engine, intake or exhaust Inspect and repair. See CTM104.
manifold
Improper clearance between turbine Remove exhaust elbow and air inlet
wheel and turbine housing hose. Inspect and repair. See
CTM104.
Broken blades on turbine Remove exhaust elbow and air inlet

hose. Inspect and repair. See
CTM104.
Oil Dripping From Turbocharger Damaged or worn bearings and/or Inspect compressor and turbine
Adapter worn seals wheel for damaged blades. Check
for proper engine service intervals or
dirt entering engine. See CTM104.
Excessive crankcase pressure Check for plugged oil drain line.

Clean.
Turbocharger oil return line carbon Remove line. Inspect and clean.
buildup where line passes exhaust
manifold.
Excessive Drag In Turbocharger Carbon build-up behind turbine Inspect and clean. See CTM104.
Rotating Members wheel caused by combustion
deposits

031504
PN=75
Dirt build-up behind compressor Inspect and repair. See CTM104.

wheel caused by air intake leaks
Bearing seizure or dirty or worn Check for plugged air filters. See
bearings caused by excessive CTM104.
temperature, unbalanced wheel, dirty
oil, oil starvation, or insufficient
lubrication
9010
15
14 TX,15,SS3184 –19–09JUL98–11/11

031504
PN=76
Group 20
Adjustments
POWERTECH 4.5L (4045) and 6.8L (6068)
John Deere Engines

manuals (CTM).
–UN–07SEP88
M44215
20
1
OUO1010,0000660 –19–18FEB04–1/1

Installation
SERVICE EQUIPMENT AND TOOLS
JT05801 Electronic Tachometer Contains of:
A—Clamp-On Transducer. Remove paint using emery cloth and
–UN–28FEB89
connect to a straight section of injection line within 100 mm (4 in.) of
pump. Finger tighten only. DO NOT overtighten.
B—Black Clip (-). Connect to main frame.
C—Red Clip (+). Connect to transducer.
T6813AG
D—Tachometer Readout. Install cable.
TX,25,SS3189 –19–12AUG96–1/1

031504
PN=77
Adjustments
Adjust Speed Control Lever Tension
SPECIFICATIONS
Lever Nut Torque 40—49 N (9—11 lb force)
Tighten nut (11) until 40—49 N (9—11 lb force) is
–UN–12OCT00
required to move lever using a spring scale.
Specification
Lever Nut—Torque ........................................... 40—49 N (9—11 lb force)
T134467
9010
20 If new nylon washers (6) are installed, recycle the speed
2 control lever approximately 10 times before adjustment of
speed control lever. 1—Knob
2—Washer (2 used)
3—Cap Screw (2 used)
4—Bracket
5—Plate (2 used)
6—Washer (2 used)
7—Lever
8—Cotter Pin
9—Disk Spring (4 used)
10—Washer
11—Cap Screw
12—Cable
TX14826,00031C9 –19–12OCT00–1/1

031504
PN=78
Adjustments
9010
20
3

031504
PN=79
Adjustments
Engine Speed Control Linkage Adjustment
SPECIFICATIONS
Injection Pump Lever Override 2—8 mm (0.08—0.32 in.)
Speed Control Lever Rear 0.5 mm (0.02 in.)
Position Minimum Override
–UN–11OCT00
High Idle Minimum Override 2 mm (0.08 in.)
Foot Control Pedal Adjustment. 41 mm (1.614 in.)
41 mm (1.614 in.) from bottom of
horizontal part of pedal rod to cab
T134401B
9010 floor.
20
4
1. Move speed control lever to extreme forward position.
2. Measure injection pump lever override. Override must

be 2—8 mm (0.08—0.32 in.).
Specification
Injection Pump Lever—Override ....................... 2—8 mm (0.08—0.32 in.)
3. Adjust yoke on speed control rod to provide override.
4. Move speed control lever to rear most position and

check override. Override must be at least 0.5 mm (0.02
in.) minimum.
Specification
Speed Control Lever Rear
Position—Minimum Override .......................................... 0.5 mm (0.02 in.)
5. Recheck high idle for a minimum of 2 mm (0.08 in.)

override.
Specification
High Idle—Minimum Override ........................................... 2 mm (0.08 in.)
Continued on next page TX14826,00031C6 –19–06OCT00–1/3

031504
PN=80
Adjustments
6. Remove floor mat and floor plates and open front cowl.
7. Move engine speed lever to rear most position (Turtle

“Low Idle”).
8. When installing cable (17), center the threaded part of
–UN–16OCT00
cable (20) into bracket (25) for a starting point of cable
(17) to cross shaft (26) adjustment.
Adjust hand control cable to cross shaft (26) so that
T134481B
foot throttle arm (19) on shaft (26) is horizontal. 9010
20
1—Washer 5
2—Pedal
3—Cotter Pin (3 Used)
4—Pedal Rod
5—Cap screw (3 Used)
6—Plate
7—Support
8—Support
10—Nut
11—Swivel
12—Rod
13—Arm
14—Spring
15—Arm
16—Washer (3 Used)
17—Cable
18—Spring Pin
19—Lever
20—Threaded Part of Cable
21—Grommet (2 Used)
22—Swivel
24—Spring Pin
25—Bracket
–UN–12OCT00
T134480

031504
PN=81
Adjustments
9. Move engine speed lever into forward position (Rabbit

“WOT”). Disconnect swivel pin (11) from pedal rod (4).
Measure 41 mm (1.614 in.) from the bottom of
horizontal part of pedal rod (4) to cab floor. Adjust
vertical rod swivel pin (11) on vertical rod (12) up or
down to get a slip fit of swivel pin (11) into end of
–UN–16OCT00
pedal rod (4).
Specification
Foot Control Pedal Adjustment.—
T134482B
41 mm (1.614 in.) from bottom of
9010
horizontal part of pedal rod to cab
20
floor. ............................................................................... 41 mm (1.614 in.)
6
10. When adjustment is made connect washer (16) and

cotter pin (9). Tighten lock nut (10) on vertical rod
(12) against the swivel pin (11).
1—Washer
2—Pedal
4—Pedal Rod
5—Cap screw (3 Used)
6—Plate
7—Support
8—Support
10—Nut
11—Swivel
12—Rod
13—Arm
14—Spring
15—Arm
17—Cable
18—Spring Pin
19—Lever
20—Threaded Part of Cable
–UN–12OCT00
21—Grommet (2 Used)
22—Swivel
24—Spring Pin
25—Bracket
T134480
TX14826,00031C6 –19–06OCT00–3/3

031504
PN=82
Adjustments
9010
20
7

031504
PN=83
Adjustments
Slow and Fast Idle
SPECIFICATIONS
Slow Idle Speed 900 + 25 - 0 rpm
Fast Idle Speed 2375 + 25 - 0 rpm
–UN–07OCT00
Electronic Tachometer
Sealing Wire Pliers
T134395B
9010
20 1. Run engine until it is at normal operating temperature.
8
2. Install tachometer. See Electronic tachometer 1—Slow Idle Adjusting Screw
Installation. In this Group. 2—Speed Control Rod Pin
3—Fast Idle Adjusting Screw
CAUTION: Take care to avoid rotating fan

blades while making injection pump
adjustments.
3. Remove pin (2) and disconnect speed control rod from

fuel injection pump lever.
4. Start engine.
5. Hold injection pump lever forward (toward radiator).

Check to make sure slow idle is to specifications.
Specification
Slow Idle—Speed ............................................................ 900 + 25 - 0 rpm
6. If slow idle is not correct:
a. Check air cleaner elements.
b. Remove sealing wire.
c. Loosen slow idle screw lock. Turn screw (1)

clockwise to increase speed and counterclockwise
to decrease engine speed. Tighten lock nut.
7. Hold injection pump lever rearward (away from

radiator). Check to make sure fast idle is to
specifications
Specification
Fast Idle—Speed ........................................................... 2375 + 25 - 0 rpm

031504
PN=84
Adjustments
8. If fast idle is not correct:
a. Remove sealing wire.
b. Loosen lock nut and turn screw (3)

counterclockwise to increase rpm or clockwise to
decrease rpm.
c. Tighten lock nut and install a new sealing wire using

a seal wire pliers.
9010
9. Connect rod. 20
9
TX14826,00031C7 –19–12OCT00–2/2

031504
PN=85
Adjustments
9010
20
10

031504
PN=86
Group 25
Tests
POWERTECH 4.5L (4045) and 6.8L (6068)
John Deere Engines

manuals (CTM).
–UN–07SEP88
M44215
25
1
OUO1010,0000660 –19–18FEB04–1/1

Installation
JT05801 Electronic Tachometer Contains of:
–UN–28FEB89
T6813AG
TX,25,SS3189 –19–12AUG96–1/1
JT05800 Digital Thermometer Installation

JT05800 Digital Thermometer Consists of:
A—Temperature Probe
B—Cable
–UN–28FEB89
C—Digital Thermometer
T6808CE
TX,25,SS3190 –19–12AUG96–1/1

031504
PN=87
Tests
Air Intake System Leakage Test
SPECIFICATIONS
Air Intake System Pressure 13.8—20.7 kPa (0.13—0.21 bar)
(2—3 psi)
–UN–23FEB89
JDG51 Adapter
Air Regulator With Gauge
T5906AP
9010
IMPORTANT: Anytime the air intake system is opened
25
2 it must be tested for leaks before the
machine is returned to service.
1. Remove air cleaner cover and main filter element.
2. Put a plastic bag over safety element and install main

element and cover.
–UN–05SEP96
3. Remove plug or either start aid from air intake tube
and install adapter (A).
T103547
4. Connect air pressure regulator to adapter using hose
and fitting.
CAUTION: Plastic bag can be sucked into

engine if engine is started when trying to close
valves.
5. Pressurize air intake system to specifications.
Specification
Air Intake System—Pressure ................. 13.8—20.7 kPa (0.13—0.21 bar)
(2—3 psi)
If system cannot be pressurized, turn engine slightly to

close valves. Check plastic bag.
6. Spray soap solution over all connections from the air

cleaner to the turbocharger or air inlet to check for
leaks. Repair all leaks.
TX,25,SS3194 –19–12AUG96–1/1

031504
PN=88
Tests
9010
25
3

031504
PN=89
Tests
Radiator Air Flow Test
SPECIFICATIONS
Engine Speed 2375 + 25 - 0 rpm
Voltage Reading (typical) Voltage 5.30 volts
ESSENTIAL TOOLS
JT05529 Air Flow Meter

9010
25 Tachometer
4 Multimeter
1. Apply parking brake, put transmission in neutral and

lower equipment to the ground. Stop engine.
2. Install tachometer. See Electronic Tachometer

Installation. (See procedure in this group.)
3. Check that all sheet metal is in place. Close side
–UN–01NOV88
shields.
4. Divide the surface of the grille into 16 equal squares.
T6080AH
5. Start engine and run at specified speed.
Specification
Engine—Speed ............................................................. 2375 + 25 - 0 rpm
6. Connect air flow meter to digital multimeter. Turn

switch on multimeter to 20 volts A.C.
7. Place air flow meter in contact with grille. Arrow on

meter must point in direction of air flow (away from
machine).
8. Record voltage reading for each area.
9. Combined total of air flow test readings must be

approximately at specifications.
Specification
Voltage Reading (typical)—
Voltage......................................................................................... 5.30 volts
Continued on next page TX,9010,SS4105 –19–23JUN98–1/3

031504
PN=90
Tests
If readings are less than specifications remove oil cooler

and clean external surfaces of both oil cooler and radiator.
Install oil cooler and repeat test. If reading is still low,
check for correct fan installation. Be sure sheet metal is in
place.
NOTE: Air flow readings minus 20% is a number used as

a guideline to determine when a partially plugged
radiator and or cooler core may cause
overheating.
9010
25
Continued on next page TX,9010,SS4105 –19–23JUN98–2/3 5

031504
PN=91
Tests
9010
25
6
–19–21MAR89
T6500AK
• Divide the surface of the grille into 16 equal squares.
• Park brake ON.
• Transmission in Neutral and side shields closed.
• Divide the surface of the grille into 16 equal squares.
• Start engine.
• Perform AIR FLOW TEST at fast idle. Observe correct
air flow direction and place air flow meter in direct
contract with grille.
• Record air flow in each square.
• Combine total of air flow test readings must be
approximately at specifications.
–UN–25MAY89
T95955
TX,9010,SS4105 –19–23JUN98–3/3

031504
PN=92
Tests
9010
25
7

031504
PN=93
Tests
Turbocharger Boost Pressure—Engine

Performance Test
SPECIFICATIONS
Engine Temperature 82° ± 10° C (180° ± 20° F)
Engine Speed 2200 rpm
–UN–27AUG96
Turbocharger Boost Pressure 40—55 kPa (0.41—0.55 bar) (6—
(Using No. 2 Fuel) 8 psi)
ESSENTIAL TOOLS
T103239
9010
25 JT07248 Turbocharger Boost Test Kit
8
30 psi Gauge
Digital Thermometer
IMPORTANT: On power shift transmissions ONLY,

never operate machine equipped with
MFWD with front wheels (axle) on the
ground, rear wheels (axle) off the
ground and transmission in fourth gear
forward. Damage to the MFWD will
occur.
NOTE: Reduce the boost specifications by 7% if using

No. 1 fuel.
1. Remove plug (A) and install adapter and gauge.
2. Install tachometer and thermometer. See Electronic

Tachometer Installation. See Digital Thermometer
3. Apply park brake and put FNR lever in neutral. Run

engine until it is at normal operating temperature.
Specification
Engine—Temperature ..................................... 82° ± 10° C (180° ± 20° F)
4. Adjust engine speed to specification.
Specification
Engine—Rated Speed ................................................................. 2200 rpm
Activate the loader control valve and hold over relief to

apply a hydraulic load to engine. The gauge will show a
pressure rise and then a pressure drop.
Continued on next page CED,TX03399,4245 –19–09JUN98–1/2

031504
PN=94
Tests
Specification
Turbocharger—Boost Pressure
(Using No. 2 Fuel) ........................................ 40—55 kPa (0.41—0.55 bar)
(6—8 psi)
5. If engine rpm DOES NOT drop to specification, use the

following procedure to apply additional load to engine.
6. Lower stabilizers and loader to raise wheels off ground.
7. Put machine in 3rd gear and FNR lever in forward or

9010
reverse.
25
9
8. Run engine at fast idle (2375 + 25 - 0 rpm). Apply
service brakes until engine rpm begins to drop to
specifications.
Specification
9. Record highest boost pressure at rated rpm.
Specification
Turbocharger—Boost Pressure
(Using No. 2 Fuel) ........................................ 40—55 kPa (0.41—0.55 bar)
(6—8 psi)
10. Repeat test several times.
11. If boost pressure is too high, remove and test fuel

injection pump for high fuel delivery.
12. If boost pressure is too low, check for the following:
• Restricted air filter elements.

• Restricted fuel filter elements.
• Incorrect fast idle adjustment.
• Incorrect injection pump timing.
• Exhaust manifold leaks.
• Intake manifold leaks.
• Faulty fuel transfer pump.
• Low compression pressure.
• Faulty fuel injection nozzle.
• Carbon build-up in turbocharger.
• Turbocharger compressor or turbine wheel rubbing
housing.
• Low fuel injection pump fuel delivery, remove and
test fuel injection pump for low fuel delivery.
CED,TX03399,4245 –19–09JUN98–2/2

031504
PN=95
Tests
Injection Pump Timing
SPECIFICATIONS
Engine Model 4045
Net hp (kW) 80hp (60 kW)
Engine Rated Speed 2200 rpm
–UN–03NOV97
Engine Dynamic Timing (BTDC) 6.5 + 0 - 1
ESSENTIAL TOOLS

RG6293
9010 JT07158 TIME TRAC Kit
25
10 IMPORTANT: On power shift transmissions ONLY,
never operate machine equipped with A—Front Plate
MFWD with front wheels (axle) on the B—Pump Flange
occur.
The JT07158 TIME TRACThe JT07158 kit electronically

indicates start of injection with respect to piston top dead
center, and allows setting injection pump timing to provide
optimum power, smoke and exhaust emissions.
Timing engines with this tool improves consistency

between engines and helps to control cylinder firing
pressures which can be a factor in head gasket failures as
well as improve overall engine efficiencies.
1. Install JT07158 TIME TRAC. See CTM104.
2. Raise the machine off the ground with stabilizers and

loader. Put transmission in third forward.
3. Operate machine at WOT. Slowly depress service

brakes until engine is at 2200 rpm.
Specification
4. Record dynamic timing.
Specification
Engine—Dynamic Timing (BTDC)............................................. 6.5 + 0 - 1
TIME TRAC is a registered trademark of the Stanadyne Automotive

Corp. Continued on next page CED,TX03399,4246 –19–10JUN98–1/2

031504
PN=96
Tests
5. If timing is not to specification, follow procedure in

CTM104.
CED,TX03399,4246 –19–10JUN98–2/2
Fuel Line Leakage Test
Connections may allow air to enter the fuel system without

allowing fuel to leak out. Follow this procedure to find air 9010
25
leaks in the system.
11
Disconnect fuel supply and fuel return lines at fuel tank.
Drain all fuel from system, including fuel transfer pump,

fuel injection pump, and fuel filter(s).
Close end of fuel return line using a plug, cap, or a short

length of hose, plug, and clamps.
CAUTION: Never exceed 103 kPa (1 bar) (15 psi)

to prevent damage to fuel system components.
Specification
Prevent Damage To Fuel
System—Pressure ..................................... Never exceed 103 kPa (1 bar)
(15 psi)
Pressurize the system to 69 kPa (0.7 bar) (10 psi) at the

fuel supply line using a regulated pressure air source.
Specification
Fuel System—Pressurize To.............................. 69 kPa (0.7 bar) (10 psi)
Apply liquid soap and water solution to all joints and

connections in the fuel system and inspect for leaks.
Repair any leaks.
Connect supply and return lines and prime system.
Start machine and let run for approximately 10 minutes.
NOTE: For engines with an in-line fuel injection pump, an

internal leak path may allow air to enter the fuel
system. If an internal pump leak is suspected,
remove the pump and have a pressure test
performed by an authorized repair station.
TX,25,SS3209 –19–16AUG96–1/1

031504
PN=97
Tests
9010
25
12

031504
PN=98
Section 9015
Electrical System
Contents
Page Page
Group 05—System Information Cab/ROPS Harness (W6) Component

Electrical System Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-32
Visual Inspection . . . . . . . . . . . . . . . . . . . .9015-05-1 Engine/Transmission Harness (W7) Wiring
Electrical Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-44
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 Engine/Transmission Harness (W7)
Circuit Malfunction Component Location . . . . . . . . . . . . . . . .9015-10-46
High Resistance. . . . . . . . . . . . . . . . . . . . .9015-05-3 Radio Harness (W8) Wiring Diagram . . . . .9015-10-60 9015
Open Circuit . . . . . . . . . . . . . . . . . . . . . . .9015-05-5 Radio Harness (W8) Component
Grounded Circuit . . . . . . . . . . . . . . . . . . . .9015-05-8 Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-62
Circuit Shorted. . . . . . . . . . . . . . . . . . . . .9015-05-10 A/C Compressor Harness (W9) Wiring
Sensor Circuit Shorted to Power . . . . . . .9015-05-12 Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-64
Sensor Circuit Shorted to Itself . . . . . . . .9015-05-14 A/C Compressor Harness (W9) Component
Sensor Circuit Shorted to Ground . . . . . .9015-05-16 Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-66
Using Test Equipment A/C Cab Harness (W10) Wiring Diagram . .9015-10-68
Multimeter . . . . . . . . . . . . . . . . . . . . . . . .9015-05-17 A/C Cab Harness (W10) Component
Seven Step Electrical Test Procedure . . .9015-05-18 Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-70
Schematic, Wiring Diagram, and Component Pilot Control Harness (W11) Wiring
Location Information . . . . . . . . . . . . . . . .9015-05-20 Diagram (S.N. 913484— ) . . . . . . . . . . . .9015-10-73
Reading a System Functional Schematic . .9015-05-22 Pilot Control Harness (W11) Component
Reading a Wiring Diagram . . . . . . . . . . . . .9015-05-24 Location (S.N. 913484— ) . . . . . . . . . . .9015-10-74
Reading a Component Location Pilot Control Harness (W12) Wiring
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-26 Diagram (S.N. 913484— ) . . . . . . . . . . . .9015-10-76
Reading a Connector End View Pilot Control Harness (W12) Component
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-28 Location (S.N. 913484— ) . . . . . . . . . . . .9015-10-78
Electrical Schematic Symbols . . . . . . . . . . .9015-05-30 Ride Control Solenoid Harness (W13) Wiring
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-80
Ride Control Solenoid Harness (W13)
Group 10—System Diagrams Component Location . . . . . . . . . . . . . . . .9015-10-82
Component Identification Table . . . . . . . . . . .9015-10-1 Ride Control Harness (W14) Wiring
Fuse Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-84
Color Codes (Blade-Type) . . . . . . . . . . . . .9015-10-2 Ride Control Harness (W14) Component
Specifications. . . . . . . . . . . . . . . . . . . . . . .9015-10-3 Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-86
Wiring and Schematic Diagrams Legend. . . .9015-10-4 Canopy Heater Control Harness (W15) Wiring
System Functional Schematic Section Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-90
Legend (S.N. —913483) . . . . . . . . . . . . . .9015-10-8 Canopy Heater Control Harness (W15)
System Functional Schematic (S.N. — Component Location . . . . . . . . . . . . . . . .9015-10-92
913483) . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-9 Selective Flow Harness (W17) Wiring
System Functional Schematic Section Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-94
Legend (S.N. 913484— ) . . . . . . . . . . . . .9015-10-18 Selective Flow Harness (W17) Component
System Functional Schematic (S.N. Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-96
913484— ). . . . . . . . . . . . . . . . . . . . . . . .9015-10-19 Pattern Select Harness (W19) Wiring
Cab Roof Harness (W5) Wiring Diagram. . .9015-10-20 Diagram (S.N. 913484— ) . . . . . . . . . . . 9015-10-100
Cab Roof Harness (W5) Component Pattern Select Harness (W19) Component
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-22 Location (S.N. 913484— ) . . . . . . . . . . . 9015-10-102
Cab/ROPS Harness (W6) Wiring
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-27 Continued on next page

031504
PN=1
Contents
Page Page
Group 15—Sub-System Diagnostics Ride Control Circuit Diagnostic

Power Circuit Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-51
Operational Information . . . . . . . . . . . . . . .9015-15-1 Selective Flow Valve Circuit
Theory Of Operation . . . . . . . . . . . . . . . . .9015-15-2 Operational Information . . . . . . . . . . . . . .9015-15-53
Schematic . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-3 Theory of Operation. . . . . . . . . . . . . . . . .9015-15-54
Diagnostic Procedures . . . . . . . . . . . . . . . .9015-15-4 Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-56
Power Circuit Diagnostic Procedures . . . . . .9015-15-4 Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-57
Start Circuit Selective Flow Valve Diagnostic
Operational Information . . . . . . . . . . . . . . .9015-15-6 Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-57
Theory Of Operation . . . . . . . . . . . . . . . . .9015-15-7 Pilot Control Circuit Operational Information,
Schematic . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-8 Theory of Operation and Circuit
Diagnostic Procedures . . . . . . . . . . . . . . . .9015-15-9 Schematic (S.N. 913484— ) . . . . . . . . . .9015-15-60
Start Circuit Diagnostic Procedures . . . . . . . .9015-15-9
9015 Charging Circuit Group 20—References
Operational Information . . . . . . . . . . . . . .9015-15-12 Alternators and Starting Motors—Use
Theory Of Operation . . . . . . . . . . . . . . . .9015-15-12 CTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-13 JTO5801 Clamp-On Electronic Tachometer
Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Charging Circuit Diagnostic Procedures . . .9015-15-14 Battery Operation . . . . . . . . . . . . . . . . . . . . .9015-20-2
Differential Lock Circuit Battery Specifications . . . . . . . . . . . . . . . . . .9015-20-3
Operational Information . . . . . . . . . . . . . .9015-15-17 Diagnose Battery Malfunctions . . . . . . . . . . .9015-20-4
Theory of Operation. . . . . . . . . . . . . . . . .9015-15-17 Check Battery Electrolyte Level and
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-18 Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-5
Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-19 Using Booster Batteries—12 Volt System . . .9015-20-7
Differential Lock Circuit Diagnostic Alternator Operation—65 Amp Bosch and 95
Amp Bosch . . . . . . . . . . . . . . . . . . . . . . . .9015-20-8
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-19
Alternator Operation—65 Amp Bosch and
MFWD Circuit
95 Amp Bosch—Continued . . . . . . . . . . . .9015-20-9
Operational Information . . . . . . . . . . . . . .9015-15-20
Calibrate Tachometer . . . . . . . . . . . . . . . . .9015-20-10
Theory of Operation. . . . . . . . . . . . . . . . .9015-15-21
Program Display Monitor (S.N. —
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-22
910055) . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-11
Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-23
Program Display Monitor (S.N. 910056—
MFWD Circuit Diagnostic Procedures . . . . .9015-15-23
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-12
Display Monitor/Indicator Circuit
Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-26
Theory Of Operation . . . . . . . . . . . . . . . .9015-15-27
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-31
Display Monitor Diagnostic Procedures . . . .9015-15-32
Park Brake/FNR Circuit
Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-36
Theory Of Operation . . . . . . . . . . . . . . . .9015-15-37
Schematic (Power Shift) . . . . . . . . . . . . .9015-15-39
Park Brake/FNR Circuit Diagnostic
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-41
Ride Control Circuit
Theory of Operation. . . . . . . . . . . . . . . . .9015-15-49
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-50

031504
PN=2
Group 05
System Information
Electrical System Visual Inspection
Make the following visual electrical inspection prior to

starting the machine after receiving customer complaint:
1. Look for bare wires that could ground a component or

short across to another component.
2. Look for missing or worn conduit. This could indicate a

wire problem.
3. Look for loose or broken connectors and wires.
4. Inspect batteries for:
• Corroded terminals
9015
• Loose terminals or battery posts 05
• Dirty condition 1
• Damp condition
• Cracked case
• Proper electrolyte level
5. Check alternator belt tension.
6. Turn the key switch to the IGN position. Try out the
accessory circuits, indicator lights, gauge lights. How
does each of these components work? Look for sparks
or smoke which might indicate shorts.
7. Start machine. Check all gauges for good operation

and check to see if system is charging or discharging.
8. After machine has been shut down for five minutes

inspect for overheated parts. They will often smell like
burned insulation. Put your hand on the alternator.
Heat in these parts when the unit has not been
operated for some time is a sure clue to charging
circuit problems.
9. In general, look for anything unusual.
Many electrical failures cannot be detected even if the

machine is started. Therefore, a systematic and complete
inspection of the electrical system is necessary.
CED,OUTX466,1353 –19–03FEB99–1/1

031504
PN=101
System Information
Electrical Circuit Malfunctions
9015
05
2
–UN–17JUL03
T128740
1—Battery 3—Switch 4—Load (Light) 5—Ground
2—Fuse
CIRCUIT MALFUNCTIONS • Between the component, light (4) and ground (5).
There are four common circuit malfunctions: Component malfunctions can easily be confused with
circuit malfunctions, as illustrated in the following
• High-Resistance Circuit. example:
• Open Circuit.
• Grounded Circuit. Example: Light (4) does not operate switch (3) is
• Shorted Circuit. turned ON. After disconnecting and connecting switch
(3), light (4) functions normally.
LOCATION OF CIRCUIT MALFUNCTIONS
Reason: Corrosion on the terminals of switch (3)
There are three sections in a simple circuit where have restricted or prevented the flow of current in the
these malfunctions can occur: circuit. The failure of light (4) to come ON appears to
be a component malfunction, but further examination
• Between the battery (1) and the controlling switch of the circuit reveals a circuit malfunction in the form of
(3). a bad connection.
• Between the controlling switch (3) and before the
component, light (4).
CED,TX17984,438 –19–24FEB00–1/1

031504
PN=102
System Information
High Resistance Circuit
9015
05
3
–UN–17JUL03
T128750
1—Battery 4—Switch Terminal 6—Connector 8—Load (Light)
2—Fuse 5—High Resistance 7—Component Terminal 9—Ground
3—Switch
Definition of a High Resistance Circuit: A high until normal voltage is found. The malfunction is
resistance circuit has additional resistance which can between last two points of measurement.
prevent a component from operating normally. High
resistance can be caused by loose, dirty, corroded, or 4. If voltage at component terminal (7) is less than
oily terminals. Broken strands inside a wire or a wire voltage at switch terminal (4), the high resistance is
that is too small for an application may also cause high between these two points. Starting at component
resistance. In the above circuit, high resistance (5) terminal (7), continue measuring voltage toward
may cause light (8) to be dim or not to function. switch terminal (4) until normal voltage is found.
The malfunction is between last two points of
Troubleshooting a High Resistance Circuit: measurement.
1. Turn switch (3) ON. In the example, battery voltage will be present at
switch terminal (4), but voltage will be low at
2. Measure voltage at switch terminal (4) and component terminal (7). Checking voltage toward
component terminal (7). switch terminal (4), low voltage will be present at
connector (6), indicating high resistance (5) in the
3. If voltage is low at switch terminal (4), the harness between switch terminal (4) and connector
malfunction is between the switch (3) and battery (6).
(1). Continue measuring voltage toward battery (1)
Continued on next page CED,TX17984,446 –19–25FEB00–1/2

031504
PN=103
System Information
5. If voltage is normal at component terminal (7), the ground (9) until low voltage is found. The
malfunction is between the component (8) and malfunction is between last two points of
ground (9). Continue measuring voltage toward measurement.
CED,TX17984,446 –19–25FEB00–2/2
9015
05
4

031504
PN=104
System Information
Open Circuit
9015
05
5
–UN–17JUL03
T128784
1—Battery 4—Switch Terminal 6—Connector 8—Load (Light)
2—Fuse 5—Broken Wire 7—Component Terminal 9—Ground
3—Switch
Definition of an Open Circuit: An open circuit has a 4. If no voltage is at switch terminal (4), the
physical break that prevents the flow of current and malfunction is between the switch (3) and battery
results in no component operation. Open circuits can (1). Continue check for voltage toward battery (1)
be caused by a broken wire (5), disconnected until normal voltage is found. The malfunction is
connector (6), blown fuse (2), or disconnected ground between last two points of measurement.
(9).
5. If battery voltage is indicated at switch terminal (4)
Troubleshooting an Open Circuit: but not at component terminal (7), the malfunction
is between these two points. Starting at component
1. Check fuse (2). If blown, replace and operate terminal (7), continue checking for voltage toward
circuit. If fuse blows a second time, continue check. switch terminal (4) until normal voltage is found.
The malfunction is between last two points of
2. Turn switch (3) ON. measurement. Connector (6) might be an easy
location to check for voltage or a disconnected pin.
3. Measure battery voltage between switch terminal
(4) and component terminal (7).

031504
PN=105
System Information
In the example, voltage will be present at switch 6. If voltage is normal at component terminal (7), the
terminal (4), but no voltage at component terminal malfunction is between the component (8) and
(7). Checking voltage toward switch terminal (4), ground (9). Continue checking for voltage toward
zero voltage will be present at connector (6), ground (9) until normal voltage is found. The
indicating a broken wire (5) in the harness between malfunction is between last two points of
switch terminal (4) and connector (6). measurement.
CED,TX17984,447 –19–25FEB00–2/2
9015
05
6

031504
PN=106
System Information
9015
05
7

031504
PN=107
System Information
Grounded Circuit
9015
05
8
–UN–17JUL03
T128751
1—Battery 4—Fuse Terminal (Circuit side) 7—Wire Insulation Burned or 9—Component Terminal
2—Fuse 5—Switch Worn 10—Load (Light)
3—Fuse Terminal (Battery 6—Switch Terminal 8—Short to Ground 11—Ground
Side)
Definition of a Grounded Circuit: A grounded circuit 2. Turn switch (5) OFF.

occurs when a spot in the circuit is exposed, or has
zero resistance to machine ground. This can be 3. Measure continuity to ground at fuse side of switch
caused when the insulation is worn or burned off of a (5).
wire and usually results in no component operation or
fuses repeatedly being blown. a. If continuity to ground is indicated, there is a
short to ground between fuse terminal (4) and
Troubleshooting a Grounded Circuit: switch (5). Inspect wire harness in this area.
1. Remove and inspect fuse (2). b. If continuity to ground does not exist, go to next
step.
a. If fuse is good, the circuit is grounded between
battery and fuse, wire will be burned and circuit 4. Disconnect component terminal (9).
will be open.
5. Measure continuity to ground at wire lead from
b. If fuse is blown, do not replace fuse and component terminal (9).
continue checking for short to ground.

031504
PN=108
System Information
a. If continuity to ground is indicated, there is a 6. Disconnect ground (11), leave component terminal
short to ground between switch terminal (6) and (9) disconnected.
component terminal (9). Inspect wire harness in
this area. 7. Measure continuity to ground at ground connection
(11).
In the example, continuity to ground will be
present at the wire lead from component a. If continuity to ground is indicated, there is a
terminal (9). Inspecting the wire harness toward short to ground between component (10) and
switch terminal (6), an area of burned wire ground connection (11). Inspect wire harness in
insulation (7) will be found making contact to this area.
machine ground (8).
b. If continuity to ground does not exist, replace
b. If continuity to ground does not exist, go to next component (10). The component may have an
step. internal short to ground.
9015
05
9
CED,TX17984,448 –19–25FEB00–2/2

031504
PN=109
System Information
Shorted Circuit
9015
05
10
–UN–29FEB00
T128752
1—Battery 5—Switch S2 8—Light E2 11—Light E1
2—Fuse F1 6—Circuit Wire Shorted to 9—Circuit Ground 12—Switch S1
3—Fuse F2 Circuit 10—Circuit Ground
4—Battery Wire Shorted to 7—Circuit Wire Shorted to
Circuit Ground
Definition of a Shorted Circuit: A shorted circuit has 2. Light E1 (11) remains ON.
a power wire with its insulation burned or rubbed
through, contacting a wire in another circuit causing a 3. A short to battery power (4) is located before switch
short (4, 6, or 7). This allows current to flow to several S2 (5) and after switch S1 (12).
components when a switch from either circuit is turned
ON. Fuse (3) will blow immediately when switch (5) is 4. Inspect wire harness for burned or pinched wires
turned ON, whenever a wire is shorted to ground (7). between switch S1 (12) and light E1 (11) of circuit 1
and between fuse F2 (3) and switch S2 (5) of circuit
Troubleshooting a Shorted Circuit: The above 2.
diagram shows two circuits shorted in three different
locations. A troubleshooting procedure is given for Power Wire Shorted to Circuit
each shorted location.
1. Turn switch S1 (12) ON and switch S2 (5) OFF.
Battery Wire Shorted to Circuit
2. Light E1 (11) and light E2 (8) come ON. One or
1. Turn switch S1 (12) and switch S2 (5) OFF. both lights may be dim.

031504
PN=110
System Information
3. Turn switch S1 (12) OFF and switch S2 (5) ON. 3. Turn switch S1 OFF.
4. Light E2 (8) and light E1 (11) come ON. One or 4. Turn switch S2 (5) ON.
both lights may be dim.
5. Fuse F2 (3) will blow immediately when switch S2
5. A short to switched power (6) is located between (5) is turned ON.
circuit 1 and 2, after switches S1 and S2 (12, 5),
and before light E1 and E2 (11, 8). 6. A short to ground (7) is located between switch S2
(5) and light E2 (8) of circuit 2, and after light E1 of
6. Inspect wire harness for burned or pinched wires circuit 1.
between switch S1 (12) and light E1 (11) of circuit 1
and between switch S2 (5) and light E2 (8) of circuit 7. Inspect wire harness for burned or pinched wires
2. between switch S2 (5) and light E2 (8) of circuit 2,
and between light E1 (11) and ground (10) of circuit
Power Wire Shorted to Ground 1.
9015
1. Turn switch S1 (12) ON, leave switch S2 (5) OFF. 05
11
2. Light E1 (11) and light E2 (8) come ON. One or
both lights may be dim. Light E1 and E2 (11, 8) can
come ON even if fuse F2 (3) is blown.
CED,TX17984,449 –19–25FEB00–2/2

031504
PN=111
System Information
Sensor Circuit Shorted to Power
9015
05
12
–UN–17JUL03
T128748
1—Battery 5—Sensor Power Wire Shorted 7—Sensor Ground Wire 10—Sensor
2—Fuse F1 to Power Shorted to Power 11—Controller
3—Fuse F2 6—Sensor Signal Wire Shorted 8—Load (Light) 12—Controller Ground
4—Switch to Power 9—Circuit Ground
Definition of a Sensor Circuit Shorted to Power: A Sensor Power Wire Shorted to Power (5)
sensor circuit shorted to power has one or more
sensor wires shorted to a power source. A sensor 1. The controller may display a maximum upper or
power wire shorted to power (5) may damage the lower reading.
sensor. A sensor signal wire shorted to battery power
(6) may cause the sensor to display a false reading, or 2. The sensor may be damaged, with no signal given
damage the sensor. A sensor ground wire shorted to to the controller.
power (7) may cause fuse F2 (3) to blow when switch
S2 (4) is turned ON. 3. The controller may be damaged, with no display for
that sensor.
Troubleshooting a Sensor Circuit Shorted to
Power: The above diagram shows a sensor circuit 4. The controller may or may not generate a service
shorted to power in three different locations. A few code.
symptoms for each shorted location are given below.
Due to the complexity of sensor and controller, not all Sensor Signal Wire Shorted to Power (6)
symptoms are listed.

031504
PN=112
System Information
1. The controller may display a maximum upper or Sensor Ground Wire Shorted to Power (7)
lower reading.
1. The sensor and controller may function normally
2. The sensor may be damaged, with no signal given when switch (4) is OFF.
to the controller.
2. Fuse F2 (3) may blow when switch (4) is turned
3. The controller may be damaged, with no display for ON.
that sensor.
3. The controller may generate a “Short to Ground”
4. The controller may or may not generate a service service code.
code.
5. The sensor and controller may function normally

when switch (4) is OFF.
9015
05
13
CED,TX17984,450 –19–28FEB00–2/2

031504
PN=113
System Information
Sensor Circuit Shorted to Itself
9015
05
14
–UN–17JUL03
T128785
1—Battery 4—Controller 6—Sensor Power Wire Shorted 8—Sensor
2—Fuse 5—Sensor Power Wire Shorted to Sensor Ground Wire
3—Controller Ground to Sensor Signal Wire 7—Sensor Signal Wire shorted
to Sensor Ground Wire
Definition of a Sensor Circuit Shorted to Itself: A Sensor Power Wire Shorted to Sensor Signal Wire (5)
sensor circuit shorted to itself has one or more sensor
wires making contact with another wire between the 1. The controller may display a maximum upper or
controller and sensor. A sensor power wire shorted to lower reading.
a sensor signal wire (5) may display a maximum upper
or lower reading. A sensor power wire shorted to a 2. The sensor may be damaged, with no signal given
sensor ground wire (6) may cause fuse (2) to blow. A to the controller.
sensor signal wire shorted to a sensor ground wire (7)
may allow the controller to display a false reading. 3. The controller may generate a “ Short to Power”
service code, or the controller may shutdown for
Troubleshooting a Sensor Circuit Shorted to Itself: protection until the short to power is corrected.
The above diagram shows a sensor circuit shorted to
itself in three different locations. A few symptoms for Sensor Power Wire Shorted to a Sensor Ground Wire
each shorted location are given below. Due to the (6)
complexity of sensor and controller, not all symptoms
are listed.

031504
PN=114
System Information
1. The sensor may be damaged, with no signal given Sensor Signal Wire Shorted to a Sensor Ground Wire
to the controller. (7)
2. The controller may be damaged, with no display for 1. The controller may display a maximum upper or
that sensor. lower reading.
3. The controller may or may not generate a service 2. The controller may generate a “Short to Ground”
code. service code.
4. Fuse (2) may be blown. 3. Fuse (2) may be blown.
CED,TX17984,451 –19–28FEB00–2/2
9015
05
15

031504
PN=115
System Information
Sensor Circuit Shorted to Ground
9015
05
16
–UN–17JUL03
T128753
1—Battery 4—Sensor Power Wire Shorted 6—Sensor Ground Wire 7—Sensor
2—Fuse to Ground Shorted to Ground 8—Controller Ground
3—Controller 5—Sensor Signal Wire Shorted
to Ground
Definition of a Sensor Circuit Shorted to Ground: Sensor Power Wire Shorted to Ground (4)
A sensor circuit shorted to ground has one or more
sensor wires shorted to machine ground or a grounded 1. Fuse (2) may be blown.
wire. A sensor power wire shorted to a ground (4) may
blow a fuse or the controller may shutdown for 2. The controller may be damaged, with no display for
protection. A sensor signal wire shorted to ground (5) that sensor.
may cause a “Short to Ground” service code to be
generated. A sensor ground wire shorted to ground (6) 3. The controller may generate a “Short to Ground”
will allow the sensor to continue normal operation. service code, or the controller may shutdown for
protection until the short to ground is corrected.
Troubleshooting a Sensor Circuit Shorted to
Ground: The above diagram shows a sensor circuit Sensor Signal Wire Shorted to Ground (5)
shorted to ground in three different locations. A few
symptoms for each shorted location are given below. 1. The controller may display a maximum upper or
Due to the complexity of sensor and controller, not all lower reading.
symptoms are listed.

031504
PN=116
System Information
2. The controller may generate a “Short to Ground” 1. The sensor and controller may function normally.
service code.
Sensor Ground Wire Shorted to Ground (6)

CED,TX17984,452 –19–28FEB00–2/2
Multimeter
The multimeter is a hand-held instrument use for taking

accurate measurements of electrical circuits.
1—Ampere Input Terminal (Red Lead)

2—Milliamp, Microamp Input Terminal (Red Lead)
3—Volts AC (Alternating Current)
4—Volts DC (Direct Current)
9015
5—Millivolts DC (Direct Current)
05
6—Display
17
7—Continuity, Resistance, and Capacitance
8—Diode Test
9—Milliamps or Amperes
10—Microamps
11—Common or Ground Terminal (Black Lead)
12—Volt, Ohms, Diode Test Input Terminal (Red Lead)
–UN–28FEB00
T128730
CED,TX17984,439 –19–25FEB00–1/1

031504
PN=117
System Information
Seven Step Electrical Test Procedure
9015
05
18
–UN–17JUL03
T128754
1—Battery 4—Component Side of Fuse or 6—Battery Side of Component 8—Ground Side of Component
2—Fuse or Circuit Breaker Circuit Breaker Terminal Terminal
3—Battery Side of Fuse or 5—Switch 7—Light (Component) 9—Component Ground
Circuit Breaker
1. Turn switch (5) ON. Check battery side of circuit 3. Turn switch (5) OFF. Check component side of
breaker (3) for battery voltage. circuit breaker (4) for continuity to ground.
a. Battery voltage normal. Go to step 2. a. Continuity to ground. Repair grounded circuit at

or before switch (5).
b. Low voltage, repair high resistance
b. No continuity to ground, replace circuit breaker
c. Open circuit from battery (2).
2. Turn switch (5) OFF. Check component side of 4. Turn switch (5) ON. Check component side of
circuit breaker (4) for battery voltage. circuit breaker (4) for battery voltage.
a. Battery voltage normal. Go to step 4. a. Battery voltage normal. Go to step 6.
b. Low voltage, repair high resistance. b. Low voltage, repair high resistance.
c. No voltage. Go to step 3. c. No voltage. Go to step 5.

031504
PN=118
System Information
5. Turn switch (5) OFF. Disconnect wire at battery c. No voltage, repair high resistance or open circuit
side on component (6). between circuit breaker (2) and component (7).
Turn switch (5) ON. Check wire at (6) for battery 7. Turn switch (5) ON. Check ground wire of
voltage. component at (8) for voltage.
a. Battery voltage, repair component. a. No voltage, good continuity to ground.
b. No voltage, repair grounded or open circuit at or b. Repair component (7).

after switch (5).
c. Voltage, poor continuity to ground. Repair high
6. Turn switch (5) ON. Check lead on component at resistance or open ground circuit.
(6) for battery voltage.
a. Battery voltage normal. Go to step 7.

9015
b. Low voltage, repair high resistance or open 05
circuit between circuit breaker (2) and 19
component (7).
CED,TX17984,454 –19–28FEB00–2/2

031504
PN=119
System Information
Schematic, Wiring Diagram, and Component Location Information
System Functional Schematic Diagram will be identified by a letter/number designation and

description (X1 CAB HARNESS TO ENGINE
The System Functional Schematic is a schematic HARNESS CONNECTOR, X3 DASH HARNESS TO
diagram of the complete machine. Each wire is HEATER BLOWER HARNESS CONNECTOR, Etc.).
identified by number and/or color (G01 BLK, R02 RED,
RED/WHT, BLU/GRN, Etc.). All components are Component Location Diagram
identified by letter/number designation, description and
are represented by a schematic symbol. Component The Component Location Diagram is a pictorial view
letter/number designation, (K1 Start Relay, S1 Key by harness showing location of all electrical
Switch, B9 Horn, Etc.) will indicate that component components, connectors, harness main ground
throughout the manual. The System Functional locations and harness band and clamp location. Each
Schematic Diagram is divided into Sections. Each component will be identified by the same identification
section contains one or more electrical circuits. Each letter/number and description used in the System
section is indicated by a number and circuit (SE1 Functional Schematic Diagram.
9015
05 CHARGING CIRCUIT, SE2 STARTING CIRCUIT,
20 Etc.). NOTE: All System Functional Schematics, Circuit
Schematics, and Wiring Diagrams are shown
Wiring Diagram—If Provided with key switch in the OFF position.
The Wiring Diagram shows each wiring harness, wire Connector End View Diagram—If Provided
color, wire destination, harness connectors, and
schematic symbols for each electrical component The Connector End View Diagram is a pictorial end
connected to that harness. All harnesses are identified view of the component connectors showing the
by letter/number designation and description (W1 number of pins in the connector and the wire color and
Engine Harness, W2 Dash Harness, Etc.). Each identifier of the wire in every connector. Each
component schematic symbol will be identified by the component will be identified by the same identification
same letter/number designation used in the System letter/number and description used in the System
Functional Schematic Diagram. Harness connectors Functional Schematic Diagram.
CED,TX17984,455 –19–28FEB00–1/1

031504
PN=120
System Information
9015
05
21

031504
PN=121
System Information
Reading a System Functional Schematic
9015
05
22
–UN–29FEB00
T128818

031504
PN=122
System Information
1—Continuity Chart 4—Wire Identification 7—Section Number 10—Component Schematic

2—Power Wires 5—Ground Wires 8—Component Name Symbol
3—Routing Location 6—Circuit Name 9—Component Identification
Information Number
NOTE: A component identification number and name Each electrical component is shown by a schematic
will remain the same throughout the Operation symbol (10), the component name (8), and a
and Test Technical Manual. This will allow for component identification number (9). A continuity chart
easy cross-referencing of all electrical (1) is included for each multi-terminal switch.
drawings (Schematics, Wiring Diagrams, and
Component Location). Routing location information (3) is presented to let the
reader know when a wire is connected to a component
The System Functional Schematic is made up of in another section. TO and FROM statements identify
sections which contain one or more Subsystem when power is going “To” or coming “From” a
Functional Schematics laid out side by side in a logical component in a different location. The section and
sequence of related functions. Each subsystem is a component number are given in parenthesis at the
major group of components like starting components or bottom of the statement. In the example, power is 9015
charging components. Each section of the System going TO component F15 Horn Fuse, in section SE15. 05
Functional Schematic is assigned a number (7) and a 23
name (6) that reflects a group of components. The See Group 9015-10 for Component Identification
System Functional Schematic is formatted with power Legend.
supply wires (2) shown across the top of the drawing
and ground wires (5) across the bottom. The
schematic contains no harness or connector
information.
CED,TX17984,456 –19–28FEB00–2/2

031504
PN=123
System Information
Reading a Wiring Diagram
9015
05
24
–UN–29FEB00
T128819

031504
PN=124
System Information
1—Harness Connector Pin 3—Component Identification 6—Component Connector 9—Component Identification

Letter or Number Number 7—Component Connector Pin Number Wire is Routed TO
2—Harness Connector Number 4—Wire Color or Number Letter or Number 10—Wire Color or Number
Identification 5—Component Identification 8—Wiring Harness
Number Wire is Routed TO
NOTE: A component identification number and name Wires from harness to components are identified by
will remain the same throughout the Operation color or number designation (4). Component
and Test Technical Manual. This will allow for identification number (5) indicates the component a
easy cross-referencing of all electrical wire is routed TO.
drawings (Schematics, Wiring Diagrams, and
Component Location). Main harness connectors (2) are identified by a “X”
component identification number and description (X28
Each harness on the machine is drawn showing CAB TO ENGINE BULKHEAD CONNECTOR, Etc.).
components, connectors, and wires. Harnesses are Harness connector description indicates which
identified by a “W” component identification number harnesses connect together. Connector pin letters or
and description (W6 ENGINE HARNESS, Etc.). numbers (1) are indicated as they are marked on the 9015
connector. Wires attached to each connector pin are 05
Each component is represented by a schematic identified by color or number (10). Component 25
symbol and is identified by a component identification identification number (9) indicates destination of each
number and name (3). Components with integral wire.
connectors (6) have pin number/letters indicated (7).
CED,TX17984,457 –19–28FEB00–2/2

031504
PN=125
System Information
Reading a Component Location Diagram
9015
05
26
–UN–01MAR00
T128843

031504
PN=126
System Information
1—Component Identification 4—Connector Identification 7—Wire Color or Number 9—End View of Harness
Number Number 8—Routing Destination of Wire Connector
2—Component Name 5—Connector Name (Shown as Component
3—Additional Information 6—Pin Number of Mating Identification Number)
Connector
NOTE: A component identification number and name component name (2). In the example shown, the
will remain the same throughout the Operation component is also identified by an R number (3) that is
and Test Technical Manual. This will allow for actually marked on the part.
easy cross-referencing of all electrical
drawings (Schematics, Wiring Diagrams, and Each connector that joins one harness to another is
Component Location). identified by an “X” component identification number
(4) and connector name (5). An end view of the
The component location by harness drawing is a connector (9) is shown. Also, a diagram view of the
pictorial representation that shows harness routing, connector shows pin number (6), wire color or number
component location and mating harness connector (7), and destination component (8) of each wire.
information. 9015
In the example shown, X23 Connector connects the 05
The location of each component that is connected to Monitor and Relay Harness to the Cab Harness. Pin 1 27
the harness is shown and identified by its (6) of the connector contains a BRN wire (7), which is
alpha-numeric identification number (1), and routed to component G4 (8) 24 volt power plug.
CED,TX17984,459 –19–29FEB00–2/2

031504
PN=127
System Information
Reading a Connector End View Diagram
9015
05
28
–UN–01MAR00
T128896
1—Connector End View 4—Component Name 6—Wire Number 7—Wire Color
2—Connector Pins 5—Terminal Pin Letter or
3—Component Identification Number
Number
NOTE: A component identification number and name pictorial end view of a connector (1), shows the
will remain the same throughout the Operation location and number of pins (2) in the connector. The
and Test Technical Manual. This will allow for component identification number (3) and name (4) are
easy cross-referencing of all electrical given for each connector. A diagram view of the
drawings (Schematics, Wiring Diagrams, and connector shows connector pin number (5), wire
Component Location). number (6), and wire color (7).
The connector end view diagram gives a description of

the connector associated with each component. A
CED,TX17984,460 –19–01MAR00–1/1

031504
PN=128
System Information
9015
05
29

031504
PN=129
System Information
Electrical Schematic Symbols

T128823 –UN–03MAR00
CED,TX17984,458 –19–28FEB00–1/2

031504
PN=130
System Information
1—Battery 24—Sensor 46—Resistor 62—Momentary Switch

2—Wire Splice 25—Sensor with Normally 47—Variable Resistor Normally Open
3—Fuse Open Switch 48—Multi-Pin Connector 63—Momentary Switch
4—Circuit Breaker 26—Speed Sensor 49—Single Pin Connector Normally Closed
5—Fusible Link 27—Rotary Sensor 50—Connector 64—Toggle Switch Normally
6—Power Outlet 28—Single Element Bulb 51—4 Pin Relay Open
7—Alternator 29—Dual Element Bulb 52—5 Pin Relay 65—Toggle Switch Normally
8—Air Conditioner 30—Electrically Operated 53—5 Pin Relay With Internal Closed
Compressor hydraulic Valve Suppression Diode 66—2 Way Toggle Switch
9—Compressor 31—Solenoid Normally Open 54—5 Pin Relay With Internal Normally Open
10—Liquid Pump 32—Solenoid Normally Closed Suppression Resistor 67—2 Way Toggle Switch
11—Antenna 33—Starter Motor 55—Key Switch Normally Closed
12—Diode 34—Starter Motor 56—Temperature Switch 68—Manual Switch Operation
13—Zener Diode 35—DC Motor Normally Open 69—Push Switch Operation
14—Capacitor 36—DC Stepping Motor 57—Temperature Switch 70—Pull Switch Operation
15—Magnet 37—Wiper Motor Normally Closed 71—Turn Switch Operation
16—Flasher 38—Blower Motor 58—Pressure Switch Normally 72—Toggle Switch Operation
17—Buzzer 39—Servo Motor Open 73—Pedal Switch Operation
18—Horn 40—Speedometer 59—Pressure Switch Normally 74—Key Switch Operation
19—Alarm 41—Tachometer Closed 75—Detent Switch Operation 9015
20—Clock 42—Temperature Gauge 60—Liquid Level Switch 76—Temperature Sensor 05
21—Internal Ground 43—Liquid Level Gauge Normally Open 77—Solar Sensor 31
22—Single Point Ground 44—Gauge 61—Liquid Level Switch 78—Pressure Sensor
23—External Ground 45—Hour Meter Normally Closed 79—Liquid Level Sensor
CED,TX17984,458 –19–28FEB00–2/2

031504
PN=131
System Information
9015
05
32

031504
PN=132
Group 10
System Diagrams
Component Identification Table
Each component (electrical device) and main connector

will have and identification letter assigned to it. A number
is added to the letter to separate and indicate the total
components within that letter group.
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 9015
tape recorders 10
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

031504
PN=133
System Diagrams
Identification Letter Type Examples

S Switch Switches and push-buttons, general key switch light switch,
horn switch, flasher switch,
T Transformer Ignition coil, ignition transformer
U Modulator, 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
Z Electrical filter Interference suppression filters
9015
10
2
CED,TX14826,12561 –19–12JUN00–2/2
Fuse (Blade-Type) Color Codes
Amperage Rating Color

1 Black
3 Violet
4 Pink
5 Tan
7-1/2 Brown
10 Red
15 Light Blue
20 Yellow
25 Natural (White)
30 Light Green
CED,TX14826,12562 –19–12JUN00–1/1

031504
PN=134
System Diagrams
Fuse Specifications
9015
10
3
–19–28SEP00
T131649
T131649
F1—7.5A F7—15A Fuel Shut-Off/Start F13—10A Start Fuse F17—10A Return-to-Dig Fuse
MFWD/Alternator/Differential Aid/Back-Up Alarm Fuse F14—20A F18—20A Auxiliary Power/Air
Lock Fuse F8—30A Blower/AC Fuse Turn/Stop/Flash/Horn Seat Fuse
F2—15A Power Port/Auxiliary F9—15A Wiper/Washer Fuse Fuse K4—Back-Up Alarm Relay
Power Fuse F10—20A Rear Work Lights F15—15A Docking K5—Park Brake Latching
F5—5A Auxiliary/Radio Circuit Breaker Lights/Beacon Circuit Relay
(Unswitched) Fuse F11—25A Drive/Work/Tail Breaker K6—Neutral Start Relay
F6—10 Amp Dome Light/Radio Lights Circuit Breaker F16—10A Monitor/Alarm Fuse K8—Flasher Relay
Fuse F12—10A FNR/Park Brake/SG
Unload Valve Fuse
IMPORTANT: Install fuse with correct amperage The following relays are located inside side console
rating to prevent electrical system behind display monitor.
damage from overload.
• K7—Timer Relay
The fuse block is located on the top of the front • K10—Mode Door Relay
console inside an access cover.
The following relay is located inside right rear engine
The following relay is located inside front console by compartment.
fuse block.
• K1—Start Relay
• K2—Accessory Relay
CED,TX14826,12690 –19–22JAN04–1/1

031504
PN=135
System Diagrams
Wiring and Schematic Diagrams Legend
NOTE: A1—Radio (SE7, W8). E5 — Left Front Work Light (optional) (SE15, W5 [1 of
3])
• A1 indicates component identification E6 — Right Front Work Light (optional) (SE15, W5 [3
number. of 3])
• Radio indicates component name. E7 — Left Front Work Light (SE15, W5 [3 of 3])
• SE7 indicates section number of SYSTEM E8 — Right Front Work Light (SE15, W5 [3 of 3])
FUNCTIONAL SCHEMATIC where E9 — Left Brake/Tail Lights (SE15, W5 [2 of 3])
component is located. E10 — Right Brake/Tail Lights (SE15, W5 [1 of 3])
• W8 indicates HARNESS WIRING DIAGRAM E11 — Rear Left Turn Light (SE19, W5 [2 of 3])
and HARNESS COMPONENT LOCATION E12 — Front Left Turn Light (SE19, W5 [3 of 3])
drawings where component is located. (For E13 — Rear Right Turn Light (SE19, W5 [1 of 3])
component location of fuses and some E14 — Front Right Turn Light (SE19, W5 [3 of 3])
relays, see Fuse Specifications. (This E15 — Left Docking Light (SE20, W5 [2 of 3])
group.) E16 — Right Docking Light (SE20, W5 [1 of 3])
9015
10 E17 — Beacon Light (SE21, W6 [1 of 7])
4 A1 — Radio (SE7, W8) E18 — Dome Light (SE6, W6 [1 of 7])
A2 — Right Speaker (SE7, W8) F1 — 7.5A MFWD/Alternator/Differential Lock Fuse
A3 — Left Speaker (SE7, W8) (SE2, W6)
A4 — Selective Flow Controller (SE29, W17 [1 of 2]) F2 — 15A Power Port/Auxiliary Power Fuse (SE4, W6)
B1 — Back-Up Alarm (SE10, W7 [4 of 9]) F5 — 5A Auxiliary/Radio (Unswitched) Fuse (SE7, W6)
B2 — A/C Freeze Switch (SE12, W10 [2 of 2]) F6 — 10A Dome Light/Radio Fuse (SE6, W6)
B3 — A/C Low Pressure Switch (SE12, W10 [2 of 2]) F7 — 15A Fuel Shut-Off/Start Aid/Back-Up Alarm Fuse
B4 — A/C High Pressure Switch (SE12, W10 [2 of 2]) (SE9, W6)
B5 — Engine Coolant Temperature Sender (SE22, W7 F8 — 30A Blower/AC Fuse (SE11, W6)
[1 of 9]) F9 — 15A Wiper/Washer Fuse (SE13, W6)
B6 — Converter Oil Temperature Sender (SE22, W7 [2 F10 — 20A Rear Work Lights Circuit Breaker (SE14,
of 9]) W6)
B7 — Engine Oil Pressure Switch (SE22, W7 [1 of 9]) F11 — 25A Drive/Work/Tail Lights Circuit Breaker
B8 — Fuel Level Sender (SE22, W7 [8 of 9]) (SE15, W6)
B9 — Air Filter Restriction Switch (SE22, W7 [9 of 9]) F12 — 10A FNR/Park Brake Fuse (SE16, W6)
B10 — Hydraulic Oil Temperature Sender (SE22, W7 F13 — 10A Start Fuse (SE17, W6)
[6 of 9]) F14 — 20A Turn/Stop/Flash/Horn Fuse (SE18, W6)
B12 — Hydraulic Filter Restriction Switch (SE22, W7 [5 F15 — 15A Docking Lights/Beacon Circuit Breaker
of 9]) (SE21, W6)
B13 — Park Brake Pressure Switch (SE22, W7 [5 of F16 — 10A Monitor/Alarm Fuse (SE22, W6)
9]) F17 — 10A Return-to-Dig Fuse (SE23, W6)
B14 — Horn Switch (SE18, W7 [3 of 9]) F18 — 20A Auxiliary Power/Air Seat Fuse (SE25, W6)
E1 — Lift Rear Work Light (SE14, W5 [2 of 3]) G1 — Batteries (SE1)
E2 — Left Rear Work Light (optional) (SE14, W5 [2 of G2 — Alternator (SE1, W7)
3]) H1 — Display Monitor (8 Function) (SE22, W6 [5 of 7])
E3 — Right Rear Work Light (optional) (SE14, W5 [1 of H2 — Alarm (SE22, W6 [5 of 7])
3]) K1 — Start Relay (SE1, W7 [2 of 9])
E4 — Right Rear Work Light (optional) (SE14, W5 [1 of K2 — Accessory Relay (SE1, W6 [3 of 7])
3]) K4 — Back-Up Alarm Relay (SE10, W6)
Continued on next page CED,TX14826,12691 –19–09MAR04–1/4

031504
PN=136
System Diagrams
K5 — Park Brake Latching Relay (SE16, W6) S22 — FNR Range Switch (SE17, W6 [3 of 7])
K6 — Neutral Start Relay (SE17, W6) S23 — Horn Switch (SE18, W6 [5 of 7])
K7 — Timer Relay (SE17, W6 [5 of 7]) S24 — Turn Signal Switch (SE19, W6 [3 of 7])
K8 — Flasher Relay (SE19, W6) S25 — 4-Way Flasher Switch (SE19, W6 [3 of 7])
K10 — Mode Door Relay (SE12, W10 [1 of 2]) S26 — Docking Light Switch (SE20, W6 [5 of 7])
K11 — Seat Forward Position Relay (S.N. 913484— ) S27 — Beacon Switch (SE21, W6 [5 of 7])
(SE31, W11) S28 — Seat Position Switch (SE22, W6 [6 of 7])
K12 — Seat In Position Relay (S.N. 913484— ) (SE31, S29 — Return-to-Dig Switch (SE23, W7 [7 of 9])
W11) S30 — Differential Lock Switch (SE2, W6 [2 of 7])
K13 — In Position Latch Relay (S.N. 913484— ) S32 — Air Seat Switch (SE25, W6 [5 of 7])
(SE31, W11) S33 — Brake Light Switch (SE15, W6 [4 of 7])
K14 — Out of Position Latch Relay (S.N. 913484— ) S34 — Selective Flow Control Valve Switch Setting
(SE31, W11) (SE29, W17 [1 of 2])
K15 — Seat Not Rear Relay (S.N. 913484— ) (SE31, S35 — Rear Window Switch (SE13, W6 [1 of 7])
W11) S36 — Canopy Heater Blower Switch (SE30, W15)
K16 — Override Relay (S.N. 913484— ) (SE31, W11) S39 — Battery Disconnect Switch (optional) (SE1)
9015
M1 — Starter Motor (SE1, W7) S40 — Seat Position Rear Switch (S.N. 913484— ) 10
M2 — Heater Blower Motor (SE11, W6 [5 of 7]) (SE31, W11) 5
M3 — Washer Motor (SE13, W7 [2 of 9]) S41 — Pilot Disable Switch (S.N. 913484— ) (SE31,
M4 — Front Wiper Motor (SE13, W6 [3 of 7]) W12)
M5 — Rear Wiper Motor (SE13, W6 [1 of 7]) S42 — Pattern Select Switch (S.N. 913484— ) (SE32,
M6 — Air Seat Compressor (SE25, W6 [6 of 7]) W19)
M7 — Canopy Heater Blower Motor (SE30, W15) V1 — Start Solenoid Diode (SE1, W7 [1 of 9])
M8 — Mode Door Motor (SE12, W6 [3 of 7]) V2 — Alternator Diode (SE1, W7 [2 of 9])
R1 — Blower Resistor (SE11, W6 [6 of 7]) V3 — Differential Lock Diode (SE2, W7 [5 of 9])
R2 — Canopy Blower Resistor (SE30, W15) V4 — MFWD Solenoid Diode (SE3, W7 [5 of 9])
S1 — Key Switch (SE1, W6 [5 of 7]) V5 — Ride Control Diode (SE27, W14 [1 of 2])
S2 — MFWD Switch (SE3, W6 [5 of 7]) V6 — Pin Disconnect Diode (SE28)
S5 — Ride Control Switch (SE27, W14 [1 of 2]) V7 — Timer Relay Diode (Reverse) (SE17, W6 [5 of 7])
S6 — Pin Disconnect Switch (SE28) V8 — Timer Relay Diode (Forward) (SE17, W6 [5 of 7])
S8 — Selective Flow Control Switch (SE29, W17 [1 of V9 — Reverse Solenoid Diode (SE17, W7 [5 of 9])
2]) V10 — Forward Solenoid Diode (SE17, W7 [5 of 9])
S9 — Selective Flow Control Foot Switch (SE29, W17 V11 — Low Range Solenoid Diode (SE17, W7 [5 of 9])
[2 of 2]) V12 — Speed Solenoid (3) Diode (SE17, W7 [8 of 9])
S10 — Dome Light Switch (SE6, W6 [1 of 7]) V13 — Speed Solenoid (2) Diode (SE17, W7 [8 of 9])
S11 — Start Aid Switch (SE9, W6 [5 of 7]) V14 — Speed Solenoid (1) Diode (SE17, W7 [8 of 9])
S12 — Blower Switch (SE11, W6 [5 of 7]) V15 — 4-Way Flasher Diode (SE19, W6 [3 of 7])
S13 — A/C Defrost Mode Switch (SE11, W10 [1 of 2]) V16 — 4-Way Flasher Diode (SE19, W6 [3 of 7])
S14 — Windshield Washer Switch (SE13, W6 [3 of 7]) V18 — A/C Compressor Clutch Diode (SE12, W9)
S15 — Rear Wiper Switch (SE13, W6 [5 of 7]) V19 — Park Brake Relay Diode (SE16, W6 [3 of 7])
S16 — Front Wiper Switch (SE13, W6 [3 of 7]) V20 — Seat Position Switch Diode (1) (SE22, W6 [5 of
S17 — Rear Light Switch (SE14, W6 [5 of 7]) 7])
S18 — Front Light Switch (SE15, W6 [3 of 7]) V21 — Park Brake Diode (SE16, W7 [5 of 9])
S19 — Brake Light Switch (SE15, W6 [4 of 7]) V27 — Seat Forward Position Relay Diode (1) (S.N.
S20 — Park Brake Dash Switch (SE16, W6 [5 of 7]) 913484— ) (SE31, W11)
S21 — Loader Lever Switch (SE17, W6 [5 of 7])

031504
PN=137
System Diagrams
V28 — Seat Forward Position Relay Diode (2) (S.N. X20 — Cab/ROPS Harness-to-Engine/Transmission
913484— ) (SE31, W11) Harness Connector (W7 [8 of 9])
W1 — Machine Frame Ground (left side) (SE1, W7 [1 X21 — Cab/ROPS Harness-to-Engine/Transmission
of 9]) Harness Connector (W7 [8 of 9])
W2 — Machine Frame Ground (right side) (SE1) X22 — Cab/ROPS Harness-to-Engine/Transmission
W3 — Ground At Cab Floor (SE1, W6 [5 of 7]) Harness Connector (W7 [8 of 9])
W4 — Roof Ground (SE14, W5 [1 of 3]) X23 — Selective Flow Harness-to-Cab/ROPS Harness
W5 — Roof Harness Connector X4 (SE29, W17 [1 of 2])
W6 — Cab/ROPS Harness X24 — Transmission FNR Solenoids Connector (W7 [6
W7 — Engine/Transmission Harness of 9])
W8 — Radio Harness X25 — Transmission Range Speed Solenoids
W9 — A/C Compressor Harness Connector (W7 [8 of 9])
W10 — A/C Cab Harness X26 — Cab/ROPS Harness-to-Roof Harness Connector
W11 — Pilot Control Harness (S.N. 913484— ) (W5 [1 of 3], W6 [1 of 7])
W12 — Pilot Control Harness (S.N. 913484— ) X27 — Spare Auxiliary Connector (S.N. 913484— )
W13 — Ride Control Harness (SE31, W11)
9015
10 W14 — Ride Control Harness X28 — Pilot Control Power Connector (S.N. 913484— )
6 W15 — Canopy Heater Control Harness (SE32, W11)
W17 — Selective Flow Harness X29 — Pattern Select Power Connector (S.N.
W19 — Pattern Select Harness (S.N. 913484— ) 913484— ) (SE32, W19)
X1 — Selective Flow Control Controller 18 Pin X30 — A/C Harness-to-Cab/ROPS Harness Connector
Connector (SE29, W17 [1 of 2]) (W10, W6)
X2 — Selective Flow Control Controller 30 Pin X31 — A/C Compressor-to-Engine Harness Connector
Connector (SE29, W17 [1 of 2]) (W7, W9)
X3 — Selective Flow Diagnostic Connector (not used) X33 — A/C Compressor-to-Engine Harness Connector
(SE29, W17 [1 of 2]) (W7, W9)
X4 — Cab/ROPS Harness-to-Selective Flow Harness X34A — Cab/ROPS Harness-to-Pilot Control Harness
Connector (SE5, W6 [5 of 7]) Connector X34B (S.N. 913484— ) (SE16, W6 [5 of
X5 — Power Port 1 Connector (SE4, W6 [6 of 7]) 7])
X6 — Power Port 2 Connector (SE4, W6 [6 of 7]) X34B — Pilot Control Harness-to-Cab/ROPS Harness
X7 — Power Port 3 Connector (cab only) (SE4, W6 [7 Connector X34A (S.N. 913484— ) (SE31, W11)
of 7]) X34C — Pilot Control Harness-to-Unload Valve
X8 — Roof Harness-to-Radio Harness Connector (SE7, Harness Connector X34D (If Equipped) (S.N.
W6 [1 of 7]) 913484— ) (SE31, W11)
X9 — Cab/ROPS Harness-to-Auxiliary Harness X37 — Splice G01 Black Wire (W7)
Connector (SE25, W6 [5 of 7]) X38 — Splice G01 Black Wire (W7)
X12 — Ride Control Harness-to-X9 (Connector (SE27, X39 — Splice G10 Black Wire (W12)
W14) X40 — Pilot Control Monitor Input Connector (SE31)
X13 — Spare Auxiliary Connector (SE27, W14) X41 — Splice G10 Black Wire (W14)
X14 — Pin Disconnect Harness-to-X9 Connector X42 — Splice G10 Black Wire (W17)
(SE28) X43 — Splice G10 Black Wire (W6)
X15 — Spare Auxiliary Connector (SE28) X44 — Splice G10 Black Wire (W6)
X18 — Canopy Heater Harness-to-X9 Connector X45 — Splice G10 Black Wire (W6)
(SE30, W15) X48 — Splice G10 Black Wire (W6)
X19 — Spare Auxiliary Connector (SE30, W15) X49 — Splice G20 Black Wire (W5)

031504
PN=138
System Diagrams
X50 — Splice G20 Black Wire (W5) X84 — Pilot Control Harness (W12)-to-Pilot Control
X51 — Splice G30 Black Wire (W6) Harness Connector X83 (S.N. 913484— ) (W11)
X52 — Ride Control Harness-to-Ride Control Solenoid X85 — Splice P30 Red Wire (W11)
Harness Connector (W13, W14 [2 of 2]) X86 — Splice P30 Red Wire (W11)
X53 — Splice G30 Black Wire (W17) X87 — Splice G10 Black Wire (W11)
X54 — Splice H03 Green Wire (W17) X88 — Splice H18 Green Wire (W19)
X55 — Splice H03 Green Wire (W17) X89 — Splice G10 Black Wire (W19)
X56 — Splice L40 Brown Wire (W5) X111 — Connector (not used) (W7)
X57 — Splice L41 Brown Wire (W5) Y1 — Differential Lock Solenoid (SE2, W7 [6 of 9])
X58 — Splice L42 Brown Wire (W5) Y2 — MFWD Solenoid (SE3, W7 [6 of 9])
X59 — Splice L43 Brown Wire (W5) Y5 — Ride Control Solenoid (SE27, W13)
X60 — Splice L44 Brown Wire (W5) Y6 — Pin Disconnect Solenoid (SE28)
X61 — Splice L46 Brown Wire (W5) Y8 — Start Aid Solenoid (SE9, W7 [3 of 9])
X62 — Splice L47 Brown Wire (W5) Y9 — A/C Compressor Clutch Solenoid (SE12, W9)
X63 — Splice L48 Brown Wire (W5) Y10 — Park Brake Solenoid (SE16, W7 [6 of 9])
X64 — Splice P01 Red Wire (W6) Y11 — Reverse Solenoid (SE17, W7)
9015
X65 — Splice P01 Red Wire (W17) Y12 — Forward Solenoid (SE17, W7) 10
X66 — Splice P17 Red Wire (W6) Y13 — Low Range Solenoid (SE17, W7) 7
X67 — Splice P24 Red Wire (W6) Y14 — Speed Solenoid (3) (SE17, W7)
X70 — Splice P30 Red Wire (W12) Y17 — Return-to-Dig Solenoid (SE23, W7 [8 of 9])
X71 — Splice P30 Red Wire (W11) Y19 — Air Seat Release Valve Solenoid (SE25, W6)
X73 — Splice P30 Red Wire (W14) Y20 — Fuel Shut-Off Solenoid (SE8, W7 [1 of 9])
X74 — Splice R20 Black Wire (W7) Y21 — Selective Flow Control Solenoid (SE29, W17 [2
X75 — Splice A10 Orange Wire (W6) of 2])
X76 — Cab/ROPS Harness-to-Display Monitor Y24 — Backhoe Hydraulic Solenoid Valve (S.N.
Connector 913484— ) (SE31, W12)
X77 — Cab/ROPS Harness-to-Display Monitor Y26 — Pattern Select Solenoid Valve (S.N. 913484— )
Connector (SE32, W19)
X78 — Pilot Control Harness-to-X9 Connector (S.N. Y27 — Pattern Select Solenoid Valve (S.N. 913484— )
913484— ) (SE31, W11) (SE32, W19)
X83 — Pilot Control Harness (W11)-to-Pilot Control
Harness Connector X84 (S.N. 913484— ) (W12)
CED,TX14826,12691 –19–09MAR04–4/4

031504
PN=139
System Diagrams
System Functional Schematic Section

Legend (S.N. —913483)
NOTE: SE1—Power, Charging, and Start Circuit
• SE1 indicates section number of system

functional schematic where circuit is located.
• Power, Charging, and Start Circuits indicates
circuit name.
SE1 — Power, Charging, and Start Circuits

SE2 — Differential Lock Circuit
SE3 — MFWD Circuit
SE4 — Power Circuit Connectors
SE5 — Power Circuit Connectors Continued
9015 SE6 — Dome Light Circuit
10 SE7 — Radio Circuit
8 SE8 — Fuel Shut-Off Circuit
SE9 — Start Aid Circuit
SE10 — Back-Up Alarm Circuit
SE11 — Blower Circuit
SE12 — Air Conditioning Circuit
SE13 — Wiper and Washer Circuit
SE14 — Rear Work Lights Circuit
SE15 — Front Work, Drive, and Tail/Brake Lights Circuits
SE16 — Park Brake/FNR Circuit
SE17 — Park Brake/FNR Circuit (continued)
SE18 — Horn Circuit
SE19 — Flasher and Turn Signal Light Circuit
SE20 — Docking Lights Circuit
SE21 — Beacon Light Circuit
SE22 — Display Monitor/Indicator Circuit
SE23 — Return-to-Dig Circuit
SE24 — Not Used
SE25 — Air Seat Circuit
SE26 — Boom Lock/Slideshift Circuit
SE27 — Ride Control Circuit
SE28 — Pin Disconnect Circuit
SE29 — Selective Flow Control Circuit
SE30 — Canopy Heater Control Circuit
OUO1020,00013DE –19–20JAN04–1/1

031504
PN=140
System Diagrams
System Functional Schematic (S.N. —913483)

T132602 –19–07SEP00
TX14826,00031D0 –19–15JAN03–1/9

031504
PN=141
System Diagrams
T132603 –19–07SEP00
TX14826,00031D0 –19–15JAN03–2/9

031504
PN=142
System Diagrams
T132604 –19–08SEP00
TX14826,00031D0 –19–15JAN03–3/9

031504
PN=143
System Diagrams
T132605 –19–08SEP00
TX14826,00031D0 –19–15JAN03–4/9

031504
PN=144
System Diagrams
T132606 –19–25SEP00
TX14826,00031D0 –19–15JAN03–5/9

031504
PN=145
System Diagrams
T132608 –19–07SEP00
TX14826,00031D0 –19–15JAN03–6/9

031504
PN=146
System Diagrams
T132609 –19–07SEP00
TX14826,00031D0 –19–15JAN03–7/9

031504
PN=147
System Diagrams
T132610 –19–07SEP00
TX14826,00031D0 –19–15JAN03–8/9

031504
PN=148
System Diagrams
T132611 –19–07SEP00
TX14826,00031D0 –19–15JAN03–9/9

031504
PN=149
System Diagrams
System Functional Schematic Section

Legend (S.N. 913484— )
NOTE: SE1—Power, Charging, and Start Circuit
• SE1 indicates section number of system

functional schematic where circuit is located.
• Power, Charging, and Start Circuits indicate
circuit name.
SE1 — Power, Charging, and Start Circuits

SE2 — Differential Lock Circuit
SE3 — MFWD Circuit
SE4 — Power Circuit Connectors
SE5 — Power Circuit Connectors Continued
9015 SE6 — Dome Light Circuit
10 SE7 — Radio Circuit
18 SE8 — Fuel Shut-Off Circuit
SE9 — Start Aid Circuit
SE10 — Back-Up Alarm Circuit
SE11 — Blower Circuit
SE12 — Air Conditioning Circuit
SE13 — Wiper and Washer Circuit
SE14 — Rear Work Lights Circuit
SE15 — Front Work, Drive, and Tail/Brake Lights Circuits
SE16 — Park Brake/FNR Circuit
SE17 — Park Brake/FNR Circuit (continued)
SE18 — Horn Circuit
SE19 — Flasher and Turn Signal Light Circuit
SE20 — Docking Lights Circuit
SE21 — Beacon Light Circuit
SE22 — Display Monitor/Indicator Circuit
SE23 — Return-to-Dig Circuit
SE24 — Not Used
SE25 — Air Seat Circuit
SE26 — Not Used
SE27 — Ride Control Circuit
SE28 — Pin Disconnect Circuit
SE29 — Selective Flow Control Circuit
SE30 — Canopy Heater Control Circuit
SE31 — Pilot Control Circuit
SE32 — Pattern Select Circuit
OUO1020,00013D4 –19–15JAN04–1/1

031504
PN=150
System Diagrams
System Functional Schematic (S.N. 913484— )

T197688 –19–12MAR04
OUO1020,00013D5 –19–15JAN04–1/1

031504
PN=151
System Diagrams
Cab Roof Harness (W5) Wiring Diagram

T132617 –19–07SEP00
CED,TX14826,12693 –19–16JAN04–1/1

031504
PN=152
System Diagrams
9015
10
21

031504
PN=153
System Diagrams
Cab Roof Harness (W5) Component Location
E16
RIGHT
DOCKING
LIGHT
9015
10
22
E10
RIGHT BRAKE/
TAIL LIGHT
E4
RIGHT REAR
WORK LIGHT W4
ROOF GROUND
X26
CAB/ROPS HARNESS-
TO-ROOF HARNESS
CONNECTOR
E3
RIGHT REAR
WORK LIGHT E13
(OPTION) RIGHT REAR
TURN LIGHT
–19–10MAR04
ROOF HARNESS (W5)

COMPONENT LOCATION (1 OF 3)
T196736
T196736
Continued on next page TX14826,00031C4 –19–16JAN04–1/5

031504
PN=154
System Diagrams
E3—Right Rear Work Light E10—Right Brake/Tail Light W4—Roof Ground X26—Roof Harness-to-
(optional) E13—Right Rear Turn Light Cab/ROPS Harness
E4—Right Rear Work Light E16—Right Docking Light Connector
9015
10
23

031504
PN=155
System Diagrams
9015
10
24
–19–11SEP00
T133647

031504
PN=156
System Diagrams
E1—Left Rear Work Light E9—Left Brake/Tail Light E11—Left Rear Turn Light E15—Left Docking Light
E2—Left Rear Work Light
(optional)
9015
10
25

031504
PN=157
System Diagrams
9015
10
26
–19–11SEP00
T133648
E5—Left Front Work Light E6—Right Front Work Light E7—Left Front Drive Light E12—Left Front Turn Light
(optional) (optional) E8—Right Front Drive Light E14—Right Front Turn Light
TX14826,00031C4 –19–16JAN04–5/5

031504
PN=158
System Diagrams
Cab/ROPS Harness (W6) Wiring Diagram

T132940 –19–11SEP00
CED,TX14826,12695 –19–16JAN04–1/4

031504
PN=159
System Diagrams
T132941 –19–11SEP00
CED,TX14826,12695 –19–16JAN04–2/4

031504
PN=160
System Diagrams
T132942 –19–11SEP00
CED,TX14826,12695 –19–16JAN04–3/4

031504
PN=161
System Diagrams
T132943 –19–11SEP00
CED,TX14826,12695 –19–16JAN04–4/4

031504
PN=162
System Diagrams
9015
10
31

031504
PN=163
System Diagrams
Cab/ROPS Harness (W6) Component Location
9015
10
32
–19–29SEP00
T134036
Continued on next page OUO1020,00013D6 –19–16JAN04–1/11

031504
PN=164
System Diagrams
E17—Beacon Light S10—Dome Light Switch X8—Cab/ROPS Harness X26—Cab/ROPS Harness

E18—Dome Light S35—Rear Window Switch Connector-to-Radio Connector-to-Roof
M5—Rear Wiper Motor Harness Connector Harness Connector
9015
10
33

031504
PN=165
System Diagrams
9015
10
34
–19–29SEP00
T134037

031504
PN=166
System Diagrams
S30—Diff Lock Switch X20—Cab/ROPS Harness X21—Cab/ROPS Harness X22—Cab/ROPS Harness

Connector-to-Engine / Connector-to-Engine / Connector-to-Engine /
Transmission Harness Transmission Harness Transmission Harness
Connector Connector Connector
9015
10
35

031504
PN=167
System Diagrams
9015
10
36
–19–29SEP00
T134039

031504
PN=168
System Diagrams
K2—Accessory Relay S16—Front Wiper Switch S25—4-Way Flasher Switch V16—4-Way Flasher Switch
M4—Front Wiper Motor S18—Front Light Switch V15—4-Way Flasher Switch Diode
M8—Mode Door Motor S22—FNR Range Switch Diode V19—Park Brake Relay Diode
S14—Windshield Washer S24—Turn Signal Switch
Switch
9015
10
37

031504
PN=169
System Diagrams
9015
10
38
–19–29SEP00
T134040
S19—Brake Light Switch S33—Brake Light Switch

031504
PN=170
System Diagrams
9015
10
39

031504
PN=171
System Diagrams
S23 H2 S27 S32 S1 H1

HORN ALARM BEACON AIR SEAT KEY SWITCH DISPLAY
SWITCH SWITCH SWITCH MONITOR
(8 FUNCTION)
S17
REAR LIGHTS
SWITCH S20
PARK BRAKE
DASH SWITCH
S26
DOCKING S11
LIGHTS START AID
SWITCH SWITCH
S15 S2
9015 REAR WIPER
MFWD
10 SWITCH
40
SWITCH
S12 X34A
BLOWER CAB/ROPS
SWITCH HARNESS-TO-PILOT
CONTROL HARNESS
V20 CONNECTOR
SEAT
POSITION S21
SWITCH LOADER
DIODE (1) LEVER
SWITCH
V7 K7
TIMER TIMER
RELAY
M2
RELAY HEATER
DIODE
BLOWER
MOTOR
V8 X30
TIMER A/C HARNESS-
RELAY TO-CAB/ROPS
DIODE HARNESS
CONNECTOR
W3
X4 X9 GROUND
CAB/ROPS HARNESS- CAB/ROPS HARNESS- AT CAB FLOOR
TO-AUXILIARY TO-AUXILIARY
HARNESS CONNECTOR HARNESS CONNECTOR
(USED FOR CB AND RADIO) (USED FOR ATTACHMENTS)
–19–10MAR04
CAB/ROPS HARNESS (W6)

T197644
T197644 COMPONENT LOCATION (5 OF 7) (POWER SHIFT)

031504
PN=172
System Diagrams
H1—Display Monitor (8 S17—Rear Light Switch V8—Timer Relay Diode X30—A/C Harness-to-
Function) S20—Park Brake Dash Switch (forward) Cab/ROPS Harness
H2—Alarm S21—Loader Lever Switch V20—Seat Position Switch Connector
K7—Timer Relay S23—Horn Switch Diode X34A—Cab/ROPS
M2—Heater Blower Motor S26—Docking Lights Switch W3—Ground At Cab Floor Harness-to-Pilot
S1—Key Switch S27—Beacon Switch X4—Cab/ROPS Control Harness
S2—MFWD Switch S32—Air Seat Switch Harness-to-Selective Flow Connector
S11—Start Aid Switch V7—Timer Relay Diode Harness Connector
S12—Blower Switch (reverse) X9—Cab/ROPS
S15—Rear Wiper Switch Harness-to-Auxiliary
Harness Connector
9015
10
41

031504
PN=173
System Diagrams
9015
10
42
–19–29SEP00
T134043
M6—Air Seat Compressor R1—Blower Resistor X5—Power Port 1 Connector Y19—Air Seat Release
Motor S28—Seat Position Switch X6—Power Port 2 Connector Solenoid

031504
PN=174
System Diagrams
9015
10
43
X7
POWER
PORT 3
CONNECTOR
(CAB ONLY)
–19–22JAN04
CAB/ROPS HARNESS (W6) COMPONENT LOCATION (7 OF 7)

T134044
T134044
X7—Power Port 3 Connector

(cab only)
OUO1020,00013D6 –19–16JAN04–11/11

031504
PN=175
System Diagrams
Engine/Transmission Harness (W7) Wiring Diagram

T133593 –19–11SEP00
OUO1020,00013D7 –19–16JAN04–1/2

031504
PN=176
System Diagrams
T198411 –19–11MAR04
S29
RETURN-
X111 TO-DIG
CONNECTOR
SWITCH
(NOT USED)
A B
B8
FUEL
X24 X25 LEVEL
TRANSMISSION FNR TRANSMISSION RANGE SENDER
SOLENOIDS CONNECTOR SPEED SOLENOIDS
CONNECTOR
T198411
OUO1020,00013D7 –19–16JAN04–2/2

031504
PN=177
System Diagrams
Engine/Transmission Harness (W7) Component Location
B5
ENG COOLANT
TEMPERATURE
SENDER
9015 V1
10 START
46 SOLENOID
DIODE
Y20
FUEL
SHUT-OFF
SOLENOID
M1
STARTER
MOTOR
X33 X31 B7 W1
A/C COMPRESSOR- A/C COMPRESSOR- ENG OIL MACHINE FRAME
TO-ENGINE/TRANS TO-ENGINE/TRANS PRESSURE GROUND (LEFT
HARNESS HARNESS SWITCH SIDE)*
CONNECTOR CONNECTOR
* Ground located
inside left frame,
near starter.
–19–10MAR04
ENG/TRANS HARNESS (W7)
T198298
T198298
COMPONENT LOCATION (1 OF 9)

031504
PN=178
System Diagrams
B5—Engine Coolant M1—Starter Motor X31—A/C Compressor-to- Y20—Fuel Shut-Off Solenoid

Temperature Sender V1—Starter Solenoid Diode Engine/Trans Harness
B7—Engine Oil Pressure W1—Machine Frame Ground Connector
Switch (left side) X33—A/C Compressor-to-
Engine/Trans Harness
Connector
9015
10
47

031504
PN=179
System Diagrams
9015
10
48
–19–27SEP00
T133705
B6—Converter Oil G2—Alternator M3—Washer Motor V2—Alternator Diode

Temperature Sender K1—Start Relay

031504
PN=180
System Diagrams
9015
10
49
–19–27SEP00
T133706
B14—Horn Y8—Start Aid Solenoid

031504
PN=181
System Diagrams
9015
10
50
–19–27SEP00
T133707
B1—Back-Up Alarm

031504
PN=182
System Diagrams
9015
10
51

031504
PN=183
System Diagrams
9015
10
52
–19–27SEP00
T133708

031504
PN=184
System Diagrams
B12—Hydraulic Filter V3—Diff Lock Diode V9—Reverse Solenoid Diode V11—Range Solenoid Diode
Restriction Switch V4—MFWD Solenoid Diode V10—Forward Solenoid Diode V21—Park Brake Diode
B13—Park Brake Pressure
Switch
9015
10
53

031504
PN=185
System Diagrams
9015
10
54
–19–27SEP00
T133709
B10—Hydraulic Oil X24—Solenoid Connector Y2—MFWD Solenoid Y10—Park Brake Solenoid

Temperature Sensor Y1—Diff Lock Solenoid

031504
PN=186
System Diagrams
9015
10
55
–19–12FEB04
T197608
S29—Return-To-Dig Switch

031504
PN=187
System Diagrams
V13
X21 SPEED V12
CAB/ROPS HARNESS- SOLENOID SPEED SOLENOID
TO-ENGINE/TRANSMISSION (2) DIODE (3) DIODE
HARNESS CONNECTOR
X22 V14
CAB/ROPS HARNESS- SPEED
TO-ENGINE/TRANSMISSION SOLENOID
HARNESS CONNECTOR (1) DIODE
X20
CAB/ROPS HARNESS- B8
TO-ENGINE/TRANSMISSION FUEL
HARNESS CONNECTOR LEVEL
SENDER
9015
10
56
X111
CONNECTOR
(NOT USED)
X25
TRANSMISSION
RANGE SPEED
Y17 SOLENOIDS
RETURN- CONNECTOR
TO-DIG
–19–11MAR04
SOLENOID
ENGINE/TRANSMISSION HARNESS (W7)

COMPONENT LOCATION (8 OF 9) (POWER SHIFT)
T198410
T198410

031504
PN=188
System Diagrams
B8—Fuel Level Sender X20—Cab/ROPS X22—Cab/ROPS X111—Connector (not used)

V12—Speed Solenoid Diode Harness-to-Engine / Harness-to-Engine / Y17—Return-to-Dig Solenoid
(3) Transmission Harness Transmission Harness
V13—Speed Solenoid Diode Connector Connector
(2) X21—Cab/ROPS X25—Transmission Range
V14—Speed Solenoid Diode Harness-to-Engine / Speed Solenoids
(1) Transmission Harness Connector
Connector
9015
10
57

031504
PN=189
System Diagrams
9015
10
58
–19–17JAN02
T148961
Engine/Transmission Harness (W7) Component Location (9 of 9)

031504
PN=190
System Diagrams
B9—Air Filter Restriction

Switch
OUO1020,00013D8 –19–16JAN04–13/13
9015
10
59

031504
PN=191
System Diagrams
Radio Harness (W8) Wiring Diagram
9015
10
60
–19–07SEP00
T132616
CED,TX14826,12708 –19–19JAN04–1/1

031504
PN=192
System Diagrams
9015
10
61

031504
PN=193
System Diagrams
Radio Harness (W8) Component Location
9015
10
62
–19–21SEP00
T133782
Continued on next page CED,TX14826,12707 –19–19JAN04–1/2

031504
PN=194
System Diagrams
A1—Radio A2—Right Speaker A3—Left Speaker X8—Radio Harness

Connector-to-Roof
Harness Connector
CED,TX14826,12707 –19–19JAN04–2/2
9015
10
63

031504
PN=195
System Diagrams
A/C Compressor Harness (W9) Wiring Diagram
V18
X31 A/C
A/C COMPRESSOR- COMPRESSOR
TO-ENGINE/TRANS CLUTCH
HARNESS DIODE
CONNECTOR
9015
10
64
X33
A/C COMPRESSOR-
TO-ENGINE/TRANS Y9
HARNESS A/C
CONNECTOR COMPRESSOR
CLUTCH
SOLENOID
–19–10MAR04
T198301
T198301
CED,TX14826,12709 –19–19JAN04–1/1

031504
PN=196
System Diagrams
9015
10
65

031504
PN=197
System Diagrams
A/C Compressor Harness (W9) Component Location
9015
10
66
V18
A/C COMPRESSOR
CLUTCH DIODE
Y9
A/C COMPRESSOR
CLUTCH
SOLENOID
X31
X33 A/C COMPRESSOR-
A/C COMPRESSOR- TO-ENGINE/TRANS
TO-ENGINE/TRANS HARNESS
HARNESS CONNECTOR
CONNECTOR
–19–10MAR04
A/C COMPRESSOR HARNESS (W9)

COMPONENT LOCATION
T198302
T198302

031504
PN=198
System Diagrams
V18—A/C Compressor Clutch X31—A/C Compressor-to- X33—A/C Compressor-to- Y9—A/C Compressor Clutch
Diode Engine/Trans Harness Engine/Trans Harness Solenoid
Connector Connector
CED,TX14826,12705 –19–19JAN04–2/2
9015
10
67

031504
PN=199
System Diagrams
A/C Cab Harness (W10) Wiring Diagram
9015
10
68
–19–07SEP00
T132613
CED,TX14826,12711 –19–19JAN04–1/1

031504
PN=200
System Diagrams
9015
10
69

031504
PN=201
System Diagrams
A/C Cab Harness (W10) Component Location
9015
10
70
–19–21SEP00
T133851

031504
PN=202
System Diagrams
K10—Mode Door Relay S13—A/C Defrost Mode Switch X30—A/C Harness-to-

Cab/ROPS Harness
Connector
9015
10
71

031504
PN=203
System Diagrams
9015
10
72
–19–21SEP00
T133852
B2—A/C Freeze Switch B3—A/C Low Pressure Switch B4—A/C High Pressure Switch
CED,TX14826,12710 –19–19JAN04–3/3

031504
PN=204
System Diagrams
Pilot Control Harness (W11) Wiring Diagram (S.N. 913484— )

T197389 –19–10FEB04
T197389
TX14826,0000011 –19–09FEB04–1/1

031504
PN=205
System Diagrams
Pilot Control Harness (W11) Component Location (S.N. 913484— )
9015
10
74
T197390
–UN–21JAN04
T197390
Continued on next page TX14826,0000012 –19–09FEB04–1/2

031504
PN=206
System Diagrams
K11—Seat Forward Position V27—Seat Forward Position X34B—Pilot Control Harness X40—Pilot Control Monitor
Relay Relay Diode (1) Connector-to-Cab/ROPS Input Connector
K12—Seat In Position Relay V28—Seat Forward Position Harness Connector X78—Pilot Control Harness
K13—In Position Latch Relay Relay Diode (2) X34A (W6) Connector-to-X9
K14—Out of Position Latch W11—Pilot Control Harness X34C—Pilot Control Harness Connector
Relay X27—Spare Auxiliary Connector-to-Unload X83—Pilot Control Harness
K15—Seat Not Rear Relay Connector Valve Harness Connector W11-to-Pilot
K16—Override Relay X28—Pilot Control Power Connector X34D (If Control Harness
S40—Seat Position Rear Connector Equipped) Connector X84 (W12)
Switch (W11)-to-Pattern Select
Power Connector X29
(W19)
TX14826,0000012 –19–09FEB04–2/2
9015
10
75

031504
PN=207
System Diagrams
Pilot Control Harness (W12) Wiring Diagram (S.N. 913484— )
9015
10
76
–19–12DEC02
T156401
TX14826,0000013 –19–16JAN03–1/1

031504
PN=208
System Diagrams
9015
10
77

031504
PN=209
System Diagrams
Pilot Control Harness (W12) Component Location (S.N. 913484— )
9015
10
78
–UN–14JAN03
T156402
Continued on next page TX14826,0000014 –19–16JAN03–1/2

031504
PN=210
System Diagrams
S41—Pilot Disable Switch W12—Pilot Control Harness X84—Pilot Control Harness Y24—Backhoe Hydraulic
Connector (W12)-to-Pilot Solenoid Valve
Control Harness
Connector X83 (W11)
TX14826,0000014 –19–16JAN03–2/2
9015
10
79

031504
PN=211
System Diagrams
Ride Control Solenoid Harness (W13) Wiring Diagram
9015
10
80
–19–25SEP00
T133611
CED,TX14826,12713 –19–19JAN04–1/1

031504
PN=212
System Diagrams
9015
10
81

031504
PN=213
System Diagrams
Ride Control Solenoid Harness (W13) Component Location
9015
10
82
–19–13OCT00
T134447

031504
PN=214
System Diagrams
X52—Ride Control Solenoid Y5—Ride Control Solenoid

Harness
Connector-to-Ride
Control Harness
Connector
CED,TX14826,12715 –19–19JAN04–2/2
9015
10
83

031504
PN=215
System Diagrams
Ride Control Harness (W14) Wiring Diagram
X52 V5
RIDE
X12 RIDE CONTROL
CONTROL
RIDE CONTROL SOLENOID HARNESS- X73 DIODE
HARNESS- TO-RIDE CONTROL SPLICE
TO-X9 OR SPARE HARNESS CONNECTOR P30
9015
10
84
X13 X41
SPARE SPLICE
AUXILIARY G10
CONNECTOR
S5
RIDE
CONTROL
SWITCH
–19–15MAR04
T198303
T198303
TX14826,00031FD –19–19JAN04–1/1

031504
PN=216
System Diagrams
9015
10
85

031504
PN=217
System Diagrams
Ride Control Harness (W14) Component Location
9015
10
86
–19–11OCT00
T133870

031504
PN=218
System Diagrams
S5—Ride Control Switch V5—Ride Control Diode X12—Ride Control Harness X13—Spare Auxiliary
Connector-to-X9 or Connector
Spare Connector
9015
10
87

031504
PN=219
System Diagrams
9015
10
88
–19–11OCT00
T133871

031504
PN=220
System Diagrams
X52—Ride Control Harness

Connector-to-Cab/ROPS
Harness Connector
CED,TX14826,12717 –19–19JAN04–4/4
9015
10
89

031504
PN=221
System Diagrams
Canopy Heater Control Harness (W15) Wiring Diagram
9015
10
90
–19–10MAR04
T198299
T198299
CED,TX14826,12716 –19–19JAN04–1/1

031504
PN=222
System Diagrams
9015
10
91

031504
PN=223
System Diagrams
Canopy Heater Control Harness (W15) Component Location
9015 S36
10 CANOPY HEATER
92 BLOWER SWITCH
X19
SPARE
AUXILIARY
CONNECTOR
X18
CANOPY HEATER
HARNESS CONNECTOR-
TO-X9 OR SPARE
M7
CANOPY HEATER
BLOWER MOTOR
R2
CANOPY INTERNAL
BLOWER RESISTER
–UN–23JAN04
CANOPY HEATER HARNESS (W15) COMPONENT LOCATION

T196744
T196744

031504
PN=224
System Diagrams
M7—Canopy Heater Blower S36—Canopy Heater Blower X18—Canopy Heater Harness X19—Spare Auxiliary
Motor Switch Connector-to-X9 or Connector
R2—Canopy Blower Resistor Spare Connector
OUO1020,00013D9 –19–19JAN04–2/2
9015
10
93

031504
PN=225
System Diagrams
Selective Flow Harness (W17) Wiring Diagram

T197643 –19–11MAR04
T197643
CED,TX14826,12721 –19–19JAN04–1/1

031504
PN=226
System Diagrams
9015
10
95

031504
PN=227
System Diagrams
Selective Flow Harness (W17) Component Location
9015
10
96
X23
SELECTIVE FLOW
CONTROL HARNESS-
TO-CAB/ROPS HARNESS
CONNECTOR X4
–19–10MAR04
T197391
T197391
Continued on next page OUO1020,00013DA –19–19JAN04–1/3

031504
PN=228
System Diagrams
A4—Selective Flow Controller X1—Selective Flow Controller X3—Selective Flow Diagnostic X23—Selective Flow Harness
S8—Selective Flow Control 18 Pin Connector Connector Connector-to-Cab/ROPS
Switch X2—Selective Flow Controller Harness Connector X4
S34—Selective Flow Valve 30 Pin Connector
Switch
Continued on next page OUO1020,00013DA –19–19JAN04–2/3
9015
10
97

031504
PN=229
System Diagrams
9015
10
98
–19–04OCT00
T133903
S9—Selective Flow Control Y21—Selective Flow Control

Foot Switch Solenoid
OUO1020,00013DA –19–19JAN04–3/3

031504
PN=230
System Diagrams
9015
10
99

031504
PN=231
System Diagrams
Pattern Select Harness (W19) Wiring Diagram (S.N. 913484— )
9015
10
,100
–19–22JAN03
T156405

031504
PN=232
System Diagrams
S42—Pattern Select Switch X88—Splice H18 Green Wire Y26—Pattern Select Solenoid Y27—Pattern Select Solenoid
X29—Pattern Select Power X89—Splice G10 Black Wire Valve Valve
Connector (W19)-to-Pilot
Control Power Connector
X28 (W11)
TX14826,0000017 –19–19JAN04–2/2
9015
10
,101

031504
PN=233
System Diagrams
Pattern Select Harness (W19) Component Location (S.N. 913484— )
9015
10
,102
–UN–15JAN03
T156403

031504
PN=234
System Diagrams
S42—Pattern Select Switch X29—Pattern Select Power Y26—Pattern Select Solenoid Y27—Pattern Select Solenoid
W19—Pattern Select Harness Connector (W19)-to-Pilot Valve Valve
Control Power Connector
X28 (W11)
TX14826,0000018 –19–19JAN04–2/2
9015
10
,103

031504
PN=235
System Diagrams
9015
10
,104

031504
PN=236
Group 15
Sub-System Diagnostics
Power Circuit Operational Information
The following conditions must exist for power circuit to

function:
Voltage must be present at these distribution points for

other circuits to operate.
• BAT terminal of key switch

• Accessory relay
• Start relay
• B+ terminal of alternator
• Starter motor
• Radio fuse
9015
15
1
CED,TX14826,12592 –19–12JUN00–1/1

031504
PN=237
Power Circuit Theory Of Operation
Unswitched power from the battery is available at the

following components:
• Starter Motor (M1)

• Start Relay (K1)
• Alternator (G2)
• Accessory Relay (K2)
• Key Switch (S1)
• Radio (Unswitched) Fuse (F5)
• Display Monitor (H1) (J2-A)
When the key switch is turned to ACC or ON position,

power becomes available at the following fuses:
9015
15 • F6—Dome Light/Radio Fuse (10 Amp)
2 • F7—Fuel Shut-Off/Start Aid/Back-Up Alarm Fuse (15
Amp)
• F12—FNR/Park Brake/SG Unload Valve Fuse (10 Amp)
• F16—Monitor/Alarm Fuse (10 Amp)
With the key switch in the ACC or ON position, current

flows to the coil of accessory relay (K2), energizing the
relay. With the accessory relay energized, power becomes
available at the following fuses and circuit breakers:
• F1—MFWD/Alt/Diff Lock Fuse (7.5 Amp)

• F2—Power Port/Aux Power Fuse (15 Amp)
• F8—Blower/AC Fuse (30 Amp)
• F9—Wiper/Washer Fuse (15 Amp)
• F10—Rear Work Lights Circuit Breaker (20 Amp)
• F11—Drive/Work/Tail Lights Circuit Breaker (25 Amp)
• F14—Turn/Stop/Flash/Horn Fuse (20 Amp)
• F15—Docking Lights/Beacon Circuit Breaker (15 Amp)
• F17—Return-To-Dig Fuse (10 Amp)
• F18—Aux Power/Air Seat Fuse (20 Amp)
The key switch “G” terminal is connected to ground and is

not used.
NOTE: For component identification code description, see

Wiring and Schematic Diagrams Legend. (Group
9015-10.)
CED,TX14826,12593 –19–12MAR04–1/1

031504
PN=238
Power Circuit Schematic

T197641 –19–11MAR04
B03B 0.8 RED B03A 0.8 RED
E22A 0.8 WHT
S1
E22A 0.8 WHT

KEY
B03B 0.8 RED
B11C 13 RED
SWITCH
B14 1 RED
K6
NEUTRAL
START
RELAY
F13
10A
F1 F2 F5 F10 START F15
G1 K2 F8 20A FUSE F17
BATTERIES ACCESSORY 7.5A 15A 5A 30A 15A 10A
K1 MFWD/ALT/ REAR DOCKING
START RELAY POWER RADIO BLOWER/ RETURN-TO-
DIFFERENTIAL WORK LIGHTS/
RELAY PORT/ (UN- AC FUSE DIG FUSE
LOCK FUSE LIGHTS BEACON
+ AUXILIARY SWITCHED)
CIRCUIT CIRCUIT
W3 POWER FUSE
BREAKER
GROUND FUSE BREAKER
B11C 13 RED
B11D 13 RED
—
AT CAB
FLOOR
RED BAT CABLE
F11
G01AN 0.8 BLK
F7 F9 F12 F14 F16 F18

OFF ON M1 F6 25A
10A 10A
STARTER 10A 15A 15A DRIVE/ 20A 20A
FUEL WIPER/ FNR/PARK TURN/ MONITOR/
DOME AUXILIARY
B03A 0.8 RED

MOTOR WORK/ ALARM
SHUTOFF/ WASHER BRAKE/SG STOP/ POWER/ AIR
G2 LIGHT/ TAIL LIGHTS FUSE
START AID/ FUSE UNLOAD FLASH/ SEAT FUSE
ALTERNATOR RADIO CIRCUIT
BACK-UP VALVE HORN
BLACK BAT CABLE GND STRAP FUSE BREAKER
ALARM FUSE FUSE
S39
BATTERY FUSE
DISCONNECT W1 G02AG 0.8 BLK
MACHINE J2-A
SWITCH
(OPTIONAL) FRAME
GROUND (LEFT SIDE) H1
DISPLAY
MONITOR
T197641
POWER CIRCUIT SCHEMATIC
CED,TX14826,12594 –19–09FEB04–1/1

031504
PN=239
Sub-System Diagnostics/Power Circuit
CED,TX14826,12595 –19–12MAR04–1/1
Power Circuit Diagnostic Procedures
– – –1/1
Battery State Of Charge YES: Clean battery cable

CAUTION: Engine may crank during this check. terminals. Repeat test.
9015
15 Move light switch to ON position. If lights still get dim, test
4
battery.
Do work lights go out or get very dim while cranking engine?
NO: Battery Charge is
good. Go to next check.
– – –1/1
Starter Motor Key switch OFF. YES: Check complete.
With harness connected, check voltage at terminal of NO: Check wiring

starter with red cable. harness between battery
and starter. See System
Are 12 volts measured? Functional Schematic
(S.N. —913483) or see
System Functional
T7199BK –19–17SEP90
Schematic (S.N.
913484— ) (SE1—Power,
Starting, and Charging
Circuits). (Group
9015-10.)
– – –1/1
Alternator Key switch OFF. YES: Go to next check.
With harness connected, check voltage at B+ terminal of NO: Check wiring

alternator harness between battery
and alternator. See
Are 12 volts measured? System Functional
Schematic (S.N. —
T7828AA –19–23SEP92
(S.N. 913484— ) (SE1—
Power, Starting, and
Charging Circuits).
(Group 9015-10.)
– – –1/1

031504
PN=240
Start Relay Key switch OFF. YES: Go to next check.
With harness connected, check voltage at terminal with NO: Check wiring
BO3 red wire. harness between battery
and start relay. See
Schematic (S.N. —
T7199BM –19–17SEP90
(S.N. 913484— ) (SE1—
Charging Circuits).
(Group 9015-10.)
– – –1/1
Key Switch Check Key switch OFF. YES: Go to next step in

this check.
9015
Disconnect harness from switch.
15
NO: Check wiring
5
Check voltage on B11 red wire at BAT terminal of key harness between battery
switch. and key switch. See
System Functional
Are 12 volts measured? Schematic (S.N. —
T7199BO –UN–17SEP90
(S.N. 913484— ) (SE1—
Charging Circuits).
(Group 9015-10.)
Switch disconnected from harness. YES: Go to next step in

this check.
Turn key switch to START position.
NO: Replace key switch.
Check for continuity between BAT and IGN terminals
and BAT and ST terminals.
Is continuity measured?
Switch disconnected from harness. YES: Go to next check.
Key switch ON. NO: Replace key switch.
Check for continuity between BAT and ACC terminal.
– – –1/1

031504
PN=241
Accessory Relay Key switch OFF. YES: Go to next check.
With harness connected, check voltage at large terminal NO: Check wiring
with B11 red wire. harness between battery
and accessory relay. See
Schematic (S.N. —
T7199BN –UN–16AUG90
(S.N. 913484— ) (SE1—
Charging Circuits).
(Group 9015-10.)
– – –1/1
Accessory Relay Key switch ON. YES: Go to next check.

Check—Continued
9015
With harness connected, check voltage at small terminal NO: Check wiring
15
6
Schematic (S.N. —
(S.N. 913484— ) (SE1—
Charging Circuits).
(Group 9015-10.)
– – –1/1
Accessory Relay Disconnect harness from relay. YES: Relay is good.

Check—Continued
Connect battery voltage to small terminal. Ground NO: Replace accessory
mounting bracket. relay.
Does relay click?
Measure continuity between the two large terminals.

– – –1/1
Start Circuit Operational Information
The following conditions must exist for start circuit to

function:
• FNR lever in neutral

• Key switch in START position
CED,TX14826,12596 –19–12JUN00–1/1

031504
PN=242
Start Circuit Theory Of Operation
Unswitched power from battery is available at the

following components:
• Starter motor (M1)

• Start relay (K1)
• Accessory relay (K2)
• Key switch (S1)
When key switch (S1) is turned to the ON position and the

FNR/range lever is in the NEUTRAL position, current
flows from key switch IGN terminal, through FNR/park
brake/unload valve fuse (F12), across the normally closes
contacts of loader lever switch (S21), to FNR/range switch
(S22). From the FNR/range switch, current flows to the
9015
coil of neutral start relay (K6), energizing the relay. 15
7
When the key switch is turned to the START position,
current flows from key switch ST terminal, through start
fuse (F13), across the neutral start relay contacts, to the
coil of start relay (K1), energizing the relay. With the start
relay energized, current flows through B03 red wire,
across the start relay contacts, through E03 white wire, to
starter solenoid “S” terminal, energizing the starter
solenoid. With the starter solenoid energized, heavy
current flows from the battery to the starter windings,
causing the motor to operate.
NOTE: For component identification code descriptions,

see Wiring and Schematic Diagrams Legend.
(Group 9015-10.)
CED,TX14826,12597 –19–12MAR04–1/1

031504
PN=243
Start Circuit Schematic

T132754 –19–11SEP00
CED,TX14826,12598 –19–12JUN00–1/1

031504
PN=244
Sub-System Diagnostics/Start Circuit
CED,TX14826,12599 –19–12MAR04–1/1
Start Circuit Diagnostic Procedures
– – –1/1
Key Switch Check Switch disconnected from harness. YES: Go to next step in
this check.
9015
15
9
– – –1/1

031504
PN=245
FNR Lever Key switch ON. FNR lever in neutral YES: Go to next step in
this check.
With harness connected, check voltage at terminals with
P24 red wire and T12 blue wire. NO: Check wiring
harness. See System
Are 12 volts measured at each terminal? Functional Schematic
(S.N. —913483) or see
System Functional
Schematic (S.N.
913484— ) (SE17—Park
Brake and FNR Circuit).
(Group 9015-10.)
9015
15 T115867 –19–19JUN98
10
Key switch ON. YES: FNR lever is good.

Go to next check.
With harness connected, and FNR lever moved to
forward, check voltage at terminal with T11 blue wire. NO: Replace FNR lever.
Move FNR lever to reverse, check voltage at T13 blue

wire.
Are 12 volts measured at each terminal?
T115868 –19–19JUN98
– – –1/1
Neutral Start Relay Key switch OFF. YES: Relay is good.

Check wiring harness.
Disconnect harness from relay. See System Functional
Schematic (S.N. —
Connect battery voltage to terminal #1. Ground terminal 913483) or see System
#2. Functional Schematic
(S.N. 913484— ) (SE17—
Does relay click? Park Brake/FNR Circuit).
T130926 –UN–15MAY00
(Group 9015-10.)
Measure continuity between terminals #3 and #5.
NO: Replace neutral start
Is continuity measured? relay.
– – –1/1

031504
PN=246
Start Relay Key switch OFF. YES: Relay is good.
Disconnect harness from relay. NO: Replace start relay.
Connect battery voltage to one of the small blade

terminals and ground the other. Does relay click?
Measure continuity between two large terminals. Is

continuity measured?
T7287BK –19–16AUG90
– – –1/1
Starter Solenoid Check YES: Solenoid is OK.

CAUTION: Starter will crank engine if metal Check starter motor.
strap is NOT disconnected from starter 9015
motor. 15
NO: Replace starter
11
solenoid.
Disconnect metal strap from starter motor terminal.
Connect battery voltage to solenoid small terminal.
T6534BI –UN–19OCT88
Ground metal strap from solenoid with heavy gauge
wire.
Does solenoid “click”?
Remove jumper wires.
– – –1/1
Starter Motor YES: Starter motor is

CAUTION: Starter will crank engine if metal good. Check wiring
strap is NOT disconnected from starter harness. See
motor. Engine/Transmission
Harness (W7) Wiring
Disconnect metal strap from starter motor large terminal. Diagram. (Group
9015-10.)
Connect a heavy gauge jumper wire from battery
positive cable to starter motor terminal. NO: Repair or replace
T6534BJ –UN–07JAN97
starter motor.
Connect a heavy gauge jumper wire from battery
positive cable to starter motor terminal.
Does starter motor turn, but NOT crank engine?
– – –1/1

031504
PN=247
Charging Circuit Operational Information
The following conditions must exist for charging circuit to

function:
• Key switch in ON position

• Engine running
CED,TX14826,12600 –19–12JUN00–1/1
Charging Circuit Theory of Operation

9015
15 The alternator (B+) terminal is connected to battery
12 voltage at all times. When key switch (S1) is in the ACC,
ON, or START positions, current flows to the coil of
accessory relay (K2), energizing the relay. With the
accessory relay energized, current flows across the
accessory relay contacts, through MFWD/alt/diff lock/RTD
fuse (F1), to the D+ terminal of the alternator, energizing
(exciting) the rotor field windings.
The display monitor senses unswitched voltage from the

starter motor battery terminal. When the key switch is in
the ON position and system voltage is less than 12.5
volts, the alternator voltage light on the display monitor
will come on.

9015-10.)
CED,TX14826,12601 –19–12MAR04–1/1

031504
PN=248
Charging Circuit Schematic
9015
15
13
–19–07SEP00
T132755
CED,TX14826,12602 –19–12JUN00–1/1

031504
PN=249
Sub-System Diagnostics/Charging Circuit
CED,TX14826,12603 –19–12MAR04–1/1
Charging Circuit Diagnostic Procedures
– – –1/1
Alternator Output Key switch OFF. YES: Alternator is good.

Check battery. Check
9015
Measure and record battery voltage. wiring harness. See
15
System Functional
14
Start and run engine at 1500 rpm, and check battery Schematic (S.N. —
voltage. 913483) or see System
Specification (S.N. 913484— ) (SE1—
T6569AZ –UN–23AUG93
Alternator Output Power, Starting, and
Check—Engine Speed....................................... 1500 rpm Charging Circuits).
Does battery voltage increase? NO: Check alternator.
– – –1/1
Alternator Key switch ON. Engine running. Park brake ON. YES: Alternator is good.
Using a multimeter, check for DC voltage at terminals NO: Alternator is failed.

(D+) and (B+). Repair or replace.
Is 14 DC volts measured?
Using a multimeter, check for AC voltage at terminal

(W).
Is 7.63 AC volts measured?
T7835AT –19–23SEP92
– – –1/1

031504
PN=250
Alternator Diode Test Remove diode from connector. YES: If continuity is

measured in both checks,
NOTE: A diode can fail in Using a multimeter, turn to diode test and connect diode has failed in a
two modes, either shorted probes to diode terminals. shorted mode. Replace.
or open. A good diode will
have continuity only in one Is continuity measured? NO: If continuity is NOT
direction. measured in either check
Reverse probes diode has failed in an
open mode. Replace.
T7961AA –UN–10MAR93
NO: If continuity is
measured in one check
and not the other, diode
is OK.
– – –1/1

this check.
9015
15
NO: Check wiring
15
System Functional
(S.N. 913484— ) (SE1—
Charging Circuits).
(Group 9015-10.)

this check.
– – –1/1

031504
PN=251
Key Switch Check— Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next check.
Continued
Remove FNR/park brake fuse. NO: Replace key switch.
Remove start fuse.
With harness connected, check voltage at IGN and ST

terminals.
Are 12 volts measured at each terminal?
– – –1/1
Key Switch Check— Key switch ON. YES: Go to next check.

Continued
9015
With harness connected, check voltage at ACC terminal NO: Replace key switch.
15
of key switch.
16
Are 12 volts measured?
– – –1/1
Accessory Relay Key switch OFF. YES: Go to next check.
With harness connected, check voltage at large terminal NO: Check wiring
Schematic (S.N. —
(S.N. 913484— ) (SE1—
Charging Circuits).
(Group 9015-10.)
– – –1/1
Accessory Relay Key switch ON. YES: Go to next check.

Check—Continued
With harness connected, check voltage at small terminal NO: Check wiring
Schematic (S.N. —
(S.N. 913484— ) (SE-1—
Charging Circuits).
(Group 9015-10.)
– – –1/1

031504
PN=252
Accessory Relay Disconnect harness from relay. YES: Relay is good.

Check—Continued
Connect battery voltage to small terminal. Ground NO: Replace accessory
mounting bracket. relay.
Does relay click?
Measure continuity between the two large terminals.

– – –1/1
Differential Lock Circuit Operational

Information 9015
15
17
The following conditions must exist for differential lock to
function.
• Key switch in ON position.

• Engine running
• Differential lock switch held down.
CED,TX14826,12604 –19–12JUN00–1/1
Differential Lock Circuit Theory of Operation
When the key switch is in the ON position and the

differential lock switch (S30) is pushed to the momentary
ON position, current flows from MFWD/alt/diff lock fuse
(F1), across the differential lock switch contacts, to
differential lock solenoid (Y1), energizing the solenoid.
Releasing the differential lock switch stops current flow,

thus de-energizing the differential solenoid. The differential
lock diode (V3) acts as a surge suppressor to prevent
arcing across the switch terminals when the differential
lock switch is released.

9015-10.)
CED,TX14826,12605 –19–12MAR04–1/1

031504
PN=253
Differential Lock Circuit Schematic
9015
15
18
–19–07SEP00
T132756
CED,TX14826,12606 –19–12JUN00–1/1

031504
PN=254
Sub-System Diagnostics/Differential Lock

Circuit
CED,TX14826,12607 –19–12JUN00–1/1
Differential Lock Circuit Diagnostic Procedures
– – –1/1
Differential Lock Switch Disconnect harness from switch. YES: Go to next step in
this check.
9015
Connect multimeter to switch terminals.
15
NO: Replace switch.
19
Depress differential lock switch.
T115875 –19–19JUN98
Release differential lock switch. YES: Replace switch.
Is continuity measured? NO: Go to next check.
T115875 –19–19JUN98
– – –1/1
Differential Lock Key switch ON. YES: Repair or replace

Solenoid solenoid. See Differential
Differential lock switch depressed and held. Lock Circuit Schematic.
(Group 9015.)
Disconnect harness from solenoid.
NO: Repair harness. See
Measure voltage at terminals in harness. Differential Lock Circuit
Schematic. (Group 9015.)
T115864 –19–19JUN98
– – –1/1

031504
PN=255
Differential Lock Diode Remove diode from connector. YES: If continuity is

open mode. Replace.
is OK.
– – –1/1
MFWD Circuit Operational Information

9015
15 The following conditions must exist for MFWD to function.
20
• Key switch in ON position.
• Engine running
• MFWD switch on.
CED,TX14826,12608 –19–12JUN00–1/1

031504
PN=256
MFWD Circuit Theory of Operation
NOTE: The MFWD is spring applied, hydraulically

released. See Mechanical Front Wheel Drive
(MFWD) Operation. (Group 9020-05.)
When the key switch is in the ON position and MFWD

switch (S2) is in the DISENGAGE position, current flows
from the MFWD/alt/diff lock fuse (F1), across the MFWD
switch contacts, to MFWD solenoid (Y2), energizing the
solenoid. The energized solenoid allows pressurized oil to
release the MFWD clutch.
When the MFWD switch is moved to the ENGAGE

position, the switch contacts open, causing the MFWD
solenoid to de-energize. The de-energized solenoid blocks
9015
pressurized oil from flowing to the MFWD clutch, thus 15
allowing the MFWD to engage. 21
The MFWD diode (V4) acts as a surge suppressor to

prevent arcing across the MFWD switch terminals.

9015-10.)
CED,TX14826,12609 –19–12MAR04–1/1

031504
PN=257
MFWD Circuit Schematic
9015
15
22
–19–07SEP00
T132757
CED,TX14826,12610 –19–12JUN00–1/1

031504
PN=258
Sub-System Diagnostics/MFWD Circuit
CED,TX14826,12611 –19–12MAR04–1/1
MFWD Circuit Diagnostic Procedures
– – –1/1
MFWD Switch YES: MFWD switch is

good. Check wiring
9015
harness. See System
15
23
(S.N. —913483) or see
System Functional
Schematic (S.N.
913484— ) (SE3—MFWD
Circuit). (Group 9015-10.)
NO: Replace MFWD

switch.
T100731 –UN–28MAY96
MFWD switch OFF.
Check for continuity between terminals 2B and 1.
MFWD switch ON.
– – –1/1

031504
PN=259
MFWD Solenoid Key switch ON. YES: Repair or replace

solenoid.
MFWD switch OFF.
NO: Repair harness. (See
Disconnect harness from solenoid. group 10 of this section)
Measure voltage at terminals in harness.
T126771 –19–20DEC99
– – –1/1
MFWD Diode Remove diode from connector. YES: If continuity is

9015
15
24
open mode. Replace.
is OK.
– – –1/1

031504
PN=260
Display Monitor/Indicator Circuit Operational

Information
Display Monitor:
The following conditions must exist for display module to

function.
The key switch must be in the “ON” position so failures

will be indicated.
Indicator:
The indicator circuit has “Two” modes of operation.
• Bulb check mode 9015

• Failure mode 15
25
The following conditions must exist for indicator circuit to
function in bulb check mode:
Key switch when first moved to “ON” and “ACC” position

for bulb check.
The following conditions must exist for indicator circuit to

function in a failure mode:
Engine must be running for a failure to be indicated on

display monitor. An indicator sensor or alternator senses a
failure and supplies a high or low level warning to display
monitor.
CED,TX14826,12612 –19–12JUN00–1/1

031504
PN=261
Display Monitor/Indicator Circuit

Specifications
Specification
Engine Oil Pressure Switch
(Normally Closed)—Opening
Pressure ........................................................... 37—72 kPa (0.4—0.7 bar)
(5.5—10.5 psi)
Air Filter Restriction Switch
(Normally Open)—Closes on
Increased Vacuum................................. 4.98—7.48 kPa Vacuum (20—30
in. H2O)
Hydraulic Filter Restriction Switch
(Normally Open)—Closing
Pressure ......................................................... 344 kPa (3.45 bar) (50 psi)
9015
15
26
CED,TX14826,12728 –19–17JUL00–1/1

031504
PN=262
Display Monitor/Indicator Circuit Theory Of Operation
9015
15
27
–UN–17JUL00
T132517B
1—S26-Docking Light Switch 5—S23-Horn Switch 9—S15-Rear Wiper Switch 13—S2 Beacon Switch
2—S17-Rear Lights Switch 6—Heater Temperature Control (S.N. 919464— ) 14—S5-Ride Control Switch
3—S15-Rear Wiper Switch 7—S13-A/C Defrost Mode 10—S32-Air Seat Switch 15—S2-MFWD Switch
(S.N. —919463) Switch 11—S1-Key Switch 16—S11-Start Aid Switch
3—S42-Pattern Select Switch 8—S7-Selective Flow Control 12—S6-Pin Disconnect Switch 17—S20-Park Brake Dash
(S.N. 919464—) Switch (if equipped) Switch
4—S12-Blower Switch
Continued on next page TX14826,00031D2 –19–20JAN04–1/4

031504
PN=263
9015
15
28
–UN–17JUL00
T132516
1—Select Button 5—Fuel Level Gauge 9—Engine Air Filter Restriction 11—Engine Oil Pressure Light
2—Display Window 6—Hydraulic Oil Filter Light Light 12—Red STOP Light
3—Engine Coolant 7—Park Brake Light 10—Engine Alternator Voltage 13—Hydraulic Oil Temperature
Temperature Gauge 8—Fasten Seat Belt Light Light Light
4—Convertor Oil Temperature
Gauge
Power is supplied to the display monitor through the the machine should be stopped immediately and
10 AMP Monitor/Alarm fuse. problem corrected.
Each display indicator will be colored either (RED) or CONDITION: High Level Warning Indicators
(YELLOW) to indicate the severity of the situation. Red (RED) — STOP MACHINE
is a high level warning and the yellow is a low level
warning. • Red STOP Light
• Audible Alarm
When a high level warning occurs, a red light, the red • Park Brake Light
STOP light, and the audible alarm will be activated. • Engine Oil Pressure Light
When a low level warning occurs, only a yellow light • Seat Position Warning: The seat position warning
will come on. On low level warnings, the operation of has no indicator. The STOP light and audible alarm
the machine can continue, but the problem should be will come on when the seat position is rotated away
investigated and solved as soon as it is convenient to from the forward-facing driving position and the FNR
do so. On high level warnings, except when the engine lever is not in neutral position.
coolant temperature light comes on, the operation of

031504
PN=264
CONDITION: Low Level Warning Indicators several minutes, then stop engine
(YELLOW) — SERVICE MACHINE and service machine.
• Fasten Seat Belt Light Engine Coolant Temperature Gauge: The engine
• Engine Alternator Voltage Light coolant temperature gauge displays various
• Air Filter Restriction Light temperature levels. As the voltage level is read, it is
• Charging System Light diagnostically checked to verify that it is within the
• Hydraulic Oil Temperature Light valid range. If an out of range signal is received from
• Hydraulic Oil Filter Light the corresponding sender, the pointer will loose all
function and move to the extreme left. At temperatures
Select Button The Select button is used to change greater than 88°C (190°F), the gauge pointer will be in
the information mode on the display window. the red zone and the STOP light and audible alarm will
be activated.
Display Window The information displayed will
change sequence from Hour Meter icon, to Gauge Range Temperature Sensor Resistance
Tachometer icon, to Voltmeter icon, to Hydraulic Oil Ranges Ranges (Ohms)
(Fahrenheit) 9015
Temperature icon and then back to Hour Meter icon. 15
1 0-70 25.65K-3383
29
Key ON, Engine Off: The display window will default to 2 70-170 3383-372
the Hour Meter. 3 170-190 372-259
4 190-240 259-135
Key ON, Engine Running: The display window will 5 240-250 Less Than 134
default to Tachometer.
Converter Oil Temperature Gauge: The converter oil
The Tachometer function in the display window shows
temperature gauge will display various temperature
the engine speed. The tachometer can be calibrated.
levels. As the voltage level is read, it is diagnostically
See Calibrate Tachometer. (Group 9015-20.)
checked to verify that it is within the valid range. If an
out of range signal is received from the corresponding
The Voltmeter function in the display window shows
sender, the pointer will loose all function and move to
system Voltage.
the extreme left. At temperatures greater than 121°C
(250°F), the gauge pointer will be in the red zone and
Bulb Check: With the key switch in the ON or ACC
the “STOP” light and audible alarm will be activated.
position, a bulb check will be executed for five
seconds. During this mode the display, all warning Gauge Range Temperature Sensor Resistance
lights, and analog gauges will be activated. The Ranges Ranges (Ohms)
audible alarm will sound twice at the beginning. (Fahrenheit)
1 0-70 25.65K-3383
DISPLAY MONITOR GAUGES 2 70-130 3383-816
3 130-145 816-607
IMPORTANT: DO NOT immediately stop engine
4 145-250 607-134
when the engine coolant temperature
becomes too high. Stopping an 5 250 Less Than 134
overheated engine too quickly may
produce hot spots, which could Fuel Level Gauge: The fuel level is determined by the
damage the engine. Instead, reduce float sensor, which provides a change in resistance as
load and run engine at slow idle for a function of the fuel level.

031504
PN=265
Gauge Range Tank Percentage Sensor Voltage when the engine is started, the fasten seat belt light
1 0-10% 0-1.07V will activate for only five seconds to remind the
2 10-18.75% 1.08-1.42 operator to fasten the seat belt.
3 18.75%-27.5% 1.43-2.43
Park Brake Light: Absence of pressure in the brake
4 27.5%-36.25% 2.44-2.81
cavity causes the park brake pressure switch to close,
5 36.25%-45% 2.82-3.16 causing the park brake light to come on. When the
6 45%-57.5% 3.17-3.53 park brake light is on and the FNR lever is move out of
7 57.5%-70% 3.54-3.67 neutral, the park brake light will flash in unison with the
8 70%-82.5% 3.68-3.86 STOP light and audible alarm.
9 82.5%-95% 3.87-3.89
Seat Position Warning: When the seat position is
10 95%-100% 3.89
rotated away from the forward-facing driving position,
the red STOP light and the audible alarm will be
DISPLAY MONITOR INDICATORS activated.
9015 Engine Oil Pressure Light: When the engine is
15 Hydraulic Oil Temperature Light: The temperature of
running and the engine oil pressure switch senses oil the hydraulic oil in the reservoir can be displayed on
30
pressure is less than 69 kPa (10 psi), the engine oil the monitor. The resistance of the temperature sensor
pressure light and the STOP light will come on. The positioned at the bottom of the hydraulic reservoir
audible alarm will activate. changes as the hydraulic oil temperature changes. The
change in resistance causes the voltage level input to
Hydraulic Oil Filter Restriction Light: When the the monitor to change. The monitor is able to equate
engine is running and hydraulic oil filter becomes various voltage levels to specific temperatures. When
restricted, the contacts of the normally open pressure the oil temperature is more than 110°C (230°F), the
switch close, causing the hydraulic oil filter restriction amber hydraulic oil temperature light comes on
light to come on. continuously. When the oil temperature is less than
99°C (210°F), the light is off. The red “STOP” light and
Engine Air Filter Restriction Light: When the engine audible alarm are NOT activated during this event. The
is running and the air filter becomes restricted, the digital display of the hydraulic oil temperature is limited
contacts of the normally open pressure switch close, to a range of 100°F—250°F. Outside of this range the
causing the engine air filter restriction light to come on. digital display will show dashes.
Engine Alternator Voltage Light: The alternator NOTE: For component identification code description,
voltage light comes on when alternator/battery voltage, see Wiring and Schematic Diagrams Legend.
measured at the starter motor battery terminal, is less (Group 9015-10.)
than 12.5 volts.
Fasten Seat Belt Light: The fasten seat belt light is

not directly tied to any hardware inputs. Therefore,
TX14826,00031D2 –19–20JAN04–4/4

031504
PN=266
Display Monitor/Indicator Circuit Schematic

T197393 –19–11MAR04
T197393
OUO1020,00013DB –19–20JAN04–1/1

031504
PN=267
Sub-System Diagnostics/Display
Monitor/Indicator
CED,TX14826,12615 –19–12MAR04–1/1
Display Monitor Diagnostic Procedures
– – –1/1
Fuse Remove fuse cover. YES: Replace fuse

9015
Check 10 amp monitor/gauge fuse. NO: Go to next check
15
32
Is fuse blown?
– – –1/1

this check.
NO: Check wiring
System Functional
(S.N. 913484— ) (SE1—
Power, Starting and
Charging Circuits).

this check.
– – –1/1

031504
PN=268
Display Monitor YES: Check connector

pins in connector.
IF OK: Check indicators.

See Display
Theory Of Operation.
(Group 9015-15.)
IF OK: Replace display

monitor.
NO: Check wiring

harness. See Display
Schematic. (Group
9015-15.)
9015
T133081 –19–17AUG00 15
33
Unplug 10 pin display monitor harness connector X76 from display monitor.
Key switch to ON position.
Check for voltage on P21 red wire
Key switch to OFF position.
Check for continuity between G30 black wire and ground.
– – –1/1
Engine Coolant Disconnect X36 yellow wire from switch and ground to YES: Replace switch.
Temperature Indicator frame.
Switch NO: Switch is good. Go
Without starting engine, turn key switch to BULB to next check.
CHECK, then release to ON.
Is engine coolant indicator light on?
T7199CG –19–16AUG90
– – –1/1

031504
PN=269
Engine Oil Pressure Disconnect N34 yellow wire from switch and ground to YES: Replace switch.
Switch frame.
NO: Switch is good. Go
Is engine oil pressure indicator light on?
T7199DZ –19–26SEP90
– – –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
9015
alternator.
15
Without starting engine, turn key switch to BULB CHECK, then release to ON.
34
Is alternator indicator light off?
Remove voltage from M39 purple wire.
Is alternator indicator light on?
– – –1/1
Engine Air Filter Disconnect M40 purple wire from switch and ground to YES: Replace switch.
Restriction Switch frame.
NO: Switch is good. Go
CHECK, then release to ON?
Is air filter restriction indicator light on?
T7199CI –19–17SEP90
– – –1/1
Converter Oil Disconnect X38 yellow wire from sender and ground to YES: Replace sender.
Temperature Sender frame.
NO: Sender is good. Go
Without starting engine, turn key to BULB CHECK, then to next check.
release to ON.
Is converter oil temperature light on?
T7199CJ –19–17SEP90
– – –1/1

031504
PN=270
Hydraulic Oil Disconnect X41A yellow wire from sender and ground to YES: Replace sender.
Temperature Sender frame.
NO: Sender is good. Go
Without starting engine, turn key to BULB CHECK, then to next check.
release to ON.
Is hydraulic oil temperature light on?
T197396 –UN–22JAN04
– – –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
15
35
Is hydraulic filter restriction indicator light on?
T7199CK –19–17SEP90
– – –1/1
Seat Position Switch Key switch OFF. YES: Seat position switch
is good. Check wiring
Seat in loader function position. harness. See System
NOTE: Seat position switch is located in the operator (S.N. —913483) or see
seat base. System Functional
Schematic (S.N.
Check for continuity between terminals with M1 purple 913484— ). (SE25—Seat
T102968 –19–12AUG96
wire and G10 black wire Position Switch Circuit).
(Group 9015-10.)
Is continuity “NOT” measured?
NO: Replace seat
Move seat into backhoe function position position switch.
Check for continuity between terminals with M1 purple

wire and G10 black wire
Is continuity measured:
– – –1/1

031504
PN=271
Park Brake/FNR Circuit Operational

Information
The following condition or conditions must exist for park

brake/FNR circuit to function:
• Key switch OFF

• Park brake dash switch in ON position with machine
running
• Machine Mechanically Shut Down
CED,TX14826,12621 –19–12JUN00–1/1
Park Brake/FNR Circuit Specifications

9015
15 Specification
36 Park Brake Pressure Switch
(Normally Closed)—Opening
Pressure ............................................... 1103 ± 110 kPa (11.3 ± 1.10 bar)
(160 ± 16 psi)
Closing Pressure ......................................... 896 ± 89.6 kPa (8.96 ± 0.896
bar) (130 ± 13 psi)
CED,TX14826,12622 –19–12JUN00–1/1

031504
PN=272
Park Brake/FNR Circuit Theory Of Operation
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 will be on 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
Park brake cannot be hydraulically released if position: 15
FNR/Park Brake Fuse is blown. 37
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
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 (S20) and then to park brake sound and the stop light will flash. This occurs
latching relay terminal 2, energizing the park brake because the park brake solenoid is not energized, thus
latching relay (K5) causing it to latch terminals 3 and the park brake pressure switch is closed and sending
5. 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 (Y10) 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 2 of the park brake latching relay causing the
With the FNR Range switch (S22) in neutral, power relay to close. With the relay closed, power can now
flows from the FNR switch to the display monitor (H1). flow from terminal 5 of the park brake latching relay to
Combine this with the park brake pressure switch terminal 2B of the park brake switch.
being closed and providing a ground for the park brake
indicator light, the park brake indicator light in the • Key ON:
display monitor is on signaling that the park brake is • Engine Running:
applied. • Park Brake Switch OFF:
• Key ON: With the park brake dash switch in the OFF position,
• Engine Running: voltage is sent to both the timer relay and the park
• Park Brake Dash Switch In ON position: brake solenoid.
• FNR Lever Shifted Out of Neutral:
With the park brake dash switch ON, and FNR lever
shifted out of neutral, the signal from the FNR lever to
Continued on next page OUO1020,00013DD –19–20JAN04–1/2

031504
PN=273
The park brake solenoid is now energized and sending Power flows through the loader lever switch (S21) to
pressurized oil to the park brake to release it. This also the FNR range switch (S22). With FNR switch in either
opens the park brake pressure switch, thus the ground forward or reverse power flows to the timer relay
signal to the display monitor is removed and the park terminal 3. This signal closes the timer relay terminals
brake indicator light goes out. 6 and 1 allowing power to flow from the park brake
dash switch through the timer relay to the FNR switch.
• Key ON: Depending on FNR switch position, the proper
• Engine Running: direction and speed solenoids in the transmission are
• Park Brake Switch OFF: energized.
• FNR Switch in Forward or Reverse:
NOTE: If the signal to the timer relay terminal 3
With the park brake dash switch in the OFF position, disappears for more than one second, the
voltage is sent to both the timer relay (K7) terminal 4 timer relay terminals 6 and 1 will open.
and the park brake solenoid.
NOTE: For component identification code description,
The park brake solenoid is now energized and sending see Wiring and Schematic Diagrams Legend.
9015
15 pressurized oil to the park brake to release it. This also (Group 9015-10.)
38 opens the park brake pressure switch, thus the ground
signal to the display monitor is removed and the park
brake indicator light goes out.
OUO1020,00013DD –19–20JAN04–2/2

031504
PN=274
Park Brake/FNR Circuit Schematic

T132760 –19–12SEP00
OUO1020,00013DC –19–20JAN04–1/2

031504
PN=275
T133087 –19–07SEP00
OUO1020,00013DC –19–20JAN04–2/2

031504
PN=276
Sub-System Diagnostics/Park Brake/FNR

Circuit
CED,TX14826,12627 –19–12MAR04–1/1
Park Brake/FNR Circuit Diagnostic Procedures
– – –1/1
Park Brake Switch YES: Park brake switch is

“Dash” good. Check wiring
9015
harness.See System
15
41
(S.N. —913483) (SE16—
Park Brake/FNR Circuit).
(Group 9015-10.)
NO: Replace park brake

switch.
T100731 –UN–28MAY96
Disconnect harness from park brake switch.
Park brake switch OFF.
Park brake switch ON.
– – –1/1

031504
PN=277
Transmission Solenoids YES: Transmission

Check solenoids are electrically
good. See Solenoid
Circuit Leakage Test.
(Group 9020-25.)
NO: Check wiring

harnesses in Group
9015-10.See
Engine/Transmission
Harness (W7) Wiring
Diagram.
T133897B –UN–21SEP00
Remove fuse block cover.
Remove FNR/park brake unload valve fuse.

9015
15 Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and black
42 lead into (COM.) terminal.
Place probe ends of multimeter at locations (1 and 2) in fuse block.
Move seat into backhoe position.
Key switch ON and engine OFF.
Park brake switch “OFF”. Approximately (1.65—1.85) amp value will display.
NOTE: If approximately 2.57 amp value is not displayed, cycle park brake on then off
again.
FNR lever in forward position.
NOTE: Each solenoid in the transmission draws approximately 0.5 amps. If measured
amperage value is approximately 0.5 amps less than specification, a problem with one
solenoid is indicated.
Does the amp value match the following specifications for each speed?
Specification
FNR Current—1st Speed Forward
Amperage ............................................................................................... 3.05—3.25 amps
2nd Speed Forward Amperage .............................................................. 3.05—3.25 amps
3rd Speed Forward Amperage ............................................................... 3.05—3.25 amps
4th Speed Forward Amperage ............................................................... 2.70—2.90 amps
FNR lever in reverse position.
Does the amp value match the following specifications for each speed?
Specification
FNR Current—1st Speed Reverse
Amperage ............................................................................................... 3.15—3.35 amps
2nd Speed Reverse Amperage .............................................................. 3.15—3.35 amps
3rd Speed Reverse Amperage .............................................................. 3.15—3.35 amps
NOTE: The current value measurement is controlled by the number of components

that are connected within the circuit.
– – –1/1

031504
PN=278
Park Brake Solenoid YES: Park brake solenoid

Check electrically is good. See
Park Brake Release
Pressure Test. (Group
9020-25.)
NO: Check wiring

harness. See
Engine/Transmission
Harness (W7) Wiring
Diagram. (Group
9015-10.)
T133897B –UN–21SEP00
Remove fuse block cover.
Remove FNR/park brake fuse.

9015
Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and black 15
lead into (COM.) terminal. 43
FNR lever in neutral position.
Key switch ON and engine OFF.
Place probe ends of multimeter at locations (1 and 2) in fuse block.
Park brake switch “ON”. Approximately 1.16 amp value will display.
Move park brake switch to “OFF” position.
Does the amp value increase by approximately 1.5 amps?
– – –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 P24 red wire
and V01 pink wire. NO: Replace loader lever
switch.
T134093 –UJN–
Disconnect harness from loader lever switch YES: Replace loader

lever switch.
Depress loader lever switch and check for continuity
between terminals with P24 red wire and V01 pink wire. NO: Loader lever switch
is good. Check wiring
Is continuity measured? harness. See Cab/ROPS
Harness (W6) Wiring
Diagram. (Group
T134093 –UN–28SEP00
9015-10.)
– – –1/1

031504
PN=279
Park Brake Latching Key switch OFF. YES: Relay is good.

Relay Check wiring harness.
Disconnect harness from relay. See Engine/Transmission
Harness (W7) Wiring
Connect battery voltage to terminal #1. Ground terminal Diagram. (Group
#2. 9015-10.)
Does relay click? NO: Replace relay.

T130926 –UN–15MAY00
Measure continuity between terminals #3 and #5.
– – –1/1
Timer Relay Check YES: Go to next check

9015
NO: Replace timer relay.
15
44
T126811 –UN–15DEC99
Disconnect timer relay from front console harness.
Connect a 12 power supply and ground to the timer relay as shown.
Check for continuity across terminals 5 and 6 of timer relay.
– – –1/1
Park Brake Pressure Disconnect harness from switch. YES: Switch is good.
Switch Check wiring harness.
Measure continuity between terminals A and B on See Engine/Transmission
connector end of switch. Harness (W7) Wiring
Diagram. (Group
Is continuity measured? 9015-10.)
NO: Replace switch

T7199EE –UN–02OCT90
– – –1/1

031504
PN=280
FNR Lever Check YES: Continue with check
NO: Replace FNR lever.
T114633 –19–21JUL98
Disconnect FNR lever from harness.
Connect a 12 volt power supply to FNR lever as shown.

9015
15
Place FNR lever in neutral.
45
Are 12 volts measured at only terminal D of four pin connector?
Place FNR lever in reverse.
Are 12 volts measured at only terminal C of four pin connector?
Place FNR lever in forward.
Are 12 volts measured at only terminal B of four pin connector?

– – –1/2

031504
PN=281
NO: Replace FNR lever.
T114633 –19–21JUL98
Disconnect FNR lever from harness.
Connect a 12 volt power supply to FNR lever as shown.

9015
15
Place FNR lever in first speed forward.
46
Are 12 volts measured at only terminals A, C, and D of six pin connector?
Place FNR lever in second speed forward.
Are 12 volts measured at only terminals A, B, and C of six pin connector?
Place FNR lever in third speed forward.
Are 12 volts measured at only terminals B, C, and D of six pin connector?
Place FNR lever in fourth speed forward.
Are 12 volts measured at only terminals B and D of six pin connector?
–19– –2/2
Park Brake Relay Diode Remove diode from connector. YES: If continuity is
open mode. Replace.
is OK.
– – –1/1

031504
PN=282
Park Brake Solenoid Remove diode from connector. YES: If continuity is

Diode measured in both checks,
Using a multimeter, turn to diode test and connect diode has failed in a
NOTE: A diode can fail in probes to diode terminals. shorted mode. Replace.
two modes, either shorted
or open. A good diode will Is continuity measured? NO: If continuity is NOT
have continuity only in one measured in either check
direction. Reverse probes diode has failed in an
open mode. Replace.
is OK.
– – –1/1
Reverse Solenoid Diode Remove diode from connector. YES: If continuity is

9015
15
47
open mode. Replace.
is OK.
– – –1/1
Forward Solenoid Diode Remove diode from connector. YES: If continuity is

open mode. Replace.
is OK.
– – –1/1
Low Range Solenoid Remove diode from connector. YES: If continuity is

Diode measured in both checks,
open mode. Replace.
is OK.
– – –1/1

031504
PN=283
Speed Solenoid Diodes Remove diode from connector. YES: If continuity is

open mode. Replace.
is OK.
– – –1/1
9015
15
48

031504
PN=284
Ride Control Circuit Operational Information
The following conditions must exist for the ride control

circuit to function.
• Key switch ON
• Ride control switch ON
CED,TX14826,12640 –19–12JUN00–1/1
Ride Control Circuit Theory of Operation

9015
Power flow from the auxiliary fuse (F18) to the ride control 15
switch (S5). 49
When the ride control switch is switched on, power flows

to both the ride control solenoid (Y5), energizing the
solenoid, and to the light in the ride control switch causing
it to illuminate alerting the operator that the ride control
system is on.
When the switch is switched off and the circuit is broken

the ride control diode (V5) allows the current to dissipate.

9015-10.)
CED,TX14826,12641 –19–12JUN00–1/1

031504
PN=285
Ride Control Circuit Schematic
9015
15
50
–19–07SEP00
T132763
CED,TX14826,12642 –19–12JUN00–1/1

031504
PN=286
Sub-System Diagnostics/Ride Control Circuit
CED,TX14826,12643 –19–12MAR04–1/1
Ride Control Circuit Diagnostic Procedures
– – –1/1
Fuse Check Remove fuse cover. YES: Replace fuse.

9015
Check 10 amp auxiliary fuse. NO: Go to next check.
15
51
Is fuse blown?
– – –1/1

031504
PN=287
Ride Control Switch YES: Go to next check.

Check
NO: Check wiring
harness. See System
(S.N. —913483) or see
System Functional
Schematic (S.N.
913484— ) (SE27—Ride
Control Circuit). (Group
9015-10.)
9015
15 T100731 –UN–28MAY96
52
Unplug harness from ride control switch.
Key switch to ON position.
Check for voltage in receptacle 2B (P30 RED wire) of switch connector.
NO: Replace switch.
T100731 –UN–28MAY96
Unplug harness from ride control switch.
Switch ride control switch ON.
– – –1/1

031504
PN=288
Ride Control Solenoid Disconnect harness from solenoid. YES: Replace solenoid.
Check
Key switch and ride control switch ON. NO: Check wire harness.
Measure voltage at harness connector.

T116136 –19–06JUL98
– – –1/1
Ride Control Solenoid Remove diode from connector. YES: If continuity is

Diode Check measured in both checks,
9015
15
53
open mode. Replace.
is OK.
– – –1/1
Selective Flow Valve Circuit Operational

Information
The following conditions must exist for the selective flow

valve circuit to function.
NOTE: The selective flow valve circuit has two different

modes of operation. It can be either continuously
on or momentarily on using the foot switch. This is
selected using the two different positions on the
switch in the dash.
• Key switch ON
• Selective flow valve switch in either foot ON or
continuous ON.
• Foot switch held ON if selective flow valve switch is in
foot ON position.
CED,TX14826,12734 –19–31JUL00–1/1

031504
PN=289
Selective Flow Valve Circuit Theory of

Operation
Power flows from the Auxiliary Power Port/Auxiliary Power

fuse (F2) to (X4) Cab/ ROPS Harness Connector to (X23)
Selective Flow Harness Connector to both the selective
–UN–12OCT00
flow valve switch setting (S34) and the selective flow
control switch (S8).
The selective flow valve switch setting controls the flow
T134594B
rate out of the selective flow valve depending on the
position of switch (S34). If terminals 2B and 3 are
connected, the 25 gpm position is set and power flows
through the V03 PNK wire to the selective flow controller
30 pin connector. If terminals 2B and 2A are connected,
9015 the 13 gpm position is set and power flows through the
15 V02 PNK wire to the selective flow controller 30 pin
54 connector. If terminals 5B and 4 are connected, the 9 gpm
position is set and no power flows to the controller.
–UN–16OCT00
The selective flow control switch (S8) (1) has three
positions; off, foot on, and continuous on.
T134593B
With the selective flow valve switch in the foot on position,
power flows to the selective flow valve controller and to
the foot switch (S9). When the foot switch is depressed,
power flows to the selective flow valve switch to illuminate
the light in the switch and also to selective flow valve
controller.
With the selective flow valve switch in the continuous on

position, power immediately flows to the selective flow
controller and bypasses the foot switch.
Auxiliary Flow Control Valve—If Equipped Auxiliary

hydraulic valve is equipped with three different flow
settings. Each setting is identified and changed at (2)
(S34) Selective Flow Valve Switch Setting, located inside
of side console. The switch can be set to 9 GPM, 13 GPM
and 25 GPM.
To Set And Change Flow: See Selective Flow Valve

Adjustment in Group 9025-20. Go to Selective Flow Valve
Adjustment.
Continued on next page CED,TX14826,12733 –19–31JUL00–1/2

031504
PN=290

9015-10.)
CED,TX14826,12733 –19–31JUL00–2/2
9015
15
55

031504
PN=291
Selective Flow Valve Circuit Schematic

T197642 –19–10FEB04
OPTIONAL
T197642
CED,TX14826,12732 –19–09FEB04–1/1

031504
PN=292
Sub-System Diagnostics/Selective Flow

Valve Circuit
CED,TX14826,12731 –19–31JUL00–1/1
Selective Flow Valve Diagnostic Procedures
– – –1/1
Fuse Check Remove fuse cover. YES: Replace fuse.

9015
Check 10 amp auxiliary fuse. NO: Go to next check.
15
57
Is fuse blown?
– – –1/1
Selective Flow Valve YES: Go to next check.

Switch Check
NO: If switch fails any of
the above continuity
checks, replace switch.
T100731 –UN–28MAY96
Disconnect harness from selective flow valve switch.
Selective Flow Valve Switch to foot on position.
Check for continuity between terminals 5B and 3 of switch.
Selective Flow Valve Switch to continuous on position.
Check for continuity between terminals 5B and 6 of switch.
– – –1/1

031504
PN=293
Foot Switch Check Disconnect foot switch from harness. YES: Go to next check.
Depress foot switch. NO: Replace foot switch.
Check for continuity at connector.
T116147 –19–27JUL98
– – –1/1
Auxiliary Power Remove fuse cover. YES: Replace fuse.

Port/Auxiliary Power fuse
9015
Check fuse (F2) in fuse block. NO: Go to next check.
15
58
Is fuse blown?
– – –1/1
Selective Flow Hydraulic Turn hydraulic switch to OFF position and start engine. LOOK: Does attachment
Operational Check operate?
YES: Check electrical

connections, attachment
should not operate.
– – –1/1
. Depress foot switch. Release foot switch. Attachment and light should not operate. LOOK: Did attachment
operate?
LOOK: Did switch light

turn ON?
YES: Check electrical

and light should not
operate.
– – –1/1
. Place switch in FOOT ON position. Does attachment operate and does switch light YES: Go to next check.
come ON?
and light should operate.
– – –1/1

031504
PN=294
. With switch in CONT ON position, shut engine off. Leave switch in CONT ON position YES: Go to next check.
and restart engine. Does attachment operate and does switch light come ON.
operate.
– – –1/1
. Cycle switch to OFF position and then to CONT ON position. Does attachment operate YES: Go to next check.
and is switch ON?
operate.
– – –1/1
Selective Flow Valve Disconnect selective flow valve harness under cab. YES: Check all wiring
Solenoid Check harnesses. If harness are
9015
Measure resistance across selective flow valve solenoid by placing multi meter probes OK replace controller.
15
in end of harness coming from valve.
59
NO: Replace solenoid.
Do resistance meet specification?
Specification
Selective Flow Valve Solenoid—
Resistance (at 20°C (68°F) ..................................................................... 4.93 ± 0.2 ohms
– – –1/1

031504
PN=295
Pilot Control Circuit Operational Information, Theory of Operation and Circuit Schematic
(S.N. 913484— )
T197412 –UN–23JAN04
TO DISPLAY MONITOR
(TERMINAL J2-K)
X78
86 30
85 87a 87
T197412
OUO1020,00013DF –19–21JAN04–1/2

031504
PN=296
Go to SE31—Pilot Control Circuit and SE32—Pattern With the Pilot Disable Switch S41 in the off position,
Select Circuit in system functional schematic. See power is sent to (K12) Seat In Position Relay, (K13) In
System Functional Schematic (S.N. —913483) or see Position Latch Relay and (K14) Out Of Position Latch
System Functional Schematic (S.N. 913484— ). Relay.
Enable Pilot Control System: With the Pilot Disable Switch (S41) in the on position
power is sent to (Y24) Backhoe Hydraulic Solenoid
• Engine running. Valve enabling the pilot system. Power is also sent to
• Moving the Pilot Disable Switch (S41) to the on (K16) Override Relay.
position.
• Seat can be in loader position, in backhoe position, The (K15) Seat Not Rear Relay and (K16) Override
or in between loader and backhoe position. Relay control the monitor alarm for the pilot control
system. The alarm activates when the pilot control
Disable Pilot Control System: system is enabled and the backhoe seat is not facing
rear of machine. With seat facing rear of machine,
• Moving the pilot disable switch (S41) from the on (K15) relay activates closing the Seat Position Rear
9015
position to the off position. Switch (S40). 15
• Movement of the seat into or out of the forward or 61
rear positions. The pattern select option for pilot controls powers two
• Turning the key switch to the off position. solenoid valves selecting the SAE/ISO control pattern.
Power flows to the Pattern Select Switch (S42). With
When the pilot control system is enabled and the seat Pattern Select Switch (S42) on, the power flows to
is not facing rear of machine the display monitor will both Pattern Select Solenoid Valves (Y26, Y27),
show a text message “HOE” followed by “ON” energizing the solenoids.
indicating the pilot control system is on and you are
out of backhoe position. The alarm will sound. When the engine stops during operation, the boom
cannot be lowered using the pilot controller because
Pilot Control Theory of Operation: The operation of there is no pilot pressure oil to activate boom. Turn
the pilot control system requires pressured oil to be key switch on and cycle the pilot disable switch (S41)
metered through each joystick to control the position of to on and lower boom using the pilots controls.
each valve spool providing precise control of machine
functions. The pilot control electrical system enables
the pilot oil pressure by powering the backhoe
hydraulic solenoid valve (Y24).
OUO1020,00013DF –19–21JAN04–2/2

031504
PN=297
9015
15
62

031504
PN=298
Group 20
References
Alternators and Starting Motors—Use CTM77
For additional information, the component technical

manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
–UN–17JAN89
TS225
CED,TX14826,12652 –19–12JUN00–1/1
JTO5801 Clamp-On Electronic Tachometer

Installation 9015
20
SERVICE EQUIPMENT AND TOOLS 1
Tachometer
–UN–28FEB89
T6813AG
CED,TX14826,12653 –19–12JUN00–1/1

031504
PN=299
References
Battery Operation
A battery is a device for converting chemical energy to solution. After washing, flush battery and compartment
electrical energy. It is not a storage tank for electricity, with clear water. Keep caps in place when cleaning
but stores electrical energy in chemical form. and charging.
Because of the constant chemical to electrical change Batteries should be maintained at an open circuit
(self-discharge, discharge, or charge), the battery has voltage of 12.50 volts or greater.
a limited life. Proper care (cleaning, adding water,
charging) will extend the life of the battery. Specification
Battery—Minimum Open Circuit
Voltage ................................................................................ 12.50 volts
The battery is made up of positive plates, negative
plates, separators, plate straps, and chemical solution
To determine open circuit voltage do the following:
(electrolyte). The electrolyte is a solution of sulfuric
acid and water. Sulfuric acid is not lost during
1. Turn master disconnect switch to ON position.
overcharging; therefore, if the liquid solution is low,
9015
20 only water should be added.
2. For machines that have not been run during the
2
past ten hours, go to Step 4.
In a fully charged battery, the positive plate is lead
peroxide (PBQ2), the negative plate is "spongy" lead
3. For machines that have been run in the past ten
(Pb), and the electrolyte solution is about 1.270 times
hours, remove surface charge. Turn key switch to
heavier than water.
START, turn on 3 or 4 work lights and leave them
Specification on for 3 to 5 minutes. Turn key switch OFF, then
Fully Charged Battery—Specific wait two minutes. (If machine does not have lights,
Gravity......................................................................................... 1.270 turn key switch to START position for at least 5
minutes, then turn off.)
The amount that the solution is heavier than water is
called specific gravity. 4. Measure voltage at alternator by placing the
negative lead of a multimeter to case of alternator
All batteries will self discharge at a rate of .001 specific and the positive lead to the sense terminal of the
gravity point per 24 hour period at a constant 85°F. alternator.
Specification Specification
Battery—Self Discharge Rate............... .001 specific gravity point per 100% Charged Stabilized Open
24 hour period at a constant Circuit—Voltage ...................................................... 12.5 volts or more
85°F 75% Charged Stabilized Open
Circuit—Voltage ............................................................................ 12.4
The discharge rate increases as temperature 50% Charged Stabilized Open
Circuit—Voltage ............................................................................ 12.2
increases and decreases as temperature decreases. If 25% Charged Stabilized Open
the machine is not used for a period of time, the Circuit—Voltage ............................................................................ 12.0
batteries must be maintained or stored in a cool place. 0% Charged Stabilized Open
Circuit—Voltage ................................................................ 11.7 or less
Wipe batteries with a damp cloth. If terminals are
corroded, use a stiff brush and wash with an ammonia
CED,TX14826,12654 –19–12JUN00–1/1

031504
PN=300
References
Battery Specifications
Specification
Standard Battery (Single
Battery)—Voltage .......................................................................... 12 Volts
Cold Cranking Power ......................................... 625 amps at -18°C (0°F)
Reserve Capacity ................................................ 160 minutes at 25 amps
BCI Group Size .................................................................................... 30H
Fully Charged Specific Gravity .......................................................... 1.265
Specification
Heavy Duty Battery (Dual
Battery)—Voltage .......................................................................... 12 Volts
Cold Cranking Power ......................................... 950 amps at -18°C (0°F)
Reserve Capacity ................................................ 190 minutes at 25 amps
BCI Group Size .................................................................................... 31H
Fully Charged Specific Gravity .......................................................... 1.265
9015
20
3
CED,TX14826,12655 –19–12JUN00–1/1

031504
PN=301
References
Diagnose Battery Malfunctions
Battery Using Too Much Water Shorted battery cell Check battery state of charge. See
Battery Operation.
High ambient temperature Add distilled water.
Cracked battery case Check battery hold down clamps.

Replace battery.
Regulator Do Alternator Output Check. See

Sub-System Diagnostics/Charging
Circuit.
9015
20 Cracked Battery Case Battery hold down clamp too tight, Install new battery. Install hold down
4 too loose or missing clamps correctly.
Frozen battery Keep electrolyte at correct level and

battery fully charged during cold
weather.
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.
Broken or loose battery posts Wiggle posts by hand. If posts are

loose or will turn, replace battery.
Loose fan/alternator belt or worn Inspect belt or pulley. Adjust or

pulleys replace as necessary.
CED,TX14826,12656 –19–12JUN00–1/1

031504
PN=302
References
Check Battery Electrolyte Level and

Terminals
CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first

and replace it last.
Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in 9015
20
clothing, and cause blindness if splashed into
5
eyes.
Avoid the hazard by:
–UN–23AUG88
• Filling batteries in a well-ventilated area.
• Wearing eye protection and rubber gloves.
• Avoiding breathing fumes when electrolyte is
TS203
added.
• Avoiding spilling or dripping electrolyte.
• Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10—15
minutes. Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
1. Remove hold-down clamps.
2. Remove battery covers.

031504
PN=303
References
IMPORTANT: During freezing weather, batteries must

be charged after water is added to
prevent battery freezing. Charge battery
using a battery charger or by running
the engine.
–UN–09SEP03
3. Fill each cell to within specified range with distilled
water. DO NOT overfill.
T6996DB
A—Battery Post
B—Fill Tube
C—Electrolyte Level Range
Single Level Fill Tube Application
9015
20
6
–UN–09SEP03
T6996DA
Dual Level Fill Tube Application
CED,TX14826,12657 –19–12JUN00–2/2

031504
PN=304
References
Using Booster Batteries—12 Volt System
9015
20
–UN–24OCT91 7
–UN–24OCT91
T6508AE1
T6713AI1
Single Battery Application Two Battery Application
A—Machine Battery(s) B—Booster Battery(s)
Before boost starting, machine must be properly shut 1. Connect one end of the positive cable to the
down and secured to prevent unexpected machine positive terminal of the machine batteries and the
movement when engine starts. other end to the positive terminal of the booster
batteries.
CAUTION: An explosive gas is produced
2. Connect one end of the negative cable to the
while batteries are in use or being charged.
negative terminal of the booster batteries. Then
Keep flames or sparks away from the battery
connect other end of the negative cable to the
area. Make sure the batteries are charged in
machine frame as far away from the machine
a well ventilated area.
batteries as possible.
Always remove grounded (—) battery clamp
3. Start engine.
first and replace it last.
IMPORTANT: The machine electrical system is a

12-volt negative (—) ground. Use
only 12-volt booster batteries.

031504
PN=305
References
4. Immediately after starting engine, disconnect end of 5. Disconnect positive cable from booster batteries
the negative cable from the machine frame and and machine batteries.
disconnect the other end of the negative cable from
the negative terminal of the booster batteries.
CED,TX14826,12658 –19–12JUN00–2/2
Alternator Operation—65 Amp Bosch and 95 Amp Bosch
9015
20
8
–19–04DEC94
T8301AL
A—Alternator F—Positive Diodes K—Regulator P—Key Switch
B—Internal Ground G—D+ Terminal L—External Ground Terminal Q—Display Monitor
C—Negative Diodes H—B+ Terminal M—Rotor R—Brushes
D—Exciter Diodes I—W Terminal N—Alternator Diode S—Sense Circuit
E—Stator Windings J—Excitation Winding O—Battery T—Noise Filter
CED,TX14826,12659 –19–12JUN00–1/1

031504
PN=306
References
Alternator Operation—65 Amp Bosch and 95 Amp Bosch—Continued
The Bosch alternator has three basic stages for proper and C) and delivered to the battery and current
operation. The operating principles are as follows. consuming accessories. The currents in the stator
winding (E) are constantly changing magnitude and
Pre-Excitation Stage direction. However, current flowing to the battery and
accessories always maintains the same direction. This
When key switch (P) is turned to ON position, battery is because no matter what position the rotor (M) is in,
power flows to (G) terminal D+ on alternator, excitation all the diodes are simultaneously involved in the
winding (J), through regulator (K) and to internal process of rectification. The regulator (K) measures the
ground (B). B+ voltage (H) and compares it to an internal
reference. When the B+ voltage (H) starts to rise
Excitation Stage above the reference voltage the regulator (K) switches
off the field current. When the B+ voltage (H) starts to
During alternator start (as the engine speeds up from 0 fall below the reference voltage the regulator (K)
to idle) current supplied by the external alternator switches on the field current. The regulator (K)
9015
diode to the field coil of the rotor produces a magnetic switches the field ON and OFF several thousand times 20
field which induces current in the three-phase winding a second in response to the current load placed on the 9
of the stator (E). The alternator reaches cut-in RPM alternator output and the engine RPM.
when the induced current is large enough to produce
voltage equal to the battery voltage plus 1.0 volt. At When the alternator is operating, the W terminal
this time, some current from the stator is rectified by voltage out put is (7 to 8 volts) (AC).
the exciter diodes (D) (producing battery voltage at the
D+ terminal (G) and is supplied to the carbon brushes Specification
and slip rings of the excitation winding (J), W Terminal Output—Voltage
With Alternator Operating .................................................... 7—8 volts
strengthening the magnetic field in the excitation
winding. This in turn will increase the stator voltage.
This voltage is supplied to the display monitor and
This will occur continuously until the alternator (A) is
tachometer or hour meter. Current available from the
fully excited and the alternator regulated voltage is
alternator is dependent on engine RPM. Depending on
reached.
pulley ratios.
Normal Operation
The alternating current induced in the stator winding

(E) is rectified by the positive and negative diodes (F
CED,TX14826,12660 –19–12JUN00–1/1

031504
PN=307
References
Calibrate Tachometer
1. Install digital tachometer. See Electronic Tachometer

Installation. In Group 9015-20.
2. Park brake ON.
–UN–26SEP00
SELECT
3. Hold select button down and start engine.

- +
VOLTS
n/m.n
4. Continue to HOLD select button down until (ECAL)
T133956
appears in display window. T133956
5. With (ECAL) displayed in window run engine until

speed reaches 2000 ± 2 rpm on digital tachometer.
While holding speed at 2000 rpm, (PUSH AND
RELEASE) select button. This will calibrate the monitor
9015
20 tachometer.
10
NOTE: To exit tachometer calibration without performing
calibration, turn key switch to OFF
6. Turn key OFF; then restart engine.
7. After monitor tachometer has been calibrated, check

slow and fast idle engine speeds against the digital
tachometer. If there is more than 10 rpm difference,
repeat calibration procedure.
CED,TX14826,12723 –19–28JUN00–1/1

031504
PN=308
References
Program Display Monitor (S.N. —910055)
IMPORTANT: Whenever Display Monitor is replaced,

Display Monitor MUST be programed to
machine as follows:
SELECT
–UN–26SEP00
1. Engine OFF, park brake ON.
- +
2. Press and hold the SELECT button down and turn key n/m.n
VOLTS
switch to ON position.
T133957
T133957
3. Hold SELECT button until dIAG appears in display

window and then release the SELECT button. Wait
until ProG is displayed in window, then push and
immediately release SELECT button
9015
The display monitor will scroll through all programmed 20
vehicle models (310, 315, 410, 710). 11
SELECT
–UN–26SEP00
To Program: Press and immediately release the
SELECT button while the model you want is displayed. - +
VOLTS
n/m.n
T133958
To Exit: Turn key switch to off position. T133958
IMPORTANT: After programming display monitor,

tachometer MUST be calibrated before
any other function is performed.
Calibrate Tachometer. Install digital tachometer. See

Electronic Tachometer Installation. In Group 9015-20.
CED,TX14826,12727 –19–12JUN03–1/1

031504
PN=309
References
Program Display Monitor (S.N. 910056— )
NOTE: Key must be in off position for 10 seconds before

calibrating the throttle position sensor.
1. Engine Off. Park Brake On. FNR in Neutral.
–UN–10SEP01
2. Press the “SELECT” button and hold while turning the
key to “ON” position, continue to hold the “SELECT”
button until the Hour Meter icon appears in the display
T145332
window then release the “SELECT” button.
3. Press and HOLD “SELECT” button until the Battery

icon appears in display window and then release the
“SELECT” button.
9015
20 4. Press and HOLD “SELECT” button until the Hour
12 Meter icon appears in display window and then release
the “SELECT” button.
5. (DIAG) will appear in the display window. Wait for 5

seconds until (PROG) appears in display window.
Press the “SELECT” button with in 5 seconds after

(PROG) appears.
If you wait more than five seconds to press the

“SELECT” button , the display monitor displays (PCAL)
and then goes back to normal working mode (Hour
Meter) and you must start procedure over again.
The display window will scroll through all four models

and then immediately take you out of the (PROG) and
return you to normal working mode.
(PROG) will be used to program the display monitor to

a machine model. The display monitor will scroll
through all four machine models. Each machine model
will be displayed for 5 seconds each. To program,
press and immediately release the “SELECT” button
while the machine model you want is displayed. It will
then immediately take you out of the (PROG) and
return you to normal working mode.
Continued on next page TX14826,000321A –19–25FEB03–1/2

031504
PN=310
References
NOTE: If you program the Display Monitor to the wrong

machine model you will get a “F9d5” or “F985”
display monitor service code.
If this occurs Program the display monitor again.
Turning the key switch to OFF position at any time will

exit programming mode.
MACHINE MODELS
DISPLAYED
310-1 310G, 310SG, 315SG -NO
ENGINE CONTROL UNIT
310-2 310G, 310SG, 315SG WITH
ENGINE CONTROL UNIT
410-1 410G-NO ENGINE CONTROL
UNIT 9015
20
710-2 710G-WITH ENGINE CONTROL 13
UNIT AND ANTI-STALL
TX14826,000321A –19–25FEB03–2/2

031504
PN=311
References
9015
20
14

031504
PN=312
Section 9020
Power Train
Contents
Page Page
Group 05—Theory of Operation Group 15—System Diagnostic Information

Forward, Reverse, Low Range Forward Diagnose Power Shift Power Train
and Third Speed Clutch Pack Malfunction . . . . . . . . . . . . . . . . . . . . . . . .9020-15-1
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-1 Diagnose MFWD Malfunction . . . . . . . . . . .9020-15-12
Power Shift High Range Forward, First Diagnose Rear Axle Malfunction . . . . . . . . .9020-15-14
Speed and Second Speed Clutch Hydraulic Circuit Symbols . . . . . . . . . . . . . .9020-15-19
Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-2
Torque Converter Operation . . . . . . . . . . . . .9020-05-3 Group 20—Adjustments
Transmission Pump Operation . . . . . . . . . . .9020-05-4 Release Park Brake for Towing. . . . . . . . . . .9020-20-1
Transmission Filter Operation . . . . . . . . . . . .9020-05-6 Brake Pedals
Power Shift Power Train Overview . . . . . . . .9020-05-8 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-2
Power Shift Transmission Gear Flow . . . . .9020-05-10 Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . .9020-20-4
Mechanical Front Wheel Drive (MFWD) Tracking Angle Check and Adjust . . . . . . . . .9020-20-5 9020
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9020-05-12 Toe-In Check and Adjust. . . . . . . . . . . . . . . .9020-20-5
Power Shift Transmission Steering Angle Check and Adjust . . . . . . . . .9020-20-7
Clutch Engagement and Solenoids
Activated . . . . . . . . . . . . . . . . . . . . . . .9020-05-14 Group 25—Tests
Control Circuit-Neutral . . . . . . . . . . . . . . .9020-05-15 JT05801 Clamp-On Electronic Tachometer
Control Valve and Shift Valve-Neutral . . .9020-05-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-1
Control Circuit-First Forward . . . . . . . . . .9020-05-20 JT05800 Digital Thermometer Installation . . .9020-25-1
Control Valve and Shift Valve-First Transmission Oil Warm-Up Procedure . . . . .9020-25-2
Forward . . . . . . . . . . . . . . . . . . . . . . . .9020-05-22 Power Shift Transmission Overall Test
Control Circuit-High Range (Fourth) Connections, Ports, and Locations. . . . . . .9020-25-3
Forward . . . . . . . . . . . . . . . . . . . . . . . .9020-05-24 Torque Converter Stall Speed Test . . . . . . . .9020-25-4
Control Valve and Shift Valve-High Range Converter-In Relief Valve Test . . . . . . . . . . .9020-25-6
(Fourth) Forward . . . . . . . . . . . . . . . . .9020-05-26 Brake Valve Leakage Test . . . . . . . . . . . . . .9020-25-8
Control Circuit-First Reverse . . . . . . . . . .9020-05-28 Park Brake Release Pressure Test . . . . . . .9020-25-10
Control Valve and Shift Valve-First System Pressure Test . . . . . . . . . . . . . . . . .9020-25-12
Reverse . . . . . . . . . . . . . . . . . . . . . . . .9020-05-30 Power Shift Low Range Forward, High Range
Power Shift Modulation Valve Operation . . .9020-05-32 Forward, Reverse and Speed Clutch Pressure
Differential Operation . . . . . . . . . . . . . . . . .9020-05-34 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-14
Differential Lock Operation . . . . . . . . . . . . .9020-05-36 Reducing Valve Pressure Test . . . . . . . . . .9020-25-16
MICO Power Boost Brake Valve—Neutral Modulation Valve Pressure Test . . . . . . . . .9020-25-18
Position . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-37 Differential Lock Pressure Test . . . . . . . . . .9020-25-20
MICO Power Boost Brake Valve—Both MFWD Pressure Test—If Equipped. . . . . . .9020-25-22
Pedals Applied Position . . . . . . . . . . . . . .9020-05-38 Cooler In and Cooler Out Pressure Test . . .9020-25-23
MICO Power Boost Brake Valve—One Pedal Solenoid Circuit Leakage Test. . . . . . . . . . .9020-25-26
Applied Position . . . . . . . . . . . . . . . . . . . .9020-05-40 Pump Flow Test . . . . . . . . . . . . . . . . . . . . .9020-25-28
MICO Power Boost Brake Valve—Both
Pedals Applied, Engine Off Position. . . . .9020-05-41
Service Brake Operation . . . . . . . . . . . . . . .9020-05-42
Park Brake Operation . . . . . . . . . . . . . . . . .9020-05-44
MFWD Differential Operation—Unequal
Traction . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-46
MFWD Differential Operation—Equal
Traction—If Equipped . . . . . . . . . . . . . . .9020-05-47

031504
PN=1
Contents
9020

031504
PN=2
Group 05
Theory of Operation
Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation
9020
–19–27MAR98
05
1
T113896
Manual Shift Clutch Pack Shown
A—Disk (as required between C—Separator Plate (as E—Hub H—Spring Disks
manual shift and power required between manual F—End Plate I—Lubrication Oil
shift) shift and power shift) G—Piston J—Clutch Pack
B—Clutch Drum D—Pressure Oil
NOTE: This operation covers the manual shift forward The plates are splined to the clutch drum (B) and the
and reverse clutch packs and the power shift disks are splined to hub (E) locking them together. The
low range forward, reverse and third speed input drive shaft is splined to the hub on the manual
clutch packs. The function of the packs are the shift forward and reverse packs and on the power shift
same, but the quantity on the disks and the input drive shaft gear is splined to the low range
separator plates will be different between forward, reverse, and high range forward (4th) gear. All
clutch packs. gears are constantly meshed and supported by
antifriction bearings. The bearings and clutches are
When the FNR lever is placed in forward or reverse lubricated with cooled lubrication oil (I). Spring disks
and the shift lever (manual shift) is placed in a gear, (H) push back the piston (G) when the clutch pack (J)
pressure oil (D) from the control valve forces the clutch is disengaged, thus releasing the multi-disk clutch.
piston (G) to compress the plates (C) and disks (A).
CED,TX03399,4248 –19–23JUN98–1/1

031504
PN=315
Theory of Operation
Power Shift High Range Forward, First Speed and Second Speed Clutch Packs
9020
05
–19–02JUN98
2
T115656
High Range Forward Clutch Pack Shown
A—Separator Plate (as C—Clutch Drum G—Hub K—Tapered Bearing

required per clutch packs D—Roller Bearings H—End Plate L—Lubrication Oil
B—Disk (as required per E—Tapered Bearing I—Piston M—Clutch Pack
clutch pack) F—Pressure Oil J—Spring
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 –19–29MAY98–1/1

031504
PN=316
Theory of Operation
Torque Converter Operation
9020
–19–04MAR98
05
3
T101172
1—Turbine 4—Input Shaft 7—Turbine Shaft 10—Stator
2—Impeller 5—Shaft Seal 8—Pump Drive Shaft 11—Torque Converter
3—Stator Shaft 6—Drain Plug 9—Free-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.

031504
PN=317
Theory of Operation
Oil leaving the turbine enters the stator (10). The stator unlocks, allowing the stator to free-wheel or rotate with
is curved so that the oil flow changes direction. Oil the turbine and impeller as a unit. Input speed and
leaving the stator is moving in the same direction as torque are equal to output speed and torque when the
the impeller. This adds to the force of the oil entering stator is free-wheeling. The transmission pump is
the impeller. The turbine will be rotating at a slower constantly pumping oil through the converter. The
speed than the impeller, but it will produce a higher converter multiplies the torque and at the same time,
torque. It is this increased force developed by the the heat created in the converter is eliminated through
stator that makes a converter able to multiply torque. the circulation of oil from converter to cooler and back
Under light load the speed of the turbine will increase to sump.
until it equals impeller speed. The free-wheel clutch (9)
TX,05,SS3120 –19–22JUN98–2/2
Transmission Pump Operation
9020
05
4
–UN–12JUL96
T101251
1—Angle Disk 3—O-Ring (2 used) 5—Pump Housing 7—Needle Bearing

2—Washer 4—Cap Screw (4 used) 6—O-Ring 8—Stop Sleeve

031504
PN=318
Theory of Operation
The transmission uses a high capacity fixed displacement

gear-type pump to provide constant flow for the
transmission hydraulic system. Pump flow is proportional
to engine speed.
The input shaft to the pump is driven by the engine. The
–UN–12JUL96
pump gears rotate inside of the pump housing. As the
gears rotate, oil is trapped between the gear teeth and the
pump housing which forces oil to move from the pump
inlet around the gears to the pump outlet.
T101252
TX,05,SS3124 –19–22JUN98–2/2
9020
05
5

031504
PN=319
Theory of Operation
Transmission Filter Operation
9020
05
–19–12JUL96
6
T101250
A—Filter C—Bypass Valve D—To Transmission Circuit E—From Transmission Pump
B—Spring
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 –19–22JUN98–1/1

031504
PN=320
Theory of Operation
9020
05
7

031504
PN=321
Theory of Operation
Power Shift Power Train Overview
9020
05
8
–19–10JUL98
T115039

031504
PN=322
Theory of Operation
A—Torque Converter C—Transmission Pump F—Third Speed Clutch I—First Speed Clutch
B—High Range (4th) Forward D—Reverse Clutch G—Second Speed Clutch J—Pump Drive Shaft
Clutch E—Low Range Forward Clutch H—MFWD K—Transmission
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 foot operated brake valve. The park
one speed range clutch pack either 1st, 2nd or 3rd. brake is a wet multi-disk design which is spring applied
and hydraulically released. The differential lock is a
The transmission may also have an optional front sliding sleeve design, which is hydraulically engaged
output shaft (H) for mechanical front wheel drive and spring released.
(MFWD) which is spring applied and hydraulically
released.
The transmission pump (C) is a gear type pump. The

transmission pump is driven at engine speed through
the impeller drive from the torque converter.
9020
05
9
CED,TX03399,4205 –19–03MAR98–2/2

031504
PN=323
Theory of Operation
Power Shift Transmission Gear Flow
1st FORWARD 4th FORWARD (HIGH RANGE)
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
2nd FORWARD 1st REVERSE
9020 A B A B
05
10
C C
G G
F D D
F
E E
3rd FORWARD 2nd REVERSE 3rd REVERSE
A B A B A B
C C C
G G G
F D D F D
F
–19–02JUN98
E E E
T115189
T115189

031504
PN=324
Theory of Operation
A—4th Forward (High Range) C—Low Range Forward E—MFWD Output G—2nd Speed
B—Reverse D—1st Speed F—3rd 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 –19–03MAR98–2/2
9020
05
11

031504
PN=325
Theory of Operation
Mechanical Front Wheel Drive (MFWD) Operation
SLIDING A
SLEEVE
SPRING G
B
F FRONT
OUTPUT MFWD
SHAFT SOLENOID
VALVE
9020 D DRIVE GEAR C

05 FROM
12 TRANSMISSION
PUMP
BACKING E H MANUAL SHIFT MFWD - ON (ENGAGED)
PLATE
SLIDING
SLEEVE I
SPRING O
FRONT N
OUTPUT
SHAFT
J
MFWD
SOLENOID
VALVE
BACKING M
PLATE
DRIVE
GEAR FROM K
L
–19–20APR98
TRANSMISSION
PUMP
P SYSTEM PRESSURE
T114902
T114902
R POWER SHIFT MFWD - ON (ENGAGED) Q RETURN PRESSURE
Continued on next page CED,TX03399,4226 –19–15APR98–1/2

031504
PN=326
Theory of Operation
A—Sliding Sleeve F—Front Output Shaft J—MFWD Solenoid Valve O—Spring

B—MFWD Solenoid Valve G—Spring K—From Transmission Pump P—System Pressure
C—From Transmission Pump H—Manual Shift MFWD—ON L—Drive Gear Q—Return Pressure
D—Drive Gear (Engaged) M—Backing Plate R—Power Shift MFWD—On
E—Backing Plate I—Sliding Sleeve N—Front Output Shaft (Engaged)
The MFWD is powered by transmission. The disengagement of the MFWD is controlled by an

electric solenoid located on the transmission. When
The MFWD is spring applied, hydraulically released. energized, with MFWD switch in the “OFF” position,
When the MFWD switch is “ON”, spring (G or O) force transmission pressure oil (P) is routed through the
holds the sliding sleeve (A or I) in mesh with the drive MFWD sliding sleeve (A or I). Pressure pushes the
gear (D or L). The drive gear is connected to the front sleeve back against the spring (G or O) and backing
output shaft (F or N) and transmits power to the front plate (E or M). The drive gear (D or L) and front output
axle. shaft (F or N) are disengaged.
CED,TX03399,4226 –19–15APR98–2/2
9020
05
13

031504
PN=327
Theory of Operation
Power Shift Transmission Clutch

Engagement And Solenoids Activated
Transmission Clutch Engagement
Low and High Range Forward and Reverse Pack Engaged Speed Pack Engaged
Lo-Range Forward Hi-Range Forward Reverse 1st 2nd 3rd
N
F1 X X
F2 X X
F3 X X
F4 X X
R1 X X
R2 X X
R3 X X
Solenoids Activated
Gear Selection Low Range, Forward, & Reverse Solenoid Energized Speed Solenoid Energized
Forward Low Range Reverse 1 2 3
Neutral
9020
1st Forward X X X X
05
14 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 –19–24MAR98–1/1

031504
PN=328
Theory of Operation
Power Shift Transmission Control Circuit—Neutral With Park Brake Off—With Power
Boost MICO Brake Valve
T129427 –UN–13APR00
7 HIGH RANGE
FORWARD CLUTCH
9 10 11
1 1ST SPEED 6
CLUTCH LOW RANGE 8 DIFFERENTIAL LOCK MFWD PARK
5 BRAKE
FORWARD REVERSE
TRANSMISSION CLUTCH CLUTCH
2 2ND SPEED CONTROL VALVE
CLUTCH
4 LOW RANGE 17
3 3RD SPEED TRANSMISSION SPEED SHIFT VALVE
CLUTCH SHIFT VALVE
SPEED SHIFT
VALVE 18 FORWARD/REVERSE
3 SHIFT VALVE
28
SPEED SHIFT ORIFICE IN
VALVE SEQUENCE
19 VALVE VALVE MODULATION
2 HOUSING
26 PISTON 29
LOW
RANGE 30 DIFFERENTIAL
FORWARD MFWD PARK BRAKE
SPEED SOLENOID REVERSE SOLENOID SOLENOID SOLENOID SOLENOID
SHIFT VALVE SOLENOID VALVE VALVE VALVE VALVE
VALVE 24 VALVE 15
1 20 27 16 14 12
25
ORIFICE IN 13 SCREEN
MODULATION MODULATION
SPOOL IN ALL
SPEED SPEED SPEED VALVE 31 SOLENOIDS
PRESSURE
SOLENOID SOLENOID SOLENOID REDUCING
VALVE VALVE VALVE ORIFICE ORIFICE IN VALVE 32
3 21 2 22 1 23 35 IN DUCT MODULATION 33
PLATE PISTON
PRESSURE
REGULATING 34
VALVE ORIFICE IN
INTERMEDIATE 44 FROM HYDRAULIC
36 OIL COOLER RETURN
LOW RANGE, FORWARD, & REVERSE SPEED PLATE
GEAR SOLENOID ENERGIZED SOLENOID ENERGIZED CONVERTER
SELECTION FORWARD LOW RANGE REVERSE 1 2 3 RELIEF
NEUTRAL VALVE
TORQUE 38
1ST FORWARD X X X X CONVERTER
2ND FORWARD X X X X 45 SYSTEM PRESSURE 37 TRANSMISSION 40
OIL COOLER FILTER
3RD FORWARD X X X X 46 MEDIUM PRESSURE TRANSMISSION
39 AND
HIGH RANGE BYPASS PUMP 41
X X X 47 LOW PRESSURE 43 POWER
(4TH FORWARD)
48 LUBE PRESSURE BOOST
1ST REVERSE X X X X SUMP 42 BRAKE
2ND REVERSE 49 RETURN PRESSURE VALVE
X X X X
3RD REVERSE X X X X 50 POWER SHIFT TRANSMISSION CONTROL CIRCUIT - NEUTRAL
T129427 WITH PARK BRAKE OFF - WITH POWER BOOST MICO BRAKE VALVE
TX03543,0000917 –19–31OCT00–1/3

031504
PN=329
Theory of Operation
1—1st Speed Clutch 14—MFWD Solenoid Valve 28—Forward/Reverse Shift 41—Transmission Pump
2—2nd Speed Clutch 15—Differential Solenoid Valve Valve 42—Sump
3—3rd Speed Clutch 16—Forward Solenoid Valve 29—Modulation Piston 43—Power Boost MICO Brake
4—Transmission Speed Shift 17—Low Range Shift Valve 30—Orifice in Valve Housing Valve
Valve 18—Speed Shift Valve 3 31—Modulation Valve 44—Oil From Hydraulic Oil
5—Transmission Control Valve 19—Speed Shift Valve 2 32—Pressure Reducing Valve Cooler Return
6—Low Range Forward 20—Speed Shift Valve 1 33—Orifice In Modulation 45—System Pressure
Clutch 21—Speed Solenoid Valve 3 Piston 46—Medium Pressure
7—High Range Forward Clutch 22—Speed Solenoid Valve 2 34—Orifice In Intermediate 47—Low Pressure
8—Reverse Clutch 23—Speed Solenoid Valve 1 Plate 48—Lube Pressure
9—Differential Lock 24—Low Range Solenoid 35—Orifice in Duct Plate 49—Return Pressure
10—MFWD (Mechanical Front Valve 36—Pressure Regulating Valve 50—Power Shift Transmission
Wheel Drive) 25—Reverse Solenoid Valve 37—Torque Converter Control Circuit—Neutral
11—Park Brake 26—Sequence Valve 38—Converter Relief Valve With Park Brake OFF—
12—Park Brake Solenoid Valve 27—Orifice In Modulation 39—Transmission Oil Cooler With Power Boost MICO
13—Screen In All Solenoids Spool 40—Filter and Bypass Brake Valve
NOTE: Transmission control valve (5) and with shims. It regulates main system pressure. Excess
transmission speed shift valve (4) components oil from the circuit is directed to the torque converter
are shown in detail on the "Power Shift through this valve. The modulation valve (31) is a
Transmission Control Valve and Shift Valve spring loaded spool which controls the rate of clutch
Operation—Neutral in this group. Keys and engagement during a shift. Within the valve is the
nomenclature will match where applicable. modulation piston (29).
9020
The transmission control valve regulates the hydraulic When a gear is selected the speed solenoid valves
05
16 oil pressures and controls circuits required for (21, 22, or 23) are energized in combinations of two
operation of the transmission. Electrical signals from which shift two of the speed shift valves (18, 19, or
the FNR lever and park brake switch are used to 20). The shift valves direct system pressure oil to one
energize the solenoids which direct oil to move the of the speed clutches 1st, 2nd or 3rd.
shift valves and engage the appropriate selected
clutches. The forward/reverse shift valve (28), is a spring loaded
spool valve which routes system pressure oil to the
The transmission control valve contains the main low range shift valve (17). The low range shift valve
frame harness which connects to the transmission (17), is a spring loaded spool valve which routes
control valve, forward solenoid valve (16), low range system oil to the low range (6), high range forward (7),
solenoid valve (24), reverse solenoid valve (25), and reverse clutches (8). The forward and reverse
converter relief valve (38), pressure regulating valve solenoid valves, (16) and (25), are activated by the
(36), modulation valve (31), modulation piston (29), FNR lever. Each directs medium pressure oil to the
forward/reverse shift valve (28), low range shift valve forward/reverse shift valve (28). The low range
(17), and the pressure reducing valve (32). The solenoid valve (24), directs medium pressure oil to the
transmission speed shift valve contains the speed low range shift valve (17). The low range solenoid
solenoid valves 1, 2 and 3 (23, 22 and 21) and speed valve is controlled by the gear selection on the FNR
shift valves 1, 2 and 3 (20, 19 and 18). lever.
The converter relief valve (38) controls the maximum The pressure reducing valve (32) supplies medium
pressure to the torque converter. The pressure pressure oil to the speed, forward, reverse and low
regulating valve (36) is a spring loaded spool valve range solenoid valves.
Continued on next page TX03543,0000917 –19–31OCT00–2/3

031504
PN=330
Theory of Operation
Flow from the transmission charge pump (41) passes The oil is then routed to the oil cooler (39). The oil
through the filter to the pressure regulating valve (36). returning from the cooler provides lubrication to the
The pressure regulating valve regulates system clutches.
pressure and directs high pressure oil to the reducing
valve (32), differential solenoid valve (15), MFWD In neutral, with park brake OFF, the forward and
solenoid valve (14) and the park brake solenoid valve reverse solenoids (16 and 25) are de-energized
(12). (open), medium pressure oil is not directed to the
forward/reverse shift valve (28). The low range
When pressure exceeds the pressure regulating valve solenoid valve is de-energized (open) and no pressure
setting the valve opens. Low pressure oil then flows oil is routed to the end of the low range shift valve
through the torque converter (37). Converter flow is (17). In neutral all speed clutch packs also dump to
excess oil from the pressure regulating valve. A torque sump and all speed clutch solenoids are de-energized.
converter relief valve (38) protects the circuit by The reducing valve (32) controls the pressure by
dumping to tank when pressure exceeds the setting. dumping oil to tank when pressure exceeds its setting.
TX03543,0000917 –19–31OCT00–3/3
9020
05
17

031504
PN=331
Theory of Operation
Power Shift Transmission Control Valve and Shift Valve Operation—Neutral
16 FORWARD 24 LOW RANGE

SOLENOID SOLENOID
25 REVERSE
SOLENOID
38
CONVERTER
RELIEF
VALVE
32
9020 36
PRESSURE
05 REDUCING PRESSURE
18 VALVE REGULATING
VALVE
17
LOW RANGE
SHIFT VALVE 30
ORIFICE 29
28
31
FORWARD MODULATION
OR REVERSE PISTON MODULATION
SHIFT VALVE VALVE
23
SPEED
SOLENOID
VALVE 1
21 22
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2
43 SYSTEM PRESSURE OIL

44 MEDIUM PRESSURE OIL
45 LOW PRESSURE OIL 20
47 RETURN OIL SPEED
SHIFT
VALVE 1
18
SPEED
–19–10FEB00
SHIFT
VALVE 3
19 SPEED
49 TRANSMISSION CONTROL VALVE SHIFT
T127893
VALVE 2
T127893 AND SHIFT VALVE - NEUTRAL

031504
PN=332
Theory of Operation
16—Forward Solenoid Valve 23—Speed Solenoid Valve 1 30—Orifice In Valve Housing 44—Medium Pressure Oil
17—Low Range Shift Valve 24—Low Range Solenoid 31—Modulation Valve 45—Low Pressure Oil
18—Speed Shift Valve 3 Valve 32—Pressure Reducing Valve 47—Return Oil
19—Speed Shift Valve 2 25—Reverse Solenoid Valve 36—Pressure Regulating Valve 49—Transmission Control
20—Speed Shift Valve 1 28—Forward/Reverse Shift 38—Converter Relief Valve Valve And Shift Valve—
21—Speed Solenoid Valve 3 Valve 43—System Pressure Oil Neutral
22—Speed Solenoid Valve 2 29—Modulation Piston
For theory See Power Shift Transmission Control 9020.) Keys and nomenclature will match where
Circuit—Neutral With Park Brake Off. (Go to Group applicable.
CED,TX03399,5911 –19–28JAN00–2/2
9020
05
19

031504
PN=333
Theory of Operation
Power Shift Transmission Control Circuit—First Forward—With Power Boost MICO Brake
Valve
T129432 –UN–13APR00
7 HIGH RANGE
FORWARD CLUTCH
1 1ST SPEED 6 9 10 11
5 BRAKE
FORWARD REVERSE
CLUTCH
4 LOW RANGE
CLUTCH SHIFT VALVE 17
SPEED SHIFT
3 SHIFT VALVE
28
SEQUENCE
SPEED SHIFT VALVE
VALVE ORIFICE IN
2 19 26 VALVE MODULATION PARK BRAKE
HOUSING PISTON 29 SOLENOID
LOW
RANGE 30 DIFFERENTIAL VALVE
FORWARD MFWD
SPEED SOLENOID REVERSE SOLENOID SOLENOID SOLENOID 12
SHIFT VALVE SOLENOID VALVE VALVE VALVE
VALVE 24 VALVE 15
1 20 27 16 14
25
ORIFICE IN
SPOOL SCREEN
SPEED SPEED SPEED VALVE 31 PRESSURE IN ALL
SOLENOID SOLENOID SOLENOID REDUCING SOLENOIDS
3 2 22 1 35 IN DUCT 13
21 23 MODULATION 33
PLATE PISTON
PRESSURE
REGULATING 34
VALVE ORIFICE IN
NEUTRAL VALVE
45 TORQUE 38
1ST FORWARD X X X X SYSTEM PRESSURE
CONVERTER
2ND FORWARD X X X X 46 MEDIUM PRESSURE 37 TRANSMISSION 40
LOW PRESSURE OIL COOLER FILTER
3RD FORWARD X X X X 47
39 AND TRANSMISSION
HIGH RANGE 48 LUBE PRESSURE BYPASS PUMP 41
X X X 43 POWER
(4TH FORWARD)
49 RETURN PRESSURE BOOST
1ST REVERSE X X X X BRAKE
SUMP 42 VALVE
2ND REVERSE X X X X
3RD REVERSE X X X X
50 POWER SHIFT TRANSMISSION CONTROL CIRCUIT - FIRST FORWARD
T129432 WITH POWER BOOST MICO BRAKE VALVE
TX03543,0000918 –19–31OCT00–1/2

031504
PN=334
Theory of Operation
1—1st Speed Clutch 14—MFWD Solenoid Valve 28—Forward/Reverse Shift 40—Filter and Bypass
2—2nd Speed Clutch 15—Differential Solenoid Valve Valve 41—Transmission Pump
3—3rd Speed Clutch 16—Forward Solenoid Valve 29—Modulation Piston 42—Sump
4—Transmission Speed Shift 17—Low Range Shift Valve 30—Orifice in Valve Housing 43—Power Boost Brake Valve
Wheel Drive) 25—Reverse Solenoid Valve 37—Torque Converter Control Circuit—First
11—Park Brake 26—Sequence Valve 38—Converter Relief Valve Forward—With Power
12—Park Brake Solenoid Valve 27—Orifice In Modulation 39—Transmission Oil Cooler Boost MICO Brake Valve
13—Screen In All Solenoids Spool
NOTE: Transmission control valve (5) and compress the clutch plates. Shifting of the
transmission speed shift valve (4) components forward/reverse spool (28) and the low range shift
are shown in detail on the "Power Shift spool (17) allows oil to flow from the modulation valve
Transmission Control Valve and Shift Valve (31) to fill the low range forward clutch pack (6) and
Operation—First Forward in this group. Keys compress the clutch plates. Shifting of the
and nomenclature will match where applicable. forward/reverse spool also blocks the flow of oil
downstream of the orifice (30) in valve housing from
9020
NOTE: Refer to Power Shift Transmission Control returning to tank and allows the pressure in the
05
Circuit—Neutral for pressure reducing, modulation valve to build. As pressure builds, the 21
converter relief and pressure regulating valve balance between orifice size and spring load in the
theory of operation. modulation valve controls the rate of shift and pushes
the modulation piston down.
During 1st gear forward operation the forward solenoid
valve (16), low range solenoid valve (24), speed The sequence valve (26) insures that the speed clutch
solenoid valve 2 (22), and speed solenoid valve 3 (21) fills and engages before the direction clutch by
are energized. The energized low range solenoid valve allowing oil to flow from the modulation valve (31) to
routes medium pressure oil to the low range shift valve the speed clutch circuit downstream of the orifice in
(17) and moves the spool down. The energized duct plate (replenishing orifice) (35) when the pressure
forward solenoid valve (16) routes medium pressure oil in the speed clutch circuit is lower than the pressure in
to the forward/reverse shift valve (28) moving its spool the direction clutch circuit. The downward force from
up. The energized speed solenoids 2 and 3 (22 and the modulation piston (29) pushes on the modulation
21) route medium pressure oil to the shift valves 2 and springs which drive the modulation spool down to the
3 (19 and 18) moving the spools down. Shifting of the fully open position. In the fully open position, high
speed shift spools allows oil to flow from the regulating pressure oil from the pressure regulating valve (36)
valve (36) through the orifice in duct plate (replenishing keeps the speed and direction clutches engaged.
orifice) (35) to fill the 1st speed clutch pack (1) and
TX03543,0000918 –19–31OCT00–2/2

031504
PN=335
Theory of Operation
Power Shift Transmission Control Valve and Shift Valve—First Forward

SOLENOID SOLENOID
25 REVERSE
SOLENOID
38
CONVERTER
RELIEF
VALVE
32
9020 36
PRESSURE
22
VALVE REGULATING
VALVE
17
LOW RANGE
SHIFT VALVE 30
28 ORIFICE 29
31
FORWARD MODULATION
SHIFT VALVE VALVE
23
SPEED
SOLENOID
VALVE 1
21 22
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2

20
47 RETURN OIL
SPEED
SHIFT
VALVE 1
18
SPEED
–19–10FEB00
SHIFT
VALVE 3
19 SPEED
T127897
VALVE 2
T127897 AND SHIFT VALVE - FIRST FORWARD

031504
PN=336
Theory of Operation
16—Forward Solenoid Valve 23—Speed Solenoid Valve 1 29—Modulation Piston 43—System Pressure Oil
17—Low Range Shift Valve 24—Low Range Solenoid 30—Orifice In Valve Housing 44—Medium Pressure Oil
18—Speed Shift Valve 3 Valve 31—Modulation Valve 47—Return Oil
19—Speed Shift Valve 2 25—Reverse Solenoid Valve 32—Pressure Reducing Valve 49—Transmission Control
20—Speed Shift Valve 1 28—Forward/Reverse Shift 36—Pressure Regulating Valve Valve And Shift Valve—
21—Speed Solenoid Valve 3 Valve 38—Converter Relief Valve First Forward
22—Speed Solenoid Valve 2
For theory See Power Shift Transmission Control

Circuit—First Forward. (Go to Group 9020). Keys and
nomenclature will match where applicable.
CED,TX03399,5912 –19–28JAN00–2/2
9020
05
23

031504
PN=337
Theory of Operation
Power Shift Transmission Control Circuit—High Range (Fourth) Forward—With Power

Boost MICO Brake Valve
T129428 –UN–13APR00
7 HIGH RANGE
FORWARD CLUTCH
10 11
1 1ST SPEED 6 9
5 BRAKE
FORWARD REVERSE
CLUTCH
4 LOW RANGE 17
CLUTCH SHIFT VALVE
SPEED SHIFT
3 SHIFT VALVE
28
26
SPEED SHIFT ORIFICE IN
VALVE SEQUENCE
19 VALVE VALVE MODULATION
2 PISTON PARK BRAKE
HOUSING SOLENOID
LOW 29
RANGE 30 DIFFERENTIAL VALVE 12
FORWARD MFWD
SOLENOID REVERSE SOLENOID SOLENOID SOLENOID
VALVE SOLENOID VALVE VALVE VALVE
SPEED 24 VALVE 15 14
27 16
SHIFT 25
VALVE ORIFICE IN 13
1 20 MODULATION
SPOOL MODULATION SCREEN
3 21 2 22 1 23 35 IN DUCT MODULATION 33
PLATE PISTON
PRESSURE
REGULATING 34
VALVE ORIFICE IN
NEUTRAL VALVE
TORQUE 38
2ND FORWARD X X X X 45 SYSTEM PRESSURE 37 TRANSMISSION 40
OIL COOLER FILTER
3RD FORWARD X X X X 46 MEDIUM PRESSURE 39 AND TRANSMISSION
HIGH RANGE 47 LOW PRESSURE BYPASS PUMP 41
X X X 43 POWER
(4TH FORWARD)
48 LUBE PRESSURE BOOST
1ST REVERSE X X X X BRAKE
49 RETURN PRESSURE SUMP 42 VALVE
2ND REVERSE X X X X
3RD REVERSE X X X X 50 POWER SHIFT TRANSMISSION CONTROL CIRCUIT - FOURTH FORWARD
T129428
WITH POWER BOOST MICO BRAKE VALVE
TX03543,0000919 –19–31OCT00–1/2

031504
PN=338
Theory of Operation
1—1st Speed Clutch 14—MFWD Solenoid Valve 28—Forward/Reverse Shift 40—Filter and Bypass
2—2nd Speed Clutch 15—Differential Solenoid Valve Valve 41—Transmission Pump
3—3rd Speed Clutch 16—Forward Solenoid Valve 29—Modulation Piston 42—Sump
4—Transmission Speed Shift 17—Low Range Shift Valve 30—Orifice in Valve Housing 43—Power Boost Brake Valve
Wheel Drive) 25—Reverse Solenoid Valve 37—Torque Converter Control Circuit—Fourth
11—Park Brake 26—Sequence Valve 38—Converter Relief Valve Forward—With Power
13—Screen In All Solenoids Spool
NOTE: Transmission control valve (5) and the 3rd speed clutch pack and compress the clutch
transmission speed shift valve (4) components plates. Shifting of the forward/reverse spool (28) allows
are shown in detail on the "Power Shift oil to flow from the modulation valve (31) to fill the high
Transmission Control Valve and Shift Valve range forward clutch pack (7) and compress the clutch
Operation—High Range (Fourth) Forward in plates. Shifting of the forward/reverse spool also
this group. Keys and nomenclature will match blocks the flow of oil downstream of the orifice (30) in
where applicable. valve housing from returning to tank and allows the
9020
pressure in the modulation valve to build. As pressure
05
NOTE: Refer to Power Shift Transmission Control builds, the balance between orifice size and spring 25
Circuit—Neutral for pressure reducing, load in the modulation valve controls the rate of shift
converter relief and pressure regulating valve and pushes the modulation piston (29) down.
theory of operation.
The sequence valve (26) insures that the speed clutch
During 4th gear forward operation the forward solenoid fills and engages before the direction clutch by
valve (16), speed solenoid valve 1 (23), and speed allowing oil to flow from the modulation valve (31) to
solenoid valve 3 (21) are energized. Both the low the speed clutch circuit downstream of the orifice in
range shift valve (17) and the forward/reverse shift duct plate (replenishing orifice) (35) when the pressure
valve (28) are in the up position. The energized speed in the speed clutch circuit is lower than the pressure in
solenoids 1 and 3 (23 and 21) routes oil to the shift the direction clutch circuit. The downward force from
valves 1 and 3 (20 and 18) moving the spools down. the modulation piston (29) pushes on the modulation
Pressure oil is routed through the shift valves to the springs which drive the modulation spool down to the
3rd speed clutch (3). Shifting of the speed shift spools fully open position. In the fully open position, high
allows oil to flow from the regulating valve (36) through pressure oil from the pressure regulating valve (36)
the orifice in duct plate (replenishing orifice) (35) to fill keeps the speed and direction clutches engaged.
TX03543,0000919 –19–31OCT00–2/2

031504
PN=339
Theory of Operation
Power Shift Transmission Control Valve and Shift Valve—High Range (Fourth) Forward

SOLENOID SOLENOID
25 REVERSE
SOLENOID
38
CONVERTER
RELIEF
VALVE
32
9020 36
PRESSURE
26 VALVE REGULATING
VALVE
17
LOW RANGE
SHIFT VALVE 30
ORIFICE 29
31
28 MODULATION
PISTON MODULATION
FORWARD VALVE
OR REVERSE
SHIFT VALVE 23
SPEED
SOLENOID
VALVE 1
21 22
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2
45 SYSTEM PRESSURE OIL 20

46 MEDIUM PRESSURE OIL SPEED
SHIFT
49 RETURN OIL VALVE 1
18
SPEED
–19–01FEB00
SHIFT
VALVE 3
19 SPEED
T127844
VALVE 2
T127844 AND SHIFT VALVE - FOURTH FORWARD

031504
PN=340
Theory of Operation
21—Speed Solenoid Valve 3 Valve 38—Converter Relief Valve Fourth Forward
For theory see Power Shift Transmission Control

Circuit—High Range (Fourth) Forward in this group.
Keys and nomenclature will match where applicable.
CED,TX03399,4228 –19–27JAN00–2/2
9020
05
27

031504
PN=341
Theory of Operation
Power Shift Transmission Control Circuit—First Reverse—With Power Boost MICO Brake
Valve
T129409 –UN–11APR00
7 HIGH RANGE
FORWARD CLUTCH
9 10 11
1 1ST SPEED 6
5 BRAKE
FORWARD REVERSE
CLUTCH
4
TRANSMISSION SPEED LOW RANGE
3 3RD SPEED SHIFT VALVE SHIFT VALVE
CLUTCH 17
SPEED SHIFT
3 SHIFT VALVE
28
SEQUENCE
SPEED SHIFT VALVE
VALVE ORIFICE IN
19 26 VALVE MODULATION PARK BRAKE
2 PISTON
HOUSING SOLENOID
LOW 29
RANGE 30 DIFFERENTIAL VALVE
FORWARD MFWD 12
SPEED SOLENOID SOLENOID SOLENOID SOLENOID
SHIFT VALVE REVERSE VALVE
SOLENOID VALVE VALVE
VALVE 24 15
1 20 VALVE 27 16 14
25 ORIFICE IN
SPOOL SCREEN
VALVE VALVE VALVE ORIFICE ORIFICE IN 33 VALVE 32
3 2 22 1 35 IN DUCT 13
21 23 MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE 34
44 FROM HYDRAULIC
36 ORIFICE IN OIL COOLER RETURN
LOW RANGE, FORWARD, & REVERSE SPEED INTERMEDIATE
GEAR SOLENOID ENERGIZED SOLENOID ENERGIZED PLATE
CONVERTER
NEUTRAL VALVE
TORQUE 38
45 SYSTEM PRESSURE
2ND FORWARD X X X X 37 40
46 MEDIUM PRESSURE
3RD FORWARD X X X X FILTER
47 LOW PRESSURE TRANSMISSION AND TRANSMISSION
HIGH RANGE OIL COOLER BYPASS PUMP
X X X LUBE PRESSURE 41 43 POWER
(4TH FORWARD) 48
39 BOOST
1ST REVERSE X X X X 49 RETURN PRESSURE SUMP 42 BRAKE
2ND REVERSE VALVE
X X X X
3RD REVERSE X X X X 50 POWER SHIFT TRANSMISSION CONTROL CIRCUIT
T129409 FIRST REVERSE - WITH POWER BOOST MICO BRAKE VALVE
TX03543,000091B –19–31OCT00–1/2

031504
PN=342
Theory of Operation
1—1st Speed Clutch 14—MFWD Solenoid Valve 28—Forward/Reverse Shift 41—Transmission Pump
2—2nd Speed Clutch 15—Differential Solenoid Valve Valve 42—Sump
3—3rd Speed Clutch 16—Forward Solenoid Valve 29—Modulation Piston 43—Power Boost MICO Brake
4—Transmission Speed Shift 17—Low Range Shift Valve 30—Orifice in Valve Housing Valve
Wheel Drive) 25—Reverse Solenoid Valve 37—Torque Converter Control Circuit—First
11—Park Brake 26—Sequence Valve 38—Converter Relief Valve Reverse—With Power
13—Screen In All Solenoids Spool 40—Filter and Bypass
NOTE: Transmission control valve (5) and (35) to fill the 1st speed clutch pack and compress the
transmission speed shift valve (4) components clutch plates. Shifting of the forward/reverse spool (28)
are shown in detail on the "Power Shift and the low range shift spool (17) allows oil to flow
Transmission Control Valve and Shift Valve from the modulation valve (31) to fill the reverse clutch
Operation—First Reverse in this group. Keys pack (8) and compress the clutch plates. Shifting of
and nomenclature will match where applicable. the forward/reverse spool also blocks the flow of oil
downstream of the orifice (30) in valve housing from
9020
NOTE: Refer to Power Shift Transmission Control returning to tank and allows the pressure in the
05
Circuit—Neutral for pressure reducing, modulation valve (31) to build. As pressure builds, the 29
converter relief and pressure regulating valve balance between orifice size and spring load in the
theory of operation. modulation valve controls the rate of shift and pushes
the modulation piston down.
During 1st gear reverse operation the reverse solenoid
valve (25), low range solenoid valve (24), speed The sequence valve (26) insures that the speed clutch
solenoid valve 2 (22), and speed solenoid valve 3 (21) fills and engages before the direction clutch by
are energized. The energized reverse solenoid valve allowing oil to flow from the modulation valve to the
(25) routes pressure oil to the forward/reverse shift speed clutch circuit downstream of the orifice in duct
valve (28) moving its spool down. The energized low plate (replenishing orifice) (36) when the pressure in
range solenoid valve (24) routes pressure oil to the low the speed clutch circuit is lower than the pressure in
range shift valve (17), shifting it down. The energized the direction clutch circuit. The downward force from
speed solenoids 2 and 3 (22 and 21) routes oil to the the modulation piston (29) pushes on the modulation
shift valves 2 and 3 (19 and 18) moving the spools springs which drive the modulation spool down to the
down. Pressure oil is routed through the shift valves to fully open position. In the fully open position, high
the lst. speed clutch (1). Shifting of the speed shift pressure oil from the pressure regulating valve (36)
spools allows oil to flow from the regulating valve (36) keeps the speed and direction clutches engaged.
through the orifice in duct plate (replenishing orifice)
TX03543,000091B –19–31OCT00–2/2

031504
PN=343
Theory of Operation
Power Shift Transmission Control Valve and Shift Valve—First Reverse

SOLENOID SOLENOID
25 REVERSE
SOLENOID
38
CONVERTER
RELIEF
VALVE
32
9020 36
PRESSURE
30 VALVE REGULATING
VALVE
17
LOW RANGE
SHIFT VALVE 30
ORIFICE 29
28
31
FORWARD MODULATION
SHIFT VALVE VALVE
23
SPEED
SOLENOID
VALVE 1
21 22
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2

20
47 RETURN OIL
SPEED
SHIFT
VALVE 1
18
SPEED
–19–10FEB00
SHIFT
VALVE 3
19 SPEED
T127903
VALVE 2
T127903 AND SHIFT VALVE - FIRST REVERSE

031504
PN=344
Theory of Operation
21—Speed Solenoid Valve 3 Valve 38—Converter Relief Valve First Reverse
For theory See Power Shift Transmission Control

Circuit—First Reverse. (Go to Group 9020). Keys and
nomenclature will match where applicable.
CED,TX03399,5914 –19–28JAN00–2/2
9020
05
31

031504
PN=345
Theory of Operation
Power Shift Modulation Valve Operation
M ORIFICES
G PISTON FILL PRE MODULATION ENGAGEMENT

MOD.
H OUTER
SPRING
F
I INNER
ORIFICE SPRING
J SEQUENCE
VALVE B C D
E
ORIFICE
M6 M6
K ORIFICE
A
NEUTRAL L MODULATION
SPOOL
9020 B C D
05 START OF FILL MODULATION ENGAGEMENT
32
N SYSTEM PRESSURE
O MEDIUM HIGH PRESSURE
–19–26JUN98
P MEDIUM PRESSURE
Q LOW PRESSURE
R RETURN PRESSURE
T114787
T114787 S MODULATION VALVE

031504
PN=346
Theory of Operation
A—Neutral F—Orifice (in Valve Housing) K—Orifice In Duct Plate O—Medium High Pressure
B—Start of Fill G—Piston (Replenishing Orifice) P—Medium Pressure
C—Modulation H—Outer Spring L—Modulation Spool Q—Low Pressure
D—Engagement I—Inner Spring M—Orifice (2 used) R—Return Pressure
E—Orifice J—Sequence Valve N—System Pressure S—Modulation 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 forces
oil (N), bleeds by the edge of the modulation spool (L). on 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
05
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 –19–27MAR98–2/2

031504
PN=347
Theory of Operation
Differential Operation
9020
05
34
–19–03SEP96
T101246

031504
PN=348
Theory of Operation
A—Final Drive Ring Gear D—Bevel Pinion Shaft (2 used) G—Side Gear J—Output Shaft
B—Differential Housing E—Bevel Pinion (4 used) H—Sun Pinion Shaft K—Differential
C—Differential Ring Gear F—Input Pinion Shaft I—Planet Pinion Carrier
The differential allows independent rotation of the The sun pinion shaft meshes with the planet pinion
axles when the machine is steered. The final drive carrier assembly (I) which rotates around the inside of
planetaries are attached to the axles. Their purpose is the stationary planetary final drive ring gear (A).
to reduce speed and increase torque through gear Torque is transferred into the output shaft (J) causing it
reduction. The input pinion shaft to differential ring to rotate at a reduced speed but with greater torque.
gear also provides a reduction in speed and an
increase to torque. As the machine is steered, the inside wheel slows
down in relation to the outside wheel. This causes the
Input torque from the drive shaft rotates the input bevel side gear, attached to the inside wheel’s axle, to slow
pinion shaft (F) which meshes with the differential ring down. The rotating differential housing and bevel
gear (C), causing it to turn. The ring gear is fastened pinion shafts allow the differential bevel pinions to
to the differential housing (B) which drives the bevel rotate around the slow moving side gear; this allows
pinion shafts (D) and bevel pinions (E). The bevel the opposite side gear to rotate at a faster speed. This
pinions located on the bevel pinion shaft are in mesh rotation causes the outside wheel’s axle to rotate
with the side gears (G) which spline to the sun pinion faster than the inside axle which prevents tire scuffing.
shaft (H).
9020
05
35
TX,05,SS3139 –19–23JUN98–2/2

031504
PN=349
Theory of Operation
Differential Lock Operation
SIDE A B DIFFERENTIAL
GEAR HOUSING
C BEARING
D BRAKE
HOUSING
E PISTON
DIFFERENTIAL
SOLENOID
VALVE
9020
F
05
36
G SLIDING
GEAR
FROM H
TRANSMISSION
PUMP
–19–04SEP98
I SPRING
J SYSTEM PRESSURE
K RETURN PRESSURE
L DIFFERENTIAL LOCK
T101241
T101241
A—Side Gear D—Brake Housing G—Sliding Gear J—System Pressure

B—Differential Housing E—Piston H—From Transmission Pump K—Return Pressure
C—Bearing F—Differential Solenoid Valve I—Spring L—Differential Lock
When the operator has the differential lock foot control energizes the differential lock solenoid on the
switch in the "OFF" position, the spring force (I) moves transmission. When the differential lock solenoid (F) is
the sliding gear (G) and piston (E) back releasing the energized, pressure oil flows to the inlet and through
differential lock. The return oil returns through the the cross-drilled passages to the piston (E). The
same port as when the switch is in the "ON" position. pressurized oil moves the piston (E) against the sliding
gear locking the sliding gear with side gear (A) of the
When the operator pushes the differential lock foot differential, causing both axles to rotate at the same
control switch to the "ON" position, the switch speed.
TX,05,SS3130 –19–23JUL98–1/1

031504
PN=350
Theory of Operation
MICO Power Boost Brake Valve—Neutral Position
1 26 25
2 24
3 23
4 22
5 21
6 20
7 19
8 18
9 17
9020
05
10 16 37
–UN–17MAR00
27 PRESSURE FREE OIL
28 LOW PRESSURE OIL
11 12 13 14 15
T129233
T129233 29 NEUTRAL POSITION - ENGINE ON
1—Push Rod (Brake Pedal) 9—Valve Assembly 17—Valve Assembly 25—Push Rod (Brake Pedal)
2—Check Ball 10—Hydraulic Reservoir Port 18—Piston 26—Transmission Reservoir
3—Land 11—Spring 19—Seal Port
4—Inlet Port 12—Brake Port 20—Spring 27—Pressure Free Oil
5—Spring 13—Spool 21—Spring 28—Low Pressure Oil
6—Spring 14—Brake Port 22—Inlet port 29—Neutral Position—Engine
7—Seal 15—Spring 23—Land On
8—Piston 16—Hydraulic Reservoir Port 24—Check Ball
Oil from the transmission enter ports (4 and 22) small flow of oil thru these ports keeps the master
separately. This oil flows thru land areas (3 and 23), cylinder reservoir full.
thru the center of pistons (8 and 18) and on to the
transmission reservoir port (26). In the neutral position, pistons (8 and 18) are fully
retracted and valve assemblies (9 and 17) are open.
The two halves of the master cylinder reservoir are The brake system is at reservoir pressure thru brake
open to one another. Hydraulic oil enters the master ports (12 and 14).
cylinder reservoir at port (10) and exits at port (16). A

031504
PN=351
Theory of Operation
The pedals are held in the neutral position by spring (5

and 6) and springs (20 and 21).
CED,TX03768,2711 –19–14MAR00–2/2
MICO Power Boost Brake Valve—Both Pedals Applied Position
1 26 25
2 24
3 23
4 22
5 21
6 20
9020
05 7 19
38
8 18
9 17
10 16
–UN–17MAR00
28 LOW PRESSURE OIL
11 12 13 14 15
30 HIGH PRESSURE OIL T129234
T129234 31 BOTH PEDALS APPLIED - ENGINE ON
1—Push Rod (Brake Pedal) 10—Hydraulic Reservoir Port 18—Piston 26—Transmission Reservoir
2—Check Ball 11—Spring 19—Seal Port
3—Land 12—Brake Port 20—Spring 27—Pressure Free Oil
4—Inlet Port 13—Spool 21—Spring 28—Low Pressure Oil
5—Spring 14—Brake Port 22—Inlet port 29—Medium Pressure Oil
6—Spring 15—Spring 23—Land 30—High Pressure Oil
7—Seal 16—Hydraulic Reservoir Port 24—Check Ball 31—Both Pedals Applied—
8—Piston 17—Valve Assembly 25—Push Rod (Brake Pedal) Engine On
9—Valve Assembly

031504
PN=352
Theory of Operation
Oil from the transmission enters ports (4 and 22) differences between right and left brake pack fill
separately and drains to transmission reservoir port volumes.
(26). Both pedals are depressed forcing springs (5 and
21) to compress. Oil flowing thru land areas (3 and 23) After the brakes are filled, higher brake pressure is
becomes restricted. Oil flow moves to close check developed by the inlet oil pressure being modulated at
balls (2 and 24). Restricted oil flow and lands (3 and lands (3 and 23). causing piston (8 and 18) to
23) causes pressure to act against the large diameter generate a higher pressure at the brake ports. Brake
of pistons (8 and 18). Pistons (8 and 18) move to pedal modulated feel is determined by the hydraulic
compress springs (6 and 20). As more push rod areas of push rods (1 and 25) and modulated pressure
displacement occurs, valve assemblies (9 and 17) at lands (3 and 23).
close, stopping brake system oil from moving to
reservoir or atmosphere pressure. Additional Maximum boosted brake pressure is limited by the
movement of the push rods and pistons (8 and 18) inlet oil pressure at ports (4 and 22). Additional pedal
forces brake system oil to the brakes causing brakes effort can cause higher brake pressure and is
to fill thru ports (12 and 14). dependent only by the amount of pedal force applied.
Spool (13) moves against either spring (11 or 15) to

perform an equalization function by compensating for
9020
05
39
CED,TX03768,2712 –19–14MAR00–2/2

031504
PN=353
Theory of Operation
MICO Power Boost Brake Valve—One Pedal Applied Position
1 26 25
2 24
3 23
4 22
5 21
6 20
7 19
8 18
9 17
9020
05
10 16
40
–UN–17MAR00
28 LOW PRESSURE OIL
11 12 13 14 15 30 HIGH PRESSURE OIL
T129235
T129235 31 ONE PEDAL APPLIED - ENGINE ON
1—Push Rod (Brake Pedal) 10—Hydraulic Reservoir Port 18—Piston 26—Transmission Reservoir
2—Check Ball 11—Spring 19—Seal Port
3—Land 12—Brake Port 20—Spring 27—Pressure Free Oil
4—Inlet Port 13—Spool 21—Spring 28—Low Pressure Oil
5—Spring 14—Brake Port 22—Inlet port 29—Medium Pressure Oil
6—Spring 15—Spring 23—Land 30—High Pressure Oil
7—Seal 16—Hydraulic Reservoir Port 24—Check Ball 31—One Pedal Applied—
8—Piston 17—Valve Assembly 25—Push Rod (Brake Pedal) Engine On
9—Valve Assembly
When only one pedal is applied, the opposite side when apply both pedals to obtain the same brake
brake remains at reservoir pressure. The effort pressure.
required on one pedal is one half that of the effort
CED,TX03768,2713 –19–14MAR00–1/1

031504
PN=354
Theory of Operation
MICO Power Boost Brake Valve—Both Pedals Applied, Engine Off Position
1 25
26
2 24
3 23
4 22
5 21
6 20
7 19
8 18
9 17
10 16 9020
05
41
–UN–17MAR00
28 HIGH PRESSURE OIL
11 12 13 14 15
T129236
T129236 29 BOTH PEDALS APPLIED - ENGINE OFF
1—Push Rod (Brake Pedal) 9—Valve Assembly 17—Valve Assembly 25—Push Rod (Brake Pedal)
2—Check Ball 10—Hydraulic Reservoir Port 18—Piston 26—Transmission Reservoir
3—Land 11—Spring 19—Seal Port
4—Inlet Port 12—Brake Port 20—Spring 27—Pressure Free Oil
5—Spring 13—Spool 21—Spring 28—High Pressure Oil
6—Spring 14—Brake Port 22—Inlet port 29—Both Pedals Applied—
7—Seal 15—Spring 23—Land Engine Off
8—Piston 16—Hydraulic Reservoir Port 24—Check Ball
When the engine is not running, one or both brakes reservoir. More push rod travel fills the brakes and
can be actuated manually. When push rods (1 and 25) pressure is developed to provide pedal force. The
are displaced by the pedals, springs (5 and 21) amount of pressure to the brakes depends on how
compress until lands (3 and 23) are mechanically hard the pedals are pushed. When the pedals return to
closed. Additional push rod displacement forces the neutral position, valve assemblies (9 and 17) open
pistons (8 and 18) to move. Valve assemblies (9 and and return brakes to reservoir pressure.
17) close, stopping oil from gong to the hydraulic
CED,TX03768,2714 –19–14MAR00–1/1

031504
PN=355
Theory of Operation
Service Brake Operation
9020
05
42
–19–04MAR98
T101300
A—Disk (3 used) D—From Brake Valve F—Adjusting Screw H—Sun Gear Shaft
B—Plate (4 used) E—Brake Housing G—Hub I—Service Brake
C—Piston
The rear axle assembly uses wet multi-disk brakes disks are splined to the sun gear shaft and the plates
which are self-adjusting to compensate for wear. The are splined to the rear axle housing.
Continued on next page TX,05,SS3133 –19–16MAY96–1/2

031504
PN=356
Theory of Operation
When the service brakes are applied, the pressure oil rotation of the sun gear shaft (H). When the brakes are
from the brake valve (D), forces the brake piston (C) released the return oil flows back out the same port to
against the brake plates (B) and disks (A) which stops the brake valve.
TX,05,SS3133 –19–16MAY96–2/2
9020
05
43

031504
PN=357
Theory of Operation
Park Brake Operation
9020
05
44
H
PARK BRAKE
SOLENOID A SPRING
VALVE PLATE
B SPRING
WASHER
F PISTON
G
FROM C TOWING
TRANSMISSION CAP SCREW
PUMP E PLATE
D DISK –19–04SEP98
I SYSTEM PRESSURE
J RETURN PRESSURE
T101244
T101244 K PARK BRAKE - ON
A—Spring Plate D—Disk (3 used) G—From Transmission Pump J—Return Pressure

B—Spring Washer E—Plate (2 used) H—Park Brake Solenoid Valve K—Park Brake—ON
C—Towing Cap Screw F—Piston I—System Pressure
The park brake is spring applied and hydraulically brake. The spring washer (B) forces the piston (F)
released. When the park brake is applied (ON) or against brake disks (D) and plates (E) on the axle
machine is shut-off, spring force applies the park input shaft.

031504
PN=358
Theory of Operation
When park brake switch is cycled to the OFF position, The piston moves against the spring washer (B) and
the switch energizes the park brake solenoid (H) on releases the disks and plates (D and E). Two manual
the transmission. The solenoid routes transmission operated cap screws (C) release the park brake for
system pressure oil (I) to the park brake piston (F). emergency towing.
TX,05,SS3134 –19–16MAY96–2/2
9020
05
45

031504
PN=359
Theory of Operation
MFWD Differential Operation—Unequal Traction
9020
05
46
–UN–24MAY89
T6058AL
A—Tire With Most Traction D—Left Side Drive Gear G—Clutch Disks I—Power Flow
B—Drive Shaft E—Pinion Gears H—Clutch Plate J—Rotation Direction
C—Right Side Drive Gear F—Differential 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
Continued on next page TX,05,SS3140 –19–26JAN00–1/2

031504
PN=360
Theory of Operation
With MFWD engaged, differential works to

automatically balance driving power to available
traction.
TX,05,SS3140 –19–26JAN00–2/2
MFWD Differential Operation—Equal Traction—If Equipped
9020
05
47
–UN–24MAY89
T6058AM
A—Differential Drive Shaft C—Differential Housing E—Bevel Drive Gears G—Power Flow
B—Ring Gear D—Pinions F—Drive Shafts H—Rotation Direction
Differential unit has self-applied, limited slip feature. Power flows into axle housing through differential drive
When engaged under slippery field conditions, this shaft (A), turning ring gear (B) and attached differential
system automatically applies correct amount of torque housing (C). When both wheels have equal traction,
to match traction available to each tire. pinions (D) remain stationary within rotating housing.
Pinions turn bevel drive gears (E) and drive shafts (F)
With MFWD engaged, when tractor is moving in a splined to drive gears.
straight line and each tire has equal traction, equal
power is supplied to left and right axle. No differential
action occurs.
TX,05,SS3141 –19–26JAN00–1/1

031504
PN=361
Theory of Operation
9020
05
48

031504
PN=362
Group 15
System Diagnostic Information
Diagnose Power Shift Power Train
Malfunction
Machine Will Not Move in Low Low oil level in transmission, park Add oil to correct level.See Backhoe
Range Forward, High Range (4th) brake will not release and light on Drain and Refill Capacities. (Go to
or Reverse console is ON. Group 9000-02.)
Service Brakes Dragging Adjust Brake Pedals. (Go to Group

9020-20.) Do Remove and Install
Brake Valve. (Go to repair manual
Group 1060.)
If light in console OFF and park Check console light and /or pressure
brake not releasing switch. Do Transmission Solenoids
Check (Power Shift). Go to Group
9015-15.) Do Park Brake Solenoid
Check (Power Shift). (Go to Group
9015-15.) Check park brake disks
and separator plates. Do Remove
and Install Rear Axle. (Go to repair 9020
15
manual Group 0250.)
1
FNR/Gear Selection Lever Internal Transmission operates in forward

Diode Open low speeds, but does not operate in
reverse low speeds.
Check for open in FNR internal

diode. See FNR Lever Check
(Power Shift). (Group 9015-20.)
Proper solenoids not energized Test solenoids. Do Transmission

Solenoids Check (Power Shift). (Go
to Group 9015-15.)
Low or no system pressure Do System Pressure Test. (Go to

Group 9020-25.)
Leaking clutch piston O-ring Do Power Shift Low Range Forward,

High Range Forward, Reverse and
Speed Clutch Pressure Test. (Go to
Group 9020-25.) Do Modulation
Valve Pressure Test (Go to Group
9020-25.)
Continued on next page CED,TX03399,4235 –19–11DEC00–1/11

031504
PN=363
Piston in clutch pack stuck Check System Pressure.Do System

Pressure Test. (Go to Group
9020-25.) Do Power Shift Low
Range Forward, High Range
Forward, Reverse and Speed Clutch
9020-25.)
Piston ball does not seat Do Power Shift Low Range Forward,
Valve Pressure Test. (Go to Group
9020-25.)
Torque Converter Flexplate broken Inspect and repair. Do Remove

Powershift or Manual Transmission.
(Go to repair manual Group 0300.)
See Disassemble and Assemble
9020 Torque Converter. (Go to repair
15 manual Group 0651.)
2
Worn or slipping low range forward, Check system pressure. Do System

high range forward reverse, or speed Pressure Test. (Go to Group
clutch disks 9020-25.)
Incorrect shim under modulation Do Modulation Valve Pressure Test.

piston (Go to Group 9020-25.)
Restricted modulation orifice Do Modulation Valve Pressure Test.

(Go to Group 9020-25.)
Stuck spool in control valve Do Power Shift Low Range Forward,

Group 9020-25.)
Clutch malfunction in torque Do Torque Converter Stall Speed

converter Test. (Go to Group 9020-25.)
Low torque converter oil Do Cooler In and Cooler Out

flow/pressure Pressure Test. (Go to Group
9020-25.)

031504
PN=364
Charge pump stop sleeve out of Remove and Install Transmission

location Charge Pump—Powershift. (Go to
repair manual Group 0360.)
Clutch shaft sealing rings leaking Do Power Shift Low Range Forward,
Group 9020-25.)Do Modulation
9020-25.)
Converter drive splines worn or not Replace converter. Do Remove

engaged in pump drive shaft Powershift or Manual Transmission.
Pump gears seized Replace pump assembly, inspect

and replace pump drive parts as
necessary. Remove and Install
Transmission Charge Pump—
Powershift. (Go to repair manual 9020
Group 0360.) 15
3
Mechanical failure in transmission Inspect transmission and repair. Do

Remove Powershift or Manual
Transmission. (Go to repair manual
Group 0300.)
Broken drive shafts or pump drive Inspect drive shafts, universal joints,
shaft and pump drive shaft for external or
internal damage. Do Remove and
Install Drive Shaft. (Go to repair
manual Group 0325.)
Broken ring or pinion gear If drive shafts rotate with

transmission in gear but machine
does not move a differential failure is
indicated. Repair. Do Remove and
Install Rear Axle. (Go to repair
manual Group 0250.)
Machine Will Not Move In One Leakage in speed clutch Do Power Shift Low Range Forward,
Gear High Range Forward, Reverse and
Group 9020-25.)

031504
PN=365
Proper solenoids not working Do Transmission Solenoids Check

(Power Shift). (Go to Group
9015-15.)
Worn or slipping in one clutch pack Do Power Shift Low Range Forward,
Group 9020-25.)
Transmission Slippage Low oil level and park indicator light Add oil.See Backhoe Drain and Refill
ON Capacities. (Go to Group 9000-02.)
Wrong oil grade Change oil. See Transmission, Axles

and Mechanical Front Wheel Drive
Oil. (Go to operator’s manual.)

9020 Leaking clutch piston O-ring Do Power Shift Low Range Forward,
15 High Range Forward, Reverse and
4
9020-25.)
Group 9020-25.)
Clutch shaft sealing rings leaking. Do Power Shift Low Range Forward,
9020-25.)
Worn or slipping clutch disks Do Power Shift Low Range Forward,

Group 9020-25.) Do System
9020-25.)

031504
PN=366
Leak in transmission control valve, Do Power Shift Low Range Forward,

shift valve or gaskets High Range Forward, Reverse and
Group 9020-25.)
Low torque converter oil Do Cooler In and Cooler Out

flow/pressure Pressure Test. (Go to Group
9020-25.)
Low transmission pump flow due to Do Pump Flow Test. (Go to Group
worn pump 9020-25.)Do Remove and Install
Transmission Charge Pump—
Powershift. (Go to repair manual
Group 0360.)
Weak or broken pressure regulating Do System Pressure Test. (Go to

valve spring Group 9020-25.)
Weak or broken modulation valve Do Modulation Valve Pressure Test.

spring (Go to Group 9020-25.) 9020
15
5
Machine “Creeps” with FNR in Warped disks and plates in Check transmission.Do Remove
Neutral transmission Powershift or Manual Transmission.
Piston in clutch pack stuck. Do System Pressure Test. (Go to

Group 9020-25.) Do Power Shift Low
Range Forward, High Range
9020-25.)
Ball pressed in end of clutch shafts Do Power Shift Low Range Forward,
(lube passage) came out High Range Forward, Reverse and
Group 9020-25.)
Clutch ball stuck shut Do Power Shift Low Range Forward,

Group 9020-25.)
Internal leakage in control valve Do Pump Flow Test. (Go to Group

9020-25.)

031504
PN=367
Solenoids stuck Do Transmission Solenoids Check

(Power Shift). (Go to Group
9015-15.)
Machine Lacks Power or Moves Oil level is low and park brake Add oil to correct level. See Backhoe
Slow indicator light is ON Drain and Refill Capacities. (Go to
Group 9000-02.)
Wrong oil, aerated oil Change oil. See Transmission, Axles

Service Brake dragging Check for excessive heat in brake

area of axle housing after operating
machine. Adjust Brake Pedals. (Go
to Group 9020-20.) Do Remove and
Install Brake Valve. (Go to repair
manual Group 1060.)
9020 Park brake dragging, piston stuck Repair park brake in rear axle. Do
15 Remove and Install Rear Axle. (Go
6
to repair manual Group 0250.)
Engine fast idle speed set too low Check fast idle adjustment. Do Slow
and Fast Idle. (Go to Group
9010-20.)
Low pressure in transmission system Do System Pressure Test. (Go to

Group 9020-25.)

Leaking clutch piston O-ring Do Power Shift Low Range Forward,

9020-25.)
Group 9020-25.)

031504
PN=368
Clutch pack slipping Do System Pressure Test. (Go to

Group 9020-25.)
Clutch pack dragging, disks warped Repair clutch pack.Do Remove

Clutch shaft sealing ring leaking Do Power Shift Low Range Forward,
9020-25.)
Clutch ball stuck shut Do Power Shift Low Range Forward,

Group 9020-25.)
Internal leakage in control valve Do Pump Flow Test. (Go to Group 9020
9020-25.) 15
7
Failed torque converter Do Torque Converter Stall Speed

Test. (Go to Group 9020-25.)
Low torque converter oil Do Torque Converter Stall Speed

flow/pressure Test. (Go to Group 9020-25.)
Wrong torque converter Do Torque Converter Stall Speed

Test. (Go to Group 9020-25.) Check
number of torque converter through
access hole under machine either
247002 or 4168-028-211.
Low engine power Do Turbocharger Boost Pressure—

Engine Performance Test. (Go to
Group 9010-25.)
Mechanical failure in transmission or Inspect.Do Remove Powershift or

axle Manual Transmission. (Go to repair
manual Group 0300.) Do Remove
and Install Rear Axle. (Go to repair
manual Group 0250.)

031504
PN=369
Transmission Shifts Too Slow Low or high oil level (aeration of oil) Add oil or drain. See Backhoe Drain
and Refill Capacities. (Go to Group
9000-02.)
Wrong oil Change oil. See Transmission, Axles

Pressure reducing valve setting Do Reducing Valve Pressure Test.

incorrect (Go to Group 9020-25.)
Pressure regulating valve setting Do System Pressure Test. (Go to

incorrect Group 9020-25.)
Clutch pack slipping Do System Pressure Test. (Go to

Group 9020-25.)
Control valve leaking internally Do Pump Flow Test. (Go to Group

9020-25.)
9020
15 Control valve modulation piston not Do Modulation Valve Pressure Test.
8
shimmed properly (Go to Group 9020-25.)

Modulation piston spring broken Do Modulation Valve Pressure Test.

Restricted oil passage to clutch pack Do Power Shift Low Range Forward,
Group 9020-25.)
Transmission pump malfunction Do Pump Flow Test. (Go to Group

9020-25.)Do System Pressure Test.
Transmission pump oil pickup Do Remove Powershift or Manual

blocked Transmission. (Go to repair manual
Group 0300.)
Transmission Shifts Too Fast Modulation piston orifice blocked Do Modulation Valve Pressure Test.

031504
PN=370
Modulation valve piston stuck Do Modulation Valve Pressure Test.

Modulation orifice out of place or Do Modulation Valve Pressure Test.

missing (Go to Group 9020-25.)
Modulation orifice oversized Do Modulation Valve Pressure Test.

Transmission Overheats Oil level too high or too low Add or drain oil. See Backhoe Drain
and Refill Capacities. (Go to Group
9000-02.)
Incorrect type of oil Drain and replace oil. . See

Transmission, Axles and Mechanical
Front Wheel Drive Oil. (Go to
operator’s manual.)
Converter Oil Temperature Sender Check sensor. See Sub-System

malfunction Diagnostics/Display 9020
Monitor/Indicator. (Go to Group 15
9
9015-15.)
Clutch pack dragging, worn disks Do Remove Powershift or Manual

Group 0300.)
Torque converter malfunction Do Torque Converter Stall Speed

Torque converter stalled excessively Use neutral disconnect switch in

machine operations to reduce stall.
Operating in too high a gear Operate one gear lower. See

Operator’s Manual.
Oil cooler air flow restricted Inspect and clean exterior of cooler.
Do Radiator Air Flow Test. (Go to
Group 9010-25.)
Missing baffles, damaged fan Inspect and check belt. Check

shrouds or loose fan belt baffles and repair. See Remove and
Install Fan Belt. (Go to repair manual
Group 0510.)

031504
PN=371
Oil cooler restricted internally Do Cooler In and Cooler Out

9020-25.) Flush Cooling System.
See CTM104.
Converter flow blocked by pump Do Cooler In and Cooler Out

stop sleeve. Pressure Test. (Go to Group
9020-25.)
Oil flow to or from cooler restricted Do Cooler In and Cooler Out

9020-25.)
Converter-In relief valve stuck open Do Converter-In Relief Valve Test.

or broken spring (Go to Group 9020-25.)
Low transmission pump flow Do Pump Flow Test. (Go to Group

9020-25.)
9020 Transmission mechanical Inspect transmission and repair. Do

15 malfunction Remove Powershift or Manual
10
Group 0300.)
Engine Over-fueled Remove fuel injection pump. See

your authorized Injection Pump
Service Center
Excessive Power Train Noise Engine low idle too slow Do Slow and Fast Idle. (Go to Group
9010-20.)
Oil level low See Backhoe Drain and Refill

Capacities. (Go to Group 9000-02.)
Worn or damaged parts in Check transmission filter for metal

transmission or axle particles. Repair as necessary. Do
Group 0300.) Do Remove and Install
Rear Axle. (Go to repair manual
Group 0250.)
Worn universal joints on drive shaft Inspect universal joints or drive

shaft. Do Replace Drive Shaft
U-Joints. (Go to repair manual
Group 0325.)

031504
PN=372
Misalignment of power train Check position of components. Be

components sure they are setting on mounts
correctly.
No oil in lube circuit Do Cooler In and Cooler Out

Pressure Test.
Do Converter-In Relief Valve Test.

Hydraulic lines in contact with power Inspect all hydraulic lines and
train components repairSee Hydraulic Component
Location. (Go to Group 9025-05.)
Transmission assembly adjustments Isolate where noise is coming from.

or setting made incorrectly Adjust. Repair. Check mounts. Do
Group 0300.)
9020
Excessive Gear Clash When Rate of shift too fast Do Modulation Valve Pressure Test. 15
11
Shifting (Go to Group 9020-25.)
Worn Gears Inspect transmission. Do Remove

Park Brake Pressure Light Transmission oil level too low Add oil. See Backhoe Drain and
Comes On Refill Capacities. (Go to Group
9000-02.)
Park brake solenoid not working Test solenoid. Do Park Brake

Solenoid Check (Power Shift). (Go to
Group 9015-15.)
Park brake piston leak Do Park Brake Release Pressure

Park brake hose leaking Do Park Brake Release Pressure

Test. (Go to Group 9020-25.) Locate
leak and repair.
CED,TX03399,4235 –19–11DEC00–11/11

031504
PN=373
Diagnose MFWD Malfunction
NOTE: See CTM4687 for repair for MFWD axle.
No Power to MFWD Solenoid not actuated Check electrical connection. Check

MFWD Solenoid. See Sub-System
Diagnostics/MFWD Circuit. (Go to
Group 9015-15.)
Drive shaft failure Inspect and repair. Do Remove and

Install Drive Shaft. (Go to repair
manual Group 0325.)
Failed MFWD output shaft spline Inspect and repair.Do Remove

Failed axle shaft in MFWD Inspect and repair. Do Remove and

Install Powered Front Axle (MFWD).
9020 (Go to Group 0240 in repair
15 manual.)
12
Failed ring gear or pinion in front Inspect and repair. Do Remove and
axle. Install Powered Front Axle (MFWD).
(Go to Group 0240 in repair
manual.)
Failed MFWD gear train components Inspect and repair.Do Remove

in transmission Powershift or Manual Transmission.
No Power to One Wheel of MFWD Wheel U-Joint failure Inspect and repair. Do Remove and
manual.)
Failed outboard planetary Inspect and repair. Do Remove and

manual.)
Continued on next page TX,15,MA17 –19–11DEC00–1/2

031504
PN=374
Failed axle shaft in MFWD Inspect and repair. Do Remove and

manual.)
Failed limited-slip in MFWD Inspect and repair. Do Remove and

manual.)
TX,15,MA17 –19–11DEC00–2/2
9020
15
13

031504
PN=375
Diagnose Rear Axle Malfunction
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.
See Differential Lock Operational

Checks. (Go to Group 9015-15).
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. See
Engine/Transmission Harness (W7)
Wiring Diagram. (Go to Group
9015-10.) Disassemble Rear Axle.
manual.)
9020
15 Excessive leakage in differential lock See Differential Lock Pressure Test.
14
piston seals (Go to Group 9020-25). Check rear
axle oil level. (See operator’s
manual.)
Stuck differential lock piston See Differential Lock Pressure Test.

Disassemble, inspect, repair. See
Disassemble Rear Axle. (Go to
Group 0250).
Excessive wear on differential lock Disassemble, inspect, repair. See

engaging gears Disassemble Rear Axle. (Go to
Group 0250 in repair manual).
Continued on next page TX,15,MA18 –19–28JAN00–1/5

031504
PN=376
Differential Lock Slips or Excessive leakage differential lock Do Differential Lock Pressure Test.
Chatters When Engaged piston seals See Group 9020-25.
Failed seals on differential lock Remove and inspect seals. See

solenoid valve Disassemble Rear Axle. Group
0360.
Stuck differential lock piston Disassemble, inspect and repair.

See Disassemble Rear Axle. Group
0250.
Excessive wear of differential lock Disassemble, inspect, and repair.

engaging gears See Disassemble Rear Axle. Group
0250.
Differential Lock Will Not Release Stuck foot switch Inspect. See electrical, Group
9015-15.
Malfunction in electrical circuit With engine stopped and key switch

on, activate differential lock and 9020
listen for a click from solenoid valve. 15
15
See Differential Lock Circuit. (Go to
Group 9015-15).
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 See
Group 0360).
Stuck differential lock piston See Differential Lock Pressure Test.

Disassemble, inspect, repair. See
See Disassemble Rear Axle. (Go to
Group 0250).
Stuck differential lock engaging Disassemble, inspect, repair. See

gears or clutch See Disassemble Rear Axle. (Go to
Group 0250).
Oil level low in transmission Add oil to correct level. (See

operator’s manual.) Check axle for
overfill.

031504
PN=377
Rear Axle Overfilled With Oil Differential lock piston seals leaking See Differential Lock Pressure Test.
(Go to Group 9020-25). Inspect,
repair. See See Disassemble Rear
Axle. (Go to Group 0250).
Service brake piston seals leaking See Brake Valve Leakage Test. (Go
to Group 9020-25). Inspect and
repair. See See Disassemble Rear
Axle. (Go to Group 0250).
Park brake piston seals leaking See Park Brake Release Pressure
Test. (Go to Group 9020-25). Inspect
and repair. See See Disassemble
Rear Axle. (Go to Group 0250).
Poor Service Brakes Low oil level Check oil level and fill. (See
operator’s manual.)
Air in brake valve or lines or piston See Bleeding Brakes. (Go to Group
9020 9020-20).
15
16
Brake valve leaks See Brake Valve Leakage Test. (Go
to Group 9020-25).
Brake piston seals leak Inspect and repair. See See

Group 0250).
Brake disks worn excessively Inspect disks through axle brake

inspection hole. Disassemble,
inspect and repair. See See
Group 0250).
Restriction in brake circuit Remove lines and components and

inspect.

031504
PN=378
Service Brakes Will Not Release Brake pedal not returning to full up Inspect brake pedal linkage. See
position or not adjusted properly Group 1060.
Brake valve malfunction Remove, disassemble and inspect.

Repair brake valve. See
Group 1060).
Warped brake disks Disassemble, inspect and repair.

Group 0250).
Stuck brake piston See Disassemble Rear Axle. (Go to

Repair, Group 0250).
No free travel on brake adjusters Disassemble and inspect, check

specifications. See Disassemble
Rear Axle. (Go to Group 0250).
Service Brakes Chatter or Noisy Air in brake system See Bleeding Brakes. (Go to Group 9020
9020-20. 15
17
Wrong oil in rear axle See Transmission, Axles and

Mechanical Front Wheel Drive Oil.
(Go to operator’s manual).
Disks worn excessively Disassemble, inspect and repair.

Group 0250).
Brake Valve leakage See Brake Valve Leakage Test. (Go

to Group 9020-25). Repair.
Park Brake Will Not Hold Worn parts See Disassemble and Assemble
Park Brake.( Go to Repair Manual,
Group 0250).
Park brake piston stuck See Park Brake Release Pressure

Test. (Go to Group 9020-25).
Park brake manually released See System Pressure Test. and See
Park Brake Release Pressure Test.
(Go to Group 9020-25)
Park brake solenoid plugged See Park Brake Solenoid Check.

(Go to Group 9015-15). Repair.

031504
PN=379
Park Brake Will Not Release Park brake hose leaking Inspect and repair all leaks.
Low hydraulic pressure oil to park Do See Park Brake Release

brake Pressure Test. (Go to Group
9020-25)
Park Brake Solenoid not working See Park Brake Solenoid Check.
Park brake piston stuck See Disassemble and Assemble

Park Brake. (Go to Group 0250).
Park Brake piston seals leaking Do See Park Brake Release

9020-25). See Disassemble and
Assemble Park Brake. (Go to Group
0250).
9020
15
18
TX,15,MA18 –19–28JAN00–5/5

031504
PN=380
Hydraulic Circuit Symbols
9020
15
19
–19–28SEP89
TS700
TX,9020,SS3253 –19–30AUG96–1/1

031504
PN=381
9020
15
20

031504
PN=382
Group 20
Adjustments
Release Park Brake for Towing
IMPORTANT: Engine cannot be started by towing.

Damage to transmission may result. DO
NOT tow machine faster than 10 km/h
(6.21 mph) or any longer than 1 hour.
–UN–02DEC96
Towing IS NOT recommended. If you MUST tow machine,
use the following procedure:
T105300
1. Turn engine off.
Access Plate Removed

CAUTION: Prevent possible injury or death from
unexpected machine movement. Block wheels
to prevent machine movement before
disengaging park brake.
2. Block tires
3. If your machine is equipped with mechanical front

wheel drive (MFWD), remove the front axle drive shaft.
9020
20
4. Move FNR and gear shift levers to neutral. 1
CAUTION: Prevent possible injury or death from

unexpected machine movement. Only release
the park brake through the access hole in floor
of operator’s station
5. Remove access plate in floor of operator’s station.
Continued on next page TX03543,0000920 –19–01NOV00–1/2

031504
PN=383
Adjustments
IMPORTANT: To avoid damage to park brake

assembly from heat build-up, brake
must be manually disengaged.
6. Release park brake for tow by turning cap screws (A)

completely in. Loosen hex nuts (B) to adjust park brake
–UN–17DEC96
screws (A).
7. Remove blocks from tires.
T102654
8. When towing is completed, enable park brake to hold
machine by turning both cap screws out to
specification (C) as illustrated.
Specification
Cap Screw—Position from
Housing ......................................................... 27 + 1 mm (1.06 + 0.04 in.)
Lock cap screws with hex nuts (B).
–UN–10SEP96
9. Close access plate when complete.
9020
20
T102655
2
TX03543,0000920 –19–01NOV00–2/2
Adjust Brake Pedals
SPECIFICATIONS
Brake Valve Piston-to-Pedal 0.127—0.381 mm (.005—.015 in.)
Clearance
Jam Nut Torque 37 +7 -18 N.m (27 + 5 - 13 lb-ft)
Continued on next page TX03543,0000914 –19–31OCT00–1/2

031504
PN=384
Adjustments
1. Adjust left and right brake pedal cap screws (A and B)

to provide clearance between brake pedal and piston
in the released position.
Specification
Brake Valve Piston-to-Pedal—
–UN–30OCT90
Clearance ................................................. 0.127—0.381 mm (.005—.015
in.)
2. Hold cap screw and tighten jam nut to specification.
T7407AS
Specification
Jam Nut—Torque ................................... 37 +7 -18 N.m (27 + 5 - 13 lb-ft)
A—Left Brake Pedal Cap Screw (Stop)

B—Right Brake Pedal Cap Screw (Stop)
TX03543,0000914 –19–31OCT00–2/2
9020
20
3

031504
PN=385
Adjustments
Bleeding Brakes
SPECIFICATIONS
Brake Pedal Travel Firm within 133 mm (5.25 in.)
after 10 second wait cycle
–UN–26OCT88
NOTE: Air will "gravity bleed" from brake system through
brake valve without use of bleed screws. Brake
lines must be inclined toward brake valve.
T6838AE
Low ambient temperature or aeration of oil will
slow bleed process.
This procedure will require two technicians.
1. Leave ON park brake. Bleed brakes one pedal at a

time.
2. Run engine at 1500 rpm and cycle a hydraulic function

such as backhoe bucket.
9020
20 Specification
4 Engine—Speed ........................................................................... 1500 rpm
3. Open service brake bleed screws on rear axle.
4. Pump the brake pedal slowly until air free oil comes
out of service brakes rear axle bleed screws.
5. Close bleed screw.
6. Release brake pedal completely and wait a minimum

of 10 seconds.
CAUTION: Do not operate machine if pedal

travel exceeds 133 mm (5.25 in.) while applying
267 N (60 lb) force. Operating machine with
excessive brake travel could cause brakes not
to stop machine on first application.
7. Repeat step 4 through 5 until a firm pedal is obtained

within 133 mm (5.25 in.) of pedal travel after a 10
second wait cycle.
Specification
Brake Pedal—Travel ................................... Firm within 133 mm (5.25 in.)
after 10 second wait cycle

031504
PN=386
Adjustments
8. As brakes continue to self-bleed, pedal firmness should

improve.
9. If unable to obtain firm brake pedal, inspect lines and

connections for leakage. If no external leaks, test axle.
Do See Service Brake Leakage Test (Go to Group
9020-25. See repair manual.
TX,20,SS3172 –19–25JUN98–2/2
Tracking Angle Check and Adjust
1. Center steering cylinder so dimension (1) is equal on

both sides.
2. Locate center of tie rod end (5).
–UN–21APR03
9020
3. Adjust tie rod length so dimension (2) is equal on both
20
sides of steering cylinder. 5
T189644
4. Adjust toe-in. Perform Toe-In Check and Adjust.
(Group 9020-20.)
1—Steering Cylinder Rod Dimension

2—Tie Rod Dimension
3—Tie Rod Inner Ball Joint
4—Jam Nut
5—Tie Rod End Ball Joint
BT40170,0000054 –19–17APR03–1/1
Toe-In Check and Adjust

SPECIFICATIONS
Non-Powered Axle (S.N. — 3—9 mm
911131) Toe-In Distance 0.13—0.35 in.
Non-Powered Axle (S.N. 3—6 mm
911132— ) and MFWD Axle 0.13—0.25 in.
Toe-In Distance
Tie Rod Clamp Cap Screws 81—109 N•m
Torque 60—80 lb-ft
Tie Rod Jam Nut Torque 120 N•m
89 lb-ft
Tie Rod Clamping Nut Torque 50 N•m
35 lb-ft
Perform Tracking Angle Check and Adjust procedure in

this group before checking and adjusting axle toe-in.
Continued on next page BT40170,0000053 –19–17APR03–1/4

031504
PN=387
Adjustments
1. Measure distance from ground to center of both hubs

(A). Mark front (B) and rear (C) of each front tire in
center of tread.
2. Measure distance between front marks (B) and rear

marks (C).
–UN–02NOV88
3. Front marks must be closer than rear marks within
specification.
T6382JW
Toe-In Measurement—Specification
Non-Powered Axle (S.N. —
911131)—Distance ....................................................................... 3—9 mm
Toe-In Measurement
0.13—0.35 in.
Non-Powered Axle (S.N. A—Center of Hub
911132— ) and MFWD Axle— B—Front of Tire
Distance ........................................................................................ 3—6 mm C—Rear of Tire
0.13—0.25 in. D—Tie Rod Tube
BT40170,0000053 –19–17APR03–2/4
9020
20 Non-Powered Axle (S.N. —911131)
6
1. To adjust toe-in, loosen both tie rod clamps (1) and
turn tie rod adjustment tube (2).
2. Turn clamps so cap screws face rear of machine and
–UN–14MAR03
are tipped down approximately 45°.
3. Tighten clamp cap screws to specification.
T188521B
Specification
Tie Rod Clamp Cap Screws—
Torque ................................................................................. 81—109 N•m
60—80 lb-ft
1—Clamp (2 used)
2—Tie Rod Tube

031504
PN=388
Adjustments
Non-Powered Axle (S.N. 911132— ) and MFWD Axle
1. Loosen nuts (2) or clamps (3).
NOTE: Adjust toe-in equally on both tie rods.
–UN–14MAR03
2. Turn threaded rod (1) to adjust toe-in to specification.
3. Tighten jam nut or clamping nut to specification.
T188523B
Specification
Tie Rod Jam Nut—Torque ........................................................... 120 N•m
89 lb-ft Non-Powered (S.N. 911132— ) and MFWD With Jam Nut
Tie Rod Clamping Nut—Torque ..................................................... 50 N•m
35 lb-ft
IMPORTANT: If tracking angle and toe-in adjustment

procedures are performed on MFWD
axle, maximum steering angle stop
screws must be adjusted.
–UN–14MAR03
See Steering Angle Check and Adjust in this group.
9020
20
1—Threaded Rod (2 used) 7
T188527B
2—Jam Nut (2 used)
3—Tie Rod Clamp (2 used)
MFWD With Clamping Nut
BT40170,0000053 –19–17APR03–4/4
Steering Angle Check and Adjust

SPECIFICATIONS
Maximum Steering Angle Stop 32—34 mm
Screw Distance 1.26—1.34 in.
Maximum Steering Angle Stop 150 N•m
Screw Jam Nut Torque 110 lb-ft
This procedure is only used on MFWD axle. Non-powered

axle is not adjustable.
Perform Tracking Angle Check and Adjust procedure in

this group before checking and adjusting steering angle.
1. Measure dimension as shown.

031504
PN=389
Adjustments
2. Loosen jam nut (2) and adjust steering angle stop

screw (1) to specification.
Specification
Maximum Steering Angle Stop
Screw—Distance ...................................................................... 32—34 mm
–UN–16APR03
1.26—1.34 in.
3. Tighten jam nut to specification.
T189693B
Specification
Maximum Steering Angle Stop
Screw Jam Nut—Torque .............................................................. 150 N•m
110 lb-ft
1—Cap Screw
2—Jam Nut
BT40170,0000052 –19–17APR03–2/2
9020
20
8

031504
PN=390
Group 25
Tests
Installation
Tachometer
–UN–28FEB89
T6813AG
TX,25,SS3151 –19–17JUN96–1/1
9020
JT05800 Digital Thermometer Installation 25
1
B—Cable
–UN–28FEB89
NOTE: Cooler In and Cooler Out lines can be switched
depending on installation.
T6808CE
For transmission testing, run machine for two minutes.
Use a temperature probe and determine which line is the
hottest and install temperature probe on metal part of line
for cooler IN or feel both cooler hoses and start machine,
whichever one pressurizes first is cooler inlet. On Torque
Converter Stall, Converter-In Relief Pressure Test, and
Cooler In and Out Pressure Test, install digital
thermometer probe into sump using dipstick tube.
TX,25,SS3152 –19–23JUN98–1/1

031504
PN=391
Tests
Transmission Oil Warm-Up Procedure
SPECIFICATIONS
Engine Speed Slow Idle (900 + 25 - 0 rpm) and
Fast Idle (2375 + 25 - 0 rpm)
–UN–07JAN91
IMPORTANT: On power shift transmissions ONLY,
never operate machine equipped with
MFWD with front wheels (axle) on the
T7446AF
occur.
NOTE: Have test equipment installed before warm-up.

Cooling system is highly efficient and may require
blocking air flow around the transmission cooling
system to control temperature.
1. Raise machine off ground using loader and stabilizers.
9020 2. Put transmission in third gear (A) for manual shift or

25 move lever (B) to 3rd speed for power shift. Park brake
2
OFF.
IMPORTANT: Do not stall converter for longer than 20

seconds or serious converter damage
could result.
3. Cycle from slow idle (900 + 25 - 0 rpm) to fast idle

(2375 + 25 - 0 rpm) with service brakes engaged.
Approximately 10 seconds in high idle and 5 seconds
in low idle until desired temperature is reached.
Specification
Engine—Speed ..................................... Slow Idle (900 + 25 - 0 rpm) and
Fast Idle (2375 + 25 - 0 rpm)
NOTE: To cool machine, shift to neutral and run at fast

idle. Temperature should drop approximately 1°
every 5 seconds.
CED,TX03399,4231 –19–09DEC99–1/1

031504
PN=392
Tests
Power Shift Transmission Overall Test Connections, Ports, and Locations
9020
25
3
–19–18MAY98
T113993
A—Differential Lock Solenoid H—Filter P—System Pressure Test Port U—Reverse Clutch Pressure
B—Park Brake Pressure Port I—Transmission Pump Q—Third Speed Clutch Test Port
C—Differential Lock Pressure J—MFWD Solenoid Pressure Test Port V—Reducing Valve Pressure
Port K—MFWD Test Port R—Second Speed Clutch Test Port
D—Transmission Control L—Park Brake Solenoid Pressure Test Port W—Output Flange to Rear
Valve M—Low Range Forward Clutch S—First Speed Clutch Axle
E—Transmission Speed Shift Pressure Test Port Pressure Test Port X—Rear of Transmission
Valve N—Converter-In Relief Valve T—High Range Forward Clutch Y—Control Valve
F—Oil Drain Pressure Port Pressure Test Port Z—Speed Shift Valve
G—Model Identification Plate O—Modulation Valve Pressure
Test Port
CED,TX03399,4230 –19–08MAY98–1/1

031504
PN=393
Tests
Torque Converter Stall Speed Test
SPECIFICATIONS 5. Apply and hold service brakes during test.

Transmission/Hydraulic Oil 65 ± 5°C (150 ± 10°F)
Temperature 6. Cycle from low idle to high idle with service brakes
Engine Speed High idle engaged. The highest stabilized speed measured is
Torque Converter Stall Speed 1900—2050 rpm converter stall speed.
Combined Torque 1250—1550 rpm
Converter/Hydraulic Engine Specification
Stall Speed Engine—Speed ....................................................... Low and High idle
Torque Converter—Stall Speed ............................... 1900—2050 rpm

IMPORTANT: Minimum engine speed listed is for
Electronic Tachometer an engine that is broken-in and
Digital Thermometer using No. 2 fuel.
NOTE: Before doing either of the following NOTE: Combined stall is done by stalling torque
procedures, See Pump Load Sense Differential converter, holding loader bucket dump over
Pressure Test and See Loader and Backhoe relief and raising loader boom at the same
Load Sense Relief Tests, must be performed time.
and adjustments made as needed. See Group
9025-25. NOTE: Specifications of combined stall are nominal
9020
25 for machines that have not been altered to
4 1. Torque Converter Stall: See JTO5801 Clamp-On bias the hydraulic system toward increased
Electronic Tachometer Installation. (See procedure backhoe performance.
in this group.)
7. Combined Torque Converter Stall: Stall converter
2. Install digital thermometer probe into the as described above and hold loader bucket dump
transmission and hydraulic sump through the over relief, raise loader boom at the same time.
dipstick tube.
Specification
Transmission/Hydraulic Oil—
3. Heat oil to specifications.
Temperature .................................................... 65 ± 5°C (150 ± 10°F)
Specification
Transmission/Hydraulic Oil— Observe tachometer reading while boom is raising.
Temperature .................................................... 65 ± 5°C (150 ± 10°F)
Specification
See See Transmission Oil Warm-Up Procedure. (Go Combined Torque
Converter/Hydraulic Engine—
to Group 9020) See Hydraulic Oil Warm-Up Stall Speed ............................................................... 1250—1550 rpm
Procedure. (Go to Group 9025-25).
8. If converter stall speed is low, check for:
IMPORTANT: Converter should NOT be stalled
longer than 20 seconds or serious • See Turbocharger Boost Pressure—Engine
converter damage may result. Return Performance Test. See Group 9010-25.
FNR lever to neutral position for 10 • Incorrect torque converter. Check part number
seconds before doing next stall test. through inspection hole in bottom of transmission
housing, number should be either 247002 or
4. With machine off the ground, put transmission in 4168-028-211.
third gear. • Failed freewheel clutch in torque converter.

031504
PN=394
Tests
9. If converter stall speed is too high, check for: housing, number should be either 247002 or
4168-028-211.
• Incorrect oil temperature. • See Turbocharger Boost Pressure—Engine
• Low oil level. Performance Test. See Group 9010-25.
• Incorrect oil in machine. • Converter failed.
• Restricted suction screen. See repair manual. • Failed transmission clutch pack.
• Incorrect torque converter. Check part number • Low system (pump) pressure in transmission.
through inspection hole in bottom of transmission
TX,25,SS3154 –19–22JUL98–2/2
9020
25
5

031504
PN=395
Tests
Converter-In Relief Valve Test
SPECIFICATIONS
Oil Temperature at Sump 65 ± 5°C (150 ± 10°F)
Converter-in Relief Valve 800 + 200 kPa (8 + 2 bar) (116 +
Pressure (SN —895368 29 psi)
Converter-in Relief Valve 900—1150 kPa (9 — 11.5 bar)
Pressure (SN 895369—) (130—167 psi)
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler

Gauge 0—2000 kPa (0—20 bar) (0—300 psi)
1. Remove floor panel in cab or ROPS.
2. Install adapter and gauge in port (A).
–UN–12JUL96
9020 3. Install digital thermometer probe into sump using
25 dipstick tube. See Transmission Oil Warm-Up
6 Procedure.. (Go to Group 9025).
T101750
Specification
Oil—Temperature at Sump .................................... 65 ± 5°C (150 ± 10°F)
4. Put FNR lever in neutral.
IMPORTANT: DO NOT exceed 1000 kPa (10 bar) (145

psi) or converter damage could result.
5. Slowly increase rpm until maximum pressure is

reached on gauge.
Specification
Engine—Speed .................................................................... 2375 + 25 - 0
Converter-In Relief Valve (SN —
895368)—Pressure............................... 800 + 200 kPa (8 + 2 bar) (116 +
29 psi)
Converter-In Relief Valve (SN
895369—)—Pressure ............................... 900—1150 kPa (9 — 11.5 bar)
(130—167 psi)
6. If maximum pressure is reached at low idle, check for

a plugged cooler. Back flush using an oil caddy or
replace cooler.
Continued on next page TX,25,SS3155 –19–17APR01–1/2

031504
PN=396
Tests
7. If pressure is too high, remove relief valve.

Disassemble, clean and inspect valve.
8. If pressure is low, check for weak or broken spring and

scored or sticking valve.
9. Install and check relief valve after repair.
TX,25,SS3155 –19–17APR01–2/2
9020
25
7

031504
PN=397
Tests
Brake Valve Leakage Test
SPECIFICATIONS
Brake Valve Leakage Pressure drops more than 100
psi in 30 seconds with brake
pedal applied
Brake Pedals Released Pressure 0
ESSENTIAL TOOLS
A—JT03455 (7/16 M JIC x —4 F ORFS) Fitting
B—38H1029 (—4 M x —4 F x —4 M ORFS) (Parker No. 4R6LO-S)
Tee
38H1352 (—4 ORFS) Nut (2 Used)
38H1138 (—4 ORFS) Plug (2 Used)

(C) Gauge 0—6895 kPa (0—69 bar) (0—1000 psi)
1. Heat oil. See Hydraulic Oil Warm-up in Group 9025-25.
–UN–19SEP96
9020 2. Stop engine.
25
8 3. Push left and right brake pedal individually. If either
pedal settles, leakage is indicated in final drive brake
T102934
piston or brake valve reservoir.
4. Disconnect brake line and clamp. Tee gauge (C) at

A—Fitting
brake valve line of pedal that settled.
B—Tee
C—Gauge
5. Push brake pedal down and block in place to set
gauge at 500 psi starting point.
6. Monitor gauge. If pressure drops more than 100 psi in

30 seconds, excessive leakage is indicated.
Specification
Brake Valve—Leakage .............................. Pressure drops more than 100
psi in 30 seconds with brake
pedal applied
NOTE: When pedals are release pressure should be

zero.
7. To isolate leakage, disconnect line going to axle.
Specification
Brake Pedals Released—
Pressure ................................................................................................... 0

031504
PN=398
Tests
8. If leakage continues, replace check valve.
9. No pressure drop indicates leakage at piston seals in

axle housing. See Repair, Group 0250.
TX,25,SS3156 –19–15MAY98–2/2
9020
25
9

031504
PN=399
Tests
Park Brake Release Pressure Test
SPECIFICATIONS
Oil Temperature 65 ± 5°C (150 ± 10°F)
Engine Speed 1500 ± 25 rpm
Park Brake Release Pressure 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
Park Brake Applied Pressure 0
ESSENTIAL TOOLS
D—38H1032 (—10 M x —10 F x —10 M ORFS) (Parker No.
10R6IO-S) Tee
B—JT03458 (7/16 —20 M JIC x 1-14 F ORFS —10) Adapter
A—PD34BTX Quick Coupler

Digital Thermometer
Gauge 0—3500 kPa (0—35 bar) (0—500 psi)
–UN–06AUG96
9020
25
10
2. Install See JT05801 Clamp-On Electronic Tachometer
T101901
Installation. and See JT05800 Digital Thermometer
Installation. (Go to Group 9010). (See procedures in
this group.)
A—Quick Coupler
B—Adapter
3. Make test connections. C—Park Brake-to-Transmission Line
D—Tee
Specification
Oil—Temperature ................................................... 65 ± 5°C (150 ± 10°F)
See Transmission Oil Warm-Up Procedure (Go to Group

9020).
5. Increase rpm to specification and record pressure

reading with park brake OFF, FNR in neutral , MFWD
engaged (if equipped) and differential lock disengaged.
Specification
Engine—Speed .................................................................. 1500 ± 25 rpm
Park Brake—Release Pressure .......... 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
With park brake switch ON pressure should be zero.

031504
PN=400
Tests
Specification
Park Brake Applied—Pressure ................................................................ 0
6. If park brake pressure is not to specification, do See

System Pressure Test. (Go to Group 9020-25.) If
system pressure is OK, but park brake pressure is low,
it indicates leakage in park brake circuit. Check axle oil
level. If oil level is high park brake piston seals may be
leaking. If axle oil level is OK, but park brake pressure
is low, leakage is indicated in transmission control
valve, park brake solenoid or gasket.
TX,25,SS3157 –19–22JUL98–2/2
9020
25
11

031504
PN=401
Tests
System Pressure Test
SPECIFICATIONS
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

Digital Thermometer
Gauge 0—3500 kPa (0—35 bar) (0—500 psi)

–UN–12JUL96
9020 Installation. see procedures in this group.
25
12
T101892
3. Make test connections in port (A).
Specification
See Transmission Oil Warm-up Procedure. (Go to Group

9020).
5. With FNR lever in neutral and gear shift lever (manual

shift) in neutral. Operate machine to specifications and
record pressure.
Specification
Engine—Speed .................................................................. 1500 ± 25 rpm
System—Pressure ............................... 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
6. If pressure is too low, run test at 80° C (176° F) if

pressure is still low check pressure regulating valve,
repair or shim adjust. A 1.00 mm (0.039 in.) shim is
equal to 115 kPa (1.15 bar) (16.68 psi) (see See
Reducing Valve Pressure Test. (Go to Group 9025-25).

031504
PN=402
Tests
Specification
Each 1.00 mm (0.039 in.) Shim
Changes—Pressure .................................. 115 kPa (1.15 bar) (16.68 psi)
If adjustment does not raise pressure, do See

Transmission Pump Flow Test. (Go to Group 9025-25).
7. If pressure is too high redo test using 80° C (176° F)

temperature. If pressure is still to high check pressure
regulating valve, repair or shim adjust.
Specification
Changes—Pressure .................................. 115 kPa (1.15 bar) (16.68 psi)
Make sure test was performed at correct specifications.
CED,TX03399,4265 –19–22JUL98–2/2
9020
25
13

031504
PN=403
Tests
Power Shift Low Range Forward, High Range

Pressure Test
SPECIFICATIONS
Forward or Reverse Pressure 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Neutral Disconnect De-Activated 0
Pressure
ESSENTIAL TOOLS

Digital Thermometer
Gauge 0—3500 kPa (0—35 bar) (0—500 psi)
–UN–21MAY98
9020
25
14 Installation. and See JT05800 Digital Thermometer
T115471
3. Make test connection in appropriate port (A, B, C, D, E A—Low Range Forward Clutch Pressure Test Port
B—Reverse Clutch Pressure Test Port
or F).
C—High Range Forward Clutch Pressure Test
Port
4. Heat oil to specifications. D—First Speed Clutch Pressure Test Port
E—Second Speed Clutch Pressure Test Port
Specification F—Third Speed Clutch Pressure Test Port
(See See Transmission Oil Warm-up Procedure. (Go to

Group 9025.)
NOTE: All clutch pressures should be the same.
5. Machine off ground. Engine speed at specifications

and park brake OFF and FNR lever in forward or
reverse, record pressure in all speed ranges.
Specification
Engine—Speed .................................................................. 1500 ± 25 rpm
Forward or Reverse—Pressure........... 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Continued on next page CED,TX03399,4233 –19–15MAY98–1/2

031504
PN=404
Tests
6. Low pressure in one direction indicates a leakage in

that pack or solenoid. Low pressure in both directions
indicates a leakage in the speed clutch or low system
pressure. (Do See System Pressure Test. (Go to
Group 9025-25.)
7. With FNR lever in neutral, a slight pressure recorded in

either the forward or reverse test port could indicate
that the ball in the clutch shaft came out (lube
passage) or a problem in control valve. See Remove
Low Range Forward, Reverse and Third Speed Clutch
Packs—Powershift (Go to Group 0350). See See
Remove and Install Control Valve—Powershift (Go to
Group 0360).
8. With FNR lever in neutral, pressure recorded in the

speed clutch test ports could indicate a problem with
the time delay relay. See Park Brake/FNR Circuit
Schematic. (Go to Group 9015-15).
NOTE: When neutral disconnect is de-activated, pressure

should be zero. 9020
25
Specification 15
Neutral Disconnect
De-Activated—Pressure ........................................................................... 0
CED,TX03399,4233 –19–15MAY98–2/2

031504
PN=405
Tests
Reducing Valve Pressure Test
SPECIFICATIONS
Reducing Valve Pressure 850—1050 kPa (8.5—10.5 bar)
(123—152 psi)
ESSENTIAL TOOLS

Digital Thermometer
Gauge 0—2000 kPa (0—20 bar) (0—300 psi)

Installation., see procedure in this group
–UN–22AUG96
9020 2. Remove floor panel in cab or ROPS.
25
16
T101897
Specification
See See Transmission Oil Warm-up Procedure. (Go to

Group 9025).
5. With FNR lever in neutral and gear shift lever (manual

shift) in neutral. Operate machine to specifications and
record pressure.
Specification
Engine—Speed .................................................................. 1500 ± 25 rpm
Reducing Valve—Pressure ...................... 850—1050 kPa (8.5—10.5 bar)
(123—152 psi)
6. If reducing valve pressure is not to specification do

See System Pressure Test (Go to Group 9025-25). If
system pressure is OK, but reducing valve pressure is
low, it indicates a leak in the circuit. See Remove and
Install Control Valve—Powershift. (Go to Repair Group
0360).

031504
PN=406
Tests
7. If pressure is too high check reducing valve for sticky

spool or binding. See Remove and Install Control
Valve—Powershift. (Go to Group 0360). Make sure test
was performed at correct specifications.
CED,TX03399,4266 –19–22JUL98–2/2
9020
25
17

031504
PN=407
Tests
Modulation Valve Pressure Test
SPECIFICATIONS
Neutral Pressure 270—300 kPa (2.7—3 bar) (39—
44 psi)
System Modulated (Final) 1600 + 300 kPa (16 + 3 bar) (232
Pressure + 44 psi)
Modulation Phase Pressure 300—1200 kPa (3—12 bar) (44—
174 psi)
Modulation Valve Pressure Test Neutral into gear 0—1600 kPa
Shift Time (0—16 bar) (0—232 psi) in 2
seconds and from
Forward/Reverse or
Reverse/Forward into a gear 1.7
seconds Maximum
Each 1.00 mm (0.039 in.) Shim 42 kPa (0.42 bar) (6.09 psi)
Changes Pressure
–UN–12JUL96
9020 ESSENTIAL TOOLS
25 AT202955 (Parker No. PD357) Diagnostic Coupler (Power Shift Only)
18
Parker No. 4M10C80MX (7/16-20 37° x M10 x 1) Elbow (Manual Shift
T101898
Only)
Parker No. PD34BTX Diagnostic Coupler (Manual Shift Only)

Digital Thermometer
Gauge 0—3500 kPa (0—35 bar) (0—500 psi)

Installation.. (See procedure in this group.)
Specification
(See See Transmission Oil Warm-Up Procedure. (Go to

Group 9025.)
Continued on next page TX,25,SS3170 –19–14OCT03–1/2

031504
PN=408
Tests
5. FNR lever in neutral, record pressure reading.
Specification
Engine—Speed .................................................................. 1500 ± 25 rpm
Neutral—Pressure ......................................... 270—300 kPa (2.7—3 bar)
(39—44 psi)
NOTE: Forward and reverse pressures should be the

same.
6. Machine off the ground. FNR lever in forward or

reverse, record pressure gauge readings.
Specification
Engine—Speed .................................................................. 1500 ± 25 rpm
System Modulated (Final)—
Pressure .............................................. 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Modulation Phase—Pressure ......................... 300—1200 kPa (3—12 bar)
(44—174 psi)
7. If total shift time from 0—1600 kPa (0—16 bar) (0—

232 psi) takes more than specifications while doing this
test, it indicates a problem in the modulation valve. 9020
25
19
Specification
Modulation Valve Pressure
Test—Shift Time ........................................ Neutral into gear 0—1600 kPa
(0—16 bar) (0—232 psi) in 2
seconds and from
Forward/Reverse or
Reverse/Forward into a gear 1.7
seconds Maximum
8. If shift is slow (long modulation time only), and neutral

pressure is between 270—300 kPa (2.7—3 bar) (39—
44 psi) orifice in modulation circuit is restricted. If shift
is hard or neutral pressure is high, orifice is oversized,
loose or missing. If shift is long (hesitation or long fill
time) or neutral pressure is low, spring is weak, orifice
is plugged. A shim 1 mm (0.039 in.) is equal to 42 kPa
(0.42 bar) (6.09 psi), see repair manual for See
Disassemble and Assemble Control Valve—Powershift.
if modulation shift is not acceptable. (Go to Group
0360). Clean orifice.
Specification
Changes—Pressure ...................................... 42 kPa (0.42 bar) (6.09 psi)
TX,25,SS3170 –19–14OCT03–2/2

031504
PN=409
Tests
Differential Lock Pressure Test
SPECIFICATIONS
Differential Lock Pressure 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
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

Digital Thermometer
Gauge 0—3500 kPa (0—35 bar) (0—500 psi)
–UN–16JUL96
9020
25
20
T101983
3. Make test connections.
4. Heat oil to specifications. A—Tee

B—Quick Coupler
C—Adapter
Specification
D—Transmission-to-Differential Lock Rear Axle
Hose

Group 9025.)
5. MFWD and park brake engaged.
6. Increase rpm to specification and record pressure

reading with differential lock pedal switch pressed
down.
Specification
Engine—Speed .................................................................. 1500 ± 25 rpm
Differential Lock—Pressure ................. 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)

031504
PN=410
Tests
NOTE: When differential lock pedal switch is released

pressure should be zero.
7. If differential pressure is not to specification, do See

System Pressure Test (Go to Group 9025). If system
pressure is OK, but differential lock pressure is low, it
indicates a leak in the circuit. See Remove and Install
Rear Axle.(Go to Group 0250).
Check axle oil level. See Section 9000. Group 4. If oil

level is high, seals may be leaking. If axle oil level is
OK, but differential lock pressure is low leakage is
indicated in transmission control valve, differential lock
solenoid or gasket.
TX,25,SS3165 –19–22JUL98–2/2
9020
25
21

031504
PN=411
Tests
MFWD Pressure Test—If Equipped
SPECIFICATIONS
MFWD Pressure 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
ESSENTIAL TOOLS
(M10 x 1.0 ORB) (Parker No. PD357) Quick Coupler

Digital Thermometer
Gauge 0—3500 kPa (0—35 bar) (0—500 psi)

–UN–12JUL96
9020 2. Remove floor panel in cab or ROPS.
25
22
T101916
Specification
(See See Transmission Oil Warm-Up Procedure.
5. Increase rpm to specifications and record pressure

reading with MFWD switch OFF, park brake engaged
and differential lock disengaged.
Specification
Engine—Speed ........................................................................... 1500 rpm
MFWD—Pressure................................ 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
NOTE: When MFWD switch is ON pressure should be

zero.
6. If pressure is low, check See System Pressure Test

(Go to Group 9020). If low, leakage in MFWD circuit is
indicated . Possible locations include the delivery tube
(inside case), the MFWD piston seal, the transmission
control valve gasket, or the MFWD solenoid.
TX,25,SS3166 –19–28JAN00–1/1

031504
PN=412
Tests
Cooler In and Cooler Out Pressure Test
SPECIFICATIONS
Oil Temperature at Sump 65 ± 5° C (150 ± 10° F)
Standard Cooler
Standard Cooler-Cooler In 317 ± 35 kPa (3.17 ± 0.35 bar)
Pressure (39 ± 5 psi)
Standard Cooler-Cooler Out 152 ± 35 kPa (1.52 ± 0.35 bar)
Standard Cooler-Normal Cooler 165 ± 35 kPa (1.65 ± 0.35 bar)
Pressure Difference (Drop) (15 ± 5 psi)
Standard Cooler-Normal Cooler 30 L/min (8 gpm)
Flow
Standard Cooler-Minimum Cooler 23 L/min (6 gpm)
Flow
High Ambient Cooler
High Ambient Cooler-Cooler In 207 ± 35 kPa (2.07 ± 0.35 bar)
–19–02JUN98
High Ambient Cooler-Cooler Out 124 ± 35 kPa (1.24 ± 0.35 bar)
9020
High Ambient Cooler-Normal 83 ± 35 kPa (0.83 ± 0.35 bar) (12 25
Cooler Pressure Difference ± 5 psi) 23
T115564
(Drop)
High Ambient Cooler-Normal 34 L/min (9 gpm)
Cooler Flow High Ambient Cooler
High Ambient-Minimum Cooler 23 L/min (6 gpm)
Flow
ESSENTIAL TOOLS
(1/2 M NPT x 3/4) (C) Barb Fitting (4 Used)
(1/2 M NPT x 1/2 F NPT) (D) Elbow 90°
XPD343 (F) Quick Coupler
JT03105 (1/2 M NPT x 1/4 F NPT) (G) Connector
JT03348 (1/2 F NPT x 1/2 F NPT x 1/2 F NPT) (H) Tee

Digital Thermometer
Gauge 0—2000 kPa (0—20 bar) (0—300 psi) (2 Used)
(E) Flowmeter
(A) Hose Piece 3/4 in., cut to length required
(B) Hose Piece 3/4 in., cut to length required
–UN–02JUN98
T115565
Standard Cooler

031504
PN=413
Tests
NOTE: High ambient cooler shown with test connections.

Same test connections are also used for the
standard cooler. Make test connection to standard
cooler at location key (I).

Installation., (Go to Group 9010-20).
2. Install digital thermometer probe into sump using

dipstick tube.
3. Make test connections to high ambient cooler or

standard cooler.
Specification
Oil—Temperature at Sump .................................. 65 ± 5° C (150 ± 10° F)
See See Transmission Oil Warm-Up Procedure. (Go to

Group 9020).
9020
25 5. With FNR lever in neutral and gear shift lever (manual
24 shift only) in neutral. Operate machine to specifications
and record pressure and flow.
Specification
Engine—Speed .................................................................. 1500 ± 25 rpm
Standard Cooler—Specification
Standard Cooler-Cooler In—
Pressure ................................................... 317 ± 35 kPa (3.17 ± 0.35 bar)
(39 ± 5 psi)
Standard Cooler-Cooler Out—
Pressure ................................................... 152 ± 35 kPa (1.52 ± 0.35 bar)
(24 ± 5 psi)
Standard Cooler-Normal Cooler—
Pressure Difference (Drop) ...................... 165 ± 35 kPa (1.65 ± 0.35 bar)
(15 ± 5 psi)
Standard Cooler-Normal Cooler—
Flow ................................................................................ 30 L/min (8 gpm)
Standard Cooler-Minimum
Cooler—Flow .................................................................. 23 L/min (6 gpm)
High Ambient Cooler—Specification

High Ambient Cooler-Cooler In—
Pressure ................................................... 207 ± 35 kPa (2.07 ± 0.35 bar)
(30 ± 5 psi)
High Ambient Cooler-Cooler
Out—Pressure .......................................... 124 ± 35 kPa (1.24 ± 0.35 bar)
(18 ± 5 psi)

031504
PN=414
Tests
High Ambient Cooler-Normal

Cooler—Pressure Difference
(Drop).................................................... 83 ± 35 kPa (0.83 ± 0.35 bar) (12
± 5 psi)
High Ambient Cooler-Normal
Cooler—Flow .................................................................. 34 L/min (9 gpm)
High Ambient-Minimum Cooler—
Flow ................................................................................ 23 L/min (6 gpm)
6. If cooler restriction is high, inspect cooler hoses and

cooler for damage. If no damage found, clean cooler
using oil caddy.
7. If cooler pressures are low, see See Solenoid Circuit

Leakage Test. (Go to Group 9020).
8. Check cooler pressures in all shifts. If pressure is low,

FNR solenoid or pump problems are indicated. Pump
stop sleeve may be blocking flow to torque converter
or torque converter may be plugged. See Torque
Converter Stall (Go to Group 9020).
9020
25
25
TX03543,0000921 –19–02NOV00–3/3

031504
PN=415
Tests
Solenoid Circuit Leakage Test
NOTE: See Cooler In and Cooler Out Pressure Test. (Go

to Group 9020-25).in conjunction with this test.
SPECIFICATIONS
Oil Temperature at Sump 65° C (150° F )
If cooler pressures are low from the Cooler In and Cooler

Out Pressure Test do the following test.
1. Install test equipment, see See Cooler In and Cooler

Out Pressure Test.( Go to Group 9020).
2. See Transmission Oil Warm-Up Procedure. (Go to

Group 9020).
Specification
Oil—Temperature at Sump ............................................... 65° C (150° F )
9020 3. Machine off the ground. FNR lever in neutral and gear
25 shift lever (manual shift only) in neutral, operate
26
machine to specifications. Record pressures and flows
in forward, high range forward (power shift only)
reverse, neutral, speed clutches (power shift only),
MFWD, differential lock and park brake.
Specification
Engine—Speed ............................................................... 900 + 25 - 0 rpm
There should be a momentary fluctuation in pressure/flow

if circuit is normal. If pressure and cooler pressure in and
out and flow remains down, this indicates a leakage in
that circuit. See 9015-15 to See Solenoid Circuit Leakage
Test(Go to Group 9020)
CED,TX03399,4268 –19–22JUL98–1/1

031504
PN=416
Tests
9020
25
27

031504
PN=417
Tests
Pump Flow Test
SPECIFICATIONS
New Pump Flow 42 L/min (11.2 gpm)
Used Pump Flow 36 L/min (9.5 gpm)
ESSENTIAL TOOLS
A—JDG596 Filter Adapter
JDG596A1 Spacer and Sealing Washer Kit

B—Flowmeter
Digital Thermometer
–UN–07AUG96
IMPORTANT: On early machines use the washers and
spacer to make filter adapter fit. This
will keep filter from leaking. On later
9020
T102857
25 machines just use the filter adapter.
28
1. Make test connections. When installing filter adapter
use a washer on both sides of spacer on early
machines.

IMPORTANT: Before starting engine, check that

flowmeter loading valve is open. Pump
can be damaged if engine is started
with loading valve closed.
Specification

Group 9020).
4. Run engine at test specification.
Specification
Engine—Speed .................................................................. 1500 ± 25 rpm

031504
PN=418
Tests
Measure flow.
Specification
Pump—Flow .............................................................. 42 L/min (11.2 gpm)
5. Low transmission pump flow can be caused by:
• Low oil level in transmission

• Cold transmission oil
• Plugged intake tube
• Air leak in pump suction tube
• Pump mounting cap screws loose
• Worn transmission pump
TX,25,SS3207 –19–22JUL98–2/2
9020
25
29

031504
PN=419
Tests
9020
25
30

031504
PN=420
Section 9025
Hydraulic System
Contents
Page Page

Circuit Relief Valve with
Backhoe Hydraulic System . . . . . . . . . . . . . .9025-05-1
Anti-Cavitation—Loader and Backhoe . . .9025-05-65
Hydraulic Component Location . . . . . . . . . . .9025-05-2 Backhoe Auxiliary Flow Control Circuit
Hydraulic System Schematic . . . . . . . . . . . .9025-05-14 Relief Valve . . . . . . . . . . . . . . . . . . . . . . .9025-05-68
Load Sense Isolator . . . . . . . . . . . . . . . . . .9025-05-20 Backhoe Inlet Section with Swing Section
Load Sense With All Functions in Activated . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-70
Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-22 Backhoe Auxiliary Flow Valve—Solenoid
Load Sense With One Function Energized . . . . . . . . . . . . . . . . . . . . . . . .9025-05-74
Activated . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-24 Backhoe Swing Section—Swing Right
Load Sense With Multiple Functions Position . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-76
Activated . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-26 Backhoe Boom Section—Boom Raise
Load Sense With Multiple Functions Position (S.N. —913483) . . . . . . . . . . . . .9025-05-78
Activated (One Function Stalled) . . . . . . .9025-05-28 Backhoe Boom Section—Boom Raise
Hydraulic Pump—Neutral Operation . . . . . .9025-05-30 Position (Pilot Control) (S.N. 913484—
Hydraulic Pump—Full Stroke. . . . . . . . . . . .9025-05-31 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-80
Hydraulic Pump Controls—Neutral (S.N. Backhoe Bucket Section—Bucket Curl
—907932) . . . . . . . . . . . . . . . . . . . . . . . .9025-05-32 Position (S.N. —913483) . . . . . . . . . . . . .9025-05-82
Hydraulic Pump Controls—Neutral (S.N. Backhoe Crowd Section—Crowd In Position
907933— ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-34 (S.N. —913483). . . . . . . . . . . . . . . . . . . .9025-05-84 9025
Hydraulic Pump Controls—Function Metering Backhoe Auxiliary Section—Neutral . . . . . .9025-05-86
(S.N. —907932). . . . . . . . . . . . . . . . . . . .9025-05-36 Backhoe Valve End Cap . . . . . . . . . . . . . . .9025-05-88
Hydraulic Pump Controls—Function Pilot Control Valve Theory of Operation (S.N.
Metering (S.N. 907933—) . . . . . . . . . . . .9025-05-38 913484— ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-92
Hydraulic Pump Controls—Full Flow . . . . . .9025-05-40 Pilot Control Manifold Valve Operation (S.N.
Hydraulic Pump Controls—Flow Limited (High 913484— ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-94
Pressure) . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-42 Pattern Select Valve Operation (S.N.
Hydraulic Filter—Normal Operation . . . . . . .9025-05-44 913484— ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-95
Hydraulic Filter Operation—Restricted. . . . .9025-05-46 Loader Inlet Section with Bucket Section
Steering—No Steering. . . . . . . . . . . . . . . . .9025-05-48 Activated (S.N. —913479) . . . . . . . . . . . .9025-05-96
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-50 Loader Bucket Section—Bucket Rollback
Secondary Steering. . . . . . . . . . . . . . . . . . .9025-05-53 Position (S.N. —913479) . . . . . . . . . . . . .9025-05-98
Ride Control Hydraulic Component Loader Boom Section—Boom Raise Position
Location Circuit—Off (S.N. —911133) . . .9025-05-54 (S.N. —913479). . . . . . . . . . . . . . . . . . . 9025-05-100
Ride Control Hydraulic Circuit Component Loader Auxiliary Section—Load Position
Location and Valve Operation—On Position (S.N. — (S.N. —913479). . . . . . . . . . . . . . . . . . . 9025-05-102
Loader Valve Outlet Section (S.N. —
911132) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-56
913479) . . . . . . . . . . . . . . . . . . . . . . . . . 9025-05-104
Ride Control Hydraulic Circuit Component
Loader and Stabilizer Valve (S.N.
Location and Valve Operation (S.N. 911133—
913480— ). . . . . . . . . . . . . . . . . . . . . . . 9025-05-106
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-58
Loader Valve Steering Load Sense
Loader Valve Load Sense Relief (S.N. Isolator (S.N. 913480— ) . . . . . . . . . . . . 9025-05-109
913480— ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-60
Circuit Relief Valve without Anti-Cavitation Group 15—Diagnostic Information
and Load Sense Relief Valve—Loader Use These Seven Basic Steps to
and Backhoe (S.N. —913479) . . . . . . . . .9025-05-62 Diagnose and Test the Hydraulic
Circuit Relief Valve without Anti-Cavitation System . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-1
and Load Sense Relief—Loader and
Backhoe (S.N. 913480— ) . . . . . . . . . . . .9025-05-63 Continued on next page

031504
PN=1
Contents
Page Page
Hydraulic System Pretest . . . . . . . . . . . . . . .9025-15-2 Circuit Relief Valve Test With Remote
Diagnose Steering System Malfunctions . . . .9025-15-3 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-32
Diagnose Hydraulic System Problems. . . . . .9025-15-6 Charging the Ride Control Accumulator . . .9025-25-35
Ride Control Accumulator (If Equipped)
Group 20—Adjustments Discharge Procedure . . . . . . . . . . . . . . . .9025-25-37
Selective Flow Valve Adjustment. . . . . . . . . .9025-20-1 Steering System Leakage Test . . . . . . . . . .9025-25-38
Loader Lever and Stabilizer Lever Steering Cylinder Leakage Test . . . . . . . . .9025-25-41
Adjustment (S.N. 913480— ) . . . . . . . . . . .9025-20-2 Hydraulic Cylinder Drift Test Procedure. . . .9025-25-43
Backhoe Valve Linkage Adjustment . . . . . . .9025-20-7 Function Drift Test. . . . . . . . . . . . . . . . . . . .9025-25-44
Backhoe Valve Linkage Adjustment—Four Cylinder Leakage Test . . . . . . . . . . . . . . . .9025-25-47
Lever If Equipped . . . . . . . . . . . . . . . . . . .9025-20-9 Stabilizer Valve Lockout Leakage Test . . . .9025-25-48
Adjusting Loader Bucket Self-Leveling Cycle Time Specifications . . . . . . . . . . . . . .9025-25-49
Linkage and Return-to-Dig Switch (S.N. —
913479) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-11
Loader Bucket Self-Leveling Linkage and
Return-to-Dig Switch Adjustment (S.N. 913480—
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-14
Backhoe Valve Linkage Adjustment . . . . . .9025-20-19
Charging the Ride Control Accumulator . . .9025-20-21
Checking Ride Control Accumulator
Charge. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-24
Ride Control Accumulator (If Equipped)
Discharge Procedure . . . . . . . . . . . . . . . .9025-20-26
Pilot Control Pressure Adjustment (S.N.
9025
913484— ). . . . . . . . . . . . . . . . . . . . . . . .9025-20-27
Pilot Control Manifold Valve Accumulator
Discharge Procedure . . . . . . . . . . . . . . . .9025-20-28
Group 25—Tests
Pre-Test Diagnostics . . . . . . . . . . . . . . . . . . .9025-25-1
Diagnostics Flow Charts . . . . . . . . . . . . . . . .9025-25-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-9
Digital Pressure and Temperature Analyzer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-9
JT05800 Digital Thermometer
Installation . . . . . . . . . . . . . . . . . . . . . . . .9025-25-10
Hydraulic Oil Warm-Up Procedure. . . . . . . .9025-25-10
Pump Load Sense Differential Pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-11
Pump Flow Test . . . . . . . . . . . . . . . . . . . . .9025-25-16
Backhoe Load Sense and Loader Load
Sense Relief Stall Pressure Test . . . . . . .9025-25-18
Steering Load Sense Relief Valve Stall
Pressure Test (S.N.—911132) . . . . . . . . .9025-25-23
Steering Valve Pressure Test (S.N.
911133— ). . . . . . . . . . . . . . . . . . . . . . . .9025-25-26
Flow Limiter Test. . . . . . . . . . . . . . . . . . . . .9025-25-28
Pilot Control Pressure Test (S.N.
913484— ). . . . . . . . . . . . . . . . . . . . . . . .9025-25-30
Hydraulic Oil Cooler Restriction Test. . . . . .9025-25-31

031504
PN=2
Group 05
Theory of Operation
Backhoe Hydraulic System
The hydraulic system is a closed center, load sensing functions. The backhoe system pressure is regulated
system. A variable displacement, axial piston pump by a backhoe load sense relief valve (30) located in
(23) supplies oil for the hydraulic system. Flow from the inlet section of the backhoe stack. The loader
the pump is supplied to the inlet section of the system pressure is regulated by a loader load sense
backhoe control valve (2) and then is sent to the relief valve (25) in the loader valve inlet section. The
stabilizer valve (4). Pump supply oil is also routed from hydraulic system is protected from extreme oil
the backhoe inlet section to the loader control valve pressure by a system relief valve (3) located in the
(24) and also to the steering valve (14). The steering outlet section of the backhoe valve. Load sensing
valve will always receive pump supply oil through improves fuel economy and reduces heat build-up
steering pressure regulating valve (15). because horsepower is not wasted on excessive pump
flow that is not being used.
The pump will adjust to the highest work port pressure
sensed through the isolator valve (29) and then Return oil flows through the anti-cavitation function
through the load sense shuttle check valve (26). Pump check valve (10) into the filter (12) and then flows
pressure will be 275 psi higher than the highest through both the cooler flow check valve (11) and the
pressure sensed at anytime. cooler (18), and on to the reservoir. The return filter
uses a spin-on filter element which attaches to a filter
Specification housing. The return filter has a by-pass valve with a
Load Sense—Differential pressure switch to indicate when the filter is restricted.
Pressure................................................................................... 275 psi
The oil cooler is an air-to-oil heat exchanger. Oil is
provided off the cooler return circuit through an orifice
The pump will only supply the amount of oil required
to the service brake valve reservoir (13).
by a work port function or a combination of work port
9025
05
1
TX,9025,RR7523 –19–19FEB01–1/1

031504
PN=423
Theory of Operation
Hydraulic Component Location

T132881 –19–27OCT00
RIDE 8 9 LOAD SENSE BRAKE 13 STEERING 14 15 STEERING PRESSURE REGULATING VALVE

CONTROL LINE VALVE VALVE
16 HYDRAULIC 17 LEFT LOADER CYLINDER
RIDE CONTROL 7 VALVE RESERVOIR
ACCUMULATOR
10 ANTI-CAVITATION 18 HYDRAULIC COOLER
CHECK VALVE
ATTENUATOR 6
(CAB MACHINE)
11 COOLER FLOW
CHECK VALVE
RIGHT 5
STABILIZER
CYLINDER
19 BUCKET
CYLINDER
12 HYDRAULIC
FILTER STABILIZER 4
VALVE
BACKHOE VALVE
SYSTEM RELIEF
VALVE 3
BACKHOE 2
VALVE
20 RIGHT LOADER CYLINDER
LEFT AND 1
RIGHT SWING
CYLINDERS 21 FRONT AXLE
22 TRANSMISSION 31 LOW STANDBY PRESSURE OIL

24 LOADER
VALVE 32 TRAPPED OIL
BACKHOE 30 29 ISOLATOR
VALVE LOAD VALVE 23 33 RETURN OIL
SENSE RELIEF HYDRAULIC 34 LOAD SENSE PRESSURE OIL
VALVE LEFT 28 PUMP
STABILIZER REAR 27 LOAD SENSE 26 25 LOADER VALVE 35 MAIN HYDRAULIC COMPONENT LOCATION
T132881 CYLINDER AXLE SHUTTLE VALVE LOAD SENSE RELIEF VALVE NEUTRAL - 410G
CED,TX03768,2805 –19–11FEB03–1/12

031504
PN=424
Theory of Operation
1—Left and Right Swing 9—Load Sense Line 18—Hydraulic Cooler 28—Left Stabilizer Cylinder
Cylinders 10—Anti-cavitation Check 19—Bucket Cylinder 29—Isolator Valve
2—Backhoe Valve Valve 20—Right Loader Cylinder 30—Backhoe Valve Load
3—Backhoe Valve System 11—Cooler Flow Check Valve 21—Front Axle Sense Relief Valve
Relief Valve 12—Hydraulic Filter 22—Transmission 31—Low Standby Pressure Oil
4—Stabilizer Valve 13—Brake Valve 23—Hydraulic Pump 32—Trapped Oil
5—Right Stabilizer Cylinder 14—Steering Valve 24—Loader Valve 33—Return Oil
6—Hydraulic Oil Pump 15—Steering Pressure 25—Loader Valve Load Sense 34—Load Sense Oil
7—Ride Control Accumulator Regulating Valve Valve 35—Main Hydraulic
(If Equipped) 16—Hydraulic Reservoir 26—Load Sense Shuttle Valve Component Location
8—Ride Control Valve (If 17—Left Loader Cylinder 27—Isolator Valve (Neutral)
Equipped
9025
05
3

031504
PN=425
Theory of Operation
2 CROWD
CYLINDER
1 BUCKET
CYLINDER
3 BOOM
CYLINDER
9025
05
4
4 EXTENDABLE
DIPPERSTICK
CYLINDER
TO
6
AUXILIARY
7 FUNCTION
8 15
9
10
14
–19–17OCT00
11 TO ROD END
12 13
RIGHT SWING
TO ROD END CYLINDER
LEFT SWING
T132880
T132880 CYLINDER
Backhoe Hydraulic Component Location

031504
PN=426
Theory of Operation
1—Bucket Cylinder 5—To Extendable Dipperstick 9—To Bucket Cylinder Head 12—To Boom Cylinder Rod
2—Crowd Cylinder Cylinder Head end end end
3—Boom Cylinder from 6—To Extendable Dipperstick 10—To Bucket Cylinder Rod 13—To Right Swing Cylinder
Auxiliary Pump Cylinder Rod end end 14—To Left Swing Cylinder
4—Extendible Dipperstick 7—To Crowd Cylinder Rod end 11—To Boom Cylinder Head 15—To Auxiliary Function
Cylinder 8—To Crowd Cylinder Head end
end
9025
05
5

031504
PN=427
Theory of Operation
T129552 –UN–14APR00
OIL 7
COOLER
2 BRAKE
VALVE
3
HYDRAULIC
RESERVOIR
4 RADIATOR
1 AXLE
5 TRANSMISSION
6 PUMP
8 PRESSURE FREE OIL

9 LOW PRESSURE OIL
11 HIGH PRESSURE OIL
T129552 12 POWER BOOST MICO BRAKE VALVE - BOTH PEDALS APPLIED

Hydraulic Component Location—Power Boost MICO Brake Valve Circuit— Both Pedals Applied (S.N. —910944)

031504
PN=428
Theory of Operation
1—Axle 5—Transmission 8—Pressure Free Oil 11—High Pressure Oil

2—MICO Brake Valve 6—Hydraulic Pump 9—Low Pressure Oil 12—Power Boost MICO Brake
3—Hydraulic Reservoir 7—Oil Cooler 10—Medium Pressure Oil Valve-Both Pedals Applied
4—Radiator
9025
05
7

031504
PN=429
Theory of Operation
T163635 –UN–17JAN03
Hydraulic Component Location—Power Boost MICO Brake Valve Circuit— Both Pedals Applied (S.N. 910945— )

031504
PN=430
Theory of Operation
1—Axle 5—Transmission 8—Pressure Free Oil 11—High Pressure Oil

2—MICO Brake Valve 6—Hydraulic Pump 9—Low Pressure Oil 12—To Steering Valve Return
3—Hydraulic Reservoir 7—Oil Cooler 10—Medium Pressure Oil Port
4—Radiator
9025
05
9

031504
PN=431
Theory of Operation
T163858 –UN–14JAN03
Hydraulic Component Location—Loader and Stabilizer Valve (S.N. 913480— )

031504
PN=432
Theory of Operation
1—Loader Self Leveling 8—Boom Height Kick-Out 15—Hydraulic Supply Line 20—Pressure Line to Steering
Linkage Wiring Connector From Backhoe Valve Valve
2—Auxiliary Hydraulic Line 9—Loader and Stabilizer Valve 16—Load Sense Line From 21—Load Sense Line From
3—Auxiliary Hydraulic Line 10—Load Sense Line to Hydraulic Pump Steering Valve
4—Bucket Cylinder Hydraulic Backhoe Valve 17—Left Stabilizer Hydraulic 22—Left Boom Cylinder
Line (Bucket Curl) 11—Right Stabilizer Linkage Line (Up) Hydraulic Line (Boom Up)
5—Bucket Cylinder Hydraulic 12—Left Stabilizer Linkage 18—Right Stabilizer Hydraulic 23—Right Stabilizer Cylinder
Line (Bucket Dump) 13—Right Stabilizer Hydraulic Line (Down) 24—Left Stabilizer Cylinder
6—Right Boom Cylinder Line (Up) 19—Left Boom Cylinder 25—Right Boom Cylinder
Hydraulic Line (Boom Up) 14—Left Stabilizer Hydraulic Hydraulic Line (Boom 26—Left Boom Cylinder
7—Right Boom Cylinder Line (Down) Down) 27—Bucket Cylinder
Hydraulic Line (Boom
Down)
9025
05
11

031504
PN=433
Theory of Operation
T165163 –UN–20FEB03
Hydraulic Component Location—Pilot Controls (S.N. 913484— )

031504
PN=434
Theory of Operation
1—Pilot Control Manifold 11—Backhoe Valve Extendible 20—Pilot Enable Solenoid 29—Left Pilot Control
Valve (PCMV) Dipperstick Section 21—PCMV Diagnostic 30—Pilot Control Hydraulic
2—Pilot Control Manifold 12—Backhoe System Relief Pressure Test Port Line—Bucket Curl
Valve Relief Valve 22—PCMV-to-Tank 31—Pilot Control Hydraulic
3—Pilot Control Manifold 13—Backhoe Valve Outlet 23—Pilot Control Hydraulic Line—Crowd In
Valve Accumulator Section Line—Boom Down 32—Pilot Control Hydraulic
4—Pressure From 14—System Return-to-Filter 24—Pilot Control Hydraulic Pressure Supply Line—
PCMV-to-Pilot Controls 15—Backhoe Valve Inlet Line—Swing Left Right Pilot Control
5—PCMV Return Line Section 25—Pilot Control Hydraulic 33—Pilot Control Hydraulic
6—Pattern Select Valve 16—Hydraulic Supply From Pressure Supply Line— Return Line—Right Pilot
7—Backhoe Valve Swing Pump Left Pilot Control Control
Section 17—Pressure From Backhoe 26—Pilot Control Hydraulic 34—Pilot Control Hydraulic
8—Backhoe Valve Boom Valve to PCMV Return Line—Left Pilot Line—Bucket Dump
Section 18—Load Sense Control 35—Pilot Control Hydraulic
9—Backhoe Valve Bucket Line-to-Loader and 27—Pilot Control Hydraulic Line—Crowd Out
Section Stabilizer Valve Line—Boom Up 36—Right Pilot Control
10—Backhoe Valve Crowd 19—PCMV Filter 28—Pilot Control Hydraulic
Section Line—Swing Right
CED,TX03768,2805 –19–11FEB03–12/12
9025
05
13

031504
PN=435
Theory of Operation
Hydraulic System Schematic

T133340 –19–14SEP00
10 ATTENUATOR
- CAB MACHINE ONLY
11 BACKHOE CONTROL VALVE

INLET
L.S. END CAP
3 4 ANTI-CAVITATION 12 ISOLATOR RELIEF
COOLER FLOW FUNCTION
CHECK VALVE CHECK VALVE
6 STEERING COMPENSATOR
1 VALVE 9 LOAD SENSE
HYDRAULIC SHUTTLE CHECK
OIL COOLER VALVE AUXILIARY
FROM (FLOW CONTROL)
2 HYDRAULIC TRANSMISSION
FILTER PUMP
COMPENSATOR
7
L.S. SWING
RELIEF
8 PRESSURE COMPENSATOR
REGULATING
TO VALVE
TRANSMISSION
LUBE 5 POWER BOOST BRAKE VALVE
BOOM
ANTI-DRIFT
BREATHER
COMPENSATOR
FILL
SCREEN
16 LOADER CONTROL VALVE 14 STABILIZER BUCKET
VALVE
20 HYDRAULIC OIL RESERVOIR COMPENSATOR

17
21 RIDE
PUMP OUTLET CONTROL
PRESSURE M CROWD
TEST PORT A
G
19 HYDRAULIC ANTI-DRIFT
PUMP 22 COMPENSATOR
23 LOW STANDBY PRESSURE
ISOLATOR
24 TRAPPED OIL
ANTI-DRIFT
15 25 RETURN OIL
AUXILIARY
L.S. 26 LOAD SENSE PRESSURE OIL (EXT. DIPPER)
18 LOAD SENSE RELIEF
PRESSURE COMP. COMP. (PRESSURE FREE)
TEST PORT COMP.
27 LUBRICATION OIL
INLET END BUCKET BOOM AUXILIARY OUTLET
CAP (OPTIONAL) 13 SYSTEM RELIEF END CAP
T133340
28 HYDRAULIC SCHEMATIC - NEUTRAL
CED,TX03768,2804 –19–10FEB03–1/6

031504
PN=436
Theory of Operation
T133339 –19–14SEP00
10 ATTENUATOR
- CAB MACHINE ONLY
11 BACKHOE CONTROL VALVE

INLET
L.S. END CAP
6 STEERING 9 COMPENSATOR
VALVE
1 LOAD SENSE
HYDRAULIC SHUTTLE CHECK
OIL COOLER VALVE AUXILIARY
(ATTACH)
2 HYDRAULIC FROM
FILTER TRANSMISSION
PUMP COMPENSATOR
7
L.S. SWING
RELIEF
8 PRESSURE COMPENSATOR
REGULATING
VALVE
TO
TRANSMISSION 5 POWER BOOST BRAKE VALVE BOOM
LUBE
ANTI-DRIFT
COMPENSATOR
BREATHER
FILL
SCREEN
16 LOADER CONTROL VALVE 14 STABILIZER BUCKET
VALVE
20 HYDRAULIC OIL RESERVOIR COMPENSATOR

17
21 RIDE
PUMP OUTLET CONTROL
PRESSURE M CROWD
A
TEST PORT G
19 HYDRAULIC 23 HIGHEST WORKPORT PRESSURE

ANTI-DRIFT
PUMP 22 COMPENSATOR
ISOLATOR
25 LOWEST WORKPORT PRESSURE ANTI-DRIFT
15 26 TRAPPED OIL AUXILIARY
L.S. 27 LUBRICATION OIL (EXT. DIPPER)
18 LOAD SENSE RELIEF
PRESSURE COMP. COMP. COMP.
TEST PORT 28 LOAD SENSE PRESSURE OIL
(PRESSURE FREE)
INLET END BUCKET BOOM AUXILIARY OUTLET
(OPTIONAL) 29 RETURN OIL 13 SYSTEM RELIEF END CAP
CAP
T133339
30 HYDRAULIC SCHEMATIC - MULTIPLE FUNCTIONS ACTIVATED
CED,TX03768,2804 –19–10FEB03–2/6

031504
PN=437
Theory of Operation
T163598 –19–11FEB03
10 ATTENUATOR 11 BACKHOE CONTROL VALVE

(CAB MACHINE ONLY) INLET
L.S.
COMPENSATOR
1
HYDRAULIC
OIL COOLER AUXILIARY
FROM (FLOW CONTROL)
2 HYDRAULIC TRANSMISSION 23 LOW STANDBY PRESSURE
FILTER PUMP
24 TRAPPED OIL COMPENSATOR
9 STEERING 25 RETURN OIL

VALVE SWING
26 LOAD SENSE PRESSURE
OIL (PRESSURE FREE)
COMPENSATOR
27 LUBRICATION OIL
TO
TRANSMISSION 28 HIGH PRESSURE OIL
LUBE 5 POWER BOOST BRAKE VALVE
BOOM
ANTI-DRIFT
FILL COMPENSATOR
BREATHER SCREEN
BUCKET
7 LOADER AND
20 HYDRAULIC OIL RESERVOIR STABILIZER VALVE COMPENSATOR
6
19 CROWD
RIDE
HYDRAULIC 21 CONTROL ANTI-DRIFT
PUMP
PUMP
COMPENSATOR
OUTLET ISO-
PRESSURE LATOR
TEST PORT ANTI-DRIFT
AUXILIARY
(EXT. DIPPER)
18 14
LOAD SENSE STEERING
PRESSURE LOAD 15 LOAD
TEST PORT SENSE ISOLATOR COMPENSATOR SENSE 13 SYSTEM RELIEF
RELIEF OUTLET
STABILIZER STABILIZER BOOM BUCKET AUXILIARY
T163598
CED,TX03768,2804 –19–10FEB03–3/6

031504
PN=438
Theory of Operation
1—Hydraulic Oil Cooler 8—Pressure Regulating Valve 15—Load Sense Relief 23—Low Standby Pressure
2—Hydraulic Filter 9—Steering Valve 18—Load Sense Pressure Test 24—Trapped Oil
3—Cooler Flow Check Valve 10—Attenuator Port 25—Return Oil
4—Anti-Cavitation Function 11—Backhoe Control Valve 19—Hydraulic Pump 26—Load Sense Pressure Oil
Check Valve 12—Load Sense Isolator 20—Hydraulic Oil Reservoir 27—Lubrication Oil
5—Power Boost Brake Valve 13—System Relief 21—Pump Outlet Pressure 28—High Pressure Oil
6—Ride Control Valve 14—Steering Load Sense Test Port
7—Loader and Stabilizer Isolator
Control Valve
9025
05
17

031504
PN=439
Theory of Operation
10 ATTENUATOR
(CAB MACHINE ONLY)
3 4 ANTI-CAVITATION
1
HYDRAULIC 29 PILOT
OIL COOLER 31 CONTROL
FROM MANIFOLD
2 HYDRAULIC TRANSMISSION PILOT
FILTER PUMP CONTROL 30 PILOT
23 LOW STANDBY PRESSURE MANIFOLD PRESSURE
24 TRAPPED OIL ACCUMULATOR TEST PORT
9 STEERING
VALVE
25 RETURN OIL
26 LOAD SENSE PRESSURE
OIL (PRESSURE FREE)
TO
TRANSMISSION 27 LUBRICATION OIL PILOT
LUBE 5 POWER BOOST BRAKE VALVE CONTROL
28 HIGH PRESSURE OIL MANIFOLD 32
FILTER
33 LEFT PILOT 34 RIGHT PILOT

FILL CONTROL CONTROL
9025 BREATHER SCREEN
05
18
7 LOADER AND
20 HYDRAULIC OIL RESERVOIR STABILIZER VALVE
6
19 RIDE
HYDRAULIC 21 CONTROL
PUMP
PUMP
OUTLET ISO-
PRESSURE LATOR
TEST PORT
35 PATTERN
18 14 SELECT
VALVE
LOAD SENSE STEERING
PRESSURE LOAD 15 LOAD
TEST PORT SENSE ISOLATOR COMPENSATOR SENSE
–19–11FEB03
RELIEF
STABILIZER STABILIZER BOOM BUCKET AUXILIARY
T164341
T164341

031504
PN=440
Theory of Operation
1—Hydraulic Oil Cooler 9—Steering Valve 19—Hydraulic Pump 29—Pilot Control Manifold
2—Hydraulic Filter 10—Attenuator 20—Hydraulic Oil Reservoir 30—Pilot Pressure Test Port
3—Cooler Flow Check Valve 11—Backhoe Control Valve 21—Pump Outlet Pressure 31—Pilot Control Manifold
4—Anti-Cavitation Function 12—Load Sense Isolator Test Port Accumulator
Check Valve 13—System Relief 23—Low Standby Pressure 32—Pilot Control Manifold
5—Power Boost Brake Valve 14—Steering Load Sense 24—Trapped Oil Filter
6—Ride Control Valve Isolator 25—Return Oil 33—Left Pilot Control
7—Loader and Stabilizer 15—Load Sense Relief 26—Load Sense Pressure Oil 34—Right Pilot Control
Control Valve 18—Load Sense Pressure Test 27—Lubrication Oil 35—Pattern Select Valve
8—Pressure Regulating Valve Port 28—High Pressure Oil
CED,TX03768,2804 –19–10FEB03–6/6
9025
05
19

031504
PN=441
Theory of Operation
Load Sense Isolator
E F
SPRING C D
A
SPOOL
9025
05 B
20
G
F
TO COMPENSATORS
H RETURN PRESS
I LOAD SENSE PRESS
–19–05JUN97
J PUMP PRESS
T109416
T109416
K LOAD SENSE ISOLATOR-METERING

Load Sense Isolator-Neutral Position
A—Input from Valve Load D—Return Passage G—Orifice J—Pump Pressure

Sensing Network E—Damping Orifice H—Return Pressure K—Load Sense Isolator—
B—Supply from Pump F—Pilot Passage I—Load Sense Pressure Metering
C—Load Sense Output (to
compensators and pump
load sense input)
Continued on next page TX,9025,RR7541 –19–08NOV96–1/2

031504
PN=442
Theory of Operation
The load sense isolators are used to sense the loader input port (A) of the isolator. That pressure will now
or backhoe valve’s highest bridge pressure, become the equalized pressure and will therefore be
representing the highest load at a work port. It then output at passage (C) to the pump load sense port.
sends an equal pressure to the pump’s load sense The pump will then output port (C) pressure plus the
port. load sense differential pressure.
When all of the control valve spools are in neutral, the As a result, the pump load sense port sees the highest
highest work port pressure at the input (A) of the work port pressure, but the oil in the load sensing
isolator is equal to return pressure. Pump output shuttle system does not leave the valve assembly. It is
pressure is transmitted into port (B) of the isolator and stopped at the isolator input (A), which is located at
out port (C). This pressure, also sensed at the end of the inlet section of the valve assembly. The pump
the spool through the damping orifice (E) and pilot provides it’s own constant source of oil, through the
passage (F) tends to push the spool toward the inlet isolator, to keep the hose between the load sense
chamber (to the left). As the spool moves in that output port of the valve and the load sense port of the
direction, the flow path created by the connection of pump filled with oil. When load sense pressure
pump port (B) to load sense output port (C) begins to changes, the new pressure is transmitted to the load
be choked off by the spool land and metering occurs. sense port without the need to first fill the hose with
This will tend to limit the pressure in the load sense oil, and load dipping is eliminated.
output port (C) to some equalized value. Since the
spring force is light, the pump load sense port sees A load sense relief valve is present downstream of
zero pressure and therefore the pump puts out orifice (G), it’s poppet will unseat when load sense
pressure equal to the load sense differential setting. pressure at (C) exceeds the relief’s pressure setting.
The existing return passage pressure will increase The orifice (G) is added in the inlet housing to limit the
pump outlet pressure by the same value. flow through the load sense relief valve.
If one of the control valve spools is moved in order to

move a load, the work port pressure is sensed at the
9025
05
21
TX,9025,RR7541 –19–08NOV96–2/2

031504
PN=443
Theory of Operation
Load Sense With All Functions in Neutral
OPTIONAL LS 275-425 PSI

SIGNAL FROM 0-150 PSI
I J T
ANOTHER VALVE
LS RELIEF
B
AUX
SECTION
9025
05
22 N
BOOM
SECTION
F
G
O L M
N
E K
D H
C
Q S R BUCKET
P C SECTION
A
275-425 PSI
V RETURN OIL
–19–22AUG00
U MAIN RELIEF W LOAD SENSE OIL

X TRAPPED OIL
Z LOAD SENSE WITH Y LOW STANDBY PRESSURE
T133342
T133342 ALL FUNCTIONS IN NEUTRAL

Continued on next page CED,TX03768,2807 –19–30AUG00–1/2

031504
PN=444
Theory of Operation
A—Load Sense Isolator H—Load N—Compensator Feeder U—Main Relief

B—Load Sense Relief Valve Sense-to-Compensator Passage V—Return Oil
C—Compensator Connection O—Bridge Passage W—Load Sense Oil
D—Load Sense Shuttle Check I—Load Sense Port P—Pump X—Trapped Oil
E—Compensator Lock J—Load Sense to Pump Port Q—Load Sense Orifice Y—Low Standby Pressure
F—Load Sense Shuttle K—Main Spool R—Work Port Z—Load Sense with All
Connection L—Exhaust (Tank) Passage S—Work Port Functions in Neutral
G—Load Sense-to-Pump M—Pump Passages T—Outlet Housing
Connection
The backhoe and loader control valves are closed 4. Boom stalls at maximum height with bucket still
center, load sensing, sectional valves with individual dumping.
section compensation. The compensators located
between sections divide pump flow to control multiple With all valve spools (K) in neutral, the pump (P) has
functions. Flow from each function remains constant no load sense pressure signal. The load sense
regardless of pressure requirement until pump capacity passages (F) within the valve are connected internally
is exceeded. When flow demand does exceed pump to the return circuit. Return circuit pressure, however,
capacity, all functions will continue to operate at can vary between 0 and 150 psi during operation. This
reduced flows. means with a load sense differential pressure of 275
psi, pump outlet pressure with the valve spools in
To illustrate how the valve works within the pressure neutral can vary between 275 and 425 psi. The load
compensated load sensing system, consider this sense differential pressure is always a constant 275
sequence of events: psi.
1. Valve in neutral. Specification

Load Sense—Differential
2. Operate boom raise function requiring 500 psi.
Pressure................................................................................... 275 psi
3. While raising the boom, dump the bucket requiring
1000 psi.
9025
05
23
CED,TX03768,2807 –19–30AUG00–2/2

031504
PN=445
Theory of Operation
Load Sense With One Function Activated
OPTIONAL LS 775 PSI

SIGNAL FROM I J T
ANOTHER VALVE
LS RELIEF
B
F AUX
SECTION
500 PSI
D
O
9025
05
500 PSI
N
24 BOOM
SECTION
G
O L M
N
E K
H
C
Q S R BUCKET
P C SECTION
A
775 PSI V SYSTEM PRESSURE OIL

U
–19–22AUG00
MAIN RELIEF W LOAD PRESSURE

X LOAD SENSE OIL
Y RETURN OIL
AA LOAD SENSE WITH
T133343
Z TRAPPED OIL
T133343 ONE FUNCTION ACTIVATED

031504
PN=446
Theory of Operation
A—Load Sense Isolator H—Load N—Compensator Feeder U—Main Relief

B—Load Sense Relief Valve Sense-to-Compensator Passage V—System Pressure Oil
C—Compensator Connection O—Bridge Passage W—Load Pressure
D—Load Sense Shuttle Check I—Load Sense Port P—Pump X—Load Sense Oil
E—Compensator Lock J—Load Sense to Pump Port Q—Load Sense Orifice Y—Return Oil
F—Load Sense Shuttle K—Main Spool R—Work Port Z—Trapped Oil
Connection L—Exhaust (Tank) Passage S—Work Port AA—Load Sense with One
G—Load Sense-to-Pump M—Pump Passages T—Outlet Housing Function Activated
Connection
When the boom spool is moved in, several This pressure is seen in all valve sections at the
connections are made within the valve section; the pump passages (M).
bridge passage (O) load sense internal bleed is shut
off, work port (S) is connected to the return passage As the pressure in the compensator feeder passage
(L) through the spool notches, the pump passage (M) (N) increases slightly over 500 psi (the compensator
is connected to the compensator feeder passage (N) bias spring force is light), the compensator spool (C)
through spool notches and the bridge passage (O) is moves allowing oil flow into the bridge (O) and then
connected to work port (R) through spool notches. past the spool notches to work port (R). The flow to
the work port is determined by the 275 psi differential
With the above connections made, the 500 psi work pressure across the spool notches between the pump
port pressure is sensed at the isolator through the load output passage (M) and the feeder passage (N).
sense shuttle check (D). The isolator then sends the
500 psi signal through passage (G) to the pump’s load Specification
Load Sense—Differential
sense port. The pump adds 275 psi load sense
Pressure................................................................................... 275 psi
differential pressure to the 500 psi signal pressure and
outputs 775 psi.
Specification
Load Sense—Differential 9025
Pressure................................................................................... 275 psi 05
25
CED,TX03768,2808 –19–30AUG00–2/2

031504
PN=447
Theory of Operation
Load Sense With Multiple Functions Activated
OPTIONAL LS 1275 PSI

SIGNAL FROM 0-150 PSI
I J T
ANOTHER VALVE
LS RELIEF
B
F AUX
SECTION
1000 PSI
D
O
9025 500 PSI 500 PSI

05 N
26 BOOM
SECTION
G
O L M
N
E K
H
C
Q S R BUCKET
P 1000 PSI C SECTION
A
V SYSTEM PRESSURE OIL
1275 PSI
W HIGHEST LOAD PRESSURE
U
–19–22AUG00
MAIN RELIEF
X LOWEST LOAD PRESSURE
Y LOAD SENSE OIL
BB LOAD SENSE WITH Z RETURN OIL
T133341
T133341 MULTI-FUNCTIONS ACTIVATED AA TRAPPED OIL

031504
PN=448
Theory of Operation
A—Load Sense Isolator H—Load O—Bridge Passage W—Highest Load Pressure

B—Load Sense Relief Valve Sense-to-Compensator P—Pump X—Lowest Load Pressure
C—Compensator Connection Q—Load Sense Orifice Y—Load Sense Oil
D—Load Sense Shuttle Check I—Load Sense Port R—Work Port Z—Return Oil
E—Compensator Lock J—Load Sense to Pump Port S—Work Port AA—Trapped Oil
F—Load Sense Shuttle K—Main Spool T—Outlet Housing BB—Load Sense with Multiple
Connection L—Exhaust (tank) Passage U—Main Relief Functions Activated
G—Load Sense-to-Pump M—Pump Passages V—System Pressure Oil
Connection N—Compensator Feeder
Passage
When the bucket spool is moved out, the connections The compensator (C) in the boom section must now
made within the valve section are the same as for the react to the increase in load sense pressure (to 1000
boom section previously discussed, except that work psi) since this pressure is on the load sense side of
port (R) is connected to return passage (L) and bridge the compensator (C) and the pressure in the bridge
passage (O) is connected to workport (S). (O) is still 500 psi. The pressure in the compensator
feeder passage (N) must build to slightly over 1000 psi
The pressure required is now 1000 psi at workport (S) to overcome the load sense pressure. This allows flow
of the bucket section. This pressure is sent through the to the bridge (O) of the boom section through the
load sense shuttle check (D). Since this pressure is compensator (C). At this time there is still 500 psi in
higher than the 500 psi required in the boom section, the bridge (O), but the compensator feeder passage
the shuttle check (D) in the bucket section moves to (N) is at 1000 psi, and the pump passage (M) is at
block the 500 psi signal allowing the 1000 psi signal to 1275 psi. Note that the differential pressure of 275 psi
the isolator and then to the pump’s load sense port. still exists across the spool notches between the pump
The pump adds 275 psi load sense differential to the output passage (M) and the feeder passage (N).
1000 psi signal pressure and outputs 1275 psi.
Specification
Specification Load Sense—Differential
Load Sense—Differential Pressure................................................................................... 275 psi
9025
Pressure................................................................................... 275 psi
05
Therefore, even though the pump output pressure 27
Again this pressure is seen at the pump passages required increases from 775 psi to 1275 psi, the flow
(M). to the boom workport remains the same.
CED,TX03768,2809 –19–30AUG00–2/2

031504
PN=449
Theory of Operation
Load Sense With Multiple Functions Activated (One Function Stalled)
OPTIONAL LS 3375 PSI

SIGNAL FROM I J T
ANOTHER VALVE
LS RELIEF
B
F AUX
SECTION
3350 PSI
D
O
9025 3350 PSI

05 N
28 BOOM
SECTION
G
O L M
N
E K
H
C
1000 PSI
3350 PSI
Q S R BUCKET
P 1000 PSI C SECTION
A
V SYSTEM PRESSURE OIL
3625 PSI
W HIGHEST LOAD PRESSURE
U
–19–22AUG00
MAIN RELIEF
X LOWEST LOAD PRESSURE
Y LOAD SENSE OIL
BB LOAD SENSE WITH MULTI-FUNCTIONS Z RETURN OIL
T133344
ACTIVATED (ONE FUNCTION STALLED) AA TRAPPED OIL

T133344

031504
PN=450
Theory of Operation
A—Load Sense Isolator H—Load O—Bridge Passage W—Highest Load Pressure

B—Load Sense Relief Valve Sense-to-Compensator P—Pump X—Lowest Load Pressure
C—Compensator Connection Q—Load Sense Orifice Y—Load Sense Oil
D—Load Sense Shuttle Check I—Load Sense Port R—Workport Z—Return Oil
E—Compensator Lock J—Load Sense to Pump Port S—Work Port AA—Trapped Oil
F—Load Sense Shuttle K—Main Spool T—Outlet Housing BB—Load Sense with Multiple
Connection L—Exhaust (tank) Passage U—Main Relief Functions Activated and
G—Load Sense-to-Pump M—Pump Passages V—System Pressure Oil One Function Stalled
Connection N—Compensator Feeder
Passage
When the boom stalls at maximum height, the load port sense this pressure and the pump will output 3625
sense relief (B) unseats limiting load sense pressure to psi. The bucket function will continue to operate, but
3350 psi. All compensators and the pump’s load sense the speed will be reduced as the flow limiter engages.
CED,TX03768,2810 –19–30AUG00–2/2
9025
05
29

031504
PN=451
Theory of Operation
Hydraulic Pump—Neutral Operation
C SUCTION
D PISTON
CONTROL PIN
E UPPER CRESCENT
TO PUMP PORT "A"
DRIVE A
SHAFT
F
B
B A
SECTION "A-A"
A
LOWER CRESCENT
G TO PUMP PORT "B"
SWASH PLATE
H PRESSURE
9025
05
–19–20DEC96
30 J PUMP - NEUTRAL
I LOW PRESSURE
T105504
T105504
Pump in Neutral
A—Outlet Port D—Pump Piston G—Swash Plate I—Low Pressure

B—Pump Inlet Port E—Control Pin H—Pressure J—Pump—Neutral
C—Suction F—Drive Shaft
The main hydraulic pump is an axial piston, variable plate angle is now zero and swash plate face is now
displacement pump. The pump mounts to the parallel to cylinder face. Therefore, no inward or
machine’s transmission auxiliary drive case and the outward motion of the pump pistons (D) exists as
pump’s drive shaft (F) splines into the external pump piston shoes rotate around the swash plate face. The
drive. The drive shaft is supported by a ball bearing on lack of inward and outward motion results in no fluid
the spline end and a bearing sleeve in the valve being displaced from the piston bores (A and B) to the
plate’s end cap. crescents (A and B) in the valve plate and therefore no
delivery from the pump ports.
Neutral position results when the pump control centers
the swash plate (G) with its control pin (E). The swash
TX,9025,RR7554 –19–03DEC96–1/1

031504
PN=452
Theory of Operation
Hydraulic Pump—Full Stroke
C SUCTION
D PISTON
CONTROL PIN
E UPPER CRESCENT
TO PUMP PORT "A"
DRIVE A
SHAFT
F
B
B A
SECTION "A-A"
A
LOWER CRESCENT
G TO PUMP PORT "B"
SWASH PLATE
H PRESSURE
9025
05
–19–20DEC96
I HIGH PRESSURE
K PUMP - FULL STROKE 31
J LOW PRESSURE
T105505
T105505
Pump-Full Stroke
A—Pump Inlet D—Piston G—Swash Plate J—Low Pressure

B—Pump Outlet E—Control Pin H—Pump Suction Inlet K—Pump—Full Stroke
C—Suction F—Drive Shaft I—High Pressure
With the engine running, and full stroke is required, the pressure ports (A) in valve plate. While connected to
drive shaft drives the splined cylinder block which the suction port, each piston moves outward, drawing
contains the pumping pistons (D). When the cylinder is fluid into its bore until its’s outermost stroke is reached.
rotated, the pistons move in and out of their bores as As the cylinder continues to rotate, each piston moves
the shoes “ride” against the angled swash plate (G). across the angled swash plate face. Thus, each piston
The angled swash plate rides on two journal bearings is forced inward. Each piston displaces fluid out the
and is moved by a control pin (E) that moves with the pressure port until it’s innermost stroke is reached. At
pump control’s control piston. this point, the piston bore passes from the suction port
again and the operating cycle is repeated.
As the cylinder rotates, the individual piston bores are
connected, alternately, to suction ports (B) and
TX,9025,YY2137 –19–19DEC96–1/1

031504
PN=453
Theory of Operation
Hydraulic Pump Controls—Neutral (S.N. —907932)
DISPLACEMENT K H LOAD SENSE

CONTROL LINE
LOAD SENSE
VALVE I VALVE
PUMP M
C
F FLOW LIMITER
CONTROL
BIAS PIN TO
A A PISTON B BIAS SWASH PLATE
SPRING PISTON IN PUMP
FROM PUMP
OUTLET
L
DISPLACEMENT
CONTROL
9025 VALVE
05 K
32
D CONTROL
PISTON
E
PIN FROM
FLOW LIMITER
TO CONTROL
G PISTON
F
POPPET FLOW LIMITER
A
J
ORIFICE
N LOW STANDBY
PRESSURE OIL
–19–20DEC96
O CONTROL
I H LOAD SENSE PORT PRESSURE OIL
P BIAS PRESSURE
LOAD SENSE VALVE A-A
M HYDRAULIC PUMP- Q RETURN OIL
T105467
T105467 SECTION
NEUTRAL
Hydraulic Pump-Neutral
Continued on next page TX,9025,RR7526 –19–10OCT96–1/2

031504
PN=454
Theory of Operation
A—Bias Piston Spring F—Flow Limiter K—Control Displacement N—System Pressure Oil
B—Bias Piston G—Poppet Valve O—Load Sense Pressure Oil
C—Control Pin-to-Swash Plate H—Load Sense Line (Port) L—From Pump Outlet P—Control Pressure Oil
in Pump I—Load Sense Valve M—Hydraulic Pump Function Q—Bias Pressure Oil
D—Control Piston J—Orifice Metering R—Return Oil
E—Pin From Flow
Limiter-to-Control Piston
The hydraulic system is a closed center load-sensing Pump outlet pressure (L) will increase until the signal
system. The pump senses both pressure and flow pressure oil that flows through orifice (J) opens the
needs, and also senses hydraulic power. When none load sense valve spool (I) against the spring force,
of the hydraulic circuits are being used the pump is at allowing signal oil to flow to return. This allows pump
low pressure standby. outlet pressure acting on the displacement control
valve spool (K) to move it to the left.
The pump has three control valves, load sense valve
(I), displacement control valve (K), and flow limiter The displacement control valve spool (K) moves to the
valve (F). left until the bias pressure (P) oil can flow to return oil
(Q) passage and pump outlet pressure oil can flow to
• Pump outlet pressure is maintained at about 1865— control piston (D) passage.
1965 kPa (19—20 bar) (275—285 psi) above load
sense pressure. Pump outlet pressure acting on the control piston (D)
causes the swashplate to destroke the pump to near
Specification zero flow condition or standby mode, by overcoming
Hydraulic Pump Outlet— the bias piston spring (A).
Pressure............................................... 1865—1965 kPa (19—20 bar)
(275—285 psi) above load
sense pressure In neutral, pump outlet pressure (N) (low pressure
standby pressure), should be 1900—2930 kPa (19—
29.3 bar) (275—425 psi) (differential pressure plus 0—
9025
The pump has two control pistons, bias piston (B) and 1034 kPa {0—10 bar} {0—150 psi} return pressure).
05
control piston (D). Bias piston (B) and bias spring (A) 33
causes the swashplate to increase pump stroke. Specification
Pump Low Pressure—Standby
Control pressure oil (O) acting on the control piston (D) Pressure............................................ 1900—2930 kPa (19—29.3 bar)
causes the swashplate to decrease the pump stroke. (275—425 psi) (differential
pressure plus 0—1034 kPa
With all control valve sections in neutral, load sensing {0—10 bar} {0—150 psi} return
pressure from the valves is equal to return oil pressure)
pressure.
In standby mode the load sense valve spool (I)
Before cranking the engine, bias piston spring (A) continues to meter signal oil during neutral operation to
holds control piston (D) and pump swashplate at maintain standby pressure.
maximum angle. As the pump begins to turn, causing
oil to flow, pressure builds in the pump outlet passage
(L) because the closed center valves are closed.
TX,9025,RR7526 –19–10OCT96–2/2

031504
PN=455
Theory of Operation
Hydraulic Pump Controls—Neutral (S.N. 907933— )
12 7 8
12 14
13 10
15
5
1 2
6
5
4
14 3
9025 13
05
34
10
9
12
11
–UN–30AUG02
8
T153894
T153894
Continued on next page DW09104,0000023 –19–30AUG02–1/2

031504
PN=456
Theory of Operation
1—Bias Piston Spring 5—Flow Limiter 10—Displacement Control 13—Low Standby Pressure Oil
2—Bias Piston 6—Poppet Valve 14—Load Sense Oil (Pressure
3—Control Pin-to-Swash Plate 7—Load Sense Line (Port) 11— Directional Control Valve Free)
in Pump 8—Load Sense Valve 12—Pump Outlet Pressure Oil 15—Return Oil
4—Control Piston 9—Orifice
The hydraulic system is a closed center load-sensing Pump outlet pressure (12) will increase until signal
system. The pump senses pressure, flow needs, and pressure oil flowing through the orifice (9) opens the
hydraulic power. When none of the hydraulic functions load sense valve spool (8) against the spring force,
are being used the pump is at low pressure standby. allowing signal oil to flow to return. This allows pump
outlet pressure acting on the displacement control
The pump has three control valves: load sense valve valve spool (10) to move it to the left.
(8), displacement control valve (10), and flow limiter
valve (5). The displacement control valve spool (10) moves left
until bias pressure (14) oil can flow to return oil
• Pump outlet pressure is maintained at 1865—1965 passage and pump outlet pressure oil can flow to
kPa (19—20 bar) (275—285 psi) above load sense control piston (4) passage.
pressure.
Pump outlet pressure acting on the control piston (4)
Specification causes the swashplate to destroke the pump to near
Hydraulic Pump Outlet— zero flow condition or standby mode, by overcoming
Pressure............................................... 1865—1965 kPa (19—20 bar)
(275—285 psi) above load
the bias piston spring (1).
sense pressure
In neutral, pump outlet pressure (12) (low pressure
standby pressure), should be 1900—2930 kPa (19—
The pump has two pistons: bias piston (2) and control 29.3 bar) (275—425 psi) (differential pressure plus 0—
piston (4). Bias piston (2) and bias spring (1) cause 1034 kPa {0—10 bar} {0—150 psi} return pressure).
the swashplate to increase pump stroke. Control 9025
Specification
pressure oil (13) acting on the control piston (4) 05
Pump Low Pressure—Standby 35
causes the swashplate to decrease pump stroke. Pressure............................................ 1900—2930 kPa (19—29.3 bar)
(275—425 psi) (differential
With all control valve sections in neutral, load sensing pressure plus 0—1034 kPa
pressure from the valves is equal to return oil {0—10 bar} {0—150 psi} return
pressure)
pressure.
Before cranking engine, bias piston spring (1) holds In standby mode the load sense valve spool (8)
control piston (2) and pump swashplate at full continues to meter signal oil during neutral operation to
displacement. As the pump begins to turn causing oil maintain standby pressure.
to flow, pressure builds in the pump outlet passage
(12) because the closed center valves are closed.
DW09104,0000023 –19–30AUG02–2/2

031504
PN=457
Theory of Operation
Hydraulic Pump Controls—Function Metering (S.N. —907932)

CONTROL LINE
LOAD SENSE
VALVE I VALVE
PUMP M
C
F FLOW LIMITER
CONTROL
BIAS PIN TO
FROM PUMP
OUTLET
L
DISPLACEMENT
CONTROL
9025 VALVE
05 K
36
D CONTROL
PISTON
E
PIN FROM
FLOW LIMITER
TO CONTROL
G PISTON
F
POPPET FLOW LIMITER
A
N SYSTEM
J PRESSURE OIL
ORIFICE O LOAD SENSE
PRESSURE OIL
P CONTROL
PRESSURE OIL
–19–20DEC96
I H LOAD SENSE PORT Q BIAS

PRESSURE OIL
M HYDRAULIC PUMP- R RETURN OIL
T105590
T105590 SECTION
FUNCTION METERING
Continued on next page TX,9025,SS3471 –19–10DEC96–1/2

031504
PN=458
Theory of Operation
A—Bias Piston Spring F—Flow Limiter K—Control Displacement N—System Pressure Oil
B—Bias Piston G—Poppet Valve O—Load Sense Pressure Oil
C—Control Pin-to-Swash Plate H—Load Sense Line (Port) L—From Pump Outlet P—Control Pressure Oil
in Pump I—Load Sense Valve M—Hydraulic Pump Function Q—Bias Pressure Oil
D—Control Piston J—Orifice Metering R—Return Oil
E—Pin From Flow
In the function metering mode, as the control lever is Specification

Hydraulic Pump Outlet—
moved to change cylinder velocity, load sense
Pressure................................................. Approximately 1900 kPa (19
Pressurer is connected with the load sense circuit bar) (275 psi) above load sense
through load sense port (H) on the load sense valve pressure
(I). Load sense pressure is equal to the highest work
port pressure created by the cylinder and is variable, If the demand for flow or pressure in the circuit
dependent on the cylinder load. decreases, reducing the load sense pressure (O), load
sense pressure and spring force acting on the load
If the demand for flow or pressure in the circuit sense valve spool (I), cause the spool to move,
increases, raising the load sense pressure (O), load opening the valve. With the load sense spool opened,
sense pressure and spring force acting on the load pressure is reduced on the left side of the
sense valve spool (I) cause the spool to move, closing displacement control valve (K), shifting it to the left,
the valve. With the load sense spool closed, pressure allowing bias pressure oil to drain to return and pump
builds on the left side of the displacement control valve outlet pressure (L) oil to flow to the large end of the
(K) shifting it to the right, allowing control pressure oil control piston (D). This pressure moves the control
(P) on the large end of the control piston (D) to drain piston to the left, decreasing pump stroke. Once the
to return and pump outlet pressure (L) oil to flow lower flow requirements are met, the displacement
through the center of the displacement control valve control valve (K) moves right to the metering position.
(K) to the bias piston passage. This pressure plus the The pump displacement is then maintained to provide
bias piston spring (A) force moves the control piston to the lower pressure required.
9025
the right, increasing pump stroke. Pump outlet
05
pressure will increase until it is maintained at about When the control valves are returned to neutral, the 37
1900 kPa (19 bar) (275 psi) higher than load sense pump will go to low pressure standby.
pressure.
TX,9025,SS3471 –19–10DEC96–2/2

031504
PN=459
Theory of Operation
Hydraulic Pump Controls—Function Metering (S.N. 907933—)
12 7 8
12 14
13 10
15
5
1 2
6
5
4
14 3
9025 13
05
38
10
9
12
11
–UN–30AUG02
8
T159037
T159037
Continued on next page DW09104,0000024 –19–30AUG02–1/2

031504
PN=460
Theory of Operation
1—Bias Piston Spring 5—Flow Limiter 10—Displacement Control 13—Low Standby Pressure Oil
2—Bias Piston 6—Poppet Valve 14—Load Sense Oil (Pressure
3—Control Pin-to-Swash Plate 7—Load Sense Line (Port) 11— Directional Control Valve Free)
in Pump 8—Load Sense Valve 12—Pump Outlet Pressure Oil 15—Return Oil
4—Control Piston 9—Orifice
In function metering mode, load sense and spring If the demand for flow or pressure in the circuit
pressure are equal to the highest work port pressure. decreases, reducing the load sense pressure (7), load
When the control lever is moved to change cylinder sense pressure and spring force acting on the load
velocity, load sense pressure (7) is increased to match sense valve spool (8), cause the spool to move,
the load. opening the valve. With the load sense spool opened,
pressure is reduced on the left side of the
If the demand for flow or pressure in the circuit displacement control valve (10), shifting it to the left,
increases, raising the load sense pressure (7), load allowing bias pressure oil to drain to return and pump
sense pressure and spring force acting on the load outlet pressure (12) oil to flow to the large end of the
sense valve spool (8) cause the spool to move left, control piston (4). This pressure moves the control
closing the valve. With the load sense spool closed, piston to the left, decreasing pump stroke. Once the
pressure builds on the left side of the displacement lower flow requirements are met, the displacement
control valve (10) shifting it to the right, allowing control valve (10) moves right to the metering position.
control pressure oil (13) on the large end of the control The pump displacement is then maintained to provide
piston (4) to drain to return and pump outlet pressure the lower pressure required.
(12) oil to flow through the center of the displacement
control valve (10) to the bias piston passage. This When the control valves are returned to neutral, the
pressure plus the bias piston spring (1) force moves pump will go to low pressure standby.
the control piston to the right, increasing pump stroke.
Pump outlet pressure will increase until it is maintained
at about 1900 kPa (19 bar) (275 psi) higher than load
sense pressure. 9025
05
Specification 39
Hydraulic Pump Outlet—
Pressure................................................. Approximately 1900 kPa (19
bar) (275 psi) above load sense
pressure
DW09104,0000024 –19–30AUG02–2/2

031504
PN=461
Theory of Operation
Hydraulic Pump Controls—Full Flow

CONTROL LINE
LOAD SENSE
VALVE I VALVE
PUMP M
C
F FLOW LIMITER
CONTROL
BIAS PIN TO
FROM PUMP
OUTLET
L
DISPLACEMENT
CONTROL
9025 VALVE
05 K
40
D CONTROL
PISTON
E
PIN FROM
FLOW LIMITER
TO CONTROL
G PISTON
F
POPPET FLOW LIMITER
A
J
ORIFICE
N SYSTEM
PRESSURE OIL
–19–20DEC96
O RETURN OIL
I H LOAD SENSE LINE (PORT)

M HYDRAULIC PUMP-FULL FLOW
T105589
T105589 SECTION
(LOW-MEDIUM PRESSURE)

031504
PN=462
Theory of Operation
A—Bias Piston Spring E—Pin From Flow I—Load Sense Valve M—Pump
B—Bias Piston Limiter-to-Control Piston J—Orifice N—System Pressure Oil
C—Control Pin-to-Swash Plate F—Flow Limiter K—Pressure compensator O—Return Oil
in Pump G—Poppet Valve P—Hydraulic Pump—Full Flow
D—Control Piston H—Load Sense Line (Port) L—From Pump Outlet (Low—Medium Pressure)
If several functions are engaged at the same time, to load sense valve (I) to close. With the load sense
require full flow, the pump displacement will increase spool closed, pressure builds on the left side of the
with flow demand until full displacement is achieved. displacement control valve (K) shifting it to the right,
allowing control pressure oil (P) on the large end of the
The load sense signal will be the highest work port control piston (D) to drain to return and pump outlet
pressure sensed. The sensed pressure is routed to the pressure (L) oil to flow through the center of the
load sense valve (I) spring area. displacement control valve (K) to the bias piston
passage. This pressure, plus the bias piston spring (A)
As the increased oil flow demand occurs at low to force moves the bias piston (B) to the right, increasing
medium pressures, the pressure difference between pump stroke until maximum displacement is achieved.
pump outlet and load sense is reduced, causing the
TX,9025,SS3472 –19–10DEC96–2/2
9025
05
41

031504
PN=463
Theory of Operation
Hydraulic Pump Controls—Flow Limited (High Pressure)

CONTROL LINE
LOAD SENSE
VALVE I VALVE
PUMP M
C
F FLOW LIMITER
CONTROL
BIAS PIN TO
FROM PUMP
OUTLET
L
DISPLACEMENT
CONTROL
9025 VALVE
05 K
42
D CONTROL
PISTON
E
PIN FROM
FLOW LIMITER
TO CONTROL
G PISTON
F
POPPET FLOW LIMITER
A
J
ORIFICE N SYSTEM
PRESSURE OIL
O CONTROL
–19–20DEC96
PRESSURE OIL
I H LOAD SENSE PORT P BIAS
PRESSURE OIL
M HYDRAULIC PUMP-
FLOW LIMITER Q RETURN OIL
T105468
T105468 SECTION
(HIGH PRESSURE)

031504
PN=464
Theory of Operation
A—Bias Piston Spring F—Flow Limiter K—Pressure Compensator O—Control Pressure Oil
B—Bias Piston G—Poppet Valve P—Bias Pressure Oil
C—Control Pin-to-Swash Plate H—Load Sense Line (Port) L—From Pump Outlet Q—Return Oil
in Pump I—Load Sense Valve M—Pump R—Hydraulic Pump—Flow
D—Control Piston J—Orifice N—System Pressure Oil Limiter (High Pressure)
E—Pin From Flow
As hydraulic system pressure increases during high oil to drain to return and the pump outlet pressure (L)
load applications, the flow limiter (F) senses pump oil to flow to the large end of the control piston (D).
displacement swash and system pressure from the This pressure moves the control piston to the left,
pump outlet to limit the maximum engine speed decreasing pump stroke. The control pin (E) from the
pulldown. control piston to flow limiter also moves to the left,
increasing spring force on the poppet (G).
The flow limiter maintains the pump displacement in
relation to pump outlet pressure. As system pressure As the poppet (G) displacement control valve closes,
increases, less pump displacement is available. pressure increases on the left side of the displacement
control valve (K), allowing the spool to shift to the right,
As hydraulic system pressure is increased to above maintaining a constant pump displacement setting.
the flow limiter setting, the pump outlet pressure is
sensed through the orifice in the center of the If the system pressure is again increased, the flow
displacement control valve (K) and the pressure opens limiter poppet (G) will again open and cause the pump
the flow limiter poppet (G), allowing oil to flow to displacement to decrease until flow limiter setting is
return. This causes a pressure drop through the orifice reached.
and lowers the signal to the left side of the
displacement control valve (K). As the system pressure is lowered below the flow
limiter setting, the flow limiter poppet (G) is closed,
The lower signal oil pressure causes the displacement stopping signal oil flow to return.
9025
control valve to shift to the left, allowing bias pressure
05
43
TX,9025,SS3473 –19–10DEC96–2/2

031504
PN=465
Theory of Operation
Hydraulic Filter—Normal Operation
2 3 4 5
1
6
7
A
8 9
9025
05
44
–UN–21MAR02
10
SECTION A-A
T152677
T152677
1—Main Inlet 4—Bypass Valve Spring 7—Filter 9—Switch

2—Inlet Check Valve 5—Outlet Check Valve 8—cooler Outlet 10—Return Oil
3—Bypass Valve 6—Outlet

031504
PN=466
Theory of Operation
The hydraulic filter assembly removes contaminants the pressure increases enough to overcome the force
from the hydraulic system return oil (10), produces of the inlet check valve spring. The oil flows into the
inlet back-pressure, and regulates outlet back-pressure filter element (7) then to the outlet pressure check
which forces flow through the hydraulic oil cooler. The valve (5). The outlet pressure check valve forces flow
filter housing contains an inlet check valve (2), bypass through the cooler outlet (8) port to the oil cooler.
valve (3), filter restriction switch (9), and an outlet When the restriction in the oil cooler becomes high
pressure check valve (5). Return oil (10) flows from the enough to overcome outlet pressure plus the set
loader valve, stabilizer valve and backhoe valve into spring force of the outlet check valve (5), the outlet
the main and auxiliary inlet (1). The oil then flows valve opens and allows oil to return to the reservoir.
through the inlet check valve (2), through the filter Pressure on the inlet side of the filter element is
element (7), through the auxiliary outlet (8) to the sensed on the left side of the bypass valve (3). Any
cooler, or through the outlet check valve (5), and then pressure at the filter outlet due to line restriction is
through the main outlet to the reservoir. Pressure on sensed on the right side of the bypass valve. Pressure
the inlet side of the filter assembly is sensed on the in the outlet passage and the by-pass spring (4) force,
left side of the inlet valve (2). The valve opens when hold the bypass valve closed.
CED,TX03768,2811 –19–21MAR02–2/2
9025
05
45

031504
PN=467
Theory of Operation
Hydraulic Filter Operation—Restricted

A
HIGH BYPASS BYPASS
PRESSURE VALVE 6 VALVE
PASSAGE 4 SPRING TO
5 RESERVOIR
1
MAIN
INLET 7 OUTLET
2 FILTER 3 8 LOW PRESSURE

COOLER PASSAGE
INLET
A
COOLER
OUTLET SWITCH
9 10
9025 SWITCH
05 SPRING
46
11
12
SWITCH
PISTON
–19–29AUG00
13 RETURN OIL PRESSURE 5 HIGH PRESSURE
14 RESTRICTED OIL PRESSURE PASSAGE
SECTION A-A 8 LOW PRESSURE
T133489
PASSAGE
T133489 15 HYDRAULIC FILTER - RESTRICTED OPERATION
1—Main Inlet 5—High Pressure Passage 9—Cooler Outlet 13—Return Oil Pressure
2—Cooler Inlet 6—Bypass Valve Spring 10—Switch 14—Restricted Oil Pressure
3—Filter 7—Outlet 11—Switch Spring 15—Hydraulic Filter-Restricted
4—bypass Valve 8—Low Pressure Passage 12—Switch Piston Operation

031504
PN=468
Theory of Operation
As the filter starts to plug or when the oil is cold, the switch, the piston (12) moves up (closes) providing
pressure at the inlet side of the filter element a ground for the filter restriction indicator. The switch
increases. When the filter becomes restricted to the will cause the filter restriction indicator light to
point where pressure at the filter element inlet illuminate. The indicator switch is set to close 10 psi
increases enough to overcome outlet pressure plus a before the bypass valve (4) opens allowing the
set spring force (6), the bypass valve opens allowing operator to perform maintenance on the hydraulic
unfiltered oil to flow to the oil cooler or to the reservoir. system before the unclean oil passes through the
hydraulic oil system.
The filter restriction indicator switch (10) works on the
same principle as the filter bypass valve. Under normal operation, the restriction indicator light
High-pressure oil is sensed through the high-pressure will glow when operating the hydraulic functions with
passage (5). Restricted oil (14) caused by a clogged cold oil. If the restriction indicator light continues to
filter or cold oil will create higher oil pressure on the glow after the oil reaches operating temperature, the
inlet side of the filter element. When this inlet pressure return filter is being bypassed. Extended operation in
overcomes the outlet pressure, sensed by the the bypass mode will cause damage to the hydraulic
low-pressure passage (8), plus a set spring (6) force in system.
CED,TX03768,2812 –19–12FEB02–2/2
9025
05
47

031504
PN=469
Theory of Operation
Steering—No Steering
PUMP PRESSURE A
LOAD
SENSE
ORIFICE B PORT
D
C SPRING
TO STEERING
PORTS
E SIGNAL FROM STEERING
STEERING F G H I
LOAD SENSE RELIEF VALVE
9025
M J
05 L
48 K
N LOAD SENSE
RELIEF ADJUSTING
SCREW
O PUMP PRESSURE OIL

–19–20DEC96
P RETURN OIL
Q TRAPPED OIL
R LOAD SENSE OIL
T105008
T105008 S NO STEERING
Steering—No Steering
Continued on next page TX,9025,RR7527 –19–01APR03–1/2

031504
PN=470
Theory of Operation
A—Pump Pressure F—Port “T” K—Load Sense Passage O—Pump Pressure Oil
B—Orifice G—Port “L” L—Load Sense Spring P—Return Oil
C—Spring H—Port “R” M—Load Sense Relief Valve Q—Trapped Oil
D—To Steering Port I—Port “P” N—Load Sense Relief R—Load Sense Oil
E—Signal From Steering J—Steering Unit Adjusting Screw S—No Steering
The steering valve is essentially a closed-center type When steering valve is in neutral, there is no oil
valve. The steering valve and pressure regulating flowing through it except neutral leakage. Neutral
valve provide a smooth pressure compensated leakage is used for lubrication and cooling the steering
steering system. valve.
TX,9025,RR7527 –19–01APR03–2/2
9025
05
49

031504
PN=471
Theory of Operation
Steering
PUMP PRESSURE A
LOAD
SENSE
ORIFICE B PORT
D
C SPRING
TO STEERING
PORTS
E SIGNAL FROM STEERING
STEERING F G H I
LOAD SENSE RELIEF VALVE
9025
M J
05 L
50 K
N LOAD SENSE
RELIEF ADJUSTING
SCREW
O PUMP PRESSURE OIL

–19–20DEC96
P RETURN OIL
Q LOAD SENSE OIL
R STEERING
T105007
T105007
Steering Valve Cross Section (S.N. —911133)
Continued on next page TX,9025,YY2136 –19–01APR03–1/4

031504
PN=472
Theory of Operation
A—Pump Pressure F—Port “T” K—Load Sense Passage O—Pump Pressure Oil
B—Orifice G—Port “L” L—Load Sense Spring P—Return Oil
C—Spring H—Port “R” M—Load Sense Relief Valve Q—Load Sense Oil
D—To Steering Port I—Port “P” N—Load Sense Relief R—Steering
E—Signal From Steering J—Steering Unit Adjusting Screw
(S.N. —911133) The steering control valve has a flow through the steering control valve. The pressure
pressure regulating valve bolted to its port face. The caused by the spring is referred to as the control
pressure regulating valve in conjunction with the load pressure.
sense relief valve regulates flow and pressure to the
steering control valve. When the operator speeds up the steering, the
pressure drop across the orifice is reduced. The spool
A constant pressure drop is established across the in the pressure regulating valve must shift to provide
orifice (B) in the pressure regulating valve by means of more flow for the steering until the pressure drop
a spring (C) in the regulating valve which will bias the across the orifice is equal to the control pressure. The
spool for steering. The pressure caused by the spring pressure regulating valve with a given spring will
is equal to the pressure drop across the orifice in the supply a predetermined amount of flow to the steering
pressure regulating valve which produces a constant control unit as the control orifice is varied.

9025
05
51

031504
PN=473
Theory of Operation
F G H I
O
P
Q
9025
05
52
S
–UN–15JAN03
S
T163733
S
T163733
Steering Valve Cross Section (S.N. 911133— )
F—Port “T” J—Steering Unit O—Pump Pressure Oil S—Anti-Cavitation Valves

G—Port “L” N—Load Sense Relief P—Return Oil T—Manual Steering Check
H—Port “R” Adjusting Screw Q—Load Sense Oil Valve Location
I—Port “P”
NOTE: Steering wheel or front wheels may rotate regulating valve. Actual operation of steering valve
slowly while operating backhoe or loader. This does not change.
is normal operation with newer series steering
valve. As steering valve is operated, the spool is turned by a
direct connection to the steering shaft. This movement
(S.N. 911133— ) The steering valve operates from aligns the spool passages with the sleeve ports and
system pressure eliminating the need for a pressure pressure oil begins to flow through the valve.

031504
PN=474
Theory of Operation
Oil flows through the sleeve and into spool passages • Oil is directed to the rod end of the steering cylinder.
backing out the sleeve into valve housing. Passages in Return oil from the cylinder is forced back through
the housing direct oil to one side of the gerotor moving the valve and out to the reservoir.
the gerotor gear. As the gear is rotated, it performs the • Rotation of the gerotor gear also turns the gerotor
following functions: drive which is connected to and turns the valve
sleeve.
• Oil is forced out of the gerotor into outlet passages
in the housing, back through the sleeve and spool,
and out the work port.
TX,9025,YY2136 –19–01APR03–4/4
Secondary Steering 8
If there is no power to supply pressure oil to the steering

valve, the machine can be turned manually. When the
steering wheel is turned, the spool will come into contact
with the pin (7). The pin then will provide a direct 9
7
mechanical connection to the gerotor gear assembly (5).
As the gerotor is turned, it pumps oil to the steering
cylinder. Return oil form the cylinder is drawn through a
check valve (6) between port “P” (12) and port “T” (9) to 10
provide oil for the secondary manual steering operation.
Make up oil is drawn from the hydraulic reservoir through
return line of the steering valve. 11
6 9025
05
53
1—Pressure Oil
2—Suction Oil
3—Return Oil 12
4—Trapped Oil
5—Gerotor Gear Assembly 1
6—Check Valve 2
–UN–04SEP98
7—Pin
8—Control Spool 3
9—Port “T”
4
10—Port “L”
11—Port “R”
T80790
5 T80790
12—Port “P”
Oil Flow for Secondary Steering
TX,9025,RR7548 –19–01APR03–1/1

031504
PN=475
Theory of Operation
Ride Control Hydraulic Component Location Circuit—Off (S.N. —911133)
ORIFICE 10
6
9
8
TO LEFT
BOOM
CYLINDER
HEAD END TO RIGHT
TO LEFT BOOM TO RIGHT
BOOM 2 5 BOOM
CYLINDER
CYLINDER ROD END CYLINDER
ROD END HEAD END
3
1 4
9025
05
54
5 ACCUMULATOR
TO RESERVOIR 9 6 VALVE
SOLENOID 8
–19–29SEP00
TO ACCUMULATOR 7 11 PRESSURE OIL

12 TRAPPED OIL
14 RIDE CONTROL HYDRAULIC CIRCUIT-
T133807
OFF POSITION 13 RETURN OIL

T133807
Continued on next page TX03768,0000B1B –19–02OCT00–1/3

031504
PN=476
Theory of Operation
1—To Left Boom Cylinder Rod 4—To Right Boom Cylinder 8—Solenoid 12—Trapped Oil
End Head End 9—To Reservoir 13—Return Oil
2—To Left Boom Cylinder 5—Accumulator 10—Orifice 14—Ride Control Hydraulic
Head End 6—Valve 11—Pressure Oil Circuit-OFF
3—To Right Boom Cylinder 7—To Accumulator
Rod End
TX03768,0000B1B –19–02OCT00–2/3
NOTE: The oil pressures illustrated on this page and the

previous page are indicative of the boom being SOLENOID 8
raised when the ride control is OFF.
TO BOOM
When the ride control is OFF, the machine is in normal CYLINDER
operating mode. In this mode, solenoid (8) and valve (6) ROD END 1 3
are deactivated and rod ends (1 and 3) of right and left
boom cylinders are disconnected from the hydraulic
TO RESERVOIR
reservoir. The head ends (2 and 4) of right and left boom
cylinders are still connected to accumulator (5) through 9 C2
orifice (10).
TO ACCU-
Orifice, located in the ride control valve, maintains the MULATOR 9025
accumulator oil pressure to approximately the same 7 05
pressure as the boom cylinder head end oil pressure. This 55
allows activation of the ride control without boom sag.
–19–29SEP00
10 ORIFICE
2 4 TO BOOM
CYLINDER
T134143
C1 HEAD END
T134143
TX03768,0000B1B –19–02OCT00–3/3

031504
PN=477
Theory of Operation
Ride Control Hydraulic Circuit Component Location and Valve Operation—On Position
(S.N. —911132)
ORIFICE 10
6
8
TO LEFT
BOOM
CYLINDER
HEAD END TO RIGHT
TO LEFT BOOM TO RIGHT
BOOM 2 5 CYLINDER BOOM
CYLINDER ROD END CYLINDER
ROD END HEAD END
3
1 4
9025
05
56
5 ACCUMULATOR
TO RESERVOIR 9 6 VALVE
SOLENOID 8
–19–29SEP00
TO ACCUMULATOR 7
11 TRAPPED OIL
13 RIDE CONTROL HYDRAULIC CIRCUIT-
T134053
ON POSITION 12 RETURN OIL

T134053
Continued on next page TX03768,0000B1C –19–02OCT00–1/3

031504
PN=478
Theory of Operation
1—To Left Boom Cylinder Rod 4—To Right Boom Cylinder 8—Solenoid 12—Trapped Oil
End Head End 9—To Reservoir 13—Return Oil
2—To Left Boom Cylinder 5—Accumulator 10—Orifice 14—Ride Control Hydraulic
Head End 6—Valve 11—Pressure Oil Circuit-OFF
3—To Right Boom Cylinder 7—To Accumulator
Rod End
TX03768,0000B1C –19–02OCT00–2/3
When traveling over rough terrain at high speed with a

loaded or empty bucket, the bucket produces a pitching SOLENOID 8
motion which is common to wheel loaders. Ride control
allows oil from the head end of the boom cylinders to
TO BOOM
travel in and out of the accumulator (5). This provides a CYLINDER
cushioning effect which reduces the pitching motion and ROD END 1 3
improves machine ride.
TO RESERVOIR
When the ride control is ON, solenoid (8) and valve (6)
are activated. Pressure spikes from head ends (2 and 4) 9 C2
of the right and left boom cylinders flow into the
accumulator where they are absorbed. The rod ends (1 TO ACCU-
and 3) of the right and left boom cylinders are open to MULATOR 9025
return. The return oil (11) is free to flow in and out of the 7 05
rod ends. The boom can be lowered, but only because of 57
the weight of boom and bucket. The boom cannot be
powered down while ride control is ON. Ride control can
be engaged during bucket loading, but may be turned
OFF if more rigid operation is desired.
–19–02OCT00
10 ORIFICE
2 4 TO BOOM
CYLINDER
T134157
C1 HEAD END
T134157
TX03768,0000B1C –19–02OCT00–3/3

031504
PN=479
Theory of Operation
Ride Control Hydraulic Circuit Component

Location and Valve Operation (S.N. 911133—
)
3—To Accumulator
4—Solenoid
5—Manifold Block
6—Accumulator 12 13
7—To Reservoir
8—To Left Boom Cylinder Head End
10
9—To Left Boom Cylinder Rod End 9
10—To Right Boom Cylinder Head End
11—To Right Boom Cylinder Rod End
12—To Accumulator
13—To Reservoir
11
–UN–23OCT02
5
T159774
3 4
Ride Control Component Location

9025
05
58
Continued on next page DW09104,0000055 –19–03SEP03–1/2

031504
PN=480
Theory of Operation
When traveling over rough terrain or at high speed with 1

loaded or empty bucket, machine develops a rocking
motion, which is common to loader backhoes. Ride control
allows oil from the head end of the boom cylinders to
travel in and out of the ride control accumulator. Ride
control allows rod end of boom cylinder to be connected
to the reservoir, which prevents cylinder cavitation. This
provides a cushioning effect reducing the rocking motion
and improving machine ride.
When ride control is “OFF”, the machine is in normal

operating mode. In this mode, both solenoids are
deenergized and rod ends of right and left boom cylinders
are blocked from the hydraulic reservoir. The heads ends
of boom cylinders are connected to an accumulator
through a two-way pressure balancing orifice. This orifice,
located in the ride control valve, maintains accumulator oil
pressure to approximately the same pressure as the boom
cylinder head end oil pressure. This allows activation of
the ride control function without boom sag. When loader
–UN–30SEP02
boom is raised and accumulator oil pressure is lower than
boom cylinder head end pressure the accumulator will
begin to charge to cylinder pressure through the orifice. 2
This will cause boom to settle until equal pressure is
T159775
reached. This may take several seconds, depending on
load.
Ride Control Solenoid
9025
When ride control is “ON”, both ride control solenoids (1) 05
1—Solenoid (2 Used)
are energized connecting head end of loader boom 2—Poppet 59
cylinders to the accumulator. Pressure spikes from head
ends of the boom cylinders flow into the accumulator
where they are absorbed. The rod ends of the boom
cylinders are open to bi-directional free flow to the
reservoir. As loader boom is raised accumulator is
charged with oil through ride control valve and pressure
balancing orifice maintaining equal loader head end
pressure and accumulator pressure. Cylinder rod end is
connected directly to reservoir. Because of this, power
boom down function will not operate. Boom will lower
because of boom weight and gravity. Ride control can be
engaged during bucket loading, but may be turned “OFF”
if a power down operation is desired.
DW09104,0000055 –19–03SEP03–2/2

031504
PN=481
Theory of Operation
Loader Valve Load Sense Relief (S.N. 913480— )
20 19 12 13 14
18
17 11 16
–UN–04APR03
21
22
15
T165988
9025 23
T165988
05
60
11—Metering Hole 15—Low Pressure Exhaust 18—Load Sense Pressure 21—High Pressure Oil
12—Main Poppet Bias Spring Vent Passage 22—Medium Pressure
13—Pilot Poppet 16—Rear Metering Edge 19—Main Poppet Orifice 23—Return Oil
14—Pilot Spring 17—Front Metering Edge 20—Main Poppet
The pilot operated adjustable load sense (LS) relief the poppet. This cavity is connected to the return
valve with drain regulator on this machine provides two passage through metering hole (11) in the side of the
separate functions. The drain regulator function allows relief valve body. Flow across main poppet orifice (19)
for constant controlled flow from the LS pressure causes a pressure drop in the main poppet. This
passage (18) to the low pressure return passage (15). imbalance pushes the main poppet (20) against the
Flow is constant regardless of the pressure differential bias spring (12) until the rear metering edge (16)
between the two passages. This function allows load restricts oil flowing through metering hole (11). Main
sense pressure to drop to tank pressure when no poppet (20) will open and close metering hole (11) as
functions are activated. The load sense relief function required to maintain a constant flow across the main
limits the maximum pressure in the LS pressure poppet orifice regardless of pressure level in LS
passage. When LS pressure reaches specification, LS pressure passage.
relief will open dumping regulated flow to tank.
Load Sense Relief
Drain Regulator
The relief valve setpoint is controlled by a pilot spring
In normal operation, high pressure oil flows through (14) holding the pilot poppet (13) on its seat.
orifice (19) in the main poppet (20) to the cavity behind
Continued on next page DW09104,000002C –19–01APR03–1/2

031504
PN=482
Theory of Operation
In normal operation, pressure oil less than the relief a pressure differential across the main poppet. The
valve setting flows through the orifice (19) in the main main poppet moves against the bias spring until it
poppet into the cavity behind the main poppet. This opens the front metering edge to a metering hole in
pressure and the bias spring (12) hold the main poppet the relief valve body. This allows high pressure oil to
closed. flow from work port to return port. When pressure in
LS passage (18) drops below relief specification pilot
In relief operation, high pressure oil overcomes spring poppet (13) closes stopping flow through the main
(14) force holding pilot poppet (13) on its seat. When poppet orifice. Pressure will equalizes on both sides of
pilot poppet (13) opens, oil flows through the main the main poppet and the bias spring will push the
poppet orifice (19), into the cavity behind the main poppet closed shutting off flow through the side
poppet, and past the pilot poppet (13) to tank. metering hole.
Pressure drop through the main poppet orifice causes
DW09104,000002C –19–01APR03–2/2
9025
05
61

031504
PN=483
Theory of Operation
Circuit Relief Valve without Anti-Cavitation and Load Sense Relief Valve—Loader and
Backhoe (S.N. —913479)
MAIN
POPPET
A
B PRESSURE OIL
–19–27SEP96
C RETURN OIL
D CIRCUIT RELIEF VALVE WITHOUT ANTI-CAVITATION
T101165
9025 T101165
05
62 Circuit Relief Valve without Anti-Cavitation and Load Sense Relief
A—Main Poppet B—Pressure Oil C—Return Oil D—Circuit Relief Valve without
Anti-Cavitation
Used on backhoe control valve boom raise, bucket The pressure set point is adjustable by turning the
dump, crowd out, and load sense relief valve. Also adjustment screw at the end of the relief. Turning the
used on loader control valve bucket rollback, load screw in increases pressure setting.
sense, and boom raise. The relief is direct acting,
screw adjustable, and does not have anti-cavitation In relief operation, pressure oil overcomes main poppet
operation. (A) and oil flows from the pressurized port to tank.
TX,9025,RR7290 –19–15JAN03–1/1

031504
PN=484
Theory of Operation
Circuit Relief Valve without Anti-Cavitation and Load Sense Relief—Loader and Backhoe
(S.N. 913480— )
–UN–11JAN03
2
3
9025
T163731
05
T163731 63
22.35 mm (0.88 in.) Port Size Shown
1—Main Poppet 2—Pressure Oil 3—Return Oil
This 22.35 mm (0.88 in.) port size metal to metal seal

relief without anti-cavitation is used on the inlet of the
load sensing backhoe control valve.
Continued on next page BT40170,0000040 –19–10JAN03–1/2

031504
PN=485
Theory of Operation
–UN–13JAN03
2
3
T163713
T163713
26 mm (1.06 in.) Port Size Shown
9025
05 1—Main Poppet 2—Pressure Oil 3—Return Oil
64
This 26 mm (1.06 in.) port size O-ring seal relief is The pressure set point is adjustable by turning the
used on backhoe control valve boom up, crowd out, adjustment screw at the end of the relief. Turning the
and bucket dump. It is also used on loader control screw in increases the pressure setting.
valve boom up and bucket curl.
In relief operation, pressure oil overcomes main poppet
These reliefs are direct acting, screw adjustable, and (1) and oil flows from the pressurized port to tank.
do not have anti-cavitation operation.
BT40170,0000040 –19–10JAN03–2/2

031504
PN=486
Theory of Operation
Circuit Relief Valve with Anti-Cavitation—Loader and Backhoe
ANTI-
CAVITATION
POPPET
F
C CAVITY
ORIFICE A
B POPPET D PRESSURE OIL
–19–10SEP98
E RETURN OIL
T7742AE
TXC7742AE CV
9025
05
65
A—Orifice C—Cavity E—Return Oil F—Anti-Cavitation Poppet
B—Relief Poppet D—Pressure Oil
The relief valve is used on the backhoe control valve In relief operation, pressure oil overcomes relief poppet
sections: swing, boom lower, crowd in, and system (B) pressure setting and opens a path to return.
relief. Also used on the loader control valve auxiliary
section. The relief is direct acting and has During anti-cavitation operation, the pressure in the
anti-cavitation operation except as a system relief work port is less than pressure in the return port. The
valve. pressure difference pushes the anti-cavitation poppet
(F) off its seat allowing oil to flow from return port to
In normal operation, pressure oil less than relief valve work port to prevent cavitation.
setting flows through orifice (A) into cavity (C) behind
relief valve poppet. Pressure oil and spring in cavity The circuit relief is not adjustable.
hold the anti-cavitation poppet closed because
effective area on this side is greater than on work port
side.
TX03768,0000B02 –19–01SEP00–1/1

031504
PN=487
Theory of Operation
Circuit Relief Valve with Anti-Cavitation—Loader and Backhoe
H ORIFICE C ANTI-CAVITATION
POPPET D ANTI-CAVITATION
B MAIN I CAVITY SPRING G PILOT
POPPET SPRING
A PISTON
J RELIEF E MAIN F PILOT
POPPET
–19–01SEP00
BODY SPRING K PRESSURE OIL
L RETURN OIL
T133578
M CIRCUIT RELIEF VALVE WITH ANTI-CAVITATION
9025 T133578
05
66
A—Piston E—Main Spring I—Cavity L—Return Oil
B—Main Poppet F—Pilot Poppet J—Relief Body M—Loader Circuit Relief Valve
C—Anti-Cavitation Poppet G—Pilot Spring K—Pressure Oil with Anti-Cavitation
D—Anti-Cavitation Spring H—Orifice
The relief valve is used on the backhoe control valve In relief operation, pressure oil overcomes pilot poppet
bucket curl and the loader control valve bucket dump. (F) and oil flows from the pressurized port through
The relief is a pilot operated, screw adjustable, with orifice (H) into cavity (I) past pilot poppet (F) to tank
anti-cavitation operation. through a path between relief body (J) and
anti-cavitation poppet (C). The pressure drop through
The relief valve setting is controlled by the spring load orifice (H) causes a pressure difference across piston
(G) holding the pilot poppet (F) on its seat. The setting (A) and it moves against main spring (E) until it rests
is adjustable. Loosen lock nut and screw adjustment on pilot poppet (F). This movement shuts off orifice (H)
cap IN to increase pressure setting. and further reduces the pressure in cavity (I). When
the pressure difference is large enough to overcome
In normal operation, pressure oil less than relief valve the differential area effect holding the main poppet (B)
setting flows though orifice (H) in piston (A) into cavity on its seat and oil is allowed to flow from the work port
(I) behind the anti-cavitation poppet (C) and main relief to the return port.
valve poppet (B). This oil pressure and the springs
hold the main poppet (B) and anti-cavitation poppet (C)
closed because the effective areas of the poppets on
the cavity side is greater than the work port side.
Continued on next page TX03768,0000B03 –19–01SEP00–1/2

031504
PN=488
Theory of Operation
During anti-cavitation operation, the pressure in the differential area effect holding the anti-cavitation
work port and cavity (I) is less than the pressure in the poppet (C) on it’s seat and oil is allowed to flow from
return port. This pressure difference overcomes the return port to work port to prevent cavitation.
TX03768,0000B03 –19–01SEP00–2/2
9025
05
67

031504
PN=489
Theory of Operation
Backhoe Auxiliary Flow Control Circuit Relief Valve
C ANTI-CAVITATION
POPPET
B MAIN I OIL D ANTI-CAVITATION
POPPET CAVITY SPRING
G PILOT
SPRING
H ORIFICE
A
PISTON
E MAIN F POPPET
SPRING PILOT
RELIEF J
–19–20DEC96
BODY
K PRESSURE OIL
M CIRCUIT RELIEF VALVE L RETURN OIL
T105523
T105523
9025
05
Circuit Relief Valve
68
A—Piston E—Main Spring H—Orifice K—Pressure Oil
B—Main Poppet F—Poppet Pilot I—Oil Cavity L—Return Oil
C—Anti-Cavitation Poppet G—Pilot Spring J—Relief Body M—Circuit Relief Valve
D—Anti-Cavitation Spring
The relief is pilot operated and screw adjustable. In relief operation, pressure oil overcomes pilot poppet
(F) and oil flows from the pressurized port through
The relief valve setting is controlled by the spring load orifice (H) into cavity (I) past pilot poppet (F) to tank
(G) holding the pilot poppet (F) on its seat. This setting through a path between relief body (J) and
is adjustable by turning the adjustment screw at the anti-cavitation poppet (C). The pressure drop through
end of the relief. orifice (H) causes a pressure difference across piston
(A) and it moves against main spring (E) until it rests
In normal operation, pressure oil less than relief valve on pilot poppet (F). This movement shuts off orifice (H)
setting flows through orifice (H) in piston (A) into cavity and further reduces the pressure in cavity (I). When
(I) behind the anti-cavitation poppet (C) and main relief the pressure difference is large enough to overcome
valve poppet (B). This oil pressure and the springs the differential area effect holding the main poppet (B)
hold the main poppet (B) and anti-cavitation poppet (C) on it’s seat and oil is allowed to flow from the work
closed because the effective areas of the poppets on port to return port.
the cavity side is greater than the work port side.
TX,9025,RR7557 –19–03DEC96–1/1

031504
PN=490
Theory of Operation
9025
05
69

031504
PN=491
Theory of Operation
Backhoe Inlet Section with Swing Section Activated
BACKHOE STABILIZER
CONTROL VALVE VALVE RETURN
L.S. RELIEF
VALVE
B
SYSTEM RELIEF
A STABILIZER
VALVE L. S.
(EXT. DIPPER)
AUXILIARY
ISOLATOR
BUCKET
CROWD
AUXILIARY
(ATTACH)
BOOM
SWING
OUTLET
INLET C END CAP
END CAP
C PUMP LOAD SENSE PORT
9025
05 STABILIZER
VALVE B LOAD SENSE
70
PRESSURE RELIEF VALVE
ISOLATOR A
G AUX. PILOT OIL

—OPTIONAL
E HIGH PRESSURE OIL

–19–05JUN97
D INLET PRESSURE OIL F RETURN PRESSURE OIL

I TRAPPED OIL
H BACKHOE INLET SECTION
T109415
T109415 WITH SWING SECTION ACTIVATED

Backhoe Inlet Section with Swing Section Activated (S.N. —913483)
Continued on next page TX,9025,RR7549 –19–12FEB03–1/4

031504
PN=492
Theory of Operation
A—Isolator D—Inlet Pressure Oil G—Auxiliary Pilot Oil I—Trapped Oil

B—Load Sense Relief Valve E—High Pressure Oil (optional)
C—Pump Load Sense Port F—Return Pressure Oil H—Backhoe Inlet Section,
Boom Swing Activated
9025
05
71

031504
PN=493
Theory of Operation
BACKHOE STABILIZER
CONTROL VALVE VALVE RETURN
L.S. RELIEF
VALVE
B
SYSTEM RELIEF
A STABILIZER
VALVE L. S.
(EXT. DIPPER)
AUXILIARY
BUCKET
ISOLATOR
CROWD
AUXILIARY
BOOM
(ATTACH)
SWING
OUTLET
INLET C END CAP
END CAP
C
J K B
9025
05
72
G
E
F
I
–19–10JAN03
D
T163625
T163625
Backhoe Inlet Section with Swing Section Activated (S.N. 913484— )
A—Isolator F—Return Pressure Oil I—Trapped Oil K—Plugged Port (Manual

B—Load Sense Relief Valve G—Auxiliary Pilot Oil J—Hydraulic Line to Pilot Control Machines Only)
C—Pump Load Sense Port (optional) Control Manifold Valve
D—Inlet Pressure Oil H—Backhoe Inlet Section, (Pilot Control Machines
E—High Pressure Oil Boom Swing Activated Only)

031504
PN=494
Theory of Operation
The inlet section of the backhoe valve provides a section is the electro-hydraulic auxiliary section. This
means of connecting the valve to the pump. The pump passage supplies pressure to the spool section’s
output is connected to the valve’s inlet pressure port actuator, which reduces the pressure for use as a pilot
(D). The load sense port (C) connects to the pump’s signal to shift the spool. An O-ring is installed in the
load sense port. inlet section around the pilot supply port for sealing
between the inlet section and spool section.
The isolator valve assembly (A) is used to supply a
signal equal to the highest work port pressure to the On machine equipped with pilot controls, backhoe
pump load sense port without allowing load sense oil valve inlet section is connected to the pilot control
to exit the valve. manifold (PCMV) through port (J). On machines
equipped with manual controls, port (J) is plugged (K).
A direct acting load sense relief valve (B) limits the
maximum load sense pressure signal sent to the (S.N. 913480— ) Load sense shuttle check between
pump, which limits the pump pressure sent to the last backhoe valve section and end cap has been
hydraulic system. removed. LS signal to stabilizer valve is connected
with loader valve.
The auxiliary pilot oil passage (G) is present in the
inlet section if the spool section next to the inlet
TX,9025,RR7549 –19–12FEB03–4/4
9025
05
73

031504
PN=495
Theory of Operation
Backhoe Auxiliary Flow Valve—Solenoid Energized
B
STABILIZER
VALVE RETURN
BACKHOE
CONTROL F
VALVE
L.S.
RELIEF
ISOLATOR
SYSTEM RELIEF
STABILIZER
VALVE L. S.
AUX. SWING BOOM BUCKET CROWD AUX. OUTLET

(ATTACH) (EXT. DIPPER) ENDCAP
INLET D
ENDCAP
STABILIZER
VALVE
PRESSURE
9025
05
74
WORK C LOAD SENSE

F LOGIC CHECK G PLUG
PORT
CIRCUIT RELIEF D COMPENSATOR/LIFT CHECK
WITHOUT B
ANTI-CAVITATION TANK PASSAGE E INLET
A PRESSURE
H BRIDGE
BLEED
ORIFICE
FLOW
I ADJUSTER
SCREW
PILOT L
PRESSURE
PASSAGE
J SPRING
–19–21SEP00
M HIGH PRESSURE OIL

ELECTRO-HYDRAULIC N PILOT PRESSURE
K PILOT ACTUATOR
O LOW PRESSURE OIL
T133585
T133585 P BACKHOE AUXILIARY FLOW VALVE - SOLENOID ENERGIZED

031504
PN=496
Theory of Operation
A—Tank passage E—Inlet Pressure Passage J—Spring N—Pilot Pressure Oil

B—Circuit Relief without F—Load Sense Logic Check K—Electron-Hydraulic Pilot O—Low Pressure Oil
Anti-Cavitation G—Plug Actuator P—Backhoe Auxiliary
C—Work Port H—Bridge Bleed Orifice L—Pilot Pressure Oil Passage Valve-Solenoid Energized
D—Compensator/Lift Check I—Flow Adjuster Screw M—High Pressure Oil Low
Pressure Oil
The auxiliary section is a two-position, two-way, When current is supplied to the actuator (A), pilot
closed-center, spool-type valve. The section contains a pressure (J) is metered to the end of the main spool,
solenoid pilot actuator (A) which is used to causing it to shift against the return spring (H). Oil
proportionally shift the main spool. The auxiliary flow flows from the inlet passage (E), past the spool and
valve is designed to give three distinct flows, 9, 13, compensator (D), out the work port to the cylinder.
and 25 gpm. Additional oil flows between 13 and 34 Return oil from the attachment is directed back to the
gpm is available by selecting the 25 gpm setting and hydraulic reservoir through the auxiliary return port of
then adjusting the valve spool adjuster (P). Turning the the backhoe valve. When setting oil flow from 13 to 34
adjuster in lowers flow while backing the adjuster out gpm to meet the specification of an attachment, an oil
increases flow. The flow is set by depressing a switch flow meter must be used to set the flow before using
to one of three positions located under the side the attachment.
console of the machine. The side console must be
removed to access the switch. Refer to decal next to (S.N. 913480— ) Load sense shuttle check between
the switch. When setting the flow, both the ignition and last backhoe valve section and end cap has been
auxiliary flow switches must be turned OFF which are removed. LS signal to stabilizer valve is connected
located on the side console. The section includes a with loader valve.
circuit relief valve without anti-cavitation (B).
The valve section contains a bleed orifice (G) to bleed

the section’s load sense signal to tank when the spool
is in neutral.
9025
05
75
TX,9025,RR7532 –19–17APR03–2/2

031504
PN=497
Theory of Operation
Backhoe Swing Section—Swing Right Position
B B
STABILIZER
VALVE RETURN
BACKHOE
CONTROL
VALVE H
L.S.
RELIEF
ISOLATOR
SYSTEM RELIEF
STABILIZER
VALVE L. S.
INLET AUX. AUX. OUTLET

ENDCAP (ATTACH) SWING BOOM BUCKET CROWD
(EXT. DIPPER) ENDCAP
D E
STABILIZER
VALVE
9025
PRESSURE
05
76
SWING LEFT C LOAD SENSE

WORK PORT H LOGIC CHECK F SWING RIGHT
WORK PORT
D COMPENSATOR/LIFT CHECK G BRIDGE BLEED
E INLET ORIFICE
PRESSURE
B
CIRCUIT
RELIEF
WITH
B ANTI-
CAVITATION
CIRCUIT
RELIEF
WITH
ANTI-
CAVITATION
–19–09OCT97
I HIGH PRESSURE OIL

A J RETURN
PRESSURE OIL
T109409
T109409 K BACKHOE SWING SECTION - SWING RIGHT POSITION

Backhoe Swing Section-Swing Right Position

031504
PN=498
Theory of Operation
A—Return Passage D—Compensator H—Load Sense Logic Check K—Backhoe Swing

B—Circuit Relief with E—Inlet Pressure Passage Shuttle Section-Swing Right
Anti-cavitation F—Swing Right Work Port I—High Pressure Oil Position
C—Swing Left Work Port G—Bridge Bleed Orifice J—Return Pressure Oil
The swing section is a three-position, four-way, compensator (D), out the work port to the cylinders.
closed-center, spool-type valve. The valve contains Return oil from the cylinders flows into the other work
two circuit relief valves with anti-cavitation (B). port, past the spool, into the return passage (A), then
out of the control valve to the system reservoir.
The valve section contains a bleed orifice (G) to bleed
the section’s load sense signal to the return passage (S.N. 913480— ) Load sense shuttle check between
when the spool is in neutral. last backhoe valve section and end cap has been
removed. LS signal to stabilizer valve is connected
When the spool is moved to activate a function, oil with loader valve.
flows from the inlet passage (E), past the spool and
TX,9025,RR7533 –19–17APR03–2/2
9025
05
77

031504
PN=499
Theory of Operation
Backhoe Boom Section—Boom Raise Position (S.N. —913483)
B H
BACKHOE
CONTROL STABILIZER
VALVE VALVE RETURN
M
L.S.
RELIEF
SYSTEM RELIEF
STABILIZER
ISOLATOR
VALVE L. S.
INLET AUX. SWING BOOM BUCKET CROWD AUX. OUTLET

ENDCAP (ATTACH) (EXT. DIPPER) ENDCAP
D E
STABILIZER
VALVE
PRESSURE
9025
05
78
COMPENSATOR/ D LOAD SENSE

LIFT CHECK LOGIC CHECK M BOOM RAISE
F WORK PORT
BOOM LOWER C E INLET PRESSURE
WORK PORT BRIDGE BLEED
ORIFICE J G ORIFICE
CIRCUIT RELIEF
WITH I ANTI-DRIFT
ANTI-CAVITATION CHECK
B
H CIRCUIT RELIEF
WITHOUT
ANTI-CAVITATION
N HIGH PRESSURE OIL

–19–09OCT97
O LOW PRESSURE OIL

TANK PASSAGE A WORK PORT K L VENT
PASSAGE PASSAGE
T109408
T109408
P BACKHOE BOOM SECTION - BOOM RAISE POSITION
Backhoe Boom Section-Boom Raise Position (S.N. —913483)

031504
PN=500
Theory of Operation
A—Return Passage E—Inlet Pressure Passage I—Anti-Drift Check N—High Pressure Oil
B—Circuit Relief with F—Boom Raise Work Port J—Orifice O—Low Pressure Oil
Anti-cavitation G—Bridge Bleed Orifice K—Work Port Passage P—Backhoe Boom Section—
C—Boom Lower Work Port H—Circuit Relief without L—Vent Passage Boom Raise Position
D—Compensator Anti-Cavitation M—Load Sense Logic Check
Shuttle
The boom valve is three-position, four-way, raise work port (F) enters orifice (J) and is passed to
closed-center, spool-type valve section. The section the spring side of the check. Pressure in the work port
contains a circuit relief valve (H) in the boom raise (K) falls due to oil leakage past the spool to the return
circuit and a circuit relief with anti-cavitation (B) in the passage (A). The higher work port pressure on the
boom lower work port. spring side of the check forces the check securely into
the seat forming a seal. The spring side of the check
The valve section contains a bleed orifice (G) to bleed may be vented to the return passage through a vent
the section’s load sense signal to return passage when passage (L). This passage is open and closed
the spool is in neutral. depending on the position on the main spool. With the
main spool in neutral or boom raise position the vent
When the spool is moved to activate a function, oil passage (L) is blocked. When the main spool is moved
flows from the inlet passage (E), past the spool and to the boom lower position the vent passage (L) is
compensator (D), out the work port to the cylinders. opened to the return passage (A). Oil flows from the
Return oil from the cylinders flows into the other work work port (F) through orifice (J) in the check (I), though
port, past the spool, into the return passage (A), then the vent passage (L) to the return passage (A).
out of the control valve to the system reservoir. Pressure drop across the orifice (J) causes the
pressure on the spring side of the check to drop lower
An anti-drift check valve (I) is provided to significantly than the pressure in work port (F). This pressure
reduce oil leakage back into the boom raise work port imbalance causes the check (I) to open allowing flow
(F). With the valve in neutral, the check (I) is spring to main spool.
loaded to the closed position. Pressure in the boom
9025
05
79
TX,9025,RR7534 –19–08NOV96–2/2

031504
PN=501
Theory of Operation
Backhoe Boom Section—Boom Raise Position (Pilot Control) (S.N. 913484— )
3 4 5 11 6
9 10
8
2
14 13
–UN–25FEB03
15
16 18 1 7 12
T165252
9025
17
T165252
05
80
1—Return Passage 6—Boom Raise Work Port 11—Work Port Passage 15—High Pressure Oil
2—Circuit Relief with 7—Bridge Bleed Orifice 12—Vent Passage 16—Low Pressure Oil
Anti-cavitation 8—Circuit Relief without 13—Pilot Cap 17—Pilot Pressure Oil
3—Boom Lower Work Port Anti-Cavitation 14—Pilot Cap with Centering 18—Backhoe Boom Section—
4—Compensator 9—Anti-Drift Check Spring Boom Raise Position
5—Inlet Pressure Passage 10—Orifice
The boom valve is three-position, four-way, Return oil from the cylinders flows into the other work
closed-center, spool-type valve section. The section port (3), past the spool, into the return passage (1),
contains circuit relief valves (2, 8) in the boom raise then out of the control valve to the system reservoir.
and boom lower circuits respectively.
An anti-drift check valve (9) is provided to significantly
The valve section contains a bleed orifice (7) to bleed reduce oil leakage back from the boom raise work port
the sections load sense signal to return passage (1) (6). With the valve in neutral, the check (9) is spring
when the spool is in neutral. loaded to the closed position. Pressure in the boom
raise work port (6) enters orifice (10) and is passed to
When the spool is moved to activate a function, oil the spring side of the check. The work port pressure
flows from the inlet passage (5), past the spool and on the spring side of the check forces the check
compensator (4), out the work port (6) to the cylinders. securely into the seat forming a seal.

031504
PN=502
Theory of Operation
The spring side of the check may be vented to the the orifice (10) causes the pressure on the spring side
return passage through vent passage (12). This of the check to drop lower than the pressure in work
passage is open and closed depending on the position port (6). This pressure imbalance causes the check (9)
on the main spool. With the main spool in neutral or to open allowing flow to main spool.
boom raise position the vent passage (12) is blocked.
When the main spool is moved to the boom lower (S.N. 913480— ) Load sense shuttle check between
position the vent passage is opened to the return last backhoe valve section and end cap has been
passage. Oil flows from the work port (6) through removed. LS signal to stabilizer valve is connected
orifice (10) in the check (9), though the vent passage with loader valve.
(12) to the return passage (1). Pressure drop across
BT40170,0000049 –19–17APR03–2/2
9025
05
81

031504
PN=503
Theory of Operation
Backhoe Bucket Section—Bucket Curl Position (S.N. —913483)
BACKHOE
K B
CONTROL
H
VALVE
STABILIZER
VALVE RETURN
RELIEF
L.S.
SYSTEM RELIEF
STABILIZER
ISOLATOR
VALVE L. S.

E
STABILIZER D
VALVE
PRESSURE
9025
05
82
BUCKET LOAD
C LOAD SENSE BUCKET DUMP
WORK PORT H LOGIC CHECK
COMPENSATOR/
F WORK PORT
D
LIFT CHECK
INLET
CIRCUIT RELIEF E G BRIDGE BLEED
WITH ANTI- PRESSURE
ORIFICE
B CAVITATION
K
CIRCUIT
RELIEF
WITHOUT
ANTI-
–19–05SEP00
A CAVITATION
I HIGH PRESSURE OIL

L BACKHOE BUCKET SECTION -
T133582
J RETURN PRESSURE OIL

T133582 BUCKET CURL POSTION

031504
PN=504
Theory of Operation
A—Return Passage D—Compensator H—Load Sense Logic Check J—Return Pressure Oil
B—Circuit Relief with E—Inlet Pressure Passage Shuttle K—Circuit Relief without
Anti-Cavitation F—Bucket Dump Work Port I—High Pressure Oil Anti-Cavitation
C—Bucket Load Work Port G—Bridge Bleed Orifice
The bucket valve is three-position, four-way, compensator (D), out the work port to the cylinders.
closed-center, spool-type valve section. The section Return oil from the cylinders flows into the other work
contains a circuit relief valve with anti-cavitation (B) in port, past the spool, into the return passage (A), then
the bucket load circuit and circuit relief valve (K) in the out of the control valve to the system reservoir.
bucket dump circuit.
(S.N. 913480— ) Load sense shuttle check between
The valve section contains a bleed orifice (G) to bleed last backhoe valve section and end cap has been
the section’s load sense signal to the return passage removed. LS signal to stabilizer valve is connected
when the spool is in neutral. with loader valve.
When the spool is moved to activate a function, oil

TX,9025,RR7535 –19–08FEB00–2/2
9025
05
83

031504
PN=505
Theory of Operation
Backhoe Crowd Section—Crowd In Position (S.N. —913483)
M B H STABILIZER
VALVE RETURN
BACKHOE
CONTROL
VALVE
L.S.
RELIEF
SYSTEM RELIEF
STABILIZER
VALVE L. S.
ISOLATOR
E
D
STABILIZER
VALVE
PRESSURE
9025
05
84
LOAD SENSE
ORIFICE M LOGIC CHECK
CROWD IN
CROWD OUT J F WORK PORT
WORK PORT C D COMPENSATOR/LIFT CHECK
E INLET PRESSURE
G BRIDGE BLEED
ORIFICE
ANTI-DRIFT I CIRCUIT
CHECK RELIEF
WITH
B ANTI-
CAVITATION
CIRCUIT H
RELIEF
WITHOUT
ANTI-
CAVITATION
–19–09OCT97
VENT PASSAGE L TANK WORK PORT N HIGH PRESSURE OIL

PASSAGE A K PASSAGE O LOW PRESSURE OIL
T109406
T109406
P BACKHOE CROWD SECTION -CROWD IN

031504
PN=506
Theory of Operation
A—Return Passage E—Inlet Pressure Passage I—Anti-Drift M—Load Sense Logic Check
B—Circuit Relief with F—Crowd In Work Port J—Orifice Shuttle
Anti-Cavitation G—Bridge Bleed Orifice K—Work Port Passage N—Pump Oil
C—Crowd Out Work Port H—Circuit Relief without L—Vent Passage O—Return Pressure Oil
D—Compensator Anti-Cavitation
The crowd valve is a three-position, four-way, (K) falls due to oil leakage past the spool to the return
closed-center, spool-type valve section. The section passage (A). The higher work port pressure on the
contains a circuit relief valve (H) in the crowd out spring side of the check forces the check securely into
circuit and a circuit relief with anti-cavitation (B) in the the seat forming a seal. The spring side of the check
crowd in circuit may be vented to the return passage (A) through a
vent passage (L). This passage is open and closed
The valve section contains a bleed orifice (G) to bleed depending on the position of the main spool. With the
the section’s load sense signal to the return passage main spool in neutral or the crowd out position the vent
when the spool is neutral. passage (L) is blocked. When the main spool is moved
to the crowd in position the vent passage (L) is opened
When the spool is moved to activate a function, oil to the return passage (A). Oil flows from the work port
flows from the inlet passage (E), past the spool and (F) through orifice (J) in the check (I), through the vent
compensator (D), out the work port to the cylinders. passage (L) to the return passage (A). Pressure drop
Return oil from the cylinders flows into the other work across the orifice (J) causes the pressure on the
port, past the spool, into the return passage (A), then spring side of the check to drop lower than the
out of the control valve to the system reservoir. pressure in work port (F). This pressure imbalance
causes the check (I) to open allowing flow to the main
An anti-drift check valve (I) is provided to significantly spool.
reduce oil leakage back into the crowd out work port
(C). With the valve in neutral, the check (I) is spring (S.N. 913480— ) Load sense shuttle check between
loaded to the closed position. Pressure in the work last backhoe valve section and end cap has been
port (F) enters orifice (J) and is passed to the spring removed. LS signal to stabilizer valve is connected 9025
side of the check. Pressure in the work port passage with loader valve. 05
85
TX,9025,RR7536 –19–08FEB00–2/2

031504
PN=507
Theory of Operation
Backhoe Auxiliary Section—Neutral
I
BACKHOE M STABILIZER
CONTROL VALVE RETURN
VALVE
L.S.
RELIEF
SYSTEM RELIEF
STABILIZER
VALVE L. S.
ISOLATOR
INLET AUX. SWING BOOM BUCKET CROWD AUXILIARY

ENDCAP (ATTACH)
E
STABILIZER OUTLET
VALVE END CAP
9025 PRESSURE
05
86
M LOAD SENSE
LOGIC CHECK F EXTENDABLE IN
EXTENDABLE OUT C D COMPENSATOR/LIFT CHECK WORK PORT
WORK PORT
INLET PRESSURE ORIFICE
G BRIDGE BLEED ORIFICE
E J
RELIEF PORT I ANTI-DRIFT CHECK
SHUTOFF PLUG
B H RELIEF PORT
SHUTOFF PLUG
–19–09OCT97
N HIGH PRESSURE OIL

O LOW PRESSURE OIL
TANK PASSAGE A WORKPORT K L VENT PASSAGE
T109405
T109405
P BACKHOE AUXILIARY SECTION - LOAD POSITION
Backhoe Auxiliary Section-Neutral
Continued on next page CED,TX03768,2675 –19–19NOV99–1/2

031504
PN=508
Theory of Operation
A—Return Passage E—Inlet Pressure Passage I—High Pressure Oil L—Trapped Oil
B—Relief Valve Port Shut-Off F—Rod End Work Port J—Return Pressure Oil M—Loader Auxiliary Section—
Plug G—Bridge Bleed Orifice K—Relief Valve with Neutral Position
C—Head End Work Port H—Load Sense Logic Check Anti-Cavitation
D—Compensator Shuttle
The backhoe auxiliary valve section is a three-position, Return oil form the cylinders flows into the other work
four-way, closed-center, spool-type valve section. The port, past the spool, into return passage (A), then out
section contains a circuit relief valve with of the control valve to the system reservoir.
anti-cavitation (K) in the head end work port.
The auxiliary valve is normally used to control
The valve section contains a bleed orifice (G) to bleed extendible buckets.
the section’s load sense signal to the return passage
when the spool is in neutral. (S.N. 913480— ) Load sense shuttle check between
last backhoe valve section and end cap has been
When the spool is moved to activate a function, oil removed. LS signal to stabilizer valve is connected
flows from the inlet passage (E), past the spool and with loader valve.
compensator (D), out the work port to the cylinders.
CED,TX03768,2675 –19–19NOV99–2/2
9025
05
87

031504
PN=509
Theory of Operation
Backhoe Valve End Cap
STABILIZER
VALVE RETURN
BACKHOE
CONTROL
VALVE
L.S.
RELIEF
ISOLATOR
SYSTEM RELIEF
STABILIZER
D VALVE L. S.
(EXT. DIPPER)
AUXILIARY
BUCKET
AUXILIARY
CROWD
BOOM
(ATTACH)
SWING
9025
05 OUTLET
INLET END CAP
88 END CAP
STABILIZER
VALVE C LOAD SENSE INPUT PORT
PRESSURE
D SYSTEM RELIEF
VALVE
–19–09OCT97
E HIGH PRESSURE OIL

F RETURN PRESSURE OIL
RETURN PORTS A
T109404
T109404 B BACKHOE ENDCAP OUTLET

Backhoe Valve End Cap (S.N. —913479)

031504
PN=510
Theory of Operation
A—Return Ports D—System Relief Valve E—High Pressure Oil F—Return Pressure Oil
C—Load Sense Input Port
Backhoe Valve End Cap (S.N. —913479) sense port. The outlet section includes a system relief
valve (D) which is used to relieve pressure spikes in
The outlet section provides a means to connect the the pump output passage.
valve to the hydraulic reservoir via the return ports (A).
The load sense (LS) input port allows a load sense The system relief valve also protects the system in
signal to be input from the stabilizer valve. This signal case the pump would fail to destroke with all valves in
is compared to the work port pressures in this valve neutral.
and the highest pressure is sent to the pump’s load
9025
05
89

031504
PN=511
Theory of Operation
STABILIZER
VALVE RETURN
BACKHOE
CONTROL
VALVE
L.S.
RELIEF
ISOLATOR
SYSTEM RELIEF
D
(EXT. DIPPER)
AUXILIARY
BUCKET
AUXILIARY
CROWD
BOOM
(ATTACH)
SWING
OUTLET
INLET END CAP
9025 END CAP
05
90
STABILIZER
VALVE C LOAD SENSE INPUT PORT
PRESSURE
D SYSTEM RELIEF
VALVE
–19–21APR03
E HIGH PRESSURE OIL

RETURN PORTS A
T189163
B BACKHOE ENDCAP OUTLET

T189163
Backhoe Valve End Cap (S.N. 913480— )

031504
PN=512
Theory of Operation
A—Return Ports D—System Relief Valve E—High Pressure Oil F—Return Pressure Oil
C—Load Sense Input Port
Backhoe Valve End Cap (S.N. 913480— ) backhoe valve section and end cap has been
removed. LS signal to stabilizer valve is connected
The outlet section provides a means to connect the with loader valve.
valve to the hydraulic reservoir via the return ports (A).
The load sense (LS) input port allows a load sense The pilot control system (S.N. 913484— ) includes two
signal to be input from the stabilizer valve. This signal pilot controls, pilot control manifold valve, and optional
is compared to the work port pressures in this valve pattern select valve. System pressure is reduced to
and the highest pressure is sent to the pump’s load pilot pressure through the pressure reducing valve.
sense port. The outlet section includes a system relief With pilot enable solenoid energized, pilot control
valve (D) which is used to relieve pressure spikes in regulated pressure flows to pilot control levers in cab.
the pump output passage. When a function is activated, pilot oil flows to pilot cap
of control valve to shift the spool.
The system relief valve also protects the system in
case the pump would fail to destroke with all valves in The pattern select valve switches control of backhoe
neutral. Load sense shuttle check between last boom and crowd functions for operator preference.
TX,9025,RR7550 –19–15APR03–4/4
9025
05
91

031504
PN=513
Theory of Operation
Pilot Control Valve Theory of Operation (S.N. 913484— )
1 6
9025
05 4
92
9
–UN–28JAN03
13
10
14
T162914
11 12
T162914
Continued on next page BT40170,000003D –19–16DEC02–1/2

031504
PN=514
Theory of Operation
1—Wobble Plate 5—Metering Spring (4 used) 8—Internal Pressure Port 12—Pressure Port
2—Plunger (4 used) 6—Plunger Assembly (4 used) 9—Metering Spool (4 used) 13—Return Pressure Oil
3—Spring Guide (4 used) 7—Metering Spool Orifice (4 10—Tank Port 14—Pilot Pressure Oil
4—Return Spring (4 used) used) 11—Work Port
Two pilot control valve assemblies are used to control Metering Operation
backhoe functions. Each control valve contains four
plunger assemblies (6), one for each direction of each During operation, pilot pressure oil from the pilot
function. control manifold valve enters the pilot control valve at
pressure port (12). Wobble plate (1) depresses plunger
NOTE: Plunger, bearing and O-ring, spring guide, (2) contacting spring guide (3). The spring guide
return spring, metering spring, metering spool compresses both return spring (4) and metering
and integral washers are serviced as an (pressure control) spring (5). The compressed springs
assembly (6). move metering spool (9) down to a metering position
allowing oil to flow out connected workport. As
Neutral Operation workport pressure builds to meet spring force the
metering spool moves between neutral and metered
In neutral, with no other functions activated, return position maintaining commanded pressure.
spring (4) holds the metering spool (9) closed. This
blocks pressure oil (14) from entering the work ports
allowing oil to return to tank.
BT40170,000003D –19–16DEC02–2/2
9025
05
93

031504
PN=515
Theory of Operation
Pilot Control Manifold Valve Operation (S.N.

913484— )
The pilot control manifold valve (PCMV) contains:
• Pressure reducing valve (PRV)

• Pilot enable solenoid
• Pilot control accumulator
The PCMV receives system pressure from the inlet

section of the backhoe valve through the pilot control
manifold filter. See Hydraulic System Schematic. (Group
9025-15.) System pressure oil flows through the
adjustable pressure reducing valve (PRV) and check valve
allowing regulated pressure oil to charge pilot control
accumulator. The PRV ensures that pressure in the pilot
control system and accumulator is within specification.
Specification
Pilot Control—Regulated
Pressure .......................................................................... 4309—4654 kPa
41—47 bar
625—675 psi
NOTE: Pilot control accumulator is not serviceable.

Replace accumulator if necessary.
9025 NOTE: The pilot enable solenoid coil is an integral part of

05 the PCMV and is not serviceable. Replace PCMV
94 if necessary.
When system pressure is below pilot control regulated

pressure specification, the PRV allows unrestricted flow to
pass through the PCMV. When system pressure
increases above pilot control regulated pressure
specification, the PRV cartridge shifts restricting pressure
to pilot controls and bleeding excess pressure to tank.
With pilot enable solenoid de-energized, a bias spring

holds pilot enable spool right venting oil in pilot controls to
tank. With pilot enable solenoid energized, spool shifts left
connecting regulated pilot pressure to pilot controls. See
Hydraulic System Schematic. (Group 9025-15.)
TX17994,000000A –19–21JAN03–1/1

031504
PN=516
Theory of Operation
Pattern Select Valve Operation (S.N.

913484— )
The pattern select valve is used to switch control of

backhoe boom and crowd functions for operator
preference.
This valve contains two two-position four-way solenoid

operated valves. These valves are controlled by the
two-position pattern select switch. See Hydraulic System
Schematic. (Group 9025-15.)
With pattern select switch in backhoe position, both

solenoid valves are de-energized. This directs oil to
control boom functions with the left pilot control and crowd
functions with the right pilot control.
With pattern select switch in excavator position, both

solenoid valves are energized. This directs oil to control
boom functions with the right pilot control and crowd
functions with the left pilot control.
BT40170,000003C –19–16DEC02–1/1
9025
05
95

031504
PN=517
Theory of Operation
Loader Inlet Section with Bucket Section Activated (S.N. —913479)
LOADER CONTROL VALVE TO

STEERING
LOAD
SENSE
M
A
G
ISOLATOR A LOAD
SENSE
RELIEF
VALVE
D
INLET BUCKET BOOM AUXILIARY OUTLET

ENDCAP (OPTIONAL) ENDCAP
9025
05
96
ISOLATOR A
D INLET PRESSURE OIL

–19–22AUG00
E HIGH PRESSURE OIL

H LOADER INLET ENDCAP SECTION

T133346
T133346 WITH BUCKET SECTION ACTIVATED

031504
PN=518
Theory of Operation
A—Isolator D—Inlet Pressure Oil F—Return Pressure Oil H—Loader Inlet Section
B—Load Sense Relief Valve E—High Pressure Oil
The inlet section of the loader valve provides a means A direct acting load sense relief valve (B) limits the
of connecting the valve to the pump. The pump output maximum load sense pressure signal sent to the
is connected to the valve’s inlet pressure port (D). pump, which limits the pump pressure sent to the
hydraulic system.
The isolator valve assembly (A) is used to supply a
signal equal to the highest work port pressure to the
pump load sense port without allowing load sense oil
to exit the valve.
CED,TX03768,2813 –19–30AUG00–2/2
9025
05
97

031504
PN=519
Theory of Operation
Loader Bucket Section—Bucket Rollback Position (S.N. —913479)
I B
LOADER CONTROL VALVE
ISOLATOR
H TO
STEERING
L.S. L. S.
RELIEF
INLET END CAP BUCKET BOOM AUXILIARY

(OPTIONAL)
D E
9025
05
98
BUCKET LOAD C LOAD SENSE BUCKET DUMP

WORK PORT H LOGIC CHECK F WORK PORT
D COMPENSATOR/LIFT CHECK G BRIDGE BLEED
ORIFICE
CIRCUIT RELIEF E INLET
WITHOUT PRESSURE K CIRCUIT RELIEF
ANTI-CAVITATION WITH
B ANTI-CAVITATION
RETURN TO DIG
L ELECTROMAGNET
SPOOL
A POSITIONER
–19–06SEP00
I HIGH PRESSURE OIL

T133583
M LOADER BUCKET SECTION - BUCKET ROLLBACK POSITION

T133583

031504
PN=520
Theory of Operation
A—Return Passage E—Inlet Pressure Passage I—High Pressure Oil L—Return-to-Dig

B—Circuit Relief without F—Bucket Dump Work Port J—Return Pressure Oil Electromagnet
Anti-Cavitation G—Bridge Bleed Orifice K—Circuit Relief with M—Loader Bucket Section—
C—Bucket Load Work Port H—Load Sense Logic Check Anti-Cavitation Rollback Position
The bucket valve is a three-position, four-way, port, past the spool, into the return passage (A), then
closed-center, spool-type valve section. The section out of the control valve to the system reservoir.
contains a circuit relief valve with anti-cavitation (K) in
the bucket dump circuit and circuit relief valve (B) in The valve is equipped with a return-to-dig spool
the bucket load circuit. positioner. When loader control lever is moved to the
bucket rollback position, a plate fastened to the end of
The valve section contains a bleed orifice (G) to bleed valve spool contacts an electromagnet. If the bucket is
the section’s load sense signal to the return passage in dump position, the return-to-dig switch is closed
when the spool is in neutral. which energizes the electromagnet and holds the spool
in the load position. When the bucket rolls back to the
When the spool is moved to activate a function, oil dig position, the self-leveling linkage opens the
flows from the inlet passage (E), past the spool and return-to-dig switch, which de-energizes the
compensator (D), out the work port to the cylinders. electromagnet allowing the spool centering spring to
Return oil from the cylinders flows into the other work move the spool to neutral.
CED,TX03768,2814 –19–30AUG00–2/2
9025
05
99

031504
PN=521
Theory of Operation
Loader Boom Section—Boom Raise Position (S.N. —913479)
K B
TO
LOADER CONTROL VALVE STEERING
LOAD
SENSE
M
A
G
ISOLATOR LOAD
H SENSE
RELIEF
VALVE

D E
9025
05
,100
BOOM RAISE C LOAD SENSE

WORK PORT H LOGIC CHECK F BOOM LOWER
WORK PORT
D COMPENSATOR/LIFT CHECK
G BRIDGE BLEED
CIRCUIT RELIEF E INLET ORIFICE
WITHOUT PRESSURE
ANTI-CAVITATION
K ANTI-CAVITATION
B CHECK VALVE
DETENT SPOOL
L POSITIONER
–19–22AUG00
A
I HIGH PRESSURE OIL
T133347
T133347 M LOADER BOOM SECTION - BOOM RAISE POSITION

031504
PN=522
Theory of Operation
A—Return Passage E—Inlet Pressure Passage I—High Pressure Oil L—Detent Spool Positioner
B—Circuit Relief without F—Boom Lower Work Port J—Return Pressure Oil M—Loader Boom Section—
Anti-Cavitation G—Bridge Bleed Orifice K—Anti-Cavitation Check Boom Raise Position
C—Boom Raise Work Port H—Load Sense Logic Check Valve
The boom valve is a four-position, four-way, compensator (D), out the work port to the cylinders.
closed-center, spool-type valve section. The section Return oil from the cylinders flows into the other work
contains a circuit relief valve (B) in the boom raise port, past the spool, into return passage (A), then out
circuit and anti-cavitation check valve (K) in the boom of the control valve to the system reservoir.
lower circuit.
When the spool is moved to the boom float detent
The valve section contains a bleed orifice (G) to bleed position (two positions out from neutral), both work
the section’s load sense signal to the return passage ports (C and F) are open to return passage (A)
when the spool is in neutral. allowing oil to flow in and out both ends of the
cylinders.
When the spool is moved to activate a function, oil
CED,TX03768,2815 –19–30AUG00–2/2
9025
05
,101

031504
PN=523
Theory of Operation
Loader Auxiliary Section—Load Position (S.N. —913479)
TO
K STEERING
LOADER CONTROL VALVE LOAD
SENSE
A
M
A
G
ISOLATOR
H LOAD SENSE
RELIEF VALVE

9025
05
,102
INLET HEAD END
PRESSURE H WORK PORT
COMPENSATOR/ F
ROD END C
LIFT CHECK LOAD SENSE
WORK PORT D LOGIC CHECK
E BRIDGE BLEED
CIRCUIT RELIEF G ORIFICE
K WITH ANTI-CAVITATION
B RELIEF VALVE PORT
SHUTOFF PLUG
A
RETURN
–19–27OCT00
PASSAGE I HIGH PRESSURE OIL

L TRAPPED OIL
T133349
T133349 M LOADER AUXILIARY SECTION-NEUTRAL POSITION

031504
PN=524
Theory of Operation
A—Return Passage F—extendable In Work Port K—Work Port Passage N—High Pressure Oil
B—Relief Port Shut-Off Plug G—Bridge Bleed Orifice L—Vent Passage O—Low Pressure Oil
C—extendable Out Work Port H—Relief Port Shut-Off Plug M—Load Sense Logic Check P—Loader Auxiliary Section—
D—Compensator I—Anti-Drift Check Valve Shuttle Load Position
E—Inlet Pressure Passage J—Orifice
The auxiliary valve is a three-position, four-way, extendable in work port (F) enters orifice (J) and is
closed-center, spool-type valve section. The section passed to the spring side of the check. Pressure in the
contains shut-off plugs in place of relief valves in both work port passage (K) falls due to oil leakage past the
work ports. spool to the return passage (A). The higher work port
pressure on the spring side of the check forces the
The valve section contains a bleed orifice (G) to bleed check securely into the seat forming a seal. The spring
the section’s load sense signal to the return passage side of the check may be vented to the return passage
when the spool is in neutral. (A) through a vent passage (L). This passage is open
and closed depending on the position of the main
When the spool is moved to activate a function, oil spool. With the main spool in neutral or the boom raise
flows from the inlet passage (E), past the spool and position the vent passage (L) is blocked. When the
compensator (D), out the work port to the cylinders. main spool is moved to the lower position the vent
Return oil from the cylinders flows into the other work passage (L) is opened to the return passage (A). Oil
port, past the spool, into the return passage (A), then flows from the work port (F) through orifice (J) in the
out of the control valve to the system reservoir. check (I), through the vent passage (L) to the return
passage (A). Pressure drop across the orifice (J)
An anti-drift check valve (I) is provided to significantly causes the pressure on the spring side of the check to
reduce oil leakage back into the extendable in work drop lower than the pressure in work port (F). This
port (F). With the valve in neutral, the check (I) is pressure imbalance causes the check (I) to open
spring loaded to the closed position. Pressure in the allowing flow to the main spool.
9025
05
,103
CED,TX03768,2816 –19–30AUG00–2/2

031504
PN=525
Theory of Operation
Loader Valve Outlet Section (S.N. —913479)
LOADER CONTROL VALVE
M
A
G
C
ISOLATOR
D
INLET BUCKET AUXILIARY OUTLET

BOOM (OPTIONAL) ENDCAP
B PUMP LOAD SENSE PORT

9025
05
,104 D LOAD SENSE
RELIEF VALVE
C LOAD SENSE
INPUT PORT
–19–22AUG00
RETURN PORT A F HIGH PRESSURE OIL

G RETURN PRESSURE OIL
T133355
T133355 H LOADER OUTLET ENDCAP

031504
PN=526
Theory of Operation
A—Return Port C—Load Sense Input Port E—High Pressure Oil G—Loader Outlet Section
B—Pump Load Sense Port D—Plug F—Return Pressure Oil
The outlet section provides a means to connect the sense signal to be input from the steering valve. This
valve to the hydraulic reservoir via the return ports (A). signal is compared to the work port pressures in this
The load sense port (B) connects to the pump’s load valve and the highest pressure is sent to the pump’s
sense port. The load sense input port (C) allows a load controller.
CED,TX03768,2817 –19–30AUG00–2/2
9025
05
,105

031504
PN=527
Theory of Operation
Loader and Stabilizer Valve (S.N. 913480— )
A A
3
B B
23
9025
05
,106
6 7
10 21 SECTION B 9 8
12
11 13
17
–19–21APR03
18
19
16
T188468
22 SECTION A 15 14 20
T188468
Continued on next page TX17994,000000D –19–01APR03–1/3

031504
PN=528
Theory of Operation
23
30
32
29
28
31
27
26
–UN–21APR03
25 34
33 35
24
T189173
36
T189173
9025
1—Left Stabilizer Spool 11—Lockout Valve Assembly 20—Standby Pressure Oil 29—Isolator
05
2—Right Stabilizer Spool 12—Shuttle 21—Bucket Section 30—Drain Regulator
,107
3—Boom Spool 13—Lockout Valve Assembly 22—Stabilizer Section 31—Loader Valve Load Sense
4—Bucket Spool 14—Spring Seat 23—Isolator Compensator Relief Valve
5—Auxiliary Spool 15—Spring Assembly 32—Load Sense Passage
6—Relief Valve Assembly 16—Stabilizer Actuation 24—Hydraulic Pump 33—Spool Metered Pressure
7—Relief Valve Assembly Linkage 25—Main Valve Spool 34—Load Sense Pressure Oil
8—Spring 17—Load Sense Pressure Oil 26—Bridge 35—Standby Pressure Oil
9—Spring Seat 18—Trapped Oil 27—Compensator 36—Return Oil
10—Bucket Self-Leveling 19—Return Oil 28—Secondary Pump Passage
Linkage Pin
The loader control valve is a closed center, load secondary pump passage (28). Compensator (27) is
sensing (LS), monoblock valve with individual isolator used to maintain LS margin across valve by ensuring
and compensator functions to divide pump flow highest workport pressure is seen down stream of all
between multiple functions. The isolator compensator activated functions.
system will maintain constant flow to activated
functions regardless of changing load conditions. In neutral, LS pressure is equal to tank pressure. Any
When demanded flow exceeds pump capacity, leakage in to LS gallery is bled off by compensated
activated functions will continue to operate at reduced drain regulator orifice (30) inside LS relief valve. See
flows while maintaining the flow ratio between all Loader Valve Load Sense Relief Valve (S.N. 913480—
activated functions. Isolator (23) is used to separate ) in this group.
workport pressure from LS pressure (32) through
Continued on next page TX17994,000000D –19–01APR03–2/3

031504
PN=529
Theory of Operation
When loader or stabilizer functions are activated, When multiple loader and stabilizer functions are
workport pressure is connected to bridge (26) and activated, function with higher workport load will
bottom of isolator (29) through connecting passage in provide LS signal to pump control. The isolator for the
compensator (27). This pressure causes the isolator to function demanding less pressure will move down to
continually meter up and down matching bridge (26) contact compensator. If compensation is required, high
pressure and LS (32) pressure. If spool metered pressure in LS passage (32) will force compensator
pressure (33) exceeds workport pressure, (27) down restricting flow to function with less demand
compensator (27) moves up to provide full flow from for pressure.
activated spool. During full flow operation, the
compensator is against the isolator resulting in lowest
possible pressure drop across compensator.
TX17994,000000D –19–01APR03–3/3
9025
05
,108

031504
PN=530
Theory of Operation
Loader Valve Steering Load Sense Isolator 9

(S.N. 913480— )
The steering load sense (LS) isolator is used to separate 1

steering LS pressure (13) from loader LS pressure (3) to 10
provide quicker steering response. This is accomplished
by using pump pressure (6) to match the steering LS
pressure.
When steering LS pressure (9) is greater than spool 2

balancing pressure (7), isolator spool (4) moves down
causing pump pressure (6) to dump to loader LS pressure
(3) until loader LS pressure matches steering LS pressure
(9). Spool balancing pressure (7) is supplied through a 3
damping orifice (5) and is equal to pump pressure (3).
4
The isolator continually matches steering LS pressure (9)
with spool balancing pressure (7) by balancing thee two 5
pressures. If pressure pump pressure is greater than
6
steering load sense pressure, the isolator spool will
remain up and not provide any steering pressure. The 8
–UN–12MAR03
steering isolator will only provide pressure if the steering
valve requests a higher LS pressure than is already in the 11
loader LS passage.
7 12
T188469
13
9025
1—Fitting
05
2—Spring
,109
3—Load Valve Load Sense Passage
4—Spool
5—Damping Orifice
6—Pump Pressure
7—Spool Balancing Pressure
8—Orifice Set Screw
9—Steering Load Sense Pressure
10—Plug
11—Standby Pressure Oil
12—Load Sense Pressure Oil
13—Steering Valve Load Sense Signal
DW09104,000002E –19–10MAR03–1/1

031504
PN=531
Theory of Operation
9025
05
,110

031504
PN=532
Group 15
Use These Seven Basic Steps to Diagnose and Test the Hydraulic System
1. KNOW THE SYSTEM. Study the information on the the filters plugged? Are the hydraulic oil lines hotter
system and component operation given in the front than normal; covered with dirt; paint peeled off from
part of Section 9025. Learn the basic principles of heat; dented or collapsed; show signs of leakage?
hydraulics by reading the Fundamentals of Service
manual on hydraulics. 5. LIST THE POSSIBLE CAUSES. What unusual
conditions did you find when the machine was
2. ASK THE OPERATOR. The operator can tell you inspected? What are the possible causes? Are
how the machine performed when it started to fail; there other possibilities? Remember, one failure
what was unusual about it. Try to find out if any often leads to another.
do-it-yourself service has been performed. Ask
about how the machine was operated and when it NOTE: You can use the Hydraulic System Pretest
was serviced. Check Sheet to list the possible causes.
3. OPERATE THE MACHINE. Are the gauge 6. REACH A CONCLUSION. Decide which possible
indications normal? How is the performance? Do causes are the most likely and the easiest to verify.
the controls feel normal? Do you smell or hear Use the Diagnose Malfunctions section of Group
anything unusual. 9025 to help you.
4. INSPECT THE MACHINE. Use your eyes, ears, 7. TEST YOUR CONCLUSION. Do individual
and nose to find signs of trouble. Check the level component tests to verify your conclusion before
and condition of the hydraulic oil. Is the oil dirty; are you repair or replace any components.
9025
15
1
TX,9025,RR7304 –19–10JUN96–1/1

031504
PN=533
Hydraulic System Pretest
1. Clean machine as needed.
2. Perform all inspections.
3. Correct any problems.
4. Perform Operational Checks:
• Hydraulic Oil:
– Correct Oil
– Correct Level
– Bubbles in Oil
• Control Valve(s):
– Bent Linkage
– Proper Linkage Adjustment
• Filters: Hydraulic, Transmission:
– Ruptured
– Plugged
– Metal Particles
– Packing Particles
– Install New Filter
• Oil Cooler:
– Clean of Dirt and Debris
– Fan or Shroud Damaged
– Belt Tension and Condition
9025
15 – Leaking Lines or Cooler
2 • Hydraulic System:
– Bent or Damaged Lines
– External Oil Lines
– Cylinder Rod(s) Bent
– Blown Seals and Fittings
TX,9025,RR7306 –19–09AUG96–1/1

031504
PN=534
Diagnose Steering System Malfunctions

probable and simplest to verify, to least likely
• Step 1. Operational Check Out Procedure

• Step 2. Diagnostic Charts
• Step 3. Adjustments and/or Tests
Slow or Hard Steering Air in system. Check oil level.
Check suction hose clamps.
Steering lines or load sensing "LS" Check and replace.

lines damaged (bent).
Shaft in steering wheel column Check for bent steering column.

binding.
Internal leakage in system. See Steering Cylinder Leakage

Check.. Go to Group 9025-10.)
Hydraulic pump (low pressure). See Backhoe Load Sense and

9025
Loader Load Sense Relief Stall 15
Pressure Test. (Go to Group 3
9025-25.)
Steering pressure regulating valve Inspect and Repair.

spool.
Excessive Steering Wheel Turns Steering cylinder leakage. See Steering System Leakage
to Steer Machine Check.. (Go to Group 9025-10.)
Excessive wear in steering valve. See Steering System Leakage

Check. (Go to Group 9025-10.)
Erratic ("Spongy") Steering Air in system. Check oil level.
Check suction hose clamps.
Steering Wheel "Locks" Up Debris in gerotor section. Disassemble and inspect. Flush.
Broken drive shaft to gerotor pin. Replace.
Low hydraulic flow. Check system pressure and flow.

031504
PN=535
Poor Centering of Steering Wheel Binding or misalignment in steering Inspect column and spline to
(Wheels Continue to Move After column or splined connection. steering valve connection. Repair.
Steering Wheel is Stopped)
Steering Wheel or Front Wheels None, normal operation of steering See Steering (Group 9025-05) for
Slowly Turn by Themselves valve. normal operation of steering valve.
When Using Backhoe or Loader
(S.N. 911133— )
Steering Wheel Oscillates or Parts mis-assembled (steering valve Disassemble, inspect and
Turns by Itself After Starting improperly timed) reassemble.
Machine
Line connected to wrong ports. Inspect and connect correctly.
Wander—Vehicle 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.
Worn mechanical linkage. See Remove and Install Steering

Cylinder Bushings.. Go to Repair
Manual Group 09-0960.
Bending of linkage or cylinder rod. See Remove and Install

Non-Powered Axle Steering
9025
15 Cylinder.. Go to Repair Manual
4 Group 09-0960.
Loose steering cylinder piston. See Remove and Install

Cylinder.. Go to Repair Manual
Group 09-0960.
Severe wear in steering control unit. Replace the steering control unit.
Erratic Steering Loose cylinder piston. Replace cylinder.
Sticking pressure regulating valve Replace.

spool
Steering Valve Does Not Return Broken centering springs See Remove and Install Steering
to Neutral Valve. Go to Repair Manual Group
09-0960.

031504
PN=536
Damaged steering valve sleeve See Remove and Install Steering

Valve. Go to Repair Manual Group
09-0960.
No Response When Steering Low or no oil Check reservoir oil level.

Wheel Is Turned
External leakage Check for leakage. Repair as

necessary.
Steering valve leakage See Steering System Leakage Test.

Steering cylinder leakage See Steering System Leakage Test.

Steering column shaft broken. Replace.
Splines on shaft disengaged from Check and repair.

steering valve.
Worn main pump See Pump Flow Test. Go to Group

9025-25.
Steering lines broken Repair.

9025
15
Machine Turns in Opposite Steering cylinder lines not connected Connect steering cylinder lines to 5
Direction properly opposite ports.
Excessive Vibration of Steering Misalignment of steering valve See Remove and Install Steering
Wheel geroter Valve. Go to Repair Manual Group
09-0960.
Machine Turns When Steering Steering valve leakage See Steering System Leakage Test.
Valve Is in Neutral Go to Group 9025-25.
Misalignment of steering column to See Remove and Install Steering

steering valve. Column. Go to Repair Manual Group
09-0960.
Steering Wheel Kickback Check valve leakage See Steering System Leakage Test.
Go to Repair Manual Group
9025-25.
TX,9025,SS3536 –19–14OCT03–3/3

031504
PN=537
Diagnose Hydraulic System Problems
Reservoir Drains When Changing Oil cooler return tube vent hole in See Remove and Install Hydraulic
Hydraulic Filter reservoir may be plugged and Transmission Oil Coolers. Go to
Repair Manual Group 21-2160.
Vent tube broken off inside reservoir See Remove and Install Hydraulic
and Transmission Oil Coolers. Go to
Cooler flow check valve stuck open Inspect and repair.
No Hydraulics Low oil level Add oil to correct level.
Failed pump drive shaft See Remove and Install Hydraulic

Pump. Go to Repair Manual Group
21-2160.
Pump problem See Remove and Install Hydraulic

Filter Assembly.Go to Group
21-2160. If filter contains excessive
amounts of metal material, remove,
and inspect pump. See Remove and
Install Hydraulic Pump. Go to Group
21-2160.
9025
15
6 Load sense shuttle check valve See Hydraulic Pump Control Piston
and Load Sense Module. Go to
Obstruction in oil lines or valves See Remove and Install Hydraulic

Pump. Go to Repair Manual Group
21-2160l.
Low Loader Hydraulic Power Incorrect loader load sense relief Check relief setting at the loader
pressure setting. valve. See Backhoe Load Sense and
Loader Load Sense Relief Stall
Pressure Test., Go to Group
9025-25.
Incorrect flow limiter setting See Flow Limiter Test. (Go to Group
9025-25).

031504
PN=538
Low Backhoe Hydraulic Power Incorrect backhoe load sense relief See Backhoe Load Sense and
setting Loader Load Sense Relief Stall
Pressure Test.and Pump Load
Sense Differential Pressure Test.
9025-25).
Low Hydraulic Power Hydraulic oil aerated Incorrect oil, drain and refill. Suction
hose has air leak. Inspect and
tighten. See repair manual.
Leakage within work circuit Check circuit for leakage. See

Cylinder Leakage Test. (Go to Group
9025-25). See Circuit Relief Valve
Test with Remote Pump. (Go to
Group 9025-25).
Low oil level Check oil levels.
9025-25).
Incorrect relief pressure setting Check load sense and system

9025
reliefs. See Loader Load Sense 15
Relief, and Backhoe Load Sense 7
Relief. See Steering Load Sense
Relief Valve Stall Pressure Test
(S.N.—911132). (Early Machines)
(Group 9025-25.) See Steering
Valve Pressure Test (S.N. 911133—
). (Later Machines) (Group 9025-25.)

031504
PN=539
Slow Steering Hydraulics Pressure Regulating Valve Test operation. See Steering Load
Sense Relief Valve Stall Pressure
Test (S.N.—911132). (Early
Machines) (Group 9025-25. )See
Steering Valve Pressure Test (S.N.
911133— ). (Later Machines) (Group
9025-25.)
Worn steering valve Inspect and repair.
Steering valve leakage See Steering System Leakage Test.

Steering cylinder leakage See Steering Cylinder Leakage Test.

Steering linkage See Remove and Install Steering

Bushings.. Go to Repair Manual
Group 09-0960.
No Steering Hydraulics (Loader Pressure Regulating Valve See Remove and Install Steering
Hydraulics OK) Valve.. See Repair Manual Group
09-0960.
Worn steering pressure regulating See Steering Load Sense Valve

9025
15 valve Pressure Test. (Go to Group
8 9025-25).
Obstruction in steering load sense Inspect and repair.

hose
Machine Transport Speed Is Slow Engine or transmission problem See Diagnose Power Shift Power
Train Malfunction. (Go to Section
9020-15).
Go to Section 9010-10. See Slow

and Fast Idle. (Go to Section
9010-10).

031504
PN=540
Engine Pulls Down Excessively Relief pressure setting too high See Loader Load Sense Relief Valve
During Loader Operation Pressure Test. (Go to Group
9025-25).
Engine not operating to Check engine performance. See

specifications. Turbocharger Boost Pressure—
Engine Performance Test. (Go to
Group 9010).
Pump flow limiter set too high See Flow Limiter Test. (Go to Group
9025-25).
Engine Pulls Down Excessively Relief pressure setting too high See Backhoe Load Sense Relief
During Backhoe Operation Pressure Test. (Go to Group
9025-25).
Pump Flow limiter setting too high See Flow Limiter Test. (Go to Group
9025-25).
Slow Backhoe Hydraulics— Control Valve worn. See Function Drift Tests.(Go to
Loader OK Group 9025-25).
Also see Slow Hydraulic

Functions. Higher hydraulic
demand by backhoe can make a
9025
system problem appear to be 15
isolated to backhoe. 9
Backhoe valve isolator stuck See Hydraulic System. Go to Repair

Manual Group 333-3360.
Load sense relief set too low See Backhoe Load Sense Relief
9025-25).
Flow limiter setting too low See Flow Limiter Test. (Go to Group
9025-25).

031504
PN=541
Slow Loader Hydraulics— Control Valve worn. See Function Drift Tests. (Go to
Backhoe OK Group 9025-25).
Loader valve isolator stuck Remove and inspect. See repair

manual.
Load sense relief set too low See Loader Load Sense Relief Valve
9025-25).
Flow limiter setting too low See Flow Limiter Test. (Go to Group
9025-25).
Slow Hydraulic Functions Low pump flow See Pump Flow Test. (Go to
9025-25).
Relief valve leaking See Loader Load Sense Relief, and

Backhoe Load Sense Relief See
System Relief Valve Tests. (Go to
9025-25).
Isolator valve stuck Remove and inspect. See repair

manual.
Low oil level Add oil to correct level.

9025
15
10 Engine rpm too low See Slow and Fast Idle. (Go to
Group 9010-20).
Hydraulic oil aerated. Incorrect oil, drain and refill. Suction

tighten. See Technical Repair
manual.
Low load sense differential pressure See Pump Load Sense Differential
9025-25).
Hose or line leakage Inspect and tighten fittings.

031504
PN=542
Loader or Backhoe Operates Control Valve section problem. See Function Drift Test. (Go to
Slowly in One Function Group 9025-25).
Control lever and linkage out of Inspect lever and linkage. See
adjustment. Backhoe Valve Linkage Adjustment.
Circuit Relief valve or plug leakage See Hydraulic Pump Control Piston
in control valve. and Load Sense. (Go to Group
2160-10).
See Circuit Relief Valve Test with

Remote Pump. (Go to Group
9025-25).
Compensator spool stuck See Disassemble and Assemble

Loader Control Valve. (Go to Repair
Manual).
Hydraulic cylinder leakage See Cylinder Leakage Test. (Go to

Group 9025-25).
Bent or restricted line Inspect and repair. See Technical

Repair manual.
9025
Hydraulic control valve not operating See Stabilizer Valve Lockout 15
properly Leakage Test. (Go to Group 11
9025-25). See Remove and Install
Loader Control Valve. (Go to Group
3160-10).
Bent cylinder rod. See Remove and Install

Cylinder. (Go to Group 0960).

031504
PN=543
No Loader or Backhoe Power in Control lever and linkage out of Inspect lever and linkage. Adjust to
One Function adjustment get equal valve spool travel in each
direction.
Circuit relief valve or plug leakage in See Remove and Install Loader
control valve Control Valve. Go to Group 3160.
See Circuit Relief Valve Test with

Remote Pump. (Go to Group
9025-25).
See Function Drift Test. (Go to

Group 9025-25).
Bent or restricted line Inspect and repair.
Hydraulic control valve not operating See Remove and Install Loader
properly Control Valve. (Go to Group 3160).
Compensator stuck See Disassemble and Assemble

Loader Control Valve. (Go to Repair
Manual Group 3160).
9025
15
12

031504
PN=544
Low Hydraulic Power (Low Low oil level (aeration of oil) Add oil to correct level.
Hydraulic Pressure)
Load sense shuttle check valve See Disassemble and Assemble

stuck Backhoe Boom Raise, Bucket Dump,
Crowd Out Circuit Relief Valves with
Anti-Cavitation and Load Sense
Relief Valve without Anti-Cavitation.
Go to Repair Manual Group 3160.
Hydraulic oil aerated Incorrect oil, drain and refill. Suction

Incorrect relief valve setting See Backhoe Load Sense and

Pressure Test and Circuit Relief
Valve Test with Remote Pump.. (Go
to Group 9025-25).
Leakage within work circuit Feel components for heat. See

Cylinder Drift Test.. (Go to Group
9025-25).
Excessive leakage in hydraulic See Leakage Test. (Go to Group

9025
system 9025-25). 15
13
Hydraulic Function Makes Low oil level Add oil to correct level.
"Chattering" Noise
Hydraulic oil aerated Incorrect oil, drain and refill. Suction

Worn or wrong circuit relief valve Inspect, remove and repair. See
installed in backhoe valve. Remove and Install Backhoe Circuit
Relief and System Relief Valves.
(Go to Repair Manual Group 3160).

031504
PN=545
Functions Drift Oil leaking past valve port See Hydraulic System Checks. to
pinpoint cylinder or valve leakage.
Oil leaking past cylinders or valve. See Function Drift test. to pinpoint
cylinder or valve leakage. (Go to
Group 9025-25).
Anti-drift check valve not functioning Remove and inspect. Repair as

necessary.
Control Valve Lever Sticks or Control valve lever linkage binding See Backhoe Valve Linkage
Works Hard Adjustment. Go to Group 9025-20.
See Remove and Install Loader
Control Valve Linkage (Two Spool).
(Go to Repair Manual Group 3160).
Hydraulic system overheating See Cylinder Leakage Test.. (Go to

Group 9025-25).
See Converter Oil Temperature

Sender. (Go to Group 9015-10)
Return spring rubbing on spring cap See Remove and Install Loader
Control Valve. Go to Repair Manual
9025
15 Group 3160).
14
Broken return spring See Remove and Install Loader
Group 3160).
Contamination in control valve See Remove and Install Loader

Group 3160). Locate source of
contamination. Repair and clean oil
in system.
Scored valve bore or bent spool See Remove and Install Loader
Control Valve.

031504
PN=546
Hydraulic Oil Overheats Excessive load Reduce load.
Operator holding hydraulic system Return levers to neutral when not in

over relief use.
Oil levels too low in reservoir. Check levels and add oil. Use
recommended oil. See
TMS16109000 Section.
Using low viscosity oil in hot weather Use recommended oil. See
TMS16109000 Section.
Hydraulic cooling system restricted. Clean radiator and coolers. See

Hydraulic Oil Cooler Restriction Test.
(Go to Group 9025-25) .
Temperature sender not working See Wiring and Schematic Diagrams

Legend. (Go to Group 9015-10)
Incorrect relief valve pressure See Backhoe Load Sense and

Pressure Test and Circuit Relief
Valve with Anti-Cavitation—Loader
and Backhoe.( Go to Group
9025-25).
9025
15
Excessive leakage in the hydraulic See Cylinder Leakage Test. (Go to 15
system Group 9025-25).
Foaming Oil Oil level too low or too high Check oil level. Adjust to full mark
on sight gauge.
Incorrect type of oil Drain and replace. See Operator’s

Manual.
Air leak on suction side of pump Locate and repair leak. See
Technical Repair manual.
Oil maintenance not performed. See Operator’s Manual.

031504
PN=547
Hydraulic Pump Leaking Cap screws that hold pump together Tighten to specification or replace
are loose seals and gaskets. See
Disassemble, Inspect and Assemble
Hydraulic Pump. (Go to Repair
Manual Group 3160).
Worn shaft seal Replace seal. See Disassemble,

Inspect and Assemble Hydraulic
Pump. (Go to Repair Manual Group
3160).
Hydraulic oil overheating Determine cause of overheating,

See Diagnose Hydraulic System
Problems. Go to Group 9025-15.
Excessive Pump Noise Low oil level Add oil to correct level.
Hydraulic filter by-pass valve Replace hydraulic filter. Inspect,

chattering clean, and repair.
Worn pump drive Inspect and repair. See Technical

Repair manual.
Oil lines in contact with operators Inspect, repair or replace. See repair
station (Worn cab, transmission, or manual.
9025
15 canopy rubber isolators)
16
Pump attaching hardware loose See Disassemble, Inspect and
Assemble Hydraulic Pump. (See
Repair Manual Group 3160).
Leakage in hydraulic circuit See Cylinder Leakage Test (Go to

Group 9025-25).
TX,9025,RR7542 –19–08NOV96–11/11

031504
PN=548
Group 20
Adjustments
Selective Flow Valve Adjustment
1. Press selective flow switch (1) to the OFF position.
–UN–12OCT00
T134594B
TX03768,0000B29 –19–13OCT00–1/4
2. Remove four cap screws (1) from side console and lay
console aside.
NOTE: The valve selective oil flow setting is pre-set at 25

gpm at the factory.
–UN–12OCT00
3. Press gpm selective flow switch (2) to the “25” gpm
(rabbit) setting if desired gpm flow needed varies
between 14—34 gpm. For lower gpm flow below 14
gpm, push switch to either “9” or “13” gpm (turtle)
T134595B
9025
20
1
–UN–16OCT00
T134593B
TX03768,0000B29 –19–13OCT00–2/4
Attach side console back on the machine. Start the

machine. Push selective flow switch (1) fully forward
(third position); at this position the oil flow through the
valve and to the working attachment is continuous.
–UN–12OCT00
T134594B
Continued on next page TX03768,0000B29 –19–13OCT00–3/4

031504
PN=549
Adjustments
IMPORTANT: Avoid tool attachment damage when

adjusting the selective flow valve when
turning the selective flow valve adjuster
screw. To set the oil flow range from
14—34 gpm using the selective flow
adjustor screw, a flow meter MUST be
used.
4. To adjust flow between 14 and 34 gpm (rabbit), go to

the backhoe valve assembly (2) and loosen lock nut on
the selective flow valve. Turn adjustment screw (1) in
or out for desired flow. Tighten lock nut.
–UN–12OCT00
T134592B
TX03768,0000B29 –19–13OCT00–4/4
9025
20
2
Loader Lever and Stabilizer Lever
Adjustment (S.N. 913480— )
Loader Lever Adjustment
1. Park machine on level surface. Lower attachments and

stabilizers to ground.
2. Stop engine and operate all hydraulic controls to

relieve pressure from hydraulic system.
3. Remove front and rear floor mats.
Continued on next page DW09104,000002A –19–15JAN03–1/8

031504
PN=550
Adjustments
4. Remove floor access plate (2).
5. Remove rear floor plate.
1—Floor Access Plate

2—Floor Access Plate
–UN–27SEP00
T133998B
Floor Plates
DW09104,000002A –19–15JAN03–2/8
NOTE: Measuring distance is from center of loader lever

to level area shown on ROPS post.
6. Locate loader lever linkage.
9025
–UN–14JAN03
1—Loader Linkage
20
3
T163940B
Loader Lever Linkage

031504
PN=551
Adjustments
7. Adjust linkage turnbuckle to specification using ROPS

posts as reference.
Specification
Right Front ROPS to Loader
Lever—Length ........................................................ 694.44 mm (27.34 in.)
–UN–13JAN03
1—Right Front ROPS to Loader Lever
T163836B
Right Front ROPS to Loader Lever
DW09104,000002A –19–15JAN03–4/8
Specification
Right Rear ROPS to Loader
Lever—Length ........................................................ 567.80 mm (22.35 in.)
8. Locate auxiliary loader lever linkage.

9025
–UN–13JAN03
20 1—Right Rear ROPS to Loader Lever
4
T163832B
Right Rear ROPS to Loader Lever

031504
PN=552
Adjustments
9. Adjust linkage turnbuckle to specification using ROPS

posts as reference.
Specification
Right Front ROPS to Auxiliary
Loader Lever—Length ............................................ 670.15 mm (26.38 in.)
–UN–13JAN03
1—Right Front ROPS Post to Auxiliary Loader Lever
T163837B
Right Front ROPS Post to Auxiliary Loader Lever
DW09104,000002A –19–15JAN03–6/8
Specification
Right Rear ROPS to Auxiliary
Loader Lever—Length ............................................ 531.59 mm (20.93 in.)
1—Right Rear ROPS to Auxiliary Handle

9025
–UN–13JAN03
20
5
T163828B
Right Rear ROPS to Auxiliary Handle

031504
PN=553
Adjustments
Stabilizer Lever Adjustment
1. Adjust stabilizer linkage turnbuckles until levers (1) are

centered (2) between stops.
2. Install floor plates.
–UN–14JAN03
3. Install floor mats.
T163968B
1—Stabilizer Levers
2—Center Location
Stabilizer Lever Adjustment
DW09104,000002A –19–15JAN03–8/8
9025
20
6

031504
PN=554
Adjustments
Backhoe Valve Linkage Adjustment
Checking Backhoe Control Lever-to-Valve Linkage
NOTE: Levers must be adjusted correctly to ensure

clearance with seat and allow full lever travel.
–UN–23OCT00
1. Move backhoe control levers to NEUTRAL.
2. Attach a piece of masking tape across rear surface of
T134736B
rear ROPS posts at height of backhoe lever knobs.
3. Measure from knob edges-to-tape. Adjust both knob Two-Lever Configuration Shown
edge-to-tape distances (A) to specification. (See
A—Knob Edge-to-Tape Distance
Adjusting Backhoe Control Lever-to-Valve Linkage B—Knob Center-to-Knob Center Distance
procedure.)
Specification
Knob Edge-to-Tape—Distance........................................ 240 mm (9.5 in.)
4. Measure from knob center-to-knob center. Adjust knob

center-to-knob center distance (B) to specification.
(See Adjusting Backhoe Control Lever-to-Valve
Linkage procedure.)
Specification
Knob Center-to-Knob Center—
Distance ....................................................................... 260 mm (10.25 in.) 9025
20
5. Check levers for full travel and proper operation. 7
Linkage rods should not contact each other at any
lever position.
Continued on next page CED,OUO1079,490 –19–21JUL00–1/3

031504
PN=555
Adjustments
Adjusting Backhoe Control Lever-to-Valve Linkage
CAUTION: Prevent possible injury from

unexpected machine movement. NEVER rely on
FNR lever alone to keep machine from moving.
Always set park brake to hold machine.
Prevent possible injury from unexpected

machine movement. Lower all equipment to
ground and release hydraulic pressure before
working near hydraulic equipment.
1. Engage park brake. Lower all equipment to ground.

Turn engine OFF. Release hydraulic pressure by
–UN–24JUL00
moving control levers until equipment does not move.
(See Practice Safe Maintenance in Safety chapter for
more information.)
T132841B
2. Remove rear floor mat, cap screws, and backhoe lever
console cover. John Deere Two-Lever Configuration Shown
3. Move upper rear window, middle rear window, and A—Jam Nut (2 used per Linkage Rod)
lower rear window to maximum UP position. Install B—Linkage Rod (1 used per Control Valve)
screw to hold lower rear window in UP position.
4. Adjust knob edge-to-tape distance for each backhoe

9025 control lever, then adjust knob center-to-knob center
20 distance.
8
For each linkage adjustment:
a. Loosen jam nuts (A).
b. Turn linkage rod (B) to adjust lever position.
c. Measure lever position. Repeat steps b and c as

necessary to meet specifications.
Specification
Distance ....................................................................... 260 mm (10.25 in.)
d. Tighten jam nuts.
5. Move rear windows to suit operator’s preference.

031504
PN=556
Adjustments
6. Install backhoe lever console cover, cap screws, and

rear floor mat.
CED,OUO1079,490 –19–21JUL00–3/3
Backhoe Valve Linkage Adjustment—Four

Lever If Equipped
–19–17AUG01
T144912B
3. Measure from knob edges-to-tape. Adjust all four knob
edge-to-tape distances (1) to specification. (See
procedure.)
Specification
9025
20
lever position.
Continued on next page TX03768,0000BC6 –19–15MAR02–1/2

031504
PN=557
Adjustments
NOTE: One rod assembly contains two short links and

bellcrank.

control lever.
a. Loosen jam nuts (1).
–UN–17AUG01
b. Turn linkage rod (2) to adjust lever position.

T144914B
Specification
Four Lever Configuration Shown
1—Jam Nut (2 used per Linkage Rod)

2—Linkage Rod

rear floor mat.
9025
20
10
TX03768,0000BC6 –19–15MAR02–2/2

031504
PN=558
Adjustments
Adjusting Loader Bucket Self-Leveling

Linkage and Return-to-Dig Switch (S.N. —
913479)
When the self-leveling linkage is adjusted correctly, it will

cause the loader control lever to move from bucket
roll-back to neutral when the front loader boom is fully
raised, automatically leveling the bucket and preventing
spillage of material.
When self-leveling linkage and return-to-dig switch are

both adjusted correctly, the return-to-dig function will
cause the front loader bucket to roll back until flat on the
ground or be slightly forward (dumped) when boom is
lowered to ground after dumping.
NOTE: The front loader bucket self-leveling linkage and

return-to-dig switch must be adjusted together to
ensure proper operation. Perform these three
procedures in the order shown to obtain proper
adjustment.
1. Adjust the bellcrank-to-loader control lever linkage

yoke. (See Adjust Bellcrank-to-Loader Control Lever
Linkage Yoke procedure.)
2. Adjust the sensor tube-to-actuator yoke. (See Adjust 9025

Sensor Tube-to-Actuator Yoke procedure.) 20
11
3. Adjust the return-to-dig switch. (See Adjust
Return-to-Dig Switch procedure.)
Continued on next page CED,OUO1079,470 –19–09JAN03–1/4

031504
PN=559
Adjustments
Adjust Bellcrank-to-Loader Control Lever Linkage

Yoke
1. Position bucket flat on ground and turn engine OFF.
NOTE: Bellcrank-to-loader control lever linkage yoke must
–UN–10NOV00
be adjusted so that gap is at specification when
linkage is fully extended and loader control lever
is fully in BUCKET DUMP position.
T132550
2. Rotate bellcrank (C) fully clockwise (I). With bellcrank
in this position, linkage should pull loader control lever
fully to its stop in BUCKET DUMP position (K).
3. Measure gap (A) between guard/stop (B) and bellcrank

(C).
Specification
Guard/Stop-to-Bellcrank—Gap .......................... 1—2 mm (0.04—0.08 in.)
4. If gap is not to specification, adjust bellcrank-to-loader

control lever linkage yoke (D) to obtain correct gap.
A—Guard/Stop-to-Bellcrank Gap
B—Guard/Stop
C—Bellcrank
D—Bellcrank-to-Loader Control Lever Linkage Yoke
–UN–11SEP00
9025 I—Fully Clockwise
20 K—Loader Control Lever—BUCKET DUMP Position
12
T133654B

031504
PN=560
Adjustments
Adjust Sensor Tube-to-Actuator Yoke
NOTE: Sensor tube-to-actuator yoke must be adjusted so

that gap is at specification when loader control
lever is in NEUTRAL but bellcrank is rotated to H
put slight tension on bellcrank-to-loader control
lever linkage.
1. Rotate bellcrank partially counterclockwise (J) to allow

loader control lever to return to NEUTRAL position (L).
Hold bellcrank in partially rotated position, to keep
slight tension on loader control lever linkage.
G
2. Measure gap (E) between top of bellcrank pin (F) and E
bottom of actuator tang (G).
F
Specification
Top of Bellcrank Pin-to-Bottom of
Actuator Tang—Gap ....................................................... 140 mm (5.5 in.)
3. If gap is not to specification, adjust sensor J
–UN–10NOV00
tube-to-actuator yoke (H) to obtain correct gap.
E—Top of Bellcrank Pin-to-Bottom of Actuator Tang
Gap
F—Bellcrank Pin
T132877
T132877
G—Actuator Tang
H—Sensor Tube-to-Actuator Yoke
J—Partially Counterclockwise
9025
L—Loader Control Lever—NEUTRAL Position
20
13
–UN–11SEP00
T133655B

031504
PN=561
Adjustments
Adjust Return-to-Dig Switch
1. Loosen cap screw (A) and move return-to-dig switch so

roller (B) is touching cam surface (C) as shown.
2. Tighten cap screw without moving return-to-dig switch
–UN–18JUL00
out of position.
3. Test operation of the return-to-dig switch.
T132567B
a. Disconnect the sensor tube yoke from the
self-leveling actuator.
NOTE: Be sure that switch arm and roller do not bottom

on switch housing.
b. Turn the self-leveling actuator back-and-forth while

watching the return-to-dig switch roller move on the
cam surface. If the cam surface hits the switch
–UN–18JUL00
bracket, or the return-to-dig switch roller arm
bottoms against the switch housing when
depressed, reposition the return-to-dig switch.
Repeat steps 1—3.
T132566
c. Reconnect the sensor tube yoke to the self-leveling
actuator.
A—Cap Screw
9025 B—Roller
20 C—Cam Surface
14
CED,OUO1079,470 –19–09JAN03–4/4
Loader Bucket Self-Leveling Linkage and

Return-to-Dig Switch Adjustment (S.N.
913480— )
When self-leveling linkage is adjusted correctly and boom

rises to maximum height, loader control lever will move
from bucket roll back to neutral position and automatically
level bucket, preventing material spillage.
With self-leveling linkage and return-to-dig switch both

adjusted correctly, as boom lowers return-to-dig function
will cause loader bucket to roll back until slightly dumped
or flat on ground.
Continued on next page BT40170,000003E –19–14FEB03–1/4

031504
PN=562
Adjustments
9025
20
15

031504
PN=563
Adjustments
9025
20
16
–UN–21OCT02
T160372
Self-Leveling Linkage Adjustment

031504
PN=564
Adjustments
1—Actuator Tube Turnbuckle 4—Pick-Up Pin Adjustment 5—Pick-Up Pin Adjustment 6—Vertical Link
2—Actuator Plate Lock Nuts Distance 7—Pick-Up Pin
3—Actuator Plate Adjustment
Distance
NOTE: For proper adjustment of loader bucket of bottom of slot (5).

self-leveling linkage and return-to-dig switch,
perform Loader Bucket Self Leveling Linkage Specification
Pick-Up Pin—Adjustment
Adjustment before Return-to-Dig Switch
Distance ...................................................................................... 2 mm
Adjustment. 0.08 in.
Adjust Loader Bucket Self-Leveling Linkage 5. Release pick-up pin.
1. Position loader bucket flat on ground. 6. Adjust actuator tube turnbuckle (1) so actuator plate
(2) to pick-up pin (3) distance is to specification.
2. With machine off, operate all loader hydraulic
functions to relieve system pressure. Specification
Actuator Plate—Adjustment
3. Push pick-up pin (7) on vertical link (6) down so Distance .................................................................................... 85 mm
that loader valve spool is lifted to maximum height. 3.35 in.
4. While holding pick-up pin down, adjust lock nuts (4)

so that bottom of pick-up pin is within specification

9025
20
17

031504
PN=565
Adjustments
Adjust Return-to-Dig Switch
1. Loosen cap screw (A) and move return-to-dig switch so

roller (B) is touching cam surface (C) as shown.
2. Tighten cap screw without moving return-to-dig switch
–UN–18JUL00
out of position.
3. Test operation of the return-to-dig switch.
T132567B
a. Disconnect sensor tube yoke from self-leveling
actuator.
Return-to-Dig Switch Adjustment
NOTE: Be sure that switch arm and roller do not bottom
on switch housing.
b. Turn self-leveling actuator back-and-forth while

watching return-to-dig switch roller move on cam
surface. If cam surface hits switch bracket, or
return-to-dig switch roller arm bottoms against
–UN–18JUL00
switch housing when depressed, reposition
return-to-dig switch. Repeat steps 1—3.
T132566
c. Reconnect sensor tube yoke to self-leveling
actuator.
Line Art—Return-to-Dig Switch Adjustment
9025 A—Cap Screw

20 B—Roller
18 C—Cam Surface
BT40170,000003E –19–14FEB03–4/4

031504
PN=566
Adjustments
Backhoe Valve Linkage Adjustment

–UN–23OCT00
T134736B
3. Measure from knob edges-to-tape. Adjust both knob Two-Lever Configuration Shown
edge-to-tape distances (A) to specification. (See
Adjusting Backhoe Control Lever-to-Valve Linkage B—Knob Center-to-Knob Center Distance
procedure.)
Specification
4. Measure from knob center-to-knob center. Adjust knob

center-to-knob center distance (B) to specification.
(See Adjusting Backhoe Control Lever-to-Valve
Linkage procedure.)
Specification
Distance ....................................................................... 260 mm (10.25 in.) 9025
20
lever position.

031504
PN=567
Adjustments

unexpected machine movement. NEVER rely on
FNR lever alone to keep machine from moving.
Always set park brake to hold machine.
Prevent possible injury from unexpected

machine movement. Lower all equipment to
ground and release hydraulic pressure before
working near hydraulic equipment.
1. Engage park brake. Lower all equipment to ground.

Turn engine OFF. Release hydraulic pressure by
–UN–24JUL00
moving control levers until equipment does not move.
(See Practice Safe Maintenance in Safety chapter for
more information.)
T132841B
2. Remove rear floor mat, cap screws, and backhoe lever
console cover. John Deere Two-Lever Configuration Shown
3. Move upper rear window, middle rear window, and A—Jam Nut (2 used per Linkage Rod)
lower rear window to maximum UP position. Install B—Linkage Rod (1 used per Control Valve)
screw to hold lower rear window in UP position.

9025 control lever, then adjust knob center-to-knob center
20 distance.
20
a. Loosen jam nuts (A).
b. Turn linkage rod (B) to adjust lever position.

Specification
Distance ....................................................................... 260 mm (10.25 in.)
5. Move rear windows to suit operator’s preference.

031504
PN=568
Adjustments

rear floor mat.
CED,OUO1079,490 –19–21JUL00–3/3
Charging the Ride Control Accumulator
CAUTION: Hydraulic oil may escape at pressure

high enough to penetrate skin from
components in the Ride Control solenoid circuit
if components are removed without discharging
–UN–23AUG88
this accumulator. Hydraulic oil in accumulator
can be stored at pressures equal to or above
system relief pressures. Escaping fluid under
pressure can penetrate the skin causing serious
X9811
injury. Avoid the hazard by relieving pressure
before disconnecting hydraulic or other lines.
pressure. Search for leaks with a piece of
cardboard. Protect hands and body from high
pressure fluids.
If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be
surgically removed within a few hours or 9025
20
gangrene may result. Doctors unfamiliar with
21
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.
Specification
Oil—Temperature .................................................................. 40°C (104°F)
Ride Control Accumulator
Charge—Pre-charge Pressure .................. 2930 ± 241 kPa (29 ± 2.4 bar)
(425 ± 35 psi)
TX03768,0000B0D –19–19SEP00–1/5
Gas Cock . . . . . . . . . . . . . . . . . . . . . . . . . . JT01735
Charge Accumulator
Continued on next page TX03768,0000B0D –19–19SEP00–2/5

031504
PN=569
Adjustments
9025
20
22

031504
PN=570
Adjustments
1.
IMPORTANT: Charge accumulator using only dry

nitrogen. Dry nitrogen does not mix
with oil and is non-combustible. It will
not cause oxidation or condensation
–UN–03MAR00
inside accumulator and is not harmful
to piston seal. DO NOT use air or any
combustible gas as these can cause
oxidation and condensation. Oxidation
T128981
and condensation are harmful to piston
seal and accumulator.
If accumulator is to be charged on machine and has

some nitrogen pressure left, turn key to ON position.
Move ride control switch to OFF then back to ON.
Move control lever to float position to drain oil from
accumulator.
–UN–03MAR00
2. Loosen hose fitting on bottom of ride control
accumulator to release any trapped oil pressure. Leave
fitting loose until after charge pressure process is
complete.
T128982
3. Remove cover and cap from top of accumulator.
4. Turn handle on gas cock fully counterclockwise. Attach A—Top Nut

B—Bottom Nut 9025
gas cock, hose, and regulator to accumulator. 20
23
CAUTION: Loosen only the top nut (A). The

bottom nut (B) is actually the accumulator gas
valve fitting. Do Not loosen bottom fitting.
Loose fitting under pressure can cause injury.
5. Loosen top nut (A) (counterclockwise) 2 1/2 turns to

open gas valve in accumulator. (Resistance may be
felt at approximately 1 1/2 turns.)
6. Slowly open regulator valve to pressurize accumulator

to specification 2930 kPa (29 bar )(425 psi).
7. Ttighten nut (A) clockwise until snug to close gas

valve.
8. Shut-off the gas pressure from the nitrogen tank.

031504
PN=571
Adjustments
9. Slowly loosen the connector at the pressure regulator

valve to release pressure from the hose.
10. Remove the gas cock from the accumulator and

install cap.
11. Tighten hydraulic hose fitting on bottom of

accumulator.
TX03768,0000B0D –19–19SEP00–5/5
Checking Ride Control Accumulator Charge

–UN–23AUG88
X9811
9025
20
24 pressure. Search for leaks with a piece of
pressure fluids.

surgically removed within a few hours or
Specification
Oil—Temperature .................................................................. 40°C (104°F)
Ride Control Accumulator
(425 ± 35 psi)
The following procedure should be used for charging

accumulator that is already installed on the machine.

031504
PN=572
Adjustments
1. To determine proper nitrogen charge pressure for the

machine, install a gage (1) into the head end of the
loader cylinder.
2. Raise the loader 3 to 4 ft. off the ground. Note the

head end pressure required to support the loader. (The
–UN–06OCT00
accumulator charge pressure should be 50 psi below
this pressure.)
3. If accumulator is to be charged on machine and has
T134279B
accumulator.

complete.
5. Remove cover and cap from the top of accumulator.
6. Turn handle on gas cock fully counterclockwise. Attach

gas cock, hose, and regulator to accumulator.
9025
20
25

031504
PN=573
Adjustments
7.

–UN–03MAR00
Loosen top nut (A) counterclockwise 2 1/2 turns to
felt in approximately 1 1/2 turns.)
T128981
8. Slowly open the regulator valve to pressurize
accumulator to 345 kPa (3.5 bar )(50 psi) below head
end psi measured earlier.
9. Tighten nut (A) clockwise until snug to close gas valve.
–UN–03MAR00
T128982
install cap.
13. Tighten hydraulic hose fitting on bottom of A—Top Nut

9025 accumulator. B—Bottom Nut
20
26
TX03768,0000B30 –19–21OCT00–3/3
Ride Control Accumulator Discharge Procedure
2. Make sure area around bucket is clear and move

ride control switch to OFF position.
unexpected boom or bucket movement when
equipped with ride control. Ride control
3. Turn key switch to ON position, but do not start
accumulator energy must be discharged
engine. Move ride control switch to ON position.
when working on hydraulic components.
Turn key switch to ON position and move
4. Move loader control lever to float position. Bucket
the loader control lever into the float
should lower to ground.
position.
1. Position loader bucket approximately 30 cm (1 ft)

off the ground.
TX03768,0000B2F –19–21OCT00–1/1

031504
PN=574
Adjustments
Pilot Control Pressure Adjustment (S.N.

913484— )
This procedure is used to adjust regulated pilot pressure

in the pilot control system.
1. Perform hydraulic oil warm-up procedure. (Group

9025-25.)
2. Turn machine off.
3. Discharge pilot control manifold valve accumulator.

See Pilot Control Manifold Valve Accumulator
Discharge Procedure. (This Group.)
DW09104,0000023 –19–21NOV03–1/2
4. Connect 1000 psi transducers to JT02156A Digital

Pressure and Temperature Analyzer (Group 9025-25)
and pilot control pressure test port (1).
5. Start machine and hold a backhoe function over relief

for at least 30 seconds. 9025
20
27
6. Check pressure with function held over relief. Pressure
should be within specification.
Specification
Pilot Control—Pressure .................................................. 4309—4654 kPa
43—47 bar
625—675 psi
–UN–20FEB03
NOTE: Pilot control pressure adjustment screw is located
under end cap of pilot control pressure adjustment
cartridge (2).
7. If pressure is not to specification, remove end cap on T162864B

pilot control pressure adjustment cartridge (2) using a
5/16 inch standard allen wrench and turn adjustment
1—Pilot Control Pressure Test Port
screw in to increase pressure and out to decrease 2—Pilot Control Pressure Adjustment Cartridge
pressure.
DW09104,0000023 –19–21NOV03–2/2

031504
PN=575
Adjustments
Pilot Control Manifold Valve Accumulator

Discharge Procedure

unexpected backhoe boom or bucket movement
when equipped with Pilot Controls. Pilot Control
Manifold Valve Accumulator energy must be
discharged when working on hydraulic
components.
1. Turn keyswitch to ON position.
2. Turn pilot enable switch to unlocked position.
3. Cycle pilot functions to relieve system pressure.
OUT3019,00000DD –19–20NOV03–1/1
9025
20
28

031504
PN=576
Group 25
Tests
Pre-Test Diagnostics
• Check for external oil leaks: i.e. fittings, hoses, and

valves.
• Check for valve spool return-to-neutral that might be
caused from: i.e. spool sticking, linkage binding, detent
mechanism, self-leveling adjustment, vibration, control
valve tie-rod torque.
• Hydraulic reservoir oil level and the viscosity/condition
of hydraulic oil.
• Transmission oil level and the viscosity/condition of
engine oil.
• Radiator and oil cooler fins are clean and free of debris.
• Hydraulic System: Check for leaks, missing or loose
clamps, kinked hoses and lines, and hoses or lines that
rub against each other or other parts.
• Boom, Bucket, Sheet Metal: Check for bent, broken,
loose, or missing parts.
• Hardware: Check for loose or missing parts.
• Protective Devices: Check that guards, shields, and
covers are in place and in good condition.
CED,TX03768,2673 –19–18NOV99–1/1
9025
25
1

031504
PN=577
Tests
Diagnostics Flow Charts
9025
25
2
–19–15JUN99
T121126

031504
PN=578
Tests
9025
25
3
–19–10JUN99
T121148

031504
PN=579
Tests
9025
25
4
–19–10JUN99
T121147

031504
PN=580
Tests
9025
25
5
–19–10JUN99
T121125

031504
PN=581
Tests
9025
25
6
–19–10JUN99
T121146

031504
PN=582
Tests
9025
25
7
–19–10JUN99
T121146
CED,TX03768,2672 –19–18NOV99–6/6

031504
PN=583
Tests
.
T125994 –19–16FEB00
RUN REPAIR:
LOADER LOAD SENSE RELIEF
VALVE, ADJUST
LOW HYDRAULIC POWER
(LOW PRESSURE AND/OR FLOW) NOT OK
RUN REPAIR:
LOADER LOAD SENSE RELIEF
RUN TEST: VALVE, REPAIR/REPLACE
HYDRAULIC SYSTEM MAINTENANCE CHECK NOT OK
RUN REPAIR:
LOADER VALVE LOAD SENSE
RUN TEST: LEAKAGE TEST
RUN TEST:
TORQUE CONVERTER STALL SPEED TEST
BACKHOE LOAD SENSE RELIEF STALL NOT OK
RUN TEST:
PRESSURE TEST
PUMP LOAD SENSE DIFFERENTIAL YES - RPM WITHIN SPECS
PRESSURE, TEST RUN REPAIR:
SUSPICION: YES - BACKHOE RELIEF STALL PRESSURE IS
ISOLATOR, CHECK/REPAIR
YES - PRESSURE IS WITHIN/ DIAGNOSE ENGINE WITHIN SPECIFICATION FOR ALL FUNCTIONS
NO - RPM OUT OF SPEC.
ADJUSTED TO SPECIFICATION PERFORMANCE PROBLEM.
NO - BACKHOE RELIEF STALL PRESSURE IS NOT OK
OPERATIONAL CHECKOUT NOT OK
NO - PRESSURE CANNOT BE OUT OF SPECIFICATION FOR ALL FUNCTIONS
ADJUSTED TO BE WITHIN RUN REPAIR:
NO - BACKHOE RELIEF STALL PRESSURE IS
SPECIFICATION RUN TEST: LOAD SENSE SHUTTLE CHECK
OUT OF SPECIFICATION FOR SOME FUNCTIONS RUN TEST:
LOADER LOAD SENSE RELIEF STALL VALVE, CHECK/REPLACE
NOT OK SYSTEM RELIEF VALVE PRESSURE
PRESSURE TEST (ALL FUNCTIONS)
NOT OK WITH REMOTE PUMP, TEST NOT OK
RUN REPAIR: YES - LOADER RELIEF STALL PRESSURE IS NOT OK
HYDRAULIC OIL PUMP LOAD SENSE WITHIN SPECIFICATION FOR ALL FUNCTIONS YES - WITHIN SPEC RUN REPAIR:
VALVE MODULE. CHECK/REPAIR RUN REPAIR: LOADER VALVE, REPAIR
NO - LOADER RELIEF STALL PRESSURE IS LOADER LOAD SENSE RELIEF NO - OUT OF SPEC
NOT OK OUT OF SPECIFICATION FOR ALL FUNCTIONS VALVE, ADJUST NOT OK RUN TEST:
BACKHOE LOAD SENSE RELIEF STALL
RUN REPAIR: NO - LOADER RELIEF STALL PRESSURE IS YES - WITHIN SPEC
NOT OK CALL DTAC PRESSURE TEST
HYDRAULIC OIL PUMP. REPLACE OUT OF SPECIFICATION FOR SOME FUNCTIONS
NO - OUT OF SPEC YES - BACKHOE RELIEF STALL PRESSURE IS
NOT OK RUN REPAIR:
SYSTEM RELIEF VALVE, REPLACE WITHIN SPECIFICATION FOR ALL FUNCTIONS
CALL DTAC NO - BACKHOE RELIEF STALL PRESSURE IS NOT OK
NOT OK NOT OK
RUN TEST: OUT OF SPECIFICATION FOR ALL FUNCTIONS
RUN REPAIR: RUN TEST: PUMP PRESSURE TEST
PUMP PRESSURE, TEST NO - BACKHOE RELIEF STALL PRESSURE IS
LOADER LOAD SENSE RELIEF VALVE,
OUT OF SPECIFICATION FOR SOME FUNCTIONS
RUN TEST: REPAIR/REPLACE YES - PUMP DELIEVERS SYSTEM
YES - PUMP DELIVERS SYSTEM
BACKHOE LOAD SENSE RELIEF STALL RELIEF PRESSURE
NOT OK RELIEF PRESSURE. NOT OK
PRESSURE TEST
RUN TEST: NO - PUMP PRESSURE IS BELOW NO - PUMP PRESSURE IS BELOW
YES - BACKHOE RELIEF STALL PRESSURE IS NOT OK
SYSTEM RELIEF PRESSURE. SYSTEM RELIEF PRESSURE RUN TEST: RUN REPAIR:
WITHIN SPECIFICATION FOR ALL FUNCTIONS LOADER VALVE LOAD SENSE RUN REPAIR:
LEAKAGE TEST NO PRESSURE (ZERO PSI) IS CIRCUIT RELIEF VALVE WITH REMOTE BACKHOE LOAD SENSE CIRCUIT RELIEF VALVE WITH REMOTE
NO PRESSURE (ZERO PSI) IS
NO - BACKHOE RELIEF STALL PRESSURE IS NOT OK MEASURED FROM PUMP PUMP TEST RELIEF VALVE ADJUST PUMP, ADJUST/REPLACE
NOT OK MEASURED FROM PUMP
OUT OF SPECIFICATION FOR ALL FUNCTIONS NOT OK
NOT OK NOT OK OK NOT OK
NO - BACKHOE RELIEF STALL PRESSURE IS RUN REPAIR:
ISOLATOR CHECK/REPAIR RUN REPAIR:
OUT OF SPECIFICATION FOR SOME FUNCTIONS RUN REPAIR: RUN TEST:
RUN REPAIR: CIRCUIT RELIEF VALVE WITH REMOTE NOT OK
HYDRAULIC OIL PUMP, REPLACE LOADER VALVE LOAD SENSE LEAKAGE
NOT OK HYDRAULIC OIL PUMP, REPLACE PUMP ADJUST/REPLACE
NOT OK TEST
RUN REPAIR:
RUN REPAIR: RUN REPAIR: LOAD SENSE SHUTTLE CHECK VALVE NOT OK RUN REPAIR: OK
BACKHOE LOAD SENSE RUN TEST: RUN TEST:
CIRCUIT RELIEF VALVE WITH REMOTE CYCLE TIME (NO LOAD) TEST CHECK/REPLACE BACKHOE LOAD SENSE
RELIEF VALVE ADJUST RUN REPAIR: CIRCUIT RELIEF VALVE WITH REMOTE
PUMP, ADJUST/REPALCE (BACKHOE BUCKET DUMP, LOADER RELIEF VALVE NOT OK
NOT OK DISPLACEMENT CONTROL VALVE, PUMP TEST
NOT OK NOT OK BUCKET DUMP REPAIR/REPLACE
RUN REPAIR: CHECK/REPAIR NOT OK NOT OK
NOT OK NOT OK
RUN TEST: RUN REPAIR: YES - WITHIN SPECS LOADER VALVE REPAIR NOT OK RUN REPAIR: RUN REPAIR: CALL DTAC
BACKHOE VALVE LOAD SENSE BACKHOE LOAD SENSE RUN TEST:
LEAKAGE TEST RELIEF VALVE RUN REPAIR: DISPLACEMENT CONTROL CIRCUIT RELIEF VALVE WITH REMOTE BACKHOE VALVE LOAD
REPAIR/REPLACE
NO - OUT OF SPEC.
FLOW LIMITER, CHECK/REPAIR VALVE, CHECK/REPAIR PUMP ADJUST/REPLACE SENSE LEAKAGE TEST
NOT OK NOT OK RUN REPAIR:
NOT OK RUN TEST: NOT OK NOT OK ISOLATOR, CHECK/REPAIR
RUN REPAIR: NOT OK OK
RUN TEST: NOT OK CIRCUIT RELIEF VALVE WITH REMOTE RUN REPAIR:
ISOLATOR CHECK/REPAIR RUN TEST:
BACKHOE VALVE LOAD PUMP, TEST HYDRAULIC OIL PUMP LOAD SENSE RUN REPAIR: NOT OK NOT OK
RUN TEST: LOADER VALVE LOAD SENSE
NOT OK SENSE LEAKAGE TEST PUMP LOAD SENSE DIFFERENTIAL NOT OK VALVE MODULE, CHECK/REPAIR FLOW LIMITER, CHECK/REPAIR LEAKAGE TEST RUN REPAIR:
RUN REPAIR: PRESSURE, TEST
NOT OK RUN REPAIR: NOT OK NOT OK LOAD SENSE SHUTTLE CHECK VALVE,
LOAD SENSE SHUTTLE CHECK VALVE OK CHECK/REPLACE
YES - WITHIN SPECS CIRCUIT RELIEF VALVE WITH REMOTE RUN REPAIR: CALL DTAC
CHECK/REPLACE RUN REPAIR: RUN REPAIR:
PUMP, ADJUST/REPLACE HYDRAULIC OIL PUMP, REPLACE NOT OK
ISOLATOR CHECK/REPAIR NOT OK
NOT OK HYDRAULIC OIL PUMP LOAD
NO - OUT OF SPEC. NOT OK SENSE VALVE MODULE,
RUN REPAIR: NOT OK NOT OK RUN REPAIR:
LOADER VALVE REPAIR RUN TEST: CHECK/REPAIR LOADER VALVE, REPAIR
RUN REPAIR: RUN REPAIR:
BACKHOE VALVE LOAD SENSE CALL DTAC
LOAD SENSE SHUTTLE NOT OK NOT OK ISOLATOR CHECK/REPAIR
NOT OK LEAKAGE TEST RUN REPAIR:
CHECK VALVE NOT OK
CHECK/REPLACE RUN REPAIR: LOAD SENSE SHUTTLE CHECK NOT OK
HYDRAULIC OIL PUMP LOAD SENSE LEAKAGE VALVE, CHECK/REPLACE RUN REPAIR:
CALL DTAC
NOT OK HYDRAULIC OIL PUMP, REPLACE RUN REPAIR: CALL DTAC
VALVE MODULE, CHECK/REPAIR
RUN REPAIR: NOT OK NOT OK LOAD SENSE SHUTTLE
BACKHOE VALVE REPAIR CHECK VALVE
RUN TEST: RUN REPAIR: CHECK/REPLACE
FLOW LIMITER TEST LOAD SENSE RELIEF VALVES, RUN REPAIR:
NOT OK
ADJUST ISOLATOR CHECK/REPAIR NOT OK
CALL DTAC
NOT OK
NOT OK RUN REPAIR:
CALL DTAC NOT OK
RUN REPAIR: BACKHOE VALVE REPAIR
FLOW LIMITER, ADJUST NOT OK RUN REPAIR: RUN REPAIR:
CALL DTAC
LOAD SENSE SHUTTLE CHECK LOAD SENSE SHUTTLE CHECK VALVE NOT OK
NOT OK RUN REPAIR:
VALVE, CHECK/REPLACE CHECK/REPLACE
ISOLATOR CHECK/REPAIR CALL DTAC
CALL DTAC NOT OK NOT OK
NOT OK
RUN REPAIR: RUN REPAIR:
RUN REPAIR: LOAD SENSE RELIEF VALVES, LOADER VALVE REPAIR
RUN TEST: LOAD SENSE SHUTTLE CHECK VALVE ADJUST
FLOW LIMITER TEST CHECK/REPLACE
NOT OK NOT OK
NOT OK NOT OK
CALL DTAC CALL DTAC
RUN REPAIR:
RUN REPAIR:
FLOW LIMITER, ADJUST
BACKHOE VALVE REPAIR
NOT OK NOT OK
CALL DTAC CALL DTAC DIAGNOSTICS CHART FOR MACHINE LOW HYDRAULIC POWER CED,TX03768,2683 –19–10DEC99–1/1
T125994
031504
PN=584
Tests

Installation
Tachometer
A—Clamp-On Transducer. Remove paint with emery cloth and
–UN–28FEB89
T6813AG
TX,9025,RR7313 –19–10AUG95–1/1
Digital Pressure And Temperature Analyzer

Installation
Service Equipment And Tools
JT02156A Digital Pressure and Temperature Analyzer 9025
–UN–25AUG95
25
9
Use the digital pressure and temperature analyzer in
place of analog gauges and a separate temperature
reader.
T8543AI
Transducers (B) are temperature sensitive. Allow
transducer to warm to system temperature. After JT02156A Digital Pressure And Temperature Analyzer
transducer is warmed and no pressure applied, push A—Digital Pressure and Temperature Analyzer
sensor zero button for 1 second to set the true zero point. B—3400 kPa (35 bar) (500 psi) Transducer
34 000 kPa (350 bar) (5000 psi) Transducer
When using for different pressures, turn selector to OFF 70 000 kPa (700 bar) (10 000 psi) Transducer
for 2 seconds and then to the pressure range. Readings
are inaccurate if proper range for transducer is not used.
DW09104,0000078 –19–10SEP02–1/1

031504
PN=585
Tests
JT05800 Digital Thermometer Installation

Digital Thermometer
B—Cable
–UN–28FEB89
T6808CE
TX,9025,RR7314 –19–28FEB95–1/1
Hydraulic Oil Warm-Up Procedure

SPECIFICATIONS
Engine Speed Fast idle
Hydraulic Oil Temperature 65 ± 5°C (150 ± 10°F)
ESSENTIAL TOOLS
JT03111 (9/16 -18 M ORB x 7/16 -20 M JIC) Connector

Digital Thermometer
9025
25 1. Install temperature probe in reservoir.
10
2. Put FNR and transmission gear shift lever in neutral
and engage park brake.
3. Start engine and run at fast idle.
Specification
Engine—Speed ............................................................................ Fast idle
4. Lower loader bucket to the ground.
5. Place backhoe in transport position and apply boom

lock. Stall the boom down circuit by pushing the boom
down lever fully for one minute, then cycle function to
reduce localized over-heating in control valve and to
equalize temperature in circuits being tested. Repeat
cycle until oil, after cycling, is at test specifications.
Specification
Hydraulic Oil—Temperature ................................... 65 ± 5°C (150 ± 10°F)
TX,9025,RR7558 –19–07DEC96–1/1

031504
PN=586
Tests
Pump Load Sense Differential Pressure Test
A—Pump Outlet Coupler

B—Load Sense Coupler
C—Load Sense Differential Pressure Screw
D—Load Sense Line
–UN–13DEC96
T104871
9025
25
11

031504
PN=587
Tests
SPECIFICATIONS
Engine Speed Slow idle (900 + 25 - 0 rpm)
Pump Load Sense Differential 1930 ± 34 kPa (19 ± 0.5 bar)
Pressure Setting (280 ±10 psi)
One Full Turn of Load Sense Approximately 30 psi
Differential Pressure Screw
Changes Pressure

Method I - JT02156A Digital Pressure and Temperature Analyzer or
Equivalent
Digital Thermometer
Digital Tachometer
Method II - Gauge 0—3450 kPa (0—35 bar) (0—500 psi)
The purpose of this test is to check the pump load sense

differential pressure setting. This test should be performed
when the pump performance is in doubt.
–UN–15AUG02
1. Method I Operate all hydraulic control valves to relieve
pressure in the hydraulic system.
2. Install digital pressure transducers or equivalent to
T158566
pump outlet coupler (4) and load sense coupler (2).
Install temperature analyzer coupler to reservoir.
9025
25 1—Load Sense Differential Pressure Screw
3. Warm oil to specification. 2—Load Sense Coupler
12
3—Load Sense Line
Specification 4—Pump Outlet Coupler
4. Set digital pressure analyzer to 500 psi delta.
IMPORTANT: Do not operate hydraulic control levers

during this test.
5. Run engine at low idle.
Specification
Engine—Speed ............................................. Slow idle (900 + 25 - 0 rpm)

031504
PN=588
Tests
6. Record pressure.
Specification
Pump Load Sense—Differential
Pressure Setting .......................................... 1930 ± 34 kPa (19 ± 0.5 bar)
(280 ±5 psi)
Stop engine.
7. If adjustment is necessary turn load sense differential

pressure screw (3) IN (clockwise) to raise pressure and
OUT (counterclockwise) to lower pressure. One turn
equals approximately 30 psi.
Specification
One Full Turn of Load Sense
Changes—Pressure ................................................. Approximately 30 psi
8. Repeat step 5 and 6 until pressure is at specification.
Specification
(280 ±10 psi)

9025
25
13

031504
PN=589
Tests
1. Method II: Operate all hydraulic control valves to

relieve pressure in the hydraulic system.
2. Install temperature probe in reservoir.
3. Connect gauge to pump outlet coupler (1).
4. Install tachometer.
5. Warm oil to specifications.
Specification
(See Hydraulic Warm-Up Procedure. (Go to Group 9025.)
–UN–13DEC96
IMPORTANT: DO NOT cap or plug load sense line or
port.
6. Shut engine off and disconnect load sense line (4) at
T104871
pump. Place line in bucket without being capped. Also,
do not plug load sense port at pump.
CAUTION: To prevent injury from spraying hot

oil, do not operate hydraulic control levers
during this test.
9025
25 7. Start engine and run at slow idle.
14
Specification
Engine—Speed ............................................. Slow idle (900 + 25 - 0 rpm)
Do not operate hydraulic control levers during this test.

Record pressure.
Specification
(280 ±5 psi)
8. Engine off. Adjust the pump load sense pressure by

turning screw (3) in to raise pressure and out to lower
pressure. (Each full turn is approximately 30 psi.)
–UN–15AUG02
Specification
One Full Turn of Load Sense
Changes—Pressure ................................................. Approximately 30 psi
T158568

031504
PN=590
Tests
9. Repeat step 7 and 8 until pressure is to specification.
Specification
(280 ±5 psi)
TX,9025,SS3533 –19–10DEC96–5/5
9025
25
15

031504
PN=591
Tests
Pump Flow Test
SPECIFICATIONS
Flowmeter Pressure 13 700 ± 70 kPa (137 ± 0.7 bar)
(2000 ± 100 psi)
New Pump Flow 151 L/min (40 gpm)
Used Pump Minimum Flow 129 L/min (34 gpm)
ESSENTIAL TOOLS
JT05688 (1-1/16 -12 M 37° x -8 F ORFS) Adapter (2 Used)
38H1279* (-8 M x -8 M ORFS) Union

Flowmeter
Digital Thermometer
–UN–13DEC96
1. See Pump Load Sense Differential Pressure Test. (Go
to Group 9025-25).
2. See Backhoe Load Sense and Loader Load Sense
T104864
Relief Stall Pressure Test. (Go to Group 9025-25).
9025 3. Put FNR and transmission control levers in neutral and A—Bucket Cylinder Rod End Hose
25 engage park brake. B—Flowmeter
16 C—Bucket Head End Hose
4. Stop engine. Operate all hydraulic control valves to
release pressure in the hydraulic system.
5. Connect hose and flowmeter (B) with analyzer to

bucket cylinder rod end hose (A) and head end hose
(C).
6. Open flowmeter. Install digital thermometer sensor in

reservoir. Install electronic tachometer.
7. Warm oil to specification.
Specification
See Hydraulic Warm-Up Procedure. (Go to Group 9025).)
Continued on next page TX,9025,SS3537 –19–22AUG96–1/2

031504
PN=592
Tests
8. Run engine to specified temperature and engine rpm.
Specification
Engine—Speed ........................................................................... 2200 rpm
9. Slowly apply 13,700 ± 70 kPa (137 ± 0.7 bar) (2000 ±

10 psi) to pump and record pump flow.
Specification
Flowmeter—Pressure ............................. 13 700 ± 70 kPa (137 ± 0.7 bar)
(2000 ± 100 psi)
New Pump—Flow ....................................................... 151 L/min (40 gpm)
Used Pump—Minimum Flow ...................................... 129 L/min (34 gpm)
TX,9025,SS3537 –19–22AUG96–2/2
9025
25
17

031504
PN=593
Tests
Backhoe Load Sense and Loader Load

Sense Relief Stall Pressure Test
SPECIFICATIONS
Engine Speed Fast Idle
Backhoe Load Sense Relief Stall 24 300—25 700 kPa (243—257
Pressure Setting bar) 3525—3725 psi
Hydraulic Oil Temperature 60—70°C (140—160°F)
Loader Load Sense Relief Stall 24 300—25 700 kPa (243—257
Pressure Setting bar) 3525—3725 psi
ESSENTIAL TOOLS

Digital Thermometer
Gauge 0—35 000 kPa (0—350 bar) (0—5000 psi)
NOTE: Before performing these two tests, the Pump Load

Sense Differential Pressure Test must be done
and adjusted if necessary. (See procedure in this
section).
Both the backhoe and loader control valves have a load

sense relief valve. The load sense relief valves are
adjusted to set stall pressures.
9025
25
18 1. Backhoe Load Sense Relief Stall Pressure Test:
See Pump Load Sense Differential Pressure Test. (Go

to Group 9025).
2. Operate all hydraulic control valves to relieve pressure

in the hydraulic system.
Continued on next page TX03768,0000B2A –19–07APR03–1/6

031504
PN=594
Tests
4.
1—Pump Outlet Coupler
–UN–18DEC96
T104872
TX03768,0000B2A –19–07APR03–2/6
9025
25
19
Connect gauge to pump outlet coupler (1)(4).
Specification
Engine—Speed ............................................................................ Fast Idle
Hydraulic Oil—Temperature ................................. 60—70°C (140—160°F)
See Hydraulic Warm-Up Procedure. (Go to Group 9025.)

–UN–15AUG02
T158567

031504
PN=595
Tests
6. Raise the backhoe boom fully to transport position and

hold over relief to stall the circuit. Record the backhoe
load sense relief stall pressure setting from the gauge.
Specification
Backhoe Load Sense—Relief
Stall Pressure Setting .............................. 24 300—25 700 kPa (243—257
bar) 3525—3725 psi
7. To adjust the backhoe load sense relief valve, turn

adjusting screw (1).
NOTE: One gauge can be used if necessary.
1. Loader Load Sense Relief Stall Pressure Test:
See Pump Load Sense Differential Pressure Test. (Go

to Group 9025-25).

–UN–16OCT00
T134544B
9025
25
20

031504
PN=596
Tests
4. Connect gauge to pump outlet coupler (1) or (4).
Specification
Engine—Speed ............................................................................ High Idle
6. Loader bucket fully dumped and held over relief at

ground level. Record the loader load sense relief stall
pressure setting from gauge.
Specification
Loader Load Sense—Relief Stall
Pressure Setting ........................................................ 24 300—25 700 kPa
243—257 bar
3525—3725 psi
1—Pump Outlet Coupler (S.N. —907932)

4—Pump Outlet Coupler (S.N. 907933—)
–UN–18DEC96
T104872
9025
25
21
–UN–15AUG02
T158567

031504
PN=597
Tests
–UN–16OCT00
T134543B
9025
25
22
–UN–17FEB03
T165506B
1—Load Sense Relief Valve 2—Pressure Gauge 5—Load Sense Relief Valve
(S.N. —913479) (S.N. 913480— )
7. To adjust the load sense relief valve, loosen lock

nut and adjust set screw (1) or (5) in to required
specification.
TX03768,0000B2A –19–07APR03–6/6

031504
PN=598
Tests
Steering Load Sense Relief Valve Stall

Pressure Test (S.N.—911132)
–UN–18DEC96
T104872
Continued on next page TX,9025,RR7567 –19–16SEP03–1/4
9025
25
23

031504
PN=599
Tests
SPECIFICATIONS
Engine Speed WOT
Steering Load Sense Relief Valve 24 300—25 700 kPa (243—257
Stall Pressure Setting bar) 3525—3725 psi)
One Turn IN of Hex Screw Approximately 1000 psi
Increases Pressure
ESSENTIAL TOOLS

Digital Thermometer
Gauge 0—35 000 kPa (0—350 bar) (0—5000 psi)
The purpose of this test is to check the setting of the

steering load sense relief valve. The steering load sense
relief valve is adjusted to set stall pressure.
1. See Pump Load Sense Differential Pressure Test. (Go
–UN–15AUG02
to Group 9025).

T158567
9025
25 4—Pump Outlet Coupler
24 4. Connect gauge to pump outlet coupler (1).
5. Install tachometer.
Specification
Engine—Speed .................................................................................. WOT
Specification
7. Turn the steering wheel either left or right and hold

against stop.
Continued on next page TX,9025,RR7567 –19–16SEP03–2/4

031504
PN=600
Tests
8. Read gauge and record value.
Specification
Steering Load Sense Relief
Valve—Stall Pressure Setting ................................... 24 300—25 700 kPa
243—257 bar
3525—3725 psi
TX,9025,RR7567 –19–16SEP03–3/4
9. To adjust the steering load sense relief valve, turn hex

screw (A), (One turn IN increases pressure
approximately 1000 psi).
Specification
One Turn IN of Hex Screw
Increases—Pressure ............................................ Approximately 1000 psi
NOTE: The adjustment of the steering valve load sense

relief can only be done when the steering valve is
removed from the machine. (See Technical Repair
Manual.)
9025
25
25
–UN–13DEC96
T104869
TX,9025,RR7567 –19–16SEP03–4/4

031504
PN=601
Tests
Steering Valve Pressure Test (S.N. 911133— )
SPECIFICATIONS
Hydraulic Oil Temperature 60—70°C (140—160°F)
Engine Speed Fast Idle
Loader and Steering Load Sense 24 300—25 700 kPa (243—257
Relief Pressure Setting bar) 3525—3725 psi
Essential Tools

JT02156A Digital Pressure and Temperature Analyzer
NOTE: Steering valve is tied to loader control valve.

Loader load sense relief is the same pressure as
the steering pressure. Adjusting loader load sense
relief will change loader and steering pressures.
1. Perform Pump Load Sense Differential Pressure Test.

(Group 9025-25.)

3. Connect 5000 psi transducer to digital pressure and

9025 temperature analyzer and pump outlet test port (1).
25
26
4. Warm oil to specifications.Perform Hydraulic Warm-Up
Procedure. (Group 9025-25.)
Specification
5. Run engine at fast idle with steering wheel fully turned

against stops and held over relief. Pressure must be to
specification.
Specification
Loader and Steering Load
Sense—Relief Pressure Setting .............. 24 300—25 700 kPa (243—257
bar) 3525—3725 psi
Continued on next page DW09104,000006D –19–16SEP03–1/2

031504
PN=602
Tests
–UN–17FEB03
T165506B
Loader Load Sense Relief Valve Adjustment Screw
5—Loader Load Sense Relief

Valve Adjusting Screw
6. To adjust load sense relief valve, turn loader load

sense relief valve adjusting screw (5).
9025
25
27
DW09104,000006D –19–16SEP03–2/2

031504
PN=603
Tests
Flow Limiter Test
SPECIFICATIONS
Transmission and Hydraulic Oil 65 ± 5°C (150 ± 10°F)
Temperature
Engine Speed Fast idle (2375 -2400 rpm)
Engine RPM (Flow Limited) 1250—1450 rpm*
One Full Turn IN of Flow Limiter Approximately 50 rpm
Screw Decreases Engine RPM
One Full Turn IN of Flow Limiter Approximately 5 hp
Screw Increases Horsepower to
Hydraulic Pump

Digital Thermometer
The purpose of this test is to adjust the maximum power

that can be used by the hydraulic pump.
NOTE: Increasing the power level to the hydraulic pump

can result in additional engine pulldown during
certain loader operations.
NOTE: Before doing the following procedure, see Pump

Load Sense Differential Pressure Test and see
9025 Backhoe Load Sense and Loader Load Sense
25 Relief Stall Pressure Tests. These tests must be
28
performed and adjustments made as needed (Go
to Group 9025-25). Also See the Torque
Converter Stall Speed Test. (Go to Group
9020-25).
1. See Install electronic tachometer. (Go to Group 9025.)
2. Install digital thermometer probe into the transmission

and hydraulic reservoir through the dipstick tube.
Specification
Transmission and Hydraulic Oil—
Temperature ........................................................... 65 ± 5°C (150 ± 10°F)
See Transmission Warm-Up Procedure. (Go to Group

9020-25) and See Hydraulic Warm-Up Procedure. (Go to
Group 9025-25.
Continued on next page TX,9025,RB23 –19–14OCT00–1/4

031504
PN=604
Tests
4. Lower stabilizers to raise wheels off ground.
IMPORTANT: Converter should NOT be stalled longer

than 20 seconds or serious converter
damage may result. Return FNR lever to
neutral position for 10 seconds before
doing next stall test.
5. Put transmission in fourth gear.
TX,9025,RB23 –19–14OCT00–2/4
6.
1—Flow Limiter Screw
9025
25
29
–UN–16OCT00
T134545B
Continued on next page TX,9025,RB23 –19–14OCT00–3/4

031504
PN=605
Tests
Apply and hold service brakes during test.
7. Move FNR lever to forward position.
8. Run engine at fast idle with speed control lever.
Specification
Engine—Speed .............................................. Fast idle (2375 - 2400 rpm)
IMPORTANT: Minimum engine speed listed is for an

engine that is broken-in and using No. 2
fuel.
9. Loader bucket fully dumped and held over relief at

ground level. Record tachometer reading while raising
loader boom to maximum height.
10. Record rpm.
Specification
Engine—RPM .................................................................. 1250—1450 rpm
–UN–15AUG02
This rpm is the dependent on the flow limiter setting.
11. Adjust Flow Limiter:
T158568
Turning the flow limiter screw (1) IN (clockwise) one
9025 full turn will decrease the engine rpm measured
25 during the above test approximately 50 rpm and 5—Flow Limiter Screw
30 6—Hydraulic Oil Inlet Line
provide approximately five more horsepower to the
hydraulic pump.
Specification
One Full Turn IN of Flow Limiter
Screw—Decreases Engine RPM ............................ Approximately 50 rpm
Increases Horsepower to
Hydraulic Pump ........................................................... Approximately 5 hp
Adjusted Engine RPM ............................................................... 1250-1450
TX,9025,RB23 –19–14OCT00–4/4
Pilot Control Pressure Test (S.N. 913484— )
To test pilot control pressure, see Pilot Control Pressure

Adjustment. (Group 9025-20.)
DW09104,0000024 –19–13DEC02–1/1

031504
PN=606
Tests
Hydraulic Oil Cooler Restriction Test
–UN–26AUG96
T102207
9025
25
31
A—Hydraulic Analyzer B—Tee Fittings (2 used) C—Oil Cooler
SPECIFICATIONS 1. Make test connection.

Engine Speed Low idle 2. Open flowmeter. Heat oil to test specification.
Flowmeter Flow 28.4 L/min. (7.5 gpm)
Specification
Hydraulic Oil Cooler Maximum 207 kPa (2.1 bar) (30 psi) Hydraulic Oil—Temperature ............................ 65 ± 5°C (120 ± 10°F)
Differential Pressure
See Hydraulic Warm-Up Procedure. (Go to Group

ESSENTIAL TOOLS 9025-25.)
3/4 M NPT x 5/8 Barb Fitting
JT03012 (1-1/16 F 37° SW x 3/4 F NPT) Fitting 3. Meter backhoe bucket dump at low idle to obtain
JT03048 (1-1/16 M ORB x 1-1/16 M 37°) Fitting specified cooler flow.
JT03348 (1/2 F NPT) Tee (2 Used)
Specification
JT03213 (5/8 I.D. Hose x 1/2 M NPT) Adapter (6 Used) Engine—Speed ....................................................................... Low idle
Flowmeter—Flow .............................................. 28.4 L/min. (7.5 gpm)
Hydraulic Analyzer 4. Read pressure gauges at inlet and outlet of cooler.
Gauge 0—345 kPa (0—3.5 bar) (0—50 psi) Difference in gauge reading is pressure drop in
cooler.
Flowmeter with Temperature Gauge
Continued on next page TX,9025,RR7320 –19–12AUG96–1/2

031504
PN=607
Tests
Specification
Hydraulic Oil Cooler—Maximum
Differential Pressure .................................. 207 kPa (2.1 bar) (30 psi)
TX,9025,RR7320 –19–12AUG96–2/2
Circuit Relief Valve Test With Remote Pump

SPECIFICATIONS
Hydraulic Source Maximum Flow 7.5 L/min (2 gpm)
Rate
Oil Temperature 40 ± 6°C (104 ±10°F)
Set Tolerance Pressure +1380 -0 kPa (+13.8 -0 bar)
(+200 -0 psi)
Loader Circuits
Auxiliary Extend Pressure 26200 kPa (262 bar) (3800 psi)
(non-adjustable)
Bucket Curl Pressure (screw 31715 kPa (317 bar) (4600 psi)
adjustable)
Bucket Dump Pressure (screw 31715 kPa (317 bar) (4600 psi)
adjustable)
Boom Up Pressure (screw 34473 kPa (344 bar) (5000 psi)
adjustable)
Backhoe Circuits
Crowd Out Pressure (screw 32800 kPa (327 bar) (4750 psi)
9025 adjustable)
25
Crowd In Pressure 26200 kPa (276 bar) (3800 psi)
32
(non-adjustable)
Bucket Curl Pressure (screw 31700 kPa (317 bar) (4600 psi)
adjustable)
Bucket Dump Pressure (screw 31700 kPa (317 bar) (4600 psi)
adjustable)
Boom Raise Pressure (screw 34500 kPa (345 bar) (5500 psi)
adjustable)
Boom Down Pressure 14800 kPa (148 bar) (2150 psi)
(non-adjustable)
Swing Left Pressure 28900 kPa (290 bar) (4200 psi)
(non-adjustable)
Swing Right Pressure 28900 kPa (290 bar) (4200 psi)
(non-adjustable)
System Relief Valve Pressure 27600 kPa (276 bar) (4000 psi)
(non-adjustable)
Continued on next page TX,9025,RB17 –19–25APR03–1/3

031504
PN=608
Tests
ESSENTIAL TOOLS
JT07192 Electric/Hydraulic Pump
38H1355 (—10 ORFS) Nut
38H1470 (—10 F x —6 M ORFS) Reducer
38H1356 (—12 ORFS) Nut
38H1358 (—16 F x —8 M ORFS) Nut

Digital Thermometer
Gauge 0—48 260 kPa (0—482 bar) (0—7000 psi)
IMPORTANT: Relief valve is flow sensitive. A flow

rate greater than 7.5 L/min (2 gpm) will
flood the valve causing an inaccurate
pressure reading. A hydraulic source
must be used that will provide a
continuous flow to get an accurate
reading.
1. Operate hydraulic functions to relieve pressure.
Specification
Hydraulic Source—Maximum 9025
Flow Rate ...................................................................... 7.5 L/min (2 gpm) 25
33
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.
2. Place container (C) under hoses to catch any oil

leakage.
Specification
Oil—Temperature .................................................... 40 ± 6°C (104 ±10°F)
Continued on next page TX,9025,RB17 –19–25APR03–2/3

031504
PN=609
Tests
3. Connect remote pump pressure hose (A) to circuit inlet

hoses and cap all other ends of hose during this test.
4. Start remote pump to pressurize valve inlet.
NOTE: Take reading when pressure on gauge starts to

decrease. The point at which pressure decreases
is the opening pressure of the relief valve.
5. Adjust or replace as required.
1. System Relief Test: Remove system relief valve from

backhoe end cap outlet section.
2. Remove upper work port circuit relief valve from swing

section of backhoe control valve and install the system
relief valve.
3. Start pump to pressurize circuit and record reading

from gauge.
–UN–23AUG96
Specification
Pump Set Tolerance—Pressure.................... +1380 -0 kPa (+13.8 -0 bar)
(+200 -0 psi)
T102189
System relief valve is not adjustable, replace if not to
specification.
9025
25
34
TX,9025,RB17 –19–25APR03–3/3

031504
PN=610
Tests
Charging the Ride Control Accumulator

–UN–23AUG88
X9811
pressure. Search for leaks with a piece of
pressure fluids.

Specification 9025
Oil—Temperature .................................................................. 40°C (104°F) 25
Ride Control Accumulator 35
(425 ± 35 psi)
TX03768,0000B0D –19–19SEP00–1/5
Gas Cock . . . . . . . . . . . . . . . . . . . . . . . . . . JT01735
Charge Accumulator
TX03768,0000B0D –19–19SEP00–2/5

031504
PN=611
Tests
1.
IMPORTANT: Charge accumulator using only dry

nitrogen. Dry nitrogen does not mix
with oil and is non-combustible. It will
not cause oxidation or condensation
–UN–03MAR00
inside accumulator and is not harmful
to piston seal. DO NOT use air or any
combustible gas as these can cause
oxidation and condensation. Oxidation
T128981
and condensation are harmful to piston
seal and accumulator.
If accumulator is to be charged on machine and has

accumulator.
–UN–03MAR00
complete.
T128982
3. Remove cover and cap from top of accumulator.
4. Turn handle on gas cock fully counterclockwise. Attach A—Top Nut

9025 B—Bottom Nut
25 gas cock, hose, and regulator to accumulator.
36

5. Loosen top nut (A) (counterclockwise) 2 1/2 turns to

felt at approximately 1 1/2 turns.)
6. Slowly open regulator valve to pressurize accumulator

to specification 2930 kPa (29 bar )(425 psi).
7. Ttighten nut (A) clockwise until snug to close gas

valve.

031504
PN=612
Tests


install cap.
11. Tighten hydraulic hose fitting on bottom of

accumulator.
TX03768,0000B0D –19–19SEP00–5/5
Ride Control Accumulator Discharge Procedure
2. Make sure area around bucket is clear and move

ride control switch to OFF position.
unexpected boom or bucket movement when
equipped with ride control. Ride control
3. Turn key switch to ON position, but do not start
accumulator energy must be discharged
engine. Move ride control switch to ON position.
when working on hydraulic components.
Turn key switch to ON position and move
4. Move loader control lever to float position. Bucket
the loader control lever into the float
should lower to ground.
position.
1. Position loader bucket approximately 30 cm (1 ft)

9025
off the ground.
25
37
CED,OUTX466,955 –19–16APR98–1/1

031504
PN=613
Tests
Steering System Leakage Test
SPECIFICATIONS
Hydraulic Oil (Steering System 60—70 °C
Leakage Test) Temperature 140—160 °F
Steering Wheel (Steering System 11.3 N•m (100 lb-in.)
Leakage Test) Torque
Steering Wheel (Steering System 7 rpm maximum
Leakage Test) Turns

Digital Thermometer
1. Install digital thermometer. See JT05800 Digital

Thermometer Installation. (Group 9010-25.)
2. Heat hydraulic oil to specification. See Hydraulic Oil

Warm-Up Procedure in this group.
Specification
Hydraulic Oil (Steering System
Leakage Test)—Temperature .................................................. 60—70 °C
140—160 °F
3. Apply park brake and put transmission in neutral.
4. Run engine at slow idle.

9025
25
38
Continued on next page CED,OUO1010,419 –19–17FEB03–1/3

031504
PN=614
Tests
5. Remove steering wheel cap.
6. Bend locking tab away from steering wheel nut.
7. Turn wheels to the maximum right position against the

stop.
–UN–26OCT88
8. Continue to turn the steering wheel clockwise at a
constant specified torque. While maintaining specified
torque, continue to turn the steering wheel and count
T93024
steering wheel rpm.
Specification
Steering Wheel (Steering System
Leakage Test)—Torque............................................. 11.3 N•m (100 lb-in.)
Specification
Steering Wheel (Steering System
Leakage Test)—Turns ...................................................... 7 rpm maximum
9. Turn the steering wheel to the maximum left position

and repeat previous two steps.
• If the steering wheel can be turned faster than 7 rpm

in either direction, excessive leakage is indicated.
Perform the following steps to isolate steering valve
or steering cylinder leakage.
• If the steering wheel cannot be turned faster than 7
9025
rpm in both directions, the steering valve and 25
steering cylinder are good. Stop test here. 39
10. Stop engine.
11. Operate all hydraulic control valves to release

pressure in system.
Continued on next page CED,OUO1010,419 –19–17FEB03–2/3

031504
PN=615
Tests
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
–UN–23AUG88
Protect hands and body from high pressure
fluids.
X9811
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
12. Disconnect lines (1) from steering cylinder and install
–UN–19FEB03
caps and plugs as shown.
13. Start engine and run at slow idle.
T165589B
14. Turn steering wheel counterclockwise and then
clockwise at previously specified torque. Count the
rpm. MFWD Axle Shown (Left Side)
1—Steering Cylinder Line (2 used)

9025 15. If steering wheel can be turned faster than
25 specification in either direction, steering valve is
40
leaking excessively. If the rpm is less than
specification, perform Steering Cylinder Leakage Test
in this group.
CED,OUO1010,419 –19–17FEB03–3/3

031504
PN=616
Tests
Steering Cylinder Leakage Test
SPECIFICATIONS
Hydraulic Oil (Steering System 60—70 °C
Leakage Test) Temperature 140—160 °F
Steering Cylinder Leakage 5 ml/min
0.3 cu in./min

Digital Thermometer
1. Install digital thermometer. See JT05800 Digital

Thermometer Installation. (Group 9010-25.)
2. Heat hydraulic oil to specification. See Hydraulic Oil

Warm-Up Procedure in this group.
Specification
Hydraulic Oil (Steering System
Leakage Test)—Temperature .................................................. 60—70 °C
140—160 °F
3. Put FNR lever in neutral and engage park brake.
4. Start engine. Turn the steering wheel to left turn stop

to extend cylinder rod.
5. Stop engine. Move steering wheel back and forth to 9025

relieve hydraulic pressure. 25
41

031504
PN=617
Tests
6. Disconnect pressure hose on right side of cylinder and

install plug (3).
7. Install hose (1) to steering cylinder fitting (2) and route

into a calibrated container.
–UN–19FEB03
8. Start engine and run at slow idle.
9. Using constant pressure, hold steering wheel in full left

turn for one minute.
T165624B
10. Stop engine.
MFWD Axle Shown (Left Side)
11. Measure oil collected and reconnect hose. If oil
1—Hose
collected is over specified amount, repair cylinder. For 2—Fitting
machines with non-powered axles, see Remove and 3—Plug
Install Non-Powered Axle Steering Cylinder (S.N. —
911131). (Group 0960.) For machines with MFWD
axles, see Remove Steering Cylinders in CTM4687
(Group 05).
Specification
Steering Cylinder—Leakage......................................................... 5 ml/min
0.3 cu in./min
12. Repeat procedure for opposite end of steering

cylinder.
9025
25
42
TX,9025,RR7504 –19–18FEB03–2/2

031504
PN=618
Tests
Hydraulic Cylinder Drift Test Procedure
9025
25
43
–19–20SEP96
T103936
TX,9025,RR7336 –19–20SEP96–1/1

031504
PN=619
Tests
Function Drift Test
SPECIFICATIONS
Engine Speed Low idle
Backhoe Function Max Allowable 50 mm/min (2.00 in/min)
Drift
BH Boom Cylinder, (Std. Dipper) 5 mm/min (0.20 in/min)
Max Allowable Drift
BH Crowd Cylinder, (Std. Dipper) 6 mm/min (0.25 in/min)
Max Allowable Drift
BH Bucket Cylinder Max 3 mm/min (0.12 in/min)
Allowable Drift
Swing Cylinder Max Allowable 150 mm/min (6.00 in/min)
Drift
Loader Function Max Allowable 50 mm/min (2.00 in/min)
Drift
Loader Boom and Bucket Drift 3 mm/min (0.12 in/min)
Ext. Dipper Cylinder Max 6 mm/min (0.25 in/min)
Allowable Drift

Digital Thermometer
NOTE: The following tests are used to check leakage

past the cylinder piston seals and through the
9025 main control valve spool and reliefs. Weighting the
25
machine is not required to perform these tests. On
44
extendable dipperstick machines fully retract
dipperstick for all testing.
1. Install digital thermometer probe in reservoir. Warm

hydraulic oil to specifications.
Specification
2. Put FNR lever in neutral and engage park brake.
Function Drift
3. Position backhoe bucket side cutters at 45° angle to

ground and lower boom until bucket cutting edge is 50
mm (2.00 in.) off ground.
Continued on next page TX,9025,RB42 –19–03SEP03–1/5

031504
PN=620
Tests
NOTE: For machines equipped with ride control,See Ride

Control Hydraulic Circuit Component Location and
Valve Operation—On Position (S.N. —911132)
See Ride Control Hydraulic Circuit Component
Location and Valve Operation (S.N. 911133— ) in
thus group before preforming test.
–UN–19SEP96
4. Position loader bucket cutting edge approximately 2
inches off ground.
T102956
NOTE: If bucket cutting edges touch the ground within
one minute, excessive leakage is indicated in the
cylinders or control valve. Position machine as
shown, with the bucket pivot pin one meter (36
in.) off ground.
5. Run engine at slow idle and observe bucket cutting

edges for one minute.
Specification
Engine—Speed ............................................................................. Low idle
Backhoe Function—Max
Allowable Drift...................................................... 50 mm/min (2.00 in/min)
TX,9025,RB42 –19–03SEP03–2/5
9025
25
45
6. Position the crowd cylinder with rod 20—50 mm
(0.75—2.00 in.) extended from the fully retracted
position.
7. Position the bucket cylinder with rod 20—50 mm

(0.75—2.00 in) retracted from the fully extended
–UN–26MAY89
position.
8. Measure movement of boom, crowd, and bucket

cylinder rods for five minutes. Divide measured rod drift
T6222AM
by five to determine drift per minute.
Specification Backhoe Cylinder Drift

BH Boom Cylinder, (Standard
Dipper)—Max Allowable Drift ................................ 5 mm/min (0.20 in/min)
BH Crowd Cylinder, (Standard
Dipper)—Max Allowable Drift ................................ 6 mm/min (0.25 in/min)
BH Bucket Cylinder—Max
Allowable Drift........................................................ 3 mm/min (0.12 in/min)
Continued on next page TX,9025,RB42 –19–03SEP03–3/5

031504
PN=621
Tests
9. To measure swing drift tilt machine by fully extending

right hand stabilizer. Fully extend dipperstick and
bucket straight behind following centerline of machine,
so bucket is approximately 300 mm (12 in.) off ground.
Boom should be parallel to ground. Position left hand
stabilizer 75 mm (3 in.) off ground.
–UN–19SEP96
10. Measure swing drift from side of bucket, to vertical
rod placed in ground next to bucket, for five minutes.
Divide measured drift by five to determine drift per
T102957
minute.
Specification
Swing Cylinder—Max Allowable
Drift .................................................................... 150 mm/min (6.00 in/min)
11. Measure swing drift in opposite direction by reversing

stabilizer positions and vertical rod.
TX,9025,RB42 –19–03SEP03–4/5
9025
25
46
12. Position the machine as shown with the loader bucket
cutting edge one meter (36 in.) above ground, with
bucket level.
13. Measure movement of boom and bucket cylinders for

five minutes. Divide measured rod drift by five to
–UN–26MAY89
determine drift per minute.
Specification
Loader Function—Max Allowable
T6222AM
Drift ...................................................................... 50 mm/min (2.00 in/min)
Loader Boom and Bucket—Drift ........................... 3 mm/min (0.12 in/min)
Loader Cylinder Drift

Extendible Dipperstick Cylinder Drift
14. Machine in transport position. Curl backhoe bucket.

Remove extendable dipperstick locking pin. Measure
drift from end of dipperstick housing to ground for five
minutes. Divide measured drift by five to determine
drift per minute.
Specification
Extendible Dipper Cylinder—Max
Allowable Drift........................................................ 6 mm/min (0.25 in/min)
TX,9025,RB42 –19–03SEP03–5/5

031504
PN=622
Tests
Cylinder Leakage Test
SPECIFICATIONS
Cylinder Leakage 5 ml/min (1/6 oz/min)
–UN–26OCT88
ESSENTIAL TOOLS
38H1353 Nuta
T6222AL
38H1139 Pluga
38H1354 Nuta
38H1140 Pluga
38H1146 Pluga
38H1147 Pluga
a
These ORFS fittings should be ordered through normal service parts
channels.

Digital Thermometer
1. Install digital thermometer probe in reservoir.
Specification
2. Put FNR lever in neutral and engage park brake. 9025

25
3. Start engine. Fully extend cylinder rod. Stop engine. 47
Activate a hydraulic function to relieve pressure in the
system.
4. Remove rod end hose and plug hose. Use a

measuring beaker, after oil stops dripping, to catch oil.
This can also be done at control valve, which would
require capping control valve port and putting hose end
into measuring beaker after oil stops dripping.
5. Start engine and actuate cylinder extend function for

one minute.
Specification
Continued on next page TX,9025,RR7326 –19–21JUL94–1/2

031504
PN=623
Tests
6. Stop engine. Measure oil collected and connect hose.
Specification
Cylinder—Leakage ................................................... 5 ml/min (1/6 oz/min)
7. Repair as necessary. (See repair manual.)
8. Repeat procedure to test each cylinder.
TX,9025,RR7326 –19–21JUL94–2/2
Stabilizer Valve Lockout Leakage Test

SPECIFICATIONS
Rod Travel Max. Distance 0.15 mm/min (.006 in/min)
–UN–26OCT88
Digital Thermometer
T6222AN
Dial Indicator
9025 1. Install digital thermometer probe in reservoir. Heat

25 hydraulic oil to test specifications.
48
Specification
2. Lower stabilizers to lift machine off ground. Check for

cylinder rod movement with dial indicator.
Specification
Rod Travel—Max. Distance ............................. 0.15 mm/min (.006 in/min)
NOTE: The stabilizer valve has lockouts to prevent

cylinder drift up or down. If cylinder rod drift is
above specification, remove the lockout and check
for scratches on the seat and poppet. Replace if
required. Check that the lockout plunger which
slides between the two lockouts is not sticking.
Also check for contamination in the thermal relief
poppet seat and cylinder packing.
TX,9025,RR7517 –19–02OCT96–1/1

031504
PN=624
Tests
Cycle Time Specifications
INDIVIDUAL CIRCUIT CYCLE TIME SPECIFICATIONS

Oil temperature: 65 ± 5°C (150 ± 10°F)
Engine speed: Fast idle
Function Operating Conditions Maximum Cycle Time in Seconds
Loader boom raise Bucket flat on ground to full height (includes 4.9
bucket self-leveling)
Loader boom lower 2.8
Loader bucket dump Bucket just clears ground 2.3
Loader bucket rollback Bucket just clears ground 2.3
Backhoe boom raise Backhoe at maximum reach with bucket teeth 2.7
on ground up to cylinder cushion
Backhoe boom lower Backhoe at maximum reach. Transport 2.9
position to bucket teeth on ground
Crowd in Boom in transport position 3.6
Crowd out 3.4
Backhoe bucket dump 2.1
Backhoe bucket curl 3.0
Backhoe swing Boom raised to cushion, bucket curled, 4.1
dipperstick parallel to ground. Time cycle to
cylinder cushion
Right stabilizer down Full up to ground level 2.8
Left stabilizer down Full up to ground level 1.9
Stabilizer up left and right Ground level to full up 2.4
9025
Extendible dipperstick extend and retract 3.2 25
49
TURNS
Steering right to left Turns 2.3 to 3
Steering left to right Turns 2.3 to 3
Steering right to left (MFWD) Turns 2.3 to 3
Steering left to right (MFWD) Turns 2.3 to 3
TX,9025,SS3534 –19–02FEB00–1/1

031504
PN=625
Tests
9025
25
50

031504
PN=626
Section 9031
Heating and Air Conditioning
Contents
Page Page
Group 05—Theory of Operation Air Conditioner System Cleaning

Proper Refrigerant Handling . . . . . . . . . . . . .9031-05-1 Procedures . . . . . . . . . . . . . . . . . . . . . . .9031-20-13
R134a Refrigerant Cautions . . . . . . . . . . . . .9031-05-1 Purge Air Conditioner System . . . . . . . . . . .9031-20-13
R134a Refrigerant Theory Of Operation . . . .9031-05-2 Flush Air Conditioner System . . . . . . . . . . .9031-20-14
Air Conditioning Circuit Specifications . . . . . .9031-05-4
Air Conditioning Circuit Operational Group 25—Test
Information. . . . . . . . . . . . . . . . . . . . . . . . .9031-05-4 Special or Essential Tools . . . . . . . . . . . . . . .9031-25-1
Air Conditioning Circuit Theory Of Heating and Air Conditioning
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-5 Service Equipment and Tools . . . . . . . . . .9031-25-2
Air Conditioning Circuit Schematic. . . . . . . . .9031-05-7 Specifications . . . . . . . . . . . . . . . . . . . . . . . .9031-25-3
Air Conditioning Proper Refrigerant Handling . . . . . . . . . . . . .9031-25-4
Wiring Diagram . . . . . . . . . . . . . . . . . . . . .9031-05-8 R12 And R134a Refrigerant Cautions . . . . . .9031-25-4
Wiring Diagram . . . . . . . . . . . . . . . . . . . . .9031-05-9 R134a Air Conditioning System Test . . . . . . .9031-25-5
Heater Blower Circuit Operational Pressure Diagnostic Chart. . . . . . . . . . . . . . .9031-25-7
Information. . . . . . . . . . . . . . . . . . . . . . . .9031-05-10 Expansion Valve Operating Test . . . . . . . . . .9031-25-8
Heater Blower Circuit Theory Of Blower Switch Test . . . . . . . . . . . . . . . . . . . .9031-25-9
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9031-05-10 Blower Resistor Test . . . . . . . . . . . . . . . . . .9031-25-10
Heater Blower Circuit Schematic . . . . . . . . .9031-05-11 Heater Blower Motor Test . . . . . . . . . . . . . .9031-25-11
Receiver/Dryer Operation . . . . . . . . . . . . . .9031-05-12 Freeze Control Test . . . . . . . . . . . . . . . . . .9031-25-11
Expansion Valve Operation . . . . . . . . . . . . .9031-05-14 Air Conditioning Switch Test . . . . . . . . . . . .9031-25-12
Compressor Relief Valve Operation . . . . . .9031-05-15 Air Conditioner Low Pressure Switch
Temperature Control . . . . . . . . . . . . . . . . . .9031-05-15 Check . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-12
Freeze Control Switch Operation. . . . . . . . .9031-05-16 Air Conditioner Low Pressure Switch
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-13 9031
Group 15—Diagnostic Information Air Conditioner High Pressure Switch
Diagnose Air Conditioning Electrical Check . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-14
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9031-15-1 Air Conditioner High Pressure Switch
Air Conditioning Component Location . . . . . .9031-15-2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-15
Air Conditioning Compressor Clutch Coil
Group 20—Adjustments Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-16
Special or Essential Tools . . . . . . . . . . . . . . .9031-20-1 Freeze Control Switch Test . . . . . . . . . . . . .9031-25-17
Heating and Air Conditioning Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .9031-25-17
Service Equipment and Tools . . . . . . . . . .9031-20-2 Refrigerant Hoses And Tubing
Other Materials . . . . . . . . . . . . . . . . . . . . .9031-20-2 Inspection . . . . . . . . . . . . . . . . . . . . . . . .9031-25-18
Specifications. . . . . . . . . . . . . . . . . . . . . . .9031-20-3
Proper Refrigerant Handling . . . . . . . . . . . . .9031-20-3
R134a Refrigerant Cautions . . . . . . . . . . . . .9031-20-4
R134a Compressor Oil Charge Check . . . . .9031-20-4
R134a Compressor Oil Removal . . . . . . . . . .9031-20-5
R134a Component Oil Charge . . . . . . . . . . .9031-20-6
R134a Refrigerant Recovery, Recycling
and Charging Station Installation
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-8
Recover R134a System . . . . . . . . . . . . . . . .9031-20-9
Evacuate R134a System . . . . . . . . . . . . . . .9031-20-10
Charge R134a System . . . . . . . . . . . . . . . .9031-20-12

031504
PN=1
Contents
9031

031504
PN=2
Group 05
Theory of Operation
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits intended for use with R12
discharge of any refrigerant into the atmosphere, and refrigerant.
requires that refrigerant be recovered using the
approved recovery equipment. Recovery, recycling and charging stations for R12 and
R134a refrigerants MUST NOT be interchanged.
IMPORTANT: Use correct refrigerant recovery, Systems containing R12 refrigerant use a different oil
recycling and charging stations. DO than systems using R134a. Certain seals are not
NOT use refrigerant, hoses, fittings, compatible with both types of refrigerants.
components or refrigerant oils
CED,OUTX466,1304 –19–28SEP98–1/1
R134a Refrigerant Cautions
develop high pressure which can burst the

CAUTION: DO NOT allow liquid refrigerant to
container.
contact eyes or skin. Liquid refrigerant will
freeze eyes or skin on contact. Wear
Keep refrigerant containers away from heat
goggles, gloves and protective clothing.
sources. Store refrigerant in a cool place.
If liquid refrigerant contacts eyes or skin, DO
DO NOT handle damp refrigerant container
NOT rub the area. Splash large amounts of
with your bare hands. Skin may freeze to
COOL water on affected area. Go to a
container. Wear gloves.
physician or hospital immediately for 9031
treatment. 05
If skin freezes to container, pour COOL 1
water over container to free the skin. Go to a
DO NOT allow refrigerant to contact open
physician or hospital immediately for
flames or very hot surfaces such as electric
treatment.
welding arc, electric heating element and
lighted smoking materials.
DO NOT heat refrigerant over 52°C (125°F) in

a closed container. Heated refrigerant will
CED,OUTX466,1305 –19–28SEP98–1/1

031504
PN=629
Theory of Operation
R134a Refrigerant Theory Of Operation
–19–31JUL00
T132734
A—Compressor E—High Pressure Liquid I—Expansion Valve M—A/C Freeze Switch
B—High Pressure Gas F—High Pressure Switch J—Low Pressure Liquid N—Low Pressure Gas
C—Condenser Fans G—Low Pressure Switch K—Evaporator O—Low Pressure Test Port
9031 D—Condenser H—Receiver Dryer L—Blower P—High Pressure Test Port
05
2 The compressor (A) draws low pressure gas (N) from temperature drop in the refrigerant causing refrigerant
the evaporator (K) and compresses it into high to vaporize. The expansion valve (I) is one of the
pressure gas (B). Increasing the pressure of the dividing lines between the high side and low side of
R134a refrigerant causes its boiling point to rise to a the air conditioning system. At this point in the system,
temperature higher than the outside air temperature. the high pressure/high temperature liquid R134a is
sprayed into the evaporator (K) where it changes and
High pressure gas (B) leaves the compressor (A) and becomes a gas.
passes through the condenser (D), the condenser fans
(C) draws air through the condenser core which cools The high pressure liquid passes through two switches
the R134a refrigerant. Cooling the refrigerant causes it (F and G). These switches monitor R134a refrigerant
to condense and it leaves the condenser (D) as a high pressure. Should the pressure become too great or too
pressure liquid (E). small, either the high or low pressure switch will open
and stop the compressor, interrupting the cycle. From
The refrigerant flows from the receiver-dryer (H) to the the switches the high pressure liquid flows into the
expansion valve (I). The expansion valve (I) is a receiver-dryer (H) where moisture and contaminants
variable orifice used to cause a pressure and are removed.

031504
PN=630
Theory of Operation
The expansion valve diaphragm is activated by expansion valve variable orifice to decrease in size,
sensing temperature and pressure within the valve restricting refrigerant flow. If the evaporator outlet
body. The internal bulb senses the evaporator outlet or temperature is too warm, the orifice will increase in
discharge temperature and pressure of R134a as it size, allowing more refrigerant into evaporator.
passes through the valve back to the low pressure or
suction side of the compressor. See Expansion Valve If evaporator (K) temperature becomes too low, the
Operation in this group for additional information on A/C freeze switch (M) will interrupt current flow to the
theory of operation. compressor clutch coil, stopping system operation until
the temperature becomes normal, between 31° and
If too much refrigerant is flowing into evaporator, the 36°.
liquid refrigerant will still be evaporating as it leaves
the evaporator, causing a low temperature at the Specification
evaporator outlet. The low temperature causes the Evaporator—Temperature ................................. Between 31° and 36°
CED,TX14826,12664 –19–16JUN00–2/2
9031
05
3

031504
PN=631
Theory of Operation
Air Conditioning Circuit Specifications
Item Measurement Specification
High Pressure Switch (Normally

Closed)
High Pressure Switch Opens Pressure Above 2760 ± 138 kPa (400 ± 20
psi)
High Pressure Switch Closes Pressure Below 1310 ± 138 kPa (190 ± 20 psi)
Low Pressure Switch (Normally

Open)
Low Pressure Switch Closes Pressure Above 345 ± 35 kPa (50 ± 5 psi)
Low Pressure Switch Opens Pressure Below 173 ± 35 kPa (25 ± 5 psi)
Compressor Relief Valve (Normally

Closed)
Compressor Relief Valve Opens Pressure Above 4137 kPa (600 psi)
Freeze Control (Clutch Cycle) Switch

(Normally Closed)
Freeze Control (Clutch Cycle) Temperature Below -0.56 ± 0.84°C (31 ± 1.5°F)
Switch Opens
9031
05 Freeze Control (Clutch Cycle) Temperature Above 2.22 ± 0.84°C (36 ± 1.5°F)
4
Switch Closes
CED,TX14826,12665 –19–07DEC00–1/1
Air Conditioning Circuit Operational

Information
The following conditions must exist for air conditioning

circuit to function:
• Key switch ON
• Machine running
• Air conditioning switch turned ON
• Blower switch turned to low, medium or high
CED,TX14826,12666 –19–16JUN00–1/1

031504
PN=632
Theory of Operation
Air Conditioning Circuit Theory Of Operation
Power form the blower/A/C Compressor fuse goes to

heater switch.
With blower switch turned to position 1, 2, 3 or 4, power

flows to blower resistor and then to heater blower motor.
See Blower Circuit in this group for more information
Power also flows from terminal (1) of blower switch, to the

A/C defrost mode switch.
With A/C defrost mode switch turned “ON” to A/C ,

terminals 5B and 4 are connected and power flows
through low and high pressure switches to compressor.
With A/C defrost mode switch turned “ON”to defrost

mode, terminals 2B and 1 are connected and power flows
to mode door relay energizing relay sending power to
mode door motor.
With A/C defrost mode switch turned “ON” to A/C and

defrost mode, terminals 5B and 6 are connected and
terminals 2B and 3 are connected. Power then is sent to
both compressor and mode door motor.
Low Pressure Switch:
Low pressure switch is normally open, but is closed when

refrigerant pressure is normal, and opens if pressure is
too low for operation without damage to the compressor.
The low pressure switch will open if the air conditioning
system loses its refrigerant charge. The switch opens to 9031
stop current flow to the compressor which prevents 05
5
compressor engagement. The low pressure switch is
located in the high pressure line.
High Pressure Switch:
High pressure switch is normally closed, and opens to

shut the compressor off if refrigerant pressure becomes
too high for safe operation. The high pressure switch
protects the system from high pressure. If a malfunction or
line restriction causes refrigerant pressure to increase
above the setting of the switch, the switch will open to
stop current flow to the compressor clutch. The high
pressure switch is located in the high pressure line.

031504
PN=633
Theory of Operation
Freeze Control Switch:
Freeze control switch is normally closed and opens to

shut the compressor off when evaporator temperature is
too low. The freeze control switch is used to sense the
temperature in the evaporator core. When the temperature
is too low, the freeze control switch opens, shutting the
compressor off. When the temperature in the evaporator
core raises, the switch closes sending voltage to the
compressor.
NOTE: For component identification code description.

See System Functional Schematic in Group
9015-10. See Wiring And Schematic Diagrams
Legend.
CED,TX14826,12667 –19–16JUN00–2/2
9031
05
6

031504
PN=634
Theory of Operation
Air Conditioning Circuit Schematic

T132840 –19–07SEP00
CED,TX14826,12668 –19–16JUN00–1/1

031504
PN=635
Theory of Operation
Air Conditioning Compressor Harness (W9) Wiring Diagram
9031
05
8
–19–07SEP00
T132614
TX14826,00031DA –19–23APR01–1/1

031504
PN=636
Theory of Operation
Air Conditioning Cab Harness (W10) Wiring Diagram
9031
05
9
–19–07SEP00
T132613
CED,TX14826,12669 –19–16JUN00–1/1

031504
PN=637
Theory of Operation
Heater Blower Circuit Operational

Information
The following conditions must exist for heater blower

circuit to function:
• Key switch in ON or ACC position

• Heater blower switch turned ON
CED,TX14826,12670 –19–16JUN00–1/1
Heater Blower Circuit Theory Of Operation
Power from heater blower fuse goes to blower switch. With heater blower switch in position 4 , power
With heater blower switch in position 1, power is sent by-passes resistor and 12 volts is applied to blower
to blower resistor. Voltage goes through complete motor, causing it to run at high speed.
resistor and is reduced to approximate 3.0 volts.
NOTE: For component identification code description.
With heater blower switch in position 2, power is sent See System Functional Schematic in Group
through the blower resistor and is reduced to 9015-10. See Wiring And Schematic Diagrams
approximate 6.0 volts. Legend.
With heater blower switch in position 3, power is sent

through the blower resistor and is reduced to
approximate 9.0 volts.
9031
05
CED,TX14826,12671 –19–16JUN00–1/1
10

031504
PN=638
Theory of Operation
Heater Blower Circuit Schematic
9031
05
11
–19–08SEP00
T132839
CED,TX14826,12672 –19–16JUN00–1/1

031504
PN=639
Theory of Operation
Receiver/Dryer Operation
The receiver/dryer is a reservoir to store excess liquid

refrigerant in the system. Excess refrigerant is required for
two reasons:
Outside air temperature and humidity have an effect on

the minimum quantity of refrigerant required in the system
for the air conditioner to operate at maximum efficiency.
The higher the temperature and humidity, the more
refrigerant required in the system. More refrigerant is
required due to the expansion valve opening farther
allowing more refrigerant into the low pressure side of the
system.
Refrigerant hoses allow a small amount of refrigerant to

migrate through their walls. Extra refrigerant stored in the
system allows for a longer period of time before additional
refrigerant is needed.
–UN–19OCT93
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).
Desiccant is used to absorb moisture. If too much

moisture gets into the system, the desiccant may not be
able to absorb it all. When moisture is combined with
refrigerant oil, a sludge is formed. This sludge does not
9031 permit moving parts to be adequately lubricated. When
05 moisture is combined with refrigerant, hydrofluoric and
–UN–10JAN94
12
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 A—Inlet Port
moisture in the desiccant. Evacuating the system will not B—Sight Glass
remove moisture from the desiccant. You must replace C—Outlet Port
D—Pickup Tube
the receiver/dryer.
E—Filter
F—Desiccant
G—Strainer
H—Spring
I—Receiver/Dryer
J—Wet/Dry Indicator
Continued on next page CED,OUTX466,1315 –19–28SEP98–1/2

031504
PN=640
Theory of Operation
A sight glass is installed in the receiver/dryer outlet port. If

the refrigerant level is low, a steady stream of gas
bubbles will be present in the liquid flowing from the
receiver/dryer. These gas bubbles can be seen in the
sight glass and are an indication that the system needs
charging. However, bubbles may be present when the
compressor clutch first engages but must disappear after
a few seconds. If the sight glass is clear, the system
either has a sufficient charge or is completely discharged.
CED,OUTX466,1315 –19–28SEP98–2/2
9031
05
13

031504
PN=641
Theory of Operation
Expansion Valve Operation
–19–24SEP92
T7828AY
A—Valve Diaphragm D—Operating Pin G—Valve Spring J—Discharge from Evaporator
B—Sealed Sensing Bulb E—Inlet Flow H—Ball Seat K—Internal Equalization
C—Outlet to Compressor F—Metering Orifice I—Outlet 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
14 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
discharge (J) temperature and pressure of the
refrigerant as it passes through the valve back to the
low pressure or suction side of the compressor.
CED,OUTX466,1316 –19–28SEP98–1/1

031504
PN=642
Theory of Operation
Compressor Relief Valve 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.
Specification
Compressor Relief Valve
Opens—Pressure .............................. Near 4137 kPa (41.4 bar) (600
psi)
CED,OUTX466,1317 –19–28SEP98–1/1
Temperature Control
Heater Temperature Control Knob: Temperature core, and cab heater core if equipped thus controlling
control is adjusted by the position of the Heater the temperature inside the cab.
Temperature Control Knob in the cab. This knob is
electrically connected to the water valve located under In certain conditions when the air conditioning switch is
floor plate, below bracket and harness connectors. turned on and the blower switch is in low position, the
Turning the heater temperature knob towards cab temperature may still be too cool. It may be
maximum Heat (Red) and/or towards maximum Cold necessary to blend heat with cooling to get a
(Blue) opens and closes the water valve controlling comfortable cab temperature.
engine coolant flow through the under seat heater
9031
05
15
CED,OUTX466,1318 –19–28SEP98–1/1

031504
PN=643
Theory of Operation
Freeze Control Switch Operation
NOTE: See Air Conditioning Component Location 1.5°F), the switch opens and shuts the compressor off.
drawing in 9031—15 for location of this part on When the temperature of the coil rises to 2°C (36 ±
the machine. 1.5°F), the switch contacts close and turn the
compressor on.
The freeze control switch is located on the back side
of the evaporator. It has a capillary tube that is The freeze control switch is set to prevent the
inserted into the evaporator to sense the temperature evaporator from becoming cold enough to freeze
of the core. moisture that condenses on the evaporator. This is the
reason that the capillary tube must be placed in the
The freeze control switch controls the evaporator correct location to sense the coldest temperature of
temperature by turning the compressor on and off the evaporator coil. It is also important to insert the
according to the temperature of the coil. If the correct length of capillary tube into the core and
temperature of the coil cools to a minus 1°C (31 ± prevent kinking of the tube.
CED,OUTX466,1319 –19–28SEP98–1/1
9031
05
16

031504
PN=644
Group 15
Diagnose Air Conditioning Electrical
Malfunctions

probable and simplest to verify, to least likely
• Step 1. Operational Check Out Procedure

• Step 2. Diagnostic Charts
• Step 3. Adjustments and/or Tests
Air Conditioning System Does (F8) Heater Blower/AC Fuse Replace fuse. See Fuse
Not Operate Specifications.
Blower switch See Blower Switch Test. In Group

9031-25.
Blower resistor See Blower Resistor Test. In Group

9031-25. , Group 9031-25.
Heater/blower motor See Heater Blower Motor Test. In

Group 9031-25.
A/C freeze switch See Freeze Control Switch Test. In

Group 9031-25.
Air conditioning switch See Air Conditioning Switch Test. In

Group 9031-25.
Low pressure switch See Low Pressure Switch Test. In 9031

15
Group 9031-25.
1
High pressure switch See High Pressure Switch Test. In

Group 9031-25.
Compressor clutch coil See A/C Compressor Clutch Coil

Test. In Group 9031-25.
Air Conditioning Circuit See Air Conditioning Circuit

Heater Blower Circuit See Heater Blower Circuit

CED,TX14826,12673 –19–16JUN00–1/1

031504
PN=645
Air Conditioning Component Location

T136946 –19–09JAN01
CED,TX14826,12674 –19–09JAN01–1/2

031504
PN=646
1—R1 Blower Resistor 7—S12-Blower Switch 12—Hose Line (High Pressure 17—Hose Line-to-Water Pump
2—Expansion Valve 8—S39-Heater Temperature Gas) Hose Line-to-Engine Block
3—Evaporator Control 13—Receiver Dryer 18—Hose Line ( High Pressure
4—B3-A/C Low Pressure 9—S13-A/C Defrost Mode 14—Hose Line (High Pressure Gas)
Switch Switch Liquid) 19—Condenser
5—B4-A/C High Pressure 10—B2-A/C Freeze Switch 15—Hose Line-to-Engine Block 20—M8-Mode Door Motor
Switch 11—Hose Line (Low Pressure 16—Y9-A/C Compressor
6—A/C Freeze Switch Probe Gas)
NOTE: For component identification code description. 9015-10. See Wiring And Schematic Diagrams
See System Functional Schematic in Group Legend.
CED,TX14826,12674 –19–09JAN01–2/2
9031
15
3

031504
PN=647
9031
15
4

031504
PN=648
Group 20
Adjustments
Special or Essential Tools
NOTE: Order tools according to information given in the

U.S. SERVICEGARDCatalog or in the European
Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company. CED,OUTX466,1323 –19–28SEP98–1/4
Charging Station . . . . . . . . . . . . . . . . . . . . . . JT02046
Used with JT02050 Recovery and Recycling Station.

JT02047 Recovery, Recycling, and Charging Station can
be substituted for JT02046 and JT02050. Servicing air
conditioning system using R134a refrigerant
–UN–17AUG92
RW21595
CED,OUTX466,1323 –19–28SEP98–2/4
Recovery and Recycling Station . . . . . . . . . . . . JT02050
Used with JT02046 Charging Station. JT02050 Recovery,

Recycling, and Charging Station can be substituted for 9031
JT02046 and JT02050. Servicing air conditioning system 20
using R134a refrigerant 1
–UN–17AUG92
RW21613
CED,OUTX466,1323 –19–28SEP98–3/4
Schrader Valve Tool . . . . . . . . . . . . . . . . . . . JT02130

–UN–03JAN95
To replace Schrader valve in compressor manifold on

R134a A/C Systems.
T8389AF
CED,OUTX466,1323 –19–28SEP98–4/4

031504
PN=649
Adjustments
Service Equipment and Tools
NOTE: Order tools from the U.S. SERVICEGARD

Catalog or from the European Microfiche Tool
Catalog (MTC). Some tools may be available from
a local supplier.
Electronic Leak Detector . . . . . . . . . . . . . . . . . JT02081
Detect refrigerant leaks
CED,OUTX466,1324 –19–28SEP98–2/4
Air Conditioning Fitting Kit . . . . . . . . . . . . . . . . JT02098
Used with JT02075 to flush R134a air conditioning

systems.
CED,OUTX466,1324 –19–28SEP98–3/4
Air Conditioning Flusher . . . . . . . . . . . . . . . . . JT02075
To flush R134a air conditioning systems.

9031
20
CED,OUTX466,1324 –19–28SEP98–4/4
2
Other Materials
Number Name Use
TY16134 (U.S.) R134a Flushing Solvent Flush R134a air conditioning system.
TY15949 (12 oz) (U.S.) R134a Refrigerant Charge R134a air conditioning
system.
TY15950 (15 lb) (U.S.) R134a Refrigerant Charge R134a air conditioning
system.
TY15951 (30 lb) (U.S.) R134a Refrigerant Charge R134a air conditioning
system.
TY22025 (8.5 oz) (U.S.) R134a Compressor Oil Lubricate R134a air conditioning
system.
CED,OUTX466,1325 –19–28SEP98–1/1

031504
PN=650
Adjustments
Specifications
Compressor Oil Capacity 45 mL (1.5 fl oz)
Condenser Oil Capacity 133.1 mL (4.5 fl oz)
Evaporator Oil Capacity 171.5 mL (5.8 fl oz)
Receiver/Dryer Oil Capacity 30 mL (1.0 fl oz)
Air Conditioning System Oil Capacity 440.6 mL (14.8 fl oz)
Air Conditioning System Refrigerant Capacity 3.062 kg (6.75 lb)
CED,TX14826,12675 –19–07DEC00–1/1
9031
20
3
CED,OUTX466,1327 –19–28SEP98–1/1

031504
PN=651
Adjustments
R134a Refrigerant Cautions

container.
treatment.
If skin freezes to container, pour COOL
treatment.

CED,OUTX466,1328 –19–28SEP98–1/1
R134a Compressor Oil Charge Check
Remove compressor if R134a leakage was detected 3. Flush the complete system with TY16134 air
9031 and repaired. See Remove and install Compressor in conditioning flushing solvent.
20 Repair Manual.
4 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.
Specification 7. Connect all components, evacuate and charge the

Compressor Oil—Volume ............................ 6 mL (0.2 fl oz) minimum system.
1. Remove and discard the receiver-dryer.
2. Remove, clean, but do not disassemble the valve.
CED,OUTX466,1329 –19–28SEP98–1/1

031504
PN=652
Adjustments
R134a Compressor Oil Removal
1. Remove compressor from machine. See Remove 4. Record measured oil and discard oil properly.
and Install Compressor in Repair Manual.
5. Install new oil. See R134a Component Oil Charge.
2. Remove inlet/outlet manifold from compressor, and In this Group.
clutch dust cover.
6. Install compressor. See Remove and Install
3. Drain oil into graduated container while rotating Compressor in Repair Manual.
compressor shaft.
CED,OUTX466,1330 –19–28SEP98–1/1
9031
20
5

031504
PN=653
Adjustments
R134a Component Oil Charge
2. When the complete system was not flushed add the

CAUTION: All new compressors are charged
correct amount of oil for the compressor plus the
with a mixture of nitrogen, R134a refrigerant
amount of oil for each component that was
and TY22025 (R134a) refrigerant oil. Wear
serviced.
safety goggles and discharge the
compressor slowly to avoid possible injury.
• New compressor from parts depot, drain and
return 45 mL (1.5 fl oz) of oil to the compressor.
Compressors can be divided into three categories
(See Compressor Oil Removal procedure in this
when determining the correct oil charge for the system.
group.)
• New compressor from parts depot Specification
• Used compressor removed from operation Oil, New Compressor
• Compressor internally washed with flushing solvent Installation, Complete System
Not Flushed—Volume........................... drain and return 45 mL (1.5 fl
Use the following procedure to determine the oz)
amount of system oil charge prior to installation of
compressor on a machine.
1. When the complete system, lines, and components • Used compressor removed from operation and oil
were flushed add the correct amount of oil as drained. (See Compressor Oil Removal
described. procedure in this group.) Add 45 mL (1.5 fl oz) of
new oil.
• New compressor from parts depot contains the
Specification
amount of new oil of 230 ± 20 mL (7.7 ± .7 fl oz). Oil, Used Compressor
System requires an additional amount of new oil Installation, Complete System
of 210 mL (7.1 fl oz) of new oil. Not Flushed, Oil Drained—
Volume ............................................................... add 45 mL (1.5 fl oz)
Specification
Oil, New Compressor
Installation, Complete System
Flushed—Volume .................................... 230 ± 20 mL (7.7 ± .7 fl oz)
supplied by parts depot • Used compressor removed from operation, oil
9031
Volume .................................................... 210 mL (7.1 fl oz) additional drained, and flushed add 60 mL (2.0 fl oz) of new
20
6 amount required oil.
Specification
Oil, Used Compressor
• Used compressor removed from operation, oil Not Flushed, Oil Drained,
drained, and flushed requires 438 mL (14.8 fl oz) Flushed—Volume .............................................. add 60 mL (2.0 fl oz)
of new oil.
Specification
Oil, Used Compressor
Flushed—Volume ................................................. 438 mL (14.8 fl oz)

031504
PN=654
Adjustments
NOTE: Hoses = 3 mL per 0.3 m (0.1 fl oz per ft). R134a compressor oil on acrylic or ABS
Approximate total length equals 12.5 m (41.0 plastic. This oil will deteriorate these
ft). materials rapidly. Identify R134a oil
containers and measures to eliminate
3. If any section of hose is removed and flushed or accidental mixing of different oils.
replaced, measure the length of hose and use the
formula to determine the correct amount of oil to be Components listed below which have been removed,
added. drained or flushed, require the removal of the
compressor to determine the correct oil charge. Use
the following chart as a guide for adding oil to
CAUTION: DO NOT leave the system or
components:
R134a compressor oil containers open. This
oil easily absorbs moisture. DO NOT spill
Compressor Oil Charge 45 mL (1.5 fl oz)
Evaporator Oil Charge 171.5 mL (5.8 fl oz)
Condenser Oil Charge 133.1 mL (4.5 fl oz)
Receiver/Dryer Oil Charge 30 mL (1.0 fl oz)
Hoses Oil Charge Approximate 60 mL (2.0 fl oz)
CED,TX14826,12676 –19–16JUN00–2/2
9031
20
7

031504
PN=655
Adjustments
R134a Refrigerant Recovery, Recycling and 2

Charging Station Installation Procedure 8
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging
1
Stationa
a
JT02046 and JT02050 recovery and charging stations can be
substituted for the JT02045 station.
CAUTION: Do not remove high pressure relief

valve (A). Air conditioning system will 4
3
discharge rapidly causing possible injury.
IMPORTANT: Use correct refrigerant recovery, 5

recycling and charging stations. DO
NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
1. Close both high and low pressure valves on refrigerant

recovery, recycling and charging station (6). 7
–UN–11AUG00
2. Remove cap from low pressure test port (3). 6
T132733
3. Connect low pressure blue hose (5) from refrigerant
recovery, recycling and charging station (6) to low T132733
pressure test port (3) on compressor.
1—High Pressure Hose
4. Connect high pressure red hose (7) to high pressure 2—High Pressure Test Port
(quick disconnect) test port (2). 3—Low Pressure Test Port
4—Low Pressure Hose
5—Blue Hose
5. Follow the manufacturer’s instructions when using the 6—Refrigerant Recovery/Recycling and Charging
9031 refrigerant recovery, recycling and charging station. Station
20 7—Red Hose
8 8—High Pressure Relief Valve
CED,TX14826,12677 –19–16JUN00–1/1

031504
PN=656
Adjustments
Recover R134a System 2

8
ESSENTIAL TOOLS
Stationa
a
1

valve (A). Air conditioning system will
discharge rapidly causing possible injury. 4
3
IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations. DO 5
NOTE: Run the air conditioning system for three minutes

to help in the recovery process. Turn air
conditioning system off before proceeding with 7
–UN–11AUG00
recovery steps.
6
1. Connect refrigerant recovery, recycling and charging
station. See R134a Refrigerant Recovery, Recycling
T132733
and Charging Station installation Procedure. In this T132733
group.
2. Follow the manufacturer’s instructions when using the 2—High Pressure Test Port
refrigerant recovery, recycling and charging station. 3—Low Pressure Test Port
5—Blue Hose
6—Refrigerant Recovery/Recycling and Charging
Station 9031
7—Red Hose 20
8—High Pressure Relief Valve 9
CED,TX14826,12678 –19–16JUN00–1/1

031504
PN=657
Adjustments
Evacuate R134a System 2

8
SPECIFICATIONS
Vacuum Pressure at Sea Level 98 kPa (980 mbar) (29 in. Hg)
Vacuum Pressure Above Sea Subtract 3.4 kPa (34 mbar) (1 in.
1
Level Hg) from 98 kPa (980 mbar) (29
in. Hg) for each 300 m (1000 ft)
elevation
ESSENTIAL TOOLS
Stationa 4
3
a
5
discharge rapidly causing possible injury.
IMPORTANT: Use correct refrigerant recovery, 7
–UN–11AUG00
components or refrigerant oils. 6
T132733
Do not run compressor while T132733
evacuating.
1. Connect refrigerant recovery, recycling and charging 2—High Pressure Test Port
station. See R134a Refrigerant Recovery, Recycling 3—Low Pressure Test Port
and Charging Station installation Procedure. In this 4—Low Pressure Hose
group. 5—Blue Hose
6—Refrigerant Recovery/Recycling and Charging
9031 Station
2. Open low and high pressure valves on refrigerant 7—Red Hose
20
10 recovery, recycling and charging station. 8—High Pressure Relief Valve
3. Follow the manufacturer’s instructions and evacuate

the system.
NOTE: The vacuum specifications listed are for sea level

conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg)
from 98 kPa (980 mbar) (29 in. Hg) for each 300
m (1000 ft) elevation above sea level.
4. Evacuate system until low pressure gauge registers 98

kPa (980 mbar) (29 in. Hg) vacuum.

031504
PN=658
Adjustments
If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be

obtained in 15 minutes, test the system for leaks. (See
Leak Testing, 9031-25). Correct any leaks.
Specification
Vacuum—Pressure at Sea Level .............. 98 kPa (980 mbar) (29 in. Hg)
Pressure Above Sea Level ................... Subtract 3.4 kPa (34 mbar) (1 in.
Hg) from 98 kPa (980 mbar) (29
in. Hg) for each 300 m (1000 ft)
elevation
5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close

low-side and high-side valves. Turn vacuum pump off.
6. If the vacuum decreases more than 3.4 kPa (34 mbar)

(1 in. Hg) in 5 minutes, there is a leak in the system.
7. Repair leak.
8. Start to evacuate.
9. Open low-side and high-side valves.
10. Evacuate system for 30 minutes after 98 kPa (980

mbar) (29 in. Hg) vacuum is reached.
11. Close low-side and high-side valves. Stop evacuation.
12. Charge the system. See Charge R134a System. In

this Group.
9031
20
CED,TX14826,12679 –19–16JUN00–2/2
11

031504
PN=659
Adjustments
Charge R134a System 2

8
SPECIFICATIONS
Refrigerant Weight 3.062 Kg (6.75 lbs)
1
ESSENTIAL TOOLS
Stationa
a
3 4
discharge rapidly causing possible injury. 5
IMPORTANT: Use correct refrigerant recovery,

7
–UN–11AUG00
1. Connect JT02045 R134a refrigerant recovery, recycling
and charging station.See R134a Refrigerant Recovery, 6
Recycling and Charging Station installation
T132733
Procedure.In this group.
T132733
2. Evacuate the system. See Evacuate R134a System. In
this group. 1—High Pressure Hose
2—High Pressure Test Port
NOTE: Before beginning to charge air conditioning 3—Low Pressure Test Port
system, the following conditions must exist: 4—Low Pressure Hose
5—Blue Hose
Engine STOPPED, the pump must be capable of 6—Refrigerant Recovery/Recycling and Charging
9031 pulling at least 28.6 in. Hg vacuum (sea level). Station
20 Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa 7—Red Hose
12 (980 mbar) (29 in. Hg) for each 300 m (1000 ft) 8—High Pressure Relief Valve
elevation above sea level.
3. Follow the manufacturer’s instructions and charge the

system.
4. Add refrigerant until system is charged with 3.062 Kg

(6.75 lbs).
Specification
Refrigerant—Weight .................................................... 3.062 Kg (6.75 lbs)
5. Do air conditioner tests in TM1858 Group 9031-25.
CED,TX14826,12680 –19–16JUN00–1/1

031504
PN=660
Adjustments
Air Conditioner System Cleaning Procedures
Flushing: Flushing the system or component is a • TY16134 Air Conditioning System Flushing Solvent
cleaning process using a liquid solvent to remove oil
and debris. Purging is always necessary after flushing Purging: Purging the system or a component is a
to remove solvent from the system or component. cleaning process using a gas to force liquid from the
system. Purging alone will not remove refrigerant oil
Following is a list of situations that require a flushing from the system.
procedure be done:
Following is a list of situations that require a purging
1. The compressor has an internal failure. procedure be done:
2. No oil remains in used compressor.
3. Oil drained from compressor appears or smells • After flushing system with solvent, to prevent oil
overheated. dilution
4. System was contaminated with a mixture of • System was contaminated with nitrogen or two
refrigerant oils. refrigerants.
5. System was left open to the atmosphere long • System was left open to the atmosphere and
enough for dirt, moisture, or debris to enter the flushing could not be performed.
tubing or components. • Installation of new lines, condenser, or evaporator
6. System has an internal blockage. was required.
The following solvent is recommended for flushing air Evacuating: Evacuating the system is a process to
conditioner systems. Use only solvents with an remove air and moisture from the system, creating a
equivalent MSDS. vacuum.
9031
20
CED,OUTX466,1337 –19–28SEP98–1/1
13
Purge Air Conditioner System

SPECIFICATIONS 2. Connect gauge manifold suction hose to
Nitrogen Purge Pressure. 275 kPa (40 psi) (2.75 bar) for compressor suction port, and open valves.
two minutes 3. Connect gauge manifold discharge hose to
compressor discharge post, and open valve.
IMPORTANT: Air compressors used for purging Disconnect discharge hose from gauge manifold to
systems require a water separator. allow purging nitrogen to atmosphere.
Purging without a separator adds 4. Open nitrogen tank valve and adjust regulator to
moisture, creating hydrofluoric acid Specification. Purge system for two minutes.
when combined with refrigerant oil. Disconnect nitrogen supply.
Acid is corrosive to metal tubing.
Specification
1. Connect dry nitrogen hose to gauge manifold center Nitrogen Purge—Pressure.................. 275 kPa (40 psi) (2.75 bar) for
two minutes
hose.
5. Evacuate system. (See procedure in this group.)
CED,OUTX466,1338 –19–28SEP98–1/1

031504
PN=661
Adjustments
Flush Air Conditioner System
SPECIFICATIONS b. Turn compressor end for end and roll it side to

Compressor Flushing Solvent 240 mL (8 fl oz) In Suction Port side.
Quantity
Compressor Flushing Solvent 120 mL (4 fl oz) In Discharge c. Remove both plugs from manifold ports and
Quantity Port drain solvent from compressor.
Flusher Tank Capacity 4 L (1 gal)
Regulated Air Pressure 620 kPa (6.2 bar) (90 psi) d. Connect battery power to compressor clutch coil.
Minimum Rotate pulley at least five revolutions to move
Condenser Purging Time 10—12 Minutes solvent out of cylinders.
Evaporator Purging Time 12—15 Minutes
e. Invert compressor, roll end for end, and side to
ESSENTIAL TOOLS side. Drain thoroughly.
JT02075 Air Conditioning Flusher
f. Let compressor sit inverted for three to five
JT02098 Fitting Kit
minutes.
JT02099 and JT02100 with JT03194 Cap
JT02102 Adapter g. Repeat previous two steps at least three times.
SERVICE EQUIPMENT AND TOOLS 4. Remove and discard receiver-dryer.

JT03188 Adapter
JT02101 Adapter
5. Divide system into two circuits:
a. Condenser, including inlet and outlet hoses.

Add flushing solvent to system with JT02075 Air
(Steps 6—12)
Conditioning Flusher and JT02098 Fitting Kit.
b. Evaporator, including inlet and outlet hoses.
NOTE: Flushing can be performed on vehicle.
(Steps 13—26)
1. Recover refrigerant. (See procedure in this group.)
IMPORTANT: DO NOT attempt to flush through
compressor or receiver-dryer.
2. Remove compressor and measure oil drained from
9031 Flushing through expansion valve is
20 both manifold ports.
acceptable if refrigerant oil has
14
normal odor and appearance.
3. Clean compressor as follows:
6. To Flush/Purge Condenser:
a. Pour specified amount of flushing solvent into
suction port and Specified amount of flushing
Connect flusher outlet hose to inlet end of
solvent into discharge port. Plug both ports in
compressor discharge line using JT02102 Adapter.
compressor manifold, using Caps.
Specification
7. Attach a return hose and aerator nozzle to outlet
Compressor Flushing Solvent— end of receiver-dryer inlet hose using JT03197
Quantity............................................. 240 mL (8 fl oz) In Suction Port Adapter. Put nozzle in container to collect flushing
Quantity................................................. 120 mL (4 fl oz) In Discharge solvent.
Port

031504
PN=662
Adjustments
8. Fill flusher tank with 4 L (1 gal) of solvent and 14. Force flushing solvent through evaporator inlet
fasten all connections. with compressed air.
Specification 15. Purge system until dry.

Flusher Tank—Capacity .................................................... 4 L (1 gal)
16. Reinstall evaporator.
NOTE: Air pressure must be at least 620 kPa (6.2
bar) (90 psi) for flushing and purging. 17. Go to Step 22.
9. Connect a supply line of moisture-free compressed 18. To Flush Evaporator Through Expansion
air or dry nitrogen to flusher air valve. Adjust Valve:
regulator to specification.
Connect flusher outlet hose to connection of
Specification
Regulated Air—Pressure ........................... 620 kPa (6.2 bar) (90 psi)
receiver-dryer outlet hose using JT03188 Adapter.
Minimum
19. Attach a hose and aerator nozzle to compressor
10. Open air valve to force flushing solvent into inlet line using JT02101 Adapter. Put nozzle in a
condenser circuit. Flusher tank is empty when container to collect solvent.
hose pulsing stops. Additional flushing cycles are
required if system is heavily contaminated with 20. Repeat Steps 8, 9 and 10 to flush evaporator.
burned oil or metal particles.
NOTE: Purging the evaporator circuit takes 12—15
NOTE: Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent.
minutes to thoroughly remove solvent.
21. Disconnect hose from aeration nozzle to check
Specification circuit for solvent. Hold hose close to a piece of
Condenser Purging—Time ......................................... 10—12 Minutes cardboard. Continue purging until cardboard is dry.
11. Disconnect hose from aeration nozzle to check 22. Install a new receiver-dryer compatible with R134a
circuit for solvent. Hold hose close to a piece of refrigerant. Tighten connections and mounting
cardboard; continue purging until cardboard is dry. bracket.
12. Go to Step 13 to flush evaporator. Go to Step 22 if 23. Add required oil. (See procedure in this group.) 9031
evaporator does not require flushing. 20
15
24. Install compressor, and connect refrigerant lines to
13. To Flush Evaporator: manifold.
If system is contaminated with burned refrigerant 25. Connect clutch coil wire. Install drive belt.
oil or debris, remove and bench flush evaporator.
Go to Step 18 to flush evaporator through 26. Purge system. (See procedure in this group.)
expansion valve, if oil appears normal. Remove
evaporator. (See procedure in this group.)
CED,OUTX466,1339 –19–28SEP98–2/2

031504
PN=663
Adjustments
9031
20
16

031504
PN=664
Group 25
Test
Special or Essential Tools
NOTE: Order tools according to information given in the

U.S. SERVICEGARDCatalog or in the European
Microfiche Tool Catalog (MTC).
Charging Station . . . . . . . . . . . . . . . . . . . . . JT02046
Servicing air conditioning systems
–UN–17AUG92
RW21595
CED,OUTX466,1340 –19–28SEP98–2/6
Recovery and Recycling Station . . . . . . . . . . . . JT02050
Servicing air conditioning systems

9031
25
1
–UN–17AUG92
RW21613
CED,OUTX466,1340 –19–28SEP98–3/6
Schrader Valve Tool . . . . . . . . . . . . . . . . . . . JT02130

–UN–03JAN95
To replace Schrader valve in compressor manifold

T8389AF

031504
PN=665
Test
Air Conditioning Test Equipment Kit . . . . . . . D18018KD
Used to test air conditioning.
–UN–29MAY91
T7541AD
CED,OUTX466,1340 –19–28SEP98–5/6
Straight Connector. . . . . . . . . . . . . . . . . . . . . JT02148
Used to test air conditioning high and low pressure

switches.
–UN–04DEC96
T105533
CED,OUTX466,1340 –19–28SEP98–6/6
Service Equipment and Tools
NOTE: Order tools from the U.S. SERVICEGARD

9031 Catalog or from the European Microfiche Tool
25 Catalog (MTC). Some tools may be available from
2 a local supplier.
Manifold Pressure Gauge Assembly . . . . . . . . . JT02051
Test air conditioning system.
CED,OUTX466,1341 –19–28SEP98–2/6
Electronic Leak Detector . . . . . . . . . . . . . . . . . JT02081
Detect refrigerant leaks.

031504
PN=666
Test
Air Conditioning Service Fitting Kit . . . . . . . . . . JT05419
Connect test equipment.
CED,OUTX466,1341 –19–28SEP98–4/6
Air Conditioning Fitting Kit . . . . . . . . . . . . . . . . JT02098
Used with JT02075 to flush R134a air conditioning

systems.
CED,OUTX466,1341 –19–28SEP98–5/6
Volt-Ohm-Amp Multimeter
To test thermostat switch.
CED,OUTX466,1341 –19–28SEP98–6/6
Specifications
Air Conditioning System Oil Capacity 438 mL (14.8 fl oz)
Air Conditioning System Refrigerant Capacity 3.062 kg (6.75 lb)
Freeze Control Switch Open Temperature —0.56 ± 0.84°C (31 ± 1.5°F)
Freeze Control Switch Close Temperature 2.22 ± 0.84°C (36 ± 1.5°F)

9031
25
Low Pressure Switch Open Decreasing Pressure 173 ± 35 kPa (1.73 ± 0.3 bar) (25 ± 3
5 psi)
Low Pressure Switch Close Increasing Pressure 345 ± 35 kPa (3.45 ± 0.3 bar) (50 ±
5 psi)
High Pressure Switch Open Increasing Pressure 2760 ± 138 kPa (27.6 ± 1.38 bar)
(400 ± 20 psi)
High Pressure Switch Close Decreasing Pressure 1310 ± 138 kPa (13.11 ± 1.38 bar)
(190 ± 20 psi)
CED,TX14826,12681 –19–16JUN00–1/1

031504
PN=667
Test
CED,OUTX466,1344 –19–28SEP98–1/1
R12 And R134a Refrigerant Cautions

If skin freezes to container, pour COOL
9031 physician or hospital immediately for
25 physician or hospital immediately for
treatment.
4 treatment.
(R12 ONLY) Refrigerant exposed to high
temperature forms phosgene gas. Inhaling
toxic phosgene gas may result in serious
illness or death. Phosgene gas has an odor
like new mown hay or green corn. If you
inhale phosgene gas, go to a physician or
hospital immediately for treatment.
container.
CED,OUTX466,1345 –19–28SEP98–1/1

031504
PN=668
Test
R134a Air Conditioning System Test
SPECIFICATIONS
Engine rpm 2200
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station
Maximum Louver
Ambient Temperature (F) Temperature (F) Suction Pressure (psig) Discharge Pressure (psig)
15—21°C (60—70°F) 8°C (47°F) 34—69 kPa (0.34—0.69 bar) (5—10 689—896 kPa (6.89—8.96 bar) (100—
psi) 130 psi)
21—27°C (70—80°F) 10°C (50°F) 48—76 kPa (0.48—0.76 bar) (7—11 861—1137kPa (8.61—11.37 bar) (125—
psi) 165 psi)
27—32°C (80—90°F) 11°C (52°F) 62—90 kPa (0.62—0.90 bar) (9—13 1103—1241 kPa (11.03—12.41 bar)
psi) (160—180 psi)
psi) (175—210 psi)
38—43°C (100—110°F) 16°C (61°F) 96—124 kPa (0.96—1.24 bar) (14—18 1413—1758 kPa (14.13—17.58bar)
psi) (205—255 psi)
psi) (250—305 psi)
psi) (300—355 psi)
IMPORTANT: Use correct refrigerant

recovery/recycling and charging
stations. DO NOT use refrigerant,
hoses, fittings, components or
refrigerant oils intended for R12
refrigerant.
1. Connect R134a Refrigerant Recovery/Recycling and 9031

25
Charging Station.See R134a Refrigerant Recovery,
5
Recycling and Charging Station installation Procedure..
See installation procedure in Group 9031-20.
2. Close both low and high pressure valves on refrigerant

recovery/recycling and charging station.
3. Open cab doors and windows.

031504
PN=669
Test
4. Connect low pressure blue hose (4) from refrigerant 2

recovery/recycling and charging station (6) to low 8
pressure test port (3) on compressor.
5. Connect high pressure red hose (7) to high pressure

1
quick-disconnect (2) on compressor.
6. Follow the manufacture’s instructions when using the

refrigerant recovery/recycling and charging station.
7. Start engine and operate at rated engine speed.

3 4
Specification
Rated Engine Speed—RPM .............................................................. 2200
5
8. Turn temperature control switch to the maximum
cooling position.
9. Turn blower switch to high speed.
–UN–11AUG00
10. Check sight glass in receiver/dryer.
11. Operate machine for at least 5 minutes. 6
T132733
12. Measure air temperature at condenser air inlet and at
air ducts in air conditioning unit. T132733
13. Compare air duct temperature reading to the 1—High Pressure Hose
temperatures shown in the specifications. 2—High Pressure Test Port
3—Low Pressure Test Port
14. Observe low and high pressure gauges on refrigerant
5—Blue Hose
recovery/recycling and charging station. 6—Refrigerant Recovery/Recycling and Charging
9031 Station
25 15. Compare pressure readings to the pressure shown in 7—Red Hose
6 specifications. 8—High Pressure Relief Valve
Use the Pressure Diagnostic Chart in this group to

diagnose the malfunction. See Pressure Diagnostic
Chart.
CED,TX14826,12729 –19–15FEB01–2/2

031504
PN=670
Test
Pressure Diagnostic Chart
9031
25
7
–19–28FEB89
T6609AB
CED,OUTX466,1346 –19–28SEP98–1/1

031504
PN=671
Test
Expansion Valve Operating Test

D18018KD Air Conditioning Gauge Set
1. Close valves on air conditioning gauge set.
2. Connect blue hose (B) to low pressure service fitting.
3. Connect red hose (A) to high pressure service fitting.
4. Locate expansion valve.
5. Start engine and run at 2000 rpm.
6. Turn blower switch to maximum position.
7. Turn air conditioner switch to ON position.
8. Rotate heater temperature control switch clockwise to
–UN–21OCT88
maximum heat position.
NOTE: Any solution that does not contribute to

deterioration of the ozone layer and can produce
T6579AC
sub-zero cooling, is acceptable for this test.
9. Spray top of expansion valve with dry nitrogen, to cool

and close expansion valve. Have a second person A—High Pressure Hose (red)
note the low-side pressure. B—Low Pressure Hose (blue)
C—High Pressure Relief Valve
10. Let expansion valve warm. Again have a second
person note the low-side pressure.
9031
25
If the low-side pressure decreases when top of valve
8
is cooled, and increases when top of valve warms,
the expansion valve is operating properly. If not,
replace expansion valve.
CED,OUTX466,1347 –19–28SEP98–1/1

031504
PN=672
Test
Blower Switch Test
–19–23NOV98
1. Disconnect harness from blower switch.
2. Use a multimeter and check for continuity.
T117798
3. Move blower switch into position 1, checking between
terminals B and 1, in position 2 check terminals B and
2, in position 3 check terminals B and 3, in position 4
check terminals B and 4.
4. Is continuity measured at each position on switch?
YES: Blower switch is good.
NO: Replace blower switch.
CED,TX14826,12682 –19–16JUN00–1/1
9031
25
9

031504
PN=673
Test
Blower Resistor Test
1. Disconnect harness connector (5) from resistor.
2. Connect ohmmeter to outside resistor terminal (2) and

terminal (4).
–UN–21SEP00
3. Does ohmmeter read about 1.0 ohm?
Specification
T133889B
Outside Resistor Terminal (2) to
Terminal (4)—Resistance .............................................................. 1.0 ohm

terminal (1).
5. Does ohmmeter read about 0.5 ohm?
Specification
–UN–21SEP00
Outside Resistor Terminal (2) to
Terminal (1)—Resistance .............................................................. 0.5 ohm

terminal (3).
T133859B
7. Does ohmmeter read 0.2 ohms?
Specification 1—Terminal 1
Outside Resistor Terminal (2) to 2—Terminal 2
terminal (3)—Resistance ............................................................. 0.2 ohms 3—Terminal 3
4—Terminal 4
5—Harness Connector
YES: Resistor is OK. Check wiring harness.
NO: Replace resistor.

9031
25
10
CED,TX14826,12683 –19–16JUN00–1/1

031504
PN=674
Test
Heater Blower Motor Test
1. Disconnect harness connector (1) from heater blower

motor.
2. Connect 12 volts to heater blower motor connector with

red wire, and apply ground to heater blower motor
connector with black wire.
3. Does heater blower motor operate?
YES: Heater blower motor is good. Check wiring

harness.
NO: Replace heater blower motor.
–UN–01OCT03
T133888B
CED,TX14826,12684 –19–16JUN00–1/1
Freeze Control Test –19–24SEP92
1. With freeze control switch at room temperature.

9031
2. Disconnect harness from switch. 25
T7835AV
11
3. Measure continuity across switch terminals.
4. Is continuity measured?
YES: Do Freeze Control Switch Test. See Group

9031-25. If Switch is OK. Check wiring harness.
NO: Switch has failed. Replace switch.
CED,TX14826,12730 –19–24JUL00–1/1

031504
PN=675
Test
Air Conditioning Switch Test
–UN–08JUL94
1. Disconnect harness from air conditioning switch.
2. Turn switch ON, and measure for continuity between
T8274AQ
connector terminals.
3. Is continuity measured?
YES: A/C switch is OK. Check wiring harness.
NO: Replace A/C switch.
CED,TX14826,12685 –19–16JUN00–1/1
Air Conditioner Low Pressure Switch Check
–UN–05OCT93
1. Disconnect harness from switch.
2. Check for continuity between outer terminals. Is

continuity measured? T8093AB
YES: Replace switch.
NO: Continue with this check

9031
25 3. Remove switch from system. (The line that attaches
12 the low pressure switch has a valve to prevent
discharging the air conditioning system when switch is
removed.)
4. Does ohmmeter read open?
YES: Switch is good. Check wiring harness.
NO: See Air Conditioner Low Pressure Switch Test. In

this Group 9031-25.
CED,TX14826,12006 –19–29OCT98–1/1

031504
PN=676
Test
Air Conditioner Low Pressure Switch Test
SPECIFICATIONS
Low Pressure Switch Opens 173 ± 35 kPa (1.73 ± 0.3 bar) (25
(Normally Open) Decreasing ± 5 psi)
Pressure
–UN–06MAR95
Low Pressure Switch Closes 345 ± 35 kPa (3.45 ± 0.3 bar) (50
(Normally Open) Increasing ± 5 psi)
Pressure
T8426AD
JT05791 Multimeter
NOTE: Low pressure switch is normally open when

removed from machine. When installed the switch
becomes closed because of normal system
pressure.
1. Turn key switch ON but DO NOT start engine. Turn

blower switch ON. Turn temperature control switch to
the maximum cooling position.
2. Disconnect and connect low pressure switch at

harness connector. Compressor clutch must engage
and disengage (click).
NOTE: The line that attaches the low pressure switch has
a valve to prevent discharging the air conditioning
system when switch is removed.
3. Disconnect harness from switch and remove switch

from line. Connect low pressure switch to harness.
9031
Compressor clutch must not engage (click). 25
13
4. The actual pressure setting of switch can be checked
by connecting it to a regulated pressure source such
as dry nitrogen.
Specification
Low Pressure Switch Opens
(Normally Open)—Decreasing
Pressure ............................................... 173 ± 35 kPa (1.73 ± 0.3 bar) (25
± 5 psi)
Low Pressure Switch Closes
(Normally Open)—Increasing
Pressure ............................................... 345 ± 35 kPa (3.45 ± 0.3 bar) (50
± 5 psi)

031504
PN=677
Test
5. Switch must not have continuity between terminals until

pressure increases to switch closing pressure
specification. Slowly release pressure. Switch must
have continuity until pressure decreases to switch
opening pressure specification.
CED,TX14826,12686 –19–16JUN00–2/2
Air Conditioner High Pressure Switch Check
–UN–05OCT93
1. Disconnect harness from switch.
2. Measure continuity across outer switch terminals.
T8093AD
3. Does ohmmeter read continuity?
YES: Continue with this check.
NO: Replace switch.
4. Remove switch from system. (The line that attaches

the high pressure switch has a valve to prevent
discharging the air conditioning system when switch is
removed.)
5. Measure continuity across switch terminals.

9031
25
14 Does ohmmeter read continuity?
YES: Switch is good. Check wiring harness.
NO: System pressure is too high. See Pressure

Diagnostic Chart. Go to Group 9031-25.
CED,TX14826,12687 –19–16JUN00–1/1

031504
PN=678
Test
Air Conditioner High Pressure Switch Test
SPECIFICATIONS
High Pressure Switch Opens 2760 ± 138 kPa (27.6 ± 1.38 bar)
(Normally Closed) Increasing (400 ± 20 psi)
Pressure
–UN–06MAR95
High Pressure Switch Closes 1310 ± 138 kPa (13.11 ± 1.38
(Normally Closed) Decreasing bar) (190 ± 20 psi)
Pressure
T8426AE
Multimeter
D18018KD Air Conditioning Gauge Set
NOTE: The line that attaches the high pressure switch

has a valve installed to prevent discharging the air
conditioning system when switch is removed. The
high pressure switch is normally closed when
removed from the machine. It does not open
when installed in the A/C system until pressure
exceeds specification.
1. Remove high pressure switch.
2. Connect a regulated pressure source, such as dry

nitrogen to high pressure switch.
3. Switch must have continuity between terminals until

pressure increases to switch opening pressure
specification.
Specification
High Pressure Switch Opens 9031
(Normally Closed)—Increasing 25
Pressure ............................................... 2760 ± 138 kPa (27.6 ± 1.38 bar) 15
(400 ± 20 psi)
High Pressure Switch Closes
(Normally Closed)—Decreasing
Pressure ..................................................... 1310 ± 138 kPa (13.11 ± 1.38
bar) (190 ± 20 psi)
4. Slowly release pressure. Switch must not have

continuity until pressure decreases to switch closing
pressure specification.
5. The switch can also be checked when installed in air

conditioning system, however, pressure is slow to
increase to test specification.

031504
PN=679
Test
Connect an air conditioning gauge set to service

fittings at compressor. Cover condenser with paper or
plastic to stop air flow. Operate air conditioner on
maximum cooling. Note high-side pressure when high
pressure switch opens and then closes.
CED,TX14826,12688 –19–16JUN00–2/2
Air Conditioning Compressor Clutch Coil

Test
1. Disconnect harness connectors (1) and (2) from

compressor harness.
2. Apply 12 volts to compressor harness connector with

orange wire, and apply ground to compressor harness
connector with black wire.
3. Does Clutch "click"?
YES: A/C compressor clutch coil is good. Check wiring

harness.
NO: Check compressor harness and diode. If ok

replace clutch coil.
9031
25 1—Harness Connector
16 2—Harness Connector
–UN–21SEP00
T133858B
CED,TX14826,12689 –19–16JUN00–1/1

031504
PN=680
Test
Freeze Control Switch Test
SPECIFICATIONS
Freeze Control Switch Opens -0.56 ± 0.84°C (31 ± 1.5 °F)
(Normally Closed) Temperature
Drops
–UN–13NOV90
Freeze Control Switch Closes 2.22 ± 0.84°C (36 ± 1.5°F)
(Normally Closed) Temperature
Rises
T7199EZ
JT05791 Multimeter
1. Remove freeze control switch from evaporator.
2. Connect ohmmeter to switch terminals. Switch must be

closed at room temperature.
3. Put switch into a freezer (temperature must be below

-0.56 ± 0.84°C (31 ± 1.5 °F). Switch must open, and
continuity must not be read.
Specification
Freeze Control Switch Opens
(Normally Closed)—Temperature
Drops ............................................................. -0.56 ± 0.84°C (31 ± 1.5 °F)
Freeze Control Switch Closes
(Normally Closed)—Temperature
Rises ................................................................ 2.22 ± 0.84°C (36 ± 1.5°F)
4. Remove switch from freezer. Put sensing tube into a

glass of warm water. Switch must close, and continuity
must be read.
9031
5. If switch does not open and close during testing, install 25
new switch. 17
CED,OUTX466,1350 –19–28SEP98–1/1
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.
CED,OUTX466,1351 –19–28SEP98–1/1

031504
PN=681
Test
Refrigerant Hoses And Tubing Inspection
IMPORTANT: Hose used for air conditioning material. If such contamination is present in hoses,
systems contains special barriers in tubing, or fittings and cannot be removed by cleaning,
its walls to prevent migration of then replace parts.
refrigerant gas.
Fittings that have grease or dirt on them should be
DO NOT use hydraulic hoses as wiped clean with a cloth dampened with alcohol.
replacement hoses in the air Chlorinated solvents (such as trichloroethylene) are
conditioning system. Use ONLY contaminants, and must not be used for cleaning.
certified hose meeting SAE J51B
requirements. To assist in making leak proof joints, use a small
amount of clean correct viscosity refrigerant oil on all
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
CED,OUTX466,1352 –19–28SEP98–1/1
9031
25
18

031504
PN=682
Index
Page Page
A Battery
Electrolyte level. . . . . . . . . . . . . . . . . . . .9015-20-5
Accumulator, ride control . . . 9025-20-21, 9025-25-35 Explosions, prevent. . . . . . . . . . . . . . . . .9000-01-5
Adjustment Jump starting . . . . . . . . . . . . . . . . . . . . .9015-20-7
Loader Lever and Stabilizer Lever . . . . .9025-20-2 Malfunctions . . . . . . . . . . . . . . . . . . . . . .9015-20-4
Pilot control pressure . . . . . . . . . . . . . .9025-20-27 Operation . . . . . . . . . . . . . . . . . . . . . . . .9015-20-2
Steering angle. . . . . . . . . . . . . . . . . . . . .9020-20-7 Specifications . . . . . . . . . . . . . . . . . . . . .9015-20-3
Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-5 Brake
Air conditioning Pedal adjustments . . . . . . . . . . . . . . . . .9020-20-2
Cleaning procedures . . . . . . . . . . . . . . .9031-20-13 Brake valve
Flush. . . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-14 Leakage test . . . . . . . . . . . . . . . . . . . . . .9020-25-8
Freeze control switch . . . . . . . . . . . . . .9031-05-16 Brake valve, mico . . . . . . . . . . . . . . . . . . .9020-05-37
Purge . . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-13 Brake, park
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9031-05-7 Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-44
System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-5 Brake, service
Air conditioning and heating . . .9031-20-1, 9031-25-1 Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-42
Air conditioning system Brakes
Specifications . . . . . . . . . . . . . . . . . . . . .9031-25-3 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-4
Air flow Bucket
Radiator . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-4 Front loader
Air system Adjustment, self-leveling linkage and
Air intake leakage test. . . . . . . . . . . . . . .9010-25-2 return-to-dig switch. . . . . . . . . . . . .9025-20-11
Alternators Loader
Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1 Adjustment, self-leveling linkage and
Auxiliary flow control valve section . . . . . .9025-05-74 return-to-dig switch. . . . . . . . . . . . .9025-20-14
Auxiliary valve section, loader Bucket valve section operation . . . . . . . . 9025-05-82,
Operation . . . . . . . . . . . . . . . . . . . . . . 9025-05-102 9025-05-98
B C
Backhoe Calibrate
Auxiliary flow control operation . . . . . . .9025-05-74 Tachometer. . . . . . . . . . . . . . . . . . . . . .9015-20-10
Auxiliary valve section operation . . . . . .9025-05-86 Charge ride control accumulator. . . . . . . 9025-20-21,
Boom valve section operation . . . . . . . .9025-05-78 9025-25-35
Indx
Bucket valve section operation . . . . . . 9025-05-82, Check 1
9025-05-84 A/C high pressure switch . . . . . . . . . . .9031-25-14
Controls A/C low pressure switch . . . . . . . . . . . .9031-25-12
Linkage adjustment . . . . . 9025-20-7, 9025-20-9, Circuit Malfunction
9025-20-19 Electrical . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-2
Outlet section operation . . . . . . . . . . . .9025-05-88 Circuit operational information . . . . . . . . . .9031-05-4
Swing valve section operation. . . . . . . .9025-05-76 Circuit relief valve . . . . . . . . . . . . . . . . . . .9025-05-66
Backhoe auxiliary valve section Backhoe auxiliary flow operation . . . . . .9025-05-68
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-86 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-32
Backhoe inlet section Circuit relief valve, anti-cavitation
Swing section activated operation . . . . .9025-05-70 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-65
Backhoe load sense relief Circuit specifications . . . . . . . . . . . . . . . . . .9031-05-4
Stall pressure test . . . . . . . 9025-25-18, 9025-25-26 Circuit theory of operation . . . . . . . . . . . . .9031-05-5
Backhoe outlet section operation . . . . . . .9025-05-88 Clutch pack
Backhoe swing valve section Forward, reverse, low range forward or speed
operation. . . . . . . . . . . . . . . . . . . . . . . .9025-05-76 operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-1
TM1881 (15MAR04) Index-1 410G Backhoe Loader

031504
PN=1
Index
Page Page
Clutch packs High resistance circuit . . . . . . . . . . . . . . .9015-05-3

Power shift, high range forward 1st and 2nd Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-5
speed . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-2 Sensor circuit shorted to ground . . . . . .9015-05-16
Component location . . . . . . . . . . . . . . . . . .9031-15-2 Sensor circuit shorted to itself . . . . . . . .9015-05-14
A/C Cab harness (W10 . . . . . . . . . . . . .9015-10-70 Sensor circuit shorted to power. . . . . . .9015-05-12
A/C Compressor harness (W9 . . . . . . .9015-10-66 Shorted circuit. . . . . . . . . . . . . . . . . . . .9015-05-10
Cab roof harness (W5) . . . . . . . . . . . . .9015-10-22 Diagnostic chart, pressure . . . . . . . . . . . . .9031-25-7
Cab/rops harness (W6) . . . . . . . . . . . . .9015-10-32 Diagnostic Information
Engine/Transmission harness (W7). . . .9015-10-46 Steering . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-3
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20 Diagnostic procedure . . . . . . . . . . . . . . . . .9025-15-1
Radio harness (W8) . . . . . . . . . . . . . . .9015-10-62 Differential
Reading a component diagram . . . . . . .9015-05-26 Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-34
(W13) Ride control harness . . . . . . . . .9015-10-82 Differential lock
(W14) Ride control harness . . . . . . . . .9015-10-86 Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-36
(W15) Canopy heater control Differential lock pressure
harness . . . . . . . . . . . . . . . . . . . . . . .9015-10-92 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-20
(W17) Selective flow harness Digital pressure and temperature analyzer
harness . . . . . . . . . . . . . . . . . . . . . . .9015-10-96 installation. . . . . . . . . . . . . . . . . . . . . . . .9025-25-9
Compressor Digital thermometer . . . . . . . . . . . . . . . . .9025-25-10
Oil charge check . . . . . . . . . . . . . . . . . . .9031-20-4 Digital Thermometer Installation . . . . . . . . 9010-25-1,
Oil removal . . . . . . . . . . . . . . . . . . . . . . .9031-20-5 9020-25-1, 9025-25-10
Compressor relief valve operation . . . . . .9031-05-15 Drift test, cylinder . . . . . . . . . . . . . . . . . . .9025-25-43
Connector end view diagram
Reading an end view diagram. . . . . . . .9015-05-28
Control valve
Loader and stabilizer. . . . . . . . . . . . . . 9025-05-106
Control valve and shift valve transmission power shift E
Operation-First Forward . . . . . . . . . . . .9020-05-22
Operation-first reverse. . . . . . . . . . . . . .9020-05-30 Electrical
Operation-neutral . . . . . . . . . . . . . . . . .9020-05-18 Charging circuit . . . . . . . . . . . . . . . . . . .9015-15-12
Control valve transmission power shift Circuit Malfunction . . . . . . . . . . . . . . . . .9015-05-2
Operation-Fourth Forward . . . . . . . . . . .9020-05-26 Component identification . . . . . . . . . . . . .9015-10-1
Control Valve, Pilot Component location . . . . . . . . . . . . . . .9015-05-26
Theory . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-92 Connector end view diagram. . . . . . . . .9015-05-28
Converter, torque Display monitor circuit . . . . . . . . . . . . . .9015-15-25
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-3 FNR circuit
Converter, torque,stall Park brake circuit. . . . . . . . . . . . . . . .9015-15-36
Indx
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-4 Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-8
2
Converter-in relief valve High resistance circuit . . . . . . . . . . . . . . .9015-05-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-6 Indicator circuit . . . . . . . . . . . . . . . . . . .9015-15-26
Cooler in and cooler out Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-5
Transmission pressure test . . . . . . . . . .9020-25-23 Power circuit . . . . . . . . . . . . . . . . . . . . . .9015-15-1
Cooler restriction test . . . . . . . . . . . . . . . .9025-25-31 Program display monitor . . . . . . . . . . . 9015-20-11,
Cooling system 9015-20-12
Service safely . . . . . . . . . . . . . . . . . . . .9000-01-13 Schematic symbols . . . . . . . . . . . . . . . .9015-05-30
Cycle time specifications . . . . . . . . . . . . .9025-25-49 Schematic, wiring diagram, and component
Cylinder drift test procedure . . . . . . . . . . .9025-25-43 location information . . . . . . . . . . . . . .9015-05-20
Cylinder leakage test . . . . . . . . . . . . . . . .9025-25-47 Sensor circuit shorted to ground . . . . . .9015-05-16
Sensor circuit shorted to itself . . . . . . . .9015-05-14
D Sensor circuit shorted to power. . . . . . .9015-05-12
Shorted circuit. . . . . . . . . . . . . . . . . . . .9015-05-10
Definition Start circuit . . . . . . . . . . . . . . . . . . . . . . .9015-15-6
Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-8 System Functional Schematic . . . . . . . . .9015-10-9

031504
PN=2
Index
Page Page
System Functional Schematic Legend (S.N. Function drift

-913483) . . . . . . . . . . . . . . . . . . . . . . .9015-10-8 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-44
System Functional Schematic Legend (S.N. Fuse
913484- ). . . . . . . . . . . . . . . . . . . . . .9015-10-18 Color Codes . . . . . . . . . . . . . . . . . . . . . .9015-10-2
System Functional Schematic (S.N. 913484- Location . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-3
). . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-19 Specifications . . . . . . . . . . . . . . . . . . . . .9015-10-3
System functional schematic, reading a
schematic . . . . . . . . . . . . . . . . . . . . .9015-05-22
Test equipment . . . . . . . . . . . . . . . . . . .9015-05-17
Test procedure . . . . . . . . . . . . . . . . . . .9015-05-18 H
Visual inspection . . . . . . . . . . . . . . . . . . .9015-05-1
Wiring & schematic diagrams legend . . .9015-10-4
Handholds
Wiring diagram, reading . . . . . . . . . . . .9015-05-24
Use correctly. . . . . . . . . . . . . . . . . . . . . .9000-01-7
Electrical malfunctions, diagnose . . . . . . . .9031-15-1
Heater blower circuit
Electronic tachometer
Installation. . . . . . . . . . . . . . . . . . . . . . . .9020-25-1 Operational information . . . . . . . . . . . . .9031-05-10
JT0 5801 clamp-on . . . . . . . .9010-20-1, 9010-25-1 Schematic . . . . . . . . . . . . . . . . . . . . . . .9031-05-11
Emergencies Theory of operation. . . . . . . . . . . . . . . .9031-05-10
Prepare for . . . . . . . . . . . . . . . . . . . . . . .9000-01-6 Heating and air conditioning . . . 9031-20-1, 9031-25-1
Engine Hose and tubing inspection . . . . . . . . . . .9031-25-18
Boost starting . . . . . . . . . . . . . . . . . . . . .9015-20-7 Hydraulic
Diagnose malfunction . . . . . . . . . . . . . . .9010-15-4 Warm-up procedure . . . . . . . . . . . . . . .9025-25-10
Idle adjustment . . . . . . . . . . . . . . . . . . . .9010-20-8 Hydraulic Circuit Symbols. . . . . . . . . . . . .9020-15-19
Visual inspection . . . . . . . . . . . . . . . . . . .9010-15-2 Hydraulic component location. . . . . . . . . . .9025-05-2
Engine speed control Hydraulic cooler test. . . . . . . . . . . . . . . . .9025-25-31
Adjust lever tension. . . . . . . . . . . . . . . . .9010-20-2 Hydraulic filter . . . . . . . . . . . . . . . . . . . . .9025-05-44
Adjust linkage . . . . . . . . . . . . . . . . . . . . .9010-20-4 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-44
Equipment, Protective Hydraulic oil cooler
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-3 Restriction test . . . . . . . . . . . . . . . . . . .9025-25-31
Expansion valve operation . . . . . . . . . . . .9031-05-14 Hydraulic oil warm-up test . . . . . . . . . . . .9025-25-10
Hydraulic pump
Controls operation. . . . . . . 9025-05-32, 9025-05-34
Flow limited operation . . . . . . . . . . . . . .9025-05-42
F Full flow operation. . . . . . . . . . . . . . . . .9025-05-40
Function metering operation . . . . . . . . 9025-05-36,
9025-05-38
Filter operation . . . . . . . . . . . . . . . . . . . . .9025-05-44 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-30 Indx
Filter, transmission Hydraulic system 3
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-6 Component location . . . . . . . . . . . . . . . .9025-05-2
Fires, prevent . . . . . . . . . . . . . . . . . . . . . . .9000-01-5 Diagnose. . . . . . . . . . . . . . . . . . . . . . . . .9025-15-6
Flow limiter
Pretest system . . . . . . . . . . . . . . . . . . . .9025-15-2
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-28
Hydraulic system operation
Fluids, high pressure
Componet location . . . . . . . . . . . . . . . . .9025-05-1
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-4
Schematic-neutral . . . . . . . . . . . . . . . . .9025-05-14
Freeze control switch operation . . . . . . . .9031-05-16
Hydraulic system schematic . . . . . . . . . . .9025-05-14
Front loader
Hydraulic system test . . . . . . . . . . . . . . . . .9025-15-2
Adjustment, bucket self-leveling linkage and
return-to-dig switch . . . . 9025-20-11, 9025-20-14
Front wheel drive, mechanical
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-12
Fumes, exhaust I
Beware . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-5
Function & and cylinder drift test . . . . . . .9025-25-44 Injection pump timing . . . . . . . . . . . . . . . .9010-25-10

031504
PN=3
Index
Page Page
J Machine warm-up . . . . . . . . . . . . . . . . . . .9025-25-10

Macine, inspect . . . . . . . . . . . . . . . . . . . . .9000-01-4
JT05800 thermometer . . . . . . . . . . . . . . .9025-25-10 MFWD
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-12
MFWD differential-equal traction
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-47
L
MFWD differential-unequal traction
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-46
Leak testing . . . . . . . . . . . . . . . . . . . . . . .9031-25-17
MFWD pressure test . . . . . . . . . . . . . . . .9020-25-22
Legend
Mico brake valve . . . . . . . . . . . . . . . . . . .9020-05-37
System Functional Schematic Section (S.N.
Modulation valve
-913483) . . . . . . . . . . . . . . . . . . . . . . .9015-10-8
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-18
System Functional Schematic Section (S.N.
Modulation valve power shift
913484- ). . . . . . . . . . . . . . . . . . . . . .9015-10-18
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-32
Wiring and Schematic Diagrams . . . . . . .9015-10-4
Multimeter
Load sense
Basic description. . . . . . . . . . . . . . . . . .9015-05-17
All function neutral operation. . . . . . . . .9025-05-22
Mulitiple function activated operation. . .9025-05-26
One function activated operation. . . . . .9025-05-24
Load sense isolator O
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-20
Load sense multiple function Oil charge, component . . . . . . . . . . . . . . . .9031-20-6
One function stalled operation. . . . . . . .9025-05-28 Operational checkout procedures . . . . . . . .9005-10-1
Load Sense relief Operational checks
Loader valve . . . . . . . . . . . . . . . . . . . . .9025-05-60 Accessories . . . . . . . . . . . . . . . . . . . . .9005-10-19
Load sense, circuit relief (S.N. 913480- ) Brake system . . . . . . . . . . . . . . . . . . . . .9005-10-6
Loader and backhoe . . . . . . . . . . . . . . .9025-05-63 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-20
Loader Clutch disconnect solenoid . . . . . . . . . . .9005-10-9
Adjustment, bucket self-leveling linkage and Driving . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-10
return-to-dig switch . . . . 9025-20-11, 9025-20-14 Gauge and indicator . . . . . . . . . . . . . . . .9005-10-1
Auxiliary valve section operation . . . . . 9025-05-102 Hydraulic system. . . . . . . . . . . . . . . . . .9005-10-15
Boom valve section operation . . . . . . . 9025-05-100 Indicators . . . . . . . . . . . . . . . . . . . . . . . .9005-10-3
Bucket valve section operation . . . . . . .9025-05-98 MFWD . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-14
Loader and stabilizer valve Steering system . . . . . . . . . . . . . . . . . . .9005-10-8
Bucket section . . . . . . . . . . . . . . . . . . 9025-05-106 Switches . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2
Steering load sense isolator . . . . . . . . 9025-05-109
Loader boom valve section operation . . . 9025-05-100
Indx Loader inlet section
4 P
Bucket section activated operation . . . .9025-05-96
Loader Lever and Stabilzer Lever
Park brake
Adjustment . . . . . . . . . . . . . . . . . . . . . . .9025-20-2
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-44
Loader load sense relief stall
Release pressure test . . . . . . . . . . . . . .9020-25-10
Pressure test. . . . . . . . . . . 9025-25-18, 9025-25-26
Parts, moving
Loader outlet section operation. . . . . . . . 9025-05-104
Stay clear . . . . . . . . . . . . . . . . . . . . . . . .9000-01-4
Loader valve
Pilot control
Drain regulator . . . . . . . . . . . . . . . . . . .9025-05-60
Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-30
Loader valve load sense relief . . . . . . . . .9025-05-60
Pilot Control
Theory of operation. . . . . . . . . . . . . . . .9015-15-60
Pilot control manifold valve
M Theory of operation. . . . . . . . . . . . . . . .9025-05-94
Pilot control manifold valve accumualtor discharge
Machine modifications procedure . . . . . . . . . . . . . . . . . . . . . . .9025-20-28
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-3 Pilot control pressure adjustment . . . . . . .9025-20-27

031504
PN=4
Index
Page Page
Pilot Control Valve Reducing valve presssure

Theory . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-92 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-16
Pins, metal Refrigerant caution . . . . . . . . . . . . . . . . . . .9031-25-4
Drive safely . . . . . . . . . . . . . . . . . . . . . .9000-01-15 Refrigerant handling . . . . . . . . 9031-05-1, 9031-20-3,
Power shift high range forward clutch 9031-25-4
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-14 Refrigerant R134a caution . . . .9031-05-1, 9031-20-4
Power shift low range forward clutch Refrigerant theory of operation . . . . . . . . . .9031-05-2
Pressure Test . . . . . . . . . . . . . . . . . . . .9020-25-14 Relief valve, anti-cavitation
Power shift modulation valve Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-66
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-32 Relief valve, circuit (S.N. -913479)
Power shift power train Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-62
Diagnose malfunctions . . . . . . . . . . . . . .9020-15-1 Relief valve, circuit (S.N. 913480- )
Overview. . . . . . . . . . . . . . . . . . . . . . . . .9020-05-8 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-63
Power shift speed clutch Return-to-dig switch adjustment . . . . . . . 9025-20-11,
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-14 9025-20-14
Power shift transmission Ride control
Control valve operation-fourth Accumulator
forward . . . . . . . . . . . . . . . . . . . . . . .9020-05-26 Discharge procedure . . . . . . . . . . . . .9025-25-37
Gear flow . . . . . . . . . . . . . . . . . . . . . . .9020-05-10 Ride control accumulator . . . 9025-20-21, 9025-25-35
Power shift transmission control circuit Ride control valve. . . . . . . . 9025-05-54, 9025-05-56,
First forward . . . . . . . . . . . . . . . . . . . . .9020-05-20 9025-05-58
First Reverse . . . . . . . . . . . . . . . . . . . .9020-05-28
Roads
Fourth forward . . . . . . . . . . . . . . . . . . .9020-05-24
Operating or traveling . . . . . . . . . . . . . .9000-01-12
Neutral . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-15
ROPS
Power shift transmission control valve and shift valve
Inpsect . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-12
Operation-first forward. . . . . . . . . . . . . .9020-05-22
Maintain . . . . . . . . . . . . . . . . . . . . . . . .9000-01-12
Operation-first reverse. . . . . . . . . . . . . .9020-05-30
R134a system
Operation-neutral . . . . . . . . . . . . . . . . .9020-05-18
Charge . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-12
Power train overview
Power shift . . . . . . . . . . . . . . . . . . . . . . .9020-05-8 Evacuate. . . . . . . . . . . . . . . . . . . . . . . .9031-20-10
Pressure diagnostic chart . . . . . . . . . . . . . .9031-25-7 Recover . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-9
Pressure regulating valve . . . . . . . . . . . . .9025-05-48
Pressure test
Pilot control . . . . . . . . . . . . . . . . . . . . . .9025-25-30
Pump S
Auxiliary . . . . . . . . . . . . . . 9025-05-32, 9025-05-34
Flow test . . . . . . . . . . . . . . . . . . . . . . . .9025-25-16 Indx
Safety 5
Main . . . . . . . . . . . . . . . . . 9025-05-32, 9025-05-34 Information, recognize. . . . . . . . . . . . . . .9000-01-2
Pump load sense differential pressure Instructions, follow . . . . . . . . . . . . . . . . .9000-01-2
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-11 Park and prepare for service safely. . . .9000-01-13
Pump, transmission Schematic
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-4 Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20
Reading a schematic . . . . . . . . . . . . . .9015-05-22
Symbols . . . . . . . . . . . . . . . . . . . . . . . .9015-05-30
Seat belt
R Use and maintain . . . . . . . . . . . . . . . . . .9000-01-7
Self-leveling linkage adjustment . . . . . . . 9025-20-11,
Radiator 9025-20-14
Air flow test. . . . . . . . . . . . . . . . . . . . . . .9010-25-4 Service brake
Receiver/dryer operation. . . . . . . . . . . . . .9031-05-12 Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-42
Recovery/charging station Solenoid circuit leakage
Installation procedure . . . . . . . . . . . . . . .9031-20-8 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-26

031504
PN=5
Index
Page Page
Solenoids activated Heater blower motor . . . . . . . . . . . . . . .9031-25-11

Transmission clutch engagement power Hydraulic cooler restriction . . . . . . . . . .9025-25-31
shift . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-14 Hydraulic cylinder drift. . . . . . . . . . . . . .9025-25-43
Stabilizer lockout leakage test . . . . . . . . .9025-25-48 Hydraulic system pretest. . . . . . . . . . . . .9025-15-2
Staring motors Loader load sense relief stall
Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1 pressure . . . . . . . . . . . . . . . . . . . . . .9025-25-26
Steering . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-50 loader load sense relief stall
Cylinder leakage test . . . . . . . . . . . . . .9025-25-41 pressure . . . . . . . . . . . . . . . . . . . . . .9025-25-18
Steering angle Pump flow. . . . . . . . . . . . . . . . . . . . . . .9025-25-16
Adjustment . . . . . . . . . . . . . . . . . . . . . . .9020-20-7 Pump load sense differential
Steering load sense isolator . . . . . . . . . . 9025-05-109 pressure . . . . . . . . . . . . . . . . . . . . . .9025-25-11
Steering load sense relief valve Stabilizer valve lockout leakage . . . . . .9025-25-48
Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-23 Steering cylinder leakage . . . . . . . . . . .9025-25-41
Steering system Steering load sense relief valve stall . . .9025-25-23
Leakage test . . . . . . . . . . . . . . . . . . . . .9025-25-38 Tachometer installaation . . . . . . . . . . . . .9025-25-9
Steering valve . . . . . . . . . . . . . . . . . . . . .9025-05-48 Test procedure . . . . . . . . . . . . . . . . . . . . . .9025-15-1
Steering valve operation . . . . . . . . . . . . . .9025-05-53 Testing electrical circuits
Steps Seven step procedure . . . . . . . . . . . . . .9015-05-18
Use correctly. . . . . . . . . . . . . . . . . . . . . .9000-01-7 Theory of operation
System functional schematic Pilot Control . . . . . . . . . . . . . . . . . . . . .9015-15-60
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20 Theory op operation
Reading a schematic . . . . . . . . . . . . . .9015-05-22 Pilot control manifold valve . . . . . . . . . .9025-05-94
System pressure Thermometer Installation, Digital . . . . . . . 9010-25-1,
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-12 9020-25-1, 9025-25-10
System problems diagnosis . . . . . . . . . . . .9025-15-6 Toe-in, check and adjust . . . . . . . . . . . . . .9020-20-5
Torque converter
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-3
Torque converter stall speed
T Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-4
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1
Tachometer Installation . . . . . . . . . . . . . . .9015-20-1 Tracking angle
Tachometer installation. . . . . . . . . . . . . . . .9025-25-9 Check and adjust . . . . . . . . . . . . . . . . . .9020-20-5
Tachometer, electronic Transmission
Installation. . . . . . . . . . . . . . . . . . . . . . . .9020-25-1 Cooler in and cooler out press. test . . .9020-25-23
JT05801 clamp-on . . . . . . . .9010-20-1, 9010-25-1 Modulation valve pressure test . . . . . . .9020-25-18
Temperature control . . . . . . . . . . . . . . . . .9031-05-15 Reducing valve pressure test . . . . . . . .9020-25-16
Indx Test System pressure test . . . . . . . . . . . . . .9020-25-12
6 A/C compressor clutch coil . . . . . . . . . .9031-25-16 Transmission clutch engagement power shift
A/C High pressure switch . . . . . . . . . . .9031-25-15 Solenoids activated . . . . . . . . . . . . . . . .9020-05-14
A/C Low pressure switch. . . . . . . . . . . .9031-25-13 Transmission filter
A/C switch. . . . . . . . . . . . . . . . . . . . . . .9031-25-12 Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-6
Backhoe load sense relief stall . . . . . . 9025-25-18, Transmission Gear Flow
9025-25-26 Power Shift . . . . . . . . . . . . . . . . . . . . . .9020-05-10
Blower resistor . . . . . . . . . . . . . . . . . . .9031-25-10 Transmission oil warm-up
Blower switch . . . . . . . . . . . . . . . . . . . . .9031-25-9 Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-25-2
Circuit relief valve . . . . . . . . . . . . . . . . .9025-25-32 Transmission Pump
Cycle times . . . . . . . . . . . . . . . . . . . . . .9025-25-49 Flow test . . . . . . . . . . . . . . . . . . . . . . . .9020-25-28
Cylinder leakage . . . . . . . . . . . . . . . . . .9025-25-47 Transmission pump
Expansion valve . . . . . . . . . . . . . . . . . . .9031-25-8 Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-4
Flow limiter . . . . . . . . . . . . . . . . . . . . . .9025-25-28 Transmission Pump Flow
Freeze control. . . . . . . . . . . . . . . . . . . .9031-25-11 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-28
Freeze control swiitch . . . . . . . . . . . . . .9031-25-17 Transmission, power shift
Function drift . . . . . . . . . . . . . . . . . . . . .9025-25-44 Control circuit-first forward . . . . . . . . . .9020-05-20

031504
PN=6
Index
Page Page
Control circuit-first reverse . . . . . . . . . .9020-05-28 Welding repairs

Control circuit-fourth forward . . . . . . . . .9020-05-24 Make safely . . . . . . . . . . . . . . . . . . . . .9000-01-14
Control circuit-neutral . . . . . . . . . . . . . .9020-05-15 Wiring diagram
Traveling Air conditioning . . . . . . . . . . . 9031-05-8, 9031-05-9
On public roads. . . . . . . . . . . . . . . . . . .9000-01-12 Information . . . . . . . . . . . . . . . . . . . . . .9015-05-20
Troubleshooting Reading a wiring diagram . . . . . . . . . . .9015-05-24
Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-8 (W10) A/C Cab harness . . . . . . . . . . . .9015-10-68
High resistance . . . . . . . . . . . . . . . . . . . .9015-05-3 (W11) Pilot control harness . . . . . . . . . .9015-10-73
Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-5 W12 Pilot control harness . . . . . . . . . . .9015-10-76
Sensor circuit shorted to ground . . . . . .9015-05-16 (W13) Ride control harness . . . . . . . . .9015-10-80
Sensor circuit shorted to itself . . . . . . . .9015-05-14 (W14) Ride control harness . . . . . . . . .9015-10-84
Sensor circuit shorted to power. . . . . . .9015-05-12 (W15) Canopy heater control
Shorted circuit. . . . . . . . . . . . . . . . . . . .9015-05-10 harness . . . . . . . . . . . . . . . . . . . . . . .9015-10-90
Turbocharger boost pressure test . . . . . . . .9010-25-8 (W17) Selective flow harness
harness . . . . . . . . . . . . . . . . . . . . . . .9015-10-94
(w19) Pattern select harness. . . . . . . . 9015-10-100
(W5) Cab roof harness . . . . . . . . . . . . .9015-10-20
V (W6) Cab/Rops harness . . . . . . . . . . . .9015-10-27
(W7) Engine/Transmission harness. . . .9015-10-44
Valve (W8) Radio harness . . . . . . . . . . . . . . .9015-10-60
Auxiliary section . . . . . . . . . . . . . . . . . .9025-05-74 (W9) A/C Compressor harness . . . . . . .9015-10-64
Backhoe auxiliary section operation . . .9025-05-86
Backhoe boom section operation . . . . .9025-05-78
Backhoe bucket section operation. . . . .9025-05-84
Backhoe swing section operation . . . . .9025-05-76
Bucket section operation . . . . . . . . . . . .9025-05-82
Circuit relief, anti-cavitation . . . . . . . . . 9025-05-65,
9025-05-66
Circuit relief, without anti-cavitation (S.N.
-913479) . . . . . . . . . . . . . . . . . . . . . .9025-05-62
Circuit relief, without anti-cavitation (S.N.
913480- ). . . . . . . . . . . . . . . . . . . . . .9025-05-63
Loader auxiliary section operation. . . . 9025-05-102
Loader boom operation . . . . . . . . . . . . 9025-05-100
Loader bucket section operation . . . . . .9025-05-98
Pressure regulating valve . . . . . . . . . . .9025-05-48
Steering . . . . . . . . . . . . . . 9025-05-48, 9025-05-53 Indx
Valve, converter-in relief 7
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-6
Valve, mico brake. . . . . . . . . . . . . . . . . . .9020-05-37
Valve, modulation
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-18
Valve, reducing, pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-16
Valve, ride control. . . . . . . . 9025-05-54, 9025-05-56,
9025-05-58
Waste
Dispose of properly . . . . . . . . . . . . . . . . .9000-01-6

031504
PN=7
Index
Indx
8

031504
PN=8

John Deere 410G Operation Test Manual TM1881 Service Manual 690 Páginas

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Introduction

TM1881 (15MAR04) 410G Backhoe Loader

Technical Information Feedback Form

We need your help to continually improve our technical

SEND TO: John Deere Dubuque Works

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TM1881 (15MAR04) 410G Backhoe Loader

TM1881 (15MAR04) 410G Backhoe Loader

SECTION 9005—Operational Checkout Procedure

SECTION 9015—Electrical System

SECTION 9020—Power Train

SECTION 9025—Hydraulic System

SECTION 9031—Heating and Air Conditioning

All information, illustrations and specifications in this manual are based on

TM1881 (15MAR04) i 410G Backhoe Loader

TM1881 (15MAR04) ii 410G Backhoe Loader

Group 01—Safety Information

TM1881 (15MAR04) 9000-1 410G Backhoe Loader

TM1881 (15MAR04) 9000-2 410G Backhoe Loader

TM1881 (15MAR04) 9000-01-1 410G Backhoe Loader

This is the safety alert symbol. When you see this

Follow the precautions and safe operating practices

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

Follow Safety Instructions

Read the safety messages in this manual and on the

Be sure all operators of this machine understand every

TM1881 (15MAR04) 9000-01-2 410G Backhoe Loader

Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;

Wear close fitting clothing and safety equipment

Avoid Unauthorized Machine Modifications

TM1881 (15MAR04) 9000-01-3 410G Backhoe Loader

Inspect machine carefully each day by walking around it

Keep all guards and shields in good condition and

Stay Clear Of Moving Parts

Stop engine before examining, adjusting or maintaining

Avoid High-Pressure Fluids

This machine uses a high-pressure hydraulic system.

Never search for leaks with your hands. Protect hands.

If hydraulic fluid penetrates your skin, see a doctor

Contact a knowledgeable medical source or the Deere &

TM1881 (15MAR04) 9000-01-4 410G Backhoe Loader

Prevent asphyxiation. Engine exhaust fumes can cause

Keep A Fire Extinguisher Available: Always keep a

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,

Never check battery charge by placing a metal object

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

TM1881 (15MAR04) 9000-01-5 410G Backhoe Loader

Exposure to hazardous chemicals can cause serious

Dispose Of Waste Properly

Improper disposal of waste can threaten the environment.

Never pour waste onto the ground, down a drain, or into

Air conditioning refrigerants can damage the atmosphere.

If uncertain about the safe disposal of waste, contact your

Prepare For Emergencies

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.