310D TM1496

300D, 310D, 315D Backhoe Loader Operation and Test
TECHNICAL MANUAL
TM1496 21SEP05 (ENGLISH)
For complete service information also see: 300D, 310D, 315D Backhoe Loaders Repair (Complete) . . . . . . . . . . . . . . . . . . . . . 300D, 310D, 315D Backhoe Loaders Operation and Test (Complete) . . . . . . . . . . TM1497 TM1496
Worldwide Construction And Forestry Division

LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. See DB1990 Service Publications Catalog to order a complete Technical Manual (TM) or a Technical Manual Section (TMS). A complete Operation and Test manual includes the following sections: TMS14969000 Section 9000 General Information TMS14969005 Section 9005 Operational Checkout Procedure Section 9010 Engine TMS14969015 Section 9015 Electrical System TMS14969020 Section 9020 Power Train TMS14969025 Section 9025 Hydraulics TMS14969031 Section 9031 Heating and Air Conditioning
TX,1496,RR4512 1920JUN941/1
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Contents
9000
SECTION 9000General Information Group 01Safety Information Group 02General Specifications Group 03Torque Values Group 04Fuels And Lubricants SECTION 9005Operational Checkout Procedure Group 10Operational Checkout Procedure SECTION 9010Engine Group 05Theory Of Operation Group 10System Operational Checks Group 15System Diagnostic Information Group 20Adjustments Group 25Tests SECTION 9015Electrical System Group 05System Information Group 10System Diagrams Group 15Sub-System Diagnostics Group 20References SECTION 9020Power Train Group 05Theory Of Operation Group 10System Operational Checks Group 15System Diagnostic Information Group 20Adjustments Group 25Tests SECTION 9025Hydraulics Group 05Theory Of Operation Group 10System Operational Checks Group 15Diagnostic Information Group 20Adjustments Group 25Tests SECTION 9031Heating And Air Conditioning Group 05Theory Of Operation Group 10System Operational Checks Group 15Diagnostic Information Group 20Adjustments Group 25Test
9005
9010
9015
9020
9025
9031
INDX
All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
COPYRIGHT 1994 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 1993,1990
TM1496 (21SEP05)

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Contents
9000
9005
9010
9015
9020
9025
9031
INDX
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9000
Section 9000
General Information
Contents
Page Page
Group 01Safety Information Handle Fluids SafelyAvoid Fires . . . . . . . .9000-01-1 Prevent Battery Explosions . . . . . . . . . . . . . .9000-01-1 Prepare for Emergencies. . . . . . . . . . . . . . . .9000-01-1 Prevent Acid Burns . . . . . . . . . . . . . . . . . . . .9000-01-2 Handle Chemical Products Safely . . . . . . . . .9000-01-3 Avoid High-Pressure Fluids . . . . . . . . . . . . . .9000-01-3 Park Machine Safely . . . . . . . . . . . . . . . . . . .9000-01-4 Support Machine Properly . . . . . . . . . . . . . . .9000-01-4 Wear Protective Clothing. . . . . . . . . . . . . . . .9000-01-4 Work in Clean Area. . . . . . . . . . . . . . . . . . . .9000-01-5 Service Machines Safely . . . . . . . . . . . . . . . .9000-01-5 Work In Ventilated Area . . . . . . . . . . . . . . . .9000-01-5 Illuminate Work Area Safely . . . . . . . . . . . . .9000-01-5 Replace Safety Signs . . . . . . . . . . . . . . . . . .9000-01-6 Use Proper Lifting Equipment . . . . . . . . . . . .9000-01-6 Remove Paint Before Welding or Heating . . .9000-01-6 Avoid Heating Near Pressurized Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-7 Keep ROPS Installed Properly . . . . . . . . . . .9000-01-7 Service Tires Safely . . . . . . . . . . . . . . . . . . .9000-01-8 Avoid Harmful Asbestos Dust . . . . . . . . . . . .9000-01-8 Practice Safe Maintenance . . . . . . . . . . . . . .9000-01-9 Use Proper Tools . . . . . . . . . . . . . . . . . . . . .9000-01-9 Dispose of Waste Properly . . . . . . . . . . . . .9000-01-10 Live With Safety . . . . . . . . . . . . . . . . . . . . .9000-01-10 Group 02General Specifications 300D Specifications. . . . . . . . . . . . . . . . . . . .9000-02-1 300D Backhoe Loader. . . . . . . . . . . . . . . . . .9000-02-2 300D Backhoe Loader (Continued) . . . . . . . .9000-02-3 300D Backhoe Loader Buckets . . . . . . . . . . .9000-02-4 300D Backhoe Loader Drain And Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-5 300D Backhoe Loader Lifting Capacities KG (LB) . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-6 310D Specifications. . . . . . . . . . . . . . . . . . . .9000-02-9 310D Backhoe Loader. . . . . . . . . . . . . . . . .9000-02-10 310D Backhoe Loader (Continued) . . . . . . .9000-02-11 310D Buckets . . . . . . . . . . . . . . . . . . . . . . .9000-02-13 310D Drain And Refill Capacities . . . . . . . .9000-02-14 310D Backhoe Loader Lifting Capacities KG (LB) . . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-14 315D Specifications. . . . . . . . . . . . . . . . . . .9000-02-17 315D Sideshift Backhoe Loader . . . . . . . . .9000-02-18 TM1496 (21SEP05)
315D Sideshift Backhoe Loader (Continued) . . . . . . . . . . . . . . . . . . . . . . .9000-02-19 315D Buckets . . . . . . . . . . . . . . . . . . . . . . .9000-02-20 315D Sideshift Backhoe Loader Drain And Refill Capacities . . . . . . . . . . . . . . . . . . . .9000-02-20 315D Lift CapacityLB (KG). . . . . . . . . . . .9000-02-21 Group 03Torque Values Hardware Torque Specifications . . . . . . . . . .9000-03-1 Checking Wheel Fasteners . . . . . . . . . . . . . .9000-03-1 Unified Inch Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-2 Additional Metric Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-3 Check Oil Lines And Fittings . . . . . . . . . . . . .9000-03-5 Service Recommendations for 37 Flare and 30 Cone Seat Connectors . . . . . . . . .9000-03-6 Service Recommendations for O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .9000-03-7 Service Recommendations for Flat Face O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .9000-03-9 Service Recommendations For Inch Series Four Bolt Flange Fittings. . . . . . . .9000-03-10 Service Recommendations for Metric Series Four Bolt Flange Fitting . . . . . . . .9000-03-11 Group 04Fuels And Lubricants Fuel Specifications . . . . . . . . . . . . . . . . . . . .9000-04-1 Low Sulfur Diesel Fuel Conditioner . . . . . . . .9000-04-1 Storing Fuel. . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-2 Do Not Use Galvanized Containers. . . . . . . .9000-04-2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-2 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-3 Transaxle Oil. . . . . . . . . . . . . . . . . . . . . . . . .9000-04-4 Hydraulic And Reverser Oil . . . . . . . . . . . . . .9000-04-5 Mechanical Front Wheel Drive Oil . . . . . . . . .9000-04-6 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7 Grease For Extendible Dipperstick . . . . . . . .9000-04-7 Alternative and Synthetic Lubricants . . . . . . .9000-04-8 Lubricant Storage . . . . . . . . . . . . . . . . . . . . .9000-04-8 Mixing of Lubricants . . . . . . . . . . . . . . . . . . .9000-04-9 Diesel Engine Coolant. . . . . . . . . . . . . . . . . .9000-04-9
9000-1 300D, 310D, 315D Backhoe Loader Operation and Test

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9000
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Group 01
Safety Information
Handle Fluids SafelyAvoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously.
9000 01 1
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. Do not charge a frozen battery; it may explode. Warm battery to 16C (60F).
DX,SPARKS 1903MAR931/1
Prepare for Emergencies

Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy.
UN23AUG88
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
DX,FIRE2 1903MAR931/1
TM1496 (21SEP05)
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TS291
TS204
UN23AUG88
TS227
UN23AUG88
Safety Information
9000 01 2
Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. 2. 3. 4. 5. Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. Use proper jump start procedure.
If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 1530 minutes. Get medical attention immediately. If acid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately.
UN23AUG88
DX,POISON 1921APR931/1
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Safety Information
Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment. (See your John Deere dealer for MSDSs on chemical products used with John Deere equipment.)
UN26NOV90
9000 01 3
DX,MSDS,NA 1903MAR931/1
Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury.
UN23AUG88
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID 1903MAR931/1
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TS1132
Safety Information
9000 01 4
Park Machine Safely

Before working on the machine: Lower all equipment to the ground. Stop the engine and remove the key. Disconnect the battery ground strap. Hang a "DO NOT OPERATE" tag in operator station.
DX,PARK 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. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. When implements or attachments are used with a tractor, always follow safety precautions listed in the implement 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 while operating machine.
DX,WEAR2 1903MAR931/1
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UN23AUG88
TS229
UN23AUG88
TS230
UN24MAY89
Safety Information
Work in Clean Area

Before starting a job: Clean work area and machine. Make sure you have all necessary tools to do your job. Have the right parts on hand. Read all instructions thoroughly; do not attempt shortcuts.
9000 01 5
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. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
UN23AUG88
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. If you do not have an exhaust pipe extension, open the doors and get outside air into the area
UN23AUG88
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.
DX,LIGHT 1904JUN901/1
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UN23AUG88
TS220
TS228
T6642EJ
UN18OCT88
Safety Information
9000 01 6
Replace Safety Signs

Replace missing or damaged safety signs. See the machine operators manual for correct safety sign placement.
UN23AUG88
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.
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. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
UN23AUG88
DX,PAINT 1903MAR931/1
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TS226
UN23AUG88
TS201
Safety Information
Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.
9000 01 7
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. The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.
UN23AUG88
DX,ROPS3 1903MAR931/1
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TS953
UN15MAY90
Safety Information
9000 01 8
Service Tires Safely

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.
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 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 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.
UN23AUG88
DX,DUST 1915MAR911/1
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TS211
UN23AUG88
Safety Information
Practice Safe Maintenance

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 or welding on machine. On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.
9000 01 9
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. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.
DX,REPAIR 1917FEB991/1
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UN08NOV89
TS218
UN23AUG88
Safety Information
9000 01 10
Dispose of Waste Properly

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants escaping into the air can damage the 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.
UN26NOV90
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
DX,LIVE 1925SEP921/1
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TS1133
Group 02
General Specifications
300D Specifications
9000 02 1
NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with SAE Standards. Except where otherwise noted, these specifications are based on a standard machine with 16.9-24, 8PR, R4 rear tires;
11L-15, 8PR, F3 front tires with 75 percent CaCl 2 fill; 0.67 m 3 (.88 cu. yd.) loader bucket; 610 mm (24 in.) backhoe bucket; ROPS/FOPS; full fuel tank and 79 kg (175 lb) operator.
TX115DH1384 1926SEP911/1
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T7412AL
UN15NOV90
9000 02 2
300D Backhoe Loader

Key: Retracted ALoading height, truck loading position BReach from center of swing mast CReach from center of rear axle DDigging depth (SAE): (1) 2 ft (610 mm) flat bottom (2) 8 ft (2440 mm) flat bottom EMaximum digging depth FGround clearance, minimum GBucket rotation HTransport height IOverall length, transport JStabilizer width, transport KStabilizer spread, operating LOverall width (less loader bucket) Digging force, bucket cylinder (power dig position) Digging force, crowd cylinder Swing arc Operator control Bucket positions Stabilizer angle rearward Lifting capacity, maximum boom @ 65 13 ft 10 in. (4.21 m) 12 ft 8 in. (3.87 m) 14 ft (4.27 m) 13 in. (330 mm) 160 or 180 12 ft 0 in. (3.67 m) 22 ft 6 in. (6.85 m) 7 ft 4 in. (2.23 m) 8 ft 11 in.(2.71 m) 6 ft 11 in. (2.11 m) 10225 lb (45.5 kN) 5530 lb (24.6 kN) 180 degrees Two levers 21 or 30 rollback 12 2700 lb (1225 kg) 13 ft 10 in. (4.21 m) 12 ft 8 in. (3.87 m) 14 ft (4.27 m) 13 in. (330 mm) 160 or 180 12 ft 0 in. (3.67 m) 22 ft 6 in. (6.85 m) 7 ft 4 in. (2.23 m) 8 ft 11 in. (2.71 m) 6 ft 11 in. (2.11 m) 10250 lb (45.6 kN) 5530 lb (24.6 kN) 180 degrees Right foot treadle 19 or 28 rollback 12 2600 lb (1180 kg) 17 ft 8 in. (5.38 m) 16 ft 10 in. (5.13 m) 17 ft 9. in. (5.41 m) 13 in. (330 mm) 160 or 180 12 ft 0 in. (3.67 m) 22 ft 6 in. (6.85 m) 7 ft 4 in. (2.23 m) 8 ft 11 in. (2.71 m) 6 ft 11 in. (2.11 m) 10225 lb (45.5 kg) 3365 lb (15.0 kN) 180 degrees Right foot treadle 22 or 32 rollback 12 1550 lb (700 kg) Backhoe Extended 10 ft 9 in. (3.29 m) 17 ft 3 in. (5.25 m) 20 ft 7 in. (6.28 m) 11 ft 1 in. (3.37 m) 17 ft 3 in. (5.25 m) 20 ft 7 in. (6.28 m) 12 ft 9 in. (3.88 m) 20 ft 10 in. (6.36 m) 24 ft 3 in. (7.39 m) Extendible Dipperstick
NOTE: Backhoe specifications are with 24-in. (610 mm) standard bucket.
Key: MWheelbase NDig below groundbucket level ORollback at ground level PDump clearance, bucket at 40 QMaximum height to bucket hinge pin RMaximum bucket dump angle SReach at full height, bucket at 40 Loader With 1.5 yd 3(1.15 m 3) Bucket 83 in. (2100 mm) 4 in. (100 mm) 40 8 ft. 10 in. (2.69 m) 10 ft. 11 in. (3.33 m) 45 28 in. (711 mm)
TX,115,DH1385 1917APR931/1
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300D Backhoe Loader (Continued)

NOTE: (Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with ICED and SAE Standards.)
Power Net Engine: John Deere 4039D Rated power @ 2200rpm Cylinders Displacement Maximum torque @ 1200 rpm Lubrication Cooling Air cleaner Electrical system Alternator Transmission: John Deere 4-speed helical gear, synchronized collar shift transmission with hydraulic reverser. Torque converter 11 in (280 mm) with 2.78:1 stall ratio. Travel Speeds: mph With Standard 16.9-24 rear and 11L-15 front tires 2 3 4 Final Drives: Heavy-duty inboard mounted planetary. Evenly distributes axle shock loads over three oil cooled gears. 1 60 SAE net hp (45 kW) 63 SAE gross hp (47 kW) 4 239 cu. in. (3.91 L) 172 lb-ft (233 Nm) Pressure system w/full-flow filter Pressurized w/thermostat and fixed bypass Dry 12-volt 65 amps Steering: Hydrostatic Power Non-powered axle curb turning radius (brakes applied) (without brakes) Bucket clearance circle (brakes applied) (without brakes) Steering wheel turns Stop to stop 2.2 to 2.9 32 ft 5 in. (9.89 m) 34 ft 7 in. (10.55 m) 12 ft 0 in. (3.67 m) 13 ft 2 in. (4.00 m) SAE 60 hp (45 kW) Service Brakes: Manual hydraulic, applied with separate pedals; hydraulically equalized when both pedals are depressed. Wet disks and facings are fully enclosed and self-adjusting. Park Brake: Independent system, spring applied, hydraulically released, and controlled by an electric switch on the side console.
9000 02 3
Powered axle (MFWD) curb turning radius (brakes applied (without brakes) Bucket clearance circle (brakes applied) (without brakes) Steering wheel turns Stop to stop Hydraulic System: Open center Pressure setting 2700 psi (18 620 kPa) Gear type 24 gpm (91 L/min) 10 micron replaceable element 2.5 30 ft 9 in. (9.38 m) 34 ft 3 in. (10.44 m) 11 ft 9 in. (3.57 m) 13 ft 5 in. (4.10 m)
Gear km/h
Forward mph 3.4 km/h 5.4 3.3
Reverse
5.2
Pump Flow @ 2200 rpm Filter, return oil Tires:
5.7 12.3 22.4
9.2 19.8 36.1
5.6 12.2 22.3
9.0 19.6 35.9
Front With MFWD Rear With MFWD
11L-15, 8PR, F3 12-16.5, 8 PR 16.924 8PR, R4 17.5L24 8PR, R4 16.924 8PR R4A
Continued on next page
TX,115,DH1388 1922JUL991/2
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9000 02 4 Transporting: SAE operating weight with ROPS Cab adds MFWD w/tires adds Extendible dipperstick adds Optional front counterweight Optional front counterweight 12,200 lb (5533 kg) 500 lb (227 kg) 220 lb (100 kg) 360 lb (163 kg) 370 lb (169 kg) 770 lb (349 kg)
TX,115,DH1388 1922JUL992/2
300D Backhoe Loader Buckets

Width mm (in.) 2057 (81) 0.76 (1.00) 2134 (84) Heaped Capacity m 3 (Cu Yd) 0.67 (0.88) 367 (810) 0.86 (1.12) Heaped Capacity m 3 (Cu Yd) 0.07 (2.5) 122 (268) 126 (278) 149 (328) 165 (364) 195 (439) 0.07 (2.5) 0.14 (5.1) 151 (334) 158 (348) 0.14 (5.1) 0.21 (7.5) 0.28 (10.0) 164 (362) 192 (424) 215 (474) 117 (258) 137 (302) 345 (760)
Loader: General purpose 2340 (92) Multi-purpose
Weight kg (lb) 249 (550)
Backhoe: Standard 406 (16) 457 (18) 610 (24) 762 (30) 914 (36) Heavy Duty 610 (24) 610 (24) Extra Heavy Duty
Width mm (in.) 305 (12) 0.10 (3.6) 0.12 (4.1) 0.17 (6.0) 0.22 (7.9) 0.28 (10.0) 305 (12) 457 (18) 0.17 (6.0) 0.21 (7.5) 457 (18) 610 (24) 762 (30)
Weight kg (lb) 111 (244)
TX,115,DH1386 1917APR931/1
TM1496 (21SEP05)

092105
PN=20
300D Backhoe Loader Drain And Refill Capacities

Metric Engine coolant Engine oil (including filter) Torque converter and reverser Transaxle (without MFWD) (with MFWD) Fuel tank Serial No. 802199 Serial No. 802200 Hydraulic system reservoir 106 L 129 L 41.5 L 28 gal 34 gal 44 qt 21 L 22 L 22 qt 23 qt 16 L 8.5 L 7.5 L U.S. 17 qt 9 qt 8 qt
9000 02 5
TX,115,DH1387 1912OCT941/1
TM1496 (21SEP05)

092105
PN=21
9000 02 6
300D Backhoe Loader Lifting CapacitiesKG (LB)
Lift Capacity, Backhoe With Standard Dipperstick Based On SAE J31 (Except With Loader Bucket On Ground)
TM1496 (21SEP05)

092105
T7634AA
UN18OCT91
TX,115,DH1390 1929OCT911/3
PN=22
9000 02 7
Lift Capacity, Backhoe With Extendible Dipperstick, Retracted Based On SAE J31 (Except With Loader Bucket On Ground)
TM1496 (21SEP05)

092105
T7634AB
UN18OCT91
TX,115,DH1390 1929OCT912/3
PN=23
9000 02 8
Lift Capacity, Backhoe With Extendible Dipperstick, Extended Based On SAE J31 (Except With Loader Bucket On Ground)
Lifting capacity ratings are made with bucket hinge pin, loader bucket, and stabilizers on firm, level ground. Lift capacities are hydraulically limited. Lifting capacities are 87 percent of the maximum lift over any point on the swing arc and do not exceed 75 percent of the tipping load. Angle between boom and ground is 65 degrees. Machine is equipped with 610 mm (24 in.)
standard bucket, standard or extendible dipperstick and standard equipment.
NOTE: Loader bucket on ground significantly improves side stability, therefore improving lift capacity to the side. Lift capacity over the rear is not affected.
TM1496 (21SEP05)

092105
T7634AC
UN18OCT91
TX,115,DH1390 1929OCT913/3
PN=24
310D Specifications
9000 02 9
NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with SAE Standards. Except where otherwise noted, these specifications are based on a standard machine with 17.5L-24, 10PR, R4 rear tires;
11L-15, 8PR, F3 front tires with 75 percent CaCl 2 fill; 0.76 m 3 (1.0 cu. yd.) loader bucket; 610 mm (24 in.) backhoe bucket; ROPS/FOPS; full fuel tank and 79 kg (175 lb) operator.
TX,115,DH1393 1926SEP911/1
TM1496 (21SEP05)

092105
PN=25
T7412AL
UN15NOV90
9000 02 10
310D Backhoe Loader

Key: Retracted ALoading height, truck loading position BReach from center of swing mast CReach from center of rear axle DDigging depth (SAE): (1) 2 ft (610 mm) flat bottom (2) 8 ft (2440 mm) flat bottom EMaximum digging depth FGround clearance, minimum GBucket rotation HTransport height IOverall length, transport JStabilizer width, transport KStabilizer spread, operating LOverall width (less loader bucket) Digging force, bucket cylinder (power dig position) Digging force, crowd cylinder Swing arc Operator control Bucket positions Stabilizer angle rearward Lifting capacity, maximum boom @ 65 14 ft 4 in. (4.37 m) 13 ft 2 in. (4.02 m) 14 ft 6 in. (4.42 m) 13 in. (330 mm) 160 or 180 12 ft 0 in. (3.67 m) 22 ft 7 in. (6.88 m) 7 ft 0 in. (2.12 m) 10 ft 0 in.(3.05 m) 7 ft 1 in. (2.15 m) 11570 lb (51.5 kN) 6650 lb (29.6 kN) 180 degrees Two levers 12 or 21 rollback 13 4600 lb (2087 kg) 14 ft 4 in. (4.37 m) 13 ft 2 in. (4.02 m) 14 ft 6 in. (4.42 m) 13 in. (330 mm) 160 or 180 12 ft 2 in. (3.72 m) 22 ft 7 in. (6.88 m) 7 ft 0 in. (2.12 m) 10 ft 0 in. (3.05 m) 7 ft 1 in. (2.15 m) 11530 lb (51.3 kN) 6700 lb (29.8 kN) 180 degrees Right foot treadle 8 or 17 rollback 13 4400 lb (1996 kg) 18 ft 2 in. (5.53 m) 17 ft 4 in. (5.28 m) 18 ft 3 in. (5.56 m) 13 in. (330 mm) 160 or 180 12 ft 2 in. (3.72 m) 22 ft 7 in. (6.88 m) 7 ft 0 in. (2.12 m) 10 ft 0 in. (3.05 m) 7 ft 1 in. (2.15 m) 11530 lb (51.3 kg) 4550 lb (20.2 kN) 180 degrees Right foot treadle 13 or 21 rollback 13 2700 lb (1225 kg) Backhoe Extended 11 ft 4 in. (3.45 m) 17 ft 7 in. (5.36 m) 21 ft 0 in. (6.40 m) 11 ft 8 in. (3.55 m) 17 ft 7 in. (5.36 m) 21 ft 0 in. (6.40 m) 13 ft 11 in. (4.24 m) 21 ft 3 in. (6.47 m) 24 ft 7 in. (7.50 m) Extendible Dipperstick
NOTE: Backhoe specifications are with 24-in. (610 mm) standard bucket.
Key: MWheelbase NDig below groundbucket level ORollback at ground level PDump clearance, bucket at 40 QMaximum height to bucket hinge pin RMaximum bucket dump angle SReach at full height, bucket at 40 Loader With 1.5 yd 3(1.15 m 3) Bucket 83 in. (2100 mm) 4 in. (100 mm) 40 8 ft. 10 in. (2.69 m) 10 ft. 10 in. (3.30 m) 45 28 in. (711 mm)
TX,115,DH1394 1917APR931/1
TM1496 (21SEP05)

092105
PN=26
310D Backhoe Loader (Continued)

Engine: John Deere 4039D and 4039T Rated power @ 2200 rpm (Naturally aspirated) Rated power @ 2200 rpm (Turbocharged) Cylinders Displacement Torque rise at 1200 rpm with turbocharger without turbocharger Lubrication Cooling Air cleaner Electrical system Alternator Transmission: John Deere 4-speed helical gear, synchronized collar shift transmission with hydraulic reverser. Torque converter 11 in. (280 mm) with 2.83:1 stall ratio. 25% 20% Pressure system w/full-flow filter Pressurized w/thermostat and fixed bypass Dry 12-volt 78 amps SAE net 67 hp (50 kW) SAE net 72 hp (53.7 kW) 4 239 cu. in. (3.91 L) Travel Speeds: mph With Standard 17.5L-24 rear and 11L-15 front tires 2 3 4 With MFWD and required 19.5L-24 rear and 12-16.5 front tires 2 3 4 Final Drives: Heavy-duty inboard mounted planetary. Evenly distributes axle shock loads over three oil cooled gears. 1 Gear km/h Forward mph 3.3 km/h 5.3 3.0 4.8 Reverse
9000 02 11
5.7 12.3 22.4 1
9.2 19.8 36.1 3.4
5.1 11.1 20.2 5.5
8.2 17.9 32.5 3.1 5.0
5.9 12.6 23.0
9.5 20.3 37.0
5.3 11.3 20.7
8.5 18.2 33.3
TX,115,DH1397 1922JUL991/2
TM1496 (21SEP05)

092105
PN=27
9000 02 12 Service Brakes: Manual hydraulic, applied with separate pedals; hydraulically equalized when both pedals are depressed. Wet disks and facings are fully enclosed and self-adjusting. Park Brake: Independent system, spring applied, hydraulically released, and controlled by an electric switch on the side console. Steering: Hydrostatic Power Non-powered axle curb turning radius (brakes applied) (without brakes) Bucket clearance circle (brakes applied) (without brakes) Steering wheel turns Stop to stop 2.2 to 2.9 31 ft 6 in. (9.61 m) 34 ft 7 in. (10.55 m) With MFWD 11 ft 9 in. (3.57 m) 13 ft 3 in. (4.04 m) Rear With MFWD Hydraulic System: Open center Pressure setting Pump Flow @ 2200 rpm Filter, return oil Tires: Front 11L-15, 8PR, F3 11L-16, 12PR, F3 12-16.5, 8PR 14-17.5, 8PR, NHS 16.9-24 8PR, R4 17.5L-24 10PR, R4 19.5L-24, 8PR R4 19.5-24 8PR R4 21L-24, 10 PR R4 2700 psi (18 620 kPa) Gear type 35 gpm (133 L/min) 10 micron replaceable element
Powered axle (MFWD) curb turning radius (brakes applied) (without brakes) Bucket clearance circle (brakes applied) (without brakes) Steering wheel turns Stop to stop 2.5 29 ft 9 in. (9.07 m) 35 ft 3 in. (10.74 m) 10 ft 11 in. (3.34 m) 13 ft 8 in. (4.17 m)
TX,115,DH1397 1922JUL992/2
TM1496 (21SEP05)

092105
PN=28
310D Buckets
Width In. (mm) 92 (2340) 1.30 (1.00) 89 (2270) 1.25 (0.96) Heaped Capacity Cu. Yd. (m 3) 1.00 (0.76) 800 (363) 1.25 (0.96) 1560 (708) Heaped Capacity Cu. Ft. (m 3) 2.5 (0.07) 268 (122) 322 (146) 370 (168) 410 (186) 430 (195) 556 (252) 2.5 (0.07) 5.1 (0.14) 396 (180) 476 (216) 444 (201) 480 (217) 5.1 (0.14) 7.5 (0.21) 10.0 (0.28) 362 (164) 424 (192) 474 (215) 258 (117) 334 (151) 750 (340)
9000 02 13
Loader: General Purpose 92 (2340) Long Lip Multi-purpose 92 (2340)
Weight lb (kg) 760 (345)
Backhoe: Standard 16 (406) 18 (457) 24 (610) 30 (762) 36 (914) 36 (914) Heavy Duty 24 (610) 24 (610) 30 (762) 36 (914) Extra Heavy Duty Transporting:
Width In. (mm) 12 (305) 3.6 (0.10) 5.1 (0.14) 7.5 (0.21) 10.0 (0.28) 9.9 (0.28) 14.5 (0.41) 12 (305) 18 (457) 7.5 (0.21) 8.8 (0.25) 10.0 (0.28) 10.0 (0.28) 18 (457) 24 (610) 30 (762)
Weight lb (kg) 244 (111)
SAE operating weight with ROPS Cab added MFWD w/tires added Extendible dipperstick Optional front counterweight Optional front counterweight
13,600 lb (6169 kg) 500 lb (227 kg) 220 lb (100 kg) 430 lb (195 kg) 770 lb (349 kg) 200 lb (91 kg)
TX,115,DH1395 1917APR931/1
TM1496 (21SEP05)

092105
PN=29
9000 02 14
310D Drain And Refill Capacities

Metric Engine coolant Engine oil (including filter) Torque converter and reverser Transaxle (without MFWD) (with MFWD) Fuel tank Serial No. 802199 Serial No. 802200 Hydraulic system reservoir 106 L 129 L 41.5 L 28 gal 34 gal 44 qt 21 L 22 L 22 qt 23 qt 16 L 8.5 L 7.5 L U.S. 17 qt 9 qt 8 qt
TX,115,DH1396 1912OCT941/1
310D Backhoe Loader Lifting CapacitiesKG (LB)
Lift Capacity, Backhoe With Standard Dipperstick Based On SAE J31 (Except With Loader Bucket On Ground)
TM1496 (21SEP05)

092105
T7634AD
UN18OCT91
TX,115,DH1398 1929OCT911/3
PN=30
9000 02 15
Lift Capacity, Backhoe With Extendible Dipperstick, Extended Based On SAE J31 (Except With Loader Bucket On Ground)
TM1496 (21SEP05)

092105
T7634AE
UN18OCT91
TX,115,DH1398 1929OCT912/3
PN=31
9000 02 16
Lift Capacity, Backhoe With Extendible Dipperstick, Retracted Based On SAE J31 (Except With Loader Bucket On Ground)
Lifting capacity ratings are made with bucket hinge pin, loader bucket, and stabilizers on firm, level ground. Lift capacities are hydraulically limited. Lifting capacities are 87 percent of the maximum lift over any point on the swing arc and do not exceed 75 percent of the tipping load. Angle between boom and ground is 65 degrees. Machine is equipped with 610 mm (24 in.)
standard bucket, standard or extendible dipperstick and standard equipment.
TM1496 (21SEP05)

092105
T7634AF
UN18OCT91
TX,115,DH1398 1929OCT913/3
PN=32
315D Specifications
9000 02 17
TX,115,DH1611 1901DEC901/1
TM1496 (21SEP05)

092105
PN=33
T7181BG
UN30NOV89
9000 02 18
315D Sideshift Backhoe Loader

Key: A B C D E Key: Retracted F-Overall length, transport G-Reach from center of swing mast H-Ground clearance, minimum I-Loading height, truck loading position J-Transport height K-Digging depth (SAE) (1) 2 ft (610 mm) flat bottom (2) 8 ft (2440 mm) flat bottom L-Maximum digging depth M-Side shift from tractor centerline N-Wall to swing centerline P-Stabilizer width-pads turned in R-Overall width (less loader bucket) S-Stabilizer width-pads turned out Digging force, bucket cylinder (power dig position) Digging force, crowd cylinder Swing arc Operator control Bucket positions Lifting capacity, maximum boom @ 65 13 ft 11.5 in. (4.25 m) 12 ft 9 in. (3.89 m) 14 ft 1 in. (4.29 m) 23.5 in. (597 mm) 20.6 in. (523 mm) 88.2 in. (2240 mm) 97.6 in. (2480 mm) 103.5 in. (2630 mm) 11570 lb (51.5 kN) 6650 lb (29.6 kN) 180 degrees Two levers 12 or 21 rollback 4600 lb (2087 kg) 13 ft 11.5 in. (4.25 m) 12 ft 9 in. (3.89 m) 14 ft 1 in. (4.29 m) 23.5 in. (597 mm) 20.6 in. (523 mm) 88.2 in. (2240 mm) 97.6 in. (2480 mm) 103.5 in. (2630 mm) 11530 lb (51.3 kN) 6700 lb (29.8 kN) 180 degrees Right foot treadle 8 or 17 rollback 4400 lb (1996 kg) 17 ft 9.5 in. (5.42 m) 16 ft 10 in. (5.13 m) 18 ft 0 in. (5.49 m) 23.5 in. (597 mm) 20.6 in. (523 mm) 88.2 in. (2240 mm) 97.6 in. (2480 mm) 103.5 in. (2630 mm) 11530 lb (51.3 kg) 4550 lb (20.2 kN) 180 degrees Right foot treadle 13 or 21 rollback 2700 lb (1225 kg) Backhoe Extended 18 ft 6 in. (5.63 m) 17 ft 9 in. (5.32 m) 13.8 in. (350 mm) 11 ft 7 in. (3.53 m) 12 ft 3 in. (3.73 m) 18 ft 6 in. (5.63 m) 17 ft 10 in. (5.44 m) 13.8 in. (350 mm) 12 ft 0 in. (3.66 m) 12 ft 5 in. (3.78 m) 18 ft 6 in. (5.63 m) 21 ft 4 in. (6.41 m) 13.8 in. (350 mm) 14 ft 2 in. (4.24 m) 12 ft 5 in. (3.78 m) 10 ft 11 in. (3.33 m) 8 ft 11.5 in. (2.73 m) 28 in. (711 mm) 72.4 in. (1839 mm) 82.7 in. (2100 mm) Extendable Dipperstick
NOTE: Backhoe specifications are with 24 in. (610 mm) standard bucket.
TX,115,DH1612 1917APR931/1
TM1496 (21SEP05)

092105
PN=34
315D Sideshift Backhoe Loader (Continued)

Power: Net Engine: John Deere 4039T Cylinders Displacement Maximum torque @ 1200 rpm Lubrication Cooling Air cleaner Electrical system Alternator Transmission: John Deere 4-speed helical gear, synchronized collar shift transmission with hydraulic reverser. Travel Speeds: mph With Standard 17.5L-24 rear and 11L-15 front tires 2 3 4 Final Drives: Heavy-duty inboard mounted planetary. Evenly distributes axle shock loads over three oil cooled gears. Service Brakes: Manual hydraulic, applied with separate pedals; hydraulically equalized when both pedals are depressed. Wet disks and facings are fully enclosed and self-adjusting. 1 4 239 cu. in. (3.91 L) 215 lb-ft (292 Nm) Pressure system w/full-flow filter Pressurized w/thermostat and fixed bypass Dry 12-volt 78 amps SAE 67 hp (50 kW) Park Brake: Independent system, spring applied, hydraulically released, and controlled by an electric switch on the side console. Steering: Hydrostatic Power Non-powered axle curb turning radius (brakes applied) (without brakes) Bucket clearance circle (brakes applied) (without brakes) Steering wheel turns Stop to stop 2.2 to 2.9 31 ft 6 in. (9.61 m) 34 ft 7 in. (10.55 m) 11 ft 9 in. (3.57 m) 13 ft 3 in. (4.04 m)
9000 02 19
Powered axle (MFWD) curb turning radius (brakes applied) (without brakes) Bucket clearance circle (brakes applied) (without brakes) Steering wheel turns Stop to stop Hydraulic System:Open center 29 ft 9 in. (9.07 m) 35 ft 3 in. (10.74 m) 10 ft 11 in. (3.34 m) 13 ft 8 in. (4.17 m)
Gear km/h
Forward mph 3.3 km/h 5.3 3.0
Reverse
Pressure setting Pump
2700 psi (18 620 kPa) Gear type 35 gpm (133 L/min) 10 micron replaceable element
4.8
Flow @ 2200 rpm Filter, return oil Tires: Front
5.7 12.3 22.4
9.2 19.8 36.1
5.1 11.1 20.2
8.2 17.9 32.5 Transporting: SAE operating weight with ROPS Rear
14 x 17.5, 10PR NHS 10.5/80 x 18, 10PR, I-3 11L-16, 12PR, F3 16.9 X 28 8PR R4
14,000 lb (6350 kg)
TX,115,DH1613 1922JUL991/1
TM1496 (21SEP05)

092105
PN=35
9000 02 20
315D Buckets
Width In. (mm) 92 (2340) 1.07 (0.88) 89.4 (2270) Struck Capacity Cu. Yd. (m 3) 0.88 (0.67) 1.3 (1.00) 1.05 Struck Capacity Cu. Ft. (m 3) 2.6 (0.07) 4.5 (0.13) 5.1 (0.14) 7.5 (0.21) 8.8 (0.25) 10.0 (0.28) 10.0 (0.28) 14.5(0.41) 1.25 Heaped Capacity Cu. Yd. (m 3) 1.0 (0.76)
Loader: General Purpose 92 (2340) Long Lip
Backhoe: Standard 16 (406) 18 (457) 24 (610) 24 (610) 30 (762) 36 (914) 36 (914)
Width In. (mm) 12 (305) 3.7 (0.10) 4.2 (0.12) 5.9 (0.17) 7.2 (0.20) 7.5(0.21) 7.5 (0.21) 11.2 (0.32)
Capacity Cu. Ft. (m 3) 3.0 (0.08)
TX,115,DH1614 1913DEC901/1
315D Sideshift Backhoe Loader Drain And Refill Capacities

U.S. Engine coolant Engine oil (including filter) Torque converter and reverser Transaxle (without MFWD) (with MFWD) Fuel tank Hydraulic reservoir MFWD Planetary 22 qt 23 qt 28 gal 11 gal 1.1 qt 23 L 24 L 106 L 41.5 L 1L 17 qt 9 qt 8 qt Metric 16 L 8.5 L 7.6 L
TX,115,DH1615 1924FEB961/1
TM1496 (21SEP05)

092105
PN=36
315D Lift CapacityLB (KG)
9000 02 21
Backhoe With Standard Dipperstick Lifting capacity ratings are made with bucket hinge pin, loader bucket and stabilizers on firm, level ground. Lifting capacities are 87 percent of the maximum lift over any point on the swing arc and do not exceed 75 percent of the tipping load. Angle between boom and ground is 65 degrees. Machine is equipped with 24 in.
(610 mm) standard bucket, standard or extendible dipperstick, and standard equipment. Backhoe in center position.
TM1496 (21SEP05)

092105
T7412AJ
1927NOV90
TX115DH1620 1911JAN911/3
PN=37
9000 02 22
Backhoe With Extendible Dipperstick, Retracted Lifting capacity ratings are made with bucket hinge pin, loader bucket and stabilizers on firm, level ground. Lifting capacities are 87 percent of the maximum lift over any point on the swing arc and do not exceed 75 percent of the tipping load. Angle between boom and ground is 65 degrees. Machine is equipped with 24 in.
TM1496 (21SEP05)

092105
T7412AI
1927NOV90
TX115DH1620 1911JAN912/3
PN=38
9000 02 23
Backhoe With Extendible Dipperstick, Extended Lifting capacity ratings are made with bucket hinge pin, loader bucket and stabilizers on firm, level ground. Lifting capacities are 87 percent of the maximum lift over any point on the swing arc and do not exceed 75 percent of the tipping load. Angle between boom and ground is 65 degrees. Machine is equipped with 24 in.
TM1496 (21SEP05)

092105
T7412AK
1927NOV90
TX115DH1620 1911JAN913/3
PN=39
9000 02 24
TM1496 (21SEP05)

092105
PN=40
Group 03
Torque Values
Hardware Torque Specifications
Check cap screws and nuts to be sure they are tight. If hardware is loose, tighten to torque shown on the following charts unless a special torque is specified.
9000 03 1
TX,90,FF1225 1915MAR931/1
Checking Wheel Fasteners

Tighten wheel cap screws and fasteners.
Front AxleSpecification Standard AxleTorque ............................ 136 +20 -27 Nm (100 +15 -20 lb-ft) MFWD AxleTorque ............................. 300 +110 -40 Nm (221 +81 -29 lb-ft) Rear AxleSpecification Standard AxleTorque ............................. 575 +170 -115 Nm (425 +125 -85 lb-ft)
TX,90,DH1383 1909DEC931/1
TM1496 (21SEP05)

092105
PN=41
T87507
UN21OCT88
T6000AU
UN18OCT88
Torque Values
9000 03 2
Unified Inch Bolt and Cap Screw Torque Values
DX,TORQ1 1920JUL941/1
TM1496 (21SEP05)

092105
PN=42
TS1656
1902APR97
Torque Values
Additional Metric Cap Screw Torque Values

CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when tightening. Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.
UN18OCT88
9000 03 3
04T,90,M170 1901AUG941/2
TM1496 (21SEP05)

092105
PN=43
T6873AC
UN18OCT88
T6873AB
UN18OCT88
T6873AA
Torque Values
9000 03 4 METRIC CAP SCREW TORQUE VALUESa Nominal Dia Nm 8 10 12 14 16 18 20 22 24 27 30 33 36
a
T-Bolt lb-ft 29 63 108 176 265 392 539 735 931 1372 1911 2548 3136 46 80 130 195 289 398 542 687 1012 1410 1890 2314 Nm 21
H-Bolt lb-ft 20 45 88 137 206 294 392 539 686 1029 1421 1911 2401 Nm 15 33 65 101 152 217 289 398 506 759 1049 1410 1772
M-Bolt lb-ft 10 20 34 54 78 118 167 216 274 392 539 735 931 7 15 25 40 58 87 125 159 202 289 398 542 687
Torque tolerance is 10%.
04T,90,M170 1901AUG942/2
TM1496 (21SEP05)

092105
PN=44
Torque Values
Check Oil Lines And Fittings

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately. Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings.
9000 03 5
TX,90,DH1559 1901AUG941/1
TM1496 (21SEP05)

092105
PN=45
X9811
UN23AUG88
Torque Values
9000 03 6
Service Recommendations for 37 Flare and 30 Cone Seat Connectors

1. Inspect flare and flare seat. They must be free of dirt or obvious defects. 2. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 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 3/8 - 24 UNF 7/16 - 20 UNF 1/2 - 20 UNF 9/16 - 18 UNF 3/4 - 16 UNF 7/8 - 14 UNF 1-1/16 - 12 UN 1-3/16 - 12 UN 1-5/16 - 12 UN 1-5/8 - 12 1-7/8 - 12 UN Nm 8 12 16 24 46 62 102 122 142 190 217 lb-ft 6 9 12 18 34 46 75 90 105 140 160
UN18OCT88
NOTE: Torque tolerance is 10%.
T82,BHMA,EL 1919MAR961/1
TM1496 (21SEP05)

092105
PN=46
T6234AC
Torque Values
Service Recommendations for O-Ring Boss Fittings

Straight Fitting
UN18OCT88
9000 03 7
1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart.
TX, I,DY356 1929MAY961/2
TM1496 (21SEP05)

092105
PN=47
T6243AE
Torque Values
9000 03 8
Angle Fitting 1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.
UN18OCT88
2. Turn fitting into threaded boss until back-up washer contacts face of boss. 3. Turn fitting head-end counterclockwise to proper index (maximum of one turn).
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 3/8-24 UNF 7/16-20 UNF 1/2-20 UNF 9/16-18 UNF 3/4-16 UNF 7/8-14 UNF 1-1/16-12 UN 1-3/16-12 UN 1-5/16-12 UN 1-5/8-12 UN 1-7/8-12 UN Nm 8 12 16 24 46 62 102 122 142 190 217 lb-ft 6 9 12 18 34 46 75 90 105 140 160
NOTE: Torque tolerance is 10%.
TX, I,DY356 1929MAY962/2
TM1496 (21SEP05)

092105
PN=48
T6520AB
Torque Values
Service Recommendations for Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring. It must be free of damage or defects. 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place. 4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly. 5. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 6. Tighten fitting or nut to torque value shown on the chart per dash size stamped on the fitting. Do not allow hoses to twist when tightening fittings.
FLAT FACE O-RING SEAL FITTING TORQUE Nominal Tube O.D. mm 6.35 9.52 12.70 15.88 19.05 22.22 25.40 31.75 38.10 0.250 0.375 0.500 0.625 0.750 0.875 1.000 1.250 1.500 in. -4 -6 -8 -10 -12 -14 -16 -20 -24 Dash Size Nm Thread Size in. lb-ft 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 3/16-12 1 7/16-12 1 11/16-12 2-12 16 24 50 69 102 102 142 190 217 Nm 12 18 37 51 75 75 105 140 160 Swivel Nut lb-ft 5.0 9.0 17.0 17.0 17.0 17.0 17.0 17.0 17.0 3.5 6.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 Bulkhead Nut
UN18OCT88
9000 03 9
NOTE: Torque tolerance is +15 -20%.
04T,90,K67 1901AUG941/1
TM1496 (21SEP05)

092105
PN=49
T6243AD
Torque Values
9000 03 10
Service Recommendations For Inch Series Four Bolt Flange Fittings
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange TORQUE CHART Nm lb-ft
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
Nominal Flange Size 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5
Cap Screw Size Min 5/16-18 UNC 3/8-16 UNC 3/8-16 UNC 7/16-14 UNC 1/2-13 UNC 1/2-13 UNC 1/2-13 UNC 5/8-11 UNC 5/8-11 UNC 5/8-11 UNC 5/8-11 UNC 20 28 37 47 62 73 107 158 158 158 158 Max 31 54 54 85 131 131 131 264 264 264 264 Min 15 21 27 35 46 54 79 117 117 117 117 Max 23 40 40 63 97 97 97 195 195 195 195
04T,90,K174 1901AUG941/1
TM1496 (21SEP05)

092105
PN=50
T6890BB
UN01MAR90
Torque Values
Service Recommendations for Metric Series Four Bolt Flange Fitting
9000 03 11
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw,
a
then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
TORQUE CHARTa Thread M6 M8 M10 M12 M14 M16 M18 M20
b
Nm 12 30 57 95 157 217 334 421
lb-ft 9 22 42 70 116 160 246 318
Tolerance 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures.
b
Metric standard thread.
04T,90,K175 1905JAN961/1
TM1496 (21SEP05)

092105
PN=51
T6890BB
UN01MAR90
Torque Values
9000 03 12
TM1496 (21SEP05)

092105
PN=52
Group 04
Fuels And Lubricants

Fuel Specifications
Use ONLY clean, high-quality fuel. Use Grade No. 2-D fuel above 40F (4C).
Specification Grade No. 2-D Fuel Temperature ............................................................ Above 40F (4C) 9000 04 1
Use fuel with less than 1.0 per cent sulfur. If possible, use fuel with less than 0.5 per cent sulfur. For maximum filter life, sediment and water should not be more than 0.10 per cent. The cetane number should be 40 minimum. If you operate your machine where air temperatures are normally low or where altitudes are high, you may need fuel with a higher cetane number. Cloud PointFor cold weather operation, cloud point should be 10F (6C) below lowest normal air temperature.
Use Grade No. 1-D fuel below 40F (4C). Use Grade No. 1-D fuel for all air temperatures at altitudes above 5000 ft (1 500 m). IMPORTANT: If fuel sulfur content exceeds 0.5 per cent, the engine oil drain interval must be reduced by 50 per cent (to 125 hours).
TX,45,DH1223 1915MAY921/1
Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations for engines used off-highway. This fuel will not require any additives to provide good performance and engine reliability. However, many local fuel distributors will not carry both low and regular sulfur diesel fuels. If the local fuel distributor will supply only low sulfur fuel, order and use John Deere TY22030 Diesel Fuel Conditioner. It provides lubricating properties along with other useful benefits, such as cetane improver, anti-oxidant, fuel stabilizer, corrosion inhibitor and others. TY22030 is specifically for use with low sulfur fuels. Nearly all other diesel fuel conditioners only improve cold weather flow and stabilize long-term fuel storage. They do not contain the lubrication additives needed by rotary fuel injection pumps.
TX,45,DH3124 1920OCT931/1
TM1496 (21SEP05)

092105
PN=53

9000 04 2
Storing Fuel
If there is a very slow turnover of fuel in the fuel tank or supply tank, it may be necessary to add a fuel conditioner to prevent water condensation. Contact your John Deere dealer for proper service or maintenance recommendations.
DX,FUEL 1903MAR931/1
Do Not Use Galvanized Containers

IMPORTANT: Diesel fuel stored in galvanized containers reacts with zinc coating on the container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters and damage fuel injectors and fuel pumps. DO NOT USE a galvanized container to store diesel fuel. Store fuel in: plastic containers. aluminum containers. specially coated steel containers made for diesel fuel. DO NOT USE brass-coated containers: brass is an alloy of copper and zinc.
MX,FLBT,C 1904JUN901/1
Fuel Tank
CAUTION: Handle fuel carefully. If the engine is hot or running, DO NOT fill the fuel tank. DO NOT smoke while you fill fuel tank or work on fuel system. To avoid condensation, fill the fuel tank at the end of each days operation. Shut off engine before filling.
TX,45,DH1588 1924AUG941/1
TM1496 (21SEP05)

092105
PN=54
TS185
UN23AUG88
Engine Oil
9000 04 3
Depending upon the expected air temperature range between oil changes, use oil viscosity shown on the temperature chart above. Additives are not required nor recommended. John Deere engine oil filters are highly recommended because they are of known high quality and effectiveness. John Deere TORQ-GARD SUPREME PLUS 50engine oil is recommended. It is a specifically balanced formulation to provide superior protection against oil thickening, carbon deposits, lacquer, and mechanical wear during high temperature operation. John Deere TORQ-GARD SUPREMEengine oil is also recommended. If other oils are used, the required specification is:
API Service Class CE or CD (1) Military Spec MIL-L-2104D or MIL-L-2104C Most oil containers or specifications list several API Service Classes (such as SC, SG, CE, CC) met by the oil. For the oil you use, either CE or CD must be among the classes listed.
NOTE: Oils meeting API Service Classes CE or CD are not always available in viscosity grades SAE 5W20, SAE 5W30, and Arctic Oils. For these viscosity grades only, the following oil specification may be used but the oil and filter change interval must be reduced to 125 hours
API Service Class CC (MIL-L-46152B) Military Spec MIL-L-46167A (arctic oil)
TORQ-GARD SUPREME PLUS 50 is a registered trademark of Deere & Company TORQ-GARD SUPREME is a registered trademark of Deere & Company
TX,45,DH1532 1901AUG941/1
TM1496 (21SEP05)

092105
T7396BK
1919JUN91
PN=55

9000 04 4
Transaxle Oil
Depending on the expected air temperature range between oil changes, use oil viscosity shown on the chart above. JOHN DEERE HY-GARDTRANSMISSION AND HYDRAULIC OIL IS RECOMMENDED because it is specifically formulated to minimize brake chatter, and to provide maximum protection against mechanical wear.
You may also use oils which meet minimum John Deere standards, or other oils meeting John Deere Standard JDM J20A or J20C and J20B or J20D. Oils meeting MIL-L46167A may be used as arctic oil.
HY-GARD is a registered trademark of Deere & Company
TX,45,DH2079 1927NOV911/1
TM1496 (21SEP05)

092105
PN=56
T6186AG
1918OCT91
Hydraulic And Reverser Oil
9000 04 5
Depending on the expected air temperature range between oil changes, use oil viscosity shown on the chart above. JOHN DEERE HY-GARDTRANSMISSION AND HYDRAULIC OIL IS RECOMMENDED because it is specifically formulated to minimize brake chatter, and to provide maximum protection against mechanical wear.
You may also use oils which meet minimum John Deere standards, or other oils meeting John Deere Standard JDM J20A or J20C and J20B or J20D. Oils meeting MIL-L46167A may be used as arctic oil.
HY-GARD is a registered trademark of Deere & Company
TX,45,DH2074 1927NOV911/1
TM1496 (21SEP05)

092105
PN=57
T6249AY
1915NOV91

9000 04 6
Mechanical Front Wheel Drive Oil
Depending on the expected air temperature range between oil changes, use oil viscosity shown on the chart above. The following oils are recommended:
John Deere API GL-5 Gear Oil Oils meeting API Service GL-5 (MIL-L-2105B or MIL-2105C) Oil meeting MIl-L-10324A may be used as arctic oil.
T82,45,C11 1915MAR931/1
TM1496 (21SEP05)

092105
PN=58
T6247AB
1905JAN89
Grease
9000 04 7
Depending on the expected air temperature range, use grease shown on chart above. Greases recommended are: John Deere Moly High Temperature/EP Grease (Preferred)
SAE Multipurpose Grease with Extreme Pressure (EP) performance and containing 3 to 5 per cent molybdenum disulfide SAE multi-purpose EP Grease Grease meeting MIL-G-10924C specifications may be used as arctic grease.
02T,45,C49 1901AUG941/1
Grease For Extendible Dipperstick

SAE Multipurpose Grease with Extreme Pressure (EP) performance and containing 3 to 5 per cent molybdenum disulfide (preferred).
TX,45,DH1576 1921JAN921/1
TM1496 (21SEP05)

092105
PN=59
T6722AA
1927JAN89

9000 04 8
Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere brand coolants and lubricants may not be available in your location. Consult your John Deere dealer to obtain information and recommendations. Synthetic lubricants may be used if they meet the performance requirements as shown in this manual. The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils. Rerefined base stock products may be used if the finished lubricant meets the performance requirements.
DX,ALTER 1918MAR961/1
Lubricant Storage
Your equipment can operate at top efficiency only when clean lubricants are used. Use clean containers to handle all lubricants. Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their side to avoid water and dirt accumulation. Make certain that all containers are properly marked to identify their contents. Properly dispose of all old containers and any residual lubricant they may contain.
DX,LUBST 1918MAR961/1
TM1496 (21SEP05)

092105
PN=60
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance. Consult your John Deere dealer to obtain specific information and recommendations.
9000 04 9
DX,LUBMIX 1918MAR961/1
Diesel Engine Coolant

The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37C (-34F). The following engine coolant is preferred for service: John Deere COOL-GARD Prediluted Coolant The following engine coolant is also recommended: John Deere COOL-GARD Coolant Concentrate in a 40 to 60% mixture of concentrate with quality water. Other low silicate ethylene glycol base coolants for heavy-duty engines may be used if they meet one of the following specifications: ASTM D5345 (prediluted coolant) ASTM D4985 (coolant concentrate) in a 40 to 60% mixture of concentrate with quality water Coolants meeting these specifications require use of supplemental coolant additives, formulated for heavy-duty diesel engines, for protection against corrosion and cylinder liner erosion and pitting. A 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -37C (-34F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations. Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate. IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives. Coolant Drain Intervals Drain the factory fill engine coolant, flush the cooling system, and refill with new coolant after the first 3 years or 3000 hours of operation. Subsequent drain intervals are determined by the coolant used for service. At each interval, drain the coolant, flush the cooling system, and refill with new coolant. When John Deere COOL-GARD is used, the drain interval may be extended to 5 years or 5000 hours of operation, provided that the coolant is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive. If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation.
DX,COOL 1904JUN901/1
TM1496 (21SEP05)

092105
PN=61

9000 04 10
TM1496 (21SEP05)

092105
PN=62
Section 9005
Operational Checkout Procedure

Contents
Page 9005
Group 10Operational Checkout Procedure Operational Checkout Procedure. . . . . . . . . .9005-10-1 Gauge And Indicator Check With Engine Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-1 FNR And Neutral Start Switches, Start Circuit And Reverse Warning Alarm Checks . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2 Park Brake, Charge Indicator Light, Tachometer/Hour Meter Circuit And Engine Speed Control Linkage Checks . . .9005-10-4 Brake System Checks . . . . . . . . . . . . . . . . . .9005-10-5 Steering System Checks . . . . . . . . . . . . . . . .9005-10-7 Reverser Clutch Disconnect Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-8 Driving Checks . . . . . . . . . . . . . . . . . . . . . . .9005-10-8 Mechanical Front Wheel Drive (MFWD) Driving Check . . . . . . . . . . . . . . . . . . . . .9005-10-10 Hydraulic System Checks . . . . . . . . . . . . . .9005-10-12 Check Operation Of Accessories (Engine Stopped) . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-16 Cab Component Checks . . . . . . . . . . . . . . .9005-10-17 Miscellaneous Checks. . . . . . . . . . . . . . . . .9005-10-21
TM1496 (21SEP05)

092105
PN=1
Contents
9005
TM1496 (21SEP05)

092105
PN=2
Group 10

Use this procedure to check all systems and functions on the machine. This checkout procedure is designed so technician can make a quick check of the operation of machine while sitting in operators seat. A location will be required which is level, has adequate space to complete the driving checks and to work machine. The engine, power train and hydraulic oil must be at operating temperature. Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, loose linkage) prior to doing the checkout procedure. No special tools or gauges are needed. Always start in the left column and read completely, follow this sequence from left to right. Read each check completely before performing. Make a copy of the Operational Checkout Record Sheet and record the results of each check on this sheet. At the end of each check if no problem is found (OK:), you will instructed to GO TO NEXT CHECK. If problem (NOT OK:) is indicated, you will be given repair required or CTM number. If verification is needed, you will be given next best source of information after GO TO: Group 10 (System Operational Checks) Group 15 (System Diagnostic Checks) Group 20 (Adjustments) Group 25 (Test) CTM (Component Technical Manual)
9005 10 1
TX,D300,DS1984 1906APR951/1
Gauge And Indicator Check With Engine Off
1/1
1 Gauge And Indicator Check
Engage park brake. Move FNR lever to neutral (N) position. Apply slight effort to FNR lever forward and reverse. Turn key switch to ON position.
OK: Go to next check. NOT OK: Go to Group 9015-15 , Gauge and Monitor Circuit (Fuel Gauge Does Not Work or Give Accurate Reading). NOT OK: Adjust.
LISTEN: Solenoid "click" should be heard when key switch is turned to ON position.
1/1
TM1496 (21SEP05)

092105
PN=65

2 Monitor Indicator Lights And Alarm Checks Turn key switch to BULB CHECK position and hold. OK: Go to next check. NOT OK: Check monitor fuse. NOT OK: Go to Group 9015-15 , Gauges and Monitor Checks, Display Monitor Check. NOT OK: If motor starts and bulb check position is OK, key switch is failed or there is a short in wiring. Go to Group 9015-15 , Key Switch Test.
LOOK: All six monitor indicator lights and CAUTION light must be on. STOP light must flash and alarm must "beep". LISTEN: Starting motor must NOT operate.
T7394BH UN10DEC90
9005 10 2
1/1
FNR And Neutral Start Switches, Start Circuit And Reverse Warning Alarm Checks
1/1
1 FNR Switch Check
OK: Go to next check. NOT OK: If no "click", inspect neutral start fuse. NOT OK: See Start Circuit Diagnostic Procedures , Group 9015-15.
T7447AG UN04JAN91
T7447AI UN04JAN91
T7447AI UN04JAN91
Engine off. Put FNR lever in neutral. Turn key switch to ON position. Move FNR lever to forward (F), reverse (R), then neutral (N) position. Observe and feel forward, neutral and reverse detents.
LOOK: FNR lever must align with neutral position in quadrant when reverser valve is in neutral detent position. LISTEN: You must hear neutral start switch "click" as FNR lever is moved EQUAL distance from neutral to forward position and from neutral to reverse position. FEEL: You must feel detent engagement in each position of FNR lever.
1/1
TM1496 (21SEP05)

092105
PN=66

2 Neutral Start Switch Check Put FNR lever in neutral. Move FNR lever to forward (F) position and turn key switch to start position. Move FNR lever to reverse (R) position and turn key switch to start position. OK: Go to next check. NOT OK: See Start Circuit Diagnostic Procedures , Group 9015-15.
LISTEN: Starting motor must NOT operate.
9005 10 3
1/1
3 Start Circuit Check
Move FNR lever to neutral (N) position and turn key switch to START position. Observe and listen to monitor as engine is cranking.
OK: Go to next check. NOT OK: If engine turns but does not start, check fuel shut-off/start aid/reverse alarm fuse NOT OK: If starting motor does not operate check start fuse. NOT OK: See Start Circuit Diagnostic Procedures , Group 9015-15.
LISTEN: Starting motor must operate. LISTEN: Alarm must sound.

T7394BH UN10DEC90
LOOK: During engine cranking, all six indicator lights must be on, CAUTION must light and STOP must flash.
1/1
4 Reverse Warning Alarm Check (S.N. 794639)
Operate engine at slow idle. Put FNR lever in neutral (N). Turn park brake switch to OFF position. Move FNR lever to reverse (R) position.
T7447AH UN04JAN91
OK: Go to next check. NOT OK: Increase engine speed to fast idle. If alarm now sounds, low reverser clutch pressure is indicated. Go to Group 9020-10 , Reverser System Check. NOT OK: Check wiring connector at alarm. Go to Group 9015-15 , Reverse Alarm Circuit.
1/1
LISTEN: Reverse warning alarm must sound.
TM1496 (21SEP05)

092105
PN=67

5 Reverse Warning Alarm Check (S.N.794640 ) Key switch ON. Move FNR lever to reverse (R) position. OK: Go to next check. NOT OK: See Reverse Alarm Circuit. Go to Group 9015-15.
LISTEN: Reverse warning alarm must sound.

9005 10 4
T7447AH UN04JAN91
1/1
Park Brake, Charge Indicator Light, Tachometer/Hour Meter Circuit And Engine Speed Control Linkage Checks
1/1
1 Park Brake Indicator Check
OK: Go to next check. NOT OK: If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY and check oil level. Go to Group 9010-15 , Engine Low Oil Pressure. NOT OK: If alternator indicator light is on, increase engine speed to 1200 rpm and alternator light MUST go out. Go to Group 9015-15 , Charge Circuit Checks. NOT OK: If no park brake light, inspect wiring connector at switch on park brake linkage. Go to Group 9015-15 , Park Brake Circuit.
T7447AG UN04JAN91
T7394BH UN10DEC90
IMPORTANT: If engine oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY, check oil level. Engage park brake. Put FNR lever in neutral (N) and start the engine. Put FNR lever in forward (F) position.
LOOK: STOP indicator must stay ON and flashing. Alarm must "beep". Park brake light must be ON. All other lights must go out.
1/1
TM1496 (21SEP05)

092105
PN=68

2 Tachometer/Hourmeter Circuit Check IMPORTANT: If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY and check oil level. Engage park brake. Put FNR lever in neutral and start the engine.
T7447AH UN04JAN91
OK: Go to next check. NOT OK: If park brake indicator light stays ON, adjust park brake switch on park brake linkage until light goes out. Go to Group 9015-15 , Park Brake Circuit. NOT OK: If no hour meter or tachometer movement, go to Group 9015-15 , Gauge and Hour Meter Circuit.
Put FNR lever in forward (F) position.
9005 10 5
LOOK: STOP indicator must stay ON and flashing. Alarm must "beep". Park brake light must be ON. All other lights must go out. LOOK: Hourmeter indicator must be rotating. LOOK: Tachometer (if equipped) must indicate rpm.
Release park brake. Park brake indicator light and STOP light must go out. Alarm must stop "beeping".
1/1
3 Engine Speed Control Lever Linkage Check
Engage park brake. Put FNR lever in neutral (N) position. Note rpm on tachometer (if equipped). Move speed control lever to fast idle position.
T7989AP UN19APR93
OK: Go to next check. NOT OK: Tighten friction lock. Go to Group 9010-20. NOT OK: Check engine speed. Go to Group 9010-20.
LOOK: Tachometer must read 850 50 rpm (slow idle) or 2375 50 rpm (fast idle). LOOK: Speed control lever must remain at selected position.
1/1
4 Engine Speed Control Pedal Linkage Check
Depress speed control pedal
OK: Go to next check. NOT OK: Adjust Speed Control Linkage Override. Go to Group 9010-20.
LISTEN: Engine speed must be the same as with speed control lever in fast idle position.
T7394BF UN06JAN92
1/1
Brake System Checks
1/1
TM1496 (21SEP05)

092105
PN=69

1 Pedal Stop Check Lift left and right brake pedals. OK: Go to next check. NOT OK: Adjust brake pedal stops. Go to Group 9020-20.
LOOK: Brake pedals must be against pedal stop screws. NOTE: This ensures that brake check valves are opened and brakes released.
9005 10 6
T7394BG UN17JAN92
1/1
2 Brake System Leakage Check
Depress and hold left brake pedal, then right brake pedal using approximately 267 N (60 lb force). Specification Left Brake Pedal Approximate Force ............................. 267 N (60 lb force) Right Brake Pedal Approximate Force ............................. 267 N (60 lb force)
T7367AM UN17JAN92
OK: Go to next check. NOT OK: Bleed brake system. Go to Group 9020-20. NOT OK: Check light fuse. OK: Check wiring. Go to Group 9015-15 , Lighting Circuit Checks.
LOOK: Brake pedal must NOT feel spongy (caused by air in system) or settle more than 25 mm (1.0 in.) per minute.
Specification Brake PedalMaximum Settle .................................................. 25 mm (1.0 in.) per minute
LOOK: Rear brake light must come ON when either pedal is depressed with key switch in ON position.
1/1
3 Park Brake Capacity Check
Engage park brake. Put stabilizers in up position. Put backhoe in transport position. Use loader functions to pull machine forward or push machine backward.
OK: Go to next check. NOT OK: Adjust park brake linkage. Go to Group 9020-20.
LOOK: Rear wheels should not turn. If loader can pull or push machine, rear tires should drag. LOOK: Park brake switch light will be ON.
1/1
TM1496 (21SEP05)

092105
PN=70

4 Brake Drag Check Position machine on a gradual grade with front of machine downhill. Lift bucket so it clears ground. Shift FNR lever to neutral, differential lock pedal up, disengage park brake and release service brakes.
T6171AL UN09DEC88
OK: Go to next check. NOT OK: Brakes dragging. Go to Group 9020-10, Brake Drag Check.
LOOK: Machine must move or coast. NOTE: If machine does not move freely on slope, drive the machine for five minutes. Feel axle housing area to locate which brake is dragging.
1/1
9005 10 7
Steering System Checks
1/1
1 Steering System Checks
Operate engine at approximately 1000 rpm. Turn steering wheel from full left to full right several times.
OK: Go to next check. NOT OK: Go to Group 9025-15, Steering Valve Does Not Return to Neutral.
LOOK: Front wheels must move smoothly in both directions. LOOK: When steering wheel is stopped, the front wheels must stop moving. NOTE: Internal leakage or a sticking steering valve spool can cause wheels to continue to move after steering wheel is stopped.
1/1
2 Steering System Leakage Check
NOTE: Hydraulic oil must be at operating temperature.

Run engine at slow idle. Turn steering wheel until wheels are in maximum right turn position. Continue turning steering wheel, using approximately 11.3 Nm (100 lb-in.) force while counting steering wheel rpm. Repeat leakage check turning steering wheel to the left.
OK: Go to next check. NOT OK: If steering wheel turns more than 5 rpm, verify whether valve or cylinder is leaking. Go to Group 9025-25 , Steering System Leakage Test.
LOOK: Steering wheel must not turn more than 5 rpm to the left or right. Use good judgement, excessive steering wheel rpm does not mean steering will be affected.
1/1
TM1496 (21SEP05)

092105
PN=71

3 Steering Priority Valve Check Operate engine at slow idle. Turn steering wheel to stop left and right. Note effort required to turn wheel. Turn wheel to stop and apply constant pressure. 9005 10 8 OK: Go to next check. NOT OK: Steers hard and no decrease in engine rpm. Go to Group 9025-25, Steering Priority Valve Test.
LOOK/FEEL: Wheels must stop at both axle stops and require normal steering wheel effort. LOOK/LISTEN: Tachometer (if equipped) must decrease 2550 rpm or hear decrease in engine rpm when steering wheel is held against stop.
1/1
Reverser Clutch Disconnect Solenoid Check
1/1
1 Clutch Disconnect Circuit Check
OK: Go to next check. CAUTION: Machine should try to move forward as FNR lever is moved. NOT OK: Check fuse. Start engine, set idle speed at approximately 1500 rpm. Put transaxle in fourth gear. Release park brake. Shift FNR lever to forward (F) position. Actuate clutch disconnect on gear shift lever or loader control lever individually and note sound of engine. OK: Go to Group 9015-15 , Park Brake/Clutch Disconnect Circuit.
LISTEN: When FNR lever is shifted to forward (F) position, a noticeable drop in engine speed should be heard. LISTEN: Engine rpm must increase when the reverser clutch disconnect solenoid switches are activated.
1/1
Driving Checks
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TM1496 (21SEP05)

092105
PN=72

1 Transaxle Shift Linkage Synchronizer And Noise Check IMPORTANT: Use clutch disconnect when shifting gears. Run engine at approximately 1500 rpm with FNR lever in forward (F) position. Shift transaxle into each gear and drive for a short distance.
T7447AG UN04JAN91
OK: Go to next check. NOT OK: Go to Group 9020-15 , Excessive Gear Noise When Shifting Gears.
9005 10 9
LISTEN: 300DSome gear noise can be expected when shifting into first or second gear. There must NOT be any gear noise when shifting into third or fourth gear. Third and fourth gears are synchronized. LISTEN: 310D,315DExcessive gear or FNR lever noise must NOT be heard in any gear. All gears are synchronized.
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2 Differential Lock And Linkage Check
Shift transaxle to first gear. Move FNR lever to forward (F) position and operate engine at approximately 1500 rpm. Depress differential lock pedal. Turn steering wheel slightly right or left.
T7447AG UN04JAN91
OK: Go to next check. NOT OK: Go to Group 9020-15, No Differential Lock Operation.
Release differential lock pedal.
LOOK: Machine must try to go straight forward and pedal must return to UP position when traction is equal.
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3 Differential Gear And Pinion Check
NOTE: Hold the wheel which is being braked stationary during this test or brake chatter could be confused with differential gear noise.
Shift transaxle to first gear and operate engine at approximately 1500 rpm. Move FNR lever to forward (F) position. Steer machine in a maximum left turn and depress left brake pedal to stop the left wheel. Steer machine in a maximum right turn and depress right brake pedal to stop the right wheel.
OK: Go to next check. NOT OK: Go to Group 9020-10, Differential and Pinion Gear Check.
LISTEN: NO excessive gear noise must be heard in the differential or pinion gear area.
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TM1496 (21SEP05)

092105
PN=73

4 Front Wheel Alignment (Toe-In) Check Drive machine in fourth gear forward on a surface with loose material. OK: Go to next check. NOT OK: If material is thrown, excessive tire wear will result. Go to Group 9020-20, Adjust Toe-In.
LOOK: Material behind front wheels must not be thrown excessively inward or outward.
9005 10 10
T6264AI UN22OCT91
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5 Engine And Torque Converter Check
Position machine with loader bucket at ground level against dirt bank or immovable object. Shift transaxle into first gear. Move FNR lever to forward (F) position. Engage differential lock.
T6171AM UN09DEC88
OK: Go to next check. NOT OK: If the wheels can be easily stalled, go to Group 9020-15, Power TrainMachine Lacks Power or Moves Slow.
Increase engine speed to fast idle.
LOOK: Rear wheels must NOT stall. NOTE: This test will give a general indication of engine reverser and torque converter performance.
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6 Reverser Hydraulic System Check
Run engine at approximately 1500 rpm. Shift transaxle into third gear. Move FNR lever to forward (F) position. Make several shifts from third forward to third reverse. Start counting the number of seconds when FNR lever is moved to opposite direction.
OK: Go to next check. NOT OK: If shifts are slow, go to Group 9020-25 , Reverser Element Leakage Using Four-Gauge Method.
LOOK: A normal shift from forward to reverse or reverse to forward must be completed in three seconds. The machine must be up to speed in four seconds. NOTE: Excessive internal leakage is indicated if reverse warning alarm (if equipped) does not sound at slow idle, but sounds when rpm is increased.
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Mechanical Front Wheel Drive (MFWD) Driving Check
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TM1496 (21SEP05)

092105
PN=74

1 MFWD Switch Check OK: Go to next check. NOT OK: Check electrical circuit. Go Group 9015-15, MFWD circuit 9005 10 11
T7860AA9 UN13NOV92
Drive machine at transport speed. Push switch (A) and engage MFWD.
LOOK: Light in MFWD switch must be ON, and all four wheels must be engaged.
Push switch (A) and disengage MFWD.
LOOK: Light in MFWD switch must be OFF, with MFWD disengaged. NOTE: Indicator light in MFWD switch will remain ON while MFWD is engaged. If MFWD is turned OFF while operating, light could remain on for several seconds until load on drive train is released.
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2 MFWD Limited-Slip Differential And Control Linkage Check
Shift transaxle to first reverse. Engage MFWD and drive machine. Run engine at approximately 1200 rpm. Turn steering wheel for a full left or right turn and observe how the front tires attempt to slide sideways (side load) and the amount of tire scuffing. Disengage MFWD.
OK: Go to next check. NOT OK: Move MFWD control linkage to feel engagement detents. No detents, inspect linkage to transfer case. OK: Go to Group 9020-15, No Power to MFWD.
LOOK: Tire side loading and scuffing must stop when MFWD is disengaged. NOTE: If tires attempt to slide sideways and tire scuffing is seen with MFWD engaged, limited-slip differential is working and power is being transmitted to MFWD.
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3 Engine And Torque Converter Check
With loader bucket level and cutting edge at the centerline of front wheels, put machine against a dirt bank or immovable object. Engage MFWD and differential lock. Shift transaxle to first forward.
T6171AN UN09DEC88
OK: Go to next check. NOT OK: If all wheels stop, a torque converter problem is indicated. If the front wheels stop, MFWD problem is indicated. Go to Group 9020-15 , Machine Lacks Power or Moves Slow.
Increase engine speed to fast idle
LOOK: All four wheels must turn.
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TM1496 (21SEP05)

092105
PN=75

4 MFWD Gear And Pinion Check Drive machine at transport speed with MFWD engaged, then disengaged. OK: Go to next check. NOT OK: If MFWD whines, check oil levels and fill to correct levels. OK: Check backlash. Go to repair manual.
LISTEN: MFWD must NOT whine.
9005 10 12
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Hydraulic System Checks
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1 Main Hydraulic Pump Performance Check
NOTE: If hydraulic oil is not at operating temperature, heat hydraulic oil until loader and backhoe cylinders feel warm to touch.
Put loader bucket flat on ground. Run engine at slow idle.
T7374CG UN04OCT90
OK: Go to next check. NOT OK: If cycle time slow, go to 9025-15, Slow Hydraulic Functions.
Measure cycle time of loader raise to maximum height (including bucket leveling).
LOOK: The maximum cycle time is 15 seconds. NOTE: Take the average cycle time for at least three complete cycles. This time will give a general indication of hydraulic pump performance.
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2 Auxiliary Hydraulic Pump Performance Check
NOTE: Hydraulic oil should be at operating temperature.

Put backhoe in transport position. Run engine at fast idle with hand speed control lever. While holding loader boom raise over relief, extend backhoe dipperstick and measure cycle time.
OK: Go to next check. NOT OK: If cycle time is slow, go to 9025-15, Slow Hydraulic Functions.
LOOK: 300DThe maximum cycle time is 15 seconds. LOOK: 310D,315DThe maximum cycle time is 19 seconds.
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TM1496 (21SEP05)

092105
PN=76

3 Cylinder Cushion Check Run engine at approximately 1000 rpm. Activate backhoe swing left and right and boom raise. Note sound and speed as cylinders near end of their stroke. OK: Go to next check. NOT OK: Remove and repair cylinder cushion. Go to repair manual. 9005 10 13
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.
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4 Stabilizer Cylinder And Valve Check
Operate machine at approximately 1500 rpm. Position loader bucket above ground. Extend each stabilizer cylinder.
OK: Go to next check. NOT OK: Cylinders drift up or down. Inspect lock outs.Go to repair manual. NOT OK: Cylinders drift down rapidly. Go to Group 9025-25, Cylinder Leakage Test.
LOOK/FEEL: Cylinder must extend smoothly and hold machine up.

Retract each stabilizer cylinder.
LOOK/FEEL: Cylinders must retract smoothly and remain up.
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5 Backhoe And Loader Function Drift Check
NOTE: Feel backhoe cylinders. Cylinder must be warm to touch (3852C [100125F]). If cylinders are not warm, heat oil to specifications.
315DSwitch side shift lock switch to OFF position. With backhoe fully extended, put backhoe bucket at a 45 angle to ground. Lower boom until bucket cutting edge is 50 mm (2.0 in.) off the ground. Position loader bucket same distance off ground as backhoe bucket. Run engine at slow idle and observe bucket cutting edge.
OK: Go to next check. NOT OK: Verify which function is drifting. Go to Group 9025-25, Drift Test.
T7374CI UN04OCT90
LOOK: Cutting edges must NOT touch ground within one minute.
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TM1496 (21SEP05)

092105
PN=77

6 Hydraulic Control Valve Lift Check Test
NOTE: Gresen valve lift checks must be checked in both directions because the section has a separate lift check for each work port. Husco valves have one lift check for both work ports, and therefore only need to be checked in one direction.
Raise loader bucket 1 m (3.0 ft) off the ground with the bucket level.
OK: Go to next check. NOT OK: Inspect control valve lift check. Go to repair manual. OK: Go to Group 9025-25, Cylinder Leakage Test.
9005 10 14
Position backhoe at maximum reach with bottom of bucket level with ground, 1 m (3.0 ft) off the ground. Stop the engine. Activate each function one at a time. Loader boom raise Loader bucket rollback Backhoe boom up Dipperstick extend Backhoe bucket curl
Start engine, raise front of machine with bucket tipped 45 down. 300D OnlyActivate each function one at a time. Loader boom lower Loader bucket dump Backhoe boom down Dipperstick retracted Backhoe bucket dump
LOOK: These functions must not move when the control lever is activated.
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7 Loader Boom Float Check
Put loader bucket at maximum height position with bucket dumped. Run engine at approximately 1500 rpm. Move the loader control lever forward into boom float detent position, and at the same time into bucket rollback detent position. Remove hand from control lever.
T7390AA UN12OCT90
OK: Go to next check. NOT OK: If it jumps out of detent, check detent spring and detent balls. Go to repair manual.
LOOK: Loader control lever must remain in the boom float detent position.
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TM1496 (21SEP05)

092105
PN=78

8 Loader Return-To-Dig Check (If Equipped) OK: Go to next check. NOT OK: Adjust switch till it is activated in cam. Go to Group 9025-20, Loader Bucket Level Indicator and Return-to-Dig.
T6171AT UN09DEC88 T7374CH UN04OCT90
9005 10 15
Put loader bucket at maximum height position with bucket dumped. Run engine at approximately 2000 rpm. Move the loader control lever forward into boom float detent position, and at the same time into bucket rollback detent position. Remove hand from control lever.
NOT OK: Adjust linkage as necessary. Go to Group 9025-20, Adjust Loader Bucket Level Indicator and Return-to-Dig.
LOOK: Loader control lever must disengage from the bucket rollback detent when the bucket is level. LOOK/LISTEN: Notch on cam must allow switch to "click". LOOK: When the bucket is at ground level, bucket must be level and the bucket indicator pointer must be aligned with mark on the boom pivot. NOTE: When return-to-dig is used with loader boom in full up position, the bucket leveling linkage will move the bucket control valve out of return-to-dig position before bucket is actually level.
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9 Bucket Leveling Mechanism Check
NOTE: The loader bucket leveling feature functions during the boom raise cycle only. When bucket is lowered, the operator must level the bucket unless machine is equipped with optional return-to-dig.
Put loader bucket in the rollback position with the boom near ground level.
T7374CJ UN05OCT90
OK: Go to next check. NOT OK: Adjust loader control valve linkage. Go to Group 9025-20.
Raise the loader and at the same time hold the control lever in the bucket rollback position. Observe bucket and loader control lever as the loader raises.
LOOK/FEEL: Loader control lever must move into the bucket dump position and the bucket dump function must slowly activate. When the loader control lever moves to activate the bucket dump function, the bucket position must remain stationary the remainder of the loader boom raise cycle. LOOK: The bucket side cutting edge must be level through the loader raise cycle.
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TM1496 (21SEP05)

092105
PN=79

10 Side Shift Frame Lock Check315D Operate engine at slow idle. Lock backhoe in transport position. Depress side shift lock switch mounted on backhoe boom control lever. OK: Go to next check. NOT OK: Side shift frame lock does not release. Check fuse. OK: Inspect wiring from switch to valve solenoid. Go to Group 9015-15. OK: If power to solenoid, replace solenoid valve. Go to repair manual. NOT OK: Side shift frame will not lock. Remove and inspect check valve and solenoid seals. Go to repair manual. NOT OK: Side shift frame does not remain locked. Test leakage of side shift valve. Go to Group 9025-25.
9005 10 16
T7394BE 1917OCT90
LOOK: Side shift frame must drop slightly as locking pistons retract.
Release switch to ON position. Hold boom-up function over relief.
LOOK: Side shift frame must raise slightly when backhoe valve is held over relief.
Return boom lever to neutral position.
LOOK: Side shift frame must remain locked in position for one minute minimum. NOTE: It is normal for sliding frame to settle if no backhoe functions are operated for a few minutes.
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Check Operation Of Accessories (Engine Stopped)
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1 Front Light Switch Check
Turn key switch to ON position. Push front light rocker switch to middle position.
OK: Go to next check. NOT OK: Check fuse and bulbs. OK: Check wiring. Go to Group 9015-10, Light Circuit Checks.
LOOK: Two front lights, two red tail lights and gauge lights must come on.
Push front light rocker switch in completely.
LOOK: All four front lights, two red tail lights and gauge lights must come on.
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TM1496 (21SEP05)

092105
PN=80

2 Rear Light Switch Check Turn key switch to ON position. Push side console rear light rocker switch in. OK: Go to next check. NOT OK: Check fuse and bulbs. OK: Check wiring. Go to Group 9015-10, Light Circuit Checks. 9005 10 17
LOOK: Rear light (s) must come on.
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3 Turn Signal Check
Turn key switch to ON position. Push right side of turn signal rocker switch down.
OK: Go to next check. NOT OK: Check fuses and wiring. Go to Group 9015-15, Lighting Circuit Checks.
LOOK: Right front and rear amber lights must flash. Right indicator light on top of steering column must flash.
Push left side of turn signal rocker switch down.
LOOK: Left front and rear amber lights must flash. Left indicator light on top of steering column must flash.
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4 Warning Light Check
Key switch ON. Push bottom of warning light rocker switch in.
OK: Go to next check . NOT OK: Check fuses and wiring. Go to Group 9015-15, Lighting Circuit Checks.
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LOOK: Both front and rear amber lights must come one. Both turn signal indicators and light in warning light rocker switch must flash.
5 Horn Check
Turn key switch to ON position. Push horn button
OK: Go to next check. NOT OK: Check fuses and wiring. Go to Group 9015-15, Accessory Checks.
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LISTEN: Horn must sound.
Cab Component Checks
1/1
TM1496 (21SEP05)

092105
PN=81

1 Seat Linkage Check Move lever (A) to the right. Move seat forward and rearward and release lever. OK: Go to next check . NOT OK: Repair linkage. Go to repair manual.
9005 10 18
T7394BD UN29NOV90
LOOK: Lever must move freely and lock seat in desired position.
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2 Height Adjustable Seat Check (If Equipped)
Pull lever (C) up and at the same time remove your weight from the seat. Raise seat several positions and engage latch.
OK: Go to next check. NOT OK: Lubricate seat pedestal. Go to repair manual.
LOOK: Seat must raise upward and must remain in desired latched position.
T7394BD UN29NOV90
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3 Seat Swivel Linkage Check
Pull lever (B) up. Move seat from loader to backhoe position and engage latch.
OK: Go to next check. NOT OK: Lubricate or 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.
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4 Left Cab Door Latch And Opener Check
Unlatch door. Observe door as it opens. Pull door closed and latch it.
OK: Go to next check. NOT OK: Adjust cab door. Go to repair 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.
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TM1496 (21SEP05)

092105
PN=82

5 Right Door Latch And Opener Check Unlatch door and pull door open. Close and latch door. OK: Go to next check. NOT OK: Adjust door. Go repair manual. 9005 10 19
FEEL: Cab door latch must work freely.

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6 Rear Window Latch And Opener Checks
Squeeze latches on both sides of middle rear window. Lower window to rubber bumpers. Push latch releases on upper rear window. Observe window as it opens. Push window up and into window catches and note fit. Observe cylinders while closing window. Raise middle window and push into latches.
OK: Go to next check. NOT OK: Check for obstructions. Go to repair manual.
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.
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7 Side Window Checks
Open left and right rear side window. Fasten rear window against front window.
OK: Go to next check. NOT OK: Adjust windows. Go to repair manual.
LOOK: Sleeve on rear window must align with knob on front window. LOOK/FEEL: Hinges must move freely. Locking latches must be equally loaded when closed.
T6171DF UN09DEC88
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8 Blower
OK: Go to next check. NOT OK: Go to Sub-System Diagnostics, Group 9015-15.
T7840AX UN06OCT92
Turn blower switch (A) to low, medium and high speeds.
FEEL/LISTEN: Blower must have three speeds and OFF.

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TM1496 (21SEP05)

092105
PN=83

9 Heater OK: Go to next check. NOT OK: Go to Sub-System Diagnostics, Group 9015-15. 9005 10 20
T7840AY UN06OCT92
Start engine and run at fast idle. Wait two minutes. Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high speed.
FEEL: Air from ducts must be warm.
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10 Air Conditioner (If Equipped)
OK: Go to next check. NOT OK: Go to Heating and Air Conditioning, Group 9031-10.
T7835AX 1930SEP92
Start engine and run at fast idle. Turn air conditioner switch (A) to ON position. Turn blower switch (B) to high speed. Wait for any warm air in duct system to dissipate.
FEEL: Air from ducts must be cool.
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11 Rear Windshield Wiper Check
Turn key to ON position. Push rear wiper rocker switch to first detent, middle position. Push rear wiper rocker switch all the way in.
OK: Go to next check. NOT OK: Check fuse. OK: Check rear wiper. Go to Group 9015-15, Wiper/Washer Circuit.
LOOK: Rear wiper must operate and have two speeds. LOOK: Wipers must return to park position.
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TM1496 (21SEP05)

092105
PN=84

12 Front Windshield Wiper Check Turn key switch to ON position. Push front wiper rocker switch to first detent, middle position. Push front wiper switch all the way in. OK: Go to next check. NOT OK: Check fuse. OK: Check front wiper. Go to Group 9015-15, Wiper/Washer Circuit.
LOOK: Both front wipers must operate and have two speeds. LOOK: Wipers must return to park position.
9005 10 21
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13 Front Windshield Washer Check
Turn key switch to ON position. Push windshield washer rocker switch in.
OK: Go to next check. NOT OK: Check fluid level, and fluid lines for blockage. NOT OK: Check wiring. Go to Group 9015-15, Wiper/Washer Circuit.
LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF position.
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14 Cab Dome Light And Swivel Light Check
Turn key switch to ON position. Push dome light switch to ON position. Push swivel light switch to ON position.
OK: Go to next check. NOT OK: Check fuse and bulbs. NOT OK: Check wiring. Go to Group 9015-15, Dome Light Circuit.
LOOK: Lights must come ON.
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Miscellaneous Checks
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1 Vandal Protection Check
Lock engine access door, reservoir door and cab doors using ignition key.
OK: Go to next check. NOT OK: Lubricate or repair lock. Go to repair manual.
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FEEL: All locks must operate freely and key must not stick in locks.
TM1496 (21SEP05)

092105
PN=85

2 Check Periodic Maintenance Decal Check periodic maintenance decal on inside of reservoir access door. OK: Go to next check. NOT OK: Replace decal. Go to John Deere Dealer for part.
LOOK: Periodic maintenance decal must be legible.

9005 10 22
T6171DG UN09DEC88
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3 Backhoe Transport Pin Check
OK: Operational Checkout completed. NOT OK: Adjust boom lock. Go to 9025-20. NOT OK: Repair or replace swing lock pin. NOT OK: Check pin bore for burrs or obstruction.
T8181AD UN20FEB94
Raise boom into transport position and lower boom lock pin (A). Remove swing lock pin (B) from holder in cab and install through top and bottom holes of swing frame and through main frame.
LOOK: Boom lock pin (A) must stay in boom lock mechanism and support weight of boom. LOOK: Swing lock pin (B) must install freely.
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TM1496 (21SEP05)

092105
PN=86
Section 9010
Engine
Contents
Page
Group 05Theory Of Operation 4039 John Deere EngineUse CTM8 . . . . .9010-05-1 General Engine Description. . . . . . . . . . . . . .9010-05-2 EngineSectional View . . . . . . . . . . . . . . . .9010-05-4 Group 10System Operational Checks System Operational Checks . . . . . . . . . . . . .9010-10-1 4039 John Deere EngineUse CTM8 . . . . .9010-10-1 Cooling System Checks . . . . . . . . . . . . . . . .9010-10-1 Air System Checks . . . . . . . . . . . . . . . . . . . .9010-10-3 Lubrication System Checks . . . . . . . . . . . . . .9010-10-3 Fuel System Checks . . . . . . . . . . . . . . . . . . .9010-10-4 Engine Speed And Performance Checks. . . .9010-10-5 Group 15System Diagnostic Information 4039 John Deere EngineUse CTM8 . . . . .9010-15-1 Make Visual Inspection Of Engine And Supporting Systems. . . . . . . . . . . . . . . . . .9010-15-2 Diagnose Engine Malfunctions . . . . . . . . . . .9010-15-4 Group 20Adjustments JT05801 Clamp-On Electronic Tachometer Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-1 Fan Belt Tension Adjustment . . . . . . . . . . . .9010-20-2 Adjust Speed Control Lever Tension . . . . . . .9010-20-3 Engine Speed Control Linkage . . . . . . . . . . .9010-20-3 Slow And Fast Idle . . . . . . . . . . . . . . . . . . . .9010-20-5 Group 25Tests JT05801 Clamp-On Electronic Tachometer Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-1 JT05800 Digital Thermometer Installation . . .9010-25-1 JT07158 TIME TRAC INSTALLATION. . . . .9010-25-2 Cooling System . . . . . . . . . . . . . . . . . . . . . . .9010-25-4 Air Filter Restriction Indicator Switch . . . . . . .9010-25-5 Air Intake System Leakage Test . . . . . . . . . .9010-25-6 Radiator Air Flow Test. . . . . . . . . . . . . . . . . .9010-25-7 JT05529 Air Flow Meter Test Record . . . . . .9010-25-9 Turbocharger Boost Pressure-Engine Performance Test310D, 315D . . . . . . .9010-25-10 Injection Pump Timing. . . . . . . . . . . . . . . . .9010-25-12 Injection Pump Static Timing Adjustment. . .9010-25-13
9010
TM1496 (21SEP05)

092105
PN=1
Contents
9010
TM1496 (21SEP05)

092105
PN=2
Group 05
Theory Of Operation
4039 John Deere EngineUse CTM8
For additional engine information, the component technical manual (CTM) is also required. Use the CTM in conjunction with this machine manual.
UN07SEP88 M44215
TX,9010,YY507 1905MAR931/1
9010 05 1
TM1496 (21SEP05)

092105
PN=89
Theory Of Operation
General Engine Description

Model 3029, 4039, 4045, 6059, and 6068 engines are vertical, in-line, valve-in-head, 4-cycle (stroke) diesel engines. Direct fuel injection is provided by a distributor-type injection pump and 9.5 mm injection nozzles mounted in cylinder head. The gear driven injection pump is timed to the crankshaft by the timing gear train.
9010 05 2
used on Dubuque engines, and a 5/6-piece bearing insert is used on Saran engines. The 5/6-piece bearing has high thrust load capability, and may be retro-fitted to Dubuque engines1 at service repair if so desired. IMPORTANT: Service thrust bearing kits are now supplied with a six-piece thrust bearing assembly. It is acceptable to use a six-piece bearing where five-piece was previously used. Follow instructions provided. If a crankshaft has excessive end play, thrust washer sets are available in standard size or 0.007 in. oversize. Cylinder liners are "wet" (surrounded by coolant) and are individually replaceable. O-rings seals are used at the lower connection between cylinder block and liners. Pistons are made of high-grade cast aluminum alloy with internal ribbing. The skirt is cam ground to allow for expansion during operation. The piston crown has a cut-out combustion bowl with a truncated cone center. All piston rings are located above the piston pin. Two compression rings and one oil control ring are used. The top compression ring is a keystone shaped ring located close to the top of the piston for improved engine performance. The hardened, fully-floating piston pins are held in place by snap rings. Spray jets (piston cooling orifices) in cylinder block spray pressurized oil on the underside of the piston to lubricate piston pins and cool pistons. The forged steel connecting rods have replaceable pin bushing and bearing inserts. 3029 connecting rods have a tapered pin-end.
Some engines are equipped with a turbocharger. The turbocharger uses energy from exhaust gases to compress intake air and force it into the combustion chamber. The cylinder block is a one-piece casting. The block is available in structural and non-structural configurations. The camshaft is timed to the crankshaft through the timing gear train. The camshaft rotates in honed bores in the cylinder block. Camshaft gear-driven auxiliary drive engines and all 3029 engines use a bushing in No. 1 camshaft bore. The camshaft lobes determine the duration and lift of each valve, and operate the fuel transfer pump. Intake and exhaust valves are operated by camshaft followers, push rods and rocker arm assembly. Valve seat inserts in cylinder head are used for intake and exhaust valves. The crankshaft is a one-piece, heat treated, steel or nodular-iron forging which operates in replaceable two-piece main bearings. Steel crankshafts may have either ground-fillets, or undercut and rolled fillets. All nodular-iron crankshafts are machined with undercut and rolled fillets. Two different types of main thrust bearing inserts are used to control end-play, depending on the producing factory. Normally, a two-piece thrust bearing insert is
1 Main (thrust) bearing web undercut in block and or bearing cap MUST be 113.8 mm (4.48 in.) in order to accept five piece thrust bearings.
CTM8,GR01,11 1918FEB951/2
TM1496 (21SEP05)

092105
PN=90
Theory Of Operation
The engine is equipped with a gear driven oil pump and full-flow oil filter. The oil filter has an internal bypass valve which opens if the filter element becomes restricted. Most engines are equipped with an oil cooler mounted externally on the cylinder block. The engine is equipped with a pressure regulator valve to relieve excessive pressure build-up in the main oil gallery, and a bypass valve to prevent oil starvation if the oil cooler and filter become plugged. Balancer shafts are used on some four-cylinder engines to reduce vibration. The two shafts rotate on bushings in cylinder block and are counter-rotating at twice engine speed. The engine has a pressurized cooling system, consisting of radiator, water pump, multi-blade fan, and one or two thermostats.
CTM8,GR01,11 1918FEB952/2
9010 05 3
TM1496 (21SEP05)

092105
PN=91
Theory Of Operation
EngineSectional View
9010 05 4
ARocker Arm Shaft BCylinder Head CPush Rod DCam Follower ECamshaft
FCylinder Block GCrankshaft HCrankshaft Counterweight IOil Pan JBalancer Shafts
KConnecting Rod LLiner Packing Rings MCylinder Liner NPiston OPiston Pin
PPiston Rings QValve RFuel Injection Nozzle SValve Spring TRocker Arm
S11,2000,EH 1911JUL951/1
TM1496 (21SEP05)

092105
PN=92
RG7248
UN11JUL95
Group 10
System Operational Checks

This procedure is designed so the mechanic can make a quick check of the engine using a minimum amount of diagnostic equipment. If you need additional information, read Theory of Operation, Group 9010-05. A location will be required which is level and has adequate space to complete the driving checks. The engine and all other major components must be at operating temperature for some checks. Locate system check needed in the left column and read completely, follow this sequence from left to right. Read each check completely before performing. At the end of each check, if no problem is found (OK:), you will be instructed to GO TO NEXT CHECK. If problem is indicated (NOT OK:), you will be given repair required and Group location or CTM number. If verification is needed, you will be given next best source of information after GO TO: Group 10 (System Operational Checks) Group 15 (System Diagnostic Checks) Group 20 (Adjustments) Group 25 (Tests) CTM (Component Technical Manual)
9010 10 1
T59,9010,J1 1905MAR931/1

UN07SEP88
TX,9010,YY507 1905MAR931/1
Cooling System Checks
1/1
TM1496 (21SEP05)

092105
PN=93
M44215

1 2 Coolant Condition Checks OK: Check completed. CAUTION: DO NOT remove radiator cap unless engine is cool. Then turn cap slowly to the stop. Release all pressure before you remove cap. Open radiator cap. NOT OK: If vacuum release valve is plugged or spring corroded, replace radiator cap. NOT OK: If coolant is oily or foamy. Go to Group 9010-15 Oil In Coolant Or Coolant In Oil. NOT OK: If rust in coolant, drain, flush and replace coolant. Go to Operators Manual.
LISTEN: If radiator is warmer than air temperature, a "whoosh" must be heard when radiator cap is opened to first stop position. FEEL: The radiator cap must have a stop position and must be pushed down to turn to remove.
9010 10 2 Inspect coolant level, coolant condition.
LOOK: The radiator cap must have a good seal and gasket. The seal must move freely and the spring must not be corroded. LOOK: The vacuum release valve (center of cap rubber seal) must move freely and holes must not be plugged. LOOK: The coolant must not be oily, foamy, or rusty.
1/1
2 Hose And Water Pump Check
Inspect all radiator and heater hoses and water pump for cracks or leaks.
OK: Check completed. NOT OK: Replace defective hoses, tighten clamps as necessary. NOT OK: Repair water pump. See Remove Water Pump in CTM8.
LOOK: Radiator hoses must not be brittle or show signs of leaks.

Check all hose clamps.
LOOK: All hose clamps must be tight.

Squeeze lower radiator hose.
FEEL: Lower hose must have wire insert. LOOK: Water pump must not show any signs of leaks.
1/1
3 Radiator Bubble Check
a. Radiator to proper level. b. Install radiator cap and tighten. c. Start engine. Run engine until at normal operating temperature. d. Place overflow tube in jar of water.
T6171AR UN25MAY89
OK: Check complete. NOT OK: If constant flow of bubbles is seen, a loose cylinder head or a damaged head gasket could be the cause. See Head Gasket Inspection and Repair Sequence in CTM8.
LOOK: Amount of bubbles in glass jar.
1/1
TM1496 (21SEP05)

092105
PN=94

4 Fan And Fan Shroud Check OK: Check complete. NOT OK: Adjust belt tension. Go to Group 9010-20. NOT OK: If fan blades have any bends, replace fan. If fan has nicks, locate interference and repair. Go to repair manual. 9010 NOT OK: Replace fan 10 belt. Go to repair manual. 3 NOT OK: If fan is on backwards, remove and install. Go to repair manual.
T6171CA UN25MAY89 T6171CB UN25MAY89
Inspect fan and shroud clearance. Inspect fan blades for damages. Check fan belts for tightness.
LOOK/FEEL: Fan belt deflection should be about 7/16 in. with 25 lbs of push. LOOK: Fan blades must not have any nicks or bends. LOOK: Make sure there is no oil or grease on fan belt or pulleys. LOOK: Inside surface of fan belt must not have any cracks or contact bottom of pulley groove. NOTE: If the fan blade has been installed backwards about 50% of its capacity is lost. LOOK: Cupped portion of fan blades must be away from radiator.
1/1
Air System Checks
1/1
1 Air Filter Restriction Indicator Switch Check
Run engine at slow idle. Slowly cover air intake tube
OK: Check complete. NOT OK: Check engine air filter restriction light and switch. Go to Group 9015-15.
1/1
LOOK: Engine air filter restriction monitor light must come on.
Lubrication System Checks
1/1
TM1496 (21SEP05)

092105
PN=95

1 Oil Level Check a. Pull out oil level dipstick and check level. b. Clean off oil from dipstick with finger or thumb. c. Smell the oil. OK: Check complete. NOT OK: If oil level is high, smell the oil for fuel oil. Replace fuel transfer pump spindle seal. Go to Remove Fuel Supply Pump CTM8. NOT OK: Drain small quantity of oil and check for antifreeze. If coolant in oil. See Diagnosing Head Gasket Joint Failures in CTM8. Check for leak in liner wall or packing. NOT OK: If oil level is low, check for oil leaks.
LOOK: Oil level must be between add and full marks and must NOT look "milky". SMELL: Oil must NOT smell burnt or smell like fuel oil.
9010 10 4
1/1
Fuel System Checks
1/1
1 Engine Fuel System Inspection Checks
Engine off, engine speed control lever at fast idle position. Inspect water drain, cap, strainer and inside fuel tank (flashlight). Operate pump primer by hand. Inspect all fuel lines, line clamps, and speed control linkage stop.
OK: Check complete. NOT OK: If excessive amount of water is found in fuel tank, change fuel filter. NOT OK: If air "hisses" from tank or enters tank when cap is removed, replace fuel cap. NOT OK: If excessive debris is found in the bottom of the fuel tank, remove fuel line and observe flow. If flow is restricted, clean tank.
LOOK: Water drain must NOT contain an excessive amount of water. LOOK: Inside of fuel tank must NOT contain any foreign matter. LOOK: No fuel leakage must be noted at any of the fuel line connections. The injection line rubber clamps must be in position and NO wiring banded to the injection lines.
1/1
TM1496 (21SEP05)

092105
PN=96

2 Fuel Pump Check "Crack" open bleed screw on fuel filter and operate hand primer on fuel pump. Tighten bleed screw of fuel filter and again operate hand primer on fuel pump. OK: Check complete. NOT OK: Be certain fuel filter is clean. If not, replace filter and recheck fuel pump.
LOOK: Fuel must come out of bleed screw when hand primer is operated.
T6488GR UN19OCT88
FEEL: Resistance must be felt when fuel is being pumped and no resistance will be felt after system is pumped up.
9010 10 5
1/1
3 Fuel System Check
Engine OFF. Disconnect fuel return hose from leak-off line. Connect a hose to leak-off line to route excess fuel into a container. Start engine and run at fast idle. Put engine under load by operating a hydraulic function over relief. Observe fuel flow from leak-off line.
OK: Check completed. NOT OK: Check for plugged fuel filters, plugged fuel tank cap vent, restricted lines, stuck injection pump overflow valve, or a bad fuel pump. Repair or replace as necessary.
LOOK: Fuel must flow from leak-off line with engine at full load. NOTE: Fuel that flows from leak-off line is excess fuel not required by the engine.
1/1
Engine Speed And Performance Checks
1/1
TM1496 (21SEP05)

092105
PN=97

1 Engine Speed Check (Tachometer Installed) Start engine, run at slow idle, and record rpm. Increase engine speed to fast idle with speed control pedal and record rpm. OK: Check complete. NOT OK: Check spring loaded injection pump lever override. Go to Group 9010-20, AdjustmentsEngine Speed Control Linkage. NOT OK: If idle speeds are out of specifications, adjust. Go to Group 9010-20, Adjustments Slow and Fast Idle.
LOOK: Slow idle must be 850 50 rpm. LOOK: Fast idle must be 2375 50 rpm. NOTE: Override adjustment 6 mm (.250 in.)
9010 10 6
T6008AE1 UN09DEC88
1/1
2 Engine Power Check
NOTE: Engine rpm pull down is valid for No. 2 fuel. If No. 1 fuel is used, engine may pull down more.
Operate engine at fast idle. a. With loader boom fully raised, activate boom raise and backhoe stabilizer to create full hydraulic stall. b. Observe exhaust smoke as load is applied to engine.
OK: Check complete. NOT OK: If exhaust smoke is excessive, go to Group 9010-15 Engine Emits Excessive Black Smoke or Gray Exhaust Smoke. NOT OK: If engine speed decreases to less than 1520 rpm, low power of misadjusted or malfunctioning system relief valve is indicated. Go to Group 9010-15 Engine Does Not Develop Full Power.
LOOK: Exhaust smoke should not be evident at approximately 2200 rpm (rated speed). LOOK: Exhaust smoke should not be obvious with engine at full hydraulic stall.
1/1
TM1496 (21SEP05)

092105
PN=98

3 Low Compression Check OK: Check Complete. NOT OK: If starting motor runs at an uneven speed, low compression is indicated on one or two cylinders. Perform Test Engine Compression Pressure in CTM8.
T7367AD UN17SEP90
Remove fuel shut off fuse. Crank engine for 10 seconds. 9010 10 7
LISTEN: Air must not be heard leaking past valves. LISTEN: Starting motor must run at a constant speed.
1/1
4 Engine Blow-By Check
Run engine at fast idle and check the blow-by tube.
OK: Check complete. NOT OK: If blow-by is excessive, perform Test Engine Compression Pressure in CTM8.
LOOK: Fumes should be barely visible at the blow-by tube at fast idle no load. NOTE: Excessive blow-by indicates that piston rings and cylinder liners do not seal off the combustion chamber. This is a comparative check test that requires some experience to determine excessive blow-by.
1/1
5 Loose Or Worn Engine Parts Check
a. Run engine at slow idle. b. With loader boom fully raised, activate boom raise and run loader valve hydraulics over relief to load engine to minimum rpm.
OK: Check complete. NOT OK: Go to Group 9010-15, Abnormal Engine Noise. NOT OK: Go to next check.
LISTEN: Knock or rattling noise must NOT be heard from engine.
1/1
6 Operators Complaint Was Not Identified
If you completed the Operational Checkout and did not isolate a malfunction, the problem may be intermittent. Try to duplicate the condition of the malfunction identified by operator.
OK: Go to Group 9010-15, Diagnose Engine Malfunctions.
1/1
TM1496 (21SEP05)

092105
PN=99
9010 10 8
TM1496 (21SEP05)

092105
PN=100
Group 15
System Diagnostic Information

UN07SEP88 M44215
TX,9010,YY507 1905MAR931/1
9010 15 1
TM1496 (21SEP05)

092105
PN=101
Make Visual Inspection Of Engine And Supporting Systems

1. Inspect for coolant leaks at:
9010 15 2
Radiator Water pump Hoses Coolant manifold Thermostat cover
The condition of the belts and their tension must be checked periodically. Adjust belt tension, see Adjust Fan Belt Tension, Group 0510. 8. Inspect fuel tank: a. Inspect the tank mounting hardware to ensure they are in position and tight. b. Inspect fuel tank for cracks and leakage. c. Inspect fuel tank outlet strainer and water trap for accumulated debris by shining a flashlight through the filler neck toward bottom right corner of fuel tank. 9. Inspect fuel transfer pump. See if there is fuel leaking from inlet and outlet connections. 10. Inspect fuel filter for water in base of filter. Look for fuel leaking from inlet and outlet connections. Check for debris and air in filters. Drain or bleed filters if necessary. Replace filters as required. CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. DO NOT use your hand. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. 11. Inspect injection pump and nozzles.
Check for proper coolant level in radiator. Look at coolant for evidence of oil and/or debris. 2. Inspect for oil leaks around the oil pan, drain plug, oil filter, and clutch housing at drain hole. 3. Inspect hoses to see if they are hard, cracked, soft, or swelled. Replace as necessary. 4. Inspect radiator for bent fins, kinks, dents, cracked side frames, seams and tubes. Check radiator mounts for loose hardware. 5. Check fan to ensure it has been installed correctly. See Cooling System Inspection, in this section. 6. Inspect fan blades. They must be straight and not striking the radiator core or shroud. Bent blades reduce the efficiency of the fan and make the fan out of balance. An out of balance condition can add additional load to the water pump bearings. Check water pump bearings by moving fan and note looseness of bearings. 7. Inspect fan belts. They must not be too tight, too loose, or cracked. Check to see if belt pulleys are worn excessively (if belts run against bore of groove) and that the pulleys are in proper alignment. A belt which is too tight puts extra load on the bearings and shortens the life of the bearings as well as the belts. A belt which is too loose allows slippage and reduces fan and alternator speed, causes excess belt wear. Belt slippage can lead to overheating of the cooling and/or hydraulic system, and undercharged batteries.
TX,9010,YY509 1902JUN931/2
TM1496 (21SEP05)

092105
PN=102

Check fuel inlet and outlet connections and injection line connections. If any of the lines are twisted, kinked, or broken, repair or replace as necessary. Check injection line clamps to ensure they are in position and tight. 12. Inspect speed control linkage. Check for free movement. Be sure the injection pump lever contacts the fast idle stop on the injection pump. 13. Inspect air cleaner elements for debris, filter condition and air restriction indicator to ensure indicator isnt in red. Check all air intake system connections to be sure they are tight. Clean or replace filters when indicator shows red or when there is excessive smoke or loss of power. 14. Check muffler for any signs of leakage or areas that have rusted through. Exhaust leaks can result in a fire in the engine compartment. 15. Check for debris on exhaust manifold.
9010 15 3
TX,9010,YY509 1902JUN932/2
TM1496 (21SEP05)

092105
PN=103
Diagnose Engine Malfunctions

NOTE: Diagnostic charts are arranged from most probable and simplest to verify, to least likely and more difficult to verify. Remember the following steps when diagnosing a problem: Step 1. Operational Checkout Procedure (See Group 9005-10) .
9010 15 4
Step 2. Engine Operational Checkout Procedure (See Group 9010-10) . Step 3. Adjustments and/or Tests (See Group 9010-20 and/or 9010-25).
Symptom Problem Solution
Engine Will Not Start Or Starts Hard
Fuel tank empty
Check fuel quantity
Fuel tank vent plugged
Remove cap and listen for sound of air entering tank. Replace cap. Turn key switch to "On". Must hear click at injection pump. Replace fuse. Repair wiring. Drain water from fuel tank. Inspect fuel filter for water. Change filter. Check fuel tank outlet strainer for type of fuel debris. Check bottom of fuel tank for debris. Check for bubbles in fuel filter and tighten connections. Inspect fuel lines for damage. Check engine oil for fuel dilution. Replace fuel pump. Check battery and connections. Incorrect engine oil (Cold weather). Check air filter restriction indicator and air filters. Clean.
No electrical power to injection pump solenoid
Water in fuel or water frozen in fuel line. Debris in fuel or wrong grade of fuel
Air leak on suction side of fuel system
Fuel transfer pump diaphragm leaking Slow cranking speed
Restricted air filter
TX,901015,QQ815 1924JUN941/12
TM1496 (21SEP05)

092105
PN=104

Symptom Problem
Solution
Stuck injection pump metering valve.
Tap injection pump housing (lightly) if engine now starts. Replace metering valve. See your authorized injection pump service center. Test shut-off solenoid. See 9015-15. Inspect solenoid wiring and linkage. Check timing. See Injection Pump Timing in Group 9010-25. Remove and test pump. See Remove Injection Pump in CTM8. Remove and test nozzles. See Test Fuel Injection Nozzles in CTM8. Check compression. Repair. Perform Test Engine Compression Pressure in CTM8. Remove. Route radiator overflow into container of fluid and check for bubbles. Bubbles indicate head gasket linkage. See Head Gasket Inspection and Repair Sequence in CTM8. Inspect filter for evidence of air in fuel. Tighten connections and bleed fuel system. Remove cap and listen for sound of air entering tank. Replace cap. Check fuel tank outlet strainer for debris. Check bottom of fuel tank for debris. Check grade of fuel. Drain fuel tank and inspect filter element for water. Replace filters. Replace filter.
9010 15 5
Faulty electric shut-off
Improper injection pump timing
Injection pump
Injection nozzle(s)
Worn compression rings or low compression
Blown head gasket
Engine Surges Or Stalls Frequently
Air in fuel
Fuel tank vent plugged
Debris in fuel or wrong grade of fuel
Water in fuel
Fuel filter plugged
TX,901015,QQ815 1924JUN942/12
TM1496 (21SEP05)

092105
PN=105

Symptom Problem
Solution
Return line from injection pump to tank restricted
Route return line at the pump into a separate container. If engine now operates normally, check return line to tank for restriction. Replace. Time injection pump. See Injection Pump Timing in Group 9010-25. Remove, inspect and clean. Determine source of debris. See Remove Injection Pump in CTM8. See your authorized injection pump service center. Remove pump top cover and inspect. Replace metering valve. See Remove Injection Pump in CTM8. See your authorized injection pump service center. Test cooling system. See Check and Service Cooling System in CTM8. Test transfer pump pressure. See Measure Fuel Supply Pump Pressure in CTM8. Remove fuel injection pump. See Remove Injection Pump in CTM8. Test pump. See your authorized injection pump service center. Remove and test nozzle(s). See Test Fuel Injection Nozzles in CTM8. Check and adjust valve clearance. See Check and Adjust Valve Clearance in CTM8. Do compression pressure test. Perform Test Engine Compression Pressure in CTM8.
Fuel injection pump out of time
9010 15 6
Check return oil fitting on top of injection pump control cover plugged.
Injection pump metering valve sticking
Engine overheating
Fuel transfer pump
Fuel injection pump
Injection nozzles(s)
Improper valve clearance
Valve sticking or burned
TX,901015,QQ815 1924JUN943/12
TM1496 (21SEP05)

092105
PN=106

Symptom Problem
Solution
Worn or broken compression rings or cylinder head gasket leaking
Route radiator overflow hose into a container of fluid and check. Check for bubbles. Bubbles indicate head gasket leakage. See Head Gasket Inspection and Repair Sequence in CTM8. Do compression pressure test. Perform Test Engine Compression Pressure in CTM8. Check for evidence of air in filter. Tighten connections and bleed fuel system. Check fuel tank for water. Check fuel tank strainer and fuel filter for debris. Clean. Check grade of fuel. Test slow idle speeds. See Engine Speed Control Linkage . Time injection pump. See Injection Pump Timing in Group 9010-25. Test fuel system pressure. See Measure Fuel Supply Pump Pressure in CTM8. Inspect. Repair. See Remove Injection Pump in CTM8. See your authorized injection pump service center. Verify engine temperature. Test thermostat. Replace. See Remove, Test, and Install Thermostats in CTM8. Check and adjust valve clearance. See Check and Adjust Valve Clearance in CTM8. Inspect. Replace.
9010 15 7
Engine Misses
Air in fuel
Debris in fuel or wrong grade of fuel
Idle speeds out of adjustment (too low) Fuel injection pump out of time
Fuel transfer pump
Injection pump governor faulty or metering valve sticking
Engine overheating
Incorrect valve clearance
Bent push rods
TX,901015,QQ815 1924JUN944/12
TM1496 (21SEP05)

092105
PN=107

Symptom Problem
Solution
Cylinder head gasket leaking
Route radiator overflow hose into container of fluid and check for bubbles. Bubbles indicate head gasket leakage. See Diagnosing Head Gasket Joint Failures in CTM8. Do compression pressure test. Perform Test Engine Compression Pressure in CTM8. Do compression pressure test. Perform Test Engine Compression Pressure in CTM8. Remove and test fuel injection pump. See Remove Injection Pump in CTM8. Remove and test nozzles. See Test Fuel Injection Nozzles in CTM8. Check fuel tank for water or debris. Remove and clean. Replace fuel filter. Drain and add correct fuel. Check air filter restriction and air filters. Clean. Adjust linkage. Check high idle speed. See Engine Speed Control Linkage . Check. Adjust timing. See Injection Pump Timing in Group 9010-25. Adjust valve clearance. See Check and Adjust Valve Clearance in CTM8. Route return line at the pump into a separate container. If engine now operates normal, check return line for restriction. Replace.
Valve sticking or burned

9010 15 8
Worn or broken compression rings
Fuel injection pump
Injection nozzles(s) plugged
Engine Does Not Develop Power
Fuel tank outlet strainer plugged
Fuel filter plugged Wrong grade of fuel Air system restricted
Incorrect high idle speed (too low) or linkage out adjustment.
Incorrect engine or injection pump timing Incorrect valve clearance
Injection pump return fuel tube or fittings are restricted
TX,901015,QQ815 1924JUN945/12
TM1496 (21SEP05)

092105
PN=108

Symptom Problem
Solution
Fuel transfer pump malfunction
Test fuel transfer pump pressure. See Measure Fuel Supply Pump Pressure in CTM8. Route an external fuel source to fuel transfer pump. If engine operation is normal clean fuel line. Check axle and park brake drag. See Operational Checkout, Procedure 9005-10. Test drag. See Operational Checkout Procedure 9005-10. Operate without muffler. If engine operation is now normal, replace muffler. Remove pump and test. See Remove Injection Pump in CTM8. See your authorized injection pump service center. Remove and test nozzle(s). See Test Fuel Injection Nozzles in CTM8. Do compression pressure test. Perform Test Engine Compression Pressure in CTM8. Do valve lift check. Replace. See Measure Valve Lift in CTM8. Check air filter restriction and air filters. Clean or replace. Drain and add correct fuel. Time injection pump. See Injection Pump Timing in Group 9010-25. Remove fuel injection pump. See Remove Injection Pump in CTM8. See your authorized injection pump service center.
9010 15 9
Fuel line restricted
Excess drag in brake system
Excess drag in transaxle
Muffler restricted
Injection pump delivery or governor faulty
Injection nozzle(s)
Low compression
Worn camshaft
Engine Emits Excessive Black or Gray Exhaust Smoke
Restricted air filter
Incorrect grade of fuel Incorrect injection pump timing
Excessive fuel delivery
TX,901015,QQ815 1924JUN946/12
TM1496 (21SEP05)

092105
PN=109

Symptom Problem
Solution
Injection nozzle(s)
Remove and test nozzle(s). See Test Fuel Injection Nozzles in CTM8. Check batteries and connections.
Engine Emits Excessive Blue or White Smoke
Cranking speed too slow
Incorrect grade of fuel

9010 15 10
Drain and add correct fuel. Check thermostat operation. Replace. Time injection pump. See Injection Pump Timing in Group 9010-25. Remove and test nozzle(s). See Test Fuel Injection Nozzles in CTM8. Do compression test. Perform Test Engine Compression Pressure in CTM8. Disassemble, inspect, repair.
Engine running too cold
Injection pump out of time
Injection nozzle(s)
Low compression
Excessive wear in liners and/or piston rings stuck Slow Acceleration Wrong grade of fuel Injection nozzle(s)
Drain and add correct fuel. Remove and test nozzle(s). See Test Fuel Injection Nozzles in CTM8. Remove and test fuel injection. See Remove Injection Pump in CTM8. Repair.
Fuel injection pump
Detonation (Excess Engine Knock)
Stuck cold weather starting aid
Incorrect injection pump timing.
Time injection pump. See Injection Pump Timing in Group 9010-25. Add correct oil to proper level. Inspect. Repair.
Abnormal Engine Noise
Low or incorrect engine oil (too thin). Loose or worn hydraulic pump drive coupling Engine oil diluted with fuel
Inspect engine oil. Determine cause of fuel dilution.
TX,901015,QQ815 1924JUN947/12
TM1496 (21SEP05)

092105
PN=110

Symptom Problem
Solution
Incorrect fuel injection pump timing
Time injection pump. See Injection Pump Timing in Group 9010-25. Adjust valve clearance. See Check and Adjust Valve Clearance in CTM8. Inspect. Replace. Replace. Inspect, tighten connecting rod cap screws. See Torque-Turn Connecting Rod Cap Screws in CTM8. Inspect, tighten main bearing cap screws. See procedure under Install Crankshaft in CTM8. Replace bearings. See Remove Crankshaft Main Bearings in CTM8. Replace bearings. See Inspect and Measure Connecting Rod Bearings in CTM8. Check engine timing. Repair. See procedure under Install and Time Camshaft in CTM8. Inspect. Replace. Inspect. Replace pins and bushings. See Inspect Piston Pins and Bushings in CTM8. Add oil to proper lever. Inspect engine oil. Change oil. Check injection pump shaft seals and transfer pump diaphragm. See Remove Injection Pump in CTM8.
9010 15 11
Excessive valve clearance
Bent push rods Worn rocker arm shafts Loose connecting rod caps
Loose main bearing caps
Worn main bearings
Worn connecting rod bearings
Incorrect cam timing
Scored piston Worn piston pin bushings and pins
Low Oil Pressure (Oil Pressure Light onRed "Stop" Flashing)
Low oil level
Wrong viscosity oil/oil diluted with diesel fuel
TX,901015,QQ815 1924JUN948/12
TM1496 (21SEP05)

092105
PN=111

Symptom Problem
Solution
Oil pressure switch or indicator
Check engine oil pressure. Test switch and indicator. See 9015-15. Test or replace. See CTM8. Inspect. Clean.
Oil pressure regulating valve Plugged or broken oil pump intake screen
9010 15 12
Loose oil pump drive gear Worn oil pump gear or housing Excessive main bearing, connecting rod or balance shaft clearance Cracked cylinder block
Inspect. Repair. Remove, inspect and repair. See CTM8.
Replace cylinder block. See Complete Disassembly of Cylinder Block in CTM8. Inspect piston cooling jets. Check all possible internal leakage paths. Repair. Fill cooling system and check for leaks. See Check and Service Cooling System in CTM8. Add oil. Adjust belt tension or replace belt. See Adjust Fan Belt Tension in CTM8. Reduce load.
Leakage at internal oil passage.
Engine Overheats (Engine Coolant Indicator Light On and Red "Stop" Flashing)
Low coolant level
Low engine oil level Loose or broken fan belt.
Engine overloaded, operating in wrong gear Fan on backwards
Check for correct fan installation. See Check and Service Cooling System in CTM8. Check air flow. Clean radiator. See Check and Service Cooling System in CTM8. Inspect. Repair or replace.
Radiator dirty or plugged
Radiator shroud missing, damaged or baffles missing
TX,901015,QQ815 1924JUN949/12
TM1496 (21SEP05)

092105
PN=112

Symptom Problem
Solution
Improper fuel Radiator cap Faulty temperature sender Incorrect injection pump timing
Drain and add correct fuel. Replace cap. Test, repair or replace.See 9015-15. Time injection pump. See Injection Pump Timing in Group 9010-25. Check transaxle drag. See Operational Checkout Procedure 9005-10. Check Brake drag. See Operational Checkout Procedure 9005-10. Inspect thermostat. Replace. Replace thermostats Flush cooling system. See Check and Service Cooling System in CTM8. Remove. Inspect. Repair. Remove. Check for proper fuel delivery, adjust. See Remove Injection Pump in CTM8. Replace piston. See Engine Disassembly Sequence in CTM8. Replace. See Remove, Test, and Install Thermostats in CTM8. Replace gasket. See Head Gasket Inspection and Repair Sequence in CTM8. Replace packings. See Engine Disassembly Sequence in CTM8. Replace liner. See Engine Disassembly Sequence in CTM8.
9010 15 13
Excessive transaxle drag
Excessive brake drag
Faulty thermostat (Struck closed) Thermostat missing, cooling system coated with lime deposits
Water pump Excessive fuel delivery
Scored piston
Engine Runs Cold
Thermostat (stuck open)
Oil in Coolant Or Coolant in Oil
Leaking cylinder head gasket
Leaking cylinder liner packing
Cracked cylinder liner
TX,901015,QQ815 1924JUN9410/12
TM1496 (21SEP05)

092105
PN=113

Symptom Problem
Solution
Cracked cylinder block
Replace block. See Complete Disassembly of Cylinder Block in CTM8. Check filter restriction indicator and air filters. Replace Inspect. Repair. Refill with correct fuel. Return control levers to neutral position. Test system relief valve pressure. See 9025-25. Time injection pump. See Injection Pump Timing in Group 9010-25. Test nozzle(s). Repair. See Test Fuel Injection Nozzles in CTM8. Insufficient oil pressure. Check for restricted turbocharger oil line. Replace. See Turbocharger Failure Analysis in CTM8. Inspect and repair. See Intake Air Leak Test in CTM8. Remove exhaust elbow and air inlet hose. Inspect and repair. See Turbocharger Failure Analysis in CTM8. Remove exhaust elbow and air inlet hose. Inspect and repair. See Turbocharger Failure Analysis in CTM8.
Excessive Fuel Consumption
Air system restricted
Leakage in fuel system

9010 15 14
Incorrect grade of fuel Operator holding hydraulics over relief. High system relief valve setting
Incorrect injection pump timing
Faulty injection nozzle(s)
Turbocharger Excessively Noisy or Vibrates
Bearings not lubricated
Worn bearings
Air leak in engine, intake or exhaust manifold Improper clearance between turbine wheel and turbine housing
Broken blades on turbine
TX,901015,QQ815 1924JUN9411/12
TM1496 (21SEP05)

092105
PN=114

Symptom Problem
Solution
Oil Dripping From Turbocharger Adapter
Damaged or worn bearings and/or worn seals
Inspect compressor and turbine wheel for damaged blades. Check for proper engine service intervals or dirt entering engine. See Turbocharger Failure Analysis in CTM8. Check for plugged oil drain line. Clean. Remove line. Inspect and clean.
Excessive crankcase pressure
Turbocharger oil return line carbon buildup where line passes exhaust manifold. Excessive Drag In Turbocharger Rotating Members Carbon build-up behind turbine wheel caused by combustion deposits Dirt build-up behind compressor wheel caused by air intake leaks
9010 15 15
Inspect and clean. See Turbocharger Failure Analysis in CTM8.
Inspect and repair. See Turbocharger Failure Analysis in CTM8. Check for plugged air filters.
Bearing seizure or dirty or worn bearings caused by excessive temperature, unbalanced wheel, dirty oil, oil starvation, or insufficient lubrication
TX,901015,QQ815 1924JUN9412/12
TM1496 (21SEP05)

092105
PN=115
9010 15 16
TM1496 (21SEP05)

092105
PN=116
Group 20
Adjustments
JT05801 Clamp-On Electronic Tachometer Installation
SERVICE EQUIPMENT AND TOOLS Tachometer
UN28FEB89 T6813AG
AClamp-On Transducer Remove paint with emery cloth and connect to a straight section of injection line within 100 mm (4 in.) of pump. Finger tighten onlyDO NOT overtighten. BBlack Clip (-). Connect to main frame. CRed Clip (+). Connect to transducer. DTachometer readout. Install Cable.
9010 20 1
10T,9010,K182 1910AUG951/1
TM1496 (21SEP05)

092105
PN=117
Adjustments
Fan Belt Tension Adjustment

SPECIFICATIONS New Belt Deflection Used Belt (Cold) Deflection Adjusting Strap Cap Screw Torque 5/16 in. at 25 lb 7/16 in. at 25 lb 27 3 Nm (20 2 lb-ft)
9010 20 2
IMPORTANT: The alternator belt is considered used after 12 minutes of running. DO NOT overtighten belts. Overtightening may cause belt cord damage or excessively loud alternator bearings.
NOTE: Belt deflection measured using JDST28 Belt Deflection Gauge.

SERVICE EQUIPMENT AND TOOLS JDST28 Belt Deflection Gauge
UN01JUN89
Specification New BeltDeflection.............................................. 5/16 in. at 25 lb Force
A used belt will deflect 7/16 in. at 25 lb force at a point halfway between the pulleys.
Specification Used Belt (Cold)Deflection ................................. 7/16 in. at 25 lb Force
AAlternator Pulley BFan Pulley CCrankshaft Pulley DStraight Edge EBelt Deflection Gauge
2. If belt deflection is not within specifications, loosen alternator mounting cap screws. Apply force only to the front of alternator housing (near the belt) and tighten cap screws.
Specification Adjusting Strap Cap Screw Torque ................................................................. 27 3 Nm (20 2 lb-ft)
3. Check belt tension. If not correct repeat Step 2 until within specifications.
TX,901020,QQ818 1924FEB941/1
TM1496 (21SEP05)

092105
PN=118
T6030AT
1. Check alternator belt deflection using a belt deflection gauge. A new belt will deflect 5/16 in. at 25 lb force at a point halfway between the pulleys.
Adjustments
Adjust Speed Control Lever Tension

SPECIFICATIONS Tension Adjusting Nut Torque 6271 N (1416 lb force) required to move lever using a spring scale
UN11MAY94 T8219CA
Tighten nut (A) until 6271 N (1416 lb force) is required to move lever using a spring scale.
Specification Tension Adjusting NutTorque ..................... 6271 N (1416 lb force) required to move lever using a spring scale
9010 20 3
TX,9010,QQ2722 1924JUN941/1
Engine Speed Control Linkage

SPECIFICATIONS Injection Pump Lever Override (Speed Control Lever in Extreme Forward Position) 46 mm (1/81/4 in.)
1. Move speed control lever to extreme forward position. 2. Measure injection pump lever override. Override must be 46 mm (1/81/4 in.).
Specification Injection Pump LeverOverride (Speed Control Lever in Extreme Forward Position) .................................................. 46 mm (1/81/4 in.)
3. Adjust yoke on speed control rod to provide override. 4. Move speed control lever to rear most position and check override. Override must be at least 1.5 mm minimum. 5. Recheck high idle for a minimum of 2 mm override.
TX,9010,YY511 1908JUN941/2
TM1496 (21SEP05)

092105
PN=119
T6030AU
UN18OCT88
Adjustments
9010 20 4
6. Remove reservoir cowling to adjust foot control pedal. 7. Disconnect yoke (A) from rod (B). Adjust vertical rod (C) length to allow foot control pedal to stop on floor with hand lever in the extreme forward position.
TX,9010,YY511 1908JUN942/2
TM1496 (21SEP05)

092105
T7387AB
UN16DEC91
PN=120
Adjustments
Slow And Fast Idle

SPECIFICATIONS Slow Idle RPM Fast Idle RPM 850 50 2375 50 SERVICE EQUIPMENT AND TOOLS Tachometer Sealing Wire Pliers
UN18OCT88 T6023AD
1. Run engine until it is at normal operating temperature. 2. Install tachometer. See procedure in this group. CAUTION: Take care to avoid rotating fan blades while making injection pump adjustments. 3. Disconnect speed control rod (B) from fuel injection pump lever. 4. Start engine. 5. Hold injection pump lever forward (toward radiator). Check to make sure slow idle is 850 50 rpm.
Specification Slow IdleRPM ........................................................................... 850 50 ALever Stop Screw BSpeed Control Rod CFast Idle Adjusting Screw DSealing Wire ESlow Idle Adjusting Screw
9010 20 5
6. If slow idle is not correct: a. Check air cleaner elements. b. Loosen lock nut and turn screw (A) out one or two turns. c. Loosen lock nut and turn screw (E) to adjust slow idle. d. Turn screw (A) in until rpm starts to increase then turn screw out one full turn. Tighten lock nuts. 7. Hold injection pump lever rearward (away from radiator). Check to make sure fast idle is 2375 50 rpm.
Specification Fast IdleRPM .......................................................................... 2375 50
TX,9010,YY513 1902JUN931/2
TM1496 (21SEP05)

092105
PN=121
Adjustments
8. If fast idle is not correct: a. Remove sealing wire. b. Loosen lock nut and turn screw (C) counterclockwise to increase rpm or clockwise to decrease rpm. c. Tighten lock nut and install a new sealing wire using a seal wire pliers.
9010 20 6
9. Connect rod (B).
TX,9010,YY513 1902JUN932/2
TM1496 (21SEP05)

092105
PN=122
Group 25
Tests
UN28FEB89 T6813AG
AClamp-On Transducer Remove paint with emery cloth and connect to a straight section of injection line within 100 mm (4 in.) of pump. Finger tighten onlyDO NOT overtighten. BBlack Clip (-). Connect to main frame. CRed Clip (+). Connect to transducer. DTachometer readout. Install Cable.
9010 25 1
10T,9010,K182 1910AUG951/1
JT05800 Digital Thermometer Installation

SERVICE EQUIPMENT AND TOOLS Digital Thermometer ATemperature Probe
UN28FEB89
Fasten to a bare metal line using a tie band. Wrap with shop towel. BCable CDigital Thermometer
902525,AA4 1928FEB951/1
TM1496 (21SEP05)

092105
PN=123
T6808CE
Tests
JT07158 TIME TRAC INSTALLATION
ESSENTIAL TOOLS JT07158 TIME TRAC Kit JT07155 9/16-in. In-Line SOI Sensor (Optional) JT07173 SOI Clamp Assembly JT07177 6 mm Clamp-On Transducer (Green) JDG793 Magnetic Pick-Up Adapter JT07171 Magnetic Pick-Up
TIME TRAC is a registered trademark of the Stanadyne Automotive Corp.
T8010AN
UN18MAY93
T8010AM
UN20MAY93
T8010AL
9010 25 2
UN18MAY93
ASOI Sensor BTransducer Clamp CGround DMeter Connection EClamp-On Transducer FInjection Line GGround HMeter Connection IAdapter JMagnetic Probe KMeter Connection
TX,TIMETRAC,300 1920JUN951/2
TM1496 (21SEP05)

092105
PN=124
Tests
Remove paint and clean injection line for installation of clamp-on transducer (E). IMPORTANT: Install clamp-on transducer as close as possible to fuel injection nozzle.
TX,TIMETRAC,300 1920JUN952/2
9010 25 3
TM1496 (21SEP05)

092105
PN=125
Tests
Cooling System
SPECIFICATIONS Cooling System Test Pressure Cooling System Pressure Cap Opening Pressure Vacuum Valve Opening Pressure 69 kPa (0.7 bar) (10 psi) 4352 kPa (0.40.5 bar) (6.2 7.5 psi) 03.5 kPa (00.04 bar) (00.5 psi) 01.0 in Hg)
9010 25 4
Cooling System Pressure Pump
1. Check coolant level. 2. Check belt tension. (See procedure in this group). 3. Check radiator fin condition. Make sure fins are not bent or damaged. 4. Check fan tips and shroud for damage. Fan tip shroud should be equal at top and bottom.
UN25OCT88
5. Check for correct fan installation. 6. Test cooling system for leaks using a cooling system pressure pump (A). Pressurize system to maximum of 69 kPa (0.7 bar) (10 psi).
Specification Cooling SystemTest Pressure ........................ 69 kPa (0.7 bar) (10 psi)
7. Test radiator cap using a cooling system pressure pump. Pressurize radiator cap valve. Valve must start to open at 4352 kPa (0.40.5 bar) (6.27.5 psi).
Specification Cooling System Pressure Cap Opening Pressure ............................................ 4352 kPa (0.40.5 bar) (6.27.5 psi)
8. Vacuum valve must open at 03.5 kPa (00.04 bar) (00.5 psi).
Specification Vacuum ValveOpening Pressure ................................................ 03.5 kPa (00.04 bar) (00.5 psi) 01.0 in Hg)
TX,9010,YY514 1902JUN931/1
TM1496 (21SEP05)

092105
PN=126
T95940
NOTE: Sucker fan has six blades with concave sides away from radiator.
T6487AT
SERVICE EQUIPMENT AND TOOLS
UN24OCT88
Tests
Air Filter Restriction Indicator Switch

SPECIFICATIONS Restriction Indicator Light Must Come On 57.5 kPa (49.874.7 mbar) (2030 in. water) (1.8 0.2 in. Hg) vacuum
UN15OCT90 T7390AR
SERVICE EQUIPMENT AND TOOLS 0150 kPa (015 bar) (060 in. water) Vacuum Gauge Reducer, 1/4 in. x 1/8 in. Pipe Barb Fitting, 1/8 in. Pipe (2 Used) Air Restriction Indicator Tee Fitting, 1/4 in. Pipe
9010 25 5
1. Remove air restriction indicator switch. 2. Install hose nipple, tee fitting and gauge from water vacuum gauge kit into air restriction indicator hole. Install air restriction indicator into tee fitting. 3. Start engine and slowly cover the air cleaner inlet with a piece of paper or cardboard. 4. Yellow warning light and air filter restriction indicator light on monitor panel must come on when gauge is at specified pressure.
Specification Restriction Indicator LightMust Come On .................................................... 57.5 kPa (49.874.7 mbar) (2030 in. water) (1.8 0.2 in. Hg) vacuum
TX,901025,QQ819 1902JUN931/1
TM1496 (21SEP05)

092105
PN=127
Tests
Air Intake System Leakage Test

SPECIFICATIONS Air Intake System Regulated Pressure 13.820.7 kPa (0.130.21 bar) (23 psi)
UN25OCT88
SERVICE EQUIPMENT AND TOOLS JDG51 Adapter Air Regulator With Gauge 9010 25 6
IMPORTANT: Anytime the air intake system is opened it must be tested for leaks before the machine is returned to service. 1. Remove air cleaner cover and main filter element. 2. Put a plastic bag over safety element and install main element and cover. 3. Remove plug from air intake tube and install JDG51 adapter (A). 4. Connect air pressure regulator to adapter using hose and fitting (B). CAUTION: Plastic bag can be sucked into engine if engine is started when trying to close valves. 5. Pressurize air intake system to specifications.
Specification Air Intake SystemRegulated Pressure ................................................. 13.820.7 kPa (0.130.21 bar) (23 psi)
If system cannot be pressurized, turn engine slightly to close valves. Check plastic bag. 6. Spray soap solution over all connections from the air cleaner to the turbocharger or air inlet to check for leaks. Repair all leaks.
TX,901025,QQ816 1928NOV901/1
TM1496 (21SEP05)

092105
PN=128
T92027
UN25OCT88
T92026
Tests
Radiator Air Flow Test

SPECIFICATIONS 410D Engine Speed 510D Engine Speed 410D Suction Fan Actual Voltage Reading 410D Suction Fan Actual Voltage Reading Minus 20% 510D Suction Fan Actual Voltage Reading 510D Suction Fan Actual Voltage Reading Minus 20% 1000 10 rpm 1000 10 rpm 1.49 volts 1.19 volts 1.45 volts 1.16 volts 9010 25 7
SERVICE EQUIPMENT AND TOOLS JT05801 Electronic Tachometer Air Flow Meter Heavy Duty Digital Multimeter or Analog/Digital Multimeter
UN01NOV88
1. Apply parking brake, put transmission in neutral and lower equipment to the ground. Stop engine. 2. Install tachometer. (See procedure in this group.) 3. Check that all sheet metal is in place. Close side shields. 4. Divide the surface of the grille into 16 equal squares. 5. Start engine and run at 1000 10 rpm.
Specification 410D EngineSpeed ......................................................... 1000 10 rpm 510D EngineSpeed ......................................................... 1000 10 rpm AJT05529 Air Flow Meter
6. Connect air flow meter to digital multimeter. Turn switch on multimeter to 20 volts A.C. 7. Place air flow meter in contact with grille. Arrow on meter must point in direction of air flow (toward unit). 8. Record voltage reading for each area.
TX,901025,QQ834 1902JUN931/2
TM1496 (21SEP05)

092105
PN=129
T6080AH
Tests NOTE: Air flow readings minus 20% is a number used as a guideline to determine when a partially plugged radiator and or cooler core may cause overheating.
9. Combined total of air flow test readings must be greater than specifications.
Specification 410D Suction FanActual Voltage Reading .......................................................................... Actual Voltage Reading Minus 20%.............................................................................................. 510D Suction FanActual Voltage Reading .......................................................................... Actual Voltage Reading Minus 20%..............................................................................................
9010 25 8
1.49 volts 1.19 volts 1.45 volts 1.16 volts
If readings are less than specifications remove oil cooler and clean external surfaces of both oil cooler and radiator. Install oil cooler and repeat test. If reading is still low, check for correct fan installation. Be sure sheet metal is in place.
TX,901025,QQ834 1902JUN932/2
TM1496 (21SEP05)

092105
PN=130
Tests
JT05529 Air Flow Meter Test Record

CUSTOMER NAME AND ADDRESS
DATE:
UN20APR89 T6041AL
MACHINE MODEL NO. SERIAL NO.
9010 25 9
PRE-TEST INSPECTION OK SERV REQD Coolant Level Belt Tension Radiator Fin Condition Fan Tip & Shroud Condition AIR FLOW TEST Correct Fan Installation (Sucker Fan) Radiator Cap OK SERV REQD
1. Park brake ON. 2. Transmission in Neutral and side shields closed. 3. Divide the surface of the grille into 16 equal squares. 4. Start engine. 5. Perform air flow test at fast idle. Observe correct air flow direction and place air flow meter in direct contact with grille. (Arrow pointing to grille). 6. Record air flow in each square. 7. Combined total of air flow test readings must be greater than specifications.
TX,9010,YY518 1902JUN931/1
TM1496 (21SEP05)

092105
PN=131
Tests
Turbocharger Boost Pressure-Engine Performance Test310D, 315D

SPECIFICATIONS Engine Normal Operating Temperature Engine Speed Turbocharger Boost Pressure (Using No. 2 Fuel) 9010 25 10 82 10C (180C 20F) Fast Idle 4055 kPa (.04.055 bar) (68 psi)
UN26MAY89
NOTE: Reduce the boost specifications by 7% if using No. 1 fuel.

SERVICE EQUIPMENT AND TOOLS JDE147 Adapter 030 psi Gauge JT05801 Electronic Tachometer JT05800 Digital Thermometer
1. Make test connections. 2. Install tachometer and thermometer. (See procedure in this group.) 3. Apply park brake and put transaxle and reverser in neutral. Run engine until it is at normal operating temperature.
Specification EngineNormal Operating Temperature .................................................... 82 10C (180C 20F)
4. Adjust engine speed to fast idle.

Specification EngineSpeed ............................................................................ Fast Idle
Activate the loader control valve and hold over relief to apply a hydraulic load to engine. The gauge will show a pressure rise and then a pressure drop.
Specification TurbochargerBoost Pressure (Using No. 2 Fuel) ................................ 4055 kPa (.04.055 bar) (68 psi)
5. If boost pressure DOES NOT drop, use the following procedure to apply additional load to engine.
T59,9010,J111 1905MAR931/2
TM1496 (21SEP05)

092105
PN=132
T6225AS
Tests
Lower stabilizers to raise wheels off ground. Put machine in first gear with FNR lever in forward or reverse. Apply brake pressure until boost pressure begins to drop. 6. Record highest boost pressure and RPM it was obtained at. 7. Repeat test several times. 8. If boost pressure is too high, remove and test fuel injection pump for high fuel delivery. 9. If boost pressure is too low, check for the following: Restricted air filter elements. Restricted fuel filter elements. Incorrect fast idle adjustment. Incorrect injection pump timing. Exhaust manifold leaks. Intake manifold leaks. Faulty fuel transfer pump. Low compression pressure. Faulty fuel injection nozzle. Carbon build-up in turbocharger. Turbocharger compressor or turbine wheel rubbing housing. Low fuel injection pump fuel delivery, remove and test fuel injection pump for low fuel delivery.
9010 25 11
T59,9010,J111 1905MAR932/2
TM1496 (21SEP05)

092105
PN=133
Tests
Injection Pump Timing

SPECIFICATIONS 300D, 310D and 315D Engine Models 300D, 310D and 315D Engine Net hp (kW) 300D, 310D and 315D Engine Rated RPM 9010 25 12 300D, 310D and 315D Injection Pump Dynamic Timing at +0 -1 BTDC 4039D and 4039T 67 hp (50 kW) 2200 15.5
UN03NOV97
ESSENTIAL TOOLS JT07158 TIME TRAC Kit
AFront Plate BPump Flange
The JT07158 timing kit electronically indicates start of injection with respect to piston top dead center, and allows setting injection pump timing to provide optimum power, smoke and exhaust emissions. Timing engines with this tool improves consistency between engines and helps to control cylinder firing pressures which can be a factor in head gasket failures as well as improve overall engine efficiencies. 1. Install JT07158 TIME TRAC. See procedure in this group. (Also found on JT07175 Quick Reference Sheet.) 2. Raise rear of machine off the ground with stabilizers. Put transaxle in fourth forward. 3. Operate machine at WOT.
Specification 300D, 310D and 315D Engine Models ........................................................................... 4039D and 4039T Net hp (kW) ......................................................................... 67 hp (50 kW)
Slowly depress service brakes until engine is at 2200 rpm.

Specification 300D, 310D and 315D Engine Rated RPM ......................................................................................... 2200
TIME TRAC is a registered trademark of the Stanadyne Automotive Corp.
TX,9010,QQ2715 1924JUN941/2
TM1496 (21SEP05)

092105
PN=134
RG6293
Tests
4. Record dynamic timing.
Specification 300D, 310D and 315D Injection PumpDynamic Timing at +0 -1 BTDC ................................................................................................... 15.5
5. If timing is not to specification, follow procedure on JT07175 Quick Reference Sheet.

9010 25 13
TX,9010,QQ2715 1924JUN942/2
Injection Pump Static Timing Adjustment

SPECIFICATIONS No. 1 Cylinder Position Line on Governor Weight Retainer Alignment At TDC on compression stroke With line on cam ring
ESSENTIAL TOOLS JDE811 Flywheel Turning Tool JDE814 Timing Pin
T59,9010,C111 1925MAR861/3
1. Install flywheel turning tool (A). Rotate flywheel in engine running direction until pin (B) goes into hole in flywheel. 2. Remove timing hole cover from fuel injection pump.
UN29MAR90
T59,9010,C111 1925MAR862/3
TM1496 (21SEP05)

092105
PN=135
T6024AP
Tests
3. If timing line (C) on weight retainer cannot be seen, turn engine one revolution to get No. 1 cylinder at TDC on compression stroke.
Specification No. 1 CylinderPosition .......................... At TDC on compression stroke Line on Governor Weight RetainerAlignment................................................. With line on cam ring
9010 25 14
4. To avoid backlash, always approach the timing lines by turning engine in direction of rotation. The normal backlash of gears is enough to throw the pump timing off several degrees, resulting in poor engine performance. 5. If lines are not aligned, loosen pump mounting flange retaining nuts and rotate pump housing until timing lines are aligned.
T59,9010,C111 1925MAR863/3
TM1496 (21SEP05)

092105
PN=136
T6193AA1
UN25MAY89
Section 9015
Electrical System
Contents
Page Page
Group 05System Information Visually Inspect Electrical System . . . . . . . . .9015-05-1 Electrical Circuit Malfunctions . . . . . . . . . . . .9015-05-2 High Resistance Circuit . . . . . . . . . . . . . . . . .9015-05-3 Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-4 Grounded Circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-6 Shorted Circuit . . . . . . . . . . . . . . . . . . . . . . .9015-05-8 Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-9 Seven Step Electrical Test Procedure . . . . .9015-05-10 Wiring Diagram And Schematic Information. . . . . . . . . . . . . . . . . . . . . . . .9015-05-12 Reading A System Functional Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-05-13 Reading A Wiring Diagram . . . . . . . . . . . . .9015-05-14 Electrical Schematic Symbols . . . . . . . . . . .9015-05-15 Group 10System Diagrams Component Identification Table . . . . . . . . . . .9015-10-1 Fuse Specifications . . . . . . . . . . . . . . . . . . . .9015-10-3 Wiring And Schematic Diagrams Legend . . .9015-10-4 System Functional Schematic . . . . . . . . . . .9015-10-10 Cab Roof Harness (W5) Wiring Diagram. . .9015-10-18 Cab Roof Harness (W5) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-19 Cab Side Console Harness (W6) Wiring Diagram (S.N. 778668) . . . . . . . . . . . .9015-10-20 Cab Side Console Harness (W6) Component Location (S.N. 778668) . . .9015-10-21 Cab Floor Harness (W6) Wiring Diagram (S.N. 778668). . . . . . . . . . . . . . . . . . . .9015-10-22 Cab Floor Harness (W6) Component Location (S.N. 778668) . . . . . . . . . . . .9015-10-23 Cab Side Console Harness (W6) Wiring Diagram (S.N. 778669XXXXXX). . . . . .9015-10-24 Cab Side Console Harness (W6) Wiring Diagram (S.N. XXXXXX ) . . . . . . . . . . .9015-10-26 Cab Side Console Harness (W6) Component Location (S.N. 778669 ) . .9015-10-28 Front Console Harness (W7) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-30 Front Console Harness (W7) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-31 Engine Harness (W8) Wiring Diagram. . . . .9015-10-32 Engine Harness (W8) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-34 TM1496 (21SEP05)
Blower Harness (W10) Wiring Diagram . . . .9015-10-35 Blower Harness (W10) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-36 Radio Harness (W12) Wiring Diagram. . . . .9015-10-37 Radio Harness (W12) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-38 Air Conditioning Compressor Harness (W11) Wiring Diagram . . . . . . . . . . . . . . . . . . . .9015-10-39 Air Conditioning Compressor Harness (W11) Component Location . . . . . . . . . . . . . . . .9015-10-40 Auxiliary Valve Harness (W14) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-41 Auxiliary Valve Harness (W14) Component Location . . . . . . . . . . . . . . . .9015-10-42 Group 15Sub-System Diagnostics Power Circuit Operational Information . . . . . .9015-15-1 Power Circuit Theory Of Operation . . . . . . . .9015-15-1 Power Circuit Schematic . . . . . . . . . . . . . . . .9015-15-2 Power Circuit Diagnostic Procedures . . . . . .9015-15-5 Start Circuit Operational Information . . . . . . .9015-15-8 Start Circuit Theory Of Operation . . . . . . . . .9015-15-9 Start Circuit Schematic . . . . . . . . . . . . . . . .9015-15-10 Start Circuit Diagnostic Procedures . . . . . . .9015-15-12 Charging Circuit Operational Information . . .9015-15-15 Charging Circuit Theory Of Operation . . . . .9015-15-15 Charge Circuit Schematic . . . . . . . . . . . . . .9015-15-16 Charging Circuit Diagnostic Procedures . . .9015-15-21 Display Module And Logic Module Circuit Operational Information (S.N. XXXXXX) With Logic Module . . . . . . . . . .9015-15-24 Display Module And Logic Module Circuit Theory Of Operation (S.N. XXXXXX) With Logic Module . . . . . . . . . . . . . . . . . .9015-15-25 Display Module And Logic Module Circuit Operational Information (S.N. XXXXXX ) Without Logic Module . . . . .9015-15-26 Display Module Circuit Theory Of Operation (S.N. XXXXXX ) Without Logic Module. . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-27 Display Module And Logic Module Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-29 Display Module And Logic Module Circuit Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-32
9015

092105
PN=1
Contents
Page
Page
9015
Logic Module (S.N. XXXXXX) . . . . . . . . .9015-15-32 Indicator Circuit Specifications. . . . . . . . . . .9015-15-32 Indicator Circuit Operational Information . . .9015-15-33 Indicator Circuit Theory Of Operation (S.N. XXXXXX) With Logic Module . . . . . . . .9015-15-34 Indicator Circuit Theory Of Operation (S.N.XXXXXX ) Without Logic Module. . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-35 Indicator Circuit Schematic . . . . . . . . . . . . .9015-15-36 Indicator Circuit Diagnostic Procedures . . . .9015-15-40 MFWD Circuit Operational Information . . . .9015-15-44 MFWD Circuit Theory Of Operation. . . . . . .9015-15-44 MFWD Circuit Schematic . . . . . . . . . . . . . .9015-15-45 MFWD Circuit Diagnostic Procedures . . . . .9015-15-46 Start Aid Circuit Operational Information . . .9015-15-47 Start Aid Circuit Theory Of Operation . . . . .9015-15-48 Start Aid Circuit Schematic . . . . . . . . . . . . .9015-15-49 Start Aid Circuit Diagnostic Procedures. . . .9015-15-51 Fuel Shut-Off Circuit Operational Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-53 Fuel Shut-Off Circuit Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-54 Fuel Shut-Off Circuit Schematic . . . . . . . . .9015-15-55 Fuel Shut-Off Circuit Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-56 Reverse Alarm Circuit Specifications Cab (S.N. 794216) ROPS (S.N. 794259) . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-56 Reverse Alarm Circuit Operational Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-56 Reverse Alarm Circuit Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-57 Reverse Alarm Circuit Schematic . . . . . . . .9015-15-58 Reverse Alarm Circuit Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-60 Dome Light Circuit Operational Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-62 Dome Light Circuit Theory Of Operation . . .9015-15-62 Dome Light Circuit Schematic . . . . . . . . . . .9015-15-63 Dome Light Circuit Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-64 Radio Circuit Operational Information . . . . .9015-15-64 Radio Circuit Theory Of Operation . . . . . . .9015-15-65 Radio Circuit Schematic . . . . . . . . . . . . . . .9015-15-66 Radio Circuit Diagnostic Procedures . . . . . .9015-15-67 Wiper/Washer Circuit Operational Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-68 Wiper/Washer Circuit Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-68 Wiper/Washer Circuit Schematic . . . . . . . . .9015-15-69 Wiper/Washer Circuit Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-70 Blower Circuit Operational Information . . . .9015-15-72 TM1496 (21SEP05)
Blower Circuit Theory Of Operation. . . . . . .9015-15-72 Blower Circuit Schematic. . . . . . . . . . . . . . .9015-15-73 Blower Circuit Diagnostic Procedures . . . . .9015-15-74 Drive And Work Light Circuit Operational Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-75 Drive And Work Light Circuit Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-75 Drive And Work Light Circuit Schematic . . .9015-15-76 Drive And Work Light Circuit Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-77 Park Brake/Clutch Disconnect Circuit Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-78 Park Brake/Clutch Disconnect Circuit Operational Information . . . . . . . . . . . . . .9015-15-78 Park Brake/Clutch Disconnect Circuit Theory Of Operation . . . . . . . . . . . . . . . . . . . . . .9015-15-79 Park Brake/Clutch Disconnect Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-80 Park Brake/Neutral Disconnect Circuit Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-83 Horn Circuit Operational Information . . . . . .9015-15-88 Horn Circuit Theory Of Operation . . . . . . . .9015-15-88 Horn Circuit Schematic . . . . . . . . . . . . . . . .9015-15-89 Horn Circuit Diagnostic Procedures. . . . . . .9015-15-90 Turn Signal, Flasher And Brake Light Circuit Operational Information . . . . . . . . . . . . . .9015-15-90 Turn Signal, Flasher And Brake Light Circuit Theory Of Operation . . . . . . . . . . .9015-15-91 Turn Signal, Flasher And Brake Light Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-93 Turn Signal, Flasher And Brake Light Circuit Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-94 Beacon Circuit Operational Information . . . .9015-15-96 Beacon Circuit Theory Of Operation . . . . . .9015-15-97 Beacon Circuit Schematic . . . . . . . . . . . . . .9015-15-98 Beacon Circuit Diagnostic Procedures. . . . .9015-15-99 Return-To-Dig Circuit Operational Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-99 Return-To-Dig Circuit Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . 9015-15-100 Return-To-Dig Circuit Schematic . . . . . . . . 9015-15-101 Return-To-Dig Circuit Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . 9015-15-103 Fuel Gauge And Hour Meter Circuit Specifications. . . . . . . . . . . . . . . . . . . . . 9015-15-104 Fuel Gauge And Hour Meter Circuit Operational Information . . . . . . . . . . . . . 9015-15-104 Fuel Gauge And Hour Meter Circuit Theory Of Operation . . . . . . . . . . . . . . . . . . . . . 9015-15-105 Fuel Gauge And Hour Meter Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . 9015-15-106

092105
PN=2
Contents
Page
Fuel Gauge And Hour Meter Circuit Diagnostic Procedures . . . . . . . . . . . . . . 9015-15-108 Side Shift Locking Valve Circuit Operational Information315D. . . . . . . . . . . . . . . . . 9015-15-110 Side Shift Locking Valve Circuit Theory Of Operation315D . . . . . . . . . . . . . . . . . . 9015-15-110 Side Shift Locking Valve Circuit Schematic315D . . . . . . . . . . . . . . . . . 9015-15-111 Side Shift Locking Valve Circuit Diagnostic Procedures315D . . . . . . . . . . . . . . . . 9015-15-112 Auxiliary Valve Circuit Operational Information. . . . . . . . . . . . . . . . . . . . . . . 9015-15-112 Auxiliary Valve Circuit Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . 9015-15-113 Auxiliary Valve Circuit Schematic . . . . . . . 9015-15-114 Auxiliary Valve Diagnostic Procedures . . . 9015-15-115 Group 20References Alternators And Starting MotorsUse CTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1 JT05801 Clamp-On Electronic Tachometer Installation . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1 Battery Operation . . . . . . . . . . . . . . . . . . . . .9015-20-2 Battery Specifications . . . . . . . . . . . . . . . . . .9015-20-3 Diagnose Battery Malfunctions . . . . . . . . . . .9015-20-4 Check Battery Electrolyte Level And Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-5 Procedure For Testing Batteries . . . . . . . . . .9015-20-7 Using Booster Batteries12 Volt System . . .9015-20-9 Alternator Operation78 Amp Delco Remy (Serial No.787513) . . . . . . . . . . .9015-20-10 Alternator Operation95 Amp Bosch (Serial No. 787514 ) . . . . . . . . . . . . . . .9015-20-11 Alternator Operation95 Amp Bosch . . . . .9015-20-12 Monitor Test In Machine . . . . . . . . . . . . . . .9015-20-14 Logic Module Test In Machine (S.N. XXXXXX) . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-15 Logic Module Bench Test (S.N. XXXXXX) . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-17 Tachometer Calibration . . . . . . . . . . . . . . . .9015-20-18
9015
TM1496 (21SEP05)

092105
PN=3
Contents
9015
TM1496 (21SEP05)

092105
PN=4
Group 05
System Information
Visually Inspect Electrical System
Make the following visual electrical inspection prior to starting the tractor after receiving customer complaint: 1. Look for bare wires that could ground a component or short across to another component. 2. Look for missing or worn conduit. This could indicate a wire problem. 3. Look for loose or broken connectors and wires. 4. Inspect batteries for: Corroded terminals Loose terminals or battery posts Dirty condition Damp condition Cracked case Proper electrolyte level
9015 05 1
5. Check alternator belt tension. 6. After machine has been shut down for five minutes inspect for overheated parts. They will often smell like burned insulation. Put your hand on the alternator. Heat in these parts when the unit has not been operated for some time is a sure clue to charging circuit problems. 7. If your visual inspection does not indicate the possible malfunction, but your inspection does indicate that the machine can be run, turn the key switch to the IGN position. Try out the accessory circuits, indicator lights, gauge lights. How does each of these components work? Look for sparks or smoke which might indicate shorts. 8. Start machine. Check all gauges for good operation and check to see if system is charging or discharging. 9. In general, look for anything unusual. Many electrical failures cannot be detected even if the machine is started. Therefore, a systematic and complete inspection of the electrical system is necessary.
TX,901505,QQ369 1907FEB961/1
TM1496 (21SEP05)

092105
PN=139
System Information
Electrical Circuit Malfunctions
9015 05 2
ABattery BFuse
CSwitch
DLight
EGround
There are four common circuit malfunctions. High-Resistance Circuit Open Circuit Grounded Circuit Shorted Circuit
After the component. Component malfunctions can easily be confused with circuit malfunctions. Therefore, care must be exercised when isolating the cause of a problem. Example: Light does not operate or is dim when switch is turned ON, until switch connector is disconnected and reconnected. Reason: High resistance caused by a dirty switch connector, caused a voltage drop which prevented the proper amount of current from flowing to the light.
Three sections in a simple circuit where these malfunctions can occur; Before the controlling switch (C). Between the controlling switch and before the component, light (D).
TX,9015,DY357 1931MAY961/1
TM1496 (21SEP05)

092105
PN=140
T7713AD
1927FEB92
System Information
High Resistance Circuit
9015 05 3
ABattery BFuse CSwitch
DSwitch Terminal EHigh Resistance
FHarness Connector GLight Terminal
HLight IGround
A high resistance circuit can result in slow, dim or no component operation. Examples: Loose, corroded, dirty or oily terminals. Wire size too small strands broken inside the wire. Poor ground connection to frame. To locate the cause of high resistance: With switch (C) ON, check for battery voltage between switch and ground (I) at an easily accessible location, like harness connector (F). If less than battery voltage is measured, check again closer to switch.
If battery voltage is measured, check closer to ground to locate point of voltage drop. The example shows high resistance (E) between switch and harness connector. Repair circuit as required. In the example, strands were broken inside the wire, replace that section of wire. Repeat check-out procedure after repair.
TX,901505,RP968 1910AUG951/1
TM1496 (21SEP05)

092105
PN=141
T7713AG
1926FEB92
System Information
Open Circuit
9015 05 4
ABattery BFuse CSwitch
DSwitch Terminal EHarness Connector
FOpen Circuit GLight Terminal
HLight IGround
An open circuit will result in no components operating. Fuse may or may not be blown. Example: Broken wire, disconnected component terminal, pins inside a connector not making contact, blown fuse, open circuit breaker, failed switch or component, or a disconnected ground wire. To locate an open circuit: Check fuse. If blown, replace and operate circuit. If fuse blows a second time, continue check. With switch (C) ON check for battery voltage at switch terminal (D). If no voltage is measured, check switch, fuse and wiring to battery.
If battery voltage is measured, check for voltage closer to ground at harness connector (E). If no voltage is measured, wire may be broken between switch and connector. If battery voltage is measured, inspect connector pins. If pins are OK check for voltage at light terminal (G). In the example, zero voltage will be measured at light terminal, indicating a broken wire between harness connector and light terminal. If battery voltage had been measured, the next check for voltage would be at ground connection (I). Normal measured voltage at a ground connection should be 0.0 to 0.5 volts.
TX,901505,RP964 1910AUG951/2
TM1496 (21SEP05)

092105
PN=142
T7713AF
1927FEB92
System Information
If battery voltage is measured, poor connection to frame or broken wire is indicated. When problem is located, repair as needed then repeat last check.
TX,901505,RP964 1910AUG952/2
9015 05 5
TM1496 (21SEP05)

092105
PN=143
System Information
Grounded Circuit
9015 05 6
ABattery BFuse CFuse Terminal
DSwitch ESwitch Terminal FHarness Connector
GHarness Connector HGrounded Circuit ILight (Component) Terminal
JLight KGround
If no component operates, the fuse is blown and replacement fuses blow immediately or the circuit breaker is open and reopens when reset, a grounded circuit exists. (Example: power wire contacting frame or other metal component). A wire may be pinched or insulation may be worn from a wire. To isolate the location of a grounded circuit: If circuit is grounded between battery and fuse, wire will be burned and circuit will be open, fuse will not be blown. If fuse is blown, remove fuse from circuit, disconnect circuit near its center, such as harness connector (F), turn switch (D) ON, check for continuity to ground at
harness connector (F). This will check harness from harness connector to fuse. If continuity to ground is measured, there is a pinched or bare wire between fuse (C) and harness connector (F). If continuity to ground does not exist, disconnect ground (K) from frame. Measure continuity to ground at harness connector (G). This checks harness from harness connector to ground terminal. In the example continuity to ground will exist because circuit is grounded (wire is pinched) at (H).
TX,901505,RP969 1910AUG951/2
TM1496 (21SEP05)

092105
PN=144
T7713AE
1927FEB92
System Information
If continuity exists, disconnect circuit at light terminal (I) and measure continuity to ground on light terminal. This checks harness from light to ground terminal. In the example continuity will not exist, indicating a grounded circuit between the light and harness connector (G). Repeat check-out procedure after repair.
TX,901505,RP969 1910AUG952/2
9015 05 7
TM1496 (21SEP05)

092105
PN=145
System Information
Shorted Circuit
9015 05 8
ABattery BFuse CFuse DSwitch
ESwitch Terminal FSwitch GHarness Connector HShorted Circuit
IHarness Connector JLight KLight Terminal
LLight MGround NGround
A shorted circuit causes components in separate circuits to operate when a switch in either circuit is turned ON. (Example: two harnesses rubbing together until insulation is worn through allowing bare wires to touch). Components can also become shorted. However, shorted components will usually blow the fuse. To locate a shorted circuit: 1. Turn Switch (F) ON then OFF, turn switch (D) ON then OFF, both lights (J and L) will be ON when either switch (D or F) is ON. 2. Turn switch (F) ON. Both lights (J and L) will be ON, only light (L) should be ON.
3. Disconnect wire from switch of component that should not be ON. In the example, disconnect wire from terminal (E) at switch (D). Light (J) remains ON. 4. Disconnect circuit at convenient places like harness connectors (G), (I) and light terminal (K) until light (J) goes OFF. The short circuit will be between the last two places the circuit was disconnected. In the example, it is between harness connectors (G and I). Light (J) will go OFF when harness connector (I) is disconnected. Inspect harness between connectors (G and I).
TX,901505,RP970 1910AUG951/2
TM1496 (21SEP05)

092105
PN=146
T7713AH
1927FEB92
System Information
Repair or replace wires and harnesses as needed. Install tie bands and clamps on harnesses as required to prevent future failures. Repeat check-out procedure after repair.
TX,901505,RP970 1910AUG952/2
Multimeter
The multimeter is an autoranging digital display that allows very accurate readings to be taken.
9015 05 9
TX,901505,QQ374 1910AUG951/1
TM1496 (21SEP05)

092105
PN=147
T7199AI
1917JAN90
System Information
Seven Step Electrical Test Procedure
9015 05 10
ABattery Ground BBattery CBattery Side Of Fuse Or Circuit Breaker
DFuse Or Circuit Breaker EComponent Side Of Fuse Or Circuit Breaker FSwitch
GBattery Side Of Component Terminal HLight (Component)
IGround Side Of Component Terminal JComponent Ground
TX,9015,QQ1697 1910AUG951/2
TM1496 (21SEP05)

092105
PN=148
T7719AA
1905MAR92
System Information
Step 1Switch ON Check battery side of circuit breaker (C) for battery voltage Battery voltage normal. Go to Step 2. Low voltage, repair high resistance. Open circuit from battery. Step 2Switch OFF Check component side of circuit breaker for battery voltage Battery voltage normal. Go to Step 4. Low voltage, repair high resistance. No voltage. Go to Step 3. 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. Low voltage, repair high resistance. No voltage. Go to Step 5. Step 5aDisconnect wire at battery side of component (G). Switch ON. Check wire at (G) for battery voltage Battery voltage, repair component. 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. No voltage, repair high resistance or open circuit between fuse and 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.
a
9015 05 11
A multimeter will not apply a load to the circuit at step 5. The multimeter result is tested as a voltage condition in the result column.
TX,9015,QQ1697 1910AUG952/2
TM1496 (21SEP05)

092105
PN=149
System Information
Wiring Diagram And Schematic Information

System Functional Schematic Diagram The System Functional Schematic is a schematic diagram of the complete machine. All harnesses are identified by letter/number designation and description (W1 Engine Harness, W2 Dash Harness Etc.). Each wire is identified by number and/or color (G01 BLK, R02 Red, RED/WHT, BLU/GRN Etc.). All components are identified by letter/number designation, description and are represented by a schematic symbol. Component letter/number designation, (K1 Start Relay, S1 Key Switch, B9 Horn, Etc.) will indicate that component throughout the manual. The System Functional Schematic Diagram is divided into Sections. Each section contains one or more electrical circuits. Each section is indicated by a number and circuit (SE1 CHARGING CIRCUIT, SE2 STARTING CIRCUIT Etc). Wiring Diagram The Wiring Diagram shows each wiring harness, wire 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.). 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.
9015 05 12
TX,9015,DY360 19 3JUN961/1
TM1496 (21SEP05)

092105
PN=150
System Information
Reading A System Functional Schematic
9015 05 13
APower Wires BContinuity Chart CComponent Schematic Symbol
DComponent Identification Code
EComponent Name FGround Wires
GCircuit Name HSection Number
The System Functional Schematic is made up of sections which contain one or more Subsystem Functional Schematic laid out side by side in a logical sequence of related functions. Each Subsystem is a major group of components like starting components or charging components (H). Sections are named to reflect that group of components (G). The System Functional Schematic is formatted with power supply wires (A) shown across the top of the drawing and ground wires (F) across the bottom. The diagram contains no harness or connector information. Each electrical component is shown by a schematic symbol (C), the component name (E), and a
component identification code (D). A continuity chart (B) is included for each multi-terminal switch. The same names and identification letter codes are used on all machine drawingsthe System Functional Schematic, System Wiring and Harness Diagram, and the System Component Location Drawing. Components and connectors can easily be cross-referenced from one drawing to another. See Group -10 for Component Identification Legend.
TX,9015,RP751 1912APR941/1
TM1496 (21SEP05)

092105
PN=151
T7502CE
1929MAY91
System Information
Reading A Wiring Diagram
9015 05 14
AHarness Connector Letter/Number Identification BComponent Letter/Number Identification CComponent Connector Pin Number or Letter
DComponent Connector EWire Number and/or Color FComponent(s) Identification Number/Letter Wire is Routed To
GHarness Identification Letter/Number and Description HWiring Harness IComponent(s) Identification Number/Letter Wire is Routed To
JWire Number and/or Color KHarness Connector Pin Number or Letter
Each harness on the machine is drawn showing components, connectors and wires. Harnesses (G) are identified by a letter/number designation and description, (W3 PARK BRAKE HARNESS Etc.). Each component (B) is represented by a schematic symbol and is identified by the same letter/number designation and description used in the System Functional Schematic. Components with integral connectors (D) have pin number/letters indicated (C). Wires from harness to components are identified by letter/number designation (E). Component identification letter/number (F) indicates component wire is routed to.
Main harness connectors (A) are identified by a letter/number designation and description, (X2 PARK BRAKE HARNESS TO DASH HARNESS CONNECTOR Etc.). Harness connector description indicates which harnesses connect together. Connector pin numbers or letters (K) are indicated as they are marked on the connector. Wires attached to each connector pin are identified by number and/or color designation (J). Component identification number/letter (I) indicates destination of each wire. Harness, harness connector and component identification letter/numbers and description are the same as used on the System Functional Schematic.
TX,9015,RP971 1931AUG951/1
TM1496 (21SEP05)

092105
PN=152
T8534AC
1910AUG95
System Information
Electrical Schematic Symbols
9015 05 15
TX,901505,QQ378 1910AUG951/2
TM1496 (21SEP05)

092105
PN=153
T7186AA
1930OCT90
System Information
9015 05 16
TX,901505,QQ378 1910AUG952/2
TM1496 (21SEP05)

092105
PN=154
T7186AB
1930OCT90
Group 10
System Diagrams
Component Identification Table
Each component (electrical device) and main connector will have and identification letter assigned to it. A number is added to the letter to separate and indicate the total components within that letter group.
Identification Letter Type A B Examples System, subassembly, parts group Transducer for conversion of non-electrical variables to electrical and vice versa Control units, trigger boxes, two-way radios, logic module, FNR logic module Speed sensors, pressure sensors, pressure switches horns, sensors, pickups, limit-value sensors, pulse generators, loudspeakers, inductive pickups, probes, air-flow sensors, oil-pressure switches, temperature sensors, ignition-voltage pickups Condensers and capacitors, general Digital devices, integrated circuits, pulse counters, magnetic tape recorders Heating devices, air conditioners, light, headlights, spark plugs, ignition distributors Release mechanisms, polarity protection devices, fuses, current protection circuits Batteries, generators, alternators, charging units Audible alarms, indicator lights, turn-signal lights, brake lights, alarms, warning lights, buzzers Battery relays, turn-signal relays, solenoid switches, starting relays, warning flashers Choke coils, coils, windings Blower motors, fan motors, starter motors Regulators (electronic or electromechanical), voltage stabilizers Ammeter, diagnostic connectors, tachometers, fuel gauge, pressure gauges, measuring points, test points, speedometers 9015 10 1
C D E F G H K L M N P
Condenser, capacitor Binary device, memory Various devices and equipment Protection device Power supply, generator Monitor, alarm, signalling device Relay Inductor Motor Regulator, amplifier Measuring instrument
TX,901505,QQ381 1916SEP921/2
TM1496 (21SEP05)

092105
PN=155
System Diagrams
R Resistor Flame glow plugs, sheathed-element flame glow plugs, glow plugs, heating resistors, NTC resistors, PTC resistors, potentiometers, regulating resistors Switches and pushbuttons, general key switch, light switch, horn switch, flasher switch Ignition coil, ignition transformer DC transformers Transistors, diodes, electron tubes, rectifiers, semiconductors, thyristors, zener diodes Antennas, shielding components, shielded conductors, cable harnesses, conductors, ground conductors Terminal studs, electrical connections, connectors electrical line couplers, line connectors, sockets, plugs, terminals, plug-and-socket connections Permanent magnets, (solenoid-operated) injection valves, electromagnetic clutches and brakes, air valves, fuel pumps, solenoids, switching valves, start valves, locking systems Interference suppression filters
Switch
T U V W
Transformer Modulator, converter Semiconductor, electron tubes Transmission path, conductor, antenna
X 9015 10 2
Terminal, plug, plug and socket connection
Electrically actuated mechanical device
Electrical filter
TX,901505,QQ381 1916SEP922/2
TM1496 (21SEP05)

092105
PN=156
System Diagrams
Fuse Specifications
9015 10 3
F17.5 Amp MFWD/Alternator/Diff Lock Fuse F215 Amp Fuel/Ether Aid and Reverse Alarm Fuse F35 Amp Dome Light/Radio Fuse F45 Amp Radio Fuse (Unswitched Power) F515 Amp Wiper Fuse
F630 Amp Heater/AC Circuit Breaker F715 Amp Rear Light Fuse F825 Amp Front Light/Tail Light Fuse F910 Amp FNR/Park Brake Fuse F1020 Amp Turn/Stop and Horn Fuse F117.5 Amp Left Turn Fuse
F127.5 Amp Right Turn Fuse F1310 Amp RTD/Beacon Fuse F145 Amp Monitor/Gauge Fuse F1515 Amp Hazard/Monitor Fuse (Unswitched Power) F1610 Amp Start Fuse K3Park Light Relay
K4Ether Aid Relay CAB (S.N. 794216) ROPS (SN794259) Backup Alarm Relay CAB (S.N.794217 ) ROPS (SN794260 ) K5Park Brake Relay K6Neutral Relay K7Alternator Sense Relay S21Flasher
IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload.
The fuse block is located on the side console inside an access cover.
TX,9015,QQ2719 1931AUG951/1
TM1496 (21SEP05)

092105
PN=157
T8240AP
1931MAY94
System Diagrams
Wiring And Schematic Diagrams Legend

NOTE: A2Radio (SE3, W12)
A2 indicates component identification number. Radio indicates component name. SE3 indicates section number of SYSTEM FUNCTIONAL SCHEMATIC where component is located. W12 indicates HARNESS WIRING DIAGRAM and HARNESS COMPONENT LOCATION drawings where component is located.
V1MFWD Solenoid Diode (SE2,W8)

9015 10 4
V1 indicates component identification number. MFWD Solenoid Diode indicates component name. SE1 indicates section number of SYSTEM FUNCTIONAL SCHEMATIC where component is located. W8 indicates HARNESS WIRING DIAGRAM and HARNESS COMPONENT LOCATION drawings where component is located. A2Radio (SE3,W12) B1Backup Warning Alarm (SE5,W8) B2Park Brake Sensing Switch (SE9,W8) B3Horn (SE12,W8) B4Fuel Sender (SE15,W8) B5Engine Coolant Temp. Switch (SE17,W8) B6Engine Oil Pressure Switch (SE17,W8) B7Air Filter Restriction Switch (SE17,W8) B8Converter Temperature Switch (SE17,W8) B9Hydraulic Filter Switch (SE17,W8) B10Reverse Alarm Switch (SE9,W8) (SN794216) B11Brake Light Switches (SE13,W6) B12Reverser Pressure Switch (SN778668) (SE9,W8) B13Radio Speaker (W12) B14Radio Speaker (W13) E1Dome Light (SE3,W5) E2Swivel Light (SE3,W5) E3Left Front Work Light (SE8,W5) E4Right Front Work Light (SE8,W5) E5Left Rear Work Light (SE8,W5)
TX,9015,QQ3060 1931AUG951/6
TM1496 (21SEP05)

092105
PN=158
System Diagrams
E6Right Rear Work Light (SE8,W5) E7Left Front Drive Light (SE8,W5) E8Right Front Drive Light (SE8,W5) E9Left Tail Light (SE8,W5) E10Right Tail Light (SE8,W5) E11Left Brake Light (SE13,W5) E12Right Brake Light (SE13,W5) E13Beacon Light (SE14,W5) E14Fuel Gauge Light (SE15,W8) E15Seat Belt Light (SE9,W6) (SN789401 ) F1MFWD/ALT Fuse (SE2,W6) F2Fuel Shutoff/Start Aid/Reverse Alarm Fuse (SE5,W6) F3Dome Light Fuse (SE3,W6) F4Radio Fuse (Unswitched Power) (SE3,W6) F5Windshield Wiper/Washer Fuse (SE6,W6) F6Heater Circuit Breaker (SE5,W6) F7Rear Work Light Fuse (SE7,W6) F8Front Work Light/Tail Light Fuse (SE8,W6) F9FNR/Park Brake Fuse (SE9,W6) F10Turn/Stop/Horn Fuse (SE12,W6) F11Left Turn Light Fuse (SE13,W6) F12Right Turn Light Fuse (SE13,W6) F13Return-To-Dig/Beacon Fuse (SE14,W6) F14Monitor Fuse (SE15,W6) F15Hazard/Monitor Fuse (Unswitched Power) (SE16,W6) F16Start Fuse (SE11,W6) F17Fuse Block (W6) G1Battery (SE1,W8) G2Alternator (SE1,W8) H1Left Indicator Turn Light (SE13,W7) H2Left Front Turn Light (SE13,W5) H3Left Rear Turn Light (SE13,W5) H4Right Front Turn Light (SE13,W5) H5Right Rear Turn Light (SE13,W5) H6Right Indicator Turn Light (SE13,W7) H7Logic Module (SE16,W6) (SNXXXXXX) H8Display Module (SE16,W6) H9Red Warning Light (SE17,W6) H10Yellow Warning Light (SE17,W6) H11Alarm (SE17,W6) K1Start Relay (SE1,W8) K2Accessory Relay (SE1,W6) K3Park Light Relay (SE9,W6) K4Ether Aid Relay (SE4,W6) (SN794216)
9015 10 5
TX,9015,QQ3060 1931AUG952/6
TM1496 (21SEP05)

092105
PN=159
System Diagrams
K4Backup Alarm Relay (SE4,W6 (SN794217) K5Park Brake Latching Relay (SE9,W6) K6Neutral Start Relay (SE9,W6) K7Alternator Relay (SE16,W6) K8Auxiliary Valve Relay (W14) M1Starter Motor (SE1,W8) M2Rear Wiper Motor (SE6,W5) M3Left Hand Door Wiper Motor (SE6,W5) M4Right Hand Door Wiper Motor (SE6,W5) M5Washer Motor (SE6,W8) M6Heater Blower Motor (SE5,W6) M7Heater Blower Motor (SE5,W6) P1Fuel Gauge (SE15,W6) P2Tachometer (SE15,W6) P3Hour Meter (SE15,W6) R1Heater Motor Resistor (SE5,W6) S1Key Switch (SE2,W6) S2MFWD Switch (SE2,W6) S3MFWD Indicator Switch (SE2,W8) S4Start Aid Switch (SE5,W6) S5Front Wiper Switch (SE6,W7) S6Rear Wiper Switch (SE6,W6) S7Windshield Washer Switch (SE6,W6) S8Blower Switch (SE5,W6) S9Front Light Switch (SE8,W7) S10Rear Light Switch (SE7,W6) S11FNR Switch (SE9,W7) S12Park Brake Dash Switch (SE9,W6) S13Loader Lever Switch (SE8,W6) S14Gear Shift Lever Switch (SE8,W6) S15Horn Switch (SE12,W6) S16Turn Signal Switch (SE13,W7) S174-Way Flasher Switch (SE13,W7) S18Beacon Switch (Optional) (SE14,W6) S19Not Used S20Return-To-Dig Switch (SE14,W8) S21Flasher (SE13,W6) S22Heater Temperature Switch (W6) S23Low Pressure Switch (W11) S24High Pressure Switch (W11) S25A/C Switch (If Equipped) (W6) S26Clutch Cycle Switch (W10) S27Dome Light Switch (SE3,W5) S28Swivel Light Switch (SE3,W5) S29Auxiliary Valve Switch (W14) S30Auxiliary Valve Foot Switch (W14)
9015 10 6
TX,9015,QQ3060 1931AUG953/6
TM1496 (21SEP05)

092105
PN=160
System Diagrams
V1MFWD Solenoid Diode (SE2,W8) V2Park Brake Solenoid Diode (SE9,W8) V3Reverse Solenoid Diode (SE9,W8) V4Forward Solenoid Diode (SE9,W8) V5Clutch Disconnect Solenoid Diode (SE9,W8) V64-Way Flasher Switch Diode (SE13,W7) V74-Way Flasher Switch Diode (SE13,W7) V8Logic Module/Display Module Diode (SE15,W6) V9Alternator Diode (SE1,W8) V10Auxiliary Valve Diode (W14) V11Park Brake Relay Diode (SE9,W6) (SN778669) W1Machine Frame/Engine Block Ground (SN 796033) (SE1,W8) Machine Frame To Eng. Ground Strap (SN796034) (SE1,W8) W2Ground To Cab Frame (SE14,W5) W3Ground At Cab Floor (SE1,W8) W4Engine Ground Strap (W8) W5Cab Roof Harness (W5) W6Cab Floor Harness (W6) W6Cab Side Console Harness (W6) W7Front Console Harness (W7) W8Engine Harness (W8) W9Not Used W10Blower Harness (W10) W11A/C Compressor Harness (W11) W12Radio Harness (W12) W13Radio Antenna (W12) W14Auxiliary Valve Harness (W14) W15Ground to A/C Compressor (W8) (S.N.801200) W16Alternator Harness (SN796034) X1Side Console Harness To Roof Harness Connectors (W5,W6) X2Side Console Harness To Roof Harness Connectors (W5,W6) X3Side Console Harness To Roof Harness Connectors (W5,W6) X4Side Console To Floor Harness Connectors (W6) (SN778668) X5Side Console To Floor Harness Connectors (W6) (SN778668) X6Blower Switch Connector (W10) X7Display Module Connectors (W6) X8Horn Switch Connector (W6) X9Rear Light Switch Connector (W6) X10Rear Wiper Switch Connector (W6) X11Beacon Switch Connector (W6)
9015 10 7
TX,9015,QQ3060 1931AUG954/6
TM1496 (21SEP05)

092105
PN=161
System Diagrams

9015 10 8
X12MFWD Switch Connector (W6) X13Park Brake Switch Connector (W6) X14Start Aid Switch Connector (W6) X15Fuel Gauge Connector (W6) X16Key Switch Connector (W6) X17Logic Module 4-Pin Connector (W6) (SN XXXXXX) X18Logic Module 6-Pin Connector (W6) (SN XXXXXX) X19Logic Module 4-Pin Connector (W6) (SN XXXXXX) X20Logic Module 6-Pin Connector (W6) (SN XXXXXX) X21Floor Harness To Engine Harness (W6,W8) (SN778669) X21Side Console To Engine Harness (W6,W8) (SN 778668) X22Floor Harness To Engine Harness (W6,W8) (SN778669) X22Side Console To Engine Harness (W6,W8) (SN 778668) X23Floor Harness To Engine Harness (W6,W8) (SN778669) X23Side Console To Engine Harness (W6,W8) (SN 778668) X24Not Used X25Floor To Front Console Connectors (W6,W7)(SN778668) X25Side To Front Console Connectors (W6,W7)(SN778669) X26FNR Switch Connector (W7) X27Turn Signal Switch Connector (W7) X28Beacon Light Connector (W5) X29Roof Harness to Radio Harness Connector (W5,W12) X30Splice (Inside Harness) (W6) X31Forward/Reverse Solenoid Connector (W8) X32Clutch Disconnect Solenoid Connector (W8) X33Connectors For A/C Switch (W6) (SN778668) X34Engine Harness To A/C Compressor Harness Connector (W8,W11) X35Side Console Harness To Blower Harness Connectors (W8,W10) X36A/C Clutch Cycle Switch Connectors (W10) X37Seat Belt Light Connector (W6) X38A/C Switch Connector (W6)
TX,9015,QQ3060 1931AUG955/6
TM1496 (21SEP05)

092105
PN=162
System Diagrams
X39Radio Harness To Radio Connector (W12) X40Not Used X41Hourmeter Or Auxiliary Valve Connector (SE13,W6) X41AAuxiliary Valve Harness Connector (W14) X42Auxiliary Valve Harness Connector (W14) X43Not Used Y1MFWD Solenoid (SE2,W8) Y2Start Aid Solenoid (SE5,W8) Y3Fuel Shutoff Solenoid (SE5,W8) Y4Park Brake Solenoid (SE9,W8) Y5Reverse/Solenoid (SE9,W8) Y6Forward/Solenoid (SE9,W8) Y7Clutch Disconnect Solenoid (SE9,W8) Y8Not Used Y9Return-To-Dig Solenoid (SE14,W8) Y10A/C Compressor (W11) Y11Auxiliary Valve Solenoid (W14)
9015 10 9
TX,9015,QQ3060 1931AUG956/6
TM1496 (21SEP05)

092105
PN=163
System Diagrams
System Functional Schematic

T8462AB 1906JAN99
TX,9015,DY375 1926AUG021/8
TM1496 (21SEP05)

092105
PN=164
System Diagrams
SE1Battery/Ignition, Power, Charging and Start Circuit(12 Volt System) SE2MFWD/Alternator Circuit SE3Dome Light and Radio Circuit SE4Start Aid, Fuel Shut Off and Reverse Alarm Circuit SE5Blower Circuit SE6Wiper and Washer Circuit SE7Rear Work Light Circuit SE8Front Work and Drive Light Circuit SE9Park Brake/Clutch Disconnect Circuit SE10Horn Circuit SE11Turn Signal, Flasher and Brake Light Circuit SE12Beacon and Return-To-Dig Circuit SE13Gauge, Side Shift and Hour Meter Circuit SE14Display Module and Logic Module Circuit SE15Indicator Circuit
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.
9015 10 11
Continued on next page TX,9015,DY375 1926AUG022/8
TM1496 (21SEP05)

092105
PN=165
System Diagrams
T8462AC 1906JAN99
TX,9015,DY375 1926AUG023/8
TM1496 (21SEP05)

092105
PN=166
System Diagrams
T8462AD 1906JAN99
TX,9015,DY375 1926AUG024/8
TM1496 (21SEP05)

092105
PN=167
System Diagrams
T8462AE 1906JAN99
TX,9015,DY375 1926AUG025/8
TM1496 (21SEP05)

092105
PN=168
System Diagrams
T8462AF 1906JAN99
TX,9015,DY375 1926AUG026/8
TM1496 (21SEP05)

092105
PN=169
System Diagrams
T8462AG 1906JAN99
TX,9015,DY375 1926AUG027/8
TM1496 (21SEP05)

092105
PN=170
System Diagrams
T8462AH 1906JAN99
TX,9015,DY375 1926AUG028/8
TM1496 (21SEP05)

092105
PN=171
System Diagrams
Cab Roof Harness (W5) Wiring Diagram

T7812AH 1923APR97
E1
DOME LIGHT
GRY
E2
SWIVEL LIGHT
M2
REAR WIPER MOTOR
E6 E10 H5
R.H. REAR TURN LIGHT
M4
R.H. DOOR WIPER MOTOR
H4
R.H. FRONT TURN LIGHT
E8
R.H. FRONT DRIVE LIGHT
E4
R.H. FRONT WORK LIGHT
E12
R.H. BRAKE LIGHT
R.H. REAR TAIL LIGHT
R.H. REAR WORK LIGHT
X2
ROOF HARNESS TO SIDE CONSOLE HARNESS CONNECTOR X29 E1, X29 P25 RED P15 RED B A
M
RED BLU BRN YEL
P15 RED
G20 BLK
G20 BLK
GRN
BRN
RED
* WIRES A68 AND A69
(SHOWN AS DASHED LINES) ARE USED FOR (S.N. 816286)
BLU
YEL
X3
A66 ORG
* A69 ORG
A65 ORG
A64 ORG
P14 RED
A63 ORG
P14 RED
G20 BLK
G20 BLK
G20 BLK
G20 BLK
G20 BLK
L41 BRN
G20 BLK
G20 BLK
L47 BRN
L47 BRN
G20 BLK
L43 BRN
G20 BLK
L46 BRN
DOME LIGHT SWITCH

X2
G20 BLK
SWIVEL LIGHT SWITCH

W2 E6 X3
L47 BRN
L43 BRN
L42 BRN
S27
S28
ROOF HARNESS TO SIDE CONSOLE HARNESS CONNECTOR M4 M3 M2 M2 M4 M4 M3 M3
* A69 ORG * A68 ORG

A66 ORG A65 ORG A64 ORG A63 ORG A62 ORG A61 ORG
H G F E D C B A
W2
W2
W2
W2
M2
H4
M4
H4
E4
X3
X3
X3
X1
X3
X1
E8
X1
X1
X1
H5
X1
W2
X1
W2
W2
W2
W2
W2
W2
H2
X3
X3
X1
X1
X1
E3
X1
X3
X2
X1
H3
X1
X1
E12, M4
E10, H5
S28, M2
X29, M3
H4, E13
E7, H2
E9, H3
E11
E5
E7
X1
A61 ORG
P14 RED
A62 ORG
A68 ORG
P15 RED
G20 BLK
L46 BRN
G20 BLK
X2
P25 RED
G20 BLK
L41 BRN
L48 BRN
L48 BRN
G20 BLK
L48 BRN
L43 BRN
L43 BRN
G20 BLK
L42 BRN
G20 BLK
G20 BLK
G20 BLK
L43 BRN
G20 BLK
G20 BLK
L45 BRN
X1
X1
G20 BLK
X1
ROOF HARNESS TO SIDE CONSOLE HARNESS CONNECTOR P14 RED H M3 M2, M4 L41 BRN G E6, E5 L48 BRN F H2, H3 L43 BRN E X29 E7, E9, E10, E8 L45 BRN D E13 L47 BRN C H4, H5 E11, E12 L46 BRN B L42 BRN A E4, E3
A
RED BLU YEL GRN
W2
GROUND TO CAB FRAME
X29
ROOF HARNESS TO RADIO HARNESS CONNECTOR
E5
L.H. REAR WORK LIGHT
E11
L.H. BRAKE LIGHT
H3
L.H. REAR TURN LIGHT
E9
L.H. REAR TAIL LIGHT
H2
L.H. FRONT TURN LIGHT
E7
L.H. FRONT DRIVE LIGHT
E3
L.H. FRONT WORK LIGHT
E13
BEACON LIGHT
M3
L.H. DOOR WIPER MOTOR
T7812AH
TX,9015,QQ2664 1931AUG951/1
TM1496 (21SEP05)

092105
PN=172
System Diagrams
Cab Roof Harness (W5) Component Location

T7812AI 1925APR97
TX,9015,QQ2665 1931AUG951/1
TM1496 (21SEP05)

092105
PN=173
System Diagrams
Cab Side Console Harness (W6) Wiring Diagram (S.N. 778668)

T7915BE 1905MAR99
TX,9015,QQ2666 1931AUG951/1
TM1496 (21SEP05)

092105
PN=174
System Diagrams
Cab Side Console Harness (W6) Component Location (S.N. 778668)

T7915BF 1919FEB99
TX,9015,QQ2667 1931AUG951/1
TM1496 (21SEP05)

092105
PN=175
System Diagrams
Cab Floor Harness (W6) Wiring Diagram (S.N. 778668)

T7915BG 1905MAR99
TX,9015,QQ2668 1931AUG951/1
TM1496 (21SEP05)

092105
PN=176
System Diagrams
Cab Floor Harness (W6) Component Location (S.N. 778668)

T8170AO 1918DEC98
TX,9015,QQ2669 1931AUG951/1
TM1496 (21SEP05)

092105
PN=177
System Diagrams
Cab Side Console Harness (W6) Wiring Diagram (S.N. 778669XXXXXX)

T8240AF 1918DEC98
TX,9015,QQ3226 1931AUG951/2
TM1496 (21SEP05)

092105
PN=178
System Diagrams
T8240AG 1918DEC98
TX,9015,QQ3226 1931AUG952/2
TM1496 (21SEP05)

092105
PN=179
System Diagrams
Cab Side Console Harness (W6) Wiring Diagram (S.N. XXXXXX )

T8462AJ 1925APR97
TX,9015,QQ3228 1931AUG951/2
TM1496 (21SEP05)

092105
PN=180
System Diagrams
T8462AI 1906JAN99
TX,9015,QQ3228 1931AUG952/2
TM1496 (21SEP05)

092105
PN=181
System Diagrams
Cab Side Console Harness (W6) Component Location (S.N. 778669 )

T8462AK 1906JAN99
TX,9015,QQ3230 1931AUG951/2
TM1496 (21SEP05)

092105
PN=182
System Diagrams
T7915BL 1919FEB99
TX,9015,QQ3230 1931AUG952/2
TM1496 (21SEP05)

092105
PN=183
System Diagrams
Front Console Harness (W7) Wiring Diagram

T7915BM 1905MAR99
TX,9015,QQ2674 1931AUG951/1
TM1496 (21SEP05)

092105
PN=184
System Diagrams
Front Console Harness (W7) Component Location

T7915BN 1919FEB99
TX,9015,QQ2675 1931AUG951/1
TM1496 (21SEP05)

092105
PN=185
System Diagrams
Engine Harness (W8) Wiring Diagram

T8240AK 1919FEB99
TX,9015,QQ2676 1931AUG951/2
TM1496 (21SEP05)

092105
PN=186
System Diagrams
T8240AL 1918DEC98
TX,9015,QQ2676 1931AUG952/2
TM1496 (21SEP05)

092105
PN=187
System Diagrams
Engine Harness (W8) Component Location

T8240AM 1906JAN99
TX,9015,QQ2678 1931AUG951/1
TM1496 (21SEP05)

092105
PN=188
System Diagrams
Blower Harness (W10) Wiring Diagram

T7812AT 1925APR97
TX,9015,QQ2115 1931AUG951/1
TM1496 (21SEP05)

092105
PN=189
System Diagrams
Blower Harness (W10) Component Location

T7812AV 1925APR97
TX,9015,QQ2116 1904MAY931/1
TM1496 (21SEP05)

092105
PN=190
System Diagrams
Radio Harness (W12) Wiring Diagram

T7931BO 1919FEB99
TX,9015,QQ2117 1904MAY931/1
TM1496 (21SEP05)

092105
PN=191
System Diagrams
Radio Harness (W12) Component Location

T7931BN 1919FEB99
TX,9015,QQ2118 1904MAY931/1
TM1496 (21SEP05)

092105
PN=192
System Diagrams
Air Conditioning Compressor Harness (W11) Wiring Diagram

T7812AU 1925APR97
TX,9015,QQ2119 1912APR941/1
TM1496 (21SEP05)

092105
PN=193
System Diagrams
Air Conditioning Compressor Harness (W11) Component Location

T8240AN 1906JAN99
TX,9015,QQ2679 1931AUG951/1
TM1496 (21SEP05)

092105
PN=194
System Diagrams
Auxiliary Valve Harness (W14) Wiring Diagram

T8166BR 1918DEC98
TX,9015,QQ2449 1912APR941/1
TM1496 (21SEP05)

092105
PN=195
System Diagrams
Auxiliary Valve Harness (W14) Component Location

T8166BP 1918DEC98
TX,9015,QQ2451 1912APR941/1
TM1496 (21SEP05)

092105
PN=196
Group 15
Sub-System Diagnostics
Power Circuit Operational Information
The following conditions must exist for power circuit to function: Voltage must be present at these distribution points for other circuits to operate. BAT terminal of key switch Terminal 30 of accessory relay Start relay BAT terminal of alternator (S.N. 787513) B+ terminal of alternator (S.N.787514 ) Starter Radio fuse Hazard/monitor fuse
9015 15 1
TX,9015,QQ2150 1902JUN931/1
Power Circuit Theory Of Operation

The power circuit includes battery and main current paths to primary distribution points. With key switch OFF, power from battery goes to key switch, accessory relay, start relay, alternator, starter motor, 4-way flasher switch, logic module, alternator sense relay and dome light fuse. When key switch is moved from OFF position, power continues through IGN and ST terminals to main fuse block. ACC terminal power goes to accessory relay, energizing relay sending power to the main fuse block. The key switch G terminal is a ground terminal only in "Bulb Check" and "Start" positions.
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
TX,9015,QQ2151 1902JUN931/1
TM1496 (21SEP05)

092105
PN=197
Power Circuit Schematic
9015 15 2
TX,9015,QQ3171 1931AUG951/3
TM1496 (21SEP05)

092105
PN=198
T8527AF
1910AUG95
9015 15 3
TX,9015,QQ3171 1931AUG952/3
TM1496 (21SEP05)

092105
PN=199
T8527AG
1910AUG95
9015 15 4
TX,9015,QQ3171 1931AUG953/3
TM1496 (21SEP05)

092105
PN=200
T8527AE
1910AUG95
Power Circuit Diagnostic Procedures
1/1
Battery State Of Charge CAUTION: Engine may crank during this check. Move light switch to ON position. Turn key to START. Do work lights go out or get very dim while cranking engine?
YES: Clean battery cable terminals. Repeat test. If lights still get dim, test battery. If battery charge is low, recharge or replace it. NO: Battery charge is good. Go to next check.
9015 15 5
1/1
Starter Motor
Key switch OFF. With harness connected, check voltage at terminal of starter with red cable. Are 12 volts measured?
YES: Check complete. NO: Check wiring harness between battery and starter motor.
T7199BK 1917SEP90
1/1
Alternator (S.N. 778740)
Key switch OFF. With harness connected, check voltage at B+ terminal of alternator. Are 12 volts measured?
YES: Go to next check. NO: Check wiring harness between battery and alternator.
T7199BL 1909OCT90
1/1
TM1496 (21SEP05)

092105
PN=201
Alternator (S.N.778741 787513) Key switch OFF. With harness connected, check voltage at B+ terminal of alternator. Are 12 volts measured? YES: Go to next check. NO: Check wiring harness between battery and alternator.
T7934AV 1915FEB93
1/1
9015 15 6
Alternator (S.N.787514 )
Key switch OFF. With harness connected, check voltage at B+ terminal of alternator. Are 12 volts measured?
YES: Go to next check . NO: Check wiring harness between battery and alternator.
T7828AA 1923SEP92
1/1
Start Relay
Key switch OFF. With harness connected, check voltage at terminal with BO3 red wire. Are 12 volts measured?
YES: Go to next check. NO: Check wiring harness between battery and start relay.
T7199BM 1917SEP90
1/1
TM1496 (21SEP05)

092105
PN=202
Key Switch Check Key switch OFF. With harness connected, check voltage of B11 red wire at BAT terminal of key switch. Are 12 volts measured? YES: Go to next step in this check. NO: Check wiring harness between battery and key switch.
T7199BO UN17SEP90
Remove fuel shut off/start aid/reverse alarm fuse. Remove FNR/park brake fuse.
YES: Go to next step in this check. 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?
9015 15 7
Key switch ON. With harness connected, check voltage at ACC terminal of key switch. Are 12 volts measured?
YES: Go to next check. NO: Replace key switch.
T7199BO UN17SEP90
1/1
TM1496 (21SEP05)

092105
PN=203
Accessory Relay Key switch OFF. With harness connected, check voltage at large terminal with B11 red wire. Are 12 volts measured? YES: Go to next step in this check. NO: Check wiring harness between battery and accessory relay.
T7199BN UN16AUG90
Key switch ON. With harness connected, check voltage at small terminal with B14 red wire. Are 12 volts measured? 9015 15 8
YES: Go to next step in this check. NO: Check wiring harness between battery and accessory relay.
T7199BN UN16AUG90
Disconnect harness from relay. Connect battery voltage to small terminal. Ground mounting bracket. Does relay click? Measure continuity between the two large terminals.
T7199BN UN16AUG90
YES: Relay is good. NO: Replace accessory relay.
Is continuity measured?
1/1
Start Circuit Operational Information

The following conditions must exist for start circuit to function: FNR lever in neutral Key switch in START position
TX,9015,QQ1942 1916MAR931/1
TM1496 (21SEP05)

092105
PN=204
Start Circuit Theory Of Operation

The start circuit converts the electrical energy from the battery to mechanical energy by the starter. A heavy current draw takes place in the starter. With key switch OFF, power flows from battery to starter motor terminal, start relay spade terminal, accessory relay, and key switch BAT terminal. With key in ON or IGN, power flows from IGN terminal through FNR/park brake fuse, to FNR switch. With the FNR in neutral power flows to the neutral start relay terminal 86, energizing relay. With key switch in START, power flows from ST terminal through start fuse, neutral start relay, to the start relay closing the relay. With relay closed, power flows from starter motor through BO3 red wire to start relay, through 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 15 9
NOTE: For component identification code description, see Legend For Schematic and Wiring Diagram , Group 9015-10.
TX,9015,QQ1985 1916MAR931/1
TM1496 (21SEP05)

092105
PN=205
Start Circuit Schematic
9015 15 10
TX,9015,QQ3180 1931AUG951/2
TM1496 (21SEP05)

092105
PN=206
T8527AI
1910AUG95
9015 15 11
TX,9015,QQ3180 1931AUG952/2
TM1496 (21SEP05)

092105
PN=207
T8527AH
1910AUG95
Start Circuit Diagnostic Procedures
1/1
Key Switch Check
Remove fuel shut off/start aid/reverse alarm fuse. Remove FNR/park brake fuse. Remove start fuse. Turn key switch to START position.
T7199BO UN17SEP90
9015 15 12
1/1
TM1496 (21SEP05)

092105
PN=208
FNR Lever Key switch ON. FNR lever in neutral With harness connected, check voltage at terminals with P24 red wire and T12 blue wire. Are 12 volts measured at each terminal? YES: Go to next step in this check. NO: Check wiring harness.
T7199BP 1902OCT90
9015 15 13 Key switch ON. With harness connected, and FNR lever moved to forward, check voltage at terminal with T11 blue wire. Move FNR lever to reverse, check voltage at T13 blue wire. Are 12 volts measured at each terminal? YES: FNR lever is good. Go to next check. NO: Replace FNR lever.
T7199BQ 1902OCT90
1/1
Neutral Start Relay
Key switch OFF. Disconnect harness from relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay click? Measure continuity between terminals #30 and #87.
T7287BH UN16AUG90
YES: Relay is good. Check wiring harness. NO: Replace neutral start relay
1/1
TM1496 (21SEP05)

092105
PN=209
Start Relay Key switch OFF. Disconnect harness from relay. Connect battery voltage to one of the small blade terminals and ground the other. Does relay click? Measure continuity between two large terminals. Is continuity measured? YES: Relay is good. NO: Replace start relay.
T7287BK 1916AUG90
1/1
Starter Solenoid Check 9015 15 14 CAUTION: Starter will crank engine if metal strap is NOT disconnected from starter motor. Disconnect metal strap from starter motor terminal. Connect battery voltage to solenoid small terminal.
T6534BI UN19OCT88
YES: Solenoid is OK. Check starter motor. NO: Replace starter solenoid.
Ground metal strap from solenoid with heavy gauge wire. Does solenoid "click"? Remove jumper wires.
1/1
Starter Motor CAUTION: Starter will crank engine if metal strap is NOT disconnected from starter motor. Disconnect metal strap from starter motor large terminal. Connect a heavy gauge jumper wire from battery positive cable to starter motor terminal.
T6534BJ UN07JAN97
YES: Starter motor is good. Check wiring harness. NO: Repair or replace starter motor.
Does starter motor turn, but NOT crank engine?
1/1
TM1496 (21SEP05)

092105
PN=210
Charging Circuit Operational Information

The following conditions must exist for charging circuit to function: Key switch in ON position Engine running
TX,9015,QQ1827 1912MAR931/1
Charging Circuit Theory Of Operation

The charging circuit consists of the battery, alternator, alternator relay, key switch, accessory relay, and indicator light in the monitor panel. 78 AMP DELCO ALTERNATOR (S.N. 787513) The alternator BAT terminal is connected to battery voltage at all times. The voltage sensing terminal No. 2 is connected to the BAT terminal of alternator. The alternator terminal No. 1 gets power from ACC terminal of the key switch. With key switch ON and engine running, power flows from terminal R of alternator to alternator relay, energizing it. Terminals 30 and 87 are connected, and indicator light 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. 95 AMP BOSCH ALTERNATOR (S.N.787514 ) 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 alternator relay, energizing it. Terminals 30 and 87 are connected, and indicator light 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 15 15
TX,9015,QQ2684 1931AUG951/1
TM1496 (21SEP05)

092105
PN=211
Charge Circuit Schematic
9015 15 16
TX,9015,QQ3182 1931AUG951/5
TM1496 (21SEP05)

092105
PN=212
T8527AJ
1910AUG95
9015 15 17
TX,9015,QQ3182 1931AUG952/5
TM1496 (21SEP05)

092105
PN=213
T8527AK
1910AUG95
9015 15 18
TX,9015,QQ3182 1931AUG953/5
TM1496 (21SEP05)

092105
PN=214
T8527AL
1910AUG95
9015 15 19
TX,9015,QQ3182 1931AUG954/5
TM1496 (21SEP05)

092105
PN=215
T8462AR
1910AUG95
9015 15 20
TX,9015,QQ3182 1931AUG955/5
TM1496 (21SEP05)

092105
PN=216
T8462AS
1925APR97
Charging Circuit Diagnostic Procedures
1/1
Alternator Output
Key switch OFF. Measure and record battery voltage. Start and run engine at 1500 rpm, and check battery voltage. Does battery voltage increase?
T6569AZ UN23AUG93
YES: Alternator is good. Check wiring harness. Check battery. NO: Check alternator.
9015 15 21
1/1
Alternator And Regulator Check (S.N. 787513)
YES: Alternator is good, replace regulator. NO: Alternator is failed. Repair or replace.
T7320AR 1901AUG90
Using a multimeter, connect to battery voltage at large terminal of starter, and ground other lead. Start and run engine at 1500 rpm. Turn drive lights ON. Insert a small screwdriver in alternator test hole and ground tab to alternator case. Does voltage steadily increase and lights get brighter when tab is grounded?
1/1
TM1496 (21SEP05)

092105
PN=217
Alternator (S.N.787514 ) Key switch ON. Engine running. Park brake ON. Using a multimeter, check for DC voltage at terminals (D+) and (B+). Is 14 DC volts measured? Using a multimeter, check for AC voltage at terminal (W). Is 7.63 AC volts measured? YES: Alternator is good. NO: Alternator is failed. Repair or replace.
9015 15 22
T7835AT 1923SEP92
1/1
Alternator Relay
IMPORTANT: Relay is a six volt relay. Do not apply more than 6 volts when testing. Disconnect harness from relay. Measure continuity between terminals #30 and #87A. Is continuity measured?
T7596AQ 1903OCT91
YES: Relay is good. Check wiring harness. NO: Replace relay.
Connect battery voltage to terminal #86. Ground terminal #85. Does relay click? Measure continuity between terminals #30 and #87. Is continuity measured?
1/1
Alternator Diode
Remove diode from connector. Connect an ohmmeter to diode terminals. Is continuity measured? Reverse ohmmeter probes.
T7961AA UN10MAR93
YES: If continuity is measured in both checks, diode has failed in a shorted mode. Replace. NO: If continuity is NOT measured in either check diode has failed in an open mode. Replace. NO: If continuity is measured in one check and not the other, diode is OK.
1/1
TM1496 (21SEP05)

092105
PN=218
Key Switch Check Key switch OFF. With harness connected, check voltage of B11 red wire at BAT terminal of key switch. Are 12 volts measured? YES: Go to next step in this check. NO: Check wiring harness between battery and key switch.
T7199BO UN17SEP90
Remove fuel shut off/start aid/reverse alarm fuse. Remove FNR/park brake fuse.
YES: Go to next step in this check. NO: Replace key switch
Remove start fuse. Turn key switch to START position.

T7199BO UN17SEP90
9015 15 23
Key switch ON. With harness connected, check voltage at ACC terminal of key switch. Are 12 volts measured?
T7199BO UN17SEP90
1/1
TM1496 (21SEP05)

092105
PN=219
Accessory Relay Key switch OFF. With harness connected, check voltage at large terminal with B11 red wire. Are 12 volts measured? YES: Go to next step in this check. NO: Check wiring harness between battery and accessory relay.
T7199BN UN16AUG90
Key switch ON. With harness connected, check voltage at small terminal with B14 red wire. Are 12 volts measured? 9015 15 24
YES: Go to next check. NO: Check wiring harness between battery and accessory relay.
T7199BN UN16AUG90
Disconnect harness from relay. Connect battery voltage to small terminal. Ground mounting bracket. Does relay click? Measure continuity between the two large terminals.
T7199BN UN16AUG90
YES: Relay is good. NO: Replace accessory relay.
1/1
Display Module And Logic Module Circuit Operational Information (S.N. XXXXXX) With Logic Module
The following conditions must exist for display module and logic module to function. The key switch must be in BULB CHECK or START position to "arm" the logic module so failures will be indicated.
TX,9015,QQ3185 1931AUG951/1
TM1496 (21SEP05)

092105
PN=220
Display Module And Logic Module Circuit Theory Of Operation (S.N. XXXXXX) With Logic Module
Key Switch OFF Power is supplied to the logic module through the Hazard/Monitor Unswitched fuse to pin A of logic module (6 pin connector). Key Switch ON Power is supplied to the logic module through the Monitor Switched fuse. No power is supplied from the logic module to the display module since the logic module has not been "armed." Key Switch In BULB CHECK Or START The key switch connects all indicator lights in the display module to ground when the key switch is in the BULB CHECK or START positions. The key switch also grounds the logic module, signaling the logic module to supply power to all bulbs in the display module, the primary and secondary indicators and the 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. The logic module stops current flow to the display monitor. Failure Occurs The indicator switch (sensor) closes, grounding an indicator light and also the logic module. The logic module supplies power to all bulbs in the display module, the secondary failure indicator light, primary indicator light, and alarm. The logic module then connects either the red light and alarm or the yellow light to ground, turning them ON.
9015 15 25
TX,9015,DY361 19 3JUN961/2
TM1496 (21SEP05)

092105
PN=221
If the key switch is momentarily turned OFF and back ON while the engine is running, power from the alternator indicator terminal will keep the logic module activated.
TX,9015,DY361 19 3JUN962/2
9015 15 26
Display Module And Logic Module Circuit Operational Information (S.N. XXXXXX ) Without Logic Module
The following conditions must exist for display module to function. The key switch must be in the "ON" position so failures will be indicated.
TX,9015,QQ3187 1931AUG951/1
TM1496 (21SEP05)

092105
PN=222
Display Module Circuit Theory Of Operation (S.N. XXXXXX ) Without Logic Module
Power is supplied to the display module through the Monitor Switched fuse. Elimination of the logic module allows the monitor on the backhoe to be active when the key switch is turned to the ON position. Moving the key switch to the BULB CHECK position to activate the monitor is no longer necessary. CONDITION: Key ON Engine OFF:
WITH LOGIC MODULE No Lights or alarm. WITHOUT LOGIC MODULE Red warning, yellow warning, engine oil pressure, alternator charging light are ON, and alarm is beeping.
9015 15 27
CONDITION: BULB CHECK:

WITH LOGIC MODULE Red warning light is flashing, yellow warning is ON, and alarm is beeping. WITHOUT LOGIC MODULE Red warning light is ON but NOT flashing, yellow warning is ON, and alarm is beeping.
CONDITION: Engine Running And Engine Water Temperature And Alternator Lights Are ON:
WITH LOGIC MODULE Red warning light is flashing and alarm is beeping. WITHOUT LOGIC MODULE Red warning light is on but NOT 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.
TX,9015,DY362 19 3JUN961/2
TM1496 (21SEP05)

092105
PN=223
Sub-System Diagnostics NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
TX,9015,DY362 19 3JUN962/2
9015 15 28
TM1496 (21SEP05)

092105
PN=224
Display Module And Logic Module Circuit Schematic
9015 15 29
TX,9015,QQ2707 1931AUG951/3
TM1496 (21SEP05)

092105
PN=225
T8174AA
1920FEB94
9015 15 30
TX,9015,QQ2707 1931AUG952/3
TM1496 (21SEP05)

092105
PN=226
T8462AL
1910AUG95
9015 15 31
TX,9015,QQ2707 1931AUG953/3
TM1496 (21SEP05)

092105
PN=227
T8462AM
1925MAR97
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. Check 5 amp monitor fuse, and 15 amp hazard/monitor fuse. Is fuse blown?
YES: Replace fuse. NO: Go to next check.
T7199BR 1916AUG90
9015 15 32
1/1
Logic Module (S.N. XXXXXX)

See Logic Module Test in Machine and Logic Module Bench Test , in Group 9015-20.
TX,9015,DY377 19 5JUN961/1
Indicator Circuit Specifications

Specification Engine Coolant Temperature Switch (Normally Open)Closing Temperature ..................................................................... 101.7C (215F) Engine Oil Pressure (Normally Closed)Opening Pressure............................. 3772 kPa (0.40.7 bar) (5.510.5 psi) Air Filter Restriction Switch (Normally Open)Closes on Increased Vacuum at ............................ 4.987.48 kPa Vacuum (2030 in. H2O) Converter Oil Temperature Switch (Normally Open)Closes On Increasing Temperature ................................................ 114.3C121.2C (238F252F) Hydraulic Filter Restriction Switch (Normally Open)Closing Pressure ......................................................... 344 kPa (3.45 bar) (50 psi)
TX,9015,QQ1972 1916MAR931/1
TM1496 (21SEP05)

092105
PN=228
Indicator Circuit Operational Information

The Indicator Circuit has TWO modes of operation: Bulb check mode Failure mode The following conditions must exist for indicator circuit to function in bulb check mode: Key switch moved to BULB CHECK position The following conditions must exist for indicator circuit to function in a failure mode: Engine must be running for a failure to be indicated on a display module light. An indicator switch or alternator relay senses a failure and supplies a ground for an indicator light, warning light and buzzer.
9015 15 33
TX,901515,QQ534 1907DEC901/1
TM1496 (21SEP05)

092105
PN=229
Indicator Circuit Theory Of Operation (S.N. XXXXXX) 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 indicator light ON. 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.
9015 15 34
NOTE: For component identification code description, see Wiring and Schematic diagrams Legend , Group 9015-10.
TX,9015,DY363 19 3JUN961/1
TM1496 (21SEP05)

092105
PN=230
Indicator Circuit Theory Of Operation (S.N.XXXXXX ) Without 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 indicator light ON. SERVICE Warning Level: Yellow WARNING light and a function indicator light ON. 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: 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 turns on the red STOP light and alarm or the yellow SERVICE REQUIRED light.
9015 15 35
NOTE: For component identification code description, see Wiring and Schematic diagrams Legend , Group 9015-10.
TX,9015,DY369 19 3JUN961/1
TM1496 (21SEP05)

092105
PN=231
Indicator Circuit Schematic
9015 15 36
TX,9015,QQ3175 1931AUG951/4
TM1496 (21SEP05)

092105
PN=232
T8527AC
1929AUG95
9015 15 37
TX,9015,QQ3175 1931AUG952/4
TM1496 (21SEP05)

092105
PN=233
T8527AD
1910AUG95
9015 15 38
TX,9015,QQ3175 1931AUG953/4
TM1496 (21SEP05)

092105
PN=234
T8462AN
1910AUG95
9015 15 39
TX,9015,QQ3175 1931AUG954/4
TM1496 (21SEP05)

092105
PN=235
T8462AO
1925MAR97
Indicator Circuit Diagnostic Procedures This circuit is powered by the monitor fuse, and hazard/monitor fuse.
1/1
Engine Coolant Temperature Indicator Switch
Disconnect X36 yellow wire from switch and ground to frame. Without starting engine, turn key switch to BULB CHECK, then release to ON. Is engine coolant indicator light on?
T7199CG 1916AUG90
YES: Replace switch. NO: Switch is good. Go to next check.
9015 15 40
1/1
Engine Coolant Temperature Indicator Light
Disconnect connector from display module. Connect 12 volts to pin terminal 1 for Z33 gray wire. Ground pin terminal 2 for X36 yellow wire to machine frame. Is engine coolant temperature indicator light on?
T6877AB UN18OCT88
YES: Indicator light is good. Check wiring harness. NO: Check display module. Replace bulb or module.
1/1
Engine Oil Pressure Switch
Disconnect N34 yellow wire from switch and ground to frame. Without starting engine, turn key switch to BULB CHECK, then release to ON. Is engine oil pressure indicator light on?
T7199DZ 1926SEP90
1/1
TM1496 (21SEP05)

092105
PN=236
Engine Oil Pressure Indicator Light Disconnect connector from display module. Connect 12 volts to pin terminal 1 for Z33 gray wire. Ground pin terminal 3 for N34 yellow wire to machine frame. Is engine oil pressure indicator light on?
T6877AC UN18OCT88
1/1
Engine Alternator Indicator Circuit (S.N. 787513)
Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39 purple wire. Without starting engine, turn key switch to BULB CHECK, then release to ON.
YES: Circuit is good. Repair or replace alternator. NO: Go to next check.
9015 15 41
Is alternator indicator light off? Remove voltage from M39 purple wire. Is alternator indicator light on?
1/1
Engine Alternator Indicator Circuit (S.N.787514 )
Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39 purple wire. Without starting engine, turn key switch to BULB CHECK, then release to ON.
YES: Circuit is good. Repair or replace alternator. NO: Go to next check.
Is alternator indicator light off? Remove voltage from M39 purple wire. Is alternator indicator light on?
1/1
Alternator Relay
IMPORTANT: Relay is a six volt relay. Do not apply more than 6 volts when testing. Disconnect harness from relay. Measure continuity between terminals #30 and #87A. Is continuity measured?
T7596AQ 1903OCT91
Connect battery voltage to terminal #86. Ground terminal #85. Does relay click? Measure continuity between terminals #30 and #87. Is continuity measured?
1/1
TM1496 (21SEP05)

092105
PN=237
Engine Alternator Indicator Light Disconnect middle connector on display module. Ground pin terminal 13 for M37 purple wire to machine frame. Without starting engine, turn key switch to BULB CHECK, then release to ON.
T6877AE UN18OCT88
Is engine alternator indicator light on?
1/1
9015 15 42
Engine Air Filter Restriction Switch
Disconnect M40 purple wire from switch and ground to frame. Without starting engine, turn key switch to BULB CHECK, then release to ON? Is air filter restriction indicator light on?
T7199CI 1917SEP90
1/1
Engine Air Filter Restriction Indicator Light
Disconnect middle connector of display module. Ground pin terminal 14 for M40 purple wire to machine frame. Without starting engine, turn key switch to BULB CHECK, then release to ON.
T6877AG UN18OCT88
Is air restriction indicator light on?
1/1
Converter Oil Temperature Switch
Disconnect X38 yellow wire from switch and ground to frame. Without starting engine, turn key to BULB CHECK, then release to ON. Is converter oil temperature light on?
T7199CJ 1917SEP90
1/1
TM1496 (21SEP05)

092105
PN=238
Converter Oil Temperature Light Disconnect middle connector from display module. Ground pin terminal 15 for X38 yellow wire from switch and ground to frame. Without starting engine, turn key to BULB CHECK, then release to ON.
T7199BS 1916AUG90
Is converter oil temperature light on?
1/1
Hydraulic Filter Restriction Indicator Switch
Disconnect F39 yellow wire from switch and ground to frame. Without starting engine, turn key switch to BULB CHECK, then release to ON. Is hydraulic filter restriction indicator light on?
T7199CK 1917SEP90
YES: Replace switch. NO: Switch is good. Go to next check. 9015 15 43
1/1
Hydraulic Filter Restriction Indicator Light
Disconnect middle connector on display module. Ground pin terminal 16 for F39 yellow wire to machine frame. Without starting engine, turn key switch to BULB CHECK, then release to ON.
T7199BT 1916AUG90
Is hydraulic filter restriction indicator light on?
1/1
Display Module And Logic Module Diode
T7961AA UN10MAR93
1/1
TM1496 (21SEP05)

092105
PN=239
MFWD Circuit Operational Information

The following conditions must exist for MFWD circuit to function: Key switch ON position MFWD Switch ON
TX,901515,QQ811 1919NOV901/1
MFWD Circuit Theory Of Operation

9015 15 44
With the key switch ON or ACC position, power flows from MFWD fuse to terminal 5 of MFWD switch. With MFWD switch in ON position, power flows to the MFWD solenoid, energizing and engaging MFWD. MFWD indicator switch closes making light in MFWD switch to come on. With MFWD switch turned to OFF position, the MFWD solenoid is de-energized and disengages MFWD.
NOTE: Indicator light in MFWD switch will remain ON while MFWD is engaged. If MFWD is turned OFF while operating, light could remain on for several seconds until load on drive train is released. For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
TX,9015,QQ2688 1931AUG951/1
TM1496 (21SEP05)

092105
PN=240
MFWD Circuit Schematic
9015 15 45
TX,9015,QQ1956 1916MAR931/1
TM1496 (21SEP05)

092105
PN=241
T7934BG
1915FEB93
MFWD Circuit Diagnostic Procedures This circuit is powered by MFWD fuse.
1/1
MFWD Switch
Disconnect harness from MFWD switch. With MFWD switch ON, measure continuity between terminals 1 and 5. Is continuity measured?
YES: Switch is good. Go to next check. NO: Replace MFWD switch.
T7199BU UN02OCT90
9015 15 46
1/1
MFWD Solenoid Diode
T7961AA UN10MAR93
1/1
MFWD Indicator Switch
Disconnect harness from switch connector. Remove switch. Push switch actuator (steel ball). Check continuity. Is continuity measured?
YES: Go to next step in this check. NO: Replace MFWD indicator switch.
T7287BJ UN16AUG90
Disconnect harness from switch connector. Remove switch. With switch actuator (steel ball) released, check continuity. Is continuity measured?
T7287BJ UN16AUG90
YES: Replace MFWD indicator switch. NO: MFWD indicator switch is good. Go to next check.
1/1
TM1496 (21SEP05)

092105
PN=242
MFWD Solenoid Disconnect harness from MFWD solenoid. Connect one lead from connector to ground and the other to battery voltage. Does solenoid click? YES: Solenoid is good. Check wiring harness. NO: Replace solenoid.
T7199BV UN16AUG90
1/1
Start Aid Circuit Operational Information

The following conditions must exist for start aid circuit to function: CAB (S.N. 794216) ROPS (S.N. 794259) FNR lever in neutral Key switch in IGN or ON position Start aid switch depressed CAB (S.N.794217 ) ROPS (S.N.794260 ) Key switch in IGN or ON position Start aid switch depressed
9015 15 47
TX,9015,QQ2655 1931AUG951/1
TM1496 (21SEP05)

092105
PN=243
Start Aid Circuit Theory Of Operation

CAB (S.N. 794216) ROPS (S.N. 794259) Power flows from key switch IGN terminal to fuel shut-off/start aid and reverse warning alarm fuse to start aid button. When button is pushed, power is supplied to start aid solenoid. Power flows from key switch IGN terminal to FNR/park brake fuse, FNR lever, neutral start relay and ether aid relay. This energizes ether aid relay, closing terminal 30 and 87 suppling a ground and activating start aid solenoid. CAB (S.N.794217 ) ROPS (S.N.794260 ) Power flows from key switch IGN terminal to fuel shut-off/start aid and reverse warning alarm fuse to start aid button. When button is pushed, power is supplied to start aid solenoid. Ground is supplied through GO1 black wire energizing solenoid.
9015 15 48
TX,9015,QQ2656 1931AUG951/1
TM1496 (21SEP05)

092105
PN=244
Start Aid Circuit Schematic
9015 15 49
TX,9015,QQ2689 1931AUG951/2
TM1496 (21SEP05)

092105
PN=245
T8245AQ
1931MAY94
9015 15 50
TX,9015,QQ2689 1931AUG952/2
TM1496 (21SEP05)

092105
PN=246
T8245AS
1931MAY94
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. With start aid button pushed, check for continuity between terminals with P12 red wire and E25 white wire. Is continuity measured?
YES: Start aid switch is good. Go to next check. NO: Replace start aid switch.
T7199BW 1916AUG90
9015 15 51
1/1
TM1496 (21SEP05)

092105
PN=247
FNR Lever Cab (S.N.794216) ROPS (S.N.794259) Key switch ON. FNR lever in neutral With harness connected, check voltage at terminals with P24 red wire and T12 blue wire. Are 12 volts measured at each terminal? YES: Go to next step in this check. NO: Check wiring harness.
9015 15 52
T7199BP 1902OCT90
Key switch ON. With harness connected, and FNR lever moved to forward, check voltage at terminal with T11 blue wire. Move FNR lever to reverse, check voltage at T13 blue wire. Are 12 volts measured at each terminal?
YES: FNR lever is good. Go to next check. NO: Replace FNR lever.
T7199BQ 1902OCT90
1/1
Ether Aid Relay Cab (S.N.794216) ROPS (S.N.794259)
Key switch OFF. Disconnect harness from relay. Connect battery voltage to terminal #86 with T12 blue wire. Ground terminal #85 with G10 black wire. Does relay click?
T7287BH UN16AUG90
YES: Relay is good. Check wiring harness. NO: Replace ether aid relay.
Measure continuity between terminals #30 and #87 with G10 black wire and E27 white wire. Is continuity measured?
1/1
TM1496 (21SEP05)

092105
PN=248
Start Aid Solenoid Cab (S.N.794216) ROPS (S.N.794259)
NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into engine.
Key switch OFF. Disconnect harness from solenoid. Connect battery voltage to terminal with E25 white wire. Ground terminal with E27 white wire. Does solenoid "click"?
YES: Start aid solenoid is good. Check wiring harness. NO: Replace start aid solenoid.
T7199BX 1917SEP90
1/1
Start Aid Solenoid Cab (S.N.794217 ) ROPS (S.N.794260 )
NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into engine.
Key switch OFF. Disconnect harness from solenoid. Connect battery voltage to terminal with E25 white wire. Ground terminal with GO1 black wire. Does solenoid "click"?
YES: Start aid solenoid is good. Check wiring 9015 harness. 15 53 NO: Replace start aid solenoid.
T7828AK 1923SEP92
1/1
Fuel Shut-Off Circuit Operational Information

The following conditions must exist for fuel shut-off circuit to function: Key switch in IGN or ON position
TX,9015,QQ1814 1912MAR931/1
TM1496 (21SEP05)

092105
PN=249
Fuel Shut-Off Circuit Theory Of Operation

Power flows from key switch IGN terminal to fuel shut-off/start aid/reverse alarm fuse, start aid switch and fuel shut-off solenoid. Solenoid is grounded to frame. When the fuel shut-off solenoid is "energized" fuel is allowed into the injection pump.
9015 15 54
TX,9015,QQ1754 1912MAR931/1
TM1496 (21SEP05)

092105
PN=250
Fuel Shut-Off Circuit Schematic
9015 15 55
TX,901515,QQ825 1912MAR931/1
TM1496 (21SEP05)

092105
PN=251
T7418AZ
1912DEC90
Fuel Shut-Off Circuit Diagnostic Procedures This circuit is powered by the fuel shutoff/start aid/reverse alarm fuse.
1/1
Injection Pump Fuel Shut-Off Solenoid
Connect battery voltage to solenoid P12 red wire terminal. Does solenoid "click"? Remove voltage from terminal. Does solenoid "click" again?
T6785AG UN18OCT88
YES: Solenoid is good. Check wiring harness. NO: Replace fuel shut-off solenoid.
9015 15 56
1/1
Reverse Alarm Circuit Specifications Cab (S.N. 794216) ROPS (S.N. 794259)
Specification Reverse Alarm Switch (Normally Open)Closes on Increasing Pressure ............................................... 296 kPa599 kPa (3 bar6 bar) (43 psi87 psi)
TX,9015,QQ2693 1931AUG951/1
Reverse Alarm Circuit Operational Information

The following conditions must exist for reverse alarm circuit to function: Key switch ON FNR lever must be in reverse position
TX,9015,QQ1815 1912MAR931/1
TM1496 (21SEP05)

092105
PN=252
Reverse Alarm Circuit Theory Of Operation

CAB (S.N. 794216) ROPS (S.N. 794259) Power flows from fuel shutoff/start aid/reverse alarm fuse to reverse alarm switch. When FNR lever is moved into reverse the reverse solenoid is activated. Rising pressure closes the reverse alarm switch sending power to activate reverse alarm. CAB (S.N.794217 ) ROPS (S.N.794260 ) 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 T13 blue wire 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 15 57
TX,9015,QQ2698 1931AUG951/1
TM1496 (21SEP05)

092105
PN=253
Reverse Alarm Circuit Schematic
9015 15 58
TX,9015,QQ2694 1931AUG951/2
TM1496 (21SEP05)

092105
PN=254
T8245AU
1931MAY94
9015 15 59
TX,9015,QQ2694 1931AUG952/2
TM1496 (21SEP05)

092105
PN=255
T8245AV
1931MAY94
Reverse Alarm Circuit Diagnostic Procedures This circuit is powered by the fuel shut-off/start aid/reverse alarm fuse.
1/1
FNR Lever Cab (S.N.794217 ) ROPS(S.N.794260 )
Key switch ON. FNR lever in neutral With harness connected, check voltage at terminals with P24 red wire and T12 blue wire. Are 12 volts measured at each terminal?
YES: Go to next step in this check. NO: Check wiring harness.
9015 15 60
T7199BP 1902OCT90
T7199BQ 1902OCT90
1/1
TM1496 (21SEP05)

092105
PN=256
Reverse Alarm Relay Cab (S.N.794217 ) ROPS(S.N.794260 ) Key switch OFF. Disconnect harness from relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay click? Measure continuity between terminals #30 and #87.
T7287BH UN16AUG90
YES: Relay is good. Check wiring harness. NO: Replace reverse alarm relay.
1/1
Reverse Alarm Switch Cab (S.N.794216) ROPS(S.N.794259)
Key switch ON. Remove spade terminals with P12 red wire and M62 purple wire from switch. Using a jumper wire connect P12 red wire and M62 purple wire.
T7199BY 1916AUG90
YES: Replace reverse alarm switch. NO: Reverse alarm switch is good. Go to next check.
9015 15 61
Does reverse alarm sound?
1/1
Reverse Alarm
Disconnect harness from reverse alarm. Connect battery voltage to reverse warning alarm positive (+) terminal. Connect jumper wire from reverse warning alarm negative (-) terminal to ground.
T7199BZ UN16AUG90
YES: Reverse alarm is good. Check wiring harness. NO: Replace reverse alarm.
Does reverse alarm sound?
1/1
Reverse Solenoid Diode
T7961AA UN10MAR93
1/1
TM1496 (21SEP05)

092105
PN=257
Dome Light Circuit Operational Information

The following conditions must exist for dome light circuit to function: Key switch in ACC position
TX,9015,QQ1816 1912MAR931/1
Dome Light Circuit Theory Of Operation

9015 15 62
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.
TX,9015,QQ1762 1912MAR931/1
TM1496 (21SEP05)

092105
PN=258
Dome Light Circuit Schematic
9015 15 63
TX,9015,QQ1763 1912MAR931/1
TM1496 (21SEP05)

092105
PN=259
T7828AP
1923SEP92
Dome Light Circuit Diagnostic Procedures This circuit is powered by the dome light fuse
1/1
Dome Light And Swivel Light Switch
Disconnect harness from switch. Turn dome light/swivel light switch ON.
YES: Switch is good. Check wiring harness NO: Replace switch.
Using a multimeter check continuity at switch terminals for dome and swivel light switch. Does multimeter read continuity?
T6622BB UN09DEC88
9015 15 64
1/1
Dome And Swivel Light
Disconnect harness from light. Connect battery voltage to light terminal. Ground light housing. Does light come on?
YES: Light is good. Check wiring harness. NO: Replace bulbs or dome/swivel lights.
T6534DZ UN19OCT88
1/1
Radio Circuit Operational Information

The following condition or conditions must exist for radio circuit to function. Key switch in ACC or ON position Radio turned ON
TX,9015,QQ1769 1912MAR931/1
TM1496 (21SEP05)

092105
PN=260
Radio Circuit Theory Of Operation

When key switch is ON or in ACC position of switch, power flows to accessory relay energizing relay. Power is then sent to dome light fuse and front work light fuse. Switched power is sent to radio fuse and radio. Unswitched power from radio fuse is to maintain station memory. Power from the front work light fuse is for light in radio. Power from the dome light fuse is to power the radio and speakers.
9015 15 65
TX,9015,QQ1770 1931AUG951/1
TM1496 (21SEP05)

092105
PN=261
Radio Circuit Schematic
9015 15 66
TX,9015,QQ1771 1912MAR931/1
TM1496 (21SEP05)

092105
PN=262
T7828AS
1923SEP92
Radio Circuit Diagnostic Procedures This circuit is powered by the unswitched radio fuse and the dome light fuse.
1/1
Radio
YES: Go to next check. NO: Check wiring harness between radio and fuses.
9015 15 67
T7828AT 1923SEP92
Key switch ON Front work/drive light switch ON Measure 12 volts at wire terminals L43 brown, P25 red and P15 red. Is 12 volts measured at wire terminals?
1/1
Radio Speaker
Disconnect harness from radio speaker. Measure resistance between radio speaker terminals. Is 7.3 ohms measured?
YES: Replace radio. NO: Replace speaker
T7828AU 1923SEP92
1/1
TM1496 (21SEP05)

092105
PN=263
Wiper/Washer Circuit Operational Information

The following conditions must exist for wiper/washer circuit to function. Key switch must be in ON or ACC position. Front/rear wiper or washer switch must be turned on.
TX,9015,QQ1817 1912MAR931/1
Wiper/Washer Circuit Theory Of Operation

9015 15 68
Power flows from wiper/washer fuse through wires P14 red to terminal 3 on front wiper switch, terminal 1 of washer switch and terminal 3 of rear wiper switch. Front wipers on HIGH, power flows through terminal 3 and out terminal 1 to left hand door wiper motor. Power also flows through terminal 4 and out terminal 2 to right hand door wiper motor. Front wipers on LOW, power flows through terminal 3 and out terminal 5 to left hand door wiper motor. Power also flows through terminal 4 and out terminal 6 to right hand door wiper motor. Front wiper in PARK position, power flows through P14 red wire to right hand door wiper motor, through A69 orange wire to terminal 8 of front wiper switch, out terminal 6 of front wiper switch through A63 orange wire to right hand door wiper motor and to ground by G20 black wire. Power also flows through P14 red wire 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.
Rear wiper in HIGH position, power flows from rear wiper switch terminal 1 through A66 orange wire to rear wiper motor. Rear wiper in LOW position, power flows from rear wiper switch terminal 5 through A65 orange wire to rear wiper motor. Rear wiper in PARK position, power flows through P14 red to rear wiper motor deactivating a switch in rear wiper motor putting wiper in park position. Washer: Power flows from 15 amp wiper/washer fuse to terminal 5 of washer switch. With washer switch pushed in power flows from terminal 1 to washer motor, activating pump.
TX,9015,QQ1764 1912MAR931/1
TM1496 (21SEP05)

092105
PN=264
Wiper/Washer Circuit Schematic
9015 15 69
TX,9015,QQ1974 1916MAR931/1
TM1496 (21SEP05)

092105
PN=265
T7938AA
1915FEB93
Wiper/Washer Circuit Diagnostic Procedures This circuit is powered by the wiper/washer fuse.
1/1
Front Wiper Switch
Wiper switch ON. Disconnect harness from front wiper switch. Measure for continuity between terminals 2 and 4, 6 and 8, 1 and 3, and 5 and 7. Is continuity measured?
T7199CA UN02OCT90
YES: Front wiper switch is good. Go to next check. NO: Replace front wiper switch.
9015 15 70
1/1
Wiper Motor LH Door And RH DoorLow Speed
Disconnect harness from wiper motor. Connect battery voltage to terminal with red wire and yellow wire. Ground terminal with black wire. Does motor run in LOW speed? Remove voltage from terminal with red wire, and connect red and green wire together using a jumper wire. Does motor run until blade reaches PARK position?
YES: Go to next check. NO: Replace wiper motor.
T7199CB UN17SEP90
1/1
Wiper Motor LH Door And RH DoorHigh Speed
Disconnect harness from wiper motor. Connect battery voltage to terminal with blue wire and yellow wire. Ground terminal with black wire. Does motor run in HIGH speed? Remove voltage from terminal with blue wire, and connect blue and green wires together using a jumper wire. Does motor run until blade reaches PARK position?
YES: Wiper motor is good. Check wiring harness. NO: Replace wiper motor.
T7199CB UN17SEP90
1/1
TM1496 (21SEP05)

092105
PN=266
Rear Wiper Switch Wiper switch ON. Disconnect harness from rear wiper switch. Using a multimeter measure for continuity between terminals 1 and 3, and 5 and 7. Is continuity measured?
T7199CC UN02OCT90
YES: Rear wiper switch is good. Go to next check. NO: Replace rear wiper switch.
1/1
Rear Wiper MotorLow Speed
Disconnect harness from wiper motor. Connect battery voltage to terminal with red wire and yellow wire. Ground terminal with black wire. Does motor run in LOW speed? Remove voltage from terminal with red wire.
T7199CD 1916AUG90
YES: Go to next check. NO: Replace wiper motor. 9015 15 71
Does motor run until blade reaches PARK position?
1/1
Rear Wiper MotorHigh Speed
Disconnect harness from wiper motor. Connect battery voltage to terminal with blue wire and yellow wire. Ground terminal with black wire. Does motor run in HIGH speed? Remove voltage from terminal with blue wire.
T7199CD 1916AUG90
YES: Wiper motor is good. Check wiring harness. NO: Replace wiper motor.
Does motor run until blade reaches PARK position?
1/1
Washer Switch
Washer switch ON. Disconnect harness from washer switch. Using a multimeter measure continuity between terminals 1 and 5. Is continuity measured?
T7199CE UN02OCT90
YES: Washer switch is good. Go to next check. NO: Replace washer switch.
1/1
TM1496 (21SEP05)

092105
PN=267
Windshield Washer Motor Disconnect harness from washer motor. Connect battery voltage to terminal with S71 orange wire. Ground motor. Does motor run and operate the pump? YES: Washer motor is good. Check wiring harness. NO: Replace washer motor.
T7199CF 1916AUG90
1/1
Blower Circuit Operational Information

9015 15 72
The following conditions must exist for blower circuit to function: Key switch in ON or ACC position Blower switch turned ON
TX,9015,QQ1818 1917JUN941/1
Blower Circuit Theory Of Operation

Power from heater circuit breaker goes to blower switch. With blower switch in low position power is sent to blower resistor. Voltage goes through complete resistor and is reduced to 3.03.5 volts, blower motor runs in low speed. With blower switch in medium position power is sent through half the blower resistor and is reduced to 6.06.5 volts, blower motor runs in medium speed. With blower switch in high position power by-passes resistor and 12 volts is applied to blower motor, causing it to run at high speed.
TX,9015,QQ1766 1917JUN941/1
TM1496 (21SEP05)

092105
PN=268
Blower Circuit Schematic
9015 15 73
TX,901515,QQ809 1917JUN941/1
TM1496 (21SEP05)

092105
PN=269
T7857AD
1930SEP92
Blower Circuit Diagnostic Procedures This circuit is powered by the heater circuit breaker.
1/1
Blower Switch
Disconnect harness from blower switch. Use a multimeter and check for continuity. Move blower switch to LOW, MEDIUM and HIGH checking terminals B and L, B and M, and B and H. Is continuity measured?
T7199CL UN17SEP90
YES: Blower switch is good. NO: Replace blower switch.
9015 15 74
1/1
Heater Blower Motor
Disconnect harness from heater blower motor. Connect 12 volts to heater blower motor, and ground motor. Does heater blower motor operate?
YES: Heater blower motor is good. Check wiring harness. NO: Replace heater blower motor.
T7199CM UN16AUG90
1/1
Blower Resistor Check
Disconnect harness from resistor. Connect ohmmeter to outer terminals of resistor. Does ohmmeter read continuity?
YES: Resistor is OK. Check harness and blower motor. NO: Blower resistor has failed. Replace.
T8134AK UN03DEC93
1/1
TM1496 (21SEP05)

092105
PN=270
Drive And Work Light Circuit Operational Information

The following conditions must exist for drive and work lights to function: Key switch in ON or ACC Front light switch and/or rear light switch in ON position
TX,9015,QQ1820 1912MAR931/1
Drive And Work Light Circuit Theory Of Operation

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 15 75
TX,9015,QQ1767 1912MAR931/1
TM1496 (21SEP05)

092105
PN=271
Drive And Work Light Circuit Schematic
9015 15 76
TX,9015,QQ1768 1912MAR931/1
TM1496 (21SEP05)

092105
PN=272
T7828AR
1923SEP92
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. Light switch ON. Measure for continuity between terminals 3 and 1, and 2 and 8. Is continuity measured?
T7199CN UN16AUG90
YES: Front light switch is good. Check wiring harness. NO: Replace switch.
9015 15 77
1/1
Rear Light Switch
Disconnect harness from rear light switch. Light switch ON. Measure for continuity between terminals 1 and 5. Is continuity measured?
T7199CO UN16AUG90
YES: Rear light switch is good. Check wiring harness. NO: Replace switch.
1/1
Work/Drive Light
Disconnect harness from work/drive light. Connect 12 volts to blue wire and ground black wire. Does light come ON?
YES: Work light is good. Check wiring harness. NO: Replace bulb. If bulb is good replace light.
T7199CP UN17SEP90
1/1
TM1496 (21SEP05)

092105
PN=273
Tail Light Disconnect harness from turn/tail/brake light. Connect 12 volts to terminal marked TAIL, and ground terminal marked GROUND. Does tail light come on? YES: Tail light is good. Check wiring harness. NO: Replace bulb. If bulb is good replace light.
T7199CQ 1902OCT90
1/1
9015 15 78
Park Brake/Clutch Disconnect Circuit Specifications

Specification Reverser Switch (S.N. 778668) (Normally Open)Closes on Increasing Pressure.................................. 345621 kPa (3.456.21 bar) (5090 psi) Opening Pressure .................................... 103345 kPa (1.033.45 bar) (1550 psi)
TX,9015,QQ2746 1931AUG951/1
Park Brake/Clutch Disconnect Circuit Operational Information

The following condition or conditions must exist for park brake/clutch disconnect circuit to function: Key switch OFF Park brake dash switch in ON position with machine running Machine Mechanically Shut Down Reverser pressure
TX,901515,QQ575 1907DEC901/1
TM1496 (21SEP05)

092105
PN=274
Park Brake/Clutch Disconnect Circuit Theory Of Operation

The Park Brake/Clutch Disconnect Circuit consists of FNR/park brake fuse, park brake dash switch, park brake latching relay, FNR switch, loader lever switch, gear shift lever switch, park brake solenoid, clutch disconnect solenoid, reverser pressure switch, park light relay and park brake sensing switch. park brake sensing switch closes providing a ground for the park brake dash switch light.
NOTE: For (S.N. 778824)ground is supplied to the park brake latching relay through the reverser switch. For (S.N.778669 )ground is supplied to the park brake latching relay from the "S" terminal of the starter motor.
Key ON: Park Brake Dash Switch in ON position. FNR Lever Shifted Out of Neutral: With the park brake dash switch ON, and the FNR lever shifted out of neutral the park light relay K3 is de-energized connecting terminals 30 and 87A causing red light and alarm to come ON. Key ON: Engine running.
9015 15 79
NOTE: The park brake applies automatically when machine is mechanically shut down or when key switch is turned off. Park brake dash switch must be cycled first to applied position (ON), then to released position (OFF) before park brake can be released when engine is running.
Key OFF: Park brake cannot be hydraulically released if there is a blown fuse or key switch is OFF. Key ON: Park Brake Dash Switch in ON Position. FNR Lever in Neutral: Power flows from terminal 1 to terminal 6 of park brake dash switch and then to park brake latching relay terminal 85, energizing relay K5 causing it to latch terminals 30 and 87. Ground is supplied to the park brake latching relay through the reverser pressure switch. Power is disconnected from park brake solenoid, and clutch disconnect solenoid de-energizing solenoids. This applies the park brake and puts the reverser in neutral. When the park brake is applied the
With machine mechanically shut down the reverser pressure switch opens a contact removing ground for park brake latching relay, de-energizing park brake latching relay connecting terminals 30 and 87A. Power is then removed from terminals 6 and 8 of park brake dash switch, de-energizing park brake solenoid and clutch disconnect solenoid. Park brake is applied.
TX,9015,QQ2705 1931AUG951/1
TM1496 (21SEP05)

092105
PN=275
Park Brake/Clutch Disconnect Circuit Schematic
9015 15 80
TX,9015,QQ2701 1931AUG951/3
TM1496 (21SEP05)

092105
PN=276
T8245AY
1931MAY94
9015 15 81
TX,9015,QQ2701 1931AUG952/3
TM1496 (21SEP05)

092105
PN=277
T8462AP
1910AUG95
9015 15 82
TX,9015,QQ2701 1931AUG953/3
TM1496 (21SEP05)

092105
PN=278
T8462AQ
1910AUG95
Park Brake/Neutral Disconnect Circuit Diagnostic Procedures This circuit is powered by FNR/park brake fuse.
1/1
Park Brake Switch Dash
Disconnect harness from park brake switch. Park brake switch OFF. Check for continuity between terminals 5 and 7, and 6 and 8. Is continuity measured?
T7199CS UN16AUG90
YES: Park brake switch is good. Check wiring harness. NO: Replace park brake switch.
Park brake switch ON. Check for continuity between terminals 5 and 1, and 6 and 2. Is continuity measured? 9015 15 83
1/1
Park Brake Solenoid CAUTION: Solenoid may be damaged if voltage is applied to connector terminal A with black wire. Key switch OFF. Disconnect harness from park brake solenoid.
T7199CT UN16AUG90
YES: Solenoid is good. Check wiring harness. NO: Replace solenoid.
Connect battery voltage to solenoid connector terminal B with red wire and ground connector terminal A with black wire. Does solenoid click?
1/1
TM1496 (21SEP05)

092105
PN=279
Loader Lever Switch Disconnect harness from loader lever switch Check for continuity between terminals with J27 tan wire and T53 blue wire. Is continuity measured? YES: Go to next step in this check NO: Replace loader lever switch.
T7199CU 1902OCT90
Disconnect harness from loader lever switch Depress loader lever switch and check for continuity between terminals with J27 tan wire and T53 blue wire. Is continuity measured? 9015 15 84
YES: Replace loader lever switch. NO: Loader lever switch is good. Check wiring harness.
T7199CU 1902OCT90
1/1
Gear Shift Lever Switch
Disconnect harness from gear shift lever switch. Check for continuity between terminals with T53 blue wire and T52 blue wire. Is continuity measured?
YES: Go to next step in this check. NO: Replace gear shift lever switch.
T7199CV 1902OCT90
Disconnect harness from gear shift lever switch. Depress gear shift lever switch and check for continuity between terminals with T53 blue wire and T52 blue wire. Is continuity measured?
YES: Replace gear shift lever switch. NO: Gear shift lever switch is good. Check wiring harness.
T7199CV 1902OCT90
1/1
Clutch Disconnect Solenoid
Key switch OFF. Disconnect harness from clutch disconnect solenoid.
Connect battery voltage to solenoid terminal B, and ground terminal A. Does solenoid click?
T7938AL UN24FEB93
1/1
TM1496 (21SEP05)

092105
PN=280
Forward/Reverse Solenoid Key switch OFF. Disconnect harness from forward/reverse solenoid. NO: Replace solenoid. Connect battery voltage to solenoid terminal A, and ground terminal B. Does solenoid click?
T7938AK UN24FEB93
YES: Solenoid is good. Check wiring harness.
Connect battery voltage to solenoid terminal C, and ground terminal B. Does solenoid click?
1/1
Park Brake Latching Relay
Key switch OFF. Disconnect harness from relay.
Connect battery voltage to terminal #86. Ground terminal #85. Does relay click?
T7287BH UN16AUG90
9015 15 85
Measure continuity between terminals #30 and #87. Is continuity measured?
1/1
Reverser Pressure Switch (S.N. 778668)
Disconnect harness from switch. Measure continuity between terminals A and B on connector end of switch. Is continuity measured?
YES: Replace switch. NO: Switch is good. Check wiring harness.
T7199EE UN02OCT90
1/1
TM1496 (21SEP05)

092105
PN=281
FNR Lever Key switch ON. FNR lever in neutral With harness connected, check voltage at terminals with P24 red wire and T12 blue wire. Are 12 volts measured at each terminal? YES: Go to next step in this check. NO: Check wiring harness.
9015 15 86
T7199BP 1902OCT90
T7199BQ 1902OCT90
1/1
Park Light Relay
Key switch OFF. Disconnect harness from relay.
Connect battery voltage to terminal #86. Ground terminal #85. Does relay click?
T7287BH UN16AUG90
1/1
TM1496 (21SEP05)

092105
PN=282
Park Brake Sensing Switch Key switch OFF. Disconnect harness from switch connector. Measure for continuity. Is continuity measured?
T7199CX UN16AUG90
YES: Go to next step in this check. NO: Replace park brake sensing switch.
Key switch OFF. Disconnect harness from switch connector. Depress switch actuator (spring pin). Measure for continuity.
T7199CX UN16AUG90
YES: Replace park brake sensing switch. NO: Park brake sensing switch is good. Check wiring harness. 9015 15 87
1/1
Park Brake Relay Diode
T7961AA UN10MAR93
1/1
Clutch Disconnect Solenoid
T7961AA UN10MAR93
1/1
TM1496 (21SEP05)

092105
PN=283
Horn Circuit Operational Information

The following conditions must exist for horn circuit to function: Key switch must be in ON or ACC position Horn switch must be depressed
TX,9015,QQ1821 1912MAR931/1
Horn Circuit Theory Of Operation

9015 15 88
Power flows from turn/stop/horn fuse to horn switch. When horn button is pushed, switch closes and power flows to activate horn.
TX,9015,QQ1786 1912MAR931/1
TM1496 (21SEP05)

092105
PN=284
Horn Circuit Schematic
9015 15 89
TX,9015,QQ1787 1912MAR931/1
TM1496 (21SEP05)

092105
PN=285
T7835AE
1923SEP92
Horn Circuit Diagnostic Procedures This circuit is powered by the turn/stop/horn fuse.
1/1
Horn Switch
Disconnect harness from horn switch. Push horn switch and measure for continuity.
YES: Horn switch is good. NO: Replace horn switch.
T7199CY UN16AUG90
9015 15 90
1/1
Horn
Key switch OFF. Disconnect harness from horn.
YES: Horn is good. Check wiring harness. 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

The following conditions must exist for turn signal, flasher and brake light circuit to function: Key switch in ON position
TX,9015,QQ1822 1912MAR931/1
TM1496 (21SEP05)

092105
PN=286
Turn Signal, Flasher And Brake Light Circuit Theory Of Operation

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 signal switch and out terminal 7 to left turn lights and left turn indicator light making them flash. Power is also sent 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.
9015 15 91
TX,9015,DY370 19 3JUN961/2
TM1496 (21SEP05)

092105
PN=287
Sub-System Diagnostics 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 15 92
TX,9015,DY370 19 3JUN962/2
TM1496 (21SEP05)

092105
PN=288
Turn Signal, Flasher And Brake Light Circuit Schematic
9015 15 93
TX,9015,QQ1999 1916MAR931/1
TM1496 (21SEP05)

092105
PN=289
T7938AB
1915FEB93
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. With 4-way flasher switch OFF, check for continuity between terminals 6 and 8. Is continuity measured? Flasher switch ON.
T7199CZ UN16AUG90
YES: 4-way flasher switch is good. Check wiring harness. NO: Replace 4-way flasher switch.
9015 15 94
Check for continuity between terminals 6 and 2, 5 and 3, 5 and 10, and 5 and 1. Is continuity measured?
1/1
Flasher
Key switch ON. 4-way flasher switch ON. Connect jumper wire from terminal with L49 brown wire to terminal with L50 brown wire. Do all turn lights function?
T7199DA 1917SEP90
YES: Replace flasher. NO: Check bulbs. Check wiring harness.
1/1
Turn Signal Switch
Disconnect harness from turn signal switch. With turn signal switch turned right, check for continuity between connector terminals 5 and 7, and 6 and 3. Is continuity measured? With turn signal switch turned left, check for continuity between connector terminals 5 and 3, and 6 and 7. Is continuity measured?
YES: Turn signal switch is good. Go to next check. NO: Replace turn signal switch.
T7199DB UN01OCT90
1/1
TM1496 (21SEP05)

092105
PN=290
Brake Light Disconnect harness from turn/tail/brake light. Connect 12 volts to terminal marked STOP, and ground terminal marked GROUND. Does brake light function? YES: Brake light is good. Check wiring harness. NO: Replace bulb. If bulb is good replace light.
T7199DS 1902OCT90
1/1
Turn Signal Light
Disconnect harness from turn/tail/brake light. Connect 12 volts to terminal marked DIRECTIONAL, and ground terminal marked GROUND. Does turn signal light function?
YES: Turn signal light is good. Check wiring harness. NO: Replace bulb. If bulb is good replace light.
9015 15 95
T7199DT 1902OCT90
1/1
Left/Right Indicator Light
Disconnect harness from indicator light. Connect battery voltage to purple wire and ground black wire. Does indicator light function?
YES: Indicator light is good. Check wiring harness. NO: Check bulb, if good replace indicator light.
T7199DC 1916AUG90
1/1
TM1496 (21SEP05)

092105
PN=291
Brake Light Switch Disconnect harness from brake light switch. Check for continuity between the two terminals. Is continuity measured? YES: Replace switch. NO: Go next step in this check.
T7199DD UN16AUG90
Disconnect harness from brake light switch. With brake light switch pushed (closed), check for continuity between the two terminals. Is continuity measured? 9015 15 96
YES: Brake light switch is good. Check wiring harness. NO: Replace switch.
T7199DD UN16AUG90
1/1
4-Way Flasher Switch Diode
T7961AA UN10MAR93
1/1
Beacon Circuit Operational Information

The following conditions must exist for beacon circuit to function: Key switch to ACC or ON position Beacon switch to ON position
TX,9015,QQ1823 1912MAR931/1
TM1496 (21SEP05)

092105
PN=292
Beacon Circuit Theory Of Operation

Power flows from return-to dig/beacon fuse to beacon switch. With beacon switch ON, power flows to the beacon. Ground for beacon is provided through G20 black wire.
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend, Group 9015-10.
TX,9015,QQ1791 1912MAR931/1
9015 15 97
TM1496 (21SEP05)

092105
PN=293
Beacon Circuit Schematic
9015 15 98
TX,9015,QQ1792 1912MAR931/1
TM1496 (21SEP05)

092105
PN=294
T7835AG
1923SEP92
Beacon Circuit Diagnostic Procedures This circuit is powered by the return-to-dig/beacon fuse.
1/1
Beacon Switch
Disconnect harness from beacon switch. Beacon switch ON. Check for continuity between terminals 1 and 5. Is continuity measured?
T7199DE UN02OCT90
YES: Beacon switch is good. Go to next check. NO: Replace beacon switch.
9015 15 99
1/1
Beacon
Disconnect harness from beacon. Connect 12 volts to beacon terminal (white wire), and ground beacon (black wire). Does beacon function?
YES: Beacon is good. Check wiring harness. NO: Check bulb, if good replace beacon.
T7199DF UN16AUG90
1/1
Return-To-Dig Circuit Operational Information

The following conditions must exist for return-to-dig circuit to function: Key switch ON Engine running
TX,9015,QQ1824 1912MAR931/1
TM1496 (21SEP05)

092105
PN=295
Return-To-Dig Circuit Theory Of Operation

Return-to-dig circuit consists of return-to-dig/beacon fuse, return-to-dig-switch and return-to-dig solenoid. Power flows from return-to-dig/beacon fuse to return-to-dig switch. When the bucket is not in the "LEVEL" position, the return-to-dig switch is closed which routes battery power to the return-to-dig solenoid. The return-to-dig solenoid is grounded through ground wire GO1 black.
9015 15 ,100
TX,9015,QQ1793 1912MAR931/1
TM1496 (21SEP05)

092105
PN=296
Return-To-Dig Circuit Schematic
9015 15 ,101
TX,9015,QQ1983 1916MAR931/2
TM1496 (21SEP05)

092105
PN=297
T7938AE
1915FEB93
9015 15 ,102
TX,9015,QQ1983 1916MAR932/2
TM1496 (21SEP05)

092105
PN=298
T7938AF
1915FEB93
Return-To-Dig Circuit Diagnostic Procedures This circuit is powered by the return-to-dig/beacon fuse.
1/1
Return-To-Dig Switch
Disconnect harness from return-to-dig switch. Check for continuity between common terminal and open terminal. Is continuity measured?
YES: Replace return-to-dig switch. NO: Go to next step in this check.
9015 15 ,103
T7199DG UN17SEP90
Disconnect harness from return-to-dig switch. Actuate return-to-dig switch. Check for continuity between common terminal and open terminal. Is continuity measured?
YES: Return-to-dig switch is good. Go to next check. NO: Replace return-to-dig switch.
T7199DG UN17SEP90
1/1
TM1496 (21SEP05)

092105
PN=299
Return-To-Dig Solenoid Disconnect harness from return-to-dig solenoid. Apply battery voltage to solenoid, and ground solenoid. Move control lever to return-to-dig detent position. Remove voltage from solenoid.
T7199DH 1917SEP90
YES: Return-to-dig solenoid is good. NO: Replace return-to-dig solenoid.
Does control lever stay in return-to-dig detent position until voltage is removed, and then return to neutral?
1/1
9015 15 ,104
Fuel Gauge And Hour Meter Circuit Specifications

Specification Fuel Gauge Level Sender Resistance of Empty Tank ........................................................... 10 ohms Resistance of Full Tank.............................................................. 180 ohms
TX,9015,QQ1825 1931AUG951/1
Fuel Gauge And Hour Meter Circuit Operational Information

The following conditions must exist for fuel gauge circuit to function: Key switch in ON position The following conditions must exist for tachometer/hour meter circuit to function: Key switch in ON position Engine running
TX,901515,QQ600 1931AUG951/1
TM1496 (21SEP05)

092105
PN=300
Fuel Gauge And Hour Meter Circuit Theory Of Operation

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: Power flows from W terminal of alternator through M39 purple wire to S terminal on tachometer/hour meter. 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 15 ,105
NOTE: For component identification code description,see Wiring and Schematic Diagrams Legend , Group 9015-10.
TX,9015,DY371 19 3JUN961/1
TM1496 (21SEP05)

092105
PN=301
Fuel Gauge And Hour Meter Circuit Schematic
9015 15 ,106
TX,9015,QQ2703 1931AUG951/2
TM1496 (21SEP05)

092105
PN=302
T8245BB
1931MAY94
9015 15 ,107
TX,9015,QQ2703 1931AUG952/2
TM1496 (21SEP05)

092105
PN=303
T8245BC
1931MAY94
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.

Key switch ON. Engine OFF.
YES: Fuel gauge is good. Go to next check. NO: Replace fuel gauge.
Disconnect harness from fuel gauge. Does gauge read EMPTY?

T7199DI UN02OCT90
Connect battery voltage to (+) terminal and ground GND terminal. Does gauge read FULL?
9015 15 ,108
1/1
Fuel Gauge Sender
Key switch ON. Engine OFF. Disconnect wire Y33 yellow from center of sender. Does gauge read EMPTY? Reconnect wire Y33 yellow to center of sender.
T6431AJ UN19OCT88
YES: Replace sender. NO: Fuel gauge sender is good. Check wiring harness to sender.
Attach a jumper wire from center screw to ground. Does gauge read FULL?
1/1
TM1496 (21SEP05)

092105
PN=304
Tachometer/Hour Meter Machine running. Lower all equipment to ground. FNR lever in neutral. 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? YES: Hour meter is bad, replace tachometer/hour meter. NO: Check wiring harness.
T7199DJ 1902OCT90
9015 15 ,109 Using a voltmeter, check voltage on terminal (SIG) M39 purple wire. Are 7.63 volts (AC) measured? NO: Check wiring harness. YES: Tachometer is bad, replace tachometer/hour meter.
T7199DK 1917SEP90
1/1
Alternator Relay
IMPORTANT: Relay is a six volt relay. Do not apply more than 6 volts when testing. Disconnect harness from relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay click?
T7596AQ 1903OCT91
1/1
TM1496 (21SEP05)

092105
PN=305
Alternator Diode Remove diode from connector. Connect an ohmmeter to diode terminals. Is continuity measured? Reverse ohmmeter probes.
T7961AA UN10MAR93
1/1
9015 15 ,110
Side Shift Locking Valve Circuit Operational Information315D

The following conditions must exist for side shift valve circuit to function: Key switch in ON position Side shift valve switch ON Engine running
TX,901515,QQ605 1916MAR931/1
Side Shift Locking Valve Circuit Theory Of Operation315D

Power flows from return-to-dig/beacon fuse through P20 red wires to side shift switch. With side shift switch pushed ON, power flows to solenoid through orange wire energizing side shift solenoid. With solenoid energized hydraulic pressure is released. With solenoid de-energized hydraulic pressure is applied.
NOTE: For component identification code description, see Legend For Schematic and Wiring Diagram , Group 9015-10.
TX,901515,QQ606 1916MAR931/1
TM1496 (21SEP05)

092105
PN=306
Side Shift Locking Valve Circuit Schematic315D
9015 15 ,111
TX,901515,QQ607 1916MAR931/1
TM1496 (21SEP05)

092105
PN=307
T7199BD
1927SEP90
Side Shift Locking Valve Circuit Diagnostic Procedures315D This circuit is powered by the Return-To-Dig/Beacon fuse.
1/1
Side Shift Locking Valve Switch
Disconnect harness from side shift valve switch. Check continuity between P20 red wire and orange wire. Is continuity measured?
YES: Replace side shift valve switch. NO: Go to next step in this check.
T7199DM 1917SEP90
9015 15 ,112
Disconnect harness from side shift valve switch. Push valve switch and measure continuity between P20 red wire and orange wire. Is continuity measured?
YES: Switch is good. Go to next check. NO: Replace side shift valve switch.
T7199DM 1917SEP90
1/1
Side Shift Locking Valve Solenoid
Disconnect harness from side shift solenoid. Connect battery voltage to terminal with orange wire and ground terminal with GO1 black wire. Does solenoid click?
T7199DL UN16AUG90
1/1
Auxiliary Valve Circuit Operational Information

The following conditions must exist for auxiliary valve circuit to function: Key switch ON position Machine running Auxiliary valve switch in FOOT ON or CONTINUOUS ON position
TX,9015,QQ2581 1912APR941/1
TM1496 (21SEP05)

092105
PN=308
Auxiliary Valve Circuit Theory Of Operation

The circuit consists of auxiliary valve relay, auxiliary valve switch, auxiliary valve diode, auxiliary valve foot switch and auxiliary valve solenoid. Components are grounded by the RO1 black wire through cab side console harness. With key switch on, power is routed through PO1 red wire to auxiliary valve relay terminal 30 and to auxiliary valve switch terminal 7. With auxiliary valve switch in OFF position power is routed out terminal 3 of auxiliary valve switch to terminals 85 and 87 of auxiliary valve relay. The relay is energized latching terminals 30 and 87 of auxiliary valve relay. When auxiliary valve switch is moved to FOOT ON position, power is routed out terminals 5 and 6. Power from terminal 6 is sent to terminal 9 for light in switch. Power from terminal 5 is sent to auxiliary valve foot switch. When foot switch is depressed power is sent to auxiliary valve solenoid energizing solenoid. When auxiliary valve switch is moved to CONTINUOUS ON position, power is routed out terminal 1 and 2. Power from terminal 2 is sent to terminal 9 for light in switch. Power from terminal 1 is sent to auxiliary valve solenoid energizing solenoid, keeping continuous power on solenoid.
9015 15 ,113
TX,9015,QQ2582 1912APR941/1
TM1496 (21SEP05)

092105
PN=309
Auxiliary Valve Circuit Schematic
9015 15 ,114
TX,9015,QQ2583 1912APR941/1
TM1496 (21SEP05)

092105
PN=310
T8166BL
1922FEB94
Auxiliary Valve Diagnostic Procedures This circuit is powered by monitor fuse.
1/1
Auxiliary Valve Relay
Key switch OFF. Disconnect harness from relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay click? Measure continuity between terminals #30 and #87.
T7287BH UN16AUG90
YES: Relay is good. Check wiring harness. NO: Replace auxiliary valve relay.
Is continuity measured? 9015 15 ,115

1/1
Auxiliary Valve Switch
Disconnect harness from auxiliary valve switch. Move auxiliary valve switch to FOOT ON. Measure for continuity between terminals 3 and 5, 3 and 6. Is continuity measured?
T8173BN UN20FEB94
YES: Auxiliary valve switch is good. Check wiring harness. NO: Replace auxiliary valve switch.
Measure for continuity between terminals 3 and 1, 3 and 2. Is continuity measured?

1/1
Auxiliary Valve Diode Check
T7961AA UN10MAR93
1/1
TM1496 (21SEP05)

092105
PN=311
Auxiliary Valve Foot Switch Disconnect harness from auxiliary valve foot switch. Foot switch pressed. Measure for continuity between terminals A and B of connector end. Is continuity measured? YES: Auxiliary valve foot switch is good. Check wiring harness. NO: Replace auxiliary valve foot switch.
9015 15 ,116
T8173BP UN20FEB94
1/1
TM1496 (21SEP05)

092105
PN=312
Auxiliary Valve Solenoid Key switch ON. Auxiliary valve switch to CONTINUOUS ON. Harness wires connected. Check battery voltage at (A). Is battery voltage measured? Check continuity at (B). Is continuity measured? YES: Continue on. NO: Check ground connection at (B). Check wiring harness.
T8176AF UN20FEB94
9015 15 ,117 Disconnect harness wires from valve. Check continuity at (A). Is continuity measured? YES: Solenoid is good. NO: Replace solenoid.
T8176AF UN20FEB94
1/1
TM1496 (21SEP05)

092105
PN=313
9015 15 ,118
TM1496 (21SEP05)

092105
PN=314
Group 20
References
Alternators And Starting MotorsUse CTM77
For additional information, the component technical manual (CTM) is also required. Use the CTM in conjunction with this machine manual.
UN17JAN89
TX,9010,SS2208 1901SEP941/1

UN28FEB89
TS225
9015 20 1
AClamp-on Transducer. Remove paint with emery cloth and connect to a straight section of injection line within 100 mm (4 in.) of pump. Finger tighten only. DO NOT overtighten. BBlack Clip (-). Connect to main frame. CRed Clip (+). Connect to transducer. DTachometer Readout. Install cable.
10T,9010,K182 1910AUG951/1
TM1496 (21SEP05)

092105
PN=315
T6813AG
References
Battery Operation
A battery is a device for converting chemical energy to electrical energy. It is not a storage tank for electricity, but stores electrical energy in chemical form. Because of the constant chemical to electrical change (self-discharge, discharge, or charge), the battery has a limited life. Proper care (cleaning, adding water, charging) will extend the life of the battery. The battery is made up of positive plates, negative plates, separators, plate straps, and chemical solution (electrolyte). The electrolyte is a solution of sulfuric acid and water. Sulfuric acid is not lost during overcharging; therefore, if the liquid solution is low, only water should be added. In a fully charged battery, the positive plate is lead peroxide (PBQ2), the negative plate is "spongy" lead (Pb), and the electrolyte solution is about 1.270 times heavier than water. The amount that the solution is heavier than water is called specific gravity. All batteries will self discharge at a rate of .001 specific gravity point per 24 hour period at a constant 85 F.
Specification BatteryDischarge Rate .................... .001 Specific Gravity Point per 24 Hour Period at a Constant 85 F
Batteries should be maintained at an open circuit voltage of 12.50 volts or greater. To determine open circuit voltage do the following: 1. Turn master disconnect switch to ON position. 2. For machines that have not been run during the past ten hours, go to Step 4. 3. For machines that have been run in the past ten hours, remove surface charge. Turn key switch to START, turn on 3 or 4 work lights and leave them on for 3 to 5 minutes. Turn key switch OFF, then wait two minutes. (If machine does not have lights, turn key switch to START position for at least 5 minutes, then turn off.) 4. Measure voltage at alternator by placing the negative lead of a multimeter to case of alternator and the positive lead to the sense terminal of the alternator.
Specification Stabilized Open Circuit 12.5 Volts or MorePercent Charged ...................................................................................... 100% Stabilized Open Circuit 12.4 Volts or MorePercent Charged ........................................................................................ 75% Stabilized Open Circuit 12.2 Volts or MorePercent Charged ........................................................................................ 50% Stabilized Open Circuit 12.0 Volts or MorePercent Charged ........................................................................................ 25% Stabilized Open Circuit 11.7 Volts or LessPercent Charged .......................................................................................... 0%
9015 20 2
The discharge rate increases as temperature increases and decreases as temperature decreases. If the machine is not used for a period of time, the batteries must be maintained or stored in a cool place. Wipe batteries with a damp cloth. If terminals are corroded, use a stiff brush and wash with an ammonia solution. After washing, flush battery and compartment with clear water. Keep caps in place when cleaning and charging.
TX,9015,MM1631 1910AUG951/1
TM1496 (21SEP05)

092105
PN=316
References
Battery Specifications
Specification BatteryVoltage............................................................................. 12 volts Cold Cranking Power ............................................ 625 amps18C (0F) Reserve Capacity ................................................ 160 minutes at 25 amps BCI Group Size ...................................................................................... 31 Fully Charged Electrolyte Specific Gravity ................................................................................... 1.2651.280
TX,901505,QQ368 1910AUG951/1
9015 20 3
TM1496 (21SEP05)

092105
PN=317
References
Diagnose Battery Malfunctions

Battery Using Too Much Water
Shorted battery cell
Check battery state of charge. (See Procedure for Testing Batteries.) Add distilled water. Check battery hold down clamps. Replace battery. Do Alternator Output Check. (See Charging Circuit Operational Checks.) Install new battery. Install hold down clamps correctly. Keep electrolyte at correct level and battery fully charged during cold weather. See Battery Using Too Much Water and Cracked Battery Case symptoms. Clean battery top. Recharge battery.
High ambient temperature Cracked battery case
Regulator
9015 20 4
Cracked Battery Case
Battery hold down clamp too tight, too loose or missing Frozen battery
Low Battery Output
Low water level
Dirty or wet battery top, causing discharge Corroded or loose battery cable ends Broken or loose battery posts
Clean and tighten cable end clamps. Recharge battery. Wiggle posts by hand. If posts are loose or will turn, replace battery. Inspect belt or pulley. Adjust or replace as necessary.
Loose fan/alternator belt or worn pulleys
TX,901505,QQ365 1910AUG951/1
TM1496 (21SEP05)

092105
PN=318
References
Check Battery Electrolyte Level And Terminals

1. Remove hold-down clamps. 2. Remove battery covers.
ABattery Post BFill Tube CElectrolyte Level Range
9015 20 5
Single Level Fill Tube Application
Dual Level Fill Tube Application
TX,9015,QQ1696 1901SEP951/2
TM1496 (21SEP05)

092105
PN=319
T6996DA
UN09SEP03
T6996DB
UN09SEP03
TS203
UN23AUG88
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 6
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 1015 minutes. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. IMPORTANT: During freezing weather, batteries must be charged after water is added to prevent battery freezing. Charge battery using a battery charger or by running the engine. 3. Fill each cell to within specified range with distilled water. DO NOT overfill.
TX,9015,QQ1696 1901SEP952/2
TM1496 (21SEP05)

092105
PN=320
References
Procedure For Testing Batteries

VISUAL CHECK 1. Check for damage such as cracked or broken case and electrolyte leakage. If damage is seen, replace battery. 2. Check electrolyte level. (See procedure in this group) If low, add distilled water to specified level and charge battery. 3. Check terminals for corrosion. If corroded, clean using a wire brush or battery post cleaner such as JT05838 Battery Post/Clamp Cleaner. 4. Check posts for looseness. If posts are loose, replace battery. HYDROMETER TEST Check specific gravity with a hydrometer or battery tester such as JT05460 Coolant/Battery Tester. Record specific gravity reading for each cell. If high and low readings vary LESS than 0.050 and average specific gravity is between 1.225 and 1.280, battery is fully charged, go to LOAD TEST. If high and low readings vary LESS than 0.050 and average specific gravity is LESS than 1.225, charge battery and repeat test. If average specific gravity is still LESS than 1.225, replace both batteries. If high and low readings vary MORE than 0.050, charge battery and repeat test. If high and low readings still vary MORE than 0.050, replace both batteries.
9015 20 7
TX,9015,DY374 19 4JUN961/2
TM1496 (21SEP05)

092105
PN=321
References
LOAD TEST Check battery capacity with a load tester such as JT05832 Battery Load Tester. Follow tester manufacturers instructions for proper load test procedures. If one battery fails load test, replace both batteries.
TX,9015,DY374 19 4JUN962/2
9015 20 8
TM1496 (21SEP05)

092105
PN=322
References
Using Booster Batteries12 Volt System

Before boost starting, machine must be properly shut down and secured to prevent unexpected machine movement when engine starts. CAUTION: An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Make sure the batteries are charged in a well ventilated area. IMPORTANT: The machine electrical system is a 12 volt negative (-) ground. Use only 12 volt booster batteries. Connect booster batteries as shown for your battery application. Make last connection to frame.
UN24OCT91
9015 20 9
AMachine Batteries BBooster Batteries
Single Battery Application
Two Battery Application

TX,901505,QQ364 1901SEP951/1
TM1496 (21SEP05)

092105
PN=323
T6713AI1
UN24OCT91
T6508AE1
References
Alternator Operation78 Amp Delco Remy (Serial No.787513)
9015 20 10
AAlternator BBattery CKey Switch DIndicator Light
EAlternator Relay FBAT terminal GR Terminal HTerminal 2
ITerminal 1 JRegulator KDiode Trio LRotor (Field)
MStator NRectifier ODiode
The alternator is a 12 volt system. The operating principles are as follows: When key switch (C) is turned ON, voltage is applied to terminal 1 (I) of the alternator. The regulator (J) switches the rotor (L) ON or OFF. Once the engine reaches alternator cut in RPM, alternating output current is produced in the stator (M) windings. This alternating current is changed to direct current by the rectifier (N) diodes. Voltage is available at BAT (F) terminal. The current is used to charge the 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.
The regulator (J) acts like a switch for the rotor (L). A wire runs from BAT terminal (F) to terminal 2 (H). If the regulator (J) senses a low battery voltage, rotor is switched on. Field current increases and alternator output increases. When high battery voltage is sensed by the regulator the rotor is switched off, reducing current output from stator. This on and off occurs many times a second. The voltage regulator is temperature compensated to provide a slightly higher voltage at low temperature to charge the battery. When the alternator is operating, the R terminal voltage is approximately 7.8 volts AC.
TX,9015,QQ1926 1910AUG951/2
TM1496 (21SEP05)

092105
PN=324
T7596AR
1903OCT91
References
Specification R TerminalApproximate Voltage (when Alternator is Operating) ........................................................................ 7.8 volts AC
energizing the relay and removing the ground for the alternator indicator light (D) in the display module, turning off the alternator indicator light.
This voltage is supplied to the alternator relay,
TX,9015,QQ1926 1910AUG952/2
Alternator Operation95 Amp Bosch (Serial No. 787514 )

9015 20 11
AAlternator BInternal Ground CNegative Diodes DExciter Diodes EStator Windings FPositive Diodes
GD+ Terminal HB+ Terminal IW Terminal JExcitation Winding KRegulator
LExternal Ground Terminal MRotor NAlternator Diode OBattery PKey Switch
QAlternator Relay RIndicator Light SBrushes TSense Circuit UNoise Filter
TX,9015,QQ1927 1910AUG951/1
TM1496 (21SEP05)

092105
PN=325
T7812AZ
1923SEP92
References
Alternator Operation95 Amp Bosch

The 95 AMP Bosch alternator has three basic stages for proper operation. The operating principles are as follows. PRE-EXCITATION STAGE: When key switch (P) is turned to ON position, battery power flows to (G) terminal D+ on alternator, excitation winding (J), through regulator (K) and to internal ground (B). EXCITATION STAGE: During alternator start (as the engine speeds up from 0 to idle) current supplied by the external alternator diode to the field coil of the rotor produces a magnetic field which induces current in the three-phase winding of the stator (E). The alternator reaches cut-in RPM when the induced current is large enough to produce voltage equal to the battery voltage plus 1.0 volt. At this time, some current from the stator is rectified by the exciter diodes (D) (producing battery voltage at the D+ terminal (G)) and is supplied to the carbon brushes and slip rings of the excitation winding (J), strengthening the magnetic field in the excitation winding. This in turn will increase the stator voltage. This will occur continuously until the alternator (A) is fully excited and the alternator regulated voltage is reached.
9015 20 12
TX,9015,DY373 19 3JUN961/2
TM1496 (21SEP05)

092105
PN=326
References
NORMAL OPERATION: The alternating current induced in the stator winding (J) is rectified by the positive and negative diodes (C and F) and delivered to the battery and current consuming accessories. The currents in the stator winding (E) are constantly changing magnitude and direction. However, current flowing to the battery and accessories always maintains the same direction. This is because no matter what position the rotor (M) is in, all the diodes are simultaneously involved in the process of rectification. The regulator (K) measures the B+ voltage (H) and compares it to an internal reference. When the B+ voltage (H) starts to rise above the reference voltage the regulator (K) switches off the field current. When the B+ voltage (H) starts to fall below the reference voltage the regulator (K) switches on the field current. The regulator (K) switches the field ON and OFF several thousand times a second in response to the current load placed on the alternator output and the engine RPM. When the alternator is operating, the W terminal voltage is (7 to 8) volts (AC). This voltage is supplied to the alternator relay, energizing the relay and removing the ground for the alternator indicator light (Q) in the display module, turning off the alternator indicator light. Current available from the alternator is dependent on engine RPM. Depending on pulley ratios, little or no current is available below abut 700 RPM. Full rated current is not available below about 1500 RPM.
9015 20 13
TX,9015,DY373 19 3JUN962/2
TM1496 (21SEP05)

092105
PN=327
References
Monitor Test In Machine

1. Turn key switch to "bulb Check" position. All indicator and warning lights and the buzzer must come on. If none of the lights come on, check the "monitor" fuse. If one or two lights fail to light, replace the bulb. 2. Return key switch to "on" position from "bulb check". Hold just momentarily in "bulb check". If held too long, the logic modules with time delay will have no delay. With machines that have time delay logic modules, after 2-3 seconds the engine oil pressure and engine alternator volts indicator lights and the red warning light and buzzer should come on. With no time delay the lights and buzzer will come on immediately. On some machines additional indicator lights may come on, depending on sending unit switches being closed and sending a ground signal to the monitor. 3. Turn key switch to "off" position. Disconnect lead from engine oil pressure switch and all other sending unit switches that are closed and sending a ground signal for a primary (red light) failure indication. 4. Turn key switch to "bulb check" momentarily and back to "on". After 2-3 seconds, the alternator indicator light and the yellow warning light should come on. There may be additional indicator lights on, depending on which secondary (yellow light) failure sending unit switches are closed. 5. If the warning lights do not come on, with (S.N XXXXXX) the next step is to isolate the logic module from the display module and the machine wiring and sending units. See Logic Module Test In Machine, and Logic Module Bench Test in this group.
9015 20 14
TX,9015,QQ3203 1931AUG951/1
TM1496 (21SEP05)

092105
PN=328
References
Logic Module Test In Machine (S.N. XXXXXX)

1. Disconnect 6 wire connector (G) from left side of display. Turn key switch ON. Ground pins "D" "E" and "F" one at a time. 2. Pin "D" must be grounded first to "arm" logic module. 3. With pin "D" grounded, yellow service required light, red STOP light and alarm must come on. 4. With pin "E" grounded, yellow service required light must come on. 5. With pin "F" grounded, red STOP light and alarm must come on. If logic module does not work when grounding pins "D", "E" and "F", check logic module wiring by continuing with step 6. If wiring is OK, replace logic module. 6. To check wiring, reconnect wiring at display module.
9015 20 15
TX,9015,QQ3201 1931AUG951/2
TM1496 (21SEP05)

092105
PN=329
T6883BE
UN03NOV88
References
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: A12 Volts C12 Volts Continuity ChecksKey Switch OFF A of 4-Pin to C of 4-Pin A of 4-Pin to D of 6-Pin 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.
9015 20 16
TX,9015,QQ3201 1931AUG952/2
TM1496 (21SEP05)

092105
PN=330
T8174AM
UN09FEB94
References
Logic Module Bench Test (S.N. XXXXXX)

IMPORTANT: DO NOT allow wires to touch one another after being connected to logic module. 1. Connect wires (A and B) from positive (+) battery post to pins A and C in large connector. 2. Connect wire (C) from negative battery post to pin F in large connector. 3. Using a 12V indicator light with two wire leads, connect one lead to pin D in large connector, and one lead to pin A in small connector. 4. Connect wire (D) to pin E in large connector, and negative battery post. Light must come on. If it does, remove wire from pin E and go to next step. If light does not come on, replace module. 5. Connect wire (E) to pin B in small connector. Light must come on. If it does, remove wire (E) from pin B and go to next step. If light does not come on, replace module. 6. Remove the indicator light lead from pin D in large connector and connect to pin C in small connector. Connect wire (D) to pin D in small connector. Light must pulse on and off. If it does not, replace module.
UN28FEB94
9015 20 17
TX,9015,QQ3202 1931AUG951/1
TM1496 (21SEP05)

092105
PN=331
T8188AN
UN28FEB94
T8188AM
References
Tachometer Calibration
1. Remove heater control knob, blower speed knob and four side console panel screws to remove panel.
UN27JUN91
2. Verify engine speed using tachometer. See Tachometer Installation in this group. 3. Adjust screw (B) to adjust machine tachometer to high idle speed.
TX,9015,QQ1798 1931AUG951/1
9015 20 18
TM1496 (21SEP05)

092105
PN=332
T7545BQ
Section 9020
Power Train
Contents
Page Page
Group 05Theory Of Operation Park Brake Operation . . . . . . . . . . . . . . . . . .9020-05-1 Reverser Operation . . . . . . . . . . . . . . . . . . . .9020-05-2 Reverser Operation (SN 792482). . . . . . . .9020-05-4 Reverser Oil Flow (SN 792483 ) . . . . . . . .9020-05-9 Disconnect Clutch Solenoid Activated (SN 792482) . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-14 Directional Control Valve (SN 792482). . .9020-05-16 Torque Converter Operation . . . . . . . . . . . .9020-05-18 Oil Flow To And From Torque Converter (SN 792482) . . . . . . . . . . . . . . . . . . . . . . . .9020-05-20 Transaxle300D . . . . . . . . . . . . . . . . . . . .9020-05-22 Transaxle310D, 315D (SN 796033) . . .9020-05-23 Transaxle310D, 315D (SN 796034 ). . .9020-05-24 Second Speed Operation . . . . . . . . . . . . . .9020-05-25 Third Speed Operation . . . . . . . . . . . . . . . .9020-05-26 Synchronizer Operation. . . . . . . . . . . . . . . .9020-05-27 Brake Valve Operation . . . . . . . . . . . . . . . .9020-05-28 Service Brake Pressure Lubrication (SN 796851) . . . . . . . . . . . . . . . . . . . . . . . .9020-05-29 Service Brake Pressure Lubrication (SN 796852 ). . . . . . . . . . . . . . . . . . . . . . . .9020-05-30 MFWD System Operation . . . . . . . . . . . . . .9020-05-32 MFWD Differential OperationUnequal Traction . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-34 MFWD Differential OperationEqual Traction . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-36 Group 10System Operational Checks System Operational Procedure . . . . . . . . . . .9020-10-1 Brake System Checks . . . . . . . . . . . . . . . . . .9020-10-1 Reverser Checks. . . . . . . . . . . . . . . . . . . . . .9020-10-2 Transaxle Checks . . . . . . . . . . . . . . . . . . . . .9020-10-4 Mechanical Front Wheel Drive (MFWD) Driving Checks . . . . . . . . . . . . . . . . . . . . .9020-10-5 Group 15System Diagnostic Information Reverser Oil Passage Identification. . . . . . . .9020-15-1 Diagnose Power Train Malfunctions . . . . . . .9020-15-4 Group 20Adjustments Adjust Brake Pedals And Equalizing Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1 Adjust Park Brake . . . . . . . . . . . . . . . . . . . . .9020-20-3 TM1496 (21SEP05)
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . .9020-20-6 Check And Adjust Toe-In . . . . . . . . . . . . . . .9020-20-8 Group 25Tests JT05801 Clamp-On Electronic Tachometer Installation . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-1 JT05800 Digital Thermometer Installation . . .9020-25-1 Transaxle Oil Warm-Up Procedure . . . . . . . .9020-25-1 Transaxle Pump Flow Test . . . . . . . . . . . . . .9020-25-3 Reverser Oil Warm-Up Procedure . . . . . . . . .9020-25-4 Torque Converter Speed Test . . . . . . . . . . . .9020-25-5 Brake Valve Leakage Test . . . . . . . . . . . . . .9020-25-6 Park Brake Release Pressure Test . . . . . . . .9020-25-7 Reverser Disconnect Clutch Solenoid (SN 792482) . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-9 Reverser Disconnect Clutch Solenoid Test (SN 792483 ) . . . . . . . . . . . . . . . . . . . .9020-25-11 Reverser Cooler Pressure Test (SN 792482) . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-13 Reverser Cooler Pressure Test (SN 792483 ). . . . . . . . . . . . . . . . . . . . . . . .9020-25-15 Reverser/Converter-In Relief Valve Test (SN 792482) . . . . . . . . . . . . . . . . . . . . . . . .9020-25-17 Reverser/Converter-In Relief Valve Test (SN 792483 ). . . . . . . . . . . . . . . . . . . . . . . .9020-25-19 Reverser Oil Cooler Restriction Test (SN 792482) . . . . . . . . . . . . . . . . . . . . . . . .9020-25-21 Reverser Oil Cooler Restriction Test (SN 792483 ). . . . . . . . . . . . . . . . . . . . . . . .9020-25-23 Reverser Leakage Test Using Four-Gauge Method (SN 792482) . . . . . . . . . . . . . .9020-25-25 Reverser Leakage Test Using Four-Gauge Method (SN 792483 ). . . . . . . . . . . . . .9020-25-27 Reverser Pump Flow Test (SN 792482) . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-29 Reverser Pump Flow (SN 792483 ) . . . . .9020-25-31 Complete Reverser Test (SN 792482) . . .9020-25-33 Complete Reverser System Test (SN 792483 ). . . . . . . . . . . . . . . . . . . . . . . .9020-25-34 Test Procedure . . . . . . . . . . . . . . . . . . . . . .9020-25-35 Reverser Test Procedure Chart. . . . . . . . . .9020-25-37 Specifications And Analysis. . . . . . . . . . . . .9020-25-38
9020

092105
PN=1
Contents
9020
TM1496 (21SEP05)

092105
PN=2
Group 05
Theory Of Operation
Park Brake Operation
C
E D B
A
TXC7387AH CV
UN26FEB99
F BRAKE ACTUATOR-PRESSURIZED
APressure Oil BParking Brake Linkage
CFacing DRelease Rod
ERelease Nut
FBrake Actuator Pressurized
The parking brake drum is mounted on the differential cover and turns with the ring gear. The brake band that is installed on the brake drum operates in oil and locks the final drive power train to the case when applied. The parking brake is spring applied and hydraulically released during normal machine operation. Pressure oil from the reverser hydraulic system is controlled with
a solenoid valve that is actuated by a switch on the console. Pressure oil from the energized parking brake solenoid is routed to the parking brake actuator facing (C) and brake linkage (B). The pressure oil releases the brake. Brake can also be manually released for towing by turning nut (E) until rod (D) bottoms.
TX,300D,1973 1908MAR931/1
TM1496 (21SEP05)

092105
PN=335
T7387AH
9020 05 1
Theory Of Operation
Reverser Operation
9020 05 2
Reverser (S.N. 792482) Shown

AReverse Brake BForward Clutch CDirectional Control Valve DPlanetary EOil Pump
T59,9020,340 1912JUL941/2
TM1496 (21SEP05)

092105
PN=336
T7366BE
UN30OCT90
Theory Of Operation
C CLUTCH DISCONECT SOLENOID A PUMP D FNR SOLENOID
B PRESSURE REGULATING VALVE
E CONVERTER-IN RELIEF VALVE LUBE
LUBE
LUBE
J HIGH PRESSURE OIL K MEDIUM PRESSURE OIL L LUBE OIL M PRESSURE FREE OIL
TXC8266AD CV
H TORQUE CONVERTER I COOLER
G REVERSE CLUTCH
F
1901JAN99
092105
FORWARD CLUTCH
9020 05 3
N REVERSER SYSTEM SCHEMATIC FORWARD

(S.N.792483 ) Shown
The reverser is a forward-neutral-reverse gearbox that receives input from torque converter. It contains a forward multi-disk direct drive clutch (B), reverse multidisk brake (A), planetary gear set (D) and a directional control valve (C). Power flow through reverser provides input to transaxle assembly.
Lubrication oil and element engagement pressure oil is supplied by a crescent type oil pump (E). The pump is mounted on the reverser front cover and is driven at engine speed by torque converter drive tangs.
T59,9020,340 1912JUL942/2
TM1496 (21SEP05)

PN=337
T8266AD
Theory Of Operation
Reverser Operation (SN 792482)
9020 05 4
A B C
C
TXC7366BG
OIL FLOW IN NEUTRAL
TX,210D,1937 1912JUL941/6
TM1496 (21SEP05)

092105
PN=338
T7366BG
UN26FEB99
Theory Of Operation
AHigh Pressure Oil BLubrication Oil CReturn Oil (Pressure Free) DOil Flow in Neutral
Oil Flow In Neutral When the directional control lever is moved to the neutral position, pressure oil (A) is blocked from the forward clutch and reverse brake by the directional control solenoid valve. The directional control solenoid valve is de-energized.
Reverser pump and torque converter continue to operate providing lubrication oil and oil to the cooler. Both the forward clutch and reverse brake pistons dump oil (C) to reservoir which results in a complete interruption of power flow through the reverser.
TX,210D,1937 1912JUL942/6
9020 05 5
TM1496 (21SEP05)

092105
PN=339
Theory Of Operation
D
9020 05 6
A B C
TXC7366BH
E OIL FLOW IN FORWARD

CReturn Oil (Pressure Free) DPlanetary (Viewed from Front)
APressure Oil BLubrication Oil
EOil Flow in Forward

TX,210D,1937 1912JUL943/6
TM1496 (21SEP05)

092105
PN=340
T7366BH
UN26FEB99
Theory Of Operation
Oil Flow In Forward When the FNR lever is shifted to forward position, the directional control solenoid is energized and forces the inner spool IN. This allows high pressure regulated oil (A) from the reverser pump to flow through the valve and internal housing passages to the output shaft. Oil flows through passages in the output shaft to the forward clutch piston. Pressure oil moves the piston against the disks and plates. With the forward clutch engaged the input shaft, planetary and output shaft rotate as one assembly. Oil behind the reverse brake piston is routed to return to disengage reverse brake. Forward clutch lubrication requirements are increased when clutch is engaged causing lower pressure in the forward clutch circuit. This pressure will be slightly lower than system pressure and reverse brake engagement.
TX,210D,1937 1912JUL944/6
9020 05 7
TM1496 (21SEP05)

092105
PN=341
Theory Of Operation
E
9020 05 8
A B C
TXC7366BI
AHigh Pressure Oil BLubrication Oil
CReturn Oil
DOil Flow in Reverse

EPlanetary (Viewed from Front)

TX,210D,1937 1912JUL945/6
TM1496 (21SEP05)

092105
PN=342
T7366BI
D OIL FLOW IN REVERSE
UN26FEB99
Theory Of Operation
Oil Flow In Reverse When FNR lever is moved to reverse position, the directional control valve solenoid is energized and pulls the inner valve spool OUT and allows high pressure regulated oil (A) from the reverser pump to flow through the valve and internal housing passages to the reverse brake piston. Oil pressure moves the piston against disks, plates, and the reverser housing. With reverse brake engaged, the ring gear cannot rotate. The input shaft turns inside the planetary assembly. This rotation causes the pinion gears to rotate against the inside of the ring gear causing planetary and output shaft assembly to rotate in opposite directions of input shaft. This causes a 10 percent speed reduction in reverse gears. Forward clutch continues to receive lubrication oil (B). Forward clutch piston oil is open to return to disengage forward clutch.
TX,210D,1937 1912JUL946/6
Reverser Oil Flow (SN 792483 )

Reverser oil flows from the oil pan through suction strainer to the reverser pump (O). The reverser pump is driven at engine speed by the torque converter drive tangs. High pressure oil (S) flows from the reverser pump through internal passages to the clutch disconnect solenoid. The clutch disconnect solenoid is energized with engine running and allows oil flow to FNR solenoid. Pressure oil is also routed through an external line to the parking brake solenoid valve. Pressure regulating valve (K) maintains high pressure oil for forward clutch, reverse brake and lubrication oil. Oil not needed for element engagement or lubrication flows through external line to the torque converter. Torque converter-in (cooler) relief valve (I) protects torque converter and oil cooler components from damage. Low pressure oil from the torque converter flows to cooler. Oil from the cooler returns to the oil pan.
9020 05 9
TX,9020,YY748 1912JUL941/5
TM1496 (21SEP05)

092105
PN=343
Theory Of Operation
T7949AA 1901JAN99
A TO PARK BRAKE B TO TORQUE CONVERTER INLET
CLUTCH D DISCONNECT SOLENOID
C FNR SOLENOID
CONVERTER OUT/ N TO COOLER
REVERSER PUMP O
INLET FROM DISCONNECT SOLENOID G
F TO FNR SOLENOID
E INLET FROM PRESSURE REGULATING VALVE CONVERTER-IN I RELIEF VALVE J RETURN TUBE
FORWARD CLUTCH P M REVERSER (SIDE VIEW) REVERSE BRAKE Q
FROM H REVERSER PUMP
R REVERSER OIL FLOW IN NEUTRAL S PRESSURE OIL T CONVERTER-IN OIL U CONVERTER OUT/TO COOLER V LUBRICATION OIL W RETURN OIL
TXC7949AA CV
K PRESSURE REGULATING VALVE L REVERSER (REAR VIEW)
TX,9020,YY748 1912JUL942/5
TM1496 (21SEP05)

092105
PN=344
Theory Of Operation
ATo Park Brake BTo Torque Converter Inlet CFNR Solenoid DClutch Disconnect Solenoid EInlet from Pressure Regulating Valve FTo FNR Solenoid GInlet from Disconnect Solenoid HFrom Reverser Pump IConverter-in Relief Valve JReturn Tube KPressure Regulating Valve LReverser (Rear View) MReverser (Side View) NConverter Out/To Cooler OReverser Pump PForward Clutch QReverse Brake RReverse Oil Flow in Neutral SPressure Oil TConverter-in Oil UConverter Out/To Cooler VLubrication Oil WReturn Oil
TX,9020,YY748 1912JUL943/5
9020 05 11
TM1496 (21SEP05)

092105
PN=345
Theory Of Operation
T7949AB 1901JAN99
A TO PARK BRAKE B TO TORQUE CONVERTER INLET D CLUTCH DISCONNECT SOLENOID
C FNR SOLENOID
CONVERTER OUT/ N TO COOLER REVERSER PUMP O
INLET FROM DISCONNECT SOLENOID G
F TO FNR SOLENOID
INLET FROM E PRESSURE REGULATING VALVE
FORWARD CLUTCH P M REVERSER (SIDE VIEW) REVERSE BRAKE Q
FROM H REVERSER PUMP
I CONVERTER-IN RELIEF VALVE J RETURN TUBE
R REVERSER OIL FLOW IN FORWARD S PRESSURE OIL T CONVERTER-IN OIL U CONVERTER OUT/TO COOLER V LUBRICATION OIL W RETURN OIL
TXC7949AB CV
PRESSURE K REGULATING VALVE L REVERSER (REAR VIEW)
TX,9020,YY748 1912JUL944/5
TM1496 (21SEP05)

092105
PN=346
Theory Of Operation
ATo Park Brake BTo Torque Converter Inlet CFNR Solenoid DClutch Disconnect Solenoid EInlet from Pressure Regulating Valve FTo FNR Solenoid GInlet from Disconnect Solenoid HFrom Reverser Pump IConverter-in Relief Valve JReturn Tube KPressure Regulating Valve LReverser (Rear View) MReverser (Side View) NConverter Out/To Cooler OReverser Pump PForward Clutch QReverse Brake RReverse Oil Flow in Forward SPressure Oil TConverter-In Oil UConverter Out/To Cooler VLubrication Oil WReturn Oil
When the FNR lever is shifted to forward position, the FNR solenoid is energized allowing high pressure regulated oil (S) from the reverser pump to flow through the valve and internal housing passages to the output shaft. Oil flows through passages in the output shaft to the forward clutch piston. Pressure oil moves the piston against the disks and plates. With the forward clutch engaged the input shaft, planetary and output shaft rotate as one assembly.
Oil behind the reverse brake piston is routed to return to disengage reverse brake. Forward clutch lubrication requirements are increased when clutch is engaged causing lower pressure in the forward clutch circuit. This pressure will be slightly lower than system pressure and reverse brake engagement.
9020 05 13
TX,9020,YY748 1912JUL945/5
TM1496 (21SEP05)

092105
PN=347
Theory Of Operation
Disconnect Clutch Solenoid Activated (SN 792482)
9020 05 14
A B C
TXC7366BJ
D DISCONNECT CLUTCH SOLENOID ACTIVATED

Continued on next page TX,300D,1966 1912JUL941/2
TM1496 (21SEP05)

092105
PN=348
T7366BJ
UN26FEB99
Theory Of Operation
AHigh Pressure Oil BLubrication Oil CReturn Oil (Pressure Free) DDisconnect Clutch Solenoid
The disconnect clutch solenoid is used to disengage the forward clutch or reverse brake without moving the FNR lever. This provides maximum engine power to the hydraulic function during loader operation. The disconnect clutch solenoid can be de-energized by pressing the button on the transmission shift lever or loader control valve lever. When de-energized, spring force moves the inner spool IN which blocks the flow of high pressure oil to the direction control valve solenoid. At the same time, the spool connects the forward clutch and reverse brake passages to sump which disengages power flow by releasing all previous engagement pressure oil.
With reverse brake engaged, the ring gear cannot rotate. The input shaft turns inside the planetary assembly. This rotation causes the pinion gears to rotate against the inside of the ring gear causing planetary and output shaft assembly to rotate in opposite directions of input shaft. This causes a 10% speed reduction in reverse gears. Forward clutch continues to receive lubrication oil (B). Forward clutch piston oil is open to return to disengage forward clutch.
9020 05 15
TX,300D,1966 1912JUL942/2
TM1496 (21SEP05)

092105
PN=349
Theory Of Operation
Directional Control Valve (SN 792482)
ADirection Control Solenoid
BClutch Cut-off Solenoid
CInner Valve Spool
DCentering Spring
The directional control valve has two electrically actuated solenoids that control oil flow for element engagement. The disconnect clutch cut-off solenoid (B) is a continuous-duty solenoid that actuates and holds inner valve spool against spring during normal machine operation. High pressure oil flow is allowed to pass through the valve and is routed to the directional control solenoid. When the clutch cut-off solenoid is de-energized, element engagement oil flow is blocked and oil
previously used to engage the clutch or brake pack is allowed to return to sump. The direction control solenoid (A) is a bi-directional solenoid that moves the inner valve spool in or out from a neutral position that is established by the centering spring. Movement of the valve when solenoid is energized directs oil flow to engage either the forward clutch or reverse brake.
TX,210D,1934 1912JUL941/1
TM1496 (21SEP05)

092105
PN=350
T7392AE
UN30OCT90
9020 05 16
Theory Of Operation
9020 05 17
TM1496 (21SEP05)

092105
PN=351
Theory Of Operation
Torque Converter Operation
9020 05 18
10T,9020,K127 1912JUL941/2
TM1496 (21SEP05)

092105
PN=352
T7927AQ
UN22JAN93
Theory Of Operation
APilot Shaft BTurbine Spline CBoss DImpeller ETurbine FStator GFree Wheel Clutch HDrain Plug IStator Spline JPump Drive Tang (2 used)
There are three main parts to the torque converter. They are: Impeller Turbine Stator The impeller is driven by the engine. As it rotates, centrifugal force throws oil out of the impeller against the blades of the turbine. This forces the turbine to rotate in the same direction as the impeller. The turbine is connected to the turbine shaft which provides input to the reverser. As the oil leaves the turbine, it is moving in the opposite direction of the impeller. This would tend to slow down the impeller, robbing engine horsepower. The function of the stator is to prevent this.
Oil leaving the turbine enters the stationary stator. The stator is curved so that the oil flow changes direction. Oil leaving the stator is moving in the same direction as the impeller. This adds to the force of the oil entering the impeller. The turbine will be rotating at a slower speed than the impeller, but it will produce a higher torque. It is this increased force developed by the stator that makes a converter able to multiply torque. Under light load the speed of the turbine will increase until it equals impeller speed. The free wheel clutch will unlock, allowing the stator to freewheel or rotate with the turbine and impeller as a unit. Input speed and torque are equal to output speed and torque when the stator is freewheeling.
9020 05 19
10T,9020,K127 1912JUL942/2
TM1496 (21SEP05)

092105
PN=353
Theory Of Operation
Oil Flow To And From Torque Converter (SN 792482)
9020 05 20
H M
J A B K C D
L
UN26FEB99
TXC7366BF
TX,210D,1935 1912JUL941/2
TM1496 (21SEP05)

092105
PN=354
T7366BF
Theory Of Operation
AHigh Pressure Oil BMedium Pressure Oil CLow Pressure Oil DReturn Oil (Pressure Free) EDirectional Control Valve FPressure Regulating Piston GControl Valve-to-Converter In Line HDrive Tangs IReverser Pump JConverter Out/Cooler In KCooler Out/Reverser In LSuction Screen MCooler Relief Valve
Reverser oil flows from the oil pan through suction strainer (L) to the reverser pump (I). The reverser pump is driven at engine speed by the torque converter drive tangs (H). High pressure oil (A) flows from the reverser pump through internal passages to the clutch cut-off and directional control solenoid valves. Pressure oil is also routed through an external line to the parking brake solenoid valve. Pressure regulating piston (F) maintains high pressure oil for forward clutch, reverse brake and lubrication oil.
Oil not needed for element engagement or lubrication flows through external lines (G) to reverser front cover. Oil flows through internal passages to the torque converter. Low pressure oil (C) from the torque converter flows through front cover bearing on input shaft through internal passages to converter out/cooler in hydraulic line (J). Oil from the cooler (K) returns to the oil pan. Torque converter in (cooler) relief valve (M) protects torque converter and oil cooler components form damage.
9020 05 21
TX,210D,1935 1912JUL942/2
TM1496 (21SEP05)

092105
PN=355
Theory Of Operation
Transaxle300D
9020 05 22
APump Outlet to Cooler BPump Outlet Line CLube Pump DClamp EDrive Shaft Sleeve
FPump Drive Shaft GSpring Pin HLube Trough IThird and Fourth Gear Synchronizer
JTransmission Drive Shaft KDifferential Drive Shaft LCase Inlet from Cooler MShift Collar NInlet Line to Brake Cavity
ORing Gear PParking Brake Band QSuction Line RPump Support Bracket SPin
The transaxle case houses the four-speed constant mesh transmission, differential and parking brake assemblies. Output from the reverser drives the transmission drive shaft (J). Axle housings are mounted to the transaxle case and contain the planetary final drive assemble, brake disks and brake pistons.
Oil in the transaxle case provides a source of splash lubrication for the power train drive components and pressure lube/cooling to the brakes.
TX,D300,YY919 1912JUL941/1
TM1496 (21SEP05)

092105
PN=356
T7510AA
UN25APR91
Theory Of Operation
Transaxle310D, 315D (SN 796033)
9020 05 23
APump Outlet to Cooler BPump Outlet Line CLube Pump DClamp EDrive Shaft Sleeve FPump Drive Shaft
GSpring Pin HLube Trough IThird and Fourth Gear Synchronizer JTransmission Drive Shaft
KDifferential Drive Shaft LCase Inlet from Cooler MFirst and Second Gear Synchronizer NInlet Line to Brake Cavity
TX,0350,DS3529 1912JUL941/1
TM1496 (21SEP05)

092105
PN=357
T7511AA
UN25APR91
Theory Of Operation
Transaxle310D, 315D (SN 796034 )
9020 05 24
APump Outlet to Cooler BPump Outlet Line CLube Pump DDrive Shaft Sleeve ELock Nut FPump Drive Shaft
GSpring Pin HLube Line IThird and Fourth Gear Synchronizer JTransmission Drive Shaft
KDifferential Drive Shaft LCase Inlet from Cooler MFirst and Second Gear Synchronizer NInlet Line to Brake Cavity
TX,0350,BD1323 1912JUL941/1
TM1496 (21SEP05)

092105
PN=358
T8131AK
UN07FEB94
Theory Of Operation
Second Speed Operation
UN18APR89
ADifferential Drive Shaft BTransmission Drive Shaft
CFirst Speed Driving Gear DSecond Speed Driving Gear
ETransmission Input Shaft FSecond Speed Driven Gear
GShifter Collar (300D)
The transmission input shaft (E) is driven by the reverser. It, in turn, drives the transmission drive shaft, and is in constant mesh with the second speed driven gear (F). When the transmission is in second speed the shifter collar (G) is slid to the right. The second speed driven
gear is locked to the differential drive shaft (A). Power is thereby transmitted to the differential assembly. 310D, 315D ONLYA synchronizer collar is used on differential drive shaft between first and second speed driven gears which provides a fully synchronized transmission.
TX,300D,1970 1908MAR931/1
TM1496 (21SEP05)

092105
PN=359
T92938
9020 05 25
Theory Of Operation
Third Speed Operation
9020 05 26
ADifferential Drive Shaft BTransmission Drive Shaft
CThird Speed Driving Gear DSynchronizer Collar
EFourth Speed Driving Gear FTransmission Input Shaft
GThird Speed Driven Gear
In third speed, the synchronizer collar (D) is moved to the left. The third speed driving gear (C) is then locked to the transmission drive shaft (B). Power is transferred to the third speed driven gear (G). Since the third and fourth speed driven gear is splined to the differential drive shaft (A), there is power flow into the differential assembly.
Notice that the shift collar on the differential drive shaft is in neutral. This allows the first and second speed driven gears to rotate freely on the shaft. Transmission gears and bearing are lubricated by non-pressurized splash oiling system.
TX,300D,1971 1908MAR931/1
TM1496 (21SEP05)

092105
PN=360
T92939
UN18APR89
Theory Of Operation
Synchronizer Operation
T92937
UN18APR89
9020 05 27
ABlocking Rings BSynchronizer Collar CHub
DThird Speed Drive Gear EBlocking Ring FClip
GFourth Speed Drive Gear HSynchronizing ITransmission Drive Shaft
JThird Gear Engaged KSynchronizer
The components of the synchronizer are the hub (C), collar (B), clip (F) and blocking rings (A). The hub is splined to the transmission drive shaft (I). The synchronizer collar is splined to the hub. Three of the splines in the hub are omitted and a clip is inserted between the hub and the collar. A spring (not shown on the illustration) pushes the clips out against the collar. The ends of the clips extend into slots in the blocking rings, causing the rings to rotate with the clips. The hub, collar, clips, and blocking rings always rotate as an assembly with the shaft. With the synchronizer in neutral (K), the blocking rings do not contact either drive gear. Since the gears are not splined to the shaft, they are free to rotate at different speeds. When a shift to third gear is made, the first step is synchronizing (H) the speed of transmission drive shaft
(I) and third speed drive gear (D). As the collar moves across the hub, the clip moves with it. The clip pushes the blocking ring (E) against the tapered portion of the third speed drive gear. The brass blocking ring will accelerate until the speed of the transmission drive shaft matches the speed of the third speed drive gear. After the gear and the shaft have been synchronized, the collar slides over the teeth of the blocking ring and the gear. Third gear is engaged (J). The synchronizer operates during up shifts into third and fourth gears and the down shift into third gear on the 300D. All speeds are synchronized on the 310D and 315D due to an additional synchronizer that is installed between the first and second driven gears.
TX,300D,1972 1907DEC901/1
TM1496 (21SEP05)

092105
PN=361
Theory Of Operation
Brake Valve Operation

E A B C M D
F G I H
9020 05 28
T87128
AHigh Pressure Oil BReturn Oil CReturn Port DCheck Valve (2 used)
ERight Brake Pedal FLeft Brake Pedal GEqualizing Valve (2 used) HPiston (2 used)
IBrake Bleed Screw (2 used) JBrake Disk and Facings (2 used) KBrake Pressure Plate (2 used)
LInlet to Brake Piston MInlet Port
The brake system is hydraulic with no mechanical connection between the brake valve and the brake pressure plates. The brake valve reservoir is filled with return oil from the hydraulic system. The brake valve is activated by two brake pedals that allow individual or simultaneous operation of brake
pressure plates that are located in the final drive housings. When the brakes are engaged, the brake pressure plate applies force on the brake disk and facings which is connected to the final drive pinion shaft.
TX,300D,1974 1908MAR931/1
TM1496 (21SEP05)

092105
T87128
UN25FEB99
PN=362
Theory Of Operation
Service Brake Pressure Lubrication (SN 796851)

FACING C D BRAKE DISK
TRANSMISSION B CASE
E BRAKE PISTON
PRESSURE LUBE SUPPLY A
F LUBE OIL G RESERVOIR OIL

1925FEB99 T7397AA
092105
9020 05 29
TXC7397AA
H SERVICE BRAKE LUBRICATION

CFacing DBrake Disk EBrake Piston FLube Oil GReservoir Oil HService Brake Lubrication
APressure Lube Supply BTransmission Case
A constant supply of cooled oil from the main hydraulic oil cooler is routed to the transaxle. Oil from the pressure lube supply (A) is routed to the outside diameter of the brake disk (D). There is a constant flow of oil between the brake facings (C) and the transmission case (B) and brake piston (E). When the brakes are rotating, centrifugal force draws oil around the entire diameter of the brake disk. This
constant flow of cooled oil over the entire facing of the brake disk prevents contact between the facing and the housing when the brakes are not applied. It also provides excellent cooling. Notice the grooves in the brake facings. These grooves provide a path for a constant flow of cool oil across the facings even when the brakes are engaged.
TX,300D,1975 1912JUL941/1
TM1496 (21SEP05)

PN=363
Theory Of Operation
Service Brake Pressure Lubrication (SN 796852 )

FACING C D BRAKE DISK
TRANSMISSION CASE B BRAKE E PISTON
TXC8167AM CV
H SERVICE BRAKE LUBRICATION
G RESERVOIR OIL
APressure Lube Supply BTransmission Case
CFacing DBrake Disk
EBrake Piston FLube Oil
GReservoir Oil HService Brake Lubrication
A constant supply of cooled oil from the main hydraulic oil cooler is routed to the transaxle. Oil from the pressure lube supply (A) is routed to the outside diameter of the brake disk (D). There is a constant flow of oil between the brake facings (C) and the transmission case (B) and brake piston (E). When the brakes are rotating, centrifugal force draws oil around the entire diameter of the brake disk. This
constant flow of cooled oil over the entire facing of the brake disk prevents contact between the facing and the housing when the brakes are not applied. It also provides excellent cooling. Notice the grooves in the brake facings. These grooves provide a path for a constant flow of cool oil across the facings even when the brakes are engaged.
TX,9020,YY922 1912JUL941/1
TM1496 (21SEP05)

092105
PN=364
T8167AM
F LUBE OIL
1901JAN99
9020 05 30
A PRESSURE LUBE SUPPLY
Theory Of Operation
9020 05 31
TM1496 (21SEP05)

092105
PN=365
Theory Of Operation
MFWD System Operation
9020 05 32
TX,300D,1977 1907DEC901/2
TM1496 (21SEP05)

092105
PN=366
T6771AF
UN19OCT88
Theory Of Operation
ATransaxle Case BFirst Speed Driven Gear CSecond Speed Driven Gear DThird Speed Driven Gear ESynchronizer Collar FFourth Speed Driven Gear GTransmission Drive Shaft HDifferential Drive Shaft IFourth Speed Driven Gear JThird Speed Driven Gear KSecond Speed Driven Gear LShift Collar MFirst Speed Driven Gear NTransfer Case OIdler Gear PShift Collar QOutput Gear ROutput Drive
The MFWD transfer case is located on the left side of the transaxle case. The differential drive shaft (H) supplies power to the MFWD idler gear (O) and output gear (Q). Output gear (Q) spins freely around the MFWD output drive shaft (R) when the MFWD is not engaged. Engagement of the MFWD is controlled by an electric solenoid that moves shift collar (P) forward when energized by a switch on the console. The shift collar engages the driven output gear (Q) to the output drive shaft (R).
When the MFWD shift collar is in the engaged position, power flows forward through the U-jointed drive shaft to the front axle differential drive shaft. The differential drive shaft meshes with the ring gear to drive a limited slip differential. See MFWD Differential Operation in this group for operation. The limited slip differential powers a sun gear of wheel hub planetaries on each front wheel. The sun gears drive a fixed planetary system to reduce drive shaft speed and increase torque at the front wheels.
9020 05 33
TX,300D,1977 1907DEC902/2
TM1496 (21SEP05)

092105
PN=367
Theory Of Operation
MFWD Differential OperationUnequal Traction
9020 05 34
ATire with Most Traction BDrive Shaft CRH Drive Gear
DLH Drive Gear EPinion Gears FDifferential Housing
GClutch Disks HClutch Plate
IPower Flow JRotation Direction
As available traction changes, tire with better traction (A) can use more power. Self-limiting differential action begins to occur. When one wheel begins to slip more than the other, wheel with better traction holds its drive shaft (B) and
drive gear (C) from rotating. Wheel with less traction provides less resistance against its drive gear (D).
TX,300D,1980 1907DEC901/2
TM1496 (21SEP05)

092105
PN=368
T6771AH
UN19OCT88
Theory Of Operation
Pinion gears (E) continue to be driven by rotating differential housing (F). These pinion gears push against bevel drive gears as before. Angle of gear teeth tries to force meshed gears apart. On the side with more traction, pinion gears begin to "walk" around drive gear and push against restraining force transmitted from tire. Drive gear is wedged outward and compresses a clutch pack with disks (G) splined to axle and plates (H) tanged to housing. Disks begin to slip less against plates as compressing force increases. As the pack slippage decreases driveshaft begins to receive driving force through the differential housing. Since the tire with less traction is exerting less force trying to keep its axle from turning, the bevel gear does not force is being transmitted to this drive shaft. As long as the difference in traction between tires remains the same, the clutch pack on the side with less traction will continue to slip more than the clutch pack for the other side. With MFWD engaged, differential works to automatically balance driving power to available traction.
TX,300D,1980 1907DEC902/2
9020 05 35
TM1496 (21SEP05)

092105
PN=369
Theory Of Operation
MFWD Differential OperationEqual Traction
9020 05 36
ADifferential Driveshaft BRing Gear
CDifferential Housing DPinions
EBevel Drive Gears FDrive Shafts
GPower Flow HRotation Direction
Differential unit has self-applied, limited slip feature. When engaged under slippery field conditions, this system automatically applies correct amount of torque to match traction available to each wheel.
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,300D,1979 1907DEC901/2
TM1496 (21SEP05)

092105
PN=370
T6771AG
UN19OCT88
Theory Of Operation
Power flows into axle housing through differential drive shaft (A), turning ring gear (B) and attached differential housing (C). When both wheels have equal traction, pinions (D) remain stationary within rotating housing. Pinions turn bevel drive gears (E) and drive shafts (F) splined to drive gears.
TX,300D,1979 1907DEC902/2
9020 05 37
TM1496 (21SEP05)

092105
PN=371
Theory Of Operation
9020 05 38
TM1496 (21SEP05)

092105
PN=372
Group 10

System Operational Procedure
The procedure is designed so that mechanic can make a quick check of the power train using a minimum amount of diagnostic equipment. If you need additional information, read the Theory of Operation in Group 9020-05. A location will be required which is level and has adequate space to operate machine. The engine and all major components must be at operating temperature for some checks. Locate system check in the left column and read completely. Follow this sequence from left to right. Read each check completely before performing. At the end of each check, if no problem is found (OK:), you will be instructed to GO TO NEXT CHECK. If
9020 10 1
problem is indicated (NOT OK:), you will be given repair required and Group location or CTM number. If verification is needed, you will be given next best source of information after GO TO: Group 10 (System Operational Checks) Group 15 (System Diagnostic Checks) Group 20 (Adjustments) Group 25 (Test) CTM (Component Technical Manual)
TX,300D,1960 1908MAR931/1
Brake System Checks
1/1
Pedal Stop Check
Lift the left and right brake pedals.
OK: Check complete. NOT OK: Adjust brake pedal stops. Go to Group 9020-20 NOT OK: Inspect and repair brake valve as necessary. Go to repair manual.
LOOK: Brake pedals must be against the pedal stop screws.
T7394BG UN17JAN92
1/1
TM1496 (21SEP05)

092105
PN=373

Brake System Leakage Check Depress and hold left brake pedal, then right brake pedal using approximately 267 N (60 lb force). OK: Check complete. NOT OK: Adjust brake pedals. Do Brake Valve Adjustment. Go to Group 9020-20. NOT OK: Bleed brake system. Go to Group 9020-20. NOT OK: Check light fuse. OK: Check wiring. Go to Group 9015-15, Lighting Circuit Checks. NOT OK: Do Brake Valve Leakage Test. Go to Group 9020-25.
LOOK: Brake pedal must NOT feel spongy (caused by air in system) or settle more than 25 mm (1.0 in.) per minute. LOOK: Rear brake light must come on when either pedal is depressed with key switch in ON position.
T7367AM UN17JAN92
1/1
9020 Park Brake Capacity 10 Check 2
Engage park brake. Put stabilizers in transport position. Put backhoe in transport position. Use loader functions to pull machine forward or push machine backward.
T7394BH UN10DEC90
OK: Check complete. NOT OK: Adjust park brake linkage. Go to Group 9020-20.
LOOK: Rear wheels should not turn. If loader can pull or push machine, rear tires should drag. LOOK: Park brake switch light will be ON.
1/1
Brake Drag Check
Position machine on a gradual grade with front of machine downhill. Lift bucket so it clears ground. Shift FNR lever to neutral, differential lock pedal up, disengage park brake and release service brakes.
T6171AL UN09DEC88
OK: Check complete. NOT OK: Brakes dragging. Go to Group 9020-15, Unit Will Not Move.
LOOK: Machine must move or coast. NOTE: If machine does not move freely on slope, drive machine for five minutes. Feel axle housing area to locate which brake is dragging.
1/1
Reverser Checks
1/1
TM1496 (21SEP05)

092105
PN=374

Clutch Disconnect Circuit Check OK: Check complete. CAUTION: Machine should try to move forward as FNR lever is moved. NOT OK: Check fuse. Park brake OFF. Service brake applied. Put transaxle in fourth gear. Start engine, set idle speed at approximately 1500 rpm. Move FNR lever to forward (F) position. Actuate clutch disconnect on FNR lever or loader control lever individually and note sound of engine. NOT OK: Go to group 9015-15, Park Brake/Clutch Disconnect Circuit Check.
LISTEN: When FNR lever is shifted to forward (F) position, a noticeable drop in engine speed should be heard. LISTEN: Engine rpm must increase when the reverser clutch disconnect solenoid switch is activated.
1/1
FNR Switch Check
OK: Check complete. NOT OK: If no "click", inspect neutral start fuse. NOT OK: Go to Group 9015-15 , Neutral Start Switch Check.
T7367AN UN17SEP90 T7394BI 1917OCT90 T7394BJ 1917OCT90
9020 10 3
Engine off. Put FNR lever in neutral. Turn key switch to ON position. Move FNR lever to forward (F), reverse (R), then neutral (N) position. Observe and feel forward, neutral and reverse detents.
LOOK: FNR lever must align with neutral position in quadrant when reverser valve is in neutral detent position. LISTEN: You must hear neutral start switch "click" as FNR lever is moved EQUAL distance from neutral to forward position and from neutral to reverse position. FEEL: You must feel detent engagement in each position of FNR lever.
1/1
TM1496 (21SEP05)

092105
PN=375

Reverser Hydraulic System Check Run engine at approximately 1500 rpm. Put transaxle into third gear. Move FNR lever to forward (F) position. Make several shifts from third forward to third reverse. Start counting the number of seconds when FNR lever is moved to opposite direction. OK: Check complete. NOT OK: If shifts are slow, go to Group 9020-25 , Reverser Element Leakage Using Four-Gauge Method.
LOOK: A normal shift from forward to reverse or reverse to forward must be completed in three seconds. The machine must be up to speed in four seconds. NOTE: Excessive internal leakage is indicated if reverse warning alarm (if equipped) does not sound at slow idle, but sounds when rpm is increased.
1/1
Engine And Torque Converter Check
Position machine with loader bucket at ground level against dirt bank or immovable object. Put transaxle into first gear. Move FNR lever to forward (F) position. Engage differential lock.
OK: Check complete. NOT OK: If the wheels can be easily stalled, go to Group 9020-15 , Machine Lacks Power or Moves Slow.
9020 10 4
T6171AM UN09DEC88
LOOK: Rear wheels must NOT stall. NOTE: This test will give a general indication of engine reverser and torque converter performance.
1/1
Transaxle Checks
1/1
Transaxle Shift Linkage Synchronizer And Noise Check
Run engine at approximately 1500 rpm with FNR lever in forward (F) position. Put transaxle in each gear and drive machine for a short distance.
OK: Check complete. NOT OK: Go to Group 9020-15 , Excessive Gear Noise When Shifting Gears.
LISTEN: 300DSome gear noise can be expected when shifting into first or second gear. There must NOT be any gear noise when shifting into third or fourth gear. Third and fourth gears are synchronized. LISTEN: 310D,315DExcessive gear or FNR lever noise must NOT be heard in any gear. All gears are synchronized.
1/1
TM1496 (21SEP05)

092105
PN=376

Differential Lock And Linkage Check Put transaxle in first gear. Move FNR lever to forward (F) position and operate engine at approximately 1500 rpm. Depress differential lock pedal. Turn steering wheel slightly right or left. Release differential lock pedal. OK: Check complete. NOT OK: Go to Group 9020-15 , No Differential Lock Operation.
LOOK: Machine must try to go straight forward and pedal must return to UP position when traction is equal.
1/1
Differential Gear And Pinion Check
NOTE: Hold the wheel which is being braked stationary during this test or brake chatter could be confused with differential gear noise.
Put transaxle in first gear and operation engine at approximately 1500 rpm. Move FNR lever to forward (F) position. Steer machine in a maximum left turn and depress left brake pedal to stop the left wheel. Steer machine in a maximum left turn and depress left brake pedal to stop the left wheel. Steer machine in a maximum right turn and depress right brake pedal to stop right wheel.
OK: Check complete. NOT OK: Go to Group 9020-15 , Unit Makes Excessive Noise.
9020 10 5
LISTEN: NO excessive gear noise must be heard in the differential or pinion gear area.
1/1
Front Wheel Alignment (Toe-In) Check
Drive machine in fourth gear forward on a surface with loose material.
OK: Check complete. NOT OK: If material is thrown, excessive tire wear will result. Go to Group 9020-20 , Adjust Toe-In.
LOOK: Material behind front wheels must not be thrown excessively inward or outward.
T6264AI UN22OCT91
1/1
Mechanical Front Wheel Drive (MFWD) Driving Checks
1/1
TM1496 (21SEP05)

092105
PN=377

MFWD Limited Slip Differential And Control Linkage Check Shift transaxle to first reverse. Engage MFWD and drive machine. Run engine at approximately 1200 rpm. Turn steering wheel for a full left or right turn and observe how the front tires attempt to slide sideways (side load) and the amount of tire scuffing. Disengage MFWD. OK: Check complete. NOT OK: Move MFWD control linkage to feel engagement detents. No detents, inspect linkage to transfer case. NOT OK: Go to Group 9020-15 , No Power to MFWD.
LOOK: Tire side loading and scuffing must stop when MFWD is disengaged. NOTE: If tires attempt to slide sideways and tire scuffing is seen with MFWD engaged, limited-slip differential is working and power is being transmitted to MFWD.
1/1
9020 MFWD Engine And 10 Torque Converter ChecK 6
With loader bucket lever and cutting edge at the centerline of front wheels, put machine against a dirt bank or immovable object. Engage MFWD and differential lock. Shaft transaxle to first forward.
T6171AN UN09DEC88
OK: Check complete. NOT OK: If all wheels stop, a torque converter problem is indicated. If the front wheels stop, MFWD problem is indicated. Go to Group 9020-15 , Machine Lacks Power or Moves Slow.
LOOK: All four wheels must turn.
1/1
MFWD Gear And Pinion Check
Drive machine at transport speed with MFWD engaged, then disengaged.
OK: System Operational Checkout Completed. NOT OK: If MFWD whines, check oil levels and fill to correct levels. NOT OK: Check backlash. Go to repair manual.
LISTEN: MFWD must NOT whine.
1/1
TM1496 (21SEP05)

092105
PN=378
Group 15

Reverser Oil Passage Identification
ATorque Converter Oil Out BTorque Converter Oil In
UN02NOV88
9020 15 1
Torque Converter Support
TX,300D,1946 1908MAR931/5
TM1496 (21SEP05)

092105
PN=379
T5982AK1

Torque converter oil out (A) lubes the bushing. Torque converter oil in (B) lubes the front bearing.
ATorque Converter Oil Out BTorque Converter Oil In CInlet Oil Passage for Reverser Pump DPressure Oil Passage for Reverser Pump
9020 15 2
Reverser Front Cover Assembly
TX,300D,1946 1908MAR932/5
TM1496 (21SEP05)

092105
PN=380
T5988BB1
UN02NOV88

From the directional control valve, forward clutch engagement oil flows into center of the planetary output shaft (A) to the input shaft.
UN02NOV88
9020 15 3
TX,300D,1946 1908MAR933/5
From the planetary output shaft, forward clutch engagement oil flows into the center of a non-serviceable tube (B) in the shaft (A) through the center of the tube to the forward clutch.
UN02NOV88
Lubrication oil flows on the outside of the tube in the input shaft to lube forward clutch.
TX,300D,1946 1908MAR934/5
TM1496 (21SEP05)

092105
PN=381
T6218AS
UN26MAY89
T5984AA1
T5988AK
A(S.N. 792482) Reverser Pump Pressure Oil to Directional Control Valve (S.N.792483 ) Reverser Pump Pressure Oil to FNR Solenoid B(S.N. 792482) From Directional Control Valve to Reverse Brake (S.N.792483 ) From FNR Solenoid to Reverse Brake CFrom Suction Screen to Reverser Pump DReverse Brake Lubrication Orifice
9020 15 4
Reverser Housing
TX,300D,1946 1908MAR935/5
Diagnose Power Train Malfunctions

Park Brake Will Not Hold
Park brake actuator
Inspect and replace. See repair manual. Burnish brake. See repair manual. See Group 9015-15, Park Brake Circuit Checks. Inspect and repair. See repair manual.
Glazed park brake lining Park Brake Will Not Release Park brake circuit not operating correctly Internal linkage binding
TX,300D,2091 1908MAR931/18
TM1496 (21SEP05)

092105
PN=382
T7942AF
UN02MAR93

Symptom Problem
Solution
Machine Will Not Move in Forward or Reverse
Low oil level
Add oil to correct level. See Hydraulic And Reverser Oil in Group 9000-04. Check brake valve and repair. See repair manual. Check to hear "click" when switch is depressed. See Group 9015-15. Remove, inspect, clean and repair. See repair manual. Do Four Gauge Leakage Test , Group 9020-25. Check oil level. Do Four Gauge Leakage Test , Group 9020-25. Repair or replace parts as required. See repair manual. Replace converter. See repair manual. Replace pump assembly and converter. See repair manual. Inspect transaxle and repair. See repair manual. Repair or replace parts as necessary. See repair manual. Repair or replace parts as necessary. See repair manual . Replace. See repair manual. Repair and time correctly. See repair manual. Replace ring gear and pinion. See repair manual. Replace. See repair manual.
9020 15 5
Brakes dragging
Disconnect clutch not disengaging properly Directional control valve solenoid spring stuck or broken Reverser clutch disk slipping
Loss of system pressure
Mechanical failure in reverser
Converter drive tangs sheared or not engaged in pump Pump gears seized and converter tangs sheared Mechanical failure in transaxle
Transaxle shifter forks and/or shafts broken Transaxle shaft or gear failure
Transaxle shifter collars broken Planetary assembly out of time or improperly assembled Differential ring gear teeth sheared
Final drive axle shaft broken
TX,300D,2091 1908MAR932/18
TM1496 (21SEP05)

092105
PN=383

Symptom Problem
Solution
Final drive shaft and sun pinion broken Transaxle Will Not Pull in Forward Only Reverser Will Not Disconnect (Drags) Disconnect clutch solenoid loose on reverser Disconnect clutch not disengaging properly
Replace parts as necessary. See repair manual. Inspect and tighten. See repair manual. Check to hear "click" when switch is depressed. See Reverser Disconnect Clutch Solenoid (SN 792482) or see Reverser Disconnect Clutch Solenoid Test (SN 792483 ). Remove, inspect, clean and repair spring. See repair manual. Inspect and repair. See repair manual. Do Four Gauge Leakage Test , Group 9020-25. Disassemble and inspect clutch assembly. Replace parts as necessary. See repair manual. Disassemble and inspect clutch assembly. Replace parts as necessary. See repair manual.
Directional control valve solenoid spring stuck or broken Warped or dragging clutch pack.
9020 15 6
Worn or broken sealing rings in forward clutch of reverser
Clutch plates worn or broken in forward clutch assembly of reverser
TX,300D,2091 1908MAR933/18
TM1496 (21SEP05)

092105
PN=384

Symptom Problem
Solution
Machine Lacks Power or Moves Slow
Operating in too high a gear
Operate in next lower gear.
Low oil level in reverser
Add oil to correct level. See Group 9000-04. Check for excessive heat in brake area of axle housings after operating unit. See Remove And Inspect Brake Disk And Pressure Plate (SN 796851) or Remove And Inspect Brake Disk And Pressure Plate (SN 796852 ) in repair manual. Do Four Gauge Leakage Test , Group 9020-25. Clean screen. See repair manual. Do Four Gauge Leakage Test , Group 9020-25. See Group 9010-15. Check converter part number through inspection hole in bottom of reverser housing. Drain oil sample from converter and inspect for contamination. Inspect transaxle. See Remove Transaxle in repair manual.
9020 15 7
Brakes dragging
Low "P" port pressure
Restricted suction screen in reverser Reverser leaks
Low engine output Incorrect torque converter installed
Failed torque converter
Mechanical failure in transaxle
TX,300D,2091 1908MAR934/18
TM1496 (21SEP05)

092105
PN=385

Symptom Problem
Solution
Reverser Shifts Slow
Low oil level
Add oil to correct level. See Hydraulic And Reverser Oil in Group 9000-04. Check to hear "click" when switch is depressed. See Reverser Disconnect Clutch Solenoid (SN 792482) or see Reverser Disconnect Clutch Solenoid Test (SN 792483 ). Remove and clean. See repair manual. Remove, inspect and repair. See repair manual. Remove, inspect and clean. See repair manual. Do Four Gauge Leakage Test . See Group 9020-25. Do Reverser Pump Flow Test. See Group 9020-25.
Disconnect clutch not disengaging properly
Restricted suction screen
Converter-in (cooler) relief valve stuck open Pressure regulating valve sticking
9020 15 8
Leakage in reverser
Worn reverser pump
TX,300D,2091 1908MAR935/18
TM1496 (21SEP05)

092105
PN=386

Symptom Problem
Solution
Reverser Will Not Shift
FNR switch failure.
Do FNR Switch Check, Group 9015-15. Check to hear "click" when switch is depressed. See Reverser Disconnect Clutch Solenoid (SN 792482) or see Reverser Disconnect Clutch Solenoid Test (SN 792483 ). Remove, inspect and repair. See repair manual. See Reverser Repair Information in repair manual. Check oil level. Do Four Gauge Leakage Test , Group 9020-25. Repair or replace parts. See repair manual. Disassemble and replace parts as necessary. See repair manual.
9020 15 9
Disconnect clutch not disengaging properly
Directional control valve not operating properly Reverser clutch disk slipping
Loss of system pressure in reverser
Mechanical failure in reverser
Worn or broken sealing rings on reverse brake piston. Broken or worn reverse brake plates. Foaming Oil in Reverser Oil level too low or too high
Check oil level and correct. See Group 9000-04. Drain and replace oil. See Group 9000-04. Clean suction screen. See repair manual. Inspect gaskets and housings. See repair manual.
Incorrect type of oil.
Restricted suction screen in reverser
Air leak on suction side of oil pump
TX,300D,2091 1908MAR936/18
TM1496 (21SEP05)

092105
PN=387

Symptom Problem
Solution
Reverser Oil Overheats
Oil level too high or too low.
Check oil level and correct. See Group 9000-04. Use disconnect clutch switch in these operations to reduce stalls. See Reverser Disconnect Clutch Solenoid (SN 792482) or see Reverser Disconnect Clutch Solenoid Test (SN 792483 ) . Operate one gear lower. Inspect and clean exterior of reverser cooler. Do Air Flow Test, Group 9010-25. Inspect and check belt tension. See Group 9010-20. Check baffles and repair. See repair manual. Remove valve, inspect and repair. See repair manual. Do Reverser Pump Flow Test. See Group 9020-25. Remove and clean. See repair manual. Do Four Gauge Leakage Test , Group 9020-25. Do Converter Stall Test, Group 9020-25. Repair as needed. See repair manual. Remove fuel injection pump. See authorized injection pump service center.
Converter stalled excessively
Operating in too high a gear Oil cooler air flow restricted
Missing baffles, damaged fan shrouds or loose fan belts

9020 15 10
Converter-in (cooler) relief valve stuck open or broken spring Low pump oil flow
Leakage in reverser
Excessive drag in reverser
Engine over-fueled
TX,300D,2091 1908MAR937/18
TM1496 (21SEP05)

092105
PN=388

Symptom Problem
Solution
Low System Pressure in Reverser
Low oil level
Add oil to correct level.
Wrong oil
Drain and replace oil. See Group 9000-04. Remove and clean. See repair manual. Remove, inspect, clean and repair. See repair manual. Inspect and repair spring. See repair manual. Do Reverser System Pressure Test. See Group 9020-25. Do Four Gauge Leakage Test , Group 9020-25. Do Reverser Pump Flow Test. See Group 9020-25. Add oil to correct level.
9020 15 11
Converter-in (cooler) relief valve stuck open or broken Directional control valve solenoid spring stuck or broken
Leakage in reverser
Worn reverser oil pump
Low Forward Pressure in Reverser
Low oil level
Wrong oil
Drain and replace oil. See Group 9000-04. Remove and clean. See repair manual. Remove, inspect, clean and repair. See repair manual. Inspect and repair spring. See repair manual. Do Reverser System Pressure Test, Group 9020-25. Do stall test. Do Four Gauge Leakage Test , Group 9020-25. Do Reverser Pump Flow Test, Group 9020-25.
Leakage in forward clutch
TX,300D,2091 1908MAR938/18
TM1496 (21SEP05)

092105
PN=389

Symptom Problem
Solution
Low Reverse Pressure in Reverser
Low oil level
Wrong oil
Drain and replace oil. See Group 9000-04. Remove and clean. See repair manual. Remove, inspect, clean and repair. See repair manual. Inspect, clean and replace spring. See repair manual . Do Reverser System Pressure Test, Group 9020-25. Do Four Gauge Leakage Test , Group 9020-25. Do Reverser Pump Flow Test, Group 9020-25. Add oil to correct level. See Group 9000-04. Drain and replace. See Group 9000-04. Remove and clean. See repair manual. Remove, inspect, clean and repair. See repair manual. Inspect and repair spring. See repair manual. Do Reverser System Pressure Test. See Group 9020-25. Do Four Gauge Leakage Test , Group 9020-25. Do Reverser Pump Flow Test. See Group 9020-25.
Converter-in (cooler) relief valve stuck open or broken spring Directional control valve solenoid spring stuck or broken
Leakage in reverse brake

9020 15 12
Low Lube Pressure in Reverser
Low oil level
Wrong oil
Leakage in reverser
TX,300D,2091 1908MAR939/18
TM1496 (21SEP05)

092105
PN=390

Symptom Problem
Solution
High Lube Pressure in Reverser
Converter-in relief valve stuck in closed position Lube passage to reverser sump restricted
Do Converter-in (cooler) Relief Valve Test, Group 9020-25. Do Reverser Cooler Pressure Drop Test and inspect lines, Group 9020-25. Drain and refill. See Group 9000-04. Check converter part number through inspection hole in bottom of reverser housing. Replace torque converter. See repair manual. Add oil to correct level. See Group 9000-04. Check converter part number through inspection hole in bottom of reverser housing. Drain oil sample from converter and inspect for contamination. See repair manual. Remove fuel injection pump. See authorized injection pump service center.
9020 15 13
Converter Stall Speed Too Low
Wrong oil in machine Incorrect torque converter
Failed free wheel clutch in torque converter Converter Stall Speed Too High Low oil level.
Incorrect torque converter
Failed torque converter
Engine over-fueled
TX,300D,2091 1908MAR9310/18
TM1496 (21SEP05)

092105
PN=391

Symptom Problem
Solution
Valve Buzz or Noise In Reverser
Air in hydraulic system Low oil level
Running machine will remove air. Add oil to correct level. See Group 9000-04. Inspect gasket and housing. See repair manual. Inspect and remove restrictions. See repair manual. Remove and clean. See repair manual. Remove and clean valve. See repair manual. Inspect oil for contamination. Do Converter-in Relief Valve Test. See Group 9020-25. Inspect and service as necessary. See repair manual. Align converter assembly. See repair manual. Inspect reverser mounts for wear or damage. See repair manual. Fill to correct oil level. See Group 9000-04. Inspect pump assemble and replace if necessary. See repair manual. Replace converter assemble. See repair manual.
Air leak on suction side of pump
Restrictions in oil passages
Restricted suction screen
Sticky pressure regulating
9020 15 14
Reverser Noisy In Forward and Reverse
Worn universal joints
Misalignment of converter with engine Misalignment of reverser and transaxle Noisy In Neutral Only Oil level low
Worn bushings in pump assembly
Worn sprag or sprag races in converter assemble
TX,300D,2091 1908MAR9311/18
TM1496 (21SEP05)

092105
PN=392

Symptom Problem
Solution
Excessive Gear Clash When Shifting
Attempting to shift too fast
See Operators Manual for instructions. Depress disconnect switch on transaxle or loader levers when shifting. Inspect and replace as necessary. See repair manual. Check for solenoid "click" when disconnect switch is depressed. See Reverser Disconnect Clutch Solenoid (SN 792482) or see Reverser Disconnect Clutch Solenoid Test (SN 792483 ) . Lower to correct level. See Group 9000-04. Do System Operational Check, Brake Drag Check, Group 9020-10. Replace. See repair manual. Replace. See repair manual. Fill to correct level. See Group 9000-04. Replace bearings and make all necessary adjustments. See repair manual. Repair or replace parts as needed. See Transaxle300D , Transaxle 310D, 315D (SN 796033) , or Transaxle310D, 315D (SN 796034 ) in repair manual. Repair or replace as needed. See repair manual.
9020 15 15
Not using disconnect clutch on reverser
Shifters worn or broken
Gears rotate with disconnect clutch switch depressed
Transaxle Overheating
Oil level high
Brake dragging
Loss of Lubricant in Transaxle
Worn or broken oil seal Housing gasket broken
Excessive Transaxle Noise
Transaxle low on oil
Worn bearings
Damaged or worn gears
Parts worn or damaged
TX,300D,2091 1908MAR9312/18
TM1496 (21SEP05)

092105
PN=393

Symptom Problem
Solution
Excessive Transaxle Noise (Under Load)
Worn bearings
Replace bearings and make all necessary adjustments. See repair manual. Adjust to specifications. See repair manual. Adjust to specifications. See repair manual.
Bearing preload out of adjustment
Ring gear backlash out of adjustment
TX,300D,2091 1908MAR9313/18
9020 15 16
TM1496 (21SEP05)

092105
PN=394

Symptom Problem
Solution
Machine Makes Excessive Noise When Moving
Transaxle oil level low
Add oil to correct level. See Group 9000-04. Replace cap screws and tighten to specifications. See repair manual. Repair or replace parts as needed. See repair manual. Replace. See repair manual. Repair or replace parts as needed. See repair manual. Adjust to specifications. See repair manual. Adjust to specifications. See repair manual. Repair or replace part as needed. See repair manual. Repair or replace ring gear and pinion. See repair manual. Replace bearings and make all necessary adjustments. See repair manual. Adjust to specifications. See repair manual. Repair or replace planetary pinions or bearings. See repair manual. Repair or replace. See repair manual. Replace. See repair manual. Replace. See repair manual. Replace and adjust to specifications. See repair manual.
9020 15 17
Flywheel loose on crankshaft
Transaxle parts worn or damaged
Shifter forks on shafts worn Reverser parts worn or damaged
Cone point out of adjustment
Incorrect backlash adjustment
Differential gears damaged or worn
Differential ring gear loose
Worn bearings
Axle shaft improperly adjusted
Final drive planetary pinions or bearings damaged Sun pinion damaged
Worn final drive shaft and sun pinion Damaged final drive gear Worn planet pinion bearing rollers
TX,300D,2091 1908MAR9314/18
TM1496 (21SEP05)

092105
PN=395

Symptom Problem
Solution
Axle bearings damaged
Replace and adjust to specifications. See repair manual. Replace. See repair manual. Repair or replace. See repair manual. Adjust rpm to specifications. See Group 9010-20. Inspect and tight to specifications. See repair manual. Inspect and repair. See repair manual. Replace cap screws and tighten to specifications. See repair manual. Replace parts as needed. See repair manual. Adjust to specifications. See repair manual. Repair or replace ring gear. See repair manual. Adjust to specifications. See repair manual. Adjust to specifications. See repair manual. Adjust to specifications. See repair manual. Remove fuel injection pump. See your authorized fuel injection service center.
No Differential Lock Operation
Lock collar splines worn or damaged Differential lock shaft sticking in housing
Excessive Machine Vibration
Engine idle too low
Reverser mounting hardware loose
Loose or failed hydraulic pump drive
Flywheel loose on crankshaft

9020 15 18
Transaxle shafts bent or damaged
Transaxle bearings improperly adjusted Differential ring gear loose
Cone point out of adjustment
Incorrect backlash adjustment
Axle shaft bent or damaged
Engine over-fueled
TX,300D,2091 1908MAR9315/18
TM1496 (21SEP05)

092105
PN=396

Symptom Problem
Solution
Axles Will Not Turn
Brakes dragging
Check brake valve and repair. See Group 9020-25. Replace. See repair manual. Replace. See repair manual. Bleed brakes. See Group 9020-20, Bleed Brakes. Do Brake Valve Leakage Test, Group 9020-25. Remove lines and components and inspect Inspect brake pedal linkage. Do Brake Valve Stop and Equalizer Valve Adjustment, Group 9020-20. Remove, inspect, and clean. See Disassemble And Assemble Brake Valve in repair manual. Bleed brakes, see Group 9020-20. Drain and refill with correct oil. See Group 9000-04. Disassemble, inspect and repair. See Remove And Inspect Brake Disk And Pressure Plate (SN 796851) or Remove And Inspect Brake Disk And Pressure Plate (SN 796852 ) in repair manual.
9020 15 19
Broken rear axle Broken planetary gears or shafts. Poor or No Brakes (Steering OK) Air in system
Internal brake valve leakage
Internal restriction in circuit
Brakes Will Not Release
Brake pedal not returning to full up position
Plunger return orifice plugged
Brakes Chatter or Noisy
Air in brake system Wrong oil in transaxle
Loose brake pads
TX,300D,2091 1908MAR9316/18
TM1496 (21SEP05)

092105
PN=397

Symptom Problem
Solution
No Power to MFWD
Solenoid not actuated Drive shaft failure
See Group 9015-15. Inspect and repair. See repair manual. Inspect and repair. See Disassemble And Assemble MFWD Transfer Case in repair manual. Inspect and repair. See Disassemble Axle Shaft And Constant Velocity JointAPL-735 (SN 796033) or Disassemble Axle Shaft And Constant Velocity JointAPL-2025 Axle (SN 796034 ) in repair manual. Inspect and repair. See repair manual. Inspect and repair. See repair manual. Inspect and repair. See repair manual. Inspect and repair. See Disassemble Knuckle Housing And Wheel Hub With Planetary DriveAPL-735 (SN 796033) or Disassemble Knuckle Housing And Wheel Hub With Planetary DriveAPL-2025 (SN 796034 ) in repair manual. Inspect and repair. See repair manual. Inspect and repair. See Disassemble Differential in repair manual. Inspect and repair. See Disassemble Differential in repair manual.
Failed spline transaxle output shaft
Failed axle shaft in MFWD
Failed ring gear or pinion in transaxle

9020 15 20
Failed gear in MFWD drop box in transaxle No Power to One Wheel Wheel U-Joint failure
Failed outboard planetary
Failed axle shaft in MFWD
Failed limited-slip in MFWD differential No Power to One Wheel (Under Load) Failed limited-slip in MFWD differential
TX,300D,2091 1908MAR9317/18
TM1496 (21SEP05)

092105
PN=398

Symptom Problem
Solution
MFWD Jumps Out of Gear
Worn U-Joints in drive shaft
Inspect and repair. See repair manual. Adjust backlash. See repair manual.
Incorrect differential backlash
TX,300D,2091 1908MAR9318/18
9020 15 21
TM1496 (21SEP05)

092105
PN=399
9020 15 22
TM1496 (21SEP05)

092105
PN=400
Group 20
Adjustments
Adjust Brake Pedals And Equalizing Valves
SPECIFICATIONS Brake Pedal Minimum Applied Force Brake Pedal Travel 44.5 N (10 lb) 19 mm (0.75 in.)
1. Remove brake valve from machine. (See repair manual.) 2. Clamp brake valve level in bench vise.
TX,D300,DS2080 1912JUL941/5
3. Install caps (A). Fill brake valve reservoir with oil.
9020 20 1
TX,D300,DS2080 1912JUL942/5
IMPORTANT: DO NOT allow pedal to return abruptly before the stop screws are adjusted. Check valves could be damaged if stop screws are not properly adjusted.
UN30OCT90
4. Remove left cap and hold finger over end to stop oil flow. Slowly pump left pedal until air is purged. Install cap and repeat procedure on other side. Refill reservoir.
TX,D300,DS2080 1912JUL943/5
TM1496 (21SEP05)

092105
PN=401
T7407AT
T7407AU
UN30OCT90
Adjustments
5. Adjust right-hand brake pedal cap screw (B) so brake piston is fully extended from the housing and brake pedal arm is tight against the piston. 6. Apply a minimum of 44.5 N (10 lb) force to the left-hand brake pedal.
Specification Brake PedalMinimum Applied Force .................................................................................... 44.5 N (10 lb)
If the pedal starts to settle, turn right-hand cap screw (B) out (counterclockwise) until the settling stops. Turn the right-hand cap screw (B) and additional 1/3 turn (two wrench flats) out (counterclockwise). 7. Adjust left-hand brake pedal cap screw (A) so brake piston is fully extended from the housing and brake pedal arm is tight against the piston. 8. Apply a minimum of 44.5 N (10 lb) force to right-hand brake pedal. If pedal starts to settle, turn the left-hand cap screw (A) out (counterclockwise) until settling stops. Turn the left-hand cap screw (A) an additional 1/3 turn (two wrench flats) out (counterclockwise). 9. After both pedals have been adjusted, align pedals by turning cap screws for the highest pedal, a maximum of 1/6 turn (one wrench flat) out (counterclockwise). Lock both stop screws.
9020 20 2
TX,D300,DS2080 1912JUL944/5
TM1496 (21SEP05)

092105
PN=402
T7407AS
UN30OCT90
Adjustments
10. Remove cap (A). A steady stream of oil must flow to indicate that check valve is in "open" position with pedals up. Depress pedal up to 13 mm (0.5 in.) and flow must stop which indicates that check valve is in "closed" position and sealing. Slowly release pedal; pedal must return to stop screw by return spring force alone. Install cap. Repeat for other side. Fill reservoir.
11. Depress one brake pedal. Brake pedal must be solid within first 19 mm (0.75 in.) of pedal travel.
Specification Brake PedalTravel ....................................................... 19 mm (0.75 in.)
Repeat for other pedal.
NOTE: Excessive pedal travel indicates air in brake valve; repeat step 4.
T7407AU
NOTE: If oil does not flow, readjust valve stop screws. If flow does not stop with pedal depressed, inspect or replace check valve.
UN30OCT90
9020 20 3
TX,D300,DS2080 1912JUL945/5
Adjust Park Brake

1. Park machine on level surface and lower all equipment to ground.
Continued on next page TX,55,DH1673 1912JUL941/6
TM1496 (21SEP05)

092105
PN=403
Adjustments
2. Move FNR lever (B) to neutral "N". 3. Move transaxle gear shift lever (A) to neutral. 4. Stop engine. CAUTION: Prevent possible injury from unexpected machine movement. Block wheels to prevent movement of machine during adjustment. 5. Block wheels to prevent movement.
UN07JAN91
NOTE: Park brake must be disengaged while adjusting.

6. Move park brake switch to OFF position. 7. Remove front and rear floor plates. 8. Start engine. Disengage park brake.
9020 20 4
TX,55,DH1673 1912JUL942/6
CAUTION: Prevent possible personal injury from flying hardware. Actuator contains spring under load. DO NOT disassemble or remove from mounting bracket.
NOTE: Nut (A) is pinned to shaft (B). DO NOT remove pin.

9. Turn shaft assembly counterclockwise until it reaches the end of the canister. Assembly will back out approximately 2.0 in. (51 mm). 10. Stop engine.
TX,55,DH1673 1912JUL943/6
TM1496 (21SEP05)

092105
PN=404
T7351AR
UN15NOV90
T7446AF
Adjustments
11. Remove plug (A) from top rear of transaxle.
NOTE: Screw is adjusted at 1/2 turn increments.

12. Use a screwdriver and turn set screw (B) clockwise until it cannot be tightened another 1/2 turn. 13. Loosen screw approximately one turn making certain concave surface (C) on bottom screw head mates with convex surface of pivot pin. It will feel like a detented position.
TX,55,DH1673 1912JUL944/6
T6148AD
UN18OCT88
14. Loosen lock nut (A). 15. Turn brake band stop screw clockwise until it contacts brake band.
UN02NOV88
9020 20 5
16. Loosen stop screw one full turn. 17. Hold screw and tighten lock nut.
TX,55,DH1673 1912JUL945/6
TM1496 (21SEP05)

092105
PN=405
T6001AP
Adjustments
18. Turn shaft assembly (B) clockwise until nut (A) contacts end of canister. 19. Install floor plates.
9020 20 6
TX,55,DH1673 1912JUL946/6
Bleeding Brakes
SPECIFICATIONS Brake Pedal Travel at 267 N (60 lb) 115 mm (4.5 in.) after a 10 second wait cycle
TX,D300,DS2087 1912JUL941/2
TM1496 (21SEP05)

092105
PN=406
T7351AR
UN15NOV90
Adjustments NOTE: Air will "gravity bleed" from brake system through brake valve without use of bleed screws. Brake lines must be inclined toward brake valve. Low ambient temperature or aeration of oil will slow bleed process.
1. Engage park brake. Lock brake pedals together to bleed both brakes. 2. Run engine at low idle. Put bucket in dump position and raise front of machine. Steer to axle stop and hold over relief for 30 seconds to fill brake reservoir. 3. While holding steering over relief, pump the brake pedal slowly 12 times. 4. Release brake pedal completely and wait a minimum of 10 seconds. CAUTION: Do not operate machine if pedal travel exceeds 115 mm (4.5 in.) while applying 267 N (60 lb) force. Operating machine with excessive brake travel could cause brakes not to stop machine on first application. 5. Repeat step 3 and 4 until a firm pedal is obtained within 115 mm (4.5 in.) of pedal travel after a 10 second wait cycle.
Specification Brake PedalTravel at 267 N (60 lb) .............................................................. 115 mm (4.5 in.) after a 10 second wait cycle
T6838AE
UN26OCT88
9020 20 7
Brakes will continue to self-bleed as you machine and pedal firmness should improve. 6. If unable to obtain firm brake pedal, inspect lines and connections for leakage. If not external leaks, test axle. See repair manual.
TX,D300,DS2087 1912JUL942/2
TM1496 (21SEP05)

092105
PN=407
Adjustments
Check And Adjust Toe-In

SPECIFICATIONS Machine Toe-In Front marks must be 12 6 mm (0.5 0.25 in.) closer than rear marks 95 14 Nm (70 10 lb-ft)
UN02NOV88
Tie Rod Clamp Cap Screws Torque
1. Measure distance from ground to hub center (A). At this height, mark front (B) and rear (C) in center of tread of each front tire. 2. Measure distance between front marks (B) and rear marks (C). MACHINES WITHOUT MFWD
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. Tighten clamp cap screws to 95 14 Nm (70 10 lb-ft).
UN12NOV90
Specification Tie Rod Clamp Cap Screws Torque ............................................................. 95 14 Nm (70 10 lb-ft)
4. Front marks must 12 6 mm (0.5 0.25 in.) closer than rear marks. 5. Loosen nut (F) on each side of axle. Turn each tie rod (G) equally to adjust. Tighten nuts.
ACenter of Hub BFront of Tire CRear of Tire DTie Rod Tube ETie Rod Clamp FNut GTie Rod
TX,D300,DS2088 1912JUL941/1
TM1496 (21SEP05)

092105
PN=408
T7417BA
MACHINES WITH MFWD
T6162AT
9020 20 8
Specification MachineToe-In .................................... Front marks must be 12 6 mm (0.5 0.25 in.) closer than rear marks
UN02NOV88
3. Front marks must 12 6 mm (0.5 0.25 in.) closer than rear marks.
T6382JW
Group 25
Tests
UN28FEB89
AClamp-On Transducer Remove paint with emery cloth and connect to a straight section of injection line within 100 mm (4 in.) of pump. Finger tighten only. DO NOT over tighten. BBlack Clip (-). Connect to main frame. CRed Clip (+). Connect to transducer. DTachometer Readout. Install cable.
10T,9010,K182 1910AUG951/1
T6813AG

SERVICE EQUIPMENT AND TOOLS Digital Thermometer ATemperature Probe
UN28FEB89
9020 25 1
Fasten to a bare metal line using a tie band. Wrap with shop towel. BCable CDigital Thermometer
902525,AA4 1928FEB951/1
Transaxle Oil Warm-Up Procedure

SPECIFICATIONS Engine Speed Fast idle (2375 25 rpm)
1. Raise machine off ground using loader and stabilizers.
TX,9020,YY914 1921APR941/2
TM1496 (21SEP05)

092105
PN=409
T6808CE
Tests
2. Put transaxle in second gear (A). 3. Operate engine at fast idle (2375 25 rpm).
Specification EngineSpeed ................................................. Fast idle (2375 25 rpm)
IMPORTANT: Do not hold brakes for longer than 20 seconds or brake system damage could result. 4. Put FNR lever (B) in forward position and apply moderate pressure to brake pedals for 20 seconds. DO NOT stall wheels while applying brakes. 5. Shift FNR lever to neutral position for 10 seconds to circulate oil. 6. Repeat steps 4 and 5 until transaxle oil reaches necessary test temperature.
9020 25 2
TX,9020,YY914 1921APR942/2
TM1496 (21SEP05)

092105
PN=410
T7446AF
UN07JAN91
Tests
Transaxle Pump Flow Test

SPECIFICATIONS Oil Temperature Engine Speed Oil Minimum Flow 40 4C (104 7F) 1500 25 rpm 11.3 L/m (3 gpm) ESSENTIAL TOOLS (1/2 Male NPT x 1/2 Male) (Parker No. 30182-8-8) Push-Lok Connector (2 used) SERVICE EQUIPMENT AND TOOLS Flowmeter Digital Thermometer Electronic Tachometer
1. Make test connections. IMPORTANT: Open flowmeter loading valve before starting unit to prevent damage to system. 2. Open flowmeter loading valve. 3. Raise machine off ground using loader and stabilizers. 4. Heat oil to specifications.
Specification OilTemperature ..................................................... 40 4C (104 7F) EngineSpeed .................................................................. 1500 25 rpm
UN23JUN94
9020 25 3
(See procedure in this group.) 5. Put transaxle in neutral and FNR lever in forward. Adjust engine speed to specification. Record flow rate.
Specification OilMinimum Flow ........................................................ 11.3 L/m (3 gpm)
If flow rate is low, remove and repair or replace pump.
TX,9020,YY925 1912JUL941/1
TM1496 (21SEP05)

092105
PN=411
T8274AB
Tests
Reverser Oil Warm-Up Procedure

SPECIFICATIONS Engine Speed Fast idle (2375 25 rpm)
1. Hold service brakes on.
TX,300D,YY923 1912JUL941/2
2. Put transaxle in fourth gear (A). 3. Operate engine at fast idle (2375 25 rpm).
Specification EngineSpeed ................................................. Fast idle (2375 25 rpm) 9020 25 4
IMPORTANT: Do not stall converter for longer than 20 seconds or serious converter damage could result. 4. Put FNR lever (B) in forward position and stall for 20 seconds. 5. Shift FNR lever to neutral position for 10 seconds to circulate oil before doing next converter stall. 6. Repeat steps 4 and 5 until reverser oil reaches necessary test temperature.
TX,300D,YY923 1912JUL942/2
TM1496 (21SEP05)

092105
PN=412
T7446AF
UN07JAN91
Tests
Torque Converter Speed Test

SPECIFICATIONS Fast Idle Speed Oil Temperature 300D Minimum Engine Speed 310D and 315D Minimum Engine Speed 300D Maximum Engine Speed 310D and 315D Maximum Engine Speed 2375 25 rpm 65 5C (150 10F) 2000 rpm 2150 rpm 2200 rpm 2360 rpm
6. When reverser oil temperature is at test specification, record engine speed.

Specification OilTemperature ............................................ 65 5C (150 10F) 300DMinimum Engine Speed ........................................... 2000 rpm 310D and 315DMinimum Engine Speed ....................................................................... 2150 rpm 300DMaximum Engine Speed.................................................................................... 2200 rpm 310D and 315DMaximum Engine Speed ....................................................................... 2360 rpm
SERVICE EQUIPMENT AND TOOLS Digital Thermometer Electronic Tachometer
7. If converter stall speed is low, check for: Low engine output. See Group 9010-25. Incorrect torque converter (check part number through inspection hole in bottom of reverser housing). Failed freewheel clutch in torque converter. 8. If converter stall speed is too high, check for: Incorrect oil temperature. Low oil level. Incorrect oil in machine. Restricted suction screen. See repair manual. Incorrect torque converter (check part number through inspection hole in bottom of reverser housing). Engine over fueled. See Turbocharger Boost Pressure-Engine Performance Test310D, 315D in Group 9010-25. Converter failed. Failed reverser clutch disk. Low system (pump) pressure in reverser.
9020 25 5
1. Install electronic tachometer and digital thermometer. (See procedure in this group.) IMPORTANT: Converter should NOT be stalled longer than 20 seconds or serious converter damage may result. Return FNR lever to neutral position for 10 seconds before doing next stall test. 2. Put transaxle in fourth gear. 3. Apply and hold service brakes throughout test. 4. Move FNR lever to forward position. 5. Run engine at fast idle with speed control pedal.
Specification Fast IdleSpeed ......................................................... 2375 25 rpm
IMPORTANT: Minimum engine speed listed is for an engine that is broken-in and using No. 2 fuel.
TX,300D,1952 1912JUL941/1
TM1496 (21SEP05)

092105
PN=413
Tests
Brake Valve Leakage Test

SPECIFICATIONS Oil Temperature 40 5 C (104 10F) ESSENTIAL TOOLS 38H1352 (-4 ORFS) Nut (2 used) 38H1138 (-4 ORFS) Plug (2 used) JT03455 (7/16 JIC M x -4 ORFS F) Fitting 38H1029 Tee SERVICE EQUIPMENT AND TOOLS Gauge 06895 kPa (069 bar) (01000 psi)
1. Heat oil to specifications.

Specification OilTemperature .................................................. 40 5 C (104 10F)
UN14DEC91
See Hydraulic Oil Warm-up in Group 9025-25.

9020 25 6
2. Stop engine. 3. Push left and right brake pedal individually. If either pedal settles, leakage is indicated in final drive brake piston or brake valve reservoir. 4. Disconnect brake line and tee gauge at brake valve line of pedal that settled. 5. Push brake pedal down and block in place to set gauge at 500 psi starting point. 6. Monitor gauge. If pressure drops more than 100 psi in 30 seconds, excessive leakage is indicated. 7. To isolate leakage, disconnect and cap line at gauge. 8. If leakage continues, replace check valve. 9. No pressure drop indicates leakage at piston seals in axle housing.
300D,DS4660 1912JUL941/1
TM1496 (21SEP05)

092105
PN=414
T7668AL
Tests
Park Brake Release Pressure Test

SPECIFICATIONS Oil Temperature Engine Speed Park Brake Release Pressure 65 5C (150 10F) 1500 25 931 100 kPa (9.3 1.0 bar) (135 15 psi)
ESSENTIAL TOOLS 10R6LOS Tee JT03458 (7/16-20 M JIC) Adapter SERVICE EQUIPMENT AND TOOLS Electronic Tachometer Digital Thermometer Gauge 02000 kPa (020 bar) (0300 psi)
1. Install tachometer and thermometer. (See procedure in this group.)

9020 25 7
TX,9020,YY924 1912JUL941/2
TM1496 (21SEP05)

092105
PN=415
Tests
2. Disconnect park brake actuator hose (E) at park brake solenoid valve (A). Install tee (B), adapter (C) and gauge (D). Connect hose to tee. 3. Heat oil to specifications.
Specification OilTemperature ................................................... 65 5C (150 10F)
(See procedure in this group.) 4. Increase rpm to specification and record pressure reading.
Specification EngineSpeed .......................................................................... 1500 25 Park BrakeRelease Pressure ................. 931 100 kPa (9.3 1.0 bar) (135 15 psi)
9020 25 8
APark Brake Solenoid Valve BTee CAdapter DGauge ETo Park Brake Actuator FPark Brake Actuator GPark Brake Solenoid Valve Hose HTo Reverser System Pressure Port IReverser System Pressure Port
(S.N. 802199)
(S.N. 802200 )
TX,9020,YY924 1912JUL942/2
TM1496 (21SEP05)

092105
PN=416
T8262BW
UN06JUL94
T7952AB
UN02MAR93
5. If park brake pressure is not to specification, do Reverser Leakage TestFour-Gauge Method. (See procedure in this group.)
Tests
Reverser Disconnect Clutch Solenoid (SN 792482)

SPECIFICATIONS Oil Temperature Engine Speed Forward and Reverse Pressure with Disconnect Switch Activated Forward and Reverse Maximum Allowable Pressure Difference with Disconnect Switch not Activated 65 5C (150 10F) 1500 25 rpm 0.0 kPa (0.0 bar) (0.0 psi) 70 kPa (0.7 bar) (10 psi)
ESSENTIAL TOOLS BJT05487 (1/8 M NPT 7/16-20 M 37) Connector CJT05483 (7/16-20 37 x 7/16-20 M 37) 90 Swivel Elbow DJT03104 (3/8 M NPT 7/16-20 M 37) Connector SERVICE EQUIPMENT AND TOOLS
UN30OCT90
Electronic Tachometer Digital Thermometer AGauge 02000 kPa (020 bar) (0300 psi) (2 used)
9020 25 9
1. Install tachometer and thermometer. (See procedure in this group.) 2. Make test connections. 3. Heat oil to specifications.
(See Reverser Oil Warm-Up procedure in this group.) 4. Run engine at specifications.
Specification EngineSpeed .................................................................. 1500 25 rpm
Shift FNR lever to forward. Make a record of "F" port pressure gauge reading. Depress disconnect clutch switch. "F" port pressure must decrease to zero pressure.
Specification Forward and ReversePressure with Disconnect Switch Activated .................... 0.0 kPa (0.0 bar) (0.0 psi)
TX,300D,1953 1912JUL941/2
TM1496 (21SEP05)

092105
PN=417
T7393AG
Tests
Release disconnect clutch switch and watch "F" port pressure gauge return to previous pressure gauge reading. Repeat procedure in reverse position. "R" port pressure must decrease to zero when disconnect clutch switch is pressed.
Specification Forward and ReversePressure with Disconnect Switch Activated .................... 0.0 kPa (0.0 bar) (0.0 psi)
Reading must be within 70 kPa (0.7 bar) (10 psi) higher than "F" port pressure.
Specification Forward and ReverseMaximum Allowable Pressure Difference with Disconnect Switch not Activated ............................................................. 70 kPa (0.7 bar) (10 psi)
9020 25 10
Pressures out of specifications between "F" and "R" pressure ports indicated leakage in circuit with lowest pressure. Do Four-Gauge Leakage Test in this group. If pressures do not drop to zero, listen for a "click" sound from reverser disconnect clutch solenoid when switch is depressed. If no "click" is heard, inspect fuse, wiring, or test solenoid. (See Group 9015-25.) If pressures do not drop to zero, check to make sure that FNR lever is moving to forward and reverse detent positions.
TX,300D,1953 1912JUL942/2
TM1496 (21SEP05)

092105
PN=418
Tests
Reverser Disconnect Clutch Solenoid Test (SN 792483 )

SPECIFICATIONS Oil Temperature Engine Speed Forward and Reverse Pressure with Disconnect Switch Activated Forward and Reverse Maximum Allowable Pressure Difference with Disconnect Switch not Activated 65 5C (150 10F) 1500 25 rpm 0.0 kPa (0.0 bar) (0 psi) 70 kPa (0.7 bar) (10 psi)
ESSENTIAL TOOLS JT05487 (1/8 M NPT 7/16-20 M 37) Connector (2 used) SERVICE EQUIPMENT AND TOOLS Digital Thermometer Electronic Tachometer
1906JUL94
AGauge 02000 kPa (020 bar) (0300 psi) (2 used)
1. Install tachometer and thermometer. (See procedure in this group.) 2. Make test connections. 3. Heat oil to specifications.
9020 25 11
(See Reverser Oil Warm-Up procedure in this group.) 4. Run engine at specifications.
Shift FNR lever to forward. Make a record of forward pressure gauge reading. Depress disconnect clutch switch. Forward pressure must decrease to zero pressure.
Specification Forward and ReversePressure with Disconnect Switch Activated ....................... 0.0 kPa (0.0 bar) (0 psi)
Release disconnect clutch switch. Forward pressure must return to recorded pressure.
300D,DS4661 1912JUL941/2
TM1496 (21SEP05)

092105
PN=419
T8262CA
Tests
5. Shift FNR lever to reverse. Make a record of reverse pressure gauge reading. Depress disconnect clutch switch. Reverse pressure must decrease to zero pressure and return to recorded pressure when disconnect clutch switch is released.
Specification Forward and ReversePressure with Disconnect Switch Activated ....................... 0.0 kPa (0.0 bar) (0 psi)
6. Maximum difference between forward and reverse pressure must not exceed 70 kPa (0.7 bar) (10 psi).
Specification Forward and ReverseMaximum Allowable Pressure Difference with Disconnect Switch not Activated ............................................................. 70 kPa (0.7 bar) (10 psi)
Pressures out of specifications indicate leakage in circuit with lowest pressure. Do Reverser Element Leakage Test in this group.
9020 25 12
7. If pressures do not drop to zero, listen for a "click" from reverser disconnect clutch solenoid when switch is depressed. If no "click" is heard, inspect fuse, wiring or test solenoid. See Reverser Disconnect Clutch Solenoid (SN 792482) or see Reverser Disconnect Clutch Solenoid Test (SN 792483 ) . 8. If pressures do not drop to zero, check to make sure that FNR lever is moving to forward and reverse detent positions.
300D,DS4661 1912JUL942/2
TM1496 (21SEP05)

092105
PN=420
Tests
Reverser Cooler Pressure Test (SN 792482)

SPECIFICATIONS Oil Temperature Engine Speed Neutral Cooler and Forward or Reverse Cooler Maximum Pressure Difference 65 5C (150 10F) 1500 25 rpm 35 kPa (0.35 bar) (5 psi)
ESSENTIAL TOOLS BJT05487 (1/8 M NPT 7/16-20 M 37) Connector SERVICE EQUIPMENT AND TOOLS Electronic Tachometer Digital Thermometer AGauge 01000 kPa (0100 bar) (0150 psi)
1. Install tachometer and thermometer. (See procedure in this group.) 2. Make test connections. 3. Warm reverser oil to specifications.
UN30OCT90
9020 25 13
(See Reverser Oil Warm-Up procedure in this group.) 4. Run engine at specifications and record cooler pressure in forward, neutral, and reverse positions.
Specification EngineSpeed .................................................................. 1500 25 rpm Neutral Cooler and Forward or Reverse CoolerMaximum Pressure Difference ............................................ 35 kPa (0.35 bar) (5 psi)
5. If cooler pressure is high, inspect cooler hoses and cooler for damage. If no damage is found, back flush reverser cooler. See Reverser Oil Cooler Restriction Test in this group. 6. If cooler pressure is lower when forward or reverse is activated, leakage is indicated in that circuit.
TX,300D,1954 1912JUL941/2
TM1496 (21SEP05)

092105
PN=421
T7393AF
Tests
7. If cooler pressure is low in all positions, directional control valve or reverser pump problems are indicated. Do a Four-Gauge System Leakage Test to analysis results. See procedure in this group.
TX,300D,1954 1912JUL942/2
9020 25 14
TM1496 (21SEP05)

092105
PN=422
Tests
Reverser Cooler Pressure Test (SN 792483 )

SPECIFICATIONS Oil Temperature Engine Speed Neutral Cooler and Forward or Reverse Cooler Maximum Pressure Difference 65 5C (150 10F) 1500 25 rpm 35 kPa (0.35 bar) (5 psi)
ESSENTIAL TOOLS BJT05487 (1/8 M NPT 7/16-20 37) Connector SERVICE EQUIPMENT AND TOOLS Electronic Tachometer Digital Thermometer AGauge 01000 kPa (0100 bar) (0150 psi)
UN02MAR93
1. Install tachometer and thermometer. (See procedure in this group.) 2. Make test connections. 3. Warm reverser oil to specifications.
9020 25 15
(See Reverser Oil Warm-Up procedure in this group.) 4. Run engine at specifications and record cooler pressure with FNR lever in forward, neutral and reverse positions.
Specification EngineSpeed .................................................................. 1500 25 rpm Neutral Cooler and Forward or Reverse CoolerMaximum Pressure Difference ............................................ 35 kPa (0.35 bar) (5 psi)
5. If cooler pressure is high, inspect cooler hoses and cooler for damage. If no damage is found, back flush reverser cooler. See Reverser Oil Cooler Restriction Test in this group. 6. If cooler pressure is lower when forward or reverse is activated, leakage is indicated in that circuit.
300D,DS4662 1912JUL941/2
TM1496 (21SEP05)

092105
PN=423
T7949AM
Tests
7. If cooler pressure is low in all positions, FNR solenoid or reverser pump problems are indicated. Do the Reverser element Leakage Test to analyze results. See procedure in this group.
300D,DS4662 1912JUL942/2
9020 25 16
TM1496 (21SEP05)

092105
PN=424
Tests
Reverser/Converter-In Relief Valve Test (SN 792482)

SPECIFICATIONS Oil Temperature Engine Speed Converter-in Relief Valve Pressure Warm to touch Varying rpm 550 10 kPa (5.5 1 bar) (80 15 psi)
ESSENTIAL TOOLS JT05487 (1/8 M NPT 7/16-20 M 37) Connector SERVICE EQUIPMENT AND TOOLS Gauge 01000 kPa (010 bar) (0150 psi) Locking Pliers
1. Make test connections. 2. Put FNR lever in neutral. 3. Warm reverser oil until cooler lines are warm to touch.
Specification OilTemperature ............................................................... Warm to touch
UN30OCT90
9020 25 17
4. Block cooler-in hose with locking pliers (D) to stop cooler flow. IMPORTANT: DO NOT exceed 700 kPa (7 bar) (100 psi) or converter damage could result. 5. Slowly increase rpm until maximum pressure is reached on gauge.
Specification EngineSpeed ....................................................................... Varying rpm Converter-in Relief Valve Pressure ................................................ 550 10 kPa (5.5 1 bar) (80 15 psi)
AGauge BConnector CRelief Valve DLocking Pliers ETorque Converter Out-Cooler In
DO NOT exceed 700 kPa (7 bar) (100 psi) or converter damage could result. 6. If pressure is too high, remove relief valve (C). Disassembly, clean and inspect valve. 7. If pressure is low, check for broken spring, damaged ball or damaged valve seat in relief valve.
TX,300D,1955 1912JUL941/2
TM1496 (21SEP05)

092105
PN=425
T7393AE
Tests
8. Install and check relief valve after repair.
TX,300D,1955 1912JUL942/2
9020 25 18
TM1496 (21SEP05)

092105
PN=426
Tests
Reverser/Converter-In Relief Valve Test (SN 792483 )

SPECIFICATIONS Oil Temperature Engine Speed Converter-In Relief Valve Pressure Warm to touch Varying rpm 550 100 kPa (5.5 1 bar) (80 15 psi)
ESSENTIAL TOOLS JT05487 (1/8 M NPT 7/16-20 M 37) Connector SERVICE EQUIPMENT AND TOOLS Gauge 01000 kPa (010 bar) (0150 psi) Locking Pliers
1. Make test connections. 2. Put FNR lever in neutral. 3. Warm reverser oil until cooler lines are warm to touch.
Specification OilTemperature ............................................................... Warm to touch
UN02MAR93
9020 25 19
4. Block cooler-in hose with locking pliers (D) to stop cooler flow. IMPORTANT: DO NOT exceed 700 kPa (7 bar) (100 psi) or converter damage could result. 5. Slowly increase rpm until maximum pressure is reached on gauge.
Specification EngineSpeed ....................................................................... Varying rpm Converter-In Relief Valve Pressure .............................................. 550 100 kPa (5.5 1 bar) (80 15 psi)
AGauge BConnector CTorque Converter Out-Cooler In DLocking Pliers ERelief Valve
Do not exceed 700 kPa (7 bar) (100 psi) or converter damage could result. 6. If pressure is too high, remove relief valve (E). Disassemble, clean and inspect valve. 7. If pressure is low, check for broken spring, damaged ball or damaged valve seat in relief valve.
TX,300D,DS4663 1912JUL941/2
TM1496 (21SEP05)

092105
PN=427
T7949AL
Tests
8. Install relief valve. Repeat test.
TX,300D,DS4663 1912JUL942/2
9020 25 20
TM1496 (21SEP05)

092105
PN=428
Tests
Reverser Oil Cooler Restriction Test (SN 792482)

SPECIFICATIONS Oil Temperature Oil Flow Inlet and Outlet Maximum Pressure Difference 65 1C (150 2F) 11.4 L/min (3.0 gpm) 140 kPa (1.4 bar) (20 psi)
ESSENTIAL TOOLS 203654 (1/2 M NPT 7/16-20 M 37) Connector (2 used) JT03348 (1/2 F NPT) Tee (2 used) IJT03212 (1/2 ID 1/2 M NPT) Adapter (6 used) JJT03070 (1/2 F NPT 1-1/6-12 37 SW) Adapter (2 used) SERVICE EQUIPMENT AND TOOLS Flowmeter with Temperature Gauge AHydraulic Analyzer or Pressure Gauge BGauge 0200 kPa (02.0 bar) (030 psi) Hydrostatic Switching Unit or Two Similarly Calibrated Gauges 9020 25 21
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.
1. To back flush the cooler, connect reverser pump outlet to cooler outlet. Disconnect cooler inlet line and put end of hose in a five gallon bucket. 2. Start engine and run at slow idle for 20 seconds. DO NOT empty reverser sump. 3. Connect cooler hoses to original position on flowmeter.
AHydraulic Analyzer BGauge CGauge Port DNo. 2 Input ENo. 1 Input FSwitch Unit GConnector HTee IAdapter JAdapter KFlowmeter
TX,300D,1956 1912JUL941/2
TM1496 (21SEP05)

092105
PN=429
T7393AC
UN30OCT90
Tests
4. Make test connection. Refill reverser, then start engine to fill to proper level before test. 5. Open flowmeter. Heat oil to test specification.
Specification OilTemperature ..................................................... 65 1C (150 2F)
(See Reverser Oil Warm-Up procedure in this group.) 6. Increase engine speed until flow is at specification.
Specification OilFlow .................................................................. 11.4 L/min (3.0 gpm)
7. Read pressure gauges at inlet and outlet of cooler.

Specification Inlet and OutletMaximum Pressure Difference .......................................... 140 kPa (1.4 bar) (20 psi)
9020 25 22
TX,300D,1956 1912JUL942/2
TM1496 (21SEP05)

092105
PN=430
Tests
Reverser Oil Cooler Restriction Test (SN 792483 )

SPECIFICATIONS Oil Temperature Oil Flow Inlet and Outlet Maximum Pressure Difference 65 1C (150 2F) 12.1 L/min (3.2 gpm) 140 kPa (1.4 bar) (20 psi)
ESSENTIAL TOOLS JT03348 (1/2 F NPT) Tee (2 used) DJT03212 (1/2 ID 1/2 M NPT) Adapter (6 used) EJT03070 (1/2 F NPT 1-1/16-12 37 SW) Adapter (2 used) SERVICE EQUIPMENT AND TOOLS Flowmeter Gauge 0200 kPa (02.0 bar) (030 psi) (2 used) Digital Thermometer Electronic Tachometer
NOTE: If an internal restriction in the oil cooler is indicated, the oil cooler can be back flushed to check for debris. (See Steps 13.)
IMPORTANT: Reverser and torque converter capacity is 7.6 L (8 qt). 1. To back flush the cooler, connect reverser pump outlet to cooler outlet. Disconnect cooler inlet line (G) and put end of hose in a five gallon container. 2. Start engine and run at slow idle for 20 seconds. DO NOT empty reverser sump. 3. Connect cooler hoses to original position on flowmeter. 4. Make test connections. Refill reverser, then start engine to fill to proper level before test.
AGauge (2 used) BOil Cooler CTee (2 used) DAdapter (2 used) EAdapter (2 used) FFlowmeter GCooler Inlet
UN02MAR93
9020 25 23
TX,300D,DS4664 1912JUL941/2
TM1496 (21SEP05)

092105
PN=431
T7949AJ
Tests
5. Open flowmeter. Heat oil to test specification.
(See Reverser Oil Warm-Up procedure in this group.) 6. Increase engine speed until flow is at specification.
Specification OilFlow .................................................................. 12.1 L/min (3.2 gpm)
7. Read pressure gauges at inlet and outlet of cooler.

Specification Inlet and OutletMaximum Pressure Difference .......................................... 140 kPa (1.4 bar) (20 psi)
TX,300D,DS4664 1912JUL942/2
9020 25 24
TM1496 (21SEP05)

092105
PN=432
Tests
Reverser Leakage Test Using Four-Gauge Method (SN 792482)

SPECIFICATIONS Engine Speed Oil Temperature Cooler Pressure "P" System Pressure "P" System and "F" Forward Maximum Pressure Difference "P" System and "R" Forward Maximum Pressure Difference 1500 25 rpm 65 5C (150 10F) 175 35 kPa (1.7 0.3 bar) (25 5 psi) 931 100 kPa (9.3 1 bar) (135 15 psi) 70100 kPa (0.71.0 bar) (10 15 psi) 3570 kPa (0.030.07 bar) (5 10 psi)
ESSENTIAL TOOLS CJT05483 (7/16-20 F JIC x 7/16-20 M) 90 Swivel Elbow (2 used) DJT05486 (1/4 M NPT 7/16-20 M 37) Connector EJT05487 (1/8 M NPT 7/16-20 M 37) Connector (2 used) FJT03104 (3/8 M NPT 7/16-20 M 37) Connector SERVICE EQUIPMENT AND TOOLS Electronic Tachometer Digital Thermometer AGauge 02000 kPa (020 bar) (0300 psi) (3 used) BGauge 01000 kPa (010 bar) (0150 psi)
UN30OCT90
9020 25 25
1. Pressure higher than specification indicates stuck pressure regulator valve in directional control valve.
Specification EngineSpeed .................................................................. 1500 25 rpm OilTemperature ................................................... 65 5C (150 10F) CoolerPressure ................................... 175 35 kPa (1.7 0.3 bar) (25 5 psi)
Remove, inspect and clean to repair. 2. Low pressure in one circuit indicates leakage in that circuit. Low pressure in all circuits indicates low oil flow caused by plugged filter screen in oil pan or low reverser pump output.
Specification "P" SystemPressure........................... 931 100 kPa (9.3 1 bar) (135 15 psi)
TX,300D,1957 1912JUL941/2
TM1496 (21SEP05)

092105
PN=433
T7393AA
Tests
Specification "P" System and "F" Forward Maximum Pressure Difference ....................... 70100 kPa (0.71.0 bar) (1015 psi) "P" System and "R" Forward Maximum Pressure Difference ..................... 3570 kPa (0.030.07 bar) (510 psi)
Inspect and clean filter and repeat test. If pressure in all circuits is still low, do complete reverser system check in this group to find problem.
TX,300D,1957 1912JUL942/2
9020 25 26
TM1496 (21SEP05)

092105
PN=434
Tests
Reverser Leakage Test Using Four-Gauge Method (SN 792483 )

SPECIFICATIONS Engine Speed Oil Temperature Cooler Pressure System (Pump) Minimum Pressure System (Pump) and Forward Maximum Pressure Difference System (Pump) and Reverse Maximum Pressure Difference 1500 25 rpm 65 5C (150 10F) 175 35 kPa (1.7 0.3 bar) (25 5 psi) 827 kPa (8.2 bar) (120 psi) 70100 kPa (0.71.0 bar) (10 15 psi) 3570 kPa (0.030.07 bar) (5 10 psi)
ESSENTIAL TOOLS BJT03104 (3/8 M NPT 7/16-20 M 37) Connector CJT05487 (1/8 M NPT 7/16-20 M 37) Connector (3 used) SERVICE EQUIPMENT AND TOOLS BGauge 02000 kPa (020 bar) (0300 psi) (3 used) CGauge 01000 kPa (010 bar) (0150 psi) Electronic Tachometer Digital Thermometer
1906JUL94
9020 25 27
1. Pressure higher than specification indicates stuck pressure regulator valve in reverser.
Specification EngineSpeed .................................................................. 1500 25 rpm OilTemperature ................................................... 65 5C (150 10F) CoolerPressure ................................... 175 35 kPa (1.7 0.3 bar) (25 5 psi)
Remove, inspect and clean to repair. 2. Low pressure in one circuit indicates leakage in that circuit. Low pressure in all circuits indicates low oil flow caused by plugged filter screen in oil pan or low reverser pump output.
Specification System (Pump)Minimum Pressure ......................................................... 827 kPa (8.2 bar) (120 psi) System (Pump) and Forward Maximum Pressure Difference ....................... 70100 kPa (0.71.0 bar) (1015 psi)
AGauge (3 used) BConnector CConnector (3 used) DGauge
TX,300D,DS4665 1912JUL941/2
TM1496 (21SEP05)

092105
PN=435
T8262BW
UN06JUL94
T8262CB
Tests
Specification System (Pump) and Reverse Maximum Pressure Difference ..................... 3570 kPa (0.030.07 bar) (510 psi)
Inspect and clean filter and repeat test. If pressure in all circuits is still low, do complete reverser system check in this group to diagnose problem.
TX,300D,DS4665 1912JUL942/2
9020 25 28
TM1496 (21SEP05)

092105
PN=436
Tests
Reverser Pump Flow Test (SN 792482)

SPECIFICATIONS Engine Speed Oil Temperature New Reverser Pump Flow Used Reverser Pump Flow "P" System Pressure 1500 5 rpm 65 1C (150 2F) 11.3 L/min (3.00 gpm) 7.6 L/min (2.00 gpm) 931 100 kPa (9.3 1.0 bar) (135 15 psi) ESSENTIAL TOOLS JT03064 (1-1/16-12 M 37 1/2 F NPT) Adapter JT05483 (7/16-20 F 37 x 7/16-20 M) 90 Swivel Elbow (2 used) JT03104 (3/8 M NPT 7/16-20 M 37) Connector JT05487 (1/8 M NPT 7/16-20 M 37) Fitting JT03025 (3/4-16 M 37) Cap JT03221 (3/4-16 M 37) Plug SERVICE EQUIPMENT AND TOOLS Electronic Tachometer Digital Thermometer Flowmeter EGauge 02000 kPa (020 bar) (0300 psi) DGauge 01000 kPa (010 bar) (0150 psi) 9020 25 29
1. Install tachometer and thermometer. (See procedure this group.) IMPORTANT: Flowmeter loading valve must be open before starting machine to prevent damage to reverser pump.
UN30OCT90
2. Make flowmeter connection and install gauges. Open flowmeter. 3. Disconnect converter-in relief valve hose. Install cap (H) and plug (I). 4. Slowly increase rpm from low idle to test specification.
Specification EngineSpeed .................................................................... 1500 5 rpm AOil Cooler BFlowmeter CAdapter DGauge EGauge FSwivel Elbow GConnector HCap IPlug JFitting KFitting
TX,300D,1958 1912JUL941/2
TM1496 (21SEP05)

092105
PN=437
T7393AD
Tests
Watch cooler pressure gauge "D." If it exceeds 275 kPa (2.7 bar) (40 psi), stop test. Locate and repair restriction in cooler circuit before proceeding with flow test. Pressure above 275 kPa (2.9 bar) (40 psi) could damage torque converter or oil cooler. 5. Heat reverser oil to specifications.
(See procedure in this group.) 6. Put FNR and transaxle levers in neutral. Record flow and "P" pressure (E).
Specification New Reverser PumpFlow ................................... 11.3 L/min (3.00 gpm) Used Reverser PumpFlow .................................... 7.6 L/min (2.00 gpm) "P" SystemPressure................................ 931 100 kPa (9.3 1.0 bar) (135 15 psi) 9020 25 30
7. Connect hose to converter-in relief valve. 8. If pump flow is low, do complete reverser system test to find problem. (See procedure in this group.)
TX,300D,1958 1912JUL942/2
TM1496 (21SEP05)

092105
PN=438
Tests
Reverser Pump Flow (SN 792483 )

SPECIFICATIONS Engine Speed Oil Temperature New Reverser Pump Flow Used Reverser Pump Flow System (Pump) Pressure 1500 5 rpm 65 1C (150 2F) 12.1 L/min (3.2 gpm) 8.5 L/min (2.25 gpm) 931 100 kPa (9.3 1.0 bar) (135 15 psi)
ESSENTIAL TOOLS JT03064 (1-1/16-12 M 37 1/2 F NPT) Adapter EJT05487 (1/8 M NPT 7/16-20 37) Connector FJT03104 (3/8 M NPT 7/16-20 M 37) Connector (2 used) SERVICE EQUIPMENT AND TOOLS Electronic Tachometer Digital Thermometer
1906JUL94
Flowmeter Gauge 02000 kPa (020 bar) (0300 psi) DGauge 01000 kPa (010 bar) (0150 psi)
9020 25 31
1. Install tachometer and thermometer. (See procedure in this group.) 2. Install flowmeter and gauges. IMPORTANT: Flowmeter must be open before starting machine to prevent damage to reverser pump. 3. Open flowmeter. 4. Disconnect converter-in relief valve hose. Install cap and plug. 5. Slowly increase rpm from slow idle to test specification.
Specification EngineSpeed .................................................................... 1500 5 rpm AOil Cooler BFlowmeter CAdapter DGauge EConnector FConnector (2 used)
Watch cooler pressure gauge (D). If it exceeds 275 kPa (2.7 bar) (40 psi), stop test. Locate and repair restriction in cooler circuit before proceeding with test. Pressure above 275 kPa (2.7 bar) (40 psi) could damage torque converter or oil cooler.
TX,300D,DS4666 1912JUL941/2
TM1496 (21SEP05)

092105
PN=439
T8262BW
UN06JUL94
T8268AA
Tests
6. Heat oil to specification.
(See procedure in this group.) 7. Put FNR and transaxle levers in neutral. Record flow and system (pump) pressure.
Specification New Reverser PumpFlow ..................................... 12.1 L/min (3.2 gpm) Used Reverser PumpFlow .................................... 8.5 L/min (2.25 gpm) System (Pump)Pressure ......................... 931 100 kPa (9.3 1.0 bar) (135 15 psi)
8. Connect hose to converter-in relief valve. 9. If pump flow is low, do complete reverser system test to diagnose problem. (See procedure in this group.)
9020 25 32
TX,300D,DS4666 1912JUL942/2
TM1496 (21SEP05)

092105
PN=440
Tests
Complete Reverser Test (SN 792482)

ESSENTIAL TOOLS JT03064 (1-1/16-12 M 37 1/2 F NPT) Adapter FJT05487 (1/8 M NPT 1/16-20 37) Connector (2 used) JT05483 (7/16-20 F 37 x 7/16-20 M) 90 Swivel Elbow (2 used) HJT03104 (3/8 M NPT 7/16-20 M 37) Connector JT05486 (1/4 M NPT 7/16-20 M 37) Fitting JJT03043 (1/2 M NPT 1-1/16-12 M 37) Connector JT03221 (3/4-16 M 37) Plug SERVICE EQUIPMENT AND TOOLS Flowmeter DGauge 02000 kPa (020 bar) (0300 psi) EGauge 01000 kPa (010 bar) (0150 psi) Electronic Tachometer Digital Thermometer
A complete reverser system test consists of test connection, test procedures, test procedure chart, specifications and analysis. The purpose of this test is to check overall performance of reverser hydraulic system. Use a copy of the reverser test procedure chart to record data obtained during test procedure. After the test, use the data and the specifications and analysis to make a diagnosis. IMPORTANT: DO NOT block converter-in relief valve until Step 7 of test procedure. Make test connections.
AOil Cooler BFlowmeter CAdapter DGauge (3 used) EGauge FConnector GSwivel Elbow (2 used) HConnector IFitting JConnector KPlug LCap
9020 25 33
TX,300D,1959 1912JUL941/1
TM1496 (21SEP05)

092105
PN=441
T7393AB
UN30OCT90
Tests
Complete Reverser System Test (SN 792483 )

ESSENTIAL TOOLS JT03064 (1/8 M NPT 1/16-20 37) Adapter (2 used) EJT05487 (1/8 M NPT 1/16-20 37) Connector (3 used) FJT03104 (3/8 M NPT 7/16-20 M 37) Connector (2 used) SERVICE EQUIPMENT AND TOOLS Flowmeter IGauge 02000 kPa (020 bar) (0300 psi) (3 used) DGauge 01000 kPa (010 bar) (0150 psi) Electronic Tachometer Digital Thermometer
9020 25 34
IMPORTANT: DO NOT block converter-in relief valve until step 7 of test procedure. Make test connections.
AOil Cooler BFlowmeter CAdapter (2 used) DGauge EConnector (3 used) FConnector (2 used) GPlug HCap IGauge
TX,9020,DY387 1910JUN961/1
TM1496 (21SEP05)

092105
PN=442
T8262BW
UN06JUL94
T8268AR
A complete reverser system test consists of test connections and procedures, test procedure chart, specifications and analysis. The purpose of this test is to check overall performance of reverser hydraulic system. Use a copy of the reverser test procedure chart to record data obtained during test procedure. After the test, use the data and the specifications and analysis to make a diagnosis.
1906JUL94
Tests
Test Procedure
SPECIFICATIONS Cooler Maximum Pressure Reverser Pump Flow Test Maximum Cooler Pressure 690 kPa (6.9 bar) (100 psi) 275 kPa (2.7 bar) (40 psi) Specification CoolerMaximum Pressure .................... 690 kPa (6.9 bar) (100 psi)
If pressure does reach 690 kPa (6.9 bar) (100 psi), stop test and repair relief valve before continuing test. Record reading for converter-in (cooler) pressure. Open flowmeter. STEP 5Converter Stall Speed Check Run engine at approximately 2150 rpm.
SERVICE EQUIPMENT AND TOOLS Flowmeter Locking Pliers
Do the steps below and record data on a copy of the Reverser Test Procedure Chart. STEP 1Start engine and run at slow idle. Check reverser oil level. STEP 2Heat oil to specification. (See Reverser Oil Warm-Up procedure in this group.) Reverser oil temperature must stay at specifications for accurate data. STEP 3Disconnect Clutch Check
Heat oil to 65 1C (150 2F). (See Reverser Warm-Up Procedure in the group.) Do Converter Stall Speed Test (See procedure in this group.) STEP 6Reverser Clutch Valve Circuit Check Put FNR lever in neutral position.
9020 25 35
Put FNR lever in forward position. Run engine at 1500 25 rpm. Depress clutch disconnect switch. Forward pressure must decrease to zero. Record reading. STEP 4Converter-In (Cooler) Relief Valve Pressure Check IMPORTANT: Cooler pressure MUST NOT exceed 690 kPa (6.9 bar) (100 psi). Put FNR lever in neutral position. Close flowmeter. Slowly increase engine speed until cooler pressure stops increasing. DO NOT exceed 690 kPa (6.9 bar) (100 psi). Run engine at 1500 25 rpm. Record reading for cooler flow, cooler and system (pump) pressure. Put FNR lever in forward position. Record pressure readings for cooler flow, cooler and forward. Put FNR lever in reverse. Record pressure readings for cooler flow, cooler and reverse. STEP 7Reverser Pump Flow Check Block converter-in (cooler) relief valve line with locking pliers. Disconnect converter-in hose and plug. Cap relief valve. Put FNR lever in neutral.
TX,D300,DS2090 1908MAR931/2
TM1496 (21SEP05)

092105
PN=443
Tests
Slowly increase rpm from slow idle to 1500 25 rpm while watching cooler pressure gauge. Stop test if cooler pressure increases above 275 kPa (2.7 bar) (40 psi) or torque converter could be damaged.
Specification Reverser Pump Flow Test Maximum Cooler Pressure ........................ 275 kPa (2.7 bar) (40 psi)
Record cooler flow and cooler pressure at 1500 3 rpm. Connect hose to converter-in relief valve. Remove locking pliers from converter-in (cooler) relief valve line.
TX,D300,DS2090 1908MAR932/2
9020 25 36
TM1496 (21SEP05)

092105
PN=444
Tests
Reverser Test Procedure Chart

Converter In Relief Cooler Pressure
Step 1 2
RPM Slow Idle Fast Idle
Temperature
Element Tested
Shift Mode NN
Cooler Flow
Pressure
Test Port Pressure
Operating Condition Check oil level Brakes on, 4th gear converter stall
65 5C (150 10F) 65 5C (150 10F) Clutch solenoid disengaged
Converter
4F
1500 25 65 5C (150 10F) Slow Idle to 2000
Clutch solenoid
NF
Forward
Depress clutch disconnect switch Release clutch disconnect switch Close flow meter
1500 25
NF
Forward
40 5C (100 10F)
Converter-in relief valve
NN
Increase rpm until pressure stops increasing Open flow meter. 5 Fast Idle Note rpm 1500 25 1500 25 1500 25 7 1500 25 65 5C (150 10F) 65 5C (150 10F) 65 5C (150 10F) 65 5C (150 10F) 65 5C (150 10F) Converter 4F Brakes on, 4th gear converter stall System Forward Reverse Converter-in relief valve blocked. Slowly increase rpm to specified speed while watching cooler pressure gauge.
9020 25 37
System pressure System pressure System pressure System pressure
NN NF NR NN
T59,9025,375 1908MAR931/1
TM1496 (21SEP05)

092105
PN=445
Tests
Specifications And Analysis

SPECIFICATIONS F Port Pressure With Clutch Disconnect Switch Depressed F Port Pressure With Clutch Disconnect Switch Released Torque Converter-In (Cooler) Relief Valve Pressure Setting 300D Minimum Engine Speed 310D and 315D Minimum Engine Speed 300D Maximum Engine Speed 310D and 315D Maximum Engine Speed Neutral and Forward or Reverse Maximum Allowable Difference in Flow System (Pump) Pressure System (Pump) and Forward Maximum Allowable Pressure Difference System (Pump) and Reverse Maximum Allowable Pressure Difference Cooler Maximum Allowable Pressure Difference Between Circuits Cooler Maximum Pressure New Reverser Charge Pump Minimum Flow Rate Used Reverser Charge Pump Minimum Flow Rate Neutral and Forward or Reverse Maximum Allowable Flow Difference Reverser Pump Flow Test Maximum Cooler Pressure System (Pump) Pressure 0 931 100 kPa (9.3 1.0 bar) (135 15 psi) 550 100 kPa (5.5 1 bar) (80 15 psi) 2000 2150 2200 2360 2.0 L/min (0.5 gpm)
STEP 3Forward pressure must decrease to zero when clutch disconnect switch is depressed. Pressure must return to "F" port specifications 931 100 kPa (9.3 1.0 bar) (135 15 psi) when clutch disconnect switch is released.
Specification F PortPressure With Clutch Disconnect Switch Depressed ........................................................... 0 Pressure With Clutch Disconnect Switch Released ............... 931 100 kPa (9.3 1.0 bar) (135 15 psi)
If specifications are not met, inspect disconnect solenoid wiring. See Group 9015-15. STEP 4Torque converter-in (cooler) relief valve setting is 550 100 kPa (5.5 1 bar) (80 15 psi).
Specification Torque Converter-In (Cooler) Relief ValvePressure Setting ........ 550 100 kPa (5.5 1 bar) (80 15 psi)
931 100 kPa (9.3 1.0 bar) (135 15 psi) 100 kPa (1 bar) (15 psi)
9020 25 38
70 kPa (0.7 bar) (10 psi)
70 kPa (0.7 bar) (5 psi)
200 kPa (2.0 bar) (30 psi) 12.1 L/min (3.2 gpm) 8.5 L/min (2.25 gpm) 2.0 L/min (0.5 gpm)
When the pressure stops increasing is when relief valve opens. If charge pump flow and cooler pressure are to specification (see Step 7) and this pressure is not to specifications, remove and inspect valve for damaged spring, ball, or valve seat. Repair and retest. STEP 5Torque converter stall speed:
Specification 300DMinimum Engine Speed .................................................. 310D and 315DMinimum Engine Speed .............................................................................. 300DMaximum Engine Speed........................................................................................... 310D and 315DMaximum Engine Speed .............................................................................. 2000 2150 2200 2360
275 kPa (2.7 bar) (40 psi) 931 100 kPa (9.3 1 bar) (135 15 psi)
If converter stall speed is low, check for: Low engine output. See Group 9010-25. Incorrect torque converter (part number through inspection hole in bottom of reverser housing. Failed freewheel clutch in torque converter.
Use the following analysis to determine if reverser meets the specifications given and hydraulic system for reverser is acceptable. Information is also given to help identify the cause of possible problems.
TX,D300,DS2078 1908MAR931/3
TM1496 (21SEP05)

092105
PN=446
Tests
If converter stall speed is high, check for: Incorrect oil temperature. Low oil level. Incorrect oil in machine. Restricted suction screen. See repair manual. Incorrect torque converter (part number through inspection hole in bottom of reverser housing. Engine over-fueled. See Turbocharger Boost Pressure-Engine Performance Test310D, 315D in Group 9010-25. Converter failed. Check for failed reverser clutch disk. STEP 6The maximum allowable difference of flow between neutral, forward and reverse is 2.0 L/min (0.5 gpm).
Specification Neutral and Forward or ReverseMaximum Allowable Difference in Flow ................................................ 2.0 L/min (0.5 gpm)
Pressure below specifications indicated leakage in circuits with low pressure. If all pressures are low and pump flow is low, remove reverser and repair charge pump. If pressures are at zero, drive tangs on torque converter are failed. Replace torque converter. If all pressures are too high or low, pressure regulating valve is sticking. Remove, inspect, clean and install. Repeat test. The maximum allowable difference in cooler pressure between circuits is 70 kPa (0.7 bar) (10 psi).
Specification CoolerMaximum Allowable Pressure Difference Between Circuits ......................................................... 70 kPa (0.7 bar) (10 psi)
Circuit with lowest cooler (lube) pressure indicates excessive leakage in that circuit. Maximum cooler pressure is 200 kPa (2.0 bar) (30 psi).
Specification CoolerMaximum Pressure ...................... 200 kPa (2.0 bar) (30 psi) 9020 25 39
Difference in flow between pressure circuits indicates leakage in circuit with lowest flow. System (pump) pressure specifications are 931 100 kPa (9.3 1.0 bar) (135 15 psi).
Specification System (Pump)Pressure .................. 931 100 kPa (9.3 1.0 bar) (135 15 psi)
If pressure is too high and converter-in relief in Step 4 was at specifications, inspect oil cooler circuit for damage. If no damage is found, back flush oil cooler. See Group 9020-25, Reverser Cooler Pressure Test. If system (pump) pressure was to specifications and lube pressure was low in neutral-neutral, a damaged torque converter is indicated. Replace torque converter. See repair manual. STEP 7Minimum acceptable reverser charge pump flow with new pump is 12.1 L/min (3.2 gpm) or a used pump is 8.5 L/min (2.25 gpm) in forward, reverse or neutral.
Specification New Reverser Charge Pump Minimum Flow Rate ........................................... 12.1 L/min (3.2 gpm) Used Reverser Charge Pump Minimum Flow Rate ........................................... 8.5 L/min (2.25 gpm)
Maximum allowable difference between system (pump) pressure and forward pressure is 100 kPa (1 bar) (15 psi).
Specification System (Pump) and Forward Maximum Allowable Pressure Difference...................................................... 100 kPa (1 bar) (15 psi)
Maximum allowable difference between system (pump) pressure and reverse pressure is 70 kPa (0.7 bar) (10 psi).
Specification System (Pump) and Reverse Maximum Allowable Pressure Difference..................................................... 70 kPa (0.7 bar) (10 psi)
The maximum allowable difference of flow between neutral, forward and reverse is 2.0 L/min (0.5 gpm).
TX,D300,DS2078 1908MAR932/3
TM1496 (21SEP05)

092105
PN=447
Tests
Specification Neutral and Forward or ReverseMaximum Allowable Flow Difference .................................................... 2.0 L/min (0.5 gpm)
System (pump) pressure specification is 931 100 kPa (9.3 1 bar) (135 15 psi).
Specification System (Pump)Pressure ..................... 931 100 kPa (9.3 1 bar) (135 15 psi)
If cooler pressure is above 275 kPa (2.7 bar) (40 psi), inspect cooler circuit for damaged parts or debris in system.
Specification Reverser Pump Flow Test Maximum Cooler Pressure ........................ 275 kPa (2.7 bar) (40 psi)
If system (pump) pressure is too high or low, disassemble, inspect, clean and repair pressure regulating valve.
See Group 9025-25, Reverser Cooler (Lube) Pressure Test.
TX,D300,DS2078 1908MAR933/3
9020 25 40
TM1496 (21SEP05)

092105
PN=448
Section 9025
Hydraulics
Contents
Page Page
Group 05Theory Of Operation Open-Center Hydraulic System . . . . . . . . . . .9025-05-1 Main Hydraulic System . . . . . . . . . . . . . . . . .9025-05-3 Main Hydraulic Pump . . . . . . . . . . . . . . . . . .9025-05-5 Priority Valve (300D, 310D S.N. 802199) (315D, All Machines) . . . . . . . . . .9025-05-6 Hydraulic Filter Operation . . . . . . . . . . . . . . .9025-05-9 Steering Valve Operation . . . . . . . . . . . . . .9025-05-11 Loader Control ValveGRESEN (300D, 310D S.N. 802199) (315D, All Machines) . . . . . . . . . . . . . . . . . . . . . . . .9025-05-14 Loader Control Valve OperationHUSCO (300D, 310D S.N. 802200 ) . . . . . . . . .9025-05-20 Loader Circuit Relief Valve With Anti-CavitationHUSCO (300D, 310D, S.N. 802200 ). . . . . . . . . . . . . . . . . . . .9025-05-27 Loader Circuit Relief Valve Without Anti-Cavitation HUSCO (300D, 310D, S.N. 802200 ). . . . . . . . . . . . . . . . . . . .9025-05-28 Stabilizer Valve Operation . . . . . . . . . . . . . .9025-05-29 Backhoe Control Valve Operation GRESEN (300D, S.N. 802199). . . . . . .9025-05-30 Backhoe Control Valve OperationHUSCO (310D, 315D, All Machines) (300D, S.N. 802200 ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-35 Regenerative OutletHUSCO . . . . . . . . . .9025-05-41 Side Shift Locking Valve315D . . . . . . . . .9025-05-43 Group 10System Operational Checks System Operational Procedure . . . . . . . . . . .9025-10-1 Steering System Checks . . . . . . . . . . . . . . . .9025-10-1 Hydraulic System Checks . . . . . . . . . . . . . . .9025-10-2 Loader Control Valve Checks . . . . . . . . . . . .9025-10-5 Group 15Diagnostic Information Use These Seven Basic Steps To Diagnose And Test The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-1 Make A Pretest Inspection And An Operation Check Of The Machine . . . . . . .9025-15-1 Hydraulic System Pretest . . . . . . . . . . . . . . .9025-15-2 Diagnose Hydraulic System Malfunction . . . .9025-15-3 Hydraulic System Component Location And System Schematic (300D, 310D, S.N. 802199) (315D, All Machines) . . . . . . .9025-15-11 TM1496 (21SEP05)
Hydraulic System Component Location (300D, 310D, S.N. 802200 ). . . . . . . . .9025-15-12 Hydraulic System Schematic (300D, 310D, S.N. 802200 ) . . . . . . . . . . . . . .9025-15-13 Group 20Adjustments Loader Bucket Level Indicator And Return-To-Dig Switch Adjustment . . . . . . .9025-20-1 Loader Control Valve Linkage Adjustment. . .9025-20-3 Backhoe Valve Linkage Adjustment . . . . . . .9025-20-5 Stabilizer Valve Linkage Adjustment . . . . . . .9025-20-7 Group 25Tests JT05801 Clamp-On Electronic Tachometer Installation . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1 JT05800 Digital Thermometer Installation . . .9025-25-1 Hydraulic Oil Warm-Up Procedure. . . . . . . . .9025-25-1 System Relief Test (300D, 310D S.N. 802199) (315D, All Machines) . . . . . . . .9025-25-2 System Relief Test (300D, 310D S.N. 802200 ). . . . . . . . . . . . . . . . . . . . . . . . .9025-25-4 Main Pump Flow Test . . . . . . . . . . . . . . . . . .9025-25-6 Priority Relief Valve Pressure Test (300D, 310D S.N. 802199) (315D, All Machines) . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-8 Priority Relief Valve Pressure Test (300D, 310D S.N. 802200 ) . . . . . . . . . . . . . . .9025-25-10 Steering Pump Relief Pressure Test (300D, 310D S.N. 802199) (315D, All Machines) . . . . . . . . . . . . . . . . . . . . . . . .9025-25-13 Auxiliary Pump Relief Pressure Test (300D, 310D S.N. 802200 ) . . . . . . . . .9025-25-14 Steering Pump Flow Test (300D, 310D S.N. 802199) (315D, All Machines) . . .9025-25-16 Auxiliary Pump Flow Test (300D, 310D S.N. 802200 ). . . . . . . . . . . . . . . . . . . . . . . .9025-25-18 Hydraulic Oil Cooler Restriction Test. . . . . .9025-25-20 Circuit Relief Valve TestWith Remote Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-21 Circuit Relief Valve Test300D, With Amplification Cylinder . . . . . . . . . . . . . . .9025-25-26 Circuit Relief Valve Test310D, 315D, With Amplification Cylinder . . . . . . . . . . . . . . .9025-25-33 Steering System Leakage Test . . . . . . . . . .9025-25-38
9025

092105
PN=1
Contents
Page
Steering Cylinder Leakage Test . . . . . . . . .9025-25-41 Hydraulic Cylinder Drift Test Procedure. . . .9025-25-43 Function Drift Test. . . . . . . . . . . . . . . . . . . .9025-25-44 Cylinder Leakage Test . . . . . . . . . . . . . . . .9025-25-48 Backhoe Or Loader Valve Leakage Test . . .9025-25-50 Stabilizer Valve Lockout Leakage Test . . . .9025-25-53 Side Shift Valve Leakage Test315D. . . . .9025-25-54 Cycle Time Specifications . . . . . . . . . . . . . .9025-25-56
9025
TM1496 (21SEP05)

092105
PN=2
Group 05
Theory Of Operation
Open-Center Hydraulic System
NOTE: This illustration is for example only. This particular valve is not used on 300D, 310D or 315D Loader Backhoe.
Open-center system requires that the control valve spool be OPEN in the center to allow pump flow to pass through the valve and return to the reservoir. The main hydraulic pump supplies a constant flow of oil. This pressure oil must have a path for return when it is not required to operate a function.
TX,902505,BR40 1907JAN931/2
9025 05 1
TM1496 (21SEP05)

092105
PN=451
Theory Of Operation
F D D F E E A C
UN24SEP96
092105
T7416AA 9025 05 2
E
BReturn Oil (Pressure Free) CTrapped Oil DValve Spool EInlet (From Pump) FPower Passage
APressure Oil (From Main Hydraulic Pump)
A power passage (F) in the valve allows pressure oil to flow to all the control valve sections regardless of their spool positions. With spool (D) moved to activate a function, pressure oil flows to that function. Without a power passage, no flow would be available to the other valves downstream of the activated function. With a power passage, a parallel connection is made to the other valves downstream.
With the power passage providing a parallel connection, more than one function may be operated at a time. However, the function requiring the least amount of pressure will move first.
TX,902505,BR40 1907JAN932/2
TM1496 (21SEP05)

PN=452
T7416AA
Theory Of Operation
Main Hydraulic System

I J Q R F L O C P D K E
TXC7383AA CV
MAIN HYDRAULIC SYSTEM

(S.N. 802199) Shown
NSteering Valve OPark Brake Solenoid PPark Brake Actuator QTo Brakes RMain Hydraulic Filter SPressure From Reverser
T7383AA
092105
UN26FEB99
U V W X Y
9025 05 3
AMain Hydraulic System BTo Side Shift Locks CTest Port DMain Hydraulic Pump EAuxiliary Pump FCooler GLoader Control Valve
HSide Shift Locking Valve (315D) IStabilizer Valve JBackhoe Control Valve KReservoir LSteering Priority Valve MService Brake Valve
TReturn To Reverser UHigh Pressure Oil VLow Pressure Oil WReturn Oil (Low Pressure) XReturn Oil (Pressure Free) YTrapped Oil
Hydraulic oil flows from reservoir (K) to the main hydraulic pump (D) and auxiliary pump (E). Pressure oil (U) from the main hydraulic pump flows to the loader control valve (G). Pressure oil from the auxiliary pump flows to the steering priority valve (S.N. 802199) or directly to the backhoe valve (S.N. 802200). With the loader control valve in neutral, pressure oil is routed to the stabilizer valve (I). When the steering valve (N) is in neutral, pressure oil from the priority valve is available to the loader valve , stabilizer valve, and backhoe valve.
When the stabilizer valve is in neutral, pressure oil is routed through the stabilizer valve and to the backhoe control valve (J). With the backhoe control valve in neutral, pressure oil is routed through the valve and into the return circuit. When the control valves are in neutral, oil is trapped in the cylinders and lines preventing movement of components. Return oil (W) from the backhoe and loader valves combine and flow through the main hydraulic filter (R).
TX,9025,BS384 1921JUL941/2
TM1496 (21SEP05)

PN=453
Theory Of Operation
Return oil is then routed to reservoir (K) and hydraulic oil cooler (F). A surge relief valve (spring and poppet) located in the return line fitting on the bottom of the reservoir creates enough back pressure on returning oil to force a specific amount of oil through the cooler then to reservoir. Pressure oil from the reverser (S) is sent to a park brake solenoid (O) which directs it to the park brake actuator (P) or returns it to reverser sump (T). On (S.N. 802199) machines the brake valve is supplied with oil from the priority valve. On (S.N. 802200 ) machines the brake valve is supplied oil from the hydraulic cooler return line. Brake pressure oil is routed to the right and left inboard disks in the transaxle through individual lines (Q). 315D OnlyThe side shift lock valve (H) receives pressure oil from the pressure port on the loader control valve. When the side shift lock valve is applied, pressure oil is directed to locks (B) on the slide frame through hydraulic lines. A test port (C) is provided for hydraulic diagnosis on (S.N. 802199) machines.
TX,9025,BS384 1921JUL942/2
9025 05 4
TM1496 (21SEP05)

092105
PN=454
Theory Of Operation
Main Hydraulic Pump

F G D E
A
TXC7347AA CV
MAIN HYDRAULIC PUMP

FAuxiliary Pump GAuxiliary Pump Relief Valve HInlet Port
T7347AA
092105
UN26FEB99
APressure Oil BReturn Oil CMain Hydraulic Pump
DMain Pump Pressure Port ESteering Pump Pressure Port
9025 05 5
The main hydraulic pump is a fixed displacement gear-type pump. The auxiliary pump, a smaller fixed displacement pump is mounted in line with the main hydraulic pump. They are mounted ahead of the engine and driven by the engine crankshaft. Oil is drawn from the hydraulic reservoir and delivered to a common inlet port (H) at the pumps. Pressure oil from the main pump is at port (D) and sent to the loader
control valve. A system relief valve in the loader control valve regulates main pump pressure. Pressure oil from the auxiliary pump leaves through port (E) and is sent to the steering priority valve on (S.N. 802199) machines. Oil is sent directly to the backhoe valve on (S.N. 802200 ) machines. The auxiliary pump has a relief valve (G) built into the pump housing.
TX,9025,BS386 1921JUL941/1
TM1496 (21SEP05)

PN=455
Theory Of Operation
Priority Valve (300D, 310D S.N. 802199) (315D, All Machines)

E F D I E G I H B K J D C F
J
UN04FEB99
T6365AD
B
Engine Stopped
APressure Free Oil BFrom Steering Pump CSpool
DOrifice ETo Steering FTo Backhoe
GSpring HLoad Sensing Line IOrifice
JTo Return KRelief Valve Poppet
9025 05 6
The priority valve maintains priority pressure oil to the steering valve. When the engine is stopped, spool (C)
is pushed to the left blocking oil to backhoe (F) and opening the passage to steering (E).
TX,D300,DS2093 1921JUL941/4
TM1496 (21SEP05)

092105
T6365AD
PN=456
Theory Of Operation
H I J H N K J L F G F I E E
T6365AE
UN04FEB99 T6365AE
A B C
Engine RunningSteering In Neutral

AHigh Pressure Oil BReduced Pressure Oil CReturn Oil DFrom Steering Pump ESpool FOrifice GBackhoe Activated HTo Steering ITo Backhoe JOrifice KSpring LLoad Sensing Line MTo Return NRelief Valve Poppet
When the machine is first started, all pump flow is routed to the steering valve (H) which blocks the flow. With the flow blocked, the pressure increases. Pressure at the steering valve inlet is sensed at the load sensing line (L) on the priority valve. This causes the spool to shift to the right against the spring and open to backhoe (I). As long as the steering valve is in neutral, just enough pressure is maintained at the steering valve to keep the priority valve spool shifted to the right. The operating pressure in the backhoe circuit has no effect on operation of the priority valve. With the
backhoe activated (G) in relief, the priority valve spool will not shift to the left unless the machine is steered. Flow from the steering port (H) is routed through orifice (J) in the priority valve spool in the load sensing line (L). It flows through the steering valve, which is in neutral, to return. This provides flow to the steering valve warm-up circuit which prevents binding of the steering valve caused by extreme oil temperature variation.
9025 05 7
TX,D300,DS2093 1921JUL942/4
TM1496 (21SEP05)

092105
PN=457
Theory Of Operation
H I J H K J L F G F
UN04FEB99 T6365AF
A B C
T6365AF
Engine RunningSteering Activated

ASteering Inlet Pressure BSteering Work Port Pressure CReturn Pressure 9025 05 8 DFrom Steering Pump ESpool FOrifice GFull Rate Steer HTo Steering ITo Backhoe JOrifice KSpring LLoad Sensing Line MTo Return NRelief Valve Poppet
When the operator steers the machine, load-sensing pressure oil from the steering valve flows to the load sensing line (L) on the priority valve. Load-sensing pressure plus spring (K) act against pilot pressure to move the spool to the left. This restricts flow through the backhoe port while the steering port (H) is opened to the steering valve. The load-sensing circuit is a control circuit that routes steering valve outlet pressure to the spring side of the priority valve spool (E). It allows the priority valve to sense the pressure that is required to move the steering cylinders under varying steering conditions.
During normal steering operation, oil is metered into the load sensing circuit (L) through an orifice in the steering valve. When steering at full steer rate (G), the orifice opens to an unrestricted passage. At low engine speed the spool will shift to the full left position directing all flow to the steering valve. At fast idle, the steering system can use about one half of the pump flow. Therefore, the excess oil flows to the backhoe. The load sensing circuit receives the majority of its flow from the load sensing orifice in the steering valve. Some flow is also supplied from the steering port (H) through orifice (J) in the priority valve spool.
TX,D300,DS2093 1921JUL943/4
TM1496 (21SEP05)

092105
PN=458
Theory Of Operation
G H I G J I K F E H
M F
A B C
T6365AG
Engine RunningSteering To Stop

AHigh Pressure Oil BRelief Pressure Oil CReturn Oil DFrom Steering Pump ESpool FOrifice GTo Steering HTo Backhoe IOrifice JSpring KLoad Sensing Line LTo Reservoir MRelief Valve Poppet
T6365AG
UN04FEB99
When the operator steers the machine for a full turn the cylinder bottoms against the steering stops. To limit steering system pressure a relief system is built into the priority valve assembly. When the cylinder bottoms, the pressure in the steering cylinder increases. This pressure is sensed at the load sensing port (K). When the pressure in the load sensing port increases enough to push poppet
(M) off of its seat, oil in the load sensing circuit flows to return. Load sensing pressure is limited to the pressure setting of the relief valve. Pressure to the steering valve (pilot pressure), which is sensed at the orifice (F), continues to increase until it can move the spool (E) to the right against the load sensing pressure plus spring (J) force. At this time, all oil flows out the backhoe port (H).
9025 05 9
TX,D300,DS2093 1921JUL944/4
Hydraulic Filter Operation

The hydraulic return filter removes contaminants from the hydraulic system oil. The filter housing contains a bypass valve and a filter restriction switch.
TX,9025,3011 1907JAN931/2
TM1496 (21SEP05)

092105
PN=459
Theory Of Operation
I A A C
INLET A
HOUSING G VALVE B PISTON C SPRING D
SPRING F J
H TERMINAL J TO RESERVOIR K OUTLET

TXC6903AC
L RESTRICTED FLOW
1925FEB99 T6903AC
I ELEMENT K O RETURN FILTER
M SEMI-RESTRICTED FLOW N RETURN FLOW
9025 05 10
AInlet Port BFilter Housing CPiston DSpring
FSpring GValve HTerminal IFilter Element
JTo Reservoir KOutlet Port LRestricted Flow
MSemi-Restricted Flow NReturn Flow OReturn Filter
Under normal operation, return flow from the steering, loader and priority valve enters the inlet (A), flows through the filter element (I), through the filter canister and out the outlet (K), or to reservoir (J). If the pressure differential between the inlet and outlet increases past a set level due to cold oil or a partially restricted filter element, inlet pressure in the housing (B) increases, moving the piston (C) down against spring (D) force and outlet pressure. The piston contacts the terminal (H), completing a circuit which causes the filter restriction indicator light to glow. As the filter element becomes plugged, the pressure differential between the inlet and outlet increases. Inlet
pressure is sensed on one side of the valve (G) which opens against spring (F) force and outlet pressure. The return oil then bypasses the filter while the restriction indicator lights glow. Under normal operation, the restriction indicator light will glow when operating the hydraulic functions with cold oil. If the restriction indicator light continues to glow after the oil reaches operating temperature, the return filter is being bypassed. Extended operation in the bypass mode will cause damage to the hydraulic system.
TX,9025,3011 1907JAN932/2
TM1496 (21SEP05)

092105
PN=460
Theory Of Operation
Steering Valve Operation

The steering valve is essentially a closed-center type valve. The steering valve and priority valve provide a smooth pressure compensated steering system. When steering valve is in neutral, there is no oil flowing through it except neutral leakage from the priority valve. Neutral leakage is used for lubrication and cooling the steering valve.
1Pressure Oil 2Return Oil 3Trapped Oil 4Port "T" 5Port "L" 6Port "R" 7Port "P"
5 6
2 3
T80788
Steering Valve In Neutral
TX,9025,DS3006 1909MAR931/4
T80788
UN04SEP98
A right turn on the steering wheel activates the gerotor gear assembly (7) to pump metered pressure oil (1) to the rod end of steering cylinder. Return oil (2) from the steering cylinder flows through the steering valve and back to the hydraulic reservoir. 3
1Pressure Oil 2Return Oil 3Port "T" 4Port "L" 5Port "R" 6Port "P" 7Gerotor Gear Assembly
9025 05 11
4 5
6 7 1 2
T80789
UN04SEP98
Oil Flow For A Right Turn

Continued on next page TX,9025,DS3006 1909MAR932/4
TM1496 (21SEP05)

092105
PN=461
T80789
Theory Of Operation
A left turn on the steering wheel actuates the gerotor gear assembly (7) to pump metered pressure oil (1) to the head end of steering cylinder. Return oil (2) from the steering cylinder flows through the steering valve and back to the reservoir. 3
1Pressure Oil 2Return Oil 3Port "T" 4Port "L" 5Port "R" 6Port "P" 7Gerotor Gear Assembly
4 5
6 7 1 2
T80787
UN04SEP98
Oil Flow For A Left Turn

9025 05 12
Continued on next page TX,9025,DS3006 1909MAR933/4
TM1496 (21SEP05)

092105
PN=462
T80787
Theory Of Operation
If there is no power to supply pressure oil to the steering valve, the machine can be turned manually. When the steering wheel is turned, the spool will come into contact with the pin (7). The pin then will provide a direct mechanical connection to the gerotor gear assembly (5). As the gerotor is turned, it pumps oil to the steering cylinder. Return oil from the cylinder is drawn through a check valve (6) between port "P" (12) and port "T" (9) to provide oil for the secondary manual steering operation. Make up oil is drawn from the hydraulic reservoir through return line of the steering valve.
1Pressure Oil 2Suction Oil 3Return Oil 4Trapped Oil 5Gerotor Gear Assembly 6Check Valve 7Pin 8Control Spool 9Port "T" 10Port "L" 11Port "R" 12Port "P"
10 6 11
12 1 3 4 5
Oil Flow For Secondary Steering
9025 05 13 T80790
UN04SEP98
TX,9025,DS3006 1909MAR934/4
TM1496 (21SEP05)

092105
PN=463
T80790
Theory Of Operation
Loader Control ValveGRESEN (300D, 310D S.N. 802199) (315D, All Machines)
A B C
F G
9025 05 14 TXC7379AF
LOADER CONTROL VALVE INLET PLATE

DFrom Pump ELoader Control Valve Inlet Plate FPressure Oil GPressure Free Oil HPoppet
ASystem Relief Valve BReturn Passage CPressure Passage
Oil enters the inlet plate and pressure is sensed by the system relief valve (A). The system relief valve is a direct acting valve. When oil pressure is less than the setting of the relief valve, spring force holds the poppet (H) closed. When pressure exceeds the setting of the valve, pressure acting on the flanged area of the poppet overcomes spring force to open the poppet. Oil then flows through the radial holes in the valve body, into the end of the poppet and to return (B).
When the control valves are in neutral, pressure oil flows through the center passage and out the outlet plate. When a valve spool is moved, the center passage is blocked and oil flows to the power passage. From there oil is directed out to the function and is returned back to the end plate where it is routed to the return passage.
TX,902505,BR41 1921JUL941/6
TM1496 (21SEP05)

092105
PN=464
T7379AF
1915JAN98
Theory Of Operation
K G F E D I O M K H J L
F D
A O
TXC7349BF CV
B C
M LOADER BUCKET - NEUTRAL

EPoppet FAnti-Cavitation Valve GCylinder Rod End Work Port HLift Checks IFunctional Inlet Passage JCylinder Head End Work Port KCircuit Relief Valve with Lift Check LBucket Rollback MNeutral NBucket Dump OReturn Passage
T7349BF
UN26FEB99
APressure Oil BReturn Oil CTrapped Oil DCircuit Relief Valve with Anti-Cavitation and Lift Checks
9025 05 15
The loader bucket section is a three-position, four-way, spool-type valve. The valve contains one circuit relief with lift check (K) and one circuit relief with anti-cavitation with lift check (D). Relief valves with anti-cavitation feature are identified by notches in the hex head. The operation of all circuit relief valves in the loader and backhoe control valves are the same. During operation, a pressure spike is generated in the bucket rod end circuit (G). When pressure in the rod end circuit exceeds the setting of the relief valve (D), the poppet (E) is moved off its seat allowing pressure
oil to move into the return circuit (O). The spring will reseat the poppet when pressure drops below the valve setting. When the valve is in neutral oil is trapped (C) between the spool and bucket cylinder piston. During anti-cavitation operation, the pressure in the rod end work port is less than pressure in return work port and return oil circuit. The difference in pressure pushes anti-cavitation poppet off its seat allowing oil to flow from return port into work ports to prevent cavitation.
TX,902505,BR41 1921JUL942/6
TM1496 (21SEP05)

092105
PN=465
Theory Of Operation
D G E D H K L M F J N F I
A
TXC7349BE 9025 05 16
LOADER BOOM RAISE

HPressure Passage ICylinder Head End Work Port JPlug with Lift Check KBoom Float LBoom Lower MNeutral NBoom Raise
APressure Oil BReturn Oil CLoader Boom Raise DAnti-Cavitation Valve with Lift Check
EAnti-Cavitation Ball FLift Check Valve GCylinder Rod End Work Port
The loader boom valve section is a four-position, four-way, spool-type valve. The boom section contains one lift check assembly (J) and one anti-cavitation valve with lift check (D). The lift check (F) creates a trapped oil circuit when system pressure is below the pressure required to move the function. When a function is activated, system pressure must increase above pressure in the work circuit to open lift check and move the function. When the spool is moved to raise the boom (N), oil flows from the pressure passage (H), past lift check (F)
to cylinder head end port (I) and out work port to cylinders. Return oil from cylinder rod end flows into other work port (G) past spool, into return passage and then out of control valve to return circuit. During anti-cavitation operation, the pressure in the rod end work port is less than pressure in return work port and return oil circuit. The difference in pressure pushes anti-cavitation poppet off its seat allowing oil to flow from return port into work ports to prevent cavitation.
TX,902505,BR41 1921JUL943/6
TM1496 (21SEP05)

092105
PN=466
T7349BE
1915JAN98
Theory Of Operation
D G E D H K L M F J N F I
A B
TXC7355AC APressure Oil BReturn Oil CLoader Boom Lower DAnti-Cavitation with Lift Check
LOADER BOOM LOWER

HPressure Passage ICylinder Head End Work Port JLift Check Valve KBoom Float LBoom Lower MNeutral NBoom Raise
T7355AC
1915JAN98
EAnti-Cavitation Ball FLift Check Valve (2 used) GCylinder Rod End Work Port
9025 05 17
When the loader control valve spool is moved to lower the boom (L), pressure oil (A) flows from the pressure passage (H) past lift check (F) to cylinder rod end port (G) and out to cylinders. Return oil (B) from cylinder head end flows into other work port (I) past spool, into return passage and then out of control valve to return circuit.
When the loader boom is lowered quickly, the pressure of the oil in work passage (G) can be less than that of oil in the return passage. The higher pressure in return passage will unseat ball (E) and allow return oil into the work passage preventing the cylinders from cavitating.
TX,902505,BR41 1921JUL944/6
TM1496 (21SEP05)

092105
PN=467
Theory Of Operation
G E D
N H K L F J M
A B
TXC7355AD APressure Oil BReturn Oil CTrapped Oil DAnti-Cavitation with Lift Check Valve
LOADER BOOM FLOAT

HPressure Passage ICylinder Head End Work Port JLift Check Valve KBoom Float LBoom Lower MNeutral NBoom Raise
9025 05 18
EAnti-Cavitation Ball FLift Check Valve (2 used) GCylinder Rod End Work Port
When the loader control valve spool is moved to the float position (K), it is mechanically held in this position. A spring-loaded ramp and ball mechanism locks the spool in position. With the spool held in float (K) both work ports (G and I) are open to return allowing oil to flow in and out both
ends of cylinder. This allows the boom to raise or lower as it follows the contour of the ground. Pressure oil passes through the valve and both lift checks remain seated.
TX,902505,BR41 1921JUL945/6
TM1496 (21SEP05)

092105
PN=468
T7355AD
1915JAN98
Theory Of Operation
CYLINDER E ROD END WORK PORT RELIEF VALVE WITH LIFT CHECK AND ANTICAVITATION D
LIFT CHECK VALVE F PRESSURE PASSAGE I
CYLINDER G HEAD END WORK PORT
D M K F H LIFT CHECK VALVE L
B C
TXC7931BJ CV
RETURN OIL TRAPPED OIL
LOADER AUXILIARY VALVE - NEUTRAL

HLift Check Valve IPressure Passage JLoader Auxiliary Valve-Neutral KRetract Cylinders LNeutral MExtend Cylinders
T7931BJ
1901JAN99
PRESSURE OIL
APressure Oil BReturn Oil CTrapped Oil DRelief Valve with Lift Check and Anti-Cavitation
ECylinder Rod End Work Port FLift Check Valve (2 used) GCylinder Head End Work Port
9025 05 19
The loader auxiliary section is a three-position, four-way, spool-type valve. The auxiliary section contains one lift check/relief valve (D) and one anti-cavitation check valve (I). When the valve spool is in neutral, the oil is trapped in the work circuits (E and G). This prevents movement of cylinders and linkage.
Pressure oil flows through the center of the spool and valve section. The lift checks (F) remain seated because the pressure passage (I) remains lower than the pressure in work circuits.
TX,902505,BR41 1921JUL946/6
TM1496 (21SEP05)

092105
PN=469
Theory Of Operation
Loader Control Valve OperationHUSCO (300D, 310D S.N. 802200 )
S R B A E J
M A G
N LOADER VALVE
F H
I K BUCKET SECTION L BOOM SECTION
M AUXILIARY SECTION
INLET GAUGE A PORT SYSTEM J RELIEF VALVE

9025 05 20
LOADER FUNCTION PRESSURE METERING Q HOLES P
S STEERING LOAD SENSE RELIEF STEERING LOAD B SENSE PORT
C ORIFICE I SPOOL
H STEERING SUPPLY PORT RETURN O PASSAGE RETURN OUTLET G PORT
D SPRING R ORIFICE
E ORIFICE
T HIGH PRESSURE OIL U MEDIUM PRESSURE OIL V RETURN OIL

1901JAN99 T8249AC
092105
F PRESSURE INLET PORT
TXC8249AC CV
W LOADER PRIORITY VALVE - NEUTRAL - NOT STEERING
TX,9025,BS387 1921JUL941/8
TM1496 (21SEP05)

PN=470
Theory Of Operation
AGauge Port BSteering Load Sense Port CSpool DSpring EOrifice FPressure Inlet Port GReturn Outlet Port HSteering Supply Port IOrifice JSystem Relief Valve KBucket Section LBoom Section MAuxiliary Section NLoader Valve OReturn Passage PMetering Holes QLoader Function Pressure ROrifice SSteering LS Relief Valve THigh Pressure Oil UMedium Pressure Oil VReturn Oil WLoader Priority Valve-Neutral-Not Steering
The priority valve maintains priority oil to the steering valve. When the engine is stopped, spool (C) is pushed to the left by the bias spring (D) restricting the oil to loader (Q) and opening the passage to steering (H). When the machine is first started, all pump flow is routed to the steering valve thru port (H). The steering valve blocks the flow except for a small amount of flow to sump thru an orifice in the priority valve. With the flow blocked, the pressure increases at port (H). This causes the spool (C) to shift to the right against the bias spring (D) and limit the flow to port (H) by closing the priority metering holes (P). This also opens inlet pump flow (F) to loader (Q) functions. As long as the steering valve is in neutral, just enough flow is allowed to pass through the metering holes (P) to maintain a steer pressure at port (H) that keeps the spool shifted to the right and balanced against the bias spring (D). If through the use of loader functions the pump is unable to supply adequate flow to maintain steering pressure at port (H) then spool (C) will shift left and restrict flow to loader (Q) until steer supply pressure is satisfied. Flow from the steering port (H) is also routed through orifice (E) in the priority spool to the load sensing port (B). This flow provides oil to the steering valve warm up circuit which prevents binding of the steering valve caused by extreme oil temperature variation.
The load sensing circuit is a control circuit that routes steering valve outlet pressure to the spring side of the priority valve spool (C). It allows the priority valve to sense the pressure that is required to move the steering cylinders under varying steering conditions. When the operator steers the machine, load sensing pressure oil from the steering valve flows to the load sense port (B) on the priority valve. Load sensing pressure plus spring (D) act against steer pilot pressure to move the spool to the left. This restricts flow to the loader (Q) while the priority metering holes (P) are opened to the priority steering port (H). To limit steering system pressure a steering load sense relief valve (S) is built into the priority valve. When the operator steers the machine fully the steer cylinder will bottom against the steer stops. Pressure in the load sense circuit will increase. When the pressure in the load sense port (B) increases enough to push the steer relief valve (S) poppet off its seat, oil in the load sense circuit flows to return. Load sensing pressure is limited to the pressure setting of the relief valve. System relief valve (J) is located in the priority valve section. The relief is pilot operated, screw adjustable, and does not have anti-cavitation operation. The function of the relief is to regulate system (main pump) pressure.
9025 05 21
TX,9025,BS387 1921JUL942/8
TM1496 (21SEP05)

092105
PN=471
Theory Of Operation
LOADER VALVE K G
M A G
N AUXILIARY SECTION L PRIORITY VALVE M BOOM SECTION
9025 05 22
CIRCUIT RELIEF WITHOUT ANTICAVITATION BUCKET LOAD C B WORK PORT
D LIFT CHECK
E INLET PRESSURE
BUCKET DUMP F WORK PORT CIRCUIT RELIEF WITH ANTICAVITATION H
RETURN A PASSAGE
O RETURN-TO-DIG ELECTROMAGNET
1901JAN99
092105
I HIGH PRESSURE OIL J RETURN OIL

TXC8249AE CV
P LOADER BUCKET VALVE - BUCKET LOAD POSITION
TX,9025,BS387 1921JUL943/8
TM1496 (21SEP05)

PN=472
T8249AE
Theory Of Operation
AReturn Passage BCircuit Relief Valve Without Anti-Cavitation CBucket Load Work Port DLift Check EInlet Pressure FBucket Dump Work Port GSystem Relief Valve HCircuit Relief Valve With Anti-Cavitation IHigh Pressure Oil JReturn Pressure Oil KLoader Valve LPriority Valve Section MBoom Valve Section NAuxiliary Valve Section OReturn-To-Dig Electromagnet PLoader Bucket Valve-Bucket Load Position
The bucket valve is a three position, four way, spool-type valve. It contains a lift check (D) and two circuit relief valves. Relief valve (H) also contains an anti-cavitation valve for the bucket dump circuit. In the bucket load position oil flows from the inlet pressure passage (E) past lift check (D) and spool, out the bucket load workport to the cylinder. Return oil from the cylinder flows into the return passage (A) and out of the control valve to the return circuit. When bucket dump function is activated and pressure in circuit is less than return pressure, oil flows from return passage (A) past anti-cavitation valve (H) to the bucket dump circuit (F).
The valve is equipped with a return-to-dig. When loader control lever is moved to the bucket rollback position, a plate fastened to end of valve spool contacts an electromagnet (O). If the bucket is in dump position, the return-to-dig switch is closed which energizes the electromagnet and holds the spool in the load position. When the bucket rolls back to the dig position, a mechanical linkage opens the return-to-dig switch, which de-energizes the electromagnet (O) letting the spool centering spring move the spool to neutral. An orifice is located between the bucket valve section pressure port and cylinder head end to reduce function cycle times and protect system components.
TX,9025,BS387 1921JUL944/8
9025 05 23
TM1496 (21SEP05)

092105
PN=473
Theory Of Operation
LOADER VALVE M G
M A G
PRIORITY J VALVE
D K BUCKET SECTION
N AUXILIARY SECTION
9025 05 24
BOOM RAISE WORK PORT C B CIRCUIT RELIEF WITHOUT ANTICAVITATION
LIFT CHECK D
INLET PRESSURE E
BOOM LOWER WORK PORT F
ANTI-CAVITATION VALVE A
A RETURN PASSAGE
I CAP WITH DETENT N HIGH PRESSURE OIL O RETURN PRESSURE OIL

TXC8249AF CV
1901JAN99
092105
P LOADER BOOM VALVE - BOOM RAISE POSITION
TX,9025,BS387 1921JUL945/8
TM1496 (21SEP05)

PN=474
T8249AF
Theory Of Operation
AReturn Passage BCircuit Relief Valve Without Anti-Cavitation CBoom Raise Work Port DLift Check EInlet Pressure FBoom Lower Work Port GSystem Relief Valve HAnti-Cavitation Valve ICap With Detent JPriority Valve Section KBucket Valve Section LAuxiliary Valve Section MLoader Valve NHigh Pressure Oil OReturn Pressure Oil PLoader Boom Valve-Boom Raise Position
The spool has grooves in both ends to meter oil through the valve to prevent abrupt starts and stops. When the spool is moved to activate a function, oil flows from functional inlet passage (E), past lift check (D) and spool, out the work port to the cylinders. Return oil from the cylinders flows into the other work port, past the spool, into the return passage (A), then out of the control valve to the charge circuit. When the boom lower function is activated and pressure in circuit is less than return pressure, oil flows from return passage (A), past anti-cavitation plug (H) into the boom lower circuit (F).
When spool is moved to the boom float (detent) position, both work ports (C and F) are open to return passage (A) allowing oil to flow in and out both ends of cylinders. When the machine is equipped with a two function valve the boom section has a power beyond port located on the main frame side of the valve. The section is similar to the loader valve auxiliary section illustrated in this group.
TX,9025,BS387 1921JUL946/8
9025 05 25
TM1496 (21SEP05)

092105
PN=475
Theory Of Operation
LOADER VALVE L G
M A G
I PRIORITY VALVE
J BUCKET SECTION
K BOOM SECTION
9025 05 26
ROD END C WORK PORT PLUG B
LIFT D CHECK
INLET PRESSURE E
F HEAD END WORK PORT
CIRCUIT RELIEF WITH ANTICAVITATION H
RETURN PASSAGE A
M HIGH PRESSURE OIL N RETURN PRESSURE OIL

TXC8249AD CV
TX,9025,BS387 1921JUL947/8
TM1496 (21SEP05)

092105
PN=476
T8249AD
O TRAPPED OIL P LOADER AUXILIARY VALVE - NEUTRAL POSITION
1901JAN99
Theory Of Operation
AReturn Passage BPlug CRod End Work Port DLift Check EInlet Pressure FHead End Work Port GSystem Relief Valve HCircuit Relief With Anti-Cavitation IPriority Valve Section JBucket Valve Section KBoom Valve Section LLoader Valve MHigh Pressure Oil NReturn Pressure Oil OTrapped Oil PLoader Auxiliary Valve-Neutral Position
The loader auxiliary valve is a three position, four way, spool type valve. It contains a lift check (D), relief valve with anti-cavitation (H), and a plug (B). The valve spool is returned to neutral by a centering spring in the spool end cap. The auxiliary valve is normally used to control clam buckets or other front-mounted hydraulic functions. If an auxiliary valve is field installed both the boom and auxiliary sections must be replaced. The boom section of a two function loader valve has a power beyond port
which is not compatible with the installation of a third function auxiliary valve. When the auxiliary valve is moved to the extend position, oil flows from pressure passage (E) by lift check (D) and spool, out head end work port (F) to cylinder head end. Oil from rod end of cylinder flows back to valve through rod end work port (C) to return passage (A). Oil in the return passage is sent to main hydraulic filter where it combines with other return pressure oil and becomes available to main pump.
TX,9025,BS387 1921JUL948/8
Loader Circuit Relief Valve With Anti-CavitationHUSCO (300D, 310D, S.N. 802200 )
The relief is direct acting and has anti-cavitation operation.
Continued on next page TX,9025,BS395 1921JUL941/2
9025 05 27
TM1496 (21SEP05)

092105
PN=477
Theory Of Operation
ANTICAVITATION POPPET F
C CAVITY
ORIFICE A B POPPET D PRESSURE OIL E RETURN OIL

1910SEP98
TXC7742AE CV
9025 05 28
AOrifice BRelief Poppet
CCavity DPressure Oil
EReturn Oil
FAnti-Cavitation Poppet
In normal operation, pressure oil less than relief valve setting flows through orifice (A) into cavity (C) behind relief valve poppet. Pressure oil and spring in cavity hold the anti-cavitation poppet closed because effective area on this side is greater than on work port side. In relief operation, pressure oil overcomes relief poppet (B) pressure setting and opens a path to return.
During anti-cavitation operation, the pressure in the work port is less than pressure in the return port. The pressure difference pushes the anti-cavitation poppet (F) off its seat allowing oil to flow from return port to work port to prevent cavitation.
TX,9025,BS395 1921JUL942/2
Loader Circuit Relief Valve Without Anti-Cavitation HUSCO (300D, 310D, S.N. 802200 )
This circuit relief valve is direct acting, screw adjustable and does not have anti-cavitation operation.
TX,9025,BS396 1921JUL941/1
TM1496 (21SEP05)

092105
PN=478
T8165AR
UN21MAR94
T7742AE
Theory Of Operation
Stabilizer Valve Operation

D F G E G F D
A H H J
TXC7348AD
B
1910SEP98 T7348AD
J C STABILIZER VALVE - LOWER
9025 05 29
APressure Oil BReturn Oil CStabilizer ValveLower
DReturn Passage EPressure Passage FConnecting Passage
GPower Passage HPoppet
IThermal Relief Valve JWork Port
The stabilizer valve is a two-spool valve containing two lockout poppets for each spool. When the spool is in neutral, oil from the hydraulic pump flows through the pressure passage (E) to the backhoe control valve. When the spool is moved to lower the stabilizer (as shown), the spool is pulled out. This directs oil into connecting passage (F), pushing the shuttle valve against left hand poppet (H). As pressure increases, the left poppet opens allowing that work port to be connected to return passage (D). As pressure
increases, the right-hand poppet (H) is pushed off its seat filling the cylinder head end circuit (J) and pushing the stabilizer arm down. When the spool is returned to neutral, pressure oil is cut off from the shuttle valve and poppets. The poppets are seated by pressure oil in cylinder work port and held by trapped oil. The thermal relief valve (I) opens when there is an expansion of oil in the trapped circuit due to external heat.
TX,902505,BR65 1907JAN931/1
TM1496 (21SEP05)

092105
PN=479
Theory Of Operation
Backhoe Control Valve OperationGRESEN (300D, S.N. 802199)

F K F D D D
K E F
A B
9025 05 30 TXC7349AF CV
BACKHOE SWING RIGHT

FAnti-Cavitation Poppet GLift Check HSwing Left INeutral JSwing Right KOrifice
AReturn Oil BPressure Oil CBackhoe SwingRight
DCircuit Relief with Lift Check Valve (2 used) ERelief Valve Poppet
The swing section is a three-position, four-way spool-type valve. The valve contains two combination circuit relief valves with lift checks and anti-cavitation valves (D). During swing operation, oil flows from the pressure passage, past the lift checks (G) and out the work port
to rod end of one cylinder and head end of the other cylinder. Return oil flows from the opposite ends of the swing cylinder into the other work port, past spool to the return passage.
TX,9025,BS397 1921JUL941/5
TM1496 (21SEP05)

092105
PN=480
T7349AF
UN26FEB99
Theory Of Operation
D F E D I K G H J M D
O L N
A B
TXC7349AG CV
C BACKHOE BOOM RAISE

ERelief Valve Poppet FCylinder Rod End Work Port GOrifice HLift Check (2 used) IPressure Passage JCylinder Head End Work Port KRelief Valve Poppet LCircuit Relief with Lift Check Valve MBoom Raise NNeutral OBoom Lower
APressure Oil BReturn Oil CBackhoe Boom Raise DCircuit Relief with Lift Check Valve
T7349AG
UN26FEB99
9025 05 31
The boom section is a three-position, four-way spool type valve. The valve contains two circuit relief with lift check valves (D and L). During boom raise operation, oil flows from the pressure passage (I) past the lift
checks (H) and out to the cylinder rod end port (F). Return oil from the cylinder head end port (J) flows past the spool into return passage.
TX,9025,BS397 1921JUL942/5
TM1496 (21SEP05)

092105
PN=481
Theory Of Operation
9025 05 32
APressure Oil BReturn Oil CBackhoe Bucket Dump DCircuit Relief Valve with Lift Check
ERelief Valve Poppet FCylinder Rod End Work Port GLift Check (2 used)
HPressure Passage ICylinder Head End Work Port JCircuit Relief Valve with Lift Check
KBucket Dump LNeutral MBucket Roll-Back
The bucket section is a three-position, four-way spool type valve. The valve contains two circuit relief with lift check valves (D and J). During bucket dump operation, oil flows from the pressure passage (H) past the lift check (G) and out
the cylinder rod end work port (F). Return oil from the cylinder flows into port (I), past the spool and into the return passage.
TX,9025,BS397 1921JUL943/5
TM1496 (21SEP05)

092105
PN=482
T7349AH
1930DEC98
Theory Of Operation
G E
I J L
H D N
A B
TXC7349AI CV
C BACKHOE CROWD-IN
ERelief Valve Poppet FLift Check (2 used) GCylinder Head End Work Port HPressure Passage ICylinder Rod End Work Port JOrifice KCircuit Relief with Lift Check Valve LCrowd-In MNeutral NCrowd-Out
T7349AI
UN26FEB99
APressure Oil BReturn Oil CBackhoe Crowd-In DCircuit Relief Valve with Lift Check
9025 05 33
The crowd section is a three-position, four-way spool type valve. The valve section contains two circuit relief with lift check valves (D and K). During crowd-in operation, oil flows from the pressure passage (H) past lift check (F) and out cylinder head
end work port (G). Return oil flows from port (I), past spool into return passages.
TX,9025,BS397 1921JUL944/5
TM1496 (21SEP05)

092105
PN=483
Theory Of Operation
F N L F D M
A B
TXC7349AJ CV
BACKHOE AUXILIARY - NEUTRAL

HCylinder Head End Work Port IBackhoe AuxiliaryNeutral LExtend MNeutral NRetract
9025 05 34
APressure Oil BReturn Oil CTrapped Oil DPlug with Lift Check (2 used)
ELift Check FPressure Passage GCylinder Rod End Work Port
The auxiliary section is a three-position, four-way spool type valve. The valve contains two plugs with lift checks and no relief valve.
When the valve is in neutral, pressure oil flows through the valve section. The spool traps oil in the work circuits preventing movement of cylinder and linkage.
TX,9025,BS397 1921JUL945/5
TM1496 (21SEP05)

092105
PN=484
T7349AJ
UN26FEB99
Theory Of Operation
Backhoe Control Valve OperationHUSCO (310D, 315D, All Machines) (300D, S.N. 802200 )
CROWD E A A AA BB
BUCKET A A AA BB CIRCUIT RELIEF VALVE A BB AA
CIRCUIT RELIEF VALVE A
9025 05 35
B
BUCKET DUMP CROWD IN NEUTRAL
D
BUCKET IN CROWD OUT
1925FEB99 T6733AM
092105
F PRESSURE OIL E LIFT CHECK H BACKHOE BUCKET AND CROWD VALVES G RETURN OIL
TXC6733AM
ACircuit Relief Valve (2 used) BBucket Dump/Crowd In
CNeutral DBucket In/Crowd Out ELift Check
FPressure Oil GReturn Oil
HBackhoe Bucket and Crowd Valves
The crowd and bucket valves are three-position, four-way, spool-type valves. Each valve section contains two circuit relief valves and a lift check valve.
TX,9025,BS398 1921JUL941/7
TM1496 (21SEP05)

PN=485
Theory Of Operation
When the valve spool is moved to activate the function, oil flows past the left check (E) to work port (BB). Return oil flows from port (AA) past spool into the return passage.
TX,9025,BS398 1921JUL942/7
LEFT C A B D RIGHT D A
A B C H
E F
TXC7371BC
G BACKHOE SWING VALVE - LEFT

(Swing Section S.N. 802199)
ACircuit Relief Valve with Anti-Cavitation BRight Work Port
CLift Check DLeft Work Port EPressure Oil
FReturn Oil GBackhoe Swing Valve Left
HPressure Passage
The swing section is a three-position, four-way, open-center, spool-type valve. The valve contains two combination circuit relief and anti-cavitation valves. During a left swing, oil flows to the lift check (C), into pressure passage, past the spool and out work port
(D). Return oil from the cylinder flows into work port (B), past the spool, into the return passage.
TX,9025,BS398 1921JUL943/7
TM1496 (21SEP05)

092105
PN=486
T7371BC
UN26FEB99
9025 05 36
Theory Of Operation
9025 05 37
TM1496 (21SEP05)

092105
PN=487
Theory Of Operation
A LEFT
H RIGHT A
9025 05 38
CIRCUIT RELIEF WITH ANTI-CAVITATION A
LEFT WORK B PORT
G PRESSURE C LIFT PASSAGE CHECK
RIGHT WORK D PORT CIRCUIT RELIEF WITH ANTI-CAVITATION A
E PRESSURE OIL F RETURN OIL

TXC8249AB CV
H BACKHOE SWING VALVE - SWING LEFT

(Swing Section S.N. 802200 )
TX,9025,BS398 1921JUL944/7
TM1496 (21SEP05)

092105
PN=488
T8249AB
1901JAN99
Theory Of Operation
ACircuit Relief Valve with Anti-Cavitation BLeft Work Port CLift Check DRight Work Port EPressure Oil FReturn Oil GPressure Passage HBackhoe Swing ValveLeft
The swing section is a three-position, four-way, open-center, spool-type valve. The valve contains two combination circuit relief and anti-cavitation valves. During a left swing, oil flows to the lift check (C), into pressure passage, past the spool and out work port
(B). Return oil from the cylinder flows into work port (D), past the spool, into the return passage. The 300D has a one way orifice fitting located in outlet ports (B) and (D) to regulate swing cycle time and protect system components.
TX,9025,BS398 1921JUL945/7
E D
A D B I E
C
9025 05 39
F G
TXC7355AF
H BACKHOE BOOM VALVE - LOWER
ACircuit Relief Valve with Anti-Cavitation BLift Check
CCircuit Relief DWork Port EWork Port
FPressure Oil GReturn Oil HBackhoe Boom Valve Lower
IFunctional Inlet
The boom section is a three-position, four-way, open-center, spool-type valve. The valve contains a circuit relief (C) and a pilot operated circuit relief with anti-cavitation valve (A).
During boom lower operation, oil flows to the lift check (B), to the work port (D). Return oil from the cylinder flows into work port (E) past the spool, into the return passage.
NOTE: On later machines boom lower relief (A) is direct acting with anti-cavitation.
TX,9025,BS398 1921JUL946/7
TM1496 (21SEP05)

092105
PN=489
T7355AF
UN26FEB99
Theory Of Operation
AA BB
PLUG B
A LIFT CHECK
B PLUG
9025 05 40
C
AA
D
NEUTRAL
E
BB
G RETURN OIL
TXC6733AQ
H BACKHOE AUXILIARY VALVE
ALift Check BPlug (2 used)
C"AA" DNeutral
E"BB" FPressure Oil
GReturn Oil HBackhoe Auxiliary Valve
The backhoe auxiliary section is a three-position, four-way, spool-type valve. This valve is commonly used for an extendable dipperstick. The auxiliary valve contains only a lift check (A). When the spool is moved to activate the functions, oil flows
past the lift check (A), into the pressure passage to work port (BB). Return oil from the cylinder flows into work port (AA) past the spool into return passage.
TX,9025,BS398 1921JUL947/7
TM1496 (21SEP05)

092105
PN=490
T6733AQ
1925FEB99
F PRESSURE OIL
Theory Of Operation
Regenerative OutletHUSCO
C F
H E I D
G A B
TXC7351AB CV
UN26FEB99 T7351AB
092105
J
APressure Oil BReturn Oil CPressure Passage
BACKHOE OUTLET SECTION - CONTROL VALVE OPEN

DReturn from Cylinder EReturn to Filter FReturn from Stabilizer Valve GControl Valve Poppet HAnti-Cavitation Poppet IOrifice JOutlet SectionControl Valve Open
9025 05 41
When one or more backhoe spools are moved from the neutral position, oil in pressure passage (C) increases to the pressure required to move the functions. This pressure acts to unseat poppet (G), allowing unrestricted flow of oil through cylinder return passage (D) to outlet (E). When the operator is metering pump flow, and the parallel passage pressure is not enough to unseat the high flow poppet, the cylinder return oil pressure acts upon the area differential of the high flow poppet body diameter and seat diameter. When the pressure on
this area exceeds the poppet spring force, the poppet opens allowing flow of cylinder return oil to outlet, while regulating cylinder return passage pressure. When a valve spool is moved from neutral and external load on the cylinder causes the return pressure to exceed the pressure passage, the anti-cavitation valve opens, allowing pressure regulated cylinder return oil to supplement pump oil to the cylinder. The regenerative system is used to supplement oil flow to the backhoe cylinders to prevent cavitation when cylinder travel outruns pump delivery.
TX,902505,BR64 1921JUL941/2
TM1496 (21SEP05)

PN=491
Theory Of Operation
H E I
G
UN26FEB99
092105
A
TXC7375AV CV
BACKHOE OUTLET SECTION - ANTI-CAVITATION

CPressure Passage DReturn from Cylinders EReturn to Filter FReturn from Stabilizer GControl Valve Poppet HAnti-Cavitation Poppet IOrifice
9025 05 42
AReturn Oil BOutlet Section Anti-Cavitation
When the backhoe valve spools are all in neutral, oil from the pump flows through the valve stack neutral passage to the outlet and filter. All the regenerative valves remain closed. When machine has all valves in neutral and is being driven over rough terrain, the circuit relief valves may be opening to protect
components from pressure spikes. As oil is relieved on one side of the cylinder, oil must be supplied to the other side or the cylinder will cavitate. The orifice (I) allows oil to be pulled from the filter return side to be the make-up oil.
TX,902505,BR64 1921JUL942/2
TM1496 (21SEP05)

PN=492
T7375AV
Theory Of Operation
Side Shift Locking Valve315D

A B
G C F
G F
D
T6419AE APressure Oil BReturn Oil (Pressure Free) CInlet DReturn
F D F
ERelief Valve FOutlet
GCheck Valve 9025 05 43
When the solenoid is not energized, spring pressure pushes the valve spool down, so oil flows to side shift locking pistons. The check valve (G) in the inlet port traps oil to maintain pressure on locking pistons. When the solenoid is energized, the valve spool is pulled up against spring pressure, blocking inlet oil and releasing pressure on the side shift pistons to the reservoir.
The relief valve (E) is a direct acting relief valve. When pressure increases above the pressure setting, pressure overcomes spring force and seat is pushed away from the poppet. Oil flows through the seat to the reservoir.
T60,9025,C418 1907JAN931/1
TM1496 (21SEP05)

092105
PN=493
T6419AE
UN30DEC96
Theory Of Operation
9025 05 44
TM1496 (21SEP05)

092105
PN=494
Group 10

System Operational Procedure
The procedure is designed so the mechanic can make a quick check of the hydraulic system using a minimum amount of diagnostic equipment. If you need additional information read the Theory of Operation in Group 9025-05. A location will be required which is level, and has adequate space to operate unit. The engine, and all other major components must be at operating temperature for some checks. Locate system check needed in the left column and read completely, follow this sequence from left to right. Read each check completely before performing. At the end of each check, if no problem is found (OK:), you will be instructed where to GO TO ( ) for next check. If problem, (NOT OK:) is indicated, you will be given repair required and Group location or CTM number. If verification is needed you will be given next best source of information after GO TO: Group 10 (System Operational Checks) Group 15 (System Diagnostic Checks) Group 20 (Adjustments) Group 25 (Tests) CTM(Component Technical Manual)
T60,9025,C235 1909MAR931/1
Steering System Checks
9025 10 1
1/1
1 Steering System Operational Check
1. Operate engine at approximately 1000 rpm. 2. Turn steering wheel from full left to full right and back several times.
OK: Go to next check. NOT OK: Check Hydraulic Oil Level. NOT OK: Go to next check.
LOOK: Front wheels must move smoothly in both directions. LOOK: When steering wheel is stopped the front wheels must stop moving. NOTE: Internal leakage or a sticking steering valve spool can cause the wheels to continue to move after the steering wheel has stopped.
1/1
TM1496 (21SEP05)

092105
PN=495

2 Steering System Leakage Check
NOTE: Hydraulic oil must be at operating temperature for this test.

1. Run engine at approximately 1000 rpm. 2. Turn steering wheel until wheels are in the maximum right turn position. 3. Continue turning steering wheel using approximately 11.3 Nm. (100 lb-in) force while counting steering wheel rpm. 4. Repeat leakage check turning steering wheel to the left.
OK: Go to next check. NOT OK: Cap off steering cylinder lines. Rerun check. NOT OK: Repair steering cylinder. NOT OK: Repair steering valve. Go to repair manual.
LOOK: Steering wheel must not turn more than 5 rpm, left or right. NOTE: Use good judgement, excessive steering wheel rpm does not mean steering will be affected.
1/1
3 Backhoe Loader Steering Priority Operational Check
1. 300D, operate engine at slow idle. 310D and 315D, operate engine at 1500 RPM. 2. Turn steering wheel full left to right and note effort needed to turn wheel. 3. Bottom a backhoe function and then turn steering wheel. Make a note of the time and effort now needed to turn wheel.
OK: Go to next check. NOT OK: Steering effort decreases. Go to next check. NOT OK: No jerk in steering wheel. Go to group 9025-25, Priority Valve Test.
9025 10 2
4. While holding steering wheel against axle stop, hold backhoe function over relief by bottoming cylinder.
FEEL: Effort to turn steering wheel must NOT decrease when operating steering wheel and backhoe function is bottomed. FEEL: It is normal for steering wheel to jerk as backhoe function is bottomed.
1/1
Hydraulic System Checks
1/1
TM1496 (21SEP05)

092105
PN=496

1 Main Hydraulic Pump Performance Check
NOTE: If hydraulic oil is not at operating temperature, heat hydraulic oil until loader and backhoe cylinders feel warm to touch.
1. Put loader bucket flat on ground. 2. Run engine at approximately 1000 rpm. 3. Measure cycle time of loader raise to maximum height, including bucket leveling.
OK: Go to next check. NOT OK: Go to group 9025-15, Slow Hydraulic Functions.
LOOK: The maximum cycle time is 15 seconds. NOTE: Take the average cycle time for at least 3 complete cycles. This cycle time will give a general indication of main hydraulic pump performance.
T7374CG UN04OCT90
1/1
2 Auxiliary Pump Performance Check
NOTE: Hydraulic oil should be at operating temperature.

Put backhoe in transport position. Run engine at fast idle. While holding loader boom raise function over relief, extend dipperstick from retracted position to fully extended and measure cycle time.
OK: Go to next check. NOT OK: Go to next check. NOT OK: Go to group 9025-25, Single Gauge Hydraulic System Relief Check.
9025 10 3
NOTE: Take the average cycle time for at least 3 complete cycles. This cycle time will give a general indication of auxiliary pump performance.
Specification 300DCycle Time ................................................ 15 sec. 310D/315DCycle Time ...................................... 19 sec.
T7374CK UN04OCT90
1/1
3 Hydraulic Filter Check
If cycle times are slow remove and inspect hydraulic filter for aluminum or brass particles. If metal particles are present, remove and inspect pump.
OK: Go to group 9025-25, Main Pump Flow Test. NOT OK: Remove and inspect pumps. Go to Repair manual.
LOOK: Inspect hydraulic filter bypass valve when filter canister is off. NOTE: If bypass valve is held open by trapped foreign material, the filter restriction indicator switch will not close since pressure differential is not great enough between inlet and outlet of the filter.
1/1
TM1496 (21SEP05)

092105
PN=497

4 Hydraulic Cylinder Cushion Check 1. Run engine at approximately 1000 rpm. 2. Activate the following functions and note sound and speed as cylinders near end of stroke. Backhoe swing left and right. Boom raise. OK: Go to next check. NOT OK: Remove cylinder and inspect cushion. Go to repair manual.
LISTEN: Must hear oil flowing through orifice as cylinder rod nears the end of stroke. LOOK: Speed of cylinder rod must decrease near the end of stroke.
1/1
5 Backhoe And Loader Function Drift Checks
1. Cylinder must be warm to touch. 2. Put backhoe bucket at a 45 angle to ground. Lower boom until bucket cutting edge is 50 mm (2 in.) off ground. 3. Position loader bucket same distance off ground as backhoe bucket.
T7374CI UN04OCT90
OK: Go to next check. NOT OK: Go to group 9025-25, Do Cylinder Drift Test.
4. Run engine at slow idle and observe buckets cutting edges.
LOOK: If bucket cutting edges touch the ground within 1 minute, excessive leakage is indicated in the bucket or boom cylinders or control valve.
9025 10 4
1/1
TM1496 (21SEP05)

092105
PN=498

6 Hydraulic Control Valve Lift Check Test
NOTE: Gresen valve sections must be tested in both directions because each work port has its own lift check. Husco valve sections have one lift check for both work ports, and therefore only need to be checked in one direction.
1. Raise loader until bucket is 1 m (3 ft) off the ground with the bucket level. 2. Position backhoe at maximum reach with bottom of bucket level with ground, 1 m (3 ft) off the ground. 3. Stop the engine. 4. Activate each function one at a time. a. loader boom raise b. loader bucket rollback c. backhoe boom up d. dipperstick extend e. backhoe bucket curl 5. Start engine, raise front of unit with bucket tipped 45 down. Put backhoe so each function is loaded opposite to Step B trying to raise rear of unit. Stop engine. 6. Activate each function one at a time. a. loader boom lower b. loader bucket dump c. backhoe boom down d. dipperstick retracted e. backhoe bucket dump
OK: Go to next check. NOT OK: Remove and inspect relief valves checks. Go to repair manual.
9025 10 5
LOOK: These functions must not move when the control lever is activated. FEEL: It is normal for first function operated to "jerk" because of stored hydraulic pressure in system but must not continue to move.
1/1
Loader Control Valve Checks
1/1
TM1496 (21SEP05)

092105
PN=499

1 Loader Boom Float Check 1. Put loader at maximum height position with bucket dumped. 2. Run engine at approximately 1500 rpm. 3. Move the loader control lever forward into boom float detent position, and at the same time into bucket rollback detent position. Remove hand from control lever. OK: Go to next check. NOT OK: If it jumps out of detent, inspect detent spring and balls, repair as necessary. Go to repair manual.
LOOK: Loader control lever must remain in the boom float detent position.
T7390AA UN12OCT90
1/1
2 Return-To-Dig Check (If Equipped)
LOOK: Loader control lever must disengage from the bucket roll-back detent when the bucket is level. LOOK: The notch on cam must allow switch to "click" deactivating the circuit when bucket is in dig position.
OK: Go to next step in this check. NOT OK: If bucket rollback does not stay in detent. With bucket to full dump position, compress switch roller. If a click is heard, adjust switch till it is activated on cam. NOT OK: Inspect fuse and wiring. Go to group 9015-10, Return-To-Dig Solenoid Check. NOT OK: If bucket rollback releases before bucket is level, adjust linkage. Go to Repair manual, Adjust Loader Bucket Level Indicator And Return-To-Dig.
9025 10 6
T6171AT UN09DEC88
LOOK: When the bucket is at ground level, bucket must be level and the bucket indicator pointer must be aligned with mark on the boom pivot. NOTE: When return-to-dig is used with loader boom in full up position, the bucket leveling linkage will move the bucket control valve out of return-to-dig position before bucket is actually level.
T7374CH UN04OCT90
OK: Go to next check. NOT OK: Adjust linkage as necessary. Go to Repair manual.
1/1
TM1496 (21SEP05)

092105
PN=500

3 Bucket Leveling Mechanism Check 1. Put bucket in the rollback position with the boom near ground level. 2. Raise the loader and at the same time hold the control lever in the bucket rollback position. 3. Observe bucket and loader control lever as the loader raises.
T7374CJ UN05OCT90
OK: System Operational Checkout Complete. NOT OK: Adjust linkage on the Loader Control Valve. Go to Repair manual. NOT OK: Operators complaint was not identified. Go to next check.
LOOK/FEEL: Loader control lever must move into the bucket dump position and the bucket dump function must slowly activate. When the loader control lever moves to activate the bucket dump function, the bucket position must remain stationary the remainder of the loader boom raise cycle. LOOK: The bucket side cutting edge must be level through the loader raise cycle. NOTE: The loader bucket leveling feature functions during the boom raise cycle only. When bucket is lowered, the operator must level the bucket unless unit is equipped with optional return-to-dig.
1/1
4 Operator Complaint Was Not Identified
If you completed the Operational Checkout and did not isolate a malfunction, the problem may be intermittent. Try to duplicate the condition of the malfunction identified by operator.
NOT OK: Go to group 9025-15, Diagnose Hydraulic System Malfunctions.
9025 10 7
1/1
TM1496 (21SEP05)

092105
PN=501
9025 10 8
TM1496 (21SEP05)

092105
PN=502
Group 15
Diagnostic Information
Use These Seven Basic Steps To Diagnose And Test The Hydraulic System
1. KNOW THE SYSTEM. Study the information on the system and component operation given in the front part of Section 9025. Learn the basic principles of hydraulics by reading the Fundamentals of Service manual on hydraulics. 2. ASK THE OPERATOR. The operator can tell you how the machine performed when it started to fail; what was unusual about it. Try to find out if any do-it-yourself service has been performed. Ask about how the machine was operated and when it was serviced. 3. OPERATE THE MACHINE. Are the gauge indications normal? How is the performance? Do the controls feel normal? Do you smell or hear anything unusual. 4. INSPECT THE MACHINE. Use your eyes, ears, and nose to find signs of trouble. Check the level and condition of the hydraulic oil. Is the oil dirty; are the filters plugged? Are the hydraulic oil lines hotter than normal; covered with dirt; paint peeled off from heat; dented or collapsed; show signs of leakage? 5. LIST THE POSSIBLE CAUSES. What unusual conditions did you find when the machine was inspected? What are the possible causes? Are there other possibilities? Remember, one failure often leads to another.
NOTE: You can use the Hydraulic System Pretest Check Sheet to list the possible causes.
6. REACH A CONCLUSION. Decide which possible causes are the most likely and the easiest to verify. Use the Diagnose Malfunctions section of Group 9025 to help you. 7. TEST YOUR CONCLUSION. Do individual component tests to verify your conclusion before you repair or replace any components.
9025 15 1
T60,9025,1013 1907JAN931/1
Make A Pretest Inspection And An Operation Check Of The Machine

1. Write the pretest inspection and operation check information on the Hydraulic System Pretest Check Sheet (Form M-5107 is available from Deere and Company, Distribution Service Center). 2. Go to Diagnose Malfunctions to determine the cause of the customer complaint. If necessary, do tests of individual component to verify the malfunction. 3. Repair or replace the faulty component.
T60,9025,725 1921JUL941/1
TM1496 (21SEP05)

092105
PN=503
Hydraulic System Pretest

1. Clean machine as needed. 2. Perform all inspections. 3. Correct any problems. 4. Perform Operational Check. Hydraulic Oil Correct Oil Correct Level Bubbles In Oil Other Control Valve(s) Bent Linkage Proper Linkage Adjustment Filters: Hydraulic, Reverser Ruptured Plugged Metal Particles Packing Particles New Filter Installed Oil Cooler Clean Of Dirt And Debris Fan Or Shroud Damaged Belt Tension And Condition Leaking Lines Or Cooler Hydraulic System Bent Or Damaged Lines External Oil Lines Cylinder Rod(s) Bent Frequently Blown Seals And Fittings
9025 15 2
T60,9025,J236 1921JUL941/1
TM1496 (21SEP05)

092105
PN=504
Diagnose Hydraulic System Malfunction

Reservoir Drains When Changing Hydraulic Filter No Loader Or Steering Hydraulics
Return tube vent hole in reservoir may be plugged. Low oil level
Remove, inspect and repair. See repair manual. Add oil to correct level.
Failed pump drive shaft Reservoir suction screen plugged. (300D, 310D, S.N. 802199) (315D, All Machines) Pump failed
Replace. See repair manual. Remove and clean screen in hydraulic reservoir.
Remove hydraulic filter and inspect. If filter contains excessive amounts of brass or aluminum, remove, and inspect pump. See repair manual. Inspect for pinched lines or stuck valve spools. See repair manual. Remove and repair. Do Main Hydraulics System Relief Test. See Group 9025-25. Remove hydraulic filter and inspect. If filter contains excessive amounts of brass or aluminum, remove, and inspect pump. See repair manual. Do Priority Valve Test. See Group 9025-25. Test Steering Pump Relief pressure. See Group 9025-25.
Obstruction in oil lines or valves.
No Loader Hydraulics (Steering OK)
Failed system relief valve
Main pump failure
9025 15 3
No Steering Hydraulics (Loader Hydraulics OK)
Malfunction of priority valve
Failed steering pressure regulating valve
TX,902515,BR89 1921JUL941/8
TM1496 (21SEP05)

092105
PN=505
Symptom Problem
Solution
Slow Hydraulic Functions
Low oil level Engine rpm too low
Add oil to correct level. Increase rpm or check engine speed. See Group 9010-20. Remove and clean screen in hydraulic reservoir.
Reservoir suction screen restricted (300D, 310D, S.N. 802199) (315D, All Machines) Hydraulic oil aerated.
Incorrect oil, drain and refill. Suction hose has air leak. Inspect and tighten. See Hydraulic And Reverser Oil . Inspect and tighten fittings. Remove, clean and test. See repair manual. Also see Group 9025-25. Do System Operational Checkout 9025-10 to determine which pump has low flow. Test pump flow. See Group 9025-25. Test operation of priority valve. Test Steering System for leakage. See Group 9025-25. Test Auxiliary Pump flow. See Group 9025-25. Do Steering Cylinder Leakage Test. See Group 9025-25.
Hose or line leakage System relief valve stuck or leaking
Low pump flow
9025 15 4
Slow Steering Hydraulics
Malfunction of priority valve Steering valve leakage
Low auxiliary pump flow
Steering cylinder leakage
TX,902515,BR89 1921JUL942/8
TM1496 (21SEP05)

092105
PN=506
Symptom Problem
Solution
Loader Or Backhoe Operates Slowly In One Function
Control lever and linkage out of adjustment.
Inspect lever and linkage. Adjust to get equal valve spool travel in each direction. See Group 9025-20. Remove, inspect and repair sealing rings on relief valve or plug. See repair manual. Do Cylinder Leakage Test. See Group 9025-25. Inspect and repair. Do Valve Leakage Test. See Group 9025-25. Remove, inspect and repair. See repair manual. Inspect lever and linkage. Adjust to get equal valve spool travel in each direction. Remove inspect and repair sealing rings on relief valve or plug. See Disassemble And Assemble Loader Control Valve (SN 802199) or Disassemble And Assemble Loader Control Valve (SN 802200 ) in repair manual. Inspect and repair. Do Valve Leakage Test. See Group 9025-25. Remove, inspect and repair. See repair manual.
Relief valve or plug leakage in control valve.
Hydraulic cylinder leakage
Bent or restricted line Hydraulic control valve not operating properly
No Loader Or Backhoe Power In One Function
Control lever and linkage out of adjustment
Relief valve or plug leakage in control valve
9025 15 5
Bent or restricted line Hydraulic control valve not operating properly
TX,902515,BR89 1921JUL943/8
TM1496 (21SEP05)

092105
PN=507
Symptom Problem
Solution
Slow Loader And Backhoe Hydraulics (Low Pump Output)
Hydraulic oil aerated
Incorrect oil, drain and refill. Suction hose has air leak. Inspect and tighten. Hydraulic And Reverser Oil Test System Relief Pressure at loader valve. See Group 9025-25. Replace or repair. See repair manual. Remove and clean screen in hydraulic reservoir.
Incorrect system relief valve setting
Hydraulic pump suction screen restricted (300D, 310D, S.N. 802199) (315D, All Machines) Worn main pump
Do System Operational Checkout 9025-10 to check pump flow. Remove hydraulic filter and inspect. If filter contains excessive amounts of brass or aluminum, remove and inspect pump. In no metal particles, Test Main Pump Flow. See Group 9025-25. Also see repair manual. Add oil to correct level.
Low Hydraulic Power (Low Hydraulic Pressure)

9025 15 6
Low oil level (aeration of oil)
Incorrect oil, drain and refill. Suction hose has air leak. Inspect and tighten. Hydraulic And Reverser Oil Remove and clean screen in hydraulic reservoir.
Hydraulic pump suction screen restricted (300D, 310D, S.N. 802199) (315D, All Machines) Incorrect system relief valve setting
Test System Relief Valve Pressure. See Group 9025-25. Repair or replace. Also see repair manual. Feel components for heat. Do Cylinder Drift Test. See Group 9025-25. Do Leakage Test. See Group 9025-25.
Leakage within work circuit
Excessive leakage in hydraulic system
TX,902515,BR89 1921JUL944/8
TM1496 (21SEP05)

092105
PN=508
Symptom Problem
Solution
Hydraulic Function Makes "Chattering" Noise
Low oil level
Incorrect oil, drain and refill. Suction hose has air leak. Inspect and tighten. Hydraulic And Reverser Oil Remove and clean screen in hydraulic reservoir
Hydraulic pump suction screen restricted (300D, 310D, S.N. 802199) (315D, All Machines) Malfunctioning or wrong circuit relief valve installed in backhoe valve. Functions Drift Oil leaking past cylinders or control valve.
Inspect, remove and repair. See repair manual. Do System Operational Checkout drift test to pinpoint cylinder or valve leakage. See Group 9025-10 . Inspect and adjust linkage. See Group 9025-20. Inspect valve spools. See repair manual. Test component leakage. See Group 9025-25. Remove and replace. See repair manual. Remove and clean. See repair manual. Locate source of contamination. Repair and clean oil in system. See repair manual.
9025 15 7
Control Valve Sticks Or Works Hard
Control valve lever linkage binding
Hydraulic system overheating
Broken return spring
Contamination in control valve
Scored valve bore or bent spool
TX,902515,BR89 1921JUL945/8
TM1496 (21SEP05)

092105
PN=509
Symptom Problem
Solution
Hydraulic Oil Overheats
Excessive load Operator holding hydraulic system over relief Using low viscosity oil in hot weather
Reduce load. Return levers to neutral when not in use. Use recommended oil. See Operators Manual. Test System Relief Valve. See Group 9025-25. Do Leakage Test. See Group 9025-25. Check oil level. Adjust to full mark on dipstick. Drain and replace. See repair manual. Inspect and clean screen in hydraulic reservoir.
Incorrect system relief valve pressure Excessive leakage in the hydraulic system Foaming Oil Oil level too low or too high
Incorrect type of oil
Pump suction screen restricted (aeration of inlet oil) (300D, 310D, S.N. 802199) (315D, All Machines)
9025 15 8
Air leak on suction side of pump
Locate and repair leak. See repair manual. Tighten to specification. See repair manual. Replace seal. See repair manual. Replace seal or gasket. See repair manual. Determine cause of overheating, see above.
Hydraulic Pump Leaking
Cap screws that hold pump sections together are loose Worn shaft seal Broken diaphragm "V" seal or backup gasket Hydraulic oil overheating
TX,902515,BR89 1921JUL946/8
TM1496 (21SEP05)

092105
PN=510
Symptom Problem
Solution
Excessive Pump Noise
Low oil level Hydraulic filter by-pass valve chattering Loose pump drive coupling
Add oil to correct level. Replace filter. Inspect, clean, and repair. See repair manual. Inspect and tighten coupling. See repair manual. Inspect and clean screen in hydraulic reservoir.
Pump suction screen restricted (aeration of inlet oil) (300D, 310D, S.N. 802199) (315D, All Machines) Oil lines in contact with operators station (Failed rubber cab or canopy isolators) Pump attaching hardware loose
Inspect, repair or replace.
Retighten to specification. See repair manual. Do Leakage Tests. See Group 9025-25. Align correctly. See repair manual.
9025 15 9
Leakage in hydraulic circuit
Misalignment between pump and pump support Steering Valve Does Not Return To Neutral Broken centering springs
Inspect steering valve. See repair manual. Inspect steering valve. See repair manual.
Damaged steering valve spool
TX,902515,BR89 1921JUL947/8
TM1496 (21SEP05)

092105
PN=511
Symptom Problem
Solution
No Response When Steering Wheel Is Turned
Low oil level
Check reservoir oil level.
External leakage
Check for leakage. Repair as necessary. Do Priority Valve Test. See Group 9025-25. Do Steering System Leakage Test. See Group 9025-25. Test steering valve or cylinder for leakage. See Group 9025-25. Do System Operational Check, Steering Pump Performance. See 9025-10. Connect steering cylinder lines to opposite ports. Put steering valve geroter in alignment. See repair manual. Do Steering System Leakage Test. See Group 9025-25. Inspect check valve in "P" port of steering valve. See repair manual.
Malfunctioning of priority valve
Steering valve leakage
Steering cylinder leakage
Worn steering pump
Unit Turns In Opposite Direction
Steering cylinder lines not connected properly Misalignment of steering valve geroter Steering valve leakage
Violent Oscillation Of Steering Wheel

9025 15 10
Unit Turns When Steering Valve Is In Neutral Steering Wheel Kickback
Check valve leakage
TX,902515,BR89 1921JUL948/8
TM1496 (21SEP05)

092105
PN=512
Hydraulic System Component Location And System Schematic (300D, 310D, S.N. 802199) (315D, All Machines)
T7932AC 1901JAN99
FILTER RESTRICTION INDICATOR SWITCH
HYDRAULIC FILTER PRIORITY VALVE FILTER BYPASS VALVE
BRAKE VALVE
STEERING VALVE
OUTLET END CAP
INLET END CAP
SWING
BOOM
BUCKET
CROWD
AUX
STEERING PUMP
STABILIZER VALVE
BOOM VALVE
BUCKET VALVE MAIN HYDRAULIC PUMP
PRESSURE OIL SIDE SHIFT LOCKING VALVE (315D) LOW PRESSURE` OIL RETURN OIL (LOW PRESSURE) RETURN OIL (PRESSURE FREE) TRAPPED OIL SYSTEM RELIEF VALVE
TXC7932AC CV
TX,9025,BS408 1921JUL941/1
HYDRAULIC SYSTEM SCHEMATIC
TM1496 (21SEP05)

092105
PN=513
Hydraulic System Component Location (300D, 310D, S.N. 802200 )

T8246AB 1901JAN99
BRAKE VALVE J HYDRAULIC OIL RESERVOIR I
STEERING VALVE K
STABILIZER VALVE N
BACKHOE O CONTROL VALVE
PARK BRAKE ACTUATOR M PARK BRAKE VALVE L
PRIORITY VALVE SECTION H
LOADER CONTROL G VALVE SURGE RELIEF F VALVE HYDRAULIC E OIL COOLER REVERSER D OIL COOLER
P TRANSAXLE OIL FILTER (NOT USED 300D)
Q HYDRAULIC OIL FILTER
R HIGH PRESSURE OIL TRANSAXLE C OIL COOLER S MEDIUM PRESSURE OIL T TRAPPED OIL U PRESSURE FREE OIL MAIN HYDRAULIC B PUMP
TXC8246AB CV
AUXILIARY A PUMP
V MAIN HYDRAULIC COMPONENT LOCATION (NEUTRAL)
TX,9025,BS403 1921JUL941/1
TM1496 (21SEP05)

092105
PN=514
Hydraulic System Schematic (300D, 310D, S.N. 802200 )

T8257AL 1901JAN99
J BRAKE VALVE HYDRAULIC E OIL COOLER N STABILIZER VALVE
O BACKHOE CONTROL VALVE

INLET END CAP
SWING
SURGE RELIEF F VALVE
BOOM
I HYDRAULIC OIL RESERVOIR
BUCKET
G LOADER CONTROL VALVE
K STEERING VALVE FILTER RESTRICTION INDICATOR SWITCH
CROWD
B MAIN HYDRAULIC PUMP
AUX
BUCKET A AUXILIARY PUMP H PRIORITY VALVE
BOOM
AUX
Q HYDRAULIC FILTER
FILTER BYPASS VALVE
R HIGH PRESSURE OIL

OUTLET END CAP
S MEDIUM PRESSURE OIL T TRAPPED OIL U PRESSURE FREE OIL
TXC8257AL CV
H HYDRAULIC SCHEMATIC - NEUTRAL

TX,9025,BS402 1921JUL941/1
TM1496 (21SEP05)

092105
PN=515
9025 15 14
TM1496 (21SEP05)

092105
PN=516
Group 20
Adjustments
Loader Bucket Level Indicator And Return-To-Dig Switch Adjustment
SPECIFICATIONS Guard and Stop-to-Bell Crank Gap Top of Bell Crank Pin-to-Bottom of Actuator Tang Gap 1 mm (0.04 in.) 130 mm (5.1 in.)
NOTE: Later machines have new design guard/stop (B). Adjustment is the same for all machines.
1. Position bucket flat on ground. Turn engine off. 2. Hold bucket lever in roll-back position.
TX,9025,BS404 1921JUL941/3
9025 20 1
TM1496 (21SEP05)

092105
PN=517
Adjustments
3. Measure gap (A) between guard and stop (B) and bell crank (C). Gap should be 1 mm (0.04 in.).
Specification Guard and Stop-to-Bell Crank Gap .................................................................................... 1 mm (0.04 in.)
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 bottom of actuator tang (G). Gap should be 130 mm (5.1 in.).
Specification Top of Bell Crank Pin-to-Bottom of Actuator TangGap ................................................... 130 mm (5.1 in.)
6. If gap is not to specification, adjust sensor tube jam nut and yoke (H) to correct length.
A1 mm (0.04 in.) gap BGuard/Stop CBell Crank-Neutral Position DRod Jam Nut and Yoke E130 mm (5.1 in.) gap FBell Crank Pin GActuator Tang HSensor Tube Jam Nut and Yoke IBucket Dump JBucket Rollback
9025 20 2
TX,9025,BS404 1921JUL942/3
TM1496 (21SEP05)

092105
PN=518
T7864AD
1915OCT92
T7864AE
1915OCT92
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. 10. Tighten cap screw without moving switch. 11. Remove pin from sensor tube yoke. 12. While watching clearance between cam and switch, turn command pointer back and forth to be sure cam does not hit switch bracket.
ACap Screw 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.)
9025 20 3
TX,9025,BS404 1921JUL943/3
Loader Control Valve Linkage Adjustment

SPECIFICATIONS Right Side of Knob-to-Tape Distance Front of Loader Knob-to-Tape Distance 250 mm (10 in.) 130 mm (5.25 in.)
NOTE: Levers must be positioned correctly to allow full travel and proper operation of loader valves. Cab and other components have been removed in some photographs for clarity.
1. Put loader control valve spools in neutral position.
TX,9025,BS405 1921JUL941/5
TM1496 (21SEP05)

092105
PN=519
T87154
UN09NOV88
NOTE: On later machines switch will have a plastic roller on actuator arm. Omit steps 8 and 9 on these machines. Older machines have a metal roller on actuator arm.
Adjustments
2. Adjust rods (A) so tabs (B) on bell crank are horizontal. 3. Put a piece of masking tape from right front to right rear ROPS posts on inside surface at loader knob height.
UN30OCT90
(S.N. 802199) Shown
TX,9025,BS405 1921JUL942/5
4. Distance (C) from right side of knob to tape should be 250 mm (10 in.).
Specification Right Side of Knob-to-Tape Distance ............................................................................ 250 mm (10 in.)
5. Put a piece of masking tape from left front to right front ROPS posts on inside surface at loader knob height. 6. Distance (D) from front of loader knob to tape should be 130 mm (5.25 in.).
Specification Front of Loader Knob-to-Tape Distance ......................................................................... 130 mm (5.25 in.)
TX,9025,BS405 1921JUL943/5
7. The distances in steps 4 and 6 can be obtained by adjusting rods (E).
TX,9025,BS405 1921JUL944/5
TM1496 (21SEP05)

092105
PN=520
T7407AP
UN30OCT90
T7407AO
UN14NOV90
9025 20 4
T7407AN
Adjustments NOTE: Pivot (F) must remain in slot when holding the loader lever in the roll-back position.
TX,9025,BS405 1921JUL945/5
Backhoe Valve Linkage Adjustment

SPECIFICATIONS 300D, 310D (S.N. 801199) Center of Clevis Pin Hole-to-Center of Ball Joint Rod Length 300D, 310D (S.N. 802200 ) Center of Clevis Pin Hole-to-Center of Ball Joint Rod Length 315D Center of Clevis Pin Hole-to-Center of Ball Joint Rod Length 300D, 310D, (S.N. 802199) Center of Clevis Pin Hole-to-Center of Ball Joint Rod Length (With Extendible Dipperstick) 300D, 310D, (S.N. 802200 ) Center of Clevis Pin Hole-to-Center of Ball Joint Rod Length (With Extendible Dipperstick) 315D Center of Clevis Pin Hole-to-Center of Ball Joint Rod Length (With Extendible Dipperstick) Edge of Knobs-to-Tape Distance Knob-to-Knob Distance 292 mm (11.4 in.)
338 mm (13.3 in.)
193 mm (7.6 in.) 9025 20 5
208 mm (8.2 in.)
248 mm (9.75 in.)
105 mm (4.1 in.)
140 mm (5.5 in.) 250 mm (10.25 in.)
NOTE: Levers must be positioned correctly to allow full travel and proper operation of backhoe valves. Cab and other components have been removed in some photographs for clarity.
1. Put backhoe valve spools in neutral position.
TX,9025,BS406 1921JUL941/3
TM1496 (21SEP05)

092105
PN=521
T7407AQ
UN30OCT90
Adjustments
2. Measure rods (A) from center of clevis pin hole to center of ball joint.
Specification 300D, 310D (S.N. 801199) Center of Clevis Pin Hole-to-Center of Ball JointRod Length ............................................................................ 292 mm (11.4 in.) 300D, 310D (S.N. 802200 ) Center of Clevis Pin Hole-to-Center of Ball JointRod Length ............................................................................ 338 mm (13.3 in.) 315D Center of Clevis Pin Hole-to-Center of Ball JointRod Length .............................................................................. 193 mm (7.6 in.)
3. On machines with extendable dipperstick, auxiliary valve linkage adjustment is also required. Measure rod from center of clevis pin hole to center of ball joint.
Specification 300D, 310D, (S.N. 802199) Center of Clevis Pin Hole-to-Center of Ball JointRod Length (With Extendible Dipperstick) ...................................................................... 208 mm (8.2 in.) 300D, 310D, (S.N. 802200 ) Center of Clevis Pin Hole-to-Center of Ball JointRod Length (With Extendible Dipperstick) .................................................................... 248 mm (9.75 in.) 315D Center of Clevis Pin Hole-to-Center of Ball JointRod Length (With Extendible Dipperstick) ...................................................................... 105 mm (4.1 in.)
9025 20 6
4. Put a piece of masking tape across the rear ROPS posts on inside surface at backhoe lever knob height.
TX,9025,BS406 1921JUL942/3
5. Measure from edge of knobs to tape. Distance (B) should be 140 mm (5.5 in.).
Specification Edge of Knobs-to-Tape Distance ........................................................................... 140 mm (5.5 in.)
Knobs should be 250 mm (10.25 in.) apart.

Specification Knob-to-KnobDistance ............................................. 250 mm (10.25 in.)
TX,9025,BS406 1921JUL943/3
TM1496 (21SEP05)

092105
PN=522
T7407AJ
UN30OCT90
T7407AI
UN30OCT90
Adjustments
Stabilizer Valve Linkage Adjustment

SPECIFICATIONS Edge of Right Stabilizer Knob-to-Tape Distance Edge of Left Stabilizer Knob-to-Tape Distance 260 mm (10.25 in.) 295 mm (11.6 in.)
NOTE: Levers must be positioned correctly to allow full travel and proper operation of stabilizer valves. Cab and other components have been removed in some photographs for clarity.
1. Put stabilizer valve spools in neutral position.
TX,9025,BS407 1921JUL941/3
2. Adjust linkage rods (A) so that tabs (B) are vertical. 3. Put masking tape across left and right rear ROPS posts on inside surface at stabilizer knob height.
UN30OCT90
9025 20 7
(S.N. 802199)
(S.N. 802200 )
Continued on next page TX,9025,BS407 1921JUL942/3
TM1496 (21SEP05)

092105
PN=523
T8187AL
UN20FEB94
T7407AK
Adjustments
4. Measure the distance (C) from edge of right stabilizer knob to tape. It should be 260 mm (10.25 in.).
Specification Edge of Right Stabilizer Knob-to-TapeDistance ............................................. 260 mm (10.25 in.)
Measure the distance (D) from edge of left stabilizer knob to tape. It should be 295 mm (11.6 in.).
Specification Edge of Left Stabilizer Knob-to-TapeDistance ............................................... 295 mm (11.6 in.)
Adjust rods (E) as necessary.
9025 20 8
TX,9025,BS407 1921JUL943/3
TM1496 (21SEP05)

092105
PN=524
T7407AM
UN30OCT90
T7407AL
UN30OCT90
Group 25
Tests
UN28FEB89
AClamp-on Transducer. Remove paint with emery cloth and connect to a straight section of injection line within 100 mm (4 in.) of pump. Finger tighten only. DO NOT overtighten. BBlack Clip (-). Connect to main frame. CRed Clip (+). Connect to transducer. DTachometer Readout. Install cable.
10T,9010,K182 1910AUG951/1

SERVICE EQUIPMENT AND TOOLS Digital Thermometer ATemperature Probe Fasten to a bare metal line using a tie band. Wrap with shop towel. BCable CDigital Thermometer 9025 25 1
902525,AA4 1928FEB951/1
Hydraulic Oil Warm-Up Procedure

1. Put FNR lever in neutral and engage park brake. 2. Run engine at fast idle. 3. Raise loader boom to full height, then hold lever and stall hydraulics. This forces the hydraulic oil over the loader relief valve causing oil to heat up. Hold the lever over relief for one minute, then cycle function to reduce localized over-heating in control valve and to equalize temperature in circuits being tested. Repeat cycle until oil, after cycling, is at test specifications.
T60,9025,1061 1909MAR931/1
TM1496 (21SEP05)

092105
PN=525
T6808CE
UN28FEB89
T6813AG
Tests
System Relief Test (300D, 310D S.N. 802199) (315D, All Machines)
SPECIFICATIONS Oil Temperature Engine Speed Priority Valve Relief Valve Pressure Setting Main Hydraulic System Relief Valve Pressure Setting Steering Pump Relief Valve Pressure Setting Steering Pump Relief Valve Pressure Setting 65 5C (150 10F) (cylinder hot to touch) Fast idle 16 89018 250 kPa (169182 bar) (24502650 psi) 17 92519 650 kPa (179197 bar) (26002850 psi) 20 50023 800 kPa (205238 bar) (29753450 psi) 20 50023 800 kPa (205238 bar) (29753450 psi)
ESSENTIAL TOOLS AT05688 (1-1/10 12 M x -8F ORFS) Adapter BT03103 (7/16-20 M x 1-1/16-12F 37) Adapter
1917OCT90
T01608 (2-1/16-20F x 1/8) Nipple Quick Coupler SERVICE EQUIPMENT AND TOOLS Gauge 035 000 kPa (0350 bar) (05000 psi) Digital Thermometer
9025 25 2
1. Operate all hydraulic control valves to relieve pressure in the hydraulic system. 2. Remove left engine side shield. Make test connection at tee provided in steering pump to priority valve line. 3. Warm oil to specifications.
Specification OilTemperature .................................... 65 5C (150 10F) (cylinder hot to touch)
See Hydraulic Oil Warm-up in Group 9025-25. 4. Run engine at high idle.
Specification EngineSpeed ............................................................................ Fast idle
Turn steering wheel to full turn against steering stop and hold against stop. Make record of priority valve pressure on gauge.
TX,9025,BS409 1921JUL941/2
TM1496 (21SEP05)

092105
PN=526
T7390AC
Tests
Specification Priority ValveRelief Valve Pressure Setting ...................................... 16 89018 250 kPa (169182 bar) (24502650 psi)
(See Priority Valve Test in this section if adjustment is required.) 5. Activate and hold backhoe boom raise over relief. Make a record of main hydraulic system relief setting on gauge.
Specification Main Hydraulic SystemRelief Valve Pressure Setting ............................ 17 92519 650 kPa (179197 bar) (26002850 psi)
(See System Relief Test (300D, 310D S.N. 802199) (315D, All Machines) and System Relief Test (300D, 310D S.N. 802200 ) in this group if adjustment is required.) 6. Test steering pump relief setting. 310D, 315D Activate and hold backhoe boom raise and loader boom raise over relief. Record steering pump relief setting on gauge.
Specification Steering PumpRelief Valve Pressure Setting ...................................... 20 50023 800 kPa (205238 bar) (29753450 psi) 9025 25 3
300D Remove steering pump inlet line to priority valve. Cap valve and connect gauge to line. Run machine at fast idle and observe steering pump relief setting on gauge.
Specification Steering PumpRelief Valve Pressure Setting ...................................... 20 50023 800 kPa (205238 bar) (29753450 psi)
Steering relief cartridge is not adjustable. Replace if necessary.
TX,9025,BS409 1921JUL942/2
TM1496 (21SEP05)

092105
PN=527
Tests
System Relief Test (300D, 310D S.N. 802200 )

SPECIFICATIONS Engine Speed Oil Temperature System Relief Valve Setting Pressure Fast idle 65 5C (150 10F) (cylinder hot to touch) 17 92519 650 kPa (179197 bar) (26002850 psi)
ESSENTIAL TOOLS JT03111 (9/16 -18 M ORB x 7/16 -20 M JIC) Connector SERVICE EQUIPMENT AND TOOLS DGauge 035 000 kPa (0350 bar) (05000 psi) Digital Thermometer
1. Operate all hydraulic control valves to relieve pressure in the hydraulic system.
9025 25 4
TX,9025,BS410 1921JUL941/2
TM1496 (21SEP05)

092105
PN=528
Tests
2. Make test connection at priority valve gauge port (A). 3. Install temperature probe in reservoir. Warm oil to specifications.
Specification EngineSpeed ............................................................................ Fast idle OilTemperature .................................... 65 5C (150 10F) (cylinder hot to touch)
See Hydraulic Oil Warm-up in Group 9025-25. 4. Activate and hold loader boom raise over relief. Record main hydraulic system relief setting from gauge.
Specification System Relief Valve Setting Pressure .................................................. 17 92519 650 kPa (179197 bar) (26002850 psi)
5. Adjust or replace system relief (B) as required.
T8258AD
UN02JUN94
NOTE: System relief is screw adjustable. Remove relief end cap and adjust to specification. Turn clockwise to increase pressure.
9025 25 5
TX,9025,BS410 1921JUL942/2
TM1496 (21SEP05)

092105
PN=529
Tests
Main Pump Flow Test

SPECIFICATIONS Oil Temperature Engine Speed Oil Pressure 300D New Main Pump Minimum Flow 300D Used Main Pump Minimum Flow 315D New Main Pump Minimum Flow 315D Used Main Pump Minimum Flow 310D (S.N. 802199) New Main Pump Minimum Flow 310D (S.N. 802199) Used Main Pump Minimum Flow 310D (S.N. 802200 ) New Main Pump Minimum Flow 310D (S.N. 802200 ) Used Main Pump Minimum Flow 65 5C (150 10F) 2000 10 rpm 13 700 70 kPa (137 0.7 bar) (2000 10 psi) 64 L/min (17 gpm) 55 L/min (14.5 gpm) 91 L/min (24 gpm) 76 L/min (20 gpm) 91 L/min (24 gpm) 76 L/min (20 gpm) 87 L/min (23 gpm) 72 L/min (19 gpm)
1923JUN94
ESSENTIAL TOOLS (Parker HLO-S) 16 M x 16 M ORFSa 9025 25 6 JT05691 (1-5/16-12 M37 x -16 F ORFS) Adaptera (2 used)
a
These ORFS fittings should be ordered through normal service parts channels. SERVICE EQUIPMENT AND TOOLS Flowmeter Electronic Tachometer Digital Thermometer
A16 F ORFS (on hose) BHLO-S (Parker), 16 M x 16 M ORFS CAdapter (2 used) D16 M ORFS (on pipe)
1. Make test connections. Install electronic tachometer, and digital thermometer probe in reservoir.(See procedure in this group.) IMPORTANT: Flowmeter must be open to prevent damage to hydraulic pump. 2. Open flowmeter. 3. Put FNR lever in neutral and engage park brake.
TX,9025,BS411 1922JUL941/2
TM1496 (21SEP05)

092105
PN=530
T7390AD
Tests
4. Heat hydraulic oil to test specifications.
See Hydraulic Oil Warm-up in Group 9025-25. 5. Adjust engine speed to test specifications.
Slowly close loading valve to read test pressure on flowmeter. 6. Record the flow rate.
Specification OilPressure ......................................... 13 700 70 kPa (137 0.7 bar) (2000 10 psi) 300D New Main PumpMinimum Flow .............................................................................. 64 L/min (17 gpm) 300D Used Main Pump Minimum Flow ........................................................... 55 L/min (14.5 gpm) 315D New Main PumpMinimum Flow .............................................................................. 91 L/min (24 gpm) 315D Used Main Pump Minimum Flow .............................................................. 76 L/min (20 gpm) 310D (S.N. 802199) New Main PumpMinimum Flow ................................................. 91 L/min (24 gpm) 310D (S.N. 802199) Used Main PumpMinimum Flow ................................................. 76 L/min (20 gpm) 310D (S.N. 802200 ) New Main PumpMinimum Flow ................................................. 87 L/min (23 gpm) 310D (S.N. 802200 ) Used Main PumpMinimum Flow ........................................ 72 L/min (19 gpm)
9025 25 7
TX,9025,BS411 1922JUL942/2
TM1496 (21SEP05)

092105
PN=531
Tests
Priority Relief Valve Pressure Test (300D, 310D S.N. 802199) (315D, All Machines)
SPECIFICATIONS Oil Temperature Engine Speed Relief Setting Pressure 65 5C (150 10F) Fast idle 16 89018 250 kPa (169182 bar) (24502650 psi) ESSENTIAL TOOLS AJT05688 (1-1/16 M 37 x -8F ORFS) Adapter BJT03103 (7/16-20 M 37 x 1-1/16 F 37) Adapter JT01608 (7/16-20 F 37 x 1/8) Nipple Quick Coupler SERVICE EQUIPMENT AND TOOLS Gauge 020 000 kPa (0200 bar) (03000 psi) Digital Thermometer
1. Remove left engine side shield. Make test connection at tee fitting provided in steering pump to priority valve line. Install digital thermometer temperature probe in reservoir. 2. Put FNR lever in neutral and engage park brake.
9025 25 8
3. Warm oil to specifications.

See Hydraulic Oil Warm-up in Group 9025-25. 4. Run engine at specified speed, turn steering wheel to stop and hold against stop.
Record pressure on gauge.

Specification Relief SettingPressure ......................... 16 89018 250 kPa (169182 bar) (24502650 psi)
TX,9025,BS412 1921JUL941/2
TM1496 (21SEP05)

092105
PN=532
Tests
5. Adjust or replace relief valve (D) in priority valve as necessary. 6. Adjustment procedure: Stop engine. Lower all equipment to ground and operate steering valve to release pressure in the hydraulic system. Disconnect tube from connector (F). Remove connector (F). IMPORTANT: The steering system priority relief valve pressure adjustment is very sensitive. Turn adjustment screw (E) a maximum of 1/8 turn. Test again and adjust if necessary. 7. Turn adjustment screw (E) 1/8 turn clockwise to increase the pressure setting or 1/8 turn counterclockwise to decrease pressure setting. Install connector (H) and connect tube. Recheck pressure setting using steps 3, 4 and 5 as necessary. 8. If relief valve (D) cannot be adjusted, replace. See repair manual.
AAdapter BAdapter CNipple DRelief Valve EAdjustment Screw FConnector
UN30OCT90
T7390AC
1917OCT90
9025 25 9
TX,9025,BS412 1921JUL942/2
TM1496 (21SEP05)

092105
PN=533
T7407AA
Tests
Priority Relief Valve Pressure Test (300D, 310D S.N. 802200 )

SPECIFICATIONS Oil Temperature Engine Speed Priority Relief Valve Relief Pressure Setting 1/8 Turn of Adjustment Screw Changes Pressure 65 5C (150 10F) Fast idle 15 50016 900 kPa (155169 bar) (22502450 psi) 50-75 psi
ESSENTIAL TOOLS 38H1031 (-8 ORFS) Swivel Run Tee SERVICE EQUIPMENT AND TOOLS Gauge 020 000 kPa (0200 bar) (03000 psi) Digital Thermometer
9025 25 10
TX,9025,BS413 1921JUL941/3
TM1496 (21SEP05)

092105
PN=534
Tests
1. Install test tee and gauge (A) at pressure inlet to steering valve. 2. Install digital thermometer temperature probe in reservoir. 3. Put FNR lever in neutral and engage park brake. 4. Warm oil to specifications.
UN02JUN94 T8256AB
See Hydraulic Oil Warm-up in Group 9025-25. 5. Run engine at specified speed, turn steering wheel to stop and hold against stop.
Record pressure on gauge.

Specification Priority Relief ValveRelief Pressure Setting ...................................... 15 50016 900 kPa (155169 bar) (22502450 psi) 9025 25 11
TX,9025,BS413 1921JUL942/3
TM1496 (21SEP05)

092105
PN=535
Tests
6. Adjust or replace relief valve (B) in priority valve as necessary. 7. Adjustment procedure:
UN02JUN94
Stop engine. Lower all equipment to ground and operate steering valve to release pressure in the hydraulic system. Remove cap from steering relief valve (C). IMPORTANT: The steering system priority relief valve pressure adjustment is very sensitive. Turn adjustment screw a maximum of 1/8 turn. (1/8 turn is equal to 50-75 psi.) 8. Turn adjustment screw 1/8 turn clockwise to increase the pressure setting or 1/8 turn counterclockwise to decrease pressure setting.
Specification 1/8 Turn of Adjustment Screw ChangesPressure .................................................................... 50-75 psi
Check pressure again to verify it is to specification. 9. If relief valve (B) cannot be adjusted, replace. See repair manual.
9025 25 12
TX,9025,BS413 1921JUL943/3
TM1496 (21SEP05)

092105
PN=536
T8256AA
Tests
Steering Pump Relief Pressure Test (300D, 310D S.N. 802199) (315D, All Machines)
SPECIFICATIONS Oil Temperature Engine Speed Steering Pump Relief Pressure Setting 65 5C (150 10F) Fast idle 20 50023 800 kPa (205238 bar) (29753450 psi)
ESSENTIAL TOOLS AJT05688 (1-1/16 12 M -8 F ORFS) Adapter BJT03103 (7/16-20 M 37 x 1-1/16-12 F 37) Adapter JT01608 (7/16-20 F 37 x 1/8) Nipple Quick Coupler SERVICE EQUIPMENT AND TOOLS Digital Thermometer Gauge 035 000 kPa (0350 bar) (05000 psi)
3. Test steering pump relief setting. 310D, 315D Remove left engine side shield. Make test connection at tee provided in line from steering pump to priority valve. Warm oil to specifications.
T7390AC
2. Stop engine, operate hydraulic control levers to release pressure in system, and install digital thermometer probe in reservoir.
1917OCT90
1. Put FNR lever in neutral and engage park brake.
9025 25 13
Run engine at fast idle.

Activate and hold loader raise and backhoe boom raise over relief. Record pressure on gauge.
Specification Steering PumpRelief Pressure Setting...................................................... 20 50023 800 kPa (205238 bar) (29753450 psi)
TX,9025,BS414 1921JUL941/2
TM1496 (21SEP05)

092105
PN=537
Tests
300D Remove steering pump inlet line to priority valve. Cap valve and connect gauge to line. Warm oil to specifications. Run machine at fast idle and observe gauge reading. IMPORTANT: Steering pump relief valve must be set higher than main hydraulic system relief valve to prevent damage to steering pump relief. See Main Hydraulic Relief Pressure Test in this group. 4. Relief cartridge is not adjustable. Replace if necessary.
TX,9025,BS414 1921JUL942/2
Auxiliary Pump Relief Pressure Test (300D, 310D S.N. 802200 )

SPECIFICATIONS Oil Temperature 9025 25 14 Engine Speed Auxiliary Pump Relief Pressure Setting 65 5C (150 10F) Fast idle 20 50023 800 kPa (205238 bar) (29753450 psi)
ESSENTIAL TOOLS 38H1279 (-8 ORFS) Union 38H1415 (-8 ORFS) Cap SERVICE EQUIPMENT AND TOOLS Gauge 035 000 kPa (0350 bar) (05000 psi) Digital Thermometer
1. Put FNR lever in neutral and engage park brake. 2. Stop engine.
TX,9025,BS415 1921JUL941/2
TM1496 (21SEP05)

092105
PN=538
Tests
3. Operate all hydraulic control valves to release pressure in the hydraulic system. Remove auxiliary pump inlet line to backhoe valve. Cap valve (A) and connect gauge (B) to inlet line (C). 4. Install digital thermometer probe in reservoir. Warm oil to specifications.
See Hydraulic Oil Warm-up in Group 9025-25. 5. Run engine at specified speed and record pressure on gauge.
Specification EngineSpeed ............................................................................ Fast idle Auxiliary PumpRelief Pressure Setting...................................................... 20 50023 800 kPa (205238 bar) (29753450 psi)
T8257BA
IMPORTANT: Steering pump relief valve must be set higher than main hydraulic system relief valve to prevent damage to steering pump relief. See Main Hydraulic Relief Pressure Test in this group. 6. Relief cartridge is not adjustable. Replace if necessary.
UN02JUN94
9025 25 15
TX,9025,BS415 1921JUL942/2
TM1496 (21SEP05)

092105
PN=539
Tests
Steering Pump Flow Test (300D, 310D S.N. 802199) (315D, All Machines)
SPECIFICATIONS Oil Temperature Engine Speed Oil Pressure New Steering Pump Minimum Flow Used Steering Pump Minimum Flow 65 5C (150 10F) 2000 10 rpm 13,700 70 kPa (137 0.7 bar) (2000 10 psi) 24 L/min (6.4 gpm) 18 L/min (4.8 gpm)
ESSENTIAL TOOLS AJT05688 (1-1/16-12 M 37 x -8 F ORFS) Adapter (2 used) B38H1279 (-8 M x -8 M ORFS) Uniona
a
These ORFS fittings should be ordered through normal service parts channels.
1917OCT90
SERVICE EQUIPMENT AND TOOLS Flowmeter Electronic Tachometer Digital Thermometer
9025 25 16
NOTE: An in-line flowmeter is shown in the illustration. Any flowmeter capable of measuring the specified flow is suitable.
1. Make test connections. Install electronic tachometer, and digital thermometer probe in reservoir. (See procedure in this group.) 2. Open flowmeter. 3. Put FNR lever in neutral and engage park brake. 4. Heat hydraulic oil to test specifications.
See Hydraulic Oil Warm-up in Group 9025-25.
TX,9025,BS416 1921JUL941/2
TM1496 (21SEP05)

092105
PN=540
T7390AE
Tests
5. Adjust engine speed to test specification.
Slowly close loading valve to get test pressure reading on flowmeter gauge.
Specification OilPressure ......................................... 13,700 70 kPa (137 0.7 bar) (2000 10 psi)
6. Record the flow rate.

Specification New Steering PumpMinimum Flow ............................................................................. 24 L/min (6.4 gpm) Used Steering PumpMinimum Flow ............................................................................. 18 L/min (4.8 gpm)
TX,9025,BS416 1921JUL942/2
9025 25 17
TM1496 (21SEP05)

092105
PN=541
Tests
Auxiliary Pump Flow Test (300D, 310D S.N. 802200 )

SPECIFICATIONS Oil Temperature Engine Speed Oil Pressure New Auxiliary Pump Minimum Flow Used Auxiliary Pump Minimum Flow 65 5C (150 10F) 2000 10 rpm 13 700 70 kPa (137 0.7 bar) (2000 10 psi) 28 L/min (7.3 gpm) 23 L/min (6.1 gpm)
ESSENTIAL TOOLS JT05688 (1-1/16-12 M 37 x -8 F ORFS) Adapter (2 used) 38H1279 (-8 M x -8 M ORFS) Union SERVICE EQUIPMENT AND TOOLS Flowmeter Electronic Tachometer Digital Thermometer
1. Make test connections. Install electronic tachometer, and digital thermometer probe in reservoir. Heat oil to specification.
9025 25 18 Specification OilTemperature ................................................... 65 5C (150 10F)
(See procedure in this group.)
TX,9025,BS417 1921JUL941/2
TM1496 (21SEP05)

092105
PN=542
Tests
2. Connect flowmeter at auxiliary pump inlet to backhoe valve (A). 3. Open flowmeter. 4. Put FNR lever in neutral and engage park brake. 5. Heat hydraulic oil to test specifications. See Hydraulic Oil Warm-up in Group 9025-25. 6. Adjust engine speed to test specification.
Slowly close loading valve to get test pressure reading on flowmeter gauge.
Specification OilPressure ......................................... 13 700 70 kPa (137 0.7 bar) (2000 10 psi)
7. Record the flow rate.

Specification New Auxiliary PumpMinimum Flow ............................................................................. 28 L/min (7.3 gpm) Used Auxiliary PumpMinimum Flow ............................................................................. 23 L/min (6.1 gpm)
T8257AZ
UN02JUN94
9025 25 19
TX,9025,BS417 1921JUL942/2
TM1496 (21SEP05)

092105
PN=543
Tests
Hydraulic Oil Cooler Restriction Test

SPECIFICATIONS Oil Temperature Hydraulic Oil Cooler Flow Hydraulic Oil Cooler Maximum Pressure Differential 65 5C (150 10F) 26.5 L/min. (7 gpm) 200 kPa (2 bar) (30 psi)
ESSENTIAL TOOLS G(3/4 M NPT x 5/8 barb) Barb Fitting HJT03012 (1-1/16 F 37 SW x 3/4 F NPT) Adapter IJT03048 (1-1/16 M ORB x 1-1/16 M 37) Adapter JJT03348 (1/2 F NPT) Tee (2 used) KJT03213 (5/8 I.D. Hose x 1/2 M NPT) Adapter (6 used) SERVICE EQUIPMENT AND TOOLS AHydraulic Analyzer or Pressure Gauge BGauge 0200 kPa (02.0 bar) (030 psi)
1917OCT90
FHydrostatic Switching Unit Flowmeter with Temperature Gauge
9025 25 20
1. Make test connection. 2. Open flowmeter. Heat oil to test specification.

Specification OilTemperature ................................................... 65 5C (150 10F) AHydraulic Analyzer BGauge CGauge Port DNo. 2 Input ENo. 1 Input FSwitch Unit GFitting HAdapter IAdapter JTee KBarb Fitting LClamp MFlow Rater
See Hydraulic Oil Warm-up in Group 9025-25. 3. Increase engine speed until flow is at specification.
Specification Hydraulic Oil CoolerFlow ........................................ 26.5 L/min. (7 gpm)
4. Read pressure gauges at inlet and outlet of cooler. Difference in gauge reading is pressure drop in cooler.
Specification Hydraulic Oil CoolerMaximum Pressure Differential ............................................ 200 kPa (2 bar) (30 psi)
TX,9025,BS418 1921JUL941/1
TM1496 (21SEP05)

092105
PN=544
T7390AF
NOTE: Two gauges can be used in place of analyzer and switch box.
Tests
Circuit Relief Valve TestWith Remote Pump

SPECIFICATIONS Oil Temperature Pressure Set Tolerance 388D, 310D, 315D Gresen/Husco Loader Circuit Pressure (Auxiliary Extend (S.N. 802200 )) 388D, 310D, 315D Gresen/Husco Loader Circuit Pressure (Bucket Curl) 388D, 310D, 315D Gresen/Husco Loader Circuit Pressure (Bucket Dump) 388D, 310D, 315D Gresen/Husco Loader Circuit Pressure (Boom Up (S.N.802200 )) (300D, S.N. 802199) Gresen Backhoe Circuit Pressure (Crowd Out) (300D, S.N. 802199) Gresen Backhoe Circuit Pressure (Bucket Curl) (300D, S.N. 802199) Gresen Backhoe Circuit Pressure (Boom Down) (300D, S.N. 802199) Gresen Backhoe Circuit Pressure (Swing Left) (300D, S.N. 802199) Gresen Backhoe Circuit Pressure (Swing Right) (300D, S.N. 802199) Gresen Backhoe Circuit Pressure (Boom Raise) (300D, S.N. 802199) Gresen Backhoe Circuit Pressure (Bucket Dump) (300D, S.N. 802199) Gresen Backhoe Circuit Pressure (Crowd In) (300D, S.N.802200 ) Husco Backhoe Circuit Pressure (Crowd Out) (300D, S.N.802200 ) Husco Backhoe Circuit Pressure (Bucket Curl) 40 6C (104 10F) +1380 -0 kPa (+13.8 -0 bar) (+200 -0 psi) 19 200 kPa (192 bar) (3000 psi)
22 060 kPa (220 bar) (3200 psi)
22 060 kPa (220 bar) (3200 psi)
26 200 kPa (262 bar) (3800 psi)
22,000 kPa (220 bar) (3200 psi)
18,600 kPa (186 bar) (2700 psi)
13,700 kPa (138 bar) (2000 psi)
18,100 kPa (181 bar) (2625 psi)
9025 25 21
18,100 kPa (181 bar) (2625 psi)
22,000 kPa (220 bar) (3200 psi)
22,064 kPa (220 bar) (3200 psi)
17,235 kPa (172 bar) (2500 psi)
22,000 kPa (220 bar) (3200 psi)
22,000 kPa (220 bar) (2750 psi)
TX,9025,BS419 1922JUL941/5
TM1496 (21SEP05)

092105
PN=545
Tests
SPECIFICATIONS (300D, S.N.802200 ) Husco Backhoe Circuit Pressure (Boom Down) (300D, S.N.802200 ) Husco Backhoe Circuit Pressure (Swing Left) (300D, S.N.802200 ) Husco Backhoe Circuit Pressure (Swing Right) (300D, S.N.802200 ) Husco Backhoe Circuit Pressure (Boom Raise) (300D, S.N.802200 ) Husco Backhoe Circuit Pressure (Bucket Dump) (300D, S.N.802200 ) Husco Backhoe Circuit Pressure (Crowd In) 310D, 315D Husco Backhoe Circuit Pressure (Crowd Out) 310D, 315D Husco Backhoe Circuit Pressure (Bucket Curl) 310D, 315D Husco Backhoe Circuit Pressure (Boom Down) 310D, 315D Husco Backhoe Circuit Pressure (Swing Left) 9025 25 22 310D, 315D Husco Backhoe Circuit Pressure (Crowd In) 310D, 315D Husco Backhoe Circuit Pressure (Bucket Dump) 310D, 315D Husco Backhoe Circuit Pressure (Boom Raise) 310D, 315D Husco Backhoe Circuit Pressure (Swing Right) 12,900 kPa (129 bar) (1875 psi)
19 000 kPa (190 bar) (2750 psi)
19 000 kPa (190 bar) (2750 psi)
22,000 kPa (220 bar) (3200 psi)
22,000 kPa (220 bar) (3200 psi)
19 000 kPa (190 bar) (2750 psi)
24 100 kPa (241 bar) (3500 psi) 24 100 kPa (241 bar) (3500 psi) 12,900 kPa (129 bar) (1875 psi) 19 000 kPa (190 bar) (2750 psi) 19 000 kPa (190 bar) (2750 psi) 24 100 kPa (241 bar) (3500 psi) 26 200 kPa (262 bar) (3800 psi) 19 000 kPa (190 bar) (2750 psi)
ESSENTIAL TOOLS JT07192 Electric/Hydraulic Pump 38H1355 (-10 ORFS) Nut 38H1470 (-10 -6 ORFS) Reducer 38H1356 (-12 ORFS) Nut 38H1473 (-12 -6 ORFS) Reducer 38H1358 (-16 ORFS) Nut 38H1475 (-16 -8 ORFS) Reducer 38H1481 (-8 -6 ORFS) Reducer
TX,9025,BS419 1922JUL942/5
TM1496 (21SEP05)

092105
PN=546
Tests
SERVICE EQUIPMENT AND TOOLS Digital Thermometer 035 000 kPa (0350 bar) (05000 psi) Gauge
IMPORTANT: Relief valve is flow sensitive. A flow rate greater than 7.5 L/min 2 gpm will flood the valve causing an inaccurate pressure reading. A hydraulic source must be used that will provide a continuous flow to get an accurate reading.
NOTE: Relief valves may also be tested with an amplification cylinder using machine hydraulics. (See Relief Valve Test Using Amplification Cylinder in this section.)
1. Operate hydraulic functions to relieve pressure.
Specification OilTemperature ...................................................... 40 6C (104 10F)
TX,9025,BS419 1922JUL943/5
9025 25 23
TM1496 (21SEP05)

092105
PN=547
Tests
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Disconnect pressure line (A) at inlet port of relief valve to be tested. Cap line. 3. Connect test pump pressure hose (B) to inlet port using adapters. Install gauge. 4. Start pump to pressurize valve inlet.
NOTE: Take reading when pressure on gauge starts to decrease. The point at which pressure decreases is the opening pressure of the relief valve.
5. Adjust or replace as required.
Specification PressureSet Tolerance .............................. +1380 -0 kPa (+13.8 -0 bar) (+200 -0 psi) 388D, 310D, 315D Gresen/Husco Loader CircuitPressure (Auxiliary Extend (S.N. 802200 )) ............................................................. 19 200 kPa (192 bar) (3000 psi) Pressure (Bucket Curl) ........................... 22 060 kPa (220 bar) (3200 psi) Pressure (Bucket Dump) ........................ 22 060 kPa (220 bar) (3200 psi) Pressure (Boom Up (S.N.802200 )) .................................... 26 200 kPa (262 bar) (3800 psi) (300D, S.N. 802199) Gresen Backhoe CircuitPressure (Crowd Out) ............................................ 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Curl) ........................... 18,600 kPa (186 bar) (2700 psi) Pressure (Boom Down) .......................... 13,700 kPa (138 bar) (2000 psi) Pressure (Swing Left) ............................. 18,100 kPa (181 bar) (2625 psi) Pressure (Swing Right) .......................... 18,100 kPa (181 bar) (2625 psi) Pressure (Boom Raise) .......................... 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Dump) ........................ 22,064 kPa (220 bar) (3200 psi) Pressure (Crowd In) ............................... 17,235 kPa (172 bar) (2500 psi) (300D, S.N.802200 ) Husco Backhoe CircuitPressure (Crowd Out) ............................................ 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Curl) ........................... 22,000 kPa (220 bar) (2750 psi) Pressure (Boom Down) .......................... 12,900 kPa (129 bar) (1875 psi) Pressure (Swing Left) ............................. 19 000 kPa (190 bar) (2750 psi) Pressure (Swing Right) .......................... 19 000 kPa (190 bar) (2750 psi) Pressure (Boom Raise) .......................... 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Dump) ........................ 22,000 kPa (220 bar) (3200 psi) Pressure (Crowd In) ............................... 19 000 kPa (190 bar) (2750 psi)
UN18FEB94
9025 25 24
TX,9025,BS419 1922JUL944/5
TM1496 (21SEP05)

092105
PN=548
T8187AJ
Tests
Specification 310D, 315D Husco Backhoe CircuitPressure (Crowd Out)............... 24 100 Pressure (Bucket Curl) ........................... 24 100 Pressure (Boom Down) .......................... 12,900 Pressure (Swing Left) ............................. 19 000 Pressure (Crowd In) ............................... 19 000 Pressure (Bucket Dump) ........................ 24 100 Pressure (Boom Raise) .......................... 26 200 Pressure (Swing Right) .......................... 19 000
kPa kPa kPa kPa kPa kPa kPa kPa
(241 (241 (129 (190 (190 (241 (262 (190
bar) bar) bar) bar) bar) bar) bar) bar)
(3500 (3500 (1875 (2750 (2750 (3500 (3800 (2750
psi) psi) psi) psi) psi) psi) psi) psi)
TX,9025,BS419 1922JUL945/5
9025 25 25
TM1496 (21SEP05)

092105
PN=549
Tests
Circuit Relief Valve Test300D, With Amplification Cylinder

SPECIFICATIONS Test Cylinder Rod End Flow Oil Temperature Engine Speed Test Cylinder Rod Extend Cycle Time Relief Valve Oil Pressure Tolerance (S.N. 802199) Gresen Backhoe Circuits Pressure (Crowd Out) (S.N. 802199) Gresen Backhoe Circuits Pressure (Bucket Curl) (S.N. 802199) Gresen Backhoe Circuits Pressure (Swing Left) (S.N. 802199) Gresen Backhoe Circuits Pressure (Swing Right) (S.N. 802199) Gresen Backhoe Circuits Pressure (Boom Raise) (S.N. 802199) Gresen Backhoe Circuits Pressure (Bucket Dump) (S.N. 802199) Gresen Backhoe Circuits Pressure (Crowd In) 9025 25 26 (S.N.802200 ) Husco Backhoe Circuits Pressure (Crowd Out) (S.N.802200 ) Husco Backhoe Circuits Pressure (Bucket Curl) (S.N.802200 ) Husco Backhoe Circuits Pressure (Boom Lower) (S.N.802200 ) Husco Backhoe Circuits Pressure (Swing Left) (S.N.802200 ) Husco Backhoe Circuits Pressure (Swing Right) (S.N.802200 ) Husco Backhoe Circuits Pressure (Boom Raise) (S.N.802200 ) Husco Backhoe Circuits Pressure (Bucket Dump) (S.N.802200 ) Husco Backhoe Circuits Pressure (Crowd In) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Crowd Out) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Bucket Curl) 3.78 L/min (1 gpm) 40 6C (104 10F) Approximately 1000 rpm 1.5 sec. +1380 -0 kPa (+13.8 -0 bar) (+200 -0 psi) 22 000 kPa (220 bar) (3200 psi) 18 600 kPa (186 bar) (2700 psi) 18,100 kPa (181 bar) (2625 psi) 18,100 kPa (181 bar) (2625 psi) 22,000 kPa (220 bar) (3200 psi) 22,064 kPa (220 bar) (3200 psi) 17,235 kPa (172 bar) (2500 psi) 22,000 kPa (220 bar) (3200 psi) 19 000 kPa (190 bar) (2750 psi) 12 900 kPa (129 bar) (1875 psi) 19 000 kPa (190 bar) (2750 psi) 19 000 kPa (190 bar) (2750 psi) 22,000 kPa (220 bar) (3200 psi) 22 000 kPa (220 bar) (3200 psi) 19 000 kPa (190 bar) (2750 psi) 22,000 kPa (220 bar) (3200 psi)
22,000 kPa (220 bar) (2750 psi)
TX,902525,BR78 1921JUL941/8
TM1496 (21SEP05)

092105
PN=550
Tests
SPECIFICATIONS (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Boom Down) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Swing Left) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Swing Right) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Boom Raise) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Bucket Dump) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Crowd In) Gresen/Husco Loader Circuits Pressure (Bucket Head End) Gresen/Husco Loader Circuits Pressure (Bucket Rod End) Gresen/Husco Loader Circuits Pressure (Boom Head End (S.N.802200 )) Gresen/Husco Loader Circuits Pressure (Auxiliary Head End (S.N.802200 )) 12,900 kPa (129 bar) (1875 psi)
19 000 kPa (190 bar) (2750 psi)
19 000 kPa (190 bar) (2750 psi)
22,000 kPa (220 bar) (3200 psi)
22,000 kPa (220 bar) (3200 psi)
19 000 kPa (190 bar) (2750 psi)
22,000 kPa (220 bar) (3200 psi) 22,000 kPa (220 bar) (3200 psi) 26 200 kPa (262 bar) (3800 psi)
20 700 kPa (207 bar) (3000 psi) 9025 25 27
TX,902525,BR78 1921JUL942/8
TM1496 (21SEP05)

092105
PN=551
Tests
ESSENTIAL TOOLS DAH120121 Test Cylindera (Cancelled) DAH93323 Test Cylindera (Replaces AH120121) B38H1030 (-6 ORFS) Teea B38H1031 (-8 ORFS) Teea B38H1032 (-10 ORFS) Teea G38H1415 (-6 ORFS) Capa (2 used) I(-6 M ORFS x 3/8 M NPT) Adapter K(3/8 M NPT x 3/8 F NPT) 90 Elbow L(9/16-18 M ORB x 3/8 F NPT) Adapter MAT81867 Check Valvea N(1/4 M NPT x 9/16 -18 F 37) Adapter ON/A Quick-Coupler P(1/8 M NPT x 1/4 F NPT) Nipple Q(1/4 M NPT x 1/4 F NPT) 90 Elbow R(1/4 M NPT x 1/4 F NPT x 1/4 F NPT) Tee S(9/16 M ORB x 1/4 F NPT) Adapter 38H1146 (-6 ORFS) Pluga 38H1147 (-8 ORFS) Pluga 38H1148 (-10 ORFS) Pluga JJT03408 Hydraulic Flow Regulator
a
These ORFS fittings and parts should be ordered through normal service parts channels. 9025 25 28 SERVICE EQUIPMENT AND TOOLS ARod End Hose To Tee Gauge 35,000 kPa (350 bar) (5000 psi)
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. Install test tee at most accessible part of circuit being tested.
TX,902525,BR78 1921JUL943/8
TM1496 (21SEP05)

092105
PN=552
Tests
AExtendible Dipperstick Head End Lift Check Plug BCrowd Rod End Relief Valve And Lift Check CBucket Head End Relief Valve And Lift Check DBoom Head End Relief Valve And Lift Check ESwing Left Combination Relief/Lift Check/Anti-Cavitation Valve FSwing Right Combination Relief/Lift Check/Anti-Cavitation Valve GBoom Rod End Relief Valve And Lift Check HBucket Rod End And Relief Valve End Lift ICrowd Head End Relief Valve And Lift Check JExtendible Dipperstick Rod End Lift Check Plug KOrifice Plate With Springs (4 Used) Orifices Used In Boom Rod End Port (Lower Port) Both Swing Ports, And Crowd Rod End Port LLoader Bucket Rod End Combination Relief/Lift Check/Anti- Cavitation Valve MLoader Boom Rod End Lift Check/Anti-Cavitation Plug NLoader Boom Head End Lift Check Plug OLoader Bucket Head End Relief Valve And Lift Check
UN03NOV88
(S.N. 802199) Shown
T6157AL
9025 25 29
(S.N. 802199) Shown

TX,902525,BR78 1921JUL944/8
1. Lower stabilizers to ground and stop engine.
TX,902525,BR78 1921JUL945/8
TM1496 (21SEP05)

092105
PN=553
T6725AB
UN26OCT88
T7401AF
UN25OCT90
Tests
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. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 2. Operate hydraulic controls to relieve pressure in hydraulic system. 3. Install stabilizer hoses on test cylinder.
9025 25 30
UN23AUG88
TX,902525,BR78 1921JUL946/8
TM1496 (21SEP05)

092105
PN=554
X9811
Tests
T6773AN
1921MAR89
ARod End Hose To Tee BTee
CGauge DCylinder
EStabilizer Hose (Rod End) FStabilizer Hose (Head End)
G38H1415 Cap (2 Used)
9025 25 31
4. Install adapter in relief valve port to be tested. Tee in test gauge (C) and rod end hose (A) from test cylinder.
Specification Test CylinderRod End Flow .............................. 3.78 L/min (1 gpm)
7. Activate stabilizer to extend test cylinder and record pressure reading on gauge (C). 8. Retract cylinder rod for next test cycle. Repeat steps 7 and 8 if required. 9. Move tee (B) to next relief valve port to be tested. Repeat steps 7 and 8. IMPORTANT: To prevent structural damage of machine, do not adjust relief valves above specifications. 10. Adjust or replace reliefs as required.
Specification Relief Valve OilPressure Tolerance ................................................ +1380 -0 kPa (+13.8 -0 bar) (+200 -0 psi)
5. Start engine, use stabilizer lever to cycle test cylinder until temperature is to test specifications.
Specification OilTemperature ............................................ 40 6C (104 10F) EngineSpeed ............................................. Approximately 1000 rpm
6. Adjust JT03408 hydraulic flow regulator on head end of test cylinder, until rod extends in 1.5 seconds.
Specification Test CylinderRod Extend Cycle Time .............................................................................. 1.5 sec.
Lock flow regulator at this setting.
TX,902525,BR78 1921JUL947/8
TM1496 (21SEP05)

092105
PN=555
Tests
Specification (S.N. 802199) Gresen Backhoe CircuitsPressure (Crowd Out) ............................................ 22 000 kPa (220 bar) (3200 psi) Pressure (Bucket Curl) ........................... 18 600 kPa (186 bar) (2700 psi) Pressure (Swing Left) ............................. 18,100 kPa (181 bar) (2625 psi) Pressure (Swing Right)........................... 18,100 kPa (181 bar) (2625 psi) Pressure (Boom Raise) .......................... 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Dump) ........................ 22,064 kPa (220 bar) (3200 psi) Pressure (Crowd In) ............................... 17,235 kPa (172 bar) (2500 psi) (S.N.802200 ) Husco Backhoe CircuitsPressure (Crowd Out) ............................................ 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Curl) ........................... 19 000 kPa (190 bar) (2750 psi) Pressure (Boom Lower).......................... 12 900 kPa (129 bar) (1875 psi) Pressure (Swing Left) ............................. 19 000 kPa (190 bar) (2750 psi) Pressure (Swing Right)........................... 19 000 kPa (190 bar) (2750 psi) Pressure (Boom Raise) .......................... 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Dump) ........................ 22 000 kPa (220 bar) (3200 psi) Pressure (Crowd In) ............................... 19 000 kPa (190 bar) (2750 psi) (300D, S.N.802200 ) Husco Backhoe CircuitsPressure (Crowd Out) ............................................ 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Curl) ........................... 22,000 kPa (220 bar) (2750 psi) Pressure (Boom Down) .......................... 12,900 kPa (129 bar) (1875 psi) Pressure (Swing Left) ............................. 19 000 kPa (190 bar) (2750 psi) Pressure (Swing Right)........................... 19 000 kPa (190 bar) (2750 psi) Pressure (Boom Raise) .......................... 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Dump) ........................ 22,000 kPa (220 bar) (3200 psi) Pressure (Crowd In) ............................... 19 000 kPa (190 bar) (2750 psi) Gresen/Husco Loader CircuitsPressure (Bucket Head End)............................................... 22,000 kPa (220 bar) (3200 psi) Pressure (Bucket Rod End).................... 22,000 kPa (220 bar) (3200 psi) Pressure (Boom Head End (S.N.802200 ))..................................... 26 200 kPa (262 bar) (3800 psi) Pressure (Auxiliary Head End (S.N.802200 ))..................................... 20 700 kPa (207 bar) (3000 psi)
9025 25 32
TX,902525,BR78 1921JUL948/8
TM1496 (21SEP05)

092105
PN=556
Tests
Circuit Relief Valve Test310D, 315D, With Amplification Cylinder

SPECIFICATIONS Oil Temperature Engine Speed Test Cylinder Rod Extend Cycle Time Test Cylinder Rod End Flow Relief Valve Oil Pressure Tolerance (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Crowd Out) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Bucket Curl) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Boom Lower) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Swing Left) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Swing Right) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Boom Raise) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Bucket Dump) (300D, S.N.802200 ) Husco Backhoe Circuits Pressure (Crowd In) Gresen/Husco Loader Circuits Pressure (Bucket Head End) Gresen/Husco Loader Circuits Pressure (Bucket Rod End) Gresen/Husco Loader Circuits Pressure (Boom Head End (S.N.802200 )) Gresen/Husco Loader Circuits Pressure (Auxiliary Head End (S.N.802200 )) 40 6C (104 10F) 1.5 sec. 3.78 L/min (1 gpm) +1380 -0 kPa (+13.8 -0 bar) (+200 -0 psi) 24,100 kPa (241 bar) (3500 psi)
UN01NOV90
Approximately 1000 rpm
(S.N. 802199) Shown
24,100 kPa (241 bar) (3500 psi)
12,900 kPa (129 bar) (1875 psi)

UN25OCT90
19 000 kPa (190 bar) (2750 psi)
26,200 kPa (262 bar) (3800 psi)
(S.N. 802199) Shown

AExtendible Dipperstick Head End Plug BCrowd Rod End Relief Valve CBucket Head End Relief Valve DBoom Head End Relief Valve ESwing Right Relief/Orifice FSwing Left Relief/Orifice GBoom Rod End Relief Valve HBucket Rod End Relief ICrowd Head End Relief Valve JExtendible Dipperstick Rod End Plug K(Not Used) LLoader Bucket Rod End Combination Relief/Lift Check/Anti-Cavitation Valve MLoader Boom Rod End Lift Check/Anti-Cavitation Plug NLoader Boom Head End Lift Check Plug OLoader Bucket Head End Relief Valve And Lift Check 9025 25 33
24,100 kPa (241 bar) (3500 psi)
19 000 kPa (190 bar) (2750 psi)
22,064 kPa (220 bar) (3200 psi) 22,060 kPa (220 bar) (3200 psi) 26 200 kPa (262 bar) (3800 psi)
20 700 kPa (207 bar) (3000 psi)
TX,9025,BS422 1922JUL941/6
TM1496 (21SEP05)

092105
PN=557
T7401AF
19 000 kPa (190 bar) (2750 psi)
T7401AE
Tests
ESSENTIAL TOOLS DAH120121 Test Cylindera (Cancelled) DAH93323 Test Cylindera (Replaces AH120121) B38H1030 (-6 ORFS) Teea B38H1031 (-8 ORFS) Teea B38H1032 (-10 ORFS) Teea G38H1415 Capa (2 used) I( -6 M ORFS x 3/8 M NPT) Adapter K(3/8 M NPT x 3/8 F NPT) 90 Elbow L(9/16-18 M ORB x 3/8 F NPT) Adapter MAT81867 Check Valvea N(1/4 M NPT x 9/16 -18 F 37) Adapter ON/A Quick-Coupler P(1/8 M NPT x 1/4 F NPT) Nipple Q(1/4 M NPT x 1/4 F NPT) 90 Elbow R(1/4 M NPT x 1/4 F NPT x 1/4 F NPT) Tee S(9/16 M ORB x 1/4 F NPT) Adapter 38H1146 (-6 ORFS) Pluga 38H1147 (-8 ORFS) Pluga 38H1148 (-10 ORFS) Pluga JJT03408 Hydraulic Flow Regulator
a
These ORFS fittings and parts should be ordered through normal service parts channels. 9025 25 34 SERVICE EQUIPMENT AND TOOLS ARod End Hose To Tee BGauge 35,000 kPa (350 bar) (5000 psi)
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. Install test tee at most accessible part of circuit being tested.
TX,9025,BS422 1922JUL942/6
TM1496 (21SEP05)

092105
PN=558
Tests
TX,9025,BS422 1922JUL943/6
T6725AB
UN26OCT88
9025 25 35
ARod End Hose To Tee BTee
CGauge DCylinder
EStabilizer Hose (Rod End) FStabilizer Hose (Head End)
G38H1415 Cap (2 Used)
1. Lower stabilizers to ground and stop engine.
TX,9025,BS422 1922JUL944/6
TM1496 (21SEP05)

092105
PN=559
T6773AN
1921MAR89
Tests
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. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 2. Operate hydraulic controls to relieve pressure in the hydraulic system. 3. Slowly loosen stabilizer hoses to bleed off stored pressure. Install stabilizer hoses on test cylinder. 4. Install adapter in relief valve port to be tested. Tee in test gauge (C) and rod end hose (A) from test cylinder. 5. Start engine, use stabilizer lever to cycle test cylinder until temperature is to test specifications.
Specification OilTemperature ................................................... 40 6C (104 10F) EngineSpeed ................................................... Approximately 1000 rpm
UN23AUG88
9025 25 36
6. Adjust JT03408 hydraulic flow regulator on head end of test cylinder, until rod extends in 1.5 seconds.
Specification Test CylinderRod Extend Cycle Time ............................................................................................... 1.5 sec. Test CylinderRod End Flow ..................................... 3.78 L/min (1 gpm)
Lock flow regulator at this setting.
TX,9025,BS422 1922JUL945/6
TM1496 (21SEP05)

092105
PN=560
X9811
Tests
7. Activate stabilizer to extend test cylinder and record pressure reading on gauge (C). 8. Retract cylinder rod for next test cycle. Repeat steps 7 and 8 if required. 9. Move tee (B) to next relief valve port to be tested. Repeat steps 7 and 8. IMPORTANT: To prevent structural damage of machine, do not adjust relief valves above specifications. 10. Adjust or replace reliefs as required.
Specification Relief Valve OilPressure Tolerance ....................................................... +1380 -0 kPa (+13.8 -0 bar) (+200 -0 psi) (300D, S.N.802200 ) Husco Backhoe CircuitsPressure (Crowd Out) ............................................ 24,100 kPa (241 bar) (3500 psi) Pressure (Bucket Curl) ........................... 24,100 kPa (241 bar) (3500 psi) Pressure (Boom Lower) ......................... 12,900 kPa (129 bar) (1875 psi) Pressure (Swing Left) ............................. 19 000 kPa (190 bar) (2750 psi) Pressure (Swing Right) .......................... 19 000 kPa (190 bar) (2750 psi) Pressure (Boom Raise) .......................... 26,200 kPa (262 bar) (3800 psi) Pressure (Bucket Dump) ........................ 24,100 kPa (241 bar) (3500 psi) Pressure (Crowd In) ............................... 19 000 kPa (190 bar) (2750 psi) Gresen/Husco Loader Circuits Pressure (Bucket Head End) ................. 22,064 kPa (220 bar) (3200 psi) Pressure (Bucket Rod End) ................... 22,060 kPa (220 bar) (3200 psi) Pressure (Boom Head End (S.N.802200 )) .................................... 26 200 kPa (262 bar) (3800 psi) Pressure (Auxiliary Head End (S.N.802200 )) .................................... 20 700 kPa (207 bar) (3000 psi)
9025 25 37
TX,9025,BS422 1922JUL946/6
TM1496 (21SEP05)

092105
PN=561
Tests
Steering System Leakage Test

SPECIFICATIONS Oil Temperature Engine Speed Steering Wheel Torque Steering System Maximum Leakage 65 5C (150 10F) Low idle 11.3 Nm (100 lb-in.) 5 rpm
ESSENTIAL TOOLS 38H1145 (-4 ORFS) Pluga (2 used) 38H1352 (-4 ORFS) Nuta (2 used) 38H1138 (-4 ORFS) Pluga (2 used)
a
These ORFS fittings should be ordered through normal service parts channels. SERVICE EQUIPMENT AND TOOLS Digital Thermometer
9025 25 38
TX,902525,BS221 1921JUL941/4
TM1496 (21SEP05)

092105
PN=562
Tests
1. Install digital thermometer probe in reservoir. 2. Heat hydraulic oil to specifications.
(See procedure in this group.) 3. Put FNR lever in neutral and engage park brake. 4. Run the engine at low idle.
Specification EngineSpeed ............................................................................. Low idle
5. Remove steering wheel emblem. 6. Bend locking tab away from steering wheel nut. 7. Turn the steering wheel clockwise at a constant torque of 11.3 Nm (100 lb-in.) with wheels in the maximum right position.
Specification Steering WheelTorque ........................................... 11.3 Nm (100 lb-in.)
Count the rpm. 8. Turn the steering wheel counterclockwise at a constant torque of 11.3 Nm (100 lb in.) with wheels in the maximum left turn position. Count the rpm. 9. If the steering wheel can be turned faster than 5 rpm in either direction, excessive leakage is indicated.
Specification Steering SystemMaximum Leakage ............................................................................................. 5 rpm
T93024
UN26OCT88
9025 25 39
Go to steps 12-16 to isolate steering valve or cylinder leakage. 10. If the steering wheel cannot be turned faster than 5 rpm in both directions, the steering valve and cylinder are good. Stop the test here. 11. Stop the engine.
TX,902525,BS221 1921JUL942/4
TM1496 (21SEP05)

092105
PN=563
Tests
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. 12. Operate all hydraulic control valves to release pressure in system.
9025 25 40
TX,902525,BS221 1921JUL943/4
13. Disconnect hydraulic lines from steering cylinder and install caps (B) and plugs (A). 14. Start the engine and run at low idle. 15. Turn steering wheel counterclockwise and then clockwise at a constant torque of 11.3 Nm (100 lb-in.). Count the rpm. 16. If steering wheel can be turned faster than 5 rpm in either direction, steering valve is leaking excessively.
Axle Without MFWD Shown
TX,902525,BS221 1921JUL944/4
TM1496 (21SEP05)

092105
PN=564
T6076AM
UN25MAY89
X9811
UN23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
Tests
Steering Cylinder Leakage Test

SPECIFICATIONS Engine Speed Oil Temperature Steering Cylinder Leakage Low idle 65 5C (150 10F) 5 ml/min (1/6 oz/min)
ESSENTIAL TOOLS 38H1145 (-4 ORFS) Pluga

a
These ORFS fittings should be ordered through normal service parts channels. SERVICE EQUIPMENT AND TOOLS Digital Thermometer
1. Install digital thermometer probe in reservoir. 2. Put FNR lever in neutral and engage park brake. 3. Start engine. Turn the steering wheel to left turn stop to extend cylinder rod. Stop engine. Move steering wheel back and forth to relieve hydraulic pressure.
9025 25 41
T60,9025,1065 1921JUL941/2
TM1496 (21SEP05)

092105
PN=565
Tests
4. Remove rod end hose and plug (A). Put beaker under cylinder port after oil stops dripping. 5. Start engine and hold steering wheel in full left turn with constant pressure for one minute.
Specification EngineSpeed ............................................................................. Low idle OilTemperature ................................................... 65 5C (150 10F)
Stop engine. 6. Measure oil collected and connect hose.

Specification Steering CylinderLeakage..................................... 5 ml/min (1/6 oz/min)
UN25MAY89
Axle Without MFWD Shown
9025 25 42
T60,9025,1065 1921JUL942/2
TM1496 (21SEP05)

092105
PN=566
T6076AL
Tests
Hydraulic Cylinder Drift Test Procedure
9025 25 43
TX,902525,BS230 1909MAR931/1
TM1496 (21SEP05)

092105
PN=567
T7949AC
1923FEB93
Tests
Function Drift Test

SPECIFICATIONS Oil Temperature Engine Speed Function Max Allowable Drift BH Boom, Crowd Cylinder Max Allowable Drift (Std. Dipper) BH Boom, Crowd Cylinder Max Allowable Drift (Ext. Dipper) BH Bucket Cylinder Max Allowable Drift Swing Cylinder Max Allowable Drift Loader Boom and Bucket Cylinder Maximum Allowable Drift John Deere Ext. Dipper Cylinder Maximum Allowable Drift 65 5C (150 10F) Low idle 50 mm/min (2.00 in/min) 5 mm/min (0.20 in/min) 6 mm/min (0.25 in/min) 3 mm/min (0.12 in/min) 150 mm/min (6.00 in/min) 3 mm/min (0.12 in/min) 6 mm/min (0.25 in/min)
SERVICE EQUIPMENT AND TOOLS JT05800 Digital Thermometer
9025 25 44
NOTE: The following tests are used to check leakage past the cylinder piston seals and through the main control valve spool and reliefs. Weighting the machine is not required to perform these tests. On extendable dipperstick machines fully retract dipperstick for all testing.
1. Install digital thermometer probe in reservoir. Warm hydraulic oil to specifications.
See Hydraulic Oil Warm-up in Group 9025-25. 2. Put FNR lever in neutral and engage park brake. Function Drift 3. Position backhoe bucket side cutters at 45 angle to ground and lower boom until bucket cutting edge is 50 mm (2.00 in.) off ground.
TX,902525,BS231 1921JUL941/7
TM1496 (21SEP05)

092105
PN=568
Tests
4. Position level loader bucket cutting edge same distance off ground as backhoe bucket.
Specification EngineSpeed ............................................................................. Low idle FunctionMax Allowable Drift ............................ 50 mm/min (2.00 in/min)
Backhoe Cylinder Drift
TX,902525,BS231 1921JUL942/7
6. Position the crowd cylinder with rod 2050 mm (0.752.00 in.) extended from the fully retracted position. 7. Position the bucket cylinder with rod 2050 mm (0.752.00 in) retracted from the fully extended position. 8. Measure movement of boom, crowd, and bucket cylinders for five minutes.
Specification BH Boom, Crowd CylinderMax Allowable Drift (Std. Dipper) .................................. 5 mm/min (0.20 in/min) Max Allowable Drift (Ext. Dipper) .......................... 6 mm/min (0.25 in/min) BH Bucket CylinderMax Allowable Drift........................................................ 3 mm/min (0.12 in/min)
T7949AE
5. Run engine at slow idle and observe bucket cutting edges for one minute.
UN25FEB93
NOTE: If bucket cutting edges touch the ground within one minute, excessive leakage is indicated in the cylinders or control valve. Position machine as shown, with the bucket pivot pin one meter (36 in.) off ground.
Divide measured rod drift by five to determine drift per minute.
TX,902525,BS231 1921JUL943/7
TM1496 (21SEP05)

092105
PN=569
T7949AF
UN26MAR93
9025 25 45
Tests
9. To measure swing drift tilt machine by fully extending RH stabilizer. Fully extend dipperstick and bucket, so bucket is approximately 300 mm (12 in.) off ground. Boom should be parallel to ground. Position LH stabilizer 75 mm (3 in.) off ground. 10. Measure swing drift from side of bucket, to vertical rod placed in ground next to bucket, for five minutes. Divide measured drift by five to determine drift per minute.
Specification Swing CylinderMax Allowable Drift .................................................................... 150 mm/min (6.00 in/min)
UN26MAY89
TX,902525,BS231 1921JUL944/7
11. Measure swing drift in opposite direction by reversing stabilizer positions and vertical rod. Loader Cylinder Drift
UN25FEB93
9025 25 46
TX,902525,BS231 1921JUL945/7
12. Position the machine as shown with the loader bucket pivot pin one meter (36 in.) above ground, with bucket level. 13. Measure movement of boom and bucket cylinders for five minutes. Divide measured rod drift by five to determine drift per minute.
Specification Loader Boom and Bucket CylinderMaximum Allowable Drift ........................................................................ 3 mm/min (0.12 in/min)
Extendable Dipperstick Cylinder Drift
TX,902525,BS231 1921JUL946/7
TM1496 (21SEP05)

092105
PN=570
T7949AH
UN25FEB93
T7949AG
T6222AM
Tests
14. Machine in transport position. Mark or tape end of exposed internal dipperstick tube. Measure drift from end of external dipperstick housing for five minutes. Divide measured drift by five to determine drift per minute.
Specification John Deere Ext. Dipper CylinderMaximum Allowable Drift ........................................................................ 6 mm/min (0.25 in/min)
UN26MAY89
TX,902525,BS231 1921JUL947/7
T6222AM
9025 25 47
TM1496 (21SEP05)

092105
PN=571
Tests
Cylinder Leakage Test

SPECIFICATIONS Oil Temperature Engine Speed Cylinder Leakage 65 5C (150 10F) Low idle
UN26OCT88
5 ml/min (1/6 oz/min) ESSENTIAL TOOLS
38H1353 (-6 ORFS) Nuta 38H1139 (-6 ORFS) Pluga 38H1354 (-8 ORFS) Nuta 38H1140 (-8 ORFS) Pluga 38H1146 (-6 ORFS) Pluga 38H1147 (-8 ORFS) Pluga
a
These ORFS fittings should be ordered through normal service parts channels. SERVICE EQUIPMENT AND TOOLS JT05800 Digital Thermometer
1. Install digital thermometer probe in reservoir.

Specification OilTemperature ................................................... 65 5C (150 10F) 9025 25 48
2. Put FNR lever in neutral and engage park brake. 3. Start engine. Fully extend cylinder rod. Stop engine. Activate a hydraulic function to relieve pressure in the system. 4. Remove rod end hose and plug hose. Use a measuring beaker, after oil stops dripping, to catch oil. This can also be done at control valve, which would require capping control valve port and putting hose end into measuring beaker after oil stops dripping. 5. Start engine and actuate cylinder extend function for one minute.
Specification EngineSpeed ............................................................................. Low idle
T60,9025,1068 1921JUL941/2
TM1496 (21SEP05)

092105
PN=572
T6222AL
Tests
6. Stop engine. Measure oil collected and connect hose.
Specification CylinderLeakage ................................................... 5 ml/min (1/6 oz/min)
7. Repair as necessary. (See repair manual.) 8. Repeat procedure to test each cylinder.
T60,9025,1068 1921JUL942/2
9025 25 49
TM1496 (21SEP05)

092105
PN=573
Tests
Backhoe Or Loader Valve Leakage Test

SPECIFICATIONS Oil Temperature Engine Speed Oil Pressure 300D, 310D Maximum Cylinder Rod Travel 315D Maximum Cylinder Rod Travel 65 5C (150 10F) Low idle 6900 690 kPa (69 6.9 bar) (1000 100 psi) 7 mm/min (0.280 in/min) 15 mm/min (0.600 in/min)
ESSENTIAL TOOLS 38H1030 (-6 ORFS) Swivel Run Teea 38H1338 (1-1/16-12 Male ORB x -6 ORFS Male) Adaptera 38H1172 (7/8-14 Male ORB x -6 ORFS Male) Adaptera (Parker No. 1JS4366) Female Hose Ends Test Hose (Parker No. 4316) 96 in. Cut Length Test Hose 38H1146 (-6 ORFS) Pluga 38H1147 (-8 ORFS) Pluga
a
These ORFS fittings should be ordered through normal service parts channels. SERVICE EQUIPMENT AND TOOLS JT05800 Digital Thermometer 9025 25 50 Gauge 035 000 kPa (0350 bar) (05000 psi) Dial Indicator AAdapter BTest Hose CTee DGauge EPlug FBackhoe Valve GLoader Valve
1. Put FNR lever in neutral and engage park brake. 2. Install digital thermometer probe in reservoir. Heat oil to test specification.
See Hydraulic Oil Warm-up in Group 9025-25. 3. Lower stabilizers to ground and stop engine.
TX,902525,BS225 1921JUL941/3
TM1496 (21SEP05)

092105
PN=574
T7949AD
UN25FEB93
Tests
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. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 4. Operate hydraulic controls to relieve pressure in the hydraulic system. 5. Do stabilizer cylinder leakage test to verify it is within allowable leakage specification. (See procedure in this group.) 6. Make test connections. 7. The stabilizer and circuit being tested must be activated together in order to retract stabilizer cylinder to start test cycle. 8. Install dial indicator to measure rod movement. 9. Start engine. Slowly meter stabilizer cylinder lever (down) until 7000 kPa (70 bar) (1000 psi) reading is obtained on gauge.
Specification EngineSpeed ............................................................................. Low idle OilPressure ............................................ 6900 690 kPa (69 6.9 bar) (1000 100 psi)
UN23AUG88 T6222AN UN26OCT88 X9811
9025 25 51
TX,902525,BS225 1921JUL942/3
TM1496 (21SEP05)

092105
PN=575
Tests
Maintain this pressure and record cylinder rod travel on dial indicator for one minute.
Specification 300D, 310DMaximum Cylinder Rod Travel: .......................................................... 7 mm/min (0.280 in/min) 315DMaximum Cylinder Rod Travel ................................................................. 15 mm/min (0.600 in/min)
10. Stop engine and lower stabilizer to relieve pressure. Move test hose to next valve port to be tested. Reinstall previously tested lines. Plug hose of function being tested. Repeat Steps 4 thru 9 (as required).
NOTE: If leakage is high on both ports of a valve section, valve spool is worn and section should be replaced. If one port of a section is above specification remove the relief for that section and inspect seals, replace if required. If seals are good, replace relief.
9025 25 52
TX,902525,BS225 1921JUL943/3
TM1496 (21SEP05)

092105
PN=576
Tests
Stabilizer Valve Lockout Leakage Test

SPECIFICATIONS Engine Speed Oil Temperature 300D, 310D Max. Rod Travel 315D Max. Rod Travel Low idle 65 5C (150 10F) 0.25 mm/min (0.010 in/min)
UN23AUG88 T6222AN UN26OCT88 X9811
0.15 mm/min (0.006 in/min)
SERVICE EQUIPMENT AND TOOLS JT05800 Digital Thermometer Dial Indicator
1. Install digital thermometer probe in reservoir. Heat hydraulic oil to test specifications.
Specification EngineSpeed ............................................................................. Low idle OilTemperature ................................................... 65 5C (150 10F)
See Hydraulic Oil Warm-up in Group 9025-25. 2. Lower stabilizers to lift machine off ground. Check for cylinder rod movement with dial indicator.
Specification 300D, 310DMax. Rod Travel ...................... 0.15 mm/min (0.006 in/min) 315DMax. Rod Travel ................................. 0.25 mm/min (0.010 in/min)
NOTE: The stabilizer valve has lockouts to prevent cylinder drift up or down. If cylinder rod drift is above specification, remove the lockout and check for scratches on the seat and poppet. Replace if required. Check that the lockout plunger which slides between the two lockouts is not sticking. Also check for contamination in the thermal relief poppet seat and cylinder packings.
9025 25 53
TX,902525,BS227 1921JUL941/1
TM1496 (21SEP05)

092105
PN=577
Tests
Side Shift Valve Leakage Test315D

SPECIFICATIONS Engine Speed Oil Temperature Oil Maximum Leakage Low idle 40 6C (104 10F) (warm to touch) 125 mL (4.2 oz)
SERVICE EQUIPMENT AND TOOLS Measuring Beaker
1. Install digital thermometer probe in reservoir. Heat hydraulic oil to test specification.
Specification EngineSpeed ............................................................................. Low idle OilTemperature .................................... 40 6C (104 10F) (warm to touch)
See Hydraulic Oil Warm-up in Group 9025-25. 2. Put FNR lever in neutral and engage park brake. Install boom lock pin.
9025 25 54
T60,9025,C420 1921JUL941/2
TM1496 (21SEP05)

092105
PN=578
Tests
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. 3. Operate controls to relieve pressure in hydraulic system. 4. Hold side shift switch in ON position. 5. Remove return line and plug. Put beaker under fitting. 6. Start unit and hold boom raise function for one minute. Measure oil.
Specification OilMaximum Leakage ................................................... 125 mL (4.2 oz)
X9811
UN23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
9025 25 55
If leakage is excessive, replace O-ring or replace valve as necessary. See repair manual.
T60,9025,C420 1921JUL942/2
TM1496 (21SEP05)

092105
PN=579
Tests
Cycle Time Specifications

Item Measurement Specification
Oil Engine 300D Backhoe Loader Loader Boom Raise (Bucket Flat on Ground to Full Height) (Includes Bucket Self-Leveling) Loader Boom Lower (Power Down) (Full Up to Ground) Loader Boom Lower (Float Down) (Full Up to Ground) Loader Bucket Dump (Bucket Just Clears Ground) Loader Bucket Rollback (Bucket Just Clears Ground)
9025 25 56
Temperature Speed
65 5C (150 10F) Fast idle
Maximum Cycle Time
5.4 sec.
Maximum Cycle Time
3.0 sec.
Maximum Cycle Time
3.3 sec.
Maximum Cycle Time
2.5 sec.
Maximum Cycle Time
2.4 sec.
Backhoe Boom Raise (Backhoe at Max. Reach With Bucket Teeth on Ground up to Cylinder Cushion)
Maximum Cycle Time
2.2 sec.
Backhoe Boom Lower (Backhoe at Maximum Cycle Time Max. Reach. Transport Position to Bucket Teeth on Ground) Crowd In (Boom in Transport Position) Crowd Out Backhoe Bucket Dump Backhoe Bucket Curl Backhoe Swing (Boom Raised to Cushion, Bucket Curled, Dipperstick Parallel to Ground. Time Cycle to Cylinder Cushion) Maximum Cycle Time
2.3 sec.
3.5 sec.
Maximum Cycle Time Maximum Cycle Time Maximum Cycle Time Maximum Cycle Time
2.8 sec. 2.3 sec. 2.8 sec. 4.0 sec.
TX,9025,BS423 1921JUL941/4
TM1496 (21SEP05)

092105
PN=580
Tests
Item
Measurement
Specification
Stabilizer Up (Ground Level to Full Up)
Maximum Cycle Time
3.5 sec.
Stabilizer Down (Full Up to Ground Maximum Cycle Time Level) Extendible Dipperstick Extend and Retract Steering Right to Left Steering Left to Right Steering Right to Left (MFWD) Steering Left to Right (MFWD) Maximum Cycle Time
3.3 sec.
3.0 sec.
3.2 turns 2.4 turns 3.5 turns 3.5 turns 15 sec.
Main Hydraulic Pump (Bucket Flag Maximum Cycle Time at 1000 25 on Ground to Max. Height) rpm Engine Speed (Includes Bucket Self-Leveling) (S.N. 802199) Steering Pump Maximum Cycle Time at Fast Idle (Full Crowd Out Cycle of Dipperstick, While Loader Boom at Max. Height and Held Over Relief) (S.N. 802200 ) Steering Pump Maximum Cycle Time (Full Crowd Out Cycle of Dipperstick, While Loader Boom at Max. Height and Held Over Relief)
15 sec.
12 sec.
9025 25 57
310D/315D Backhoe Loader Loader Boom Raise (Bucket Flat on Ground to Full Height) (Includes Bucket Self-Leveling) Loader Boom Lower (Power Down) (Full Up to Ground) Loader Boom Lower (Float Down) (Full Up to Ground) Loader Bucket Dump (Bucket Just Clears Ground) Maximum Cycle Time 3.8 sec.
Maximum Cycle Time
2.6 sec.
Maximum Cycle Time
4.2 sec.
Maximum Cycle Time
2.5 sec.
TX,9025,BS423 1921JUL942/4
TM1496 (21SEP05)

092105
PN=581
Tests
Item
Measurement
Specification
Loader Bucket Rollback (Bucket Just Clears Ground) Backhoe Boom Raise (Backhoe at Max. Reach With Bucket Teeth on Ground up to Cylinder Cushion)
Maximum Cycle Time
2.4 sec.
Maximum Cycle Time
2.4 sec.
Backhoe Boom Lower (Backhoe at Maximum Cycle Time Max. Reach. Transport Position to Bucket Teeth on Ground) Crowd In (Boom in Transport Position) Crowd Out Backhoe Bucket Dump Backhoe Bucket Curl Backhoe Swing (Boom Raised to Cushion, Bucket Curled, Dipperstick Parallel to Ground. Time Cycle to Cylinder Cushion)
9025 25 58
2.5 sec.
Maximum Cycle Time
3.6 sec.
3.1 sec. 2.7 sec. 3.1 sec. 4.5 sec.
Stabilizer Up (Ground Level to Full Up)
Maximum Cycle Time
3.5 sec.
Stabilizer Down (Full Up to Ground Maximum Cycle Time Level) Extendible Dipperstick Extend and Retract Steering Right to Left Steering Left to Right Steering Right to Left (MFWD) Steering Left to Right (MFWD) Maximum Cycle Time
3.3 sec.
3.0 sec.
3.2 turns 2.4 turns 3.5 turns 3.5 turns 15 sec.
Main Hydraulic Pump (Bucket Flag Maximum Cycle Time at 1000 25 on Ground to Max. Height) rpm Engine Speed (Includes Bucket Self-Leveling)
TX,9025,BS423 1921JUL943/4
TM1496 (21SEP05)

092105
PN=582
Tests
Item
Measurement
Specification
315D Steering Pump (Full Crowd Out Cycle of Dipperstick, While Loader Boom at Max. Height and Held Over Relief)
Maximum Cycle Time
22 sec.
(310D, S.N. 802199) Steering Maximum Cycle Time at Fast Idle Pump (Full Crowd Out Cycle of Dipperstick, While Loader Boom at Max. Height and Held Over Relief) (310D, S.N. 802200 ) Steering Maximum Cycle Time Pump (Full Crowd Out Cycle of Dipperstick, While Loader Boom at Max. Height and Held Over Relief)
22 sec.
18 sec.
TX,9025,BS423 1921JUL944/4
9025 25 59
TM1496 (21SEP05)

092105
PN=583
Tests
9025 25 60
TM1496 (21SEP05)

092105
PN=584
Section 9031
Heating And Air Conditioning

Contents
Page Page
Group 05Theory Of Operation Proper Refrigerant Handling . . . . . . . . . . . . .9031-05-1 R12 And R134A Refrigerant Cautions . . . . . .9031-05-1 Refrigerant Theory Of Operation . . . . . . . . . .9031-05-2 Air Conditioning Circuit Operational Information. . . . . . . . . . . . . . . . . . . . . . . . .9031-05-3 Air Conditioning Circuit Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-4 Air Conditioning Circuit Schematic. . . . . . . . .9031-05-5 Blower Circuit Operational Information . . . . .9031-05-6 Blower Circuit Theory Of Operation. . . . . . . .9031-05-6 Blower Circuit Schematic. . . . . . . . . . . . . . . .9031-05-7 Receiver/Dryer Operation . . . . . . . . . . . . . . .9031-05-8 Expansion Valve Operation . . . . . . . . . . . . .9031-05-10 Compressor Relief Valve Operation . . . . . .9031-05-11 Temperature Control . . . . . . . . . . . . . . . . . .9031-05-11 Group 10System Operational Checks Air Conditioning Operational Checks . . . . . . .9031-10-1 Visual Inspection Of Components . . . . . . . . .9031-10-1 System Operating Checks. . . . . . . . . . . . . . .9031-10-3 System Performance Checks . . . . . . . . . . . .9031-10-5 Blower/Air Conditioning Circuit Checks . . . . .9031-10-6 Group 15Diagnostic Information Diagnose Air Conditioning Electrical Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9031-15-1 Air Conditioning Component Location . . . . . .9031-15-2 Group 20Adjustments Proper Refrigerant Handling . . . . . . . . . . . . .9031-20-1 R12 And R134A Refrigerant Cautions . . . . . .9031-20-1 R12 Component Air Charge . . . . . . . . . . . . .9031-20-2 R12 Refrigerant Recovery, Recycling Station Installation Procedure . . . . . . . . . . . . . . . .9031-20-3 R12 Refrigerant Evacuation And Charging Station Installation Procedure . . . . . . . . . .9031-20-4 Recover R12 System . . . . . . . . . . . . . . . . . .9031-20-5 Evacuate R12 System. . . . . . . . . . . . . . . . . .9031-20-6 Charge R12 System . . . . . . . . . . . . . . . . . . .9031-20-8 R134A Compressor Oil Charge Check . . . . .9031-20-9 R134A Compressor Oil Removal. . . . . . . . . .9031-20-9 R134A Component Oil Charge . . . . . . . . . .9031-20-10 TM1496 (21SEP05)
R134A Refrigerant Recovery, Recycling And Charging Station Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . .9031-20-11 Recover R134A System . . . . . . . . . . . . . . .9031-20-12 Evacuate R134A System. . . . . . . . . . . . . . .9031-20-13 Charge R134A System . . . . . . . . . . . . . . . .9031-20-15 Check And Adjust Compressor Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-16 Group 25Test Proper Refrigerant Handling . . . . . . . . . . . . .9031-25-1 R12 And R134A Refrigerant Cautions . . . . . .9031-25-1 R134A Air Conditioning System Test . . . . . .9031-25-2 Pressure Diagnostic Chart. . . . . . . . . . . . . . .9031-25-6 Low Pressure Switch Test. . . . . . . . . . . . . . .9031-25-7 High Pressure Switch Test . . . . . . . . . . . . . .9031-25-8 Clutch Cycle Switch . . . . . . . . . . . . . . . . . .9031-25-10 Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .9031-25-11 Refrigerant Hoses And Tubing Inspection . . . . . . . . . . . . . . . . . . . . . . . .9031-25-11
9031

092105
PN=1
Contents
9031
TM1496 (21SEP05)

092105
PN=2
Group 05
Theory Of Operation
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and requires that refrigerant be recovered using the approved recovery equipment. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT use refrigerant, hoses, fittings, components or refrigerant oils intended for use with R12 refrigerant. Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT be interchanged. Systems containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants.
TX,9031,QQ2009 1919AUG941/1
R12 And R134A Refrigerant Cautions

CAUTION: DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment. DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials. DO NOT heat refrigerant over 52C (125F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment. (R12 ONLY) Refrigerant exposed to high temperature forms phosgene gas. Inhaling toxic phosgene gas may result in serious illness or death. Phosgene gas has an odor like new mown hay or green corn. If you inhale phosgene gas, go to a physician or hospital immediately for treatment.
9031 05 1
TX,9031,QQ2010 1917JUN941/1
TM1496 (21SEP05)

092105
PN=587
Theory Of Operation
Refrigerant Theory Of Operation
9031 05 2
ACompressor BLow Pressure Switch CHigh Pressure Switch DHigh Pressure Gas
ECondenser FEngine Fan GHigh Pressure Liquid HReceiver Dryer
IExpansion Valve JLow Pressure Liquid KEvaporator
LBlowers MClutch Cycle Switch NLow Pressure Gas
The compressor (A) draws low pressure gas (N) from the evaporator (K) and compresses it into high pressure gas (D). Increasing the pressure of the refrigerant causes its boiling point to rise to a temperature higher than the outside air temperature. High pressure gas (D) leaves the compressor (A) and passes through two switches (B and C). These switches monitor refrigerant pressure. Should the pressure become too great or too small, either the high or low pressure switch will open and stop the compressor, interrupting the cycle. As the high pressure gas flows through the condenser (E), the engine fan (F) draws air through the condenser core which cools the refrigerant. Cooling
the refrigerant causes it to condense and it leaves the condenser (E) as a high pressure liquid (G). The high pressure liquid flows into the receiver-dryer (H) where moisture and contaminants are removed. The refrigerant flows from the receiver-dryer (H) to the expansion valve (I). The expansion valve (I) is a variable orifice used to cause a pressure and temperature drop in the refrigerant causing refrigerant to vaporize. The expansion valve (I) is one of the dividing lines between the high side and low side of the air conditioning system. At this point in the system, the high pressure/high temperature liquid is sprayed into the evaporator (K) where it changes and becomes a gas.
TX,9031,QQ2011 1917JUN941/2
TM1496 (21SEP05)

092105
PN=588
T7828AX
1920OCT97
Theory Of Operation
The expansion valve diaphragm is activated by sensing temperature and pressure within the valve body. The internal bulb senses the evaporator outlet or discharge temperature and pressure of refrigerant as it passes through the valve back to the low pressure or suction side of the compressor. (See Expansion Valve Operation in this group for additional information on theory of operation.) If too much refrigerant is flowing into evaporator, the liquid refrigerant will still be evaporating as it leaves the evaporator, causing a low temperature at the evaporator outlet. The low temperature causes the expansion valve variable orifice to decrease in size, restricting refrigerant flow. If the evaporator outlet temperature is too warm, the orifice will increase in size, allowing more refrigerant into evaporator. If evaporator (K) temperature becomes too low, the clutch cycle switch (M) will interrupt current flow to the compressor clutch coil, stopping system operation until the temperature becomes normal, between 31 and 40.
TX,9031,QQ2011 1917JUN942/2
Air Conditioning Circuit Operational Information

The following conditions must exist for air conditioning circuit to function: Key switch ON Machine running Air conditioning switch turned ON Blower switch turned to low, medium or high.
9031 05 3
TX,9031,QQ1840 1917JUN941/1
TM1496 (21SEP05)

092105
PN=589
Theory Of Operation
Air Conditioning Circuit Theory Of Operation

Power from 30 amp heater fuse flows through P16 red and 518 red wires to blower switch. With blower switch turned to low, medium or high position, power flows to blower resistor and then to heater blower motors. Power also flows from C terminal of blower switch, through 522 white wire to clutch cycle switch, through 517 dark blue wire to air conditioning switch. With air conditioning switch turned ON, power flows through A17 orange wire to the low pressure switch. With low pressure switch closed, power flows through A18 green wire to high pressure switch. With high pressure switch closed power flows through A19 green wire to the coil terminal of the compressor coil to energize the compressor clutch. Low Pressure Switch The low pressure switch will open if the air conditioning system loses its refrigerant charge. The switch opens to stop current flow to the compressor which prevents compressor engagement. The low pressure switch is located near the compressor in high pressure line. The clutch cycle switch receives power from the blower switch when blower switch is turned to low, medium or high position. High Pressure Switch The high pressure switch protects the system from high pressure. If a malfunction or line restriction causes the high pressure to increase above the setting of the switch, the switch will open to stop current flow to the compressor clutch. The high pressure switch is located near the compressor in the high pressure line. Clutch Cycle Switch The clutch cycle switch is used to sense the temperature in the evaporator core. When the temperature drops, the clutch cycle switch opens, shutting the compressor off. When the temperature in the evaporator core raises, the clutch cycle switch closes sending voltage to the compressor.
9031 05 4
TX,9031,DY357 1930MAY961/1
TM1496 (21SEP05)

092105
PN=590
Theory Of Operation
Air Conditioning Circuit Schematic
9031 05 5
TX,90310,QQ1842 1917JUN941/1
TM1496 (21SEP05)

092105
PN=591
T7835AU
1924SEP92
Theory Of Operation
Blower Circuit Operational Information

The following conditions must exist for blower circuit to function: Key switch in ON or ACC position Blower switch turned ON
TX,9015,QQ1818 1917JUN941/1
Blower Circuit Theory Of Operation

Power from heater circuit breaker goes to blower switch. With blower switch in low position power is sent to blower resistor. Voltage goes through complete resistor and is reduced to 3.03.5 volts, blower motor runs in low speed. With blower switch in medium position power is sent through half the blower resistor and is reduced to 6.06.5 volts, blower motor runs in medium speed. With blower switch in high position power by-passes resistor and 12 volts is applied to blower motor, causing it to run at high speed.
9031 05 6
TX,9015,QQ1766 1917JUN941/1
TM1496 (21SEP05)

092105
PN=592
Theory Of Operation
Blower Circuit Schematic
9031 05 7
TX,901515,QQ809 1917JUN941/1
TM1496 (21SEP05)

092105
PN=593
T7857AD
1930SEP92
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. 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 procedures, or particles caused by corrosion of metal parts due to moisture and acids in the system (also caused by improper service procedures). Desiccant is used to absorb moisture. If too much moisture gets into the system, the desiccant may not be able to absorb it all. When moisture is combined with refrigerant oil, a sludge is formed. This sludge does not permit moving parts to be adequately lubricated. When moisture is combined with refrigerant, hydrofluoric and hydrochloric acids are formed. These acids are very corrosive to metal surfaces and leakage will eventually develop. If the air conditioning system is left open for a period of time or if the plugs are removed from the receiver/dryer, the desiccant will also absorb moisture from the air. The receiver/dryer contains a color moisture indicator. (Blue) indicates dryer is dry. (Pink) indicates moisture in the desiccant. Evacuating the system will not remove moisture from the desiccant. You must replace the receiver/dryer.
UN19OCT93
AInlet Port BSight Glass COutlet Port DPickup Tube EFilter FDesiccant GStrainer HSpring IReceiver/Dryer JWet/Dry Indicator
TX,9031,QQ2341 1917JUN941/2
TM1496 (21SEP05)

092105
PN=594
T8104AF
UN10JAN94
9031 05 8
T8104AE
Theory Of Operation
A sight glass is installed in the receiver/dryer outlet port. If the refrigerant level is low, a steady stream of gas bubbles will be present in the liquid flowing from the receiver/dryer. These gas bubbles can be seen in the sight glass and are an indication that the system needs charging. However, bubbles may be present when the compressor clutch first engages but must disappear after a few seconds. If the sight glass is clear, the system either has a sufficient charge or is completely discharged.
TX,9031,QQ2341 1917JUN942/2
9031 05 9
TM1496 (21SEP05)

092105
PN=595
Theory Of Operation
Expansion Valve Operation
AValve Diaphragm BSealed Sensing Bulb COutlet to Compressor 9031 05 10
DOperating Pin EInlet Flow FMetering Orifice
GValve Spring HBall Seat IOutlet to Evaporator
JDischarge from Evaporator KInternal Equalization Passage
The expansion valve is used to regulate the amount of refrigerant flowing into the evaporator. At this point in the system, the high pressure/high temperature liquid is sprayed into the evaporator where it changes state and becomes a gas. The valve diaphragm (A) is activated by sensing temperature and pressure within the valve body. The sealed sensing bulb (B) senses the evaporator outlet (I) or discharge temperature and pressure of the refrigerant as it passes through the valve back to the low pressure or suction side of the compressor.
The metering orifice (F) and ball seat area (H) in the expansion valve is relatively small. The rapidly expanding refrigerant passing through this area can cause any moisture in the system to freeze at this point and block refrigerant flow. Other contaminants in the system can also cause a valve to malfunction. If expansion valve malfunctions, it must be replaced. Expansion valve is not repairable.
TX,9031,QQ2012 1917JUN941/1
TM1496 (21SEP05)

092105
PN=596
T7828AY
1924SEP92
Theory Of Operation
Compressor Relief Valve Operation

The compressor relief valve is a direct acting pressure limiting valve. If a malfunction in the system occurs that would cause high pressure, such as a restricted line, the valve will open near 4137 kPa (41.4 bar) (600 psi) and remain open until pressure drops to below the valve setting. If the relief valve opens, a loud popping noise will be heard. Some oil may also be lost from the system. Correct any condition that would cause the valve to open.
TX,9031,QQ1879 1917JUN941/1
Temperature Control
Temperature control is adjusted by the position of the heater temperature switch in the cab. This switch is mechanically connected to the water valve at the base of the heater core. Turning the heater temperature switch towards maximum and/or towards off opens and closes the water valve controlling engine coolant flow through the heater core, thus controlling the temperature inside the cab. In certain conditions when the air conditioning switch is turned on and the blower switch is in low position, the cab temperature may still be too cool. It may be necessary to blend heat with cooling to get a comfortable cab temperature.
9031 05 11
TX,903105,QQ775 1917JUN941/1
TM1496 (21SEP05)

092105
PN=597
Theory Of Operation
9031 05 12
TM1496 (21SEP05)

092105
PN=598
Group 10

Air Conditioning Operational Checks
This procedure is designed so the mechanic can make a quick check of the system using a minimum amount of diagnostic equipment. If you need additional information, read Theory of Operation (Group 9031-05). The engine or other major components must be at operating temperature for some checks. Locate system check in the left column and read completely, following this sequence from left to right. Read each check completely before performing. At the end of each check, if no problem is found, that check is complete. When a problem is indicated, additional checks or repair information will be given.T.M. Group or CTM number required for repair will be given. If verification is needed, you will be given next best source of information: Group: 10 (System Operational Checks) Group: 15 (Diagnostic Information) Group: 20 (Adjustments) Group: 25 (Tests) CTM (Component Technical Manual)
TX,9031,QQ1862 1917JUN941/1
1 Visual Inspection Of Components
1/1
9031 10 1
All Lines And Hoses
Engine OFF. Inspect all lines and hoses. Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts or weather checked? Are hose and line connections clean NOT showing signs of leakage, such as oil or dust accumulation at fittings? 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?
YES: Check Complete. NO: Reposition hoses or lines and tighten or replace clamps. Tighten fittings or replace O-rings in fittings. Replace hoses or lines as required.
1/1
TM1496 (21SEP05)

092105
PN=599

Air Conditioner Compressor Check Inspect compressor. Is compressor drive belt tight? Is belt in good condition, NOT frayed, worn or glazed? Is compressor belt pulley in good condition, NOT worn or grooved?
T6488GD UN02SEP93
YES: Check complete. NO: Repair or replace components as required.
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. Inspect condenser cores. Is condenser core free of dirt or debris? Does condenser show signs of leakage, dust accumulation or oily areas? Are condenser fins straight, not bent or damaged? Inspect engine fan. Are fan blades in good condition, not worn, bent, broken or missing?
YES: Check complete. NO: Clean, repair or replace condenser core. Replace engine fan.
9031 10 2 Evaporator Core Check Engine OFF. Inspect core. Are fins straight? Is evaporator core free of dirt and debris?
1/1
YES: Check complete. NO: Repair, replace or clean evaporator.
1/1
TM1496 (21SEP05)

092105
PN=600

Clutch Cycle Switch Sensing Tube Check Engine OFF. Inspect clutch cycle switch sensing tube. Is sensing tube straight, NOT kinked or broken? Is sensing tube inserted into evaporator core and secured in place? YES: Check complete. NO: If sensing tube is kinked, replace clutch cycle switch . NO: If tube is positioned in evaporator incorrectly, re-route.
1/1
Air Conditioner Compressor Check
Engine OFF. Inspect compressor. Is compressor drive belt tight? Is belt in good condition? Is belt tightening strap straight? Is compressor belt pulley in good condition (NOT grooved)? Are compressor to bracket and bracket to engine mounting cap screws tight? Is compressor pulley aligned with engine pulley? Are electrical connections to compressor clutch clean and tight? Is wiring to compressor in good condition?
YES: Go to next check. NO: Repair or replace components as required.
1/1
9031 10 3
Cab Door And Window Seals Check
Open and close door and windows. Inspect seals. Do door and windows contact seals evenly? Are seals in position and in good condition?
YES: Check complete. NO: Adjust door and windows to close against seals properly. Replace seals as necessary.
1/1
2 System Operating Checks
1/1
TM1496 (21SEP05)

092105
PN=601

Blower Motor Check YES: Check complete. NO: See Circuit Checks in Group 9031-10. Check wiring harness.
T7828AW 1930SEP92
Engine OFF. Key switch ON. Turn blower switch (A) to LOW, MEDIUM and HIGH. Does fan have three speeds? Does air exit from ducts?
1/1
Heater
YES: Check complete. NO: See Circuit Checks in Group 9031-10. Check wiring harness.
T7835AW 1930SEP92
Start engine and allow to warm several minutes. 9031 10 4 Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high speed. Does warm air exit from ducts?
1/1
TM1496 (21SEP05)

092105
PN=602

Air Conditioner (If Equipped) YES: Check complete. NO: See Blower/Air Conditioning Circuit Checks in Group 9031-10. See Charging the system in Group 9031-20.
T7835AX 1930SEP92
Start engine and run at fast idle. Turn air conditioner switch (A) to ON position. Turn blower switch (B) to high speed. Wait for any warm air in duct system to dissipate. Is air from ducts cool?
1/1
Compressor Clutch Check
Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner switch ON. Does compressor clutch click as switch is pushed?
YES: Check complete. NO: Replace compressor clutch.
1/1
3 System Performance Checks
1/1
9031 10 5
Expansion Valve Check
Is expansion valve outlet line free of frost? Is insulating tape wound tightly around outlet line and is tape in good condition?
YES: Check complete. NO: Go to Expansion Valve Operation in Group 9031-05.

1/1
Evaporator Check
Remove seat and heater/blower cover. Is ice forming on evaporator core? Is fan motor failing or fan blades damaged? Is clutch cycle sensing tube properly positioned? Is heater temperature balance control misadjusted or damaged? Is evaporator drain tubes plugged?
YES: Check complete. NO: Go to Clutch Cycle Switch Bench Test in Group 9031-25
1/1
TM1496 (21SEP05)

092105
PN=603

4 Blower/Air Conditioning Circuit Checks
1/1
Blower Switch
Disconnect harness from blower switch. Using a multimeter check for continuity. Move blower switch to LOW, MEDIUM and HIGH checking terminals B to L and C, B to M and C and B to H and C.
T7199CL UN17SEP90
YES: Blower switch is good. Go to next check. NO: Replace blower switch.
1/1
Blower Resister
Measure ohms between terminals 3 and 1. Does ohmmeter read 1.0 ohms?
YES: Resistor is good. Check wiring harness. NO: Replace resistor
Measure ohms between terminals 3 and 2. Does ohmmeter read 0.5 ohms?
T6534CR UN19OCT88
9031 10 6 Heater/Blower Motor Check Disconnect harness from heater blower motor. Connect 12 volts to heater blower motor, and ground motor. Does heater blower motor operate?
1/1
YES: Heater blower motor is good. Check wiring harness. NO: Replace heater blower motor.
T7199CM UN16AUG90
1/1
TM1496 (21SEP05)

092105
PN=604

Clutch Cycle Switch With clutch cycle switch at room temperature. Disconnect harness from switch. Measure continuity across switch terminals. Is continuity measured?
T7835AV 1924SEP92
YES: Do Clutch Cycle Switch Test. See Group 9031-25. If Switch is OK. Check wiring harness. NO: Switch has failed. Replace switch.
1/1
Air Conditioning Switch
Disconnect harness from air conditioning switch. Turn switch ON, and measure for continuity between terminals 1 and 5. Is continuity measured?
YES: A/C switch is good. Check wiring harness. NO: Replace A/C switch.
T7199DE UN02OCT90
1/1
Air Conditioner Low Pressure Switch Check
Disconnect harness from switch. Check for continuity between outer terminals. Is continuity measured?
YES: Replace switch. NO: Continue with this check. 9031 10 7
T8093AB UN05OCT93
Remove switch from system. (The line that attaches the low pressure switch has a valve to prevent discharging the air conditioning system when switch is removed.) Does ohmmeter read open?
YES: Switch is good. Check wiring harness. NO: Go to Low Pressure Switch Test, Group 9031-25.
1/1
TM1496 (21SEP05)

092105
PN=605

Air Conditioner High Pressure Switch Check Disconnect harness from switch. Measure continuity across outer switch terminals. NO: Replace switch. Does ohmmeter read continuity? YES: Continue with this check.
T8093AD UN05OCT93
Remove switch from system. (The line that attaches the high pressure switch has a valve to prevent discharging the air conditioning system when switch is removed.) Measure continuity across switch terminals. Does ohmmeter read continuity?
YES: Switch is good. Check wiring harness. NO: System pressure is too high. Go to Air Conditioning Pressure Diagnostic Chart, Group 9031-25.
1/1
Air Conditioning Compressor Clutch Coil
Disconnect harness from clutch. Connect battery voltage to clutch terminal that has orange wire. Ground black wire terminal. Does Clutch click?
YES: A/C compressor clutch coil is good. Check wiring harness. NO: Replace clutch coil.
T6534CV UN19OCT88
9031 10 8
1/1
TM1496 (21SEP05)

092105
PN=606
Group 15
Diagnose Air Conditioning Electrical Malfunctions
NOTE: Diagnostic charts are arranged from most probable and simplest to verify, to least likely more difficult to verify. Remember the following steps when diagnosing a problem:
Step 1. Operational Check Out Procedure Step 2. Diagnostic Charts Step 3. Adjustments and/or Tests
Air Conditioning System Does Not Operate
Circuit Breaker
Replace circuit breaker.
Blower switch
See Blower/Air Conditioning Circuit Checks, Group 9031-10. See Blower/Air Conditioning Circuit Checks, Group 9031-10. See Blower/Air Conditioning Circuit Checks, Group 9031-10. See Blower/Air Conditioning Circuit Checks, Group 9031-10. See Blower/Air Conditioning Circuit Checks, Group 9031-10. See Blower/Air Conditioning Circuit Checks, Group 9031-10. See Blower/Air Conditioning Circuit Checks, Group 9031-10. See Blower/Air Conditioning Circuit Checks, Group 9031-10. Check wiring harness. (See Group 9015-10.)
9031 15 1
Blower resistor
Heater/blower motor
Clutch cycle switch
Air conditioning switch
Low pressure switch
High pressure switch
Compressor clutch coil
Wiring harness
TX,9031,QQ2003 1917JUN941/1
TM1496 (21SEP05)

092105
PN=607
Air Conditioning Component Location

T8234AE 1920FEB99
TX,9031,QQ2606 1917JUN941/2
TM1496 (21SEP05)

092105
PN=608
A30 AMP Heater/A.C. Circuit Breaker BHeater Temperature Switch (S22) CBlower Switch (S8) DGround at Cab Floor EBlower Harness (W10) FHeater Blower Motor (M7) GHeater Blower Motor (M6) HBlower Resistor (R1) IEvaporator JClutch cycle switch (S26) KReceiver Dryer LCondenser MCompressor R12/R134a (Y10) NHigh Pressure Switch (S24) OLow Pressure Switch (S23) PAir Conditioning Compressor Harness (W11) QBlower Harness to Side console Harness Connector (X35) RAir Conditioning Switch (S25) SExpansion Valve TLow Pressure Test Port UHigh Pressure Relief Valve VHigh Pressure Quick Disconnect
NOTE: For electrical call-outs in parenthesis, see Wiring and Schematic Diagrams Legend in Group 9015-10.
TX,9031,QQ2606 1917JUN942/2
9031 15 3
TM1496 (21SEP05)

092105
PN=609
9031 15 4
TM1496 (21SEP05)

092105
PN=610
Group 20
Adjustments
TX,9031,QQ2009 1919AUG941/1

9031 20 1
TX,9031,QQ2010 1917JUN941/1
TM1496 (21SEP05)

092105
PN=611
Adjustments
R12 Component Air Charge

IMPORTANT: The compressor takes a special 525 viscosity oil R49856 that has special additives which give better compressor life. If complete system was flushed to remove contamination, the full charge of oil 326 mL (11 fl oz) must be added to the system. 5. When installing a compressor that has been disassembled and reassembled with no oil charge, add an extra 30 mL (1 fl oz) to the amounts specified in steps 2, 3 or 4. 6. When installing a new or remanufactured compressor, drain the oil. Replace with new oil per steps 2, 3 or 4. 7. If components of the system were drained and flushed, add 330 mL (11 fl oz) to the compressor. 8. After adding proper amount of oil, rotate the compressor shaft four or five times to insure proper lubrication of the compressor seal. IMPORTANT: DO NOT add any more oil than necessary or maximum cooling will be reduced. 9. When servicing individual components, determine the oil charge needed using following chart:
Component Condenser Evaporator Receiver/Dryer Oil Charge 59 mL (2 fl oz) 118 mL (4 fl oz) 15 mL (0.4 fl oz)
NOTE: Dispose oil drained from compressor in accordance with Federal, State and Local regulations. Do not reuse oil drained from the system. Always add NEW oil to the system.
1. Remove compressor. Drain the oil from the suction port and record amount of oil. 2. If 90240 mL (38 fl oz) was drained from the original compressor, add 180 mL (6 fl oz) of new oil back into the compressor. 3. If more than 240 mL (8 fl oz) was drained from the original compressor, add 180 mL (6 fl oz) of new oil back into the compressor. Replace receiver/dryer to remove excess oil from the system. 4. If less than 90 mL (3 fl oz) was drained from the original compressor, flush all components of the system. Replace the receiver/dryer and add 330 mL (11 fl oz) of new oil back into the system.
9031 20 2
TX,9031,QQ2081 1912SEP951/1
TM1496 (21SEP05)

092105
PN=612
Adjustments
R12 Refrigerant Recovery, Recycling Station Installation Procedure

ESSENTIAL TOOLS JT02020 R12 Refrigerant Recovery and Recycling Stationa
a
JT02021 recovery/recycling station can be substituted for the JT02020 station.
NOTE: JT02021 recovery/recycling station can be substituted for the JT02020 station.
CAUTION: Do not remove high pressure relief valve (H). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Close both high and low pressure valves on gauge assembly (D). 2. Remove cap from low pressure test port (G). 3. Connect (C) low pressure hose blue from refrigerant recovery, recycling station (F) to low pressure test port (G) on compressor. 4. Remove high pressure switch (A) and connect high pressure red hose (B) from refrigerant recovery, recycling station. 5. Follow the manufactures instructions when using the refrigerant recovery, recycling station.
UN25FEB93
AHigh Pressure Switch BRed Hose (High Pressure) CBlue Hose (Low Pressure) DGauge Assembly EYellow Hose FRecovery/Recycling Station GLow Pressure Test Port HHigh Pressure Relief Valve
T7938AI
9031 20 3
TX,9031,QQ2013 1917JUN941/1
TM1496 (21SEP05)

092105
PN=613
Adjustments
R12 Refrigerant Evacuation And Charging Station Installation Procedure

ESSENTIAL TOOLS JT02023 R12 Refrigerant Charging and Evacuation Station
CAUTION: Do not remove high pressure relief valve (H). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Close both high and low pressure valves on gauge assembly (D). 2. Remove cap from low pressure test port (G). 3. Connect (C) low pressure hose blue from refrigerant recovery, recycling station (F) to low pressure test port (G) on compressor. 4. Remove high pressure switch (A) and connect high pressure red hose (B) from refrigerant charging and evacuation station. 5. Follow the manufactures instructions when using the refrigerant evacuation and charging station.
9031 20 4
UN25FEB93
TX,9031,QQ2014 1917JUN941/1
TM1496 (21SEP05)

092105
PN=614
T7938AJ
Adjustments
Recover R12 System

ESSENTIAL TOOLS JT02020 R12 Refrigerant Recovery and Recycling Station
NOTE: JT02020 recovery and recycling station can be substituted for the JT02021 station.
CAUTION: Do not remove high pressure relief valve (H). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.
2. Follow the manufactures instructions when using the refrigerant recovery and recycling station.
T7938AI
1. Connect refrigerant recovery and recycling station. (See installation procedure in this group.)
UN25FEB93
NOTE: Run the air conditioning system for three minutes to help in the recovery process. Turn air conditioning system off before proceeding with recovery steps.
9031 20 5
TX,9031,QQ2016 1917JUN941/1
TM1496 (21SEP05)

092105
PN=615
Adjustments
Evacuate R12 System

SPECIFICATIONS Vacuum Pressure 98 kPa (980 mbar) (29 in. Hg) minus 3.4 kPa (34 mbar) (1 in. Hg) for each 300 m (1000 ft) elevation above sea level ESSENTIAL TOOLS JT02023 R12 Refrigerant Charging and Evacuation Station
CAUTION: Do not remove high pressure relief valve (H). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. Do not run compressor while evacuating. 1. Connect refrigerant charging and evacuation station. (See installation procedure in this group.) 2. Open low and high pressure valves on refrigerant charging and evacuation station. 3. Follow the manufactures instructions and evacuate the system.
9031 20 6
UN25FEB93
4. Evacuate system until low pressure gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum.
Specification VacuumPressure.................................... 98 kPa (980 mbar) (29 in. Hg) minus 3.4 kPa (34 mbar) (1 in. Hg) for each 300 m (1000 ft) elevation above sea level
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.
TX,9031,QQ2017 1917JUN941/2
TM1496 (21SEP05)

092105
PN=616
T7938AJ
Adjustments NOTE: The vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low and high pressure valves. Turn vacuum pump off. 6. If the vacuum decreases more than 3.4 kPa (34 mbar) (1 in. Hg) in 5 minutes, there is a leak in the system. 7. Repair leak. 8. Start to evacuate. 9. Open low and high pressure valves. 10. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 11. Close low and high pressure valves. Stop evacuation. 12. Charge the system. (See procedure in this group.)
TX,9031,QQ2017 1917JUN942/2
9031 20 7
TM1496 (21SEP05)

092105
PN=617
Adjustments
Charge R12 System

SPECIFICATIONS Air Conditioning System Refrigerant Charge 2.3 Kg (5 lbs)
ESSENTIAL TOOLS JT02023 R12 Refrigerant Charging and Evacuation Station
CAUTION: Do not remove high pressure relief valve (H). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Connect refrigerant charging and evacuation station. (See installation procedure in this group.) 2. Evacuate the system. (See Evacuate Air Conditioning System, this group.)
NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
9031 20 8
3. Follow the manufacturers instructions and charge the system. 4. Add refrigerant until system is charged with 2.3 Kg (5 lbs).
Specification Air Conditioning System Refrigerant Charge ............................................................... 2.3 Kg (5 lbs)
5. Do air conditioner checks and tests in Groups 9031-10 and 9031-25.
TX,9031,QQ2027 1917JUN941/1
TM1496 (21SEP05)

092105
PN=618
T7938AJ
UN25FEB93
Adjustments
R134A Compressor Oil Charge Check

OTHER MATERIAL TY16134 U.S. Air Conditioning Flushing Solvent TY22025 U.S. Refrigerant Oil
2. Remove, clean, but do not disassemble the valve. 3. Flush the complete system with TY16134 air conditioning flushing solvent. 4. If the compressor is serviceable, pour flushing solvent in the manifold ports and internally wash out the old oil. 5. Install a new receiver-dryer. 6. Install required amount of TY22025 refrigerant oil in the compressor. (See R134a Component Oil Charge in this group.) 7. Connect all components, evacuate and charge the system.
Remove compressor if R134a leakage was detected and repaired. See Remove and install Compressor in Repair Manual. Drain oil from the compressor and record the amount. See Compressor Oil Removal procedure in this group.
NOTE: Drain oil and save if this is a new compressor.

If the oil drained from a compressor removed from operation is very black or the amount of oil is less than 6 mL (0.2 fl oz), perform the following: 1. Remove and discard the receiver-dryer.
TX,9031,QQ2366 1907MAR951/1
R134A Compressor Oil Removal

1. Remove compressor from machine. See Remove and Install Compressor in Repair Manual. 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.
9031 20 9
TX,9015,QQ2299 1917JUN941/1
TM1496 (21SEP05)

092105
PN=619
Adjustments
R134A Component Oil Charge

CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. Compressors can be divided into three categories when determining the correct oil charge for the system. New compressor from parts depot Used compressor removed from operation Compressor internally washed with flushing solvent Determining the amount of system oil charge prior to installation of compressor on a machine. 1. When the complete system, lines, and components were flushed add the correct amount of oil as described. New compressor from parts depot contains the amount of new oil of 230 20 mL (7.7 .7 fl oz). System requires an additional amount of new oil of 100 mL (3.4 fl oz) of new oil. Used compressor removed from operation, oil drained, and flushed requires 330 20 mL (11.1 .7 fl oz) of new oil. 2. When the complete system was not flushed add the correct amount of oil for the compressor plus amount of oil for each component that was serviced. New compressor from parts depot, drain and return 45 mL (1.5 fl oz) of oil to the compressor. (See Compressor Oil Removal procedure in this group) Used compressor removed from operation and oil drained, (See Compressor Oil Removal procedure in this group.) Add 45 mL (1.5 fl oz) of new oil. Used compressor removed from operation, oil drained, and flushed add 60 mL (2.0 fl oz) of new oil.
NOTE: Components listed below which have been removed, drained or flushed, require the removal of the compressor to determine the correct oil charge. Use the following chart as a guide for adding oil to components:
Evaporator Condenser Receiver-Dryer Hoses 130 mL (4.4 fl oz) 65 mL (2.2 fl oz) 30 mL (1.0 fl oz) 60 mL (2.0 fl oz)
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft). Approximate total length equals 600 cm (20 ft).
If any section of hose is removed and flushed or replaced, measure the length of hose and use the formula to determine the correct amount of oil to be added. CAUTION: DO NOT leave the system or R134a compressor oil containers open. This oil easily absorbs moisture. DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils.
9031 20 10
TX,9015,QQ2300 1917JUN941/1
TM1496 (21SEP05)

092105
PN=620
Adjustments
R134A Refrigerant Recovery, Recycling And Charging Station Installation Procedure

ESSENTIAL TOOLS JT02047 R134a Refrigerant Recovery/Recycling and Charging Station
NOTE: JT02046 and JT02050 recovery and charging stations can be substituted for the JT02047 station.
CAUTION: Do not remove high pressure relief valve (B). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Close both high and low pressure valves on refrigerant recovery, recycling and charging station (J). 2. Remove cap from low pressure test port (A). 3. Connect low pressure blue hose (I) from refrigerant recovery, recycling and charging station (J) to low pressure test port (A) on compressor. 4. Connect high pressure red hose (G) to high pressure quick disconnect (F). 5. Follow the manufactures instructions when using the refrigerant recovery, recycling and charging station.
UN01MAR94
ALow Pressure Test Port BHigh Pressure Relief Valve CLow Pressure Hose DLow Pressure Switch EHigh Pressure Switch FHigh Pressure Quick-Disconnect GRed Hose HHigh Pressure Hose IBlue Hose JRefrigerant Recovery/Recycling and Charging Station
T8178AH
9031 20 11
TX,9031,QQ2607 1917JUN941/1
TM1496 (21SEP05)

092105
PN=621
Adjustments
Recover R134A System

CAUTION: Do not remove high pressure relief valve (B). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.
2. Follow the manufactures instructions when using the refrigerant recovery, recycling and charging station.
9031 20 12
TX,9031,QQ2608 1925OCT951/1
TM1496 (21SEP05)

092105
PN=622
T8178AH
1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.)
UN01MAR94
NOTE: Run the air conditioning system for three minutes to help in the recovery process. Turn air conditioning system off before proceeding with recovery steps.
Adjustments
Evacuate R134A System

CAUTION: Do not remove high pressure relief valve (B). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. Do not run compressor while evacuating. 1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.) 2. Open low and high pressure valves on refrigerant recovery, recycling and charging station. 3. Follow the manufactures instructions and evacuate the system. 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.
ALow Pressure Test Port BHigh Pressure Relief Valve CLow Pressure Hose DLow Pressure Switch EHigh Pressure Switch FHigh Pressure Quick-Disconnect GRed Hose HHigh Pressure Hose IBlue Hose JRefrigerant Recovery/Recycling and Charging station
T8178AH
UN01MAR94
9031 20 13
NOTE: The vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
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.
TX,9031,QQ2609 1925OCT951/2
TM1496 (21SEP05)

092105
PN=623
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,QQ2609 1925OCT952/2
9031 20 14
TM1496 (21SEP05)

092105
PN=624
Adjustments
Charge R134A System

SPECIFICATIONS System Refrigerant Charge 2.3 Kg (5 lbs)
CAUTION: Do not remove high pressure relief valve (B). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Connect JT02047 R134a refrigerant recovery, recycling and charging station. (See installation procedure in this group.) 2. Evacuate the system. (See Evacuate Air Conditioning System , this group.)
NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
3. Follow the manufacturers instructions and charge the system. 4. Add refrigerant until system is charged with 2.3 Kg (5 lbs).
Specification SystemRefrigerant Charge ............................................... 2.3 Kg (5 lbs)
T8178AH
UN01MAR94
9031 20 15
5. Do air conditioner checks and tests in Groups 9031-10 and 9031-25.
TX,9031,QQ2610 1925OCT951/1
TM1496 (21SEP05)

092105
PN=625
Adjustments
Check And Adjust Compressor Belt Tension

SPECIFICATIONS Belt Deflection 19 mm (0.75 in.) at 400 N (90 lb force)
2. Belt must deflect 19 mm (0.75 in.) at 400 N (90 lb force).

Specification BeltDeflection ................................... 19 mm (0.75 in.) at 400 N (90 lb force)
SERVICE EQUIPMENT AND TOOLS Belt Tension Gauge
IMPORTANT: Never over tighten belt. Over tightening may cause belt cord damage and excessive load on bearings. 1. Run engine for five minutes. Stop the engine, then immediately check tension using a belt tension gauge. Measure strand tension or deflection at a point halfway between pulleys.
If not, allow belt to cool for 810 minutes. IMPORTANT: Force to adjust belt must be applied to front of compressor housing only to prevent damage to compressor. 3. Loosen compressor mounting cap screws. Apply force to front of compressor housing to tighten belt. Tighten cap screws. 4. Repeat Steps 1 and 2 to check belts.
TX,9031,QQ2082 1917JUN941/1
9031 20 16
TM1496 (21SEP05)

092105
PN=626
Group 25
Test
TX,9031,QQ2009 1919AUG941/1

9031 25 1
TX,9031,QQ2010 1917JUN941/1
TM1496 (21SEP05)

092105
PN=627
Test
R134A Air Conditioning System Test

SPECIFICATIONS Engine Speed Air Conditioning Cooling Blower Speed Ambient Temperature Ambient Temperature Ambient Temperature Ambient Temperature Ambient Temperature Ambient Temperature Air Duct Temperature Air Duct Temperature Air Duct Temperature Air Duct Temperature Air Duct Temperature Air Duct Temperature Low Pressure Gauge Pressure Low Pressure Gauge Pressure Low Pressure Gauge Pressure Low Pressure Gauge Pressure Low Pressure Gauge Pressure Low Pressure Gauge Pressure 9031 25 2 High Pressure Gauge Pressure High Pressure Gauge Pressure High Pressure Gauge Pressure High Pressure Gauge Pressure High Pressure Gauge Pressure High Pressure Gauge Pressure 2200 rpm Maximum High 16C (60F) 21C (70F) 27C (80F) 32C (90F) 38C (100F) 43C (110F) 13C (55F) 16C (60F) 18C (65F) 21C (70F) 27C (80F) 29C (85F) 7165 kPa (0.071.6 bar) (1 24 psi) 7180 kPa (0.071.8 bar) (1 26 psi) 7205 kPa (0.072.1 bar) (1 30 psi) 7240 kPa (0.072.4 bar) (1 35 psi) 7280 kPa (0.072.7 bar) (1 40 psi) 7330 kPa (0.073.3 bar) (1 48 psi) 6301095 kPa (611 bar) (90 160 psi) 7851225 kPa (7.612 bar) (110175 psi) 9551410 kPa (9.614.1 bar) (140205 psi) 11451645 kPa (11.416.5 bar) (165240 psi) 13551935 kPa (13.419.3 bar) (195280 psi) 15802275 kPa (15.822.7 bar) (230330 psi)
TX,9031,QQ2358 1919AUG941/4
TM1496 (21SEP05)

092105
PN=628
Test
IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT use refrigerant, hoses, fittings, components or refrigerant oils intended for R12 refrigerant. 1. Connect refrigerant recovery, recycling and charging station.(See installation procedure in this group.) 2. Close both low and high pressure valves on refrigerant recovery, recycling and charging station. 3. Open cab doors and windows.
TX,9031,QQ2358 1919AUG942/4
9031 25 3
TM1496 (21SEP05)

092105
PN=629
Test
4. Connect low pressure blue hose (I) from refrigerant recovery, recycling and charging station (J) to low pressure test port (A) on compressor. 5. Connect high pressure red hose (G) to high Pressure Quick-Disconnect (F) on compressor. 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
9. Turn blower switch to high speed.

Specification BlowerSpeed .................................................................................... High
10. Check sight glass in receiver-dryer. 11. Run unit for at least 5 minutes. 12. Measure air temperature at condenser air inlet and at air ducts in air conditioning unit.
9031 25 4 ALow Pressure Test Port BHigh Pressure Relief Valve CLow Pressure Hose DLow Pressure Switch EHigh Pressure Switch FHigh Pressure Quick-Disconnect GRed Hose HHigh Pressure Hose IBlue Hose JRefrigerant Recovery/Recycling and Charging Station
13. Compare air duct temperature reading to the temperatures shown in the specifications.
Specification AmbientTemperature ........................................................... 16C (60F) Temperature ............................................................................ 21C (70F) Temperature ............................................................................ 27C (80F) Temperature ............................................................................ 32C (90F) Temperature .......................................................................... 38C (100F) Temperature .......................................................................... 43C (110F) Air DuctTemperature............................................................ 13C (55F) Temperature ............................................................................ 16C (60F) Temperature ............................................................................ 18C (65F) Temperature ............................................................................ 21C (70F) Temperature ............................................................................ 27C (80F) Temperature ............................................................................ 29C (85F)
TX,9031,QQ2358 1919AUG943/4
TM1496 (21SEP05)

092105
PN=630
T8178AH
UN01MAR94
Test
14. Observe low and high pressure gauges on refrigerant recovery, recycling and charging station. 15. Compare pressure readings to the pressure shown in specifications.
Specification Low Pressure GaugePressure.................... 7165 kPa (0.071.6 bar) (124 psi) Pressure ......................................................... 7180 kPa (0.071.8 bar) (126 psi) Pressure ......................................................... 7205 kPa (0.072.1 bar) (130 psi) Pressure ......................................................... 7240 kPa (0.072.4 bar) (135 psi) Pressure ......................................................... 7280 kPa (0.072.7 bar) (140 psi) Pressure ......................................................... 7330 kPa (0.073.3 bar) (148 psi) High Pressure GaugePressure ................... 6301095 kPa (611 bar) (90160 psi) Pressure ...................................................... 7851225 kPa (7.612 bar) (110175 psi) Pressure ................................................... 9551410 kPa (9.614.1 bar) (140205 psi) Pressure ............................................... 11451645 kPa (11.416.5 bar) (165240 psi) Pressure ............................................... 13551935 kPa (13.419.3 bar) (195280 psi) Pressure ............................................... 15802275 kPa (15.822.7 bar) (230330 psi)
Use the Operating Pressure Diagnostic Chart in this group to diagnose the malfunction.
9031 25 5
TX,9031,QQ2358 1919AUG944/4
TM1496 (21SEP05)

092105
PN=631
Test
Pressure Diagnostic Chart
9031 25 6
TX,9031,QQ2145 1925FEB941/1
TM1496 (21SEP05)

092105
PN=632
T6609AB
1928FEB89
Test
Low Pressure Switch Test

SPECIFICATIONS Low Pressure Switch (Normally Open) Closes on Increasing Pressure Low Pressure Switch (Normally Open) Opens on Decreasing Pressure 276 20 kPa (2.76 0.2 bar) (40 3 psi) 220 20 kPa (2.2 0.2 bar) (32 3 psi)
SERVICE EQUIPMENT AND TOOLS Regulated Air Supply or Hydraulic Hand Pump Volt-Ohm-Amp Meter
NOTE: Low pressure switch is normally open when removed from machine. When installed the switch becomes closed because of normal system pressure.
1. Turn key switch ON but DO NOT start engine. Turn blower switch ON. Turn temperature control switch to the maximum cooling position. 2. Disconnect and connect low pressure switch at harness connector. Compressor clutch must engage and disengage (click).
NOTE: The line that attaches the low pressure switch has a valve to prevent discharging the air conditioning system when switch is removed.
3. Disconnect harness from switch and remove switch from line. Connect low pressure switch to harness. Compressor clutch must not engage (click). 4. The actual pressure setting of switch can be checked by connecting it to a pressure source such as a regulated air supply or hydraulic hand pump. 5. Switch must not have continuity between terminals (A and C) until pressure increases to switch closing pressure specification.
Specification Low Pressure Switch (Normally Open)Closes on Increasing Pressure ............................................... 276 20 kPa (2.76 0.2 bar) (40 3 psi)
T88001
UN08NOV88
9031 25 7
TX,903125,QQ731 1917JUN941/2
TM1496 (21SEP05)

092105
PN=633
Test
Slowly release pressure. Switch must have continuity until pressure decreases to switch opening pressure specification.
Specification Low Pressure Switch (Normally Open)Opens on Decreasing Pressure ................................................. 220 20 kPa (2.2 0.2 bar) (32 3 psi)
TX,903125,QQ731 1917JUN942/2
High Pressure Switch Test

SPECIFICATIONS High Pressure Switch (Normally Closed) Opens on Increasing Pressure Low Pressure Switch (Normally Closed) Closes on Decreasing Pressure 2410 100 kPa (24.1 1 bar) (350 15 psi) 1516 100 kPa (13.91 1 bar) (220 15 psi)
SERVICE EQUIPMENT AND TOOLS Hydraulic Hand Pump Volt-Ohm-Amp Meter Air Conditioning Gauge Set
9031 25 8
TX,903125,QQ774 1926JAN951/2
TM1496 (21SEP05)

092105
PN=634
Test NOTE: The high pressure switch has a valve under it to prevent discharging the air conditioning system when switch is removed.
UN08NOV88 T88002
1. Remove high pressure switch. 2. Connect a portable pressure source, such as a hydraulic hand pump, to high pressure switch. 3. Switch must have continuity between terminals (A and C) until pressure increases to switch opening pressure specification.
Specification High Pressure Switch (Normally Closed)Opens on Increasing Pressure .................................................... 2410 100 kPa (24.1 1 bar) (350 15 psi)
4. Slowly release pressure. Switch must not have continuity until pressure decreases to switch closing pressure specification.
Specification Low Pressure Switch (Normally Closed)Closes on Decreasing Pressure .................................................. 1516 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. 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 9
TX,903125,QQ774 1926JAN952/2
TM1496 (21SEP05)

092105
PN=635
Test
Clutch Cycle Switch

SPECIFICATIONS Freezer Maximum Test Temperature Clutch Cycle Switch (Normally Closed) Opens as Temperature Drops Clutch Cycle Switch (Normally Closed) Closes as Temperature Rises -0.5C (31F) -0.5C (31F)
4C (39F)
SERVICE EQUIPMENT AND TOOLS Multimeter
1. Remove clutch cycle switch from evaporator. 2. Connect ohmmeter to switch terminals. Switch must be closed at room temperature. 3. Put switch into a freezer (assure freezer temperature is below -0.5C (31F).
Specification FreezerMaximum Test Temperature .......................................................................... -0.5C (31F)
Switch must open, and continuity must not be read.

Specification Clutch Cycle Switch (Normally Closed)Opens as Temperature Drops ..................................................................................... -0.5C (31F) 9031 25 10
4. Remove switch from freezer. Put sensing tube into a glass of warm water. Switch must close, and continuity must be read.
Specification Clutch Cycle Switch (Normally Closed)Closes as Temperature Rises .......................................................................................... 4C (39F)
5. If switch does not open and close during testing, install new switch.
TX,9031,QQ777 1905AUG941/1
TM1496 (21SEP05)

092105
PN=636
Test
Leak Testing
1. Inspect all lines, fittings, and components for oily or dusty spots. When refrigerant leaks from the system, a small amount of oil is carried out with it. 2. A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak. 3. If a leak detector is used, move the leak detector probe under the hoses and around the connections at a rate of 25 mm (1 in.) per second. 4. Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.
TX,9031,QQ1881 1919AUG941/1
Refrigerant Hoses And Tubing Inspection

When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts. Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning. To assist in making leak-proof joints, use a small amount of clean correct viscosity refrigerant oil on all hose and tube connections. Dip O-rings in correct viscosity oil before assembling. IMPORTANT: Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas. DO NOT use hydraulic hoses as replacement hoses in the air conditioning system. Use ONLY certified hose meeting SAE J51B requirements.
TX,9031,QQ1882 1917JUN941/1
9031 25 11
TM1496 (21SEP05)

092105
PN=637
Test
9031 25 12
TM1496 (21SEP05)

092105
PN=638
Index
Page Page
A
Adjustment Loader bucket level indicator. . . . . . . . . .9025-20-1 Park brake . . . . . . . . . . . . . . . . . . . . . . .9020-20-3 Return-to-dig switch . . . . . . . . . . . . . . . .9025-20-1 Adjustments Backhoe valve linkage . . . . . . . . . . . . . .9025-20-5 Loader valve linkage . . . . . . . . . . . . . . . .9025-20-3 Stabilizer valve linkage . . . . . . . . . . . . . .9025-20-7 Air conditioning Charge R12 system . . . . . . . . . . . . . . . .9031-20-8 Charge R134a system . . . . . . . . . . . . .9031-20-15 Circuit checks . . . . . . . . . . . . . . . . . . . . .9031-10-6 Clutch cycle switch test. . . . . . . . . . . . .9031-25-10 Component location . . . . . . . . . . . . . . . .9031-15-2 Compressor belt tension . . . . . . . . . . . .9031-20-16 Compressor oil removal . . . . . . . . . . . . .9031-20-9 Compressor relief valve operation . . . . .9031-05-11 Electrical circuit . . . . . . . . . . . . . . . . . . . .9031-05-3 Evacuate R12 system . . . . . . . . . . . . . . .9031-20-6 Evacuate R134a system . . . . . . . . . . . .9031-20-13 Evacuation/charging R12 system . . .9031-20-4 Expansion valve . . . . . . . . . . . . . . . . . .9031-05-10 High pressure switch test . . . . . . . . . . . .9031-25-8 Hoses and tubing inspection . . . . . . . . .9031-25-11 Leak testing . . . . . . . . . . . . . . . . . . . . .9031-25-11 Low pressure switch test. . . . . . . . . . . . .9031-25-7 Malfunctions . . . . . . . . . . . . . . . . . . . . . .9031-15-1 Operating checks . . . . . . . . . . . . . . . . . .9031-10-3 Performance checks . . . . . . . . . . . . . . . .9031-10-5 Receiver/dryer operation . . . . . . . . .9031-05-8 Recover R12 system. . . . . . . . . . . . . . . .9031-20-5 Recover R134a system. . . . . . . . . . . . .9031-20-12 Recovery/recycling R12 system . . . .9031-20-3 Recovery/recycling/charging R134a . . . . . . . . . . . . . . . . . . . . . . . .9031-20-11 Refrigerant handling . . . . . . 9031-05-1, 9031-20-1, 9031-25-1 Refrigerant (R12/R134a) caution . . 9031-05-1, 9031-20-1, 9031-25-1 R12 Component Oil Charge . . . . . . . . . .9031-20-2 R12 refrigerant operation . . . . . . . . . . . .9031-05-2 System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-2 Temperature control . . . . . . . . . . . . . . .9031-05-11 Visual inspection of components . . . . . . .9031-10-1 Air system Air intake leakage test. . . . . . . . . . . . . . .9010-25-6 Checks . . . . . . . . . . . . . . . . . . . . . . . . . .9010-10-3 Restriction indicator test . . . . . . . . . . . . .9010-25-5 Alternator Belt tension . . . . . . . . . . . . . . . . . . . . . . .9010-20-2 TM1496 (21SEP05)
Alternators Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1
B
Backhoe control valve Swing left . . . . . . . . . . . . . . . . . . . . . . .9025-05-35 Battery Booster . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-9 Electrolyte level. . . . . . . . . . . . . . . . . . . .9015-20-5 Malfunctions . . . . . . . . . . . . . . . . . . . . . .9015-20-4 Operation . . . . . . . . . . . . . . . . . . . . . . . .9015-20-2 Specifications . . . . . . . . . . . . . . . . . . . . .9015-20-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-7 Brake pedals Adjustment . . . . . . . . . . . . . . . . . . . . . . .9020-20-1 Brake system Operation checks . . . . . . . . . . . . . . . . . .9020-10-1 Brake valve Leakage test . . . . . . . . . . . . . . . . . . . . . .9020-25-6 Brakes Bleeding . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-6
C
Cap screw torque . . . . . . . . . . . . . . . . . . . .9000-03-1 Circuit, electrical Reverse alarm . . . . . . . . . . . . . . . . . . .9015-15-56 Component location A.C. compressor harness (W11) . . . . . .9015-10-40 Auxiliary valve harness (W14). . . . . . . .9015-10-42 Blower harness (W10). . . . . . . . . . . . . .9015-10-36 Cab roof harness (W5) . . . . . . . . . . . . .9015-10-19 Cab side console harness (W6) . . . . . .9015-10-28 Engine harness (W8) . . . . . . . . . . . . . .9015-10-34 Floor harness (W6) . . . . . . . . . . . . . . . .9015-10-23 Front console harness (W7) . . . . . . . . .9015-10-31 Radio harness (W12) . . . . . . . . . . . . . .9015-10-38 Coolant Diesel engine . . . . . . . . . . . . . . . . . . . . .9000-04-9 Cooling system Checks . . . . . . . . . . . . . . . . . . . . . . . . . .9010-10-1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-4 Cylinder drift test procedure . . . . . . . . . . .9025-25-43
Indx 1
D
Digital Thermometer Installation . . . . . . . . 9010-25-1, 9020-25-1, 9025-25-1
Index-1 310D, 315D Backhoe Loader Operation and Test 300D,

092105
PN=1
Index
Page
Page
Directional control valve Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-16
E
Electrical Auxiliary valve circuit. . . . . . . . . . . . . . 9015-15-112 Beacon circuit . . . . . . . . . . . . . . . . . . . .9015-15-96 Blower circuit . . . . . . . . . . . 9015-15-72, 9031-05-6 Charging circuit . . . . . . . . . . . . . . . . . . .9015-15-15 Circuit malfunctions. . . . . . . . . . . . . . . . .9015-05-2 Component identification . . . . . . . . . . . . .9015-10-1 Display module circuit . . . . 9015-15-24, 9015-15-26 Dome light circuit . . . . . . . . . . . . . . . . .9015-15-62 Drive and work light circuit . . . . . . . . . .9015-15-75 Fuel shut-off circuit . . . . . . . . . . . . . . . .9015-15-54 Gauge/hour meter circuit . . . . . . . 9015-15-104 Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-6 High resistance circuit . . . . . . . . . . . . . . .9015-05-3 Horn circuit . . . . . . . . . . . . . . . . . . . . . .9015-15-88 Indicator circuit . . . . . . . . . . . . . . . . . . .9015-15-32 Inspection . . . . . . . . . . . . . . . . . . . . . . . .9015-05-1 Logic module bench test . . . . . . . . . . . .9015-20-17 Logic module test in machine . . . . . . . .9015-20-15 Monitor test in machine. . . . . . . . . . . . .9015-20-14 Neutral disconnect circuit . . . . . . . . . . .9015-15-78 Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-4 Power circuit . . . . . . . . . . . . . . . . . . . . . .9015-15-1 Radio circuit . . . . . . . . . . . . . . . . . . . . .9015-15-64 Return-to-dig circuit. . . . . . . . . . . . . . . 9015-15-100 Reverse alarm circuit . . . . . . . . . . . . . .9015-15-57 Schematic diagrams legend . . . . . . . . .9015-10-10 Schematic symbols . . . . . . . . . . . . . . . .9015-05-15 Shorted circuit. . . . . . . . . . . . . . . . . . . . .9015-05-8 Side shift valve . . . . . . . . . . . . . . . . . . 9015-15-110 Start aid circuit . . . . . . . . . . . . . . . . . . .9015-15-47 Start circuit . . . . . . . . . . . . . . . . . . . . . . .9015-15-8 System functional schematic . . . . . . . . .9015-10-10 System functional schematic reading . .9015-05-13 Tachometer calibration . . . . . . . . . . . . .9015-20-18 Test equipment . . . . . . . . . . . . . . . . . . . .9015-05-9 Test procedure . . . . . . . . . . . . . . . . . . .9015-05-10 Turn/flasher/brake light circuit. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-90 Wiper/washer circuit . . . . . . . . . . . .9015-15-68 Wiring diagram information . . . . . . . . . .9015-05-12 Wiring diagram, reading . . . . . . . . . . . .9015-05-14 Wiring/schematic diagrams legend . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-4 Engine Diagnose malfunction . . . . . . . . . . . . . . .9010-15-4 TM1496 (21SEP05)
General description . . . . . . . . . . . . . . . . .9010-05-4 Idle adjustment . . . . . . . . . . . . . . . . . . . .9010-20-5 Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-3 Sectional view. . . . . . . . . . . . 9010-05-4, 9010-10-1 Speed and performance check . . . . . . . .9010-10-5 Visual inspection . . . . . . . . . . . . . . . . . . .9010-15-2 Engine speed control Adjust lever tension. . . . . . . . . . . . . . . . .9010-20-3 Adjust linkage . . . . . . . . . . . . . . . . . . . . .9010-20-3 Extendible dipperstick Grease specification . . . . . . . . . . . . . . . .9000-04-7
F
Fuel Specifications . . . . . . . . . . . . . . . . . . . . .9000-04-1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-2 Tank capacity . . . . . . . . . . . . . . . . . . . . .9000-04-2 Fuel system System operational check . . . . . . . . . . . .9010-10-4 Function/Cylinder drift test . . . . . . . . .9025-25-44 Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-3 Specifications . . . . . . . . . . . . . . . . . . . . .9015-10-3
G
Grease Extendible dipperstick . . . . . . . . . . . . . . .9000-04-7 Specification . . . . . . . . . . . . . . . . . . . . . .9000-04-7
Indx 2
H
Hydraulic Fittings, 30° cone seat. . . . . . . . . . .9000-03-6 Fittings, 37° flare . . . . . . . . . . . . . . .9000-03-6 Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-5 Hydraulic filter Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-9 Hydraulic oil cooler Restriction test . . . . . . . . . . . . . . . . . . .9025-25-20 Hydraulic oil warm-up test . . . . . . . . . . . . .9025-25-1 Hydraulic system Checks . . . . . . . . . . . . . . . . . . . . . . . . . .9025-10-2 Diagnose. . . . . . . . . . . . . . . . . . . . . . . . .9025-15-3 Main . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-3 Open-center . . . . . . . . . . . . . . . . . . . . . .9025-05-1 Pretest inspection . . . . . . . . . . . . . . . . . .9025-15-1

092105
PN=2
Index
Page
Page
Pretest system . . . . . . . . . . . . . . . . . . . .9025-15-2
I
Inch torque values . . . . . . . . . . . . . . . . . . .9000-03-2 Injection pump timing . . . . . . . . . . . . . . . .9010-25-12
Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-17 Clutch disconnect solenoid . . . . . . . . . . .9005-10-8 Driving . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-8 Gauge and indicator . . . . . . . . . . . . . . . .9005-10-1 Hydraulic system. . . . . . . . . . . . . . . . . .9005-10-12 Indicators . . . . . . . . . . . . . . . . . . . . . . . .9005-10-4 MFWD . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-10 Miscellaneous . . . . . . . . . . . . . . . . . . . .9005-10-21 Steering system . . . . . . . . . . . . . . . . . . .9005-10-7 Switches . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2
L
Loader control valve Checks . . . . . . . . . . . . . . . . . . . . . . . . . .9025-10-5 Lubricant Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-9 Storage . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-8 Lubrication system Check . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-10-3
P
Park brake Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-3 Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-1 Release pressure test . . . . . . . . . . . . . . .9020-25-7 Priority valve Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-6 Pump Main hydraulic. . . . . . . . . . . . . . . . . . . . .9025-05-5
M
Main hydraulic pump . . . . . . . . . . . . . . . . .9025-05-5 Main hydraulic system . . . . . . . . . . . . . . . .9025-05-3 Main pump Flow test . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-6 MFWD Differential operation . . . . . . . . . . . . . . .9020-05-36 Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-6 Operational checks . . . . . . . . . . . . . . . . .9020-10-5 Transfer case . . . . . . . . . . . . . . . . . . . .9020-05-32 Mixing lubricants. . . . . . . . . . . . . . . . . . . . .9000-04-9
R
Radiator Air flow test. . . . . . . . . . . . . . . . . . . . . . .9010-25-7 Receiver/dryer Operation . . . . . . . . . . . . . . . . . . . . . . . .9031-05-8 Reverser Complete system test . . . . 9020-25-33, 9020-25-34 Converter-in relief valve test . . . . . . . . 9020-25-17, 9020-25-19 Cooler pressure test . . . . . . . . . . . . . . .9020-25-13 Disconnect clutch solenoid . . . . . . . . . .9020-05-14 Disconnect clutch solenoid test . . . . . . . 9020-25-9, 9020-25-11 Forward position . . . . . . . . . . . . . . . . . . .9020-05-7 Leakage test, four-gauge method . . . . 9020-25-25, 9020-25-27 Neutral position . . . . . . . . . . . . . . . . . . . .9020-05-5 Oil cooler restriction test . . . . . . . . . . . 9020-25-21, 9020-25-23 Oil passage identification . . . . . . . . . . . .9020-15-1 Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-5 Oil warm-up procedure . . . . . . . . . . . . . .9020-25-4 Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-2 Operational checks . . . . . . . . . . . . . . . . .9020-10-2 Pump flow. . . . . . . . . . . . . . . . . . . . . . .9020-25-31 Pump flow test . . . . . . . . . . . . . . . . . . .9020-25-29 Reverse position . . . . . . . . . . . . . . . . . . .9020-05-9
O
O-ring boss fittings . . . . . . . . . . . . . . . . . . .9000-03-7 Oil Lines and fittings. . . . . . . . . . . . . . . . . . .9000-03-5 MFWD specification . . . . . . . . . . . . . . . .9000-04-6 Specification engine . . . . . . . . . . . . . . . .9000-04-3 Specification, hydraulic . . . . . . . . . . . . . .9000-04-5 Specification, reverser. . . . . . . . . . . . . . .9000-04-5 Specification, transaxle . . . . . . . . . . . . . .9000-04-4 Oil lines and fittings . . . . . . . . . . . . . . . . . .9000-03-5 Open-center hydraulic system Theory . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-1 Operational checkout procedures . . . . . . . .9005-10-1 Operational checks Accessories . . . . . . . . . . . . . . . . . . . . .9005-10-16 Brake system . . . . . . . . . . . . . . . . . . . . .9005-10-5 TM1496 (21SEP05)
Indx 3

092105
PN=3
Index
Page
Page
Test procedure . . . . . . . . . . . . . . . . . . .9020-25-35
S
Service brake Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-28 Specification Engine oil . . . . . . . . . . . . . . . . . . . . . . . .9000-04-3 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1 Grease . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .9000-04-5 Mechanical front wheel drive oil . . . . . . .9000-04-6 Reverser oil . . . . . . . . . . . . . . . . . . . . . .9000-04-5 Transaxle oil . . . . . . . . . . . . . . . . . . . . . .9000-04-4 Specifications chapter. . . . . . . . . . . . . . . .9000-02-17 Stabilizer valve Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-29 Staring motors Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1 Steering Cylinder Leakage . . . . . . . . . . . .9025-25-41 Steering system Checks . . . . . . . . . . . . . . . . . . . . . . . . . .9025-10-1 Steering System Leakage. . . . . . . . . . . . .9025-25-38 Steering valve Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-11 Storing lubricants . . . . . . . . . . . . . . . . . . . .9000-04-8 System operational check Fuel system . . . . . . . . . . . . . . . . . . . . . .9010-10-4 System operational procedure Hydraulics . . . . . . . . . . . . . . . . . . . . . . . .9025-10-1 Power train . . . . . . . . . . . . . . . . . . . . . . .9020-10-1
Metric four bolt flange fitting . . . . . . . . .9000-03-11 O-Ring boss fitting . . . . . . . . . . . . . . . . .9000-03-7 Wheel cap screw . . . . . . . . . . . . . . . . . .9000-03-1 30° cone seat hydraulic fittings . . . .9000-03-6 37° flare hydraulic fittings . . . . . . . .9000-03-6 Torque values Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-2 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-22 Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-4 Oil warm-up procedure . . . . . . . . . . . . . .9020-25-1 Operational checks . . . . . . . . . . . . . . . . .9020-10-4 Pump flow test . . . . . . . . . . . . . . . . . . . .9020-25-3 Second speed operation . . . . . . . . . . . .9020-05-25 Synchronizer operation . . . . . . . . . . . . .9020-05-27 Third speed operation . . . . . . . . . . . . . .9020-05-26 Turbocharger boost pressure test . . . . . . .9010-25-10
V
Valve Directional control . . . . . . . . . . . . . . . . .9020-05-16 Priority . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-6 Side shift locking. . . . . . . . . . . . . . . . . .9025-05-43 Stabilizer . . . . . . . . . . . . . . . . . . . . . . . .9025-05-29 Steering . . . . . . . . . . . . . . . . . . . . . . . .9025-05-11 Valve leakage test, backhoe or loader . . .9025-25-50
W
Wheel fasteners . . . . . . . . . . . . . . . . . . . . .9000-03-1 Wiring diagram A.C. compressor harness (W11) . . . . . .9015-10-39 Auxiliary valve harness (W14). . . . . . . .9015-10-41 Blower harness (W10). . . . . . . . . . . . . .9015-10-35 Cab roof harness (W5) . . . . . . . . . . . . .9015-10-18 Cab side console harness (W6) . . . . . .9015-10-20 Engine harness (W8) . . . . . . . . . . . . . .9015-10-32 Floor harness (W6) . . . . . . . . . . . . . . . .9015-10-22 Front console harness (W7) . . . . . . . . .9015-10-30 Radio harness (W12) . . . . . . . . . . . . . .9015-10-37
T
Indx 4
Test Transaxle pump flow. . . . . . . . . . . . . . . .9020-25-3 Thermometer Installation, Digital . . . . . . . 9010-25-1, 9020-25-1, 9025-25-1 Time Trac™ Installation. . . . . . . . . . . . . . . . . . . . . . . .9010-25-2 Toe-In Adjustment . . . . . . . . . . . . . . . . . . . . . . .9020-20-8 Torque converter Oil flow . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-20 Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-18 Stall speed test . . . . . . . . . . . . . . . . . . . .9020-25-5 Torque value Flat face O-ring seal fitting . . . . . . . . . . .9000-03-9 Inch SAE four bolt flange fitting. . . . . . .9000-03-10 Metric cap screw. . . . . . . . . . . . . . . . . . .9000-03-3 TM1496 (21SEP05)

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What are the main components covered in the manual?

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300D, 310D, 315D Backhoe Loader Operation and Test

Worldwide Construction And Forestry Division

300D, 310D, 315D Backhoe Loader Operation and Test

300D, 310D, 315D Backhoe Loader Operation and Test

300D, 310D, 315D Backhoe Loader Operation and Test

9000-1 300D, 310D, 315D Backhoe Loader Operation and Test

9000-2 300D, 310D, 315D Backhoe Loader Operation and Test

Prevent Battery Explosions

Prepare for Emergencies

9000-01-1 310D, 315D Backhoe Loader Operation and Test 300D,

Prevent Acid Burns

9000-01-2 310D, 315D Backhoe Loader Operation and Test 300D,

Handle Chemical Products Safely

Avoid High-Pressure Fluids

9000-01-3 310D, 315D Backhoe Loader Operation and Test 300D,

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

9000-01-4 310D, 315D Backhoe Loader Operation and Test 300D,

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

9000-01-5 310D, 315D Backhoe Loader Operation and Test 300D,

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

9000-01-6 310D, 315D Backhoe Loader Operation and Test 300D,

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

9000-01-7 310D, 315D Backhoe Loader Operation and Test 300D,

Service Tires Safely

Avoid Harmful Asbestos Dust

9000-01-8 310D, 315D Backhoe Loader Operation and Test 300D,

Practice Safe Maintenance

Use Proper Tools

9000-01-9 310D, 315D Backhoe Loader Operation and Test 300D,

Dispose of Waste Properly

Live With Safety

9000-01-10 310D, 315D Backhoe Loader Operation and Test 300D,

9000-02-1 310D, 315D Backhoe Loader Operation and Test 300D,

300D Backhoe Loader

9000-02-2 310D, 315D Backhoe Loader Operation and Test 300D,

300D Backhoe Loader (Continued)

Forward mph 3.4 km/h 5.4 3.3

Pump Flow @ 2200 rpm Filter, return oil Tires:

5.7 12.3 22.4

9.2 19.8 36.1

5.6 12.2 22.3

9.0 19.6 35.9

Front With MFWD Rear With MFWD

Continued on next page

9000-02-3 310D, 315D Backhoe Loader Operation and Test 300D,

300D Backhoe Loader Buckets

Loader: General purpose 2340 (92) Multi-purpose

Weight kg (lb) 249 (550)