John Deere 310SE Operation and Test TM1608 PDF

310SE and 315SE
Backhoe Loaders
Operation and Test
TECHNICAL MANUAL
TM1608 20SEP06 (ENGLISH)
For complete service information also see:

310SE and 315SE Backhoe Loader Repair
(Complete) . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM1609
310E and 315SE Backhoe Loader Operation
and Test (Complete) . . . . . . . . . . . . . . . . . . .
TM1608
310SE Backhoe Loader and 315SE Sideshift
Backhoe Loader . . . . . . . . . . . . . . . . . . . . . . OMT184377
POWERTECH 4.5L (4045) and 6.8L (6068)
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTM104
POWERTECH 4.5L & 6.8L Diesel Engines
Mechanical Fuel Systems . . . . . . . . . . . . . . .
CTM207
Alternators and Starting Motors . . . . . . . . . .
CTM77
Front Wheel Drive Axles APL-2025 . . . . . . . CTM4509
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.
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.
Live with safety: Read the safety messages in the

introduction of this manual and the cautions presented
throughout the text of the manual.
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.
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.
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:
Section
Section
Section
Section
Section
Section
Section
9000
9005
9010
9015
9020
9025
9031
General Information
Operational Checkout Procedure
Engine
Electrical System
Power Train
Hydraulics
Air Conditioning
TX,INTR,RR7339 1915FEB001/1
TM1608 (20SEP06)
310SE and 315SE Backhoe Loaders

092006
PN=2
Introduction
John Deere Dealers
IMPORTANT: Please remove this page and route
through your service department.
Listed below is a brief explanation of WHAT was change
and WHY it was changed.
These sectionalize manuals were revised to include the
following changes
1. Section 9000:
To include any specifications, oil capacity and safety
updates.
2. Section 9005:
To include miscellaneous updates.
3. Section 9010:
To include miscellaneous updates.
4. Section 9015:
To include serial number for tachometer, updates for
selective flow control valve harness, timer relay
updates, and miscellaneous updates.
5. Section 9020:
To add keys and legend to foldout pages and control
valves in theory of operation section. To add
miscellaneous updates.
6. Section 9025:
To update cycle times, change ride control accumulator
specifications and miscellaneous updates.
7. Section 9031:
To update miscellaneous nomenclature.
CED,TX03399,5915 1910FEB001/1
TM1608 (20SEP06)

092006
PN=3
Introduction
Technical Information Feedback Form

We need your help to continually improve our technical
publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO:
John Deere Dubuque Works

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538
FAX NUMBER:
563-589-5800
Ideas, Comments (Please State Page Number):
OVERALL, how would you rate the quality of this publication? (Check one)
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Technician Name:
Address:
Phone:
Fax No.:
Dealer Acct. No.:
THANK YOU!
TX,II,FAX 1910JUL011/1
TM1608 (20SEP06)

092006
PN=4
Contents
9000
SECTION 9000General Information

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

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

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

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

Group 20Adjustments
Group 25Tests
9031
SECTION 9031Heating And Air Conditioning

Group 05Theory Of Operation
Group 10System Operational Checks
Group 20Adjustments
Group 25Test
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 2006
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright 1997, 1998, 2000
TM1608 (20SEP06)

092006
PN=1
Contents
9000
9005
9010
9015
9020
9025
9031
INDX
TM1608 (20SEP06)
ii

092006
PN=2
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 . . .9000-01-7
Avoid Heating Near Pressurized Fluid
Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-7
Keep ROPS Installed Properly . . . . . . . . . . .9000-01-8
Service Tires Safely . . . . . . . . . . . . . . . . . . .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
310SE And 315SE Backhoe Loader Lifting

CapacitiesExtendible Dipperstick
(Extended) . . . . . . . . . . . . . . . . . . . . . . . .9000-02-19
Group 02General Specifications

310SE and 315SE Specifications . . . . . . . . .9000-02-1
310SE and 315SE Backhoe Loader
Dimensions . . . . . . . . . . . . . . . . . . . . . . . .9000-02-2
Specifications. . . . . . . . . . . . . . . . . . . . . . .9000-02-9
310SE and 315SE Backhoe LoaderOther
Information. . . . . . . . . . . . . . . . . . . . . . . .9000-02-13
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-14
310SE and 315SE Backhoe and Loader
Buckets . . . . . . . . . . . . . . . . . . . . . . . . . .9000-02-15
310SE and 315SE Backhoe Loader Drain
and Refill Capacities . . . . . . . . . . . . . . . .9000-02-16
CapacitiesStandard Dipperstick . . . . . .9000-02-17
(Retracted). . . . . . . . . . . . . . . . . . . . . . . .9000-02-18
TM1608 (20SEP06)
Group 03Torque Values

Hardware Torque Specifications . . . . . . . . . .9000-03-1
ROPS Torque Specifications . . . . . . . . . . . . .9000-03-1
Metric Bolt and Screw Torque Values . . . . . .9000-03-2
Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-3
Unified Inch Bolt and Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-5
Check Oil Lines And Fittings . . . . . . . . . . . . .9000-03-6
O-Ring Groove Connections . . . . . . . . . . . . .9000-03-7
Service Recommendations For Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .9000-03-8
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .9000-03-9
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . .9000-03-11
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . .9000-03-12
Group 04Fuels and Lubricants
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1
Diesel Engine Coolant. . . . . . . . . . . . . . . . . .9000-04-2
Low Sulfur Diesel Fuel Conditioner . . . . . . . .9000-04-3
Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . .9000-04-4
Do Not Use Galvanized Containers. . . . . . . .9000-04-5
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-5
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . .9000-04-6
Transmission, Axles and Mechanical Front
Wheel Drive Oil . . . . . . . . . . . . . . . . . . . . .9000-04-7
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-8
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-9
Grease For Extendible Dipperstick,
Sideshift Frame, And Stabilizer Leg Wear
Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-9
Alternative and Synthetic Lubricants . . . . . .9000-04-10
Lubricant Storage . . . . . . . . . . . . . . . . . . . .9000-04-10
Mixing of Lubricants . . . . . . . . . . . . . . . . . .9000-04-11
9000-1

092006
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Contents
9000
TM1608 (20SEP06)
9000-2

092006
PN=2
Group 01
Safety Information
9000
01
1
Handle Fluids SafelyAvoid Fires
Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
TS227
Do not store oily rags; they can ignite and burn

spontaneously.
UN23AUG88
When you work around fuel, do not smoke or work near

heaters or other fire hazards.
DX,FLAME 1929SEP981/1
Prevent Battery Explosions
Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.
TS204
Do not charge a frozen battery; it may explode. Warm

battery to 16C (60F).
UN23AUG88
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
DX,SPARKS 1903MAR931/1
Prepare for Emergencies

Be prepared if a fire starts.
TS291
Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.
UN23AUG88
Keep a first aid kit and fire extinguisher handy.
DX,FIRE2 1903MAR931/1
TM1608 (20SEP06)
9000-01-1

092006
PN=9
Safety Information
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:
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
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.
TS203
9000
01
2
DX,POISON 1921APR931/1
TM1608 (20SEP06)
9000-01-2

092006
PN=10
Safety Information
9000
01
3
Handle Chemical Products Safely
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.
TS1132
A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
UN26NOV90
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.
(See your John Deere dealer for MSDSs on chemical

products used with John Deere equipment.)
DX,MSDS,NA 1903MAR931/1
Avoid High-Pressure Fluids
Search for leaks with a piece of cardboard. Protect hands

and body from high pressure fluids.
X9811
Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
UN23AUG88
Escaping fluid under pressure can penetrate the skin

causing serious injury.
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
TM1608 (20SEP06)
9000-01-3

092006
PN=11
Safety Information
Park Machine Safely
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.
TS230
UN24MAY89
Before working on the machine:
DX,PARK 1904JUN901/1
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.
TS229
Always lower the attachment or implement to the ground

before you work on the machine. If the work requires that
the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
UN23AUG88
Support Machine Properly
When implements or attachments are used with a

machine, always follow safety precautions listed in the
implement or attachment operators manual.
DX,LOWER 1924FEB001/1
Wear Protective Clothing
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
while operating machine.
UN23AUG88
Wear close fitting clothing and safety equipment

appropriate to the job.
TS206
9000
01
4
DX,WEAR2 1903MAR931/1
TM1608 (20SEP06)
9000-01-4

092006
PN=12
Safety Information
9000
01
5
Work in Clean Area
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.
T6642EJ
UN18OCT88
Before starting a job:
DX,CLEAN 1904JUN901/1
Service Machines Safely
TS228
Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.
UN23AUG88
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.
DX,LOOSE 1904JUN901/1
Work In Ventilated Area
TS220
If you do not have an exhaust pipe extension, open the

doors and get outside air into the area
UN23AUG88
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.
DX,AIR 1917FEB991/1
TS223
Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
UN23AUG88
Illuminate Work Area Safely
DX,LIGHT 1904JUN901/1
TM1608 (20SEP06)
9000-01-5

092006
PN=13
Safety Information
Replace Safety Signs
TS201
UN23AUG88
Replace missing or damaged safety signs. See the

machine operators manual for correct safety sign
placement.
DX,SIGNS1 1904JUN901/1
Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe
injury or machine damage.
UN23AUG88
Follow recommended procedure for removal and

installation of components in the manual.
TS226
9000
01
6
DX,LIFT 1904JUN901/1
TM1608 (20SEP06)
9000-01-6

092006
PN=14
Safety Information
9000
01
7
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
TS220
Remove paint before heating:
UN23AUG88
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT 1924JUL021/1
TS953
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
accidentally burst when heat goes beyond the immediate
flame area.
UN15MAY90
Avoid Heating Near Pressurized Fluid Lines
DX,TORCH 1910DEC041/1
TM1608 (20SEP06)
9000-01-7

092006
PN=15
Safety Information
Keep ROPS Installed Properly
TS212
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
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.
DX,ROPS3 1903MAR931/1
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.
Check wheels for low pressure, cuts, bubbles, damaged

rims or missing lug bolts and nuts.
UN23AUG88
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.
TS211
9000
01
8
DX,RIM 1924AUG901/1
TM1608 (20SEP06)
9000-01-8

092006
PN=16
Safety Information
9000
01
9
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.
On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or
welding on machine.
TS218
On self-propelled equipment, disconnect battery ground

cable (-) before making adjustments on electrical systems
or welding on machine.
UN23AUG88
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.
DX,SERV 1917FEB991/1
Use Proper Tools
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.
TS779
Use power tools only to loosen threaded parts and

fasteners.
UN08NOV89
Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.
Use only service parts meeting John Deere specifications.
DX,REPAIR 1917FEB991/1
TM1608 (20SEP06)
9000-01-9

092006
PN=17
Safety Information
Dispose of Waste Properly
Do not pour waste onto the ground, down a drain, or into

any water source.
TS1133
Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.
UN26NOV90
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.
Air conditioning refrigerants escaping into the air can

damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN 1903MAR931/1
Live With Safety
1907OCT88
Before returning machine to customer, make sure

machine is functioning properly, especially the safety
systems. Install all guards and shields.
TS231
9000
01
10
DX,LIVE 1925SEP921/1
TM1608 (20SEP06)
9000-01-10

092006
PN=18
Group 02
General Specifications
9000
02
1
T103503
UN10SEP96
310SE and 315SE Specifications
TX,110,BD2218 1908OCT961/1
TM1608 (20SEP06)
9000-02-1

092006
PN=19
9000
02
2

Dimensions
NOTE: Specifications and design subject to change
without notice. Whenever applicable,
specifications are in accordance with SAE
Standards unless otherwise noted, these
specifications are based on a standard machine
with 19.5L-24, 8PR, R4 rear tires; 11L-16, 12PR,
F3 front tires; 0.86 m3 (1.12 cu yd) loader bucket;
610 mm (24 in.) backhoe bucket; ROPS/FOPS;
full fuel tank and 79 kg (175 lb) operator.
Item
Measurement
Specification
Backhoe w/o Ext. Dipperstick
Height
3.43 m (11 ft 3 in.)
Backhoe w/Ext. Dipperstick

Retracted
Height
3.53 m (11 ft 7 in.)

Extended
Height
4.29 m (14 ft 1 in.)
Distance
5.56 m (18 ft 3 in.)

Retracted
Distance
5.66 m (18 ft 7 in.)

Extended
Distance
6.68 m (21 ft 11 in.)
Distance
6.63 m (21 ft 9 in.)

Retracted
Distance
6.73 m (22 ft 1 in.)

Extended
Distance
7.72 m (25 ft 4 in.)
ALoading Height, Truck Loading

Position
BReach from Center of Swing

Mast
CReach from Center of Rear Axle
Continued on next page
TM1608 (20SEP06)
9000-02-2
CED,OUO1040,162 1910JUN981/7

092006
PN=20
Item
9000
02
3
Measurement
Specification
Depth
4.42 m (14 ft 6 in.)

Retracted
Depth
4.55 m (14 ft 11 in.)

Extended
Depth
5.61 m (18 ft 5 in.)
Distance
4.37 m (14 ft 4 in.)

Retracted
Distance
4.50 m (14 ft 9 in.)

Extended
Distance
5.56 m (18 ft 3 in.)
Distance
4.06 m (13 ft 4 in.)

Retracted
Distance
4.19 m (13 ft 9 in.)

Extended
Distance
5.33 m (17 ft 6 in.)
Clearance
330 mm (13 in.)

Retracted
Clearance
330 mm (13 in.)

Extended
Clearance
330 mm (13 in.)
DMaximum Digging Depth
EDigging Depth (SAE)(1) 10 mm

(2 ft) Flat Bottom
FDigging Depth (SAE)(2) 2440

mm (8 ft) Flat Bottom
GGround Clearance Minimum
TM1608 (20SEP06)
9000-02-3
CED,OUO1040,162 1910JUN982/7

092006
PN=21
9000
02
4
Item
Measurement
Specification
Rotation
190

Retracted
Rotation
190

Extended
Rotation
190
Height
3.51 m (11 ft 6 in.)

Retracted
Height
3.48 m (11 ft 5 in.)
Length
7.16 m (23 ft 6 in.)
Width
2.18 m (7 ft 2 in.)
Width
3.10 m (10 ft 2 in.)
Width
3.53 m (11 ft 7 in.)
Width
2.24 m (7 ft 6 in.)
HBucket Rotation
ITransport Height
JOverall Length, Transport

Backhoe
KStabilizer Width, Transport

Backhoe
LStabilizer Spread, Operating

Backhoe
MOverall Width, Stabilizer Spread

(Less Loader Bucket)310SE
Backhoe
MOverall Width, Stabilizer

Spread315SE
Backhoe
TM1608 (20SEP06)
9000-02-4
CED,OUO1040,162 1910JUN983/7

092006
PN=22
Item
9000
02
5
Measurement
Specification
Width
2.18 m (7 ft 2 in.)
NWidth Over Tires

Backhoe
OHeight to Cab/ROPS Top

Backhoe
Height
2.79 m (9 ft 2 in.)
Distance
1.12 m (3 ft 8 in.)
Length
2.10 m (6 ft 10 in.)
Heavy Duty Long Lip 0.86 m3

(1.12 yd3)
Height
3.4 m (11 ft 2 in.)
Heavy Duty Long Lip 1.0 m3 (1.30

yd3)
Height
3.4 m (11 ft 2 in.)
Multipurpose 0.76 m3 (1.00 yd3)
Height
3.4 m (11 ft 2 in.)

(1.12 yd3)
Clearance
2.69 m (8 ft 10 in.)

yd3)
Clearance
2.64 m (8 ft 8 in.)
Clearance
2.62 m (8 ft 7 in.)
PFront Wheel to Loader Dig

Position
Backhoe
QWheelbase
Backhoe
RMaximum Height to Loader

Bucket Hinge Pin
SDump Clearance, Loader Bucket

at 45
TM1608 (20SEP06)
9000-02-5
CED,OUO1040,162 1910JUN984/7

092006
PN=23
9000
02
6
Item
Measurement
Specification

(1.12 yd3)
Angle
45

yd3)
Angle
45
Angle
45

(1.12 yd3)
Distance
767 mm (30.2 in.)

yd3)
Distance
765 mm (30.1 in.)
Distance
818 mm (32.2 in.)

(1.12 yd3)
Angle
40

yd3)
Angle
40
Angle
40

(1.12 yd3)
Depth
163 mm (6.4 in.)

yd3)
Depth
206 mm (8.1 in.)
Depth
185 mm (7.3 in.)
TMaximum Loader Bucket Dump

Angle
UReach at Full Height, Loader

Bucket at 45
VLoader Bucket Rollback at

Ground Level
WDig Below GroundLoader

Bucket Level
TM1608 (20SEP06)
9000-02-6
CED,OUO1040,162 1910JUN985/7

092006
PN=24
Item
9000
02
7
Measurement
Specification
Force
53.3 kN (11,990 lb)

Retracted
Force
54.1 kN (12,158 lb)

Extended
Force
54.1 kN (12,158 lb)
Force
36.0 kN (8090 lb)

Retracted
Force
34.7 kN (7796 lb)

Extended
Force
25.0 kN (5628 lb)
Rotation
180

Retracted
Rotation
180

Extended
Rotation
180
Rotation
190

Retracted
Rotation
190

Extended
Rotation
190
Angle
18
Digging Force, Bucket Cylinder
Digging Force, Crowd Cylinder
Swing Arc
Bucket Rotation
Stabilizer Angle Rearward

TM1608 (20SEP06)
9000-02-7
CED,OUO1040,162 1910JUN986/7

092006
PN=25
9000
02
8
Item
Measurement
Specification

Retracted
Angle
18

Extended
Angle
18
CED,OUO1040,162 1910JUN987/7
TM1608 (20SEP06)
9000-02-8

092006
PN=26
9000
02
9
310SE and 315SE Backhoe LoaderSpecifications

NOTE: Specifications and design subject to change
without notice. Wherever applicable,
Item
specifications are in accordance with

Standards.
Measurement
Specification
Rated Power @ 2200 rpm
Power
SAE gross 66 kW (88 hp)
Rated Power @ 2200 rpm
Power
SAE net 60 kW (80 hp)
Cylinders
Quantity
Displacement
Volume
4.52 L (276 in.3)
Engine Torque Rise
Torque
42%
Maximum Engine Net Torque
Torque
368 Nm (271 lb-ft)
Electrical System
Voltage
12-volt
Alternator
Amperage
65 amps
Alternator with Cab
Amperage
95 amps
Measurement
Specification
Gear 1
Speed
5.8 km/h (3.6 mph)
Gear 2
Speed
9.5 km/h (5.9 mph)
Gear 3
Speed
23.2 km/h (14.4 mph)
Gear 4
Speed
39.3 km/h (24.4 mph)
Speed
6.4 km/h (4.0 mph)
EngineJohn Deere 4045T
Item
310SE Forward Travel Speeds1 with

Manual Transmission
310SE Reverse Travel Speeds1 with

Manual Transmission
Gear 1
With standard 19.5L-24 rear tires.

TM1608 (20SEP06)
9000-02-9
TX,115,BG321 1910JUN981/4

092006
PN=27
9000
02
10
Item
Measurement
Specification
Gear 2
Speed
10.6 km/h (6.6 mph)
Gear 3
Speed
25.9 km/h (16.1 mph)
Gear 4
Speed
43.8 km/h (27.2 mph)
Gear 1
Speed
5.8 km/h (3.6 mph)
Gear 2
Speed
9.5 km/h (5.9 mph)
Gear 3
Speed
23.2 km/h (14.4 mph)
Gear 4
Speed
39.3 km/h (24.4 mph)
Gear 1
Speed
6.4 km/h (4.0 mph)
Gear 2
Speed
10.6 km/h (6.6 mph)
Gear 3
Speed
25.9 km/h (16.1 mph)
Gear 4
Speed
43.8 km/h (27.2 mph)
Gear 1
Speed
6.1 km/h (3.8 mph)
Gear 2
Speed
10.1 km/h (6.3 mph)
Gear 3
Speed
24.6 km/h (15.3 mph)
Gear 4
Speed
41.5 km/h (25.8 mph)

Powershift Transmission


Manual Transmission

TM1608 (20SEP06)
9000-02-10
TX,115,BG321 1910JUN982/4

092006
PN=28
Item
9000
02
11
Measurement
Specification
Gear 1
Speed
6.8 km/h (4.2 mph)
Gear 2
Speed
11.3 km/h (7.0 mph)
Gear 3
Speed
27.4 km/h (17.1 mph)
Gear 4
Speed
46.3 km/h (28.8 mph)
Gear 1
Speed
6.1 km/h (3.8 mph)
Gear 2
Speed
10.1 km/h (6.3 mph)
Gear 3
Speed
24.6 km/h (15.3 mph)
Gear 4
Speed
41.5 km/h (25.8 mph)
Gear 1
Speed
6.8 km/h (4.2 mph)
Gear 2
Speed
11.3 km/h (7.0 mph)
Gear 3
Speed
27.4 km/h (17.1 mph)
Gear 4
Speed
46.3 km/h (28.8 mph)

Manual Transmission


NOTE: With powershift transmission, third and fourth

gear speeds are the same in reverse.
Item
Measurement
Specification
Radius
3.57 m (11 ft 9 in.)
Steering: Hydrostatic Power

Non-Powered Axle Curb Turning
RadiusBrakes Applied

TM1608 (20SEP06)
9000-02-11
TX,115,BG321 1910JUN983/4

092006
PN=29
9000
02
12
Item
Measurement
Specification
Non-Powered Axle Curb Turning

RadiusWithout Brakes
Radius
4.04 m (13 ft 3 in.)
Non-Powered Axle Bucket

Clearance CircleBrakes Applied
Radius
9.07 m (29 ft 9 in.)
Non-Powered Axle Bucket

Clearance CircleWithout Brakes
Radius
10.74 m (35 ft 3 in.)
Non-Powered Axle Steering Wheel Quantity

TurnsStop to Stop
2.33.0 turns
Powered Axle (MFWD) Curb

Turning RadiusBrakes Applied
Radius
3.34 m (10 ft 11 in.)
Powered Axle (MFWD) Curb

Turning RadiusWithout Brakes
Radius
4.17 m (13 ft 8 in.)
Powered Axle Bucket Clearance

CircleBrakes Applied
Radius
9.07 m (29 ft 9 in.)
Powered Axle Bucket Clearance

CircleWithout Brakes
Radius
10.74 m (35 ft 3 in.)
Powered Axle Steering Wheel

TurnsStop to Stop
Quantity
2.5 turns
Measurement
Specification
Pressure Relief SettingBackhoe
Pressure
25 000 kPa (3625 psi)
Pressure Relief SettingLoader
Pressure
19 000 kPa (2750 psi)
Flow @ 2200 rpm, Backhoe
Flow Rate
136 L/min. (36 gpm)
Flow @ 2200 rpm, Loader
Flow Rate
106 L/min. (28 gpm)
Item
Hydraulic System: Open Center
TX,115,BG321 1910JUN984/4
TM1608 (20SEP06)
9000-02-12

092006
PN=30
9000
02
13
310SE and 315SE Backhoe LoaderOther

Information
Hydraulic system:
Gear-type pump, tandem with unloader
10 micron replaceable element return oil filter
Final drives:
Heavy-duty inboard mounted planetary
Evenly distributes axle shock loads over three oil
cooled gears
Brakes:
Hydraulic wet disk

Mounted inboard
Self-adjusting
Self-equalizing
Park brake:
Independent system
Spring applied
Hydraulically released
Controlled by an electric switch on the side console
Operator control:
Backhoe w/o Ext. Dippersticktwo levers
Backhoe w/Ext. Dipperstick Retractedright foot
treadle
Backhoe w/Ext. Dipperstick Extendedright food
treadle
Transmission:
4-speed helical gear
Synchronized collar shift transmission with hydraulic
reverser
Torque converter 280 mm (11 in.) with 2.63:1 stall
ratio
Lubrication:
Pressure system with spin-on filter
Air cleaner
TM1608 (20SEP06)
9000-02-13
CED,OUO1032,1006 1909JUN981/2

092006
PN=31
9000
02
14
Dual stage dry, with element and precleaner

Tires:
Front w/o MFWD11L-15, 8 PR F3

Front w/o MFWD11L-16, 12PR F3
Front with MFWD12.5/80, 10PR
Rear w/o MFWD16.9-24, 8PR R4
Rear w/o MFWD19.5L-24, 8PR R4
Rear with MFWD19.5L-24, 8PR R4
CED,OUO1032,1006 1909JUN982/2
310SE and 315SE Backhoe Loader Weight

Item
Measurement
Specification
SAE Operating Weight with ROPS
Weight
6123 kg (13,500 lb)
Cab Added
Weight
263 kg (580 lb)
MFWD with Tires Added
Weight
220 kg (485 lb)
Extendible Dipperstick
Weight
222 kg (490 lb)
Optional Front Counterweight
Weight
181 kg (400 lb)
Optional Front Counterweight
Weight
295 kg (650 lb)
Transporting
TX,110,BD2420 1906DEC961/1
TM1608 (20SEP06)
9000-02-14

092006
PN=32
9000
02
15
310SE and 315SE Backhoe and Loader

Buckets
Loader:
Heavy duty long lip
Multipurpose
Width
Heaped Capacity
Weight
mm
(In.)
m3
(Cu Yd)
kg
2180
(86)
0.86
(1.12)
426
(940)
2340
(92)
1.00
(1.30)
476
(1050)
2180
(86)
0.76
(1.00)
725
(1600)
2340
(92)
0.96
(1.25)
762
(1680)
Width
Heaped Capacity
lb
Weight
Backhoe:
mm
(In.)
m3
(Cu Ft)
kg
(lb)
Standard duty
610
(24)
0.21
(7.5)
159
(350)
Heavy duty with lift loops
305
(12)
0.09
(3.3)
117
(258)
457
(18)
0.14
(5.1)
151
(334)
610
(24)
0.21
(7.5)
180
(396)
610
(24)
0.25
(8.8)
216
(476)
762
(30)
0.28
(10.0)
202
(444)
Severe duty
Ditch cleaning
914
(36)
0.35
(12.5)
231
(510)
457
(18)
0.14
(5.1)
164
(362)
610
(24)
0.21
(7.5)
192
(424)
610
(24)
0.25
(8.8)
206
(455)
762
(30)
0.28
(10.0)
215
(475)
914
(36)
0.35
(12.5)
231
(510)
TX,110,BD2212 1908OCT961/1
TM1608 (20SEP06)
9000-02-15

092006
PN=33
9000
02
16
310SE and 315SE Backhoe Loader Drain and

Refill Capacities
Item
Measurement
Specification
Engine Coolant
Capacity
16 L (17 qt)
Engine Oil (including filter)
Capacity
8.5 L (9.0 qt)
Torque Converter and Transmission

System
Capacity
15 L (16 qt)
Rear Axle (S.N. 851673)
Capacity
13 L (14 qt)
Rear Axle (S.N. 851674)
Capacity
16 L (17 qt)
MFWD Front Axle Housing
Capacity
6.5 L (7 qt)
MFWD Front Wheel Planetary

Housing (each)
Capacity
1 L (1.1 qt)
Fuel Tank
Capacity
136 L (36 gal)
Hydraulic System Reservoir
Capacity
37 L (39 qt)
TX,110,BG271 1901DEC991/1
TM1608 (20SEP06)
9000-02-16

092006
PN=34
9000
02
17

CapacitiesStandard Dipperstick
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.
T103504
1910SEP96
NOTE: Loader bucket on ground significantly improves

side stability, therefore improving lift capacity to
the side. Lift capacity over the rear is not affected.
Lift Capacity, Backhoe with Standard Dipperstick

Based on SAE J31 (Except with Loader Bucket on Ground)
TX,110,BD2214 1908OCT961/1
TM1608 (20SEP06)
9000-02-17

092006
PN=35
1910SEP96

(Retracted)
T103505
9000
02
18
Lift Capacity, Backhoe with Extendible Dipperstick, Retracted

TX,110,BD2215 1908OCT961/1
TM1608 (20SEP06)
9000-02-18

092006
PN=36
9000
02
19
T103506
1910SEP96

(Extended)
Lift Capacity, Backhoe with Extendible Dipperstick, Retracted

TX,110,BD2216 1908OCT961/1
TM1608 (20SEP06)
9000-02-19

092006
PN=37
9000
02
20
TM1608 (20SEP06)
9000-02-20

092006
PN=38
Group 03
Torque Values
9000
03
1
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.
T82,SKMA,AT 1901AUG941/1
ROPS Torque Specifications
UN23AUG88
CAUTION: Make certain all parts are reinstalled

correctly if the roll-over protective structure
(ROPS) is loosened or removed for any reason.
Tighten mounting bolts to proper torque.
TS176
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. A damaged ROPS should
be replaced, not reused.
When installation of equipment on a machine necessitates
loosening or removing ROPS, mounting bolts must be
tightened to specification.
Item
Measurement
Specification
ROPS Mounting Bolts
Torque
420 84 Nm (310 62 lb-ft)
TX,03,SS3509 1907DEC991/1
TM1608 (20SEP06)
9000-03-1

092006
PN=39
Torque Values
4.8
8.8
9.8
10.9
12.9
12.9
4.8
8.8
9.8
10.9
12.9
12.9
UN01MAY03
Metric Bolt and Screw Torque Values
TS1670
9000
03
2
Bolt or
Screw
Class 4.8
Lubricateda
Class 8.8 or 9.8

Dryb
Lubricateda
Class 10.9
Dryb
Lubricateda
Size
Nm
lb-in
Nm
lb-in
Nm
lb-in
Nm
lb-in
M6
4.7
42
53
8.9
79
11.3
100
Nm
13
Nm
M8
11.5
102
14.5
Nm
M10
23
Nm
204
29
128
lb-ft
21
22
Nm
194
lb-ft
43
32
27.5
Nm
55
243
lb-in
115
lb-ft
Class 12.9
Dryb
Nm
16.5
Nm
Lubricateda
lb-in
146
lb-ft
Nm
15.5
Nm
lb-in
137
lb-ft
Dryb
Nm
lb-in
19.5
172
Nm
lb-ft
32
23.5
40
29.5
37
27.5
47
35
40
63
46
80
59
75
55
95
70
lb-ft
lb-ft
M12
40
29.5
50
37
75
55
95
70
110
80
140
105
130
95
165
120
M14
63
46
80
59
120
88
150
110
175
130
220
165
205
150
260
190
M16
100
74
125
92
190
140
240
175
275
200
350
255
320
235
400
300
M18
135
100
170
125
265
195
330
245
375
275
475
350
440
325
560
410
M20
190
140
245
180
375
275
475
350
530
390
675
500
625
460
790
580
M22
265
195
330
245
510
375
650
480
725
535
920
680
850
625
1080
800
M24
330
245
425
315
650
480
820
600
920
680
1150
850
1080
800
1350
1000
M27
490
360
625
460
950
700
1200
885
1350
1000
1700
1250
1580
1160
2000
1475
M30
660
490
850
625
1290
950
1630
1200
1850
1350
2300
1700
2140
1580
2700
2000
M33
900
665
1150
850
1750
1300
2200
1625
2500
1850
3150
2325
2900
2150
3700
2730
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2770
4750
3500
Torque values listed are for general use only, based on the strength
of the bolt or screw. DO NOT use these values if a different torque
value or tightening procedure is given for a specific application. For
stainless steel fasteners or for nuts on U-bolts, see the tightening
instructions for the specific application. Tighten plastic insert or
crimped steel type lock nuts by turning the nut to the dry torque
shown in the chart, unless different instructions are given for the
specific application.
Shear bolts are designed to fail under predetermined loads. Always

replace shear bolts with identical property class. Replace fasteners
with the same or higher property class. If higher property class
fasteners are used, tighten these to the strength of the original. Make
sure fastener threads are clean and that you properly start thread
engagement. When possible, lubricate plain or zinc plated fasteners
other than lock nuts, wheel bolts or wheel nuts, unless different
instructions are given for the specific application.
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with
JDM F13C zinc flake coating.
b
Dry means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 1924APR031/1
TM1608 (20SEP06)
9000-03-2

092006
PN=40
Torque Values
9000
03
3
UN18OCT88
Additional Metric Cap Screw Torque Values
T6873AA
CAUTION: Use only metric tools on metric

hardware. Other tools may not fit properly. They
may slip and cause injury.
UN18OCT88
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.
T6873AB
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.
UN18OCT88
Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from
failing when tightening.
T6873AC
Tighten cap screws having lock nuts to approximately 50

percent of amount shown in chart.
TM1608 (20SEP06)
9000-03-3
04T,90,M170 1929SEP991/2

092006
PN=41
Torque Values
9000
03
4
METRIC CAP SCREW TORQUE VALUESa

T-Bolt
Nominal
Dia
8
H-Bolt
Nm
lb-ft
29
21
Nm
lb-ft
M-Bolt
Nm
lb-ft
20
15
10
10
63
46
45
33
20
15
12
108
80
88
65
34
25
14
176
130
137
101
54
40
16
265
195
206
152
78
58
18
392
289
294
217
118
87
20
539
398
392
289
167
125
22
735
542
539
398
216
159
24
931
687
686
506
274
202
27
1372
1012
1029
759
392
289
30
1911
1410
1421
1049
539
398
33
2548
1890
1911
1410
735
542
36
3136
2314
2401
1772
931
687
Torque tolerance is 10%.
04T,90,M170 1929SEP992/2
TM1608 (20SEP06)
9000-03-4

092006
PN=42
Torque Values
9000
03
5
Unified Inch Bolt and Screw Torque Values

TS1671 UN01MAY03
Bolt or
SAE Grade 2a
SAE Grade 1
b
Screw
Lubricated
Size
1/4
Dry
Lubricated
Dry
SAE Grade 5, 5.1 or 5.2

c
Lubricated
Dry
SAE Grade 8 or 8.2
Lubricatedb
Nm
Nm
lb-in
Nm
lb-in
Nm
lb-in
Nm
lb-in
Nm
lb-in
Nm
lb-in
3.7
33
4.7
42
53
7.5
66
9.5
84
12
106
13.5
Nm
5/16
7.7
68
9.8
86
12
106
15.5
137
3/8
13.5
120
17.5
155
22
194
27
240
7/16
22
194
19.5
Nm
Nm
Nm
1/2
lb-ft
Nm
lb-ft
Nm
172
lb-ft
25
Nm
221
lb-in
120
lb-ft
Dryc
Nm
17
Nm
lb-in
150
lb-ft
28
20.5
35
26
lb-ft
35
26
44
32.5
49
36
63
46
lb-ft
28
20.5
35
26
44
32.5
56
41
70
52
80
59
100
74
42
31
53
39
67
49
85
63
110
80
120
88
155
115
lb-ft
34
25
9/16
48
35.5
60
45
76
56
95
70
125
92
155
115
175
130
220
165
5/8
67
49
85
63
105
77
135
100
170
125
215
160
240
175
305
225
3/4
120
88
150
110
190
140
240
175
300
220
380
280
425
315
540
400
7/8
190
140
240
175
190
140
240
175
490
360
615
455
690
510
870
640
285
210
360
265
285
210
360
265
730
540
920
680
1030
760
1300
960
1-1/8
400
300
510
375
400
300
510
375
910
670
1150
850
1450
1075
1850
1350
1-1/4
570
420
725
535
570
420
725
535
1280
945
1630
1200
2050
1500
2600
1920
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2140
1580
2700
2000
3400
2500
1-1/2
990
730
1250
930
990
730
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
Torque values listed are for general use only, based on the strength of the
bolt or screw. DO NOT use these values if a different torque value or
tightening procedure is given for a specific application. For plastic insert or
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on
U-bolts, see the tightening instructions for the specific application. Shear
bolts are designed to fail under predetermined loads. Always replace shear
bolts with identical grade.
Replace fasteners with the same or higher grade. If higher

grade fasteners are used, tighten these to the strength of the
original. Make sure fastener threads are clean and that you
properly start thread engagement. When possible, lubricate
plain or zinc plated fasteners other than lock nuts, wheel bolts
or wheel nuts, unless different instructions are given for the
specific application.
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with
JDM F13C zinc flake coating.
c
Dry means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
DX,TORQ1 1924APR031/1
TM1608 (20SEP06)
9000-03-5

092006
PN=43
Torque Values
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.
UN23AUG88
Check Oil Lines And Fittings
X9811
9000
03
6
If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.
Tubing with dents may cause the oil to overheat. If you
find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified in torque
chart.
When you tighten connections, use two wrenches to
prevent bending or breaking tubing and fittings.
TX,90,DH1559 1901AUG941/1
TM1608 (20SEP06)
9000-03-6

092006
PN=44
Torque Values
9000
03
7
O-Ring Groove Connections

Face seal grooves (2 and 4) on fittings (3) should be
identified before the O-ring (1) is installed into the fitting
(use a O-ring pick to feel for the dovetail edge). Applying
petroleum jelly on an O-ring to install it in a Standard
Groove is appropriate. However, do not use petroleum
jelly or grease on an O-ring to install it into a Half Dovetail
Groove (Captive O-ring Groove). If petroleum jelly is used
in a Half Dovetail groove, the jelly could push the O-ring
out of the groove before the fitting is tighten.
T127838
UN31JAN00
1O-Ring
2Half Dovetail Groove
3Fitting
4Standard Groove
Face Seal Groves
CED,TX03768,2691 1901FEB001/1
TM1608 (20SEP06)
9000-03-7

092006
PN=45
Torque Values
9000
03
8
Service Recommendations For Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces and O-ring. They
must be free of dirt or defects.
fittings, use backup wrench on straight hose

couplings.
2. Lubricate O-rings and install into grove using

petroleum jelly to hold in place.
IMPORTANT: Tighten fittings to 150% of listed

torque value if indexing is necessary
or if fitting is attached to an
actuating devise.
3. Index angle fittings and tighten by hand pressing

joint together to insure O-ring remains in place.
Tighten fittings to 50% of listed

torque value if used in aluminum
housing.
4. Tighten fitting or nut to torque value shown on the

chart. Do not allow hoses to twist when tightening
FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D.
Thread Size
Swivel Nut
Bulkhead Nut
mm
in.
in.
Nm
lb-ft
Nm
lb-ft
6.35
0.250
9/16-18
16
12
12
9.52
0.375
11/16-16
24
18
24
18
12.70
0.500
13/16-16
50
37
46
34
15.88
0.625
1-14
69
51
62
46
19.05
0.750
1 3/16-12
102
75
102
75
22.22
0.875
1 3/16-12
102
75
102
75
25.40
1.000
1 7/16-12
142
105
142
105
31.75
1.250
1 11/16-12
190
140
190
140
38.10
1.500
2-12
217
160
217
160
*Torque tolerance is +15 -20% unless otherwise specified.

Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size
Straight Hex Size
Locknut Hex Size
Inch
Inch
Inch
Straight Fitting or Locknut Toque

Nm
lb-ft
3/8-24
5/8
9/16
12
7/16-20
5/8
5/8
21
15
1/2-20
3/4
11/16
26
19
9/16-18
3/4
3/4
34
25
3/4-16
7/8
15/16
73
55
7/8-14
1 1/16
1 1/16
104
76
1 1/16-12
1 1/4
1 3/8
176
130
1 3/16-12
1 3/8
1 1/2
230
170
1 5/16-12
1 1/2
1 5/8
285
210
*Torque tolerance is +15 -20% unless otherwise specified.
04T,90,K67 1902MAR001/1
TM1608 (20SEP06)
9000-03-8

092006
PN=46
Torque Values
9000
03
9
Service Recommendations for O-Ring Boss

Fittings
Straight Fitting
UN18OCT88
1. Inspect O-ring boss seat for dirt or defects.
T6243AE
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.
TM1608 (20SEP06)
9000-03-9
TX,90,DY323 1919SEP061/2

092006
PN=47
Torque Values
Angle Fitting
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.
UN18OCT88
1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.
T6520AB
9000
03
10
4. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size
Nm
lb-ft
3/8-24 UNF
7/16-20 UNF
12
1/2-20 UNF
16
12
9/16-18 UNF
24
18
3/4-16 UNF
46
34
7/8-14 UNF
62
46
1-1/16-12 UN
102
75
1-3/16-12 UN
122
90
1-5/16-12 UN
142
105
1-5/8-12 UN
190
140
1-7/8-12 UN
217
160
NOTE: Torque tolerance is 10%.
TX,90,DY323 1919SEP062/2
TM1608 (20SEP06)
9000-03-10

092006
PN=48
Torque Values
9000
03
11
T6890BB
UN01MAR90
Service Recommendations for Metric Series Four Bolt Flange Fitting
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange
then tighten the diagonally opposite cap screw.

Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.
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.
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
2. Install the correct O-ring (and backup washer if

required) into groove using petroleum jelly to hold it
in place.
TORQUE CHARTa
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).
Thread
Nm
lb-ft
M6
12
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.
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
5. After components are properly positioned and cap

screws are hand tightened, tighten one cap screw,
M8
30
22
M10
57
42
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.
a
Metric standard thread.
04T,90,K175 1929SEP991/1
TM1608 (20SEP06)
9000-03-11

092006
PN=49
Torque Values
UN01MAR90
Service Recommendations For Inch Series Four Bolt Flange Fittings
T6890BB
9000
03
12
ASealing Surface
BSplit Flange
CPinched O-Ring
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.
DSingle Piece Flange

TORQUE CHART
Nm
Nominal
Flange
Size
1/2
lb-ft
Cap Screw
Size
5/16-18
UNC
Min
Max
Min
Max
20
31
15
23
3/4
3/8-16 UNC
28
54
21
40
3/8-16 UNC
37
54
27
40
1-1/4
7/16-14
UNC
47
85
35
63
1-1/2
1/2-13 UNC
62
131
46
97
1/2-13 UNC
73
131
54
97
2-1/2
1/2-13 UNC
107
131
79
97
5/8-11 UNC
158
264
117
195
3-1/2
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
04T,90,K174 1901AUG941/1
TM1608 (20SEP06)
9000-03-12

092006
PN=50
Group 04
Fuels and Lubricants

9000
04
1
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
scar diameter of 0.45 mm as measured by ASTM

D6079 or ISO 12156-1.
In general, diesel fuels are blended to satisfy the low

temperature requirements of the geographical area in
which they are marketed.
Sulfur content:
Diesel fuels specified to EN 590 or ASTM D975 are

recommended.
Required fuel properties
In all cases, the fuel shall meet the following
properties:
Cetane number of 45 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20C (-4F) or elevations above
1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature.
Fuel lubricity should pass a minimum level of 3100
grams as measured by ASTM D6078 or maximum
Diesel fuel quality and fuel sulfur content must

comply with all existing emissions regulations for the
area in which the engine operates.
Use of diesel fuel with sulfur content less than
0.10% (1000 ppm) is STRONGLY recommended.
Use of diesel fuel with sulfur content 0.10% (1000
ppm to 0.50% (5000 ppm) may result in REDUCED
oil and filter change intervals.
BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 ppm), contact your John Deere
dealer.
DO NOT use diesel fuel with sulfur content greater
than 1.0%.
IMPORTANT: Do not mix used diesel engine oil or
any other type of lubricating oil with
diesel fuel.
IMPORTANT: Improper fuel additive usage may
cause damage on fuel injection
equipment of diesel engines.
DX,FUEL1 1917NOV051/1
TM1608 (20SEP06)
9000-04-1

092006
PN=51

9000
04
2
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). If protection at lower temperatures is required,
consult your John Deere dealer for recommendations.
John Deere COOL-GARD Prediluted Coolant is
preferred for service.
John Deere COOL-GARD Prediluted Coolant is
available in a concentration of either 50% ethylene
glycol or 55% propylene glycol.
Additional recommended coolants
The following engine coolant is also recommended:
John Deere COOL-GARD Coolant Concentrate in a
40% to 60% mixture of concentrate with quality
water.
John Deere COOL-GARD coolants do not require use
of supplemental coolant additives, except for periodic
replenishment of additives during the drain interval.
Other fully formulated coolants
Other fully formulated low silicate ethylene or
propylene glycol base coolants for heavy-duty engines
may be used if they meet one of the following
specifications:
ASTM D6210 prediluted (50%) coolant
ASTM D6210 coolant concentrate in a 40% to 60%
mixture of concentrate with quality water
Coolants meeting ASTM D6210 do not require use of
supplemental coolant additives, except for periodic
replenishment of additives during the drain interval.
Other low silicate ethylene glycol base coolants for

heavy-duty engines may also be used if they meet one
of the following specifications:
ASTM D4985 ethylene glycol base prediluted (50%)
coolant
ASTM D4985 ethylene glycol base coolant
concentrate in a 40% to 60% mixture of concentrate
with quality water
Coolants meeting ASTM D4985 require an initial
charge of supplemental coolant additives, formulated
for protection of heavy duty diesel engines against
corrosion and cylinder liner erosion and pitting. They
also require periodic replenishment of additives during
the drain interval.
Other coolants
It is possible that neither John Deere COOL-GARD nor
coolants meeting one of the coolant standards listed
above is available in the geographical area where
service is performed. If these coolants are unavailable,
use a coolant concentrate or prediluted coolant with a
quality additive package that provides cylinder liner
cavitation protection and protects the cooling system
metals (cast iron, aluminum alloys, and copper alloys
such as brass) from corrosion.
The additive package must be part of one of the
following coolant mixtures:
ethylene glycol or propylene glycol base prediluted
(40% to 60%) coolant
ethylene glycol or propylene glycol base coolant
concentrate in a 40% to 60% mixture of concentrate
with quality water
Water quality
Coolants requiring supplemental coolant additives
COOL-GARD is a trademark of Deere & Company
TM1608 (20SEP06)
9000-04-2
DX,COOL3 1927OCT051/2

092006
PN=52

Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
and propylene glycol base engine coolant concentrate.
9000
04
3
IMPORTANT: Do not mix ethylene glycol and

propylene glycol base coolants.
IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains
sealing additives.
DX,COOL3 1927OCT052/2
Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations for engines
used off-highway. This fuel will not require any additives
to provide good performance and engine reliability.
However, many local fuel distributors will not carry both
low and regular sulfur diesel fuels.
If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere PREMIUM DIESEL FUEL
CONDITIONER. It provides lubricating properties along
with other useful benefits, such as cetane improver,
anti-oxidant, fuel stabilizer, corrosion inhibitor and others.
John Deere PREMIUM DIESEL FUEL CONDITIONER is
specifically for use with low sulfur fuels. Nearly all other
diesel fuel conditioners only improve cold weather flow
and stabilizer long-term fuel storage. They do not contain
the lubrication additives needed by rotary fuel injection
pumps.
TX,45,BG348 1901OCT971/1
TM1608 (20SEP06)
9000-04-3

092006
PN=53

9000
04
4
Diesel Fuel Storage

Proper fuel storage is critically important. Use clean
storage and transfer tanks. Periodically drain water and
sediment from bottom of tank. Store fuel in a convenient
place away from buildings.
IMPORTANT: DO NOT store diesel fuel in galvanized
containers. Diesel fuel stored in
galvanized containers reacts with zinc
coating on container to form zinc
flakes. If fuel contains water, a zinc gel
will also form. The gel and flakes will
quickly plug fuel filters, damage
injection nozzles and injection pump.
DO NOT use brass-coated containers
for fuel storage. Brass is an alloy of
copper and zinc.
Store diesel fuel in plastic, aluminum, and steel containers
specially coated for diesel fuel storage.
Avoid storing fuel over long periods of time. If fuel is
stored for more than a month prior to use, or there is a
slow turnover in fuel tank or supply tank, add a fuel
conditioner such as John Deere PREMIUM DIESEL FUEL
CONDITIONER or equivalent to stabilize the fuel and
prevent water condensation. John Deere PREMIUM
DIESEL FUEL CONDITIONER is available in winter and
summer formulas. Fuel conditioner also reduces fuel
gelling and controls wax separation during cold weather.
Consult your John Deere engine distributor or servicing
dealer for recommendations and local availability. Always
follow manufacturers directions on label.
TX,45,BG313 1929SEP971/1
TM1608 (20SEP06)
9000-04-4

092006
PN=54

9000
04
5
Do Not Use Galvanized Containers

IMPORTANT: Diesel fuel stored in galvanized
containers reacts with zinc coating
on the container to form 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 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
To avoid condensation, fill the fuel tank at the end of each

days operation. Shut off engine before filling.
Specification
Fuel TankCapacity ........................................................... 106 L (112 qt)
TS185
CAUTION: Handle fuel carefully. If the engine is

hot or running, DO NOT fill fuel tank. DO NOT
smoke while you fill fuel tank or work on fuel
system.
UN23AUG88
Fuel Tank
TX,45,BD2125 1906MAY981/1
TM1608 (20SEP06)
9000-04-5

092006
PN=55
Diesel Engine Oil

Use oil viscosity based on the expected air temperature
range during the period between oil changes.
John Deere PLUS-50 oil is preferred
Oils meeting one of the following specifications are also
recommended:
ACEA
ACEA
ACEA
ACEA
Oil
Oil
Oil
Oil
Sequence
Sequence
Sequence
Sequence
E7
E6
E5
E4
Extended service intervals may apply when John Deere

PLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4
engine oils are used. Consult your John Deere dealer for
more information.
UN18DEC03
TS1681
9000
04
6
Other oils may be used if they meet one or more of the

following:
John Deere TORQ-GARD SUPREME

API Service Category CI-4 PLUS
API Service Category CI-4
API Service Category CH-4
API Service Category CG-4
API Service Category CF-4
ACEA Oil Sequence E3
ACEA Oil Sequence E2
If oils meeting API CG-4, API CF-4, or ACEA E2 are

used, reduce the service interval by 50%.
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply
with all existing emissions regulations for the area in
which the engine operates. If diesel fuel with sulfur
content greater than 0.50% (5000 ppm) is used, reduce
the service interval by 50%. DO NOT use diesel fuel with
sulfur content greater than 1.00% (10 000 ppm).
PLUS-50 is a trademark of Deere & Company

TORQ-GARD SUPREME is a trademark of Deere & Company
TM1608 (20SEP06)
DX,ENOIL 1923NOV051/1
9000-04-6

092006
PN=56

9000
04
7
T103849
1919SEP96
Transmission, Axles and Mechanical Front Wheel Drive Oil
Depending on the expected air temperature range

between oil changes, use oil viscosity shown on the
chart above.
You may also use oils which meet minimum John

Deere standards, or other oils meeting John Deere
Standard JDM J20C and J20D.
JOHN DEERE HY-GARD TRANSMISSION AND

HYDRAULIC OIL IS RECOMMENDED because it is
specifically formulated to minimize brake chatter, and
to provide maximum protection against mechanical
wear.
Oils meeting MIL-L-46167A may be used as arctic oil.
HY-GARD is a registered trademark of Deere & Company
TM1608 (20SEP06)
TX,45,BD2126 1907OCT961/1
9000-04-7

092006
PN=57
1919SEP96
Hydraulic Oil
T103848
9000
04
8
Depending on the expected air temperature range

between oil changes, use oil viscosity shown on the
chart above.
You may also use oils which meet minimum John

Deere standards, or other oils meeting John Deere
Standard JDM J20C and J20D.
JOHN DEERE HY-GARD TRANSMISSION AND

HYDRAULIC OIL IS RECOMMENDED because it is
specifically formulated to minimize brake chatter, and
to provide maximum protection against mechanical
wear.
Oils meeting MIL-L-46167A may be used as arctic oil.
HY-GARD is a registered trademark of Deere & Company
TM1608 (20SEP06)
TX,45,BD2127 1907OCT961/1
9000-04-8

092006
PN=58

9000
04
9
Grease
Use grease based on NLGI consistency numbers and the
expected air temperature range during the service interval.
John Deere SD POLYUREA GREASE is preferred.
The following greases are also recommended
John Deere HD LITHIUM COMPLEX GREASE
John Deere HD WATER RESISTANT GREASE
John Deere GREASE-GARD
IMPORTANT: Some types of grease thickeners are

not compatible with others. Consult
your grease supplier before mixing
different types of grease
GREASE-GARD is a trademark of Deere & Company
TS1673
NLGI Performance Classification GC-LB
UN31OCT03
Other greases may be used if they meet the following:
DX,GREA1 1907NOV031/1
Grease For Extendible Dipperstick, Sideshift

Frame, And Stabilizer Leg Wear Strips
SAE Multipurpose Grease with Extreme Pressure (EP)
performance and containing 3 to 5 per cent molybdenum
disulfide (preferred).
TX,45,BD1972 1924SEP961/1
TM1608 (20SEP06)
9000-04-9

092006
PN=59

9000
04
10
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.
Re-refined base stock products may be used if the
finished lubricant meets the performance requirements.
DX,ALTER 1915JUN001/1
Lubricant Storage
Your equipment can operate at top efficiency only
when clean lubricants are used.
Make certain that all containers are properly marked to

identify their contents.
Use clean containers to handle all lubricants.
Properly dispose of all old containers and any residual

lubricant they may contain.
Whenever possible, store lubricants and containers in

an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
DX,LUBST 1918MAR961/1
TM1608 (20SEP06)
9000-04-10

092006
PN=60

9000
04
11
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.
Consult your John Deere dealer to obtain specific

information and recommendations.
Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricant
performance.
DX,LUBMIX 1918MAR961/1
TM1608 (20SEP06)
9000-04-11

092006
PN=61

9000
04
12
TM1608 (20SEP06)
9000-04-12

092006
PN=62
Section 9005

Contents
9005
Page
Group 10Operational Checkout Procedure

Operational Checkout Procedure. . . . . . . . . .9005-10-1
Gauge and Indicator Check With Engine
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-1
FNR, Neutral Start Circuit and Reverse
Warning Alarm Checks . . . . . . . . . . . . . . .9005-10-2
Park Brake, Charge Indicator Light,
Tachometer/Hour Meter Circuit and
Engine Speed Control Linkage Checks . . .9005-10-3
Brake System Checks . . . . . . . . . . . . . . . . . .9005-10-4
Steering System Checks . . . . . . . . . . . . . . . .9005-10-6
Transmission Neutral Disconnect Circuit
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-7
Driving Checks . . . . . . . . . . . . . . . . . . . . . . .9005-10-8
Ride Control Operational Checks (If
Equipped) . . . . . . . . . . . . . . . . . . . . . . . .9005-10-10
Mechanical Front Wheel Drive (MFWD)
Driving Check . . . . . . . . . . . . . . . . . . . . .9005-10-12
Hydraulic System Checks . . . . . . . . . . . . . .9005-10-13
Check Operation Of Accessories (Engine
Stopped) . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-20
Cab Component Checks . . . . . . . . . . . . . . .9005-10-21
Miscellaneous Checks. . . . . . . . . . . . . . . . .9005-10-26
TM1608 (20SEP06)
9005-1

092006
PN=1
Contents
9005
TM1608 (20SEP06)
9005-2

092006
PN=2
Group 10

Use this procedure to check all systems and functions
on the machine. It is designed so you can make a
quick check of machine operation while doing both a
walk around inspection and performing specific checks
from the operators seat.
Should you experience a problem with your machine,
you will find helpful diagnostic information in this
checkout that will pinpoint the cause. Use the table of
contents to help find adjustment procedures. This
information may allow you to perform simple repairs
yourself, reducing machine down time.
The information obtained after completing the
operational checkout will allow you or your authorized
dealer to pinpoint a specific test or repair needed to
restore the machine to specifications.
A location will be required which is level and has

adequate space to complete the checks. No tools or
equipment are needed to perform this checkout.
Complete the necessary visual checks (oil levels, oil
condition, external leaks, loose hardware, linkage,
wiring, etc.) prior to doing the checkout. The machine
must be at operating temperature for many of the
checks.
Locate the check to be performed at the top of the left
column and read completely down the column before
performing the check. Follow this sequence from left to
right. In the far right column, if no problem is found,
you will be instructed to go to next check. If a problem
is indicated, you will be referred to either a group in
this manual or to your authorized dealer for repair.
TX,9005,YY2037 1908AUG961/1
1 Gauge and Indicator Check With Engine Off
1/1
Monitor Indicator Lights

and Alarm Checks
YES: Go to next check.

NO: Check monitor/gauge
fuse. Go to Group
9015-15, Display Monitor
Checks. 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,
Start Circuit.
T103007 UN30OCT98
Turn key switch to BULB CHECK position and hold.
LOOK: Are all monitor indicator lights on? Is STOP light ON and does alarm sound?
NOTE: Starting motor MUST NOT operate.
1/1
TM1608 (20SEP06)
9005-10-1

092006
PN=65
9005
10
1

2 FNR, Neutral Start Circuit and Reverse Warning Alarm Checks
9005
10
2
1/1
FNR Switch Check
Engine off.
Move FNR lever to forward (F), reverse (R), then neutral

(N) position.
NO: If no "click", inspect

neutral start relay. Go to
Group 9015-15, Start
Circuit.
FEEL: Observe and feel forward, neutral and reverse

detents.
T7447AH UN04JAN91
Turn key switch to ON position. Move FNR lever into

forward and reverse.
LISTEN: Did you hear a "click" from the side console

neutral start relay as FNR lever was moved?
1/1
Neutral Start Check
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.
NO: Go to Group
9015-15, Start Circuit.
LISTEN: Did starting motor operate?

1/1
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.
LISTEN: Did starting motor operate?

LISTEN: Did alarm sound?
T7447AH UN04JAN91
LOOK: During engine cranking, were all indicator lights

ON? Is STOP indicator ON?

NO: If engine turns but
does not start, check fuel
shut-off/start aid/reverse
alarm fuse. If starting
motor does not operate
check start fuse. Go to
Group 9015-15, Start
Circuit. If indicator lights
are NOT ON, check
monitor/gauge fuse. Go to
Group 9015-15, Display
Monitor Checks.
1/1
Reverse Warning Alarm

Check
Key switch ON.
Move FNR lever to reverse (R) position.
NO: See Reverse Alarm

Circuit. Go to Group
9015-10.
LISTEN: Does reverse warning alarm sound?
T7447AI UN04JAN91
1/1
TM1608 (20SEP06)
9005-10-2

092006
PN=66

3 Park Brake, Charge Indicator Light, Tachometer/Hour Meter Circuit and Engine Speed Control Linkage
Checks
1/1
Park Brake Indicator

Check
T7447AG UN04JAN91
T103007 UN30OCT98
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: Is STOP indicator ON? Does alarm sound? Is park brake and seat belt light
ON? Are all other indicator lights out?
NO: 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. 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. If no park
brake light, inspect wiring
connector at switch on
park brake linkage. Go to
Group 9015-15, Park
Brake Circuit.
Release park brake.
LOOK/LISTEN: Is park brake indicator and STOP light out? Alarm will not sound.
1/1
Seat Position Sensor

Check
Engine speed at low idle.
Specification
Seat Position Sensor CheckEngine
Speed ................................................................................................................... Low idle
NO: Go to indicator circuit

in Group 9015-15.
Lower all equipment to ground.

Release park brake.
Transmission gear shift lever in neutral, FNR in forward or reverse.
Operators seat in backhoe position.
LISTEN: Does monitor alarm sound and is STOP indicator ON?
1/1
TM1608 (20SEP06)
9005-10-3

092006
PN=67
9005
10
3

Tachometer/
Hourmeter Circuit Check
IMPORTANT: If engine low oil pressure indicator

light stays ON, STOP ENGINE IMMEDIATELY and
check oil level.
Engage park brake.
9005
10
4
Put FNR lever in neutral and start the engine.

T7447AH UN04JAN91
LOOK/LISTEN: Is hourmeter indicator rotating? Does

tachometer (if equipped) indicate rpm?

NO: If park brake
indicator light is not ON,
go to Group 9015-15,
Park Brake Circuit. If no
hour meter or tachometer
movement, go to Group
9015-10, Gauge and
Hour Meter Circuit.
1/1
Engine Speed Control

Lever Linkage Check
Engage park brake.

Put FNR lever in neutral and start engine.
NO: Tighten friction lock.

Go to Group 9010-20.
Check engine speed. Go
to Group 9010-20.
Note rpm on tachometer (if equipped).

Move speed control lever to fast idle position.
T102991 UN20AUG96
LOOK: Does tachometer read 900 + 25 0 rpm (slow

idle) or 2400 + 25 0 rpm (fast idle)?
Specification
Slow IdleSpeed ............................... 900 + 25 0 rpm
Fast IdleSpeed .............................. 2400 + 25 0 rpm
LOOK: Does speed control lever remain at selected

position?
1/1
Engine Speed Control

Pedal Linkage Check
Depress speed control pedal
YES: Yes: Go to next

check.
LISTEN: Does engine speed stay the same as with

speed control lever in fast idle position?
NO: Adjust Speed Control

Linkage. Go to Group
9010-20.
T7367AM UN17JAN92
1/1
4 Brake System Checks
1/1
TM1608 (20SEP06)
9005-10-4

092006
PN=68

Pedal Stop Check
Lift left and right brake pedals.
LOOK: Are brake pedals against pedal stop screws?
NO: Adjust brake pedal

stops. Go to Group
9020-20.
NOTE: This ensures that brake check valves are opened

and brakes released.
9005
10
5
T7394BG UN17JAN92
1/1
Brake System Leakage

Check
Depress and hold left brake pedal, then right brake pedal
using approximately 267 N (60 lb. force).
LOOK: Brake pedal must NOT feel spongy (caused by

air in system). Does pedal settle more than 25 mm (1.0
in.) per minute?
T7394BF UN06JAN92
NO: Go to next check.

YES: Bleed brake
system. Go to Group
9020-20.
Specification
Brake SystemMaximum
Leakage ............................................. 25 mm (1.0 in.) per
minute with approximately
267 N (60 lb. force)
applied
1/1
Brake Drag/Park Brake

Check
Position machine on a gradual slope with front of

machine downhill.
Lift bucket so it clears ground.
Shift FNR lever to neutral, differential lock control up,
disengage park brake and release service brakes.
T6171AL UN09DEC88

NO: Go to Group
9020-25, Brake Valve
Leakage Test or Park
Brake Release Pressure
Test.
Let machine coast freely for several feet. Apply park

brake.
LOOK: Did machine stop?

Release park brake.
LOOK: Did machine move or coast freely?

NOTE: If machine does not move freely on slope, drive
the machine for five minutes. Feel axle housing area to
locate which brake is dragging.
1/1
TM1608 (20SEP06)
9005-10-5

092006
PN=69

Park Brake Function
Check
Start machine, move throttle to 1200 rpm.
YES: If the machine

moves in any gear, see
your authorized dealer.
Leave park brake ON.

Put FNR lever in forward position.
9005
10
6
Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds in
each gear.
YES: If the indicators do

not work, see your
authorized dealer.
Move FNR lever to reverse position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds in
each gear.
Move FNR lever back to neutral position.
Move throttle back to slow idle and shut the machine off.
LOOK: The machine MUST NOT move in any gear.

LOOK: STOP light and Park Brake indicators MUST be lit.
LOOK: Hazard light MUST be flashing.
LISTEN: An audible beeping alarm MUST be heard.
LISTEN: With the FNR In the reverse position, the reverse audible alarm MUST be
heard.
1/1
5 Steering System Checks
1/1
Steering Check
Raise loader bucket above ground level.
Raise rear of machine off ground using stabilizers.
NO: Go to Group
9025-15, Steering Valve
Does Not Return to
Neutral.
Operate engine at approximately 1000 rpm.

Specification
Steering CheckApproximate Engine
Speed ................................................................................................................. 1000 rpm
Turn steering wheel from full left to full right several times.
LOOK: Did front wheels move smoothly in both directions?

LOOK: When steering wheel was stopped, did front wheels stop moving?
NOTE: Internal leakage or a sticking steering valve spool can cause wheels to
continue to move after steering wheel is stopped.
1/1
TM1608 (20SEP06)
9005-10-6

092006
PN=70

Steering System Leakage
Check
NOTE: Hydraulic oil must be at operating temperature.
Run engine at slow idle.
NO: If steering wheel

turns more than 5 rpm,
verify whether valve or
cylinder is leaking.
Specification
Steering System Leakage Check
Engine Speed ...................................................................................................... Slow idle
Hydraulic OilTemperature .......................................................... Operating temperature
Steering SystemMaximum Leakage ..................................................................... 5 rpm
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.
Specification
Test.
Specification
Steering WheelTorque .................................................................. 11.3 Nm (100 lb-in.)
Repeat leakage check turning steering wheel to the left.
LOOK: Did steering wheel turn 5 rpm or less to the left or right?
Specification
Steering SystemLeakage ...................................................................................... 5 rpm
This represents acceptable steering wheel movement during normal operation.
1/1
Steering Priority Valve

Check
Operate engine at slow idle.
Specification
Steering Priority Valve CheckEngine
Speed .................................................................................................................. Slow idle
NO: Steers hard and no

decrease in engine rpm.
Steering Priority Valve
Test.
Turn steering wheel to stop left and right. Note effort required to turn wheel.
Turn wheel to stop and apply constant pressure.
LOOK/FEEL: Does wheel stop at both axle stops and require normal steering wheel
effort?
LOOK/LISTEN: Does tachometer (if equipped) decrease in rpm or does engine rpm
decrease when steering wheel is held against stop?
1/1
6 Transmission Neutral Disconnect Circuit Check
1/1
TM1608 (20SEP06)
9005-10-7

092006
PN=71
9005
10
7

Neutral Disconnect
Circuit Check

CAUTION: Machine will move forward as FNR lever is moved.
Start engine, set idle speed at approximately 1500 rpm.
Specification
Neutral Disconnect Circuit Check
Approximate Engine Idle Speed ........................................................................ 1500 rpm
9005
10
8
NO: Check switch. Go to

Group 9015-15, Park
Brake/Neutral Disconnect
Circuit.
Put transmission in fourth gear.

Release park brake.
Shift FNR lever to forward (F) position.
LISTEN: When FNR lever is shifted to forward (F) position, can a noticeable drop in
engine speed should be heard?
Press button on gear shift lever (manual shift only) or loader control lever individually
and note sound of engine.
LISTEN: Does engine rpm increase when the neutral solenoid switches are
depressed?
1/1
7 Driving Checks
1/1
7a Transmission Noise
Check
IMPORTANT: Press button on gear shift lever when shifting gears (manual shift
only).
Run engine at approximately 1500 rpm with FNR lever in forward (F) position.
Specification
Transmission Noise Check
Approximate Engine Speed ............................... 1500 rpm with FNR lever in forward (F)
position

YES: Go to Group
9020-15, Excessive
Power Train Noise or
Excessive Gear Clash
When Shiftingfor manual
shift or power shift.
Shift transmission into each gear and drive for a short distance.
LISTEN: Can excessive gear noise be heard when shifting between gears?
1/1
TM1608 (20SEP06)
9005-10-8

092006
PN=72

7b Differential Lock
Check
Raise wheels off ground with stabilizers and loader

bucket.
Unlock brake pedals. Turn MFWD switch OFF (if
equipped).
Operate machine at approximately 1500 rpm in 1st
forward.
T6295AD UN19OCT88

NO: Check differential
lock switch and solenoid.
Differential Lock Pressure
9005
test.
10
9
Specification
Differential Lock Check
Approximate Engine
Speed .......................................... 1500 rpm in 1st forward
Depress differential lock control.
Apply one brake pedal.
LOOK: Both wheels must stop.
1/1
7c Differential Gear and

Pinion Check
Shift transmission to first gear and operate engine at approximately 1500 rpm.
Specification
Differential Gear and Pinion Check
Approximate Engine Speed ............................................................ 1500 rpm in 1st gear
YES: Go to Group
9020-15, Diagnose Rear
Axle Malfunctions.
Move FNR lever to forward (F) position.

Steer machine in a maximum left turn and depress left brake pedal to stop the left
wheel.
Steer machine in a maximum right turn and depress right brake pedal to stop the right
wheel.
LISTEN: Can excessive gear noise be heard in the differential or pinion gear area?
1/1
7d Front Wheel
Alignment (Toe-In)
Check
Drive machine in fourth gear forward on a surface with

loose material.
LOOK: Is material from behind front wheels thrown

excessively inward or outward?

YES: If material is
thrown, excessive tire
wear will result. Go to
Group 9020-20, Adjust
Toe-In.
T6264AI UN22OCT91
1/1
TM1608 (20SEP06)
9005-10-9

092006
PN=73

7e Engine and Torque
Converter Check
(Without MFWD)
Position machine with loader bucket at ground level

against dirt bank or immovable object.
YES: If the wheels can

be easily stalled, go to
Group 9020-15, Power
TrainMachine Lacks
Power or Moves Slow.
Shift transmission into first gear.

9005
10
10
Engage differential lock.

T6171AM UN09DEC88
Increase engine speed to fast idle.
LOOK: Do rear wheels stall?

NOTE: This test will give a general indication of engine,
transmission and torque converter performance.
1/1
7f Transmission
Hydraulic System
Check
Run engine at approximately 1500 rpm.
Specification
Transmission Hydraulic System Check
Approximate Engine Speed ............................................................................... 1500 rpm
NO: Check torque

converter or modulation
valve. Go to Group
9020-25.
Shift transmission into third gear.

Make several shifts from third forward to third reverse. Start counting the number of
seconds when FNR lever is moved to opposite direction.
LOOK: Is shift from one direction to the other completed in three seconds.
NOTE: If bad in one direction ONLY, check direction pack.
1/1
8 Ride Control Operational Checks (If Equipped)
1/1
TM1608 (20SEP06)
9005-10-10

092006
PN=74

Electrical Checks
Turn key switch on (do not start engine).
Turn ride control switch on.
NO: Check and replace

ride control switch light.
LOOK: Does ride control switch light turn on?

IF OK: Check wiring.
9005
10
11
Turn ride control switch off.
LOOK: Does ride control switch light turn off?

Turn ride control switch on.
Turn key switch off.
LOOK: Does ride control switch light turn off?
1/1
Hydraulic Checks
Start tractor and set throttle about 1000 - 1500 rpm.
NO: Continue check.
NOTE: Make sure park

brake is off during
hydraulic checks.
Turn ride control on.
YES: Check ride control

hydraulics.
Try to lift front end of tractor off ground using loader boom lever.
Release loader boom lever.
LOOK/FEEL: Will front end of tractor lift off of ground and hold?
Turn ride control off.
Try to lift front end of tractor off ground using loader boom lever.
NO: Check ride control

hydraulics.
Release loader boom lever.
LOOK/FEEL: Will front end of tractor lift off of ground and hold?
1/1
Ride Control Check
CAUTION: Boom
will jump upward
during this
check. Make sure
area around
bucket is clear.
Start engine.
YES: Check complete.
Push Ride Control Switch to OFF position.
NO: Check accumulator

charge.
Raise boom to maximum height and hold control lever over relief for 2 seconds.
Lower boom and bucket to ground and stop engine. Put boom control lever in neutral.
Turn key switch on. Turn ride control switch on.
Does boom jump up?
1/1
TM1608 (20SEP06)
9005-10-11

092006
PN=75

9 Mechanical Front Wheel Drive (MFWD) Driving Check
9005
10
12
1/1
MFWD Switch Check
Push switch and engage MFWD.
LOOK: Does MFWD light in display monitor come ON

when switch is pressed?
NO: Check electrical

circuit. Go Group
9015-10, MFWD circuit.
MFWD Pressure Test.
Push switch to disengage MFWD.
T102991 UN20AUG96
LOOK: Is MFWD light in display monitor OFF with

MFWD disengaged?
NOTE: Indicator light in MFWD switch will remain ON
while MFWD is engaged. If MFWD is turned OFF while
operating, light will go out but MFWD could stay on until
load on drive train is released.
1/1
MFWD Differential Check
Start engine and run at low idle.
Specification
MFWD Differential CheckEngine
Speed ................................................................................................................... Low idle
NO: If at least one front

wheel does not turn with
MFWD applied, go to
group 9020-25 MFWD
pressure test. Check
electrical circuit, go to
Group 9015-10 MFWD
circuit.
Raise machine off ground with stabilizers and loader.

Release park brake.
Shift transmission to first gear and put FNR in forward.
Engage MFWD.
Lower front wheels to just contact ground.
LOOK: Does at least one front wheel turn?
1/1
TM1608 (20SEP06)
9005-10-12

092006
PN=76

Engine and Torque
Converter Check (With
MFWD)
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 transmission to first forward.
T6171AN UN09DEC88
Increase engine speed to fast idle
LOOK: Do both rear wheels and both front wheels turn?

NO: If all wheels stop, a
torque converter or
transmission control valve
problem is indicated. If
9005
the front wheels stop,
10
MFWD problem is
13
indicated. Go to Group
9020-15, Machine Lacks
Power or Moves Slow.
1/1
MFWD Gear and Pinion

Check
Drive machine at transport speed with MFWD engaged, then disengaged.
LISTEN: Does MFWD whine when disengaged.
YES: If MFWD whines,

check oil levels and fill to
correct levels. Go to
Diagnose MFWD
Malfunctions in Group
9020-15.
NOTE: It is normal for MFWD to whine when engaged.
1/1
10 Hydraulic System Checks
1/1
TM1608 (20SEP06)
9005-10-13

092006
PN=77

Main Hydraulic Pump
Performance Check
NOTE: If hydraulic oil is not at operating temperature, heat oil to 3852 C (100
125F).

NO: If cycle time slow, go
to 9025-15, Slow
Hydraulic Functions.
Put loader bucket flat on ground.

Specification
Hydraulic OilTemperature ....................................................... 3852 C (100125F)
9005
10
14
Transmission in neutral, FNR in Forward.

Run engine at slow idle.
Specification
Main Hydraulic Pump Performance
CheckEngine Speed ........................................................................................ Slow idle
Measure cycle time of loader raise to maximum height (including bucket leveling).
LOOK: Does loader raise to maximum height in 15 seconds or less?

Specification
Loader Raise to Maximum Height
(Including Bucket Leveling)Maximum
Cycle Time ...................................................................................................... 15 seconds
NOTE: Take the average cycle time for at least three cycles. This time will give a
general indication of main hydraulic pump performance.
1/1
Auxiliary Hydraulic Pump

Performance Check
NOTE: Hydraulic oil should be at operating temperature 3852 C (100125 F).
FNR in neutral.
NO: If cycle time is slow,

go to 9025-15, Slow
Hydraulic Functions.
Specification
Hydraulic OilTemperature ....................................................... 3852 C (100125F)
Put backhoe in transport position.
Run engine at fast idle.
Specification
Auxiliary Hydraulic Pump Performance
CheckEngine Speed ........................................................................................ Fast idle
While holding loader bucket curl over relief, move dipperstick from fully retracted
position to fully extended position and measure cycle time.
LOOK: Is the cycle time 12 seconds or less?

Specification
Dipperstick Fully Retracted to Fully
Extended Position (Loader Bucket Curl
Held Over Relief)Maximum Cycle
Time ................................................................................................................. 12 seconds
1/1
TM1608 (20SEP06)
9005-10-14

092006
PN=78

Cylinder Cushion Check
Raise wheels off ground with stabilizers.
Boom MUST be lowered from the transport position.
NO: Remove and repair

cylinder cushion. Go to
repair manual.
Run engine at high idle.
9005
10
15
Specification
Cylinder Cushion CheckEngine Speed ........................................................... High idle
Activate backhoe swing left and right.
Note sound and speed as cylinders near end of their stroke.
LOOK: Does speed of cylinder rod decrease near the end of its stroke?
LISTEN: Can hydraulic oil be heard flowing through orifice as cylinder rod nears the
end of its stroke?
Repeat check using backhoe boom raise function.
NOTE: Crowd cylinder does not have cylinder cushion.
1/1
Stabilizer Cylinder and

Valve Check
Operate machine at approximately 1500 rpm.
Specification
Stabilizer Cylinder and Valve Check
NO: Cylinders drift up or

down. Inspect lock outs.
Go to repair manual.
Cylinders drift down
rapidly. Go to Group
9025-25, Cylinder
Leakage Test.
Position loader bucket above ground.

Lower each stabilizer cylinder and raise rear of machine off ground.
LOOK/FEEL: Do cylinders extend smoothly and hold machine up?

Retract each stabilizer cylinder.
LOOK/FEEL: Do cylinders retract smoothly and remain up?
1/1
TM1608 (20SEP06)
9005-10-15

092006
PN=79

NOTE: Feel backhoe cylinders. Cylinder must be warm
to touch (3852C [100125F]). If cylinders are not
warm, heat oil to specifications.
Backhoe and Loader

Function Drift Check
With backhoe fully extended, put backhoe bucket at a

45 angle to ground.
9005
10
16
T7374CI UN04OCT90

YES: Verify which
function is drifting. Go to
Group 9025-25, Drift
Test.
Specification
Hydraulic Oil
Temperature................................ 3852C (100125F)
(Cylinders warm to touch)
Lower boom until bucket cutting edge is 50 mm (2.0 in.)
off the ground.
Position loader bucket same distance off ground as
backhoe bucket.
Run engine at slow idle and observe bucket cutting
edge.
Specification
Backhoe and Loader
Function Drift Check
Engine Speed ..................................................... Slow idle
LOOK: Do cutting edges touch ground within one

minute?
Specification
Backhoe and Loader
FunctionMaximum Drift ............. 50 mm (2.0 in.) in one
minute
1/1
Hydraulic Control Valve

Lift Check Test
NOTE: 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.
Position backhoe at maximum reach with bucket in dump position, 1 m (3.0 ft.) off the
ground.

YES: Inspect control
valve lift check. Go to
repair manual. Do
cylinder leakage test, go
to group 9025-25.
Stop the engine.

Activate each function one at a time.
Loader boom raise

Loader bucket rollback
Backhoe boom up
Dipperstick extend
Backhoe bucket dump
LOOK: Do functions move when the control lever is activated?
1/1
TM1608 (20SEP06)
9005-10-16

092006
PN=80

Loader Boom Float
Check
Put loader bucket at maximum height position with bucket dumped.
NO: If it jumps out of

detent, check detent
spring and detent balls.
Specification
Loader Boom Float CheckApproximate
Engine Speed ..................................................................................................... 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.
LOOK: Does loader control lever remain in the boom float detent position?
1/1
Loader Return-to-Dig
Check
T6171AT UN09DEC88
NO: Adjust switch until it

is activated in cam. Go to
Group 9025-20, Loader
Bucket Self-Leveling
Indicator Linkage and
Return-to-Dig Switch
Adjustment.
T7374CH UN04OCT90
Put loader bucket at maximum height position with bucket dumped.

Specification
Loader Return-to-Dig Check
Move the loader control lever forward into boom float detent position, and at the same
time into bucket rollback detent position. Remove hand from control lever.
LOOK: Does the loader control lever disengage from the bucket rollback detent when
the bucket is level.
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.
1/1
TM1608 (20SEP06)
9005-10-17

092006
PN=81
9005
10
17

NOTE: The loader bucket leveling feature functions
during the boom raise cycle only. When bucket is
lowered, the operator can manually level the bucket or
use the return-to-dig.
Bucket Leveling Linkage

Check
Put loader bucket in the rollback position with the boom

near ground level.
9005
10
18
T7374CJ UN05OCT90
Raise the loader and at the same time hold the control
lever in the bucket rollback position.

NO: Adjust switch until it
is activated in cam. Go to
Group 9025-20, Loader
Bucket Self-Leveling
Indicator Linkage and
Return-to-Dig Switch
Adjustment.
Observe bucket and loader control lever as the loader

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

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

Check315SE
Specification
315SE Sideshift Frame
Lock CheckEngine
Speed .................................................................. Slow idle
NO: Side shift frame lock

does not release. Check
fuse.
Inspect wiring from switch
to valve solenoid. Go to
Group 9015-15.
(Lock backhoe in transport position.)

T105815 UN20DEC96
Depress side shift lock switch mounted on backhoe

boom control lever.
LOOK: Side shift frame must drop slightly as locking

pistons retract.
If power to solenoid,
replace solenoid valve.
1/1

Check315SE
Continued
Release switch to ON position.
Hold boom-up function over relief.
NO: Side shift frame will

not lock. Remove and
inspect check valve and
solenoid seals. Go to
repair manual.
LOOK: Side shift frame must raise slightly when backhoe valve is held over relief.
1/1
TM1608 (20SEP06)
9005-10-18

092006
PN=82

Check315SE
Continued
Return boom lever to neutral position.
LOOK: Side shift frame must remain locked in position for one minute minimum.
NO: Side shift frame does

not remain locked. Test
leakage of side shift
valve. Go to Group
9005
9025-25.
10
19
1/1
Boom Lock Check

315SE

NO: Check fuse.
Inspect wiring from foot
switch to valve solenoid.
T105817 UN20DEC96
If both boom locks do not

raise and release, go to
Group 9025-10 and
9020-15.
T105820 UN20DEC96
Engage park brake.

Put FNR lever in neutral (N) and start the engine.
Specification
315SE Boom Lock CheckEngine
Speed .................................................................................................................. Slow idle
If only one boom lock

raises/releases, inspect
and repair boom release
cylinder, hose and fittings.
Move boom control back in the boom raise (over relief) position.
Depress boom lock foot switch.
LOOK: Are both locks in the raised and released position?
1/1
Boom Lock Check

315SEContinued
Release boom lock foot switch.
YES: Go to the next

check.
LOOK: Are both locks in the engaged position?

NO: Inspect and repair
boom lock cylinder return
springs.
Inspect and repair
solenoid valve. Go to
Group 9025-10.
T105818 UN20DEC96
1/1
TM1608 (20SEP06)
9005-10-19

092006
PN=83

11 Check Operation Of Accessories (Engine Stopped)
9005
10
20
1/1
Front Light Switch Check
Turn key switch to ON position.
Push front light rocker switch to middle position.
NO: Check fuse and

bulbs. Check wiring. Go
to Group 9015-10, Front
Work and Drive Light
Circuit.
LOOK: Are two front lights, two red tail lights and gauge lights ON?
Push front light rocker switch in completely.
LOOK: Are four front lights (if equipped), two red tail lights and gauge lights ON?
1/1
Rear Light Switch Check
Push side console rear light rocker switch in.
NO: Check fuse and

to Group 9015-10, Front
Work and Drive Light
Circuit.
LOOK: Are rear lights ON?
1/1
Turn Signal Check
Push right side of turn signal rocker switch down.
NO: Check fuses and

wiring. Go to Group
9015-10, Turn Signal,
Flasher and Brake Light
Circuit.
LOOK: Are right front and rear amber lights flashing? Does right indicator light on top
of steering column flash?
Push left side of turn signal rocker switch down.
LOOK: Are left front and rear amber lights flashing? Does left indicator light on top of
steering column flash?
1/1
TM1608 (20SEP06)
9005-10-20

092006
PN=84

Brake Light Switch
Check
Key switch in the ON position.
Depress and hold left brake pedal, then right brake pedal.
NO: Check fuse and

to Group 9015-10, Turn
Signal, Flasher and Brake
9005
Light Circuit.
10
21
LOOK: Rear brake light must come ON when either pedal is depressed with key switch
in ON position.
1/1
Warning Light Check
Key switch ON.
Push bottom of warning light rocker switch in.
NO: Check fuses and

wiring. Go to Group
9015-10, Turn Signal,
Flasher and Brake Light
Circuit.
LOOK: Are both front and rear amber lights ON? Are both turn signal indicators and
light in warning light rocker switch flashing?
1/1
Horn Check
Push horn button
NO: Check fuses and

wiring. Go to Group
9015-10, Horn Circuit.
LISTEN: Did horn sound?
1/1
12 Cab Component Checks
1/1
Seat Linkage Check
Lift lever (1).
Move seat forward and rearward and release lever.
NO: Repair linkage. Go to

repair manual.
LOOK: Does lever move freely and lock seat in desired

position?
T103194 UN20AUG96
1/1
TM1608 (20SEP06)
9005-10-21

092006
PN=85

Seat Height Adjustment
Check
Turn knob (3) to raise or lower seat to desired position.
LOOK: Does seat move up or down and remain in

desired position?
NO: Go to repair manual.
9005
10
22
T103194 UN20AUG96
1/1
Seat Swivel Linkage

Check
Lift lever (2) up.
Move seat from loader to backhoe position and engage

latch.
NO: Lubricate or repair

linkage. Go to repair
manual.
LOOK: Does seat latch move freely and hold seat in

desired position?
T103194 UN20AUG96
FEEL: Does lever move freely and hold seat in loader

and backhoe positions?
1/1
Seat Back Linkage

Check
Lift lever (4) up.
Position seat back as desired and engage latch.

linkage. Go to repair
manual.
FEEL: Does lever move freely and hold seat in desired

positions?
T103194 UN20AUG96
1/1
Left Cab Door Latch and

Opener Check
Unlatch door.
Observe door as it opens.
NO: Adjust cab door. Go

to repair manual.
Pull door closed and latch it.
FEEL: Does cab door latch work freely?

LOOK: Will door cylinder push door open?
LOOK: Does cab door contact door stop bumper before door cylinder bottoms?
1/1
TM1608 (20SEP06)
9005-10-22

092006
PN=86

Right Door Latch and
Opener Check (If
Equipped)
Unlatch door and pull door open.
Close and latch door.
NO: Adjust door. Go

repair manual.
FEEL: Does cab door latch work freely?

1/1
Rear Window Latch and

Opener Checks
Squeeze latches on both sides of middle rear window. Lower window to rubber
bumpers.

NO: Check for
obstructions. Go to repair
manual.
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.
LOOK: Do window latches and hinges move freely?

LOOK: Will the gas-filled cylinders slowly assist raising the window to open position?
NOTE: Cylinders must not be at end of travel when closing window.
LOOK: Do window catches hold and not bow the window in the up position?
1/1
Side Window Checks
Open left and right rear side window.
Fasten rear window against front window.
NO: Adjust windows. Go

to repair manual.
LOOK: Does sleeve on rear window align with knob on

front window?
T6171DF UN09DEC88
LOOK/FEEL: Do hinges move freely? Are locking latches

equally loaded when closed?
1/1
TM1608 (20SEP06)
9005-10-23

092006
PN=87
9005
10
23

Blower Motor Check

NO: Check wiring
harness. See Group
9015-10, Blower Circuit.
9005
10
24
T101677 UN28JUN96
Engine OFF key switch ON.

Turn blower switch (A) to position 1, 2, 3 and 4.
FEEL/LISTEN: Does blower fan have four speeds?

Does air exit from ducts?
1/1
Heater

NO: See to Group
9015-10, Blower Circuit.
T101678 UN28JUN96
Start engine and run at fast idle.

Specification
Heater CheckEngine Speed ............................................................................ Fast idle
Wait two minutes.
Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high
speed.
FEEL: Is air from ducts warm?
1/1
TM1608 (20SEP06)
9005-10-24

092006
PN=88

Air Conditioner (If
Equipped)

NO: Go to Air
Conditioning, Group
9031-10. See Charging
the system in Group
9031-20.
T101679 UN28JUN96

Specification
Air Conditioner CheckEngine Speed ............................................................... 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 be exhausted.
FEEL: Is air from ducts cool?

1/1
Rear Windshield Wiper

Check
Turn key to ON position.
Push rear wiper rocker switch to first detent, middle position.
NO: Check fuse. Check

rear wiper. Go to Group
9015-10, Wiper/Washer
Circuit.
Push rear wiper rocker switch all the way in.

Push rear wiper switch to OFF position.
LOOK: Rear wiper must operate and have two speeds.

LOOK: Wipers must return to park position.
1/1
Front Windshield Wiper

Check
Push front wiper rocker switch to first detent, middle position.
NO: Check fuse. Check

front wiper. Go to Group
9015-10, Wiper/Washer
Circuit.
Push front wiper switch all the way in.

Push front wiper switch to OFF position.
LOOK: Do both front wipers operate and have two speeds?

LOOK: Do wipers return to the park position?
1/1
TM1608 (20SEP06)
9005-10-25

092006
PN=89
9005
10
25

Front Windshield Washer
Check
Push windshield washer rocker switch in.
NO: Check fluid level,

and fluid lines for
blockage. Check wiring.
Wiper/Washer Circuit.
LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF
position.
9005
10
26
1/1
Cab Dome Light Check
Push dome light switch to ON position.
NO: Check fuse and

to Group 9015-10, Dome
Light Circuit.
LOOK: Does lights come ON?
1/1
13 Miscellaneous Checks
1/1
Vandal Protection Check
Lock cab door (s) using ignition key.
FEEL: Does lock operate freely and key not stick in lock?

lock. Go to repair manual.
1/1
Check Periodic
Maintenance Decal
Check periodic maintenance decal on inside of hood access door.
LOOK: Is periodic maintenance decal legible?
NO: Replace decal. Go to

John Deere Dealer for
part.
1/1
Backhoe Transport Pin

Check
Raise boom into transport position.
YES: Operational
Checkout completed.
Remove swing lock pin from holder in cab and install through top and bottom holes of
swing frame and through main frame.
LOOK: Does swing lock pin install freely?
NO: Repair or replace

swing lock pin. Check pin
bore for burrs or
obstruction.
1/1
TM1608 (20SEP06)
9005-10-26

092006
PN=90
Section 9010
ENGINE
Contents
Page

PowerTech 4.5 L (4045) John Deere
EngineUse CTM104 . . . . . . . . . . . . . . . .9010-05-1
Engine Sectional View. . . . . . . . . . . . . . . . . .9010-05-2
General Engine Description. . . . . . . . . . . . . .9010-05-3
9010

EngineUse CTM104 . . . . . . . . . . . . . . . .9010-15-1
Make Visual Inspection of Engine and
Supporting Systems. . . . . . . . . . . . . . . . . .9010-15-2
Diagnose Engine Malfunctions . . . . . . . . . . .9010-15-4
Group 20Adjustments
EngineUse CTM104 . . . . . . . . . . . . . . . .9010-20-1
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
Adjust Speed Control Lever Tension . . . . . . .9010-20-2
Engine Speed Control Linkage . . . . . . . . . . .9010-20-4
Slow and Fast Idle . . . . . . . . . . . . . . . . . . . .9010-20-6
Group 25Tests
PowerTech 4.5 L (4045) John Deere Engine
Use CTM104 . . . . . . . . . . . . . . . . . . . . . . .9010-25-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-1
JT05800 Digital Thermometer Installation . . .9010-25-1
Air Intake System Test Leakage . . . . . . . . . .9010-25-2
Radiator Air Flow Test. . . . . . . . . . . . . . . . . .9010-25-4
Turbocharger Boost PressureEngine
Performance Test . . . . . . . . . . . . . . . . . . .9010-25-8
Injection Pump Timing. . . . . . . . . . . . . . . . .9010-25-10
Fuel Line Test Leakage. . . . . . . . . . . . . . . .9010-25-11
TM1608 (20SEP06)
9010-1

092006
PN=1
Contents
9010
TM1608 (20SEP06)
9010-2

092006
PN=2
Group 05
Theory of Operation
For additional engine information, the component technical

manual (CTM) is also required.See PowerTech 4.5 L
(4045) John Deere Engine . (CTM104.)
M44215
Use the CTM in conjunction with this machine manual.
UN07SEP88

Use CTM104
TX,05,SS3179 1905AUG961/1
TM1608 (20SEP06)
9010-05-1

092006
PN=93
9010
05
1
Theory of Operation
Engine Sectional View
T102831
UN06AUG96
9010
05
2
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
TX,05,SS3181 1907SEP061/1
TM1608 (20SEP06)
9010-05-2

092006
PN=94
Theory of Operation
General Engine Description

Engines are vertical, in-line, valve-in-head, 4-cycle
(stroke) diesel engines.
Direct fuel injection is provided by a rotary-type
injection pump and 9.5 mm injection nozzles mounted
in cylinder head. The camshaft gear-driven injection
pump is timed to the crankshaft by the timing gear
train.
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. All engines use a bushing in No.
1 camshaft bore. The camshaft lobes determine the
duration and lift of each valve.
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,
nodular-iron or steel forging which operates in
replaceable two-piece main bearings. Crankshafts are
dynamically balanced and are machined with undercut
and rolled fillets. Two-piece main thrust bearing inserts
are used to control crankshaft endplay.
Cylinder liners are wet sleeve type 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 shirt 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. Some connecting rods
have a tapered pin-end while others have a straight
pin end.
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. Engines are equipped with an oil
cooler mounted on the right side of 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 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.
TX,05,SS3180 1907SEP061/1
TM1608 (20SEP06)
9010-05-3

092006
PN=95
9010
05
3
Theory of Operation
9010
05
4
TM1608 (20SEP06)
9010-05-4

092006
PN=96
Group 15
Diagnostic Information
Use CTM104
M44215
UN07SEP88

manual (CTM) is also required.
TX,05,SS3179 1905AUG961/1
TM1608 (20SEP06)
9010-15-1

092006
PN=97
9010
15
1
Make Visual Inspection of Engine and Supporting Systems

1. Inspect for coolant leaks at:
9010
15
2
The condition of the belts and their tension must be

checked periodically.
Radiator
Water pump
Hoses
Coolant manifold
Thermostat cover
8. Inspect fuel tank:

a. Inspect the tank mounting hardware to ensure
they are in position and tight.
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.
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 fan support and bearing.
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. See Bleed the Fuel System in
CTM207. 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.
7. Inspect fan belt and belt tensioner. Belt 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. Tensioner must turn freely and smoothly.
Tensioner must hold constant pressure on belt.
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.
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.
TM1608 (20SEP06)
9010-15-2
TX,15,SS3183 1909AUG961/2

092006
PN=98
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.
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.
12. Inspect speed control linkage.

Check for free movement. Be sure the injection
pump lever contacts the fast idle stop on the
injection pump.
15. Check for debris on exhaust manifold.

9010
15
3
13. Inspect air cleaner elements for debris, filter

condition and air restriction indicator to ensure
indicator isnt in red.
TX,15,SS3183 1909AUG962/2
TM1608 (20SEP06)
9010-15-3

092006
PN=99
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. 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.
No electrical power to injection pump

solenoid
Turn key switch to "On". Must hear

click at injection pump. Replace
fuse. See Fuse Specifications.
Repair wiring. See Engine Harness
(W8) Component Location in Group
9015-10.
Water in fuel or water frozen in fuel

line.
Drain water from fuel tank. See

Drain Fuel Tank Water and
Sediment in Operators Manual.
Inspect fuel filter for water. See
Draining Fuel Filter Sediment in
Operators Manual.
Change filter. See Replace Fuel
Filter in Operators Manual.
TM1608 (20SEP06)
9010-15-4
TX,15,SS3184 1909JUL981/15

092006
PN=100
Symptom
Problem
Solution
Debris in fuel or wrong grade of fuel
Check fuel tank outlet strainer for

type of fuel debris. Check bottom of
fuel tank for debris. See Drain Fuel
Tank Water and Sediment in
Operators Manual. Clean tank. Add
fuel.
Check grade of fuel. Add correct
fuel. See Diesel Fuel Group 9000-04
or CTM207.
Air leak on suction side of fuel

system
Check for bubbles in fuel filter and

tighten connections. See Test Air in
Fuel in CTM207. Inspect fuel lines
for damage.
Fuel transfer pump diaphragm

leaking
Check engine oil for fuel dilution.

See Oilscan Plus Test Kit in
Operators Manual. Check fuel
transfer pump. See Bench Test
Lucas and Stanadyne Fuel Supply
Pump in CTM207.
Slow cranking speed
Check battery and connections. See

Check Battery Electrolyte Level and
Terminals. Go to Group 9015-20.
Incorrect engine oil (Cold weather).
See Diesel Engine Oil in CTM104.
Restricted air filter
Check air filter restriction indicator

and air filters. Clean. See Inspect Air
Cleaner Elements in Operators
Manual.
Stuck injection pump metering valve.
Tap injection pump housing (lightly)

if engine now starts. Replace
metering valve. See your authorized
injection pump service center.
Faulty electric shut-off
Test shut-off solenoid. See 9015-15.

Inspect solenoid wiring and linkage.
Improper injection pump timing
Check timing. See Lucas and

Stanadyne Rotary Fuel Injection
Pump Timing in CTM207.
TM1608 (20SEP06)
9010-15-5
TX,15,SS3184 1909JUL982/15

092006
PN=101
9010
15
5
Symptom
9010
15
6
Engine Surges Or Stalls

Frequently
Problem
Solution
Injection pump
Remove and test pump. See

Remove Stanadyne Model DB2 and
DB4 Injection Pump in CTM207.
Injection nozzle(s)
Remove and test nozzles. See Test

Fuel Injection Nozzles in CTM207.
Worn compression rings or low

compression
Check compression. Repair. See

Test Engine Compression Pressure
in CTM104.
Blown head gasket
Remove. Route radiator overflow

into container of fluid and check for
bubbles. Bubbles indicate head
gasket linkage. See Check for Head
Gasket Failures or Head Gasket
Inspection and Repair Sequence in
CTM104.
Air in fuel
Inspect filter for evidence of air in

fuel. See Test Air in Fuel in
CTM207. Tighten connections and
bleed fuel system. See Bleed the
Fuel System in CTM207.
Fuel tank vent plugged
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. Clean tank. Add fuel. Check
grade of fuel. See Diesel Fuel in
Group 9000-04 or CTM207
Water in fuel
Drain fuel tank and inspect filter

element for water. Replace filters.
Fuel filter plugged
Replace filter.
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.
TM1608 (20SEP06)
9010-15-6
TX,15,SS3184 1909JUL983/15

092006
PN=102
Symptom
Problem
Solution
Fuel injection pump out of time
Time injection pump. See Lucas and

Check return oil fitting on top of

injection pump control cover
plugged.
Remove, inspect and clean.

Determine source of debris. See
DB4 Injection Pump in CTM207. See
your authorized injection pump
service center.
Injection pump metering valve

sticking
Remove pump top cover and

inspect. Replace metering valve.
See Remove Stanadyne Model DB2
and DB4 Injection Pump in CTM207.
See your authorized injection pump
service center.
Engine overheating
Test cooling system. See Check and

Service Cooling System in CTM104.
Fuel transfer pump
Test transfer pump pressure. See

Measure Fuel Supply Pump
PressureRotary Injection Pump in
CTM207.
Fuel injection pump
Remove fuel injection pump. See

DB4 Injection Pump in CTM207.
Test pump. See your authorized
injection pump service center.
Injection nozzle(s)
Remove and test nozzle(s). See

Test Fuel Injection Nozzles in
CTM207.
Improper valve clearance
Check and adjust valve clearance.

See Check and Adjust Valve
Clearance in CTM104.
Valve sticking or burned
Do compression pressure test. See

in CTM104.
TM1608 (20SEP06)
9010-15-7
TX,15,SS3184 1909JUL984/15

092006
PN=103
9010
15
7
Symptom
9010
15
8
Engine Misses
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 Check for Head
CTM104. Do compression pressure
test. See Test Engine Compression
Pressure in CTM104.
Air in fuel
Check for evidence of air in filter.

See Test Air in Fuel in CTM207.
Tighten connections and bleed fuel
system. See Bleed the Fuel System
in CTM207.
Check fuel tank for water. Check fuel

tank strainer and fuel filter for debris.
Clean. Check grade of fuel. See
Diesel Fuel in CTM207.
Idle speeds out of adjustment (too

low)
Test slow idle speeds. See Check

and Adjust Engine Speeds on
Stanadyne Pump in CTM207.
Fuel injection pump out of time

Fuel transfer pump
Test fuel system pressure. See

Measure Fuel Supply Pump
CTM207.
Injection pump governor faulty or

metering valve sticking
Inspect. Repair. See Remove

Stanadyne Model DB2 and DB4
Injection Pump in CTM207. See your
authorized injection pump service
center.
Engine overheating
Verify engine temperature. Test

thermostat. See Inspect Thermostat
and Test Opening Temperature in
CTM104. Replace.
TM1608 (20SEP06)
9010-15-8
TX,15,SS3184 1909JUL985/15

092006
PN=104
Symptom
Engine Does Not Develop Power
Problem
Solution
Incorrect valve clearance
Check and adjust valve clearance.

See Check and Adjust Valve
Clearance in CTM104.
Bent push rods
Inspect. Replace.
Cylinder head gasket leaking
Route radiator overflow hose into

container of fluid and check for
bubbles. Bubbles indicate head
gasket leakage. See Check for Head
CTM104.
Valve sticking or burned

in CTM104.
Worn or broken compression rings

in CTM104.
Fuel injection pump
Remove and test fuel injection

pump. See Remove Stanadyne
Model DB2 and DB4 Injection Pump
in CTM207.
Injection nozzles(s) plugged
Remove and test nozzles. See Test

Fuel Injection Nozzles in CTM207.
Fuel tank outlet strainer plugged
Check fuel tank for water or debris.

Remove and clean.
Fuel filter plugged
Replace fuel filter.
Wrong grade of fuel
Drain and add correct fuel. See

Air system restricted
Check air filter restriction and air

filters. Clean. See Inspect Air
Manual.
TM1608 (20SEP06)
9010-15-9
TX,15,SS3184 1909JUL986/15

092006
PN=105
9010
15
9
Symptom
9010
15
10
Problem
Solution
Incorrect high idle speed (too low) or

linkage out adjustment.
Adjust linkage. Check high idle

speed. See Check and Adjust
Engine Speeds on Stanadyne Pump
in CTM207.
Incorrect engine or injection pump

timing
Check. Adjust timing. See Lucas and

Incorrect valve clearance
Adjust valve clearance. See Check

and Adjust Valve Clearance in
CTM104.
Injection pump return fuel tube or

fittings are restricted
Route return line at the pump into a

separate container. If engine now
operates normal, check return line
for restriction. Replace.
Fuel transfer pump malfunction
Test fuel transfer pump pressure.

See Measure Fuel Supply Pump
CTM207.
Fuel line restricted
Route an external fuel source to fuel

transfer pump. If engine operation is
normal clean fuel line.
Excess drag in brake system
Check axle and park brake drag.

See Operational Checkout
Procedure, 9005-10.
Excess drag in axle
Test drag. See Operational

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

operation is now normal, replace
muffler.
Injection pump delivery or governor

faulty
Remove pump and test. See

service center.
TM1608 (20SEP06)
9010-15-10
TX,15,SS3184 1909JUL987/15

092006
PN=106
Symptom
Engine Emits Excessive Black or

Gray Exhaust Smoke
Engine Emits Excessive Blue or

White Smoke
Problem
Solution
Injection nozzle(s)

CTM207.
Low compression

in CTM104.
Worn camshaft
Do valve lift check. See Measure

Valve Lift and Remove Camshaft in
CTM104.
Restricted air filter
Check air filter restriction and air

filters. Clean or replace. See Inspect
Air Cleaner Elements in Operators
Manual.
Incorrect grade of fuel

Incorrect injection pump timing

Excessive fuel delivery

service center.
Injection nozzle(s)

CTM207.
Turbocharger not functioning.
Repair. See Turbocharger

Seven-Step Inspection and Remove
Turbocharger in CTM104.
Cranking speed too slow
See Test Engine Cranking Speed in

CTM104.
Check batteries and connections.
See Check Battery Electrolyte Level
and Terminals. Go to Group
9015-20.
TM1608 (20SEP06)
9010-15-11
TX,15,SS3184 1909JUL988/15

092006
PN=107
9010
15
11
Symptom
Problem
Solution

Engine running too cold
Check thermostat operation. See

Inspect Thermostat and Test
Opening Temperature in CTM104.
Injection pump out of time

Injection nozzle(s)

CTM207.
Low compression
Do compression test. See Test

Engine Compression Pressure in
CTM104.
Excessive wear in liners and/or

piston rings stuck
Disassemble, inspect, repair.
Wrong grade of fuel

Injection nozzle(s)

CTM207.
Fuel injection pump
Remove and test fuel injection

pump. See Remove Stanadyne
in CTM207.
Low engine oil level.
Add oil.
Stuck cold weather starting aid
Repair.
Incorrect injection pump timing.

Low coolant temperature.
Remove and check thermostat. See

Inspect Thermostat and Test
Opening Temperature in CTM104.
9010
15
12
Slow Acceleration
Detonation (Excess Engine

Knock)
TM1608 (20SEP06)
9010-15-12
TX,15,SS3184 1909JUL989/15

092006
PN=108
Symptom
Problem
Solution
Abnormal Engine Noise
Low or incorrect engine oil (too thin).
Add correct oil to proper level.
Loose or worn hydraulic pump drive

coupling
Inspect. Repair.
Engine oil diluted with fuel
Inspect engine oil. Determine cause

of fuel dilution.
Incorrect fuel injection pump timing

Excessive valve clearance
Adjust valve clearance. See Check

and Adjust Valve Clearance in
CTM104.
Bent push rods
Inspect. Replace.
Worn rocker arm shafts
Replace.
Loose connecting rod caps
Inspect, tighten connecting rod cap

screws. See Torque-Turn
Connecting Rod Cap Screws in
CTM104.
Loose main bearing caps
Inspect, tighten main bearing cap

screws. See procedure under Install
Crankshaft in CTM104.
Worn main bearings
Replace bearings. See Remove

Crankshaft Main Bearings in
CTM104.
Worn connecting rod bearings
Replace bearings. See procedure

under Remove Pistons and
Connecting Rods in CTM104.
Incorrect cam timing
Check engine timing. Repair. See

procedure under Install Camshaft in
CTM104.
Scored piston
Inspect. Replace.
Worn piston pin bushings and pins
Inspect. Replace pins and bushings.

See Inspect Piston Pins and
Bushings in CTM104.
TM1608 (20SEP06)
9010-15-13
TX,15,SS3184 1909JUL9810/15

092006
PN=109
9010
15
13
Symptom
Problem
Solution
Low Oil Pressure (Oil Pressure

Light onRed "Stop" Flashing)
Low oil level
Add oil to proper level. Inspect

engine oil.
Wrong viscosity oil/oil diluted with

diesel fuel
Change oil. Check injection pump

shaft seals and transfer pump
diaphragm. See Remove Stanadyne
in CTM207.
Oil pressure switch or indicator
Check engine oil pressure. See

Check Engine Oil Pressure in
CTM104. Test switch and indicator.
See 9015-15.
Oil pressure regulating valve
Test or replace. See Remove and

Install Oil Pressure Regulating Valve
and Seat in CTM104.
Plugged or broken oil pump intake

screen
Inspect. Clean.
Loose oil pump drive gear
Inspect. Repair. See Inspect and

Measure Clearances in CTM104.
Worn oil pump gear or housing
Remove, inspect and repair. See

Remove Engine Oil Pump in
CTM104.
Excessive main bearing, connecting

rod or balance shaft clearance
See Check Main Bearing Oil

Clearance, Inspect and Measure
Connecting Rod Bearings, and
Inspect and Measure Balancer Shaft
Bushings and Journals in CTM104.
Cracked cylinder block
Replace cylinder block. See Engine

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

paths. Repair.
Low coolant level
Fill cooling system and check for

leaks. See Check and Service
Cooling System in CTM104.
Low engine oil level
Add oil.
9010
15
14
Engine Overheats (Engine

Coolant Indicator Light On and
Red "Stop" Flashing)
TM1608 (20SEP06)
9010-15-14
TX,15,SS3184 1909JUL9811/15

092006
PN=110
Symptom
Problem
Solution
Loose or broken fan belt.
Inspect belt tensioner or replace belt.

See Remove and Install Fan Belt in
Group 1609-0510.
Engine overloaded, operating in

wrong gear
Reduce load.
Fan on backwards
Check for correct fan installation.

See Inspect and Install Fan
Assembly in CTM104.
Radiator dirty or plugged
Check air flow. See Group 9010

25. Clean radiator. See Check and
Radiator shroud missing, damaged

or baffles missing
Inspect. Repair or replace.
Improper fuel

Radiator cap
Replace cap.
Faulty temperature sender
Test, repair or replace. See 9015-15.

Excessive axle drag
Check axle drag. See Operational

Excessive brake drag
Check Brake drag. See Operational

Faulty thermostat (Struck closed)
Inspect thermostat. See Inspect

Thermostat and Test Opening
Temperature in CTM104.
Thermostat missing, cooling system

coated with lime deposits
Replace thermostats. See Inspect

Thermostat and Test Opening
Temperature in CTM104. Flush
cooling system. See Flush and
TM1608 (20SEP06)
9010
15
15
9010-15-15
TX,15,SS3184 1909JUL9812/15

092006
PN=111
Symptom
Problem
Solution
Water pump

Disassemble Water Pump CTM104.
Excessive fuel delivery
Remove. Check for proper fuel

delivery, adjust. See Remove
Stanadyne Model DB2 and DB4
Injection Pump in CTM207.
Scored piston
Replace piston. See Engine

Engine Runs Cold
Thermostat (stuck open)
Replace. See Inspect Thermostat

and Test Opening Temperature in
CTM104.
Oil in Coolant Or Coolant in Oil
Leaking cylinder head gasket
Replace gasket. See Check for

Head Gasket Failures or Head
Gasket Inspection and Repair
Sequence in CTM104.
Leaking cylinder liner packing
Replace packings. See Engine

Cracked cylinder liner
Replace liner. See Engine

Oil cooler
Replace oil cooler. See Remove,

Inspect, and Install Oil Cooler in
CTM104
Cracked cylinder block
Replace block. See Engine

Air system restricted
Check filter restriction indicator and

air filters. Replace. See Inspect Air
Manual.
Leakage in fuel system
Inspect. Repair.
Refill with correct fuel. See Diesel

Fuel in CTM207.
Operator holding hydraulics over

relief.
Return control levers to neutral

position.
9010
15
16
Excessive Fuel Consumption
TM1608 (20SEP06)
9010-15-16
TX,15,SS3184 1909JUL9813/15

092006
PN=112
Symptom
Turbocharger Excessively Noisy

or Vibrates
Oil Dripping From Turbocharger

Adapter
Problem
Solution
High system relief valve setting
Test system relief valve pressure.

See 9025-25

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

Injection Nozzles in CTM207.
Bearings not lubricated
Insufficient oil pressure. Check for

restricted turbocharger oil line.
Worn bearings
Replace. See Turbocharger

Air leak in engine, intake or exhaust

manifold
Inspect and repair. See Test for

Intake Air Leaks or Check for
Exhaust Air Leaks in CTM104.
Improper clearance between turbine

wheel and turbine housing
Remove exhaust elbow and air inlet

hose. Inspect and repair. See
Turbocharger Seven-Step Inspection
and Remove Turbocharger in
CTM104.
Broken blades on turbine
Remove exhaust elbow and air inlet

hose. Inspect and repair. See
CTM104.
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 Check for
Turbocharger Oil Seal Leak,
CTM104.
Excessive crankcase pressure
Check for plugged oil drain line.

Clean. See Check for Turbocharger
Oil Seal Leak in CTM104
TM1608 (20SEP06)
9010
15
17
9010-15-17
TX,15,SS3184 1909JUL9814/15

092006
PN=113
Symptom
Excessive Drag In Turbocharger

Rotating Members
9010
15
18
Problem
Solution
Turbocharger oil return line carbon

buildup where line passes exhaust
manifold.
Remove line. Inspect and clean.
Carbon build-up behind turbine

wheel caused by combustion
deposits
Inspect and clean. See Turbocharger

Dirt build-up behind compressor

wheel caused by air intake leaks
Inspect and repair. See

CTM104.
Bearing seizure or dirty or worn

bearings caused by excessive
temperature, unbalanced wheel, dirty
oil, oil starvation, or insufficient
lubrication
Check for plugged air filters. See

Inspect Air Cleaner Elements in
Operators Manual.
TX,15,SS3184 1909JUL9815/15
TM1608 (20SEP06)
9010-15-18

092006
PN=114
Group 20
Adjustments
Use CTM104
M44215
UN07SEP88

TX,05,SS3179 1905AUG961/1

Installation
SERVICE EQUIPMENT AND TOOLS
AClamp-On Transducer. Remove paint using 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.
T6813AG
CRed Clip (+). Connect to transducer.
UN28FEB89
JT05801 ElectonicTachometer Contains of:
DTachometer Readout. Install cable.
TX,25,SS3189 1912AUG961/1
TM1608 (20SEP06)
9010-20-1

092006
PN=115
9010
20
1
Adjustments
Adjust Speed Control Lever Tension

SPECIFICATIONS
Tighten nut (A) until 6271 N (1416 lb force) is

required to move lever using a spring scale.
Specification
Lever NutTorque ......................................... 6271 N (1416 lb force)
9010
20
2
UN11MAY94
6271 N (1416 lb force)
T8219CA
Lever Nut Torque
TX,20,SS3186 1912AUG961/1
TM1608 (20SEP06)
9010-20-2

092006
PN=116
Adjustments
9010
20
3
TM1608 (20SEP06)
9010-20-3

092006
PN=117
Adjustments
Engine Speed Control Linkage

Injection Pump Lever Override
28 mm (0.080.32 in.)
Speed Control Lever Rear

Position Minimum Override
0.5 mm (0.02 in.)
High Idle Minimum Override
2 mm (0.08 in.)
UN27AUG96
SPECIFICATIONS
9010
20
4
T103046
1. Move speed control lever to extreme forward position.

2. Measure injection pump lever override. Override must
be 28 mm (0.080.32 in.).
Specification
Injection Pump LeverOverride ....................... 28 mm (0.080.32 in.)
3. Adjust yoke on speed control rod to provide override.

4. Move speed control lever to rear most position and
check override. Override must be at least 0.5 mm (0.02
in.) minimum.
Specification
Speed Control Lever Rear
PositionMinimum Override .......................................... 0.5 mm (0.02 in.)
5. Recheck high idle for a minimum of 2 mm (0.08 in.)

override.
Specification
High IdleMinimum Override ........................................... 2 mm (0.08 in.)
6. Remove reservoir cowling to adjust foot control pedal.
TM1608 (20SEP06)
9010-20-4
TX,20,SS3187 1912AUG961/2

092006
PN=118
Adjustments
7. Disconnect swivel (A) from rod (B). Adjust vertical rod
(C) length to allow foot control pedal to stop on floor
with hand lever in the extreme forward position.
T7387AB
UN16DEC91
9010
20
5
TX,20,SS3187 1912AUG962/2
TM1608 (20SEP06)
9010-20-5

092006
PN=119
Adjustments
Slow and Fast Idle

Slow Idle Speed
900 + 25 - 0 rpm
Fast Idle Speed
2375 + 25 - 0 rpm
UN27AUG96
SPECIFICATIONS

Electronic Tachometer
9010
20
6
T103088
Sealing Wire Pliers
1. Run engine until it is at normal operating temperature.

2. Install tachometer. See procedure in this group.
ASlow Idle Adjusting Screw

BSpeed Control Rod Pin
CFast Idle Adjusting Screw
CAUTION: Take care to avoid rotating fan

blades while making injection pump
adjustments.
3. Remove pin (B) and disconnect speed control rod from
fuel injection pump lever.
4. Start engine.
5. Hold injection pump lever forward (toward radiator).
Check to make sure slow idle is to specifications.
Specification
Slow IdleSpeed ............................................................ 900 + 25 - 0 rpm
6. If slow idle is not correct:

a. Check air cleaner elements.
b. Remove sealing wire.
c. Loosen slow idle screw lock. Turn screw (A)
clockwise to increase speed and counterclockwise
to decrease engine speed. Tighten lock nut.
7. Hold injection pump lever rearward (away from
radiator). Check to make sure fast idle is to
specifications
Specification
Fast IdleSpeed ........................................................... 2375 + 25 - 0 rpm
TM1608 (20SEP06)
9010-20-6
TX,20,SS3188 1923JUN981/2

092006
PN=120
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
7
9. Connect rod.
TX,20,SS3188 1923JUN982/2
TM1608 (20SEP06)
9010-20-7

092006
PN=121
Adjustments
9010
20
8
TM1608 (20SEP06)
9010-20-8

092006
PN=122
Group 25
Tests

manual (CTM) is also required.See POWERTECH 4.5L
(4045) and 6.8L (6068) Diesel Engines Base Engine.
(CTM104.)
M44215
UN07SEP88

Use CTM104
TX,05,SS3179 1907SEP061/1

Installation

T6813AG
UN28FEB89
JT05801 ElectonicTachometer Contains of:
TX,25,SS3189 1912AUG961/1
JT05800 Digital Thermometer Installation

JT05800 Digital Thermometer Consists of:
ATemperature Probe
UN28FEB89
BCable
T6808CE
CDigital Thermometer
TX,25,SS3190 1907SEP061/1
TM1608 (20SEP06)
9010-25-1

092006
PN=123
9010
25
1
Tests
Air Intake System Test Leakage

SPECIFICATIONS
13.820.7 kPa
0.130.21 bar
23 psi
UN23FEB89
Air Intake System Pressure

JDG51 Adapter
T5906AP
Air Regulator With Gauge
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.
UN05SEP96
2. Put a plastic bag over safety element and install main

element and cover.
3. Remove plug or either start aid from air intake tube
and install adapter (A).
T103547
9010
25
2
4. Connect air pressure regulator to adapter using hose

and fitting.
CAUTION: Plastic bag can be sucked into
engine if engine is started when trying to close
valves.
5. Pressurize air intake system to specifications.
Specification
Air Intake SystemPressure ............................................ 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.
TM1608 (20SEP06)
9010-25-2
TX,25,SS3194 1907SEP061/2

092006
PN=124
Tests
IMPORTANT: Prevent possible damage to machine.
The red dot on outside of adapter must
face up when installing the adapter.
7. Install plug or starting aid adapter if equipped. The red
dot on outside of adapter must face up when installing
the adapter.
TX,25,SS3194 1907SEP062/2
TM1608 (20SEP06)
9010-25-3

092006
PN=125
9010
25
3
Tests
Radiator Air Flow Test

SPECIFICATIONS
Engine Speed
2375 + 25 - 0 rpm
Voltage Reading (typical) Voltage
4.85 volts
ESSENTIAL TOOLS
JT05529 Air Flow Meter
Tachometer
Multimeter
1. Apply parking brake, put transmission in neutral and

lower equipment to the ground. Stop engine.
2. Install tachometer. (See procedure in this group.)
UN01NOV88
3. Check that all sheet metal is in place. Close side

shields.
4. Divide the surface of the grille into 16 equal squares.
T6080AH
9010
25
4
5. Start engine and run at specified speed.

Specification
EngineSpeed ............................................................. 2375 + 25 - 0 rpm
6. Connect air flow meter to digital multimeter. Turn

switch on multimeter to 20 volts A.C.
7. Place air flow meter in contact with grille. Arrow on
meter must point in direction of air flow (away from
machine).
8. Record voltage reading for each area.
9. Combined total of air flow test readings must be
approximately at specifications.
Specification
Voltage Reading (typical)
Voltage......................................................................................... 4.85 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.
TM1608 (20SEP06)
9010-25-4
TX,9010,SS4105 1923JUN981/3

092006
PN=126
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.
TX,9010,SS4105 1923JUN982/3
9010
25
5
TM1608 (20SEP06)
9010-25-5

092006
PN=127
Tests
T6500AK
1921MAR89
9010
25
6
T95955
UN25MAY89
Divide the surface of the grille into 16 equal squares.

Park brake ON.
Transmission in Neutral and side shields closed.
Divide the surface of the grille into 16 equal squares.
Start engine.
Perform AIR FLOW TEST at fast idle. Observe correct
air flow direction and place air flow meter in direct
contract with grille.
Record air flow in each square.
Combine total of air flow test readings must be
approximately at specifications.
TX,9010,SS4105 1923JUN983/3
TM1608 (20SEP06)
9010-25-6

092006
PN=128
Tests
9010
25
7
TM1608 (20SEP06)
9010-25-7

092006
PN=129
Tests
Turbocharger Boost PressureEngine

Performance Test
82 10 C (180 20 F)
Engine Speed
2200 rpm
Turbocharger Boost Pressure

(Using No. 2 Fuel)
4055 kPa (0.410.55 bar) (6

8 psi)
UN27AUG96
SPECIFICATIONS
Engine Temperature
T103239
ESSENTIAL TOOLS
9010
25
8
JT07248 Turbocharger Boost Test Kit

30 psi Gauge
Digital Thermometer
IMPORTANT: On power shift transmissions ONLY,

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

No. 1 fuel.
1. Remove plug (A) and install adapter and gauge.
2. Install tachometer and thermometer. (See procedure in
this group.)
3. Apply park brake and put FNR lever in neutral. Run
engine until it is at normal operating temperature.
Specification
EngineTemperature ..................................... 82 10 C (180 20 F)
4. Adjust engine speed to specification.

Specification
EngineRated Speed ................................................................. 2200 rpm
Activate the loader control valve and hold over relief to

apply a hydraulic load to engine. The gauge will show a
pressure rise and then a pressure drop.
TM1608 (20SEP06)
9010-25-8
CED,TX03399,4245 1909JUN981/2

092006
PN=130
Tests
Specification
TurbochargerBoost Pressure
(Using No. 2 Fuel) ........................................ 4055 kPa (0.410.55 bar)
(68 psi)
5. If engine rpm DOES NOT drop to specification, use the

following procedure to apply additional load to engine.
6. Lower stabilizers and loader to raise wheels off ground.
7. Put machine in 3rd gear and FNR lever in forward or
reverse.
9010
25
9
8. Run engine at fast idle (2375 + 25 - 0 rpm). Apply

service brakes until engine rpm begins to drop to
specifications.
Specification
9. Record highest boost pressure at rated rpm.

Specification
TurbochargerBoost Pressure
(Using No. 2 Fuel) ........................................ 4055 kPa (0.410.55 bar)
(68 psi)
10. Repeat test several times.

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

Restricted fuel filter elements.
Incorrect fast idle adjustment.
Incorrect injection pump timing.
Exhaust manifold leaks.
Intake manifold leaks.
Faulty fuel transfer pump.
Low compression pressure.
Faulty fuel injection nozzle.
Carbon build-up in turbocharger.
Turbocharger compressor or turbine wheel rubbing
housing.
Low fuel injection pump fuel delivery, remove and
test fuel injection pump for low fuel delivery.
CED,TX03399,4245 1909JUN982/2
TM1608 (20SEP06)
9010-25-9

092006
PN=131
Tests
Injection Pump Timing

Engine Model
4045
Net hp (kW)
80hp (60 kW)
Engine Rated Speed
2200 rpm
Engine Dynamic Timing (BTDC)
6.5 + 0 - 1
UN03NOV97
SPECIFICATIONS
ESSENTIAL TOOLS
RG6293
9010
25
10
JT07158 TIME TRAC Kit

occur.
AFront Plate
BPump Flange
The JT07158 TIME TRACThe JT07158 kit electronically

indicates start of injection with respect to piston top dead
center, and allows setting injection pump timing to provide
optimum power, smoke and exhaust emissions.
Timing engines with this tool improves consistency
between engines and helps to control cylinder firing
pressures which can be a factor in head gasket failures as
well as improve overall engine efficiencies.
1. Install JT07158 TIME TRAC. See Check and Adjust
Rotary Injection Pump Dynamic Timing CTM207.
2. Raise the machine off the ground with stabilizers and
loader. Put transmission in third forward.
3. Operate machine at WOT. Slowly depress service
brakes until engine is at 2200 rpm.
Specification
4. Record dynamic timing.

Specification
EngineDynamic Timing (BTDC)............................................. 6.5 + 0 - 1
TIME TRAC is a registered trademark of the Stanadyne Automotive

Corp.
TM1608 (20SEP06)
9010-25-10
CED,TX03399,4246 1910JUN981/2

092006
PN=132
Tests
5. If timing is not to specification, follow Lucas and
Stanadyne Rotary Fuel Injection Pump Timing
procedure in CTM207.
CED,TX03399,4246 1910JUN982/2
Fuel Line Test Leakage

Connections may allow air to enter the fuel system without
allowing fuel to leak out. Follow this procedure to find air
leaks in the system.
9010
25
11
Disconnect fuel supply and fuel return lines at fuel tank.

Drain all fuel from system, including fuel transfer pump,
fuel injection pump, and fuel filter(s).
Close end of fuel return line using a plug, cap, or a short
length of hose, plug, and clamps.
CAUTION: Never exceed 103 kPa (1 bar) (15 psi)
to prevent damage to fuel system components.
Specification
Prevent Damage To Fuel
SystemPressure ..................................... Never exceed 103 kPa (1 bar)
(15 psi)
Pressurize the system to 69 kPa (0.7 bar) (10 psi) at the

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

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

internal leak path may allow air to enter the fuel
system. If an internal pump leak is suspected,
remove the pump and have a pressure test
performed by an authorized repair station.
TX,25,SS3209 1907SEP061/1
TM1608 (20SEP06)
9010-25-11

092006
PN=133
Tests
9010
25
12
TM1608 (20SEP06)
9010-25-12

092006
PN=134
Section 9015
Electrical System
Contents
Page
Page
Group 05System Information

Visually Inspect Electrical System . . . . . . . . .9015-05-1
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
System Functional Schematic
Information. . . . . . . . . . . . . . . . . . . . . . . .9015-05-11
Reading a System Functional Schematic . .9015-05-12
Reading a Component Location
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-05-14
Electrical Schematic Symbols . . . . . . . . . . .9015-05-18
Lock Harness (W9)

Component Location-315SE Only . . . . . .9015-10-41
Connectors, Wire and Pin
Location315SE Only. . . . . . . . . . . . . . .9015-10-42
Air Conditioning Compressor Harness (W11)
Component Location . . . . . . . . . . . . . . . .9015-10-43
Connectors, Wire and Pin Location. . . . .9015-10-44
Radio Harness (W12)
Connectors, Wire and Pin Location . . . . .9015-10-46
Selective Flow Valve Harness (W15)
Ride Control Harness (W17)
Pin Disconnect Harness (W18)
Group 10System Diagrams

Component Identification Table . . . . . . . . . . .9015-10-1
Fuse
Color Codes (Blade-Type) . . . . . . . . . . . . .9015-10-2
Specifications. . . . . . . . . . . . . . . . . . . . . . .9015-10-3
Wiring and Schematic Diagrams Legend. . . .9015-10-4
System Functional Schematic Section
Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-8
System Functional Schematic . . . . . . . . . . . .9015-10-9
Cab Roof Harness (W5)
Cab Roof Harness (W5)
Cab Side Console Harness (W6)
Front Console Harness (W7)
Component Location (With Optional
Power Shift) . . . . . . . . . . . . . . . . . . . . .9015-10-29
Engine Harness (W8)
Component Location (With Optional
Power Shift) . . . . . . . . . . . . . . . . . . . . .9015-10-33
Blower Harness (W10)
TM1608 (20SEP06)
Group 15Sub-System Diagnostics

Power Circuit
Operational Information . . . . . . . . . . . . . . .9015-15-1
Theory Of Operation . . . . . . . . . . . . . . . . .9015-15-1
Schematic . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-2
Sub-System Diagnostics . . . . . . . . . . . . . .9015-15-3
Power Circuit Diagnostic Procedures . . . . . .9015-15-3
Start Circuit Operational Information . . . . . . .9015-15-5
Start Circuit Theory Of Operation . . . . . . . . .9015-15-6
Start Circuit Schematic . . . . . . . . . . . . . . . . .9015-15-7
Start Circuit
Diagnostic Procedures . . . . . . . . . . . . . . . .9015-15-8
Start Circuit Diagnostic Procedures . . . . . . . .9015-15-8
Charging Circuit Operational Information . . .9015-15-11
Charging Circuit Theory of Operation . . . . .9015-15-11
Charging Circuit Schematic . . . . . . . . . . . . .9015-15-12
Sub-System Diagnostics/Charging
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-13
Charging Circuit Diagnostic Procedures . . .9015-15-13
Differential Lock Circuit
Operational Information . . . . . . . . . . . . . .9015-15-16
Theory of Operation. . . . . . . . . . . . . . . . .9015-15-16
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-17
9015-1

092006
PN=1
9015
Contents
9015
Page
Page
Diagnostic Procedures . . . . . . . . . . . . . . .9015-15-17

Differential Lock Circuit Diagnostic
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-17
MFWD Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-20
MFWD Circuit Diagnostic Procedures . . . . .9015-15-20
Display Monitor Circuit Operational
Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-22
Display Monitor Circuit Theory Of
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-23
Display Monitor Circuit Schematic . . . . . . . .9015-15-25
Sub-System Diagnostics/Display Monitor . .9015-15-26
Display Monitor Diagnostic Procedures . . . .9015-15-26
Indicator Circuit Operational Information . . .9015-15-28
Indicator Circuit Specifications. . . . . . . . . . .9015-15-28
Indicator Circuit Theory Of Operation . . . . .9015-15-29
Indicator Circuit Schematic . . . . . . . . . . . . .9015-15-30
Sub-System Diagnostics/Indicator Circuit . .9015-15-31
Indicator Circuit Diagnostic Procedures . . . .9015-15-31
Park Brake/FNR Circuit
Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-33
Theory of Operation (Manual Shift) . . . . .9015-15-34
Schematic (Manual Shift) . . . . . . . . . . . . .9015-15-35
Theory Of Operation (Power Shift). . . . . .9015-15-36
Schematic (Power Shift) . . . . . . . . . . . . .9015-15-38
Park Brake/Neutral Disconnect Circuit
Pump Unloading Valve Circuit Operational
Information. . . . . . . . . . . . . . . . . . . . . . . .9015-15-54
Pump Unloading Valve Circuit Theory of
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-54
Pump Unloading Valve Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-55
Sub-System Diagnostics/Pump Unloading
Valve Circuit . . . . . . . . . . . . . . . . . . . . . .9015-15-56
Pump Unloading Valve Diagnostic
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-56
Sideshift Circuit Operational Information
315SE . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-57
Sideshift Circuit Theory of Operation
315SE . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-57
Sideshift Circuit Schematic315SE . . . . . .9015-15-58
Subsystem Diagnostics/Sideshift Circuit
315SE . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-58
Sideshift Circuit Diagnostic Procedures . . . .9015-15-59
Boom Lock Circuit Operational
Information315SE. . . . . . . . . . . . . . . . .9015-15-61
Boom Lock Circuit Theory of Operation

315SE . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-61
Boom Lock Circuit Schematic315SE . . . .9015-15-62
Subsystem Diagnostic/Boom Lock
Circuit315SE . . . . . . . . . . . . . . . . . . . .9015-15-63
Boom Lock Diagnostic Procedures
315SE . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-63
Ride Control Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-65
Ride Control Circuit Diagnostic
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-66
Selective Flow Valve Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-70
Sub-System Diagnostics . . . . . . . . . . . . .9015-15-71
Selective Flow Valve Diagnostic
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-71
Pin Disconnect Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . . .9015-15-74
Pin Disconnect Circuit Diagnostic
Procedures . . . . . . . . . . . . . . . . . . . . . . .9015-15-75
TM1608 (20SEP06)
Group 20References
Alternators and Starting MotorsUse
CTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
JTO5801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Battery Operation . . . . . . . . . . . . . . . . . . . . .9015-20-2
Battery Specifications . . . . . . . . . . . . . . . . . .9015-20-3
Diagnose Battery Malfunctions . . . . . . . . . . .9015-20-4
Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-5
Using Booster Batteries12 Volt System . . .9015-20-7
Alternator Operation65 Amp Bosch and 95
Amp Bosch . . . . . . . . . . . . . . . . . . . . . . . .9015-20-8
Alternator Operation65 Amp Bosch and
95 Amp BoschContinued . . . . . . . . . . . .9015-20-9
Tachometer Calibration
(S.N. -852337) . . . . . . . . . . . . . . . . . . . . . .9015-20-9
(S.N. 852338- ) . . . . . . . . . . . . . . . . . . . .9015-20-10
9015-2

092006
PN=2
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.
6. 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.
Look for missing or worn conduit. This could

indicate a wire problem.
2. Look for loose or broken connectors and wires.
3. Inspect batteries for:
like burned insulation. Put your hand on the

alternator. Heat in these parts when the machine
has not been operated for some time is a sure clue
to charging circuit problems.
7. Start machine. Check all gauges for good operation

and check to see if system is charging or
discharging.
Corroded terminals
Loose terminals or battery posts
Dirty condition
Damp condition
Cracked case
Proper electrolyte level
8. In general, look for anything unusual.
4. Check alternator belt tension.

5. After machine has been shut down for five minutes
inspect for overheated parts. They will often smell
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,9015,QQ6283 1901MAY951/1
TM1608 (20SEP06)
9015-05-1

092006
PN=137
9015
05
1
System Information
Malfunctions
T7713AD
1927FEB92
9015
05
2
ABattery
BFuse
CSwitch
DLight
1. There are four common circuit malfunctions.
EGround
Component malfunctions can easily be confused

with circuit malfunctions. Therefore, care must be
exercised when isolating the cause of a problem.
High-Resistance Circuit
Open Circuit
Grounded Circuit
Shorted Circuit
Example: Light does not operate or is dim when

switch is turned ON, until switch connector is
disconnected and reconnected.
2. 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).
After the component.
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.
TX,9015,QQ6284 1926SEP961/1
TM1608 (20SEP06)
9015-05-2

092006
PN=138
System Information
High Resistance Circuit
T7713AG
1926FEB92
9015
05
3
ABattery
BFuse
CSwitch
DSwitch Terminal
EHigh Resistance
FHarness Connector
GLight Terminal
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).
HLight
IGround
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.
If less than battery voltage is measured, check again

closer to switch.
TX,9015,QQ6285 1926SEP961/1
TM1608 (20SEP06)
9015-05-3

092006
PN=139
System Information
Open Circuit
T7713AF
1927FEB92
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.
If battery voltage is measured, check for voltage closer

to ground at harness connector (E).
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.
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).
To locate an open circuit:

Check fuse. If blown, replace and operate circuit. If
fuse blows a second time, continue check.
In the example, zero voltage will be measured at light

terminal, indicating a broken wire between harness
connector and light terminal.
With switch (C) ON check for battery voltage at switch

terminal (D).
If battery voltage had been measured, the next check

for voltage would be at ground connection (I).
If no voltage is measured, check switch, fuse and

wiring to battery.
Normal measured voltage at a ground connection

should be 0.0 to 0.5 volts.
TM1608 (20SEP06)
9015-05-4
TX,9015,QQ6286 1926SEP961/2

092006
PN=140
System Information
Specification
Ground ConnectionNormal
Voltage ........................................................................... 0.00.5 volts
When problem is located, repair as needed then

repeat last check.
If battery voltage is measured, poor connection to

frame or broken wire is indicated.
TX,9015,QQ6286 1926SEP962/2
9015
05
5
TM1608 (20SEP06)
9015-05-5

092006
PN=141
System Information
Grounded Circuit
T7713AE
1927FEB92
9015
05
6
ABattery
BFuse
CFuse Terminal
DSwitch
ESwitch Terminal
FHarness Connector
GHarness Connector
HGrounded Circuit
ILight (Component) Terminal
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).
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).
TM1608 (20SEP06)
JLight
KGround
9015-05-6
TX,9015,QQ6287 1926SEP961/2

092006
PN=142
System Information
TX,9015,QQ6287 1926SEP962/2
9015
05
7
TM1608 (20SEP06)
9015-05-7

092006
PN=143
System Information
Shorted Circuit
T7713AH
1927FEB92
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.
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.
To locate a shorted circuit:
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).
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.
Disconnect circuit at convenient places like harness

connectors (G), (I) and light terminal (K) until light (J)
goes OFF.
Turn switch (F) ON. Both lights (J and L) will be ON,

only light (L) should be ON.
TM1608 (20SEP06)
9015-05-8
TX,9015,QQ6288 1926SEP961/2

092006
PN=144
System Information
Repair or replace wires and harnesses as needed.
Install tie bands and clamps on harnesses as required
to prevent future failures.
TX,9015,QQ6288 1926SEP962/2
Multimeter
The multimeter is an autoranging digital display that
allows very accurate readings to be taken.
ADisplay
BVoltage AC (Alternating Current)
CVoltage DC (Direct Current)
DResistance
EDiode Test/Continuity
FCurrent AC (Alternating Current)
GCurrent DC (Direct Current)
HVoltage, Resistance, Diode/Continuity (Red Lead
Input)
IGround (Black Lead Input)
JCurrent/Amps (Red Lead Input)
T8074AA
1903SEP93
9015
05
9
TX,9015,QQ6289 1920MAR961/1
TM1608 (20SEP06)
9015-05-9

092006
PN=145
System Information
Seven Step Electrical Test Procedure
T7719AA
1905MAR92
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
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

No voltage. Go to Step 3.
TM1608 (20SEP06)
9015-05-10
TX,9015,QQ6290 1901MAY951/2

092006
PN=146
System Information
Step 3Switch OFF
Check component side of circuit breaker for continuity to ground
Continuity to ground. Repair grounded circuit at or before switch.

No continuity to ground, replace circuit breaker.
Step 4Switch ON
Check component side of circuit breaker for battery voltage

No voltage. Go to Step 5.
Step 5
Disconnect 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

Low voltage, repair high resistance in circuit between fuse and
component.
9015
05
11
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.
TX,9015,QQ6290 1901MAY952/2
System Functional 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).
NOTE: All System Functional Schematics are shown

with key switch in the off position.
TX,9015,QQ6291 1920MAR961/1
TM1608 (20SEP06)
9015-05-11

092006
PN=147
System Information
Reading a System Functional Schematic
T7502CE
1929MAY91
9015
05
12
APower Wires
BContinuity Chart
CComponent Schematic
Symbol
DComponent Identification
Code
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.
EComponent Name
FGround Wires
GCircuit Name
HSection Number
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 drawings, the 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.
Each electrical component is shown by a schematic

symbol (C), the component name (E), and a
TX,9015,QQ6292 1912APR941/1
TM1608 (20SEP06)
9015-05-12

092006
PN=148
System Information
9015
05
13
TM1608 (20SEP06)
9015-05-13

092006
PN=149
System Information
Reading a Component Location Diagram
T102966
1904SEP96
9015
05
14
TM1608 (20SEP06)
9015-05-14
TX,9015,QQ6293 1917AUG961/4

092006
PN=150
System Information
AComponent Identification
Number
BComponent Name
CEnd View of Connector
DMating Connector X
Identification Number
EHarness Component
Identification Number
NOTE: The same names and identification numbers

are used on all machine schematic and
harness electrical drawings throughout the
operation and test technical manual, so
components can easily be cross-referenced
from one drawing to another.
The component location by harness drawing is a
pictorial representation that shows harness routing,
component location and mating harness connector
information.
The location of each component that is connected to
the harness is shown and identified by its
alpha-numeric identification number.
FName of Harness
GDiagram View of
Connector
HTerminal Number
IWire Number and Color

JRouting Destination(s) of
Wire
and a name. An end view of the connector is shown.

Also, a diagram view of the connector shows
connector terminal number, wire number and color and
destination of each wire.
For example, X18 connector connects the Cab Work
Light Harness to the Load Center Harness. Terminal 5
of the connector contains L02 Brn Wire, which routes
to E20 Left Front Work Light, E22 Left Rear Work
Light, and E23 Right Rear Work Light.
Each wiring harness component location is followed by
individual component connector drawings. These
drawings show an end view and a diagram view of
each connector in the harness that connects to a
component.
Each connector that joins one harness to another is

identified by an X component identification number
TM1608 (20SEP06)
9015-05-15
TX,9015,QQ6293 1917AUG962/4

092006
PN=151
9015
05
15
System Information
T102978
1905SEP97
9015
05
16
TM1608 (20SEP06)
9015-05-16
TX,9015,QQ6293 1917AUG963/4

092006
PN=152
System Information
In the preceding example, to see the location of L02
Brn Wire in connectors for E20, E22, and E23 Work
Lights, the connection would reference the
Connectors for Cab Work Light Harness on the page
following the component location drawing. This
drawing shows the end view of the wiring harness

connector for each component. In the case of L02
Brown wire, it is located in Terminal A for all three
work lights.
TX,9015,QQ6293 1917AUG964/4
9015
05
17
TM1608 (20SEP06)
9015-05-17

092006
PN=153
System Information
Electrical Schematic Symbols
T7719BA
1911OCT93
9015
05
18
TM1608 (20SEP06)
9015-05-18
TX,9015,QQ6294 1926OCT931/3

092006
PN=154
System Information
T7719BB
1911OCT93
9015
05
19
TM1608 (20SEP06)
9015-05-19
TX,9015,QQ6294 1926OCT932/3

092006
PN=155
System Information
T8295BI
1904DEC94
9015
05
20
TX,9015,QQ6294 1926OCT933/3
TM1608 (20SEP06)
9015-05-20

092006
PN=156
Group 10
System Diagrams
Component Identification Table
Each component (electrical device) and main connector
will have and identification letter assigned to it. A number
is added to the letter to separate and indicate the total
components within that letter group.
Identification Letter
Type
Examples
System, subassembly, parts group
Control units, trigger boxes, two-way radios, logic module,

FNR logic module
Transducer for conversion of non-electrical

variables to electrical and vice versa
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
Condenser, capacitor
Condensers and capacitors, general
Binary device, memory
Digital devices, integrated circuits, pulse counters, magnetic

tape recorders
Various devices and equipment
Heating devices, air conditioners, light, headlights, spark

plugs, ignition distributors
Protection device
Release mechanisms, polarity protection devices, fuses,

current protection circuits
Power supply, generator
Batteries, generators, alternators, charging units
Monitor, alarm, signalling device
Audible alarms, indicator lights, turn-signal lights, brake lights,

alarms, warning lights, buzzers
Relay
Battery relays, turn-signal relays, solenoid switches, starting

relays, warning flashers
Inductor
Choke coils, coils, windings
Motor
Blower motors, fan motors, starter motors
Regulator, amplifier
Regulators (electronic or electromechanical), voltage

stabilizers
Measuring instrument
Ammeter, diagnostic connectors, tachometers, fuel gauge,

pressure gauges, measuring points, test points,
speedometers
Resistor
Flame glow plugs, sheathed-element flame glow plugs, glow

plugs, heating resistors, NTC resistors, PTC resistors,
potentiometers, regulating resistors
TM1608 (20SEP06)
9015-10-1
9015
10
1
TX,9015,QQ6295 1920MAY961/2

092006
PN=157
System Diagrams
9015
10
2
Identification Letter
Type
Examples
Switch
Switches and push-buttons, general key switch light switch,

horn switch, flasher switch,
Transformer
Ignition coil, ignition transformer
Modulator, converter
DC transformers
Semiconductor, electron tubes
Transistors, diodes, electron tubes, rectifiers,

semiconductors, thyristors, zener diodes
Transmission path, conductor, antenna
Antennas, shielding components, shielded conductors, cable

harnesses, conductors, ground conductors
Terminal, plug, plug and socket connection
Terminal studs, electrical connections, connectors electrical

line couplers, line connectors, sockets, plugs, terminals,
plug-and-socket connections
Electrically actuated mechanical device
Permanent magnets, (solenoid-operated) injection valves,

electromagnetic clutches and brakes, air valves, fuel pumps,
solenoids, switching valves, start valves, locking systems
Electrical filter
Interference suppression filters
TX,9015,QQ6295 1920MAY962/2
Fuse (Blade-Type) Color Codes

Amperage Rating
Color
Black
Violet
Pink
Tan
7-1/2
Brown
10
Red
15
Light Blue
20
Yellow
25
Natural (White)
30
Light Green
TX,9015,QQ6743 1928SEP921/1
TM1608 (20SEP06)
9015-10-2

092006
PN=158
System Diagrams
Fuse Specifications
T100712
1928MAY96
9015
10
3
F17.5 Amp
MFWD/Alternator/Diff.
Lock Fuse
F215 Amp Fuel/Start 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 Fuse
F715 Amp Rear Light Fuse
F825 Amp Front Light/Tail
Light Fuse
F910 Amp FNR/Park Brake
Fuse
F1020 Amp Turn/Stop/Flash
and Horn Fuse
IMPORTANT: Install fuse with correct amperage

rating to prevent electrical system
damage from overload.
F11Not Used
F12Not Used
F1310 Amp RTD/Beacon and
Pump cutout Fuse
F1410 Amp Monitor/Gauge
Fuse
F1510 Amp Auxiliary Fuse
F15315SE onlyBoom and
Sideshift Locks Fuse
F1610 Amp Start Fuse

K3Hydraulic Pump Relay
K4Backup Alarm Relay
K5Park Brake Relay
K6Neutral Relay
K7Timer Relay (Behind Side
Console)
S21Flasher
The fuse block is located on the side console inside an

access cover.
TX,9015,BG226 1914JAN001/1
TM1608 (20SEP06)
9015-10-3

092006
PN=159
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.
9015
10
4
A2Radio (SE3, W12)

B1Backup Warning Alarm (SE5,W8)
B2Not Used
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)
B10Park Brake Pressure Switch (SE15)
B11Brake Light Switches (SE13,W6)
B12Not Used
B13Radio Speaker (W12)
B14Radio Speaker (W13)
E1Dome Light (SE3, W5)
E2Not Used
E3Left Front Work Light (SE8,W5)
E4Right Front Work Light (SE8,W5)
E5Left Rear Work Light (SE8,W5)
E6Right Rear Work Light (SE8,W5)
E7Left Front Drive Light (SE8,W5)
E8Right Front Drive Light (SE8,W5)
E9Left Tail Light (SE8,W5)
E10Right Tail Light (SE8,W5)
E11Left Brake Light (SE13,W5)
E12Right Brake Light (SE13,W5)
E13Beacon Light (SE14,W5)
E14Fuel Gauge Light (SE15,W8)
E15 Not Used
E16Tachometer Lights (S.N. 852338 ) (SE14)
F1MFWD/ALT/Diff. Lock Fuse (SE2,W6)

F2Fuel Shutoff/Start Aid/Reverse Alarm Fuse
(SE5,W6)
F3Dome Light/Radio 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)
F11Not Used
F12Not Used
F13Return-To-Dig/Beacon Fuse (SE14,W6)
F14Monitor Fuse (SE15,W6)
F15Auxiliary Fuse
F16Start Fuse (SE11,W6)
F17Fuse Block (W6)
G1Battery (SE1,W8)
G2Alternator (SE1,W8)
H1Not Used
H2Left Front Turn Light (SE13,W5)
H3Left Rear Turn Light (SE13,W5)
H4Right Front Turn Light (SE13,W5)
H5Right Rear Turn Light (SE13,W5)
H6Not Used
H7Not Used
H8Display Monitor (SE16,W6)
H9Not Used
H10Not Used
H11Display Monitor Alarm (SE17, W6)
K1Start Relay (SE1,W8)
K2Accessory Relay (SE1,W6)
K3Pump Unloading Valve Relay (SE10,W6)
K4Backup Alarm Relay (SE4,W6 )
K5Park Brake Latching Relay (SE9,W6)
K6Neutral Start Relay (SE9,W6)
K7Timer Relay (Power Shift Only) (SE10, W7)
K8Selective Flow Valve Relay (SE18, W15)
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)
TM1608 (20SEP06)
9015-10-4
TX,9015,QQ6745 1914JAN001/4

092006
PN=160
System Diagrams
M6Heater Blower Motor (SE5,W6)

M7Air Adjust Seat Motor (SE6, W10)
P1Fuel Gauge (SE15,W6)
P2Tachometer (SE15,W6)
P3Hour Meter (SE15,W6)
R1Heater Motor Resistor (SE5,W6)
S1Key Switch (SE2,W6)
S2MFWD Switch (SE2,W6)
S3Diff. Lock Switch (SE2,W6)
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)
S19Seat Position Sensor (SE15,W6)
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)
S26A/C Freeze Switch (W10)
S27Dome Light Switch (SE3,W5)
S28Selective Flow Valve Switch (SE18, W15)
S29Foot Switch (SE18, W15)
SE30Ride Control Switch (SE17, W17)
S31 Pin Disconnect Switch (SE19, W18)
S32Air Adjust Seat Switch (SE6, W10)
S33Sideshift Switch (SE2, W9)
S34Boom Lock Switch (SE2, W9)
V1MFWD Solenoid Diode (SE2,W8)
V2Park Brake Solenoid Diode (SE9,W8) (S.N.
828221)
V3Reverse Solenoid Diode (SE9,W8)
V4Forward Solenoid Diode (SE9,W8)
V5Neutral Disconnect Solenoid Diode (SE10, W8)
V64-Way Flasher Switch Diode (SE13,W7)

V74-Way Flasher Switch Diode (SE13,W7)
V8Start Solenoid Diode (SE1,W4)
V9Alternator Diode (SE1,W8)
V10Diff. Lock Diode (SE2,W)
V11Park Brake Relay Diode (SE9,W6) (SN
778669)
V12Speed Solenoid (1) Diode (Power Shift only)
(SE10, W8)
(SE10, W8)
(SE10, W8)
V15Ride Control Diode (SE17, W17)
V16Not Used
V17Pin Disconnect Diode (SE19, W18)
V18 Low Range Solenoid Diode (Power Shift only)
(SE10, W8)
V19Timer Relay Diode (Power Shift only) (SE10,
W7)
V20Timer Relay Diode (Power Shift only) (SE10,
W7)
V21Tachometer Isolation Diode (SE15, W6)
V22Selective Valve Flow Diode (SE18, W15)
W1Machine Frame Ground Right Side Of
Flywheel Housing (SE1,W8)
W2Ground To Cab Frame (SE14,W5)
W3Ground At Cab Floor (SE1,W8)
W4Engine Ground Strap (W8)
W5Cab Roof Harness (W5)
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)
W14Ground to A/C Compressor (W8)
W15Selective Flow Valve Harness (W15)
W16Selective Flow Valve Harness Ground
Connector (W15)
W17Ride Control Harness (W17)
W18Pin Disconnect Harness (W18)
W19Pin Disconnect Harness Ground Connector
(W18)
TM1608 (20SEP06)
9015-10-5
TX,9015,QQ6745 1914JAN002/4

092006
PN=161
9015
10
5
System Diagrams
9015
10
6
W20Ride Control Harness Ground Connector

(W17)
X1Side Console Harness To Roof Harness
Connectors (W5,W6)
Connectors (W5,W6)
Connectors (W5,W6)
X4Display Monitor Alarm Connector (SE15,W6)
X5Side Console Harness to Blower Harness
Connector (W6, W10)
X6Blower Switch Connector (W10)
X7Display Monitor Connectors (W6)
X8Horn Switch Connector (W6)
X9Rear Light Switch Connector (W6)
X10Rear Wiper Switch Connector (W6)
X11Beacon Switch Connector (W6)
X12MFWD Switch Connector (W6)
X13Park Brake Switch Connector (W6)
X14Start Aid Switch Connector (W6)
X15Fuel Gauge Connector (W6)
X16Key Switch Connector (W6)
X17Accessory Relay Connectors
X18Tachometer Connectors with Separate
Terminals (S.N. 852337) Tachometer Connector
(S.N. 852338 )
X19Not Used
X20Side Console To Engine Harness (W6,W8)
X25Side To Front Console Connectors (W6,W7)
X26FNR Switch Connector (W7)
X27Turn Signal Switch Connector (W7)
X28Beacon Light Connector (W5)
X29Roof Harness to Radio Harness Connector
(W5,W12)
X30Spliced G40 To G10,G30 (Inside Side
Console Harness) (W6)
X31Forward/Reverse Solenoid Connector (W8)
X32Clutch Disconnect Solenoid Connector (W8)
X33Connectors For A/C Switch (W6)
X34Engine Harness To A/C Compressor Harness
Connector (W8,W11)
X35Side Console Harness To Blower Harness

Connectors (W8,W10)
X36A/C Freeze Switch Connector (W10)
X37Not Used
X38A/C Switch Connector (W6)
X39Radio Harness To Radio Connector (W12)
X40Not Used
X41Hour Meter Connector with Tachometer Lead
(SE14,W6) (S.N. 852337), Hour Meter Connector
(S.N. 852338 )
X42Auxiliary Harness Connector (W15)
X43Auxiliary Flow Control Switch Connector
(W15)
X44Auxiliary Power Connector (W15)
X45Selective Flow Valve Switch Connector (W15)
X46Selective Flow Valve Foot Switch Connector
(W15)
X47Selective Flow Valve Relay Connector (W15)
X48Selective Flow Valve Solenoid Connector
(W15)
X49Selective Flow Valve Ground Connector (W15)
X50Auxiliary Flow Control Solenoid Connector
(W15)
X51Side Console Harness to Ride Control
Harness Connector (W6, W17)
X52Ride Control Harness to Ride Control Engine
Harness Connector (W17)
X53Engine Harness to Auxiliary Gauge Harness
Connector (W8)
X54Engine Harness to Transmission Control Valve
Connector (W8)
X55Side Console Harness to Air Adjust Seat
Harness Connector (ROPS Machines Only) (W6)
X56Blower Harness to Air Adjust Seat Harness
Connector (Cab Machines Only) (W10)
X57Engine Harness to Transmission Control Valve
Connector (W8)
X58Side Console Harness Auxiliary Connector
(W6)
X59Lock Harness Ground Connector (W9)
X60Selective Flow Valve Connector-to-Y11 Pump
Unloading Valve Solenoid
X61Selective Flow Valve Connector-to-Y11 Pump
Unloading Valve Solenoid Connector
Y1MFWD Solenoid (SE2,W8)
TM1608 (20SEP06)
9015-10-6
TX,9015,QQ6745 1914JAN003/4

092006
PN=162
System Diagrams
Y2Start Aid Solenoid (SE5,W8)

Y3Fuel Shutoff Solenoid (SE5,W8)
Y4Park Brake Solenoid (SE9,W8)
Y5Reverse/Solenoid (SE9,W8)
Y6Forward/Solenoid (SE9,W8)
Y7Neutral Disconnect Solenoid (SE9,W8)
Y8Diff. Lock Solenoid (SE1,W8)
Y9Return-To-Dig Solenoid (SE14,W8)
Y10A/C Compressor (W11)
Y11Pump Unloading Valve Solenoid (SE10,W8)
Y12Speed Solenoid (1) (Power Shift only) (SE10,
W8)

W8)
W8)
Y15Ride Control Solenoid (SE17, W17)
Y16Selective Flow Valve Solenoid (SE18, W15)
Y17Pin Disconnect Solenoid (SE19, W18)
Y18 Low Range Solenoid (Power Shift only) (SE10,
W8)
Y19Sideshift Lock Solenoid (SE2, W9)
Y20Boom Lock Solenoid (SE2, W9)
9015
10
7
TX,9015,QQ6745 1914JAN004/4
TM1608 (20SEP06)
9015-10-7

092006
PN=163
System Diagrams
System Functional Schematic Section

Legend
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
8
SE1Battery/Ignition, Power, Charging and Start Circuit

(12 Volt System)
SE2Differential, Sideshift, and Boom Lock Circuit
SE3MFWD Circuit
SE4Dome Light and Radio Circuit
SE5Start Aid, Fuel Shut Off and Reverse Alarm
Circuit
SE6Blower Circuit
SE7Wiper and Washer Circuit
SE8Rear Work Light Circuit
SE9Front Work and Drive Light Circuit
SE10Park Brake/Clutch Disconnect Circuit
SE11Horn Circuit
SE12Turn Signal, Flasher and Brake Light Circuit
SE13Beacon/Return-to-Dig and Unloading Valve
Circuit
SE14Gauge and Hour Meter Circuit
SE15Monitor Circuit
SE16Indicator Circuit
SE17Ride Control Circuit
SE18Selective Flow Valve Circuit
SE19Pin Disconnect Circuit
TX,9015,QQ6299 1931JUL981/1
TM1608 (20SEP06)
9015-10-8

092006
PN=164
System Diagrams

T127520 1920JAN00
ACC
OFF
ON
BULB CHECK
START
OFF
ON
KEY
SWITCH
2B 3 1
BAT IGN ACC ST G BODY

B11 RED
B12 RED
R31 BLK
B15 RED
F1
MFWD/ALT/
DIFF. LOCK FUSE
ACCESSORY
RELAY
G
R31 BLK
P13 RED
X42
V9
AUXILIARY
HARNESS
CONNECTOR
ALTERNATOR
DIODE
BOOM LOCK
SWITCH
(315SE)
BATTERIES
+
E23
WHT
DIFF.
LOCK
SOLENOID
B11 RED
W4
TO PARK BRAKE
LATCHING RELAY
SE10, K5
GROUND STRAP
(LEFT SIDE OF ENGINE)
G02 BLK
G10 BLK
G40 BLK
G40 BLK
G01 BLK
SE1 POWER, CHARGING AND START CIRCUIT
MACHINE FRAME GROUND

(RIGHT SIDE OF FLYWHEEL HOUSING)
DIFF.
LOCK
DIODE
W55
BLU
V1
MFWD
SOLENOID
DIODE
Y1
MFWD
SOLENOID
G04 BLK
BOOM LOCK
SOLENOID
(315SE)
G10 BLK
TO DISPLAY
MONITOR (SE15, H8)
G10 BLK
SE2 DIFFERENTIAL, SIDESHIFT & BOOM LOCK CIRCUITS
G40 BLK
G01 BLK
SE3 MFWD CIRCUIT

CONTINUED ON NEXT PAGE
SYSTEM FUNCTIONAL SCHEMATIC (1 OF 8)
T127520
TX,9015,QQ6300 1919JAN001/8
9015-10-9
Y20
G04 BLK
G10
BLK
E02 WHT
SIDESHIFT
LOCK
SOLENOID
(315SE)
G04 BLK
START
RELAY
V8
START
SOLENOID
DIODE
G02 BLK
STARTER
MOTOR
E02 WHT
M1
G01 BLK
TO NEUTRAL
START RELAY
SE10, K6
E02
WHT
Y19
K1
W1
TM1608 (20SEP06)
Y8
B+
B03 RED
E23
WHT
G10 BLK
G01
BLK
G01
BLK
V10
E02 WHT
W3
GROUND
AT CAB
FLOOR
B14 RED
W02
BLU
ALTERNATOR
B16 RED
D+
G01
BLK
G2
MFWD
SWITCH
0
3
G01 BLK
G1
SIDESHIFT
LOCK
SWITCH
(315SE)
W02
BLU
B11 RED
RED CABLE
S33
H10
DK GRN
G10 BLK
S2
DIFF.
LOCK
SWITCH
K05
LT GRN
P13 RED
B16
RED
B11 RED
G10 BLK
2B
ON
OFF
S3
G01 BLK
B15 RED
K2
P13 RED
S34
W55
BLU
E22 WHT
P01
RED
P01
RED
P13
RED
ST
P30
RED
M55 PUR
F15
AUX.
FUSE
P13 RED
M55 PUR
B12
RED
B12A
RED
B11 RED
M39 PUR
M39 PUR
B14 RED
IGN
E22 WHT
R31 BLK
R31 BLK
B15 RED
ACC
BAT
B12 RED
B12A RED
M39 PUR
KEY
SWITCH
B11 RED
E22 WHT
E22 WHT
ACC
OFF
ON
BULB CHECK
START
S1
MFWD
SWITCH
B11 RED
B12 RED
B12A RED
GROUND CIRCUIT
(WIRE COLOR)
G01 BLK - ENGINE HARNESS
G10 BLK - SIDE CONSOLE HARNESS
G20 BLK - ROOF HARNESS
G30 BLK - FRONT CONSOLE HARNESS
G40 BLK - ENGINE HARNESS TO SIDE CONSOLE HARNESS

092006
PN=165
System Diagrams
T126723 1920JAN00
TX,9015,QQ6300 1919JAN002/8
TM1608 (20SEP06)
9015-10-10

092006
PN=166
System Diagrams
T127521 1920JAN00
TX,9015,QQ6300 1919JAN003/8
TM1608 (20SEP06)
9015-10-11

092006
PN=167
System Diagrams
T126725 1920JAN00
TX,9015,QQ6300 1919JAN004/8
TM1608 (20SEP06)
9015-10-12

092006
PN=168
System Diagrams
T126726 1920DEC99
TX,9015,QQ6300 1919JAN005/8
TM1608 (20SEP06)
9015-10-13

092006
PN=169
System Diagrams
T127522 1920JAN00
TX,9015,QQ6300 1919JAN006/8
TM1608 (20SEP06)
9015-10-14

092006
PN=170
System Diagrams
T127518 1920JAN00
TX,9015,QQ6300 1919JAN007/8
TM1608 (20SEP06)
9015-10-15

092006
PN=171
System Diagrams
T127523 1920JAN00
TX,9015,QQ6300 1919JAN008/8
TM1608 (20SEP06)
9015-10-16

092006
PN=172
System Diagrams
Cab Roof Harness (W5) Component Location

T100583 1910SEP98
H5/E12/E10
R.H. REAR
TURN/BRAKE/TAIL LIGHT
E6
R.H. REAR
WORK LIGHT
H3/E11/E9
L.H. REAR
TURN/BRAKE/TAIL LIGHT
S27
DOME
LIGHT
SWITCH
H4
R.H. FRONT
TURN LIGHT
X28
BEACON
LIGHT
CONNECTOR
E1
DOME
LIGHT
E8
E5
X1
L.H. REAR
WORK LIGHT
ROOF HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
P14 RED H
M3
M2,M4
E6,E5
L41 BRN G
L48 BRN F
H2,H3
X29
L43 BRN E
E7,E9,E10,E8
E13
L45 BRN D
L47 BRN C
H4,H5
E11,E12 L46 BRN B
L42 BRN A
E4,E3
M2
REAR WIPER
MOTOR
R.H. FRONT
DRIVE
LIGHT
X29
E4
R.H. FRONT
WORK LIGHT
D
E
X1
W2
H2
L.H. FRONT
TURN LIGHT
M4
ROOF HARNESS
TO SIDE
CONSOLE
HARNESS
CONNECTOR
GROUND
TO CAB
FRAME
R.H. DOOR
WIPER
MOTOR
ROOF HARNESS
TO RADIO
HARNESS
CONNECTOR
X3
ROOF HARNESS
TO SIDE
CONSOLE
HARNESS
CONNECTOR
E3
L.H. FRONT
WORK
LIGHT
E7
L.H. FRONT
DRIVE LIGHT
TX,9015,QQ6301 1920MAR961/1
9015-10-17
L.H. DOOR
WIPER MOTOR
CAB ROOF HARNESS COMPONENT LOCATION
T100583
TM1608 (20SEP06)
M3

092006
PN=173
X2
ROOF HARNESS
TO SIDE
CONSOLE
HARNESS
CONNECTOR
X3
ROOF HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
M4
A69 ORG H
M3
A68 ORG G
M2
A66 ORG F
M2
A65 ORG E
M4
A64 ORG D
M4
A63 ORG C
M3
A62 ORG B
M3
A61 ORG A
X2
ROOF HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
X29
P25 RED B
E1,X29
P15 RED A
System Diagrams
Cab Roof Harness (W5) Connectors, Wire and Pin Location
T101266
1908AUG96
9015
10
18
TM1608 (20SEP06)
9015-10-18
TX,9015,QQ6302 1920MAY961/2

092006
PN=174
System Diagrams
T101396
1908AUG96
9015
10
19
TX,9015,QQ6302 1920MAY962/2
TM1608 (20SEP06)
9015-10-19

092006
PN=175
System Diagrams
Cab Side Console Harness (W6) Component Location

T126757 1920JAN00
TX,9015,QQ6750 1919JAN001/3
TM1608 (20SEP06)
9015-10-20

092006
PN=176
System Diagrams
T126759 1908FEB00
X20
X24
SIDE CONSOLE HARNESS

TO ENGINE HARNESS
CONNECTOR
X30
G40 BLK

TO ENGINE HARNESS
CONNECTOR
M1
B11 RED
X25
TO FRONT CONSOLE
CONNECTOR
X3
A61 ORG 1
X3
A62 ORG 2
A63 ORG 3
X3
A64 ORG 4
X3
X22
A71 ORG 5
P14 RED 6
F5,S6,X1
L47 BRN 7
F12
8
9
B11,F10,S15 P19 RED 10
11
S21
L49 BRN 12
L48 BRN 13
F11
G30 BLK 14
X30
X21
T11 BLU 15
X23
T13 BLU 16
P24 RED 17
F9
18
19
P18 RED 20
F8
L43 BRN 21
X1
P18 RED 22
F8
X1
L42 BRN 23
K6
T12 BLU 24
25
26
27
28
29
30
31
T126759
X23
TO ENGINE HARNESS
CONNECTOR
K6
E23 WHT 1
S4
P12 RED 2
S4
E25 WHT 3
S2,F1
P13 RED 4
S14
T52 BLU 5
S2
W55 BLU 6
S12
J27 TAN 7
E15
M32 PUR 8
X25
T11 BLU 9
X25
T13 BLU 10
V11
E02 WHT 11
Y8
W02 BLU 12
X22
TO ENGINE HARNESS
CONNECTOR
1
H8
X41 YEL 2
3
F13
P20 RED 4
5
A17 ORG 6
X38
X25
A71 ORG 7
8
X24
9015-10-21
31
X20
29
7
17
28
21
10
3
1
6
16
22
11
15
23
12
5
26
BRAKE
LIGHT
SWITCHES
9
2
18
B11
20
8
19
27
13
14
24
25
X25
SIDE CONSOLE
HARNESS TO FRONT
CONSOLE HARNESS
CONNECTOR
SEAT POSITION
SENSOR
(ROPS ONLY)
X55
SIDE CONSOLE
HARNESS TO
AIR ADJUST
SEAT HARNESS
CONNECTOR
(ROPS ONLY)

TO ENGINE HARNESS
CONNECTOR
7
10 11 12
X21
TO ENGINE HARNESS
CONNECTOR
7
10 11 12
S14
GEAR SHIFT
LEVER SWITCH
X23
TO ENGINE HARNESS
CONNECTOR
5
S3
DIFF.
LOCK
SWITCH
X22
TO ENGINE HARNESS
CONNECTOR
TX,9015,QQ6750 1919JAN002/3
TM1608 (20SEP06)
30

TO ENGINE HARNESS
CONNECTOR
X21
TO ENGINE HARNESS
CONNECTOR
H8
X36 YEL 1
H8
N34 YEL 2
H8
X38 YEL 3
H8
F39 YEL 4
H8
M40 PUR 5
P2,H8
M39 PUR 6
P1
Y33 YEL 7
NOT USED Y1 YEL 8
NOT USED Y2 YEL 9
NOT USED K1 BLU 10
S15
A67 ORG 11
V14
M62 PUR 12
S19

092006
PN=177
CAB SIDE CONSOLE HARNESS COMPONENT LOCATION
System Diagrams
T114518 1908JUL98
X20
X24

TO ENGINE HARNESS
CONNECTOR
X30
G40 BLK

TO ENGINE HARNESS
CONNECTOR
M1
B11 RED
X25
TO FRONT CONSOLE
CONNECTOR
X3
A61 ORG 1
X3
A62 ORG 2
X3
A63 ORG 3
X3
A64 ORG 4
X22
A71 ORG 5
F5,S6,X1
P14 RED 6
F12
L47 BRN 7
8
9
B11,F10,S15 P19 RED 10
11
S21
L49 BRN 12
F11
L48 BRN 13
X30
G30 BLK 14
X21
T11 BLU 15
F9
F8
X1
F8
X1
S12
K6
X22
X22
X22
X22
S13
T114518
T13 BLU 16
P24 RED 17
18
19
P18 RED 20
L43 BRN 21
P18 RED 22
L42 BRN 23
J27 TAN 24
T12 BLU 25
T16 BLU 26
T17 BLU 27
T18 BLU 28
T19 BLU 29
V01 PNK 30
31
X23
TO ENGINE HARNESS
CONNECTOR
K6
E23 WHT 1
S4
P12 RED 2
S4
E25 WHT 3
S2,F1
P13 RED 4
5
S2
W55 BLU 6
S12
J27 TAN 7
E15
M32 PUR 8
X25
T11 BLU 9
X25
T13 BLU 10
V11
E02 WHT 11
Y8
W02 BLU 12
X22
TO ENGINE HARNESS
CONNECTOR
X25
T18 BLU 1
H8
X41 YEL 2
X25
T19 BLU 3
F13
P20 RED 4
X25
T16 BLU 5
X38
A17 ORG 6
X25
A71 ORG 7
X25
T17 BLU 8
X20
29
21
10
3
1
6
16
22
11
15
23
12
5
26
BRAKE
LIGHT
SWITCHES
7
17
28
B11
20
8
2
18
27
X24
31
19

TO ENGINE HARNESS
CONNECTOR
X21
TO ENGINE HARNESS
CONNECTOR
H8
X36 YEL 1
H8
N34 YEL 2
H8
X38 YEL 3
H8
F39 YEL 4
H8
M40 PUR 5
P2,H8
M39 PUR 6
P1
Y33 YEL 7
P4
Y1 YEL 8
P4
Y2 YEL 9
NOT USED K1 BLU 10
S15
A67 ORG 11
V14
M62 PUR 12
30
13
14
24
25
X25
SIDE CONSOLE
HARNESS TO FRONT
CONSOLE HARNESS
CONNECTOR

TO ENGINE HARNESS
CONNECTOR
7
10 11 12
X21
TO ENGINE HARNESS
CONNECTOR
7
10 11 12
X23
TO ENGINE HARNESS
CONNECTOR
5
S3
DIFF.
LOCK
SWITCH
X22
TO ENGINE HARNESS
CONNECTOR
CAB SIDE CONSOLE HARNESS (WITH OPTIONAL POWER SHIFT) COMPONENT LOCATION
TX,9015,QQ6750 1919JAN003/3
TM1608 (20SEP06)
9015-10-22

092006
PN=178
System Diagrams
Cab Side Console Harness (W6) Connectors, Wire and Pin Location
T126763
1924JAN00
9015
10
23
TM1608 (20SEP06)
9015-10-23
TX,9015,QQ6751 1919JAN001/5

092006
PN=179
System Diagrams
T115813
1919JUN98
9015
10
24
TM1608 (20SEP06)
9015-10-24
TX,9015,QQ6751 1919JAN002/5

092006
PN=180
System Diagrams
T115818
1904AUG98
9015
10
25
TM1608 (20SEP06)
9015-10-25
TX,9015,QQ6751 1919JAN003/5

092006
PN=181
System Diagrams
T126826
1904FEB00
9015
10
26
TM1608 (20SEP06)
9015-10-26
TX,9015,QQ6751 1919JAN004/5

092006
PN=182
System Diagrams
T115923
1919JUN98
9015
10
27
TX,9015,QQ6751 1919JAN005/5
TM1608 (20SEP06)
9015-10-27

092006
PN=183
System Diagrams
Front Console Harness (W7) Component Location

T100586 1910SEP98
X25
30
31
20
8
21
19
9
2
18
29
10
7
17
28
23
5
26
S11
11
4
15
27
22
1
6
16
FRONT CONSOLE
HARNESS TO
SIDE CONSOLE
HARNESS CONNECTOR
12
S16
24
TURN SIGNAL
SWITCH
13
14
25
FNR/RANGE
SWITCH
S17
4-WAY FLASHER
SWITCH
S5
FRONT WIPER
SWITCH
S7
V6
WINDSHIELD
WASHER
SWITCH
4-WAY FLASHER
SWITCH DIODE
V7
4-WAY FLASHER
SWITCH DIODE
X25
FRONT CONSOLE
HARNESS TO
SIDE CONSOLE
HARNESS CONNECTOR
S5
S5
S5
S5
S7
S7,S6,S5
V7
A61
A62
A63
A64
A71
P14
L47
S17
P19 RED
S16,S17
V6,S16
S17
S11
S11
L49
L48
G30
T11
T13
T100586
ORG
ORG
ORG
ORG
ORG
RED
BRN
BRN
BRN
BLK
BLU
BLU
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
S9
FRONT
LIGHT SWITCH
S11
S9
S9
S9
S9
S11
P24 RED 17
18
19
P18 RED 20
L43 BRN 21
P18 RED 22
L42 BRN 23
T12 BLU 24
25
26
27
28
29
30
31
FRONT CONSOLE HARNESS COMPONENT LOCATION
TX,9015,QQ6752 1921JUL981/1
TM1608 (20SEP06)
9015-10-28

092006
PN=184
System Diagrams
Front Console Harness (W7) Component Location (With Optional Power Shift)
T126766 1920DEC99
CED,TX17864,100 1919JAN001/1
TM1608 (20SEP06)
9015-10-29

092006
PN=185
System Diagrams
Front Console Harness (W7) Connectors, Wire and Pin Location
T101267
1909AUG96
9015
10
30
TM1608 (20SEP06)
9015-10-30
TX,9015,QQ6753 1921JUL981/2

092006
PN=186
System Diagrams
T126767
1920DEC99
9015
10
31
TX,9015,QQ6753 1921JUL982/2
TM1608 (20SEP06)
9015-10-31

092006
PN=187
System Diagrams
Engine Harness (W8) Component Location

T116590 1904AUG98
B2
M5
WASHER
MOTOR
B3
W1
HYDRAULIC
OIL TEMP.
SWITCH
(NOT USED)
S20
G1
RETURN-TO-DIG
SWITCH
BATTERIES
Y9
RETURN-TO-DIG
SOLENOID
MACHINE
FRAME
GROUND
W1
G40 BLK
X20
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
Y11
PUMP CUTOUT
SOLENOID
HORN
K1
Y2
START
RELAY
X54
ENGINE HARNESS TO
TRANSMISSION CONTROL
VALVE CONNECTOR
START
AID
SOLENOID
X24
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
B10
PARK BRAKE
PRESSURE SWITCH
B7
AIR FILTER
RESTRICTION
SWITCH
7 8
10 11 12
6 5
3 2 1
V9
ALTERNATOR
DIODE
X53
ENGINE HARNESS
TO AUXILIARY
GAUGE HARNESS
X21
B9
HYDRAULIC
FILTER
RESTRICTION
SWITCH
V3
GROUND TO
CAB FLOOR
V8
B5
START
SOLENOID
DIODE
Y8
CONVERTER
OIL
TEMP.
Y4
T116590
ENGINE HARNESS TO
AC COMPRESSOR HARNESS
CONNECTOR
FUEL
SHUTOFF
SOLENOID
ENGINE OIL
PRESSURE SWITCH
DIFF.
LOCK
SOLENOID
MFWD
SOLENOID
B4
STARTER
MOTOR
B6
W4
GROUND
STRAP
10 11 12
3 2
FUEL
SENDER
X23
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
V10
Y1
M1
Y3
FORWARD
SOLENOID
DIODE
PARK BRAKE
SOLENOID
ENGINE COOLANT
TEMP. SWITCH
X34
BACKUP
WARNING
ALARM
V4
B8
ALTERNATOR
B1
REVERSE
SOLENOID
DIODE
W3
G2
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
V5
NEUTRAL
DISCONNECT
SOLENOID
DIODE
(LATER
MACHINES)
V1
DIFF.
LOCK
DIODE
MFWD
PARK BRAKE SOLENOID
DIODE
SOLENOID
DIODE
(EARLY MACHINES)
V2
ENGINE HARNESS COMPONENT LOCATION
M1
B11 RED
B5
B6
B8
B9
B7
G2
S4
NOT USED
NOT USED
NOT USED
B3
B1
X36
N34
X38
F39
M40
M39
Y33
Y1
Y2
K1
A67
M62
YEL
YEL
YEL
YEL
PUR
PUR
YEL
YEL
YEL
BLU
ORG
PUR
1
2
3
4
5
6
7
8
9
10
11
12
K1
Y3
Y2
G2
X54
Y1,V1
S2
B10
X54,V4
X54,V3
M1
Y8,V10
E23
P12
E25
P13
T52
W55
J27
M32
T11
T13
E02
W02
WHT
RED
WHT
RED
BLU
BLU
TAN
PUR
BLU
BLU
WHT
BLU
1
2
3
4
5
6
7
8
9
10
11
12
B2
7
X22
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
S20
X34
M5
1
X41 YEL 2
3
P20 RED 4
5
A17 ORG 6
A71 ORG 7
8
CED,TX17864,112 1931JUL981/1
TM1608 (20SEP06)
9015-10-32

092006
PN=188
System Diagrams
Engine Harness (W8) Component Location (With Optional Power Shift)

T116591 1904AUG98
B2
M5
WASHER
MOTOR
B3
W1
HYDRAULIC
OIL TEMP.
SWITCH
(NOT USED)
S20
G1
BATTERIES
RETURN-TO-DIG
SWITCH
RETURN-TO-DIG
SOLENOID
V13
SPEED
SOLENOID (2)
DIODE
MACHINE
FRAME
GROUND
W1
G40 BLK
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
SPEED
SOLENOID (1)
DIODE
K1
START
RELAY
X54
ENGINE HARNESS TO
TRANSMISSION CONTROL
VALVE CONNECTOR
START
AID
SOLENOID
X24
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
B10
PARK BRAKE
PRESSURE SWITCH
B7
AIR FILTER
RESTRICTION
SWITCH
V14
7 8
10 11 12
6 5
3 2 1
SPEED
SOLENOID (3)
DIODE
V9
ALTERNATOR
DIODE
X53
ENGINE HARNESS
TO AUXILIARY
GAUGE HARNESS
X21
B9
V3
GROUND TO
CAB FLOOR
Y8
CONVERTER
OIL
TEMP.
V8
ALTERNATOR
B5
START
SOLENOID
DIODE
ENGINE COOLANT
TEMP. SWITCH
M1
T116591
ENGINE HARNESS TO
AC COMPRESSOR HARNESS
CONNECTOR
STARTER
MOTOR
Y3
B6
FUEL
SHUTOFF
SOLENOID
ENGINE OIL
PRESSURE SWITCH
W4
GROUND
STRAP
CED,TX17864,113 1931JUL981/1
TM1608 (20SEP06)
9015-10-33
Y4

092006
PN=189
BACKUP
WARNING
ALARM
FORWARD
SOLENOID
DIODE
10 11 12
B4
FUEL
SENDER
Y11
PUMP CUTOUT
SOLENOID
3 2
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
Y1
MFWD
SOLENOID
X23
DIFF.
LOCK
SOLENOID
PARK BRAKE
SOLENOID
X57
ENGINE HARNESS
TO TRANSMISSION
CONTROL VALVE
CONNECTOR
B1
V4
B8
G2
HYDRAULIC
FILTER
RESTRICTION
SWITCH
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
REVERSE
SOLENOID
DIODE
W3
X34
X20
V12
HORN
Y2
Y9
V2
PARK BRAKE
SOLENOID
DIODE
V1
MFWD
SOLENOID
DIODE
V10
DIFF.
LOCK
DIODE
ENGINE HARNESS (WITH OPTIONAL POWERSHIFT) COMPONENT LOCATION
V18
LOW RANGE
SOLENOID
DIODE
X22
ENGINE HARNESS
TO SIDE CONSOLE
HARNESS CONNECTOR
M1
B11 RED
B5
B6
B8
B9
B7
G2
S4
NOT USED
NOT USED
NOT USED
B3
B1
X36
N34
X38
F39
M40
M39
Y33
Y1
Y2
K1
A67
M62
YEL
YEL
YEL
YEL
PUR
PUR
YEL
YEL
YEL
BLU
ORG
PUR
1
2
3
4
5
6
7
8
9
10
11
12
K1
Y3
Y2
G2
E23
P12
E25
P13
WHT
RED
WHT
RED
Y1,V1
S2
B10
X54,V4
X54,V3
M1
Y8,V10
W55
J27
M32
T11
T13
E02
W02
BLU
TAN
PUR
BLU
BLU
WHT
BLU
1
2
3
4
5
6
7
8
9
10
11
12
V13,X57
B2
V14,X57
S20
V18,X54
X34
M5
V12,X57
T18
X41
T19
P20
T16
A17
A71
T17
BLU
YEL
BLU
RED
BLU
ORG
ORG
BLU
1
2
3
4
5
6
7
8
System Diagrams
Engine Harness (W8) Connectors, Wire and Pin Location
T126769
1920DEC99
9015
10
34
TM1608 (20SEP06)
9015-10-34
CED,TX17864,114 1919JAN001/4

092006
PN=190
System Diagrams
T116671
1904AUG98
9015
10
35
TM1608 (20SEP06)
9015-10-35
CED,TX17864,114 1919JAN002/4

092006
PN=191
System Diagrams
T115799
1906JUL98
9015
10
36
TM1608 (20SEP06)
9015-10-36
CED,TX17864,114 1919JAN003/4

092006
PN=192
System Diagrams
T126770
1920DEC99
9015
10
37
CED,TX17864,114 1919JAN004/4
TM1608 (20SEP06)
9015-10-37

092006
PN=193
System Diagrams
Blower Harness (W10) Component Location

T116040 1929JUN98
TX,9015,QQ6756 1921JUL981/1
TM1608 (20SEP06)
9015-10-38

092006
PN=194
System Diagrams
Blower Harness (W10) Connectors, Wire and Pin Location
T101392
1908AUG96
9015
10
39
TM1608 (20SEP06)
9015-10-39
TX,9015,QQ6757 1921JUL981/2

092006
PN=195
System Diagrams
T116079
1927JUL98
9015
10
40
TX,9015,QQ6757 1921JUL982/2
TM1608 (20SEP06)
9015-10-40

092006
PN=196
System Diagrams
Lock Harness (W9) Component Location315SE Only
T116677
1904AUG98
9015
10
41
TX,9015,BG227 1903AUG981/1
TM1608 (20SEP06)
9015-10-41

092006
PN=197
System Diagrams
Lock Harness (W9) Connectors, Wire and Pin Location315SE Only
T116676
1903AUG98
9015
10
42
TX,9015,BD2436 1903AUG981/1
TM1608 (20SEP06)
9015-10-42

092006
PN=198
System Diagrams
Air Conditioning Compressor Harness (W11) Component Location

T116041 1929JUN98
TX,9015,QQ6760 1921JUL981/1
TM1608 (20SEP06)
9015-10-43

092006
PN=199
System Diagrams
Air Conditioning Compressor Harness (W11) Connectors, Wire and Pin Location
T101360
1908AUG96
9015
10
44
TX,9015,QQ6761 1921JUL981/1
TM1608 (20SEP06)
9015-10-44

092006
PN=200
System Diagrams
Radio Harness (W12) Component Location

T100589 1910SEP98
W13
ANTENNA
A2
B13
RADIO
RADIO SPEAKER
W12
RADIO HARNESS
X39
RADIO HARNESS
TO RADIO CONNECTOR
B14
RADIO SPEAKER
P15 A10
A12
RED ORG
ORG
G20 L43 P23 A11 A13

BLK
P15
RED
P25
RED
G20
BLK
L43
BRN
BRN RED ORG ORG
X29
RADIO HARNESS
TO ROOF HARNESS
CONNECTOR
RADIO HARNESS W-12 COMPONENT LOCATION
T100589
TX,9015,QQ6758 1920MAR961/1
TM1608 (20SEP06)
9015-10-45

092006
PN=201
System Diagrams
Radio Harness (W12) Connectors, Wire and Pin Location
T101356
1908AUG96
9015
10
46
TX,9015,QQ6759 1921MAY961/1
TM1608 (20SEP06)
9015-10-46

092006
PN=202
System Diagrams
Selective Flow Valve Harness (W15) Component Location
T126993
1920JAN00
9015
10
47
TX,9015,BA2150 1919JAN001/1
TM1608 (20SEP06)
9015-10-47

092006
PN=203
System Diagrams
Selective Flow Valve Harness (W15) Connectors, Wire and Pin Location
T127482
1919JAN00
9015
10
48
TX,9015,BA2151 1914JAN001/1
TM1608 (20SEP06)
9015-10-48

092006
PN=204
System Diagrams
Selective Flow Valve Harness (W15) Connectors, Wire and Pin LocationContinued
T127557
1924JAN00
9015
10
49
CED,TX03399,5907 1919JAN001/1
TM1608 (20SEP06)
9015-10-49

092006
PN=205
System Diagrams
Ride Control Harness (W17) Component Location

T116113 1921JUL98
CED,TX17864,104 1929JUN981/1
TM1608 (20SEP06)
9015-10-50

092006
PN=206
System Diagrams
Ride Control Harness (W17) Connectors, Wire and Pin Location
T116114
1906JUL98
9015
10
51
CED,TX17864,105 1929JUN981/1
TM1608 (20SEP06)
9015-10-51

092006
PN=207
System Diagrams
Pin Disconnect Harness (W18) Component Location
T116110
1902JUL98
9015
10
52
CED,TX17864,106 1929JUN981/1
TM1608 (20SEP06)
9015-10-52

092006
PN=208
System Diagrams
Pin Disconnect Harness (W18) Connectors, Wire and Pin Location
T116112
1906JUL98
9015
10
53
CED,TX17864,107 1929JUN981/1
TM1608 (20SEP06)
9015-10-53

092006
PN=209
System Diagrams
9015
10
54
TM1608 (20SEP06)
9015-10-54

092006
PN=210
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
B+ terminal of alternator
Starter motor
Radio fuse
9015
15
1
TX,9015,QQ6315 1906JUN961/1
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 and unswitched radio fuse.
When key switch is moved from OFF position, power
continues through IGN and ST terminals to main fuse
block. ACC terminal power goes to accessory relay,
energizing relay sending power to the main fuse block.
The key switch G terminal is a ground terminal only in
Bulb Check and Start positions.
NOTE: For component identification code description, see

Wiring and Schematic diagrams Legend, Group
9015-10.
TX,9015,QQ6316 1906JUN961/1
TM1608 (20SEP06)
9015-15-1

092006
PN=211
Power Circuit Schematic
T111584
1903NOV97
9015
15
2
TX,9015,QQ6317 1906JUN961/1
TM1608 (20SEP06)
9015-15-2

092006
PN=212
Sub-System Diagnostics/Power Circuit
TX,9015,QQ6318 1906JUN961/1
Power Circuit Diagnostic Procedures
1/1
Battery State Of Charge
YES: Clean battery cable

terminals. Repeat test.
CAUTION: Engine may crank during this check.

Move light switch to ON position.
If lights still get dim, test

battery.
Do work lights go out or get very dim while cranking engine?

NO: Battery Charge is
good. Go to next check.
1/1
Starter Motor
Key switch OFF.
With harness connected, check voltage at terminal of

starter with red cable.
NO: Check wiring

harness between battery
and starter
Are 12 volts measured?
T7199BK 1917SEP90
1/1
Alternator
Key switch OFF.
With harness connected, check voltage at B+ terminal of

alternator
NO: Check wiring

and alternator
T7828AA 1923SEP92
1/1
TM1608 (20SEP06)
9015-15-3

092006
PN=213
9015
15
3
Start Relay
Key switch OFF.
With harness connected, check voltage at terminal with

BO3 red wire.
NO: Check wiring

and start relay.
T7199BM 1917SEP90
1/1
Key Switch Check
Key switch OFF.
9015
15
4
YES: Go to next step in

this check.
Disconnect harness from switch.

Check voltage on B11 red wire at BAT terminal of key
switch.
NO: Check wiring

and key switch.

T7199BO UN17SEP90
Switch disconnected from harness.

this check.
Turn key switch to START position.

NO: Replace key switch.
Check for continuity between BAT and IGN terminals
and BAT and ST terminals.
Is continuity measured?
T7199BO UN17SEP90
Key switch ON.
Check for continuity between BAT and ACC terminal.

T7199BO UN17SEP90
1/1
Accessory Relay
Key switch OFF.
With harness connected, check voltage at large terminal

with B11 red wire.
NO: Check wiring

and accessory relay.
T7199BN UN16AUG90
1/1
TM1608 (20SEP06)
9015-15-4

092006
PN=214
Accessory Relay
CheckContinued
Key switch ON.
With harness connected, check voltage at small terminal

with B14 red wire.
NO: Check wiring

and accessary relay.
T7199BN UN16AUG90
1/1
Accessory Relay
CheckContinued
Disconnect harness from relay.
YES: Relay is good.
Connect battery voltage to small terminal. Ground

mounting bracket.
NO: Replace accessory

relay.
Does relay click?

Measure continuity between the two large terminals.
T7199BN UN16AUG90
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,QQ6319 1926SEP961/1
TM1608 (20SEP06)
9015-15-5

092006
PN=215
9015
15
5
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.
9015
15
6
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
EO2 white wire to starting motor solenoid S terminal,
closing solenoid contacts. With solenoid contacts closed,
power flows from battery to the starter windings.

Wiring And Schematic Diagrams Legend, Group
9015-10.
TX,9015,QQ6320 1926SEP961/1
TM1608 (20SEP06)
9015-15-6

092006
PN=216
Start Circuit Schematic
T111585
1907NOV97
9015
15
7
TX,9015,QQ6321 1926SEP961/1
TM1608 (20SEP06)
9015-15-7

092006
PN=217
Sub-System Diagnostics/Start Circuit
TX,9015,QQ6769 1921JUL981/1
Start Circuit Diagnostic Procedures
1/1
Key Switch Check
9015
15
8

this check.

T7199BO UN17SEP90
1/1
TM1608 (20SEP06)
9015-15-8

092006
PN=218
FNR Lever
Key switch ON. FNR lever in neutral

this check.
With harness connected, check voltage at terminals with

P24 red wire and T12 blue wire.
NO: Check wiring

harness.
Are 12 volts measured at each terminal?
9015
15
9
T115867 1919JUN98
Key switch ON.
YES: FNR lever is good.

Go to next check.
With harness connected, and FNR lever moved to

forward, check voltage at terminal with T11 blue wire.
NO: Replace FNR lever.
Move FNR lever to reverse, check voltage at T13 blue

wire.
T115868 1919JUN98
1/1
Neutral Start Relay
Key switch OFF.
YES: Relay is good.

Check wiring harness.

NO: Replace neutral start
relay.
Connect battery voltage to terminal #85.

Does relay click?
T7287BH UN16AUG90
Measure continuity between terminals #30 and #87.

1/1
TM1608 (20SEP06)
9015-15-9

092006
PN=219
Start Relay
Key switch OFF.
YES: Relay is good.
NO: Replace start relay.
Connect battery voltage to one of the small blade

terminals and ground the other. Does relay click?
T7287BK 1916AUG90
Measure continuity between two large terminals. Is

continuity measured?
1/1
Starter Solenoid Check

CAUTION: Starter will crank engine if metal
strap is NOT disconnected from starter
motor.
9015
15
10
YES: Solenoid is OK.

Check starter motor.
NO: Replace starter
solenoid.
Disconnect metal strap from starter motor terminal.

Connect battery voltage to solenoid small terminal.
T6534BI UN19OCT88
Ground metal strap from solenoid with heavy gauge

wire.
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.
YES: Starter motor is

good. Check wiring
harness.
starter motor.
Connect a heavy gauge jumper wire from battery

positive cable to starter motor terminal.
T6534BJ UN07JAN97
Connect a heavy gauge jumper wire from battery

positive cable to starter motor terminal.
Does starter motor turn, but NOT crank engine?
1/1
TM1608 (20SEP06)
9015-15-10

092006
PN=220
Charging Circuit Operational Information

The following conditions must exist for charging circuit to
function:
Key switch in ON position
Engine running
TX,9015,QQ6323 1906JUN961/1
Charging Circuit Theory of Operation

9015
15
11
65 or 95 AMP Bosch Alternator: The alternator (B+)

terminal is connected to battery voltage at all times.
The alternator terminal (D+) gets power from ACC
terminal of the key switch by energizing the accessory
relay, closing relay contacts and sending power to
MFWD/Alternator/Diff. Lock fuse.
With key switch ON and engine running, power flows from
terminal (W) of alternator to display monitor, ground is
removed and indicator light goes out.
When key is on but engine is not running or if alternator
fails, a ground is supplied to the display monitor and
indicator lights come on.

Wiring And Schematic Diagrams Legend, Group
9015-10
TX,9015,QQ6324 1906JUN961/1
TM1608 (20SEP06)
9015-15-11

092006
PN=221
Charging Circuit Schematic
T100798
1903NOV97
9015
15
12
TX,9015,QQ6325 1906JUN961/1
TM1608 (20SEP06)
9015-15-12

092006
PN=222
Sub-System Diagnostics/Charging Circuit
TX,9015,QQ6326 1928JAN001/1
Charging Circuit Diagnostic Procedures
1/1
Alternator Output
Key switch OFF.
YES: Alternator is good.

Check battery.
Measure and record battery voltage.

Start and run engine at 1500 rpm, and check battery
voltage.
T6569AZ UN23AUG93
NO: Check alternator.
Specification
Alternator Output
CheckEngine Speed....................................... 1500 rpm
Does battery voltage increase?
1/1
Alternator
Key switch ON. Engine running. Park brake ON.
YES: Alternator is good.
Using a multimeter, check for DC voltage at terminals

(D+) and (B+).
NO: Alternator is failed.

Repair or replace.
Is 14 DC volts measured?
Using a multimeter, check for AC voltage at terminal
(W).
Is 7.63 AC volts measured?
T7835AT 1923SEP92
1/1
TM1608 (20SEP06)
9015-15-13

092006
PN=223
9015
15
13
Alternator Diode Test
Remove diode from connector.
NOTE: A diode can fail in

two modes, either shorted
or open. Continuity will be
measured in one direction
only in a serviceable
diode.
Using a multimeter, turn to diode test and connect

probes to diode terminals.
NO: If continuity is NOT

measured in either check
diode has failed in an
open mode. Replace.
Reverse probes
T7961AA UN10MAR93
YES: If continuity is
measured in both checks,
diode has failed in a
shorted mode. Replace.
NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1
Key Switch Check
Key switch OFF.
9015
15
14

this check.

switch.
NO: Check wiring

and key switch.

T7199BO UN17SEP90

this check.

T7199BO UN17SEP90
Key switch ON.

T7199BO UN17SEP90
1/1
Key Switch Check

Continued
Remove fuel shut off/start aid/reverse alarm fuse.
Remove FNR/park brake fuse.
Remove start fuse.

T7199BO UN17SEP90
With harness connected, check voltage at IGN and ST

terminals.
1/1
TM1608 (20SEP06)
9015-15-14

092006
PN=224
Key Switch Check
Continued
Key switch ON.
With harness connected, check voltage at ACC terminal

of key switch.
T7199BO UN17SEP90
1/1
Accessory Relay
Key switch OFF.
With harness connected, check voltage at large terminal

with B11 red wire.
NO: Check wiring

and accessory relay.
T7199BN UN16AUG90
1/1
Accessory Relay
CheckContinued
Key switch ON.
With harness connected, check voltage at small terminal

with B14 red wire.
NO: Check wiring

and accessary relay.
T7199BN UN16AUG90
1/1
Accessory Relay
CheckContinued
YES: Relay is good.
Connect battery voltage to small terminal. Ground

mounting bracket.
NO: Replace accessory

relay.
Does relay click?

Measure continuity between the two large terminals.
T7199BN UN16AUG90
1/1
TM1608 (20SEP06)
9015-15-15

092006
PN=225
9015
15
15
Differential Lock Circuit Operational

Information
The following conditions must exist for differential lock to
function.
Key switch in ON position.
Engine running
Differential lock switch held down.
CED,TX17864,86 1912JUN981/1
Differential Lock Circuit Theory of Operation

9015
15
16
Power flows from the MFWD/Alternator/Differential lock

fuse (F1) to the differential lock switch (S3). The
differential lock switch is normally open. When the
operator depresses the differential lock switch, power
continues to flow to the differential lock solenoid (Y8) and
energize the solenoid.
When the operator releases the switch, the switch opens
and the differential solenoid is de-energized. The
differential lock diode (V11) prevents voltage spikes from
arching across the terminals of the switch when the switch
is released.
CED,TX17864,87 1912JUN981/1
TM1608 (20SEP06)
9015-15-16

092006
PN=226
Differential Lock Circuit Schematic
T115838
1919JUN98
9015
15
17
CED,TX17864,88 1912JUN981/1
Sub-System Diagnostics/Differential Lock

Circuit
CED,TX17864,89 1928JAN001/1
Differential Lock Circuit Diagnostic Procedures
1/1
TM1608 (20SEP06)
9015-15-17

092006
PN=227
Differential Lock Switch

this check.
Connect multimeter to switch terminals.

NO: Replace switch.
Depress differential lock switch.
T115875 1919JUN98
9015
15
18
Release differential lock switch.
YES: Replace switch.
T115875 1919JUN98
1/1
Differential Lock
Solenoid
Key switch ON.
YES: Repair or replace

solenoid.
Differential lock switch depressed and held.

NO: Repair harness. (See
group 10 of this section)
Disconnect harness from solenoid.

Measure voltage at terminals in harness.
T115864 1919JUN98
1/1
Differential Lock Diode

diode.

Reverse probes
T7961AA UN10MAR93
open mode. Replace.
is OK.
1/1
TM1608 (20SEP06)
9015-15-18

092006
PN=228
MFWD Circuit Operational Information

The following conditions must exist for MFWD to function.
Key switch in ON position.
Engine running
MFWD switch on.
CED,TX17864,86 1912JUN981/1
MFWD Circuit Theory of Operation

9015
15
19
NOTE: The MFWD is spring applied, hydraulically

released. See Mechanical Front Wheel Drive
(MFWD) Operation in Group 9020-05.
Power flows from the MFWD/Alternator/Differential lock
fuse (F1) to the MFWD switch (S2). When MFWD switch
is in disengaged position, power continues to flow to the
MFWD solenoid (Y1) and energize the solenoid.
When switch is in engaged position, the switch opens and
the MFWD solenoid is de-energized. The MFWD diode
(V10) prevents voltage spikes from arching across the
terminals of the switch.
CED,TX17864,87 1902MAY021/1
TM1608 (20SEP06)
9015-15-19

092006
PN=229
MFWD Circuit Schematic
T115840
1919JUN98
9015
15
20
CED,TX17864,88 1912JUN981/1
Sub-System Diagnostics/MFWD Circuit
CED,TX17864,89 1919JAN001/1
MFWD Circuit Diagnostic Procedures
1/1
TM1608 (20SEP06)
9015-15-20

092006
PN=230
MFWD Switch
YES: MFWD switch is

good. Check wiring
harness.
NO: Replace MFWD
switch.
9015
15
21
T100731 UN28MAY96

MFWD switch OFF.
Check for continuity between terminals 2B and 1.
MFWD switch ON.
1/1
MFWD Solenoid
Key switch ON.
YES: Repair or replace

solenoid.
MFWD switch OFF.

NO: Repair harness. (See

group 10 of this section)
Measure voltage at terminals in harness.

T126771 1920DEC99
1/1
TM1608 (20SEP06)
9015-15-21

092006
PN=231
MFWD Diode

diode.

Reverse probes
T7961AA UN10MAR93
open mode. Replace.
is OK.
1/1
9015
15
22
Display Monitor Circuit Operational

Information
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,QQ6327 1906JUN961/1
TM1608 (20SEP06)
9015-15-22

092006
PN=232
Display Monitor Circuit Theory Of Operation

Power is supplied to the display monitor through the 10
AMP Monitor/Gauge fuse.
Each display indicator will be colored either (RED) or
(YELLOW) to indicate the severity of the situation. Red is
a high level warning and the yellow is a low level warning.
When the RED high level warning is indicated, the
operator will see a (RED COLORED INDICATOR), (RED
STOP INDICATOR) and (AUDIBLE ALARM). When the
YELLOW low level warning is indicated, the operator will
see only the (YELLOW COLORED INDICATOR). On Low
Level warnings the operation of the machine can
continue but the problem should be investigated and
solved. On High Level warnings except Engine Coolant
Temperature Indicator the operation of the machine
should be stopped immediately and problem corrected,
9015
15
23
CONDITION: High Level Warning Indicators (RED)

STOP
Red Stop Indicator:

Park Brake Indicator:
Engine Oil Pressure Indicator:
Engine Coolant Temperature Indicator: DO NOT stop
engine when engine coolant temperature indicator
comes on, or temperature will rise further. Reduce load
and run engine at slow idle for several minutes, stop
engine and service machine.
CONDITION: Low Level Warning Indicators (YELLOW)

SERVICE
Air Filter Restriction Indicator:

Charging System Indicator:
Converter Oil Temperature Indicator:
Hydraulic Oil Filter Indicator:
CONDITION: Seat Belt Indicator (WHITE)

The seat belt indicator will be back-lighted White when
ever the key switch is on and park brake is applied.
CONDITION: MFWD Indicator (GREEN)
TM1608 (20SEP06)
9015-15-23
TX,9015,QQ6328 1906JUN961/2

092006
PN=233
MFWD indicator will be back-lighted Green when
switch is on.
CONDITION: Beacon Indicator (GREEN)
Beacon indicator will be back-lighted Green when
switch is on.
TX,9015,QQ6328 1906JUN962/2
9015
15
24
TM1608 (20SEP06)
9015-15-24

092006
PN=234
Display Monitor Circuit Schematic
T100799
1903NOV97
9015
15
25
TX,9015,QQ6329 1906JUN961/1
TM1608 (20SEP06)
9015-15-25

092006
PN=235
Sub-System Diagnostics/Display Monitor
TX,9015,QQ6330 1906JUN961/1
Display Monitor Diagnostic Procedures
1/1
Fuse
9015
15
26
Remove fuse cover.
YES: Replace fuse
Check 10 amp monitor/gauge fuse.
NO: Go to next check
Is fuse blown?
1/1
Key Switch Check
Key switch OFF.

this check.

switch.
NO: Check wiring

and key switch.

T7199BO UN17SEP90

this check.

T7199BO UN17SEP90
Key switch ON.

T7199BO UN17SEP90
1/1
TM1608 (20SEP06)
9015-15-26

092006
PN=236
Display Monitor

NO: Check wiring
harness
9015
15
27
T102886 1908AUG96
Unplug 12 pin harness connector from display monitor.

Key switch to ON position.
Check for voltage on P21 red wire
1/1
Display Monitor
(Continued)
YES: Check connector

pins in connector.
IF OK: Go to indicator
circuit and check
indicators.
IF OK: Replace display
monitor.
NO: Check wiring
harness.
T102887 1908AUG96
Unplug 8 pin harness connector from display monitor.

Key switch to OFF position.
Check for continuity between R31 black wire and ground.
1/1
TM1608 (20SEP06)
9015-15-27

092006
PN=237
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 between ON and START position
for bulb check.
The following conditions must exist for indicator circuit to
function in a failure mode:
9015
15
28
Engine must be running for a failure to be indicated on

display monitor. An indicator switch or alternator senses a
failure and supplies a high or low level warning to display
monitor.
TX,9015,QQ6332 1906JUN961/1
Indicator Circuit Specifications

Specification
Engine Coolant Temperature
Switch (Normally Open)Closing
Temperature ..................................................................... 115.6C (240F)
Engine Oil Pressure Switch
(Normally Closed)Opening
Pressure ........................................................... 3772 kPa (0.40.7 bar)
(5.510.5 psi)
Air Filter Restriction Switch
(Normally Open)Closes on
Increased Vacuum................................. 4.987.48 kPa Vacuum (2030
in. H2O)
Converter Oil Temperature Switch
(Normally Open)Closes on
Increasing Temperature ........................... 114C122C (238F252F)
Hydraulic Filter Restriction Switch
(Normally Open)Closing
Pressure ......................................................... 344 kPa (3.45 bar) (50 psi)
TX,9015,QQ6331 1931JUL981/1
TM1608 (20SEP06)
9015-15-28

092006
PN=238
Indicator Circuit Theory Of Operation

Indicator switches to the display monitor are:
Bulb Check Mode
Key switch is moved between ON and START

position to activate bulb check mode. All high and low
level indicator lights will activate and audible alarm will
sound. The seat belt (White) indicator will be on.
B10-Park Brake Pressure Switch: (Stop)

B6-Engine Oil Pressure Switch: (Stop)
B5-Engine Coolant Temperature Switch: (Stop)
B7-Air Filter Restriction Switch: (Service)
B8-Converter Oil Temperature Switch: (Service)
B9-Hydraulic Filter Restriction Switch: (Service)
G2-Alternator: (Service)
The following indicators will be displayed on display

monitor when a signal from a High Level Warning
Indicator switch is activated:
Red Colored Indicator
Red Stop Indicator
Audible Alarm
High Or Low Level Warning Mode

During normal operation the indicator lights are turned
on when an indicator switch or the alternator provides
a signal to the display monitor indicating a STOP
High Level Warning or SERVICE Low Level Warning
indicator.
The following indicator will be displayed on display

monitor when a signal from a Low Level Warning
Indicator switch is activated or the signal from the
alternator disappears.
Yellow Colored Indicator
On Mode
The seat position sensor is located in the operator seat

base. When the seat is moved to operate backhoe
functions the sensor is closed. When the sensor is
closed (seat moved to operate backhoe functions) A
signal is sent to the display monitor. When the FNR
lever is moved into forward or reverse position during
backhoe operation the display monitor is activated
turning on the audible alarm and the red STOP
indicator light.
Key switch is moved to ON position. The park brake,

seat belt, engine oil pressure, charging system light
and stop warning light will be on.
TX,9015,QQ6333 1925JUN961/1
TM1608 (20SEP06)
9015-15-29

092006
PN=239
9015
15
29
Indicator Circuit Schematic
T100800
1927SEP96
9015
15
30
TX,9015,QQ6334 1901OCT961/1
TM1608 (20SEP06)
9015-15-30

092006
PN=240
Sub-System Diagnostics/Indicator Circuit
TX,9015,QQ6335 1906JUN961/1
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.

NO: Switch is good. Go
to next check.
Is engine coolant indicator light on?

T7199CG 1916AUG90
1/1
Engine Oil Pressure

Switch
Disconnect N34 yellow wire from switch and ground to

frame.

to next check.
Is engine oil pressure indicator light on?

T7199DZ 1926SEP90
1/1
Engine Alternator
Indicator Circuit
Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39
purple wire.
YES: Circuit is good.

Repair or replace
alternator.
Without starting engine, turn key switch to BULB CHECK, then release to ON.
Is alternator indicator light off?
Remove voltage from M39 purple wire.
Is alternator indicator light on?
1/1
TM1608 (20SEP06)
9015-15-31

092006
PN=241
9015
15
31
Engine Air Filter
Restriction Switch
Disconnect M40 purple wire from switch and ground to

frame.
CHECK, then release to ON?

to next check.
Is air filter restriction indicator light on?

T7199CI 1917SEP90
1/1
9015
15
32
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.

to next check.
Is converter oil temperature light on?

T7199CJ 1917SEP90
1/1
Hydraulic Filter
Restriction Indicator
Switch
Disconnect F39 yellow wire from switch and ground to

frame.

to next check.
Is hydraulic filter restriction indicator light on?

T7199CK 1917SEP90
1/1
TM1608 (20SEP06)
9015-15-32

092006
PN=242
Key switch OFF.
T102968 1912AUG96
Seat in loader function position.
YES: Seat position

sensor is good. Check
wiring harness.
NOTE: Seat position sensor is located in the operator

seat base.
NO: Replace seat

position sensor.
Check for continuity between terminals with M1 purple

wire and G10 black wire
Is continuity NOT measured?
Move seat into backhoe function position
Check for continuity between terminals with M1 purple
wire and G10 black wire
Is continuity measured:
9015
15
33
1/1
Park Brake/FNR Circuit Operational

Information
The following condition or conditions must exist for park
brake/FNR circuit to function:
Key switch OFF
Park brake dash switch in ON position with machine
running
Machine Mechanically Shut Down
TX,9015,QQ6784 1921JUL981/1
Park Brake/FNR Circuit Specifications

Specification
Park Brake Pressure Switch
(Normally Closed)Opening
Pressure ............................................... 1103 110 kPa (11.3 1.10 bar)
(160 16 psi)
Closing Pressure ......................................... 896 89.6 kPa (8.96 0.896
bar) (130 13 psi)
TX,9015,QQ6783 1921JUL981/1
TM1608 (20SEP06)
9015-15-33

092006
PN=243
Park Brake/Neutral Disconnect Circuit (Manual Shift) Theory Of Operation
9015
15
34
The Park Brake/FNR 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, neutral
disconnect solenoid, starter motor, neutral start relay,
pump unloading valve relay and park brake pressure
switch.
solenoid, and neutral disconnect solenoid

de-energizing solenoids. With the engine not running
hydraulic pressure is not present, this putts the
reverser in neutral applying the park brake. When the
park brake is applied the park brake pressure switch
closes providing a ground for the park brake indicator
light in the display monitor to come on.
The park brake is spring applied and hydraulically

released.
Key ON:
Park Brake Dash Switch In ON position:
FNR Lever Shifted Out of Neutral:
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.
With the park brake dash switch ON, and FNR lever
shifted out of neutral, a signal is sent to the display
monitor. With engine not running the park brake is
spring applied and park brake pressure switch is
closed, causing park brake indicator light on display
monitor to come on and alarm to sound.
Park brake cannot be hydraulically released if

FNR/Park Brake Fuse is blown.
Key ON:
Engine Running:
Key ON:
Park Brake Dash Switch in On Position:
FNR Lever in Neutral:
With engine running and is then mechanically shut

down, the park brake latching relay is de-energized,
removing power from terminal 2B on park brake dash
switch. This, in turn, de-energizes the park brake
solenoid and neutral disconnect solenoid. Engine is not
running, so hydraulic pressure goes to zero, which
puts the reverser in neutral and park brake is applied.
When the park brake is applied, the park brake
pressure switch closes providing a ground for the park
brake indicator light in the display monitor to come on.
Power flows from terminal 3 to terminal 2B 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 S terminal of
starter motor. Power is disconnected from park brake
TX,9015,QQ6785 1921JUL981/1
TM1608 (20SEP06)
9015-15-34

092006
PN=244
Park Brake/FNR Circuit (Manual Shift) Schematic

T115983 1929JUN98
TX,9015,QQ6786 1921JUL981/1
TM1608 (20SEP06)
9015-15-35

092006
PN=245
Park Brake/FNR Circuit (Power Shift) Theory Of Operation

The Park Brake/FNR circuit controls the park brake
and transmission.
released.
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.
9015
15
36
Park brake cannot be hydraulically released if

FNR/Park Brake Fuse is blown.
Key ON:
Park Brake Dash Switch in On Position:
FNR Lever in Neutral:
Power flows from terminal 3 to terminal 2B of park
brake dash switch (S12) and then to park brake
latching relay terminal 85, energizing the park brake
latching relay (K5) causing it to latch terminals 30 and
87. Ground is supplied to the park brake latching relay
through the S terminal of starter motor. Power is
disconnected from park brake solenoid (Y4), and timer
relay (K7).
With the FNR switch (S11) in neutral, power flows from
the FNR switch to the display monitor (H8). Combine
this with the park brake pressure switch being closed
and providing a ground for the park brake indicator
light, the park brake indicator light in the display
monitor glows signaling that the park brake is applied.
Key ON:
Engine Running:
Park Brake Dash Switch In ON position:
FNR Lever Shifted Out of Neutral:
the display monitor disappears. With the park brake

switch on, the park brake pressure switch is closed
sending a ground signal to the display monitor. With
the ground signal present from the park brake
pressure switch without the power signal from the FNR
switch, the park brake indicator light on display monitor
glows and the alarm sounds. The red stop light will
also blink on and off.
The machine is unable to move because the park
brake dash switch is NOT sending voltage to the timer
relay, thus all of the speed solenoids are de-energized.
Machine started with park brake switch in OFF
position:
When the machine is started with the park brake dash
switch in the OFF position the park brake latching
relay is unlatched or open. When the park brake
latching relay is open the park brake dash switch does
receive voltage to terminal 2B. If the FNR switch is
placed out of neutral the display monitor alarm will
sound and the stop light will flash. This occurs
because the park brake solenoid is not energized, thus
the park brake pressure switch is closed and sending
a ground signal to the display monitor.
To enable the machine to operate, place the park dash
switch in the ON position. This allows power to flow to
terminal 85 of the park brake latching relay causing the
relay to close. With the relay closed, power can now
flow from terminal 87 of the park brake latching relay
to terminal 2B of the park brake switch.
Key ON:
Engine Running:
Park Brake Switch OFF:
With the park brake dash switch in the OFF position,
voltage is sent to both the timer relay and the park
brake solenoid.
With the park brake dash switch ON, and FNR lever
shifted out of neutral, the signal from the FNR lever to
TM1608 (20SEP06)
9015-15-36
CED,TX17864,101 1922JUN981/2

092006
PN=246
The park brake solenoid is now energized and sending
pressurized oil to the park brake to release it. This also
opens the park brake pressure switch, thus the ground
signal to the display monitor is removed and the park
brake indicator light goes out.
Key ON:
Engine Running:
Park Brake Switch OFF:
FNR Switch in Forward or Reverse:
With the park brake dash switch in the OFF position,

voltage is sent to both the timer relay (K7) terminal 2
and the park brake solenoid.
The park brake solenoid is now energized and sending
pressurized oil to the park brake to release it. This also
opens the park brake pressure switch, thus the ground

signal to the display monitor is removed and the park
brake indicator light goes out.
Power flows through the loader lever switch (S13) to
the FNR switch (S11). With FNR switch in either
forward or reverse power flows to the timer relay
terminal 7. This signal closes the timer relay allowing
power to flow from the park brake dash switch through
the timer relay to the FNR switch. Depending on FNR
switch position, the proper direction and speed
solenoids in the transmission are energized.
NOTE: If the signal to the timer relay terminal 7

disappears for more than one second, the
timer relay will open.
9015
15
37
CED,TX17864,101 1922JUN982/2
TM1608 (20SEP06)
9015-15-37

092006
PN=247
Park Brake/FNR Circuit (Power Shift) Schematic

T126773 1920DEC99
CED,TX17864,102 1919JAN001/1
TM1608 (20SEP06)
9015-15-38

092006
PN=248
Sub-System Diagnostics/Park Brake/FNR

Circuit
TX,9015,QQ6787 1919JAN001/1
Park Brake/Neutral Disconnect Circuit Diagnostic Procedures
1/1
Park Brake Switch

Dash
YES: Park brake switch is

good. Check wiring
9015
harness.
15
39
NO: Replace park brake
switch.
T100731 UN28MAY96
Disconnect harness from park brake switch.

Park brake switch OFF.
Check for continuity between terminals 2A and 1.
Park brake switch ON.
1/1
TM1608 (20SEP06)
9015-15-39

092006
PN=249
Forward Solenoid Check
(Manual Shift)
YES: Forward solenoid

electrically is good. See
Group 9020-25 Power
Train Test.
NO: Check wiring
harnesses. See Group
9015-10.
9015
15
40
T101725 1912SEP96
Remove fuse block cover.

Using a Fluke multimeter, turn to DC current. Red lead into (10A) terminal and black
lead into (COM.) terminal.
Key switch ON and engine OFF.
Place probe ends of multimeter at locations (A and B) in fuse block.
Park brake switch ON applied.
Move FNR into forward position.
Is (.52.65) amps measured?
NOTE: The current value measurement is controlled by the number of components

that are connected within the circuit.
1/1
TM1608 (20SEP06)
9015-15-40

092006
PN=250
Reverse Solenoid Check
(Manual Shift)
YES: Reverse solenoid

Group 9020-25 Power
Train Test.
NO: Check wiring
9015-10.
9015
15
41
T101725 1912SEP96

Park brake switch ON applied.
Move FNR into reverse position.
Is (.70.82) amps measured?

1/1
TM1608 (20SEP06)
9015-15-41

092006
PN=251
Neutral Solenoid Check
(Manual Shift)
YES: Neutral solenoid

Group 9020-25 Power
Train Test.
NO: Check wiring
9015-10.
9015
15
42
T101725 1912SEP96

FNR lever in neutral position.
Cycle Park brake switch ON and then to OFF position. Approximately 2.40 amp
value will display.
Push the loader lever disconnect button.
Does the amp value drop to 0.4 amps?
1/1
TM1608 (20SEP06)
9015-15-42

092006
PN=252
Transmission Solenoids
Check (Power Shift)
YES: Transmission
solenoids are electrically
good. See Group 9020-25
Power Train Test.
NO: Check wiring
harness or transmission
solenoids.
9015
15
43
T101725 1912SEP96

Park brake switch OFF. Approximately 1.9 amp value will display.
NOTE: If 1.9 amp value is not displayed, cycle park brake on then off again.
FNR lever in forward position.
NOTE: Each solenoid in the transmission draws approximately 0.5 amps. If measured
amperage value is approximately 0.5 amps less than specification, a problem with one
solenoid is indicated.
Does the amp value match the following specifications for each speed?
Specification
FNR Current1st Speed Forward
Amperage ................................................................................................ 3.12
2nd Speed Forward Amperage ............................................................... 3.12
3rd Speed Forward Amperage ................................................................ 3.12
4th Speed Forward Amperage .................................................................. 2.8
0.1
0.1
0.1
0.1
amps
amps
amps
amps
FNR lever in reverse position.

Does the amp value match the following specifications for each speed?
Specification
FNR Current1st Speed Reverse
Amperage ................................................................................................ 3.22 0.1 amps
2nd Speed Reverse Amperage ............................................................... 3.22 0.1 amps
3rd Speed Reverse Amperage ............................................................... 3.22 0.1 amps

1/1
TM1608 (20SEP06)
9015-15-43

092006
PN=253
Park Brake Solenoid
Check (Manual Shift)
YES: Park brake solenoid

Group 9020-25 Power
Train Test.
NO: Check wiring
9015-10.
9015
15
44
T101725 1912SEP96

Park brake switch ON. Approximately 0.45 amp value will display.
Move park brake switch to OFF position.
Does the amp value increase by approximately 2.0 amps?
1/1
TM1608 (20SEP06)
9015-15-44

092006
PN=254
Park Brake Solenoid
Check (Power Shift)
YES: Park brake solenoid

Group 9020-25 Power
Train Test.
NO: Check wiring
9015-10.
9015
15
45
T101725 1912SEP96

Park brake switch ON. Approximately 0.45 amp value will display.
Move park brake switch to OFF position.
Does the amp value increase by approximately 1.5 amps?
1/1
Loader Lever Switch
Disconnect harness from loader lever switch

Check for continuity between terminals with J27 tan wire
and T53 blue wire.

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.
YES: Replace loader

lever switch.
NO: Loader lever switch
is good. Check wiring
harness.
T7199CU 1902OCT90
1/1
TM1608 (20SEP06)
9015-15-45

092006
PN=255
Gear Shift Lever Switch
(Manual Shift)
Disconnect harness from gear shift lever switch.

Check for continuity between terminals with T53 blue
wire and T52 blue wire.

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.
9015
15
46
YES: Replace gear shift

lever switch.
NO: Gear shift lever
switch is good. Check
wiring harness.
T7199CV 1902OCT90
1/1
Park Brake Latching

Relay
Key switch OFF.
YES: Relay is good.


NO: Replace relay.
Connect battery voltage to terminal #86. Ground terminal
#85.
Does relay click?
T7287BH UN16AUG90
Measure continuity between terminals #30 and #87.

1/1
TM1608 (20SEP06)
9015-15-46

092006
PN=256
Timer Relay Check
(Power Shift)
YES: Go to next check

NO: Replace timer relay.
9015
15
47
T126811 UN15DEC99
Disconnect timer relay from front console harness.

Connect a 12 power supply and ground to the timer relay as shown.
Check for continuity across terminals 5 and 6 of timer relay.
1/1
Park Brake Pressure

Switch
YES: Switch is good.

Measure continuity between terminals A and B on

connector end of switch.
NO: Replace switch
T7199EE UN02OCT90
1/1
TM1608 (20SEP06)
9015-15-47

092006
PN=257
FNR Lever (Manual Shift)
Disconnect FNR switch from harness.

this check.
Connect a 12 volt power supply to FNR lever as shown.

NO: Check wiring
harness.
Place FNR lever in neutral.

Check voltage at terminal D as shown.
9015
15
48
T115867 1919JUN98
Disconnect FNR switch from harness.
YES: FNR lever is good.

Go to next check.

Place FNR lever in forward.
Check voltage at terminal C as shown.
Place FNR lever in reverse.
Check voltage at terminal B.
T115868 1919JUN98
1/1
TM1608 (20SEP06)
9015-15-48

092006
PN=258
FNR Lever Check (Power
Shift)
YES: Continue with check

T114633 1921JUL98
Disconnect FNR lever from harness.

9015
15
49
Place FNR lever in neutral.

Are 12 volts measured at only terminal D of four pin connector?
Place FNR lever in reverse.
Are 12 volts measured at only terminal B of four pin connector?
Place FNR lever in forward.
Are 12 volts measured at only terminal C of four pin connector?
1/2
TM1608 (20SEP06)
9015-15-49

092006
PN=259
T114633 1921JUL98
Disconnect FNR lever from harness.

9015
15
50
Place FNR lever in first speed forward.

Are 12 volts measured at only terminals A, C, and D of six pin connector?
Place FNR lever in second speed forward.
Are 12 volts measured at only terminals A, B, and C of six pin connector?
Place FNR lever in third speed forward.
Are 12 volts measured at only terminals B, C, and D of six pin connector?
Place FNR lever in fourth speed forward.
Are 12 volts measured at only terminals B and D of six pin connector?
19 2/2
Park Brake Relay Diode

diode.

Reverse probes
T7961AA UN10MAR93
open mode. Replace.
is OK.
1/1
TM1608 (20SEP06)
9015-15-50

092006
PN=260
Park Brake Solenoid
Diode

diode.


open mode. Replace.
Reverse probes
T7961AA UN10MAR93
is OK.
1/1
Reverse Solenoid Diode

diode.


open mode. Replace.
Reverse probes
T7961AA UN10MAR93
9015
15
51
is OK.
1/1
Forward Solenoid Diode

diode.


open mode. Replace.
Reverse probes
T7961AA UN10MAR93
is OK.
1/1
Neutral Disconnect
Solenoid Diode (Manual
Shift)

diode.

Reverse probes
T7961AA UN10MAR93
open mode. Replace.
is OK.
1/1
TM1608 (20SEP06)
9015-15-51

092006
PN=261
Low Range Solenoid
Diode (Power Shift)

diode.


open mode. Replace.
Reverse probes
T7961AA UN10MAR93
is OK.
1/1
Speed Solenoid Diodes

(Power Shift)
9015
15
52
diode.

Reverse probes
T7961AA UN10MAR93
open mode. Replace.
is OK.
1/1
TM1608 (20SEP06)
9015-15-52

092006
PN=262
9015
15
53
TM1608 (20SEP06)
9015-15-53

092006
PN=263
Pump Unloading Valve Circuit Operational

Information
The following condition or conditions must exist for pump
unloading valve to work.
Key switch ON
Engine ON
FNR in Neutral
TX,9015,BA2153 1906NOV971/1
9015
15
54
Pump Unloading Valve Circuit Theory of

Operation
With the key switch ON and FNR in neutral the unloading
valve pump relay is energized connecting contacts 30 and
87. Contacts 30 and 87A are broken and power is then
removed from unloading valve pump solenoid
de-energizing solenoid.
When unloading valve pump solenoid is de-energized, it
routes auxiliary pump oil for backhoe functions only.
TX,9015,BA2154 1906NOV971/1
TM1608 (20SEP06)
9015-15-54

092006
PN=264
Pump Unloading Valve Circuit Schematic
T102943
1904OCT96
9015
15
55
TX,9015,BA2155 1906NOV971/1
TM1608 (20SEP06)
9015-15-55

092006
PN=265
Sub-System Diagnostics/Pump Unloading

Valve Circuit
This circuit is powered by the Return-to-Dig, Beacon,
Pump fuse.
TX,9015,BA2156 1906NOV971/1
Pump Unloading Valve Diagnostic Procedures

9015
15
56
1/1
Unloading Valve Pump

Relay
Key switch OFF.
YES: Relay is good.


Connect battery voltage to terminal 86. Ground terminal
85. Does relay click?
T7287BH UN16AUG90
NO: Replace neutral start

relay.
Measure continuity between terminals 30 and 87. Is

continuity measured?
1/1
Unloading Valve Pump

Solenoid
Disconnect harness from unloading valve pump solenoid.
YES: Solenoid is good.

check wiring harness.
Apply battery voltage to pin (A) of solenoid, and ground pin (B) of solenoid.
NO: Replace solenoid.
Does solenoid click?
1/1
TM1608 (20SEP06)
9015-15-56

092006
PN=266
Sideshift Circuit Operational Information

315SE
The following conditions must exist for sideshift circuit to
function:
Key switch ON
Engine operating
Sideshift lock switch pressed
TX,9015,BD2437 1917DEC961/1
Sideshift Circuit Theory of Operation315SE

9015
15
57
With the key switch ON, voltage is present at sideshift

lock switch. When the switch button is pressed, current
energizes the sideshift lock solenoid. When the switch
button is released current flow stops and solenoid is
de-energized.
When the sideshift lock solenoid is de-energized, pressure
oil to the sideshift lock solenoid is routed to the sideshift
frame lock pistons. When solenoid is energized pressure
oil is blocked and oil from lock pistons is routed to the
reservoir.
TX,9015,BD2438 1917DEC961/1
TM1608 (20SEP06)
9015-15-57

092006
PN=267
Sideshift Circuit Schematic315SE
T116678
1903AUG98
9015
15
58
TX,9015,BD2439 1917DEC961/1
Subsystem Diagnostics/Sideshift Circuit

315SE
This circuit is protected by the Auxiliary fuse, F15.
TX,9015,BG228 1902JAN971/1
TM1608 (20SEP06)
9015-15-58

092006
PN=268
Sideshift Circuit Diagnostic Procedures
1/1
Sideshift Solenoid Check
YES: Sideshift solenoid

Group 9025-25 Sideshift
Valve Leakage Test.
NO: Check wiring
9015-10.
9015
15
59
T105769 1923DEC96

Remove AUX. fuse.
Key switch ON with engine OFF.
Approximately 0.01 amp value will display.
Press sideshift switch on backhoe lever.
Does the amp value increase by approximately 1.0 amp?
1/1
TM1608 (20SEP06)
9015-15-59

092006
PN=269
Sideshift Lock Switch
Check
Disconnect harness from sideshift lock switch.

Check for continuity between connector terminals with
P01 red wire and K05 light green wire.
YES: Replace sideshift

switch.
NO: Go to next step in
this check.
T105770 1923DEC96
Disconnect harness from sideshift lock switch.

Depress sideshift lock switch and check for continuity
between connector terminals with P01 red wire and K05
light green wire.
YES: Sideshift lock switch

is good. Check wiring
harness
NO: Replace sideshift
lock switch.
9015
15
60
T105770 1923DEC96
1/1
TM1608 (20SEP06)
9015-15-60

092006
PN=270
Boom Lock Circuit Operational Information

315SE
The following conditions must exist for boom lock circuit to
function:
Key switch ON
Engine operating
Boom lock switch pressed
TX,9015,BD2441 1917DEC961/1
Boom Lock Circuit Theory of Operation

315SE
9015
15
61
With the key switch ON, voltage is present at the boom

lock switch. When the switch button is pressed, current
energizes the boom lock solenoid. When the switch button
is released, current flow stops and solenoid is
de-energized.
When the boom lock solenoid is energized, pressure oil is
routed to the boom lock cylinders. When the boom lock
solenoid is de-energized, pressure oil to the boom lock
cylinders is blocked and the oil is routed back to the
transmission.
TX,9015,BD2442 1917DEC961/1
TM1608 (20SEP06)
9015-15-61

092006
PN=271
Boom Lock Circuit Schematic315SE
T116679
1903AUG98
9015
15
62
TX,9015,BD2443 1917DEC961/1
TM1608 (20SEP06)
9015-15-62

092006
PN=272
Subsystem Diagnostic/Boom Lock Circuit

315SE
This circuit is protected by the Auxiliary fuse, F15.
TX,9015,BG229 1902JAN971/1
Boom Lock Diagnostic Procedures315SE
1/1
Boom Lock Solenoid

Check
YES: Boom lock solenoid

is good. See Group
9015
9025-25 Boom Lock
15
Valve Leakage Test.
63
NO: Check wiring
harness. See Group
9015-10.
T105769 1923DEC96

Remove Aux. fuse.
Key switch ON with engine OFF.
Place probe ends of multimeter leads at locations (A and B) in fuse block.
Approximately 0.01 amp will display.
Press boom lock switch on floor.
Does the amp value increase by approximately 1.0 amp?
1/1
TM1608 (20SEP06)
9015-15-63

092006
PN=273
Boom Lock Switch
Check
Disconnect harness from boom lock switch.
YES: Replace boom lock

switch.
Check for continuity between connector terminals with

P01 red wire and H10 dark green wire.
NO: Go to next step in

this check.
T105772 1923DEC96
Disconnect harness from boom lock switch.

Depress boom lock switch and check for continuity
between connector terminals with P01 red wire and H10
dark green wire.
YES: Boom lock switch is

good. Check wiring
harness.
NO: Replace boom lock
switch.
9015
15
64
T105772 1923DEC96
1/1
Ride Control Circuit Operational Information

The following conditions must exist for the ride control
circuit to function.
Key switch ON
Ride control switch ON
CED,OUTX782,528 1930JUN991/1
Ride Control Circuit Theory of Operation

Power flow from the auxiliary fuse (F15) to the ride control
switch (S30).
When the ride control switch is switched on, power flows
to both the ride control solenoid (Y15), energizing the
solenoid, and to the light in the ride control switch causing
it to illuminate alerting the operator that the ride control
system is on.
When the switch is switched off and the circuit is broken
the ride control diode (V15) allows the current to dissipate.
CED,OUTX782,530 1930JUN991/1
TM1608 (20SEP06)
9015-15-64

092006
PN=274
Ride Control Circuit Schematic
T115841
1919JUN98
9015
15
65
CED,TX17864,88 1912JUN981/1
TM1608 (20SEP06)
9015-15-65

092006
PN=275
Sub-System Diagnostics/Ride Control Circuit
CED,TX17864,89 1928JAN001/1
Ride Control Circuit Diagnostic Procedures
1/1
Fuse Check
9015
15
66
Remove fuse cover.
YES: Replace fuse.
Check 10 amp auxiliary fuse.
Is fuse blown?
1/1
TM1608 (20SEP06)
9015-15-66

092006
PN=276
Ride Control Switch
Check

NO: Check wiring
harness.
9015
15
67
T100731 UN28MAY96
Unplug harness from ride control switch.

Check for voltage in receptacle 2B (P30 RED wire) of switch connector.

NO: Replace switch.
T100731 UN28MAY96
Unplug harness from ride control switch.

Switch ride control switch ON.
1/1
TM1608 (20SEP06)
9015-15-67

092006
PN=277
Ride Control Solenoid
Check
YES: Replace solenoid.
Key switch and ride control switch ON.
NO: Check wire harness.
Measure voltage at harness connector.

T116136 1906JUL98
1/1
Ride Control Solenoid

Diode Check
9015
15
68
diode.

Reverse probes
T7961AA UN10MAR93
open mode. Replace.
is OK.
1/1
Selective Flow Valve Circuit Operational

Information
The following conditions must exist for the selective flow
valve circuit to function.
NOTE: The selective flow valve circuit has two different

modes of operation. It can be either continuously
on or momentarily on using the foot switch. This
selected using the two different positions on the
switch in the dash.
NOTE: If the selective flow valve switch is in either
continuous on or foot on position when the
machine is started, the switch must be cycled to
off and then back on for the system to operate.
Key switch ON
Selective flow valve switch in either foot ON or
continuous ON.
Foot switch held ON if selective flow valve switch is in
foot ON position.
CED,TX17864,119 1931JUL981/1
TM1608 (20SEP06)
9015-15-68

092006
PN=278
Selective Flow Valve Circuit Theory of

Operation
NOTE: If the selective flow valve switch is in either
continuous on or foot on position when the
machine is started, the switch must be cycled to
off and then back on for the system to operate.
Power flows from the auxiliary fuse (F15) to both the
selective flow valve relay (K8) and the selective flow valve
switch (S28). With the selective flow valve switch in the off
position, power flows through the switch to back to the coil
side of the selective flow valve relay to energize the relay.
With the selective flow valve relay energized, power now
flows from the relay to the selective flow valve switch
through the H01 GRN wire.
9015
15
69
With the selective flow valve switch in the foot on position,

power flows through the switch lighting the bulb in the
switch and through the H04 GRN wire to the foot switch
(S29). When the foot switch is depressed, power
continues to flow through the H03 GRN wire to the
selective flow valve solenoid (Y16) . When the foot switch
is released, power stops flowing to the solenoid and the
selective flow valve relay diode (V5) allows the current to
dissipate.
With the selective flow valve is in the continuous on
position, power flows through the switch lighting the bulb
in the switch and through H03 GRN wire to the selective
flow valve solenoid. When the switch is switched off,
power stops flowing to the solenoid and the selective flow
valve relay diode (V5) allows the current to dissipate.
CED,TX17864,116 1931JUL981/1
TM1608 (20SEP06)
9015-15-69

092006
PN=279
Selective Flow Valve Circuit Schematic
T116668
1931JUL98
9015
15
70
CED,TX17864,117 1931JUL981/1
TM1608 (20SEP06)
9015-15-70

092006
PN=280
Sub-System Diagnostics/Selective Flow

Valve Circuit
CED,TX17864,118 1931JUL981/1
Selective Flow Valve Diagnostic Procedures
1/1
Fuse Check
Remove fuse cover.
YES: Replace fuse.
Is fuse blown?
1/1
TM1608 (20SEP06)
9015-15-71

092006
PN=281
9015
15
71
Selective Flow Valve
Switch Check

NO: If switch fails any of
the above continuity
checks, replace switch.
9015
15
72
T100731 UN28MAY96
Disconnect harness from selective flow valve switch.

Selective Flow Valve Switch to OFF position
Is Continuity measured?
Selective Flow Valve Switch to foot on position.
Check for continuity between terminals 5B and 3 of switch.
Selective Flow Valve Switch to continuous on position.
Check for continuity between terminals 5B and 6 of switch.
1/1
Foot Switch Check
Disconnect foot switch from harness.
Depress foot switch.
NO: Replace foot switch.
Check for continuity at connector.

T116147 1927JUL98
1/1
TM1608 (20SEP06)
9015-15-72

092006
PN=282
Selective Flow Valve
Solenoid Check
Key switch ON.
Selective flow valve switch in continuous on position.
NO: Check wiring

harness.
Disconnect selective flow valve harness under cab.

Measure voltage at end of harness.
T116672 1931JUL98
1/1
Pin Disconnect Circuit Operational

Information
9015
15
73
The following conditions must exist for the pin disconnect

circuit to function.
Key switch ON
Pin disconnect switch held in the unlocked position
CED,TX17864,94 1912JUN981/1
Pin Disconnect Circuit Theory of Operation

Power flow from the auxiliary fuse (F15) to the pin
disconnect switch (S31).
The pin disconnect switch is a spring loaded momentary
style switch. The switch must be held in the unlocked
position to allow power to flow through the switch. If the
switch is released it will return to the locked position by
itself.
When the pin disconnect switch is held in the unlocked
position on, power flows to the pin disconnect solenoid
(Y17), energizing the solenoid.
When the switch is released and the circuit is broken, the
pin disconnect diode (V17) allows the current to dissipate.
CED,TX17864,95 1912JUN981/1
TM1608 (20SEP06)
9015-15-73

092006
PN=283
Pin Disconnect Circuit Schematic
T115843
1908JUL98
9015
15
74
CED,TX17864,96 1912JUN981/1
TM1608 (20SEP06)
9015-15-74

092006
PN=284
Sub-System Diagnostics/Pin Disconnect

Circuit
CED,TX17864,97 1912JUN981/1
Pin Disconnect Circuit Diagnostic Procedures
1/1
Fuse Check
Remove fuse cover.
YES: Replace fuse.
Is fuse blown?
1/1
Pin Disconnect Switch

Check
Unplug harness from pin disconnect switch.
NO: Check wiring

harness.
Check for voltage in receptacle A (P01 RED wire) of

switch connector.
T116137 1906JUL98
Unplug harness from pin disconnect switch.
Hold pin disconnect switch in the unlocked position.
NO: Replace switch.
Check for continuity between terminals A and B.

T116137 1906JUL98
1/1
TM1608 (20SEP06)
9015-15-75

092006
PN=285
9015
15
75
Pin Disconnect Solenoid
Check
Key switch ON.
NO: Check wire harness.
Pin disconnect switch held in the unlocked position.

Measure voltage at harness connector.
T116138 UN02JUL98
1/1
Pin Disconnect Solenoid

Diode Check
9015
15
76
diode.

Reverse probes
T7961AA UN10MAR93
open mode. Replace.
is OK.
1/1
TM1608 (20SEP06)
9015-15-76

092006
PN=286
Group 20
References
Alternators and Starting MotorsUse CTM77
For additional information, the component technical
TS225
UN17JAN89
TX,9015,QQ6468 1921MAY961/1
JTO5801 Clamp-On Electronic Tachometer

Installation
9015
20
1

T6813AG
UN28FEB89
Tachometer
TX,9015,QQ6469 1921MAY961/1
TM1608 (20SEP06)
9015-20-1

092006
PN=287
References
Battery Operation
9015
20
2
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.
solution. After washing, flush battery and compartment

with clear water. Keep caps in place when cleaning
and charging.
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.
Batteries should be maintained at an open circuit

voltage of 12.50 volts or greater.
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.
Specification
Fully Charged BatterySpecific
Gravity......................................................................................... 1.270
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 85F.
Specification
BatterySelf Discharge Rate............... .001 specific gravity point per
24 hour period at a constant
85F
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.
Specification
BatteryMinimum Open Circuit
Voltage ................................................................................ 12.50 volts
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
100% Charged Stabilized Open
CircuitVoltage ...................................................... 12.5 volts or more
CircuitVoltage ............................................................................ 12.4
CircuitVoltage ............................................................................ 12.2
CircuitVoltage ............................................................................ 12.0
CircuitVoltage ................................................................ 11.7 or less
Wipe batteries with a damp cloth. If terminals are

corroded, use a stiff brush and wash with an ammonia
TX,9015,QQ6347 1921MAY961/1
TM1608 (20SEP06)
9015-20-2

092006
PN=288
References
Battery Specifications
Specification
BatteryVolts ................................................................................ 12 Volts
Cold Cranking Power ............................................ 750 amps18C (0F)
Reserve Capacity ................................................ 150 minutes at 25 amps
BCI Group Size ...................................................................................... 31
Fully Charged Electrolyte Specific
Gravity ................................................................................... 1.2651.280
TX,9015,QQ6348 1921MAY961/1
9015
20
3
TM1608 (20SEP06)
9015-20-3

092006
PN=289
References
Diagnose Battery Malfunctions
9015
20
4
Symptom
Problem
Solution
Battery Using Too Much Water
Shorted battery cell
Check battery state of charge.
High ambient temperature
Add distilled water.
Cracked battery case
Check battery hold down clamps.

Replace battery.
Regulator
Do Alternator Output Check. (See

Charging Circuit Operational
Checks.)
Battery hold down clamp too tight,

too loose or missing
Install new battery. Install hold down

clamps correctly.
Frozen battery
Keep electrolyte at correct level and

battery fully charged during cold
weather.
Low water level
See Battery Using Too Much Water

and Cracked Battery Case
symptoms.
Dirty or wet battery top, causing

discharge
Clean battery top. Recharge battery.
Corroded or loose battery cable

ends
Clean and tighten cable end clamps.

Recharge battery.
Broken or loose battery posts
Wiggle posts by hand. If posts are

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

pulleys
Inspect belt or pulley. Adjust or

replace as necessary.
Cracked Battery Case
Low Battery Output
TX,9015,QQ6349 1921MAY961/1
TM1608 (20SEP06)
9015-20-4

092006
PN=290
References

Terminals
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first
and replace it last.
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
9015
20
5
UN23AUG88
Avoid the hazard by:
TS203
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 1015
minutes. Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
1. Remove hold-down clamps.
2. Remove battery covers.
TM1608 (20SEP06)
9015-20-5
TX,9015,QQ6350 1921MAY961/2

092006
PN=291
References
UN09SEP03
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.
T6996DB
3. Fill each cell to within specified range with distilled

water. DO NOT overfill.
ABattery Post
BFill Tube
CElectrolyte Level Range
Single Level Fill Tube Application
T6996DA
UN09SEP03
9015
20
6
Dual Level Fill Tube Application

TX,9015,QQ6350 1921MAY962/2
TM1608 (20SEP06)
9015-20-6

092006
PN=292
References
Using Booster Batteries12 Volt System
T6713AI1
T6508AE1
UN24OCT91
UN24OCT91
9015
20
7
Single Battery Application
Two Battery Application
AMachine Battery(s)
BBooster Battery(s)
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.
Always remove grounded () battery clamp
first and replace it last.
1. Connect one end of the positive cable to the

positive terminal of the machine batteries and the
other end to the positive terminal of the booster
batteries.
2. Connect one end of the negative cable to the
negative terminal of the booster batteries. Then
connect other end of the negative cable to the
machine frame as far away from the machine
batteries as possible.
3. Start engine.
IMPORTANT: The machine electrical system is a

12-volt negative () ground. Use
only 12-volt booster batteries.
TM1608 (20SEP06)
9015-20-7
TX,25,BD2079 1901SEP061/2

092006
PN=293
References
4. Immediately after starting engine, disconnect end of
the negative cable from the machine frame and
disconnect the other end of the negative cable from
the negative terminal of the booster batteries.
5. Disconnect positive cable from booster batteries

and machine batteries.
TX,25,BD2079 1901SEP062/2
Alternator Operation65 Amp Bosch and 95 Amp Bosch
T8301AL
1904DEC94
9015
20
8
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
QDisplay Monitor
RBrushes
SSense Circuit
TNoise Filter
TX,9015,QQ6352 1921MAY961/1
TM1608 (20SEP06)
9015-20-8

092006
PN=294
References
Alternator Operation65 Amp Bosch and 95 Amp BoschContinued

The 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.
and C) 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 out put is (7 to 8 volts) (AC).
Specification
W Terminal OutputVoltage
With Alternator Operating .................................................... 78 volts
This voltage is supplied to the display monitor and

tachometer or hour meter. Current available from the
alternator is dependent on engine RPM. Depending on
pulley ratios.
Normal Operation
The alternating current induced in the stator winding
(E) is rectified by the positive and negative diodes (F
TX,9015,QQ6353 1926JUL991/1
Tachometer Calibration (S.N. 852337)
3. Adjust screw (B) to adjust machine tachometer to high

idle speed.
T7545BQ
2. Verify engine speed using tachometer. See

Tachometer Installation in this group.
UN27JUN91
1. Remove heater control knob, blower speed knob and

four side console panel screws to remove panel.
TX,9015,QQ6797 1919JAN001/1
TM1608 (20SEP06)
9015-20-9

092006
PN=295
9015
20
9
References
Tachometer Calibration (S.N. 852338 )

1. Remove side console panel.
2. Verify engine speed using tachometer. See
Tachometer Installation in this group.
6. When either UP or DN is showing, press button

again and hold it in to move pointer. If button is held in
for just a short time, pointer will move slowly either
upwards or downwards, depending on which mode is
selected. Holding button in for a longer period of time
makes pointer move faster.
T114688B
NOTE: If pointer is moved past upper limit of calibration

range, LCD display will flash and pointer can only
be adjusted downward. If pointer is moved past
lower calibration limit, LCD display will also flash
and pointer can only be adjusted upward.
UN02APR98
5. Press calibration button once, and UP will be

displayed on LCD readout for upward calibration of
pointer. Press calibration button again, and DN will be
displayed for downward calibration of pointer.
7. When pointer is in desired position, release calibration

button and wait. If no further adjustments are made
within one minute, tachometer will perform self-test and
revert back to normal operating mode.
8. After calibration is complete, cover hole for calibration
button (E) with a small amount of non-corrosive
Form-in-Place Gasket sealer.
1903APR98
CTachometer
ECalibration Button
T114523
9015
20
10
4. Press and hold in calibration button as you turn on

ignition and start engine. Hold button until ADJUST is
displayed on LCD readout. When it does, release
calibration button.
T114085
3. Cut and remove plastic covering from calibration button

(E) on back of tachometer (C).
UN09APR98
NOTE: Calibration of tachometer should be performed at

an engine speed near 2000 rpm.
CED,TX17864,110 1919JAN001/1
TM1608 (20SEP06)
9015-20-10

092006
PN=296
Section 9020
Power Train
Contents
Page
Page

Forward, Reverse, Low Range Forward
and Third Speed Clutch Pack
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-1
Power Shift High Range Forward, First
Speed and Second Speed Clutch
Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-2
Manual Shift Power Train Overview . . . . . . .9020-05-4
Torque Converter Operation . . . . . . . . . . . . .9020-05-6
Manual Shift Synchronizer Operation . . . . . .9020-05-8
Transmission Pump Operation . . . . . . . . . .9020-05-10
Transmission Filter Operation . . . . . . . . . . .9020-05-11
Manual Shift Transmission OperationFirst
Gear Forward . . . . . . . . . . . . . . . . . . . . .9020-05-12
Manual Shift Transmission OperationThird
Gear Reverse . . . . . . . . . . . . . . . . . . . . .9020-05-14
Power Shift Power Train Overview . . . . . . .9020-05-16
Power Shift Transmission Gear Flow . . . . .9020-05-18
Mechanical Front Wheel Drive (MFWD)
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9020-05-20
Manual Shift Transmission
Control Valve Operation. . . . . . . . . . . . . .9020-05-22
Control Circuit-Neutral . . . . . . . . . . . . . . .9020-05-24
Control Circuit-Forward . . . . . . . . . . . . . .9020-05-26
Control Circuit-Reverse . . . . . . . . . . . . . .9020-05-28
Power Shift Transmission
Clutch Engagement and Solenoids
Activated . . . . . . . . . . . . . . . . . . . . . . .9020-05-30
Control Circuit-Neutral . . . . . . . . . . . . . . .9020-05-32
Control Valve and Shift Valve-Neutral . . .9020-05-36
Control Circuit-First Forward . . . . . . . . . .9020-05-38
Control Valve and Shift Valve-First
Forward . . . . . . . . . . . . . . . . . . . . . . . .9020-05-40
Control Circuit-High Range (Fourth)
Forward . . . . . . . . . . . . . . . . . . . . . . . .9020-05-42
Control Valve and Shift Valve-High Range
(Fourth) Forward . . . . . . . . . . . . . . . . .9020-05-44
Control Circuit-First Reverse . . . . . . . . . .9020-05-46
Control Valve and Shift Valve-First
Reverse . . . . . . . . . . . . . . . . . . . . . . . .9020-05-48
Manual Shift Modulation Valve
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9020-05-50
Power Shift Modulation Valve Operation . . .9020-05-52
Differential Operation . . . . . . . . . . . . . . . . .9020-05-54
Differential Lock Operation . . . . . . . . . . . . .9020-05-56
Brake Valve Operation . . . . . . . . . . . . . . . .9020-05-58
Service Brake Operation . . . . . . . . . . . . . . .9020-05-60

Park Brake Operation . . . . . . . . . . . . . . . . .9020-05-62
MFWD Differential OperationUnequal
Traction (If Equipped) . . . . . . . . . . . . . . .9020-05-64
MFWD Differential OperationEqual
Traction . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-65
Boom Lock Operation315SE . . . . . . . . . .9020-05-66
TM1608 (20SEP06)
Group 15System Diagnostic Information

Diagnose Manual Shift Power Train
Malfunction . . . . . . . . . . . . . . . . . . . . . . . .9020-15-1
Diagnose Power Shift Power Train
Malfunction . . . . . . . . . . . . . . . . . . . . . . .9020-15-10
Diagnose MFWD Malfunction . . . . . . . . . . .9020-15-20
Diagnose Rear Axle Malfunction . . . . . . . . .9020-15-21
Diagnose Boom Lock Malfunction . . . . . . . .9020-15-25
Hydraulic Circuit Symbols . . . . . . . . . . . . . .9020-15-26
Group 20Adjustments
Adjust Brake Pedals and Equalizing
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-1
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . .9020-20-4
Check and Adjust Toe-In. . . . . . . . . . . . . . . .9020-20-6
Group 25Tests
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-1
Transmission Oil Warm-Up Procedure . . . . .9020-25-2
Manual Shift Overall Test Connections, Ports,
and Locations . . . . . . . . . . . . . . . . . . . . . .9020-25-3
Power Shift Transmission Overall Test
Connections, Ports, and Locations. . . . . . .9020-25-4
Torque Converter Stall Speed Test . . . . . . . .9020-25-6
Converter-In Relief Valve Test . . . . . . . . . . .9020-25-7
Brake Valve Leakage Test . . . . . . . . . . . . . .9020-25-9
Park Brake Release Pressure Test . . . . . . .9020-25-11
System Pressure Test . . . . . . . . . . . . . . . . .9020-25-13
Manual Shift Forward and Reverse Clutch
Pressure Test . . . . . . . . . . . . . . . . . . . . .9020-25-15
Power Shift Low Range Forward, High Range
Forward, Reverse and Speed Clutch Pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-17
Reducing Valve Pressure Test . . . . . . . . . .9020-25-19
9020-1

092006
PN=1
9020
Contents
Page
Modulation Valve Pressure Test . . . . . . . . .9020-25-20

Differential Lock Pressure Test . . . . . . . . . .9020-25-22
Boom Lock Valve Leakage Test
315SE . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-24
MFWD Pressure TestIf Equipped. . . . . . .9020-25-26
Cooler In and Cooler Out Pressure Test . . .9020-25-28
Solenoid Circuit Leakage Test. . . . . . . . . . .9020-25-30
Pump Flow Test . . . . . . . . . . . . . . . . . . . . .9020-25-32
9020
TM1608 (20SEP06)
9020-2

092006
PN=2
Group 05
Theory of Operation
T113896
1927MAR98
Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation
Manual Shift Clutch Pack Shown

ADisk (as required between
manual shift and power
shift)
BClutch Drum
CSeparator Plate (as

required between manual
shift and power shift)
DPressure Oil
NOTE: This operation covers the manual shift forward

and reverse clutch packs and the power shift
low range forward, reverse and third speed
clutch packs. The function of the packs are the
same, but the quantity on the disks and
separator plates will be different between
clutch packs.
When the FNR lever is placed in forward or reverse
and the shift lever (manual shift) is placed in a gear,
pressure oil (D) from the control valve forces the clutch
piston (G) to compress the plates (C) and disks (A).
EHub
FEnd Plate
GPiston
HSpring Disks
ILubrication Oil
JClutch Pack
The plates are splined to the clutch drum (B) and the
disks are splined to hub (E) locking them together. The
input drive shaft is splined to the hub on the manual
shift forward and reverse packs and on the power shift
the input drive shaft gear is splined to the low range
forward, reverse, and high range forward (4th) gear. All
gears are constantly meshed and supported by
antifriction bearings. The bearings and clutches are
lubricated with cooled lubrication oil (I). Spring disks
(H) push back the piston (G) when the clutch pack (J)
is disengaged, thus releasing the multi-disk clutch.
CED,TX03399,4248 1907SEP061/1
TM1608 (20SEP06)
9020-05-1

092006
PN=299
9020
05
1
Theory of Operation
Power Shift High Range Forward, First Speed and Second Speed Clutch Packs
T115656
1902JUN98
9020
05
2
High Range Forward Clutch Pack Shown

ASeparator Plate (as
required per clutch packs
BDisk (as required per
clutch pack)
CClutch Drum
DRoller Bearings
ETapered Bearing
FPressure Oil
GHub
HEnd Plate
IPiston
JSpring Disks
NOTE: This operation covers the power shift high

range forward, first and second speed clutch
packs. The function of the packs are the same,
but the quantity on the disks and separator
plates will be different between packs.
When the FNR lever is placed in forward or reverse,
pressure oil (F) from the control valve forces the clutch
piston (I) to compress the plates (A) and disks (B). The
KTapered Bearing
LLubrication Oil
MClutch Pack
plates are splined to the clutch drum (C) and the disks
are splined to hub (G) locking them together. The input
drive shaft gear is splined to the low range forward,
reverse, and high range forward (4th) gear. All gears
are constantly meshed and supported by antifriction
bearings. The bearings and clutches are lubricated
with cooled lubrication oil (L). Spring disks (J) push
back the piston (I) when the clutch pack (M) is
disengaged, thus releasing the multi-disk clutch.
CED,TX03399,4234 1907SEP061/1
TM1608 (20SEP06)
9020-05-2

092006
PN=300
Theory of Operation
9020
05
3
TM1608 (20SEP06)
9020-05-3

092006
PN=301
Theory of Operation
Manual Shift Power Train Overview
T113897
1927MAR98
9020
05
4
TM1608 (20SEP06)
9020-05-4
CED,TX03399,4198 1907SEP061/2

092006
PN=302
Theory of Operation
ATorque Converter
BReverse Clutch Pack
CTransmission Pump
DGear Shift Lever
ERear Output Shaft

FSynchronizer 3rd and 4th
GSynchronizer 1st and 2nd
The power train elements consist of a torque

converter, reverser, four speed fully synchronized
manual transmission, an optional MFWD, and a
separate rear axle with service brakes, park brake and
differential lock.
The transmission is a forward, neutral, reverse
countershaft design with multi-disk clutches that
receive input from a torque converter (A). Machine
direction is controlled by engagement of the forward
clutch pack (K) or the reverse clutch pack (B). A four
speed manual transmission is composed of an
intermediate shaft (J) and rear output shaft (E), each
with a synchronizer (F and G). The synchronizers for
1st and 2nd speed (G) are located on the rear output
shaft and the 3rd and 4th speed (F) on the
intermediate shaft. The synchronizers are controlled by
a mechanical gearshift lever (D).
HMFWD Output Shaft

IIdler Shaft
JIntermediate Shaft
KForward Clutch Pack

LPump Drive Shaft
MTransmission
(MFWD) which is spring applied and hydraulically

released.
The transmission pump (C) is a gear type pump. The
transmission pump is driven at engine speed through
the impeller drive from the torque converter.
The optional MFWD front axle is a self applied limited
slip design. It consists of a differential with outboard
planetary final drives.
The rear axle is an inboard planetary design with
internal wet multi-disk service brakes that are self
adjusting. Pressure oil for the service brakes is
supplied by a foot operated brake valve. The park
brake is a wet multi-disk design which is spring applied
and hydraulically released. The differential lock is a
sliding sleeve design, which is hydraulically engaged
and spring released.
The transmission may also have an optional front

output shaft (H) for mechanical front wheel drive
CED,TX03399,4198 1907SEP062/2
TM1608 (20SEP06)
9020-05-5

092006
PN=303
9020
05
5
Theory of Operation
Torque Converter Operation
T101172
1904MAR98
9020
05
6
1Turbine
2Impeller
3Stator Shaft
4Input Shaft
5Shaft Seal
6Drain Plug
7Turbine Shaft
8Pump Drive Shaft
9Free-wheel Clutch
The three main parts of the torque converter include

the impeller, turbine and stator.
The impeller (2) is driven by the engine. As it rotates,
centrifugal force throws oil out of the impeller against
the blades of the turbine (1). This forces the turbine to
rotate in the same direction as the impeller.
10Stator
11Torque Converter
Pump drive shaft (8) is driven by the engine directly

and at engine speed. The pump drive shaft provides
input to the transmission pump and the hydraulic
system pump.
As the oil leaves the turbine, it is redirected by the
stator (10) back into the impeller which increases the
torque converter performance.
The turbine (1) is connected to the turbine shaft (7)

which provides input to the transmission gear train.
TM1608 (20SEP06)
9020-05-6
TX,05,SS3120 1907SEP061/2

092006
PN=304
Theory of Operation
Oil leaving the turbine enters the stator (10). 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 (9)
unlocks, allowing the stator to free-wheel 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 free-wheeling. The transmission pump is
constantly pumping oil through the converter. The
converter multiplies the torque and at the same time,
the heat created in the converter is eliminated through
the circulation of oil from converter to cooler and back
to sump.
TX,05,SS3120 1907SEP062/2
9020
05
7
TM1608 (20SEP06)
9020-05-7

092006
PN=305
Theory of Operation
Manual Shift Synchronizer Operation
T101275
1904MAR98
9020
05
8
TM1608 (20SEP06)
9020-05-8
CED,TX03399,4210 1907SEP061/2

092006
PN=306
Theory of Operation
ASynchronizer Collar
BShift Fork
CFourth Speed Drive Gear
DSynchronizer Ring
ENeedle Bearing
FHub
GSnap Ring
HIntermediate Shaft
IThird Speed Drive Gear

JSpring
KSynchronizer Ring
LSynchronizer Detent
(Pressure Piece)
The components of the synchronizer are the hub (F),

collar (A), synchronizer ring (D and K), spring (J) and
synchronizer detent (pressure piece) (L).
The hub (F) is splined to the intermediate shaft (H).
The synchronizer collar (A) is splined to the hub. Three
of the splines in the hub are omitted and a
synchronizer detent (L) is inserted between the hub
and the collar. Springs (J) push the detents (L) out
against the collar.
The synchronizer detents extend into slots in the
synchronizer collar. The hub, collar, synchronizer
detent, and synchronizer rings always rotate as an
assembly with the shaft.
MThird Gear Engaged

NSynchronizer
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 the speed of intermediate drive shaft (H)
and third speed drive gear (I). As the collar (A) moves
across the hub, the synchronizer detents move down
and force the synchronizer ring (K) against the tapered
portion of third speed gear. The synchronizer rings 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 synchronizer ring
and the gear to allow smooth engagement of third gear
(M).
9020
05
9
With the synchronizer in neutral, the synchronizer rings

do not contact either drive gear. Since the gears are
CED,TX03399,4210 1907SEP062/2
TM1608 (20SEP06)
9020-05-9

092006
PN=307
Theory of Operation
Transmission Pump Operation
T101251
UN12JUL96
9020
05
10
1Angle Disk
2Washer
3O-Ring (2 used)
4Cap Screw (4 used)
5Pump Housing
6O-Ring
7Needle Bearing
8Stop Sleeve
TX,05,SS3124 1907SEP061/2
T101252
The input shaft to the pump is driven by the engine. The

pump gears rotate inside of the pump housing. As the
gears rotate, oil is trapped between the gear teeth and the
pump housing which forces oil to move from the pump
inlet around the gears to the pump outlet.
UN12JUL96
The transmission uses a high capacity fixed displacement

gear-type pump to provide constant flow for the
transmission hydraulic system. Pump flow is proportional
to engine speed.
TX,05,SS3124 1907SEP062/2
TM1608 (20SEP06)
9020-05-10

092006
PN=308
Theory of Operation
T101250
1912JUL96
Transmission Filter Operation
AFilter
BSpring
CBypass Valve
DTo Transmission Circuit
EFrom Transmission Pump
NOTE: Filter housing removed to show element and

bypass valve.
through the middle of the element to the transmission

control system.
The transmission filter is a spin on replaceable

element. If the filter (A) becomes obstructed, a bypass
valve (C) opens to maintain flow to the transmission.
If the filter element becomes obstructed or during

extremely cold conditions, the pressure difference
across the filter element exceeds the set value of the
bypass spring (B), causing the bypass valve (C) to
unseat. This unseated valve allows unfiltered oil to
pass through the filter housing. Bypass operation for
extended periods of time is not recommended.
Oil from the transmission pump enters from outside of

the filter element. The filter element traps contaminants
as the oil passes through it. Filtered oil flows up
TX,05,SS3125 1907SEP061/1
TM1608 (20SEP06)
9020-05-11

092006
PN=309
9020
05
11
Theory of Operation
Manual Shift Transmission OperationFirst Gear Forward
T113898
1927MAR98
9020
05
12
TM1608 (20SEP06)
9020-05-12
CED,TX03399,4200 1907SEP061/2

092006
PN=310
Theory of Operation
ATorque Converter
BInput Drive Shaft
CGear Shift Lever
DForward Clutch Hub
EPlates and Disks

FIntermediate Shaft
GSynchronizer
HRear Output Shaft
IIdler Shaft
JMFWD Output Shaft
KFirst Gear
LIntermediate Gear
With the transmission in first speed forward (P), the

torque converter (A) supplies torque to the input drive
shaft gear (B) which meshes with the input gear on the
forward clutch hub (D).
System pressure oil, from the transmission control
valve, is routed through a drilled passage in the
forward clutch shaft (O). This causes the piston (M) to
move compressing the plates and disks (E) causing
the clutch to rotate as a unit. The forward clutch gear
(N) meshes with the intermediate gear (L) and shaft
(F).
MPiston
NForward Clutch Gear
OForward Clutch Shaft
PFirst SpeedForward
As the shift is made in first gear the synchronizer collar

is moved to the left. The first gear (K) and rear output
shaft (H) are in mesh to the intermediate shaft (F). The
idler shaft (I) is in mesh with the rear output shaft (H)
and the MFWD output shaft (J) is in mesh with the
idler shaft (I) and turns at a constant speed with the
rear output shaft. This transfers torque to the rear
output shaft and the MFWD shaft if engaged.
CED,TX03399,4200 1907SEP062/2
9020
05
13
TM1608 (20SEP06)
9020-05-13

092006
PN=311
Theory of Operation
Manual Shift Transmission OperationThird Gear Reverse
T113899
1927MAR98
9020
05
14
TM1608 (20SEP06)
9020-05-14
CED,TX03399,4201 1907SEP061/2

092006
PN=312
Theory of Operation
ATorque Converter
BReverse Clutch Pack
CPlates and Disks
DReverse Clutch Hub
EInput Drive Shaft
FGear Shift Lever

GIntermediate Shaft
HSynchronizer
IRear Output Shaft
JIdler Shaft
KMFWD Output Shaft
LThird Gear
MForward Clutch Gear
With the transmission in third speed reverse (Q), the

torque converter (A) supplies torque to the input drive
shaft gear (E) which meshes with the input gear on the
reverse clutch hub (D).
System pressure oil, from the transmission control
valve, is routed through a drilled passage in the
reverse clutch shaft (P). This causes the piston (O) to
move compressing the plates and disks (C) causing
the clutch to rotate as a unit. The reverse clutch gear
(N) meshes with the forward clutch gear (M) which
NReverse Clutch Gear

OPiston
PReverse Clutch Shaft
QThird SpeedReverse
acts as a countershaft and reverses the direction of

input to the intermediate shaft (G).
As the shift is made in third gear the synchronizer
collar is moved to the left. The third gear (L) and rear
output shaft (I) are locked to the intermediate shaft
(G). The idler shaft (J) is in mesh with the rear output
shaft (I) and the MFWD shaft (K) is in mesh with the
idler shaft (J) and turns at a constant speed with the
rear output shaft (I). This transfers torque to the rear
output shaft (I) and the MFWD shaft if engaged.
CED,TX03399,4201 1907SEP062/2
9020
05
15
TM1608 (20SEP06)
9020-05-15

092006
PN=313
Theory of Operation
Power Shift Power Train Overview
T115039
1910JUL98
9020
05
16
TM1608 (20SEP06)
9020-05-16
CED,TX03399,4205 1907SEP061/2

092006
PN=314
Theory of Operation
ATorque Converter
BHigh Range (4th) Forward
Clutch
CTransmission Pump
DReverse Clutch
ELow Range Forward Clutch
FThird Speed Clutch

GSecond Speed Clutch
HMFWD
IFirst Speed Clutch

JPump Drive Shaft
KTransmission
A single stage torque converter drives a hydraulically

engaged four speeds forward and three speeds
reverse countershaft type power shift transmission.
The optional MFWD front axle is a self applied limited

slip design. It consists of a differential with outboard
planetary final drives.
Six clutch packs provide four forward and three

reverse speeds. Two clutch packs have to be engaged
for movement. One directional clutch pack, either
low-range forward, high-range forward or reverse and
one speed range clutch pack either 1st, 2nd or 3rd.
The rear axle is an inboard planetary design with

internal wet multi-disk service brakes that are self
adjusting. Pressure oil for the service brakes is
supplied by a foot operated brake valve. The park
brake is a wet multi-disk design which is spring applied
and hydraulically released. The differential lock is a
sliding sleeve design, which is hydraulically engaged
and spring released.
The transmission may also have an optional front

output shaft (H) for mechanical front wheel drive
(MFWD) which is spring applied and hydraulically
released.
The transmission pump (C) is a gear type pump. The
transmission pump is driven at engine speed through
the impeller drive from the torque converter.
9020
05
17
CED,TX03399,4205 1907SEP062/2
TM1608 (20SEP06)
9020-05-17

092006
PN=315
Theory of Operation
Power Shift Transmission Gear Flow

1st FORWARD
4th FORWARD
(HIGH RANGE) A
4th FORWARD (HIGH RANGE)
B REVERSE
C LOW RANGE
FORWARD
2nd SPEED G
C
G
D 1st SPEED
F
3rd SPEED
(REAR OUTPUT)
E MFWD
OUTPUT
2nd FORWARD
B
A
C
3rd FORWARD
A
2nd REVERSE
3rd REVERSE
C
G
T115189
1902JUN98
9020
05
18
1st REVERSE
T115189
TM1608 (20SEP06)
9020-05-18
CED,TX03399,4206 1907SEP061/2

092006
PN=316
Theory of Operation
A4th Forward (High Range)
BReverse
CLow Range Forward

D1st Speed
EMFWD Output
F3rd Speed (Rear Output)
The torque converter supplies torque to the drive gear

which is in constant mesh with the low-range forward,
reverse and high range forward clutch hubs.
The low-range forward clutch, reverse, high range
forward and second speed clutch outer gears are in
mesh. As are the first speed hub gear and third speed
clutch outer gear.
With MFWD (if equipped) the first speed hub is in
mesh with the MFWD output gear.
G2nd Speed
As a example, with the transmission in second speed

forward, the low range forward clutch (C) and the
second speed clutch (G) are engaged. The torque
converter supplies torque to the drive gear which
meshes with the gear on the low-range forward clutch.
Power flow continues through the reverse (B) and high
range forward clutch (A) output gears to the second
speed (G) output gear which drives the third speed
clutch (F) rear axle output which is in mesh with first
speed clutch (D) hub which is in mesh with the MFWD
(E) (if equipped) output gear.
CED,TX03399,4206 1907SEP062/2
9020
05
19
TM1608 (20SEP06)
9020-05-19

092006
PN=317
Theory of Operation
Mechanical Front Wheel Drive (MFWD) Operation
SLIDING A
SLEEVE
SPRING G
B
MFWD
SOLENOID
VALVE
F FRONT
OUTPUT
SHAFT
D DRIVE GEAR
9020
05
20
BACKING E
PLATE
C
FROM
TRANSMISSION
PUMP
H MANUAL SHIFT MFWD - ON (ENGAGED)
SLIDING
SLEEVE I
SPRING O
FRONT N
OUTPUT
SHAFT
J
MFWD
SOLENOID
VALVE
FROM K
TRANSMISSION
PUMP
P SYSTEM PRESSURE
T114902
R POWER SHIFT MFWD - ON (ENGAGED)

TM1608 (20SEP06)
9020-05-20
Q RETURN PRESSURE
T114902
DRIVE
GEAR
1920APR98
BACKING M
PLATE
CED,TX03399,4226 1907SEP061/2

092006
PN=318
Theory of Operation
ASliding Sleeve
BMFWD Solenoid Valve
CFrom Transmission Pump
DDrive Gear
EBacking Plate
FFront Output Shaft

GSpring
HManual Shift MFWDON
(Engaged)
ISliding Sleeve
The MFWD is powered by transmission.

The MFWD is spring applied, hydraulically released.
When the MFWD switch is ON, spring (G or O) force
holds the sliding sleeve (A or I) in mesh with the drive
gear (D or L). The drive gear is connected to the front
output shaft (F or N) and transmits power to the front
axle.
JMFWD Solenoid Valve

KFrom Transmission Pump
LDrive Gear
MBacking Plate
NFront Output Shaft
OSpring
PSystem Pressure
QReturn Pressure
RPower Shift MFWDON
(Engaged)
The disengagement of the MFWD is controlled by an

electric solenoid located on the transmission. When
energized, with MFWD switch in the OFF position,
transmission pressure oil (P) is routed through the
MFWD sliding sleeve (A or I). Pressure pushes the
sleeve back against the spring (G or O) and backing
plate (E or M). The drive gear (D or L) and front output
shaft (F or N) are disengaged.
CED,TX03399,4226 1907SEP062/2
9020
05
21
TM1608 (20SEP06)
9020-05-21

092006
PN=319
Theory of Operation
Manual Shift Transmission Control Valve Operation
11
10
9
4 REVERSE
SOLENOID
2 FORWARD
SOLENOID
MAIN
FRAME
1 HARNESS
3 NEUTRAL
SOLENOID
4
7
12
6
19
TO
SOLENOIDS
20
TO TORQUE
CONVERTER
5
18 FROM PUMP
9020
05
22
5
CONVERTER
RELIEF
VALVE
12
PRESSURE
REDUCING
VALVE
11
NEUTRAL
10
SHIFT
VALVE
FORWARD
OR REVERSE
SHIFT VALVE
13 SYSTEM PRESSURE
14 MEDIUM PRESSURE
6
PRESSURE
REGULATING
VALVE
9
ORIFICE
8
MODULATION
PISTON
7 MODULATION
VALVE
16 RETURN PRESSURE
T127723
17 TRANSMISSION CONTROL VALVE - NEUTRAL
TM1608 (20SEP06)
9020-05-22
T127723
1901FEB00
15 LOW PRESSURE
CED,TX03399,4249 1907SEP061/2

092006
PN=320
Theory of Operation
1Main Frame Harness
2Forward Solenoid
3Neutral Solenoid
4Reverse Solenoid
5Converter Relief Valve
6Pressure Regulating Valve
7Modulation Valve
8Modulation Piston
9Orifice
10Forward or Reverse Shift
Valve
11Neutral Shift Valve
The transmission control valve regulates the hydraulic

oil pressures and controls circuits required for
operation of the transmission. Electrical signals from
the FNR lever and park brake switch are used to
energize the solenoids which direct oil to move the
shift valves and engage the directional clutches.
The transmission control valve contains the pressure
regulating valve (6), converter relief valve (5),
modulation piston (8), modulation valve (7), shift valves
(forward or reverse) (10), neutral shift valve (11),
pressure reducing valve (12), forward, neutral, and
reverse solenoids (2, 3, and 4).
The pressure regulating valve (6) is a spring loaded
spool valve with shims, which regulates main system
pressure. Excess oil from the circuit is directed to the
torque converter.
12Pressure Reducing Valve

13System Pressure
14Medium Pressure
15Low Pressure
16Return Pressure
17Transmission Control
ValveNeutral
18From Pump
19To Solenoids
20To Torque Converter
The modulation valve (7) is a spring loaded spool

which controls the rate of clutch engagement during a
shift.
The pressure reducing valve (12) supplies reduced
pressure oil to the solenoid valves (forward, neutral,
reverse).
The forward/reverse shift valve (10) is a spring loaded
spool valve which engages the directional clutches.
The neutral shift valve (11) is a spring loaded spool
valve which also must be shifted to allow pressure oil
to be directed to the selected directional clutch. The
forward or reverse shift valve solenoids (2 or 4) are
activated by the FNR lever. The neutral solenoid (3) is
controlled by the park brake switch and must be
energized before forward or reverse clutches can be
engaged. The loader and shift lever disconnect
switches also control the neutral solenoid.
The converter relief valve (5) controls the maximum

pressure to the torque converter.
CED,TX03399,4249 1907SEP062/2
TM1608 (20SEP06)
9020-05-23

092006
PN=321
9020
05
23
Theory of Operation
Manual Shift Transmission Control CircuitNeutral With Park Brake Off

T127728 1901FEB00
2
FORWARD
CLUTCH
1
TRANSMISSION
CONTROL VALVE
3
REVERSE
CLUTCH
4
DIFFERENTIAL LOCK
5
MFWD
6
PARK
BRAKE
NEUTRAL
SHIFT VALVE
13
12
FORWARD/REVERSE
SHIFT VALVE
ORIFICE IN
MODULATION
SPOOL 16
14
NEUTRAL
SOLENOID
VALVE
18 ORIFICE IN
VALVE
HOUSING
15
REVERSE
SOLENOID
VALVE
19 MODULATION
PISTON
MODULATION
17
VALVE
22 PRESSURE
REGULATING
VALVE
ORIFICE IN
TRANSMISSION 26
FRONT HOUSING
TRANSMISSION
OIL COOLER
25
PARK BRAKE
SOLENOID
VALVE
8
SCREEN IN
ALL SLOENOIDS
PRESSURE
REDUCING
VALVE 20
DIRECTION
SOLENOID ENERGIZED
FORWARD NEUTRAL REVERSE
X
FORWARD
27
FILTER
AND
BYPASS
28
TRANSMISSION
PUMP
T127728
MFWD
SOLENOID
VALVE
ORIFICE IN
INTERMEDIATE
PLATE
21
24
CONVERTER
RELIEF
VALVE
TORQUE
CONVERTER
23
DIFFERENTIAL
SOLENOID
VALVE
10
FORWARD
SOLENOID
VALVE
11
SUMP 29
BOOM 30
LOCK
SOLENOID
31 BOOM
LOCK
CYLINDERS
NEUTRAL
REVERSE
32
SYSTEM PRESSURE
33
MEDIUM PRESSURE
34
LOW PRESSURE
35
LUBE PRESSURE
36
RETURN PRESSURE
37 MANUAL SHIFT TRANSMISSION CONTROL CIRCUIT NEUTRAL WITH PARK BRAKE OFF
CED,TX03399,4250 1927APR001/2
TM1608 (20SEP06)
9020-05-24

092006
PN=322
Theory of Operation
1Transmission Control Valve
2Forward Clutch
3Reverse Clutch
4Differential Lock
5MFWD (Mechanical Front
Wheel Drive)
6Park Brake
7Park Brake Solenoid Valve
8Screen In All Solenoids
9MFWD Solenoid Valve
10Differential Solenoid Valve
11Forward Solenoid Valve
12Forward/Reverse Shift
Valve
14Neutral Solenoid Valve
15Reverse Solenoid Valve
16Orifice In Modulation
Spool
17Modulation Valve
18Orifice in Valve Housing
19Modulation Piston
21Orifice In Intermediate
Plate
Flow from the transmission charge pump (28) passes

through the filter to the pressure regulating valve (22),
reducing valve (20), differential lock solenoid valve
(10), MFWD solenoid valve (9), and the park brake
solenoid valve (7). The pressure regulating valve
regulates system pressure and directs high pressure
oil to the modulation valve. For the 315SE, system
pressure is also routed to the boom lock solenoid
valve (30).
When pressure exceeds the pressure regulating valve
setting the valve opens. Low pressure oil (34) then
flows through the torque converter (23). Converter flow
is excess oil from the pressure regulating valve. A
torque converter relief valve (24) protects the circuit by
dumping to tank when pressure exceeds the setting.
The oil is then routed to the oil cooler (25). A portion of
the oil returning from the cooler provides lubrication to
the clutches, and the remaining oil goes to sump.

23Torque Converter
25Transmission Oil Cooler
26Orifice In Transmission
Front Housing
27Filter And Bypass
28Transmission Pump
29Sump
30Boom Lock Solenoid
(315SE Only)
31Boom Lock Cylinders

(315SE Only)
32System Pressure
33Medium Pressure
34Low Pressure
35Lube Pressure
36Return Pressure
37Manual Shift Transmission
Control CircuitNeutral
with Park Brake Off
The pressure reducing valve (20) supplies medium

pressure oil (33) to the solenoid valves (neutral,
reverse and forward). In neutral, with park brake OFF,
the forward and reverse solenoids (11 and 15) are
de-energized (open), and medium pressure oil is not
directed to the forward/reverse shift valve (12). The
neutral solenoid valve (14) is energized (closed) and
medium pressure oil (33) is routed to the end of the
neutral shift valve. The reducing valve controls the
pressure by dumping oil to tank when pressure
exceeds its setting.
In neutral, pressure oil flows to the modulation valve
(17) through an orifice. Flow to the modulation valve is
reduced by the orifice.
Forward and reverse clutch packs (2 and 3) dump to
sump when in neutral or park brake is ON.
CED,TX03399,4250 1927APR002/2
TM1608 (20SEP06)
9020-05-25

092006
PN=323
9020
05
25
Theory of Operation
Manual Shift Transmission Control CircuitForward

T127729 1901FEB00
1
TRANSMISSION
CONTROL VALVE
3
REVERSE
CLUTCH
2
FORWARD
CLUTCH
4
DIFFERENTIAL LOCK
6
PARK
BRAKE
5
MFWD
NEUTRAL
13
SHIFT VALVE
FORWARD/REVERSE
SHIFT VALVE
12
14
NEUTRAL
SOLENOID
VALVE
15
REVERSE
SOLENOID
VALVE
ORIFICE IN
VALVE
18
HOUSING
ORIFICE IN
MODULATION
SPOOL 16
MODULATION
PISTON 19
MODULATION 17
VALVE
PRESSURE
22 REGULATING
VALVE
DIFFERENTIAL
SOLENOID
VALVE
10
FORWARD
SOLENOID
VALVE
11
ORIFICE IN
TRANSMISSION 26
FRONT HOUSING
SCREEN IN 8
ALL SOLENOIDS
DIRECTION
FORWARD
TRANSMISSION
OIL COOLER
25
ORIFICE IN
INTERMEDIATE
PLATE
21
27
FILTER
AND
BYPASS
28
TRANSMISSION
PUMP
T127729
MFWD
SOLENOID
VALVE
9
PRESSURE
REDUCING
VALVE 20
24
CONVERTER
RELIEF
VALVE
TORQUE
CONVERTER
23
PARK BRAKE
SOLENOID
VALVE
SUMP 29
BOOM 30
LOCK
SOLENOID
31 BOOM
LOCK
CYLINDERS
SOLENOID ENERGIZED
X
NEUTRAL
REVERSE
32
SYSTEM PRESSURE
33
MEDIUM PRESSURE
34
LOW PRESSURE
35
LUBE PRESSURE
36
RETURN PRESSURE
37 MANUAL SHIFT TRANSMISSION CONTROL CIRCUIT FORWARD

CED,TX03399,4252 1927APR001/2
TM1608 (20SEP06)
9020-05-26

092006
PN=324
Theory of Operation
2Forward Clutch
3Reverse Clutch
4Differential Lock
Wheel Drive)
6Park Brake
Valve
Spool
17Modulation Valve
19Modulation Piston
During forward operation, forward and neutral solenoid

valves (11 and 14) are energized. The neutral solenoid
valve (14) routes pressure oil (33) to the neutral shift
valve (13) and moves the spool down. The energized
forward solenoid (11) routes pressure oil to the
forward/reverse shift valve (12) moving the spool up.
Shifting of the forward/reverse spool allows oil to flow
from the modulation valve (17) to fill the forward clutch
pack (2) and compress the clutch plates. Shifting of
the forward/reverse spool also blocks the flow of oil
downstream of the orifice in valve housing (18) from
Plate
23Torque Converter
Front Housing
27Filter And Bypass
28Transmission Pump
29Sump

(315SE Only)
(315SE Only)
32System Pressure
33Medium Pressure
34Low Pressure
35Lube Pressure
36Return Pressure
Control CircuitForward
returning to tank and allows the pressure in the

modulation valve to build. As pressure builds, the
balance between orifice size and spring load in the
modulation valve controls the rate of shift and pushes
the modulation piston down. The downward force from
the modulation piston pushes on the modulation
springs which drive the modulation spool down to the
fully open position. In the fully open position, high
pressure oil (32) from the pressure regulating valve
(22) keeps the forward clutch engaged.
9020
05
27
CED,TX03399,4252 1927APR002/2
TM1608 (20SEP06)
9020-05-27

092006
PN=325
Theory of Operation
Manual Shift Transmission Control CircuitReverse

T127730 1901FEB00
2
FORWARD
CLUTCH
1
TRANSMISSION
CONTROL VALVE
3
REVERSE
CLUTCH
4
DIFFERENTIAL LOCK
5
MFWD
6
PARK
BRAKE
NEUTRAL
SHIFT VALVE
13
12
FORWARD/REVERSE
SHIFT VALVE
14
NEUTRAL
SOLENOID
VALVE
15
REVERSE
SOLENOID
VALVE
18 ORIFICE IN
VALVE
HOUSING
19 MODULATION
PISTON
16
ORIFICE IN
MODULATION
SPOOL
MODULATION
17
VALVE
22 PRESSURE
REGULATING
VALVE
ORIFICE IN
TRANSMISSION
FRONT
26
HOUSING
SCREEN IN 8
ALL SOLENOIDS
21
ORIFICE IN
INTERMEDIATE
PLATE
DIRECTION
SOLENOID ENERGIZED
X
FORWARD
TRANSMISSION
OIL COOLER
25
27
FILTER
AND
BYPASS
28
TRANSMISSION
PUMP
T127730
PRESSURE
REDUCING
VALVE
20
24
CONVERTER
RELIEF
VALVE
TORQUE
CONVERTER
23
MFWD
SOLENOID
VALVE
DIFFERENTIAL
SOLENOID
VALVE
10
FORWARD
SOLENOID
VALVE
11
PARK BRAKE
SOLENOID
VALVE
7
SUMP 29
BOOM 30
LOCK
SOLENOID
31 BOOM
LOCK
CYLINDERS
NEUTRAL
REVERSE
32
SYSTEM PRESSURE
33
MEDIUM PRESSURE
34
LOW PRESSURE
35
LUBE PRESSURE
36
RETURN PRESSURE
37 MANUAL SHIFT TRANSMISSION CONTROL CIRCUIT REVERSE

CED,TX03399,4253 1927APR001/2
TM1608 (20SEP06)
9020-05-28

092006
PN=326
Theory of Operation
2Forward Clutch
3Reverse Clutch
4Differential Lock
Wheel Drive)
6Park Brake
Valve
Spool
17Modulation Valve
19Modulation Piston
During reverse operation, solenoid valves reverse (15)

and neutral (14) are energized. The neutral solenoid
valve (14) routes pressure oil (33) to the neutral shift
valve (13) and moves the spool down. The energized
reverse solenoid (15) routes pressure oil to the
forward/reverse shift valve (12) moving the spool
down. Shifting of the forward/reverse spool allows oil
to flow from the modulation valve (17) to fill the
reverse clutch pack (3) and compress the clutch
plates. Shifting of the forward/reverse spool also
blocks the flow of oil downstream of the orifice in valve
Plate
23Torque Converter
Front Housing
27Filter And Bypass
28Transmission Pump
29Sump

(315SE Only)
(315SE Only)
32System Pressure
33Medium Pressure
34Low Pressure
35Lube Pressure
36Return Pressure
Control CircuitReverse
housing (18) from returning to tank and allows the

pressure in the modulation valve to build. As pressure
builds, the balance between orifice size and spring
load in the modulation valve controls the rate of shift
and pushes the modulation piston down. The
downward force from the modulation piston pushes on
the modulation springs which drive the modulation
spool down to the fully open position. In the fully open
position, high pressure oil (32) from the pressure
regulating valve keeps the reverse clutch engaged
9020
05
29
CED,TX03399,4253 1927APR002/2
TM1608 (20SEP06)
9020-05-29

092006
PN=327
Theory of Operation
Power Shift Transmission Clutch

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

Forward
Low Range
Reverse
Speed Solenoid Energized

1
Neutral
9020
05
30
1st Forward
2nd Forward
3rd Forward
4th Forward (High Range)
X
X
1st Reverse
2nd Reverse
3rd Reverse
X
X
X
X
CED,TX03399,4223 1907SEP061/1
TM1608 (20SEP06)
9020-05-30

092006
PN=328
Theory of Operation
9020
05
31
TM1608 (20SEP06)
9020-05-31

092006
PN=329
Theory of Operation
Power Shift Transmission Control CircuitNeutral With Park Brake OFF

T127733 1907FEB00
7 HIGH RANGE
FORWARD CLUTCH
1 1ST SPEED
CLUTCH
5
TRANSMISSION
CONTROL VALVE
2 2ND SPEED
CLUTCH
6
LOW RANGE
FORWARD
CLUTCH
8
REVERSE
CLUTCH
4
TRANSMISSION SPEED
SHIFT VALVE
3 3RD SPEED
CLUTCH
LOW RANGE 17
SHIFT VALVE
SPEED SHIFT
VALVE 18
3
FORWARD/REVERSE
SHIFT VALVE
28
SPEED SHIFT
VALVE
19
2
SEQUENCE
VALVE
SPEED
SHIFT
VALVE
1 20
SPEED
SOLENOID
VALVE
3
21
SPEED
SOLENOID
VALVE
2 22
LOW
RANGE
SOLENOID
VALVE
24
26
REVERSE
SOLENOID
VALVE
25
SPEED
SOLENOID
VALVE
1
23
ORIFICE IN
VALVE
HOUSING
30
ORIFICE
35 IN DUCT
PLATE
36
LOW RANGE, FORWARD, & REVERSE

SPEED
SOLENOID ENERGIZED
SOLENOID ENERGIZED
FORWARD LOW RANGE REVERSE
1
2
3
NEUTRAL
1ST FORWARD
2ND FORWARD
3RD FORWARD
HIGH RANGE
(4TH FORWARD)
1ST REVERSE
2ND REVERSE
3RD REVERSE
T127733
TORQUE
CONVERTER
37
DIFFERENTIAL
SOLENOID
VALVE
15
FORWARD
SOLENOID
VALVE
16
MODULATION
VALVE 31
ORIFICE IN
MODULATION 33
PISTON
13 SCREEN
IN ALL
SOLENOIDS
PRESSURE
REDUCING
VALVE 32
ORIFICE IN
INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
38
TRANSMISSION
OIL COOLER
39
40
FILTER
AND
BYPASS
BOOM 43
LOCK
SOLENOID
50 POWER SHIFT TRANSMISSION CONTROL CIRCUIT
NEUTRAL WITH PARK BRAKE OFF
PARK BRAKE
SOLENOID
VALVE
12
MFWD
SOLENOID
VALVE
14
34
TRANSMISSION
PUMP 41
X
X
MODULATION
PISTON 29
27
ORIFICE IN
MODULATION
SPOOL
PRESSURE
REGULATING
VALVE
GEAR
SELECTION
11
PARK
BRAKE
10
MFWD
9
DIFFERENTIAL LOCK
44 BOOM
LOCK
CYLINDERS
45
SYSTEM PRESSURE
46
MEDIUM PRESSURE
47
LOW PRESSURE
48
LUBE PRESSURE
49
RETURN PRESSURE
SUMP 42
CED,TX03399,4236 1927APR001/3
TM1608 (20SEP06)
9020-05-32

092006
PN=330
Theory of Operation
11st Speed Clutch
22nd Speed Clutch
33rd Speed Clutch
4Transmission Speed Shift
Valve
6Low Range Forward
Clutch
7High Range Forward Clutch
8Reverse Clutch
9Differential Lock
Wheel Drive)
11Park Brake

17Low Range Shift Valve
18Speed Shift Valve 3
21Speed Solenoid Valve 3
24Low Range Solenoid
Valve
26Sequence Valve
Spool
Valve
29Modulation Piston
31Modulation Valve
Piston
Plate
35Orifice in Duct Plate
37Torque Converter
40Filter and Bypass

41Transmission Pump
42Sump
(315SE Only)
(315SE Only)
45System Pressure
46Medium Pressure
47Low Pressure
48Lube Pressure
49Return Pressure
50Power Shift Transmission
Control CircuitNeutral
With Park Brake OFF
NOTE: Transmission control valve (5) and

transmission speed shift valve (4) components
are shown in detail on the "Power Shift
Transmission Control Valve and Shift Valve
OperationNeutral in this group. Keys and
nomenclature will match where applicable.
with shims. It regulates main system pressure. Excess

oil from the circuit is directed to the torque converter
through this valve. The modulation valve (31) is a
spring loaded spool which controls the rate of clutch
engagement during a shift. Within the valve is the
modulation piston (29).
The transmission control valve regulates the hydraulic

oil pressures and controls circuits required for
operation of the transmission. Electrical signals from
the FNR lever and park brake switch are used to
energize the solenoids which direct oil to move the
shift valves and engage the appropriate selected
clutches.
When a gear is selected the speed solenoid valves

(21, 22, or 23) are energized in combinations of two
which shift two of the speed shift valves (18, 19, or
20). The shift valves direct system pressure oil to one
of the speed clutches 1st, 2nd or 3rd.
The transmission control valve contains the main

frame harness which connects to the transmission
control valve, forward solenoid valve (16), low range
solenoid valve (24), reverse solenoid valve (25),
converter relief valve (38), pressure regulating valve
(36), modulation valve (31), modulation piston (29),
forward/reverse shift valve (28), low range shift valve
(17), and the pressure reducing valve (32). The
transmission speed shift valve contains the speed
solenoid valves 1, 2 and 3 (23, 22 and 21) and speed
shift valves 1, 2 and 3 (20, 19 and 18).
The forward/reverse shift valve (28), is a spring loaded

spool valve which routes system pressure oil to the
low range shift valve (17). The low range shift valve
(17), is a spring loaded spool valve which routes
system oil to the low range (6), high range forward (7),
and reverse clutches (8). The forward and reverse
solenoid valves, (16) and (25), are activated by the
FNR lever. Each directs medium pressure oil to the
forward/reverse shift valve (28). The low range
solenoid valve (24), directs medium pressure oil to the
low range shift valve (17). The low range solenoid
valve is controlled by the gear selection on the FNR
lever.
The converter relief valve (38) controls the maximum

pressure to the torque converter. The pressure
regulating valve (36) is a spring loaded spool valve
The pressure reducing valve (32) supplies medium

pressure oil to the speed, forward, reverse and low
range solenoid valves.
TM1608 (20SEP06)
9020-05-33
CED,TX03399,4236 1927APR002/3

092006
PN=331
9020
05
33
Theory of Operation
Flow from the transmission charge pump (41) passes
through the filter to the pressure regulating valve (36).
The pressure regulating valve regulates system
pressure and directs high pressure oil to the reducing
valve (32), differential solenoid valve (15), MFWD
solenoid valve (14) and the park brake solenoid valve
(12). For the 315SE system pressure oil is also routed
to the boom lock solenoid valve (43).
When pressure exceeds the pressure regulating valve
setting the valve opens. Low pressure oil then flows
through the torque converter (37). Converter flow is
excess oil from the pressure regulating valve. A torque
converter relief valve (38) protects the circuit by
dumping to tank when pressure exceeds the setting.
The oil is then routed to the oil cooler (39). The oil
returning from the cooler provides lubrication to the
clutches.
In neutral, with park brake OFF, the forward and
reverse solenoids (16 and 25) are de-energized
(open), medium pressure oil is not directed to the
forward/reverse shift valve (28). The low range
solenoid valve is de-energized (open) and no pressure
oil is routed to the end of the low range shift valve
(17). In neutral all speed clutch packs also dump to
sump and all speed clutch solenoids are de-energized.
The reducing valve (32) controls the pressure by
dumping oil to tank when pressure exceeds its setting.
CED,TX03399,4236 1927APR003/3
9020
05
34
TM1608 (20SEP06)
9020-05-34

092006
PN=332
Theory of Operation
9020
05
35
TM1608 (20SEP06)
9020-05-35

092006
PN=333
Theory of Operation
Power Shift Transmission Control Valve and Shift Valve OperationNeutral

16 FORWARD
SOLENOID
24 LOW RANGE
SOLENOID
25 REVERSE
SOLENOID
38
CONVERTER
RELIEF
VALVE
32
PRESSURE
REDUCING
VALVE
36
PRESSURE
REGULATING
VALVE
17
LOW RANGE
SHIFT VALVE
30
ORIFICE 29
28
FORWARD
MODULATION
OR REVERSE
PISTON
SHIFT VALVE
31
MODULATION
VALVE
23
SPEED
SOLENOID
VALVE 1
22
SPEED
SOLENOID
VALVE 2
21
SPEED
SOLENOID
VALVE 3
45 SYSTEM PRESSURE OIL
46 MEDIUM PRESSURE OIL
47 LOW PRESSURE OIL
49 RETURN OIL
18
SPEED
SHIFT
VALVE 3
51 TRANSMISSION CONTROL VALVE
T127750
AND SHIFT VALVE - NEUTRAL

TM1608 (20SEP06)
9020-05-36
1901FEB00
20
SPEED
SHIFT
VALVE 1
19 SPEED
SHIFT
VALVE 2
T127750
9020
05
36
CED,TX03399,4224 1927APR001/2

092006
PN=334
Theory of Operation

Valve
Valve
29Modulation Piston
30Orifice In Valve Housing

31Modulation Valve
45System Pressure Oil
46Medium Pressure Oil

47Low Pressure Oil
49Return Oil
Valve And Shift Valve
Neutral
For theory see Power Shift Transmission Control

CircuitNeutral With Park Brake Off in this group.
Keys and nomenclature will match where applicable.
CED,TX03399,4224 1927APR002/2
9020
05
37
TM1608 (20SEP06)
9020-05-37

092006
PN=335
Theory of Operation
Power Shift Transmission Control CircuitFirst Forward

T127837 1907FEB00
7 HIGH RANGE
FORWARD CLUTCH
1 1ST SPEED
CLUTCH
5
TRANSMISSION
CONTROL VALVE
2 2ND SPEED
CLUTCH
6
LOW RANGE
FORWARD
CLUTCH
4
TRANSMISSION SPEED
SHIFT VALVE
3 3RD SPEED
CLUTCH
LOW RANGE
SHIFT VALVE
17
SPEED SHIFT
VALVE 18
3
FORWARD/REVERSE
SHIFT VALVE
28
SEQUENCE
VALVE
26
SPEED SHIFT
VALVE
19
2
SPEED
SHIFT
VALVE
1 20
SPEED
SOLENOID
VALVE
3
21
SPEED
SOLENOID
VALVE
2 22
LOW
RANGE
SOLENOID
VALVE
24
REVERSE
SOLENOID
VALVE
25
SPEED
SOLENOID
VALVE
1
23
ORIFICE IN
VALVE
MODULATION
HOUSING
PISTON 29
30
27
ORIFICE IN
MODULATION
SPOOL
ORIFICE
35 IN DUCT
PLATE
PRESSURE
REGULATING
VALVE
GEAR
SELECTION
36

SPEED
SOLENOID ENERGIZED
SOLENOID ENERGIZED
1
2
3
NEUTRAL
1ST FORWARD
2ND FORWARD
3RD FORWARD
HIGH RANGE
(4TH FORWARD)
1ST REVERSE
2ND REVERSE
3RD REVERSE
T127837
11
PARK
BRAKE
10
MFWD
9
DIFFERENTIAL LOCK
8
REVERSE
CLUTCH
TORQUE
CONVERTER
37
MODULATION
VALVE 31
ORIFICE IN
MODULATION 33
PISTON
DIFFERENTIAL
SOLENOID
VALVE
15
FORWARD
SOLENOID
VALVE
16
PARK BRAKE
SOLENOID
VALVE
MFWD
SOLENOID
VALVE
14
12
SCREEN
IN ALL
SOLENOIDS
13
PRESSURE
REDUCING
VALVE 32
34
ORIFICE IN
INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
38
TRANSMISSION
OIL COOLER
39
40
FILTER
AND
BYPASS
TRANSMISSION
PUMP 41
BOOM 43
LOCK
SOLENOID
X
50 POWER SHIFT TRANSMISSION CONTROL CIRCUIT FIRST FORWARD
44 BOOM
LOCK
CYLINDERS
45
SYSTEM PRESSURE
46
MEDIUM PRESSURE
47
LOW PRESSURE
48
LUBE PRESSURE
49
RETURN PRESSURE
SUMP 42
CED,TX03399,4238 1927APR001/2
TM1608 (20SEP06)
9020-05-38

092006
PN=336
Theory of Operation
11st Speed Clutch
22nd Speed Clutch
33rd Speed Clutch
Valve
6Low Range Forward
Clutch
8Reverse Clutch
9Differential Lock
Wheel Drive)
11Park Brake

Valve
26Sequence Valve
Spool

OperationFirst Forward in this group. Keys
and nomenclature will match where applicable.
NOTE: Refer to Power Shift Transmission Control
CircuitNeutral for pressure reducing,
converter relief and pressure regulating valve
theory of operation.
During 1st gear forward operation the forward solenoid
valve (16), low range solenoid valve (24), speed
solenoid valve 2 (22), and speed solenoid valve 3 (21)
are energized. The energized low range solenoid valve
routes medium pressure oil to the low range shift valve
(17) and moves the spool down. The energized
forward solenoid valve (16) routes medium pressure oil
to the forward/reverse shift valve (28) moving its spool
up. The energized speed solenoids 2 and 3 (22 and
21) route medium pressure oil to the shift valves 2 and
3 (19 and 18) moving the spools down. Shifting of the
speed shift spools allows oil to flow from the regulating
valve (36) through the orifice in duct plate (replenishing
orifice) (35) to fill the 1st speed clutch pack (1) and
Valve
29Modulation Piston
31Modulation Valve
Piston
Plate
37Torque Converter
40Filter and Bypass

41Transmission Pump
42Sump
(315SE Only)
(315SE Only)
45System Pressure
46Medium Pressure
47Low Pressure
48Lube Pressure
49Return Pressure
Control CircuitFirst
Forward
compress the clutch plates. Shifting of the

forward/reverse spool (28) and the low range shift
spool (17) allows oil to flow from the modulation valve
(31) to fill the low range forward clutch pack (6) and
compress the clutch plates. Shifting of the
forward/reverse spool also blocks the flow of oil
downstream of the orifice (30) in valve housing from
modulation valve to build. As pressure builds, the
the modulation piston down.
The sequence valve (26) insures that the speed clutch
fills and engages before the direction clutch by
allowing oil to flow from the modulation valve (31) to
the speed clutch circuit downstream of the orifice in
duct plate (replenishing orifice) (35) when the pressure
in the speed clutch circuit is lower than the pressure in
the direction clutch circuit. The downward force from
the modulation piston (29) pushes on the modulation
keeps the speed and direction clutches engaged.
CED,TX03399,4238 1927APR002/2
TM1608 (20SEP06)
9020-05-39

092006
PN=337
9020
05
39
Theory of Operation
Power Shift Transmission Control Valve and Shift ValveFirst Forward

24 LOW RANGE
SOLENOID
16 FORWARD
SOLENOID
25 REVERSE
SOLENOID
38
CONVERTER
RELIEF
VALVE
32
PRESSURE
REDUCING
VALVE
36
PRESSURE
REGULATING
VALVE
17
LOW RANGE
SHIFT VALVE
30
ORIFICE
29
28
FORWARD
MODULATION
OR REVERSE
PISTON
SHIFT VALVE
31
MODULATION
VALVE
23
SPEED
SOLENOID
VALVE 1
22
SPEED
SOLENOID
VALVE 2
21
SPEED
SOLENOID
VALVE 3
18
SPEED
SHIFT
VALVE 3
T127839
AND SHIFT VALVE - FIRST FORWARD

TM1608 (20SEP06)
9020-05-40
1901FEB00
20
SPEED
SHIFT
VALVE 1
49 RETURN OIL
19 SPEED
SHIFT
VALVE 2
T127839
9020
05
40
CED,TX03399,4227 1927APR001/2

092006
PN=338
Theory of Operation

Valve
Valve
29Modulation Piston
31Modulation Valve

49Return Oil
First Forward

CircuitFirst Forward in this group. Keys and
CED,TX03399,4227 1927APR002/2
9020
05
41
TM1608 (20SEP06)
9020-05-41

092006
PN=339
Theory of Operation
Power Shift Transmission Control CircuitHigh Range (Fourth) Forward

T127843 1907FEB00
7 HIGH RANGE
FORWARD CLUTCH
1 1ST SPEED
CLUTCH
5
TRANSMISSION
CONTROL VALVE
2 2ND SPEED
CLUTCH
6
LOW RANGE
FORWARD
CLUTCH
8
REVERSE
CLUTCH
4
TRANSMISSION SPEED
SHIFT VALVE
3 3RD SPEED
CLUTCH
LOW RANGE 17
SHIFT VALVE
SPEED SHIFT
VALVE 18
3
FORWARD/REVERSE
SHIFT VALVE
28
26
SEQUENCE
VALVE
SPEED SHIFT
VALVE
19
2
SPEED
SHIFT
VALVE
1 20
SPEED
SOLENOID
VALVE
3
21
LOW
RANGE
SOLENOID
VALVE
24
REVERSE
SOLENOID
VALVE
25
SPEED
SOLENOID
VALVE
1
23
SPEED
SOLENOID
VALVE
2 22
ORIFICE IN
VALVE
HOUSING
30
27
ORIFICE IN
MODULATION
SPOOL
ORIFICE
35 IN DUCT
PLATE
PRESSURE
REGULATING
VALVE
GEAR
SELECTION
36

SPEED
SOLENOID ENERGIZED
SOLENOID ENERGIZED
1
2
3
NEUTRAL
1ST FORWARD
2ND FORWARD
3RD FORWARD
HIGH RANGE
(4TH FORWARD)
1ST REVERSE
2ND REVERSE
3RD REVERSE
T127843
11
PARK
BRAKE
10
MFWD
9
DIFFERENTIAL LOCK
TORQUE
CONVERTER
37
MODULATION
PISTON
29
DIFFERENTIAL
SOLENOID
VALVE
15
FORWARD
SOLENOID
VALVE
16
MODULATION
VALVE 31
ORIFICE IN
MODULATION 33
PISTON
PARK BRAKE
SOLENOID
VALVE 12
MFWD
SOLENOID
VALVE
14
13
SCREEN
IN ALL
SOLENOIDS
PRESSURE
REDUCING
VALVE 32
34
ORIFICE IN
INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
38
TRANSMISSION
OIL COOLER
39
40
FILTER
AND
BYPASS
TRANSMISSION
PUMP 41
BOOM 43
LOCK
SOLENOID
X
50 POWER SHIFT TRANSMISSION CONTROL CIRCUIT FOURTH FORWARD
44 BOOM
LOCK
CYLINDERS
45
SYSTEM PRESSURE
46
MEDIUM PRESSURE
47
LOW PRESSURE
48
LUBE PRESSURE
49
RETURN PRESSURE
SUMP 42
CED,TX03399,4240 1927APR001/2
TM1608 (20SEP06)
9020-05-42

092006
PN=340
Theory of Operation
11st Speed Clutch
22nd Speed Clutch
33rd Speed Clutch
Valve
6Low Range Forward
Clutch
8Reverse Clutch
9Differential Lock
Wheel Drive)
11Park Brake

Valve
26Sequence Valve
Spool

OperationHigh Range (Fourth) Forward in
this group. Keys and nomenclature will match
where applicable.
During 4th gear forward operation the forward solenoid
valve (16), speed solenoid valve 1 (23), and speed
solenoid valve 3 (21) are energized. Both the low
range shift valve (17) and the forward/reverse shift
valve (28) are in the up position. The energized speed
solenoids 1 and 3 (23 and 21) routes oil to the shift
valves 1 and 3 (20 and 18) moving the spools down.
Pressure oil is routed through the shift valves to the
3rd speed clutch (3). Shifting of the speed shift spools
allows oil to flow from the regulating valve (36) through
the orifice in duct plate (replenishing orifice) (35) to fill
Valve
29Modulation Piston
31Modulation Valve
Piston
Plate
37Torque Converter
40Filter and Bypass

41Transmission Pump
42Sump
(315SE Only)
(315SE Only)
45System Pressure
46Medium Pressure
47Low Pressure
48Lube Pressure
49Return Pressure
Control CircuitFourth
Forward
the 3rd speed clutch pack and compress the clutch

plates. Shifting of the forward/reverse spool (28) allows
oil to flow from the modulation valve (31) to fill the high
range forward clutch pack (7) and compress the clutch
plates. Shifting of the forward/reverse spool also
blocks the flow of oil downstream of the orifice (30) in
valve housing from returning to tank and allows the
pressure in the modulation valve to build. As pressure
builds, the balance between orifice size and spring
load in the modulation valve controls the rate of shift
and pushes the modulation piston (29) down.
allowing oil to flow from the modulation valve (31) to
the speed clutch circuit downstream of the orifice in
duct plate (replenishing orifice) (35) when the pressure
in the speed clutch circuit is lower than the pressure in
(36) keeps the speed and direction clutches engaged.
CED,TX03399,4240 1927APR002/2
TM1608 (20SEP06)
9020-05-43

092006
PN=341
9020
05
43
Theory of Operation
Power Shift Transmission Control Valve and Shift ValveHigh Range (Fourth) Forward
24 LOW RANGE
SOLENOID
16 FORWARD
SOLENOID
25 REVERSE
SOLENOID
38
CONVERTER
RELIEF
VALVE
32
PRESSURE
REDUCING
VALVE
36
PRESSURE
REGULATING
VALVE
17
LOW RANGE
SHIFT VALVE
30
ORIFICE 29
28
MODULATION
PISTON
FORWARD
OR REVERSE
SHIFT VALVE
31
MODULATION
VALVE
23
SPEED
SOLENOID
VALVE 1
22
SPEED
SOLENOID
VALVE 2
21
SPEED
SOLENOID
VALVE 3
20
SPEED
SHIFT
VALVE 1

49 RETURN OIL

T127844
AND SHIFT VALVE - FOURTH FORWARD

TM1608 (20SEP06)
9020-05-44
1901FEB00
18
SPEED
SHIFT
VALVE 3
19 SPEED
SHIFT
VALVE 2
T127844
9020
05
44
CED,TX03399,4228 1927JAN001/2

092006
PN=342
Theory of Operation

Valve
Valve
29Modulation Piston
31Modulation Valve

49Return Oil
Fourth Forward

CircuitHigh Range (Fourth) Forward in this group.
Keys and nomenclature will match where applicable.
CED,TX03399,4228 1927JAN002/2
9020
05
45
TM1608 (20SEP06)
9020-05-45

092006
PN=343
Theory of Operation
Power Shift Transmission Control CircuitFirst Reverse

T127845 1907FEB00
7 HIGH RANGE
FORWARD CLUTCH
1 1ST SPEED
CLUTCH
5
TRANSMISSION
CONTROL VALVE
2 2ND SPEED
CLUTCH
6
LOW RANGE
FORWARD
CLUTCH
8
REVERSE
CLUTCH
4
TRANSMISSION SPEED
SHIFT VALVE
3 3RD SPEED
CLUTCH
FORWARD/REVERSE
SHIFT VALVE
28
SEQUENCE
VALVE
SPEED SHIFT
VALVE
19
2
26
SPEED
SHIFT
VALVE
1 20
SPEED
SOLENOID
VALVE
2 22
LOW
RANGE
SOLENOID
VALVE
24
REVERSE
SOLENOID
VALVE
25
SPEED
SOLENOID
VALVE
1
23
ORIFICE IN
MODULATION
VALVE
PISTON
HOUSING
29
30
27
ORIFICE IN
MODULATION
SPOOL
ORIFICE
35 IN DUCT
PLATE
PRESSURE
REGULATING
VALVE
GEAR
SELECTION
36

SPEED
SOLENOID ENERGIZED
SOLENOID ENERGIZED
1
2
3
NEUTRAL
1ST FORWARD
2ND FORWARD
3RD FORWARD
HIGH RANGE
(4TH FORWARD)
1ST REVERSE
2ND REVERSE
3RD REVERSE
T127845
11
PARK
BRAKE
LOW RANGE
SHIFT VALVE
17
SPEED SHIFT
VALVE 18
3
SPEED
SOLENOID
VALVE
3
21
10
MFWD
9
DIFFERENTIAL LOCK
TORQUE
CONVERTER
37
MODULATION
VALVE 31
ORIFICE IN
33
MODULATION
PISTON
DIFFERENTIAL
SOLENOID
VALVE
15
FORWARD
SOLENOID
VALVE
16
PARK BRAKE
SOLENOID
VALVE
12
MFWD
SOLENOID
VALVE
14
SCREEN
IN ALL
SOLENOIDS
13
PRESSURE
REDUCING
VALVE 32
34
ORIFICE IN
INTERMEDIATE
PLATE
CONVERTER
RELIEF
VALVE
38
TRANSMISSION
OIL COOLER
39
40
FILTER
AND
BYPASS
TRANSMISSION
PUMP
41
BOOM 43
LOCK
SOLENOID
X
50 POWER SHIFT TRANSMISSION CONTROL CIRCUIT FIRST REVERSE
44 BOOM
LOCK
CYLINDERS
45
SYSTEM PRESSURE
46
MEDIUM PRESSURE
47
LOW PRESSURE
48
LUBE PRESSURE
49
RETURN PRESSURE
SUMP 42
CED,TX03399,4241 1927APR001/2
TM1608 (20SEP06)
9020-05-46

092006
PN=344
Theory of Operation
11st Speed Clutch
22nd Speed Clutch
33rd Speed Clutch
Valve
6Low Range Forward
Clutch
8Reverse Clutch
9Differential Lock
Wheel Drive)
11Park Brake

Valve
26Sequence Valve
Spool

OperationFirst Reverse in this group. Keys
and nomenclature will match where applicable.
During 1st gear reverse operation the reverse solenoid
valve (25), low range solenoid valve (24), speed
solenoid valve 2 (22), and speed solenoid valve 3 (21)
are energized. The energized reverse solenoid valve
(25) routes pressure oil to the forward/reverse shift
valve (28) moving its spool down. The energized low
range solenoid valve (24) routes pressure oil to the low
range shift valve (17), shifting it down. The energized
speed solenoids 2 and 3 (22 and 21) routes oil to the
shift valves 2 and 3 (19 and 18) moving the spools
down. Pressure oil is routed through the shift valves to
the lst speed clutch (1). Shifting of the speed shift
spools allows oil to flow from the regulating valve (36)
through the orifice in duct plate (replenishing orifice)
Valve
29Modulation Piston
31Modulation Valve
Piston
Plate
37Torque Converter
40Filter and Bypass

41Transmission Pump
42Sump
(315SE Only)
(315SE Only)
45System Pressure
46Medium Pressure
47Low Pressure
48Lube Pressure
49Return Pressure
Control CircuitFirst
Reverse
(35) to fill the 1st speed clutch pack and compress the
clutch plates. Shifting of the forward/reverse spool (28)
and the low range shift spool (17) allows oil to flow
from the modulation valve (31) to fill the reverse clutch
pack (8) and compress the clutch plates. Shifting of
the forward/reverse spool also blocks the flow of oil
downstream of the orifice (30) in valve housing from
modulation valve (31) to build. As pressure builds, the
the modulation piston down.
allowing oil to flow from the modulation valve to the
speed clutch circuit downstream of the orifice in duct
plate (replenishing orifice) (36) when the pressure in
the speed clutch circuit is lower than the pressure in
pressure oil from the pressure regulating valve (36)
keeps the speed and direction clutches engaged.
CED,TX03399,4241 1927APR002/2
TM1608 (20SEP06)
9020-05-47

092006
PN=345
9020
05
47
Theory of Operation
Power Shift Transmission Control Valve and Shift ValveFirst Reverse

24 LOW RANGE
SOLENOID
16 FORWARD
SOLENOID
25 REVERSE
SOLENOID
38
CONVERTER
RELIEF
VALVE
32
PRESSURE
REDUCING
VALVE
36
PRESSURE
REGULATING
VALVE
17
LOW RANGE
SHIFT VALVE
30
ORIFICE 29
28
FORWARD
MODULATION
OR REVERSE
PISTON
SHIFT VALVE
31
MODULATION
VALVE
23
SPEED
SOLENOID
VALVE 1
22
SPEED
SOLENOID
VALVE 2
21
SPEED
SOLENOID
VALVE 3
18
SPEED
SHIFT
VALVE 3
T127861
AND SHIFT VALVE - FIRST REVERSE

TM1608 (20SEP06)
9020-05-48
1901FEB00
20
SPEED
SHIFT
VALVE 1
49 RETURN OIL
19 SPEED
SHIFT
VALVE 2
T127861
9020
05
48
CED,TX03399,4229 1927JAN001/2

092006
PN=346
Theory of Operation

Valve
Valve
29Modulation Piston
31Modulation Valve

49Return Oil
First Reverse

CircuitFirst Reverse in this group. Keys and
CED,TX03399,4229 1927JAN002/2
9020
05
49
TM1608 (20SEP06)
9020-05-49

092006
PN=347
Theory of Operation
Manual Shift Modulation Valve Operation
FILL
PRE
MOD.
MODULATION
ENGAGEMENT
G PISTON
H OUTER
SPRING
F
ORIFICE
I INNER
SPRING
B
J
MODULATION
SPOOL
E
ORIFICE
M6
M6
A
NEUTRAL
B
START OF FILL
C
MODULATION
D
ENGAGEMENT
B
START OF FILL
C
MODULATION
D
ENGAGEMENT
9020
05
50
L MEDIUM PRESSURE
O MODULATION VALVE
M LOW PRESSURE
T115940
N RETURN PRESSURE
T115940
TM1608 (20SEP06)
1904SEP98
K SYSTEM PRESSURE
9020-05-50
CED,TX03399,4254 1907SEP061/2

092006
PN=348
Theory of Operation
ANeutral
BStart of Fill
CModulation
DEngagement
EOrifice In Valve Spool

FOrifice In Valve Housing
GPiston
HOuter Spring
Rate of shift from neutral into forward or reverse is

controlled by movement of the modulation valve and
modulation piston during a shift. By regulating the
amount of oil flow being sent to engage the direction
pack, the time required is extended to assure a
smooth shift.
When the machine is in neutral (A), system pressure
oil (K) bleeds by the edge of the modulation spool (J).
This oil (M) (low pressure) flows through orifice (F) and
that passage is open to return. Low pressure oil (M)
also flows through the orifice (E) to the bottom side of
the modulation spool (J). This oil applies sufficient
force on the spring to hold the valve on the edge of
pressure port opening.
Forward and reverse clutch packs are also open to
sump when in neutral.
The start of fill (B) mode begins when a shift to
forward or reverse occurs. Shifting of the
forward/reverse spool allows oil to flow from the
modulation valve to the neutral shift valve and fill the
clutch pack. Shifting of the forward/reverse spool also
blocks the flow of oil downstream of the orifice (F) from
modulation valve to build. The clutch pack fills rapidly
at the low pressure level.
IInner Spring
JModulation Spool
KSystem Pressure
LMedium Pressure
MLow Pressure
NReturn Pressure
OModulation Valve
sensed through orifice (F). Pressure on the back side

of orifice (F) is building to low pressure (M). This
pressure starts moving the piston (G), springs (H and
I) and modulation spool (J) down. There are two small
orifices toward the top of the piston (G) (not shown).
The orifices allow return oil to dump to sump during
the start of fill and half way through modulation mode.
This helps control the rate of shift. The orifices in the
piston close off as the piston moves down. An
equalization of spring and pressure forces on the
modulation valve regulates the rate of clutch
engagement during modulation.
When the final engagement mode (D) is reached, the
modulation spool (J) is in the fully open position, and
the two small orifices (not shown) in the modulation
piston (G) are closed off. With the spool in the fully
open position, high pressure oil from the pressure
regulating valve maintains the downward force on the
modulation piston and keeps the clutch engaged until
the next shift.
Cycling the forward/reverse spool or the neutral shift
spool allows the high pressure oil in the engaged
clutch and between the orifice (F) and the top of the
modulation piston to vent to tank. The resulting loss in
pressure allows the modulation valve to reset to begin
the next shift sequence.
Modulation mode (C) begins as pressure in the clutch

pack begins to rise (L). The pressure is also being
CED,TX03399,4254 1907SEP062/2
TM1608 (20SEP06)
9020-05-51

092006
PN=349
9020
05
51
Theory of Operation
Power Shift Modulation Valve Operation

M ORIFICES
FILL
G PISTON
PRE MODULATION
MOD.
ENGAGEMENT
H OUTER
SPRING
F
ORIFICE
I INNER
SPRING
J SEQUENCE
VALVE
E
ORIFICE
M6
M6
A
NEUTRAL
B
START OF FILL
L MODULATION
SPOOL
C
MODULATION
D
ENGAGEMENT
N SYSTEM PRESSURE
1926JUN98
O MEDIUM HIGH PRESSURE

P MEDIUM PRESSURE
Q LOW PRESSURE
R RETURN PRESSURE
T114787
S MODULATION VALVE
TM1608 (20SEP06)
T114787
9020
05
52
K ORIFICE
9020-05-52
CED,TX03399,4225 1907SEP061/2

092006
PN=350
Theory of Operation
ANeutral
BStart of Fill
CModulation
DEngagement
EOrifice
FOrifice (In Valve Housing)

GPiston
HOuter Spring
IInner Spring
JSequence Valve
Rate of shift is controlled by movement of the

modulation valve and modulation piston during a shift.
By regulating the amount of oil flow being sent to
engage the direction pack, the time required is
extended to assure a smooth shift.
When the machine is in neutral (A), system pressure
oil (N), bleeds by the edge of the modulation spool (L).
This oil (Q) (low pressure) flows through orifice (F),
which is open to return. Low pressure oil (Q), also
flows through orifice (E) to the bottom side of the
modulation spool (L). This oil applies sufficient force on
the spring to hold the valve on the edge of pressure
port opening.
All direction and speed clutch packs are also open to
sump when the FNR is in neutral.
The start of fill mode (B), begins when a shift occurs.
Shifting of the speed shift spools allows oil to flow from
the regulating valve through the orifice (K) to fill the
speed clutch pack. Shifting of the forward/reverse
spool allows oil to flow from the modulation valve and
will fill the direction clutch pack. Shifting of the
forward/reverse spool also blocks the flow of oil
downstream of the orifice (F) from returning to tank
and allows the pressure in the modulation valve to
build. Both direction and speed clutch packs fill rapidly
at the low pressure level.
Modulation mode (C), begins as pressure in the clutch
pack begins to rise (P). The pressure is also being
sensed through orifice (F). Pressure on the back side
of orifice (F) is building to low pressure (Q). This
pressure starts moving the modulation piston (G),
KDuct Plate Orifice

LModulation Spool
MOrifice (2 used)
NSystem Pressure
OMedium High Pressure
PMedium Pressure
QLow Pressure
RReturn Pressure
SModulation Valve
springs (H and I) and modulation spool (L), down.

There are two small orifices (M) located near the top of
the piston (G). These orifices allow return oil to dump
to sump during start of fill and half way through
modulation mode. This helps control the rate of shift.
The orifices in the piston close off as the piston moves
down. An equalization of spring and pressure forces
on the modulation valve regulates the rate of clutch
engagement during modulation.
The orifice in duct plate (replenishing orifice) (K),
supplies oil from the pressure regulating valve to the
speed shift valves. The sequence valve (J) supplies oil
from the modulation valve to the speed shift valves
also, but only when the oil downstream of the orifice in
duct plate (replenishing orifice) (K) is below the
modulation pressure filling the direction clutch pack.
This insures that the speed clutch fills and engages
before the direction clutch.
When the final engagement mode (D) is reached, the
modulation spool (L) is in the fully open position, and
the two small orifices (M) in the modulation piston (G)
are closed off. With the spool in the fully open position,
high pressure oil from the pressure regulating valve
maintains the downward force on the modulation
piston and keeps the clutches engaged until the next
shift.
Cycling the forward/reverse spool allows the high
pressure oil in the engaged clutch and between the
orifice (F) and the top of the modulation piston to vent
to tank. The resulting loss in pressure allows the
modulation valve to reset to begin the next shift
sequence.
CED,TX03399,4225 1907SEP062/2
TM1608 (20SEP06)
9020-05-53

092006
PN=351
9020
05
53
Theory of Operation
Differential Operation
T101246
1903SEP96
9020
05
54
TM1608 (20SEP06)
9020-05-54
TX,05,SS3139 1907SEP061/2

092006
PN=352
Theory of Operation
AFinal Drive Ring Gear
BDifferential Housing
CDifferential Ring Gear
DBevel Pinion Shaft (2 used)

EBevel Pinion (4 used)
FInput Pinion Shaft
The differential allows independent rotation of the

axles when the machine is steered. The final drive
planetaries are attached to the axles. Their purpose is
to reduce speed and increase torque through gear
reduction. The input pinion shaft to differential ring
gear also provides a reduction in speed and an
increase to torque.
Input torque from the drive shaft rotates the input bevel
pinion shaft (F) which meshes with the differential ring
gear (C), causing it to turn. The ring gear is fastened
to the differential housing (B) which drives the bevel
pinion shafts (D) and bevel pinions (E). The bevel
pinions located on the bevel pinion shaft are in mesh
with the side gears (G) which spline to the sun pinion
shaft (H).
GSide Gear
HSun Pinion Shaft
IPlanet Pinion Carrier
JOutput Shaft
KDifferential
The sun pinion shaft meshes with the planet pinion

carrier assembly (I) which rotates around the inside of
the stationary planetary final drive ring gear (A).
Torque is transferred into the output shaft (J) causing it
to rotate at a reduced speed but with greater torque.
As the machine is steered, the inside wheel slows
down in relation to the outside wheel. This causes the
side gear, attached to the inside wheels axle, to slow
down. The rotating differential housing and bevel
pinion shafts allow the differential bevel pinions to
rotate around the slow moving side gear, this allows
the opposite side gear to rotate at a faster speed. This
rotation causes the outside wheels axle to rotate
faster than the inside axle which prevents tire scuffing.
9020
05
55
TX,05,SS3139 1907SEP062/2
TM1608 (20SEP06)
9020-05-55

092006
PN=353
Theory of Operation
Differential Lock Operation

SIDE A
GEAR
B DIFFERENTIAL
HOUSING
C BEARING
D BRAKE
HOUSING
E PISTON
DIFFERENTIAL
SOLENOID
VALVE
9020
05
56
J SYSTEM PRESSURE
FROM H
TRANSMISSION
PUMP
SPRING
K RETURN PRESSURE
ASide Gear
BDifferential Housing
CBearing
L DIFFERENTIAL LOCK
DBrake Housing
EPiston
FDifferential Solenoid Valve
When the operator has the differential lock foot control

switch in the off position, the spring force (I) moves
the sliding gear (G) and piston (E) back releasing the
differential lock. The return oil returns through the
same port as when the switch is in the ON position.
When the operator pushes the differential lock foot
control switch to the ON position, the switch
T101241
T101241
1904SEP98
G SLIDING
GEAR
GSliding Gear
HFrom Transmission Pump
ISpring
JSystem Pressure
KReturn Pressure
LDifferential Lock
energizes the differential lock solenoid on the

transmission. When the differential lock solenoid (F) is
energized, pressure oil flows to the inlet and through
the cross-drilled passages to the piston (E). The
pressurized oil moves the piston (E) against the sliding
gear locking the sliding gear with side gear (A) of the
differential, causing both axles to rotate at the same
speed.
TX,05,SS3130 1907SEP061/1
TM1608 (20SEP06)
9020-05-56

092006
PN=354
Theory of Operation
9020
05
57
TM1608 (20SEP06)
9020-05-57

092006
PN=355
Theory of Operation
Brake Valve Operation

A HIGH PRESSURE
E RIGHT BRAKE PEDAL
B RETURN OIL
RETURN
C
PORT
INLET
PORT
M
CHECK
VALVE
D
LEFT
BRAKE F
PEDAL
EQUALIZING G
VALVE
9020
05
58
PISTON H
I
BLEED
SCREW
L INLET TO
PISTON
J BRAKE DISKS
AND PLATES
ERight Brake Pedal

FLeft Brake Pedal
GEqualizing Valve
HPiston (2 used)
IBrake Bleed Screw (2 used)

JBrake Disk and Plates (3
used)
KBrake Pressure Plate (2
used)
TM1608 (20SEP06)
T101247
N BRAKE VALVE
T101247
AHigh Pressure
BReturn Oil
CReturn Port
DCheck Valve
1904SEP98
K
BRAKE
PRESSURE
PLATE
9020-05-58
LInlet to Brake Piston

MInlet Port
NBrake Valve
TX,05,SS3131 1923JUL981/2

092006
PN=356
Theory of Operation
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 brake housing

of each axle.
When the brakes are engaged, the brake pressure
plate applies force on the brake disk and plates which
are connected to the final drive pinion shaft.
TX,05,SS3131 1923JUL982/2
9020
05
59
TM1608 (20SEP06)
9020-05-59

092006
PN=357
Theory of Operation
Service Brake Operation
T101300
1904MAR98
9020
05
60
ADisk (3 used)
BPlate (4 used)
CPiston
DFrom Brake Valve

EBrake Housing
FAdjusting Screw
GHub
The rear axle assembly uses wet multi-disk brakes

which are self-adjusting to compensate for wear. The
disks are splined to the sun gear shaft and the plates
are splined to the rear axle housing.
TM1608 (20SEP06)
HSun Gear Shaft

IService Brake
9020-05-60
TX,05,SS3133 1907SEP061/2

092006
PN=358
Theory of Operation
When the service brakes are applied, the pressure oil
from the brake valve (D), forces the brake piston (C)
against the brake plates (B) and disks (A) which stops
rotation of the sun gear shaft (H). When the brakes are
released the return oil flows back out the same port to
the brake valve.
TX,05,SS3133 1907SEP062/2
9020
05
61
TM1608 (20SEP06)
9020-05-61

092006
PN=359
Theory of Operation
Park Brake Operation
9020
05
62
H
PARK BRAKE
SOLENOID
VALVE
A SPRING
PLATE
B SPRING
WASHER
F PISTON
G
FROM
TRANSMISSION
PUMP
E PLATE
TOWING
CAP SCREW
1904SEP98
D DISK
I
SYSTEM PRESSURE
T101244
ASpring Plate
BSpring Washer
CTowing Cap Screw
K PARK BRAKE - ON
DDisk (3 used)
EPlate (2 used)
FPiston

released. When the park brake is applied (ON) or
machine is shut-off, spring force applies the park
GFrom Transmission Pump

HPark Brake Solenoid Valve
ISystem Pressure
JReturn Pressure
KPark BrakeON
brake. The spring washer (B) forces the piston (F)

against brake disks (D) and plates (E) on the axle
input shaft.
TM1608 (20SEP06)
T101244
J RETURN PRESSURE
9020-05-62
TX,05,SS3134 1907SEP061/2

092006
PN=360
Theory of Operation
When park brake switch is cycled to the OFF position,
the switch energizes the park brake solenoid (H) on
the transmission. The solenoid routes transmission
system pressure oil (I) to the park brake piston (F).
The piston moves against the spring washer (B) and

releases the disks and plates (D and E). Two manual
operated cap screws (C) release the park brake for
emergency towing.
TX,05,SS3134 1907SEP062/2
9020
05
63
TM1608 (20SEP06)
9020-05-63

092006
PN=361
Theory of Operation
MFWD Differential OperationUnequal Traction (If Equipped)
T6058AL
UN24MAY89
9020
05
64
ATire With Most Traction

BDrive Shaft
CR.H. Drive Gear
DL.H. Drive Gear

EPinion Gears
FDifferential Housing
GClutch Disks
HClutch Plate
As available traction changes, tire with better traction

(A) can use move power. Self-limiting differential action
begins to occur.
When one wheel begins to slip more than the other,
wheel with better traction hold its drive shaft (B) and
drive gear (C) from rotating. Wheel with less traction
provides less resistance against its drive gear (D).
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 the drive gear outward and its clutch
pack increases its slip. Less drive 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 pack for other side.
TM1608 (20SEP06)
IPower Flow
JRotation Direction
9020-05-64
TX,05,SS3140 1907SEP061/2

092006
PN=362
Theory of Operation
With MFWD engaged, differential works to
automatically balance driving power to available
traction.
TX,05,SS3140 1907SEP062/2
MFWD Differential OperationEqual Traction
T6058AM
UN24MAY89
9020
05
65
ADifferential Driveshaft
BRing Gear
CDifferential Housing
DPinions
EBevel Drive Gears

FDrive Shafts
Differential unit in MFWD axle has self-applied,

limited-slip feature. When MFWD is engaged under
slippery field conditions, this system automatically
applies correct amount of torque to match traction
available to each wheel.
GPower Flow
HRotation Direction
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.
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,05,SS3141 1907SEP061/1
TM1608 (20SEP06)
9020-05-65

092006
PN=363
Theory of Operation
Boom Lock Operation315SE

BOOM
LOCK
E
SOLENOID
TRANSMISSION
A
B PRESSURE SYSTEM PORT
E
D
RETURN
PORT
C
BOOM
H LOCK
CYLINDERS
G
RETURN
PORT
D
INLET
PORT
RETURN I
SPRINGS
9020
05
66
F OUTLET
PORT
T105773
K BOOM LOCK ACTIVATED
TRANSMISSION
SYSTEM PRESSURE OIL
RETURN OIL
T105773
1930DEC96
J BOOM LOCK NOT ACTIVATED
Boom Lock Activated-Manual Shift Shown

TM1608 (20SEP06)
9020-05-66
CED,TX03399,4242 1904JUN981/3

092006
PN=364
Theory of Operation
ATransmission
BSystem Pressure Port
CReturn Port
DInlet Port
EBoom Lock Solenoid

FOutlet Port
GReturn Port
HBoom Lock Cylinders
IReturn Springs
JBoom LockNot Actuated
KBoom LockActuated
When the boom lock solenoid (E) is not energized,

spring pressure pushes the valve spool down so
pressure oil is blocked at inlet port (D). The outlet port
(F) and return port (G) are connected. The return
springs (I) collapse the cylinder rods, pushing oil from
boom lock cylinders to the transmission return port (C).
Cylinder locks are in the down position.
LTransmission System
Pressure Oil
MReturn Oil
When the boom lock solenoid is energized, the valve

spool is pulled up against spring pressure so pressure
oil is allowed to flow from inlet port (D) to outlet port
(F). This allows pressure oil to flow to the boom lock
cylinders extending the rods against the return springs
(I). Cylinder locks are now in the up position.
CED,TX03399,4242 1904JUN982/3
9020
05
67
T115751
UN08JUN98
NOTE: Art shows location of pressure and return hoses

for power shift. Theory of operation is the same
between the manual and power shift transmission.
Power Shift Boom Lock Hose Location
CED,TX03399,4242 1904JUN983/3
TM1608 (20SEP06)
9020-05-67

092006
PN=365
Theory of Operation
9020
05
68
TM1608 (20SEP06)
9020-05-68

092006
PN=366
Group 15
System Diagnostic Information

Diagnose Manual Shift Power Train
Malfunction
NOTE: Diagnose malfunction charts are arranged from
most probable and simplest to verify. Remember
the following steps when troubleshooting a
problem:
Step 1. Operational Checkout Procedure (See
Group 9005-10.)
Step 2. Diagnose Malfunctions Charts (See Group
9020-15.)
Step 3. Adjustments and/or Tests (See Group
9020-20 and/or 9020-25.)
Symptom
Problem
Solution
Machine Will Not Move in

Forward or Reverse
Low oil level in transmission
Add oil to correct level. See Group

9000-04.
Brakes Dragging

Valves. See Group 9020-20. Check
brake valve and repair. See repair
manual, Group 1060.
Park brake not releasing
Check park brake solenoid. See

Group 9015-10.
Neutral disconnect not disengaging
Check switch. See Group 9015-15.
Leaking clutch piston O-ring
Do Forward and Reverse Pressure

Test in Group 9020-25. See repair
manual, Group 0350.
Piston in clutch pack stuck
Check System Pressure, Forward

and Reverse Clutch Pressure. See
Group 9020-25. If OK, mechanical
problem is indicated. See repair
manual, Group 0350.
Piston ball does not seat
Do Forward and Reverse Clutch

Pressure Test. See Group 9020-25.
TM1608 (20SEP06)
9020-15-1
TX,15,SS3144 1927JAN001/9

092006
PN=367
9020
15
1

Symptom
9020
15
2
Problem
Solution
Torque Converter Flexplate broken
Inspect and repair. See repair

manual, See Remove and Install
Transmission in Group 0300 for
remove of Torque converter. See
Group 0651 for Disassemble and
Assemble.
Worn or slipping forward/reverse

clutch disks
Check system pressure. See Group

9020-25.
Incorrect shim under modulation

piston.
Do Modulation Pressure Test. See

Group 9020-25. Repair, and adjust.
See Group 0360.
Restricted modulation orifice
Do Modulation Valve Pressure Test

in Group 9020-25. Remove orifice
and check for contamination and/or
plugged. See repair manual, Group
0360.
Stuck spool in control valve
Remove and inspect control valve

spools. See repair manual, Group
0360.
Low or no system pressure

9020-25.
Low torque converter oil

flow/pressure
Do Torque Converter Stall Speed

Test. See Group 9020-25
Clutch shaft sealing rings leaking
Do Forward or Reverse Pressure

Synchronizer worn
Repair transmission synchronizers.

See repair manual, Group 0350.
FNR solenoids not working
See 9015-15. Check solenoids for

leakage. See group 9020-25.
Converter drive splines worn or not

engaged in pump drive shaft
Replace converter. See repair

manual, Group 0651.
Pump gears seized
Replace pump assembly, Inspect

and replace pump drive parts as
necessary. See repair manual,
Group 0360.
TM1608 (20SEP06)
9020-15-2
TX,15,SS3144 1927JAN002/9

092006
PN=368

Symptom
Transmission Slippage
Problem
Solution
Mechanical failure in transmission
Inspect transmission and repair. See

repair manual, Group 0350.
Transmission shifter forks and/or

shaft broken
Repair or replace parts as

Group 0350.
Broken drive shafts
Inspect drive shafts and universal

joints for external damage. See
Broken ring or pinion gear
If drive shafts rotate with

transmission in gear but machine
does not move a differential failure is
indicated. Repair. See Rear Axle,
Group 0250.
Low oil level
Add oil. See Group 9000-04.
Wrong oil grade
Change oil. See Group 9000-04

0360.

manual, Group 0350.


Test. See Group 9020-25. See
Worn or slipping forward/reverse

clutch disks
Check system pressure or circuit

pressure. See Group 9020-25. See
Leak in transmission control valve or

gaskets
Remove valve and inspect gaskets.

TM1608 (20SEP06)
9020-15-3
TX,15,SS3144 1927JAN003/9

092006
PN=369
9020
15
3

Symptom
Machine Creeps with FNR in

Neutral
9020
15
4
Machine Lacks Power or Moves

Slow
Problem
Solution

flow/pressure

Test. See Group 9020-25.
Low transmission pump flow due to

worn pump
Do Transmission Pump Flow Test.

See Group 9020-25. See repair
manual, Group 0360.
Weak or broken pressure regulating

valve spring
Do Transmission System Pressure

repair manual 0360.
Warped disks and plates in

transmission
Check transmission. See Repair,

Group 0350.
Check System Pressure and

Forward and Reverse Clutch
pressure. See Group 9020-25. See
Ball pressed in end of clutch shafts

(lube passage) came out
Check Forward or Reverse Clutch

Pressure. See Group 9020-25. See
Clutch ball stuck shut

Internal leakage in control valve
Do Pump Flow Test. See Group

9020-25.
Solenoids stuck
Check Solenoids. See Group

9015-15.
Oil level is low

9000-04.
Wrong oil, aerated oil
Change oil. See Group 9000-4.
Brake dragging
Check for excessive heat in brake

area of axle housing after operating
machine. See repair manual, Group
0250.
Park brake dragging, piston stuck
Repair park brake in rear axle. See

TM1608 (20SEP06)
9020-15-4
TX,15,SS3144 1927JAN004/9

092006
PN=370

Symptom
Problem
Solution
Engine fast idle speed set too low
Check fast idle adjustment. See

Group 9020-20.
Low pressure in transmission system


and check for contamination and /or
0360.

manual, Group 0350.

Pressure Test. See Group 9020-25
Clutch pack slipping

Clutch pack dragging, disks warped
Repair clutch pack. See repair

manual, Group 0350.
Clutch shaft sealing ring leaking



9020-25.
Failed torque converter

Wrong torque converter
Do Torque Converter Stall Test in

Group 9020-25. Check number of
torque converter through access
hole under machine either 247002 or
4168-028-211.
Low engine power
Do Engine Performance Test. See

Group 9010-25.
TM1608 (20SEP06)
9020-15-5
9020
15
5
TX,15,SS3144 1927JAN005/9

092006
PN=371

Symptom
Transmission Shifts Too Slow
9020
15
6
Transmission Shifts Too Fast
Problem
Solution
Mechanical failure in transmission or

axle
Inspect. See repair manual, Group

0250, or 0350.
Low or high oil level (aeration of oil)
Add oil or drain. See Group 9000-04.
Wrong oil
Pressure regulating valve setting

incorrect
Do Reducing Valve Pressure Test.

See Group 9020-25.
Do System Pressure Test. See

Group 9020-25. Repair, see repair
manual, Group 0350.
Control valve leaking internally

9020-25 Repair.
Control valve modulation piston not

shim properly

in Group 9020-25. Repair. See
Modulation piston spring broken
Do Modulation Valve Pressure Test.

See Group 9020-25. Remove control
valve cover and inspect modulation
piston and spring. See repair
manual, Group 0360.
Restricted oil passage to clutch pack

Transmission pump malfunction
Do Pump Flow Test and System

Transmission pump oil pickup

blocked
Repair transmission. See repair

manual, Group 0350.
Modulation valve blocked

See Group 9020-25.
Modulation valve piston stuck or

spring broken

in Group 9020-25. Remove control
piston and spring. Repair, see Group
0360.
TM1608 (20SEP06)
9020-15-6
TX,15,SS3144 1927JAN006/9

092006
PN=372

Symptom
Transmission Overheats
Problem
Solution
Modulation orifice out of place or

missing

Group 9020-25. See repair manual,
Group 0360.
Oil level too high or too low
Check oil level and correct. See

Group 9000-04.
Incorrect type of oil
Drain and replace oil. See Group

9000-04.
Transmission Temperature Indicator

Light is ON
Check temperature switch. See

Group 9015-15.
Clutch pack dragging, worn disks
Repair transmission. See Group

0350.
Torque converter malfunction

Torque converter stalled excessively
Use neutral disconnect switch in

machine operations to reduce stall.
Operating in too high a gear
Operate one gear lower.
Oil cooler air flow restricted
Inspect and clean exterior of cooler.

Do Air Flow Test. See Group
9010-25.
Missing baffles, damaged fan

shrouds or loose fan belt
Inspect and check belt. See Group

9010-20. Check baffles and repair.
Oil cooler restricted internally
Flush Cooling System. See CTM104.
Converter flow blocked by pump

stop
Do Converter In/Out Pressure Test.

See Group 9020-25.
Oil flow to or from cooler restricted
Do Cooler-In/Out Pressure Test. See

Group 9020-25.
Converter-in relief valve stuck open

or broken spring
Remove valve, inspect and repair.

See Repair, Group 0360.
Low transmission pump flow

9020-25.
TM1608 (20SEP06)
9020-15-7
9020
15
7
TX,15,SS3144 1927JAN007/9

092006
PN=373

Symptom
Excessive Power Train Noise
Problem
Solution
Transmission mechanical
malfunction

Repair manual, Group 0350.
Engine Over-fueled

your authorized Injection Pump
Service Center
Engine low idle too slow
Check engine slow idle speed. See

Group 9010-20.
Oil level low
Fill to correct oil level. See Group

9000-04.
Worn or damaged parts in

transmission or axle
Check transmission filter for metal

particles. Repair as necessary. See
repair manual, Groups 0250 and
0350.
Worn universal joints on drive shaft
Inspect universal joints or drive

shaft. See repair manual, Group
0325.
Misalignment of power train

components
Check position of components. Be

sure they are setting on mounts
correctly.
No oil in lube circuit
Do Converter Relief Valve Pressure

Hydraulic lines in contact with power

train components
Inspect all hydraulic lines and repair.

See Hydraulic Component Location
in Group 9025-05.
Assembly adjustments or setting

made incorrectly
Isolate where noise is coming from.

Adjust. Repair. Check mounts. See
Groups 0315 and 0350.
Attempt to shift too fast
See Operators Manual for

instructions.
Shifting without using neutral

disconnect
Depress neutral disconnect when

shifting. See Operators Manual.
Shifters worn or broken
Inspect and replace as necessary.

9020
15
8
Excessive Gear Clash When

Shifting
TM1608 (20SEP06)
9020-15-8
TX,15,SS3144 1927JAN008/9

092006
PN=374

Symptom
Park Brake Pressure Light

Comes On
Problem
Solution
Synchronizer malfunction
Repair transmission synchronizers.

Park brake solenoid not working
Test solenoid. See Group 9015-15.
Park brake piston leak
Do Park Brake Release Pressure

Park brake hose leaking

Test. See Group 9020-25. Inspect
and repair leak.
TX,15,SS3144 1927JAN009/9
9020
15
9
TM1608 (20SEP06)
9020-15-9

092006
PN=375
Diagnose Power Shift Power Train

Malfunction
Symptom
Problem
Solution
Machine Will Not Move in Low

Range Forward, High Range (4th)
or Reverse
Low oil level in transmission, park

brake will not release and light on
console is ON.

9000-04.
Service Brakes Dragging

Valves. See group 9020-20. Check
brake valve and repair. See repair
manual, Group 1060.
If light in console OFF and park

brake not releasing
Check console light and /or pressure

switch. See Group 9015-15. Check
park brake disks and separator
plates. See repair in Group 0250.
Proper solenoids not energized
Test solenoids. See Group 9015-15.

9020-25.
Do Low Range Forward, High Range

Forward, Reverse and Speed Clutch
Pressure Test or Modulation
Pressure Test in Group 9020-25.
Check System Pressure, Do Low

Range Forward, High Range
Pressure Test. See Group 9020-25 If
OK, mechanical problem is
indicated. See repair manual, Group
0350.

Torque Converter Flexplate broken

manual, Group 0350 for Removal
and Installation. See Group 0651 for
Disassemble and Assemble.
9020
15
10
TM1608 (20SEP06)
9020-15-10
CED,TX03399,4235 1927JAN001/10

092006
PN=376

Symptom
Problem
Solution
Worn or slipping low range forward,

high range forward reverse, or speed
clutch disks

9020-25.
Incorrect shim under modulation

piston

Group 9020-25. Repair and adjust.
See Group 0360.

plugged. See repair manual Group
0360.
Stuck spool in control valve
Do Clutch Pressure Tests in Group

9020-25. Remove and inspect
control valve spools. See repair
manual, Group 0360.
Clutch malfunction in torque

converter


flow/pressure
Do Cooler In and Out Pressure Test.

See Group 9020-25.
Charge pump stop sleeve out of

location
Remove and repair charge pump.


Converter drive splines worn or not

engaged in pump drive shaft
Replace converter. See repair

manual, Group 0651.
Pump gears seized
Replace pump assembly, Inspect

and replace pump drive parts as
Group 0360.
Mechanical failure in transmission

TM1608 (20SEP06)
9020-15-11
9020
15
11
CED,TX03399,4235 1927JAN002/10

092006
PN=377

Symptom
Machine Will Not Move In One

Gear
Problem
Solution
Broken drive shafts or pump drive

shaft
Inspect drive shafts, universal joints,

and pump drive shaft for external or
internal damage. See repair manual,
Group 0325 or 0360.
Broken ring or pinion gear
If drive shafts rotate with

transmission in gear but machine
does not move a differential failure is
indicated. Repair. See Rear Axle,
Group 0250.
Leakage in speed clutch

Pressure Test.
Proper solenoids not working
Check solenoids. See Group

9015-15.
Worn or slipping in one clutch pack

Low oil level and park indicator light

ON
Wrong oil grade

0360.


9020
15
12
Transmission Slippage
TM1608 (20SEP06)
9020-15-12
CED,TX03399,4235 1927JAN003/10

092006
PN=378

Symptom
Machine Creeps with FNR in

Neutral
Problem
Solution
Clutch shaft sealing rings leaking.

Worn or slipping clutch disks
Do individual clutch pressure tests.

See Group 9020-25. Check system
pressure or circuit pressure. See
Group 0350.
Leak in transmission control valve,

shift valve or gaskets
Do Clutch Pressure Test. See Group

9020-25. Remove valve and inspect
gaskets. See repair manual, Group
0360.

flow/pressure
Do Cooler In and Cooler Out

Low transmission pump flow due to

worn pump
Do Transmission Pump Flow Test.

See Group 9020-25. See repair
manual, Group 0360.
Weak or broken pressure regulating

valve spring

Weak or broken modulation valve

spring

Group 0360.
Warped disks and plates in

transmission
Check transmission. See repair

manual, Group 0350.
Piston in clutch pack stuck.
Check System Pressure and Low

Range Forward, High Range
Pressure. See Group 9020-25. See
TM1608 (20SEP06)
9020-15-13
9020
15
13
CED,TX03399,4235 1927JAN004/10

092006
PN=379

Symptom
Machine Lacks Power or Moves

Slow
9020
15
14
Problem
Solution
Ball pressed in end of clutch shafts

(lube passage) came out
Check Low Range Forward, High

Range Forward, Reverse and Speed
Clutch Pressure. See Group
9020-25. See repair manual, Group
0350.


9020-25.
Solenoids stuck
Check Solenoids. See Group

9015-15.
Oil level is low and park brake

indicator light is ON

9000-04
Wrong oil, aerated oil
Change oil. See Group 9000-4
Service Brake dragging
Check for excessive heat in brake

area of axle housing after operating
machine. See repair manual, Group
0250.
Park brake dragging, piston stuck
Repair park brake in rear axle. See

Engine fast idle speed set too low
Check fast idle adjustment. See

Group 9010-20.
Low pressure in transmission system


0360.

TM1608 (20SEP06)
9020-15-14
CED,TX03399,4235 1927JAN005/10

092006
PN=380

Symptom
Transmission Shifts Too Slow
Problem
Solution


Clutch pack dragging, disks warped
Repair clutch pack. See repair

manual, Group 0350.
Clutch shaft sealing ring leaking



9020-25.
Failed torque converter


flow/pressure
Do Torque converter Stall Speed

Wrong torque converter
Do Torque Converter Stall Test in

Group 9020-25. Check number of
torque converter through access
hole under machine either 247002 or
4168-028-211.
Low engine power
Do Engine Performance Test. See

Group 9010-25.
Mechanical failure in transmission or

axle
Inspect. See repair manual, Group

0250 or 0350.
Low or high oil level (aeration of oil)
Add oil or drain. See Group 9000-04
Wrong oil
Pressure reducing valve setting

incorrect
Do Reducing Valve Pressure Test.

See Group 9020-25.
TM1608 (20SEP06)
9020-15-15
9020
15
15
CED,TX03399,4235 1927JAN006/10

092006
PN=381

Symptom
Problem
Solution
Pressure regulating valve setting

incorrect

Group 9020-25.

Group 9020-25. Repair, see repair
manual, Group 0350
Control valve leaking internally

9020-25 Repair.
Control valve modulation piston not

shimmed properly

in Group 9020-25. Repair. See

Group 9020-25.
Modulation piston spring broken

See Group 9020-25. Remove control
piston and spring. See repair
manual, Group 0360.
Restricted oil passage to clutch pack

Transmission pump malfunction
Do Pump Flow Test and System

Transmission pump oil pickup

blocked
Repair transmission. See repair

manual, Group 0350.
Modulation piston orifice blocked

See Group 9020-25. Repair, see
Group 0360.
Modulation valve piston stuck

in Group 9020-25. Remove control
piston and spring. Repair, see Group
0360.
Modulation orifice out of place or

missing

Group 0360.
9020
15
16
Transmission Shifts Too Fast
TM1608 (20SEP06)
9020-15-16
CED,TX03399,4235 1927JAN007/10

092006
PN=382

Symptom
Transmission Overheats
Problem
Solution
Modulation orifice oversized

Group 0360.
Oil level too high or too low
Check oil level and correct. See

Group 9000-04.
Drain and replace oil. See Group

9000-04.
Temperature sensor malfunction
Check sensor, see Group 9015-15.
Clutch pack dragging, worn disks
Repair transmission. See Group

0350.
Torque converter malfunction

Torque converter stalled excessively
Use neutral disconnect switch in

machine operations to reduce stall.
Operating in too high a gear
Operate one gear lower.
Oil cooler air flow restricted
Inspect and clean exterior of cooler.

Do Air Flow Test. See Group
9010-25.
Missing baffles, damaged fan

shrouds or loose fan belt
Inspect and check belt. See Group

9010-20. Check baffles and repair.
Oil cooler restricted internally

See Group 9020-25. Flush Cooling
System. See CTM104.
Converter flow blocked by pump

stop sleeve.
Do Converter In/Out Pressure Test.

See Group 9020-25
Oil flow to or from cooler restricted
Do Cooler-In/Out Pressure Test. See

Group 9020-25.
Converter-In relief valve stuck open

or broken spring
Do Converter-In Relief Valve Test in

Group 9020-25. Remove valve,
inspect and repair. See repair
manual, Group 0350.
TM1608 (20SEP06)
9020-15-17
9020
15
17
CED,TX03399,4235 1927JAN008/10

092006
PN=383

Symptom
Excessive Power Train Noise
9020
15
18
Excessive Gear Clash When

Shifting
Problem
Solution
Low transmission pump flow

9020-25.
Transmission mechanical
malfunction

Repair, Group 0350.
Engine Over-fueled

your authorized Injection Pump
Service Center
Engine low idle too slow
Check engine slow idle speed. See

Group 9010-20.
Oil level low
Fill to correct oil level. See Group

9000-04.
Worn or damaged parts in

transmission or axle
Check transmission filter for metal

particles. Repair as necessary. See
repair manual, Groups 0250 and
0350.
Worn universal joints on drive shaft
Inspect universal joints or drive

shaft. See repair manual, Group
0325.
Misalignment of power train

components
Check position of components. Be

sure they are setting on mounts
correctly.
No oil in lube circuit

See Group 9020-25. Do Converter
Relief Valve Pressure Test. See
Group 9020-25.
Hydraulic lines in contact with power

train components
Inspect all hydraulic lines and repair.

See Hydraulic Component Location
in Group 9025-05.
Transmission assembly adjustments

or setting made incorrectly
Isolate where noise is coming from.

Adjust. Repair. Check mounts. See
Groups 0315, 0325 and 0350.
Rate of shift too fast
Do Modulation Pressure Test in

Group 9020-25.
TM1608 (20SEP06)
9020-15-18
CED,TX03399,4235 1927JAN009/10

092006
PN=384

Symptom
Park Brake Pressure Light

Comes On
Problem
Solution
Worn Gears
Inspect transmission. See repair

manual, Group 0350.
Transmission oil level too low
Park brake solenoid not working
Test solenoid. See Group 9015-15.
Park brake piston leak

and repair. See repair manual,
Group 0250.

and repair leak.
9020
15
19
CED,TX03399,4235 1927JAN0010/10
TM1608 (20SEP06)
9020-15-19

092006
PN=385
Diagnose MFWD Malfunction

NOTE: See CTM4509 for repair for MFWD axle.
Symptom
Problem
Solution
No Power to MFWD
Solenoid not actuated
Check electrical connection. Inspect

solenoid. See Group 9015-10.
Drive shaft failure

manual, Group 0325.
Failed MFWD output shaft spline

manual, Group 0350.
Failed axle shaft in MFWD

manual, Group 0240.
Failed ring gear or pinion in front

axle.

manual, Group 0240.
Failed MFWD gear train components

in transmission

manual, Group 0350.
Wheel U-Joint failure

manual, Group 0240.
Failed outboard planetary

manual, Group 0240.
Failed axle shaft in MFWD

manual, Group 0240
Failed limited-slip in MFWD

manual, Group 0240.
9020
15
20
No Power to One Wheel of MFWD
TX,15,MA17 1923JUL981/1
TM1608 (20SEP06)
9020-15-20

092006
PN=386
Diagnose Rear Axle Malfunction

Symptom
Problem
Solution
No Differential Lock Operation
Malfunction in electrical circuit to

solenoid
With engine stopped and key switch

turned to accessory, activate
differential lock and listen for a click
from solenoid valve.
Do Differential Lock Operational
Checks. See Group 9015-15.
Differential Lock Slips or

Chatters When Engaged
Stuck differential lock solenoid valve

turned to accessory, activate
differential lock and listen for a click
from solenoid valve. Remove and
inspect valve. See repair manual,
Group 0360.
Excessive leakage in differential lock

piston seals
Do Differential Lock Pressure Test.

See Group 9020-25. Check rear axle
oil level. See Group 9000-04
Stuck differential lock piston

See Group 9020-25. Disassemble,
inspect, repair. See repair manual,
Group 0250.
Excessive wear on differential lock

engaging gears
Disassemble, inspect, repair. See

Excessive leakage differential lock

piston seals

See Group 9020-25.
Failed seals on differential lock

solenoid valve
Remove and inspect seals. See

Disassemble, inspect and repair.

Excessive wear of differential lock

engaging gears
Disassemble, inspect, and repair.

TM1608 (20SEP06)
9020-15-21
TX,15,MA18 1927JAN001/4

092006
PN=387
9020
15
21

Symptom
Problem
Solution
Differential Lock Will Not Release
Stuck foot switch
Inspect. See electrical, Group

9015-10.
Malfunction in electrical circuit

on, activate differential lock and
listen for a click from solenoid valve.
See Differential Lock Circuit, Group
9015-15.
Stuck differential lock solenoid valve

on, activate differential lock and
listen for a click from solenoid valve.
Remove and inspect valve. See

See Group 9020-25. Disassemble,
inspect, repair. See repair manual,
Group 0250.
Stuck differential lock engaging

gears or clutch
Disassemble, inspect, repair. See

Oil level low in transmission

9000-04. Check axle for overfill.
Differential lock piston seals leaking

See Group 9020-25. Inspect, repair.
Service brake piston seals leaking
Do Brake Valve Leakage Test. See

Group 9020-25. Inspect and repair.
Park brake piston seals leaking

and repair. See repair manual,
Group 0250.
9020
15
22
Rear Axle Overfilled With Oil
TM1608 (20SEP06)
9020-15-22
TX,15,MA18 1927JAN002/4

092006
PN=388

Symptom
Problem
Solution
Poor Service Brakes
Low oil level
Check oil level and fill. See Group

9000-04.
Air in brake valve or lines or piston
Bleed brakes. See Group 9020-20.
Brake valve leaks

Group 9020-25.
Brake piston seals leak

manual, Group 0250.
Brake disks worn excessively
Inspect disks through axle brake

inspection hole. Disassemble,
inspect and repair. See repair
manual, Group 0250.
Restriction in brake circuit
Remove lines and components and

inspect.
Brake pedal not returning to full up

position or not adjusted properly
Inspect brake pedal linkage.

Repair/Adjust. See Group 1060.
Brake valve malfunction
Remove, disassemble and inspect.

Repair brake valve. See repair
manual, Group 1060.
Warped brake disks

Stuck brake piston
Remove and inspect. See Repair,

Group 0250.
No free travel on brake adjusters
Disassemble and inspect, check

specifications. See repair manual,
Group 0250.
Air in brake system
Bleed brakes. See Group 9020-20.
Wrong oil in rear axle
Drain and refill with correct oil. See

Group 9000-04.
Disks worn excessively

Brake Valve leakage

Group 9020-25. Repair.
Service Brakes Will Not Release
Service Brakes Chatter or Noisy
TM1608 (20SEP06)
9020-15-23
9020
15
23
TX,15,MA18 1927JAN003/4

092006
PN=389

Symptom
Problem
Solution
Park Brake Will Not Hold
Worn parts
Inspect and replace. See repair

manual, Group 0250.
Park brake piston stuck

Park brake manually released
Do System and Park Brake Release

Park brake solenoid plugged
Check solenoid. See Group 9015-15.

Repair.
Inspect and repair all leaks.
Low hydraulic pressure oil to park

brake

Park Brake Solenoid not working
Park brake piston stuck
Remove and inspect. See Repair.
Park Brake piston seals leaking
Do Park Brake Pressure Test. See

Group 9020-25. Inspect and repair.
See Group 0250.
Park Brake Will Not Release
9020
15
24
TX,15,MA18 1927JAN004/4
TM1608 (20SEP06)
9020-15-24

092006
PN=390
Diagnose Boom Lock Malfunction

Symptom
Problem
Solution
Boom Lock Cylinders Will Not

Lift
Boom locks binding
Check boom lock pivots for binding

or corrosion. Clean and lubricate.
Boom lock solenoid not working

Check solenoid valve for leakage.
See Group 9020-25.
Boom lock switch not working
Check switch continuity. See Group

9015-15.
Check transmission system

pressure. See Group 9020-25.
Boom lock return springs broken or

disconnected
Connect or replace return spring.
Boom locks binding
Check boom lock pivots for binding

or corrosion. Clean and lubricate.
Boom Lock Cylinders Will Not

Lower
Boom lock solenoid not working

Check solenoid valve for leakage.
See Group 9020-25.
Boom lock switch not working
Check switch continuity. See Group

9015-15.
TX,9020,BD2446 1923JUL981/1
TM1608 (20SEP06)
9020-15-25

092006
PN=391
9020
15
25
Hydraulic Circuit Symbols
TS700
1928SEP89
9020
15
26
TX,9020,SS3253 1907SEP061/1
TM1608 (20SEP06)
9020-15-26

092006
PN=392
Group 20
Adjustments
Adjust Brake Pedals and Equalizing Valves
1. Remove brake valve from machine. (See repair
manual.)
2. Clamp brake valve level in bench vise.
TX,20,SS3171 1922JUL981/6
T7407AU
UN30OCT90
3. Install caps (A). Fill brake valve reservoir with oil.
TX,20,SS3171 1922JUL982/6
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.
T7407AT
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.
TM1608 (20SEP06)
9020-20-1
TX,20,SS3171 1922JUL983/6

092006
PN=393
9020
20
1
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.
UN30OCT90
6. Apply a minimum of 44.5 N (10 lb) force to the

left-hand brake pedal.
T7407AS
Specification
Left-Hand Brake PedalForce ............................ 44.5 N (10 lb) Minimum
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) an additional 1/3 turn (two
wrench flats) out (counterclockwise).
Specification
Right-Hand Cap ScrewTorque
Turn ......................................................... If pedal starts to settle, turn cap
screw out (counterclockwise) until
settling stops. Turn the right-hand
cap screw an additional 1/3 turn
(two wrench flats) out
(counterclockwise)
9020
20
2
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.
Specification
Right-Hand Brake PedalForce .......................... 44.5 N (10 lb) Minimum
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).
Specification
Left-Hand Cap ScrewTorque
Turn ......................................................... If pedal starts to settle, turn cap
screw out (counterclockwise) until
settling stops. Turn left-hand cap
screw an additional 1/3 turn (two
wrench flats) out
(counterclockwise)
TM1608 (20SEP06)
9020-20-2
TX,20,SS3171 1922JUL984/6

092006
PN=394
Adjustments
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.
Specification
Pedal AlignmentTorque Turn ............... Turn cap screws for the highest
pedal, a maximum of 1/6 turn
(one wrench flat) out
(counterclockwise).
TX,20,SS3171 1922JUL985/6
11. Slowly release pedal; pedal must return to stop screw

by return spring force alone. Install cap. Repeat for
other side. Fill reservoir.
T7407AU
Specification
Check Valve Closes atBrake
Pedal Travel ......................................... Before 13 mm (0.5 in.) (flow must
stop)
UN30OCT90
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.
NOTE: If oil does not flow, readjust valve stop screws. If

flow does not stop with pedal depressed, inspect
or replace check valve.
12. Depress one brake pedal. Brake pedal must be solid
within first 19 mm (0.75 in.) of pedal travel.
Specification
Brake PedalTravel ............................. Solid within first 19 mm (0.75 in.)
Repeat for other pedal.
NOTE: Excessive pedal travel indicates air in brake valve;

repeat step 4.
TX,20,SS3171 1922JUL986/6
TM1608 (20SEP06)
9020-20-3

092006
PN=395
9020
20
3
Adjustments
Bleeding Brakes
Engine Speed
1500 rpm
Brake Pedal Travel
Firm within 133 mm (5.25 in.)

after 10 second wait cycle
UN26OCT88
SPECIFICATIONS
T6838AE
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.
This procedure will require two technicians.
1. Leave ON park brake. Bleed brakes one pedal at a
time.
2. Run engine at 1500 rpm and cycle a hydraulic function
such as backhoe bucket.
9020
20
4
Specification
EngineSpeed ........................................................................... 1500 rpm
3. Open service brake bleed screws on rear axle.

4. Pump the brake pedal slowly until air free oil comes
out of service brakes rear axle bleed screws.
5. Close bleed screw.
6. Release brake pedal completely and wait a minimum
of 10 seconds.
CAUTION: Do not operate machine if pedal
travel exceeds 133 mm (5.25 in.) while applying
267 N (60 lb) force. Operating machine with
excessive brake travel could cause brakes not
to stop machine on first application.
7. Repeat step 4 through 5 until a firm pedal is obtained
within 133 mm (5.25 in.) of pedal travel after a 10
second wait cycle.
Specification
Brake PedalTravel ................................... Firm within 133 mm (5.25 in.)
after 10 second wait cycle
TM1608 (20SEP06)
9020-20-4
TX,20,SS3172 1925JUN981/2

092006
PN=396
Adjustments
8. As brakes continue to self-bleed, pedal firmness should
improve.
9. If unable to obtain firm brake pedal, inspect lines and
connections for leakage. If no external leaks, test axle.
Do Service Brake Leakage Test in Group 9020-25.
Repair, see repair manual.
TX,20,SS3172 1925JUN982/2
9020
20
5
TM1608 (20SEP06)
9020-20-5

092006
PN=397
Adjustments
Check and Adjust Toe-In

Front marks (B) must be 6 3
mm (0.24 0.12 in.) closer than
rear marks (C)
Tie Rod Clamp Cap Screw

Torque
95 14 Nm (70 10 lb-ft)
Machine (With MFWD) Toe-In
Front marks (B) must be 12 6

rear marks (C)
T6382JW
Machine (Without MFWD) Toe-In
UN02NOV88
SPECIFICATIONS
1. Measure distance from ground to hub center (A). At

this height, mark front (B) and rear (C) in center of
tread of each front tire.
UN02NOV88
2. Measure distance between front marks (B) and rear

marks (C).
MACHINES WITHOUT MFWD
T6162AT
3. Front marks must 6 3 mm (0.24 0.12 in.) closer

than rear marks.
Specification
Machine (Without MFWD)
Toe-In ........................................................ Front marks (B) must be 6 3
rear marks (C)
UN12NOV90
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).
Specification
Tie Rod Clamp Cap Screw
Torque ............................................................. 95 14 Nm (70 10 lb-ft)
T7417BA
9020
20
6
MACHINES WITH MFWD
ACenter of Hub
BFront of Tire
CRear of Tire
DTie Rod Tube
ETie Rod Clamp
FNut
GTie Rod
4. Front marks must 3 3 mm (0.12 0.12 in.) closer

than rear marks.
Specification
Machine (With MFWD)Toe-In .............. Front marks (B) must be 12 6
rear marks (C)
TM1608 (20SEP06)
9020-20-6
TX,20,SS3173 1927JAN001/2

092006
PN=398
Adjustments
5. Loosen nut (F) on each side of axle. Turn each tie rod
(G) equally to adjust. Tighten nuts.
TX,20,SS3173 1927JAN002/2
9020
20
7
TM1608 (20SEP06)
9020-20-7

092006
PN=399
Adjustments
9020
20
8
TM1608 (20SEP06)
9020-20-8

092006
PN=400
Group 25
Tests
Installation

T6813AG
UN28FEB89
Tachometer
TX,25,SS3151 1907SEP061/1
9020
25
1

ATemperature Probe
NOTE: Cooler In and Cooler Out lines can be switched

depending on installation.
For transmission testing, run machine for two minutes.
Use a temperature probe and determine which line is the
hottest and install temperature probe on metal part of line
for cooler IN or feel both cooler hoses and start machine,
whichever one pressurizes first is cooler inlet. On Torque
Converter Stall, Converter-In Relief Pressure Test, and
Cooler In and Out Pressure Test, install digital
thermometer probe into sump using dipstick tube.
T6808CE
UN28FEB89
BCable
TX,25,SS3152 1907SEP061/1
TM1608 (20SEP06)
9020-25-1

092006
PN=401
Tests
Transmission Oil Warm-Up Procedure

SPECIFICATIONS

occur.
UN07JAN91
Low Idle (900 + 25 - 0 rpm) and

High Idle (2375 + 25 - 0 rpm)
T7446AF
Engine Speed
NOTE: Have test equipment installed before warm-up.

Cooling system is highly efficient and may require
blocking air flow around the transmission cooling
system to control temperature.
1. Raise machine off ground using loader and stabilizers.
9020
25
2
2. Put transmission in third gear (A) for manual shift or

move lever (B) to 3rd speed for power shift. Park brake
OFF.
IMPORTANT: Do not stall converter for longer than 20
seconds or serious converter damage
could result.
3. Cycle from low idle (900 + 25 - 0 rpm) to high idle
(2375 + 25 - 0 rpm) with service brakes engaged.
Approximately 10 seconds in high idle and 5 seconds
in low idle until desired temperature is reached.
Specification
EngineSpeed ...................................... Low Idle (900 + 25 - 0 rpm) and
High Idle (2375 + 25 - 0 rpm)
NOTE: To cool machine, shift to neutral and run at high

idle. Temperature should drop approximately 1
every 5 seconds.
CED,TX03399,4231 1915MAY981/1
TM1608 (20SEP06)
9020-25-2

092006
PN=402
Tests
T105837
1920DEC96
Manual Shift Overall Test Connections, Ports, and Locations
AMFWD Solenoid
BPark Brake Solenoid
CDifferential Lock Solenoid
DPark Brake Pressure Port
EDifferential Lock Pressure
Port
FTransmission Control Valve
GGearshift Lever
HOil Drain
IModel Identification Plate
JOutput Flange-to-Rear Axle
KFilter
LTransmission Pump
MRear of Transmission
NMFWD Pressure Test Port
OReverse Clutch Pressure
Test Port
PForward Clutch Pressure

Test Port
QConverter-In Relief Valve
Pressure Port
RSystem Pressure Test Port
SModulation Valve Pressure
Test Port
TReducing Valve Pressure
Test Port
UTransmission Control
Valve
VBoom Lock Pressure
Port315SE only
WBoom Lock Return
315SE only
CED,TX03399,4269 1922JUL981/1
TM1608 (20SEP06)
9020-25-3

092006
PN=403
9020
25
3
Tests
Power Shift Transmission Overall Test Connections, Ports, and Locations
T115754
1908JUN98
9020
25
4
ADifferential Lock Solenoid

BPark Brake Pressure Port
CDifferential Lock Pressure
Port
DTransmission Control
Valve
ETransmission Speed Shift
Valve
FOil Drain
GModel Identification Plate
HFilter
ITransmission Pump
JMFWD Solenoid
KMFWD Test Port
LPark Brake Solenoid
MLow Range Forward Clutch
Pressure Test Port
NConverter-In Relief Valve
Pressure Port
OModulation Valve Pressure
Test Port
PSystem Pressure Test Port
QThird Speed Clutch

Pressure Test Port
RSecond Speed Clutch
Pressure Test Port
SFirst Speed Clutch
Pressure Test Port
THigh Range Forward Clutch
Pressure Test Port
UReverse Clutch Pressure
Test Port
VReducing Valve Pressure
Test Port
WOutput Flange to Rear

Axle
XRear of Transmission
YControl Valve
ZSpeed Shift Valve
XXBoom Lock Pressure
Port 315E only
ZZBoom Lock Return Port
315E only
CED,TX03399,4243 1905JUN981/1
TM1608 (20SEP06)
9020-25-4

092006
PN=404
Tests
9020
25
5
TM1608 (20SEP06)
9020-25-5

092006
PN=405
Tests
Torque Converter Stall Speed Test

SPECIFICATIONS
Transmission/Hydraulic Oil
Temperature
65 5C (150 10F)
Engine Speed
Fast idle
Torque Converter Stall Speed
20502250 rpm
Combined Torque
Converter/Hydraulic Engine
Stall Speed
16001800 rpm
Specification
EngineSpeed ....................................................... Low and High idle
Torque ConverterStall Speed ............................... 20502250 rpm
IMPORTANT: Minimum engine speed listed is for

an engine that is broken-in and
using No. 2 fuel.
7. Combined Torque Converter Stall: Stall converter
as described above and hold a loader function over
relief. Record combine torque converter stall.

Digital Thermometer
Specification
Temperature .................................................... 65 5C (150 10F)
1. Torque Converter Stall:Install electronic

tachometer. (See procedure in this group).
9020
25
6
Observe tachometer reading while boom is raising.
2. Install digital thermometer probe into the

transmission and hydraulic sumps through the fill
tube.
Specification
Combined Torque
Converter/Hydraulic Engine
Stall Speed ............................................................... 16001800 rpm
3. Heat oil to specifications.

8. If converter stall speed is low, check for:
Specification
Temperature .................................................... 65 5C (150 10F)
(See Transmission Warm-Up Procedure in this Group

and Hydraulics Warm-Up Procedure in Group
9025-25.)
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.
4. With machine off the ground. Put transmission in
third gear.
Low engine output. See Group 9010-25.

Incorrect torque converter. Check part number
through inspection hole in bottom of transmission
housing, number should be either 247001 or
4168-028-209.
Failed freewheel clutch in torque converter.
9. If converter stall speed is too high, check for:
5. Apply and hold service brakes throughout test.

6. Cycle from low idle to high idle with service brakes
engaged. The highest stabilized speed measured is
converter stall speed.
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 transmission
housing, number should be either 247001 or
4168-028-209.
. See Group 9010-25.
Converter failed.
Failed transmission clutch pack.
Low system (pump) pressure in transmission.
TX,9020,BA2161 1910NOV971/1
TM1608 (20SEP06)
9020-25-6

092006
PN=406
Tests
Converter-In Relief Valve Test

SPECIFICATIONS
Oil Temperature at Sump
65 5C (150 10F)
Engine Speed
2375 + 25 - 0 rpm
Converter-in Relief Valve

Pressure
800 + 200 kPa (8 + 2 bar) (116 +

29 psi)
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler
Gauge 02000 kPa (020 bar) (0300 psi)
1. Remove floor panel in cab or ROPS.

2. Install adapter and gauge in port (A).
UN12JUL96
3. Install digital thermometer probe into sump using

dipstick tube. Warm transmission oil, see procedure in
this group.
T101750
Specification
OilTemperature at Sump .................................... 65 5C (150 10F)
4. Put FNR lever in neutral.

IMPORTANT: DO NOT exceed 1000 kPa (10 bar) (145
psi) or converter damage could result.
5. Slowly increase rpm until maximum pressure is
reached on gauge.
Specification
EngineSpeed .................................................................... 2375 + 25 - 0
Converter-In Relief Valve
Pressure ............................................... 800 + 200 kPa (8 + 2 bar) (116 +
29 psi)
6. If maximum pressure is reached at low idle, check for

a plugged cooler. Back flush using an oil caddy or
replace cooler.
7. If pressure is too high, remove relief valve.
Disassemble, clean and inspect valve.
8. If pressure is low, check for weak or broken spring and
scored or sticking valve.
TM1608 (20SEP06)
9020-25-7
TX,25,SS3155 1915MAY981/2

092006
PN=407
9020
25
7
Tests
9. Install and check relief valve after repair.
TX,25,SS3155 1915MAY982/2
9020
25
8
TM1608 (20SEP06)
9020-25-8

092006
PN=408
Tests
Brake Valve Leakage Test

SPECIFICATIONS
Brake Valve Leakage
Pressure drops more than 100

psi in 30 seconds with brake
pedal applied
Brake Pedals Released Pressure
ESSENTIAL TOOLS
AJT03455 (7/16 M JIC x 4 F ORFS) Fitting
B38H1029 (4 M x 4 F x 4 M ORFS) (Parker No. 4R6LO-S)
Tee
38H1352 (4 ORFS) Nut (2 Used)
38H1138 (4 ORFS) Plug (2 Used)
(C) Gauge 06895 kPa (069 bar) (01000 psi)
UN19SEP96
1. Heat oil. See Hydraulic Oil Warm-up in Group 9025-25.

2. Stop engine.
T102934
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 clamp. Tee gauge (C) at
brake valve line of pedal that settled.
AFitting
BTee
CGauge
5. Push brake pedal down and block in place to set

gauge at 500 psi starting point.
6. Monitor gauge. If pressure drops more than 100 psi in
30 seconds, excessive leakage is indicated.
Specification
Brake ValveLeakage .............................. Pressure drops more than 100
psi in 30 seconds with brake
pedal applied
NOTE: When pedals are release pressure should be

zero.
7. To isolate leakage, disconnect line going to axle.
Specification
Brake Pedals Released
Pressure ................................................................................................... 0
TM1608 (20SEP06)
9020-25-9
TX,25,SS3156 1915MAY981/2

092006
PN=409
9020
25
9
Tests
8. If leakage continues, replace check valve.
9. No pressure drop indicates leakage at piston seals in
axle housing. See Repair, Group 0250.
TX,25,SS3156 1915MAY982/2
9020
25
10
TM1608 (20SEP06)
9020-25-10

092006
PN=410
Tests
Park Brake Release Pressure Test

SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
1500 25 rpm
Park Brake Release Pressure
1600 + 400 kPa (16 + 4 bar) (232

+ 58 psi)
Park Brake Applied Pressure
ESSENTIAL TOOLS
D38H1032 (10 M x 10 F x 10 M ORFS) (Parker No.
10R6IO-S) Tee
BJT03458 (7/16 20 M JIC x 1-14 F ORFS 10) Adapter
APD34BTX Quick Coupler
Digital Thermometer
UN06AUG96
Gauge 03500 kPa (035 bar) (0500 psi)
T101901

this group.)
3. Make test connections.
AQuick Coupler
BAdapter
CPark Brake-to-Transmission Line
DTee

Specification
OilTemperature ................................................... 65 5C (150 10F)
(See Transmission Oil Warm-up Procedure in this group.)

5. Increase rpm to specification and record pressure
reading with park brake OFF, FNR in neutral , MFWD
engage (if equipped) and differential lock disengaged.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Park BrakeRelease Pressure .......... 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
With park brake switch ON pressure should be zero.

Specification
Park Brake AppliedPressure ................................................................ 0
TM1608 (20SEP06)
9020-25-11
TX,25,SS3157 1922JUL981/2

092006
PN=411
9020
25
11
Tests
6. If park brake pressure is not to specification, do
System Pressure Test. (See procedure in this group.) If
system pressure is OK, but park brake pressure is low,
it indicates leakage in park brake circuit. Check axle oil
level. See Section 9000, Group 4. If oil level is high
park brake piston seals may be leaking. If axle oil level
is OK, but park brake pressure is low, leakage is
indicated in transmission control valve, park brake
solenoid or gasket.
TX,25,SS3157 1922JUL982/2
9020
25
12
TM1608 (20SEP06)
9020-25-12

092006
PN=412
Tests
System Pressure Test

SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
1500 25 rpm
System Pressure
1600 + 300 kPa (16 + 3 bar) (232

+ 44 psi)
Each 1.00 mm (0.039 in.) Shim

Changes Pressure
115 kPa (1.15 bar) (16.68 psi)
ESSENTIAL TOOLS
Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)
UN12JUL96
1. Install Electronic Tachometer and Digital Thermometer,

see procedures in this group.
T101892

3. Make test connections in port (A).
Specification
See Transmission Oil Warm-up Procedure in this group.

5. With FNR lever in neutral and gear shift lever (manual
shift) in neutral. Operate machine to specifications and
record pressure.
Specification
EngineSpeed .................................................................. 1500 25 rpm
SystemPressure ............................... 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
6. If pressure is too low, run test at 80 C (176 F) if

pressure is still low check pressure regulating valve,
repair or shim adjust. A 1.00 mm (0.039 in.) shim is
equal to 115 kPa (1.15 bar) (16.68 psi) (see Pressure
Regulating Valve Adjustment in repair manual).
TM1608 (20SEP06)
9020-25-13
CED,TX03399,4265 1922JUL981/2

092006
PN=413
9020
25
13
Tests
Specification
ChangesPressure .................................. 115 kPa (1.15 bar) (16.68 psi)
If adjustment does not raise pressure, do Transmission

Pump Flow Test see procedure in this group.
7. If pressure is too high redo test using 80 C (176 F)
temperature. If pressure is still to high check pressure
regulating valve, repair or shim adjust.
Specification
ChangesPressure .................................. 115 kPa (1.15 bar) (16.68 psi)
Make sure test was performed at correct specifications.
CED,TX03399,4265 1922JUL982/2
9020
25
14
TM1608 (20SEP06)
9020-25-14

092006
PN=414
Tests
Manual Shift Forward and Reverse Clutch

Pressure Test
SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
1500 25 rpm
Forward or Reverse Pressure
1600 + 300 kPa (16 + 3 bar) (232

+ 44 psi)
Neutral Disconnect De-Activated

Pressure
ESSENTIAL TOOLS
Digital Thermometer
UN12JUL96
Gauge 03500 kPa (035 bar) (0500 psi)

this group.)
T101895

3. Make test connections in port (A) forward or (B)
reverse.
Forward Clutch Test Port

Specification
(See Transmission Oil Warm-Up procedure in this group.)
NOTE: Forward and reverse pressures should be the

same.
5. Gear shift lever in neutral and park brake OFF and
FNR lever in forward or reverse, record pressure
gauge readings.
T101896
UN12JUL96
Specification
EngineSpeed .................................................................. 1500 25 rpm
Forward or ReversePressure........... 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
Reverse Clutch Test Port

TM1608 (20SEP06)
9020-25-15
CED,TX03399,4232 1915MAY981/2

092006
PN=415
9020
25
15
Tests
6. Low pressure in one direction indicates leakage in that
pack or solenoid. Low pressure in both directions
indicates low system pressure. (Do System Pressure
Test in this group.)
7. With FNR lever in neutral, a slight pressure recorded in
either the forward or reverse test port could indicate
that the ball in the clutch shaft came out (lube
passage) or a problem with the control valve. Repair
clutch pack, see Group 0350. Repair control valve, see
Group 0360.
NOTE: When neutral disconnect is de-activated pressure

should be zero.
Specification
Neutral Disconnect
De-ActivatedPressure ........................................................................... 0
9020
25
16
CED,TX03399,4232 1915MAY982/2
TM1608 (20SEP06)
9020-25-16

092006
PN=416
Tests
Power Shift Low Range Forward, High Range

Pressure Test
SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
1500 25 rpm
Forward or Reverse Pressure
1600 + 300 kPa (16 + 3 bar) (232

+ 44 psi)
Neutral Disconnect De-Activated

Pressure
ESSENTIAL TOOLS
Digital Thermometer
UN21MAY98
Gauge 03500 kPa (035 bar) (0500 psi)
T115471

this group.)
3. Make test connection in appropriate port (A, B, C, D, E
or F).
ALow Range Forward Clutch Pressure Test Port

BReverse Clutch Pressure Test Port
CHigh Range Forward Clutch Pressure Test
Port
DFirst Speed Clutch Pressure Test Port
ESecond Speed Clutch Pressure Test Port
FThird Speed Clutch Pressure Test Port

Specification
NOTE: All clutch pressures should be the same.

5. Machine off ground. Engine speed at specifications
and park brake OFF and FNR lever in forward or
reverse, record pressure in all speed ranges.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Forward or ReversePressure........... 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
TM1608 (20SEP06)
9020-25-17
CED,TX03399,4233 1915MAY981/2

092006
PN=417
9020
25
17
Tests
6. Low pressure in one direction indicates a leakage in
that pack or solenoid. Low pressure in both directions
indicates a leakage in the speed clutch or low system
pressure. (Do System Pressure Test in this group.)
7. With FNR lever in neutral, a slight pressure recorded in
either the forward or reverse test port could indicate
that the ball in the clutch shaft came out (lube
passage) or a problem in control valve. Repair clutch
pack, see Group 0350. Repair control valve, see Group
0360.
8. With FNR lever in neutral, pressure recorded in the
speed clutch test ports could indicate a problem with
the time delay relay. See Group 9015-15.
NOTE: When neutral disconnect is de-activated pressure

should be zero.
9020
25
18
Specification
Neutral Disconnect
De-ActivatedPressure ........................................................................... 0
CED,TX03399,4233 1915MAY982/2
TM1608 (20SEP06)
9020-25-18

092006
PN=418
Tests
Reducing Valve Pressure Test

SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
1500 25 rpm
Reducing Valve Pressure
8501050 kPa (8.510.5 bar)

(123152 psi)
ESSENTIAL TOOLS
Digital Thermometer
Gauge 02000 kPa (020 bar) (0300 psi)
UN22AUG96
1. Install Electronic Tachometer and Digital Thermometer,

see procedure in this group
T101897

Specification

shift) in neutral. Operate machine to specifications and
record pressure.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Reducing ValvePressure ...................... 8501050 kPa (8.510.5 bar)
(123152 psi)
6. If reducing valve pressure is not to specification do

System Pressure Test in this group. If system pressure
is OK, but reducing valve pressure is low, it indicates a
leak in the circuit. See repair Group 0360.
7. If pressure is too high check reducing valve for sticky
spool or binding. See repair manual, Group 0360.
Make sure test was performed at correct specifications.
CED,TX03399,4266 1922JUL981/1
TM1608 (20SEP06)
9020-25-19

092006
PN=419
9020
25
19
Tests
Modulation Valve Pressure Test

SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
1500 25 rpm
Neutral Pressure
270300 kPa (2.73 bar) (39

44 psi)
System Modulated (Final)

Pressure
1600 + 300 kPa (16 + 3 bar) (232

+ 44 psi)
NeutralModulation Phase
Pressure
3001200 kPa (312 bar) (44

174 psi)
Modulation Valve Pressure Test

Shift Time
Neutral into gear 01600 kPa

(016 bar) (0232 psi) in 2
seconds and from
Forward/Reverse or
Reverse/Forward into a gear 1.7
seconds Maximum

Changes Pressure
42 kPa (0.42 bar) (6.09 psi)
Parker No. 4M10C80MX (7/16-20 37 x M10 x 1) Elbow (Manual Shift

Only)
T101898
9020
25
20
UN12JUL96
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) Diagnostic Coupler (Power Shift Only)
Parker No. PD348 Diagnostic Coupler (Manual Shift Only)

Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)

this group.)
Specification
TM1608 (20SEP06)
9020-25-20
TX,25,SS3170 1927JAN001/2

092006
PN=420
Tests
5. FNR lever in neutral, record pressure reading.
Specification
EngineSpeed .................................................................. 1500 25 rpm
NeutralPressure ......................................... 270300 kPa (2.73 bar)
(3944 psi)
NOTE: Forward and reverse pressures should be the

same.
6. Machine off the ground. FNR lever in forward or
reverse, record pressure gauge readings.
Specification
EngineSpeed .................................................................. 1500 25 rpm
System Modulated (Final)
Pressure .............................................. 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
NeutralModulation Phase
Pressure ......................................................... 3001200 kPa (312 bar)
(44174 psi)
7. If total shift time from 01600 kPa (016 bar) (0

232 psi) takes more than specifications while doing this
test, it indicates a problem in the modulation valve.
9020
25
21
Specification
Modulation Valve Pressure
TestShift Time ........................................ Neutral into gear 01600 kPa
(016 bar) (0232 psi) in 2
seconds and from
Forward/Reverse or
Reverse/Forward into a gear 1.7
seconds Maximum
8. If shift is slow (long modulation time only), and neutral

pressure is between 270300 kPa (2.73 bar) (39
44 psi) orifice in modulation circuit is restricted. If shift
is hard or neutral pressure is high, orifice is oversized,
loose or missing. If shift is long (hesitation or long fill
time) or neutral pressure is low, spring is weak, orifice
is plugged. A shim 1 mm (0.039 in.) is equal to 42 kPa
(0.42 bar) (6.09 psi), see repair manual for modulation
shim adjustment if modulation shift is not acceptable.
See Group 0360. Clean orifice, see Group 0360.
Specification
ChangesPressure ...................................... 42 kPa (0.42 bar) (6.09 psi)
TX,25,SS3170 1927JAN002/2
TM1608 (20SEP06)
9020-25-21

092006
PN=421
Tests
Differential Lock Pressure Test

SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
1500 25 rpm
Differential Lock Pressure
1600 + 400 kPa (16 + 4 bar) (232

+ 58 psi)
ESSENTIAL TOOLS
38H1022 (1/4 M x 1/4 F x 1/4 M) (Parker No. 4R6LO-S) Tee
PD34BTX Quick Coupler
JT03455 (7/16 20 M JIC x 9/16 18 x 4 F ORFS) Adapter
Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)
UN16JUL96
T101983
9020
25
22
1. Install tachometer and thermometer (See procedure in

this group.).

4. Heat oil to specifications. (See Transmission Oil
Warm-Up procedure in this group.)
ATee
BQuick Coupler
CAdapter
DTransmission-to-Differential Lock Rear Axle
Hose
Specification
5. Engage MFWD and the park brake.

6. Increase rpm to specification and record pressure
reading with differential lock pedal switch pressed
down.
Specification
EngineRPM ............................................................................. 1500 25
Differential LockPressure ..................... 1600 + 400 0 kPa (16 + 4 0
bar) (232 + 58 0 psi)
TM1608 (20SEP06)
9020-25-22
TX,25,SS3165 1925JAN001/2

092006
PN=422
Tests
NOTE: When differential lock pedal switch is released
pressure should be zero.
7. If differential pressure is not to specification, do System
Pressure Test. (See procedure in this group). If system
pressure is OK but differential lock pressure is low, a
leak in the circuit is indicated. (See Group 0360 in
Repair Manual.)
Check axle oil level. (See Group 900004.) If oil level
is high, seals may be leaking. If axle oil level is OK but
differential lock pressure is low, leakage is indicated in
transmission control valve, differential lock solenoid, or
gasket.
TX,25,SS3165 1925JAN002/2
9020
25
23
TM1608 (20SEP06)
9020-25-23

092006
PN=423
Tests
Boom Lock Valve Leakage Test315SE

65 5C (150 10F)
Engine Speed
1500 25 rpm
Boom Lock Valve Pressure
1600 + 300 kPa (16 + 3 bar) (232

+ 44 psi)
Boom Lock Valve Maximum

Leakage
125 ml (4.2 oz) per minute
X9811
Oil Temperature
UN23AUG88
SPECIFICATIONS

Digital Thermometer
Measuring Beaker
UN20DEC96
1. Install tachometer and thermometer. (See procedures

in this Group.)
Specification
T105774
9020
25
24
(See Transmission Oil Warm-Up Procedure in this

Group.)
3. Put FNR lever in neutral and engage park brake.
Lower backhoe to the ground.
TM1608 (20SEP06)
9020-25-24
TX,9020,BA2170 1905JUN981/2

092006
PN=424
Tests

fluids.
4. Stop engine and operate controls to relieve pressure in
hydraulic system.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Boom Lock ValvePressure .............. 1600 + 300 kPa (16 + 3 bar) (232
+ 44 psi)
9020
25
25
5. Remove return line (A) and install plug in hose end.

Connect a hose to open fitting and put other end into
measuring beaker.
6. Start machine and operate for one minute.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Measure oil. If leakage is excessive, replace O-ring or

replace valve as necessary.
Specification
Boom Lock ValveMaximum
Leakage ........................................................... 125 ml (4.2 oz) per minute
See repair manual.
TX,9020,BA2170 1905JUN982/2
TM1608 (20SEP06)
9020-25-25

092006
PN=425
Tests
MFWD Pressure TestIf Equipped

SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
1500 rpm
MFWD Pressure
1600 + 400 kPa (16 + 4 bar) (232

+ 58 psi)
ESSENTIAL TOOLS
AT202955 (Parker No. PD357) (M10 x 1.0 ORB) Diagnostic Coupler

Digital Thermometer
Gauge 03500 kPa (035 bar) (0500 psi)

this group.)
UN12JUL96

T101916
9020
25
26

Specification

5. Increase rpm to specifications and record pressure
reading with MFWD switch OFF, park brake engaged
and differential lock disengaged.
Specification
EngineSpeed ........................................................................... 1500 rpm
MFWDPressure................................ 1600 + 400 kPa (16 + 4 bar) (232
+ 58 psi)
NOTE: When MFWD switch is ON pressure should be

zero.
6. If pressure is low, check System Pressure, see
procedure in this group. If low, leakage in MFWD
circuit is indicated . Possible locations include the
delivery tube (inside case), the MFWD piston seal, the
transmission control valve gasket, or the MFWD
solenoid.
TX,25,SS3166 1927JAN001/1
TM1608 (20SEP06)
9020-25-26

092006
PN=426
Tests
9020
25
27
TM1608 (20SEP06)
9020-25-27

092006
PN=427
Tests
Cooler In and Cooler Out Pressure Test

SPECIFICATIONS
65 5C (150 10F)
Engine Speed
1500 25 rpm
Cooler In Pressure
248 35 kPa (2.48 0.35 bar)

(36 5 psi)
Cooler Out Pressure
159 35 kPa (1.59 0.35 bar)

(23 5 psi)
Normal Cooler Pressure

Difference (Drop)
90 35 kPa (0.90 0.35 bar) (13

5 psi)
Maximum Allowable Cooler

Pressure Difference (Drop)
165 35 kPa (1.65 0.35 bar)

(85 5 psi)
Normal Cooler Flow
38 1 L/min (10 0.264 gpm)
Minimum Cooler Flow
25 1 L/min (6.6 0.264 gpm)

ESSENTIAL TOOLS
C(3/4 F NPT x 3/4 F NPT x 3/4 F NPT) Tee (2 Used)

UN10SEP96
D(7/8 pipe x -6 ORS) Adapter

EJT03456 (7/16-20 M JIC x 11/16-16 F ORFS) Adapter
FPD34BTX Quick Coupler
G(3/4 M NPT x 3/4) Barb Fitting (2 Used)
T103078
9020
25
28

Air Conditioning Option Shown
Digital Thermometer
AFlow Meter
BHose Piece (2 used)
CTee (2 used)
DAdapter
EAdapter
FQuick Coupler
GBarb Fitting
Gauge 02000 kPa (020 bar) (0300 psi) (2 Used)

AFlow Meter
BHose Piece (2 Used)
1. Install Electronic Tachometer, see procedure in this

group.
2. Install digital thermometer probe into sump using
dipstick tube.
Specification
OilTemperature at Sump .................................... 65 5C (150 10F)
TM1608 (20SEP06)
9020-25-28
CED,TX03399,4244 1905JUN981/2

092006
PN=428
Tests
shift only) in neutral. Operate machine to specifications
and record pressure.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Cooler InPressure ................................. 248 35 kPa (2.48 0.35 bar)
(36 5 psi)
Cooler OutPressure .............................. 159 35 kPa (1.59 0.35 bar)
(23 5 psi)
Normal CoolerPressure
Difference (Drop) .................................. 90 35 kPa (0.90 0.35 bar) (13
5 psi)
Maximum Allowable Cooler
Pressure Difference (Drop) ...................... 165 35 kPa (1.65 0.35 bar)
(85 5 psi)
Standard Cooler-Normal Cooler
Flow ........................................................... 38 1 L/min (10 0.264 gpm)
Standard Cooler-Minimum
CoolerFlow ............................................ 25 1 L/min (6.6 0.264 gpm)
6. If cooler restriction is high, inspect cooler hoses and

cooler for damage. If no damage found, clean cooler
using oil caddy.
9020
25
29
7. If cooler pressures are low, see Solenoid Circuit

Leakage Test in this group.
8. Check cooler pressures in all shift. If pressure is low,
FNR solenoid or pump problems are indicated. Pump
stop sleeve may be blocking flow to torque converter
or torque converter may be plugged. Do Torque
Converter Stall in this group.
CED,TX03399,4244 1905JUN982/2
TM1608 (20SEP06)
9020-25-29

092006
PN=429
Tests
Solenoid Circuit Leakage Test

NOTE: Do Cooler In and Cooler Out Pressure Test in
conjunction with this test.
SPECIFICATIONS
65 C (150 F )
Engine Speed
900 + 25 - 0 rpm
If cooler pressures are low from the Cooler In and Cooler

Out Pressure Test do the following test.
1. Install test equipment, see Cooler In and Cooler Out
Pressure Test in this group.
2. Heat oil to specification. See procedure in this group.
Specification
OilTemperature at Sump ............................................... 65 C (150 F )
9020
25
30
3. Machine off the ground. FNR lever in neutral and gear

shift lever (manual shift only) in neutral, operate
machine to specifications. Record pressures and flows
in forward, high range forward (power shift only)
reverse, neutral, speed clutches (power shift only),
MFWD, differential lock and park brake.
Specification
EngineSpeed ............................................................... 900 + 25 - 0 rpm
There should be a momentary fluctuation in pressure/flow

if circuit is normal. If pressure and cooler pressure in and
out and flow remains down, this indicates a leakage in
that circuit. See 9015-15 to check solenoids.
CED,TX03399,4268 1922JUL981/1
TM1608 (20SEP06)
9020-25-30

092006
PN=430
Tests
9020
25
31
TM1608 (20SEP06)
9020-25-31

092006
PN=431
Tests
Pump Flow Test

SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
1500 25 rpm
New Pump Flow
42 L/min (11.2 gpm)
Used Pump Flow
36 L/min (9.5 gpm)

ESSENTIAL TOOLS
AJDG596 Filter Adapter

JDG596A1 Spacer and Sealing Washer Kit
BFlowmeter
IMPORTANT: On early machines use the washers and

spacer to make filter adapter fit. This
will keep filter from leaking. On later
machines just use the filter adapter.
T102857
9020
25
32
UN07AUG96
Digital Thermometer
1. Make test connections. When installing filter adapter

use a washer on both sides of spacer on early
machines.
2. Install electronic tachometer and digital thermometer.
(See procedure in this group.)
IMPORTANT: Before starting engine, check that
flowmeter loading valve is open. Pump
can be damaged if engine is started
with loading valve closed.
Specification
(See Transmission Oil Warm-up Procedure in this group.)

4. Run engine at test specification.
Specification
EngineSpeed .................................................................. 1500 25 rpm
Measure flow.
TM1608 (20SEP06)
9020-25-32
TX,25,SS3207 1922JUL981/2

092006
PN=432
Tests
Specification
PumpFlow .............................................................. 42 L/min (11.2 gpm)
5. Low transmission pump flow can be caused by:
Low oil level in transmission

Cold transmission oil
Plugged intake tube
Air leak in pump suction tube
Pump mounting cap screws loose
Worn transmission pump
TX,25,SS3207 1922JUL982/2
9020
25
33
TM1608 (20SEP06)
9020-25-33

092006
PN=433
Tests
9020
25
34
TM1608 (20SEP06)
9020-25-34

092006
PN=434
Section 9025
Hydraulic System
Contents
Page
Page

Open-Center Hydraulic System . . . . . . . . . . .9025-05-1
Hydraulic System Component Location . . . . .9025-05-2
Hydraulic System Component Location
315SE . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-6
Hydraulic System
Schematic-Neutral-310SE . . . . . . . . . . . .9025-05-10
Hydraulic System
Schematic-Neutral-315SE . . . . . . . . . . . .9025-05-11
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . .9025-05-12
Unloading ValveBackhoe Operation. . . . .9025-05-14
Unloading ValveLoader Operation . . . . . .9025-05-16
Hydraulic Filter Operation . . . . . . . . . . . . . .9025-05-18
Steering Valve Operation . . . . . . . . . . . . . .9025-05-19
Priority Valve Operation . . . . . . . . . . . . . . .9025-05-22
Ride Control Hydraulic Component Location
Circuit-Off . . . . . . . . . . . . . . . . . . . . . . . .9025-05-24
Ride Control Valve Operation OFF
PositionContinued . . . . . . . . . . . . . . . .9025-05-26
Ride Control Hydraulic Component Location
Circuit-On Position . . . . . . . . . . . . . . . . . .9025-05-28
Ride Control Valve Operation ON
Position-Continued. . . . . . . . . . . . . . . . . .9025-05-30
Dual Stage System Relief Valve (310SE
and [315SE (S.N. 870248)] . . . . . . . . .9025-05-32
System Relief Valve (S.N. 943225) . . . . .9025-05-34
System Relief Valve (S.N. 943226) . . . . .9025-05-36
Circuit Anti-Cavitation Valve . . . . . . . . . . . .9025-05-37
Circuit Relief Valve without
Anti-Cavitation . . . . . . . . . . . . . . . . . . . . .9025-05-38
Circuit Relief Valve with Anti-Cavitation. . . .9025-05-39
Circuit Relief Valve with Anti-Cavitation
Continued . . . . . . . . . . . . . . . . . . . . . . . .9025-05-40
Loader Bucket Valve SectionBucket
Rollback Position . . . . . . . . . . . . . . . . . . .9025-05-42
Loader Boom Valve SectionBoom Raise
Position . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-44
Loader Auxiliary Valve Section-Neutral . . . .9025-05-46
Stabilizer Valve Operation . . . . . . . . . . . . . .9025-05-48
Backhoe Valve
Auxiliary Flow Control Section . . . . . . . .9025-05-50
Backhoe Valve Swing Section-Left . . . . . . .9025-05-56
Backhoe Valve Boom Section-Boom
Lower Position . . . . . . . . . . . . . . . . . . . . .9025-05-58
Backhoe Valve Bucket Section-Bucket
Curl Position . . . . . . . . . . . . . . . . . . . . . .9025-05-60
Backhoe Valve Crowd SectionCrowd

Out Position . . . . . . . . . . . . . . . . . . . . . . .9025-05-62
Backhoe Valve Auxiliary SectionNeutral
Position . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-64
Backhoe Valve Regenerative Outlet
Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-66
Sideshift Lock Solenoid Valve315SE . . . .9025-05-69
TM1608 (20SEP06)

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 Problems. . . . . .9025-15-3
Group 20Adjustments
Loader Bucket Self-Leveling Linkage
Indicator and Return-to-Dig Switch
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .9025-20-1
Loader Control Valve Linkage Adjustment. . .9025-20-4
Backhoe Valve Linkage Adjustment . . . . . . .9025-20-6
Dual Stage System Relief AdjustmentDual
Stage System Relief Valve (310SE and
[315SE (S.N. 870248)] . . . . . . . . . . . . . .9025-20-8
Stabilizer Valve Linkage Adjustment . . . . . .9025-20-10
Group 25Tests
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Hydraulic Oil Warm-Up Procedure. . . . . . . . .9025-25-2
Loader and Backhoe System Relief
Pressure Test . . . . . . . . . . . . . . . . . . . . . .9025-25-3
Steering Load Sense Relief Test. . . . . . . . . .9025-25-6
Pump Unloading Valve Relief Pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-7
Main and Auxiliary Pump Flow Test . . . . . . .9025-25-9
Hydraulic Oil Cooler Restriction Test. . . . . .9025-25-12
Charging the Ride Control Accumulator . . .9025-25-13
Charging the Ride Control
AccumulatorProcedure A (14.2 in.
accumulator) . . . . . . . . . . . . . . . . . . . . . .9025-25-15
9025-1

092006
PN=1
9025
Contents
Page
Charging the Ride Control

AccumulatorProcedure B (17.2 in.
accumulator) . . . . . . . . . . . . . . . . . . . . . .9025-25-16
Ride Control Accumulator (If Equipped)
Discharge Procedure . . . . . . . . . . . . . . . .9025-25-18
Circuit Relief Valve Test with Remote
Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-19
Steering System Leakage Test . . . . . . . . . .9025-25-21
Steering Cylinder Leakage Test . . . . . . . . .9025-25-25
Hydraulic Cylinder Drift Test Procedure. . . .9025-25-27
Function Drift Test. . . . . . . . . . . . . . . . . . . .9025-25-28
Cylinder Leakage Test . . . . . . . . . . . . . . . .9025-25-31
Stabilizer Valve Lockout Leakage Test . . . .9025-25-32
Sideshift Valve Leakage Test315SE . . . .9025-25-33
Cycle Time Specifications . . . . . . . . . . . . . .9025-25-35
9025
TM1608 (20SEP06)
9025-2

092006
PN=2
Group 05
Theory of Operation
Open-Center Hydraulic System
NEUTRAL
ACTIVATED
BReturn Oil (Pressure free)

CTrapped Oil
NOTE: This illustration is for example only.

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
hydraulic pump supplies a constant flow of oil. This
pressure oil (A) must have a path for return when it is
not required to operate a function.
A power passage (F) in the valve allows pressure oil to
flow to all the control valve sections regardless of their
spool positions.
DInlet (From pump)
T111630
T111630
APressure Oil (From

hydraulic pump)
1929OCT97
9025
05
1
EPower Passage
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.
With spool moved to activate a function, pressure oil

flows to that function. Without a power passage, no
TX,9025,RR7281 1915MAY961/1
TM1608 (20SEP06)
9025-05-1

092006
PN=437
Theory of Operation
Hydraulic System Component Location
T111644
1929OCT97
9025
05
2
310SE Backhoe Hydraulic Component Location

TM1608 (20SEP06)
9025-05-2
TX,9025,RR7282 1922AUG961/3

092006
PN=438
Theory of Operation
1Bucket Cylinder
2Crowd Cylinder
3Boom Cylinder
4Backhoe Valve
5From Auxiliary Pump
6From Stabilizer Valve
7To Auxiliary Function

8To Right Swing Cylinder
9To Left Swing Cylinder
10Extendible Dipperstick
Cylinder
TX,9025,RR7282 1922AUG962/3
9025
05
3
TM1608 (20SEP06)
9025-05-3

092006
PN=439
Theory of Operation
T111645 1907NOV97
310SE Main Hydraulic System Component Location
TX,9025,RR7282 1922AUG963/3
TM1608 (20SEP06)
9025-05-4

092006
PN=440
Theory of Operation
9025
05
5
TM1608 (20SEP06)
9025-05-5

092006
PN=441
Theory of Operation
Hydraulic System Component Location315SE
T105709
1907JAN97
9025
05
6
315SE Backhoe Hydraulic Component Location

TM1608 (20SEP06)
9025-05-6
EX,9025,BG100 1927MAR001/4

092006
PN=442
Theory of Operation
1Backhoe Valve
26Bucket Cylinder
27Crowd Cylinder
28From Auxiliary Pump

29Boom Cylinder
30From Stabilizer Valve
33To Sideshift Locks

34Extendible Cylinder
35Backhoe
Hydraulic-Component
Location
38Bulkhead
EX,9025,BG100 1927MAR002/4
9025
05
7
TM1608 (20SEP06)
9025-05-7

092006
PN=443
Theory of Operation
T111646 1907NOV97
TM1608 (20SEP06)
9025-05-8
EX,9025,BG100 1927MAR003/4

092006
PN=444
Theory of Operation
1Backhoe Valve
2Stabilizer Valve
3auxiliary Hydraulic Pump
4Hydraulic Oil Filter
5Main Hydraulic Pump
6Orifice
7Hydraulic Oil Reservoir
8Brake Valve
9Steering Valve
10Bucket Cylinder
11Hydraulic Oil Cooler

12Front Axle
13Transmission
14Loader Cylinder
15Priority Valve
16Loader Valve
17Dual Stage System Relief
18Backhoe Sensing Line
19Auxiliary Section-If
Equipped
Hydraulic oil flows from hydraulic oil reservoir (7 ) to

the larger main hydraulic pump (5) and smaller
auxiliary pump (3) that are mounted on the rear of the
transmission. Both pumps are a fixed displacement
gear type design and are driven by the transmission
input shaft.
A solenoid controlled/pressure actuated unloading
valve (20) is located between the pump sections to
control the flow of oil from the auxiliary pump. When
the Forward-Neutral-Reverse (FNR) lever is in forward
or reverse position for use of the loader or to drive the
machine, the solenoid controlled unloading valve
routes the flow of oil from the auxiliary pump directly
back to main pump inlet. Consequently, the power
requirement for the hydraulic system operation is
reduced.
Pressure oil from the pump flows to the priority valve
(15) that is located on the top of the loader control
valve (16). An adjustable steering load sense relief
valve assures that minimum pressure is provided to
steering during the use of any other hydraulic
functions. A dual stage system relief (17) limits main
pump pressure provided to operate the loader. When
the loader is not being operated, oil from the main
pump flows on to the stabilizer and backhoe control
valves. during backhoe operation, pressure oil from the
auxiliary pump (3) is routed directly to the backhoe
control valve to supplement the main pump when
system pressure is at a low to medium level. As
system pressure increases, the pressure actuated
unloading valve (20) returns auxiliary pump flow to
20Unloading Valve
21Main Hydraulic
Component Location
(Neutral)-Backhoe
Operation
22Rear Axle
23Stabilizer Cylinder
24Swing Left Cylinder
25Swing Right Cylinder
36Boom Lock Cylinder (2
Used)
37To Sideshift Frame

Pistons
38Bulkhead
39Sideshift Lock Solenoid
Valve
Valve
41Transmission
pump inlet to reduce power requirements for

hydraulics. The dual stage system relief (17) provides
a higher operating pressure for backhoe functions due
to a backhoe pressure sensing line (18) that increases
the relief valve setting as the operating pressure rises.
Return oil from the backhoe and loader valves
combine flow through the main hydraulic filter (4) and
hydraulic oil cooler (11) enroute to reservoir (7). An
orifice (6) 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 hydraulic oil cooler and then back to reservoir.
315SE OnlyThe sideshift lock solenoid valve (39)
receives pressure oil from the GP (gauge pressure)
port on the loader control valve. When pressure oil is
available at the loader valve, pressure oil is directed to
the sideshift frame lock pistons (37) through hydraulic
lines.
315SE OnlyThe boom lock solenoid valve (40) and
cylinders (36) receive pressure oil from the
transmission (41). Refer to Section 9020 for boom lock
operation.
A test port located on the priority valve (15) at the
loader inlet is provided for hydraulic diagnostics.
Steering pressure, loader relief, and backhoe relief can
be determined at this test location.
An additional test port is located on the unloading
valve which is used to check pump pressure relief.
EX,9025,BG100 1927MAR004/4
TM1608 (20SEP06)
9025-05-9

092006
PN=445
9025
05
9
Theory of Operation
Hydraulic System Schematic-Neutral-310SE

T115948 1916JUL98
2 STABILIZER VALVE
INLET END CAP
10 HYDRAULIC OIL
COOLER
9 STEERING
VALVE
8 BRAKE VALVE
SWING
)(
RIDE CONTROL
6 ORIFICE
)( )(
)(
AUXILIARY
FLOW
CONTROL
1 BACKHOE
CONTROL
VALVE
BOOM
)(
15 LOADER
VALVE
)(
)(
7 HYDRAULIC OIL
RESERVOIR
)(
5 MAIN HYDRAULIC
PUMP
3 AUXILIARY HYDRAULIC
PUMP
UNLOADING
VALVE
20
BUCKET
BOOM
18
AUXILIARY
FILTER
BYPASS
VALVE
HIGH PRESSURE OIL
MEDIUM PRESSURE OIL
SOLENOID
TRAPPED OIL
AUX
14
PRIORITY VALVE
FILTER
RESTRICTION
SWITCH
CROWD
)(
NOISE
ATTENUATOR
(CAB MACHINES
ONLY)
HYDRAULIC
FILTER
BUCKET
PRESSURE FREE OIL

OUTLET
ENDCAP
T115948
21 HYDRAULIC SCHEMATIC NEUTRAL BACKHOE OPERATION 310SE
TX,9025,RR7283 1918SEP061/1
TM1608 (20SEP06)
9025-05-10

092006
PN=446
Theory of Operation
Hydraulic System Schematic-Neutral-315SE

T115947 1916JUL98
37 SIDESHIFT
FRAME PISTONS
STABILIZER VALVE
BACKHOE
CONTROL
VALVE
10 HYDRAULIC OIL
COOLER
INLET END CAP

8
BRAKE VALVE
39 SIDESHIFT LOCK
SOLENOID VALVE
RIDE
CONTROL
7 HYDRAULIC OIL
RESERVOIR
SWING
6 ORIFICE
40 BOOM LOCK
SOLENOID VALVE
BOOM
36 BOOM LOCK
CYLINDER
15 LOADER
VALVE
41 TRANSMISSION
5 MAIN HYDRAULIC
PUMP
HYDRAULIC
FILTER
FILTER
RESTRICTION
SWITCH
BUCKET
3 AUXILIARY HYDRAULIC
PUMP
9 STEERING
VALVE
UNLOADING
VALVE
20
BUCKET
BOOM
18
AUXILIARY
MEDIUM PRESSURE OIL

NOISE ATTENUATOR
(CAB MACHINES ONLY)
21 HYDRAULIC SCHEMATIC NEUTRAL BACKHOE OPERATION 315SE
CED,TX03543,2273 1927MAR001/1
TM1608 (20SEP06)
SOLENOID
9025-05-11

092006
PN=447
TRAPPED OIL
PRESSURE FREE OIL
OUTLET
END CAP
T115947
HIGH PRESSURE OIL

AUX
14
PRIORITY VALVE
CROWD
FILTER
BYPASS
VALVE
Theory of Operation
Hydraulic Pumps
D
A
E
H
B
D
E
C
F
9025
05
12
G
O
K
M PRESSURE OIL
N INLET/RETURN OIL
T101265
P HYDRAULIC PUMPBACKHOE OPERATION
T101265
1923SEP96
Hydraulic Pumps
TM1608 (20SEP06)
9025-05-12
TX,9025,RR7284 1927OCT001/2

092006
PN=448
Theory of Operation
APump Inlet
BAuxiliary Pump Test Port
CAuxiliary Pump
DCheck Valve
EBackhoe
FUnloading Valve Housing

GMain Pump Outlet Port
HUnloading Valve Solenoid
IUnloading Valve Spool
JRelief Valve
The main hydraulic pump (L) is a fixed displacement

gear-type pump. The auxiliary pump (C) is a smaller
fixed displacement pump that is driven from the rear of
the main pump. An unloading valve housing (F) for the
auxiliary pump is located between the pump units. The
entire pump assembly is mounted on the rear of the
transmission and is driven at engine speed by the
transmission input shaft.
Oil is drawn from the hydraulic reservoir into a
common inlet port (A) located in the unloading valve
housing (F). Flow from the main pump outlet port (G)
is routed to the priority valve inlet on loader control
valve. If the loader is not being used, oil flows on to
the stabilizer and backhoe. A dual function system
relief valve is located at the priority valve and protects
the main pump during both lower pressure loader
operation and higher pressure backhoe operation.
Oil flow from the auxiliary pump is routed within the
unloading valve (F) to either the outlet port to backhoe
(E) or returns through an inlet passage (O) to pump
inlet (A) depending upon the position of the FNR lever.
During loader or transport operation with seat forward,
the unloading valve solenoid (H) is energized and
remains open. Consequently, auxiliary pump flow
returns back to inlet through the unloading spool (I)
which reduces hydraulic load requirement on engine.
KRelief Valve Adjustment

Screw
LMain Hydraulic Pump
MPressure Oil
NInlet/Return Oil
OInlet Passage
PHydraulic Pump-Backhoe
Operation
When the FNR lever in neutral position, the unloading

valve solenoid (H) is de-energized and the unloading
spool blocks auxiliary pump flow from returning to
pump inlet. Therefore, auxiliary pump supplemental oil
is provided for backhoe operation only. As backhoe
operating pressure increases to 3000 psi, the relief
valve (J) senses pressure and opens to allow auxiliary
pump flow to return to pump inlet through the
unloading spool.
Specification
Relief ValveOpening
Pressure................................................................................. 3000 psi
Since the specified pressure adjustment for the

unloading spool to open is below backhoe system
relief, the power demanded from the engine to operate
the auxiliary pump is reduced. A one way check valve
(D) within the unloading valve prevents backflow of oil
from backhoe control valve during high pressure
backhoe operation. The external relief valve adjusting
screw (K) is used to control the opening of the
unloading spool. Pressure can be checked at test port
(B) located on the auxiliary pump housing.
TX,9025,RR7284 1927OCT002/2
TM1608 (20SEP06)
9025-05-13

092006
PN=449
9025
05
13
Theory of Operation
Unloading ValveBackhoe Operation

A MAIN PUMP FLOW
AUX. PUMP FLOW H
B CHECK
VALVE
UNLOADING G
RELIEF
VALVE
C PRESSURE
SENSING
ORIFICE
D UNLOADING
SPOOL
PUMP F
INLET
TO BACKHOE
E SOLENOID VALVE
TO LOADER CONTROL VALVE
9025
05
14
A
F
G
C
D
I HIGH PRESSURE OIL

J RETURN OIL
T101457
L UNLOADING VALVE - BACKHOE OPERATION (BELOW 3000 P.S.I.)
1923SEP96
T101457
Backhoe Operation (Below 3000 psi)

TM1608 (20SEP06)
9025-05-14
TX,9025,RR7285 1931MAY961/2

092006
PN=450
Theory of Operation
AMain Pump Flow
BCheck Valve
CPressure Sensing Orifice
DUnloading Spool
ESolenoid Valve
FPump Inlet
GUnloading Relief Valve
Hauxiliary Pump Flow
Oil flow from the auxiliary pump is controlled by the

unloading valve (L) during different type of operating
conditions. Key elements involved include solenoid
valve (E), relief valve (G), unloading spool (D),
pressure sensing orifice (C) and check valve (B).
During loader operation, auxiliary pump oil flow is
returned to main pump inlet through the unloading
spool (D). When the FNR lever is in the neutral
position, the solenoid valve (E) is de-energized and
blocks oil that flows through the pressure sensing
orifice (C) to pump inlet passage. Consequently,
system operating pressure up to 3000 psi is trapped
between the spring end of unloading spool (D),
solenoid valve (E), and relief valve (G). Since the
same pressure exists on both ends of the spool, spring
force holds the unloading spool to the right. In this
position, the spool blocks pump outlet passage (H)
from the passage which is connected to pump inlet (F).
During this condition, auxiliary pump flow is routed
past the one-way check valve (B) to supplemental
main pump flow (A) during backhoe operation.
IHigh Pressure
JReturn Inlet Oil
KRelief Valve Adjustment
Screw
LUnloading Valve-Backhoe
Operation (below 3000 psi)
As operating pressure increases above 3000 psi, the

relief valve (G) opens and trapped oil after the orifice
(C) flows to pump inlet.
Specification
Relief ValveOpening
Pressure................................................................................. 3000 psi
Since a pressure drop occurs after the orifice

restriction (C), the pressure on the spring end of the
unloading spool is lower than the pressure on back
side of spool before the orifice. Higher pressure
overcomes spring force and moves the unloading
spool (D) left to open position which allows the return
of auxiliary pump flow back to pump inlet. Check valve
(B) closes to prevent backhoe pressure from unloading
the auxiliary pump oil to pump inlet. The relief valve
adjusting screw (K) is used to regulate the pressure
which allows auxiliary pump flow to be routed back to
pump inlet.
9025
05
15
TX,9025,RR7285 1931MAY962/2
TM1608 (20SEP06)
9025-05-15

092006
PN=451
Theory of Operation
Unloading ValveLoader Operation

A MAIN PUMP FLOW
AUX. PUMP FLOW H
B CHECK
VALVE
UNLOADING G
RELIEF
VALVE
C PRESSURE
SENSING
ORIFICE
D UNLOADING
SPOOL
PUMP F
INLET
TO BACKHOE
E SOLENOID VALVE
TO LOADER CONTROL VALVE
9025
05
16
A
F
I HIGH PRESSURE OIL

D
J RETURN OIL
T101458
K UNLOADING VALVE - LOADER OPERATION
1923SEP96
T101458
Loader Operation
TM1608 (20SEP06)
9025-05-16
TX,9025,RR7286 1916JUL961/2

092006
PN=452
Theory of Operation
AMain Pump Flow
BCheck Valve
CPressure Sensing Orifice
DUnloading Spool
ESolenoid Valve
FMain Pump Inlet
GUnloading Relief Valve

HAuxiliary Pump Flow
IHigh Pressure
When the FNR lever is in forward or reverse position,

the solenoid valve (E) is energized and opens a path
to main pump inlet for oil between unloading spool (D)
and relief valve (G). Since pressure increase is
prevented from occurring on the spring end of the
unloading spool (D), a pressure imbalance is created
which forces the spool left against the spring. When
the spool is held in the open position, auxiliary pump
flow (H) returns back to main pump inlet (F).
JReturn Inlet Oil

KUnloading Valve-Loader
Operation
Power requirement from the engine is reduced to

operate loader operating condition because auxiliary
pump flow is routed back to main pump inlet. System
operating pressure is not affected by operation of the
unloading spool.
TX,9025,RR7286 1916JUL962/2
9025
05
17
TM1608 (20SEP06)
9025-05-17

092006
PN=453
Theory of Operation
Hydraulic Filter Operation

A
P
INLET
I
INLET
A
HOUSING
B PISTON
C
J
G BYPASS
VALVE
A
NORMAL OPERATION
SPRING
D
SPRING F
H TERMINAL
I ELEMENT
J
TO
RESERVOIR
T101460
AInlet Port
BFilter Housing
CPiston
DSpring
L RESTRICTED FLOW
INDICATOR LIGHT
ON AND BYPASS OIL
K
OUTLET
O RETURN FILTER
FSpring
GValve
HTerminal
IFilter Element
N RETURN FLOW
JTo Cooler and Reservoir

KOutlet Port to Reservoir
LRestricted flow
MSemi-Restricted Flow
The hydraulic return filter removes contaminants from

the hydraulic system oil. The filter housing contains a
bypass valve (G) and a filter restriction switch (P).
Under normal operation, return flow from the loader
valve, stabilizer valve and backhoe valve enters the
inlet (A), flows through the filter element (I), through
the filter canister and out the outlet (K) to reservoir, or
to cooler and then to reservoir (J).
NReturn Flow
OReturn Filter
PFilter Restriction Switch
If the pressure differential between the inlet and outlet

increases past a set level due to cold oil or a partially
restricted filter element, pressure drop across the filter
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.
TM1608 (20SEP06)
M SEMI-RESTRICTED
FLOW INDICATOR
LIGHT ON
T101460
9025
05
18
1910SEP98
9025-05-18
TX,9025,RR7516 1930SEP961/2

092006
PN=454
Theory of Operation
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. This bypass
valve differential pressure setting is slightly higher than
the indicator light switch, therefore, the indicator light
will always glow just before oil begins to bypass the
filter element.
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,RR7516 1930SEP962/2
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 the 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.
5
6
When steering, the steering valve blocks leakage to the

priority valve, which increases steering pressure.
9025
05
19
2
3
T80788
T80788
UN04SEP98
1Pressure Oil
2Return Oil
3Trapped Oil
4Port T
5Port L
6Port R
7Port P
Steering Valve in Neutral
TM1608 (20SEP06)
9025-05-19
TX,9025,RR7288 1912AUG961/4

092006
PN=455
Theory of Operation
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
4
5
1
2
T80789
T80789
UN04SEP98
Oil Flow for a Right Turn

TX,9025,RR7288 1912AUG962/4
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
4
5
1
2
T80787
UN04SEP98
T80787
9025
05
20
Oil Flow for a Left Turn

TM1608 (20SEP06)
9025-05-20
TX,9025,RR7288 1912AUG963/4

092006
PN=456
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 form 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.
10
11
1Pressure Oil
2Suction Oil
3Return Oil
4Trapped Oil
6Check Valve
7Pin
8Control Spool
9Port T
10Port L
11Port R
12Port P
12
3
4
T80790
T80790
UN04SEP98
Oil Flow for a Secondary Steering

9025
05
21
TX,9025,RR7288 1912AUG964/4
TM1608 (20SEP06)
9025-05-21

092006
PN=457
Theory of Operation
Priority Valve Operation

X PILOT PRESSURE PORT
S
J
LOADER
VALVE
R
A
C
E
F
H
I
PRIORITY VALVE
BUCKET
BOOM
K BUCKET SECTION
SYSTEM
PILOT
RELIEF
PRESSURE VALVE J
PORT
X
INLET
GAUGE
A
PORT
M AUXILIARY
SECTION
L BOOM SECTION
LOADER
S STEERING LOAD
STABILIZER AND
SENSE RELIEF
BACKHOE PRESSURE
Q
B STEERING LOAD
METERING
SENSE PORT
HOLES P
C SPOOL
STEERING
SUPPLY PORT H
I
D SPRING
ORIFICE
R ORIFICE
RETURN
PASSAGE O
T HIGH PRESSURE OIL
G
OUTLET PORT
T100662
1903NOV97
E ORIFICE
F
INLET PORT
U STEERING PRESSURE OIL

V RETURN OIL
T100662
9025
05
22
AUXILIARY
W LOADER PRIORITY VALVE SECTION NOT STEERING

Loader Priority Valve Section-Not Steering
TM1608 (20SEP06)
9025-05-22
TX,9025,RR7293 1915MAY961/2

092006
PN=458
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, Stabilizer and
Backhoe Pressure
ROrifice
The priority valve is located at the inlet to the loader

control valve and maintains priority oil to the steering
valve. When the engine is stopped, spool (C) is
pushed to the left by bias spring (D) restricting oil to
the loader, stabilizer and backhoe functions (Q) by
opening the passage to steering (H).
When the machine is first started, all pump flow is
routed to the steering valve through port (H). The
steering valve blocks flow except for a small amount of
flow to sump through an orifice in the priority valve.
With flow blocked, pressure increases at port (H). This
causes spool (C) to shift to the right against spring (D)
and limits the flow to port (H) by closing the priority
metering holes (P). This opens inlet pump flow (F) to
loader, stabilizer and backhoe functions (Q). As long
as the steering valve is in neutral, limited flow is
allowed to pass through the metering holes (P) to
maintain steering pressure at port (H) keeping the
spool shifted to the right and balanced against the bias
spring (D).
If the pump is unable to supply adequate flow to
maintain steering pressure at port (H) during the use of
any hydraulic functions, spool (C) will shift left and
restrict flow to loader, stabilizer and backhoe functions
(Q) until steering 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.
SSteering LS Relief Valve

THigh Pressure Oil
USteering Pressure Oil
VReturn Oil
WLoader Priority Valve-Not
Steering
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 steering pilot
pressure to move the spool to the left. This restricts
flow to the loader, stabilizer and backhoe functions (Q)
while the priority metering holes (P) are open 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
steering cylinder bottoms against the steering stops
and pressure in the load sense circuit will increase.
When the pressure in the load sense port (B)
increases enough to push the steering 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.
The dual stage system relief valve (J) for both loader
and backhoe or stabilizer functions is located in the
priority valve section. The relief is pilot operated and
screw adjustable with anti-cavitation. The function of
the relief is to regulate system (main pump) pressure
at a lower level for loader use and higher operating
pressure for backhoe or stabilizer.
315SE OnlyPressure oil present at gauge port (A) is
directed to the sideshift lock solenoid valve.
The load sensing circuit is a control circuit that routes

steering valve outlet pressure to the spring side of the
TX,9025,RR7293 1915MAY962/2
TM1608 (20SEP06)
9025-05-23

092006
PN=459
9025
05
23
Theory of Operation
Ride Control Hydraulic Component Location Circuit-Off
RIDE CONTROL
J
F
I
E
D
D ACCUMULATOR
G TO BOOM CYLINDER
ROD END
E RESERVOIR
9025
05
24
TO RESERVOIR
F
H TO BOOM CYLINDER
HEAD END
RIGHT SIDE
M FRAME
J VALVE
SOLENOID
N TO ACCUMULATOR
A PRESSURE OIL
K TO BOOM CYLINDER
ROD END
TO
BOOM
CYLINDER
L
HEAD END
P RIDE CONTROL HYDRAULIC CIRCUIT OFF

TM1608 (20SEP06)
1910SEP98
C RETURN OIL
T116262
T116262
B TRAPPED OIL
9025-05-24
CED,TX03543,2275 1917JUL981/2

092006
PN=460
Theory of Operation
APressure Oil
BTrapped Oil
CReturn Oil
DAccumulator
EReservoir
FTo Reservoir
GTo Boom Cylinder Rod

End
HTo Boom Cylinder Head
End
ISolenoid
In this operation, the machine is in normal operation

with the boom being raised and lowered. In this
position, the solenoid (I) and valve (J) are deactivated
and the boom cylinder rod end (K and G) are
disconnected from the reservoir (E). The boom cylinder
head end (L and H) are still connected to the
JRide Control Valve

KTo Boom Cylinder Rod End
LTo Boom Cylinder Head
End
MRight Side Frame
NRide Control Hydraulic

Circuit
OOrifice
PRide Control Hydraulic
Circuit-OFF
accumulator (D) through ride control valve internal

orifice. The orifice maintains the accumulator oil
pressure closely to boom cylinder head end oil
pressure. This allows activation of the ride control
without boom sag.
CED,TX03543,2275 1917JUL982/2
9025
05
25
TM1608 (20SEP06)
9025-05-25

092006
PN=461
Theory of Operation
Ride Control Valve Operation OFF PositionContinued
RIDE CONTROL
J
I
I
E
D
TO BOOM
G
CYLINDER ROD
END
TO RESERVOIR F
TO ACCUMULATOR N
A PRESSURE OIL
H TO BOOM CYLINDER
HEAD END
T116556
B TRAPPED OIL
P RIDE CONTROL HYDRAULIC CIRCUIT - OFF

TM1608 (20SEP06)
9025-05-26
1910SEP98
O ORIFICE
T116556
9025
05
26
C RETURN OIL
CED,TX03768,8499 1922JUN981/2

092006
PN=462
Theory of Operation
APressure Oil
BTrapped Oil
CReturn Oil
DAccumulator
EReservoir
FTo Reservoir

End
End
ISolenoid
JRide Control Valve

End
MRight Side Frame

Circuit
OOrifice
Circuit-OFF
CED,TX03768,8499 1922JUN982/2
9025
05
27
TM1608 (20SEP06)
9025-05-27

092006
PN=463
Theory of Operation
Ride Control Hydraulic Component Location Circuit-On Position
RIDE CONTROL
J
F
I
E
D
D ACCUMULATOR
G TO BOOM CYLINDER
ROD END
E RESERVOIR
9025
05
28
TO RESERVOIR
F
H TO BOOM CYLINDER
HEAD END
RIGHT SIDE
M FRAME
J
VALVE
SOLENOID
N TO ACCUMULATOR
A PRESSURE OIL
K TO BOOM CYLINDER
ROD END
L TO BOOM CYLINDER
HEAD END
C RETURN OIL
P RIDE CONTROL HYDRAULIC CIRCUIT ON

TM1608 (20SEP06)
T116261
T116261
1910SEP98
B TRAPPED OIL
9025-05-28
CED,TX03543,2276 1922JUL981/2

092006
PN=464
Theory of Operation
APressure Oil
BTrapped Oil
CReturn Oil
DAccumulator
EReservoir
FTo Reservoir

End
End
ISolenoid
In this operation, there is no loader boom operation

and the machine is in transport position. In the ON
position, the solenoid (I) and valve (J) are activated.
Pressure spikes from the boom cylinder head end (L
and H) flow into the accumulator (D). The boom
cylinder rod end (K and G) is open to return (F). Oil is
JRide Control Valve

End
MRight Side Frame

Circuit
OOrifice
Circuit-OFF
free to flow in and out of the rod end, therefore the

boom cannot be powered down while ride control is
ON. Ride control can be engaged during bucket
loading, but may be turned OFF if more rigid operation
is desired.
CED,TX03543,2276 1922JUL982/2
9025
05
29
TM1608 (20SEP06)
9025-05-29

092006
PN=465
Theory of Operation
Ride Control Valve Operation ON Position-Continued
RIDE CONTROL
J
I
I
E
D
TO BOOM
G
CYLINDER ROD
END
TO RESERVOIR F
TO ACCUMULATOR N
A PRESSURE OIL
H TO BOOM CYLINDER
HEAD END
T116295
B TRAPPED OIL
P RIDE CONTROL HYDRAULIC CIRCUIT - ON

TM1608 (20SEP06)
9025-05-30
1910SEP98
O ORIFICE
T116295
9025
05
30
C RETURN OIL
CED,TX03768,8500 1922JUN981/2

092006
PN=466
Theory of Operation
APressure Oil
BTrapped Oil
CReturn Oil
DAccumulator
EReservoir
FTo Reservoir

End
End
ISolenoid
JRide Control Valve

End
MRight Side Frame

Circuit
OOrifice
Circuit-ON
CED,TX03768,8500 1922JUN982/2
9025
05
31
TM1608 (20SEP06)
9025-05-31

092006
PN=467
Theory of Operation
Dual Stage System Relief Valve (310SE and [315SE (S.N. 870248)]
PILOT PRESSURE O
PORT
L LOW PRESSURE
ADJUSTMENT SCREW
PISTON N
K HIGH PRESSURE
ADJUSTMENT SCREW
SPRING SEAT M
PILOT SPRING G
9025
05
32
F PILOT POPPET
ANTI-CAVITATION D
SPRING
ANTI-CAVITATION C
POPPET
E MAIN SPRING
OIL CAVITY I
J RELIEF BODY
MAIN POPPET B
P PRESSURE OIL
A PISTON
Q RETURN OIL
T100669
(NORMAL OPERATION)
T100669
R DUAL STAGE SYSTEM RELIEF VALVE
1923SEP96
ORIFICE H
Dual Stage System Relief Valve-Normal Operation

TM1608 (20SEP06)
9025-05-32
TX,9025,RR7289 1916FEB001/2

092006
PN=468
Theory of Operation
APiston
BMain Poppet
CAnti-Cavitation Poppet
DAnti-Cavitation Spring
EMain Spring
FPilot Poppet
GPilot Spring
HOrifice
I Oil Cavity
JRelief Body
KHigh Pressure Adjustment

LLow Pressure Adjustment
MSpring Seat
NPiston
OPilot port
The relief is a dual stage pilot operated and screw

adjustable.
The relief valve setpoint is controlled by the spring
load (G) holding the pilot poppet (F) on its seat. The
high pressure setting is adjustable by turning the high
pressure adjustment screw (K). The low pressure
setting is adjustable by turning the low pressure
adjustment screw (L). The relief setting will change
from low to high when a pressure oil pilot signal from
the backhoe sensing line is sent to the pilot port (O).
This pressure oil biases the piston (N) and spring seat
(M) against the pilot spring (G) changing the spring
load. When the pilot signal is lowered the relief returns
to the low pressure setting.
In normal operation, pressure oil less than relief valve
setting flows through orifice (H) in piston (A) into cavity
(I) behind the anti-cavitation poppet (C) and main relief
PPressure Oil
QReturn Oil
RDual Stage System Relief
Valve
valve poppet (B). This oil pressure and the springs

hold the main poppet (B) and anti-cavitation poppet (C)
closed because the effective areas of the poppets on
the cavity side is greater than the workport side.
In relief operation, pressure oil overcomes pilot poppet
(F) and oil flows from the pressurized port through
orifice (H) into cavity (I) past pilot poppet (F) to tank
through a path between relief body (J) and
anti-cavitation poppet (C). The pressure drop through
orifice (H) causes a pressure difference across piston
(A) and it moves against main spring (E) until it rests
on pilot poppet (F). This movement shuts off orifice (H)
and further reduces the pressure in cavity (I). When
the pressure difference is large enough to overcome
the differential area effect holding the main poppet (B)
on its seat and oil is allowed to flow from the work port
to the return port.
9025
05
33
TX,9025,RR7289 1916FEB002/2
TM1608 (20SEP06)
9025-05-33

092006
PN=469
Theory of Operation
System Relief Valve (S.N. 943225)
B MAIN
POPPET
C ANTI-CAVITATION
POPPET
D ANTI-CAVITATION
I OIL
SPRING
CAVITY
G PILOT
SPRING
H ORIFICE
E MAIN
SPRING
RELIEF J
BODY
F PILOT
POPPET
T117760
9025
05
34
APiston
BMain Poppet
M SYSTEM RELIEF VALVE
EMain Spring
FPilot Poppet
GPilot Spring
HOrifice
IOil Cavity
JRelief Body
This relief valve is pilot operated and screw adjustable.

The relief valve setting is controlled by the spring load
(G) holding the pilot poppet (F) on its seat. This setting
is adjustable by turning the adjustment screw at the
end of the relief valve.
During normal operation, pressure oil less than relief
valve setting flows through orifice (H) into cavity (I). At
this time, oil pressure is equal at both sides of main
poppet (B) and anti-cavitation poppet (C). Because the
surface area of the poppets is greater at cavity (I) side
than the work port side, the effective area and spring
tension will hold both poppets in the closed position.
L RETURN OIL
T117760
K PRESSURE OIL
1919OCT98
PISTON
KPressure Oil
LReturn Oil
MSystem Relief Valve
pressurized port through orifice (H), into cavity (I), past

pilot poppet (F), and then to tank through a path
between relief body (J) and anti-cavitation poppet (C).
When pilot poppet (F) is unseated, a pressure drop is
produced in cavity (I). The pressure drop creates a
pressure differential across piston (A) causing the
piston to move against main spring (E) until the piston
seats against pilot poppet (F). When this happens,
orifice (H) is closed off which further reduces the
pressure in cavity (I). When the pressure differential is
large enough to overcome the surface area effect and
spring tension, main poppet (B) will move off its seat
and allow oil from the work port to flow to the return
port.
During relief operation, pressure oil pushes pilot

poppet (F) of its seat allowing oil to flow from the
MG76653,0000065 1914JUL051/1
TM1608 (20SEP06)
9025-05-34

092006
PN=470
Theory of Operation
9025
05
35
TM1608 (20SEP06)
9025-05-35

092006
PN=471
Theory of Operation
System Relief Valve (S.N. 943226)
10
6
1
3
9025
05
36
7
11
T212526
UN19JUL05
12
T212526
System Relief Valve
TM1608 (20SEP06)
9025-05-36
MG76653,0000066 1914JUL051/2

092006
PN=472
Theory of Operation
1Valve Body
2Lock Nut
3Adjusting Screw
4Valve Poppet
5Flat Washer
6O-Ring (3 used)
7Seal
8Spring
Used on backhoe control valve and loader control

valve. The relief is direct acting, screw adjustable, and
does not have anti-cavitation operation.
The pressure set point is adjustable by loosing locking
nut (2) and adjusting screw (3). Turning the screw in
increases pressure setting.
9Back Up Ring
10Valve Plug
In relief operation, pressure oil overcomes poppet (4)

and oil flows from the pressurized port to tank.
NOTE: The 310SG and 315SG use this control valve

in the backhoe control valve only, 310E & G
series use this valve in backhoe and loader
control valves.
MG76653,0000066 1914JUL052/2
Circuit Anti-Cavitation Valve

The anti-cavitation valve is used in the loader boom and
backhoe boom sections.
ASpring
BValve Body
CO-Ring
DPoppet
EBackup Ring
FO-Ring
T100609
UN27JAN97
9025
05
37
CED,TX03768,2692 1903FEB001/1
TM1608 (20SEP06)
9025-05-37

092006
PN=473
Theory of Operation
Circuit Relief Valve without Anti-Cavitation

MAIN
POPPET
C RETURN OIL
D CIRCUIT RELIEF VALVE WITHOUT ANTI-CAVITATION
T101165
9025
05
38
T101165
B PRESSURE OIL
1927SEP96
Circuit Relief Valve without Anti-Cavitation

AMain Poppet
BPressure Oil
The relief is a direct action, screw adjustable, and

does not have anti-cavitation operation
The pressure set point is adjustable by turning the
adjustment screw at the end of the relief.
CReturn Oil
The valves are used in the loader bucket curl section

and boom raise section workports. They are also used
in the backhoe sections boom raise, bucket dump,
bucket curl, crowd in, and crowd out.
In relief operation, pressure oil overcomes main poppet

(A) and oil flows from the pressurized port to tank.
TX,9025,RR7290 1903FEB001/1
TM1608 (20SEP06)
9025-05-38

092006
PN=474
Theory of Operation
ANTICAVITATION
POPPET
F
C CAVITY
ORIFICE A
B POPPET
1910SEP98
D PRESSURE OIL
T7742AE
E RETURN OIL
TXC7742AE CV
AOrifice
BRelief Poppet
CCavity
DPressure Oil
EReturn Oil
The relief is direct acting and has anti-cavitation

operation.
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.
FAnti-Cavitation Poppet
During anti-cavitation operation, the pressure in the

workport 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
workport to prevent cavitation.
The valves are used in the loader section auxiliary
headend and the backhoe sections swing right, swing
left, and boom lower.
In relief operation, pressure oil overcomes relief poppet

(B) pressure setting and opens a path to return.
TX,9025,RR7291 1903FEB001/1
TM1608 (20SEP06)
9025-05-39

092006
PN=475
9025
05
39
Theory of Operation
Circuit Relief Valve with Anti-CavitationContinued

H ORIFICE
C ANTI-CAVITATION
POPPET
B MAIN
POPPET
D ANTI-CAVITATION
SPRING
I CAVITY
G PILOT
SPRING
J RELIEF
BODY
K PRESSURE OIL
F PILOT
POPPET
L RETURN OIL
M CIRCUIT RELIEF VALVE WITH ANTI-CAVITATION
9025
05
40
T101164
T101164
E MAIN
SPRING
1910SEP98
A PISTON

APiston
BMain Poppet
CAnti-Cavitation
EMain Spring
FPilot Poppet
GOrifice
HOil Cavity
IRelief Body
JRelief Body
KPressure Oil
The relief is a pilot operated, screw adjustable, with

anti-cavitation operation. It is used on the loader
bucket dump section.
The relief valve setting is controlled by the spring load
(G) holding the pilot poppet (F) on its seat. This
setting is adjustable by turning the adjustment cap at
the relief.
setting flows though orifice (H) in piston (A) into cavity
(I) behind the anti-cavitation poppet (C) and main relief
valve poppet (B). This oil pressure and the springs
hold the main poppet (B) and anti-cavitation poppet (C)
closed because the effective areas of the poppets on
the cavity side is greater tan the workport side.
In relief operation, pressure oil overcomes pilot poppet

(F) and oil flows from the pressurized port through
orifice (H) into cavity (I) past pilot poppet (F) to tank
through a path between relief body (J) and
anti-cavitation poppet (C). The pressure drop through
orifice (H) causes a pressure difference across piston
(A) and it moves against main spring (E) until it rests
on pilot poppet (F). This movement shuts off orifice (H)
and further reduces the pressure in cavity (I). When
the pressure difference is large enough to overcome
the differential area effect holding the main poppet (B)
on its seat and oil is allowed to flow from the work
port to the return port.
TM1608 (20SEP06)
LReturn Oil
MLoader Circuit Relief Valve
with Anti-Cavitation
9025-05-40
TX,9025,RR7292 1912AUG961/2

092006
PN=476
Theory of Operation
During anti-cavitation operation, the pressure in the
work port {and cavity (I)} is less than the pressure in
the return port. This pressure difference overcomes the
differential area effect holding the anti-cavitation

poppet (C) on its seat and oil is allowed to flow from
return port to work port to prevent cavitation.
TX,9025,RR7292 1912AUG962/2
9025
05
41
TM1608 (20SEP06)
9025-05-41

092006
PN=477
Theory of Operation
Loader Bucket Valve SectionBucket Rollback Position
SYSTEM
RELIEF
VALVE
I
LOADER
VALVE
INLET
PORT
PRIORITY
SECTION
BUCKET
J SECTION
BOOM
K SECTION
L AUXILIARY SECTION
9025
05
42
CIRCUIT RELIEF
B WITHOUT ANTICAVITATION
LIFT
D CHECK
INLET
PASSAGE
F BUCKET DUMP
WORK PORT
RETURN TO DIG
ELECTROMAGNET
H
M HIGH PRESSURE OIL
A
RETURN
PASSAGE
N RETURN OIL
O LOADER BUCKET VALVE BUCKET LOAD POSITION
T100666
T100666
CIRCUIT RELIEF
G WITH ANTICAVITATION
1903NOV97
BUCKET LOAD
WORK PORT
Loader Bucket Valve-Bucket Rollback Position

TM1608 (20SEP06)
9025-05-42
TX,9025,RR7294 1910JUN961/2

092006
PN=478
Theory of Operation
AReturn Passage
BCircuit Relief Valve without
Anti-Cavitation
CBucket Load Work Port
DLift Check
EInlet Passage
FBucket Dump Work Port
GCircuit Relief with
Anti-Cavitation
HReturntoDig
Electromagnet
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 (G) also contains an
anti-cavitation valve for the bucket dump circuit.
In the bucket load position, oil flows from the inlet
passage (E) past lift check (D) and spool and out the
bucket load workport (C) to the cylinder. Return oil
from the cylinder flows in the bucket dump workport
(F) past the spool and into the return passage (A) and
out of the control valve to the return circuit.
When bucket dump function circuit pressure is less
than return pressure, oil flows from return passage (A)
ILoader Valve
JBucket Section
KBoom Section
LAuxiliary Section
MHigh Pressure Oil
NReturn Oil
OLoader Bucket
Valve-Bucket Rollback
Position
past circuit relief anti-cavitation valve (G) to bucket

dump circuit (F).
The valve is equipped with a return-to-dig feature.
When loader control lever is moved to the bucket
rollback position, a plate fastened to end of valve spool
contacts an electromagnet (H). 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 (H)
letting the spool centering spring move the spool to
neutral.
TX,9025,RR7294 1910JUN962/2
TM1608 (20SEP06)
9025-05-43

092006
PN=479
9025
05
43
Theory of Operation
Loader Boom Valve SectionBoom Raise Position

B
G
SYSTEM
RELIEF
VALVE
P
LOADER
VALVE
PRIORITY
SECTION
BUCKET
N SECTION
BOOM
M SECTION
O AUXILIARY SECTION
9025
05
44
BOOM C
CIRCUIT
RAISE
RELIEF
PORT
WITHOUT
ANTICAVITATION
B
BOOM LOWER WORK PORT

F ORIFICE
D LOAD E INLET
PRESSURE
CHECK
K I ANTI-DRIFT CHECK
G ANTI-CAVITATION VALVE
H CAP WITH DETENT
A
RETURN
PASSAGE
1903NOV97
Q HIGH PRESSURE OIL

R RETURN OIL
T107002
VENT PASSAGE
T107002
WORK PORT L
PASSAGE
S LOADER BOOM VALVE SECTION BOOM RAISE POSITION

Loader Boom Valve Section-Boom Raise Position
TM1608 (20SEP06)
9025-05-44
TX,9025,RR7295 1902MAY961/2

092006
PN=480
Theory of Operation
AReturn Passage
BCircuit Relief Valve Without
Anti-Cavitation
CBoom Raise Work Port
DLoad Check
EInlet Pressure
FBoom Lower Work Port

GAnti-Cavitation Valve
HCap With Detent
IAnti-drift Check
JVent Passage
K Inlet Pressure Orifice
The boom valve is a four-position, four-way, spool type

valve. It contains a lift check (D), one circuit relief
valve (B), one anti-cavitation check (G), and a anti-drift
check (I).
When the spool is moved to activate a function, oil
flows from the functional inlet passage (E), past the
load check (D), main spool, and out the workport to
the cylinders. Return oil from the cylinders flows into
the other work port, past the main spool, into the
return passage (A), then out of the control valve to the
system reservoir. The main spool has grooves that
meter the oil through the valve to allow smooth starts
and stops.
An anti-drift check (I) is provided to control oil leakage
back into the boom lower work port (F). With the valve
in neutral the check (I) is spring loaded to the closed
position. Pressure in the workport (F) enters orifice (K)
and is passed to the spring side of the check.
Pressure in the work port passage (L) falls due to oil
leakage past the spool to the return passage (A). The
higher workport pressure on the spring side of the
check forces the check securely into the seat forming
a seal. The spring side of the check may be vented to
the return passage (A) through a vent passage (J).
This passage is open and closed depending on the
position of the main spool. With the spool in neutral or
the boom lower position, the vent passage (J) is
LWork Port Passage

MBoom Section
NBucket Valve Section
OAuxiliary Valve Section
PLoader Valve
QHigh Pressure Oil

RReturn Pressure Oil
SLoader Boom Valve
Section-Boom Raise
Position
blocked. With the spool in the boom raise or float

position the vent passage (J) is open to the return
passage (A). This vent is necessary to allow oil to be
able to return through the lower workport (F). When
the main spool is moved to the boom raise position the
vent passage (J) is opened. Oil flows from the work
port (F) through orifice (K) in the check (I) to the return
passage (A). Pressure drop across the orifice (K)
causes the pressure on the spring side of the check to
drop lower than the pressure in workport (F). This
pressure imbalance causes the check (J) to open
allowing flow to the main spool.
When the boom lower function pressure in the circuit is
less than return pressure, oil flows from the return
passage (A), past anti-cavitation valve (G) into the
boom raise circuit (F).
When the main spool is moved to the boom float
(detent) position, both work ports (C, F) are open to
the return passage (A) allowing oil to flow in and out
both ends of the cylinders.
9025
05
45
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 port
is similar to the port on the loader valve auxiliary
section illustrated in this group.
TX,9025,RR7295 1902MAY962/2
TM1608 (20SEP06)
9025-05-45

092006
PN=481
Theory of Operation
Loader Auxiliary Valve Section-Neutral

G
L
LOADER
VALVE
D
H
POWER
BEYOND
I
PRIORITY
SECTION
J BUCKET SECTION
K BOOM SECTION
AUXILIARY SECTION
9025
05
46
ROD END
WORK PORT C
LIFT
CHECK D
INLET
E PRESSURE
HEAD END
F WORK PORT
CIRCUIT
RELIEF
G WITH ANTICAVITATION
M HIGH PRESSURE OIL
A
RETURN
PASSAGE
1903NOV97
N RETURN PRESSURE OIL

O TRAPPED OIL
T100668
T100668
H POWER BEYOND PORT

P LOADER AUXILIARY VALVE SECTION NEUTRAL
Loader Auxiliary Valve Section-Neutral
TM1608 (20SEP06)
9025-05-46
TX,9025,RR7296 1916MAY961/2

092006
PN=482
Theory of Operation
AReturn Oil (Passage to
Stabilizer)
BPlug
CRod End Work Port
DLift Check
EInlet Pressure
FHead End Work Port
GCircuit Relief with
Anti-Cavitation
HPower Beyond
IPriority Valve Section

JBucket Valve Section
KBoom Valve Section
LLoader Valve
MHigh Pressure Oil
The loader auxiliary valve section is a three position,

four way, spool type valve. It contains a fit 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
functions auxiliary valve.
NReturn Pressure Oil

OTrapped Oil
PLoader Auxiliary
Valve-Neutral Position
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. If
no loader functions are being used, oil (A) flows to the
stabilizer valve and then to the backhoe valve.
TX,9025,RR7296 1916MAY962/2
TM1608 (20SEP06)
9025-05-47

092006
PN=483
9025
05
47
Theory of Operation
Stabilizer Valve Operation

D
F
D
A
H
1910SEP98
B
H
J
TXC7348AD
T7348AD
9025
05
48
J
C STABILIZER VALVE - LOWER
Stabilizer Valve-Lower
APressure Oil
BReturn Oil
CStabilizer Valve-Lower
DReturn Passage
EPressure Passage
FConnecting Passage
GPower Passage
HPoppet (2 used)
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
IThermal Relief Valve

JWork Port
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,9025,RR7515 1927SEP961/1
TM1608 (20SEP06)
9025-05-48

092006
PN=484
Theory of Operation
9025
05
49
TM1608 (20SEP06)
9025-05-49

092006
PN=485
Theory of Operation
Backhoe Valve Auxiliary Flow Control SectionIf Equipped

BACKHOE
CONTROL
VALVE
INLET
END
CAP
)(
)(
)(
)(
B
AUXILIARY
FLOW
CONTROL
SWING
BOOM
BUCKET
AUXILIARY
(EXT.
DIPPER)
CROWD
OUTLET
END
CAP
B
Y
L
P
9025
05
50
D
G
T
F
N
E
V RETURN PRESSURE OIL
Z BACKHOE AUXILIARY FLOW VALVE SOLENOID ENERGIZED

T128059
TM1608 (20SEP06)
9025-05-50
T128059
X HIGH PRESSURE OIL
1908FEB00
W MEDIUM PRESSURE OIL
TX,9025,RR7480 1916FEB001/5

092006
PN=486
Theory of Operation
AControlled Flow Port
BSolenoid
CRelief Valve
DSpring
EMetering Holes
FSpool
GControl Orifice
HFlow Adjustment Control
IDetent Arm
JSpring
KRestrictor Check
LOrifice
MPassage to Backhoe
Functions
NReturn Passage
OPump Passage
PPassage
QSpool End Cavity
ROrifice
SFlow Passage
TSpool End Cavity
UMetering Notches
VReturn Pressure Oil
WMedium Pressure Oil

XHigh Pressure Oil
YOrifice
ZMedium Pressure Oil
AABackhoe Auxiliary Flow
Valve-Solenoid
De-Energized
TX,9025,RR7480 1916FEB002/5
9025
05
51
TM1608 (20SEP06)
9025-05-51

092006
PN=487
Theory of Operation
BACKHOE
CONTROL
VALVE
INLET
END
CAP
)(
)(
()
)(
B
AUXILIARY
FLOW
CONTROL
SWING
BOOM
BUCKET
AUXILIARY
(EXT.
DIPPER)
CROWD
OUTLET
END
CAP
B
L
A
K
J
9025
05
52
D
G
T
F
N
E
V RETURN PRESSURE OIL

W LOW PRESSURE OIL
Z MEDIUM PRESSURE OIL
BACKHOE AUXILIARY FLOW VALVE SOLENOID DE-ENERGIZED
T128060
AA
T128060
TM1608 (20SEP06)
1908FEB00
X HIGH PRESSURE OIL
9025-05-52
TX,9025,RR7480 1916FEB003/5

092006
PN=488
Theory of Operation
The priority flow control section maintains a specified
flow rate to auxiliary hydraulic attachments regardless
of changing loads on the hydraulic system. When the
engine is stopped, spool (F) is pushed to the left by
bias spring (D) closing the pump passage (O) to
downstream backhoe functions (M) and opening the
spool metering holes (E) to create an oil passage to
controlled flow port (A).
When the solenoid is not energized, passage (P) is
blocked from cavity (Q) by the solenoid valve (B).
Cavity (Q) is connected through orifice (R) and
solenoid valve (B) to the return passage (N).
When the machine is first started, all pump flow is
routed through metering holes (E) into cavity (T) and
out control orifice (G) to passage (S). Flow is blocked
from controlled flow port (A) by a spring loaded check
(K). The pressure required to open the check (K) is
designed to be slightly higher than the pressure
generated by spool bias spring (D).
With the flow blocked, the pressure increases at cavity
(T). This causes the spool (F) to shift to the right
against bias spring (D) and reduce the opening
through the spool by closing the metering holes (E).
This spool movement simultaneously opens metering
notches (U) and creates a passage between pump oil
(O) and downstream backhoe functions (M). As long
as the solenoid valve is not activated the spool will
keep a position that maintains a pressure in cavity (T)
that keeps the spool shifted to the right and balanced
against the bias spring (D).
The solenoid is activated when flow is required out
controlled flow port (A). The valve now generates
sufficient pressure in passage (S) to overcome
restrictor check (K) and open a passage to controlled
flow port (A). Passage (P) is now connected to cavity
(Q) through the solenoid valve (B) and orifice (R).
Cavity (Q) is now disconnected from return passage
(N) by the solenoid valve (B).
With the solenoid activated the valve will now sense
the load induced by the auxiliary attachments. Load
pressure at the controlled flow port (A) is routed
through orifice (L), through passage (P), and solenoid

(B) to cavity (Q) on the bias spring side of the spool.
This pressure plus the spring bias (D) acts against the
pilot pressure in cavity (T) to move the spool to the
left. This restricts flow to the backhoe functions while
the priority spool metering holes (E) are opened to
allow flow to the controlled flow port (A). The spool will
keep a position that maintains a pressure in cavity (T)
equal to the combination of load pressure and bias
spring (D) pressure.
If the pump is unable to supply adequate flow to
maintain selected backhoe function speeds and output
load pressure at the controlled flow port (A), spool (F)
will shift left and restrict flow to the backhoe functions
(M) until load pressure is restored. If through the use
of backhoe functions the inlet pressure rises higher
than is required by the attachment, spool (F) will shift
right and restrict flow to the controlled flow port (A).
Flow output is controlled by the size of the control
orifice (G). As flow is passed through this orifice there
will be a pressure drop from cavity (T) to passage (S).
When this pressure drop is equal to the effect of the
bias spring (D) then the flow rate will be maintained at
that level. Flow rates can be changed by turning flow
adjustment control (H) to vary the size of the flow
control orifice (G). The flow adjustment control (H) is
attached to a detent arm (I) that can be moved to
three distinct positions. The position of the detent arm
and output flow per arm position is as follows:
Center83.3 L/min(f) (22 gpm)
Left68 L/min(f) (18 gpm)
Right34 L/min(f) (9 gpm)
Load pressure at the controlled flow port (A) is limited
by a relief valve (C). Passage (P) is connected to the
relief. When controlled flow port (A) pressure reaches
the relief set point oil is passed to return passage (N)
through the relief. Orifice (L) limits the amount of oil
lost to return when the relief opens. This relief limits
the maximum pressure that can be supplied to cavity
(Q). At this point the valve will not be able to supply
any greater output pressure at the controlled flow port
(A).
TM1608 (20SEP06)
9025-05-53
TX,9025,RR7480 1916FEB004/5

092006
PN=489
9025
05
53
Theory of Operation
An orifice (Y) is located in restrictor check (K) to
eliminate the possibility of high pressure oil being
trapped in the controlled flow port (A) when the flow
control is de-energized. Trapped oil would make it

difficult to connect or disconnect hydraulic quick
connect fittings.
TX,9025,RR7480 1916FEB005/5
9025
05
54
TM1608 (20SEP06)
9025-05-54

092006
PN=490
Theory of Operation
9025
05
55
TM1608 (20SEP06)
9025-05-55

092006
PN=491
Theory of Operation
Backhoe Valve Swing Section-Left

BACKHOE
CONTROL
VALVE
INLET
END
CAP
AUXILIARY
FLOW
CONTROL
SWING
BOOM
BUCKET
CROWD
AUXILIARY
(EXT.
DIPPER)
OUTLET
END
CAP
SWING LEFT
WORKPORT
B
A CIRCUIT RELIEF
WITH ANTICAVITATION
C LIFT
CHECK
H INLET
PRESSURE
SWING RIGHT
D WORKPORT
CIRCUIT RELIEF A
WITH ANTICAVITATION
G
1905NOV97
RETURN
PASSAGE
E HIGH PRESSURE OIL
F RETURN OIL
T100675
T100675
9025
05
56
BACKHOE SWING VALVE SECTION SWING LEFT POSITION

Backhoe Swing Valve Section-Swing Left Position
TM1608 (20SEP06)
9025-05-56
TX,9025,RR7298 1917MAY961/2

092006
PN=492
Theory of Operation
ACircuit Relief Valve with
Anti-Cavitation (2 used)
BSwing Left Work Port
CLift Check
DSwing Right Work Port
EHigh Pressure Oil
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 (A).
FReturn Oil
GReturn Passage
HHigh Pressure Passage
IBackhoe Valve
Section-Swing Left Position
port (B). Return oil from the cylinder flows into work
port (D), past the spool, into the return passage (G).
During a left swing, oil flows to the lift check (C), into
pressure passage through holes in spool and out work
TX,9025,RR7298 1917MAY962/2
9025
05
57
TM1608 (20SEP06)
9025-05-57

092006
PN=493
Theory of Operation
Backhoe Valve Boom Section-Boom Lower Position

BACKHOE
CONTROL
VALVE
)(
)(
()
)(
INLET
END
CAP
G
AUXILIARY
FLOW
CONTROL
SWING
BOOM LOWER C
WORKPORT
9025
05
58
BOOM
LOAD D
CHECK
BUCKET
CROWD
A INLET
PRESSURE
ORIFICE I
AUXILIARY
(EXT.
DIPPER)
OUTLET
END
CAP
F BOOM RAISE
WORKPORT
G LOW LEAK
CHECK
H CIRCUIT RELIEF
WITHOUT ANTICAVITATION
CIRCUIT RELIEF
B WITH ANTICAVITATION
RETURN E
PASSAGE
T100676
L HIGH PRESSURE OIL

M RETURN PRESSURE OIL
N BACKHOE BOOM SECTION BOOM LOWER POSITION
T100676
J WORKPORT
PASSAGE
1905NOV97
K VENT
PASSAGE
Backhoe Boom Valve Section-Boom Lower Position

TM1608 (20SEP06)
9025-05-58
TX,9025,RR7299 1917MAY961/2

092006
PN=494
Theory of Operation
AInlet Pressure
BCircuit Relief with
Anti-Cavitation
CBoom Lower Work Port
DLift Check
EReturn Passage
FBoom Raise Work Port
GLow Leak Check
HCircuit Relief without
Anti-Cavitation
The boom valve is three-position, four-way, spool-type

valve. It contains a lift check (D), one circuit relief
valve with anti-cavitation check (B), one circuit relief
valve without anti-cavitation check (H), and a leakage
control check (G).
flows from the functional inlet passage (A), past the
the other work port past the main spool, into the return
passage (E), then out of the control valve to the
and stops.
A low leakage check (G) is provided to control oil
leakage back into the boom raise work port (F). With
the valve in neutral, the check (G) is spring loaded to
the closed position. Pressure in the work port (F)
enters orifice (I) and is passed to the spring side of the
check. Pressure in the work port passage (J) falls due
IOrifice
JWork Port Passage
KVent Passage
LHigh Pressure Oil
MReturn Pressure Oil

NBackhoe Boom Valve
Section-Boom Lower
Position
to oil leakage past the spool to the return passage (E).

The higher work port pressure on the spring side of
the check forces the check securely into the seat
forming a seal. The spring side of the check may be
vented to the return passage (E) through a vent
passage (K). This passage is open and closed
depending on the position of the main spool. With the
main spool in neutral or the boom raise position the
vent passage (K) is closed to the return passage (E).
When the main spool is moved to the boom lower
position the vent passage (K) is opened. Oil flows from
the work port (F) through orifice (I) in the check (G) to
the return passage (E). Pressure drop across the
orifice (I) causes the pressure on the spring side of the
check to drop lower than the pressure in work port (F).
This pressure imbalance causes the check (G) to open
When the boom lower function pressure in the circuit is
less than return pressure, oil flows from the return
passage (E), past anti-cavitation valve (B) and into the
boom lower circuit.
TX,9025,RR7299 1917MAY962/2
TM1608 (20SEP06)
9025-05-59

092006
PN=495
9025
05
59
Theory of Operation
Backhoe Valve Bucket Section-Bucket Curl Position

BACKHOE
CONTROL
VALVE
)(
)(
()
)(
INLET
END
CAP
AUXILIARY
FLOW
CONTROL
9025
05
60
SWING
BUCKET CURL B
WORKPORT
A CIRCUIT RELIEF
BOOM
C LIFT
CHECK
BUCKET
CROWD
H INLET
PRESSURE
AUXILIARY
(EXT.
DIPPER)
OUTLET
END
CAP
D BUCKET DUMP
WORKPORT
CIRCUIT RELIEF A
F RETURN OIL
T100677
I BACKHOE BUCKET SECTION BUCKET CURL POSITION
T100677
E HIGH PRESSURE OIL
1905NOV97
RETURN G
PASSAGE
Backhoe Bucket Valve SectionBucket Curl

TM1608 (20SEP06)
9025-05-60
TX,9025,RR7300 1917MAY961/2

092006
PN=496
Theory of Operation
ACircuit Relief Valve without
Anti-Cavitation (2 used)
BBucket Curl Workport
CLoad Lift Check

DBucket Dump Workport
EHigh Pressure Oil
The bucket valve is three-position, four-way, spool-type

valve. It contains a lift check (C), and two circuit relief
valves without anti-cavitation checks (A).
flows from the functional inlet passage (H), past the
load check (C), main spool, and out the workport to
FReturn Pressure Oil

GReturn Passage
HInlet Pressure
IBackhoe Bucket Valve

SectionBucket Curl
Position

the other workport, past the main spool, into the return
passage (G), and then out of the control valve to the
and stops.
TX,9025,RR7300 1917MAY962/2
9025
05
61
TM1608 (20SEP06)
9025-05-61

092006
PN=497
Theory of Operation
Backhoe Valve Crowd SectionCrowd Out Position

BACKHOE
CONTROL
VALVE
INLET
END
CAP
)(
)(
)(
()
AUXILIARY
FLOW
CONTROL
SWING
BOOM
BUCKET
CROWD
AUXILIARY
(EXT.
DIPPER)
OUTLET
END
CAP
CROWD OUT
WORKPORT C
9025
05
62
ANTI-DRIFT
G
CHECK
LOAD
CHECK D
ORIFICE
I
INLET
E PRESSURE
F CROWD IN
WORKPORT
CIRCUIT RELIEF
H
CIRCUIT RELIEF
B
VENT
PASSAGE K
L HIGH PRESSURE OIL
J WORKPORT
PASSAGE
N BACKHOE CROWD SECTION CROWD OUT POSITION
T107001
T107001
M RETURN PRESSURE OIL
1917NOV98
A
RETURN
PASSAGE
Backhoe Valve Crowd SectionCrowd Out Position

TM1608 (20SEP06)
9025-05-62
TX,9025,RR7301 1917MAY961/2

092006
PN=498
Theory of Operation
AReturn Passage
BCircuit Relief without
Anti-Cavitation
CCrowd Out Workport
DLoad Lift Check
EInlet Pressure
FCrowd In Workport
GLow Leak Check
HCircuit Relief without
Anti-Cavitation
IOrifice
JWorkport Passage
KVent Passage
LHigh Pressure Oil
The crowd valve is a three-position, four-way,

spool-type valve. It contains a lift check (D), two circuit
relief valves without anti-cavitation checks (B and H),
and a leakage control check.
flows from the functional inlet passage (E), past the
the other workport, past the main, into the return
passage (A), then out of the control valve to the
and stops.
A low leakage check (G) is provided to control oil
leakage back into he crowd out workport (C). With the
valve in neutral, the check (G) is spring loaded to the
closed position. Pressure in the workport (C) enters
orifice (I) and is passed to the spring side of the check.
Pressure in the workport (J) falls due to oil leakage
MReturn Pressure Oil

NBackhoe Crowd Section
Crowd Out Position
past the spool to the return passage (A). The higher

workport pressure on the spring side of the check
forces the check securely into the seat forming a seal.
The spring side of the check may be vented to the
return passage (A) though a vent passage (K). This
passage is open and closed depending on the position
of the main spool. With the main spool in neutral or in
the crowdout position, the vent passage (K) is
blocked. With the spool in the crowdin position, the
vent passage (K) is open to the return passage (A).
This vent is necessary to allow oil to be able to return
through the crowdout workport (C). When the main
spool is moved to the crowdin position, the vent
passage (K) is opened. Oil flows from the workport (C)
through orifice (I) in the check (G) to the return
passage (A). Pressure drop across the orifice (I)
causes the pressure on the spring side of the check to
drop lower than the pressure in workport (F). This
pressure imbalance causes the check (G) to open
9025
05
63
TX,9025,RR7301 1917MAY962/2
TM1608 (20SEP06)
9025-05-63

092006
PN=499
Theory of Operation
Backhoe Valve Auxiliary SectionNeutral Position

B
)(
)(
)(
()
INLET
END
CAP
AUXILIARY
FLOW
CONTROL
9025
05
64
SWING
BOOM
BUCKET
EXTEND
WORKPORT
A SHUT-OFF
PLUG
C LIFT
CHECK
H INLET
PRESSURE
CROWD
AUXILIARY
(EXT.
DIPPER)
OUTLET
END
CAP
D RETRACT
WORKPORT
A SHUT-OFF
PLUG
RETURN
PASSAGE
J BACKHOE AUXILIARY SECTION NEUTRAL POSITION
WITH UPSTREAM FUNCTION ACTIVATED
F RETURN OIL
I
TRAPPED OIL
T100681
T100681
E HIGH PRESSURE OIL
1905NOV97
Backhoe Valve Auxiliary Section-Neutral Position

TM1608 (20SEP06)
9025-05-64
TX,9025,RR7302 1917MAY961/2

092006
PN=500
Theory of Operation
AShut-Off Plug (2 used)
BExtend Workport
CLoad Lift Check
DRetract Workport
EHigh Pressure Oil
FReturn Oil
GReturn Passage
HInlet Pressure
ITrapped Oil
The auxiliary valve is three-position, four-way,

spool-type valve. It contains a lift check (C) and two
shut-off plugs (A).
flows from the functional inlet passage (H), past the
load check (C), main spool and out the workport to the
JBackhoe Auxiliary
SectionNeutral Position
cylinders. Return oil from the cylinders flows into the

other workport, past the main spool, into the return
passage (G), then out of the control valve to the
and stops.
TX,9025,RR7302 1917MAY962/2
9025
05
65
TM1608 (20SEP06)
9025-05-65

092006
PN=501
Theory of Operation
Backhoe Valve Regenerative Outlet Cover

B
D
K
E
J
9025
05
66
PRESSURE OIL
RETURN OIL
L BACKHOE REGENERATIVE END PLATE - VALVE OPEN
T101323
T101323
1923SEP96
Backhoe Valve Regenerative Outlet CoverValve Open

AOutlet Cover
BPressure Passage
DPiston
EReturn from Filter

FControl Valve Poppet
GSpring
HO-Ring
IOrifice
JOutlet Section-Control
Valve Open
The function of the low pressure regeneration outlet is

to reduce cavitation during backhoe operation. The
generative system is used to supplement oil flow to
backhoe cylinders to prevent cavitation when cylinder
travel outruns pump delivery.
KOutlet Port
LBackhoe Regenerative End
Plate-Valve Open
increases to the pressure required to move the

functions. This pressure acts on piston (D) to unseat
the control valve poppet (F), allowing unrestricted flow
of oil through cylinder return passage (E) to outlet port
(K).
When one or more backhoe spools are moved from

the neutral position, oil in pressure passage (B)
TM1608 (20SEP06)
9025-05-66
TX,9025,RR7303 1923AUG961/3

092006
PN=502
Theory of Operation
When the operator is metering pump flow, and the
parallel passage pressure (B) 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 (G) 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, external

loads on the cylinders may cause the return pressure
to exceed the pressure passage, the anti-cavitation
valve (C) opens, allowing pressure regulated cylinder
return oil to supplement pump oil to the cylinder.
TX,9025,RR7303 1923AUG962/3
9025
05
67
TM1608 (20SEP06)
9025-05-67

092006
PN=503
Theory of Operation
B
D
K
E
J
G
RETURN OIL
T101324
L BACKHOE REGENERATIVE END PLATE - VALVE NEUTRAL
T101324
9025
05
68
1923SEP96
Backhoe Valve Regenerative Outlet CoverValve Neutral
When the backhoe valve spools are all in neutral, oil

from the pump flows through the valve stack neutral
passage to the outlet passage (K) 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 pressures 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 passage (K) to provide make-up oil.
TX,9025,RR7303 1923AUG963/3
TM1608 (20SEP06)
9025-05-68

092006
PN=504
Theory of Operation
Sideshift Lock Solenoid Valve315SE

A
B
E
F
UN30DEC96
D
T6419AE
APressure Oil
BReturn Oil (Pressure Free)
CInlet
DReturn
ERelief Valve
FOutlet
When the solenoid is not energized, spring pressure

pushes the valve spool down, so oil flows to sideshift
locking pistons. The check valve (G) in the inlet port
traps oil to maintain pressure on locking pistons.
T6419AE
GCheck Valve
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.
When the solenoid is energized, the valve spool is

pulled up against spring pressure, blocking inlet oil and
releasing pressure on the sideshift pistons to the
reservoir.
EX,9025,BG103 1913DEC961/1
TM1608 (20SEP06)
9025-05-69

092006
PN=505
9025
05
69
Theory of Operation
9025
05
70
TM1608 (20SEP06)
9025-05-70

092006
PN=506
Group 15
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.
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.
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.
NOTE: You can use the Hydraulic System Pretest

Check Sheet to list the possible causes.
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.
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.
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
7. TEST YOUR CONCLUSION. Do individual

component tests to verify your conclusion before
you repair or replace any components.
9025
15
1
TX,9025,RR7304 1910JUN961/1
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).
tests of individual component to verify the

malfunction.
3. Repair or replace the faulty component.
2. Go to Diagnose Malfunctions to determine the

cause of the customer complaint. If necessary, do
TX,9025,RR7305 1910JUN961/1
TM1608 (20SEP06)
9025-15-1

092006
PN=507
Hydraulic System Pretest

1. Clean machine as needed.
2. Perform all inspections.
3. Correct any problems.
4. Perform Operational Checks:
9025
15
2
Hydraulic Oil:
Correct Oil
Correct Level
Bubbles in Oil
Control Valve(s):
Bent Linkage
Proper Linkage Adjustment
Filters: Hydraulic, Transmission:
Ruptured
Plugged
Metal Particles
Packing Particles
Install New Filter
Oil Cooler:
Clean of Dirt and Debris
Fan or Shroud Damaged
Belt Tension and Condition
Leaking Lines or Cooler
Hydraulic System:
Bent or Damaged Lines
External Oil Lines
Cylinder Rod(s) Bent
Blown Seals and Fittings
TX,9025,RR7306 1909AUG961/1
TM1608 (20SEP06)
9025-15-2

092006
PN=508
Diagnose Hydraulic System Problems

Symptom
Problem
Solution
Reservoir Drains When Changing

Hydraulic Filter
Return tube vent hole in reservoir

may be plugged.

Technical Repair manual.
Vent tube broken off inside reservoir
Remove and repair. See Technical

Repair manual.
Low oil level
Add oil to correct level.
Failed pump drive shaft
Replace. See Technical Repair

manual.
Pump problem
Remove hydraulic filter and inspect.

If filter contains excessive amounts
of metal material, remove, and
inspect pump. See Technical Repair
manual.
Obstruction in oil lines or valves.
Inspect for pinched lines or stuck

valve spools. See Technical Repair
manual.
No Loader Hydraulics (Steering

OK)
Loader system relief problem
Check system relief. Do Loader and

Backhoe System Relief Pressure
Test in Group 9025-25.
Low Loader Hydraulic Power
Incorrect loader system relief

pressure setting.
No Loader or Steering Hydraulics
TM1608 (20SEP06)
9025-15-3
Check relief setting at the loader

valve. Do Loader and Backhoe
System Relief Pressure Test in
Group 9025-25.
TX,9025,RR7307 1910JUN961/11

092006
PN=509
9025
15
3
Symptom
Problem
Solution
Low Hydraulic Power
Hydraulic oil aerated.
Incorrect oil, drain and refill. Suction

hose has air leak. Inspect and
tighten. See repair manual.
Leakage within work circuit
Check circuit for leakage. Do

Cylinder Leakage Test in Group
9025-25 and Circuit Relief Valve
Test with Remote Pump in Group
9025-25.
Low oil level
Check oil levels.
Incorrect system relief pressure

setting
Check system relief. Do Loader and

Backhoe System Relief Pressure
Test in Group 9025-25.
Priority Valve
Test operation of priority valve. Do

Steering Priority System Relief Test
in Group 9025-25.
Steering valve leakage
Test Steering System for leakage.

See Group 9025-25,
Steering cylinder leakage.
Do Steering Cylinder Leakage Test.

See Group 9025-25.
Steering linkage
Inspect and repair. See Technical

Repair manual.
Priority valve problem
Do Steering Priority System Relief

Worn steering pressure regulating

valve
Test Steering Priority Relief

pressure. See Group 9025-25.
Engine or transmission problem
See Section 9020-15, Machine

Lacks Power/Moves Slow
Slow Steering Hydraulics
9025
15
4
No Steering Hydraulics (Loader

Hydraulics OK)
Machine Transport Speed is Slow
See Section 9010-10, Engine Speed

and Performance Operational Check
TM1608 (20SEP06)
9025-15-4
TX,9025,RR7307 1910JUN962/11

092006
PN=510
Symptom
Problem
Solution
Engine Pulls Down Excessively

During Loader Operation
System relief pressure setting too

high
Do Loader and Backhoe System

Pressure Relief Test, see Group
9025-25
Engine not operating to

specifications.
Check engine performance. Do

Engine Performance Operational
Checks in Group 9005
System relief high pressure setting

too high

Pressure Relief Test, see Group
9025-25
Pump unloading problem
Do Pump Unloading Valve Relief

Pressure Test, see Group 9025-25
Auxiliary pump flow low.
Check auxiliary pump flow. Do Main

and Auxiliary Pump Flow Test, see
Group 9025-25.
Pump unloading relief setting too

low.
Do Pump Unloading Valve Relief

Pressure Test. See 9025-25.
Control Valve worn.
Do Function Drift Test in Group

9025-25.
Problem in boom lock circuit.
Refer to Section 9020.
Engine Pulls Down Excessively

During Backhoe Operation
Slow Backhoe Hydraulics

Loader OK
Backhoe Boom Lock Does Not

Operate
TM1608 (20SEP06)
9025-15-5
9025
15
5
TX,9025,RR7307 1910JUN963/11

092006
PN=511
Symptom
Problem
Solution
Slow Hydraulic Functions
Low pump flow
Do Main Pump and Auxiliary Pump

Performance Test. See 9025-25.
System relief leaking

Relief Test. See 9025-25.
Low oil level
Engine rpm too low
Increase rpm or check engine

speed. See Group 9010-20.
Hydraulic oil aerated.

tighten. See Technical Repair
manual.
Hose or line leakage
Inspect and tighten fittings.
System relief valve stuck or leaking
Remove, clean and test. See

Low pump flow
Do Main and Auxiliary Pump Flow

9025
15
6
TM1608 (20SEP06)
9025-15-6
TX,9025,RR7307 1910JUN964/11

092006
PN=512
Symptom
Problem
Solution
Loader or Backhoe Operates

Slowly in One Function
Control Valve section problem.
Do Function Drift Test. See Group

9025-25.
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.
Circuit Relief valve or plug leakage

in control valve.
Remove, inspect and repair sealing

rings on relief valve or plug. See
Do Circuit Relief Valve Test with
Remote Pump. See Group 9025-25.
Hydraulic cylinder leakage
Do Cylinder Leakage Test. See

Group 9025-25.
Bent or restricted line

Repair manual.
Hydraulic control valve not operating

properly
Do Valve Leakage Test. See Group

9025-25. Remove, inspect and
repair. See Technical Repair
manual.
Bent cylinder rod.
Remove and inspect. See Technical

Repair manual.
TM1608 (20SEP06)
9025-15-7
TX,9025,RR7307 1910JUN965/11

092006
PN=513
9025
15
7
Symptom
Problem
Solution
No Loader or Backhoe Power in

One Function
Control lever and linkage out of

adjustment
Inspect lever and linkage. Adjust to

get equal valve spool travel in each
direction.
Circuit relief valve or plug leakage in

control valve
Remove inspect and repair sealing

rings on relief valve or plug. See
repair manual.
Also see Low Hydraulic Power.

Higher hydraulic demand by
backhoe can make a system
problem appear to be isolated to
backhoe.
Do Circuit Relief Valve Test with

Remote Pump. See Group 9025-25.
Do Function Drift Test. See Group
9025-25.
9025
15
8
Slow Loader and Backhoe

Hydraulics (Low Pump Output)
Bent or restricted line
Inspect and repair.
Hydraulic control valve not operating

properly

Hydraulic oil aerated

tighten. See Technical Repair
manual.
Incorrect system relief valve setting

Relief Pressure Test. See Group
9025-25.
Main pump
Do System Operational Checkout

9005-10 to check pump flow.
Remove hydraulic filter and inspect.
If filter contains excessive amounts
of metal material, remove and
inspect pump. Test Main Pump
Flow. See Group 9025-25. Also see
repair manual.
TM1608 (20SEP06)
9025-15-8
TX,9025,RR7307 1910JUN966/11

092006
PN=514
Symptom
Problem
Solution
Low Hydraulic Power (Low

Hydraulic Pressure)
Low oil level (aeration of oil)

Incorrect system relief valve
Do System Relief Test. See Group

9025-25.
Incorrect system relief valve setting
Test System Relief Valve Pressure.

See Group 9025-25. Repair or
replace. Also see repair manual.
Leakage within work circuit
Feel components for heat. Do

Cylinder Drift Test. See Group
9025-25.
Excessive leakage in hydraulic

system
Do Leakage Test. See Group

9025-25.
Low oil level

Worn or wrong circuit relief valve

installed in backhoe valve.
Inspect, remove and repair. See

Oil leaking past valve port
Do System Operational Checkout

drift test to pinpoint cylinder or valve
leakage. See Group 9005-10.
Oil leaking past cylinders or valve.
Do Function Drift test to pinpoint

cylinder or valve leakage. See Group
9025-25.
Hydraulic Function Makes

"Chattering" Noise
Functions Drift
TM1608 (20SEP06)
9025-15-9
TX,9025,RR7307 1910JUN967/11

092006
PN=515
9025
15
9
Symptom
Problem
Solution
Control Valve Sticks Or Works

Hard
Control valve lever linkage binding
Inspect and adjust linkage. See

Group 9025-20. Inspect valve
spools. See repair manual.
Hydraulic system overheating
Test component leakage. See Group

9025-25.
Return spring rubbing on spring cap
Inspect and adjust. See Technical

Repair manual.
Broken return spring
Remove and replace. See Technical

Repair manual.
Contamination in control valve
Remove and clean. See Technical

Repair manual. Locate source of
contamination. Repair and clean oil
in system.
Scored valve bore or bent spool
See Technical Repair manual.
9025
15
10
TM1608 (20SEP06)
9025-15-10
TX,9025,RR7307 1910JUN968/11

092006
PN=516
Symptom
Problem
Solution
Hydraulic Oil Overheats
Excessive load
Reduce load.
Operator holding hydraulic system

over relief
Return levers to neutral when not in

use.
Oil levels too low in reservoir.
Check levels and add oil. Use

recommended oil . See
TMS16489000 Section.
Using low viscosity oil in hot weather
Use recommended oil. See

TMS16489000 Section.
Hydraulic cooling system restricted.
Clean radiator and coolers. Do

Hydraulic Cooler Restriction Test.
See 9025-25.
Incorrect system relief valve

pressure

Pressure Relief Valve Test. See
Group 9025-25.
Do Priority System Pressure Relief

Test, see Group 9025-25.
Cooling system plugged
Do Hydraulic Cooler Restriction Test,

see 9025-25
Foaming Oil
Excessive leakage in the hydraulic

system
Do Leakage Test. See Group

9025-25.
Oil level too low or too high
Check oil level. Adjust to full mark

on sight gauge.
Drain and replace. See Operators

Manual.
Air leak on suction side of pump
Locate and repair leak. See

Oil maintenance not performed.
See Operators Manual.
TM1608 (20SEP06)
9025-15-11
TX,9025,RR7307 1910JUN969/11

092006
PN=517
9025
15
11
Symptom
Problem
Solution
Hydraulic Pump Leaking
Cap screws that hold pump sections

together are loose
Tighten to specification. See repair

manual.
Worn shaft seal
Replace seal. See repair manual.
Broken pump seal or backup gasket
Replace seal or gasket. See Repair

Manual.
Hydraulic oil overheating
Determine cause of overheating, see

Hydraulics Oil Overheats in this
Group.
Low oil level
Hydraulic filter by-pass valve

chattering
Replace filter. Inspect, clean, and

repair. See Technical Repair
manual.
Worn pump drive

Repair manual.
Oil lines in contact with operators

station (Worn cab, transmission, or
canopy rubber isolators)
Inspect, repair or replace. See repair

manual.
Pump attaching hardware loose
Retighten to specification. See

Leakage in hydraulic circuit
Do Leakage Tests. See Group

9025-25.
Broken centering springs
Inspect steering valve. See

Damaged steering valve sleeve
Inspect steering valve. See

Excessive Pump Noise
9025
15
12
Steering Valve Does Not Return

To Neutral
TM1608 (20SEP06)
9025-15-12
TX,9025,RR7307 1910JUN9610/11

092006
PN=518
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 Steering Priority System Test.

See Group 9025-25.
Do Steering System Leakage Test.

See Group 9025-25.
Steering cylinder leakage
Test steering valve or cylinder for

leakage. See Group 9025-25.
Worn main pump
Do Main Pump Flow Test. See

9025-25.
Machine Turns in Opposite

Direction
Steering cylinder lines not connected

properly
Connect steering cylinder lines to

opposite ports.
Excessive Vibration of Steering

Wheel
Misalignment of steering valve

gerotor
Put steering valve gerotor in

alignment. See Technical Repair
manual.
Machine Turns When Steering

Valve Is in Neutral
Do Steering System Leakage Test.

See Group 9025-25.
Mis-alignment of steering column to

steering valve.
See Technical Repair manual to

repair.
Check valve leakage
Inspect check valve in "P" port of

steering valve. See repair manual.
Steering Wheel Turns Hard
Check P port orifice. See repair

manual.
Steering Wheel Kickback
9025
15
13
TX,9025,RR7307 1910JUN9611/11
TM1608 (20SEP06)
9025-15-13

092006
PN=519
9025
15
14
TM1608 (20SEP06)
9025-15-14

092006
PN=520
Group 20
Adjustments
Loader Bucket Self-Leveling Linkage
Indicator and Return-to-Dig Switch
Adjustment
SPECIFICATIONS
Guard and Stop-to-Bell Crank
Gap
1 mm (0.04 in.)
Top of Bell Crank Pin-to-Bottom

of Actuator Tang Gap
152 mm (6 in.)
TX,9025,RR7308 1919AUG961/4
9025
20
1
TM1608 (20SEP06)
9025-20-1

092006
PN=521
Adjustments
1. Position bucket flat on ground. Turn engine off.
2. Remove cover that covers linkage and reinstall cap
screw.
3. Hold bucket lever in roll-back position.
4. Measure gap (A) between guard and stop (B) and bell
crank (C). Gap should be 1 mm (0.04 in.).
Specification
Gap .................................................................................... 1 mm (0.04 in.)
5. If gap is not to specification, adjust rod jam nut and

yoke (D) to obtain correct gap.
UN26JUL96
Specification
Gap .................................................................................... 1 mm (0.04 in.)
Allow bucket lever to return to neutral position.
Specification
of Actuator TangGap ...................................................... 152 mm (6 in.)
UN05SEP96
7. If gap is not to specification, adjust sensor tube jam nut

and yoke (H) to correct length.
Specification
of Actuator TangGap ...................................................... 152 mm (6 in.)
T102231
9025
20
2
T102233
6. Measure gap (E) between top of bell crank pin (F) and
bottom of actuator tang (G). Gap should be 152 mm (6
in.).
A1 mm (0.04 in.) gap

BGuard/Stop
CBell Crank-Neutral Position
DRod Jam Nut and Yoke
E152 mm (6 in.) gap
FBell Crank Pin
GActuator Tang
HSensor Tube Jam Nut and Yoke
IBucket Dump
JBucket Rollback
TM1608 (20SEP06)
9025-20-2
TX,9025,RR7308 1919AUG962/4

092006
PN=522
Adjustments
8. Loosen cap screw (A) and move return-to-dig switch so
roller (B) is touching area (C) on the cam.
9. Move switch toward cam until a "click" is heard.
UN09NOV88
10. Move switch away from cam until a "click" is heard.

11. Tighten cap screw without moving switch.
NOTE: Be sure that switch arm and roller does not

bottom on switch housing.
T87154
12. While watching clearance between cam and switch,

turn bucket level pointer back and forth to be sure
cam does not hit switch bracket.
ACap Screw
BRoller
CArea on Cam
13. If cam touches bracket or switch arm, and roller

bottoms on switch housing, reposition switch. (See
steps 812.)
14. Install cover.
TX,9025,RR7308 1919AUG963/4
T6161AA
16. Check bucket level indicator to leveling decal. For

operators preference, the decal may be moved to
align with the bucket pointer.
UN18OCT88
15. When self-leveling mechanism is adjusted correctly,

bucket position will be approximately level or slightly
forward with the ground.
TX,9025,RR7308 1919AUG964/4
TM1608 (20SEP06)
9025-20-3

092006
PN=523
9025
20
3
Adjustments
Loader Control Valve Linkage Adjustment

SPECIFICATIONS
Right Side of Loader
Knob-to-Masking Tape Distance
250 mm (10 in.)
Front of Loader Knob-to-Masking

Tape Distance
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,RR7309 1917FEB001/5
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.
T7407AN
UN30OCT90
9025
20
4
T121805B
UN16JUN99
Loader Control Valve Linkage AdjustmentEarlier Machines
TM1608 (20SEP06)
9025-20-4
TX,9025,RR7309 1917FEB002/5

092006
PN=524
Adjustments
4. Distance (C) from right side of knob to tape should be
250 mm (10 in.).
6. Distance (D) from front of loader knob to tape should

be 130 mm (5.25 in.).
T7407AO
5. Put a piece of masking tape from left front to right front

ROPS posts on inside surface at loader knob height.
UN14NOV90
Specification
Right Side of Loader
Knob-to-Masking TapeDistance.................................... 250 mm (10 in.)
Specification
Front of Loader Knob-to-Masking
TapeDistance ............................................................. 130 mm (5.25 in.)
TX,9025,RR7309 1917FEB003/5
T7407AP
UN30OCT90
7. The distances in steps 4 and 6 can be obtained by

adjusting rods (E).
TX,9025,RR7309 1917FEB004/5
T7407AQ
UN30OCT90
NOTE: Pivot (F) must remain in slot when holding the

loader lever in the roll-back position.
TX,9025,RR7309 1917FEB005/5
TM1608 (20SEP06)
9025-20-5

092006
PN=525
9025
20
5
Adjustments
Backhoe Valve Linkage Adjustment

SPECIFICATIONS
Backhoe Lever Knob
Edge-to-Masking Tape Distance
140 mm (5.5 in.)
Backhoe Lever Knob-to-Knob

Distance
250 mm (10.25 in.)

travel and proper operation of backhoe valves.
Cab and other components have been removed in
1. Put backhoe valve spools in neutral position.
2. Put a piece of masking tape across the rear ROPS
posts on inside surface at backhoe lever knob height.
TX,9025,RR7310 1910JUN961/2
3. Measure from edge of knobs to tape. Distance (B)

should be 140 mm (5.5 in.).
Specification
Backhoe Lever Knob-to-Knob
Distance ....................................................................... 250 mm (10.25 in.)
UN30OCT90
Knobs should be 250 mm (10.25 in.) apart.
T7407AJ
9025
20
6
Specification
Backhoe Lever Knob
Edge-to-Masking TapeDistance................................... 140 mm (5.5 in.)
TX,9025,RR7310 1910JUN962/2
TM1608 (20SEP06)
9025-20-6

092006
PN=526
Adjustments
9025
20
7
TM1608 (20SEP06)
9025-20-7

092006
PN=527
Adjustments
T102959
UN23AUG96
Dual Stage System Relief AdjustmentDual

Stage System Relief Valve (310SE and
[315SE (S.N. 870248)]
T102958
UN18SEP96
9025
20
8
Dual Stage System Relief Valve

APilot Pressure Port
BLow Pressure Adjustment
Screw
CLow Pressure Lock Nut

DHigh Pressure Adjustment
EHigh Pressure Lock Nut
TM1608 (20SEP06)
9025-20-8
FGP Port
TX,9025,RR7311 1902FEB001/2

092006
PN=528
Adjustments
SPECIFICATIONS
Backhoe System Relief Valve
Setting Pressure
24 821 kPa (248 bar) (3525

psi)
High Pressure Lock Nut Torque
45 Nm (33 ft-lb.)
Loader System Relief Valve

Setting Pressure
20 684 kPa (207 bar) (2900

psi)
Low Pressure Lock Nut Torque
45 Nm (33 ft-lb.)
10. Adjust low pressure adjustment screw (B) to set

loader relief to specification (this screw should
have been turned in earlier in this procedure at
step no. 3; if it was not, start this procedure over).
Specification
SettingPressure ................................... 20 684 kPa (207 bar) (3000
psi)
11. Tighten lock nut (C) to 45 Nm (33 ft-lb.).
Gauge 035 000 kPa (0350 bar) (05000 psi)
The dual stage relief is designed to operate at two

relief pressures, one setting for the backhoe control
valve and the other for the loader control valve.
12. Release the loader function from over relief.

Tighten pilot pressure hose to port (A).
1. Loosen hose from pilot pressure port (A) by

loosening low pressure adjustment screw (B).
13. Move a loader function over relief to check the

system relief setting of the loader.
2. Loosen low pressure lock nut (C).

3. Turn in low pressure adjustment (B) screw until it
bottoms out.
4. Loosen high pressure lock nut (E).
Specification
psi)
Move a backhoe function over relief to check the

system relief setting of the backhoe.
5. Move a backhoe function over relief.

6. Adjust high pressure adjustment screw (D) to set
backhoe relief.
Specification
psi)
7. Tighten lock nut (E) to 45 Nm (33 ft-lb.).

Specification
High Pressure Lock Nut
Torque...................................................................... 45 Nm (33 ft-lb.)
8. Release backhoe function.
Specification
Low Pressure Lock Nut
Torque...................................................................... 45 Nm (33 ft-lb.)
Specification
psi)
If the settings are not to specification, start the entire

procedure over.
Specification
psi)
psi)
9. Move a loader function over relief.
TX,9025,RR7311 1902FEB002/2
TM1608 (20SEP06)
9025-20-9

092006
PN=529
9025
20
9
Adjustments
Stabilizer Valve Linkage Adjustment

SPECIFICATIONS
Right Stabilizer Knob
260 mm (10.25 in.)
Left Stabilizer Knob

295 mm (11.6 in.)

travel and proper operation of stabilizer valves.
Cab and other components have been removed in
1. Put stabilizer valve spools in neutral position.
TX,9025,RR7312 1910JUN961/3
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.
T8187AL
UN20FEB94
9025
20
10
Adjust Linkage Rods so Tabs are Vertical
TM1608 (20SEP06)
9025-20-10
TX,9025,RR7312 1910JUN962/3

092006
PN=530
Adjustments
4. Measure the distance (C) from edge of right stabilizer
knob to tape. It should be 260 mm (10.25 in.).
Specification
Left Stabilizer Knob
Edge-to-Masking TapeDistance................................. 295 mm (11.6 in.)
T7407AL
Measure the distance (D) from edge of left stabilizer knob

to tape. It should be 295 mm (11.6 in.).
UN30OCT90
Specification
Right Stabilizer Knob
Edge-to-Masking TapeDistance............................... 260 mm (10.25 in.)
T7407AM
UN30OCT90
Adjust rods (E) as necessary.
TX,9025,RR7312 1910JUN963/3
TM1608 (20SEP06)
9025-20-11

092006
PN=531
9025
20
11
Adjustments
9025
20
12
TM1608 (20SEP06)
9025-20-12

092006
PN=532
Group 25
Tests
Installation

T6813AG
UN28FEB89
Tachometer
TX,9025,RR7313 1910AUG951/1

ATemperature Probe Fasten to a bare metal line using a tie band.

Wrap with shop towel.
BCable
T6808CE
UN28FEB89
Digital Thermometer
TX,9025,RR7314 1928FEB951/1
TM1608 (20SEP06)
9025-25-1

092006
PN=533
9025
25
1
Tests
Hydraulic Oil Warm-Up Procedure

SPECIFICATIONS
Engine Speed
Fast idle

2. Run engine at fast idle.
Specification
EngineSpeed ............................................................................ Fast idle
3. Raise backhoe boom to full height, then hold lever and

stall hydraulics. This forces the hydraulic oil over the
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.
TX,9025,RR7315 1909AUG961/1
9025
25
2
TM1608 (20SEP06)
9025-25-2

092006
PN=534
Tests
Loader and Backhoe System Relief Pressure

Test
SPECIFICATIONS
Engine Speed
WOT
Oil Temperature
65 5C (150 10F)

Pressure Setting310SE
Backhoe
21374 690 kPa (214 7 bar)

(3100 100 psi)

Backhoe (S.N. 943225)
25683 690 kPa (257 7 bar)

(3725 100 psi)

Pressure Setting 310/315SE
(S.N. 943226)
24993 689.4 kPa (250 6.8)

(3625 100 psi)
Loader and Backhoe Single

Stage System Relief Valve
Backhoe (S.N.870248)
25683 690 kPa (257 7 bar)

(3725 100 psi)
ESSENTIAL TOOLS
JT03111 (9/16 -18 M ORB x 7/16 -20 M JIC) Connector
Gauge 035 000 kPa (0350 bar) (05000 psi)
Digital Thermometer
9025
25
3
1. Operate all hydraulic control valves to relieve pressure

in the hydraulic system.
TM1608 (20SEP06)
9025-25-3
TX,9025,RR7316 1907JUL051/3

092006
PN=535
Tests
2. Remove cover from battery box and connect pressure
gauge at the dual stage valve GP port (A).
3. Install temperature probe in reservoir. Warm oil to
specifications.
Specification
EngineSpeed .................................................................................. WOT
OilTemperature .................................... 65 5C (150 10F) (Cylinder
hot to touch)
(See Hydraulic Oil Warm-Up procedure in this group.)
NOTE: 315SE Machine only (S.N.870248): A single

stage relief valve is used. Record same pressure
for both the backhoe and loader control valves.
UN03SEP96
4. Hold loader bucket in rollback position and hold

function over relief. Record loader hydraulic system
relief setting from gauge.
9025
25
4
T102949
Specification
310SEPressure Setting ........................ 21374 690 kPa (214 7 bar)
(3100 100 psi)
315SE (S.N.870248)Pressure ........... 25683 690 kPa (257 7 bar)
(3725 100 psi)
Return bucket to neutral position.

5. Raise the backhoe boom fully and hold over relief.
Record the backhoe system relief setting from the
gauge.
Specification
(S.N.943225)Pressure
Setting....................................................... 25683 690 kPa (257 7 bar)
(3725 100 psi)
Setting....................................................... 24993 689.4 kPa (250 6.8)
(3625 100 psi)
Return boom raise lever to neutral position.

6. To adjust the loader and backhoe system reliefs, the
dual stage (310SE only) relief valve (B) is screw
adjustable. The 315SE (S.N.870248) has a single
stage relief valve that is screw adjustable.
TM1608 (20SEP06)
9025-25-4
TX,9025,RR7316 1907JUL052/3

092006
PN=536
Tests
Specification
310SE OnlyPressure Setting ................ 21374 690 kPa (214 7 bar)
(3100 100 psi)
315SE Only (S.N.870248)
Pressure ................................................... 25683 690 kPa (257 7 bar)
(3725 100 psi)
Setting....................................................... 25683 690 kPa (257 7 bar)
(3725 100 psi)
Setting....................................................... 24993 689.4 kPa (250 6.8)
(3625 100 psi)
(See Dual Stage System Relief Adjustment in 9025-20 in

this Section.)
TX,9025,RR7316 1907JUL053/3
9025
25
5
TM1608 (20SEP06)
9025-25-5

092006
PN=537
Tests
Steering Load Sense Relief Test

SPECIFICATIONS
Engine Speed
WOT
Oil Temperature
65 5C (150 10F)
Steering Load Sense Valve Relief

Pressure Setting
19650 690 kPa (196 7 bar)

(2850 100 psi)
ESSENTIAL TOOLS
JT03111 (9/16 -18 M ORB x 7/16 -20 M JIC) Connector
Gauge 035 000 kPa (0350 bar) (05000 psi)
UN10SEP96
Digital Thermometer
2. Remove cover from battery box and connect pressure

gauge at the dual stage valve GP port (A).
T103269
1. Operate all hydraulic control valves to relieve pressure

in the hydraulic system.
Priority Relief Test
3. Install temperature probe in reservoir. Warm oil to

specifications.
9025
25
6
Specification
EngineSpeed .................................................................................. WOT
OilTemperature .................................... 65 5C (150 10F) (Cylinder
hot to touch)
(See Hydraulic Oil Warm-Up procedure in this group.)

4. Rotate the steering wheel to the right or left until wheel
contacts stop. Hold steering wheel over relief and
record the priority system relief setting from the gauge.
Specification
Priority Valve Load Sense
ReliefPressure Setting .......................... 19650 690 kPa (196 7 bar)
(2850 100 psi)
Return steering wheel to center position.

5. To adjust the priority load sense relief if necessary, the
relief valve (B) is screw adjustable.
Specification
Priority Valve load sense Relief
Pressure Setting ....................................... 20689 690 kPa (207 7 bar)
(3000 100 psi)
TX,9025,RR7317 1909NOV011/1
TM1608 (20SEP06)
9025-25-6

092006
PN=538
Tests
Pump Unloading Valve Relief Pressure Test

SPECIFICATIONS
Engine Speed
Fast idle
Oil Temperature
65 5C (150 10F) (Cylinder

hot to touch)
Pump Unloading Valve Relief

Pressure Setting
20700 690 kPa (193 7 bar)

(3000 100 psi)
ESSENTIAL TOOLS
JT05688 (1-1/16 M 37 x -8F ORFS) Adapter
JT03103 Adapter
JT01608 Quick Coupler Nipple
Gauge 034 473 kPa (0344 bar) (05000 psi)
TM1608 (20SEP06)
9025-25-7
TX,9025,RR7318 1902FEB001/3

092006
PN=539
9025
25
7
T103655
UN10SEP96
Tests
T102954
UN17SEP96
9025
25
8
OilTemperature ............................. 65 5C (150 10F) (Cylinder

hot to touch)
1. Install digital thermometer temperature probe in

reservoir.
2. Connect pressure gauge at unloading test port (A).
4. Warm oil to specifications.
Specification
EngineSpeed ...................................................................... Fast idle
See Hydraulic Oil Warm-Up Procedure in this group.

5. Raise the backhoe boom fully and feather function
over relief watching the pressure gauge and note
maximum pressure before gauge needle drops off
(unloading). Record the backhoe system relief
setting from the gauge. Return boom raise lever to
neutral position.
TM1608 (20SEP06)
9025-25-8
TX,9025,RR7318 1902FEB002/3

092006
PN=540
Tests
6. Record pressure on gauge.
Specification
Pump Unloading Valve Relief
Pressure Setting ................................ 20700 690 kPa (193 7 bar)
(3000 100 psi)
7. The unloading relief is screw adjustable. After

loosening jam nut, turn screw (B) to make
adjustments.
TX,9025,RR7318 1902FEB003/3
Main and Auxiliary Pump Flow Test

SPECIFICATIONS
Oil Temperature
49 5C (120 10F)
Engine Speed
2000 rpm
Load Pressure
13,700 70 kPa (137 0.7 bar)

(2000 10 psi)
New Main Pump Minimum Flow

Rate
83 L/min (22 gpm)
Used Main Pump Minimum Flow

Rate
66 L/min (17.5 gpm
New Auxiliary Pump Minimum

Flow Rate
22 L/min (6 gpm)
Used Auxiliary Pump Minimum

Flow Rate
18 L/min (4.8 gpm)
New Combined Pump Minimum

Flow Rate
105 L/min (28 gpm)
Used Combined Pump Minimum

Flow Rate
84 L/min (22.3 gpm)
9025
25
9
ESSENTIAL TOOLS
38H1279* (-8 M x -8 M ORFS) Union
JT05688 (1-1/16 -12 M 37 x -8 F ORFS) Adapter (2 used)
Digital Thermometer
Flowmeter
TM1608 (20SEP06)
9025-25-9
TX,9025,RR7319 1920AUG961/3

092006
PN=541
T102952
UN17SEP96
Tests
Pump Flow Test

9025
25
10
AHydraulic Analyzer
BFlowmeter
CTee
DAuxiliary Pump Pressure
Hose
1. Put FNR and transmission control levers in neutral,

and engage park brake.
2. Install digital thermometer temperature probe in
reservoir.
3. Remove pressure line from backhoe to stabilizer
and add Tee (C) to stabilizer outlet port.
4. Remove auxiliary pressure hose (D) from backhoe
and connect to Tee (C). Connect other end of Tee
with hose from backhoe inlet (G).
5. Connect flowmeter (B) at backhoe inlet.
EMain Pump Pressure Hose

FStabilizer Valve
GBackhoe Inlet Cover
7. Warm hydraulic oil to test specifications.

Specification
OilTemperature ............................................ 49 5C (120 10F)
See Hydraulic Oil Warm-Up Procedure in this group.

8. Adjust engine speed to test specification.
Specification
EngineSpeed ..................................................................... 2000 rpm
Slowly close flowmeter to load pressure 13,700 70

kPa (137 0.7 bar) (2000 10 psi).
6. Open flowmeter.
TM1608 (20SEP06)
9025-25-10
TX,9025,RR7319 1920AUG962/3

092006
PN=542
Tests
Specification
LoadPressure ....................................... 13,700 70 kPa (137 0.7
bar) (2000 10 psi)
CAUTION: Prevent possible injury from

unexpected machine movement. Place the
transmission in neutral and engage the park
brake before moving the FNR to the forward
position.
9. Move the FNR lever to the forward position. Record
the flow rate of the main pump.
Specification
New Main PumpMinimum
Flow Rate............................................................... 83 L/min (22 gpm)
Used Main PumpMinimum
Flow Rate.............................................................. 66 L/min (17.5 gpm
10. Return the FNR lever to neutral position. Fully

rollback the loader bucket and hold over relief.
Record the pump flow of the auxiliary pump.
Specification
New Auxiliary PumpMinimum
Flow Rate................................................................. 22 L/min (6 gpm)
Used Auxiliary Pump
Minimum Flow Rate .............................................. 18 L/min (4.8 gpm)
11. Return the bucket rollback position to neutral.

Record the combined flow of the pumps.
Specification
New Combined Pump
Minimum Flow Rate ............................................. 105 L/min (28 gpm)
Used Combined Pump
Minimum Flow Rate ............................................ 84 L/min (22.3 gpm)
TX,9025,RR7319 1920AUG963/3
TM1608 (20SEP06)
9025-25-11

092006
PN=543
9025
25
11
Tests
T111701
1915OCT97
Hydraulic Oil Cooler Restriction Test
9025
25
12
AHydraulic Analyzer
BTee Fittings (2 used)
SPECIFICATIONS
Oil Temperature
65 5C (120 10F)
Flowmeter Flow Rate
28.4 L/min. (7.5 gpm)
Hydraulic Oil Cooler Maximum

Pressure Differential
379 kPa (3.8 bar) (55 psi)
ESSENTIAL TOOLS
(3/4 M NPT x 5/8 barb) Barb Fitting
COil Cooler
2. Open flowmeter. Heat oil to test specification.

Specification
OilTemperature ............................................ 65 5C (120 10F)
(See Hydraulic Oil Warm-Up Procedures in this

group.)
3. Increase engine speed until flow is at specification.
JT03012 (1-1/16 F 37 SW x 3/4 F NPT)

JT03048 (1-1/16 M ORB x 1-1/16 M 37)
JT03348 (1/2 F NPT) Tee (2 used)
JT03213 (5/8 I.D. Hose x 1/2 M NPT) Adapter (6 used)
Specification
FlowmeterFlow Rate ..................................... 28.4 L/min. (7.5 gpm)
4. Read pressure gauges at inlet and outlet of cooler.

Difference in gauge reading is pressure drop in
cooler.
Hydraulic Analyzer
Gauge 0670 kPa (06.9 bar) (0100 psi)
Flowmeter with Temperature Gauge
Specification
Hydraulic Oil CoolerMaximum
Pressure Differential .................................. 379 kPa (3.8 bar) (55 psi)
1. Make test connection.
TX,9025,RR7320 1912AUG961/1
TM1608 (20SEP06)
9025-25-12

092006
PN=544
Tests
Charging the Ride Control Accumulator
X9811
UN23AUG88
CAUTION: Hydraulic oil may escape at pressure

high enough to penetrate skin from
components in the Ride Control solenoid circuit
if components are removed without discharging
this accumulator. Hydraulic oil in accumulator
can be stored at pressures equal to or above
system relief pressures. Escaping fluid under
pressure can penetrate the skin causing serious
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.
this type of injury should reference a
knowledgeable medical source. Such
information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.
Specification
OilTemperature .................................................................. 40C (104F)
Ride Control Accumulator
Charge17.2 in. accumulator
canister lengthPre-charge
Pressure (310E, 310SE, 315SE
Machines) .................................................. 2482 241 kPa (25 2.4 bar)
(360 35 psi)
Charge17.2 in accumulator
Pressure (410E Machine) ......................... 3447 241 kPa (35 2.4 bar)
(500 35 psi)
Charge14.2 in. accumulator
Pressure (310E, 310SE, 315SE
and 410E Machines) ................................. 2930 241 kPa (29 2.4 bar)
(425 35 psi)
9025
25
13
TM1608 (20SEP06)
9025-25-13
CED,TX03768,8501 1908MAR001/3

092006
PN=545
Tests
Gas Cock . . . . . . . . . . . . . . . . . . . . . . . . . . JT01735
Charge Accumulator
CED,TX03768,8501 1908MAR002/3
Two different length accumulators have been used in

production and field installed ride control kits. The nitrogen
charge pressure is different for the two accumulators;
measure the length of the accumulator to determine the
proper charge. If the accumulator length is 14.2 in., use
procedure A. If the length is 17.2 in., use procedure B.
CED,TX03768,8501 1908MAR003/3
9025
25
14
TM1608 (20SEP06)
9025-25-14

092006
PN=546
Tests

Procedure A (14.2 in. accumulator)
1.
T128981
UN03MAR00
IMPORTANT: Charge accumulator using only dry

nitrogen. Dry nitrogen does not mix
with oil and is non-combustible. It will
not cause oxidation or condensation
inside accumulator and is not harmful
to piston seal. DO NOT use air or any
combustible gas as these can cause
oxidation and condensation. Oxidation
and condensation are harmful to piston
seal and accumulator.
UN03MAR00
If accumulator is to be charged on machine and has

some nitrogen pressure left, turn key to ON position.
Move ride control switch to OFF then back to ON.
Move control lever to float position to drain oil from
accumulator.
T128982
2. Loosen hose fitting on bottom of ride control

accumulator to release any trapped oil pressure. Leave
fitting loose until after charge pressure process is
complete.
ATop Nut
BBottom Nut
3. Remove cover and cap from top of accumulator.
9025
25
15
4. Turn handle on gas cock fully counterclockwise. Attach

gas cock, hose, and regulator to accumulator.
CAUTION: Loosen only the top nut (A). The
bottom nut (B) is actually the accumulator gas
valve fitting. Do Not loosen bottom fitting.
Loose fitting under pressure can cause injury.
5. Loosen top nut (A) (counterclockwise) 2 1/2 turns to
open gas valve in accumulator. (Resistance may be
felt at approximately 1 1/2 turns.)
6. Slowly open regulator valve to pressurize accumulator
to specification 2930 kPa (29 bar )(425 psi).
7. Ttighten nut (A) clockwise until snug to close gas
valve.
TM1608 (20SEP06)
9025-25-15
CED,TX03768,2708 1913MAR001/2

092006
PN=547
Tests
8. Shut-off the gas pressure from the nitrogen tank.
9. Slowly loosen the connector at the pressure regulator
valve to release pressure from the hose.
10. Remove the gas cock from the accumulator and
install cap.
11. Tighten hydraulic hose fitting on bottom of
accumulator.
CED,TX03768,2708 1913MAR002/2

Procedure B (17.2 in. accumulator)
The following procedure should be used for charging
accumulator that is already installed on the machine. See
specifications above to charge accumulator that needs a
precharge before it is installed on the machine.
9025
25
16
TM1608 (20SEP06)
9025-25-16
CED,TX03768,2709 1919SEP061/3

092006
PN=548
Tests
1. To determine proper nitrogen charge pressure for the
machine, install a gage into the head end of the loader
cylinder.
UN29MAY98
2. Raise the loader 3 to 4 ft. off the ground. Note the

head end pressure required to support the loader. (The
accumulator charge pressure should be 50 psi below
this pressure.)
T115658B
3. If accumulator is to be charged on machine and has

some nitrogen pressure left, turn key to ON position.
Move ride control switch to OFF then back to ON.
Move control lever to float position to drain oil from
accumulator.
4. Loosen hose fitting on bottom of ride control
accumulator to release any trapped oil pressure. Leave
fitting loose until after charge pressure process is
complete.
5. Remove cover and cap from the top of accumulator.
6. Turn handle on gas cock fully counterclockwise. Attach
gas cock, hose, and regulator to accumulator.
9025
25
17
TM1608 (20SEP06)
9025-25-17
CED,TX03768,2709 1919SEP062/3

092006
PN=549
Tests
7.
UN03MAR00
CAUTION: Loosen only the top nut (A). The

bottom nut (B) is actually the accumulator gas
valve fitting. Do Not loosen bottom fitting.
Loose fitting under pressure can cause injury.
T128981
Loosen top nut (A) counterclockwise 2 1/2 turns to

open gas valve in accumulator. (Resistance may be
felt in approximately 1 1/2 turns.)
8. Slowly open the regulator valve to pressurize
accumulator to 345 kPa (3.5 bar )(50 psi) below head
end psi measured earlier.
9. Tighten nut (A) clockwise until snug to close gas valve.
UN03MAR00
10. Shut-off the gas pressure from the nitrogen tank.

11. Slowly loosen the connector at the pressure regulator
valve to release pressure from the hose.
9025
25
18
T128982
12. Remove the gas cock from the accumulator and

install cap.
13. Tighten hydraulic hose fitting on bottom of
accumulator.
ATop Nut
BBottom Nut
CED,TX03768,2709 1919SEP063/3
Ride Control AccumulatorDischarge Procedure

CAUTION: Prevent possible injury from
unexpected boom or bucket movement when
equipped with ride control. Ride control
accumulator energy must be discharged
when working on hydraulic components.
Turn key switch to ON position and move
the loader control lever into the float
position.
2. Make sure area around bucket is clear and move

ride control switch to OFF position.
3. Turn key switch to ON position, but do not start
engine. Move ride control switch to ON position.
4. Move loader control lever to float position. Bucket
should lower to ground.
1. Position loader bucket approximately 30 cm (1 ft)

off the ground.
CED,OUTX466,955 1914SEP061/1
TM1608 (20SEP06)
9025-25-18

092006
PN=550
Tests
Circuit Relief Valve Test with Remote Pump

SPECIFICATIONS
Hydraulic Source Maximum Flow
Rate
7.5 L/min (2 gpm)
Oil Temperature
40 6C (104 10F)
Set Tolerance Pressure
+1380 -0 kPa (+13.8 -0 bar)

(+200 -0 psi)
Loader Circuits
Auxiliary Extend Pressure
(non-adjustable)
26200 kPa (262 bar) (3800 psi)
Bucket Curl Pressure (screw

adjustable)
31715 kPa (317 bar) (4600 psi)
Bucket Dump Pressure (screw

adjustable)
31715 kPa (317 bar) (4600 psi)
Boom Up Pressure (screw

adjustable)
34473 kPa (344 bar) (5000 psi)
Backhoe Circuits
Crowd Out Pressure (screw
adjustable)
32800 kPa (327 bar) (4750 psi)
Crowd In Pressure
(non-adjustable)
26200 kPa (276 bar) (3800 psi)
Bucket Curl Pressure (screw

adjustable)
31700 kPa (317 bar) (4600 psi)
Bucket Dump Pressure (screw

adjustable)
31700 kPa (317 bar) (4600 psi)
Boom Raise Pressure (screw

adjustable)
34500 kPa (345 bar) (5000 psi)
Boom Down Pressure

(non-adjustable)
14800 kPa (148 bar) (2150 psi)
Swing Left Pressure

(non-adjustable)
26200 kPa (262 bar) (3800 psi)
Swing Right Pressure

(non-adjustable)
26200 kPa (262 bar) (3800 psi)
9025
25
19
ESSENTIAL TOOLS
JT07192 Electric/Hydraulic Pump
38H1355 (-10 ORFS) Nut
38H1470 (-10FX -6 M ORFS) Reducer
38H1356 (-12 ORFS) Nut
38H1473 (-12 -6 ORFS) Reducer
38H1358 (-16 ORFS) Nut
TM1608 (20SEP06)
9025-25-19
TX,9025,RR7321 1902FEB001/3

092006
PN=551
Tests
Gauge 048 260 kPa (0482 bar) (07000 psi)
Digital Thermometer
IMPORTANT: Relief valve is flow sensitive. A flow

rate greater than 7.5 L/min (2 gpm) will
flood the valve causing an inaccurate
pressure reading. A hydraulic source
must be used that will provide a
continuous flow to get an accurate
reading.
1. Operate hydraulic functions to relieve pressure.
TX,9025,RR7321 1902FEB002/3
2. Place container (C) under hoses to catch any oil

leakage.
3. Connect test pump pressure hose (A) to circuit inlet
hoses and cap all other ends of hose during this test.
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.
UN23AUG96
Specification
Hydraulic SourceMaximum Test
Flow Rate ...................................................................... 7.5 L/min (2 gpm)
T102189
9025
25
20
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.
TX,9025,RR7321 1902FEB003/3
TM1608 (20SEP06)
9025-25-20

092006
PN=552
Tests
Steering System Leakage Test

SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
Low idle
Steering Wheel Torque
11.3 Nm (100 lb-in.)
5 to 7 rpm for hot oil
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.
Digital Thermometer
TM1608 (20SEP06)
9025-25-21
TX,9025,RR7322 1912AUG961/5

092006
PN=553
9025
25
21
Tests
1. Install digital thermometer probe in reservoir.
2. Heat hydraulic oil to specifications.
UN26OCT88
Specification
(See procedure in this group.)
T93024

4. Remove steering wheel emblem.
5. Bend locking tab away from steering wheel nut.
6. Run the engine at low idle.
Specification
EngineSpeed ............................................................................. Low idle
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.)
9025
25
22
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.
Specification
Count the rpm.

9. If the steering wheel can be turned faster than 7 rpm in
either direction, excessive leakage is indicated.
Specification
Steering SystemLeakage ....................................... 5 to 7 rpm for hot oil
Go to steps 12-16 to isolate steering valve or cylinder

leakage.
10. If the steering wheel cannot be turned faster than 7
rpm in both directions, the steering valve and cylinder
are good.
TM1608 (20SEP06)
9025-25-22
TX,9025,RR7322 1912AUG962/5

092006
PN=554
Tests
Specification
Stop the test here.

11. Stop the engine.
TX,9025,RR7322 1912AUG963/5
UN23AUG88

fluids.
X9811

9025
25
23
12. Operate all hydraulic control valves to release

pressure in system.
TM1608 (20SEP06)
9025-25-23
TX,9025,RR7322 1912AUG964/5

092006
PN=555
Tests
13. Disconnect hydraulic lines from steering cylinder and
install caps (B) and plugs (A).
14. Start the engine and run at low idle.
Specification
15. Turn steering wheel counterclockwise and then

clockwise at a constant torque of 11.3 Nm (100
lb-in.).
UN25MAY89
Specification
Count the rpm.
Specification
T6076AM
16. If steering wheel can be turned faster than 7 rpm in

either direction, steering valve is leaking excessively.
Axle Without MFWD Shown
If the rpm is less than 7, do Steering Cylinder Leakage

Test in this section.
9025
25
24
TX,9025,RR7322 1912AUG965/5
TM1608 (20SEP06)
9025-25-24

092006
PN=556
Tests
Steering Cylinder Leakage Test

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

channels.
Digital Thermometer

Specification

3. Start engine. Turn the steering wheel to left turn stop
to extend cylinder rod. Stop engine. Move steering
wheel back and forth to relieve hydraulic pressure.
9025
25
25
TM1608 (20SEP06)
9025-25-25
TX,9025,RR7323 1921JUL941/2

092006
PN=557
Tests
4. Remove rod end hose and plug (A) and recover
excess oil from cylinder. Place a beaker under cylinder
port. Remove rod end hose and plug (A).
5. Start engine and hold steering wheel in full left turn
with constant pressure for one minute.
Specification
Stop engine.
UN25MAY89
6. Measure oil collected and connect hose.
T6076AL
Specification
Steering CylinderLeakage..................................... 5 ml/min (1/6 oz/min)
Axle Without MFWD Shown
TX,9025,RR7323 1921JUL942/2
9025
25
26
TM1608 (20SEP06)
9025-25-26

092006
PN=558
Tests
Hydraulic Cylinder Drift Test Procedure
T103936
1920SEP96
9025
25
27
TX,9025,RR7336 1920SEP961/1
TM1608 (20SEP06)
9025-25-27

092006
PN=559
Tests
Function Drift Test

SPECIFICATIONS
Oil Temperature
65 5C (150 10F)
Engine Speed
Low idle
Max. Allowable Backhoe Function

Drift
40 mm/min (1.58 in/min)
Max. Allowable Loader Function

Drift
Max. Allowable BH Boom (Std.

Dipper) Cylinder Drift
Max. Allowable BH Crowd (Std.

Dipper) Cylinder Drift
Max. Allowable BH Bucket

Cylinder Drift
Max. Allowable Swing (Right or

Left) Drift
Loader Boom Cylinder Drift
Loader Bucket Cylinder Drift
Extendible Dipperstick Cylinder

Drift

Digital Thermometer
9025
25
28
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
extendible dipperstick machines fully retract
dipperstick for all testing.
1. Install digital thermometer probe in reservoir. Warm
hydraulic oil to specifications.
Specification
(See Hydraulic Oil Warm-Up Procedure in this group.)

TM1608 (20SEP06)
9025-25-28
TX,9025,RR7330 1909SEP961/5

092006
PN=560
Tests
3. Function Drift
UN19SEP96
4. Position backhoe bucket side cutters at 45 angle to

ground and lower boom until bucket cutting edge is 51
mm (2.0 in.) off ground.
5. Position cutting edge of loader bucket with bucket
level, approximately 51 mm (2.0 in.) off ground.
T102956
NOTE: If bucket cutting edges touch the ground within

one minute, excessive leakage is indicated in the
cylinders or control valve. Position machine as
shown, with the bucket pivot pin one meter (36
in.) off ground.
6. Run engine at slow idle and observe bucket cutting
edges for one minute.
Specification
Max. Allowable Backhoe
FunctionDrift ..................................................... 40 mm/min (1.58 in/min)
Max. Allowable Loader
FunctionDrift ..................................................... 20 mm/min (0.79 in/min)
TX,9025,RR7330 1909SEP962/5
7. Position the crowd cylinder with rod 2050 mm

(0.752.00 in.) extended from the fully retracted
position and mark rod with tape as shown.
UN26MAY89
8. Position the bucket cylinder with rod 2050 mm

(0.752.00 in) retracted from the fully extended
position and mark rod with tape as shown.
T6222AM
9. Measure movement of boom, crowd, and bucket

cylinder rods after five minutes. Divide measured rod
drift by five to determine drift per minute.
Backhoe Cylinder Drift
Specification
Max. Allowable BH Boom (Std.
Dipper) CylinderDrift .......................................... 3 mm/min (0.12 in/min)
Max. Allowable BH Crowd (Std.
Dipper) CylinderDrift .......................................... 2 mm/min (0.08 in/min)
Max. Allowable BH Bucket
CylinderDrift ....................................................... 3 mm/min (0.12 in/min)
TM1608 (20SEP06)
9025-25-29
TX,9025,RR7330 1909SEP963/5

092006
PN=561
9025
25
29
Tests
UN19SEP96
10. To measure swing drift tilt machine by fully extending

right stabilizer. Fully extend dipperstick and bucket
straight behind following centerline of machine, so
bucket is approximately 300 mm (12 in.) off ground.
Boom should be parallel to ground. Position left
stabilizer 75 mm (3 in.) off ground.
T102957
11. Measure swing drift from side of bucket, to vertical

rod placed in ground next to bucket (see illustration),
after five minutes. Divide measured drift by five to
determine drift per minute.
Specification
Left)Drift ......................................................... 100 mm/min (3.94 in/min)
12. Measure swing drift in opposite direction by reversing

stabilizer positions and vertical rod.
Specification
Left)Drift ......................................................... 100 mm/min (3.94 in/min)
TX,9025,RR7330 1909SEP964/5
13. Position the machine with the loader bucket pivot pin
one meter (36 in.) above ground, with bucket level.
UN26MAY89
14. Mark boom and bucket cylinder rods with tape as

shown. Measure movement of cylinder rods after five
minutes. Divide measured rod drift by five to
determine drift per minute.
Specification
Loader Boom CylinderDrift ................................ 2 mm/min (0.08 in/min)
Loader Bucket CylinderDrift ............................... 3 mm/min (0.12 in/min)
Extendible Dipperstick Cylinder Drift
T6222AM
9025
25
30
Loader Cylinder Drift
15. With machine in transport position. Curl backhoe

bucket. Remove extendible dipperstick locking pin.
Measure drift from end of dipperstick housing to
ground after five minutes. Divide measured drift by
five to determine drift per minute.
Specification
Extendible Dipperstick Cylinder
Drift ........................................................................ 6 mm/min (0.25 in/min)
TX,9025,RR7330 1909SEP965/5
TM1608 (20SEP06)
9025-25-30

092006
PN=562
Tests
Cylinder Leakage Test

Oil Temperature
65 5C (150 10F)
Engine Speed
Low idle
Cylinder Leakage
5 ml/min (1/6 oz/min)
UN26OCT88
SPECIFICATIONS
ESSENTIAL TOOLS
T6222AL
38H1353 (-6 ORFS) Nuta

38H1354 (-8 ORFS) Nuta
a

channels.
Digital Thermometer

Specification
9025
25
31
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
TM1608 (20SEP06)
9025-25-31
TX,9025,RR7326 1921JUL941/2

092006
PN=563
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.
TX,9025,RR7326 1921JUL942/2
Stabilizer Valve Lockout Leakage Test

Low idle
Oil Temperature
65 5C (150 10F)
Max. Cylinder Rod Travel
0.15 mm/min (0.006 in/min)
T6222AN
Digital Thermometer
Dial Indicator
9025
25
32
UN26OCT88
SPECIFICATIONS
Engine Speed
1. Install digital thermometer probe in reservoir. Heat

hydraulic oil to test specifications.
Specification

2. Lower stabilizers to lift machine off ground. Check for
cylinder rod movement with dial indicator.
Specification
Max. Cylinder RodTravel ............................ 0.15 mm/min (0.006 in/min)
NOTE: The stabilizer valve has lockouts to prevent

cylinder drift up or down. If cylinder rod drift is
above specification, remove the lockout and check
for scratches on the seat and poppet. Replace if
required. Check that the lockout plunger which
slides between the two lockouts is not sticking.
Also check for contamination in the thermal relief
poppet seat and cylinder packing.
TX,9025,RR7517 1902OCT961/1
TM1608 (20SEP06)
9025-25-32

092006
PN=564
Tests
Sideshift Valve Leakage Test315SE

40 6C (104 10F) (Warm to
touch)
Engine Speed
Slow idle
Sideshift Valve Leakage Test

Pressure
Boom raise (system relief)2 5000

690 kPa (249 7 bar) (3625
100 psi)
Sideshift Valve Maximum

Leakage
125 mL (4.2 oz)
X9811
Oil Temperature
UN23AUG88
SPECIFICATIONS

Digital Thermometer
Measuring Beaker
UN23DEC96
1. Install digital thermometer probe in reservoir. Heat

hydraulic oil to test specification.
T105743
Specification
OilTemperature ................................... 40 6C (104 10F) (Warm to
touch)

9025
25
33

fluids.
3. Stop engine and operate controls to relieve pressure in
hydraulic system.
TM1608 (20SEP06)
9025-25-33
EX,9025,BG104 1902FEB001/2

092006
PN=565
Tests
4. Remove return line (A) and install plug in hose end.
Connect a hose to open fitting and put other end into
measuring beaker.
5. Start machine and hold boom raise function for one
minute.
Specification
EngineSpeed ............................................................................ Slow idle
Sideshift Valve Leakage Test
Pressure ................................................ Boom raise (system relief) 25000
690 kPa (249 7 bar) (3625
100 psi)
Measure oil. If leakage is excessive, replace O-ring or

replace valve as necessary.
Specification
Sideshift ValveMaximum
Leakage ............................................................................ 125 mL (4.2 oz)
See repair manual.
EX,9025,BG104 1902FEB002/2
9025
25
34
TM1608 (20SEP06)
9025-25-34

092006
PN=566
Tests
Cycle Time Specifications

Item
Measurement
Specification
Oil
Temperature
65 5C (150 10F)
Engine
Speed
Fast idle
INDIVIDUAL CIRCUIT CYCLE TIME SPECIFICATIONS

Oil temperature: 65 5C (150 10F)
Engine speed: Fast idle
Function
Operating Conditions
Maximum Cycle Time in Seconds
Loader boom raise
Bucket flat on ground to full height (includes

bucket self-leveling)
4.9
Loader boom lower

Loader bucket dump
2.8
Bucket just clears ground
2.3
Loader bucket rollback
Bucket just clears ground
2.3
Backhoe boom raise
Backhoe at maximum reach with bucket teeth

on ground up to cylinder cushion
2.7
Backhoe boom lower
Backhoe at maximum reach. Transport

position to bucket teeth on ground
2.9
Crowd in
Boom in transport position
3.6
Crowd out
3.4
Backhoe bucket dump
2.1
Backhoe bucket curl
3.0
Backhoe swing
Boom raised to cushion, bucket curled,

dipperstick parallel to ground. Time cycle to
cylinder cushion
4.1
Right stabilizer down
Full up to ground level
2.8
Left stabilizer down
Full up to ground level
1.9
Stabilizer up left and right
Ground level to full up
9025
25
35
2.4
Extendible dipperstick extend and retract
3.2
TURNS
Steering right to left
Turns
2.3 to 3
Steering left to right
Turns
2.3 to 3
Steering right to left (MFWD)
Turns
2.3 to 3
Steering left to right (MFWD)
Turns
2.3 to 3
Item
Measurement
Specification
Oil
Temperature
65 5C (150 10F)
Engine
Speed
Fast idle
TM1608 (20SEP06)
9025-25-35
TX,9025,RR7329 1902FEB001/2

092006
PN=567
Tests
Maximum Cycle Time
Operating Conditions
310SE
Main hydraulic pump
Function
Engine speed: 1000 25 rpm. Bucket flat on ground to

maximum height. (Includes bucket self-leveling)
15
Steering pump
Engine speed: Fast Idle

Full crowd out cycle of dipperstick, while loader boom is
at maximum height and held over relief.
18 sec.
TX,9025,RR7329 1902FEB002/2
9025
25
36
TM1608 (20SEP06)
9025-25-36

092006
PN=568
Section 9031
Heating And Air Conditioning

Contents
Page
Page
Group 05Theory Of Operation

Proper Refrigerant Handling . . . . . . . . . . . . .9031-05-1
R134A Refrigerant Cautions . . . . . . . . . . . . .9031-05-1
Refrigerant Theory Of Operation . . . . . . . . . .9031-05-2
Air Conditioning Circuit
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-4
Schematic . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-5
Blower Circuit
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-6
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 25Test
Heating and Air Conditioning
Special or Essential Tools . . . . . . . . . . . . .9031-25-1
Service Equipment and Tools . . . . . . . . . .9031-25-3
R134A Air Conditioning System Test . . . . . .9031-25-5
Pressure Diagnostic Chart. . . . . . . . . . . . . . .9031-25-7
Low Pressure Switch Test. . . . . . . . . . . . . . .9031-25-8
High Pressure Switch Test . . . . . . . . . . . . . .9031-25-9
A/C Freeze Control Switch . . . . . . . . . . . . .9031-25-11
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .9031-25-11
Refrigerant Hoses And Tubing
Inspection . . . . . . . . . . . . . . . . . . . . . . . .9031-25-12
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 . . . . . . . . . . . .9031-10-4
Blower/Air Conditioning Circuit Checks . . . . .9031-10-5
9031

Diagnose Air Conditioning Electrical
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9031-15-1
Air Conditioning Component Location . . . . . .9031-15-2
Group 20Adjustments
Heating and Air Conditioning
Special or Essential Tools . . . . . . . . . . . . .9031-20-1
Service Equipment and Tools . . . . . . . . . .9031-20-2
Other Materials . . . . . . . . . . . . . . . . . . . . .9031-20-2
R134A Compressor Oil Charge Check . . . . .9031-20-4
R134A Compressor Oil Removal. . . . . . . . . .9031-20-4
R134A Component Oil Charge . . . . . . . . . . .9031-20-5
R134A Refrigerant Recovery, Recycling
And Charging Station Installation
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9031-20-7
Recover R134A System . . . . . . . . . . . . . . . .9031-20-8
Evacuate R134A System. . . . . . . . . . . . . . . .9031-20-9
Charge R134A System . . . . . . . . . . . . . . . .9031-20-11
TM1608 (20SEP06)
9031-1

092006
PN=1
Contents
9031
TM1608 (20SEP06)
9031-2

092006
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: To meet government standards
relating to the use of refrigerants,
R134a is used in the air conditioning
system. Because it does not contain
chlorine, R134a is not detrimental to
the ozone in the atmosphere.
However, it is illegal to discharge
any refrigerant into the atmosphere.
It must be recovered using the

appropriate recovery stations.
Use correct refrigerant recovery,
recycling and charging stations. DO
NOT mix refrigerants, hoses, fittings,
components or refrigerant oils.
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,QQ6357 1905AUG961/1
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
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.
TX,9031,QQ6358 1911JUN961/1
TM1608 (20SEP06)
9031-05-1

092006
PN=571
9031
05
1
Theory Of Operation
T126716
1911FEB00
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
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.
TM1608 (20SEP06)
LBlowers
MA/C Freeze Switch
NLow Pressure Gas
9031-05-2
TX,9031,QQ6359 1902FEB001/2

092006
PN=572
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
A/C freeze 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,QQ6359 1902FEB002/2
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 position 1, 2, 3 or 4.
TX,9031,QQ6465 1907OCT961/1
TM1608 (20SEP06)
9031-05-3

092006
PN=573
9031
05
3
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 1, 2, or 3 position, power flows to blower
resistor and then to heater blower motor. With blower
switch turned to position 4 the resistor is bypassed and
blower motor is in max speed.
Power also flows from blower switch, through white
wire to A/C freeze switch, through black/white and A16
orange 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.
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.
A/C Freeze Switch
The A/C freeze switch is used to sense the
temperature in the evaporator core. When the
temperature drops, the A/C freeze switch opens,
shutting the compressor off. When the temperature in
the evaporator core raises, the A/C freeze switch
closes sending voltage to the compressor.
The A/C freeze switch receives power from the blower
switch when blower switch is turned to each position.
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.
NOTE: For component identification code description,

see Wiring and Schematic Diagrams Legend,
Group 9015-10.
9031
05
4
TX,9031,QQ6361 1902FEB001/1
TM1608 (20SEP06)
9031-05-4

092006
PN=574
Theory Of Operation
Air Conditioning Circuit Schematic
T126713
1920DEC99
9031
05
5
TX,9031,QQ6362 1902FEB001/1
TM1608 (20SEP06)
9031-05-5

092006
PN=575
Theory Of Operation
Blower Circuit Operational Information

The following conditions must exist for blower circuit to
function:
Key switch in ON or ACC position
Blower switch turned ON
TX,9031,QQ6363 1911JUN961/1
Blower Circuit Theory Of Operation

Power from heater circuit breaker goes to blower switch.
With blower switch in positions 1, 2, or 3 power is sent to
blower resistor reducing blower motor speed. With blower
switch in position 4 the resister is bypassed and blower
motor will run in max speed.

Wiring and Schematic Diagrams Legend, Group
9015-10.
9031
05
6
TX,9031,QQ6364 1911JUN961/1
TM1608 (20SEP06)
9031-05-6

092006
PN=576
Theory Of Operation
Blower Circuit Schematic
T126714
1920DEC99
9031
05
7
TX,9031,QQ6365 1902FEB001/1
TM1608 (20SEP06)
9031-05-7

092006
PN=577
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.
UN19OCT93
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.
UN10JAN94
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.
T8104AF
9031
05
8
T8104AE
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).
AInlet Port
BSight Glass
COutlet Port
DPickup Tube
EFilter
FDesiccant
GStrainer
HSpring
IReceiver/Dryer
JWet/Dry Indicator
TM1608 (20SEP06)
9031-05-8
TX,9031,QQ6366 1911JUN961/2

092006
PN=578
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,QQ6366 1911JUN962/2
9031
05
9
TM1608 (20SEP06)
9031-05-9

092006
PN=579
Theory Of Operation
T7828AY
1924SEP92
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
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.
JDischarge from Evaporator

KInternal Equalization
Passage
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,QQ6367 1911JUN961/1
TM1608 (20SEP06)
9031-05-10

092006
PN=580
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.
Specification
Compressor Relief Valve
Pressure............................................... 4137 kPa (41.4 bar) (600 psi)
TX,9031,QQ6368 1911JUN961/1
Temperature Control
Temperature control is adjusted by the position of the
heater temperature switch in the cab. This switch is
mechanically connected to the water valve at the base of
the heater core. Turning the heater temperature switch
towards maximum and/or towards off opens and closes
the water valve controlling engine coolant flow through the
heater core, thus controlling the temperature inside the
cab.
9031
05
11
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.
TX,9031,QQ6369 1911JUN961/1
TM1608 (20SEP06)
9031-05-11

092006
PN=581
Theory Of Operation
9031
05
12
TM1608 (20SEP06)
9031-05-12

092006
PN=582
Group 10
System Operational Checks

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).
additional checks or repair information will be given.

TM 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)
The engine or other major components must be at

operating temperature for some checks.
Group: 15 (Diagnostic Information)
Locate system check in the left column and read

completely, following this sequence from left to right.
Read each check completely before performing.
Group: 20 (Adjustments)
At the end of each check, if no problem is found, that

check is complete. When a problem is indicated,
CTM (Component Technical Manual)
Group: 25 (Tests)
TX,9031,QQ6370 1902FEB001/1
1 Visual Inspection Of Components
1/1
Check All Lines And

Hoses
Engine OFF.
Inspect all lines and hoses.
NO: Reposition hoses or

lines and tighten or
replace clamps. Tighten
fittings or replace O-rings
in fittings. Replace hoses
or lines as required.
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?
1/1
TM1608 (20SEP06)
9031-10-1

092006
PN=583
9031
10
1

Condenser Check
Engine OFF.
Inspect condenser cores.
NO: Clean, repair or

replace condenser core.
Replace engine fan.
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?
1/1
Evaporator Core Check
Engine OFF.
Inspect core.
NO: Repair, replace or

clean evaporator.
Are fins straight?

Is evaporator core free of dirt and debris?
1/1
A/C Freeze Switch

Sensing Tube Check
Engine OFF.
Inspect A/C freeze switch sensing tube.
NO: If sensing tube is

kinked, replace A/C
freeze switch.
Is sensing tube straight, NOT kinked or broken?
9031
10
2
Is sensing tube inserted into evaporator core and secured in place?
NO: If tube is positioned

in evaporator incorrectly,
re-route.
1/1
TM1608 (20SEP06)
9031-10-2

092006
PN=584

Air Conditioner
Compressor Check
Engine OFF.
Inspect compressor.

components as required.
Is compressor drive belt tight? Is belt in good condition? Is belt tightening strap
straight?
Is compressor belt pulley in good condition (NOT grooved)?
Are compressor to bracket and bracket to engine mounting cap screws tight?
Is compressor pulley aligned with engine pulley?
Are electrical connections to compressor clutch clean and tight? Is wiring to
compressor in good condition?
1/1
Cab Door And Window

Seals Check
Open and close door and windows. Inspect seals.
Do door and windows contact seals evenly?
NO: Adjust door and

windows to close against
seals properly. Replace
seals as necessary.
Are seals in position and in good condition?
1/1
2 System Operating Checks
1/1
Blower Motor Check

NO: See Circuit Checks
in Group 9031-10. Check
wiring harness.
T101677 UN28JUN96
Engine OFF. Key switch ON.

Turn blower switch (A) to position 1, 2, 3 and 4.
Does fan have four speeds?
Does air exit from ducts?
1/1
TM1608 (20SEP06)
9031-10-3

092006
PN=585
9031
10
3

Heater Check
NO: See Circuit Checks

in Group 9031-10. Check
wiring harness.
T101678 UN28JUN96
Start engine and allow to warm several minutes.

Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high
speed.
Does warm air exit from ducts?
1/1
Air Conditioner (If

Equipped) Check

NO: See Blower/Air
Conditioning Circuit
Checks in Group
9031-10. See Charging
the system in Group
9031-20.
T101679 UN28JUN96

Turn air conditioner switch (A) to ON position.
9031
10
4
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?
NO: Replace compressor

clutch.
1/1
3 System Performance Checks
1/1
TM1608 (20SEP06)
9031-10-4

092006
PN=586

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?
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?
NO: Go to Clutch Cycle

Switch Bench Test in
Group 9031-25.
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?
1/1
4 Blower/Air Conditioning Circuit Checks
1/1
Blower Switch Check
Disconnect harness from blower switch.
YES: Blower switch is

good. Go to next check.
Using a multimeter check for continuity.

Move blower switch to position 1, 2, 3, and 4 checking
terminals B and 1, B and 2, B and 3, B and 4.
NO: Replace blower

switch.
9031
10
5
T101680 UN28JUN96
1/1
TM1608 (20SEP06)
9031-10-5

092006
PN=587

Blower Resister Check
Measure ohms between terminals 4 and 2.
YES: Resistor is good.

Does ohmmeter read 1.0 ohms?

NO: Replace resistor
T102849 UN06AUG96
1/1
Heater/Blower Motor
Check
Disconnect harness from heater blower motor.

Connect 12 volts to heater blower motor, and ground
motor.
YES: Heater blower

motor is good. Check
wiring harness.
NO: Replace heater
blower motor.
Does heater blower motor operate?
T7199CM UN16AUG90
9031
10
6
1/1
A/C Freeze Switch Check
With A/C freeze switch at room temperature.

YES: Do A/C Freeze

Switch Test. See Group
9031-25. If Switch is OK.
Measure continuity across switch terminals.

NO: Switch has failed.

Replace switch.
T7835AV 1924SEP92
1/1
TM1608 (20SEP06)
9031-10-6

092006
PN=588

Air Conditioning Switch
Check
YES: A/C switch is good.

NO: Replace A/C switch.
T100731 UN28MAY96
Disconnect harness from air conditioning switch.

A/C switch OFF, and measure for continuity between terminals 2A and 1.
Turn switch ON, and measure for continuity between terminals 2B and 3.
1/1
Air Conditioner Low

Pressure Switch Check
YES: Continue with this

check.
Check for continuity between terminals. Is continuity

measured?
NO: Replace switch.

9031
10
7
T101619 1913JUN96
1/1
Air Conditioner Low

(Continued)
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.)

Measure for continuity across switch terminals.
NO: Go to Low Pressure

Switch Test, Group
9031-25.
Does ohmmeter read open?
1/1
TM1608 (20SEP06)
9031-10-7

092006
PN=589

Air Conditioner High
YES: Continue with this

check.
Measure continuity across outer switch terminals.

NO: Replace switch.
Does ohmmeter read continuity?
T101618 1913JUN96
1/1
Air Conditioner High

(Continued)
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.
NO: System pressure is

too high. Go to Air
Conditioning Pressure
Diagnostic Chart, Group
9031-25.
Does ohmmeter read continuity?
1/1
Air Conditioning
Compressor Clutch Coil
Check
Disconnect harness from clutch.

Connect battery voltage to clutch terminal that has
orange wire. Ground black wire terminal.
YES: A/C compressor

clutch coil is good. Check
wiring harness.
NO: Replace clutch coil.
9031
10
8
Does clutch "click"?
T6534CV UN19OCT88
1/1
TM1608 (20SEP06)
9031-10-8

092006
PN=590
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
Symptom
Problem
Solution
Air Conditioning System Does

Not Operate
Circuit Breaker
Replace circuit breaker.
Blower Switch
See Blower/Air Conditioning Circuit

Checks, Group 9031-10.
Blower Resistor

Heater/Blower Motor

A/C Freeze Switch

Air Conditioning Switch

Low Pressure Switch

High Pressure Switch

Compressor Clutch Coil

Wiring Harness
Check wiring harness. See Group

9015-10.
9031
15
1
TX,9031,QQ6371 1912JUN961/1
TM1608 (20SEP06)
9031-15-1

092006
PN=591
Air Conditioning Component Location

T116041 1929JUN98
CED,OUTX466,1106 1920JUL981/2
TM1608 (20SEP06)
9031-15-2

092006
PN=592
1Condenser
2High Pressure Switch (S24)
3Low Pressure Switch (S23)
4A/C Compressor Harness
(W11)
5Engine Harness (W8)
6Expansion Valve
7Cab Floor Ground (W3)
8Blower Switch Connector
(X6)
9Blower Harness To Side

Console Harness
Connector (X35)
10Blower Switch (S8)
11Heater Temp. Switch (S22)
12Blower Harness (W10)
13Blower Harness To Side
Console Harness
Connector (X5)
14Seat Position Sensor

(S19)
15Blower Harness To Air
Adjust Seat Harness
Connector (X56)
16Blower Resister (R1)
17Heater Blower Motor (M6)
18A/C Freeze Switch (S26)
19Evaporator
20Line To Water Pump
21Line To Engine Block
22Receiver Dryer
23Compressor (Y10)
24High Pressure Service
Port
NOTE: 310SE machine is shown but all component

locations apply to 315SE also.
NOTE: For electrical call-outs in parenthesis, see
Wiring and Schematic Diagrams Legend in
Group 9015-10.
CED,OUTX466,1106 1920JUL982/2
9031
15
3
TM1608 (20SEP06)
9031-15-3

092006
PN=593
9031
15
4
TM1608 (20SEP06)
9031-15-4

092006
PN=594
Group 20
Adjustments
Special or Essential Tools
NOTE: Order tools according to information given in the
U.S. SERVICEGARDCatalog or in the European
Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company.
TX,9031,QQ6692 1915JUN981/4
Charging Station . . . . . . . . . . . . . . . . . . . . . JT020461
UN17AUG92
Servicing air conditioning system using R134a refrigerant.
RW21595
1
Used with JT02050 Recovery and Recycling Station. JT02045
Recovery, Recycling, and Charging Station can be substituted for
JT02046 and JT02050.
TX,9031,QQ6692 1915JUN982/4
Recovery and Recycling Station . . . . . . . . . . . JT020501
RW21613
UN17AUG92
1
Used with JT02046 Charging Station. JT02045 Recovery, Recycling,
and Charging Station can be substituted for JT02046 and JT02050.
TX,9031,QQ6692 1915JUN983/4
T8389AF
To replace Schrader valve in compressor manifold on

R134a A/C Systems.
UN03JAN95
Schrader Valve Tool . . . . . . . . . . . . . . . . . . . JT02130
TX,9031,QQ6692 1915JUN984/4
TM1608 (20SEP06)
9031-20-1

092006
PN=595
9031
20
1
Adjustments
Service Equipment and Tools

NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche Tool
Catalog (MTC). Some tools may be available from
a local supplier.
TX,9031,QQ6693 1911NOV961/2
Electronic Leak Detector . . . . . . . . . . . . . . . . . JT02081

Detect refrigerant leaks.
Air Conditioning Fitting Kit . . . . . . . . . . . . . . . . JT02098
Used with JT02075 to flush R134a air conditioning
systems.
Air Conditioning Flusher . . . . . . . . . . . . . . . . . JT02075
To flush R134a air conditioning systems.
Belt Tension Gauge
To check compressor belt tension.
9031
20
2
TX,9031,QQ6693 1911NOV962/2
Other Materials
Number
Name
Use
TY16134 (U.S.)
R134A Flushing Solvent
Flush R134A air conditioning system.
TY15949 (12 oz) (U.S.)
R134A Refrigerant
Charge R134A air conditioning

system.
TY15950 (15 lb) (U.S.)
R134A Refrigerant

system.
TY15951 (30 lb) (U.S.)
R134A Refrigerant

system.
TY22025 (8.5 oz) (U.S.)
R134A Compressor Oil
Lubricate R134A air conditioning

system.
TX,9031,QQ6694 1923APR961/1
TM1608 (20SEP06)
9031-20-2

092006
PN=596
Adjustments


TX,9031,QQ6373 1912JUN961/1

treatment.
container.

treatment.
TX,9031,QQ6374 1912JUN961/1
TM1608 (20SEP06)
9031-20-3

092006
PN=597
9031
20
3
Adjustments
R134A Compressor Oil Charge Check

Remove compressor if R134a leakage was detected
and repaired. See Remove And Install Compressor in
Repair Manual.
3. Flush the complete system with TY16134 air

conditioning flushing solvent.
Drain oil from the compressor and record the amount.

See Compressor Oil Removal procedure in this group.
4. If the compressor is serviceable, pour flushing

solvent in the manifold ports and internally wash out
the old oil.
NOTE: Drain oil and save if this is a new compressor.
5. Install a new receiver-dryer.
If the oil drained from a compressor removed from

operation is very black or the amount of oil is less than
6 mL (0.2 fl oz), perform the following:
6. Install required amount of TY22025 refrigerant oil in

the compressor. (See R134a Component Oil
Charge in this group.)
Specification
OilVolume ............................................... Less than 6 mL (0.2 fl oz)
7. Connect all components, evacuate and charge the

system.
1. Remove and discard the receiver-dryer.

2. Remove, clean, but do not disassemble the valve.
TX,9031,QQ6375 1912JUN961/1
R134A Compressor Oil Removal
9031
20
4
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.
TX,9031,QQ6376 1912JUN961/1
TM1608 (20SEP06)
9031-20-4

092006
PN=598
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
Used 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 230
20 mL (7.8 0.7 fl oz) of new oil. System
requires an additional 80 mL (2.7 fl oz) of new oil
added to it.
Specification
New CompressorVolume ................... 230 20 mL (7.8 0.7 fl oz)
New Oil
SystemVolume ..................................... Additional 80 mL (2.7 fl oz)
New Oil
Used compressor removed from operation, oil

drained and flushed requires 310 20 mL (10.5
0.7 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.)
Specification
New CompressorVolume ................. Drain and return 45 mL (1.5 fl
oz) Oil
Used compressor removed from operation; drain

and add 45 mL (1.5 fl oz) of new oil. (See
Compressor Oil Removal procedure in this
group.)
Specification
Oil, Used Compressor
Installation, Complete System
Not Flushed, Oil Drained
Volume ............................................................... Add 45 mL (1.5 fl oz)
Used compressor removed from operation, oil

drained, and flushed; add 60 mL (2.0 fl oz) of
new oil.
Specification
Oil, Used Compressor
Installation, Complete System
Not Flushed, Oil Drained,
FlushedVolume .............................................. Add 60 mL (2.0 fl oz)
Specification
Used CompressorVolume ................ 310 20 mL (10.5 0.7 fl oz)
New Oil
TM1608 (20SEP06)
9031-20-5
TX,9031,QQ6377 1912JUN961/2

092006
PN=599
9031
20
5
Adjustments
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:
Specification
EvaporatorOil Charge ......................................... 130
CondenserOil Charge ........................................... 65
Receiver-DryerOil Charge ..................................... 30
HosesOil Charge ................................................... 60
mL
mL
mL
mL
(4.4
(2.2
(1.0
(2.0
fl
fl
fl
fl
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.
oz)
oz)
oz)
oz)
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft).

Specification
HosesOil Charge ............................... 3 mL per 30 cm (0.1 fl oz per
ft)
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.
Approximate total length equals 600 cm (20 ft).
TX,9031,QQ6377 1912JUN962/2
9031
20
6
TM1608 (20SEP06)
9031-20-6

092006
PN=600
Adjustments
R134A Refrigerant Recovery, Recycling And

Charging Station Installation Procedure
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging
Stationa
a
JT02046 and JT02050 recovery and charging stations can be

substituted for the JT02045 station.
CAUTION: Do not remove high pressure relief

valve (B). Air conditioning system will
discharge rapidly causing possible injury.
IMPORTANT: Use correct refrigerant recovery,
NOT mix refrigerant, hoses, fittings,
UN10SEP96
1. Close both high and low pressure valves on refrigerant

recovery, recycling and charging station (J).
T101551
2. Remove cap from low pressure test port (A).

3. Connect low pressure blue hose (G) from refrigerant
recovery, recycling and charging station (J) to low
pressure test port (A) on compressor.
4. Connect high pressure red hose (I) to high pressure
quick disconnect (F).
5. Follow the manufacturers instructions when using the
refrigerant recovery, recycling and charging station.
ALow Pressure Test Port

BHigh Pressure Relief Valve
CLow Pressure Hose
DLow Pressure Switch
EHigh Pressure Switch
FHigh Pressure Quick-Disconnect
GBlue Hose
HHigh Pressure Hose
IRed Hose
JRefrigerant Recovery/Recycling and Charging
Station
9031
20
7
TX,9031,QQ6378 1912JUN961/1
TM1608 (20SEP06)
9031-20-7

092006
PN=601
Adjustments
Recover R134A System

ESSENTIAL TOOLS
Stationa
a


UN10SEP96
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
8
T101551
1. Connect refrigerant recovery, recycling and charging

station. (See installation procedure in this group.)

CLow Pressure Hose
GBlue Hose
HHigh Pressure Hose
IRed Hose
Station
TX,9031,QQ6379 1912JUN961/1
TM1608 (20SEP06)
9031-20-8

092006
PN=602
Adjustments
Evacuate R134A System

ESSENTIAL TOOLS
Stationa
a


UN10SEP96
Do not run compressor while

evacuating.
T101551
2. Open low and high pressure valves on refrigerant

recovery, recycling and charging station.
3. Follow the manufacturers instructions and evacuate
the system.

CLow Pressure Hose
GBlue Hose
HHigh Pressure Hose
IRed Hose
station
NOTE: The vacuum specifications listed are for sea level

conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg)
from 98 kPa (980 mbar) (29 in. Hg) for each 300
m (1000 ft) elevation above sea level.
4. Evacuate system until low pressure gauge registers 98
kPa (980 mbar) (29 in. Hg) vacuum.
9031
20
9
If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be

obtained in 15 minutes, test the system for leaks. (See
Leak Testing, 9031-25). Correct any leaks.
Specification
VacuumPressure at Sea Level .............. 98 kPa (980 mbar) (29 in. Hg)
Pressure Above Sea Level ................... Subtract 3.4 kPa (34 mbar) (1 in.
Hg) from 98 kPa (980 mbar) (29
in. Hg) for each 300 m (1000 ft)
elevation
TM1608 (20SEP06)
9031-20-9
TX,9031,QQ6380 1912JUN961/2

092006
PN=603
Adjustments
5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close
low-side and high-side valves. Turn vacuum pump off.
Specification
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.
Specification
VacuumPressure Above Sea
Level ...................................................... Subtract 3.4 kPa (34 mbar) (1 in.
Hg) (1 in. Hg) from 98 kPa (980
mbar) (29 in. Hg) for each 300 m
(1000 ft) elevation
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.
Specification
11. Close low-side and high-side valves. Stop evacuation.

12. Charge the system. (See procedure in this group.)
9031
20
10
TX,9031,QQ6380 1912JUN962/2
TM1608 (20SEP06)
9031-20-10

092006
PN=604
Adjustments
Charge R134A System

ESSENTIAL TOOLS
Stationa
a


UN10SEP96
1. Connect JT02045 R134a refrigerant recovery, recycling

and charging station. (See installation procedure in this
group.)
T101551
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.

CLow Pressure Hose
GBlue Hose
HHigh Pressure Hose
IRed Hose
Station
Specification
Pressure Above Sea Level ................... Subtract 3.4 kPa (34 mbar) (1 in.
Hg) from 98 kPa (980 mbar) (29
in. Hg) for each 300 m (1000 ft)
elevation
9031
20
11
3. Follow the manufacturers instructions and charge the

system.
4. Add refrigerant until system is charged with 2.04 Kg
(4.50 lbs).
TM1608 (20SEP06)
9031-20-11
TX,9031,QQ6381 1912JUN961/2

092006
PN=605
Adjustments
Specification
R134a SystemRefrigerant
Charge ........................................................................... 2.04 Kg (4.50 lbs)
5. Do air conditioner checks and tests in Groups 9031-10

and 9031-25.
TX,9031,QQ6381 1912JUN962/2
9031
20
12
TM1608 (20SEP06)
9031-20-12

092006
PN=606
Group 25
Test
Special or Essential Tools
NOTE: Order tools according to information given in the
U.S. SERVICEGARDCatalog or in the European
Microfiche Tool Catalog (MTC).
TX,9031,QQ6705 1915JUN981/6
Charging Station . . . . . . . . . . . . . . . . . . . . . JT020461
UN17AUG92
RW21595
1
Used with JT02050 Recovery and Recycling Station. JT02045
Recovery, Recycling, and Charging Station can be substituted for
JT02046 and JT02050.
TX,9031,QQ6705 1915JUN982/6
Recovery and Recycling Station . . . . . . . . . . . JT020501
RW21613
UN17AUG92
1
Used with JT02046 Charging Station. JT02045 Recovery, Recycling,
and Charging Station can be substituted for JT02046 and JT02050.
TX,9031,QQ6705 1915JUN983/6
UN03JAN95
Schrader Valve Tool . . . . . . . . . . . . . . . . . . . JT02130
T8389AF
To replace Schrader valve in compressor manifold on

R134a A/C Systems and to replace Schrader valve in
ports where high and low pressure switches are located in
R134a A/C Systems.
TM1608 (20SEP06)
9031-25-1
TX,9031,QQ6705 1915JUN984/6

092006
PN=607
9031
25
1
Test
Air Conditioning Test Equipment Kit . . . . . . . D18018KD
T7541AD
UN29MAY91
Used to test air conditioning.
TX,9031,QQ6705 1915JUN985/6
Straight Connector. . . . . . . . . . . . . . . . . . . . . JT02148
T105533
UN04DEC96
Used to test air conditioning high and low pressure

switches.
TX,9031,QQ6705 1915JUN986/6
9031
25
2
TM1608 (20SEP06)
9031-25-2

092006
PN=608
Test
Service Equipment and Tools

NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche Tool
Catalog (MTC). Some tools may be available from
a local supplier.
TX,9031,QQ6706 1912NOV961/2
Manifold Pressure Gauge Assembly . . . . . . . . . JT02051

Test air conditioning system.
Electronic Leak Detector . . . . . . . . . . . . . . . . . JT02081
Detect refrigerant leaks.
Air Conditioning Service Fitting Kit . . . . . . . . . . JT05419
Connect test equipment.
Air Conditioning Fitting Kit . . . . . . . . . . . . . . . . JT02098
Used with JT02075 to flush R134a air conditioning
systems.
Volt-Ohm-Amp Multimeter
9031
25
3
To test thermostat switch.
TX,9031,QQ6706 1912NOV962/2
TM1608 (20SEP06)
9031-25-3

092006
PN=609
Test


TX,9031,QQ6383 1913AUG961/1

9031
25
4

treatment.
container.

treatment.
TX,9031,QQ6384 1913AUG961/1
TM1608 (20SEP06)
9031-25-4

092006
PN=610
Test
R134A Air Conditioning System Test

Specification
Engine SpeedRPM .................................................................. 2200 rpm
BlowerSpeed ............................................................................ Maximum
Air Conditioning Cooling
Temperature ................................................................................ Maximum
Ambient Temperature
Maximum Louver
Temperature
1621C (6070F)
7.3C (45F)
4189 kPa (0.410.89 bar) (613

psi)
6551172 kPa (6.5511.72 bar) (95

170 psi)
2127C (7080F)
10C (50F)
55103 kPa (0.551.03 bar) (815

psi)
7921516 kPa (7.9215.16 bar)

(115220 psi)
2732C (8090F)
13C (55F)
68124 kPa (0.681.24 bar) (1018

psi)
11721792 kPa (11.7217.92 bar)

(170260 psi)
3238C (90100F)
16C (60F)
82137 kPa (0.821.37 bar) (1220

psi)
14822068 kPa (14.8220.68 bar)

(215300 psi)
3843C (100110F)
19C (65F)
103151 kPa (1.031.51 bar) (1522

psi)
11722275 kPa (11.7222.75 bar)

(260330 psi)
Suction Pressure
Discharge Pressure
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery, Recycling and Charging
Stationa
a


NOT use refrigerant, hoses, fittings,
components or refrigerant oils intended
for R12 refrigerant.
9031
25
5
2. Close both low and high pressure valves on refrigerant

3. Open cab doors and windows.
TM1608 (20SEP06)
9031-25-5
TX,9031,QQ6385 1913AUG961/2

092006
PN=611
Test
4. Connect low pressure blue hose (G) from refrigerant
recovery, recycling and charging station (J) to low
pressure test port (A) on compressor.
5. Connect high pressure red hose (I) to high pressure
quick-disconnect (F) on compressor.
7. Start engine and run at rated engine speed.
8. Turn temperature control switch to the maximum
cooling position.
9. Turn blower switch to high speed.
10. Check sight glass in receiver-dryer.
UN10SEP96
11. Run machine for at least 5 minutes.
T101551
12. Measure air temperature at condenser air inlet and at

air ducts in air conditioning unit.
13. Compare air duct temperature reading to the
temperatures shown in the specifications.
14. Observe low and high pressure gauges on refrigerant
15. Compare pressure readings to the pressure shown in
specifications.
9031
25
6
Use the Operating Pressure Diagnostic Chart in this

group to diagnose the malfunction.

CLow Pressure Hose
GBlue Hose
HHigh Pressure Hose
IRed Hose
Station
TX,9031,QQ6385 1913AUG962/2
TM1608 (20SEP06)
9031-25-6

092006
PN=612
Test
Pressure Diagnostic Chart
T6609AB
1928FEB89
9031
25
7
TX,9031,QQ6386 1913AUG961/1
TM1608 (20SEP06)
9031-25-7

092006
PN=613
Test
Low Pressure Switch Test

Specification
Switch Test (Normally Open)
Opens on DecreasingPressure ........ 173 35 kPa (1.73 0.3 bar) (25
53 psi)
Switch Test (Normally Open)
Closes on IncreasingPressure .......... 345 35 kPa (3.45 0.3 bar) (50
5 psi)
ESSENTIAL TOOLS
JT02148 Straight Connector For Testing Switch
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.
9031
25
8
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.
TM1608 (20SEP06)
9031-25-8
TX,9031,QQ6387 1913AUG961/2

092006
PN=614
Test
T8426AD
UN06MAR95
5. Switch must not have continuity between terminals (A

and C) until pressure increases to switch closing
pressure specification. Slowly release pressure. Switch
must have continuity until pressure decreases to switch
opening pressure specification.
TX,9031,QQ6387 1913AUG962/2
High Pressure Switch Test

Specification
Switch Test (Normally Closed)
Opens on IncreasingPressure .......... 2760 138 kPa (27.6 1.38 bar)
(400 20 psi)
Switch Test (Normally Closed)
Closes on DecreasingPressure .............. 1310 138 kPa (13.11 1.38
bar) (190 20 psi)
ESSENTIAL TOOLS
JT02148 Straight Connector For Testing Switch
Volt-Ohm-Amp Meter
Air Conditioning Gauge Set
NOTE: The line that attaches the high pressure switch

has a valve installed to prevent discharging the air
conditioning system when switch is removed. The
high pressure switch is normally closed when
removed from the machine. It does not open
when installed in the A/C system until pressure
exceeds specification.
9031
25
9
1. Remove high pressure switch.

2. Connect a portable pressure source, such as a
hydraulic hand pump, to high pressure switch.
TM1608 (20SEP06)
9031-25-9
TX,9031,QQ6388 1913AUG961/2

092006
PN=615
Test
5. The switch can also be checked when installed in air

conditioning system, however, pressure is slow to
increase to test specification.
T8426AE
4. Slowly release pressure. Switch must not have

continuity until pressure decreases to switch closing
pressure specification.
UN06MAR95
3. Switch must have continuity between terminals (A and

C) until pressure increases to switch opening pressure
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.
TX,9031,QQ6388 1913AUG962/2
9031
25
10
TM1608 (20SEP06)
9031-25-10

092006
PN=616
Test
A/C Freeze Control Switch

Specification
A/C Control Switch (Normally
Closed)Opens as Temperature
Drops ..................................................................................... -0.5C (31F)
A/C Control Switch (Normally
Closed)Closes as Temperature
Rises .......................................................................................... 4C (39F)
Multimeter
1. Remove A/C freeze switch from evaporator.

2. Connect ohmmeter to switch terminals. Switch must be
closed at room temperature.
3. Put switch into a freezer (assure freezer temperature is
below -0.5C (31F). Switch must open, and continuity
must not be read.
4. Remove switch from freezer. Put sensing tube into a
glass of warm water. Switch must close, and continuity
must be read.
5. If switch does not open and close during testing, install
new switch.
TX,9031,QQ6389 1913AUG961/1
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.
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.
2. A soap and water solution can be sprayed on the

components in the system to form bubbles at the
source of the leak.
4. Some refrigerant manufacturers add dye to

refrigerant to aid in leak detection.
TX,9031,QQ6390 1913AUG961/1
TM1608 (20SEP06)
9031-25-11

092006
PN=617
9031
25
11
Test
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.
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.
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
DO NOT use hydraulic hoses as

replacement hoses in the air
conditioning system. Use ONLY
certified hose meeting SAE J51B
requirements.
TX,9031,QQ6391 1913AUG961/1
9031
25
12
TM1608 (20SEP06)
9031-25-12

092006
PN=618
Index
Page
Page
Accumulator, ride control . . . . . . . . . . . . .9025-25-13

Discharge procedure. . . . . . . . . . . . . . .9025-25-18
Adjustment
Dual stage system relief . . . . . . . . . . . . .9025-20-8
Loader bucket level indicator. . . . . . . . . .9025-20-1
Loader bucket self-leveling . . . . . . . . . . .9025-20-1
Loader control linkage. . . . . . . . . . . . . . .9025-20-4
Return-to-dig switch . . . . . . . . . . . . . . . .9025-20-1
Adjustments
Backhoe valve linkage . . . . . . . . . . . . . .9025-20-6
Loader valve linkage . . . . . . . . . . . . . . . .9025-20-4
Stabilizer valve linkage . . . . . . . . . . . . .9025-20-10
Air conditioning
Charge R134a system . . . . . . . . . . . . .9031-20-11
Circuit checks . . . . . . . . . . . . . . . . . . . . .9031-10-5
Clutch cycle switch test. . . . . . . . . . . . .9031-25-11
Component location . . . . . . . . . . . . . . . .9031-15-2
Compressor oil removal . . . . . . . . . . . . .9031-20-4
Compressor relief valve operation . . . . .9031-05-11
Electrical circuit . . . . . . . . . . . . . . . . . . . .9031-05-3
Evacuate R134a system . . . . . . . . . . . . .9031-20-9
Expansion valve . . . . . . . . . . . . . . . . . .9031-05-10
High pressure switch test . . . . . . . . . . . .9031-25-9
Hoses and tubing inspection . . . . . . . . .9031-25-12
Leak testing . . . . . . . . . . . . . . . . . . . . .9031-25-11
Low pressure switch test. . . . . . . . . . . . .9031-25-8
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9031-15-1
Operating checks . . . . . . . . . . . . . . . . . .9031-10-3
Performance checks . . . . . . . . . . . . . . . .9031-10-4
Receiver/dryer operation . . . . . . . . . . . . .9031-05-8
Recover R134a system. . . . . . . . . . . . . .9031-20-8
Recovery/recycling/charging R134a . . . .9031-20-7
Refrigerant handling . . . . . . 9031-05-1, 9031-20-3,
9031-25-4
Refrigerant (R12/R134a) caution. . . . . . .9031-05-1
Refrigerant (R134a) caution . . . . . . . . . 9031-20-3,
9031-25-4
R12 refrigerant operation . . . . . . . . . . . .9031-05-2
System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-5
Temperature control . . . . . . . . . . . . . . .9031-05-11
Visual inspection of components . . . . . . .9031-10-1
Air flow
Radiator . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-4
Air intake system
Test Leakage . . . . . . . . . . . . . . . . . . . . .9010-25-2
Alternators
Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Auxiliary flow control section, backhoe . . .9025-05-50
Auxiliary valve section, backhoe . . . . . . . .9025-05-64
Backhoe
Auxiliary flow valve section . . . . . . . . . .9025-05-50
Auxiliary valve section. . . . . . . . . . . . . .9025-05-64
Boom valve section. . . . . . . . . . . . . . . .9025-05-58
Bucket valve section . . . . . . . . . . . . . . .9025-05-60
Crowd valve section . . . . . . . . . . . . . . .9025-05-62
Linkage adjustment . . . . . . . . . . . . . . . . .9025-20-6
Regenerative valve section . . . . . . . . . .9025-05-66
Swing valve section . . . . . . . . . . . . . . .9025-05-56
Backhoe swing valve section . . . . . . . . . .9025-05-56
Battery
Electrolyte level. . . . . . . . . . . . . . . . . . . .9015-20-5
Jump starting . . . . . . . . . . . . . . . . . . . . .9015-20-7
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9015-20-4
Operation . . . . . . . . . . . . . . . . . . . . . . . .9015-20-2
Specifications . . . . . . . . . . . . . . . . . . . . .9015-20-3
Boom lock
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-66
Boom lock circuit
Diagnostic procedures. . . . . . . . . . . . . .9015-15-63
Operational information . . . . . . . . . . . . .9015-15-61
Theory of operation. . . . . . . . . . . . . . . .9015-15-61
Brake pedals
Adjustments . . . . . . . . . . . . . . . . . . . . . .9020-20-1
Brake valve
Leakage test . . . . . . . . . . . . . . . . . . . . . .9020-25-9
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-58
Brake, park
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-62
Brake, service
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-60
Brakes
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-4
Bucket self-leveling adjustment. . . . . . . . . .9025-20-1
Bucket valve section. . . . . . . 9025-05-42, 9025-05-60
TM1608 (20SEP06)
C
Charge ride control accumulator. . . . . . . .9025-25-13
Circuit relief valve . . . . . . . . . 9025-05-40, 9025-25-19
Circuit relief valve, anti-cavitation . . . . . . .9025-05-39
Circuit, transmission control
Operation-forward . . . . . . . . . . . . . . . . .9020-05-26
Operation-neutral . . . . . . . . . . . . . . . . .9020-05-24
Operation-reverse . . . . . . . . . . . . . . . . .9020-05-28
Clutch pack
Forward, reverse, low range forward or speed
operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-1
Index-1

092006
PN=1
Indx
1
Index
Indx
2
Page
Page
Clutch packs
Power shift, high range forward 1st and 2nd
speed . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-2
Component location
Air conditioning compressor harness
(W11) . . . . . . . . . . . . . . . . . . . . . . . .9015-10-43
Blower harness (W10). . . . . . . . . . . . . .9015-10-38
Cab roof harness (W5) . . . . . . . . . . . . .9015-10-17
Cab side console harness (W6) . . . . . .9015-10-20
Component Location-315SE Only . . . . .9015-10-41
Electrical . . . . . . . . . . . . . . . . . . . . . . . .9015-05-14
Engine harness (W8) . . . . . . . . . . . . . .9015-10-32
Engine harness (W8) (with optional power
shift) . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-33
Front console harness (W7) . . . . . . . . .9015-10-28
Front console harness (W7) (with optional power
shift) . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-29
Pin disconnect harness (W18) . . . . . . .9015-10-52
Radio harness (W12) . . . . . . . . . . . . . .9015-10-45
Ride control harness (W17) . . . . . . . . .9015-10-50
Selective flow valve harness (W15) (S.N. 849185) . . . . . . . . . . . . . . . . . . . . . . .9015-10-47
Connectors, wire and pin location
Air Conditioning Compressor harness
(W11) . . . . . . . . . . . . . . . . . . . . . . . .9015-10-44
Blower harness (W10). . . . . . . . . . . . . .9015-10-39
Cab roof harness (W5) . . . . . . . . . . . . .9015-10-18
Cab side console harness (W6) . . . . . .9015-10-23
Engine harness (W8) . . . . . . . . . . . . . .9015-10-34
Front console harness (W7) . . . . . . . . .9015-10-30
Lock harness (W9)-315SE only. . . . . . .9015-10-42
Pin disconnect harness (W18) . . . . . . .9015-10-53
Radio harness (W12) . . . . . . . . . . . . . .9015-10-46
Ride control harness (W17) . . . . . . . . .9015-10-51
Selective flow valve harness (W15). . . .9015-10-49
Control valve and shift valve transmission power shift
Operation-First Forward . . . . . . . . . . . .9020-05-40
Operation-first reverse. . . . . . . . . . . . . .9020-05-48
Control valve transmission power shift
Operation-Fourth Forward . . . . . . . . . . .9020-05-44
Converter, torque
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-6
Converter, torque,stall
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-6
Converter-in relief valve
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-7
Coolant
Diesel engine . . . . . . . . . . . . . . . . . . . . .9000-04-2
Cooler in and cooler out
Transmission pressure test . . . . . . . . . .9020-25-28
Cooler restriction test . . . . . . . . . . . . . . . .9025-25-12
Cycle time specifications . . . . . . . . . . . . .9025-25-35
Cylinder drift test procedure . . . . . . . . . . .9025-25-27

Cylinder leakage test . . . . . . . . . . . . . . . .9025-25-31
TM1608 (20SEP06)
D
Diagnostic procedure . . . . . . . . . . . . . . . . .9025-15-1
Diesel engine oil. . . . . . . . . . . . . . . . . . . . .9000-04-6
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1
Diesel fuel storage . . . . . . . . . . . . . . . . . . .9000-04-4
Differential
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-54
Differential lock
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-56
Differential lock pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-22
Digital thermometer . . . . . . . . . . . . . . . . . .9025-25-1
Digital Thermometer Installation . . . . . . . . 9010-25-1,
9020-25-1, 9025-25-1
Dipperstick
Grease specification . . . . . . . . . . . . . . . .9000-04-9
Discharge procedure
Accumulator, ride control . . . . . . . . . . .9025-25-18
Drift test, cylinder . . . . . . . . . . . . . . . . . . .9025-25-27
Dual stage relief valve . . . . . . . . . . . . . . .9025-05-32
Dual stage valve. . . . . . . . . . . . . . . . . . . .9025-05-32
Dual stage valve adjustment. . . . . . . . . . . .9025-20-8
E
Electrical
Blower circuit . . . . . . . . . . . . . . . . . . . . .9031-05-6
Charging circuit . . . . . . . . . . . . . . . . . . .9015-15-11
Component identification . . . . . . . . . . . . .9015-10-1
Display monitor circuit . . . . . . . . . . . . . .9015-15-22
FNR circuit
Park brake circuit. . . . . . . . . . . . . . . .9015-15-33
Grounded circuit . . . . . . . . . . . . . . . . . . .9015-05-6
High resistance circuit . . . . . . . . . . . . . . .9015-05-3
Indicator circuit . . . . . . . . . . . . . . . . . . .9015-15-28
Inspection . . . . . . . . . . . . . . . . . . . . . . . .9015-05-1
Open circuit . . . . . . . . . . . . . . . . . . . . . .9015-05-4
Power circuit . . . . . . . . . . . . . . . . . . . . . .9015-15-1
Schematic symbols . . . . . . . . . . . . . . . .9015-05-18
Shorted circuit. . . . . . . . . . . . . . . . . . . . .9015-05-8
Start circuit . . . . . . . . . . . . . . . . . . . . . . .9015-15-5
System Functional Schematic . . . . . . . . .9015-10-9
System Functional Schematic Legend . .9015-10-8
System functional schematic reading . .9015-05-12
Test equipment . . . . . . . . . . . . . . . . . . . .9015-05-9
Test procedure . . . . . . . . . . . . . . . . . . .9015-05-10
Index-2

092006
PN=2
Index
Page
Page
Wiring & schematic diagrams legend . . .9015-10-4

Electronic tachometer
Installation. . . . . . . . . . . . . . . . . . . . . . . .9020-25-1
JT0 5801 clamp-on . . . . . . . .9010-20-1, 9010-25-1
Engine
Boost starting . . . . . . . . . . . . . . . . . . . . .9015-20-7
Diagnose malfunction . . . . . . . . . . . . . . .9010-15-4
Idle adjustment . . . . . . . . . . . . . . . . . . . .9010-20-6
Sectional view. . . . . . . . . . . . . . . . . . . . .9010-05-2
Visual inspection . . . . . . . . . . . . . . . . . . .9010-15-2
Engine oil
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-6
Engine speed control
Adjust lever tension. . . . . . . . . . . . . . . . .9010-20-2
Adjust linkage . . . . . . . . . . . . . . . . . . . . .9010-20-4
Harness selective flow valve

Component location (S.N. -849185) . . .9015-10-47
Hydraulic
Oil specification. . . . . . . . . . . . . . . . . . . .9000-04-8
Open-center theory . . . . . . . . . . . . . . . . .9025-05-1
Warm-up procedure . . . . . . . . . . . . . . . .9025-25-2
Hydraulic Circuit Symbols. . . . . . . . . . . . .9020-15-26
Hydraulic cooler test. . . . . . . . . . . . . . . . .9025-25-12
Hydraulic filter . . . . . . . . . . . . . . . . . . . . .9025-05-18
Hydraulic oil cooler
Restriction test . . . . . . . . . . . . . . . . . . .9025-25-12
Hydraulic oil warm-up test . . . . . . . . . . . . .9025-25-2
Hydraulic pump
Opetration . . . . . . . . . . . . . . . . . . . . . . .9025-05-12
Hydraulic system
Componet location . . . . . . . . . . . . . . . . .9025-05-2
Diagnose. . . . . . . . . . . . . . . . . . . . . . . . .9025-15-3
Pretest inspection . . . . . . . . . . . . . . . . . .9025-15-1
Pretest system . . . . . . . . . . . . . . . . . . . .9025-15-2
310SE schematic . . . . . . . . . . . . . . . . .9025-05-10
315SE schematic . . . . . . . . . . . . . . . . .9025-05-11
Hydraulic system test . . . . . . . . . . . . . . . . .9025-15-2
F
Filter operation . . . . . . . . . . . . . . . . . . . . .9025-05-18
Filter, transmission
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-11
Front wheel drive, mechanical
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-20
Fuel
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-1
Tank capacity . . . . . . . . . . . . . . . . . . . . .9000-04-5
Fuel line
Test, Leakage . . . . . . . . . . . . . . . . . . . .9010-25-11
Fuel storage . . . . . . . . . . . . . . . . . . . . . . . .9000-04-4
Function & and cylinder drift test . . . . . . .9025-25-28
Fuse
Color Codes . . . . . . . . . . . . . . . . . . . . . .9015-10-2
Location . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-3
Specifications . . . . . . . . . . . . . . . . . . . . .9015-10-3
I
Injection pump timing . . . . . . . . . . . . . . . .9010-25-10
J
JT05800 thermometer . . . . . . . . . . . . . . . .9025-25-1
L
G
Gear, 1st forward, manual shift transmission
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-12
Gear, 3rd reverse, manual shift transmission
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-14
Grease
Extreme pressure and multipurpose . . . .9000-04-9
Specification, dipperstick . . . . . . . . . . . . .9000-04-9
H
Hardware
Torque specifications . . . . . . . . . . . . . . .9000-03-1
TM1608 (20SEP06)
Indx
3
Legend
System Functional Schematic Section. . .9015-10-8
Wiring and Schematic Diagrams . . . . . . .9015-10-4
Linkage adjustment, linkage . . . . . . . . . . .9025-20-10
Linkage, backhoe control valve. . . . . . . . . .9025-20-6
Linkage, loader control adjustment . . . . . . .9025-20-4
Loader
Auxiliary valve section. . . . . . . . . . . . . .9025-05-46
Boom valve section. . . . . . . . . . . . . . . .9025-05-44
Bucket valve section . . . . . . . . . . . . . . .9025-05-42
Linkage adjustment . . . . . . . . . . . . . . . . .9025-20-4
Loader auxiliary valve section. . . . . . . . . .9025-05-46
Loader boom valve section. . . . . . . . . . . .9025-05-44
Lubricant
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-11
Index-3

092006
PN=3
Index
Page
Page
Storage . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-10
Brake system . . . . . . . . . . . . . . . . . . . . .9005-10-4

Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-21
Clutch disconnect solenoid . . . . . . . . . . .9005-10-7
Driving . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-8
Gauge and indicator . . . . . . . . . . . . . . . .9005-10-1
Hydraulic system. . . . . . . . . . . . . . . . . .9005-10-13
Indicators . . . . . . . . . . . . . . . . . . . . . . . .9005-10-3
MFWD . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-12
Miscellaneous . . . . . . . . . . . . . . . . . . . .9005-10-26
Steering system . . . . . . . . . . . . . . . . . . .9005-10-6
Switches . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-2
Outlet cover, backhoe. . . . . . . . . . . . . . . .9025-05-66
M
Machine warm-up . . . . . . . . . . . . . . . . . . . .9025-25-2
Manual shift forward and reverse
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-15
Manual shift modulation valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-50
Manual shift power train
Diagnose malfunctions . . . . . . . . . . . . . .9020-15-1
Overview. . . . . . . . . . . . . . . . . . . . . . . . .9020-05-4
Manual shift synchronizer
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-8
Manual shift transmission control valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-22
Manual shift transmission, 1st gear forward
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-12
Manual shift transmission, 3rd gear reverse
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-14
MFWD
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-20
MFWD differential-equal traction
MFWD differential-unequal traction
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-64
MFWD pressure test . . . . . . . . . . . . . . . .9020-25-26
Mixing lubricants. . . . . . . . . . . . . . . . . . . .9000-04-11
Modulation valve
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-20
Modulation valve manual shift
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-50
Modulation valve power shift
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-52
Indx
4
O
O-ring boss fittings . . . . . . . . . . . . . . . . . . .9000-03-9
Oil
Lines and fittings. . . . . . . . . . . . . . . . . . .9000-03-6
Specification, hydraulic . . . . . . . . . . . . . .9000-04-8
Specification, MFWD. . . . . . . . . . . . . . . .9000-04-7
Specification, reverser. . . . . . . . . . . . . . .9000-04-8
Specification, transmission . . . . . . . . . . .9000-04-7
Oil lines and fittings . . . . . . . . . . . . . . . . . .9000-03-6
Open-center hydraulic operation. . . . . . . . .9025-05-1
Operational checkout procedures . . . . . . . .9005-10-1
Operational checks
Accessories . . . . . . . . . . . . . . . . . . . . .9005-10-20
TM1608 (20SEP06)
P
Park brake
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-62
Release pressure test . . . . . . . . . . . . . .9020-25-11
Power shift high range forward clutch
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-17
Power shift low range forward clutch
Pressure Test . . . . . . . . . . . . . . . . . . . .9020-25-17
Power shift modulation valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-52
Power shift power train
Diagnose malfunctions . . . . . . . . . . . . .9020-15-10
Overview. . . . . . . . . . . . . . . . . . . . . . . .9020-05-16
Power shift speed clutch
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-17
Power shift transmission
Control valve operation-fourth
forward . . . . . . . . . . . . . . . . . . . . . . .9020-05-44
Gear Flow . . . . . . . . . . . . . . . . . . . . . . .9020-05-18
Power shift transmission control circuit
First forward . . . . . . . . . . . . . . . . . . . . .9020-05-38
First Reverse . . . . . . . . . . . . . . . . . . . .9020-05-46
Fourth forward . . . . . . . . . . . . . . . . . . .9020-05-42
Neutral . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-32
Power shift transmission control valve and shift valve
Operation-first forward. . . . . . . . . . . . . .9020-05-40
Operation-first reverse. . . . . . . . . . . . . .9020-05-48
Power train
Manual shift overview . . . . . . . . . . . . . . .9020-05-4
Power train overview
Power shift . . . . . . . . . . . . . . . . . . . . . .9020-05-16
Priority valve. . . . . . . . . . . . . . . . . . . . . . .9025-05-22
Pump
Auxiliary . . . . . . . . . . . . . . . . . . . . . . . .9025-05-12
Main . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-12
Main, auxiliary flow test. . . . . . . . . . . . . .9025-25-9
Index-4

092006
PN=4
Index
Page
Page
Pump unloading valve

Circuit Schematic . . . . . . . . . . . . . . . . .9015-15-55
Sub-system diagnostics . . . . . . . . . . . .9015-15-56
Pump, transmission
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-10
Specifications
Hardware torque . . . . . . . . . . . . . . . . . . .9000-03-1
Specifications chapter. . . . . . . . . . . . . . . . .9000-02-1
Stabilizer lockout leakage test . . . . . . . . .9025-25-32
Stabilizer Valve. . . . . . . . . . . . . . . . . . . . .9025-05-48
Staring motors
Use CTM77 . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Steering Cylinder Leakage . . . . . . . . . . . .9025-25-25
Steering load sense relief test . . . . . . . . . .9025-25-6
Steering System Leakage. . . . . . . . . . . . .9025-25-21
Steering valve operation . . . . . . . . . . . . . .9025-05-19
Storage
Diesel fuel. . . . . . . . . . . . . . . . . . . . . . . .9000-04-4
Storing lubricants . . . . . . . . . . . . . . . . . . .9000-04-10
Synchronizer manual shift
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-8
Information . . . . . . . . . . . . . . . . . . . . . .9015-05-11
System pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-13
System problems diagnosis . . . . . . . . . . . .9025-15-3
System relief test . . . . . . . . . . . . . . . . . . . .9025-25-3
System relief valve . . . . . . . . . . . . . . . . . .9025-05-32
R
Radiator
Air flow test. . . . . . . . . . . . . . . . . . . . . . .9010-25-4
Receiver/dryer
Operation . . . . . . . . . . . . . . . . . . . . . . . .9031-05-8
Reducing valve presssure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-19
Relief valve, anti-cavitation . . . . . . . . . . . .9025-05-40
Relief valve, circuit . . . . . . . . . . . . . . . . . .9025-05-38
Relief valve, relief . . . . . . . . . . . . . . . . . . .9025-05-32
Return-to-dig adjustment . . . . . . . . . . . . . .9025-20-1
Reverser
Ride control accumulator . . . . . . . . . . . . .9025-25-13
Ride control circuit . . . . . . . . . . . . . . . . . .9025-05-24
Ride control valve. . . . . . . . . . . . . . . . . . .9025-05-26
Roll-over protective structure
Torque values . . . . . . . . . . . . . . . . . . . . .9000-03-1
S
Sectional view
Engine . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-2
Service brake
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-60
Sideshift circuit
Diagnostic procedures. . . . . . . . . . . . . .9015-15-58
Solenoid circuit leakage
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-30
Solenoids activated
Transmission clutch engagement power
shift . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-30
Specification
Dipperstick grease . . . . . . . . . . . . . . . . .9000-04-9
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .9000-04-8
MFWD oil . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7
Reverser oil . . . . . . . . . . . . . . . . . . . . . .9000-04-8
Transmission oil . . . . . . . . . . . . . . . . . . .9000-04-7
TM1608 (20SEP06)
T
Tachometer Installation . . . . . . . . . . . . . . .9015-20-1
Tachometer installation. . . . . . . . . . . . . . . .9025-25-1
Tachometer, electronic
Installation. . . . . . . . . . . . . . . . . . . . . . . .9020-25-1
JT05801 clamp-on . . . . . . . .9010-20-1, 9010-25-1
Test
Circuit relief valve . . . . . . . . . . . . . . . . .9025-25-19
Cycle times . . . . . . . . . . . . . . . . . . . . . .9025-25-35
Cylinder leakage . . . . . . . . . . . . . . . . . .9025-25-31
Function drift . . . . . . . . . . . . . . . . . . . . .9025-25-28
Hydraulic cooler restriction . . . . . . . . . .9025-25-12
Hydraulic cylinder drift. . . . . . . . . . . . . .9025-25-27
Hydraulic system pretest. . . . . . . . . . . . .9025-15-2
Loader, backhoe, priority relief . . . . . . . .9025-25-3
Main, auxiliary pump flow . . . . . . . . . . . .9025-25-9
Pretest operation. . . . . . . . . . . . . . . . . . .9025-15-1
Stabilizer valve lockout leakage . . . . . .9025-25-32
Steering cylinder leakage . . . . . . . . . . .9025-25-25
Steering load sense relief . . . . . . . . . . . .9025-25-6
Steering sytem leakage. . . . . . . . . . . . .9025-25-21
Tachometer installaation . . . . . . . . . . . . .9025-25-1
Unloading relief . . . . . . . . . . . . . . . . . . . .9025-25-7
Test Leakage
Air intake system . . . . . . . . . . . . . . . . . .9010-25-2
Test procedure . . . . . . . . . . . . . . . . . . . . . .9025-15-1
Index-5

092006
PN=5
Indx
5
Index
Page
Indx
6
Test, Leakage
Fuel line . . . . . . . . . . . . . . . . . . . . . . . .9010-25-11
Theory of operation
MFWD differential-equal traction . . . . . .9020-05-65
Thermometer Installation, Digital . . . . . . . 9010-25-1,
9020-25-1, 9025-25-1
Toe-In
Adjustment . . . . . . . . . . . . . . . . . . . . . . .9020-20-6
Torque converter
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-6
Torque converter stall speed
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-6
Torque specifications
Hardware . . . . . . . . . . . . . . . . . . . . . . . .9000-03-1
Torque value
Flat face O-ring seal fitting . . . . . . . . . . .9000-03-8
Inch SAE four bolt flange fitting. . . . . . .9000-03-12
Metric cap screw. . . . . . . . . . . . . . . . . . .9000-03-3
Metric four bolt flange fitting . . . . . . . . .9000-03-11
O-Ring boss fitting . . . . . . . . . . . . . . . . .9000-03-9
Torque values
Roll-over protective structure. . . . . . . . . .9000-03-1
Trans. overall test connections . . . . . . . . . .9020-25-3
Transmission
Cooler in and cooler out press. test . . .9020-25-28
Modulation valve pressure test . . . . . . .9020-25-20
Reducing valve pressure test . . . . . . . .9020-25-19
System pressure test . . . . . . . . . . . . . .9020-25-13
Transmission clutch engagement power shift
Solenoids activated . . . . . . . . . . . . . . . .9020-05-30
Transmission control circuit
Operation-forward . . . . . . . . . . . . . . . . .9020-05-26
Operation-reverse . . . . . . . . . . . . . . . . .9020-05-28
Transmission filter
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-11
Transmission Gear Flow
Power Shift . . . . . . . . . . . . . . . . . . . . . .9020-05-18
Transmission oil warm-up
Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-25-2
Transmission Pump
Flow test . . . . . . . . . . . . . . . . . . . . . . . .9020-25-32
Transmission pump
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-10
Transmission Pump Flow
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-32
Transmission, power shift
Control circuit-first forward . . . . . . . . . .9020-05-38
Control circuit-first reverse . . . . . . . . . .9020-05-46
Control circuit-fourth forward . . . . . . . . .9020-05-42
Control circuit-neutral . . . . . . . . . . . . . .9020-05-32
Turbocharger boost pressure test . . . . . . . .9010-25-8
TM1608 (20SEP06)
Page
U
Unloading relief test . . . . . . . . . . . . . . . . . .9025-25-7
Unloading valve . . . . . . . . . . . . . . . . . . . .9025-05-14
Backhoe operation . . . . . . . . . . . . . . . .9025-05-14
Loader operation. . . . . . . . . . . . . . . . . .9025-05-16
V
Valve
Backhoe auxiliary flow section . . . . . . .9025-05-50
Backhoe auxiliary section . . . . . . . . . . .9025-05-64
Backhoe boom section . . . . . . . . . . . . .9025-05-58
Backhoe crowd section . . . . . . . . . . . . .9025-05-62
Backhoe swing section . . . . . . . . . . . . .9025-05-56
Bucket section . . . . . . . . . . . . . . . . . . .9025-05-60
Circuit relief, anti-cavitation . . . . . . . . . 9025-05-38,
9025-05-39, 9025-05-40
Dual stage . . . . . . . . . . . . . . . . . . . . . . .9025-20-8
Dual stage relief . . . . . . . . . . . . . . . . . .9025-05-32
Loader auxiliary section . . . . . . . . . . . .9025-05-46
Loader boom. . . . . . . . . . . . . . . . . . . . .9025-05-44
Loader bucket section . . . . . . . . . . . . . .9025-05-42
Priority . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-22
Regenerative section . . . . . . . . . . . . . .9025-05-66
Sideshift Lock Solenoid. . . . . . . . . . . . .9025-05-69
Stabilizer . . . . . . . . . . . . . . 9025-05-48, 9025-20-10
Stabilizer linkage adjustment. . . . . . . . .9025-20-10
Steering . . . . . . . . . . . . . . . . . . . . . . . .9025-05-19
Unloading . . . . . . . . . . . . . . . . . . . . . . .9025-05-14
Valve, brake
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-58
Valve, converter-in relief
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-7
Valve, manual shift transmission control
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-22
Valve, modulation
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-20
Valve, reducing, pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-19
Valve, ride control. . . . . . . . . . . . . . . . . . .9025-05-26
Index-6

092006
PN=6

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310SE and 315SE

For complete service information also see:

Technical Manuals are concise guides for specific

Live with safety: Read the safety messages in the

Fundamental service information is available from

This is the safety-alert symbol. When you see this

See DB1990 Service Publications Catalog to order a

310SE and 315SE Backhoe Loaders

310SE and 315SE Backhoe Loaders

Technical Information Feedback Form

John Deere Dubuque Works

Ideas, Comments (Please State Page Number):

310SE and 315SE Backhoe Loaders

SECTION 9000General Information

SECTION 9005Operational Checkout Procedure

SECTION 9015Electrical System

SECTION 9020Power Train

SECTION 9025Hydraulic System

SECTION 9031Heating And Air Conditioning

All information, illustrations and specifications in this manual are based on

310SE and 315SE Backhoe Loaders

310SE and 315SE Backhoe Loaders

Group 01Safety Information

310SE And 315SE Backhoe Loader Lifting

Group 02General Specifications

Group 03Torque Values

310SE and 315SE Backhoe Loaders

310SE and 315SE Backhoe Loaders

Handle Fluids SafelyAvoid Fires

Store flammable fluids away from fire hazards. Do not

Do not store oily rags; they can ignite and burn

When you work around fuel, do not smoke or work near

Prevent Battery Explosions

Never check battery charge by placing a metal object

Do not charge a frozen battery; it may explode. Warm

Keep sparks, lighted matches, and open flame away from

Prepare for Emergencies

Keep emergency numbers for doctors, ambulance service,

Keep a first aid kit and fire extinguisher handy.

310SE and 315SE Backhoe Loaders

Prevent Acid Burns

Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

310SE and 315SE Backhoe Loaders

Handle Chemical Products Safely

Check the MSDS before you start any job using a

A Material Safety Data Sheet (MSDS) provides specific

Direct exposure to hazardous chemicals can cause

(See your John Deere dealer for MSDSs on chemical

Avoid High-Pressure Fluids

Search for leaks with a piece of cardboard. Protect hands

Avoid the hazard by relieving pressure before

Escaping fluid under pressure can penetrate the skin

If an accident occurs, see a doctor immediately. Any fluid

310SE and 315SE Backhoe Loaders

Park Machine Safely

Lower all equipment to the ground.

Before working on the machine:

Do not support the machine on cinder blocks, hollow tiles,

Always lower the attachment or implement to the ground

Support Machine Properly

When implements or attachments are used with a