John Deere 410d-510d Retroexcavadora Funcionamiento y Pruebas

Backhoe Loaders
Operation and Test
TECHNICAL MANUAL
TM1512 07NOV03 (ENGLISH)
For complete service information also see:

410D, 510D, Backhoe Loader
Operation and Test (Complete) . . . . . . . . . . TM1512
410D, 510D Backhoe Loader
Repair (Complete) . . . . . . . . . . . . . . . . . . . . . TM1513
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. beginning of each group are summary listings of all
Essential tools required in performing certain service applicable essential tools, service equipment and tools,
work are identified in this manual and are other materials needed to do the job, service parts kits,
recommended for use. specifications, wear tolerances, and torque values.
Live with safety: Read the safety messages in the Technical Manuals are concise guides for specific
introduction of this manual and the cautions presented machines. They are on-the-job guides containing only
throughout the text of the manual. the vital information needed for diagnosis, analysis,
testing, and repair.
This is the safety-alert symbol. When you see this
Fundamental service information is available from
symbol on the machine or in this manual, be alert to
other sources covering basic theory of operation,
the potential for personal injury.
fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
See DB1990 Service Publications Catalog to order a
the components. Operation and tests sections help you
Technical Manual (TM).
identify the majority of routine failures quickly.
Information is organized in groups for the various

components requiring service instruction. At the
TX,410DIFC 1931AUG951/1
TM1512 (07NOV03) Backhoe Loaders Operation and Test

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Contents
9000
SECTION 9000General Information
Group 01Safety Information
Group 02General Specifications
Group 03Torque Values
Group 04Fuels And Lubricants
9005
SECTION 9005Operational Checkout Procedure

Group 10Operational Checkout Procedure
SECTION 9010Engine
Group 05Theory Of Operation 9010
Group 10System Operational Checks
Group 15System Diagnostic Information
Group 20Adjustments
Group 25Tests
9015
SECTION 9015Electrical System
Group 05System Information
Group 10System Diagrams
Group 15Sub-System Diagnostics
Group 20References
9020
SECTION 9020Power Train
Group 05Theory Of Operation
Group 20Adjustments
9025
Group 25Test
SECTION 9025Hydraulics
Group 15Diagnostic Information 9031
Group 20Adjustments
Group 25Tests
SECTION 9031Heating And Air Conditioning

INDX
Group 15Diagnostic Information
Group 20Adjustments
Group 25Test
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 1996
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
TM1512 (07NOV03) i Backhoe Loaders Operation and Test

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Contents
9000
9005
9010
9015
9020
9025
9031
INDX
TM1512 (07NOV03) ii Backhoe Loaders Operation and Test

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9000
Section 9000
General Information
Contents
Page Page
Group 01Safety Information Checking Wheel Fastener Torque . . . . . . . . .9000-03-1

Handle Fluids SafelyAvoid Fires . . . . . . . .9000-01-1 ROPS Torque Specifications . . . . . . . . . . . . .9000-03-1
Prevent Battery Explosions . . . . . . . . . . . . . .9000-01-1 Unified Inch Bolt and Cap Screw Torque
Prepare for Emergencies. . . . . . . . . . . . . . . .9000-01-1 Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-2
Prevent Acid Burns . . . . . . . . . . . . . . . . . . . .9000-01-2 Metric Bolt and Cap Screw Torque
Handle Chemical Products Safely . . . . . . . . .9000-01-3 Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-3
Avoid High-Pressure Fluids . . . . . . . . . . . . . .9000-01-3 Additional Metric Cap Screw Torque
Park Machine Safely . . . . . . . . . . . . . . . . . . .9000-01-4 Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-4
Support Machine Properly . . . . . . . . . . . . . . .9000-01-4 Service Recommendations for Metric
Wear Protective Clothing. . . . . . . . . . . . . . . .9000-01-4 Series Four Bolt Flange Fitting . . . . . . . . .9000-03-6
Work in Clean Area. . . . . . . . . . . . . . . . . . . .9000-01-5 Service Recommendations For Inch
Service Machines Safely . . . . . . . . . . . . . . . .9000-01-5 Series Four Bolt Flange Fittings. . . . . . . . .9000-03-7
Work In Ventilated Area . . . . . . . . . . . . . . . .9000-01-5 Check Oil Lines And Fittings . . . . . . . . . . . . .9000-03-8
Illuminate Work Area Safely . . . . . . . . . . . . .9000-01-5 Service Recommendations for 37 Flare
Replace Safety Signs . . . . . . . . . . . . . . . . . .9000-01-6 and 30 Cone Seat Connectors . . . . . . . . .9000-03-9
Use Proper Lifting Equipment . . . . . . . . . . . .9000-01-6 Service Recommendations for O-Ring
Remove Paint Before Welding or Heating . . .9000-01-6 Boss Fittings . . . . . . . . . . . . . . . . . . . . . .9000-03-10
Avoid Heating Near Pressurized Fluid Service Recommendations for Flat Face
Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-7 O-Ring Seal Fittings. . . . . . . . . . . . . . . . .9000-03-12
Keep ROPS Installed Properly . . . . . . . . . . .9000-01-7
Service Tires Safely . . . . . . . . . . . . . . . . . . .9000-01-8 Group 04Fuels And Lubricants
Avoid Harmful Asbestos Dust . . . . . . . . . . . .9000-01-8 Fuel Specifications . . . . . . . . . . . . . . . . . . . .9000-04-1
Practice Safe Maintenance . . . . . . . . . . . . . .9000-01-9 Low Sulfur Diesel Fuel Conditioner . . . . . . . .9000-04-1
Use Proper Tools . . . . . . . . . . . . . . . . . . . . .9000-01-9 Storing Fuel. . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-2
Dispose of Waste Properly . . . . . . . . . . . . .9000-01-10 Do Not Use Galvanized Containers. . . . . . . .9000-04-2
Live With Safety . . . . . . . . . . . . . . . . . . . . .9000-01-10 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-2
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-3
Group 02General Specifications Transaxle Oil. . . . . . . . . . . . . . . . . . . . . . . . .9000-04-4
410D Backhoe Loader With Standard Hydraulic And Reverser Oil . . . . . . . . . . . . . .9000-04-5
Dipperstick. . . . . . . . . . . . . . . . . . . . . . . . .9000-02-1 Mechanical Front Wheel Drive Oil . . . . . . . . .9000-04-6
410D Heavy Lift Backhoe Loader . . . . . . . . .9000-02-3 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7
410D Backhoe Loader Specifications . . . . . .9000-02-5 Grease For Extendible Dipperstick . . . . . . . .9000-04-7
410D Backhoe Specifications . . . . . . . . . . . .9000-02-7 Alternative and Synthetic Lubricants . . . . . . .9000-04-8
410D Backhoe Loader And Backhoe Lubricant Storage . . . . . . . . . . . . . . . . . . . . .9000-04-8
Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-9 Mixing of Lubricants . . . . . . . . . . . . . . . . . . .9000-04-9
410D And 510D Backhoe Loader Drain And Engine Coolant . . . . . . . . . . . . . . . . . . . . . . .9000-04-9
Refill Capacities . . . . . . . . . . . . . . . . . . . .9000-02-10
410D Backhoe Loader Lifting Capacities . . .9000-02-11
510D Backhoe Loader With Standard 2.1
M (6 Ft 11.7 In.) Dipperstick . . . . . . . . . .9000-02-17
510D Backhoe Loader Specifications . . . . .9000-02-19
510D Backhoe And Loader Buckets . . . . . .9000-02-20
510D Backhoe Loader Lifting Capacities . . .9000-02-21
Group 03Torque Values

Hardware Torque Specifications . . . . . . . . . .9000-03-1
TM1512 (07NOV03) 9000-1 Backhoe Loaders Operation and Test

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9000

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Group 01
Safety Information
9000
Handle Fluids SafelyAvoid Fires 01
1
When you work around fuel, do not smoke or work near

heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.
UN23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
TS227
spontaneously.
DX,FLAME 1929SEP981/1
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.
UN23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16C (60F).
TS204
DX,SPARKS 1903MAR931/1
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

UN23AUG88
hospital, and fire department near your telephone.

TS291
DX,FIRE2 1903MAR931/1
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Safety Information
9000
01 Prevent Acid Burns
2
Sulfuric acid in battery electrolyte is poisonous. It is strong

enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
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 1530 minutes. Get
medical attention immediately.
UN23AUG88
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not
TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.
DX,POISON 1921APR931/1

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Safety Information
9000
Handle Chemical Products Safely 01
3
Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
UN26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDSs on chemical

products used with John Deere equipment.)
DX,MSDS,NA 1903MAR931/1
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
UN23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
X9811
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID 1903MAR931/1

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Safety Information
9000
01 Park Machine Safely
4
Before working on the machine:
Lower all equipment to the ground.

Stop the engine and remove the key.
Disconnect the battery ground strap.
UN24MAY89
Hang a "DO NOT OPERATE" tag in operator station.
TS230
DX,PARK 1904JUN901/1
Support Machine Properly
Always lower the attachment or implement to the ground

before you work on the machine. If you must work on a
lifted machine or attachment, securely support the
machine or attachment. If left in a raised position,
hydraulically supported devices can settle or leak down.
UN23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
TS229
Follow recommended procedures in this manual.
When implements or attachments are used with a tractor,

always follow safety precautions listed in the implement
operators manual.
DX,LOWER 1917FEB991/1
Wear Protective Clothing
Wear close fitting clothing and safety equipment

appropriate to the job.
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
UN23AUG88
while operating machine.

TS206
DX,WEAR2 1903MAR931/1

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Safety Information
9000
Work in Clean Area 01
5
Before starting a job:
Clean work area and machine.

Make sure you have all necessary tools to do your job.
UN18OCT88
Have the right parts on hand.
Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN 1904JUN901/1
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
UN23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228
DX,LOOSE 1904JUN901/1
Work In Ventilated Area
Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
UN23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR 1917FEB991/1
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
UN23AUG88
TS223
DX,LIGHT 1904JUN901/1

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Safety Information
9000
01 Replace Safety Signs
6
Replace missing or damaged safety signs. See the

machine operators manual for correct safety sign
placement.
UN23AUG88
TS201
DX,SIGNS1 1904JUN901/1
Use Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe

injury or machine damage.
Follow recommended procedure for removal and

installation of components in the manual.
UN23AUG88
TS226
DX,LIFT 1904JUN901/1
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
UN23AUG88
Do all work outside or in a well ventilated area. Dispose of
paint and solvent properly.
Remove paint before welding or heating: TS220
If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
DX,PAINT 1903MAR931/1

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Safety Information
9000
Avoid Heating Near Pressurized Fluid Lines 01
7
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
UN15MAY90
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH 1903MAR931/1
Keep ROPS Installed Properly
Make certain all parts are reinstalled correctly if the

roll-over protective structure (ROPS) is loosened or
removed for any reason. Tighten mounting bolts to proper
torque.
UN23AUG88
The protection offered by ROPS will be impaired if ROPS
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting. A damaged ROPS should be
TS212
replaced, not reused.
DX,ROPS3 1903MAR931/1

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Safety Information
9000
01 Service Tires Safely
8
Explosive separation of a tire and rim parts can cause

serious injury or death.
Do not attempt to mount a tire unless you have the proper

equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate

the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension

hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, damaged

rims or missing lug bolts and nuts.
UN23AUG88
TS211
DX,RIM 1924AUG901/1
Avoid Harmful Asbestos Dust
Avoid breathing dust that may be generated when

handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers
UN23AUG88
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as TS220
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for

cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A
special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
Keep bystanders away from the area.
DX,DUST 1915MAR911/1

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Safety Information
9000
Practice Safe Maintenance 01
9
Understand service procedure before doing work. Keep

area clean and dry.
Never lubricate, service, or adjust machine while it is

moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be

raised for service work.
Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground

cable (-) before making adjustments on electrical systems
UN23AUG88
or welding on machine.
On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or
TS218
welding on machine.
DX,SERV 1917FEB991/1
Use Proper Tools
Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.
Use power tools only to loosen threaded parts and

fasteners.
UN08NOV89
For loosening and tightening hardware, use the correct

size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR 1917FEB991/1

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Safety Information
9000
01 Dispose of Waste Properly
10
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
UN26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can

damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN 1903MAR931/1
Live With Safety
Before returning machine to customer, make sure

machine is functioning properly, especially the safety
systems. Install all guards and shields.
1907OCT88
TS231
DX,LIVE 1925SEP921/1

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Group 02
General Specifications
9000
410D Backhoe Loader With Standard Dipperstick 02
1
UN15NOV90
T7412AL
Continued on next page TX,9000,DY609 1924JUL961/2

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9000
02 NOTE: Specifications and design subject to change machine with 17.5L-24 rear tires; 11L-15 front
2
without notice. Wherever applicable, tires; 1.0 cu. yd. (0.76 m 3 ) loader bucket; 24
specifications are in accordance with SAE in. (610 mm) backhoe bucket; ROPS/FOPS;
Standards. Except where otherwise noted, full fuel tank and 175 lb. (79 kg) operator.
these specifications are based on a standard
Key: Standard Dipperstick 1.22 m (4 ft) Extendible Dipperstick

Retracted Extended
ALoading height, truck loading position 3.61 m (11 ft 10 in.) 3.51 m (11 ft 6 in.) 4.24 m (13 ft 11 in.)
BReach from center of swing mast 5.61 m (18 ft 5 in.) 5.42 m (17 ft 9 in.) 6.53 m (21 ft 5 in.)
CReach from center of rear axle 6.76 m (22 ft 2 in.) 6.55 m (21 ft 6 in.) 7.67 m (25 ft 2 in.)
DDigging depth (SAE):
(1) 610 mm (2 ft.) flat bottom 4.65 m (15 ft 3 in.) 4.42 m (14 ft 6 in.) 5.61 m (18 ft 5 in.)
EMaximum digging depth 4.67 m (15 ft 4 in.) 4.46 m (14 ft 8 in.) 5.62 m (18 ft 5 in.)
FGround clearance, minimum 305 mm (12 in.) 305 mm (12 in.) 305 mm (12 in.)
GBucket rotation 160 and 180 160 and 180 160 and 180
HTransport height 3.49 m (11 ft 5 in.) 3.56 m (11 ft 8 in.) 3.56 m (11 ft 8 in.)
IOverall length, transport 6.99 m (23 ft 5 in.) 7.01 m (23 ft) 7.01 m (23 ft)
JStabilizer width-transport 2.34 m (7 ft 8 in.) 2.34 m (7 ft 8 in.) 2.34 m (7 ft 8 in.)
KStabilizer spread-operating 3 m (9 ft 10 in.) 3 m (9 ft 10 in.) 3 m (9 ft 10 in.)
LWidth over tires 2.15 m (7 ft 1 in.) 2.16 m (7 ft 1 in.) 2.16 m (7 ft 1 in.)
MWheelbase 2100 mm (83 in.)
NDig below groundbucket level 100 mm (4 in.) 100 mm (4 in.) 100 mm (4 in.)
ORollback at ground level 40 40 40
PDump clearance, bucket at 40 2.74 m (9 ft) 2.74 m (9 ft) 2.74 m (9 ft)
QMaximum height to bucket hinge pin 3.35 m (11 ft) 3.35 m (11 ft) 3.35 m (11 ft)
RMaximum bucket dump angle 45
SReach at full height, bucket at 40 711 mm (28 in.) 711 mm (28 in.) 711 mm (28 in.)
Backhoe Performance Ratings:
Digging force, bucket cylinder (power dig
position) 52 kN (11 700 lb) 52 kN (11 700 lb) 52 kN (11 700 lb)
Digging force, crowd cylinder 28 kN (6300 lb) 30.3 kN (6800 lb) 20.50 kN (4600 lb)
Swing arc 180 180 180
Operator control Two levers Right foot treadle Right foot treadle
Bucket positions 9 and 18 rollback 8 and 17 rollback 12 and 22 rollback
Stabilizer angle rearward 14.5 14.5 14.5
Lifting capacity, maximum boom @ 65 1980 kg (4400 lb) 2087 kg (4600 lb) 1310 kg (2900 lb)
Leveling angle 14 14 14
NOTE: Backhoe specifications are with 610 mm x 0.21 m3 (24 in. x 7.5 cu ft standard bucket. Loader specifications are with 1.5 m 3 (1.5 yd3 )
bucket.
TX,9000,DY609 1924JUL962/2

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9000
410D Heavy Lift Backhoe Loader 02
3
UN15NOV90
T7412AL

110703
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9000
4
without notice. Wherever applicable, tires; 0.76 m 3 (1.0 cu yd) loader bucket; 610
specifications are in accordance with SAE mm (24 in.) backhoe bucket; ROPS/FOPS; full
Standards. Except where otherwise noted, fuel tank and 79 kg (175 lb) operator.
Standard Dipperstick with

Key: Heavy Lift Package 1.52 m (5 ft) Extendible Dipperstick
Retracted Extended
ALoading height, truck loading position 3.76 m (12 ft 4 in.) 3.76 m (12 ft 4 in.) 4.65 m (15 ft 3 in.)
CReach from center of rear axle 7.01 m (23 ft) 7.01 m (23 ft) 8.43 m (27 ft 8 in.)
KStabilizer spread-operating 3.00 m (9 ft 10 in.) 3.00 m (9 ft 10 in.) 3 m (9 ft 10 in.)
MWheelbase 215 mm (85 in.) 215 mm (85 in.) 215 mm (85 in.)
NDig below groundbucket level 100 mm (4 in.) 100 mm (4 in.) 100 mm (4 in.)
ORollback at ground level 40 40 40
PDump clearance, bucket at 40 2.74 m (9 ft) 2.74 m (9 ft) 2.74 m (9 ft)
QMaximum height to bucket hinge pin 3.35 m (11 ft) 3.35 m (11 ft) 3.35 m (11 ft)
RMaximum bucket dump angle 45 45 45
SReach at full height, bucket at 40 711 mm (28 in.) 711 mm (28 in.) 711 mm (28 in.)
Backhoe Performance Ratings:
Digging force, bucket cylinder (power dig
position) 48.9 kN (11 000 lb) 58.9 kN (11 000 lb) 58.9 kN (11 000 lb)
Digging force, crowd cylinder 36 kN (8100 lb) 36 kN (8100 lb) 23.60 kN (5300 lb)
Swing arc 180 180 180
Lifting capacity, maximum boom @ 65 2925 kg (6500 lb) 2790 kg (6200 lb) 1530 kg 3400 lb (1530 kg)
Leveling angle 13 13 13
NOTE: Backhoe specifications are with 610 mm x 0.21 m 3 (24 in. x 7.5 cu ft) standard bucket. Loader specifications are with 1.5 m 3 (1.5 yd
3
) bucket
TX,9000,DY611 1924JUL962/2

110703
PN=20
9000
410D Backhoe Loader Specifications 02
5
Engine
John Deere 4045D
SAE
Rated power @ 2200 rpm net, 56 kW (75 hp)
gross, 60 kW (80 hp)
Rated power @ 2200 rpm with net, 63.5 kW (85 hp)
optional turbocharger gross, 67 kW (90 hp)
Cylinders 4
Displacement 4.52 L (276 cu in.)
Fuel consumption, typical 3.8 to 7.6 L/h (1.0 to 2.0 gal/hr)
Torque rise 25%
with optional turbocharger 25%
Maximum net torque 303 Nm (224 lb-ft)
with optional turbocharger 344 Nm (254 lb-ft)
Lubrication Pressure system w/full-flow filter
and cooler
Cooling Pressurized w/thermostat and
fixed bypass
Air cleaner Dual stage dry type with
secondary element and
precleaner
Electrical system 12-volt
Alternator 95 amps
Transmission:
John Deere 4-speed helical gear, synchronized collar shift
transmission with hydraulic reverser. Uses single stage, dual phase,
280 mm (11 in.) torque converter with 2:23:1 stall ratio.
Travel
Speeds: Gear Forward Reverse
km/h mph km/h mph
With 1 5.5 (3.4) 6.3 (3.9)
Standard
19.5L-24
rear and
11L-16
front tires
2 9.5 (5.9) 10.9 (6.8)
3 20.3 (12.6) 23.3 (14.5)
4 32.7 (19.7) 36.4 (22.6)

110703
PN=21
9000
02 Service Brakes:
6
Manual hydraulic, applied with separate pedals; hydraulically
equalized when both pedals are depressed. Wet disks and facings are
fully enclosed and self-adjusting.
Park Brake:
Independent system, spring applied, hydraulically released, and
controlled by an electric switch on the side console.
Steering: Hydrostatic Power

Non-powered axle curb turning radius
(brakes applied) 3.55 m (11 ft 8 in.)
(without brakes) 4.04 m (13 ft 3 in.)
Bucket clearance circle
Steering wheel turns
Stop to stop 2.2 to 2.9
(after 1Dec91) 3.1 to 3.7
Powered axle (MFWD) curb turning radius
Bucket clearance circle
Steering wheel turns
Stop to stop 2.6 to 2.7
TX,9000,DY612 1924JUL962/2

110703
PN=22
9000
410D Backhoe Specifications 02
7
Final Drives:
Heavy-duty inboard mounted planetary. Evenly distributes axle shock
loads over three oil cooled gears.
Axle ratings:
Static Dynamic SAEJ43
Front 25 300 kg 25 300 kg 8800 kg
(56 000 lb) (56 000 lb) (19 600 lb)
Rear 23 100 kg 30 800 kg 7200 kg
(51 000 lb) (68 000 lb) (15 960 lb)
Hydraulic System: Closed center

Pressure setting 19 000 kPa (2755 psi)
Pump radial piston
Flow @ 2200 rpm 133 L/min (35 gpm)
Filter, return oil 10 micron replaceable element
Tires:
Front standard axle 11L-16, 12PR, F3
14.5/75-16.1, 10PR, F3
Front MFWD axle 12-16.5, 8 PR, NHS
14-17.5, 8 PR, NHS
Rear standard axle 21L-24, 10PR, R4
19.5L-24, 10PR, R4
Rear MFWD axle 21L-24, 10PR R4
18.4-28, 12PR R4
19.5L-24, 10PR R4
Transporting:
Operating weight (SAE) 7075 kg (15,600 lb)
cab adds 227 kg (500 lb)
MFWD adds 125 kg (275 lb)
extendible dipperstick with 482 kg (1063 lb)
counterweights adds
optional front counterweights adds 113 kg (250 lb)
backhoe bucket coupler adds 91 kg (200 lb)

110703
PN=23
9000
02 Loader Bucket Cycle Times:
8
0.76 m 3 (w/1.0 cu. yd.) Standard
Bucket
Raising time to full height 4.5 sec.
Bucket dump time 1.0 sec.
Bucket lowering time (power 3.0 sec.
down)
Bucket breakout force 44.5 kN (10 000 lb)
Lifting capacity, full 3040 kg (6700 lb)
TX,9000,DY613 1924JUL962/2

110703
PN=24
9000
410D Backhoe Loader And Backhoe Buckets 02
9
Loader: Width Heaped
Capacity Weight
3
mm (in.) m (Cu Yd) kg (lb)
General purpose 2340 (92) 0.76 (1.0) 345 (760)
2340 (92) 1.00 (1.3) 361 (796)
Long lip multi-purpose 2270 (89) 0.96 (1.25) 340 (750)
2340 (92) 0.96 (1.25) 708 (1560)
Backhoe: Width Heaped

Capacity Weight
3
mm (in.) m (Cu. Ft.) kg lb
Standard 305 (12) 0.07 (2.5) 112 (247)
457 (18) 0.14 (5.1) 153 (338)
610 (24) 0.21 (7.5) 171 (378)
762 (30) 0.28 (10.0) 194 (428)
914 (36) 0.28 (10.0) 196 (432)
914 (36) 0.41 (14.5) 306 (674)
Heavy Duty 305 (12) 0.07 (2.5) 117 (258)
457 (18) 0.14 (5.1) 158 (348)
610 (24) 0.21 (7.5) 181 (400)
610 (24) 0.25 (8.8) 209 (460)
762 (30) 0.28 (10.0) 214 (472)
Extra heavy duty 457 (18) 0.14 (5.1) 164 (362)
610 (24) 0.21 (7.5) 192 (424)
762 (30) 0.28 (10.0) 215 (474)
TX,9000,DY614 1925JUL961/1

110703
PN=25
9000
02 410D And 510D Backhoe Loader Drain And
10
Refill Capacities
Metric U.S.
Engine coolant 16 L 17 qt
Engine oil (including filter) 8.5 L 9 qt
Torque converter and reverser 13 L 14 qt
Fuel tank 129 L 34 gal
Hydraulic reservoir:
410D (SN 796855 )
510D (SN 796891 ) 41.5 L 11 gal
Transaxle:
410D (SN 796854)
510D (SN 796890)
Without MFWD 23 L 24 qt
With MFWD 24 L 25 qt
410D (SN 796855801199)
510D (SN 796891801199)
410D, 510D (SN 801200 )
Front axle 6.5 L 7 qt
Front wheel planetary (MFWD) (per side) 1L 1 qt
TX,9000,DY615 1925JUL961/1

110703
PN=26
9000
410D Backhoe Loader Lifting Capacities 02
11
UN16DEC91
T7646AI
Lift Capacity, Backhoe With Standard Dipperstick Based On SAE J31. Rated Lift Capacities Are In Kg (lb). Lift
Capacities Are Hydraulically Limited.
ADipper Lift at 65 BSwing Pivot CBoom Lift
Lifting capacity ratings are made with bucket hinge pin, load. Angle between boom and ground is 65 .
loader bucket and stabilizers on firm, level ground Lift Machine is equipped with 610 mm (24 in.) standard
capacities are hydraulically limited. Lifting capacities bucket, standard or extendible dipperstick and
are 87 % of the maximum lift over any point on the standard equipment.
swing arc and do not exceed 75 percent of the tipping

110703
PN=27
9000
02
12
UN16DEC91
T7646AE
Lift Capacity, Backhoe With 1.22 M (4 Ft) Dipperstick, Retracted. Based On SAE J31. Rated Lift Capacities Are In
Kg (lb). Lift Capacities Are Hydraulically Limited.
NOTE: Loader bucket on ground significantly improves to the side. Lift capacity over the rear is not
side stability, therefore improving lift capacity affected.

110703
PN=28
9000
02
13
UN16DEC91
T7646AG
Lift Capacity, Backhoe With 1.22 M (4 Ft) Extendible Dipperstick, Extended Based On SAE J31. Rated Lift
Capacities Are In Kg (lb). Lift Capacities Are Hydraulically Limited.

110703
PN=29
9000
02
14
UN16DEC91
T7646AJ
Lift Capacity, Backhoe With Optional Heavy Lift Package. Based On SAE J31. Rated Lift Capacities Are In Kg (lb).
Lift Capacities Are Hydraulically Limited.

110703
PN=30
9000
02
15
UN16DEC91
T7646AF
Lift Capacity, Backhoe With 1.52 M (5 Ft) Extendible Dipperstick, Retracted Based On SAE J31. Rated Lift

110703
PN=31
9000
02
16
UN16DEC91
T7646AH
Lift Capacity, Backhoe With 1.52 M (5 Ft) Extendible Dipperstick, Extended Based On SAE J31. Rated Lift
TX,9000,DY616 1925JUL966/6

110703
PN=32
9000
510D Backhoe Loader With Standard 2.1 M (6 Ft 11.7 In.) Dipperstick 02
17
UN15NOV90
T7412AL

110703
PN=33
9000
18
without notice. Wherever applicable, tires; 1.15 m 3 (1.5 cu yd) loader bucket; 610
specifications are in accordance with SAE mm (24 in.) backhoe bucket; ROPS/FOPS; full
Standards. Except where otherwise noted, fuel tank and 79 kg (175 lb) operator.
Backhoea w/Standard
Key: Dipperstick 1.52 m (5 ft) Extendible Dipperstick
Retracted Extended
ALoading height, truck loading 3.96 m (13 ft) 3.76 m (12 ft 4 in.) 4.65 m (15 ft 3 in.)
position
CReach from center rear axle 23 ft 8 in. (7.21 m) 7.01 m (23 ft) 8.43 m (27 ft 8 in.)
(1) 2 ft. (610 mm) flat bottom 4.98 m (16 ft 4 in.) 4.78 m (15 ft 8 in.) 6.27 m (20 ft 7 in.)
(2) 8 ft. (2440 mm) flat bottom 4.67 m (15 ft 4 in.) 4.47 m (14 ft 8 in.) 6.05 m (19 ft 10 in.)
KStabilizer spread-operating 3.0 m (9 ft 10 in.) 3.0 m (9 ft 10 in.) 3.0 m (9 ft 10 in.)
MWheelbase 2.15 m (85 in.)
NDig below groundbucket level 100 mm (4 in.)
ORollback at ground level 40
PDump clearance, bucket at 40 2.67 m (8 ft 9 in.)
QMaximum height to bucket hinge pin 3.35 m (11 ft 0 in.)
RMaximum bucket dump angle 45
SReach at full height, bucket at 40 762 mm (30 in.)
Digging force, bucket cylinder (power 48.9 kN (11000 lb) 48.9 kN (11000 lb) 48.9 kN (11000 lb)
dig position)
Digging force, crowd cylinder 36.0 kN (7600 lb) 36.0 kN (8100 lb) 23.6 kN (5300 lb)
Swing arc 180 180 180
Lifting capacity, maximum boom @ 65 2700 kg (6000 lb) 2790 kg (6200 lb) 1530 kg (3400 lb)
a
Backhoe specifications are with 610 mm (24 in.) standard bucket. Loader specifications are with 1.15 m[sup3 ] (1.5 yd[sup3 ]) bucket.
TX,9000,DY618 1925JUL962/2

110703
PN=34
9000
510D Backhoe Loader Specifications 02
19
NOTE: (Specifications and design subject to change

without notice. Wherever applicable, specifications
are in accordance with SAE Standards.)
Power SAE
Net 67 kW (90 hp)
Engine:
John Deere 4045T and 4045D
Rated power @ 2200 rpm
naturally aspirated
Cylinders 4
Displacement 4.524 L (276 cu. in.)
Lubrication Pressure system w/full-flow filter
Cooling Pressurized w/thermostat and
fixed bypass
Fuel consumption, typical 6.0 to 9.8 L/h (1.6 to 2.6 gal/hr)
Torque rise at 1300 rpm
with turbocharger 25%
Air cleaner Dry
Electrical system 12-volt
Alternator 65 amps
Transmission:
John Deere 4-speed helical gear, synchronized collar shift
transmission with hydraulic reverser.
280 mm (11 in.)
Torque converter with 223:1 stall ratio
Travel
Speeds: Gear Forward Reverse
mph km/h mph km/h
With Standard 1 3.2 5.2 3.7 6.0
19.5L-24 rear
and 11L-16
front tires
2 5.5 8.8 6.4 10.3
3 11.7 18.8 13.6 21.9
4 19.0 30.5 22.2 35.7
With MFWD 1 3.3 5.3 3.8 6.1
and required
21L-24 rear
and
12.00-16.5
front tires
2 5.7 9.2 6.6 10.6
3 12.1 19.5 14.0 22.5
4 20.2 32.5 23.6 37.9
Final Drives:
Heavy-duty inboard mounted planetary. Evenly distributes axle shock
loads over three oil cooled gears.
TX,115,RR4105 1925MAR941/1
TM1512
Service(07NOV03)
Brakes: 9000-02-19 Backhoe Loaders Operation and Test
110703
Manual hydraulic, applied with separate pedals; hydraulically PN=35

equalized when both pedals are depressed. Wet disks and facings are
9000
02 510D Backhoe And Loader Buckets
20
Loader: Width Heaped
Capacity Weight
(cu (lb)
3
mm (in.) m yd) kg
General 2340 (92) 1.0 (1.3) 361 (796)
purpose
2340 (92) 1.15 (1.5) 490 (1080)
Long lip 2270 (89) 0.96 (1.25) 340 (750)
multi-purpose
2340 (92) 0.96 (1.25) 708 (1560)
Backhoe: Width Heaped

Capacity Weight
3
mm (in.) m (cu ft) kg (lb)
Standard 305 (12) 0.07 (2.5) 112 (247)
406 (16) 0.10 (3.6) 122 (270)
457 (18) 0.14 (5.1) 153 (338)
610 (24) 0.21 (7.5) 171 (378)
762 (30) 0.28 (10.0) 194 (428)
914 (36) 0.28 (10.0) 196 (432)
914 (36) 0.41 (14.5) 306 (674)
Heavy Duty 305 (12) 0.07 (2.5) 117 (258)
457 (18) 0.14 (5.1) 158 (348)
610 (24) 0.21 (7.5) 181 (400)
610 (24) 0.25 (8.8) 209 (460)
762 (30) 0.28 (10.0) 214 (472)
Extra heavy 457 (18) 0.14 (5.1) 164 (362)
duty
610 (24) 0.21 (7.5) 192 (424)
762 (30) 0.28 (10.0) 215 (474)
TX,115,RR,2079 1914MAY931/1

110703
PN=36
9000
510D Backhoe Loader Lifting Capacities 02
21
UN16DEC91
T7646AK
Lift Capacity, Backhoe With Standard 2.1 M (6 Ft 11.7 In.) Dipperstick Based On SAE J31. Rated Lift Capacities
Are In Kg (lb). Lift Capacities Are Hydraulically Applied.
ADipperstick Lift at 65 BSwing Pivot CBoom Lift
Lifting capacity ratings are made with bucket hinge pin, Angle between boom and ground is 65 degrees.
loader bucket and stabilizers on firm, level ground. Lift Machine is equipped with 610 mm (24 in.) standard
capacities are hydraulically limited. Lifting capacities 87 bucket, standard or extendible dipperstick and
% of the maximum lift over any point on the swing arc standard equipment.
and do not exceed 75 percent of the tipping load.
Continued on next page TX,115,RR,2081 1914MAY931/3

110703
PN=37
9000
02
22
UN16DEC91
T7646AF
Lift Capacity, Backhoe With Extendible Dipperstick, Retracted Based On SAE J31.
NOTE: Loader bucket on ground significantly improves to the side. Lift capacity over the rear is not
side stability, therefore improving lift capacity affected.
Continued on next page TX,115,RR,2081 1914MAY932/3

110703
PN=38
9000
02
23
UN16DEC91
T7646AH
Lift Capacity, Backhoe With Extendible Dipperstick, Extended Based On SAE J31.
TX,115,RR,2081 1914MAY933/3

110703
PN=39
9000
02
24

110703
PN=40
Group 03
Torque Values
9000
Hardware Torque Specifications 03
1
Check cap screws and nuts to be sure they are tight. If

hardware is loose, tighten to torque shown on the
following charts unless a special torque is specified.
TX,90,FF1225 1915MAR931/1
Checking Wheel Fastener Torque
Tighten wheel cap screws and fasteners.
410D/510D Wheel Fastener Torque ValuesSpecification

Front Standard AxleTorque ................ 136 20 -27 Nm (100 15 -20
lb-ft)
Front MFWD AxleTorque ....................... 300 110 -115 Nm (221 81
-29 lb-ft)
Rear AxleTorque .................................. 575 170 -115 Nm (425 125
-85 lb-ft)
TX,90,RR4055 1926JUL991/1
ROPS Torque Specifications
CAUTION: Make certain all parts are reinstalled

correctly if the roll-over protective structure
(ROPS) is loosened or removed for any reason.
Tighten mounting bolts to proper torque.
UN23AUG88
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or
TS176
is in any way altered. A damaged ROPS should
be replaced, not reused.
When installation of equipment on a machine necessitates

loosening or removing ROPS, mounting bolts must be
tightened to 400 64 Nm (295 47 lb-ft).
Item Measurement Specification
ROPS Mounting Bolts Torque 400 64 Nm (295 47 lb-ft)
CED,OUTX782,574 1926JUL991/1

110703
PN=41
Torque Values
9000
03 Unified Inch Bolt and Cap Screw Torque Values
2
1902APR97
TS1656
DX,TORQ1 1920JUL941/1

110703
PN=42
Torque Values
9000
Metric Bolt and Cap Screw Torque Values 03
3
1902APR97
TS1657
DX,TORQ2 1920JUL941/1

110703
PN=43
Torque Values
9000
03 Additional Metric Cap Screw Torque Values
4
UN18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
UN18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from
failing when tightening.
UN18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
Continued on next page 04T,90,M170 1901AUG941/2

110703
PN=44
Torque Values
9000
METRIC CAP SCREW TORQUE VALUESa 03
5
Nominal
Dia T-Bolt H-Bolt M-Bolt
Nm lb-ft Nm lb-ft Nm lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
Torque tolerance is 10%.
a
04T,90,M170 1901AUG942/2

110703
PN=45
Torque Values
9000
03 Service Recommendations for Metric Series Four Bolt Flange Fitting
6
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Thread b
Nm lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42
4. Single piece flange (D): Place hydraulic line in M12 95 70
center of flange and install four cap screws. Flange M14 157 116
must be centrally located on port. Hand tighten cap M16 217 160
screws to hold flange in place. Do not pinch O-ring. M18 334 246
M20 421 318
5. After components are properly positioned and cap a
Tolerance 10%. The torques given are enough for the given
screws are hand tightened, tighten one cap screw, size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
b
Metric standard thread.
04T,90,K175 1905JAN961/1

110703
PN=46
Torque Values
9000
Service Recommendations For Inch Series Four Bolt Flange Fittings 03
7
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches TORQUE CHART

cause leaks. Roughness causes seal wear. Nm lb-ft
Out-of-flat causes seal extrusion. If defects cannot Nominal Cap Screw
be polished out, replace component. Flange Size
Size Min Max Min Max
2. Install O-ring (and backup washer if required) into 1/2 5/16-18 20 31 15 23
groove using petroleum jelly to hold it in place. UNC
3/4 3/8-16 UNC 28 54 21 40
3. Split flange: Loosely assemble split flange (B) 1 3/8-16 UNC 37 54 27 40
halves. Make sure split is centrally located and 1-1/4 7/16-14 47 85 35 63
perpendicular to port. Hand tighten cap screws to UNC
hold parts in place. Do not pinch O-ring (C). 1-1/2 1/2-13 UNC 62 131 46 97
2 1/2-13 UNC 73 131 54 97
4. Single piece flange (D): Place hydraulic line in
center of flange and install cap screws. Flange 2-1/2 1/2-13 UNC 107 131 79 97
must be centrally located on port. Hand tighten cap 3 5/8-11 UNC 158 264 117 195
screws to hold flange in place. Do not pinch O-ring. 3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 5 5/8-11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
04T,90,K174 1901AUG941/1

110703
PN=47
Torque Values
9000
03 Check Oil Lines And Fittings
8
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
UN23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.
Tubing with dents may cause the oil to overheat. If you

find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified in torque

chart.
When you tighten connections, use two wrenches to

prevent bending or breaking tubing and fittings.
TX,90,DH1559 1901AUG941/1

110703
PN=48
Torque Values
9000
Service Recommendations for 37 Flare and 03
9
30 Cone Seat Connectors
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
UN18OCT88
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6234AC
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or petroleum

jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on torque

chart. Do not allow hoses to twist when tightening
fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size Nm lb-ft
3/8 - 24 UNF 8 6
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
1-5/16 - 12 UN 142 105
1-5/8 - 12 190 140
1-7/8 - 12 UN 217 160
NOTE: Torque tolerance is 10%.
T82,BHMA,EL 1919MAR961/1

110703
PN=49
Torque Values
9000
03 Service Recommendations for O-Ring Boss
10
Fittings
Straight Fitting
1. Inspect O-ring boss seat for dirt or defects.
UN18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
T6243AE
3. Tighten fitting to torque value shown on chart.
Continued on next page 04T,90,K66 1919MAR961/2

110703
PN=50
Torque Values
9000
Angle Fitting 03
11
1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.
2. Turn fitting into threaded boss until back-up washer
UN18OCT88
contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index

(maximum of one turn).
T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.
4. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size Nm lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
NOTE: Torque tolerance is 10%.
04T,90,K66 1919MAR962/2

110703
PN=51
Torque Values
9000
03 Service Recommendations for Flat Face
12
O-Ring Seal Fittings
1. Inspect the fitting sealing surfaces. They must be free

of dirt or defects.
UN18OCT88
2. Inspect the O-ring. It must be free of damage or
defects.
3. Lubricate O-rings and install into groove using
T6243AD
petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of petroleum

jelly so O-ring is not displaced during assembly.
5. Index angle fittings and tighten by hand pressing joint

together to insure O-ring remains in place.
6. Tighten fitting or nut to torque value shown on the

chart per dash size stamped on the fitting. Do not allow
hoses to twist when tightening fittings.
FLAT FACE O-RING SEAL FITTING TORQUE

Thread Size
Nominal Tube O.D. Dash Size in. Swivel Nut Bulkhead Nut
mm in. Nm lb-ft Nm lb-ft
6.35 0.250 -4 9/16-18 16 12 5.0 3.5
9.52 0.375 -6 11/16-16 24 18 9.0 6.5
12.70 0.500 -8 13/16-16 50 37 17.0 12.5
15.88 0.625 -10 1-14 69 51 17.0 12.5
19.05 0.750 -12 1 3/16-12 102 75 17.0 12.5
22.22 0.875 -14 1 3/16-12 102 75 17.0 12.5
25.40 1.000 -16 1 7/16-12 142 105 17.0 12.5
31.75 1.250 -20 1 11/16-12 190 140 17.0 12.5
38.10 1.500 -24 2-12 217 160 17.0 12.5
NOTE: Torque tolerance is +15 -20%.
04T,90,K67 1901AUG941/1

110703
PN=52
Group 04
Fuels And Lubricants
9000
Fuel Specifications 04
1
Use ONLY clean, high-quality fuel. For maximum filter life, sediment and water should not
be more than 0.10 percent.
Use Grade No. 2-D fuel above 4C (40F).
The cetane number should be 40 minimum. If you
Use Grade No. 1-D fuel below 4C (40F). operate your machine where air temperatures are
normally low or where altitudes are high, you may
Use Grade No. 1-D fuel for all air temperatures at need fuel with a higher cetane number.
altitudes above 1500 m (5000 ft).
Cloud PointFor cold weather operation, cloud point
IMPORTANT: Use fuel with less than 1.0 percent should be 6C (10F) below lowest normal air
sulfur. If possible, use fuel with less temperature.
than 0.5 percent sulfur.
If fuel sulfur content exceeds 0.5

percent, change the engine oil at 1/2
the normal interval.
TX,DH,54 1901AUG941/1
Low Sulfur Diesel Fuel Conditioner
When possible, use existing fuel formulations for engines

used off-highway. This fuel will not require any additives
to provide good performance and engine reliability.
However, many local fuel distributors will not carry both
low and regular sulfur diesel fuels.
If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere PREMIUM DIESEL FUEL
CONDITIONER. It provides lubricating properties along
with other useful benefits, such as cetane improver,
anti-oxidant, fuel stabilizer, corrosion inhibitor and others.
John Deere PREMIUM DIESEL FUEL CONDITIONER is
specifically for use with low sulfur fuels. Nearly all other
diesel fuel conditioners only improve cold weather flow
and stabilize long-term fuel storage. They do not contain
the lubrication additives needed by rotary fuel injection
pumps.
TX,45,DH3124 1920OCT931/1

110703
PN=53
9000
04 Storing Fuel
2
If there is a very slow turnover of fuel in the fuel tank or

supply tank, it may be necessary to add a fuel conditioner
to prevent water condensation. Contact your John Deere
dealer for proper service or maintenance
recommendations.
DX,FUEL 1903MAR931/1
Do Not Use Galvanized Containers
IMPORTANT: Diesel fuel stored in galvanized Store fuel in:

containers reacts with zinc coating
on the container to form zinc flakes. plastic containers.
If fuel contains water, a zinc gel will aluminum containers.
also form. The gel and flakes will specially coated steel containers made for diesel
quickly plug fuel filters and damage fuel.
fuel injectors and fuel pumps.
DO NOT USE brass-coated containers: brass is an
DO NOT USE a galvanized container to store diesel alloy of copper and zinc.
fuel.
MX,FLBT,C 1904JUN901/1
Fuel Tank
CAUTION: Handle fuel carefully. If the engine is

hot or running, DO NOT fill the fuel tank. DO
NOT smoke while you fill fuel tank or work on
fuel system.
To avoid condensation, fill the fuel tank at the end of each

days operation. Shut off engine before filling.
TX,45,DH1588 1924AUG941/1

110703
PN=54
9000
Engine Oil 04
3
1919JUN91
T7396BK
Depending upon the expected air temperature range API Service Class CE or CD (1)
between oil changes, use oil viscosity shown on the Military Spec MIL-L-2104D or MIL-L-2104C
temperature chart above.
Most oil containers or specifications list several API
Additives are not required nor recommended. Service Classes (such as SC, SG, CE, CC) met by the
oil. For the oil you use, either CE or CD must be
John Deere engine oil filters are highly recommended among the classes listed.
because they are of known high quality and
effectiveness. NOTE: Oils meeting API Service Classes CE or CD
are not always available in viscosity grades
John Deere PLUS-50 engine oil is recommended. It is SAE 5W20, SAE 5W30, and Arctic Oils. For
a specifically balanced formulation to provide superior these viscosity grades only, the following oil
protection against oil thickening, carbon deposits, specification may be used but the oil and filter
lacquer, and mechanical wear during high temperature change interval must be reduced to 125 hours.
operation.
API Service Class CC (MIL-L-46152B)
John Deere TORQ-GARD SUPREME engine oil is Military Spec MIL-L-46167A (arctic oil)
also recommended.
If other oils are used, the required specification is:
PLUS-50 is a registered trademark of Deere & Company

TORQ-GARD SUPREME is a registered trademark of Deere &
Company TX,45,DH1532 1901AUG941/1

110703
PN=55
9000
04 Transaxle Oil
4
1918OCT91
T6186AG
Depending on the expected air temperature range You may also use oils which meet minimum John
between oil changes, use oil viscosity shown on the Deere standards, or other oils meeting John Deere
chart above. Standard JDM J20A or J20C and J20B or J20D.
JOHN DEERE HY-GARD TRANSMISSION AND Oils meeting MIL-L46167A may be used as arctic oil.
HYDRAULIC OIL IS RECOMMENDED because it is
specifically formulated to minimize brake chatter, and
to provide maximum protection against mechanical
wear.
HY-GARD is a registered trademark of Deere & Company TX,45,DH2079 1927NOV911/1

110703
PN=56
9000
Hydraulic And Reverser Oil 04
5
1915NOV91
T6249AY
Depending on the expected air temperature range You may also use oils which meet minimum John
between oil changes, use oil viscosity shown on the Deere standards, or other oils meeting John Deere
chart above. Standard JDM J20A or J20C and J20B or J20D.
JOHN DEERE HY-GARD TRANSMISSION AND Oils meeting MIL-L46167A may be used as arctic oil.
HYDRAULIC OIL IS RECOMMENDED because it is
specifically formulated to minimize brake chatter, and
to provide maximum protection against mechanical
wear.
HY-GARD is a registered trademark of Deere & Company TX,45,DH2074 1927NOV911/1

110703
PN=57
9000
04 Mechanical Front Wheel Drive Oil
6
1905JAN89
T6247AB
Depending on the expected air temperature range John Deere API GL-5 Gear Oil
between oil changes, use oil viscosity shown on the Oils meeting API Service GL-5 (MIL-L-2105B or
chart above. MIL-2105C)
The following oils are recommended: Oil meeting MIl-L-10324A may be used as arctic oil.
T82,45,C11 1915MAR931/1

110703
PN=58
9000
Grease 04
7
1927JAN89
T6722AA
Depending on the expected air temperature range, use SAE Multipurpose Grease with Extreme Pressure
grease shown on chart above. (EP) performance and containing 3 to 5 per cent
molybdenum disulfide
Greases recommended are: SAE multi-purpose EP Grease
Grease meeting MIL-G-10924C specifications may
John Deere Moly High Temperature/EP Grease be used as arctic grease.
(Preferred)
02T,45,C49 1901AUG941/1
Grease For Extendible Dipperstick
SAE Multipurpose Grease with Extreme Pressure (EP)

performance and containing 3 to 5 per cent molybdenum
disulfide (preferred).
TX,45,DH1576 1921JAN921/1

110703
PN=59
9000
04 Alternative and Synthetic Lubricants
8
Conditions in certain geographical areas may require

lubricant recommendations different from those printed in
this manual.
Some John Deere brand coolants and lubricants may not

be available in your location.
Consult your John Deere dealer to obtain information and

recommendations.
Synthetic lubricants may be used if they meet the

performance requirements as shown in this manual.
The temperature limits and service intervals shown in this

manual apply to both conventional and synthetic oils.
Rerefined base stock products may be used if the

finished lubricant meets the performance requirements.
DX,ALTER 1918MAR961/1
Lubricant Storage
Your equipment can operate at top efficiency only Make certain that all containers are properly marked to
when clean lubricants are used. identify their contents.
Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
DX,LUBST 1918MAR961/1

110703
PN=60
9000
Mixing of Lubricants 04
9
In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet information and recommendations.
certain specifications and performance requirements.
Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricant
performance.
DX,LUBMIX 1918MAR961/1
Engine Coolant
John Deere Low Silicate Antifreeze is recommended. Check container label or consult with antifreeze
supplier before using.
Also recommended is low silicate antifreeze formulated
to GM6038M or equivalent. Mix 50-67 percent low silicate antifreeze with 33-50
percent distilled or deionized water.
Other antifreezes that may be used:
Low silicate antifreeze provides:
Ethylene-glycol type.
Those containing not more than 0.1 percent Adequate heat transfer.
anhydrous metasilicate. Corrosion-resistant environment within the cooling
Those meeting General Motors Performance system.
Specification GM1899M Compatibility with cooling system hose and seal
material.
IMPORTANT: Some types of ethylene-glycol Protection during cold and hot weather operations.
antifreeze are intended for
automotive use. These products are Certain geographical areas may require special
often labeled for use in aluminum antifreeze or coolant practices. If you have any
engines and usually contain more questions, consult your authorized servicing dealer to
than 0.1 percent of anhydrous obtain the latest information and recommendations.
metasilicate.
DX,COOL 1904JUN901/1

110703
PN=61
9000
04
10

110703
PN=62
Section 9005
Operational Checkout Procedure
Contents 9005
Page
Group 10Operational Checkout Procedure

Operational Checkout Procedure. . . . . . . . . .9005-10-1
Gauge And Indicator Check With Engine
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-1
FNR And Neutral Start Switches, Start
Circuit And Reverse Warning Alarm
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2
Park Brake, Charge Indicator Light,
Tachometer/Hourmeter Circuit And
Engine Speed Control Linkage Checks . . .9005-10-3
Brake System Checks . . . . . . . . . . . . . . . . . .9005-10-5
Steering System Checks . . . . . . . . . . . . . . . .9005-10-7
Reverser Clutch Disconnect Solenoid
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-7
Driving Checks . . . . . . . . . . . . . . . . . . . . . . .9005-10-8
Mechanical Front Wheel Drive (MFWD)
Driving Check . . . . . . . . . . . . . . . . . . . . .9005-10-10
Hydraulic System Checks . . . . . . . . . . . . . .9005-10-12
Check Operation Of Accessories (Engine
Stopped) . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-18
Cab Component Checks . . . . . . . . . . . . . . .9005-10-20
Miscellaneous Checks. . . . . . . . . . . . . . . . .9005-10-24

110703
PN=1
Contents
9005

110703
PN=2
Group 10
Use this procedure to check all systems and functions Operational Checkout Record Sheet and record the
on the machine. results of each check on this sheet.
9005
This checkout procedure is designed so technician can At the end of each check if no problem is found (OK:), 10
make a quick check of the operation of machine while you will instructed to GO TO NEXT CHECK. If problem 1
sitting in operators seat. (NOT OK:) is indicated, you will be given repair
required or CTM number. If verification is needed, you
A location will be required which is level, has adequate will be given next best source of information after GO
space to complete the driving checks and to work TO:
machine. The engine, power train and hydraulic oil
must be at operating temperature. Group 10 (System Operational Checks)
Complete the necessary visual checks (oil levels, oil Group 15 (System Diagnostic Checks)
condition, external leaks, loose hardware, loose
linkage) prior to doing the checkout procedure. Group 20 (Adjustments)
No special tools or gauges are needed. Always start in Group 25 (Test)

the left column and read completely, follow this
sequence from left to right. Read each check CTM (Component Technical Manual)
completely before performing. Make a copy of the
TX,D300,DS1984 1906APR951/1
Gauge And Indicator Check With Engine Off
1/1
1 Monitor Indicator Turn key switch to BULB CHECK position and hold. OK: Go to next check .
Lights And Alarm
Check LOOK: All six monitor indicator lights and CAUTION light NOT OK: Check monitor
must be on. STOP light must flash and alarm must fuse.
"beep".
NOT OK: Go to Group
LISTEN: Starting motor must NOT operate. 9015-15, Gauges and
Monitor Checks, Display
T7394BH UN10DEC90
Monitor Check .
NOT OK: If motor starts

and bulb check position is
OK, key switch is failed or
there is a short in wiring.
Go to Group 9015-15,
Key Switch Test .
1/1

110703
PN=65
FNR And Neutral Start Switches, Start Circuit And Reverse Warning Alarm Checks
9005 1/1
10
2
1 FNR Switch Check OK: Go to next check .
NOT OK: If no "click",

inspect neutral start fuse.
NOT OK: Go to Group

9015-15, Start Circuit
Diagnostic Procedures .
T7447AG UN04JAN91 T7447AI UN04JAN91 T7447AH UN04JAN91
Engine off.
Put FNR lever in neutral.
Turn key switch to ON position.
Move FNR lever to forward (F), reverse (R), then neutral (N) position.
Observe and feel forward, neutral and reverse detents.
LOOK: FNR lever must align with neutral position in quadrant when reverser valve is in
neutral detent position.
LISTEN: You must hear relay "click" as FNR lever is moved EQUAL distance from
neutral to forward position and from neutral to reverse position.
FEEL: You must feel detent engagement in each position of FNR lever.
1/1
2 Start Circuit Check Move FNR lever to neutral (N) position and turn key OK: Go to next check .
switch to START position.
NOT OK: If engine turns
Observe and listen to monitor as engine is cranking. but does not start, check
fuel shut-off/start
LISTEN: Starting motor must operate. aid/reverse alarm fuse
LISTEN: Alarm must sound. NOT OK: If starting motor

T7394BH UN10DEC90
does not operate check
LOOK: During engine cranking, all six indicator lights start fuse.
must be on, CAUTION must light and STOP must flash.
NOT OK: Go to Group
9015-15, Start Circuit .
1/1

110703
PN=66
3 Reverse Warning Operate engine at slow idle. OK: Go to next check .

Alarm Check (S.N.
794639) Put FNR lever in neutral (N). NOT OK: Increase
engine speed to fast idle.
Turn park brake switch to OFF position. If alarm now sounds, low
reverser clutch pressure
9005
Move FNR lever to reverse (R) position. is indicated. Go to Group
10
9020-10, Reverser
3
T7447AH UN04JAN91
LISTEN: Reverse warning alarm must sound. System Check .
NOT OK: Check wiring

connector at alarm. Go to
Group 9015-15, Reverse
Alarm Circuit .
1/1
4 Reverse Warning Key switch ON. OK: Go to next check .

Alarm Check
(S.N.794640 ) Move FNR lever to reverse (R) position. NOT OK: See Reverse
Alarm Circuit . Go to
LISTEN: Reverse warning alarm must sound. Group 9015-15.
T7447AH UN04JAN91
1/1
Park Brake, Charge Indicator Light, Tachometer/Hourmeter Circuit And Engine Speed Control Linkage
Checks
1/1

110703
PN=67
1 Park Brake Indicator OK: Go to next check .

Check
NOT OK: If engine low oil
pressure indicator light
stays ON, STOP ENGINE
IMMEDIATELY and check
9005
oil level. Go to Group
10
9010-15, Engine Low Oil
4
Pressure .
T7447AG UN04JAN91 T7394BH UN10DEC90
IMPORTANT: If engine oil pressure indicator light stays ON, STOP ENGINE NOT OK: If alternator
IMMEDIATELY, check oil level. indicator light is on,
increase engine speed to
Engage park brake. 1200 rpm and alternator
light MUST go out. Go to
Put FNR lever in neutral (N) and start the engine. Group 9015-15, Charge
Circuit Checks .
Put FNR lever in forward (F) position.
NOT OK: If no park brake
light, inspect wiring
LOOK: STOP indicator must stay ON and flashing. Alarm must "beep". Park brake light
must be ON. All other lights must go out. connector at switch on
park brake linkage. See
Park Brake/Clutch
Disconnect Circuit
Diagnostic in Group
9015-15, .
1/1
2 Tachometer/Hourmeter IMPORTANT: If engine low oil pressure indicator OK: Go to next check .
Circuit Check light stays ON, STOP ENGINE IMMEDIATELY and
check oil level. NOT OK: If park brake
indicator light stays ON,
Engage park brake. adjust park brake switch
on park brake linkage
Put FNR lever in neutral and start the engine. until light goes out. See
Park Brake/Clutch
T7447AH UN04JAN91
Put FNR lever in forward (F) position. Disconnect Circuit
Diagnostic in Group
LOOK: STOP indicator must stay ON and flashing. 9015-15.
Alarm must "beep". Park brake light must be ON. All
other lights must go out. NOT OK: If no hour
meter or tachometer
LOOK: Hourmeter indicator must be rotating. movement, go to Group
9015-15, Gauge and
LOOK: Tachometer (if equipped) must indicate rpm. Hour Meter Circuit .
Release park brake.
Park brake indicator light and STOP light must go out.

Alarm must stop "beeping".
1/1

110703
PN=68
3 Engine Speed Control Engage park brake. OK: Go to next check .

Lever Linkage Check
Put FNR lever in neutral (N) position. NOT OK: Tighten friction
lock. See Adjust Speed
Note rpm on tachometer (if equipped). Control Lever Tension .
Go to Group 9010-20.
9005
Move speed control lever to fast idle position.
10
NOT OK: Check engine
5
T7989AP UN19APR93
LOOK: Tachometer must read 850 50 rpm (slow idle) speed . Go to Group
or 2375 50 rpm (fast idle). 9010-20.
LOOK: Speed control lever must remain at selected

position.
1/1
4 Engine Speed Control Depress speed control pedal OK: Go to next check .
Pedal Linkage Check
LISTEN: Engine speed must be the same as with speed NOT OK: Adjust Speed
control lever in fast idle position. Control Linkage Override
. Go to Group 9010-20.
T7394BF UN06JAN92
1/1
5 Start Aid Check (If Operate engine at slow idle. OK: Go to next check .
Equipped)
Push start aid button once. NOT OK: Check can
contents by shaking.
LISTEN: Engine speed must increase then return to slow idle.
NOT OK: Check fuse. Go
to Group 9015Start Aid
Check .
1/1
Brake System Checks
1/1

110703
PN=69
1 Pedal Stop Check Lift left and right brake pedals. OK: Go to next check .
LOOK: Brake pedals must be against pedal stop screws. NOT OK: Adjust brake
pedal stops . Go to
NOTE: This ensures that brake check valves are opened Group 9020-20.
and brakes released.
9005
10
6
T7394BG UN17JAN92
1/1
2 Brake System Depress and hold left brake pedal, then right brake pedal OK: Go to next check .
Leakage Check using approximately 267 N (60 lb force).
NOT OK: Bleed brake
LOOK: Brake pedal must NOT feel spongy (caused by system . Go to Group
air in system) or settle more than 25 mm (1.0 in.) per 9020-20.
minute.
NOT OK: Check light
LOOK: Rear brake light must come ON when either fuse.
pedal is depressed with key switch in ON position.
T7367AM UN17JAN92
OK: Check wiring. Go to
Group 9015-15, Lighting
Circuit Checks .
1/1
3 Park Brake Capacity Engage park brake. OK: Go to next check .

Check
Put stabilizers in up position. NOT OK: Adjust park
brake linkage . Go to
Put backhoe in transport position. Group 9020-20.
Use loader functions to pull machine forward or push machine backward.
LOOK: Rear wheels should not turn. If loader can pull or push machine, rear tires
should drag.
LOOK: Park brake switch light will be ON.
1/1
4 Brake Drag Check Position machine on a gradual grade with front of OK: Go to next check .
machine downhill.
NOT OK: Brakes
Lift bucket so it clears ground. dragging. Go to Group
9020-10, Brake Drag
Shift FNR lever to neutral, differential lock pedal up, Check .
disengage park brake and release service brakes.
T6171AL UN09DEC88
LOOK: Machine must move or coast.
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

110703
PN=70
Steering System Checks
1/1 9005
10
7
1 Steering System Operate engine at approximately 1000 rpm. OK: Go to next check .
Checks
Turn steering wheel from full left to full right several times. NOT OK: Go to Group
9025-15, Poor Centering
LOOK: Front wheels must move smoothly in both directions. of Steering Wheel .
LOOK: When steering wheel is stopped, the front wheels must 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
2 Steering System NOTE: Hydraulic oil must be at operating temperature. OK: Go to next check .
Leakage Check
Run engine at slow idle. Turn steering wheel until wheels are in maximum right turn NOT OK: If steering
position. Continue turning steering wheel, using approximately 11.3 Nm (100 lb-in) wheel turns more than 5
force while counting steering wheel rpm. rpm, verify whether valve
or cylinder is leaking. Go
Repeat leakage check turning steering wheel to the left. to Group 9025-25,
Steering System Leakage
LOOK: Steering wheel must not turn more than 5 rpm to the left or right. Use good Test .
judgement, excessive steering wheel rpm does not mean steering will be affected.
1/1
3 Steering Priority Operate engine at slow idle. OK: Go to next check .

Valve Check
Turn steering wheel to stop left and right. Note effort required to turn wheel. NOT OK: Steers hard
and no decrease in
Turn wheel to stop and apply constant pressure. engine rpm. Go to Group
9025-25, Steering Priority
LOOK/FEEL: Wheels must stop at both axle stops and require normal steering wheel Valve Test .
effort.
LOOK/LISTEN: Tachometer (if equipped) must decrease 2550 rpm or hear decrease
in engine rpm when steering wheel is held against stop.
1/1
Reverser Clutch Disconnect Solenoid Check
1/1

110703
PN=71
1 Clutch Disconnect OK: Go to next check .

Circuit Check CAUTION: Machine should try to move forward as FNR lever is moved.
NOT OK: Check fuse.
Start engine, set idle speed at approximately 1500 rpm.
OK: Go to Group
Put transaxle in fourth gear. 9015-15, Park
9005
Brake/Clutch Disconnect
10 Release park brake. Circuit Diagnostic .
8
Shift FNR lever to forward (F) position.
Actuate clutch disconnect on gear shift lever or loader control lever individually and
note sound of engine.
LISTEN: When FNR lever is shifted to forward (F) position, a noticeable drop in engine
speed should be heard.
LISTEN: Engine rpm must increase when the reverser clutch disconnect solenoid
switches are activated.
1/1
Driving Checks
1/1
1 Transaxle Shift IMPORTANT: Use clutch disconnect when shifting OK: Go to next check .
Linkage Synchronizer gears.
And Noise Check NOT OK: Go to Group
Run engine at approximately 1500 rpm with FNR lever in 9020-15, Excessive Gear
forward (F) position. Noise When Shifting
Gears .
Shift transaxle into each gear and drive for a short
distance.
T7447AG UN04JAN91
LISTEN: Excessive gear or FNR lever noise must NOT
be heard in any gear. All gears are synchronized.
1/1
2 Differential Lock And Shift transaxle to first gear. OK: Go to next check .
Linkage Check
Move FNR lever to forward (F) position and operate NOT OK: Go to Group
engine at approximately 1500 rpm. 9020-15, No Differential
Lock Operation .
Depress differential lock pedal.
Turn steering wheel slightly right or left.

T7447AG UN04JAN91
Release differential lock pedal.
LOOK: Machine must try to go straight forward and

pedal must return to UP position when traction is equal.
1/1

110703
PN=72
3 Differential Gear And NOTE: Hold the wheel which is being braked stationary during this test or brake OK: Go to next check .
Pinion Check chatter could be confused with differential gear noise.
NOT OK: Go to Group
Shift transaxle to first gear and operate engine at approximately 1500 rpm. 9020-10, Differential and
Pinion Gear Check .
Move FNR lever to forward (F) position.
9005
10
Steer machine in a maximum left turn and depress left brake pedal to stop the left
9
wheel.
Steer machine in a maximum right turn and depress right brake pedal to stop the right
wheel.
LISTEN: NO excessive gear noise must be heard in the differential or pinion gear area.
1/1
4 Front Wheel Drive machine in fourth gear forward on a surface with OK: Go to next check .
Alignment (Toe-In) loose material.
Check NOT OK: If material is
LOOK: Material behind front wheels must not be thrown thrown, excessive tire
excessively inward or outward. wear will result. Go to
Group 9020-20, Adjust
Toe-In .
T6264AI UN22OCT91
1/1
5 Engine And Torque Position machine with loader bucket at ground level OK: Go to next check .
Converter Check against dirt bank or immovable object.
NOT OK: If the wheels
Shift transaxle into first gear. can be easily stalled, go
to Group 9020-15, Power
Move FNR lever to forward (F) position. TrainMachine Lacks
Power or Moves Slow .
Engage differential lock.
T6171AM UN09DEC88
Increase engine speed to fast idle.
LOOK: Rear wheels must NOT stall.
NOTE: This test will give a general indication of engine

reverser and torque converter performance.
1/1

110703
PN=73
6 Reverser Hydraulic Run engine at approximately 1500 rpm. OK: Go to next check .
System Check
Shift transaxle into third gear. NOT OK: If shifts are
slow, go to Group
Move FNR lever to forward (F) position. 9020-25, Reverser
Element Leakage Test
9005
Make several shifts from third forward to third reverse. Start counting the number of Using Element Pressure
10
seconds when FNR lever is moved to opposite direction. (Three-Gauge Method) .
10
LOOK: A normal shift from forward to reverse or reverse to forward must be completed
in three seconds. The machine must be up to speed in four seconds.
NOTE: Excessive internal leakage is indicated if reverse warning alarm (if equipped)
does not sound at slow idle, but sounds when rpm is increased.
1/1
Mechanical Front Wheel Drive (MFWD) Driving Check
1/1
1 MFWD Switch Check OK: Go to next check .
NOT OK: Check electrical

circuit. Go Group
9015-15, MFWD circuit
T7860AA9 UN13NOV92
Drive machine at transport speed.
Push switch (A) and engage MFWD.
LOOK: Light in MFWD switch must be ON, and all four wheels must be engaged.
Push switch (A) and disengage MFWD.
LOOK: Light in MFWD switch must be 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 could remain on for several seconds until
load on drive train is released.
1/1

110703
PN=74
2 MFWD Limited-Slip Lift machine off ground with stabilizers and loader bucket. OK: Check complete.
Differential And
Control Valve Check Apply brakes and engage MFWD. NOT OK: If both wheels
stall, check MFWD valve
Put FNR lever in forward and transaxle in first gear. pressure test . Go to
Group 9025-25.
9005
Run engine at approximately 1200 rpm.
10
NOT OK: If only one
11
Lower front wheels until tire scuffing is observed on both tires. wheel spins, turn wheel to
axle stop and see if
LOOK: Both wheels must turn and MFWD indicator light must be ON. constant velocity U-joint is
turning. If U-joint is
Turn MFWD switch OFF. turning, check wheel
outboard planetary. If
NOTE: If MFWD is turned OFF while operating, indicator light and MFWD could remain U-joint does not turn
on until load on drive train is released. Shifting to opposite direction should release inspect axle and
load on drive train. limited-slip in MFWD
differential.
LOOK: Both wheels must stop when MFWD switch is OFF.
LOOK: MFWD indicator light must be OFF.
NOTE: If tire scuffing is seen with MFWD engaged, limited-slip differential is working
and power is being transmitted to MFWD.
1/1
3 Engine And Torque With loader bucket level and cutting edge at the OK: Go to next check .
Converter Check centerline of front wheels, put machine against a dirt
bank or immovable object. NOT OK: If all wheels
stop, a torque converter
Engage MFWD and differential lock. problem is indicated. If
the front wheels stop,
Shift transaxle to first forward. MFWD problem is
indicated. Go to Group
T6171AN UN09DEC88
Increase engine speed to fast idle 9020-15, Machine Lacks
Power or Moves Slow .
LOOK: All four wheels must turn.
1/1

110703
PN=75
4 MFWD Gear And Drive machine at transport speed with MFWD engaged, then disengaged. OK: Go to next check .
Pinion Check
LISTEN: MFWD must NOT whine. NOT OK: If MFWD
whines, check oil levels
and fill to correct levels.
9005
OK: Check backlash. See
10
procedure under
12
Assemble Differential in
repair manual.
See Assemble
DifferentialAPL-745Axle
Assemble Differential
HousingAPL-2035Axle
410D-(SN
796854)510D-(SN
796890)
410D-(SN 796855)
510D-(SN 796891 )
1/1
Hydraulic System Checks
1/1

110703
PN=76
1 Hydraulic Pump OK: Go to next check .

Performance Check
NOT OK: Replace
hydraulic filter and check
for types of
contamination. Rerun this
9005
check .
10
13
NOT OK: Cycle times still
T6295AH UN19OCT88
slow. Go to Group
NOTE: If hydraulic oil is not at operating temperature, heat hydraulic oil until loader 9025-25-Backhoe Relief
and backhoe feel warm to touch using following procedure: Valve Test .
Put backhoe in transport position and engage boom and swing lock.
Activate boom down function and run engine at 2000 rpm.
NOTE: If activating boom down does not load engine, boom down relief valve is set
too high or hydraulic pump stand-by pressure is too low.
Operate all functions periodically to distribute heated oil to all cylinders.
Put backhoe at maximum reach with bucket fully dumped at ground level.
Run engine at 2000 rpm.
Measure cycle time by simulating loading the bucket, retracting the dipperstick and
raising the boom to the boom cylinder cushion. Do not time boom cylinder through
cushion.
LOOK: The maximum cycle time is as follows:
410D - 9 seconds
510D - 12 seconds
NOTE: Take the average cycle time for at least 3 complete cycles. This average cycle
time will give a general indication of hydraulic pump performance.
1/1

110703
PN=77
2 Hydraulic System OK: Go to next check .

Charge And Return
Check NOT OK: Check for
plugged hydraulic oil filter.
IF OK: Test charge

9005
system. Go to Group
10
9025-25 Charge Pump
14
Pressure Test .
T6295AJ UN17APR89
Raise unit with stabilizers until tires are 150 mm ( 6 in.) off ground.
Fully extend dipperstick, put bucket in loaded position and lower boom until dipperstick
is horizontal to ground.
Slowly retract dipperstick to insure that bucket clears ground.
Fully extend dipperstick.
Retract dipperstick while holding control valve fully open.
LOOK: Dipperstick can slow down, but must NOT stop moving during test.
1/1
3 Hydraulic Control Raise loader until bucket is 1 m (3 ft.) off the ground with the bucket level. OK: Go to next check .
Valve Lift Check Test
Position backhoe at maximum reach with bottom of bucket level with ground, 1 m (3 NOT OK: If a function
ft.) off the ground. cylinder moves, problem
could be a leak in
Stop the engine. cylinder of lift check. Go
to next check .
Activate each function one at a time:
IF OK: Inspect and repair
Loader boom raise lift check. See Remove
Loader bucket rollback And Install Gresen
Backhoe boom up Backhoe Valve Lift Check
Dipperstick extend Valves(SN 796033) .
Backhoe bucket dump
LOOK: These functions must NOT move when the control lever is activated.
1/1

110703
PN=78
4 Backhoe Circuit Put backhoe in transport position and engage boom lock. OK: Continue on.
Leakage Check
Retract extendible dipperstick (if equipped). NOT OK: If boom down
does not decrease engine
Raise stabilizers to full up position. rpm, check main pump
stand-by pressure . Go to
9005
Run engine at slow idle. Group 9025-25.
10
15
T6295AD UN19OCT88
Fully activate functions, one at a time: On machines equipped
with GRESEN valve
Boom up pressure seal passages
Bucket up are used in boom valve
Dipperstick retract and leakage return
Extendible dipperstick retract (if equipped). passages are used in
swing valve. When boom
LISTEN: When these functions are activated, NO down or swing functions
decrease in engine rpm must be noted. are bottomed and control
valves "metered", rpm will
Fully activate functions, one at a time: decrease and leakage
within circuit will be
Boom down apparent. This is normal.
Swing left then right
Stabilizer up left then right. On machines equipped
with HUSCO valve a very
LISTEN: Boom down must cause rpm to decrease since small decrease in engine
relief valve setting is below standby pressure. RPM may be observed
when a function is
LISTEN: Swing left and right may cause rpm to decrease bottomed or metered. The
slightly because relief valve setting is close to standby valve spool center
pressure. sections are undercut to
allow for some return
LISTEN: Stabilizer circuit can cause rpm to decrease leakage. This minimizes
slightly because of normal valve leakage. power drift at the
cylinders.
NOT OK: Go to next step

in this check.
Lower stabilizer to maximum down position, extend OK: Go to next check .

dipperstick to maximum reach, extend extendible
dipperstick (if equipped) and put bucket in dump position NOT OK: If rpm
1 m (3 ft) off ground. decreases with a function
bottomed and control
Fully activate functions, one at a time: Extend dipperstick lever fully open, a leak is
Extend extendible dipperstick (if equipped) Bucket dump indicated in the circuit.
T6295AF UN17APR89
Fully activate functions, one at a time: Stabilizer down NOT OK: If rpm
left Stabilizer down right increases when a function
is bottomed and control
LISTEN: When these functions are activated, NO valve is fully open, a
decrease in engine rpm must be noted. neutral leak indicated.
NOT OK: An rpm

decrease with a function
bottomed in both
directions is normally
cylinder leakage. An rpm
decrease in one direction
is normally circuit relief
valve leakage. Go to
Group 9025-25-Hydraulic
Component Leakage Test
.
1/1

110703
PN=79
5 Loader Circuit Raise loader to full height and put bucket in dump OK: Check complete.
Leakage Check position.
NOT OK: If rpm
Run engine at slow idle. decreases with a function
Fully activate functions, one at a time: lever fully open, a leak is
9005
indicated in the circuit.
10
Loader boom up
16
T6295AG UN17APR89
Bucket dump NOT OK: If rpm
increases when a function
Put bucket in rollback position and lower loader to full is bottomed and control
down position. valve is fully open, a
neutral leak indicated.
Fully activate functions, one at a time:
NOT OK: A rpm
Loader boom down decrease with a function
Bucket rollback bottomed in both
LISTEN: When functions are activated, engine rpm must cylinder leakage. A rpm
NOT decrease. decrease in one direction
NOTE: Leakage return passages are used in GRESEN valve leakage. Go to
boom valve. When boom cylinders are retracted and Group 9025-25, Hydraulic
valve is "metered", rpm will decrease and leakage within Component Leakage Test
circuit will be apparent. This is normal. .
On machines equipped with HUSCO valve a very small

decrease in engine RPM may be observed when a
function is bottomed or metered. The valve spool center
sections are undercut to allow for some return leakage.
This minimizes power drift at the cylinders.
1/1
6 Cylinder Cushion Run engine at slow idle. OK: Go to next check .

Checks
Lower stabilizers to ground. NOT OK: Remove and
repair cylinder cushion.
Lower backhoe boom 45 outward.
Activate the following functions:
Backhoe swing left and right

Backhoe boom raise
Dipperstick retract
Note sound and speed as cylinders near the end of their stroke.
LOOK: Speed of cylinder rod must decrease near the end of its stroke.
LISTEN: Must hear oil flowing through orifice as cylinder rod near the end of its stroke.
1/1

110703
PN=80
7 Backhoe And Loader FEEL: Backhoe cylinders. Cylinders must be warm to OK: Go to next check .
Function Drift Check touch 3852C (100125F). If cylinders are not warm,
heat hydraulic oil to specification. (See Group 9025-25.) NOT OK: Use good
judgment in determining if
Raise machine off ground with stabilizers. the amount of drift is
objectionable for the type
9005
Put backhoe bucket at a 45 angle to ground. Lower of operation the unit is
10
boom until bucket cutting edge is 75 mm (3 in.) off performing.
17
T7374CI UN04OCT90
ground.
NOT OK: Isolate which
Position loader bucket at same angle and distance off function is leaking. Go to
ground as backhoe bucket. Group 9025-25Cylinder
Drift Test .
Run engine at slow idle and observe buckets cutting
edges.
LOOK: If bucket cutting edges touch the ground within 1

minute, leakage is indicated in the bucket or boom
cylinders or control valves.
1/1
8 Loader Boom Float Put loader at maximum height position with bucket OK: Go to next step in
And Return-To-Dig dumped. this check.
Check
Run engine at approximately 2000 rpm. NOT OK: If lever jumps
out of detent, inspect
Move the loader control lever forward into boom float detent spring and balls.
detent position, and at the same time into bucket
rollback detent position. Remove hand from control lever.
T7440BS UN03JAN91
LOOK: Loader control lever must remain in the boom
float detent position.
LOOK: Loader control lever must disengage from the OK: Go to next step in
bucket rollback detent when the bucket is level. this check.
NOT OK: With bucket

rolled back, compress
switch roller. If a click is
heard, adjust switch till it
is activated on cam. Go
T6171AT UN09DEC88
to Group 9025-15.
LOOK: When the bucket is at ground level, bucket must OK: Go to next check .
be level and the bucket indicator pointer must be aligned
with mark on the boom pivot. NOT OK: Adjust linkage
as necessary. Go to
NOTE: When return-to-dig is used with loader boom in Group 9025-20 Loader
full up position, the bucket leveling linkage will move the Bucket Level Indicator
bucket control valve out of return-to-dig position before And Return-To-Dig
bucket is actually level. Adjustment .
T7374CH UN04OCT90
1/1

110703
PN=81
9 Bucket Leveling NOTE: The loader bucket leveling feature functions during the boom raise cycle only. OK: Go to next check .
Linkage Check When bucket is lowered, the operator must level the bucket unless unit is equipped
with optional return-to-dig. NOT OK: Adjust linkage
on the loader control
Put bucket in the rollback position with the boom near valve. Go to Group
the ground level. 9025-20. Loader Bucket
9005
Level Indicator And
10
Raise the loader and at the same time hold the control Return-To-Dig Adjustment
18
lever in the bucket rollback position. .
Observe bucket and loader control lever as the loader

raises.
T7374CJ UN05OCT90
LOOK/FEEL: Loader control lever must move into the
bucket dump position and the bucket dump function
must slowly activate. When the loader control lever
moves to activate the bucket dump function, the bucket
position must remain stationary the remainder of the
loader boom raise cycle.
LOOK: The bucket side cutting edge must be level

during entire loader raise cycle.
1/1
Check Operation Of Accessories (Engine Stopped)
1/1
1 Front Light Switch Turn key switch to ON position. OK: Go to next check .
Push front light rocker switch to middle position. NOT OK: Check fuse and
bulbs.
LOOK: Two front lights, two red tail lights and gauge lights must come on.
OK: Check switch . Go to
Push front light rocker switch in completely. Group 9015-15, Drive and
Work Light Circuit.
LOOK: All four front lights, two red tail lights and gauge lights must come on.
1/1
2 Rear Light Switch Turn key switch to ON position. OK: Go to next check .
Push side console rear light rocker switch in. NOT OK: Check fuse and
bulbs.
LOOK: Rear light (s) must come on.
OK: Check switch . Go to
Group 9015-15, Drive and
Work Light Circuit.
1/1

110703
PN=82
3 Turn Signal Switch Turn key switch to ON position. OK: Go to next check .
Push right side of turn signal rocker switch down. NOT OK: Check fuses
and bulbs
LOOK: Right front and rear amber lights must flash. Right indicator light on top of
steering column must flash. OK: Check turn signal
9005
switch . Go to Group
10
Push left side of turn signal rocker switch down. 9015-15, Turn Signal,
19
Flasher and Brake Light
LOOK: Left front and rear amber lights must flash. Left indicator light on top of steering Circuit.
column must flash.
1/1
4 4-Way Flasher Key switch may be ON or OFF. OK: Go to next check .
Push bottom of warning light rocker switch in. NOT OK: Check fuses
and bulbs.
LOOK: Both front and rear amber lights must come ON. Both turn signal indicators and
light in warning light rocker switch must flash. OK: Check 4-Way
Flasher Switch . Go to
Group 9015-15, Brake
Light Circuit.
1/1
5 Horn Turn key switch to ON position. OK: Go to next check .
Push horn button NOT OK: Check fuse.
LISTEN: Horn must sound. OK: Check horn switch .

Horn Circuit.
1/1
6 Start Aid Check (If Operate engine at slow idle. OK: Go to next check .
Equipped)
Push start aid button once. NOT OK: Check can
contents by shaking or
LISTEN: Engine speed must increase then return to slow idle. weight.
NOT OK: Check fuel

shut-off/start aid/reverse
alarm fuse.
IF OK: Go to Group
9015-15, Start Aid Circuit
.
1/1

110703
PN=83
Cab Component Checks
9005 1/1
10
20
1 Seat Linkage Check Move lever (A) to the right. OK: Go to next check .
Move seat forward and rearward and release lever. NOT OK: Repair linkage.
See Disassemble And
LOOK: Lever must move freely and lock seat in desired Assemble Seat Base
position. Non-Suspended repair
manual , Disassemble
And Assemble
T7394BD UN29NOV90
Suspended Seat Adjuster
, or Disassemble And
Assemble Seat
Suspension .
1/1
2 Height Adjustable Pull lever (C) up and at the same time remove your OK: Go to next check .
Seat Check (If weight from the seat.
Equipped) NOT OK: Lubricate seat
Raise seat several positions and engage latch. pedestal. See
Disassemble And
LOOK: Seat must raise upward and must remain in Assemble Seat Base
desired latched position. Non-Suspended repair
T7394BD UN29NOV90
And Assemble
Suspended Seat Adjuster
Assemble Seat
Suspension .
1/1
3 Seat Swivel Linkage Pull lever (B) up. OK: Go to next check .
Check
Move seat from loader to backhoe position and engage NOT OK: Lubricate or
latch. repair linkage. See
Disassemble And
LOOK: Seat latch must move freely and hold seat at the Assemble Seat Base
desired position. Non-Suspended repair
T7394BD UN29NOV90
FEEL: Lever must move freely and hold seat in loader And Assemble
and backhoe positions. Suspended Seat Adjuster
Assemble Seat
Suspension .
1/1

110703
PN=84
4 Left Cab Door Latch Unlatch door. OK: Go to next check .

And Opener Check
Observe door as it opens. NOT OK: Adjust cab
door. See Adjust Cab Left
Pull door closed and latch it. Door Latch And Hinges
and Adjust Cab Door
9005
FEEL: Cab door latch must work freely. Handle Screw in repair
10
manual.
21
LOOK: Door cylinder must push door open.
LOOK: Cab door must contact door stop bumper before door cylinder bottoms.
1/1
5 Right Door Latch And Unlatch door and pull door open. OK: Go to next check .
Opener Check
Close and latch door. NOT OK: Adjust door.
See Adjust Cab Right
FEEL: Cab door latch must work freely. Door Latch And Hinges
and Adjust Cab Door
Handle Screw .
1/1
6 Rear Window Latch Squeeze latches on both sides of middle rear window. Lower window to rubber OK: Go to next check .
And Opener Checks bumpers.
NOT OK: Check for
Push latch releases on upper rear window. obstructions. See Adjust
Upper Rear Window and
Observe window as it opens. Adjust Lower Rear
Window in repair manual.
Push window up and into window catches and note fit.
Observe cylinders while closing window. Raise middle window and push into latches.
LOOK: Window latches and hinges must move freely.
LOOK: The gas-filled cylinders must slowly assist raising the window to open position.
Cylinders must not be at end of travel when closing window.
LOOK: The window catches must hold and not bow the window in the up position.
1/1

110703
PN=85
7 Side Window Checks Open left and right rear side window. OK: Go to next check .
Fasten rear window against front window. NOT OK: Adjust

windows. See Adjust Cab
LOOK: Sleeve on rear window must align with knob on Side Windows in repair
front window. manual.
9005
10
LOOK/FEEL: Hinges must move freely. Locking latches
22
T6171DF UN09DEC88
must be equally loaded when closed.
1/1
8 Blower OK: Go to next check .
NOT OK: Check heater

circuit breaker.
OK: Check blower switch

. Go to Group 9015-15,
Blower Circuit.
T7828AW 1930SEP92
Turn key switch ON.
Turn blower switch (A) to low, medium and high speeds.
FEEL/LISTEN: Blower must have three speeds and OFF.
1/1
9 Heater OK: Go to next check .
NOT OK: Check heater

components . Go to
Group 9015-15, Blower
Circuit.
T7835AW 1930SEP92
Start engine and allow to warm several minutes.
Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high
speed.
FEEL: Air from ducts must be warm.
1/1

110703
PN=86
10 Air Conditioner (If OK: Go to next check .

Equipped)
NOT OK: Go to Heating
and Air Conditioning ,
Group 9031-10.
9005
10
23
T7835AX 1930SEP92
Start engine and run at fast idle.
Turn air conditioner switch (A) to ON position.
Turn blower switch (B) to high speed.
Wait for any warm air in duct system to dissipate.
FEEL: Air from ducts must be cool.
1/1
11 Rear Windshield Turn key to ON position. OK: Go to next check .

Wiper Check
Push rear wiper rocker switch to first detent, middle position. NOT OK: Check fuse.
Push rear wiper rocker switch all the way in. OK: Check rear wiper .
LOOK: Rear wiper must operate and have two speeds. Wiper/Washer Circuit.
LOOK: Wipers must return to park position.
1/1
12 Front Windshield Turn key switch to ON position. OK: Go to next check .

Wiper Check
Push front wiper rocker switch to first detent, middle position. NOT OK: Check fuse.
Push front wiper switch all the way in. OK: Check front wiper .
LOOK: Both front wipers must operate and have two speeds. Wiper/Washer Circuit.
LOOK: Wipers must return to park position.
1/1

110703
PN=87
13 Front Windshield Turn key switch to ON position. OK: Go to next check .

Washer Check
Push windshield washer rocker switch in. NOT OK: Check fluid
level, and fluid lines for
LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF blockage.
position.
9005
NOT OK: Check wiring .
10
24
Wiper/Washer Circuit.
1/1
14 Cab Dome Light And Turn key switch to ON position. OK: Go to next check .
Swivel Light Check
Push dome light switch to ON position. NOT OK: Check fuse and
bulbs.
Push swivel light switch to ON position.
NOT OK: Check wiring .
LOOK: Lights must come ON. Go to Group 9015-15,
Dome Light Circuit.
1/1
Miscellaneous Checks
1/1
1 Vandal Protection Lock engine access door, reservoir door and cab doors using ignition key. OK: Go to next check .
Check
FEEL: All locks must operate freely and key must not stick in locks. NOT OK: Lubricate or
repair lock.
1/1
2 Check Periodic Check periodic maintenance decal on inside of reservoir OK: Go to next check .
Maintenance Decal access door.
NOT OK: Replace decal.
LOOK: Periodic maintenance decal must be legible. Go to John Deere Dealer
for part.
T6171DG UN09DEC88
1/1

110703
PN=88
3 Backhoe Transport OK: Operational

Pin Check Checkout completed.
NOT OK: Adjust boom

lock. See Adjust Standard
Lift Boom Lock Linkage
9005
or Adjust Heavy Lift
10
Boom Lock Linkage in
25
repair manual.
NOT OK: Repair or

replace swing lock pin.
NOT OK: Check pin bore

for burrs or obstruction.
T8181AD UN20FEB94
Raise boom into transport position and lower boom lock pin (A).
Remove swing lock pin (B) from holder in cab and install through top and bottom holes
of swing frame and through main frame.
LOOK: Boom lock pin (A) must stay in boom lock mechanism and support weight of
boom.
LOOK: Swing lock pin (B) must install freely.
1/1

110703
PN=89
9005
10
26

110703
PN=90
Section 9010
Engine
Contents
Page

4045 John Deere EngineUse CTM8 . . . . .9010-05-1 9010
General Engine Description. . . . . . . . . . . . . .9010-05-2
EngineSectional View . . . . . . . . . . . . . . . .9010-05-4

4045 John Deere EngineUse CTM8 . . . . .9010-10-1
System Operational Checks . . . . . . . . . . . . .9010-10-1
Cooling System Checks . . . . . . . . . . . . . . . .9010-10-1
Air System Checks . . . . . . . . . . . . . . . . . . . .9010-10-3
Lubrication System Checks . . . . . . . . . . . . . .9010-10-3
Fuel System Checks . . . . . . . . . . . . . . . . . . .9010-10-4
Engine Speed And Performance Checks. . . .9010-10-5

Make Visual Inspection Of Engine And
Supporting Systems. . . . . . . . . . . . . . . . . .9010-15-2
Diagnose Engine Malfunctions . . . . . . . . . . .9010-15-4
Group 20Adjustments
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
Fan Belt Tension Adjustment . . . . . . . . . . . .9010-20-2
Adjust Speed Control Lever Tension . . . . . . .9010-20-3
Engine Speed Control Linkage . . . . . . . . . . .9010-20-4
Slow And Fast Idle . . . . . . . . . . . . . . . . . . . .9010-20-6
Group 25Tests
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-1
JT05800 Digital Thermometer Installation . . .9010-25-1
JT07158 TIME TRAC Installation. . . . . . . . .9010-25-2
Cooling System . . . . . . . . . . . . . . . . . . . . . . .9010-25-3
Air Filter Restriction Indicator Switch . . . . . . .9010-25-4
Air Intake System Leakage Test . . . . . . . . . .9010-25-5
Radiator Air Flow Test. . . . . . . . . . . . . . . . . .9010-25-6
JT05529 Air Flow Meter Test Record . . . . . .9010-25-8
Turbocharger Boost PressureEngine
Performance Test . . . . . . . . . . . . . . . . . . .9010-25-9
Injection Pump Timing. . . . . . . . . . . . . . . . .9010-25-11
Injection Pump Static Timing Adjustment. . .9010-25-12

110703
PN=1
Contents
9010

110703
PN=2
Group 05
Theory Of Operation
4045 John Deere EngineUse CTM8
For additional engine information, the component technical

manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
UN07SEP88
M44215
9010
05
TX,9010,SS495 1923AUG931/1 1

110703
PN=93
Theory Of Operation
General Engine Description
Model 3029, 4039, 4045, 6059, and 6068 engines are used on Dubuque engines, and a 5/6-piece bearing
vertical, in-line, valve-in-head, 4-cycle (stroke) diesel insert is used on Saran engines. The 5/6-piece bearing
engines. has high thrust load capability, and may be retro-fitted
to Dubuque engines1 at service repair if so desired.
Direct fuel injection is provided by a distributor-type
injection pump and 9.5 mm injection nozzles mounted IMPORTANT: Service thrust bearing kits are now
in cylinder head. The gear driven injection pump is supplied with a six-piece thrust
timed to the crankshaft by the timing gear train. bearing assembly. It is acceptable to
9010 use a six-piece bearing where
05 Some engines are equipped with a turbocharger. The five-piece was previously used.
2
turbocharger uses energy from exhaust gases to Follow instructions provided.
compress intake air and force it into the combustion
chamber. If a crankshaft has excessive end play, thrust washer
sets are available in standard size or 0.007 in.
The cylinder block is a one-piece casting. The block is oversize.
available in structural and non-structural configurations.
Cylinder liners are "wet" (surrounded by coolant) and
The camshaft is timed to the crankshaft through the are individually replaceable. O-rings seals are used at
timing gear train. The camshaft rotates in honed bores the lower connection between cylinder block and
in the cylinder block. Camshaft gear-driven auxiliary liners.
drive engines and all 3029 engines use a bushing in
No. 1 camshaft bore. The camshaft lobes determine Pistons are made of high-grade cast aluminum alloy
the duration and lift of each valve, and operate the fuel with internal ribbing. The skirt is cam ground to allow
transfer pump. for expansion during operation. The piston crown has
a cut-out combustion bowl with a truncated cone
Intake and exhaust valves are operated by camshaft center. All piston rings are located above the piston
followers, push rods and rocker arm assembly. Valve pin. Two compression rings and one oil control ring are
seat inserts in cylinder head are used for intake and used. The top compression ring is a keystone shaped
exhaust valves. ring located close to the top of the piston for improved
engine performance.
The crankshaft is a one-piece, heat treated, steel or
nodular-iron forging which operates in replaceable The hardened, fully-floating piston pins are held in
two-piece main bearings. Steel crankshafts may have place by snap rings. Spray jets (piston cooling orifices)
either ground-fillets, or undercut and rolled fillets. All in cylinder block spray pressurized oil on the underside
nodular-iron crankshafts are machined with undercut of the piston to lubricate piston pins and cool pistons.
and rolled fillets.
The forged steel connecting rods have replaceable pin
Two different types of main thrust bearing inserts are bushing and bearing inserts. 3029 connecting rods
used to control end-play, depending on the producing have a tapered pin-end.
factory. Normally, a two-piece thrust bearing insert is
1
Main (thrust) bearing web undercut in block and or bearing cap
MUST be 113.8 mm (4.48 in.) in order to accept five piece thrust
bearings.
Continued on next page CTM8,GR01,11 1918FEB951/2

110703
PN=94
Theory Of Operation
The engine is equipped with a gear driven oil pump Balancer shafts are used on some four-cylinder
and full-flow oil filter. The oil filter has an internal engines to reduce vibration. The two shafts rotate on
bypass valve which opens if the filter element bushings in cylinder block and are counter-rotating at
becomes restricted. Most engines are equipped with twice engine speed.
an oil cooler mounted externally on the cylinder block.
The engine is equipped with a pressure regulator valve The engine has a pressurized cooling system,
to relieve excessive pressure build-up in the main oil consisting of radiator, water pump, multi-blade fan, and
gallery, and a bypass valve to prevent oil starvation if one or two thermostats.
the oil cooler and filter become plugged.
9010
05
CTM8,GR01,11 1918FEB952/2 3

110703
PN=95
Theory Of Operation
EngineSectional View
9010
05
4
UN11JUL95
RG7248
ARocker Arm Shaft FCylinder Block KConnecting Rod PPiston Rings
BCylinder Head GCrankshaft LLiner Packing Rings QValve
CPush Rod HCrankshaft Counterweight MCylinder Liner RFuel Injection Nozzle
DCam Follower IOil Pan NPiston SValve Spring
ECamshaft JBalancer Shafts OPiston Pin TRocker Arm
S11,2000,EH 1911JUL951/1

110703
PN=96
Group 10
System Operational Checks

UN07SEP88
M44215
9010
10
TX,9010,SS495 1923AUG931/1 1
This procedure is designed so the mechanic can make problem is indicated (NOT OK:), you will be given
a quick check of the engine using a minimum amount repair required and Group location or CTM number. If
of diagnostic equipment. If you need additional verification is needed, you will be given next best
information, read Theory of Operation, Group 9010-05. source of information after GO TO:
A location will be required which is level and has Group 10 (System Operational Checks)
adequate space to complete the driving checks.
Group 15 (Diagnostic Information)
The engine and all other major components must be at
operating temperature for some checks. Group 20 (Adjustments)
Locate system check needed in the left column and Group 25 (Tests)
read completely, follow this sequence from left to right.
Read each check completely before performing. CTM (Component Technical Manual)
At the end of each check, if no problem is found (OK:),

you will be instructed to GO TO NEXT CHECK. If
TX,901010,QQ812 1919DEC901/1
Cooling System Checks
1/1

110703
PN=97
1 Radiator Cap, Coolant OK: Check completed.

Level, Coolant CAUTION: DO NOT remove radiator cap unless engine is cool. Then turn
Condition Checks cap slowly to the stop. Release all pressure before you remove cap. NOT OK: If vacuum
release valve is plugged
Open radiator cap. or spring corroded,
replace radiator cap.
LISTEN: If radiator is warmer than air temperature, a "whoosh" must be heard when
radiator cap is opened to first stop position. NOT OK: If coolant is oily
or foamy. Go to Group
FEEL: The radiator cap must have a stop position and must be pushed down to turn to 9010-15 Oil In Coolant Or
remove. Coolant In Oil .
9010 Inspect coolant level, coolant condition. NOT OK: If rust in

10 coolant, drain, flush and
2 LOOK: The radiator cap must have a good seal and gasket. The seal must move replace coolant. Go to
freely and the spring must not be corroded. Operators Manual.
LOOK: The vacuum release valve (center of cap rubber seal) must move freely and
holes must not be plugged.
LOOK: The coolant must not be oily, foamy, or rusty.
1/1
2 Hose And Water Inspect all radiator and heater hoses and water pump for cracks or leaks. OK: Check completed.
Pump Check
LOOK: Radiator hoses must not be brittle or show signs of leaks. NOT OK: Replace
defective hoses, tighten
Check all hose clamps. clamps as necessary.
LOOK: All hose clamps must be tight. NOT OK: Repair water
pump. See General
Squeeze lower radiator hose. Water Pump Information
and Remove Water Pump
FEEL: Lower hose must have wire insert. in CTM8.
LOOK: Water pump must not show any signs of leaks.
1/1
3 Radiator Bubble a. Radiator to proper level. OK: Check complete.

Check
b. Install radiator cap and tighten. NOT OK: If constant flow
of bubbles is seen, a
c. Start engine. Run engine until at normal operating loose cylinder head or a
temperature. damaged head gasket
could be the cause. See
d. Place overflow tube in jar of water. Diagnosing Head Gasket
T6171AR UN25MAY89
Joint Failures in CTM8.
LOOK: Amount of bubbles in glass jar.
1/1

110703
PN=98
4 Fan And Fan Shroud OK: Check complete.

Check
NOT OK: Adjust belt
tension . Go to Group
9010-20.
NOT OK: If fan blades

have any bends, replace
fan. If fan has nicks,
locate interference and
repair. Go to repair
manual.
9010
NOT OK: Replace fan 10
belt. See Remove And 3
Install Fan Belts in repair
manual.
NOT OK: If fan is on

backwards, remove and
T6171CA UN25MAY89 T6171CB UN25MAY89 install. See Remove And
Install Fan in repair
Inspect fan and shroud clearance. manual.
Inspect fan blades for damages.
Check fan belts for tightness.
LOOK/FEEL: Fan belt deflection should be about 7/16 in. with 25 lbs of push.
LOOK: Fan blades must not have any nicks or bends.
LOOK: Make sure there is no oil or grease on fan belt or pulleys.
LOOK: Inside surface of fan belt must not have any cracks or contact bottom of pulley
groove.
NOTE: If the fan blade has been installed backwards about 50% of its capacity is lost.
LOOK: Cupped portion of fan blades must be away from radiator.

1/1
Air System Checks
1/1
1 Air Filter Restriction Run engine at slow idle. OK: Check complete.
Indicator Switch
Check Slowly cover air intake tube NOT OK: Check engine
air filter restriction light
LOOK: Engine air filter restriction monitor light must come on. and switch . Go to Group
9015-15.
1/1
Lubrication System Checks
1/1

110703
PN=99
1 Oil Level Check a. Pull out oil level dipstick and check level. OK: Check complete.
b. Clean off oil from dipstick with finger or thumb. NOT OK: If oil level is
high, smell the oil for fuel
c. Smell the oil. oil. Replace fuel transfer
pump spindle seal. See
LOOK: Oil level must be between add and full marks and must NOT look "milky". Bench Test Fuel Supply
Pump in CTM8.
SMELL: Oil must NOT smell burnt or smell like fuel oil.
NOT OK: Drain small
quantity of oil and check
for antifreeze. If coolant in
9010 oil. Go to Radiator Bubble
10 Check .
4
Send oil sample to
laboratory. See OILSCAN
Plus .
NOT OK: If oil level is

low, check for oil leaks.
1/1
Fuel System Checks
1/1
1 Engine Fuel System Engine off, engine speed control lever at fast idle position. OK: Check complete.
Inspection Checks
Inspect water drain, cap, strainer and inside fuel tank (flashlight.). NOT OK: If excessive
amount of water is found
Operate pump primer by hand. in fuel tank, change fuel
filter.
Inspect all fuel lines, line clamps, and speed control linkage stop.
NOT OK: If air "hisses"
LOOK: Water drain must NOT contain an excessive amount of water. from tank or enters tank
when cap is removed,
Inside of fuel tank must NOT contain any foreign matter. replace fuel cap.
LOOK: No fuel leakage must be noted at any of the fuel line connections. The injection NOT OK: If excessive
line rubber clamps must be in position and NO wiring banded to the injection lines. debris is found in the
bottom of the fuel tank,
remove fuel line and
observe flow. If flow is
restricted, clean tank.
1/1

110703
PN=100
2 Fuel Pump Check "Crack" open bleed screw on fuel filter and operate hand OK: Check complete.
primer on fuel pump.
NOT OK: Be certain fuel
Tighten bleed screw of fuel filter and again operate hand filter is clean. If not,
primer on fuel pump. replace filter and recheck
fuel pump.
LOOK: Fuel must come out of bleed screw when hand
primer is operated.
T6488GR UN19OCT88
FEEL: Resistance must be felt when fuel is being
pumped and no resistance will be felt after system is
pumped up.
9010
10
1/1 5
3 Fuel System Check Engine OFF. OK: Check completed.
Disconnect fuel return hose from leak-off line. NOT OK: Check for
plugged fuel filters,
Connect a hose to leak-off line to route excess fuel into a container. plugged fuel tank cap
vent, restricted lines,
Start engine and run at fast idle. stuck injection pump
overflow valve, or a bad
Put engine under load by operating a hydraulic function over relief. fuel pump. Repair or
replace as necessary.
Observe fuel flow from leak-off line.
LOOK: Fuel must flow from leak-off line with engine at full load.
NOTE: Fuel that flows from leak-off line is excess fuel not required by the engine.
1/1
Engine Speed And Performance Checks
1/1

110703
PN=101
1 Engine Speed Check Start engine, run at slow idle, and record rpm. OK: Check complete.
(Tachometer
Installed) Increase engine speed to fast idle with speed control NOT OK: Check spring
pedal and record rpm. loaded injection pump
lever override. Go to
LOOK: Slow idle must be 850 50 rpm. Group 9010-20,
AdjustmentsEngine
LOOK: Fast idle must be 2375 50 rpm. Speed Control Linkage .
NOTE: Override adjustment 6 mm (.250 in.) NOT OK: If idle speeds

are out of specifications,
adjust. Go to Group
9010 9010-20, Adjustments
10 See Slow And Fast Idle .
6
T6008AE1 UN09DEC88
1/1
2 Engine Power Check NOTE: Engine rpm pull down is valid for No. 2 fuel. If No. 1 fuel is used, engine may OK: Check complete.
pull down more.
NOT OK: If exhaust
Operate engine at fast idle. smoke is excessive, go to
Group 9010-15Engine
a. With loader boom fully raised, activate boom raise and backhoe stabilizer to create Emits Excessive Black
full hydraulic stall. Smoke or Gray Exhaust
Smoke .
b. Observe exhaust smoke as load is applied to engine.
NOT OK: If engine speed
LOOK: Exhaust smoke should not be evident at approximately 2200 rpm (rated decreases to less than
speed). 1520 rpm, low power of
misadjusted or
LOOK: Exhaust smoke should not be obvious with engine at full hydraulic stall. malfunctioning system
relief valve is indicated.
Go to Group 9010-15
Engine Does Not Develop
Full Power .
1/1

110703
PN=102
3 Low Compression OK: Check Complete.

Check
NOT OK: If starting motor
runs at an uneven speed,
low compression is
indicated on one or two
cylinders. Perform Test
Engine Compression
Pressure in CTM8.
T7367AD UN17SEP90
Remove fuel shut off fuse.
Crank engine for 10 seconds. 9010

10
LISTEN: Air must not be heard leaking past valves. 7
LISTEN: Starting motor must run at a constant speed.
1/1
4 Engine Blow-By Run engine at fast idle and check the blow-by tube. OK: Check complete.
Check
LOOK: Fumes should be barely visible at the blow-by tube at fast idle no load. NOT OK: If blow-by is
excessive, perform Test
NOTE: Excessive blow-by indicates that piston rings and cylinder liners do not seal off Engine Compression
the combustion chamber. This is a comparative check test that requires some Pressure in CTM8.
experience to determine excessive blow-by.
1/1
5 Loose Or Worn a. Run engine at slow idle. OK: Check complete.

Engine Parts Check
b. With loader boom fully raised, activate boom raise and run loader valve hydraulics NOT OK: Go to Group
over relief to load engine to minimum rpm. 9010-15, Abnormal
Engine Noise .
LISTEN: Knock or rattling noise must NOT be heard from engine.
NOT OK: Go to next
check .
1/1

110703
PN=103
6 Turbocharger Noise NOT OK: If excessive

Check (If Equipped) CAUTION: Machine will attempt to move forward during this check. noise is heard from
turbocharger, remove air
a. Start engine, put transaxle in 4th gear. intake tube and exhaust
elbow. Leading edge of
b. Hold service brakes, depress speed control pedal to fast idle, then move direction compressor vanes must
lever to "forward" position. be sharp and straight.
Compressor wheel must
c. When engine reaches stall speed turn key "OFF" and note sound of turbocharger. turn easily without any
binding or unusual noise.
LISTEN: Excessive noise must NOT be heard from turbocharger. Move turbine and
compressor wheels in all
9010 d. Reduce speed control pedal to slow idle position, restart engine, and run for 1 directions with light
10 minute to lubricate turbocharger. pressure while turning
8 shaft. Wheels must NOT
rub housing. See
Turbocharger Failure
Analysis in CTM8.
OK: System Operational

Checkout Completed.
NOT OK: Go to next

check .
1/1
7 Operators Complaint If you completed the Operational Checkout and did not isolate a malfunction, the OK: Go to Group
Was Not Identified problem may be intermittent. 9010-15, Diagnose
Engine Malfunctions .
Try to duplicate the condition of the malfunction identified by operator.
1/1

110703
PN=104
Group 15
System Diagnostic Information

UN07SEP88
M44215
9010
15
TX,9010,SS495 1923AUG931/1 1

110703
PN=105
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. Adjust belt tension, see Adjust
Radiator Fan Belt Tension , Group 0510.
Water pump
Hoses 8. Inspect fuel tank:
Coolant manifold
Thermostat cover a. Inspect the tank mounting hardware to ensure
they are in position and tight.
9010 Check for proper coolant level in radiator. Look at
15 coolant for evidence of oil and/or debris. b. Inspect fuel tank for cracks and leakage.
2
2. Inspect for oil leaks around the oil pan, drain plug, c. Inspect fuel tank outlet strainer and water trap
oil filter, and clutch housing at drain hole. for accumulated debris by shining a flashlight
through the filler neck toward bottom right corner
3. Inspect hoses to see if they are hard, cracked, soft, of fuel tank.
or swelled. Replace as necessary.
9. Inspect fuel transfer pump. See if there is fuel
4. Inspect radiator for bent fins, kinks, dents, cracked leaking from inlet and outlet connections.
side frames, seams and tubes. Check radiator
mounts for loose hardware. 10. Inspect fuel filter for water in base of filter. Look
for fuel leaking from inlet and outlet connections.
5. Check fan to ensure it has been installed correctly.
See Cooling System Inspection, in this section. 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 the water pump bearings. Check
disconnecting hydraulic or other lines.
water pump bearings by moving fan and note
Tighten all connections before applying
looseness of bearings.
pressure. Keep hands and body away from
pinholes and nozzles which eject fluids
7. Inspect fan belts. They must not be too tight, too
under high pressure. Use a piece of
loose, or cracked. Check to see if belt pulleys are
cardboard or paper to search for leaks. DO
worn excessively (if belts run against bore of
NOT use your hand.
groove) and that the pulleys are in proper
alignment.
If ANY fluid is injected into the skin, it must
be surgically removed within a few hours by
A belt which is too tight puts extra load on the
a doctor familiar with this type injury or
bearings and shortens the life of the bearings as
gangrene may result.
well as the belts. A belt which is too loose allows
slippage and reduces fan and alternator speed,
11. Inspect injection pump and nozzles.
causes excess belt wear. Belt slippage can lead to
overheating of the cooling and/or hydraulic system,
and undercharged batteries.
Continued on next page TX,9010,YY509 1902JUN931/2

110703
PN=106
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 isnt in red.
TX,9010,YY509 1902JUN932/2

110703
PN=107
Diagnose Engine Malfunctions
NOTE: Diagnostic charts are arranged from most

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

Group 9005-10).
Step 2. Engine Operational Checkout Procedure
9010 (See Group 9010-10).
15 Step 3. Adjustments and/or Tests (See Group
4
9010-20 and/or 9010-25).
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.
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,901015,QQ815 1924JUN941/12

110703
PN=108
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 . See 9015-15.

Inspect solenoid wiring and linkage.
Improper injection pump timing Check timing. See Injection Pump 9010
Timing in Group 9010-25. 15
5
Injection pump Remove and test pump. See

Remove Injection Pump in CTM8.
Injection nozzle(s) Remove and test nozzles. See Test

Fuel Injection Nozzles in CTM8.
Worn compression rings or low Check compression. Repair. Perform

compression Test Engine Compression Pressure
in CTM8.
Blown head gasket Remove. Route radiator overflow

into container of fluid and check for
bubbles. Bubbles indicate head
gasket linkage. See Diagnosing
Head Gasket Joint Failures in CTM8.
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. Check grade of fuel.
Water in fuel Drain fuel tank and inspect filter

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

110703
PN=109
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 Injection
Pump Timing in Group 9010-25.
9010 Check return oil fitting on top of Remove, inspect and clean.
15 injection pump control cover Determine source of debris. See
6
plugged. Remove Injection Pump in CTM8.
See your authorized injection pump
service center.
Injection pump metering valve Remove pump top cover and

sticking inspect. Replace metering valve.
See Remove Injection Pump in
CTM8. See your authorized injection
pump service center.
Engine overheating Test cooling system. See Cooling

System in Group 9010-25.
Fuel transfer pump Test transfer pump pressure. See

Measure Fuel Supply Pump
Pressure in CTM8.
Fuel injection pump Remove fuel injection pump. See

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

Test Fuel Injection Nozzles in CTM8.
Improper valve clearance Check and adjust valve clearance.

See Check and Adjust Valve
Clearance in CTM8.
Valve sticking or burned Do compression pressure test.

Perform Test Engine Compression
Pressure in CTM8.

110703
PN=110
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 Diagnosing
Perform Test Engine Compression
Pressure in CTM8.
Engine Misses Air in fuel Check for evidence of air in filter. 9010
Tighten connections and bleed fuel 15
7
system.
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 Slow
low) And Fast Idle in Group 9010-20.
Fuel injection pump out of time Time injection pump. See Injection
Fuel transfer pump Test fuel system pressure. See

Measure Fuel Supply Pump
Pressure in CTM8.
Injection pump governor faulty or Inspect. Repair. See Remove

metering valve sticking Injection Pump in CTM8. See your
authorized injection pump service
center.
Engine overheating Verify engine temperature. Test

thermostat. Replace. See Remove,
Test, and Install Thermostats in
CTM8.
Incorrect valve clearance Check and adjust valve clearance.

See Check and Adjust Valve
Clearance in CTM8.
Bent push rods Inspect. Replace.

110703
PN=111
Cylinder head gasket leaking Route radiator overflow hose into

container of fluid and check for
bubbles. Bubbles indicate head
gasket leakage. See Diagnosing
Valve sticking or burned Perform Test Engine Compression

Pressure in CTM8.
9010
15 Worn or broken compression rings Perform Test Engine Compression
8
Pressure in CTM8.
Fuel injection pump Remove and test fuel injection

pump. See Remove Injection Pump
in CTM8.
Injection nozzles(s) plugged Remove and test nozzles. See Test

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.
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. Check high idle
linkage out adjustment. speed. See Slow And Fast Idle in
Group 9010-20.
Incorrect engine or injection pump Check. Adjust timing. See Injection

timing Pump Timing in Group 9010-25.
Incorrect valve clearance Adjust valve clearance. See Check

and Adjust Valve Clearance in
CTM8.
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.

110703
PN=112
Fuel transfer pump malfunction Test fuel transfer pump pressure.

See Measure Fuel Supply Pump
Pressure in CTM8.
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 axle and park brake drag . 9010
See Operational Checkout, 15
9
Procedure 9005-10.
Excess drag in transaxle Test drag . See Operational

Checkout Procedure 9005-10.
Muffler restricted Operate without muffler. If engine

operation is now normal, replace
muffler.
Injection pump delivery or governor Remove pump and test. See

faulty Remove Injection Pump in CTM8.
service center.
Injection nozzle(s) Remove and test nozzle(s). See

Low compression Perform Test Engine Compression

Pressure in CTM8.
Worn camshaft Do valve lift check. Replace. See

Measure Valve Lift in CTM8.
Engine Emits Excessive Black or Restricted air filter Check air filter restriction and air
Gray Exhaust Smoke filters. Clean or replace.
Incorrect grade of fuel Drain and add correct fuel.
Incorrect injection pump timing Time injection pump. See Injection

Excessive fuel delivery Remove fuel injection pump. See

service center.

110703
PN=113

Engine Emits Excessive Blue or Cranking speed too slow Check batteries and connections.
White Smoke
Incorrect grade of fuel Drain and add correct fuel.
9010 Engine running too cold Check thermostat operation.

15 Replace. See Remove, Test, and
10
Install Thermostats in CTM8.
Injection pump out of time Time injection pump. See Injection


Low compression Perform Test Engine Compression

Pressure in CTM8.
Excessive wear in liners and/or Disassemble, inspect, repair.

piston rings stuck
Slow Acceleration Wrong grade of fuel Drain and add correct fuel.

Fuel injection pump Remove and test fuel injection. See

Detonation (Excess Engine Stuck cold weather starting aid Repair.

Knock)
Incorrect injection pump timing. Time injection pump. See Injection

Abnormal Engine Noise Low or incorrect engine oil (too thin). Add correct oil to proper level.
Loose or worn hydraulic pump drive Inspect. Repair.

coupling
Engine oil diluted with fuel Inspect engine oil. Determine cause
of fuel dilution.

110703
PN=114
Incorrect fuel injection pump timing Time injection pump. See Injection
Excessive valve clearance Adjust valve clearance. See Check

and Adjust Valve Clearance in
CTM8.
Bent push rods Inspect. Replace.

9010
Worn rocker arm shafts Replace. 15
11
Loose connecting rod caps Inspect, tighten connecting rod cap

screws. See Torque-Turn
Connecting Rod Cap Screws in
CTM8.
Loose main bearing caps Inspect, tighten main bearing cap

screws. See procedure under Install
Crankshaft in CTM8.
Worn main bearings Replace bearings. See Check Main

Bearing Oil Clearance in CTM8.
Worn connecting rod bearings Replace bearings. See Inspect and

Measure Connecting Rod Bearings
in CTM8.
Incorrect cam timing Check engine timing. Repair. See

Install and Time Camshaft and Fuel
Injection Pump in CTM8.
Scored piston Inspect. Replace.
Worn piston pin bushings and pins Inspect. Replace pins and bushings.
See Inspect Piston Pins and
Bushings in CTM8.
Low Oil Pressure (Oil Pressure Low oil level Add oil to proper lever. Inspect
Light onRed "Stop" Flashing) engine oil.
Wrong viscosity oil/oil diluted with Change oil. Check injection pump
diesel fuel shaft seals and transfer pump
diaphragm. See Remove Injection
Pump in CTM8.

110703
PN=115
Oil pressure switch or indicator Check engine oil pressure. Test

switch and indicator . See 9015-15.
Oil pressure regulating valve Test or replace.
Plugged or broken oil pump intake Inspect. Clean.

screen
9010 Loose oil pump drive gear Inspect. Repair.

15
12
Worn oil pump gear or housing Remove, inspect and repair.
Excessive main bearing, connecting Perform Check Main Bearing Oil

rod or balance shaft clearance Clearance , Inspect and Measure
Connecting Rod Bearings , and
Inspect and Measure Camshaft
Bearing Bore ID and Journal OD in
CTM8.
Cracked cylinder block Replace cylinder block. See

Complete Disassembly of Cylinder
Block in CTM8. 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. See Cooling System in Group
Red "Stop" Flashing) 9010-25.
Low engine oil level Add oil.
Loose or broken fan belt. Adjust belt tension or replace belt.

See Fan Belt Tension Adjustment in
Group 9010-20.
Engine overloaded, operating in Reduce load.

wrong gear
Fan on backwards Check for correct fan installation.

See Cooling System in Group
9010-25.
Radiator dirty or plugged Check air flow. Clean radiator. See

Cooling System in Group 9010-25.

110703
PN=116
Radiator shroud missing, damaged Inspect. Repair or replace.

or baffles missing
Improper fuel Drain and add correct fuel.
Radiator cap Replace cap.
Faulty temperature sender Test , repair or replace. See

9015-15. 9010
15
13
Excessive transaxle drag Check transaxle drag.
Excessive brake drag Check Brake drag . See Operational

Checkout Procedure 9005-10.
Faulty thermostat (Stuck closed) Inspect thermostat. Replace. See

Remove, Test, and Install
Thermostats in CTM8.
Thermostat missing, cooling system Replace thermostats. See Remove,

coated with lime deposits Test, and Install Thermostats in
CTM8. Flush cooling system.
Water pump Remove. Inspect. Repair. See

General Water Pump Information
and Remove Water Pump in CTM8.
Excessive fuel delivery Remove. Check for proper fuel

delivery, adjust. See Remove
Injection Pump in CTM8.
Scored piston Replace piston. See Engine

Disassembly Sequence in CTM8.
Engine Runs Cold Thermostat (stuck open) Replace. See Remove, Test, and
Install Thermostats in CTM8.
Oil in Coolant Or Coolant in Oil Leaking cylinder head gasket Replace gasket. See Diagnosing
Leaking cylinder liner packing Replace packings. See Engine


110703
PN=117
Cracked cylinder liner Replace liner. See Engine

Cracked cylinder block Replace block. See Complete

Disassembly of Cylinder Block in
CTM8.
Excessive Fuel Consumption Air system restricted Check filter restriction indicator and
9010 air filters. Replace
15
14
Leakage in fuel system Inspect. Repair.
Incorrect grade of fuel Refill with correct fuel.
Operator holding hydraulics over Return control levers to neutral

relief. position.
High system relief valve setting Test system relief valve pressure .
See 9025-25

Faulty injection nozzle(s) Test nozzle(s). Repair. See Test

Turbocharger Excessively Noisy Bearings not lubricated Insufficient oil pressure. Check for
or Vibrates restricted turbocharger oil line.
Worn bearings Replace. See Turbocharger Failure

Analysis in CTM8.
Air leak in engine, intake or exhaust Inspect and repair. See Intake Air
manifold Leak Test and Exhaust Leak Check
in CTM8.
Improper clearance between turbine Remove exhaust elbow and air inlet
wheel and turbine housing hose. Inspect and repair. See
Turbocharger Failure Analysis in
CTM8.
Broken blades on turbine Remove exhaust elbow and air inlet

hose. Inspect and repair. See
CTM8.

110703
PN=118
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
CTM8.
Excessive crankcase pressure Check for plugged oil drain line.

Clean. 9010
15
15
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 Turbocharger
Rotating Members wheel caused by combustion Failure Analysis in CTM8.
deposits
Dirt build-up behind compressor Inspect and repair. See

wheel caused by air intake leaks Turbocharger Failure Analysis in
CTM8.
Bearing seizure or dirty or worn Check for plugged air filters.

bearings caused by excessive
temperature, unbalanced wheel, dirty
oil, oil starvation, or insufficient
lubrication
TX,901015,QQ815 1924JUN9412/12

110703
PN=119
9010
15
16

110703
PN=120
Group 20
Adjustments

UN07SEP88
M44215
9010
20
TX,9010,SS495 1923AUG931/1 1

Installation
SERVICE EQUIPMENT AND TOOLS
Tachometer
AClamp-on Transducer. Remove paint with emery cloth and
UN28FEB89
connect to a straight section of injection line within 100 mm (4 in.) of
pump. Finger tighten only. DO NOT overtighten.
BBlack Clip (-). Connect to main frame.
CRed Clip (+). Connect to transducer.
T6813AG
DTachometer Readout. Install cable.
10T,9010,K182 1910AUG951/1

110703
PN=121
Adjustments
Fan Belt Tension Adjustment

SPECIFICATIONS
New Belt Deflection 5/16 in. at 25 lbs.
Used Belt (Cold) Deflection 7/16 in. at 25 lbs.
Adjusting Strap Cap Screw 27 3 Nm (20 2 lb-ft)
Torque

JDST28 Belt Deflection Gauge
9010
20
2 NOTE: Belt deflection measured using JDST28 Belt
Deflection Gauge.
IMPORTANT: The alternator belt is considered used

after 12 minutes of running.
DO NOT overtighten belts.

Overtightening may cause belt cord
damage or excessively loud alternator
UN01JUN89
bearings.
1. Check alternator belt deflection using a belt deflection

gauge. A new belt will deflect 5/16 in. at 25 lb force at
T6030AT
a point halfway between the pulleys.
Specification
New BeltDeflection...................................................... 5/16 in. at 25 lbs. AAlternator Pulley
BFan Pulley
CCrankshaft Pulley
A used belt will deflect 7/16 in. at 25 lb force at a point
DStraight Edge
halfway between the pulleys. EBelt Deflection Gauge
Specification
Used Belt (Cold)Deflection ......................................... 7/16 in. at 25 lbs.
2. If belt deflection is not within specifications, loosen

alternator mounting cap screws. Apply force only to the
front of alternator housing (near the belt) and tighten
cap screws.
Specification
Adjusting Strap Cap Screw
Torque ................................................................. 27 3 Nm (20 2 lb-ft)
3. Check belt tension. If not correct repeat Step 2 until

within specifications.
TX,901020,QQ818 1924FEB941/1

110703
PN=122
Adjustments
Adjust Speed Control Lever Tension
UN04OCT90
9010
20
T7387AA
3
SPECIFICATIONS
Nut Torque Until 4462 N (1014 lb force)
is required to move lever using a
spring scale
Tighten nut (A) until 4462 N (1014 lb force) is

required to move lever using a spring scale.
Specification
NutTorque ........................................... Until 4462 N (1014 lb force)
is required to move lever using a
spring scale
TX,9010,YY510 1919APR941/1

110703
PN=123
Adjustments
Engine Speed Control Linkage

SPECIFICATIONS
Injection Pump Lever Override 46 mm (1/81/4 in.)
With Speed Control Lever in
Extreme Forward Position
UN18OCT88
Injection Pump Lever Minimum 1.5 mm
Override With Speed Control
Lever in Rear Most Position
Injection Pump Lever Minimum 2 mm
T6030AU
Override at High Idle
9010
20
4 1. Move speed control lever to extreme forward position.
2. Measure injection pump lever override. Override must

be 46 mm (1/81/4 in.).
Specification
Injection Pump LeverOverride
With Speed Control Lever in
Extreme Forward Position ..................................... 46 mm (1/81/4 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 1.5 mm
minimum.
Specification
Injection Pump LeverMinimum
Override With Speed Control
Lever in Rear Most Position ........................................................... 1.5 mm
5. Recheck high idle for a minimum of 2 mm override.
Specification
Injection Pump LeverMinimum
Override at High Idle ......................................................................... 2 mm
6. Remove reservoir cowling to adjust foot control pedal.
Continued on next page TX,9010,DS4840 1902JUN931/2

110703
PN=124
Adjustments
7. Disconnect yoke (A) from rod (B). Adjust vertical rod

(C) length to allow foot control pedal to stop on floor
with hand lever in the extreme forward position.
9010
20
5
UN16DEC91
T7387AB
TX,9010,DS4840 1902JUN932/2

110703
PN=125
Adjustments
Slow And Fast Idle

SPECIFICATIONS
Slow Idle Speed 850 50 rpm
Fast Idle Speed 2375 50 rpm
UN18OCT88
JT05801 Electronic Tachometer
Sealing Wire Pliers
T6023AD
9010
20 1. Run engine until it is at normal operating temperature.
6
2. Install tachometer . See procedure in this group. ALever Stop Screw
BSpeed Control Rod
CFast Idle Adjusting Screw
CAUTION: Take care to avoid rotating fan DSealing Wire
blades while making injection pump ESlow Idle Adjusting Screw
adjustments.
3. Disconnect speed control rod (B) from fuel injection

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

Check to make sure slow idle is 850 50 rpm.
Specification
Slow IdleSpeed ................................................................. 850 50 rpm
6. If slow idle is not correct:
a. Check air cleaner elements.
b. Loosen lock nut and turn screw (A) out one or two
turns.
c. Loosen lock nut and turn screw (E) to adjust slow

idle.
d. Turn screw (A) in until rpm starts to increase then

turn screw out one full turn. Tighten lock nuts.
7. Hold injection pump lever rearward (away from

radiator). Check to make sure fast idle is 2375 50
rpm.
Specification
Fast IdleSpeed ................................................................ 2375 50 rpm

110703
PN=126
Adjustments
8. If fast idle is not correct:
a. Remove sealing wire.
b. Loosen lock nut and turn screw (C)

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 (B). 20
7
TX,9010,YY513 1902JUN932/2

110703
PN=127
Adjustments
9010
20
8

110703
PN=128
Group 25
Tests

UN07SEP88
M44215
9010
25
TX,9010,SS495 1923AUG931/1 1

Installation
Tachometer
UN28FEB89
T6813AG
10T,9010,K182 1910AUG951/1
JT05800 Digital Thermometer Installation

Digital Thermometer
ATemperature Probe. Fasten to a bare metal line using tie band.
Wrap with shop towel. UN28FEB89
BCable
CDigital Thermometer
T6808CE
902525,AA4 1928FEB951/1

110703
PN=129
Tests
JT07158 TIME TRAC Installation

ESSENTIAL TOOLS

JT07158 TIME TRAC Kit
JT07155 In-Line SOI Sensor
JT07173 SOI Clamp Assembly
UN18MAY93
JT07177 Clamp-On Transducer
JDG793 Magnetic Pick-up Adapter
JT07171 Magnetic Pick-up
T8010AL
9010
25 Remove paint and clean injection line for installation of
2
clamp-on transducer (E).
IMPORTANT: Install clamp-on transducer as close as

possible to fuel injection nozzle.
ASOI Sensor
BTransducer Clamp
UN20MAY93
CGround
DMeter Connection
EClamp-On Transducer
FInjection Line
T8010AM
GGround
HMeter Connection
IAdapter
JMagnetic Probe
KMeter Connection
UN18MAY93
T8010AN
JT07158 TIME TRAC is a registered trademark of the Stanadyne
Automotive Corp.
TIME TRAC is a registered trademark of the Stanadyne Automotive
Corp. TX,TIMETRAC,300 1920JUN951/1

110703
PN=130
Tests
Cooling System
SPECIFICATIONS
Cooling System Test Pressure 69 kPa (0.7 bar) (10 psi)
Cooling System Pressure Cap 4352 kPa (0.40.5 bar) (6.2
Opening Pressure 7.5 psi)
UN24OCT88
Vacuum Valve Opening Pressure 03.5 kPa (00.04 bar) (00.5
psi)
T6487AT
Cooling System Pressure Pump 9010
25
3
1. Check coolant level.
2. Check belt tension . (See procedure in this group).
3. Check radiator fin condition. Make sure fins are not

bent or damaged.
UN25OCT88
4. Check fan tips and shroud for damage. Fan tip shroud
should be equal at top and bottom.
NOTE: Sucker fan has six blades with concave sides
T95940
away from radiator.
5. Check for correct fan installation.
6. Test cooling system for leaks using a cooling system

pressure pump (A). Pressurize system to maximum of
69 kPa (0.7 bar) (10 psi).
Specification
Cooling SystemTest Pressure ........................ 69 kPa (0.7 bar) (10 psi)
7. Test radiator cap using a cooling system pressure

pump. Pressurize radiator cap valve. Valve must start
to open at 4352 kPa (0.40.5 bar) (6.27.5 psi).
Specification
Cooling System Pressure Cap
Opening Pressure ............................................ 4352 kPa (0.40.5 bar)
(6.27.5 psi)
8. Vacuum valve must open at 03.5 kPa (00.04 bar)

(00.5 psi).
Specification
Vacuum ValveOpening
Pressure ................................................ 03.5 kPa (00.04 bar) (00.5
psi)
TX,9010,YY514 1902JUN931/1

110703
PN=131
Tests
Air Filter Restriction Indicator Switch

SPECIFICATIONS
Restriction Indicator Light 57.5 kPa (49.874.7 mbar)
Activation Pressure (2030 in. water) (1.8 0.2 in.
Hg) vacuum
UN15OCT90
Vacuum Gauge
1/4 in. x 1/8 in. Pipe Reducer
T7390AR
9010 Air Restriction Indicator
25
4 1/8 in. Barb Fitting (2 used)
1/4 in. Pipe Tee Fitting
1. Remove air restriction indicator switch.
2. Install hose nipple, tee fitting and gauge from water

vacuum gauge kit into air restriction indicator hole.
Install air restriction indicator into tee fitting.
3. Start engine and slowly cover the air cleaner inlet with
a piece of paper or cardboard.
4. Yellow warning light and air filter restriction indicator

light on monitor panel must come on when gauge is at
specified pressure.
Specification
Restriction Indicator Light
Activation Pressure..................................... 57.5 kPa (49.874.7 mbar)
(2030 in. water) (1.8 0.2 in.
Hg) vacuum
TX,901025,QQ819 1902JUN931/1

110703
PN=132
Tests
Air Intake System Leakage Test
SPECIFICATIONS
Air Intake System Test Regulated 13.820.7 kPa (0.130.21 bar)
Pressure (23 psi)
UN25OCT88
ESSENTIAL TOOLS
JDG51 Adapter
T92026
Air Regulator With Gauge 9010
25
5
IMPORTANT: Anytime the air intake system is opened
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
UN25OCT88
element and cover.
3. Remove plug from air intake tube and install JDG51

adapter (A).
T92027
4. Connect air pressure regulator to adapter using hose
and fitting (B).
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 Test
Regulated Pressure ................................ 13.820.7 kPa (0.130.21 bar)
(23 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,901025,QQ816 1928NOV901/1

110703
PN=133
Tests
Radiator Air Flow Test

SPECIFICATIONS
410D Engine Speed 1000 10 rpm
510D Engine Speed 1000 10 rpm
410D Suction Fan Actual Voltage 1.49 volts
Reading
Reading Minus 20%
9010 Reading
25
6 510D Suction Fan Actual Voltage 1.16 volts
Reading Minus 20%

Flowmeter
Volt-Ohm-Amp Multimeter
1. Apply parking brake, put transmission in neutral and
UN01NOV88
lower equipment to the ground. Stop engine.
2. Install tachometer . (See procedure in this group.)
T6080AH
3. Check that all sheet metal is in place. Close side
shields.
4. Divide the surface of the grille into 16 equal squares.
5. Start engine and run at 1000 10 rpm.
Specification
410D EngineSpeed ......................................................... 1000 10 rpm
510D EngineSpeed ......................................................... 1000 10 rpm
6. Connect air flowmeter to digital multimeter. Turn switch

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

meter must point in direction of air flow (toward unit).
8. Record voltage reading for each area.

110703
PN=134
Tests
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.
9. Combined total of air flow test readings must be

greater than specifications.
Specification
410D Suction FanActual
Voltage Reading .......................................................................... 1.49 volts
9010
Actual Voltage Reading Minus
25
20%.............................................................................................. 1.19 volts
7
510D Suction FanActual
Voltage Reading .......................................................................... 1.45 volts
Actual Voltage Reading Minus
20%.............................................................................................. 1.16 volts
If readings are less than specifications remove oil cooler

and clean external surfaces of both oil cooler and radiator.
Install oil cooler and repeat test. If reading is still low,
check for correct fan installation. Be sure sheet metal is in
place.
TX,901025,QQ834 1902JUN932/2

110703
PN=135
Tests
JT05529 Air Flow Meter Test Record
CUSTOMER NAME AND ADDRESS
DATE:
MACHINE MODEL NO.
UN20APR89
SERIAL NO.
T6041AL
9010
25
8
PRE-TEST INSPECTION
OK SERV REQD OK SERV REQD
Coolant Level
Belt Tension Correct Fan Installation (Sucker
Fan)
Radiator Fin Condition Radiator Cap
Fan Tip & Shroud Condition
AIR FLOW TEST
1. Park brake ON.
2. Transmission in Neutral and side shields closed.
3. Divide the surface of the grille into 16 equal squares.
4. Start engine.
5. Perform air flow test at fast idle. Observe correct air

flow direction and place air flow meter in direct contact
with grille. (Arrow pointing to grille).
6. Record air flow in each square.
7. Combined total of air flow test readings must be

greater than specifications.
TX,9010,YY518 1902JUN931/1

110703
PN=136
Tests
Turbocharger Boost PressureEngine

Performance Test
NOTE: Maximum boost pressure will be found within 200

RPM of fast idle.
UN26MAY89
SPECIFICATIONS
410D Engine Speed Fast idle
410D Engine Normal Operating 82 10C (180C 20F)
Temperature
T6225AS
9010
510D Engine Speed Fast idle
25
510D Engine Normal Operating 82 10C (180C 20F) 9
Temperature
410D Turbocharger Boost 3448 kPa (0.340.48 bar) (5
Pressure (Using No. 2 Fuel) 7 psi)
510D Turbocharber Boost 6276 kPa (0.620.76 bar) (9
Pressure (Using No. 2 Fuel) 11 psi)
NOTE: Reduce the boost specifications by 7% if using

No. 1 fuel.

JDE147 (1/2 NPT x 1/4 in. hose barb) Adapter
Gauge 0200 kPa (02 bar) (030 psi)
JT05800 Digital Thermometer
1. Make test connections.
2. Install tachometer and thermometer . (See procedure

in this section.)
3. Apply park brake and put transaxle and reverser in

neutral. Run engine until it is at normal operating
temperature.
Specification
410D EngineSpeed ................................................................... Fast idle
Normal Operating Temperature ....................... 82 10C (180C 20F)
510D EngineSpeed ................................................................... Fast idle
Normal Operating Temperature ....................... 82 10C (180C 20F)
4. Lower stabilizers and bucket to raise wheels off

ground.
Put unit in first gear with reverser lever in forward or

reverse.

110703
PN=137
Tests
Release park brake and apply brake pressure until

boost pressure begins to drop.
5. Record highest boost pressure and RPM it was

obtained at.
Specification
410D TurbochargerBoost
Pressure (Using No. 2 Fuel) ........................ 3448 kPa (0.340.48 bar)
(57 psi)
510D TurbocharberBoost
9010 Pressure (Using No. 2 Fuel) ........................ 6276 kPa (0.620.76 bar)
25 (911 psi)
10
Repeat test several times.
6. If boost pressure is too high, remove and test fuel

injection pump for high fuel delivery.
If boost pressure is too low, check for the following:
a. Restricted air filter elements.
b. Restricted fuel filter elements.
c. Incorrect fast idle adjustment.
d. Incorrect injection pump timing.
e. Exhaust manifold leaks.
f. Intake manifold leaks.
g. Faulty fuel transfer pump.
h. Low compression pressure.
i. Faulty fuel injection nozzle.
j. Carbon build-up in turbocharger.
k. Turbocharger compressor or turbine wheel rubbing

housing.
l. Low fuel injection pump fuel delivery, remove and

test fuel injection pump for low fuel delivery.
TX,901025,QQ833 1902JUN932/2

110703
PN=138
Tests
Injection Pump Timing
SPECIFICATIONS
410D Engine Model Numbers 4045D and 4045T
410D Engine Net hp (kW) 75 hp (56.2 kW)
510D Engine Model Number 4045T
UN03NOV97
510D Engine Net hp (kW) 90 hp (67 kW)
410D Engine Rated Speed 2200 rpm
510D Engine Rated Speed 2200 rpm
RG6293
410D Injection Pump Dynamic 16.5 9010
Timing at +0 -1 BTDC 25
11
510D Injection Pump Dynamic 15
Timing at +0 -1 BTDC AFront Plate
BPump Flange
ESSENTIAL TOOLS
JT07158 TIME TRAC Kit
The JT07158 TIME TRAC timing kit electronically

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

between engines and helps to control cylinder firing
pressures which can be a factor in head gasket failures as
well as improve overall engine efficiencies.
1. Install JT07158 TIME TRAC. See procedure in this

group. (Also found on JT07175 Quick Reference
Sheet.)
2. Raise rear of machine off the ground with stabilizers.

Put transaxle in fourth forward.
3. Operate machine at WOT.
Specification
410D EngineModel Numbers..................................... 4045D and 4045T
Net hp (kW) ...................................................................... 75 hp (56.2 kW)
510D EngineModel Number ......................................................... 4045T
Net hp (kW) ......................................................................... 90 hp (67 kW)
Slowly depress service brakes until engine is at 2200

rpm.
TIME TRAC is a registered trademark of the Stanadyne Automotive

Corp. Continued on next page TX,410D,DS4888 1902JUN931/2

110703
PN=139
Tests
Specification
410D EngineRated Speed ....................................................... 2200 rpm
510D EngineRated Speed ....................................................... 2200 rpm
4. Record dynamic timing.
Specification
410D Injection PumpDynamic
Timing at +0 -1 BTDC........................................................................ 16.5
510D Injection PumpDynamic
Timing at +0 -1 BTDC........................................................................... 15
9010
25 5. If timing is not to specification, follow procedure on
12 JT07175 Quick Reference Sheet.
TX,410D,DS4888 1902JUN932/2
Injection Pump Static Timing Adjustment

SPECIFICATIONS
No. 1 Cylinder Position At TDC on compression stroke
Line on Governor Weight Aligned with line on cam ring
Retainer Position
ESSENTIAL TOOLS
JDE811 Flywheel Turning Tool

JDE814 Timing Pin
T59,9010,C111 1925MAR861/3
1. Install flywheel turning tool (A). Rotate flywheel in

engine running direction until pin (B) goes into hole in
flywheel.
2. Remove timing hole cover from fuel injection pump.

UN29MAR90
T6024AP
Continued on next page T59,9010,C111 1925MAR862/3

110703
PN=140
Tests
3. If timing line (C) on weight retainer cannot be seen,

turn engine one revolution to get No. 1 cylinder at TDC
on compression stroke.
Specification
No. 1 CylinderPosition .......................... At TDC on compression stroke
UN25MAY89
Line on Governor Weight
RetainerPosition ....................................... Aligned with line on cam ring
4. To avoid backlash, always approach the timing lines by
T6193AA1
turning engine in direction of rotation. The normal
9010
backlash of gears is enough to throw the pump timing
25
off several degrees, resulting in poor engine 13
performance.
5. If lines are not aligned, loosen pump mounting flange

retaining nuts and rotate pump housing until timing
lines are aligned.
T59,9010,C111 1925MAR863/3

110703
PN=141
Tests
9010
25
14

110703
PN=142
Section 9015
Electrical System
Contents
Page Page
Group 05System Information Engine Harness (W8) Component

Visually Inspect Electrical System . . . . . . . . .9015-05-1 Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-33
Electrical Circuit Malfunctions . . . . . . . . . . . .9015-05-2 Blower Harness (W10) Wiring Diagram . . . .9015-10-34
High Resistance Circuit . . . . . . . . . . . . . . . . .9015-05-3 Blower Harness (W10) Component
Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-4 Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-35
Grounded Circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-6 Radio Harness (W12) Wiring Diagram. . . . .9015-10-36
Shorted Circuit . . . . . . . . . . . . . . . . . . . . . . .9015-05-8 Radio Harness (W12) Component 9015
Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-9 Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-37
Seven Step Electrical Test Procedure . . . . .9015-05-10 Air Conditioning Compressor Harness (W11)
Wiring Diagram And Schematic Wiring Diagram . . . . . . . . . . . . . . . . . . . .9015-10-38
Information. . . . . . . . . . . . . . . . . . . . . . . .9015-05-12 Air Conditioning Compressor Harness (W11)
Reading A System Functional Component Location . . . . . . . . . . . . . . . .9015-10-39
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-05-13 Auxiliary Valve Harness (W14) Wiring
Reading A Wiring Diagram . . . . . . . . . . . . .9015-05-14 Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-40
Electrical Schematic Symbols . . . . . . . . . . .9015-05-15 Auxiliary Valve Harness (W14)
Component Location . . . . . . . . . . . . . . . .9015-10-41
Group 10System Diagrams
Component Identification Table . . . . . . . . . . .9015-10-1 Group 15Sub-System Diagnostics
Power Circuit Operational Information . . . . . .9015-15-1
Fuse Specifications . . . . . . . . . . . . . . . . . . . .9015-10-3
Power Circuit Theory Of Operation . . . . . . . .9015-15-1
Wiring And Schematic Diagrams Legend . . .9015-10-4
Power Circuit Schematic . . . . . . . . . . . . . . . .9015-15-2
System Functional Schematic Section
Power Circuit Diagnostic Procedures . . . . . .9015-15-5
Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-9
Start Circuit Operational Information . . . . . . .9015-15-8
System Functional Schematic . . . . . . . . . . .9015-10-10
Start Circuit Theory Of Operation . . . . . . . . .9015-15-9
Cab Roof Harness (W5) Wiring Diagram. . .9015-10-17
Start Circuit Schematic . . . . . . . . . . . . . . . .9015-15-10
Cab Roof Harness (W5) Component
Start Circuit Diagnostic Procedures . . . . . . .9015-15-12
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-18
Charging Circuit Operational Information . . .9015-15-15
Cab Side Console Harness (W6) Wiring
Charging Circuit Theory Of Operation . . . . .9015-15-15
Diagram (SN 778668) . . . . . . . . . . . . .9015-10-19
Charge Circuit Schematic . . . . . . . . . . . . . .9015-15-16
Cab Side Console Harness (W6) Charging Circuit Diagnostic Procedures . . .9015-15-21
Component Location (SN 778668) . . . .9015-10-20 Display Module And Logic Module Circuit
Cab Floor Harness (W6) Wiring Diagram (SN Operational Information (SN
778668) . . . . . . . . . . . . . . . . . . . . . . . .9015-10-21 XXXXXX) With Logic Module . . . . . . . . . .9015-15-24
Cab Floor Harness (W6) Component Display Module And Logic Module Circuit
Location (SN 778668) . . . . . . . . . . . . .9015-10-22 Theory Of Operation (SN XXXXXX) With Logic
Cab Side Console Harness (W6) Wiring Module. . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-25
Diagram (SN 778669XXXXXX). . . . . . .9015-10-23 Display Module And Logic Module Circuit
Cab Side Console Harness (W6) Wiring Operational Information (SN XXXXXX
Diagram (SN XXXXXX ) . . . . . . . . . . . .9015-10-25 ) Without Logic Module . . . . . . . . . . . . . .9015-15-25
Cab Side Console Harness (W6) Display Module Circuit Theory Of
Component Location (SN 778669 ) . . .9015-10-27 Operation (SN XXXXXX ) Without Logic
Front Console Harness (W7) Wiring Module. . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-26
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-29 Display Module And Logic Module Circuit
Front Console Harness (W7) Component Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-31
Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-30
Engine Harness (W8) Wiring Diagram. . . . .9015-10-31 Continued on next page

110703
PN=1
Contents
Page Page
Logic Module (SN XXXXXX) . . . . . . . . . .9015-15-31 Blower Circuit Diagnostic Procedures . . . . .9015-15-74
Indicator Circuit Specifications. . . . . . . . . . .9015-15-32 Drive And Work Light Circuit Operational
Indicator Circuit Operational Information . . .9015-15-32 Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-75
Indicator Circuit Theory Of Operation (SN Drive And Work Light Circuit Theory Of
XXXXXX) With Logic Module . . . . . . . .9015-15-33 Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-75
Indicator Circuit Theory Of Operation (SN Drive And Work Light Circuit Diagnostic
XXXXXX) Without Logic Module. . . . . .9015-15-34 Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-77
Indicator Circuit Schematic . . . . . . . . . . . . .9015-15-35 Park Brake/Clutch Disconnect Circuit
Indicator Circuit Diagnostic Procedures . . . .9015-15-39 Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-78
MFWD Circuit Operational Information . . . .9015-15-43 Park Brake/Clutch Disconnect Circuit
MFWD Circuit Theory Of Operation. . . . . . .9015-15-43 Operational Information . . . . . . . . . . . . . .9015-15-78
MFWD Circuit Schematic . . . . . . . . . . . . . .9015-15-44 Park Brake/Clutch Disconnect Circuit Theory
MFWD Circuit Diagnostic Procedures . . . . .9015-15-46 Of Operation . . . . . . . . . . . . . . . . . . . . . .9015-15-79
9015 Start Aid Circuit Operational Information . . .9015-15-47 Park Brake/Clutch Disconnect Circuit
Start Aid Circuit Theory Of Operation . . . . .9015-15-48 Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-80
Start Aid Circuit Schematic . . . . . . . . . . . . .9015-15-49 Park Brake/Clutch Disconnect Circuit
Start Aid Circuit Diagnostic Procedures. . . .9015-15-51 Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-83
Fuel Shut-Off Circuit Operational Horn Circuit Operational Information . . . . . .9015-15-88
Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-53 Horn Circuit Theory Of Operation . . . . . . . .9015-15-88
Fuel Shut-Off Circuit Theory Of Horn Circuit Schematic . . . . . . . . . . . . . . . .9015-15-89
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-54 Horn Circuit Diagnostic Procedures. . . . . . .9015-15-90
Fuel Shut-Off Circuit Schematic . . . . . . . . .9015-15-55 Turn Signal, Flasher And Brake Light Circuit
Fuel Shut-Off Circuit Diagnostic Operational Information . . . . . . . . . . . . . .9015-15-90
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-56 Turn Signal, Flasher And Brake Light
Reverse Alarm Circuit Specifications (SN Circuit Theory Of Operation . . . . . . . . . . .9015-15-91
794639) . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-56
Turn Signal, Flasher And Brake Light Circuit
Reverse Alarm Circuit Operational
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-92
Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-56
Reverse Alarm Circuit Theory Of
Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-93
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-57
Beacon Circuit Operational Information . . . .9015-15-95
Reverse Alarm Circuit Schematic . . . . . . . .9015-15-58
Beacon Circuit Theory Of Operation . . . . . .9015-15-96
Reverse Alarm Circuit Diagnostic
Beacon Circuit Schematic . . . . . . . . . . . . . .9015-15-97
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-60
Beacon Circuit Diagnostic Procedures. . . . .9015-15-98
Dome Light Circuit Operational
Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-62 Return-To-Dig Circuit Operational
Dome Light Circuit Theory Of Operation . . .9015-15-62 Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-98
Dome Light Circuit Schematic . . . . . . . . . . .9015-15-63 Return-To-Dig Circuit Theory Of
Dome Light Circuit Diagnostic Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-99
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-64 Return-To-Dig Circuit Schematic . . . . . . . . 9015-15-100
Radio Circuit Operational Information . . . . .9015-15-64 Return-To-Dig Circuit Diagnostic
Radio Circuit Theory Of Operation . . . . . . .9015-15-65 Procedures . . . . . . . . . . . . . . . . . . . . . . 9015-15-102
Radio Circuit Schematic . . . . . . . . . . . . . . .9015-15-66 Fuel Gauge And Hour Meter Circuit
Radio Circuit Diagnostic Procedures . . . . . .9015-15-67 Specifications. . . . . . . . . . . . . . . . . . . . . 9015-15-103
Wiper/Washer Circuit Operational Fuel Gauge And Hour Meter Circuit
Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-68 Operational Information . . . . . . . . . . . . . 9015-15-103
Wiper/Washer Circuit Theory Of Fuel Gauge And Hour Meter Circuit Theory
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-68 Of Operation . . . . . . . . . . . . . . . . . . . . . 9015-15-104
Wiper/Washer Circuit Schematic . . . . . . . . .9015-15-69 Gauge And Hour Meter Circuit
Wiper/Washer Circuit Diagnostic Schematic . . . . . . . . . . . . . . . . . . . . . . . 9015-15-105
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-70 Fuel Gauge And Hour Meter Circuit
Blower Circuit Operational Information . . . .9015-15-72 Diagnostic Procedures . . . . . . . . . . . . . . 9015-15-107
Blower Circuit Theory Of Operation. . . . . . .9015-15-72
Blower Circuit Schematic. . . . . . . . . . . . . . .9015-15-73 Continued on next page

110703
PN=2
Contents
Page
Auxiliary Valve Circuit Operational

Information. . . . . . . . . . . . . . . . . . . . . . . 9015-15-109
Auxiliary Valve Circuit Theory Of
Operation. . . . . . . . . . . . . . . . . . . . . . . . 9015-15-109
Auxiliary Valve Circuit Schematic . . . . . . . 9015-15-110
Auxiliary Valve Diagnostic Procedures . . . 9015-15-111
Group 20References
Alternators And Starting MotorsUse
CTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Battery Operation . . . . . . . . . . . . . . . . . . . . .9015-20-2
Battery Specifications . . . . . . . . . . . . . . . . . .9015-20-3 9015
Diagnose Battery Malfunctions . . . . . . . . . . .9015-20-4
Check Battery Electrolyte Level And
Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-5
Procedure For Testing Batteries . . . . . . . . . .9015-20-8
Using Booster Batteries12 Volt System . . .9015-20-9
Alternator Operation78 AMP Delco
Remy (Serial No. 787513) . . . . . . . . . .9015-20-10
Alternator Operation95 AMP Bosch
(Serial No. 787514 ) . . . . . . . . . . . . . . .9015-20-11
Alternator Operation95 AMP Bosch . . . . .9015-20-12
Monitor Test In Machine . . . . . . . . . . . . . . .9015-20-13
Logic Module Test In Machine (SN
XXXXXX) . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-14
Logic Module Bench Test (SN
XXXXXX) . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-16
Tachometer Calibration . . . . . . . . . . . . . . . .9015-20-17

110703
PN=3
Contents
9015

110703
PN=4
Group 05
System Information
Visually Inspect Electrical System
Make the following visual electrical inspection prior to

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

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

wire problem.
3. Look for loose or broken connectors and wires.
4. Inspect batteries for:
Corroded terminals
9015
Corroded terminals 05
Loose terminals or battery posts 1
Dirty condition
Damp condition
Cracked case Proper electrolyte level
5. Check alternator belt tension.
6. After machine has been shut down for five minutes

inspect for overheated parts. They will often smell like
burned insulation. Put your hand on the alternator.
Heat in these parts when the unit has not been
operated for some time is a sure clue to charging
circuit problems.
7. If your visual inspection does not indicate the possible

malfunction, but your inspection does indicate that the
machine can be run, turn the key switch to the IGN
position. Try out the accessory circuits, indicator lights,
gauge lights. How does each of these components
work? Look for sparks or smoke which might indicate
shorts.
8. Start machine. Check all gauges for good operation

and check to see if system is charging or discharging.
9. In general, look for anything unusual.
Many electrical failures cannot be detected even if the

machine is started. Therefore, a systematic and
complete inspection of the electrical system is
necessary.
TX,901505,QQ369 1907FEB961/1

110703
PN=145
System Information
Electrical Circuit Malfunctions
9015
05
2
1927FEB92
T7713AD
ABattery CSwitch DLight EGround
BFuse
There are four common circuit malfunctions. After the component
High-Resistance Circuit Component malfunctions can easily be confused with

Open Circuit circuit malfunctions. Therefore, care must be exercised
Grounded Circuit when isolating the cause of a problem.
Shorted Circuit
Example: Light does not operate or is dim when switch
Three sections in a simple circuit where these is turned ON, until switch connector is disconnected
malfunctions can occur; and reconnected.
Before the controlling switch (C) Reason: High resistance caused by a dirty switch
Between the controlling switch and before the connector, caused a voltage drop which prevented the
component, light (D) proper amount of current from flowing to the light.
TX,901505,RP967 1907FEB941/1

110703
PN=146
System Information
High Resistance Circuit
9015
05
3
1926FEB92
T7713AG
ABattery DSwitch Terminal FHarness Connector HLight
BFuse EHigh Resistance GLight Terminal IGround
CSwitch
A high resistance circuit can result in slow, dim or no If battery voltage is measured, check closer to ground
component operation. to locate point of voltage drop. The example shows
high resistance (E) between switch and harness
Examples: Loose, corroded, dirty or oily terminals. connector.
Wire size too small. Strands broken inside the wire.
Poor ground connection to frame. Repair circuit as required. In the example, strands
were broken inside the wire, replace that section of
To locate the cause of high resistance: wire.
With switch (C) ON, check for battery voltage between Repeat check-out procedure after repair.
switch and ground (I) at an easily accessible location,
like harness connector (F).
If less than battery voltage is measured, check again

closer to switch.
TX,901505,RP968 1910AUG951/1

110703
PN=147
System Information
Open Circuit
9015
05
4
1927FEB92
T7713AF
ABattery DSwitch Terminal FOpen Circuit HLight
BFuse EHarness Connector GLight Terminal IGround
CSwitch
An open circuit will result in no components operating. If battery voltage is measured, check for voltage closer
Fuse may or may not be blown. to ground at harness connector (E).
Example: Broken wire, disconnected component If no voltage is measured, wire may be broken
terminal, pins inside a connector not making contact, between switch and connector.
blown fuse, open circuit breaker, failed switch or
component, or a disconnected ground wire. If battery voltage is measured, inspect connector pins.
If pins are OK check for voltage at light terminal (G).
To locate an open circuit:
In the example, zero voltage will be measured at light
Check fuse. If blown, replace and operate circuit. If terminal, indicating a broken wire between harness
fuse blows a second time, continue check. connector and light terminal.
With switch (C) ON check for battery voltage at switch If battery voltage had been measured, the next check
terminal (D). for voltage would be at ground connection (I).
If no voltage is measured, check switch, fuse and Normal measured voltage at a ground connection
wiring to battery. should be 0.0 to 0.5 volts.
Continued on next page TX,901505,RP964 1910AUG951/2

110703
PN=148
System Information
If battery voltage is measured, poor connection to When problem is located, repair as needed then
frame or broken wire is indicated. repeat last check.
TX,901505,RP964 1910AUG952/2
9015
05
5

110703
PN=149
System Information
Grounded Circuit
9015
05
6
1927FEB92
T7713AE
ABattery DSwitch GHarness Connector JLight
BFuse ESwitch Terminal HGrounded Circuit KGround
CFuse Terminal FHarness Connector ILight (Component) Terminal
If no component operates, the fuse is blown and If continuity to ground is measured, there is a pinched
replacement fuses blow immediately or the circuit or bare wire between fuse (C) and harness connector
breaker is open and reopens when reset, a grounded (F).
circuit exists. (Example: power wire contacting frame
or other metal component). A wire may be pinched or If continuity to ground does not exist, disconnect
insulation may be worn from a wire. ground (K) from frame. Measure continuity to ground
at harness connector (G). This checks harness from
To isolate the location of a grounded circuit: harness connector to ground terminal. In the example
continuity to ground will exist because circuit is
If circuit is grounded between battery and fuse, wire grounded (wire is pinched) at (H).
will be burned and circuit will be open, fuse will not be
blown. If continuity exists, disconnect circuit at light terminal
(I) and measure continuity to ground on light terminal.
If fuse is blown, remove fuse from circuit, disconnect This checks harness from light to ground terminal. In
circuit near its center, such as harness connector (F), the example continuity will not exist, indicating a
turn switch (D) ON, check for continuity to ground at grounded circuit between the light and harness
harness connector (F). This will check harness from connector (G).
harness connector to fuse.

110703
PN=150
System Information
Repeat check-out procedure after repair.
TX,901505,RP969 1910AUG952/2
9015
05
7

110703
PN=151
System Information
Shorted Circuit
9015
05
8
1927FEB92
T7713AH
ABattery ESwitch Terminal IHarness Connector LLight
BFuse FSwitch JLight MGround
CFuse GHarness Connector KLight Terminal NGround
DSwitch HShorted Circuit
A shorted circuit causes components in separate Disconnect wire from switch of component that should
circuits to operate when a switch in either circuit is not be ON. In the example, disconnect wire from
turned ON. (Example: two harnesses rubbing together terminal (E) at switch (D). Light (J) remains ON.
until insulation is worn through allowing bare wires to
touch). Components can also become shorted. Disconnect circuit at convenient places like harness
However, shorted components will usually blow the connectors (G), (I) and light terminal (K) until light (J)
fuse. goes OFF.
To locate a shorted circuit: The short circuit will be between the last two places
the circuit was disconnected. In the example, it is
Turn Switch (F) ON then OFF, turn switch (D) ON then between harness connectors (G and I). Light (J) will go
OFF, both lights (J and L) will be ON when either OFF when harness connector (I) is disconnected.
switch (D or F) is ON. Inspect harness between connectors (G and I).
Turn switch (F) ON. Both lights (J and L) will be ON,

only light (L) should be ON.

110703
PN=152
System Information
Repair or replace wires and harnesses as needed. Repeat check-out procedure after repair.
Install tie bands and clamps on harnesses as required
to prevent future failures.
TX,901505,RP970 1910AUG952/2
Multimeter
The multimeter is an autoranging digital display that

allows very accurate readings to be taken.
9015
05
9
1917JAN90
T7199AI
TX,901505,QQ374 1910AUG951/1

110703
PN=153
System Information
Seven Step Electrical Test Procedure
9015
05
10
1905MAR92
T7719AA
ABattery Ground DFuse Or Circuit Breaker GBattery Side Of IGround Side Of Component
BBattery EComponent Side Of Fuse Component Terminal Terminal
CBattery Side Of Fuse Or Or Circuit Breaker HLight (Component) JComponent Ground
Circuit Breaker FSwitch
Continued on next page TX,9015,QQ1697 1910AUG951/2

110703
PN=154
System Information
Step 1Switch ON Battery voltage normal. Go to Step 2. Low voltage, repair high
Check battery side of circuit breaker (C) for battery voltage resistance. Open circuit from battery.
Step 2Switch OFF Battery voltage normal. Go to Step 4. Low voltage, repair high
Check component side of circuit breaker for battery voltage resistance. No voltage. Go to Step 3.
Step 3Switch OFF Continuity to ground. Repair grounded circuit at or before switch. No
Check component side of circuit breaker for continuity to ground continuity to ground, replace circuit breaker.
Check component side of circuit breaker for battery voltage resistance. No voltage. Go to Step 5.
Step 5a Disconnect Battery voltage, repair component. No voltage, repair grounded or
wire at battery side of component (G). Switch ON. Check wire at (G) open circuit at or after switch.
for battery voltage
Check lead to component at (G) for battery voltage resistance in circuit between fuse and component. No voltage, repair
high resistance or open circuit between fuse and component.
Step 7Switch ON No voltage, good continuity to ground. Repair component. Voltage,
Check ground wire of component at (I) for voltage poor continuity to ground. Repair high resistance or open ground
circuit. 9015
a
A multimeter will not apply a load to the circuit at step 5. The multimeter result is tested as a voltage condition in the result column 05
11
TX,9015,QQ1697 1910AUG952/2

110703
PN=155
System Information
Wiring Diagram And Schematic Information
System Functional Schematic Diagram schematic symbols for each electrical component
connected to that harness. Harnesses are identified by
The System Functional Schematic is a schematic the same letter/number designation and description
diagram of the complete machine. All harnesses are used in the System Functional Schematic Diagram
identified by letter/number designation and description (W1 Engine Harness, W2 Dash Harness Etc.). Each
(W1 Engine Harness, W2 Dash Harness Etc.). Each component schematic symbol will be identified by the
wire is identified by number and/or color (G01 BLK, same letter/number designation used in the System
R02 Red, RED/WHT, BLU/GRN Etc.). All components Functional Schematic Diagram. Harness connectors
are identified by letter/number designation, description will be identified by a letter/number designation and
and are represented by a schematic symbol. description (X1 CAB HARNESS TO ENGINE
Component letter/number designation, (K1 Start Relay, HARNESS CONNECTOR, X3 DASH HARNESS TO
S1 Key Switch, B9 Horn, Etc.) will indicate that HEATER BLOWER HARNESS CONNECTOR Etc.).
component throughout the manual. The System
Functional Schematic Diagram is divided into Sections. Component Location Diagram
9015
05 Each section contains one or more electrical circuits.
12 Each section is indicated by a number and circuit (SE1 The Component Location Diagram is a pictorial view
CHARGING CIRCUIT, SE2 STARTING CIRCUIT Etc). by harness showing location of all electrical
components, connectors, harness main ground
Wiring Diagram locations and harness band and clamp location. Each
component will be identified by the same identification
The Wiring Diagram shows each wiring harness, wire letter/number and description used in the System
color, wire destination, harness connectors and Functional Schematic Diagram.
TX,901505,RP548 1910AUG951/1

110703
PN=156
System Information
Reading A System Functional Schematic
9015
05
13
1929MAY91
T7502CE
APower Wires DComponent Identification EComponent Name GCircuit Name
BContinuity Chart Code FGround Wires HSection Number
CComponent Schematic
Symbol
The System Functional Schematic is made up of component identification code (D). A continuity chart
sections which contain one or more Subsystem (B) is included for each multi-terminal switch.
Functional Schematic laid out side by side in a logical
sequence of related functions. Each Subsystem is a The same names and identification letter codes are
major group of components like starting components or used on all machine drawingsthe System Functional
charging components (H). Sections are named to Schematic, System Wiring and Harness Diagram, and
reflect that group of components (G). The System the System Component Location Drawing.
Functional Schematic is formatted with power supply Components and connectors can easily be
wires (A) shown across the top of the drawing and cross-referenced from one drawing to another. See
ground wires (F) across the bottom. The diagram Group -10 for Component Identification Legend .
contains no harness or connector information.
Each electrical component is shown by a schematic

symbol (C), the component name (E), and a
TX,9015,RP751 1912APR941/1

110703
PN=157
System Information
Reading A Wiring Diagram
9015
05
14
1910AUG95
T8534AC
AHarness Connector DComponent Connector GHarness Identification JWire Number and/or Color
Letter/Number EWire Number and/or Color Letter/Number and KHarness Connector Pin
Identification FComponent(s) Identification Description Number or Letter
BComponent Letter/Number Number/Letter Wire is HWiring Harness
Identification Routed To IComponent(s) Identification
CComponent Connector Pin Number/Letter Wire is
Number or Letter Routed To
Each harness on the machine is drawn showing Main harness connectors (A) are identified by a
components, connectors and wires. Harnesses (G) are letter/number designation and description, (X2 PARK
identified by a letter/number designation and BRAKE HARNESS TO DASH HARNESS
description, (W3 PARK BRAKE HARNESS Etc.). CONNECTOR Etc.). Harness connector description
indicates which harnesses connect together.
Each component (B) is represented by a schematic Connector pin numbers or letters (K) are indicated as
symbol and is identified by the same letter/number they are marked on the connector. Wires attached to
designation and description used in the System each connector pin are identified by number and/or
Functional Schematic. Components with integral color designation (J). Component identification
connectors (D) have pin number/letters indicated (C). number/letter (I) indicates destination of each wire.
Wires from harness to components are identified by
letter/number designation (E). Component identification Harness, harness connector and component
letter/number (F) indicates component wire is routed identification letter/numbers and description are the
to. same as used on the System Functional Schematic.
TX,9015,RP971 1931AUG951/1

110703
PN=158
System Information
Electrical Schematic Symbols
9015
05
15
1930OCT90
T7186AA

110703
PN=159
System Information
9015
05
16
1930OCT90
T7186AB
TX,901505,QQ378 1910AUG952/2

110703
PN=160
Group 10
System Diagrams
Component Identification Table
Each component (electrical device) and main connector

will have an identification letter assigned to it. A number is
added to the letter to separate and indicate the total
components within that letter group.
Continued on next page TX,901505,QQ381 1916SEP921/2
9015
10
1

110703
PN=161
System Diagrams
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 variables Speed sensors, pressure sensors, pressure switches
to electrical and vice versa horns, sensors, pickups, limit-value sensors, pulse
generators, loudspeakers, inductive pickups, probes,
air-flow sensors, oil-pressure switches, temperature
sensors, ignition-voltage pickups
C Condenser, capacitor Condensers and capacitors, general
D Binary device, memory Digital devices, integrated circuits, pulse counters,
magnetic tape recorders
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
9015
H Monitor, alarm, signalling device Audible alarms, indicator lights, turn-signal lights, brake
10
lights, alarms, warning lights, buzzers
2
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 test
points, speedometers
R Resistor Flame glow plugs, sheathed-element flame glow plugs,
glow plugs, heating resistors, NTC resistors, PTC
resistors, potentiometers, regulating resistors
S Switch Switches and pushbuttons, general key switch, light
switch, horn switch, flasher switch
T Transformer Ignition coil, ignition transformer
U Modulator, converter DC transformers
V Semiconductor, electron tubes Transistors, diodes, electron tubes, rectifiers,
semiconductors, thyristors, zener diodes
W Transmission path, conductor, antenna Antennas, shielding components, shielded conductors,
cable harnesses, conductors, ground conductors
X Terminal, plug, plug and socket connection Terminal studs, electrical connections, connectors
electrical line couplers, line connectors, sockets, plugs,
terminals, plug-and-socket connections
Y Electrically actuated mechanical device Permanent magnets, (solenoid-operated) injection
valves, electromagnetic clutches and brakes, air
valves, fuel pumps, solenoids, switching valves, start
valves, locking systems
Z Electrical filter Interference suppression filters
TX,901505,QQ381 1916SEP922/2

110703
PN=162
System Diagrams
Fuse Specifications
9015
10
3
1922FEB94
T8168AA
F17.5 Amp MFWD/ F630 Amp Heater/AC Circuit F117.5 Amp Left Turn Fuse F1610 Amp Start Fuse
Alternator/Diff Lock Fuse Breaker F127.5 Amp Right Turn Fuse K3Park Light Relay
F215 Amp Fuel/Ether Aid F715 Amp Rear Light Fuse F1310 Amp RTD/Beacon K4Ether Aid Relay (S.N.
and Reverse Alarm Fuse F825 Amp Front Light/Tail Fuse 794639) Backup Alarm
F35 Amp Dome Light/Radio Light Fuse F145 Amp Monitor/Gauge Relay (S.N.794640 )
Fuse F910 Amp FNR/Park Brake Fuse K5Park Brake Relay
F45 Amp Radio Fuse Fuse F1515 Amp Hazard/Monitor K6Neutral Relay
(Unswitched Power) F1020 Amp Turn/Stop and Fuse (Unswitched K7Alternator Sense Relay
F515 Amp Wiper Fuse Horn Fuse Power) S21Flasher
IMPORTANT: Install fuse with correct amperage The fuse block is located on the side console inside an
rating to prevent electrical system access cover.
damage from overload.
TX,9015,QQ2435 1912APR941/1

110703
PN=163
System Diagrams
Wiring And Schematic Diagrams Legend
NOTE: A2Radio (SE3, W12)
A2 indicates component identification number.

Radio indicates component name.
SE3 indicates section number of SYSTEM
FUNCTIONAL SCHEMATIC where component
is located.
W12 indicates HARNESS WIRING DIAGRAM
and HARNESS COMPONENT LOCATION
drawings where component is located.
A2Radio (SE3,W12)
B1Backup Warning Alarm (SE5,W8)
B2Park Brake Sensing Switch (SE9,W8)
9015
10 B3Horn (SE12,W8)
4 B4Fuel Sender (SE15,W8)
B5Engine Coolant Temp. Switch (SE17,W8)
B6Engine Oil Pressure Switch (SE17,W8)
B7Air Filter Restriction Switch (SE17,W8)
B8Converter Temperature Switch (SE17,W8)
B9Hydraulic Filter Switch (SE17,W8)
B10Backup Alarm Switch (SE9,W8) (S.N.794639)
B11Brake Light Switches (SE13,W6)
B12Reverser Pressure Switch (S.N. 778668)
(SE9,W8)
B13Radio Speaker (W12)
B14Radio Speaker (W13)
E1Dome Light (SE3,W5)
E2Swivel Light (SE3,W5)
E3Left Front Work Light (SE8,W5)
E4Right Front Work Light (SE8,W5)
E5Left Rear Work Light (SE8,W5)
E6Right Rear Work Light (SE8,W5)
E7Left Front Drive Light (SE8,W5)
E8Right Front Drive Light (SE8,W5)
E9Left Tail Light (SE8,W5)
E10Right Tail Light (SE8,W5)
E11Left Brake Light (SE13,W5)
E12Right Brake Light (SE13,W5)
E13Beacon Light (SE14,W5)
E14Fuel Gauge Light (SE15,W8)
E15Seat Belt Light (SE9,W6) (S.N.789401 )
F1MFWD/ALT Fuse (SE2,W6)
Continued on next page TX,9015,QQ2436 1912APR941/6

110703
PN=164
System Diagrams
F2Fuel Shutoff/Start Aid/Reverse Alarm Fuse

(SE5,W6)
F3Dome Light Fuse (SE3,W6)
F4Radio Fuse (Unswitched Power) (SE3,W6)
F5Windshield Wiper/Washer Fuse (SE6,W6)
F6Heater Circuit Breaker (SE5,W6)
F7Rear Work Light Fuse (SE7,W6))
F8Front Work Light/Tail Light Fuse (SE8,W6)
F9FNR/Park Brake Fuse (SE9,W6)
F10Turn/Stop/Horn Fuse (SE12,W6)
F11Left Turn Light Fuse (SE13,W6)
F12Right Turn Light Fuse (SE13,W6)
F13Return-To-Dig/Beacon Fuse (SE14,W6)
F14Monitor Fuse (SE15,W6)
F15Hazard/Monitor Fuse (Unswitched Power)
(SE16,W6)
9015
F16Start Fuse (SE11,W6) 10
F17Fuse Block (W6) 5
G1Battery (SE1,W8)
G2Alternator (SE1,W8)
H1Left Indicator Turn Light (SE13,W7)
H2Left Front Turn Light (SE13,W5)
H3Left Rear Turn Light (SE13,W5)
H4Right Front Turn Light (SE13,W5)
H5Right Rear Turn Light (SE13,W5)
H6Right Indicator Turn Light (SE13,W7)
H7Logic Module (SE16,W6)
H8Display Module (SE16,W6)
H9Red Warning Light (SE17,W6)
H10Yellow Warning Light (SE17,W6)
H11Alarm (SE17,W6)
K1Start Relay (SE1,W8)
K2Accessory Relay (SE1,W6)
K3Park Light Relay (SE9,W6)
K4Ether Aid Relay (SE4,W6) (S.N.794639)
K4Backup Alarm Relay (SE4,W6 (S.N.794640)
K5Park Brake Latching Relay (SE9,W6)
K6Neutral Start Relay (SE9,W6)
K7Alternator Relay (SE16,W6)
K8Auxiliary Valve Relay (W14)
M1Starter Motor (SE1,W8)
M2Rear Wiper Motor (SE6,W5)
M3Left Hand Door Wiper Motor (SE6,W5)
M4Right Hand Door Wiper Motor (SE6,W5)
M5Washer Motor (SE6,W8)
M6Heater Blower Motor (SE5,W6)

110703
PN=165
System Diagrams
M7Heater Blower Motor (SE5,W6)

P1Fuel Gauge (SE15,W6)
P2Tachometer (SE15,W6)
P3Hour Meter (SE15,W6)
R1Heater Motor Resistor (SE5,W6)
S1Key Switch (SE2,W6)
S2MFWD Switch (SE2,W6)
S3MFWD Indicator Switch (SE2,W8)
S4Start Aid Switch (SE5,W6)
S5Front Wiper Switch (SE6,W7)
S6Rear Wiper Switch (SE6,W6)
S7Windshield Washer Switch (SE6,W6)
S8Blower Switch (SE5,W6)
S9Front Light Switch (SE8,W7)
S10Rear Light Switch (SE7,W6)
S11FNR Switch (SE9,W7)
9015
10 S12Park Brake Dash Switch (SE9,W6)
6 S13Loader Lever Switch (SE8,W6)
S14Gear Shift Lever Switch (SE8,W6)
S15Horn Switch (SE12,W6)
S16Turn Signal Switch (SE13,W7)
S174-Way Flasher Switch (SE13,W7)
S18Beacon Switch (Optional) (SE14,W6)
S19Not Used
S20Return-To-Dig Switch (SE14,W8)
S21Flasher (SE13,W6)
S22Heater Temperature Switch (W6)
S23Low Pressure Switch (W11)
S24High Pressure Switch (W11)
S25A/C Switch (If Equipped) (W6)
S26Clutch Cycle Switch (W10)
S27Dome Light Switch (SE3,W5)
S28Swivel Light Switch (SE3,W5)
S29Auxiliary Valve Switch (W14)
S30Auxiliary Valve Foot Switch (W14)
V1MFWD Solenoid Diode (SE2,W8)
V2Park Brake Solenoid Diode (SE9,W8)
V3Reverse Solenoid Diode (SE9,W8)
V4Forward Solenoid Diode (SE9,W8)
V5Clutch Disconnect Solenoid Diode (SE9,W8)
V64-Way Flasher Switch Diode (SE13,W7)
V74-Way Flasher Switch Diode (SE13,W7)
V8Logic Module/Display Module Diode (SE15,W6)
V9Alternator Diode (SE1,W8)
V10Auxiliary Valve Diode (W14)

110703
PN=166
System Diagrams
V11Park Brake Relay Diode (SE9,W6) (S.N.

778669)
W1Machine Frame/Engine Block Ground 410D (SN
796854) (SE1,W8) Machine Frame/Engine Block
Ground 510D (SN796890) (SE1,W8) Machine Frame
To Eng. Ground Strap 410D (SN796855) (SE1,W8)
Machine Frame To Eng. Ground Strap 510D
(SN796891) (SE1,W8)
W2Ground To Cab Frame (SE14,W5)
W3Ground At Cab Floor (SE1,W8)
W4Engine Ground Strap (W8)
W5Cab Roof Harness (W5)
W6Cab Floor Harness (W6)
W6Cab Side Console Harness (W6)
W7Front Console Harness (W7)
W8Engine Harness (W8)
9015
W9Not Used 10
W10Blower Harness (W10) 7
W11A/C Compressor Harness (W11)
W12Radio Harness (W12)
W13Radio Antenna (W12)
W14Auxiliary Valve Harness (W14)
W15Ground to A/C Compressor (W8) (S.N.801200)
W16Alternator Harness 410D (SN796854) 510D
(SN796890) (W8)
X1Side Console Harness To Roof Harness
Connectors (W5,W6)
Connectors (W5,W6)
Connectors (W5,W6)
X4Side Console To Floor Harness Connectors (W6)
(SN778668)
X5Side Console To Floor Harness Connectors (W6)
(SN778668)
X6Blower Switch Connector (W10)
X7Display Module Connectors (W6)
X8Horn Switch Connector (W6)
X9Rear Light Switch Connector (W6)
X10Rear Wiper Switch Connector (W6)
X11Beacon Switch Connector (W6)
X12MFWD Switch Connector (W6)
X13Park Brake Switch Connector (W6)
X14Start Aid Switch Connector (W6)
X15Fuel Gauge Connector (W6)
X16Key Switch Connector (W6)

110703
PN=167
System Diagrams
X17Logic Module 4-Pin Connector (W6)

X21Floor Harness To Engine Harness (W6,W8)
(SN778669)
X21Side Console To Engine Harness (W6,W8) (SN
778668)
(SN778669)
778668)
(SN778669)
778668)
9015
10 X24Not Used
8 X25Floor To Front Console Connectors
(W6,W7)(SN778668)
X25Side To Front Console Connectors
(W6,W7)(SN778669)
X26FNR Switch Connector (W7)
X27Turn Signal Switch Connector (W7)
X28Beacon Light Connector (W5)
X29Roof Harness to Radio Harness Connector
(W5,W12)
X30Splice (Inside Harness) (W6)
X31Forward Solenoid Connector (W8)
X32Clutch Disconnect Solenoid Connector (W8)
X33Connectors For A/C Switch (W6) (SN778668)
X34Engine Harness To A/C Compressor Harness
Connector (W8,W11)
X35Side Console Harness To Blower Harness
Connectors (W8,W10)
X36A/C Clutch Cycle Switch Connectors (W10)
X37Seat Belt Light Connector (W6)
X38A/C Switch Connector (W6)
X39Radio Harness To Radio Connector (W12)
X40ACC. Power/Ground Connectors (SE12,W8)
(SN749639)
X41Hourmeter Or Auxiliary Valve Connector
(SE13,W6)
X41AAuxiliary Valve Harness Connector (W14)
X42Auxiliary Valve Harness Connector (W14)
X43Reverse Solenoid Connector (W8)
Y1MFWD Solenoid (SE2,W8)

110703
PN=168
System Diagrams
Y2Start Aid Solenoid (SE5,W8)

Y3Fuel Shutoff Solenoid (SE5,W8)
Y4Park Brake Solenoid (SE9,W8)
Y5Reverse/Solenoid (SE9,W8)
Y6Forward/Solenoid (SE9,W8)
Y7Clutch Disconnect Solenoid (SE9,W8)
Y8Hydraulic Pump destroke Solenoid (SE9,W8)
Y9Return-To-Dig Solenoid (SE14,W8)
Y10A/C Compressor (W11)
Y11Auxiliary Valve Solenoid (W14)
TX,9015,QQ2436 1912APR946/6
System Functional Schematic Section

Legend 9015
10
9
NOTE: SE1Battery/Ignition, Power, Charging and Start
Circuit (12 Volt System)
SE1 indicates section number of system

functional schematic where circuit is located.
Battery/Ignition, Power, Charging and Start
Circuit (12 Volt System) indicates circuit name.
SE1Battery/Ignition, Power, Charging and Start

Circuit (12 Volt System)
SE2MFWD/Alternator Circuit
SE3Dome Light and Radio Circuit
SE4Start Aid, Fuel Shut Off and Reverse Alarm
Circuit
SE5Blower Circuit
SE6Wiper and Washer Circuit
SE7Rear Work Light Circuit
SE8Front Work and Drive Light Circuit
SE9Park Brake/Clutch Disconnect Circuit
SE10Horn Circuit
SE11Turn Signal, Flasher and Brake Light Circuit
SE12Beacon and Return-To-Dig Circuit
SE13Gauge and Hour Meter Circuit
SE14Display Module and Logic Module Circuit
SE15Indicator Circuit
TX,9015,QQ2438 1912APR941/1

110703
PN=169
System Diagrams
System Functional Schematic

T8535AA 1906JAN99
TX,9015,QQ3192 1931AUG951/7

110703
PN=170
System Diagrams
T8535AB 1906JAN99
TX,9015,QQ3192 1931AUG952/7

110703
PN=171
System Diagrams
T8535AC 1906JAN99
TX,9015,QQ3192 1931AUG953/7

110703
PN=172
System Diagrams
T8166BG 1919FEB99
TX,9015,QQ3192 1931AUG954/7

110703
PN=173
System Diagrams
T8535AE 1906JAN99
TX,9015,QQ3192 1931AUG955/7

110703
PN=174
System Diagrams
T8535AF 1906JAN99
TX,9015,QQ3192 1931AUG956/7

110703
PN=175
System Diagrams
T8535AG 1906JAN99
TX,9015,QQ3192 1931AUG957/7

110703
PN=176
System Diagrams
Cab Roof Harness (W5) Wiring Diagram

T7812AH 1923APR97
E1 E2 M2
DOME SWIVEL REAR
LIGHT LIGHT WIPER MOTOR E6 M4 H4 E8 E4
GRY
R.H. R.H. DOOR R.H. R.H. R.H.
REAR WIPER MOTOR FRONT FRONT FRONT X2
E10 H5 E12 WORK TURN DRIVE WORK ROOF HARNESS
R.H. R.H. R.H. LIGHT LIGHT LIGHT LIGHT TO SIDE CONSOLE
REAR REAR BRAKE HARNESS CONNECTOR
M
TAIL TURN LIGHT
LIGHT LIGHT X29 P25 RED B
M E1, X29 P15 RED A
RED
BLU
YEL
BRN
GRN
RED
BRN
YEL
BLU
* WIRES A68 AND A69
G20 BLK
G20 BLK
P15 RED
(SHOWN AS DASHED
LINES) ARE USED FOR
(S.N. 816286) X3
ROOF HARNESS
TO SIDE CONSOLE
S27 S28 HARNESS CONNECTOR
G20 BLK
DOME SWIVEL M4 * A69 ORG H
A66 ORG
P14 RED
A63 ORG
A65 ORG
G20 BLK
G20 BLK
G20 BLK
L42 BRN
A64 ORG
G20 BLK
L43 BRN
G20 BLK
L47 BRN
L41 BRN
G20 BLK
G20 BLK
L47 BRN
P14 RED
LIGHT LIGHT
* A69 ORG
M3 * A68 ORG G
SWITCH SWITCH
L47 BRN
L46 BRN
G20 BLK
G20 BLK
L43 BRN
M2 A66 ORG F
M2 A65 ORG E
E6
W2
X3
X3
X1
W2
H4
E4
W2
X3
X3
X3
X1
E8
W2
X1
M4
X1
X2
W2
X1
M2
X1
X1
H4
X1
H5
M4 A64 ORG D
W2
X3
X3
X3
X1
X1
H2
X1
X1
W2
W2
W2
E3
X1
X2
X2
W2
X1
W2
X1
X1
W2
H3
X1
E7
E5
M4 A63 ORG C
M3 A62 ORG B
E10, H5
E11
E12, M4
E7, H2
E9, H3
H4, E13
X29, M3
S28, M2
M3 A61 ORG A
X1
L46 BRN
G20 BLK
A61 ORG
L41 BRN
G20 BLK
L48 BRN
L48 BRN
G20 BLK
L48 BRN
G20 BLK
A62 ORG
L43 BRN
G20 BLK
L43 BRN
L45 BRN
G20 BLK
L42 BRN
G20 BLK
G20 BLK
G20 BLK
P14 RED
P15 RED
L43 BRN
G20 BLK
P25 RED
ROOF HARNESS
*A68 ORG
G20 BLK
TO SIDE CONSOLE
HARNESS CONNECTOR
M3 P14 RED H
M2, M4
E6, E5 L41 BRN G
H2, H3 L48 BRN F
A B C D X29 L43 BRN E
E7, E9, E10, E8
RED
YEL
BLU
GRN
W2 X29 E13 L45 BRN D

GROUND ROOF HARNESS H4, H5 L47 BRN C
TO CAB E5 E7 E3 M TO RADIO E13
L.H. H2 L.H. L.H. HARNESS BEACON E11, E12 L46 BRN B
FRAME H3 E9
REAR E11 L.H. FRONT FRONT CONNECTOR LIGHT E4, E3 L42 BRN A
L.H. L.H. L.H. FRONT DRIVE M3
WORK REAR WORK L.H. DOOR
BRAKE REAR TURN LIGHT
LIGHT TAIL LIGHT WIPER MOTOR
LIGHT TURN LIGHT
LIGHT LIGHT
T7812AH
TX,9015,QQ2093 1912APR941/1

110703
PN=177
System Diagrams
Cab Roof Harness (W5) Component Location

T7812AI 1925APR97
TX,9015,QQ2094 1904MAY931/1

110703
PN=178
System Diagrams
Cab Side Console Harness (W6) Wiring Diagram (SN 778668)

T7994AA 1919FEB99
TX,9015,QQ2100 1904MAY931/1

110703
PN=179
System Diagrams
Cab Side Console Harness (W6) Component Location (SN 778668)

T7915BF 1919FEB99
TX,9015,QQ2095 1904MAY931/1

110703
PN=180
System Diagrams
Cab Floor Harness (W6) Wiring Diagram (SN 778668)

T7915BG 1905MAR99
TX,9015,QQ2096 1904MAY931/1

110703
PN=181
System Diagrams
Cab Floor Harness (W6) Component Location (SN 778668)

T8170AO 1918DEC98
TX,9015,QQ2554 1912APR941/1

110703
PN=182
System Diagrams
Cab Side Console Harness (W6) Wiring Diagram (SN 778669XXXXXX)

T8167AO 1919FEB99
TX,9015,QQ3224 1931AUG951/2

110703
PN=183
System Diagrams
T8167AP 1902MAR99
TX,9015,QQ3224 1931AUG952/2

110703
PN=184
System Diagrams
Cab Side Console Harness (W6) Wiring Diagram (SN XXXXXX )

T8462AJ 1925APR97
TX,9015,QQ3231 1931AUG951/2

110703
PN=185
System Diagrams
T8535AH 1906JAN99
TX,9015,QQ3231 1931AUG952/2

110703
PN=186
System Diagrams
Cab Side Console Harness (W6) Component Location (SN 778669 )

T8535AI 1906JAN99
TX,9015,QQ3200 1931AUG951/2

110703
PN=187
System Diagrams
T7915BL 1919FEB99
TX,9015,QQ3200 1931AUG952/2

110703
PN=188
System Diagrams
Front Console Harness (W7) Wiring Diagram

T7994AU 1919FEB99
TX,9015,QQ2103 1904MAY931/1

110703
PN=189
System Diagrams
Front Console Harness (W7) Component Location

T7915BN 1919FEB99
TX,9015,QQ2111 1904MAY931/1

110703
PN=190
System Diagrams
Engine Harness (W8) Wiring Diagram

T8167AQ 1919FEB99
TX,9015,QQ2447 1912APR941/2

110703
PN=191
System Diagrams
T8167AR 1919FEB99
TX,9015,QQ2447 1912APR942/2

110703
PN=192
System Diagrams
Engine Harness (W8) Component Location

T8168AB 1919FEB99
TX,9015,QQ2450 1912APR941/1

110703
PN=193
System Diagrams
Blower Harness (W10) Wiring Diagram

T7812AT 1925APR97
TX,9015,QQ2115 1931AUG951/1

110703
PN=194
System Diagrams
Blower Harness (W10) Component Location

T7812AV 1925APR97
TX,9015,QQ2116 1904MAY931/1

110703
PN=195
System Diagrams
Radio Harness (W12) Wiring Diagram

T7931BO 1919FEB99
TX,9015,QQ2117 1904MAY931/1

110703
PN=196
System Diagrams
Radio Harness (W12) Component Location

T7931BN 1919FEB99
TX,9015,QQ2118 1904MAY931/1

110703
PN=197
System Diagrams
Air Conditioning Compressor Harness (W11) Wiring Diagram

T7812AU 1925APR97
TX,9015,QQ2119 1912APR941/1

110703
PN=198
System Diagrams
Air Conditioning Compressor Harness (W11) Component Location

T8169AR 1919FEB99
TX,9015,QQ2553 1912APR941/1

110703
PN=199
System Diagrams
Auxiliary Valve Harness (W14) Wiring Diagram

T8166BR 1918DEC98
TX,9015,QQ2449 1912APR941/1

110703
PN=200
System Diagrams
Auxiliary Valve Harness (W14) Component Location

T8166BP 1918DEC98
TX,9015,QQ2451 1912APR941/1

110703
PN=201
System Diagrams
9015
10
42

110703
PN=202
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

Terminal 30 of accessory relay
Start relay
BAT terminal of alternator (S.N. 787551)
B+ terminal of alternator (S.N.787552 )
Starter
Radio fuse
Hazard/monitor fuse
9015
15
1
TX,9015,QQ2105 1904MAY931/1
Power Circuit Theory Of Operation
The power circuit includes battery and main current paths

to primary distribution points.
With key switch OFF, power from battery goes to key

switch, accessory relay, start relay, alternator, starter
motor, 4-way flasher switch, logic module, alternator
sense relay and dome light fuse.
When key switch is moved from OFF position, power

continues through IGN and ST terminals to main fuse
block. ACC terminal power goes to accessory relay,
energizing relay sending power to the main fuse block.
The key switch G terminal is a ground terminal only in

Bulb Check and Start positions.
NOTE: For component identification code description, see

Wiring and Schematic Diagrams Legend , Group
9015-10.
TX,9015,QQ1726 1912MAR931/1

110703
PN=203
Power Circuit Schematic
9015
15
2
1921SEP95
T8538AB

110703
PN=204
9015
15
3
1922AUG95
T8538AC

110703
PN=205
9015
15
4
1922AUG95
T8538AD
TX,9015,QQ3234 1931AUG953/3

110703
PN=206
Power Circuit Diagnostic Procedures
1/1
Battery State Of Charge YES: Clean battery cable

CAUTION: Engine may crank during this check. terminals. Repeat test.
Move light switch to ON position. Turn key to START. Do work lights go out or get very If lights still get dim, test
dim while cranking engine? battery.
If battery charge is low,

recharge or replace it.
NO: Battery charge is

good. Go to next check . 9015
15
5
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 motor.
Are 12 volts measured?
T7199BK 1917SEP90
1/1
Alternator (SN 778740) 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.
T7199BL 1909OCT90
1/1

110703
PN=207
Alternator (SN 778741 Key switch OFF. YES: Go to next check .

787551)
and alternator.
T7934AV 1915FEB93
1/1
Alternator (SN 787552 ) Key switch OFF. YES: Go to next check .

9015
15
6
and alternator.
T7828AA 1923SEP92
1/1
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.
T7199BM 1917SEP90
1/1

110703
PN=208
Key Switch Check Key switch OFF. YES: Go to next step in

this check.
With harness connected, check voltage of B11 red wire
at BAT terminal of key switch. NO: Check wiring
harness between battery
Are 12 volts measured? and key switch.
T7199BO UN17SEP90
Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next step in
this check.
Remove FNR/park brake fuse.
NO: Replace key switch
Remove start fuse.
Turn key switch to START position.

9015
T7199BO UN17SEP90
With harness connected, check voltage at IGN and ST
15
terminals.
7
Are 12 volts measured at each terminal?
Key switch ON. YES: Go to next check .
With harness connected, check voltage at ACC terminal NO: Replace key switch.
of key switch.
T7199BO UN17SEP90
1/1

110703
PN=209
Accessory Relay Key switch OFF. YES: Go to next step in

this check.
With harness connected, check voltage at large terminal
with B11 red wire. NO: Check wiring
Are 12 volts measured? and accessory relay.
T7199BN UN16AUG90
Key switch ON. YES: Go to next step in

this check.
With harness connected, check voltage at small terminal
9015
15 T7199BN UN16AUG90
8
Disconnect harness from relay. YES: Relay is good.
Connect battery voltage to small terminal. Ground NO: Replace accessory

mounting bracket. relay.
Does relay click?
Measure continuity between the two large terminals.

T7199BN UN16AUG90
Is continuity measured?
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
TX,9015,QQ1942 1916MAR931/1

110703
PN=210
Start Circuit Theory Of Operation
The start circuit converts the electrical energy from the

battery to mechanical energy by the starter. A heavy
current draw takes place in the starter.
With key switch OFF, power flows from battery to starter

motor terminal, start relay spade terminal, accessory
relay, and key switch BAT terminal.
With key in ON or IGN, power flows from IGN terminal

through FNR/park brake fuse, to FNR switch. With the
FNR in neutral power flows to the neutral start relay
terminal 86, energizing relay.
With key switch in START, power flows from ST terminal

9015
through start fuse, neutral start relay, to the start relay 15
closing the relay. With relay closed, power flows from 9
starter motor through BO3 red wire to start relay, through
E02 white wire to starting motor solenoid S terminal,
closing solenoid contacts. With solenoid contacts closed,
power flows from battery to the starter windings.

Legend For Schematic and Wiring Diagram ,
Group 9015-10.
TX,9015,QQ1985 1916MAR931/1

110703
PN=211
Start Circuit Schematic
9015
15
10
1922AUG95
T8538AE

110703
PN=212
9015
15
11
1922AUG95
T8538AF
TX,9015,QQ3237 1931AUG952/2

110703
PN=213
Start Circuit Diagnostic Procedures
1/1
Key Switch Check Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next check .
Remove FNR/park brake fuse. NO: Replace key switch.
Remove start fuse.
T7199BO UN17SEP90
terminals.
9015
15 Are 12 volts measured at each terminal?
12
1/1

110703
PN=214
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.
9015
T7199BP 1902OCT90 15
13
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.
T7199BQ 1902OCT90
1/1
Neutral Start Relay Key switch OFF. YES: Relay is good.

Check wiring harness.
Disconnect harness from relay.
NO: Replace neutral start
Connect battery voltage to terminal #86. Ground terminal relay
#85. Does relay click?
Measure continuity between terminals #30 and #87.

T7287BH UN16AUG90
1/1

110703
PN=215
Hydraulic Pump Key switch OFF. YES: Solenoid is good.

Destroke Solenoid Check wiring harness.
Disconnect harness from destroke solenoid.
NO: Replace solenoid.
Connect battery voltage to solenoid terminal A and
ground terminal B.
Does solenoid click?

T7418AN 1927NOV90
1/1
Start Relay Key switch OFF. YES: Relay is good.

9015
Disconnect harness from relay. NO: Replace start relay.
15
14
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 1916AUG90
1/1
Start Solenoid Check YES: Solenoid is OK.

CAUTION: Starter will crank engine if metal strap is NOT disconnected Check starter motor .
from starter motor.
NO: Replace starter
Disconnect metal strap from starter motor terminal. solenoid.
Connect battery voltage to solenoid small terminal.
Ground metal strap from solenoid with heavy gauge

wire.

T6534BI UN19OCT88
Remove jumper wires.
1/1
Starter Motor YES: Starter motor is

CAUTION: Starter will crank engine if metal strap is NOT disconnected good. Check wiring
from starter motor. harness.
Disconnect metal strap from starter motor large terminal. NO: Repair or replace
starter motor.
Connect a heavy gauge jumper wire from battery
positive cable to starter motor terminal.
Does starter motor turn, but NOT crank engine?
T6534BJ UN07JAN97
1/1

110703
PN=216
Charging Circuit Operational Information
The following conditions must exist for charging circuit to

function:
Key switch in ON position

Engine running
TX,9015,QQ1827 1912MAR931/1
Charging Circuit Theory Of Operation

9015
The charging circuit consists of the battery, alternator, The alternator terminal (D+) gets power from ACC 15
alternator relay, key switch, accessory relay, and terminal of the key switch by energizing the accessory 15
indicator light in the monitor panel. relay, closing relay contacts and sending power to
MFWD/Alternator/Diff. Lock fuse.
78 AMP DELCO ALTERNATOR (S.N. 787551)
With key switch ON and engine running, power flows
The alternator BAT terminal is connected to battery from terminal (W) of alternator to alternator relay,
voltage at all times. The voltage sensing terminal No. 2 energizing it. Terminals 30 and 87 are connected, and
is connected to the BAT terminal of alternator. indicator light goes out.
The alternator terminal No. 1 gets power from ACC When key is on but engine is not running or if
terminal of the key switch. With key switch ON and alternator fails, alternator relay de-energizes and
engine running, power flows from terminal R of terminals 30 and 87A are connected. This grounds the
alternator to alternator relay, energizing it. Terminals indicator light and light comes on.
30 and 87 are connected, and indicator light goes out.
NOTE: For component identification code description,
When key is on but engine is not running or if see Wiring and Schematic Diagrams Legend ,
alternator fails, alternator relay de-energizes and Group 9015-10.
terminals 30 and 87A are connected. This grounds the
indicator light and light comes on.
95 AMP BOSCH ALTERNATOR (S.N.787552 )
The alternator (B+) terminal is connected to battery

voltage at all times.
TX,9015,QQ2124 1912APR941/1

110703
PN=217
Charge Circuit Schematic
9015
15
16
1922AUG95
T8538AG

110703
PN=218
9015
15
17
1922AUG95
T8538AH

110703
PN=219
9015
15
18
1922AUG95
T8538AI

110703
PN=220
9015
15
19
1922AUG95
T8538AJ

110703
PN=221
9015
15
20
1922AUG95
T8538AK
TX,9015,QQ3239 1931AUG955/5

110703
PN=222
Charging Circuit Diagnostic Procedures
1/1
Alternator Output Key switch OFF. YES: Alternator is good.

Measure and record battery voltage. Check battery.
Start and run engine at 1500 rpm, and check battery NO: Check alternator .
voltage.
Does battery voltage increase?

T6569AZ UN23AUG93
9015
15
21
1/1
Alternator And Regulator YES: Alternator is good,

Check (SN 787551) replace regulator.
NO: Alternator is failed.

Repair or replace.
T7320AR 1901AUG90
Using a multimeter, connect to battery voltage at large terminal of starter, and ground
other lead.
Start and run engine at 1500 rpm. Turn drive lights ON.
Insert a small screwdriver in alternator test hole and ground tab to alternator case.
Does voltage steadily increase and lights get brighter when tab is grounded?
1/1

110703
PN=223
Alternator (SN 787552 ) 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?
9015
15 T7835AT 1923SEP92
22
1/1
Alternator Relay IMPORTANT: Relay is a six volt relay. Do not apply YES: Relay is good.
more than 6 volts when testing. Check wiring harness.
Disconnect harness from relay. NO: Replace relay.
Measure continuity between terminals #30 and #87A. Is

T7596AQ 1903OCT91
Connect battery voltage to terminal #86. Ground terminal
Measure continuity between terminals #30 and #87. Is

1/1
Alternator Diode Remove diode from connector. YES: If continuity is

measured in both checks,
Connect an ohmmeter to diode terminals. diode has failed in a
shorted mode. Replace.
NO: If continuity is NOT
Reverse ohmmeter probes. measured in either check
diode has failed in an
T7961AA UN10MAR93
Is continuity measured? open mode. Replace.
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1

110703
PN=224
Key Switch Check Key switch OFF. YES: Go to next step in

this check.
With harness connected, check voltage of B11 red wire
at BAT terminal of key switch. NO: Check wiring
Are 12 volts measured? and key switch.
T7199BO UN17SEP90
Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next step in
this check.
Remove FNR/park brake fuse.
NO: Replace key switch
Remove start fuse.

9015
T7199BO UN17SEP90
15
terminals.
23
Key switch ON. YES: Go to next check .
With harness connected, check voltage at ACC terminal NO: Replace key switch.
of key switch.
T7199BO UN17SEP90
1/1

110703
PN=225
Accessory Relay Key switch OFF. YES: Go to next step in

this check.
With harness connected, check voltage at large terminal
T7199BN UN16AUG90
Key switch ON. YES: Go to next step in

this check.
With harness connected, check voltage at small terminal
9015
15 T7199BN UN16AUG90
24
Disconnect harness from relay. YES: Relay is good.
Connect battery voltage to small terminal. Ground NO: Replace accessory

mounting bracket. relay.
Does relay click?
Measure continuity between the two large terminals.

T7199BN UN16AUG90
1/1
Display Module And Logic Module Circuit

Operational Information (SN XXXXXX) With
Logic Module
The following conditions must exist for display module and

logic module to function.
The key switch must be in BULB CHECK or START

position to arm the logic module so failures will be
indicated.
TX,9015,QQ3185 1931AUG951/1

110703
PN=226
Display Module And Logic Module Circuit Theory Of Operation (SN XXXXXX) With
Logic Module
Key Switch OFF The logic module stops current flow to the display
monitor.
Power is supplied to the logic module through the
Hazard/Monitor Unswitched fuse to pin A of logic Failure Occurs
module (6 pin connector).
The indicator switch (sensor) closes, grounding an
Key Switch ON indicator light and also the logic module. The logic
module supplies power to all bulbs in the display
Power is supplied to the logic module through the module, the secondary failure indicator light, primary
Monitor Switched fuse. No power is supplied from the indicator light, and alarm. The logic module then
logic module to the display module since the logic connects either the red light and alarm or the yellow
module has not been armed. light to ground, turning them ON.
9015
Key Switch In BULB CHECK Or START If the key switch is momentarily turned OFF and back 15
ON while the engine is running, power from the 25
The key switch connects all indicator lights in the alternator indicator terminal will keep the logic module
display module to ground when the key switch is in the activated.
BULB CHECK or START positions. The key switch
also grounds the logic module, signaling the logic NOTE: For component identification code description,
module to supply power to all bulbs in the display see Wiring and Schematic Diagrams Legend ,
module, the primary and secondary indicators and the Group 9015-10.
alarm, turning them ON. Turning the key switch to
BULB CHECK or START also arms the logic module
so failures will be indicated.
Engine Started And Key Switch ON
All indicator switches (sensors) are open and the

ground circuits to the indicator lights and logic module
are broken.
TX,9015,QQ3186 1931AUG951/1
Display Module And Logic Module Circuit

Operational Information (SN XXXXXX )
Without Logic Module
The following conditions must exist for display module to

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

be indicated.
TX,9015,QQ3187 1931AUG951/1

110703
PN=227
Display Module Circuit Theory Of Operation

(SN XXXXXX ) Without Logic Module
Power is supplied to the display module through the

Monitor Switched fuse.
Elimination of the logic module allows the monitor on the

backhoe to be active when the key switch is turned to the
ON position. Moving the key switch to the BULB CHECK
position to activate the monitor is no longer necessary.
CONDITION: Key ON Engine OFF:
WITH LOGIC MODULE WITHOUT LOGIC MODULE

No Lights or alarm. Red warning, yellow warning,
engine oil pressure, alternator
9015
charging light are ON, and alarm
15
is beeping.
26
CONDITION: BULB CHECK:

Red warning light is flashing, Red warning light is ON but NOT
yellow warning is ON, and alarm flashing, yellow warning is ON,
is beeping. and alarm is beeping.
CONDITION: Engine Running and engine water

temperature and alternator lights are ON:

Red warning light is flashing and Red warning light is on but NOT
alarm is beeping. flashing, yellow warning is ON,
and alarm is beeping.
When failure occurs the indicator switch (sensor) closes,

grounding an indicator light, the red light and alarm or the
yellow light turning them ON.

110703
PN=228
9015
15
27
1922AUG95
T8538AL

110703
PN=229

see Wiring and Schematic Diagrams Legend ,
Group 9015-10.
9015
15
28

110703
PN=230
9015
15
29
1922AUG95
T8538AM

110703
PN=231
9015
15
30
1925MAR97
T8462AM
TX,9015,QQ3188 1931AUG955/5

110703
PN=232
Display Module And Logic Module Circuit Diagnostic Procedures
This circuit is powered by the monitor fuse, and the hazard/monitor unswitched fuse.
1/1
Fuse Remove fuse cover. YES: Replace fuse.
Check 5 amp monitor fuse, and 15 amp hazard/monitor NO: Go to next check
fuse.
Is fuse blown?
T7199BR 1916AUG90
9015
15
31
1/1
Display Module And Remove diode from connector. YES: If continuity is

Logic Module Diode measured in both checks,
T7961AA UN10MAR93
is OK.
1/1
Logic Module (SN XXXXXX)
See Logic Module Test in Machine and Logic Module

Bench Test , in Group 9015-20.
TX,901515,QQ363 1931AUG951/1

110703
PN=233
Indicator Circuit Specifications

Specification
Engine Coolant Temperature
Switch (Normally Open)Closing
Temperature ..................................................................... 101.7C (215F)
Engine Oil Pressure Switch
(Normally Closed)Opening
Temperature .................................................... 3772 KPa (0.40.7 bar)
(5.510.5 psi)
Air Filter Restriction Switch
(Normally Open)Closes on
Increased Vacuum................................. 4.987.48 kPa Vacuum (2030
in. H2O)
Converter Oil Temperature Switch
Increasing Temperature ................................................ 114.3C121.2C
(238F252F)
9015 Hydraulic Filter Restriction Switch
15 (Normally Open)Closing
32 Temperature ................................................... 344 kPa (3.45 bar) (50 psi)
TX,9015,QQ1972 1916MAR931/1
Indicator Circuit Operational Information
The Indicator Circuit has TWO modes of operation.
Bulb check mode

Failure mode
The following conditions must exist for indicator circuit to

function in bulb check mode:
Key switch moved to BULB CHECK position
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 a

display module light. An indicator switch or alternator relay
senses a failure and supplies a ground for an indicator
light, warning light and buzzer.
TX,901515,QQ534 1907DEC901/1

110703
PN=234
Indicator Circuit Theory Of Operation (SN XXXXXX) With Logic Module
Indicator lights and switches of the display module are: supplied to display module by key switch during BULB
CHECK. Power then flows through logic module and
Engine Coolant Temperature (Stop) display module to ground. Logic module is activated
Engine Oil Pressure (Stop) and all display module lights and buzzer are checked.
Engine Alternator Volts (Service Required)
Engine Air Filter (Service Required) Failure Mode:
Converter Oil Temperature (Stop)
Hydraulic Oil Filter (Service Required) During normal operation the indicator lights are turned
on when an indicator switch or the alternator relay
STOP Warning Level: provides a ground circuit for the light. This ground
circuit also signals logic module and turns on red
Red STOP light ON, audible alarm ON and function STOP light and alarm or yellow SERVICE REQUIRED
indicator light ON. light.
9015
SERVICE Warning Level: NOTE: For component identification code description, 15
see Wiring and Schematic Diagrams Legend , 33
Yellow WARNING light and a function indicator light Group 9015-10.
ON.
Bulb Check Mode:
Key switch in BULB CHECK position connects logic

module and display module to ground. The ground is
TX,9015,QQ3189 1931AUG951/1

110703
PN=235
Indicator Circuit Theory Of Operation (SN XXXXXX) Without Logic Module
Indicator lights and switches of the display module are: Bulb Check Mode:
Engine Coolant Temperature (Stop) Key switch in BULB CHECK position connects warning
Engine Oil Pressure (Stop) lights, buzzer and display module to ground. All display
Engine Alternator Volts (Service Required) module lights and buzzer are checked.
Engine Air Filter (Service Required)
Converter Oil Temperature (Stop) Failure Mode:
Hydraulic Oil Filter (Service Required)
During normal operation the indicator lights are turned
STOP Warning Level: on when an indicator switch or the alternator relay
provides a ground circuit for the light. This ground
Red STOP light ON, audible alarm ON and function circuit turns on the red STOP light and alarm or the
indicator light ON. yellow SERVICE REQUIRED light.
9015
15 SERVICE Warning Level: NOTE: For component identification code description,
34 see Wiring and Schematic Diagrams Legend ,
Yellow WARNING light and a function indicator light Group 9015-10.
ON.
TX,9015,QQ3190 1931AUG951/1

110703
PN=236
Indicator Circuit Schematic
9015
15
35
1922AUG95
T8538AN

110703
PN=237
9015
15
36
1922AUG95
T8538AO

110703
PN=238
9015
15
37
1908SEP95
T8538AP

110703
PN=239
9015
15
38
1925MAR97
T8462AO
TX,9015,QQ3245 1931AUG954/4

110703
PN=240
Indicator Circuit Diagnostic Procedures
This circuit is powered by the monitor fuse, and hazard/monitor fuse.
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 1916AUG90
9015
15
39
1/1
Engine Coolant Disconnect connector from display module. YES: Indicator light is
Temperature Indicator good. Check wiring
Light Connect 12 volts to pin terminal 1 for Z33 gray wire. harness.
Ground pin terminal 2 for X36 yellow wire to machine
frame. NO: Check display
module. Replace bulb or
Is engine coolant temperature indicator light on? module.
T6877AB UN18OCT88
1/1
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 1926SEP90
1/1

110703
PN=241
Engine Oil Pressure Disconnect connector from display module. YES: Indicator light is
Indicator Light good. Check wiring
Connect 12 volts to pin terminal 1 for Z33 gray wire. harness.
Ground pin terminal 3 for N34 yellow wire to machine
frame. NO: Check display
module. Replace bulb or
Is engine oil pressure indicator light on? module.
T6877AC UN18OCT88
1/1
Engine Alternator Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39 YES: Circuit is good.
Indicator Circuit (SN purple wire. Repair or replace
9015
787551) alternator.
15
Without starting engine, turn key switch to BULB CHECK, then release to ON.
40
NO: Go to next check .
Is alternator indicator light off?
Remove voltage from M39 purple wire.
Is alternator indicator light on?
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 (SN purple wire. Repair or replace
787552 ) alternator.
Without starting engine, turn key switch to BULB CHECK, then release to ON.
NO: Go to next check .
Is alternator indicator light off?
Remove voltage from M39 purple wire.
Is alternator indicator light on?
1/1
Measure continuity between terminals #30 and #87A. Is

T7596AQ 1903OCT91

1/1

110703
PN=242
Engine Alternator Disconnect middle connector on display module. YES: Indicator light is
Indicator Light good. Check wiring
Ground pin terminal 13 for M37 purple wire to machine harness.
frame.
NO: Check display
Without starting engine, turn key switch to BULB module. Replace bulb or
CHECK, then release to ON. module.
Is engine alternator indicator light on?

T6877AE UN18OCT88
1/1
Engine Air Filter Disconnect M40 purple wire from switch and ground to YES: Replace switch.
Restriction Switch frame.
9015
15
41
CHECK, then release to ON?
Is air filter restriction indicator light on?
T7199CI 1917SEP90
1/1
Engine Air Filter Disconnect middle connector of display module. YES: Indicator light is
Restriction Indicator good. Check wiring
Light Ground pin terminal 14 for M40 purple wire to machine harness.
frame.
NO: Check display
T6877AG UN18OCT88
Is air restriction indicator light on?
1/1
Converter Oil Disconnect X38 yellow wire from switch and ground to YES: Replace switch.
Temperature Switch frame.
Without starting engine, turn key to BULB CHECK, then to next check .
release to ON.
Is converter oil temperature light on?
T7199CJ 1917SEP90
1/1

110703
PN=243
Converter Oil Disconnect middle connector from display module. YES: Indicator light is
Temperature Light good. Check wiring
Ground pin terminal 15 for X38 yellow wire from switch harness.
and ground to frame.
NO: Check display
Without starting engine, turn key to BULB CHECK, then module. Replace bulb or
release to ON. module.
Is converter oil temperature light on?

T7199BS 1916AUG90
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
42
Is hydraulic filter restriction indicator light on?
T7199CK 1917SEP90
1/1
Hydraulic Filter Disconnect middle connector on display module. YES: Indicator light is
Restriction Indicator good. Check wiring
Light Ground pin terminal 16 for F39 yellow wire to machine harness.
frame.
NO: Check display
T7199BT 1916AUG90
Is hydraulic filter restriction indicator light on?
1/1
Display Module And Remove diode from connector. YES: If continuity is

Logic Module Diode measured in both checks,
T7961AA UN10MAR93
is OK.
1/1

110703
PN=244
MFWD Circuit Operational Information
The following conditions must exist for MFWD circuit to

function:
Key switch ON position

MFWD Switch ON
TX,901515,QQ811 1919NOV901/1
MFWD Circuit Theory Of Operation

9015
(S.N. 796854) 410D, (S.N. 796890) 510D MFWD switch in ON position, power flows to the 15
MFWD solenoid, energizing and engaging MFWD. 43
With the key switch ON or ACC position, power flows MFWD switch turned to OFF position, the MFWD
from MFWD fuse to terminal 6 of MFWD switch. With solenoid is de-energized and disengages MFWD.
MFWD switch in OFF position, power flows out
terminal 8 to MFWD solenoid keeping MFWD solenoid NOTE: Indicator light in MFWD switch will remain ON
energized. Power also flows from terminal 5 to terminal while MFWD is engaged. If MFWD is turned
9 and out terminal 10 to MFWD indicator switch. When OFF while operating, light could remain on for
MFWD switch is in OFF position the solenoid is several seconds until load on drive train is
energized maintaining reverser pressure keeping released.
MFWD indicator switch open.
For component identification code description,
With MFWD switch in ON position, power is removed see Legend For Schematic and Wiring
from terminal 8 of switch too solenoid. The solenoid is Diagram , Group 9015-10.
de-energized, releasing reverser pressure and closing
MFWD indicated switch making light in MFWD switch
to come on.
(S.N.796855 ) 410D, (S.N.796891 ) 510D
With the key switch ON or ACC position, power flows

from MFWD fuse to terminal 5 of MFWD switch. With
TX,9015,QQ2557 1912APR941/1

110703
PN=245
MFWD Circuit Schematic
9015
15
44
1904MAR94
T8171AO

110703
PN=246
9015
15
45
1922FEB94
T8171AP
TX,9015,QQ2558 1912APR942/2

110703
PN=247
MFWD Circuit Diagnostic Procedures
This circuit is powered by MFWD fuse.
1/1
MFWD Switch 410D Disconnect harness from MFWD switch. YES: Switch is good. Go
(S.N. 796854) 510D to next check .
(S.N. 796890) With MFWD switch OFF, measure continuity between
terminals 6 and 8. NO: Replace MFWD
switch.
With MFWD switch ON, measure continuity between

T7812AG UN16JUL92
terminals 6 and 8.
9015 Continuity should NOT be measured?

15
46
1/1
MFWD Switch 410D Disconnect harness from MFWD switch. YES: Switch is good. Go
(S.N.796855 ) 510D to next check .
(S.N.796891 ) With MFWD switch ON, measure continuity between
terminals 1 and 5. NO: Replace MFWD
switch.
T7199BU UN02OCT90
1/1
MFWD Solenoid Diode Remove diode from connector. YES: If continuity is

T7961AA UN10MAR93
is OK.
1/1

110703
PN=248
MFWD Indicator Switch Disconnect harness from switch connector. Remove YES: Go to next step in
switch. this check.
Push switch actuator (steel ball). Check continuity. NO: Replace MFWD
indicator switch.
T7287BJ UN16AUG90
Disconnect harness from switch connector. Remove YES: Replace MFWD

switch. indicator switch.
With switch actuator (steel ball) released, check NO: MFWD indicator
continuity. switch is good. Go to next
check .
9015
T7287BJ UN16AUG90 15
47
1/1
MFWD Solenoid Disconnect harness from MFWD solenoid. YES: Solenoid is good.
Connect one lead from connector to ground and the
other to battery voltage. NO: Replace solenoid.
T7199BV UN16AUG90
1/1
Start Aid Circuit Operational Information
(S.N. 794639)
The following conditions must exist for start aid circuit to

function:
FNR lever in neutral

Key switch in IGN or ON position
Start aid switch depressed
(S.N. 794640 )

Start aid switch depressed
TX,9015,QQ2562 1912APR941/1

110703
PN=249
Start Aid Circuit Theory Of Operation
(S.N. 794639)
Power flows from key switch IGN terminal to fuel

shut-off/start aid and reverse warning alarm fuse to start
aid button. When button is pushed, power is supplied to
start aid solenoid.
Power flows from key switch IGN terminal to FNR/park

brake fuse, FNR lever, neutral start relay and ether aid
relay. This energizes ether aid relay, closing terminal 30
and 87 suppling a ground and activating start aid
solenoid.
(S.N. 794640 )
9015
15
48 Power flows from key switch IGN terminal to fuel
shut-off/start aid and reverse warning alarm fuse to start
aid button. When button is pushed, power is supplied to
start aid solenoid. Ground is supplied through GO1 black
wire energizing solenoid.

9015-10.
TX,9015,QQ2563 1912APR941/1

110703
PN=250
Start Aid Circuit Schematic
9015
15
49
1920FEB94
T8172AA

110703
PN=251
9015
15
50
1922FEB94
T8172AB
TX,9015,QQ2564 1912APR942/2

110703
PN=252
Start Aid Circuit Diagnostic Procedures
This circuit is powered by the fuel shutoff/start aid/reverse alarm fuse.
1/1
Start Aid Switch Disconnect harness from start aid switch. YES: Start aid switch is
good. Go to next check .
With start aid button pushed, check for continuity
between terminals with P12 red wire and E25 white wire. NO: Replace start aid
switch.
T7199BW 1916AUG90
9015
15
51
1/1

110703
PN=253
FNR Lever (SN 794639) Key switch ON. FNR lever in neutral YES: Go to next step in
this check.
harness.
9015
15 T7199BP 1902OCT90
52

Go to next check .

wire.
T7199BQ 1902OCT90
1/1
Ether Aid Relay (SN Key switch OFF. YES: Relay is good.
794639) Check wiring harness.
NO: Replace ether aid
Connect battery voltage to terminal #86 with T12 blue relay.
wire. Ground terminal #85 with G10 black wire.
Does relay click?

T7287BH UN16AUG90
Measure continuity between terminals #30 and #87 with
G10 black wire and E27 white wire.
1/1

110703
PN=254
Start Aid Solenoid (SN NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into YES: Start aid solenoid is
794639) engine. good. Check wiring
harness.
Key switch OFF.
NO: Replace start aid
Disconnect harness from solenoid. solenoid.
Connect battery voltage to terminal with E25 white wire.

Ground terminal with E27 white wire.

T7199BX 1917SEP90
1/1
Start Aid Solenoid (SN NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into YES: Start aid solenoid is
794640 ) engine. good. Check wiring
9015
harness.
15
Key switch OFF.
53
NO: Replace start aid
Disconnect harness from solenoid. solenoid.
Connect battery voltage to terminal with E25 white wire.

Ground terminal with GO1 black wire.

T7828AK 1923SEP92
1/1
Fuel Shut-Off Circuit Operational Information
The following conditions must exist for fuel shut-off circuit

to function:
TX,9015,QQ1814 1912MAR931/1

110703
PN=255
Fuel Shut-Off Circuit Theory Of Operation
Power flows from key switch IGN terminal to fuel

shut-off/start aid/reverse alarm fuse, start aid switch and
fuel shut-off solenoid. Solenoid is grounded to frame.
When the fuel shut-off solenoid is energized fuel is
allowed into the injection pump.

9015-10.
9015
15
54
TX,9015,QQ1754 1912MAR931/1

110703
PN=256
Fuel Shut-Off Circuit Schematic
9015
15
55
1912DEC90
T7418AZ
TX,901515,QQ825 1912MAR931/1

110703
PN=257
Fuel Shut-Off Circuit Diagnostic Procedures
This circuit is powered by the fuel shutoff/start aid/reverse alarm fuse.
1/1
Injection Pump Fuel Connect battery voltage to solenoid P12 red wire YES: Solenoid is good.
Shut-Off Solenoid terminal. Check wiring harness.
Does solenoid click? NO: Replace fuel shut-off

solenoid.
Remove voltage from terminal.
Does solenoid click again?

T6785AG UN18OCT88
9015
15
56
1/1
Reverse Alarm Circuit Specifications (SN

794639)
Specification
Reverse Alarm Switch (Normally
Open)Closes on Pressure
Increase ............................................... 296 kPa599 KPa (3 bar6 bar)
(43 psi87 psi)
TX,9015,QQ2571 1912APR941/1
Reverse Alarm Circuit Operational

Information
The following conditions must exist for reverse alarm

circuit to function:
Key switch ON
FNR lever must be in reverse position
TX,9015,QQ1815 1912MAR931/1

110703
PN=258
Reverse Alarm Circuit Theory Of Operation
(S.N. 794639)
Power flows from fuel shutoff/start aid/reverse alarm fuse

to reverse alarm switch. When FNR lever is moved into
reverse the reverse solenoid is activated. Rising pressure
closes the reverse alarm switch sending power to activate
reverse alarm. When FNR lever is shifted to forward or
neutral or when loader lever switch or gear shift lever
switch is depressed the reverse alarm will shut off.
(S.N. 794640 )
Power flows from fuel shutoff/start aid/reverse alarm fuse

to reverse alarm relay terminal 30. When FNR lever is
9015
moved into reverse, power flows through T13 blue wire to 15
terminal 86 of reverse alarm relay , energizing relay. 57
Contacts 30 and 87 are connected sending power to
reverse warning alarm. Power is also sent to the reverse
solenoid energizing solenoid.

9015-10.
TX,9015,QQ2572 1912APR941/1

110703
PN=259
Reverse Alarm Circuit Schematic
9015
15
58
1920FEB94
T8172AM

110703
PN=260
9015
15
59
1920FEB94
T8172AO
TX,9015,QQ2573 1912APR942/2

110703
PN=261
Reverse Alarm Circuit Diagnostic Procedures
This circuit is powered by the fuel shut-off/start aid/reverse alarm fuse.
1/1
FNR Lever (SN 794640 Key switch ON. FNR lever in neutral YES: Got to next step in
) this check.
harness.
9015
15
60
T7199BP 1902OCT90

Go to next check .

wire.
T7199BQ 1902OCT90
1/1

110703
PN=262
Reverse Solenoid Diode Remove diode from connector. YES: If continuity is

T7961AA UN10MAR93
is OK.
1/1
Reverse Alarm Relay (SN Key switch OFF. YES: Relay is good.
794640 ) Check wiring harness.
9015
15
NO: Replace reverse
61
Connect battery voltage to terminal #86. Ground terminal alarm relay.

T7287BH UN16AUG90
1/1
Reverse Alarm Switch Key switch ON. YES: Replace reverse

(SN 794639) alarm switch.
Remove spade terminals with P12 red wire and M62
purple wire from switch. NO: Reverse alarm
switch is good. Go to next
Using a jumper wire connect P12 red wire and M62 check .
purple wire.
T7199BY 1916AUG90
Does reverse alarm sound?
1/1
Reverse Alarm Disconnect harness from reverse alarm. YES: Reverse alarm is
good. Check wiring
Connect battery voltage to reverse warning alarm harness.
positive (+) terminal.
NO: Replace reverse
Connect jumper wire from reverse warning alarm alarm.
negative (-) terminal to ground.
T7199BZ UN16AUG90
Does reverse alarm sound?
1/1

110703
PN=263
Dome Light Circuit Operational Information
The following conditions must exist for dome light circuit to

function:
Key switch in ACC position
TX,9015,QQ1816 1912MAR931/1
Dome Light Circuit Theory Of Operation

9015
15 Power from key switch ACC terminal flows through
62 accessory relay, dome light fuse, dome lights, dome light
switch, swivel light and swivel light switch. With dome light
switch or swivel light switch turned on, contacts close
grounding circuit and lights come on.

9015-10.
TX,9015,QQ1762 1912MAR931/1

110703
PN=264
Dome Light Circuit Schematic
9015
15
63
1923SEP92
T7828AP
TX,9015,QQ1763 1912MAR931/1

110703
PN=265
Dome Light Circuit Diagnostic Procedures
This circuit is powered by the dome light fuse
1/1
Dome Light And Swivel Disconnect harness from switch. YES: Switch is good.
Light Switch Check wiring harness
Turn dome light/swivel light switch ON.
NO: Replace switch.
Using a multimeter check continuity at switch terminals
for dome and swivel light switch.
Does multimeter read continuity?

T6622BB UN09DEC88
9015
15
64
1/1
Dome And Swivel Light Disconnect harness from light. YES: Light is good.
Connect battery voltage to light terminal. Ground light
housing. NO: Replace bulbs or
dome/swivel lights.
Does light come on?
T6534DZ UN19OCT88
1/1
Radio Circuit Operational Information
The following condition or conditions must exist for radio

circuit to function.
Key switch in ACC or ON position

Radio turned ON
TX,9015,QQ1769 1912MAR931/1

110703
PN=266
Radio Circuit Theory Of Operation
When key switch is ON or in ACC position of switch,

power flows to accessory relay energizing relay. Power is
then sent to dome light fuse and front work light fuse.
Switched power is sent to radio fuse and radio.
Unswitched power from radio fuse is to maintain station

memory. Power from the front work light fuse is for light in
radio. Power from the dome light fuse is to power the
radio and speakers.
9015
15
65
TX,9015,QQ1770 1931AUG951/1

110703
PN=267
Radio Circuit Schematic
9015
15
66
1923SEP92
T7828AS
TX,9015,QQ1771 1912MAR931/1

110703
PN=268
Radio Circuit Diagnostic Procedures
This circuit is powered by the unswitched radio fuse and the dome light fuse.
1/1
Radio YES: Go to next check .
NO: Check wiring

harness between radio
and fuses.
9015
15
67
T7828AT 1923SEP92
Key switch ON Front work/drive light switch ON
Measure 12 volts at wire terminals L43 brown, P25 red and P15 red.
Is 12 volts measured at wire terminals?
1/1
Radio Speaker Disconnect harness from radio speaker. YES: Replace radio.
Measure resistance between radio speaker terminals. NO: Replace speaker
Is 7.3 ohms measured?
T7828AU 1923SEP92
1/1

110703
PN=269
Wiper/Washer Circuit Operational Information
The following conditions must exist for wiper/washer

circuit to function.
Key switch must be in ON or ACC position.

Front/rear wiper or washer switch must be turned on.
TX,9015,QQ1817 1912MAR931/1
Wiper/Washer Circuit Theory Of Operation

9015
15 Power flows from wiper/washer fuse through wires P14 Rear wiper in HIGH position, power flows from rear
68 red to terminal 3 on front wiper switch, terminal 1 of wiper switch terminal 1 through A66 orange wire to
washer switch and terminal 3 of rear wiper switch. rear wiper motor.
Front wipers on HIGH, power flows through terminal 3 Rear wiper in LOW position, power flows from rear
and out terminal 1 to left hand door wiper motor. wiper switch terminal 5 through A65 orange wire to
Power also flows through terminal 4 and out terminal 2 rear wiper motor.
to right hand door wiper motor.
Rear wiper in PARK position, power flows through P14
Front wipers on LOW, power flows through terminal 3 red to rear wiper motor deactivating a switch in rear
and out terminal 5 to left hand door wiper motor. wiper motor putting wiper in park position.
Power also flows through terminal 4 and out terminal 6
to right hand door wiper motor. Washer: Power flows from 15 amp wiper/washer fuse
to terminal 5 of washer switch. With washer switch
Front wiper in PARK position, power flows through P14 pushed in power flows from terminal 1 to washer
red wire to right hand door wiper motor, through A69 motor, activating pump.
orange wire to terminal 8 of front wiper switch, out
terminal 6 of front wiper switch through A63 orange NOTE: For component identification code description,
wire to right hand door wiper motor and to ground by see Wiring and Schematic Diagrams Legend ,
G20 black wire. Power also flows through P14 red wire Group 9015-10.
to left hand door wiper motor, through A68 orange wire
to terminal 7 of front wiper switch, out terminal 5
through A61 orange wire to left hand door wiper motor
and to ground by G20 black wire.
TX,9015,QQ1764 1912MAR931/1

110703
PN=270
Wiper/Washer Circuit Schematic
9015
15
69
1915FEB93
T7938AA
TX,9015,QQ1974 1916MAR931/1

110703
PN=271
Wiper/Washer Circuit Diagnostic Procedures
This circuit is powered by the wiper/washer fuse.
1/1
Front Wiper Switch Wiper switch ON. YES: Front wiper switch
is good. Go to next check
Disconnect harness from front wiper switch. .
Measure for continuity between terminals 2 and 4, 6 and NO: Replace front wiper
8, 1 and 3, and 5 and 7. switch.
T7199CA UN02OCT90
9015
15
70
1/1
Wiper Motor LH Door Disconnect harness from wiper motor. YES: Go to next check .
And RH DoorLow
Speed Connect battery voltage to terminal with red wire and NO: Replace wiper motor.
yellow wire. Ground terminal with black wire.
Does motor run in LOW speed?
Remove voltage from terminal with red wire, and connect

T7199CB UN17SEP90
red and green wire together using a jumper wire.
Does motor run until blade reaches PARK position?
1/1
Wiper Motor LH Door Disconnect harness from wiper motor. YES: Wiper motor is
And RH DoorHigh good. Check wiring
Speed Connect battery voltage to terminal with blue wire and harness.
NO: Replace wiper motor.
Does motor run in HIGH speed?
Remove voltage from terminal with blue wire, and

T7199CB UN17SEP90
connect blue and green wires together using a jumper
wire.
1/1

110703
PN=272
Rear Wiper Switch Wiper switch ON. YES: Rear wiper switch is
Disconnect harness from rear wiper switch.
NO: Replace rear wiper
Using a multimeter measure for continuity between switch.
terminals 1 and 3, and 5 and 7.
T7199CC UN02OCT90
1/1
Rear Wiper MotorLow Disconnect harness from wiper motor. YES: Go to next check .
Speed
9015
Connect battery voltage to terminal with red wire and NO: Replace wiper motor.
15
71
Does motor run in LOW speed?
Remove voltage from terminal with red wire.

T7199CD 1916AUG90
1/1
Rear Wiper MotorHigh Disconnect harness from wiper motor. YES: Wiper motor is
Speed good. Check wiring
Connect battery voltage to terminal with blue wire and harness.
NO: Replace wiper motor.
Does motor run in HIGH speed?
Remove voltage from terminal with blue wire.

T7199CD 1916AUG90
1/1
Washer Switch Washer switch ON. YES: Washer switch is

Disconnect harness from washer switch.
NO: Replace washer
Using a multimeter measure continuity between switch.
terminals 1 and 5.
T7199CE UN02OCT90
1/1

110703
PN=273
Windshield Washer Disconnect harness from washer motor. YES: Washer motor is
Motor good. Check wiring
Connect battery voltage to terminal with S71 orange harness.
wire. Ground motor.
NO: Replace washer
Does motor run and operate the pump? motor.
T7199CF 1916AUG90
1/1
Blower Circuit Operational Information

9015
15 The following conditions must exist for blower circuit to
72 function:
Key switch in ON or ACC position

Blower switch turned ON
TX,9015,QQ1818 1917JUN941/1
Blower Circuit Theory Of Operation
Power from heater circuit breaker goes to blower switch.

With blower switch in low position power is sent to blower
resistor. Voltage goes through complete resistor and is
reduced to 3.03.5 volts, blower motor runs in low speed.
With blower switch in medium position power is sent

through half the blower resistor and is reduced to 6.06.5
volts, blower motor runs in medium speed.
With blower switch in high position power by-passes

resistor and 12 volts is applied to blower motor, causing it
to run at high speed.

9015-10.
TX,9015,QQ1766 1917JUN941/1

110703
PN=274
Blower Circuit Schematic
9015
15
73
1930SEP92
T7857AD
TX,901515,QQ809 1917JUN941/1

110703
PN=275
Blower Circuit Diagnostic Procedures
This circuit is powered by the heater circuit breaker.
1/1
Blower Switch Disconnect harness from blower switch. YES: Blower switch is
good.
Use a multimeter and check for continuity.
NO: Replace blower
Move blower switch to LOW, MEDIUM and HIGH switch.
checking terminals B and L, B and M, and B and H.
T7199CL UN17SEP90
9015
15
74
1/1
Heater Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
motor is good. Check
Connect 12 volts to heater blower motor, and ground wiring harness.
motor.
NO: Replace heater
Does heater blower motor operate? blower motor.
T7199CM UN16AUG90
1/1
Blower Resistor Check Disconnect harness from resistor. YES: Resistor is OK.
Check harness and
Connect ohmmeter to outer terminals of resistor. blower motor.
Does ohmmeter read continuity? NO: Blower resistor has

failed. Replace.
T8134AK UN03DEC93
1/1

110703
PN=276
Drive And Work Light Circuit Operational

Information
The following conditions must exist for drive and work

lights to function:
Key switch in ON or ACC

Front light switch and/or rear light switch in ON position
TX,9015,QQ1820 1912MAR931/1
Drive And Work Light Circuit Theory Of

Operation 9015
15
75
Power flows from front work light fuse to terminal 3 and
terminal 2 of front light switch.
With front light switch in the first position, power flows

from terminal 8 of front light switch to make the front drive
lights, and tail lights come on.
With front light switch in the second position, power flows

from terminal 8 and terminal 1 of front light switch to make
the front drive lights, tail lights, and front work lights come
on.
Rear work lights, power flows from rear work light fuse to
terminal 1 of rear light switch.
With rear light switch in the first position, power flows from
terminal 5 of rear light switch to make rear work lights
come on.
Continued on next page TX,9015,QQ1767 1912MAR931/3

110703
PN=277
9015
15
76
1930APR93
T7996AO

110703
PN=278

see Wiring and Schematic Diagrams Legend ,
Group 9015-10.
TX,9015,QQ1767 1912MAR933/3
Drive And Work Light Circuit Diagnostic Procedures
This circuit is powered by the front work and drive light fuse, and the rear work light fuse.
1/1
Front Light Switch Disconnect harness from front light switch. YES: Front light switch is
good. Check wiring
9015
Light switch ON. harness.
15
77
Measure for continuity between terminals 3 and 1, and 2 NO: Replace switch.
and 8.
T7199CN UN16AUG90
1/1
Rear Light Switch Disconnect harness from rear light switch. YES: Rear light switch is
good. Check wiring
Light switch ON. harness.
Measure for continuity between terminals 1 and 5. NO: Replace switch.
T7199CO UN16AUG90
1/1
Work/Drive Light Disconnect harness from work/drive light. YES: Work light is good.
Connect 12 volts to blue wire and ground black wire.
NO: Replace bulb. If bulb
Does light come ON? is good replace light.
T7199CP UN17SEP90
1/1

110703
PN=279
Tail Light Disconnect harness from turn/tail/brake light. YES: Tail light is good.
Connect 12 volts to terminal marked TAIL, and ground
terminal marked GROUND. NO: Replace bulb. If bulb
is good replace light.
Does tail light come on?
T7199CQ 1902OCT90
1/1
Park Brake/Clutch Disconnect Circuit

9015 Specifications
15
78 Specification
Park Brake Sensing Switch
(Normally Closed)Closes on
Decreasing Pressure .................................. 5516 kPa (55.2 bar) (800 psi)
Opening Pressure .................................. 7585 689 kPa (75.9 6.9 bar)
(1100 100 psi)
(S.N. 778824) Reverser Switch
Increasing Pressure.................................. 345621 kPa (3.456.21 bar)
(5090 psi)
Opening Pressure .................................... 103345 kPa (1.033.45 bar)
(1550 psi)
TX,9015,QQ3252 1931AUG951/1
Park Brake/Clutch Disconnect Circuit

Operational Information
The following condition or conditions must exist for park

brake/clutch disconnect circuit to function:
Key switch OFF

Park brake dash switch in ON position with machine
running
Machine Mechanically Shut Down
Reverser pressure
TX,901515,QQ575 1907DEC901/1

110703
PN=280
Park Brake/Clutch Disconnect Circuit Theory Of Operation
The Park Brake/Clutch Disconnect Circuit consists of Power is disconnected from park brake solenoid, and
FNR/park brake fuse, park brake dash switch, park clutch disconnect solenoid de-energizing solenoids.
brake latching relay, FNR switch, loader lever switch, This applies the park brake and puts the reverser in
gear shift lever switch, park brake solenoid, clutch neutral. When the park brake is applied the park brake
disconnect solenoid, reverser pressure switch, park sensing switch closes providing a ground for the park
light relay and park brake sensing switch. brake dash switch light.
NOTE: The park brake applies automatically when Key ON:

machine is mechanically shut down or when
key switch is turned off. Park brake dash Park Brake Dash Switch in ON position. FNR Lever
switch must be cycled first to applied position Shifted Out of Neutral:
(ON), then to released position (OFF) before
park brake can be released when engine is With the park brake dash switch ON, and the FNR
running. lever shifted out of neutral the park light relay K3 is
9015
de-energized connecting terminals 30 and 87A causing 15
Key OFF: red light and alarm to come ON. 79
Park brake cannot be hydraulically released if there is Key ON:

a blown fuse or key switch is OFF.
Engine running.
Key ON:
With machine mechanically shut down the reverser
Park Brake Dash Switch in ON Position. FNR Lever in pressure switch opens a contact removing ground for
Neutral: park brake latching relay, de-energizing park brake
latching relay connecting terminals 30 and 87A. Power
Power flows from terminal 1 to terminal 6 of park brake is then removed from terminals 6 and 8 of park brake
dash switch and then to park brake latching relay dash switch, de-energizing park brake solenoid and
terminal 85, energizing relay K5 causing it to latch clutch disconnect solenoid. Park brake is applied.
terminals 30 and 87.
For (S.N. 778824)ground is supplied to the park see Wiring and Schematic Diagrams Legend ,
brake latching relay through the reverser switch. Group 9015-10.
For (S.N.778825 )ground is supplied to the park

brake latching relay from the S terminal of the starter
motor.
TX,9015,QQ2580 1912APR941/1

110703
PN=281
Park Brake/Clutch Disconnect Circuit Schematic
9015
15
80
1930APR93
T7996AP
Continued on next page TX,9015,QQ2136 1904MAY931/3

110703
PN=282
9015
15
81
1922AUG95
T8538AQ
Continued on next page TX,9015,QQ2136 1904MAY932/3

110703
PN=283
9015
15
82
1922AUG95
T8538AR
TX,9015,QQ2136 1904MAY933/3

110703
PN=284
Park Brake/Clutch Disconnect Circuit Diagnostic Procedures
This circuit is powered by FNR/Park Brake fuse.
1/1
Park Brake Switch Disconnect harness from park brake switch. YES: Park brake switch is
Dash good. Check wiring
Park brake switch OFF. harness.
Check for continuity between terminals 5 and 7, and 6 NO: Replace park brake
and 8. switch.
T7199CS UN16AUG90
Park brake switch ON.
9015
Check for continuity between terminals 5 and 1, and 6 15
and 2. 83
1/1
Park Brake Solenoid YES: Solenoid is good.

CAUTION: Solenoid may be damaged if Check wiring harness.
voltage is applied to connector terminal A
with black wire. NO: Replace solenoid.
Key switch OFF.
Disconnect harness from park brake solenoid.
T7199CT UN16AUG90
Connect battery voltage to solenoid connector terminal B
with red wire and ground connector terminal A with black
wire.
1/1

110703
PN=285
Loader Lever Switch Disconnect harness from loader lever switch YES: Go to next step in
this check.
Check for continuity between terminals with J27 tan wire
and T53 blue wire. NO: Replace loader lever
switch.
T7199CU 1902OCT90
Disconnect harness from loader lever switch YES: Replace loader

lever switch.
Depress loader lever switch and check for continuity
between terminals with J27 tan wire and T53 blue wire. NO: Loader lever switch
is good. Check wiring
Is continuity measured? harness.
9015
15 T7199CU 1902OCT90
84
1/1
Gear Shift Lever Switch Disconnect harness from gear shift lever switch. YES: Go to next step in
this check.
Check for continuity between terminals with T53 blue
wire and T52 blue wire. NO: Replace gear shift
lever switch.
T7199CV 1902OCT90
Disconnect harness from gear shift lever switch. YES: Replace gear shift
lever switch.
Depress gear shift lever switch and check for continuity
between terminals with T53 blue wire and T52 blue wire. NO: Gear shift lever
switch is good. Check
Is continuity measured? wiring harness.
T7199CV 1902OCT90
1/1
Clutch Disconnect Key switch OFF. YES: Solenoid is good.

Solenoid Check wiring harness.
Disconnect harness from clutch disconnect solenoid.
NO: Replace solenoid.
Connect battery voltage to solenoid terminal B, and
ground terminal A.

T7938AL UN24FEB93
1/1

110703
PN=286
Park Brake Latching Key switch OFF. YES: Relay is good.

Relay Check wiring harness.
NO: Replace relay.
#85.
Does relay click?

T7287BH UN16AUG90
1/1
Reverser Pressure Disconnect harness from switch. YES: Replace switch.

Switch (SN 778824)
9015
Measure continuity between terminals A and B on NO: Switch is good.
15
connector end of switch. Check wiring harness.
85
T7199EE UN02OCT90
1/1

110703
PN=287
FNR Lever Key switch ON. FNR lever in neutral YES: Go to next step in
this check.
harness.
9015
15 T7199BP 1902OCT90
86

Go to next check .

wire.
T7199BQ 1902OCT90
1/1
Park Light Relay Key switch OFF. YES: Relay is good.

NO: Replace relay.
#85.
Does relay click?

T7287BH UN16AUG90
1/1

110703
PN=288
Park Brake Sensing Key switch OFF. YES: Go to next step in

Switch this check.
Disconnect harness from switch connector.
NO: Replace park brake
Measure for continuity. sensing switch.
T7199CX UN16AUG90
Key switch OFF. YES: Replace park brake

sensing switch.
Disconnect harness from switch connector.
NO: Park brake sensing
Depress switch actuator (spring pin). switch is good. Check
wiring harness.
Measure for continuity.
9015
T7199CX UN16AUG90
15
87
1/1
Park Brake Relay Diode Remove diode from connector. YES: If continuity is
T7961AA UN10MAR93
is OK.
1/1
Clutch Disconnect Diode Remove diode from connector. YES: If continuity is

T7961AA UN10MAR93
is OK.
1/1

110703
PN=289
Horn Circuit Operational Information
The following conditions must exist for horn circuit to

function:
Key switch must be in ON or ACC position

Horn switch must be depressed
TX,9015,QQ1821 1912MAR931/1
Horn Circuit Theory Of Operation

9015
15 Power flows from turn/stop/horn fuse to horn switch.
88 When horn button is pushed, switch closes and power
flows to activate horn.

9015-10.
TX,9015,QQ1786 1912MAR931/1

110703
PN=290
Horn Circuit Schematic
9015
15
89
1923SEP92
T7835AE
TX,9015,QQ1787 1912MAR931/1

110703
PN=291
Horn Circuit Diagnostic Procedures
This circuit is powered by the turn/stop/horn fuse.
1/1
Horn Switch Disconnect harness from horn switch. YES: Horn switch is
good.
Push horn switch and measure for continuity.
NO: Replace horn switch.
T7199CY UN16AUG90
9015
15
90
1/1
Horn Key switch OFF. YES: Horn is good.

Disconnect harness from horn.
NO: Replace horn.
Connect battery voltage to horn (+) positive terminal.
Ground horn body.
Does horn sound?

T6573AO UN23AUG93
1/1

The following conditions must exist for turn signal, flasher

and brake light circuit to function:
TX,9015,QQ1822 1912MAR931/1

110703
PN=292
Turn Signal, Flasher And Brake Light Circuit Theory Of Operation
Power flows from turn/stop/horn fuse, to terminal 8 of also sent out terminal 7 of turn signal switch lighting up
4-way flasher switch. With 4-way flasher switch in OFF left turn lights and left turn indicator light.
position power flows from terminal 6 to terminal 5 of
turn signal switch. Power also flows from unswitched 4-Way Flasher:
hazard/monitor fuse to terminal 2 of 4-way flasher
switch. Power flows from terminal 6 of 4-way flasher With 4-way flasher in the ON position and power on
switch to flasher energizing flasher. terminal 2, power flows out terminal 6 of 4-way flasher
switch to flasher, energizing flasher. Pulsing power is
Turn Signal: sent from flasher through L49 brown wire to terminal 5
of 4-way flasher switch and out terminals 1 and 3.
With power on terminal 5 of turn signal switch and turn Pulsing power is sent to left and right turn lights and
signal switch turned left, pulsing power is sent from indicator lights, making them flash.
flasher through L49 brown wires to terminal 6 of turn
signal switch and out terminal 7 to left turn lights and Brake Light:
9015
left turn indicator light making them flash. Power is 15
also sent out terminal 3 of turn signal switch lighting up Power flows from turn/stop/horn fuse to brake light 91
right turn lights and right turn indicator light. switches. When brakes are applied the brake light
switches close and power is routed to brake lights.
With power on terminal 5 of turn signal switch and turn Lights are grounded through G20 black wire.
signal switch turned right, pulsing power is sent from
flasher through L49 brown wires to terminal 6 of turn NOTE: For component identification code description,
signal switch and out terminal 3 to right turn lights and see Wiring and Schematic Diagrams Legend ,
right turn indicator light making them flash. Power is Group 9015-10.
TX,9015,QQ1981 1904MAY931/1

110703
PN=293
Turn Signal, Flasher And Brake Light Circuit Schematic
9015
15
92
1930APR93
T7996AR
TX,9015,QQ2140 1904MAY931/1

110703
PN=294
Turn Signal, Flasher And Brake Light Circuit Diagnostic Procedures
This circuit is powered by the turn/stop/horn fuse, left turn fuse and right turn fuse.
1/1
4-Way Flasher Switch Disconnect harness from 4-way flasher switch. YES: 4-way flasher
With 4-way flasher switch OFF, check for continuity wiring harness.
between terminals 6 and 8.
NO: Replace 4-way
Is continuity measured? flasher switch.
Flasher switch ON.

T7199CZ UN16AUG90
Check for continuity between terminals 6 and 2, 5 and 3,
5 and 10, and 5 and 1. 9015
15
Is continuity measured? 93
1/1
Flasher Key switch ON. YES: Replace flasher.
4-way flasher switch ON. NO: Check bulbs. Check

wiring harness.
Connect jumper wire from terminal with L49 brown wire
to terminal with L50 brown wire.
Do all turn lights function?

T7199DA 1917SEP90
1/1
Turn Signal Switch Disconnect harness from turn signal switch. YES: Turn signal switch
With turn signal switch turned right, check for continuity .
between connector terminals 5 and 7, and 6 and 3.
NO: Replace turn signal
Is continuity measured? switch.
With turn signal switch turned left, check for continuity

between connector terminals 5 and 3, and 6 and 7.
T7199DB UN01OCT90
1/1

110703
PN=295
Brake Light Disconnect harness from turn/tail/brake light. YES: Brake light is good.
Connect 12 volts to terminal marked STOP, and ground
terminal marked GROUND. NO: Replace bulb. If bulb
is good replace light.
Does brake light function?
T7199DS 1902OCT90
1/1
Turn Signal Light Disconnect harness from turn/tail/brake light. YES: Turn signal light is
good. Check wiring
9015
Connect 12 volts to terminal marked DIRECTIONAL, and harness.
15
ground terminal marked GROUND.
94
NO: Replace bulb. If bulb
Does turn signal light function? is good replace light.
T7199DT 1902OCT90
1/1
Left/Right Indicator Light Disconnect harness from indicator light. YES: Indicator light is
good. Check wiring
Connect battery voltage to purple wire and ground black harness.
wire.
NO: Check bulb, if good
Does indicator light function? replace indicator light.
T7199DC 1916AUG90
1/1

110703
PN=296
Brake Light Switch Disconnect harness from brake light switch. YES: Replace switch.
Check for continuity between the two terminals. NO: Go to next step in
this check.
T7199DD UN16AUG90
Disconnect harness from brake light switch. YES: Brake light switch is
good. Check wiring
With brake light switch pushed (closed), check for harness.
continuity between the two terminals.
NO: Replace switch.
9015
T7199DD UN16AUG90 15
95
1/1
4-Way Flasher Switch Remove diode from connector. YES: If continuity is

Diode measured in both checks,
T7961AA UN10MAR93
is OK.
1/1
Beacon Circuit Operational Information
The following conditions must exist for beacon circuit to

function:
Key switch to ACC or ON position

Beacon switch to ON position
TX,9015,QQ1823 1912MAR931/1

110703
PN=297
Beacon Circuit Theory Of Operation
Power flows from return-to dig/beacon fuse to beacon

switch. With beacon switch ON, power flows to the
beacon. Ground for beacon is provided through G20 black
wire.

9015-10.
TX,9015,QQ1791 1912MAR931/1
9015
15
96

110703
PN=298
Beacon Circuit Schematic
9015
15
97
1923SEP92
T7835AG
TX,9015,QQ1792 1912MAR931/1

110703
PN=299
Beacon Circuit Diagnostic Procedures
This circuit is powered by the return-to-dig/beacon fuse.
1/1
Beacon Switch Disconnect harness from beacon switch. YES: Beacon switch is
Beacon switch ON.
NO: Replace beacon
Check for continuity between terminals 1 and 5. switch.
T7199DE UN02OCT90
9015
15
98
1/1
Beacon Disconnect harness from beacon. YES: Beacon is good.

Connect 12 volts to beacon terminal (white wire), and
ground beacon (black wire). NO: Check bulb, if good
replace beacon.
Does beacon function?
T7199DF UN16AUG90
1/1
Return-To-Dig Circuit Operational

Information
The following conditions must exist for return-to-dig circuit

to function:
Key switch ON
Engine running
TX,9015,QQ1824 1912MAR931/1

110703
PN=300
Return-To-Dig Circuit Theory Of Operation
Return-to-dig circuit consists of return-to-dig/beacon fuse,

return-to-dig-switch and return-to-dig solenoid.
Power flows from return-to-dig/beacon fuse to return-to-dig

switch. When the bucket is not in the LEVEL position, the
return-to-dig switch is closed which routes battery power
to the return-to-dig solenoid. The return-to-dig solenoid is
grounded through ground wire GO1 black.

9015-10.
9015
15
99
TX,9015,QQ1793 1912MAR931/1

110703
PN=301
Return-To-Dig Circuit Schematic
9015
15
,100
1915FEB93
T7938AE

110703
PN=302
9015
15
,101
1915FEB93
T7938AF
TX,9015,QQ1983 1916MAR932/2

110703
PN=303
Return-To-Dig Circuit Diagnostic Procedures
This circuit is powered by the return-to-dig/beacon fuse.
1/1
Return-To-Dig Switch Disconnect harness from return-to-dig switch. YES: Replace

return-to-dig switch.
Check for continuity between common terminal and open
terminal. NO: Go to next step in
this check.
9015
15
,102
T7199DG UN17SEP90
Disconnect harness from return-to-dig switch. YES: Return-to-dig switch

Actuate return-to-dig switch. .
Check for continuity between common terminal and open NO: Replace return-to-dig
terminal. switch.
T7199DG UN17SEP90
1/1

110703
PN=304
Return-To-Dig Solenoid Disconnect harness from return-to-dig solenoid. YES: Return-to-dig

solenoid is good.
Apply battery voltage to solenoid, and ground solenoid.
NO: Replace return-to-dig
Move control lever to return-to-dig detent position. solenoid.
Remove voltage from solenoid.
Does control lever stay in return-to-dig detent position

T7199DH 1917SEP90
until voltage is removed, and then return to neutral?
1/1
Fuel Gauge And Hour Meter Circuit

Specifications 9015
15
Specification ,103
Fuel Gauge Level Sender
Empty Resistance......................................................................... 10 ohms
Full Resistance ........................................................................... 180 ohms
TX,9015,QQ1825 1931AUG951/1
Fuel Gauge And Hour Meter Circuit

The following conditions must exist for fuel gauge circuit

to function:
The following conditions must exist for tachometer/hour

meter circuit to function:

Engine running
TX,901515,QQ600 1931AUG951/1

110703
PN=305
Fuel Gauge And Hour Meter Circuit Theory Of Operation
Fuel Gauge: With key switch ON and engine running, hour meter
gets power from W terminal of alternator through M39
The circuit consists of monitor fuse, fuel gauge/light purple wires to alternator relay, energizing the relay
and fuel sender. Power flows from monitor fuse to (+) and connecting terminals 30 and 87 suppling power for
terminal of fuel gauge, out S terminal of fuel gauge to hour meter, causing the hour meter to run. With engine
fuel sender. Fuel sender is grounded through G10 OFF key switch ON alternator relay is de-energized
black wire. Power also flows from (+) terminal of fuel connecting terminals 30 and 87A removing power for
gauge to fuel gauge light. Fuel gauge light is grounded hour meter and suppling ground for alternator indicator
through G10 black wire. light in display module, causing the alternator indicator
light to come on.
Tachometer/Hour Meter:
Power flows from W terminal of alternator through M39 see Wiring and Schematic Diagrams Legend ,
purple wire to S terminal on tachometer/hour meter. Group 9015-10.
9015
15
,104 Tachometer light gets power from P21 red wire and is
grounded through G10 black wire.
TX,9015,QQ1795 1912MAR931/1

110703
PN=306
Gauge And Hour Meter Circuit Schematic
9015
15
,105
1928FEB94
T8175AL

110703
PN=307
9015
15
,106
1928FEB94
T8175AJ
TX,9015,QQ2600 1912APR942/2

110703
PN=308
Fuel Gauge And Hour Meter Circuit Diagnostic Procedures
This circuit is powered by the monitor fuse and hazard/monitor fuse
1/1
Fuel Gauge NOTE: Be sure some fuel is in tank. YES: Fuel gauge is good.
Go to next check .
Key switch ON. Engine OFF.
NO: Replace fuel gauge.
Disconnect harness from fuel gauge.
Does gauge read EMPTY?
T7199DI UN02OCT90
Connect battery voltage to (+) terminal and ground GND
terminal.
9015
Does gauge read FULL? 15
,107
1/1
Fuel Gauge Sender Key switch ON. Engine OFF. YES: Replace sender.
Disconnect wire Y33 yellow from center of sender. NO: Fuel gauge sender is
good. Check wiring
Does gauge read EMPTY? harness to sender.
Reconnect wire Y33 yellow to center of sender.
T6431AJ UN19OCT88
Attach a jumper wire from center screw to ground.
Does gauge read FULL?
1/1

110703
PN=309
Tachometer/Hour Meter Machine running. YES: Hour meter is bad,

replace tachometer/hour
Lower all equipment to ground. meter.
FNR lever in neutral. NO: Check wiring

harness.
Park brake ON.
Check ground (-) terminal for good connection.
Using a voltmeter check voltage on (+) terminal with M37

purple wire.
Are 1214 volts (DC) measured?
9015
15 T7199DJ 1902OCT90
,108
Using a voltmeter, check voltage on terminal (SIG) M39 YES: Tachometer is bad,
purple wire. replace tachometer/hour
meter.
Are 7.63 volts (AC) measured?
NO: Check wiring
harness.
T7199DK 1917SEP90
1/1

T7596AQ 1903OCT91
1/1

110703
PN=310
Alternator Diode Remove diode from connector. YES: If continuity is

T7961AA UN10MAR93
is OK.
1/1
Auxiliary Valve Circuit Operational

Information 9015
15
,109
The following conditions must exist for auxiliary valve
Key switch ON position

Machine running
Auxiliary valve switch in FOOT ON or CONTINUOUS
ON position
TX,9015,QQ2581 1912APR941/1
Auxiliary Valve Circuit Theory Of Operation
The circuit consists of auxiliary valve relay, auxiliary from terminal 6 is sent to terminal 9 for light in switch.
valve switch, auxiliary valve diode, auxiliary valve foot Power from terminal 5 is sent to auxiliary valve foot
switch and auxiliary valve solenoid. Components are switch. When foot switch is depressed power is sent to
grounded by the RO1 black wire through cab side auxiliary valve solenoid energizing solenoid.
console harness. With key switch on, power is routed
through PO1 red wire to auxiliary valve relay terminal When auxiliary valve switch is moved to
30 and to auxiliary valve switch terminal 7. With CONTINUOUS ON position, power is routed out
auxiliary valve switch in OFF position power is routed terminal 1 and 2. Power from terminal 2 is sent to
out terminal 3 of auxiliary valve switch to terminals 85 terminal 9 for light in switch. Power from terminal 1 is
and 87 of auxiliary valve relay. The relay is energized sent to auxiliary valve solenoid energizing solenoid,
latching terminals 30 and 87 of auxiliary valve relay. keeping continuous power on solenoid.
When auxiliary valve switch is moved to FOOT ON

position, power is routed out terminals 5 and 6. Power
TX,9015,QQ2582 1912APR941/1

110703
PN=311
Auxiliary Valve Circuit Schematic
9015
15
,110
1922FEB94
T8166BL
TX,9015,QQ2583 1912APR941/1

110703
PN=312
Auxiliary Valve Diagnostic Procedures
This circuit is powered by monitor fuse.
1/1
Auxiliary Valve Relay Key switch OFF. YES: Relay is good.

NO: Replace auxiliary
Connect battery voltage to terminal #86. Ground terminal valve relay.

T7287BH UN16AUG90
9015
15
,111
1/1
Auxiliary Valve Switch Disconnect harness from auxiliary valve switch. YES: Auxiliary valve
Move auxiliary valve switch to FOOT ON. wiring harness.
Measure for continuity between terminals 3 and 5, 3 and NO: Replace auxiliary
6. valve switch.
T8173BN UN20FEB94
Measure for continuity between terminals 3 and 1, 3 and
2.
1/1
Auxiliary Valve Diode Remove diode from connector. YES: If continuity is

Check measured in both checks,
T7961AA UN10MAR93
is OK.
1/1

110703
PN=313
Auxiliary Valve Foot Disconnect harness from auxiliary valve foot switch. YES: Auxiliary valve foot
Switch switch is good. Check
Foot switch pressed. wiring harness.
Measure for continuity between terminals A and B of NO: Replace auxiliary

connector end. valve foot switch.
9015
15 T8173BP UN20FEB94
,112
1/1

110703
PN=314
Auxiliary Valve Solenoid Key switch ON. Auxiliary valve switch to CONTINUOUS YES: Go to next step in
ON. Harness wires connected. this check.
Check battery voltage at (A). NO: Check ground

connection at (B). Check
Is battery voltage measured? wiring harness.
Check continuity at (B).
9015
T8176AF UN20FEB94 15
,113
Disconnect harness wires from valve. YES: Solenoid is good.
Check continuity at (A). NO: Replace solenoid.
T8176AF UN20FEB94
1/1

110703
PN=315
9015
15
,114

110703
PN=316
Group 20
References
Alternators And Starting MotorsUse CTM77
For additional information, the component technical

UN17JAN89
TS225
TX,9010,SS2208 1901SEP941/1

Installation 9015
20
SERVICE EQUIPMENT AND TOOLS 1
Tachometer
UN28FEB89
T6813AG
10T,9010,K182 1910AUG951/1

110703
PN=317
References
Battery Operation
A battery is a device for converting chemical energy to Batteries should be maintained at an open circuit
electrical energy. It is not a storage tank for electricity, voltage of 12.50 volts or greater. To determine open
but stores electrical energy in chemical form. circuit voltage do the following:
Because of the constant chemical to electrical change 1. Turn master disconnect switch to ON position.
(self-discharge, discharge, or charge), the battery has
a limited life. Proper care (cleaning, adding water, 2. For machines that have not been run during the
charging) will extend the life of the battery. past ten hours, go to Step 4.
The battery is made up of positive plates, negative 3. For machines that have been run in the past ten
plates, separators, plate straps, and chemical solution hours, remove surface charge. Turn key switch to
(electrolyte). The electrolyte is a solution of sulfuric START, turn on 3 or 4 work lights and leave them
acid and water. Sulfuric acid is not lost during on for 3 to 5 minutes. Turn key switch OFF, then
overcharging; therefore, if the liquid solution is low, wait two minutes. (If machine does not have lights,
9015
20 only water should be added. turn key switch to START position for at least 5
2 minutes, then turn off.)
In a fully charged battery, the positive plate is lead
peroxide (PBQ2), the negative plate is spongy lead 4. Measure voltage at alternator by placing the
(Pb), and the electrolyte solution is about 1.270 times negative lead of a multimeter to case of alternator
heavier than water. The amount that the solution is and the positive lead to the sense terminal of the
heavier than water is called specific gravity. alternator.
All batteries will self discharge at a rate of .001 specific Stabilized Open Circuit Voltage And Percentage Charged
gravity point per 24 hour period at a constant 85 F. Specification
12.5 Volts or MoreCharge
The discharge rate increases as temperature increases Percentage.................................................................................. 100%
and decreases as temperature decreases. If the 12.4 VoltsCharge Percentage ................................................... 75%
machine is not used for a period of time, the batteries 12.2 VoltsCharge Percentage ................................................... 50%
must be maintained or stored in a cool place. 12.0 VoltsCharge Percentage ................................................... 25%
11.7 Volts or LessCharge
Percentage...................................................................................... 0%
Wipe batteries with a damp cloth. If terminals are
corroded, use a stiff brush and wash with an ammonia
solution. After washing, flush battery and compartment
with clear water. Keep caps in place when cleaning
and charging.
TX,9015,MM1631 1910AUG951/1

110703
PN=318
References
Battery Specifications
Specification
BatteryVoltage............................................................................. 12 volts
Cold Cranking Power ............................................. 625 amps18c (0F)
Reserve Capacity ................................................ 160 minutes at 25 amps
BCI Group Size ...................................................................................... 31
Fully Charged Electrolyte Specific
Gravity ................................................................................... 1.2651.280
TX,901505,QQ368 1910AUG951/1
9015
20
3

110703
PN=319
References
Diagnose Battery Malfunctions

Battery Using Too Much Water Shorted battery cell Check battery state of charge . (See
Procedure for Testing Batteries.)
High ambient temperature Add distilled water.
Cracked battery case Check battery hold down clamps.

Replace battery.
Regulator Do Alternator Output Check . (See

Charging Circuit Operational
Checks.)
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.
TX,901505,QQ365 1910AUG951/1

110703
PN=320
References
Check Battery Electrolyte Level And

Terminals
9015
20
5
UN23AUG88
TS203

110703
PN=321
References
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
clothing, and cause blindness if splashed into
eyes.
9015
20 Avoid the hazard by:
6
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
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 1015
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.
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.
1. Remove hold-down clamps.

110703
PN=322
References
2. Remove battery covers.
TX,9015,QQ1696 1901SEP953/4
3. Fill each cell to within specified range with distilled

water. DO NOT overfill.
ABattery Post
BFill Tube
CElectrolyte Level Range
UN09SEP03
9015
T6996DB
20
7
Single Level Fill Tube Application
UN09SEP03
T6996DA
Dual Level Fill Tube Application
TX,9015,QQ1696 1901SEP954/4

110703
PN=323
References
Procedure For Testing Batteries

ESSENTIAL TOOLS Hydrometer Test
JT05838 Battery Post/Clamp Cleaner
JT05460 Coolant/Battery Tester Check specific gravity with a hydrometer or battery
JT05832 Battery Load Tester tester such as JT05460 Coolant/Battery Tester.
Record specific gravity reading for each cell.

Visual Check
If high and low readings vary LESS than 0.050 and
1. Check for damage such as cracked or broken case
average specific gravity is between 1.225 and 1.280,
and electrolyte leakage.
battery is fully charged, go to LOAD TEST.
If damage is seen, replace battery.
If high and low readings vary LESS than 0.050 and
average specific gravity is LESS than 1.225, charge
2. Check electrolyte level . (See procedure in this
battery and repeat test. If average specific gravity is
9015 group)
20 still LESS than 1.225, replace both batteries.
8
If low, add distilled water to specified level and
If high and low readings vary MORE than 0.050,
charge battery.
charge battery and repeat test. If high and low
readings still vary MORE than 0.050, replace both
3. Check terminals for corrosion.
batteries.
If corroded, clean using a wire brush or battery post
Load Test
cleaner such as JT05838 Battery Post/Clamp
Cleaner.
Check battery capacity with a load tester such as
JT05832 Battery Load Tester. Follow tester
4. Check posts for looseness.
manufacturers instructions for proper load test
procedures.
If posts are loose, replace battery.
If one battery fails load test, replace both batteries.
TX,901500,RP313 1901SEP951/1

110703
PN=324
References
Using Booster Batteries12 Volt System
Before boost starting, machine must be properly shut

down and secured to prevent unexpected machine
movement when engine starts.
CAUTION: An explosive gas is produced while

batteries are in use or being charged. Keep
flames or sparks away from the battery area.
Make sure the batteries are charged in a well
ventilated area.
IMPORTANT: The machine electrical system is a 12

volt negative (-) ground. Use only 12
volt booster batteries.
9015
Connect booster batteries as shown for your battery 20
9
application. Make last connection to frame.
AMachine Batteries
UN24OCT91
BBooster Batteries
T6508AE1
Single Battery Application
UN24OCT91
T6713AI1
Two Battery Application

TX,901505,QQ364 1901SEP951/1

110703
PN=325
References
Alternator Operation78 AMP Delco Remy (Serial No. 787513)
9015
20
10
1903OCT91
T7596AR
AAlternator EAlternator Relay ITerminal 1 MStator
BBattery FBAT terminal JRegulator NRectifier
CKey Switch GR Terminal KDiode Trio ODiode
DIndicator Light HTerminal 2 LRotor (Field)
The alternator is a 12 volt system. The operating The regulator (J) acts like a switch for the rotor (L). A
principles are as follows: wire runs from BAT terminal (F) to terminal 2 (H). If the
regulator (J) senses a low battery voltage, rotor is
When key switch (C) is turned ON, voltage is applied switched on. Field current increases and alternator
to terminal 1 (I) of the alternator. The regulator (J) output increases.
switches the rotor (L) ON or OFF.
When high battery voltage is sensed by the regulator
Once the engine reaches alternator cut in RPM, the rotor is switched off, reducing current output from
alternating output current is produced in the stator (M) stator. This on and off occurs many times a second.
windings. This alternating current is changed to direct The voltage regulator is temperature compensated to
current by the rectifier (N) diodes. Voltage is available provide a slightly higher voltage at low temperature to
at BAT (F) terminal. The current is used to charge the charge the battery.
battery (B) and supply electrical current to the machine
electrical system. Once alternator is charging, field
current is supplied by the diode trio. Diode (O) protects
the diode trio from external loads.

110703
PN=326
References
When the alternator is operating, the R terminal and removing the ground for the alternator indicator
voltage is approximately 7.8 volts AC. This voltage is light (D) in the display module, turning off the
supplied to the alternator relay, energizing the relay alternator indicator light.
TX,9015,QQ1926 1910AUG952/2
Alternator Operation95 AMP Bosch (Serial No. 787514 )
9015
20
11
1923SEP92
T7812AZ
AAlternator GD+ Terminal LExternal Ground Terminal QAlternator Relay
BInternal Ground HB+ Terminal MRotor RIndicator Light
CNegative Diodes IW Terminal NAlternator Diode SBrushes
DExciter Diodes JExcitation Winding OBattery TSense Circuit
EStator Windings KRegulator PKey Switch UNoise Filter
FPositive Diodes
TX,9015,QQ1927 1910AUG951/1

110703
PN=327
References
Alternator Operation95 AMP Bosch
The 95 AMP Bosch alternator has three basic stages and F) and delivered to the battery and current
for proper operation. The operating principles are as consuming accessories. The currents in the stator
follows. winding (E) are constantly changing magnitude and
direction. However, current flowing to the battery and
PRE-EXCITATION STAGE: accessories always maintains the same direction. This
is because no matter what position the rotor (M) is in,
When key switch (P) is turned to ON position, battery all the diodes are simultaneously involved in the
power flows to (G) terminal D+ on alternator, excitation process of rectification. The regulator (K) measures the
winding (J), through regulator (K) and to internal B+ voltage (H) and compares it to an internal
ground (B). reference. When the B+ voltage (H) starts to rise
above the reference voltage the regulator (K) switches
EXCITATION STAGE: off the field current. When the B+ voltage (H) starts to
fall below the reference voltage the regulator (K)
During alternator start (as the engine speeds up from 0 switches on the field current. The regulator (K)
9015
20 to idle) current supplied by the external alternator switches the field ON and OFF several thousand times
12 diode to the field coil of the rotor produces a magnetic a second in response to the current load placed on the
field which induces current in the three-phase winding alternator output and the engine RPM.
of the stator (E). The alternator reaches cut-in RPM
when the induced current is large enough to produce When the alternator is operating, the W terminal
voltage equal to the battery voltage plus 1.0 volt. At voltage is (7 to 8) volts (AC). This voltage is supplied
this time, some current from the stator is rectified by to the alternator relay, energizing the relay and
the exciter diodes (D) (producing battery voltage at the removing the ground for the alternator indicator light
D+ terminal (G)) and is supplied to the carbon brushes (Q) in the display module, turning off the alternator
and slip rings of the excitation winding (J), indicator light.
strengthening the magnetic field in the excitation
winding. This in turn will increase the stator voltage. Current available from the alternator is dependant on
This will occur continuously until the alternator (A) is engine RPM. Depending on pulley ratios, little or no
fully excited and the alternator regulated voltage is current is available below abut 700 RPM. Full rated
reached. current is not available below about 1500 RPM.
NORMAL OPERATION:
The alternating current induced in the stator winding

(J) is rectified by the positive and negative diodes (C
TX,9015,QQ1837 1910AUG951/1

110703
PN=328
References
Monitor Test In Machine
1. Turn key switch to bulb Check position. All sending unit switches that are closed and sending a
indicator and warning lights and the buzzer must ground signal for a primary (red light) failure
come on. If none of the lights come on, check the indication.
monitor fuse. If one or two lights fail to light,
replace the bulb. 4. Turn key switch to bulb check momentarily and
back to on. After 2-3 seconds, the alternator
2. Return key switch to on position from bulb check. indicator light and the yellow warning light should
Hold just momentarily in bulb check. If held too come on. There may be additional indicator lights
long, the logic modules with time delay will have no on, depending on which secondary (yellow light)
delay. With machines that have time delay logic failure sending unit switches are closed.
modules, after 2-3 seconds the engine oil pressure
and engine alternator volts indicator lights and the 5. If the warning lights do not come on, with (S.N
red warning light and buzzer should come on. With XXXXXX) the next step is to isolate the logic
no time delay the lights and buzzer will come on module from the display module and the machine
9015
immediately. On some machines additional indicator wiring and sending units. See Logic Module Test In 20
lights may come on, depending on sending unit Machine , and Logic Module Bench Test in this 13
switches being closed and sending a ground signal group.
to the monitor.
3. Turn key switch to off position. Disconnect lead

from engine oil pressure switch and all other
TX,9015,QQ3203 1931AUG951/1

110703
PN=329
References
Logic Module Test In Machine (SN

XXXXXX)
1. Disconnect 6 wire connector (G) from left side of

display. Turn key switch ON. Ground pins D E and
F one at a time.
2. Pin D must be grounded first to arm logic module.
3. With pin D grounded, yellow service required light, red

STOP light and alarm must come on.
4. With pin E grounded, yellow service required light

must come on.
9015 5. With pin F grounded, red STOP light and alarm must
20 come on.
14
If logic module does not work when grounding pins D,
E and F, check logic module wiring by continuing
UN03NOV88
with step 6. If wiring is OK, replace logic module.
T6883BE

110703
PN=330
References
6. To check wiring, reconnect wiring at display module.
7. Disconnect harness connectors from logic module.
NOTE: Some of the continuity checks are made on

circuits that contain warning lights or diodes in the
display module. A test light will not work on these
circuits, an ohmmeter must be used. If a digital
ohmmeter is used, it must be set on the Diode
Test position.
8. Make the following voltage and continuity checks at the

logic module connectors in the wiring harness.
Voltage ChecksEngine OFF, Key Switch ON:

9015
6Pin Connector 20
A12 Volts 15
C12 Volts
UN09FEB94
Continuity ChecksKey Switch OFF
A of 4-Pin to C of 4-Pin
A of 4-Pin to D of 6-Pin
T8174AM
B of 4-Pin to Ground
D of 4-Pin to Ground
B of 6-Pin to Alternator Relay NO Terminal
E of 6-Pin to Ground (With key in BULB CHECK
position only)
F of 6-Pin to Ground
If voltage or continuity is not correct, see the schematic

and wiring diagram to trace the circuit.
TX,9015,QQ3201 1931AUG952/2

110703
PN=331
References
Logic Module Bench Test (SN XXXXXX)
IMPORTANT: DO NOT allow wires to touch one

another after being connected to logic
module.
1. Connect wires (A and B) from positive (+) battery post

to pins A and C in large connector.
2. Connect wire (C) from negative battery post to pin F in

large connector.
3. Using a 12V indicator light with two wire leads, connect

one lead to pin D in large connector, and one lead to
pin A in small connector.
9015
20 4. Connect wire (D) to pin E in large connector, and
16 negative battery post. Light must come on. If it does,
remove wire from pin E and go to next step. If light
does not come on, replace module.
UN28FEB94
5. Connect wire (E) to pin B in small connector. Light
must come on. If it does, remove wire (E) from pin B
and go to next step. If light does not come on, replace
T8188AM
module.
6. Remove the indicator light lead from pin D in large

connector and connect to pin C in small connector.
Connect wire (D) to pin D in small connector. Light
must pulse on and off. If it does not, replace module.
UN28FEB94
T8188AN
TX,9015,QQ3202 1931AUG951/1

110703
PN=332
References
Tachometer Calibration
1. Remove heater control knob, blower speed knob and

four side console panel screws to remove panel.
2. Verify engine speed using tachometer. See
UN27JUN91
Tachometer Installation in this group.
3. Adjust screw (B) to adjust machine tachometer to high

idle speed.
T7545BQ
TX,9015,QQ1798 1931AUG951/1
9015
20
17

110703
PN=333
References
9015
20
18

110703
PN=334
Section 9020
Power Train
Contents
Page Page
Group 05Theory Of Operation Reverser Oil Cooler Restriction Test . . . . . . .9020-25-8

Reverser Hydraulic System Operation. . . . . .9020-05-1 Torque Converter Stall Speed Test . . . . . . .9020-25-10
Torque Converter Operation . . . . . . . . . . . . .9020-05-4 Reverser Element Leakage Test Using
Reverser Operation . . . . . . . . . . . . . . . . . . . .9020-05-6 Element Pressure (Three-Gauge
Reverser Hydraulic Filter Operation. . . . . . .9020-05-10 Method) . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-12
Accumulator Operation . . . . . . . . . . . . . . . .9020-05-11 Complete Reverser System Test. . . . . . . . .9020-25-14
Pressure Regulating Valve Operation . . . . .9020-05-12 Reverser Test Procedure . . . . . . . . . . . . . .9020-25-16
Solenoid Operation . . . . . . . . . . . . . . . . . . .9020-05-13 Specifications And Analysis. . . . . . . . . . . . .9020-25-19
Reverser Control Valve . . . . . . . . . . . . . . . .9020-05-14 Brake Valve Leakage Test . . . . . . . . . . . . .9020-25-20
Synchronizer Operation. . . . . . . . . . . . . . . .9020-05-20 Brake Element Leakage Test . . . . . . . . . . .9020-25-21
Second Speed Operation . . . . . . . . . . . . . .9020-05-21 Mechanical Front Wheel Drive (MFWD)
Third Speed Operation . . . . . . . . . . . . . . . .9020-05-22 Clutch Pressure Test (410D SN
Park Brake Operation . . . . . . . . . . . . . . . . .9020-05-23 796854, 510D SN 796890). . . . . . . . . .9020-25-22 9020
Brake Valve Operation . . . . . . . . . . . . . . . .9020-05-24
Service Brake Pressure Lubrication (SN
796851) . . . . . . . . . . . . . . . . . . . . . . . .9020-05-25

System Operational Procedure . . . . . . . . . . .9020-10-1
Brake System Checks . . . . . . . . . . . . . . . . . .9020-10-1
Reverser Checks. . . . . . . . . . . . . . . . . . . . . .9020-10-2
Transaxle Checks . . . . . . . . . . . . . . . . . . . . .9020-10-4
Driving Checks . . . . . . . . . . . . . . . . . . . . .9020-10-5

Reverser Oil Passage Identification. . . . . . . .9020-15-1
Diagnose Power Train Malfunctions . . . . . . .9020-15-4
Group 20Adjustments
Adjust Brake Pedals And Equalizing
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1
Adjust Park Brake . . . . . . . . . . . . . . . . . . . . .9020-20-3
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . .9020-20-4
Check And Adjust Toe-In . . . . . . . . . . . . . . .9020-20-6
Group 25Test
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-1
Reverser Oil Warm-Up Procedure . . . . . . . . .9020-25-1
Reverser System Pressure Test . . . . . . . . . .9020-25-3
Reverser Pump Flow Test (410D, SN
796854) (510D, SN 796890) . . . . . . . .9020-25-4
Reverser Converter-In (Cooler) Relief
Valve Test . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-6

110703
PN=1
Contents
9020

110703
PN=2
Group 05
Theory Of Operation
Reverser Hydraulic System Operation
The reverser hydraulic system is separate from the and rate-of-shift orifice are used to modulate the
main hydraulic system. The reverser case is the engagement of forward clutch or reverse brake.
reservoir for the reverser hydraulic system.
The pressure regulating valve housing contains the
Oil is pulled through a suction screen by the reverser pressure regulating valve, converter-in (cooler) relief
pump. All output from the pump flows to the reverser valve and lube relief valve. The pressure regulating
filter. A filter relief valve protects the element by valve maintains reverser system pressure to engage
releasing oil to the lubrication circuit if there is the forward clutch or reverse brake. The converter-in
excessive differential pressure. Oil flows from the filter (cooler) relief valve protects the reverser oil cooler and
to the accumulator, rate-of-shift orifice, reverser control torque converter from excessive pressure by releasing
valve and pressure regulating valve housing. oil to the reverser lube circuit. The lube relief valve
protects the lube circuit from excessive pressure by
The reverser control valve contains the directional releasing oil to the reservoir.
control valve spool and clutch disconnect spool. The
clutch disconnect spool is used to stop the flow of Oil not used for engagement is used to charge the
engagement oil and lube oil to forward clutch and torque converter and for lubrication. Oil from the torque
reverser brake so transmission can be shifted. converter flows to the reverser oil cooler, then to the
reservoir. The oil cooler is a two-section cooler with
The directional control valve spool is used to direct the bottom section used as the reverser oil cooler and
flow of engagement oil to forward clutch or reverse the top section as hydraulic oil cooler. 9020
brake or stop flow in neutral position. The accumulator 05
1

110703
PN=337
Theory Of Operation
I CLUTCH J K
DISCONNECT FORWARD REVERSE
SOLENOID SOLENOID SOLENOID
G
ACCUMULATOR
H
CLUTCH
DISCONNECT
SPOOL L FORWARD
CLUTCH
9020
E OIL F TORQUE M N REVERSE
05 COOLER CONVERTER DIRECTIONAL BRAKE
2
SPOOL
D PRIORITY O REVERSER
LUBE
LUBE PARK BRAKE
P SOLENOID
C LUBE R Q AND
RELIEF
VALVE CONVERTER-IN PRESSURE ACTUATOR
RELIEF VALVE REGULATING
VALVE
FILTER
B REVERSER RELIEF T
PUMP S VALVE TRANSMISSION
FILTER
A SUCTION
SCREEN
U CONTROL PRESSURE OIL
V CONVERTER-IN PRESSURE OIL
W LUBE OIL
1901JAN99
X RETURN OIL
Y REVERSER HYDRAULIC SCHEMATIC - NEUTRAL

T7998AA
TXC7998AA CV WITH PARK BRAKE RELEASED

110703
PN=338
Theory Of Operation
ASuction Screen HClutch Disconnect Spool OReverser Lube UPressure Oil

BReverser Pump IClutch Disconnect Solenoid PPark Brake Solenoid and VConverter-In Pressure Oil
CLube Relief Valve JForward Solenoid Actuator WLube Oil
DPriority Valve KReverse Solenoid QPressure Regulating Valve XReturn oil
EOil Cooler LForward Clutch RConverter-In Relief Valve YReverser Hydraulic
FTorque Converter MDirectional Spool SFilter Relief Valve Schematic - Neutral
GAccumulator NReverse Brake TTransmission Filter
TX,9020,YY754 1904JUN933/3
9020
05
3

110703
PN=339
Theory Of Operation
Torque Converter Operation
9020
05
4
UN22JAN93
T7927AQ
Continued on next page 10T,9020,K127 1912JUL941/2

110703
PN=340
Theory Of Operation
APilot Shaft DImpeller GFree Wheel Clutch IStator Spline

BTurbine Spline ETurbine HDrain Plug JPump Drive Tang (2 used)
CBoss FStator
There are three main parts to the torque converter. Oil leaving the turbine enters the stationary stator. The
They are: stator is curved so that the oil flow changes direction.
Oil leaving the stator is moving in the same direction
Impeller as the impeller. This adds to the force of the oil
Turbine entering the impeller.
Stator
The turbine will be rotating at a slower speed than the
The impeller is driven by the engine. As it rotates, impeller, but it will produce a higher torque. It is this
centrifugal force throws oil out of the impeller against increased force developed by the stator that makes a
the blades of the turbine. This forces the turbine to converter able to multiply torque.
rotate in the same direction as the impeller.
Under light load the speed of the turbine will increase
The turbine is connected to the turbine shaft which until it equals impeller speed. The free wheel clutch
provides input to the reverser. will unlock, allowing the stator to freewheel or rotate
with the turbine and impeller as a unit. Input speed
As the oil leaves the turbine, it is moving in the and torque are equal to output speed and torque when
opposite direction of the impeller. This would tend to the stator is freewheeling.
slow down the impeller, robbing engine horsepower.
9020
The function of the stator is to prevent this. 05
5
10T,9020,K127 1912JUL942/2

110703
PN=341
Theory Of Operation
Reverser Operation
CLUTCH
PISTON
CARRIER A
F
9020
05
6
C
SECOND SUN
GEAR
E
COMPOUND
PLANET PINION
D
FIRST SUN
GEAR
B
CLUTCH DRUM
G PRESSURE OIL
H CONVERTER-IN PRESSURE
I CONVERTER-OUT PRESSURE
1901JAN99
J LUBE OIL
K RETURN OIL
T7985AB
TXC7985AB CV
L REVERSER FORWARD OPERATION

110703
PN=342
Theory Of Operation
AClutch Piston ECompound Planet Pinion HConverter-In Pressure KReturn Oil

BClutch Drum FCarrier IConverter-Out Pressure LReverser - Forward
CSecond Sun Gear GPressure Oil JLube Oil Operation
DFirst Sun Gear
When the FNR lever is placed in the forward position, shaft, the compound planet pinion (E) cannot orbit the
the clutch piston (A) locks the clutch disks and plates sun gears, locking the carrier (F) to the output shaft.
together. The clutch drum (B) is then locked to the
output shaft through the clutch hub. Because the The result is a direct drive through the planetary
second sun gear (C) is splined to the clutch drum, it is assembly. The output shaft will turn at the same speed
now locked to the output shaft. and in the same direction as the turbine shaft.
The first sun gear (D) is splined to the output shaft.

With the second sun gear also locked to the output
9020
05
7

110703
PN=343
Theory Of Operation
C HOUSING
BRAKE
PISTON
A
CARRIER
D
SECOND SUN
FIRST SUN GEAR
GEAR B
F
9020
05
8
COMPOUND
PLANET PINION
E
G PRESSURE OIL
H CONVERTER-IN PRESSURE
I CONVERTER-OUT PRESSURE
1901JAN99
J LUBE OIL
K RETURN OIL
T7998AC
TXC7998AC CV
L REVERSER REVERSE OPERATION

110703
PN=344
Theory Of Operation
ABrake Piston ECompound Planet Pinion HConverter-In Pressure KReturn Oil

BSecond Sun Gear FFirst Sun Gear IConverter-Out Pressure LReverser - Reverse
CHousing GPressure Oil JLube Oil Operation
DCarrier
When the FNR lever is put in reverse position, the The larger gear on the compound planet pinion drives
brake piston (A) locks the brake disks and plates the first sun gear (F) in the opposite direction of the
together, locking the clutch drum and the second sun carrier.
gear (B) to the housing (C). The second sun gear
cannot rotate. The output shaft is driven in the opposite direction of
the turbine shaft. Due to the gear ratios in the
As the carrier (D) rotates, the smaller gear on the planetary assembly, reverse speed is faster than the
compound planet pinion (E) will orbit the second sun forward speed in each gear.
gear. The compound planet pinion rotates in the same
direction as the carrier.
TX,9020,YY757 1904JUN934/4
9020
05
9

110703
PN=345
Theory Of Operation
Reverser Hydraulic Filter Operation
G H
9020
05
10
E F
D I
E
F
A
B
C
G H
1929JAN97
I
T6300AG
T6300AG
AHigh Pressure Oil DRestricted Filter FTo Lube HTo Control Circuit
BMedium Pressure Oil EFilter Relief Valve GFrom Reverser Pump IFilter Element
CLow Pressure Oil
The reverser hydraulic filter has a filter relief valve (E) The orifice in relief valve does not affect operation of
in the filter base. The filter relief valve protects the filter valve in this application.
element from excessive differential pressure. When the
filter relief valve opens (D), the unfiltered oil flows to
the reverser lube circuit (F).
D410,9020,3025 1904JUN931/1

110703
PN=346
Theory Of Operation
Accumulator Operation
B FROM FILTER
A PISTON C METERING NOTCH
D TO SOLENOIDS
E RATE-OF-SHIFT
ORIFICE
F TO CLUTCH
PACKS
G DIRECTIONAL
H SLOT CONTROL
VALVE J ACCUMULATOR CHARGING
I ACCUMULATOR CHARGED
L HIGH PRESSURE OIL

M MEDIUM PRESSURE OIL
N LOW PRESSURE OIL 9020
1901JAN99
O RETURN OIL 05
11
K ACCUMULATOR DISCHARGED
T7434AD
TXC7434AD CV P ACCUMULATOR OPERATION
APiston ERate-of-Shift Orifice IAccumulator Charged MMedium Pressure Oil

BFrom Filter FTo Clutch Packs JAccumulator Charging NLow Pressure Oil
CMetering Notch GDirectional Control Valve KAccumulator Discharged OReturn Oil
DTo Solenoids HSlot LHigh Pressure Oil PAccumulator Operation
The accumulator piston (A) and rate-of-shift orifice (E) stopping the flow of oil around the piston. Oil can only
in the directional control valve work together to provide flow through the rate-of-shift orifice providing a gradual
a smooth shift from forward to reverse. increase of engagement pressure.
When the FNR lever is moved from neutral to either As pressure increases in the accumulator, the
forward or reverse, the accumulator discharges (K). Oil metering notches (C) are uncovered. Engagement
flows from the accumulator through the rate-of-shift pressure begins to increase at a faster rate.
orifice in the directional control valve to fill either the
brake or clutch piston. When the accumulator piston nears the fully charged
position (I), the slots (H) are uncovered. The oil flow is
As pressure in the clutch or brake piston increases, oil increased greatly providing a fast final fill. The piston is
pressure begins charging the accumulator (J). The now in the fully charged position.
accumulator piston moves back against the springs
D410,9020,3026 1904JUN931/1

110703
PN=347
Theory Of Operation
Pressure Regulating Valve Operation
K L P L
J N M
F R
I
I
Q
G
H
M
N
G
O
F A
B
C
UN25FEB99
9020 D
05 S
E
12
T88948
T88948
AMedium Pressure Oil EReturn Oil KFrom Reverser Filter and OExcess Converter-In (and
(Engagement Pressure) FLube Relief Valve Control Circuit Cooler) Pressure
BLow Pressure GTo Reservoir LTo Converter-In PTo Element Lube Orifice
CTorque Converter Charge HExcess Lube Pressure MFrom Lube Circuit QPlanetary Lube Orifice
Oil IPressure Regulating Valve NConverter-In (and Cooler) RFrom Filter Bypass Valve
DLube Oil JReduced Flow Relief Valve SHoles to Reservoir
The three spools in pressure regulating valve housing The converter-in (and cooler) relief valve is used to
are the pressure regulating valve (I), lube relief valve control the pressure of oil in the converter-in and oil
(F), and converter-in (and cooler) relief valve (N). cooler circuit. Pressure setting is controlled by the
spring. The pressure is not adjustable. If pressure
The pressure regulating valve is used to give priority setting is low, install a new spring. The shims in plug
and control engagement pressure (A) in control circuit are only used as spacers. Excess converter-in (cooler)
for reverser brake and forward clutch operation. pressure (O) because of cold oil or a restriction pushes
Pressure setting is controlled by the spring and can be the spool down opening a passage for oil flow to
adjusted using shims. In operation, the valve spool lubrication circuit.
moves up and down controlling pressure by regulating
oil flow past spool to converter-in (L), element lube The lube relief valve is used to control pressure of oil
orifice (P), and planetary lube orifice (Q). in the lubrication circuit. Pressure setting is controlled
by the spring. If pressure setting is low, install a new
When the FNR lever is moved, engagement pressure spring. Excess lube pressure (H) pushes the spool
decreases causing spool to move up reducing flow (J) down opening a passage from oil flow to reservoir.
past spool.
Continued on next page D410,9020,3027 1904JUN931/2

110703
PN=348
Theory Of Operation
The holes (S) allow oil leakage into spring area to

return to reservoir to prevent hydraulic lock.
D410,9020,3027 1904JUN932/2
Solenoid Operation
F SOLENOID
COIL
9020
05
13
E PLUNGER
D TO
RETURN
C BALL G PRESSURE OIL
1915JAN98
B FROM PRESSURE H RETURN OIL
REGULATING VALVE
A ENERGIZED I DE-ENERGIZED
T7864AN
TXC7864AN J SOLENOID VALVE OPERATION
AEnergized CBall FSolenoid Coil IDe-Energized

BFrom Pressure Regulating DTo Return GPressure Oil JSolenoid Valve Operation
Valve EPlunger HReturn Oil
Solenoids are used to control the flow of hydraulic oil When a solenoid is de-energized (I), the plunger (E) is
through the reverser during normal operation. When a in the down position. In this position, pressure oil from
solenoid is energized (A), the solenoid coil (F) draws the pressure regulating valve (B) is blocked.
the plunger (E) up and opens the passage.
TX,9020,YY765 1904JUN931/1

110703
PN=349
Theory Of Operation
Reverser Control Valve
M PRESSURE
REGULATING
VALVE HOUSING
L
TO TORQUE
CONVERTER
AND OIL
COOLER
K CONVERTER-IN TO
RELIEF VALVE FORWARD
J CLUTCH
LUBE RELIEF N
DIRECTIONAL
VALVE SPOOL
I
TO R
PRESSURE REVERSE P
REGULATING FORWARD
VALVE H O BRAKE SOLENOID
ACCUMULATOR Q CLUTCH
PISTON DISCONNECT
SPOOL
9020
05
14
FROM FILTER TO
CONTROL G
CIRCUIT
FROM
REVERSER F
PUMP TO
FILTER
REVERSER D
LUBRICATION
T S
CLUTCH REVERSE
DISCONNECT SOLENOID
SOLENOID
REVERSER E
SUCTION PUMP
SCREEN FILTER C
A U CONTROL PRESSURE
RELIEF
VALVE V CONVERTER-IN PRESSURE
W LUBE PRESSURE
X RETURN OIL
1901JAN99
B REVERSER
FILTER
T7996AL
TXC7996AL CV Y REVERSER CONTROL VALVE NEUTRAL

110703
PN=350
Theory Of Operation
ASuction Screen HAccumulator Piston NTo Forward Clutch UPressure Oil

BReverser Filter IPressure Regulating Valve OTo Reverse Brake VConverter-In Pressure
CFilter Relief Valve JLube Relief Valve PDirectional Spool WLube Pressure
DReverser Lubrication KConverter-In Relief Valve QClutch Disconnect Spool XReturn Oil
EReverser Pump LTo Torque Converter and RForward Solenoid YReverser Control Valve -
FFrom Reverser Pump to Oil Cooler SReverse Solenoid Neutral
Filter MPressure Regulating Valve TClutch Disconnect
GFrom Filter to Control Housing Solenoid
Circuit
The reverser control valve contains the directional With the engine running, FNR lever in neutral position
spool and the clutch disconnect spool. The directional and the clutch disconnect switch released, the forward
spool has three positionsforward, reverse and (R) and reverse (S) solenoids are not energized and
neutral. pressure oil is blocked at the solenoids. The clutch
disconnect solenoid (T) is energized allowing pressure
The reverser control valve has three electrically oil to shift the clutch disconnect spool (Q). Clutch
actuated solenoids that control oil flow for element engagement oil from the accumulator and rate-of-shift
engagement. orifice is blocked at the directional spool.
9020
05
15

110703
PN=351
Theory Of Operation
TO
FORWARD
ACCUMULATOR CLUTCH
PISTON D
C
TO H
REVERSE FORWARD
BRAKE SOLENOID
E DIRECTIONAL
SPOOL
F
CLUTCH
G DISCONNECT
SPOOL
9020
05 "F" PORT
16 I
"R" PORT
J
K
"L" PORT
B
FROM L
A
FILTER TO "P" PORT
FROM CONTROL
REVERSER CIRCUIT
PUMP TO
FILTER
N
CLUTCH REVERSE
M SOLENOID
DISCONNECT
SOLENOID
O CONTROL PRESSURE
1901JAN99
P LUBE PRESSURE
Q RETURN OIL
T7996AM
TXC7996AM CV R REVERSER CONTROL VALVE - FORWARD

110703
PN=352
Theory Of Operation
AFrom Reverser Pump to DTo Forward Clutch IF Port (Forward Pressure) NClutch Disconnect
Filter ETo Reverse Brake JR Port (Reverse Pressure) Solenoid
BFrom Filter to Control FDirectional Spool KL Port (Lube Pressure) OPressure Oil
Circuit GClutch Disconnect Spool LP Port (System Pressure) PLube Pressure
CAccumulator Piston HForward Solenoid MReverse Solenoid QReturn oil
With engine running, move FNR lever to forward flow to the forward clutch. This pressure oil is
position energizing the forward solenoid (H). Pressure regulated by the accumulator and rate-of-shift orifice.
oil flows to the forward end of directional spool (F), Oil in the reverse end of the directional spool is
shifting the spool. The directional spool uncovers the directed to return.
clutch engagement passage directing pressure oil to
9020
05
17

110703
PN=353
Theory Of Operation
TO
FORWARD
ACCUMULATOR CLUTCH
PISTON D
C
TO H
REVERSE FORWARD
BRAKE SOLENOID
E DIRECTIONAL
SPOOL
F
CLUTCH
DISCONNECT
SPOOL
G
9020
05 "F" PORT
18 I
"R" PORT
J
K
"L" PORT
B
FROM L
A
FILTER TO "P" PORT
FROM CONTROL
REVERSE CIRCUIT
PUMP TO
FILTER
N
CLUTCH REVERSE
M SOLENOID
DISCONNECT
SOLENOID
O CONTROL PRESSURE
P LUBE PRESSURE
1901JAN99
Q RETURN OIL
R REVERSER CONTROL VALVE - FORWARD

T7996AN
TXC7996AN CV WITH CLUTCH DISCONNECT DEPRESSED

110703
PN=354
Theory Of Operation
AFrom Reverse Pump to ETo Reverse Brake KL Port (Lube Pressure) PLube Pressure
Filter FDirectional Spool LP Port (System Pressure) QReturn Oil
BFrom Filter to Control GClutch Disconnect Spool MReverse Solenoid RReverser Control Valve -
Circuit HForward Solenoid NClutch Disconnect Forward with Clutch
CAccumulator Piston IF Port (Forward Pressure) Solenoid Disconnect Depressed
DTo Forward Clutch JR Port (Reverse Pressure) OPressure Oil
With engine running, FNR lever in forward position and solenoid. Oil already at the end of clutch disconnect
either clutch disconnect switch depressed, flow to the spool is directed to return passages. Spring force shifts
drive wheels is interrupted. the clutch disconnect spool and connects clutch pack
engagement passage and a return passage. The pack
Depressing a clutch disconnect switch de-energizes is dumped and power to the wheels stops. The forward
the clutch disconnect solenoid (N). Pressure oil to the solenoid is energized and the directional spool is
end of clutch disconnect spool is blocked at the shifted to forward.
TX,9020,YY761 1904JUN936/6
9020
05
19

110703
PN=355
Theory Of Operation
Synchronizer Operation
UN18APR89
T92937
9020
05
20
ABlocking Rings DThird Speed Drive Gear GFourth Speed Drive Gear JThird Gear Engaged
BSynchronizer Collar EBlocking Ring HSynchronizing KSynchronizer
CHub FClip ITransmission Drive Shaft
The components of the synchronizer are the hub (C), When a shift to third gear is made, the first step is
collar (B), clip (F) and blocking rings (A). synchronizing (H) the speed of transmission drive shaft
(I) and third speed drive gear (D). As the collar moves
The hub is splined to the transmission drive shaft (I). across the hub, the clip moves with it. The clip pushes
The synchronizer collar is splined to the hub. Three of the blocking ring (E) against the tapered portion of the
the splines in the hub are omitted and a clip is inserted third speed drive gear. The brass blocking ring will
between the hub and the collar. A spring (not shown accelerate until the speed of the transmission drive
on the illustration) pushes the clips out against the shaft matches the speed of the third speed drive gear.
collar.
After the gear and the shaft have been synchronized,
The ends of the clips extend into slots in the blocking the collar slides over the teeth of the blocking ring and
rings, causing the rings to rotate with the clips. The the gear. Third gear is engaged (J).
hub, collar, clips, and blocking rings always rotate as
an assembly with the shaft. All speeds are synchronized due to an additional
synchronizer that is installed between the first and
With the synchronizer in neutral (K), the blocking rings second driven gears.
do not contact either drive gear. Since the gears are
not splined to the shaft, they are free to rotate at
different speeds.
TX,D410,3028 1914JAN911/1

110703
PN=356
Theory Of Operation
Second Speed Operation
9020
05
UN28JAN94
21
T8006AB
ATransmission Drive Shaft CSecond Speed Driving DTransmission Input Shaft FSynchronizer Collar
BFirst Speed Driving Gear Gear ESecond Speed Driven Gear GDifferential Drive Shaft
The transmission input shaft (D) is driven by the speed driven gear is locked to the differential drive
reverser. It, in turn, drives the transmission drive shaft, shaft (B). Power is thereby transmitted to the
and is in constant mesh with the second speed driven differential assembly.
gear (E).
When the transmission is in second speed the

synchronizer collar (F) is slid to the right. The second
TX,410D,YY769 1911JUN961/1

110703
PN=357
Theory Of Operation
Third Speed Operation
9020
05
UN28JAN94
22
T8006AC
ATransmission Drive Shaft CSynchronizer Collar ETransmission Input Shaft GDifferential Drive Shaft
BThird Speed Driving Gear DFourth Speed Driving Gear FThird Speed Driven Gear
In third speed, the synchronizer collar (C) is moved to Notice that the shift collar on the differential drive shaft
the left. The third speed driving gear (B) is then locked is in neutral. This allows the first and second speed
to the transmission drive shaft (A). Power is driven gears to rotate freely on the shaft. Transmission
transferred to the third speed driven gear (F). Since gears and bearing are lubricated by non-pressurized
the third and fourth speed driven gear is splined to the splash oiling system.
differential drive shaft (G), there is power flow into the
differential assembly.
TX,410D,YY770 1911JUN961/1

110703
PN=358
Theory Of Operation
Park Brake Operation
E
B
D
UN26FEB99
A
9020
05
T7387AH
F BRAKE ACTUATOR-PRESSURIZED 23
TXC7387AH CV
APressure Oil CFacing ERelease Nut FBrake Actuator

BParking Brake Linkage DRelease Rod Pressurized
The parking brake drum is mounted on the differential a solenoid valve that is actuated by a switch on the
cover and turns with the ring gear. The brake band console.
that is installed on the brake drum operates in oil and
locks the final drive power train to the case when Pressure oil from the energized parking brake solenoid
applied. is routed to the parking brake actuator facing (C) and
brake linkage (B). The pressure oil releases the brake.
The parking brake is spring applied and hydraulically
released during normal machine operation. Pressure Brake can also be manually released for towing by
oil from the reverser hydraulic system is controlled with turning nut (E) until rod (D) bottoms.
TX,300D,1973 1908MAR931/1

110703
PN=359
Theory Of Operation
Brake Valve Operation
D RIGHT BRAKE PEDAL

A RETURN PORT
B INLET PORT
C CHECK
VALVE
I LEFT BRAKE
PEDAL
H EQUALIZING BRAKE
VALVE G PISTON
DISC
9020
E AND
05 FACINGS
24
BRAKE
F PRESSURE
PLATE
1901JAN99
J HIGH PRESSURE OIL
K RETURN OIL
TXC7431AI L BRAKE VALVE OPERATION T7431AI
AReturn Port EBrake Disk and Facings (2 GPiston (2 used) JHigh Pressure Oil
BInlet Port used) HEqualizing Valve KReturn Oil
CCheck Valve (2 used) FBrake Pressure Plate (2 ILeft Brake Pedal
DRight Brake Pedal used)
The brake system is hydraulic with no mechanical pressure plates that are located in the final drive
connection between the brake valve and the brake housings.
pressure plates. The brake valve reservoir is filled with
return oil from the hydraulic system. When the brakes are engaged, the brake pressure
plate applies force on the brake disk and facings which
The brake valve is activated by two brake pedals that is connected to the final drive pinion shaft.
allow individual or simultaneous operation of brake
TX,D410,DS3064 1914JAN911/1

110703
PN=360
Theory Of Operation
Service Brake Pressure Lubrication (SN 796851)
FACING C D BRAKE DISK
TRANSMISSION B
CASE E BRAKE PISTON
PRESSURE
LUBE SUPPLY A F LUBE OIL
1925FEB99
G RESERVOIR OIL
9020
05
25
T7397AA
TXC7397AA H SERVICE BRAKE LUBRICATION
APressure Lube Supply CFacing EBrake Piston GReservoir Oil

BTransmission Case DBrake Disk FLube Oil HService Brake Lubrication
A constant supply of cooled oil from the main hydraulic constant flow of cooled oil over the entire facing of the
oil cooler is routed to the transaxle. Oil from the brake disk prevents contact between the facing and
pressure lube supply (A) is routed to the outside the housing when the brakes are not applied. It also
diameter of the brake disk (D). There is a constant provides excellent cooling. Notice the grooves in the
flow of oil between the brake facings (C) and the brake facings. These grooves provide a path for a
transmission case (B) and brake piston (E). constant flow of cool oil across the facings even when
the brakes are engaged.
When the brakes are rotating, centrifugal force draws
oil around the entire diameter of the brake disk. This
TX,300D,1975 1912JUL941/1

110703
PN=361
Theory Of Operation
9020
05
26

110703
PN=362
Group 10
System Operational Procedure
The procedure is designed so that mechanic can make problem is indicated (NOT OK:), you will be given
a quick check of the power train using a minimum repair required and Group location or CTM number. If
amount of diagnostic equipment. If you need additional verification is needed, you will be given next best
information, read the Theory of Operation in Group source of information after GO TO:
9020-05.
Group 10 (System Operational Checks)
A location will be required which is level and has
adequate space to operate machine. Group 15 (System Diagnostic Checks)
The engine and all major components must be at Group 20 (Adjustments)

operating temperature for some checks.
Group 25 (Test)
Locate system check in the left column and read
completely. Follow this sequence from left to right. CTM (Component Technical Manual)
Read each check completely before performing.
At the end of each check, if no problem is found (OK:),

you will be instructed to GO TO NEXT CHECK. If
9020
10
1
TX,300D,1960 1908MAR931/1
Brake System Checks
1/1
Pedal Stop Check Lift the left and right brake pedals. OK: Check complete.
LOOK: Brake pedals must be against the pedal stop NOT OK: Adjust brake
screws. pedal stops . Go to
Group 9020-20
NOT OK: Inspect and

repair brake valve as
T7394BG UN17JAN92
necessary. Go to
Disassemble And
Assemble Brake Valve in
repair manual.
1/1

110703
PN=363
Brake System Leakage Depress and hold left brake pedal, then right brake pedal OK: Check complete.
Check using approximately 267 N (60 lb force).
NOT OK: Adjust brake
LOOK: Brake pedal must NOT feel spongy (caused by pedals. Do Brake Valve
air in system) or settle more than 25 mm (1.0 in.) per Adjustment . Go to Group
minute. 9020-20.
LOOK: Rear brake light must come on when either pedal NOT OK: Bleed brake
is depressed with key switch in ON position. system . Go to Group
T7394BF UN06JAN92
9020-20.
NOT OK: Check light

fuse.
OK: Check wiring. Go to

Group 9015-15, Lighting
Circuit Checks .
NOT OK: Do Brake Valve

Leakage Test . Go to
Group 9020-25.
1/1
9020
Park Brake Capacity Engage park brake. OK: Check complete.
10
Check
2
Put stabilizers in transport position. NOT OK: Adjust park
brake linkage . Go to
Put backhoe in transport position. Group 9020-20.
Use loader functions to pull machine forward or push

machine backward.
T7394BH UN10DEC90
LOOK: Rear wheels should not turn. If loader can pull or
push machine, rear tires should drag.
LOOK: Park brake switch light will be ON.
1/1
Brake Drag Check Position machine on a gradual grade with front of OK: Check complete.
machine downhill.
NOT OK: Brakes
Lift bucket so it clears ground. dragging. Go to Group
9020-15, Unit Will Not
Shift FNR lever to neutral, differential lock pedal up, Move .
disengage park brake and release service brakes.
T6171AL UN09DEC88
LOOK: Machine must move or coast.
NOTE: If machine does not move freely on slope, drive

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

110703
PN=364
Clutch Disconnect Park brake OFF. OK: Check complete.

Circuit Check
Service brake applied. NOT OK: Check fuse.
CAUTION: Put transaxle in fourth gear. NOT OK: Go to group

Machine should 9015-15, Park
try to move Start engine, set idle speed at approximately 1500 rpm. Brake/Clutch Disconnect
forward as FNR Circuit Diagnostic .
lever is moved. Move FNR lever to forward (F) position.
Actuate clutch disconnect on FNR lever or loader control lever individually and note
sound of engine.
LISTEN: When FNR lever is shifted to forward (F) position, a noticeable drop in engine
speed should be heard.
LISTEN: Engine rpm must increase when the reverser clutch disconnect solenoid
switch is activated.
1/1
9020
FNR Switch Check OK: Check complete.
10
3
NOT OK: If no click,
inspect neutral start fuse.
NOT OK: Go to Group

9015-15, Start Circuit
Diagnostic Procedures .
T7367AN UN17SEP90 T7394BJ 1917OCT90 T7394BI 1917OCT90
Engine off.
Put FNR lever in neutral.
Turn key switch to ON position.
Move FNR lever to forward (F), reverse (R), then neutral (N) position.
Observe and feel forward, neutral and reverse detents.
LOOK: FNR lever must align with neutral position in quadrant when reverser valve is in
neutral detent position.
LISTEN: You must hear neutral start switch click as FNR lever is moved EQUAL
distance from neutral to forward position and from neutral to reverse position.
FEEL: You must feel detent engagement in each position of FNR lever.
1/1

110703
PN=365
Reverser Hydraulic Run engine at approximately 1500 rpm. OK: Check complete.
System Check
Put transaxle into third gear. NOT OK: If shifts are
slow, go to Group
Move FNR lever to forward (F) position. 9020-25, Reverser
Element Leakage Test
Make several shifts from third forward to third reverse. Start counting the number of Using Element Pressure
seconds when FNR lever is moved to opposite direction. (Three-Gauge Method) .
LOOK: A normal shift from forward to reverse or reverse to forward must be completed
in three seconds. The machine must be up to speed in four seconds.
NOTE: Excessive internal leakage is indicated if reverse warning alarm (if equipped)
does not sound at slow idle, but sounds when rpm is increased.
1/1
Engine And Torque Position machine with loader bucket at ground level OK: Check complete.
Converter Check against dirt bank or immovable object.
NOT OK: If the wheels
Put transaxle into first gear. can be easily stalled, go
to Group 9020-15,
Move FNR lever to forward (F) position. Machine Lacks Power or
Moves Slow .
Engage differential lock.
9020 T6171AM UN09DEC88
10 Increase engine speed to fast idle.
4
LOOK: Rear wheels must NOT stall.
NOTE: This test will give a general indication of engine

reverser and torque converter performance.
1/1
Transaxle Checks
1/1
Transaxle Shift Linkage, Run engine at approximately 1500 rpm with FNR lever in forward position. OK: Check complete.
Synchronizer And Noise
Check Put transaxle in each gear and drive for a short distance. NOT OK: If excessive
gear clash or noise,
IMPORTANT: Use clutch LISTEN: There must NOT be any gear clash when shifting into any gear. All gears are remove transaxle suction
disconnect when shifting synchronized. screen. If metal particles
gears. are present, clean and
replace.
1/1

110703
PN=366
Differential Lock And Put transaxle in first gear. OK: Check complete.
Linkage Check
Move FNR lever to forward (F) position and operate engine at approximately 1500 NOT OK: Go to Group
rpm. 9020-15, No Differential
Lock Operation .
Depress differential lock pedal.
Turn steering wheel slightly right or left.
Release differential lock pedal.
LOOK: Machine must try to go straight forward and pedal must return to UP position
when traction is equal.
1/1
Differential Gear And Put transaxle in first gear and operate engine at approximately 1500 rpm. OK: Check complete.
Pinion Check
Move FNR lever to forward position. NOT OK: Go to Group
NOTE: Hold the wheel 9020-15, Unit Makes
which is being braked Steer machine in a maximum left turn and depress left brake pedal to stop the left Excessive Noise .
stationary during this test wheel.
or brake chatter could be
confused with differential Steer machine in a maximum right turn and depress right brake pedal to stop right
gear noise. wheel. 9020
10
LISTEN: NO excessive gear noise must be heard in the differential or pinion gear area. 5
1/1
Mechanical Front Wheel Drive (MFWD) Driving Checks
1/1

110703
PN=367
MFWD Clutch Drag Lift unit off ground with stabilizers and loader bucket. OK: Go to next check .
Check
Put FNR lever in forward position and transaxle in first NOT OK: If light is on,
gear. cycle a hydraulic function.
If light remains on, control
Run engine at approximately 1000 rpm. valve pressure is set too
low. Go to Group 9025-25
Check that MFWD switch is off. MFWD Valve Pressure
T6295AB UN17APR89
Test .
Lower front wheels to ground.
NOT OK: If all wheels
LOOK: MFWD indicator light must be off. stop, an MFWD control
valve problem or clutch
LOOK: Front wheels may turn while wheels are off drag is indicated. Slowly
ground, but must stop when lowered to ground. Rear increase engine speed
wheels must continue to turn. until rear wheels start to
turn.
NOT OK: If front wheels

also turn, a valve problem
is indicated. Go to Group
9025-25, MFWD Valve
Pressure Test .
NOT OK: If front wheels

9020 remain stopped, clutch
10 drag is indicated. Inspect
6 and repair. See
procedure under
Disassemble And
Assemble MFWD
Transfer Case in repair
manual.
1/1

110703
PN=368
MFWD Limited-Slip Lift machine off ground with stabilizers and loader bucket. OK: Check complete.
Differential And Control
Valve Check Apply brakes and engage MFWD. NOT OK: If both wheels
stall, check MFWD valve
Put FNR lever in forward and transaxle in first gear. pressure test . Go to
Group 9025-25.
Run engine at approximately 1200 rpm.
NOT OK: If only one
Lower front wheels until tire scuffing is observed on both tires. wheel spins, turn wheel to
axle stop and see if
LOOK: Both wheels must turn and MFWD indicator light must be ON. constant velocity U-joint is
turning. If U-joint is
Turn MFWD switch OFF. turning, check wheel
outboard planetary. If
NOTE: If MFWD is turned OFF while operating, indicator light and MFWD could remain U-joint does not turn
on until load on drive train is released. Shifting to opposite direction should release inspect axle and
load on drive train. limited-slip in MFWD
differential.
LOOK: Both wheels must stop when MFWD switch is OFF.
See Assemble
LOOK: MFWD indicator light must be OFF. DifferentialAPL-745Axle
NOTE: If tire scuffing is seen with MFWD engaged, limited-slip differential is working Assemble Differential
and power is being transmitted to MFWD. HousingAPL-2035Axle
Assemble Differential 9020

410D-(SN 10
796854)510D-(SN 7
796890)
410D-(SN 796855)
510D-(SN 796891 )
1/1
MFWD Engine And With loader bucket level and cutting edge at the centerline of front wheels, put OK: Check complete.
Torque Converter Check machine against a dirt bank or immovable object.
NOT OK: If the front
Engage MFWD and differential lock. wheels stop, a MFWD
problem is indicated. Go
Put FNR lever in forward and transaxle in first gear. to Group 9020-15, No
Power to MFWD .
Increase engine speed to fast idle.
NOT OK: If all wheels
LOOK: All four wheels must turn. can be easily stalled,
check reverser oil level.
LOOK: MFWD indicator must be ON.
NOT OK: Inspect and
replace reverser filter.
Repeat MFWD Engine
and Torque Converter
Check.
NOT OK: Check reverser

system pressure. Go to
Group 9010-25, Torque
Converter Stall Test .
1/1

110703
PN=369
Front Wheel Alignment Drive machine in fourth gear forward on a surface with OK: Check complete.
(Toe-In) Check loose material.
NOT OK: If material is
LOOK: Material behind front wheels must not be thrown thrown, excessive tire
excessively inward or outward. wear will result. Go to
Group 9020-20, Adjust
Toe-In .
T6264AI UN22OCT91
1/1
9020
10
8

110703
PN=370
Group 15
Reverser Oil Passage Identification
ATo Element Lubrication Orifice behind Reverser

Control Valve from Converter-In Passage,
Pressure Regulating Valve Housing
BPump Outlet to Reverser Filter
CReverser Pump Seal Drain
UN07FEB90
DFrom Suction Screen in Reservoir to Pump Inlet
EFrom Pressure Regulating Valve Housing to
Converter-In Lubrication Circuit, Planetary
Lubrication and Converter-In
FFrom Converter-Out to Oil Cooler
T93058
GTo Planetary Lubrication from Converter-In
Passage, Pressure Regulating Valve Housing
Reverser Oil Manifold Passages
UN07FEB90
9020
15
1
T93059
UN07FEB90
T93060
Continued on next page TX,D410,DS3066 1921APR941/5

110703
PN=371
AFrom Pressure Regulating Valve to Converter-In,

Element Lubrication Orifice Behind Reverser
Control Valve, and Planetary Lubrication Orifice
BFrom Filter Outlet (clean oil) to Pressure
Regulating Valve
CFrom Converter-In Relief Valve to Element
UN07FEB90
Lubrication Circuit
DFrom Lube Relief Valve to Reservoir
T93062
Pressure Regulating Valve Passages
TX,D410,DS3066 1921APR942/5
9020
15
2 AFilter Outlet to Reverser Control Circuit
BFrom Filter Relief Valve to Element Lubrication
Circuit
CFrom Pump to Filter Inlet
UN07FEB90
T93063
Reverser Filter Passages

110703
PN=372
ATo Solenoids
BAccumulator Piston
CTo Forward Clutch
DTo Reverse Brake
ELube
UN14MAY93
9020
15
3
T8008AB
TX,D410,DS3066 1921APR944/5
ATo Forward Clutch

BTo Reverse Brake
CTo Element Lube
UN07FEB90
T93064
Reverser Rear Cover Passage
TX,D410,DS3066 1921APR945/5

110703
PN=373
Diagnose Power Train Malfunctions
NOTE: Diagnostic charts are arranged from most Step 1. Operational Check Out Procedure
probable and simplest to verify, to least likely Step 2. Diagnostic Charts
and more difficult to verify. Remember the Step 3. Adjustments and/or Tests
following steps when diagnosing a problem.
Park Brake Will Not Hold Park brake actuator Inspect and replace. See Remove
Park Brake Active Elements in repair
manual.
Glazed park brake lining Burnish brake. See Adjust Park

Brake in repair manual.
Reverser pressure Perform Reverser System Pressure

Test . See Group 9020-25.
Park Brake Will Not Release Park brake circuit not operating See Group 9015-15, See Park
correctly Brake/Clutch Disconnect Circuit
Diagnostic .
9020
15 Internal linkage binding Inspect and repair. See Remove
4
Park Brake Active Elements in repair
manual.
Unit Will Not Move in Forward or Low oil level Add oil to correct level. See
Reverse Hydraulic And Reverser Oil .
Brakes dragging Check brake valve and repair. See

Adjust Brake Pedals And Equalizing
Valves in Group 9020-20.
Disconnect clutch not disengaging Check to hear click when switch is

properly depressed. See Group 9015-15.
Directional control valve solenoid Remove, inspect, clean and repair.

springs stuck or broken See Disassemble And Assemble
Directional Control Valve in repair
manual.
Reverser clutch disk slipping Do Reverser Element Leakage Test

, Group 9020-25.
Loss of system pressure Check oil level. Do Reverser

Element Leakage Test , Group
9020-25.
Continued on next page TX,D410,3022 1921APR941/17

110703
PN=374
Reverser Repair or replace parts as required.

See Disassemble And Assemble
Reverser Housing in repair manual.
Converter drive tangs sheared or not Replace converter. See Disassemble

engaged in pump And Assemble Reverser Housing in
repair manual.
Pump gears seized and converter Replace pump assembly and

tangs sheared converter. See Disassemble And
Assemble Reverser Housing in
repair manual.
Transaxle Inspect transaxle and repair. See

Remove Transaxle in repair manual.
Transaxle shifter forks and/or shafts Repair or replace parts as

broken necessary. See Remove Transaxle
in repair manual.
9020
Transaxle shaft or gear failure Repair or replace parts as 15
5
necessary. See Remove Transaxle
in repair manual.
Transaxle shifter collars broken Replace. See Remove Transaxle in

repair manual.
Planetary assembly out of time or Repair and time correctly. See

improperly assembled Disassemble And Assemble
Planetary Pinion Carrier in repair
manual.
Differential ring gear teeth sheared Replace ring gear and pinion. See
Remove Differential Assembly
410D-(SN 796854)510D-(SN
796890) or Remove Differential
410D-(SN 796855 ) 510D-(SN
796891 ) in repair manual.
Final drive axle shaft broken Replace. See Disassemble Rear

Axle Housing in repair manual.
Final drive shaft and sun pinion Replace parts as necessary. See
broken Remove And Install Rear Axle in
repair manual.

110703
PN=375
Transaxle Will Not Pull in Disconnect clutch solenoid loose on Inspect and tighten.
Forward Only reverser
Worn or broken sealing rings in Do Reverser Element Leakage Test

forward clutch of reverser . See Group 9020-20. Disassemble
and inspect clutch assembly.
Replace parts as needed. See
Disassemble And Assemble
Reverser Will Not Disconnect Disconnect clutch not disengaging Check to hear click when switch is
(Drags) properly depressed. See Group 9015-15.
Directional control valve solenoid Remove, inspect, clean and repair

spring stuck or broken spring. See Disassemble And
Assemble Directional Control Valve
in repair manual.
Warped or dragging clutch pack. Inspect and repair. See Disassemble

9020 And Assemble Reverser Housing in
15 repair manual.
6
Worn or broken sealing rings in Do Reverser Element Leakage Test

forward clutch of reverser , Group 9020-25. Disassemble and
inspect clutch assembly. Replace
parts as necessary. See
Clutch plates worn or broken in Disassemble and inspect clutch

forward clutch assembly of reverser assembly. Replace parts as
necessary. See Disassemble And
repair manual.
Unit Lacks Power or Moves Slow Operating in too high a gear Operate in next lower gear.
Low oil level in reverser Add oil to correct level. See

Hydraulic And Reverser Oil .
Brakes dragging Check for excessive heat in brake

area of axle housings after operating
unit.
Low P port pressure Do Reverser Element Leakage Test

, Group 9020-25.

110703
PN=376
Restricted suction screen in reverser Clean screen. See procedure under

Reverser leaks Do Reverser Element Leakage Test

, Group 9020-25.
Low engine output See Diagnose Engine Malfunctions ,

Group 9010-15.
Incorrect torque converter installed Check converter part number

through inspection hole in bottom of
reverser housing.
Failed torque converter Drain oil sample from converter and

inspect for contamination. See
OILSCANPlus .
Transaxle Inspect transaxle. See Remove

Transaxle in repair manual. 9020
15
7
Reverser Shifts Slow Low oil level Add oil to correct level. See

Restricted suction screen Remove and clean. See procedure

under Disassemble And Assemble
Converter-in (cooler) relief valve Remove, inspect and repair. See

stuck open Reverser Converter-In (Cooler)
Relief in Group 9020-25.
Leakage in reverser Do Reverser Element Leakage Test

. See Group 9020-25.
Worn reverser pump Do Reverser Pump Flow Test . See

Group 9020-25.
Reverser Will Not Shift FNR Switch. Do FNR Lever Check , Group
9015-15.


110703
PN=377
Directional control valve not Remove, inspect and repair. See

operating properly Disassemble And Assemble
manual.
Reverser clutch disk slipping See Disassemble And Assemble

Loss of system pressure in reverser Check oil level. Do Reverser

Element Leakage Test , Group
9020-25.
Reverser Repair or replace parts. See

Worn or broken sealing rings on Disassemble and replace parts as

reverse brake piston. Broken or worn necessary. SeeDisassemble And
reverse brake plates. Assemble Reverser Housing in
9020 repair manual.
15
8
Foaming Oil in Reverser Oil level too low or too high Check oil level.
Incorrect type of oil. Drain and replace oil. See Hydraulic

And Reverser Oil .
Restricted suction screen in reverser Clean suction screen. See procedure

Air leak on suction side of oil pump Inspect gaskets and housings. See
Remove And Disassemble Oil Pump
And Manifold in repair manual.
Reverser Oil Overheats Oil level too high or too low. Check oil level. See Hydraulic And
Reverser Oil .
Converter stalled excessively Use disconnect clutch switch in

these operations to reduce stalls.
Operating in too high a gear Operate one gear lower.
Oil cooler air flow restricted Inspect and clean exterior of

reverser cooler. Do Radiator Air
Flow Test , Group 9010-25.

110703
PN=378
Missing baffles, damaged fan Inspect and check belt tension. See
shrouds or loose fan belts Group 9010-20. Check baffles and
repair.
Converter-in (cooler) relief valve Remove valve, inspect and repair.

stuck open or broken spring See Reverser Converter-In (Cooler)
Relief Valve Test in Group 9020-25.
Low pump oil flow Do Reverser Pump Flow Test . See

Group 9020-25.
Restricted suction screen in reverser Remove and clean. See procedure


, Group 9020-25.
Excessive drag in reverser Do Torque Converter Stall Speed

Test , Group 9020-25. Repair as 9020
needed. See Disassemble And 15
9
repair manual.
Engine over-fueled Remove fuel injection pump. See

See authorized injection pump
service center.
Low P Port Pressure in Low oil level Add oil to correct level. See
Reverser Hydraulic And Reverser Oil .
Wrong oil Drain and replace oil. See Hydraulic

And Reverser Oil .

Converter-in (cooler) relief valve Remove, inspect, clean and repair.

stuck open or broken See Reverser Converter-In (Cooler)

110703
PN=379
Directional control valve solenoid Inspect and repair spring. See

spring stuck or broken Disassemble And Assemble
manual.
Perform Reverser System Pressure


, Group 9020-25.
Restricted filter Change filter.
Worn reverser oil pump Do Reverser Pump Flow Test . See

Group 9020-25.
Filter bypass valve stuck open Inspect valve. See repair manual.
Low F Port Pressure in Low oil level Add oil to correct level.
9020 Reverser
15
10
And Reverser Oil .



manual.
Perform Reverser System Pressure

Test , Group 9020-25.
Leakage in forward clutch Do stall test. Do Reverser Element

Leakage Test , Group 9020-25.
Worn reverser oil pump Perform Reverser Pump Flow Test ,

Group 9020-25.

110703
PN=380
Low R Port Pressure in Low oil level Add oil to correct level.
Reverser

And Reverser Oil .


stuck open or broken spring See Reverser Converter-In (Cooler)
Directional control valve solenoid Inspect, clean and replace spring.

spring stuck or broken See Disassemble And Assemble
manual. Perform Reverser System
Pressure Test , Group 9020-25.
9020
Leakage in reverse brake Do Reverser Element Leakage Test 15
11
, Group 9020-25.
Worn reverser oil pump Do Reverser Pump Flow Test ,

Group 9020-25.
Low Lube Pressure in Reverser Low oil level Add oil to correct level.
Wrong oil Drain and replace. See Hydraulic

And Reverser Oil .



manual. Perform Reverser System
Pressure Test . See Group 9020-25.

110703
PN=381

, Group 9020-25.
Worn reverser oil pump Do Reverser Pump Flow Test . See

Group 9020-25.
High Lube Pressure in Reverser Converter-in relief valve stuck in Do Reverser Converter-In (Cooler)
closed position Relief Valve Test , Group 9020-25.
Lube passage to reverser sump Do Reverser Oil Cooler Restriction

restricted Test and inspect lines, Group
9020-25.
Converter Stall Speed Too Low Wrong oil in machine Drain and refill. See Hydraulic And
Reverser Oil .
Incorrect torque converter Check converter part number

reverser housing.
9020
15 Failed free wheel clutch in torque Replace torque converter. See
12
converter Remove Torque Converter in repair
manual.
Converter Stall Speed Too High Low oil level. Add oil to correct level. See
Incorrect torque converter Check converter part number

reverser housing.
Failed torque converter Drain oil sample from converter and

inspect for contamination. See
OILSCANPlus .

Remove Injection Pump . See
authorized injection pump service
center.
Valve Buzz or Noise In Reverser Air in hydraulic system Running machine will remove air.
Low oil level Add oil to correct level. See


110703
PN=382
Air leak on suction side of pump Inspect gasket and housing. See
Remove And Disassemble Oil Pump
And Manifold in repair manual.
Restrictions in oil passages Inspect and remove restrictions.
Restricted suction screen Remove and clean. See procedure

Sticky pressure regulating valve Remove and clean valve. Inspect oil
for contamination. Do Reverser
Converter-In(Cooler) Relief Valve
Reverser Noisy In Forward and Worn universal joints Inspect and service as necessary.
Reverse
Misalignment of converter with Align converter assembly. See Install

engine Torque Converter in repair manual. 9020
15
13
Misalignment of reverser and Inspect reverser mounts for wear or
transaxle damage. See repair manual.
Reverser Noisy In Neutral Only Oil level low Fill to correct oil level. See Hydraulic
And Reverser Oil .
Worn bushings in pump assembly Inspect pump assemble and replace

if necessary. See repair manual.
Worn sprag or sprag races in Replace converter assemble. See

converter assemble repair manual.
Excessive Gear Clash When Attempting to shift too fast See Operators Manual for
Shifting instructions.
Not using disconnect clutch on Depress disconnect switch on

reverser transaxle or loader levers when
shifting. See Operators Manual.
Shifters worn or broken Inspect and replace as necessary.

See repair manual.
Gears rotate with disconnect clutch Check for solenoid click when
switch depressed disconnect switch is depressed. See
Group 9015-15.

110703
PN=383
Transaxle Overheating Oil level high Lower to correct level. See

Transaxle Oil .
Brake dragging Do System Operational Check,

Brake Drag Check , Group 9020-10.
Inadequate pump flow Plugged filter. See Operators

Manual for instructions.
Loss of Lubricant in Transaxle Worn or broken oil seal Replace. See Remove Transaxle in
repair manual.
Housing gasket broken Replace. See Remove Transaxle in

repair manual.
Excessive Transaxle Noise Transaxle low on oil Fill to correct level. See Transaxle
Oil .
Worn bearings Replace bearings and make all

9020 necessary adjustments. See
15 Remove Transaxle in repair manual.
14
Damaged or worn gears Repair or replace parts as needed.

See Remove Transaxle in repair
manual.
Parts worn or damaged Repair or replace as needed. See

Excessive Transaxle Noise Worn bearings Replace bearings and make all
(Under Load) necessary adjustments. See
Bearing preload out of adjustment Adjust to specifications. See

Ring gear backlash out of Adjust to specifications. See

adjustment Remove Transaxle in repair manual.
Unit Makes Excessive Noise Transaxle oil level low Add oil to correct level. See
When Moving Transaxle Oil .
Flywheel loose on crankshaft Replace cap screws and tighten to

specifications. See repair manual.

110703
PN=384
Transaxle parts worn or damaged Repair or replace parts as needed.

See Remove Transaxle in repair
manual.
Shifter forks on shafts worn Replace. See Remove Transaxle in

repair manual.
Reverser parts worn or damaged Repair or replace parts as needed.

Cone point out of adjustment Adjust to specifications. See

410D-(SN 796854)510D-(SN
410D-(SN 796855 ) 510D-(SN
Incorrect backlash adjustment Adjust to specifications. See

Remove Differential Assembly 9020
410D-(SN 796854)510D-(SN 15
15
410D-(SN 796855 ) 510D-(SN
Differential gears damaged or worn Repair or replace part as needed.

See Remove Differential Assembly
410D-(SN 796854)510D-(SN
410D-(SN 796855 ) 510D-(SN
Differential ring gear loose Repair or replace ring gear and

pinion. See Remove Differential
Assembly410D-(SN 796854)
510D-(SN 796890) or Remove
Differential 410D-(SN 796855 )
510D-(SN 796891 ) in repair
manual.
Worn bearings Replace bearings and make all

necessary adjustments. See repair
manual.

110703
PN=385
Axle shaft improperly adjusted Adjust to specifications. See

Disassemble Rear Axle Housing in
repair manual.
Final drive planetary pinions or Repair or replace planetary pinions

bearings damaged or bearings. See Disassemble And
Assemble Planetary Pinion Carrier in
repair manual.
Sun pinion damaged Repair or replace. See Disassemble

And Assemble Planetary Pinion
Carrier in repair manual.
Worn final drive shaft and sun pinion Replace. See Disassemble And
repair manual.
Damaged final drive gear Replace. See Disassemble And

9020 repair manual.
15
16
Worn planet pinion bearing rollers Replace and adjust to specifications.
Planetary Pinion Carrier in repair
manual.
Axle bearings damaged Replace and adjust to specifications.

See Disassemble Rear Axle Housing
in repair manual.
No Differential Lock Operation Lock collar splines worn or damaged Replace. See Remove Differential
Assembly 410D-(SN 796854)
510D-(SN 796890) or Remove
Differential 410D-(SN796855 )
510D-(SN 796891 ) in repair
manual.
Differential lock shaft sticking in Repair or replace. See Remove

housing Differential Assembly 410D-(SN
796854) 510D-(SN 796890) or
Remove Differential
410D-(SN796855 ) 510D-(SN

110703
PN=386
Excessive Unit Vibration Engine idle too low Adjust rpm to specifications . See
Group 9010-20.
Reverser mounting hardware loose Inspect and tighten to specifications.

See Install Reverser With Torque
Converter in repair manual.
Loose or failed hydraulic pump drive Inspect and repair.
Flywheel loose on crankshaft Replace cap screws and tighten to

specifications. See procedure under
Install Reverser With Torque
Converter in repair manual.
Transaxle shafts bent or damaged Replace parts as needed. See

Transaxle bearings improperly Adjust to specifications. See

adjusted Remove Transaxle in repair manual.
9020
Differential ring gear loose Repair or replace ring gear. See 15
17
410D-(SN 796854)510D-(SN
410D-(SN 796855 ) 510D-(SN
Cone point out of adjustment Adjust to specifications. See

410D-(SN 796854)510D-(SN
410D-(SN 796855 ) 510D-(SN
Incorrect backlash adjustment Adjust to specifications. See

410D-(SN 796854)510D-(SN
410D-(SN 796855 ) 510D-(SN
Axle shaft bent or damaged Adjust to specifications. See

Disassemble Rear Axle Housing in
repair manual.

110703
PN=387

Remove Injection Pump . See your
authorized fuel injection service
center.
Axles Will Not Turn Brakes dragging Check brake valve and repair. See
Group 9020-20.
Broken rear axle Replace. See Disassemble Rear

Axle Housing in repair manual.
Broken planetary gears or shafts. Replace. See Disassemble And

repair manual
Poor or No Brakes (Steering OK) Air in system Bleed brakes . See Group 9020-20.
Internal brake valve leakage Do Brake Valve Leakage Test ,

Group 9020-25.
9020
15 Internal restriction in circuit Remove lines and components and
18
inspect.
Brakes Will Not Release Brake pedal not returning to full up Inspect brake pedal linkage. Do
position Adjust Brake Pedals and Equalizing
Valves , Group 9020-20.
Plunger return orifice plugged Remove, inspect, and clean. See

repair manual.
Brakes Chatter or Noisy Wrong oil in transaxle Drain and refill with correct oil. See
Transaxle Oil .
Loose brake pads Disassemble, inspect and repair.

See repair manual.
No Power to MFWD Solenoid not actuated See Group 9015-15.
Drive shaft failure Inspect and repair. See repair

manual.
Failed spline transaxle output shaft Inspect and repair. See repair
manual.
Failed axle shaft in MFWD Inspect and repair. See repair

manual.

110703
PN=388
Failed ring gear or pinion in Inspect and repair.

transaxle
See Assemble Differential
APL-745Axle
Assemble Differential Housing

APL-2035Axle
Assemble Differential 410D-(SN

796854)510D-(SN 796890)
Assemble Differential 410D-(SN

796855) 510D-(SN 796891 )
Failed gear in MFWD drop box in Inspect and repair. See repair
transaxle manual.
No Power to One MFWD Wheel Wheel U-Joint failure Inspect and repair. See repair
manual.
9020
Failed outboard planetary Inspect and repair. See repair 15
19
manual.
Failed axle shaft in MFWD Inspect and repair. See repair

manual.
Failed limited-slip in MFWD Inspect and repair. See Remove

differential Differential Assembly 410D-(SN
796854) 510D-(SN 796890) or
Remove Differential
410D-(SN796855 ) 510D-(SN
No Power to One Wheel (Under Failed limited-slip in MFWD Inspect and repair. See Remove
Load) differential Differential Assembly 410D-(SN
796854) 510D-(SN 796890) or
Remove Differential
410D-(SN796855 ) 510D-(SN

110703
PN=389
MFWD Jumps Out of Gear Worn U-Joints in drive shaft Inspect and repair.
Incorrect differential backlash Adjust backlash. See Remove

Differential Assembly 410D-(SN
796854) 510D-(SN 796890) or
Remove Differential
410D-(SN796855 ) 510D-(SN
TX,D410,3022 1921APR9417/17
9020
15
20

110703
PN=390
Group 20
Adjustments
Adjust Brake Pedals And Equalizing Valves
SPECIFICATIONS
Left-Hand Brake Pedal Minimum 44.5 N (10 lb)
Force
Right-Hand Brake Pedal Minimum 44.5 N (10 lb)
Force
Pedal Travel 19 mm (0.75 in.)
1. Remove brake valve from machine. (See repair

manual.)
2. Clamp brake valve level in bench vise.
TX,D300,DS2080 1912JUL941/5
9020
3. Install caps (A). Fill brake valve reservoir with oil. 20
1
UN30OCT90
T7407AU
TX,D300,DS2080 1912JUL942/5
IMPORTANT: DO NOT allow pedal to return abruptly

before the stop screws are adjusted.
Check valves could be damaged if stop
screws are not properly adjusted.
4. Remove left cap and hold finger over end to stop oil UN30OCT90
flow. Slowly pump left pedal until air is purged. Install
cap and repeat procedure on other side. Refill
reservoir.
T7407AT
Continued on next page TX,D300,DS2080 1912JUL943/5

110703
PN=391
Adjustments
5. Adjust right-hand brake pedal cap screw (B) so brake

piston is fully extended from the housing and brake
pedal arm is tight against the piston.
6. Apply a minimum of 44.5 N (10 lb) force to the

left-hand brake pedal.
UN30OCT90
Specification
Left-Hand Brake PedalMinimum
Force..................................................................................... 44.5 N (10 lb)
T7407AS
If the pedal starts to settle, turn right-hand cap screw (B)
out (counterclockwise) until the settling stops. Turn the
right-hand cap screw (B) and additional 1/3 turn (two
wrench flats) out (counterclockwise).
7. Adjust left-hand brake pedal cap screw (A) so brake

piston is fully extended from the housing and brake
pedal arm is tight against the piston.
8. Apply a minimum of 44.5 N (10 lb) force to right-hand

brake pedal.
9020
20
2 Specification
Right-Hand Brake Pedal
Minimum Force ..................................................................... 44.5 N (10 lb)
If pedal starts to settle, turn the left-hand cap screw (A)

out (counterclockwise) until settling stops. Turn the
left-hand cap screw (A) an additional 1/3 turn (two wrench
flats) out (counterclockwise).
9. After both pedals have been adjusted, align pedals by

turning cap screws for the highest pedal, a maximum
of 1/6 turn (one wrench flat) out (counterclockwise).
Lock both stop screws.

110703
PN=392
Adjustments
10. Remove cap (A). A steady stream of oil must flow to

indicate that check valve is in open position with
pedals up. Depress pedal up to 13 mm (0.5 in.) and
flow must stop which indicates that check valve is in
closed position and sealing. Slowly release pedal;
pedal must return to stop screw by return spring force
UN30OCT90
alone. Install cap. Repeat for other side. Fill reservoir.
NOTE: If oil does not flow, readjust valve stop screws. If

flow does not stop with pedal depressed, inspect
T7407AU
or replace check valve.
11. Depress one brake pedal. Brake pedal must be solid

within first 19 mm (0.75 in.) of pedal travel.
Specification
PedalTravel .................................................................. 19 mm (0.75 in.)
Repeat for other pedal.
NOTE: Excessive pedal travel indicates air in brake valve;

repeat step 4. 9020
20
3
TX,D300,DS2080 1912JUL945/5
Adjust Park Brake
CAUTION: Block wheels to prevent movement

of machine during adjustment.
1. Park machine on level surface and lower all equipment

to ground.
2. Remove rear floor plate.
TX,D300,DS2084 1904JUN931/4
3. Move transaxle lever (A) to neutral and move FNR

lever (B) to neutral position.
4. Start the engine.
NOTE: Park brake must be engaged while adjusting.

UN30AUG90
T7351BW
Continued on next page TX,D300,DS2084 1904JUN932/4

110703
PN=393
Adjustments
5. Remove plug (A) from top rear of transaxle.
6. Use a socket to adjust screw (B) clockwise until it

cannot tightened another half turn.
7. Loosen screw approximately 1 turns until concave
UN18OCT88
surface (C) on bottom of screw head mates with
convex surface of pivot pin. (It will feel like a detented
position.)
T6148AD
8. Stop engine and engage park brake.
TX,D300,DS2084 1904JUN933/4
9020
20 9. Loosen lock nut (A).
4
10. Turn brake band stop screw until it contacts brake
band.
11. Back stop screw out one full turn.
UN02NOV88
12. Hold set screw and tighten lock nut (A).
T6001AP
TX,D300,DS2084 1904JUN934/4
Bleeding Brakes
SPECIFICATIONS
Pedal Travel 115 mm (4.5 in.) at 267 N (60 lb)
force after a 10 second wait cycle

110703
PN=394
Adjustments
NOTE: Air will gravity bleed from brake system through

brake valve without use of bleed screws. Brake
lines must be inclined toward brake valve.
Low ambient temperature or aeration of oil will

slow bleed process.
UN26OCT88
1. Engage park brake. Lock brake pedals together to
bleed both brakes.
T6838AE
2. Run engine at low idle. Put bucket in dump position
and raise front of machine. Steer to axle stop and hold
over relief for 30 seconds to fill brake reservoir.
3. While holding steering over relief, pump the brake

pedal slowly 12 times.
4. Release brake pedal completely and wait a minimum

of 10 seconds.
5. Repeat step 3 and 4 until a firm pedal is obtained

within 115 mm (4.5 in.) of pedal travel after a 10 9020
second wait cycle. 20
5
Specification
PedalTravel ........................................ 115 mm (4.5 in.) at 267 N (60 lb)
force after a 10 second wait cycle
Brakes will continue to self-bleed as you machine and

pedal firmness should improve.
CAUTION: Do not operate machine if pedal

travel exceeds 115 mm (4.5 in.) while applying
267 N (60 lb) force. Operating machine with
excessive brake travel could cause brakes not
to stop machine on first application.
6. If unable to obtain firm brake pedal, inspect lines and

connections for leakage. If not external leaks, test axle.
See repair manual.
TX,D300,DS2087 1912JUL942/2

110703
PN=395
Adjustments
Check And Adjust Toe-In
SPECIFICATIONS
Toe-In Adjustment Front marks must be 12 6 mm
(0.5 0.25 in.) closer than rear
marks
Clamp Cap Screw Torque 95 14 Nm (70 10 lb-ft)
9020
20
6

110703
PN=396
Adjustments
1. Measure distance from ground to hub center (A). At

this height, mark front (B) and rear (C) in center of
tread of each front tire.
2. Measure distance between front marks (B) and rear

marks (C).
UN02NOV88
Machines Without MFWD
1. Front marks must 12 6 mm (0.5 0.25 in.) closer
T6382JW
than rear marks.
Specification
Toe-InAdjustment ................................ Front marks must be 12 6 mm
(0.5 0.25 in.) closer than rear
marks
2. To adjust toe-in, loosen both tie rod clamps (E) and

turn tie rod tube (D). After adjustment, tip cap screws
45 down toward rear of machine.
UN02NOV88
3. Tighten clamp cap screws to 95 14 Nm (70 10
9020
lb-ft).
20
T6162AT
7
Specification
Clamp Cap ScrewTorque ............................ 95 14 Nm (70 10 lb-ft)
Machines With MFWD
1. Front marks must 12 6 mm (0.5 0.25 in.) closer

than rear marks.
2. Loosen nut (F) on each side of axle. Turn each tie rod
UN12NOV90
(G) equally to adjust. Tighten nuts.
ACenter of Hub
BFront of Tire
T7417BA
CRear of Tire
DTie Rod Tube
ETie Rod Clamp
FNut
GTie Rod
TX,D300,DS2088 1912JUL942/2

110703
PN=397
Adjustments
9020
20
8

110703
PN=398
Group 25
Test
Installation
Tachometer
UN28FEB89
T6813AG
10T,9010,K182 1910AUG951/1
9020
JT05800 Digital Thermometer Installation 25
1
Digital Thermometer
Wrap with shop towel.
UN28FEB89
BCable
T6808CE
902525,AA4 1928FEB951/1
Reverser Oil Warm-Up Procedure

SPECIFICATIONS
Transaxle Gear Selected Fourth gear
Engine Speed Fast idle (2375 25 rpm)
1. Hold service brakes on.
Continued on next page TX,300D,1951 1921APR941/2

110703
PN=399
Test
2. Put transaxle in fourth gear (A).
Specification
TransaxleGear Selected ....................................................... Fourth gear
3. Operate engine at fast idle (2375 25 rpm).
UN07JAN91
Specification
EngineSpeed ................................................. Fast idle (2375 25 rpm)
IMPORTANT: Do not stall converter for longer than 20
T7446AF
seconds or serious converter damage
could result.
4. Put FNR lever (B) in forward position and stall for 20

seconds.
5. Shift FNR lever to neutral position for 30 seconds to

circulate oil before doing next converter stall.
NOTE: Heating oil to rapidly will cause CAUTION light on

side console to come ON. Allow sufficient time for
9020
oil to circulate through cooler and back to sump
25
2 and stabilize temperature.
6. Repeat steps 4 and 5 until reverser oil reaches

necessary test temperature.
TX,300D,1951 1921APR942/2

110703
PN=400
Test
Reverser System Pressure Test

SPECIFICATIONS
Oil Temperature 40 4C (104 7F)
Engine Speed 1500 25 rpm
Reverser System Pressure 1240 35 kPa (12.4 0.35 bar)
(180 5 psi)
Each Shim Changes Pressure 35 kPa (0.35 bar) (5 psi)
ESSENTIAL TOOLS
JT01608 (1/8 Nipple x 7/16-20 F 37) Quick Coupler Adapter
JT03111 (9/16-18 M ORB x 7/16-20M 37) Connector
JT05483 (7/16-20 F 37 x 7/16-20 37) 90 Elbow

Hose
Gauge 02000 kPa (020 bar) (0300 psi)
UN07JAN91
9020
1. Install digital thermometer on dipstick. Install electronic 25
tachometer . (See procedure in this group.) 3
T7440AA
2. Connect gauge or hydraulic analyzer (F) to P port on
directional control valve (A).
ADirectional Control Valve
3. Start engine and heat oil to specification. See Reverser BQuick Coupler Adapter
Oil Warm-Up Procedure . CHose
DConnector
Specification E90 Elbow
OilTemperature ..................................................... 40 4C (104 7F) FHydraulic Analyzer
GGauge
(See procedure in this group.)
4. Put FNR lever in neutral position. Adjust engine speed

to specification.
Specification
EngineSpeed .................................................................. 1500 25 rpm
5. If pressure is not specification, adjust shim pack behind

pressure regulating valve.
Specification
Reverser SystemPressure .................. 1240 35 kPa (12.4 0.35 bar)
(180 5 psi)
Each Shim ChangesPressure......................... 35 kPa (0.35 bar) (5 psi)
TX,D410,DS3049 1904JUN931/1

110703
PN=401
Test
Reverser Pump Flow Test (410D, SN

796854) (510D, SN 796890)
SPECIFICATIONS
Test Pressure 1240 35 kPa (12.4 3.5 bar)
(180 5 psi)
New Pump Minimum Flow 28.5 L/m (7.5 gpm)
Used Pump Minimum Flow 21 L/m (5.5 gpm)
ESSENTIAL TOOLS
JT03059 (1-1/16-12M 37) 90 Elbow (2 used)
JT03045 (1-1/16-12M 37 x 1-1/16 M 37) Connector (2 used)
JDG419 Pump Adapter

UN17APR89
9020
25 1. Install digital thermometer on dipstick. Install electronic
4 tachometer . (See procedure in this group).
T6280AH
2. Remove reverser filter housing. Inspect filter element
and filter bypass valve to make sure they are not
causing low flow.
AElbow (2 used)
BConnector (2 used)
3. Make test connections. CPump Adapter
DHoses
IMPORTANT: Flow meter loading valve must be open EFlow Meter
FLoading Valve
before starting unit to prevent damage
to reverser pump.
4. Open flow meter loading valve.
5. Heat oil to specifications. See Reverser Oil Warm-Up

Procedure
Specification
OilTemperature ................................................... 65 5C (150 10F)
6. Adjust engine speed to specification.
Specification
EngineSpeed .................................................................. 1500 25 rpm

110703
PN=402
Test
Record flow rate.
Specification
TestPressure ......................................... 1240 35 kPa (12.4 3.5 bar)
(180 5 psi)
New PumpMinimum Flow ........................................ 28.5 L/m (7.5 gpm)
Used PumpMinimum Flow .......................................... 21 L/m (5.5 gpm)
If flow rate is low, remove and repair or replace pump.
TX,D410,DS3050 1921APR942/2
9020
25
5

110703
PN=403
Test
Reverser Converter-In (Cooler) Relief Valve

Test
SPECIFICATIONS
UN07FEB90
Reverser Converter-In (Cooler) 620760 kPa (6.27.6 bar)
Relief Valve Pressure Setting (90110 psi)
ESSENTIAL TOOLS
T93054
JT03110 Connector
JT03212 Barbed Fitting (410D S.N. 796854, 510D S.N. 796854)

Gauge 01000 kPa (010 bar) (0150 psi)
JT03017 High Pressure Hose
UN26MAR94
1. Install digital thermometer on dipstick. Install electronic
9020
25 tachometer . (See procedure in this group.)
6
T8209AI
2. Heat oil to specification. See Reverser Oil Warm-Up
Procedure
(410D S.N.796855 , 510D S.N.796891 )
Specification
OilTemperature ..................................................... 40 2C (104 4F) ACap
BGauge
CHigh Pressure Hose
(See procedure in this group.) DConnector
EBarbed Fitting
3. Stop engine. Disconnect cooler inlet hose and install FCooler Inlet
cap (A) on cooler fitting.
4. Connect gauge (B) to cooler inlet hose.
5. Start engine and adjust engine speed to specification.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Record pressure reading.
Specification
Reverser Converter-In (Cooler)
Relief ValvePressure Setting .................... 620760 kPa (6.27.6 bar)
(90110 psi)

110703
PN=404
Test
6. A low pressure reading can be caused by a weak,

broken or incorrect spring, or a sticking valve spool.
The four shims under spring are used only as spacers,
not for pressure adjustment.
TX,D410,DS3051 1921APR942/2
9020
25
7

110703
PN=405
Test
Reverser Oil Cooler Restriction Test

SPECIFICATIONS
Oil Flow 11.4 L/min (3.0 gpm)
Cooler Inlet and Outlet Maximum 210 kPa (2.1 bar) (30 psi)
Pressure Difference
ESSENTIAL TOOLS
203654 (1/2 M NPT x 7/16-20 M 37) Connector (2 used)
JT03348 (1/2 F NPT) Tee (2 used)
(Parker No. 30182-8-8) (1/2 M NPT x 1/2 M) Push-Lok Connector (4
used)

Gauge 01000 kPa (010 bar) (0150 psi)
Flowmeter With Temperature Gauge
NOTE: If an internally restricted oil cooler is suspected,
UN01JUN93
the oil cooler can be back flushed to check for
9020 debris. Steps 13 describe how to back flush the
25 cooler and Steps 47 describe how to test cooler
8
for an internal restriction.
T8014AA
1. To back flush cooler, connect reverser pump outlet line
to cooler outlet. Disconnect cooler inlet line and put (410D S.N. 796854, 510D S.N. 796890)
end of hose in a five gallon bucket.
IMPORTANT: Reverser can be emptied of oil if engine

is run too long.
2. Start engine and run at slow idle for 20 seconds. Do

not empty reverser completely.
UN29MAR94
3. Connect cooler hoses to original position on oil cooler.
4. Make test connections. Refill reverser, then start

T8209AF
engine to fill to proper level before test.
5. Open flow meter. Heat oil to test specification. See (410D S.N.796855 , 510D S.N.796891 )
Reverser Oil Warm-Up Procedure
AGauge (2 used)
BConnector (2 used)
Specification CTee (2 used)
OilTemperature ................................................... 65 5C (150 10F) DAdapter (4 used)
EReverser Oil Cooler
(See procedure in this group.) FReverser-to-Cooler Inlet Line
GShut-Off Valve
HCooler Outlet-to-Reverser Line
IFlow Meter
Continued on next page TX,D410,YY774 1921APR941/2

110703
PN=406
Test
6. Increase engine speed until flow is at specification.
Specification
OilFlow .................................................................. 11.4 L/min (3.0 gpm)
7. Read pressure gauges at inlet and outlet of cooler.
Specification
Cooler Inlet and Outlet
Maximum Pressure Difference ......................... 210 kPa (2.1 bar) (30 psi)
If pressure difference is still too high after back flushing,

remove oil cooler and clean or replace. (See repair
manual.)
TX,D410,YY774 1921APR942/2
9020
25
9

110703
PN=407
Test
Torque Converter Stall Speed Test

SPECIFICATIONS
410D Naturally Aspirated Engine 18002000 rpm
Speed
UN14JAN91
410D Turbocharged Engine 19252125 rpm
Speed
510D Turbocharged Engine 20502250 rpm
Speed
T7440AD

tachometer . (See procedure in this group.)
IMPORTANT: Converter should NOT be stalled longer

than 20 seconds or serious converter
damage may result. Return FNR lever to
9020
25 neutral position for 30 seconds before
10 doing next stall test.
2. Destroke hydraulic pump using manual destroke screw

or destroke jumper wire . (See procedure in group
9025-25.)
3. Put transaxle in fourth gear. Apply service brakes.
4. Put FNR lever in forward position.
IMPORTANT: Minimum engine speed listed is for an

engine that is broken-in and using NO.2
fuel.
5. Run engine at fast idle until oil reaches specification.
Specification
410D Naturally Aspirated
EngineSpeed ............................................................... 18002000 rpm
410D Turbocharged Engine
Speed .............................................................................. 19252125 rpm
510D Turbocharged Engine
Speed .............................................................................. 20502250 rpm
6. If converter stall speed is low, check for:

110703
PN=408
Test
Low engine output. (See Group 9010.)

Incorrect torque converter.
Failed freewheel clutch in torque converter.
7. If converter stall is too high, check for:
Incorrect oil temperature.

Low oil level.
Incorrect oil in machine.
Restricted suction screen. (See repair manual.)
Incorrect torque converter.
Engine over-fueled. (See Group 9010.)
Converter failure.
TX,D410,DS3052 1904JUN932/2
9020
25
11

110703
PN=409
Test
Reverser Element Leakage Test Using

Element Pressure (Three-Gauge Method)
SPECIFICATIONS
Reverser System Pressure 1240 35 kPa (12.4 0.35 bar)
(180 5 psi)
Neutral and Forward or Reverse 5070 kPa (0.50.7 bar) (710
Maximum Pressure Difference psi)
ESSENTIAL TOOLS
JT03111 (9/16-18 M ORB x 9/16-20 M 37) Connector (2 used)
JT03114 (7/16-20 F 37 x 7/16-20 M 37) 45 Elbow
JT01608 (7/16-20 F 37 x 1.8 Nipple) Quick Coupler Adapter (3 used)
JT05487 (1/8 M NPT x 7/16-20 M 37) Connector
JT05483 90 Elbow
UN07JAN91
9020
25 JT05801 Electronic Tachometer
12 High Pressure Hoses (3 used)
T7440AB
Hydrostatic Analyzer

tachometer . (See procedure in this group.) AConnector (2 used)
B45 Elbow
2. Connect test ports to hydrostatic analyzer. CDirectional Control Valve
DQuick Coupler Adapter (3 used)
EConnector
3. Heat oil to specification. FR Test Port
GHigh Pressure Hose (3 used)
Specification H90 Elbow
OilTemperature ................................................... 65 5C (150 10F) IHydrostatic Analyzer
4. Move FNR lever to neutral position. Adjust engine

speed to test specification.
Specification
EngineSpeed .................................................................. 1500 25 rpm
5. Record pressure reading from P port.
Specification
Reverser SystemPressure .................. 1240 35 kPa (12.4 0.35 bar)
(180 5 psi)
6. Move FNR lever to forward and record pressure from

F port.

110703
PN=410
Test
Specification
Neutral and Forward or
ReverseMaximum Pressure
Difference ............................................. 5070 kPa (0.50.7 bar) (710
psi)
7. Move FNR lever to reverse and record pressure from

R port.
8. If pressure decreases more than specification when

shifting from neutral to either forward or reverse,
excessive leakage is indicated in that system.
TX,D410,DS3054 1904JUN932/2
9020
25
13

110703
PN=411
Test
Complete Reverser System Test

ESSENTIAL TOOLS
203654 (1/2 M NPT x 7/16-20 M 37) Connector (2 used)
JT03348 (1/2 F NPT) Tee (2 used)
used)
38H1004 (-6 ORFS M x 9/16-18 M ORB) Elbow

Flowmeter
High Pressure Hoses (3 used)
Gauge 02760 kPa (027 bar) (0400 psi)

tachometer . (See procedure in this group.)
UN01JUN93
2. Connect directional control valve P port and R port to
9020
analyzer.
25
14
3. Connect directional control valve F port and L port to
T8014AA
analyzer.
4. Disconnect reverser-to-cooler hose from cooler.
5. Connect flow meter to cooler hose.
6. Install 02760 kPa (027 bar)(0400 psi) gauge in

flowmeter inlet line.
AGauge (2 used)
BConnector (2 used)
CTee (2 used)
DAdapter (4 used)
EReverser Oil Cooler
FCooler-to-Reverser Line
GShut-Off Valve
HReverser-to-Cooler Line
IFlow Meter
JP Port
KF Port
LR Port
ML Port
UN14MAR94
T8197AA

110703
PN=412
Test
IMPORTANT: DO NOT install pin behind cooler relief

valve until Step 6 of test procedure.
7. Make a 9.5 mm (0.38 in.) diameter by 92 mm (3.62 in.)

length pin.
TX,D410,DS3055 1921APR942/3
In Step 6 of test procedure, remove plug (A) and

spring from behind cooler relief valve. Install pin and
plug (A). Hand tighten plug only. One or two threads
must be showing when valve is tight against seat.
UN07FEB90
9020
25
15
T93051
TX,D410,DS3055 1921APR943/3

110703
PN=413
Test
Reverser Test Procedure
Do the steps below and record data on a copy of the Release park brake.
Reverser Test Procedure Chart. Put FNR lever in neutral position.
Run engine at 1500 3 rpm.
Step 1: Start engine. Run at slow idle. Check oil level. Record reading for cooler flow, lube, and P port
pressures.
Step 2. Heat oil to 40 2C (104 4F). (See Put FNR lever in forward position, then record
Reverser Oil Warm-Up Procedure in this group.) Oil readings for cooler flow, lube and P port pressures
temperature must be kept at specifications to record to check forward clutch.
accurate data. Put FNR lever in reverse position, record readings
for cooler flow, lube and P port pressure to check
Release park brake. reverse brake.
Put FNR lever in 4th forward and hold service
brakes. Step 9. Accumulator check.
Step 3. Pressure regulating valve check. Put FNR lever in neutral position.
Release park brake. Move FNR lever from neutral to forward, forward to
Put FNR lever in neutral position. reverse, reverse to neutral several times to observe
Run engine at 1500 25 rpm. accumulator action on gauge connected to P port.
9020 Record reading for P port pressure. See gauge illustrations on chart for normal
25 accumulator operation for a shift.
16
Step 4. Converter-in (cooler) relief valve pressure Remove pin from behind cooler relief.
check.
Put FNR lever in neutral position.

Close flow meter.
Record reading for converter-in (cooler relief)
pressure.
Step 5. Lube relief valve pressure check.
Run engine at slow idle.

Close flow meter.
Put FNR lever in 4th forward and hold service
brakes.
Slowly increase rpm until lube pressure stops
increasing.
Record reading for lube pressure.
Step 6. Stop engine. Open flow meter. Install pin to

hold converter-in (cooler) relief valve closed.
Step 7. Heat oil to 60 1C (140 2F).
Step 8. Directional control valve check.

110703
PN=414
Test
REVERSER TEST PROCEDURE CHART

Converter
Element Shift Cooler Lube in Relief P Port Operating
Step RPM Temperature Tested Mode Flow Pressure Pressure Pressure Condition
1 Slow idle N Check oil
2 Fast idle 402C F Brakes on, 4th
1044F gear converter
stall
3 150025 402C Pressure N
1044F regulating
valve
4 150025 402C Converter-in N Close flow meter
1044F relief valve
5 Slow idle to 402C Lube relief F Increase rpm
2000 1044F valve until pressure
stops increasing
6 0 Install pin Open flow meter
into
converter-in
(cooler) R
bore
7 Fast idle 601C F Brakes on, 4th
1402F gear converter 9020
stall 25
8 15003 601C Forward F Clutch 17
1402F clutch disconnect
switch
depressed
15003 601C Reverse R Clutch
1402F brake disconnect
switch released
9 15003 601C Accumulator N to F See Make several
1402F F to R illustration shifts
R to F or below
N to R

110703
PN=415
Test
UN18APR89
T93052
9020
25
18
Step 10. The gauge illustration of P port pressure UN18APR89

T93053
indicates normal accumulator operation for a shift.

TX,D410,DS3060 1904JUN933/3

110703
PN=416
Test
Specifications And Analysis

SPECIFICATIONS Step 5. Lube pressure is 220 to 290 kPa (2.2 to 2.9
Reverser System Pressure 1240 35 kPa (12 0.35 bar) bar) (32 to 42 psi) when the pressure stops increasing.
(180 5 psi)
Converter-in (Cooler) Relief 620760 kPa (6.27.6 bar) Specification
Valve Pressure (90110 psi) LubePressure ..................................... 220290 kPa (2.22.9 bar)
(3242 psi)
Lube Pressure 220290 kPa (2.22.9 bar)
(3242 psi)
The point at which pressure stops increasing is when
New Reverser Cooler Minimum 11.35 L/min (3.0 gpm)
Acceptable Flow the relief valve opens. If pressure is low, do test again
in reverse to make sure excessive leakage in forward
Used Reverser Cooler 5.7 L/min (1.5 gpm)
Minimum Acceptable Flow clutch is not causing low reading. Low lube pressure
can be caused by a stuck valve spool, weak or broken
Neutral, Forward And Reverse 1.8 L/min (0.5 gpm)
Maximum Allowable Flow spring, or excessive leakage in reverser.
Difference
Forward or Reverse Lube 151 to 220 kPa (1.5 to 2.2 bar) Step 8. Minimum acceptable reverser cooler flow with
Pressure (22 to 32 psi) a new pump is 11.35 L/min (3.0 gpm) or a used pump
is 5.7 L/min (1.5 gpm) in forward, reverse, or neutral.
After testing the reverser and recording data on the
Specification
chart, use the following analysis to determine if New Reverser Cooler
reverser meets the specifications given and hydraulic Minimum Acceptable Flow............................... 11.35 L/min (3.0 gpm) 9020
system for reverser is acceptable. Information is also Used Reverser Cooler 25
given to help identify the cause of possible problems. Minimum Acceptable Flow................................... 5.7 L/min (1.5 gpm) 19
Step 3. P port pressure (reverser system pressure) is The maximum allowable difference of flow between
1240 35 kPa (12 0.35 bar) (180 5 psi). neutral, forward and reverse is 1.8 L/min (0.5 gpm).
Specification Specification
Reverser SystemPressure .............. 1240 35 kPa (12 0.35 bar) Neutral, Forward And
(180 5 psi) ReverseMaximum Allowable
Flow Difference .................................................... 1.8 L/min (0.5 gpm)
A low pressure reading can be caused by a weak,

broken or wrong spring or a valve spool that does not A difference in P port pressure of 50 to 70 kPa (0.5 to
slide freely in bore. 0.7 bar) (7 to 10 psi) from neutral to forward or reverse
indicates excessive leakage in that circuit.
Step 4. Converter-in (cooler) relief valve pressure is
620 to 760 kPa (6.2 to 7.6 bar) (90 to 110 psi). A difference in lube pressure of 21 to 35 kPa (0.21 to
0.35 bar) (3 to 5 psi) from forward to reverse indicates
Specification excessive leakage in circuit with lowest pressure.
Converter-in (Cooler) Relief
ValvePressure .................................... 620760 kPa (6.27.6 bar) Lube pressure in forward or reverse is 151 to 220 kPa
(90110 psi) (1.5 to 2.2 bar) (22 to 32 psi).
A low pressure reading can be caused by a stuck Specification
valve spool, weak, broken or wrong spring. The four Forward or Reverse Lube
shims under spring are used only as spacers, not for Pressure............................................. 151 to 220 kPa (1.5 to 2.2 bar)
pressure adjustment. (22 to 32 psi)

110703
PN=417
Test
When the clutch disconnect is depressed, lube Step 9. If accumulator operation is not to specification,
pressure must decrease to zero. If pressure does not check for a bad spring, stuck spool, or restricted
decrease, check for a broken disconnect spool spring orifice.
or solenoid.
TX,D410,DS3063 1904JUN932/2
Brake Valve Leakage Test
SPECIFICATIONS
Oil Temperature 40 5 C (104 10F)
ESSENTIAL TOOLS
38H1352 (-4 ORFS) Nut (2 used)
38H1138 (-4 ORFS) Plug (2 used)
38H1029 Tee
JT03455 (7/16 JIC M x -4 ORFS F) Fitting

Gauge 06895 kPa (069 bar) (01000 psi)
9020
25
1. Heat oil to specifications.
20
Specification
OilTemperature .................................................. 40 5 C (104 10F)
See Hydraulic Oil Warm-up in Group 9025-25.
UN14DEC91
2. Stop engine.
3. Push left and right brake pedal individually. If either
T7668AL
pedal settles, leakage is indicated in final drive brake
piston or brake valve reservoir.
4. Disconnect brake line and tee gauge at brake valve

line of pedal that settled.
5. Push brake pedal down and block in place to set

gauge at 500 psi starting point.
6. Monitor gauge. If pressure drops more than 100 psi in

30 seconds, excessive leakage is indicated.
7. To isolate leakage, disconnect and cap line at gauge.
8. If leakage continues, replace check valve.
9. No pressure drop indicates leakage at piston seals in

axle housing.
300D,DS4660 1912JUL941/1

110703
PN=418
Test
Brake Element Leakage Test

SPECIFICATIONS
Test Pressure 241 34 kPa (2.4 0.3 bar) (35
5 psi)
ESSENTIAL TOOLS
Connector
JT03104 Connector
JT05687 Adapter
JT03103 Adapter
JT03086 Adapter
JT03001 Tee
38H1164 Plug

JT03402 Shut-Off Valve
Gauge
UN17APR89
9020
25
2. Open regulator to pressurize brake circuit. 21
T6288BG
3. Close regulator. Note gauge reading after five minutes.
Pressure should remain at specification.
Specification AQuick Couple Nipple

TestPressure ....................................... 241 34 kPa (2.4 0.3 bar) (35 BConnector
5 psi) CShut-Off Valve
DConnector
EAdapter
4. If pressure decreases, apply liquid soap to joints and FAdapter
do test again. GAdapter
HTee
IPlug
JAir Hose
KGauge
LHose
TX,D410,DS3058 1904JUN931/1

110703
PN=419
Test

Clutch Pressure Test (410D SN 796854,
510D SN 796890)
SPECIFICATIONS
UN31JAN90
MFWD Clutch Pressure When 0 kPa (0 bar) (0 psi)
Engaged
MFWD Clutch Pressure When 1030 100 kPa (10.3 + 1 bar)
T94736
Disengaged (150 15 psi)
Each Shim Changes Pressure 138 kPa (20 psi)
ESSENTIAL TOOLS
JT05487 (1/8 M NPT x 7/16-20 M 37) Connector
202850 (7/16-20 F 37 x 1/8 Nip) Quick Coupler Adapter
36952 Hose From Hydraulic Analyzer

Tachometer/Temperature Reader
9020
25 Gauge 02760 kPa (027.6 bar) (0400 psi)
22
1. Connect tachometer/temperature reader. (See
procedure in this group.)
2. Connect gauge to sender port using fittings (B and C).
3. Heat oil to test specifications .
Specification
(See Hydraulic Oil Warm-Up Procedure in this group.)
4. Raise unit off ground using loader and stabilizers. Put

transmission in 1st forward.
5. Run engine at 1000 25 rpm.
Specification
EngineSpeed .................................................................. 1000 25 rpm
6. Engage MFWD. Record pressure reading.
Specification
MFWD ClutchPressure When
Engaged .................................................................... 0 kPa (0 bar) (0 psi)
Continued on next page T60,9025,C142 1921APR941/2

110703
PN=420
Test
Disengage MFWD. Record pressure reading.
Specification
MFWD ClutchPressure When
Disengaged................................................ 1030 100 kPa (10.3 + 1 bar)
(150 15 psi)
7. If pressure is not correct, add or remove shims in valve

to adjust pressure.
Specification
Each Shim ChangesPressure...................................... 138 kPa (20 psi)
T60,9025,C142 1921APR942/2
9020
25
23

110703
PN=421
Test
9020
25
24

110703
PN=422
Section 9025
Hydraulics
Contents
Page Page
Group 05Theory Of Operation Backhoe Crowd Valve Operation

Charge Pump Operation . . . . . . . . . . . . . . . .9025-05-1 HUSCO . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-46
Main Hydraulic Pump Operation . . . . . . . . . .9025-05-2 Backhoe Swing Valve Operation
Pressure Compensator Operation . . . . . . . . .9025-05-4 HUSCO . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-48
Return Filter Operation . . . . . . . . . . . . . . . . .9025-05-6 Backhoe Auxiliary Valve Operation
Priority Valve Operation (S.N. 801199) . . .9025-05-7 HUSCO . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-50
Steering Valve Operation . . . . . . . . . . . . . .9025-05-10 Backhoe Circuit Relief Valve With
Loader Circuit Relief Operation GRESEN Anti-CavitationHUSCO . . . . . . . . . . . . .9025-05-52
(S.N. 801199). . . . . . . . . . . . . . . . . . . .9025-05-14 Backhoe Circuit Relief Valve Without
Loader Bucket Valve OperationGRESEN Anti-CavitationHUSCO . . . . . . . . . . . . .9025-05-53
(S.N. 801199). . . . . . . . . . . . . . . . . . . .9025-05-15 Backhoe System Relief Valve Operation
Loader Boom Valve OperationGRESEN HUSCO 410D(S.N. 796855
(S.N. 801199). . . . . . . . . . . . . . . . . . . .9025-05-17 801199), 510D(S.N. 796891
Loader Auxiliary Valve OperationGRESEN 801199) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-54
(S.N. 801199). . . . . . . . . . . . . . . . . . . .9025-05-19 Stabilizer Valve Operation . . . . . . . . . . . . . .9025-05-56
Loader Priority Valve Operation HUSCO Backhoe Solenoid Controlled Auxiliary
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-57
(S.N. 801200 ) . . . . . . . . . . . . . . . . . . .9025-05-22
Loader Boom Valve OperationHUSCO 9025
(S.N. 801200 ) . . . . . . . . . . . . . . . . . . .9025-05-24 System Operational Procedure . . . . . . . . . . .9025-10-1
Loader Bucket Valve OperationHUSCO Steering System Checks . . . . . . . . . . . . . . . .9025-10-1
(S.N. 801200 ) . . . . . . . . . . . . . . . . . . .9025-05-26 Hydraulic System Checks . . . . . . . . . . . . . . .9025-10-3
Loader Auxiliary Valve Operation
HUSCO (S.N. 801200 ) . . . . . . . . . . . .9025-05-28 Group 15Diagnostic Information
Loader Circuit Relief Valve With Diagnose Steering System Malfunctions . . . .9025-15-1
Anti-CavitationHUSCO (S.N. 801200 Diagnose Main Hydraulic System
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-30 Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9025-15-4
Loader Circuit Relief Valve Without Main Hydraulic System Operation . . . . . . . . .9025-15-7
Anti-Cavitation HUSCO (S.N. 801200 Hydraulic System Schematic, 410D (S.N.
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-32 796854), 510D (S.N. 796890) . . . . . . .9025-15-8
Backhoe Circuit Relief And Anti-Cavitation Hyd. Component Location, 410D (S.N.
Valve OperationGRESEN. . . . . . . . . . .9025-05-33 796855801199), 510D (S.N. 796891
Backhoe Boom Valve Operation 801199) . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-9
GRESEN . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-35 Hydraulic Schematic, 410D (S.N.
Backhoe Crowd Valve Operation 796855801199), 510D (S.N. 796891
801199) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-10
GRESEN . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-37
Hydraulic Component Location, 410D
Backhoe Bucket Valve Operation
(S.N. 801200 ), 510D (S.N. 801200
GRESEN . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-38
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-11
Backhoe Swing Valve Operation
Hydraulic Schematic, 410D (S.N.
GRESEN . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-39
801200 ), 510D (S.N. 801200 ). . . . .9025-15-12
Backhoe Auxiliary Valve Operation
GRESEN . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-40 Group 20Adjustments
Backhoe Boom Valve Operation Loader Bucket Level Indicator And
HUSCO . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-42 Return-To-Dig Switch Adjustment . . . . . . .9025-20-1
Backhoe Bucket Valve Operation
HUSCO . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-44 Continued on next page

110703
PN=1
Contents
Page
Loader Control Valve Linkage Adjustment. . .9025-20-3

Backhoe Valve Linkage Adjustment . . . . . . .9025-20-5
Stabilizer Valve Linkage Adjustment . . . . . . .9025-20-7
Group 25Tests
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Hydraulic Oil Warm-Up Procedure. . . . . . . . .9025-25-1
Diagnostic Destroke Wire Harness Installation
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-3
Main Hydraulic Pump Flow And Stroke
Control Valve Test . . . . . . . . . . . . . . . . . . .9025-25-4
Charge Pump Pressure Test . . . . . . . . . . . . .9025-25-6
Charge Pump Flow Test . . . . . . . . . . . . . . . .9025-25-8
Main Pump Standby Pressure Test . . . . . . .9025-25-11
Priority Valve Test (S.N. 801199). . . . . . .9025-25-13
Priority Valve "LS" Port Flow Test . . . . . . . .9025-25-16
Hydraulic Oil Cooler Restriction Test 410D
(S.N. 796854) 510D (S.N.
796890) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-18
(S.N. 796855 ) 510D (S.N. 796891
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-21
9025 Cycle Time Test . . . . . . . . . . . . . . . . . . . . .9025-25-23
Relief Valve Testwith Remote Pump . . . .9025-25-29
Relief Valve Test Using Amplification
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-32
Steering System Leakage Test . . . . . . . . . .9025-25-38
Steering Cylinder Leakage Test . . . . . . . . .9025-25-41
Steering Valve Neutral Drift Test . . . . . . . . .9025-25-42
Hydraulic Component Leakage Test . . . . . .9025-25-44
Hydraulic Cylinder Drift Test Procedure. . . .9025-25-49
Function Drift Test. . . . . . . . . . . . . . . . . . . .9025-25-50
Cylinder Leakage Test . . . . . . . . . . . . . . . .9025-25-54
MFWD Valve Test 410D (S.N. 796854)
510D (S.N. 796890) . . . . . . . . . . . . . . .9025-25-55
Flowmeter Calibration Procedure . . . . . . . .9025-25-57

110703
PN=2
Group 05
Theory Of Operation
Charge Pump Operation
The charge pump is located on the front of the main When main hydraulic pump is at standby, charge oil
hydraulic pump. It is driven by the main pump flows through oil cooler and is returned to hydraulic
crankshaft. reservoir. Excess charge flow is returned to reservoir
through surge relief check valve. This surge relief
The charge pump is a low pressure, constant check valve is located in reservoir return line from filter
displacement gear pump. Charge oil is drawn from the base and regulates charge pressure.
hydraulic reservoir suction screen and pumped into
return line ahead of hydraulic filter to supply main
hydraulic pump.
TX,9025,BS239 1924MAY931/1
9025
05
1

110703
PN=425
Theory Of Operation
Main Hydraulic Pump Operation
K
J
N
L
O
U
A
M
H
F G
D
B
9025
05
2 E
1915JAN98
Q
R C
T6902AA
S
TXC6902AA
Single Bank Pump Shown
AInlet HCrankcase MDestroke Plug (Optional QCrankcase Pressure Oil

BHigh Pressure Outlet IOrifice Manual or Electric RInlet Pressure Oil
CDischarge Valve JPressure Compensator Solenoid) SPump Housing
DPiston Adjusting Screw NShuttle Valve TInlet Housing
EShaft KSpring OCrankcase Relief Valve UValve Housing
FBearing Race LPressure Compensator PDischarge Pressure Oil
GInlet Valve Valve
The 3000 Series radial piston pump is a variable double bank pump is essentially two single bank
displacement pump. Single and double bank versions pumps sharing a common drive shaft and control
operate the same to provide high pressure oil flow. A valve.
Continued on next page 27T,9025,M65 1924MAR931/2

110703
PN=426
Theory Of Operation
Inlet oil (R) enters through inlet ports (A) in the inlet oil in the outlet gallery closes the discharge valve (C).
housing (T). A common inlet gallery in the housing All discharge valves share a common outlet gallery in
provides oil to eight inlet valves (G) in pump housing the pump housing (S). An orifice (I) is located between
(S). Pistons (D) radially surround an eccentric cam. the crankcase and the inlet gallery. Any oil leakage
The pistons ride on the cam bearing race (F). A spring past the pistons is routed through the orifice (I) to the
behind each piston hold it against the bearing race. As inlet gallery. This flow allows for cooling and
pump shaft (E) rotates, a low pressure cavity develops lubrication. Pressure compensation pumps (both older
in the piston spring area during downward stroke of style non-unutized and newer style unitized designs)
piston. This low pressure allows inlet valve (G) to open are designed to provide "on demand" discharge
filling the piston cavity with oil. Inlet valves close at the pressure oil (P) regardless of flow requirements. As
end of intake stroke of pistons. High pressure oil is demand for oil decreases, system pressure increases.
developed as bearing race pushes pistons outward. Pressure compensator valve (L) then routes system oil
into crankcase (H). Increased pressure in the
As pressure increases, the discharge valve (C) opens crankcase overcomes piston spring pressure and holds
allowing discharge pressure oil (P) to pass into the pistons (D) away from race (F), thereby destroying the
outlet gallery. At the end of stroke, discharge pressure pump.
27T,9025,M65 1924MAR932/2
9025
05
3

110703
PN=427
Theory Of Operation
Pressure Compensator Operation
B P
P
G
E G B N
C
E
I F
J
H K
9025
L
05
4
1915JAN98
TXC6902AB
D O
T6902AB
APressure Compensator ECrankcase Relief Valve JDischarge Pressure Oil OPlug (or Optional Electric
Adjusting Screw FExternal Control Valve (Not KCrankcase Pressure Oil Solenoid)
BPressure Compensator Used On 410D/510D) LInlet Pressure Oil PValve Housing
Spring(s) GSpring MPressure Compensator
CSpring Guide HShuttle Valve (Shown in First Position)
DPressure Compensator ISpring NPressure Compensator
Valve (Shown in Second
Position)
Continued on next page TX,9025,BS234 1924MAY931/2

110703
PN=428
Theory Of Operation
The 3000 Series unitized designed pump provides a Valve continues to move to second position (N)
bolt-on control valve. The pressure compensator valve dumping discharge pressure oil (J) into the crankcase
(D) controls the flow of the pump. Valve movement is increasing crankcase pressure. Crankcase pressure
controlled by discharge pressure oil (J) on one end of overcomes the combined spring force on the pump
the valve and by inlet pressure oil (L) and force from pistons. Pistons are then held away from the pump
spring (B) on the other end. Discharge pressure can shaft bearing race and the pump is destroked.
be increased or deceased by changing the force on
spring (B) using the pressure compensator adjusting The pump goes into quick destroke when there is a
screw (A). Shuttle valve (H) is used in conjunction with sudden drop in demand for oil flow, creating a sudden
either a manual destroke screw or an electric destroke increase in discharge pressure oil. Discharge pressure
solenoid in place of plug (O). Valve (H) moves against oil increases greatly allowing crankcase relief valve (E)
crankcase relief valve (E) and spring (G) allowing to move against spring (G). This allows crankcase
discharge pressure oil to be dumped into crankcase pressure oil (K) to dump into inlet pressure oil (L). This
and inlet thereby destroking the pump. limits high pressure spikes caused by discharge
pressure oil being too rapidly routed into crankcase
Pump is in full stroke when pressure compensator cavity.
valve (D) is in first position (M). As demand for oil
decreases, discharge pressure increases moving
pressure compensator valve (D) toward spring (B).
TX,9025,BS234 1924MAY932/2
9025
05
5

110703
PN=429
Theory Of Operation
Return Filter Operation
INLET HOUSING I
G VALVE
A C
A B A
PISTON
C
SPRING
K
D
SPRING F
H TERMINAL
L RESTRICTED FLOW
J
TO I ELEMENT M SEMI-RESTRICTED
1925FEB99
RESERVOIR FLOW
K K N RETURN FLOW
OUTLET
T6903AC
TXC6903AC
O RETURN FILTER
9025
05
6
AInlet Passage FSpring JTo Reservoir MSemi-Restricted Flow
BHousing GValve KOutlet Passage NReturn Flow
CPiston HTerminal LRestricted Flow OReturn Filter
DSpring IElement
The hydraulic return filter removes contaminants from As the filter element becomes plugged, the pressure
the hydraulic system oil. The filter housing contains a differential between the inlet and outlet increases. Inlet
bypass valve and a filter restriction switch. pressure is sensed on one side of the valve (G) which
opens against spring (F) force and outlet pressure.
Under normal operation, return flow from the steering, The return oil then bypasses the filter while the
loader and priority valve enters the inlet (A), flows restriction indicator lights glow.
through the filter element (I), up through the filter
canister and out the outlet (K) or to the reservoir (J). Under normal operation, the restriction indicator light
will glow when operating the hydraulic functions with
If the pressure differential between the inlet and outlet cold oil. If the restriction indicator light continues to
increases past a set level due to cold oil or partially glow after the oil reaches operating temperature, the
restricted filter element, inlet pressure in the housing return filter is being bypassed and the filter element
(B) increases, moving the piston (C) down against should be replaced. Extended operation in the bypass
spring (D) force and outlet pressure. The piston mode will cause damage to the hydraulic system.
contacts the terminal (H), completing a circuit which
causes the filter restriction indicator light to glow.
TX,9025,BS240 1924MAY931/1

110703
PN=430
Theory Of Operation
Priority Valve Operation (S.N. 801199)
D P PORT C A E
E SPOOL
RETURN C F
B
H G
LS PORT B
SPRING A
ORIFICE H J SYSTEM PRESSURE

LOADER K STEERING CIRCUIT
VALVE I G F
PRESSURE
ACTUATED EF PORT CF PORT
1901JAN99
L RETURN PRESSURE
T7421BC
TXC7421BC M PRIORITY VALVE NEUTRAL
9025
ASpring ESpool HOrifice KSteering Circuit Pressure 05
B"LS" Port F"CF" Port, To Steering ILoader Valve Actuated LReturn Pressure 7
CReturn Valve JSystem Pressure MPriority Valve-Neutral
D"P" Port, Inlet G"EF" Port, To Loader Valve
The priority valve is a pressure control valve that spring and open the "EF" port. As long as the steering
maintains priority pressure to the closed-center valve is in neutral, just enough pressure to the steering
steering valve. With the steering valve in neutral, flow valve is maintained to keep the priority valve spool
to the steering valve is not required and almost all flow shifted to the left.
through the priority valve is directed out the "EF" port
(G) to the loader control valve. The operating pressure in the loader circuit does not
effect the operation of the priority valve. With a loader
With the engine off, the spool (E) is pushed to the right function over relief (I), the priority valve will not shift
by the spring (A). The passage to the "CF" port (F) is until the unit is steered.
open.
Flow through the priority valve spool passes through
When the machine is first started, all pump flow is the orifice (H) and into the "LS" port (B) flowing
routed to the steering valve which, if not being through the steering valve "LS" passage which is
operated, blocks the flow. This causes pump pressure routed to return when the steering valve is in neutral.
to increase. Steering inlet pressure is supplied through This provides a warm-up circuit to prevent binding of
the pilot orifice to the right end of the spool. This the steering valve due to temperature extremes.
causes the priority valve spool to shift left against the
Continued on next page TX,2505,DS3034 1906APR941/3

110703
PN=431
Theory Of Operation
E
D P PORT B H D
ORIFICE C
E SPOOL
RETURN B F
A G
C
LS PORT A
SPRING H J HIGH PRESSURE

K MEDIUM PRESSURE
L LOW PRESSURE
FULL G F
STEER I M TRAPPED OIL
RATE EF PORT CF PORT
N RETURN PRESSURE
1901JAN99
PRIORITY VALVE STEERING ACTIVATED
T7421BD
O
9025 TXC7421BD LOADER VALVE IN NEUTRAL
05
8
A"LS" Port F"CF" Port, To Steering JHigh Pressure NReturn Oil
BReturn Valve KMedium Pressure OPriority ValveSteering
COrifice G"EF" Port, To Loader Valve LLow Pressure ActivatedLoader Valve in
D"P" Port, Inlet HSpring MTrapped Oil Neutral
ESpool IFull Steer Rate
When steering the machine, load-sensing pressure conditions. During normal conditions, oil is metered
from the steering valve flows through the orificed "LS" into the load sensing circuit through an orifice in the
port (A) in the priority valve. Load sensing pressure steering valve. When steering is at the full steer rate
plus spring (H) force moves the spool to the right (I), the orifice opens to the full right position, directing
against the pilot pressure on the right end of the spool. all flow to the steering valve. At fast idle, the steering
This restricts flow through the "EF" port (G) while the system will not use all of the pump flow. Therefore, the
"CF" port (F) is open to the steering valve. excess oil flows to the loader control valve.
The load sensing circuit is a control circuit that routes The load sensing circuit receives the majority of its
steering work port pressure oil to the spring side of the flow from the load sensing orifice in the steering valve.
priority valve spool to sense the pressure that is Some flow is also supplied from the "CF" port through
required to steer the machine under various load orifice (C) in the priority valve spool.
Continued on next page TX,2505,DS3034 1906APR942/3

110703
PN=432
Theory Of Operation
POPPET C D SPRING E PORT C

E
B
F SPOOL
RETURN B G
A
H
LS PORT A
I HIGH PRESSURE
H G J MEDIUM PRESSURE
1901JAN99
EF PORT CF PORT K RETURN PRESSURE
L PRIORITY VALVE STEERING CYLINDER
T7421BE
TXC7421BE BOTTOMED AND LOADER ACTIVATED
A"LS" Port E"P" Port, Inlet H"EF" Port, To Loader Valve LReturn Pressure
BReturn FSpool IHigh Pressure MPriority ValveSteering
CPoppet G"CF" Port, To Steering JMedium Pressure Cylinder Bottomed, Loader 9025
DSpring Valve KLow Pressure Activated 05
9
With steering turned fully against stop, maximum Pressure to the steering valve (internal pilot pressure),
steering system pressure is created. To limit steering which is sensed at the right end of the priority valve
system pressure, a relief valve poppet (C) is built into spool (F), continues to increase until it can move the
the priority valve assembly. spool to the left against the load sensing pressure plus
spring force. At this time, all oil flows out of the "EF"
The steering system pressure is sensed at the "LS" port (H) to the loader valve. If a machine function is
port (A). When the pressure in the "LS" port increases operated while steering, the operating function will
enough to push poppet (C) off its seat, oil in the load slow until the machine reaches steering turn limit. At
sense circuit flows to return port (B). Load sensing that time, the function speed will increase to normal
pressure is limited to the pressure setting of the relief until the machine is steered again.
valve which is adjustable.
TX,2505,DS3034 1906APR943/3

110703
PN=433
Theory Of Operation
Steering Valve Operation
The steering valve is a closed-center valve. The steering

valve and priority valve provide a smooth pressure 4
compensated steering system.
The steering valve consists of a rotary spool and sleeve

assembly located inside the valve housing with a gerotor
at the end of assembly. 5
Whenever the steering wheel is not moving, the spool and 6

sleeve are lined up so the oil flow through the valve is
blocked. Oil cannot flow from the pump or the steering
cylinder through the valve.
7
1High Pressure Oil
2Pressure-Free or Return Oil
3Trapped Oil 1
UN04SEP98
4Port "T"
5Port "L" 2
6Port "R"
3
7Port "P"
T80788
T80788
Steering Valve In Neutral
Continued on next page TX,902505,BR141 1924MAY931/4

9025
05
10

110703
PN=434
Theory Of Operation
As the steering wheel is turned to the left, the spool is

turned by means of its direct connection to the steering
shaft. This movement aligns the spool passages with the
sleeve ports and pressure oil begins to flow in the valve.
The oil flows through the sleeve, into spool passages, and 3
back out of the sleeve into the valve housing. The
passages in the housing direct oil to one side of the
gerotor moving the gerotor gear. As the gear is rotated, it
performs the following functions:
4
1. It forces oil out of the gerotor into outlet passages in
the housing, back through the sleeve and spool, and 5
out the left outlet (4).
2. The oil is directed to the rod end of the steering

cylinder. Return oil from the cylinder is forced back 6
through the valve and out to the reservoir.
7
3. The rotation of the gerotor gear also turns the gerotor
UN04SEP98
drive which is connected to and turns the valve sleeve. 1
2
1Pressure Oil
T80787
2Return Oil T80787
3Port "T"
4Port "L" Oil Flow For A Left Turn
5Port "R"
6Port "P" 9025
7Gerotor Gear Assembly 05
11

110703
PN=435
Theory Of Operation
When the steering wheel is turned to the right,

movement takes place in the valve which is similar to
the movement occurring during a left-hand turn.
The movement of the spool, however, is in the

opposite direction to a left turn and oil is routed 3
through different ports and passages in the sleeves
and spool, directing oil out the right outlet port (marked
"R").
4
A load sensing orifice is located between the sleeve
and gerotor. This orifice feeds the load sensing circuit
between the steering valve and the priority valve 5
through the LS port. (See Hydraulic Schematic in
9025-15.)
When rotation of the steering wheel stops, the gerotor 6

gear continues to move turning the valve sleeve until
the sleeve is in the correct relationship with the spool 7
to stop the flow of oil to the gerotor. At this point, the
UN04SEP98
valve is in the neutral position and will remain there 1
until the steering wheel is moved.
2
T80789
T80789
1Pressure Oil
2Pressure-Free or Return Oil
3Port "T"
4Port "L"
9025 5Port "R"
05 6Port "P"
12 7Gerotor Gear Assembly

110703
PN=436
Theory Of Operation
If there is no power to supply pressure oil to the valve, 8

the machine can be steered manually. If no pressure
oil is available, the control spool (8) will come into
contact with the pin (7). The pin then provides a direct
mechanical connection through the drive shaft to the
gerotor gear assembly (5). As the gerotor is turned, it 9
7
pumps oil to the steering cylinder. Return oil (3) from
the cylinder is drawn through a check valve (6)
between the inlet and outlet ports providing oil for
manual steering operation. The machine can be 10
steered manually until the machine is brought to a
stop.
11
6
1Pressure Oil
2Suction Oil
3Return Oil
4Trapped Oil 12
5Gerotor Gear Assembly
6Check Valve 1
7Pin
2
UN04SEP98
8Control Spool
9Port "T" 3
10Port "L"
11Port "R" 4
12Port "P"
T80790
5 T80790
Oil FlowSecondary Steering Right Turn
9025
05
13
TX,902505,BR141 1924MAY934/4

110703
PN=437
Theory Of Operation
Loader Circuit Relief Operation GRESEN (S.N. 801199)
E
N
H I
D G
9025 A
05 L
14 B
UN06MAR97
C
K
J
T6298BF
T6298BF
AHigh Pressure Oil DRelief ValveOpen GReturn Port KPoppet

BLow Pressure Oil ERelief ValveClosed HCollar LOrifice
CCharge Pressure (Return to FAnti-Cavitation Valve IReturn Passage MWork Port
Charge Circuit) Open JPilot Valve NSnap Ring
When the circuit relief valve is closed (E), oil from work flow through orifice causing pressure to decrease.
port (M) flows through orifice (L) into the area behind Then high pressure oil pushes the poppet off its seat
poppet (K). With pressure equal on both sides of releasing oil through return port (G) to return passage
poppet, spring force holds poppet (K) closed and stops of valve.
flow through return port (G).
During anti-cavitation operation (F) the pressure in
During relief operation (D) when pressure in the circuit return port is greater than pressure in work port. The
increases above relief valve setting, high pressure oil difference in pressure pushes collar (H) against snap
pushes pilot valve (J) off its seat. Oil behind the ring (N) pulling the poppet off its seat. Oil then flows
poppet flows out return passage (K) faster than oil can from return port into work port to prevent cavitation.
TX,9025,BS342 1906APR941/1

110703
PN=438
Theory Of Operation
Loader Bucket Valve OperationGRESEN (S.N. 801199)
F G
E E
D
A
K
B
H
C
UN20FEB97
J I
T6298BN
T6298BN
9025
05
Valve Shown In Neutral Position 15
AHigh Pressure Oil DReturn-To-Dig GBucket Rollback Work Port JLift Check
BTrapped Oil Electromagnet HCircuit Relief Valve KCircuit Relief With
CCharge Pressure Oil EReturn Passage IInlet Passage Anti-Cavitation
(Return to Charge Circuit) FBucket Dump Work Port
The bucket valve is a three-position, four-way, When bucket dump function is activated and pressure
spool-type valve. It contains a lift check (J) and two in circuit is less than charge pressure, oil flows from
circuit relief valves. Relief valve (K) also contains an return passage (E) past anti-cavitation valve (K) to the
anti-cavitation valve. bucket dump circuit (F).
Continued on next page TX,9025,BS343 1906APR941/2

110703
PN=439
Theory Of Operation
E F
D D
C
A
J
B G
I H
N C
9025
UN20FEB97
05
16
I
L K
G J D H
T6298BM
T6298BM
Valve In Bucket Rollback Position
AHigh Pressure Oil DReturn Passage GCircuit Relief Valve JCircuit Relief Valve With
BCharge Pressure Oil EBucket Dump Work Port HInlet Passage Anti-Cavitation
(Return to Charge Circuit) FBucket Rollback Work Port ILift Check
CReturn-To-Dig
Electromagnet
The valve can be equipped with a return-to-dig. When rollback position. When the bucket rolls back to the dig
loader control lever is moved to the bucket rollback position, a mechanical linkage opens the return-to-dig
position, a plate fastened to end of valve spool, switch, which de-energizes electromagnet (D) letting
contacts an electromagnet (D). If the bucket is in dump the spool centering spring move the spool to neutral
position, the return-to-dig switch is closed which position.
energizes the electromagnet and holds spool in the
TX,9025,BS343 1906APR942/2

110703
PN=440
Theory Of Operation
Loader Boom Valve OperationGRESEN (S.N. 801199)
D E
F F
L I
A
B
K J
C
N
P
9025
05
17
UN20FEB97
L
M O Q
N
F J
T6298BG
T6298BG
Valve Shown In Neutral Position
AHigh Pressure Oil EBoom Raise Work Port JInlet Passage NBoom Cylinders
BTrapped Oil FReturn Passage KDrift Check OBoom Float Position
CCharge Pressure Oil GLeakage Return Passage LCircuit Relief Valve with PBoom Lower Position
(Return to Charge Circuit) HBoom Spool Anti-Cavitation QBoom Raise Position
DBoom Lower Work Port ICircuit Plug MCap With Detent
The spool (H) has grooves in both ends to meter oil return passage (F), then out of control valve to charge
through the valve to prevent abrupt starts and stops. circuit.
A leakage return passage (G) is used to prevent Valve spool can be metered to restrict oil flow to the
leakage from the inlet passage to boom raise circuit cylinder. This valve has pressure side metering control
causing function drift. Leakage flows from the inlet spools.
passage, through the leakage return passage, into the

110703
PN=441
Theory Of Operation
When spool (H) is moved to activate a function, oil Return oil from the cylinders flows into the other work
flows from functional inlet passage (J), past lift check port, past the spool, into the return passage (F), then
(K) and spool (H), out the work port to the cylinders. out of control valve to charge circuit.
TX,9025,BS344 1906APR942/3
D E
C F F
G
N M
L H
9025
A
UN20FEB97
05 B
18 J I
K
T6298BH
T6298BH
Valve Shown In Float Position
AHigh Pressure Oil DBoom Lower Work Port HCircuit Plug LPlug with Anti-Cavitation
BCharge Pressure Oil EBoom Raise Work Port IInlet Passage MDetent Balls (4 used)
(Return To Charge Circuit) FReturn Passage JLift Check NDetent Spring
CDetent Housing GSpool KFloat Oil Passage (Compressed)
When the boom lower function is activated and When spool (E) is moved to the boom float (detent)
pressure in circuit is less than charge pressure, oil position, both work ports (D and E) are open to return
flows from return passage (F), past anti-cavitation plug passage (F) connected by float passage (K) allowing
(L) into the boom lower circuit (D). oil to flow in and out both ends of cylinders.
TX,9025,BS344 1906APR943/3

110703
PN=442
Theory Of Operation
Loader Auxiliary Valve OperationGRESEN (S.N. 801199)
RETURN ROD END HEAD END

PASSAGE WORK PORT WORK PORT
LIFT CHECK
C D F
E
CENTERING
SPRING
B
A
E
C H
G PLUG
I HIGH PRESSURE OIL
1915JAN98
A J CHARGE PRESSURE
RELIEF VALVE H OIL
PRESSURE PASSAGE K TRAPPED OIL
T7419BC
TXC7419BC M LOADER AUXILIARY VALVE NEUTRAL
9025
05
Valve Shown In Neutral Position 19
ARelief Valve ELift Check HPressure Passage KTrapped Oil

BCentering Spring FHead End Work Port IHigh Pressure Oil MLoader Auxiliary Valve
CReturn Passage GPlug JCharge Pressure Oil Neutral
DRod End Work Port
The loader auxiliary valve is a three position, four-way, The relief valve is in the cylinder head end circuit. The
spool-type valve. It contains a lift check (E), relief valve auxiliary valve is used to control clam buckets or other
(A) and a plug (G). front-mounted hydraulic functions.
The valve spool is returned to neutral by a centering

spring (B).

110703
PN=443
Theory Of Operation
RETURN ROD END HEAD END

PASSAGE WORK PORT WORK PORT
C D E
B
C A
F HIGH PRESSURE OIL
1915JAN98
G CHARGE PRESSURE
LIFT CHECK B A PRESSURE OIL
PASSAGE
T7419BB
TXC7419BB H LOADER AUXILIARY VALVE EXTEND
Valve Shown In Extend Position

9025
05 APressure Passage CReturn Passage EHead End Work Port GCharge Pressure Oil
20 BLift Check DRod End Work Port FHigh Pressure Oil
When the auxiliary valve is moved to the extend through rod end work port (D) to return passage. Oil in
position, oil flows from pressure passage (A) by lift the return passage is sent to main hydraulic filter
check (B) out head end work port (E) to cylinder head where it combines with other return oil and becomes
end. Oil from rod end of cylinder flows back to valve charge oil for main pump.
TX,9025,BS345 1906APR942/2

110703
PN=444
Theory Of Operation
9025
05
21

110703
PN=445
Theory Of Operation
Loader Priority Valve Operation HUSCO (S.N. 801200 )
B LOADER VALVE N
A R K L
BUCKET BOOM
SECTION SECTION
F E
O
H
I AUXILIARY M
LOADER SECTION
INLET FUNCTION
GAUGE A PRESSURE STEERING LOAD
METERING B SENSE PORT
PORT HOLES Q
SYSTEM P
J RELIEF
VALVE
9025
05
22 ORIFICE
O SLOT
C
ORIFICE I SPOOL
H D
SPRING
STEERING
SUPPLY PORT
R
ORIFICE
E
ORIFICE
RETURN S HIGH PRESSURE OIL
OUTLET G F
1901JAN99
PORT T LOW PRESSURE OIL

PRESSURE
INLET PORT U RETURN OIL
T8169AM
TXC8169AM CV V LOADER PRIORITY VALVE - NEUTRAL - NOT STEERING
Priority Valve-Neutral-Not Steering


110703
PN=446
Theory Of Operation
AGauge Port GReturn Outlet Port MAuxiliary Section SHigh Pressure Oil
BSteering Load Sense Port HSteering Supply Port NLoader Valve TLow Pressure Oil
CSpool IOrifice OOrifice Slot UReturn Oil
DSpring JSystem Relief Valve PMetering Holes VLoader Priority
EOrifice KBucket Section QLoader Function Pressure Valve-Neutral-Not Steering
FPressure Inlet Port LBoom Section ROrifice
The priority valve maintains priority oil to the steering priority valve spool (C). It allows the priority valve to
valve. When the engine is stopped, spool (C) is sense the pressure that is required to move the
pushed to the left by the bias spring (D) restricting the steering cylinders under varying steering conditions.
oil to loader (Q) and opening the passage to steering When the operator steers the machine, load sensing
(H). pressure oil from the steering valve flows to the load
sense port (B). Load sensing pressure plus spring (D)
When the machine is first started, all pump flow is act against steer pilot pressure to move the spool to
routed to the steering valve thru port (H). The steering the left. This restricts flow to the loader (Q) while the
valve blocks the flow except for a small amount of flow priority metering holes (P) are opened to the priority
to sump thru an orifice in the steering valve. With the steering port (H).
flow blocked, the pressure increases at port (H). This
causes the spool (C) to shift to the right against the When the operator steers the machine fully the
bias spring (D) and limit the flow to port (H) by closing steering cylinder will bottom against the steer stops.
the priority metering holes (P). This also opens inlet Pressure in the load sense circuit (B) will rise to full
pump flow (F) to loader (Q) functions. As long as the system pressure. This pressure and the bias spring (D)
steering valve is in neutral, just enough flow is allowed will shift the spool fully to the left blocking flow to the
to pass through the metering holes (P) to maintain a loader (Q) function. To maintain loader operation an
steer pressure at port (H) that keeps the spool shifted orifice slot (O) is located on the priority steering spool
to the right and balanced against the bias spring (D). (C) that allows some flow to pass to the loader valve.
This slot is sized such that at engine idle sufficient
If through the use of loader functions the pump is restriction is maintained to loader oil flow (Q) that
9025
unable to supply adequate flow to maintain steering steering pressure can be maintained. 05
pressure at port (H) then spool (C) will shift left and 23
restrict flow to loader (Q) until steer supply pressure is System relief valve (J) is located in the priority valve
satisfied. section. The relief is pilot operated, screw adjustable,
and does not have anti-cavitation operation. The
Flow from the steering port (H) is also routed through primary function of the relief is to minimize pressure
orifice (E) in the priority spool to the load sensing port spikes when the hydraulic pump destrokes. System
(B). This flow provides oil to the steering valve warm pressure is controlled by the pump standby pressure
up circuit which prevents binding of the steering valve adjustment.
caused by extreme oil temperature variation.
The load sensing circuit is a control circuit that routes

steering valve outlet pressure to the spring side of the
TX,9025,BS346 1906APR942/2

110703
PN=447
Theory Of Operation
Loader Boom Valve OperationHUSCO (S.N. 801200 )
LOADER
M VALVE B
H
BUCKET
PRIORITY SECTION
VALVE
K
J
G
D
AUXILIARY
SECTION
L
9025
05
24
BOOM LOWER
BOOM RAISE LIFT WORK PORT
WORK PORT C CHECK INLET
PRESSURE F
D
B CIRCUIT RELIEF E ORIFICE
WITHOUT ANTI- G
CAVITATION ANTI-CAVITATION
H
VALVE
A
RETURN
PASSAGE
I CAP WITH
DETENT
1901JAN99
N HIGH PRESSURE OIL

O CHARGE PRESSURE OIL
T8169AN
TXC8169AN CV P LOADER BOOM VALVE - BOOM RAISE POSITION
Loader Boom Valve-Boom Raise Position


110703
PN=448
Theory Of Operation
AReturn Passage EInlet Pressure JPriority Valve Section NHigh Pressure Oil
BCircuit Relief Valve Without FBoom Lower Work Port KBucket Valve Section OCharge Pressure Oil
Anti-Cavitation GOrifice LAuxiliary Valve Section PLoader Boom Valve-Boom
CBoom Raise Work Port HAnti-Cavitation Valve MLoader Valve Raise Position
DLift Check ICap With Detent
The spool has grooves in both ends to meter oil port, past the spool, into the return passage (A), then
through the valve to prevent abrupt starts and stops. out of the control valve to the charge circuit.
The valve section contains a bleed orifice (G) to When the boom lower function is activated and
minimize power drift. Any inlet pressure (E) leakage pressure in circuit is less than charge pressure, oil
past the spool is bled to the return passage (A) flows from return passage (A), past anti-cavitation plug
through this orifice. (H) into the boom lower circuit (F).
When the spool is moved to activate a function, oil When spool is moved to the boom float (detent)
flows from functional inlet passage (E), past lift check position, both work ports (C and F) are open to return
(D) and spool, out the work port to the cylinders. passage (A) allowing oil to flow in and out both ends of
Return oil from the cylinders flows into the other work cylinders.
TX,9025,BS348 1906APR942/2
9025
05
25

110703
PN=449
Theory Of Operation
Loader Bucket Valve OperationHUSCO (S.N. 801200 )
LOADER
VALVE B
K
H
PRIORITY BOOM
VALVE
SECTION
M
L
G
D AUXILIARY
SECTION
9025
05 CIRCUIT RELIEF
26 WITHOUT ANTI-
CAVITATION E INLET BUCKET DUMP
BUCKET LOAD C D LIFT PRESSURE F WORK PORT
B WORK PORT CHECK
G ORIFICE CIRCUIT RELIEF
WITH ANTI-
CAVITATION
H
RETURN A
PASSAGE
O RETURN-TO-DIG
ELECTROMAGNET
1901JAN99
I HIGH PRESSURE
J CHARGE PRESSURE OIL
T8169AO
TXC8169AO CV P LOADER BUCKET VALVE - BUCKET LOAD POSITION
Loader Bucket Valve-Bucket Load Position


110703
PN=450
Theory Of Operation
AReturn Passage EInlet Pressure IHigh Pressure Oil NAuxiliary Valve Section
BCircuit Relief Valve Without FBucket Dump Work Port JCharge Pressure Oil OReturn-To-Dig
Anti-Cavitation GOrifice KLoader Valve Electromagnet
CBucket Load Work Port HCircuit Relief Valve With LPriority Valve Section PLoader Bucket
DLift Check Anti-Cavitation MBoom Valve Section Valve-Bucket Load Position
The bucket valve is a three position, four way, past the spool is bled to the return passage (A)
spool-type valve. It contains a lift check (D) and two through this orifice.
circuit relief valves. Relief valve (H) also contains an
anti-cavitation valve for the bucket dump circuit. The valve is equipped with a return-to-dig. When
loader control lever is moved to the bucket rollback
In the bucket load position oil flows from the inlet position, a plate fastened to end of valve spool
pressure passage (E) past lift check (D) and spool, out contacts an electromagnet (O). If the bucket is in dump
the bucket load workport to the cylinder. Return oil position, the return-to-dig switch is closed which
from the cylinder flows into the return passage (A) and energizes the electromagnet and holds the spool in the
out of the control valve to the charge circuit. load position. When the bucket rolls back to the dig
position, a mechanical linkage opens the return-to-dig
When bucket dump function is activated and pressure switch, which de-energizes the electromagnet (O)
in circuit is less than charge pressure, oil flows from letting the spool centering spring move the spool to
return passage (A) past anti-cavitation valve (H) to the neutral.
bucket dump circuit (F).
The valve section contains a bleed orifice (G) to

minimize power drift. Any inlet pressure (E) leakage
9025
05
27
TX,9025,BS350 1906APR942/2

110703
PN=451
Theory Of Operation
Loader Auxiliary Valve OperationHUSCO (S.N. 801200 )
PRIORITY BOOM
K SECTION
VALVE J LOADER
I BUCKET VALVE
SECTION G L
9025 CIRCUIT
INLET RELIEF
05 LIFT D
28
ROD END C PRESSURE
F HEAD END WITH ANTI-
WORK PORT CHECK WORK PORT CAVITATION
E
G ORIFICE H
PLUG
B
RETURN A
PASSAGE A
M HIGH PRESSURE OIL

1901JAN99
N CHARGE PRESSURE OIL

O TRAPPED OIL
T8169AP
TXC8169AP CV P LOADER AUXILIARY VALVE - NEUTRAL POSITION


110703
PN=452
Theory Of Operation
AReturn Passage FHead End Work Port JBucket Valve Section NCharge Pressure Oil
BPlug GOrifice KBoom Valve Section OTrapped Oil
CRod End Work Port HCircuit Relief With LLoader Valve PLoader Auxiliary
DLift Check Anti-Cavitation MHigh Pressure Oil Valve-Neutral Position
EInlet Pressure IPriority Valve Section
The loader auxiliary valve is a three position, four way, When the auxiliary valve is moved to the extend
spool type valve. It contains a lift check (D), relief position, oil flows from pressure passage (E) by lift
valve with anti-cavitation (H), and a plug (B). The valve check (D) and spool, out head end work port (F) to
spool is returned to neutral by a centering spring in the cylinder head end. Oil from rod end of cylinder flows
spool end cap. back to valve through rod end work port (C) to return
passage (A). Oil in the return passage is sent to main
The valve section contains a bleed orifice (G) to hydraulic filter where it combines with other charge
minimize power drift. Any inlet pressure (E) leakage pressure oil and becomes available to main pump.
past the spool is bled to the return passage (A)
through this orifice.
The auxiliary valve is normally used to control clam

buckets or other front-mounted hydraulic functions.
TX,9025,BS352 1906APR942/2
9025
05
29

110703
PN=453
Theory Of Operation
Loader Circuit Relief Valve With Anti-CavitationHUSCO (S.N. 801200 )
ANTI-
CAVITATION
POPPET
F
C CAVITY
ORIFICE A
B POPPET D PRESSURE OIL
1910SEP98
E RETURN OIL
T7742AE
TXC7742AE CV
9025
05
30
AOrifice CCavity EReturn Oil FAnti-Cavitation Poppet
BRelief Poppet DPressure Oil
The relief is direct acting and has anti-cavitation In relief operation, pressure oil overcomes relief poppet
operation. (B) pressure setting and opens a path to return.
In normal operation, pressure oil less than relief valve During anti-cavitation operation, the pressure in the
setting flows through orifice (A) into cavity (C) behind work port is less than pressure in the return port. The
relief valve poppet. Pressure oil and spring in cavity pressure difference pushes the anti-cavitation poppet
hold the anti-cavitation poppet closed because (F) off its seat allowing oil to flow from return port to
effective area on this side is greater than on work port work port to prevent cavitation.
side.

110703
PN=454
Theory Of Operation
G H I
E
K
D
F
J
K J H
L NORMAL OPERATION
1915JAN98
A
M RELIEF OPERATION B 9025
T6739AQ
05
TXC6739AQ CV C
31
Relief Without Anti-Cavitation Shown
ARelief Pressure Oil ESleeve HPilot Poppet KMain Poppet

BOperating Pressure Oil FReturn Passage IPilot Poppet Spring LNormal Operation
CReturn Oil GMain Poppet Spring JPiston MRelief Operation
DPump Inlet Passage
This circuit relief valve is a pilot-operated, screw into the cavity and decreases the pressure against the
adjustable relief. It will operate to protect the circuit back side of the main poppet. Some oil still flows into
from excessive pressures with the valve activated. the cavity through the clearance between the piston
During normal operation (L) oil pressure in the circuit is and the main poppet. The main poppet opens in the
less than relief setting so the relief valve remains third step and relieves pressure oil to return.
closed.
When the relief valve closes, the piston and poppet
During relief operation (M) the relief valve will operate move together until the pilot poppet is seated. Oil flows
in three steps. In the first step, the pilot poppet (H) into the cavity through the clearance between the
opens. Flow restriction through the hollow piston (J) piston and main poppet to move the piston away from
causes the pressure in the cavity behind the main the pilot poppet. This permits flow into the cavity
poppet (K) to decrease. In the second step, the piston through the piston to seat the main poppet.
seats against the pilot poppet. This reduces oil flow

110703
PN=455
Theory Of Operation
In anti-cavitation operation, when the pressure in the the housing against a return spring located between
return passage (F) is greater than the pressure in the the rear of the sleeve and the pilot head. All other
work port (D), sleeve (E) is forced back and allows oil components and operation is the same as illustration
to flow from (F) to (D). The anti-cavitation sleeve is shown.
manufactured such that it can be pushed back from
TX,9025,BS354 1906APR943/3
Loader Circuit Relief Valve Without

Anti-Cavitation HUSCO (S.N. 801200 )
This circuit relief valve is direct acting, screw adjustable

and does not have anti-cavitation operation.
UN21MAR94
T8165AR
TX,9025,BS356 1906APR941/1
9025
05
32

110703
PN=456
Theory Of Operation
Backhoe Circuit Relief And Anti-Cavitation Valve OperationGRESEN
J K
L
D
I
O
A 9025
H
B 05
33
C
UN06MAR97
G
M
F N P
T88947
T88947
AHigh Pressure Oil DRelief Valve Open HPoppet LPilot Valve

BLow Pressure Oil EAnti-Cavitation Valve Open IWork Port MReturn Passage
CCharge Pressure Oil FRelief Valve Closed JCollar NOrifice
(Return To Charge Circuit) GReturn Port KSnap Ring ORelief Valve
When the circuit relief valve is closed (F), oil from work setting, high pressure oil pushes pilot valve (L) off its
port (I) flows through orifice (N) into the area behind seat. Oil behind the poppet flows out return passage
poppet (H). With pressure equal on both sides of (M) faster than oil can flow through orifice causing
poppet, spring force holds poppet (H) closed and stops pressure to decrease. Then high pressure oil pushes
flow through return port (G). the poppet off its seat releasing oil through return port
(G) to return passage of valve.
During relief operation (D) when pressure in the head
end work port circuit increases above relief valve

110703
PN=457
Theory Of Operation
During anti-cavitation operation (E), the pressure in without anti-cavitation operation a sleeve is added to
return port is greater than pressure in work port. The the assembly which prevents movement of collar (J).
difference in pressure pushes collar (J) against snap Oil then flows from return port into work port to prevent
ring (K) pulling the poppet off its seat. On valves cavitation.
TX,9025,BS357 1906APR942/2
9025
05
34

110703
PN=458
Theory Of Operation
Backhoe Boom Valve OperationGRESEN
E H
G
F
D I
J Q P Q K J
L
D
A
M 9025
B
UN07FEB97
05
C P 35
I N O
T88938
T88938
G
AHigh Pressure Oil FFunctional Inlet Passage JReturn Passage NBoom Down
BCharge Pressure Oil GLift Check KSpool OBoom Cylinder
CTrapped Oil HBoom Lower Work Port LAuxiliary Passage PMetering Grooves
DCircuit Relief Valve ICircuit Relief Valve with MBoom Up QPressure Seal Passage
EBoom Raise Work Port Anti-Cavitation Valve
The boom valve control spool has "pressure side" relief valve with anti-cavitation valve (I) in boom lower
metering. The spool (K) has grooves on both ends to circuit.
"meter" oil flow through valve to prevent abrupt starts
and stops. The boom down return oil metering grooves Pressure seal passages (Q) are used to prevent
(P) are longer to give more control of boom down leakage from the boom raise circuit to return passage
speed. (J) causing function drift. Oil flows from the inlet
passage, through pressure seal passage to the land
The boom valve is a three-position, four-way between boom raise work port (E) passage and return
spool-type valve. The valve contains a lift check (G), a passage to form a high pressure seal between land
circuit relief valve (D) in boom rise circuit, and a circuit and housing.
Continued on next page 27T,9025,M74 1906APR941/2

110703
PN=459
Theory Of Operation
When the spool is moved to activate a function, oil cylinder. Return oil from the cylinder flows into the
flows from the functional inlet passage (F), past the lift other work port, past the spool, into the return passage
check (G) and spool (K), out the work port to the (J), then out of control valve to charge circuit.
27T,9025,M74 1906APR942/2
9025
05
36

110703
PN=460
Theory Of Operation
Backhoe Crowd Valve OperationGRESEN
E H
G
F
D I
K J
J L
O
A
M 9025
B
UN07FEB97
05
C 37
D N
I G
T88940
T88940
Valve Shown In Crowd-In Position
AHigh Pressure Oil ECrowd-In Work Port ICircuit Relief Valve MCrowd-In
BCharge Pressure Oil FFunctional Inlet Passage JReturn Passage NCrowd-Out
(Return to Charge Circuit) GLift Check KSpool OCrowd Cylinder
CTrapped Oil HCrowd-Out Work Port LAuxiliary Passage
DCircuit Relief with
Anti-cavitation Valve
The crowd valve control spool has pressure side When the spool is moved to activate a function, oil
metering. flows from the functional inlet passage (F) past the lift
check (G) and spool (K), out the work port to the
The backhoe crowd valve is a three-position, four-way cylinder. Return oil from the cylinder flows into the
spool-type valve. The valve contains a circuit relief other work port, past the spool, into the return passage
valve with anti-cavitation valve (D) in the crowd-in (J), then out of control valve to charge circuit.
circuit and circuit relief valve (I) in the crowd-out circuit.
The spool (K) has grooves on both ends to meter oil

flow through the valve to prevent abrupt starts and
stops.
27T,9025,M75 1906APR941/1

110703
PN=461
Theory Of Operation
Backhoe Bucket Valve OperationGRESEN
E BUCKET DUMP G LIFT H BUCKET LOAD

WORK PORT CHECK WORK PORT
CIRCUIT RELIEF D O CIRCUIT RELIEF

VALVE VALVE WITH ANTI-
CAVITATION VALVE
FUNCTIONAL F
INLET
PASSAGE
AUXILIARY K RETURN
I
PASSAGE SPOOL J PASSAGE
N
A HIGH PRESSURE OIL
1915JAN98
B CHARGE PRESSURE OIL M
C TRAPPED OIL O D L G
T8381BA
TXC8381BA
P BACKHOE BUCKET VALVE - LOAD POSITION
9025
05
38 Valve In Bucket Load Position
AHigh Pressure Oil EBucket Dump Work Port JSpool OCircuit Relief Valve with
BCharge Pressure Oil FFunctional Inlet Passage KAuxiliary Passage Anti-cavitation
(Return to Charge Circuit) GLift Check LBucket Dump PBackhoe Bucket
CTrapped Oil HBucket Load Work Port MBucket Load Valve-Load Position
DCircuit Relief Valve IReturn Passage NBucket Cylinder
The bucket valve control spool has pressure side When the spool is moved to activate a function, oil
metering. flows from the functional inlet passage (F), past the lift
check (G) and spool (J), out the work port to the
The backhoe bucket valve is a three-position, four-way cylinder. Return oil from the cylinder flows into the
spool-type valve. The valve contains a circuit relief other work port, past the spool, into the return passage
valve with anti-cavitation valve (O) in the bucket load (I), then out of control valve to charge circuit.
circuit and circuit relief valve (D) in the bucket dump
circuit.
The spool (J) has grooves on both ends to meter oil

flow through the valve to prevent abrupt starts and
stops.
TX,902505,BS156 1920DEC941/1

110703
PN=462
Theory Of Operation
Backhoe Swing Valve OperationGRESEN
SWING RIGHT LIFT SWING LEFT

CIRCUIT E F G WORK PORT
WORK PORT CHECK FUNCTIONAL
RELIEF H
VALVE WITH ANTI- INLET
CAVITATION D PASSAGE
VALVE
M METERING
RETURN K GROOVES
PASSAGE
AUXILIARY I J SPOOL M
METERING O
PASSAGE
PASSAGES
A HIGH PRESSURE OIL L
1915JAN98
B CHARGE PRESSURE OIL
D K D C N
F
T8381BB
TXC8381BB P VALVE IN SWING RIGHT POSITION 9025
05
Valve In Swing Right Position 39
AHigh Pressure Oil ESwing Right Work Port JSpool NSwing Left
BCharge Pressure Oil FLift Check KReturn passage OMetering Passages
(Return To Charge Circuit) GSwing Left Work Port LSwing Cylinders (2 used) PBackhoe Swing
CSwing Right HFunctional Inlet Passage MMetering Grooves Valve-Swing Right Position
DCircuit Relief Valve with IAuxiliary Passage
Anti-cavitation Valve (2
used)
The swing valve control spool has pressure side Radial metering passages (O) are used to reduce lever
metering. effort.
The swing valve is a three-position, four-way When the spool is moved to activate a function, oil
spool-type valve. The valve contains two circuit relief flows from the functional inlet passage (H), past the lift
valves with anti-cavitation (D). check (F) and spool (J), out the work port to the
cylinders. Return oil from the cylinders flows into the
The spool (J) has grooves on both ends to meter oil other work port, past the spool, into the return passage
flow through the valve to prevent abrupt starts and (K), then out of control valve to charge circuit.
stops. The return oil metering grooves (M) are longer
to give more control of function speed.
TX,902505,BS157 1920DEC941/1

110703
PN=463
Theory Of Operation
Backhoe Auxiliary Valve OperationGRESEN
ROD END HEAD END

PRESSURE
WORK PORT LIFT WORK PORT
PASSAGE
B CHECK E
D
C
A D C
RETURN
PASSAGE
A
A RETURN
PASSAGE
1915JAN98
F HIGH PRESSURE OIL
T7419BM
G CHARGE PRESSURE
9025 TXC7419BM
H BACKHOE AUXILIARY VALVE EXTEND
OIL
05
40
AReturn Passage CLift Check EHead End Work Port GCharge Pressure Oil
BRod End Work Port DPressure Passage FHigh Pressure Oil
The auxiliary valve is a three-position, four-way and spool, out the head end work port to the cylinder.
spool-type valve. The valve has two plugs and no Return oil from the cylinder flows into the rod end work
reliefs. Plugs may be replaced with reliefs appropriate port (B), past the spool into the return passage (A),
to attachment being installed. then out of the valve to charge circuit.
When the spool is moved to extend position, oil flows

from the pressure passage (D) past the lift check (C)
TX,902505,BR124 1906APR941/1

110703
PN=464
Theory Of Operation
9025
05
41

110703
PN=465
Theory Of Operation
Backhoe Boom Valve OperationHUSCO
J H
I
9025 BOOM LOWER B INLET BOOM RAISE

05 WORK PORT PRESSURE WORK PORT
42 G C CIRCUIT RELIEF
CIRCUIT RELIEF LIFT WITHOUT
WITH ANTI- CHECK F ANTI-CAVITATION
CAVITATION H ORIFICE E
D
A A
RETURN
PASSAGE
1902MAR99
K PRESSURE OIL
L CHARGE PRESSURE OIL
T8165AP
TXC8165AP CV M BACKHOE BOOM VALVE - BOOM RAISE POSITION
Valve Shown In Boom Raise Position


110703
PN=466
Theory Of Operation
AReturn Passage ECircuit Relief Valve Without HOrifice LCharge Pressure Oil
BBoom Lower Work Port Anti-Cavitation IBoom Raise Position MBackhoe Boom
CBoom Raise Work Port FLift Check JBoom Lower Position Valve-Boom Raise Position
DCircuit Relief Valve With GInlet Pressure KPressure Oil
Anti-Cavitation
The boom valve is a three position, four way past the spool is bled to the return passage (A)
spool-type valve. The valve contains a lift check (F), a through this orifice.
circuit relief valve (E) in the boom raise circuit, and a
circuit relief valve with anti-cavitation valve (D) in the When the spool is moved to activate a function, oil
boom lower work port. flows from the functional inlet passage (G), past the lift
check (F) and spool, out the work port to the cylinder.
The boom valve control spool has notches on both Return oil from the cylinder flows into the other work
ends to "meter" oil through valve to prevent abrupt port, past the spool, into the return passage (A), then
starts and stops. out of the control valve to the charge circuit.
The valve section contains a bleed orifice (H) to

minimize power drift. Any inlet pressure (G) leakage
TX,9025,BS358 1906APR942/2
9025
05
43

110703
PN=467
Theory Of Operation
Backhoe Bucket Valve OperationHUSCO
H E
F
J I
9025 CIRCUIT RELIEF

05 WITH ANTI-
44 CAVITATION LIFT INLET BUCKET DUMP
B C WORK PORT
D CHECK PRESSURE
BUCKET LOAD F G
WORK PORT
H
RETURN
PASSAGE A
E
CIRCUIT RELIEF
WITHOUT ANTI-
CAVITATION
1901JAN99
K PRESSURE OIL
T8165AO
TXC8165AO CV M BACKHOE BUCKET VALVE - LOAD POSITION
Valve Shown In Bucket Load Position

110703
PN=468
Theory Of Operation
AReturn Passage ECircuit Relief Valve Without HOrifice LCharge Pressure Oil
BBucket Load Work Port Anti-Cavitation IBucket Dump Position MBackhoe Bucket
CBucket Dump Work Port FLift Check JBucket Load Position Valve-Load Position
DCircuit Relief Valve With GInlet Pressure KPressure Oil
Anti-Cavitation
The backhoe bucket valve is a three position, four-way past the spool is bled to the return passage (A)
spool type valve. The valve contains a circuit relief through the orifice.
valve with anti-cavitation valve (D) in the bucket load
circuit and circuit relief valve (E) in the bucket dump When the spool is moved to activate a function, oil
circuit. flows from the functional inlet passage (G), past the lift
The spool has notches on both ends to meter oil flow Return oil from the cylinder flows into the other work
through the valve to prevent abrupt starts and stops. port, past the spool, into the return passage (A), then
out of the control valve to the charge circuit.
TX,9025,BS360 1906APR942/2
9025
05
45

110703
PN=469
Theory Of Operation
Backhoe Crowd Valve OperationHUSCO
J H F E
I
9025
05
CIRCUIT RELIEF CIRCUIT RELIEF
WITHOUT ANTI- CROWD IN WITH ANTI-
46
CAVITATION F LIFT WORK PORT CAVITATION
CROWD OUT B C
D WORK PORT CHECK
INLET E
G PRESSURE H ORIFICE
RETURN A A
PASSAGE 1901JAN99
K PRESSURE OIL
T8165AN
TXC8165AN CV M BACKHOE CROWD VALVE - CROWD IN POSITION
Valve Shown In Crowd-In Position

110703
PN=470
Theory Of Operation
AReturn Passage ECircuit Relief Valve With HOrifice LCharge Pressure Oil
BCrowd Out Work Port Anti-Cavitation ICrowd In Position MBackhoe Crowd
CCrowd In Work Port FLift Check JCrowd Out Position Valve-Crowd In Position
DCircuit Relief Valve Without GInlet Pressure KPressure Oil
Anti-Cavitation
The backhoe crowd valve is a three position, four-way past the spool is bled to the return passage (A)
spool-type valve. The valve contains a circuit relief through the orifice.
valve with anti-cavitation valve (E) in the crowd-in
circuit and circuit relief valve (D) in the crowd-out When the spool is moved to activate a function, oil
circuit. flows from the functional inlet passage (G) past the lift
The spool has notches on both ends to meter oil flow Return oil from the cylinder flows into the other work
through the valve to prevent abrupt starts and stops. port, past the spool, into the return passage (A), then
out of the control valve to the charge circuit.
TX,9025,BS362 1906APR942/2
9025
05
47

110703
PN=471
Theory Of Operation
Backhoe Swing Valve OperationHUSCO
G D
I
H
SWING RIGHT
9025 WORK PORT
SWING LEFT B
05 INLET
CIRCUIT RELIEF WORK PORT C
48 PRESSURE
WITH
ANTI-CAVITATION LIFT F
E CHECK G D
D ORIFICE
RETURN A
PASSAGE A
1901JAN99
J PRESSURE OIL
K CHARGE PRESSURE OIL
T8165AQ
TXC8165AQ CV L BACKHOE SWING VALVE - SWING RIGHT POSITION
Valve Shown In Swing Right Position


110703
PN=472
Theory Of Operation
AReturn Passage ELift Check HSwing Right Position KCharge Pressure Oil
BSwing Left Work Port FInlet Pressure ISwing Left Position LBackhoe Swing
CSwing Right Work Port GOrifice JPressure Oil Valve-Swing Right Position
DCircuit Relief Valve With
Anti-Cavitation (2 used)
The swing valve is a three position, four-way spool past the spool is bled to the return passage (A) by this
type valve. The valve contains two circuit relief valves orifice.
with anti-cavitation (D).
When the spool is moved to activate a function, oil
The spool has notches on both ends to meter oil flow flows from the functional inlet passage (F), past the lift
through the valve to prevent abrupt starts and stops. check (E) and spool, out the work port to the cylinders.
Return oil from the cylinders flows into the other work
The valve section contains a bleed orifice (G) to port, past the spool, into the return passage (A), then
minimize power drift. Any inlet pressure (F) leakage out of the control valve to the charge circuit.
TX,9025,BS364 1906APR942/2
9025
05
49

110703
PN=473
Theory Of Operation
Backhoe Auxiliary Valve OperationHUSCO
D G
HEAD END B ROD END

LIFT D INLET C WORK PORT
9025 PORT PORT CHECK
05
PRESSURE
50 F
G ORIFICE
PLUG E
E
RETURN A
PASSAGE
A
H PRESSURE OIL
1901JAN99
I CHARGE PRESSURE OIL

J TRAPPED OIL
T8165AM
TXC8165AM CV K BACKHOE AUXILIARY VALVE - NEUTRAL POSITION
Valve Shown In Extend Position

110703
PN=474
Theory Of Operation
AReturn Passage DLift Check GOrifice JTrapped Oil

BHead End Work Port EPlug (2 used) HPressure Oil KBackhoe Auxiliary
CRod End Work Port FInlet Pressure ICharge Pressure Oil Valve-Neutral Position
The auxiliary valve is a three-position, four-way The valve section contains a bleed orifice (G) to
spool-type valve. The valve has two plugs (E) and no minimize power drift. Any inlet pressure (F) leakage
reliefs. Plugs may be replaced with reliefs appropriate past the spool is bled to the return passage (A)
to attachment being installed. through this orifice.
When the spool is moved to the extend position, oil Two auxiliary valve sections can be added to the
flows from the pressure passage (F) past the lift check backhoe valve for a total of six sections. Both are the
(D) and spool, out the head end work port to the same in design and operation. The fifth section is
cylinder. Return oil from the cylinder flows into the rod normally used for extendable dipper operation. The
end work port (C), past the return passage (A), then sixth section can be used to operate accessory
out of the valve to the charge circuit. hydraulic equipment.
TX,9025,BS366 1906APR942/2
9025
05
51

110703
PN=475
Theory Of Operation
Backhoe Circuit Relief Valve With Anti-CavitationHUSCO
ANTI-
CAVITATION
POPPET
F
C CAVITY
ORIFICE A
B POPPET D PRESSURE OIL
1910SEP98
E RETURN OIL
T7742AE
TXC7742AE CV
9025
05
52
AOrifice CCavity EReturn Oil FAnti-Cavitation Poppet
BRelief Poppet DPressure Oil
The relief is direct acting and has anti-cavitation In relief operation, pressure oil overcomes relief poppet
operation. (B) pressure setting and opens a path to return.
In normal operation, pressure oil less than relief valve During anti-cavitation operation, the pressure in the
setting flows through orifice (A) into cavity (C) behind work port is less than pressure in the return port. The
relief valve poppet. Pressure oil and spring in cavity pressure difference pushes the anti-cavitation poppet
hold the anti-cavitation poppet closed because (F) off its seat allowing oil to flow from return port to
effective area on this side is greater than on work port work port to prevent cavitation.
side.
TX,9025,BS368 1906APR941/1

110703
PN=476
Theory Of Operation
Backhoe Circuit Relief Valve Without

Anti-CavitationHUSCO
This circuit relief valve is direct acting, screw adjustable

and does not have anti-cavitation operation.
UN21MAR94
T8165AR
TX,9025,BS369 1906APR941/1
9025
05
53

110703
PN=477
Theory Of Operation
Backhoe System Relief Valve OperationHUSCO 410D(S.N. 796855801199), 510D

(S.N. 796891801199)
G H I
E
K
D
F
J
K J H
L NORMAL OPERATION
9025
1915JAN98
05
54 A
M RELIEF OPERATION B
T6739AQ
TXC6739AQ CV C
System Relief Without Anti-Cavitation
ARelief Pressure Oil ESleeve HPilot Poppet KMain Poppet

BOperating Pressure Oil FReturn Passage IPilot Poppet Spring LNormal Operation
CReturn Oil GMain Poppet Spring JPiston MRelief Operation
DPump Inlet Passage
This system relief valve is a pilot-operated, screw opens. Flow restriction through the hollow piston (J)
adjustable relief. It will operate to protect the system causes the pressure in the cavity behind the main
from excessive pressures with the valve activated. poppet (K) to decrease. In the second step, the piston
During normal operation (L) oil pressure in the system seats against the pilot poppet. This reduces oil flow
is less than relief setting so the relief valve remains into the cavity and decreases the pressure against the
closed. back side of the main poppet. Some oil still flows into
the cavity through the clearance between the piston
During relief operation (M) the relief valve will operate and the main poppet. The main poppet opens in the
in three steps. In the first step, the pilot poppet (H) third step and relieves pressure oil to return.

110703
PN=478
Theory Of Operation
When the relief valve closes, the piston and poppet The relief is located on the backhoe valve outlet
move together until the pilot poppet is seated. Oil flows section. The primary purpose of the relief is to
into the cavity through the clearance between the minimize pressure spikes when the hydraulic pump
piston and main poppet to move the piston away from destrokes. System pressure is controlled by the pump
the pilot poppet. This permits flow into the cavity standby pressure adjustment.
through the piston to seat the main poppet.
TX,9025,BS370 1906APR942/2
9025
05
55

110703
PN=479
Theory Of Operation
Stabilizer Valve Operation
G E G F
D F
D
A
H B
1910SEP98
H
J J
T7348AD
9025 TXC7348AD C STABILIZER VALVE - LOWER
05
56
APressure Oil DReturn Passage GPower Passage IThermal Relief Valve
BReturn Oil ENeutral Passage HPoppet JWork Passage
CStabilizer Valve-Lower FConnecting Passage
The stabilizer valve is a two-spool, unibody valve The thermal relief valve is used to release high
containing two lockout poppets (H) and one thermal pressures in the rod end of cylinder due to high
relief valve (I) for each circuit. temperatures.
When the valve is activated to lower a stabilizer, inlet When the stabilizer is in the full down position, high
oil (A) acts on the lockout plunger and lockout poppet temperatures can be generated by the forces working
(H). The inlet oil pushes the poppet off its seat and against the stabilizer. If the forces get too high, the
flows through work port (J) to head of cylinder. At the lockout plunger would not push the poppet off its seat
same time, the lockout plunger is pushed against the to raise the stabilizer.
other poppet, opening the return flow (B) from the
cylinder to the return passage (J).
The lockout poppets are used to prevent cylinder drift

while the valve is in neutral. The poppets trap oil in
both rod and head ends of the stabilizer cylinder.
TX,902505,BR125 1924MAR931/1

110703
PN=480
Theory Of Operation
Backhoe Solenoid Controlled Auxiliary Valve
RELIEF
CARTRIDGE C SPRING D THREE POSITION
B ORIFICE
G HIGH PRESSURE OIL

A SOLENOID F SPOOL E OIL
PASSAGE H REDUCED PRESSURE OIL
1915JAN98
CARTRIDGE
I RETURN PRESSURE OIL
TXC7864AC
T7864AC
9025
05
57
ASolenoid Cartridge DThree Position Orifice GHigh Pressure Oil JSolenoid Controlled
BRelief Cartridge EOil Passage HReduced pressure Oil Auxiliary Valve Operation
CSpring FSpool IReturn Pressure Oil
The Auxiliary Hydraulic Valve is a field installed flow The reduced pressure that results from oil passing
control valve that is mounted on the RH rear side of through the three position orifice to the regulated port
the backhoe valve mounting plate. Operation of the is routed through passage (E) past the energized
valve is controlled by an electrical solenoid. A pressure solenoid cartridge (A) to the spring (C) end of spool
compensated, variable volume flow rate is provided to (F). Main pressure oil "in" flows through the radial
meet specific attachment requirements. holes to the opposite end of the spool. Consequently
the position of the spool is maintained in a balanced
Priority oil flow is routed to the auxiliary valve, which is position to provide the "regulated" flow rate that was
connected to the main hydraulic system at the inlet to selected.
the backhoe valve. When the console mounted control
switch is moved to the "on" position, electrical current The relief cartridge (B) protects the regulated circuit by
is provided to the foot pedal. Pressing the foot pedal dumping excess pressure oil at the spring (C) end of
energizes solenoid cartridge (A) and oil flow "in" is the spool (F) to tank. Reduced pressure assisting the
diverted at a controlled rate past the spool (F) and spring causes the spool to shift toward the spring and
three position orifice (D) to the regulated port for the flow of oil that is being routed to the regulated
operation of the accessory attachment. circuit is decreased.
Continued on next page TX,902505,BS184 1903MAR931/2

110703
PN=481
Theory Of Operation
The regulated flow can be turned off by de-energizing forces the spool to move against the spring which
the solenoid cartridge (A). This allows oil in the spring blocks oil flow through the valve.
chamber to be released to tank and pressure oil "in"
TX,902505,BS184 1903MAR932/2
9025
05
58

110703
PN=482
Group 10
System Operational Procedure
This procedure is designed so the mechanic can make check. If problem (NOT OK) is indicated, you will be
a quick check of the hydraulic system using a given repair required and Group location or CTM
minimum amount of diagnostic equipment. If you need number. If verification is needed you will be given next
additional information, read the Theory of Operation , best source of information after GO TO:
Group 9025-05.
Group 10 (System Operational Check)
A location will be required which is level, has adequate
space to complete the backhoe loader checks. Group 15 (Diagnostic Information)
The engine, reverser and hydraulic oil must be at Group 20 (Adjustment)

operating temperature for some checks.
Group 25 (Tests)
Locate system check needed in the left column and
read completely, following this sequence from left to CTM (Component Technical Manual)
right. Read each check completely before performing.
At the end of each check, if OK:( no problem is found),

you will be instructed where to (GO TO) for next
T60,9025,J145 1924MAY931/1
9025
10
1
Steering System Checks
1/1
1 Steering System Operate engine at approximately 1000 rpm. OK: Check Complete.
Operational Checks
Turn steering wheel from full left to full right several times. NOT OK: Go to group
9025-15, Poor Centering
LOOK: Front wheels must move smoothly in both directions. of Steering Wheel .
LOOK: When steering wheel is stopped, the front wheels must stop moving. NOT OK: Go to next
check .
NOTE: Internal leakage or sticking steering valve spool can cause the wheels to
continue to move after the steering wheel is stopped.
1/1

110703
PN=483
2 Steering System NOTE: Hydraulic oil must be at operating temperature for this test. OK: Check Complete.
Leakage Check
Run engine at slow idle. Turn steering wheel until wheels are in maximum right turn NOT OK: If steering
position. Continue turning steering wheel, using approximately 11.3 Nm (100 lb-in) wheel turns more than 7
force while counting steering wheel rpm. rpm, verify whether valve
or cylinder is leaking. Go
Repeat leakage check turning steering wheel to the left. to Group 9025-25,
Steering System Leakage
LOOK: Steering wheel must not turn more than 5 rpm to the left or right. Use good Test . Go to next check .
judgment, excessive steering wheel rpm does not mean steering will be affected.
1/1
3 Steering Priority Operate engine at slow idle. OK: Check complete.

Valve Operational
Check Turn steering wheel left to right and note effort needed to turn wheel. NOT OK: If steering
wheel effort is more or
Operate the loader raise function and turn steering wheel at the same time. Note effort wheel will not turn as
needed to turn the steering wheel. hydraulic function is
activated, a malfunction is
FEEL: Effort to turn steering wheel must NOT increase when turning the wheel as a indicated in steering
hydraulic function is activated. priority valve. Go to
9025-25, Priority Valve
Test .
1/1
9025
10
2
4 Steering Priority Park front wheels on dirt or gravel. OK: Check complete.
Valve Pressure Check
(Without MFWD) Raise rear of machine so tires are just off ground using NOT OK: If front wheels
stabilizers. turn in both directions,
priority valve pressure
Operate engine at approximately 1000 rpm. setting is too high. If front
wheels DO NOT turn in
Starting with front wheels in the straight ahead position, either direction, pressure
T6295AC UN19OCT88
turn steering wheel to the left while raising loader. setting is too low. Test
and adjust priority valve
Starting with front wheels in straight ahead position, turn pressure. Go to Group
steering wheel to the right while raising loader. 9025-25, Priority Valve
Test
LOOK: Wheels must turn to the left but not to the right
while loader is being raised.
NOTE: The front wheels will not turn to the right (with
the condition of this check) because the pressure applied
to the smaller area at rod end of cylinder does not
generate enough force to turn wheels.
This check will give a general indication of priority valve

pressure setting. The results may vary if machine is
operated on dry concrete or rear wheels are raised too
high off the ground.
1/1

110703
PN=484
Hydraulic System Checks
1/1
1 Hydraulic System OK: Check complete.

Charge And Return
System Check NOT OK: Replace
for types of
contamination. Rerun
check.
NOT OK: Test charge

T6295AJ UN17APR89
system. Go to Group
Raise machine with stabilizers until tires are 150 mm (6 in.) off ground. 9025-25, Charge Pump
Pressure Test .
Fully extend dipperstick, put bucket in loaded position and lower boom until dipperstick
is horizontal to ground.
Slowly retract dipperstick to insure that bucket clears ground.
Fully extend dipperstick.
Retract dipperstick while holding control valve fully open.
LOOK: Dipperstick can slow down, but must NOT stop moving during test. 9025
10
3
1/1

110703
PN=485
2 Hydraulic Pump NOTE: If hydraulic oil is not at operating temperature, heat hydraulic oil until loader OK: Check complete.
Performance Check and backhoe cylinders feel warm to touch using following procedure:
NOT OK: Replace
for types of
contamination. Rerun this
check .
NOT OK: If boom down

relief does not load
engine, check main pump
stand-by pressure. Go to
T6295AH UN19OCT88
Group 9025-25, Main
Put backhoe in transport position and engage boom and swing lock. Pump Stand-By Pressure
Test .
Activate boom down function and run engine at 2000 rpm.
NOT OK: Go to Group
NOTE: If activating boom down does not load engine, boom down relief valve is set 9025-25, Backhoe Relief
too high or hydraulic pump stand-by pressure is too low. Valve Test
Operate all functions periodically to distribute heated oil to all cylinders. NOT OK: If cycle times
are slow. Go to Group
Put backhoe at maximum reach with bucket fully dumped at ground level. 9025-25, Hydraulic Pump
Flow Test .
Measure cycle time by simultaneously loading the bucket, retracting the dipperstick
and raising the boom cylinder to cushion. Do not time boom cylinder through cushion.
LOOK: The maximum cycle time is as below:
410D9 seconds
9025
510D12 seconds
10
4
NOTE: Take the average cycle time for at least 3 complete cycles. This average cycle
time will give a general indication of hydraulic pump performance.
1/1
3 Hydraulic Control Raise loader until bucket is 1 m (3 ft) off ground with the bucket level. OK: Check complete.
Valve Lift Check Test
Position backhoe at maximum reach with bottom of bucket level with ground, 1 m (3 ft) NOT OK: If a functions
off the ground. cylinder moves, problem
could be a leak in
Stop the engine. cylinder or lift check.
Inspect and repair lift
Activate each function one at a time: check. Go to repair
manual.
Loader boom raise
Loader bucket rollback
Backhoe boom up
Dipperstick extend (cylinder retract)
Backhoe bucket dump
LOOK: These functions must NOT move when the control lever is activated.
1/1

110703
PN=486
4 Backhoe Circuit Put backhoe in transport position and engage boom lock. OK: Continue on.
Leakage Check
Retract extendible dipperstick (if equipped). NOT OK: If boom down
does not decrease engine
Raise stabilizers to full up position. rpm, check main pump
stand-by pressure . Go to
Run engine at slow idle. Group 9025-25.
Fully activate functions, one at a time: NOT OK: Go to next step

T6295AD UN19OCT88
in this check.
Boom up
Bucket up
Dipperstick retract
Extendible dipperstick retract (if equipped).
LISTEN: When these functions are activated, NO

decrease in engine rpm must be noted.
Boom down
Swing left then right
Stabilizer up left then right.
LISTEN: Boom down must cause rpm to decrease since

relief valve setting is below standby pressure.
LISTEN: Swing left and right may cause rpm to decrease

slightly because relief valve setting is close to standby
pressure.
LISTEN: Stabilizer circuit can cause rpm to decrease

slightly because of normal valve leakage. 9025
10
NOTE: On machines equipped with GRESEN valve 5
pressure seal passages are used in boom valve and
leakage return passages are used in swing valve. When
boom down or swing functions are bottomed and control
valves "metered", rpm will decrease and leakage within
circuit will be apparent. This is normal.

1/2

110703
PN=487
Lower stabilizer to maximum down position, extend OK: Check Complete.

dipperstick to maximum reach, extend extendible
dipperstick (if equipped) and put bucket in dump position NOT OK: If rpm
1 m (3 ft) off ground. decreases with a function
Extend dipperstick
T6295AF UN17APR89
Extend dipperstick (if equipped) NOT OK: If rpm
Bucket dump increases when a function
is bottomed and control
LISTEN: When these functions are activated, NO valve is fully open, a
decrease in engine rpm must be noted. neutral leak indicated.
Fully activate functions, one at a time: NOT OK: A rpm

decrease with a function
Stabilizer down left bottomed in both
Stabilizer down right directions is normally
cylinder leakage. A rpm
LISTEN: Stabilizer circuit can cause rpm to decrease decrease in one direction
slightly because of normal valve leakage. is normally circuit relief
valve leakage. Go to
Group 9025-25, Hydraulic
Component Leakage Test
.
19 2/2
9025
10
6
5 Loader Circuit Raise loader to full height and put bucket in dump OK: Check complete.
Leakage Check position.
NOT OK: If rpm
Run engine at slow idle. decreases with a function
Loader boom up
T6295AG UN17APR89
Bucket dump NOT OK: If rpm
increases when a function
Put bucket in rollback position and lower loader to full is bottomed and control
down position. valve is fully open, a
neutral leak indicated.
NOT OK: A rpm
Loader boom down decrease with a function
Bucket rollback bottomed in both
LISTEN: When functions are activated, engine rpm must cylinder leakage. A rpm
NOT decrease. decrease in one direction
NOTE: Leakage return passages are used in GRESEN valve leakage. Go to
boom valve. When boom cylinders are retracted and Group 9025-25, Hydraulic
valve is "metered", rpm will decrease and leakage within Component Leakage Test
circuit will be apparent. This is normal. .

1/1

110703
PN=488
6 Cylinder Cushion Run engine at approximately 1000 rpm. Activate backhoe swing left, swing right and OK: Check complete.
Check boom raise.
NOT OK: Remove and
Note sound and speed as cylinders near end of their stroke. repair cylinder cushion.
Go to repair manual.
LOOK: Speed of cylinder rod must decrease near the end of its stroke.
LISTEN: Must hear oil flowing through orifice as cylinder rod nears the end of its
stroke.
1/1
7 Backhoe And Loader FEEL: Backhoe cylinders. Cylinders must be warm to OK: Check complete.
Function Drift Check touch 3852C (100125F). If cylinders are not warm,
heat hydraulic oil to specification. (See Group 9025-25, NOT OK: Use good
Hydraulic Warm-Up Procedure.) judgement in determining
if the amount of drift is
Raise machine off ground with stabilizers. objectionable for the type
of operation the machine
Put backhoe bucket at a 45 angle to ground. Lower is performing.
T7374CI UN04OCT90
boom until bucket cutting edge is 75 mm (3.0 in.) off
ground. NOT OK: Isolate which
function is leaking. Go to
Position level loader bucket cutting edge 50 mm (2.00 Group 9025-25, Cylinder
in.) off ground. Drift Test .
Run engine at slow idle and observe bucket cutting

edge. 9025
10
LOOK: If either bucket cutting edge touches the ground 7
within one minute, excessive leakage is indicated in
cylinders or control valves.
1/1

110703
PN=489
8 Loader Boom Float Put loader at maximum height position with bucket OK: Go to next step in
And Return-To-Dig dumped. this check.
Check
Run engine at approximately 2000 rpm. NOT OK: If lever jumps
out of detent, inspect
Move the loader control lever forward into boom float detent spring and balls.
detent position, and at the same time into bucket Go to repair manual.
rollback detent position. Remove hand from control lever.
T7390AA UN12OCT90
LOOK: Loader control lever must remain in the boom
float detent position.
OK: Check Complete.
NOT OK: Adjust linkage

as necessary. Go to
Group 9025-20, Loader
Bucket Level Indicator
and Return-to-Dig
Adjustment .
T6171AT UN09DEC88 T7374CH UN04OCT90
LOOK: Loader control lever must disengage from the bucket rollback detent when the
bucket is level.
FEEL/LISTEN: With bucket rolled back, compress switch roller. If a click is heard,
adjust switch until it is activated on cam.
LOOK: When the bucket is at ground level, bucket must be level and the bucket
indicator pointer must be aligned with mark on the boom pivot.
9025 NOTE: When return-to-dig is used with loader boom in full up position, the bucket
10 leveling linkage will move the bucket control valve out of return-to-dig position before
8 bucket is actually level.
1/1

110703
PN=490
9 Bucket Leveling NOTE: The loader bucket leveling feature functions during the boom raise cycle only. OK: Check complete.
Linkage Check When bucket is lowered, the operator must level the bucket unless machine is
equipped with optional return-to-dig. NOT OK: If bucket
rollback does not stay in
Put bucket in the rollback position with the boom near detent.
ground level.
NOT OK: If no click is
Observe bucket and loader control lever as the loader heard at switch, inspect
raises. fuse and wiring. Go to
Group 9015-10,
LOOK/FEEL: Loader control lever must move into bucket Return-To-Dig Solenoid
dump position and bucket dump function must slowly Check .
T7374CJ UN05OCT90
activate. When the loader control lever moves to activate
the bucket dump function, the bucket position must NOT OK: If bucket
remain stationary the remainder of the loader boom raise rollback releases before
cycle. bucket is level, adjust
linkage. Go to Group
LOOK: The bucket side cutting edge must be level 9025-20, Loader Bucket
during entire loader raise cycle. Level Indicator And
Return-To-Dig Switch
Adjustment .
NOT OK: Operators

Complaint Was Not
Identified.
1/1
9025
10
9
10 Operators Complaint If you completed the Operational Checkout and did not isolate a malfunction, the NOT OK: Go to Group
Was Not Identified problem may be intermittent. 9025-15Diagnose
Hydraulic Malfunctions
Try to duplicate the condition of the malfunction identified by operator.
1/1

110703
PN=491
9025
10
10

110703
PN=492
Group 15
Diagnostic Information
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.
Steering lines or load sensing "LS" Check and replace.

lines damaged (bent).
Priority valve. Operate loader while steering

machine. If steering effort increases,
do Priority Valve Pressure Check .
(See Group 9025-10.)
Steering valve binding internally. Check "LS" orifice for plugging.
Shaft in steering wheel column Check for bent steering column.

binding.
9025
15
Internal leakage in system. Do Steering System Leakage Check 1
. (See Group 9025-10.)
Main hydraulic pump (low pressure). Do Main Hydraulic Pump Standby

Pressure Test . (See Group
9025-25.)
Priority valve spool. Inspect and Repair.
Excessive Steering Wheel Turns Steering cylinder leakage. Do Steering System Leakage Check
to Steer Machine . (See Group 9025-10.)
Excessive wear in steering valve. Do Steering System Leakage Check

. (See Group 9025-10.)
Erratic ("Spongy") Steering Air in system. Check oil level. Check for cavitation
in charge system.
Steering Wheel "Locks" Up Debris in gerotor section. Disassemble and inspect. Flush.

110703
PN=493
Priority valve. Do Priority Valve Test . (See Group

9025-25.)
Broken drive shaft to gerotor pin. Replace.
Low hydraulic flow. Check system pressure and flow.
Steering Wheel Turns Freely But Steering column shaft broken. Replace.
No Wheel Movement
Splines on shaft disengaged from Check and repair.

steering valve.
No oil in steering valve. Can happen Verify and repair the cause of no oil.
when starting machine after a repair. Operate valve to purge air from
system.
Internal steering valve damage. Replace valve.
Poor Centering of Steering Wheel High back pressure in return line. Remove line, inspect. Replace.
(Wheels Continue to Move After
Steering Wheel is Stopped)
Binding or misalignment in steering Inspect column and spline to

column or splined connection. steering valve connection. Repair.
9025
15
2 Steering Wheel Oscillates Or Parts assembled wrong (steering Disassemble, inspect and
Turns By Itself After Starting valve improperly timed) reassemble.
Machine
Line connected to wrong ports. Inspect and connect correctly.
WanderVehicle Will Not Stay in Air in the system due to low level of Inspect and correct.
a Straight Line. oil, cavitating pump, leaky fitting,
pinched hose.
Worn mechanical linkage. Repair or replace. See Repair

Manual.
Bending of linkage or cylinder rod. Repair or replace. See Repair

Manual.
Loose steering cylinder piston. Repair or replace. See Repair

Manual.
Severe wear in steering control unit. Replace the steering control unit.

110703
PN=494
DriftVehicle Veers Slowly in Worn or damaged steering linkage. Replace linkage and align front end
One Direction (toe-in).
SlipA Slow Movement of Leakage of steering cylinder piston Replace seals.

Steering Wheel Fails to Cause seals.
any Movement of Steered Wheels
Worn steering control unit meter. Replace steering control unit.
Erratic Steering. Loose cylinder piston. Replace cylinder.
Sticking priority valve control spool. Replace.
"Spongy" or Soft Steering. Low fluid level. Add fluid and check for leaks.
Steered Wheels Turn in Wrong Lines connected to wrong cylinder Inspect and reconnect correctly.
Direction When Operator ports.
Activates Steering Wheel.
Steering Wheel Kicks at Start of Inlet check valve in steering valve Check and repair.
Steering. stuck open.
Priority valve spool not operating Inspect for damaged spool, plugged
correctly. sensing orifice, air in load sense
circuit.
9025
15
3
TX,9025,BS314 1906APR943/3

110703
PN=495
Diagnose Main Hydraulic System

Malfunctions
No Hydraulics Broken pump drive shaft. Inspect and repair. See repair
manual.
Manual destroke screw turned in. Turn screw out.
Destroke solenoid stuck or O-ring Check destroke solenoid. See repair

failed. manual.
Charge pump shaft failed. Remove oil cooler inlet hose to

check for flow. Repair pump. See
repair manual.
Stroke control valve. Inspect and repair valve. See repair

manual.
Slow Hydraulics (Low Pump Hydraulic filter restricted. Inspect and replace filter. See repair
Output) manual.
Priority valve stuck or orifice in spool Check hydraulic functions. If only

plugged. loader is affected, problem is priority
valve.
9025
15 Manual destroke screw not fully Turn screw out.
4 turned out.
Charge or return circuit. Do Charge Pump Pressure Test ,

Group 9025-25.
Charge pump suction screen Inspect and clean screen. See repair
restricted. 410D (S.N. 796854), manual.
510D (S.N. 796890)
Destroke solenoid packing failed. Inspect destroke solenoid. See

repair manual.
Low standby pressure. Do Main Pump Standby Pressure

Stroke control valve seat, spring, or Inspect valve. See repair manual.
packing failed.
Crankcase outlet valve stuck closed. Inspect valve. See repair manual.

110703
PN=496
Charge pump worn. Do Charge Pump Flow Test , Group

9025-25.
Main pump outlet valve worn. Inlet Do Cycle Time Test (overall cycle
valve broken or leaking. time), Group 9025-25.
Worn pistons. Perform Main Hydraulic Pump Flow

Low Hydraulic Power (Low Low oil level (aeration of oil) Add oil. See Hydraulic And Reverser
Hydraulic Pressure) Oil .
Hydraulic filter restricted. Inspect and replace filter. See repair

manual.
Stroke control valve setting too low. Do Main Pump Standby Pressure
Excessive leakage in hydraulic Perform Hydraulic System Leakage

system. Check and determine neutral
leakage. (See Group 9025-10.)
Leakage within work circuit. Feel components for heat. Do

Hydraulic System Leakage Check ,
Group 9025-10.
9025
15
Destroke solenoid O-ring damaged. Inspect O-ring. See repair manual. 5
Low charge flow due to surge relief Do Charge Pump Pressure Check ,
valve stuck, setting too low or Group 9025-10 and Charge Pump
restriction in filter base or lines. Flow Test , Group 9025-25.
Hydraulic Function Makes Low oil level. Add oil. See Hydraulic And Reverser
"Chattering" Noise Oil .
restricted. 410D (S.N. 796854), manual.
510D (S.N. 796890)
Hydraulic filter restricted. Inspect and change filter. See repair

manual.
Charge or return circuit leakage. Do Charge Pump Pressure Test ,

Group 9025-25.
Pump pistons sticking. Inspect pistons. See repair manual.

110703
PN=497
Outlet valve or spring broken. Inspect valves. See repair manual.
Wrong circuit relief valve (without Inspect relief valves. See repair
anti-cavitation valve) installed in manual.
backhoe valve.
Excessive Pump Noise Low oil level. Add oil. See Hydraulic And Reverser
Oil .
Hydraulic filter restricted. Inspect and replace filter. See repair

manual.
restricted (aeration of inlet oil). 410D manual.
(S.N. 796854), 510D (S.N.
796890)
Oil lines in contact with operators Inspect and repair.

station. Failed rubber isolators.
Loose pump drive coupling. Inspect and tighten coupling. See

repair manual.
Leakage in hydraulic circuit. Perform Hydraulic System Leakage

Check , Group 9025-10.
9025
15
6 Destroke solenoid O-ring failed. Inspect O-ring. See repair manual.
Stroke control valve seat, spring, or Inspect valve. See repair manual.
packing failure.
Pump pistons sticking. Inspect pistons. See repair manual.
Outlet valve broken. Inspect valve. See repair manual.
Inlet valve broken. Inspect valve. See repair manual.
Misalignment between pump and Loosen pump mounting cap screws

engine. and start engine. If noise is not
heard, misalignment is indicated.
Replace pump support.
TX,9025,BS315 1906APR943/3

110703
PN=498
Main Hydraulic System Operation
The main hydraulic system is a closed-center system. to the non-priority function to ensure the steering
On early machines the transaxle is the reservoir for the circuit has adequate oil. Later machines do not have a
main hydraulic system. Later machines have an load sense relief, therefore pump standby pressure is
independent reservoir located between the cab and measured at the priority valve.
engine compartments. Charge oil flows to inlet of
hydraulic filter. Return oil from loader, backhoe and Charge circuit flow not needed by the main hydraulic
stabilizer also flows to the filter to form a charge pump flows to the hydraulic cooler. Oil from the cooler
circuit. A surge relief valve is used to maintain charge flows to the reservoir. The brake valve also receives its
pressure and protect oil cooler from excess pressure supply from cooler return. Pump seal leakage, steering
by releasing excess oil to the reservoir. return, brake return, priority valve leakage and MFWD
return are returned to reservoir also.
Oil flows from the filter to main hydraulic pump inlet.
The pressure compensator on top of the main pump The park brake solenoid and actuator receives its oil
sets system pressure. Oil flows from main pump to the supply from the reverser. The return oil is sent back to
priority valve. The priority valve balances oil flow to the reverser.
priority and non-priority circuits. The steering valve,
MFWD valve, backhoe valve and stabilizer valve are On early machines a cooler by-pass valve allows oil to
on the priority circuit. The loader valve receives by-pass the hydraulic cooler if it becomes restricted
non-priority oil. On early machines pressure below the internally. This design is not used on later machines.
priority valve load sense relief setting restricts oil flow
TX,9025,BS316 1906APR941/1
9025
15
7

110703
PN=499
Hydraulic System Schematic, 410D (S.N. 796854), 510D (S.N. 796890)

T7990AA 1901JAN99
M.F.W.D. VALVE BACKHOE CONTROL VALVE
HYDRAULIC PRESSURE REDUCING
FILTER BRAKE VALVE
VALVE OUTLET END CAP
P
AUXILIARY
PARK BRAKE
)(
SOLENOID AND )( )( )(
ACTUATOR
SURGE RELIEF VALVE STEERING
VALVE
CROWD
)(
)(
COOLER BYPASS
VALVE
BUCKET
BOOM
HYDRAULIC
OIL )(
COOLER
TORQUE
CONVERTER BOOM VALVE BUCKET VALVE AUXILIARY VALVE LOADER CONTROL
VALVE SWING
OIL
COOLER
MAIN )(
HYDRAULIC PRIORITY VALVE )(
STABILIZER VALVE
PUMP
)(
)( SYSTEM INLET END
RELIEF CAP
VALVE
HIGH PRESSURE OIL

MEDIUM PRESSURE OIL
CHARGE CHARGE OIL
PUMP LUBE OIL
RETURN OIL
TRAPPED OIL
TXC7990AA CV
TRANSAXLE 410D AND 510D HYDRAULIC SCHEMATIC
TX,9025,DY44 19 9JUL961/1

110703
PN=500
See Page 9025-15-8 A See Page 9025-15-8 B See Page 9025-15-8 C

HYDRAULIC
FILTER BRAKE VALVE
P
SURGE RELIEF VALVE
)(
COOLER BYPASS
VALVE
HYDRAULIC
OIL
COOLER
TORQUE
CONVERTER
OIL
COOLER
MAIN
HYDRAULIC PRIORITY VALVE
PUMP
)(
)(
CHARGE
PUMP
TXC7990AA CV
TRANSAXLE 410D AND 510
Page 9025-15-8 A
Hydraulic Sy
T7990AA 1901JAN99
PARK BRAKE
)(
SOLENOID AND )( )( )(
ACTUATOR
STEERING
VALVE
BOOM VALVE BUCKET VALVE AUXILIARY VALVE LOADER CO

VALVE
ND 510D HYDRAULIC SCHEMATIC
TM1512 (07NOV
Page 9025-15-8 B
ulic System Schematic, 410D (S.N. 796854), 510D (S.N. 796890)

901JAN99
M.F.W.D. VALVE BACKHOE CONTROL VALVE
PRESSURE REDUCING
VALVE OUTLET END CAP
AUXILIARY
( )(
CROWD
)(
BUCKET
BOOM
)(
DER CONTROL
VE SWING
)( )(
STABILIZER VALVE
SYSTEM INLET END

RELIEF CAP
VALVE
HIGH PRESSURE OIL

MEDIUM PRESSURE OIL
CHARGE OIL
LUBE OIL
RETURN OIL
TRAPPED OIL
TX,9025,DY44 19 9JUL961/1
07NOV03) 9025-15-8 Backhoe Loaders Operation and Test

110703
Page 9025-15-8 C PN=500

Hyd. Component Location, 410D (S.N. 796855801199), 510D (S.N. 796891801199)

T8163AG 1911JAN99
BACKHOE
J STEERING VALVE M
CONTROL
VALVE
I BRAKE VALVE
HYDRAULIC OIL
H RESERVOIR
SYSTEM
N RELIEF
VALVE
G PRIORITY
VALVE L PARK
F LOADER PARK BRAKE
K STABILIZER
VALVE BRAKE VALVE
VALVE
O
P HYDRAULIC
OIL FILTER
E HYDRAULIC
OIL
COOLER
D TRANSAXLE
OIL COOLER
Q REVERSER
OIL FILTER
S HIGH PRESSURE OIL
C REVERSER OIL COOLER
T MEDIUM PRESSURE OIL
R TRANSAXLE U CHARGE PRESSURE OIL

B MAIN HYDRAULIC PUMP
X OIL FILTER
SURGE RELIEF
V TRAPPED OIL
VALVE
W PRESSURE FREE OIL

A CHARGE PUMP
Y 410D/510D MAIN HYDRAULIC COMPONENT LOCATION NEUTRAL

TXC8163AG CV
TX,902515,QQ869 1906APR941/1

110703
PN=501

Hydraulic Schematic, 410D (S.N. 796855801199), 510D (S.N. 796891801199)

T8163AH 1901JAN99
P HYDRAULIC OIL
FILTER I BRAKE VALVE M BACKHOE CONTROL VALVE
P
SWING
O STABILIZER VALVE
X SURGE RELIEF
VALVE
BOOM
E HYDRAULIC
OIL COOLER
)(
)( )( )(
STEERING
J VALVE
BUCKET
F LOADER CONTROL VALVE
G PRIORITY VALVE BOOM BUCKET AUXILIARY
CROWD
H HYDRAULIC OIL RESERVOIR
S HIGH PRESSURE OIL

B MAIN
HYDRAULIC
PUMP T MEDIUM PRESSURE OIL
U CHARGE OIL
V TRAPPED OIL
N SYSTEM
W PRESSURE FREE OIL RELIEF
VALVE
A CHARGE Y 410D, 510D HYDRAULIC SCHEMATIC - NEUTRAL

TXC8163AH CV PUMP
TX,9025,BS372 1906APR941/1

110703
PN=502

Hyd. Component Location, 410D (S.N. 796855801199), 510D (S.N. 796891801199)

T8163AG 1911JAN99
TX,902515,QQ869 1906APR941/1

110703
Page 9025-15-9 A PN=501

J S
I BRAKE VALV
HYDRAULIC OIL
H RESERVOIR
G PRIORITY
VALVE
F LOADER
VALVE
E HYDRAULIC
OIL
COOLER
D TRANSAXLE
OIL COOLER
C REVERSER OIL COOLER
B MAIN HYDRAULIC PUMP

X
SU
VA
A CHARGE PUMP
Y 410D/510D MAIN HYD

TXC8163AG CV
/1
est
0703
501
Page 9025-15-9 B
BACKHOE
J STEERING VALVE M
CONTROL
VALVE
E VALVE
SYSTEM
N RELIEF
VALVE
L PARK
PARK BRAKE
K STABILIZER
BRAKE VALVE
VALVE
O
P HYDRAULIC
OIL FILTER
Q REVERSER
OIL FILTER
S HIGH PRESSURE OIL
R TRANSAXLE U CHARGE PRESSURE OIL

X OIL FILTER
SURGE RELIEF
V TRAPPED OIL
VALVE
W PRESSURE FREE OIL
N HYDRAULIC COMPONENT LOCATION NEUTRAL
Page 9025-15-9 C
P HYDRAULIC
FILTER
OIL
I BRAKE VALVE
P
X SURGE
VALVE
RELIEF
E HYDRAULIC
OIL COOLER
G PRIORITY VALVE
S HIGH PRESSURE OIL

B MAIN
HYDRAULIC
U CHARGE OIL
V TRAPPED OIL
W PRESSURE FREE OIL
A CHARGE Y 410D, 510D HYDRAULIC SCHEMATIC - NEUTRA

TXC8163AH CV PUMP
Page 9025-15-10 A
Hydraulic Sc
T8163AH 1901JAN99
ALVE
O STABILIZER VALVE
)(
)( )( )(
STEERING
J VALVE
VE BOOM BUCKET AUXILIARY
EUTRAL
TM1512 (07NOV
Page 9025-15-10 B
ulic Schematic, 410D (S.N. 796855801199), 510D (S.N. 796891801199)

901JAN99
M BACKHOE CONTROL VALVE
SWING
BOOM
BUCKET
CROWD
N SYSTEM
RELIEF
VALVE
TX,9025,BS372 1906APR941/1

110703
Page 9025-15-10 C PN=502

Hydraulic Component Location, 410D (S.N. 801200 ), 510D (S.N. 801200 )

T8188AR 1901JAN99
BACKHOE M
BRAKE CONTROL
I VALVE
VALVE
HYDRAULIC
OIL RESERVOIR L PARK
H BRAKE
SYSTEM J STEERING
N VALVE
RELIEF
VALVE
K PARK
BRAKE
VALVE
PRIORITY
VALVE
G
P
LOADER
VALVE F STABILIZER
VALVE
P
TRANSAXLE
HYDRAULIC OIL FILTER
OIL COOLER
E
P HYDRAULIC
TRANSAXLE OIL FILTER
OIL COOLER
D
REVERSER S HIGH PRESSURE OIL
Q
OIL FILTER
REVERSER
C T MEDIUM PRESSURE OIL
OIL COOLER
MAIN U CHARGE PRESSURE OIL

X
HYDRAULIC B
PUMP SURGE V TRAPPED OIL
RELIEF
VALVE
CHARGE A W PRESSURE FREE OIL
PUMP Y 410D MAIN HYDRAULIC COMPONENT LOCATION
TXC8188AR
TX,9025,BS373 CV
1906APR941/1

110703
PN=503

Hydraulic Schematic, 410D (S.N. 801200 ), 510D (S.N. 801200 )

T8200AE 1901JAN99
P HYDRAULIC OIL
FILTER I BRAKE VALVE M BACKHOE CONTROL VALVE
P
SWING
O STABILIZER VALVE
X SURGE RELIEF
VALVE
BOOM
E HYDRAULIC
OIL COOLER
)(
)( )( )(
STEERING
J VALVE
BUCKET
SYSTEM
RELIEF CROWD
H HYDRAULIC OIL RESERVOIR VALVE
S HIGH PRESSURE OIL

B MAIN
HYDRAULIC
BOOM AUX
BUCKET
U CHARGE OIL
V TRAPPED OIL
W PRESSURE FREE OIL
A CHARGE Y 410D, 510D HYDRAULIC SCHEMATIC - NEUTRAL

TXC8200AE CV PUMP
TX,9025,BS374 1906APR941/1

110703
PN=504

Hydraulic Component Location, 410D (S.N. 801200 ), 510D (S.N. 801200 )

T8188AR 1901JAN99
TRA
OIL
REVER
OIL CO
MAIN
HYDRA
PUMP
TXC8188AR
TX,9025,BS373 CV
1906APR941/1

110703
Page 9025-15-11 A PN=503

BRAKE
I
VALVE
HYDRAULIC
OIL RESERVOIR
H
SYSTEM J STEERING
N VALVE
RELIEF
VALVE
K PARK
BRAKE
VALVE
PRIORITY
VALVE
G
LOADER
VALVE F
HYDRAULIC
OIL COOLER
E
TRANSAXLE
OIL COOLER
D
REVERSER
C
OIL COOLER
MAIN X
HYDRAULIC B
PUMP SURGE
RELIEF
VALVE
CHARGE A
PUMP Y 410D MAIN HYDRAULIC COMPONEN
/1
est
0703
503
Page 9025-15-11 B
BACKHOE M
CONTROL
VALVE
L PARK
BRAKE
G
P
STABILIZER
VALVE
P
TRANSAXLE
OIL FILTER
P HYDRAULIC
OIL FILTER
REVERSER S HIGH PRESSURE OIL

Q
OIL FILTER
U CHARGE PRESSURE OIL
V TRAPPED OIL
W PRESSURE FREE OIL

ONENT LOCATION
Page 9025-15-11 C
P HYDRAULIC
FILTER
OIL
I BRAKE VALVE
P
X SURGE
VALVE
RELIEF
E HYDRAULIC
OIL COOLER
S HIGH PRESSURE OIL

B MAIN
HYDRAULIC
U CHARGE OIL
V TRAPPED OIL
W PRESSURE FREE OIL
A CHARGE Y 410D, 510D HYDRAULIC SCHEMATIC - NEUTRA

TXC8200AE CV PUMP
Page 9025-15-12 A
Hydraulic Sc
T8200AE 1901JAN99
ALVE
O STABILIZER VALVE
)(
)( )( )(
STEERING
J VALVE
SYSTEM
RELIEF
VALVE
L
BOOM AUX
BUCKET
EUTRAL
TM1512 (07NOV
Page 9025-15-12 B
ulic Schematic, 410D (S.N. 801200 ), 510D (S.N. 801200 )

901JAN99
M BACKHOE CONTROL VALVE
SWING
BOOM
BUCKET
CROWD
TX,9025,BS374 1906APR941/1

110703
Page 9025-15-12 C PN=504

Group 20
Adjustments
Loader Bucket Level Indicator And
Return-To-Dig Switch Adjustment
SPECIFICATIONS
Guard and Stop-to-Bell Crank 1 mm (0.04 in.)
Gap
Top of Bell Crank Pin-to-Bottom 130 mm (5.1 in.)
of Actuator Tang Gap
NOTE: Later machines have new design guard/stop (B).

Adjustment is the same for all machines.
1. Position bucket flat on ground. Turn engine off.
2. Hold bucket lever in roll-back position.
9025
20
1

110703
PN=505
Adjustments
3. Measure gap (A) between guard and stop (B) and bell
crank (C). Gap should be 1 mm (0.04 in.).
Specification
Guard and Stop-to-Bell Crank
Gap .................................................................................... 1 mm (0.04 in.)
1915OCT92
4. If gap is not to specification, adjust rod jam nut and
yoke (D) to obtain correct gap. Allow bucket lever to
return to neutral position.
T7864AE
5. Measure gap (E) between top of bell crank pin (F) and
bottom of actuator tang (G). Gap should be 130 mm
(5.1 in.).
Specification
Top of Bell Crank Pin-to-Bottom
of Actuator TangGap ................................................... 130 mm (5.1 in.)
6. If gap is not to specification, adjust sensor tube jam nut

and yoke (H) to correct length.
A1 mm (0.04 in.) gap

BGuard/Stop
CBell Crank-Neutral Position
DRod Jam Nut and Yoke
E130 mm (5.1 in.) gap
FBell Crank Pin
9025 GActuator Tang
20 HSensor Tube Jam Nut and Yoke
2 IBucket Dump
JBucket Rollback
1915OCT92
T7864AD

110703
PN=506
Adjustments
7. Loosen cap screw (A) and move return-to-dig switch so

roller (B) is touching area (C) on the cam.
NOTE: On later machines switch will have a plastic roller

on actuator arm. Omit steps 8 and 9 on these
machines. Older machines have a metal roller on
UN09NOV88
actuator arm.
8. Move switch toward cam until a "click" is heard.
T87154
9. Move switch away from cam until a "click" is heard.
10. Tighten cap screw without moving switch.

ACap Screw
BRoller
11. Remove pin from sensor tube yoke. CArea on Cam
12. While watching clearance between cam and switch,

turn command pointer back and forth to be sure cam
does not hit switch bracket.
NOTE: Be sure that switch arm and roller does not

bottom on switch housing.
13. If cam touches bracket or switch arm, and roller

bottoms on switch housing, reposition switch. (See
steps 710 .)
9025
20
3
TX,9025,BS317 1906APR943/3
Loader Control Valve Linkage Adjustment

SPECIFICATIONS
Right Side of Knob-to-Tape 250 mm (10 in.)
Distance
Front of Loader Knob-to-Tape 130 mm (5.25 in.)
Distance
NOTE: Levers must be positioned correctly to allow full

travel and proper operation of loader valves. Cab
and other components have been removed in
some photographs for clarity.
1. Put loader control valve spools in neutral position.

110703
PN=507
Adjustments
2. Adjust rods (A) so tabs (B) on bell crank are horizontal.
3. Put a piece of masking tape from right front to right

rear ROPS posts on inside surface at loader knob
height.
UN30OCT90
4. Put a piece of masking tape from left front to right front
ROPS posts on inside surface at loader knob height.
T7407AN
(S.N. 801199) Shown
TX,9025,BS318 1906APR942/5
5. Distance (C) from right side of knob to tape should be

250 mm (10 in.).
Specification
Right Side of Knob-to-Tape
Distance ............................................................................ 250 mm (10 in.)
9025
UN14NOV90
20
4 6. Distance (D) from front of loader knob to tape should
be 130 mm (5.25 in.).
T7407AO
Specification
Front of Loader Knob-to-Tape
Distance ......................................................................... 130 mm (5.25 in.)
TX,9025,BS318 1906APR943/5
7. The distances in steps 5 and 6 can be obtained by

adjusting rods (E).
UN30OCT90
T7407AP

110703
PN=508
Adjustments
NOTE: Pivot (F) must remain in slot when holding the

loader lever in the roll-back position.
UN30OCT90
T7407AQ
TX,9025,BS318 1906APR945/5
Backhoe Valve Linkage Adjustment

SPECIFICATIONS
410D, 510D (S.N. 801199) 280 mm (11.2 in.)
Center of Clevis Pin
Hole-to-Center of Ball Joint
Length
410D, 510D (S.N. 801200 ) 338 mm (13.3 in.)
Length
410D, 510D (S.N. 801199) 190 mm (7.5 in.)
Hole-to-Center of Ball Joint 9025
Length (Machine With Extendable 20
Dipperstick) 5
410D, 510D (S.N. 801200 ) 248 mm (9.75 in.)
Length (Machine With Extendable
Dipperstick)
Edge of Knobs-to-Tape Distance 140 mm (5.5 in.)
Knob-to-Knob Distance 250 mm (9.8 in.)

travel and proper operation of backhoe valves.
Rod lengths given are nominal. Final adjustment
is to be done using knob position. Cab and other
components have been removed in some
photographs for clarity.
1. Put backhoe valve spools in neutral position.

110703
PN=509
Adjustments
2. Measure rods (A) from center of clevis pin hole to

center of ball joint.
Specification
410D, 510D (S.N. 801199)
UN30OCT90
Length ............................................................................ 280 mm (11.2 in.)
410D, 510D (S.N. 801200 )
Length ............................................................................ 338 mm (13.3 in.)
T7407AI
3. On machines with extendable dipperstick, auxiliary
valve linkage adjustment is also required. Measure rod
from center of clevis pin hole to center of ball joint.
Specification
410D, 510D (S.N. 801199)
Dipperstick) ...................................................................... 190 mm (7.5 in.)
410D, 510D (S.N. 801200 )
Dipperstick) .................................................................... 248 mm (9.75 in.)
4. Put a piece of masking tape across the rear ROPS

9025 posts on inside surface at backhoe lever knob height.
20
6
TX,9025,BS319 1906APR942/3
5. Measure from edge of knobs to tape. Distance (B)

should be 140 mm (5.5 in.). Knobs should be 250 mm
(9.8 in.) apart.
Specification
Edge of Knobs-to-Tape
UN30OCT90
Distance ........................................................................... 140 mm (5.5 in.)
Specification
Knob-to-KnobDistance ................................................. 250 mm (9.8 in.)
T7407AJ
TX,9025,BS319 1906APR943/3

110703
PN=510
Adjustments
Stabilizer Valve Linkage Adjustment
SPECIFICATIONS
Edge of Right Stabilizer 260 mm (10.25 in.)
Knob-to-Tape Distance
Edge of Left Stabilizer 295 mm (11.6 in.)
Knob-to-Tape Distance

travel and proper operation of stabilizer valves.
Cab and other components have been removed in
some photographs for clarity.
1. Put stabilizer valve spools in neutral position.
9025
20
7

110703
PN=511
Adjustments
2. Adjust linkage rods (A) so that tabs (B) are vertical.
3. Put masking tape across left and right rear ROPS

posts on inside surface at stabilizer knob height.
4. Measure the distance (C) from edge of right stabilizer
UN30OCT90
knob to tape. It should be 260 mm (10.25 in.).
Specification
Edge of Right Stabilizer
T7407AK
Knob-to-TapeDistance ............................................. 260 mm (10.25 in.)
Measure the distance (D) from edge of left stabilizer knob (S.N. 801199)
to tape. It should be 295 mm (11.6 in.). Adjust rods (E) as
necessary.
Specification
Edge of Left Stabilizer
Knob-to-TapeDistance ............................................... 295 mm (11.6 in.)
ALinkage Rods
UN20FEB94
BTabs
CDistance of Right Stabilizer Knob Edge to Tape
DDistance of Left Stabilizer Knob Edge to Tape
ERods
T8187AL
(S.N. 801200 )
9025
20
8
UN30OCT90
T7407AL
UN30OCT90
T7407AM
TX,9025,BS320 1906APR942/2

110703
PN=512
Group 25
Tests
Installation
Tachometer
UN28FEB89
T6813AG
10T,9010,K182 1910AUG951/1
JT05800 Digital Thermometer Installation

Digital Thermometer
Wrap with shop towel. 9025
UN28FEB89
25
BCable
1
T6808CE
902525,AA4 1928FEB951/1
Hydraulic Oil Warm-Up Procedure

SPECIFICATIONS
Engine Speed 2000 rpm
1. Operate all hydraulic control valves to release pressure

in the system.

110703
PN=513
Tests

UN23AUG88
fluids.
X9811
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.
UN10DEC90
2. Disconnect boom cylinder rod end hose (A) from
cylinder and boom cylinder head end hose (B) from
control valve.
T7431AF
3. Connect hose (A) to control valve and hose (B) to
boom cylinder head end port.
4. Put cardboard or other suitable material in front of oil

9025 cooler to restrict air flow.
25
2
5. Start engine and run at 2000 rpm.
Specification
EngineSpeed ........................................................................... 2000 rpm
6. Move and hold loader control valve lever to boom raise

position to heat oil.
7. Operate all hydraulic functions to distribute heated oil.
8. Heat oil to temperature specified in test.
NOTE: An alternate warm-up procedure is to lock

backhoe boom in transport position, and hold
backhoe boom down over relief. Frequently
activate crowd and bucket functions to evenly
distribute warmed oil.
TX,9025,BS236 1924MAY932/2

110703
PN=514
Tests
Diagnostic Destroke Wire Harness

Installation Procedure
See Section 99 for instructions to make harness.

TX,902525,BR145 1924MAY931/2
1. Connect ground clamp (A) to frame.
2. Disconnect solenoid wire harness. Connect diagnostic

destroke wire harness solenoid.
3. Turn switch box to "ON" to destroke pump before

starting engine. Turn switch "OFF".
AGround Clamp
BPower Cable
CInjection Pump
DSwitch Box
EConnector
FMain Hydraulic Pump
9025
UN17APR89
25
3
T6280AL
TX,902525,BR145 1924MAY932/2

110703
PN=515
Tests
Main Hydraulic Pump Flow And Stroke

Control Valve Test
SPECIFICATIONS
Oil Temperature 65 5C (150 10 F)
Oil Pressure 13 790 69 kPa (138 0.7 bar)
(2000 10 psi)
Hydraulic Pump Maximum Flow 7.5 L/min (2.0 gpm)
Decrease
ESSENTIAL TOOLS
JT15073 Connector (2 used)

Electronic Tachometer
Digital Thermometer
Flowmeter and Hoses
1. Install electronic tachometer , and digital thermometer

probe in reservoir. (See procedure in this group.)
TX,902525,BR91 1906APR941/3
9025
25
4
UN23AUG88
fluids.
If an accident occurs, see a doctor immediately. X9811

2. Operate all hydraulic control valves to release pressure

in the hydraulic system.
Continued on next page TX,902525,BR91 1906APR942/3

110703
PN=516
Tests
3. Connect flowmeter (C) to backhoe valve (E) using

hoses (B) and connectors (A). Open loading valve (D).
4. Start engine and heat oil by restricting flow through

flowmeter.
Specification
OilTemperature .................................................. 65 5C (150 10 F)
5. Adjust engine speed and oil pressure to specifications.
Specification
EngineSpeed .................................................................. 2000 10 rpm
OilPressure ......................................... 13 790 69 kPa (138 0.7 bar)
(2000 10 psi)
Record pump flow.
6. If pump flowmeter meets test specifications, next check

stroke control valve.
Maintain 2000 10 rpm for this part of test. Adjust oil
UN25MAY89
pressure to each of the following test pressures.
Record flow rate.
T6264AH
Subtract recorded flow rate recorded at 13 790 kPa
(138 bar) (2000 psi) during first part of test.
9025
Flow rate should not decrease by more than 7.5 L/min AJT15073 Connector (2 used) 25
(2.0 gpm) until oil pressure is within 2070 kPa (207 BHose (2 used) 5
bar) (300 psi) of standby pressure, then decrease CFlowmeter
DLoading Valve
sharply as pump destrokes.
EBackhoe Valve
Specification
Hydraulic PumpMaximum Flow
Decrease .................................................................... 7.5 L/min (2.0 gpm)
If stroke control valve meets specifications, do Hydraulic

Component Neutral Leakage Test in this group.
Unit Oil Pressure Flow Rate Difference

410D,510D 15 860 kPa (158.6 bar) (2200 psi)
16 550 kPa (165.5 bar) (2300 psi)
16 550 kPa (165.5 bar) (2400 psi)
17 240 kPa (172.4 bar) (2500 psi)
17 930 kPa (179.3 bar) (2600 psi)
TX,902525,BR91 1906APR943/3

110703
PN=517
Tests
Charge Pump Pressure Test

SPECIFICATIONS
Engine Speed Fast idle
Main Pump Pressure 827 140 kPa (8.2 1.4 bar)
(120 20 psi)
ESSENTIAL TOOLS
JT05490 Adapter
JT01608 Quick Coupler
JT05483 90 Elbow

Digital Thermometer
Hose (2 used)
Gauge 02000 kPa (020 bar) (0300 psi) (2 used)


9025
25
6

110703
PN=518
Tests
2. Connect hose (B) to main hydraulic pump using fittings

(A, C and D). Connect hose (B) to backhoe valve port
using fittings (A and D).
3. Connect hose to 02000 kPa (020 bar) (0300 psi)

gauge.
UN20MAR90
4. Start engine and heat oil to specifications .
Specification
T6900AL
OilTemperature .................................................... 40 4C (104 7F)
(See procedure in this group.) Gresen Valve
5. Run engine at fast idle.
Specification
EngineSpeed ............................................................................ Fast idle
Record pressure reading.
UN18FEB94
Specification
Main PumpPressure ............................... 827 140 kPa (8.2 1.4 bar)
(120 20 psi)
T8187AE
6. If pressure at backhoe valve is to specification but low
at main pump, change filter element and do test again.
Husco Valve
If pressure remains low, check operation of surge relief
9025
valve.
25
7
AJT05490 Adapter
BHose (2 used)
CJT05483 Elbow
DJT01608 Quick Coupler Adapter
UN10DEC90
T7431AH
TX,9025,BS321 1906APR942/2

110703
PN=519
Tests
Charge Pump Flow Test

SPECIFICATIONS
Loading Valve Minimum Pressure 690 kPa (6.9 bar) (100 psi)
Charge Pump Minimum Flow 68 L/min (18 gpm)
ESSENTIAL TOOLS
16 F Sw x 16 M 90 Elbow
JT05691 Adapter
1 5/16 F 37 x 1 1/16 M 37 Reducer
16 M x 16 M Adapter

Digital Thermometer
Flowmeter
Hoses
NOTE: It is faster to remove chargepump and measure

parts for wear (see Group 2160) than to do the
charge pump flow test.
1. Remove left engine side shield.

9025
25
8 2. Connect electronic tachometer , and digital
thermometer probe in reservoir. (See procedure in this
group.)

110703
PN=520
Tests

UN23AUG88
fluids.
X9811
UN17DEC90
3. Connect flowmeter using fittings (A,B,C and D) and
hoses.
IMPORTANT: Flowmeter loading valve must be open
T7438AA
before starting unit to prevent damage
to charge pump. DO NOT completely
close loading valve during test to
prevent damage to charge pump. A90 Elbow
BAdapter (2 used) 9025
CReducer (2 used) 25
4. Open flowmeter loading valve. DAdapter 9
Specification
6. Adjust engine speed to specification.
Specification
EngineSpeed .................................................................. 2000 10 rpm
Slowly close loading valve to get minimum pressure of

690 kPa (6.9 bar) (100 psi).
Specification
Loading ValveMinimum
Pressure ......................................................... 690 kPa (6.9 bar) (100 psi)

110703
PN=521
Tests
Record flow rate.
Specification
Charge PumpMinimum Flow .................................... 68 L/min (18 gpm)
7. If flow is below minimum, check for restriction in

transmission suction screen before repairing pump.
NOTE: If after inspection pump fails to produce flow or

pressure, pump drive key has fallen out of
position. Check pump flow from cooler line with
engine running. Remove charge pump and stroke
control valve housing to reinstall drive key in end
of main pump shaft. See CTM-7.
TX,902525,BR96 1906APR943/3
9025
25
10

110703
PN=522
Tests
Main Pump Standby Pressure Test
SPECIFICATIONS
410D, 510D Pump Standby 19 000 380 kPa (190 3.8 bar)
Pressure (2750 50 psi)
ESSENTIAL TOOLS
JT05490 Connector
JT05491 Connector-Metric

Digital Thermometer
Hose
Gauge
NOTE: Pump standby pressure can be measured at

priority valve test port on (S.N.801200 ). It can
also be measured at pump or backhoe valve test
ports. These machines do not have a priority
valve load sense relief valve.
1. Operate all hydraulic control valves to release pressure 9025

in the hydraulic system. 25
11


110703
PN=523
Tests

UN23AUG88
fluids.
X9811
3. Connect hose to main pump or backhoe valve using
UN07FEB90
necessary fittings.
4. Heat oil to specifications .
T93021
Specification
OilTemperature ..................................................... 40 4C (104 7F) Gresen Valve
9025 (See procedure in this group.)

25
12 5. Adjust engine speed to specification.
Specification
EngineSpeed .................................................................. 2000 25 rpm
UN18FEB94
Record pressure.
Specification
410D, 510D PumpStandby
T8187AF
Pressure ............................................... 19 000 380 kPa (190 3.8 bar)
(2750 50 psi)
Husco Valve
6. Turn adjusting screw (E) to adjust pressure to
specification. If pressure cannot be adjusted, repair or
replace valve.
AJT05490 Connector
BJT01608 Quick Coupler
CHose
DJT05491 Connector
UN17DEC90
EAdjusting Screw
T7434AA
TX,9025,BS322 1906APR942/2

110703
PN=524
Tests
Priority Valve Test (S.N. 801199)
SPECIFICATIONS
Engine Speed High idle
Steering Wheel Approximate 22 N (5 lbs)
Force
Priority Valve Pressure Setting 16 550 700 kPa (16.5 7.0
bar) (2400 100 psi)
Each 1/4 Turn of Adjusting Screw 1723 kPa (17 bar) (250 psi)
Changes Pressure
ESSENTIAL TOOLS
JT05490 Adapter

Gauge
Hose
Digital Thermometer
9025
25
13

110703
PN=525
Tests

UN23AUG88
fluids.
X9811
NOTE: (S.N.801200 ) does not have load sense relief
UN07FEB90
valve. On these machines pump standby pressure
can be measured at priority valve section test
port. The priority section is integral with the loader
T93021
valve.

AJT05490 Connector
9025 2. Install electronic tachometer , and digital thermometer BJT01608 Quick Coupler Adapter
25 CHose
14
3. Start engine and heat hydraulic oil to specifications .
Specification
OilTemperature .................................................... 40 4 C (104 7F)
4. Run engine at test specification.
Specification
EngineSpeed ............................................................................ High idle
Turn and hold steering wheel against stop with

approximately 22 N (5 lbs ) force.
Specification
Steering WheelApproximate
Force ....................................................................................... 22 N (5 lbs)

110703
PN=526
Tests
NOTE: If steering wheel is not turning, it will give an

incorrect reading.
5. Raise loader boom and read pressure gauge while

boom is raising. This is the priority valve setting.
Specification
Priority ValvePressure Setting ................ 16 550 700 kPa (16.5 7.0
bar) (2400 100 psi)
NOTE: Adjusting screw is under priority valve drain line.
6. If pressure is not to specification, disconnect drain line

from priority valve. Turn adjusting screw using a
hex-head wrench to adjust pressure.
Specification
Each 1/4 Turn of Adjusting Screw
ChangesPressure ...................................... 1723 kPa (17 bar) (250 psi)
Connect drain line and repeat test.
7. If pressure cannot be adjusted to specification,

disassemble and inspect priority valve.
TX,9025,BS324 1906APR943/3
9025
25
15

110703
PN=527
Tests
Priority Valve "LS" Port Flow Test

SPECIFICATIONS
Engine Speed Slow idle
Priority Valve LS Flow 700 100 mL/min (0.18 0.03
gpm)
ESSENTIAL TOOLS
38H1414 Cap

Digital Thermometer
Measuring Container
Stop Watch
Priority valve "LS" port flow test will check for a plugged or
missing orifice in the priority valve spool. A plugged orifice
will block warm-up flow to the steering valve which can
cause thermal shock. A missing orifice can cause the
pump to be loaded to high pressure at all times causing
overheating.
NOTE: This test is applicable for machines with priority

9025 valve integral with loader valve (S.N.801200 )
25 and remote (S.N. 801199) priority valves.
16
1. Install electronic tachometer and digital thermometer .
(See procedure this group.)
2. Heat hydraulic oil to specifications .
Specification
(See procedure this group.)

110703
PN=528
Tests

UN23AUG88
fluids.
X9811
3. Disconnect "LS" line at steering valve and cap fitting

(A).
4. Start engine and run at specification.
UN17DEC90
Specification
EngineSpeed ............................................................................ Slow idle
Catch flow from line in a measuring container (B). 9025
T7438AB
25
Specification 17
Priority Valve LSFlow .......................... 700 100 mL/min (0.18 0.03
gpm)
If flow is low, a plugged orifice in priority valve spool or

low steering system neutral pressure is indicated.
If flow is high, remove priority valve spool and inspect

orifice.
TX,9025,BS325 1906APR942/2

110703
PN=529
Tests

(S.N. 796854) 510D (S.N. 796890)
SPECIFICATIONS
Oil Flow 22.7 L/min (6 gpm)
Pressure Difference
ESSENTIAL TOOLS
1/2 M NPT x 3/4 I.D. Beaded Fitting Hose (2 used)
JT03064 Connector
JT03103 Adapter
D01083AA Switching Unit
D01082AA Analyzer

19.5 L (5.0 gal) Container
Digital Thermometer
In-Line Flowmeter
1/2 in. Heater Hose
Hose Clamps
Hydraulic Hose (2 used)
9025
25 1. Before doing test, if an internally restricted oil cooler is
18
suspected, the cooler can be back flushed to check for
debris as follows:
Disconnect inlet and outlet hoses.

Connect outlet hose from oil cooler to cooler inlet
hose from pump.
Put end of oil cooler inlet hose into a clean 19.5 L
(5.0 gal) container.
Start engine and run at approximately 1500 rpm for
20 seconds.
2. Install digital thermometer . (See procedure in this

group.)

110703
PN=530
Tests

UN23AUG88
fluids.
X9811
3. Disconnect lines from cooler bypass valve.

9025
25
19

110703
PN=531
Tests
4. Connect lines using parts (A,B,C and D). Connect to

switching unit. Connect switching unit to analyzer.
5. Connect flowmeter in line from pump to cooler using

heater hose and hose clamps. Open metering valve on
flowmeter (if equipped).
6. Start engine and heat oil to specifications.
Specification
OilTemperature ..................................................... 40 4C (100 7F)
7. Adjust engine speed until flow is at specification.
UN17DEC90
Specification
OilFlow ..................................................................... 22.7 L/min (6 gpm)
8. Record pressure readings from gauges.
T7438AC
Specification
ABeaded Fitting (2 used)
BJT03064 Adapter (2 used)
If pressure is greater than specification, cooler is CJT03103 Adapter (2 used)
restricted. Remove to clean or replace. DJT01608 Coupler (2 used)
EHose (2 used)
FSwitching Unit
GAnalyzer
HIn-Line Flowmeter (Capable of measuring 20
9025
gpm)
25
I1/2 in. Heater Hose
20
JHose Clamps
TX,9025,BS326 1906APR943/3

110703
PN=532
Tests

(S.N. 796855 ) 510D (S.N. 796891 )
SPECIFICATIONS
Oil Flow 26.5 L/min (7 gpm)
Pressure Difference
ESSENTIAL TOOLS
T113448 Female Tee
used)

Digital Thermometer
In-Line Flowmeter
1/2 in. Heater Hose
Hose Clamps (6 used)
Gauge (2 used)
TX,9025,BS327 1906APR941/3
9025
25
21
UN23AUG88
fluids.
X9811
1. Install digital thermometer probe in reservoir.
2. Disconnect lines from cooler inlet and outlet ports.

110703
PN=533
Tests
NOTE: Flowmeter is installed between hydraulic pump

and inlet to cooler.
3. Connect lines, gauges, and flowmeter (D) using parts

(A, B, C)
4. Start engine and heat oil to specifications.
Specification
OilTemperature ..................................................... 40 4C (100 7F)
5. Adjust engine speed until flow is at specification.
Specification
OilFlow ..................................................................... 26.5 L/min (7 gpm)
6. Record pressure readings from gauges.
Specification
UN18FEB94
If pressure is greater than specification, cooler is
restricted. Remove to clean or replace.
T8187AG
A1/2 in. Heater Hose
BTee
CConnectors
9025 DFlowmeter
25
22
TX,9025,BS327 1906APR943/3

110703
PN=534
Tests
Cycle Time Test
SPECIFICATIONS
Loader Boom Raise (Bucket Flat 5.0 sec.
on Ground to Full Height)
(Includes Bucket Self-Leveling)
Maximum Cycle Time
Loader Boom Lower (Power 3.5 sec.
Down) (Full Up to Ground)
Maximum Cycle Time
Loader Boom Lower (Float Down) 3.6 sec.
(Full Up to Ground) Maximum
Cycle Time
Loader Bucket Dump (Bucket 1.8 sec.
Just Clears Ground) Maximum
Cycle Time
Loader Bucket Rollback (Bucket 2.3 sec.
Cycle Time
Backhoe Boom Raise (Backhoe 2.5 sec.
at Max. Reach With Bucket Teeth
on Ground up to Cylinder
Cushion) Maximum Cycle Time
Backhoe Boom Lower (Backhoe 2.2 sec.
at Max. Reach. Transport
Position to Bucket Teeth on
Ground) Maximum Cycle Time 9025
25
Crowd In (Boom in Transport 3.3 sec.
23
Position. Time Cycle to Cylinder
Cushion)) Maximum Cycle Time
Crowd Out Maximum Cycle Time 2.5 sec.
Backhoe Bucket Dump Maximum 2.0 sec.
Cycle Time
Backhoe Bucket Curl Maximum 2.5 sec.
Cycle Time
Backhoe Swing (Boom Raised to 2.7 sec.
Cushion, Bucket Curled,
Dipperstick Parallel to Ground.
Time Cycle to Cylinder Cushion)
Maximum Cycle Time
Stabilizer Down (Full Up to 2.5 sec.
Ground Level) Maximum Cycle
Time
Stabilizer Up (Ground Level to 2.1 sec.
Full Up) Maximum Cycle Time
Extendible Dipperstick Extend 2.4 sec.
and Retract Maximum Cycle Time

110703
PN=535
Tests
SPECIFICATIONS
Steering Right to Left Number of 4.5 turns
Turns
Steering Left to Right Number of 3.5 turns
Turns
Steering Right to Left (MFWD) 2.7 turns
Number of Turns
Steering Left to Right (MFWD) 2.7 turns
Number of Turns
Simulate Backhoe Bucket 12 sec.
Loading Cycle (Extend Backhoe
to Max. Reach. Simulate Loading
Bucket, Retract Dipperstick, and
Raise Boom to Cylinder Cushion)
Maximum Cycle Time
Loader Boom Raise (Bucket Flat 5.7 sec.
Maximum Cycle Time
Loader Boom Lower (Power 3.5 sec.
Maximum Cycle Time
Loader Boom Lower (Float Down) 3.6 sec.
(Full Up to Ground) Maximum
Cycle Time
Loader Bucket Dump (Bucket 2.2 sec.
Cycle Time
9025 Loader Bucket Rollback (Bucket 3.0 sec.
25 Just Clears Ground) Maximum
24 Cycle Time
Backhoe Boom Raise (Backhoe 2.7 sec.
Cushion) Maximum Cycle Time
Backhoe Boom Lower (Backhoe 3.9 sec.
Ground) Maximum Cycle Time
Crowd In (Boom in Transport 4.6 sec.
Position) Maximum Cycle Time
Crowd Out Maximum Cycle Time 3.4 sec.
Backhoe Bucket Dump Maximum 2.0 sec.
Cycle Time
Backhoe Bucket Curl Maximum 2.5 sec.
Cycle Time

110703
PN=536
Tests
SPECIFICATIONS
Backhoe Swing (Boom Raised to 3.1 sec.
Time Cycle to Cylinder Cushion)
Maximum Cycle Time
Stabilizer Down (Full Up to 2.5 sec.
Ground Level) Maximum Cycle
Time
Stabilizer Up (Ground Level to 2.1 sec.
Full Up) Maximum Cycle Time
Extendible Dipperstick Extend 3.2 sec.
and Retract Maximum Cycle Time
Steering Right to Left Number of 4.5 turns
Turns
Steering Left to Right Number of 3.5 turns
Turns
Steering Right to Left (MFWD) 2.7 turns
Number of Turns
Steering Left to Right (MFWD) 2.7 turns
Number of Turns

Digital Thermometer
NOTE: Backhoe function cycle times for 410D Heavy Lift

machines are the same as the 510D. 9025
25
25
Specification
EngineSpeed ........................................................................... 2000 rpm
3. Check cycle times.
410D Backhoe LoaderSpecification

Loader Boom Raise (Bucket Flat
Maximum Cycle Time .................................................................... 5.0 sec.
Loader Boom Lower (Power

110703
PN=537
Tests
Loader Boom Lower (Float Down)

(Full Up to Ground)Maximum
Cycle Time..................................................................................... 3.6 sec.
Loader Bucket Dump (Bucket
Just Clears Ground)Maximum
Cycle Time..................................................................................... 1.8 sec.
Loader Bucket Rollback (Bucket
Cycle Time..................................................................................... 2.3 sec.
Backhoe Boom Raise (Backhoe
Cushion)Maximum Cycle Time .................................................. 2.5 sec.
Backhoe Boom Lower (Backhoe
Ground)Maximum Cycle Time ................................................... 2.2 sec.
Crowd In (Boom in Transport
Position. Time Cycle to Cylinder
Cushion))Maximum Cycle Time................................................. 3.3 sec.
Crowd OutMaximum Cycle
Time ............................................................................................... 2.5 sec.
Backhoe Bucket Dump
Backhoe Bucket CurlMaximum
Cycle Time..................................................................................... 2.5 sec.
Backhoe Swing (Boom Raised to
Time Cycle to Cylinder
Stabilizer Down (Full Up to
9025 Ground Level)Maximum Cycle
25 Time ............................................................................................... 2.5 sec.
26 Stabilizer Up (Ground Level to
Full Up)Maximum Cycle Time ................................................... 2.1 sec.
Extendible Dipperstick Extend
and RetractMaximum Cycle
Time ............................................................................................... 2.4 sec.
Steering Right to LeftNumber of
Turns............................................................................................. 4.5 turns
Steering Left to RightNumber of
Turns............................................................................................. 3.5 turns
Steering Right to Left (MFWD)
Number of Turns .......................................................................... 2.7 turns
Steering Left to Right (MFWD)
Simulate Backhoe Bucket
Loading Cycle (Extend Backhoe
to Max. Reach. Simulate Loading
Bucket, Retract Dipperstick, and
Raise Boom to Cylinder
Cushion)Maximum Cycle Time ................................................... 12 sec.

110703
PN=538
Tests
510D Backhoe LoaderSpecification

Loader Boom Raise (Bucket Flat
Loader Boom Lower (Power
Loader Boom Lower (Float Down)
(Full Up to Ground)Maximum
Cycle Time..................................................................................... 3.6 sec.
Loader Bucket Dump (Bucket
Cycle Time..................................................................................... 2.2 sec.
Loader Bucket Rollback (Bucket
Cycle Time..................................................................................... 3.0 sec.
Backhoe Boom Raise (Backhoe
Backhoe Boom Lower (Backhoe
Ground)Maximum Cycle Time ................................................... 3.9 sec.
Crowd In (Boom in Transport
Position)Maximum Cycle Time .................................................. 4.6 sec.
Crowd OutMaximum Cycle
Time ............................................................................................... 3.4 sec.
Backhoe Bucket Dump
Backhoe Bucket CurlMaximum
Cycle Time..................................................................................... 2.5 sec. 9025
Backhoe Swing (Boom Raised to 25
Cushion, Bucket Curled, 27
Time Cycle to Cylinder
Stabilizer Down (Full Up to
Ground Level)Maximum Cycle
Time ............................................................................................... 2.5 sec.
Stabilizer Up (Ground Level to
Full Up)Maximum Cycle Time ................................................... 2.1 sec.
Extendible Dipperstick Extend
and RetractMaximum Cycle
Time ............................................................................................... 3.2 sec.
Steering Right to LeftNumber of
Turns............................................................................................. 4.5 turns
Steering Left to RightNumber of
Turns............................................................................................. 3.5 turns
Steering Right to Left (MFWD)

110703
PN=539
Tests
Steering Left to Right (MFWD)

The individual cycle times give an indication of any

restriction in a circuit.
The overall hydraulic system performance cycle time gives

an indication of low pump flow or low charge pressure. If
cycle time is slow, change hydraulic filter and check cycle
time again.
NOTE: If backhoe loading cycle time is greater than

specification, wear in main hydraulic pump is
indicated.
T60,9025,C132 1906APR946/6
9025
25
28

110703
PN=540
Tests
Relief Valve Testwith Remote Pump
SPECIFICATIONS
Relief Valve Maximum Flow 7.5 L/min (2 gpm)
Backhoe Circuits
Crowd Out Pressure 24 100 kPa (241 bar) (3500 psi)
Bucket Curl Pressure 24 100 kPa (241 bar) (3500 psi)
Boom Down Pressure 16 000 kPa (165 bar) (2400 psi)
Swing Left Pressure 19 500 kPa (195 bar) (2825 psi)
Crown In Pressure 20 500 kPa (205 bar) (2975 psi)
Bucket Dump Pressure 24 100 kPa (241 bar) (3500 psi)
Boom Raise Pressure 31 000 kPa (310 bar) (4500 psi)
Swing Right Pressure 19 500 kPa (195 bar) (2825 psi)
Loader Circuits
Auxiliary Extend Pressure 19 200 kPa (192 bar) (3000 psi)
(S.N. 801200 ) Boom Up 26200 kPa (262 bar) (3800 psi)
Pressure
System Relief Pressure 21 718 kPa (217 bar) (3150 psi)
ESSENTIAL TOOLS
JT07192 Electric/Hydraulic Pump
9025
38H1355 Nut
25
38H1470 Reducer 29
38H1356 Nut
38H1473 Reducer
38H1358 Nut
38H1475 Reducer
38H1481 Reducer

Gauge
Digital Thermometer

110703
PN=541
Tests
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.
NOTE: Relief valves may also be tested with an

amplification cylinder using machine hydraulics.
(See Relief Valve Test Using Amplification
Cylinder in this section.)
1. Operate hydraulic functions to relieve pressure.
Specification
Relief ValveMaximum Flow ....................................... 7.5 L/min (2 gpm)
9025
25
30

110703
PN=542
Tests
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. Disconnect pressure line (A) at inlet port of relief valve

to be tested. Cap line.
3. Connect test pump pressure hose (B) to inlet port

using adapters. Install gauge.
4. Start pump to pressurize valve inlet.
Specification
Backhoe CircuitsSpecification
Crowd OutPressure ............................ 24 100 kPa (241 bar) (3500 psi)
Bucket CurlPressure ........................... 24 100 kPa (241 bar) (3500 psi)
Boom DownPressure .......................... 16 000 kPa (165 bar) (2400 psi)
Swing LeftPressure ............................. 19 500 kPa (195 bar) (2825 psi)
UN18FEB94
Crown InPressure ............................... 20 500 kPa (205 bar) (2975 psi)
Bucket DumpPressure ........................ 24 100 kPa (241 bar) (3500 psi)
Boom RaisePressure .......................... 31 000 kPa (310 bar) (4500 psi)
Swing RightPressure .......................... 19 500 kPa (195 bar) (2825 psi)
T8187AJ
Loader CircuitsSpecification
Auxiliary ExtendPressure .................... 19 200 kPa (192 bar) (3000 psi)
Bucket CurlPressure ........................... 31 000 kPa (310 bar) (4500 psi) 9025
Bucket DumpPressure ........................ 31 000 kPa (310 bar) (4500 psi) 25
(S.N. 801200 ) Boom Up 31
Pressure .................................................. 26200 kPa (262 bar) (3800 psi)
Specification
System ReliefPressure ....................... 21 718 kPa (217 bar) (3150 psi)
NOTE: Take reading when pressure on gauge starts to

decrease. The point at which pressure decreases
is the opening pressure of the relief valve.
System relief can be tested by installing in circuit

relief port. Circuit relief must be in system relief
port during test.
5. Adjust if required.
TX,9025,BS329 1906APR943/3

110703
PN=543
Tests
Relief Valve Test Using Amplification

Cylinder
SPECIFICATIONS
Rod End Flow 3.78 L/min (1 gpm)
UN07JAN91
Engine Speed Approximately 1000 rpm
Rod Extend Cycle Time 1.5 seconds
Oil Pressure + 1380 - 0 kPa (+ 13.8 - 0 bar) (+
T7440BC
200 - 0)
Backhoe Circuits
Crowd Out Pressure 24 100 kPa (241 bar) (3500 psi) Gresen Valve Shown

Boom Down Pressure 16 000 kPa (165 bar) (2400 psi)
Swing Left Pressure 19 500 kPa (195 bar) (2825 psi)
Crown In Pressure 20 500 kPa (205 bar) (2975 psi)
Boom Raise Pressure 31 000 kPa (310 bar) (4500 psi)
UN07JAN91
Swing Right Pressure 19 500 kPa (195 bar) (2825 psi)
Loader Circuits
Auxiliary Extend Pressure 19 200 kPa (192 bar) (3000 psi)
T7440BD
(S.N. -801199) Gresen Valve Shown
(S.N. 801200 ) Boom Up 26200 kPa (262 bar) (3800 psi)
9025
Pressure AAuxiliary Plug
25
32 System Relief Pressure 21 718 kPa (217 bar) (3150 psi) BCrowd Out Relief
CBucket Curl Relief w/ anti-cavitation
DBoom Lower Relief w/ anti-cavitation
ESwing Left Relief w/ anti-cavitation
FSwing Right Relief w/ anti-cavitation
GBoom Raise Relief
HBucket Dump Relief
ICrowd In Relief w/ anti-cavitation
JAuxiliary Plug
KSystem Relief
LAuxiliary Retract Plug
MBoom Raise Plug
NBucket Curl Relief
OBucket Dump Relief
PBoom Lower Plug
QAuxiliary Extend Relief

110703
PN=544
Tests
ESSENTIAL TOOLS
6 M x 3/8 M Adapter
AH120121 Test Cylinder (Cancelled)
AH93323 Test Cylinder (Replaces AH120121)
38H1030 Tee
38H1031 Tee
38H1033 Tee
38H1002 Tee
38H1415 Cap
3/8 M x 3/8 F 90 Elbow
9/1618 M x 3/8 F Adapter
AT81867 Check Valve
1/4 M x 9/16 - 18 F 37 Adapter
Quick Coupler
1/8 M x 1/4 F Nipple
1/4 M x 1/4 F 90 Elbow
1/4 M x 1/4 F x 1/4 F Tee
9/16 M x 1/4 F Adapter
38H1146 Plug
38H1148 Plug
38H1149 Plug
38H1150 Plug
JT03408 Hydraulic Pump Flow Regulator
9025
SERVICE EQUIPMENT AND TOOLS 25
33
Hose
Gauge 2750 kPa (27.5 bar) (400 psi) (2 used)
Digital Thermometer
NOTE: Backhoe and loader valve work port and relief

locations are the same for Gresen and Husco
Valves. (S.N.801200 ) machines have a relief
valve for loader boom raise.
This test uses a test cylinder to amplify system pressure

2.25 times so reliefs can be opened and tested. Flow
regulator is used to restrict flow to relief to 3.8 L/min (1
gpm) to duplicate factory calibration specifications. Test
tee (B) can be installed at most accessible part of circuit
being tested.

110703
PN=545
Tests
IMPORTANT: Hydraulic system return pressure must

be subtracted from relief valve gauge
reading to get correct valve setting.
Test Cylinder:
TX,9025,BS331 1906APR943/7
NOTE: Remaining keys for Essential Tools are shown on

corresponding pages.
1. Lower stabilizer to ground.
2. Operate hydraulic control valves to relieve pressure in
UN26OCT88
the hydraulic system.
DCylinder
IAdapter
T6725AB
JJT03408 Hydraulic Flow Regulator
KElbow
LAdapter
9025
MCheck Valve
25
NAdapter
34
OQuick Coupler
PNipple
Q90 Elbow
RTee
SAdapter

110703
PN=546
Tests

UN23AUG88
fluids.
X9811
UN20MAR90
3. Install fitting (A) and hose (B) to connect 2750 kPa
(27.5 bar) (400 psi) gauge to return side of backhoe
valve.
T6900AL
Gresen Valve
CAUTION: Stabilizer control valve contains

9025
lock-outs, which prevent releasing of hydraulic 25
pressure when engine is off. Slowly loosen 35
stabilizer hoses to bleed off stored pressure to
prevent being sprayed with high pressure oil.
UN18FEB94
5. Install stabilizer hoses to test cylinder.
AAdapter
BTest Hose-to-Gauge
T8187AE
Husco Valve

110703
PN=547
Tests
1921MAR89
T6773AN
9025
25 ARod End Hose-To-Tee CGauge EStabilizer Hose (Rod End) G38H1415 Cap (2 used)
36 BTee DCylinder FStabilizer Hose (Head End)
6. Install adapter in relief valve port to be tested. Tee Specification

Rod ExtendCycle Time ................................................. 1.5 seconds
in test gauge (C) and rod end hose (A) from test
OilPressure..................................... + 1380 - 0 kPa (+ 13.8 - 0 bar)
cylinder. (+ 200 - 0)
Specification
Rod EndFlow..................................................... 3.78 L/min (1 gpm) 9. Activate stabilizer to extend test cylinder and record
highest pressure readings on gauge (C) and on
NOTE: Test system relief valve by removing and filter housing gauge as rod extends.
installing in circuit relief valve port. Install
circuit relief valve in system relief port. NOTE: If test cylinder stalls while extending cylinder
rod, do Main Pump Standby Pressure Test in
7. Start engine, use stabilizer lever to cycle test this group.
cylinder until temperature is to test specifications.
10. Subtract backhoe return pressure gauge reading
Specification from gauge (C) reading, compare this value with
OilTemperature ............................................ 40 6C (104 10F) specifications.
EngineSpeed ............................................. Approximately 1000 rpm
Backhoe CircuitsSpecification
8. Adjust JT03408 Hydraulic Flow Regulator (3) on Crowd OutPressure............................. 24 100 kPa (241 bar) (3500
head end of test cylinder, until rod extends in 1.5 psi)
seconds. Lock flow regulator at this setting.

110703
PN=548
Tests
Bucket CurlPressure ........................... 24 100 kPa (241 bar) (3500 Bucket DumpPressure ........................ 31 000 kPa (310 bar) (4500
psi) psi)
Boom DownPressure .......................... 16 000 kPa (165 bar) (2400 (S.N. 801200 ) Boom Up
psi) Pressure............................................ 26200 kPa (262 bar) (3800 psi)
Swing LeftPressure ............................. 19 500 kPa (195 bar) (2825
psi) Specification
Crown InPressure ............................... 20 500 kPa (205 bar) (2975 System ReliefPressure........................ 21 718 kPa (217 bar) (3150
psi) psi)
Bucket DumpPressure ........................ 24 100 kPa (241 bar) (3500
psi)
Boom RaisePressure .......................... 31 000 kPa (310 bar) (4500 11. Retract cylinder rod for next test cycle. Repeat
psi) steps 8 and 9 if required.
Swing RightPressure........................... 19 500 kPa (195 bar) (2825
psi) 12. Move tee (B) to next relief valve port to be tested.
Repeat steps 7 through 11.
Loader CircuitsSpecification
Auxiliary ExtendPressure .................... 19 200 kPa (192 bar) (3000
psi) IMPORTANT: To prevent structural damage of
Bucket CurlPressure ........................... 31 000 kPa (310 bar) (4500 machine, do not adjust relief valves
psi) above specifications.
13. Adjust or replace reliefs as required.
TX,9025,BS331 1906APR947/7
9025
25
37

110703
PN=549
Tests
Steering System Leakage Test

SPECIFICATIONS
Engine Speed Low idle
Steering Wheel Torque 11.3 Nm (100 lb-in.)
UN26OCT88
Steering System Maximum 5 rpm
Leakage
ESSENTIAL TOOLS
T93024
38H1145 Plug (2 used)
38H1138 Plug (2 used)
38H1352 Nut (2 used)

Digital Thermometer
1. Install digital thermometer.
2. Heat hydraulic oil to specifications.
Specification

9025
3. Put FNR lever in neutral and engage park brake.
25
38
4. Run the engine at low idle.
Specification
EngineSpeed ............................................................................. Low idle
5. Remove steering wheel emblem.
6. Bend locking tab away from steering wheel nut.
7. Turn the steering wheel clockwise at a constant torque

of 11.3 Nm (100 lb-in.) with wheels in the maximum
right position. Count the rpm.
Specification
Steering WheelTorque ........................................... 11.3 Nm (100 lb-in.)
Steering SystemMaximum
Leakage ............................................................................................. 5 rpm
8. Turn the steering wheel counterclockwise at a constant

torque of 11.3 Nm (100 lb in.) with wheels in the
maximum left turn position. Count the rpm.

110703
PN=550
Tests
9. If the steering wheel can be turned more than 5 rpm in

either direction, excessive leakage is indicated. Go to
steps 12-16 to isolate steering valve or cylinder
leakage.
10. If the steering wheel cannot be turned more than 5

rpm in both directions, the steering valve and cylinder
are good. Stop the test here. Continue with steps 11
thru 16 if steering wheel can be turned more than 5
rpm.
11. Stop the engine.
TX,902525,BS170 1924MAY932/4

9025
UN23AUG88
25
Protect hands and body from high pressure 39
fluids.
X9811
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
12. Operate all hydraulic control valves to release

pressure in system.

110703
PN=551
Tests
13. Disconnect hydraulic lines from steering cylinder and

install caps (B) and plugs (A).
14. Start the engine and run at low idle.
15. Turn steering wheel counterclockwise and then

clockwise at a constant torque of 11.3 Nm (100
lb-in.). Count the rpm.
16. If steering wheel can be turned more than 5 rpm in

either direction, steering valve is leaking excessively.
UN25MAY89
T6076AM
Two Wheel Drive Axle Shown
TX,902525,BS170 1924MAY934/4
9025
25
40

110703
PN=552
Tests
Steering Cylinder Leakage Test
SPECIFICATIONS
Steering Cylinder Maximum 5 ml/min (1/6 oz/min)
Leakage
ESSENTIAL TOOLS
38H1145 Plug

Digital Thermometer
Specification
3. Start engine. Turn the steering wheel to left turn stop

to extend cylinder rod. Stop engine. Move steering
wheel back and forth to relieve hydraulic pressure.
9025
25
41
Continued on next page T60,9025,1065 1921JUL941/2

110703
PN=553
Tests
4. Remove rod end hose and plug (A).Put beaker under

cylinder port after oil stops dripping.
5. Start engine and hold steering wheel in full left turn

with constant pressure for one minute.
Specification
Stop engine.
6. Measure oil collected and connect hose.
Specification
UN25MAY89
Steering CylinderMaximum
Leakage .................................................................... 5 ml/min (1/6 oz/min)
T6076AL
Axle Without MFWD Shown
T60,9025,1065 1921JUL942/2
9025
25
42
Steering Valve Neutral Drift Test
SPECIFICATIONS
Oil Temperature 40 10C (100 20F) (cylinders
warm to touch)
Engine Speed Fast idle
Steering Cylinder Rod Maximum 5 mm/min (0.20 in./min)
Drift

110703
PN=554
Tests
1. Heat hydraulic oil to specifications.
Specification
OilTemperature ................................. 40 10C (100 20F) (cylinders
warm to touch)
2. Raise front wheels off of ground with loader bucket.

Position wheels straight ahead, measure and record
steering cylinder rod length sticking out of cylinder.
3. Lower stabilizers and operate backhoe for five minutes

at fast idle.
Specification
EngineSpeed ............................................................................ Fast idle
UN25MAY89
4. Stop engine and remeasure steering cylinder rod. The
difference between this reading and one in Step 1 is
drift.
T6076AN
Specification
Steering Cylinder RodMaximum
Drift ....................................................................... 5 mm/min (0.20 in./min) Two Wheel Drive Axle Shown
5. Repair as necessary. See repair manual.
NOTE: Excessive neutral drift will not affect steering 9025

25
control when driving unit.
43
TX,902525,BR119 1906APR942/2

110703
PN=555
Tests
Hydraulic Component Leakage Test

SPECIFICATIONS
Hydraulic Oil Temperature 40 4C (104 7F)
Hydraulic Component Maximum See each component
Leakage
Steering Valve Maximum 900 mL/min (30 oz/min)
Leakage
Pump Seal Maximum Leakage 2 mL/min (0.07 oz/min)
Gresen Loader Valve 2 Section 200 mL/min (7 oz/min)
Maximum Leakage
Gresen Loader Valve 3 Section 320 mL/min (11 oz/min)
Maximum Leakage
Gresen Loader Valve Work Port 31 mL/min (1 oz/min)
Maximum Leakage
Husco Loader Valve 2 Section 1000 mL/min (34 oz/min)
Maximum Leakage
Husco Loader Valve 3 Section 1200 mL/min (40 oz/min)
Maximum Leakage
Husco Loader Valve Work Port 1 mL/min (0.03 oz/min)
Maximum Leakage
Gresen Backhoe Valve 4 Section 1000 mL/min (34 oz/min)
Maximum Leakage
Gresen Backhoe Valve 5 Section 1050 mL/min (36 oz/min)
Maximum Leakage
9025 Gresen Backhoe Valve Work Port 60 mL/min (2 oz/min)
25 Maximum Leakage
44
Husco Backhoe Valve 4 Section 3800 mL/min (130 oz/min)
Maximum Leakage
Husco Backhoe Valve 5 Section 4000 mL/min (136 oz/min)
Maximum Leakage
Husco Backhoe Valve Work Port 1 mL/min (0.03 oz/min)
Maximum Leakage
Stabilizer Valve Spool Maximum 500 mL/min (17 oz/min)
Leakage
Stabilizer Valve Cylinder 0.15 mm/min (.006 in/min)
Maximum Drift

Digital Thermometer


110703
PN=556
Tests
2. Heat hydraulic oil to 40 4C (104 7F).
Specification
Hydraulic OilTemperature ..................................... 40 4C (104 7F)
3. Excessive heat in a return line can indicate leakage in

that component.
Specification
Hydraulic ComponentMaximum
Leakage .................................................................... See each component
If one return line is hotter than the others check that

component first.
TX,902525,BR118 1924MAY932/8

9025
UN23AUG88
25
Protect hands and body from high pressure 45
fluids.
X9811
4. Disconnect return lines for hydraulic components, one

at a time, to check for leakage, install cap on fitting.
5. Start engine.
Specification
EngineSpeed .................................................................. 1000 10 rpm

110703
PN=557
Tests
Specification
Steering ValveMaximum
Leakage ................................................................ 900 mL/min (30 oz/min)
ASteering Valve Return Line

BReservoir Inlet
UN07JAN91
T7440BL
410D (S.N. - 796854) Shown
UN18FEB94
T8187AI
410D (S.N.796855 - ) Shown
TX,902525,BR118 1924MAY934/8
9025
25
46
Specification
Pump SealMaximum Leakage ........................... 2 mL/min (0.07 oz/min)
If leakage is excessive, check pump shaft for excessive

end play.
Specification
UN10JAN91
Gresen Loader Valve 2 Section
Maximum Leakage ................................................. 200 mL/min (7 oz/min)
Gresen Loader Valve 3 Section
Maximum Leakage ............................................... 320 mL/min (11 oz/min)
T7440BJ
Gresen Loader Valve Work
PortMaximum Leakage ......................................... 31 mL/min (1 oz/min)
Husco Loader Valve 2 Section
Maximum Leakage ............................................. 1000 mL/min (34 oz/min) 410D (S.N. - 796854) Shown
Husco Loader Valve 3 Section
Maximum Leakage ............................................. 1200 mL/min (40 oz/min)
Husco Loader Valve Work Port
Maximum Leakage ................................................ 1 mL/min (0.03 oz/min)
APump Seal Drain Line

BReservoir inlet
UN18FEB94
T8187AH
410D (S.N.796855 - ) Shown


110703
PN=558
Tests
NOTE: Husco valve sections contain a bleed orifice which

allows any inlet pressure leakage past the spool
to bleed to return. This minimizes power drift. As
a result Husco maximum leakage specifications
are higher than Gresen.
UN07JAN91
1. Disconnect loader valve return line (A), cap fitting and
measure leakage at line.
2. If valve return leakage is high, perform individual work
T7440BM
port leakage test using beaker to collect oil.
Specification
Gresen Backhoe Valve 4 ALoader Valve Return Line
SectionMaximum Leakage.............................. 1000 mL/min (34 oz/min)
Gresen Backhoe Valve 5
SectionMaximum Leakage.............................. 1050 mL/min (36 oz/min)
Gresen Backhoe Valve Work
PortMaximum Leakage ......................................... 60 mL/min (2 oz/min)
Husco Backhoe Valve 4
SectionMaximum Leakage............................ 3800 mL/min (130 oz/min)
Husco Backhoe Valve 5
SectionMaximum Leakage............................ 4000 mL/min (136 oz/min)
Husco Backhoe Valve Work
PortMaximum Leakage ...................................... 1 mL/min (0.03 oz/min)
9025
25
47

110703
PN=559
Tests
NOTE: Husco valve sections contain a bleed orifice which

allows any inlet pressure leakage past the spool
to bleed to return. This minimizes power drift. As
a result Husco maximum leakage specifications
are higher than Gresen.
UN07JAN91
1. Disconnect backhoe return line (B), cap line and fitting.
2. Disconnect stabilizer return line (A) and cap line.
T7440BN
3. Measure leakage at fitting (C).
4. If valve return leakage is high, perform individual work Gresen Valve Shown
port leakage test using beaker to collect oil.
ABackhoe Valve Return Line
Specification
Stabilizer Valve SpoolMaximum
Leakage ................................................................ 500 mL/min (17 oz/min)
Stabilizer Valve Cylinder
Maximum Drift .................................................. 0.15 mm/min (.006 in/min)
TX,902525,BR118 1924MAY937/8
9025
25
48
1. To check cylinder drift lower stabilizers to lift machine
off ground. Check for cylinder rod movement with dial
indicator.
2. Remove stabilizer valve return line (A) to measure

spool leakage.
UN07JAN91
NOTE: Stabilizer valve has lockouts to prevent cylinder
drift up or down. If drift is above specification
remove lockout and check for scratches on seat
and poppet. Check for contamination in the T7440BO
thermal relief poppet seat. Also check the cylinder

packings, and the lockout plunger spool which Gresen Valve Shown
slides between the two lockouts . If the lockout
plunger spool is stuck it can hold a lockout open.
AStabilizer Valve Return Line

UN26OCT88
T6222AN
TX,902525,BR118 1924MAY938/8

110703
PN=560
Tests
Hydraulic Cylinder Drift Test Procedure
9025
25
49
1923FEB93
T7949AC
TX,902525,BS230 1909MAR931/1

110703
PN=561
Tests
Function Drift Test

SPECIFICATIONS
Backhoe Function Maximum Drift 75 mm/min (3.00 in/min)
Loader Function Maximum Drift 50 mm/min (2.00 in/min)
BH Bucket Cylinder Maximum 8 mm/min (0.31 in/min)
Drift
BH Crowd Cylinder (Gresen) (Std 6 mm/min (0.25 in/min)
& Ext) Maximum Drift
BH Crowd Cylinder (Husco) (Std 4 mm/min (0.16 in/min)
BH Boom Cylinder (Gresen) (Std 3 mm/min (0.12 in/min)
BH Boom Cylinder (Husco) (Std 5 mm/min (0.20 in/min)
Swing Function Maximum Drift 300 mm/min (12.00 in/min)
Loader Boom and Bucket 3 mm/min (0.12 in/min)
Cylinder Maximum Drift
John Deere Ext. Dipper Cylinder 7 mm/min (0.28 in/min)
Maximum Drift

Digital Thermometer
9025
25 NOTE: The following tests are used to check leakage
50 past the cylinder piston seals and through the
main control valve spool and reliefs. Weighting the
machine is not required to perform these tests. On
extendable dipperstick machines fully retract
dipperstick for all testing.
1. Install digital thermometer probe in reservoir. Warm

hydraulic oil to specifications.
Specification
(See Hydraulic Oil Warm-Up Procedure in this group.)
Continued on next page TX,9025,DY45 19 9JUL961/5

110703
PN=562
Tests
Function Drift
1. Position backhoe bucket side cutters at 45 angle to

ground and lower boom until bucket cutting edge is 75
mm (3.00 in.) off ground.
UN25FEB93
Specification
Backhoe FunctionMaximum
Drift ...................................................................... 75 mm/min (3.00 in/min)
2. Position level loader bucket cutting edge 50 mm (2.00
T7949AE
in.) off ground.
3. Run engine at slow idle and observe bucket cutting

edges for one minute.
Specification
Loader FunctionMaximum Drift........................ 50 mm/min (2.00 in/min)
NOTE: If bucket cutting edges touch the ground within

one minute, excessive leakage is indicated in the
cylinders or control valve.

9025
25
51

110703
PN=563
Tests
Backhoe Cylinder Drift
1. Position machine as shown, with the bucket pivot pin

one meter (36 in.) off ground.
2. Position the crowd cylinder with rod 2050 mm
UN26MAR93
(0.752.00 in.) extended from the fully retracted
position.
3. Position the bucket cylinder with rod 2050 mm
T7949AF
(0.752.00 in) retracted from the fully extended
position.
4. Measure movement of boom, crowd, and bucket

cylinders for five minutes. Divide measured rod drift by
five to determine drift per minute.
Specification
BH Bucket CylinderMaximum
UN26MAY89
Drift ........................................................................ 8 mm/min (0.31 in/min)
BH Crowd Cylinder (Gresen) (Std
& Ext)Maximum Drift .......................................... 6 mm/min (0.25 in/min)
BH Crowd Cylinder (Husco) (Std
T6222AM
BH Boom Cylinder (Gresen) (Std
BH Boom Cylinder (Husco) (Std
9025
25 5. To measure swing drift tilt machine by fully extending
52 RH stabilizer. Fully extend dipperstick and bucket, so
bucket is approximately 300 mm (12 in.) off ground.
Boom should be parallel to ground. Position LH
stabilizer 75 mm (3 in.) off ground.
UN25FEB93
6. 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
T7949AG
minute.
Specification
Swing FunctionMaximum Drift ..................... 300 mm/min (12.00 in/min)
7. Measure swing drift in opposite direction by reversing

stabilizer positions and vertical rod.

110703
PN=564
Tests
Loader Cylinder Drift
1. Position the machine as shown with the loader bucket

pivot pin one meter (36 in.) above ground, with bucket
level.
UN25FEB93
2. Measure movement of boom and bucket cylinders for
five minutes. Divide measured rod drift by five to
determine drift per minute.
T7949AH
Specification
Loader Boom and Bucket
CylinderMaximum Drift....................................... 3 mm/min (0.12 in/min)
TX,9025,DY45 19 9JUL964/5
Extendable Dipperstick Cylinder Drift
Machine in transport position. Mark or tape end of

exposed internal dipperstick tube. Measure drift from end
of external dipperstick housing for five minutes. Divide
measured drift by five to determine drift per minute. 9025
UN26MAY89
25
Specification 53
John Deere Ext. Dipper
CylinderMaximum Drift....................................... 7 mm/min (0.28 in/min)
T6222AM
TX,9025,DY45 19 9JUL965/5

110703
PN=565
Tests
Cylinder Leakage Test

SPECIFICATIONS
Cylinder Maximum Leakage 5 ml/min (1/6 oz/min)
UN26OCT88
ESSENTIAL TOOLS
38H1353 Nut
T6222AL
38H1139 Plug
38H1354 Nut
38H1140 Plug
38H1146 Plug
38H1147 Plug

Digital Thermometer
Specification
9025 3. Start engine.

25
54 Specification
Fully extend cylinder rod. Stop engine. Activate a

hydraulic function to relieve pressure in the system.
4. Remove rod end hose and plug hose. Use a

measuring beaker, after oil stops dripping, to catch oil.
This can also be done at control valve, which would
require capping control valve port and putting hose end
into measuring beaker after oil stops dripping.
5. Start engine and actuate cylinder extend function for

one minute.
6. Stop engine. Measure oil collected and connect hose.
Specification
CylinderMaximum Leakage .................................. 5 ml/min (1/6 oz/min)
7. Repair as necessary. (See repair manual.)
Continued on next page T60,9025,1068 1921JUL941/2

110703
PN=566
Tests
8. Repeat procedure to test each cylinder.
T60,9025,1068 1921JUL942/2
MFWD Valve Test 410D (S.N. 796854) 510D

(S.N. 796890)
SPECIFICATIONS
Oil Temperature 40 6 (100 + 10F)
Inlet Minimum Pressure (Steering 2068 kPa (20 bar) (300 psi)
In Neutral)
MFWD Engagement Pressure 1034 35 kPa (103 1.4 bar)
(150 20 psi)
MFWD Valve Maximum Leakage 160 ml/min (5.5 oz/min)
(With MFWD OFF)
ESSENTIAL TOOLS
38H1030 Tee

5000 psi Gauge (2 used)
Digital Thermometer
9025
25
55
fluids.

1. Disconnect pressure inlet hose at MFWD valve.

110703
PN=567
Tests
2. Install tee and 5000 psi gauge (A). Record inlet

pressure and compare to specification.
Specification
OilTemperature ...................................................... 40 6 (100 + 10F)
InletMinimum Pressure
(Steering In Neutral) ...................................... 2068 kPa (20 bar) (300 psi)
Connect hose to MFWD valve.
3. Disconnect hose from MFWD valve to MFWD clutch at

valve.
4. Install tee and 300 psi gauge (B). Record MFWD

disengagement pressure and compare to specification.
Specification
MFWD EngagementPressure ................ 1034 35 kPa (103 1.4 bar)
(150 20 psi)
Adjust pressure reducing valve (D) if not to specification.
UN18MAY93
Replace pressure reducing valve if it will not adjust.
Connect hose to MFWD valve.
5. Disconnect drain hose (C) to transmission at MFWD
T8011AK
valve. Place beaker under valve drain port. Record
leakage with MFWD switch "OFF".
9025
25 Specification AInlet Pressure Tee and Gauge
56 MFWD ValveMaximum BEngagement Pressure Tee and Gauge
Leakage (With MFWD OFF) ............................... 160 ml/min (5.5 oz/min) CDrain Hose
DPressure Reducing Valve
ESolenoid
6. Remove and inspect solenoid (E) and pressure
reducing valve (D) for o-ring and backup ring failures if
leakage exceeds specification.
TX,9025,BS340 1906APR942/2

110703
PN=568
Tests
Flowmeter Calibration Procedure
SPECIFICATIONS
Oil Temperature 60C (140F)
49 cc (3 cu in.) Radial Piston 38114 L/min (1030 gpm)
Pump Flowmeter Reading
98 cc (6 cu in.) Radial Piston 76228 L/min (2060 gpm)
Pump Flowmeter Reading

Digital Thermometer
To prevent error in tests using a flowmeter, check

calibration using a John Deere Radial Piston Pump as a
test source.

9025
25
57

110703
PN=569
Tests

UN23AUG88
fluids.
X9811
1. Connect flowmeter inlet hose as close as possible to

main pump outlet.

3. Heat oil to 60C (140F).
9025 Specification
25 OilTemperature .................................................................. 60C (140F)
58
See procedure in this group.
4. Open flowmeter. Adjust engine speed to 1800 10

rpm.
Specification
EngineSpeed .................................................................. 1800 10 rpm
Record flow.
Close flowmeter until pressure reaches 10 340 kPa (103.4

bar) (500 psi). Adjust engine speed to 1800 10 rpm.
Record flow.
Specification
49 cc (3 cu in.) Radial Piston
PumpFlowmeter Reading ........................ 38114 L/min (1030 gpm)
98 cc (6 cu in.) Radial Piston
PumpFlowmeter Reading ........................ 76228 L/min (2060 gpm)

110703
PN=570
Tests
High pressure flow must be 95% or more of low pressure

flow or pump cannot be used for test.
5. Open flowmeter to minimum restriction. Adjust voltage

calibration and zero flowmeter.
6. Record rpm versus flow at the low, medium and high

range of flowmeter.
Example: When checking a 284 L/min (75 gpm)

flowmeter, check rpm at 76, 151 and 227 (L/min (20,
30 and 60 gpm).
7. Use chart to find recorded rpm for size of pump on test

tractor. Note specified flow and compare to measure
flow.
9025
25
59

110703
PN=571
Tests
L/min (gpm) rpm L/min (gpm) rpm L/min (gpm) rpm L/min (gpm) rpm
98 cc (6 cu in.) Pump Specs
76 (20) 811 114 (30) 1216 151 (40) 1621 189 (50) 2026
80 (21) 851 117 (31) 1256 155 (41) 1661 193 (51) 2066
83 (22) 892 121 (32) 1297 159 (42) 1702 197 (52) 2107
87 (23) 932 125 (33) 1337 163 (43) 1742 201 (53) 2147
91 (24) 973 129 (34) 1378 167 (44) 1783 204 (54) 2188
95 (25) 1013 132 (35) 1418 170 (45) 1823 208 (55) 2228
98 (26) 1054 136 (36) 1459 174 (46) 1864 212 (56) 2269
102 (27) 1094 140 (37) 1499 178 (47) 1904 216 (57) 2309
106 (28) 1135 144 (38) 1540 182 (48) 1945 220 (58) 2350
110 (29) 1175 148 (39) 1580 185 (49) 1985 223 (59) 2390
227 (60) 2431
38 (10) 811 57 (15) 1216 76 (20) 1621 95 (25) 2026
42 (11) 892 61 (16) 1297 80 (21) 1702 98 (26) 2107
45 (12) 973 64 (17) 1378 83 (22) 1783 102 (27) 2188
49 (13) 1054 68 (18) 1459 87 (23) 1864 106 (28) 2269
53 (14) 1135 72 (19) 1540 91 (24) 1945 110 (29) 2350
114 (30) 2431
53 (14) 851 79 (21) 1277 106 (28) 1702 132 (35) 2127
57 (15) 911 83 (22) 1337 110 (29) 1763 136 (36) 2188
9025 61 (16) 972 87 (23) 1398 114 (30) 1823 140 (37) 2250
25
60 64 (17) 1033 91 (24) 1459 117 (31) 1884 144 (38) 2310
68 (18) 1094 95 (25) 1520 121 (32) 1945 148 (39) 2370
72 (19) 1155 98 (26) 1580 125 (33) 2006 151 (40) 2431
76 (20) 1215 102 (27) 1641 129 (34) 2067
TX,902525,BR117 1924MAY934/4

110703
PN=572
Section 9031
Heating And Air Conditioning
Contents
Page Page
Group 05Theory Of Operation Recover R134a System . . . . . . . . . . . . . . .9031-20-12

Proper Refrigerant Handling . . . . . . . . . . . . .9031-05-1 Evacuate R134a System . . . . . . . . . . . . . . .9031-20-13
R12 And R134a Refrigerant Cautions . . . . . .9031-05-1 Charge R134a System . . . . . . . . . . . . . . . .9031-20-15
Refrigerant Theory Of Operation . . . . . . . . . .9031-05-2 Check And Adjust Compressor Belt
Air Conditioning Circuit Operational Tension . . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-16
Information. . . . . . . . . . . . . . . . . . . . . . . . .9031-05-3
Air Conditioning Circuit Theory Of Group 25Test
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-4 Proper Refrigerant Handling . . . . . . . . . . . . .9031-25-1
Air Conditioning Circuit Schematic. . . . . . . . .9031-05-5 R12 And R134a Refrigerant Cautions . . . . . .9031-25-1
Blower Circuit Operational Information . . . . .9031-05-6 R134a Air Conditioning System Test . . . . . . .9031-25-2
Blower Circuit Theory Of Operation. . . . . . . .9031-05-6 Pressure Diagnostic Chart. . . . . . . . . . . . . . .9031-25-4
Blower Circuit Schematic. . . . . . . . . . . . . . . .9031-05-7 Low Pressure Switch Test. . . . . . . . . . . . . . .9031-25-5
Receiver/Dryer Operation . . . . . . . . . . . . . . .9031-05-8 High Pressure Switch Test . . . . . . . . . . . . . .9031-25-7
Expansion Valve Operation . . . . . . . . . . . . .9031-05-10 Clutch Cycle Switch . . . . . . . . . . . . . . . . . . .9031-25-9
Compressor Relief Valve Operation . . . . . .9031-05-11 Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .9031-25-10
Temperature Control . . . . . . . . . . . . . . . . . .9031-05-11 Refrigerant Hoses And Tubing
Inspection . . . . . . . . . . . . . . . . . . . . . . . .9031-25-10
Air Conditioning Operational Checks . . . . . . .9031-10-1
Visual Inspection Of Components . . . . . . . . .9031-10-1
System Operating Checks. . . . . . . . . . . . . . .9031-10-3
System Performance Checks . . . . . . . . . . . .9031-10-5
Blower/Air Conditioning Circuit Checks . . . . .9031-10-6
9031
Group 15Diagnostic Information
Diagnose Air Conditioning Electrical
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9031-15-1
Air Conditioning Component Location . . . . . .9031-15-2
Group 20Adjustments
Proper Refrigerant Handling . . . . . . . . . . . . .9031-20-1
R12 And R134a Refrigerant Cautions . . . . . .9031-20-1
R12 Component Oil Charge . . . . . . . . . . . . .9031-20-2
R12 Refrigerant Recovery, Recycling Station
Installation Procedure . . . . . . . . . . . . . . . .9031-20-3
R12 Refrigerant Evacuation And Charging
Station Installation Procedure . . . . . . . . . .9031-20-4
Recover R12 System . . . . . . . . . . . . . . . . . .9031-20-5
Evacuate R12 System. . . . . . . . . . . . . . . . . .9031-20-6
Charge R12 System . . . . . . . . . . . . . . . . . . .9031-20-8
R134a Compressor Oil Charge Check . . . . .9031-20-9
R134a Compressor Oil Removal . . . . . . . . . .9031-20-9
R134a Component Oil Charge . . . . . . . . . .9031-20-10
R134a Refrigerant Recovery, Recycling
And Charging Station Installation
Procedure . . . . . . . . . . . . . . . . . . . . . . . .9031-20-11

110703
PN=1
Contents
9031

110703
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
TX,9031,QQ2009 1919AUG941/1
R12 And R134a Refrigerant Cautions
Keep refrigerant containers away from heat

CAUTION: DO NOT allow liquid refrigerant to
sources. Store refrigerant in a cool place.
contact eyes or skin. Liquid refrigerant will
freeze eyes or skin on contact. Wear
DO NOT handle damp refrigerant container
goggles, gloves and protective clothing.
with your bare hands. Skin may freeze to
container. Wear gloves.
If liquid refrigerant contacts eyes or skin, DO
NOT rub the area. Splash large amounts of
If skin freezes to container, pour COOL
COOL water on affected area. Go to a
water over container to free the skin. Go to a
physician or hospital immediately for 9031
treatment.
treatment. 1
DO NOT allow refrigerant to contact open

(R12 ONLY) Refrigerant exposed to high
flames or very hot surfaces such as electric
temperature forms phosgene gas. Inhaling
welding arc, electric heating element and
toxic phosgene gas may result in serious
lighted smoking materials.
illness or death. Phosgene gas has an odor
like new mown hay or green corn. If you
DO NOT heat refrigerant over 52C (125F) in
inhale phosgene gas, go to a physician or
a closed container. Heated refrigerant will
hospital immediately for treatment.
develop high pressure which can burst the
container.
TX,9031,QQ2010 1917JUN941/1

110703
PN=575
Theory Of Operation
Refrigerant Theory Of Operation
1920OCT97
T7828AX
ACompressor ECondenser IExpansion Valve LBlowers
BLow Pressure Switch FEngine Fan JLow Pressure Liquid MClutch Cycle Switch
CHigh Pressure Switch GHigh Pressure Liquid KEvaporator NLow Pressure Gas
DHigh Pressure Gas HReceiver Dryer
9031
05
2 The compressor (A) draws low pressure gas (N) from the refrigerant causes it to condense and it leaves the
the evaporator (K) and compresses it into high condenser (E) as a high pressure liquid (G). The high
pressure gas (D). Increasing the pressure of the pressure liquid flows into the receiver-dryer (H) where
refrigerant causes its boiling point to rise to a moisture and contaminants are removed.
temperature higher than the outside air temperature.
The refrigerant flows from the receiver-dryer (H) to the
High pressure gas (D) leaves the compressor (A) and expansion valve (I). The expansion valve (I) is a
passes through two switches (B and C). These variable orifice used to cause a pressure and
switches monitor refrigerant pressure. Should the temperature drop in the refrigerant causing refrigerant
pressure become too great or too small, either the high to vaporize. The expansion valve (I) is one of the
or low pressure switch will open and stop the dividing lines between the high side and low side of
compressor, interrupting the cycle. the air conditioning system. At this point in the system,
the high pressure/high temperature liquid is sprayed
As the high pressure gas flows through the condenser into the evaporator (K) where it changes and becomes
(E), the engine fan (F) draws air through the a gas.
condenser core which cools the refrigerant. Cooling

110703
PN=576
Theory Of Operation
The expansion valve diaphragm is activated by evaporator outlet. The low temperature causes the
sensing temperature and pressure within the valve expansion valve variable orifice to decrease in size,
body. The internal bulb senses the evaporator outlet or restricting refrigerant flow. If the evaporator outlet
discharge temperature and pressure of refrigerant as it temperature is too warm, the orifice will increase in
passes through the valve back to the low pressure or size, allowing more refrigerant into evaporator.
suction side of the compressor. (See Expansion Valve
Operation in this group for additional information on If evaporator (K) temperature becomes too low, the
theory of operation.) clutch cycle switch (M) will interrupt current flow to the
compressor clutch coil, stopping system operation until
If too much refrigerant is flowing into evaporator, the the temperature becomes normal, between 31 and
liquid refrigerant will still be evaporating as it leaves 40.
the evaporator, causing a low temperature at the
TX,9031,QQ2011 1917JUN942/2
Air Conditioning Circuit Operational

Information
The following conditions must exist for air conditioning

Key switch ON
Machine running
Air conditioning switch turned ON
Blower switch turned to low, medium or high
9031
05
TX,9031,QQ1840 1917JUN941/1
3

110703
PN=577
Theory Of Operation
Air Conditioning Circuit Theory Of Operation
Power from 30 amp heater fuse flows through P16 red High Pressure Switch
and 518 red wires to blower switch. With blower switch
turned to low, medium or high position, power flows to The high pressure switch protects the system from
blower resistor and then to heater blower motors. high pressure. If a malfunction or line restriction
causes the high pressure to increase above the setting
Power also flows from C terminal of blower switch, of the switch, the switch will open to stop current flow
through 522 white wire to clutch cycle switch, through to the compressor clutch. The high pressure switch is
517 dark blue wire to air conditioning switch. located near the compressor in the high pressure line.
With air conditioning switch turned ON, power flows Clutch Cycle Switch
through A17 orange wire to the low pressure switch.
With low pressure switch closed, power flows through The clutch cycle switch is used to sense the
A18 green wire to high pressure switch. With high temperature in the evaporator core. When the
pressure switch closed power flows through A19 green temperature drops, the clutch cycle switch opens,
wire to the coil terminal of the compressor coil to shutting the compressor off. When the temperature in
energize the compressor clutch. the evaporator core raises, the clutch cycle switch
closes sending voltage to the compressor.
Low Pressure Switch
The clutch cycle switch receives power from the
The low pressure switch will open if the air blower switch when blower switch is turned to low,
conditioning system loses its refrigerant charge. The medium or high position.
switch opens to stop current flow to the compressor
which prevents compressor engagement. The low NOTE: For component identification code description
pressure switch is located near the compressor in high see Wiring and Schematic Diagrams Legend ,
pressure line. Group 9015-10.
9031
05
TX,9031,QQ1841 1917JUN941/1
4

110703
PN=578
Theory Of Operation
Air Conditioning Circuit Schematic
9031
05
5
1924SEP92
T7835AU
TX,90310,QQ1842 1917JUN941/1

110703
PN=579
Theory Of Operation
Blower Circuit Operational Information
The following conditions must exist for blower circuit to

function:
Key switch in ON or ACC position

Blower switch turned ON
TX,9015,QQ1818 1917JUN941/1
Blower Circuit Theory Of Operation
Power from heater circuit breaker goes to blower switch.

With blower switch in low position power is sent to blower
resistor. Voltage goes through complete resistor and is
reduced to 3.03.5 volts, blower motor runs in low speed.
With blower switch in medium position power is sent

through half the blower resistor and is reduced to 6.06.5
volts, blower motor runs in medium speed.
With blower switch in high position power by-passes

resistor and 12 volts is applied to blower motor, causing it
to run at high speed.

9015-10.
9031
05
6
TX,9015,QQ1766 1917JUN941/1

110703
PN=580
Theory Of Operation
Blower Circuit Schematic
9031
05
7
1930SEP92
T7857AD
TX,901515,QQ809 1917JUN941/1

110703
PN=581
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.
UN19OCT93
The receiver/dryer also contains two filters (E) and
desiccant (F) between the filters. The filters remove solid
materials which could be generated by a compressor
failure, debris left in the system due to improper service
T8104AE
procedures, or particles caused by corrosion of metal
parts due to moisture and acids in the system (also
caused by improper service procedures).
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
UN10JAN94
8
hydrochloric acids are formed. These acids are very
corrosive to metal surfaces and leakage will eventually
develop. If the air conditioning system is left open for a
T8104AF
period of time or if the plugs are removed from the
receiver/dryer, the desiccant will also absorb moisture
from the air. The receiver/dryer contains a color moisture
indicator. (Blue) indicates dryer is dry. (Pink) indicates AInlet Port
moisture in the desiccant. Evacuating the system will not BSight Glass
remove moisture from the desiccant. You must replace COutlet Port
DPickup Tube
the receiver/dryer.
EFilter
FDesiccant
GStrainer
HSpring
IReceiver/Dryer
JWet/Dry Indicator

110703
PN=582
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.
TX,9031,QQ2341 1917JUN942/2
9031
05
9

110703
PN=583
Theory Of Operation
Expansion Valve Operation
1924SEP92
T7828AY
AValve Diaphragm DOperating Pin GValve Spring JDischarge from Evaporator
BSealed Sensing Bulb EInlet Flow HBall Seat KInternal Equalization
COutlet to Compressor FMetering Orifice IOutlet to Evaporator Passage
9031
05 The expansion valve is used to regulate the amount of The metering orifice (F) and ball seat area (H) in the
10 refrigerant flowing into the evaporator. At this point in expansion valve is relatively small. The rapidly
the system, the high pressure/high temperature liquid expanding refrigerant passing through this area can
is sprayed into the evaporator where it changes state cause any moisture in the system to freeze at this
and becomes a gas. point and block refrigerant flow. Other contaminants in
the system can also cause a valve to malfunction. If
The valve diaphragm (A) is activated by sensing expansion valve malfunctions, it must be replaced.
temperature and pressure within the valve body. The Expansion valve is not repairable.
sealed sensing bulb (B) senses the evaporator outlet
(I) or discharge temperature and pressure of the
refrigerant as it passes through the valve back to the
low pressure or suction side of the compressor.
TX,9031,QQ2012 1917JUN941/1

110703
PN=584
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.
TX,9031,QQ1879 1917JUN941/1
Temperature Control
Temperature control is adjusted by the position of the

heater temperature switch in the cab. This switch is
mechanically connected to the water valve at the base of
the heater core. Turning the heater temperature switch
towards maximum and/or towards off opens and closes
the water valve controlling engine coolant flow through the
heater core, thus controlling the temperature inside the
cab.
In certain conditions when the air conditioning switch is

turned on and the blower switch is in low position, the cab
temperature may still be too cool. It may be necessary to
blend heat with cooling to get a comfortable cab
temperature.
9031
05
TX,903105,QQ775 1917JUN941/1
11

110703
PN=585
Theory Of Operation
9031
05
12

110703
PN=586
Group 10
Air Conditioning Operational Checks
This procedure is designed so the mechanic can make additional checks or repair information will be given.
a quick check of the system using a minimum amount T.M. Group or CTM number required for repair will be
of diagnostic equipment. If you need additional given. If verification is needed, you will be given next
information, read Theory of Operation (Group best source of information:
9031-05).
Group: 10 (System Operational Checks)
The engine or other major components must be at
operating temperature for some checks. Group: 15 (Diagnostic Information)
Locate system check in the left column and read Group: 20 (Adjustments)
completely, following this sequence from left to right.
Read each check completely before performing. Group: 25 (Tests)
At the end of each check, if no problem is found, that CTM (Component Technical Manual)
check is complete. When a problem is indicated,
TX,9031,QQ1862 1917JUN941/1
1 Visual Inspection Of Components
9031
10
1/1
1
All Lines And Hoses Engine OFF. YES: Check complete.
Inspect all lines and hoses. NO: Reposition hoses or

lines and tighten or
Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts replace clamps. Tighten
or "weather checked"? fittings or replace O-rings
in fittings. Replace hoses
Are hose and line connections clean NOT showing signs of leakage, such as oil or or lines as required.
dust accumulation at fittings?
All hose and line clamps must be in place and tight. Clamps must have rubber inserts
or cushions in place to prevent clamps from crushing or wearing into hoses or lines?
1/1

110703
PN=587
Air Conditioner Inspect compressor. YES: Check complete.

Compressor Check
Is compressor drive belt tight? NO: Repair or replace
components as required.
Is belt in good condition, NOT frayed, worn or glazed?
Is compressor belt pulley in good condition, NOT worn or

grooved?
T6488GD UN02SEP93
Are compressor mounting brackets in good condition,
and bracket cap screws tight?
Are electrical connections to compressor clutch clean

and tight? Is wiring to compressor in good condition?
1/1
Condenser Check Engine OFF. YES: Check complete.
Inspect condenser cores. NO: Clean, repair or

replace condenser core.
Is condenser core free of dirt or debris? Replace engine fan.
Does condenser show signs of leakage, dust accumulation or oily areas?
Are condenser fins straight, not bent or damaged?
Inspect engine fan.
Are fan blades in good condition, not worn, bent, broken or missing?
9031
10
1/1
2
Evaporator Core Check Engine OFF. YES: Check complete.
Inspect core. NO: Repair, replace or

clean evaporator.
Are fins straight?
Is evaporator core free of dirt and debris?
1/1

110703
PN=588
Clutch Cycle Switch Engine OFF. YES: Check complete.

Sensing Tube Check
Inspect clutch cycle switch sensing tube. NO: If sensing tube is
kinked, replace clutch
Is sensing tube straight, NOT kinked or broken? cycle switch.
Is sensing tube inserted into evaporator core and secured in place? NO: If tube is positioned
in evaporator incorrectly,
re-route.
1/1
Air Conditioner Engine OFF. YES: Go to next check.

Compressor Check
Inspect compressor. NO: Repair or replace
components as required.
Is compressor drive belt tight? Is belt in good condition? Is belt tightening strap
straight?
Is compressor belt pulley in good condition (NOT grooved)?
Are compressor to bracket and bracket to engine mounting cap screws tight?
Is compressor pulley aligned with engine pulley?
Are electrical connections to compressor clutch clean and tight? Is wiring to

compressor in good condition?
9031
10
1/1
3
Cab Door And Window Open and close door and windows. Inspect seals. YES: Check complete.
Seals Check
Do door and windows contact seals evenly? NO: Adjust door and
windows to close against
Are seals in position and in good condition? seals properly. Replace
seals as necessary.
1/1
2 System Operating Checks
1/1

110703
PN=589
Blower Motor Check YES: Check complete.
NO: See Circuit Checks

in Group 9031-10. Check
wiring harness.
T7828AW 1930SEP92
Engine OFF. Key switch ON.
Turn blower switch (A) to LOW, MEDIUM and HIGH.
Does fan have three speeds?
Does air exit from ducts?
1/1
Heater YES: Check complete.
NO: See Circuit Checks

in Group 9031-10. Check
wiring harness.
T7835AW 1930SEP92
Start engine and allow to warm several minutes.
9031 Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high
10 speed.
4
Does warm air exit from ducts?
1/1

110703
PN=590
Air Conditioner (If YES: Check complete.

Equipped)
NO: See Blower/Air
Conditioning Circuit
Checks in Group
9031-10. See Charging
the system in Group
9031-20.
T7835AX 1930SEP92
Start engine and run at fast idle.
Turn air conditioner switch (A) to ON position.
Turn blower switch (B) to high speed.
Wait for any warm air in duct system to dissipate.
Is air from ducts cool?
1/1
Compressor Clutch Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner switch ON. YES: Check complete.
Check
Does compressor clutch "click" as switch is pushed? NO: Replace compressor
clutch.
1/1
3 System Performance Checks
9031
10
1/1
5
Expansion Valve Check Is expansion valve outlet line free of frost? YES: Check complete.
Is insulating tape wound tightly around outlet line and is tape in good condition? NO: Go to Expansion
Valve Operation in Group
9031-05.
1/1
Evaporator Check Remove seat and heater/blower cover. YES: Check complete.
Is ice forming on evaporator core? NO: Go to Clutch Cycle

Switch Bench Test in
Is fan motor failing or fan blades damaged? Group 9031-25.
Is clutch cycle sensing tube properly positioned?
Is heater temperature balance control misadjusted or damaged?
Is evaporator drain tubes plugged?
1/1

110703
PN=591
4 Blower/Air Conditioning Circuit Checks
1/1
Blower Switch Disconnect harness from blower switch. YES: Blower switch is
Using a multimeter check for continuity.
NO: Replace blower
Move blower switch to LOW, MEDIUM and HIGH switch.
checking terminals B to L and C, B to M and C and B to
H and C.
T7199CL UN17SEP90
1/1
Blower Resister Measure ohms between terminals 3 and 1. YES: Resistor is good.
Does ohmmeter read 1.0 ohms?
NO: Replace resistor.
Measure ohms between terminals 3 and 2.
Does ohmmeter read 0.5 ohms?
T6534CR UN19OCT88
9031
10
1/1
6
Heater/Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
Check motor is good. Check
Connect 12 volts to heater blower motor, and ground wiring harness.
motor.
NO: Replace heater
Does heater blower motor operate? blower motor.
T7199CM UN16AUG90
1/1

110703
PN=592
Clutch Cycle Switch With clutch cycle switch at room temperature. YES: Do Clutch Cycle
Switch Test . See Group
Disconnect harness from switch. 9031-25. If Switch is OK.
Measure continuity across switch terminals.
NO: Switch has failed.
Is continuity measured? Replace switch.
T7835AV 1924SEP92
1/1
Air Conditioning Switch Disconnect harness from air conditioning switch. YES: A/C switch is good.
Turn switch ON, and measure for continuity between
terminals 1 and 5. NO: Replace A/C switch.
T7199DE UN02OCT90
1/1
Air Conditioner Low Disconnect harness from switch. YES: Replace switch.
Pressure Switch Check
Check for continuity between outer terminals. Is NO: Go to next step in
continuity measured? this check.
9031
10
7
T8093AB UN05OCT93
Remove switch from system. (The line that attaches the low pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness.
Does ohmmeter read open? NO: Go to Low Pressure

Switch Test , Group
9031-25.
1/1

110703
PN=593
Air Conditioner High Disconnect harness from switch. YES: Go to next step in
Pressure Switch Check this check.
Measure continuity across outer switch terminals.
NO: Replace switch.
Does ohmmeter read continuity?
T8093AD UN05OCT93
Remove switch from system. (The line that attaches the high pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness.
Measure continuity across switch terminals. NO: System pressure is

too high. Go to Air
Does ohmmeter read continuity? Conditioning Pressure
Diagnostic Chart , Group
9031-25.
1/1
Air Conditioning Disconnect harness from clutch. YES: A/C compressor

Compressor Clutch Coil clutch coil is good. Check
Connect battery voltage to clutch terminal that has wiring harness.
orange wire. Ground black wire terminal.
NO: Replace clutch coil.
Does Clutch "click"?
T6534CV UN19OCT88
9031
10
1/1
8

110703
PN=594
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 Circuit Breaker Replace circuit breaker.

Not Operate
Blower switch See Blower/Air Conditioning Circuit

Checks , Group 9031-10.
Blower resistor See Blower/Air Conditioning Circuit

Heater/blower motor See Blower/Air Conditioning Circuit

Clutch cycle switch See Blower/Air Conditioning Circuit

Air conditioning switch See Blower/Air Conditioning Circuit

Low pressure switch See Blower/Air Conditioning Circuit 9031

15
1
High pressure switch See Blower/Air Conditioning Circuit

Compressor clutch coil See Blower/Air Conditioning Circuit

Wiring harness Check wiring harness . (See Group

9015-10.)
TX,9031,QQ2003 1917JUN941/1

110703
PN=595
Air Conditioning Component Location

T8234AE 1920FEB99
TX,9031,QQ2606 1917JUN941/2

110703
PN=596
A30 AMP Heater/A.C. Circuit GHeater Blower Motor (M6) NHigh Pressure Switch (S24) RAir Conditioning Switch
Breaker HBlower Resistor (R1) OLow Pressure Switch (S23) (S25)
BHeater Temperature Switch IEvaporator PAir Conditioning SExpansion Valve
(S22) JClutch cycle switch (S26) Compressor Harness (W11) TLow Pressure Test Port
CBlower Switch (S8) KReceiver Dryer QBlower Harness to Side UHigh Pressure Relief Valve
DGround at Cab Floor LCondenser console Harness VHigh Pressure Quick
EBlower Harness (W10) MCompressor R12/R134a Connector (X35) Disconnect
FHeater Blower Motor (M7) (Y10)
NOTE: For electrical call-outs in parenthesis, see

Wiring and Schematic Diagrams Legend in
Group 9015-10.
TX,9031,QQ2606 1917JUN942/2
9031
15
3

110703
PN=597
9031
15
4

110703
PN=598
Group 20
Adjustments
TX,9031,QQ2009 1919AUG941/1

treatment.
treatment. 1

container.
TX,9031,QQ2010 1917JUN941/1

110703
PN=599
Adjustments
R12 Component Oil Charge

SPECIFICATIONS 4. If less than 90 mL (3 fl oz) was drained from the
Condenser Oil Charge 59 mL (2 fl oz) original compressor, flush all components of the
Evaporator Oil Charge 118 mL (4 fl oz) system. Replace the receiver/dryer and add 330 mL
Receiver/Dryer Oil Charge 15 mL (0.4 fl oz)
(11 fl oz) of new oil back into the system.
5. When installing a compressor that has been

IMPORTANT: The compressor takes a special 525
disassembled and reassembled with no oil charge,
viscosity oil R49856 that has
add an extra 30 mL (1 fl oz) to the amounts
"special additives" which give better
specified in steps 2, 3 or 4.
compressor life.
6. When installing a new or remanufactured
If complete system was flushed to
compressor, drain the oil. Replace with new oil per
remove contamination, the full
steps 2, 3 or 4.
charge of oil 326 mL (11 fl oz) must
be added to the system.
7. If components of the system were drained and
flushed, add 330 mL (11 fl oz) to the compressor.
NOTE: Dispose oil drained from compressor in
accordance with Federal, State and Local
8. After adding proper amount of oil, rotate the
regulations. Do not reuse oil drained from the
compressor shaft four or five times to insure proper
system. Always add NEW oil to the system.
lubrication of the compressor seal.
1. Remove compressor. Drain the oil from the suction
IMPORTANT: DO NOT add any more oil than
port and record amount of oil.
necessary or maximum cooling will
be reduced.
2. If 90240 mL (38 fl oz) was drained from the
original compressor, add 180 mL (6 fl oz) of new oil
9. When servicing individual components, determine
back into the compressor.
the oil charge needed using following
specifications:
3. If more than 240 mL (8 fl oz) was drained from the
original compressor, add 180 mL (6 fl oz) of new oil Specification
back into the compressor. Replace receiver/dryer to CondenserOil Charge .............................................. 59 mL (2 fl oz)
9031
20 remove excess oil from the system. EvaporatorOil Charge ............................................ 118 mL (4 fl oz)
2 Receiver/DryerOil Charge ..................................... 15 mL (0.4 fl oz)
TX,9031,QQ2081 1912SEP951/1

110703
PN=600
Adjustments
R12 Refrigerant Recovery, Recycling Station

Installation Procedure
ESSENTIAL TOOLS
JT02020 R12 Refrigerant Recovery and Recycling Station
NOTE: JT02021 recovery/recycling station can be

substituted for the JT02020 station.
CAUTION: Do not remove high pressure relief

valve (H). Air conditioning system will
discharge rapidly causing possible injury.
IMPORTANT: Use correct refrigerant recovery,

recycling and charging stations. DO
NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
1. Close both high and low pressure valves on gauge

assembly (D).
UN25FEB93
2. Remove cap from low pressure test port (G).
3. Connect (C) low pressure hose blue from refrigerant
T7938AI
recovery, recycling station (F) to low pressure test port
(G) on compressor.
AHigh Pressure Switch
4. Remove high pressure switch (A) and connect high BRed Hose (High Pressure)
pressure red hose (B) from refrigerant recovery, CBlue Hose (Low Pressure)
recycling station. DGauge Assembly
EYellow Hose
FRecovery/Recycling Station
5. Follow the manufactures instructions when using the GLow Pressure Test Port 9031
refrigerant recovery, recycling station. HHigh Pressure Relief Valve 20
3
TX,9031,QQ2013 1917JUN941/1

110703
PN=601
Adjustments
R12 Refrigerant Evacuation And Charging

Station Installation Procedure
ESSENTIAL TOOLS
JT02023 R12 Refrigerant Charging and Evacuation Station


1. Close both high and low pressure valves on gauge

assembly (D).
2. Remove cap from low pressure test port (G).
UN25FEB93
3. Connect (C) low pressure hose blue from refrigerant
recovery, recycling station (F) to low pressure test port
(G) on compressor.
T7938AJ
4. Remove high pressure switch (A) and connect high
pressure red hose (B) from refrigerant charging and
evacuation station. AHigh Pressure Switch
BRed Hose (High Pressure)
5. Follow the manufactures instructions when using the CBlue Hose (Low Pressure)
refrigerant evacuation and charging station. DGauge Assembly
EYellow Hose
9031 GLow Pressure Test Port
20 HHigh Pressure Relief Valve
4
TX,9031,QQ2014 1917JUN941/1

110703
PN=602
Adjustments
Recover R12 System

ESSENTIAL TOOLS
NOTE: JT02020 recovery and recycling station can be

substituted for the JT02021 station.


NOTE: Run the air conditioning system for three minutes

to help in the recovery process. Turn air
conditioning system off before proceeding with
UN25FEB93
recovery steps.
1. Connect refrigerant recovery and recycling station .

(See installation procedure in this group.)
T7938AI
2. Follow the manufactures instructions when using the
refrigerant recovery and recycling station.
AHigh Pressure Switch
CBlue Hose (Low Pressure)
DGauge Assembly
EYellow Hose
GLow Pressure Test Port 9031
HHigh Pressure Relief Valve 20
5
TX,9031,QQ2016 1917JUN941/1

110703
PN=603
Adjustments
Evacuate R12 System

SPECIFICATIONS
Vacuum Pressure 98 kPa (980 mbar) (29 in. Hg)
minus 3.4 kPa (34 mbar) (1 in.
Hg) for each 300 m (1000 ft)
elevation above sea level.
ESSENTIAL TOOLS
JT02023 R12 Refrigerant Charging and Evacuation Station


UN25FEB93
Do not run compressor while
evacuating.
1. Connect refrigerant charging and evacuation station .
T7938AJ
2. Open low and high pressure valves on refrigerant

charging and evacuation station. AHigh Pressure Switch
CBlue Hose (Low Pressure)
3. Follow the manufactures instructions and evacuate the DGauge Assembly
system. EYellow Hose
9031 GLow Pressure Test Port
NOTE: The vacuum specifications listed are for sea level
20 HHigh Pressure Relief Valve
6 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.
Specification
VacuumPressure.................................... 98 kPa (980 mbar) (29 in. Hg)
Hg) for each 300 m (1000 ft)
elevation above sea level.

110703
PN=604
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.
5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close

low and high pressure 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 and high pressure valves.
10. Evacuate system for 30 minutes after 98 kPa (980

mbar) (29 in. Hg) vacuum is reached.
11. Close low and high pressure valves. Stop evacuation.
12. Charge the system . (See procedure in this group.)
TX,9031,QQ2017 1917JUN942/2
9031
20
7

110703
PN=605
Adjustments
Charge R12 System

SPECIFICATIONS
System Refrigerant Charge 2.3 Kg (5 lbs)
ESSENTIAL TOOLS


1. Connect refrigerant charging and evacuation station.

UN25FEB93
2. Evacuate the system. (See Evacuate Air Conditioning
System, this group.)
NOTE: Before beginning to charge air conditioning
T7938AJ
system, the following conditions must exist:
Engine STOPPED, the pump must be capable of
pulling at least 28.6 in. Hg vacuum (sea level). AHigh Pressure Switch
Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa BRed Hose (High Pressure)
(980 mbar) (29 in. Hg) for each 300 m (1000 ft) CBlue Hose (Low Pressure)
elevation above sea level. DGauge Assembly
EYellow Hose
9031 3. Follow the manufacturers instructions and charge the GLow Pressure Test Port
20 system. HHigh Pressure Relief Valve
8
4. Add refrigerant until system is charged with 2.3 Kg (5
lbs).
Specification
SystemRefrigerant Charge ............................................... 2.3 Kg (5 lbs)
5. Do air conditioner checks and tests in Groups 9031-10

and 9031-25.
TX,9031,QQ2027 1917JUN941/1

110703
PN=606
Adjustments
R134a Compressor Oil Charge Check
OTHER MATERIAL 2. Remove, clean, but do not disassemble the valve.

TY16134 U.S. Air Conditioning Flushing Solvent
TY22025 U.S. R134a Compressor Oil (8.5 oz) 3. Flush the complete system with TY16134 air
conditioning flushing solvent.
Remove compressor if R134a leakage was detected
and repaired. See Remove and install Compressor in 4. If the compressor is serviceable, pour flushing
Repair Manual. solvent in the manifold ports and internally wash out
the old oil.
Drain oil from the compressor and record the amount.
See Compressor Oil Removal procedure in this group. 5. Install a new receiver-dryer.
NOTE: Drain oil and save if this is a new compressor. 6. Install required amount of TY22025 refrigerant oil in
the compressor. ( See R134a Component Oil
If the oil drained from a compressor removed from Charge in this group.)
operation is very black or the amount of oil is less than
6 mL (0.2 fl oz), perform the following: 7. Connect all components, evacuate and charge the
system.
1. Remove and discard the receiver-dryer.
TX,9031,QQ2366 1907MAR951/1
R134a Compressor Oil Removal
1. Remove compressor from machine. See Remove and

Install Compressor in Repair Manual. 9031
20
2. Remove inlet/outlet manifold from compressor, and 9
clutch dust cover.
3. Drain oil into graduated container while rotating

compressor shaft.
4. Record measured oil and discard oil properly.
5. Install new oil. See R134a Component Oil Charge in

this Group.
6. Install compressor. See Remove and Install

Compressor in Repair Manual.
TX,9015,QQ2299 1917JUN941/1

110703
PN=607
Adjustments
R134a Component Oil Charge

SPECIFICATIONS New compressor from parts depot, drain and
Evaporator Oil Charge 130 mL (4.4 fl oz) return 45 mL (1.5 fl oz) of oil to the compressor.
Condenser Oil Charge 65 m (2.2 fl oz) (See Compressor Oil Removal procedure in this
Receiver-Dryer Oil Charge 30 mL (1.0 fl oz) group)
Used compressor removed from operation and oil
Hoses Oil Charge 60 mL (2.0 fl oz)
drained, (See Compressor Oil Removal
procedure in this group.) Add 45 mL (1.5 fl oz) of
OTHER MATERIAL
new oil.
TY22025 U.S. R134a Compressor Oil (8.5 oz) Used compressor removed from operation, oil
drained, and flushed add 60 mL (2.0 fl oz) of new
CAUTION: All new compressors are charged oil.
with a mixture of nitrogen, R134a refrigerant
and TY22025 (R134a) refrigerant oil. Wear NOTE: Components listed below which have been
safety goggles and discharge the removed, drained or flushed, require the
compressor slowly to avoid possible injury. removal of the compressor to determine the
correct oil charge. Use the following
Compressors can be divided into three categories specifications as a guide for adding oil to
when determining the correct oil charge for the system. components:
New compressor from parts depot NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft).
Used compressor removed from operation Approximate total length equals 600 cm (20 ft).
Compressor internally washed with flushing solvent
If any section of hose is removed and flushed or
Determining the amount of system oil charge prior to replaced, measure the length of hose and use the
installation of compressor on a machine. formula to determine the correct amount of oil to be
added.
1. When the complete system, lines, and components
Specification
were flushed add the correct amount of oil as EvaporatorOil Charge ......................................... 130 mL (4.4 fl oz)
described. CondenserOil Charge ............................................. 65 m (2.2 fl oz)
Receiver-DryerOil Charge ..................................... 30 mL (1.0 fl oz)
9031
New compressor from parts depot contains the HosesOil Charge ............................... 60 mL (2.0 fl oz) or 3 mL per
20 30 cm (0.1 fl oz per ft)
10 amount of new oil of 230 20 mL (7.7 .7 fl oz).
System requires an additional amount of new oil
of 100 mL (3.4 fl oz) of new oil. CAUTION: DO NOT leave the system or
Used compressor removed from operation, oil R134a compressor oil containers open. This
drained, and flushed requires 330 20 mL (11.1 oil easily absorbs moisture. DO NOT spill
.7 fl oz) of new oil. R134a compressor oil on acrylic or ABS
plastic. This oil will deteriorate these
2. When the complete system was not flushed add the materials rapidly. Identify R134a oil
correct amount of oil for the compressor plus containers and measures to eliminate
amount of oil for each component that was accidental mixing of different oils.
serviced.
TX,9015,QQ2300 1917JUN941/1

110703
PN=608
Adjustments
R134a Refrigerant Recovery, Recycling And

Charging Station Installation Procedure
ESSENTIAL TOOLS
JT02047 R134a Refrigerant Recovery/Recycling and Charging Station
NOTE: JT02046 and JT02050 recovery and charging

stations can be substituted for the JT02047
station.

valve (B). Air conditioning system will

1. Close both high and low pressure valves on refrigerant
UN01MAR94
recovery, recycling and charging station (J).
2. Remove cap from low pressure test port (A).
T8178AH
3. Connect low pressure blue hose (I) from refrigerant
recovery, recycling and charging station (J) to low
pressure test port (A) on compressor. ALow Pressure Test Port
BHigh Pressure Relief Valve
4. Connect high pressure red hose (G) to high pressure CLow Pressure Hose
quick disconnect (F). DLow Pressure Switch
EHigh Pressure Switch
FHigh Pressure Quick-Disconnect
5. Follow the manufactures instructions when using the GRed Hose 9031
refrigerant recovery, recycling and charging station. HHigh Pressure Hose 20
IBlue Hose 11
JRefrigerant Recovery/Recycling and Charging
station
TX,9031,QQ2607 1917JUN941/1

110703
PN=609
Adjustments
Recover R134a System

ESSENTIAL TOOLS

station.


NOTE: Run the air conditioning system for three minutes

to help in the recovery process. Turn air
UN01MAR94
conditioning system off before proceeding with
recovery steps.
1. Connect refrigerant recovery, recycling and charging
T8178AH
station . (See installation procedure in this group.)

ALow Pressure Test Port
refrigerant recovery, recycling and charging station. BHigh Pressure Relief Valve
CLow Pressure Hose
DLow Pressure Switch
9031 GRed Hose
20 HHigh Pressure Hose
12 IBlue Hose
station
TX,9031,QQ2608 1925OCT951/1

110703
PN=610
Adjustments
Evacuate R134a System

SPECIFICATIONS
Vacuum Pressure 98 kPa (980 mbar) (29 in. Hg)
Hg)
ESSENTIAL TOOLS

station.


UN01MAR94
Do not run compressor while
T8178AH
evacuating.

station . (See installation procedure in this group.) ALow Pressure Test Port
CLow Pressure Hose
2. Open low and high pressure valves on refrigerant DLow Pressure Switch
recovery, recycling and charging station. EHigh Pressure Switch
GRed Hose 9031
3. Follow the manufactures instructions and evacuate the 20
HHigh Pressure Hose
system. IBlue Hose 13
NOTE: The vacuum specifications listed are for sea level station
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.
Specification
VacuumPressure.................................... 98 kPa (980 mbar) (29 in. Hg)
Hg)
Continued on next page TX,9031,QQ2609 1925OCT951/2

110703
PN=611
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.
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 procedure in this group.)
TX,9031,QQ2609 1925OCT952/2
9031
20
14

110703
PN=612
Adjustments
Charge R134a System

SPECIFICATIONS
System Refrigerant Charge 2.3 Kg (5 lbs)
ESSENTIAL TOOLS

station.


UN01MAR94
1. Connect JT02047 R134a refrigerant recovery, recycling
and charging station . (See installation procedure in
this group.)
T8178AH
2. Evacuate the system. (See Evacuate Air Conditioning
System , this group.) ALow Pressure Test Port
NOTE: Before beginning to charge air conditioning CLow Pressure Hose
system, the following conditions must exist: DLow Pressure Switch
Engine STOPPED, the pump must be capable of EHigh Pressure Switch
pulling at least 28.6 in. Hg vacuum (sea level). GRed Hose 9031
Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa HHigh Pressure Hose 20
(980 mbar) (29 in. Hg) for each 300 m (1000 ft) IBlue Hose 15
elevation above sea level. JRefrigerant Recovery/Recycling and Charging
Station
3. Follow the manufacturers instructions and charge the
system.
4. Add refrigerant until system is charged with 2.3 Kg (5

lbs).
Specification
SystemRefrigerant Charge ............................................... 2.3 Kg (5 lbs)
5. Do air conditioner checks and tests in Groups 9031-10

and 9031-25.
TX,9031,QQ2610 1925OCT951/1

110703
PN=613
Adjustments
Check And Adjust Compressor Belt Tension
SPECIFICATIONS 2. Belt must deflect 19 mm (0.75 in.) at 400 N (90 lb

Belt Deflection 19 mm (0.75 in.) at 400 N (90 force).
lb force)
Specification
SERVICE EQUIPMENT AND TOOLS BeltDeflection ................................... 19 mm (0.75 in.) at 400 N (90
lb force)
Belt Tension Gauge
If not, allow belt to cool for 810 minutes.

IMPORTANT: Never over tighten belt. Over
tightening may cause belt cord IMPORTANT: Force to adjust belt must be applied
damage and excessive load on to front of compressor housing only
bearings. to prevent damage to compressor.
1. Run engine for five minutes. Stop the engine, then 3. Loosen compressor mounting cap screws. Apply
immediately check tension using a belt tension force to front of compressor housing to tighten belt.
gauge. Measure strand tension or deflection at a Tighten cap screws.
point halfway between pulleys.
4. Repeat Steps 1 and 2 to check belts.
TX,9031,QQ2082 1917JUN941/1
9031
20
16

110703
PN=614
Group 25
Test
TX,9031,QQ2009 1919AUG941/1

treatment.
treatment. 1

container.
TX,9031,QQ2010 1917JUN941/1

110703
PN=615
Test
R134a Air Conditioning System Test

SPECIFICATIONS
Temperature Control Switch Maximum Cooling
Position
Blower Speed High
Ambient Temperature Air Duct Temperature Low Pressure Gauge High Pressure Gauge
16C (60F) 13C (55F) 7165 kPa 6301095 kPa
(0.071.6 bar) (611 bar)
(124 psi) (90160 psi)
21C (70F) 16C (60F) 7180 kPa 7851225 kPa
(0.071.8 bar) (7.612 bar)
(126 psi) (110175 psi)
27C (80F) 18C (65F) 7205 kPa 9551410 kPa
(0.072.1 bar) (9.614.1 bar)
(130 psi) (140205 psi)
32C (90F) 21C (70F) 7240 kPa 11451645 kPa
(0.072.4 bar) (11.416.5 bar)
(135 psi) (165240 psi)
38C (100F) 27C (80F) 7280 kPa 13551935 kPa
(0.072.7 bar) (13.419.3 bar)
(140 psi) (195280 psi)
43C (110F) 29C (85F) 7330 kPa 15802275 kPa
(0.073.3 bar) (15.822.7 bar)
(148 psi) (230330 psi)
ESSENTIAL TOOLS

9031
25 NOT use refrigerant, hoses, fittings,
2 components or refrigerant oils intended
for R12 refrigerant.

station . (See installation procedure in this group.)
2. Close both low and high pressure valves on refrigerant

recovery, recycling and charging station.
3. Open cab doors and windows.

110703
PN=616
Test
4. Connect low pressure blue hose (I) from refrigerant

recovery, recycling and charging station (J) to low
pressure test port (A) on compressor.
5. Connect high pressure red hose (G) to high Pressure

Quick-Disconnect (F) on compressor.

refrigerant recovery, recycling and charging station.
7. Start engine and run at rated engine speed.
Specification
EngineSpeed ........................................................................... 2200 rpm
8. Turn temperature control switch to the maximum

cooling position.
Specification
Temperature Control Switch
Position .......................................................................... Maximum Cooling
UN01MAR94
9. Turn blower switch to high speed.
Specification
T8178AH
BlowerSpeed .................................................................................... High
10. Check sight glass in receiver-dryer.

ALow Pressure Test Port
11. Run unit for at least 5 minutes. BHigh Pressure Relief Valve
CLow Pressure Hose
12. Measure air temperature at condenser air inlet and at DLow Pressure Switch
air ducts in air conditioning unit.
GRed Hose 9031
13. Compare air duct temperature reading to the HHigh Pressure Hose 25
temperatures shown in the specifications. IBlue Hose 3
14. Observe low and high pressure gauges on refrigerant Station
recovery, recycling and charging station.
15. Compare pressure readings to the pressure shown in

specifications.
Use the Operating Pressure Diagnostic Chart in this

group to diagnose the malfunction.
TX,9031,QQ2358 1919AUG942/2

110703
PN=617
Test
Pressure Diagnostic Chart
9031
25
4
1928FEB89
T6609AB
TX,9031,QQ2145 1925FEB941/1

110703
PN=618
Test
Low Pressure Switch Test

SPECIFICATIONS
Low Pressure Switch (Normally 276 20 kPa (2.76 0.2 bar) (40
Open) Closes on Increasing 3 psi)
UN08NOV88
Pressure
Low Pressure Switch (Normally 220 20 kPa (2.2 0.2 bar) (32
Open) Opens on Decreasing 3 psi)
Pressure
T88001
Volt-Ohm-Amp Meter
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
5
4. The actual pressure setting of switch can be checked
by connecting it to a pressure source such as a
regulated air supply or hydraulic hand pump.
5. Switch must not have continuity between terminals (A

and C) until pressure increases to switch closing
pressure specification.
Specification
Low Pressure Switch (Normally
Open)Closes on Increasing
Pressure ............................................... 276 20 kPa (2.76 0.2 bar) (40
3 psi)

110703
PN=619
Test
Slowly release pressure. Switch must have continuity

until pressure decreases to switch opening pressure
specification.
Specification
Low Pressure Switch (Normally
Open)Opens on Decreasing
Pressure ................................................. 220 20 kPa (2.2 0.2 bar) (32
3 psi)
TX,903125,QQ731 1917JUN942/2
9031
25
6

110703
PN=620
Test
High Pressure Switch Test

SPECIFICATIONS
High Pressure Switch (Normally 2410 100 kPa (24.1 1 bar)
Closed) Opens on Increasing (350 15 psi)
UN08NOV88
Pressure
High Pressure Switch (Normally 1390 100 kPa (13.91 1 bar)
Closed) Closes on Decreasing (220 15 psi)
Pressure
T88002
Volt-Ohm-Amp Meter
Air Conditioning Gauge Set
NOTE: The high pressure switch has a valve under it to

prevent discharging the air conditioning system
when switch is removed.
1. Remove high pressure switch.
2. Connect a portable pressure source, such as a

hydraulic hand pump, to high pressure switch.
3. Switch must have continuity between terminals (A and

C) until pressure increases to switch opening pressure
specification.
Specification
High Pressure Switch (Normally
Closed)Opens on Increasing
Pressure .................................................... 2410 100 kPa (24.1 1 bar)
(350 15 psi)
4. Slowly release pressure. Switch must not have 9031

25
continuity until pressure decreases to switch closing
7
pressure specification.
Specification
High Pressure Switch (Normally
Closed)Closes on Decreasing
Pressure .................................................. 1390 100 kPa (13.91 1 bar)
(220 15 psi)
5. The switch can also be checked when installed in air

conditioning system, however, pressure is slow to
increase to test specification.
Continued on next page TX,903125,QQ774 1926JAN951/2

110703
PN=621
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.
TX,903125,QQ774 1926JAN952/2
9031
25
8

110703
PN=622
Test
Clutch Cycle Switch

SPECIFICATIONS
Clutch Cycle Switch (Normally -5C (31F)
Open) Opens on Decreasing
Temperature
Clutch Cycle Switch (Normally 4C (39F)
Open) Closes on Increasing
Temperature

Ohmmeter
1. Remove clutch cycle switch from evaporator.
2. Connect ohmmeter to switch terminals. Switch must be

closed at room temperature.
3. Put switch into a freezer (assure freezer temperature is

below -0.5C (31F). Switch must open, and continuity
must not be read.
Specification
Clutch Cycle Switch (Normally
Open)Opens on Decreasing
Temperature ............................................................................. -5C (31F)
4. Remove switch from freezer. Put sensing tube into a

glass of warm water. Switch must close, and continuity
must be read.
Specification
Clutch Cycle Switch (Normally
Open)Closes on Increasing 9031
Temperature .............................................................................. 4C (39F) 25
9
5. If switch does not open and close during testing, install
new switch.
TX,9031,QQ777 1905AUG941/1

110703
PN=623
Test
Leak Testing
1. Inspect all lines, fittings, and components for oily or 3. If a leak detector is used, move the leak detector
dusty spots. When refrigerant leaks from the probe under the hoses and around the connections
system, a small amount of oil is carried out with it. at a rate of 25 mm (1 in.) per second.
2. A soap and water solution can be sprayed on the 4. Some refrigerant manufacturers add dye to
components in the system to form bubbles at the refrigerant to aid in leak detection.
source of the leak.
TX,9031,QQ1881 1919AUG941/1
Refrigerant Hoses And Tubing Inspection
When a component is disconnected from the system, hose and tube connections. Dip O-rings in correct
special care should be given to inspecting hoses and viscosity oil before assembling.
tubing for moisture, grease, dirt, rust, or other foreign
material. If such contamination is present in hoses, IMPORTANT: Hose used for air conditioning
tubing, or fittings and cannot be removed by cleaning, systems contains special barriers in
then replace parts. its walls to prevent migration of
refrigerant gas.
Fittings that have grease or dirt on them should be
wiped clean with a cloth dampened with alcohol. DO NOT use hydraulic hoses as
Chlorinated solvents (such as trichloroethylene) are replacement hoses in the air
contaminants, and must not be used for cleaning. conditioning system. Use ONLY
certified hose meeting SAE J51B
To assist in making leak-proof joints, use a small requirements.
amount of clean correct viscosity refrigerant oil on all
9031
25
TX,9031,QQ1882 1917JUN941/1
10

110703
PN=624
Index
Page Page
A Alternators
Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Adjustment Auxiliary Valve
Loader bucket level indicator. . . . . . . . . .9025-20-1 Soleniod controlled . . . . . . . . . . . . . . . .9025-05-57
Return-to-dig switch . . . . . . . . . . . . . . . .9025-20-1
Adjustments
Backhoe valve linkage . . . . . . . . . . . . . .9025-20-5 B
Loader valve linkage . . . . . . . . . . . . . . . .9025-20-3
Stabilizer valve linkage . . . . . . . . . . . . . .9025-20-7 Backhoe auxiliary valve
Air conditioning operation-Gresen . . . . . . . . . . . . . . . . .9025-05-40
Charge R12 system . . . . . . . . . . . . . . . .9031-20-8 Backhoe auxiliary valve
Charge R134a system . . . . . . . . . . . . .9031-20-15 Operation-Husco . . . . . . . . . . . . . . . . . .9025-05-50
Circuit checks . . . . . . . . . . . . . . . . . . . . .9031-10-6 Backhoe boom valve operation-Husco . . .9025-05-42
Clutch cycle switch test. . . . . . . . . . . . . .9031-25-9 Backhoe bucket valve
Component location . . . . . . . . . . . . . . . .9031-15-2 operation-Gresen . . . . . . . . . . . . . . . . .9025-05-38
Compressor belt tension . . . . . . . . . . . .9031-20-16 Backhoe circuit relief operation-Husco . . .9025-05-52
Compressor oil removal . . . . . . . . . . . . .9031-20-9 Backhoe crowd valve
Compressor relief valve operation . . . . .9031-05-11 operation-Gresen . . . . . . . . . . . . . . . . .9025-05-37
Electrical circuit . . . . . . . . . . . . . . . . . . . .9031-05-3 Backhoe crowd valve operation-Husco . . .9025-05-46
Evacuate R12 system . . . . . . . . . . . . . . .9031-20-6 Backhoe relief valve operation-Gresen . . .9025-05-33
Evacuate R134a system . . . . . . . . . . . .9031-20-13 Backhoe swing valve
Evacuation\charging R12 operation-Gresen . . . . . . . . . . . . . . . . .9025-05-39
system. . . . . . . . . . . . . . . . . . . . . . . . .9031-20-4 Battery
Expansion valve . . . . . . . . . . . . . . . . . .9031-05-10 Booster . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-9
High pressure switch test . . . . . . . . . . . .9031-25-7 Electrolyte level. . . . . . . . . . . . . . . . . . . .9015-20-5
Hoses and tubing inspection . . . . . . . . .9031-25-10 Malfunctions . . . . . . . . . . . . . . . . . . . . . .9015-20-4
Leak testing . . . . . . . . . . . . . . . . . . . . .9031-25-10 Operation . . . . . . . . . . . . . . . . . . . . . . . .9015-20-2
Low pressure switch test. . . . . . . . . . . . .9031-25-5 Specifications . . . . . . . . . . . . . . . . . . . . .9015-20-3
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9031-15-1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-8
Operating checks . . . . . . . . . . . . . . . . . .9031-10-3 Brake element leakage test . . . . . . . . . . .9020-25-21
Performance checks . . . . . . . . . . . . . . . .9031-10-5 Brake pedals
Receiver/dryer operation . . . . . . . . .9031-05-8 Adjustment . . . . . . . . . . . . . . . . . . . . . . .9020-20-1
Recover R12 system. . . . . . . . . . . . . . . .9031-20-5 Brake system
Recover R134a system. . . . . . . . . . . . .9031-20-12 Operation checks . . . . . . . . . . . . . . . . . .9020-10-1
Recovery/recycling R12 system . . . .9031-20-3 Brake valve
Recovery/recycling/charging Leakage test . . . . . . . . . . . . . . . . . . . . .9020-25-20
Brakes Indx
R134a . . . . . . . . . . . . . . . . . . . . . . . .9031-20-11 1
Refrigerant handling . . . . . . 9031-05-1, 9031-20-1, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-4
9031-25-1 Bucket valve operation-Husco . . . . . . . . .9025-05-44
Refrigerant (R12/R134a) caution . . 9031-05-1,
9031-20-1, 9031-25-1
R12 Component Oil Charge . . . . . . . . . .9031-20-2 C
R12 refrigerant operation . . . . . . . . . . . .9031-05-2
System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-2 Charge pump
Temperature control . . . . . . . . . . . . . . .9031-05-11 Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-1
Visual inspection of components . . . . . . .9031-10-1 Component location
Air system A.C. compressor harness (W11) . . . . . .9015-10-39
Air intake leakage test. . . . . . . . . . . . . . .9010-25-5 Auxiliary valve harness (W14). . . . . . . .9015-10-41
Check . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-10-3 Blower harness (W10). . . . . . . . . . . . . .9015-10-35
Restriction indicator test . . . . . . . . . . . . .9010-25-4 Cab roof harness (W5) . . . . . . . . . . . . .9015-10-18
Alternator Cab side console harness (W6) . . . . . .9015-10-27
Belt tension . . . . . . . . . . . . . . . . . . . . . . .9010-20-2 Engine harness (W8) . . . . . . . . . . . . . .9015-10-33
TM1512 (07NOV03) Index-1 Backhoe Loaders Operation and Test

110703
PN=1
Index
Page Page
Floor harness (W6) . . . . . . . . . . . . . . . .9015-10-22 Shorted circuit. . . . . . . . . . . . . . . . . . . . .9015-05-8

Front console harness (W7) . . . . . . . . .9015-10-30 Start aid circuit . . . . . . . . . . . . . . . . . . .9015-15-47
Radio harness (W12) . . . . . . . . . . . . . .9015-10-37 Start circuit . . . . . . . . . . . . . . . . . . . . . . .9015-15-8
Coolant, engine . . . . . . . . . . . . . . . . . . . . .9000-04-9 System Functional schematic . . . . . . . .9015-10-10
Cooling system System functional schematic reading . .9015-05-13
Checks . . . . . . . . . . . . . . . . . . . . . . . . . .9010-10-1 Tachometer calibration . . . . . . . . . . . . .9015-20-17
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-3 Test equipment . . . . . . . . . . . . . . . . . . . .9015-05-9
Crowd valve operation-Gresen . . . . . . . . .9025-05-37 Test procedure . . . . . . . . . . . . . . . . . . .9015-05-10
Cylinder drift test procedure . . . . . . . . . . .9025-25-49 Turn/flasher/brake light
circuit. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-90
Wiper/washer circuit . . . . . . . . . . . .9015-15-68
Wiring diagram information . . . . . . . . . .9015-05-12
D
Wiring diagram, reading . . . . . . . . . . . .9015-05-14
Wiring diagrams legend . . . . . . . . . . . . .9015-10-4
Wiring/schematic diagrams
Steering . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-1
legend . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-4
Diesel fuel conditioner
Engine
Low sulfur . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1
Diagnose malfunction . . . . . . . . . . . . . . .9010-15-4
Digital Thermometer Installation . . . . . . . . 9010-25-1,
General description . . . . . . . . . . . . . . . . .9010-05-2
9020-25-1, 9025-25-1
Idle adjustment . . . . . . . . . . . . . . . . . . . .9010-20-6
Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-3
Sectional view. . . . . . . . . . . . . . . . . . . . .9010-05-4
E Speed and performance check . . . . . . . .9010-10-5
Visual inspection . . . . . . . . . . . . . . . . . . .9010-15-2
Electrical Engine coolant . . . . . . . . . . . . . . . . . . . . . .9000-04-9
Auxiliary valve circuit. . . . . . . . . . . . . . 9015-15-109 Engine speed control
Beacon circuit . . . . . . . . . . . . . . . . . . . .9015-15-95 Adjust lever tension. . . . . . . . . . . . . . . . .9010-20-3
Blower circuit . . . . . . . . . . . 9015-15-72, 9031-05-6 Adjust linkage . . . . . . . . . . . . . . . . . . . . .9010-20-4
Charging circuit . . . . . . . . . . . . . . . . . . .9015-15-15 Extendible dipperstick
Circuit malfunctions. . . . . . . . . . . . . . . . .9015-05-2 Grease specification . . . . . . . . . . . . . . . .9000-04-7
Component identification . . . . . . . . . . . . .9015-10-1
Display module circuit . . . . 9015-15-24, 9015-15-25
Dome light circuit . . . . . . . . . . . . . . . . .9015-15-62
Drive and work light circuit . . . . . . . . . .9015-15-75 F
Fuel shut-off circuit . . . . . . . . . . . . . . . .9015-15-54
Gauge/hour meter circuit . . . . . . . 9015-15-103 Fuel
Indx Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-6 Specifications . . . . . . . . . . . . . . . . . . . . .9000-04-1
2 High resistance circuit . . . . . . . . . . . . . . .9015-05-3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-2
Horn circuit . . . . . . . . . . . . . . . . . . . . . .9015-15-88 Tank capacity . . . . . . . . . . . . . . . . . . . . .9000-04-2
Indicator circuit . . . . . . . . . . . . . . . . . . .9015-15-32 Fuel system
Inspection . . . . . . . . . . . . . . . . . . . . . . . .9015-05-1 System operational check . . . . . . . . . . . .9010-10-4
Logic module bench test . . . . . . . . . . . .9015-20-16 Function drift test . . . . . . . . . . . . . . . . . . .9025-25-50
Logic module test in machine . . . . . . . .9015-20-14 Fuse
Monitor test in machine. . . . . . . . . . . . .9015-20-13 Location . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-3
Neutral disconnect circuit . . . . . . . . . . .9015-15-78 Specifications . . . . . . . . . . . . . . . . . . . . .9015-10-3
Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-4
Park brake circuit . . . . . . . . . . . . . . . . .9015-15-78
Power circuit . . . . . . . . . . . . . . . . . . . . . .9015-15-1
Radio circuit . . . . . . . . . . . . . . . . . . . . .9015-15-64 G
Return-to-dig circuit. . . . . . . . . . . . . . . .9015-15-99
Reverse alarm circuit . . . . . . . . . . . . . .9015-15-56 Grease
Schematic diagrams legend . . . . . . . . . .9015-10-4 Extendible dipperstick . . . . . . . . . . . . . . .9000-04-7
Schematic symbols . . . . . . . . . . . . . . . .9015-05-15 Specification . . . . . . . . . . . . . . . . . . . . . .9000-04-7

110703
PN=2
Index
Page Page
H Specification engine . . . . . . . . . . . . . . . .9000-04-3

Specification, hydraulic . . . . . . . . . . . . . .9000-04-5
Hydraulic Specification, reverser. . . . . . . . . . . . . . .9000-04-5
Fittings, 30° cone seat. . . . . . . . . . .9000-03-9 Specification, transaxle . . . . . . . . . . . . . .9000-04-4
Fittings, 37° flare . . . . . . . . . . . . . . .9000-03-9 Oil lines and fittings . . . . . . . . . . . . . . . . . .9000-03-8
Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-5 Operational checkout procedures . . . . . . . .9005-10-1
Schematic and Component Location. . . .9025-15-8 Operational checks
Hydraulic oil warm-up procedure . . . . . . . .9025-25-1 Accessories . . . . . . . . . . . . . . . . . . . . .9005-10-18
Hydraulic system Brake system . . . . . . . . . . . . . . . . . . . . .9005-10-5
Checks . . . . . . . . . . . . . . . . . . . . . . . . . .9025-10-3 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-20
Clutch disconnect solenoid . . . . . . . . . . .9005-10-7
Driving . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-8
Gauge and indicator . . . . . . . . . . . . . . . .9005-10-1
I
Hydraulic system. . . . . . . . . . . . . . . . . .9005-10-12
Indicators . . . . . . . . . . . . . . . . . . . . . . . .9005-10-3
Inch torque values . . . . . . . . . . . . . . . . . . .9000-03-2
MFWD . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-10
Injection pump timing . . . . . . . . . . . . . . . .9010-25-11
Miscellaneous . . . . . . . . . . . . . . . . . . . .9005-10-24
Steering system . . . . . . . . . . . . . . . . . . .9005-10-7
Switches . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2
L
Loader auxiliary valve (S.N.801200- ). . . .9025-05-28

P
Loader boom valve-Husco (S.N.801200-
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-24
Park brake
Loader bucket valve (S.N.801200- ) . . . . .9025-05-26
Adjustment . . . . . . . . . . . . . . . . . . . . . . .9020-20-3
Loader circuit relief operation-(S.N.801200-
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-23
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-30
Power train
Loader priority valve (S.N.801200- ) . . . . .9025-05-22
Diagnose malfunctions . . . . . . . . . . . . . .9020-15-4
Low sulfur diesel fuel conditioner . . . . . . . .9000-04-1
Pressure compensator
Lubricant
Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-4
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-9
Priority valve operation (S.N. -801199) . . . .9025-05-7
Storage . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-8
Pump
Lubrication system
Charge . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-1
Check . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-10-3
R Indx
M 3
Radiator
Main hydraulic system
Air flow test. . . . . . . . . . . . . . . . . . . . . . .9010-25-6
Diagnose. . . . . . . . . . . . . . . . . . . . . . . . .9025-15-4
Receiver/dryer
MFWD
Operation . . . . . . . . . . . . . . . . . . . . . . . .9031-05-8
Relief Valve Test-With Remote Pump. . . .9025-25-29
Operational checks . . . . . . . . . . . . . . . . .9020-10-5
Reverser
Mixing lubricants. . . . . . . . . . . . . . . . . . . . .9000-04-9
Accumulator . . . . . . . . . . . . . . . . . . . . .9020-05-11
Complete system test . . . . . . . . . . . . . .9020-25-14
Converter-in relief valve test . . . . . . . . . .9020-25-6
O Element leakage . . . . . . . . . . . . . . . . . .9020-25-12
Filter operation . . . . . . . . . . . . . . . . . . .9020-05-10
O-ring boss fittings . . . . . . . . . . . . . . . . . .9000-03-10 Forward operation . . . . . . . . . . . . . . . . . .9020-05-6
Oil Oil cooler restriction test . . . . . . . . . . . . .9020-25-8
Lines and fittings. . . . . . . . . . . . . . . . . . .9000-03-8 Oil passage identification . . . . . . . . . . . .9020-15-1
MFWD specification . . . . . . . . . . . . . . . .9000-04-6 Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-5

110703
PN=3
Index
Page Page
Oil warm-up procedure . . . . . . . . . . . . . .9020-25-1 MFWD Valve. . . . . . . . . . . . . . . . . . . . .9025-25-55

Operational checks . . . . . . . . . . . . . . . . .9020-10-2 Priority valve ’LS’ port
Pressure regulating valve . . . . . . . . . . .9020-05-12 flow . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-16
Pump flow test . . . . . . . . . . . . . . . . . . . .9020-25-4 Priority valve (S.N. -801199) . . . . . . . . .9025-25-13
Reverse operation. . . . . . . . . . . . . . . . . .9020-05-6 Relief valve test-amplification
System pressure test . . . . . . . . . . . . . . .9020-25-3 cylinder . . . . . . . . . . . . . . . . . . . . . . .9025-25-32
Test procedure . . . . . . . . . . . . . . . . . . .9020-25-16 Reverser converter-in relief valve . . . . . .9020-25-6
Test procedure chart. . . . . . . . . . . . . . .9020-25-16 Reverser element leakage . . . . . . . . . .9020-25-12
Test specifications and analysis . . . . . .9020-25-19 Reverser oil cooler restriction . . . . . . . . .9020-25-8
Roll-over protective structure Reverser pump flow . . . . . . . . . . . . . . . .9020-25-4
Torque specifications . . . . . . . . . . . . . . .9000-03-1 Reverser system pressure . . . . . . . . . . .9020-25-3
Stabilizer Valve Leakage. . . . . . . . . . . .9025-25-44
Steering System leakage . . . . . . . . . . .9025-25-38
Steering valve neutral drift . . . . . . . . . .9025-25-42
S
Torque Converter Stall Speed. . . . . . . .9020-25-10
Thermometer Installation, Digital . . . . . . . 9010-25-1,
Service brake
9020-25-1, 9025-25-1
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-24
Time Trac™
Specification
Installation. . . . . . . . . . . . . . . . . . . . . . . .9010-25-2
Engine oil . . . . . . . . . . . . . . . . . . . . . . . .9000-04-3
Toe-In
Grease . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7
Adjustment . . . . . . . . . . . . . . . . . . . . . . .9020-20-6
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .9000-04-5
Torque
Mechanical front wheel drive oil . . . . . . .9000-04-6
Wheel cap screw . . . . . . . . . . . . . . . . . .9000-03-1
Reverser oil . . . . . . . . . . . . . . . . . . . . . .9000-04-5
Torque converter
Transaxle oil . . . . . . . . . . . . . . . . . . . . . .9000-04-4
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-4
Stabilizer valve
Stall speed test . . . . . . . . . . . . . . . . . . .9020-25-10
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-56
Torque specifications
Staring motors
Roll-over protective structure. . . . . . . . . .9000-03-1
Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Torque value
Steering Cylinder Leakage . . . . . . . . . . . .9025-25-41
Flat face O-ring seal fitting . . . . . . . . . .9000-03-12
Steering system
Inch SAE four bolt flange fitting. . . . . . . .9000-03-7
Checks . . . . . . . . . . . . . . . . . . . . . . . . . .9025-10-1
Metric cap screw. . . . . . . . . . . . . . . . . . .9000-03-4
Storing lubricants . . . . . . . . . . . . . . . . . . . .9000-04-8
Metric four bolt flange fitting . . . . . . . . . .9000-03-6
Swing valve operation-Husco . . . . . . . . . .9025-05-48
O-Ring boss fitting . . . . . . . . . . . . . . . .9000-03-10
System operational check
30° cone seat hydraulic fittings . . . .9000-03-9
Fuel system . . . . . . . . . . . . . . . . . . . . . .9010-10-4
37° flare hydraulic fittings . . . . . . . .9000-03-9
System operational procedure
Indx Torque values
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . .9025-10-1
4 Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-2
Power train . . . . . . . . . . . . . . . . . . . . . . .9020-10-1
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-3
Transaxle
T Operational checks . . . . . . . . . . . . . . . . .9020-10-4
Second speed operation . . . . . . . . . . . .9020-05-21
Test Synchronizer operation . . . . . . . . . . . . .9020-05-20
Brake element leakage . . . . . . . . . . . . .9020-25-21 Third speed operation . . . . . . . . . . . . . .9020-05-22
Charge pump flow. . . . . . . . . . . . . . . . . .9025-25-8 Turbocharger
Charge pump pressure . . . . . . . . . . . . . .9025-25-6 Boost pressure test . . . . . . . . . . . . . . . . .9010-25-9
Complete reverser system . . . . . . . . . .9020-25-14
Cycle times . . . . . . . . . . . . . . . . . . . . . .9025-25-23
Hydraulic component leakage . . . . . . . .9025-25-44 V
Hydraulic oil cooler restriction . . . . . . . .9025-25-18
Main hydraulic pump flow . . . . . . . . . . . .9025-25-4 Valve
Main pump standby pressure . . . . . . . .9025-25-11 Auxiliary valve-Gresen . . . . . . . . . . . . .9025-05-40

110703
PN=4
Index
Page
Backhoe bucket-Gresen . . . . . . . . . . . .9025-05-38

Backhoe circuit relief-Gresen . . . . . . . .9025-05-33
Backhoe swing-Gresen . . . . . . . . . . . . .9025-05-39
Loader auxiliary-Gresen (S.N.
-801199) . . . . . . . . . . . . . . . . . . . . . .9025-05-19
Loader boom-Gresen (S.N.
-810199) . . . . . . . . . . . . . . . . . . . . . .9025-05-17
Loader Bucket-Gresen (S.N.
-801199) . . . . . . . . . . . . . . . . . . . . . .9025-05-15
Loader circuit relief- Gresen (S.N.
-801199 . . . . . . . . . . . . . . . . . . . . . . .9025-05-14
Stabilizer . . . . . . . . . . . . . . . . . . . . . . . .9025-05-56
Wheel fastening torque. . . . . . . . . . . . . . . .9000-03-1

Wiring diagram
A.C. compressor harness (W11) . . . . . .9015-10-38
Auxiliary valve harness (W14). . . . . . . .9015-10-40
Blower harness (W10). . . . . . . . . . . . . .9015-10-34
Cab roof harness (W5) . . . . . . . . . . . . .9015-10-17
Cab side console harness (W6) . . . . . .9015-10-19
Engine harness (W8) . . . . . . . . . . . . . .9015-10-31
Floor harness (W6) . . . . . . . . . . . . . . . .9015-10-21
Front console harness (W7) . . . . . . . . .9015-10-29
Radio harness (W12) . . . . . . . . . . . . . .9015-10-36
Indx
5

110703
PN=5
Index
Indx
6

110703
PN=6

John Deere 410d-510d Retroexcavadora Funcionamiento y Pruebas

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John Deere 410d-510d Retroexcavadora Funcionamiento y Pruebas

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Backhoe Loaders

Operation and Test

For complete service information also see:

Information is organized in groups for the various

TM1512 (07NOV03) Backhoe Loaders Operation and Test

SECTION 9005Operational Checkout Procedure

SECTION 9031Heating And Air Conditioning

All information, illustrations and specifications in this manual are based on

TM1512 (07NOV03) i Backhoe Loaders Operation and Test

TM1512 (07NOV03) ii Backhoe Loaders Operation and Test

Group 01Safety Information Checking Wheel Fastener Torque . . . . . . . . .9000-03-1

Group 03Torque Values

TM1512 (07NOV03) 9000-1 Backhoe Loaders Operation and Test

TM1512 (07NOV03) 9000-2 Backhoe Loaders Operation and Test

When you work around fuel, do not smoke or work near

Store flammable fluids away from fire hazards. Do not

Do not store oily rags; they can ignite and burn

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from

Never check battery charge by placing a metal object

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

TM1512 (07NOV03) 9000-01-1 Backhoe Loaders Operation and Test

Sulfuric acid in battery electrolyte is poisonous. It is strong

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

1. Do not induce vomiting.

TM1512 (07NOV03) 9000-01-2 Backhoe Loaders Operation and Test

Direct exposure to hazardous chemicals can cause

(See your John Deere dealer for MSDSs on chemical

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin

Avoid the hazard by relieving pressure before

Search for leaks with a piece of cardboard. Protect hands

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

TM1512 (07NOV03) 9000-01-3 Backhoe Loaders Operation and Test

Before working on the machine:

Lower all equipment to the ground.

Support Machine Properly

Always lower the attachment or implement to the ground

When implements or attachments are used with a tractor,

Wear Protective Clothing

Wear close fitting clothing and safety equipment

Operating equipment safely requires the full attention of

while operating machine.

TM1512 (07NOV03) 9000-01-4 Backhoe Loaders Operation and Test

Before starting a job:

Clean work area and machine.

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a

TM1512 (07NOV03) 9000-01-5 Backhoe Loaders Operation and Test

Replace missing or damaged safety signs. See the

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe

Follow recommended procedure for removal and