710D Backhoe Technical Manual TM1537 PDF

!DCG!
710D Backhoe Loader

Operation and Test
TECHNICAL MANUAL
710D Backhoe Loader
Operation and Test
TM1537 26FEB02 (ENGLISH)
For complete service information also see:

710D Backhoe Loader Operation
and Test (Complete) . . . . . . . . . . . . . . . . . . . TM1537
710D Backhoe Loader Repair (Complete) . . TM1538
Radial Piston Pump. . . . . . . . . . . . . . . . . . . . CTM7
6059 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . CTM8
Engine Accessories. . . . . . . . . . . . . . . . . . . . CTM11
OEM Engine Accessories . . . . . . . . . . . . . . . CTM67
Alternators and Starting Motors . . . . . . . . . . CTM77
6068 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . CTM104
!TM1537__26FEB02!
1200 Series Axle . . . . . . . . . . . . . . . . . . . . . . CTM43
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. See DB1990 Service Publications Catalog to order a
Essential tools required in performing certain service complete Technical Manual (TM) or a Technical
work are identified in this manual and are Manual Section (TMS). A complete Operation and Test
recommended for use. manual includes the following sections:
Live with safety: Read the safety messages in the 1. 9000

introduction of this manual and the cautions presented
throughout the text of the manual. Section 9000 General Information
2. 9005
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
Section 9005 Operational Checkout Procedure
the potential for personal injury.
3. 9010
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
Section 9010 Engine
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
4. 9015
Information is organized in groups for the various
Section 9015 Electrical System
components requiring service instruction. At the
beginning of each group are summary listings of all
5. 9020
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Section 9020 Power Train
specifications, wear tolerances, and torque values.
6. 9025
Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
Section 9025 Hydraulic System
the vital information needed for diagnosis, analysis,
testing, and repair.
7. 9031
Fundamental service information is available from
Section 9031 Heating and Air Conditioning
other sources covering basic theory of operation,
fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.
TX,710D00 1925FEB021/1
TM1537 (26FEB02) 710D Backhoe Loader

022602
PN=2
Introduction
John Deere Dealers
IMPORTANT: Please remove this page and route

through your service department.
Listed below is a brief explanation of WHAT was change

and WHY it was changed.
1. Section 9000:
To include any specifications, oil capacity and safety
concerns for new rear axle, transmission, charge
pump, park brake, and service brake valve.
2. Section 9005:
To add operational checks for new transmission, park
brake, differential lock, and service brake valve.
3. Section 9010:
To include miscellaneous updates and update serial
numbers.
4. Section 9015:
To include information for new engine, front console,
and side console harnesses. To add new tachometer
and low brake pressure warning system.
5. Section 9020:
To add information for new transmission and rear axle.
For machines (S.N. 872257 ), information on the
park brake and differential lock will now be provided in
this section.
6. Section 9025:
To make required changes because of new charge
pump located on the rear of the transmission. To
change plumbing and schematics required by the
removal of the park brake/differential lock valve. To
add information on the new service brake valve.
7. Section 9031:
To improve format and add information on new side
console harness.
8. ..
CED,TX03399,4247 1912JUN981/1

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Introduction

022602
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Introduction
Help!! Help!! Help!! Help!!
We need your help to continually improve our technical

publications. Please FAX or mail your comments, ideas
and improvements on this comment sheet.
SEND TO: John Deere Dubuque Works

P.O. Box 538
Dubuque, Iowa 52004-0538
Dept. 304
Attn: Publications Supervisor
FAX NUMBER: 319-589-5800
TM1537 710D Backhoe Loader Operation and Test Manual

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THANK YOU!
TX,HELP,153715 1916SEP961/1

022602
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Introduction

022602
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Contents
9000
SECTION 9000General Information Group 20Adjustments
Group 01Safety Information Group 25Test
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 15System Diagnostic Information
Group 20Adjustments
Group 25Tests
SECTION 9015Electrical System 9015

Group 05System Information
Group 10ASystem Diagrams (S.N. 872256)
Group 10BSystem Diagrams (S.N. 872257 )
Group 15ASub-System Diagnostics (S.N.
872256)
Group 15BSub-System Diagnostics (S.N. 9020
872257 )
Group 20References
SECTION 9020Power Train

Group 05ATheory of Operation (S.N. 872256) 9025
Group 05BTheory of Operation (S.N. 872257 )
Group 15ASystem Diagnostic Information (S.N.
872256)
Group 15BSystem Diagnostic Information (S.N.
872257 )
9031
Group 20Adjustments
Group 25ATests (S.N. 872256)
Group 25BTests (S.N. 872257 )
SECTION 9025Hydraulic System

Group 05Theory of Operation INDX
Group 15Diagnostic Information
Group 20Adjustments
Group 25Tests
SECTION 9031Heating and Air Conditioning

Group 05Theory of Operation
Group 15Diagnostic Information
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 2002
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright 1993, 1997, 1998
TM1537 (26FEB02) i 710D Backhoe Loader

022602
PN=1
Contents
9000
9005
9010
9015
9020
9025
9031
INDX
TM1537 (26FEB02) ii 710D Backhoe Loader

022602
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9000
Section 9000
General Information
Contents
Page Page
Group 01Safety Information 710D Tire Pressure . . . . . . . . . . . . . . . . . . . .9000-03-1

Handle Fluids SafelyAvoid Fires . . . . . . . .9000-01-1 ROPS Torque Specifications . . . . . . . . . . . . .9000-03-2
Prevent Battery Explosions . . . . . . . . . . . . . .9000-01-1 Checking Wheel Fastener Torque . . . . . . . . .9000-03-3
Prepare for Emergencies. . . . . . . . . . . . . . . .9000-01-1 Unified Inch Bolt and Cap Screw Torque
Prevent Acid Burns . . . . . . . . . . . . . . . . . . . .9000-01-2 Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-4
Handle Chemical Products Safely . . . . . . . . .9000-01-3 Metric Bolt and Cap Screw Torque
Avoid High-Pressure Fluids . . . . . . . . . . . . . .9000-01-3 Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-5
Park Machine Safely . . . . . . . . . . . . . . . . . . .9000-01-4 Additional Metric Cap Screw Torque
Support Machine Properly . . . . . . . . . . . . . . .9000-01-4 Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-6
Wear Protective Clothing. . . . . . . . . . . . . . . .9000-01-4 Check Oil Lines And Fittings . . . . . . . . . . . . .9000-03-8
Work in Clean Area. . . . . . . . . . . . . . . . . . . .9000-01-5 Service Recommendations for 37 Flare
Service Machines Safely . . . . . . . . . . . . . . . .9000-01-5 and 30 Cone Seat Connectors . . . . . . . . .9000-03-9
Work In Ventilated Area . . . . . . . . . . . . . . . .9000-01-5 Service Recommendations for O-Ring
Illuminate Work Area Safely . . . . . . . . . . . . .9000-01-5 Boss Fittings . . . . . . . . . . . . . . . . . . . . . .9000-03-10
Replace Safety Signs . . . . . . . . . . . . . . . . . .9000-01-6 Service Recommendations for Flat Face
Use Proper Lifting Equipment . . . . . . . . . . . .9000-01-6 O-Ring Seal Fittings. . . . . . . . . . . . . . . . .9000-03-12
Remove Paint Before Welding or Heating . . .9000-01-6 Service Recommendations For Inch
Avoid Heating Near Pressurized Fluid Series Four Bolt Flange Fittings. . . . . . . .9000-03-13
Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-7 Service Recommendations for Metric
Keep ROPS Installed Properly . . . . . . . . . . .9000-01-7 Series Four Bolt Flange Fitting . . . . . . . .9000-03-14
Service Tires Safely . . . . . . . . . . . . . . . . . . .9000-01-8
Avoid Harmful Asbestos Dust . . . . . . . . . . . .9000-01-8 Group 04Fuels and Lubricants
Practice Safe Maintenance . . . . . . . . . . . . . .9000-01-9 Fuel Specifications . . . . . . . . . . . . . . . . . . . .9000-04-1
Use Proper Tools . . . . . . . . . . . . . . . . . . . . .9000-01-9 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1
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
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . .9000-04-3
Group 02General Specifications Transmission Oil, Hydraulic System Oil and
710D Backhoe Loader Specifications . . . . . .9000-02-2 Differential Oil . . . . . . . . . . . . . . . . . . . . . .9000-04-4
710D Backhoe Loader Dimensions . . . . . . . .9000-02-3 Mechanical Front Wheel Drive Oil . . . . . . . . .9000-04-5
710D Backhoe Loader Engine Specifications Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-6
(S.N. 830204). . . . . . . . . . . . . . . . . . . . .9000-02-4 Grease for Extendible Dipperstick . . . . . . . . .9000-04-6
710D Backhoe Loader Engine Alternative and Synthetic Lubricants . . . . . . .9000-04-7
Specifications (S.N. 830205 ) . . . . . . . . .9000-02-5 Mixing of Lubricants . . . . . . . . . . . . . . . . . . .9000-04-7
710D Backhoe Loader Specifications (S.N. Cold Weather Operation . . . . . . . . . . . . . . . .9000-04-7
872328) . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-6 Diesel Engine Coolant. . . . . . . . . . . . . . . . . .9000-04-8
710D Backhoe Loader Specifications (S.N.
872329 ). . . . . . . . . . . . . . . . . . . . . . . . .9000-02-8
710D Backhoe LoaderOther
Information. . . . . . . . . . . . . . . . . . . . . . . .9000-02-11
710D Backhoe Buckets . . . . . . . . . . . . . . . .9000-02-13
710D Drain and Refill Capacities. . . . . . . . .9000-02-13
710D Backhoe Loader Lifting Capacities . . .9000-02-14
Group 03Torque Values

Hardware Torque Specifications . . . . . . . . . .9000-03-1
TM1537 (26FEB02) 9000-1 710D Backhoe Loader
022602
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Contents
9000

022602
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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
TM1537 (26FEB02) 9000-01-1 710D Backhoe Loader

022602
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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

022602
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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

022602
PN=13
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

022602
PN=14
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

022602
PN=15
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

022602
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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

022602
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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

022602
PN=19
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

022602
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Group 02
General Specifications
9000
02
1

022602
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9000
02 710D Backhoe Loader Specifications
2
NOTE: Specifications and design subject to change tires; 14.5/7516.1, 10PR, F3 front tires with UN19OCT88
T6245AF1
without notice. Wherever applicable, 75 percent CaCl2 fill; 1.15 m3(1.5 cu yd) loader
specifications are in accordance with ICED bucket; 610 mm (24 in.) backhoe bucket;
and SAE Standards. Except where otherwise ROPS/FOPS; full fuel tank and 79 kg (175 lb)
noted, these specifications are based on a operator.
standard machine with 21L-24, 16PR, R4 rear
TX,115,RR2655 1919AUG991/1

022602
PN=22
9000
710D Backhoe Loader Dimensions 02
3
Extendible Dipperstick
Backhoe Standard Retracted Extended
ALoading height, truck loading position 4.03 m (13 ft 3 in.) 3.98 m (13 ft 1 in.) 4.65 m (15 ft 3 in.)
BReach from center of swing mast 6.90 m (22 ft 8 in.) 6.90 m (22 ft 8 in.) 8.31 m (27 ft 3 in.)
CReach from center of rear axle 8.15 m (26 ft 9 in.) 8.15 m (26 ft 9 in.) 9.56 m (31 ft 4 in.)
DDigging depth (SAE):
(1) 610 mm (2 ft) flat bottom 5.53 m (18 ft 2 in.) 5.51 m (18 ft 1 in.) 7.03 m (23 ft 1 in.)
(2) 2440 mm (8 ft) flat bottom 5.26 m (17 ft 3 in.) 5.24 m (17 ft 2 in.) 6.82 m (22 ft 4 in.)
EMaximum digging depth 5.55 m (18 ft 2 in.) 5.52 m (18 ft 1 in.) 7.04 m (23 ft 1 in.)
FGround clearance, minimum 356 mm (14 in.) 356 mm (14 in.) 356 mm (14 in.)
GBucket rotation 152/162 152/162 152/162
HTransport height 4.21 m (13 ft 10 in.) 4.31 m (13 ft 11 in.) 4.31 m (13 ft 11 in.)
JOverall length, transport 8.13 m (26 ft 8 in.) 8.13 m (26 ft 8 in.) 8.13 m (26 ft 8 in.)
KStabilizer widthtransport 2.44 m (8 ft 0 in.) 2.44 m (8 ft 0 in.) 2.44 m (8 ft 0 in.)
LStabilizer spreadoperating 3.48 m (11 ft 5 in.) 3.48 m (11 ft 5 in.) 3.48 m (11 ft 5 in.)
MOverall width (less loader bucket) 2235 mm (88 in.) 2235 mm (88 in.) 2235 mm (88 in.)
Digging force, bucket cylinder (power dig position) 57.5 kN (12,940 lb force) 57.5 kN (12,940 lb force) 57.5 kN (12,940 lb force)
Digging force, crowd cylinder 42.7 kN (9600 lb force) 42.7 kN (9600 lb force) 29.8 kN (6700 lb force)
Loader with 1.24 m3 (1.62 yd3 ) Loader with 1.0 m3 (1.375 yd3 ) Bucket
Bucket and MFWD
NWheelbase 2.29 m (90.5 in.) 2.29 m (90.5 in.)
ODig below groundbucket level 147 mm (5.8 in.) 152 mm (6.0 in.)
PRollback at ground level 40 40
QDump clearance, bucket at 40 2.80 m (9 ft 6 in.) 2.80 m (9 ft 6 in.)
RMaximum height to bucket hinge pin 3.57 m (11 ft 8 in.) 3.61 m (11 ft 10 in.)
SMaximum bucket dump angle 40 40
TReach at full height, bucket at 40 851 mm (33.5 in.) 836 mm (32.9 in.)
TX,115,RR2626 1919AUG991/1

022602
PN=23
9000
02 710D Backhoe Loader Engine Specifications
4
(S.N. 830204)
Item Measurement Specification
Engine: John Deere 6059T

turbocharged diesel, 4-stroke cycle
Net Power @ 2200 Power SAE 86 kW (115 hp)
Gross Power @ 2200 Power SAE 90 kW (120 hp)
Cylinders Quantity 6
Bore and Stroke Distance 106.5 x 110 mm (4.19 x 4.33 in.)
Displacement Volume 5.884 L (359 cu in.)
Fuel Consumption, Typical Consumption 7.6 to 12.5 L/h (2.03.3 gal/hr)
Compression Ratio Compression 17.8 to 1
Maximum Torque @ 25% at 1400 Torque Rise 465 Nm (343 lb-ft)

rpm
Main Bearings Quantity 7
Electrical System Voltage 12 volts
Alternator Amperage 65 amps
Lubrication Pressure system w/full-flow filter and

cooler
Fan Suction
Air Cleaner Dry
CED,OUO1032,1216 1919AUG991/1

022602
PN=24
9000
710D Backhoe Loader Engine Specifications 02
5
(S.N. 830205 )
Engine: John Deere 6068T and

PowerTech 6068T turbocharged
diesel, 4-stroke cycle, Model #
6068TT050
Net Power @ 2200 Power SAE 87 kW (116 hp)
Gross Power @ 2200 Power SAE 93 kW (125 hp)
Cylinders Quantity 6
Bore and Stroke Distance 106.5 x 127 mm (4.19 x 5.00 in.)
Displacement Volume 6.8 L (414 cu in.)
Fuel Consumption, Typical Consumption 9.5 to 14.3 L/h (2.53.8 gal/hr)
Compression Ratio Compression 17.0 to 1
Maximum Torque @ 27% at 1400 Torque Rise 515.5 Nm (380 lb-ft)

rpm
Main Bearings Quantity 7
Electrical System Voltage 12 volts
Alternator Amperage 95 amps w/AC

65 amps w/o AC
PowerTech is a registered trademark of Deere & Company CED,OUO1032,1217 1919AUG991/1

022602
PN=25
9000
02 710D Backhoe Loader Specifications (S.N. 872328)
6
Travel Speeds: Forward Travel with

standard 21L x 24 rear and 14.5/75 x
16.1 front tires
Forward 1 Speed 5.1 km/h (3.1 mph)
Travel Speeds: Reverse Travel with

16.1 front tires
Reverse 1 Speed 5.4 km/h (3.4 mph)

MFWD and 21L x 28 (required) rear
and 15 x 19.5 front tires

MFWD and 21L x 28 (required) rear
and 15 x 19.5 front tires
Continued on next page TX,9000,BG785 1919AUG991/2

022602
PN=26
9000
Item Measurement Specification 02
7
Steering
Non-Powered Axle Turning radius with brakes 4.37 m (14 ft 4 in.)

Turning radius without brakes 4.63 m (15 ft 2 in.)
Clearance circle with brakes 11.02 m (36 ft 2 in.)
Clearance circle without brakes 11.54 m (37 ft 10 in.)
Axle oscillation stop-to-stop 20
Mechanical Front-Wheel-Drive Turning radius with brakes 4.39 m (14 ft 5 in.)

Steering wheel turns stop-to-stop, 3.0 to 3.8
both axles
Hydraulic System: Closed center

(variable flow, constant pressure)
Main Relief Pressure 17 500 kPa (175 bar) (2550 psi)
Main Pump Radial Pistons Quantity 16 radial pistons, variable flow
Flow @ 15 170 kPa (151 bar) Flow Rate 201 L/min (53 gpm)
(2200 psi)
Charge Pump Flow @ Fast Idle Flow Rate 64 L/min (17 gpm)
(Minimum)
Filter, Return Oil 10 micron steel enclosed,

replaceable paper element
Screen, Pressure Oil 20/cm (50/in.) mesh
TX,9000,BG785 1919AUG992/2

022602
PN=27
9000
02 710D Backhoe Loader Specifications (S.N. 872329 )
8

16.1 front tires

16.1 front tires

MFWD and 21L x 28 rear and 15 x
19.5 front tires

MFWD and 21L x 28 rear and 15 x
19.5 front tires
Continued on next page CED,TX03679,3599 1919AUG991/3

022602
PN=28
9000
Item Measurement Specification 02
9

MFWD and 20.5L x 25 rear and 15 x
19.5 front tires
Forward 4 Speed 38.7 km/h (24.1 (mph)

MFWD and 21.5L x 25 rear and 15 x
19.5 front tires
Steering
Non-Powered Axle Turning radius with brakes 4.37 m (14 ft 4 in.)

Mechanical Front-Wheel-Drive Turning radius with brakes 4.39 m (14 ft 5 in.)

Steering wheel turns stop-to-stop, 3.0 to 3.8
both axles

022602
PN=29
9000
02 Item Measurement Specification
10
Hydraulic System: Closed center

(variable flow, constant pressure)
Main Relief Pressure 17 500 kPa (175 bar) (2550 psi)
Main Pump Radial Pistons, Quantity 16

Variable Flow
Flow @ 15 170 kPa (151 bar) Flow Rate 201 L/min (53 gpm)
(2200 psi)
Charge Pump Flow @ Fast Idle Flow Rate 90 L/min (24 gpm)
(Minimum)
CED,TX03679,3599 1919AUG993/3

022602
PN=30
9000
710D Backhoe LoaderOther Information 02
11
Transmission (S.N. 872328):
John Deere designed and built planetary power shift with

torque converter, four speeds forward and two speeds
reverse. The 310 mm (12.2 in.) single stage, dual phase
torque converter has 1.99:1 stall torque ratio.
Transmission (S.N. 872329 ):
A single stage torque converter drives a hydraulically

engaged, four speeds forward and three speeds reverse,
countershaft type power shift transmission.
MFWD AxleIf Equipped:
For machines (S.N. 872328), limited slip differential with

19.64:1 ratio.
For machines (S.N. 872329 ), limited slip differential

and opposite input rotation with 14.00:1 ratio.
Final Drives:
Heavy-duty, inboard mounted planetary type. Evenly

distributes axle shock loads over three gears that run in a
cooling oil bath.
Brakes:
Hydraulic wet disk service brakes are mounted inboard

and are pressure cooled and lubricated. They are
self-adjusting, self-equalizing, and require no periodic
service. Individual pedals allow them to be applied
together or separately. The parking brake is an
independent system that is spring-applied, hydraulically
released and controlled by an electric switch on the
control console. All brakes conform to SAEJ1473.
Tires:
Regular
Front: 14.5/75 x 16.1, 10PR, F3

Rear: 21L x 24, 16PR, R4
Axle

022602
PN=31
9000
02 Front: 14.5/75 x 16.1, 10PR, F3
12
Rear: 21L x 28, 14PR, R4
Front: 16.5L x 16.1, 10PR, I-1
Rear: 21L x 28, 14PR, R4
MFWD
Front: 15 x 19.5, 8PR, lug thread

Rear: 21L x 28, 14PR, R4
Operating Weights:
710D Basic Machine Weight 10 450 kg (23 000 lb)
Add Optional Weights:
Cab Weight 227 kg (500 lb)
MFWD Weight 590 kg (1300 lb)
Extendible Dipperstick with Weight 618 kg (1362 lb)

Required Counterweights
Optional Front Counterweight Weight 318 kg (700 lb)
Reversible Stabilizer Pads Weight 41 kg (90 lb)
Loader buckets:
1.24 m3 (1.62 cu yd) Weight 435 kg (960 lb)
1.34 m3 (1.87 cu yd) Weight 680 kg (1500 lb)
CED,TX03679,3601 1919AUG992/2

022602
PN=32
9000
710D Backhoe Buckets 02
13
Width mm (in.) Heaped Capacity m3 (cu yd)
Loader 2337 (92) 1.24 (1.62)
2438 (96) 1.34 (1.75)
Backhoe 457 (18) 0.22 (0.29)
610 (24) 0.31 (0.41)
762 (30) 0.42 (0.55)
914 (36) 0.53 (0.69)
TX,115,RR2628 1919AUG991/1
710D Drain and Refill Capacities
Engine Coolant Capacity 26 L (28 qt)
Engine Oil (Including Filter) Capacity 19 L (20 qt)
Transmission with MFWD (S.N. Capacity 13.2 L (3.5 gal)

872328)
Transmission without MFWD Capacity 9.5 L (2.5 gal)

(S.N. 872328)
Transmission (S.N. 872329 ) Capacity 15 L (4 gal)
Hydraulic Reservoir Capacity 40 L (10.5 gal)
Fuel Tank Capacity 166 L (44 gal)
Front Axle (MFWD) Capacity 12.3 L (3.25 gal)
Front Wheel Planetary (MFWD) Capacity 1 L (1.1 qt)
Rear Axle Differential (S.N. Capacity 18 L (4.75 gal)

872328)
Rear Axle (S.N. 872329 ) Capacity 16 L (4.25 gal)
TX,9000,BG788 1919AUG991/1

022602
PN=33
9000
02 710D Backhoe Loader Lifting Capacities
14
UN06OCT92
T7840AS
Lift Capacity, Backhoe with Standard Dipperstick. Based on SAE J31. Rated lift capacities are in kg (lb). Lift
capacities are hydraulically limited.
ADipper Lift at 65 BSwing Pivot CBoom Lift
Lifting capacity ratings are made with bucket hinge pin, Angle between boom and ground is 65. Machine is
loader bucket and stabilizers on firm, level ground. Lift equipped with 610 mm (24 in.) standard bucket,
capacities are hydraulically limited. Lifting capacities standard or extendible dipperstick and standard
are 87% of the maximum lift over any point on the equipment.
swing arc and do not exceed 75% of the tipping load.
Continued on next page TX,115,RR2660 1919AUG991/3

022602
PN=34
9000
02
15
UN26OCT92
T7840AU
Lift Capacity, Backhoe with 1.52 m (5 ft) Extendible Dipperstick, Retracted. Based on SAE J31. Rated lift capacities
are in kg (lb). Lift capacities are hydraulically limited.
NOTE: Loader bucket on ground significantly improves to the side. Lift capacity over the rear is not
side stability, therefore improving lift capacity affected.
Continued on next page TX,115,RR2660 1919AUG992/3

022602
PN=35
9000
02
16
UN06OCT92
T7840AT
Lift Capacity, Backhoe with 1.52 m (5 ft) Extendible Dipperstick, Extended. Based on SAE J31. Rated lift capacities
are in kg (lb). Lift capacities are hydraulically limited.
TX,115,RR2660 1919AUG993/3

022602
PN=36
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
710D Tire Pressure
NOTE: Tire shipping pressure may not be the same as

tire operating pressure. You may change tire
pressures to suit working conditions according to
tire manufacturers recommendations.
Tire Size (Front)
14.5/75 x 16.1, 10PR, F3 Pressure 276 kPa (2.8 bar) (40 psi)
15 x 19.5, 8PR (w/MFWD only) Pressure 276 kPa (2.8 bar) (40 psi)
16.5 L x 16.1, 10PR, I-1 Pressure 276 kPa (2.8 bar) (40 psi)
Tire Size (Rear)
20.5 x 25, 12PR, R4 Pressure 241 kPa (2.4 bar) (35 psi)
21 L x 24, 16PR, R4 Pressure 276 kPa (2.7 bar) (40 psi)
21 L x 28, 14PR, R4 Pressure 248 kPa (2.5 bar) (36 psi)
TX,55,RR2589 1902OCT981/1

022602
PN=37
Torque Values
9000
03 ROPS Torque Specifications
2
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 420 84 Nm (310 62 ft-lb).
ROPS Mounting Bolts Torque 420 84 Nm 310 62 lb-ft)
CED,OUTX782,583 1918AUG991/1

022602
PN=38
Torque Values
9000
Checking Wheel Fastener Torque 03
3
Tighten wheel cap screws.
Specification
Front Standard AxleTorque ................ 230 + 35 -46 Nm (170 + 26 -34
UN18OCT88
ft-lb)
Front MFWD AxleTorque .................... 407 + 60 -80 Nm (300 + 45 -60
ft-lb)
Rear AxleTorque ................................. 575 + 170 -115 Nm (425 + 125
-85 ft-lb)
T6000AU
UN14MAR94
T8196AY
TX,90,RR2625 1919AUG991/1

022602
PN=39
Torque Values
9000
03 Unified Inch Bolt and Cap Screw Torque Values
4
1902APR97
TS1656
DX,TORQ1 1920JUL941/1

022602
PN=40
Torque Values
9000
Metric Bolt and Cap Screw Torque Values 03
5
1902APR97
TS1657
DX,TORQ2 1920JUL941/1

022602
PN=41
Torque Values
9000
03 Additional Metric Cap Screw Torque Values
6
UN18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
UN18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
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

022602
PN=42
Torque Values
9000
METRIC CAP SCREW TORQUE VALUESa 03
7
Nominal
Dia T-Bolt H-Bolt M-Bolt
Nm lb-ft Nm lb-ft Nm lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is 10%.
04T,90,M170 1901AUG942/2

022602
PN=43
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

022602
PN=44
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

022602
PN=45
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

022602
PN=46
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

022602
PN=47
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

022602
PN=48
Torque Values
9000
Service Recommendations For Inch Series Four Bolt Flange Fittings 03
13
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
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
2-1/2 1/2-13 UNC 107 131 79 97
center of flange and install cap screws. Flange
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.
TX,9000,BG380 1914JAN971/1

022602
PN=49
Torque Values
9000
03 Service Recommendations for Metric Series Four Bolt Flange Fitting
14
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Threadb Nm lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42
M12 95 70
4. Single piece flange (D): Place hydraulic line in
center of flange and install four cap screws. Flange M14 157 116
must be centrally located on port. Hand tighten cap M16 217 160
screws to hold flange in place. Do not pinch O-ring. M18 334 246
M20 421 318
5. After components are properly positioned and cap a
Tolerance 10%. The torques given are enough for the given
screws are hand tightened, tighten one cap screw, size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
b
Metric standard thread.
04T,90,K175 1905JAN961/1

022602
PN=50
Group 04
Fuels and Lubricants
9000
Fuel Specifications 04
1
Use ONLY clean, high-quality fuel. For maximum filter life, sediment and water should not
be more than 0.10 percent.
Use Grade No. 2-D fuel above 40F (4C).
The cetane number should be 40 minimum. If you
Use Grade No. 1-D fuel below 40F (4C). operate your machine where air temperatures are
normally low or where altitudes are high, you may
Use Grade No. 1-D fuel for all air temperatures at need fuel with a higher cetane number.
altitudes above 1 500 m (5000 ft).
Cloud PointFor cold weather operation, cloud point
IMPORTANT: If fuel sulfur content exceeds 0.5 should be -12C (10F) below lowest normal air
percent, the engine oil drain interval temperature.
must be reduced by 50 percent (to
125 hours).
Use fuel with less than 1.0 percent

sulfur. If possible, use fuel with less
than 0.5 percent sulfur.
TX,9000,BG789 1904MAR971/1
Diesel Fuel
Consult your local fuel distributor for properties of the Fuel lubricity should pass a minimum of 3100 gram
diesel fuel available in your area. load level as measured by the BOCLE scuffing test.
In general, diesel fuels are blended to satisfy the low Sulfur content:
temperature requirements of the geographical area in
which they are marketed. Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
Diesel fuels specified to EN 590 or ASTM D975 are If diesel fuel with sulfur content greater than 0.5%
recommended. sulfur content is used, reduce the service interval for
engine oil and filter by 50%.
In all cases, the fuel shall meet the following DO NOT use diesel fuel with sulfur content greater
properties: than 1.0%.
Cetane number of 40 minimum. Cetane number Bio-diesel fuels may be used ONLY if the fuel
greater than 50 is preferred, especially for properties meet DIN 51606 or equivalent specification.
temperatures below -20C (-4F) or elevations above
1500 m (5,000 ft). DO NOT mix used engine oil or any other type of
lubricant with diesel fuel.
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature.
DX,FUEL1 1917FEB991/1

022602
PN=51
9000
04 Do Not Use Galvanized Containers
2
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 1905FEB991/1

022602
PN=52
9000
Diesel Engine Oil 04
3
1922MAY96
T101239
Use oil viscosity based on the expected air John Deere TORQ-GARD SUPREME
temperature range during the period between oil
changes. Other oils may be used if they meet one or more of
the following:
The following oil is preferred:
API Service Classification CG-4
John Deere PLUS-50
Multi-viscosity diesel engine oils are preferred.
If John Deere PLUS-50 engine oil and a John Deere
oil filter are used, the service interval for oil and filter If diesel fuel with sulfur content greater than 0.5% is
changes may be extended by 50 hours. used, reduce the service interval by 50%.
The following oil is also recommended:
PLUS-50 is a registered trademark of Deere & Company.

TORQ-GARD SUPREME is a registered trademark of Deere &
Company. TX,45,JC2234 1919AUG991/1

022602
PN=53
9000
04 Transmission Oil, Hydraulic System Oil and Differential Oil
4
1910MAY96
T100663
Use oil viscosity based on the expected air John Deere Standard JDM J20C
temperature range during the period between oil John Deere Standard JDM J20D
changes.
Use the following oil when a biodegradable fluid is
The following oils are preferred: required:
JOHN DEERE HY-GARD John Deere BIO-HY-GARD1, 2

John Deere Low Viscosity HY-GARD
Other oils may be used if they meet one of the

following:
HY-GARD is a registered trademark of Deere & Company.

BIO-HY-GARD is a trademark of Deere & Company.
1
BIO-HY-GARD meets or exceeds the minimum biodegradability of
80% within 21 days according to CEC-L-33T-82 test method.
2
BIO-HY-GARD should not be mixed with mineral oils because this
reduces the biodegradability and makes proper oil recycling
impossible.
TX,45,JC1864 1919AUG991/1

022602
PN=54
9000
Mechanical Front Wheel Drive Oil 04
5
1905JAN89
T6247AB
Depending on the expected air temperature range John Deere API GL-5 Gear Oil
between oil changes, use oil viscosity shown on the Oils meeting API Service GL-5 (MIL-L-2105B or
chart above. MIL-2105C)
The following oils are recommended: Oil meeting MIl-L-10324A may be used as arctic oil.
T82,45,C11 1915MAR931/1

022602
PN=55
9000
04 Grease
6
1927MAR95
T8358AI
Use grease based on NLGI consistency numbers and John Deere HIGH TEMPERATURE EP GREASE
the expected air temperature range during the service John Deere GREASE-GARD
interval.
Other greases may be used if they meet one of the
The following greases are preferred: following:
John Deere MOLY HIGH TEMPERATURE EP NLGI Performance Classification GC-LB

GREASE
GREASE-GARD is a registered trademark of Deere & Company. TX,45,JC1134 1919AUG991/1
Grease for Extendible Dipperstick
SAE Multipurpose Grease with Extreme Pressure (EP)

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

022602
PN=56
9000
Alternative and Synthetic Lubricants 04
7
Conditions in certain geographical areas may require

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

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

recommendations.
Synthetic lubricants may be used if they meet the

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

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

finished lubricant meets the performance requirements.
DX,ALTER 1918MAR961/1
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet information and recommendations.
certain specifications and performance requirements.
Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricant
performance.
DX,LUBMIX 1918MAR961/1
Cold Weather Operation
Additional information on cold weather operation is

available from your John Deere dealer.
T82,BHFL,E 1931MAY901/1

022602
PN=57
9000
04 Diesel Engine Coolant
8
The engine cooling system is filled to provide protection at lower temperatures is required, consult
year-round protection against corrosion and cylinder your John Deere dealer for recommendations.
liner pitting, and winter freeze protection to -37C
(-34F). Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
The following engine coolant is preferred for service: water is recommended for mixing with ethylene glycol
base engine coolant concentrate.
John Deere COOL-GARD Prediluted Coolant
IMPORTANT: Do not use cooling system sealing
The following engine coolant is also recommended: additives or antifreeze that contains
sealing additives.
John Deere COOL-GARD Coolant Concentrate in a
40 to 60% mixture of concentrate with quality water. Coolant Drain Intervals
Other low silicate ethylene glycol base coolants for Drain the factory fill engine coolant, flush the cooling
heavy-duty engines may be used if they meet one of system, and refill with new coolant after the first 3
the following specifications: years or 3000 hours of operation. Subsequent drain
intervals are determined by the coolant used for
ASTM D5345 (prediluted coolant) service. At each interval, drain the coolant, flush the
ASTM D4985 (coolant concentrate) in a 40 to 60% cooling system, and refill with new coolant.
mixture of concentrate with quality water
When John Deere COOL-GARD is used, the drain
Coolants meeting these specifications require use of interval may be extended to 5 years or 5000 hours of
supplemental coolant additives, formulated for operation, provided that the coolant is tested annually
heavy-duty diesel engines, for protection against AND additives are replenished, as needed, by adding
corrosion and cylinder liner erosion and pitting. a supplemental coolant additive.
A 50% mixture of ethylene glycol engine coolant in If COOL-GARD is not used, the drain interval is
water provides freeze protection to -37C (-34F). If reduced to 2 years or 2000 hours of operation.
DX,COOL3 1905FEB991/1

022602
PN=58
Section 9005
Operational Checkout Procedure
Contents 9005
Page
Group 10Operational Checkout Procedure

Operational Checkout Procedure. . . . . . . . . .9005-10-1
John Deere Radial Piston PumpUse
CTM7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-1
John Deere 6059 Engine (S.N. 830204)
Use CTM8 . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-1
John Deere Engine Accessories (S.N.
830204)Use CTM11 . . . . . . . . . . . . . .9005-10-2
John Deere Inboard Planetary AxlesUse
CTM43. . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2
John Deere OEM Engine Accessories
(S.N. 830205 )Use CTM67 . . . . . . . . .9005-10-2
John Deere Alternators And Starting
MotorsUse CTM77 . . . . . . . . . . . . . . . . .9005-10-2
John Deere 6068 Engine (S.N. 830205 )
Use CTM104 . . . . . . . . . . . . . . . . . . . . . . .9005-10-3
Gauges and Indicators Check With Engine
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-3
Gauge and Indicators Check With Engine
On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-6
Brake System Check. . . . . . . . . . . . . . . . . .9005-10-10
Steering System Check. . . . . . . . . . . . . . . .9005-10-14
Transmission Neutral Disconnect Circuit
Check . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-15
Driving Check (MFWD Disengaged If
Equipped) . . . . . . . . . . . . . . . . . . . . . . . .9005-10-16
Driving Check for Mechanical Front Wheel
Drive (MFWD) . . . . . . . . . . . . . . . . . . . . .9005-10-25
Hydraulic System Check . . . . . . . . . . . . . . .9005-10-27
Heater and Air Conditioning Checks . . . . . .9005-10-33
Cooling System Checks . . . . . . . . . . . . . . .9005-10-37
Air System Checks . . . . . . . . . . . . . . . . . . .9005-10-39
Lubrication System Checks . . . . . . . . . . . . .9005-10-41
Fuel System Checks . . . . . . . . . . . . . . . . . .9005-10-41
Engine Speed and Performance Checks . . .9005-10-42
Accessories Check (Engine Stopped) . . . . .9005-10-44
Cab Component Checks . . . . . . . . . . . . . . .9005-10-46
Miscellaneous Check . . . . . . . . . . . . . . . . .9005-10-51

022602
PN=1
Contents
9005

022602
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 Information)
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 (Tests)

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
John Deere Radial Piston PumpUse CTM7
For additional information, the component CTM is also

required.
Use the CTM in conjunction with this machine manual.
UN07SEP88
M44215
CED,TX03679,5015 1905FEB991/1
John Deere 6059 Engine (S.N. 830204)

Use CTM8

required.
UN07SEP88

M44215
CED,TX03679,5016 1905FEB991/1

022602
PN=61

830204)Use CTM11

9005 required.
10
UN07SEP88
2 Use the CTM in conjunction with this machine manual.
M44215
CED,TX03679,5017 1905FEB991/1

CTM43

required.
UN07SEP88
M44215
CED,TX03679,5019 1905FEB991/1
John Deere OEM Engine Accessories (S.N.

830205 )Use CTM67

required.
UN07SEP88
M44215
CED,TX03679,5016 1905FEB991/1
John Deere Alternators And Starting

MotorsUse CTM77

required.
UN07SEP88

M44215
CED,TX03679,5018 1905FEB991/1

022602
PN=62
John Deere 6068 Engine (S.N. 830205 )

Use CTM104

required. 9005
10
UN07SEP88
Use the CTM in conjunction with this machine manual. 3
M44215
CED,TX03679,5014 1905FEB991/1
Gauges and Indicators Check With Engine Off
1/1
Gauges, Indicators and OK: Go to next check.

FNR/Range Lever Check
NOT OK: No movement
of fuel gauge, check logic
module fuse. Go to
Section 9015 Gauges and
Monitor ChecksFuel
Gauge Check.
T7447AH UN04JAN91
NOT OK: Clean air
T7860AE UN06OCT92
cleaner element.
Move FNR/range lever to neutral position.
NOT OK: Check MFWD
fuse.
Turn key switch to ON position.
NOT OK: Inspect and
LOOK: Fuel gauge must move to indicate correct fuel level reading.
repair bulb. Go to Repair
Manual.
LISTEN: Accessory relay click must be heard when key is turned on.
LOOK: Front wheel drive indicator light (if equipped) must be ON.
LOOK: Hour meter must not be turning.

1/1

022602
PN=63
Start Circuit Check OK: Go to next check.
NOT OK: If starting motor

turns slowly, turn steering
wheel left and right while
cranking engine. If
9005
starting speed increases,
10
check hydraulic pump
4
T7394BH UN10DEC90 T103007 UN30OCT98 destroke solenoid wiring.
(S.N. 872256) (S.N. 872257) Go to Section 9015
Starting Circuit Checks,
Apply park brake. Hydraulic Pump Destroke
Solenoid.
Move FNR/range lever to neutral position and turn key to
START position. NOT OK: If engine turns
but does not start, check
LOOK: During engine cranking, all eight indicator lights fuel shutoff fuse.
must be on. On Machines S.N. 872256 SERVICE
REQUIRED INDICATOR light must light and STOP must NOT OK: Check fuel
flash . On Machines S.N. 872257 SERVICE supply.
T7447AH UN04JAN91
REQUIRED INDICATOR light and STOP must be on.
LISTEN: Starting motor must operate and engine must does not operate, check
FNR fuse and start relay
start.
fuse.
NOTE: It is normal for stop indicator and park brake light
to come ON as engine slows, but must go OFF when NOT OK: Go to Section
engine has stopped. 9015Starting Circuit.
Turn key switch to OFF position.
1/1
Monitor Indicator Light OK: Go to next check.

and Alarm Check
NOT OK: Check monitor
fuse.
NOT OK: Check logic

module fuse. Go to
Section 9015 Gauges and
T7394BH UN10DEC90 T103007 UN30OCT98 Monitor ChecksDisplay
(S.N. 872256) (S.N. 872257) Monitor Check.
Turn key switch to BULB CHECK position. NOT OK: If motor starts
and bulb check position is
OK, key switch failed or
LOOK: On machines S.N. 872256 all monitor indicators and SERVICE REQUIRED
INDICATOR light must be on, STOP must flash and alarm must "BEEP". On machines there is a short in the
S.N. 872257 all monitor indicators , SERVICE REQUIRED INDICATOR light and wiring. Go to Section
STOP must be on, and alarm must "BEEP". 9015 Key Switch Test.
LISTEN: Starting motor must NOT operate.
1/1

022602
PN=64
Monitor Indicator Light OK: Go to next check.

Check
NOT OK: Park Brake and
Engine Oil Indicator lights
stay on for 3 to 5
seconds after key switch
9005
is OFF.
10
5
T103007 UN30OCT98
NOT OK: Check for
T7394BH UN10DEC90
(S.N. 872257) "open" in Charging
(S.N. 872256)
Circuit. Go to Section
Turn key switch to OFF position. 9015Charging Circuit
Check.
LOOK: All lights must go out.
NOT OK: If Park Brake
Engine Oil and Alternator
Indicators stay on, check
for open in
monitor/charging section.
NOT OK: Go to Section

9015Starting Circuit
Checks.
1/1
Engine Low Oil Pressure NOT OK: No engine low

and Alternator Low pressure indicator light.
Voltage Indicator Light Check sender to wiring
Check connection. Go to Section
9015 Gauge and Monitor
ChecksMonitor Red
Light and Alarm Priority
Check.
T7394BH UN10DEC90 T103007 UN30OCT98
(S.N. 872256) (S.N. 872257) NOT OK: No alternator
low voltage indicator light.
Turn key switch to BULB CHECK position then back to ON position. Check wiring to bulb by
unplugging tachometer
LOOK: Only engine low oil pressure and alternator low voltage indicators must be on. connector at alternator.
On machines S.N. 872256 STOP light must flash, seat belt light must be on and Alternator light will come
alarm must "BEEP". On machines S.N. 872257 STOP and seat belt lights must be ON.
on and alarm must "BEEP"
1/1

022602
PN=65
FNR/Range Lever Check OK: Go to next check.
NOT OK: See Section 16

of Repair Manual.
9005
10
6
T7447AG UN04JAN91 T7447AI UN04JAN91 T7447AH UN04JAN91
Move the FNR/range lever to forward, reverse, then neutral position.
Twist range handle on FNR lever.
FEEL: Can detents be felt in forward, neutral and reverse?
Can four gear ranges be felt when twisting range handle?
LOOK: FNR/range lever must align with neutral position to quadrant when in neutral
(center) detent position.
LOOK: Does pointer on range handle line up wtih correct gear number on FNR/range
handle?
1/1
FNR/Range Lever Neutral OK: Go to next check.

Start Switch and Reverse
Warning Alarm Check NOT OK: If motor turns,
check neutral start relay
and FNR switch. Go to
Repair Manual.
NOT OK: No reverse

T7447AG UN04JAN91 T7447AI UN04JAN91
warning alarm, inspect
FNR switch and reverse
NOTE: On machines with S.N. 872256, neutral start switch is part of FNR circuit and warning alarm relay.
is not on transmission spool. Reverse warning alarm is powered by FNR switch and
reverse relay. NOT OK: Inspect wiring
to alarm. Go to Section
Put transmission in neutral. 9015, Reverse Warning
Alarm Circuit.
Move FNR/range lever to forward position and turn key to START position.
Move FNR/range lever to reverse position and turn key to START position.
LISTEN: Starting motor must NOT operate.
LISTEN: Reverse warning alarm must sound when FNR/range lever is in reverse
position.
1/1
Gauge and Indicators Check With Engine On
1/1

022602
PN=66
Park Brake Indicator and IMPORTANT: If engine low oil pressure indicator light stays ON, stop engine OK: Go to next step in
Tachometer/Hour Meter immediately and check oil level. this check.
Circuit Check
NOT OK: If engine low oil
pressure indicator light
stays on, stop engine
9005
immediately and check oil
10
level. Go to Group
7
9010-Diagnose Engine
Malfunctions, Low Oil
Pressure.
T7447AH UN04JAN91 T7394BH UN10DEC90
(S.N. 872256) NOT OK: If alternator
indicator light is on,
increase engine speed to
1200 rpm and alternator
light must go out. Go to
Section 9015 Charging
Circuit Checks.
NOT OK: If no park brake

light, go to Group 9015
Park Brake Circuit
T103007 UN30OCT98
Checks.
(S.N. 872257)
Apply park brake.
Put FNR/range lever in neutral position.
Move FNR/range lever to 1st gear position.
LOOK: On units S.N. 872256 park brake indicator and STOP indicator lights must be
on and flashing, all other lights must go out. On units S.N. 872257 park brake
indicator and STOP indicator lights must be on, all other lights must go out. Alarm
must "BEEP".
1/2

022602
PN=67
NOTE: Hour meter turns very slowly (one tenth hour every six minutes). OK: Go to next check.
NOT OK: If no hour

meter or tachometer
movement, go to Section
9015 Gauges and Monitor
9005
ChecksTachometer and
10
Hour Meter Checks.
8
NOT OK: If park brake
T7860AD UN06OCT92
light stays ON, go to
T7394BH UN10DEC90
Section 9015Park
(S.N. 872256)
Brake Circuit Checks.
T103007 UN30OCT98
(S.N. 872257)
LOOK: Hour meter indicator (A) must rotate every 3 seconds.
LOOK: Tachometer must indicate rpm.
Release park brake.
LOOK: Park brake indicator and STOP light must go out. Alarm must stop "BEEPING".
19 2/2

022602
PN=68
Engine Speed Control OK: Go to next check.

Lever Linkage Check
NOT OK: Tighten friction
lock. Go to Group
9010-20 Speed Control
Lever Tension.
9005
10
NOT OK: Check injection
9
T7447AH UN04JAN91 T7367AE UN17SEP90
pump override linkage.
Go to Group 9010-20
Apply park brake. Engine Speed Control
Linkage.
Move FNR/range lever to neutral.
Operate engine at slow idle.
Make note of rpm on tachometer.
Move speed control lever to fast idle position.
LOOK: Speed control lever must remain at selected position.
LOOK: Tachometer must read:
(S.N. 830204)
850 50 rpm slow idle

2375 50 rpm fast idle.
(S.N. 830205)
900 25 rpm slow idle

2375 25 rpm fast idle
1/1
Engine Speed Control Depress speed control pedal. OK: Go to next check.
Pedal Linkage Check
LISTEN: Engine speed must be the same as with speed NOT OK: Adjust Speed
control lever in fast idle position. Control Linkage Override.
Go to Group 9010-20
Engine Speed Control
Linkage.
T6171AF UN09DEC88
1/1

022602
PN=69
Start Aid Check (If Operate engine at slow idle. OK: Go to next check.
Equipped)
Push start aid button once. NOT OK: Check can
contents by shaking.
LISTEN: Engine speed must increase then return to slow idle.
NOT OK: Check fuse. Go
9005
to Section 9015Start
10
Aid Check.
10
1/1
Brake System Check
1/1
Service Brake System Start engine. OK: Continue check.

Check
Unlock brake pedals. NOT OK: Excessive
leakage in brake system.
Set engine at 1200 rpm. Inspect brake valve. Go
to Repair Manual.
Move FNR/range lever to 2nd gear.
T6171AH UN09DEC88
After machine has moved for 3 seconds, depress and
hold left brake pedal.
Repeat procedure for right brake pedal.
FEEL: Brake should stop tire rotation.
LOOK: Machine should pull to the side that the brake

pedal is depressed.
1/1
Service Brake Park machine on inclined surface. OK: Go to next step.

Equilization Check (SN Lock service brake pedals together.
872256 ) NOT OK: Do Service
Park brake OFF. Brake and Pedal
Adjustment, Group
Allow machine to coast forward. 9025-20.
Slowly apply service brakes to stop machine. NOT OK: Do Service

T6171AI UN09DEC88
Brake Valve Test, Group
LOOK: Does front of machine pull to either left or right 9025-25.
when service brakes are applied?
1/1

022602
PN=70
Service Brake Retraction Park machine on inclined surface. OK: Go to next check.
Check Lock service brakes together.
NOT OK: Do Service
Park brake OFF. Brake and Pedal
Adjustment, Group
Shift FNR/range lever to neutral. 9025-20.
9005
10
Release service brakes. NOT OK: Do Service
11
Brake Valve Test, Group
T6171AI UN09DEC88
LOOK: Does front of machine pull to the side when 9025-25.
service brakes are released?
1/1
Service Brake Pressure NOTE: Axles and hydraulic oil must be at operating temperature. OK: Go to next check.
Indicator And Brake
Accumulator Precharge NOT OK: If fewer than 7
(S.N 872257) brake pedal applications
are required to turn brake
pressure indicator ON,
accumulator charge
pressure may be low. Go
to Brake Accumulator
T103007 UN30OCT98
Precharge Test in Group
T6171AH UN09DEC88
9025-25.
Stop engine. NOT OK: If brake oil

pressure indicator does
Key switch ON. DO NOT start engine. Press right brake pedal and record number of not come ON, check
applications until brake pressure indicator comes ON. service brake pressure
indicator in Group
LOOK: Are at least 6 brake pedal applications needed before brake pressure indicator 9015-15.
comes ON?
Repeat procedure for left brake pedal.
1/1
Pedal Stop Check Stop engine. OK: Go to next step in

this check.
Release pedal latch.
NOT OK: Brake return
Depress and release each brake pedal. passage may be closed.
Inspect valve. Go to
LOOK: Brake pedals must move freely and return to the Repair Manual.
up position. Both pedals must be even with each other in
T6171AH UN09DEC88
the up position.
Lift each pedal. OK: Go to next check.
FEEL: (SN 872256) Pedals must have approximately 6 NOT OK: Adjust brake
mm (0.25 in.) free-travel above the rest position. light switches to get
free-travel. For (S.N.
(SN 872257 ) Pedals must have no free-travel above 872256) go to Repair
the rest position. Manual. For (SN
872257 ) go to Service
T6171AG UN09DEC88
Brake Valve and Pedal
Adjustment in Group
9020.25 .
1/1

022602
PN=71
Brake System Leakage Start engine and run for 10 seconds. OK: Go to next check.
Check
Unlock brake pedals. NOT OK: Excessive
leakage in brake system.
Run engine at slow idle. Depress and hold right brake Go to Group 9025-25
pedal. Brake Valve Leakage
9005
Test.
10
Release brake pedal.
12
NOT OK: Inspect horn,
T6171AH UN09DEC88
LISTEN/LOOK: Engine speed will not decrease as pedal brake, light fuse.
is depressed.
OK: Go to Section
LISTEN: There must NOT be any noticeable engine 9015Lighting Circuit.
speed change when pedal is released or depressed.
LOOK: Rear brake light must come "on" when either

pedal is depressed.
Repeat for left pedal.
1/1
Brake Pedal Latch Check Latch the brake pedals together. OK: Go to next check.
Kick each brake pedal three times. NOT OK: Repair latch.
LOOK: Latch must move freely and stay in desired

position.
T6171AI UN09DEC88
1/1

022602
PN=72
Park Brake Check OK: Go to next check.
NOT OK: Adjust park

brake. Go to Group
9025-20 on machines
with (S.N. 872256).
9005
10
13
T7860AF UN26OCT92
(S.N. 872256)
T103007 UN30OCT98
(S.N. 872257)
CAUTION: Prevent possible injury from unexpected machine movement.

Fasten seat belt before doing this check.
Fasten seat belt.
Start machine on dry hard pavement.
Disengage MFWD (if equipped). Raise loader bucket to transport height, stabilizers
fully up, and backhoe off the ground.
Move the park brake switch (B) to the OFF position.
Move the FNR/range lever to 2nd gear, forward position.
Operate engine at 1000 rpm and drive approximately 7 m (20 ft) before moving the
park brake switch to the "ON" position.
LOOK: The machine must stop within 2 m (6 ft).
LOOK: On machines with S.N. 872256, park brake switch light (B) will be ON. On
machines with S.N. 872257, park brake indicator in monitor will be on.
FEEL: Transmission must shift into neutral.
1/1

022602
PN=73
Brake Drag Check Engine on. OK: Go to next check.
Position machine on a gradual grade with front of NOT OK: Brakes

machine downhill. dragging. Go to Group
9025-25, Service Brake
Lift buckets so they clear ground. Valve Pressure Test.
9005
10
Shift FNR/range lever to neutral, differential lock pedal
14
up, disengage park brake and release service brakes.
T6171AL UN09DEC88
LOOK: Machine must move freely down slope.
CAUTION: Prevent possible injury from

machine unexpected movement. Apply park
brake, lower equipment, shut engine off, and
block wheels before servicing machine.
1/1
Steering System Check
1/1
Steering System Operate engine at approximately 1000 rpm. OK: Go to next check.
Operational Check
Turn steering wheel from full left to full right several times. NOT OK: Check
hydraulic oil level.
LOOK: Front wheels must move smoothly in both directions.
NOT OK: Check Steering
LOOK: When steering wheel is stopped, front wheels must stop moving. System Leakage. Go to
Group 9025-25.
NOTE: Internal leakage or sticking steering valve spool can cause wheels to continue
to move after steering wheel is stopped.
1/1
Steering System Leakage NOTE: Hydraulic oil must be at operating temperature for this test. OK: Go to next check.
Check
Run engine at approximately 1000 rpm. Turn steering wheel until wheels are against NOT OK: Go to Steering
stop. Continue turning steering wheel, using approximately 11.3 Nm (100 lb-in.) force. System Leakage Test in
Group 9025-25.
Repeat leakage check turning steering wheel to the left.
NOT OK: Repair steering
LOOK: Steering wheel should turn approximately 5 rpm, left or right. cylinder. Go to Repair
Manual.
NOTE: Use good judgment. Excessive steering wheel rpm does not mean steering
performance will be affected. NOT OK: Repair steering
valve. Go to Repair
Manual.
1/1

022602
PN=74
Steering Priority Valve Operate engine at slow idle. OK: Go to next check.
Check
Turn steering wheel left to right and note effort needed NOT OK: If steering
to turn wheel. wheel effort is more or
wheel will not turn as
Operate the loader raise function and turn steering wheel hydraulic function is
9005
at the same time. Note effort needed to turn the steering activated, a problem is
10
wheel. indicated in steering
15
priority valve. Go to
T6295AC UN19OCT88
FEEL: Effort to turn steering wheel must NOT increase Steering Valve Pressure
when turning the wheel while a hydraulic function is check.
activated.
1/1
Steering Priority Valve Put front wheels on dirt or gravel. OK: Go to next check.
Pressure Check
Raise rear of machine so tires are just off ground using NOT OK: If front wheels
stabilizers. do not turn in either
direction, pressure setting
Operate engine at approximately 1000 rpm. is too low. Go to Group
9025-25 Priority Valve
Starting with front wheels in the straight ahead position, Test.
T6295AC UN19OCT88
turn steering wheel to the left and right while raising
loader.
LOOK: Wheels must turn to the left and to the right while
loader is being raised.
1/1
Transmission Neutral Disconnect Circuit Check
1/1
Clutch Disconnect Check OK: Go to next check.

CAUTION: Machine should try to move forward as clutch is applied.
NOT OK: Go to Section
Release park brake. 9015 Neutral Disconnect
Circuit or FNR/Park Brake
Apply and hold service brakes. Circuit.
Start engine, set engine speed at approximately 1200

rpm.
Put transmission in 2nd gear.

T7447AG UN04JAN91
Shift FNR/range lever to forward position.
Press loader lever switch on loader control and note

sound of engine.
LISTEN: When FNR/range lever is shifted to forward, a

noticeable drop in engine speed should be heard.
LISTEN: Engine rpm must increase when the loader

lever switch is pressed.
1/1

022602
PN=75
Driving Check (MFWD Disengaged If Equipped)
9005 1/1
10
16
Transmission Warm-Up OK: Go to next check.
Procedure CAUTION: Machine will try to move forward during this procedure. Use
service brakes plus park brake to hold machine stationary. NOT OK: Repeat
warm-up procedure.
IMPORTANT: Transmission oil must be at correct level and operating
temperature.
Start engine.
Release park brake.
Latch service brakes together and hold during torque

converter stalls.
Move FNR/range lever to forward position.

T7447AG UN04JAN91
Put transmission in 4th gear.
IMPORTANT: Limit stalls to 30 seconds to prevent

localized overheating of torque converter.
Increase engine speed to fast idle and stall torque

converter for 30 seconds. Move FNR/range lever to
neutral position for 15 seconds to let temperature
stabilize.
Repeat stall four times to bring transmission to operating

temperature.
NOTE: Cold ambient temperatures will require more

stalls to get transmission to operating temperature. If
transmission oil temperature light comes ON during
procedure, stop stall procedure and put FNR/range lever
in neutral.
1/1

022602
PN=76
Transmission Shift Position machine on hard level surface. OK: Go to next check.
Check
Run engine at approximately 1500 rpm. NOT OK: No
corresponding change in
Shift transmission into all of the 4 forward and 2 reverse speeds, driving a short speed of machine or
distance in each speed. wrong speed when a shift
9005
is made may be caused
10
FEEL: FNR/range lever must move freely into each speed. On machines with S.N. by a stuck shift spool in
17
872256, there must be 4 forward and 2 reverse speeds. On machines with S.N. transmission control
872257, there must be 4 forward and 3 reverse speeds. valve, or a failed O-ring
on solenoid valve. Go to
LOOK: The FNR/range lever must stop at each detent. Repair Manual.
LISTEN: Excessive gear and transmission noise must not be heard in any gear. NOT OK: Excessive
engine pull-down when
NOTE: When shifting to 3rd and 4th, it is normal for torque converter to slip but shift is made may be
machine must not stop. caused by "drag" in
transmission clutch or
brake element. Go to
Brake Drag Check in this
section.
NOT OK: When a shift is

made and machine does
not move or stops,
internal leakage is
indicated. A transmission
pressure test is needed to
verify. Go to Group
9020-25 Transmission
System Pressure Test.
1/1
Front Wheel (Toe-In) Drive machine in 4th forward on a surface with loose OK: Go to the next
Alignment Check material such as gravel. check.
LOOK: Material behind front tires must not be thrown NOT OK: If material is
excessively inward or outward. thrown, excessive tire
wear will result. Go to
Group 9020-20Adjust
Toe-In.
T6264AI UN22OCT91
1/1

022602
PN=77
Engine and Position machine with loader bucket at ground level against a dirt bank or immovable OK: Go to next check.
Transmission Check object.
NOT OK: If engine stalls,
Shift transmission into 1st gear. check if fuel supply
shut-off is closed. Check
Apply differential lock. for restricted fuel or air
9005
filters. Go to Group
10
Move FNR/range lever to forward position. Increase engine speed to fast idle. 9010-10 Engine Power
18
Check.
LOOK: Engine must NOT stall.
NOT OK: If the wheels
LOOK: Rear wheels must NOT stall. can be easily stalled, go
to Group 9020-10 Engine
NOTE: This test will give a general indication of engine and transmission performance. and Transmission Check.
If loader bucket is positioned above the centerline of front axle and ground conditions
are soft, the engine can be stalled due to the weight transferred to rear wheels and
tractive conditions. The preceding situations should not be confused with low engine
power.
1/1
Lo-Range Forward OK: Drag is indicated in

Clutch Pack Drag Check the lo-range forward
clutch pack. Go to group
9020-15B, Diagnose
Power Train Malfunctions.
NOT OK: Go to next

check.
Raise rear of machine off ground using stabilizers.
MFWD OFF.
Park Brake OFF.
Engine speed at slow idle.
Operate machine in all speeds forward and reverse.

T6264AM UN19OCT88
Do rear wheels turn at correct speed in forward gears

1-3, but not in 4th forward or any reverse gears?
1/1

022602
PN=78
High-Range Forward OK: Drag is indicated in

Clutch Pack Drag Check the high-range forward
clutch pack. Go to group
9020-15B, Diagnose
9005
NOT OK: Go to next
10
check.
19
MFWD OFF.
Park Brake OFF.
T6264AM UN19OCT88
Do rear wheels turn at correct speed in 4th forward, but

not in 1st-3rd forward or any reverse gears?
1/1
Reverse Clutch Pack OK: Drag is indicated in

Drag Check the reverse clutch pack.
Go to group 9020-15B,
Diagnose Power Train
Malfunctions.
NOT OK: Go to next

check.
MFWD OFF.
Park Brake OFF.

T6264AM UN19OCT88
Do rear wheels turn at correct speed in all reverse

gears, but not in any forward gears?
1/1

022602
PN=79
1st Speed Clutch Pack OK: Drag is indicated in

Drag Check the 1st speed clutch
pack. Go to group
9020-15B, Diagnose
9005
NOT OK: Go to next
10
check.
20
MFWD OFF.
Park Brake OFF.
T6264AM UN19OCT88
Do rear wheels turn at correct speed in 1st forward and

1st reverse gears, but not in any other gears?
1/1
2nd Speed Clutch Pack OK: Drag is indicated in

Drag Check the 2nd speed clutch
pack. Go to group
9020-15B, Diagnose
NOT OK: Go to next

check.
MFWD OFF.
Park Brake OFF.

T6264AM UN19OCT88
Do rear wheels turn at correct speed in 2nd forward and

2nd reverse gears, but not in any other gears?
1/1

022602
PN=80
3rd Speed Clutch Pack OK: Drag is indicated in

Drag Check the 3rd speed clutch
pack. Go to group
9020-15B, Diagnose
9005
NOT OK: Go to next
10
check.
21
MFWD OFF.
Park Brake OFF.
T6264AM UN19OCT88
Do rear wheels turn at correct speed in 3rd & 4th

forward and 3rd reverse gears, but not in any other
gears?
1/1
Transmission Shift Raise rear of machine off ground using stabilizers. OK: Go to next check.
Modulation Check
MFWD OFF. NOT OK: Go to group
9020-15B, Diagnose
Park Brake OFF. Power Train Malfunctions.
Engine speed at 1500 rpm.
T6264AM UN19OCT88
Shift machine from neutral to 1st forward.
Twist FNR lever handle to shift from 1st forward to 2nd

forward.
Continue to twist FNR lever handle until 4th forward.

Allow machine to come up to speed before making each
sequentionial shift.
Repeat for reverse.
Does machine shift smoothly with no clunking or jerking

of power train?
1/1

022602
PN=81
B3, C2 Accumulator Perform this check on dirt or loose gravel surface. OK: Go to next check.
Check (S.N. 872256)
Operate machine at approximately 1500 rpm in 1st gear NOT OK: Too aggressive
forward. shifts or "clunk" sound.
Check accumulator
Shift to 2nd gear and observe rear tires. piston. Go to Repair
9005
Manual.
10
LOOK: Rear wheels must not spin (lose traction) as
22
machine comes up to speed. NOT OK: Slow shifts,
T6908BF UN07APR89
check oil level. Replace
FEEL: Unit must not "jerk" aggressively during this shift. transmission or inspect
suction screen. Go to
NOTE: A "clunk" sound will be heard if shift is too Repair Manual.
aggressive.
1/1
C1, B1, B2 Accumulator Operate machine on hard surface such as compacted OK: Go to next check.
Check (S.N. 872256) clay or road.
NOT OK: Slow shifts can
Operate machine at approximately 1500 rpm in 2nd be caused by low oil level
forward. or restricted filter. Repair
as required. Do
Make several forward to reverse shifts. Count the Transmission Drag
number of seconds (one thousand oneone thousand Checks in this group.
T6908BF UN07APR89
two, etc.) required for machine to change direction and
get up to speed. NOT OK: Too fast shifts
or "clunk" sound. Inspect
LOOK/FEEL: Machine must change direction within 1-1/2 accumulator piston. Go to
seconds and be up to speed in 3 seconds. Repair Manual.
1/1

022602
PN=82
C1 Clutch, B1, B2 Brake OK: Go to next check.

Drag Check (S.N.
872256) NOT OK: If wheels
continue to move but at a
slower speed, B2 is
dragging.
9005
10
NOT OK: If wheels
23
T6295AD UN19OCT88 T7447AH UN04JAN91
faster speed, C1 is
Raise wheels off ground with stabilizers and loader bucket. dragging.
Release park brake. NOT OK: If wheels

continue to move but in a
Shift transmission to 2nd forward. reverse direction at same
speed, B1 is dragging.
Adjust engine speed to 1000 rpm.
NOT OK: "Drag" causes
Move FNR/range lever to neutral position. rpm to drop excessively.
Inspect transmission. Go
LOOK: Both rear wheels must stop. to Repair Manual.
NOTE: If wheels turn, apply service brakes until wheels stop and note change in rpm
on tachometer.
If depressing brake pedal causes rpm to drop enough that difference can be seen on
tachometer (15 rpm), it indicates warped disks in that pack. Lube oil does not affect
these "drag" checks because they are done at operating temperature and at slow idle.
If "drag" is caused by lube oil within the transmission clutches and brakes, "drag" will
increase when oil is cold. When engine speed is increased to 1500 rpm or higher,
"drag" is reduced because lube relief valve opens and returns excessive cold oil to
sump. It is normal for wheels to "creep" with cold oil as engine speed is increased but
to stop moving at speeds above 2000 rpm. If "drag" is caused by warped clutch or
brake disks or plates, "drag" will be seen at any oil temperature and will increase
proportionally as engine speed is increased.
1/1
C2 Clutch, B3 Brake Raise wheels off ground with stabilizers and loader OK: Go to next check.
Drag Check (S.N. bucket.
872256) NOT OK: Engine speed
Release park brake. drops, C2 is dragging.
Repair transmission, go
Shift transmission to 1st forward. to Repair Manual.
Adjust engine speed to 1000 rpm per tachometer. NOT OK: Engine speed
T6295AD UN19OCT88
increases, B3 is dragging.
Shift transmission to 2nd forward. Repair transmission, go
to Repair Manual.
LOOK: Wheels must increase in speed but engine rpm
must return to 1000 rpm.
1/1

022602
PN=83
Differential Lock Check Raise wheels off ground with stabilizers and loader OK: Go to next check.
bucket.
NOT OK: If one wheel
Unlock brake pedals. Turn MFWD switch (if equipped) stops, on machines with
off. S.N. 872256, go to
Differential Lock Pressure
9005
Operate machine at approximately 1500 rpm in 1st Test in Group 9025-25.
10
forward. On machines with S.N.
24
872257, go to
T6295AD UN19OCT88
Depress differential lock pedal or switch. Differential Lock Pressure
Test in Group 9020-25.
Apply one brake pedal until engine rpm drops.
NOT OK: If engine rpm is
LOOK/FEEL: Both wheels must turn at same speed. reduced and stays down
while only differential lock
Release differential lock pedal or switch. is depressed, excessive
leakage is indicated. For
LOOK: Pedal or switch must return to up position and machines with S.N.
engine speed must return to 1500 rpm. 872256 go to Differential
Lock Leakage Test in
Release brake pedal and move transmission control Group 9025-25. For
levers to neutral. machines with S.N.
872257 go to
Reduce engine speed to slow idle. Differential Lock Leakage
Test in Group 9020-25.
Depress differential lock pedal or switch and note engine
rpm change.
LOOK/LISTEN: Must hear/see only slight decrease in

engine rpm as the pedal is depressed.
1/1
Differential Gear and NOTE: Hold the wheel being braked stationary during OK: Go to next check.
Pinion Noise Check this check or brake chatter could be confused with
differential gear noise. NOT OK: If wheels do
not turn at same speed,
Raise wheels off ground with stabilizers and loader brake drag is indicated.
bucket. Go to Brake Drag Check
in Group 9025-10.
Operate engine at approximately 1500 rpm in 1st gear
T6295AD UN19OCT88
forward. NOT OK: Excessive
noise. Check differential
LOOK: Both wheels must turn at same speed. oil level. Inspect pinion
assembly, go to CTM43
Depress right brake pedal until wheel stops. Observe left for machines S.N.
wheel. 872256. On machines
with S.N. 872257, see
LOOK: Wheel being braked must stop and opposite Group 0200 in the Repair
wheel must increase in speed. Manual.
Release right brake and depress left brake pedal until

wheel stops. Observe right wheel.
LOOK: Wheel being braked must stop and opposite

wheel must increase in speed.
LISTEN: No excessive gear noise must be heard in the

differential or pinion gears.
1/1

022602
PN=84
Driving Check for Mechanical Front Wheel Drive (MFWD)
1/1 9005
10
25
MFWD Clutch Drag Raise machine off ground with stabilizers and loader OK: Go to next check.
Check bucket.
NOT OK: If light is on,
Shift transmission to 2nd gear and FNR/range lever to check fuse. Go to Group
forward position. 9020-25 MFWD Clutch
Pressure Test.
Run engine speed at 1000 rpm.
NOT OK: If rear wheels
T6264AM UN19OCT88
Check that MFWD control is disengaged (switch up/light stop, MFWD control valve
off). problem or clutch "drag"
is indicated. Repeat
Lower front wheels to ground and raise bucket above check using 1st gear.
ground.
NOT OK: If front wheels
LOOK: MFWD indicator light must be off. turn, or rear wheels stall,
MFWD solenoid valve
LOOK: Front wheels may turn while wheels are off problem is indicated. Go
ground but must stop when lowered to ground. Rear to Group 9020-25 MFWD
wheels must continue to turn. Clutch Pressure Test.
NOT OK: If front wheels

remain stopped, MFWD
clutch "drag" is indicated.
Go to Repair Manual.
1/1

022602
PN=85
MFWD Limited-Slip OK: Go to next check.

Differential and Solenoid
Valve Check NOT OK: If tires do not
attempt to slide sideways
and tire scuffing is not
seen with MFWD applied.
9005
Go to Group 9020-25
10
MFWD Clutch Pressure
26
Test.
T7860AA9 UN13NOV92
(S.N. 872256)
NOT OK: Repair
limited-slip in MFWD
differential. Go to Repair
Manual.
NOT OK: If light stays on,

inspect fuse. Go to
Section 9015 MFWD
Circuit Test.
T118248 UN03NOV98
(S.N. 872257)
Shift transmission to 1st reverse.
Apply MFWD and drive machine.
Run engine at approximately 1200 rpm.
Turn steering wheel for a full left or right turn and observe the front tires.
LOOK: Observe how the front tires attempt to slide sideways (side load) and the
amount of tire scuffing. MFWD indicator lights must be on.
Disengage MFWD switch.
LOOK: Tire side loading and scuffing must stop when MFWD is disengaged.
LOOK: MFWD indicator light (A) in switch must be off.
NOTE: If tires attempt to slide sideways and tire scuffing is seen with MFWD applied,
limited-slip differential is working and power is being transmitted to MFWD.
1/1
MFWD Gear and Pinion Drive machine at transport speed with MFWD applied, then disengaged. OK: Go to next check.
Noise Check
LISTEN: MFWD must NOT "whine" when disengaged. NOT OK: If MFWD
"whines", check oil levels
and fill to specification.
NOT OK: Check

backlash. Go to Repair
Manual.
1/1

022602
PN=86
Hydraulic System Check
1/1 9005
10
27
Hydraulic Pump OK: Go to next check.
Performance Check
NOT OK: If boom down
relief does not load
engine, check main pump
stand-by pressure. Go to
Group 9025-25.
T6295AH UN19OCT88
NOT OK: Go to Group
9025-25, Backhoe Relief
NOTE: If hydraulic oil is not at operating temperature, heat hydraulic oil until loader Valve Test.
and backhoe cylinders feel warm to touch using following procedure:
NOT OK: If cycle times
Cover front of radiator to stop air flow. are slow, check hydraulic
charge system. Go to
Activate backhoe boom down function and run engine at 2000 rpm. Group 9025-25 Surge
Relief Pressure Test and
NOTE: Activating boom down may load engine, boom down relief valve is set too high Charge Pressure Test.
or hydraulic pump stand-by pressure too low.
NOT OK: Go to Group
Operate all functions periodically to distribute heated oil to all cylinders. 9025-25 Hydraulic Pump
Flow Test.
Lower stabilizers.
Put backhoe at maximum reach with bucket fully dumped at ground level.
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/LISTEN: Boom down must reduce engine rpm.
NOTE: Take the average cycle time for at least three complete cycles. This average
cycle time will give a general indication of hydraulic pump performance.
LOOK: The maximum cycle time is 11.5 seconds.
1/1

022602
PN=87
Hydraulic System Charge Raise machine with stabilizers until wheels are 150 mm OK: Go to next check.
and Return System (6.0 in.) off ground.
Check NOT OK: Check charge
Fully extend dipperstick, putting bucket in loaded position pump pressure. Test
and lower boom until dipperstick is 45 to the ground. hydraulic charge system.
Go to Group 9025-25
9005
Slowly retract dipperstick. Bucket must clear ground. Surge Relief Pressure
10
Test.
28
Fully extend dipperstick.
T118265 UN05NOV98
NOT OK: Check charge
Run engine at 1200 rpm. pump flow. Go to Group
9025-25 Charge Pump
Retract dipperstick while holding control valve fully open. Flow Test.
LOOK: Dipperstick can slow down, but must NOT stop

moving during test.
1/1
Hydraulic Control Valve Raise loader until bucket is 1 m (3 ft) off ground with the bucket level. OK: Go to next check.
Lift Check Test
Position backhoe at maximum reach with bottom of bucket level with ground, 1 m (3 ft) NOT OK: If a function
off ground. cylinder moves, problem
could be a leak in
Stop the engine. cylinder in lift check.
Inspect and repair lift
Activate each function one at a time: check. Go to Repair
Manual.
Loader boom raise
Loader bucket rollback
Backhoe boom up
Dipperstick extend
Backhoe bucket dump
LOOK: These functions must NOT move when the control lever is activated.
NOTE: It is normal for a function to jump upward but must not lower.
1/1

022602
PN=88
Backhoe Circuit Leakage Put backhoe in transport position and set boom and OK: Go to next step in
Checks swing lock. this check.
Retract extendible dipperstick (if equipped). NOT OK: Check boom

down relief valve
Raise stabilizers to full down position. pressure setting. Go to
9005
Group 9025-25.
10
Run engine at slow idle.
29
NOT OK: Continue
T118265 UN05NOV98
Fully activate functions one at a time: check.
Boom up
Bucket load
Dipperstick retract
Extendible dipperstick retract (if equipped)
LISTEN: When these functions are activated, NO

decrease in engine rpm must be noted.
Fully activate functions one at a time:
Boom down
Swing left, then right
LISTEN: Boom down may cause rpm to decrease since

relief valve setting is below standby pressure.
LOOK/LISTEN: Swing left and right may cause rpm to

decrease slightly because relief valve setting is close to
standby pressure.
NOTE: If boom down does not decrease engine rpm,

check main pump standby pressure.
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 are "metered", rpm will decrease and leakage
within circuit will be apparent. This is normal.
1/2

022602
PN=89
Raise stabilizer to maximum up 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: valve fully open, a leak is
9005
indicated in the circuit.
10
Extend dipperstick
30
Extend extendible dipperstick (if equipped) NOT OK: If rpm
T6295AF UN17APR89
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 is indicated.
NOT OK: An rpm

decrease with a function
bottomed in both
directions is normally due
to cylinder leakage. An
rpm decrease in one
direction is normally
caused by a circuit relief
valve leakage. Go to
Group 9025-25
Hydraulic Component
Leakage Test.
19 2/2
Loader Circuit Leakage OK: Go to next check.

Check
NOT OK: If rpm
decreases with a function
bottomed and control
lever fully open, a leak is
indicated in the circuit.
T6295AG UN17APR89 T6295AE UN17APR89

NOT OK: If rpm
increases when a function
Raise loader to full height, bucket in dump position. is bottomed and control
valve is fully open, a
neutral leak is indicated.
Run engine at slow idle.
Fully activate functions one at a time: NOT OK: An rpm

decrease with a function
Loader boom up bottomed in both
Bucket dump directions is normally
cylinder leakage. An rpm
Put bucket in rollback position and lower loader to full down position. decrease in one direction
is normally circuit relief
Fully activate functions, one at a time: valve leakage. Go to
Group 9025-25
Hydraulic Component
Loader boom down
Bucket rollback Leakage Test.
LISTEN: When functions are activated, engine rpm must NOT decrease.
NOTE: Leakage return passages are used in boom valve. When boom cylinders are
retracted and valve is "metered", rpm will decrease and leakage within circuit will be
apparent. This is normal.
1/1

022602
PN=90
Cylinder Cushion Check Run engine at slow idle. OK: Go to next check.
Lower stabilizers to the ground. NOT OK: Remove and

repair cylinder cushion.
Lower backhoe boom 45 outward. Go to Repair Manual.
9005
Fully activate functions, one at a time:
10
31
Backhoe swing left and right
Backhoe boom raise
Dipperstick retract
LISTEN: Note sound and speed as cylinders near the end of their stroke.
LOOK: Speed of cylinder rod must decrease near the end of its stroke.
LISTEN: Must hear oil flowing through orifice as cylinder rod nears the end of its
stroke.
1/1
Backhoe and Loader FEEL: Backhoe cylinder must be warm to touch 38 OK: Go to next check.
Function Drift Check 52C (100125F). If cylinders are not warm, heat
hydraulic oil. NOT OK: Use good
judgment in determining if
Raise machine off ground with stabilizers. the amount of drift is
objectionable for the type
Position backhoe bucket at a 45 angle to the ground. of operation that the
Lower boom until bucket cutting edge is 50 mm (2.0 in.) machine is performing.
T6171AQ UN25MAY89
off ground.
NOT OK: Isolate which
Position loader bucket at the same angle and distance function is leaking. Go to
from ground as backhoe bucket. Group 9025-25, Cylinder
Drift Test.
Run engine at slow idle and observe bucket cutting
edges.
LOOK: If bucket cutting edges touch the ground within

one minute, leakage is indicated in the crowd cylinder,
bucket or boom cylinders, or control valves.
1/1

022602
PN=91
Loader Boom Float and Put loader at maximum height position with bucket OK: Go to next step in
Return-to-Dig Check dumped. this check.
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.
9005
detent position, and at the same time into bucket Go to repair manual.
10
rollback detent position. Remove hand from control lever.
32
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
to Group 9025-15.
T6171AT UN09DEC88
LOOK: When the bucket is at ground level, bucket must OK: Go to next check.
be level and the bucket indicator pointer must be aligned
with mark on the boom pivot. NOT OK: Adjust linkage
as necessary. Go to
NOTE: When return-to-dig is used with loader boom in Group 9025-20 Loader
full up position, the bucket leveling linkage will move the Bucket Level Indicator
bucket control valve out of return-to-dig position before and Return-to-Dig
bucket is actually level. Adjustment.
T7374CH UN04OCT90
1/1
Bucket Leveling Linkage NOTE: The loader bucket leveling feature functions during the boom raise cycle only. OK: Go to next check.
Check
Put bucket in the rollback position with the boom near NOT OK: Adjust linkage
the ground level. on the loader control
valve. Go to Group
Raise the loader and at the same time, hold the control 9025-20. Loader Bucket
lever in the bucket rollback position. Level Indicator and
Return-to-Dig Adjustment.
Observe bucket and loader control lever as the loader
rises.
T7374CJ UN05OCT90
LOOK/FEEL: Loader control lever must move into the
bucket dump position and the bucket dump function
must slowly activate. When the loader control lever
moves to activate the bucket dump function, the bucket
position must remain stationary the remainder of the
loader boom raise cycle.
1/1

022602
PN=92
Heater and Air Conditioning Checks
1/1 9005
10
33
All Lines and Hoses Engine OFF. OK: Check complete.
Inspect all lines and hoses. NOT OK: Reposition

hoses or lines and tighten
Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts or replace clamps.
or "weather checked"? Tighten fittings or replace
O-rings in fittings.
Are hose and line connections clean NOT showing signs of leakage, such as oil or Replace hoses or lines as
dust accumulation at fittings? required.
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
Air Conditioner Inspect compressor. OK: Check complete.

Compressor Check
Is compressor drive belt tight? NOT OK: Repair or
replace components as
Is belt in good condition, NOT frayed, worn or glazed? required.
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. OK: Check complete.
Inspect condenser cores. NOT OK: 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?
1/1

022602
PN=93
Evaporator Check Remove seat and heater/blower cover. OK: Check complete.
Is ice forming on evaporator core? NOT OK: Go to Clutch

Cycle Switch Bench Test
Is fan motor failing or fan blades damaged? in Group 9031-25
9005
Is freeze switch sensing tube properly positioned?
10
34
Is heater temperature balance control misadjusted or damaged?
Is evaporator drain tubes plugged?
1/1
Evaporator Core Check Engine OFF. OK: Check complete.
Inspect core. NOT OK: Repair, replace

or clean evaporator.
Are fins straight?
Is evaporator core free of dirt and debris?
1/1
A/C Freeze Switch Engine OFF. OK: Check complete.

Sensing Tube Check
Inspect A/C freeze switch sensing tube. NOT OK: If sensing tube
is kinked, replace A/C
Is sensing tube straight, NOT kinked or broken? freeze switch.
Is sensing tube inserted into evaporator core and secured in place? NOT OK: If tube is
positioned in evaporator
incorrectly, re-route.
1/1
Expansion Valve Check Is expansion valve outlet line free of frost? OK: Check complete.
Is insulating tape wound tightly around outlet line and is tape in good condition? NOT OK: Go to
Expansion Valve
Operation in Group
9031-05.
1/1
Cab Door and Window Open and close door and windows. Inspect seals. OK: Check complete.
Seals Check
Do door and windows contact seals evenly? NOT OK: Adjust door and
windows to close against
Are seals in position and in good condition? seals properly. Replace
seals as necessary.
1/1

022602
PN=94
Blower Motor Check OK: Check complete.

(S.N. 816286)
NOT OK: See Circuit
Checks in Group
9031-10. Check wiring
harness.
9005
10
35
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 (S.N. 816286) OK: Check complete.
NOT OK: See Circuit

Checks in Group
harness.
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.
Does warm air exit from ducts?
1/1

022602
PN=95
Air Conditioner (S.N. OK: Check complete.

816286)
NOT OK: See Blower/Air
Conditioning Circuit
Checks in Group
9031-10. See Charging
9005
the system in Group
10
9031-20.
36
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 several minutes for any warm air in duct system to escape.
Is air from ducts cool?
1/1
Blower Motor Check OK: Check complete.

(S.N. 816287 )
NOT OK: See Circuit
Checks in Group
harness.
T101677 UN28JUN96
Engine OFF. Key switch ON.
Turn blower switch (A) to position 1, 2, 3 and 4.
Does fan have four speeds?
Does air exit from ducts?
1/1

022602
PN=96
Heater OK: Check complete.

(S.N. 816287 )
NOT OK: See Circuit
Checks in Group
harness.
9005
10
37
T101678 UN28JUN96
Start engine and allow to warm several minutes.
speed.
Does warm air exit from ducts?
1/1
Air Conditioner (S.N. OK: Check complete.

816287 )
NOT OK: See Blower/Air
Conditioning Circuit
Checks in Group
9031-10. See Charging
the system in Group
9031-20.
T101679 UN28JUN96
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. OK: Check complete.
Check
Does compressor clutch "click" as switch is pushed? NOT OK: Replace
compressor clutch.
1/1
Cooling System Checks
1/1

022602
PN=97
Radiator Cap, Coolant OK: Check complete.

Level, Coolant Condition CAUTION: DO NOT remove radiator cap unless engine is cool. Turn cap
Checks slowly to stop. Release all pressure before removing cap. NOT OK: If vacuum
release valve is plugged
Open radiator cap. or spring corroded,
replace radiator cap.
9005 LISTEN: If radiator is warmer than air temperature, a "whoosh" must be heard when
10 radiator cap is opened to first stop position. NOT OK: If coolant is oily
38
or foamy, go to Oil in
FEEL: The radiator cap must have a stop position and must be pushed down to turn to Coolant or Coolant in Oil
remove. in this section.
Inspect coolant level and coolant condition. NOT OK: If rust is in

coolant, drain, flush and
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
Hose and Water Pump Inspect all radiator and heater hoses and water pump for cracks or leaks. OK: Check complete.
Check
LOOK: Radiator hoses must not be brittle or show signs of leaks. NOT OK: Replace
defective hoses, tighten
Check all hose clamps. clamps as necessary.
LOOK: All hose clamps must be tight. NOT OK: Repair water
pump. Go to Engine
Squeeze lower radiator hose. CTM.
FEEL: Lower hose must have wire insert.
LOOK: Water pump must not show any signs of leaks.
1/1
Radiator Bubble Check Fill radiator to proper level. OK: Check complete.
Install radiator cap and tighten. NOT OK: If constant flow

of bubbles is seen, a
Start engine. Run engine until at normal operating loose cylinder head or a
temperature. damaged head gasket
could be the cause. Go to
Place overflow tube in jar of water. Engine CTM.
T6171AR UN25MAY89
LOOK: Stream of bubbles must not be seen in glass jar.
1/1

022602
PN=98
Fan and Fan Shroud Inspect fan and shroud clearance. OK: Check complete.
Check
inspect fan blades for damages. NOT OK: If fan blades
have any bends, replace
Check fan belts for wear. fan. If fan has nicks,
locate interference and
9005
LOOK: Fan blades must not have any nicks or bends. repair. See Repair
10
Manual.
39
LOOK: Make sure there is no oil or grease on fan belt or
pulleys. NOT OK: Replace fan
belt. Go to Repair
LOOK: Inside surface of fan belt must not have any Manual.
cracks or contact bottom of pulley groove.
NOT OK: If fan is
NOTE: If the fan blade has been installed backwards installed backward,
about 50% of its capacity is lost. remove and install
correctly. Go to Repair
LOOK: Cupped portion of fan blades must be away from Manual.
radiator.
T6171CB UN25MAY89
1/1
Air System Checks
1/1
Start Aid Checks (S.N OK: Check complete.

872256)
NOT OK: Reposition
lower holder.
NOT OK: Replace plastic

line.
T6477AP UN19OCT88 T6488GE UN23AUG93

NOT OK: Turn nozzle
until arrow is in correct
Remove right engine side shield. position (pointing
AGAINST incoming air
flow).
Check position of lower can holder.
LOOK: If can is missing, lower portion of holder must be upside down to seal opening
in upper holder.
Inspect plastic line from top of starting aid to air intake manifold.
LOOK: There must NOT be any kinks or breaks in line and ends must be installed
securely.
Check for arrow on either starting aid nozzle in air intake manifold.
NOTE: It may be necessary to scrape paint from nozzle.
LOOK: Arrow must be pointed AGAINST air flow of air intake manifold.
1/1

022602
PN=99
Start Aid Checks (S.N. OK: Check complete.

872257 )
NOT OK: Reposition
lower holder.
NOT OK: Replace plastic

9005
line.
10
40
NOT OK: Turn nozzle
until red dot is in correct
position (on top of
nozzle).
T105143 UN10JAN97
AClamp
BEther Aid Can
CBase
DCap
Remove right engine side shield.
Check to be sure ether aid can (B) is tight and clamp (A)
T6488GE UN23AUG93
is tight
LOOK: If can is missing, cap (D) must be installed into

base (C).
Inspect plastic line from top of starting aid to air intake

manifold.
LOOK: There must NOT be any kinks or breaks in line

and ends must be installed securely.
Check for red dot on either starting aid nozzle in air

intake manifold.
NOTE: It may be necessary to scrape paint from nozzle.
LOOK: Red dot must be on the top side of nozzle so

that the nozzle is pointed AGAINST air flow (of air intake
manifold).
1/1

022602
PN=100
Exhaust Smoke Check NOTE: Engine must be at operating temperature before performing this check. OK: Check complete.
Run engine at fast idle. NOT OK: See Engine

Emits Excessive Black,
Operate a hydraulic function over relief to load engine. Gray or Blue Smoke in
this section.
9005
Observe exhaust smoke.
10
41
LOOK: Exhaust smoke must NOT be excessive or blue
in color.
T6488GF UN19OCT88
NOTE: Excessive black smoke is caused by lack of
sufficient air to the engine. Excessive white smoke when
engine is cold can be caused by a cold engine, dirty
nozzles, or both. Excessive blue smoke can be caused
by worn or damaged rings or cylinder liners.
1/1
Lubrication System Checks
1/1
Oil Level Check OK: Check complete.
NOT OK: Add or replace

oil. Go to Group 9000-04.
T6488GG UN29JUL99 T6488GH 1923FEB89
Perform this check with engine OFF.
Remove dipstick and check oil level.
LOOK: Oil must be between add and full marks.
NOTE: If oil level is high, check for fuel in oil. Drain a small quantity of oil and check
for anti-freeze. If oil level is low check for oil leaks or oil seal problems in engine.
Remove dipstick and check condition of oil. Clean oil from dipstick with finger and
thumb.
LOOK: Oil must NOT be milky, grainy or contain fuel oil or anti-freeze.
1/1
Fuel System Checks
1/1

022602
PN=101
Engine Fuel System Engine off, speed control lever at fast idle position. OK: Check complete.
Inspection Checks
Inspect fuel drain, cap strainer and inside fuel tank (with flashlight). NOT OK: If air "hissing"
from tank or enters tank
Operate pump primer by hand. when cap is removed,
replace fuel cap.
9005
Inspect all fuel lines, line clamps and speed control linkage stop.
10
NOT OK: If excessive
42
Inside of fuel tank must NOT contain any foreign matter. debris is found in the
bottom of the fuel line,
LOOK: No fuel leakage must be noted at any of the fuel line connections. The injection observe flow. If flow is
line rubber clamps must be in position and NO wiring banded to the injection lines. restricted, clean tank.
1/1
Engine Speed and Performance Checks
1/1
Engine Speed Check OK: Check complete.

(Tachometer Installed)
NOT OK: Check spring
loaded injection pump
lever override. Go to
Engine Speed Control
Linkage Adjustment, in
this section.
T6008AE1 UN09DEC88 T105836 UN20DEC96

(S.N. 830204) (S.N. 830205 )
Start engine, run at slow idle, and record rpm.
Increase engine speed to fast idle with speed control pedal and record rpm.
LOOK: Slow idle must be 850 50 rpm (S.N. 830204)
Slow idle must be 900 25 rpm. (S.N. 830205 )
LOOK: Fast idle must be 2375 50 rpm. (S.N. 830204)
Fast idle must be 2375 25 rpm. (S.N. 830205 )
NOTE: Override adjustment is 6 mm (0.25 in.).
1/1

022602
PN=102
Engine Power Check NOTE: Engine and transmission must be at operating temperature using No. 2 fuel. OK: Check complete.
(S.N. 872256)
Start engine. NOT OK: RPM too low.
Inspect air and fuel filters.
Hold service brake.
NOT OK: Above 2000
9005
Put transmission in fourth gear. rpm, inspect transmission.
10
Go to Group 9020-10.
43
Operate engine at fast idle.
Record minimum engine rpm.
Repeat check several times to determine average rpm.
LOOK: Minimum engine speed is 1800 rpm.
1/1
Engine Power Check NOTE: Engine and transmission must be at operating temperature using No. 2 fuel. OK: Check complete.
(S.N. 872257 )
Start engine. NOT OK: RPM too low.
Inspect air and fuel filters.
Hold service brake.
NOT OK: Above 2100
Put transmission in fourth gear. rpm, inspect transmission.
Go to Group 9020-10.
Operate engine at fast idle.
Record minimum engine rpm.
Repeat check several times to determine average rpm.
LOOK: Minimum engine speed is 1875 rpm.
1/1

022602
PN=103
Low Compression Check OK: Check complete.

runs at uneven speed,
low compression is
indicated on one or two
9005
cylinders. (See Engine
10
CTM.)
44
T6552AP UN22MAR90 T105638 UN13DEC96
(S.N. 830204) (S.N. 830205 )
Remove left engine shield.
Disconnect wire to injection pump solenoid.
Crank engine for 10 seconds.
LISTEN: Air must not be heard leaking past valves.
LISTEN: Starting Motor must run at a constant speed.
Reconnect injection pump wire.
1/1
Engine Blow-By Check Run engine at fast idle and check blow-by tube. OK: Check complete.
LOOK: Fumes should be barely visible at the blow-by tube at fast idle with no load. NOT OK: If blow-by is
excessive, see Engine
NOTE: Excessive blow-by indicates that piston rings and cylinder liners do not seal off CTM.
the combustion chamber. This is a comparative check that requires some experience
to determine excessive blow-by.
1/1
Loose or Worn Engine Run engine at slow idle. OK: Check complete.
Parts
Depress brake pedals. NOT OK: Go to Abnormal
Engine Noise in this
Shift to first forward. section.
LISTEN: Knock or rattling noise must not be heard from engine.
1/1
Accessories Check (Engine Stopped)
1/1

022602
PN=104
Front Light Switch Turn key switch to ON position. OK: Go to next check.
Push front light rocker switch to middle position. NOT OK: Check fuse and
bulbs.
LOOK: Two front lights, two red tail lights and gauge lights must come on.
OK: Check switch. Go to
9005
Push front light rocker switch in completely. Group 9015-15, Drive and
10
Work Light Circuit.
45
LOOK: All four front lights, two red tail lights and gauge lights must come on.
1/1
Rear Light Switch Check Turn key switch to ON position. OK: Go to next check.
Push side console rear light rocker switch in. NOT OK: Check fuse and
bulbs.
LOOK: Rear light(s) must come on.
OK: Check switch. Go to
Section 9015, Drive and
Work Light Circuit.
1/1
Turn Signal Check Turn key switch to ON position. OK: Go to next check.
Push down right side of turn signal switch. NOT OK: Check fuses
and wiring. Go to Sub
LOOK: Right front and right rear amber lights must flash. Right indicator light on top of System
steering column must flash. Left front and left rear amber lights, and left indicator light Diagnostics/Indicator
on top of steering column will stay completely lit. Circuit, Section 9015-15.
Push down left side of turn signal switch.
LOOK: Left front and left rear amber lights must flash. Left indicator light on top of
steering column must flash. Right front and right rear amber lights, and right indicator
light on top of steering column will stay completely lit.
1/1
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 Section
9015, Brake Light Circuit.
1/1

022602
PN=105
Horn Circuit Check Turn key switch to ON position. OK: Go to next check.
Push horn button. NOT OK: Check fuse.
LISTEN: Horn must sound. NOT OK: Check horn

9005
9015, Horn Circuit.
10
46
1/1
Start Aid Check (If Operate engine at slow idle. OK: Go to next check.
Equipped)
Push start aid button once. NOT OK: Check can
contents by shaking or
LISTEN: Engine speed must increase then return to slow idle. weight.
NOT OK: Check fuel

shut-off/start aid/reverse
alarm fuse.
IF OK: Go to Section
9015, Start Aid Circuit.
1/1
Cab Component Checks
1/1
Left Cab Door Latch and Unlatch door. OK: Go to next check.
Opener Check
Observe door as it opens. NOT OK: Adjust cab
door. Go to repair
Pull door closed and latch it. manual.
FEEL: Cab door latch must work freely.
LOOK: Door cylinder must push door open.
LOOK: Cab door must contact door stop bumper before door cylinder bottoms.
1/1
Right Cab Door Latch Unlatch door and pull door open. OK: Go to next check.
and Opener Check
Close and latch door. NOT OK: Adjust door. Go
to repair manual.
FEEL: Cab door latch must work freely.
1/1

022602
PN=106
Rear Window Latch and Squeeze latches on both sides of middle rear window. Lower window to rubber OK: Go to next check.
Opener Checks bumpers.
NOT OK: Check for
Push latch releases on upper rear window. obstructions. Go to repair
manual.
Observe window as it opens.
9005
10
Push window up and into window catches and note fit.
47
Observe cylinders while closing window. Raise middle window and push into latches.
LOOK: 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
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. Go to repair
LOOK: Sleeve on rear window must align with knob on manual.
front window.
LOOK/FEEL: Hinges must move freely. Locking latches

T6171DF UN09DEC88
must be equally loaded when closed.
1/1
Blower Control Check OK: Go to next check.
NOT OK: Check heater

circuit breaker.
NOT OK: Check blower

9015, Blower Circuit.
T7840AX UN06OCT92
Turn blower switch (A) to low, medium and high speeds.
FEEL/LISTEN: Blower must have three speeds and OFF.
1/1

022602
PN=107
Heater Control Check OK: Go to next check.
NOT OK: Check heater

components. Go to
Section 9015, Blower
Circuit.
9005
10
48
T7840AY UN06OCT92
Start engine and allow to warm to operating temperature.
speed.
FEEL: Air from ducts must be warm.
1/1
Air Conditioner Check (If OK: Go to next check.

Equipped)
NOT OK: Go to Heating
and Air Conditioning,
Group 9031-10.
T7860AB UN06OCT92
Wait for any warm air in duct system to dissipate.
FEEL: Air from ducts must be cool.
1/1
Rear Windshield Wiper Turn key to ON position. OK: Go to next check.

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.
Go to Section 9015,
LOOK: Rear wiper must operate and have two speeds. Wiper/Washer Circuit.
LOOK: Wipers must return to park position.
1/1

022602
PN=108
Front Windshield Wiper Turn key switch to ON position. OK: Go to next check.
Check
Push front wiper rocker switch to first detent, middle position. NOT OK: Check fuse.
Push front wiper switch all the way in. OK: Check front wiper.
Go to Section 9015,
9005
LOOK: Both front wipers must operate and have two speeds. Wiper/Washer Circuit.
10
49
LOOK: Wipers must return to park position.
1/1
Front Windshield Washer Turn key switch to ON position. OK: Go to next check.
Check
Push windshield washer rocker switch in. NOT OK: Check fluid
level, and fluid lines for
LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF blockage.
position.
NOT OK: Check wiring.
Go to Section 9015,
Wiper/Washer Circuit.
1/1
Cab Dome Light and Turn key switch to ON position. OK: Go to next check.
Swivel Light Check
Push dome light switch to ON position. NOT OK: Check fuse and
bulbs.
Push swivel light switch to ON position (S.N. 872256).
NOT OK: Check wiring.
LOOK: Lights must come ON. Go to Group 9015-15,
Dome Light Circuit.
1/1
Seat Linkage Check Move lever (A) to the right. OK: Go to next check.
(S.N. 830204)
Move seat forward and rearward and release lever. NOT OK: Repair linkage.
Go to repair manual.
LOOK: Lever must move freely and lock seat in desired
position.
T7394BD UN29NOV90
1/1

022602
PN=109
Height Adjustable Seat Pull lever (C) up and at the same time remove your OK: Go to next check.
Check (If Equipped) weight from the seat.
(S.N. 830204) NOT OK: Lubricate seat
Raise seat several positions and engage latch. pedestal. Go to repair
manual.
LOOK: Seat must rise upward and must remain in
9005
desired latched position.
10
50
T7394BD UN29NOV90
1/1
Seat Swivel Linkage Pull lever (B) up. OK: Go to next check.
Check (S.N. 830204)
Move seat from loader to backhoe position and engage NOT OK: Lubricate or
latch. repair linkage. Go to
repair manual.
LOOK: Seat latch must move freely and hold seat at the
desired position.
T7394BD UN29NOV90
FEEL: Lever must move freely and hold seat in loader
and backhoe positions.
1/1
Seat Linkage Check (S.N. Lift lever (1). OK: Go to next check.
830205 )
Move seat forward and rearward and release lever. NOT OK: Repair linkage.
Go to repair manual.
LOOK: Does lever move freely and lock seat in desired
position?
T103194 UN20AUG96
1/1
Seat Height Adjustment Turn knob (3) to raise or lower seat to desired position. OK: Go to next check.
Check (S.N. 830205 )
LOOK: Does seat move up or down and remain in NOT OK: Go to repair
desired position? manual.
T103194 UN20AUG96
1/1

022602
PN=110
Seat Swivel Linkage Lift lever (2) up. OK: Go to next check.
Check (S.N. 830205 )
Move seat from loader to backhoe position and engage NOT OK: Lubricate or
latch. repair linkage. Go to
repair manual.
LOOK: Does seat latch move freely and hold seat in
9005
desired position?
10
51
T103194 UN20AUG96
FEEL: Does lever move freely and hold seat in loader
and backhoe positions?
1/1
Seat Back Linkage Lift lever (4) up. OK: Go to next check.
Check (S.N. 830205 )
Position seat back as desired and engage lever. NOT OK: Lubricate or
repair linkage. Go to
FEEL: Does lever move freely and hold seat in desired repair manual.
positions?
T103194 UN20AUG96
1/1
Miscellaneous Check
1/1
Vandal Protection Check Lock right side service access doors and cab doors using the ignition key. OK: Go to next check.
FEEL: All locks must operate freely and key must not stick in locks. NOT OK: Lubricate or
repair lock as necessary.
1/1
Check Periodic Check the periodic maintenance label located inside of OK: Go to next check.
Maintenance Label the hood access door.
NOT OK: Replace decal.
LOOK: Periodic maintenance label decal must be legible.
T6171DG UN09DEC88
1/1

022602
PN=111
Backhoe Transport Lock OK: Operational

Check Checkout completed.
NOT OK: Adjust, repair,

or replace lock. Go to
repair manual.
9005
10
52
T7860AC UN06OCT92
Raise boom to transport position against stop (A).

Pull lever to LOCK position to apply boom and swing lock.
LOOK/FEEL: Boom and swing lock pin must freely enter hooks (B) and fit at bottom of
slot in hooks. Lever must enter locked position and remain locked.
1/1

022602
PN=112
Section 9010
Engine
Contents
Page
Group 05Theory of Operation

General Engine Description. . . . . . . . . . . . . .9010-05-1 9010
EngineSectional View . . . . . . . . . . . . . . . .9010-05-2
Cold Weather Starting Aid Operation
(S.N. 872256). . . . . . . . . . . . . . . . . . . . .9010-05-4
(S.N. 872257 ) . . . . . . . . . . . . . . . . . . . .9010-05-4
Fan Drive Operation . . . . . . . . . . . . . . . . . . .9010-05-5
Group 15System Diagnostic Information

6059 John Deere Engine (S.N. 830204)
Use CTM8 . . . . . . . . . . . . . . . . . . . . . . . . .9010-15-1
830204)Use CTM11 . . . . . . . . . . . . . .9010-15-1
6068 John Deere POWERTECH Engine
(S.N. 830205 )Use CTM104 . . . . . . . .9010-15-1
830205 )Use CTM67 . . . . . . . . . . . . .9010-15-1
John Deere Alternators and Starting Motors
Use CTM77 . . . . . . . . . . . . . . . . . . . . . . . .9010-15-2
Make Visual Inspection of Engine and
Supporting Systems. . . . . . . . . . . . . . . . . .9010-15-3
Diagnose Engine Malfunction . . . . . . . . . . . .9010-15-5
Group 20Adjustments
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
JT05800 Digital Thermometer Installation . . .9010-20-1
Slow and Fast Idle Adjustment
(S.N. 830204). . . . . . . . . . . . . . . . . . . . .9010-20-2
(S.N. 830305 ) . . . . . . . . . . . . . . . . . . . .9010-20-4
Adjust Engine Speed Control Linkage
(S.N. 830204). . . . . . . . . . . . . . . . . . . . .9010-20-5
(S.N. 830205). . . . . . . . . . . . . . . . . . . . .9010-20-6
Adjust Speed Control Lever Tension . . . . . . .9010-20-7
Group 25Tests
Cooling System Test . . . . . . . . . . . . . . . . . . .9010-25-1
Radiator Air Flow Test. . . . . . . . . . . . . . . . . .9010-25-2
JT05529 Air Flowmeter Test Record . . . . . . .9010-25-3
Engine Performance Using Turbocharger
Boost Pressure Test . . . . . . . . . . . . . . . . .9010-25-4
Air Intake System Leakage Test . . . . . . . . . .9010-25-6
Fuel Line Leakage Test. . . . . . . . . . . . . . . . .9010-25-7

022602
PN=1
Contents
9010

022602
PN=2
Group 05
Theory of Operation
General Engine Description
John Deere engines are vertical-in-line, valve in head, insert is used on Dubuque engines. A five-piece
4-cycle (stroke) diesel engines. bearing insert normally is installed on Saran engines.
The five-piece bearing has high thrust load capability.
Direct fuel injection is provided by a distributor-type
fuel injection pump and 9.5 mm injection nozzles The five-piece thrust bearings must be installed as a
mounted in cylinder head. The pump is driven by an set. They may be retro-fitted to Dubuque engines1 at
intermediate gear in the timing gear train meshing with service repair if so desired. Should a crankshaft be
the crankshaft gear. found to have developed excessive end play, an
oversized thrust bearing plate set is available through 9010
Some engines are equipped with a turbocharger. service parts. Thrust bearing side plates are available 05
1
Operated by exhaust gases, the turbocharger in standard size or 0.007 in. oversize.
compresses intake air from air cleaner and routes it to
the combustion chamber. Cylinder liners are "wet" (surrounded by coolant) and
are individually replaceable. O-rings are used to seal
The cylinder block is made from a one-piece casting. the connection between cylinder block and liners.
The rugged, cast iron block may be structural or
non-structural. Pistons are made of cast high-grade aluminum alloy
with internal ribbing. The skirt is cam ground to allow
The camshaft is driven by an intermediate gear in the for expansion when heated during operation. The
timing gear train which meshes with the crankshaft piston crown has a cut-out swivel cup with a truncated
gear. Camshaft rotates in honed machined bores in cone in the center. Two compression rings and one oil
cylinder block; no bushings are used. The camshaft control ring are used. The top compression ring is a
lobes determine the time and rate of opening of each keystone type ring. All piston rings are located above
valve and actuates the fuel transfer pump. the piston pin. The top ring has been moved closer to
the top of the piston for improved engine performance
Intake and exhaust valves are operated by cam attributable to increased air availability during
followers, push rods and rocker arm assembly. Valve combustion and reduced heat losses in the top ring
seat inserts in cylinder head are used for intake and land.
exhaust valves.
The hardened piston pins are fully-floating and held in
The crankshaft is a one-piece, heat treated, nodular position by means of snap rings. Spray jets (piston
iron or steel forging which operates in replaceable cooling orifices) in cylinder block direct pressure oil to
two-piece main bearings. lubricate piston pins and cool pistons.
Two different types of crankshaft main thrust bearing Connecting rods are of forged steel and have
inserts are used to control end-play, depending on the replaceable bushing and bearing inserts.
producing factory. Normally a two-piece thrust bearing
1
Main (thrust) bearing web undercut in block and or bearing cap
MUST be 113.8 mm (4.48 in.) in order to accept five-piece thrust
bearings.
Continued on next page TX,901005,BR181 1924JUN941/2

022602
PN=115
Theory of Operation
The engine is supplied with lubricating oil by a gear Balancer shafts are used on some four-cylinder
pump driven by the crankshaft. The lubricating oil engines to reduce vibration. The two shafts operate on
passes through a full-flow oil filter in the main oil bushings in cylinder block and are counter-rotating at
gallery of cylinder block. To ensure engine lubrication, twice the engine speed.
the oil filter is provided with a by-pass valve which
opens when the filter element is restricted. On most The engine has a pressurized cooling system,
engines, engine oil is cooled by means of an oil cooler consisting of radiator, water pump, multi-blade fan and
mounted externally on the cylinder block. Engine oil one or two thermostats.
passes through the oil cooler before flowing to the oil
filter. A by-pass valve located between oil pump and
9010 main gallery relieves any pressure build-up in this
05 area.
2
TX,901005,BR181 1924JUN942/2
EngineSectional View
1Rocker Arm Shaft 6Cylinder Block 11Liner Packing Rings 16Valve
2Cylinder Head 7Crankshaft 12Cylinder Liner 17Fuel Injection Nozzle
3Push Rod 8Crankshaft Counterweight 13Piston 18Valve Spring
4Cam Follower 9Oil Pan 14Piston Ring 19Rocker Arm
5Cam Shaft 10Connecting Rod 15Piston Rings
Continued on next page T59,9010,335 1909MAR931/2

022602
PN=116
Theory of Operation
9010
05
3
UN01JUN89
T6030AS
T59,9010,335 1909MAR932/2

022602
PN=117
Theory of Operation
Cold Weather Starting Aid Operation (S.N.

872256)
Pushing control button on dash energizes coil (C) which

moves plunger (B) down, opening valve in the starting
fluid canister, releasing starting fluid to the engine.
Releasing control button on dash stops current flow to coil

(C) allowing spring (A) to pull plunger up, closing the
valve in the starting fluid canister.
9010
05
If engine is operated without starting fluid canister, the
4
dust seal must be properly installed to prevent engine
damage.
UN18NOV89
T6543AB
10T,9010,K181 1909MAR931/1
Cold Weather Starting Aid Operation (S.N.

872257 )
Pushing control button on dash energizes coil (C) which

moves plunger (B) up, opening valve in the starting fluid
canister, releasing starting fluid to the engine.
Releasing control button on dash stops current flow to coil

(C) allowing spring (A) to pull plunger down, closing the
valve in the starting fluid canister.
If engine is operated without starting fluid canister, the

dust seal must be properly installed to prevent engine
damage.
UN15OCT98
T117645
CED,TX17864,241 1907OCT981/1

022602
PN=118
Theory of Operation
Fan Drive Operation
The fan drive (A), driven by one fan belt from the engine
crankshaft (B), is self-adjustable. The fan belt tension
adjuster (C) automatically adjusts the belt to the correct
tension.
9010
05
5
UN01MAR93
T7950AH
TX,710D,DS4687 1909MAR931/1

022602
PN=119
Theory of Operation
9010
05
6

022602
PN=120
Group 15
System Diagnostic Information
6059 John Deere Engine (S.N. 830204)
Use CTM8
For additional engine information, the component technical

manual (CTM) is also required.
UN07SEP88
M44215
9010
15
TX,9010,BG802 1905MAR971/1 1

830204)Use CTM11

UN07SEP88
M44215
TX,9010,BG803 1905MAR971/1
6068 John Deere POWERTECH Engine

(S.N. 830205 )Use CTM104

UN07SEP88
M44215
POWERTECH is a trademark of Deere & Company. TX,9010,BG792 1905MAR971/1

830205 )Use CTM67

UN07SEP88

M44215
TX,9010,BG791 1905MAR971/1

022602
PN=121
John Deere Alternators and Starting

MotorsUse CTM77
For complete repair information the Component Technical

Manual (CTM) is also required.
Use the CTM in conjunction with this repair manual.
UN17JAN89
TS225
9010
15
2 09T,2160,K5 1912MAY941/1

022602
PN=122
Make Visual Inspection of Engine and Supporting Systems
1. Inspect for coolant leaks at: well as the belts. A belt which is too loose allows
slippage and reduces fan and alternator speed,
Radiator causing excess belt wear. Belt slippage can lead to
Water pump overheating of the cooling and/or hydraulic system,
Hoses and undercharged batteries.
Coolant manifold
Thermostat cover The condition of the belts and their tension must be
checked periodically. Adjust belt tension. See
Check for proper coolant level in radiator. Look at Adjust Fan Belt Tension, Group 0510. 9010
coolant for evidence of oil and/or debris. 15
3
8. Inspect fuel tank:
2. Inspect for oil leaks around the oil pan, drain plug,
oil filter, and clutch housing at drain hole. a. Inspect the tank mounting hardware to ensure
they are in position and tight.
3. Inspect hoses to see if they are hard, cracked, soft,
or swelled. Replace as necessary. b. Inspect fuel tank for cracks and leakage.
4. Inspect radiator for bent fins, kinks, dents, cracked c. Inspect fuel tank outlet strainer and water trap
side frames, seams and tubes. Check radiator for accumulated debris by shining a flashlight
mounts for loose hardware. through the filler neck toward bottom right corner
of fuel tank.
5. Check fan to ensure it has been installed correctly.
See Cooling System Inspection, in this section. 9. Inspect fuel transfer pump. See if there is fuel
leaking from inlet and outlet connections.
6. Inspect fan blades. They must be straight and not
striking the radiator core or shroud. Bent blades 10. Inspect fuel filter for water in base of filter. Look
reduce the efficiency of the fan and make the fan for fuel leaking from inlet and outlet connections.
out of balance. An out of balance condition can add
additional load to the water pump bearings. Check Check for debris and air in filters. Drain or bleed
water pump bearings by moving fan and note filters if necessary. Replace filters as required.
looseness of bearings.
11. Inspect injection pump and nozzles.
7. Inspect fan belts. They must not be too tight, too
loose, or cracked. Check to see if belt pulleys are Check fuel inlet and outlet connections and
worn excessively (if belts run against bore of injection line connections. If any of the lines are
groove) and that the pulleys are in proper twisted, kinked, or broken, repair or replace as
alignment. necessary. Check injection line clamps to ensure
they are in position and tight.
A belt which is too tight puts extra load on the
bearings and shortens the life of the bearings as
Continued on next page TX,9010,YY509 1902JUN931/2

022602
PN=123
13. Inspect air cleaner elements for debris, filter

CAUTION: Escaping fluid under pressure
condition and air restriction indicator to ensure
can penetrate the skin causing serious
indicator is not in red.
injury. Relieve pressure before
disconnecting hydraulic or other lines.
Check all air intake system connections to be sure
Tighten all connections before applying
they are tight. Clean or replace filters when
pressure. Keep hands and body away from
indicator shows red or when there is excessive
pinholes and nozzles which eject fluids
smoke or loss of power.
under high pressure. Use a piece of
cardboard or paper to search for leaks. DO
14. Check muffler for any signs of leakage or areas
NOT use your hand.
9010 that have rusted through. Exhaust leaks can result
15 in a fire in the engine compartment.
4 If ANY fluid is injected into the skin, it must
be surgically removed within a few hours by
15. Check for debris on exhaust manifold.
a doctor familiar with this type injury or
gangrene may result.
12. Inspect speed control linkage.
Check for free movement. Be sure the injection

pump lever contacts the fast idle stop on the
injection pump.
TX,9010,YY509 1902JUN932/2

022602
PN=124
Diagnose Engine Malfunction
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 troubleshooting a problem:
Step 1. Operational Checkout Procedure

Step 2. Diagnostic Charts
Step 3. Adjustments and/or Tests
9010
Symptom Problem Solution 15
5
Engine Cranks but Will Not Start Fuel tank empty. Check fuel level.
or Starts Hard
Water in fuel or water frozen in fuel Thaw and drain water from fuel tank.
lines. Water frozen in fuel filter. Thaw ice in fuel lines and drain.
Install new fuel filter.
Fuel shut-off solenoid not opening Turn key switch on. Solenoid
shut-off valve. "clicks". Check voltage at solenoid if
voltage is present. Check fuse and
wiring if voltage is not present.
Fuel tank cap vent plugged. Loosen cap, listen for air entering
tank suddenly. Replace cap.
Debris or dirt in fuel. Drain small amount of fuel from tank

into clean container. Inspect for
debris. Drain and flush fuel system.
Change fuel filter.
Wrong grade fuel for low ambient Fuel "jelled" in tank or lines. Warm
temperature. machine. Drain fuel system. Change
fuel filter. Refill with proper fuel.
Air entering suction side of fuel Check for bubbles in fuel filter.
system. Tighten connections. Inspect lines
for damage.
Stuck injection pump metering valve. Lightly tap injection pump housing. If
engine now starts, repair. (See
Engine CTM.)
Fuel supply pump. Check fuel supply pump pressure.

(See Engine CTM.)

022602
PN=125
Symptom Problem Solution
Slow cranking speed. Check batteries and connections.
Air filter elements restricted with dirt, Clean or replace filter elements.
snow or water. Check air filter indicator switch.
Improper injection pump timing. Check timing. (See Engine CTM.)
Injection nozzle(s). Remove and test nozzles. (See

9010 Engine CTM.)
15
6
Worn piston rings or low Remove injection pump fuse. Crank
compression. Blown head gasket. engine and listen for air leaking past
valves or an uneven starter speed.
Start engine and observe blow-by
from vent tube. Do Compression
Pressure Test. (See Engine CTM.)
Engine Cranks Slow Wrong weight oil for low ambient Drain and refill with proper weight
temperature. oil. Change oil filter.
Poor or dirty connections at batteries Clean battery posts and cable ends.
or starter. Reinstall cables. Clean connections
at start relay and starter.
Batteries discharged or failing to Remove positive and negative

take charge. battery cables from batteries.
Recharge separately. Replace both
batteries if either fails to charge.
Check alternator output. (See
Section 9015, Charging Circuit.)
Check wiring for shorting to ground.
Check alternator belt tension.
Hydraulic pump destroke valve Turn steering wheel back and forth
stuck. while cranking engine. If cranking
speed is normal, check stroke
control valve. (See CTM7.)
Starting motor. Seized or worn bushings, bent

armature shaft, armature "dragging".
Check starter current draw. (See
Engine Accessories CTM.)
Engine Surges or Stalls Air entering suction side of fuel Check fuel filter for air bubbles.
Frequently system. Tighten fittings and connections.
Inspect lines for damage.

022602
PN=126
Fuel tank cap vent plugged. Remove cap, listen for air entering
tank suddenly. Replace cap.
Water or debris in fuel. Drain water in fuel tank. Check

drained fuel for debris. Drain and
flush fuel system. Replace fuel filter.
Fuel "jelled" due to low ambient Drain fuel system. Refill with proper
temperatures. grade fuel. Replace fuel filter. 9010
15
7
Fuel filter plugged. Replace filter. Check for debris in
fuel system.
Return line from injection pump to Check line for kinks or damage.
tank restricted. Check line for debris. Clean with
compressed air.
Air filter elements plugged. Clean or replace elements.
Fuel supply pump plugged. Check fuel supply pump pressure.

(See Engine CTM.)
Fuel injection pump out of time. Check injection pump timing. (See
Engine CTM.)
Engine overheating. Test cooling system. (See test

procedure in this section.)
Injection pump or nozzle(s). Remove and test nozzles. Repair

injection pump. (See Engine CTM.)
Improper valve clearance. Check and adjust valve clearance.

(See Engine CTM.)
Valves sticking or burned. Remove injection pump fuse. Crank

engine and listen for air leaking past
Do Compression Pressure Test.
(See Engine CTM.)
Worn or broken compression rings Start engine and observe blow-by

or cylinder head gasket leaking. from vent tube. Do Compression

022602
PN=127
Engine Missing, Erratic Air entering suction side of fuel Check fuel filter for air bubbles.
Operation Or Poor Slow Speed system. Tighten fittings. Inspect lines for
Operation damage.
Water or debris in fuel. Drain water from fuel tank. Drain and
flush fuel tank to remove debris.
Fuel tank cap vent plugged. Remove cap. Listen for air entering
9010 tank suddenly. Replace cap.
15
8
Return line from injection pump to Inspect lines for kinks or damage.
tank restricted. Use compressed air to clear debris.
Engine Missing, Erratic Fuel injection pump out of time. Time injection pump. (See Engine
CTM.)
Slow idle speed set too low. Check for bent, worn or loose control
linkage. Repair as needed. Adjust
linkage and reset slow idle speed.
(See procedures in this section.)
Fuel supply pump. Check fuel pump pressure. (See

Engine CTM.)
Injection pump or nozzles. Remove and test nozzles. Repair

injection pump. (See Engine CTM.)
Engine overheats. Test cooling system. (See test

procedure in this section.)
Incorrect valve clearance. Adjust clearance. (See Engine

CTM.)
Bent push rods. Inspect and replace.
Valve sticking or burned. Remove injection pump fuse. Crank

engine and listen for air leaking past
Do Compression Pressure Test.
(See Engine CTM.)
Cylinder head gasket leaking. Do Compression Pressure Test.

(See Engine CTM.)

022602
PN=128
Worn or broken compression rings. Start engine and observe blow-by

from vent tube. Do Compression
Engine Not Developing Full Fuel filter plugged. Replace filter.

Power
Air filter elements plugged. Clean or replace elements. Check

air restriction indicator switch. (See 9010
Section 9015, Indicator Circuit.) 15
9
Water in fuel or wrong grade of fuel. Drain water from fuel tank or drain
and refill with proper fuel.
Exhaust system restriction. Check condition of muffler interior.
Fast idle speed too low. Adjust. Check for worn or damaged
linkage. Check and adjust fast idle.
(See procedure in this section.)
Incorrect valve clearance. Adjust clearance. (See Engine

CTM.)
Fuel line restriction or injection pump Clear restriction with compressed air.
line restricted. Replace line.
Service brakes dragging. Check brake linkage, brake valve

leakage, brake discs for warping or
scoring. Dragging brakes could
cause overheating
transmission/hydraulics or engine.
Fuel supply pump. Check fuel pump pressure. (See

Engine CTM.)
Injection pump metering valve Remove pump top cover and

sticking. inspect. Repair. (See Engine CTM.)
Incorrect injection pump timing. Check timing. (See Engine CTM.)
Injection pump or nozzle. Remove and test nozzles and pump.

(See Engine CTM.)
Internal hydraulic system leakage. Do Hydraulic Component Leakage

Test. (See Group 9025-25.)

022602
PN=129
Worn camshaft or incorrect camshaft Check valve lift. (See Engine CTM.)
timing.
Turbocharger. Remove air intake hose and exhaust

elbow. Leading edge of compressor
vanes must be sharp and straight.
Spin compressor wheel and listen for
noisy bearings. Turbine and
9010 compressor wheels must not rub in
15 housing.
10
Low compression. Remove fuel/ether/bk. alm. fuse.

Crank engine and listen for air
leaking past valves or an uneven
starter speed. Start engine and
observe blow-by from vent tube. Do
Compression Pressure Test. (See
Engine CTM.)
Engine Emits Excessive Black or Restricted air filter element. Incorrect Check. Clean or replace elements.
Gray Exhaust Smoke grade of fuel. Drain and refill.
Engine overloaded. Remove load. Run at fast idle to

clear engine.
Turbocharger failure. Remove air intake hose and exhaust

Spin compressor wheel and listen for
noisy bearings. Turbine and
compressor wheels MUST NOT rub
in housing.
Incorrect injection pump timing. Time injection pump. (See Engine

CTM.)
Air leak between turbo and manifold. Test air intake system for leaks.
(See test procedure in this section.)
Excessive fuel delivery. Remove and test fuel injection

pump. (See Engine CTM.)
Injection nozzle. Remove and test nozzles. (See

Engine CTM.)

022602
PN=130
Engine Emits Excessive Blue or Cranking speed too slow. Check batteries and connections.
White Exhaust Smoke
Incorrect grade of fuel. Drain and refill.
Injection pump or nozzle. Remove and test pump and nozzles.

(See Engine CTM.)
Excessive engine idling. Run at fast idle to clear. 9010

15
11
Engine running too cold. Check thermostats.
Low compression. Crank engine and listen for air

leaking fast valves. Start engine.
Observe blow-by from vent tube. Do
Compression Pressure Test. (See
Engine CTM.)
Detonation (Excessive Engine Stuck starting aid solenoid or switch. Repair or replace solenoid or switch.
Knock)
Injection pump timing or pump Time injection pump. (See Engine

advance faulty. CTM.) Repair advance.
Improper fuel (gasoline mixed with Drain and refill fuel tank. Replace
diesel fuel). fuel filter.
Abnormal Engine Noise (Rattle, Low engine oil level. Fill to correct level.
Knock or Squeal)
Too light weight engine oil for high Drain and refill with correct weight
ambient temperatures. oil.
Fuel in engine oil. Drain and refill with proper oil. Check
fuel system to find leakage.
Loose or worn hydraulic pump drive Repair or replace.

coupling, or pump failure.
Incorrect injection pump timing. Adjust timing. (See Engine CTM.)
Turbocharger bearing or turbine Remove turbo air inlet hose. Check

failure. shaft vertical movement. Repair or
replace.

022602
PN=131
Excessive valve clearance. Adjust clearance. (See Engine

CTM.)
Bent push rods. Replace. (See Engine CTM.)
Worn rocker arm shaft. Replace. (See Engine CTM.)
Loose connecting rod caps. Inspect and tighten connecting rod

9010 cap screws. (See Engine CTM.)
15
12
Loose main bearing caps. Inspect and tighten main bearing cap
screws. (See Engine CTM.)
Worn main bearings. Replace bearings. (See Engine

CTM.)
Worn connecting rod bearings. Replace bearings. (See Engine

CTM.)
Incorrect cam shaft timing. Check camshaft timing. (See Engine

CTM.)
Scored piston. Replace. (See Engine CTM.)
Worn piston pin bushings and pins. Replace pins and bushings. (See
Engine CTM.)
Low Engine Oil Pressure (Oil Low oil level. Check oil level. Fill to correct level.
Pressure Indicator Light On, Red Check for leaks. Repair leaks.
STOP Light ON and Alarm
Pulsing)
Using low viscosity winter oil in Drain and fill with summer weight oil.
summer.
Oil diluted with fuel. Drain and fill with proper weight oil.
Check fuel system for leakage.
Repair.
Oil pressure switch failure. Test sensor. (See Section 9015,

Indicator Circuit.)
Faulty oil pressure control valve. Repair valve. (See Engine CTM.)
Plugged oil pump intake screen. Inspect. Clean. (See Engine CTM.)

022602
PN=132
Loose oil pump drive gear or worn Inspect and repair. (See Engine
pump housing. CTM.)
Excessive main bearing clearance. Replace main bearings. (See Engine

CTM.)
Excessive connecting rod bearing Replace connecting rod bearings.

clearance. (See Engine CTM.)
9010
Cracked cylinder block. Replace cylinder block. (See Engine 15
13
CTM.)
Piston cooling orifice missing. Inspect piston cooling orifices. (See

Engine CTM.)
Leakage at internal oil passage Check all possible internal leakage.

Repair as needed. (See Engine
CTM.)
Engine Overheats Low coolant level. Fill to correct level and check for
leaks.
Loose, worn or broken fan belt. Tighten or replace belt.
Worn pulley grooves allowing belt Replace pulleys and belt.

slippage.
Radiator dirty or plugged. Check air flow. Clean radiator.

Recheck air flow.
Radiator shroud missing or Replace shroud.

damaged.
Engine overloaded. Reduce load. Operate in lower gear.
Radiator cap not sealing. Replace cap.
Fan on backwards or damaged. Inspect or replace fan.
Faulty sender or wires from sender Replace sender. Inspect wires.

damaged. Repair as needed.
Incorrect injection pump timing. Time injection pump. (See

adjustment procedure is this
section.)

022602
PN=133
Excessive brake drag. Check brake drag. (See Group

9005-10.)
Hydraulic system overheating due to Check hydraulic oil level. Check

internal leakage or plugged cooler. cooler for plugs. Do Hydraulic
Component Leakage Test. (See
Group 9025-25.)
9010 Thermostats stuck open or closed. Replace thermostats.

15
14
Cooling system interior coated with Flush cooling system with cleaner.
lime deposits. Refill with water/antifreeze solution.
Water pump leaking. Repair or replace water pump.
Excessive fuel delivery. Adjust or repair. (See Engine CTM.)
Oil In Coolant Or Coolant In Oil Leaking cylinder head gasket or liner Repair. (See Engine CTM.)
packings. Cracked cylinder or block.
Excessive Fuel Consumption Air system restricted. Clean or replace filter elements.
Check filter restriction indicator
switch. (See Section 9015, Indicator
Circuit.)
Fuel system leakage. Repair.
Incorrect grade of fuel. Drain and fill with proper fuel.
Incorrect injection pump timing. Time injection pump. (See Engine

CTM.)
Faulty turbocharger. Remove air intake hose and exhaust

Spin compressor wheel to check for
rough bearings. Turbine and
compressor wheels must not rub in
housing.
Faulty injection nozzles. Test nozzles. (See Engine CTM.)
Internal leakage in hydraulic system. Do Hydraulic Component Leakage

Fan Belt Noisy Belt slippage. Inspect adjuster. Replace belt.

022602
PN=134
Bearing noise. Locate and repair.
Belt misalignment. Align belt or pulley.
Driven component inducing vibration. Locate driven component and repair.
Fan Belt Slips Belt slipping because of insufficient Inspect adjuster. Replace belt.
tension.
9010
Belt subjected to substance that has Replace belt and clean pulleys. 15
15
reduced friction.
Rib or Fan Belt Wear Pulley misaligned. Align pulley.
Mismatch of belt and pulley groove Clean rust or other buildup from
widths. pulleys.
Sharp or jagged pulley groove tips. Replace pulley.
Turbocharger Excessively Noisy Bearings not lubricated. Insufficient oil pressure. Check for
or Vibrates restricted turbocharger oil line.
Air leak in engine, intake or exhaust Inspect, repair. (See test procedure
manifold. in this section.)
Improper clearance between turbine Remove exhaust elbow and air inlet
wheel and turbine housing. hose and inspect, repair. (See
Engine CTM.)
Broken blades on turbine. Remove exhaust elbow and air inlet

hose and inspect, repair. (See
Engine CTM.)
Oil Dripping from Turbocharger Damaged or worn bearings and/or Inspect compressor and turbine
Adapter worn seals. wheel for damaged blades.
Check for proper engine service

intervals or dirt entering internally
into engine.
Excessive crankcase pressure. Check vent tube to ensure tube is

not plugged. Clean.
Turbocharger oil return line carbon Remove line. Inspect, clean.

build-up where line passes exhaust
manifold.

022602
PN=135
Excessive Drag in Turbocharger Carbon build-up behind turbine Inspect and clean.
Rotating Member wheel caused by combustion
deposits.
Dirt build-up behind compressor Inspect and repair.

wheel caused by air intake leaks.
Bearing seizure or dirty or worn Check for evidence of the lack of

9010 bearings, caused by excessive proper engine service. Check for
15 temperature, unbalanced wheel, dirty extended operation with plugged air
16
oil, oil starvation or insufficient cleaners.
lubrication.
10T,9010,K81 1909MAR9312/12

022602
PN=136
Group 20
Adjustments
Installation
SERVICE EQUIPMENT AND TOOLS
Tachometer
AClamp-On Transducer. Remove paint with emery cloth and
UN28FEB89
connect to a straight section of injection line within 100 mm (4 in.) of
pump. Finger tighten onlyDO NOT overtighten.
BBlack Clip (). Connect to main frame.
CRed Clip (+). Connect to transducer.
T6813AG
9010
DTachometer Readout. Install cable. 20
1
10T,9010,K182 1910AUG951/1
JT05800 Digital Thermometer Installation

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

022602
PN=137
Adjustments
Slow and Fast Idle Adjustment (S.N.

830204)
SPECIFICATIONS
Engine Speed Slow Idle 850 50 rpm
Engine Speed Fast Idle 2375 50 rpm
UN18OCT88
Electronic Tachometer
T6023AD
9010 Sealing Wire Pliers
20
2 1. Run engine at normal operating temperature. (S.N. 830204)
ALever Stop Screw

2. Install tachometer. (See Electronic Tachometer BSpeed Control Rod
Installation procedure in this group.) CFast Idle Adjusting Screw
DSealing Wire
3. Disconnect speed control rod (B) from fuel injection ESlow Idle Adjusting Screw
pump lever.
4. Start engine.
5. Hold injection pump lever forward (toward radiator).

Check to make sure slow idle is to specification.
Specification
Engine SpeedSlow Idle .................................................... 850 50 rpm
6. If slow idle is not correct.
Check air cleaner elements.

Loosen lock nut and turn screw (A) out one or two
turns.
Loosen lock nut and turn screw (E) to adjust slow
idle.
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 to
specification
Specification
Engine SpeedFast Idle ................................................... 2375 50 rpm
8. If fast idle is not correct:
Remove sealing wire.
Continued on next page CED,TX17864,245 1922OCT981/2

022602
PN=138
Adjustments
Loosen lock nut and turn screw (C) counterclockwise

to increase rpm or clockwise to decrease rpm.
Tighten lock nut and install a new sealing wire using
a seal wire pliers.
9. Connect speed control rod (B).
9010
20
CED,TX17864,245 1922OCT982/2 3

022602
PN=139
Adjustments
Slow and Fast Idle Adjustment (S.N.

830305 )
1. Run engine at normal operating temperature.
2. Install tachometer. (See Electronic Tachometer
UN13DEC96
Installation procedure in this group.)
3. Disconnect speed control rod (B) from fuel injection

pump lever.
T105637
9010
20
4. Start engine.
4 (S.N. 830205 )
5. Hold injection pump lever forward (toward radiator). ALever Stop Screw
Check to make sure slow idle is to specification. BSpeed Control Rod
CFast Idle Adjusting Screw
Specification DSealing Wire
Engine SpeedSlow Idle .................................................... 900 25 rpm ESlow Idle Adjusting Screw
6. If slow idle is not correct.
Check air cleaner elements.

Loosen lock nut and turn screw (A) out one or two
turns.
Loosen lock nut and turn screw (E) to adjust slow
idle.
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 to
specification
Specification
Engine SpeedFast Idle ................................................... 2375 25 rpm
8. If fast idle is not correct:
Remove sealing wire.

Loosen lock nut and turn screw (C) counterclockwise
to increase rpm or clockwise to decrease rpm.
Tighten lock nut and install a new sealing wire using
a seal wire pliers.
9. Connect speed control rod (B).
CED,TX17864,246 1922OCT981/1

022602
PN=140
Adjustments
Adjust Engine Speed Control Linkage

(S.N. 830204)
SPECIFICATIONS
Injection Pump Lever Override 36 mm (1/81/4 in.)
(Fast Idle)
UN18OCT88
1. Move speed control pedal to full fast idle position.
2. Measure the spring loaded injection lever override.
T6030AU
Override must be to specification. 9010
20
5
Specification
Injection Pump LeverOverride
(Fast Idle) .............................................................. 36 mm (1/81/4 in.)
TX,9010,BG794 1905MAR971/2
3. If measurement is not within specification, remove

loader control valve cover and disconnect swivel (B)
from lever (A).
4. Disconnect yoke (D) and loosen nut (E).
UN29MAR90
5. Move pump lever by hand until override is within
specifications.
6. Turn yoke until holes align and connect yoke (D) and
T6030AV
lever. Tighten nut (E).
7. Be sure speed control pedal is against the fast idle

stop, loosen nut (C), adjust swivel (B) to align hole in
lever (A) and connect swivel and lever. Tighten nut (C).
8. Check speeds to make sure slow and fast idle are

correct. (See Slow and Fast Idle Adjustment in this
group.)
UN29MAR90
ALever
BSwivel
CNut
T6030AW
DYoke
ENut
TX,9010,BG794 1905MAR972/2

022602
PN=141
Adjustments
Adjust Engine Speed Control Linkage (S.N.

830205)
SPECIFICATIONS
Injection Pump Lever Override 36 mm (0.120.24 in.)
Override
1. Move speed control lever to extreme forward position.
UN13DEC96
2. Measure injection pump lever override. Override is
9010 measured at the top edge of the short lever (B) to the
20
edge of the long lever (B). Override must be to
6
specification.
T105635
Specification
Injection Pump Lever Override
Override ............................................................. 36 mm (0.120.24 in.)
3. Adjust swivel on speed control rod to provide override.
4. Move speed control lever to rear most position and

check override. Override must be 0.5 mm (0.02 in.)
UN30OCT98
minimum.
5. Recheck high idle for a minimum of 3 mm (0.12 in.)

override.
T118064B
6. Open access door on reservoir cowling to adjust foot
control pedal.
Continued on next page TX,9010,BG796 1905MAR971/2

022602
PN=142
Adjustments
7. Disconnect swivel (A) from rod (B). Adjust vertical rod

(C) length to allow foot control pedal to stop on floor
with hand lever in the extreme forward position.
ASwivel
BRod (Speed Control Pedal)
CVertical Rod
9010
20
7
UN13DEC96
T105636
TX,9010,BG796 1905MAR972/2
Adjust Speed Control Lever Tension
Tighten nut (A) until force required to move lever using a

spring scale is to specification.
Specification
UN11MAY94
Speed Control Lever Tension
Force .............................................................. 6271 N (1416 lb force)
T8219CA
(S.N. 830205 ) Shown
TX,9010,BG797 1901APR971/1

022602
PN=143
Adjustments
9010
20
8

022602
PN=144
Group 25
Tests
Cooling System Test
SPECIFICATIONS
Cooling System Test Pressure 70 kPa (0.7 bar) (10 psi)
Radiator Cap Opening Pressure 82.7110 kPa (0.821.02 bar)
(1215 psi)
UN27OCT88
DO5104ST Cooling System Pressure Pump
T5903AA
9010
1. Check cooling system for leaks using a DO5104ST
25
cooling system pressure pump. 1
Specification
Cooling System TestPressure ........................ 70 kPa (0.7 bar) (10 psi)
2. Test radiator cap using cooling system pressure pump.
3. If opening pressure is not within specification, install a

new cap.
Specification
Radiator Cap OpeningPressure........... 82.7110 kPa (0.821.02 bar)
(1215 psi)
10T,9010,K96 1909MAR931/1

022602
PN=145
Tests
Radiator Air Flow Test
SPECIFICATIONS
Radiator Air Flow Test Engine Fast idle
Speed
Typical Test Voltage Reading 3.00 volts
ESSENTIAL TOOLS
JT05529 Air Flowmeter
9010 SERVICE EQUIPMENT AND TOOLS

25
2 Volt-Ohm Meter
1. Lower all equipment to the ground.
2. Apply park brake.
3. Straighten any bent fins in radiator or hydraulic oil

cooler.
UN01NOV88
4. Divide grille into 16 equal squares.
5. Connect air flowmeter to voltmeter. Set meter on A.C.

volts.
T6080AH
6. Start and run engine at fast idle.
Specification
Radiator Air Flow TestEngine
Speed ........................................................................................... Fast idle
7. Place air flowmeter in contact with grille. Arrow on

meter must point in direction of air flow (toward
machine).
8. Record voltage reading for each area.
9. Average of combined total of air flow test readings

must be approximately at specifications.
Specification
Typical TestVoltage Reading ................................................... 3.00 volts
10. If readings are less than specifications, clean external

surfaces of oil cooler and radiator. Repeat test.
1025,DS4253 1909MAR931/1

022602
PN=146
Tests
JT05529 Air Flowmeter Test Record
PRE-TEST INSPECTION
CUSTOMER NAME:
CUSTOMER ADDRESS:
DATE:
MACHINE MODEL NO.
SERIAL NO.
9010
SERV SERV 25
OK REQD OK REQD 3
Coolant Level
Belt Tension Correct Fan Installation (Sucker
Fan)
Radiator Fin Condition Radiator Cap
Fan Tip & Shroud Condition
TX,1025,DS4254 1909MAR931/2
AIR FLOW TEST
1.
Park brake ON and side shields closed.
2. Divide the surface of the grille into 16 equal squares.
3. Start engine.
4. Perform air flow test at fast idle. Observe correct air

flow direction and place air flowmeter in direct contact
with grille. (Arrow pointing to grille).
5. Record air flow in each square.
6. Average of combined total of air flow test readings

must be approximately at specifications.
UN13NOV92
T7886AE
TX,1025,DS4254 1909MAR932/2

022602
PN=147
Tests
Engine Performance Using Turbocharger

Boost Pressure Test
SPECIFICATIONS
Transmission Temperature 65 4C (130F 10F)
Engine Temperature At operating temperature
UN23AUG88
Engine Using No. 1 Diesel Fuel 5165.5 kPa (0.510.65 bar)
Minimum Turbocharger Boost (7.59.5 psi)
Pressure at 2200 rpm With
Muffler Installed
X9811
9010 Engine Using No. 2 Diesel Fuel 5569 kPa (550.69 bar) 810
25 Minimum Turbocharger Boost psi)
4 Pressure at 2200 rpm With
Muffler Installed

Gauge 0200 kPa (02 bar) (030 psi)
Digital Thermometer
UN12NOV92
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
T7886AF
hydraulic or other lines. Tighten all connections
before applying pressure. Keep hands and body
away from pinholes and nozzles which eject S.N. 830204
fluids under high pressure. Use a piece of
cardboard or paper to search for leaks. Do not
use your hand.
If ANY fluid is injected into the skin, it must be

surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
UN09JAN97
may result.
1. Install gauge and digital thermometer. See procedure

in Section 9020.
T105842
2. Raise wheels off ground with stabilizer and bucket.
S.N. 830205
3. Bring transmission and engine to specified

temperature. See Transmission Warm-Up Procedure in
Section 9020.
Specification
TransmissionTemperature ............................. 65 4C (130F 10F)
EngineTemperature ........................................ At operating temperature
Continued on next page TX,9010,BG798 1905MAR971/2

022602
PN=148
Tests
4. Operate engine at fast idle speed, shift transmission to

1st forward and load engine down to rated speed by
applying service brakes. Record highest pressure
reading.
5. If boost pressure is below specification, remove muffler

and repeat test.
Specification
Engine Using No. 1 Diesel Fuel
Minimum Turbocharger Boost
9010
25
Muffler Installed ......................................... 5165.5 kPa (0.510.65 bar)
5
(7.59.5 psi)
Engine Using No. 2 Diesel Fuel
Minimum Turbocharger Boost
Muffler Installed .................................... 5569 kPa (550.69 bar) 810
psi)
6. Slowly activate the boom raise function to apply a load

to the engine. The gauge will show a pressure rise and
then a pressure drop.
If the boost pressure does not drop, use the following

procedure to apply additional load to the engine:
Lower stabilizers to raise wheels off ground.

Put machine in first gear.
Apply brake pressure until boost pressure begins to
drop.
7. Record the highest pressure and the rpm that was

obtained.
NOTE: New engines will not develop specified boost

pressure. Check after 50 hours operation.
IMPORTANT: Gauge accuracy is very critical for this

test. DO NOT make adjustment to
injection pump fuel delivery on tractor.
8. If boost pressure is too high, remove and test fuel

injection pump.
9. If boost pressure is too low, see Engine Does Not

Develop Full Power in Group 9010-15.
TX,9010,BG798 1905MAR972/2

022602
PN=149
Tests
Air Intake System Leakage Test
SPECIFICATIONS
Air Intake System Regulated 13.820.7 kPa (0.130.21 bar)
Pressure (23 psi)
UN25OCT88
JDG51 Air Regulator With Gauge
IMPORTANT: Anytime the air intake system is opened
T92026
9010 it must be tested for leaks before the
25
machine is returned to service.
6
1. Remove air cleaner cover and main filter element.
2. Put a plastic bag over safety element and install main

element and cover.
3. Remove plug from air intake tube and install JDG51
UN25OCT88
adapter (A).
4. Connect air pressure regulator to adapter using hose

and fitting (B).
T92027
CAUTION: Plastic bag can be sucked into S.N. 830204
engine if engine is started when trying to close
valves.
5. Pressurize air intake system to specifications.
Specification
Air Intake SystemRegulated
Pressure ................................................. 13.820.7 kPa (0.130.21 bar)
UN09JAN97
(23 psi)
If system cannot be pressurized, turn engine slightly to

close valves. Check plastic bag.
T105843
6. Spray soap solution over all connections from the air S.N. 830205
cleaner to the turbocharger or air inlet to check for
leaks. Repair all leaks.
TX,9010,BG799 1905MAR971/1

022602
PN=150
Tests
Fuel Line Leakage Test
Connections may allow air to enter the fuel system without

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

fuel injection pump and fuel filters.
9010
Securely plug end of fuel return pipe. 25
7
CAUTION: Do not exceed 103 kPa (1 bar) (15

psi).
Using a regulated pressure air source, pressurize the

system at the fuel supply line.
Apply liquid soap and water solution to all joints and

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

internal leak path may allow air to enter the fuel
system. If an internal pump leak is suspected,
remove the pump and have a pressure test
performed by an authorized repair station.
10T,9010,C145 1909MAR931/1

022602
PN=151
Tests
9010
25
8

022602
PN=152
Section 9015
Electrical System
Contents
Page Page
Group 05System Information Cab Side Console Harness (W6) (S.N.

Visually Inspect Electrical System . . . . . . . . .9015-05-1 815415-825657)
Electrical Wiring Diagram (1 of 2) . . . . . . . . . . . . 9015-10A-23
Circuit Malfunctions . . . . . . . . . . . . . . . . . .9015-05-2 Wiring Diagram (2 of 2) . . . . . . . . . . . . 9015-10A-24
Electrical Cab Side Console Harness (W6) (S.N.
Circuit Malfunction Definations. . . . . . . . . .9015-05-3 -825657)
Electrical Circuit Component Location (1 of 2) . . . . . . . . 9015-10A-25 9015
Malfunction Locations . . . . . . . . . . . . . . . .9015-05-8 Component Location (2 of 2) . . . . . . . . 9015-10A-26
Malfunction Troubleshooting . . . . . . . . . . .9015-05-9 Cab Side Console Harness (W6) (S.N.
Using Test Equipment 825658-872256)
Multimeter . . . . . . . . . . . . . . . . . . . . . . . .9015-05-15 Wiring Diagram (1 of 3) . . . . . . . . . . . . 9015-10A-27
Seven Step Electrical Test Procedure . . .9015-05-16 Wiring Diagram (2 of 3) . . . . . . . . . . . . 9015-10A-28
Wiring Diagram, Schematic, And Component Wiring Diagram (3 of 3) . . . . . . . . . . . . 9015-10A-29
Location Information . . . . . . . . . . . . . . . .9015-05-18 Component Location (1 of 2) . . . . . . . . 9015-10A-30
Reading a System Functional Schematic . .9015-05-20 Component Location (2 of 2) . . . . . . . . 9015-10A-31
Reading A Wiring Diagram . . . . . . . . . . . . .9015-05-21 Front Console Harness (W7)
Reading A Component Location Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10A-32
Component Location . . . . . . . . . . . . . . 9015-10A-33
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-22
Engine Harness (W8)
Reading Connector End View Diagram . . . .9015-05-24
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10A-34
Electrical Schematic Symbols . . . . . . . . . . .9015-05-26
Transmission Solenoid Harness (W9)
Group 10ASystem Diagrams (S.N. 872256) Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10A-36
Component Identification Table . . . . . . . . . 9015-10A-1 Component Location . . . . . . . . . . . . . . 9015-10A-37
Fuse Blower Harness (W10)
Color Codes (Blade-Type) . . . . . . . . . . . 9015-10A-2 Wiring Diagram (S.N. -825657) . . . . . . 9015-10A-38
Fuse Specifications . . . . . . . . . . . . . . . . . . 9015-10A-3 Component Location (S.N. -825657) . . 9015-10A-39
Wiring and Schematic Diagrams Legend. . 9015-10A-4 Wiring Diagram (S.N.
System Functional Schematic Section 825658-872256) . . . . . . . . . . . . . . . . 9015-10A-40
Legend . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-7 Component Location (S.N.
System Functional Schematic 825658-872256) . . . . . . . . . . . . . . . . 9015-10A-41
(S.N. -825657) . . . . . . . . . . . . . . . . . . . . 9015-10A-8 Air Conditioning Compressor Harness (W11)
System Functional Schematic (S.N. Wiring Diagram (S.N. -825657) . . . . . . 9015-10A-42
825658-872256) Component Location (S.N. -825657) . . 9015-10A-43
1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-14 Component Location (S.N.
2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-15 825658-872256) . . . . . . . . . . . . . . . . 9015-10A-44
3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-16 Radio Harness (W12)
4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-17 Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10A-45
5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-18
Auxiliary Valve Harness (W14)
Cab Roof Harness (W5)
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10A-47
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10A-19
Cab Side Console Harness (W6) (S.N. Group 10BSystem Diagrams (S.N. 872257 )
-815415) Component Identification Table . . . . . . . . . 9015-10B-1
Wiring Diagram (1 of 2) . . . . . . . . . . . . 9015-10A-21
Wiring Diagram (2 of 2) . . . . . . . . . . . . 9015-10A-22 Continued on next page

022602
PN=1
Contents
Page Page
Fuse Schematic (S.N. 825658872256) . . . 9015-15A-10

Color Codes (Blade-Type) . . . . . . . . . . . 9015-10B-2 Sub-System Diagnostics . . . . . . . . . . . 9015-15A-11
Fuse Specifications . . . . . . . . . . . . . . . . . . 9015-10B-3 Start Circuit Diagnostic Procedures . . . . . 9015-15A-11
Wiring and Schematic Diagrams Legend. . 9015-10B-4 Charge Circuit
System Functional Schematic Section Operational Information . . . . . . . . . . . . 9015-15A-14
Legend . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-7 Theory of Operation. . . . . . . . . . . . . . . 9015-15A-15
System Functional Schematic . . . . . . . . . . 9015-10B-8 Schematic (S.N. 815415) . . . . . . . . . 9015-15A-16
Cab Roof Harness (W5) Schematic (S.N. 815416825657) . . . 9015-15A-17
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10B-15 Schematic (S.N. 825658872256) . . . 9015-15A-18
Component Location . . . . . . . . . . . . . . 9015-10B-16 Sub-System Diagnostics . . . . . . . . . . . 9015-15A-19
Connectors, Wire and Pin Location . . . 9015-10B-17 Charging Circuit Diagnostic
Side Console Harness (W6) Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15A-19
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10B-19 Display Module and Logic Module Circuit
9015 Component Location . . . . . . . . . . . . . . 9015-10B-22 With Logic Module
Connectors, Wire and Pin Location . . . 9015-10B-24 Operational Information (S.N.
Front Console Harness (W7) -815415). . . . . . . . . . . . . . . . . . . . . . 9015-15A-21
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10B-28 Theory of Operation (S.N. -815415). . . 9015-15A-22
Component Location . . . . . . . . . . . . . . 9015-10B-29 Display Module and Logic Module Circuit
Connectors, Wire and Pin Location . . . 9015-10B-30 Without Logic Module
Engine Harness (W8) Operational Information (S.N. 815416
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10B-32 825627) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-22
Component Location . . . . . . . . . . . . . . 9015-10B-34 Theory of Operation (S.N. 815416
Connectors, Wire and Pin Location . . . 9015-10B-35 825657) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-23
Blower Harness (W10) Theory of Operation (S.N. 825628
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10B-38 872256) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-24
Component Location . . . . . . . . . . . . . . 9015-10B-39
Display Module and Logic Module Circuit
Connectors, Wire and Pin Location . . . 9015-10B-40
Schematic (S.N. 815415) . . . . . . . . . 9015-15A-25
Air Conditioning Compressor Harness (W11)
Schematic (S.N. 815416825657) . . . 9015-15A-26
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10B-41
Schematic (S.N. 825658872256) . . . 9015-15A-27
Sub-System Diagnostics (S.N.
Connectors, Wire and Pin Location. . . 9015-10B-43
815415) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-28
Radio Harness (W12)
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10B-44
815416872256). . . . . . . . . . . . . . . 9015-15A-28
Connectors, Wire and Pin Location . . . 9015-10B-46 Display Module and Logic Module Circuit
Selective Flow Valve Harness (W15) Diagnostic Procedures . . . . . . . . . . . . . 9015-15A-28
Wiring Diagram . . . . . . . . . . . . . . . . . . 9015-10B-47 Indicator Circuit
Component Location . . . . . . . . . . . . . . 9015-10B-48 Specifications. . . . . . . . . . . . . . . . . . . . 9015-15A-29
Connectors, Wire and Pin Location. . . 9015-10B-49 Operational Information . . . . . . . . . . . . 9015-15A-29
Theory of Operation (S.N. 815415) With
Group 15ASub-System Diagnostics (S.N. Logic Module . . . . . . . . . . . . . . . . . . 9015-15A-30
872256) Theory of Operation (S.N.
Power Circuit 815416825657) Without Logic
Operational Information . . . . . . . . . . . . . 9015-15A-1 Module . . . . . . . . . . . . . . . . . . . . . . . 9015-15A-31
Theory of Operation. . . . . . . . . . . . . . . . 9015-15A-1 Theory of Operation (S.N.
Schematic (S.N. -825657) . . . . . . . . . . . 9015-15A-2 825658872256) Without Logic
Schematic (S.N. 825658-872256) . . . . . 9015-15A-3 Module . . . . . . . . . . . . . . . . . . . . . . . 9015-15A-32
Subsystem Diagnostics . . . . . . . . . . . . . 9015-15A-4 Schematic With Logic Module (S.N.
Power Circuit Diagnostic Procedures . . . . 9015-15A-4 815415) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-33
Start Circuit Schematic Without Logic Module (S.N.
Operational Information . . . . . . . . . . . . . 9015-15A-8 815416825657). . . . . . . . . . . . . . . 9015-15A-34
Theory of Operation. . . . . . . . . . . . . . . . 9015-15A-8
Schematic (S.N. -825657) . . . . . . . . . . . 9015-15A-9 Continued on next page

022602
PN=2
Contents
Page Page
Schematic Without Logic Module (S.N. Wiper/Washer Circuit

825658872256). . . . . . . . . . . . . . . 9015-15A-35 Operational Information . . . . . . . . . . . . 9015-15A-63
Sub-System Diagnostics (S.N. Theory of Operation. . . . . . . . . . . . . . . 9015-15A-63
872256) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-36 Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-64
Indicator Circuit Diagnostic Procedures . . 9015-15A-36 Sub-System Diagnostics . . . . . . . . . . . 9015-15A-65
MFWD Circuit Wiper/Washer Circuit Diagnostic
Specifications ( . . . . . . . . . . . . . . . . . . 9015-15A-39 Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15A-65
Operational Information . . . . . . . . . . . . 9015-15A-40 Blower Circuit
Theory of Operation. . . . . . . . . . . . . . . 9015-15A-40 Operational Information . . . . . . . . . . . . 9015-15A-68
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-41 Theory of Operation (S.N.
Sub-System Diagnostics . . . . . . . . . . . 9015-15A-42 816286) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-68
MFWD Circuit Diagnostic Procedures . . . 9015-15A-42 Schematic (S.N. 816286) . . . . . . . . . 9015-15A-69
Differential Lock Circuit Theory of Operation (S.N. 816287
Operational Information . . . . . . . . . . . . 9015-15A-43 872256) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-70 9015
Theory of Operation. . . . . . . . . . . . . . . 9015-15A-43 Schematic (S.N. 816287872256) . . . 9015-15A-71
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-44 Sub-System Diagnostics (S.N.
Sub-System Diagnostics . . . . . . . . . . . 9015-15A-45 872256) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-72
Differential Lock Diagnostic Blower Circuit Diagnostic Procedures . . . 9015-15A-72
Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15A-45 Drive and Work Light Circuit
Start Aid Circuit Operational Information . . . . . . . . . . . . 9015-15A-74
Operational Information . . . . . . . . . . . . 9015-15A-45 Theory of Operation. . . . . . . . . . . . . . . 9015-15A-74
Theory of Operation. . . . . . . . . . . . . . . 9015-15A-46 Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-75
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-47 Sub-System Diagnostics . . . . . . . . . . . 9015-15A-76
Sub-System Diagnostics . . . . . . . . . . . 9015-15A-48 Drive and Work Light Circuit Diagnostic
Start Aid Circuit Diagnostic Procedures. . 9015-15A-48 Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15A-76
Park Brake/Neutral Disconnect Circuit
Fuel Shut-Off Circuit
Specifications. . . . . . . . . . . . . . . . . . . . 9015-15A-77
Operational Information . . . . . . . . . . . 9015-15A-48
Operational Information . . . . . . . . . . . . 9015-15A-77
Theory of Operation. . . . . . . . . . . . . . . 9015-15A-49
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-50
Schematic (S.N. 815415) . . . . . . . . . 9015-15A-79
Sub-System Diagnostics . . . . . . . . . . . 9015-15A-51
Schematic (S.N. 815416825657) . . . 9015-15A-80
Fuel Shut-Off Circuit Diagnostic
Schematic (S.N. 825658872256) . . . 9015-15A-81
Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15A-51
Reverse Alarm Circuit
872256) . . . . . . . . . . . . . . . . . . . . . . 9015-15A-82
Operational Information . . . . . . . . . . . . 9015-15A-52
Diagnostic Procedures . . . . . . . . . . . . . 9015-15A-82
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-53 FNR/Range Control Circuit
Sub-System Diagnostics . . . . . . . . . . . 9015-15A-54 Operational Information . . . . . . . . . . . 9015-15A-86
Reverse Alarm Circuit Diagnostic Theory of Operation. . . . . . . . . . . . . . . 9015-15A-87
Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15A-54 Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-89
Dome Light Circuit Sub-System Diagnostics . . . . . . . . . . . 9015-15A-90
Operational Information . . . . . . . . . . . 9015-15A-57 FNR/Range Control Circuit Diagnostic
Theory of Operation . . . . . . . . . . . . . . 9015-15A-57 Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15A-90
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-58 Horn Circuit
Sub-System Diagnostics . . . . . . . . . . . 9015-15A-59 Operational Information . . . . . . . . . . . . 9015-15A-98
Dome Light Circuit Diagnostic Theory of Operation. . . . . . . . . . . . . . . 9015-15A-98
Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15A-59 Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-99
Radio Circuit Sub-System Diagnostics . . . . . . . . . . .9015-15A-100
Operational Information . . . . . . . . . . . . 9015-15A-60 Horn Circuit Diagnostic Procedures. . . . .9015-15A-100
Theory of Operation. . . . . . . . . . . . . . . 9015-15A-60 Turn Signal, Flasher and Brake Light Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15A-61 Operational Information . . . . . . . . . . . .9015-15A-100
Sub-System Diagnostics . . . . . . . . . . . 9015-15A-62
Radio Circuit Diagnostic Procedures . . . . 9015-15A-62 Continued on next page

022602
PN=3
Contents
Page Page
Theory of Operation. . . . . . . . . . . . . . .9015-15A-101 Charging Circuit Diagnostic

Schematic . . . . . . . . . . . . . . . . . . . . . .9015-15A-103 Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-13
Sub-System Diagnostics . . . . . . . . . . .9015-15A-104 Differential Lock Circuit
Turn Signal, Flasher and Brake Light Circuit Operational Information . . . . . . . . . . . . 9015-15B-15
Diagnostic Procedures . . . . . . . . . . . . .9015-15A-104 Theory of Operation. . . . . . . . . . . . . . . 9015-15B-16
Beacon Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-17
Operational Information . . . . . . . . . . .9015-15A-106 Sub-System Diagnostics . . . . . . . . . . . 9015-15B-18
Theory of Operation. . . . . . . . . . . . . . .9015-15A-107 Differential Lock Circuit Diagnostic
Schematic . . . . . . . . . . . . . . . . . . . . . .9015-15A-108 Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-18
Sub-System Diagnostics . . . . . . . . . . .9015-15A-109 MFWD Circuit
Beacon Circuit Diagnostic Procedures. . .9015-15A-109 Operational Information . . . . . . . . . . . . 9015-15B-19
Return-to-Dig Circuit Theory of Operation. . . . . . . . . . . . . . . 9015-15B-19
Operational Information . . . . . . . . . . . .9015-15A-109 Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-20
9015 Theory of Operation. . . . . . . . . . . . . . .9015-15A-110 Sub-System Diagnostics . . . . . . . . . . . 9015-15B-20
Schematic . . . . . . . . . . . . . . . . . . . . . .9015-15A-111 MFWD Circuit Diagnostic Procedures . . . 9015-15B-20
Sub-System Diagnostics . . . . . . . . . . .9015-15A-112 Radio Circuit
Return-to-Dig Circuit Diagnostic Operational Information . . . . . . . . . . . . 9015-15B-22
Procedures . . . . . . . . . . . . . . . . . . . . .9015-15A-112 Theory of Operation. . . . . . . . . . . . . . . 9015-15B-22
Fuel Gauge and Hour Meter Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-23
Specifications . . . . . . . . . . . . . . . . . . .9015-15A-113 Sub-System Diagnostics . . . . . . . . . . . 9015-15B-24
Operational Information . . . . . . . . . . . .9015-15A-113 Radio Circuit Diagnostic Procedures . . . . 9015-15B-24
Theory of Operation. . . . . . . . . . . . . . .9015-15A-114 Dome Light Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . .9015-15A-115 Operational Information . . . . . . . . . . . 9015-15B-25
Sub-System Diagnostics . . . . . . . . . . .9015-15A-116 Theory of Operation . . . . . . . . . . . . . . 9015-15B-25
Fuel Gauge and Hour Meter Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-26
Diagnostic Procedures . . . . . . . . . . . . .9015-15A-116 Sub-System Diagnostics . . . . . . . . . . . 9015-15B-27
Auxiliary Valve Circuit Dome Light Circuit Diagnostic
Operational Information . . . . . . . . . . . .9015-15A-118 Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-27
Theory of Operation. . . . . . . . . . . . . . .9015-15A-118 Start Aid Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . .9015-15A-119 Operational Information . . . . . . . . . . . . 9015-15B-27
Sub-System Diagnostics . . . . . . . . . . .9015-15A-120 Theory of Operation. . . . . . . . . . . . . . . 9015-15B-28
Auxiliary Valve Circuit Diagnostic Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-29
Procedures . . . . . . . . . . . . . . . . . . . . .9015-15A-120 Sub-System Diagnostics . . . . . . . . . . . 9015-15B-30
Start Aid Circuit Diagnostic Procedures. . 9015-15B-30
Group 15BSub-System Diagnostics (S.N. Fuel Shut-Off Circuit
872257 ) Operational Information . . . . . . . . . . . 9015-15B-30
Power Circuit Theory of Operation. . . . . . . . . . . . . . . 9015-15B-31
Operational Information . . . . . . . . . . . . . 9015-15B-1 Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-32
Theory of Opertion. . . . . . . . . . . . . . . . . 9015-15B-1 Sub-System Diagnostics . . . . . . . . . . . 9015-15B-33
Schematic . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-2 Fuel Shut-Off Circuit Diagnostic
Sub-System Diagnostics . . . . . . . . . . . . 9015-15B-3 Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-33
Power Circuit Diagnostic Procedures . . . . 9015-15B-3 Reverse Alarm Circuit
Start Circuit Operational Information . . . . . . . . . . . . 9015-15B-33
Operational Information . . . . . . . . . . . . . 9015-15B-5 Theory of Operation. . . . . . . . . . . . . . . 9015-15B-34
Theory of Operation. . . . . . . . . . . . . . . . 9015-15B-6 Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-35
Schematic . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-7 Sub-System Diagnostics . . . . . . . . . . . 9015-15B-36
Sub-System Diagnostics . . . . . . . . . . . . 9015-15B-8 Reverse Alarm Circuit Diagnostic
Start Circuit Diagnostic Procedures . . . . . . 9015-15B-8 Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-36
Charging Circuit Air Adjust Seat Circuit
Operational Information . . . . . . . . . . . . 9015-15B-10 Operational Information . . . . . . . . . . . 9015-15B-39
Theory of Operation. . . . . . . . . . . . . . . 9015-15B-11 Theory of Operation. . . . . . . . . . . . . . . 9015-15B-39
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-12
Sub-System Diagnostics . . . . . . . . . . . 9015-15B-13 Continued on next page

022602
PN=4
Contents
Page Page
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-40 Turn Signal, Flasher, and Brake Light Circuit

Sub-System Diagnostics . . . . . . . . . . . 9015-15B-41 Specifications . . . . . . . . . . . . . . . . . . . 9015-15B-77
Air Adjust Seat Circuit Diagnostic Operational Information . . . . . . . . . . . . 9015-15B-78
Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-41 Theory Of Operation . . . . . . . . . . . . . . 9015-15B-78
Blower Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-79
Operational Information . . . . . . . . . . . . 9015-15B-42 Sub-System Diagnostics . . . . . . . . . . . 9015-15B-80
Theory of Operation. . . . . . . . . . . . . . . 9015-15B-42 Turn Signal, Flasher, and Brake Light Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-43 Diagnostic Procedures . . . . . . . . . . . . . 9015-15B-80
Sub-System Diagnostics . . . . . . . . . . . 9015-15B-44 Beacon Circuit
Blower Circuit Diagnostic Procedures . . . 9015-15B-44 Operational Information . . . . . . . . . . . 9015-15B-84
Air Conditioning Circuit Theory of Operation. . . . . . . . . . . . . . . 9015-15B-84
Specifications. . . . . . . . . . . . . . . . . . . . 9015-15B-45 Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-85
Theory of Operation. . . . . . . . . . . . . . . 9015-15B-46 Beacon Circuit Diagnostic Procedures. . . 9015-15B-86 9015
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-47 Return-to-Dig Circuit
Sub-System Diagnostics . . . . . . . . . . . 9015-15B-48 Operational Information . . . . . . . . . . . . 9015-15B-87
Blower/Air Conditioning Circuit Checks . . 9015-15B-48 Theory of Operation. . . . . . . . . . . . . . . 9015-15B-87
Wiper/Washer Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-88
Theory of Operation. . . . . . . . . . . . . . . 9015-15B-51 Return-to-Dig Circuit Diagnostic
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-52 Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-89
Sub-System Diagnostics . . . . . . . . . . . 9015-15B-53 Fuel Gauge and Hour Meter Circuit
Wiper/Washer Circuit Diagnostic Specifications . . . . . . . . . . . . . . . . . . . 9015-15B-91
Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-53 Operational Information . . . . . . . . . . . . 9015-15B-91
Rear Work Light Circuit Theory of Operation. . . . . . . . . . . . . . . 9015-15B-92
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-93
Operational Information . . . . . . . . . . . . 9015-15B-56
Sub-System Diagnostics . . . . . . . . . . . 9015-15B-94
Theory Of Operation . . . . . . . . . . . . . . 9015-15B-57
Fuel Gauge and Hour Meter Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-58
Diagnostic Procedures . . . . . . . . . . . . . 9015-15B-94
Display Monitor Circuit
Rear Work Light Circuit Diagnostic
Operational Information . . . . . . . . . . . .9015-15B-100
Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-59
Theory Of Operation . . . . . . . . . . . . . .9015-15B-101
Front Work and Drive Light Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . .9015-15B-103
Operational Information . . . . . . . . . . . . 9015-15B-60
Sub-System Diagnostics . . . . . . . . . . .9015-15B-104
Theory Of Operation . . . . . . . . . . . . . . 9015-15B-60
Display Monitor Diagnostic
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-61
Procedures . . . . . . . . . . . . . . . . . . . . .9015-15B-104
Sub-System Diagnostics . . . . . . . . . . . 9015-15B-62 Indicator Circuit
Front Work and Drive Light Circuit Diagnostic Specifications. . . . . . . . . . . . . . . . . . . .9015-15B-106
Procedures . . . . . . . . . . . . . . . . . . . . . 9015-15B-62 Operational Information . . . . . . . . . . . .9015-15B-107
Park Brake/FNR Circuit Theory of Operation. . . . . . . . . . . . . . .9015-15B-108
Operational Information . . . . . . . . . . . . 9015-15B-63 Schematic . . . . . . . . . . . . . . . . . . . . . .9015-15B-109
Specifications. . . . . . . . . . . . . . . . . . . . 9015-15B-63 Sub-System Diagnostics . . . . . . . . . . .9015-15B-110
Theory Of Operation . . . . . . . . . . . . . . 9015-15B-64 Indicator Circuit Diagnostic
Schematic (Power Shift) . . . . . . . . . . . 9015-15B-66 Procedures . . . . . . . . . . . . . . . . . . . . .9015-15B-110
Sub-System Diagnostics . . . . . . . . . . . 9015-15B-67 Selective Flow Valve Circuit
Park Brake/Neutral Disconnect Circuit Operational Information . . . . . . . . . . . .9015-15B-113
Diagnostic Procedures . . . . . . . . . . . . . 9015-15B-67 Theory of Operation. . . . . . . . . . . . . . .9015-15B-114
Horn Circuit Schematic . . . . . . . . . . . . . . . . . . . . . .9015-15B-115
Operational Information . . . . . . . . . . . . 9015-15B-75 Sub-System Diagnostics . . . . . . . . . . .9015-15B-116
Theory of Operation. . . . . . . . . . . . . . . 9015-15B-75 Selective Flow Valve Diagnostic
Schematic . . . . . . . . . . . . . . . . . . . . . . 9015-15B-76 Procedures . . . . . . . . . . . . . . . . . . . . .9015-15B-116
Horn Circuit Diagnostic Procedures. . . . . 9015-15B-77 Continued on next page

022602
PN=5
Contents
Page
Group 20References
Alternators and Starting MotorsUse
CTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Battery Operation . . . . . . . . . . . . . . . . . . . . .9015-20-2
Battery Specifications . . . . . . . . . . . . . . . . . .9015-20-3
Diagnose Battery Malfunctions . . . . . . . . . . .9015-20-4
Check Battery Electrolyte Level and
Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-5
Procedure for Testing Batteries . . . . . . . . . . .9015-20-7
Using Booster Batteries12 Volt System . . .9015-20-8
Alternator Operation
9015 78 Amp DELCO REMY (Serial No.
787513) . . . . . . . . . . . . . . . . . . . . . . . .9015-20-10
95 Amp BOSCH (Serial No. 787514
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-12
95 Amp BOSCH . . . . . . . . . . . . . . . . . . .9015-20-13
Monitor Test in Machine . . . . . . . . . . . . . . .9015-20-14
Logic Module Test in Machine (S.N.
815415) . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-15
Logic Module Bench Test (S.N.
815415) . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-17
Tachometer Calibration
(S.N. 872256). . . . . . . . . . . . . . . . . . . .9015-20-18
(S.N. 872257 ) . . . . . . . . . . . . . . . . . . .9015-20-19

022602
PN=6
Group 05
System Information
Visually Inspect Electrical System
Make the following visual electrical inspection prior to

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

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

wire problem.
3. Look for loose or broken connectors and wires.
4. Inspect batteries for:
Corroded terminals
9015
Loose terminals or battery posts 05
Dirty condition 1
Damp condition
Cracked case
Proper electrolyte level
5. Check alternator belt tension.
6. 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.
CED,OUTX466,1353 1903FEB991/1

022602
PN=155
System Information
Circuit Malfunctions
9015
05
2
1919DEC97
T112479
ABattery CSwitch DLight EGround
BFuse
There are four common circuit malfunctions: 2. Open Circuit.

3. Grounded Circuit.
1. High-Resistance Circuit. 4. Shorted Circuit.
AG,tx13067,2 1903FEB991/1

022602
PN=156
System Information
Definition of Circuit Malfunctions
9015
05
3
1917DEC97
T112473
ABattery CSwitch ELight FGround
BFuse DHigh Resistance
A High Resistance Circuit has high resistance (D). An

example would be a loose or corroded connection that
causes a voltage drop and reduces current flow.
Continued on next page AG,tx13067,4 1903FEB991/5

022602
PN=157
System Information
9015
05
4
1917DEC97
T112476
BFuse DOpen
An Open Circuit has an open (D), such as a broken

wire, that prevents current from flowing in the circuit.

022602
PN=158
System Information
9015
05
5
1917DEC97
T112477
BFuse DGrounded Circuit
A Grounded Circuit (shorted circuit) has a power wire provides continuity to the battery ground terminal
with its insulation rubbed through contacting the (shorted to ground).
machine frame causing a grounded circuit (D). This

022602
PN=159
System Information
9015
05
6
1922DEC97
T112583
ABattery ECircuit Ground ISensor Signal Wire Shorted KController
BFuse F1 FController Ground To Ground LFuse F2
CSwitch GSensor JSensor Voltage Wire
DLight HSensor Ground Wire Shorted To Ground
Shorted To Ground
A sensor circuit shorted to ground has one or more wire (H) shorted to machine ground or a grounded
sensor wires, voltage wire (J), signal wire (I) or ground wire.

022602
PN=160
System Information
9015
05
7
1922DEC97
T112584
ABattery ESensor Signal Wire GLight KController Ground
BFuse F1 Shorted to Power HCircuit Ground LFuse F2
CSwitch FSensor Ground Wire ISensor MBattery Ground
DSensor Voltage Wire Shorted to Power JController
Shorted to Power
A Sensor circuit shorted to power has one or more

sensor wires, voltage wire (D), signal wire (E) or
ground wire (F) shorted to a power source.
AG,tx13067,4 1903FEB995/5

022602
PN=161
System Information
Location of Circuit Malfunctions
9015
05
8
1903FEB99
T120026
ABattery CSwitch DLoad (Light) EGround
BFuse
In a simple electrical circuit malfunctions only occur at 3. After the load (D).
three locations:
Failed components can be diagnosed as circuit
1. Before the controlling switch (C). malfunctions. Isolate malfunctions to determine the
2. Between controlling switch (C) and load (D). cause of failure.
CED,TX13067,1 1903FEB991/1

022602
PN=162
System Information
Troubleshooting Circuit Malfunctions
9015
05
9
1903FEB99
T120025
ABattery DSwitch Terminal GOpen JLoad (Light)
BFuse EResistance HConnector KGround
CSwitch FConnector IComponent Terminal
High Resistance Circuit: 5. If voltage is normal, the malfunction is between

point of measurement and circuit ground. Continue
1. A high resistance circuit results in slow, dim or no measuring voltage toward circuit ground until low
component operation. High resistance can be voltage is found. Malfunction is between last two
caused by loose, corroded or oily connector points of measurement.
terminals.
2. High resistance can be caused by wire that is too Open Circuit:
small or has broken strands internally.
3. Troubleshoot a high resistance circuit by measuring 1. An open circuit results in no component operation.
voltage between the switch and load with the switch An open circuit can be caused broken wires,
ON. disconnected connector, blown fuse or tripped
4. If voltage is low, the malfunction is between the circuit breaker.
point of measurement and the battery. Continue 2. Troubleshoot an open circuit by replacing the fuse
measuring voltage toward battery until normal or resetting the circuit breaker, then measure
voltage is found. Malfunction is between last two voltage between the switch and load with the switch
points of measurement. ON.
Continued on next page CED,TX13067,2 1903FEB991/6

022602
PN=163
System Information
3. If voltage is zero, the malfunction is between the 4. If voltage is normal, the malfunction is between
point of measurement and the battery. Continue point of measurement and circuit ground. Continue
measuring voltage toward the battery until normal measuring voltage toward circuit ground until zero
voltage is found. Malfunction is between last two voltage is found. Malfunction is between last two
points of measurement. points of measurement.
9015
05
10

022602
PN=164
System Information
9015
05
11
1917DEC97
T112481
AFuse (Power Side) DSwitch Terminal FGrounded Circuit HLoad (Light)
BFuse (Circuit Side) EWire Terminal GComponent Terminal IGround
CSwitch
Grounded Circuit: 4. If continuity is not measured, measure continuity to

frame ground, between switch terminal (D) and
1. A grounded circuit results in no component component terminal (G).
operation and the fuse blown or circuit breaker 5. If continuity is measured, the malfunction is
open. between switch and component. Inspect wire
2. Troubleshoot a grounded circuit by turning the harness for burned areas or insulation rubbed off a
switch OFF, and checking continuity to frame wire.
ground between the fuse circuit side (B) and switch
(C).
3. If continuity is measured, the malfunction is
between fuse and switch. Inspect wire harness for
burned areas or insulation rubbed off a wire.

022602
PN=165
System Information
9015
05
12
1919DEC97
T112482

022602
PN=166
System Information
ABattery HCircuit Wire Shorted To NSensor Signal Wire QController

BFuse F1 Ground Shorted To Sensor Ground RController Ground
CFuse F2 ILight E1 Wire SFuse F3
DSwitch S2 JCircuit Ground OSensor Voltage Wire TBattery Ground
EBattery Wire Shorted To KCircuit Ground Shorted To Sensor Ground
Circuit LLight E2 Wire
FSwitch S1 MSensor PSensor Signal Wire
GCircuit Wire Shorted To Shorted To Sensor Voltage
Circuit Wire
Circuit Shorted to Power: in the component, or the sensor circuit the

controller no longer receives a normal signal.
1. Complex circuits can fail in numerous ways. Circuits Abnormal signals received by a controller mean
can short to other circuits causing components to part of the circuit has a malfunction.
operate when unrelated switches are turned ON. In 2. Sensor circuits can fail in numerous ways. Service
the example if switch S1 (F) is ON and wires are Codes will be generated when sensor circuits fail.
shorted at (G) light E1 (I) and E2 (L) will be ON. Controllers may allow the component to operate
2. Components can operate even when all switches normally, may allow operation in a reduced capacity 9015
are OFF. In the example if wires are shorted at (E), such as a limp home mode, or the controller may 05
13
light E2 will be ON all the time. prevent any component operation.
3. Components can operate strangely. In the example 3. If a sensor circuit signal wire (N) shorts to a ground
if wires are shorted at (H), fuse F1 (B) will blow wire, a Short to Ground Service Code may be
when switch S1 is turned ON. If switch S2 (D) is generated
turned ON, light E2 will operate normally and light 4. If a sensor circuit voltage wire (O) shorts to ground,
E1 may be very dim, or light E1 and E2 may be a Service Code may or may not be generated, but
dim, even if fuse F1 is blown. other sensors connected to the controller will cease
to work, because their supply voltage will also be
Sensor Circuit Shorted to Itself: shorted to ground. Erratic operation of the monitor
may result.
1. Sensors are part of a controller circuit. Controllers 5. If a sensor circuit voltage wire (P) shorts to the
are used to operate components like engines, sensor signal wire a Service Code may or may not
transmissions or hydraulic systems. Sensors send be generated. The controller may receive a signal
information such as speed, pressure or temperature indicating the sensor is reading its maximum upper
from the component to the controller to monitor or lower limit.
operation of the component. If a malfunction occurs

022602
PN=167
System Information
9015
05
14
1922DEC97
T112583
ABattery ECircuit Ground ISensor Signal Wire Shorted KController
BFuse F1 FController Ground To Ground LFuse F2
CSwitch GSensor JSensor Voltage Wire
DLight HSensor Ground Wire Shorted To Ground
Shorted To Ground
Sensor Circuit Shorted to Ground: 3. If a sensor voltage wire shorts to a machine ground
wire (J), a Service Code may be generated. The
1. If a sensor circuit ground wire shorts to a machine monitor indicator for the sensor may illuminate.
ground wire (H), a service code probably wont be
generated. Sensor operation may be normal.
2. If a sensor signal wire shorts to a machine ground
wire (I), a Short to Ground service code may be
generated.
CED,TX13067,2 1903FEB996/6

022602
PN=168
System Information
Multimeter
The multimeter is an auto-ranging digital display that

allows very accurate readings to be taken.
ADisplay
BVoltage AC (Alternating Current)
CVoltage DC (Direct Current)
DResistance
EDiode Test/Continuity
FCurrent AC (Alternating Current)
GCurrent DC (Direct Current)
HVoltage, Resistance, Diode/Continuity (Red Lead
Input)
IGround (Black Lead Input)
JCurrent/Amps (Red Lead Input)
9015
05
15
1903SEP93
T8074AA
TX,9015,MM2916A 1920MAR961/1

022602
PN=169
System Information
Seven Step Electrical Test Procedure
9015
05
16
1905MAR92
T7719AA
ABattery Ground DFuse Or Circuit Breaker GBattery Side Of IGround Side Of Component
BBattery EComponent Side Of Fuse Component Terminal Terminal
CBattery Side Of Fuse Or Or Circuit Breaker HLight (Component) JComponent Ground
Circuit Breaker FSwitch
Step 1Switch ON
Check battery side of circuit breaker (C) for battery voltage Battery voltage normal. Go to Step 2.
Low voltage, repair high resistance.
Open circuit from battery.
Step 2Switch OFF
Check component side of circuit breaker for battery voltage Battery voltage normal. Go to Step 4.
No voltage. Go to Step 3.
Continued on next page TX,9015,MM2917B 1901MAY951/2

022602
PN=170
System Information
Step 3Switch OFF

Check component side of circuit breaker for continuity to ground Continuity to ground. Repair grounded circuit at or before switch.
No continuity to ground, replace circuit breaker.
Step 4Switch ON
Check component side of circuit breaker for battery voltage Battery voltage normal. Go to Step 6.
No voltage. Go to Step 5.
Step 5
Disconnect wire at battery side of component (G). Switch ON. Check Battery voltage, repair component.
wire at (G) for battery voltage
No voltage, repair grounded or open circuit at or after switch.
Step 6Switch ON
Check lead to component at (G) for battery voltage Battery voltage normal. Go to Step 7.
Low voltage, repair high resistance in circuit between fuse and
component. 9015
05
No voltage, repair high resistance or open circuit between fuse and
17
component.
Step 7Switch ON
Check ground wire of component at (I) for voltage No voltage, good continuity to ground.
Repair component.
Voltage, poor continuity to ground. Repair high resistance or open
ground circuit.
TX,9015,MM2917B 1901MAY952/2

022602
PN=171
System Information
Wiring Diagram, Schematic, And Component

Location Information
System Functional Schematic Diagram
The System Functional Schematic is a schematic diagram

of the complete machine. All harnesses are identified by
letter/number designation and description (W1 Engine
Harness, W2 Dash Harness, Etc.). Each wire is identified
by number and/or color (G01 BLK, R02 Red, RED/WHT,
BLU/GRN, Etc.). All components are identified by
letter/number designation, description and are represented
by a schematic symbol. Component letter/number
designation, (K1 Start Relay, S1 Key Switch, B9 Horn,
Etc.) will indicate that component throughout the manual.
9015 The System Functional Schematic Diagram is divided into
05 Sections. Each section contains one or more electrical
18 circuits. Each section is indicated by a number and circuit
(SE1 CHARGING CIRCUIT, SE2 STARTING CIRCUIT,
Etc.).
UN27FEB90
Wiring DiagramIf Provided
The Wiring Diagram shows each wiring harness, wire
T85958
color, wire destination, harness connectors, and schematic
symbols for each electrical component connected to that
harness. Harnesses are identified by the same
letter/number designation and description used in the
System Functional Schematic Diagram (W1 Engine
Harness, W2 Dash Harness, Etc.). Each component
schematic symbol will be identified by the same
letter/number designation used in the System Functional
Schematic Diagram. Harness connectors will be identified
by a letter/number designation and description (X1 CAB
HARNESS TO ENGINE HARNESS CONNECTOR, X3
DASH HARNESS TO HEATER BLOWER HARNESS
CONNECTOR, Etc.).
Continued on next page CED,OUTX466,1361 1903FEB991/2

022602
PN=172
System Information
Component Location Diagram
The Component Location Diagram is a pictorial view by

harness showing location of all electrical components,
connectors, harness main ground locations and harness
band and clamp location. Each component will be
identified by the same identification letter/number and
description used in the System Functional Schematic
Diagram.
NOTE: All System Functional Schematics, Circuit

Schematics, and Wiring Diagrams are shown with
key switch in the off position.
Connector End View DiagramIf Provided

9015
The connector end view diagram is a pictoral end view of 05
the component connectors showing the number of pins in 19
the connector and the wire color and identifier of the wire
in every connector. Each component will be identified by
the same identification letter/number and description used
in the System Functional Schematic Diagram.
CED,OUTX466,1361 1903FEB992/2

022602
PN=173
System Information
Reading a System Functional Schematic
9015
05
20
1929MAY91
T7502CE
APower Wires DComponent Identification EComponent Name GCircuit Name
BContinuity Chart Code FGround Wires HSection Number
CComponent Schematic
Symbol
The System Functional Schematic is made up of component identification code (D). A continuity chart
sections which contain one or more Subsystem (B) is included for each multi-terminal switch.
Functional Schematic laid out side by side in a logical
sequence of related functions. Each Subsystem is a The same names and identification letter codes are
major group of components like starting components or used on all machine drawings, the System Functional
charging components (H). Sections are named to Schematic, System Wiring and Harness Diagram, and
reflect that group of components (G). The System the System Component Location Drawing.
Functional Schematic is formatted with power supply Components and connectors can easily be
wires (A) shown across the top of the drawing and cross-referenced from one drawing to another. See
ground wires (F) across the bottom. The diagram Group -10 for Component Identification Legend.
contains no harness or connector information.
Each electrical component is shown by a schematic

symbol (C), the component name (E), and a
TX,9015,MM2919B 1912APR941/1

022602
PN=174
System Information
Reading A Wiring Diagram
9015
05
21
1910AUG95
T8534AC
AHarness Connector DComponent Connector GHarness Identification JWire Number And/Or Color
Letter/Number EWire Number And/Or Color Letter/Number And KHarness Connector Pin
Identification FComponent(s) Identification Description Number Or Letter
BComponent Letter/Number Number/Letter Wire Is HWiring Harness
Identification Routed To IComponent(s) Identification
CComponent Connector Pin Number/Letter Wire Is
Number Or Letter Routed To
Each harness on the machine is drawn showing Main harness connectors (A) are identified by a
components, connectors, and wires. Harnesses (G) letter/number designation and description (X2 PARK
are identified by a letter/number designation and BRAKE HARNESS TO DASH HARNESS
description (W3 PARK BRAKE HARNESS, Etc.). CONNECTOR, Etc.). Harness connector description
indicates which harnesses connect together.
Each component (B) is represented by a schematic Connector pin numbers or letters (K) are indicated as
symbol and is identified by the same letter/number they are marked on the connector. Wires attached to
designation and description used in the System each connector pin are identified by number and/or
Functional Schematic. Components with integral color designation (J). Component identification
connectors (D) have pin number/letters indicated (C). number/letter (I) indicates destination of each wire.
Wires from harness to components are identified by
letter/number designation (E). Component identification Harness, harness connector, and component
letter/number (F) indicates component wire is routed identification letter/numbers and description are the
to. same as used on the System Functional Schematic.
CED,OUTX466,1363 1915OCT981/1

022602
PN=175
System Information
Reading A Component Location Diagram
9015
05
22
1909FEB98
T113251
Continued on next page TX,9015,MM2920B 1927MAY981/2

022602
PN=176
System Information
AComponent Identification DMating Connector X FName of Harness IWire Number and Color
Number Identification Number GDiagram View of JRouting Destination(s) of
BComponent Name EHarness Component Connector Wire
CEnd View of Connector Identification Number HTerminal Numbers
NOTE: The same names and identification numbers Each connector that joins one harness to another is
are used on all machine schematic and identified by an X component identification number
harness electrical drawings throughout the and a name. An end view of the connector is shown.
Operation and Test Technical Manual so Also, a diagram view of the connector shows
components can easily be cross-referenced connector terminal number, wire number and color and
from one drawing to another. destination of each wire.
The component location by harness drawing is a For example, X18 connector connects the Cab Work
pictorial representation that shows harness routing, Light Harness to the Load Center Harness. Terminal 5
component location and mating harness connector of the connector contains L02 Brn Wire, which routes
information. to E20 Left Front Work Light, E21 Right Front Work
Light, E22 Left Rear Work Light, and E23 Right Rear 9015
The location of each component that is connected to Work Light. 05
the harness is shown and identified by its 23
alpha-numeric identification number.
TX,9015,MM2920B 1927MAY982/2

022602
PN=177
System Information
Reading Connector End View Diagram
9015
05
24
1905SEP97
T102978

022602
PN=178
System Information
Each wiring harness component location is followed by Work Lights, the connection would reference the
individual component connector drawings. These Connectors for Cab Work Light Harness on the page
drawings show an end view and a diagram view of following the component location drawing. This
each connector in the harness that connects to a drawing shows the end view of the wiring harness
component. connector for each component. In the case of L02
Brown wire, it is located in Terminal A for all three
In the preceding example, to see the location of L02 work lights.
Brn Wire in connectors for E20, E21, E22, and E23
CED,TX17864,1018 1903FEB992/2
9015
05
25

022602
PN=179
System Information
Electrical Schematic Symbols
9015
05
26
1903FEB99
T120028
Continued on next page TX,9015,MM2921 1926OCT931/4

022602
PN=180
System Information
9015
05
27
1903FEB99
T120029

022602
PN=181
System Information
9015
05
28
1903FEB99
T120030

022602
PN=182
System Information
9015
05
29
1922MAR99
T120031
TX,9015,MM2921 1926OCT934/4

022602
PN=183
System Information
9015
05
30

022602
PN=184
Group 10A
System Diagrams (S.N. 872256)
Component Identification Table
Each component (electrical device) and main connector

will have and identification letter assigned to it. A number
is added to the letter to separate and indicate the total
components within that letter group.
Identification
Letter Type Examples
A System, subassembly, parts group Control units, trigger boxes, two-way radios, logic module, FNR
logic module
B Transducer for conversion of non-electrical Speed sensors, pressure sensors, pressure switches horns,
variables to electrical and vice versa sensors, pickups, limit-value sensors, pulse generators,
loudspeakers, inductive pickups, probes, air-flow sensors,
oil-pressure switches, temperature sensors, ignition-voltage pickups
C Condenser, capacitor Condensers and capacitors, general
D Binary device, memory Digital devices, integrated circuits, pulse counters, magnetic tape 9015
recorders 10A
1
E Various devices and equipment Heating devices, air conditioners, light, headlights, spark plugs,
ignition distributors
F Protection device Release mechanisms, polarity protection devices, fuses, current
protection circuits
G Power supply, generator Batteries, generators, alternators, charging units
H Monitor, alarm, signalling device Audible alarms, indicator lights, turn-signal lights, brake lights,
alarms, warning lights, buzzers
K Relay Battery relays, turn-signal relays, solenoid switches, starting relays,
warning flashers
L Inductor Choke coils, coils, windings
M Motor Blower motors, fan motors, starter motors
N Regulator, amplifier Regulators (electronic or electromechanical), voltage stabilizers
P Measuring instrument Ammeter, diagnostic connectors, tachometers, fuel gauge, pressure
gauges, measuring points, test points, speedometers
R Resistor Flame glow plugs, sheathed-element flame glow plugs, glow plugs,
heating resistors, NTC resistors, PTC resistors, potentiometers,
regulating resistors
Continued on next page TX,901505,QQ381 1916SEP921/2
TM1537 (26FEB02) 9015-10A-1 710D Backhoe Loader

022602
PN=185
Identification
S Switch Switches and pushbuttons, general key switch, light switch, horn
switch, flasher switch
T Transformer Ignition coil, ignition transformer
U Modulator, converter DC transformers
V Semiconductor, electron tubes Transistors, diodes, electron tubes, rectifiers, semiconductors,
thyristors, zener diodes
W Transmission path, conductor, antenna Antennas, shielding components, shielded conductors, cable
harnesses, conductors, ground conductors
X Terminal, plug, plug and socket connection Terminal studs, electrical connections, connectors electrical line
couplers, line connectors, sockets, plugs, terminals, plug-and-socket
connections
Y Electrically actuated mechanical device Permanent magnets, (solenoid-operated) injection valves,
electromagnetic clutches and brakes, air valves, fuel pumps,
solenoids, switching valves, start valves, locking systems
9015
Z Electrical filter Interference suppression filters
10A
2
TX,901505,QQ381 1916SEP922/2
Fuse (Blade-Type) Color Codes

Amperage Rating Color
1 Black
3 Violet
4 Pink
5 Tan
7-1/2 Brown
10 Red
15 Light Blue
20 Yellow
25 Natural (White)
30 Light Green
TX,9015,QQ6743 1928SEP921/1

022602
PN=186
Fuse Specifications (S.N. 872256)
9015
10A
3
1923SEP92
T7812AF
F17.5 Amp MFWD/ F630 Amp Heater/AC Circuit F117.5 Amp Left Turn Fuse F1610 Amp Start Fuse
Alternator/Diff Lock Fuse Breaker F127.5 Amp Right Turn Fuse K3Park Light Relay
F215 Amp Fuel/Ether Aid F715 Amp Rear Light/ Tail F1310 Amp RTD/Beacon K4Reverse Alarm Relay
and Reverse Alarm Fuse Light fuse Fuse K5Park Brake Relay
F35 Amp Dome Light/Radio F825 Amp Front Light Fuse F145 Amp Monitor/Gauge K6Neutral Relay
fuse F910 Amp FNR/Park Brake Fuse K7Alternator Sense Relay
F45 Amp Radio Fuse Fuse F1515 Amp Hazard/Monitor S21Flasher
(Unswitched Power) F1020 Amp Turn/Stop and Fuse (Unswitched
F515 Amp Wiper Fuse Horn Fuse Power)
IMPORTANT: Install fuse with correct amperage The fuse block is located on the side console inside an
rating to prevent electrical system access cover.
damage from overload.
TX,9015,QQ1700 1912MAR931/1

022602
PN=187
Wiring and Schematic Diagrams Legend (S.N. 872256)
NOTE: A1Shift Controller (SE10, W7) E6Right Rear Work Light (SE8,W5)
E7Left Front Drive Light (SE8,W5)
A1 indicates component identification E8Right Front Drive Light (SE8,W5)
number. E9Left Tail Light (SE8,W5)
Shift Controller indicates component name. E10Right Tail Light (SE8,W5)
SE10 indicates section number of SYSTEM E11Left Brake Light (SE13,W5)
FUNCTIONAL SCHEMATIC where E12Right Brake Light (SE13,W5)
component is located. E13Beacon Light (SE14,W5)
W7 indicates HARNESS WIRING DIAGRAM E14Fuel Gauge Light (SE15,W8)
and HARNESS COMPONENT LOCATION E15Seat Belt Light (SE9,W6)
drawings where component is located. F1MFWD/ALT/Diff Lock Fuse (SE2,W6)
F2Fuel Shutoff/Start Aid/Reverse Alarm Fuse
V1MFWD Solenoid Diode (SE2,W8) (SE5,W6)
F3Dome Light Fuse (SE3,W6)
9015
10A V1 indicates component identification F4Radio Fuse (Unswitched Power) (SE3,W6)
4 number. F5Windshield Wiper/Washer Fuse (SE4,W6)
MFWD Solenoid Diode indicates component F6Heater Circuit Breaker (SE6,W6)
name. F7Rear Work Light Fuse (SE7,W6))
SE1 indicates section number of SYSTEM F8Front Work Light Fuse (SE8,W6)
FUNCTIONAL SCHEMATIC where F9FNR/Park Brake Fuse (SE9,W6)
component is located. F10Turn/Stop/Horn Fuse (SE12,W6)
W8 indicates HARNESS WIRING DIAGRAM F11Left Turn Light Fuse (SE13,W6)
and HARNESS COMPONENT LOCATION F12Right Turn Light Fuse (SE13,W6)
drawings where component is located. F13Return-To-Dig/Beacon Fuse (SE14,W6)
F14Monitor Fuse (SE15,W6)
A1Shift Controller (SE10,W7) F15Hazard/Monitor Fuse (Unswitched Power)
A2Radio (W12) (SE16,W6)
B1Reverse Warning Alarm (SE5,W8) F16Start Fuse (SE11,W6)
B2Park Brake Sensing Switch (SE9,W8) F17Fuse Block (W6)
B3Horn (SE12,W8) G1Battery (SE1,W8)
B4Fuel Sender (SE15,W8) G2Alternator (SE1,W8)
B5Engine Coolant Temperature Switch (SE17,W8) H1Left Indicator Turn Light (SE13,W7)
B6Engine Oil Pressure Switch (SE17,W8) H2Left Front Turn Light (SE13,W5)
B7Air Filter Restriction Switch (SE17,W8) H3Left Rear Turn Light (SE13,W5)
B8Transmission Temperature Switch (SE17,W8) H4Right Front Turn Light (SE13,W5)
B9Hydraulic Filter Restriction Switch (SE17,W8) H5Right Rear Turn Light (SE13,W5)
B10Radio Speaker (W12) H6Right Indicator Turn Light (SE13,W7)
B11Brake Light Switches (SE13,W6) H7Logic Module (S.N. 815415) (SE16,W6)
B12Radio Speaker (W12) H8Display Module (SE16,W6)
E1Dome Light (SE3,W5) H9Red Warning Light (SE17,W6)
E2Swivel Light (SE3,W5) H10Yellow Warning Light (SE17,W6)
E3Left Front Work Light (SE8,W5) H11Alarm (SE17,W6)
E4Right Front Work Light (SE8,W5) K1Start Relay (SE1,W8)
E5Left Rear Work Light (SE8,W5) K2Accessory Relay (SE1,W6)
Continued on next page TX,9015,QQ3270 1910MAR971/3

022602
PN=188
K3Park Light Relay (SE9,W6) S28Swivel Light Switch (SE3,W5)

K4Reverse Alarm Relay (SE5,W6) S29Auxiliary Valve Solenoid (W14)
K5Park Brake Latching Relay (SE9,W6) S30Auxiliary Valve Foot Switch (W14)
K6Neutral Start Relay (SE11,W6) S31Seat Switch (S.N. 825628 )
K7Alternator Relay (SE16,W6) V1MFWD Solenoid Diode (SE2,W8)
K8Auxiliary Valve Relay (W14) V2Park Brake Solenoid Diode (SE9,W8)
M1Starter Motor (SE1,W8) V3Reverse Solenoid Diode (SE9,W8)
M2Rear Wiper Motor (SE4,W5) V4Forward Solenoid Diode (SE10,W8)
M3Left Hand Door Wiper Motor (SE4,W5) V5Neutral Disconnect Solenoid Diode (SE11,W8)
M4Right Hand Door Wiper Motor (SE4,W5) V64-Way Flasher Switch Diode (SE13,W7)
M5Washer Motor (SE4,W8) V74-Way Flasher Switch Diode (SE13,W7)
M6Heater Blower Motor (SE6,W6) V8Logic Module/Display Module Diode (SE15,W6)
M7Heater Blower Motor (S.N. 825657) V9Alternator Diode (SE1,W8)
(SE6,W6) V10Differential Lock Solenoid Diode (SE2,W8)
P1Fuel Gauge (SE15,W6) V11Park Brake Relay Diode (SE9,W6)
P2Tachometer (Optional) (SE15,W6) V12C1/B2 Solenoid Diode (SE10,W8)
9015
P3Hour Meter (SE15,W6) V13C2/B3 Solenoid Diode (SE10,W8) 10A
R1Heater Motor Resistor (SE6,W6) V14Auxiliary Valve Diode (W14) 5
S1Key Switch (SE2,W6) V15Park Warning Light Diode (S.N. 825658 )
S2MFWD Switch (SE2,W6) W1Machine Frame/Engine Block Ground/Left Side
S3MFWD Indicator Switch (SE2,W8) (SE1,W8)
S4Not Used W2Ground To Cab Frame (SE14,W5)
S5Front Wiper Switch (SE4,W7) W3Ground At Cab Floor (SE1,W8)
S6Rear Wiper Switch (SE4,W6) W4Engine Ground Strap (W8)
S7Windshield Washer Switch (SE4,W6) W5Cab Hoof Harness (W5)
S8Blower Switch (SE6,W6) W6Cab Side Console Harness (W6)
S9Front Light Switch (SE8,W7) W7Front Console Harness (W7)
S10Rear Light Switch (SE7,W6) W8Engine Harness (W8)
S11Forward and Reverse/Range Switch W9Transmission Solenoid Harness (W9)
(SE10,W7) W10Blower Harness (W10)
S12Park Brake Dash Switch (SE9,W6) W11Air Conditioning Compressor Harness (W11)
S13Neutral Disconnect Switch (SE11,W6) W12Radio Harness (W12)
S14Not Used W13Radio Antenna (W12)
S15Horn Switch (SE12,W6) W14Auxiliary Valve Harness (W14)
S16Turn Signal Switch (SE13,W7) X1Side Console Harness To Roof Harness
S174-Way Flasher Switch (SE13,W7) Connectors (W5,W6)
S18Beacon Switch (Optional) (SE14,W6) X2Side Console Harness To Roof Harness
S19Diff Lock Switch (SE2,W6) Connectors (W5,W6)
S20Return-To-Dig Switch (SE14,W8) X3Side Console Harness To Roof Harness
S21Flasher (SE13,W6) Connectors (W5,W6)
S22Heater Temperature Switch (W6) X4Transmission Solenoid Harness To Engine
S23Low Pressure Switch (W11) Harness (W8,W9)
S24High Pressure Switch (W11) X5Radio Harness To Radio Connector (W12)
S25Air Conditioning Switch (If Equipped) (W6) X6Blower Switch Connector (W10)
S26A/C Freeze Switch (W10) X7Display Module Connectors (W6)
S27Dome Light Switch (SE3,W5) X8Horn Switch Connector (W6)

022602
PN=189
X9Rear Light Switch Connector (W6) X37Seat Belt Light Connector (W6)
X10Rear Wiper Switch Connector (W6) X38A.C. Switch Connector (W6)
X11Beacon Switch Connector (W6) X41Hour Meter or Auxiliary Valve Connector
X12MFWD Switch Connector (W6) (W14)
X13Park Brake Switch Connector (W6) X41AAuxiliary Valve Harness Connector (W14)
X14Start Aid Switch Connector (W6) X42Auxiliary Valve Harness Connector (W14)
X15Fuel Gauge Connector (W6) X43Splice (Inside Harness) (S.N. 825658 )
X16Key Switch Connector (W6) X44Splice (Inside Harness) (S.N. 825658 )
X17Logic Module 4-Pin Connector (W6) X45Splice (Inside Harness) (S.N. 825658 )
X21Side Console To Engine Harness Connectors X49Splice (Inside Harness) (S.N. 825658 )
(W6,W8) X50Splice (Inside Harness) (S.N. 825658 )
X22Side Console To Engine Harness Connectors X51Splice (Inside Harness) (S.N. 825658 )
(W6,W8) X52Splice (Inside Harness) (S.N. 825658 )
9015
10A X23Floor Harness To Engine Harness Connectors X53Splice (Inside Harness) (S.N. 825658 )
6 (W6,W8) X54Splice (Inside Harness) (S.N. 825658 )
X24Side Console To Front Console Harness X55Splice (Inside Harness) (S.N. 825658 )
Connectors (W6,W7) X56Seat Switch Connector (S.N. 825658 ) (W6)
X25Side Console To Front Console Harness Y1MFWD Solenoid (SE2,W8)
Connectors (W6,W7) Y2Start Aid Solenoid (SE5,W8)
X26FNR/Range Switch Connectors (W7) Y3Fuel Shutoff Solenoid (SE5,W8)
X27Turn Signal Switch Connector (W7) Y4Park Brake Solenoid (SE9,W8)
X28Beacon Light Connector (W5) Y5Reverse/Solenoid (SE10,W9)
X29Roof Harness to Radio Harness Connector Y6Forward/Solenoid (SE10,W9)
(W5,W12) Y7Neutral Disconnect Solenoid (SE11,W9)
X30Splice (Inside Harness) (W6) Y8Hydraulic Pump Destroke Solenoid (SE 11,W8)
X31Forward Solenoid Connector (W8) Y9Return-To-Dig Solenoid (SE14,W8)
X32Clutch Disconnect Solenoid Connector (W8) Y10Air Conditioning Compressor (W11)
X33Connector for Air Conditioning Switch (W8) Y11Differential Lock Solenoid (SE2,W8)
X34Engine Harness To A/C Compressor Harness Y12C1/B2 Solenoid (SE10,W9)
Connector (W8,W11) Y13C2/B3 Solenoid (SE10,W9)
X35Side Console Harness To Blower Harness Y14Park Brake Solenoid (SE9,W8)
Connectors (W8,W10) Y15Auxiliary Valve Solenoid
X36Air Conditioning Clutch Cycle Switch
Connectors (W10)
TX,9015,QQ3270 1910MAR973/3

022602
PN=190
System Functional Schematic Section

Legend (S.N. 872256)
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

SE2MFWD and Differential Lock Circuit
SE3Dome Light and Radio Circuit
SE4Wiper and Washer circuit 9015
SE5Start Aid, Fuel Shut Off and Reverse Alarm 10A
Circuit 7
SE6Blower Circuit
SE7Rear Work Light Circuit
SE8Front Work and Drive Light Circuit
SE9Park Brake Circuit
SE10FNR/Range Control Circuit
SE11Neutral Disconnect Circuit
SE12Horn Circuit
SE13Turn Signal, Flasher and Brake Light Circuit
SE14Beacon and Return-To-Dig Circuit
SE15Gauge and Hour Meter Circuit
SE16Display Module and Logic Module Circuit
SE17Indicator Circuit
TX,9015,QQ1703 1912MAR931/1

022602
PN=191
System Functional Schematic (S.N. 825657)

T8542AF 1925APR97
TX,9015,QQ3257 1910MAR971/6

022602
PN=192
T8542AG 1925APR97
TX,9015,QQ3257 1910MAR972/6

022602
PN=193
T8542AH 1925APR97
TX,9015,QQ3257 1910MAR973/6

022602
PN=194
T8542AI 1925APR97
TX,9015,QQ3257 1910MAR974/6

022602
PN=195
T8542AJ 1925APR97
TX,9015,QQ3257 1910MAR975/6

022602
PN=196
T8542AK 1925APR97
TX,9015,QQ3257 1910MAR976/6

022602
PN=197

T117118 1916SEP98
ACC GROUND CIRCUIT

OFF (WIRE COLOR) G01 BLKENGINE HARNESS
ON KEY G10 BLKSIDE CONSOLE HARNESS OFF REAR OFF
OFF 9 MFWD LOW WIPER FRONT
BULB CHECK SWITCH ON G20 BLKROOF HARNESS OFF 9 WASHER LOW
SWITCH HIGH SWITCH WIPER
START 10 6 8 G30 BLKFRONT CONSOLE HARNESS ON SWITCH HIGH
3 5 1 SWITCH
BAT IGN ACC ST G BODY G40 BLKENGINE HARNESS TO SIDE CONSOLE HARNESS 1 5 3 5 1 7 4 6 2 8
B11B RED B11B RED
B12B RED B12B RED B12B RED
B12A RED B12A RED B12A RED
E22 WHT E22 WHT E22 WHT
ACC R31 BLK R31 BLK R31 BLK
S1 OFF B11D RED B11D RED
M39C PUR M39C PUR M39C PUR
ON
KEY B15 RED B15 RED B15 RED
BULB CHECK P13E RED
SWITCH START
F1 F4 F3
ACC F5
BAT B14 RED MFWD/ALT/ S19 DOME A61 ORG
UNSWITCHED WIPER/
DIFF. LOCK DIFF. LOCK LIGHT
RADIO FUSE A62 ORG
FUSE SWITCH FUSE WASHER FUSE
S5
FRONT A64
IGN ORG
T16 P14 RED WIPER A63
BLU
P13A RED
SWITCH ORG
P14C RED 2 6 1 5
ON
T16 OFF
ON 5 S7 II I O
P14A
RED
P13E RED BLU Y11
P13 OFF
P25 RED
P15A RED
ST RED I O WINDSHIELD
P13C DIFF.
B11B RED
RED
WASHER
LOCK P14G RED
K2 OFF 6 9 SWITCH
ON
V10 SOLENOID 4 8 3 7
G ACCESSORY M5
I O DIFF. 1
P13
RED
RELAY WASHER
B15 RED
LOCK P14 RED
B11 RED MOTOR A66 ORG
SOLENOID P15 RED
S2
M39C PUR
DIODE A65 ORG
A17 ORG
MFWD 8 10 A68 ORG
G10L BLK G10M BLK
B11C RED
SWITCH TO A2 RADIO ON 1 5 P14 RED
G05 BLK
G05 BLK
W55
BLU
RED CABLE (IF EQUIPPED) OFF
II I O
P15 RED
G1 M
M31 PUR
BATTERIES TO NEUTRAL
G20 BLK
WIRES A68 AND
E1
A69 ORG
P13B TAN
V1 W55
A63 ORG
START RELAY
P14 RED
A64 ORG
A66 ORG
A62 ORG
A65 ORG
A69 (SHOWN AS
A61 ORG
P14 RED
A68 ORG
V9
P14 RED
MFWD BLU DOME

+ SE11, K6 ALTER- 3 7 DASHED LINES)
LIGHT GRY
SOLENOID S6
NATOR ARE USED FOR
B14 RED
DIODE P14B RED REAR
DIODE (S.N. 816286)
M39
PUR
B11 RED G2 WIPER
B03 RED
RED
YEL
YEL
E23 WHT
GRN
RED
BLU
P13C
TAN
ALTERNATOR
G01 BLK
SWITCH
BLU
- E02 WHT E2
GRN
RED
YEL
BLU
W D+ SWIVEL
W3 K1 S LIGHT
BRN
GROUND START G
Y1 M2 M M
S27 M3 M4
BRN
NOT MFWD
AT CAB RELAY USED DOME REAR L.H. R.H. M
FLOOR SOLENOID WIPER
B+ S3 LIGHT DOOR DOOR
S28
E02 WHT
M MFWD SWITCH MOTOR WIPER WIPER
M1 B11 RED SWIVEL
BLK CABLE
STARTER INDICATOR MOTOR MOTOR
G10A BLK
LIGHT
G01 BLK
MOTOR SWITCH
E02 WHT
TO PARK SWITCH
G20 BLK
G20 BLK
G20 BLK
G20 BLK
G20 BLK
BRAKE
G30 BLK
G01 BLK
LATCHING RELAY
G01
BLK SE9, K5 G20 BLK
G02 BLK G02 BLK G20 BLK G20 BLK G20 BLK
G10A BLK G10 BLK G10 BLK
G40 BLK G40 BLK G40 BLK
W1 SE1 POWER, CHARGING AND START CIRCUIT SE2 MFWD AND DIFFERENTIAL LOCK CIRCUIT SE3 DOME LIGHT AND RADIO CIRCUIT SE4 WIPER AND WASHER CIRCUIT
MACHINE FRAME/ENGINE
BLOCK GROUND LEFT SIDE SYSTEM FUNCTIONAL SCHEMATIC (1 OF 5)
T117118 CONTINUED ON NEXT PAGE
CED,TX17864,148 1909SEP981/1

022602
PN=198

T117119 1916SEP98
OFF GROUND CIRCUIT

OFF REAR LIGHT OFF (WIRE COLOR) G01 BLKENGINE HARNESS
BLOWER LOW ON FRONT 2 LIGHTS PARK ON 9
SWITCH LIGHT BRAKE OFF G10 BLKSIDE CONSOLE HARNESS
SWITCH MED 1 5 4 LIGHTS G20 BLKROOF HARNESS
HIGH SWITCH 3 2 1 6 SWITCH 10 5 1 6 8
B L M H C G30 BLKFRONT CONSOLE HARNESS
G40 BLKENGINE HARNESS TO SIDE CONSOLE HARNESS
B12B RED B12B RED B12D RED
B12A RED
E22 WHT E22 WHT E22 WHT
R31 BLK R31 BLK R31 BLK
B11D RED B11D RED B11D RED
M39 PUR M39 PUR M39 PUR
B15 RED B15 RED B15 RED
F2 P24C RED
F6 F8
FUEL SHUTOFF/ F7
B12C
RED
HEATER
START AID/REVERSE REAR WORK FRONT WORK
CIRCUIT F9
ALARM FUSE LIGHT FUSE LIGHT FUSE
BREAKER FNR/PARK
BRAKE FUSE
P16 RED
OFF L43 BRN M32A PUR
P17A RED
R
L42 BRN
2C
P1 ED
1 S8 L42 BRN
ON 1 ON S12 J27A TAN
2 1 6 8
BLOWER OFF OFF
II I O
PARK BRAKE J27A TAN
3 SWITCH I O E4
4
SWITCH (DASH) M32B PUR
S4 RIGHT
P12A RED
L42 BRN
P18A RED
E3
P24B RED
1
START YEL
S10 LEFT ON 1 7 2 8 10
518 RED
AID 5 3 2 OFF
REAR S9 V15 I O
SWITCH 2
BLU LIGHT PARK WARNING
B FRONT P18B RED FRONT
T13C BLU 518 RED SWITCH LIGHT LIGHT DIODE
M32A PUR
WORK
P18C RED
K4 3 LIGHTS SWITCH
PUR 5 6 9
G20 BLK
L43 BRN L43 BRN
P12B RED
L41A BRN
REVERSE
G20 BLK
J20B TAN
ALARM 4 L43 BRN J20A TAN
ORG
M01B
PUR
RELAY TO A2 RADIO P24E RED

L41 BRN
86 30 (IF EQUIPPED) T12A BLU
YEL
Y2
L43 BRN
REAR
E25 WHT
L41
BRN
START
L43 BRN
E5 E6
L43 BRN
PUR
WORK
P24F
RED
J27A TAN
J27A TAN
AID LEFT RIGHT L43 BRN 86 30

85 87A 87 LIGHTS E9 E10 E15
BLU
TAIL
G20 BLK
SOLENOID
M01A
PUR
R1 4 LEFT LIGHTS RIGHT SEAT

M32B PUR
ORG
BLOWER
M32C PUR
BELT
J20A TAN
B1 1 E7 E8
RESISTOR 85 87A 87
L43 BRN
3 K3 LIGHT
T12 BLU
REVERSE LEFT RIGHT PARK

2
P12 RED
WARNING ORG TO
M62 PUR
FRONT LIGHT
ALARM S31 SHIFT
G10G BLK
Z36D
RELAY
G20
BLK
G20
BLK
DRIVE
G20 BLK
G20 BLK
M6 SEAT CONTROLLER
ORG
LIGHTS SWITCH SE10, A1
HEATER
K6
B2
G10P BLK
G10R BLK
G10V BLK
BLOWER
G20
BLK
G01 BLK
TO W3 PARK TO
MOTOR TO TO
NEUTRAL GROUND M TO K7 BRAKE PARK
G20 BLK G20 BLK G20 BLK TO H9 TO NEUTRAL PARK
Y3 BRAKE
G20 BLK
START TO FNR/RANGE AT CAB ALTERNATOR SENSING START
FUEL RED STOP BRAKE
RELAY SWITCH FLOOR RELAY ALTERNATOR SWITCH LATCHING
RELAY SOLENOIDS
G01
BLK
G10P BLK
SHUTOFF SE10, S11 LIGHT RELAY RELAY
G01 BLK
SE11, K6 BLK
SE14, K7 SE11, K6 SE9, Y4, Y14
SOLENOID SE15, H9 SE14, K7 SE9, K5
G20 BLK ROOF HARNESS GROUND G20 BLK G20 BLK
G10A BLK SIDE CONSOLE HARNESS GROUND G10A BLK G10A BLK
G01 BLK ENGINE HARNESS GROUND G01 BLK G01 BLK
SE5 START AID, FUEL SHUTOFF AND REVERSE ALARM CIRCUIT SE6 BLOWER CIRCUIT SE7 REAR WORK LIGHT CIRCUIT SE8 FRONT WORK AND DRIVING LIGHTS CIRCUIT SE9 PARK BRAKE CIRCUIT
T117119 SYSTEM FUNCTIONAL SCHEMATIC (2 OF 5) CONTINUED ON NEXT PAGE
CED,TX17864,149 1909SEP981/1

022602
PN=199

T117120 1916SEP98
FNR SWITCH RANGE SWITCH N C2-B3 FWD C1-B2 REV N C2-B3 FWD C1-B2 REV GROUND CIRCUIT
WIRE WIRE RANGE 1ST FORWARD 2ND NEUTRAL (WIRE COLOR) G01 BLKENGINE HARNESS
COLOR FOR NEU REV COLOR 1 2 3 4 2ND FORWARD SOLENOIDS 3RD NEUTRAL SOLENOIDS G10 BLKSIDE CONSOLE HARNESS
DENOTES CONNECTIONS F YEL BLU 3RD FORWARD ENERGIZED 4TH NEUTRAL ENERGIZED G20 BLKROOF HARNESS
TO POWER (P24 RED) N GRY GRN 4TH FORWARD 1ST REVERSE G30 BLKFRONT CONSOLE HARNESS
R PNK BLK 1ST NEUTRAL 2ND-4TH REVERSE G40 BLKENGINE HARNESS TO SIDE CONSOLE HARNESS
B11B RED B11B RED
B12D RED B12D RED
E22 WHT E22 WHT
R31 BLK R31 BLK
B11D RED B11D RED
M39 PUR M39 PUR
B15 RED B15 RED
P24C RED RED
P24A RED P24A RED
T11 BLU
T12 BLU T12 BLU
T13 BLU F16
K5 D C B A START
PARK BRAKE S11 FUSE
LATCHING FNR/RANGE
P24C RED
RELAY GRN
SWITCH A1
GRY D RED
RED
RED SHIFT
86 30 PNK C RED
GRN
FNR CONTROLLER
RED
GRN
GRN
YEL B RED
N
R F R N F RED A RED GRN
J25 TAN
85 87A 87 E23
J20C WHT
TAN 86 30
87A
K6 86 30
D
V11 GRN NEUTRAL
85 87
PARK BLU C RED
RANGE TIME START
E22A WHT
BRAKE GRN B RED DELAY

2 3 4 86 30 RELAY
1 CIRCUIT
J20A TAN
RELAY A 87A 85 87A 87
T12A BLU
DIODE 85 87
T13 BLU
E2B WHT
86 30 86 30
87A 87A
E23 WHT
85 87 85 87
RED
S13
NEUTRAL E23 WHT
J27 TAN GRN DISCONNECT

GRN
G10G BLK
GRN SWITCH
GRN
GRN A B C D
T11 BLU
T13 BLU
E23 WHT
Y8
J27 TAN
Y4 Y14 V3 T13 T11 J27 TAN HYDRAULIC
J27 TAN
G10E BLK
PARK PARK REVERSE BLU V4 BLU T53 BLU T52

TO PUMP
J27 TAN
T52 BLU
T15 BLU REVERSE

BRAKE FORWARD T14 DESTROKE
J20A TAN
E2B WHT
V2 BRAKE SOLENOID BLU
BLU Y12 ALARM
PARK SOLE- SOLE- DIODE SOLENOID V12 SOLENOID
J27 TAN
Y6 Y7
T15 BLU
BRAKE NOID NOID Y5 DIODE C1/B2 V5 RELAY

C1/B2 Y13
T14 BLU
FORWARD NEUTRAL SE5, K9

SOLENOID REVERSE TO PARK SOLENOID SOLENOID C2/B3 NEUTRAL
G04
BLK
SOLENOID DISCONNECT
G30 BLK
DIODE SOLENOID BRAKE DIODE SOLENOID DISCONNECT
V13 SOLENOID
TO PARK G04 G01 SWITCH G01
SOLENOID
G04 BLK TO STARTER G01 C2/B3
BRAKE BLK BLK G01 BLK DIODE G01
MOTOR TO PARK BLK (DASH) TO LEFT SOLENOID
BLK BLK
G01 BLK
SWITCH TO REVERSE SE9, S12 TURN INDICATOR TO PARK TO START

"S" TERMINAL BRAKE SWITCH DIODE
(DASH) SE1, M1 (DASH) SE9, S12 ALARM RELAY LIGHT LIGHT RELAY RELAY
G01 BLK
G01 BLK
G01 BLK
G01 BLK
SE5, K4
G01 BLK
G01 BLK
SE9, S12 SE13, H1 SE9, K3 SE1, K1

G20 BLK ROOF HARNESS GROUND G20 BLK G20 BLK
G10A BLK SIDE CONSOLE HARNESS GROUND G10A BLK G10A BLK
G01 BLK ENGINE HARNESS GROUND G01 BLK G01 BLK
SE9 PARK BRAKE CIRCUIT SE10 FNR/RANGE CONTROL CIRCUIT SE11 NEUTRAL DISCONNECT CIRCUIT
T117120 CONTINUED ON NEXT PAGE
SYSTEM FUNCTIONAL SCHEMATIC (3 OF 5)
CED,TX17864,150 1909SEP981/1

022602
PN=200

T117121 1916SEP98
GROUND CIRCUIT
TERMINALS (WIRE COLOR) G01 BLKENGINE HARNESS
TURN POSITION 5 6 3 7 OFF 4-WAY G10 BLKSIDE CONSOLE HARNESS
SIGNAL OFF ON FLASH BEACON OFF 9 G20 BLKROOF HARNESS
SWITCH LEFT 8 6 2 5 1 3 10 SWITCH SWITCH ON G30 BLKFRONT CONSOLE HARNESS
RIGHT 10 5 1
G40 BLKENGINE HARNESS TO SIDE CONSOLE HARNESS
B12D RED B12D RED
R31 BLK R31 BLK
B11D RED B11D RED
M39 PUR M39 PUR M39 PUR
B15 RED B15 RED
P19E RED P23A RED
F10 F13
TURN/STOP/ F11 F12 RETURN-TO-DIG/
HORN FUSE LEFT TURN RIGHT TURN BEACON FUSE
ON 2 8 3 LIGHT FUSE
S17 OFF
LIGHT FUSE
P19A
RED
P19E RED 4-WAY I O
P19D RED FLASHER

SWITCH NOT USED
P19F RED
M07 PUR
6 1 10
5
B11 S16 G30 BLK
P20A RED
BRAKE TURN
LIGHT SIGNAL SWITCH V7
L50 BRN
V6
M08 PUR
L49 BRN
4-WAY P20C RED
L50 BRN
SWITCHES 4-WAY
FLASHER L45B BRN
L48A BRN
L47A BRN
M47D PUR
L46B BRN FLASHER
7 3
M48D PUR
SWITCH
P19B RED
S15 R OFF L SWITCH L45A BRN
M47 PUR
HORN I O II DIODE DIODE
M47 PUR ON 10
M48 PUR
1
P20C RED
SWITCH M47 PUR OFF
L46A BRN
H6 I O S20
RIGHT TURN
P20B RED
M48 PUR M48D PUR

RETURN-
5 6 INDICATOR TO-DIG
G10H BLK
L49 BRN LIGHT SWITCH

L48 BRN 5 9
L47 BRN
L50 BRN
L47A BRN
L50 BRN
L46 BRN
L46 BRN
E12 H3 H2 S18
E11 RIGHT L49A BRN H5 H4 BEACON
LEFT REAR FRONT REAR FRONT SWITCH
H01 GRN
LEFT
E13
M48 PUR
TURN RIGHT
A67 ORG
+
BRAKE + LIGHTS TURN BEACON
LIGHTS
H1 LIGHT Y9
LIGHTS
G20
BLK
G30 BLK
G30 BLK
G LEFT TURN
G20
BLK
G20 BLK
RETURN-
G20 BLK
INDICATOR
B3 G20 BLK
TO-DIG
LIGHT G20 BLK G20 BLK
HORN SOLENOID
G20 BLK
S21
G30
BLK
G20 BLK
FLASHER
G20 BLK
G10H BLK
G30 BLK FRONT CONSOLE HARNESS GROUND G30 BLK G30 BLK
G10D BLK
G10E BLK
G30 BLK
G01 BLK
TO SHIFT CONTROLLER
W2
G30E BLK
GROUND TO
SE10, A1
G40 BLK G40A BLK SIDE CONSOLE HARNESS GROUND G40A BLK
CAB FRAME G10A BLK G10A BLK
G20 BLK
G40A BLK G10A BLK G10A BLK
G40 BLK
SE12 HORN CIRCUIT SE13 TURN SIGNAL, FLASHER AND BRAKE LIGHT CIRCUIT SE14 BEACON AND RETURN-TO-DIG CIRCUIT
T117121 SYSTEM FUNCTIONAL SCHEMATIC (4 OF 5) CONTINUED ON NEXT PAGE
CED,TX17864,151 1909SEP981/1
1584 X 628
022602
PN=201

T117122 1916SEP98
GROUND CIRCUIT
(WIRE COLOR) G01 BLKENGINE HARNESS
G10 BLKSIDE CONSOLE HARNESS
G20 BLKROOF HARNESS
G30 BLKFRONT CONSOLE HARNESS
B11B RED G40 BLKENGINE HARNESS TO SIDE CONSOLE HARNESS
B12D RED
R31 BLK R31 BLK
B11D RED
M39 PUR M39B PUR
B11A
RED
P23A RED
F14 F15
P21E RED MONITOR TACH./
FUSE HMTR.
P21D RED P21F RED
M39A PUR
FUSE P23A
P1 RED
FUEL H9
GAUGE RED
+ P21D RED P21D RED STOP
R31 BLK
LIGHT
P23
RED
E14 Z36B GRY
P21A
RED
G10K BLK GS
FUEL P21B RED
GAUGE Z36B GRY

Z36 GRY Z36C GRY
X41
P21C RED
LIGHT P21J RED

HOUR METER Z37 GRY
P3 OR AUXILIARY
HOUR H11
P21B RED
VALVE HARNESS Z37 GRY
METER ENG. ENG. ENG. ENG. CONVTR. HYD. ALARM
CONNECTOR COOLANT OIL ALT. AIR OIL OIL
H10
Y33 YEL
G10J BLK
TEMP. PRESS. VOLTS FILTER TEMP. FILTER
Z36A
GRY
h YELLOW
- +
1 A P21H RED
WARNING
H8 2 B LIGHT
3 C
M37C
PUR
G10B BLK
G10C BLK
DISPLAY 4 D
BLK 5 E P21B RED
B4 M37C PUR MODULE 6 F
FUEL
M37D + SIG
SENDER
M37D PUR
PUR 11 F
n
G10C BLK P23 RED 12 E
13 D
14 C
15 B
P2 M37A PUR 16 A
TACHOMETER/
M39B PUR
M39A
PUR
K7 M37B PUR
X36
YEL
B5
Z36B GRY
HOUR METER
(OPTIONAL) ALTERNATOR ENGINE
RELAY 86 30 7 A B7 COOLANT
8 B
X38 YEL
G10U BLK TO S31 9 C

F39 YEL
AIR FILTER
N34 YEL
M39A PUR 10 D
TEMPERATURE
87A SEAT RESTRICTION SWITCH
TO K3 G10R
M40 PUR
85 87 SWITCH SWITCH B9
BLK
PARK LIGHT
G10B BLK
SE9, S31 HYDRAULIC
G10J BLK
TO B8
G01 BLK
RELAY G10T BLK B6
SE8 K3 PARK CONVERTER FILTER
P23 RED ENGINE OIL
RESTRICTION
G01 BLK
G10A BLK G10A BLK LIGHT RELAY PRESSURE TEMPERATURE

(S.N. 830205- )
SE9, K3 SWITCH SWITCH

G10A BLK G10A BLK SWITCH
G01 BLK G01 BLK
SE13 GAUGE AND HOUR METER CIRCUIT SE14 DISPLAY MODULE AND LOGIC MODULE CIRCUIT SE15 INDICATOR CIRCUIT
SYSTEM FUNCTIONAL SCHEMATIC (5 OF 5)

T117122
CED,TX17864,152 1909SEP981/1

022602
PN=202
Cab Roof Harness (W5) Wiring Diagram (S.N. 872256)

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,QQ1704 1912MAR931/1

022602
PN=203
Cab Roof Harness (W5) Component Location (S.N. 872256)

T7812AI 1925APR97
TX,9015,QQ1705 1912MAR931/1

022602
PN=204
Cab Side Console Harness (W6) Wiring Diagram (S.N. 815415)

T7812AJ 1925APR97
TX,9015,QQ3265 1910MAR971/1

022602
PN=205

T7812AK 1921APR98
TX,9015,BG976 1901APR971/1

022602
PN=206

T8462AJ 1925APR97
TX,9015,BD2726 1910MAR971/1

022602
PN=207

T8543AA 1925APR97
TX,9015,BG977 1901APR971/1

022602
PN=208
Cab Side Console Harness (W6) Component Location (S.N. 825657)

T108416 1911APR97
S18 S6
S25 BEACON REAR X10
SWITCH WIPER S10 REAR WIPER F4
AC SWITCH S2 REAR LIGHT F2
(OPTIONAL) (OPTIONAL) SWITCH X12 SWITCH CONNECTOR F14 FUEL/ETHER/ RADIO F12
MFWD SWITCH F15
SWITCH MFWD MONITOR/ BK. ALARM HAZARD RTURN
S15 X37 SWITCH X11 X9 GAUGES F11
SEAT BELT REAR LIGHT MONITOR
E15 HORN CONNECTOR BEACON LTURN
SEAT LIGHT CONNECTOR SWITCH SWITCH V11 F9
SWITCH PARK BRAKE FNR/PARK
BELT X38 CONNECTOR CONNECTOR
P2 X13 RELAY DIODE F13
LIGHT AC SWITCH RTD/BEACON/PUMP
TACHOMETER PARK BRAKE CONNECTOR X8 F16
S12 SWITCH HORN SWITCH START F10
PARK
H8 CONNECTOR CONNECTOR P2 S21 TURN/STOP/HORN
-
+
DISPLAY TACHOMETER
BRAKE FLASHER F8
+
MONITOR
-
SWITCH RELAY FRONT LIGHTS/
S22
HEATER TEMP. TAIL LIGHTS
S4 X14 K7
SWITCH START AID
START AID ALTERNATOR F7
SWITCH CONNECTOR K5 REAR LIGHTS
SWITCH F3
S8 V8 PARK
BRAKE DOME/ F6
P1 BLOWER LOGIC MODULE/ K3 HEATER/AC
PARK RELAY RADIO
FUEL GAUGE SWITCH DISPLAY MODULE
S1 SEE BLOWER HARNESS DIODE LIGHT F5
KEY
K6 WIPER
(W10) K4 NEUTRAL F1
SWITCH S13 BACKUP RELAY
NEUTRAL
H10 MFWD/ALT
YELLOW ALARM
X19 DISCONNECT DIFF. LOCK
WARNING RELAY
LOGIC MODULE F SWITCH
K2 G LIGHT
4 PIN CONNECTOR X1 H E
ACCESSORY ROTATED 180
(S.N. 815415) SIDE CONSOLE X15
RELAY
HARNESS TO FUEL GAUGE
ROOF HARNESS CONNECTOR X7
X20 D DISPLAY
LOGIC MODULE H7 CONNECTOR A B C X16 MODULE
6 PIN CONNECTOR LOGIC KEY SWITCH CONNECTORS
(S.N. 815415) MODULE F G CONNECTOR H9
(S.N. 815415) X3 E H RED STOP
SIDE CONSOLE LIGHT
HARNESS TO
ROOF HARNESS
K2
A ACCESSORY
CONNECTOR D C B X17 RELAY
LOGIC MODULE
4 PIN CONNECTOR X18
X2 (S.N. 815415) LOGIC MODULE
SIDE CONSOLE B A 6 PIN CONNECTOR
HARNESS TO (S.N. 815415)
ROOF HARNESS
CONNECTOR
T108416 CAB SIDE CONSOLE COMPONENT LOCATION
TX,9015,BG972 1919AUG991/1

022602
PN=209

T7812AM 1925APR97
TX,9015,BG978 1919AUG991/1

022602
PN=210

T107052 1911APR97
X41
P2 HOUR METER OR
F14 TACHOMETER AUXILIARY
S1 ACC
FUEL HOUR METER VALVE HARNESS
X2 KEY OFF
ON CONNECTOR
GAUGE BLK
SIDE CONSOLE SWITCH BULB CHECK
START LIGHT
HARNESS TO ACC H11
E15 n
ROOF HARNESS X44 SIG
SEAT BELT +
DISPLAY
CONNECTOR SPLICE MODULE
(INSIDE HARNESS) LIGHT
B P25 RED F4 IGN ALARM
S4
A P15A RED F3 START S15 H10
G10K BLK
P21E RED
AID HORN YELLOW
P21D RED
ST WARNING
SWITCH SWITCH
P1 LIGHT
+
B14 RED
G
X3 FUEL
G10C BLK
G
G10B BLK
P21B RED
G10C BLK
M37D PUR
M37D PUR
M37C PUR
B11B RED
GAUGE
M39A PUR
SIDE CONSOLE
HARNESS TO
ROOF HARNESS
B12A RED
P21A RED
CONNECTOR
M32A PUR
Z36C GRY
R31A BLK
M32C PUR
P24F RED
A67 ORG
H A69 ORG X25
B12B RED
B12B RED
B12C RED
B12D RED
E25 WHT
G10J BLK
G A68 ORG
Y33 YEL
X25
P21J RED
P19B RED
G10L BLK
E22 WHT
P21D RED
P12A RED
P12B RED
P21B RED
Z37 GRY
P21C RED
F A66 ORG S6
E A65 ORG S6
S1
F9
F14
S12
X43
X48
H8
F16
F2
X44
K2
X25
X22
V12
S12
X48
X23
F14
F2
X21
H10
X23
X46
X51
X48
X45
X47
H8
F14
H9
D A64 ORG X25

C
X1
A63 ORG X25

K3
X3
X3
S1
K2
K3
F9
K7
H8
X41
S13
E15
K5
H9
H8
P1
H11
E15
X30
X50
F15
E15
X25
X52
X22
X22
X24
X22
X49
B A62 ORG X25
A A61 ORG X25
X1
SIDE CONSOLE
T53 BLU
T52 BLU
HARNESS TO
ROOF HARNESS
B11C RED
B11B RED
M37A PUR
M37B PUR
M37C PUR
B11A RED
W55 BLU
A66 ORG
P13D
RED
CONNECTOR P13C RED
J27 TAN
M31 PUR
M32A PUR
M01B PUR
P20B BLK
L45A BRN
A65 ORG
OFF
M32C PUR
H P14G RED X52 6 9
G10H BLK
S12 ON
J27A TAN
P21F RED
P21H RED
P21D RED
P21J RED
B I 0
J20A TAN
G L41A BRN S10 A
P14B RED
PARK
F L48A BRN F11 BRAKE
M32B PUR
P24B RED
P24F RED
GRN
E L43A BRN X25 SWITCH 8 10
D L45A BRN S18 ON
RED
ON 1 10 1 5
OFF OFF
C L47A BRN F12 ON I 0 II I 0
OFF 1 7 2 8 10
B L46A BRN B11 X43 X45 S2 V15
I 0
L45B
BRN
A L42A BRN X25 SPLICE SPLICE MFWD PARK X46

S13 (INSIDE HARNESS) 5 9 3 7 WARNING SPICE
(INSIDE HARNESS) SWITCH
NEUTRAL 5 6 9 LIGHT (INSIDE HARNESS)
J20B TAN
DISCONNECT S18 S6 DIODE
SWITCH BEACON REAR
P24E
RED
SWITCH WIPER
SWITCH
T107052
TX,9015,BD2727 1910MAR971/1

022602
PN=211
T107051
F14
P21C RED
H49
X47
LIGHT
Z36B GRY
K3
Z36D GRY
RED WARNING
X46
P21F RED
H8
Z36A GRY
H9
Z36B GRY
6
5
4
3
2
1
16
15
14
13
12
11
X47
H8
8 B
7 A
A
B
E
H11
10 D
9 C
F
C
D
E
B
A
D
C
Z36C GRY
SPLICE
X21
DISPLAY
MODULE
F39 YEL
X21
X38 YEL
X23
M40 PUR
Z36A GRY
(INSIDE HARNESS)
K7, H7, P2
M37B PUR
K3
Z36A GRY
X30 H10
G10A BLK Z37 GRY
S1
S21 R31A BLK
G10D BLK
X21
P1 N34 YEL
G10J BLK
X21
X36 YEL
K2
G10M BLK
F14, P2
X48
P21H RED
X41
G10B BLK
SPLICE
F1
S18 P13A RED
G10H BLK
X49
X23
S1 P13B RED
G10L BLK
SPLICE
S2
P13C RED
(INSIDE HARNESS)
S19
P13E RED
X23
P20C RED
(INSIDE HARNESS)
S18
P20B RED
X50
F13
P20A RED
SPLICE
X57
K7 M39B PUR
SPLICE
P2
M39A PUR
X21
M39 PUR
(INSIDE HARNESS)
(INSIDE HARNESS)
K7
X1 G10V BLK
P14G RED
X25
S31
P14C RED
SEAT
S6 K3
X52
SWITCH
P14B RED M01A PUR

SPLICE
F5
P14A RED
X44
B12C RED
P12C RED
S12
P24B RED
X48
(INSIDE HARNESS)
G10D BLK
X25
L49A BRN
X25
L50 BRN
X1
L41A BRN S1
E22 WHT
I
X57
M39B PUR
ON
O
OFF
X45
M37A PUR
F7 P24C RED
P17A RED
1
5
G10R BLK
L49A BRN
S10
REAR
LIGHT
P24C RED
E22A WHT
SWITCH
M39B PUR
L50 BRN
G10R BLK
M37A PUR
G10R BLK
G10E BLK
S31
G10V BLK
H9
S1 Z36D GRY
B14 RED
T12A BLU
S31
ALT
M01A PUR
V12
K7
X30
K3
PARK LT
G10M BLK M01B PUR

BLK
G10J
G10D BLK
WHT
E22A
X43
B11C RED P12C RED
X23
F17 M62 PUR
B15 RED
X21
FLSHR
T13C BLU
K4
S21
B15 RED
BLK
BACKUP ALM
BLK
G10P
G10E
G10G
BLK
P24B RED
X23
E22 WHT
E23 WHT
B12C RED
P23 RED
NEUTL
K6
X25
T12 BLU
K2
J20C TAN
P12C RED
T107051
RELAY
X25
F16
J24A RED
S12 START
J20A TAN
K5
PARK BRK
P24C RED
ACCESSORY
F9
V11 FNR/PARK
J25 TAN
1911APR97
X49 B12D RED
TM1537 (26FEB02)
P13A RED
F1
F14
P16 RED F6 P21A RED

MFWD/ALT MONITOR/
DIFF. LOCK GAUGES
X35
X2
P15A RED
F2
P12C RED
F3
A16 ORG X33
DOME/ FUEL/ETHER
RADIO BK. ALM.
X52
P14A RED
F5
CONNECTOR
F15
HARNESS TO
WIPER TACH/
P12A RED
B11D RED
SIDE CONSOLE
H MOTOR
X35
B12A RED
P16 RED
F4
F6
BLOWER HARNESS
HEATER/ RADIO
P23A RED
AC
S10
X35 P17A RED
F7
A16 ORG P25 RED
REAR LTS
X33
X53 B11A RED
P18A RED
F8
X22
A17 ORG
FRONT LTS/
SWITCH
TAIL LTS
X54
P19A RED
F10
F12
TURN/STOP/ R TURN
HORN
X50
P20A RED
F13
F11
CONNECTOR FOR
AIR CONDITIONING
RTD/BCON L TURN
9015-10A-28
F17
X21
FUSE
E2B WHT
K2
BLOCK
K5 B15 RED
V11
J25 TAN
X25
M48D PUR
X1
L48A BRN
X25
M47D PUR
PARK BRAKE
X1
RELAY DIODE
L47A BRN
X2
P25 RED

X25
P23A RED
K2
B11A RED
S4
P12A RED
S1
TX,9015,BG979
B12A RED
P2
P21A RED
X44
B12D RED
1901APR971/1
710D Backhoe Loader

022602
PN=212

T107053 1911APR97
X23
SIDE CONSOLE HARNESS TO
ENGINE HARNESS CONNECTOR X25
S4 P12B RED 1 SIDE CONSOLE HARNESS
TO FRONT CONSOLE
K6 E23 WHT 2 HARNESS CONNECTOR
P1 Y33 YEL 3
X3 A61 ORG 1
B11 X49 P13B RED 4
BRAKE LIGHT X3 A62 ORG 2
SWITCH K4 M62 PUR 5
X3 A63 ORG 3
P19F RED
X50 P20C RED 6
X3 A64 ORG 4
S12 J27 TAN 7
X22 A71 ORG 5
H8 M40 PUR 8
X52 P14C RED 6
F12 M47D PUR 7
X3 A69 ORG 8
X53 X53 X22
SPLICE L46B BRN SPLICE F15 P23A RED 9
SIDE CONSOLE HARNESS
(INSIDE HARNESS) (INSIDE HARNESS) TO ENGINE HARNESS CONNECTOR X54 P19E RED 10
S2 M31 PUR 1 S21 L50 BRN 11
S2 W55 BLU 2 S21 L49A BRN 12
X33 A17 ORG 3 F11 M48D PUR 13
X25 A71 ORG 4 X30 G30E BLK 14
X4 T14 BLU 5 X21 T11 BLU 15
L46A BRN
P19D RED
X4 T15 BLU 6 X55 T13 BLU 16
S15 A67 ORG 7 K5 P24A RED 17
S12 J27A TAN 18
P18B RED
P18A RED
P18C RED
T13 BLU
T13A BLU
T13C BLU
S13 T52 BLU 8
X3 A68 ORG 19
X21 X53 P18B RED 20
SIDE CONSOLE HARNESS TO
X54
X1
X21
K4
F8
X25
X25
X25
ENGINE HARNESS CONNECTOR X1 L43A BRN 21
K2 B11 RED 1 X53 P18C RED 22
X21
X21
X25
X48
X49
S15
B11
F10
X25
X30 G40A BLK 2 X1 L42A BRN 23
X25 T11 BLU 3 K6 T12 BLU 24
V11 E2B WHT 4
X55 T13A BLU 5
H8 F39 YEL 6 X24
G30E BLK
G40A BLK
G10A BLK
S4 E25 WHT 7 SIDE CONSOLE HARNESS
TO FRONT CONSOLE
H8 X38 YEL 8 HARNESS CONNECTOR
P19A RED
P19E RED
P19B RED
P19D RED
T16 BLU
P13E RED
X51 M39 PUR 9 S13 T53 BLU A
H8 N34 YEL 10
X22 T14 BLU B
S12 M32B PUR 11
C
12
X22 T15 BLU D
H8 X36 YEL 13
X30 E
X54 S19 S19 T16 BLU 14
SPLICE
(INSIDE HARNESS) SPLICE DIFFERENTIAL
(INSIDE HARNESS) LOCK SHIFT
T107053
TX,9015,BG980 1901APR971/1

022602
PN=213

T107602 1911APR97
S18 S6 X10 F14 F2

BEACON REAR S10 MONITOR/ FUEL/ETHER/ F4 F12
S25 X12 REAR WIPER F15 RTURN
SWITCH WIPER REAR LIGHT MFWD GAUGES BK. ALARM HAZARD RADIO
AC SWITCH S2 SWITCH CONNECTOR
(OPTIONAL) SWITCH SWITCH SWITCH MONITOR F11
(OPTIONAL) MFWD X37 X11
S15 CONNECTOR BEACON X9 V11 F9 LTURN
SWITCH SEAT BELT FNR/
HORN LIGHT CONNECTOR SWITCH REAR LIGHT PARK BRAKE
X38 RELAY DIODE F16 PARK
E15 SWITCH CONNECTOR SWITCH F13
X13 AC SWITCH CONNECTOR P2 START
SEAT P2 TACHOMETER RTD/BEACON/PUMP
PARK BRAKE CONNECTOR
BELT TACHOMETER
LIGHT SWITCH X56 S21 F10
S12 CONNECTOR X8 FLASHER TURN/STOP/HORN
H8 SEAT SWITCH
PARK HORN SWITCH RELAY
DISPLAY CONNECTOR
BRAKE CONNECTOR
+
-
MONITOR (CAB) F8
SWITCH +
K7
-
FRONT LIGHTS/
S22 ALTERNATOR TAIL LIGHTS
HEATER TEMP.
S4 SWITCH X14 K3 F7
START AID START AID REAR LIGHTS
PARK K5 F3
SWITCH SWITCH CONNECTOR F6
LIGHT PARK DOME/ HEATER/AC
V8 BRAKE RADIO
S8 PARK WARNING K4 RELAY
P1 BLOWER K6 F5
S1 LIGHT DIODE BACKUP NEUTRAL F1 WIPER
FUEL GAUGE SWITCH
KEY ALARM RELAY MFWD/ALT
SEE BLOWER HARNESS RELAY
SWITCH (W10) S13 DIFF. LOCK
NEUTRAL H10
DISCONNECT YELLOW
SWITCH WARNING
K2 X1 LIGHT ROTATED 180
ACCESSORY G F
SIDE CONSOLE H
RELAY E X15
HARNESS TO
FUEL GAUGE
ROOF HARNESS
CONNECTOR X7
CONNECTOR
DISPLAY
A D
B C MODULE
X16 CONNECTORS
X3 H9
F G KEY SWITCH RED STOP
SIDE CONSOLE E H CONNECTOR LIGHT
HARNESS TO
ROOF HARNESS K2
CONNECTOR ACCESSORY
D A RELAY
C B
X2 B A
SIDE CONSOLE
HARNESS TO
ROOF HARNESS X56
CONNECTOR SEAT
SWITCH
CONNECTOR
(ROPS)
T107602 CAB SIDE CONSOLE COMPONENT LOCATION
TX,9015,BG970 1925MAR971/1

022602
PN=214

T107603 1911APR97
X25
SIDE CONSOLE HARNESS TO FRONT X24 B11
CONSOLE HARNESS CONNECTOR SIDE CONSOLE HARNESS TO FRONT BRAKE
CONSOLE HARNESS CONNECTOR S31
LIGHT SEAT
B SWITCHES SWITCH
1 2 3 4 5 6 A
7 8 9 10 11 12
C E
13 14 15 16 17 18
D
19 20 21 22 23 24
X21
TO ENGINE HARNESS
CONNECTOR
13 14 2 3
4
12
11 5
6
10
7
9 1 8
X22 3 2
SIDE 4 1
CONSOLE
HARNESS TO S19
ENGINE DIFF. LOCK
HARNESS SWITCH
CONNECTOR 5 7 8
6
3 2
4 1
5 6 7 8 X23
TO ENGINE HARNESS
CONNECTOR CAB SIDE CONSOLE COMPONENT LOCATION
T107603
TX,9015,BG981 1901APR971/1

022602
PN=215
Front Console Harness (W7) Wiring Diagram (S.N. 872256)

T8077AC 1925APR97
TX,9015,QQ1708 1906OCT931/1

022602
PN=216
Front Console Harness (W7) Component Location (S.N. 872256)

T7812AO 1925APR97
TX,9015,QQ1709 1912MAR931/1

022602
PN=217
Engine Harness (W8) Wiring Diagram (S.N. 872256)

T108132 1930APR97
V9 X23
ALTERNATOR S20 ENGINE HARNESS
DIODE RETURN- TO SIDE CONSOLE
P13C TAN Y8 M1 Y3
TO-DIG HARNESS CONNECTOR
M39 PUR
Y2 B7 HYDRAULIC SWITCH STARTER FUEL Y3 P12 RED 1
RED
START AIR FILTER PUMP K1 MOTOR B5 SHUTOFF
K1 E23 WHT 2
GRN
AID RESTRICTION B3 DESTROKE START ENGINE SOLENOID
G2 SOLENOID SWITCH HORN SOLENOID RELAY Y9 B6 COOLANT B4 Y33 YEL 3
A B RETURN-
ALTERNATOR ENGINE OIL TEMPERATURE G2 P13 RED 4
TO-DIG PRESSURE SWITCH
W D+ SOLENOID B1 M62 PUR 5
G X34 SWITCH
S20 P20 RED 6
RED CABLE
P13B TAN
ENGINE HARNESS
M06 PUR
B+
TO A/C COMPRESSOR V2 J27 TAN 7
HARNESS CONNECTOR M B7 M40 PUR 8
A
B11 RED
A B C D B
+ + X22
ENGINE HARNESS TO SIDE
CONSOLE HARNESS
CONNECTOR
S3 M31 PUR 1
E02 WHT
N34 YEL
X36 YEL
P12 RED
E02 WHT
-
V1 W55 BLU 2
G01 BLK
P13 RED
B11 RED
G01 BLK
M39 PUR
H01 GRN
G1
B11 RED
A17 ORG
B11 RED
G02 BLK
G01 BLK
G01 BLK
M40 PUR
A67 ORG
G01 BLK
E23 WHT
E02 WHT
B03 RED
P20 RED
H01 GRN
B03 RED
B11 RED
E27 WHT
E23 WHT
G01 BLK
E23 WHT
X34 A17 ORG 3
(S.N. XXXXXX- )
BATTERIES
M5 A71 ORG 4
X21
X23
W1
K1
X23
Y9
W1
S20
X21
M1
X22
X23
W1
W1
Y8
W1
G2
K1
X23
X22
W1
M1
X23
K1
X21
X21
X23
X21
V12 T14 BLU 5

V13 T15 BLU 6
W1
X22
W1
V1
X22
X23
W1
G2
X21
Y14, Y4
X23
W11
V2, Y14 M1
W1
W1
X4
X22
X21
X22
X21
X21
W1
X23
Y1
W1
X21
W1
Y4, V2
V10
Y11
X21
W1
X4
X32
W1
W1
X4
W1
X4
X4
X22
X21
W1
W1
B3 A67 ORG 7
V5 T52 BLU 8
V5
V13
V4
V12
V3
W1
G01 BLK
G01 BLK
X21
J27 TAN
J27 TAN
T16 BLU
B6, Y9, B7
ENGINE HARNESS TO SIDE
T13 BLU
J27 TAN
J27 TAN
G01 BLK
M32 PUR
M62 PUR
W55 BLU
W55 BLU
G01 BLK
G01 BLK
T16 BLU
T16 BLU
T15 BLU
T15 BLU
G01 BLK
T52 BLU
T52 BLU
T13 BLU
A71 ORG
X38 YEL
W55 BLU
G01 BLK
F39 YEL
G01 BLK
Y33 YEL
G01 BLK
G01 BLK
T14 BLU
T14 BLU
G01 BLK
T11 BLU
T11 BLU
G01 BLK
G01 BLK
G01 BLK
G01 BLK
M31 PUR
Y8, B2, B1
V1, Y1, S3, Y2
Y7, V5, V3
V4, Y5, Y6
B4, B12, Y4
CONSOLE HARNESS
CONNECTOR
B
T52 BLU
T15 BLU
T11 BLU
T14 BLU
T13 BLU
G01 BLK
M1 B11 RED 1
B
B W1 G40 BLK 2
M
G02 BLK
G05 BLK
G40 BLK
G01 BLK
G05 BLK
V4 T11 BLU 3
G05 BLK
M1 E02 WHT 4
RED
A
B
C
D
E
F
A B
V3 T13 BLU 5
G04 BLK
G04 BLK
G04 BLK
G05 BLK
B X4 M5 B9 F39 YEL 6
ENGINE HARNESS WASHER
A Y2 E25 WHT 7
TO TRANSMISSION V13 V4 V3 MOTOR
B4 W3 A SOLENOID HARNESS C2/B3 B8 X38 YEL 8
GROUND V12 FORWARD V5 REVERSE
G03 BLK
FUEL A A CONNECTOR G2 M39 PUR 9
AT CAB SOLENOID C1/B2 SOLENOID NEUTRAL DIODE
SENDER DIODE
FLOOR SOLENOID DIODE DISCONNECT B8 B6 N34 YEL 10
DIODE SOLENOID TRANSMISSION B2 M32 PUR 11
B2 B1 V1 V2 V10 DIODE TEMPERATURE
REVERSE PARK BLK
DIFF. LOCK SWITCH 12
PARK MFWD
WARNING B9 W1 BRAKE SOLENOID B5 X36 YEL 13
BRAKE SOLENOID BLK BLK Y11
ALARM Y1 HYDRAULIC
S3 MACHINE SOLENOID DIODE
SENSING DIODE Y4 Y14 DIFF. LOCK V10 T16 BLU 14
MFWD MFWD FILTER FRAME/ENGINE DIODE
SWITCH PARK BRAKE PARK BRAKE SOLENOID
SOLENOID INDICATOR RESTRICTION BLOCK GROUND/
T108132 SWITCH SWITCH LEFT SIDE SOLENOID SOLENOID
TX,9015,BG973 1925MAR971/1

022602
PN=218
Engine Harness (W8) Component Location (S.N. 872256)

T7812AQ 1925APR97
TX,9015,QQ1711 1912MAR931/1

022602
PN=219
Transmission Solenoid Harness (W9) Wiring Diagram (S.N. 872256)

T7812AR 1925APR97
TX,9015,QQ1712 1912MAR931/1

022602
PN=220
Transmission Solenoid Harness (W9) Component Location (S.N. 872256)

T7812AS 1925APR97
TX,9015,QQ1713 1912MAR931/1

022602
PN=221
Blower Harness (W10) Wiring Diagram (S.N. 825657)

T7812AT 1925APR97
TX,9015,QQ1714 1910MAR971/1

022602
PN=222
Blower Harness (W10) Component Location (S.N. 825657)

T7812AV 1925APR97
TX,9015,QQ1722 1910MAR971/1

022602
PN=223
Blower Harness (W10) Wiring Diagram (S.N. 825658872256)

T107545 1911APR97
W3
GROUND AT
R1 CAB FLOOR
BLOWER X6
RESISTOR BLOWER SWITCH
4 CONNECTOR
X36
1
AIR CONDITIONING R1 YEL 1
3
CLUTCH CYCLE
2
SWITCH CONNECTORS
R1 BLU 2 OFF
200 BLK
ORG
1
S8
2
3
BLOWER
4
SWITCH
522 WHT
PUR
BLU
YEL
517 DK BLU
1
X6, M6
M6
X6
X6
X35
X6
R1 ORG 4 2
M6
W3
B
3
M7, R1, X6
4
X36 PUR 3
BLK
X35 518 RED B
ORG
M6 X35
HEATER BLOWER HARNESS TO
BLOWER M SIDE CONSOLE HARNESS
MOTOR CONNECTOR
52C BLK/WHT
X6 WHT
T107545
TX,9015,BD2729 1910MAR971/1

022602
PN=224
Blower Harness (W10) Component Location (S.N. 825658872256)

T106845 1911APR97
S22
HEATER TEMP.
SWITCH
S8
BLOWER SWITCH
X6
BLOWER SWITCH
CONNECTOR
X35
BLOWER HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
W3
GROUND AT
CAB FLOOR
W10
BLOWER
HARNESS
R1
BLOWER
RESISTOR
M6
HEATER
BLOWER
BLOWER HARNESS COMPONENT LOCATION MOTOR
T106845
TX,9015,BG971 1925MAR971/1

022602
PN=225
Air Conditioning Compressor Harness (W11) Wiring Diagram (S.N. 825657)

T7812AU 1925APR97
TX,9015,QQ1715 1910MAR971/1

022602
PN=226
Air Conditioning Compressor Harness (W11) Component Location (S.N. 825657)

T8077AD 1925APR97
TX,9015,QQ1724 1910MAR971/1

022602
PN=227
Air Conditioning Compressor Harness (W11) Component Location (S.N. 825658872256)

T106847 1922APR97
F5
30 AMP HEATER/A.C.
BLOWER SWITCH S25 CIRCUIT BREAKER
CONNECTOR AIR CONDITIONING S22
SWITCH HEATER TEMPERATURE
SWITCH
YEL 1
BLU 2
PUR 3
ORG 4
RED B
BLOWER HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
S8
BLK / W C BLOWER
SWITCH
RED B
R1
S23 BLOWER
LOW PRESSURE RESISTOR
SWITCH
CONDENSOR
S24
HIGH PRESSURE M7
SWITCH HEATER BLOWER
MOTOR
S26
AC FREEZE
SWITCH
Y10
COMPRESSOR
T106847 AIR CONDITIONING COMPONENT LOCATION
TX,9015,BD2731 1910MAR971/1

022602
PN=228
Radio Harness (W12) Wiring Diagram (S.N. 872256)

T7828AN 1925APR97
TX,9015,QQ1760 1912MAR931/1

022602
PN=229
Radio Harness (W12) Component Location (S.N. 872256)

T7828AO 1925APR97
TX,9015,QQ1761 1912MAR931/1

022602
PN=230
Auxiliary Valve Harness (W14) Wiring Diagram (S.N. 872256)

T8543AC 1925APR97
TX,9015,QQ3272 1907SEP951/1

022602
PN=231
Auxiliary Valve Harness (W14) Component Location (S.N. 872256)

T8543AD 1925APR97
TX,9015,QQ3273 1907SEP951/1

022602
PN=232
Group 10B
System Diagrams (S.N. 872257 )
Component Identification Table
Each component (electrical device) and main connector

will have and identification letter assigned to it. A number
is added to the letter to separate and indicate the total
components within that letter group.
Identification
A System, subassembly, parts group Control units, trigger boxes, two-way radios, logic module, FNR
logic module
B Transducer for conversion of non-electrical Speed sensors, pressure sensors, pressure switches horns,
variables to electrical and vice versa sensors, pickups, limit-value sensors, pulse generators,
loudspeakers, inductive pickups, probes, air-flow sensors,
oil-pressure switches, temperature sensors, ignition-voltage pickups
C Condenser, capacitor Condensers and capacitors, general
D Binary device, memory Digital devices, integrated circuits, pulse counters, magnetic tape 9015
recorders 10B
1
E Various devices and equipment Heating devices, air conditioners, light, headlights, spark plugs,
ignition distributors
F Protection device Release mechanisms, polarity protection devices, fuses, current
protection circuits
G Power supply, generator Batteries, generators, alternators, charging units
H Monitor, alarm, signalling device Audible alarms, indicator lights, turn-signal lights, brake lights,
alarms, warning lights, buzzers
K Relay Battery relays, turn-signal relays, solenoid switches, starting relays,
warning flashers
L Inductor Choke coils, coils, windings
M Motor Blower motors, fan motors, starter motors
N Regulator, amplifier Regulators (electronic or electromechanical), voltage stabilizers
P Measuring instrument Ammeter, diagnostic connectors, tachometers, fuel gauge, pressure
gauges, measuring points, test points, speedometers
R Resistor Flame glow plugs, sheathed-element flame glow plugs, glow plugs,
heating resistors, NTC resistors, PTC resistors, potentiometers,
regulating resistors
TM1537 (26FEB02) 9015-10B-1 710D Backhoe Loader

022602
PN=233
Identification
S Switch Switches and pushbuttons, general key switch, light switch, horn
switch, flasher switch
T Transformer Ignition coil, ignition transformer
U Modulator, converter DC transformers
V Semiconductor, electron tubes Transistors, diodes, electron tubes, rectifiers, semiconductors,
thyristors, zener diodes
W Transmission path, conductor, antenna Antennas, shielding components, shielded conductors, cable
harnesses, conductors, ground conductors
X Terminal, plug, plug and socket connection Terminal studs, electrical connections, connectors electrical line
couplers, line connectors, sockets, plugs, terminals, plug-and-socket
connections
Y Electrically actuated mechanical device Permanent magnets, (solenoid-operated) injection valves,
electromagnetic clutches and brakes, air valves, fuel pumps,
solenoids, switching valves, start valves, locking systems
9015
Z Electrical filter Interference suppression filters
10B
2
TX,901505,QQ381 1916SEP922/2
Fuse (Blade-Type) Color Codes

Amperage Rating Color
1 Black
3 Violet
4 Pink
5 Tan
7-1/2 Brown
10 Red
15 Light Blue
20 Yellow
25 Natural (White)
30 Light Green
TX,9015,QQ6743 1928SEP921/1

022602
PN=234
Fuse Specifications (S.N. 872257 )
9015
10B
3
1928MAY96
T100712
F17.5 Amp F515 Amp Wiper Fuse F11Not Used K3Hydraulic Pump Relay
MFWD/Alternator/Diff. F630 Amp Heater/AC/Air F12Not Used (Not Used)
Lock Fuse Seat Fuse F1310 Amp RTD/Beacon and K4Reverse Alarm Relay
F215 Amp Fuel/Start Aid and F715 Amp Rear Light Fuse Pump Cutout Fuse K5Park Brake Relay
Reverse Alarm Fuse F825 Amp Front Light/Tail F1410 Amp Monitor/Gauge K6Neutral Relay
F35 Amp Dome Light/Radio Light Fuse Fuse K7Alternator Sense Relay
Fuse F910 Amp FNR/Park Brake F1510 Auxiliary Fuse S21Flasher
F45 Amp Radio Fuse Fuse F1610 Amp Start Fuse
(Unswitched Power) F1020 Amp Turn/Stop/Flash
and Horn Fuse
IMPORTANT: Install fuse with correct amperage The fuse block is located on the side console inside an
rating to prevent electrical system access cover.
damage from overload.
CED,TX17864,121 1921AUG981/1

022602
PN=235
Wiring and Schematic Diagrams Legend (S.N. 872257 )
NOTE: A2Radio (SE4, W12). E8R. H. Front Drive Light (SE9, W5)
E9L. H. Rear Tail Light (SE9, W5)
A2 indicates component identification E10R. H. Rear Tail Light (SE9, W5)
number. E11L. H. Brake Light (SE12, W5)
Radio indicates component name. E12R. H. Brake Light (SE12, W5)
SE4 indicates section number of SYSTEM E13Beacon Light (SE13, W5)
FUNCTIONAL SCHEMATIC where E14Fuel Gauge Light (SE14, W6)
component is located. E16Tachometer Lights (SE14, W6)
W12 indicates HARNESS WIRING F1MFWD/ Alt. Diff Lock Fuse (SE3, W6)
DIAGRAM and HARNESS COMPONENT F2Fuel/Either/Backup Alarm Fuse (SE5, W6)
LOCATION drawings where component is F3Dome/Radio Fuse (SE4, W6)
located. F4Radio Fuse (SE4, W6)
F5Wiper Fuse (SE7, W6)
A2Radio (SE4, W12) F6A/C-HTR/Air Seat Fuse (SE6, W6)
9015
10B B1 Backup Warning Alarm (SE5, W8) F7Rear Lights Fuse (SE8, W6)
4 B2Hydraulic Oil Temperature Switch (SE15, W8) F8Front Lights/Tail Lights Fuse (SE9, W6)
B3Horn (SE12, W8) F9FNR/Park Brake Fuse (SE10, W6)
B4Fuel Sender (SE15, W8) F10Turn/Stop/Flasher/Horn Fuse (SE12, W6)
B5Engine Coolant Temperature Switch (SE16, F13RTD/Beacon/Pump Fuse (SE13, W6)
W8) F14Monitor Gauges Fuse (SE14, W6)
B6Engine Oil Pressure Switch (SE16, W8) F15Auxiliary Fuse (SE1, W6)
B7Air Filter Restriction Switch (SE16, W8) F16Start Fuse (SE1, W6)
B8Converter Oil Temperature Switch (SE16, W8) F17Fuse Block (, W6)
B9Hydraulic Filter Restriction Indicator Switch G1Battery (SE1, W8)
(SE16, W8) G2Alternator (SE1, W8)
B10Park Brake Pressure Switch (SE16, W8) H2L. H. Front Turn Light (SE12, W5)
B11Brake Light Switches (SE12, W6) H3L. H. Rear Turn Light (SE12, W5)
B13Radio Speaker (SE4, W12) H4R. H. Front Turn Light (SE9, W5)
B14Radio Speaker (SE4, W12) H5R. H. Rear Turn Light (SE12, W5)
B15Engine Coolant Temperature Sender (If H8Display Monitor (SE15, W6)
Equipped) (SE16, ) H11Monitor Alarm (SE15, W6)
B16Hydraulic Oil Temperature Sender (If K1Starter Relay (SE1, W8)
Equipped) (SE16, ) K2Accessory Relay (SE1, W6)
B17Brake Pressure Switch (SE16, W6) K3Pump Cutout Relay (Not Used) (SE10, W6)
B18Brake Pressure Switch (SE16, W6) K4Backup Alarm Relay (SE5, W6)
B19A/C Freeze Switch (SE6, W10) K5Park Brake Relay (SE10, W6)
B20Low Pressure Switch (SE6, W11) K6Neutral Start Relay (SE10, W6)
B21High Pressure Switch (SE6, W11) K7Timer Relay (SE10, W7)
E1Dome Light (SE4, W5) K8Selective Flow Valve Relay (SE18, W15)
E3L. H. Front Work Light (SE9, W5) M1Starter Motor (SE1, W8)
E4R. H. Front Work Light (SE9, W5) M2Rear Wiper Motor (SE7, W5)
E5L. H. Rear Work Light (SE8, W5) M3L. H. Door Wiper Motor (SE7, W5)
E6R. H. Rear Work Light (SE8, W5) M4R. H. Door Wiper Motor (SE7, W5)
E7L. H. Front Drive Light (SE9, W5) M5Washer Motor (SE6, W8)

022602
PN=236
M6Blower Motor (SE6, W10) V10Differential Lock Solenoid Diode (SE2, W8)
M7Air Adjust Seat Motor (SE6, ) V11Park Brake Relay Diode (SE10, W6)
P1Fuel Gauge (SE14, W6) V12Speed Solenoid (1) Diode (SE10, W8)
P2Tachometer/Hourmeter (Optional) (SE14, W6) V13Speed Solenoid (2) Diode (SE10, W8)
P3Hour Meter (SE14, W6) V14Speed Solenoid (3) Diode (SE10, W8)
P4Voltage Gauge (Optional) (SE14, W6) V16Selective Flow Valve Diode (SE18, W15)
P5Engine Coolant Temperature Gauge (Optional) V18Low Range Solenoid Diode (SE10, W8)
(SE14, W6) V19Timer Relay Diode (SE10, W7)
P6Transmission Temperature Gauge (Optional) V20Timer Relay Diode (SE10, W7)
(SE14, W6) W1Machine Frame Ground (SE1, W8)
R1Blower Resistor (SE6, W10) W2Ground to Cab Frame (SE13, W5)
S1Key Switch (SE1, W6) W3Ground to Cab Floor (SE1, W8)
S2 MFWD Switch (SE3, W6) W4Engine Ground Strap (, W8)
S3Differential Lock Switch (SE2, W6) W5Cab Roof Harness (, W5)
S4Start Aid Switch (SE5, W6) W6Side Console Harness (, W6)
S5Front Windshield Wiper Switch (SE7, W7) W7Front Console Harness (, W7)
9015
S6Rear Wiper Switch (SE7, W6) W8Engine Harness (, W8) 10B
S7Windshield Washer Switch (SE7, W7) W10Blower Harness (, W10) 5
S8Blower Switch (SE6, W10) W11Air Conditioning Compressor Harness (, W11)
S9Front Light Switch (SE9, W7) W12Radio Harness (, W12)
S10Rear Light Switch (SE8, W6) W13Antenna (, W12)
S11FNR/Range Switch (SE10, W7) W15Selective Flow Valve Harness (, W15)
S12Park Brake Dash Switch (SE10, W6) W16Selective Flow Valve Ground Connector
S13Loader Lever Switch (SE10, W6) (SE18, W15)
S15Horn Switch (SE11, W6) X1Roof Harness to Side Console Harness
S16Turn Signal Switch (SE12, W7) Connector (, W5, W6)
S174-Way Flasher Switch (SE12, W7) X2Roof Harness to Side Console Harness
S18Beacon Switch (Optional) (SE13, W6) Connector (, W5, W6)
S19Seat Position Sensor (SE16, W6) X3Roof Harness to Side Console Harness
S19Seat Position Sensor (SE16, W10) Connector (, W5, W6)
S20Return-to-Dig Switch (SE14, W8) X5 Side Console Harness to Blower Harness
S21Flasher (SE12, W6) Connector (Cab Only) (, W6, W10)
S22Heater Temperature Switch (, W10) X20Side Console Harness to Engine Harness
S25Air Conditioning Switch (Optional) (SE6, W6) Connector (, W6, W8)
S27Dome Light Switch (SE4, W5) X21Side Console Harness to Engine Harness
S28Selective Flow Valve Switch (SE18, W15) Connector (, W6, W8)
S29Foot Switch (SE18, W15) X22Side Console Harness to Engine Harness
S32Air Adjust Seat Switch (SE6, ) Connector (, W6, W8)
V1MFWD Solenoid Diode (SE3, W8) X23Side Console Harness to Engine Harness
V2Park Brake Solenoid Diode (SE10, W8) Connector (, W6, W8)
V3Reverse Solenoid Diode (SE10, W8) X24Side Console Harness to Engine Harness
V4Forward Solenoid Diode (SE10, W8) Connector (, W6, W8)
V64-Way Flasher Switch Diode (SE12, W7) X25Side Console Harness to Front Console
V74-Way Flasher Switch Diode (SE12, W7) Harness Connector (, W6, W7)
V8Starter Solenoid Diode (SE1, W8) X29Roof Harness to Radio Harness Connector (,
V9Alternator Diode (SE1, W8) W5, W12)

022602
PN=237
X30Splice (Inside Side Console Harness) (, W6) X59Engine Harness to AC Compressor Harness
X34Engine Harness to AC Compressor Harness Connector (, W8, W11)
Connector (, W8, W11) X60Splice (Inside Blower Harness) (, W10)
X35Side Console Harness to Blower Harness Y1MFWD Solenoid (SE3, W8)
Connector (Cab Only) (, W6 W10) Y2Start Aid Solenoid (SE5, W8)
X46Selective Flow Valve Harness to Foot Switch Y3Fuel Shutoff Solenoid (SE5, W8)
Harness Connector (, W15) Y4Park Brake Solenoid (SE9, W8)
X48Selective Flow Valve Harness to Valve Y5Reverse Solenoid (SE10, W8)
Solenoid Harness Connector (, W15) Y6Forward Solenoid (SE10, W8)
X53Engine Harness to Auxiliary Gauge Harness (, Y8Differential Lock Solenoid (SE2, W8)
W8) Y9Return-to-Dig Solenoid (SE14, W8)
X54Engine Harness to Transmission Control Valve Y10A/C Compressor Clutch (SE6, W11)
Connector (, W8) Y12Speed Solenoid (1) (SE10, W8)
X55Side Console Harness to Air Adjust Seat Y13Speed Solenoid (2) (SE10, W8)
Harness Connector (ROPS Only) (, W6) Y14Speed Solenoid (3) (SE10, W8)
X56Blower Harness to Air Adjust Seat Harness Y16Selective Flow Valve Solenoid (SE18, W15)
9015
10B (Cab Only) (, W10) Y18Low Range Solenoid (SE10, W8)
6 X57Engine Harness to Transmission Control Valve Y19Hydraulic Pump Destroke Solenoid (SE10,
Connector (, W8) W8)
X58Side Console Harness Auxiliary Power
Connector (SE1, W6, W15)
CED,TX17864,122 1921AUG983/3

022602
PN=238
System Functional Schematic Section

Legend (S.N. 872257 )
NOTE: SE1Battery/Ignition, Power, Charging and Start

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

SE2Differential Lock Circuit
SE3MFWD Circuit
SE4Dome Light and Radio Circuit 9015
SE5Start Aid, Fuel Shut Off and Reverse Alarm 10B
Circuit 7
SE6Blower, Air Adjust Seat, and A/C Circuit
SE7Wiper and Washer Circuit
SE8Rear Work Light Circuit
SE9Front Work and Drive Light Circuit
SE9Park Brake Circuit
SE10FNR/Park Brake Circuit
SE11Horn Circuit
SE12Turn Signal, Flasher and Brake Light Circuit
SE13Beacon/Return-To-Dig Circuit
SE14Gauge and Hour Meter Circuit
SE15Display Monitor Circuit
SE16Indicator Circuit
SE17Selective Flow Valve Circuit
CED,TX17864,123 1921AUG981/1

022602
PN=239
System Functional Schematic (S.N. 872257 )

T117528 1908OCT98
CED,TX17864,124 1921AUG981/7

022602
PN=240
T116836 1908OCT98
CED,TX17864,124 1921AUG982/7

022602
PN=241
T117529 1908OCT98
CED,TX17864,124 1921AUG983/7

022602
PN=242
T117085 1908OCT98
CED,TX17864,124 1921AUG984/7

022602
PN=243
T117360 1908OCT98
CED,TX17864,124 1921AUG985/7

022602
PN=244
T116992 1908OCT98
CED,TX17864,124 1921AUG986/7

022602
PN=245
9015
10B
14
T117392 1908OCT98
CED,TX17864,124 1921AUG987/7

022602
PN=246
Cab Roof Harness (W5) Wiring Diagram (S.N. 872257 )

T116856 1918SEP98
E1 M2 E10 H5 E12
DOME REAR R.H. R.H. R.H.
LIGHT WIPER MOTOR REAR REAR BRAKE E6 M4 H4 E8 E4
TAIL TURN LIGHT R.H. R.H. DOOR R.H. R.H. R.H.
LIGHT LIGHT REAR WIPER MOTOR FRONT FRONT FRONT X2
WORK TURN DRIVE WORK ROOF HARNESS
LIGHT LIGHT LIGHT LIGHT TO SIDE CONSOLE
HARNESS CONNECTOR
M
X29 P25 RED B
M E1, X29 P15 RED A
RED
BLU
YEL
BRN
RED
YEL
BLU
G20 BLK
X3
S27 ROOF HARNESS
DOME TO SIDE CONSOLE
LIGHT HARNESS CONNECTOR
SWITCH
H
A66 ORG
P14 RED
G20 BLK
L42 BRN
A65 ORG
G20 BLK
A63 ORG
G20 BLK
A64 ORG
G20 BLK
L43 BRN
L41 BRN
G20 BLK
L47 BRN
P14 RED
L47 BRN
L46 BRN
G20 BLK
L43 BRN
G
G20 BLK
P15 RED
M2 A66 ORG F
M2 A65 ORG E
W2
X3
X3
X1, M3, M4
W2
H4, X1
X1, E11
W2
W2
X3
X3
X1, M2, M3
W2
X1, E9, E10,
X29, E7
W2
X1, E3
X2
X29
W2
X1, E5
X1, H5
W2
X1, E8, X29,

E7, E9
M4 A64 ORG D
W2
X3
X3
W2
W2
X2
W2
W2
X1
W2
W2
W2
M4 A63 ORG C
H2, X1
H3, X1
X2, E1
X1, E6
X1, E4
X1, E12
M3 A62 ORG B
E9,E10,
X1, E7, E8
E10, X29,
X1, E8, E9
X1, M4, M2
E7,E8
X1, E10, X29
E3, E5
E10, H5
E11, E8
E4, E6
E12, M4
E7, H2
E9, H3
H4, E13
X29, M3
S27, M2
M3 A61 ORG A
X1
L46 BRN
G20 BLK
L41 BRN
G20 BLK
L48 BRN
L48 BRN
G20 BLK
A61 ORG
A62 ORG
L43 BRN
G20 BLK
L43 BRN
L45 BRN
G20 BLK
L42 BRN
G20 BLK
G20 BLK
P14 RED
P15 RED
L43 BRN
G20 BLK
P25 RED
ROOF HARNESS
G20 BLK
TO SIDE CONSOLE
HARNESS CONNECTOR
M3 P14 RED H
M2, M4
E6, E5 L41 BRN G
H2, H3 L48 BRN F
A B C D X29 L43 BRN E
E7, E9, E10, E8
RED
YEL
BLU
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
T116856
CED,TX17864,137 1921AUG981/1

022602
PN=247
Cab Roof Harness (W5) Component Location (S.N. 872257 )

T100583 1910SEP98
H5/E12/E10
R.H. REAR
TURN/BRAKE/TAIL LIGHT
E6
R.H. REAR
WORK LIGHT
H3/E11/E9
L.H. REAR
S27 TURN/BRAKE/TAIL LIGHT
DOME X28
H4 LIGHT
R.H. FRONT BEACON
SWITCH LIGHT E5 X1
TURN LIGHT
CONNECTOR L.H. REAR ROOF HARNESS
E1 WORK LIGHT TO SIDE CONSOLE
DOME HARNESS CONNECTOR
LIGHT M2
E8 REAR WIPER M3 P14 RED H
R.H. FRONT MOTOR X29 M2,M4
DRIVE ROOF HARNESS
TO RADIO E6,E5 L41 BRN G
LIGHT
HARNESS H2,H3 L48 BRN F
A B C D CONNECTOR X29 L43 BRN E
E7,E9,E10,E8
E4 E13 L45 BRN D
R.H. FRONT H G F E
H4,H5 L47 BRN C
WORK LIGHT X1 E11,E12 L46 BRN B
W2 ROOF HARNESS
GROUND TO SIDE E4,E3 L42 BRN A
H2 TO CAB CONSOLE
L.H. FRONT FRAME HARNESS
TURN LIGHT CONNECTOR
X3
M4 ROOF HARNESS
R.H. DOOR A B C D TO SIDE CONSOLE
WIPER HARNESS CONNECTOR
MOTOR M4 A69 ORG H
E F G H
X3 M3 A68 ORG G
ROOF HARNESS M2 A66 ORG F
TO SIDE M2 A65 ORG E
CONSOLE M4 A64 ORG D
E3 HARNESS M4 A63 ORG C
L.H. FRONT CONNECTOR
D C B M3 A62 ORG B
WORK A
LIGHT M3 A61 ORG A
A B X2 X2
ROOF HARNESS ROOF HARNESS
TO SIDE TO SIDE CONSOLE
M3 CONSOLE HARNESS CONNECTOR
E7 L.H. DOOR HARNESS X29 P25 RED B
L.H. FRONT WIPER MOTOR
DRIVE LIGHT CONNECTOR E1,X29 P15 RED A
T100583 CAB ROOF HARNESS COMPONENT LOCATION
TX,9015,QQ6748 1920MAR961/1

022602
PN=248
Cab Roof Harness (W5) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
17
1908AUG96
T101266
Continued on next page TX,9015,QQ6749 1920MAY961/2

022602
PN=249
9015
10B
18
1908AUG96
T101396
TX,9015,QQ6749 1920MAY962/2

022602
PN=250
Side Console Harness (W6) Wiring Diagram (S.N. 872257 )

T117079 1908OCT98
CED,TX17864,143 1924AUG981/3

022602
PN=251
T117078 1910SEP98
CED,TX17864,143 1924AUG982/3

022602
PN=252
T116949 1910SEP98
CED,TX17864,143 1924AUG983/3

022602
PN=253
Side Console Harness (W6) Component Location (S.N. 872257 )

T116951 1923SEP98
X20 S19
X24 SIDE CONSOLE HARNESS SEAT POSITION
SIDE CONSOLE HARNESS TO ENGINE HARNESS SENSOR
TO ENGINE HARNESS CONNECTOR 31 20
30 8 21 B11 (ROPS ONLY)
CONNECTOR X30 G40 BLK 19 9
18 2 10
BRAKE
M1 B11 RED X20 29 7 3 22 LIGHT X55
SIDE CONSOLE HARNESS 17 1 11 SWITCH SIDE CONSOLE
TO ENGINE HARNESS 28 6 4 23 HARNESS TO
X21 16 5 12 X25 B18
CONNECTOR 15 13 BRAKE AIR ADJUST
SIDE CONSOLE HARNESS 27 14 24 SIDE CONSOLE SEAT HARNESS
TO ENGINE HARNESS 26 25 PRESSURE
HARNESS TO FRONT SWITCH CONNECTOR
X25 CONNECTOR CONSOLE HARNESS (ROPS ONLY)
SIDE CONSOLE HARNESS H8 X36 YEL 1 X24 CONNECTOR
TO FRONT CONSOLE H8 N34 YEL 2 SIDE CONSOLE HARNESS
CONNECTOR H8 X38 YEL 3 TO ENGINE HARNESS
X3 A61 ORG 1 H8 F39 YEL 4 CONNECTOR B17
X3 A62 ORG 2 H8 M40 PUR 5 BRAKE
X3 A63 ORG 3 P2,H8 M39 PUR 6 7 8 9 10 11 12 PRESSURE
X3 A64 ORG 4 SWITCH
P1 Y33 YEL 7
X22 A71 ORG 5 NOT USED Y1 YEL 8
F5,S6,X1 P14 RED 6 NOT USED Y2 YEL 9
F12 L47 BRN 7 NOT USED K1 BLU 10
8 S15 A67 ORG 11
9 V14 M62 PUR 12
B11,F10,S15 P19 RED 10 6 5 4 3 2 1
11 X23 X21
S21 L49 BRN 12 SIDE CONSOLE HARNESS SIDE CONSOLE HARNESS
TO ENGINE HARNESS TO ENGINE HARNESS
F11 L48 BRN 13 CONNECTOR
X30 G30 BLK 14 CONNECTOR
K6 E23 WHT 1
X21 T11 BLU 15 S4 P12 RED 2 7 8 9 10 11 12
S4 E25 WHT 3
16 S2,F1 P13 RED 4
F9 P24 RED 17 S14 T53 BLU 5
18 S2 W55 BLU 6
19 S12 J27 TAN 7
F8 P18 RED 20 E15 M32 PUR 8
X1 L43 BRN 21 X25 T11 BLU 9 6 5 4 3 2 1
F8 P18 RED 22 X25 T13 BLU 10
X1 L42 BRN 23 V11 E02 WHT 11 X23
K6 T12 BLU 24 SIDE CONSOLE HARNESS
Y8 W02 BLU 12 TO ENGINE HARNESS
25 CONNECTOR
26 X22 S3
27 SIDE CONSOLE HARNESS 5 4 DIFF.
28 TO ENGINE HARNESS LOCK
CONNECTOR 6 3 SWITCH
29
1
30
H8 X41 YEL 2
31 7 2
3
F13 P20 RED 4 8 1
5
X22
X38 A17 ORG 6 SIDE CONSOLE HARNESS
X25 A71 ORG 7 TO ENGINE HARNESS
T116951 8 CONNECTOR SIDE CONSOLE HARNESS COMPONENT LOCATION
CED,TX17864,125 1921AUG981/2

022602
PN=254
T116952 1914OCT98
CED,TX17864,125 1921AUG982/2

022602
PN=255
Side Console Harness (W6) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
24
T116958 1910SEP98

022602
PN=256
9015
10B
25
1910SEP98
T116959

022602
PN=257
9015
10B
26
1910SEP98
T116960

022602
PN=258
9015
10B
27
1910SEP98
T116961
CED,TX17864,126 1921AUG984/4

022602
PN=259
Front Console Harness (W7) Wiring Diagram (S.N. 872257 )

T116675 1910SEP98
CED,TX17864,138 1921AUG981/1

022602
PN=260
Front Console Harness (W7) Component Location (S.N. 872257 )

T116906 1925AUG98
CED,TX17864,136 1921AUG981/1

022602
PN=261
Front Console Harness (W7) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
30
T116908 1910SEP98

022602
PN=262
9015
10B
31
1910SEP98
T116909
CED,TX17864,127 1921AUG982/2

022602
PN=263
Engine Harness (W8) Wiring Diagram (S.N. 872257 )

T116816 1910SEP98
CED,TX17864,139 1921AUG981/2

022602
PN=264
T116815 1910SEP98
CED,TX17864,139 1921AUG982/2

022602
PN=265
Engine Harness (W8) Component Location (S.N. 872257 )

T116817 1918SEP98
G1 S20 Y9
BATTERIES RETURN-TO-DIG RETURN-TO-DIG
SWITCH SOLENOID
M5 V13
WASHER W1 SPEED
MOTOR MACHINE W1 G40 BLK
FRAME SOLENOID (2) X20
GROUND DIODE ENGINE HARNESS
B3 V12 TO SIDE CONSOLE
HORN SPEED
SOLENOID (1) HARNESS CONNECTOR
K1 DIODE
START
RELAY X54
Y2 ENGINE HARNESS TO M1,G2 B11 RED
START TRANSMISSION CONTROL X24
ENGINE HARNESS
AID VALVE CONNECTOR TO SIDE CONSOLE
SOLENOID B10
PARK BRAKE HARNESS CONNECTOR
B7 PRESSURE SWITCH
B5 X36 YEL 1
AIR FILTER 7 8 9 10 11 12 B6 N34 YEL 2
RESTRICTION V14
SPEED B8 X38 YEL 3
SWITCH
SOLENOID (3) B9 F39 YEL 4
V9 DIODE B7 M40 PUR 5
ALTERNATOR G2 M39 PUR 6
DIODE S4 Y33 YEL 7
NOT USED Y1 YEL 8
X53 6 5 4 3 2 1 NOT USED Y2 YEL 9
ENGINE HARNESS
TO AUXILIARY X21 NOT USED K1 BLU 10
GAUGE HARNESS ENGINE HARNESS B3 A67 ORG 11
TO SIDE CONSOLE B1 M62 PUR 12
B9 HARNESS CONNECTOR
HYDRAULIC
B1
BACKUP 7 8 9 10 11 12 K1 E23 WHT 1
FILTER WARNING
RESTRICTION Y3 P12 RED 2
ALARM Y2 E25 WHT 3
SWITCH
Y19 V3 Y9 P13BRED 4
HYDRAULIC REVERSE
SOLENOID 5
PUMP DESTROKE Y1,V1 W55 BLU 6
SOLENOID W3 DIODE
GROUND TO Y4,V2 J27 TAN 7
V4
CAB FLOOR FORWARD B10 M32 PUR 8
6 5 4 3 2 1 X54,V4 T11 BLU 9
SOLENOID
Y8 DIODE X23 X54,V3 T13 BLU 10
B8 DIFF. ENGINE HARNESS
CONVERTER LOCK M1,V8,K1,Y19 E02 WHT 11
G2 TO SIDE CONSOLE Y8,V10 W02 BLU 12
ALTERNATOR OIL SOLENOID HARNESS CONNECTOR
V8 TEMP. Y4
START PARK BRAKE
SOLENOID 5 4
SOLENOID
DIODE X57 6 3 V13,X57 T18 BLU 1
B5 ENGINE HARNESS Y1
TO TRANSMISSION MFWD 2
ENGINE COOLANT SOLENOID V2
X59 TEMP. SWITCH CONTROL VALVE V14,X57 T19 BLU 3
ENGINE HARNESS PARK BRAKE V1 7 2
M1 CONNECTOR SOLENOID V10 V18 S20 P20 RED 4
TO AC COMPRESSOR B4 MFWD DIFF.
HARNESS CONNECTOR STARTER FUEL DIODE SOLENOID LOW RANGE 8 1 V18,X54 T16 BLU 5
X34 B6 MOTOR LOCK SOLENOID X34 A17 ORG 6
Y3 SENDER DIODE DIODE X22
ENGINE HARNESS TO ENGINE OIL W4 DIODE ENGINE HARNESS M5 A71 ORG 7
FUEL PRESSURE SWITCH
AC COMPRESSOR HARNESS SHUTOFF GROUND TO SIDE CONSOLE V12,X57 T17 BLU 8
T116817 CONNECTOR SOLENOID STRAP ENGINE HARNESS COMPONENT LOCATION HARNESS CONNECTOR
CED,TX17864,129 1921AUG981/1

022602
PN=266
Engine Harness (W8) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
35
1910SEP98
T116911

022602
PN=267
9015
10B
36
1910SEP98
T116912

022602
PN=268
9015
10B
37
T116913 1910SEP98
CED,TX17864,130 1921AUG983/3

022602
PN=269
Blower Harness (W10) Wiring Diagram (S.N. 872257 )

T116840 1910SEP98
CED,TX17864,147 1925AUG981/1

022602
PN=270
Blower Harness (W10) Component Location (S.N. 872257 )

T116921 1910SEP98
CED,TX17864,131 1921AUG981/1

022602
PN=271
Blower Harness (W10) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
40
1915OCT98
T116924
TX,9015,QQ6757 1921JUL981/1

022602
PN=272
Air Conditioning Compressor Harness (W11) Wiring Diagram (S.N. 872257 )
9015
10B
41
1908OCT98
T116838
CED,TX17864,140 1921AUG981/1

022602
PN=273
Air Conditioning Compressor Harness (W11) Component Location (S.N. 872257 )
9015
10B
42
1908OCT98
T116925
CED,TX17864,132 1921AUG981/1

022602
PN=274
Air Conditioning Compressor Harness (W11) Connectors, Wire and Pin Location (S.N.
872257 )
9015
10B
43
1915OCT98
T116926
CED,TX17864,133 1921AUG981/1

022602
PN=275
Radio Harness (W12) Wiring Diagram (S.N. 872257 )
9015
10B
44
1910SEP98
T116854
CED,TX17864,141 1921AUG981/1

022602
PN=276
Radio Harness (W12) Component Location (S.N. 872257 )

T116930 1910SEP98
TX,9015,QQ6758 1920MAR961/1

022602
PN=277
Radio Harness (W12) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
46
T101356 1908AUG96
TX,9015,QQ6759 1921MAY961/1

022602
PN=278
Selective Flow Valve Harness (W15) Wiring Diagram (S.N. 872257 )
9015
10B
47
1910SEP98
T116865
CED,TX17864,142 1921AUG981/1

022602
PN=279
Selective Flow Valve Harness (W15) Component Location (S.N. 872257 )
9015
10B
48
1910SEP98
T116866
CED,TX17864,134 1921AUG981/1

022602
PN=280
Selective Flow Valve Harness (W15) Connectors, Wire and Pin Location (S.N. 872257 )
9015
10B
49
1910SEP98
T116931
CED,TX17864,135 1921AUG981/1

022602
PN=281
9015
10B
50

022602
PN=282
Group 15A
Sub-System Diagnostics (S.N. 872256)
Power Circuit Operational Information
(S.N. 872256)
The following conditions must exist for power circuit to

function:
Voltage must be present at these distribution points for

other circuits to operate.
BAT terminal of key switch

Terminal 30 of accessory relay
Start relay
B+ terminal of alternator
Starter
Radio fuse
Hazard/monitor fuse 9015
15A
1
TX,9015,QQ1725 1912MAR931/1
Power Circuit Theory of Operation (S.N.

872256)
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

022602
PN=283
Power Circuit Schematic (S.N. 825657)

GROUND CIRCUIT
ACC (WIRE COLOR) G01 BLKENGINE HARNESS
OFF G10 BLKSIDE CONSOLE HARNESS
ON
BULB CHECK G20 BLKROOF HARNESS
KEY G30 BLKFRONT CONSOLE HARNESS
START
BAT IGN ACC ST G BODY SWITCH G40 BLKENGINE HARNESS TO SIDE
CONSOLE HARNESS
B11 RED
S1 ACC
OFF
B12 RED
KEY ON B12A RED

BULB CHECK
SWITCH START
F2 F16
ACC
BAT B14 FUEL SHUTOFF/ START
RED F4
B11 RED
START AID/ FUSE
REVERSE ALARM UNSWITCHED
FUSE RADIO FUSE
9015
15A IGN
2
B11 RED
E22 WHT
B11 RED
F9 F15
UNSWITCHED
ST FNR/PARK
HAZARD
BRAKE FUSE
G10 BLK
K2 MONITOR
ACCESSORY FUSE
G
B11 RED
RELAY
B15
G10 RED
BLK B14 RED
B15 B15 B15 B15 B15 B15 B15

RED RED RED RED RED RED RED
G1 F1
BATTERIES MFWD/
B11 RED
RED CABLE
+ ALT
DIFF F3 F6
TO NEUTRAL LOCK F8
START RELAY DOME/ HEATER/
FUSE FRONT
E23 WHT
SE11, K6 RADIO FUSE CIRCUIT

B11 RED BREAKER WORK/
B03 RED LIGHT
E02 WHT FUSE
K1
START S
CABLE
F7 F10
G10 BLK
RELAY F5
BLK
REAR WORK TURN/STOP/

WIPER LIGHT FUSE HORN FUSE
M1 WASHER
STARTER M FUSE
MOTOR
B11 RED
G01 BLK
E02 WHT
MACHINE FRAME/ENGINE W D+ F13
BLOCK GROUND/LEFT SIDE RETURN-TO-DIG/
G
BEACON FUSE
1916SEP98
G01 BLK
W1
G10
B+
BLK
G40
BLK
G40 BLK G2
G02 BLK ALTERNATOR
T117133
T117133
CED,TX17864,153 1910SEP981/1

022602
PN=284
Power Circuit Schematic (S.N. 825658872256)

GROUND CIRCUIT
ACC (WIRE COLOR) G01 BLKENGINE HARNESS
OFF G10 BLKSIDE CONSOLE HARNESS
ON
G20 BLKROOF HARNESS
BULB CHECK KEY
START G30 BLKFRONT CONSOLE HARNESS
SWITCH G40 BLKENGINE HARNESS TO SIDE
BAT IGN ACC ST G BODY
CONSOLE HARNESS
B11B RED
S1 ACC
OFF
B12B RED
B11D RED
KEY ON B12A RED
BULB CHECK
SWITCH
B12C RED
START
F2 F16
ACC
BAT B14 FUEL SHUTOFF/ START
B11A RED
RED
START AID/ F4
FUSE UNSWITCHED
REVERSE ALARM
FUSE RADIO FUSE
9015
IGN 15A
B11B RED
3
E22 WHT
B11 RED
F9 F15
UNSWITCHED
ST FNR/PARK
HAZARD
BRAKE FUSE
G10 BLK
K2 MONITOR
ACCESSORY FUSE
G
B11C RED
RELAY
B15
G10L RED
BLK B14 RED
B15 B15 B15 B15 B15 B15 B15

RED RED RED RED RED RED RED
G1 F1
BATTERIES MFWD/
B11 RED
RED CABLE
+ ALT
DIFF F3 F6
TO NEUTRAL LOCK F8
DOME/ HEATER/
START RELAY FUSE FRONT
RADIO FUSE
E23 WHT
SE11, K6 CIRCUIT
B11 RED BREAKER WORK/
B03 RED LIGHT
E02 WHT FUSE
K1
START S
CABLE
F5 F7 F10
G10 BLK
RELAY
BLK
WIPER REAR WORK TURN/STOP/

WASHER LIGHT FUSE HORN FUSE
M1
STARTER M FUSE
MOTOR
B11 RED
G01 BLK
E02 WHT
MACHINE FRAME/ENGINE W D+ F13
BLOCK GROUND/LEFT SIDE RETURN-TO-DIG/
G
BEACON FUSE
1916SEP98
G01 BLK
W1
G10
B+
BLK
G40
BLK
G40 BLK G2
G02 BLK ALTERNATOR
T117134
T117134
CED,TX17864,154 1910SEP981/1

022602
PN=285
Subsystem Diagnostics/Power Circuit

(S.N. 872256)
CED,TX17864,158 1910SEP981/1
Power Circuit Diagnostic Procedures
1/1
Battery State of Charge YES: Clean battery cable

CAUTION: Engine may crank during this check. terminals. Repeat test.
9015
15A Move light switch to ON position. Turn key to START. Do work lights go out or get very If lights still get dim, test
4 dim while cranking engine? battery.
If battery charge is low,

recharge or replace it.
NO: Battery charge is

good. Go to next check.
1/1
Starter Motor Key switch OFF. YES: Check complete.
With harness connected, check voltage at terminal of NO: Check wiring

starter with red cable. harness between battery
and starter motor.
Are 12 volts measured?
T7199BK 1917SEP90
1/1
Alternator Key switch OFF. YES: Check complete.
With harness connected, check voltage at B+ terminal of NO: Check wiring

alternator. harness between battery
and alternator.
T7828AA 1923SEP92
1/1

022602
PN=286
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
Key Switch Check Key switch OFF. YES: Go to next step in

this check.
9015
With harness connected, check voltage of B11 red wire
15A
at BAT terminal of key switch. NO: Check wiring
5
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.
T7199BO UN17SEP90
With harness connected, check voltage at IGN and ST
terminals.
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

022602
PN=287
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
15A T7199BN UN16AUG90
6
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

022602
PN=288
9015
15A
7

022602
PN=289
Start Circuit Operational Information (S.N.

872256)
The following conditions must exist for start circuit to

function:
FNR/range lever in neutral

Key switch in START position
TX,9015,QQ1732 1912MAR931/1
Start Circuit Theory of Operation (S.N.

9015 872256)
15A
8
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, shift controller to
FNR/range switch. With the FNR/range switch in neutral
power flows to the neutral start relay terminal 86,
energizing relay.
With key switch in START, power flows from ST terminal

through start fuse, neutral start relay, to the hydraulic
pump destroke solenoid and start relay closing the relay.
With relay closed, power flows from starter motor through
B03 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.

9015-10.
TX,9015,QQ1729 1912MAR931/1

022602
PN=290
Start Circuit Schematic (S.N. 825657)
ACC GROUND CIRCUIT G01 BLKENGINE HARNESS

OFF (WIRE COLOR) G10 BLKSIDE CONSOLE HARNESS
ON G20 BLKROOF HARNESS
BULB CHECK G30 BLKFRONT CONSOLE HARNESS
START KEY G40 BLKENGINE HARNESS TO SIDE
BAT IGN ACC ST G BODY SWITCH CONSOLE HARNESS
E22 WHT
S11 GRY D RED
S1 ACC FNR/RANGE PNK C
OFF
KEY ON
SWITCH YEL B
N
SWITCH BULB CHECK R F R N F
RED A RED
START FNR
ACC
BAT
E22 WHT
D
BLU C 9015
2 3 4 GRN B 15A
IGN 1
A 9
RANGE
B12 RED
B11B RED
ST
F9 D B C A
G FNR/PARK A1
RED
T12 BLU
BRAKE FUSE SHIFT

GRN
GRN
RED
P24 RED CONTROLLER

B11RED
86 30
G1 87A
B11 RED
BATTERIES 85 87
TIME
E22 WHT
K2 DELAY 30
G10 BLK
86
+ CIRCUIT
87A
ACCESSORY 85 87
RELAY
RED
CABLE 86 30
86 30
E23 WHT 87A
87A
E02
T12 BLU
85 87 85 87
WHT
BLK CABLE
B03 RED
E23 WHT
86 30 K6 F16
K1 M NEUTRAL
START 87A START
START
RELAY 85 87 FUSE
M1 RELAY
STARTER E22A WHT
MOTOR
G01
BLK
E02 WHT E23 WHT Y8

G10 BLK
HYDRAULIC
1916SEP98
G10 BLK G40 BLK

G10 PUMP
W1 BLK G01 BLK G01 BLK
E23
WHT DESTROKE
G40 BLK
MACHINE FRAME/ENGINE SOLENOID
BLOCK GROUND/LEFT SIDE
T117135
T117135
CED,TX17864,155 1910SEP981/1

022602
PN=291
Start Circuit Schematic (S.N. 825658872256)
ACC GROUND CIRCUIT G01 BLKENGINE HARNESS

OFF (WIRE COLOR) G10 BLKSIDE CONSOLE HARNESS
ON G20 BLKROOF HARNESS
BULB CHECK G30 BLKFRONT CONSOLE HARNESS
START KEY G40 BLKENGINE HARNESS TO SIDE
BAT IGN ACC ST G BODY SWITCH CONSOLE HARNESS
E22 WHT
S11 GRY D RED
S1 ACC FNR/RANGE PNK C
OFF
KEY ON
SWITCH YEL B
N
SWITCH BULB CHECK R F R N F
RED A RED
START FNR
ACC
BAT
E22 WHT
D
BLU C
9015
2 3 4 GRN B
15A IGN 1
10 A
RANGE
B12B
RED
B11B RED
B12C
RED
ST P24B
RED P24A RED
F9 D B C A
G FNR/PARK A1
RED
T12 BLU
BRAKE FUSE SHIFT

GRN
GRN
RED
CONTROLLER
B11C RED
86 30
G1 87A
B11 RED
BATTERIES 85 87
TIME
E22 WHT
K2 DELAY 30
G10 BLK
86
+ CIRCUIT
87A
ACCESSORY 85 87
RELAY
RED
CABLE 86 30
86 30
E23 WHT 87A
87A
E02
T12 BLU
85 87 85 87
WHT
BLK CABLE
B03 RED
E23 WHT
86 30 K6 F16
K1 M NEUTRAL
START 87A START
START
RELAY 85 87 FUSE
M1 RELAY
STARTER E22A WHT
MOTOR
G01
BLK
E02 WHT E23 WHT Y8

G10D BLK G10E BLK
HYDRAULIC
1916SEP98
G10 BLK G40 BLK

G10 PUMP
W1 BLK G01 BLK G01 BLK
E23
WHT DESTROKE
G40 BLK
MACHINE FRAME/ENGINE SOLENOID
T117136
T117136
CED,TX17864,156 1910SEP981/1

022602
PN=292
Sub-System Diagnostics/Start Circuit (S.N.

872256)
CED,TX17864,157 1910SEP981/1
Start Circuit Diagnostic Procedures
1/1
Key Switch Check Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next check.
9015
Remove FNR/park brake fuse. NO: Replace key switch.
15A
11
Remove start fuse.
T7199BO UN17SEP90
terminals.
1/1

022602
PN=293
FNR/Range Lever YES: Go to next step in

this check.
NO: Check wiring

harness.
9015
15A T7828AC UN09MAR93
12
Key switch ON. FNR/range lever in neutral
With harness connected, check voltage at terminals with red wire and gray wire.
YES: FNR lever is good.

Go to next check.
NO: Replace FNR lever.
T7828AD UN09MAR93
Key switch ON.
With harness connected, and FNR/range lever moved to forward, check voltage at
terminal with yellow wire.
Move FNR/range lever to reverse, check voltage at pink wire.
1/1

022602
PN=294
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
Hydraulic Pump Key switch OFF. YES: Solenoid is good.

Destroke Solenoid Check wiring harness.
9015
Disconnect harness from destroke solenoid.
15A
NO: Replace solenoid.
13
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.
Disconnect harness from relay. NO: Replace start relay.
Connect battery voltage to one of the small blade

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

T7287BK 1916AUG90
continuity measured?
1/1
Starter 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.
Does solenoid "click"?

T6534BI UN19OCT88
Remove jumper wires.
1/1

022602
PN=295
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
Charge Circuit Operational Information

9015 (S.N. 872256)
15A
14
The following conditions must exist for charging circuit to
function:
Key switch in ON position

Engine running
TX,9015,QQ1827 1912MAR931/1

022602
PN=296
Charge Circuit Theory of Operation (S.N.

872256)
The charging circuit consists of the battery, alternator,

alternator relay, key switch, accessory relay, and indicator
light in the monitor panel.
The alternator (B+) terminal is connected to battery

voltage at all times.
The alternator terminal (D+) gets power from ACC

terminal of the key switch by energizing the accessory
relay, closing relay contacts and sending power to
MFWD/Alternator/Diff. Lock fuse.
With key switch ON and engine running, power flows from 9015
terminal (W) of alternator to alternator relay, energizing it. 15A
Terminals 30 and 87 are connected, and indicator light 15
goes out.
When key is on but engine is not running or if alternator

fails, alternator relay de-energizes and terminals 30 and
87A are connected. This grounds the indicator light and
light comes on.

9015-10.
TX,9015,QQ1375 1912MAR931/1

022602
PN=297
Charge Circuit Schematic (S.N. 815415)
ACC GROUND CIRCUIT

ON G10 BLKSIDE CONSOLE HARNESS
BULB CHECK G20 BLKROOF HARNESS
START KEY G30 BLKFRONT CONSOLE HARNESS
SWITCH G40 BLKFLOOR HARNESS
BAT IGN ACC ST G BODY
POWER TO DISPLAY MODULE A A BATTERY POWER IN
B B
SECONDARY FAILURE SIGNAL (TO C C
POWER FROM ALTERNATOR
GROUND THROUGH INDICATOR SWITCH) D POWER IN FROM KEY SWITCH
RED LIGHT ALARM GROUND (PULSED) D E YELLOW LIGHT GROUND (SWITCHED)
F
PRIMARY FAILURE SIGNAL IN (TO BULB CHECK (TO GROUND IN BULB
GROUND THROUGH INDICATOR SWITCH) AND START POSITION)
LOGIC MODULE GROUND RED
ACC Z33 GRY
WARNING
S1 OFF
ON H9 LIGHT
9015 KEY BULB CHECK A Z36 GRY
15A SWITCH START H7 A B
Z36 GRY H11
16 BAT ACC LOGIC B C
Z33 GRY ALARM
C D
MODULE D E Z37 GRY
F YELLOW
B14 RED
M37 PUR H10 WARNING

IGN Z36 GRY Z33 GRY
LIGHT
Z34 GRY Z34 GRY
B11 RED
ENGINE ALT
VOLTS
ST H8 1
2
A
B
DISPLAY 3
4
C
D
E
MODULE 5
6 F
G
K2 11
12
F
E
G10 ACCESSORY 13
14
D
C
G10
BLK RELAY 15 B
BLK B11 RED

F1 16
7
A
A
B11 MFWD/ 8
9
B
C
RED D
ALT 10
RED
B11 RED
DIFF
P13
M37 PUR M37

FUSE PUR
B11 RED
F15 M37 PUR
PUR
M37
RED CABLE
B14 B15 RED

HAZARD/ TO P3
RED
MONITOR FUSE HOUR
G10 BLK
B11
RED
METER
M39
G1
BLK CABLE
PUR
S
P13B
BATTERIES
BRN
30
86
PUR
M39
M1 NOT
V9 87A
STARTER USED
ALTERNATOR 85 87
MOTOR M
DIODE
P13C
G10
D+ TAN
W BLK
RED
G40
B11
G10 BLK
G10
1916SEP98
G10 BLK P23

BLK BLK
G G2 RED
MACHINE FRAME/ W1 G40
ALTERNATOR K7
BLK
B+
ENGINE BLOCK GROUND/ ALTERNATOR
LEFT SIDE GO2 BLK RELAY
T117137
T117137
CED,TX17864,159 1910SEP981/1

022602
PN=298
ACC GROUND CIRCUIT

OFF
BULB CHECK KEY G20 BLKROOF HARNESS
START SWITCH G30 BLKFRONT CONSOLE HARNESS
BAT IGN ACC ST G BODY G40 BLKENGINE HARNESS TO SIDE
CONSOLE HARNESS
ACC
S1 OFF
ON
KEY BULBCHECK
SWITCH START
BAT ACC
ENGINE ALT VOLTS

9015
15A
IGN 1 A 17
H8 2 B
3 C
DISPLAY 4 D
MODULE 5 E
B14 RED
6 F
B11 RED
ST
11 F
12 E
13 D
14 C
G 15 B
16 A
7 A
8 B
B11 RED 9 C
10 D
G10 BLK
M37 PUR
G10
BLK
M37 PUR
B14 RED
TO P3
B11 RED
HOUR
M37 PUR
F1 METER
MFWD/ALT
G10 BLK
FUSE
B15 RED
CABLE
B11 RED
RED
F15
RED
B11 RED
P13
S
HAZARD/
MONITOR FUSE
G1 M39 PUR
CABLE
BATTERIES M1 86 30
BLK
P13B
PUR
BRN
M39
STARTER
M MOTOR B11 RED 87A
G40 P13C
W D+ 85 87
BLK TAN
G G10 BLK
G10 G2
G10 BLK
G10 BLK G40 BLK B+

BLK P23 RED
W1 G02 BLK
ALTERNATOR
MACHINE FRAME GROUND K7
1916SEP98
TO ENGINE GROUND STRAP ALTERNATOR

RELAY
T117138
T117138
CED,TX17864,161 1910SEP981/1

022602
PN=299
ACC GROUNDCIRCUIT
CONSOLE HARNESS
B11B RED
ACC
S1 OFF
ON
KEY BULB CHECK
SWITCH START
ENGINE ALT VOLTS
BAT ACC
1 A
9015 H8 2 B
3 C
15A DISPLAY 4 D
MODULE 5 E
18 IGN 6 F
11 F
12 E
B14 RED
13 D
B11B RED
14 C
ST 15 B
16 A
7 A
8 B
9 C
G D
10
M37B PUR
B11 RED
M37C PUR
G10 BLK
B11C RED TO P3
G10
BLK
HOUR
METER
B14 RED
M37A PUR
B11A RED
F1
MFWD/ALT
G10 BLK
FUSE
B15 RED
CABLE
F15
RED
P13A
RED
B11 RED
HAZARD/
S
MONITOR FUSE
G1 M39 PUR
CABLE
BATTERIES M1 86 30
BLK
P138
PUR
BRN
M39
STARTER
M MOTOR B11 RED 87A
G40 P13C
W D+ 85 87
BLK TAN
G G10T BLK
G10 G2
G10 BLK
G10 BLK G40 BLK B+

BLK P23 RED
W1 ALTERNATOR
G02 BLK
MACHINE FRAME GROUND
1916SEP98
K7
TO ENGINE GROUND STRAP ALTERNATOR
RELAY
T117139
T117139
CED,TX17864,162 1910SEP981/1

022602
PN=300
Sub-System Diagnostics/Charge Circuit

(S.N. 872256)
CED,TX17864,163 1910SEP981/1
Charging Circuit Diagnostic Procedures
1/1
Alternator Output Key switch OFF. YES: Alternator is good.

9015
Measure and record battery voltage. Check battery.
15A
19
Start and run engine at 1500 rpm, and check battery NO: Check alternator.
voltage.
Does battery voltage increase?

T6569AZ UN23AUG93
1/1
Alternator Key switch ON. Engine running. Park brake ON. YES: Alternator is good.
Using a multimeter, check for DC voltage at terminals NO: Alternator is failed.

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

(W).
Is 7.63 AC volts measured?
T7835AT 1923SEP92
1/1

022602
PN=301
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

Connect battery voltage to terminal #86. Ground terminal

T7596AQ 1903OCT91
Measure continuity between terminals #30 and #87. Is

1/1

this check.
9015
With harness connected, check voltage of B11 red wire
15A
at BAT terminal of key switch. NO: Check wiring
20
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.
NO: Replace key switch
Remove start fuse.
T7199BO UN17SEP90
terminals.
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

022602
PN=302

this check.
T7199BN UN16AUG90

this check.
9015
T7199BN UN16AUG90 15A
21

Does relay click?

T7199BN UN16AUG90
1/1

Operational Information (S.N. 815415) 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 1910MAR971/1

022602
PN=303
Display Module and Logic Module Circuit Theory of Operation (S.N. 815415) With Logic
Module
Key Switch OFF The logic module stops current flow to the display
monitor.
Power is supplied to the logic module through the
Hazard/Monitor Unswitched fuse to pin A of logic Failure Occurs
module (6 pin connector).
The indicator switch (sensor) closes, grounding an
Key Switch ON indicator light and also the logic module. The logic
module supplies power to all bulbs in the display
Power is supplied to the logic module through the module, the secondary failure indicator light, primary
Monitor Switched fuse. No power is supplied from the indicator light, and alarm. The logic module then
logic module to the display module since the logic connects either the red light and alarm or the yellow
module has not been "armed." light to ground, turning them ON.
9015
15A Key Switch in BULB CHECK or START If the key switch is momentarily turned OFF and back
22 ON while the engine is running, power from the
The key switch connects all indicator lights in the alternator indicator terminal will keep the logic module
display module to ground when the key switch is in the activated.
BULB CHECK or START positions. The key switch
also grounds the logic module, signaling the logic NOTE: For component identification code description,
module to supply power to all bulbs in the display see Wiring and Schematic Diagrams Legend,
module, the primary and secondary indicators and the Group 9015-10.
alarm, turning them ON. Turning the key switch to
BULB CHECK or START also "arms" the logic module
so failures will be indicated.
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,DY663 1910MAR971/1

Operational Information (S.N. 815416
825627) 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 1910MAR971/1

022602
PN=304

Theory of Operation (S.N. 815416825657)
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,
9015
engine oil pressure, alternator
15A
charging light are ON, and alarm
23
is beeping.
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.

9015-10.
TX,9015,QQ3188 1910MAR971/1

022602
PN=305
Display Module Circuit Theory of Operation

(S.N. 825628872256) 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:

No Lights or alarm. Red warning, yellow warning,
engine oil pressure, alternator
9015 charging light are ON, and alarm
15A is beeping.
24
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.

9015-10.
TX,9015,BD2733 1907MAR971/1

022602
PN=306
Display Module and Logic Module Circuit Schematic (S.N. 815415)
ACC GROUND CIRCUIT

CONSOLE HARNESS
POWER TO DISPLAY MODULE LOGIC MODULE BATTERY POWER IN

SECONDARY FAILURE SIGNAL (TO A A POWER FROM ALTERNATOR
GROUND THROUGH INDICATOR SWITCH) B B POWER IN FROM KEY SWITCH
C C
RED LIGHT ALARM GROUND (PULSED) D YELLOW LIGHT GROUND (SWITCHED)
PRIMARY FAILURE SIGNAL IN (TO D E BULB CHECK (TO GROUND IN BULB
F
GROUND THROUGH INDICATOR SWITCH) AND START POSITION)
B11 RED GROUND
F14 P21 RED 9015
S1 5A MONITOR F15 15A

15A UNSWITCHED 25
KEY FUSE
HAZARD/MONITOR
SWITCH
ACC FUSE
OFF
P23 RED Z33 GRY
ON
BULB CHECK R31 BLK H9
START
H7 RED
ACC
LOGIC MODULE WARNING
BAT Z33 GRY
A LIGHT
B12 RED
P23 RED
A B Z36 GRY
B C Z36 GRY
C D Z33 GRY
Z34 GRY
D E
IGN Z37 GRY
F
H11
M37 PUR H10 ALARM
Z36 GRY
YELLOW
Z32 GRY
WARNING
ST
R31 BLK LIGHT
Z33 GRY
Z34 GRY
G10 BLK
G
R31 BLK Z32 GRY
R31 BLK
M37 PUR ENG ALT VOLTS
86 30 1 A
2 B
3 C
87A
M39 PUR
4 D
G10 BLK
5 E
85 6 F
M37 PUR
87
G10 BLK
TO G2 K7 P23 RED 11 F
ALTER- ALTERNATOR H8 12
13
E
D
14 C
NATOR RELAY DISPLAY 15 B
MODULE 16 A
M37 PUR
G10 BLK
1916SEP98
7 A
G10 BLK G40 BLK G40 BLK 8 B
9 C
W1 MACHINE FRAME/ENGINE 10 D

T117140
T117140
CED,TX17864,164 1910SEP981/1

022602
PN=307
ACC GROUND CIRCUIT

ON KEY G10 BLKSIDE CONSOLE HARNESS
BULB CHECK SWITCH G20 BLKROOF HARNESS
START G30 BLKFRONT CONSOLE HARNESS
CONSOLE HARNESS
B11 RED
P21 RED
F14
S1 MONITOR F15
KEY FUSE UNSWITCHED
9015 SWITCH HAZARD/MONITOR
ACC
15A OFF
FUSE P21 RED
26 ON
H9
BULB CHECK
START RED
WARNING
ACC
BAT LIGHT
P23 RED
B12 RED
Z36 GRY
Z36 GRY
P21 RED
Z36 GRY
Z37 GRY
IGN
H10 H11
YELLOW ALARM
WARNING
LIGHT
P21 RED P21 RED
ST
V8 Z37 GRY
M38 PUR TO K3
G Z36 GRY
R31 BLK R31 BLK
M37 PUR ENG ALT VOLTS
86 30 1 A
M39 PUR
2 B
G10 BLK
3 C
87A 4 D
5 E
85 6 F
M37 PUR
87
G10 BLK
11 F
TO G2 P23 RED 12 E
ALTER- K7 H8 13
14
D
C
NATOR DISPLAY 15 B
M37 PUR
ALTERNATOR 16 A
RELAY MODULE 7 A
8 B
9 C
G10 BLK G40 BLK G40 BLK 10 D
W1 MACHINE FRAME/ENGINE
1916SEP98

T117141
T117141
CED,TX17864,164 1910SEP981/1

022602
PN=308
ACC GROUND CIRCUIT

KEY G20 BLKROOF HARNESS
BULB CHECK
SWITCH G30 BLKFRONT CONSOLE HARNESS
START
G40 BLKENGINE HARNESS TO SIDE
BAT IGN ACC ST G BODY CONSOLE HARNESS
P21 RED
T12A BLU
TO K6 NEUTRAL
START RELAY
M01B BLK
B11B RED K3
V8 PARK
FUEL GAUGE
DISPLAY
B11A RED
LIGHT
MODULE RELAY
F14 DIODE 86 30
F15
TO P1
MONITOR 9015
S1 TACH/ 15A
KEY FUSE
HMTR TO E15 SEAT 27
SWITCH
P21B RED
FUSE
M01A PUR
ACC BELT LIGHT
OFF M32A PUR 85 87A 87
ON G10R BLK
BULB CHECK
START
TO K6 NEUTRAL G10P BLK
START RELAY
ACC P21D RED
BAT
P21F RED
B12 RED
P23 RED
H9
RED
SEAT WARNING
IGN
Z36P GRY
SWITCH LIGHT
Z36B GRY
Z36C GRY
P21J RED
G10R BLK
Z37 GRY
Z36 GRY
H11
G10V BLK
ST H10
YELLOW ALARM
WARNING
P21H RED
G LIGHT
R31 BLK
P21C RED P21B RED
Z37 GRY
Z36 GRY
G10L
BLK
R31 BLK
ENG ALT VOLTS
M37A PUR
1 A
2 B
86 30 3 C
4 D
5 E
87A
M39B PUR
6 F
G10A BLK
85
87
M37B PUR
G10T BLK 11 F
12 E
TO G2
G10R BLK H8 13
14
D
C
ALTER-
P23 RED DISPLAY 15 B
ALTERNATOR MODULE 16 A
NATOR K7 RELAY 7 A
M37B PUR
8 B
1916SEP98
G10A G40A 9 C
G40 BLK
BLK BLK 10 D
W1 MACHINE FRAME/ENGINE
T117142
T117142
CED,TX17864,164 1910SEP981/1

022602
PN=309
Sub-System Diagnostics/Display Module and

Logic Module Circuit (S.N. 815415)
See Logic Module Test in Machine and Logic Module

Bench Test, in Group 9015-20.
TX,901515,QQ363 1910MAR971/1
Sub-System Diagnostics/Display Module and

9015 Logic Module Circuit (S.N. 815416872256)
15A
28
CED,TX17864,165 1910SEP981/1
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: Operational

fuse. Checkout complete.
Is fuse blown?
T7199BR 1916AUG90
1/1

022602
PN=310
Indicator Circuit Specifications (S.N.

872256)
Specification
Engine Coolant Temperature
Switch (Normally Open)Closing
Temperature ..................................................................... 103.4C (218F)
Engine Oil Pressure Switch
(Normally Closed)Opening
Pressure ........................................................... 3772 kPa (0.40.7 bar)
(5.510.5 psi)
Air Filter Restriction Switch
(Normally Open)Closes on
Increasing Vacuum at............................... 4.987.48 kPa (2030 in. H 2
O) Vacuum
Converter Oil Temperature Switch
(Normally Open)Closes on
Increasing Temperature ................................................ 114.3C121.2C
(238F252F) 9015
Hydraulic Filter Restriction Switch 15A
(Normally Open)Closing 29
Pressure ......................................................... 344 kPa (3.45 bar) (50 psi)
TX,9015,BG982 1901APR971/1
Indicator Circuit Operational Information

(S.N. 872256)
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

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

022602
PN=311
Indicator Circuit Theory of Operation (S.N.

815415) With Logic Module
Indicator lights and switches of the display module are:
Engine Coolant Temperature (Stop)

Engine Oil Pressure (Stop)
Engine Alternator Volts (Service Required)
Engine Air Filter (Service Required)
Converter Oil Temperature (Stop)
Hydraulic Oil Filter (Service Required)
STOP Warning Level:
Red STOP light ON, audible alarm ON and function

9015 indicator light ON.
15A
30 SERVICE Warning Level:
Yellow WARNING light and a function indicator light ON.
Bulb Check Mode:
Key switch in BULB CHECK position connects logic

module and display module to ground. The ground is
supplied to display module by key switch during BULB
CHECK. Power then flows through logic module and
display module to ground. Logic module is activated and
all display module lights and buzzer are checked.
Failure Mode:
During normal operation the indicator lights are turned on

when an indicator switch or the alternator relay provides a
ground circuit for the light. This ground circuit also signals
logic module and turns on red STOP light and alarm or
yellow SERVICE REQUIRED light.

Wiring and Schematic diagrams Legend, Group
9015-10.
TX,9015,QQ3189 1910MAR971/1

022602
PN=312


STOP Warning Level:
Red STOP light ON, audible alarm ON and function

indicator light ON. 9015
15A
SERVICE Warning Level: 31
Bulb Check Mode:
Key switch in BULB CHECK position connects warning

lights, buzzer and display module to ground. All display
module lights and buzzer are checked.
Failure Mode:

ground circuit for the light. This ground circuit turns on the
red STOP light and alarm or the yellow SERVICE
REQUIRED light.

Wiring and Schematic diagrams Legend, Group
9015-10.
TX,9015,QQ3190 1910MAR971/1

022602
PN=313


Seat Position (Stop)
STOP Warning Level:
9015 Red STOP light ON, audible alarm ON and function

15A indicator light ON.
32
SERVICE Warning Level:
Bulb Check Mode:
Key switch in BULB CHECK position connects warning

lights, buzzer and display module to ground. All display
module lights and buzzer are checked.
Failure Mode:

ground circuit for the light. This ground circuit turns on the
red STOP light and alarm or the yellow SERVICE
REQUIRED light.

9015-10.
TX,9015,BD2735 1910MAR971/1

022602
PN=314
Indicator Circuit Schematic With Logic Module (S.N. 815415)

GROUND CIRCUIT
G10 BLKSIDE CONSOLE HARNESS
G20 BLKROOF HARNESS
LOGIC G40 BLKFLOOR HARNESS
MODULE BATTERY POWER IN
POWER TO DISPLAY MODULE POWER FROM ALTERNATOR
SECONDARY FAILURE SIGNAL (TO A A
POWER IN FROM KEY SWITCH
B B
GROUND THROUGH INDICATOR SWITCH) C C YELLOW LIGHT GROUND (SWITCHED)
RED LIGHT ALARM GROUND (PULSED) D BULB CHECK (TO GROUND IN BULB
PRIMARY FAILURE SIGNAL IN (TO D E
AND START POSITION)
GROUND THROUGH INDICATOR SWITCH) F
GROUND
H7 A GROUND FROM S1
A B
LOGIC KEY SWITCH
B C
TERMINAL
MODULE C D
R31 BLK 9015
D E
F 15A
P21 RED
33
Z32 GRY
F14
Z32 GRY
G10 BLK
P23 RED
M37 PUR MONITOR
ENG ENG ENG ENG CONVTR HYD FUSE
COOLANT OIL ALT AIR OIL OIL
R31 BLK
TEMP PRESS VOLTS FILTER TEMP FILTER
GRY
Z32
1 A
2 B X36 YEL
V8 3
4
C
D
5 E
6 F Z32
GRY
N34 YEL
11 F
M38 PUR
H8
12
13
E
D B5
DISPLAY
14
15
C
B
ENGINE
MODULE
16 A COOLANT
7 A TEMPERATURE
TO K3
8
9
B
C
SWITCH
10 D
PARK M37 PUR M37 PUR
P23 RED
X38 YEL
LIGHT F15
RELAY UNSWITCHED B6
M37 PUR
HAZARD/ ENGINE OIL

M40 PUR
MONITOR PRESSURE
M39 PUR M39 PUR FUSE SWITCH
K7
F39 YEL
86 30
M39 PUR
P23 RED
ALTERNATOR 87A
RELAY 85
87 B8
G10 BLK CONVERTER
P23 RED OIL
W D+
B7 M40 PUR TEMPERATURE
AIR FILTER SWITCH
G RESTRICTION
B9
HYDRAULIC G01 BLK
SWITCH
1916SEP98
B+ FILTER
G02
BLK
RESTRICTION W1
G2 SWITCH MACHINE FRAME/
ALTERNATOR G01 BLK ENGINE BLOCK
G02 BLK GROUND/LEFT SIDE
T117143
T117143
CED,TX17864,166 1910SEP981/1

022602
PN=315
Indicator Circuit Schematic Without Logic Module (S.N. 815416825657)
GROUND CIRCUIT
F14 (WIRE COLOR) G01 BLKENGINE HARNESS
MONITOR G10 BLKSIDE CONSOLE HARNESS
FUSE P21 RED
G20 BLKROOF HARNESS
H9 G30 BLKFRONT CONSOLE HARNESS
RED WARNING G40 BLKENGINE HARNESS TO SIDE
P21 RED LIGHT
Z36 GRY
Z36 GRY H11
P21 RED ALARM
Z37 GRY
GROUND FROM S1
H10 KEY SWITCH
YELLOW WARNING
LIGHT TERMINAL
P21 RED
9015
Z36 GRY
15A
34 ENG ENG ENG ENG CONVTR
Z36 GRY
P21 RED
Z37 GRY
R31 BLK
COOLANT OIL ALT AIR OIL HYD
TEMP PRESS VOLTS FILTER TEMP OIL
FILTER
1 A
2 B X36 YEL
3 C
V8 4
5
D
E
6 F Z36 GRY
DISPLAY
MODULE
N34 YEL
DIODE 11 F
M38 PUR
12
13
E
D B5
H8 14
15
C
B
ENGINE
DISPLAY 16 A COOLANT
MODULE 7 A TEMPERATURE
X38 YEL
8 B
TO K3 9 C SWITCH
10 D
PARK M37 PUR
LIGHT
RELAY F15
M37 PUR
UNSWITCHED
HAZARD/
M40 PUR
F39 YEL
MONITOR
M39 PUR
FUSE B6
30
ENGINE OIL
K7 86
PRESSURE
M39 PUR
ALTERNATOR 87A SWITCH

P23 RED
RELAY 85
87
G10 BLK G10 BLK

B8
P23 RED
CONVERTER
W D+ B7 M40 PUR OIL
G AIR FILTER TEMPERATURE
RESTRICTION
B9 SWITCH
HYDRAULIC
B+
SWITCH FILTER
G01 BLK
G02 BLK RESTRICTION W1
G2
1916SEP98
SWITCH
ALTERNATOR G01 BLK
G02 BLK MACHINE FRAME/
ENGINE BLOCK
GROUND/LEFT SIDE
T117144
T117144
OUO1048,00003E0 1908SEP001/1

022602
PN=316
Indicator Circuit Schematic Without Logic Module (S.N. 825658872256)
F14 GROUND CIRCUIT G01 BLKENGINE HARNESS

MONITOR (WIRE COLOR) G10 BLKSIDE CONSOLE HARNESS
FUSE G20 BLKROOF HARNESS
P21 RED
H9 G40 BLKENGINE HARNESS TO SIDE
P21 RED RED WARNING CONSOLE HARNESS
LIGHT
Z36 GRY
Z36 GRY
H11
P21 RED ALARM GROUND FROM S1
Z37 GRY
KEY SWITCH
H10 TERMINAL
YELLOW WARNING
LIGHT
P21 RED
9015
Z36 GRY 15A
ENGINE ENGINE ENGINE ENGINE CONVERT HYDRAULIC 35
COOLANT OIL ALT. AIR OIL. OIL
Z37 GRY
H8
P21 RED
Z36 GRY
R31 BLK
TEMP. PRES. VOLTS FILTER TEMP. FILTER
DISPLAY
MODULE 1 A
2 B X36 YEL
3 C
TO S12 4 D
5 E
PARK 6 F Z36 GRY B5
BRAKE ENGINE
SWITCH COOLANT
(DASH) 11 F
TEMP.
12 E SWITCH
V8
N34 YEL
K3 13 D
DISPLAY PARK LIGHT 14 C
M32 PUR
15 B
MODULE RELAY 16 A (S.N. XXXXXX)
DIODE 7 A
T12 BLU
8 B
TO K6 9 C
10 D
86 30 NEUTRAL START
(S.N. XXXXXX )
X38 YEL
M37 PUR
S31 RELAY F15
SEAT
G01 BLK
UNSWITCHED
PUR
M37
SWITCH W2 HAZARD/ B6
F39 YEL
85 87A 87
GROUND TO MONITOR ENGINE OIL
G10 BLK
CAB FRAME FUSE PRESSURE
M39 PUR 86 30 SWITCH
M40 PUR
K7
P23 RED
M39 PUR
ALTERNATOR 85 87
87A
B8
RELAY CONVERTER
B7 G10 BLK G10 BLK
OIL TEMP.
P23 RED
W D
+ AIR FILTER M40 PUR SWITCH
G
RESTRICTION B9 G01
BLK
B+ SWITCH HYDRAULIC FILTER W1
MACHINE FRAME/
1916SEP98
G02 BLK RESTR. SWITCH

G2 G01BLK
ENGINE BLOCK
ALTERNATOR G02 BLK GROUND/LEFT SIDE
G10 BLK
T117145
T117145
OUO1048,00003E1 1908SEP001/1

022602
PN=317
Sub-System Diagnostics/Indicator Circuit

(S.N. 872256)
CED,TX17864,168 1910SEP981/1
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.
9015
Switch (S.N. 825657) NO: Switch is good. Go
15A
Without starting engine, turn key switch to BULB to next check.
36
CHECK, then release to ON.
Is engine coolant indicator light on?
T7199CG 1916AUG90
1/1
Switch (S.N. 825658 ) NO: Switch is good. Go
T107548 1925MAR97
1/1
Engine Coolant Disconnect connector from display module. YES: Indicator light is
Temperature Indicator good. Check wiring
Light Connect 12 volts to pin terminal 1 for Z33 gray wire. harness.
Ground pin terminal 2 for X36 yellow wire to machine
frame. NO: Check display
module. Replace bulb or
Is engine coolant temperature indicator light on? module.
T6877AB UN18OCT88
1/1

022602
PN=318
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
Engine Oil Pressure Disconnect connector from display module. YES: Indicator light is
Indicator Light good. Check wiring
9015
Connect 12 volts to pin terminal 1 for Z33 gray wire. harness.
15A
Ground pin terminal 3 for N34 yellow wire to machine
37
frame. NO: Check display
module. Replace bulb or
Is engine oil pressure indicator light on? module.
T6877AC UN18OCT88
1/1
Engine Alternator Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39 YES: Circuit is good.
Indicator Circuit purple wire. Repair or replace
alternator.
Without starting engine, turn key switch to BULB CHECK, then release to ON.
NO: Go to next check.
Is alternator indicator light off?
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

022602
PN=319
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
15A
38
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

022602
PN=320
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.

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
15A
39
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
1/1
MFWD Circuit Specifications (S.N. 872256)
Specification
MFWD Indicator Switch (Normally
Closed)Opening Pressure............................ 3772 KPa (0.40.7 bar)
(5.510.5 psi)
TX,9015,BG983 1901APR971/1

022602
PN=321
MFWD Circuit Operational Information

(S.N. 872256)
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 (S.N.

9015 872256)
15A
40
With the key switch ON or ACC position, power flows from
MFWD fuse to terminal 6 of MFWD switch. With MFWD
switch in OFF position, power flows out terminal 8 to
MFWD solenoid keeping MFWD solenoid energized.
Power also flows from terminal 5 to terminal 9 and out
terminal 10 to MFWD indicator switch. When MFWD
switch is in OFF position the solenoid is energized
maintaining reverser pressure keeping MFWD indicator
switch open.
With MFWD switch in ON position, power is removed from

terminal 8 of switch too solenoid. The solenoid is
de-energized, releasing reverser pressure and closing
MFWD indicated switch making light in MFWD switch to
come on.

9015-10.
TX,9015,QQ1744 1912MAR931/1

022602
PN=322
MFWD Circuit Schematic (S.N. 872256)
9015
15A
41
1923SEP92
T7828AG
TX,9015,QQ1830 1912MAR931/1

022602
PN=323
Sub-System Diagnostics/MFWD Circuit

(S.N. 872256)
CED,TX17864,1019 1904FEB991/1
MFWD Circuit Diagnostic Procedures
This circuit is powered by MFWD fuse.
1/1
MFWD Switch Disconnect harness from MFWD switch. YES: Switch is good. Go
to next check.
9015
With MFWD switch OFF, measure continuity between
15A
terminals 6 and 8. NO: Replace MFWD
42
switch.
With MFWD switch ON, measure continuity between

T7812AG UN16JUL92
terminals 6 and 8.
Continuity should NOT be measured?
1/1
MFWD Pressure Disconnect M31 purple wire from switch and ground to YES: Replace switch.
Indicator Switch frame.
NO: Switch is good.
Without starting engine, turn key switch to BULB Check wiring harness.
Is MFWD indicator light on?
T7835AS 1923SEP92
1/1
MFWD Solenoid Disconnect harness from MFWD solenoid. YES: Solenoid is good.
Connect battery voltage to solenoid terminal (B) of
connector and ground terminal (A) of connector. NO: Replace solenoid.
T7828AZ 1923SEP92
1/1

022602
PN=324
Differential Lock Circuit Operational

Information (S.N. 872256)
The following conditions must exist for differential lock

circuit to function.

Differential lock switch pedal depressed "ON"
Engine running
TX,9015,QQ1745 1912MAR931/1
Differential Lock Circuit Theory of Operation

(S.N. 872256) 9015
15A
43
With key switch ON or ACC position, power flows from
MFWD/ALT/DIFF Lock fuse to differential lock pedal.
When differential lock pedal is depressed power is routed
to the differential lock solenoid, energizing solenoid valve.
Pressure oil from the pump flows through the solenoid
valve to the rear axle engaging it for differential lock
operation.

9015-10.
TX,9015,QQ1746 1912MAR931/1

022602
PN=325
Differential Lock Circuit Schematic (S.N. 872256)
9015
15A
44
1923SEP92
T7828AH
TX,9015,QQ1747 1912MAR931/1

022602
PN=326
Sub-System Diagnostics/Differential Lock

Circuit (S.N. 872256)
CED,TX17864,1020 1904FEB991/1
Differential Lock Diagnostic Procedures
This circuit is powered by MFWD/alt/diff lock fuse.
1/1
Differential Lock Switch Disconnect harness from differential lock switch. YES: Switch is good. Go
to next check.
9015
With differential lock switch pressed, measure continuity
15A
between terminals A and B of connector. NO: Replace Differential
45
lock switch.
T7828AI 1923SEP92
1/1
Differential Lock Disconnect harness from differential lock solenoid. YES: Solenoid is good.
Solenoid Check wiring harness.
Connect ground to terminal (A) of connector on solenoid.
Apply voltage to terminal (B) of connector on solenoid. NO: Replace differential
lock solenoid.
T7828AZ 1923SEP92
1/1
Start Aid Circuit Operational Information

(S.N. 872256)
The following conditions must exist for start aid circuit to

function:
Key switch in IGN or ON position

Start aid switch depressed
TX,9015,BG984 1901APR971/1

022602
PN=327
Start Aid Circuit Theory of Operation (S.N.

872256)
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 G01 black
wire energizing solenoid.

9015-10.
9015
15A
46
TX,9015,QQ1751 1912MAR931/1

022602
PN=328
Start Aid Circuit Schematic (S.N. 872256)
9015
15A
47
1923SEP92
T7828AJ
TX,9015,QQ1752 1912MAR931/1

022602
PN=329
Sub-System Diagnostics/Start Aid Circuit

(S.N. 872256)
CED,TX17864,1022 1904FEB991/1
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
9015
With start aid button pushed, check for continuity
15A
between terminals with P12 red wire and E25 white wire. NO: Replace start aid
48
switch.
T7199BW 1916AUG90
1/1
Start Aid Solenoid NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into YES: Start aid solenoid is
engine. good. Check wiring
harness.
Key switch OFF.
NO: Replace start aid
Disconnect harness from solenoid. solenoid.
Connect battery voltage to terminal with E25 white wire.

Ground terminal with E27 white wire.

T7828AK 1923SEP92
1/1
Fuel Shut-Off Circuit Operational Information

(S.N. 872256)
The following conditions must exist for fuel shut-off circuit

to function:
TX,9015,BG985 1901APR971/1

022602
PN=330
Fuel Shut-Off Circuit Theory of Operation

(S.N. 872256)

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
15A
49
TX,9015,BG986 1901APR971/1

022602
PN=331
Fuel Shut-Off Circuit Schematic (S.N. 872256)
9015
15A
50
1912DEC90
T7418AZ
TX,901515,QQ825 1912MAR931/1

022602
PN=332
Sub-System Diagnostics/Fuel Shut-Off

CED,TX17864,1023 1904FEB991/1
Fuel Shut-Off Circuit Diagnostic Procedures
1/1
Injection Pump Fuel Connect battery voltage to solenoid P12 red wire YES: Solenoid is good.
Shut-Off Solenoid terminal. Check wiring harness.
9015
15A
Does solenoid "click"? NO: Replace fuel shut-off
51
solenoid.
Remove voltage from terminal.
Does solenoid "click" again?

T6785AG UN18OCT88
1/1

022602
PN=333
Reverse Alarm Circuit Operational

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
Reverse Alarm Circuit Theory of Operation

9015 (S.N. 872256)
15A
52
Power flows from fuel shutoff/start aid/reverse alarm fuse
to reverse alarm relay terminal 30. When FNR lever is
moved into reverse, power flows through shift controller to
terminal 86 of reverse alarm relay, energizing relay.
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,BG987 1901APR971/1

022602
PN=334
Reverse Alarm Circuit Schematic (S.N. 872256)
9015
15A
53
1916SEP93
T8077AF
TX,9015,QQ1756 1906OCT931/1

022602
PN=335
Sub-System Diagnostics/Reverse Alarm

CED,TX17864,1024 1904FEB991/1
Reverse Alarm Circuit Diagnostic Procedures
This circuit is powered by the fuel shut-off/start aid/reverse alarm fuse.
1/1
9015
15A
54

022602
PN=336
Shift Controller YES: Go to next step in

this check.
NO: Check wiring

harness, if OK replace
shift controller.
9015
T8077AO 1916SEP93 15A
55
Key switch ON. Harness connected.
Check voltage on pin (A) at connector 4
Check voltage on pin (A) at connector 2.
YES: Go to next check.
NO: Check wiring

shift controller.
T8077AP 1916SEP93
Key switch ON. Harness connected. FNR in reverse.
Check voltage on pin (C) at connector 4.
Check voltage on pin (C) at connector 2.
1/1

022602
PN=337
FNR/Range Lever Switch YES: Go to next check.
NO: Check wiring

shift controller.
9015
15A T7828AC UN09MAR93
56
Key switch ON. Harness connected. FNR in reverse.
Check voltage at terminals with red wire and pink wire.
1/1
Reverse Alarm Relay Key switch OFF. YES: Relay is good.

NO: Replace reverse
Connect battery voltage to terminal #86. Ground terminal alarm relay.

T7287BH UN16AUG90
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

022602
PN=338
Dome Light Circuit Operational Information

(S.N. 872256)
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

(S.N. 872256) 9015
15A
57
Power from key switch ACC terminal flows through
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

022602
PN=339
Dome Light Circuit Schematic (S.N. 872256)
9015
15A
58
1923SEP92
T7828AP
TX,9015,QQ1763 1912MAR931/1

022602
PN=340
Sub-System Diagnostics Dome Light Circuit

(S.N. 872256)
CED,TX17864,1025 1904FEB991/1
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
9015
Turn dome light/swivel light switch ON.
15A
NO: Replace switch.
59
Using a multimeter check continuity at switch terminals
for dome and swivel light switch.
Does multimeter read continuity?

T6622BB UN09DEC88
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

022602
PN=341
Radio Circuit Operational Information

(S.N. 872256)
The following condition or conditions must exist for radio

Key switch in ACC or ON position

Radio turned ON
TX,9015,QQ1769 1912MAR931/1
Radio Circuit Theory of Operation (S.N.

9015 872256)
15A
60
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.
TX,9015,QQ1770 1931AUG951/1

022602
PN=342
Radio Circuit Schematic (S.N. 872256)
9015
15A
61
1923SEP92
T7828AS
TX,9015,BG988 1901APR971/1

022602
PN=343
Sub-System Diagnostics/Radio Circuit

(S.N. 872256)
CED,TX17864,1026 1904FEB991/1
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.

9015
NO: Check wiring
15A
harness between radio
62
and fuses.
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

022602
PN=344
Wiper/Washer Circuit Operational Information

(S.N. 872256)
The following conditions must exist for wiper/washer

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 (S.N. 872256)

9015
Power flows from wiper/washer fuse through wires P14 Rear wiper in HIGH position, power flows from rear 15A
red to terminal 3 on front wiper switch, terminal 1 of wiper switch terminal 1 through A66 orange wire to 63
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

022602
PN=345
Wiper/Washer Circuit Schematic (S.N. 872256)
9015
15A
64
1923APR97
T7828AQ
TX,9015,QQ1765 1912MAR931/1

022602
PN=346
Sub-System Diagnostics/Wiper/Washer
CED,TX17864,1027 1904FEB991/1
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
9015
Disconnect harness from front wiper switch. check.
15A
65
Measure for continuity between terminals 2 and 4, 6 and NO: Replace front wiper
8, 1 and 3, and 5 and 7. switch.
T7199CA UN02OCT90
1/1
Wiper Motor LH Door Disconnect harness from wiper motor. YES: Go to next check.
and RH DoorLow
Speed Connect battery voltage to terminal with red wire and NO: Replace wiper motor.
yellow wire. Ground terminal with black wire.
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

022602
PN=347
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.
15A
66
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.
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

022602
PN=348
Windshield Washer Disconnect harness from washer motor. YES: Washer motor is
Motor good. Check wiring
Connect battery voltage to terminal with S71 orange harness.
wire. Ground motor.
NO: Replace washer
Does motor run and operate the pump? motor.
T7199CF 1916AUG90
1/1
9015
15A
67

022602
PN=349
Blower Circuit Operational Information

(S.N. 872256)
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 (S.N.

9015 816286)
15A
68
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 1910MAR971/1

022602
PN=350
Blower Circuit Schematic (S.N. 816286)
9015
15A
69
1930SEP92
T7857AD
TX,9015,BG989 1902APR971/1

022602
PN=351

816287872256)

With blower switch in positions 1, 2, or 3 power is sent to
blower resistor reducing blower motor speed. With blower
switch in position 4 the resistor is bypassed and blower
motor will run in max. speed.
TX,9015,BD2734 1907MAR971/1
9015
15A
70

022602
PN=352
9015
15A
71
1922APR97
T101441
TX,901515,QQ809 1910MAR971/1

022602
PN=353
Sub-System Diagnostics/Blower Circuit

(S.N. 872256)
CED,TX17864,1028 1904FEB991/1
1 Blower Circuit Diagnostic Procedures
This circuit is powered by the heater circuit breaker.
1/1
Blower Switch (S.N. Disconnect harness from blower switch. YES: Blower switch is
816286) good.
9015
Use a multimeter and check for continuity.
15A
NO: Replace blower
72
Move blower switch to LOW, MEDIUM and HIGH switch.
checking terminals B and L, B and M, and B and H.
T7199CL UN17SEP90
1/1
Blower Switch (S.N. YES: Blower switch is

816287 ) good. Go to next check.
NO: Replace blower

switch.
T109254 1924APR97
Disconnect harness from blower switch.
Using a multimeter check for continuity.
Move blower switch to position, 1, 2, 3, and 4 checking terminals B and 1, B and 2, B

and 3, B and 4)
1/1

022602
PN=354
Blower Resistor (S.N. Measure ohms between terminals 3 and 1. YES: Resistor is good.
816286) Check wiring harness.
Does ohmmeter read 1.0 ohms.
NO: Replace resistor.
Measure ohms between terminals 3 and 2)
Does ohmmeter read 0.5 ohms?
T6534CR UN19OCT88
1/1
Blower Resistor (S.N. Measure ohms between terminals 4 and 2. YES: Resistor is good.
816287 ) Check wiring harness.
9015
15A
73
T102849 UN06AUG96
1/1
Heater Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
motor is good. Check
Connect 12 volts to heater blower motor, and ground wiring harness.
motor.
NO: Replace heater
Does heater blower motor operate? blower motor.
T7199CM UN16AUG90
1/1

022602
PN=355
Drive and Work Light Circuit Operational

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

9015 Operation (S.N. 872256)
15A
74
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.

9015-10.
TX,9015,QQ1767 1912MAR931/1

022602
PN=356
Drive and Work Light Circuit Schematic (S.N. 872256)
9015
15A
75
1923SEP92
T7828AR
TX,9015,QQ1768 1912MAR931/1

022602
PN=357
Sub-System Diagnostics/Drive and Work

Light Circuit (S.N. 872256)
CED,TX17864,1029 1904FEB991/1
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.
15A
76
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

022602
PN=358
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

Specifications (S.N. 872256) 9015
15A
Specification 77
Park Brake Sensing Switch
(Normally Closed)Closes on
Pressure Decrease ..................................... 5516 kPa (55.2 bar) (800 psi)
Opening Pressure ......................................... 7585 689 (75.9 6.9 bar)
(1100 100 psi)
TX,9015,QQ1785 1912MAR931/1

Operational Information (S.N. 872256)
The following condition or conditions must exist for park

brake/neutral disconnect circuit to function:
Key switch OFF

Park brake dash switch in ON position with machine
running
Machine mechanically shut down
TX,9015,QQ1776 1912MAR931/1

022602
PN=359
Park Brake/Neutral Disconnect Circuit Theory of Operation (S.N. 872256)
The Park Brake/Neutral Disconnect Circuit consists of When the park brake is applied (ON position) the park
FNR/park brake fuse, park brake dash switch, park brake sensing switch closes providing a ground for the
brake latching relay, FNR/range switch, shift controller, park brake dash switch light and seat belt light. Power
park brake solenoids, neutral disconnect switch, is removed from park brake solenoids and neutral
neutral disconnect solenoid, park light relay, park disconnect solenoid de-energizing solenoids.
brake sensing switch and seat belt light.
Key ON:
NOTE: The park brake applies automatically when Park Brake Dash Switch in ON position.
machine is mechanically shut down or when FNR Lever Shifted Out of Neutral:
key switch is turned off. Park brake dash
switch must be cycled first to applied position With the park brake dash switch ON, and the FNR
(ON), then to released position (OFF) before lever shifted out of neutral the park light relay K3 is
park brake can be released when engine is de-energized connecting terminals 30 and 87A causing
running. red light and alarm to come ON.
9015
15A
78 Key OFF: Key ON:
Engine running.
Park brake cannot be hydraulically released if there is
a blown fuse or key switch is OFF. With machine mechanically shut down, ground from
the starter motor (S) terminal is removed from terminal
Key ON: 86 of park brake latching relay de-energizing relay.
Park Brake Dash Switch in ON Position. Terminals 30 and 87A are connected removing power
FNR Lever in Neutral: from terminals 6 and 8 of park brake dash switch,
de-energizing park brake solenoids and neutral
Power flows from terminal 1 to terminal 6 of park brake disconnect solenoid. Park brake is applied.
dash switch and then to park brake latching relay
terminal 85, energizing relay K5 causing it to latch NOTE: For component identification code description,
terminals 30 and 87. Ground is supplied to the park see Wiring and Schematic Diagrams Legend,
brake latching relay terminal 86 from the (S) terminal Group 9015-10.
of starter motor.
TX,9015,QQ1775 1912MAR931/1

022602
PN=360
Park Brake/Neutral Disconnect Circuit Schematic (S.N. 815415)

GROUND CIRCUIT G01 BLKENGINE HARNESS
ON 9 PARK (WIRE COLOR) G10 BLKSIDE CONSOLE HARNESS
OFF 0 BRAKE G20 BLKROOF HARNESS
SWITCH G30 BLKFRONT CONSOLE HARNESS
10 5 1 6 8
CONSOLE HARNESS
F9 P24 RED
J27 TAN
FNR/PARK
J27 TAN
BRAKE K5 K3
FUSE
P24 RED K6
J25 TAN PARK BRAKE PARK NEUTRAL
P24 RED V11 86 30 LATCHING LIGHT START
PARK RELAY RELAY RELAY
J27 TAN
P24 RED BRAKE T12 BLU
T12 BLU
RELAY
S12 DIODE
85 87A 87
86 30 86 30
PARK BRAKE
E02 WHT 9015
SWITCH (DASH) 15A
M32 PUR 85 87A 87 79
85 87A 87
1 7 2 10
P24 RED
8
P24 RED
ON
OFF G01 BLU TO H7
Z32 GRY
M38 PUR LOGIC
M3 2 PUR
1 0
MODULE
Z32 GRY
TO H8
J2 0 TAN
Z32 GRY DISPLAY

MODULE
T12 BLU
5 6 9 P24 RED
J20 TAN
D C B A A1
P24 RED GRN SHIFT
J27 TAN
P24 RED GRN CONTROLLER
E02 WHT
E15 S
86 30
SEAT BELT B
M32 PUR
87A
LIGHT
M1 85 87
STARTER TIME
RED
86 30
M MOTOR DELAY
CIRCUIT 87A
85 87
RED
PUR
M32
GRY D
FNR 86 30 86 30
C
N
R F R N F 87A 87A
B
B2 RED A 85 87 85 87
G01 BLK
PARK S11 GRN

BRAKE RANGE FNR/RANGE GRN
SENSING 1
2 3
4 SWITCH
A B C D
SWITCH G01 T53 BLU

J27
TAN
BLK
J27 TAN
S13 NEUTRAL T52 BLU V2 J27 TAN

Y7 PARK
J27
DISCONNECT NEUTRAL BRAKE
TAN
Y4 Y14
W2
G01
BLK
SWITCH PARK PARK

1916SEP98
GROUND DISCONNECT SOLENOID

T52
SOLENOID BRAKE BRAKE
TO CAB V5 NEUTRAL BLU DIODE G04
SOLENOID
DISCONNECT G01
BLK SOLENOID
FRAME BLK G04
SOLENOID DIODE BLK
T117146
T117146 G01 BLK G01 BLK G04 BLK
CED,TX17864,169 1910SEP981/1

022602
PN=361
G01 BLKENGINE HARNESS

ON 9 GROUND CIRCUIT
PARK G10 BLKSIDE CONSOLE HARNESS
(WIRE COLOR)
10 5 1 6 8 SWITCH G30 BLKFRONT CONSOLE HARNESS
CONSOLE HARNESS
F9 P24 RED
J27 TAN
FNR/PARK J27 TAN
BRAKE P24 RED K5 K3 K6
FUSE PARK BRAKE PARK NEUTRAL
P24 RED V11 86 30 LATCHING LIGHT START
J2 7 TAN
P24 RED BRAKE T12 BLU T12
RELAY BLU
S12 DIODE
85 87A 87
86 30 86 30
9015 PARK BRAKE
E02 WHT
15A SWITCH
80 M32 PUR
85 87A 87 87
85 87A
1 7 2 8 10
P24 RED
P24 RED
ON
OFF G01 BLU
TO H7
M38 PUR RED WARNING
1 0
M32 PUR
Z36 GRY LIGHT H11 ALARM

Z32 GRY TO H8
Z36 GRY DISPLAY
J20 TAN
MODULE
T12 BLU
5 6 9 P24 RED
J20 TAN
D C B A A1
P24 RED GRN
SHIFT
J27 TAN
P24 RED GRN
CONTROLLER
E02 WHT
E15 S
86 30
SEAT BELT B
M32 PUR
87A
LIGHT
M1 85 87
STARTER TIME
RED
86 30
M MOTOR DELAY
CIRCUIT 87A
85 87
RED
TAN
M32
GRY D
FNR 86 30 86 30
C
N
R F R N F 87A 87A
B
B2 RED A 85 87 85 87
G01 BLK
PARK S11 GRN

BRAKE RANGE
FNR/RANGE GRN
A B C D
SENSING 1
2 3
4 SWITCH
SWITCH G01
T53 BLU
J27
BLK TAN
J27 TAN
S13 NEUTRAL T52
BLU
V2 J27 TAN
DISCONNECT Y7 PARK J27
Y4
SWITCH BRAKE
TAN Y14
W2 NEUTRAL PARK
1916SEP98
PARK
G01
BLK
GROUND DISCONNECT SOLENOID BRAKE

V5 NEUTRAL T52 DIODE G04 BRAKE
TO CAB BLU SOLENOID BLK SOLENOID SOLENOID
DISCONNECT
FRAME SOLENOID DIODE
G01
BLK G04 BLK
T117147
CED,TX03610,131 1919MAR991/1

022602
PN=362
GROUND CIRCUIT G01 BLKENGINE HARNESS

ON 9 PARK G10 BLKSIDE CONSOLE HARNESS
(WIRE COLOR)
10 5 1 6 8 SWITCH G30 BLKFRONT CONSOLE HARNESS
CONSOLE HARNESS
P24C RED
J27 TAN
F9 J27 TAN
FNR/PARK P24C RED K5 K3 K6
BRAKE J25 TAN PARK BRAKE PARK NEUTRAL
FUSE V11 LATCHING LIGHT START
86 30
J27 TAN
P24C RED BRAKE T12A BLU
RELAY M0IB T12
S12 DIODE
85 87A 87 PUR BLU
PARK BRAKE 86 30 9015
E2B WHT 86 30
SWITCH 15A
M32A PUR 81
P24B RED
P24A RED
ON 1 7 2 8 10
85 87A 87
85 87A 87
OFF
G10R BLK
1 0 TO H9 RED
M32 PUR
M0IA
PUR WARNING
Z36D GRY LIGHT
J20B TAN
S31 H11 ALARM

G10 SEAT T12 BLU
BLK P24A RED
5 6 9 SWITCH
J20B TAN
D C B A A1
P24E RED SHIFT
J2 7 TAN
GRN
P24F RED W2 GRN
CONTROLLER
E02 WHT GROUND
E15 TO CAB
S
SEAT BELT B FRAME 86 30
M32C PUR
87A
LIGHT
M1 85 87
STARTER
RED
TIME 86 30
M MOTOR DELAY
CIRCUIT 87A
RED
85 87
PUR
M32
GRY D
FNR 86 30 86 30
C
N
R F R N F 87A 87A
B
B2 RED A 85 87 85 87
G10 BLK
PARK S11 GRN

BRAKE RANGE
FNR/RANGE GRN
SENSING 1
2 3
4 SWITCH
A B C D
SWITCH G01
T53 BLU
J27
TAN
BLK
J27 TAN
S13 NEUTRAL T52
BLU
V2 J27 TAN
DISCONNECT Y7 PARK J27

TAN Y4 Y14
W2 SWITCH NEUTRAL BRAKE PARK PARK
G01
BLK
1916SEP98
GROUND DISCONNECT SOLENOID BRAKE BRAKE

V5 NEUTRAL T52
SOLENOID DIODE G04
SOLENOID
TO CAB DISCONNECT BLU BLK SOLENOID
FRAME G01
SOLENOID DIODE BLK G04 BLK
T117148
CED,TX03610,132 1919MAR991/1

022602
PN=363
Sub-System Diagnostics/Park Brake/Neutral

Disconnect Circuit (S.N. 872256)
TX,9015,QQ3282 1910MAR971/1
Park Brake/Neutral 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
9015
Park brake switch OFF. harness.
15A
82
Check for continuity between terminals 5 and 7, and 6 NO: Replace park brake
and 8. switch.
T7199CS UN16AUG90
Park brake switch ON.
Check for continuity between terminals 5 and 1, and 6

and 2.
1/1
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

022602
PN=364
Park Brake Solenoids Key switch OFF. YES: Solenoid is good.

Disconnect harness from park brake solenoids.
Connect battery voltage to solenoid connector terminal B
with red wire and ground connector terminal A with black
wire.

T7828AZ 1923SEP92
1/1
Park Light Relay Key switch OFF. YES: Relay is good.

9015
15A
NO: Replace relay.
83
#85.
Does relay click?

T7287BH UN16AUG90
1/1
Park Brake Sensing YES: Go to next check.

Switch
NO: Replace park brake
sensing switch.
T7835AC 1923SEP92
Key switch OFF.
Disconnect harness from switch connector.
Measure for continuity between terminals B and C.
1/1

022602
PN=365
Seat Position Sensor Key switch OFF. YES: Seat position

sensor is good. Check
Seat in loader function position. wiring harness.
NOTE: Seat position sensor is located in the operators NO: Replace seat
seat base. position sensor.
Check for continuity between terminals with M1 purple

T102968 1912AUG96
wire and G10 black wire.
Is continuity NOT measured?
Move seat into backhoe function position.

wire and G10 black wire.
9015
15A
84
1/1
Shift Controller Bench YES: Go to next check.

Test
NO: Replace shift
controller.
T8077AJ 1916SEP93
Disconnect connectors 15 at shift controller and remove shift controller.
IMPORTANT: Connect voltage leads to correct pins, or damage to controller can

occur.
Check continuity at connectors 2 and 3 between pins A of both connectors, then D.
Set multimeter on diode test.
Check value at connectors 2 and 3 between pins B of both connectors, then C.
Is 0.40.8 value measured?
1/1

022602
PN=366
FNR/Range Lever YES: Go to next step in

this check.
NO: Check wiring

harness.
9015
T7828AC UN09MAR93 15A
85
Key switch ON. FNR/range lever in neutral
With harness connected, check voltage at terminals with red wire and gray wire.
YES: FNR lever is good.

Go to next check.
T7828AD UN09MAR93
Key switch ON.
With harness connected, and FNR/range lever moved to forward, check voltage at
terminal with yellow wire.
Move FNR/range lever to reverse, check voltage at pink wire.
1/1

022602
PN=367
Neutral Disconnect Disconnect harness from neutral disconnect switch. YES: Switch is good.
Switch Check wiring harness.
Check for continuity between terminals with T52 blue
wire and T53 blue wire. NO: Replace neutral
disconnect switch.
Depress loader lever switch and check for continuity

between terminals with T52 blue wire and T53 blue wire.
T7835AB 1923SEP92
1/1
Neutral Disconnect Key switch OFF. YES: Solenoid is good.

Solenoid Check wiring harness.
9015
Disconnect harness from neutral disconnect solenoid.
15A
86
Connect battery voltage to solenoid terminal B, and
ground terminal A.

T7828AZ 1923SEP92
1/1
FNR/Range Control Circuit Operational

The following conditions must exist for FNR/range control

Key switch ON
Power to FNR/park brake fuse
Power to Shift Controller
FNR/range switch in NEUTRAL position to allow for
engine starting
TX,9015,DY666 1916AUG961/1

022602
PN=368
FNR/Range Control Circuit Theory of Operation (S.N. 872256)
The FNR/range control circuit consists of FNR/park FNR in Neutral:

brake fuse, shift controller, FNR/range switch, neutral Park Brake Cycled OFF:
start relay, reverse solenoid, forward solenoid, neutral
disconnect solenoid, neutral disconnect switch, C1/B2 With FNR/range switch in first neutral NO solenoids
solenoid and C2/B3 solenoid. are energized. Power is routed from FNR to neutral
start relay through T12 blue wire energizing relay and
With the key switch in the ON or START position, sending power to start relay and starter motor allowing
power is routed through the FNR/park brake fuse to for engine starting. Power from P24 red wire is also
the shift controller and FNR/range switch through P24 sent to terminal 86 of neutral disconnect relay in shift
red wire. controller, when in neutral and after .5 seconds the
time delay in shift controller removes the ground from
The FNR/range switch directs the transmission to terminal 85 of relay de-energizing neutral disconnect
operate in one of four forward gear ranges and two solenoid. When in neutral and park brake switch is
reverse gear ranges. Selecting 1, 2, 3 or 4 speed cycled off power is routed through J27 tan wire to
9015
range in forward or 1 or 2 speed range in reverse is terminal 30 of neutral disconnect relay in shift 15A
controlled by rotating the end of the FNR/range lever. controller and stops. Power is sent from range switch 87
When the transmission is operating, five solenoids in through blue and red wire to shift controller energizing
the transmission control valve provide pilot operation relay in shift controller, removing power on green and
for four spools. T15 blue wire to C2-B3 solenoid.
The following chart shows the solenoids that are 2ND Neutral:
energized to obtain the transmission speeds.
With FNR/range switch in 2nd neutral the C2/B3
SOLENOIDS ENERGIZED solenoid is energized. Power is removed from blue and
N C2-B3 FWD C1-B2 REV red wire from range switch and shift controller,
1st Forward X X de-energizing relay in shift controller sending power to
2nd Forward X X X
C2-B3 solenoid through green and T15 blue wire
energizing solenoid.
3rd Forward X X X
4th Forward X X X X 3RD Neutral:
1st Neutral
2nd Neutral X With FNR/range switch in 3rd neutral the C1/B2
3rd Neutral X solenoid is energized. Power from the range switch is
4th Neutral X X
routed through green and red wire to shift controller,
out shift controller through green and T14 blue wire to
1st Reverse X X
C1/B2 solenoid, energizing solenoid.
2nd4th X X X
Reverse
1ST Neutral:
Key Switch ON:

022602
PN=369
4TH Neutral: 4TH Forward
With FNR/range switch in 4th neutral the C2/B3 and With FNR/range switch in fourth forward, the forward
C1/B2 solenoids are both energized. Power from the solenoid, neutral disconnect solenoid and C2-B3
range switch is routed through green and red wire to solenoid and C1-B2 solenoid are energized. Power
shift controller, out shift controller through green and from range switch is routed through green and red wire
T14 blue wire to C1/B2 solenoid. Power is also routed to shift controller, out shift controller through green and
through blue and red wire to shift controller, out shift T14 blue wire to C1/B2 solenoid. Power is also routed
controller through green and T15 blue wire to C2/B3 through blue and red wire to shift controller, out shift
solenoid, energizing solenoid. controller through green and T15 blue wire to C2/B3
solenoid, energizing solenoid.
1ST Forward
1ST Reverse
With FNR/range switch in first forward the forward
solenoid and neutral disconnect solenoid are With FNR/range switch in first reverse, the neutral
energized. Power from the FNR/range switch is routed disconnect solenoid and reverse solenoid are
9015
15A through yellow and blue wire to shift controller, out energized. Power from FNR switch is routed through
88 controller through green and T11 blue wire to forward pink and red wire to shift controller, out shift controller
solenoid, energizing solenoid. Power is routed through through T13 blue wire. T13 blue wire sends power to
J27 tan wire to terminal 30 and 87 of relay in shift reverse alarm relay, activating alarm and sending
controller sending power to neutral disconnect power to reverse solenoid, energizing solenoid. Power
solenoid, energizing solenoid. Power is sent from is sent from range switch through blue and red wire to
range switch through blue and red wire to shift shift controller energizing relay in shift controller,
controller energizing relay in shift controller, removing removing power on green and T15 blue wire to C2-B3
power on green and T15 blue wire to C2-B3 solenoid. solenoid, de-energizing solenoid.
2ND Forward 2ND Reverse
With FNR/range switch in second forward, the forward With FNR/range switch in second reverse, the neutral
solenoid, neutral disconnect solenoid and C2-B3 disconnect solenoid, reverse solenoid and C2-B3
solenoid are energized. Power from range switch is solenoid are energized. Power is routed through pink
removed from blue and red wire to shift controller and red wire from FNR switch to shift controller, out
de-energizing relay in shift controller supplying power shift controller through T13 blue wire. T13 blue wire
to C2-B3 solenoid through green and T15 blue wire sends power to reverse solenoid, energizing solenoid.
energizing solenoid. Power from range switch is removed from blue and red
wire to shift controller de-energizing relay in shift
3RD Forward controller, supplying power to C2-B3 solenoid through
green and T15 blue wire.
With FNR/range switch in third forward, the forward
solenoid, neutral disconnect solenoid and C1-B2 In 3RD and 4TH position of range selector switch for
solenoid are energized. Power from range switch is reverse, the shift controller continues to supply power
routed through green and red wire to shift controller, through green wire and T15 blue wire to C2-B3
out shift controller through green and T14 blue wire to solenoid, energizing solenoid.
C1-B2 solenoid, energizing solenoid.
TX,9015,QQ1799 1912MAR932/2

022602
PN=370
FNR/Range Control Circuit Schematic (S.N. 872256)
9015
15A
89
1916SEP93
T8077AH
TX,9015,QQ1797 1906OCT931/1

022602
PN=371
Sub-System Diagnostics/FNR/Range Control

CED,TX17864,1030 1904FEB991/1
FNR/Range Control Circuit Diagnostic Procedures
This circuit is powered by the FNR/park brake fuse.
1/1
Transmission Solenoids Harness connected to solenoids YES: Solenoid is good.

9015
Key switch ON. NO: Check wiring
15A
harness.
90
NOTE: Solenoid will click as power is applied.
FNR/Range Lever in fourth forward (4F)
T8077AI UN14SEP93
Touch neutral, C2-B3, forward and C1-B2 solenoid with
metal object (Screwdriver).
Does solenoid click? Is solenoid magnetized?
FNR/Range Lever in first reverse (1R).
Touch reverse solenoid with screwdriver.
Does solenoid click? Is solenoid magnetized?
1/1

022602
PN=372
FNR/Range Lever YES: FNR/range switch is

good. Check wiring
harness.
NO: Replace FNR/range

switch.
9015
T7835AM UN09MAR93 15A
91
T7835AN UN09MAR93
Disconnect FNR/range switch from shift controller.
FNR in neutral, check continuity between pins (A and D) at female connector.
FNR in forward, check continuity between pins (A and B) at female connector.
FNR in reverse, check continuity between pins (A and C) at female connector.
Range selector in 3rd, check continuity between pin A at female connector and pin B
at male connector.
Range selector in 1st, check continuity between pin A at female connector and pin C
at male connector.
Range selector in 4th, check continuity between pin A at female connector with pin B
and C at male connector.
1/1

022602
PN=373
Shift Controller
Emergency Bypass
Operation
9015
15A T8095AB 1901OCT93
92
NOTE: Use this procedure for diagnostic testing only. Do not operate machine for
extended periods with out shift controller.
T8090AF 1930SEP93
Disconnect connectors at shift controller below steering column.

Connect FNR/range lever connectors to front console harness connectors.
NOTE: With shift controller out of the circuit the machine will operate in speeds other
than indicated on FNR/range lever.
FNR/RANGE LEVER INDICATOR TRANSMISSION ENGAGEMENT

1st Forward 2nd Forward
2nd Forward 1st Forward
3rd Forward 3rd Forward
4th Forward 4th Forward
1st Reverse 2nd Reverse
2nd Reverse 1st Reverse
3rd Reverse 1st Reverse
4th Reverse 2nd Reverse
1/2

022602
PN=374
Start and operate machine. YES: Connect connectors

at shift controller and
Does problems still exist? check wiring harness.
NO: Go to Shift Controller

Bench Test.
19 2/2
Shift Controller Bench YES: Go to next step in

Test this check.
NO: Replace shift

controller.
9015
15A
93
T8077AJ 1916SEP93
Disconnect connectors 15 at shift controller and remove shift controller.

occur.
Check continuity at connectors 2 and 3 between pins A of both connectors, then D.
Check value at connectors 2 and 3 between pins B of both connectors, then C.
1/4

022602
PN=375
YES: Go to next step in

this check.
NO: Replace shift

controller.
9015
15A T8077AK 1916SEP93
94
Connect pins A and D on connector 4 to multimeter.
Ground pin A of connector 5.

occur.
Apply 12 volts to pin A of connector 3.
Is a value momentarily measured and relay click ON and OFF?
19 2/4

022602
PN=376

this check.
NO: Replace shift

controller.
9015
T8077AL 1916SEP93 15A
95

occur.
Apply 12 volts on pin C of connector 2 and ground pin A of connector 5. Check value
between pin C of connector 4 and pin B of connector 1.

this check.
NO: Replace shift

controller.
T8077AM 1916SEP93

occur.
Apply 12 volts on pin B of connector 2 and ground pin A of connector 5. Check value
between pin C of connector 4 and pin C of connector 1.
19 3/4

022602
PN=377
YES: Shift controller is

good. Check wiring
harness.
NO: Replace shift

controller.
9015
15A T8077AN 1916SEP93
96
Disconnect voltage from shift controller.
Check value between pin C of connector 4 and pin A of connector 2.

occur.
Apply 12 volts on pin C of connector 1 and ground pin A of Connector 5.
Check value between pin C of connector 4 and pin A of connector 2.
Does relay click and a value greater than 0.8 measured?
19 4/4
Neutral Disconnect Disconnect harness from neutral disconnect switch. YES: Switch is good.
Switch Check wiring harness.
Check for continuity between terminals with T52 blue
wire and T53 blue wire. NO: Replace neutral
disconnect switch.

T7835AB 1923SEP92
between terminals with T52 blue wire and T53 blue wire.
1/1

022602
PN=378
9015
15A
97

022602
PN=379
Horn Circuit Operational Information (S.N.

872256)
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 (S.N.

9015 872256)
15A
98
Power flows from turn/stop/horn fuse to horn switch.
When horn button is pushed, switch closes and power
flows to activate horn.

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

022602
PN=380
Horn Circuit Schematic (S.N. 872256)
9015
15A
99
1923SEP92
T7835AE
TX,9015,QQ1787 1912MAR931/1

022602
PN=381
Sub-System Diagnostics/Horn Circuit (S.N.

872256)
CED,TX17864,1031 1904FEB991/1
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.
9015
Push horn switch and measure for continuity.
15A
NO: Replace horn switch.
,100
T7199CY UN16AUG90
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
Turn Signal, Flasher and Brake Light Circuit Operational Information (S.N. 872256)
The following conditions must exist for turn signal, Key switch in ON position
flasher and brake light circuit to function:
TX,9015,QQ1822 1912MAR931/1

022602
PN=382
Turn Signal, Flasher and Brake Light Circuit

Power flows from turn/stop/horn fuse, to terminal 8 of

4-way flasher switch. With 4-way flasher switch in OFF
position power flows from terminal 6 to terminal 5 of turn
signal switch. Power also flows from unswitched
hazard/monitor fuse to terminal 2 of 4-way flasher switch.
Power flows from terminal 6 of 4-way flasher switch to
flasher energizing flasher.
Turn Signal:
With power on terminal 5 of turn signal switch and turn

signal switch turned left, pulsing power is sent from
flasher through L49 brown wires to terminal 6 of turn 9015
signal switch and out terminal 7 to left turn lights and left 15A
turn indicator light making them flash. Power is also sent ,101
out terminal 3 of turn signal switch lighting up right turn
lights and right turn indicator light.
With power on terminal 5 of turn signal switch and turn

signal switch turned right, pulsing power is sent from
flasher through L49 brown wires to terminal 6 of turn
signal switch and out terminal 3 to right turn lights and
right turn indicator light making them flash. Power is also
sent out terminal 7 of turn signal switch lighting up left
turn lights and left turn indicator light.
4-Way Flasher:
With 4-way flasher in the ON position and power on

terminal 2, power flows out terminal 6 of 4-way flasher
switch to flasher, energizing flasher. Pulsing power is sent
from flasher through L49 brown wire to terminal 5 of
4-way flasher switch and out terminals 1 and 3. Pulsing
power is sent to left and right turn lights and indicator
lights, making them flash.
Continued on next page TX,9015,DY667 1916AUG961/2

022602
PN=383
NOTE: P23 red wire when installed into terminal number

(2) of flasher and P19 red wire removed, the
flasher will work with key switch OFF.
Brake Light:
Power flows from turn/stop/horn fuse to brake light

switches. When brakes are applied the brake light
switches close and power is routed to brake lights. Lights
are grounded through G20 black wire.

9015-10.
9015
15A
,102
TX,9015,DY667 1916AUG962/2

022602
PN=384
Turn Signal, Flasher and Brake Light Circuit Schematic (S.N. 872256)
9015
15A
,103
1923SEP92
T7835AF
TX,9015,QQ1789 1912MAR931/1

022602
PN=385
Sub-System Diagnostics/Turn Signal, Flasher

and Brake Light Circuit (S.N. 872256)
CED,TX17864,1032 1905FEB991/1
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
switch is good. Check
9015
With 4-way flasher switch OFF, check for continuity wiring harness.
15A
between terminals 6 and 8.
,104
NO: Replace 4-way
Is continuity measured? flasher switch.
Flasher switch ON.

T7199CZ UN16AUG90
Check for continuity between terminals 6 and 2, 5 and 3,
5 and 10, and 5 and 1.
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

022602
PN=386
Turn Signal Switch Disconnect harness from turn signal switch. YES: Turn signal switch
is good. Go to next
With turn signal switch turned right, check for continuity check.
between connector terminals 5 and 7, and 6 and 3.
NO: Replace turn signal
Is continuity measured? switch.
With turn signal switch turned left, check for continuity

between connector terminals 5 and 3, and 6 and 7.
9015
T7199DB UN01OCT90 15A
,105
1/1
Brake Light Disconnect harness from turn/tail/brake light. YES: Brake light is good.
Connect 12 volts to terminal marked STOP, and ground
Does brake light function?
T7199DS 1902OCT90
1/1
Turn Signal Light Disconnect harness from turn/tail/brake light. YES: Turn signal light is
good. Check wiring
Connect 12 volts to terminal marked DIRECTIONAL, and harness.
ground terminal marked GROUND.
Does turn signal light function? is good replace light.
T7199DT 1902OCT90
1/1

022602
PN=387
Left/Right Indicator Light Disconnect harness from indicator light. YES: Indicator light is
good. Check wiring
Connect battery voltage to purple wire and ground black harness.
wire.
NO: Check bulb, if good
Does indicator light function? replace indicator light.
T7199DC 1916AUG90
1/1
Brake Light Switch Disconnect harness from brake light switch. YES: Replace switch.
9015
Check for continuity between the two terminals. NO: Go next step in this
15A
check.
,106
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.
T7199DD UN16AUG90
1/1
Beacon Circuit Operational Information

(S.N. 872256)
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

022602
PN=388
Beacon Circuit Theory of Operation (S.N.

872256)
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.
9015
15A
,107
TX,9015,QQ1791 1912MAR931/1

022602
PN=389
Beacon Circuit Schematic (S.N. 872256)
9015
15A
,108
1923SEP92
T7835AG
TX,9015,QQ1792 1912MAR931/1

022602
PN=390
Sub-System Diagnostics/Beacon Circuit

(S.N. 872256)
CED,TX17864,1033 1905FEB991/1
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
9015
Beacon switch ON.
15A
NO: Replace beacon
,109
Check for continuity between terminals 1 and 5. switch.
T7199DE UN02OCT90
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

(S.N. 872256)
The following conditions must exist for return-to-dig circuit

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

022602
PN=391
Return-to-Dig Circuit Theory of Operation

(S.N. 872256)
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 G01 black.

9015-10.
9015
15A
,110
TX,9015,QQ1793 1912MAR931/1

022602
PN=392
Return-to-Dig Circuit Schematic (S.N. 872256)
9015
15A
,111
1923SEP92
T7835AH
TX,9015,QQ1794 1912MAR931/1

022602
PN=393
Sub-System Diagnostics/Return-to-Dig
CED,TX17864,1034 1905FEB991/1
Return-to-Dig Circuit Diagnostic Procedures
1/1
Return-to-Dig Switch Disconnect harness from return-to-dig switch. YES: Replace

return-to-dig switch.
9015
Check for continuity between common terminal and open
15A
terminal. NO: Go to next step in
,112
this check.
T7199DG UN17SEP90
Disconnect harness from return-to-dig switch. YES: Return-to-dig switch

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

022602
PN=394
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

Specifications (S.N. 872256) 9015
15A
Specification ,113
Fuel Gauge Level Sender
Empty Resistance......................................................................... 10 ohms
Full Resistance ........................................................................... 180 ohms
TX,9015,QQ1825 1931AUG951/1

Operational Information (S.N. 872256)
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

022602
PN=395
Fuel Gauge and Hour Meter Circuit Theory of

Operation (S.N. 872256)
Fuel Gauge:
The circuit consists of monitor fuse, fuel gauge/light and

fuel sender. Power flows from monitor fuse to (+) terminal
of fuel gauge, out S terminal of fuel gauge to fuel sender.
Fuel sender is grounded through G10 black wire. Power
also flows from (+) terminal of fuel gauge to fuel gauge
light. Fuel gauge light is grounded through G10 black
wire.
Tachometer/Hour Meter:
9015 Power flows from W terminal of alternator through M39

15A purple wire to S terminal on tachometer/hour meter.
,114
Tachometer light gets power from P21 red wire and is
grounded through G10 black wire.
With key switch ON and engine running, hour meter gets

power from W terminal of alternator through M39 purple
wires to alternator relay, energizing the relay and
connecting terminals 30 and 87 suppling power for hour
meter, causing the hour meter to run. With engine OFF
key switch ON alternator relay is de-energized connecting
terminals 30 and 87A removing power for hour meter and
suppling ground for alternator indicator light in display
module, causing the alternator indicator light to come on.

9015-10.
TX,9015,DY668 1916AUG961/1

022602
PN=396
Gauge and Hour Meter Circuit Schematic (S.N. 872256)
9015
15A
,115
1923SEP92
T7835AI
TX,9015,QQ1796 1912MAR931/1

022602
PN=397
Sub-System Diagnostics/Fuel Gauge and

Hour Meter Circuit (S.N. 872256)
CED,TX17864,1035 1905FEB991/1
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.
9015
Key switch ON. Engine OFF.
15A
NO: Replace fuel gauge.
,116
Disconnect harness from fuel gauge.
Does gauge read EMPTY?
Connect battery voltage to (+) terminal and ground GND

terminal.
T7199DI UN02OCT90
Does gauge read FULL?
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.
1/1

022602
PN=398
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
T7199DJ 1902OCT90 15A
,117
Using a voltmeter, check voltage on terminal (SIG) M39 YES: Tachometer is bad,
purple wire. replace tachometer/hour
meter.
Are 7.63 volts (AC) measured?
NO: Check wiring
harness.
T7199DK 1917SEP90
1/1

T7596AQ 1903OCT91
1/1

022602
PN=399
Auxiliary Valve Circuit Operational

The following conditions must exist for auxiliary valve


Machine running
Auxiliary valve switch in FOOT ON or CONTINUOUS
ON position
TX,9015,QQ2581 1912APR941/1
Auxiliary Valve Circuit Theory of Operation (S.N. 872256)

9015
15A The circuit consists of auxiliary valve relay, auxiliary from terminal 6 is sent to terminal 9 for light in switch.
,118 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 R01 black wire through cab side auxiliary valve solenoid energizing solenoid.
console harness. With key switch on, power is routed
through P01 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

022602
PN=400
Auxiliary Valve Circuit Schematic (S.N. 872256)
9015
15A
,119
1929AUG95
T8544AL
TX,9015,BD2754 1918APR971/1

022602
PN=401
Sub-System Diagnostics/Auxiliary Valve

CED,TX17864,1036 1905FEB991/1
Auxiliary Valve Circuit Diagnostic Procedures
This circuit is powered by monitor fuse.
1/1
Auxiliary Valve Relay Key switch OFF. YES: Relay is good.

9015
15A
NO: Replace auxiliary
,120
Connect battery voltage to terminal #86. Ground terminal valve relay.

T7287BH UN16AUG90
1/1
Auxiliary Valve Switch Disconnect harness from auxiliary valve switch. YES: Auxiliary valve
switch is good. Check
Move auxiliary valve switch to FOOT ON. wiring harness.
Measure for continuity between terminals 3 and 5, 3 and NO: Replace auxiliary
6. valve switch.
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,
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

022602
PN=402
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
T8173BP UN20FEB94 15A
,121
1/1

022602
PN=403
Auxiliary Valve Solenoid Key switch ON. Auxiliary valve switch to CONTINUOUS YES: Continue on.
ON. Harness wires connected.
NO: Check ground
Check battery voltage at (A). connection at (B). Check
wiring harness.
Is battery voltage measured?
Check continuity at (B).
9015
15A T8176AF UN20FEB94
,122
Disconnect harness wires from valve. YES: Solenoid is good.
Check continuity at (A). NO: Replace solenoid.
T8176AF UN20FEB94
1/1

022602
PN=404
Group 15B
Sub-System Diagnostics (S.N. 872257 )
Power Circuit Operational Information (S.N.
872257 )
The following conditions must exist for power circuit to

function:
Voltage must be present at these distribution points for

other circuits to operate.
BAT terminal of key switch

Terminal 30 of accessory relay
Start relay
B+ terminal of alternator
Starter motor
Radio fuse
9015
15B
1
TX,9015,QQ6762 1906JUN961/1
Power Circuit Theory Of Operation (S.N.

872257 )
The power circuit includes battery and main current paths

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

switch, accessory relay, start relay, alternator, starter
motor and unswitched radio fuse.
When key switch is moved from OFF position, power

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

Bulb Check and Start positions.

9015-10.
TX,9015,QQ6763 1906JUN961/1

022602
PN=405
Power Circuit Schematic (S.N. 872257 )
9015
15B
2
1910SEP96
T100796
TX,9015,QQ6764 1906JUN961/1

022602
PN=406
Sub-System Diagnostics/Power Circuit (S.N.

872257 )
TX,9015,QQ6765 1906JUN961/1
Power Circuit Diagnostic Procedures
This circuit is powered by the alternator and the batteries.
1/1
Battery State Of Charge YES: Clean battery cable

CAUTION: Engine may crank during this check. terminals. Repeat test.
9015
Move light switch to ON position. 15B
If lights still get dim, test
3
battery.
Do Work lights go out or get very dim while cranking engine?
NO: Battery Charge is
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
T7199BK 1917SEP90
1/1
Alternator Key switch OFF. YES: Go to next check.
With harness connected, check voltage at B+ terminal of NO: Check wiring

alternator harness between battery
and alternator
T7828AA 1923SEP92
1/1

022602
PN=407
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

this check.
9015
Disconnect harness from switch.
15B
NO: Check wiring
4
Check voltage on B11 red wire at BAT terminal of key harness between battery
switch. and key switch.

T7199BO UN17SEP90
Switch disconnected from harness. YES: Go to next step in

this check.
NO: Replace key switch.
Check for continuity between BAT and IGN terminals
and BAT and ST terminals.
T7199BO UN17SEP90
Switch disconnected from harness. YES: Go to next check.
Key switch ON. NO: Replace key switch.
Check for continuity between BAT and ACC terminal.
T7199BO UN17SEP90
1/1

022602
PN=408

this check.
T7199BN UN16AUG90

this check.
Are 12 volts measured? and accessary relay.
9015
T7199BN UN16AUG90 15B
5

Does relay click?

T7199BN UN16AUG90
1/1
Start Circuit Operational Information (S.N.

872257 )
The following conditions must exist for start circuit to

function:
FNR lever in neutral

Loader lever switch not depressed
Key switch in START position
CED,TX17864,171 1911SEP981/1

022602
PN=409
Start Circuit Theory of Operation (S.N.

872257 )
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 and loader lever switch, to
the FNR switch. With the FNR in neutral, power flows to
the neutral start relay terminal 86, energizing relay.
9015
15B With key switch in START, power flows from ST terminal
6 through start fuse, neutral start relay, to the start relay
closing the start relay. Power also flows to the hydraulic
pump destroke solenoid and energizes the solenoid which
destrokes the pump allowing for easy starting. With start
relay closed, power flows from starter motor through BO3
red wire to start relay, through EO2 white wire to starting
motor solenoid S terminal, closing solenoid contacts.
With solenoid contacts closed, power flows from battery to
the starter windings.

9015-10.
CED,TX17864,172 1911SEP981/1

022602
PN=410
Start Circuit Schematic (S.N. 872257 )
9015
15B
7
1918SEP98
T117158
CED,TX17864,170 1910SEP981/1

022602
PN=411
Sub-System Diagnostics/Start Circuit (S.N.

872257 )
TX,9015,QQ6769 1921JUL981/1
Start Circuit Diagnostic Procedures
This circuit is powered by the FNR/park brake fuse and the start fuse.
1/1
Key Switch Check Switch disconnected from harness. YES: Go to next step in
this check.
9015
15B
8
T7199BO UN17SEP90
1/1
FNR Lever Check YES: Continue with check
T114633 1921JUL98
Disconnect FNR lever from harness.
Connect a 12 volt power supply to FNR lever as shown.
Place FNR lever in neutral.
Are 12 volts measured at only terminal D of four pin connector?
Place FNR lever in reverse.
Are 12 volts measured at only terminal B of four pin connector?
Place FNR lever in forward.
Are 12 volts measured at only terminal C of four pin connector?

1/1

022602
PN=412
Neutral Start Relay Key switch OFF. YES: Relay is good.

NO: Replace neutral start
Connect battery voltage to terminal #85. relay.
Does relay click?

T7287BH UN16AUG90
1/1
Start Relay Key switch OFF. YES: Relay is good.

9015
Disconnect harness from relay. NO: Replace start relay.
15B
9
Connect battery voltage to one of the small blade
terminals and ground the other. Does relay click?
Measure continuity between two large terminals. Is

T7287BK 1916AUG90
1/1
Starter Solenoid Check YES: Solenoid is OK.

CAUTION: Starter will crank engine if metal Check starter motor.
strap is NOT disconnected from starter
motor. NO: Replace starter
solenoid.
Disconnect metal strap from starter motor terminal.
Connect battery voltage to solenoid small terminal.
T6534BI UN19OCT88
Ground metal strap from solenoid with heavy gauge
wire.
Remove jumper wires.
1/1

022602
PN=413
Starter Motor YES: Starter motor is

CAUTION: Starter will crank engine if metal good. Check wiring
strap is NOT disconnected from starter harness.
motor.
NO: Repair or replace
Disconnect metal strap from starter motor large terminal. starter motor.

T6534BJ UN07JAN97

Does starter motor turn, but NOT crank engine?
1/1
Hydraulic Pump Key switch OFF. YES: Solenoid is good.

Destroke Solenoid Check wiring harness.
9015
Disconnect harness from destroke solenoid.
15B
10
Connect battery voltage to solenoid terminal A and
ground terminal B.

T7418AN 1927NOV90
1/1
Charging Circuit Operational Information

(S.N. 872257 )
The following conditions must exist for charging circuit to

function:

Engine running
TX,9015,QQ6770 1906JUN961/1

022602
PN=414
Charging Circuit Theory of Operation (S.N.

872257 )
65 or 95 AMP Bosch Alternator: The alternator (B+)

terminal is connected to battery voltage at all times.
The alternator terminal (D+) gets power from ACC

terminal of the key switch by energizing the accessory
relay, closing relay contacts and sending power to
MFWD/Alternator/Diff. Lock fuse.
With key switch ON and engine running, power flows from

terminal (W) of alternator to display monitor, ground is
removed and indicator light goes out.
When key is on but engine is not running or if alternator 9015

fails, a ground is supplied to the display monitor and 15B
indicator lights come on. 11

9015-10
TX,9015,QQ6771 1906JUN961/1

022602
PN=415
Charge Circuit Schematic (S.N. 872257 )
9015
15B
12
1903NOV97
T100798
TX,9015,QQ6772 1906JUN961/1

022602
PN=416
Sub-System Diagnostics/Charging Circuit

(S.N. 872257 )
TX,9015,QQ6773 1904AUG981/1
Charging Circuit Diagnostic Procedures
This circuit is powered by the MFWD/alt./diff. lock fuse.
1/1
Alternator Output Key switch OFF. YES: Alternator is good.

9015
Measure and record battery voltage. Check battery.
15B
13
Start and run engine at 1500 rpm, and check battery NO: Check alternator.
voltage.
Specification
T6569AZ UN23AUG93
Alternator Output
CheckEngine Speed....................................... 1500 rpm
Does battery voltage increase?
1/1
Alternator Key switch ON. Engine running. Park brake ON. YES: Alternator is good.
Using a multimeter, check for DC voltage at terminals NO: Alternator is failed.

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

(W).
Is 7.63 AC volts measured?
T7835AT 1923SEP92
1/1

022602
PN=417
Alternator Diode Remove diode from connector. YES: If continuity is

measured in both checks,
Reverse ohmmeter probes. measured in either check,
T7961AA UN10MAR93
is OK.
1/1

this check.
9015
15B
NO: Check wiring
14

T7199BO UN17SEP90

this check.
T7199BO UN17SEP90
T7199BO UN17SEP90
1/1

022602
PN=418

this check.
T7199BN UN16AUG90

this check.
Are 12 volts measured? and accessary relay.
9015
T7199BN UN16AUG90 15B
15

Does relay click?

T7199BN UN16AUG90
1/1
Differential Lock Circuit Operational

Information (S.N. 872257 )
The following conditions must exist for differential lock to

function.
Key switch in ON position.

Engine running
Differential lock switch held down.
CED,TX17864,86 1912JUN981/1

022602
PN=419
Differential Lock Circuit Theory of Operation

(S.N. 872257 )
Power flows from the MFWD/Alternator/Differential lock

fuse (F1) to the differential lock switch (S3). The
differential lock switch is normally open. When the
operator depresses the differential lock switch, power
continues to flow to the differential lock solenoid (Y8) and
energize the solenoid.
When the operator releases the switch, the switch opens

and the differential solenoid is de-energized. The
differential lock diode (V11) prevents voltage spikes from
arching across the terminals of the switch when the switch
is released.
9015
15B
16
CED,TX17864,87 1912JUN981/1

022602
PN=420
Differential Lock Circuit Schematic (S.N.

872257 )
9015
15B
17
1919JUN98
T115838
CED,TX17864,88 1912JUN981/1

022602
PN=421
Sub-System Diagnostics/Differential Lock

Circuit (S.N. 872257 )
CED,TX17864,89 1912JUN981/1
Differential Lock Circuit Diagnostic Procedures
1/1
Differential Lock Switch Disconnect harness from switch. YES: Go to next step in
this check.
9015
Connect multimeter to switch terminals.
15B
NO: Replace switch.
18
Depress differential lock switch.
T115875 1919JUN98
Release Switch. YES: Replace switch.
Is continuity measured? NO: Go to next check.
T115875 1919JUN98
1/1
Differential Lock Key switch ON. YES: Repair or replace

Solenoid solenoid.
Differential lock switch depressed and held.
NO: Repair harness. (See
Disconnect harness from solenoid. group 10 of this section)
Measure voltage at terminals in harness.

T115864 1919JUN98
1/1

022602
PN=422
Differential Lock Diode Remove diode from connector. YES: If continuity is

shorted mode. Replace
Is continuity measured? diode.
Reverse ohmmeter probes. NO: If continuity is NOT

measured in either check,
Is continuity measured? diode has failed in an
T7961AA UN10MAR93
open mode. Replace
diode.
measure in one check
is OK.
9015
15B
19
1/1
MFWD Circuit Operational Information (S.N.

872257 )
The following conditions must exist for MFWD to function.
Key switch in ON position.

Engine running
MFWD switch on.
CED,TX17864,86 1912JUN981/1
MFWD Circuit Theory of Operation (S.N.

872257 )
Power flows from the MFWD/Alternator/Differential lock

fuse (F1) to the MFWD switch (S2). When the operator
switches on the MFWD switch, power continues to flow to
the MFWD solenoid (Y1) and energize the solenoid.
When the operator releases the switch, the switch opens

and the differential solenoid is de-energized. The
differential lock diode (V10) prevents voltage spikes from
arching across the terminals of the switch when the switch
is released.
CED,TX17864,87 1912JUN981/1

022602
PN=423
MFWD Circuit Schematic (S.N. 872257 )
9015
15B
20
1919JUN98
T115840
OUO1048,00003E3 1913SEP001/1
Sub-System Diagnostics/MFWD Circuit (S.N.

872257 )
CED,TX17864,89 1912JUN981/1
MFWD Circuit Diagnostic Procedures
1/1

022602
PN=424
MFWD Switch YES: MFWD switch is

good. Check wiring
harness.
NO: Replace MFWD

switch.
9015
T100731 UN28MAY96 15B
21
MFWD switch OFF.
Check for continuity between terminals 2B and 1.
MFWD switch ON.
1/1
MFWD Solenoid Key switch ON. YES: Repair or replace

solenoid.
MFWD switch OFF.
NO: Repair harness. (See
Disconnect harness from solenoid. group 10 of this section)
Measure voltage at terminals in harness.

T115864 1919JUN98
1/1

022602
PN=425
MFWD Diode Remove diode from connector. YES: If continuity is

shorted mode. Replace
Is continuity measured? diode.
Reverse ohmmeter probes. NO: If continuity is NOT

measured in either check,
Is continuity measured? diode has failed in an
T7961AA UN10MAR93
open mode. Replace
diode.
measure in one check
is OK.
9015
15B
22
1/1
Radio Circuit Operational Information (S.N.

872257 )
The following condition or conditions must exist for the

radio circuit to function.
Key switch in ACC or ON position.

Radio turned ON
CED,TX17864,181 1915SEP981/1
Radio Circuit Theory of Operation (S.N.

872257 )
When the key switch is ON or in ACC position of switch,

power flows to the accessory relay energizing the relay.
Power is then sent to the dome light fuse and front work
light fuse. Switched power is sent to radio fuse and radio.
Unswitch power from radio fuse maintains station memory

and the clock. Power from the front work light fuse is for
light in the radio. Power from the dome light fuse powers
the radio and speakers.
CED,TX17864,182 1915SEP981/1

022602
PN=426
Radio Circuit Schematic (S.N. 872257 )
9015
15B
23
1918SEP98
T117203
CED,TX17864,183 1915SEP981/1

022602
PN=427
Sub-System Diagnostics/Radio Circuit (S.N.

872257 )
CED,TX17864,184 1915SEP981/1
Radio Circuit Diagnostic Procedures
This circuit is powered by the unswitched radio fuse, dome light/radio fuse, and the front work/tail light fuse.
1/1
Fuses Remove fuse cover. YES: Replace fuse.

9015
Check 5 amp radio fuse (unswitched power), 5 amp dome light/radio fuse, and 25 amp NO: Go to next check.
15B
front light/tail light fuse.
24
Are any of the fuses blown?
1/1
Front Light Switch Disconnect harness from front light switch. YES: Front light switch is
Light switch ON.
NO: Replace switch.
Measure for continuity between terminals 3 and 1, and 2
and 8.
T7199CN UN16AUG90
1/1
Radio Unplug harness from radio. YES: Go to next check.

Key switch ON and front light switch ON.
NO: An open circuit is
Check for voltage at P15, P25, and L43 receptacles. indicated. Check
harnesses.
T117205 1918SEP98
1/1

022602
PN=428
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
Dome Light Circuit Operational Information

(S.N. 872257 ) 9015
15B
25
dome light circuit to function.

Dome light switch ON
CED,TX17864,185 1915SEP981/1
Dome Light Circuit Theory of Operation (S.N.

872257 )
When the key switch is ON or in ACC position of switch,

power flows to the accessory relay energizing the relay.
Power is then sent to the dome light fuse.
Power continues to flow through the dome light/radio fuse

to the dome light switch. When the dome light switch is in
the ON position, power is allowed to flow to the dome light
causing the dome light to light.
CED,TX17864,186 1915SEP981/1

022602
PN=429
Dome Light Circuit Schematic (S.N. 872257 )
9015
15B
26
1918SEP98
T117204
CED,TX17864,187 1915SEP981/1

022602
PN=430
Sub-System Diagnostics/Dome Light Circuit

(S.N. 872257 )
CED,TX17864,188 1915SEP981/1
Dome Light Circuit Diagnostic Procedures
This circuit is powered by the dome light/radio fuse.
1/1

9015
Check 5 amp radio fuse (unswitched power), 5 amp dome light/radio fuse, and 25 amp NO: Go to next check.
15B
front light/tail light fuse.
27
Are any of the fuses blown?
1/1
Dome Light Switch and Disconnect dome light assembly from harness. YES: Replace dome light
Dome Light Key switch ON or ACC position. assembly.
Check for voltage at dome light connectors. NO: An open circuit is

indicated. Check
Are 12 volts measured? harnesses.
T117254 1918SEP98
1/1
Start Aid Circuit Operational Information

(S.N. 872257 )
The following conditions must exist for start aid circuit to

function:

Start aid switch depressed
TX,9015,BG984 1901APR971/1

022602
PN=431
Start Aid Circuit Theory of Operation (S.N.

872257 )

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 G01 black
wire energizing solenoid.

9015-10.
9015
15B
28
TX,9015,QQ1751 1912MAR931/1

022602
PN=432
Start Aid Circuit Schematic (S.N. 872257 )
9015
15B
29
1923SEP92
T7828AJ
TX,9015,QQ1752 1912MAR931/1

022602
PN=433
Sub-System Diagnostics/Start Aid Circuit

(S.N. 872257 )
CED,TX17864,243 1908OCT981/1
Start Aid Circuit Diagnostic Procedures
1/1
Start Aid Switch Disconnect harness from start aid switch. YES: Start aid switch is
9015
With start aid button pushed, check for continuity
15B
between terminals with P12 red wire and E25 white wire. NO: Replace start aid
30
switch.
T7199BW 1916AUG90
1/1
Start Aid Solenoid NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into YES: Start aid solenoid is
engine. good. Check wiring
harness.
Key switch OFF.
NO: Replace start aid
Disconnect harness from solenoid. solenoid.
Connect battery voltage to terminal with E25 white wire.

Ground terminal with E27 white wire.

T7828AK 1923SEP92
1/1
Fuel Shut-Off Circuit Operational Information

(S.N. 872257 )
The following conditions must exist for fuel shut-off circuit

to function:
TX,9015,BG985 1901APR971/1

022602
PN=434
Fuel Shut-Off Circuit Theory of Operation

(S.N. 872257 )

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
15B
31
TX,9015,BG986 1901APR971/1

022602
PN=435
Fuel Shut-Off Circuit Schematic (S.N. 872257 )
9015
15B
32
1912DEC90
T7418AZ
TX,901515,QQ825 1912MAR931/1

022602
PN=436
Sub-System Diagnostics/Fuel Shut-Off

CED,TX17864,242 1908OCT981/1
Fuel Shut-Off Circuit Diagnostic Procedures
1/1
Injection Pump Fuel Connect battery voltage to solenoid P12 red wire YES: Solenoid is good.
Shut-Off Solenoid terminal. Check wiring harness.
9015
15B
Does solenoid "click"? NO: Replace fuel shut-off
33
solenoid.
Remove voltage from terminal.
Does solenoid "click" again?

T6785AG UN18OCT88
1/1
Reverse Alarm Circuit Operational

The following conditions must exist for reverse alarm

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

022602
PN=437
Reverse Alarm Circuit Theory of Operation

(S.N. 872257 )
When the key switch is ON position of switch, power flows

to the FNR/park brake fuse. Power is then sent through
the loader lever switch to the FNR switch. With the FNR
switch in reverse, power flows to the reverse alarm relay
energizing the relay.
With reverse alarm relay energized power is allowed to

flow through the fuel shut-off/start aid/reverse alarm fuse
and reverse alarm relay to the reverse warning alarm
causing the alarm to sound.
9015
15B
34
CED,TX17864,180 1915SEP981/1

022602
PN=438
Reverse Alarm Circuit Schematic (S.N. 872257 )
9015
15B
35
1918SEP98
T117206
CED,TX17864,189 1916SEP981/1

022602
PN=439
Sub-System Diagnostics/Reverse Alarm

CED,TX17864,191 1916SEP981/1
Reverse Alarm Circuit Diagnostic Procedures
This circuit is powered by the fuel shut-off/start aid/reverse alarm fuse.
1/1

9015
Check 15 amp fuel shut-off/start aid/reverse alarm fuse and 10 amp FNR/park brake NO: Go to next check.
15B
fuse.
36
Are fuses blown?
1/1
Loader Lever Switch Disconnect harness from loader lever switch YES: Go to next step in
this check.
Check for continuity between terminals with J27 tan wire
and T53 blue wire. NO: Replace loader lever
switch.
T7199CU 1902OCT90
Disconnect harness from loader lever switch YES: Replace loader

lever switch.
between terminals with J27 tan wire and T53 blue wire. NO: Loader lever switch
is good. Go to next
Is continuity measured? check.
T7199CU 1902OCT90
1/1

022602
PN=440
T114633 1921JUL98

9015
15B
37

1/2

022602
PN=441
T114633 1921JUL98

9015
15B
Place FNR lever in first speed forward.
38
Are 12 volts measured at only terminals A, C, and D of six pin connector?
Place FNR lever in second speed forward.
Are 12 volts measured at only terminals A, B, and C of six pin connector?
Place FNR lever in third speed forward.
Are 12 volts measured at only terminals B, C, and D of six pin connector?
Place FNR lever in fourth speed forward.
Are 12 volts measured at only terminals B and D of six pin connector?
19 2/2
Reverse Alarm Relay Key switch OFF. YES: Relay is good.

NO: Replace reverse
Connect battery voltage to terminal #86. Ground terminal alarm relay.

T7287BH UN16AUG90
1/1

022602
PN=442
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.
Does reverse alarm sound?

T7199BZ UN16AUG90
1/1
Air Adjust Seat Circuit Operational

Information (S.N. 872257 ) 9015
15B
39
The following condition or conditions must exist for the air
adjust seat circuit to function

Air adjust seat switch held in ON position.
CED,TX17864,195 1916SEP981/1
Air Adjust Seat Theory of Operation (S.N.

872257 )
Power flows through the heater fuse to the air adjust seat
switch. When the switch is depressed and held, power
continues to flow to the air adjust seat motor causing the
motor to operate.
CED,TX17864,196 1916SEP981/1

022602
PN=443
Air Adjust Seat Circuit Schematic (S.N. 872257 )
9015
15B
40
1918SEP98
T117256
CED,TX17864,192 1916SEP981/1

022602
PN=444
Sub-System Diagnostics/Air Adjust Seat

CED,TX17864,197 1917SEP981/1
Air Adjust Seat Circuit Diagnostic Procedures
This circuit is powered by the heater fuse.
1/1

9015
Check 30 amp heater/air conditioning fuse. NO: Go to next check.
15B
41
Is the fuse blown?
1/1
Air Adjust Seat Switch Disconnect switch from harness. YES: Go to next check.
Connect a multi meter to switch as shown. NO: Replace switch.
Depress and hold switch and check for continuity.
T117271 1918SEP98
1/1
Air Adjust Seat Motor Disconnect harness from motor. YES: An open circuit is
indicated. Check wiring
Connect motor to 12 volts and ground as shown. harnesses.
Does motor run? NO: Replace motor.
T117270 1918SEP98
1/1

022602
PN=445
Blower Circuit Operational Information (S.N.

872257 )

blower circuit to function.

Blower switch in any of the four positions.
CED,TX17864,198 1917SEP981/1

9015 872257 )
15B
42
Power flows through the heater fuse to the blower switch.
The blower switch has five different positions, off and four
speeds. With the switch in speeds 1, 2, and 3 power is
sent to the blower resistor. The blower resistor has three
different resistance values causing the fan to have
different speeds. With the blower switch on the speed 4,
power is sent directly to the blower motor and bypasses
the blower resistor. This causes the fan to be at the
highest speed.
CED,TX17864,199 1917SEP981/1

022602
PN=446
Blower Circuit Schematic (S.N. 872257 )
9015
15B
43
1918SEP98
T117257
CED,TX17864,193 1916SEP981/1

022602
PN=447
Sub-System Diagnostics/Blower Circuit (S.N.

872257 )
CED,TX17864,200 1917SEP981/1
Blower Circuit Diagnostic Procedures
1/1

9015
15B
44
Is the fuse blown?
1/1
Blower Switch Disconnect harness from blower switch. YES: Blower switch is
NO: Replace blower
Move blower switch to position, 1, 2, 3, and 4 checking switch.
terminals B and 1, B and 2, B and 3, B and 4)
T117277 1918SEP98
1/1
Blower Resistor Measure ohms between terminals 4 and 2. YES: Resistor is good.
Does ohmmeter read approximately 0.9 ohms?
T102849 UN06AUG96
1/1

022602
PN=448
Heater Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
motor is good. Check
motor.
NO: Replace heater
T7199CM UN16AUG90
1/1
Air Conditioning Circuit Specifications (S.N.

872257 ) 9015
15B
Specification 45
A/C Freeze Switch (normally
closed)Opening Temperature ................... -0.56 0.83 C (31 1.5 F)
Closing Temperature ..................................... 2.22 0.83 C (36 1.5 F)
Specification
Air Conditioning High Pressure
Switch (normally closed)
Opening Pressure .................................. 2760 138 kPa (27.6 1.4 bar)
(400.3 20 psi)
Closing Pressure .................................... 1310 138 kPa (13.1 1.4 bar)
(190 20 psi)
Specification
Air Conditioning Low Pressure
Switch (normally open)Closing
Pressure ................................................... 345 35 kPa (3.45 0.35 bar)
(50 5.1 psi)
Opening Pressure .................................... 173 35 kPa (1.73 0.35 bar)
(25.1 5.1 psi)
CED,TX17864,205 1917SEP981/1
Air Conditioning Circuit Operational

The following condition or conditions must exist for this

circuit to operate:
Key switch ON.

Engine running.
Blower switch in any of the four ON speeds.
A/C switch ON.
CED,TX17864,202 1917SEP981/1

022602
PN=449
Air Conditioning Circuit Theory of Operation (S.N. 872257 )
Power flows through the heater fuse to the blower High Pressure Switch
switch. The blower switch has five different positions,
off and four speeds. With the switch in speeds 1, 2, The high pressure switch protects the system from
and 3 power is sent to the blower resistor. The blower high pressure. If a malfunction or line restriction
resistor has three different resistance values causing causes the high pressure to increase above the setting
the fan to have different speeds. With the blower of the switch, the switch will open to stop current flow
switch on the speed 4, power is sent directly to the to the compressor clutch. The high pressure switch is
blower motor and bypasses the blower resistor. This located near the compressor in the high pressure line.
causes the fan to be at the highest speed.
Freeze Protection Switch
When the blower switch is in any of the four ON
speeds, power also flows through the normally closed The freeze protection switch is used to sense the
freeze control switch and to the A/C on/off switch. temperature in the evaporator core. When the
When the A/C on/off switch is switched on power temperature drops, the freeze protection switch opens,
9015
15B continues to flow through the normally closed high and stopping power flow to the compressor. When the
46 low pressure switches to the A/C compressor engaging temperature in the evaporator core raises, the freeze
the compressor clutch. protection switch closes allowing power to continue to
flow to the compressor.
Low Pressure Switch
The freeze protection switch receives power from the
The low pressure switch will open if the air blower switch when the blower switch is in any of the
conditioning system loses its refrigerant charge. The four ON speeds.
switch opens to stop current flow to the compressor
which prevents compressor engagement. The low
pressure switch is located near the compressor in the
high pressure line.
CED,TX17864,203 1917SEP981/1

022602
PN=450
Air Conditioning Circuit Schematic (S.N. 872257 )
9015
15B
47
1918SEP98
T117258
CED,TX17864,194 1916SEP981/1

022602
PN=451
Sub-System Diagnostics/Air Conditioning

CED,TX17864,206 1917SEP981/1
Blower/Air Conditioning Circuit Checks
1/1

9015
15B
48
Is the fuse blown?
1/1
Blower Switch Disconnect harness from blower switch. YES: Blower switch is
NO: Replace blower
Move blower switch to position, 1, 2, 3, and 4 checking switch.
terminals B and 1, B and 2, B and 3, B and 4)
T117277 1918SEP98
1/1
Blower Resistor Measure ohms between terminals 4 and 2. YES: Resistor is good.
NO: Replace resistor
T102849 UN06AUG96
1/1

022602
PN=452
Heater/Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
Check motor is good. Check
motor.
NO: Replace heater
T7199CM UN16AUG90
1/1
A/C Freeze Switch With A/C freeze switch at room temperature. YES: Do A/C Freeze
Switch Test. See Group
9015
Disconnect harness from switch. 9031-25. If switch is OK,
15B
check wiring harness.
49
Measure continuity across switch terminals.
NO: Switch has failed.
Is continuity measured? Replace switch.
T7835AV 1924SEP92
1/1
Air Conditioning Switch Disconnect harness from air conditioning switch. YES: A/C switch is good.
(S.N. 816286) Check wiring harness.
Place switch in snowflake or A/C position, and measure
for continuity between terminals 2B and 1. NO: Replace A/C switch.
Place switch in cactus or defrost position and measure

T7199DE UN02OCT90
for continuity between terminals 2B and 3.
1/1

022602
PN=453
Air Conditioner Low Disconnect harness from switch. YES: Continue with this
Pressure Switch Check check.
Check for continuity between terminals. Is continuity
measured? NO: Replace switch.
T101619 1913JUN96
Remove switch from system. (The line that attaches the low pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness.
Measure for continuity across switch terminals. NO: Go to Low Pressure

Switch Test, Group
Does ohmmeter read open? 9031-25.
9015
15B
50
1/1
Air Conditioner High Disconnect harness from switch. YES: Continue with this
Measure continuity across outer switch terminals.
NO: Switch may be bad,
Does ohmmeter read continuity? or system pressure is too
high. Continue with this
check to verify switch
operation.
T101618 1913JUN96
Remove switch from system. (The line that attaches the high pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness and
system pressure. Go to
Measure continuity across switch terminals. Air Conditioning Pressure
Diagnostic Chart, Group
Does ohmmeter read continuity? 9031-25.
NO: Replace switch.
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
1/1

022602
PN=454
Wiper/Washer Circuit Operational Information

(S.N. 872257 )
The following conditions must exist for wiper/washer

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

(S.N. 872257 ) 9015
15B
51
Power flows from wiper/washer fuse to terminal 2B of the
front wiper switch, washer switch, and rear wiper switch.
Front Wiper
The front wiper switch has both a high and low position.
With the switch on low, power flows from terminals 2A
and 5A to both the left and right front wiper motors
causing the motors to run on low speed. With the switch
on high, power flows from terminals 6 and 3 to both the
left and right front wiper motors causing the motors to run
on high speed.
Rear Wiper
The rear wiper switch has both a high and low position.
With the switch on low, power flows from terminal 2A to
the rear wiper motor causing the motor to run on low
speed. With the switch on high, power flows from terminal
6 to the rear wiper motor causing the motor to run on high
speed.
Washer
When the washer switch is depressed and held power

flows from terminal 3 to the washer motor causing the
motor to run and activate the pump.
CED,TX17864,207 1918SEP981/1

022602
PN=455
Wiper/Washer Circuit Schematic (S.N. 872257 )
9015
15B
52
1908OCT98
T116925
CED,TX17864,209 1918SEP981/1

022602
PN=456
Sub-System Diagnostics/Wiper/Washer
CED,TX17864,210 1918SEP981/1
Wiper/Washer Circuit Diagnostic Procedures
This circuit is powered by the wiper/washer fuse.
1/1
Front Wiper Switch YES: Go to next check.

9015
NO: Replace Switch
15B
53
T100731 UN28MAY96
Front wiper switch on low.
Check for continuity between terminals 2B and 2A.
Is continuity measured for both points?
Front wiper switch on high.
Is continuity measured for both points?
1/1

022602
PN=457
Front Right Wiper Motor Connect an external ground to the eyelet on the end of YES: Wiper motor is
the G20 BLK wire. good. Check wiring
harnesses.
Connect 12 volts to the L terminal.
Does wiper run on low speed?
Connect 12 volts to the H terminal.

T117301 UN08OCT98
Does wiper run on high speed?
Connect 12 volts to the P terminal.
Does wiper return the parked position and stop?
9015
15B
54
1/1
Front Left Wiper Motor Connect an external ground to the eyelet on the end of YES: Wiper motor is
the G20 BLK wire. good. Check wiring
harnesses.
Connect 12 volts to the L terminal.
Does wiper run on low speed?
Connect 12 volts to the H terminal.

T117301 UN08OCT98
Does wiper run on high speed?
Connect 12 volts to the P terminal.
Does wiper return the parked position and stop?
1/1

022602
PN=458
Rear Wiper Switch YES: Go to next check.
NO: Replace switch.
9015
T100731 UN28MAY96 15B
55
Rear wiper switch on low.
Rear wiper switch on high.
1/1
Rear Wiper Motor Disconnect harness from wiper motor wire lead. YES: Wiper motor is
good. Check wiring
Connect battery voltage to terminal with BLU/RED wire. harnesses.
Ground terminal with black wire.
Does wiper motor run at low speed?
Connect battery voltage to terminal with BLU/BLK wire.

T7199CB UN17SEP90
Does wiper motor run at high speed?
Connect battery voltage to terminal with BLU/WHT wire.

Does wiper motor return to the parked position?
1/1

022602
PN=459
Washer Switch YES: Go to next check.
NO: Replace switch
9015
15B T100731 UN28MAY96
56
Washer switch held in the ON position.
1/1
Washer Motor Disconnect harness from washer motor. YES: An open circuit is
indicated. Check wiring
Connect battery voltage to motor A71 ORG terminal of harnesses.
motor. Ground other terminal to machine frame.
NO: Replace motor.
Does washer motor run?
T7349DJ UN27AUG90
1/1
Rear Work Light Circuit Operational


rear light circuit to function.
Key switch in ON or ACC position.

Rear work light switch ON.
CED,TX17864,211 1921SEP981/1

022602
PN=460
Rear Work Light Circuit Theory Of Operation

(S.N. 872257 )
Power flows through the rear work light fuse to the rear
light switch. With the rear light switch in the ON position,
power continues to flow to the left and right rear work
lights causing the lights to light.
CED,TX17864,212 1921SEP981/1
9015
15B
57

022602
PN=461
Rear Work Light Circuit Schematic (S.N. 872257 )
9015
15B
58
1908OCT98
T117299
CED,TX17864,213 1921SEP981/1

022602
PN=462
Sub-System Diagnostics/Rear Work Light

CED,TX17864,214 1921SEP981/1
Rear Work Light Circuit Diagnostic Procedures
This circuit is powered by the rear work light fuse.
1/1

9015
Check 15 amp rear light fuse fuse. NO: Go to next check.
15B
59
Is the fuse blown?
1/1
Rear Work Light Switch YES: Go to next check.
NO: Replace switch.
T100731 UN28MAY96
Rear work light switch ON.
1/1

022602
PN=463
Rear Work Lights Disconnect harness from rear work light. YES: Work light is good.
T7199CP UN17SEP90
1/1

9015 Operational Information (S.N. 872257 )
15B
60
front work and drive light circuit to function.
Key switch in ACC of ON position.

Front light switch ON.
CED,TX17864,215 1921SEP981/1
Front Work and Drive Light Circuit Theory Of

Operation (S.N. 872257 )
Power flows through the front work/tail light fuse to the

front light switch. The front light switch is a three position
switch: off, drive/tail lights, or drive/tail/front work lights.
With the switch in the first position or the drive/tail light

position, power flows to both the front drive lights and to
the tail lights. When the switch is in the second position or
drive/tail/front work light position, power also flows to the
front work lights in addition to the front drive lights and tail
lights.
CED,TX17864,216 1921SEP981/1

022602
PN=464
Front Work and Drive Light Circuit Schematic (S.N. 872257 )
9015
15B
61
1908OCT98
T117300
CED,TX17864,217 1921SEP981/1

022602
PN=465
Sub-System Diagnostics/Front Work and

Drive Light Circuit (S.N. 872257 )
CED,TX17864,218 1921SEP981/1
Front Work and Drive Light Circuit Diagnostic Procedures
This circuit is powered by the front work/tail light fuse.
1/1

9015
Check 25 amp front work/drive light fuse. NO: Go to next check.
15B
62
Is the fuse blown?
1/1
Front Light Switch YES: Go to next check.
NO: Replace switch.
T100731 UN28MAY96
Front light switch in the drive/tail light position.
Front light switch in the drive/tail/work light position.
Check for continuity between terminals 2B & 3 and 5B & 6.
1/1

022602
PN=466
Work/Drive Lights Disconnect harness from work/drive light. YES: Work light is good.
T7199CP UN17SEP90
1/1
Tail Light Disconnect harness from turn/tail/brake light. YES: Tail light is good.
9015
Connect 12 volts to terminal marked TAIL, and ground
15B
63
Does tail light come on?
T7199CQ 1902OCT90
1/1
Park Brake/FNR Circuit Operational

The following condition or conditions must exist for park

brake/FNR circuit to function:
Key switch OFF

Park brake dash switch in ON position with machine
running
Machine Mechanically Shut Down
TX,9015,QQ6784 1921JUL981/1
Park Brake/FNR Circuit Specifications (S.N.

872257 )
Specification
Park Brake Pressure Switch
Pressure ............................................... 1103 110 kPa (11.3 1.10 bar)
(160 16 psi)
Closing Pressure ..................................... 896 89.6 kPa (8.96 0.9 bar)
(130 13 psi)
TX,9015,QQ6783 1921JUL981/1

022602
PN=467
Park Brake/FNR Circuit Theory Of Operation (S.N. 872257 )
The Park Brake/FNR circuit controls the park brake the display monitor disappears. With the park brake
and transmission. switch on, the park brake pressure switch is closed
sending a ground signal to the display monitor. With
The park brake is spring applied and hydraulically the ground signal present from the park brake
released. pressure switch without the power signal from the FNR
switch, the park brake indicator light on display monitor
NOTE: The park brake applies automatically when glows and the alarm sounds. The red stop light will
machine is mechanically shut down or when also blink on and off.
key switch is turned off. Park brake dash
switch must be cycled first to applied position The machine is unable to move because the park
(ON), then to released position (OFF) before brake dash switch is NOT sending voltage to the timer
park brake can be released when engine is relay, thus all of the speed solenoids are de-energized.
running.
Machine started with park brake switch in OFF
9015
15B Park brake cannot be hydraulically released if position:
64 FNR/Park Brake Fuse is blown.
When the machine is started with the park brake dash
Key ON: switch in the OFF position the park brake latching
Park Brake Dash Switch in On Position: relay is unlatched or open. When the park brake
FNR Lever in Neutral: latching relay is open, the park brake dash switch does
not receive voltage to terminal 2B. If the FNR switch is
Power flows from terminal 3 to terminal 2B of park placed out of neutral the display monitor alarm will
brake dash switch (S12) and then to park brake sound and the stop light will flash. This occurs
latching relay terminal 85, energizing the park brake because the park brake solenoid is not energized, thus
latching relay (K5) causing it to latch terminals 30 and the park brake pressure switch is closed and sending
87. Ground is supplied to the park brake latching relay a ground signal to the display monitor.
through the S terminal of starter motor. Power is
disconnected from park brake solenoid (Y4), and timer To enable the machine to operate, place the park dash
relay (K7). switch in the ON position. This allows power to flow to
terminal 85 of the park brake latching relay causing the
With the FNR switch (S11) in neutral, power flows from relay to close. With the relay closed, power can now
the FNR switch to the display monitor (H8). Combine flow from terminal 87 of the park brake latching relay
this with the park brake pressure switch being closed to terminal 2B of the park brake switch.
and providing a ground for the park brake indicator
light, the park brake indicator light in the display Key ON:
monitor glows signaling that the park brake is applied. Engine Running:
Park Brake Switch OFF:
Key ON:
Engine Running: With the park brake dash switch in the OFF position,
Park Brake Dash Switch In ON position: voltage is sent to both the timer relay and the park
FNR Lever Shifted Out of Neutral: brake solenoid.
With the park brake dash switch ON, and FNR lever
shifted out of neutral, the signal from the FNR lever to
Continued on next page CED,TX17864,177 1915SEP981/2

022602
PN=468
The park brake solenoid is now energized and sending opens the park brake pressure switch, thus the ground
pressurized oil to the park brake to release it. This also signal to the display monitor is removed and the park
opens the park brake pressure switch, thus the ground brake indicator light goes out.
signal to the display monitor is removed and the park
brake indicator light goes out. Power flows through the loader lever switch (S13) to
the FNR switch (S11). With FNR switch in either
Key ON: forward or reverse power flows to the timer relay
Engine Running: terminal 7. This signal closes the timer relay allowing
Park Brake Switch OFF: power to flow from the park brake dash switch through
FNR Switch in Forward or Reverse: the timer relay to the FNR switch. Depending on FNR
switch position, the proper direction and speed
With the park brake dash switch in the OFF position, solenoids in the transmission are energized.
voltage is sent to both the timer relay (K7) terminal 2
and the park brake solenoid. NOTE: If the signal to the timer relay terminal 7
disappears for more than one second, the
The park brake solenoid is now energized and sending timer relay will open.
9015
pressurized oil to the park brake to release it. This also 15B
65
Solenoids Energized
Solenoid Y5 Y6 Y18 Y12 Y13 Y14
1st Forward X X X X
2nd Forward X X X X
3rd Forward X X X X
4th Forward X X X
1st Reverse X X X X
2nd Reverse X X X X
3rd Reverse X X X X
Neutral
CED,TX17864,177 1915SEP982/2

022602
PN=469
Park Brake/FNR Circuit Schematic (S.N. 872257 )

T116096 1929JUN98
CED,TX17864,178 1915SEP981/1

022602
PN=470
Sub-System Diagnostics/Park Brake/FNR

CED,TX17864,179 1915SEP981/1
Park Brake/Neutral Disconnect Circuit Diagnostic Procedures
This circuit is powered by the FNR/park brake fuse and the start fuse.
1/1
Park Brake Switch YES: Park brake switch is

Dash good. Check wiring
9015
harness.
15B
67
NO: Replace park brake
switch.
T100731 UN28MAY96
Disconnect harness from park brake switch.
Park brake switch OFF.
Check for continuity between terminals 2A and 1.
Park brake switch ON.
1/1

022602
PN=471
Transmission Solenoids
Check
9015
15B T101725 1912SEP96
68
Remove fuse block cover.
Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and black
lead into (COM.) terminal.
Place probe ends of multimeter at locations (A and B) in fuse block.
Key switch ON and engine OFF.
Park brake switch OFF. Approximately 1.9 amp value will display.
NOTE: If 1.9 amp value is not displayed, cycle park brake on then off again.
FNR lever in forward position.
NOTE: Each solenoid in the transmission draws approximately 0.5 amps. If measured
amperage value is approximately 0.5 amps less than specification, a problem with one
solenoid is indicated.
NOTE: The following specifications are at a voltage of 12.4 volts. Voltage should be
approximately 12.4 volts when current measurements are taken.
Does the amp value match the following specifications for each speed?
Specification
FNR Current1st Speed Forward
Amperage ................................................................................................ 3.38 0.1 amps
2nd Speed Forward Amperage ............................................................... 3.38 0.1 amps
3rd Speed Forward Amperage ................................................................ 3.38 0.1 amps
4th Speed Forward Amperage ................................................................ 3.00 0.1 amps
FNR lever in reverse position.
Does the amp value match the following specifications for each speed?
Specification
FNR Current1st Speed Reverse
Amperage .................................................................................................. 3.5 0.1 amps
2nd Speed Reverse Amperage................................................................. 3.5 0.1 amps
3rd Speed Reverse Amperage ................................................................. 3.5 0.1 amps
1/2

022602
PN=472
NOTE: The current value measurement is controlled by the number of components YES: Transmission
that are connected within the circuit. solenoids are electrically
good. See Group 9020-25
Power Train Test.
NO: Check wiring

harness or transmission
solenoids.
19 2/2
Park Brake Solenoid YES: Reverse solenoid

Check electrically is good. See
9015
Group 9020-25 Power
15B
Train Test.
69
NO: Check wiring
harnesses. See Group
9015-10.
T101725 1912SEP96
Remove fuse block cover.
Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and black
lead into (COM.) terminal.
FNR lever in neutral position.
Key switch ON and engine OFF.
Place probe ends of multimeter at locations (A and B) in fuse block.
Park brake switch ON. Approximately 0.45 amp value will display.
Move park brake switch to OFF position.
Does the amp value increase by approximately 1.5 amps?

1/1

022602
PN=473
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.
between terminals with J27 tan wire and T53 blue wire. NO: Loader lever switch
is good. Check wiring
Is continuity measured? harness.
9015
15B T7199CU 1902OCT90
70
1/1
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

022602
PN=474
Timer Relay Check YES: Go to next check.
NO: Replace timer relay.
9015
T114654 1921JUL98 15B
71
Disconnect timer relay from front console harness.
Connect a 12 power supply and ground to the timer relay as shown.
Check for continuity across terminals 5 and 6 of timer relay.
1/1
Park Brake Pressure Disconnect harness from switch. YES: Replace switch.
Switch
Measure continuity between terminals A and B on NO: Switch is good.
connector end of switch. Check wiring harness.
T7199EE UN02OCT90
1/1

022602
PN=475
T114633 1921JUL98

9015
15B
72

1/2

022602
PN=476
T114633 1921JUL98

9015
15B
Place FNR lever in first speed forward.
73
Are 12 volts measured at only terminals A, C, and D of six pin connector?
Place FNR lever in second speed forward.
Are 12 volts measured at only terminals A, B, and C of six pin connector?
Place FNR lever in third speed forward.
Are 12 volts measured at only terminals B, C, and D of six pin connector?
Place FNR lever in fourth speed forward.
Are 12 volts measured at only terminals B and D of six pin connector?
19 2/2
Park Brake Relay Diode Remove diode from connector. YES: If continuity is
T7961AA UN10MAR93
is OK.
1/1

022602
PN=477
Park Brake Solenoid Remove diode from connector. YES: If continuity is

Diode measured in both checks,
T7961AA UN10MAR93
is OK.
1/1
Reverse Solenoid Diode Remove diode from connector. YES: If continuity is

9015
15B
74
T7961AA UN10MAR93
is OK.
1/1
Forward Solenoid Diode Remove diode from connector. YES: If continuity is

T7961AA UN10MAR93
is OK.
1/1
Low Range Solenoid Remove diode from connector. YES: If continuity is

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

022602
PN=478
Speed Solenoid Diodes Remove diode from connector. YES: If continuity is

T7961AA UN10MAR93
is OK.
1/1
Horn Circuit Operational Information (S.N.

872257 ) 9015
15B
75
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 (S.N.

872257 )
Power flows from turn/stop/horn fuse to horn switch.

When horn button is pushed, switch closes and power
flows to activate horn.

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

022602
PN=479
Horn Circuit Schematic (S.N. 872257 )
9015
15B
76
1923SEP92
T7835AE
CED,TX17864,220 1922SEP981/1

022602
PN=480
Sub-System Diagnostics/Horn Circuit (S.N.

872257 )
CED,TX17864,219 1922SEP981/1
Horn Circuit Diagnostic Procedures
This circuit is powered by the turn/stop/flash/horn fuse.
1/1
Horn Switch Disconnect harness from horn switch. YES: Horn switch is
good.
9015
Push horn switch and measure for continuity.
15B
NO: Replace horn switch.
77
T7199CY UN16AUG90
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
Turn Signal, Flasher, and Brake Light Circuit

Specifications (S.N. 872257 )
Specification
Brake Light Switch (Normally
Open)Closing Pressure......................... 414758 kPa (4.147.58 bar)
(60110 psi)
CED,TX17864,234 1924SEP981/1

022602
PN=481
Turn Signal, Flasher, and Brake Light Circuit

Operational Information (S.N. 872257 )

Turn Signal, Flasher, and Brake Light Circuit to function:

Four-way flasher switch ON
Turn signal switch in either left or right position.
Brake pedal depressed.
CED,TX17864,221 1922SEP981/1
Turn Signal, Flasher, and Brake Light Circuit Theory Of Operation (S.N. 872257 )
9015
15B Power flows through the 20 amp Turn/Stop/Flash/Horn left, flashing power flows out terminal 5B and to the left
78 fuse to the flasher, 4-way flasher switch, and brake front and left rear turn light. The 4-way flasher switch
light switch. diode prevents the flashing power to flow to the right
turn lights.
4-Way Flasher
When the turn signal switch is used in combination
When the 4-way flasher switch is switched on, current with the 4-way flasher switch switched ON, the turn
is allowed to flow through the flasher and causes it to signal switch receives continuous power from the
alternate on and off or flash. This flashing power flows 4-way flasher switch and flows to terminals 1 and 6 of
in terminal 2B of the 4-way flasher switch and out the turn signal switch. The 4-way flasher switch also
terminal 3 to the 4-way flasher switch diodes. The sends flashing power to all four turn lights causing
flashing power continues to flow through the diodes to them to blink. When the turn signal switch is switched
the front and rear turn lights causing them to blink. to the right, continuous power flows from terminal 6 to
terminal 5B of the turn signal switch and on to the left
Turn Signal turn lights. This causes the left turn lights to glow
continuously. The 4-way flasher switch diode prevents
The turn signal switch can function two different ways. the right turn lights from glowing continuously and
The first is to have only the turn signal switch on by allows them to remain blinking. When the turn signal
itself, or it can work in combination with the 4-way switch is switched to the left, continuous power flows
flasher switch. from terminal 1 to terminal 2B of the turn signal switch
and on to the right turn lights. This causes the right
When the turn signal switch is on by itself, current is turn lights to glow continuously. The 4-way flasher
allowed to flow through the flasher and causes it to switch diode prevents the left turn lights from glowing
alternate on and off or flash. This flashing power flows continuously and allows them to remain blinking.
into terminals 3 and 4 of the turn signal switch. When
the turn signal switch is switched to the right, flashing Brake Light
power flows out terminal 2B and to the right front and
right rear turn light. The 4-way flasher switch diode When the brake pedals are depressed, pressurized oil
prevents the flashing power to flow to the left turn causes the brake light switch to close sending power
lights. When the turn signal switch is switched to the to the brake lights and lighting the lights.
CED,TX17864,222 1922SEP981/1

022602
PN=482
Turn Signal, Flasher, and Brake Light Circuit Schematic (S.N. 872257 )
T117361 1908OCT98
CED,TX17864,223 1922SEP981/1

022602
PN=483
Sub-System Diagnostics/Turn Signal,

Flasher, and Brake Light Circuit (S.N.
872257 )
CED,TX17864,224 1922SEP981/1
Turn Signal, Flasher, and Brake Light Circuit Diagnostic Procedures
This circuit is powered by the turn/stop/flash/horn fuse.
1/1

9015
Check 20 amp Turn/Stop/Flash/Horn fuse. NO: Go to next check.
15B
80
Is the fuse blown?
1/1
Brake Light Switch Disconnect harness from brake light switch. YES: Replace switch.
Check for continuity between the two terminals. NO: Go next step in this
check.
T7199DD UN16AUG90
Disconnect harness from brake light switch. YES: Brake light switch is
good. Check wiring
Key switch ON, engine running. harness.
Depress brake pedal and check for continuity between NO: Replace switch.
the two terminals.
T7199DD UN16AUG90
1/1
Brake Light Disconnect harness from turn/tail/brake light. YES: Brake light is good.
Connect 12 volts to terminal marked STOP, and ground
Does brake light function?
T7199DS 1902OCT90
1/1

022602
PN=484
Flasher Remove fuse cover. YES: Continue with

check.
Remove flasher from fuse block.
NO: An open circuit is
Key switch in ACC or ON position. indicated. Check
harnesses.
Check for voltage between G10 BLK and P19 RED
T117385 1908OCT98 terminals.
Is 12 volts measured?
Key switch in ACC or ON position. YES: Replace flasher.
4-way flasher switch ON. NO: An open circuit is

indicated. Check
Install a jumper wire between P19 RED and L49 BRN harnesses.
terminals.
T117386 1908OCT98 Do all turn lights light? 9015

15B
81
1/1
4-Way Flasher Switch YES: Switch is OK. Go to

next check.
NO: Replace switch.
T100731 UN28MAY96
4-way flasher switch ON.
Check for continuity between terminals 5B & 6.
1/1

022602
PN=485
Turn Signal Switch YES: Continue with

check.
NO: Replace switch.
9015
15B T100731 UN28MAY96
82
Turn signal switch in right turn position.
1/2

022602
PN=486
YES: Switch is OK. Go to

next check.
NO: Replace switch.
9015
T100731 UN28MAY96 15B
83
Turn signal switch in left turn position.
19 2/2
4-Way Flasher Switch Remove diode from connector. YES: If continuity is

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

022602
PN=487
Turn Signal Light Disconnect harness from turn/tail/brake light. YES: Turn signal light is
good. Check wiring
Connect 12 volts to terminal marked DIRECTIONAL, and harness.
ground terminal marked GROUND.
Does turn signal light function? is good replace light.
T7199DT 1902OCT90
1/1
Beacon Circuit Operational Information (S.N.

9015 872257 )
15B
84
The following conditions must exist for beacon circuit to
function:
Key switch to ACC or ON position

Beacon switch to ON position
CED,TX17864,225 1924SEP981/1
Beacon Circuit Theory of Operation (S.N.

872257 )
Power flows from return-to dig/beacon fuse to beacon

switch. With beacon switch ON, power flows to the
beacon. With beacon switch ON, power also flows to the
display monitor to illuminate the beacon indicator light in
the monitor. Ground for beacon is provided through G20
black wire.
CED,TX17864,226 1924SEP981/1

022602
PN=488
Beacon Circuit Schematic (S.N. 872257 )
9015
15B
85
1928OCT98
T117389
CED,TX17864,227 1924SEP981/1

022602
PN=489
Sub-System Diagnostics/Beacon Circuit (S.N.

872257 )
CED,TX17864,228 1924SEP981/1
Beacon Circuit Diagnostic Procedures
This circuit is powered by the return to dig/beacon fuse.
1/1

9015
Check 10 amp RTD/Beacon fuse. NO: Go to next check.
15B
86
Is the fuse blown?
1/1
Beacon Switch YES: Switch is OK. Go to

next check.
NO: Replace switch.
T100731 UN28MAY96
Beacon switch ON.
1/1

022602
PN=490
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

(S.N. 872257 ) 9015
15B
87
The following conditions must exist for return-to-dig circuit
to function:
Key switch ON
Engine running
CED,TX17864,233 1924SEP981/1
Return-to-Dig Circuit Theory of Operation

(S.N. 872257 )
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 G01 black.
CED,TX17864,232 1924SEP981/1

022602
PN=491
Return-to-Dig Circuit Schematic (S.N. 872257 )
9015
15B
88
1923SEP92
T7835AH
CED,TX17864,231 1924SEP981/1

022602
PN=492
Sub-System Diagnostics/Return-to-Dig
CED,TX17864,230 1924SEP981/1
Return-to-Dig Circuit Diagnostic Procedures
1/1

9015
Check 10 amp RTD/Beacon fuse. NO: Go to next check.
15B
89
Is the fuse blown?
1/1

022602
PN=493
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
15B T7199DG UN17SEP90
90
Disconnect harness from return-to-dig switch. YES: Return-to-dig switch

is good. Go to next
Actuate return-to-dig switch. check.
Check for continuity between common terminal and open NO: Replace return-to-dig
terminal. switch.
T7199DG UN17SEP90
1/1
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.
T7199DH 1917SEP90
Does control lever stay in return-to-dig detent position
until voltage is removed, and then return to neutral?
1/1

022602
PN=494

Specifications (S.N. 872257 )
Specification
Fuel Gauge Level Sender
Empty Resistance................................................................... 10 6 ohms
Full Resistance ................................................................... 180 12 ohms
Specification
Transmission Temperature
SenderResistance at 60C
(140F) ................................................................................ 221 26 ohms
Resistance at 90C (194F)
83 8 ohms
Resistance at 120C (248F) ........................................... 36.5 2.7 ohms
Specification
9015
SenderResistance at 60C
15B
(140F) ................................................................................ 221 26 ohms
91
Resistance at 90C (194F)
83 8 ohms
Resistance at 120C (248F) ........................................... 36.5 2.7 ohms
CED,TX17864,235 1924SEP981/1

Operational Information (S.N. 872257 )
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

022602
PN=495
Fuel Gauge and Hour Meter Circuit Theory of

Fuel Gauge:
The circuit consists of monitor fuse, fuel gauge/light and

fuel sender. Power flows from monitor/gauge fuse to (+)
terminal of fuel gauge, out S terminal of fuel gauge to fuel
sender. Fuel sender is grounded through G01 black wire.
Power also flows from (+) terminal of fuel gauge to fuel
gauge light. Fuel gauge light is grounded through G10
black wire.
As the fuel level changes, the resistance in through the

fuel sender also changes. The change in resistance
9015 causes a voltage change at terminal S of the fuel gauge,
15B this voltage change is what causes the needle in the
92 gauge to move.
Tachometer/Hour Meter:
Power flows through the monitor/gauge fuse to both the

tachometer and the tachometer lights.
With key switch ON and engine running, hour meter and

tachometer also get power from W terminal of alternator
through M39 purple wire. This is the signal power source
that causes the hour meter to begin counting time and
also indicates engine speed.
The hour meter, tachometer, and tachometer lights are all

grounded by G10 BLK.
Optional Gauge Cluster
This gauge cluster replaces the single fuel gauge with a

four gauge cluster that contains fuel, voltage, transmission
temperature, and engine coolant gauges. The fuel gauge,
transmission temperature, and engine coolant temperature
gauges all measure a changing voltage at the S terminal
of the gauge. The voltage change is caused by the
changing resistance in the sender. The voltage gauge
simply measures the system voltage.
CED,TX17864,236 1924SEP981/1

022602
PN=496
Fuel Gauge and Hour Meter Circuit Schematic (S.N. 872257 )
9015
15B
93
1908OCT98
T117535
CED,TX17864,237 1924SEP981/1

022602
PN=497
Sub-System Diagnostics/Fuel Gauge and

Hour Meter Circuit (S.N. 872257 )
CED,TX17864,238 1924SEP981/1
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.
9015
15B
NO: Replace fuel gauge.
94
Disconnect harness from fuel gauge.
Connect battery voltage to (+) terminal and ground GND

terminal.
T7199DI UN02OCT90
1/1
Fuel Gauge Sender Key switch ON. Engine OFF. YES: Fuel gauge sender
is good. Check wiring
Disconnect wire Y33 yellow from center of sender. harness to sender.
Does gauge read FULL? NO: Replace sender.
Reconnect wire Y33 yellow to center of sender.
T6431AJ UN19OCT88
Attach a jumper wire from center screw to ground.
1/1

022602
PN=498
Tachometer Machine running. YES: Hour meter is bad,

Lower all equipment to ground. meter.
FNR lever in neutral. NO: Check wiring

harness.
Park brake ON.
T117604 UN08OCT98 Disconnect tachometer from harness.
Connect multi-meter to harness as shown.
Measure voltage.
Are 1214 volts (DC) measured?
Machine running. YES: Tachometer is bad,

Lower all equipment to ground. meter. 9015
15B
FNR lever in neutral. NO: Check wiring 95
harness.
Park brake ON.
T117605 UN08OCT98
Disconnect tachometer from harness.
Measure voltage.
Are approximately 7.63 volts (AC) measured?
1/1
Hour Meter Machine running. YES: Hourmeter is bad,

replace hour meter.
Lower all equipment to ground.
NO: Check wiring
FNR lever in neutral. harness.
Park brake ON.

T117606 UN08OCT98
Disconnect hourmeter from harness.
Measure voltage.
Are approximately 7.63 volts (AC) measured?
1/1

022602
PN=499
Optional Gauge Cluster YES: Fuel gauge is good.

Continue with check.
NO: Replace gauge

cluster.
9015
15B
96
T105163 1919NOV96
Disconnect Y33 YEL and G10 BLK wires from gauge cluster.
Does fuel gauge read EMPTY?
Connect battery voltage to terminal 3 and ground to terminal G.
Does fuel gauge read FULL?
1/4

022602
PN=500
YES: Engine coolant

temperature gauge is
good. Continue with
check.
NO: Replace gauge

cluster.
9015
15B
97
T105163 1919NOV96
Does engine coolant temperature gauge read COLD?
Does engine coolant temperature gauge read HOT?
19 2/4

022602
PN=501
YES: Transmission
temperature gauge is
good. Continue with
check.
NO: Replace gauge

cluster.
9015
15B
98
T105163 1919NOV96
Does transmission temperature gauge read COLD?
Does transmission temperature gauge read HOT?
19 3/4

022602
PN=502
YES: Voltage gauge is

NO: Replace gauge

cluster.
9015
15B
99
T105163 1919NOV96
Disconnect P21 RED and G10 BLK wires from gauge cluster.
Does voltage gauge read LOW?
Connect battery voltage to terminal B+ and ground to terminal G.
Does voltage gauge read HIGH?
19 4/4
Engine Coolant Key switch ON. Engine OFF. YES: Replace sender.
Temperature Sender
(Optional) Disconnect wire Y01 YEL from engine coolant sender. NO: Sender is good.
Check wiring harness to
Does engine coolant temperature gauge read COLD? sender.
Ground Y01 YEL wire.
T117613 1908OCT98
Does engine coolant temperature gauge read HOT?
1/1

022602
PN=503
Transmission Key switch ON. Engine OFF. YES: Replace sender.

Temperature Sender
(Optional) Disconnect wire Y02 YEL from transmission temperature NO: Sender is good.
sender. Check wiring harness to
sender.
Does transmission temperature gauge read COLD?
Ground Y02 YEL wire.

T117614 1908OCT98
Does transmission temperature gauge read HOT?
1/1
Display Monitor Circuit Operational

9015 Information (S.N. 872257 )
15B
,100
The following condition must exist for display module to
function.
The key switch must be in the ON position so failures

will be indicated.
TX,9015,QQ6774 1906JUN961/1

022602
PN=504
Display Monitor Circuit Theory Of Operation (S.N. 872257 )
UN22OCT98
T118037
APark Brake Indicator FTransmission Oil IBrake Pressure Indicator MMechanical Front Wheel
BSeat Belt Indicator Temperature Indicator JAlternator Voltage Indicator Drive Indicator (If 9015
CSTOP-Engine Indicator GHydraulic Oil Filter KAir Filter Restriction Equipped) 15B
DEngine Coolant Restriction Indicator Indicator ,101
Temperature Indicator HNot Used LBeacon Indicator (If
EEngine Oil Pressure Equipped)
Indicator
Power is supplied to the display monitor through the indicator comes on, or temperature will rise further.
10 AMP Monitor/Gauge fuse. Reduce load and run engine at slow idle for several
minutes, stop engine and service machine.
Each display indicator will be colored either (RED) or Brake Pressure Indicator
(YELLOW) to indicate the severity of the situation. Red
is a high level warning and the yellow is a low level CONDITION: Low Level Warning Indicators (YELLOW)
warning. When the RED high level warning is SERVICE
indicated, the operator will see a (RED COLORED
INDICATOR), (RED STOP INDICATOR) and Air Filter Restriction Indicator:
(AUDIBLE ALARM). When the YELLOW low level Charging System Indicator:
warning is indicated, the operator will see only the Converter Oil Temperature Indicator:
(YELLOW COLORED INDICATOR). On Low Level Hydraulic Oil Filter Indicator:
warnings the operation of the machine can continue Hydraulic Oil Temperature Indicator:
but the problem should be investigated and solved. On
High Level warnings except Engine Coolant CONDITION: Seat Belt Indicator (WHITE)
Temperature Indicator the operation of the machine
should be stopped immediately and problem corrected, The seat belt indicator will be back-lighted White
when ever the key switch is on and park brake is
CONDITION: High Level Warning Indicators (RED) applied.
STOP
CONDITION: MFWD Indicator (GREEN)
Red Stop Indicator:
Park Brake Indicator: MFWD indicator will be back-lighted Green when
Engine Oil Pressure Indicator: switch is on.
Engine Coolant Temperature Indicator: DO NOT
stop engine when engine coolant temperature CONDITION: Beacon Indicator (GREEN)

022602
PN=505
Beacon indicator will be back-lighted Green when

switch is on.
CED,TX17864,173 1911SEP982/2
9015
15B
,102

022602
PN=506
Display Monitor Circuit Schematic (S.N. 872257 )
9015
15B
,103
1918SEP98
T117170
CED,TX17864,174 1911SEP981/1

022602
PN=507
Sub-System Diagnostics/Display Monitor

(S.N. 872257 )
TX,9015,QQ6777 1906JUN961/1
Display Monitor Diagnostic Procedures
This circuit is powered by the monitor/gauge fuse.
1/1
Fuse Remove fuse cover. YES: Replace fuse

9015
Check 10 amp monitor/gauge fuse. NO: Go to next check.
15B
,104
Is fuse blown?
1/1

this check.
NO: Check wiring

T7199BO UN17SEP90

this check.
T7199BO UN17SEP90
T7199BO UN17SEP90
1/1

022602
PN=508
Display Monitor YES: Go to next step in

this check.
NO: Check wiring

harness
9015
T102886 1908AUG96 15B
,105
Unplug 12 pin harness connector from display monitor.
Key switch to ON position.
Check for voltage on P21 red wire
YES: Check connector

pins in connector.
IF OK: Go to indicator
circuit and check
indicators.
IF OK: Replace display

monitor.
NO: Check wiring

harness.
T102887 1908AUG96
Unplug 8 pin harness connector from display monitor.
Key switch to OFF position.
Check for continuity between R31 black wire and ground.
1/1

022602
PN=509
Indicator Circuit Specifications (S.N.

872257 )
Specification
Switch (Normally Open)Closing
Temperature ........................................................... 110 5C (230 9F)
Specification
Engine Oil Pressure Switch
Pressure ........................................................... 3772 kPa (0.40.7 bar)
(5.510.5 psi)
Specification
Air Filter Restriction Switch
(Normally Open)Closing
Vacuum.................................................. 4.987.48 kPa Vacuum (2030
9015
in. H2O)
15B
,106
Specification
Converter Oil Temperature Switch
Temperature ............................................. 114C122C (238F252F)
Specification
Hydraulic Filter Restriction Switch
Pressure ......................................................... 344 kPa (3.45 bar) (50 psi)
Specification
Brake Pressure Switches
Pressure ............................................... 7584 690 kPa (75.84 6.9 bar)
(1100 100 psi)
CED,TX17864,175 1914SEP981/1

022602
PN=510
Indicator Circuit Operational Information

(S.N. 872257 )
The indicator circuit has Two modes of operation.
Bulb check mode

Failure mode

function in bulb check mode:
Key switch moved between ON and START position

for bulb check.

function in a failure mode: 9015
15B
Engine must be running for a failure to be indicated on ,107
display monitor. An indicator switch or alternator senses a
failure and supplies a high or low level warning to display
monitor.
TX,9015,QQ6779 1906JUN961/1

022602
PN=511
Indicator Circuit Theory Of Operation (S.N. 872257 )
Indicator switches to the display monitor are: Bulb Check Mode
B17 Brake Pressure Switch: (Stop) Key switch is moved between ON and START
B18 Brake Pressure Switch: (Stop) position to activate bulb check mode. All high and low
B10Park Brake Pressure Switch: (Stop) level indicator lights will activate and audible alarm will
B6Engine Oil Pressure Switch: (Stop) sound. The seat belt (White) indicator will be on.
B5Engine Coolant Temperature Switch: (Stop)
B7Air Filter Restriction Switch: (Service) High or Low Level Warning Mode
B8Converter Oil Temperature Switch: (Service)
B9Hydraulic Filter Restriction Switch: (Service) During normal operation the indicator lights are turned
B2Hydraulic Oil Temperature Switch (Service) on when an indicator switch or the alternator provides
G2Alternator: (Service) a signal to the display monitor indicating a STOP
High Level Warning or SERVICE Low Level Warning
The following indicators will be displayed on display indicator.
9015
15B monitor when a signal from a High Level Warning
,108 Indicator switch is activated: Seat Position Sensor
Red Colored Indicator The seat position sensor is located in the operators
Red Stop Indicator seat base. When the seat is moved to operate
Audible Alarm backhoe functions the sensor is closed. When the
sensor is closed (seat moved to operate backhoe
The following indicator will be displayed on display functions) A signal is sent to the display monitor. When
monitor when a signal from a Low Level Warning the FNR lever is moved into forward or reverse
Indicator switch is activated or the signal from the position during backhoe operation the display monitor
alternator disappears. is activated turning on the audible alarm and the red
STOP indicator light.
Yellow Colored Indicator
On Mode
Key switch is moved to ON position. The park brake,

seat belt, engine oil pressure, charging system light
and stop warning light will be on.
CED,TX17864,176 1914SEP981/1

022602
PN=512
Indicator Circuit Schematic (S.N. 872257 )
9015
15B
,109
1918SEP98
T117193
TX,9015,QQ6781 1902OCT961/1

022602
PN=513
Sub-System Diagnostics/Indicator Circuit

(S.N. 872257 )
TX,9015,QQ6782 1902OCT961/1
Indicator Circuit Diagnostic Procedures
This circuit is powered by the monitor fuse, and hazard/monitor fuse.
1/1
9015
15B
,110
T7199CG 1916AUG90
1/1
Engine Oil Pressure Disconnect N34 yellow wire from switch and ground to YES: Replace switch.
Switch frame.
Is engine oil pressure indicator light on?
T7199DZ 1926SEP90
1/1
Engine Alternator Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39 YES: Circuit is good.
Indicator Circuit purple wire. Repair or replace
alternator.
Without starting engine, turn key switch to BULB CHECK, then release to ON.
NO: Go to next check.
Is alternator indicator light off?
Remove voltage from M39 purple wire.
Is alternator indicator light on?
1/1

022602
PN=514
Engine Air Filter Disconnect M40 purple wire from switch and ground to YES: Replace switch.
Restriction Switch frame.
CHECK, then release to ON?
Is air filter restriction indicator light on?
T7199CI 1917SEP90
1/1
Converter Oil Disconnect X38 yellow wire from switch and ground to YES: Replace switch.
Temperature Switch frame.
9015
15B
Without starting engine, turn key to BULB CHECK, then to next check.
,111
release to ON.
T7199CJ 1917SEP90
1/1
Hydraulic Filter Disconnect F39 yellow wire from switch and ground to YES: Replace switch.
Restriction Indicator frame.
T7199CK 1917SEP90
1/1

022602
PN=515
Brake Pressure Switches Disconnect left brake pressure switch from harness. YES: Replace Switch
Install jumper wire into harness connector as shown. NO: Switch is good.
Continue with check.
Without starting engine, turn key switch to BULB
Is indicator light off?

T117196 1918SEP98
Disconnect right brake pressure switch from harness. YES: Replace Switch
Install jumper wire into harness connector as shown.
NO: Switch is good. An
Without starting engine, turn key switch to BULB open circuit in harnesses
CHECK, then release to ON. is indicated. Check
harnesses. Go to next
Is indicator light off? check.
9015
15B T117194 1918SEP98
,112
1/1
Seat Position Sensor Key switch OFF. YES: Seat position

sensor is good. Check
Seat in loader function position. wiring harness.
NOTE: Seat position sensor is located in the operators NO: Replace seat
seat base. position sensor.

T102968 1912AUG96 wire and G10 black wire
Move seat into backhoe function position

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

022602
PN=516
Selective Flow Valve Circuit Operational

The following conditions must exist for the selective flow

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

modes of operation. It can be either continuously
on or momentarily on using the foot switch. This
selected using the two different positions on the
switch in the dash.
NOTE: If the selective flow valve switch is in either

continuous on or foot on position when the
machine is started, the switch must be cycled to
off and then back on for the system to operate. 9015
15B
Key switch ON ,113
Selective flow valve switch in either foot ON or
continuous ON.
Foot switch held ON if selective flow valve switch is in
foot ON position.
CED,TX17864,119 1931JUL981/1

022602
PN=517
Selective Flow Valve Circuit Theory of

NOTE: If the selective flow valve switch is in either

continuous on or foot on position when the
machine is started, the switch must be cycled to
off and then back on for the system to operate.
Power flows from the auxiliary fuse (F15) to both the

selective flow valve relay (K8) and the selective flow valve
switch (S28). With the selective flow valve switch in the off
position, power flows through the switch to back to the coil
side of the selective flow valve relay to energize the relay.
With the selective flow valve relay energized, power now

9015 flows from the relay to the selective flow valve switch
15B through the H01 GRN wire.
,114
With the selective flow valve switch in the foot on position,
power flows through the switch lighting the bulb in the
switch and through the H04 GRN wire to the foot switch
(S29). When the foot switch is depressed, power
continues to flow through the H03 GRN wire to the
selective flow valve solenoid (Y16) . When the foot switch
is released, power stops flowing to the solenoid and the
selective flow valve relay diode (V5) allows the current to
dissipate.
With the selective flow valve is in the continuous on

position, power flows through the switch lighting the bulb
in the switch and through H03 GRN wire to the selective
flow valve solenoid. When the switch is switched off,
power stops flowing to the solenoid and the selective flow
valve relay diode (V5) allows the current to dissipate.
CED,TX17864,116 1931JUL981/1

022602
PN=518
Selective Flow Valve Circuit Schematic (S.N. 872257 )
9015
15B
,115
1931JUL98
T116668
CED,TX17864,117 1931JUL981/1

022602
PN=519
Sub-System Diagnostics/Selective Flow

Valve Circuit (S.N. 872257 )
CED,TX17864,118 1931JUL981/1
Selective Flow Valve Diagnostic Procedures
This circuit is powered by the auxiliary fuse.
1/1
Fuse Check Remove fuse cover. YES: Replace fuse.

9015
Check 10 amp auxiliary fuse. NO: Go to next check.
15B
,116
Is fuse blown?
1/1

022602
PN=520
Selective Flow Valve YES: Go to next check.

Switch Check
NO: If switch fails any of
the above continuity
checks, replace switch.
9015
T100731 UN28MAY96 15B
,117
Disconnect harness from selective flow valve switch.
Selective Flow Valve Switch to OFF position
Is Continuity measured?
Selective Flow Valve Switch to foot on position.
Check for continuity between terminals 5B and 3 of switch.
Selective Flow Valve Switch to continuous on position.
Check for continuity between terminals 5B and 6 of switch.
1/1
Foot Switch Check Disconnect foot switch from harness. YES: Go to next check.
Depress foot switch. NO: Replace foot switch.
Check for continuity at connector.
T116147 1927JUL98
1/1

022602
PN=521
Selective Flow Valve Key switch ON. YES: Replace solenoid.

Solenoid Check
Selective flow valve switch in continuous on position. NO: Check wiring
harness.
Disconnect selective flow valve harness under cab.
Measure voltage at end of harness.
T116672 1931JUL98 Are 12 volts measured?
1/1
9015
15B
,118

022602
PN=522
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
AClamp-On Tachometer.
UN28FEB89
Remove paint with emery cloth and connect to a straight section of
injection line within 100 mm (4 in.) of pump. Finger tighten onlyDO
NOT over tighten.
BBlack Clip (-). Connect to main frame.
T6813AG
DTachometer Readout. Install cable.
10T,9010,K182 1910AUG951/1

022602
PN=523
References
Battery Operation
A battery is a device for converting chemical energy to Batteries should be maintained at an open circuit
electrical energy. It is not a storage tank for electricity, voltage of 12.50 volts or greater. To determine open
but stores electrical energy in chemical form. circuit voltage do the following:
Because of the constant chemical to electrical change 1. Turn master disconnect switch to ON position.
(self-discharge, discharge, or charge), the battery has
a limited life. Proper care (cleaning, adding water, 2. For machines that have not been run during the
charging) will extend the life of the battery. past ten hours, go to Step 4.
The battery is made up of positive plates, negative 3. For machines that have been run in the past ten
plates, separators, plate straps, and chemical solution hours, remove surface charge. Turn key switch to
(electrolyte). The electrolyte is a solution of sulfuric START, turn on 3 or 4 work lights and leave them
acid and water. Sulfuric acid is not lost during on for 3 to 5 minutes. Turn key switch OFF, then
overcharging; therefore, if the liquid solution is low, wait two minutes. (If machine does not have lights,
9015
20 only water should be added. turn key switch to START position for at least 5
2 minutes, then turn off.)
In a fully charged battery, the positive plate is lead
peroxide (PBQ2), the negative plate is "spongy" lead 4. Measure voltage at alternator by placing the
(Pb), and the electrolyte solution is about 1.270 times negative lead of a multimeter to case of alternator
heavier than water. The amount that the solution is and the positive lead to the sense terminal of the
heavier than water is called specific gravity. alternator.
All batteries will self discharge at a rate of .001 specific STABILIZED OPEN
gravity point per 24 hour period at a constant 85 F. CIRCUIT VOLTAGE PERCENT CHARGED
The discharge rate increases as temperature increases 12.5 Volts or More 100%
and decreases as temperature decreases. If the 12.4 75%
machine is not used for a period of time, the batteries 12.2 50%
must be maintained or stored in a cool place. 12.0 25%
11.7 or less 0%
Wipe batteries with a damp cloth. If terminals are
corroded, use a stiff brush and wash with an ammonia
solution. After washing, flush battery and compartment
with clear water. Keep caps in place when cleaning
and charging.
TX,9015,MM1631 1910AUG951/1

022602
PN=524
References
Battery Specifications
Specification
BatteryVoltage............................................................................ 12 Volts
Cold Cranking Power ......................................... 625 amps at -18C (0F)
Reserve Capacity ................................................ 160 minutes at 25 amps
BCI Group Size ...................................................................................... 31
Fully Charged Electrolyte Specific
Gravity ................................................................................... 1.2651.280
TX,9015,BG993 1902APR971/1
9015
20
3

022602
PN=525
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

022602
PN=526
References
Check Battery Electrolyte Level and

Terminals
ABattery Post
BFill Tube
CElectrolyte Level Range
9015
20
5
UN23AUG88
TS203
UN10FEB89
T6996DB
Single Level Fill Tube Application
UN10FEB89
T6996DA
Dual Level Fill Tube Application

022602
PN=527
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.
1. Remove hold-down clamps.
2. Remove battery covers.

022602
PN=528
References
IMPORTANT: During freezing weather, batteries must

be charged after water is added to
prevent battery freezing. Charge battery
using a battery charger or by running
the engine.
3. Fill each cell to within specified range with distilled

water. DO NOT overfill.
TX,9015,QQ1696 1901SEP953/3
Procedure for Testing Batteries

9015
Visual Check Record specific gravity reading for each cell. 20
7
1. Check for damage such as cracked or broken case If high and low readings vary LESS than 0.050 and
and electrolyte leakage. average specific gravity is between 1.225 and 1.280,
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
2. Check electrolyte level. (See procedure in this average specific gravity is LESS than 1.225, charge
group) battery and repeat test. If average specific gravity is
still LESS than 1.225, replace both batteries.
If low, add distilled water to specified level and
charge battery. If high and low readings vary MORE than 0.050,
charge battery and repeat test. If high and low
3. Check terminals for corrosion. readings still vary MORE than 0.050, replace both
batteries.
If corroded, clean using a wire brush or battery post
cleaner such as JT05838 Battery Post/Clamp Load Test
Cleaner.
Check battery capacity with a load tester such as
4. Check posts for looseness. JT05832 Battery Load Tester. Follow tester
manufacturers instructions for proper load test
If posts are loose, replace battery. procedures.
Hydrometer Test If one battery fails load test, replace both batteries.
Check specific gravity with a hydrometer or battery

tester such as JT05460 Coolant/Battery Tester.
TX,9015,DY669 1916AUG961/1

022602
PN=529
References
Using Booster Batteries12 Volt System
9015
20
8
UN24OCT91
UN24OCT91
T6508AE1
T6713AI1
Single Battery Application Two Battery Application
AMachine Batteries BBooster Batteries
Before boost starting, machine must be properly shut IMPORTANT: The machine electrical system is a
down and secured to prevent unexpected machine 12 volt negative (-) ground. Use only
movement when engine starts. 12 volt booster batteries.
Connect booster batteries as shown for your battery

CAUTION: An explosive gas is produced
application. Make last connection to frame.
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.
TX,901505,QQ364 1901SEP951/1

022602
PN=530
References
9015
20
9

022602
PN=531
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.
Continued on next page TX,9015,QQ1926 1910AUG951/2

022602
PN=532
References
When the alternator is operating, the R terminal and removing the ground for the alternator indicator
voltage is approximately 7.8 volts AC. This voltage is light (D) in the display module, turning off the
supplied to the alternator relay, energizing the relay alternator indicator light.
TX,9015,QQ1926 1910AUG952/2
9015
20
11

022602
PN=533
References
Alternator Operation95 Amp BOSCH (Serial No. 787514 )
9015
20
12
1923SEP92
T7812AZ
AAlternator GD+ Terminal LExternal Ground Terminal QAlternator Relay
BInternal Ground HB+ Terminal MRotor RIndicator Light
CNegative Diodes IW Terminal NAlternator Diode SBrushes
DExciter Diodes JExcitation Winding OBattery TSense Circuit
EStator Windings KRegulator PKey Switch UNoise Filter
FPositive Diodes
TX,9015,QQ1927 1910AUG951/1

022602
PN=534
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
to idle) current supplied by the external alternator switches the field ON and OFF several thousand times 20
diode to the field coil of the rotor produces a magnetic a second in response to the current load placed on the 13
field which induces current in the three-phase winding alternator output and the engine RPM.
of the stator (E). The alternator reaches cut-in RPM
when the induced current is large enough to produce When the alternator is operating, the W terminal
voltage equal to the battery voltage plus 1.0 volt. At voltage is (7 to 8) volts (AC). This voltage is supplied
this time, some current from the stator is rectified by to the alternator relay, energizing the relay and
the exciter diodes (D) (producing battery voltage at the removing the ground for the alternator indicator light
D+ terminal (G)) and is supplied to the carbon brushes (Q) in the display module, turning off the alternator
and slip rings of the excitation winding (J), indicator light.
strengthening the magnetic field in the excitation
winding. This in turn will increase the stator voltage. Current available from the alternator is dependent on
This will occur continuously until the alternator (A) is engine RPM. Depending on pulley ratios, little or no
fully excited and the alternator regulated voltage is current is available below abut 700 RPM. Full rated
reached. current is not available below about 1500 RPM.
Normal Operation:
The alternating current induced in the stator winding

(J) is rectified by the positive and negative diodes (C
TX,9015,DY670 1916AUG961/1

022602
PN=535
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 indicator light and the yellow warning light should
check". Hold just momentarily in "bulb check". If come on. There may be additional indicator lights
held too long, the logic modules with time delay will on, depending on which secondary (yellow light)
have no delay. With machines that have time delay failure sending unit switches are closed.
logic modules, after 2-3 seconds the engine oil
pressure and engine alternator volts indicator lights 5. If the warning lights do not come on, with (S.N
and the red warning light and buzzer should come 815415) the next step is to isolate the logic module
on. With no time delay the lights and buzzer will from the display module and the machine wiring
9015
20 come on immediately. On some machines and sending units. See Logic Module Test In
14 additional indicator lights may come on, depending Machine, and Logic Module Bench Test in this
on sending unit switches being closed and sending group.
a ground signal to the monitor.
3. Turn key switch to "OFF" position. Disconnect lead

from engine oil pressure switch and all other
TX,9015,QQ3203 1910MAR971/1

022602
PN=536
References
Logic Module Test in Machine (S.N.

815415)
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.
5. With pin "F" grounded, red STOP light and alarm must 9015
come on. 20
15
If logic module does not work when grounding pins
"D", "E" and "F", check logic module wiring by
UN03NOV88
continuing with step 6. If wiring is OK, replace logic
module.
T6883BE

022602
PN=537
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
20 6-Pin Connector
16 A12 Volts
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 1910MAR972/2

022602
PN=538
References
Logic Module Bench Test (S.N. 815415)
9015
20
17
UN28FEB94
UN28FEB94
T8188AM
T8188AN
IMPORTANT: DO NOT allow wires to touch one does, remove wire from pin E and go to next step.
another after being connected to If light does not come on, replace module.
logic module.
5. Connect wire (E) to pin B in small connector. Light
1. Connect wires (A and B) from positive (+) battery must come on. If it does, remove wire (E) from pin
post to pins A and C in large connector. B and go to next step. If light does not come on,
replace module.
2. Connect wire (C) from negative battery post to pin
F in large connector. 6. Remove the indicator light lead from pin D in large
connector and connect to pin C in small connector.
3. Using a 12V indicator light with two wire leads, Connect wire (D) to pin D in small connector. Light
connect one lead to pin D in large connector, and must pulse on and off. If it does not, replace
one lead to pin A in small connector. module.
4. Connect wire (D) to pin E in large connector, and

negative battery post. Light must come on. If it
TX,9015,QQ3202 1910MAR971/1

022602
PN=539
References
Tachometer Calibration (S.N. 872256)
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
18

022602
PN=540
References
Tachometer Calibration (S.N. 872257 )
1. Remove side console panel.
2. Verify engine speed using tachometer. See

Tachometer Installation in this group.
NOTE: Calibration of tachometer should be performed at

an engine speed near 2000 rpm.
3. Cut and remove plastic covering from calibration button
UN09APR98
(E) on back of tachometer (C).
4. Press and hold in calibration button as you turn on

ignition and start engine. Hold button until ADJUST is
T114085
displayed on LCD readout. When it does, release
9015
calibration button. 20
19
5. Press calibration button once, and UP will be
displayed on LCD readout for upward calibration of
pointer. Press calibration button again, and DN will be
displayed for downward calibration of pointer.
UN02APR98
NOTE: If pointer is moved past upper limit of calibration
range, LCD display will flash and pointer can only
be adjusted downward. If pointer is moved past
lower calibration limit, LCD display will also flash
T114688B
and pointer can only be adjusted upward.
6. When either UP or DN is showing, press button

again and hold it in to move pointer. If button is held in
for just a short time, pointer will move slowly either
upwards or downwards, depending on which mode is
selected. Holding button in for a longer period of time
makes pointer move faster.
7. When pointer is in desired position, release calibration

button and wait. If no further adjustments are made
within one minute, tachometer will perform self-test and
revert back to normal operating mode.
8. After calibration is complete, cover hole for calibration

button (E) with a small amount of non-corrosive
Form-in-Place Gasket sealer.
CTachometer
ECalibration Button
1903APR98
T114523
CED,TX17864,110 1921JUL981/1

022602
PN=541
References
9015
20
20

022602
PN=542
Section 9020
Power Train
Contents
Page Page
Group 05ATheory of Operation (S.N. 872256) Control Circuit-First

Transmission. . . . . . . . . . . . . . . . . . . . . . . 9020-05A-1 Forward-Continued. . . . . . . . . . . . . . 9020-05B-21
Torque Converter Operation . . . . . . . . . . . 9020-05A-4 Control Valve and Shift Valve-First
Power Flow Through Transmission Forward . . . . . . . . . . . . . . . . . . . . . . 9020-05B-22
Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . 9020-05A-6 Control Circuit-High Range (Fourth)
First Forward . . . . . . . . . . . . . . . . . . . . . 9020-05A-8 Forward . . . . . . . . . . . . . . . . . . . . . . 9020-05B-24
Second Forward . . . . . . . . . . . . . . . . . 9020-05A-10 Control Circuit-High Range (Fourth)
Third Forward . . . . . . . . . . . . . . . . . . . 9020-05A-12 Forward-Continued. . . . . . . . . . . . . . 9020-05B-25
Fourth Forward . . . . . . . . . . . . . . . . . . 9020-05A-14 Control Valve and Shift Valve-High Range
First Reverse . . . . . . . . . . . . . . . . . . . . 9020-05A-16 (Fourth) Forward . . . . . . . . . . . . . . . 9020-05B-26
Second Reverse . . . . . . . . . . . . . . . . . 9020-05A-18 Control Circuit-First Reverse . . . . . . . . 9020-05B-28
Pressure Regulating Valve Operation . . . 9020-05A-20 Control Circuit-First
Reverse-Continued. . . . . . . . . . . . . . 9020-05B-29 9020
Transmission Filter Operation . . . . . . . . . 9020-05A-22
Neutral Disconnect Solenoid Operation . . 9020-05A-23 Control Valve and Shift Valve-First
Transmission Control Circuit Reverse . . . . . . . . . . . . . . . . . . . . . . 9020-05B-30
First Neutral . . . . . . . . . . . . . . . . . . . . . 9020-05A-24 Power Shift Modulation Valve
First Forward . . . . . . . . . . . . . . . . . . . . 9020-05A-28 Operation. . . . . . . . . . . . . . . . . . . . . . . 9020-05B-32
Second Reverse . . . . . . . . . . . . . . . . . 9020-05A-29 Differential Operation . . . . . . . . . . . . . . . 9020-05B-34
MFWD System Operation . . . . . . . . . . . . 9020-05A-30 Differential Lock Operation . . . . . . . . . . . 9020-05B-36
MFWD Differential Operation (S.N. 872256) Park Brake Operation . . . . . . . . . . . . . . . 9020-05B-38
Unequal Traction . . . . . . . . . . . . . . . . . 9020-05A-31 Mechanical Front Wheel Drive (MFWD)
MFWD Differential Operation Operation. . . . . . . . . . . . . . . . . . . . . . . 9020-05B-40
Equal Tractiion . . . . . . . . . . . . . . . . . . 9020-05A-33 MFWD Differential Operation
Transmission Hydraulic Schematic . . . . . 9020-05A-35 Equal Traction . . . . . . . . . . . . . . . . . . . 9020-05B-42
Unequal Traction . . . . . . . . . . . . . . . . . 9020-05B-44
Group 05BTheory of Operation (S.N. 872257 )
Power Train Conponents. . . . . . . . . . . . . . 9020-05B-1 Group 15ASystem Diagnostic Information
Torque Converter Operation . . . . . . . . . . . 9020-05B-2 (S.N. 872256)
Transmission Pump Operation . . . . . . . . . 9020-05B-4 John Deere Inboard Planetary AxlesUse
Transmission Filter Operation . . . . . . . . . . 9020-05B-5 CTM43. . . . . . . . . . . . . . . . . . . . . . . . . . 9020-15A-1
Thermal Bypass Valve Operation . . . . . . . 9020-05B-6 Diagnose Power Train Malfunctions . . . . . 9020-15A-2
Power Shift High Range Forward, First Transmission Oil Passage Identification . . 9020-15A-8
Speed and Second Speed Clutch
Packs . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-05B-8 Group 15BSystem Diagnostic Information (S.N.
Power Shift Power Train Overview . . . . . 9020-05B-10 872257 )
Power Shift Transmission Gear Flow . . . 9020-05B-12 Diagnose Power Shift Power Train
Power Shift Transmission Clutch Malfunction . . . . . . . . . . . . . . . . . . . . . . 9020-15B-1
Engagement And Solenoids Diagnose MFWD Malfunction . . . . . . . . . 9020-15B-10
Activated . . . . . . . . . . . . . . . . . . . . . . . 9020-05B-14 Diagnose Rear Axle Malfunction . . . . . . . 9020-15B-11
Power Shift Transmission Hydraulic Circuit Symbols . . . . . . . . . . . . 9020-15B-15
Control Circuit-Neutral . . . . . . . . . . . . . 9020-05B-16
Control Circuit-Neutral-Continued. . . . . 9020-05B-17 Group 20Adjustments
Control Valve and Shift Check and Adjust Toe-In. . . . . . . . . . . . . . . .9020-20-1
Valve-Neutral . . . . . . . . . . . . . . . . . . 9020-05B-18
Control Circuit-First Forward . . . . . . . . 9020-05B-20 Continued on next page

022602
PN=1
Contents
Page Page
Group 25ATests (S.N. 872256) MFWD Pressure Test . . . . . . . . . . . . . . . 9020-25B-20

JT05801 Clamp-On Electronic Tachometer Cooler In and Cooler Out Pressure
Installation . . . . . . . . . . . . . . . . . . . . . . . 9020-25A-1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-22
JT05800 Digital Thermometer Transmission Oil Cooler Thermal Bypass
Installation . . . . . . . . . . . . . . . . . . . . . . . 9020-25A-1 Valve Test . . . . . . . . . . . . . . . . . . . . . . 9020-25B-24
Transmission Warm-Up Procedure . . . . . . 9020-25A-2 Transmission Oil Cooler Thermal Bypass
Torque Converter Stall Speed Test . . . . . . 9020-25A-4 Valve Pressure Test . . . . . . . . . . . . . . 9020-25B-26
Transmission System Pressure Test . . . . . 9020-25A-6 Solenoid Circuit Leakage Test. . . . . . . . . 9020-25B-28
Transmission Pump Flow Test . . . . . . . . . 9020-25A-8 Pump Flow Test . . . . . . . . . . . . . . . . . . . 9020-25B-30
Converter-In/Cooler Relief Pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25A-10
Neutral Disconnect Solenoid Test . . . . . . 9020-25A-12
Mechanical Front Wheel Drive (MFWD)
Clutch Pressure Test . . . . . . . . . . . . . . 9020-25A-14
Transmission Leakage Test (Using
Converter-In/Cooler Pressure) . . . . . . . 9020-25A-16
Analysis of Transmission Leakage Test Using
Converter-In/Cooler Pressure. . . . . . . . 9020-25A-20
Transmission Oil Cooler Restriction
9020
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25A-22
Transmission Lube Pressure Test . . . . . . 9020-25A-24
Control Circuit Test Using Seven Gauge
Method (Modified) . . . . . . . . . . . . . . . . 9020-25A-26
Complete Transmission System Test . . . 9020-25A-28
Test Procedure . . . . . . . . . . . . . . . . . . . . 9020-25A-32
Complete Transmission System Test
Checkout Sheet . . . . . . . . . . . . . . . . . . 9020-25A-34
Analysis of Complete Transmission
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25A-36
C2,B3 (Upper) Accumulator Operation at B3
Test Port . . . . . . . . . . . . . . . . . . . . . . . 9020-25A-38
C1,B1,B2 (Lower) Accumulator Operation
at B2 Test Port . . . . . . . . . . . . . . . . . . 9020-25A-39
Transmission Drag Test . . . . . . . . . . . . 9020-25A-40
Group 25BTests (S.N. 872257 )

Installation . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-1
JT05800 Digital Thermometer
Installation . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-1
Transmission Oil Warm-Up Procedure . . . 9020-25B-2
Power Shift Transmission Overall Test
Connections, Ports, and Locations. . . . . 9020-25B-3
Torque Converter Stall Speed Test . . . . . . 9020-25B-4
Converter-In Relief Valve Test . . . . . . . . . 9020-25B-6
Park Brake Release Pressure Test . . . . . . 9020-25B-8
System Pressure Test . . . . . . . . . . . . . . . 9020-25B-10
Power Shift Low Range Forward, High Range
Forward, Reverse and Speed Clutch Pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-12
Reducing Valve Pressure Test . . . . . . . . 9020-25B-14
Modulation Valve Pressure Test . . . . . . . 9020-25B-15
Differential Lock Pressure Test . . . . . . . . 9020-25B-18
022602
PN=2
Group 05A
Transmission (S.N. 872256)
The power train consists of the engine, torque converter,

powershift transmission, a disk-type park brake, rear axle
assembly and an optional mechanical front wheel drive
axle.
NOTE: (S.N. 872256) The operation and test

procedures for the park brake, service brakes and
differential lock are found in Section 9025.
The torque converter is a fluid coupling between the

engine and the powershift transmission. It uses oil flow,
rather than a dry clutch disk, to transmit engine power to
the rest of the power train.
The torque converter powershift transmission consists of

five elements. The arrangement of the power elements is
as follows:
C1 Clutch-Input (Direct Drive)

B1 Brake-Input (Reverse Underdrive) 9020
B2 Brake-Input (Forward Underdrive) 05A
B3 Brake-Output Brake (Over Drive) 1
C2 Clutch-Output Clutch (Direct Drive)
Input/Output Sections
The input section of the transmission consists of the input

shaft, C1 clutch, B1 brake and B2 brake. The
transmission input shaft is splined to the C1 clutch hub
and the second planetary sun gear. The first planetary
sun gear is machined to the input shaft. The C1 clutch
drum is splined to the compound planetary carrier.
The output section of the transmission consists of the

reduction gear shaft, the B3 brake, the C2 clutch and the
output shaft. The reduction gear shaft is splined to the
third planetary sun gear and the C2 clutch hub and is in
mesh with the output shaft. The C2 clutch drum is splined
to the fourth planetary sun gear.
Continued on next page TX,9020,BG381 1914JAN971/3

022602
PN=545
The following chart shows the solenoids that are

energized and the clutches and brakes that must be
engaged to obtain the transmission speeds. The
transmission hydraulic control circuit controls the
engagement of each clutch and brake. One of output
sections of transmission is always pressurized when
engine is running. Two elements must be engaged to
move the machine.
SOLENOIDS ENERGIZED
- N C2-B3 FWD C1-B2 REV
1st Forward X X
2nd Forward X X X
3rd Forward X X X
4th Forward X X X X
1st Neutral
2nd Neutral X
3rd Neutral X
4th Neutral X X
1st Reverse X X
9020
05A 2nd4th X X X
2 Reverse
CLUTCH/BRAKE ENGAGEMENT CHART

- C1 B1 B2 B3 C2
1st Forward X X
2nd Forward X X
3rd Forward X X
4th Forward X X
1st Neutral X
2nd Neutral X
3rd Neutral X
4th Neutral X
1st Reverse X X
24 Reverse X X
When the neutral disconnect switch is depressed,

engagement oil is blocked from going to the neutral spool.
The rear axle assembly includes the differential, final

drives and service brakes.

022602
PN=546
A Mechanical Front Wheel Drive (MFWD) option is

available. The MFWD axle uses a limited slip differential
to provide maximum traction to the front wheels and still
provide differential action when turning.
TX,9020,BG381 1914JAN973/3
9020
05A
3

022602
PN=547
Torque Converter Operation (S.N.872256)
F IMPELLER G TURBINE
PUMP
HOUSING E
SEAL D
TRANSMISSION
INPUT
CONVERTER-IN C
H SHAFT
9020
05A
4
TO COOLER B
AND LUBE I CONVERTER-OUT
J STATOR
PUMP A
DRIVE
GEAR
K CONVERTER-IN
PRESSURE
L CONVERTER-OUT
1915JAN98
PRESSURE
M LUBE
PRESSURE
T7601AB
N TORQUE CONVERTER OPERATION

TXC7601AB
Continued on next page 10T,9020,J196 1903MAR931/2

022602
PN=548
APump Drive Gear EPump Housing IConverter-Out LConverter-Out Pressure

BTo Cooler and Lube FImpeller JStator MLube Pressure
CConverter-In GTurbine KConverter-In Pressure NTorque Converter Pressure
DSeal HTransmission Input Shaft
The single turbine torque converter is located inside stationary stator. The stator blades are curved so the
the front of the transmission housing. A drive plate is oil flow changes direction and exits the stator moving
mounted to the torque converter housing. The outer in the same direction as the impeller.
edge of the drive plate is attached to the engine
flywheel. The turbine rotates at a slower speed than the
impeller, but with more torque. The increased force
There are three main parts to the torque converter. developed by the stator makes the torque converter
able to multiply torque.
Impeller (F)
Turbine (G) During light load applications, the turbine speed
Stator (J) becomes equal to the impeller speed. The free wheel
clutch will unlock allowing the stator to rotate with the
The impeller is driven by the engine and drives the turbine and impeller. Input speed and torque from the
transmission oil pump drive gear (A). As it rotates, engine is equal to the output speed and torque of the
centrifugal force throws oil out of the impeller against converter when the stator is freewheeling.
the blades of the turbine. This forces the turbine to
rotate in the same direction as the impeller. The There are no serviceable parts inside the torque
9020
turbine is connected to the transmission input shaft converter. If it is defective, replace the entire
05A
(H). assembly. 5
As the oil leaves the turbine, it is moving in the

opposite direction of the impeller. This oil enters the
10T,9020,J196 1903MAR932/2

022602
PN=549
Power Flow Through TransmissionNeutral (S.N. 872256)
SECOND
SUN GEAR
C2 CLUTCH E
FIRST
D SUN GEAR
F
REDUCTION
FROM GEAR SHAFT
CONTROL C
VALVE
B
9020
05A
C2
6
G
POWER FROM
B1 C1
TORQUE
H CONVERTER
INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT
I PRESSURE OIL
SHAFT
J RETURN OIL
K POWER FLOW - NEUTRAL
1915JAN98
T6885AA
TXC6885AA

022602
PN=550
AOutput Shaft DC2 Clutch GPower from Torque IPressure Oil

BFrom Control Valve ESecond Sun Gear Converter JReturn Oil
CReduction Gear Shaft FFirst Sun Gear HInput Shaft KPower Flow-Neutral
In neutral, power from the engine is transmitted engaged, no power is transmitted to the output section
through the torque converter (G) to the transmission of the transmission. In neutral, engagement oil is
input shaft (H). The transmission input shaft is splined routed from the transmission control valve (B) to the
to the C1 clutch hub and the second planetary sun C2 clutch (D). With no power coming from the input
gear (E). The first planetary sun gear (F) is machined section of the transmission, the reduction gear shaft
in the input shaft. These parts rotate at engine speed. (C) and the output shaft (A) do not rotate.
Since neither B1 or B2 brakes or C1 clutch are
10T,9020,J198 1903MAR932/2
9020
05A
7

022602
PN=551
Power Flow Through TransmissionFirst Forward (S.N. 872256)
THIRD
SUN GEAR
FOURTH F
SUN GEAR
D C2 CLUTCH G B2 BRAKE
E
H B2 RING GEAR
I SECOND
REDUCTION C SUN GEAR
GEAR SHAFT
FROM
CONTROL
VALVE
B
9020
05A
8
C2
J
POWER FROM
B1 C1
TORQUE
CONVERTER
K INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT L PRESSURE OIL
SHAFT
M RETURN OIL
E POWER FLOW - FIRST FORWARD

1915JAN98
T7601AC
TXC7601AC
Continued on next page 10T,9020,J200 1922OCT911/2

022602
PN=552
AOutput Shaft EFourth Sun Gear ISecond Sun Gear LPressure Oil
BFrom Control Valve FThird Sun Gear JPower from Torque MReturn Oil
CReduction Gear Shaft GB2 Brake Converter NPower Flow-First Forward
DC2 Clutch HB2 Ring Gear KInput Shaft
When the transmission control lever is shifted to first sun gear (I). The second sun gear forces the planet
forward, transmission control oil is sent to the B2 pinion gears to orbit around the B2 ring gear rotating
Brake (under drive) (G) and the C2 Clutch (direct the planetary carrier in the same direction as the input
drive) (D). shaft, but at a slower speed.
The B2 ring gear (H) is clamped to the transmission The planetary carrier transmits power to the output
housing. planetary set. When C2 is engaged, both the third and
fourth sun gears are locked to the reduction gear shaft
The C2 clutch drum is locked to the C2 clutch hub. and provide direct drive out of the transmission at the
This ties the fourth sun gear (E) to the reduction gear same speed as the carrier.
shaft (C).
The reduction gear shaft transmits engine power
Engine power (J) flows through the torque converter to through the output shaft (A) to the differential.
the input shaft (K) and the compound planetary second
9020
05A
9
10T,9020,J200 1922OCT912/2

022602
PN=553
Power Flow Through TransmissionSecond Forward (S.N. 872256)
B3 BRAKE
D FOURTH F THIRD
SUN GEAR SUN GEAR
E
B3 RING GEAR G B2 BRAKE
C H B2 RING GEAR
REDUCTION
GEAR SHAFT
B
9020
05A
10 C2
I
POWER FROM
B1 C1
TORQUE
J CONVERTER
INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT
SHAFT K PRESSURE OIL
L RETURN OIL
M POWER FLOW - SECOND FORWARD
1915JAN98
T6885AG
TXC6885AG

022602
PN=554
AOutput Shaft EFourth Sun Gear IPower from Torque LReturn Oil
BReduction Gear Shaft FThird Sun Gear Converter MPower Flow-Second
CB3 Ring Gear GB2 Brake JInput Shaft Forward
DB3 Brake HB2 Ring Gear KPressure Oil
When the transmission control lever is shifted to second gear forces the planet pinion gears to orbit the
second forward, transmission control oil is sent to the B2 ring gear rotating the planetary carrier in the same
B2 Brake (under drive, G) and the B3 Brake (over direction as the input shaft, but at a slower speed.
drive, D).
The planetary carrier transmits power to the output
The B2 ring gear (H) is clamped to the transmission planetary set. Since the B3 brake (D) is engaged, the
housing. fourth sun gear (E) is stationary. The output planet
pinions are forced to orbit the fourth sun gear. This
The B3 ring gear (C), which is located on the external causes the third sun gear (F) and reduction gear shaft
diameter of the C2 clutch drum, is also clamped to the (B) to rotate in the same direction as the planetary
transmission case. This ties the fourth planetary sun carrier, but at a faster speed.
gear (E) to the transmission case.
Power from the reduction gear shaft is sent through
Engine power (I) flows through the torque converter to the output shaft (A) to the differential.
the input shaft (J) and the second sun gear. The
9020
05A
11
10T,9020,J202 1922OCT912/2

022602
PN=555
Power Flow Through TransmissionThird Forward (S.N. 872256)
FOURTH F THIRD
SUN GEAR SUN GEAR
C2 CLUTCH D E
G C1 CLUTCH
REDUCTION C
GEAR SHAFT
FROM
CONTROL
VALVE
B
9020
05A
12
C2
H
POWER FROM
B1
TORQUE
C1
CONVERTER
I
B3 B1 C1 B2
INPUT
SHAFT
A
OUTPUT
SHAFT J PRESSURE OIL
B FROM CONTROL VALVE K RETURN OIL
L POWER FLOW - THIRD FORWARD

1915JAN98
T7601AD
TXC7601AD

022602
PN=556
AOutput Shaft EFourth Sun Gear HPower from Torque JPressure Oil
BFrom Control Valve FThird Sun Gear Converter KReturn Oil
CReduction Gear Shaft GC1 Clutch IInput Shaft LPower Flow-Third Forward
DC2 Clutch
When the transmission control lever is moved to third Engine power (H) flows through the torque converter to
forward, transmission control oil (B) is sent to the C1 the input shaft and planetary carrier. The carrier
Clutch (direct drive, G) and the C2 Clutch (direct drive, rotates at the same speed as the input shaft.
D).
The C1 clutch drum is locked to the C1 clutch hub. planetary set. With C2 clutch engaged, both the third
This clamps the input shaft (I) to the planetary carrier and fourth sun gears are locked to the reduction gear
and causes it to rotate at the same speed as the input shaft and provide direct drive out of the transmission at
shaft. the same speed as the input shaft.
The C2 clutch drum is locked to the C2 clutch hub. The reduction gear shaft transmits engine power
This ties the fourth sun gear (E) to the reduction gear through the output shaft (A) to the differential.
shaft (C).
9020
05A
13
10T,9020,J204 1922OCT912/2

022602
PN=557
Power Flow Through TransmissionFourth Forward (S.N. 872256)
D B3 BRAKE F THIRD
FOURTH SUN GEAR
SUN GEAR
B3 RING GEAR C E
G C1 CLUTCH
REDUCTION B
GEAR SHAFT
9020
05A
14
C2
H
POWER FROM
B1 C1
TORQUE
CONVERTER
I INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT J PRESSURE OIL
SHAFT
K RETURN OIL
L POWER FLOW - FOURTH FORWARD

1915JAN98
T6885AD
TXC6885AD

022602
PN=558
AOutput Shaft EFourth Sun Gear IInput Shaft LPower Flow-Fourth

BReduction Gear Shaft FThird Sun Gear JPressure Oil Forward
CB3 Ring Gear GC1 Clutch KReturn Oil
DB3 Brake HPower from Torque
Converter
When the transmission control lever is shifted to fourth The planetary carrier transmits power to the output
forward, transmission control oil is sent to the C1 planetary set. Since the B3 brake is engaged, the
Clutch (direct drive, G) and B3 Brake (over drive, D). fourth sun gear is stationary. The output planet pinions
are forced to orbit the fourth sun gear. This causes the
The C1 clutch drum is locked to the C1 clutch hub. third sun gear (F) and reduction gear shaft (B) to
This clamps the input shaft (I) to the planetary carrier rotate in the same direction as the planetary carrier,
and causes it to rotate at the same speed as the input but at a faster speed.
shaft.
Power from the reduction gear shaft is sent through
The B3 ring gear which is located on the external the output shaft (A) to the differential.
diameter of the C2 clutch drum is clamped to the
transmission case. This ties the fourth planetary sun
gear (E) to the transmission case.
Engine power (H) flows through the torque converter to

the input shaft and planetary carrier. The carrier
rotates at the same speed as the input shaft. 9020
05A
15
10T,9020,J206 1922OCT912/2

022602
PN=559
Power Flow Through TransmissionFirst Reverse (S.N. 872256)
THIRD
SUN GEAR
FOURTH F
SUN GEAR
C2 CLUTCH D G B1 BRAKE
E
H B1 RING GEAR
I FIRST
REDUCTION C SUN GEAR
GEAR SHAFT
FROM
CONTROL
VALVE
B
9020
05A
16
C2
J
POWER FROM
B1
TORQUE
C1
CONVERTER
K
B3 B1 C1 B2
INPUT
SHAFT
A
OUTPUT
L PRESSURE OIL
SHAFT
B FROM CONTROL VALVE M RETURN OIL
N POWER FLOW - FIRST REVERSE

1915JAN98
T7601AE
TXC7601AE

022602
PN=560
AOutput Shaft EFourth Sun Gear IFirst Sun Gear LPressure Oil
BFrom Control Valve FThird Sun Gear JPower from Torque MReturn Oil
CReduction Gear Shaft GB1 Brake Converter NPower Flow-First Reverse
DC2 Clutch HB1 Ring Gear KInput Shaft
When the transmission control lever is shifted to first sun gear and the B1 ring gear. This causes the
reverse, transmission control (B) oil is sent to the B1 planetary carrier to rotate in the opposite direction of
Brake (reverse, G) and the C2 Clutch (direct drive, D). the input shaft. Carrier rotates 15 percent faster
making reverse speeds 15 percent faster than
The B1 ring gear (H) is clamped to the transmission corresponding forward speeds.
case.
The C2 clutch drum is locked to the C2 clutch hub. planetary set. When C2 is engaged, both the third and
This ties the fourth sun gear (E) to the reduction gear fourth sun gears are locked together and provide direct
shaft (C). drive out of the transmission at the same speed as the
carrier.
Engine power (J) flows through the torque converter to
the input shaft and its first sun gear (I). Since the B1 The reduction gear shaft transmits engine power
ring gear is locked to the transmission case, the first through the output shaft (A) to the differential in the
sun gear forces the planet pinion gears to orbit the B1 reverse direction of the converter input.
ring gear.
9020
There are two sets of planet pinion gears in the first
05A
planetary assembly. They are in mesh with the first 17
10T,9020,J208 1922OCT912/2

022602
PN=561
Power Flow Through TransmissionSecond Reverse (S.N. 872256)
F THIRD
SUN GEAR
D B3 BRAKE
G B1 BRAKE
B3 RING GEAR C FOURTH E

H B1 RING GEAR
SUN GEAR
I FIRST SUN GEAR
REDUCTION B
GEAR SHAFT
9020
05A
18
C2
J
POWER FROM
B1 C1
TORQUE
CONVERTER
K INPUT
SHAFT
B3 B1 C1 B2
A
OUTPUT L PRESSURE OIL
SHAFT M RETURN OIL
N POWER FLOW - SECOND REVERSE

1915JAN98
T6885AF
TXC6885AF

022602
PN=562
AOutput Shaft EFourth Sun Gear IPower from Torque MReturn Oil
BReduction Gear Shaft FThird Sun Gear Converter NPower Flow-Second
CB3 Ring Gear GB1 Brake KInput Shaft Reverse
DB3 Brake HB1 Ring Gear LPressure Oil
When the transmission is shifted into second reverse, the B1 ring gear. This causes the planetary carrier to
transmission control oil is sent to the B1 Brake rotate in the opposite direction of the input shaft.
(reverse, G) and the B3 Brake (over drive, D). Carrier rotates 15 percent faster making reverse
speeds 15 percent faster than corresponding forward
The B1 ring gear (H) is clamped to the transmission speeds.
case.
The B3 ring gear (C), which is located on the external planetary set. Since the B3 brake is engaged, the
diameter of the C2 clutch drum, is also clamped to the fourth sun gear is stationary. The output planet pinions
transmission case. This ties the fourth planetary sun are forced to orbit the fourth sun gear. This causes the
gear (E) to the transmission case. third sun gear (F) and reduction gear shaft (B) to
rotate in the same direction as the planetary carrier
Engine power (J) flows through the torque converter to (reverse), but at a faster speed.
the input shaft and its first sun gear (I). Since the B1
ring gear is locked to the transmission case, the first The reduction gear shaft transmits engine power
sun gear forces the planet pinion gears to orbit the B1 through the output shaft (A) to the differential in the
ring gear. reverse direction of the converter input.
9020
05A
There are two sets of planet gears in the first planetary 19
assembly. They are in mesh with the first sun gear and
10T,9020,J210 1922OCT912/2

022602
PN=563
Pressure Regulating Valve Operation (S.N. 872256)
PRESSURE G
H
REGULATING
VALVE
I
E
F
D REDUCED
FLOW
C
FROM
TRANSMISSION
FILTER TO
G CONVERTER - IN
F
9020
05A
20
TO
RESERVOIR
C FROM LUBE
CIRCUIT
H
CONVERTER - IN
RELIEF VALVE
I
B
LUBE
RELIEF
EXCESS VALVE
LUBE A
PRESSURE
EXCESS
CONVERTER - IN
PRESSURE
J
K CONTROL PRESSURE
L CONVERTER - IN PRESSURE
M LUBE PRESSURE
1915JAN98
N RETURN
O PRESSURE REGULATING VALVE HOUSING

T7849AL
TXC7849AL

022602
PN=564
AExcess Lube Pressure FFrom Transmission Filter JExcess Converter-In MLube Pressure
BLube Relief Valve GTo Converter-In Pressure NReturn
CTo Reservoir HFrom Lube Circuit KControl Pressure OPressure Regulating Valve
DReduced Flow IConverter-In Relief Valve LConverter-In Pressure Housing
EPressure Regulating Valve
The pressure regulating valve housing contains the subsequently, the oil cooler. Excess converter-in oil
pressure regulating valve (E), the lube relief valve (B) pressure (J) due to cold oil or a restriction in the oil
and the converter-in/cooler relief valve (I). cooler will push the valve poppet down opening a
passage for oil to flow to the lube circuit (H).
The pressure regulating valve is used to set the
pressure for the transmission control circuit. Oil from The lube relief valve is used to set the maximum
the transmission filter (F) acts on the top of the valve pressure in the lube circuit. Excess lube pressure (A)
poppet. The control pressure is determined by the pushes the valve spool down opening a passage from
valve spring and shims. During normal operation, the the lube circuit to the reservoir (C).
valve allows excess pump flow to go to the torque
converter-in circuit (G). When there is reduced flow The spring side of the three relief valves are open to
from the transmission pump (D) like during a shift, the the reservoir to prevent a hydraulic lock of the valve
valve moves up and blocks oil flow to the converter-in spool. The lube relief and the converter-in relief valves
circuit. are not adjustable. If pressure settings are low, replace
the spring.
The converter-in/cooler relief valve is used to control
the pressure of oil going to the torque converter and, 9020
05A
21
10T,9020,J214 1903MAR932/2

022602
PN=565
Transmission Filter Operation (S.N. 872256)
G H
9020
05A
22
E F
D I
E
F
A
B
C
G H
1929JAN97
I
T6300AG
T6300AG
AHigh Pressure Oil DRestricted Filter FTo Lube HTo Control Circuit
BMedium Pressure Oil EFilter Relief Valve GFrom Transmission Pump IFilter Element
CLow Pressure Oil
The transmission filter (I) is a 10 micron full-flow filter. poppet. When the filter becomes restricted (D), the
It is protected by a pressure differential type relief filter inlet oil pressure increases and the outlet oil
valve (E). Oil flow from the transmission pump (G) pressure decreases. When the pressure differential
flows through the filter to transmission control circuit exceeds the spring force of the poppet spring, the
(H). Oil from the pump acts on the end of the relief relief valve opens the routes the unfiltered oil to the
valve. Filtered oil acts on the spring side of the relief lube circuit (F).
10T,9020,J216 1903MAR931/1

022602
PN=566
Neutral Disconnect Solenoid Operation (S.N. 872256)
F SOLENOID
COIL
E PLUNGER
D TO
RETURN
C BALL G PRESSURE OIL 9020
1915JAN98
05A
B FROM PRESSURE H RETURN OIL
23
REGULATING VALVE
A ENERGIZED I DE-ENERGIZED
T7864AN
TXC7864AN J SOLENOID VALVE OPERATION
AEnergized CBall FSolenoid Coil IDe-Energized

BFrom Pressure Regulating DTo Return GPressure Oil JSolenoid Valve Operation
Valve EPlunger HReturn Oil
The neutral solenoid is used to disengage the When the operator releases the neutral disconnect
transmission during normal operation. When the switch, he energizes (A) the neutral solenoid. The coil
solenoid is de-energized (I), the plunger (E) is in the draws the plunger up and opens the passage from the
down position. In this position, pressure oil from the pressure regulating valve to the neutral spool and FNR
pressure regulating valve (B) is blocked at the neutral spool.
solenoid.
10T,9020,J219 1904MAR931/1

022602
PN=567
Transmission Control CircuitFirst Neutral (S.N. 872256)
C1 FNR
B1 SPOOL
B2 J
B3 C1, B1, B2
ACCUMULATOR C2, B3
H SHIFT K C1, B2
SPOOL SHIFT SPOOL
C2, B3 I
ACCUMULATOR
C2 G
SOLENOID
L
9020 F
05A NEUTRAL
24 SPOOL C1, B2
FROM OIL REV
COOLER TRANSMISSION FWD
D LUBRICATION C2, B3
E
PRESSURE
NEU REGULATING
VALVE
HOUSING
M
FILTER C
RELIEF
VALVE
N
TO TORQUE
CONVERTER
AND OIL
COOLER
O CONVERTER-IN
B TRANSMISSION RELIEF VALVE
FILTER R TRANSMISSION P LUBE RELIEF
PUMP VALVE
S CONTROL PRESSURE Q PRESSURE
REGULATING
T CONVERTER PRESSURE VALVE
1915JAN98
A SUCTION
SCREEN U LUBE PRESSURE
V RETURN
T7870BE
TXC7870BE W TRANSMISSION HYDRAULIC CIRCUIT-1ST NEUTRAL

022602
PN=568
ASuction Screen HC1,B1,B2 Accumulator NTo Torque Converter and SControl Pressure
BTransmission Filter IC2,B3 Shift Spool Oil Cooler TConverter Pressure
CFilter Relief Valve JFNR Spool OConverter-In Relief Valve ULube Pressure
DFrom Oil Cooler KC1,B2 Shift Spool PLube Relief Valve VReturn
ETransmission Lubrication LSolenoid QPressure Regulating Valve WTransmission Hydraulic
FNeutral Spool MPressure Regulating Valve RTransmission Pump Circuit-1st Neutral
GC2,B3 Accumulator Housing
The transmission hydraulic system is independent of FNR Spool

the machine hydraulic system. Transmission oil flows C1,B2 Shift Spool
through a suction screen (A) in the transmission case C2,B3 Shift Spool
to the transmission oil pump (R). The oil pump is Pressure Test Ports
mounted to the front of the transmission case and is
driven by the torque converter impeller. The accumulator housing is mounted to the back of
the transmission control valve and it contains the:
Pump flow is routed through the full flow oil filter (B) to
the pressure regulating valve (Q). A filter relief valve B1,B2,C1 Accumulator
(C) protects the filter element by routing oil to the B3,C2 Accumulator
transmission lubrication circuit (E) if there is excessive Neutral Spool
pressure on the filter.
Transmission operation is controlled by the FNR lever
Oil from the pressure regulating valve is used to which activates forward, neutral and reverse solenoids.
control the engagement of the clutch and brake These solenoids allow engagement of transmission 9020
elements. Oil not needed in the transmission control input elements C1,B1,B2. 05A
circuit is sent through the torque converter to the oil 25
cooler (N) and then to the transmission lubrication Speed control is accomplished by a rotary electrical
circuit. switch that is located on the end of the FNR lever.
Rotating the switch provides four forward speeds and
The pressure regulating valve housing (M) contains the two reverse speeds by energizing or de-energizing
pressure regulating valve, the converter-in/cooler relief C1,B2 and/or C2,B3 solenoids.
valve (O) and the lube relief valve (P). The pressure
regulating valve sets the pressure for the engagement Oil flow from the solenoids is used to control the
of the transmission clutches and brakes. The position of the neutral spool, FNR spool and the shift
converter-in relief valve protects the torque converter, spools. This results in main engagement pressure oil
and subsequently the oil cooler, from excessive being directed to the appropriate packs that are used
pressure. When the converter-in relief valve opens, oil in each gear. (See Transmission Hydraulic Schematic
is routed to the lube circuit. The lube relief valve in this group).
protects the lube circuit from excessive pressure by
releasing oil to the reservoir. In first neutral, pressure oil to operate the transmission
is routed from the transmission case to the oil galley
The transmission control valve contains the: that is located in the lower portion of the transmission
control valve. Since all five solenoids are de-energized
Neutral Solenoid and no control oil flow is provided, main pressure is
Forward Solenoid allowed to flow from the inlet passage to the
Reverse Solenoid accumulator housing where both accumulators are
C1,B2 Solenoid charged.
C2,B3 Solenoid

022602
PN=569
Spring force closes the neutral spool and blocks oil spool which is being held down by spring force. Oil
flow to the FNR spool. Oil flow is routed from the flow through the shift spool in this position results in
accumulator housing back through the C2,B3 shift the engagement of only the C2 clutch.
TX,9020,BG383 1914JAN973/3
9020
05A
26

022602
PN=570
9020
05A
27

022602
PN=571
Transmission Control CircuitFirst Forward (S.N. 872256)
C1 FNR
B1 SPOOL
B2 D
B3
C1, B1, B2
ACCUMULATOR C2, B3
C SHIFT E C1, B2
SPOOL SHIFT SPOOL
C2, B3 I
ACCUMULATOR
C2 B
SOLENOID
F
9020
05A
28
C1, B2
REV
FWD
A C2, B3
NEUTRAL
SPOOL NEU
1915JAN98
G CONTROL PRESSURE
H RETURN
T7840BE
TXC7840BE I TRANSMISSION HYDRAULIC CIRCUIT-1ST FORWARD
ANeutral Spool DFNR Spool GControl Pressure ITransmission Hydraulic

BC2,B3 Accumulator EC1,B2 Shift Spool HReturn CircuitFirst Forward
CC1,B1,B2 Accumulator FSolenoid
When the FNR lever is moved from the neutral the spool moves up against the spring, pressure oil
position, the neutral solenoid is energized and control from the neutral spool is allowed to flow through the
oil is allowed to flow to the neutral spool. When the FNR spool to the C1,B2 shift spool.
neutral spool is moved against the spring, main
pressure from the B1,B2,C1 accumulator is available Since the C1,B2 solenoid is not energized, pressure oil
to the FNR spool for clutch or brake engagement. flows through to engage B2 brake.
In first forward, the forward solenoid is energized and

control oil is routed to the bottom of FNR spool. When
TX,9020,YY745 1904MAR931/1

022602
PN=572
Transmission Control CircuitSecond Reverse (S.N. 872256)
B1 C1 FNR
SPOOL
B2
E
B3
C1, B1, B2
ACCUMULATOR C2, B3
C SHIFT F C1, B2
SPOOL SHIFT SPOOL
C2, B3 D
ACCUMULATOR
C2
B
SOLENOID
G
9020
05A
29
C1, B2
REV
A FWD
NEUTRAL C2, B3
SPOOL
NEU
1915JAN98
H CONTROL PRESSURE
I RETURN
T7840BD
TXC7840BD J TRANSMISSION HYDRAULIC CIRCUIT-2ND REVERSE
ANeutral Spool DC2,B3 Shift Spool GSolenoid JTransmission Hydraulic

BC2,B3 Accumulator EFNR Spool HControl Pressure CircuitSecond Reverse
CC1,B1,B2 Accumulator FC1,B2 Shift Spool IReturn
When the FNR lever is moved from neutral position, the spool moves down against the spring, pressure oil
the neutral solenoid is energized and control oil is from the neutral spool is allowed to flow through the
allowed to flow to the neutral spool. When the neutral FNR spool to engage B1 brake.
spool is moved against the spring, main pressure from
the B1,B2,C1 accumulator is available to the FNR The C2,B3 solenoid is also energized which routes
spool for clutch or brake engagement. control oil to the bottom of C2,B3 shift spool. When the
spool moves up against the spring, main pressure from
In 2nd reverse, the reverse solenoid is energized and the C2,B3 accumulator is allowed to flow to engage B3
control oil is routed to the top of the FNR spool. When brake.
TX,9020,YY746 1904MAR931/1

022602
PN=573
MFWD System Operation (S.N. 872256)
Differential drive gear supplies power to MFWD driver Drive shaft powers sun gear of wheel hub planetary.
shaft then to front MFWD drive gear set. MFWD idler Sun gear rotates fixed planetary gears which turn outer
gear shaft directs power to clutch through MFWD ring. The planetary system reduces drive shaft output
clutch drive gear. speed and increases torque at front tires.
When control valve is engaged, valve prevents flow of Wheel drive gear is meshed with outer ring. Outer ring
clutch control oil to clutch. Springs force clutch disk is meshed to wheel hub.
pack together and power is transmitted forward by
U-jointed drive shaft to front axle differential drive When MFWD control valve is disengaged, valve
shaft. Shaft drive gear and ring gear mesh turning directs pressure oil to release the MFWD clutch.
limited-slip differential unit.
Differential supplies required power to left and right

axle shafts.
TX,9020,BG382 1914JAN971/1
9020
05A
30

022602
PN=574
MFWD Differential OperationUnequal Traction (S.N. 872256)
9020
05A
31
UN19OCT88
T6771AH
ATire with Most Traction DLH Drive Gear GClutch Disks IPower Flow
BDrive Shaft EPinion Gears HClutch Plate JRotation Direction
CRH Drive Gear FDifferential Housing
As available traction changes, tire with better traction drive gear (C) from rotating. Wheel with less traction
(A) can use more power. Self-limiting differential action provides less resistance against its drive gear (D).
begins to occur.
When one wheel begins to slip more than the other,

wheel with better traction holds its drive shaft (B) and
Continued on next page TX,05,SS3140 1910SEP981/2

022602
PN=575
Pinion gears (E) continue to be driven by rotating Since the tire with less traction is exerting less force
differential housing (F). These pinion gears push trying to keep its axle from turning, the bevel gear
against bevel drive gears as before. Angle of gear force is not being transmitted to this drive shaft. As
teeth tries to force meshed gears apart. On the side long as the difference in traction between tires remains
with more traction, pinion gears begin to walk around the same, the clutch pack on the side with less traction
drive gear and push against restraining force will continue to slip more than the clutch pack on the
transmitted from tire. Drive gear is wedged outward other side.
and compresses a clutch pack with disks (G) splined
to axle and plates (H) tanged to housing. Disks begin With MFWD engaged, differential works to
to slip less against plates as compressing force automatically balance driving power to available
increases. As the pack slippage decreases drive shaft traction.
begins to receive driving force through the differential
housing.
TX,05,SS3140 1910SEP982/2
9020
05A
32

022602
PN=576
MFWD Differential OperationEqual Traction (S.N. 872256)
9020
05A
33
UN19OCT88
T6771AG
ADifferential Drives Shaft CDifferential Housing EBevel Drive Gears GPower Flow
BRing Gear DPinions FDrive Shafts HRotation Direction
Differential unit has self-applied, limited slip feature. With MFWD engaged, when tractor is moving in a
When engaged under slippery field conditions, this straight line and each wheel has equal traction, equal
system automatically applies correct amount of torque power is supplied to left and right axle. No differential
to match traction available to each wheel. action occurs.

022602
PN=577
Power flows into axle housing through differential drive pinions (D) remain stationary within rotating housing.
shaft (A), turning ring gear (B) and attached differential Pinions turn bevel drive gears (E) and drive shafts (F)
housing (C). When both wheels have equal traction, splined to drive gears.
TX,05,SS3141 1910SEP982/2
9020
05A
34

022602
PN=578
Transmission Hydraulic Schematic (S.N. 872256)

T7840BA 1915JAN98
NEUTRAL C2, B3 FWD C1, B2 REV

SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID
OIL TORQUE
COOLER CONVERTER
B3-C2 B1-B2-C1
ACCUMULATOR ACCUMULATOR
FNR
SPOOL
C1, B2
C2, B3 SHIFT
SHIFT SPOOL
SPOOL
LUBE CONVERTER-IN PRESSURE

RELIEF RELIEF VALVE REGULATING
VALVE VALVE
TRANSMISSION
LUBRICATION NEUTRAL
FILTER RELIEF SPOOL
VALVE
TRANSMISSION
PUMP
TRANSMISSION MFWD
FILTER SOLENOID
[ENGAGED]
SUCTION
SCREEN CONTROL PRESSURE
CONVERTER-IN PRESSURE C1 C2 B1 B2 B3
LUBE PRESSURE
RETURN TRANSMISSION HYDRAULIC SCHEMATIC - 2ND NEUTRAL
TXC7840BA
TX,9020,BG386 1914JAN971/1

022602
PN=579
See Page 9020-05A-35 A See Page 9020-05A-35 B

9020
05A
36

022602
PN=580
Transmission Hydraulic Schematic (S.N. 872256)

T7840BA 1915JAN98
OIL TORQUE
COOLER CONVERTER
B3-C2
ACCUMULATOR
LUBE CONVERTER-IN PRESSURE

RELIEF RELIEF VALVE REGULATING
VALVE VALVE
TRANSMISSION
LUBRICATION
FILTER RELIEF
VALVE
TRANSMISSION
PUMP
TRANSMISSION MFWD
FILTER SOLENOID
[ENGAGED]
SUCTION
SCREEN CONTROL PRESSURE
CONVERTER-IN PRESSURE
LUBE PRESSURE
RETURN TRANSMISSION HYDRAUL
TXC7840BA
TX,9020,BG386 1914JAN971/1

022602
Page 9020-05A-35 A PN=579

NEUTRAL C2, B3 FWD C1, B2 REV
SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID
B1-B2-C1
ACCUMULATOR
FNR
SPOOL
C1, B2
C2, B3 SHIFT
SHIFT SPOOL
SPOOL
NEUTRAL
SPOOL
C1 C2 B1 B2 B3
RAULIC SCHEMATIC - 2ND NEUTRAL
/1
der
22602
579
Page 9020-05A-35 B
Group 05B
Theory of Operation (S.N. 872257 )
Power Train Conponents (S.N.872257 )
NOTE: For (S.N. 872257 ) The operation and test A single stage torque converter drives a hydraulically
procedures for the park brake and differential engaged four speed forward, three speed reverse,
lock are found in Section 9020. Service brakes countershaft type power shift transmission.
are found in Section 9025.
A multiple wet disk park brake is located in the rear
The power train uses a ZF (4WG984 speed forward axle. It is spring applied and hydraulic released. The
& 3 speed reverse) reversing powershift transmission park brake switch on the side console controls a
with hydrodynamic torque converter. Optional MFWD solenoid located in the transmission duct plate to
axle is a ZF (APL355E). Rear Axle is ZF (AP-2085) activate the park brake.
with multiple disk hydraulically activated differential and
wet multiple disk brakes. Park Brake is integral with The transmission outputs through universal joints and
the rear axle housing. two drive shaft assemblies. The front axle may be
equipped with either a standard axle or optional
The power train consists of the following components: MFWD limited slip self-locking differential axle.
Torque converter The rear axle is equipped with the differential lock.
Transmission
Rear drive shafts The torque converter is a fluid coupling between the
MFWD (Optional) engine and the powershift transmission. It uses oil
Park brake (in rear axle) flow, rather than a dry clutch disk, to transmit engine 9020
Front and rear axles power to the rest of the power train. 05B
1
Engine power is transmitted to the transmission torque

converter by the engine flywheel.
TX,05,SS3678 1913FEB971/1

022602
PN=581
Torque Converter Operation (S.N. 872257 )
9020
1904MAR98
05B
2
T101172
1Turbine 4Input Shaft 7Turbine Shaft 10Stator
2Impeller 5Shaft Seal 8Pump Drive Shaft 11Torque Converter
3Stator Shaft 6Drain Plug 9Free-wheel Clutch
The three main parts of the torque converter include Pump drive shaft (8) is driven by the engine directly
the impeller, turbine and stator. and at engine speed. The pump drive shaft provides
input to the transmission pump and the hydraulic
The impeller (2) is driven by the engine. As it rotates, system pump.
centrifugal force throws oil out of the impeller against
the blades of the turbine (1). This forces the turbine to As the oil leaves the turbine, it is redirected by the
rotate in the same direction as the impeller. stator (10) back into the impeller which increases the
torque converter performance.
The turbine (1) is connected to the turbine shaft (7)
which provides input to the transmission gear train.

022602
PN=582
Oil leaving the turbine enters the stator (10). The stator torque are equal to output speed and torque when the
is curved so that the oil flow changes direction. Oil stator is free-wheeling. The transmission pump is
leaving the stator is moving in the same direction as constantly pumping oil through the converter. The
the impeller. This adds to the force of the oil entering converter multiplies the torque and at the same time,
the impeller. The turbine will be rotating at a slower the heat created in the converter is eliminated through
speed than the impeller, but it will produce a higher the circulation of oil from converter to cooler and back
torque. It is this increased force developed by the to sump.
stator that makes a converter able to multiply torque.
Under light load the speed of the turbine will increase There are no serviceable parts inside the torque
until it equals impeller speed. The free-wheel clutch (9) converter. If it is defective, replace the entire
unlocks, allowing the stator to free-wheel or rotate with assembly.
the turbine and impeller as a unit. Input speed and
TX,05,SS3120 1909SEP982/2
9020
05B
3

022602
PN=583
Transmission Pump Operation (S.N. 872257 )
9020
05B
UN12JUL96
4
T101251
1Angle Disk 3O-Ring (2 used) 5Pump Housing 7Needle Bearing
2Washer 4Cap Screw (4 used) 6O-Ring 8Stop Sleeve
TX,05,SS3124 1922JUN981/2
The transmission uses a high capacity fixed displacement

gear-type pump to provide constant flow for the
transmission hydraulic system. Pump flow is proportional
to engine speed.
The input shaft to the pump is driven by the engine. The

UN12JUL96
pump gears rotate inside of the pump housing. As the

gears rotate, oil is trapped between the gear teeth and the
pump housing which forces oil to move from the pump
inlet around the gears to the pump outlet.
T101252
TX,05,SS3124 1922JUN982/2

022602
PN=584
Transmission Filter Operation (S.N. 872257 )
9020
05B
1912JUL96
5
T101250
AFilter CBypass Valve DTo Transmission Circuit EFrom Transmission Pump
BSpring
NOTE: Filter housing removed to show element and through the middle of the element to the transmission
bypass valve. control system.
The transmission filter is a spin on replaceable If the filter element becomes obstructed or during
element. If the filter (A) becomes obstructed, a bypass extremely cold conditions, the pressure difference
valve (C) opens to maintain flow to the transmission across the filter element exceeds the set value of the
control system. bypass spring (B), causing the bypass valve (C) to
unseat. This unseated valve allows unfiltered oil to
Oil from the transmission pump enters from outside of pass through the filter housing. Bypass operation for
the filter element. The filter element traps contaminants extended periods of time is not recommended.
as the oil passes through it. Filtered oil flows up
TX,05,SS3125 1922JUN981/1

022602
PN=585
Thermal Bypass Valve Operation (S.N. 872257 )
C
D
H
C TO C G
LUBE F
9020
05B
6
FROM
D D
COOLER
SEAT B
H SPRING
VALVE A
FROM
E E
CONVERTER
I BYPASS J COOLING
THERMOSTAT G
F TO
1920JAN98
F
COOLER
K LUBE/CONVERTER-OUT FLOW
L TO COOLER (VALVE CLOSED)
T7799BX
TXC7799BX M THERMAL BYPASS VALVE FLOW
Continued on next page TX,9020,ME437 1928AUG961/2

022602
PN=586
AValve EFrom Converter IBypass LTo Cooler (Valve Closed)

BSeat FTo Cooler JCooling Flow
CTo Lube GThermostat KLube/Converter-Out Flow MThermal Bypass Valve
DFrom Cooler HSpring
The thermal bypass valve is used to maintain the enters passage (E) and flows through the valve (A) to
transmission oil temperature at a level which provides lube (C).
optimum torque converter performance and lubrication
to transmission. At higher temperatures, the thermostat (G) begins to
open, allowing flow out of passage (F) to the
The valve contains a standard automotive-type transmission oil cooler. The thermostat will go to the
thermostat element connected to a hollow valve spool. full open position, forcing the valve closed against the
seat (B). The spring loaded seat will act as a relief
The valve is designed to bypass the transmission oil valve in the event cooler flow is blocked.
cooler at low temperatures. Converter outlet flow
TX,9020,ME437 1928AUG962/2
9020
05B
7

022602
PN=587
Power Shift High Range Forward, First Speed and Second Speed Clutch Packs (S.N.
872257 )
9020
05B
8
1904SEP98
T117074
ASeparator Plate (as CClutch Drum GHub KTapered Bearing
required per clutch pack) DRoller Bearing HEnd Plate LLubrication Oil
BDisk (as required per ETapered Bearing IPiston MClutch Pack
clutch pack) FPressure Oil JSpring
NOTE: This operation covers the power shift high plates are splined to the clutch drum (C) and the disks
range forward, first and second speed clutch are splined to hub (G) locking them together. The drive
packs. The function of the packs are the same, shaft gear is splined to the low range forward, reverse,
but the quantity on the disks and separator and high range forward (4th) gear. All gears are
plates will be different between packs. constantly meshed and supported by antifriction
bearings. The bearings and clutches are lubricated
When the FNR lever is placed in forward or reverse, with cooled lubrication oil (L). Spring disks (J) push
pressure oil (F) from the control valve forces the clutch back the piston (I) when the clutch pack (M) is
piston (I) to compress the plates (A) and disks (B). The disengaged, thus releasing the multi-disk clutch.
CED,TX03399,4234 1929MAY981/1

022602
PN=588
9020
05B
9

022602
PN=589
Power Shift Power Train Overview (S.N. 872257 )
B HIGH RANGE (4TH)

FORWARD CLUTCH
TRANSMISSION
PUMP C
TORQUE A
CONVERTER
PUMP
DRIVE J
SHAFT
REVERSE
9020
D
CLUTCH
05B
10
LOW
RANGE
E
FORWARD
CLUTCH
FIRST
SPEED I
CLUTCH
THIRD
F SPEED
CLUTCH
MFWD H
SECOND
G SPEED
CLUTCH
1901FEB99
T117096
T117096 K TRANSMISSION
Continued on next page CED,TX03399,4205 1903MAR981/2

022602
PN=590
ATorque Converter CTransmission Pump FThird Speed Clutch IFirst Speed Clutch
BHigh Range (4th) Forward DReverse Clutch GSecond Speed Clutch JPump Drive Shaft
Clutch ELow Range Forward Clutch HMFWD KTransmission
A single stage torque converter drives a hydraulically The optional MFWD front axle is a self applied limited
engaged four speeds forward and three speeds slip design. It consists of a differential with outboard
reverse countershaft type power shift transmission. planetary final drives.
Six clutch packs provide four forward and three The rear axle is an inboard planetary design with
reverse speeds. Two clutch packs have to be engaged internal wet multi-disk service brakes that are self
for movement. One directional clutch pack, either adjusting. Pressure oil for the service brakes is
low-range forward, high-range forward or reverse and supplied by a full power operated brake valve. The
one speed range clutch pack either 1st, 2nd or 3rd. park brake is a wet multi-disk design which is spring
applied and hydraulically released. The differential lock
The transmission may also have an optional front is a lever activated multi-disk clutch design, which is
output shaft (H) for mechanical front wheel drive hydraulically engaged and spring released.
(MFWD) which is spring applied and hydraulically
released.
The transmission pump (C) is a gear type pump. The

transmission pump is driven at engine speed through
the impeller drive from the torque converter.
9020
05B
11
CED,TX03399,4205 1903MAR982/2

022602
PN=591
Power Shift Transmission Gear Flow (S.N. 872257 )
1st FORWARD 4th FORWARD (HIGH RANGE)
4th FORWARD
(HIGH RANGE) A B REVERSE A B
C LOW RANGE C
2nd SPEED G FORWARD G
F D 1st SPEED F D
3rd SPEED
(REAR OUTPUT)
E MFWD E
OUTPUT
2nd FORWARD 1st REVERSE
9020 A B A B
05B
12
C C
G G
F D D
F
E E
3rd FORWARD 2nd REVERSE 3rd REVERSE
A B A B A B
C C C
G G G
F D D F D
F
1902JUN98
E E E
T115189
T115189

022602
PN=592
A4th Forward (High Range) CLow Range Forward EMFWD Output G2nd Speed
BReverse D1st Speed F3rd Speed (Rear Output)
The torque converter supplies torque to the drive gear As a example, with the transmission in second speed
which is in constant mesh with the low-range forward, forward, the low range forward clutch (C) and the
reverse and high range forward clutch hubs. second speed clutch (G) are engaged. The torque
converter supplies torque to the drive gear which
The low-range forward clutch, reverse, high range meshes with the gear on the low-range forward clutch.
forward and second speed clutch outer gears are in Power flow continues through the reverse (B) and high
mesh. As are the first speed hub gear and third speed range forward clutch (A) output gears to the second
clutch outer gear. speed (G) output gear which drives the third speed
clutch (F) rear axle output which is in mesh with first
With MFWD (if equipped) the first speed hub is in speed clutch (D) hub which is in mesh with the MFWD
mesh with the MFWD output gear. (E) (if equipped) output gear.
CED,TX03399,4206 1903MAR982/2
9020
05B
13

022602
PN=593
Power Shift Transmission Clutch

Engagement And Solenoids Activated (S.N.
872257 )
Transmission Clutch Engagement
Low and High Range Forward and Reverse Pack Engaged Speed Pack Engaged
Lo-Range Forward Hi-Range Forward Reverse 1st 2nd 3rd
N
F1 X X
F2 X X
F3 X X
F4 X X
R1 X X
R2 X X
R3 X X
Solenoids Activated
Gear Selection Low Range, Forward, & Reverse Solenoid Energized Speed Solenoid Energized
Forward Low Range Reverse 1 2 3
9020
Neutral
05B
14 1st Forward X X X X
2nd Forward X X X X
3rd Forward X X X X
4th Forward (High Range) X X X
1st Reverse X X X X
2nd Reverse X X X X
3rd Reverse X X X X
CED,TX03399,4223 1924MAR981/1

022602
PN=594
9020
05B
15

022602
PN=595
Power Shift Transmission Control CircuitNeutral (S.N. 872257 )

T117376 1901FEB99
HIGH RANGE
FORWARD CLUTCH
1ST SPEED
CLUTCH LOW RANGE DIFFERENTIAL LOCK MFWD PARK
FORWARD REVERSE BRAKE
TRANSMISSION CLUTCH CLUTCH
2ND SPEED CONTROL VALVE
CLUTCH
LOW RANGE P
3RD SPEED TRANSMISSION SPEED SHIFT VALVE
CLUTCH SHIFT VALVE
SPEED SHIFT
VALVE L FORWARD/REVERSE
3 SHIFT VALVE
O
SPEED SHIFT
VALVE SEQUENCE
K VALVE ORIFICE IN
2 VALVE HOUSING
LOW N
RANGE R DIFFERENTIAL
FORWARD MFWD PARK BRAKE
SPEED SOLENOID REVERSE SOLENOID SOLENOID SOLENOID SOLENOID
SHIFT VALVE SOLENOID VALVE VALVE VALVE VALVE
VALVE C VALVE
1 J B
D
ORIFICE IN
MODULATION SCREEN
MODULATION IN ALL
SPOOL VALVE G
SPEED SPEED SPEED PRESSURE SOLENOIDS
SOLENOID SOLENOID SOLENOID REDUCING
VALVE VALVE VALVE ORIFICE ORIFICE IN VALVE Q
3 M 2 I 1 H IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
LOW RANGE, FORWARD, & REVERSE SPEED PLATE
GEAR SOLENOID ENERGIZED SOLENOID ENERGIZED CONVERTER
SELECTION FORWARD LOW RANGE REVERSE 1 2 3 RELIEF
NEUTRAL VALVE
COOLER TORQUE E
1ST FORWARD X X X X RELIEF CONVERTER
2ND FORWARD X X X X BYPASS
VALVE SYSTEM PRESSURE
3RD FORWARD X X X X FILTER
AND MEDIUM PRESSURE
HIGH RANGE THERMAL TRANSMISSION BYPASS
X X X RELIEF OIL COOLER LOW PRESSURE
(4TH FORWARD)
BYPASS
1ST REVERSE X X X X VALVE LUBE PRESSURE
TRANSMISSION
2ND REVERSE TO PUMP
X X X X LUBE RETURN PRESSURE
3RD REVERSE X X X X
T117376 TRANSMISSION CONTROL CIRCUIT NEUTRAL SUMP
CED,TX03399,4214 1906MAR981/1

022602
PN=596
See Page 9020-05B-16 A See Page 9020-05B-16 B See Page 9020-05B-16 C

1ST SPEED
CLUTCH
2ND SPEED
CLUTCH
3RD SPEED TRANSMISSION SPEED

CLUTCH SHIFT VALVE
SPEED SHIFT
VALVE L
3
SPEED SHIFT
VALVE
2 K
LOW
RANGE
SPEED SOLENO
SHIFT VALVE
VALVE C
1 J
SPEED SPEED SPEED

SOLENOID SOLENOID SOLENOID
VALVE VALVE VALVE
3 M 2 I 1 H
LOW RANGE, FORWARD, & REVERSE SPEED

GEAR SOLENOID ENERGIZED SOLENOID ENERGIZED
SELECTION FORWARD LOW RANGE REVERSE 1 2 3
NEUTRAL
COOLER
1ST FORWARD X X X X RELIEF
VALVE
3RD FORWARD X X X X
HIGH RANGE THERMAL
X X X RELIEF
(4TH FORWARD)
BYPASS
1ST REVERSE X X X X VALVE
2ND REVERSE X X X X
3RD REVERSE X X X X
T117376
Page 9020-05B-16 A
Power Shift
T117376 1901FEB99
HIGH RANGE
FORWARD CLUTCH
LOW RANGE DIFFERENTIA

FORWARD REVERSE
CONTROL VALVE
LOW RANGE P
SHIFT VALVE
FORWARD/REVERSE
SHIFT VALVE
O
SEQUENCE
VALVE ORIFICE IN
VALVE HOUSING
LOW N
RANGE R
FORWARD
SOLENOID REVERSE SOLENOID
VALVE SOLENOID VALVE
C VALVE
B
D
ORIFICE IN
MODULATION MODULATION
SPOOL VALVE G
PRESSUR
REDUCIN
ORIFICE ORIFICE IN VALVE
IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
TORQUE E
CONVERTER
FILTER
AND
TRANSMISSION BYPASS
OIL COOLER
TRANSMISSION
TO PUMP
LUBE
TRANSMISSION CONTROL CIRCUIT NEUTRAL SUMP
TM1537 (26FEB0
Page 9020-05B-16 B
Shift Transmission Control CircuitNeutral (S.N. 872257 )

901FEB99
RENTIAL LOCK MFWD PARK

BRAKE
DIFFERENTIAL MFWD PARK BRAKE

VALVE VALVE VALVE
SCREEN
IN ALL
ESSURE SOLENOIDS
DUCING
ALVE Q
SYSTEM PRESSURE
MEDIUM PRESSURE
LOW PRESSURE
LUBE PRESSURE
RETURN PRESSURE
CED,TX03399,4214 1906MAR981/1
26FEB02) 9020-05B-16 710D Backhoe Loader

022602
Page 9020-05B-16 C PN=596

Power Shift Transmission Control CircuitNeutralContinued (S.N. 872257 )
NOTE: Keys and story on control valve in the circuit is a spring loaded spool valve which routes system oil
correspond to the control valve on next page. to the low range, high range forward, and reverse
clutches. The forward and reverse solenoid valves, (B)
The transmission control valve regulates the hydraulic and (D), are activated by the FNR lever. Each directs
oil pressures and controls circuits required for medium pressure oil to the forward/reverse shift valve
operation of the transmission. Electrical signals from (O). The low range solenoid valve (C), directs medium
the FNR lever and park brake switch are used to pressure oil to the low range shift valve (P). The low
energize the solenoids which direct oil to move the range solenoid valve is controlled by the gear selection
shift valves and engage the appropriate selected on the FNR lever.
clutches.
The pressure reducing valve (Q) supplies medium
The transmission control valve contains the main pressure oil to the speed, forward, reverse and low
frame harness (A), forward solenoid valve (B), low range solenoid valves.
range solenoid valve (C), reverse solenoid valve (D),
converter relief valve (E), pressure regulating valve (F), Flow from the transmission charge pump passes
modulation valve (G), modulation piston (N), through the filter to the pressure regulating valve. The
forward/reverse shift valve (O), low range shift valve pressure regulating valve regulates system pressure
(P), and the pressure reducing valve (Q). The and directs high pressure oil to the reducing valve,
transmission speed shift valve contains the speed differential solenoid valve, MFWD solenoid valve and
solenoid valves 1, 2 and 3 (H, I and M) and speed the park brake solenoid valve. 9020
shift valves 1, 2 and 3 (J, K and L). 05B
17
When pressure exceeds the pressure regulating valve
The converter relief valve (E) controls the maximum setting the valve opens. Low pressure oil then flows
pressure to the torque converter. The pressure through the torque converter. Converter flow is excess
regulating valve (F) is a spring loaded spool valve with oil from the pressure regulating valve. A torque
shims. It regulates main system pressure. Excess oil converter relief valve protects the circuit by dumping to
from the circuit is directed to the torque converter tank when pressure exceeds the setting. The oil is
through this valve. The modulation valve (G) is a then routed to the oil cooler. The oil returning from the
spring loaded spool which controls the rate of clutch cooler provides lubrication to the clutches.
engagement during a shift. Within the valve is the
modulation piston (N). In neutral, with park brake OFF, the forward and
reverse solenoids are de-energized (open), medium
When a gear is selected the speed solenoid valves (H, pressure oil is not directed to the forward/reverse shift
I, or M) are energized in combinations of two which valve. The low range solenoid valve is de-energized
shift two of the speed shift valves (J, K, or L). The shift (open) and no pressure oil is routed to the end of the
valves direct system pressure oil to one of the speed low range shift valve. In neutral all speed clutch packs
clutches 1st, 2nd or 3rd. also dump to sump and all speed clutch solenoids are
de-energized. The reducing valve controls the pressure
The forward/reverse shift valve (O), is a spring loaded by dumping oil to tank when pressure exceeds its
spool valve which routes system pressure oil to the setting.
low range shift valve (P). The low range shift valve (P),
CED,TX03399,4218 1906MAR981/1

022602
PN=597
Power Shift Transmission Control Valve and Shift Valve OperationNeutral (S.N.
872257 )
B FORWARD C LOW RANGE

SOLENOID SOLENOID
D REVERSE
SOLENOID
E
CONVERTER
RELIEF
A MAIN VALVE
FRAME
HARNESS
9020 Q
05B F
18 PRESSURE
REDUCING PRESSURE
VALVE REGULATING
VALVE
P
LOW RANGE
SHIFT VALVE R
ORIFICE N
O
G
FORWARD MODULATION
OR REVERSE PISTON MODULATION
SHIFT VALVE VALVE
H
SPEED
SOLENOID
VALVE 1
M I
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2
S SYSTEM PRESSURE OIL

T MEDIUM PRESSURE OIL
U LOW PRESSURE OIL J
V RETURN OIL SPEED
SHIFT
VALVE 1
L
SPEED
1926JUN98
SHIFT
VALVE 3
K SPEED
W TRANSMISSION CONTROL VALVE SHIFT
T114881
VALVE 2
T114881 AND SHIFT VALVE - NEUTRAL

022602
PN=598
AMain Frame Harness HSpeed Solenoid Valve 1 OForward/Reverse Shift TMedium Pressure Oil
BForward Solenoid Valve ISpeed Solenoid Valve 2 Valve ULow Pressure Oil
CLow Range Solenoid Valve JSpeed Shift Valve 1 PLow Range Shift Valve VReturn Oil
DReverse Solenoid Valve KSpeed Shift Valve 2 QPressure Reducing Valve WTransmission Control
EConverter Relief Valve LSpeed Shift Valve 3 ROrifice (In Valve Housing) Valve And Shift Valve
FPressure Regulating Valve MSpeed Solenoid Valve 3 SSystem Pressure Oil Neutral
GModulation Valve NModulation Piston
CED,TX03399,4224 1927MAR982/2
9020
05B
19

022602
PN=599
Power Shift Transmission Control CircuitFirst Forward (S.N. 872257 )

T117377 1901FEB99
HIGH RANGE
FORWARD CLUTCH
1ST SPEED
CLUTCH
LOW RANGE
CLUTCH SHIFT VALVE P
SPEED SHIFT
3 SHIFT VALVE
O
SEQUENCE
SPEED SHIFT VALVE
VALVE ORIFICE IN
2 K PARK BRAKE
VALVE HOUSING SOLENOID
LOW N
RANGE R DIFFERENTIAL VALVE
FORWARD MFWD
SPEED SOLENOID REVERSE SOLENOID SOLENOID SOLENOID
SHIFT VALVE SOLENOID VALVE VALVE VALVE
VALVE C VALVE
1 J B
D
ORIFICE IN
SPOOL SCREEN
SPEED SPEED SPEED VALVE G PRESSURE IN ALL
SOLENOID SOLENOID REDUCING SOLENOIDS
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
NEUTRAL VALVE
COOLER TORQUE E
AND MEDIUM PRESSURE
(4TH FORWARD)
BYPASS
TRANSMISSION
2ND REVERSE TO PUMP
3RD REVERSE X X X X
T117377 TRANSMISSION CONTROL CIRCUIT FIRST FORWARD SUMP
CED,TX03399,4215 1906MAR981/1

022602
PN=600

1ST SPEED
CLUTCH
2ND SPEED
CLUTCH

CLUTCH SHIFT VALVE
SPEED SHIFT
VALVE L
3
SPEED SHIFT
VALVE
2 K
LOW
RANGE
SPEED SOLENO
SHIFT VALVE
VALVE C
1 J
SPEED SPEED SPEED

SOLENOID SOLENOID
VALVE VALVE VALVE
3 M 2 I 1 H

NEUTRAL
COOLER
VALVE
3RD FORWARD X X X X
HIGH RANGE THERMAL
X X X RELIEF
(4TH FORWARD)
BYPASS
2ND REVERSE X X X X
3RD REVERSE X X X X
T117377 TRA
Page 9020-05B-20 A
Power Shift
T117377 1901FEB99
HIGH RANGE
FORWARD CLUTCH

FORWARD REVERSE
CONTROL VALVE
LOW RANGE
SHIFT VALVE
P
FORWARD/REVERSE
SHIFT VALVE
O
SEQUENCE
VALVE
ORIFICE IN
VALVE HOUSING
LOW N
RANGE R
FORWARD
C VALVE
B
D
ORIFICE IN
SPOOL VALVE G PRESSUR
REDUCIN
IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
TORQUE E
CONVERTER
FILTER
AND
TRANSMISSION BYPASS
OIL COOLER
TRANSMISSION
TO PUMP
LUBE
TRANSMISSION CONTROL CIRCUIT FIRST FORWARD SUMP
TM1537 (26FEB0
Page 9020-05B-20 B
Shift Transmission Control CircuitFirst Forward (S.N. 872257 )

901FEB99

BRAKE
PARK BRAKE
SOLENOID
DIFFERENTIAL VALVE
MFWD
SOLENOID SOLENOID
VALVE VALVE
SCREEN
ESSURE IN ALL
DUCING SOLENOIDS
ALVE Q
SYSTEM PRESSURE
MEDIUM PRESSURE
LOW PRESSURE
LUBE PRESSURE
RETURN PRESSURE
CED,TX03399,4215 1906MAR981/1

022602
Page 9020-05B-20 C PN=600

Power Shift Transmission Control CircuitFirst ForwardContinued (S.N. 872257 )
NOTE: Keys and story on control valve in the circuit and the low range shift spool allows oil to flow from the
correspond to the control valve on next page. modulation valve to fill the low range forward clutch
pack and compress the clutch plates. Shifting of the
The relief valves are the same pressure oil as forward/reverse spool also blocks the flow of oil
shown in the neutral story. Refer to neutral downstream of the orifice (R) in valve housing from
story for pressure reducing, converter relief returning to tank and allows the pressure in the
and pressure regulating valve. modulation valve to build. As pressure builds, the
balance between orifice size and spring load in the
During 1st gear forward operation the forward solenoid modulation valve controls the rate of shift and pushes
valve (B), low range solenoid valve (C), speed the modulation piston down.
solenoid valve 2 (I), and speed solenoid valve 3 (M)
are energized. The energized low range solenoid valve The sequence valve insures that the speed clutch fills
routes medium pressure oil to the low range shift valve and engages before the direction clutch by allowing oil
(P) and moves the spool down. The energized forward to flow from the modulation valve to the speed clutch
solenoid valve (B) routes medium pressure oil to the circuit downstream of the orifice in duct plate
forward/reverse shift valve (O) moving its spool up. (replenishing orifice) when the pressure in the speed
The energized speed solenoids 2 and 3 (I and M) clutch circuit is lower than the pressure in the direction
route medium pressure oil to the shift valves 2 and 3 clutch circuit. The downward force from the modulation
(K and L) moving the spools down. Shifting of the piston pushes on the modulation springs which drive
speed shift spools allows oil to flow from the regulating the modulation spool down to the fully open position. 9020
valve through the orifice in duct plate (replenishing In the fully open position, high pressure oil form the 05B
21
orifice) to fill the 1st speed clutch pack and compress pressure regulating valve keeps the speed and
the clutch plates. Shifting of the forward/reverse spool direction clutches engaged.
CED,TX03399,4219 1906MAR981/1

022602
PN=601
Power Shift Transmission Control Valve and Shift ValveFirst Forward (S.N. 872257 )

SOLENOID SOLENOID
D REVERSE
SOLENOID
E
CONVERTER
RELIEF
A MAIN VALVE
FRAME
HARNESS
Q
9020 F
PRESSURE
05B REDUCING PRESSURE
22
VALVE REGULATING
VALVE
P
LOW RANGE
SHIFT VALVE R
O ORIFICE N
G
FORWARD MODULATION
SHIFT VALVE VALVE
H
SPEED
SOLENOID
VALVE 1
M I
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2

J
U RETURN OIL
SPEED
SHIFT
VALVE 1
L
SPEED
1926JUN98
SHIFT
VALVE 3
K SPEED
V TRANSMISSION CONTROL VALVE SHIFT
T114882
VALVE 2
T114882 AND SHIFT VALVE - FIRST FORWARD
Continued on next page CED,TX03399,4227 1922APR981/2

022602
PN=602
AMain Frame Harness HSpeed Solenoid Valve 1 NModulation Piston SSystem Pressure Oil
BForward Solenoid Valve ISpeed Solenoid Valve 2 OForward/Reverse Shift TMedium Pressure Oil
CLow Range Solenoid Valve JSpeed Shift Valve 1 Valve UReturn Pressure Oil
DReverse Solenoid Valve KSpeed Shift Valve 2 PLow Range Shift Valve VTransmission Control
EConverter Relief Valve LSpeed Shift Valve 3 QPressure Reducing Valve Valve and Shift Valve
FPressure Regulating Valve MSpeed Solenoid Valve 3 ROrifice (In Valve Housing) First Forward
GModulation Valve
CED,TX03399,4227 1922APR982/2
9020
05B
23

022602
PN=603
Power Shift Transmission Control CircuitHigh Range (Fourth) Forward (S.N. 872257 )
T117378 1901FEB99
HIGH RANGE
FORWARD CLUTCH
1ST SPEED
CLUTCH
LOW RANGE P
CLUTCH SHIFT VALVE
SPEED SHIFT
3 SHIFT VALVE
O
SPEED SHIFT
VALVE SEQUENCE
K VALVE ORIFICE IN PARK BRAKE
2 VALVE HOUSING
LOW N SOLENOID
FORWARD MFWD
SOLENOID REVERSE SOLENOID SOLENOID SOLENOID
VALVE SOLENOID VALVE VALVE VALVE
SPEED C VALVE
B
SHIFT D
VALVE ORIFICE IN
1 J MODULATION
SPOOL MODULATION SCREEN
SOLENOID SOLENOID SOLENOID REDUCING SOLENOIDS
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
NEUTRAL VALVE
COOLER TORQUE E
AND MEDIUM PRESSURE
(4TH FORWARD)
BYPASS
TRANSMISSION
2ND REVERSE TO PUMP
3RD REVERSE X X X X
T117378 TRANSMISSION CONTROL CIRCUIT FOURTH FORWARD SUMP
CED,TX03399,4216 1906MAR981/1

022602
PN=604

1ST SPEED
CLUTCH
2ND SPEED
CLUTCH

CLUTCH SHIFT VALVE
SPEED SHIFT
VALVE L
3
SPEED SHIFT
VALVE
2 K
LOW
RANGE
SOLENO
VALVE
SPEED C
SHIFT
VALVE
1 J
SPEED SPEED SPEED
VALVE VALVE VALVE
3 M 2 I 1 H

NEUTRAL
COOLER
VALVE
3RD FORWARD X X X X
HIGH RANGE THERMAL
X X X RELIEF
(4TH FORWARD)
BYPASS
2ND REVERSE X X X X
3RD REVERSE X X X X
T117378 TRAN
Page 9020-05B-24 A
Power Shift
T117378 1901FEB99
HIGH RANGE
FORWARD CLUTCH

FORWARD REVERSE
CONTROL VALVE
LOW RANGE P
SHIFT VALVE
FORWARD/REVERSE
SHIFT VALVE
O
SEQUENCE
VALVE ORIFICE IN
VALVE HOUSING
LOW N
RANGE R
FORWARD
C VALVE
B
D
ORIFICE IN
MODULATION
SPOOL MODULATION
VALVE G PRESSUR
REDUCIN
IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
TORQUE E
CONVERTER
FILTER
AND
TRANSMISSION BYPASS
OIL COOLER
TRANSMISSION
TO PUMP
LUBE
TRANSMISSION CONTROL CIRCUIT FOURTH FORWARD SUMP
TM1537 (26FEB0
Page 9020-05B-24 B
Shift Transmission Control CircuitHigh Range (Fourth) Forward (S.N. 872257 )

901FEB99

BRAKE
PARK BRAKE
SOLENOID
DIFFERENTIAL VALVE
MFWD
SOLENOID SOLENOID
VALVE VALVE
SCREEN
ESSURE IN ALL
DUCING SOLENOIDS
ALVE Q
SYSTEM PRESSURE
MEDIUM PRESSURE
LOW PRESSURE
LUBE PRESSURE
RETURN PRESSURE
CED,TX03399,4216 1906MAR981/1

022602
Page 9020-05B-24 C PN=604

Power Shift Transmission Control CircuitHigh Range (Fourth) ForwardContinued

(S.N. 872257 )
NOTE: Keys and story on control valve in the circuit clutch pack and compress the clutch plates. Shifting of
correspond to the control valve on next page. the forward/reverse spool also blocks the flow of oil
downstream of the orifice (R) in valve housing from
The relief valves are the same pressure oil as returning to tank and allows the pressure in the
shown in the neutral story. Refer to neutral modulation valve to build. As pressure builds, the
story for pressure reducing, converter relief balance between orifice size and spring load in the
and pressure regulating valve. modulation valve controls the rate of shift and pushes
the modulation piston down.
During 4th gear forward operation the forward solenoid
valve (B), speed solenoid valve 1 (H), and speed The sequence valve insures that the speed clutch fills
solenoid valve 3 (M) are energized. Both the low range and engages before the direction clutch by allowing oil
shift valve (P) and the forward/reverse shift valve (O) to flow from the modulation valve to the speed clutch
are in the up position. The energized speed solenoids circuit downstream of the orifice in duct plate
1 and 3 (H and M) route medium pressure oil to the (replenishing orifice) when the pressure in the speed
shift valves 1 and 3 (J and L) moving the spools down. clutch circuit is lower than the pressure in the direction
Pressure oil is routed through the shift valves to the clutch circuit. The downward force from the modulation
3rd speed clutch. Shifting of the speed shift spools piston pushes on the modulation springs which drive
allows oil to flow from the regulating valve through the the modulation spool down to the fully open position.
orifice in duct plate (replenishing orifice) to fill the 3rd In the fully open position, high pressure oil form the 9020
05B
speed clutch pack and compress the clutch plates. pressure regulating valve keeps the speed and
25
Shifting of the forward/reverse spool allows oil to flow direction clutches engaged.
from the modulation valve to fill the high range forward
CED,TX03399,4222 1913MAR981/1

022602
PN=605
Power Shift Transmission Control Valve and Shift ValveHigh Range (Fourth) Forward
(S.N. 872257 )

SOLENOID SOLENOID
D REVERSE
SOLENOID
E
CONVERTER
RELIEF
A MAIN VALVE
FRAME
HARNESS
9020 Q
05B F
26 PRESSURE
REDUCING PRESSURE
VALVE REGULATING
VALVE
P
LOW RANGE
SHIFT VALVE R
ORIFICE N
G
O MODULATION
PISTON MODULATION
FORWARD VALVE
OR REVERSE
SHIFT VALVE H
SPEED
SOLENOID
VALVE 1
M I
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2
S SYSTEM PRESSURE OIL J

T MEDIUM PRESSURE OIL SPEED
SHIFT
U RETURN OIL VALVE 1
L
SPEED
1926JUN98
SHIFT
VALVE 3
K SPEED
T114883
VALVE 2
T114883 AND SHIFT VALVE - FOURTH FORWARD

022602
PN=606
AMain Frame Harness HSpeed Solenoid Valve 1 OForward/Reverse Shift TMedium Pressure Oil
BForward Solenoid Valve ISpeed Solenoid Valve 2 Valve UReturn Pressure Oil
CLow Range Solenoid Valve JSpeed Shift Valve 1 PLow Range Shift Valve VTransmission Control
DReverse Solenoid Valve KSpeed Shift Valve 2 QPressure Reducing Valve Valve and Shift Valve
EConverter Relief Valve LSpeed Shift Valve 3 ROrifice (In Valve Housing) High Range (Fourth)
FPressure Regulating Valve MSpeed Solenoid Valve 3 SSystem Pressure Oil Forward
GModulation Valve NModulation Piston
CED,TX03399,4228 1922APR982/2
9020
05B
27

022602
PN=607
Power Shift Transmission Control CircuitFirst Reverse (S.N. 872257 )

T117379 1901FEB99
HIGH RANGE
FORWARD CLUTCH
1ST SPEED
CLUTCH
LOW RANGE
CLUTCH SHIFT VALVE P
SPEED SHIFT
3 SHIFT VALVE
O
SEQUENCE
SPEED SHIFT VALVE
VALVE ORIFICE IN
2 K PARK BRAKE
VALVE HOUSING SOLENOID
LOW N
FORWARD MFWD
SPEED SOLENOID SOLENOID SOLENOID SOLENOID
SHIFT VALVE REVERSE VALVE
SOLENOID VALVE VALVE
VALVE C
1 J VALVE B
D ORIFICE IN
SPOOL SCREEN
SOLENOID SOLENOID SOLENOID REDUCING SOLENOIDS
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
NEUTRAL VALVE
COOLER TORQUE E
AND MEDIUM PRESSURE
(4TH FORWARD)
BYPASS
TRANSMISSION
2ND REVERSE TO PUMP
3RD REVERSE X X X X
T117379 TRANSMISSION CONTROL CIRCUIT FIRST REVERSE SUMP
CED,TX03399,4217 1906MAR981/1

022602
PN=608

1ST SPEED
CLUTCH
2ND SPEED
CLUTCH

CLUTCH SHIFT VALVE
SPEED SHIFT
VALVE L
3
SPEED SHIFT
VALVE
2 K
LOW
RANGE
SPEED SOLENO
SHIFT VALVE
VALVE C
1 J
SPEED SPEED SPEED

VALVE VALVE VALVE
3 M 2 I 1 H

NEUTRAL
COOLER
VALVE
3RD FORWARD X X X X
HIGH RANGE THERMAL
X X X RELIEF
(4TH FORWARD)
BYPASS
2ND REVERSE X X X X
3RD REVERSE X X X X
T117379 TRA
Page 9020-05B-28 A
Power Shift
T117379 1901FEB99
HIGH RANGE
FORWARD CLUTCH

FORWARD REVERSE
CONTROL VALVE
LOW RANGE
SHIFT VALVE
P
FORWARD/REVERSE
SHIFT VALVE
O
SEQUENCE
VALVE
ORIFICE IN
VALVE HOUSING
LOW N
RANGE R
FORWARD
SOLENOID SOLENOID
VALVE REVERSE
SOLENOID VALVE
C VALVE B
D ORIFICE IN
SPOOL VALVE G PRESSUR
REDUCIN
IN DUCT MODULATION
PLATE PISTON
PRESSURE
REGULATING
VALVE ORIFICE IN
F INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
TORQUE E
CONVERTER
FILTER
AND
TRANSMISSION BYPASS
OIL COOLER
TRANSMISSION
TO PUMP
LUBE
TRANSMISSION CONTROL CIRCUIT FIRST REVERSE SUMP
TM1537 (26FEB0
Page 9020-05B-28 B
Shift Transmission Control CircuitFirst Reverse (S.N. 872257 )

901FEB99

BRAKE
PARK BRAKE
SOLENOID
DIFFERENTIAL VALVE
MFWD
SOLENOID SOLENOID
VALVE VALVE
SCREEN
ESSURE IN ALL
DUCING SOLENOIDS
ALVE Q
SYSTEM PRESSURE
MEDIUM PRESSURE
LOW PRESSURE
LUBE PRESSURE
RETURN PRESSURE
CED,TX03399,4217 1906MAR981/1

022602
Page 9020-05B-28 C PN=608

Power Shift Transmission Control CircuitFirst ReverseContinued (S.N. 872257 )
NOTE: Keys and story on control valve in the circuit low range shift spool allows oil to flow from the
correspond to the control valve on next page. modulation valve to fill the reverse clutch pack and
compress the clutch plates. Shifting of the
The relief valves are the same pressure oil as forward/reverse spool also blocks the flow of oil
shown in the neutral story. Refer to neutral downstream of the orifice (R) in valve housing from
story for pressure reducing, converter relief returning to tank and allows the pressure in the
and pressure regulating valve. modulation valve to build. As pressure builds, the
balance between orifice size and spring load in the
During 1st gear reverse operation the reverse solenoid modulation valve controls the rate of shift and pushes
valve (D), low range solenoid valve (C), speed the modulation piston down.
solenoid valve 2 (I), and speed solenoid valve 3 (M)
are energized. The energized reverse solenoid valve The sequence valve insures that the speed clutch fills
routes medium pressure oil to the forward/reverse shift and engages before the direction clutch by allowing oil
valve (O) moving its spool down. The energized low to flow from the modulation valve to the speed clutch
range solenoid valve routes medium pressure oil to the circuit downstream of the orifice in duct plate
low range shift valve (P) moving its spool down. The (replenishing orifice) when the pressure in the speed
energized speed solenoids 2 and 3 (I and M) route clutch circuit is lower than the pressure in the direction
medium pressure oil to the shift valves 2 and 3 (K and clutch circuit. The downward force from the modulation
L) moving the spools down. Shifting of the speed shift piston pushes on the modulation springs which drive
spools allows oil to flow from the regulating valve the modulation spool down to the fully open position. 9020
through the orifice in duct plate (replenishing orifice) to In the fully open position, high pressure oil form the 05B
29
fill the 1st speed clutch pack and compress the clutch pressure regulating valve keeps the speed and
plates. Shifting of the forward/reverse spool and the direction clutches engaged.
CED,TX03399,4221 1913MAR981/1

022602
PN=609
Power Shift Transmission Control Valve and Shift ValveFirst Reverse (S.N. 872257 )

SOLENOID SOLENOID
D REVERSE
SOLENOID
E
CONVERTER
RELIEF
A MAIN VALVE
FRAME
HARNESS
Q
9020 F
PRESSURE
05B REDUCING PRESSURE
30 VALVE REGULATING
VALVE
P
LOW RANGE
SHIFT VALVE R
ORIFICE N
O
G
FORWARD MODULATION
SHIFT VALVE VALVE
H
SPEED
SOLENOID
VALVE 1
M I
SPEED SPEED
SOLENOID SOLENOID
VALVE 3 VALVE 2

J
U RETURN OIL
SPEED
SHIFT
VALVE 1
L
SPEED
1926JUN98
SHIFT
VALVE 3
K SPEED
T114884
VALVE 2
T114884 AND SHIFT VALVE - FIRST REVERSE

022602
PN=610
AMain Frame Harness HSpeed Solenoid Valve 1 NModulation Piston SSystem Pressure Oil
BForward Solenoid Valve ISpeed Solenoid Valve 2 OForward/Reverse Shift TMedium Pressure Oil
CLow Range Solenoid Valve JSpeed Shift Valve 1 Valve UReturn Pressure Oil
DReverse Solenoid Valve KSpeed Shift Valve 2 PLow Range Shift Valve VTransmission Control
EConverter Relief Valve LSpeed Shift Valve 3 QPressure Reducing Valve Valve and Shift Valve
FPressure Regulating Valve MSpeed Solenoid Valve 3 ROrifice (In Valve Housing) First Reverse
GModulation Valve
CED,TX03399,4229 1922APR982/2
9020
05B
31

022602
PN=611
Power Shift Modulation Valve Operation (S.N. 872257 )
M ORIFICES
G PISTON FILL PRE MODULATION ENGAGEMENT

MOD.
H OUTER
SPRING
F
I INNER
ORIFICE SPRING
J SEQUENCE
VALVE B C D
E
ORIFICE
M6 M6
K ORIFICE
A
NEUTRAL L MODULATION
SPOOL
9020 B C D
05B START OF FILL MODULATION ENGAGEMENT
32
N SYSTEM PRESSURE
O MEDIUM HIGH PRESSURE
1926JUN98
P MEDIUM PRESSURE
Q LOW PRESSURE
R RETURN PRESSURE
T114787
T114787 S MODULATION VALVE

022602
PN=612
ANeutral FOrifice (In Valve Housing) KOrifice In Duct Plate OMedium High Pressure
BStart of Fill GPiston (Replenishing Orifice) PMedium Pressure
CModulation HOuter Spring LModulation Spool QLow Pressure
DEngagement IInner Spring MOrifice (2 used) RReturn Pressure
EOrifice JSequence Valve NSystem Pressure SModulation Valve
Rate of shift is controlled by movement of the springs (H and I) and modulation spool (L), down.
modulation valve and modulation piston during a shift. There are two small orifices (M) located near the top of
By regulating the amount of oil flow being sent to the piston (G). These orifices allow return oil to dump
engage the direction pack, the time required is to sump during start of fill and half way through
extended to assure a smooth shift. modulation mode. This helps control the rate of shift.
The orifices in the piston close off as the piston moves
When the machine is in neutral (A), system pressure down. An equalization of spring and pressure force on
oil (N), bleeds by the edge of the modulation spool (L). the modulation valve regulates the rate of clutch
This oil (Q) (low pressure) flows through orifice (F), engagement during modulation.
which is open to return. Low pressure oil (Q), also
flows through orifice (E) to the bottom side of the The orifice in duct plate (replenishing orifice) (K),
modulation spool (L). This oil applies sufficient force on supplies oil from the pressure regulating valve to the
the spring to hold the valve on the edge of pressure speed shift valves. The sequence valve (J) supplies oil
port opening. from the modulation valve to the speed shift valves
also, but only when the oil downstream of the orifice in
All direction and speed clutch packs are also open to duct plate (replenishing orifice) (K) is below the
sump when the FNR is in neutral. modulation pressure filling the direction clutch pack. 9020
05B
This insures that the speed clutch fills and engages
33
The start of fill mode (B), begins when a shift occurs. before the direction clutch.
Shifting of the speed shift spools allows oil to flow from
the regulating valve through the orifice (K) to fill the When the final engagement mode (D) is reached, the
speed clutch pack. Shifting of the forward/reverse modulation spool (L) is in the fully open position, and
spool allows oil to flow from the modulation valve and the two small orifices (M) in the modulation piston (G)
will fill the direction clutch pack. Shifting of the are closed off. With the spool in the fully open position,
forward/reverse spool also blocks the flow of oil high pressure oil from the pressure regulating valve
downstream of the orifice (F) from returning to tank maintains the downward force on the modulation
and allows the pressure in the modulation valve to piston and keeps the clutches engaged until the next
build. Both direction and speed clutch packs fill rapidly shift.
at the low pressure level.
Cycling the forward/reverse spool allows the high
Modulation mode (C), begins as pressure in the clutch pressure oil in the engaged clutch and between the
pack begins to rise (P). The pressure is also being orifice (F) and the top of the modulation piston to vent
sensed through orifice (F). Pressure on the back side to tank. The resulting loss in pressure allows the
of orifice (F) is building to low pressure (Q). This modulation valve to reset to begin the next shift
pressure starts moving the modulation piston (G), sequence.
CED,TX03399,4225 1927MAR982/2

022602
PN=613
Differential Operation (S.N. 872257 )
9020
05B
34
AFinal Drive Ring Gear DBevel Pinion Shaft (2 used) GSide Gear JOutput Shaft 1902FEB99
T117161
BDifferential Housing EBevel Pinion (4 used) HSun Pinion Shaft KDifferential

CDifferential Ring Gear FInput Pinion Shaft IPlanet Pinion Carrier
The differential allows independent rotation of the reduction. The input pinion shaft to differential ring
axles when the machine is steered. The final drive gear also provides a reduction in speed and an
planetaries are attached to the axles. Their purpose is increase to torque.
to reduce speed and increase torque through gear
Continued on next page TX,05,SS3139 1923JUN981/2

022602
PN=614
Input torque from the drive shaft rotates the input bevel Torque is transferred into the output shaft (J) causing it
pinion shaft (F) which meshes with the differential ring to rotate at a reduced speed but with greater torque.
gear (C), causing it to turn. The ring gear is fastened
to the differential housing (B) which drives the bevel As the machine is steered, the inside wheel slows
pinion shafts (D) and bevel pinions (E). The bevel down in relation to the outside wheel. This causes the
pinions located on the bevel pinion shaft are in mesh side gear, attached to the inside wheels axle, to slow
with the side gears (G) which spline to the sun pinion down. The rotating differential housing and bevel
shaft (H). pinion shafts allow the differential bevel pinions to
rotate around the slow moving side gear; this allows
The sun pinion shaft meshes with the planet pinion the opposite side gear to rotate at a faster speed. This
carrier assembly (I) which rotates around the inside of rotation causes the outside wheels axle to rotate
the stationary planetary final drive ring gear (A). faster than the inside axle which prevents tire scuffing.
TX,05,SS3139 1923JUN982/2
9020
05B
35

022602
PN=615
Differential Lock Operation (S.N. 872257 )
E BEARING
F SNAP RING
SIDE A B DIFFERENTIAL C LEVER D CAGE
GEAR HOUSING G SEAL
H BRAKE
HOUSING
DIFFERENTIAL
SOLENOID
VALVE
I
9020
05B J SEAL
36
K NEEDLE
BEARING
L PISTON
FROM M
TRANSMISSION
PUMP
1902FEB99
P CLUTCH O SPRING N SLIDING
Q SYSTEM PRESSURE SLEEVE
PACK
R RETURN PRESSURE
S DIFFERENTIAL LOCK
T117099
T117099
ASide Gear FSnap Ring KNeedle Bearing PClutch Pack

BDifferential Housing GSeal LPiston QSystem Pressure
CLever HBrake Housing MFrom Transmission Pump RReturn Pressure
DCage IDifferential Solenoid Valve NSliding Sleeve SDifferential Lock
EBearing JSeal OSpring
When the operator has the differential lock foot control piston (L) back releasing the differential lock. The
switch in the "OFF" position (unapplied), the spring return oil returns through the same port as when the
force (O) moves the sliding sleeve (N), lever (C) and switch is in the "ON" position.
Continued on next page TX,05,SS3130 1923JUL981/2

022602
PN=616
When the operator pushes the differential lock foot the cross-drilled passages to the piston (L). The
control switch to the "ON" position, the switch pressurized oil moves the piston against the sliding
energizes the differential lock solenoid (I) on the sleeve and lever to lock up the clutch pack (P) with
transmission. When the differential lock solenoid is side gear (A) of the differential, causing both axles to
energized, pressure oil flows to the inlet and through rotate at the same speed.
TX,05,SS3130 1923JUL982/2
9020
05B
37

022602
PN=617
Park Brake Operation (S.N. 872257 )
9020
05B
38
A INNER
SPRING
F PISTON
B OUTER
H SPRING
PARK BRAKE
SOLENOID
VALVE
G DISK E
FROM
TRANSMISSION D PLATE
PUMP
C TOWING
CAP SCREW
I SYSTEM PRESSURE
J RETURN PRESSURE
1902FEB99
T117163
T117163 K PARK BRAKE - ON
AInner Spring DDisk (5 used) GFrom Transmission Pump JReturn Pressure

BOuter Spring EPlate (5 used) HPark Brake Solenoid Valve KPark BrakeON
CTowing Cap Screw FPiston ISystem Pressure
Continued on next page TX,05,SS3134 1916MAY961/2

022602
PN=618
The park brake is spring applied and hydraulically the transmission. The solenoid routes transmission
released. When the park brake is applied (ON) or system pressure oil (I) to the park brake piston (F).
machine is shut-off, spring force applies the park The piston moves against the springs (A&B) and
brake. The springs (A&B) force the piston (F) against releases the disks and plates (D and E). Two manual
brake disks (D) and plates (E) on the axle input shaft. operated cap screws (C) release the park brake for
emergency towing.
When park brake switch is cycled to the OFF position,
the switch energizes the park brake solenoid (H) on
TX,05,SS3134 1916MAY962/2
9020
05B
39

022602
PN=619
Mechanical Front Wheel Drive (MFWD) Operation (S.N. 872257 )
ACTUATION DRIVE
PIN GEAR
SPRING F
D
B PISTON
C PLATES
AND DISKS
FRONT E
OUTPUT
SHAFT
A
G
MFWD
SOLENOID
VALVE
H
FROM
TRANSMISSION
9020 PUMP
05B
40
O MFWD CLUTCH ASSEMBLY (ENGAGED)
RETAINER RETAINER
J SPRING
I
G
MFWD
SOLENOID
VALVE
H
FROM
TRANSMISSION
K END PUMP
PLATE
1928OCT98
L SYSTEM PRESSURE OIL

END K
PLATE M RETURN OIL
N LUBRICATION OIL
T117105
T117105
P MFWD CLUTCH ASSEMBLY (DISENGAGED)

022602
PN=620
AFront Output Shaft EPlates and Disks IRetainer Spring MReturn Oil
BSpring FDrive Gear JRetainer NLubricatin Oil
CPiston GSolenoiod Valve KEnd Plate OMFWDOn (Engaged)
DActuation Pin HFrom Transmission Pump LSystem Pressure PMFWDOn (Disengaged)
The MFWD is spring applied, hydraulically released. When energized, with MFWD switch in the OFF
When the MFWD switch is ON, spring (B) force locks position, transmission pressure oil (H) is routed to
the clutch pack disk and plates with drive gear (F). The piston (C). Pressure pushes the piston against the
drive gear is connected to the front output shaft (A) spring (B) and releases actuation pin (D) from end
and transmits power to the front axle drive shaft. plate (K). The drive gear (F) and front output shaft (A)
are now disengaged.
The disengagement of the MFWD is controlled by an
electric solenoid (G) located on the transmission.
CED,TX03399,4226 1915APR982/2
9020
05B
41

022602
PN=621
MFWD Differential OperationEqual Traction (S.N. 872257 )
9020
05B
42
UN24MAY89
T6058AM
ADifferential Driveshaft CDifferential Housing EBevel Drive Gears GPower Flow
BRing Gear DPinions FDrive Shafts HRotation Direction
Differential unit in MFWD axle has self-applied, Power flows into axle housing through differential drive
limited-slip feature. When MFWD is engaged under shaft (A), turning ring gear (B) and attached differential
slippery field conditions, this system automatically housing (C). When both wheels have equal traction,
applies correct amount of torque to match traction pinions (D) remain stationary within rotating housing.
available to each wheel. Pinions turn bevel drive gears (E) and drive shafts (F)
splined to drive gears.
With MFWD engaged, when tractor is moving in a
straight line and each wheel has equal traction, equal
power is supplied to left and right axle. No differential
action occurs.
TX,9020,BG384 1914JAN971/1

022602
PN=622
9020
05B
43

022602
PN=623
MFWD Differential OperationUnequal Traction (S.N. 872257 )
9020
05B
44
UN24MAY89
T6058AL
ATire With Most Traction DL.H. Drive Gear GClutch Disks IPower Flow
BDrive Shaft EPinion Gears HClutch Plate JRotation Direction
CR.H. Drive Gear FDifferential Housing
As available traction changes, tire with better traction and compresses a clutch pack with disks (G) splined
(A) can use move power. Self-limiting differential action to axle and plates (H) tanged to housing. Disks begin
begins to occur. to slip less against plates as compressing force
increases. As the pack slippage decreases driveshaft
When one wheel begins to slip more than the other, begins to receive driving force through the differential
wheel with better traction hold its drive shaft (B) and housing.
drive gear (C) from rotating. Wheel with less traction
provides less resistance against its drive gear (D). Since the tire with less traction is exerting less force
trying to keep its axle from turning, the bevel gear
Pinion gears (E) continue to be driven by rotating does not force the drive gear outward and its clutch
differential housing (F). These pinion gears push pack increases its slip. Less drive force is being
against bevel drive gears as before. Angle of gear transmitted to this drive shaft. As long as the
teeth tries to force meshed gears apart. On the side difference in traction between tires remains the same,
with more traction, pinion gears begin to "walk" around the clutch pack on the side with less traction will
drive gear and push against restraining force continue to slip more than pack for other side.
transmitted from tire. Drive gear is wedged outward

022602
PN=624
With MFWD engaged, differential works to

automatically balance driving power to available
traction.
TX,9020,BG385 1914JAN972/2
9020
05B
45

022602
PN=625
9020
05B
46

022602
PN=626
Group 15A
System Diagnostic Information (S.N. 872256)
CTM43 (S.N. 872256)

required.
UN07SEP88
M44215
TX,CTM18 1909NOV921/1
9020
15A
1

022602
PN=627
Diagnose Power Train Malfunctions (S.N.

872256)

probable and simplest to verify; to least likely and
steps when diagnosing a problem.
Step 1. Operational Check Out Procedure (See

Group 9005.)
Transmission Slippage (Low Low oil level Check and add oil.
Pressure)
Restricted oil filter Inspect and replace filter.
Weak or broken pressure regulating Do Transmission System Pressure

9020 valve spring Test. (See Group 9020-25.)
15A
2
Excessive clutch or brake element Do Transmission System Pressure
seal leakage Test. (See Group 9020-25.)
Filter bypass valve stuck open Remove filter housing and inspect
valve. (See Repair Manual, Group
0360.)
Transmission pump suction screen Remove and clean screen. (See

restricted Repair Manual, Group 0360.)
Low transmission pump flow due to Do Transmission Pump Flow Test.

worn pump or manifold gasket (See Group 9020-25.)
leakage
Pressure regulating valve housing Do Control Circuit Pressure Test.

gasket, shift valve housing gasket, or (See Group 9020-25.) Remove
piston seal leakage valves and inspect gaskets. (See
Repair Manual, Group 0360.)
Transmission Shifts Too Slow Low oil level (aeration of oil) Check and add oil.
Plugged filter Inspect and replace filter.
Low transmission pressure Do Transmission System Pressure


022602
PN=628
Transmission pump suction screen Remove and clean screen. (See

restricted Repair Manual, Group 0360.)
Low transmission pump flow Do Transmission Pump Flow Test.

(See Group 9020-25.)
Excessive clutch or brake circuit Do Transmission Leakage Test.

leakage (See Group 9020-25.)
C1-B1-B2, or B3-C2 accumulator Remove and inspect accumulator.

piston stuck (in charged position) (See Repair Manual, Group 0360.)
Oil passages restricted between Remove control valve and inspect oil
control valve and clutch or brake passages. See Transmission Oil
Passage Identification in this group.
Transmission Shifts Too Fast System pressure too high Do Transmission System Pressure
Clutch or brake piston not returning Do Transmission Drag Check. (See 9020
properly or warped disks and plates Group 9005-10.) 15A
3
C1, B1-B2, or B3-C2 accumulator Remove and inspect accumulator.

piston stuck (in discharged position) (See Repair Manual, Group 0360.)
Oil Leakage From Torque Transmission overfilled with oil Check oil level. (See Group
Converter Housing 9000-04.)
Transmission breather plugged Remove and inspect breather.
Incorrect placement of cap screws in Remove cap screws and install in

oil manifold correct location. (See Repair
Manual, Group 0250.)
Failed torque converter seal Remove torque connector and

inspect. (See Repair Manual, Group
0350.)
Erratic Shifts (Wrong Gears or Shift valve stuck Do Control System Pressure Test.
No Gear Change When Gearshift (See Group 9020-25.) Remove and
Lever is Moved) inspect valve.
Return passage in control valve or Remove transmission control valve

transmission case restricted and inspect. See Transmission Oil
Passage Identification in this group.

022602
PN=629
Machine Will Not Move In Any Neutral disconnect solenoid Do Transmission Neutral Disconnect
Gear (No Load Put On Engine Solenoid Check. (See Group
When Shifted Into Gear) 9005-10.)
Drive shaft between transmission Inspect and repair drive shaft.

and differential
No system pressure Do Transmission System Pressure

Transmission Inspect transmission suction screen

for metal particles.
Machine Will Not Move (Load Put Transmission Inspect transmission suction screen
On Engine Or Engine Stalls for metal particles.
When Shifted Into Gear)
Differential Drain and inspect oil sample from

differential for metal particles.
9020
15A Transmission control valve gasket Remove control valve and inspect
4
leakage or stuck shift valve gaskets and shift valves.
Machine Creeps In Neutral (Load Transmission overfilled with oil Check oil level.
Put On Engine When Brakes Are
Applied)
Warped disks and plates in Do Transmission Drag Test. (See

transmission Group 9005-10.)
Transmission Hydraulic System Transmission overfilled with oil Check oil level.
Overheats (Slow Hydraulic
Functions And Transmission
Slippage May Also Occur)
Temperature gauge or sender Install temperature sensor to verify

temperature. See Tachometer and
Thermometer Installation Procedure.
Air flow through oil cooler or radiator Do Radiator Air Flow Test. (See
restricted Group 9010.) Clean oil cooler and
radiator.
Drag in transmission Do Transmission Drag Test. (See

Group 9005-10.)

022602
PN=630
Cooler relief valve stuck open or Remove and inspect cooler relief
spring broken valve. (See Repair Manual, Group
0360.)
Leakage in transmission hydraulic Do Control Circuit Pressure Test.

system (See Group 9020-25.)
Low transmission pump output Do Transmission Pump Flow Test.

Loss of 3rd and 4th Forward C1 element, C1 circuit leakage, or Do Transmission Pump Flow Test.
broken sealing rings on reduction (See Group 9020-25.)
gear shaft
Loss of 1st and 2nd Forward B2 element or B2 circuit leakage Do Transmission Control Circuit
Pressure Test. (See Group
9020-25.)
Loss of 1st and 2nd Reverse B1 element or B1 circuit leakage Do Transmission Control Circuit
Pressure Test. (See Group 9020
9020-25.) 15A
5
Loss of 2nd, 4th Forward and B3 element or B3 circuit leakage Do Transmission Control Circuit
2nd Reverse Pressure Test. (See Group
9020-25.)
Loss of 1st, 3rd Forward and C2 element, C2 circuit leakage, or Do Transmission Control Circuit
Reverse broken sealing rings on reduction Pressure Test. (See Group
gear shaft 9020-25.)
Lube Pressure Low, Control Lube relief valve stuck open or Inspect lube relief valve and spring.
Pressure and Charge Pressure spring broken
Normal
Lube Pressure Low, Control Excessive wear in bushings in Remove transmission filter and
Pressure Normal, And Charge transmission suction screen to inspect for metal
Pressure Low particles in filter and bottom of
transmission case.
Main hydraulic system non-return Do Hydraulic Component Leakage

leak Test. (See Group 9025-25.)
Excessive Transmission Noise Engine slow idle too low Check engine slow idle speed. (See
(Under Load or No Load) Group 9010-20.)

022602
PN=631
Parts worn or damaged in Remove transmission suction

transmission screen. Inspect for metal particles.
(See Repair Manual, Group 0360.)
Repair as necessary.
Low or no lube flow Do Transmission Lube Pressure

Test or Transmission Pump Flow
Differential Overfilled With Oil Brake piston seals leaking Remove front differential check plug.
Actuate brake and observe leakage
from check plug. Repair. (See
CTM43.)
Differential lock capture system Remove differential check plug.

seals leaking Actuate differential lock and observe
leakage from check plug. (See
CTM43.)
9020 Excessive Differential or Axle Low oil level in differential Remove drain plug and inspect for
15A Noise metal particles in differential case.
6
Disassemble and determine cause.
Brakes dragging Do Brake Drag Check. (See Group

9005-10.)
Pinion bearing Remove and inspect pinion. Check

to ensure pinion housing was
indexed. (See CTM43.)
Gear mesh pattern between ring and Remove pinion gear housing and
pinion gear incorrect inspect ring and pinion gear. (See
CTM43.)
Differential pinion gears and/or Remove differential housing drain

shafts plug and inspect for metal particles.
Disassemble and inspect. (See
CTM43.)
Axle bearing Do Ring Gear and Pinion Check.

Axle planetary Remove differential. Inspect, repair.

(See CTM43.)

022602
PN=632
Oil Seeping From Outer Axle Excessive axle end play Check axle end play. (See CTM43.)
Seal
Worn outer bearing or cup Disassemble, inspect outer axle

bearing, cup, spacer, and seal,
replace. (See CTM43.)
Differential overfilled with oil Check differential oil return system

for excessive internal restriction. See
Differential Lock Capture Circuit
Leakage Test. (See Group 9025-25.)
Internal axle seal worn or damaged Disassemble, inspect, replace. (See

CTM43.)
No Power To Either MFWD Wheel MFWD valve solenoid stuck Remove and inspect solenoid.
Drive shaft universal joints or drive Inspect and repair. (See Repair
output shaft Manual, Group 0240.)
9020
Gear in MFWD transfer case Raise all wheels off ground with 15A
7
engine running. Engage MFWD
drive. If MFWD shaft does not turn.
(See Repair Manual, Group 0350.)
Inspect MFWD transfer gears.
Ring or pinion in MFWD Raise all wheels off ground with

engine running. Engage MFWD. If
MFWD drive shaft turns and wheel
constant velocity joints do not turn.
Inspect ring gear pinions. (See
No Power To One MFWD Wheel Wheel constant velocity joint Inspect and repair. (See Repair
MFWD axle shaft Raised all wheels off ground with

engine running. Engage MFWD.
Look at wheel without power, if
MFWD constant velocity joint does
not turn, repair axle. (See Repair

022602
PN=633
Outboard planetary Raise all wheels off ground with

engine running. Engage MFWD. If
MFWD constant velocity joint will
turn but the front tire will not, repair
planetary. (See Repair Manual,
Group 0240.)
No Power To One Wheel (Under Limited-slip in MFWD Raise rear tires off ground. Turn
Load) steering wheel for a full left or right
turn. Set engine at approximately
1200 rpm and engage MFWD. If
only one wheel spins, repair
limited-slip in MFWD. (See Repair
MFWD Whines or Makes Low oil level Check MFWD oil level. Add oil as
Excessive Noises necessary.
Worn U-joints in drive shaft Inspect and repair. (See Repair

9020 Manual, Group 0240.)
15A
8
Incorrect MFWD differential Inspect and repair. (See Repair
backlash. Manual, Group 0240.)
10T,9020,J234 1903MAR937/7
Transmission Oil Passage Identification

(S.N. 872256)
AFrom Oil Filter to Pressure Regulating Valve
BFrom Pressure Regulating to Convertor-In Circuit
CFrom Lube Relief Valve to Vent of Reservoir Spring End of all
UN20MAR90
Three Valves
DFrom Filter Relief Valve to Lubrication Circuit
EFrom Regulating Valve to Transmission Control Circuit
T6917AN
Pressure Regulating Valve Oil Passages

022602
PN=634
UN22MAR90
UN22MAR90
T6921AC
T6921AB
Transmission Filter Oil Passages
AFrom Filter to BFrom Filter Relief Valve to CFrom Transmission Pump DOil Filter Housing
Transmission Control Lubrication Circuit to Filter ETransmission Housing
Circuit
10T,9020,J242 1930OCT912/3
9020
15A
9
UN22MAR90
T6917AJ
Oil Pump and Transmission Oil Passages
UN22MAR90
T6917AK
AConvertor-Out To Oil BFrom Pump To Filter DFrom Regulating Valve To EFrom Oil Cooler To
Cooler CFrom Reservoir To Pump Convertor-In Lubrication Circuit
10T,9020,J242 1930OCT913/3

022602
PN=635
9020
15A
10

022602
PN=636
Group 15B
System Diagnostic Information (S.N. 872257 )
Diagnose Power Shift Power Train
Malfunction (S.N. 872257 )
Machine Will Not Move in Low Low oil level in transmission, park Add oil to correct level. See Group
Range Forward, High Range (4th) brake will not release and light on 9000-04.
or Reverse console is ON.
Service Brakes Dragging Adjust Brake Pedals and Equalizing

Valves. See group 9025-20. Check
brake valve and repair. See repair
manual, Group 1060.
If light in console OFF and park Check console light and /or pressure
brake not releasing switch. See Group 9015-15. Check
park brake disks and separator
plates. See repair in Group 0250.
Proper solenoids not energized Test solenoids. See Group 9015-15.
Low or no system pressure Check system pressure. See Group 9020

15B
9020-25.
1
Leaking clutch piston O-ring Do Low Range Forward, High Range

Forward, Reverse and Speed Clutch
Pressure Test or Modulation
Pressure Test in Group 9020-25.
See repair manual, Group 0350.
Piston in clutch pack stuck Check System Pressure, Do Low

Range Forward, High Range
Pressure Test. See Group 9020-25 If
OK, mechanical problem is
indicated. See repair manual, Group
0350.
Piston ball does not seat Do Low Range Forward, High Range
Pressure Test. See Group 9020-25
Torque Converter Flexplate broken Inspect and repair. See repair

manual, Group 0350 for Removal
and Installation. See Group 0651 for
Disassemble and Assemble.
Continued on next page CED,TX03399,4235 1904JUN981/10

022602
PN=637
Worn or slipping low range forward, Check system pressure. See Group
high range forward reverse, or speed 9020-25.
clutch disks
Incorrect shim under modulation Do Modulation Pressure Test. See

piston Group 9020-25. Repair and adjust.
See Group 0360.
Restricted modulation orifice Do Modulation Valve Pressure Test

in Group 9020-25. Remove orifice
and check for contamination and/or
plugged. See repair manual Group
0360.
Stuck spool in control valve Do Clutch Pressure Tests in Group

9020-25. Remove and inspect
control valve spools. See repair
manual, Group 0360.
9020 Clutch malfunction in torque Do Torque Converter Stall Speed

15B converter Test. See Group 9020-25.
2
Low torque converter oil Do Cooler In and Out Pressure Test.

flow/pressure See Group 9020-25.
Clutch shaft sealing rings leaking Do Low Range Forward, High Range
Pressure Test. See Group 9020-25.
Converter drive splines worn or not Replace converter. See repair

engaged in pump drive shaft manual, Group 0651.
Pump gears seized Replace pump assembly, Inspect

and replace pump drive parts as
necessary. See repair manual,
Group 0360.
Mechanical failure in transmission Inspect transmission and repair. See

repair manual, Group 0350.
Broken drive shafts or pump drive Inspect drive shafts, universal joints,
shaft and pump drive shaft for external or
internal damage. See repair manual,
Group 0325 or 0360.

022602
PN=638
Broken ring or pinion gear If drive shafts rotate with

transmission in gear but machine
does not move a differential failure is
indicated. Repair. See Rear Axle,
Group 0250.
Machine Will Not Move In One Leakage in speed clutch Do Low Range Forward, High Range
Gear Forward, Reverse and Speed Clutch
Pressure Test.
Proper solenoids not working Check solenoids. See Group

9015-15.
Worn or slipping in one clutch pack Do Low Range Forward, High Range
Transmission Slippage Low oil level and park indicator light Add oil. See Group 9000-04.
ON
9020
Wrong oil grade Change oil. See Group 9000-04. 15B
3

plugged. See repair manual, Group
0360.

Clutch shaft sealing rings leaking. Do Low Range Forward, High Range

022602
PN=639
Worn or slipping clutch disks Do individual clutch pressure tests.

See Group 9020-25. Check system
pressure or circuit pressure. See
Group 9020-25. See repair manual,
Group 0350.
Leak in transmission control valve, Do Clutch Pressure Test. See Group

shift valve or gaskets 9020-25. Remove valve and inspect
gaskets. See repair manual, Group
0360.
Low torque converter oil Do Cooler In and Cooler Out

flow/pressure Pressure Test. See Group 9020-25.
Low transmission pump flow due to Do Transmission Pump Flow Test.

worn pump See Group 9020-25. See repair
manual, Group 0360.
Weak or broken pressure regulating Do Transmission System Pressure

9020 valve spring Test. See Group 9020-25. See
15B repair manual, Group 0360.
4
Weak or broken modulation valve Do Modulation Pressure Test. See

spring Group 9020-25. See repair manual,
Group 0360.
Machine Creeps with FNR in Warped disks and plates in Check transmission. See repair
Neutral transmission manual, Group 0350.
Piston in clutch pack stuck. Check System Pressure and Low

Range Forward, High Range
Pressure. See Group 9020-25. See
Ball pressed in end of clutch shafts Check Low Range Forward, High
(lube passage) came out Range Forward, Reverse and Speed
Clutch Pressure. See Group
9020-25. See repair manual, Group
0350.
Clutch ball stuck shut Do Low Range Forward, High Range


022602
PN=640
Internal leakage in control valve Do Pump Flow Test. See Group

9020-25.
Solenoids stuck Check Solenoids. See Group

9015-15.
Machine Lacks Power or Moves Oil level is low and park brake Add oil to correct level. See Group
Slow indicator light is ON 9000-04
Wrong oil, aerated oil Change oil. See Group 9000-04
Service Brake dragging Check for excessive heat in brake

area of axle housing after operating
machine. See repair manual, Group
0250.
Park brake dragging, piston stuck Repair park brake in rear axle. See
Engine fast idle speed set too low Check fast idle adjustment. See 9020
Group 9010-20. 15B
5
Low pressure in transmission system Do Transmission System Pressure

Test. See Group 9020-25.

plugged. See repair manual, Group
0360.

Clutch pack slipping Do Transmission System Pressure

Clutch pack dragging, disks warped Repair clutch pack. See repair
manual, Group 0350.

022602
PN=641
Clutch shaft sealing ring leaking Do Low Range Forward, High Range
Clutch ball stuck shut Do Low Range Forward, High Range

Internal leakage in control valve Do Pump Flow Test. See Group

9020-25.
Failed torque converter Do Torque Converter Stall Speed

Low torque converter oil Do Torque converter Stall Speed

flow/pressure Test. See Group 9020-25.
Wrong torque converter Do Torque Converter Stall Test in

9020 Group 9020-25. Check number of
15B torque converter through access
6
hole under machine either 247002 or
4168-028-211.
Low engine power Do Engine Performance Test. See

Group 9010-25.
Mechanical failure in transmission or Inspect. See repair manual, Group

axle 0250 or 0350.
Transmission Shifts Too Slow Low or high oil level (aeration of oil) Add oil or drain. See Group 9000-04
Wrong oil Change oil. See Group 9000-04.
Pressure reducing valve setting Do Reducing Valve Pressure Test.

incorrect See Group 9020-25.
Pressure regulating valve setting Do System Pressure Test. See

incorrect Group 9020-25.
Clutch pack slipping Do System Pressure Test. See

Group 9020-25. Repair, see repair
manual, Group 0350
Control valve leaking internally Do Pump Flow Test. See Group

9020-25 Repair.

022602
PN=642
Control valve modulation piston not Do Modulation Valve Pressure Test

shimmed properly in Group 9020-25. Repair. See
Restricted modulation orifice Do Modulation Pressure Test. See

Group 9020-25.
Modulation piston spring broken Do Modulation Valve Pressure Test.

See Group 9020-25. Remove control
valve cover and inspect modulation
piston and spring. See repair
manual, Group 0360.
Restricted oil passage to clutch pack Do Low Range Forward, High Range
Transmission pump malfunction Do Pump Flow Test and System

9020
Transmission pump oil pickup Repair transmission. See repair 15B
7
blocked manual, Group 0350.
Transmission Shifts Too Fast Modulation piston orifice blocked Do Modulation Valve Pressure Test.
See Group 9020-25. Repair, see
Group 0360.
Modulation valve piston stuck Do Modulation Valve Pressure Test

in Group 9020-25. Remove control
valve cover and inspect modulation
piston and spring. Repair, see Group
0360.
Modulation orifice out of place or Do Modulation Pressure Test. See

missing Group 9020-25. See repair manual,
Group 0360.
Modulation orifice oversized Do Modulation Pressure Test. See

Group 9020-25. See repair manual,
Group 0360.
Transmission Overheats Oil level too high or too low Check oil level and correct. See
Group 9000-04.
Incorrect type of oil Drain and replace oil. See Group

9000-04.

022602
PN=643
Temperature sensor malfunction Check sensor, see Group 9015-15.
Clutch pack dragging, worn disks Repair transmission. See Group

0350.
Torque converter malfunction Do Torque Converter Stall Speed

Test. See Group 9020-25. See
Torque converter stalled excessively Use neutral disconnect switch in

machine operations to reduce stall.
Operating in too high a gear Operate one gear lower. See

Operators Manual.
Oil cooler air flow restricted Inspect and clean exterior of cooler.
Do Air Flow Test. See Group
9010-25.
9020 Missing baffles, damaged fan Inspect and check belt. See Group
15B shrouds or loose fan belt 9010-20. Check baffles and repair.
8
Oil cooler restricted internally Do Cooler In and Out Pressure Test.

See Group 9020-25. Flush Cooling
System. See CTM104.
Oil flow to or from cooler restricted Do Cooler-In/Out Pressure Test. See

Group 9020-25.
Converter-In relief valve stuck open Do Converter-In Relief Valve Test in

or broken spring Group 9020-25. Remove valve,
inspect and repair. See repair
manual, Group 0350.
Low transmission pump flow Do Pump Flow Test. See Group

9020-25.
Transmission mechanical Inspect transmission and repair. See

malfunction Repair, Group 0350.
Engine Over-fueled Remove fuel injection pump. See

your authorized Injection Pump
Service Center

022602
PN=644
Excessive Power Train Noise Engine low idle too slow Check engine slow idle speed. See
Group 9010-20.
Oil level low Fill to correct oil level. See Group

9000-04.
Worn or damaged parts in Check transmission filter for metal

transmission or axle particles. Repair as necessary. See
repair manual, Groups 0250 and
0350.
Worn universal joints on drive shaft Inspect universal joints or drive

shaft. See repair manual, Group
0325.
Misalignment of power train Check position of components. Be

components sure they are setting on mounts
correctly.
No oil in lube circuit Do Cooler In and Out Pressure Test. 9020

See Group 9020-25. Do Converter 15B
9
Relief Valve Pressure Test. See
Group 9020-25.
Hydraulic lines in contact with power Inspect all hydraulic lines and repair.
train components See Hydraulic Component Location
in Group 9025-05.
Assembly adjustments or setting Isolate where noise is coming from.

made incorrectly Adjust. Repair. Check mounts. See
Groups 0315, 0315 and 0350.
Excessive Gear Clash When Rate of shift too fast Do Modulation Pressure Test in
Shifting Group 9020-25.
Worn Gears Inspect transmission. See repair

manual, Group 0350.
Park Brake Pressure Light Transmission oil level too low Add oil. See Group 9000-04.
Comes On
Park brake solenoid not working Test solenoid. See Group 9015-15.

022602
PN=645
Park brake piston leak Do Park Brake Release Pressure

Test. See Group 9020-25. Inspect
and repair. See repair manual,
Group 0250.
Park brake hose leaking Do Park Brake Release Pressure

and repair leak.
CED,TX03399,4235 1904JUN9810/10
Diagnose MFWD Malfunction (S.N. 872257 )
NOTE: See CTM4509 for repair for MFWD axle.
No Power to MFWD Solenoid not actuated Check electrical connection. Inspect

9020
solenoid. See Group 9015-10.
15B
10
Drive shaft failure Inspect and repair. See repair
manual, Group 0325.
Failed MFWD output shaft spline Inspect and repair. See repair
manual, Group 0350.
Failed axle shaft in MFWD Inspect and repair. See repair

manual, Group 0240.
Failed ring gear or pinion in front Inspect and repair. See repair
axle. manual, Group 0240.
Failed MFWD gear train components Inspect and repair. See repair
in transmission manual, Group 0350.
No Power to One Wheel of MFWD Wheel U-Joint failure Inspect and repair. See repair
manual, Group 0240.
Failed outboard planetary Inspect and repair. See repair

manual, Group 0240.
Failed axle shaft in MFWD Inspect and repair. See repair

manual, Group 0240
Failed limited-slip in MFWD Inspect and repair. See repair

manual, Group 0240.
TX,15,MA17 1923JUL981/1

022602
PN=646
Diagnose Rear Axle Malfunction (S.N.

872257 )
No Differential Lock Operation Malfunction in electrical circuit to With engine stopped and key switch
solenoid turned to accessory, activate
differential lock and listen for a click
from solenoid valve.
Do Differential Lock Operational

Checks. See Group 9015-10.
Stuck differential lock solenoid valve With engine stopped and key switch
turned to accessory, activate
differential lock and listen for a click
from solenoid valve. Remove and
inspect valve. See repair manual,
Group 0360.
Excessive leakage in differential lock Do Differential Lock Pressure Test.

piston seals See Group 9020-25. Check rear axle 9020
15B
oil level. See Group 9000-04
11
Stuck differential lock piston Do Differential Lock Pressure Test.

See Group 9020-25. Disassemble,
inspect, repair. See repair manual,
Group 0250.
Excessive wear on differential lock Disassemble, inspect, repair. See

engaging gears or clutch repair manual, Group 0250.
Differential Lock Slips or Excessive leakage differential lock Do Differential Lock Pressure Test.
Chatters When Engaged piston seals See Group 9020-25.
Failed seals on differential lock Remove and inspect seals. See

solenoid valve repair manual, Group 0360.
Stuck differential lock piston Disassemble, inspect and repair.

Excessive wear of differential lock Disassemble, inspect, and repair.

engaging gears or clutch See repair manual, Group 0250.
Differential Lock Will Not Release Stuck foot switch Inspect. See electrical, Group
9015-10.
Continued on next page TX,15,MA18 1923JUL981/4

022602
PN=647
Malfunction in electrical circuit With engine stopped and key switch

on, activate differential lock and
listen for a click from solenoid valve.
See Differential Lock Circuit, Group
9015-10.
Stuck differential lock solenoid valve With engine stopped and key switch
on, activate differential lock and
listen for a click from solenoid valve.
Remove and inspect valve. See
Stuck differential lock piston Do Differential Lock Pressure Test.

See Group 9020-25. Disassemble,
inspect, repair. See repair manual,
Group 0250.
Stuck differential lock engaging Disassemble, inspect, repair. See

gears or clutch repair manual, Group 0250.
9020
15B Oil level low in transmission Add oil to correct level. See Group
12
9000-04. Check axle for overfill.
Rear Axle Overfilled With Oil Differential lock piston seals leaking Do Differential Lock Pressure Test.
See Group 9020-25. Inspect, repair.
Service brake piston seals leaking Do Brake Valve Leakage Test. See
Group 9025-25. Inspect and repair.
Park brake piston seals leaking Do Park Brake Release Pressure

and repair. See repair manual,
Group 0250.
Poor Service Brakes Low oil level Check oil level and fill. See Group
9000-04.
Air in brake valve or lines or piston Bleed brakes. See Group 9025-20.
Brake valve leaks Do Brake Valve Leakage Test. See

Group 9025-25.
Brake piston seals leak Inspect and repair. See repair

manual, Group 0250.

022602
PN=648
Brake disks worn excessively Inspect disks through axle brake

inspection hole. Disassemble,
inspect and repair. See repair
manual, Group 0250.
Restriction in brake circuit Remove lines and components and

inspect.
Service Brakes Will Not Release Brake pedal not returning to full up Inspect brake pedal linkage.
position or not adjusted properly Repair/Adjust. See Group 1060.
Brake valve malfunction Remove, disassemble and inspect.

Repair brake valve. See repair
manual, Group 1060.
Warped brake disks Disassemble, inspect and repair.

Stuck brake piston Remove and inspect. See Repair,

Group 0250. 9020
15B
13
No free travel on brake adjusters Disassemble and inspect, check
specifications. See repair manual,
Group 0250.
Service Brakes Chatter or Noisy Air in brake system Bleed brakes. See Group 9025-20.
Wrong oil in rear axle Drain and refill with correct oil. See
Group 9000-04.
Disks worn excessively Disassemble, inspect and repair.

Brake Valve leakage Do Brake Valve Leakage Test. See

Group 9025-25. Repair.
Park Brake Will Not Hold Worn parts Inspect and replace. See repair
manual, Group 0250.
Park brake piston stuck Do Park Brake Release Pressure

Park brake manually released Do System and Park Brake Release


022602
PN=649
Park brake solenoid plugged Check solenoid. See Group 9015-15.

Repair.
Park Brake Will Not Release Park brake hose leaking Inspect and repair all leaks.
Low hydraulic pressure oil to park Do Park Brake Release Pressure

brake Test. See Group 9020-25
Park Brake Solenoid not working Check solenoid. See Group 9015-15.
Park brake piston stuck Remove and inspect. See Repair.
Park Brake piston seals leaking Do Park Brake Pressure Test. See
Group 9020-25. Inspect and repair.
See Group 0250.
TX,15,MA18 1923JUL984/4
9020
15B
14

022602
PN=650
Hydraulic Circuit Symbols (S.N. 872257 )
9020
15B
15
1928SEP89
TS700
TX,9020,SS3253 1930AUG961/1

022602
PN=651
9020
15B
16

022602
PN=652
Group 20
Adjustments
Check and Adjust Toe-In
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.
UN02NOV88
2. Measure distance between front marks (B) and rear
marks (C).
MACHINES WITHOUT MECHANICAL FRONT WHEEL
T6382JW
DRIVE (MFWD):
3. Front marks must be 6 3 mm (0.25 0.12 in.) closer

than rear marks.
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
Tighten clamp cap screws to 95 14 Nm (70 10
lb-ft).
9020
MACHINES WITH MECHANICAL FRONT WHEEL 20
T6162AT
1
DRIVE (MFWD):
4. Front marks must be 6 3 mm (0.25 0.12 in.) closer

than rear marks.
5. To adjust toe-in on MFWD axle, loosen nuts (H),

remove cotter pin (G) and nut (F). Remove tie rod end
from steering arm. Turn end to get proper toe-in.
UN02NOV88
Install nut (F), tighten to 220 Nm (162 lb-ft) and install
cotter pin. Tighten nuts (H).
T5983AF2
ACenter of Hub
BFront of Tire
CRear of Tire
DTie Rod Tube
FNut
GCotter Pin
HNut
10T,9020,J220 1903MAR931/1

022602
PN=653
Adjustments
9020
20
2

022602
PN=654
Group 25A
Tests (S.N. 872256)
Installation (S.N. 872256)
Tachometer
AClamp-on Transducer. Remove paint with emery cloth and
UN28FEB89
pump. Finger tighten only. DO NOT overtighten.
T6813AG
10T,9010,K182 1910AUG951/1
9020
JT05800 Digital Thermometer Installation 25A
(S.N. 872256) 1

Digital Thermometer
ATemperature ProbeFasten to a bare metal line using a tie band.
UN28FEB89
Wrap with shop towel.
BCable
T6808CE
TX,9020,BG388 1914JAN971/1

022602
PN=655
Tests (S.N. 872256)
Transmission Warm-Up Procedure (S.N.

872256)
1. Hold service brakes on.
2. Operate engine at fast idle.
IMPORTANT: Do not stall reverser for longer than 30

seconds or serious converter damage
could result.
3. Put FNR/Range lever (A) in 4th forward and stall for 30

seconds.
4. Shift FNR/Range lever to neutral position for 10

seconds to circulate oil before doing next converter
stall.
5. Repeat steps 3 and 4 until transmission oil reaches

test temperature.
UN23SEP92
9020
25A
2
T7840BB
TX,9020,BG389 1914JAN971/1

022602
PN=656
Tests (S.N. 872256)
9020
25A
3

022602
PN=657
Tests (S.N. 872256)
Torque Converter Stall Speed Test (S.N.

872256)
SPECIFICATIONS
Minimum Engine Speed With 18002000 rpm
Pump Destroked Torque
Converter Stall Speed
Oil Temperature 65 5C (150 10F)
ESSENTIAL TOOLS
JT38070 Diagnostic Destroke Wire Harness

JT05081 Electronic Tachometer
1. Install electronic tachometer and digital thermometer.

(See procedure in this group.)
2. Install hydraulic pump destroke tool. (See procedure in
UN23SEP92
9020 Group 9025-25).
25A
4 3. Hold service brakes on.
T7840BB
4. Operate engine at fast idle.
IMPORTANT: Do not stall converter for longer than 30

seconds or serious damage could
result.
5. Put FNR/Range lever (A)in 4th forward and stall for 30

seconds.
6. Shift FNR/Range lever to neutral position for 10

seconds to circulate oil before doing next converter
stall.

022602
PN=658
Tests (S.N. 872256)
IMPORTANT: Minimum engine speed listed is for an

engine that is broken-in and using No. 2
fuel.
Specification
Minimum Engine Speed With
Pump DestrokedTorque
Converter Stall Speed ..................................................... 18002000 rpm
7. Run engine at fast idle until oil reaches specification.
Specification
OilTemperature ................................................... 65 5C (150 10F)
8. If converter stall speed is low, check for:
Low engine output. (See Group 9010.)

Incorrect torque converter.
Failed freewheel clutch in torque converter.
9. If converter stall is too high, check for:
Incorrect oil temperature. 9020

Low oil level. 25A
5
Incorrect oil in machine.
Restricted suction screen. (See repair manual.)
Incorrect torque converter.
Engine over-fueled. (See Group 9010.)
Converter failure.
Failed transmission clutch pack.
Low system (pump) pressure in transmission.
TX,9020,BG390 1914JAN972/2

022602
PN=659
Tests (S.N. 872256)
Transmission System Pressure Test (S.N.

872256)
SPECIFICATIONS
Engine Speed 1500 25 rpm
One Shim Changes Pressure 70 kPa (0.7 bar) (10 psi)
Transmission Pressure 240 35 kPa (12.4 0.35 bar)
(180 5 psi)
ESSENTIAL TOOLS
JT05490 (3/8-24 M ORB x 7/16 M 37) Adapter
JT01608 (7/16-20 F 37 x 1/8) Nipple Quick Coupler Adapter

(36952) Hose
Gauge 02000 kPa (020 bar) (0300 psi)
9020
25A The pressure regulating valve setting and leakage in C-2
6 clutch is checked using this test.

Continued on next page TX,9020,YY714 1903MAR931/2

022602
PN=660
Tests (S.N. 872256)
2. Connect test equipment to transmission test port (A).
3. Heat hydraulic oil to specification. (See procedure in

this group.)
Specification
OilTemperature ..................................................... 40 4C (104 7F)
4. Run engine at specification.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Record pressure reading.
If pressure is low, depress neutral disconnect switch on

loader control lever and move gearshift lever to 2nd gear.
If system pressure increases by approximately 100 kPa (1
bar) (15 psi), excessive leakage is indicated in the C2
clutch circuit.
UN23SEP92
If low pressure is NOT caused by leakage in C2 clutch
9020
circuit, adjust pressure regulating valve. One shim will
25A
change pressure approximately 70 kPa (0.7 bar) (10 psi). 7
T7840BC
Specification
One Shim ChangesPressure .......................... 70 kPa (0.7 bar) (10 psi)
NOTE: The transmission system pressure test port is

located in the circuit before the control valve.
Depressing the neutral disconnect switch will NOT
cause pressure to decrease at this test port.
Specification
TransmissionPressure ........................ 1240 35 kPa (12.4 0.35 bar)
(180 5 psi)
TX,9020,YY714 1903MAR932/2

022602
PN=661
Tests (S.N. 872256)
Transmission Pump Flow Test (S.N.

872256)
SPECIFICATIONS
Test Pressure 240 35 kPa (12.4 0.35 bar)
(180 5 psi)
New Pump Minimum Flow 38 L/min (10 gpm)
Used Pump Minimum Flow 34 L/min (9 gpm)
ESSENTIAL TOOLS
JDG419 Pump Adapter
JT03059 (1-1/16-12 M 37 x 1-1/16-12 F 37) 90 Elbow (2 used)
JT03048 (1-1/16-12 M 37 x 1-1/16-12 M ORB) Adapter (2 used)
JT05490 (3/8-24 M ORB x 7/16-20 M 37) Adapter
9020 JT05081 Electronic Tachometer

25A JT05800 Digital Thermometer
8
Flowmeter
Hoses
(36952) Hose
Gauge 02000 kPa (020 bar) (0300 psi)

022602
PN=662
Tests (S.N. 872256)
2. Remove transmission filter housing. Inspect filter

elements and filter bypass valve to make sure these
components are not causing low flow.
3. Connect flowmeter to transmission using parts (AE).
4. Connect gauge using parts (FH).
Specification
TestPressure ....................................... 1240 35 kPa (12.4 0.35 bar)
(180 5 psi)
IMPORTANT: To prevent damage to transmission

pump, flowmeter loading valve must be
open before starting machine.
5. Open flowmeter loading valve.
6. Heat oil to specifications.
UN27MAR90
9020
Specification
25A
9
T6327AA
7. Adjust engine speed to specifications. Put FNR lever in
neutral. Record flow rate.
Specification AJT03059 90 Elbow

EngineSpeed .................................................................... 1500 5 rpm BJT03048 Adapter
CJDG419 Pump Adapter
8. If flow is below specifications, check oil level and clean DTo Flowmeter Inlet
suction screen. Repeat test. If flow is still low, remove EFrom Flowmeter Outlet
FJT01608 Quick Coupler Adapter
and inspect pump. See Repair Manual, Group 0350. GJT05490 Adapter
HHose to Gauge
Specification
New PumpMinimum Flow ......................................... 38 L/min (10 gpm)
Used PumpMinimum Flow .......................................... 34 L/min (9 gpm)
TX,9020,BG391 1914JAN972/2

022602
PN=663
Tests (S.N. 872256)
Converter-In/Cooler Relief Pressure Test

(S.N. 872256)
SPECIFICATIONS
Converter-In/Cooler Relief 793 70 kPa (7.9 0.7 bar) (115
Pressure 10 psi)
Engine Speed Approximately 1500 rpm
Each Shim Changes Pressure 35 kPa (0.35 bar) (5 psi)
ESSENTIAL TOOLS
JT05496 (7/16-20 M 37 x 1-1/16-12 M ORB) AAdapter

BGauge 02000 kPa (020 bar) (0300 psi)
CVice Grips
9020
25A
10

022602
PN=664
Tests (S.N. 872256)
This test checks that relief setting is low enough to protect

torque converter and oil cooler (D) but high enough to
provide adequate oil flow through cooler.
Specification
Converter-In/Cooler Relief
Pressure ............................................... 793 70 kPa (7.9 0.7 bar) (115
10 psi)
1. Apply park brake and put FNR lever in neutral.
2. Install adapter (A) and gauge (B).
3. Heat oil to specification. See procedure in this group.
Specification
4. Block transmission cooler (D) flow with vice grips (C)

on hose.
UN23SEP92
5. Start engine, operate at approximately 1500 rpm (1/2
speed) and record pressure. 9020
25A
Specification 11
EngineSpeed ................................................... Approximately 1500 rpm
T7845AC
6. Compare reading to specification. If required, adjust
relief to specification with shims. Each shim will change
pressure approximately 35 kPa (0.35 bar) (5 psi).
Specification
Each Shim ChangesPressure......................... 35 kPa (0.35 bar) (5 psi)
7. Remove vice grips from cooler hose.
TX,9020,BG392 1914JAN972/2

022602
PN=665
Tests (S.N. 872256)
Neutral Disconnect Solenoid Test (S.N.

872256)
SPECIFICATIONS
Oil Temperature Approximately 40C (104F)
Engine Speed Slow idle
B2 Switch Down Transmission 0 kPa (0 bar) (0 psi)
Pressure
B2 Switch Up Transmission 1206 70 kPa (12.1 0.70 bar)
Pressure (175 10 psi)
ESSENTIAL TOOLS
JT05490 (7/16 M 37 x 3/8-24 M ORB) AAdapter

9020
25A
12

022602
PN=666
Tests (S.N. 872256)
This test checks that solenoid valve is holding system

pressure and releasing all pressure in circuit when
activated.
1. Install gauge (B) in B2 test port.
UN23SEP92
2. Start engine and heat oil to specification. (See
procedure in this group.)
Specification
T7847AC
OilTemperature .......................................... Approximately 40C (104F)
3. Lower stabilizers and raise machine off ground.
4. Put transmission in 1st forward, operate at slow idle

and record pressure.
Specification
EngineSpeed ............................................................................ Slow idle
5. Depress and hold neutral disconnect switch on loader

control lever and record pressure after three second
9020
wait.
25A
13
6. Compare reading to specification:
If pressure does not drop at all, check power to

solenoid. See Section 9015.
If pressure does not drop to zero, remove solenoid
and inspect O-rings. See Repair Manual, Group
0360.
Specification
B2 Switch DownTransmission
Pressure .................................................................... 0 kPa (0 bar) (0 psi)
If pressure is low with switch up, system pressure

may be low. Shift transmission to 1st reverse, if
pressure is now OK, B2 has leakage. Do
Transmission Leakage Test in this group. If pressure
is still low, do Transmission System Pressure Test in
this group.
Specification
B2 Switch UpTransmission
Pressure ................................................. 1206 70 kPa (12.1 0.70 bar)
(175 10 psi)
TX,9020,YY716 1903MAR932/2

022602
PN=667
Tests (S.N. 872256)
Mechanical Front Wheel Drive (MFWD)

Clutch Pressure Test (S.N. 872256)
SPECIFICATIONS
Engaged MFWD Clutch Pressure 0 kPa (0 bar) (0 psi)
Disengaged MFWD Clutch 210 70 kPa (12.1 .70 bar)
Pressure (175 10 psi)
ESSENTIAL TOOLS
JT05487 (1/8 M NPT x 7/10-20 M 37) BAdapter

AGauge 02000 kPa (020 bar) 0300 psi)
9020
25A
14

022602
PN=668
Tests (S.N. 872256)

See procedure in this group.
2. Remove sender. Connect gauge to sender port using

fittings.
UN07APR89
3. Heat transmission oil to test specifications. See
procedure in this group.
Specification
T6910AW
4. Raise machine off ground using loader bucket and

stabilizers. Put transmission in 1st forward.
5. Run engine at 1500 15 rpm.
Specification
EngineSpeed .................................................................. 1500 15 rpm
6. Engage MFWD. Record pressure reading.
Specification 9020
Engaged MFWD Clutch 25A
Pressure .................................................................... 0 kPa (0 bar) (0 psi) 15
7. Disengage MFWD. Record pressure reading.
Specification
Disengaged MFWD Clutch
Pressure ................................................... 1210 70 kPa (12.1 .70 bar)
(175 10 psi)
8. If pressure is not correct:
Remove and inspect solenoid O-rings.

Do Transmission System Pressure Test in this group
to adjust pressure.
TX,9020,BG393 1914JAN972/2

022602
PN=669
Tests (S.N. 872256)
Transmission Leakage Test (Using

Converter-In/Cooler Pressure) (S.N.
872256)
SPECIFICATIONS
Lube Pressure Difference Must vary proportionally in same
direction as Converter-In/Cooler
Pressure
Converter-In/Cooler Maximum 70 kPa (0.7 bar) (10 psi)
Pressure Difference
ESSENTIAL TOOLS
JT03111 (9/16-18M 37 x 7/16-20 F 37) DAdapter
JT05496 (7/16-20 M 37 x 1-1/16-12 M ORB) AAdapter

9020 CGauge 0400 kPa (04 bar) (060 psi)
25A
16 BGauge 01000 kPa (010 bar) (0150 psi)

022602
PN=670
Tests (S.N. 872256)
This test locates and defines the amount of leakage in the

transmission using variations in cooler pressure. A new
machine has a maximum cooler pressure variation of 34
kPa (0.34 bar) (5 psi). The Transmission System Pressure
Test, in this group, should be done prior to this test.
UN23SEP92
2. Install gauge (C) in LUBE port.
T7849AC
Specification
LubePressure Difference .................... Must vary proportionally in same
direction as Converter-In/Cooler
Pressure
3. Install adapter (A) and gauge (B) in pressure regulating

valve to record converter-in/cooler pressure.
Specification
Converter-In/CoolerMaximum
Pressure Difference ............................................ 70 kPa (0.7 bar) (10 psi)
9020
25A
CAUTION: Rear wheels will turn. If machine is 17
equipped with mechanical front wheel drive,
front wheels will also turn during this test.
Machine must be supported by shop stands so
that wheels are free to turn or machine could
move during test.
5. Raise wheels off ground with stabilizers and loader

bucket and position shop stands under axles for
support.
6. Start in 1st neutral and adjust engine rpm to 1000 rpm.

This is baseline engine speed that must be maintained
during test.
Specification
EngineSpeed .................................................................... 1000 3 rpm
7. Follow procedure; record gauge readings on test chart.
8. Maintain temperature at 3C ( 5F) of starting

temperature during this test.
Specification

022602
PN=671
Tests (S.N. 872256)
UNeutral disconnect switch up.

DNeutral disconnect switch down.
Engine Speed Hold to

Step Gear 3 RPM Cooler Pressure Lube Pressure Test Instructions
1 N1 1000 Adjust engine rpm
2 F1 1000 Shift to first gear
forward
3 R1 1000 Shift to first gear
reverse
4 F3 1000 Shift to third gear
forward and adjust
engine rpm.
5 N2 1000 Shift to fourth gear
forward with clutch
cut-off down.
6 N1 1000 Shift to 1st neutral
and disengage
MFWD (light off) if
equipped.
If cooler pressures are within specification, do

9020
Transmission Drag Test in this group to isolate problem.
25A
18
If cooler pressure are out of specifications, see Analysis of
Transmission Leakage Test to interpret this data.
TX,9020,BG394 1914JAN973/3

022602
PN=672
Tests (S.N. 872256)
9020
25A
19

022602
PN=673
Tests (S.N. 872256)
Analysis of Transmission Leakage Test

Using Converter-In/Cooler Pressure (S.N.
872256)
NOTE: Oil temperature is critical during this test. If a

circuit pressure is low, repeat test with
temperature held constant before starting repairs.
See Repair Manual, Group 0360.
Step 1
This establishes a test baseline on the principle of a

constant volume of oil, (gear pump at set rpm) over a
orifice (cooler circuit). Changes in cooler pressure with
rpm and temperature held constant reflect leakage in
circuit pressurized. In N1 the lube circuit, accumulators,
gaskets, and C2 clutch sealing rings, piston rings and
O-rings are pressurized.
Step 2
9020
Any change is caused by B2 brake circuit, piston rings or
25A
20 O-rings. It is normal for cooler pressure to drop 730 kPa
(0.070.30 bar) (14 psi) when the second circuit is
pressurized.
Lube pressure must vary proportionally in the same

direction as cooler pressure. If it does not, a leak in
sealing rings on clutch circuit shaft is indicated.
Step 3
Same as step 2 but now B1 brake circuit is pressurized.
Step 4
Same as step 2 but now C1 clutch circuit is pressurized.

C1 circuit has sealing rings on shaft.
Continued on next page TX,9020,DY658 1915AUG961/2

022602
PN=674
Tests (S.N. 872256)
Step 5
Same as step 1 but now B3 brake circuit is pressurized.

Changes are caused by comparison to C2 leakage
baseline pressure. C2 circuit is no longer pressurized. If
pressure decreases 50 kPa (0.5 bar) (7 psi), B3 has
excessive leakage. It is normal for pressure to increase
slightly, 715 kPa (0.07 to 0.15 bar) (12 psi). If
pressure raises more than 50 kPa (0.5 bar) (7 psi), C2
circuit has excessive leakage.
Step 6
Same as step 1 but now MFWD clutch circuit is

pressurized. If leakage is excessive, check for failed
O-rings on MFWD solenoid first.
TX,9020,DY658 1915AUG962/2
9020
25A
21

022602
PN=675
Tests (S.N. 872256)
Transmission Oil Cooler Restriction Test

(S.N. 872256)
SPECIFICATIONS
Oil Flow 30.4 L/min. (8 gpm)
Gauge Difference Maximum 70 kPa (0.7 bar) (10 psi)
Pressure Drop
ESSENTIAL TOOLS
203654 (7/16-20 M37 x 1/2 M NPT) GConnector
JT03348 (1/2 F NPT) HTee (2 used)
JT03212 (1/2 I.D. Hose x 1/2 M NPT) IAdapter (6 used)
JT03070 (1/2 F NPT 1-1/6-12 F 37 SW) JCoupler (2 used)

AHydraulic Analyzer
FSwitch Box
9020 Flowmeter With Temperature Gauge

25A
22

022602
PN=676
Tests (S.N. 872256)
NOTE: If an internally restricted oil cooler is suspected,

the oil cooler can be back flushed to check for
debris. Steps 13 describe how to back flush the
cooler and Steps 47 describe how to test cooler
for an internal restriction.
BACK FLUSH COOLER
1. To back flush the cooler, connect cooler inlet hose to

cooler outlet. Disconnect inlet line and put end of hose
in a five gallon bucket.
2. Start engine and run at slow idle for 10 seconds.
3. Connect cooler hoses to original position on flowmeter.
INTERNAL RESTRICTION TEST
4. Make test connection. Refill transmission, then start

engine to fill to proper level before test.
5. Open flowmeter. Heat oil to test specification. See 9020

Transmission Warm-Up Procedures in this group. 25A
23
Specification
6. Increase engine speed until flow is at specification.
Specification
OilFlow .................................................................... 30.4 L/min. (8 gpm)
7. Read pressure gauges at inlet and outlet of cooler.

Difference in gauge reading is pressure drop in cooler.
Specification
Gauge DifferenceMaximum
Pressure Drop .................................................... 70 kPa (0.7 bar) (10 psi)
UN29SEP92
AHydraulic Analyzer
BGauge1000 kPa
CGauge Port
DCooler-In
T7851AD
ECooler-Out
FSwitch Box
GConnector
HTee
IAdapter
JCoupler
KFlowmeter
TX,9020,YY721 1903MAR932/2

022602
PN=677
Tests (S.N. 872256)
Transmission Lube Pressure Test (S.N.

872256)
SPECIFICATIONS
Engine Speed Variable (Slow idle to relief valve
opening)
Lube Relief Pressure 276 70 kPa (2.8 0.7 bar) (40
10 psi)
ESSENTIAL TOOLS
JT03111 (9/16-18 M ORB x 7/16-20 M 37) Adapter

(36952) Hose
9020
25A
24

022602
PN=678
Tests (S.N. 872256)
1. Install digital thermometer and electronic tachometer.

See procedure in this group.
2. Connect test equipment to lube pressure test port.
UN23SEP92
Specification
T7852AB
4. Slowly increase engine speed from slow idle until lube
pressure stops increasing (relief valve opens). Record
pressure.
Specification
EngineSpeed ..................................... Variable (Slow idle to relief valve
opening)
NOTE: If engine speed is increased too much, lube

pressure can start increasing again due to
restriction through the lube relief valve.
5. If lube pressure is high, lube relief valve may be 9020

25A
sticking in bore or passages may be restricted.
25
Specification
Lube ReliefPressure ........................... 276 70 kPa (2.8 0.7 bar) (40
10 psi)
6. If lube pressure is low, do the following:
Put gearshift in 2nd and FNR lever in forward,

depress clutch cut-off switch. If lube pressure
increases to specification, leakage is indicated in C2
clutch circuit. Do Transmission Leakage Test in this
group.
If pressure is still low, remove and inspect lube relief
valve and spring.
Remove transmission filter and suction screen to
inspect for metal particles in filter and bottom of
transmission case. Low lube pressure can be caused
by excessive wear in transmission bushings.
TX,9020,BG395 1914JAN972/2

022602
PN=679
Tests (S.N. 872256)
Control Circuit Test Using Seven Gauge Method (Modified) (S.N. 872256)
SPECIFICATIONS SERVICE EQUIPMENT AND TOOLS

Transmission System Pressure 210 70 kPa (12.1 0.7 bar) JT05081 Electronic Tachometer
(175 10 psi)
Difference Between System 69 kPa (0.69 bar) (10 psi)
Maximum Pressure and Each
Element Pressure
ESSENTIAL TOOLS
JT03111 (7/16 M 37 x 9/16 M ORB) Adapter
AT53713 (3/4-16 M ORB x 9/16-18 M JIC x 1/8 -27 NPTF)a 90
Elbow
R39832 (1/8-27 F NPFT x 1/8-27 M 37)a Adapter
JT05401 Power Shift Transmission Test Kit
a
These fittings can be ordered through normal service parts
channels.
9020
25A
26

022602
PN=680
Tests (S.N. 872256)
UN29SEP92
9020
25A
27
T7852AC
AJT05490 Adapter (C2) CJT05490 Adapter (B1) EJT05490 Adapter (B2) GJT03111 Adapter (Lube)
BJT05490 Adapter (B3) DJT05490 Adapter (C1) FJT05490 Adapter (Pressure) HGauge Kit
CLUTCH/BRAKE ENGAGEMENT CHART in control valve of that circuit.

1st Forward B2 C2
Specification
2nd Forward B2 B3
Transmission System
3rd Forward C1 C2 Pressure............................................. 1210 70 kPa (12.1 0.7 bar)
4th Forward C1 B3 (175 10 psi)
Difference Between System
1st Neutral C2 Maximum Pressure and Each
2nd Neutral B3 Element Pressure ...................................... 69 kPa (0.69 bar) (10 psi)
3rd Neutral C2
4th Neutral B3 1. Raise rear wheels off the ground and position shop
stands under axles for support. Raise front wheel if
1st Reverse B1 C2
equipped with MFWD.
2nd4th B1 B3
Reverse
2. Connect gauges to test ports.
This test checks the engagement pressure at each 3. Connect electronic tachometer and digital
pack during each shift. Difference in pressure readings thermometer. (See procedure in this group.)
may indicate leakage, stuck shift spool or failed gasket

022602
PN=681
Tests (S.N. 872256)
4. Heat oil to 65 5C (150 10F). (See procedure Shift machine into each gear and adjust engine
in this group.) Operate machine in 4th forward to speed to test specification. Record pressure reading
warm-up transmission components. of each gauge.
Specification Specification
OilTemperature ............................................ 65 5C (150 10F) EngineSpeed .............................................................. 1500 5 rpm
5. Run engine at slow idle. Engage MFWD if If pressure difference is excessive, leakage is indicated
equipped. in that element or circuit.
6. Shift to each gear and use the chart to check for

engagement of proper elements.
If element engagement is not correct in any gear, a

sticking shift spool or leaking control valve housing
gasket is indicated.
TX,9020,BG396 1914JAN973/3
9020
25A
Complete Transmission System Test (S.N. 872256)
28
SPECIFICATIONS ESSENTIAL TOOLS
Converter-in/Cooler Minimum 30.2 L/min (8 gpm) JT03111 (7/16 M 37 x 9/16 M ORB) Adapter
Flow at Fast Idle JT05490 (7/16 M 37 x 3/8-24 ORB) Adapter 6 used)
Converter-in/Cooler Maximum 3.0 L/min (0.8 gpm)
JT03212 (1/2 I.D. Hose x 1/2 M NPT) Adapter (2 used)
Flow Difference Between Gears
JT03070 (1/2 F NPT x 1-1/16-12 F 37) Adapter (2 used)
New Pump (with Cooler Relief 38 L/min (10 gpm)
Blocked) Flow
Used Pump (with Cooler Relief 34 L/min (9 gpm)
Blocked) Flow JT05081 Electronic Tachometer
Converter-in/Cooler Relief 793 70 kPa (7.9 0.7 bar) JT05800 Digital Thermometer
Pressure (115 10 psi) JT05401 Powershift Transmission Test Kit
Lube Pressure 276 70 kPa (2.8 0.7 bar) Gauge 02000 kPa (020 bar) (03000 psi) (7 used)a
(40 10 psi)
Flowmeter
Transmission System Pressure 1210 70 kPa (12.1 0.7
bar) (175 10 psi) 1/2 in. I.D. Hose 4 ft. Long
Difference Between System and 70 kPa (0.7 bar) (10 psi) 9.5 mm (0.38 in.) x 92 mm (3.62 in.) Pin
Circuit Maximum Pressure 10 Ton Shop Stands ( 2 required4 with MFWD)
a
Neutral Disconnect Switch Down 0 kPa (0 bar) (0 psi) These items are part of JT05401 Powershift Transmission Test
Pressure Kit.
Neutral Disconnect Switch Up 1210 70 kPa (12.1 0.7
Pressure bar) (175 10 psi)

022602
PN=682
Tests (S.N. 872256)
UN29SEP92
9020
25A
29
T7852AD
AJT05490 Adapter (C2) DJT05490 Adapter (C1) GJT03111 Adapter (Lube) JJT03070 Adapter
BJT05490 Adapter (B3) EJT05490 Adapter (B2) HJT05401 Gauge Kit KFlowmeter
CJT05490 Adapter (B1) FJT05490 Adapter (P) IJT03212 Adapter
This test checks the overall performance of during test. After test, use this data with Specifications
transmission hydraulic system. Use a copy of and Analysis to make diagnosis.
Transmission Test Checkout Sheet to record data

022602
PN=683
Tests (S.N. 872256)

2. Install test gauges.
Specification
Converter-in/CoolerMinimum
UN31JAN90
Flow at Fast Idle .......................................................... 30.2 L/min (8 gpm)
Maximum Flow Difference
Between Gears ........................................................... 3.0 L/min (0.8 gpm)
New Pump (with Cooler Relief
T94644
Blocked)Flow............................................................. 38 L/min (10 gpm)
Used Pump (with Cooler Relief
Blocked)Flow............................................................... 34 L/min (9 gpm)
Converter-in/Cooler Relief
Pressure ............................................... 793 70 kPa (7.9 0.7 bar) (115
10 psi)
LubePressure ...................................... 276 70 kPa (2.8 0.7 bar) (40
10 psi)
Transmission SystemPressure ............. 1210 70 kPa (12.1 0.7 bar)
(175 10 psi)
Difference Between System and
CircuitMaximum Pressure ............................... 70 kPa (0.7 bar) (10 psi)
Neutral Disconnect Switch
9020 DownPressure........................................................ 0 kPa (0 bar) (0 psi)
25A Neutral Disconnect Switch Up
30 Pressure ................................................... 1210 70 kPa (12.1 0.7 bar)
(175 10 psi)
3. Install flowmeter in cooler-in hose.
IMPORTANT: DO NOT install pin behind cooler relief

valve until Step 5 of Test Procedure.
4. Make a 9.5 mm (3/8 in.) diameter by 92 mm (3.62 in.)

length pin.
5. In Step 5 of Test Procedure, remove plug and spring

from behind cooler relief valve. Install pin and plug.
Hand tighten plug only. One or two threads must be
showing when valve is tight against seat.

022602
PN=684
Tests (S.N. 872256)
CAUTION: Rear wheels will turn. If machine is

equipped with mechanical front wheel drive,
front wheels will also turn during this test.
Machine must be supported by shop stands so
that wheels are free to turn or machine could
move during test.
6. Raise wheels off ground with stabilizers and loader

bucket. Position shop stands under axles for support.
7. Check transmission oil level.
8. Heat transmission oil to 40 4C (104 7 F). (See

Transmission Warm-Up Procedure in this group.)
TX,9020,BG397 1914JAN974/4
9020
25A
31

022602
PN=685
Tests (S.N. 872256)
Test Procedure (S.N. 872256)
NOTE: To get accurate test data, keep temperature flow and pressure, lube pressure, and C2 circuit
and rpm at specifications. pressure.
Step 1 Step 7
System Pressure Check: Run engine at 1500 15 MFWD circuit leakage check (If equipped): Disengage
rpm. Record reading on gauge from point F. MFWD switch (light off). Run engine at 1500 3 rpm.
Record cooler flow and pressures.
Step 2
Step 8
Neutral Disconnect Solenoid Check: Put transmission
in 1st forward. Run engine at 1500 15 rpm. Observe Direction Spool Leakage Check: Put FNR lever in
B2 pressure gauge. Depress neutral disconnect switch forward. Engage MFWD (light on) if equipped. Run
and record reading. engine at 1500 3 rpm. Record cooler flow.
Step 3 Step 9
Lube Relief Pressure Check: Run engine at slow idle. B1 Leakage Check: Put transmission in 1st reverse.
Slowly increase engine speed until lube pressure stops Run engine at 1500 3 rpm. Record cooler flow.
9020 increasing. Record reading for lube pressure.
25A Step 10
32
Step 4
B2 Brake Leakage Check: Put transmission in 1st
Cooler (converter-in) relief valve check: Close forward. Run engine at 1500 3 rpm. Record cooler
flowmeter. Put transmission in 1st neutral. Run engine flow.
at 1500 5 rpm. Record reading from pressure gauge
in flowmeter. Open flowmeter. Step 11
Step 5 B3 Leakage Check: Put transmission in 2nd forward.

Depress neutral disconnect switch. Run engine at
IMPORTANT: Do not close flowmeter with cooler 1500 3 rpm. Record cooler flow.
relief valve blocked or pump damage
could occur. Step 12
Block oil cooler relief valve: Stop engine. Open C1 Leakage Check: Put transmission in 3rd forward.
flowmeter. Install pin behind cooler relief valve to hold Run engine at 1500 3 rpm. Record cooler flow.
valve closed. Leave pin installed for remainder of test.
Step 13
NOTE: Flowmeter must be open for remainder of test.
Stop engine, remove pin from cooler relief valve and
Step 6 install spring. For oil cooler and accumulator check,
heat oil to 65 6C (150 10F).
Transmission pump check, C2 leakage check and
establish base cooler flow for steps 7 through 12: Put 1. Put FNR lever in 1st neutral. Increase engine speed
FNR lever in 1st neutral. Engage MFWD (light on) if to fast idle. Record cooler flow.
equipped. Run engine at 1500 3 rpm. Record cooler

022602
PN=686
Tests (S.N. 872256)
2. B1,B2,C1 accumulator check: Run engine at 1500 3. C2,B3 accumulator check: Observe gauge in B3
15 rpm. Observe gauge in B2 test port. Put FNR in test port. Put FNR in 1st forward then wait 5
1st reverse then wait 5 seconds. Shift FNR lever to seconds. Shift into 2nd forward. Compare
1st forward. Compare observations to gauge observations to gauge illustration at B3 test port.
illustration at B2 test port.
TX,9020,BG398 1914JAN972/2
9020
25A
33

022602
PN=687
Tests (S.N. 872256)
Complete Transmission System Test

Checkout Sheet (S.N. 872256)
U=Neutral Disconnect switch up.
D=Neutral Disconnect switch down.
Cooler Lube
Step Gear Engine RPM Cooler Flow Pressure Pressure Test Port Temperature
1 N-1-U 1500 15 P Start
2 F-1-U 1500 15 B2
F-1-D 1500 15 B2
3 N-1-U Variable
4 N-1-U 1500 15 With flow meter closed.
5 Stop engine, install pin in cooler relief and open flow meter.
6 MFWD (if equipped)
N-1-U 1500 3 C2
7 N-1-U 1500 3 C2
9020 8 F-1-U 1500 3 C2

25A 9 R-1-U 1500 3 B1
34
10 F-1-U 1500 3 B2
11 F-2-D 1500 3 B3
12 F-3-U 1500 3 C1 End
13 Stop engine, remove pin from cooler relief and install spring.
a N-1-U Fast Idle
b R-1-U to F-1-U Shift B2 Observe
Gauge
c F-1-U to F-2-U Shift B3 Observe
Gauge
CLUTCH/BRAKE ENGAGEMENT
1st Forward B2 C2
2nd Forward B2 B3
3rd Forward C1 C2
4th Forward C1 B3
1st Neutral C2
2nd Neutral B3
3rd Neutral C2
4th Neutral B3
1st Reverse B1 C2
2nd4th Reverse B1 B3
TX,9020,BG399 1914JAN971/1

022602
PN=688
Tests (S.N. 872256)
9020
25A
35

022602
PN=689
Tests (S.N. 872256)
Analysis of Complete Transmission Test (S.N. 872256)
After testing the transmission and recording data on Step 4

Checkout Sheet, use the following analysis to
determine if the transmission hydraulic system meets Cooler relief valve pressure must be 793 70 kPa (7.6
specified flows and pressures for proper transmission 0.7 bar) (115 10 psi). A low pressure can be
operation. Information is also given to help identify the caused by a low pressure setting of filter relief valve,
cause of possible problems. weak, broken or wrong cooler relief valve spring, or a
valve spool that does not slide freely in its bore.
Step 1
Step 5
Transmission system pressure must be 1210 70 kPa
(12.1 0.7 bar) (175 10 psi). A low pressure reading This step is required to divert full transmission pump
can be caused by a weak, broken or wrong spring or flow to the converter-in/cooler circuit and eliminates
valve spool that does not slide freely in its bore. Leak possibility of cooler relief leakage on test results.
in C2 clutch circuit can also cause low pressure
because it is pressurized also. Step 6
Step 2 Minimum cooler flow (transmission pump flow) is 38

L/min (10 gpm) for a new pump and 34 L/min (9 gpm)
B2 brake circuit pressure must be equal to system for a used pump. If flow is low in Step 11, remove
9020 pressure in step 1 when neutral disconnect switch is transmission filter and inspect filter bypass valve.
25A up. The pressure must drop to zero within 3 seconds Repeat step 6. If still low, do Transmission Pump Flow
36
after neutral disconnect switch is held down. If Test in this group.
pressure does not drop at all, see Neutral Disconnect
Solenoid Check in Group 9015. If pressure drops but Step 7
not to zero, remove and inspect O-rings on neutral
disconnect solenoid valve. Subtract cooler flow measured in step 7 from cooler
flow measured in step 6 to determine MFWD system
Step 3 leakage. Maximum allowable leakage is 3.0 L/min (0.8
gpm).
Lube relief valve pressure must be 276 70 kPa (27.6
0.7 bar) 40 10 psi). Shift to 2nd forward and Step 8
depress neutral disconnect switch. If lube pressure
increases to specification, leakage is indicated in C-2 Subtract cooler flow measured in step 8 from cooler
circuit. flow measured in step 6 to determine spool leakage.
Maximum allowable leakage is 1.0 L/min (0.2 gpm).
If lube pressure is still low, remove and inspect lube
relief valve and spring. Low lube pressure can also be Step 9
caused by excessive wear in transmission bushings.
Remove filter and suction screen to inspect for metal Subtract cooler flow measured in step 9 from cooler
particles in filter and bottom of transmission case. flow measured in step 6 to determine B1 circuit
leakage. Maximum allowable leakage is 3.0 L/min (0.8
NOTE: If during test lube pressure increases and gpm).
cooler pressure does not, a sealing ring leak is
indicated in that circuit.

022602
PN=690
Tests (S.N. 872256)
NOTE: If leakage is excessive, check shift valve The actual time required to charge the accumulator
gaskets before removing clutch or brake is difficult to measure. The charging time is
packs. important to the service life of the transmission and
can be a help in diagnosing transmission problems.
Step 10 Proper accumulator operation can be determined by
operating the tractor as follows and observing the
Subtract cooler flow measured in step 10 from cooler gauge as the specified shifts are made.
flow measured in step 6 to determine B2 circuit
leakage. Maximum allowable leakage is 3.0 L/min (0.8 As the shift is made from 1st reverse to 1st forward for
gpm). front accumulator on B2 gauge or 1st forward to 2nd
forward for rear accumulator on B3 gauge and count
Step 11 one thousand and one, one thousand and two. The
gauge must be up to system pressure by the count
Compare cooler flow measured in step 11 to cooler one thousand and one. Compare your pressure gauge
flow measured in step 6 to determine B3 circuit readings to the following gauge illustrations as the
leakage. They should be approximately equal. It is specified shift is made.
normal for flow to increase slightly, if it increases more
than 2.0 L/min (0.6 gpm), C2 leakage is excessive. If The first gauge indicator movement on the illustrations
cooler flow decreases more than 2.0 L/min (0.6 gpm), indicated the point at which the accumulator piston has
B3 leakage is excessive. moved to discharge condition.
Step 12 The second gauge indicator movement on the 9020

illustrations is the pressure rise as the accumulator is 25A
37
Subtract cooler flow measured in step 12 from cooler charged. This allows the disks and plates in the
flow measured in step 6 to determine C1 circuit transmission to pick up the load as pressure builds.
leakage. Maximum allowable leakage is 3.0 L/min (0.8
gpm). The next gauge indicator movement in the illustrations
indicates the accumulator piston is fully charged and in
Step 13 a full flow bypass condition. The time from the
midpoint pressure to normal operating pressure is very
Remove pin and install cooler relief spring to check oil short. A long charging time can be caused by
cooler restriction and accumulator modulation. excessive leakage in a given brake, clutch or plugged
orifice. A short charging time can be caused by broken
Cooler flow must be 30.2 L/min (8 gpm). If step 6 accumulator spring, accumulator installed backwards
flow and step 4 pressure was at specifications, or missing orifice or stuck accumulator
back-flush oil cooler. See Transmission Oil Cooler
Restriction Test in this group.
TX,9020,BG400 1914JAN972/2

022602
PN=691
Tests (S.N. 872256)
C2,B3 (Upper) Accumulator Operation at B3

Test Port (S.N. 872256)
(S.N. 872256)
TX,9020,BG401 1914JAN971/4
Shift lever in first forward after five seconds.
UN28OCT91
T7639AA
TX,9020,BG401 1914JAN972/4
9020
25A Shift transmission from first forward to second forward
38 with accumulator charging for 0.30.5 seconds. Pressure
must be 275 70 kPa (2.7 0.7 bar) (40 10 psi).
UN28OCT91
T7639AB
TX,9020,BG401 1914JAN973/4
0.8 seconds after shifting gears with accumulator charged.

Pressure is 1210 70 kPa (12.1 0.7 bar) (175 10 psi)
UN28OCT91
T7639AC
TX,9020,BG401 1914JAN974/4

022602
PN=692
Tests (S.N. 872256)
C1,B1,B2 (Lower) Accumulator Operation at

B2 Test Port (S.N. 872256)
Shift lever in first reverse after five seconds.
UN28OCT91
T7639AA
10T,9020,M145 1903MAR931/3
Shift FNR lever from first reverse to first forward with

accumulator charging 0.30.5 seconds. Pressure must
be 275 70 kPa (2.7 0.7 bar) (40 10 psi).
UN28OCT91
9020
25A
39
T7639AB
10T,9020,M145 1903MAR932/3
1.7 seconds after shifting gears with accumulator charged.

Pressure at 1210 70 kPa (12.1 0.7 bar) (175 10 psi).
UN28OCT91
T7639AC
10T,9020,M145 1903MAR933/3

022602
PN=693
Tests (S.N. 872256)
Transmission Drag Test
TX,9020,BG402 1914JAN971/1
Transmission Drag Test
Transmission oil must be at operating temperature for these tests.
1/1
C1 Clutch, B1, B2 Brake Raise wheels off ground with stabilizers and loader OK: Go to next test.
Drag Test bucket.
NOT OK: If wheels
Release park brake. continue to move but at a
slower speed, B2 is
Shift transmission to 2nd forward. dragging.
Adjust engine speed to 1000 rpm. NOT OK: If wheels

9020 T6295AD UN19OCT88
25A Move FNR lever to neutral position. faster speed, C1 is
40 dragging.
LOOK: Both rear wheels must stop.
NOT OK: If wheels
NOTE: If wheels turn, apply service brakes until wheels continue to move but in a
stop and note change in rpm on tachometer. reverse direction at same
speed, B1 is dragging.
If depressing brake pedal causes rpm to drop enough
that difference can be seen on tachometer (15 rpm), it NOT OK: "Drag" causes
indicates warped disks in that pack. Lube oil does not rpm to drop excessively.
affect these "drag" checks because they are done at Inspect transmission. Go
operating temperature and at slow idle. If "drag" is to Repair Manual, Group
caused by lube oil within the transmission clutches and 0350.
brakes, "drag" will increase when oil is cold. When
engine speed is increased to 1500 rpm or higher, "drag"
is reduced because lube relief valve opens and returns
excessive cold oil to sump. It is normal for wheels to
"creep" with cold oil as engine speed is increased but to
stop moving at speeds above 2000 rpm. If "drag" is
caused by warped clutch or brake disks or plates, "drag"
will be seen at any oil temperature and will increase
proportionally as engine speed is increased.
1/1
C2 Clutch, B3 Brake Raise wheels off ground with stabilizers and loader OK: Check completed.
Drag Test bucket.
NOT OK: Engine speed
Release park brake. drops, C2 is dragging.
Repair transmission. Go
Shift transmission to 1st forward. to Repair Manual, Group
0350.
Adjust engine speed to 1000 rpm.
T6295AD UN19OCT88
NOT OK: Engine speed
Shift transmission to 2nd forward. increases, B3 is dragging.
Repair transmission. Go
LOOK: Wheels must increase in speed but engine rpm to Repair Manual, Group
must return to 1000 rpm. 0350.
1/1

022602
PN=694
Group 25B
Tests (S.N. 872257 )
Installation (S.N. 872257 )
Tachometer
AClamp-On Transducer. Remove paint using emery cloth and
UN28FEB89
T6813AG
TX,25,SS3151 1917JUN961/1
9020
JT05800 Digital Thermometer Installation 25B
(S.N. 872257 ) 1

ATemperature Probe
BCable
UN28FEB89
NOTE: Cooler In and Cooler Out lines can be switched
T6808CE
depending on installation.
For transmission testing, run machine for two minutes.

Use a temperature probe and determine which line is the
hottest and install temperature probe on metal part of line
for cooler IN or feel both cooler hoses and start machine,
whichever one pressurizes first is cooler inlet. On Torque
Converter Stall, Converter-In Relief Pressure Test, and
Cooler In and Out Pressure Test, install digital
thermometer probe into sump using dipstick tube.
TX,25,SS3152 1923JUN981/1

022602
PN=695
Tests (S.N. 872257 )
Transmission Warm-Up Procedure (S.N.

872257 )
SPECIFICATIONS
Engine Speed Low Idle (900 25 rpm) and High
Idle (2375 25 rpm)
IMPORTANT: Never operate machine equipped with

MFWD with front wheels (axle) on the
ground, rear wheels (axle) off the
ground and transmission in fourth gear
forward. Damage to the MFWD will
occur.
NOTE: Have test equipment installed before warm-up.

Cooling system is highly efficient and may require
blocking air flow around the transmission cooling
system to control temperature.
1. Raise machine off ground using loader and stabilizers.
UN23SEP92
9020 2. Put transmission in third gear (A). Park brake OFF.
25B
2
IMPORTANT: Do not stall converter for longer than 20
T7840BB
seconds or serious converter damage
could result.
3. Cycle from low idle to high idle with service brakes

engaged. Approximately 10 seconds in high idle and 5
seconds in low idle until desired temperature is
reached.
Specification
EngineSpeed ................................... Low Idle (900 25 rpm) and High
Idle (2375 25 rpm)
NOTE: To cool machine, shift to neutral and run at high

idle. Temperature should drop approximately 1
every 5 seconds.
CED,TX03399,4231 1915MAY981/1

022602
PN=696
Tests (S.N. 872257 )
Power Shift Transmission Overall Test Connections, Ports, and Locations (S.N. 872257
)
9020
25B
3
1918MAY98
T113993
ADifferential Lock Solenoid HFilter PSystem Pressure Test Port UReverse Clutch Pressure
BPark Brake Pressure Port ITransmission Pump QThird Speed Clutch Test Port
CDifferential Lock Pressure JMFWD Solenoid Pressure Test Port VReducing Valve Pressure
Port KMFWD Test Port RSecond Speed Clutch Test Port
DTransmission Control LPark Brake Solenoid Pressure Test Port WOutput Flange to Rear
Valve MLow Range Forward Clutch SFirst Speed Clutch Axle
ETransmission Speed Shift Pressure Test Port Pressure Test Port XRear of Transmission
Valve NConverter-In Relief Valve THigh Range Forward Clutch YControl Valve
FOil Drain Pressure Port Pressure Test Port ZSpeed Shift Valve
GModel Identification Plate OModulation Valve Pressure
Test Port
CED,TX03399,4230 1908MAY981/1

022602
PN=697
Tests (S.N. 872257 )
Torque Converter Stall Speed Test (S.N. 872257 )
SPECIFICATIONS converter damage may result. Return

Transmission/Hydraulic Oil 65 5C (150 10F) FNR lever to neutral position for 10
Temperature seconds before doing next stall test.
Engine Speed Fast Idle
Torque Converter Stall Speed 18752100 rpm 7. Operate engine at high idle. The highest stabilized
speed measured is converter stall speed.
ESSENTIAL TOOLS
Specification
JT38070 Diagnostic Destroke Wire Harness EngineSpeed ...................................................................... Fast Idle
Torque ConverterStall Speed ............................... 18752100 rpm
Electronic Tachometer IMPORTANT: Minimum engine speed listed is for
Digital Thermometer an engine that is broken-in and
using No. 2 fuel.
1. Torque Converter Stall: Install electronic
tachometer. (See procedure in this group.) 8. If converter stall speed is low, check for:
2. Install digital thermometer probe into the Low engine output. See Group 9010-25.
transmission sump through the dipstick tube. Incorrect torque converter. Check part number
through inspection hole in bottom of transmission
9020
25B 3. Install hydraulic pump destroke tool. See procedure housing, number should be 4168-028-219).
4 in Group 9025-25. Failed freewheel clutch in torque converter.
4. Heat oil to specifications. 9. If converter stall speed is too high, check for:
Specification Incorrect oil temperature.

Transmission/Hydraulic Oil Low oil level.
Temperature .................................................... 65 5C (150 10F) Incorrect oil in machine.
Restricted suction screen. See repair manual.
See Transmission Warm-Up Procedure in this Group Incorrect torque converter. Check part number
and Hydraulic Warm-Up Procedure in Group 9025-25. through inspection hole in bottom of transmission
housing, number should be 4168-028-219.
5. Place FNR lever in 3rd gear. Engine over fueled. See Group 9010-25.
Converter failed.
6. Apply and hold service brakes. Failed transmission clutch pack.
Low system (pump) pressure in transmission.
IMPORTANT: Converter should NOT be stalled
longer than 20 seconds or serious
TX,25,SS3154 1922JUL981/1

022602
PN=698
Tests (S.N. 872257 )
9020
25B
5

022602
PN=699
Tests (S.N. 872257 )
Converter-In Relief Valve Test (S.N. 872257

)
SPECIFICATIONS
Oil Temperature at Sump 65 5C (150 10F)
Converter-in Relief Valve 800 + 200 kPa (8 + 2 bar) (116 +
Pressure (SN 895999) 29 psi)
Converter-in Relief Valve 9001150 kPa (9 11.5 bar)
Pressure (SN 896000) (130167 psi)
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler

Gauge 02000 kPa (020 bar) (0300 psi)
1. Remove floor panel in cab or ROPS.
2. Install adapter and gauge in port (A).
UN12JUL96
9020
25B 3. Install digital thermometer probe into sump using
6 dipstick tube. Warm transmission oil, see procedure in
this group.
T101750
Specification
OilTemperature at Sump .................................... 65 5C (150 10F)
4. Put FNR lever in neutral.
IMPORTANT: DO NOT exceed 1000 kPa (10 bar) (145

psi) or converter damage could result.
5. Slowly increase rpm until maximum pressure is

reached on gauge.
Specification
EngineSpeed ......................................................................... 2375 25
Converter-In Relief Valve (SN
895999)Pressure............................... 800 + 200 kPa (8 + 2 bar) (116 +
29 psi)
Converter-In Relief Valve (SN
896000)Pressure ............................... 9001150 kPa (9 11.5 bar)
(130167 psi)
6. If maximum pressure is reached at low idle, check for

a plugged cooler. Back flush using an oil caddy or
replace cooler.
Continued on next page TX,25,SS3155 1917APR011/2

022602
PN=700
Tests (S.N. 872257 )
7. If pressure is too high, remove relief valve.

Disassemble, clean and inspect valve.
8. If pressure is low, check for weak or broken spring and

scored or sticking valve.
9. Install and check relief valve after repair.
TX,25,SS3155 1917APR012/2
9020
25B
7

022602
PN=701
Tests (S.N. 872257 )
Park Brake Release Pressure Test (S.N.

872257 )
SPECIFICATIONS
Park Brake Release Pressure 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
Park Brake Applied Pressure 0
ESSENTIAL TOOLS
D38H1032 (10 M x 10 F x 10 M ORFS) (Parker No.
10R6IO-S) Tee
BJT03458 (7/16 20 M JIC x 1-14 F ORFS 10) Adapter
APD34BTX Quick Coupler

Digital Thermometer
UN06AUG96
Gauge 03500 kPa (035 bar) (0500 psi)
9020
25B
8 1. Remove floor panel in cab or ROPS.
T101901
2. Install tachometer and thermometer. (See procedure in
this group.)
AQuick Coupler
3. Make test connections. BAdapter
CPark Brake-to-Transmission Line
4. Heat oil to specifications. DTee
Specification
(See Transmission Oil Warm-up Procedure in this group.)
5. Increase rpm to specification and record pressure

reading with park brake OFF, FNR in neutral , MFWD
engage (if equipped) and differential lock disengaged.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Park BrakeRelease Pressure .......... 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
With park brake switch ON pressure should be zero.
Specification
Park Brake AppliedPressure ................................................................ 0

022602
PN=702
Tests (S.N. 872257 )
6. If park brake pressure is not to specification, do

System Pressure Test. (See procedure in this group.) If
system pressure is OK, but park brake pressure is low,
it indicates leakage in park brake circuit. Check axle oil
level. See Section 9000, Group 4. If oil level is high
park brake piston seals may be leaking. If axle oil level
is OK, but park brake pressure is low, leakage is
indicated in transmission control valve, park brake
solenoid or gasket.
TX,25,SS3157 1922JUL982/2
9020
25B
9

022602
PN=703
Tests (S.N. 872257 )
System Pressure Test (S.N. 872257 )
SPECIFICATIONS
System Pressure 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Each 1.00 mm (0.039 in.) Shim 115 kPa (1.15 bar) (16.68 psi)
Changes Pressure
ESSENTIAL TOOLS

Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)
1. Install Electronic Tachometer and Digital Thermometer,

see procedures in this group.
UN12JUL96
9020
25B 2. Remove floor panel in cab or ROPS.
10
T101892
3. Make test connections in port (A).
Specification
See Transmission Oil Warm-up Procedure in this group.
5. With FNR lever in neutral and gear shift lever (manual

shift) in neutral. Operate machine to specifications and
record pressure.
Specification
EngineSpeed .................................................................. 1500 25 rpm
SystemPressure ............................... 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
6. If pressure is too low, run test at 80 C (176 F) if

pressure is still low check pressure regulating valve,
repair or shim adjust. A 1.00 mm (0.039 in.) shim is
equal to 115 kPa (1.15 bar) (16.68 psi) (see Pressure
Regulating Valve Adjustment in repair manual).
Continued on next page CED,TX03399,4265 1922JUL981/2

022602
PN=704
Tests (S.N. 872257 )
Specification
Each 1.00 mm (0.039 in.) Shim
ChangesPressure .................................. 115 kPa (1.15 bar) (16.68 psi)
If adjustment does not raise pressure, do Transmission

Pump Flow Test see procedure in this group.
7. If pressure is too high redo test using 80 C (176 F)

temperature. If pressure is still to high check pressure
regulating valve, repair or shim adjust.
Specification
ChangesPressure .................................. 115 kPa (1.15 bar) (16.68 psi)
Make sure test was performed at correct specifications.
CED,TX03399,4265 1922JUL982/2
9020
25B
11

022602
PN=705
Tests (S.N. 872257 )
Power Shift Low Range Forward, High Range

Pressure Test (S.N. 872257 )
SPECIFICATIONS
Forward or Reverse Pressure 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Neutral Disconnect De-Activated 0
Pressure
ESSENTIAL TOOLS

Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)
UN21MAY98
9020
25B
12 this group.)
T115471
3. Make test connection in appropriate port (A, B, C, D, E

or F). ALow Range Forward Clutch Pressure Test Port
BReverse Clutch Pressure Test Port
CHigh Range Forward Clutch Pressure Test
4. Heat oil to specifications. Port
DFirst Speed Clutch Pressure Test Port
Specification ESecond Speed Clutch Pressure Test Port
OilTemperature ................................................... 65 5C (150 10F) FThird Speed Clutch Pressure Test Port
(See Transmission Oil Warm-Up procedure in this group.)
NOTE: All clutch pressures should be the same.
5. Machine off ground. Engine speed at specifications

and park brake OFF and FNR lever in forward or
reverse, record pressure in all speed ranges.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Forward or ReversePressure........... 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Continued on next page CED,TX03399,4233 1915MAY981/2

022602
PN=706
Tests (S.N. 872257 )
6. Low pressure in one direction indicates a leakage in

that pack or solenoid. Low pressure in both directions
indicates a leakage in the speed clutch or low system
pressure. (Do System Pressure Test in this group.)
7. With FNR lever in neutral, a slight pressure recorded in

either the forward or reverse test port could indicate
that the ball in the clutch shaft came out (lube
passage) or a problem in control valve. Repair clutch
pack see Group 0350. Repair control valve, see Group
0360.
8. With FNR lever in neutral, pressure recorded in the

speed clutch test ports could indicate a problem with
the time delay relay. See Group 9015-15.
NOTE: When neutral disconnect is de-activated pressure

should be zero.
Specification
Neutral Disconnect
De-ActivatedPressure ........................................................................... 0
9020
25B
13
CED,TX03399,4233 1915MAY982/2

022602
PN=707
Tests (S.N. 872257 )
Reducing Valve Pressure Test (S.N. 872257

)
SPECIFICATIONS
Reducing Valve Pressure 8501050 kPa (8.510.5 bar)
(123152 psi)
ESSENTIAL TOOLS

Digital Thermometer
Gauge 02000 kPa (020 bar) (0300 psi)
1. Install Electronic Tachometer and Digital Thermometer,

see procedure in this group
UN22AUG96
9020 2. Remove floor panel in cab or ROPS.
25B
14
T101897
Specification
See Transmission Oil Warm-up Procedure in this group.
5. With FNR lever in neutral and gear shift lever (manual

shift) in neutral. Operate machine to specifications and
record pressure.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Reducing ValvePressure ...................... 8501050 kPa (8.510.5 bar)
(123152 psi)
6. If reducing valve pressure is not to specification do

System Pressure Test in this group. If system pressure
is OK, but reducing valve pressure is low, it indicates a
leak in the circuit. See repair Group 0360.
7. If pressure is too high check reducing valve for sticky

spool or binding. See repair manual, Group 0360.
Make sure test was performed at correct specifications.
CED,TX03399,4266 1922JUL981/1

022602
PN=708
Tests (S.N. 872257 )
Modulation Valve Pressure Test (S.N.

872257 )
SPECIFICATIONS
System Modulated (Final) 1600 + 300 kPa (16 + 3 bar) (232
Pressure + 44 psi)
Neutral-Modulation Phase 2701200 kPa (2.712 bar)
Pressure (39174 psi)
Modulation Valve Pressure Test Neutral into gear 01600 kPa
Shift Time (016 bar) (0232 psi) in 2
seconds and from
Forward/Reverse or
Reverse/Forward into a gear 1.7
seconds Maximum
Each 1.00 mm (0.039 in.) Shim 42 kPa (0.42 bar) (6.09 psi)
Changes Pressure
ESSENTIAL TOOLS
UN12JUL96
9020
SERVICE EQUIPMENT AND TOOLS 25B
15
T101898
Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)

this group.)
Specification
5. FNR lever in neutral, record pressure reading.
Specification
EngineSpeed .................................................................. 1500 25 rpm
NeutralPressure ......................................... 270300 kPa (2.73 bar)
(3944 psi)

022602
PN=709
Tests (S.N. 872257 )
NOTE: Forward and reverse pressures should be the

same.
6. Machine off the ground. FNR lever in forward or

reverse, record pressure gauge readings.
Specification
EngineSpeed .................................................................. 1500 25 rpm
System Modulated (Final)
Pressure .............................................. 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Modulation PhasePressure ......................... 3001200 kPa (312 bar)
(44174 psi)
7. If total shift time from 01600 kPa (016 bar) (0

232 psi) takes more than specifications while doing this
test, it indicates a problem in the modulation valve.
Specification
Modulation Valve Pressure
TestShift Time ........................................ Neutral into gear 01600 kPa
(016 bar) (0232 psi) in 2
seconds and from
9020 Forward/Reverse or
25B Reverse/Forward into a gear 1.7
16 seconds Maximum
8. If shift is slow (long modulation time only), and neutral

pressure is between 270300 kPa (2.73 bar) (39
44 psi) orifice in modulation circuit is restricted. If shift
is hard or neutral pressure is high, orifice is oversized,
loose or missing. If shift is long (hesitation or long fill
time) or neutral pressure is low, spring is weak, orifice
is plugged. A shim 1 mm (0.039 in.) is equal to 42 kPa
(0.42 bar) (6.09 psi), see repair manual for modulation
shim adjustment if modulation shift is not acceptable.
See Group 0360. Clean orifice, see Group 0360.
Specification
ChangesPressure ...................................... 42 kPa (0.42 bar) (6.09 psi)
TX,25,SS3170 1922JUL982/2

022602
PN=710
Tests (S.N. 872257 )
9020
25B
17

022602
PN=711
Tests (S.N. 872257 )
Differential Lock Pressure Test (S.N.

872257 )
SPECIFICATIONS
Differential Lock Pressure 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
ESSENTIAL TOOLS
38H1022 (1/4 M x 1/4 F x 1/4 M) (Parker No. 4R6LO-S) Tee
PD34BTX Quick Coupler
JT03455 (7/16 20 M JIC x 9/16 18 x 4 F ORFS) Adapter

Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)
UN16JUL96
9020
25B this group.)
18
T101983
3. Make test connections.
ATee
4. Heat oil to specifications. BQuick Coupler
CAdapter
Specification DTransmission-to-Differential Lock Rear Axle
OilTemperature ................................................... 65 5C (150 10F) Hose
5. MFWD and park brake engaged.
6. Increase rpm to specification and record pressure

reading with differential lock pedal switch pressed
down.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Differential LockPressure ................. 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)

022602
PN=712
Tests (S.N. 872257 )
NOTE: When differential lock pedal switch is released

pressure should be zero.
7. If differential pressure is not to specification, do System

Pressure Test. (See procedure in this group). If system
pressure is OK, but differential lock pressure is low, it
indicates a leak in the circuit. See repair.
Check axle oil level. See Section 9000. Group 4. If oil

level is high, seals may be leaking. If axle oil level is
OK, but differential lock pressure is low leakage is
indicated in transmission control valve, differential lock
solenoid or gasket.
TX,25,SS3165 1922JUL982/2
9020
25B
19

022602
PN=713
Tests (S.N. 872257 )
MFWD Pressure Test (S.N. 872257 )
SPECIFICATIONS
Engine Speed 1500 rpm
MFWD Pressure 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
ESSENTIAL TOOLS
(M10 x 1.0 ORB) (Parker No. PD357) Quick Coupler

Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)

this group.)
UN12JUL96
9020
25B 3. Make test connections in port (A).
20
T101916
Specification
5. Increase rpm to specifications and record pressure

reading with MFWD switch OFF, park brake engaged
and differential lock disengaged.
Specification
EngineSpeed ........................................................................... 1500 rpm
MFWDPressure................................ 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
NOTE: When MFWD switch is ON pressure should be

zero.
6. If pressure is low, check System Pressure, see

procedure in this group. If low, leakage in MFWD
circuit is indicated. Possible locations include the
delivery tube (inside case), the MFWD piston seal, the
transmission control valve gasket, or the MFWD
solenoid.
TX,25,SS3166 1922JUL981/1

022602
PN=714
Tests (S.N. 872257 )
9020
25B
21

022602
PN=715
Tests (S.N. 872257 )
Cooler In and Cooler Out Pressure Test (S.N. 872257 )
9020
25B
22
UN30OCT98
T118098
A3/4 in Barb Tee B3/4 in Test Hose CGauge DFlowmeter
SPECIFICATIONS SERVICE EQUIPMENT AND TOOLS

Oil Temperature at Sump 80 5 C (176 10 F) Electronic Tachometer
Engine Speed 1500 25 rpm Digital Thermometer
Gauge 02000 kPa (020 bar) (0300 psi) (2 Used)
Cooler In Pressure Minimum 110 kPa (1 bar) (16 psi) (D) Flowmeter
Cooler Out Pressure Test 55 kPa (0.6 bar) (8 psi)
Pressure Minimum 1. Install Electronic Tachometer, see procedure in this
Normal Cooler Pressure 55 14 kPa (0.6 0.14 bar) (8 group.
Difference (Drop) 2 psi)
Cooler Flow 26 1 L/min (7 0.264 gpm) 2. Install digital thermometer probe into sump using
Minimum Cooler Flow 15 1 L/min L/min (4.0 0.264 dipstick tube.
gpm)
3. Make test connections to cooler and flow meter.
ESSENTIAL TOOLS
(1/2 M NPT x 3/4 x 3/4) (A) Barb Tee (2 Used)
3/4 in. (B) Test Hose cut to length as required (2 used)
Continued on next page CED,TX03399,4267 1922JUL981/2

022602
PN=716
Tests (S.N. 872257 )
4. Heat oil to specifications. CoolerFlow ....................................... 26 1 L/min (7 0.264 gpm)

Minimum CoolerFlow .................... 15 1 L/min L/min (4.0 0.264
gpm)
Specification
OilTemperature at Sump............................ 80 5 C (176 10 F)
6. If cooler restriction is high, inspect cooler hoses and
See Transmission Oil Warm-up Procedure in this cooler for damage. If no damage found, clean
group. cooler using oil caddy.
5. With FNR lever in neutral. Operate machine to 7. If cooler pressures are low, see Solenoid Circuit
specifications and record pressure and flow. Leakage Test in this group.
Specification 8. Check cooler pressures in all shifts. If pressure is

EngineSpeed ............................................................ 1500 25 rpm low, FNR solenoid or pump problems are indicated.
Specification Pump stop sleeve may be blocking flow to torque
Cooler InPressure Minimum ..................... 110 kPa (1 bar) (16 psi)
Cooler Out Pressure Test
converter or torque converter may be plugged. Do
Pressure Minimum ......................................... 55 kPa (0.6 bar) (8 psi) Torque Converter Stall in this group.
Normal CoolerPressure
Difference (Drop) ............................... 55 14 kPa (0.6 0.14 bar) (8
2 psi)
9020
25B
23
CED,TX03399,4267 1922JUL982/2

022602
PN=717
Tests (S.N. 872257 )
Transmission Oil Cooler Thermal Bypass Valve Test (S.N. 872257 )
9020
25B
24
UN23OCT98
T117559
ATest Hose
SPECIFICATIONS 2. Install electronic Tachometer, see procedure

Engine Speed 1500 25
Thermal Bypass Valve Flow: 80 3 C (176 5 F) 3. Connect bypass valve to flow meter with 3/4 in. test
(Starting To Open) hose (A). Connect flow meter outlet to existing
Temperature cooler hose.
Minimum Cooler Flow 15 1 L/min L/min (4.0 0.264
gpm) 4. Open restriction valve on flowmeter.
Thermal Bypass Valve Flow: 96 C (205 F)
(Full Open) Temperature 5. Start engine.
Cooler Flow 26 1 L/min (7 0.264 gpm)
6. Heat Transmission oil to specifications. See warm
SERVICE EQUIPMENT AND TOOLS up procedure in this Group.
Temperature Reader
Flow Meter
7. Run engine at test speed.
3/4 in. Test Hose
Specification
EngineSpeed .................................................................... 1500 25
1. Install digital temperature reader in sump of
transmission using the dipstick tube..
Continued on next page TX,9020,ME475 1926JUN981/2

022602
PN=718
Tests (S.N. 872257 )
8. Flow meter reading must start to increase at Specification

specified temperature. Thermal Bypass Valve Flow:
(Full Open)Temperature............................................ 96 C (205 F)
CoolerFlow ....................................... 26 1 L/min (7 0.264 gpm)
Specification
Thermal Bypass Valve Flow:
(Starting To Open) 10. If valves does meet specifications, inspect valve
Temperature .................................................... 80 3 C (176 5 F) repair or replace.
Minimum CoolerFlow .................... 15 1 L/min L/min (4.0 0.264
gpm) 11. Repeat test after repair.
9. Flow meter reading must be at maximum flow at

specified temperature.
TX,9020,ME475 1926JUN982/2
9020
25B
25

022602
PN=719
Tests (S.N. 872257 )
Transmission Oil Cooler Thermal Bypass Valve Pressure Test (S.N. 872257 )
9020
25B
26
UN23OCT98
T117560
A3/4 in. Barb Tee B3/4 in. Test Hose C3/4 in. Barb Plug
SPECIFICATIONS NOTE: If an oil cooler bypass valve malfunction is

Transmission Oil Temperature 80 6C (176 10F) suspected, the thermal bypass valve can be
Engine Speed Slow Idle removed and inspected or replaced in less
Cooler Bypass Pressure 214269 kPa (2.12.7 bar) time than it takes to perform a test.
Differential Pressure (3139 psi)
1. Install Electronic Tachometer, see procedure in this
ESSENTIAL TOOLS Group.
JTO5753 Hydraulic Switch Box or Differential Pressure Gauge
2. Install digital thermometer probe on thermal relief
SERVICE EQUIPMENT AND TOOLS bypass valve housing.
3/4 in. Barb Plug
3. Disconnect hose from oil cooler at thermal bypass
3/4 in. Barb Tee valve and install plug (C) in hose.
3/4 in. Test Hose
Temperature Reader 4. Install Tee (A) and short test hose in line going to
Electronic Tachometer torque converter from bypass valve..
Continued on next page TX,9020,ME476 1917JUL981/2

022602
PN=720
Tests (S.N. 872257 )
5. Connect differential pressure gauge or Hydraulic Specification

Switch Box to tee and bypass valve outlet going to Cooler Bypass Pressure
DifferentialPressure ............................ 214269 kPa (2.12.7 bar)
cooler. (3139 psi)
6. Heat transmission oil to specification. (See If Pressure Is Low:

A failed cooler thermal bypass valve is indicated.
Specification
Transmission OilTemperature ...................... 80 6C (176 10F)
Disassemble and inspect valve or replace. See
Repair Manual.
NOTE: Pressure differential should start out low and
then when thermal bypass valve opens, If Pressure Is High:
pressure differential will increase.
A failed torque converter relief valve. Disassemble
7. Observe pressure gauges during warm-up. and inspect relief valve or replace. See Repair
Manual.
8. With transmission in neutral, run engine at test A failed cooler thermal bypass valve is indicated.
speed. Disassemble and inspect valve or replace. See
Repair Manual.
Specification
EngineSpeed ...................................................................... Slow Idle
9020
9. Record differential pressure and compare to
25B
specification. 27
TX,9020,ME476 1917JUL982/2

022602
PN=721
Tests (S.N. 872257 )
Solenoid Circuit Leakage Test (S.N. 872257

)
SPECIFICATIONS
Oil Temperature at Sump 80 C (176 F )
Engine Speed 900 + 25 - 0 rpm
NOTE: Do Cooler In and Cooler Out Pressure Test in

conjunction with this test.
If cooler pressures are low from the Cooler In and Cooler

Out Pressure Test do the following test.
1. Install test equipment, see Cooler In and Cooler Out

Pressure Test in this group.
2. Heat oil to specification. See procedure in this group.
Specification
OilTemperature at Sump ............................................... 80 C (176 F )
9020 3. Machine off the ground. FNR lever in neutral, operate

25B
machine to specifications. Record pressures and flows
28
in forward, high range forward reverse, neutral, speed
clutches, MFWD, differential lock and park brake.
Specification
EngineSpeed ............................................................... 900 + 25 - 0 rpm
There should be a momentary fluctuation in pressure/flow

if circuit is normal. If pressure and cooler pressure in and
out and flow remains down, this indicates a leakage in
that circuit. See 9015-15 to check solenoids.
CED,TX03399,4268 1922JUL981/1

022602
PN=722
Tests (S.N. 872257 )
9020
25B
29

022602
PN=723
Tests (S.N. 872257 )
Transmission Pump Flow Test (S.N. 872257

)
SPECIFICATIONS
New Pump Flow 42 L/min (11.2 gpm)
Used Pump Flow 36 L/min (9.5 gpm)
ESSENTIAL TOOLS
AJDG596 Filter Adapter
JDG596A1 Spacer and Sealing Washer Kit

BFlowmeter
Digital Thermometer
IMPORTANT: On early machines use the washers and
UN03FEB99
9020 spacer to make filter adapter fit. This
25B will keep filter from leaking. On later
30 machines just use the filter adapter.
T119993
1. Make test connections. When installing filter adapter
use a washer on both sides of spacer on early
machines.

IMPORTANT: Before starting engine, check that

flowmeter loading valve is open. Pump
can be damaged if engine is started
with loading valve closed.
Specification
(See Transmission Oil Warm-up Procedure in this group.)
4. Run engine at test specification.
Specification
EngineSpeed .................................................................. 1500 25 rpm

022602
PN=724
Tests (S.N. 872257 )
Measure flow.
Specification
PumpFlow .............................................................. 42 L/min (11.2 gpm)
5. Low transmission pump flow can be caused by:
Low oil level in transmission

Cold transmission oil
Plugged intake tube
Air leak in pump suction tube
Pump mounting cap screws loose
Worn transmission pump
TX,25,SS3207 1922JUL982/2
9020
25B
31

022602
PN=725
Tests (S.N. 872257 )
9020
25B
32

022602
PN=726
Section 9025
Hydraulic System
Contents
Page Page
Group 05Theory of Operation Backhoe Boom Valve Operation

Main Hydraulic System Operation (S.N. Gresen. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-52
872256) . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-2 Backhoe Bucket Valve Operation
Main Hydraulic System Operation Gresen. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-53
(S.N.872329 ). . . . . . . . . . . . . . . . . . . . .9025-05-4 Backhoe Crowd Valve Operation
Hydraulic Schematic (SN 830204) . . . . . . .9025-05-5 Gresen. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-54
Hydraulic Schematic (S.N. 830205 Backhoe Auxiliary Valve Operation
850352) . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-6 Gresen. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-55
Hydraulic Schematic (S.N. 850353 Stabilizer Valve Operation . . . . . . . . . . . . . .9025-05-56
872256) . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-7 Brake Pistons, Plates and Disks Operation
Hydraulic Schematic (S.N. 872329 ) . . . . .9025-05-8 (S.N. 872256). . . . . . . . . . . . . . . . . . . .9025-05-57
Charge Pump Operation . . . . . . . . . . . . . . . .9025-05-9 Brakes Released (S.N. 872256) . . . . . . .9025-05-58
Main Hydraulic Pump Operation . . . . . . . . .9025-05-10 Brakes Engaging (S.N. 872328) . . . . . . .9025-05-62
Pressure Compensator Operation . . . . . . . .9025-05-12 Manual BrakingPrefill (S.N. 872328). . .9025-05-66
Hydraulic Return Filter Operation . . . . . . . .9025-05-14 Manual Braking (Engaging) (S.N.
Priority Valve Operation . . . . . . . . . . . . . . .9025-05-16 872328) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-70
Accumulator OperationBrake (S.N. Brake Pistons, Plates and Disks Operation
872256) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-19 (S.N. 872329 ) . . . . . . . . . . . . . . . . . . .9025-05-74 9025
Accumulator OperationBrake (S.N. Brake Valve Operation (S.N. 872329 ). . .9025-05-76
872329 ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-20 Brakes Released (S.N. 872329 ) . . . . . . .9025-05-78
Steering Valve Operation . . . . . . . . . . . . . .9025-05-22 Brakes Engaging (S.N. 872329 ) . . . . . . .9025-05-80
Loader Circuit Relief and Anti-Cavitation Brake EngagingRight Side Only (S.N.
Valve Operation . . . . . . . . . . . . . . . . . . . .9025-05-24 872329 ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-82
Loader Bucket Valve Section Operation . . .9025-05-25 Parking Brake Operation (S.N.
Loader Boom Valve Section Operation . . . .9025-05-28 872328) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-84
Loader Auxiliary Valve Section Differential Lock Operation (S.N.
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-32 872256) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-86
Backhoe Circuit Relief and Anti-Cavitation Park Brake Differential Lock Valve Operation
Valve OperationGresen . . . . . . . . . . . .9025-05-34 (S.N. 872256). . . . . . . . . . . . . . . . . . . .9025-05-88
Circuit Relief Valve with Anti-Cavitation
Husco . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-35 Group 15Diagnostic Information
Circuit Relief Valve without Diagnose Steering System Malfunctions . . . .9025-15-1
Anti-CavitationHusco . . . . . . . . . . . . . .9025-05-36 Diagnose Main Hydraulic System
Backhoe Swing Valve Operation-Swing Left Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9025-15-4
PositionHusco . . . . . . . . . . . . . . . . . . .9025-05-38 Diagnose Brake System Malfunctions . . . . .9025-15-10
Backhoe Bucket Valve OperationBucket Diagnose Park Brake and Differential Lock
Curl PositionHusco. . . . . . . . . . . . . . . .9025-05-40 System Malfunctions . . . . . . . . . . . . . . . .9025-15-12
Backhoe Boom Valve OperationHusco . .9025-05-42
Backhoe Valve Crowd OperationCrowd In Group 20Adjustments
PositionHusco . . . . . . . . . . . . . . . . . . .9025-05-44 Charge Pump Belt Tension Adjustment (SN
Backhoe Valve Auxiliary OperationExtend 830204) . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-1
OperationHusco . . . . . . . . . . . . . . . . . .9025-05-46 Loader Bucket Level Indicator and
Backhoe Solenoid Controlled Auxiliary Return-to-Dig Switch Adjustment . . . . . . . .9025-20-2
ValveStanley . . . . . . . . . . . . . . . . . . . .9025-05-48 Adjust Park Brake (S.N. 872328) . . . . . . . .9025-20-4
Backhoe Swing Valve Operation
Gresen. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-50 Continued on next page

022602
PN=1
Contents
Page Page
Service Brake Inspection (S.N. 872328) . .9025-20-5 Service Brake Valve Work Port Pressure
Service Brake Inspection (S.N. 872329 Test (S.N. 872329 ) . . . . . . . . . . . . . . .9025-25-62
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-6 Brake Accumulator Precharge Pressure Test
Service Brake Valve And Pedal (S.N. 872328) . . . . . . . . . . . . . . . . . . .9025-25-64
Adjustment (S.N. 872329 ) . . . . . . . . . . .9025-20-8 Brake Accumulator Precharge Pressure
Backhoe Valve Linkage Adjustment . . . . . .9025-20-10 Test (S.N. 872329 ) . . . . . . . . . . . . . . .9025-25-66
Loader Control Valve Linkage
Adjustment. . . . . . . . . . . . . . . . . . . . . . . .9025-20-10
Stabilizer Valve Linkage Adjustment . . . . . .9025-20-12
Group 25Tests
John Deere Radial Piston PumpUse
CTM7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
JT05800 Digital Thermometer Installation . . .9025-25-1
Hydraulic Oil Warm-Up Procedure. . . . . . . . .9025-25-2
Manual Destroke Installation Procedure . . . .9025-25-3
Diagnostic Destroke Wire Harness Installation
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-4
Charge Pressure Test . . . . . . . . . . . . . . . . . .9025-25-5
Charge Pump Flow (S.N. 872256) . . . . . . .9025-25-6
Charge Pump Flow (S.N. 872329 ) . . . . . .9025-25-8
Surge Relief Valve Pressure Test . . . . . . . . .9025-25-9
9025 Main Pump Standby Pressure Test . . . . . . .9025-25-10
Main Pump Flow Test . . . . . . . . . . . . . . . . .9025-25-12
Priority Valve Test . . . . . . . . . . . . . . . . . . . .9025-25-14
Priority Valve "LS" Port Flow Test . . . . . . . .9025-25-16
Hydraulic Oil Cooler Restriction Test. . . . . .9025-25-18
Steering Valve Neutral Drift Test . . . . . . . . .9025-25-20
Cylinder Drift Test . . . . . . . . . . . . . . . . . . . .9025-25-21
Steering System Leakage Test . . . . . . . . . .9025-25-22
Steering Cylinder Leakage Test . . . . . . . . .9025-25-26
Cylinder Leakage Test . . . . . . . . . . . . . . . .9025-25-28
Hydraulic Component Leakage Test . . . . . .9025-25-29
Circuit Relief Valve Test with Flow
RegulatorTest Cylinder Method
Gresen. . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-36
Circuit Relief Valve TestRemote Pump
Method . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-43
Cycle Time Test . . . . . . . . . . . . . . . . . . . . .9025-25-48
Cycle Time Test Continued . . . . . . . . . . . . .9025-25-49
Flowmeter Calibration Procedure . . . . . . . .9025-25-50
Differential Lock Pressure Reducing Valve
Test (S.N. 872256). . . . . . . . . . . . . . . .9025-25-52
Park Brake Circuit Pressure Test (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-54
Park Brake Thermal Relief Valve Test (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-56
Service Brake Valve Pressure Test (S.N.
872328) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-58
872329 ). . . . . . . . . . . . . . . . . . . . . . . .9025-25-60

022602
PN=2
Group 05
Theory of Operation
9025
05
1

022602
PN=729
Theory of Operation
Main Hydraulic System Operation (S.N. 872256)
UN19FEB97
T105415
9025
(Serial No. 830204)
05
2
UN19FEB97
T106263
(Serial No. 830205872256)

022602
PN=730
Theory of Operation
ABackhoe Control Valve EHydraulic Reservoir IMain Hydraulic Pump MPark Brake/Differential
BStabilizer Control Valve FBrake Accumulator JSurge Relief Valve Lock Valve
CBrake Valve GCharge Pump KLoader Control Valve NHydraulic Filter
DSteering Valve HHydraulic Oil Cooler LPriority Valve ORear Differential
This is a closed-center hydraulic system. Oil flows from brake/differential lock valve is routed to the priority
the hydraulic reservoir to the charge pump (G). Charge valve (L) and brake valve (C). Oil flows past the
oil flows to inlet of hydraulic filter (N). Return oil from priority valve spool to the non-priority circuit (loader
all hydraulic functions except steering, brakes and function). When pressure drops below setting of valve,
differential lock also flows to filter inlet to form charge flow to the loader circuit is restricted to supply priority
circuit flow. A surge relief check valve (J) is used to oil to the steering circuit.
maintain charge pressure and protect oil cooler from
excess pressure by releasing excess oil to the Charge circuit flow not required by the main hydraulic
hydraulic reservoir (E). pump flows to the hydraulic oil cooler (H). Oil cooler,
main hydraulic pump seal drain, steering valve, brake
Oil flows from the filter to main hydraulic pump (I) inlet. valve, and differential lock and park brake valve return
Oil flows from the main pump to the park oil flow directly to hydraulic reservoir.
brake/differential lock valve (M). Oil from the park
TX,9025,BG216 1902JAN972/2
9025
05
3

022602
PN=731
Theory of Operation
Main Hydraulic System Operation (S.N.872329 )
UN23OCT98
T117454
9025
05
ABackhoe Control Valve HHydraulic Reservoir OSteering Cylinder TPriority Valve
4
BStabilizer Control Valve ISurge Relief Valve PAttenuator Hose UCharge Pump
CBrake System Filter JTransmission Oil Cooler QThermal Relief Bypass VHydraulic Filter
DRight Stabilizer Cylinder KHydraulic Oil Cooler Valve WRight Swing Cylinder
ESteering Valve LLeft Loader Boom Cylinder RRight Loader Boom XLeft Swing Cylinder
FBrake Valve MLoader Bucket Cylinder Cylinder YLeft Stabilizer Cylinder
GBrake Accumulator (2 NMain Hydraulic Pump SLoader Control Valve
used)
The hydraulic system is a closed-center system. Oil (T). Oil flows to the priority valve spool to the
flows from the hydraulic reservoir to the charge pump non-priority circuit (loader function). When pressure
(U). Charge oil flows to inlet of hydraulic filter (V). drops below setting of valve, flow to the loader circuit
Return oil from all hydraulic functions except steering, is restricted to supply priority oil to the steering circuit.
brakes, transmission and differential lock flows to filter
inlet to form charge circuit flow. A surge relief check Charge circuit flow not required by the main hydraulic
valve (I) is located in the reservoir return line from the pump flows to the hydraulic oil cooler (H). Oil cooler,
filter base in the bottom of the reservoir. It is used to main hydraulic pump seal drain, steering valve, brake
maintain charge pressure and protect oil cooler from valve, and differential lock and park brake valve return
excess pressure by releasing excess oil to the oil flow directly to hydraulic reservoir.
hydraulic reservoir (H).
Oil flows from the filter to main hydraulic pump (N)

inlet. Oil flows from the main pump to the priority valve
CED,TX03610,135 1919MAR991/1

022602
PN=732
Theory of Operation
Hydraulic Schematic (SN 830204)

T119027 1913JUL99
BACKHOE SURGE RELIEF VALVE STEERING VALVE BRAKE VALVE

VALVE STABILIZER STEERING RESERVOIR (S.N. 80220 )
BACKHOE CONTROL VALVE
VALVE BRAKE VALVE L R
OUTLET END CAP VALVE
ACCUMULATOR
AUXILIARY
CHARGE PUMP
HYDRAULIC OIL
COOLER
CROWD
T LS P
HYDRAULIC
FILTER
LOADER CONTROL VALVE (S.N. 812258 )

BUCKET
BOOM BUCKET AUXILIARY PRIORITY
VALVE
PARK BRAKE/ PRIORITY ACCUMULATOR
DIFF. LOCK VALVE VALVE
MAIN HYDRAULIC
PUMP
BOOM LOADER
VALVE
LOADER CONTROL VALVE (S.N. 812257)

RESERVOIR
BOOM BUCKET AUXILIARY
SWING PRESSURE MAIN HYDRAULIC PUMP HYDRAULIC

STABILIZER VALVE REDUCING FILTER
PARK VALVE HIGH PRESSURE OIL
BRAKE
RELIEF SOLENOIDS MEDIUM PRESSURE OIL
VALVE SURGE
RELIEF CHARGE REDUCED PRESSURE OIL
VALVE PUMP
SYSTEM DIFF. CHARGE PRESSURE OIL
RELIEF LOCK
VALVE SOLENOID TRAPPED OIL
INLET END CAP PARK BRAKE PARK FILTER BYPASS
DIFF. RETURN OIL
BRAKE VALVE
LOCK SWITCH
HYDRAULIC
THERMAL
OIL COOLER
T119027 710D HYDRAULIC SCHEMATIC RELIEF VALVE
CED,TX03768,8484 1924APR981/1

022602
PN=733
See Page 9025-05-5 A See Page 9025-05-5 B See Page 9025-05-5 C

Theory of Operation
Hydraulic Schematic (S.N. 830205850352)

T119026 1917DEC98
BACKHOE STEERING VALVE BRAKE VALVE

BACKHOE CONTROL VALVE VALVE STABILIZER STEERING
VALVE BRAKE VALVE ACCUMULATOR
RESERVOIR L R
AUXILIARY SURGE RELIEF VALVE
HYDRAULIC OIL
COOLER
CROWD
T LS P
HYDRAULIC
FILTER
BUCKET
PRIORITY
VALVE
PARK BRAKE/ ACCUMULATOR
DIFF. LOCK VALVE
MAIN HYDRAULIC
PRIORITY PUMP
VALVE
LOADER CHARGE
BOOM PUMP
VALVE
LOADER CONTROL VALVE

RESERVOIR
SWING PRESSURE MAIN HYDRAULIC PUMP HYDRAULIC

STABILIZER VALVE REDUCING FILTER
PARK VALVE ATTENUATOR HIGH PRESSURE OIL
BRAKE HOSE
VALVE SURGE
VALVE PUMP
SYSTEM DIFF. CHARGE PRESSURE OIL
RELIEF LOCK
VALVE SOLENOID TRAPPED OIL
INLET END CAP PARK BRAKE PARK FILTER BYPASS
DIFF. RETURN OIL
BRAKE VALVE
LOCK SWITCH
HYDRAULIC
THERMAL
710D HYDRAULIC SCHEMATIC OIL COOLER
RELIEF VALVE
T119026
(GRESEN BACKHOE VALVE)
CED,TX03768,8485 1924APR981/1

022602
PN=734

Theory of Operation
Hydraulic Schematic (SN 830204)

T119027 1913JUL99
BACKHOE
BACKHOE CONTROL VALVE VALVE STABI
VALVE
OUTLET END CAP
AUXILIARY
CROWD
HYDRAULIC
FILTER
LOADER CONTROL VALVE (S.N. 812258 )

BUCKET
PARK BRAKE
DIFF. LOCK V
BOOM
LOADER CO
BOOM
SWING
STABILIZER VALVE
SYSTEM
RELIEF
VALVE
INLET END CAP
T119027
CED,TX03768,8484 1924APR981/1

022602
Page 9025-05-5 A PN=733

SURGE RELIEF VALVE
STABILIZER STEERING RESERVOIR (S.N. 80220 )
VALVE BRAKE VALVE
VALVE
ACCUMULATOR
CHARGE PUMP
HYDRAULIC OIL
COOLER
BRAKE/ PRIORITY ACCU

OCK VALVE VALVE
MAIN HYDRAULIC
PUMP
LOADER
VALVE
ER CONTROL VALVE (S.N. 812257)

OM BUCKET AUXILIARY
PRESSURE
REDUCING
PARK VALVE
BRAKE
RELIEF SOLENOIDS
VALVE
DIFF.
LOCK
SOLENOID
PARK BRAKE PARK
DIFF. BRAKE
LOCK SWITCH
THERMAL
710D HYDRAULIC SCHEMATIC RELIEF VALVE
/1
der
22602
733
Page 9025-05-5 B
STEERING VALVE BRAKE VALVE
L R
T LS P
PRIORITY
VALVE
ACCUMULATOR
RESERVOIR
MAIN HYDRAULIC PUMP HYDRAULIC

FILTER
HIGH PRESSURE OIL
MEDIUM PRESSURE OIL

SURGE
VALVE PUMP
CHARGE PRESSURE OIL
TRAPPED OIL
FILTER BYPASS RETURN OIL
VALVE
HYDRAULIC
OIL COOLER
Page 9025-05-5 C
BACKHOE
BACKHOE CONTROL VALVE VALVE STABILIZER
VALVE BRAKE
AUXILIARY
CROWD
HYDRAULIC
FILTER
BUCKET
PARK BRAKE/
DIFF. LOCK VALVE
PRIORITY
VALVE
BOOM
LOADER CONTROL VALVE

BOOM BU
SWING
STABILIZER VALVE
SYSTEM
RELIEF
VALVE
INLET END CAP
T119026
Page 9025-05-6 A
Hydraulic Sc
T119026 1917DEC98
STEERIN
STEERING
KE VALVE ACCUMULATOR
RESERVOIR L
E
SURGE RELIEF VALVE
HYDRAULIC OIL
COOLER
PR
VA
ACCUMULATOR
MAIN HYDRAULIC
PUMP
LOADER CHARGE
VALVE PUMP
ALVE
BUCKET AUXILIARY
PRESSURE MAIN HYDRAU

REDUCING
PARK VALVE ATTE
BRAKE HOSE
RELIEF SOLENOIDS
VALVE
DIFF.
LOCK
SOLENOID
PARK BRAKE PARK
DIFF. BRAKE
LOCK SWITCH
THERMAL
(GRESEN BACKHOE VALVE)
TM1537 (26FEB0
Page 9025-05-6 B
Theory of Operation
ulic Schematic (S.N. 830205850352)

917DEC98
TEERING VALVE BRAKE VALVE
L R
T LS P
PRIORITY
VALVE
OR
RESERVOIR
HYDRAULIC PUMP HYDRAULIC

FILTER
ATTENUATOR HIGH PRESSURE OIL
HOSE
MEDIUM PRESSURE OIL
SURGE
VALVE PUMP
CHARGE PRESSURE OIL
TRAPPED OIL
VALVE
HYDRAULIC
OIL COOLER
CED,TX03768,8485 1924APR981/1
26FEB02) 9025-05-6 710D Backhoe Loader

022602
Page 9025-05-6 C PN=734

Theory of Operation

T119025 1917DEC98
BACKHOE STEERING VALVE BRAKE VALVE

VALVE STABILIZER STEERING
VALVE BRAKE VALVE ACCUMULATOR
RESERVOIR L R
VALVE
SURGE RELIEF VALVE
OUTLET END CAP
AUXILIARY HYDRAULIC OIL

COOLER
T LS P
CROWD
HYDRAULIC
FILTER
BUCKET
PRIORITY
VALVE
PARK BRAKE/ ACCUMULATOR
DIFF. LOCK VALVE
MAIN HYDRAULIC
BOOM PRIORITY PUMP
VALVE
LOADER CHARGE
VALVE PUMP
SWING LOADER CONTROL VALVE

RESERVOIR
PRESSURE MAIN HYDRAULIC PUMP HYDRAULIC

AUXILLIARY STABILIZER VALVE REDUCING FILTER
(ATTACHMENT) PARK VALVE ATTENUATOR HIGH PRESSURE OIL
BRAKE HOSE
VALVE SURGE
VALVE PUMP
DIFF. CHARGE PRESSURE OIL
SYSTEM LOCK
RELIEF SOLENOID TRAPPED OIL
INLET END CAP VALVE
PARK BRAKE PARK FILTER BYPASS
DIFF. RETURN OIL
BRAKE VALVE
LOCK SWITCH
HYDRAULIC
THERMAL
710D HYDRAULIC SCHEMATIC OIL COOLER
RELIEF VALVE
T119025
(HUSCO BACKHOE VALVE)
CED,TX03768,8486 1924APR981/1

022602
PN=735

Theory of Operation
Hydraulic Schematic (S.N. 872329 )

T116994 1913NOV98
EXTENDIBLE RIGHT STEERING BRAKE
DIPPERSTICK CROWD BACKHOE BRAKE
CYLINDER VALVE STABILIZER VALVE VALVE BRAKE VALVE
CYLINDER CYLINDER ACCUMULATORS
SURGE RELIEF
BACKHOE CONTROL VALVE BRAKE HYDRAULIC OIL VALVE
STABILIZER
VALVE SYSTEM RESERVOIR
FILTER TRANSMISSION
OUTLET END CAP OIL COOLER HYDRAULIC
OIL COOLER
AUXILIARY
THERMAL
RELIEF
BYPASS
BUCKET VALVE
CYLINDER
LEFT LOADER
CROWD BOOM CYLINDER ACCUMULATOR ACCUMULATOR
CYLINDER
LEFT B A A B
STABILIZER LEFT I I
CYLINDER SWING
BUCKET CYLINDER HYDRAULIC P C C P
RIGHT FILTER
SWING
CYLINDER CHARGE BUCKET
PUMP CYLINDER BRAKE BRAKE BRAKE
PRIORITY
BOOM PRESSURE LIGHT PRESSURE
VALVE
SWITCH SWITCH SWITCH
TRANSMISSION
LOADER MAIN HYDRAULIC
VALVE TRANSMISSION STEERING OIL PUMP
HYDRAULIC RIGHT ATTENUATOR
CYLINDER
FILTER LOADER HOSE
CYLINDER
SWING
RESERVOIR
BOOM BUCKET AUXILIARY STEERING VALVE
L R
MAIN HYDRAULIC PUMP HYDRAULIC HIGH PRESSURE OIL
AUXILLIARY STABILIZER VALVE FILTER
(ATTACHMENT) ATTENUATOR MEDIUM PRESSURE OIL
HOSE
PRIORITY CHARGE PRESSURE OIL
VALVE SURGE
RELIEF CHARGE TRAPPED OIL
VALVE PUMP
LUBRICATION OIL
SYSTEM
RELIEF T LS P RETURN OIL
INLET END CAP VALVE
FILTER BYPASS
VALVE
HYDRAULIC
OIL COOLER
T116994
710D HYDRAULIC SCHEMATIC
Hydraulic Schematic
CED,TX04577,769 1928SEP981/1

022602
PN=736

Theory of Operation

T119025 1917DEC98
BACKHOE
VALVE STABILIZER
VALVE
OUTLET END CAP
AUXILIARY
CROWD
HYDRAULIC
FILTER
BUCKET
PARK BRAKE/
DIFF. LOCK VALVE
BOOM PRIORITY
VALVE
SWING LOADER CON

BOOM
AUXILLIARY STABILIZER VALVE

(ATTACHMENT)
SYSTEM
RELIEF
INLET END CAP VALVE
T119025
CED,TX03768,8486 1924APR981/1

022602
Page 9025-05-7 A PN=735

ER STEERING
BRAKE VALVE ACCUMULATOR
RESERVOIR
VALVE
SURGE RELIEF VALVE
HYDRAULIC OIL
COOLER
ACCU
VE
MAIN HYDRAULIC
ORITY PUMP
VE
LOADER CHARGE
VALVE PUMP
ER CONTROL VALVE
OM BUCKET AUXILIARY
PRESSURE
REDUCING
PARK VALVE
BRAKE
RELIEF SOLENOIDS
VALVE
DIFF.
LOCK
SOLENOID
PARK BRAKE PARK
DIFF. BRAKE
LOCK SWITCH
THERMAL
(HUSCO BACKHOE VALVE)
/1
der
22602
735
Page 9025-05-7 B
STEERING VALVE BRAKE VALVE
L R
T LS P
PRIORITY
VALVE
ACCUMULATOR
RESERVOIR
MAIN HYDRAULIC PUMP HYDRAULIC

FILTER
ATTENUATOR HIGH PRESSURE OIL
HOSE
MEDIUM PRESSURE OIL
SURGE
VALVE PUMP
CHARGE PRESSURE OIL
TRAPPED OIL
VALVE
HYDRAULIC
OIL COOLER
Page 9025-05-7 C
EXTENDIBLE RIGHT
DIPPERSTICK CROWD BACKHOE
CYLINDER VALVE STABILIZE
CYLINDER CYLINDER
STABILIZ
VALVE
OUTLET END CAP
AUXILIARY
BUCKET
CYLINDER
CROWD BOOM
CYLINDER
LEFT
STABILIZER LEFT
CYLINDER SWING
BUCKET CYLINDER HYDRAULIC
RIGHT FILTER
SWING
CYLINDER CHARGE
PUMP
PRIORITY
BOOM VALVE
LOADER
VALVE
SWING
BOOM BU
AUXILLIARY STABILIZER VALVE

(ATTACHMENT)
SYSTEM
RELIEF
INLET END CAP VALVE
T116994
Page 9025-05-8 A
Hydraulic S
T116994 1913NOV98
HT STEERING BRAKE
BILIZER BRAKE
VALVE VALVE ACCUMULATORS
INDER SURGE RELIEF
ABILIZER BRAKE HYDRAULIC OIL VALVE
LVE SYSTEM RESERVOIR
FILTER TRANSMISSION
OIL COOLER HYDRAULIC
OIL COOLER
THERMAL
RELIEF
BYPASS
VALVE
LEFT LOADER
CYLINDER ACCUMU
BUCKET
CYLINDER
RITY
VE
TRANSMISSION
OADER MAIN HYDRAULIC
ALVE TRANSMISSION STEERING OIL PUMP
HYDRAULIC RIGHT ATTENUATOR
CYLINDER
FILTER LOADER HOSE
CYLINDER
BUCKET AUXILIARY STEERING VALVE
L R
MAIN HYDRA
ATTE
HOS
PRIORITY
VALVE
T LS P
710D HYDRAULIC SCHEMATIC
TM1537 (26FEB
Page 9025-05-8 B
Theory of Operation
ulic Schematic (S.N. 872329 )

913NOV98
BRAKE VALVE
CUMULATOR ACCUMULATOR
B A A B
I I
P C C P
BRAKE BRAKE BRAKE

PRESSURE LIGHT PRESSURE
SWITCH SWITCH SWITCH
RESERVOIR
HYDRAULIC PUMP HYDRAULIC HIGH PRESSURE OIL

FILTER
ATTENUATOR MEDIUM PRESSURE OIL
HOSE
CHARGE PRESSURE OIL
SURGE
RELIEF CHARGE TRAPPED OIL
VALVE PUMP
LUBRICATION OIL
RETURN OIL
FILTER BYPASS
VALVE
HYDRAULIC
OIL COOLER
Hydraulic Schematic
CED,TX04577,769 1928SEP981/1
26FEB02) 9025-05-8 710D Backhoe Loader

022602
Page 9025-05-8 C PN=736

Theory of Operation
Charge Pump Operation
H
E G
F
D L
1915JAN98
A
B K
C
T6895AD
TXC6895AD
9025
05
9
ACharge Pressure DCharge Pump GLoader Control Valve JAuxiliary Valve
BReturn Oil (Low Pressure) EMain Hydraulic Pump HStabilizer Control Valve KHydraulic Filter
CReturn Oil (Pressure Free) FHydraulic Oil Cooler IBackhoe Control Valve LHydraulic Reservoir
The charge pump (D) (SN 830204) is located on left Charge pump is a low pressure, constant displacement
side of engine above injection pump. It is belt driven gear pump. Charge oil is drawn from hydraulic
off the engine crankshaft pulley and belt tension is reservoir (L) and pumped into return line ahead of
adjustable. hydraulic filter to supply main hydraulic pump (E).
The charge pump (SN 830205 872256) is located on When main hydraulic pump is at standby, charge oil
the right side of the engine beneath the alternator. It is (A) flows through oil cooler (F) and is returned to
driven by the right camshaft gear through the auxiliary hydraulic reservoir. Excess charge flow is returned to
drive assembly. reservoir through surge relief check valve. The surge
relief check valve is located in reservoir return line
The charge pump (S.N. 872329 ) is mounted on the from filter base and limits charge pressure to a
rear of the transmission. The pump is driven by the maximum of 827 kPa (120 psi).
transmission input shaft at engine speed.
TX,9025,BG217 1902JAN971/1

022602
PN=737
Theory of Operation
Main Hydraulic Pump Operation
K
J
N
L
O
U
A
M
H
F G
D
B
9025
05
10 E
1915JAN98
Q
R C
T6902AA
S
TXC6902AA
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

022602
PN=738
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-utilized and newer style unitized designs) are
piston. This low pressure allows inlet valve (G) to open designed to provide "on demand" discharge pressure
filling the piston cavity with oil. Inlet valves close at the oil (P) regardless of flow requirements. As demand for
end of intake stroke of pistons. High pressure oil is oil decreases, system pressure increases. Pressure
developed as bearing race pushes pistons outward. compensator valve (L) then routes system oil into
crankcase (H). Increased pressure in the crankcase
As pressure increases, the discharge valve (C) opens overcomes piston spring pressure and holds pistons
allowing discharge pressure oil (P) to pass into the (D) away from race (F), thereby destroking the pump.
outlet gallery. At the end of stroke, discharge pressure
27T,9025,M65 1924MAR932/2
9025
05
11

022602
PN=739
Theory of Operation
Pressure Compensator Operation
B P
P
G
E G B N
C
E
I F
J
H K
9025
L
05
12
1915JAN98
TXC6902AB
D O
T6902AB
APressure Compensator ECrankcase Relief Valve KCrankcase Pressure Oil OPlug (or Optional Manual
Adjusting Screw FExternal Control Valve LInlet Pressure Oil Destroke or Electric
BPressure Compensator GSpring MPressure Compensator Solenoid)
Spring(s) HShuttle Valve Valve in 1st Position PValve Housing
CSpring Guide ISpring NPressure Compensator
DPressure Compensator JDischarge Pressure Oil Valve in 2nd Position
Valve
Continued on next page 27T,9025,M67 1915OCT911/2

022602
PN=740
Theory of Operation
The 3000 Series unitized designed pump provides a pressure increases moving pressure compensator
bolt-on control valve. The pressure compensator valve valve (D) toward spring (B).
(D) controls the flow of oil in the pump. Valve
movement is controlled by discharge pressure oil (J) The valve continues to move to position (N) dumping
on one end of the valve and by inlet pressure oil (L) discharge pressure oil (J) into the crankcase,
and force from spring (B) on the other end. Discharge increasing crankcase pressure. Crankcase pressure
pressure can be increased or deceased by changing overcomes the combined spring force on the pump
the force on spring (B) using the pressure pistons. Pistons are then held away from the pump
compensator adjusting screw (A). Shuttle valve (H) is shaft bearing race and the pump is DESTROKED.
used in conjunction with either a manual destroke
screw or an electric destroke solenoid in place of plug The pump goes into QUICK DESTROKE when there is
(O). Valve (H) moves against crankcase relief valve a sudden drop in demand for oil flow, creating a
(E) and spring (G) allowing discharge pressure oil to sudden increase in discharge pressure oil. Discharge
be dumped into crankcase and inlet destroking the pressure oil increases greatly allowing the crankcase
pump. relief valve (E) to move against the spring (G). This
allows crankcase pressure oil (K) to dump into inlet
Pump is in FULL STROKE when pressure pressure oil (L). This limits high pressure spikes
compensator valve (D) is in the position (M) shown caused by discharge pressure oil being too rapidly
above. As demand for oil decreases, discharge routed into crankcase cavity.
27T,9025,M67 1915OCT912/2
9025
05
13

022602
PN=741
Theory of Operation
Hydraulic Return Filter Operation
A
INLET P
I
C
J
G BYPASS
INLET VALVE
HOUSING
A A
B PISTON K G
P C NORMAL OPERATION
SPRING
D
SPRING F
H TERMINAL
L RESTRICTED FLOW
9025
05 I ELEMENT INDICATOR LIGHT
J
14 ON AND BYPASS OIL
1910SEP98
TO
RESERVOIR M SEMI-RESTRICTED
K K FLOW INDICATOR
OUTLET LIGHT ON
T101460
T101460 O RETURN FILTER N RETURN FLOW
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 (B) increases, moving the piston (C) down against
the hydraulic system oil. The filter housing contains a spring (D) force and outlet pressure. The piston
bypass valve and a filter restriction switch. contacts the terminal (H), completing a circuit which
causes the filter restriction indicator light to glow.
Under normal operation, return flow from the backhoe
loader and priority valve enters the inlet (A), flows As the filter element becomes plugged, the pressure
through the filter element (I), up through the filter differential between the inlet and outlet increases. Inlet
canister and out the outlet (K) or to the reservoir (J). pressure is sensed on one side of the valve (G) which
opens against spring (F) force and outlet pressure.
If the pressure differential between the inlet and outlet The return oil then bypasses the filter while the
increases past a set level due to cold oil or partially restriction indicator lights glow.
restricted filter element, inlet pressure in the housing
Continued on next page 27T,9025,M69 1924MAR931/2

022602
PN=742
Theory of Operation
Under normal operation, the restriction indicator light return filter is being bypassed. Extended operation in
will glow when operating the hydraulic functions with the bypass mode will cause damage to the hydraulic
cold oil. If the restriction indicator light continues to system.
glow after the oil reaches operating temperature, the
27T,9025,M69 1924MAR932/2
9025
05
15

022602
PN=743
Theory of Operation
Priority Valve Operation
D P PORT A D
E
SPOOL
LAND C
NOTCHES E SPOOL
B F
H
G
LS PORT B
SPRING A
ORIFICE H
J SYSTEM PRESSURE
LOADER I K STEERING CIRCUIT
VALVE G F PRESSURE
ACTUATED EF PORT CF PORT L RETURN PRESSURE
1915JAN98
T7833AG
9025 TXC7833AG M PRIORITY VALVE NEUTRAL
05
16
ASpring ESpool HOrifice KSteering Circuit Pressure
B"LS" Port F"CF" Port, To Steering ILoader Valve Actuated LReturn Pressure
CSpool Land Notches Valve JSystem Pressure MPriority Valve-Neutral
D"P" Port, Inlet G"EF" Port, To Loader Valve
The priority valve (M) is a pressure control valve that causes the priority valve spool to shift left against the
maintains priority pressure to the closed-center spring and open the "EF" port. As long as the steering
steering valve. With the engine running and the valve is in neutral, just enough pressure to the steering
steering valve in neutral, flow to the steering valve is valve is maintained to keep the priority valve spool
not required and all flow through the priority valve is shifted to the left.
directed out the "EF" port (G) to the loader control
valve. The operating pressure in the loader circuit does not
affect the operation of the priority valve. With a loader
With the engine off, the spool (E) is pushed to the right function activated the priority valve will not shift until
by the spring (A). The passage to the "CF" port (F) is the unit is steered.
open.
Flow through the priority valve spool passes through
When the machine is first started, all pump flow is the orifice (H) and into the "LS" port (B) flowing
routed to the steering valve which, if not being through the steering valve "LS" passage which is
operated, blocks the flow. This causes pump pressure routed to return when the steering valve is in neutral.
to increase. Steering inlet pressure is supplied through This provides a warm-up circuit to prevent binding of
the pilot orifice to the right end of the spool. This the steering valve due to temperature extremes.
Continued on next page TX,902505,BS152 1903MAR931/3

022602
PN=744
Theory of Operation
D P PORT H E
D
SPOOL
LAND B
NOTCHES E SPOOL
A F
C
G
LS PORT A
SPRING H
ORIFICE C
J HIGH PRESSURE
FULL K MEDIUM PRESSURE
STEER I
RATE G F
EF PORT CF PORT
1915JAN98
L PRIORITY VALVE STEERING ACTIVATED
T7833AH
TXC7833AH LOADER VALVE IN NEUTRAL
9025
A"LS" Port ESpool HSpring LPriority ValveSteering
05
BSpool Land Notches F"CF" Port, To Steering IFull Steer Rate ActivatedLoader Valve in
17
COrifice Valve JHigh Pressure Neutral
D"P" Port, Inlet G"EF" Port, To Loader Valve KMedium Pressure
When steering the machine, load-sensing pressure conditions. During normal conditions, oil is metered
from the steering valve flows through the orificed "LS" into the load sensing circuit through an orifice in the
port (A) in the priority valve. Load sensing pressure steering valve. When steering is at the full steer rate
plus spring (H) force moves the spool (E) to the right (I), the spool shifts to the full right position, directing all
against the pilot pressure on the right end of the spool. flow to the steering valve. At fast idle, the steering
This restricts flow through the "EF" port (G) while the system will not use all of the pump flow. Therefore, the
"CF" port (F) is open to the steering valve. excess oil flows to the loader control valve.
The load sensing circuit is a control circuit that routes The load sensing circuit receives the majority of its
steering work port pressure oil to the spring side of the flow from the load sensing orifice in the steering valve.
priority valve spool to sense the pressure that is Some flow is also supplied from the "CF" port through
required to steer the machine under various load orifice (C) in the priority valve spool.

022602
PN=745
Theory of Operation
E PORT
E B
SPRING D
PLUG C
SPOOL F SPOOL
LAND B
A G
NOTCHES
H
LS PORT A
I HIGH PRESSURE
J MEDIUM PRESSURE
H G
1915JAN98
EF PORT CF PORT
K PRIORITY VALVE STEERING CYLINDER
T7833AI
TXC7833AI BOTTOMED AND LOADER ACTIVATED
9025
A"LS" Port E"P" Port, Inlet H"EF" Port, To Loader Valve KPriority ValveSteering
05
BSpool Land Notches FSpool IHigh Pressure Cylinder Bottomed, Loader
18
CPlug G"CF" Port, To Steering JMedium Pressure Activated
DSpring Valve
With steering turned fully against stop, maximum into loader valve for boom and bucket operation from
steering system pressure (I) is created, which is pump EF port. Priority flow and pressure is still given to the
standby pressure. The spool (F) is shifted to the right steering valve through the CF port (G).
as shown. Notches on spool land (B) allow limited flow
TX,902505,BS152 1903MAR933/3

022602
PN=746
Theory of Operation
Accumulator OperationBrake (S.N.

872256)
NOTE: Brake accumulator is not repairable and is

serviced as a complete unit.
F
The brake system uses one accumulator. The
accumulator is used to store pressurized oil for reserve
brake application. The top side of accumulator is
pre-charge with dry nitrogen gas (B) through valve (F).
When hydraulic system oil (A) pressure exceeds
precharge pressure (B), oil flows through inlet port (C),
past check valve (D), and into the accumulator. G
If hydraulic system pressure (A) decreases, check valve

(D) closes and traps oil in the accumulator. When the
function is activated, oil flows out outlet port (H) to valve.
E
The thermal relief valve (G) protects the system from high
pressure when the temperature changes. When pressure
in the accumulator exceeds the pressure setting of D
thermal relief valve (G), the valve opens and releases oil
to the inlet port (C).
AHigh Pressure Oil

BGas Pressure
CInlet Port 9025
DCheck Valve 05
EPiston
D 19
FGas Valve G
GThermal Relief Valve C
UN07APR98
HOutlet Port
A
B H
T94230
T94230
TX,902505,BS209 1903MAR931/1

022602
PN=747
Theory of Operation
Accumulator OperationBrake (S.N. 872329 )
1904JAN99
T119238
9025
05
20
AInlet Check Valve COutlet EBrake Circuit Pressure GBrake Accumulator
BPiston DInlet FPrecharge Pressure
NOTE: Brake accumulators are not repairable and are If pump flow stops, the inlet check valve will close
serviced as a complete unit. against inlet fitting which is machined to provide a
check valve seat, keeping the accumulator charged.
The brake system uses two accumulators. They are The accumulator will remain pressurized until the
used to store pressurized oil for reserve brake brakes are applied. The volume of the accumulator will
application. The top of the accumulator is charged with allow several brake applications in the event of a loss
dry nitrogen gas valve. When the hydraulic system of brake pump flow.
pressure exceeds the charge pressure, oil flows
through the inlet (D) and inlet check valve (A). The
piston (B) moves upward until gas pressure is equal to
hydraulic circuit pressure.
TX,9025,ME327 1928AUG961/1

022602
PN=748
Theory of Operation
9025
05
21

022602
PN=749
Theory of Operation
Steering Valve Operation
A NEUTRAL
B STEERING
CYLINDER
D GEROTOR
LOAD SENSE
PORT TO
PRIORITY
VALVE
C
J SPOOL I SLEEVE
9025
05
22
E INLET CHECK
H RETURN VALVE
RETURN H
K STEERING
SHAFT F FROM PRIORITY
VALVE
L R
D G MANUAL STEER
CHECK VALVE
G
H
E
L SYSTEM PRESSURE OIL
C
1915JAN98
F
M WORK PRESSURE OIL
T LS P
N TRAPPED OIL
O RETURN PRESURE OIL
T7849AB
TXC7849AB P STEERING VALVE OPERATION

022602
PN=750
Theory of Operation
ANeutral FPressure from Priority ISleeve MWork Pressure Oil

BSteering Cylinder Valve JSpool NTrapped Oil
CLoad Sense Port GManual Steer Check Valve KSteering Shaft OReturn Pressure Oil
DGerotor HReturn LSystem Pressure Oil PSteering Valve Operation
EInlet Check Valve
The steering valve (P) is a closed center valve that the sleeve, until the sleeve stops the flow to the
consists of a rotary spool (J) inside a sleeve (I) within gerotor. At this point, the valve is back in the neutral
a housing. When steering wheel is not moving, the position and will remain there until the steering wheel
valve is in the neutral (A) position. In neutral, the spool is moved again.
and sleeve are aligned so that oil flow through the
valve is blocked. The steering cylinder (B) is held The steering valve has a variable steering rate which
stationary by trapped oil (N) in the left and right is proportional to the speed the steering wheel is
workports. rotated. A variable orifice bypasses oil around the
gerotor. Turning the steering wheel slowly takes
When the steering valve is turned to the right or left, approximately six turns (variable orifice small)
the spool rotates relative to the sleeve, and opens stop-to-stop versus three turns (variable orifice large)
passages which allows pressure oil from priority valve when turning the steering wheel quickly.
oil (F) to flow through the spool and sleeve assembly.
Work pressure oil (M) flows to gerotor (D) causing the An inlet check valve (E) prevents oil from returning
gerotor gear to rotate. Oil flow from the gerotor flows through the steering unit, when pressure on the
back into the valve where it is directed out the right or cylinder side is greater than on the inlet side. This
left workport to the respective ends of the steering prevents steering wheel kickback.
cylinder.
If there is no power to supply pressure oil (L) to the
Return oil (O) flows back in through the right or left steering valve, the unit can be steered manually. If no
workport through the spool and sleeve assembly to pressure oil is available, there is a direct mechanical
return circuit (H). The load-sensing orifice is located connection through the drive shaft to the gerotor gear 9025
between the sleeve and the gerotor. This orifice feeds assembly (D). As the gerotor is turned it pumps oil to 05
the load-sensing circuit between the steering valve and the steering cylinder. Return oil from the cylinder is 23
the priority valve through the LS-port (C). drawn through a check valve (G) between inlet and
outlet ports to provide oil for manual steering
When the rotation of the steering wheel shaft (K) operation. Thus the unit can be steered manually until
stops, the gerotor (D) gear continues to move, turning the unit is brought to a stop.
TX,902505,BS155 1903MAR932/2

022602
PN=751
Theory of Operation
Loader Circuit Relief and Anti-Cavitation Valve Operation
E
N
H I
D G
9025 A
05 L
24 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 faster than oil can flow though orifice causing pressure
port (M) flows through orifice (L) into the area behind oil (B) to decrease. Then high pressure oil pushes the
poppet (K). With pressure equal on both sides of poppet off its seat releasing oil through return port (G)
poppet, spring force holds poppet (K) closed and stops to return passage of valve.
flow through return port (G).
During anti-cavitation operation (F) the pressure in
During relief operation (D) when pressure in the circuit return port is greater than pressure in work port. The
increases above relief valve setting, high pressure oil difference in pressure pushes collar (H) against snap
(A) pushes pilot valve (J) off its seat. Low pressure oil ring (N) pulling the poppet off its seat. Oil then flows
(B) behind the poppet flows out return passage (I) from return port into work port to prevent cavitation.
TX,9025,BG218 1902JAN971/1

022602
PN=752
Theory of Operation
Loader Bucket Valve Section Operation
E F
D D
C
A
J
B G
I H
N C
9025
05
25
UN20FEB97
I
L K
G J D H
T6298BM
T6298BM
Loader Bucket Valve in Bucket Rollback Position
AHigh Pressure Oil DReturn Passage HInlet Passage KBucket Dump Position
BCharge Pressure Oil EBucket Dump Work Port ILift Check LCheck Valve
(Return to Charge Circuit) FBucket Rollback Work Port JCircuit Relief Valve With MBucket Cylinder
CReturn-To-Dig GCircuit Relief Valve Anti-Cavitation NBucket Rollback Position
Electromagnet
The bucket valve is a three-position, four-way, When bucket dump function is activated and pressure
spool-type valve. It contains a lift check (J) and two in circuit is less than charge pressure, oil flows from
circuit relief valves. Relief valve (K) also contains an return passage (E) past anti-cavitation valve (K) to the
anti-cavitation valve. bucket dump circuit (F).

022602
PN=753
Theory of Operation
F G
E E
D
A
K
B
H
C
UN20FEB97
J I
T6298BN
T6298BN
Loader Bucket Valve Shown in Neutral Position

9025
05
AHigh Pressure Oil DReturn-To-Dig GBucket Rollback Work Port JLift Check
26
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 valve is equipped with a return-to-dig. When rollback position. When the bucket rolls back to the dig
loader control lever is moved to the bucket rollback position, a mechanical linkage opens the return-to-dig
position, a plate fastened to end of valve spool, switch, which de-energizes electromagnet (D) letting
contacts an electromagnet (D). If the bucket is in dump the spool centering spring move the spool to neutral
position, the return-to-dig switch is closed which position.
energizes the electromagnet and holds spool in the
TX,902505,BS228 1903MAR932/2

022602
PN=754
Theory of Operation
9025
05
27

022602
PN=755
Theory of Operation
Loader Boom Valve Section Operation
D E
F F
L I
A
B
K J
C
N
P
9025
05
28
UN20FEB97
L
M O Q
N
F J
T6298BG
T6298BG
Loader Boom Valve Shown in Neutral (SN812257)
AHigh Pressure Oil EBoom Lower Work Port JInlet Passage NBoom Cylinders
BTrapped Oil FReturn Passage KLift Check OBoom Float Position
CCharge Pressure Oil GLeakage Return Passage LAnti-Cavitation Valve PBoom Lower Position
(Return to Charge Circuit) HBoom Spool MCap With Detent QBoom Raise Position
DBoom Raise Work Port ICircuit Plug
The boom valve (SN812257) is a four-position, causing function drift. Leakage flows from the inlet
four-way spool type valve. The spool (H) has grooves passage, through the leakage return passage, into the
in both ends to meter oil through the valve to prevent return passage (F), then out of control valve to charge
abrupt starts and stops. The boom valve contains a lift circuit.
check (K) and an anti-cavitation valve (L).
Valve spool can be metered to restrict oil flow to the
A leakage return passage (G) is used to prevent cylinder.
leakage from the inlet passage to boom raise circuit

022602
PN=756
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.
9025
05
29

022602
PN=757
Theory of Operation
D E
F
F
G
H
M
A
L I
B
C K J
P Q N
9025
UN06MAR97
05
30
I L M O K
N
F J
T105845
T105845
Boom Valve Shown in Neutral (SN 812258 )
AHigh Pressure Oil EBoom Lower Work Port JInlet Passage NBoom Cylinders
BTrapped Oil FReturn Passage KLift Check OBoom Float Position
CCharge Pressure Oil GLeakage Return Passage LAnti-Cavitation Valve PBoom Lower Position
(Return to Charge Circuit) HBoom Spool MCap With Detent QBoom Raise Position
DBoom Raise Work Port IBoom Head Circuit Relief
Valve
The boom valve for (SN 812258 ) uses a relief valve causing function drift. Leakage flows from the inlet
in the head end circuit. The spool (H) has grooves in passage, through the leakage return passage, into the
both ends to meter oil through the valve to prevent return passage (F), then out of control valve to charge
abrupt starts and stops. The boom valve contains a lift circuit.
check (K) and an anti-cavitation valve (L).
Valve spool can be metered to restrict oil flow to the
A leakage return passage (G) is used to prevent cylinder.
leakage from the inlet passage to boom raise circuit

022602
PN=758
Theory of Operation
When spool (H) is moved to activate a function, oil The relief valve (I) protects the head end of the boom
flows from functional inlet passage (J), past lift check circuit for pressures exceeding the relief valve setting.
(K) and spool (H), out the work port to the cylinders.
Return oil from the cylinders flows into the other work
port, past the spool, into the return passage (F), then
out of control valve to charge circuit.
TX,9025,BG219 1902JAN974/5
D E
C F F
G
9025
05
31
N M
L H
UN20FEB97
B
K J I
T6298BH
T6298BH
Boom Valve Shown in Float
AHigh Pressure Oil EBoom Lower Work Port HRelief Valve (SN 812258 ) LPlug with Anti-Cavitation
BCharge Pressure Oil FReturn Passage IInlet Passage MDetent Balls (4 used)
(Return To Charge Circuit) GSpool JLift Check NDetent Spring
CDetent Housing HCircuit Plug (SN 812257) KFloat Oil Passage (Compressed)
DBoom Raise Work Port
The boom float function operates the same for all are open to return passage (F) connected by float
710D machines. When spool (G) is moved to the passage (K) allowing oil to flow in and out both ends of
boom float (detent) position, both work ports (D and E) cylinders.
TX,9025,BG219 1902JAN975/5

022602
PN=759
Theory of Operation
Loader Auxiliary Valve Section Operation
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
32 Valve Shown in Neutral Position
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).
Continued on next page TX,902505,BR122 1924MAR931/2

022602
PN=760
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
APressure Passage CReturn Passage EHead End Work Port GCharge Pressure Oil 05
BLift Check DRod End Work Port FHigh Pressure Oil 33
When the auxiliary valve is moved to the extend through rod end work port (D) to return passage. Oil in
position, oil flows from pressure passage (A) by lift the return passage is sent to main hydraulic filter
check (B) out head end work port (E) to cylinder head where it combines with other return oil and becomes
end. Oil from rod end of cylinder flows back to valve charge oil for main pump.
TX,902505,BR122 1924MAR932/2

022602
PN=761
Theory of Operation
Backhoe Circuit Relief and Anti-Cavitation Valve OperationGresen
J K
L
D
I
O
9025
A
H
05 B
34
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 through orifice causing pressure to decrease. Then
port (I) flows through orifice (N) into the area behind high pressure oil pushes the poppet off its seat
poppet (H). With pressure equal on both sides of releasing oil through return port (G) to return passage
poppet, spring force holds poppet (H) closed and stops of valve.
flow through return port (G).
During anti-cavitation operation (E), the pressure in
During relief operation (D) when high pressure oil (A) return port is greater than pressure in work port. The
in the head end work port circuit increases above relief difference in pressure pushes collar (J) against snap
valve setting, high pressure oil pushes pilot valve (L) ring (K) pulling the poppet off its seat. Oil then flows
off its seat. Low pressure oil (B) behind the poppet from return port into work port to prevent cavitation.
flows out return passage (M) faster than oil can flow
27T,9025,M78 1924MAR931/1

022602
PN=762
Theory of Operation
Circuit Relief Valve with Anti-CavitationHusco
I RETURN PASSAGE F
ANTI-CAVITATION
POPPET F
C CAVITY
H
WORK
PORT
9025
05
A 35
1903JUN98
ORIFICE B RELIEF D PRESSURE OIL
POPPET
E CHARGE PRESSURE OIL
T115031
T115031 G CIRCUIT RELIEF VALVE WITH ANTI-CAVITATION
AOrifice DPressure Oil GCircuit Relief Valve with HWork Port

BRelief Poppet ECharge Pressure Oil Anti-Cavitation IReturn Passage
CCavity FAnti-Cavitation Poppet
The relief is direct acting, non adjustable and has pressure oil overcomes relief poppet (B) pressure
anti-cavitation operation. In normal operation, pressure setting and opens a path to return passage of valve (I).
oil less than relief valve setting flows through orifice During anti-cavitation operation, the pressure in the
(A) into cavity (C) behind relief valve poppet. Pressure work port (H) is less than pressure in return passage
oil and spring in cavity hold the anti-cavitation poppet (I). The pressure difference pushes the anti-cavitation
(F) closed because effective area on the spring side is poppet (F) off the seat allowing oil to flow from the
greater than on work port side (H). In relief operation, return passage to work port to prevent cavitation.
CED,TX03768,8487 1924APR981/1

022602
PN=763
Theory of Operation
Circuit Relief Valve without Anti-CavitationHusco
D
MAIN POPPET
A
E
9025
05 WORK PORT F RETURN PASSAGE
36
1903JUN98
B HIGH PRESSURE OIL
C CHARGE PRESSURE OIL
T115029
T115029 D CIRCUIT RELIEF VALVE WITHOUT ANTI-CAVITATION
AMain Poppet CCharge Pressure Oil EWork Port FReturn Passage

BPressure Oil DCircuit Relief Valve without
Anti-Cavitation
The relief is direct acting, screw adjustable and does overcomes main poppet (A) pressure setting and oil
not have anti-cavitation operation. The pressure set flows from the pressurized work port (E) to return
point is adjustable by turning the adjustment screw at passage of valve (F).
the end of the relief. In relief operation, pressure oil
CED,TX03768,8488 1924APR981/1

022602
PN=764
Theory of Operation
9025
05
37

022602
PN=765
Theory of Operation
Backhoe Swing Valve Operation-Swing Left PositionHusco
I C
F G
R S Q C
SWING LEFT SWING RIGHT

WORK PORT D LIFT E
WORK PORT
H BRIDGE I CHECK
9025 PASSAGE CIRCUIT RELIEF
05 CIRCUIT RELIEF WITH ANTI-
38 C WITH ANTI- CAVITATION
CAVITATION C
SPOOL N
RETURN G J RETURN METERING

PASSAGE
K BRIDGE METERING
RETURN J K L F M BRIDGE BLEED PASSAGE
METERING BRIDGE INLET INLET
1903JUN98
METERING METERING PRESSURE

A HIGH PRESSURE OIL
B CHARGE PRESSURE OIL
T115025
T115025
O BACKHOE SWING SECTION-SWING LEFT POSITION

022602
PN=766
Theory of Operation
AHigh Pressure Oil FInlet Passage LInlet Metering PSwing Cylinders (2 used)
BCharge Pressure Oil GReturn Oil MBridge Bleed Passage QSwing Right
CCircuit Relief Valve with HBridge Passage NSpool RSwing Left
Anti-cavitation (2 used) ILift Check OBackhoe Swing SNeutral Position
DSwing Left Work Port JReturn metering Section-Swing Left
ESwing Right Work Port KBridge Metering Position
The swing section is a three-position, four-way, closed activate a function, oil flows from the inlet passage (F),
center, spool-type valve. The valve contains two circuit through holes in spool and inlet metering notches (L)
relief valves with anti-cavitation (C) and a lift check (I). and lift check (I), into the bridge passage (H), past
The valve section contains a bridge bleed (M) to bleed bridge metering notches (K) and out work port (D or E)
bridge passage (H) to the return passage (G) when to the cylinders (P). Return oil from the cylinders flows
spool (N) is in the neutral position (S) to prevent inlet into the other work port, through holes in spool and
pressure (F) from leaking to either work port (D or E) return metering notches (J), into the return passage
causing function drift. When the spool is moved to (G), then out of the control valve to the charge circuit.
CED,TX03768,8493 1927APR982/2
9025
05
39

022602
PN=767
Theory of Operation
Backhoe Bucket Valve OperationBucket Curl PositionHusco
J C
H
G R S Q D
BUCKET DUMP
BUCKET CURL F E WORK PORT
WORK PORT J LIFT
I BRIDGE
PASSAGE CHECK
9025 CIRCUIT RELIEF
CIRCUIT RELIEF
05 WITHOUT ANTI-
D WITH ANTI- CAVITATION
40 CAVITATION
C
SPOOL O
K RETURN METERING
RETURN H L BRIDGE METERING
PASSAGE
L T BRIDGE BLEED PASSAGE
M INLET G INLET
K BRIDGE METERING
METERING PRESSURE
RETURN
METERING
1903JUN98
A HIGH PRESSURE OIL

T115026
T115026 P BACKHOE BUCKET SECTION-BUCKET CURL POSITION

022602
PN=768
Theory of Operation
A High Pressure Oil EBucket Dump Workport KReturn metering QBucket Dump
BCharge Pressure Oil FBucket Curl Workport LBridge Metering RBucket Curl
CCircuit Relief Valve without GInlet Pressure MInlet Metering SNeutral Position
Anti-cavitation HReturn Oil NBridge Bleed Passage TBucket Cylinder
DCircuit Relief Valve with IBridge Passage OSpool
Anti-cavitation JLift Check PBackhoe Bucket
Section-Bucket Curl
Position
The bucket section is a three-position, four-way, closed causing function drift. When the spool is moved to
center, spool-type valve. The valve contains one circuit activate a function, oil flows from the inlet passage (G),
relief valve with anti-cavitation (D) in the bucket-curl through holes in spool and inlet metering notches (M)
position, one circuit relief valve without anti-cavitation and lift check (J), into the bridge passage (I), past
(C) in the bucket-dump position and a lift check (I). bridge metering notches (L) and out work port (E or F)
The valve section contains a bridge bleed (N) to bleed to the cylinder (T). Return oil from the cylinder flows
bridge passage (I) to the return passage (H) when into the other work port, through return metering
spool (O) is in the neutral position (S) to prevent inlet notches (K), into the return passage (H), then out of
pressure (G) from leaking to either work port (E or F) the control valve to the charge circuit.
CED,TX03768,8491 1927APR982/2
9025
05
41

022602
PN=769
Theory of Operation
Backhoe Boom Valve OperationHusco
K D
H S T R I E
BOOM LOWER
WORK PORT F LIFT G BOOM RAISE
K WORK PORT
J BRIDGE CHECK
PASSAGE
CIRCUIT RELIEF
CIRCUIT RELIEF
9025 WITH ANTI-
05
E WITH ANTI- CAVITATION
42
CAVITATION
D
SPOOL P
RETURN L L RETURN METERING

METERING
N BRIDGE METERING
RETURN I O BRIDGE BLEED PASSAGE
PASSAGE M INLET H
N
METERING INLET
BRIDGE PRESSURE
METERING A HIGH PRESSURE OIL
1903JUN98

C TRAPPED OIL
T115024
T115024 Q BACKHOE BOOM SECTION-BOOM NEUTRAL POSITION

022602
PN=770
Theory of Operation
AHigh Pressure Oil FBoom Lower Workport LReturn metering RBoom Raise
BCharge Pressure Oil GBoom Raise Workport MInlet Metering SBoom Lower
CTrapped Oil HInlet Pressure NBridge Metering TNeutral Position
DCircuit Relief Valve without IReturn Oil OBridge Bleed Passage UBoom Cylinder
Anti-cavitation JBridge Passage PSpool
ECircuit Relief Valve with KLift Check QBackhoe Boom
Anti-cavitation Section-Boom Neutral
Position
The boom section is a three-position, four-way, closed causing function drift. When the spool is moved to
center, spool-type valve. The valve contains one circuit activate a function, oil flows from the inlet passage (H),
relief valve with anti-cavitation (E) in the boom-lower through holes in spool and inlet metering notches (M)
position, one circuit relief valve without anti-cavitation and lift check (K), into the bridge passage (J), past
(D) in the boom-raise position and a lift check (K). The bridge metering notches (N) and out work port (F or G)
valve section contains a bridge bleed (O) to bleed to the cylinder (U). Return oil from the cylinder flows
bridge passage (J) to the return passage (I) when into the other work port, through return metering
spool (P) is in the neutral position (T) to prevent inlet notches (L), into the return passage (I), then out of the
pressure (H) from leaking to either work port (F or G) control valve to the charge circuit.
CED,TX03768,8489 1927APR982/2
9025
05
43

022602
PN=771
Theory of Operation
Backhoe Valve Crowd OperationCrowd In PositionHusco
J C
G R T Q H D
CROWD OUT CROWD IN

WORK PORT E LIFT F WORK PORT
9025
I BRIDGE J CHECK
05 CIRCUIT RELIEF PASSAGE
44 WITHOUT ANTI- CIRCUIT RELIEF
CAVITATION C WITH ANTI-
D CAVITATION
SPOOL O
RETURN K K RETURN METERING

METERING L BRIDGE METERING
H L N BRIDGE BLEED PASSAGE
RETURN M INLET G
PASSAGE BRIDGE
METERING METERING INLET
1903JUN98
PRESSURE
A HIGH PRESSURE OIL
T115027
T115027 P BACKHOE CROWD SECTION-CROWD IN POSITION

022602
PN=772
Theory of Operation
AHigh Pressure Oil ECrowd Out Workport KReturn metering QCrowd Out
BCharge Pressure Oil FCrowd In Workport LBridge Metering RCrowd In
CCircuit Relief Valve with GInlet Pressure MInlet Metering SCrowd Cylinder
Anti-cavitation HReturn Oil NBridge Bleed Passage TNeutral Position
DCircuit Relief Valve without IBridge Passage OSpool
Anti-cavitation JLift Check PBackhoe Crowd
Section-Crowd In Position
The crowd section is a three-position, four-way, closed causing function drift. When the spool is moved to
center, spool-type valve. The valve contains one circuit activate a function, oil flows from the inlet passage (G),
relief valve with anti-cavitation (C) in the crowd-in through holes in spool and inlet metering notches (M)
position, one circuit relief valve without anti-cavitation and lift check (J), into the bridge passage (I), past
(D) in the crowd-out position and a lift check (I). The bridge metering notches (L) and out work port (E or F)
valve section contains a bridge bleed (N) to bleed to the cylinder (S). Return oil from the cylinders flows
bridge passage (I) to the return passage (H) when into the other work port, through return metering
spool (O) is in the neutral position (T) to prevent inlet notches (K), into the return passage (H), then out of
pressure (G) from leaking to either work port (E or F) the control valve to the charge circuit.
CED,TX03768,8490 1927APR982/2
9025
05
45

022602
PN=773
Theory of Operation
Backhoe Valve Auxiliary OperationExtend OperationHusco
F G
R S Q
ROD END (RETRACT)

BASE END (EXTEND) D E WORK PORT
LIFT
WORK PORT BRIDGE I CHECK
H
PASSAGE
9025
05 SHUT-OFF SHUT-OFF
46 PLUG C C
PLUG
SPOOL N
J RETURN METERING
RETURN G
PASSAGE K BRIDGE METERING
RETURN J L F M BRIDGE BLEED PASSAGE

METERING K
INLET INLET
BRIDGE METERING PRESSURE
1903JUN98
METERING A HIGH PRESSURE OIL

T115028
T115028 O BACKHOE AUXILIARY SECTION-EXTEND POSITION

022602
PN=774
Theory of Operation
AHigh Pressure Oil FInlet Pressure KBridge Metering PCylinder

BCharge Pressure Oil GReturn Oil LInlet Metering QRetract Position
CShut-off Plug (two used) HBridge Passage MBridge Bleed Passage RExtend Position
DBase End (extend) ILift Check NSpool SNeutral Position
Workport JReturn metering OBackhoe auxiliary
ERod End (retract) Workport Section-extend Position
The auxiliary section is a three-position, four-way, and lift check (I), into the bridge passage (H), past
closed center, spool-type valve. The valve contains bridge metering notches (K) and out work port (D or E)
two shut-off plugs (C) in place of relief valves and a lift to the cylinder (P). Return oil from the cylinder flows
check (I). Shut-off plugs may be replaced with circuit into the other work port, through return metering
relief valves appropriate to attachment being installed. notches (J), into the return passage (G), then out of
The valve section contains a bridge bleed (M) to bleed the control valve to the charge circuit. Two auxiliary
bridge passage (H) to the return passage (G) when valve sections can be added to the backhoe valve for
spool (N) is in the neutral position (S) to prevent inlet a total of six sections. Both are the same in design
pressure (F) from leaking to either work port (D or E) and operation. The fifth section is normally used for
causing function drift. When the spool is moved to extendible dipper operation. The sixth section can be
activate a function, oil flows from the inlet passage (F), used to operate accessory hydraulic equipment.
through holes in spool and inlet metering notches (L)
CED,TX03768,8494 1927APR982/2
9025
05
47

022602
PN=775
Theory of Operation
Backhoe Solenoid Controlled Auxiliary ValveStanley
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
48
ASolenoid Cartridge DThree Position Orifice GHigh Pressure Oil JSolenoid Controlled
BRelief Cartridge EOil Passage HReduced Pressure Oil Auxiliary Valve Operation
CSpring FSpool IReturn Pressure Oil
The Auxiliary Hydraulic Valve is a flow control valve The reduced pressure (H) that results from oil passing
that is mounted on the RH rear side of the backhoe through the three position orifice to the regulated port
valve mounting plate. Operation of the valve is is routed through passage (E) past the energized
controlled by an electrical solenoid. A pressure solenoid cartridge (A) to the spring (C) end of spool
compensated, variable volume flow rate is provided to (F). Main pressure oil "in" flows through the radial
meet specific attachment requirements. holes to the opposite end of the spool. Consequently
the position of the spool is maintained in a balanced
High pressure oil (G) flow is routed to the auxiliary position to provide the "regulated" flow rate that was
valve, which is connected to the main hydraulic system selected.
at the inlet to the backhoe valve. When the console
mounted control switch is moved to the "on" position, The relief cartridge (B) protects the regulated circuit by
electrical current is provided to the foot pedal. Pressing dumping excess pressure oil at the spring (C) end of
the foot pedal energizes solenoid cartridge (A) and oil the spool (F) to tank. Reduced pressure assisting the
flow "in" is diverted at a controlled rate past the spool spring causes the spool to shift toward the spring and
(F) and three position orifice (D) to the regulated port the flow of oil that is being routed to the regulated
for operation of the accessory attachment. circuit is decreased.

022602
PN=776
Theory of Operation
The regulated flow can be turned off by de-energizing (G) forces the spool to move against the spring which
the solenoid cartridge (A). This allows oil in the spring blocks oil flow through the valve.
chamber to be released to tank and pressure inlet oil
TX,902505,BS184 1903MAR932/2
9025
05
49

022602
PN=777
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
D K D C N
F
T8381BB
9025 TXC8381BB P VALVE IN SWING RIGHT POSITION
05
50 Valve in Swing Right Position
AHigh Pressure Oil ESwing Right Work Port JSpool NSwing Left
BCharge Pressure Oil FLift Check KReturn passage OMetering Passages
(Return To Charge Circuit) GSwing Left Work Port LSwing Cylinders (2 used) PBackhoe Swing
CSwing Right HFunctional Inlet Passage MMetering Grooves Valve-Swing Right Position
DCircuit Relief Valve with IAuxiliary Passage
Anti-cavitation Valve (2
used)
The swing valve is a three-position, four-way When the spool is moved to activate a function, oil
spool-type valve. The valve contains two circuit relief flows from the functional inlet passage (H), past the lift
valves with anti-cavitation (D). check (F) and spool (J), out the work port to the
cylinders. Return oil from the cylinders flows into the
The spool (J) has grooves on both ends to meter oil other work port, past the spool, into the return passage
flow through the valve to prevent abrupt starts and (K), then out of control valve to charge circuit.
stops. The return oil metering grooves (M) are longer
to give more control of function speed.
Radial metering passages (O) are used to reduce lever

effort.
TX,902505,BS157 1920DEC941/1

022602
PN=778
Theory of Operation
9025
05
51

022602
PN=779
Theory of Operation
Backhoe Boom Valve OperationGresen
E H
G
F
D I
J Q P Q K J
L
D
A
9025 M
B
UN07FEB97
05
52 C P
I N O
T88938
T88938
G
Valve Shown in Neutral Position
AHigh Pressure Oil FFunctional Inlet Passage JReturn Passage NBoom Down
BCharge Pressure Oil GLift Check KSpool OBoom Cylinder
CTrapped Oil HBoom Lower Work Port LAuxiliary Passage PMetering Grooves
DCircuit Relief Valve ICircuit Relief Valve with MBoom Up QPressure Seal Passage
EBoom Raise Work Port Anti-Cavitation Valve
The spool (K) has grooves on both ends to "meter" oil Pressure seal passages (Q) are used to prevent
flow through valve to prevent abrupt starts and stops. leakage from the boom raise circuit to return passage
The boom down return oil metering grooves (P) are (J) causing function drift. Oil flows from the inlet
longer to give more control of boom down speed. passage, through pressure seal passage to the land
between boom raise work port (E) passage and return
The boom valve is a three-position, four-way passage to form a high pressure seal between land
spool-type valve. The valve contains a lift check (G), a and housing.
circuit relief valve (D) in boom rise circuit, and a circuit
relief valve with anti-cavitation valve (I) in boom lower
circuit.
Continued on next page 27T,9025,M74 1906APR941/2

022602
PN=780
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
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
9025
05
A HIGH PRESSURE OIL
53
1915JAN98
B CHARGE PRESSURE OIL M
C TRAPPED OIL O D L G
T8381BA
TXC8381BA
P BACKHOE BUCKET VALVE - LOAD POSITION
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 backhoe bucket valve is a three-position, four-way When the spool (J) is moved to activate a function, oil
spool-type valve. The valve contains a circuit relief flows from the functional inlet passage (F), past the lift
valve with anti-cavitation valve (O) in the bucket load check (G) and spool out the work port to the cylinder.
circuit and circuit relief valve (D) in the bucket dump Return oil from the cylinder flows into the other work
circuit. port, past the spool, into the return passage (I), then
out of control valve to charge circuit.
The spool (J) has grooves on both ends to meter oil
flow through the valve to prevent abrupt starts and
stops.
TX,902505,BS156 1920DEC941/1

022602
PN=781
Theory of Operation
Backhoe Crowd Valve OperationGresen
E H
G
F
D I
K J
J L
O
A
9025 M
B
UN07FEB97
05
54 C
D N
I G
T88940
T88940
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 backhoe crowd valve is a three-position, four-way When the spool is moved to activate a function, oil
spool-type valve. The valve contains a circuit relief flows from the functional inlet passage (F) past the lift
valve with anti-cavitation valve (D) in the crowd-in check (G) and spool (K), out the work port to the
circuit and circuit relief valve (I) in the crowd-out circuit. cylinder. Return oil from the cylinder flows into the
other work port, past the spool, into the return passage
The spool (K) has grooves on both ends to meter oil (J), then out of control valve to charge circuit.
flow through the valve to prevent abrupt starts and
stops.
27T,9025,M75 1906APR941/1

022602
PN=782
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
TXC7419BM
H BACKHOE AUXILIARY VALVE EXTEND 9025
OIL
05
55
AReturn Passage CLift Check EHead End Work Port GCharge Pressure Oil
BRod End Work Port DPressure Passage FHigh Pressure Oil
The auxiliary valve is a three-position, four-way port (B), past the spool into the return passage (A),
spool-type valve. The valve has two plugs and no then out of the valve to charge circuit.
reliefs. Plugs may be replaced with reliefs appropriate
to attachment being installed. Two auxiliary valve sections can be added to the
backhoe valve for a total of six sections. Both are the
When the spool is moved to extend position, oil flows same in design and operation. The fifth section is
from the pressure passage (D) past the lift check (C) normally used for extendable dipper operation. The
and spool, out the head end work port to the cylinder. sixth section can be used to operate accessory
Return oil from the cylinder flows into the rod end work hydraulic equipment.
TX,902505,BS158 1903MAR931/1

022602
PN=783
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 changes.
When the valve is activated to lower a stabilizer, inlet When the stabilizer is in the full down position, high
oil (A) acts on the lockout plunger and lockout poppet temperatures can be generated by the forces working
(H). The inlet oil pushes the poppet off its seat and against the stabilizer. If the forces get too high, the
flows through work port (J) to head of cylinder. At the lockout plunger would not push the poppet off its seat
same time, the lockout plunger is pushed against the to raise the stabilizer.
other poppet, opening the return flow (B) from the
cylinder to the return passage (J).
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

022602
PN=784
Theory of Operation
Brake Pistons, Plates and Disks Operation (S.N. 872256)
A
B
1915JAN98
T7879AD
TXC7879AD
9025
05
57
ABrake Disk CBacking Plate DAnnular Brake Piston EOil From Brake Valve
BFinal Drive Sun Pinion
Brake piston (A), backing plate (C), and disk (B) are (not shown). Anti-rotation pin prevents rotation of
located on each side of the transmission case final backing plate. Annular brake piston (D) seats against
drive. axle housing and is held in place by anti-rotation pins.
Force applied to a brake pedal unseats the appropriate When brakes are applied, oil pressure in annular
brake valve sending pressure oil (E), in proportion to passage forces piston out. Brake disk is squeezing
force applied, to the connected brake pistons. The against backing plate which stops rotation of disk and
right brake pedal operates the brake on the right-hand sun pinion.
side and the left brake pedal operates the left side.
Locking the pedals together provides simultaneous When force is removed, oil flows from annular pistons
braking on both sides. back through the brake valve and returns to the
hydraulic reservoir.
Brake disk (A) is tanged to final drive sun pinion (B).
Backing plate (C) seats against final drive ring gear
TX,902505,BS197 1903MAR931/1

022602
PN=785
Theory of Operation
Brakes Released (S.N. 872256)
21
5
3
RWC20537
20
4
2
1
23
24
18
12
14
9025
13
05
12
22
58
19
9
22
17
11
13
13
8 15
16
10
6
UN20AUG98
7
16
RWC20537
Continued on next page TX,902505,BS198 1920DEC941/3

022602
PN=786
Theory of Operation
1Pressure Oil Inlet 8Prefill Chamber 14Brake Chamber 20Bleed Orifice (LS)
2Inlet Check Valve 9Equalizing Passage 15Pin 21Check Ball (LS)
3Piston (LS) 10Pressure/Return Passage 16Relief Valve Ball 22To Right And Left Brake
4Capped Port (LS) 11Make-Up Check Valve 17Spool Valve Pistons
5Shuttle Valve (LS) 12Orificed Check Valve 18Return To Sump 23Pressure Oil
6Orifice Ring 13Annular Pressure Passage 19Equalizing Valve Land 24Return (Pressure Free) Oil
7Brake Piston
NOTE: The brake valve has a load sense (LS) feature Brake chamber (14) is connected to sump by passage
which is not used for this machine. Load sense (10). Oil in prefill chamber (8) returns to sump by
port (4) is closed using a cap. passing through drilled holes in forward land of brake
piston (7) and between orifice ring (6) and second land
Pressure oil (1) from main hydraulic pump opens inlet of piston.
check valve (2) to reach annular passage (13). Inlet
check valve is only required during manual braking. Orificed equalizing valve lands (19) are closed trapping
oil in equalizing passage (9).
With brake piston and spool in released position,
annular pressure passage (13) is closed to brake
chamber (14).

9025
05
59

022602
PN=787
Theory of Operation
23 PRESSURE OIL
24 RETURN OIL
18
22
1
20
2
21
3
13
12
9025 11
14
05
5
60
9
16
19
6
8
1915JAN98
TXC7879AE
T7879AE
Brake Released
TX,902505,BS198 1920DEC943/3

022602
PN=788
Theory of Operation
9025
05
61

022602
PN=789
Theory of Operation
Brakes Engaging (S.N. 872328)
21
3
4
23 20
24 1 2
25
18
9025 14
05 22
62 12
12
9
13 19
22
17
11
15
13 8
13
16
UN11JUL00
6 10
RWC20540
7
16

022602
PN=790
Theory of Operation
1Pressure Oil Inlet 8Prefill Chamber 15Pin 21Check Ball (LS)

2Inlet Check Valve 9Equalizing Passage 16Relief Valve Ball 22To Right And Left Brake
3Piston (LS) 10Pressure/Return Passage 17Spool Valve Pistons
4Capped Port (LS) 11Make-Up Check Valve 18Return To Sump 23Pressure Oil
5Shuttle Valve (LS) 12Orificed Check Valve 19Equalizing Valve Land 24Return (Pressure Free) Oil
6Orifice Ring 13Annular Pressure Passage 20Bleed Orifice (LS) 25Low Pressure Oil
7Brake Piston 14Brake Chamber
NOTE: The brake valve has a load sense (LS) feature oil flows through spool valve, opens check valve (12)
which is not used for this machine. Load sense and is routed to annular brake piston at rear axle.
port (4) is closed using a cap.
Oil pressure on pin (15) unseats relief valve ball (16)
When brake pedal is depressed, piston (7) and spool providing passage to sump for oil trapped in prefill
valve (17) moves right closing off return at passage chamber.
(10). Equalizing valve land (19) opens to equalizing
passage (9). When both pedals are depressed, When pedal release begins, passage (10) closes to
equalization of pressure in chambers (14) occurs annular pressure passage (13) and orifice ring (6)
through passage (9). moves against forward land of piston, this opens prefill
chamber to sump (18). Brake chamber pressure (14)
Additional pedal travel aligns passage (10) in spool bleeds past shuttle valve (5), check ball (21) and bleed
valve with pressure oil annular passage (13). Pressure orifice (20) to sump.

9025
05
63

022602
PN=791
Theory of Operation
23 PRESSURE OIL
24 RETURN OIL
18
22
1
20
2
21
13
12
9025
05
64 11
14
16
17
9
19
6
8
1915JAN98
TXC7879AF
7
T7879AF
Brake Engaging
TX,902505,BS200 1920DEC943/3

022602
PN=792
Theory of Operation
9025
05
65

022602
PN=793
Theory of Operation
Manual BrakingPrefill (S.N. 872328)
21
5
3
RWC20539
20
4
2
1
23
24
18
12
9025
14
05
13
66
12
22
19
9
22
17
11
13
8 15
13
16
10
6
UN20AUG98
RWC20539
16
7

022602
PN=794
Theory of Operation
3Piston (LS 10Pressure/Return Passage 16Relief Valve Ball 22To Right And Left Brake
7Brake Piston
NOTE: The brake valve has a load sense (LS) feature When pedal is depressed, piston (7) and spool (17)
which is not used for this machine. Load sense move forward. Orifice ring (6) seats to rear closing
port (4) is closed using a cap. return passage. Oil trapped in pre-fill chamber (8)
forces make-up check valve (11) forward against
When main pump pressure is unavailable for braking, spring pressure. Oil from prefill chamber flows past
inlet check valve (2) prevents loss of oil from brake check valve (12) to differential to take up free play
circuit. between brake piston, disk and backing plate.
Check ball (21) remains seated preventing lose of oil

through sensing circuit.

9025
05
67

022602
PN=795
Theory of Operation
23 PRESSURE OIL
24 RETURN OIL
18
22
1
20
2
21
3
13
9025
12
05
68
11
14
16
19
6
8
1915JAN98
TXC7879AG
7
T7879AG
Manual BrakingPrefill
TX,902505,BS202 1920DEC943/3

022602
PN=796
Theory of Operation
9025
05
69

022602
PN=797
Theory of Operation
Manual Braking (Engaging) (S.N. 872328)
21
RWC20541
3
20
4
2
1
23
24
18
12
9025
14
05
70
13
22
12
19
9
22
17
11
13
8 15
13
16
6
UN20AUG98
10
16
RWC20541
7

022602
PN=798
Theory of Operation
3Piston (LS) 10Pressure/Return Passage 16Relief Valve Ball 22To Right And Left Brake
7Brake Piston
NOTE: The brake valve has a load sense (LS) feature If operator is unable to press pedal hard enough to
which is not used for this machine. Load sense reach relief valve setting, relief of prefill chamber is
port (4) is closed using a cap. accomplished as oil bleeds through end gap of orifice
ring (6). Pedal effort is transferred to smaller diameter
When pressure in prefill chamber (8) reaches relief of spool.
valve setting, ball (16) is unseated reducing pressure
in prefill chamber. As pressure drops in prefill When pedal is released, orifice ring seats against
chamber, make-up check valve (11) is seated by forward piston land opening sump passage to pre-fill
spring and oil pressure. As pedal moves further, chamber. Relief valve ball (16) reseats. Oil is drawn
pressure increases in brake chamber (14), sensing pin past orifice ring into prefill chamber from return line as
(15) fully opens valve ball (16) relieving pressure in piston retracts. Smaller orificed check valve (12) slows
prefill chamber to sump. return of oil from rear axle to allow pumping action to
fill chambers.
Further pedal travel now works against smaller
diameter of spool (17) producing higher pressure
required to apply brakes.
9025
05
71

022602
PN=799
Theory of Operation
23 PRESSURE OIL
24 PRESSURE OIL
18
22
1
20
2
21
13
12
9025
05
11
72
14
16
9
19
6
8
1915JAN98
7
TXC7879AH
T7879AH
Manual BrakingEngaging
TX,902505,BS204 1920DEC943/3

022602
PN=800
Theory of Operation
9025
05
73

022602
PN=801
Theory of Operation
Brake Pistons, Plates and Disks Operation (S.N. 872329 )
9025
05
74
1904FEB99
T117162
Continued on next page TX,05,SS3133 1916MAY961/2

022602
PN=802
Theory of Operation
ADisk (4 used) DFrom Brake Valve FAdjusting Screw HSun Gear Shaft
BPlate (4 used) EBrake Housing GHub IService Brake
CPiston
The rear axle assembly uses wet multi-disk brakes against the brake plates (B) and disks (A) which stops
which are self-adjusting to compensate for wear. The rotation of the sun gear shaft (H). When the brakes are
disks are splined to the sun gear shaft and the plates released the return oil flows back out the same port to
are splined to the rear axle housing. the brake valve.
When the service brakes are applied, the pressure oil

from the brake valve (D), forces the brake piston (C)
TX,05,SS3133 1916MAY962/2
9025
05
75

022602
PN=803
Theory of Operation
Brake Valve Operation (S.N. 872329 )
The brake system is hydraulic with no mechanical Two accumulators provide pressure oil for secondary
connection between the brake valve and the brake braking. A pressure switch will alert operator with light
pressure plates. It consist of two accumulators which and audible warning if pressure is below specification.
are sourced from system pressure oil from the
stabilizer valve. The brake valve is a full power valve When the brakes are engaged, the brake piston
with equalization. applies force on the brake disks and plates which are
connected to the final drive pinion shaft.
The brake valve is activated by two brake pedals that
allow individual or simultaneous operation of brake
pressure pistons that are located in the brake housing
of each axle.
TX,05,SS3131 1923JUL981/1
9025
05
76

022602
PN=804
Theory of Operation
9025
05
77

022602
PN=805
Theory of Operation
Brakes Released (S.N. 872329 )
12 19
14 17
9
8 22
8
UN07JAN99
11 16
20
13 10 15 21 18
T118962
T118962
9025
05
78
13 14 15 16 17 18
12 19
11 20
10 21
9
8 22
7
23
6
5 24
4 25
3 26
2 27
1 28
1911JAN99
29 HIGH PRESSURE OIL

30 RETURN OIL
T118980
T118980
LEFT 31 BRAKES RELEASED RIGHT

022602
PN=806
Theory of Operation
1Spring 9Left Port 17Orifice 24Retainer

2Retainer 10Check Ball 18Right Pressure Switch 25Spring
3Shim 11Left Pressure Switch Port Port 26Shims
4Spring 12Spool 19Spool 27Retainer
5Retainer 13Left Pressure Switch Port 20Right Pressue Port 28Spring
6Check Ball 14Orifice 21Check Ball 29High Pressure Oil
7Spring 15Brake Light Switch Port 22Right Brake Port 30Return Oil
8Tank Port 16Shuttle Tee Check Ball 23Spring 31Brakes Released
Oil pressure from the accumulators enters pressure moving through the valve. All other internal chambers
ports (11 & 20). Pressure switches connected to ports and brake ports (9 & 22) are connected to the
(13 & 18) sense pressure in each accumulator through reservoir via the tank port (8). The pedals are held in
the valve. Spools (12 & 19) block oil pressure from the neutral position by springs (7 & 23).
CED,TX03610,138 1919MAR992/2
9025
05
79

022602
PN=807
Theory of Operation
Brakes Engaging (S.N. 872329 )
12 19
14 17
9
22
8 8
UN16DEC98
11 16
20
13 10 15 21 18
T118979
T118979
9025
05
80
13 14 15 16 17 18
12 19
11 20
10 21
9
8 22
7
23
6
5 24
4 25
3 26
2 27
1911JAN99
1 28
30 LOW PRESSURE OIL
T118981
T118981
LEFT 32 BRAKES ENGAGED RIGHT 31 RETURN OIL

022602
PN=808
Theory of Operation
1Spring 10Check Ball 18Right Pressure Switch 25Spring

2Retainer 11Left Pressure Switch Port Port 26Shims
3Shim 12Spool 19Spool 27Retainer
4Spring 13Left Pressure Switch Port 20Right Pressue Port 28Spring
5Retainer 14Orifice 21Check Ball 29High Pressure Oil
6Check Ball 15Brake Light Switch Port 22Right Brake Port 30Low Pressure Oil
7Spring 16Shuttle Tee Check Ball 23Spring 31Return Oil
8Tank Port 17Orifice 24Retainer 32Brakes Engaged
9Left Port
Oil under pressure from accumulators enters pressure (21) closes and shuttle ball (16) moves to close off the
ports (11 & 20). Both pedals are depressed forcing lower right side pressure. The higher pressure from the
spools (12 & 19) to move through springs (1 & 4) and left spool (12) moves through orifice (17) to increase
(25 & 28) respectively. When the spools travel a short the right brake pressure to equal that of the left brake.
distance, the brake ports (9 & 22) become blocked to The maximum pressure that can be reached in the
tank and are then pressurized by oil moving through brakes is limited by the force of springs (1 & 28)
spools (12 & 19), through check balls (10 & 21), again regardless of higher accumulator pressures or pedal
through spools (12 & 19) and to brake ports (9 & 22). force. The maximum brake pressures are set by shims
Pressure modulation to each brake is regulated by (3 & 26) on retainers (2 & 27). The brake light switch
springs (25 & 28) for the right brake and (1 & 4) for the is connected to port (15) and will see the higher
left brake. If the right side spool (19) is regulating modulated brake pressure of either side.
pressure lower than the left side spool (12), check ball
CED,TX03610,139 1919MAR992/2
9025
05
81

022602
PN=809
Theory of Operation
Brake EngagingRight Side Only (S.N. 872329 )
12 19
14 17
9
22
8 8
UN16DEC98
11 16
20
13 10 15 21 18
T118978
T118978
9025
05
82
13 14 15 16 17 18
12 19
11 20
10 21
9
8 22
7
23
6
5 24
4 25
3 26
2 27
1 28
1911JAN99

30 LOW PRESSURE OIL
32 BRAKE ENGAGED
T118982
T118982 RIGHT
(RIGHT ONLY) 31 RETURN OIL
LEFT
Continued on next page CED,TX04577,834 1918DEC981/2

022602
PN=810
Theory of Operation
1Spring 10Check Ball 19Spool 27Retainer

2Retainer 11Left Pressure Switch Port 20Right Pressue Port 28Spring
3Shim 12Spool 21Check Ball 29High Pressure Oil
4Spring 13Left Pressure Switch Port 22Right Brake Port 30Low Pressure Oil
5Retainer 14Orifice 23Spring 31Return Oil
6Check Ball 15Brake Light Switch Port 24Retainer 32Brake Engaged (Right
7Spring 16Shuttle Tee Check Ball 25Spring Only)
8Tank Port 17Orifice 26Shims
9Left Port 18Right Pressure Switch
Port
Oil under pressure from the accumulators enters check ball (21), again through spool (19) and to the
pressure ports (11 & 20). The right pedal is depressed right brake port (22). Brake pressure is blocked from
forcing spool (19) to move through springs (28 & 25). entering the left brake by check ball (10), shuttle ball
Spool (12) remains in the neutral position blocking (16), and spool (12). Pressure modulation is regulated
accumulator pressure from moving through the valve by springs (25 & 28). The maximum pressure to the
and the left brake port (9) remains at tank pressure. right brake is limited by the force of spring (28)
When spool (19) travels a short distance, the right regardless of higher accumulator pressures or pedal
brake port (22) becomes blocked to tank and is force. The brake light switch connected to port (15) will
pressurized with oil moving through spool (19), through see the right brake pressure.
CED,TX04577,834 1918DEC982/2
9025
05
83

022602
PN=811
Theory of Operation
Parking Brake Operation (S.N. 872328)
L PARK BRAKE
DIFFERENTIAL
LOCK VALVE
DUST B SEALS
A
SEAL
C PISTON
9025
05
84
D ADJUSTING
SCREW
DISC K E LOCK NUT
J F COVER
PADS
I G
H
SHAFT SNAP RING
SPRING
WASHERS M RETURN PRESSURE OIL
1915JAN98
N HIGH PRESSURE OIL

O ENGAGEMENT
PRESSURE OIL
T8381BC
TXC8381BC P PARKING BRAKE

022602
PN=812
Theory of Operation
ADust Seal ELock Nut JPark Brake Pads MReturn Pressure Oil
BSeals FCover KPark Brake Disc NHigh Pressure Oil
CPiston GSnap Ring LPark Brake/Differential OEngagement Pressure Oil
DParking Brake Adjusting HSpring Washers Lock Valve PParking Brake
Screw IShaft
NOTE: For (S.N. 872329 ) see Section 9020 for and the return of oil to reservoir is blocked. This
operation and test procedures for the park causes the piston to move against the spring washers
brake. (H) which releases the force on the shaft (I) and the
park brake pads (J). As the pressure on the pads is
The parking brake (P) is spring applied and hydraulic released, the parking brake disc (K) is free to turn and
released. When the operator actuates the park brake the machine can move.
switch to the "on" position or shuts the machine off,
spring washers (H) force the piston (C) against the To release the parking brake following machine
shaft (I). This force causes the park brake pads (J) to shut-down with the switch in the off position, the switch
be compressed against the parking brake disc (K) must be cycled from "off" to "on" then back to "off"
which is attached to the axle input shaft. When the after the engine is started.
park brake is applied, engagement of the brake pads
with the brake disc prevents machine movement. If required, the parking brake can be manually
released to allow movement of the machine if the
When the operator moves the parking brake switch to engine cannot be started. Remove cover (F), loosen
the "off" position with the engine running, two lock nut (E) and turn out parking brake adjustment
solenoids that are located on the park brake/differential screw (D) until brake disc is released by the brake
lock valve (L) are energized simultaneously. Main pads. The adjusting screw must be turned back in to
hydraulic pressure oil (N) is routed to the piston (C) allow the parking brake to engage.
9025
05
85
TX,902505,BS185 1920DEC942/2

022602
PN=813
Theory of Operation
Differential Lock Operation (S.N. 872256)
DIFFERENTIAL DIFFERENTIAL PARK BRAKE/

CAPTURE SYSTEM
LOCK PISTON RETURN PASSAGE LOCK SOLENOID I DIFFERENTIAL
D K LOCK VALVE
H
E OIL SEAL
F OIL SEAL
J
PRESSURE
REDUCING VALVE
1915JAN98
A HIGH PRESSURE OIL
SEALING
G RINGS B ENGAGEMENT PRESSURE OIL
C RETURN OIL
T8381BD
9025
TXC8381BD L DIFFERENTIAL LOCK OPERATION
05
86
AHigh Pressure Oil EOil Seal HCapture System Return JPressure Reducing Valve
BEngagement Pressure Oil FOil Seal IPark Brake/Differential Lock KDifferential Lock Solenoid
CReturn Oil GSealing Rings Valve LDifferential Lock Operation
DDifferential Lock Piston
NOTE: For (S.N. 872329 ) see Section 9020 for Engagement of the differential lock occurs when the
operation and test procedures for the differential lock solenoid is energized. Oil is allowed to
differential lock. flow past the energized valve and engagement
pressure (B) is routed between internal sealing rings
The hydraulic differential lock is supplied with high (G) to move the differential lock piston (D).
pressure oil (A) by the main hydraulic system. A
pressure reducing valve (J) and a differential lock Oil that seeps past the sealing rings is contained by
solenoid valve (K) are located on the park the outer oil seals (E) and (F), and is return oil (C) that
brake/differential lock valve (I) to control oil pressure is routed to reservoir through the capture system
and flow required for engagement. return passage (H).
When the differential lock is not engaged, oil flow to Refer to CTM43 for additional details on differential
the differential lock piston (D) is blocked and the lock and axle assembly.
passage to the piston is open to return. Normal
differential action occurs when the differential lock is
not activated.
TX,902505,BS186 1920DEC941/1

022602
PN=814
Theory of Operation
9025
05
87

022602
PN=815
Theory of Operation
Park Brake Differential Lock Valve Operation (S.N. 872256)
D E
C B G
H
I
N O
P
L M
K
W
R Q
SERVICE BRAKES D P1-PORT

E WORK PORT
F P2-PORT
9025
05 P3-PORT C
"P1"
88
"SERVICE PARK BRAKE
PARK BRAKE" G SOLENOID
BRAKE "P3" "P2"
B SOLENOID
"SWITCH"
H PRESSURE
"DRAIN" REDUCING
VALVE
A
DIFFERENTIAL "PARK
LOCK BRK" "DIFF N RELIEF
SOLENOID LOCK" VALVE
"REG
TEST"
M I RETURN
L J DIFFERENTIAL TO DRAIN
DIFFERENTIAL LOCK WORK
LOCK TEST PARK BRAKE
PORT
PORT WORK PORT K
PARK BRAKE
PRESSURE S HIGH PRESSURE OIL
SENSING
1915JAN98
T REDUCED PRESSURE OIL

SWITCH
U RETURN OIL
T8381BE
TXC8381BE V PARK BRAKE/DIFFERENTIAL LOCK VALVE

022602
PN=816
Theory of Operation
ADifferential Lock Solenoid FP2 Port LPark Brake Work Port SHigh Pressure Oil
Valve GPark Brake Solenoid MDifferential Lock Test Port TReduced Pressure Oil
BPark Brake Solenoid Valve-Normally Closed NRelief Valve UReturn Oil
Valve-Normally Open HPressure Reducing Valve OOrifice VPark Brake/Differential
CP3 Port IReturn To Drain PCheck Valve Lock Valve
DP1 Port JDifferential Lock Work Port QPark Brake WThermal Relief Valve
EService Brakes Work Port KPark Brake Pressure RDifferential Lock
Sensing Switch
NOTE: For (S.N. 872329 ) see Section 9020 for park brake. Since the "normally open" park brake
operation and test procedures for the solenoid valve (B) is energized at the same time and
differential lock and park brake. becomes "closed", oil is prevented from returning to
reservoir and pressure increases to release the park
The park brake/differential lock valve is mounted on brake.
the right frame member below the cab and receives oil
directly from the main hydraulic pump at P3 port A thermal relief valve (W) is located in the park brake
(SN830204) or at P1 port (SN 830205 ). pressure port (L). The relief valve prevents excessive
Solenoid valves control the internal flow of oil that pressure build-up from thermal expansion in the park
operates the park brake and differential lock functions. brake circuit.
Incoming oil is routed to the park brake solenoid valve Park brake pressure is sensed at a switch (K) which
(G) that is normally closed when de-energized and the de-activates a light on the control panel when the
park brake is "on". Therefore oil is prevented from brake is "off". Relief valve (N) is in the park brake
flowing to the park brake. circuit to protect against excessive pressure build-up
on trapped oil due to heat and expansion.
Another park brake solenoid valve (B) is normally
"open" when de-energized, which allows oil within the By energizing the differential lock solenoid valve (A)
park brake to return to reservoir. This results in the reduced pressure oil (T) is allowed to flow to the rear
spring applied, hydraulic release park brake becoming axle for differential lock engagement. When 9025
05
engaged to prevent the machine from moving. disengaged return oil flows back through the
89
de-energized solenoid and is routed to reservoir.
When the park brake switch is moved to the "off"
position with the engine running, the normally closed High pressure oil is (S) provided the service brakes
park brake solenoid valve (G) is energized and from the inlet galley through the service brake work
becomes "open". This allows pressure oil to flow port (E).
through an orifice (O) and a check valve (P) to the
TX,902505,BS187 1920DEC942/2

022602
PN=817
Theory of Operation
9025
05
90

022602
PN=818
Group 15
Diagnostic Information
Diagnose Steering System Malfunctions

probable and simplest to verify, to least likely
steps when diagnosing a problem:
Step 1. Operational Check Out Procedure

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.
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
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.

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.
Continued on next page T60,9025,C148 1924MAY931/3

022602
PN=819
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)
Debris between spool and sleeve. Inspect screen in priority valve

housing to verify. Flush.
9025
15
2 Binding or misalignment in steering Inspect column and spline to
column or splined connection. steering valve connection. Repair.
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.
Continued on next page T60,9025,C148 1924MAY932/3

022602
PN=820
Loose steering cylinder piston. Repair or replace. See Repair

Manual.
Severe wear in steering control unit. Replace the steering control unit.
DriftVehicle Veers Slowly in Worn or damaged steering linkage. Replace linkage and align front end
One Direction (toe-in).
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.
9025
Steering. stuck open. 15
3
T60,9025,C148 1924MAY933/3

022602
PN=821
Diagnose Main Hydraulic System

Malfunctions
No Hydraulics Low oil level. Check Oil level.
Broken pump drive shaft. Inspect and repair. See Repair

Manual.
Charge pump belt. (SN 830204) Inspect and replace. See Repair
Manual.
Destroke solenoid stuck or O-ring. Check destroke solenoid. See

Repair Manual.
Charge pump. Remove oil cooler inlet hose to

check for flow. Repair pump. See
Repair Manual.
Slow Hydraulics (Low Pump Hydraulic filter restricted. Inspect and replace filter. See
Output) Repair Manual.
Charge pump belt slipping or Inspect and repair. See Repair

missing. (SN 830204) Manual.
9025 Priority valve stuck or orifice in spool Check hydraulic functions. If only
15 plugged. loader is affected, problem is priority
4 valve.
Destroke solenoid stuck. Inspect and repair destroke solenoid.

See Repair Manual.
Surge relief valve stuck open. Remove and inspect surge relief
valve. See Repair Manual.
Charge pump suction screen Inspect and clean screen. See

restricted. (SN 830204) Repair Manual.
Charge or return circuit. Do Hydraulic Pump Charge and

Return System Check. (See Group
9025-25.)
Destroke solenoid packing. Inspect destroke solenoid. See

Repair Manual.
System Relief valve too low. Do System relief Valve Test. (See
Group 9025-25.)
Continued on next page 710D,DS4165 1903MAR931/6

022602
PN=822
Low standby pressure. Do Main Pump Standby Pressure

Stroke control valve seat, spring, or Inspect valve. See Repair Manual.
packing.
Crankcase relief valve stuck closed. Inspect valve. See Repair Manual.
Charge pump worn. Do Charge Pump Flow Test. (See

Group 9020-25.)
Main pump discharge valve worn. Do Cycle Time Test. (See Group
Inlet valve broken or leaking. Worn 9025-25.)
pistons.
Do Main Hydraulic Pump Flow Test.

Low Hydraulic Power (Low Low oil level (aeration of oil) Add oil. (See Group 9000-04.)
Hydraulic Pressure)
Hydraulic filter restricted. Inspect and replace filter. See

Repair Manual.
Low standby pressure. Adjust.

9025
15
Charge pump section screen Inspect and clean screen. See 5
Stroke control valve setting too low. Do Main Pump Standby Pressure
Excessive leakage in hydraulic Do Hydraulic System Component

system. Leakage Check. (See Group
9025-25.)
Leakage within work circuit. Feel component for heat.
Destroke solenoid O-ring damaged. Inspect O-ring. See Repair Manual.
Low charge flow due to filter relief Do Charge Pump Pressure Check
valve stuck or setting too low, or and Transmission Pump Flow Test
restriction in filter base or lines. Group. (See Group 9025-25.)
Hydraulic Function (Or Pump) Low oil level (pump cavitation). Check and add oil. (See Group
Makes "Chatter" Noise 9000-04.)

022602
PN=823
Pump cavitation during combined full This is normal in full cycle operation
cycle crowd and bucket curl. of both functions. Function not used
in actual digging operation.
Hydraulic filter restricted. Remove, inspect, and replace filter.
Charge pump belt slipping or Inspect and repair. See Repair

missing. (SN 830204) Manual.
Excessive non-return circuit leakage Feel components for heat. Do

(such as system relief valve Hydraulic System Component
leakage). Leakage Tests. (See Group
9025-25.)
Surge relief valve setting low . Do Surge Relief Valve Pressure

Charge or return circuit leakage. Do Charge Pressure Test. (See

Group 9025-25.)
Charge pump suction screen Remove, inspect, and clean screen.

restricted. (SN 830204)
Charge pump worn. Do Transmission Pump Flow Test.

9025
15
6 Pump pistons sticking. Inspect pistons. See Repair Manual.
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 Group 9000-04.)
Hydraulic filter restricted. Inspect and replace filter.
Charge pump belt slipping. (SN Inspect and repair. See Repair
830204) Manual.
Surge relief valve sticking open. Do Surge Relief Valve Leakage

Surge relief valve setting low. Do Surge Relief Valve Pressure


022602
PN=824
System relief valve malfunction. Feel components for heat. Do

Hydraulic System Component
Charge pump suction screen Inspect and clean screen.

restricted (aeration of inlet oil).
(SN 830204)
Oil lines in contact with operators Inspect and repair.

station.
Rubber isolators. Inspect and repair. See Repair

Manual.
Loose pump drive coupling. Inspect and tighten coupling. See

Repair Manual.
Leakage in hydraulic circuit. Do Hydraulic System Component

Destroke solenoid O-ring failed. Inspect O-ring. See Repair Manual.
Stroke control valve seat, spring or Inspect valve. See Repair Manual.
packing.
9025
Pump pistons sticking. Inspect pistons. See Repair Manual. 15
7
Outlet valve broken. Inspect valve. See Repair Manual.
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.
Hydraulic System Overheats Reservoir overfilled with oil. Check oil level. (See Group
9000-04.)
Charge pump belt slipping. (SN Inspect and repair. See Repair
830204) Manual.
Low oil level. Check and add oil. (See Group

9000-04.)

022602
PN=825
Oil cooler and radiator air flow Do Air Flow Test. (See Group
restricted. 9010-25.)
Wrong oil (viscosity too low) Verify type of oil. Change oil. (See
Group 9000-04.)
Hydraulic filter restricted. Remove, inspect, and replace filter.

See Repair Manual.
Excessive leakage in hydraulic Feel components for heat. Do

system. Hydraulic System Component
Excessive leakage in work circuit. Feel components in circuit for heat.

Do Hydraulic System Leakage Test.
Surge relief valve stuck open or Do Surge Relief Valve Leakage

spring broken. Test. (See Group 9025-25.) Remove
and inspect surge relief valve. See
Repair Manual.
Charge pump suction screen Remove and clean screen. See

9025
15 Low charge pump output. Do Charge Pump Flow Test. (See
8 Group 9025-25.)
Cooler plugged internally. Do Hydraulic Oil Cooler Restriction

Restriction in hydraulic line. Inspect lines for kinks and dents.

Check for internal restrictions by
feeling for excessive heat.
Function Drifts Down Excessive leakage in circuit. Do Hydraulic System Component


022602
PN=826
Individual Function Low On Excessive leakage in circuit. Do Hydraulic System Component

Power Leakage Test. (See Group 9025-25.)
Also see Low Hydraulic Power.

Higher hydraulic demand by
backhoe can make a system
problem appear to be isolated to
backhoe.
Incorrect circuit relief valve, low relief Do Circuit Relief Valve Pressure
valve setting, or broken spring in Test. (See Group 9025-25.)
relief valve.
710D,DS4165 1903MAR936/6
9025
15
9

022602
PN=827
Diagnose Brake System Malfunctions

Poor or No Brakes (steering and Air in system. Check for damaged O-ring or lines.
hydraulic system operation
normal)
Internal brake valve leakage. Do Brake Valve Leakage Test. (See

Group 9025-25.)
Internal leakage in axle brake Remove differential level check plug.

pistons. Actuate brakes and observe leakage
from check plug.
Internal restriction in circuit. Remove lines and components and

inspect.
Brakes Will Not Release Or Drag Brake valve sticking. Remove, inspect and repair. See
Repair Manual. (Spool valve and
housing are matched.)
Work port orifice plugged. (S.N. Remove, inspect, clean. See Repair
872256) Manual.
Malfuntioning retraction springs in Remove, inspect and repair. Do

axle. (S.N. 872329 ) Service Brake Work Port Pressure
9025
15 Test. (See Group 9025-25)
10
Brakes Chatter or Noisy Air in brake system. Check for damaged O-rings or lines.
Manual Brakes Do Not Build Inlet check valve leaking. Replace. See Repair Manual.
Pressure (S.N. 872329)
Make-up check valve leaking. Replace. See Repair Manual.
Internal leakage in axle brake Remove differential check plug.

pistons. Actuate brakes and observe leakage
from plug.
With Pedals Locked Together Equalization orifice plugged. Remove spool valve, clean and
Machine Does Not Stop in replace.
Straight Line
Brakes Dragging (S.N. 872328 ) Improper Adjustment Do Service Brake Valve and Pedal
Adjustment. (See Group 9025.25)
Continued on next page T60,9025,C198 1903MAR931/2

022602
PN=828
Brake Single Pedal Drift (S.N. Leaking shuttle valve check in brake Inspect and Repair. See Repair
872328 ) valve. Manual
Leak in circuit Inspect and repair. See Repair

Manual.
T60,9025,C198 1903MAR932/2
9025
15
11

022602
PN=829
Diagnose Park Brake and Differential Lock

System Malfunctions
No Differential Lock Operation Differential lock pressure regulating Do Differential Lock Pressure
valve stuck open or spring broken. Regulating Valve Test See Group
(S.N. 872256) 9025-25. Remove and inspect
regulating valve.
Differential lock solenoid failed. (S.N. Do Differential Lock Pressure Test.

872329 ) See Group 9020-25 Differential Lock
Pressure Test.
Excessive differential lock sealing Do Park Brake/Differential Lock

ring leakage Valve Leakage Test For (S.N.
872267) see Group 9025-25. For
(S.N. 872329 ) see 9020-25.
Seals on differential lock regulating Remove and inspect seals. (See

valve. Repair Manual, Group 1160.)
Excessive leakage in differential lock Remove differential check plugs and

circuit check leakage. See Differential Lock
Capture Circuit Leakage Test. For
(S.N. 872256) see Group 9025-25.
9025 For (S.N. 872329 ) see 9020-25.
15
12 Differential lock piston stuck in bore Disassemble, inspect, repair. For
(S.N. 872329) see CTM43. For
(S.N. 872256 ) see Repair Manual
Section 02.
Excessive wear on differential lock Disassemble, inspect, repair. (See

disks and plates Repair Manual, Group 0260.)
Differential Lock Slippage Low pressure Do Differential Lock Pressure

Regulating Valve Test. For (S.N.
872256) See Group 9025-25. For
(S.N. 872329 ) See 9020-25.
Excessive differential lock sealing Do Park Brake/Differential Lock

ring leakage Valve Leakage Test. For (S.N.
872329) See Group 9025-25. For
(S.N. 872256 ) See 9020-25.

022602
PN=830
Seals on differential lock regulating Remove and inspect seals. (See

valve. Repair Manual, Group 1160.)
Excessive leakage in differential lock Remove differential check plugs and

circuit check leakage. See Differential Lock
Capture Circuit Leakage Test. For
(S.N. 872329) see Group 9025-25.
For (S.N. 872256 ) see 9020-25.
Differential Lock Solenoid Do Differential Lock Solenoid check.

(See group 9015-15)
Differential lock pressure regulating Do Differential Lock Pressure

valve stuck open or spring weak or Regulating Valve Pressure Test.
broken. (S.N. 872256) Remove and inspect regulating
valve.
Differential lock piston sticking in Disassemble, inspect, and repair.

bore For (S.N. 872256) see CTM43.
For (S.N. 872329 ) see Repair
Manual Section 02.
Excessive wear of differential lock Disassemble, inspect, and repair.

disks and plates For (S.N. 872256) see CTM43.
9025
Manual Section 02. 15
13
Differential Lock Will Not Release Differential piston stuck in bore Disassemble, inspect, repair. For
(S.N. 872256) see CTM43. For
Section 02.
Warped differential lock disks and Disassemble, inspect, repair. For

plates (S.N. 872256) see CTM43. For
Section 02.
Differential Lock Chatters When Excessive differential lock sealing Do Park Brake/Differential Lock
Engaged ring leakage Valve Leakage For (S.N. 872329)
see Group 9025-25. For (S.N.
872256 ) see 9020-25
Differential lock regulating valve seal Remove and inspect seals. (See

022602
PN=831
Differential lock pressure regulating Do Differential Lock Pressure

valve stuck open, or spring weak or Regulating Valve Test See Group
broken (S.N. 872329 9025-25. Remove and inspect
regulating valve.
Differential lock piston sticking in Disassemble, inspect and repair. For

bore (S.N. 872256) see CTM43. For
Section 02.
Differential Lock Chatters When Warped differential lock disks and Disassemble, inspect, and repair.
Disengaged plates For (S.N. 872256) see CTM43.
Manual Section 02.)
Differential lock piston stuck in bore Disassemble, inspect, and repair..

For (S.N. 872256) see CTM43.
Manual Section 02.
Differential Overfilled With Oil Differential lock pressure oil leaking Remove differential check plugs and
at piston seals, capture seals, or check leakage with differential lock
around differential bearing cup engaged.
Brake piston seals leaking Remove differential check plugs and

9025
15 check leakage with brakes applied.
14
Park Brake Will Not Hold Incorrect park brake adjusting screw Adjust park brake. (See Group
torque. 9025-20.)
Brake disk and/or brake shoes worn Disassemble, inspect, repair. (See
Park brake solenoids Do Park Brake Solenoid check. (See

group 9015-15.)
Thermal relief valve will not open. Replace. See Repair Manual.
Park Brake Disk Overheats Incorrect park brake adjusting screw Adjust park brake. (See Group
torque. 9025-20.)
Brake not released Disassemble, inspect brake. Repair

if necessary. (See Repair Manual,
Group 1111.)
Thermal relief valve will not close. Replace. See Repair Manual.

022602
PN=832
Park Brake Will Not Apply Incorrect park brake adjusting screw Adjust park brake. See Group
torque. For (S.N. 872329) 9025-25.
Park Brake Solenoids Do Park Brake Solenoid Check.

Thermal relief valve will not open. Replace. See Repair Manual.
TX,902515,BS206 1920DEC944/4
9025
15
15

022602
PN=833
9025
15
16

022602
PN=834
Group 20
Adjustments
Charge Pump Belt Tension Adjustment
(SN 830204)
SPECIFICATIONS
Belt Strand (without Air 445 N (100 lb force)
Conditioning) Tension (New)
UN06OCT92
Belt Strand (without Air 311 N (70 lb force)
Conditioning) Tension (Used)
Belt Strand (with Air Conditioning) 623800 N (140180 lb force)
Tension (New)
T7861AF
Belt Strand (with Air Conditioning) 356512 N (80115 lb force)
Tension (Used)
SERVICE EQUIPMENT AND TOOLS ACharge Pump Drive Belt

BBelt Tension Gauge
Belt Tension Gauge
1. Remove left engine shield.
2. Loosen mounting cap screws.
3. Loosen adjusting strap cap screw and adjust belt

tension to specifications.
Specification
Belt Strand (without Air
Conditioning)Tension (New) ................................... 445 N (100 lb force)
Belt Strand (without Air
Conditioning)Tension (Used) .................................... 311 N (70 lb force) 9025
Belt Strand (with Air 20
Conditioning)Tension (New) ............... 623800 N (140180 lb force) 1
Belt Strand (with Air
Conditioning)Tension (Used) ................ 356512 N (80115 lb force)
4. Tighten adjusting strap and mounting cap screws.
TX,9025,DS4173 1903MAR931/1

022602
PN=835
Adjustments
Loader Bucket Level Indicator and

Return-to-Dig Switch Adjustment
1. Position bucket flat on ground. Turn engine off.
2. Hold bucket lever in roll-back position.
1915OCT92
3. Measure gap (A) between guard and stop (B) and bell
crank (C). Gap should be 1 mm (0.04 in.).
T7864AE
4. If gap is not to specification, adjust rod jam nut and
yoke (D) to obtain correct gap. Allow bucket lever to
return to neutral position.
5. Measure gap (E) between top of bell crank pin (F) and
top of actuator tang (G). Gap should be 130 mm (5.1
in.).
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
Continued on next page TX,9025,DS4174 1903MAR931/2

022602
PN=836
Adjustments
7. Loosen cap screw (A) and move return-to-dig switch so

roller (B) is touching area (C) on the cam.
8. Move switch toward cam until a "click" is heard.
9. Move switch away from cam until a "click" is heard.
UN09NOV88
10. Tighten cap screw without moving switch.
11. Remove pin from sensor tube yoke.
T87154
12. While watching clearance between cam and switch,
turn command pointer back and forth to be sure cam ACap Screw
does not hit switch bracket. BRoller
CArea on Cam
NOTE: Be sure that switch arm and roller does not
bottom on switch housing.
13. If cam touches bracket or switch arm, and roller

bottoms on switch housing, reposition switch. (See
steps 710.)
TX,9025,DS4174 1903MAR932/2
9025
20
3

022602
PN=837
Adjustments
Adjust Park Brake (S.N. 872328)
1914SEP92
T7799CW
9025
20
4
ADust Seal ELock Nut HSpring Washers KParking Brake Disk
BSeals FCover IShaft LCap Screw
CPiston GSnap Ring JPark Brake Pads
DParking Brake Adjusting
Screw
1. Park machine on level surface. NOTE: If this is the initial installation of new park
brake pads, install the four mounting screws
2. Lower bucket to ground. but do not tighten them.
Specification
CAUTION: Prevent possible injury from Brake Pad Assembly
unexpected machine movement. Never rely Minimum Thickness .................................................. 9 mm (0.354 in.)
on loader bucket to keep machine from Pad-to-Disk Running
moving. Machine can unexpectedly roll, Maximum Clearance ............................................ 4.76 mm (0.187 in.)
Pad-to-Disk RunningMinimum
resulting in death or serious injury. Always Clearance............................................................... 0.5 mm (0.020 in.)
block wheels to hold machine when working
on park brake. 5. Remove three park brake adjustment cover cap
screws (L) and cover (F). Loosen lock nut (E).
3. Stop engine. This will engage park brake.
4. Place blocks in front and behind tires.
Continued on next page TX,9025,DS4176 1903MAR931/2

022602
PN=838
Adjustments
6. Tighten park brake adjustment screw (D) to 100 8. Turn park brake adjustment screw counterclockwise
Nm (75 lb-ft). 1/2 turn (180).
7. If a new brake assembly is being installed, tighten 9. Hold adjusting screw (D) and tighten lock nut (E).
brake assembly mounting cap screws to 70 Nm
(50 lb-ft). 10. Install cover and tighten cap screws (L).
TX,9025,DS4176 1903MAR932/2
Service Brake Inspection (S.N. 872328)
1. Brake disks can be inspected for wear through the

external inspection ports (A).
Specification
UN13DEC90
Service Brake Inspection
Thickness (New) ......................................................... 7.57 mm (0.298 in.)
2. Remove axle housing and replace brakes if oil grooves
RW18679
on facing material are no longer visible. (See Repair
Manual.)
9025
ABrake Inspection Port 20
5
TX,2520,DS4307 1903MAR931/1

022602
PN=839
Adjustments
Service Brake Inspection (S.N. 872329 )
NOTE: Right side inspection port (A) is located on front

side of axle but is not shown in illustration.
1. Brake disks can be inspected for wear through the
UN01OCT98
external inspection ports (A).
Specification
Service Brake Inspection
T117539
Thickness (New) ......................................................... 7.24 mm (0.285 in.)
2. Remove axle housing and replace brakes if oil grooves External Inspection Ports
(B) on facing material are no longer visible. (See
Repair Manual.)
ABrake Inspection Port (Rear shown)

BOil Grove
9025
20
6
UN03DEC93
T8137AC
Oil Grooves on Brake DiskLeft Side Shown

OUO1048,00003E4 1913SEP001/1

022602
PN=840
Adjustments
9025
20
7

022602
PN=841
Adjustments
Service Brake Valve And Pedal Adjustment

(S.N. 872329 )
SPECIFICATIONS
Brake Pedal Leveling Adjustment 2022 mm (0.7870.866 in.)
Brake Valve Pressure Setting 689 kPa (7 bar) (100 psi)
Brake Pedal Linkage Adjustment 31.8 mm (1.25 in.)
Jam Nut Torque 45 Nm (33 lb-ft)
IMPORTANT: If adjustments are made to Service

Brake, the pedal leveling adjustment
must be done prior to doing the brake
pedal pressure adjustment.
1. Adjust and level pedals by adjusting jam nut (B) and

stop screw (A) to dimension (C) on left pedal. Adjust
right pedal level with left pedal allowing lock bar (D) to
engage as shown.
Specification
UN04JAN99
Brake Pedal Leveling
AdjustmentClearance ............................. 2022 mm (.07870.866 in.)
AStop Screw
T118050
BJam Nut
CLeveling Adjustment Dimension
DLock Bar Pedal Leveling Adjustment
9025
20
8

022602
PN=842
Adjustments
2.
Remove brake light indicator switch in brake valve.

Connect fittings and gauge to brake valve port. See
Service Brake Valve Pressure Test in this Group.
UN28OCT98
3. Disengage locking bar in brake pedal. Depress right
pedal 31.8 mm (1.25 in.) and measure distance (D)
using a straight edge or ruler. Measure from edge of
one pedal to other pedal as shown. Note pressure
T118051B
reading on gauge when pedal has been depressed
down one inch travel dimension (D).
Specification
Brake Valve Pressure Setting
Pressure ............................................................ 689 kPa (7 bar) (100 psi)
Brake Pedal Linkage
AdjustmentDistance .................................................. 31.8 mm (1.25 in.)
4. If pressure is not in specification, adjust pedal linkage
UN02FEB99
to obtain correct pressure setting.
5. Scribe a line (B) on jam nut (C) and push rod (A) for
ease of adjustment
T118819
6. Loosen jam nut on push rod. Adjust as required being
Brake Pedal Linkage Adjustment
careful not to tear boot. Note, one flat on jam nut
equals approximately 25 psi. Tighten jam nut to APush Rod 9025
specification. BScribe Line 20
CJam Nut 9
Specification DPedal Travel (Pressure Setting Positon)
Jam NutTorque ............................................................ 45 Nm (33 lb-ft)
CED,TX04577,768 1921SEP982/2

022602
PN=843
Adjustments
Backhoe Valve Linkage Adjustment
NOTE: Levers must be positioned correctly to allow full

travel and proper operation of backhoe valves.
Rod lengths given are nominal. Final adjustment
is to be done using knob position.
UN15OCT92
Cab and other components have been removed in
some photographs for clarity.
T7861AD
1. Put backhoe valve spools in neutral position.
2. Measure rods (A) from center of clevis pin hole to

center of ball joint. This distance should be 280 mm
(11.2 in.)
3. On machines with extendible dipperstick, auxiliary

valve linkage adjustment is also required. Measure rod
from center of clevis pin hole to center of ball joint.
UN30OCT90
Distance should be 190 mm (7.5 in.).
4. Put a piece of masking tape across the rear ROPS

posts on inside surface at backhoe lever know height.
T7407AJ
5. Measure from edge of knobs to tape. Distance (B)
should be 140 mm (5.5 in.). Knobs should be 250 mm
(9.8 in.) apart.
9025
20
10
TX,9025,DS4178 1903MAR931/1
Loader Control Valve Linkage Adjustment

travel and proper operation of loader valves.

UN06OCT92
1. Put loader control valve spools in neutral position.

T7861AE
2. Adjust rods (A) so tabs (B) on bell crank are horizontal.
ARod
BTab

022602
PN=844
Adjustments
3. Put a piece of masking tape from right front to right

rear ROPS posts on inside surface at loader know
height.
4. Distance (D) from right side of knob to tape should be

250 mm (9.8 in.).
UN14NOV90
5. Put a piece of masking tape from left front to right front
ROPS posts on inside surface at loader knob height.
T7407AO
6. Distance (C) from front of knob to tape should be 130
mm (5.1 in.).
7. The distances in steps 4 and 6 can be obtained by

adjusting rods (E).
NOTE: Pivot (F) must remain in slot when holding the

loader lever in the roll-back position.
UN30OCT90
C130 mm (5.1 in.)
D250 mm (9.8 in.)
EAdjusting Rod
FPivot
T7407AP
9025
20
11
UN30OCT90
T7407AQ
TX,9025,BG231 1906JAN972/2

022602
PN=845
Adjustments
Stabilizer Valve Linkage Adjustment

travel and proper operation of loader valves.
UN30OCT90
1. Put stabilizer valve spools in neutral position.
T7407AK
2. Adjust linkage rods (A) to position tabs (B) vertically.
3. Put masking tape across rear ROPS posts on inside

surface at stabilizer knob height.
4. Measure the distance (C) from edge of right stabilizer

knob to tape. It should be 260 mm (10.2 in.). Measure
the distance (D) from edge of left stabilizer knob to
tape. It should be 295 mm (11.6 in.). Adjust rods (E) as
UN30OCT90
necessary.
ALinkage Rods
BTab
T7407AL
C260 mm (10.2 in.)
D295 mm (11.6 in.)
9025
20
12
UN30OCT90
T7407AM
TX,9025,DS4180 1903MAR931/1

022602
PN=846
Group 25
Tests
John Deere Radial Piston PumpUse CTM7
For complete repair information the Component Technical

Manual (CTM) is also required.
Use the CTM in conjunction with this repair manual.
UN17JAN89
TS225
09T,2160,K5 1912MAY941/1

Installation
Tachometer
AClamp-on Transducer. Remove paint with emery cloth and
UN28FEB89
T6813AG
9025
25
1
10T,9010,K182 1910AUG951/1
JT05800 Digital Thermometer Installation

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

022602
PN=847
Tests
Hydraulic Oil Warm-Up Procedure
1. Operate all hydraulic control valves to release pressure

in the system.
UN23AUG88
X9811
fluids.

UN17SEP92
this type of injury should reference a
knowledgeable medical source. Such
information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.
T7839AA
2. Disconnect boom cylinder rod end hose (A) from
control valve, and boom cylinder head end hose (B)
from boom cylinder.
9025
25 3. Connect boom cylinder rod end hose (A) to cylinder
2
head end port and boom cylinder head end hose (B) to
control valve.
4. Put cardboard or other suitable material in front of oil

cooler to restrict air flow.
5. Start engine and run at 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.
TX,902525,BS159 1903MAR931/1

022602
PN=848
Tests
Manual Destroke Installation Procedure
ESSENTIAL TOOLS
a
RE25493 Manual Destroke Assembly
a
Order from John Deere parts system.
27T,9025,M100 1916OCT911/2
1. Lower all equipment to ground, stop engine and

operate hydraulic controls to relieve pressure.
2. Remove grille.
3. Remove destroke solenoid and install manual destroke
UN20MAR90
assembly.
4. Turn destroke adjusting screw in to destroke pump.
T6900AG
9025
25
3
UN20MAR90
T6900AH
27T,9025,M100 1916OCT912/2

022602
PN=849
Tests
Diagnostic Destroke Wire Harness

Installation Procedure
See Section 99 for instructions to make harness.
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" to put pump into
stroke.
AGround Clamp
BPower Cable
CInjection Pump
DSwitch Box
EConnector
FMain Hydraulic Pump
UN26OCT88
T6900AI
27T,9025,M101 1916OCT911/1
9025
25
4

022602
PN=850
Tests
Charge Pressure Test
SPECIFICATIONS
Engine Speed WOT
Charge Minimum Pressure 827 138 kPa (8 1.4 bar) (120
UN26SEP91
20 psi)
ESSENTIAL TOOLS
JT05494 (7/16-20 M 37 x 3/4-16 ORB) AAdapter
T7615AF
JT05490 (7/16-20 M 37 x 3/8-24 M ORB) BAdapter

Gauge 01000 kPa (010 bar) (0150 psi)
UN26OCT88
2. Connect gauge to hydraulic pump using fitting (A) or

backhoe valve using fitting (B).
T6900AF
3. Heat hydraulic oil to test specifications. (See procedure
in this group.)
9025
Specification 25
OilTemperature ..................................................... 66 4C (150 7F) 5
4. Run engine at fast idle. Record oil pressure reading.
Specification
EngineSpeed .................................................................................. WOT
ChargeMinimum Pressure ................... 827 138 kPa (8 1.4 bar) (120
20 psi)
If pressure is low check the following:
Loose charge pump belt (S.N. 830204).

Restricted charge pump suction screen (S.N.
872256).
Do Surge Relief Valve Pressure Test in this group.
TX,902525,BS160 1908NOV011/1

022602
PN=851
Tests
Charge Pump Flow (S.N. 872256)

SPECIFICATIONS
Charge Minimum Flow 102 L/min (27 gpm)
ESSENTIAL TOOLS
JT05690 (1-1/16-12 M 37 x -12 F ORFS) AAdapter

BFlowmeter
1. Install digital thermometer in hydraulic reservoir.
2. Remove left engine side shield.
IMPORTANT: Flowmeter must be open to prevent
UN26OCT88
damage to charge pump.
3. Connect flowmeter (B) to charge pump using hoses

and fittings (A). Open flowmeter loading valve.
T6900AM
4. Apply park brake. Start engine and warm oil to
specification (see procedure in this group or use
9025
25 flowmeter).
6
Specification
5. Operate engine at fast idle and record flow rate.
Specification
EngineSpeed ............................................................................ Fast idle
ChargeMinimum Flow ............................................. 102 L/min (27 gpm)
6. If flow is low, check the following before servicing the

pump:
Charge pump belt tension (SN 830204).

Suction screen in hydraulic reservoir restricted.
TX,902525,BS161 1903MAR931/1

022602
PN=852
Tests
9025
25
7

022602
PN=853
Tests
Charge Pump Flow (S.N. 872329 )
UN23OCT98
T117960
9025
25
8
AUnion
SPECIFICATIONS 3. Apply park brake. Start engine and warm oil to

Oil Temperature 40 4C (104 7F) specification (see procedure in this group or use
Engine Speed Fast Idle flowmeter).
Charge Minimum Flow 102 L/min (27 gpm)
Specification
OilTemperature .............................................. 40 4C (104 7F)
ESSENTIAL TOOLS
A38H1272 (12 M x 12 M ORFS) AUnion 4. Operate engine at fast idle and record flow rate.
SERVICE EQUIPMENT AND TOOLS Specification

JT05800 Digital Thermometer EngineSpeed ...................................................................... Fast idle
ChargeMinimum Flow ...................................... 102 L/min (27 gpm)
Flowmeter
5. If flow is low, check the following before servicing
1. Install digital thermometer in hydraulic reservoir. the pump:
IMPORTANT: Flowmeter must be open to prevent Do Surge Relief Valve Pressure Test in this
damage to charge pump. group.
2. Connect flowmeter test hose to charge pump and

hose removed with union (A) to flowmeter test
hose. Open flowmeter loading valve.
CED,TX03610,140 1919MAR991/1

022602
PN=854
Tests
Surge Relief Valve Pressure Test
SPECIFICATIONS
Surge Relief Pressure 827 140 kPa (8.2 1.4 bar)
UN12NOV92
(120 20 psi)
ESSENTIAL TOOLS
JT05494 (7/16-20 M 37 x 3/4-16 ORB) AAdapter
T7888AA
BHose
CGauge 02000 kPa (020 bar) (0300 psi)
Digital Thermometer
DVice Grips
Purpose of this test is check that surge relief valve is set

low enough to protect return circuit and high enough to
maintain cooler flow to cool hydraulic oil. Surge relief
valve (E) is located on bottom of reservoir in line from
hydraulic filter.
Specification
9025
25
9
2. Install gauge (C) and digital thermometer.
3. Clamp oil cooler hose (D) to stop oil flow.
4. Operate engine at fast idle and record surge relief
UN26OCT88
pressure. (Surge relief is not adjustable or repairable,
see group 2160 to replace.)
Specification
T6900AN
EngineSpeed ............................................................................ Fast idle
Surge ReliefPressure .............................. 827 140 kPa (8.2 1.4 bar)
(120 20 psi)
AAdapter
BHose
CGauge
DCooler Hose
ESurge Relief Valve
TX,902525,BS162 1903MAR931/1

022602
PN=855
Tests
Main Pump Standby Pressure Test

SPECIFICATIONS
Standby Pressure 17 580 350 kPa (176 3.5 bar)
UN07FEB90
(2550 50 psi)
ESSENTIAL TOOLS
JT05490 (7/16-20 M37 x 3/8-24 M ORB) AConnector
T93021
202850 (7/16-20 F 37 x 1/8) BNipple Adapter
JT05491 (7/16-20 M 37 x 14 M x 1.5 M ORB) EConnector

36953 CHose with Needle Valve
UN26OCT88
DGauge 034 500 kPa (0345 bar) (05000 psi)
T6900AO
AConnector
BAdapter
CHose
DGauge
9025 EConnector
25 FAdjusting Screw
10

022602
PN=856
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
UN23AUG88
in the hydraulic system. Install electronic tachometer
and digital thermometer. (See procedure in this group.)
X9811
2. Connect hose and gauge to main pump or backhoe
valve. Heat oil to specifications. (See procedure in this
group.)
Specification
3. Adjust engine speed to specification. Record pressure.
Specification
EngineSpeed .................................................................. 2000 25 rpm
StandbyPressure............................... 17 580 350 kPa (176 3.5 bar)
(2550 50 psi)
4. Turn adjusting screw (F) to adjust pressure to

specifications. If pressure cannot be adjusted, repair or
replace valve. See CTM-7.
9025
25
11
TX,9025,BR526 1903MAR932/2

022602
PN=857
Tests
Main Pump Flow Test

UN23AUG88
SPECIFICATIONS
Oil Temperature 65 5C (150 + 10F)
X9811
Oil Pressure 13 790 69 kPa (138 0.7 bar)
(2000 10 psi)
Acceptable Minimum Flow 170 L/min (45 gpm)
710D Oil Pressure 15 170 kPa (151.7 bar) (2200 psi)
Standby Oil Pressure 17 580 kPa (175.8 bar) (2550 psi)
ESSENTIAL TOOLS
JT15073 (1-1/16 Male JIC x 1-5/16-12 Male ORB) Connector

Digital Thermometer
9025
25 Flowmeter
12 Hoses


in the hydraulic system.

022602
PN=858
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 with flowmeter.
Specification
OilTemperature ................................................... 65 5C (150 + 10F)
5. Adjust engine speed and oil pressure to specifications.

Record oil flow.
6. If pump flowmeter meets test specifications, check

pressure compensator valve.
Maintain 2000 10 rpm for this part of test. Adjust

pump pressure to each of the following test pressures.
Record flow rates.
Specification
EngineSpeed .................................................................. 2000 10 rpm
UN25MAY89
Subtract recorded flow rates from rate recorded at 13 790
kPa (138 bar) (2000 psi) during first part of test.
Specification
T6264AH
OilPressure ......................................... 13 790 69 kPa (138 0.7 bar)
(2000 10 psi)
9025
Flow rate should not decrease by more than 7.5 L/min AJT15073 Connector (2 used) 25
(2.0 gpm) until pump pressure is within 2069 kPa (207 BHose (2 used) 13
bar) (300 psi) of standby pressure, then decrease sharply CFlowmeter
as pump destrokes. DLoading Valve
EBackhoe Valve
Specification
AcceptableMinimum Flow ....................................... 170 L/min (45 gpm)
If stroke control valve meets specifications, go to step 7.
7. Check for a plugged screen in priority valve inlet.
If screen is clean, do Hydraulic Component Leakage

Tests in this group.

Pressure 15 860 kPa (158.6 bar) (2300 psi)
Pressure 16 550 kPa (165.5 bar) (2400 psi)
Standby Oil Pressure 17 580 kPa (175.8 bar) (2550 psi)
TX,9025,BR527 1903MAR932/2

022602
PN=859
Tests
Priority Valve Test
SPECIFICATIONS
Oil Temperature 40 4 C (104 10F)
Engine Speed High Idle
Steering Against Stops Pressure 17 581 345 kPa (175 3.5 bar)
UN14SEP92
(2550 50 psi)
Steering in Neutral Pressure 2068 kPa (20 Bar) (300 psi)
Steering Against Stops and 17 581 345 kPa (175 3.5 bar)
(2550 50 psi)
T7845AA
Loader Boom Raising Pressure
ESSENTIAL TOOLS
-8 ORFS (Parker No. 8R6LOS) Swivel Run Tee

Hose
Gauge 034 500 kPa (0345 bar) (05000 psi)

9025
25
14

022602
PN=860
Tests

UN23AUG88
1.
Install digital thermometer and gauge (A) at priority

valve steering outlet (CF) port.
X9811
2. Start engine and heat hydraulic oil to specifications.
Specification
OilTemperature .................................................. 40 4 C (104 10F)
3. Run engine at test specification. Turn steering wheel

against stop. Continue turning steering wheel with
approximately 22 N (5 lbs ) force. Record pressure.
Specification
EngineSpeed ............................................................................ High Idle
Steering Against Stops
Pressure .............................................. 17 581 345 kPa (175 3.5 bar)
(2550 50 psi)
Steering in NeutralPressure....................... 2068 kPa (20 Bar) (300 psi)
Steering Against Stops and
9025
Loader Boom RaisingPressure ......... 17 581 345 kPa (175 3.5 bar)
25
(2550 50 psi)
15
If pressure is low or high when steering is held

against stops do pump standby pressure check in
this group.
If neutral pressure is high check for plugged orifices
in priority valve "LS" port fitting and do "LS" Port
Flow Test in this group. Also check "LS" port orifice
in steering valve. (Remove hose at steering valve to
inspect.)
Low neutral pressure can also be caused by low
spring compression (See Repair Manual) or plugged
orifices on spool ends.
TX,902525,BS165 1903MAR932/2

022602
PN=861
Tests
Priority Valve "LS" Port Flow Test

UN23AUG88
SPECIFICATIONS
X9811
Engine Speed Slow Idle
"LS" Port Flow 700 100 mL/min (.18 .03
gpm)
ESSENTIAL TOOLS
38H1414 (-4 F ORFS) (Parker No. FNL-S) Cap
UN17SEP92
Measuring Container
T7849AA
Stop Watch

9025
25
2. Heat hydraulic oil to specifications. (See procedure in
16
this group.)
Specification
3. Disconnect "LS" line (A) at inlet to valve and cap fitting.
4. Start engine and run at specification.
Specification
EngineSpeed ............................................................................ Slow Idle
Catch flow from line in a measuring container.
Specification
"LS" PortFlow ............................................ 700 100 mL/min (.18 .03
gpm)
TX,902525,BS167 1903MAR931/1

022602
PN=862
Tests
9025
25
17

022602
PN=863
Tests
Hydraulic Oil Cooler Restriction Test

SPECIFICATIONS
Oil Flow 68.1 L/min. (18 gpm)
Gauge Difference Maximum 586 kPa (5.8 bar) (85 psi)
Pressure Drop
Gauge Difference Minimum 517 kPa (5.1 bar) (75 psi)
Pressure Drop
ESSENTIAL TOOLS
203654 (7/16-20 M 37 x 1/2 M NPT) GConnector
JT03348 (1/2 F NPT) HTee (2 used)
JT03212 (1/2 I.D. Hose x 1/2 M NPT) IAdapter (6 used)
JT03070 (1/2 F NPT 1-1/6-12 F 37 SW) JCoupler (2 used)

Hydraulic Analyzer
Hydrostatic Switching Unit
KFlowmeter with Temperature Gauge
BGauge 01000 kPa (010.0 bar) (0150 psi)
NOTE: If an internally restricted oil cooler is suspected,

9025
25 the oil cooler can be back flushed to check for
18 debris. Steps 12 describe how to back flush the
cooler and Steps 36 describe how to test cooler
for an internal restriction.
BACK FLUSH COOLER
1. To back flush the cooler, connect pump return hose to

cooler outlet. Disconnect inlet line and put end of hose
in a five gallon bucket.
UN07APR89
AHydraulic Analyzer
BGauge 01000 kPa
CGauge Port
DCooler-In
ECooler-Out
T6908BG
FSwitch Unit
GFitting
HTee
IBarb Fitting
JFitting
KFlowmeter

022602
PN=864
Tests
2. Start engine and run at slow idle for 10 seconds.
INTERNAL RESTRICTION TEST
3. Make test connection. Refill reservoir, then start engine

to fill to proper level before test.
4. Open flowmeter. Heat oil to test specification. See

Hydraulic Oil Warm-Up Procedures in this group.
Specification
5. Increase engine speed until flow is at specification.
Specification
EngineSpeed ........................................................................... 2000 rpm
OilFlow .................................................................. 68.1 L/min. (18 gpm)
6. Read pressure gauges at inlet and outlet of cooler.

Difference in gauge reading as pressure drop in cooler.
Specification
Gauge DifferenceMaximum
Pressure Drop .................................................. 586 kPa (5.8 bar) (85 psi)
Gauge DifferenceMinimum
Pressure Drop .................................................. 517 kPa (5.1 bar) (75 psi)
Check charge pressure if pressure differential is not 9025

to specification. 25
19
TX,902525,BS169 1903MAR932/2

022602
PN=865
Tests
Steering Valve Neutral Drift Test

SPECIFICATIONS
Oil Temperature 40 10C (100 20F) (cylinders
warm to touch)
Steering Valve Neutral Maximum 5 mm/min (0.20 in./min)
Drift

this group.)
Specification
OilTemperature ................................. 40 10C (100 20F) (cylinders
warm to touch)
2. Raise front wheels off of ground with loader bucket.
UN25MAY89
Position wheels straight ahead, measure and record
steering cylinder rod length sticking out of cylinder.
3. Lower stabilizers and operate backhoe for five minutes
T6076AN
at fast idle.
Specification Two Wheel Drive Axle Shown

EngineSpeed ............................................................................ Fast Idle
4. Stop engine and remeasure steering cylinder rod. The

9025 difference between this reading and one in Step 1 is
25 drift.
20
Specification
Steering Valve Neutral
Maximum Drift ...................................................... 5 mm/min (0.20 in./min)
5. Repair as necessary. See repair manual.
NOTE: Excessive neutral drift will not affect steering

control when driving unit.
TX,902525,BR119 1906APR941/1

022602
PN=866
Tests
Cylinder Drift Test
SPECIFICATIONS
Oil Temperature 40 10C (104 20F) (cylinders
warm to touch)
Engine Speed Low Idle
UN26MAY89
Cylinder Maximum Drift 7 mm/min (0.28 in./min)
1. Warm hydraulic oil to specifications. (See Hydraulic Oil

Warm-Up Procedure in this group.)
T6222AM
Specification
OilTemperature ................................. 40 10C (104 20F) (cylinders
warm to touch)
2. Put FNR lever in neutral and engage park brake.
3. Retract cylinder. Put cylinder under load (so cylinder

rod is being pulled outward) by loading bucket or by
UN26OCT88
using machine weight. Measure and record cylinder
rod extension.
4. Run engine at specified speed, measure extension of
T6222AN
cylinder rod in one minute. Record measurement.
Specification
EngineSpeed ............................................................................. Low Idle
9025
5. Compare to specification. 25
21
6. Repeat procedure for each cylinder to be tested.

(Several cylinders can be done simultaneously.)
NOTE: If cylinder drifts in rod extend direction, load

cylinder in opposite direction, and check drift. If
cylinder drifts in both directions, it indicates
leakage in control valve. Repair as necessary.
See repair manual.
Specification
CylinderMaximum Drift...................................... 7 mm/min (0.28 in./min)
7. If cylinder drifts in rod extend direction only, do

Cylinder Leakage Check in this group on machine
before removing cylinder for repair. See repair manual.
T60,9025,1073 1924MAR931/1

022602
PN=867
Tests
Steering System Leakage Test

SPECIFICATIONS
Steering Wheel Torque 11.3 Nm (100 lb-in.)
UN26OCT88
Steering System Maximum 5 rpm
Leakage
ESSENTIAL TOOLS
T93024
38H1145 (4 ORFS) Plug (2 used)
38H1352 (4 ORFS) Nut (2 used)
38H1138 (4 ORFS) Plug (2 used)

Digital Thermometer
1. Install digital thermometer.

this group.)
Specification

9025
25
22 4. Run the engine at low idle.
Specification
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.)
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.
Continued on next page TX,902525,BS170 1924MAY931/3

022602
PN=868
Tests
Specification
Steering WheelTorque ........................................... 11.3 Nm (100 lb-in.)
Count the rpm.
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.
Specification
Steering SystemMaximum
Leakage ............................................................................................. 5 rpm
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.
12. Operate all hydraulic control valves to release

pressure in system.
Continued on next page TX,902525,BS170 1924MAY932/3

9025
25
23

022602
PN=869
Tests

UN23AUG88
13. Disconnect hydraulic lines from steering cylinder and
install caps (B) and plugs (A).
14. Start the engine and run at low idle.
X9811
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
9025
25
24
T6076AM
Two Wheel Drive Axle Shown
TX,902525,BS170 1924MAY933/3

022602
PN=870
Tests
9025
25
25

022602
PN=871
Tests
Steering Cylinder Leakage Test

SPECIFICATIONS
Steering Cylinder Leakage 5 ml/min (1/6 oz/min)
ESSENTIAL TOOLS
38H 1145 (4 ORFS) APluga
a
These ORFS fittings should be ordered through normal service
channels.

Digital Thermometer
1. Install digital thermometer probe in reservoir.
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.
Specification
Steering CylinderLeakage..................................... 5 ml/min (1/6 oz/min)
9025
25
26
Continued on next page T60,9025,1065 1921JUL941/2

022602
PN=872
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. Stop engine.
6. Measure oil collected and connect hose.
Specification
UN25MAY89
T6076AL
Axle Without MFWD Shown
T60,9025,1065 1921JUL942/2
9025
25
27

022602
PN=873
Tests
Cylinder Leakage Test

SPECIFICATIONS
Cylinder Leakage 5 ml/min (1/6 oz/min)
UN26OCT88
ESSENTIAL TOOLS
38H1353 (-6 ORFS) Nut
T6222AL
38H1139 (-6 ORFS) Plug
38H1354 (-8 ORFS) Nut

Digital Thermometer
1. Install digital thermometer probe in reservoir.
3. Start engine. Fully extend cylinder rod. Stop engine.

Activate a hydraulic function to relieve pressure in the
system.
9025
25 Specification
28 EngineSpeed ............................................................................. Low Idle
CylinderLeakage ................................................... 5 ml/min (1/6 oz/min)
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
7. Repair as necessary. (See repair manual.)
8. Repeat procedure to test each cylinder.
T60,9025,1068 1921JUL941/1

022602
PN=874
Tests
Hydraulic Component Leakage Test
SPECIFICATIONS
Steering Valve Return Line 900 mL/min (30 oz/min)
Maximum Leakage
Main Hydraulic Pump Seal 2 mL/min 0.07 oz/min
Maximum Leakage
Loader Valve-2 Section Maximum 220 mL/min (7 oz/min)
Leakage
Loader Valve-3 Section Maximum 320 mL/min (11 oz/min)
Leakage
Loader Valve Work Port 31 mL/min (1 oz/min)
Maximum Leakage
Backhoe Valve-4 Section 1000 mL/min (34 oz/min)
Maximum Leakage
Maximum Leakage
Maximum Leakage
Backhoe Valve Work Port 60 mL/min (2 oz/min)
Maximum Leakage
Stabilizer Valve Maximum Spool 500 mL/min (17 oz/min)
Leakage
Stabilizer Valve Maximum 0.15 mm/min (.006 in/min)
Cylinder Drift 9025
(SN872328)Brake Valve 50 mL/min (1.7 oz/min) 25
Maximum Leakage (Both pedals 29
Applied)
Diff. Lock/Park Brake Valve 160 mL/min (6 oz/min)
Maximum Leakage
Differential Lock Capture Circuit 1.9 L/min (0.5 gpm)
Maximum Leakage
Park Brake Thermal Relief Valve 10 mL/min (0.34 oz/min)
Maximum Leakage

Digital Thermometer

(See procedure in this group).
2. Heat hydraulic oil to 40 4C (104 7F). (See


022602
PN=875
Tests
Specification
3. Excessive heat in a return line can indicate leakage in

that component. If one return line is hotter than the
others check that component first.
TX,902525,BS172 1903MAR932/12
NOTE: Return line removed must be capped or hydraulic

reservoir will drain through line.

UN23AUG88
4.
X9811
Disconnect return lines for hydraulic components, one
9025
at a time, to check for leakage. Install cap on fitting.
25
30
5. Place beaker under component to be tested.
7. Start engine and run for one minute.
Specification
EngineSpeed .................................................................. 1000 10 rpm
8. Stop engine and measure leakage in beaker.

022602
PN=876
Tests
Remove steering return line (A) from reservoir.
Specification
Steering Valve Return Line
Maximum Leakage ............................................... 900 mL/min (30 oz/min)
ASteering Valve Return Line

BReservoir
UN25SEP92
T7855AI
TX,902525,BS172 1903MAR934/12
9025
25
31
If leakage is excessive, check main hydraulic pump shaft
for excessive end play.
Specification
Main Hydraulic Pump Seal
Maximum Leakage .................................................. 2 mL/min 0.07 oz/min
UN25SEP92
ANo. 4 Plug (In reservoir)
BPump Seal Drain Hose
T7855AE

022602
PN=877
Tests
1. Disconnect valve return line (A).
2. Install drain hose (B) (approximately 18 in. X 1.25 in.

I.D.) on valve return port.
3. If valve return leakage is high, perform individual work
UN25SEP92
port leakage test using beaker to collect oil.
Specification
Loader Valve-2 Section
T7855AH
Maximum Leakage ................................................. 220 mL/min (7 oz/min)
Loader Valve-3 Section
Maximum Leakage ............................................... 320 mL/min (11 oz/min)
Loader Valve Work Port
Maximum Leakage ................................................... 31 mL/min (1 oz/min)
TX,902525,BS172 1903MAR936/12
1. Disconnect return line (B), cap line and fitting.
2. Disconnect stabilizer return line (A) and cap line.
3. Measure leakage at fitting (C).

9025
UN07JAN91
25 Specification
32 Backhoe Valve-4 Section
Maximum Leakage ............................................. 1000 mL/min (34 oz/min)
Backhoe Valve-5 Section
T7440BN
Backhoe Valve-6 Section
Backhoe Valve Work Port
Maximum Leakage ................................................... 60 mL/min (2 oz/min)
4. If valve return leakage is high, perform individual work

port leakage test using beaker to collect oil.

022602
PN=878
Tests
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
thermal relief poppet seat. Also check the cylinder
packings, and the lockout plunger spool which
UN07JAN91
slides between the two lockouts . If the lockout
plunger spool is stuck it can hold a lockout open.
Specification
T7440BO
Stabilizer ValveMaximum Spool
Leakage ................................................................ 500 mL/min (17 oz/min)
Maximum Cylinder Drift .................................... 0.15 mm/min (.006 in/min)
To check cylinder drift lower stabilizers to lift machine off

ground. Check for cylinder rod movement with dial
indicator.
AStabilizer Valve Return Line
UN26OCT88
T6222AN
TX,902525,BS172 1903MAR938/12
9025
25
33
Specification
Brake ValveMaximum Leakage
(Both pedals Unapplied) ........................................ 50 mL/min (1.7 oz/min)
ABrake Valve Return Line

BReservoir Connection
UN25SEP92
T7855AJ
(SN 802550) & (SN 872329)

022602
PN=879
Tests
NOTE: For (SN 872329), see Group 9020-25.
Specification
Diff. Lock/Park Brake Valve
Maximum Leakage ................................................. 160 mL/min (6 oz/min)
UN25SEP92
ADifferential Lock and Park Brake Valve Return
Line
BNo. 6 Plug (In Reservoir)
T7855AG
TX,902525,BS172 1903MAR9310/12
Specification
Differential Lock Capture Circuit
Maximum Leakage ..................................................... 1.9 L/min (0.5 gpm)
ANo. 4 Plug (In Reservoir)

BCapture Circuit Return Line
UN25SEP92
T7855AF
9025
25
34

022602
PN=880
Tests
NOTE: For (SN 872329) See Group 9020-25.
CAUTION: Prevent possible injury from

unexpected machine movement. Never rely on
loader bucket to keep machine from moving.
Machine can unexpectedly roll, resulting in
death or serious injury. Always block wheels to
hold machine when working on park brake
components.
1. Block wheels.
2. Release park brake using switch in cab.
3. Disconnect hose (A) from thermal relief valve (B). Used

a plug to close end of hose.
Specification
Park Brake Thermal Relief
ValveMaximum Leakage.................................. 10 mL/min (0.34 oz/min)
UN04DEC94
4. Change position of tee fitting so relief valve outlet is
down.
T8373BC
5. Put beaker under relief valve. Operate engine for 1
minute at slow idle and measure leakage at relief
valve.
9025
AThermal Relief Valve Return Hose 25
6. Connect hose and engage park brake. BThermal Relief Valve 35
TX,902525,BS172 1903MAR9312/12

022602
PN=881
Tests
Circuit Relief Valve Test with Flow

RegulatorTest Cylinder MethodGresen
SPECIFICATIONS
Test Cylinder Rod End Flow 3.78 L/min (1 gpm)
Engine Speed (Approximately) 1000 rpm
Test Cylinder Rod Extend Cycle 1.5 sec
Time
Relief Valve Oil Tolerance +1380 -0 kPa (+13.8 -0 bar)
Pressure (+200 -0 psi)
System Relief Pressure 20 300 kPa (203 bar) (2950 psi)
710D Backhoe Circuits
Crowd Out Pressure 24 000 kPa (240 bar) (3480 psi)
Bucket Curl Pressure 22 000 kPa (220 bar) (3200 psi)
Boom Down Pressure 14 000 kPa (140 bar) (2030 psi)
Swing Left Pressure 19 000 kPa (190 bar) (2750 psi)
Crowd In Pressure 19 000 kPa (190 bar) (2750 psi)
Bucket Dump Pressure 24 000 kPa (240 bar) (3480 psi)
Boom Raise Pressure 27 600 kPa (276 bar) (4500 psi)
Swing Right Pressure 19 000 kPa (190 bar) (2750 psi)
Loader Circuits
Auxiliary Extend Pressure 20 600 kPa (206 bar) (3000 psi)
Bcuket Curl Pressure 31 000 kPa (310 bar) (4500 psi)
9025
25
36 Boom Raise (SN 812258 ) 31 000 kPa (310 bar) (4500 psi)
Pressure

022602
PN=882
Tests
ESSENTIAL TOOLS
38H1030 (-6 F ORFS) a Tee
38H1031 (-8 ORFS) a Tee
38H1033 (-12 ORFS) a Tee
38H1002 (-16 ORFS) a Tee
AH120121 a Test Cylinder (Cancelled)
AH93323 (Replaces AH120121) a Test Cylinder
(-6 ORFS x 3/8 M NPT) Adapter
(3/8 M NPT x 3/8 F NPT) 90 Elbow
(9/1618 M ORB x 3/8 F NPT) Adapter
AT81867 Check Valve
(1/4 M NPT x 9/16-18 F 37) Adapter
NA Quick Coupler
(1/8 M NPT x 1/4 F NPT) Nipple
(1/4 M NPT x 1/4 F NPT 90) Elbow
(1/4 M NPT x 1/4 F NPT x 1/4 F NPT) Tee
38H1146 (-6 ORFS)a Plug
38H1150 (-16 ORFS) a Plug
38H1415 (-6 ORFS) a Cap (2 used)
JT03408 Hydraulic Flow Regulator
a
These ORFS fittings and parts should be ordered through normal
service parts channels. 9025
25
SERVICE EQUIPMENT AND TOOLS 37

Rod End Hose to Tee
Gauge 35 000 kPa (350 bar) (5 000 psi)

022602
PN=883
Tests
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.
Specification
UN07JAN91
Test Cylinder Rod EndFlow ..................................... 3.78 L/min (1 gpm)
Test tee (B) can be installed at most accessible part of

circuit being tested.
T7440BC
AAuxiliary Plug
BCrowd Out Relief
CBucket Curl Relief w/ anti-cavitation
DBoom Lower Relief w/ anti-cavitation
ESwing Left Relief w/ anti-cavitation
FSwing Right Relief w/ anti-cavitation
GBoom Raise Relief
HBucket Dump Relief
ICrowd In Relief w/ anti-cavitation
UN07JAN91
JAuxiliary Plug
KSystem Relief
LAuxiliary Retract Plug
MPlug (SN 812257)
MBoom Raise Relief (SN 812258 )
T7440BD
NBucket Curl Relief
OBucket Dump Relief
PAnti-Cavitation Valve
QAuxiliary Extend Relief
9025
25
38

022602
PN=884
Tests
IMPORTANT: Hydraulic system return pressure must

be subtracted from relief valve gauge
reading to get correct valve setting.
NOTE: Remaining keys for Essential Tools are shown on

corresponding pages.
UN26OCT88
1. Lower stabilizer to ground.
T6725AB
DCylinder
IAdapter
JJT03408 Hydraulic Flow Regulator
KElbow
LAdapter
MCheck Valve
NAdapter
OQuick Coupler
PNipple
Q90 Elbow
RTee
SAdapter

9025
25
39

022602
PN=885
Tests

UN23AUG88
fluids.
X9811
UN20MAR90
2. Operate hydraulic control valves to relieve pressure in
the hydraulic system.
3. Install fitting (A) and hose (B) to connect 2750 kPa
T6900AL
(27.5 bar) (400 psi) gauge to return side of backhoe
valve.
4. Install electronic tachometer and digital thermometer. AAdapter

9025 (See procedure in this group.) BTest Hose-to-Gauge
25
40
CAUTION: Stabilizer control valve contains
lock-outs, which prevent releasing of hydraulic
pressure when engine is off. Slowly loosen
stabilizer hoses to bleed off stored pressure to
prevent being sprayed with high pressure oil.
5. Install stabilizer hoses to test cylinder.

022602
PN=886
Tests
1921MAR89
T6773AN
9025
ARod End Hose-To-Tee CGauge EStabilizer Hose (Rod End) G38H1415 Cap (2 used) 25
BTee DCylinder FStabilizer Hose (Head End) 41
6. Install adapter in relief valve port to be tested. Tee Specification

Test Cylinder Rod Extend
in test gauge (C) and rod end hose (A) from test
Cycle Time ............................................................................... 1.5 sec
cylinder.
9. Activate stabilizer to extend test cylinder and record
NOTE: Test system relief valve by removing system
pressure readings on gauge (C) and on filter
relief from inlet valve section and installing in
housing gauge.
swing section relief valve port. Install swing
circuit relief valve in system relief inlet section
NOTE: If test cylinder stalls while extending cylinder
to do test.
rod, do Main Pump Standby Pressure Test in
this group.
7. Start engine, use stabilizer lever to cycle test
cylinder until temperature is to test specifications.
10. Subtract backhoe return pressure gauge reading
Specification from gauge (C) reading, compare this value with
EngineSpeed .......................................... (Approximately) 1000 rpm specifications.
OilTemperature ............................................ 40 6C (104 10F)
Specification
8. Adjust JT03408 Hydraulic Flow Regulator (3) on Relief Valve Oil Tolerance
Pressure.................................................. +1380 -0 kPa (+13.8 -0 bar)
head end of test cylinder, until rod extends in 1.5 (+200 -0 psi)
seconds. Lock flow regulator at this setting.

022602
PN=887
Tests
710D Backhoe CircuitsSpecification Bucket DumpPressure ........................ 31 000 kPa (310 bar) (4500
Crowd OutPressure............................. 24 000 kPa (240 bar) (3480 psi)
psi) Boom Raise (SN 812258 )
Bucket CurlPressure ........................... 22 000 kPa (220 bar) (3200 Pressure.................................................. 31 000 kPa (310 bar) (4500
psi) psi)
Boom DownPressure .......................... 14 000 kPa (140 bar) (2030
psi) Specification
Swing LeftPressure ............................. 19 000 kPa (190 bar) (2750 System ReliefPressure........................ 20 300 kPa (203 bar) (2950
psi) psi)
Crowd InPressure ............................... 19 000 kPa (190 bar) (2750
psi)
Bucket DumpPressure ........................ 24 000 kPa (240 bar) (3480
11. Retract cylinder rod for next test cycle. Repeat
psi) steps 8 and 9 if required.
Boom RaisePressure .......................... 27 600 kPa (276 bar) (4500
psi) 12. Move tee (B) to next relief valve port to be tested.
Swing RightPressure........................... 19 000 kPa (190 bar) (2750 Repeat steps 7 through 11.
psi)
Loader CircuitsSpecification
IMPORTANT: To prevent structural damage of
Auxiliary ExtendPressure .................... 20 600 kPa (206 bar) (3000 machine, do not adjust relief valves
psi) above specifications.
Bucket CurlPressure ........................... 31 000 kPa (310 bar) (4500
psi) 13. Adjust or replace reliefs as required.
TX,902525,BS181 1903MAR937/7
9025
25
42

022602
PN=888
Tests
Circuit Relief Valve TestRemote Pump

Method
Specifications-Husco
SPECIFICATIONSHUSCO BACKHOE VALVE
710D Backhoe Circuits
Crowd Out Pressure 24 100 kPa (241 bar) (3500 psi)
SPECIFICATIONS
710D Backhoe CircuitsGresen 9025
Crowd Out Pressure 24 000 kPa (240 bar) (3480 psi) 25
43
Loader Circuits
Auxiliary Extend Pressure 20 600 kPa (206 bar) (3000 psi)
Bcuket Curl Pressure 31 000 kPa (310 bar) (4500 psi)
Boom Raise (SN 812258 ) 31 000 kPa (310 bar) (4500 psi)
Pressure
Continued on next page TX,9025,BD2746 1904APR971/6

022602
PN=889
Tests

38H1414-4 ORFS Capa
38H1416-8 ORFS Capa
JT07192 Electric/Hydraulic Pump
(-8 ORFS) Loader Hoses
(-4 ORFS) Hitch Hoses
Gauge 035 000 kPa (0350 bar) (05000 psi)
a
These ORFS fittings should be ordered through normal service parts
channels.
TX,9025,BD2746 1904APR972/6
AAuxiliary Plug
BCrowd Out Relief
CBucket Curl Relief w/ anti-cavitation
DBoom Lower Relief w/ anti-cavitation
9025 ESwing Left Relief w/ anti-cavitation
UN07JAN91
25 FSwing Right Relief w/ anti-cavitation
44 GBoom Raise Relief
HBucket Dump Relief
ICrowd In Relief w/ anti-cavitation
JAuxiliary Plug
T7440BC
KSystem Relief
LAuxiliary Retract Plug
MPlug (SN 812257)
Relief Valve TestGresen
MBoom Raise Relief (SN 812258 )
NBucket Curl Relief
OBucket Dump Relief
PAnti-Cavitation Valve
QAuxiliary Extend Relief
UN07JAN91
T7440BD
Relief Valve TestGresen


022602
PN=890
Tests
This test uses a remote pump to amplify system pressure

so reliefs can be opened and tested.
Specification
Relief Valve Oil Tolerance
Pressure ........................................................ +1380 -0 kPa (+13.8 -0 bar)
(+200 -0 psi)
710D Backhoe CircuitsSpecification
Crowd OutPressure ............................ 24 000 kPa (240 bar) (3480 psi)
Bucket CurlPressure ........................... 22 000 kPa (220 bar) (3200 psi)
Boom DownPressure .......................... 14 000 kPa (140 bar) (2030 psi)
Swing LeftPressure ............................. 19 000 kPa (190 bar) (2750 psi)
Crowd InPressure ............................... 19 000 kPa (190 bar) (2750 psi)
Bucket DumpPressure ........................ 24 000 kPa (240 bar) (3480 psi)
Boom RaisePressure .......................... 27 600 kPa (276 bar) (4500 psi)
Swing RightPressure .......................... 19 000 kPa (190 bar) (2750 psi)
Loader CircuitsSpecification
Auxiliary ExtendPressure .................... 20 600 kPa (206 bar) (3000 psi)
Bucket CurlPressure ........................... 31 000 kPa (310 bar) (4500 psi)
Bucket DumpPressure ........................ 31 000 kPa (310 bar) (4500 psi)
Boom Raise (SN 812258 )
Pressure ................................................. 31 000 kPa (310 bar) (4500 psi)
UN29MAY98
Specification
System ReliefPressure ....................... 20 300 kPa (203 bar) (2950 psi)
T114667
AAuxiliary Plug (4 used)
BCrowd Out Circuit Relief
CBucket Curl Circuit Relief W/Anti-Cavitation
DBoom Lower Circuit Relief W/Anti-Cavitation Backhoe Valve--Husco
9025
ESwing Left Circuit Relief W/Anti-Cavitation 25
FSwing Right Circuit Relief W/Anti-Cavitation 45
GBoom Raise Circuit Relief
HBucket Dump Circuit Relief
ICrowd In Circuit Relief W/Anti-Cavitation
JSystem Relief

022602
PN=891
Tests
IMPORTANT: Hydraulic system return pressure must

be subtracted from relief valve gauge
reading to get correct valve setting.

UN23AUG88
X9811
1.
CAUTION: Stabilizer control valve contains

lock-outs, which prevent releasing of hydraulic
pressure when engine is off. Slowly loosen
stabilizer hoses to bleed off stored pressure to
prevent being sprayed with high pressure oil.
Lower stabilizer to ground.
2. Operate hydraulic control valves to relieve pressure in

the hydraulic system.
Specification
9025
25
46

022602
PN=892
Tests
UN08APR97
T108839
9025
ACap BTest Pump CPressure Gauge 25
47
3. Disconnect pressure line at cylinder inlet port of NOTE: Take reading when pressure on gauge starts
relief valve to be tested. Install cap (A) on cylinder to decrease. The point at which pressure
port. decreases is the opening pressure of the relief
valve.
4. Connect test pump (B) pressure hose to inlet hose
of relief valve to be tested. Install gauge (C) on test 6. Adjust or replace reliefs as required.
pump.
5. Start remote pump to pressurize valve inlet.
IMPORTANT: To prevent structural damage of

machine, do not adjust relief valves
above specifications.
TX,9025,BD2746 1904APR976/6

022602
PN=893
Tests
Cycle Time Test

SPECIFICATIONS
Engine Speed Fast idle

Digital Thermometer
1. Install digital thermometer. (See procedure in this

group.)
2. Start engine and heat oil to specifications. (See

Specification
3. Check cycle times. 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.
9025
25
48
TX,9025,BR539 1916OCT911/1

022602
PN=894
Tests
Cycle Time Test Continued
CYCLE TIME SPECIFICATIONS

Individual Circuit Cycle Time Specifications
Oil temperature 65 5C (150 10F)
Engine speed: fast idle
Function Operating Conditions Maximum Cycle Time
Loader boom raise Bucket flat on ground to full height (includes bucket self leveling) 4.5 seconds
Loader boom lower (power down) Bucket rolled back at full raise 2.8 seconds
Boom float down Bucket rolled back at full raise 3.1 seconds
Loader bucket dump Bucket just clears ground 2.0 seconds
Loader bucket rollback Bucket just clears groun 2.4 seconds
Backhoe boom raise Backhoe at maximum reach with bucket teeth on ground up to 3.3 seconds
cylinder cushion
Backhoe boom lower Backhoe at maximum reach, transport position, to bucket teeth on 3.2 seconds
ground
Crowd in Boom in transport position. 3.8 seconds
Crowd out 3.0 seconds
Backhoe bucket dump 1.8 seconds
Backhoe bucket curl 2.8 seconds
Backhoe swing Boom raised to cushion, bucket curled, dipperstick parallel to 4.0 seconds
ground. Time cycle to cylinder cushion.
Stabilizer down Full up to ground level 2.8 seconds
Stabilizer up Ground level to full up 3.1 seconds
Extendible dipperstick Extend or retract 3.7 seconds 9025
25
Steering Right to left-fast turn 3.0 turns
49
Left to right-fast turn 3 turns
Right to left-slow turn 6 turns
Left to Right-slow turn 6 turns
TX,9025,BD2740 1917MAR971/1

022602
PN=895
Tests
Flowmeter Calibration Procedure
To prevent error in tests using a flowmeter, check

calibration using a John Deere Radial Piston Pump as a
test source.
UN23AUG88
Flowmeter Radial Piston Pump
38114 L/min (1030 gpm) 49 cc (3 cu in.)
76228 L/min (2060 gpm) 100 cc (6 cu in.)
X9811
1. Connect flowmeter inlet hose as close as possible to

main pump outlet.

3. Heat oil to 60C (140F). See procedure in this group.
4. Open flowmeter. Adjust engine speed to 1800 10

rpm. Record flow.
9025
25
50 5. Close flowmeter until pressure reaches 10 340 kPa
(103.4 bar) (500 psi). Adjust engine speed to 1800
10 rpm. Record flow.
High pressure flow must be 95% or more of low

pressure flow or pump cannot be used for test.
6. Open flowmeter to minimum restriction. Adjust voltage

calibration and zero flowmeter.
7. 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,
40, and 60 gpm).
8. Use chart to find recorded rpm for size of pump on test

tractor. Note specified flow and compare to measure
flow.
Continued on next page 27T,9025,M124 1916OCT911/2

022602
PN=896
Tests
L/min (gpm) rpm L/min (gpm) rpm L/min (gpm) rpm L/min (gpm) rpm
100 cc (6 cu. in.) Pump Specs
76 20 811 114 (30) 1216 151 (40) 1621 189 (50) 2026
80 (21) 851 117 (31) 1256 155 (41) 1661 193 (51) 2066
83 (22) 892 121 (32) 1297 159 (42) 1702 197 (52) 2107
87 (23) 932 125 (33) 1337 163 (43) 1742 201 (53) 2147
91 (24) 973 129 (34) 1378 167 (44) 1783 204 (54) 2188
95 (25) 1013 132 (35) 1418 170 (45) 1823 208 (55) 2228
98 (26) 1054 136 (36) 1459 174 (46) 1864 212 (56) 2269
102 (27) 1094 140 (37) 1499 178 (47) 1904 216 (57) 2309
106 (28) 1135 144 (38) 1540 182 (48) 1945 220 (58) 2350
110 (29) 1175 148 (39) 1580 185 (49) 1985 223 (59) 2390
227 (60) 2431
49 cc (3 cu. in.) Pump Specs
38 (10) 811 57 (15) 1216 76 (20) 1621 95 (25) 2026
42 (11) 892 61 (16) 1297 80 (21) 1702 98 (26) 2107
45 (12) 973 64 (17) 1378 83 (22) 1783 102 (27) 2188
49 (13) 1054 68 (18) 1459 87 (23) 1864 106 (28) 2269
53 (14) 1135 72 (19) 1540 91 (24) 1945 110 (29) 2350
114 (30) 2431
65 cc (4 cu in.) Pump Specs
53 (14) 851 79 (21) 1277 106 (28) 1702 132 (35) 2127
57 (15) 911 83 (22) 1337 110 (29) 1763 136 (36) 2188
61 (16) 972 87 (23) 1398 114 (30) 1823 140 (37) 2250 9025
25
64 (17) 1033 91 (24) 1459 117 (31) 1884 144 (38) 2310 51
68 (18) 1094 95 (25) 1520 121 (32) 1945 148 (39) 2370
72 (19) 1155 98 (26) 1580 125 (33) 2006 151 (40) 2431
76 (20) 1215 102 (27) 1641 129 (34) 2067
27T,9025,M124 1916OCT912/2

022602
PN=897
Tests
Differential Lock Pressure Reducing Valve

Test (S.N. 872256)
NOTE: For (SN 872329) Differential Lock Pressure

Reducing Valve Test see Group 9020-25.
UN23AUG88
SPECIFICATIONS
Differential Lock Pressure 36544482 kPa (3644 bar)
X9811
(550650 psi)
ESSENTIAL TOOLS
(1/2 M ORB x 7/16 M 37) (Parker No. 5-4-0503) Adapter

Gauge 06895 kPa (068 bar) (01000 psi)

1. Stop engine, FNR in neutral, park brake on.

9025
25
52

022602
PN=898
Tests
2. Install gauge and connector in port (A) of park

brake/differential lock valve.
Specification
3. Start engine.
Specification
4. Engage differential lock and record pressure.
Specification
Differential LockPressure ........................ 36544482 kPa (3644 bar)
(550650 psi)
Check standby pressure (See Test in this Group) if

differential Lock pressure is low. Adjust pressure
reducing valve if standby is to specification. If
pressure reducing valve will not adjust with
differential lock in "on" position, adjust in "off"
1905OCT92
position. If valve can be adjusted in "off" position
leakage is in differential lock assembly. To test
differential lock solenoid see group 9015-15.
T7861AA
A"Reg Test" Port
BPressure Reducing Valve
9025
25
53
TX,902525,BS189 1903MAR932/2

022602
PN=899
Tests
Park Brake Circuit Pressure Test (S.N.

872256)
NOTE: For (SN 872329) Park Brake Circuit Pressure

Test see Group 9020-25.
UN23AUG88
X9811
SPECIFICATIONS
Park Brake Pressure 17 23022750 kPa (172228
bar) (25003300 psi)
ESSENTIAL TOOLS
(-4 ORFS) (Parker No. -4 R6LO-S) Swivel Run Tee

Gauge 034 500 kPa (0345 bar) (05000 psi)
NOTE: For (S.N 872329) Park Brake Circuit Pressure

9025 Test see Section 9020.
25
54 1. Stop engine, FNR in neutral, park brake on.

022602
PN=900
Tests
2. Install gauge and tee on port (A) between park brake

differential lock valve and hose to park brake.
Specification
3. Start engine and disengage park brake. Record

pressure.
Specification
Park BrakePressure .............................. 17 23022750 kPa (172228
bar) (25003300 psi)
4. Raise loader lift arms so bucket is at hood height. Put

loader control lever in bucket roll back position. Record
pressure when bucket reaches self level stop. Repeat
3-4 times.
Pressures recorded in step 3 or 4 should be within

specified range. If pressure exceeds 3300 psi adjust
park brake relief valve. If pressure is low check
1905OCT92
pump standby pressure (See Test in this Group).
Check park brake assembly for external leakage, or
adjust park brake relief valve if standby is to
T7861AB
specification. To test park brake solenoids see group
9015-15.
9025
APark Brake Work Port 25
BRelief Valve 55
TX,902525,BS190 1920DEC942/2

022602
PN=901
Tests
Park Brake Thermal Relief Valve Test (S.N.

872256)
SPECIFICATIONS
Park Brake Thermal Relief Valve 24 130 1380 kPa (241 14
Setting Pressure bar) (3500 200 psi)
UN23AUG88
D01019AA Hydraulic Hand Pump with Gauge (from D01047AA 17-1/2
and 30 Ton Puller Set)
X9811
JT15068 (3/8 F NPT x 9/16 F ORB) BCoupler

1. Remove park brake thermal relief valve (B).
2. Connect relief valve to hand pump using coupler (A).
3. Slowly operate hand pump while watching pressure

gauge and relief valve.
4. Note the pressure when relief valve allows oil to be

9025
released.
25
56
Specification
Park Brake Thermal Relief Valve
SettingPressure....................................... 24 130 1380 kPa (241 14
bar) (3500 200 psi)
UN04DEC94
If pressure is not within specification, replace thermal
relief valve.
T8373BE
TX902525,BD1663 1920DEC941/1

022602
PN=902
Tests
9025
25
57

022602
PN=903
Tests

872328)

UN23AUG88
SPECIFICATIONS
X9811
Oil Temperature 49 2.5C (120 5F)
Brake-Engine On- LH or RH 47757 kPa (47.5 bar) (690 70
Minimum Pressure psi)
Brake-Engine Off-Manual Mode, 5 515 kPa (55 bar) (800 psi)
LH or RH Minimum Pressure
Differential, LH to RH, Engine On 1000 kPa (10 bar) (145 psi)
Maximum Pressure
ESSENTIAL TOOLS
JT05487 (1/8 M NPT x 7/16 M 37) Fitting

Gauge 034 500 kPa (0345 bar) (05000 psi)
9025 1. Engine off, park brake on, FNR neutral. Remove brake
25 light pressure switches from LH and RH brake outlet
58 lines.

022602
PN=904
Tests
2. Install connectors and gauges (B).
3. Start engine and firmly apply LH brake pedal. Record

pressure. Firmly apply RH brake pedal and record
pressure.
Specification
OilTemperature .................................................. 49 2.5C (120 5F)
Brake-Engine On- LH or RH
Minimum Pressure................................... 17 47757 kPa (47.5 bar) (690
70 psi)
Brake-Engine Off-Manual Mode,
LH or RHMinimum Pressure..................... 5 515 kPa (55 bar) (800 psi)
Differential, LH to RH, Engine
OnMaximum Pressure ............................... 1000 kPa (10 bar) (145 psi)
NOTE: Pump brake pedals if required.
Manual mode-engine off-pressures may not be to

specification when engine on pressures are to
specification. See group 9025-15 "Manual brakes
UN16OCT92
do not build pressure" for causes.
4. Stop engine and firmly apply LH brake pedal. Record

T7869CA
pressure.
5. Start engine and lock LH and RH brake pedals 9025

together. Firmly apply locked brakes, with foot on ABrake Valve 25
centerline between pedals, to obtain a pressure BGauges 59
reading on gauges of approximately 1000 psi. Record
pressure differential between gauges.
To determine excessive leakage in brake valve, do

brake valve leakage test. (See Hydraulic Component
Leakage Test in this group.)
TX,902525,BS192 1903MAR932/2

022602
PN=905
Tests

872329 )
SPECIFICATIONS
Oil Temperature 49 2.5C (120 5F)
UN23AUG88
Brake-Engine On- LH or RH 10 000 kPa 345 kP (100 3.5
Minimum Pressure bar) (1450 50 psi)
ESSENTIAL TOOLS
X9811
JT05494 ( 7/1628 M 37 x 3/416 M ORB) Connector
JT05483 ( 7/1620 M 37 x 7/1620 F 37 Deg.) Elbow (90 Degree
Swivel)

Gauge 034 500 kPa (0-345 bar) (05000 psi)

NOTE: Brakes are self bleeding but should be bled

whenever system is opened. Bleed brakes by
UN23OCT98
9025 pumping one pedal 20 times while depressing the
25 other pedal with tractor running at slow idle.
60 Repeat for the opposite pedal.
T118039
1. Engine off, park brake on, FNR neutral. Remove brake
light pressure switch and adapter fitting from port in
brake housing.
AConnector
2. Install connector (A), elbow (B) and gauge (C). BElbow
CGauge
3. Start engine and firmly apply LH brake pedal. Record

pressure.
Specification
OilTemperature .................................................. 49 2.5C (120 5F)
Brake-Engine On- LH or RH
Minimum Pressure.................................. 10 000 kPa 345 kP (100 3.5
bar) (1450 50 psi)
Continued on next page OUO1048,00003DE 1908SEP001/2

022602
PN=906
Tests
To determine excessive leakage in brake valve, do

brake valve leakage test. (See Hydraulic Component
Leakage Test in this group.)
4. Remove test equipment and bleed brakes. Brakes are

self bleeding but should be bled whenever system is
opened. Bleed brakes by pumping one pedal 20 times
while depressing the other pedal with tractor running at
slow idle. Repeat for the opposite pedal.
5. Bleed brakes by pumping one pedal 20 times while

depressing the other pedal with tractor running at slow
idle. Repeat for the opposite pedal.
OUO1048,00003DE 1908SEP002/2
9025
25
61

022602
PN=907
Tests
Service Brake Valve Work Port Pressure Test

(S.N. 872329 )
SPECIFICATIONS
Brake Work Port Pressure 0 kPa (0 bar) (0 psi)
ESSENTIAL TOOLS
38h1030 (6M x 6M x 6 F ORFS) Tee (Running)
JT03456 (7/16-20 M JIC x 6 F ORFS) Adapter

13,790 kPa (138 bar) (2,000 psi) Gauge
UN16DEC98
T119057
NOTE: This test is required only if brake drag is ATee

diagnosed or brake valve is serviced. The test will BAdapter
isolate each brake work port pressure by CGauge
connecting a gauge to right or left lines located DRight Brake Line
under cab floor access panel. ELeft Brake Line
9025 1. Engine off, park brake on, FNR neutral. Remove floor
25 plate in cab floor.
62
CAUTION: Depress both brake pedals multiple

times (approximately 25) to release brake line
pressure to reservoir.
2. Depress both brake pedals multiple times

(approximately 25) to release brake line pressure to
reservoir.
3. Install Tee (A), adapter (B), and gauge (C).
4. Start engine and apply both brakes.
5. Turn OFF engine and apply both brakes and release.
6. Record pressure on gauge from each brake line work

port with brake unapplied. There must be NO pressure
in work port lines (brake valve to rear axle) when
brakes are unapplied.
Continued on next page CED,TX04577,833 1917DEC981/2

022602
PN=908
Tests
Specification
Brake Work PortPressure ...................................... 0 kPa (0 bar) (0 psi)
If any pressure is recorded:
Do Brake Valve and Pedal Adjustment. See 9025.20
Inspect Brake valve for free spool travel. Check for

contamination. See Repair Manual Section 1062.

pumping one pedal 20 times while depressing the
other pedal with tractor running at slow idle.
Repeat for the opposite pedal.

idle. Repeat for the opposite pedal
CED,TX04577,833 1917DEC982/2
9025
25
63

022602
PN=909
Tests
Brake Accumulator Precharge Pressure Test

(S.N. 872328)
SPECIFICATIONS
Accumulator Precharge Pressure 8500 300 kPa (85 3 bar)
UN23AUG88
(1230 44 psi)
ESSENTIAL TOOLS
JT03083 (7/16 Male JIC x 1/2 ORB Male) Adapter
X9811
Gauge 034 500 kPa (0345 bar) (05000 psi)
Digital Thermometer

fluids.
9025 If an accident occurs, see a doctor immediately.

25 Any fluid injected into the skin must be
64
1. With engine off, relieve pressure in brake system by

pumping brakes until firm pedal feel is gone (brakes in
manual mode).

022602
PN=910
Tests
NOTE: Accumulator can be discharged due to normal

leakage through brake valve when machine is not
running.
2. Remove accumulator test port plug (A). Install adapter,

gauge and digital thermometer.
UN12NOV92
this group.)
T7888AB
Specification
4. Stop engine and observe pressure gauge. If pressure

reading on gauge is decreasing, leakage is indicated in
the accumulator check valve, accumulator thermal
relief valve, or brake valve.
NOTE: To determine if leakage is in brake valve, do

brake valve leakage test. (See Hydraulic
Component Leakage Test in this group.)
5. Operate brake valve and observe pressure gauge.

Pressure will slowly decrease, then drop immediately
to zero.
The last pressure observed before dropping to zero

is the accumulator precharge pressure. 9025
25
65
Specification
Accumulator Precharge
Pressure ....................................................... 8500 300 kPa (85 3 bar)
(1230 44 psi)
If accumulator precharge pressure is not correct,

repair or charge accumulator. (See repair manual.)


TX,902525,BS207 1903MAR932/2

022602
PN=911
Tests
Brake Accumulator Precharge Pressure Test

(S.N. 872329 )
SPECIFICATIONS
Accumulator Precharge Pressure 3 447 345 kPa (34.5 3.45
UN23AUG88
bar) (500 50 psi)
ESSENTIAL TOOLS
JT05494 ( 7/1628 M 37 x 3/416 M ORB) Connector
X9811
JT05483 ( 7/1620 M 37 x 7/1620 F 37 Deg.) Elbow (90 Degree
Swivel)

Gauge 034 500 kPa (0345 bar) (05000 psi)
Digital Thermometer

9025 fluids.
25
66
NOTE: Accumulators can be discharged due to normal

leakage through brake valve when machine is not
running.
1. Engine off, park brake on, FNR neutral. Remove brake

light pressure switch in brake valve and install
connector, elbow and pressure gauge. See Service
Brake Valve Pressure Test in this Group.
Continued on next page OUO1048,00003DF 1908SEP001/3

022602
PN=912
Tests

(See procedure in this Group.)

this group.)
Specification
4. Stop engine and observe pressure reading on gauge.
NOTE: To determine if leakage is in brake valve, do

brake valve leakage test. (See Hydraulic
Component Leakage Test in this group.)
5. Depress right pedal multiple times and observe

pressure gauge. Pressure will slowly decrease with
each application, then drop immediately to zero.
Repeat step for left pedal and observe pressure gauge.
NOTE: Brake pressure indicator light (on side console)

comes on at 5 515 690 kPa (55 6.9 bar) (800
100 psi). Accumulator Precharge is adequate if
light on side console and audible alarm does not
come on within the first six applications of brake
pedals.
9025
25
The last pressure observed before dropping to zero
67
is the accumulator precharge pressure.
Specification
Accumulator Precharge
Pressure ..................................................... 3 447 345 kPa (34.5 3.45
bar) (500 50 psi)
IMPORTANT: Accumulators are NOT serviceable.
An external plumbing leak between the accumulators

and brake valve may also cause low pressure.
If accumulator precharge pressure is not in
specification or zero after one applicaton of pedal,
replace accumulator
6. Remove test fittings.
Continued on next page OUO1048,00003DF 1908SEP002/3

022602
PN=913
Tests


OUO1048,00003DF 1908SEP003/3
9025
25
68

022602
PN=914
Section 9031
Heating and Air Conditioning
Contents
Page Page
Group 05Theory of Operation Sub System Diagnostics/Air Conditioning

Proper Refrigerant Handling . . . . . . . . . . . . .9031-05-1 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-15-9
R134A Refrigerant Cautions . . . . . . . . . . . . .9031-05-1 Blower/Air Conditioning Circuit Checks . . . . .9031-15-9
Refrigerant Theory of Operation . . . . . . . . . .9031-05-2
Air Conditioning Circuit Operational Group 20Adjustments
Information. . . . . . . . . . . . . . . . . . . . . . . . .9031-05-3 Proper Refrigerant Handling . . . . . . . . . . . . .9031-20-1
Air Conditioning Circuit Theory of Operation R134A Refrigerant Cautions . . . . . . . . . . . . .9031-20-1
(S.N. 816286). . . . . . . . . . . . . . . . . . . . .9031-05-4 R134A Compressor Oil Charge Check . . . . .9031-20-2
Air Conditioning Circuit Schematic (S.N. R134A Compressor Oil Removal. . . . . . . . . .9031-20-2
816286) . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-5 R134A Component Oil Charge . . . . . . . . . . .9031-20-3
Air Conditioning Circuit Theory Of R134A Refrigerant Recovery, Recycling
Operation (S.N. 816287872256). . . . . . .9031-05-6 And Charging Station Installation
Air Conditioning Circuit Schematic (S.N. Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-4
816287872256) . . . . . . . . . . . . . . . . . . .9031-05-7 Recover R134A System . . . . . . . . . . . . . . . .9031-20-5
Air Conditioning Circuit Theory of Evacuate R134A System. . . . . . . . . . . . . . . .9031-20-6
Operation (S.N. 872257 ) . . . . . . . . . . . .9031-05-8 Charge R134A System . . . . . . . . . . . . . . . . .9031-20-8
Air Conditioning Circuit Schematic (S.N. Check And Adjust Compressor Belt Tension
872257 ). . . . . . . . . . . . . . . . . . . . . . . . .9031-05-9 (S.N. 816286). . . . . . . . . . . . . . . . . . . . .9031-20-9
Blower Circuit Operational Information . . . .9031-05-10
Blower Circuit Theory Of Operation (S.N. Group 25Test
816286) . . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-10 Proper Refrigerant Handling . . . . . . . . . . . . .9031-25-1
Blower Circuit Schematic (S.N. R134A Refrigerant Cautions . . . . . . . . . . . . .9031-25-1
816286) . . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-11 R134A Air Conditioning System Test . . . . . .9031-25-2
Pressure Diagnostic Chart. . . . . . . . . . . . . . .9031-25-4 9031
816287 ). . . . . . . . . . . . . . . . . . . . . . . .9031-05-12 Low Pressure Switch Test (S.N.
816286) . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-5
Blower Circuit Schematic (S.N. 816287
Low Pressure Switch Test (S.N. 816287
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-13
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-8
Receiver/Dryer Operation . . . . . . . . . . . . . .9031-05-14
High Pressure Switch Test (S.N.
Expansion Valve Operation . . . . . . . . . . . . .9031-05-16
816286) . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-10
Compressor Relief Valve Operation . . . . . .9031-05-17
High Pressure Switch Test (S.N.
Temperature Control . . . . . . . . . . . . . . . . . .9031-05-17
816287 ). . . . . . . . . . . . . . . . . . . . . . . .9031-25-12
A/C Freeze Control Switch . . . . . . . . . . . . .9031-25-14
Group 15Diagnostic Information Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .9031-25-15
Diagnose Air Conditioning Electrical Refrigerant Hoses And Tubing
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9031-15-1 Inspection . . . . . . . . . . . . . . . . . . . . . . . .9031-25-15
Air Conditioning Component Location (S.N.
816286) . . . . . . . . . . . . . . . . . . . . . . . . .9031-15-2
816287872256) . . . . . . . . . . . . . . . . . . .9031-15-4
Blower Harness (W10)
Wiring Diagram (S.N. 872257 ) . . . . . . .9031-15-6
Air Conditioning Compressor Harness (W11)
Wiring Diagram (S.N. 872257 ) . . . . . . .9031-15-7
872257 ). . . . . . . . . . . . . . . . . . . . . . . . .9031-15-8
022602
PN=1
Contents
9031

022602
PN=2
Group 05
Theory of Operation
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits It must be recovered using the
discharge of any refrigerant into the atmosphere, and appropriate recovery stations.
requires that refrigerant be recovered using the
approved recovery equipment. Use correct refrigerant recovery,
recycling and charging stations. DO
IMPORTANT: To meet government standards NOT mix refrigerants, hoses, fittings,
relating to the use of refrigerants, components or refrigerant oils.
R134a is used in the air conditioning
system. Because it does not contain Recovery, recycling and charging stations for R12 and
chlorine, R134a is not detrimental to R134a refrigerants MUST NOT be interchanged.
the ozone in the atmosphere. Systems containing R12 refrigerant use a different oil
However, it is illegal to discharge than systems using R134a. Certain seals are not
any refrigerant into the atmosphere. compatible with both types of refrigerants.
TX,9031,QQ5732 1905AUG961/1
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,QQ5733 1911JUN961/1

022602
PN=917
Theory of Operation
Refrigerant Theory of Operation
1904MAR97
T106841
ACompressor ECondenser IExpansion Valve LBlowers
BLow Pressure Switch FEngine Fan JLow Pressure Liquid MA/C Freeze Switch
CHigh Pressure Switch GHigh Pressure Liquid KEvaporator NLow Pressure Gas
9031 DHigh Pressure Gas HReceiver Dryer
05
2 The compressor (A) draws low pressure gas (N) from the refrigerant causes it to condense and it leaves the
the evaporator (K) and compresses it into high condenser (E) as a high pressure liquid (G). The high
pressure gas (D). Increasing the pressure of the pressure liquid flows into the receiver-dryer (H) where
refrigerant causes its boiling point to rise to a moisture and contaminants are removed.
temperature higher than the outside air temperature.
The refrigerant flows from the receiver-dryer (H) to the
High pressure gas (D) leaves the compressor (A) and expansion valve (I). The expansion valve (I) is a
passes through two switches (B and C). These variable orifice used to cause a pressure and
switches monitor refrigerant pressure. Should the temperature drop in the refrigerant causing refrigerant
pressure become too great or too small, either the high to vaporize. The expansion valve (I) is one of the
or low pressure switch will open and stop the dividing lines between the high side and low side of
compressor, interrupting the cycle. the air conditioning system. At this point in the system,
the high pressure/high temperature liquid is sprayed
As the high pressure gas flows through the condenser into the evaporator (K) where it changes and becomes
(E), the engine fan (F) draws air through the a gas.
condenser core which cools the refrigerant. Cooling

022602
PN=918
Theory of Operation
The expansion valve diaphragm is activated by evaporator outlet. The low temperature causes the
sensing temperature and pressure within the valve expansion valve variable orifice to decrease in size,
body. The internal bulb senses the evaporator outlet or restricting refrigerant flow. If the evaporator outlet
discharge temperature and pressure of refrigerant as it temperature is too warm, the orifice will increase in
passes through the valve back to the low pressure or size, allowing more refrigerant into evaporator.
suction side of the compressor. (See Expansion Valve
Operation in this group for additional information on If evaporator (K) temperature becomes too low, the
theory of operation.) A/C freeze switch (M) will interrupt current flow to the
compressor clutch coil, stopping system operation until
If too much refrigerant is flowing into evaporator, the the temperature becomes normal, between 31 and
liquid refrigerant will still be evaporating as it leaves 40.
the evaporator, causing a low temperature at the
TX,9031,BG643 1929JAN972/2
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,QQ5735 1911JUN961/1
3

022602
PN=919
Theory of Operation
Air Conditioning Circuit Theory of Operation (S.N. 816286)
Power from 30 amp heater fuse flows through P16 red High Pressure Switch
and 518 red wires to blower switch. With blower switch
turned to low, medium or high position, power flows to The high pressure switch protects the system from
blower resistor and then to heater blower motors. high pressure. If a malfunction or line restriction
causes the high pressure to increase above the setting
Power also flows from C terminal of blower switch, of the switch, the switch will open to stop current flow
through 522 white wire to freeze control switch, to the compressor clutch. The high pressure switch is
through 517 dark blue wire to air conditioning switch. located near the compressor in the high pressure line.
With air conditioning switch turned ON, power flows A/C Freeze Switch
through A17 orange wire to the lower pressure switch.
With low pressure switch closed, power flows through The A/C freeze switch is used to sense the
A18 green wire to high pressure switch. With high temperature in the evaporator core. When the
pressure switch closed power flows through A19 green temperature drops, the clutch cycle switch opens,
wire to the coil terminal of the compressor coil to shutting the compressor off. When the temperature in
energize the compressor clutch. the evaporator core raises, the A/C freeze switch
closes sending voltage to the compressor.
Low Pressure Switch
The A/C freeze switch receives power from the blower
The low pressure switch will open if the air switch when blower switch is turned to low, medium or
conditioning system loses its refrigerant charge. The high position.
which prevents compressor engagement. The low NOTE: For component identification code description
pressure switch is located near the compressor in high see Wiring and Schematic Diagrams Legend,
pressure line. Group 9015-10.
9031
05
TX,9031,BG784 1904MAR971/1
4

022602
PN=920
Theory of Operation
Air Conditioning Circuit Schematic (S.N. 816286)
9031
05
5
1924SEP92
T7835AU
TX,9031,BG647 1929JAN971/1

022602
PN=921
Theory of Operation
Air Conditioning Circuit Theory Of Operation (S.N. 816287872256)
Power from 30 amp heater fuse flows through P16 red High Pressure Switch
and 518 red wires to blower switch. With blower switch
turned to 1, 2, or 3 position, power flows to blower The high pressure switch protects the system from
resistor and then to heater blower motor. With blower high pressure. If a malfunction or line restriction
switch turned to position 4 the resistor is bypassed and causes the high pressure to increase above the setting
blower motor is in max speed. of the switch, the switch will open to stop current flow
to the compressor clutch. The high pressure switch is
Power also flows from blower switch, through white located near the compressor in the high pressure line.
wire to A/C freeze switch, through black/white and A16
orange wire to air conditioning switch. A/C Freeze Switch
With air conditioning switch turned ON, power flows The A/C freeze switch is used to sense the
through A17 orange wire to the low pressure switch. temperature in the evaporator core. When the
With low pressure switch closed, power flows through temperature drops, the A/C freeze switch opens,
A18 green wire to high pressure switch. With high shutting the compressor off. When the temperature in
pressure switch closed power flows through A19 green the evaporator core raises, the A/C freeze switch
wire to the coil terminal of the compressor coil to closes sending voltage to the compressor.
energize the compressor clutch.
The A/C freeze switch receives power from the blower
Low Pressure Switch switch when blower switch is turned to low, medium or
high position.
The low pressure switch will open if the air
conditioning system loses its refrigerant charge. The NOTE: For component identification code description,
switch opens to stop current flow to the compressor see Wiring and Schematic Diagrams Legend,
which prevents compressor engagement. The low Group 9015-10.
pressure switch is located near the compressor in high
pressure line.
9031
05
TX,9031,BG645 1929JAN971/1
6

022602
PN=922
Theory of Operation
Air Conditioning Circuit Schematic (S.N. 816287872256)
9031
05
7
1931MAY96
T101444
TX,9031,BG648 1929JAN971/1

022602
PN=923
Theory of Operation
Air Conditioning Circuit Theory of Operation (S.N. 872257 )
Power flows through the heater fuse to the blower High Pressure Switch
switch. The blower switch has five different positions,
off and four speeds. With the switch in speeds 1, 2, The high pressure switch protects the system from
and 3 power is sent to the blower resistor. The blower high pressure. If a malfunction or line restriction
resistor has three different resistance values causing causes the high pressure to increase above the setting
the fan to have different speeds. With the blower of the switch, the switch will open to stop current flow
switch on the speed 4, power is sent directly to the to the compressor clutch. The high pressure switch is
blower motor and bypasses the blower resistor. This located near the compressor in the high pressure line.
causes the fan to be at the highest speed.
Freeze Protection Switch
When the blower switch is in any of the four ON
speeds, power also flows through the normally closed The freeze protection switch is used to sense the
freeze control switch and to the A/C on/off switch. temperature in the evaporator core. When the
When the A/C on/off switch is switched on power temperature drops, the freeze protection switch opens,
continues to flow through the normally closed high and stopping power flow to the compressor. When the
low pressure switches to the A/C compressor engaging temperature in the evaporator core raises, the freeze
the compressor clutch. protection switch closes allowing power to continue to
flow to the compressor.
Low Pressure Switch
The freeze protection switch receives power from the
The low pressure switch will open if the air blower switch when the blower switch is in any of the
conditioning system loses its refrigerant charge. The four ON speeds.
which prevents compressor engagement. The low
pressure switch is located near the compressor in the
high pressure line.
9031
05
CED,TX17864,203 1917SEP981/1
8

022602
PN=924
Theory of Operation
Air Conditioning Circuit Schematic (S.N. 872257 )
9031
05
9
1918SEP98
T117258
CED,TX17864,194 1916SEP981/1

022602
PN=925
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,9031,BG649 1929JAN971/1
Blower Circuit Theory Of Operation (S.N.

816286)
Power from heater fuse 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.

9031
05 9015-10.
10
TX,9031,BG650 1902OCT981/1

022602
PN=926
Theory of Operation
9031
05
11
1930SEP92
T7857AD
TX,9031,BG651 1929JAN971/1

022602
PN=927
Theory of Operation

816287 )

With blower switch in positions 1, 2, or 3 power is sent to
blower resistor reducing blower motor speed. With blower
switch in position 4 the resister is bypassed and blower
motor will run in max speed.

9015-10.
TX,9031,BG652 1929JAN971/1
9031
05
12

022602
PN=928
Theory of Operation
Blower Circuit Schematic (S.N. 816287 )
9031
05
13
1922APR97
T101441
TX,9031,BG653 1929JAN971/1

022602
PN=929
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
14
hydrochloric acids are formed. These acids are very
corrosive to metal surfaces and leakage will eventually
develop. If the air conditioning system is left open for a
T8104AF
period of time or if the plugs are removed from the
receiver/dryer, the desiccant will also absorb moisture
from the air. The receiver/dryer contains a color moisture
indicator. (Blue) indicates dryer is dry. (Pink) indicates AInlet Port
moisture in the desiccant. Evacuating the system will not BSight Glass
remove moisture from the desiccant. You must replace COutlet Port
the receiver/dryer. DPickup Tube
EFilter
FDesiccant
GStrainer
HSpring
IReceiver/Dryer
JWet/Dry Indicator
Continued on next page TX,9031,QQ5741 1911JUN961/2

022602
PN=930
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,QQ5741 1911JUN962/2
9031
05
15

022602
PN=931
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
16 refrigerant flowing into the evaporator. At this point in expansion valve is relatively small. The rapidly
the system, the high pressure/high temperature liquid expanding refrigerant passing through this area can
is sprayed into the evaporator where it changes state cause any moisture in the system to freeze at this
and becomes a gas. point and block refrigerant flow. Other contaminants in
the system can also cause a valve to malfunction. If
The valve diaphragm (A) is activated by sensing expansion valve malfunctions, it must be replaced.
temperature and pressure within the valve body. The Expansion valve is not repairable.
sealed sensing bulb (B) senses the evaporator outlet
(I) or discharge temperature and pressure of the
refrigerant as it passes through the valve back to the
low pressure or suction side of the compressor.
TX,9031,QQ5742 1911JUN961/1

022602
PN=932
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,QQ5743 1911JUN961/1
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,9031,QQ5744 1911JUN961/1
17

022602
PN=933
Theory of Operation
9031
05
18

022602
PN=934
Group 15
Diagnose Air Conditioning Electrical
Malfunctions

probable and simplest to verify, to least likely
steps when diagnosing a problem:
Step 1. Operational Check Out Procedure

Air Conditioning System Does Circuit Breaker (S.N. 816286) or Replace circuit breaker or fuse.
Not Operate Fuse (S.N. 816287 )
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

A/C Freeze 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,QQ5746 1912JUN961/1

022602
PN=935
Air Conditioning Component Location (S.N. 816286)

T7861AC 1913MAR97
S25
AIR CONDITIONING P
SWITCH F6
A 30 AMP HEATER/A.C.
CIRCUIT BREAKER
HIGH PRESSURE
QUICK DISCONNECT S26
N CLUTCH
CYCLE O
S23 SWITCH S22
LOW PRESSURE M B HEATER TEMP.
SWITCH SWITCH
S24
HIGH PRESSURE L S8
SWITCH C BLOWER
SWITCH
Y10
COMPRESSOR K
D EXPANSION
VALVE
CONDENSOR J
M7
E HEATER BLOWER
MOTOR
M6
F HEATER BLOWER
MOTOR
R1
G BLOWER
RESISTOR
H
EVAPORATOR
I
RECEIVER
DRYER
T7861AC 710D AIR CONDITIONING COMPONENT LOCATION
TX,9031,BG656 1930JAN971/2

022602
PN=936
AAir Conditioning Switch DExpansion Valve IClutch Cycle Switch (S26) NLow Pressure Switch (S23)
(S25) EHeater Blower Motor (M7) JReceiver Dryer OHigh Pressure Quick
BBlower Switch (S8) FHeater Blower Motor (M6) KCondenser Disconnect
CHeater Temperature Switch GBlower Resistor (R1) LCompressor (Y10) PHeater/A.C. Circuit Breaker
(S22) HEvaporator MHigh Pressure Switch
(S24)
NOTE: For electrical call-outs in parenthesis, see

Wiring and Schematic Diagrams Legend in
Group 9015-10.
TX,9031,BG656 1930JAN972/2
9031
15
3

022602
PN=937
Air Conditioning Component Location (S.N. 816287872256)

T106846 1911APR97
F6
BLOWER SWITCH A 30 AMP HEATER/A.C.
CONNECTOR R CIRCUIT BREAKER
S25 S22
YEL 1 AIR CONDITIONING S B HEATER TEMPERATURE
SWITCH SWITCH
BLU 2
PUR 3 S8
ORG 4 C BLOWER
SWITCH
RED B
BLOWER HARNESS Q
TO SIDE CONSOLE
HARNESS CONNECTOR D EVAPORATOR
BLK / W C
RED B
EXPANSION
E VALVE
S23
LOW PRESSURE
S24 SWITCH P R1
HIGH PRESSURE O F BLOWER
SWITCH RESISTOR
CONDENSOR N M6
G HEATER BLOWER
MOTOR
S26
H AC FREEZE
SWITCH
HIGH PRESSURE M
CHARGE PORT
LINE
J TO
ENGINE I LINE TO
BLOCK WATER PUMP
RECEIVER
K
DRYER
L
Y10
COMPRESSOR
T106846 AIR CONDITIONING COMPONENT LOCATION
TX,9031,BG655 1930JAN971/2

022602
PN=938
A30 Amp Heater/A.C. Circuit FBlower Resistor (R1) LCompressor (Y10) RBlower Switch Connector
Breaker (F6) GHeater Blower Motor (M6) MHigh Pressure Charge Port SAir Conditioning Switch
BHeater Temp. Switch (S22) HA/C Freeze Switch (S26) NCondenser (S25)
CBlower Switch (S8) ILine To Water Pump OHigh Pressure Switch (S24)
DEvaporator JLine To Engine Block PLow Pressure Switch (S23)
EExpansion Valve KReceiver Dryer QBlower Harness To Side
Console Harness
Connector
NOTE: For electrical call-outs in parenthesis, see

Wiring and Schematic Diagrams Legend in
Group 9015-10.
TX,9031,BG655 1930JAN972/2
9031
15
5

022602
PN=939
Blower Harness (W10) Wiring Diagram (S.N. 872257 )

T116840 1910SEP98
CED,TX17864,147 1925AUG981/1

022602
PN=940
Air Conditioning Compressor Harness (W11) Wiring Diagram (S.N. 872257 )
9031
15
7
T116838 1908OCT98
CED,TX17864,140 1921AUG981/1

022602
PN=941
Air Conditioning Component Location (S.N. 872257 )

T117557 1915OCT98
CED,OUTX466,1107 1920JUL981/2

022602
PN=942
1Condenser 10Blower Switch (S8) 16Blower Resister (R1) 23A/C Compressor Harness
2High Pressure Switch (S24) 11Heater Temp. Switch (S22) 17Heater Blower Motor (M6) to Engine Harness
3Low Pressure Switch (S23) 12Blower Harness (W10) 18A/C Freeze Switch (S26) Connector (X59)
4A/C Compressor Harness 13Blower Harness To Side 19Evaporator 24A/C Compressor Harness
(W11) Console Harness 20Line To Water Pump to Engine Harness
5Not Used Connector (X5) 21Line To Engine Block Connector (X34)
6Expansion Valve 14Seat Position Sensor 22Receiver Dryer 25Compressor (Y10)
7Cab Floor Ground (W3) (S19)
8Not Used 15Blower Harness To Air
9Blower Harness To Side Adjust Seat Harness
Console Harness Connector (X56)
Connector (X35)
CED,OUTX466,1107 1920JUL982/2
Sub System Diagnostics/Air Conditioning Circuit
This procedure is designed so the mechanic can make additional checks or repair information will be given.
a quick check of the system using a minimum amount T.M. Group or CTM number required for repair will be
of diagnostic equipment. If you need additional given. If verification is needed, you will be given next
information, read Theory of Operation (Group best source of information:
9031-05).
Group: 10 (System Operational Checks)
The engine or other major components must be at
operating temperature for some checks. Group: 15 (Diagnostic Information)
Locate system check in the left column and read Group: 20 (Adjustments)
completely, following this sequence from left to right.
Read each check completely before performing. Group: 25 (Tests)
At the end of each check, if no problem is found, that CTM (Component Technical Manual)
check is complete. When a problem is indicated,
9031
15
9
TX,9031,BG654 1902OCT981/1
1 Blower/Air Conditioning Circuit Checks
1/1

022602
PN=943
816286) good. Go to next check.
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 (S.N. Measure resistance between terminals 3 and 1. YES: Resistor is good.
816286) Check wiring harness.
Measure ohms between terminals 3 and 2.
T6534CR UN19OCT88
1/1
816287 ) good. Go to next check.
NO: Replace blower
9031 Move blower switch to position 1, 2, 3, and 4 checking switch.
15 terminals B and 1, B and 2, B and 3, B and 4.
10
T117277 1918SEP98
1/1

022602
PN=944
Blower Resister (S.N. Measure ohms between terminals 4 and 2. YES: Resistor is good.
816287 ) Check wiring harness.
T102849 UN06AUG96
1/1
Heater/Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
Check motor is good. Check
motor.
NO: Replace heater
T7199CM UN16AUG90
9031
15
1/1
11
A/C Freeze Switch With A/C freeze switch at room temperature. YES: Do A/C Freeze
Switch Test. See Group
Disconnect harness from switch. 9031-25. If Switch is OK.
Measure continuity across switch terminals.
NO: Switch has failed.
Is continuity measured? Replace switch.
T7835AV 1924SEP92
1/1

022602
PN=945
Air Conditioning Switch Disconnect harness from air conditioning switch. YES: A/C switch is good.
(S.N. 816286) Check wiring harness.
Place switch in snowflake or A/C position, and measure
for continuity between terminals 2B and 1. NO: Replace A/C switch.
Place switch in cactus or defrost position and measure

for continuity between terminals 2B and 3.
T7199DE UN02OCT90
1/1
Air Conditioning Switch YES: A/C switch is good.

(S.N. 816287 ) Check wiring harness.
NO: Replace A/C switch.
T100731 UN28MAY96
9031
Disconnect harness from air conditioning switch.
15
12
A/C switch OFF, and measure for continuity between terminals 2A and 1.
Turn switch ON, and measure for continuity between terminals 2B and 3.
1/1

022602
PN=946
Air Conditioner Low Disconnect harness from switch. YES: Continue with this
Check for continuity between terminals. Is continuity
measured? NO: Replace switch.
T101619 1913JUN96
Remove switch from system. (The line that attaches the low pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness.
Measure for continuity across switch terminals. NO: Go to Low Pressure

Switch Test, Group
Does ohmmeter read open? 9031-25.
1/1
Air Conditioner High Disconnect harness from switch. YES: Continue with this
Measure continuity across outer switch terminals.
NO: Switch may be bad,
Does ohmmeter read continuity? or system pressure is too
high. Continue with this
check to verify switch
operation.
T101618 1913JUN96
Remove switch from system. (The line that attaches the high pressure switch has a YES: Switch is good.
valve to prevent discharging the air conditioning system when switch is removed.) Check wiring harness and
system pressure. Go to 9031
Measure continuity across switch terminals. Air Conditioning Pressure 15
Diagnostic Chart, Group 13
Does ohmmeter read continuity? 9031-25.
NO: Replace switch.
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
1/1

022602
PN=947
9031
15
14

022602
PN=948
Group 20
Adjustments
TX,9031,QQ5748 1912JUN961/1

treatment.
treatment. 1

container.
TX,9031,QQ5749 1912JUN961/1

022602
PN=949
Adjustments
R134A Compressor Oil Charge Check
Remove compressor if R134a leakage was detected 3. Flush the complete system with TY16134 air
and repaired. See Remove and install Compressor in conditioning flushing solvent.
Repair Manual.
4. If the compressor is serviceable, pour flushing
Drain oil from the compressor and record the amount. solvent in the manifold ports and internally wash out
See Compressor Oil Removal procedure in this group. the old oil.
NOTE: Drain oil and save if this is a new compressor. 5. Install a new receiver-dryer.
If the oil drained from a compressor removed from 6. Install required amount of TY22025 refrigerant oil in
operation is very black or the amount of oil is less than the compressor. (See R134a Component Oil
6 mL (0.2 fl oz), perform the following: Charge in this group.)
1. Remove and discard the receiver-dryer. 7. Connect all components, evacuate and charge the
system.
2. Remove, clean, but do not disassemble the valve.
TX,9031,QQ5750 1912JUN961/1
R134A Compressor Oil Removal
1. Remove compressor from machine. See Remove and

9031 Install Compressor in Repair Manual.
20
2 2. Remove inlet/outlet manifold from compressor, and
clutch dust cover.
3. Drain oil into graduated container while rotating

compressor shaft.
4. Record measured oil and discard oil properly.
5. Install new oil. See R134a Component Oil Charge in

this Group.
6. Install compressor. See Remove and Install

Compressor in Repair Manual.
TX,9031,QQ5751 1912JUN961/1

022602
PN=950
Adjustments
R134A Component Oil Charge
Used compressor removed from operation and oil

CAUTION: All new compressors are charged
drained, (See Compressor Oil Removal
with a mixture of nitrogen, R134a refrigerant
procedure in this group.) Add 63 mL (2.1 fl oz) of
and TY22025 (R134a) refrigerant oil. Wear
new oil.
safety goggles and discharge the
Used compressor removed from operation, oil
compressor slowly to avoid possible injury.
drained, and flushed add 78 mL (2.6 fl oz) of new
oil.
Compressors can be divided into three categories
when determining the correct oil charge for the system.
NOTE: Components listed below which have been
removed, drained or flushed, require the
New compressor from parts depot
removal of the compressor to determine the
Used compressor removed from operation
correct oil charge. Use the following chart as a
Compressor internally washed with flushing solvent
guide for adding oil to components:
Determining the amount of system oil charge prior to Evaporator 130 mL (4.4 fl oz)
installation of compressor on a machine.
Condenser 65 mL (2.2 fl oz)
1. When the complete system, lines, and components Receiver-Dryer 30 mL (1.0 fl oz)
were flushed add the correct amount of oil as Hoses 60 mL (2.0 fl oz)
described.
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft).
New compressor from parts depot contains the Approximate total length equals 600 cm (20 ft).
amount of new oil of 230 20 mL (7.7 0.7 fl
oz). System requires an additional amount of new If any section of hose is removed and flushed or
oil of 118 mL (4.0 fl oz) of new oil. replaced, measure the length of hose and use the
Used compressor removed from operation, oil formula to determine the correct amount of oil to be
drained, and flushed requires 348 20 mL (11.6 added.
0.7 fl oz) of new oil.
CAUTION: DO NOT leave the system or
2. When the complete system was not flushed add the
R134a compressor oil containers open. This
correct amount of oil for the compressor plus
oil easily absorbs moisture. DO NOT spill 9031
amount of oil for each component that was 20
R134a compressor oil on acrylic or ABS
serviced. 3
plastic. This oil will deteriorate these
materials rapidly. Identify R134a oil
New compressor from parts depot, drain and
containers and measures to eliminate
return 63 mL (2.1 fl oz) of oil to the compressor.
accidental mixing of different oils.
(See Compressor Oil Removal procedure in this
group.)
TX,9031,BG804 1906MAR971/1

022602
PN=951
Adjustments
R134A Refrigerant Recovery, Recycling And

Charging Station Installation Procedure
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station
NOTE: JT02046 and JT02050 recovery and charging

stations can be substituted for the JT02045
station.
CAUTION: Do not remove high pressure relief

valve (B). Air conditioning system will
discharge rapidly causing possible injury.
IMPORTANT: Use correct refrigerant recovery,

NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
UN10SEP96
1. Close both high and low pressure valves on refrigerant
recovery, recycling and charging station (J).
2. Remove cap from low pressure test port (A).
T101551
3. Connect low pressure blue hose (G) from refrigerant
recovery, recycling and charging station (J) to low
pressure test port (A) on compressor. ALow Pressure Test Port
BHigh Pressure Relief Valve
4. Connect high pressure red hose (I) to high pressure CLow Pressure Hose
DLow Pressure Switch
quick disconnect (F). EHigh Pressure Switch
FHigh Pressure Quick-Disconnect
9031 5. Follow the manufactures instructions when using the GBlue Hose
20 refrigerant recovery, recycling and charging station. HHigh Pressure Hose
4 IRed Hose
JRefrigerant Recovery/Recycling and Charging
Station
TX,9031,QQ5753 1912JUN961/1

022602
PN=952
Adjustments
Recover R134A System
ESSENTIAL TOOLS

station.


NOTE: Run the air conditioning system for three minutes

to help in the recovery process. Turn air
UN10SEP96
conditioning system off before proceeding with
recovery steps.
T101551
1. Connect refrigerant recovery, recycling and charging
station. (See installation procedure in this group.)
2. Follow the manufactures instructions when using the ALow Pressure Test Port
refrigerant recovery, recycling and charging station. BHigh Pressure Relief Valve
CLow Pressure Hose
EHigh Pressure Switch
GBlue Hose 9031
HHigh Pressure Hose 20
IRed Hose 5
Station
TX,9031,QQ5754 1912JUN961/1

022602
PN=953
Adjustments
Evacuate R134A System
ESSENTIAL TOOLS

station.


Do not run compressor while

evacuating.
UN10SEP96
T101551
2. Open low and high pressure valves on refrigerant
recovery, recycling and charging station.
ALow Pressure Test Port
3. Follow the manufactures instructions and evacuate the BHigh Pressure Relief Valve
system. CLow Pressure Hose
NOTE: The vacuum specifications listed are for sea level FHigh Pressure Quick-Disconnect
9031 conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) GBlue Hose
20 from 98 kPa (980 mbar) (29 in. Hg) for each 300 HHigh Pressure Hose
6 m (1000 ft) elevation above sea level. IRed Hose
station
4. Evacuate system until low pressure gauge registers 98
kPa (980 mbar) (29 in. Hg) vacuum.
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.
Continued on next page TX,9031,QQ5755 1912JUN961/2

022602
PN=954
Adjustments
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,QQ5755 1912JUN962/2
9031
20
7

022602
PN=955
Adjustments
Charge R134A System
ESSENTIAL TOOLS

station.


1. Connect JT02045 R134a refrigerant recovery, recycling

and charging station. (See installation procedure in this
UN10SEP96
group.)
2. Evacuate the system. (See Evacuate Air Conditioning
T101551
System, this group.)
NOTE: Before beginning to charge air conditioning

system, the following conditions must exist: ALow Pressure Test Port
Engine STOPPED, the pump must be capable of BHigh Pressure Relief Valve
pulling at least 28.6 in. Hg vacuum (sea level). CLow Pressure Hose
Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa DLow Pressure Switch
(980 mbar) (29 in. Hg) for each 300 m (1000 ft) FHigh Pressure Quick-Disconnect
9031 elevation above sea level. GBlue Hose
20 HHigh Pressure Hose
8 3. Follow the manufacturers instructions and charge the IRed Hose
system. JRefrigerant Recovery/Recycling and Charging
Station
4. Add refrigerant until system is charged with 2.4 Kg (5.2

lbs).
5. Do air conditioner checks and tests in Groups 9031-10

and 9031-25.
TX,9031,BG805 1906MAR971/1

022602
PN=956
Adjustments
Check And Adjust Compressor Belt Tension (S.N. 816286)
SERVICE EQUIPMENT AND TOOLS 2. Belt must deflect 19 mm (0.75 in.) at 400 N (90 lb
Belt Tension Gauge force). If not, allow belt to cool for 810 minutes.
IMPORTANT: Never over tighten belt. Over IMPORTANT: Force to adjust belt must be applied
tightening may cause belt cord to front of compressor housing only
damage and excessive load on to prevent damage to compressor.
bearings.
3. Loosen compressor mounting cap screws. Apply
1. Run engine for five minutes. Stop the engine, then force to front of compressor housing to tighten belt.
immediately check tension using a belt tension Tighten cap screws.
gauge. Measure strand tension or deflection at a
point halfway between pulleys. 4. Repeat Steps 1 and 2 to check belts.
TX,9031,BG806 1906MAR971/1
9031
20
9

022602
PN=957
Adjustments
9031
20
10

022602
PN=958
Group 25
Test
TX,9031,QQ5758 1913AUG961/1

treatment.
treatment. 1

container.
TX,9031,QQ5759 1913AUG961/1

022602
PN=959
Test
R134A Air Conditioning System Test
SPECIFICATIONS
Air Conditioning Cooling Maximum
Blower Speed Maximum
Maximum Louver
Ambient Temperature (F) Temperature (F) Suction Pressure Discharge Pressure
1621C (6070F) 7.3C (45F) 4189 kPa (0.410.89 bar) 6551172 kPa (6.5511.72 bar)
(613 psi) (95170 psi)
2127C (7080F) 10C (50F) 55103 kPa (0.551.03 bar) 7921516 kPa (7.9215.16 bar)
(815 psi) (115220 psi)
(1018 psi) (170260 psi)
(1220 psi) (215300 psi)
(1522 psi) (260330 psi)
ESSENTIAL TOOLS

NOT use refrigerant, hoses, fittings,
components or refrigerant oils intended
for R12 refrigerant.

9031
25 2. Close both low and high pressure valves on refrigerant
2 recovery, recycling and charging station.
3. Open cab doors and windows.

022602
PN=960
Test
4. Connect low pressure blue hose (G) from refrigerant

recovery, recycling and charging station (J) to low
pressure test port (A) on compressor.
5. Connect high pressure red hose (I) to high Pressure

Quick-Disconnect (F) on compressor.
6. Follow the manufactures instructions when using the

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
Air ConditioningCooling ........................................................... Maximum
UN10SEP96
9. Turn blower switch to high speed.
Specification
BlowerSpeed ............................................................................ Maximum
T101551
10. Check sight glass in receiver-dryer.
11. Run unit for at least 5 minutes. ALow Pressure Test Port
BHigh Pressure Relief Valve
CLow Pressure Hose
12. Measure air temperature at condenser air inlet and at DLow Pressure Switch
air ducts in air conditioning unit. EHigh Pressure Switch
13. Compare air duct temperature reading to the GBlue Hose 9031
temperatures shown in the specifications. HHigh Pressure Hose 25
IRed 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,BG657 1930JAN972/2

022602
PN=961
Test
Pressure Diagnostic Chart
9031
25
4
1928FEB89
T6609AB
TX,9031,QQ5761 1913AUG961/1

022602
PN=962
Test
Low Pressure Switch Test (S.N. 816286)
SPECIFICATIONS
Low Pressure Switch (Normally 276 20 kPa (2.76 0.2 bar) (40
Open) Closes on Increasing 3 psi)
UN08NOV88
Pressure
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

connector. Compressor clutch must engage and
disengage (click).
NOTE: Low pressure switch fitting has a valve installed in

it to prevent discharging the air conditioning
system when switch is removed.
3. Remove low pressure switch. Connect low pressure

switch connector.
9031
4. The actual pressure setting of switch can be checked 25
by connecting it to a pressure source such as a 5
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)

022602
PN=963
Test
Slowly release pressure. Switch must have continuity

until pressure decreases to switch opening pressure
specification.
Specification
Open)Opens on Decreasing
Pressure ................................................. 220 20 kPa (2.2 0.2 bar) (32
3 psi)
TX,9031,BG659 1930JAN972/2
9031
25
6

022602
PN=964
Test
9031
25
7

022602
PN=965
Test
Low Pressure Switch Test (S.N. 816287 )
SPECIFICATIONS
Open) Opens on Decreasing 53 psi)
Pressure
Open) Closes on Increasing 5 psi)
Pressure

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
3. Disconnect harness from switch and remove switch

from line. Connect low pressure switch to harness.
9031
25 Compressor clutch must not engage (click).
8
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.

022602
PN=966
Test
5. Switch must not have continuity between terminals (A

and B) until pressure increases to switch closing
Specification
Open)Opens on Decreasing
UN04MAR97
Pressure ............................................... 173 35 kPa (1.73 0.3 bar) (25
53 psi)
Slowly release pressure. Switch must have continuity
T106843
until pressure decreases to switch opening pressure
specification.
Specification
Open)Closes on Increasing
Pressure ............................................... 345 35 kPa (3.45 0.3 bar) (50
5 psi)
TX,9031,BG658 1930JAN972/2
9031
25
9

022602
PN=967
Test
High Pressure Switch Test (S.N. 816286)
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: High pressure switch fitting has a valve installed

in it to prevent discharging the air conditioning
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)
9031 4. Slowly release pressure. Switch must not have

25
continuity until pressure decreases to switch closing
10
Specification
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.

022602
PN=968
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,9031,BG660 1930JAN972/2
9031
25
11

022602
PN=969
Test
High Pressure Switch Test (S.N. 816287 )
SPECIFICATIONS
High Pressure Switch (Normally 2760 138 kPa (27.6 1.38
Closed) Opens on Increasing bar) (400 20 psi)
Pressure
High Pressure Switch (Normally 1310 138 kPa (13.11 1.38
Closed) Closes on Decreasing bar) (190 20 psi)
Pressure

Volt-Ohm-Amp Meter
Air Conditioning Gauge Set
NOTE: The line that attaches the high pressure switch

has a valve installed to prevent discharging the air
conditioning system when switch is removed. The
high pressure switch is normally closed when
removed from the machine. It does not open
when installed in the A/C system until pressure
exceeds specification.
1. Remove high pressure switch.
2. Connect a portable pressure source, such as a

hydraulic hand pump, to high pressure switch.
9031
25
12

022602
PN=970
Test
3. Switch must have continuity between terminals (A and

B) until pressure increases to switch opening pressure
specification.
Specification
Closed)Opens on Increasing
UN04MAR97
Pressure ............................................... 2760 138 kPa (27.6 1.38 bar)
(400 20 psi)
4. Slowly release pressure. Switch must not have
T106842
continuity until pressure decreases to switch closing
Specification
Closed)Closes on Decreasing
Pressure ..................................................... 1310 138 kPa (13.11 1.38
bar) (190 20 psi)
5. The switch can also be checked when installed in air

conditioning system, however, pressure is slow to
increase to test specification.
Connect an air conditioning gauge set to service

fittings at compressor. Cover condenser with paper or
plastic to stop air flow. Operate air conditioner on
maximum cooling. Note high-side pressure when high
pressure switch opens and then closes.
9031
25
TX,9031,BG661 1930JAN972/2
13

022602
PN=971
Test
A/C Freeze Control Switch
SPECIFICATIONS
A/C Freeze Control Switch -0.5C (31F)
(Normally Closed) Opens as
Temperature Drops
A/C Freeze Control Switch 4C (39F)
(Normally Closed) Closes as
Temperature Rises

Multimeter
1. Remove A/C freeze switch from evaporator.
2. Connect ohmmeter to switch terminals. Switch must be

closed at room temperature.
3. Put switch into a freezer (assure freezer temperature is

below -0.5C (31F). Switch must open, and continuity
must not be read.
Specification
(Normally Closed)Opens as
Temperature Drops ............................................................... -0.5C (31F)
4. Remove switch from freezer. Put sensing tube into a

glass of warm water. Switch must close, and continuity
must be read.
Specification
9031 (Normally Closed)Closes as
25 Temperature Rises .................................................................... 4C (39F)
14
5. If switch does not open and close during testing, install
new switch.
TX,9031,QQ5764 1913AUG961/1

022602
PN=972
Test
Leak Testing
1. Inspect all lines, fittings, and components for oily or 3. If a leak detector is used, move the leak detector
dusty spots. When refrigerant leaks from the probe under the hoses and around the connections
system, a small amount of oil is carried out with it. at a rate of 25 mm (1 in.) per second.
2. A soap and water solution can be sprayed on the 4. Some refrigerant manufacturers add dye to
components in the system to form bubbles at the refrigerant to aid in leak detection.
source of the leak.
TX,9031,QQ5765 1913AUG961/1
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,QQ5766 1913AUG961/1
15

022602
PN=973
Test
9031
25
16

022602
PN=974
Index
Page Page
A Theory of Operation (S.N. 872257

). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-46
Accessories check . . . . . . . . . . . . . . . . . .9005-10-44 Air conditioning circuit schematic
Accumulator operation (S.N. 872256 S.N. -816286. . . . . . . . . . . . . . . . . . . . . .9031-05-5
Brake . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-19 (S.N. 816287872256) . . . . . . . . . . . . .9031-05-7
Accumulator operation (S.N. 872257 ) (S.N. 872257 ). . . . . . . . . . . . . . . . . . .9031-05-9
Brake . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-20 Air conditioning circuit theory of operation
Adjust Engine speed control linkage (S.N. 816286) . . . . . . . . . . . . . . . . . . .9031-05-4
(S.N. 830204) . . . . . . . . . . . . . . . . . . .9010-20-5 (S.N. 816287872256) . . . . . . . . . . . . .9031-05-6
(S.N. 830205) . . . . . . . . . . . . . . . . . . .9010-20-6 (S.N. 872257 ). . . . . . . . . . . . . . . . . . .9031-05-8
Adjustment Air conditioning compressor harness (W11)
Backhoe valve linkage . . . . . . . . . . . . .9025-20-10 Component location (S.N.
-825657) . . . . . . . . . . . . . . . . . . . . 9015-10A-43
Loader bucket level indicator. . . . . . . . . .9025-20-2
Component location (S.N.
Loader control valve linkage . . . . . . . . .9025-20-10
825658-872256) . . . . . . . . . . . . . . 9015-10A-44
Return-to-dig switch . . . . . . . . . . . . . . . .9025-20-2
Component location (S.N. 872257-
Stabilizer valve linkage . . . . . . . . . . . . .9025-20-12
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-42
Adjustment (S.N. 872256)
Air Conditioning Compressor harness (W11)
Park brake . . . . . . . . . . . . . . . . . . . . . . .9025-20-4
Connectors, wire and pin location (S.N.
Service brake . . . . . . . . . . . . . . . . . . . . .9025-20-5
872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-43
Adjustment (S.N. 872257 )
Air conditioning compressor harness (W11)
Service brake . . . . . . . . . . . . . . . . . . . . .9025-20-6
Wiring diagram (S.N. -825657) . . . . . 9015-10A-42
Air Adjust Seat Circuit
Wiring diagram (S.N. 872257- ). . . . . 9015-10B-41
Air conditioning expansion valve
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-39
Operation . . . . . . . . . . . . . . . . . . . . . . .9031-05-16
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-40
Air system, engine
Sub-System Diagnostics (S.N. 872257
Checks . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-39
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-41
Alternator Operation
Theory of Operation (S.N. 872257 78 Amp DELCO REMY (Serial No.
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-39 787513) . . . . . . . . . . . . . . . . . . . . . . .9015-20-10
Air conditioning 95 Amp BOSCH . . . . . . . . . . . . . . . . . .9015-20-13
Charge system . . . . . . . . . . . . . . . . . . . .9031-20-8 95 Amp BOSCH (Serial No. 787514
Circuit checks . . . . . . . . . .9015-15B-48, 9031-15-9 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-12
Component location . . . . . . . . . . . . . . . .9031-15-8 Alternators
S.N. -816286 . . . . . . . . . . .9031-15-2, 9031-15-4 Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Component oil charge . . . . . . . . . . . . . . .9031-20-3 Analysis of Complete Transmission Test (S.N.
Compressor relief valve operation . . . . .9031-05-17 872256) . . . . . . . . . . . . . . . . . . . . . . 9020-25A-36 Indx
Electrical circuit . . . . . . . . . . . . . . . . . . . .9031-05-3 Analysis of Transmission Leakage Test Using 1
Evacuate system. . . . . . . . . . . . . . . . . . .9031-20-6 Converter-In/Cooler Pressure
Hoses and tubing inspection . . . . . . . . .9031-25-15 (S.N. 872256) . . . . . . . . . . . . . . . . 9020-25A-20
Leak testing . . . . . . . . . . . . . . . . . . . . .9031-25-15 Anti-cavitation circuit relief valve. . . . . . . .9025-05-24
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9031-15-1 Anti-cavitation circuit relief
Operational checks . . . . . . . . . . . . . . . . .9031-15-9 valve-Husco . . . . . . . . . . . . . . . . . . . . .9025-05-35
Receiver/dryer operation . . . . . . . . . . . .9031-05-14 Auxiliary Valve
System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-2 Soleniod controlled-Gresen . . . . . . . . . .9025-05-48
Temperature control . . . . . . . . . . . . . . .9031-05-17 Auxiliary valve circuit
Air Conditioning Circuit Operational Information (S.N.
Operational Information (S.N. 872257 872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-118
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-45 Schematic (S.N. 872256). . . . . . . .9015-15A-119
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-47 Sub-System Diagnostics (S.N.
Specifications (S.N. 872257 ) . . . . 9015-15B-45 872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-120
Sub-System Diagnostics (S.N. 872257 Theory of Operation (S.N.
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-48 872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-118
TM1537 (26FEB02) Index-1 710D Backhoe Loader

022602
PN=1
Index
Page Page
Auxiliary valve harness (W14) Blower Circuit

Component location (S.N. Operational Information (S.N. 872257
-872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-48 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-42
Wiring diagram (S.N. -872256) . . . . . 9015-10A-47 Blower circuit
Schematic (S.N. 816286). . . . . . . . 9015-15A-69
Schematic (S.N. 816287872256) . . 9015-15A-71
Blower Circuit
B Schematic (S.N. 872257 ) . . . . . . . 9015-15B-43
Blower circuit
Backhoe auxiliary valve 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-72
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-55 Blower Circuit
Backhoe auxiliary valve Sub-System Diagnostics (S.N. 872257
w/soleniod-Gresen . . . . . . . . . . . . . . . .9025-05-48 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-44
Backhoe boom valve-Husco . . . . . . . . . . .9025-05-42 Blower circuit
Backhoe bucket valve Theory of Operation (S.N.
operation-Gresen . . . . . . . . . . . . . . . . .9025-05-53 816286) . . . . . . . . . . . . . . . . . . . . . 9015-15A-68
Backhoe crowd valve Theory of Operation (S.N. 816287
operation-Gresen . . . . . . . . . . . . . . . . .9025-05-54 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-70
Backhoe swing valve Blower Circuit
operation-Gresen . . . . . . . . . . . . . . . . .9025-05-50 Theory of Operation (S.N. 872257
Backhoe valve auxiliary ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-42
operation-Husco . . . . . . . . . . . . . . . . . .9025-05-46 Blower Circuit Schematic
Backhoe valve boom (S.N. 816286) . . . . . . . . . . . . . . . . . .9031-05-11
operatrion-Gresen . . . . . . . . . . . . . . . . .9025-05-52 (S.N. 816287 ). . . . . . . . . . . . . . . . . .9031-05-13
Backhoe valve crowd operation-Husco . . .9025-05-44 Blower Circuit Theory Of Operation
Backhoe valve linkage adjustment . . . . . .9025-20-10 (S.N. 816286) . . . . . . . . . . . . . . . . . .9031-05-10
Battery (S.N. 816287 ). . . . . . . . . . . . . . . . . .9031-05-12
Booster . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-8 Blower harness (W10)
Electrolyte level. . . . . . . . . . . . . . . . . . . .9015-20-5 Component location (S.N.
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9015-20-4 -825657) . . . . . . . . . . . . . . . . . . . . 9015-10A-39
Operation . . . . . . . . . . . . . . . . . . . . . . . .9015-20-2 Component location (S.N.
Specifications . . . . . . . . . . . . . . . . . . . . .9015-20-3 825658-872256) . . . . . . . . . . . . . . 9015-10A-41
Testing . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-7 Component location (S.N. 872257-
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-39
Beacon circuit
Operational Information (S.N.
Indx 872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-40
872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-106
2 Wiring diagram (S.N. -825657) . . . . . 9015-10A-38
Wiring diagram (S.N.
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-84
825658-872256) . . . . . . . . . . . . . . 9015-10A-40
Schematic (S.N. 872256). . . . . . . .9015-15A-108 Wiring diagram (S.N. 872257- ). . . . . 9015-10B-38
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-85 Brake accumulator precharge pressure test (S.N.
Sub-System Diagnostics (S.N. 872256) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-64
872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-109 Brake inspection (S.N. 872256) . . . . . . .9025-20-5
Sub-System Diagnostics (S.N. 872257 Brake inspection (S.N. 872257 ) . . . . . . .9025-20-6
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-86 Brake (S.N. 872256
Theory of Operation (S.N. Accumulator Operation . . . . . . . . . . . . .9025-05-19
872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-107 Brake (S.N. 872256)
Theory of Operation (S.N. 872257 Manual (engaging) . . . . . . . . . . . . . . . .9025-05-70
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-84 Manual (prefill) . . . . . . . . . . . . . . . . . . .9025-05-66
Blower circuit pistons, plates and disks . . . . . . . . . . . .9025-05-57
Operational Information (S.N. Brake (S.N. 872257 )
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-68 Accumulator Operation . . . . . . . . . . . . .9025-05-20

022602
PN=2
Index
Page Page
Engaging . . . . . . . . . . . . . . . . . . . . . . .9025-05-80 Wiring diagram (S.N. 815415-825656) (1 of

Released. . . . . . . . . . . . . . . . . . . . . . . .9025-05-78 2). . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-23
Valve work port pressure test . . . . . . . .9025-25-62 Wiring diagram (S.N. 815416-825657) (2 of
Brake system checks . . . . . . . . . . . . . . . .9005-10-10 2). . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-24
Brake valve presssure test (S.N. Wiring diagram (S.N. 825658-872256) (1 of
872256) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-58 3). . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-27
Brake Valve (S.N. 872257 ) Wiring diagram (S.N. 825658-872256) (2 of
Adjustment . . . . . . . . . . . . . . . . . . . . . . .9025-20-8 3). . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-28
Brake valve (S.N. 872257 ) Wiring diagram (S.N. 825658-872256) (3 of
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-76 3). . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-29
Brake, park (S.N.872257 ) Calibration
Operation . . . . . . . . . . . . . . . . . . . . . 9020-05B-38 Tachometer (S.N. 872256) . . . . . . . .9015-20-18
Brake, parking (S.N. 872256) . . . . . . . .9025-05-84 Cap screw torque . . . . . . . . . . . . . . . . . . . .9000-03-3
Brake, service (S.N. 872257 ) Capacities
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-74 Drain and refill . . . . . . . . . . . . . . . . . . .9000-02-13
Brakes (S.N. 872256) Lifting . . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-14
Engaging . . . . . . . . . . . . . . . . . . . . . . .9025-05-62 Charge pressure test . . . . . . . . . . . . . . . . .9025-25-5
Released. . . . . . . . . . . . . . . . . . . . . . . .9025-05-58 Charge Pump Belt Tension Adjustment (SN
Bucket 830204)
Backhoe specifications . . . . . . . . . . . . .9000-02-13 Charge pump belt tension . . . . . . . . . . . .9025-20-1
Bucket level adjustment . . . . . . . . . . . . . . .9025-20-2 Charge pump flow test (S.N. 872256) . . .9025-25-6
Bypass valve (S.N.872257 ) Charge pump flow test (S.N. 872257
Operation . . . . . . . . . . . . . . . . . . . . . . 9020-05B-6 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8
Pressure test. . . . . . . . . . . . . . . . . . . 9020-25B-26 Charge Pump Operation. . . . . . . . . . . . . . .9025-05-9
Charging circuit
Operational information (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-14
C
Operational information (S.N. 872257
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-10
Cab component checks . . . . . . . . . . . . . .9005-10-46
Schematic (S.N. 815415). . . . . . . . 9015-15A-16
Cab roof harness (W5)
Schematic (S.N. 815416825657) . . 9015-15A-17
Schematic (S.N. 825658872256) . . 9015-15A-18
-872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-20
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-12
Sub-system diagnostics (S.N.
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-16
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-19
872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-17 Sub-system diagnostics (S.N. 872257
Indx
Wiring diagram (S.N. -872256) . . . . . 9015-10A-19 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-13 3
Wiring diagram (S.N. 872257- ). . . . . 9015-10B-15 Theory of operation (S.N.
Cab side console harness (W6) 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-15
Component location (S.N. -825657) (1 of Theory of operation (S.N. 872257
2). . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-25 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-11
Component location (S.N. -825657) (2 of Circuit Malfunction
2). . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-26 Definitions . . . . . . . . . . . . . . . . . . . . . . . .9015-05-3
Component location (S.N. 825658-872256) (1 Locations . . . . . . . . . . . . . . . . . . . . . . . .9015-05-8
of 2). . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-30 Circuit Malfunctions
Component location (S.N. 825658-872256) (2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-2
of 2). . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-31 Circuit relief valve test
Cab Side console harness (W6) Remote pump method. . . . . . . . . . . . . .9025-25-43
Wiring diagram (S.N. -815415) (1 of Circuit relief valve test-Gresen . . . . . . . . .9025-25-36
2). . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-21 Circuit relief valve w/o anti-cav.-Husco . . .9025-05-36
Wiring diagram (S.N. -815415) (2 of Circuit relief valve,
2). . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-22 w/anti-cavitation-Husco . . . . . . . . . . . . .9025-05-35

022602
PN=3
Index
Page Page
Clutch packs (S.N.872257 ) Transmission solenoid harness (W9) (S.N.

Power shift, high range forward 1st and 2nd -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-37
speed . . . . . . . . . . . . . . . . . . . . . . . 9020-05B-8 Compressor
Cold weather starting aid . . . . . . . . . . . . . .9010-05-4 Belt tension . . . . . . . . . . . . . . . . . . . . . . .9031-20-9
Compensator, Pressure . . . . . . . . . . . . . .9025-05-12 Oil charge check . . . . . . . . . . . . . . . . . . .9031-20-2
Complete Transmission System Test Checkout Sheet Oil removal . . . . . . . . . . . . . . . . . . . . . . .9031-20-2
(S.N. 872256) . . . . . . . . . . . . . . . . 9020-25A-34 Compressor relief valve, A/C
Component location Operation . . . . . . . . . . . . . . . . . . . . . . .9031-05-17
A.C. compressor harness (W11) (S.N. Connectors, wire and pin location
-825657) . . . . . . . . . . . . . . . . . . . . 9015-10A-43 Air Conditioning Compressor harness (W11) (S.N.
A.C. compressor harness (W11) (S.N. 872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-43
825658-872256) . . . . . . . . . . . . . . 9015-10A-44 Blower harness (W10) (S.N. 872257-
A.C. compressor harness (W11) (S.N. 872257- ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-40
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-42 Cab roof harness (W5) (S.N. 872257-
Auxiliary valve harness (W14) (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-17
-872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-48 Engine harness (W8) (S.N. 872257-
Blower harness (W10) (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-35
-825657) . . . . . . . . . . . . . . . . . . . . 9015-10A-39 Front console harness (W7) (S.N. 872257-
Blower harness (W10) (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-30
825658-872256) . . . . . . . . . . . . . . 9015-10A-41 Radio harness (W12) (S.N. 872257-
Blower harness (W10) (S.N. 872257- ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-46
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-39 Selective flow valve harness (W15) (S.N. 872257-
Cab roof harness (W5) (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-49
-872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-20 Side console harness (W6) (S.N. 872257-
Cab roof harness (W5) (S.N. 872257- ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-24
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-16 Control valve and shift valve transmission power shift
(S.N.872257 )
Cab side console harness (W6) (S.N. -825657)
Operation-First Forward . . . . . . . . . . 9020-05B-22
(1 of 2) . . . . . . . . . . . . . . . . . . . . . 9015-10A-25
Operation-first reverse. . . . . . . . . . . . 9020-05B-30
(2 of 2) . . . . . . . . . . . . . . . . . . . . . 9015-10A-26
Operation-neutral . . . . . . . . . . . . . . . 9020-05B-18
Cab side console harness (W6) (S.N.
Control valve transmission power shift (S.N.872257
825658-872256)
)
(1 of 2) . . . . . . . . . . . . . . . . . . . . . 9015-10A-30
Operation-Fourth Forward . . . . . . . . . 9020-05B-26
(2 of 2) . . . . . . . . . . . . . . . . . . . . . 9015-10A-31
Converter, torque (S.N.872257 )
Component Location
Operation . . . . . . . . . . . . . . . . . . . . . . 9020-05B-2
Electrical . . . . . . . . . . . . . . . . . . . . . . . .9015-05-22
Converter, torque,stall (S.N.872257 )
Component location Test . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-4
Indx
Engine harness (W8) (S.N. Converter-in relief valve (S.N.872257 )
4
-872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-35 Test . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-6
Engine harness (W8) (S.N. 872257- Coolant
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-34 Diesel engine . . . . . . . . . . . . . . . . . . . . .9000-04-8
Front console harness (W7) (S.N. Cooler in and cooler out (S.N.872257 )
-872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-33 Transmission pressure test . . . . . . . . 9020-25B-22
Front console harness (W7) (S.N. 872257- Cooling system, engine
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-29 Checks . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-37
Radio harness (W12) (S.N. Crowd valve operation-Gresen . . . . . . . . .9025-05-54
-872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-46 CTM104
Radio harness (W12) (S.N. 872257- 6068 engine (S.N. 830205 ) . . . . . . . .9005-10-3
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-45 CTM11
Selective flow valve harness (W15) (S.N. 872257- Engine accessories (S.N. 830204). . . .9005-10-2
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-48 CTM67
Side console harness (W6) (S.N. 872257- OEM engine accessories (S.N. 830205
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-22 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2

022602
PN=4
Index
Page Page
CTM7 Differential lock (S.N. 872256)

Radial piston pump . . . . . . . . . . . . . . . . .9005-10-1 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-86
CTM77 Differential lock (S.N.872257 )
Alternators and starting motors . . . . . . . .9005-10-2 Operation . . . . . . . . . . . . . . . . . . . . . 9020-05B-36
CTM8 Differential (S.N.872257 )
6059 engine (S.N. 830204) . . . . . . . . .9005-10-1 Operation . . . . . . . . . . . . . . . . . . . . . 9020-05B-34
Cycle time test . . . . . . . . . . . . . . . . . . . . .9025-25-48 Digital Thermometer Installation . . . . . . . . .9025-25-1
Cylinder drift test . . . . . . . . . . . . . . . . . . .9025-25-21 Digital thermometer installation. . . . . . . . . .9010-20-1
Cylinder leakage test . . . . . . . . . . . . . . . .9025-25-28 Digital Thermometer Installation (S.N.
C1,B1,B2 (Lower) Accumulator Operation at B2 872256) . . . . . . . . . . . . . . . . . . . . . . . 9020-25A-1
Test Port (S.N. 872256). . . . . . . . . 9020-25A-39 Digital Thermometer Installation (S.N.872257
C2,B3 (Upper) Accumulator Operation at B3 Test ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-1
Port (S.N. 872256) . . . . . . . . . . . . 9020-25A-38 Dimensions
Machine . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-3
Display Module and logic module circuit
Schematic (S.N. 815415). . . . . . . . 9015-15A-25
D Schematic (S.N. 815416825657) . . 9015-15A-26
Schematic (S.N. 825658872256) . . 9015-15A-27
Destroke the wire hrness . . . . . . . . . . . . . .9025-25-4 Sub-system diagnostics (S.N.
Destroking the pump . . . . . . . . . . . . . . . . .9025-25-3 815415) . . . . . . . . . . . . . . . . . . . . . 9015-15A-28
Diagnose MFWD Malfunction (S.N. 872257 Sub-system diagnostics (S.N. 815416
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-15B-10 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-28
Diagnose Power Train Malfunctions (S.N. Display Module and logic module circuit with logic
872256) . . . . . . . . . . . . . . . . . . . . . . . 9020-15A-2 module
Diagnose Rear Axle Malfunction (S.N. 872257 Operational information (S.N.
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-15B-11 815415) . . . . . . . . . . . . . . . . . . . . . 9015-15A-21
Diagnostic information Theory of operation (S.N.
Brakes . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-10 815415) . . . . . . . . . . . . . . . . . . . . . 9015-15A-22
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . .9025-15-4 Display Module and logic module circuit without logic
Park brake and differential lock . . . . . . .9025-15-12 module
Steering . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-1 Operational information (S.N. 815416
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1 825627) . . . . . . . . . . . . . . . . . . . . . 9015-15A-22
Differential Theory of operation (S.N. 815416
Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-4 825627) . . . . . . . . . . . . . . . . . . . . . 9015-15A-23
Differential Lock Circuit Theory of operation (S.N. 825628
Operational Information (S.N. 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-24
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-43 Display monitor circuit Indx
Operational Information (S.N. 872257 perational Information (S.N. 872257 5
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-15 ). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15B-100
Schematic (S.N. 872256). . . . . . . . 9015-15A-44 Schematic (S.N. 872257 ) . . . . . . .9015-15B-103
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-17 Sub-System Diagnostics (S.N. 872257
Sub-System Diagnostics (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15B-104
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-45 Theory Of Operation (S.N. 872257
Sub-System Diagnostics (S.N. 872257 ). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15B-101
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-18 Dome Light Circuit
Theory of Operation (S.N. Operational Information (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-43 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-57
Theory of Operation (S.N. 872257 Operational Information (S.N. 872257
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-16 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-25
Differential lock pressure reducing valve test (S.N. Schematic (S.N. 872256). . . . . . . . 9015-15A-58
872256) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-52 Schematic (S.N. 872257 ) . . . . . . . 9015-15B-26
Differential lock pressure (S.N.872257 ) Sub-System Diagnostics (S.N.
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-18 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-59

022602
PN=5
Index
Page Page
Sub-System Diagnostics (S.N. 872257 Electrical circuit, A/C

). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-27 Malfunction diagnosis . . . . . . . . . . . . . . .9031-15-1
Theory of Operation (S.N. Operational Information. . . . . . . . . . . . . .9031-05-3
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-57 Schematic diagram
Theory of Operation (S.N. 872257 S.N. -816286 . . . . . . . . . . . . . . . . . . . .9031-05-5
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-25 Electrical circuit, blower
Drain and refill Operational information . . . . . . . . . . . . .9031-05-10
Capacities . . . . . . . . . . . . . . . . . . . . . . .9000-02-13 Electronic tachometer (S.N.872257 )
Drive and work light circuit Installation. . . . . . . . . . . . . . . . . . . . . . 9020-25B-1
Operational Information (S.N. Engine
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-74 General description . . . . . . . . . . . . . . . . .9010-05-1
Schematic (S.N. 872256). . . . . . . . 9015-15A-75 Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-3
Sub-System Diagnostics (S.N. Sectional view. . . . . . . . . . . . . . . . . . . . .9010-05-2
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-76 Visual inspection . . . . . . . . . . . . . . . . . . .9010-15-3
Theory of Operation (S.N. Engine harness (W8)
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-74 Component location (S.N.
Driving check -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-35
MFWD disengaged . . . . . . . . . . . . . . . .9005-10-16 Component location (S.N. 872257-
MFWD engaged . . . . . . . . . . . . . . . . . .9005-10-25 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-34
872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-35
E Wiring diagram (S.N. 872257- ). . . . . 9015-10B-32
Engine (S.N. -830204)
Electrical Specifications . . . . . . . . . . . . . . . . . . . . .9000-02-4
Circuit Malfunction Definitions . . . . . . . . .9015-05-3 Engine (S.N. 830205- )
Circuit Malfunction Locations. . . . . . . . . .9015-05-8 Specifications . . . . . . . . . . . . . . . . . . . . .9000-02-5
Circuit Malfunction Troubleshooting. . . . .9015-05-9 Engine system operational check
Circuit Malfunctions. . . . . . . . . . . . . . . . .9015-05-2 Fuel system . . . . . . . . . . . . . . . . . . . . .9005-10-41
Component identification . . . . . . . . . . . 9015-10A-1, Engine system operational checks
9015-10B-1 Air system checks . . . . . . . . . . . . . . . . .9005-10-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . .9015-05-1 Cooling system checks . . . . . . . . . . . . .9005-10-37
Logic module bench test . . . . . . . . . . . .9015-20-17 Lubrication checks . . . . . . . . . . . . . . . .9005-10-41
Logic module test in machine . . . . . . . .9015-20-15 Performance checks . . . . . . . . . . . . . . .9005-10-42
Monitor test in machine. . . . . . . . . . . . .9015-20-14 Speed checks . . . . . . . . . . . . . . . . . . . .9005-10-42
Schematic symbols . . . . . . . . . . . . . . . .9015-05-26 Expansion valve
Indx System functional schematic reading . .9015-05-20 Operation . . . . . . . . . . . . . . . . . . . . . . .9031-05-16
6 System Functional schematic (S.N. Extendible dipperstick
-825657) . . . . . . . . . . . . . . . . . . . . . 9015-10A-8 Grease specification . . . . . . . . . . . . . . . .9000-04-6
System Functional schematic (S.N. 825658-
). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-8
System Functional schematic (S.N.
825658-872256)
1 of 5. . . . . . . . . . . . . . . . . . . . . . . 9015-10A-14
F
2 of 5. . . . . . . . . . . . . . . . . . . . . . . 9015-10A-15
3 of 5. . . . . . . . . . . . . . . . . . . . . . . 9015-10A-16 Filter Operation, Hydraulic . . . . . . . . . . . .9025-05-14
4 of 5. . . . . . . . . . . . . . . . . . . . . . . 9015-10A-17 Filter, transmission (S.N.872257 )
5 of 5. . . . . . . . . . . . . . . . . . . . . . . 9015-10A-18 Operation . . . . . . . . . . . . . . . . . . . . . . 9020-05B-5
Test equipment . . . . . . . . . . . . . . . . . . .9015-05-15 Flowmeter calibration procedure. . . . . . . .9025-25-50
Test procedure . . . . . . . . . . . . . . . . . . .9015-05-16 FNR/Range Control Circuit
Wiring Diagram, Reading . . . . . . . . . . .9015-05-21 Operational Information (S.N.
Wiring Diagram, Schematic, And Component 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-86
Information . . . . . . . . . . . . . . . . . . . .9015-05-18 Schematic (S.N. 872256). . . . . . . . 9015-15A-89

022602
PN=6
Index
Page Page
Sub-System Diagnostics (S.N. Fuse Specifications (S.N. -872256) . . . . 9015-10A-3

872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-90 Fuse Specifications (S.N. 872257- ) . . . . 9015-10B-3
Theory of Operation (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-87
Front console harness (W7)
G
-872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-33
Gauge/hour meter circuit
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-29
872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-113
Schematic (S.N. 872256). . . . . . . .9015-15A-115
872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-30
Specifications (S.N. 872256) . . . . .9015-15A-113
Wiring diagram (S.N. 872257- ). . . . . 9015-10B-28
872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-116
872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-114
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-60
Gauges and indicators check
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-61
Engine off . . . . . . . . . . . . . . . . . . . . . . . .9005-10-3
Engine on . . . . . . . . . . . . . . . . . . . . . . . .9005-10-6
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-62
Grease
Theory Of Operation (S.N. 872257
Extendible dipperstick . . . . . . . . . . . . . . .9000-04-6
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-60
Extreme pressure and multipurpose . . . .9000-04-6
Fuel
Gresen-Backhoe circuit relief valve
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-34
Specifications . . . . . . . . . . . . . . . . . . . . .9000-04-1
Tank capacity . . . . . . . . . . . . . . . . . . . . .9000-04-2
Operational Information (S.N. 872257 H
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-91
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-93 Heater and air conditioning
Specifications (S.N. 872257 ) . . . . 9015-15B-91 Checks . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-33
Sub-System Diagnostics (S.N. 872257 High pressure A/C switch
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-94 Test
Theory of Operation (S.N. 872257 S.N. -816286 . . . . . . . . . . . . . . . . . . .9031-25-10
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-92 S.N. 816287- . . . . . . . . . . . . . . . . . . .9031-25-12
Fuel Shut-Off Circuit Horn circuit
Operational Information (S.N. Operational Information (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-48 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-98 Indx
Operational Information (S.N. 872257 Operational Information (S.N. 872257 7
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-30 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-75
Schematic (S.N. 872256). . . . . . . . 9015-15A-50 Schematic (S.N. 872256). . . . . . . . 9015-15A-99
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-32 Schematic (S.N. 872257 ) . . . . . . . 9015-15B-76
Sub-System Diagnostics (S.N. Sub-System Diagnostics (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-51 872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-100
Sub-System Diagnostics (S.N. 872257 Sub-System Diagnostics (S.N. 872257
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-33 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-77
Theory of Operation (S.N. Theory of Operation (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-49 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-98
Theory of Operation (S.N. 872257 Theory of Operation (S.N. 872257
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-31 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-75
Fuel system, engine Hydraulic
Checks . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-41 Fittings, 30° cone seat. . . . . . . . . . .9000-03-9
Fuse Fittings, 37° flare . . . . . . . . . . . . . . .9000-03-9
Color Codes . . . . . . . . . . 9015-10A-2, 9015-10B-2 Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-4

022602
PN=7
Index
Page Page
Hydraulic Circuit Symbols (S.N.872257 JT05801 Clamp-On Electronic Tachometer

) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-15B-15 Installation
Hydraulic component leakage test . . . . . .9025-25-29 (S.N. 872256) . . . . . . . . . . . . . . . . . 9020-25A-1
Hydraulic oil cooler restriction test . . . . . .9025-25-18 (S.N. 872257 ). . . . . . . . . . . . . . . . . 9020-25B-1
Hydraulic oil warm-up procedure . . . . . . . .9025-25-2
Hydraulic Pump Operation
Pump, Hydraulic Operaton . . . . . . . . . .9025-05-10
L
Hydraulic Return Filter . . . . . . . . . . . . . . .9025-05-14
Hydraulic system checks . . . . . . . . . . . . .9005-10-27
Legend
Hydraulic System Operation (S.N.
System Functional Schematic Section (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-2
-872256) . . . . . . . . . . . . . . . . . . . . . 9015-10A-7
Hydraulic System Operation (S.N.872257
System Functional Schematic Section (S.N.
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-4
872257- ). . . . . . . . . . . . . . . . . . . . . 9015-10B-7
Wiring and Schematic Diagrams (S.N.
-872256) . . . . . . . . . . . . . . . . . . . . . 9015-10A-4
I Wiring and Schematic Diagrams (S.N. 872257-
). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-4
Lifting
Inch torque values . . . . . . . . . . . . . . . . . . .9000-03-4
Capacities . . . . . . . . . . . . . . . . . . . . . . .9000-02-14
Indicator circuit
Loader auxiliary valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-32
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-29
Loader boom valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-28
). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15B-107
Loader bucket valve
Schematic With Logic Module (S.N.
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-25
815415) . . . . . . . . . . . . . . . . . . . . . 9015-15A-33
Loader control valve linkage
Schematic Without Logic Module (S.N. 815416
adjustment . . . . . . . . . . . . . . . . . . . . . .9025-20-10
825657) . . . . . . . . . . . . . . . . . . . . . 9015-15A-34
Low pressure A/C switch
Schematic Without Logic Module (S.N. 825658
Test
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-35
S.N. -816286 . . . . . . . . . . . . . . . . . . . .9031-25-5
Specifications (S.N. 872256) . . . . . 9015-15A-29
S.N. 816287- . . . . . . . . . . . . . . . . . . . .9031-25-8
Specifications (S.N. 872257 ) . . . .9015-15B-106
Lubricant
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-36
Lubrication system, engine
Checks . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-41
). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15B-110
Indx Theory of Operation (S.N. 815415) With Logic
8 Module . . . . . . . . . . . . . . . . . . . . . 9015-15A-30
Theory of Operation (S.N. 815416825657) M
Without Logic Module . . . . . . . . . . 9015-15A-31
Theory of Operation (S.N. 825658872256) Machine specifications . . . . . . . . . . . . . . . .9000-02-2
Without Logic Module . . . . . . . . . . 9015-15A-32 Main pump flow test . . . . . . . . . . . . . . . . .9025-25-12
Theory Of Operation (S.N. 872257 Main pump standby pressure test. . . . . . .9025-25-10
). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15B-108 MFWD
Inspection Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-5
Hoses and fittings, A/C . . . . . . . . . . . . .9031-25-15 MFWD circuit
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-40
J ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-19
Schematic (S.N. 872256). . . . . . . . 9015-15A-41
John Deere Inboard Planetary AxlesUse CTM43 Schematic (S.N. 872257 ) . . . . . . . 9015-15B-20
(S.N. 872256) . . . . . . . . . . . . . . . . . 9020-15A-1 Specifications (S.N. 872256) . . . . . 9015-15A-39

022602
PN=8
Index
Page Page
Sub-System Diagnostics (S.N. Transmission neutral disconnect . . . . . .9005-10-15

872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-42
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-20
Theory of Operation (S.N. P
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-40
Theory of Operation (S.N. 872257
Park brake adjustment (S.N. 872256) . . .9025-20-4
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-19
MFWD differential-unequal traction Park brake circuit pressure test (S.N.
(S.N. 872256) . . . . . . . . . . . . . . . . 9020-05A-31 872256) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-54
(S.N. 872257 ). . . . . . . . . . . . . . . . 9020-05B-44 Park brake (S.N.872257 )
MFWD operation Operation . . . . . . . . . . . . . . . . . . . . . 9020-05B-38
(S.N. 872256) . . . . . . . . . . . . . . . . 9020-05A-30 Release pressure test . . . . . . . . . . . . . 9020-25B-8
MFWD Operation Park brake thermal relief valve test (S.N.
(S.N. 872257 ). . . . . . . . . . . . . . . . 9020-05B-40 872256) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-56
MFWD operation equal tractio) Park brake/differential lock valve (S.N. 872256)
(S.N. 872256) . . . . . . . . . . . . . . . . 9020-05A-33 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-88
MFWD operation equal traction Park Brake/FNR Circuit
(S.N. 872257 ). . . . . . . . . . . . . . . . 9020-05B-42 Operational Information (S.N. 872257
MFWD pressure test (S.N.872257 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-63
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-20 Specifications (S.N. 872257 ) . . . . 9015-15B-63
Miscellaneous checks. . . . . . . . . . . . . . . .9005-10-51 Sub-System Diagnostics (S.N. 872257
Mixing lubricants. . . . . . . . . . . . . . . . . . . . .9000-04-7 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-67
Modulation valve power shift (S.N.872257 ) Theory Of Operation (S.N. 872257
Operation . . . . . . . . . . . . . . . . . . . . . 9020-05B-32 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-64
Modulation valve (S.N.872257 ) Park Brake/Neutral Disconnect Circuit
Pressure test. . . . . . . . . . . . . . . . . . . 9020-25B-15 Operational Information (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-77
Schematic (S.N. 815415). . . . . . . . 9015-15A-79
Schematic (S.N. 815416825657) . . 9015-15A-80
O Schematic (S.N. 825658872256) . . 9015-15A-81
Specifications (S.N. 872256) . . . . . 9015-15A-77
O-ring boss fittings . . . . . . . . . . . . . . . . . .9000-03-10 Sub-System Diagnostics (S.N.
Oil 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-82
Lines and fittings. . . . . . . . . . . . . . . . . . .9000-03-8 Theory of Operation (S.N.
MFWD specification . . . . . . . . . . . . . . . .9000-04-5 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-78
Specification differential . . . . . . . . . . . . .9000-04-4 Parking brake (S.N. 872256) Indx
Specification engine . . . . . . . . . . . . . . . .9000-04-3 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-84 9
Specification hydraulic system . . . . . . . .9000-04-4 Power circuit
Oil lines and fittings . . . . . . . . . . . . . . . . . .9000-03-8 Operational information (S.N.
Operational checkout procedures . . . . . . . .9005-10-1 -872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-1
Operational checks Operational information (S.N. 872257
Accessories (engine stopped) . . . . . . . .9005-10-44 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-1
Brake system . . . . . . . . . . . . . . . . . . . .9005-10-10 Schematic (S.N. -825657) . . . . . . . . . . 9015-15A-2
Cab components. . . . . . . . . . . . . . . . . .9005-10-46 Schematic (S.N. 825658-872256) . . . . 9015-15A-3
Driving checks (with MFWD) . . . . . . . . .9005-10-25 Schematic (S.N. 872257 ) . . . . . . . . 9015-15B-2
Driving checks (w/o MFWD) . . . . . . . . .9005-10-16 Subsystem Diagnostics (S.N.
Gauges and indicators (engine off) . . . . .9005-10-3 -872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-4
Gauges and indicators (engine on) . . . . .9005-10-6 Subsystem Diagnostics (S.N. 872257
Heater and air conditioning system . . . .9005-10-33 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-3
Hydraulic system. . . . . . . . . . . . . . . . . .9005-10-27 Theory of operation (S.N. -872256). . . 9015-15A-1
Miscellaneous . . . . . . . . . . . . . . . . . . . .9005-10-51 Theory of operation (S.N. 872257
Steering system . . . . . . . . . . . . . . . . . .9005-10-14 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-1

022602
PN=9
Index
Page Page
Power shift high range forward clutch (S.N.872257 Operational Information (S.N. 872257
) ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-22
Pressure test. . . . . . . . . . . . . . . . . . . 9020-25B-12 Schematic (S.N. 872256). . . . . . . . 9015-15A-61
Power shift low range forward clutch (S.N.872257 ) Schematic (S.N. 872257 ) . . . . . . . 9015-15B-23
Pressure Test . . . . . . . . . . . . . . . . . . 9020-25B-12 Sub-System Diagnostics (S.N.
Power shift modulation valve (S.N.872257 ) 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-62
Operation . . . . . . . . . . . . . . . . . . . . . 9020-05B-32 Sub-System Diagnostics (S.N. 872257
Power shift power train (S.N.872257 ) ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-24
Diagnose malfunctions . . . . . . . . . . . . 9020-15B-1 Radio harness (W12)
Overview. . . . . . . . . . . . . . . . . . . . . . 9020-05B-10 Component location (S.N.
Power shift speed clutch (S.N.872257 ) -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-46
Pressure test. . . . . . . . . . . . . . . . . . . 9020-25B-12 Component location (S.N. 872257-
Power Shift Transmission Control Circuit (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-45
872257 ) Connectors, wire and pin location (S.N.
First Forward. . . . . . . . . . . . . . . . . . . 9020-05B-20 872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-46
First Reverse . . . . . . . . . . . . . . . . . . 9020-05B-28 Wiring diagram (S.N. -872256) . . . . . 9015-10A-45
High range (fourth) forward . . . . . . . . 9020-05B-24 Wiring diagram (S.N. 872257- ). . . . . 9015-10B-44
Neutral . . . . . . . . . . . . . . . . . . . . . . . 9020-05B-16 Rear Work Light Circuit
Power shift transmission control circuit Operational Information (S.N. 872257
(S.N.872257 ) ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-56
First forward . . . . . . . . . . . . . . . . . . . 9020-05B-20 Sub-System Diagnostics (S.N. 872257
First Reverse . . . . . . . . . . . . . . . . . . 9020-05B-28 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-59
Fourth forward . . . . . . . . . . . . . . . . . 9020-05B-24 Theory Of Operation (S.N. 872257
Neutral . . . . . . . . . . . . . . . . . . . . . . . 9020-05B-16 ). . . . . . . . . . . . . . . . 9015-15B-57, 9015-15B-58
Power shift transmission control valve and shift valve Receiver/dryer
(S.N.872257 ) Operation . . . . . . . . . . . . . . . . . . . . . . .9031-05-14
Operation-first forward. . . . . . . . . . . . 9020-05B-22
Reducing valve presssure (S.N.872257 )
Operation-first reverse. . . . . . . . . . . . 9020-05B-30
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-14
Operation-neutral . . . . . . . . . . . . . . . 9020-05B-18
Refrigerant A/C
Power shift transmission (S.N.872257 )
Theory of operation. . . . . . . . . . . . . . . . .9031-05-2
Control valve operation-fourth
Refrigerant, A/C
forward . . . . . . . . . . . . . . . . . . . . . 9020-05B-26
Cautions . . . . . . . 9031-05-1, 9031-20-1, 9031-25-1
Gear flow . . . . . . . . . . . . . . . . . . . . . 9020-05B-12
Handling . . . . . . . 9031-05-1, 9031-20-1, 9031-25-1
Power train overview (S.N.872257 )
Recovery. . . . . . . . . . . . . . . . . . . . . . . . .9031-20-5
Power shift . . . . . . . . . . . . . . . . . . . . 9020-05B-10
Recovery/recycling/charging . . . . . . . . . .9031-20-4
Pressure Compensator Operation . . . . . .9025-05-12
Pressure regulating valve (S.N. Return to dig adjustment . . . . . . . . . . . . . .9025-20-2
Indx
872256) . . . . . . . . . . . . . . . . . . . . . . 9020-05A-20 Return-to-Dig Circuit
10
Priority valve Operational Information (S.N.
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-16 872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-109
Priority valve LS port flow test . . . . . . . . .9025-25-16 Operational Information (S.N. 872257
Priority valve test . . . . . . . . . . . . . . . . . . .9025-25-14 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-87
Pump, Charge . . . . . . . . . . . . . . . . . . . . . .9025-05-9 Schematic (S.N. 872256). . . . . . . .9015-15A-111
Pump, transmission (S.N.872257 ) Schematic (S.N. 872257 ) . . . . . . . 9015-15B-88
Operation . . . . . . . . . . . . . . . . . . . . . . 9020-05B-4 Sub-System Diagnostics (S.N.
872256) . . . . . . . . . 9015-15A-112, 9015-15B-89
872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-110
R Theory of Operation (S.N. 872257
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-87
Radio circuit Reverse Alarm Circuit
Operational Information (S.N. Operational Information (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-60 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-52

022602
PN=10
Index
Page Page
Operational Information (S.N. 872257 Solenoids activated (S.N.872257 )

). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-33 Transmission clutch engagement power
Schematic (S.N. 872256). . . . . . . . 9015-15A-53 shift . . . . . . . . . . . . . . . . . . . . . . . . 9020-05B-14
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-35 Specification
Sub-System Diagnostics (S.N. Differential oil . . . . . . . . . . . . . . . . . . . . .9000-04-4
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-54 Engine oil . . . . . . . . . . . . . . . . . . . . . . . .9000-04-3
Sub-System Diagnostics (S.N. 872257 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-36 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .9000-04-4
Theory of Operation (S.N. Mechanical front wheel drive oil . . . . . . .9000-04-5
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-52 Tire pressure. . . . . . . . . . . . . . . . . . . . . .9000-03-1
Theory of Operation (S.N. 872257 Specifications
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-34 Machine . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-2
Roll-over protective structure Machine (S.N. -872328) . . . . . . . . . . . . .9000-02-6
Torque specifications . . . . . . . . . . . . . . .9000-03-2 Machine (S.N. 872329-) . . . . . . . . . . . . .9000-02-8
Other information . . . . . . . . . . . . . . . . .9000-02-11
Stabilizer valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-56
Stabilizer valve linkage adjustment . . . . . .9025-20-12
S Start aid circuit
Selective Flow Valve Circuit 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-45
Operational Information (S.N. 872257 Operational Information (S.N. 872257
). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15B-113 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-27
Schematic (S.N. 872257 ) . . . . . . .9015-15B-115 Schematic (S.N. 872256). . . . . . . . 9015-15A-47
Sub-System Diagnostics (S.N. 872257 Schematic (S.N. 872257 ) . . . . . . . 9015-15B-29
). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15B-116 Sub-System Diagnostics (S.N.
Theory of Operation (S.N. 872257 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-48
). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15B-114 Sub-System Diagnostics (S.N. 872257
Selective flow valve harness (W15) ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-30
Component location (S.N. 872257- Theory of Operation (S.N.
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-48 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-46
Connectors, wire and pin location (S.N. Theory of Operation (S.N. 872257
872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-49 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-28
Wiring diagram (S.N. 872257- ). . . . . 9015-10B-47 Start circuit
Operational information (S.N.
Service Brake (S.N. 872257 )
-872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-8
Adjustment . . . . . . . . . . . . . . . . . . . . . . .9025-20-8
Operational information (S.N. 872257 Indx
Service brake (S.N. 872257 ) 11
). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-5
Engaging Right Side Only . . . . . . . . . . .9025-05-82
Schematic (S.N. -825657) . . . . . . . . . . 9015-15A-9
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-74
Schematic (S.N. 825658872256) . . 9015-15A-10
Service Brake (S.N. 872257 ) Schematic (S.N. 872257 ) . . . . . . . . 9015-15B-7
Pedal Adjustment . . . . . . . . . . . . . . . . . .9025-20-8 Sub-system diagnostics (S.N.
Side console harness (W6) 872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-11
Component location (S.N. 872257- Sub-system diagnostics (S.N. 872257
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-22 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-8
Connectors, wire and pin location (S.N. Theory of operation (S.N. -872256). . . 9015-15A-8
872257- ). . . . . . . . . . . . . . . . . . . . 9015-10B-24 Theory of operation (S.N. 872257
Wiring diagram (S.N. 872257- ). . . . . 9015-10B-19 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-6
Slow and Fast Idle Adjustment Starting motors
(S.N. 830204) . . . . . . . . . . . . . . . . . . .9010-20-2 Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1
(S.N. 830305 ). . . . . . . . . . . . . . . . . . .9010-20-4 Steering
Solenoid circuit leakage (S.N.872257 ) Valve operation . . . . . . . . . . . . . . . . . . .9025-05-22
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-28 Steering cylinder leakage . . . . . . . . . . . . .9025-25-26

022602
PN=11
Index
Page Page
Steering system checks . . . . . . . . . . . . . .9005-10-14 Switch, low pressure A/C

Steering system leakage test . . . . . . . . . .9025-25-22 S.N. -816286 . . . . . . . . . . . . . . . . . . . .9031-25-5
Steering valve S.N. 816287- . . . . . . . . . . . . . . . . . . . .9031-25-8
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-22 Torque converter stall speed(S.N.
Steering valve neutral drift test . . . . . . . . .9025-25-20 872256) . . . . . . . . . . . . . . . . . . . . . . 9020-25A-4
Surge relief valve pressure test . . . . . . . . .9025-25-9 Test (S.N. 872256)
Switch, A/C freeze control Brake Accumulator Precharge. . . . . . . .9025-25-64
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-14 Test (S.N. 872256)
System Functional Schematic (S.N. Charge Pump Flow . . . . . . . . . . . . . . . . .9025-25-6
-825657) . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-8 Diff. lock pressure reducing valve . . . . .9025-25-52
System Functional Schematic (S.N. 825658- MFWD clutch pressure . . . . . . . . . . . 9020-25A-14
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-8 Test (S.N. 872256))
System Functional Schematic Section Legend (S.N. Neutral disconnect solenoid . . . . . . . 9020-25A-12
-872256) . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-7 Test (S.N. 872256)
System Functional Schematic Section Legend (S.N. Park Brake Circuit Pressure . . . . . . . . .9025-25-54
872257- ) . . . . . . . . . . . . . . . . . . . . . . 9015-10B-7 Park Brake Thermal Relief Valve . . . . .9025-25-56
System pressure (S.N.872257 ) Service Brake Valve Pressure. . . . . . . .9025-25-58
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-10 Torque Converter . . . . . . . . . . . . . . . . 9020-25A-4
Transmission leakage . . . . . . . . . . . . 9020-25A-16
Transmission Procedure . . . . . . . . . . 9020-25A-32
Transmission pump flow . . . . . . . . . . . 9020-25A-8
T Test (S.N. 872256))
Transmission system pressure . . . . . . 9020-25A-6
Test (S.N. 872257 )
Tachometer Charge Pump Flow . . . . . . . . . . . . . . . . .9025-25-8
Calibration (S.N. 872256) . . . . . . . . .9015-20-18 Service brake valve work port pressure
Calibration (S.N. 872257 ) . . . . . . . . .9015-20-19 test . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-62
Tachometer, electronic (S.N.872257 ) Test (S.N.872256 )
Installation. . . . . . . . . . . . . . . . . . . . . . 9020-25B-1 Converter-in/cooler pressure . . . . . . . 9020-25A-10
Test Transmission control circuit. . . . . . . . 9020-25A-26
A/C leaks . . . . . . . . . . . . . . . . . . . . . . .9031-25-15 Transmission cooler restriction . . . . . 9020-25A-22
Charge Pressure. . . . . . . . . . . . . . . . . . .9025-25-5 Transmission lube pressure . . . . . . . 9020-25A-24
Complete transmission system . . . . . 9020-25A-28 Test (S.N.872257 )
Cycle time. . . . . . . . . . . . . . . . . . . . . . .9025-25-50 Converter-In Relief Valve Testest . . . . 9020-25B-6
Cyle time. . . . . . . . . . . . . . . . . . . . . . . .9025-25-48 Cooler in and cooler out pressue . . . 9020-25B-22
Cylinder drift . . . . . . . . . . . . . . . . . . . . .9025-25-21 Differential pressure . . . . . . . . . . . . . 9020-25B-18
Cylinder leakage . . . . . . . . . . . . . . . . . .9025-25-28 MFWD pressure . . . . . . . . . . . . . . . . 9020-25B-20
Indx
12 Hydraulic Component Leakage . . . . . . .9025-25-29 Modulation valve pressure . . . . . . . . 9020-25B-15
Main pump flow. . . . . . . . . . . . . . . . . . .9025-25-12 Park Brake Release Pressure . . . . . . . 9020-25B-8
Main pump standby pressure . . . . . . . .9025-25-10 Power Shift Low Range Forward, High Range
Oil cooler restriction . . . . . . . . . . . . . . .9025-25-18 Forward, Reverse and Speed Clutch
Priority valve . . . . . . . . . . . . . . . . . . . . .9025-25-14 Pressure . . . . . . . . . . . . . . . . . . . . 9020-25B-12
Priority valve LS port flow . . . . . . . . . .9025-25-16 Reducing valve pressure. . . . . . . . . . 9020-25B-14
Relief valves (with remote pump) . . . . .9025-25-43 System Pressure. . . . . . . . . . . . . . . . 9020-25B-10
Relief valves (with test cylinder) . . . . . .9025-25-36 Thermal Bypass Relief Valve . . . . . . 9020-25B-24
Steering cylinder leakage . . . . . . . . . . .9025-25-26 Torque Converter Stall Speed Test . . . 9020-25B-4
Steering System leakage . . . . . . . . . . .9025-25-22 Transmission oil cooler thermal bypass
Steering valve neutral drift . . . . . . . . . .9025-25-20 valve . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-24
Surge Relief Valve Pressure . . . . . . . . . .9025-25-9 Transmission oil cooler thermal bypass valve
Switch, A/C freeze control. . . . . . . . . . .9031-25-14 pressure . . . . . . . . . . . . . . . . . . . . 9020-25B-26
Switch, high pressure A/C Transmission pump flow . . . . . . . . . . 9020-25B-30
S.N. -816286 . . . . . . . . . . . . . . . . . . .9031-25-10 Tests
S.N. 816287- . . . . . . . . . . . . . . . . . . .9031-25-12 Air intake system leakage . . . . . . . . . . . .9010-25-6

022602
PN=12
Index
Page Page
Cooling system . . . . . . . . . . . . . . . . . . . .9010-25-1 Second forward. . . . . . . . . . . . . . . . . 9020-05A-10

Fuel line leakage. . . . . . . . . . . . . . . . . . .9010-25-7 Third Forward . . . . . . . . . . . . . . . . . . 9020-05A-12
Radiator air flow . . . . . . . . . . . . . . . . . . .9010-25-2 Transmission Pump Flow (S.N.872257 )
Turbocharger boost pressure . . . . . . . . .9010-25-4 Test . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-30
Thermal bypass valve test (S.N.872257 Transmission Pump (S.N.872257 )
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-24 Flow test . . . . . . . . . . . . . . . . . . . . . . 9020-25B-30
Thermometer Installation, Digital . . . . . . . .9025-25-1 Transmission pump (S.N.872257 )
Thermometer installation, digital . . . . . . . . .9010-20-1 Operation . . . . . . . . . . . . . . . . . . . . . . 9020-05B-4
Thermometer Installation, Digital (S.N.872257 Transmission (S.N. 872256)
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-1 Filter . . . . . . . . . . . . . . . . . . . . . . . . . 9020-05A-22
Toe-in adjustment. . . . . . . . . . . . . . . . . . . .9020-20-1 Theory . . . . . . . . . . . . . . . . . . . . . . . . 9020-05A-1
Torque Transmission (S.N.872257 )
Wheel cap screw . . . . . . . . . . . . . . . . . .9000-03-3
Cooler in and cooler out press.
Torque converter (S.N.872256) . . . . . . 9020-05A-4
test . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-22
Torque converter (S.N.872257 )
Modulation valve pressure test . . . . . 9020-25B-15
Operation . . . . . . . . . . . . . . . . . . . . . . 9020-05B-2
Reducing Valve Pressure . . . . . . . . . 9020-25B-14
Torque converter stall speed (S.N.872257 )
Test . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-4 System pressure test . . . . . . . . . . . . 9020-25B-10
Torque specifications Theory . . . . . . . . . . . . . . . . . . . . . . . . 9020-05B-1
Roll-over protective structure. . . . . . . . . .9000-03-2 Transmission solenoid harness (W9)
Torque value Component location (S.N.
Flat face O-ring seal fitting . . . . . . . . . .9000-03-12 -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-37
Inch SAE four bolt flange fitting. . . . . . .9000-03-13 Wiring diagram (S.N. -872256) . . . . . 9015-10A-36
Metric cap screw. . . . . . . . . . . . . . . . . . .9000-03-6 Transmission test connection
Metric four bolt flange fitting . . . . . . . . .9000-03-14 (S.N. 872257 ). . . . . . . . . . . . . . . . . 9020-25B-3
O-Ring boss fitting . . . . . . . . . . . . . . . .9000-03-10 Transmission Warm-Up Procedure
30° cone seat hydraulic fittings . . . .9000-03-9 (S.N. 872256) . . . . . . . . . . . . . . . . . 9020-25A-2
37° flare hydraulic fittings . . . . . . . .9000-03-9 Transmission Warm-Up Proceduredash; )
Torque values (S.N. 872257 ). . . . . . . . . . . . . . . . . 9020-25B-2
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-4 Transmission, power shift (S.N.872257 )
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-5 Control circuit-first forward . . . . . . . . 9020-05B-20
Transmission clutch engagement power shift Control circuit-first reverse . . . . . . . . 9020-05B-28
(S.N.872257 ) Control circuit-fourth forward . . . . . . . 9020-05B-24
Solenoids activated . . . . . . . . . . . . . . 9020-05B-14 Control circuit-neutral . . . . . . . . . . . . 9020-05B-16
Transmission filter (S.N.872257 ) Troubleshooting
Operation . . . . . . . . . . . . . . . . . . . . . . 9020-05B-5 Circuit Malfunctions. . . . . . . . . . . . . . . . .9015-05-9
Transmission Gear Flow (S.N.872257 ) Turn/flasher/brake light circuit Indx
Power Shift . . . . . . . . . . . . . . . . . . . . 9020-05B-12 13
Transmission hydraulic circuit (S.N.
872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-100
872256) . . . . . . . . . . . . . . . . . . . . . . 9020-05A-24
Transmission neutral disconnect circuit
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-78
check . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-15
Schematic (S.N. 872256). . . . . . . .9015-15A-103
Transmission oil cooler (S.N.872257 )
Bypass valve pressure test . . . . . . . . 9020-25B-26 Schematic (S.N. 872257 ) . . . . . . . 9015-15B-79
Thermal bypass valve test . . . . . . . . 9020-25B-24 Specifications (S.N. 872257 ) . . . . 9015-15B-77
Transmission Oil Passage Identification (S.N. Sub-System Diagnostics (S.N.
872256) . . . . . . . . . . . . . . . . . . . . . . . 9020-15A-8 872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-104
Transmission power flow (S.N. 872256) Sub-System Diagnostics (S.N. 872257
First forward . . . . . . . . . . . . . . . . . . . . 9020-05A-8 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-80
First reverse . . . . . . . . . . . . . . . . . . . 9020-05A-16 Theory of Operation (S.N.
Fourth Forward . . . . . . . . . . . . . . . . . 9020-05A-14 872256) . . . . . . . . . . . . . . . . . . . . .9015-15A-101
Neutral . . . . . . . . . . . . . . . . . . . . . . . . 9020-05A-6 Theory of Operation (S.N. 872257
Seconc Reverse . . . . . . . . . . . . . . . . 9020-05A-18 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-78

022602
PN=13
Index
Page Page
V Wiring and Schematic Diagrams Legend (S.N.

872257- ) . . . . . . . . . . . . . . . . . . . . . . 9015-10B-4
Valve Wiring diagram
Backhoe auxiliary . . . . . . . . . . . . . . . . .9025-05-55 A.C. compressor harness (W11) (S.N.
Backhoe bucket-Gresen . . . . . . . . . . . .9025-05-53 -825657) . . . . . . . . . . . . . . . . . . . . 9015-10A-42
Backhoe swing-Gresen . . . . . . . . . . . . .9025-05-50 A.C. compressor harness (W11) (S.N. 872257-
Loader auxiliary. . . . . . . . . . . . . . . . . . .9025-05-32 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-41
Loader boom. . . . . . . . . . . . . . . . . . . . .9025-05-28 Wiring Diagram
Loader bucket . . . . . . . . . . . . . . . . . . . .9025-05-25 Air conditioning compressor harness
Loader circuit relief . . . . . . . . . . . . . . . .9025-05-24 (W11) . . . . . . . . . . . . . . . . . . . . . . . . .9031-15-7
Priority . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-16 Wiring diagram
Stabilizer . . . . . . . . . . . . . . . . . . . . . . . .9025-05-56 Auxiliary valve harness (W14) (S.N.
Valve (S.N. 872257 ) -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-47
Service brake work port pressure Blower harness (W10). . . . . . . . . . . . . . .9031-15-6
test . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-62 Blower harness (W10) (S.N.
Valve, backhoe auxiliary -825657) . . . . . . . . . . . . . . . . . . . . 9015-10A-38
operation-Husco . . . . . . . . . . . . . . . . . .9025-05-46 Blower harness (W10) (S.N.
Valve, backhoe boom valve-Gresen . . . . .9025-05-52 825658-872256) . . . . . . . . . . . . . . 9015-10A-40
Valve, backhoe boom-Husco . . . . . . . . . .9025-05-42 Blower harness (W10) (S.N. 872257-
Valve, backhoe crowd ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-38
operation-Husco . . . . . . . . . . . . . . . . . .9025-05-44 Cab roof harness (W5) (S.N.
Valve, brake (S.N. 872257 ) -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-19
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-76 Cab roof harness (W5) (S.N. 872258-
Valve, converter-in relief (S.N.872257 ) ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-15
Test . . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-6 Cab side console harness (W6) (S.N. -815415)
Valve, modulation (S.N.872257 ) (1 of 2) . . . . . . . . . . . . . . . . . . . . . 9015-10A-21
Pressure test. . . . . . . . . . . . . . . . . . . 9020-25B-15 (2 of 2) . . . . . . . . . . . . . . . . . . . . . 9015-10A-22
Valve, reducing, pressure (S.N.872257 ) Cab side console harness (W6) (S.N.
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9020-25B-14 825658-872256)
Valve-Gresen (1 of 3) . . . . . . . . . . . . . . . . . . . . . 9015-10A-27
Backhoe circuit relief. . . . . . . . . . . . . . .9025-05-34 (2 of 3) . . . . . . . . . . . . . . . . . . . . . 9015-10A-28
(3 of 3) . . . . . . . . . . . . . . . . . . . . . 9015-10A-29
Engine harness (W8) (S.N.
-872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-34
W Engine harness (W8) (S.N. 872257-
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-32
Indx Wiper/washer circuit Front console harness (W7) (S.N.
14 Operational Information (S.N. -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-32
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-63 Front console harness (W7) (S.N. 872257-
Operational Information (S.N. 872257 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-28
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-51 Radio harness (W12) (S.N.
Schematic (S.N. 872256). . . . . . . . 9015-15A-64 -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-45
Schematic (S.N. 872257 ) . . . . . . . 9015-15B-52 Radio harness (W12) (S.N. 872257-
Sub-System Diagnostics (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-44
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-65 Selective flow valve harness (W15) (S.N. 872257-
Sub-System Diagnostics (S.N. 872257 ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-47
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-53 Side console harness (W6) (S.N. 872257-
Theory of Operation (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10B-19
872256) . . . . . . . . . . . . . . . . . . . . . 9015-15A-63 Transmission solenoid harness (W9) (S.N.
Theory of Operation (S.N. 872257 -872256) . . . . . . . . . . . . . . . . . . . . 9015-10A-36
). . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15B-51
Wiring and Schematic Diagrams Legend (S.N.
-872256) . . . . . . . . . . . . . . . . . . . . . . . 9015-10A-4

022602
PN=14

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710D Backhoe Loader

For complete service information also see:

Live with safety: Read the safety messages in the 1. 9000

TM1537 (26FEB02) 710D Backhoe Loader

John Deere Dealers

IMPORTANT: Please remove this page and route

Listed below is a brief explanation of WHAT was change

TM1537 (26FEB02) 710D Backhoe Loader

TM1537 (26FEB02) 710D Backhoe Loader

Help!! Help!! Help!! Help!!

We need your help to continually improve our technical

SEND TO: John Deere Dubuque Works

FAX NUMBER: 319-589-5800

TM1537 710D Backhoe Loader Operation and Test Manual

TM1537 (26FEB02) 710D Backhoe Loader

TM1537 (26FEB02) 710D Backhoe Loader

SECTION 9005Operational Checkout Procedure

SECTION 9015Electrical System 9015

SECTION 9020Power Train

SECTION 9025Hydraulic System

SECTION 9031Heating and Air Conditioning

All information, illustrations and specifications in this manual are based on

TM1537 (26FEB02) i 710D Backhoe Loader

TM1537 (26FEB02) ii 710D Backhoe Loader

Group 01Safety Information 710D Tire Pressure . . . . . . . . . . . . . . . . . . . .9000-03-1

Group 03Torque Values

TM1537 (26FEB02) 9000-2 710D Backhoe Loader

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.

TM1537 (26FEB02) 9000-01-1 710D Backhoe Loader

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.

TM1537 (26FEB02) 9000-01-2 710D Backhoe Loader

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

TM1537 (26FEB02) 9000-01-3 710D Backhoe Loader

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