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Backhoe Loaders

Operation and Test

TECHNICAL MANUAL
TM1512 07NOV03 (ENGLISH)

For complete service information also see:


410D, 510D, Backhoe Loader
Operation and Test (Complete) . . . . . . . . . . TM1512
410D, 510D Backhoe Loader
Repair (Complete) . . . . . . . . . . . . . . . . . . . . . TM1513

Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword

This manual is written for an experienced technician. beginning of each group are summary listings of all
Essential tools required in performing certain service applicable essential tools, service equipment and tools,
work are identified in this manual and are other materials needed to do the job, service parts kits,
recommended for use. specifications, wear tolerances, and torque values.

Live with safety: Read the safety messages in the Technical Manuals are concise guides for specific
introduction of this manual and the cautions presented machines. They are on-the-job guides containing only
throughout the text of the manual. the vital information needed for diagnosis, analysis,
testing, and repair.
This is the safety-alert symbol. When you see this
Fundamental service information is available from
symbol on the machine or in this manual, be alert to
other sources covering basic theory of operation,
the potential for personal injury.
fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
See DB1990 Service Publications Catalog to order a
the components. Operation and tests sections help you
Technical Manual (TM).
identify the majority of routine failures quickly.

Information is organized in groups for the various


components requiring service instruction. At the

TX,410DIFC 1931AUG951/1

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

SECTION 9005Operational Checkout Procedure


Group 10Operational Checkout Procedure

SECTION 9010Engine
Group 05Theory Of Operation 9010
Group 10System Operational Checks
Group 15System Diagnostic Information
Group 20Adjustments
Group 25Tests
9015
SECTION 9015Electrical System
Group 05System Information
Group 10System Diagrams
Group 15Sub-System Diagnostics
Group 20References
9020
SECTION 9020Power Train
Group 05Theory Of Operation
Group 10System Operational Checks
Group 15System Diagnostic Information
Group 20Adjustments
9025
Group 25Test

SECTION 9025Hydraulics
Group 05Theory Of Operation
Group 10System Operational Checks
Group 15Diagnostic Information 9031
Group 20Adjustments
Group 25Tests

SECTION 9031Heating And Air Conditioning


Group 05Theory Of Operation
INDX
Group 10System Operational Checks
Group 15Diagnostic Information
Group 20Adjustments
Group 25Test

All information, illustrations and specifications in this manual are based on


the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT 1996
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual

TM1512 (07NOV03) i Backhoe Loaders Operation and Test


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Contents

9000

9005

9010

9015

9020

9025

9031

INDX

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9000

Section 9000
General Information
Contents

Page Page

Group 01Safety Information Checking Wheel Fastener Torque . . . . . . . . .9000-03-1


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

Group 03Torque Values


Hardware Torque Specifications . . . . . . . . . .9000-03-1

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9000

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Group 01
Safety Information
9000
Handle Fluids SafelyAvoid Fires 01
1

When you work around fuel, do not smoke or work near


heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not


incinerate or puncture pressurized containers.

UN23AUG88
Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn

TS227
spontaneously.

DX,FLAME 1929SEP981/1

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from


the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object


across the posts. Use a volt-meter or hydrometer.

UN23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16C (60F).

TS204
DX,SPARKS 1903MAR931/1

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,


UN23AUG88

hospital, and fire department near your telephone.


TS291

DX,FIRE2 1903MAR931/1

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Safety Information

9000
01 Prevent Acid Burns
2

Sulfuric acid in battery electrolyte is poisonous. It is strong


enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.


2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.


2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 1530 minutes. Get
medical attention immediately.

UN23AUG88
If acid is swallowed:

1. Do not induce vomiting.


2. Drink large amounts of water or milk, but do not

TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.

DX,POISON 1921APR931/1

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Safety Information

9000
Handle Chemical Products Safely 01
3

Direct exposure to hazardous chemicals can cause


serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.

UN26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.

TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.

(See your John Deere dealer for MSDSs on chemical


products used with John Deere equipment.)

DX,MSDS,NA 1903MAR931/1

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin


causing serious injury.

Avoid the hazard by relieving pressure before

UN23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands

X9811
and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid


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

DX,FLUID 1903MAR931/1

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Safety Information

9000
01 Park Machine Safely
4

Before working on the machine:

Lower all equipment to the ground.


Stop the engine and remove the key.
Disconnect the battery ground strap.

UN24MAY89
Hang a "DO NOT OPERATE" tag in operator station.

TS230
DX,PARK 1904JUN901/1

Support Machine Properly

Always lower the attachment or implement to the ground


before you work on the machine. If you must work on a
lifted machine or attachment, securely support the
machine or attachment. If left in a raised position,
hydraulically supported devices can settle or leak down.

UN23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.

TS229
Follow recommended procedures in this manual.

When implements or attachments are used with a tractor,


always follow safety precautions listed in the implement
operators manual.

DX,LOWER 1917FEB991/1

Wear Protective Clothing

Wear close fitting clothing and safety equipment


appropriate to the job.

Operating equipment safely requires the full attention of


the operator. Do not wear radio or music headphones
UN23AUG88

while operating machine.


TS206

DX,WEAR2 1903MAR931/1

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Safety Information

9000
Work in Clean Area 01
5

Before starting a job:

Clean work area and machine.


Make sure you have all necessary tools to do your job.

UN18OCT88
Have the right parts on hand.
Read all instructions thoroughly; do not attempt
shortcuts.

T6642EJ
DX,CLEAN 1904JUN901/1

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,


scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.

UN23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.

TS228
DX,LOOSE 1904JUN901/1

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is


necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.

UN23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area

TS220
DX,AIR 1917FEB991/1

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a


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

DX,LIGHT 1904JUN901/1

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Safety Information

9000
01 Replace Safety Signs
6

Replace missing or damaged safety signs. See the


machine operators manual for correct safety sign
placement.

UN23AUG88
TS201
DX,SIGNS1 1904JUN901/1

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe


injury or machine damage.

Follow recommended procedure for removal and


installation of components in the manual.

UN23AUG88
TS226
DX,LIFT 1904JUN901/1

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated


by welding, soldering, or using a torch.

UN23AUG88
Do all work outside or in a well ventilated area. Dispose of
paint and solvent properly.

Remove paint before welding or heating: TS220

If you sand or grind paint, avoid breathing the dust.


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

DX,PAINT 1903MAR931/1

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Safety Information

9000
Avoid Heating Near Pressurized Fluid Lines 01
7

Flammable spray can be generated by heating near


pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be

UN15MAY90
accidentally cut when heat goes beyond the immediate
flame area.

TS953
DX,TORCH 1903MAR931/1

Keep ROPS Installed Properly

Make certain all parts are reinstalled correctly if the


roll-over protective structure (ROPS) is loosened or
removed for any reason. Tighten mounting bolts to proper
torque.

UN23AUG88
The protection offered by ROPS will be impaired if ROPS
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting. A damaged ROPS should be

TS212
replaced, not reused.

DX,ROPS3 1903MAR931/1

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Safety Information

9000
01 Service Tires Safely
8

Explosive separation of a tire and rim parts can cause


serious injury or death.

Do not attempt to mount a tire unless you have the proper


equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate


the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension


hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.

Check wheels for low pressure, cuts, bubbles, damaged


rims or missing lug bolts and nuts.

UN23AUG88
TS211
DX,RIM 1924AUG901/1

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when


handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers

UN23AUG88
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as TS220

airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for


cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A
special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.

Keep bystanders away from the area.

DX,DUST 1915MAR911/1

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Safety Information

9000
Practice Safe Maintenance 01
9

Understand service procedure before doing work. Keep


area clean and dry.

Never lubricate, service, or adjust machine while it is


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

Securely support any machine elements that must be


raised for service work.

Keep all parts in good condition and properly installed. Fix


damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground


cable (-) before making adjustments on electrical systems

UN23AUG88
or welding on machine.

On towed implements, disconnect wiring harnesses from


tractor before servicing electrical system components or

TS218
welding on machine.

DX,SERV 1917FEB991/1

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and


procedures can create safety hazards.

Use power tools only to loosen threaded parts and


fasteners.
UN08NOV89

For loosening and tightening hardware, use the correct


size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779

wrenches.

Use only service parts meeting John Deere specifications.

DX,REPAIR 1917FEB991/1

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Safety Information

9000
01 Dispose of Waste Properly
10

Improperly disposing of waste can threaten the


environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.

UN26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.

TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.

Air conditioning refrigerants escaping into the air can


damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste


from your local environmental or recycling center, or from
your John Deere dealer.

DX,DRAIN 1903MAR931/1

Live With Safety

Before returning machine to customer, make sure


machine is functioning properly, especially the safety
systems. Install all guards and shields.

1907OCT88
TS231

DX,LIVE 1925SEP921/1

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Group 02
General Specifications
9000
410D Backhoe Loader With Standard Dipperstick 02
1

UN15NOV90
T7412AL
Continued on next page TX,9000,DY609 1924JUL961/2

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General Specifications

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

Key: Standard Dipperstick 1.22 m (4 ft) Extendible Dipperstick


Retracted Extended
ALoading height, truck loading position 3.61 m (11 ft 10 in.) 3.51 m (11 ft 6 in.) 4.24 m (13 ft 11 in.)
BReach from center of swing mast 5.61 m (18 ft 5 in.) 5.42 m (17 ft 9 in.) 6.53 m (21 ft 5 in.)
CReach from center of rear axle 6.76 m (22 ft 2 in.) 6.55 m (21 ft 6 in.) 7.67 m (25 ft 2 in.)
DDigging depth (SAE):
(1) 610 mm (2 ft.) flat bottom 4.65 m (15 ft 3 in.) 4.42 m (14 ft 6 in.) 5.61 m (18 ft 5 in.)
(2) 2440 mm (8 ft.) flat bottom 4.32 m (14 ft 2 in.) 4.09 m (13 ft 5 in.) 5.34 m (17 ft 6 in.)
EMaximum digging depth 4.67 m (15 ft 4 in.) 4.46 m (14 ft 8 in.) 5.62 m (18 ft 5 in.)
FGround clearance, minimum 305 mm (12 in.) 305 mm (12 in.) 305 mm (12 in.)
GBucket rotation 160 and 180 160 and 180 160 and 180
HTransport height 3.49 m (11 ft 5 in.) 3.56 m (11 ft 8 in.) 3.56 m (11 ft 8 in.)
IOverall length, transport 6.99 m (23 ft 5 in.) 7.01 m (23 ft) 7.01 m (23 ft)
JStabilizer width-transport 2.34 m (7 ft 8 in.) 2.34 m (7 ft 8 in.) 2.34 m (7 ft 8 in.)
KStabilizer spread-operating 3 m (9 ft 10 in.) 3 m (9 ft 10 in.) 3 m (9 ft 10 in.)
LWidth over tires 2.15 m (7 ft 1 in.) 2.16 m (7 ft 1 in.) 2.16 m (7 ft 1 in.)
MWheelbase 2100 mm (83 in.)
NDig below groundbucket level 100 mm (4 in.) 100 mm (4 in.) 100 mm (4 in.)
ORollback at ground level 40 40 40
PDump clearance, bucket at 40 2.74 m (9 ft) 2.74 m (9 ft) 2.74 m (9 ft)
QMaximum height to bucket hinge pin 3.35 m (11 ft) 3.35 m (11 ft) 3.35 m (11 ft)
RMaximum bucket dump angle 45
SReach at full height, bucket at 40 711 mm (28 in.) 711 mm (28 in.) 711 mm (28 in.)
Backhoe Performance Ratings:
Digging force, bucket cylinder (power dig
position) 52 kN (11 700 lb) 52 kN (11 700 lb) 52 kN (11 700 lb)
Digging force, crowd cylinder 28 kN (6300 lb) 30.3 kN (6800 lb) 20.50 kN (4600 lb)
Swing arc 180 180 180
Operator control Two levers Right foot treadle Right foot treadle
Bucket positions 9 and 18 rollback 8 and 17 rollback 12 and 22 rollback
Stabilizer angle rearward 14.5 14.5 14.5
Lifting capacity, maximum boom @ 65 1980 kg (4400 lb) 2087 kg (4600 lb) 1310 kg (2900 lb)
Leveling angle 14 14 14
NOTE: Backhoe specifications are with 610 mm x 0.21 m3 (24 in. x 7.5 cu ft standard bucket. Loader specifications are with 1.5 m 3 (1.5 yd3 )
bucket.

TX,9000,DY609 1924JUL962/2

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General Specifications

9000
410D Heavy Lift Backhoe Loader 02
3

UN15NOV90
T7412AL
Continued on next page TX,9000,DY611 1924JUL961/2

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General Specifications

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

Standard Dipperstick with


Key: Heavy Lift Package 1.52 m (5 ft) Extendible Dipperstick
Retracted Extended
ALoading height, truck loading position 3.76 m (12 ft 4 in.) 3.76 m (12 ft 4 in.) 4.65 m (15 ft 3 in.)
BReach from center of swing mast 5.87 m (19 ft 3 in.) 5.87 m (19 ft 3 in.) 7.29 m (23 ft 11 in.)
CReach from center of rear axle 7.01 m (23 ft) 7.01 m (23 ft) 8.43 m (27 ft 8 in.)
DDigging depth (SAE):
(1) 610 mm (2 ft.) flat bottom 4.78 m (15 ft 8 in.) 4.78 m (15 ft 8 in.) 6.27 m (20 ft 7 in.)
(2) 2440 mm (8 ft.) flat bottom 4.47 m (14 ft 8 in.) 4.47 m (14 ft 8 in.) 6.05 m (19 ft 10 in.)
EMaximum digging depth 4.80 m (15 ft 9 in.) 4.80 m (15 ft 9 in.) 4.80 m (15 ft 9 in.)
FGround clearance, minimum 330 mm (13 in.) 330 mm (13 in.) 330 mm (13 in.)
GBucket rotation 160 and 180 160 and 180 160 and 180
HTransport height 3.68 m (12 ft 1 in.) 3.86 m (12 ft 8 in.) 3.86 m (12 ft 8 in.)
IOverall length, transport 6.99 m (22 ft 11 in.) 7.01 m (23 ft) 7.01 m (23 ft)
JStabilizer width-transport 2.34 m (7 ft 8 in.) 2.34 m (7 ft 8 in.) 2.34 m (7 ft 8 in.)
KStabilizer spread-operating 3.00 m (9 ft 10 in.) 3.00 m (9 ft 10 in.) 3 m (9 ft 10 in.)
LWidth over tires 2.15 m (7 ft 1 in.) 2.16 m (7 ft 1 in.) 2.16 m (7 ft 1 in.)
MWheelbase 215 mm (85 in.) 215 mm (85 in.) 215 mm (85 in.)
NDig below groundbucket level 100 mm (4 in.) 100 mm (4 in.) 100 mm (4 in.)
ORollback at ground level 40 40 40
PDump clearance, bucket at 40 2.74 m (9 ft) 2.74 m (9 ft) 2.74 m (9 ft)
QMaximum height to bucket hinge pin 3.35 m (11 ft) 3.35 m (11 ft) 3.35 m (11 ft)
RMaximum bucket dump angle 45 45 45
SReach at full height, bucket at 40 711 mm (28 in.) 711 mm (28 in.) 711 mm (28 in.)
Backhoe Performance Ratings:
Digging force, bucket cylinder (power dig
position) 48.9 kN (11 000 lb) 58.9 kN (11 000 lb) 58.9 kN (11 000 lb)
Digging force, crowd cylinder 36 kN (8100 lb) 36 kN (8100 lb) 23.60 kN (5300 lb)
Swing arc 180 180 180
Operator control Two levers Right foot treadle Right foot treadle
Bucket positions 8 and 17 rollback 8 and 16 rollback 12 and 21 rollback
Stabilizer angle rearward 14.5 14.5 14.5
Lifting capacity, maximum boom @ 65 2925 kg (6500 lb) 2790 kg (6200 lb) 1530 kg 3400 lb (1530 kg)
Leveling angle 13 13 13
NOTE: Backhoe specifications are with 610 mm x 0.21 m 3 (24 in. x 7.5 cu ft) standard bucket. Loader specifications are with 1.5 m 3 (1.5 yd
3
) bucket

TX,9000,DY611 1924JUL962/2

TM1512 (07NOV03) 9000-02-4 Backhoe Loaders Operation and Test


110703

PN=20
General Specifications

9000
410D Backhoe Loader Specifications 02
5
Engine
John Deere 4045D
SAE
Rated power @ 2200 rpm net, 56 kW (75 hp)
gross, 60 kW (80 hp)
Rated power @ 2200 rpm with net, 63.5 kW (85 hp)
optional turbocharger gross, 67 kW (90 hp)
Cylinders 4
Displacement 4.52 L (276 cu in.)
Fuel consumption, typical 3.8 to 7.6 L/h (1.0 to 2.0 gal/hr)
Torque rise 25%
with optional turbocharger 25%
Maximum net torque 303 Nm (224 lb-ft)
with optional turbocharger 344 Nm (254 lb-ft)
Lubrication Pressure system w/full-flow filter
and cooler
Cooling Pressurized w/thermostat and
fixed bypass
Air cleaner Dual stage dry type with
secondary element and
precleaner
Electrical system 12-volt
Alternator 95 amps

Transmission:
John Deere 4-speed helical gear, synchronized collar shift
transmission with hydraulic reverser. Uses single stage, dual phase,
280 mm (11 in.) torque converter with 2:23:1 stall ratio.

Travel
Speeds: Gear Forward Reverse
km/h mph km/h mph
With 1 5.5 (3.4) 6.3 (3.9)
Standard
19.5L-24
rear and
11L-16
front tires
2 9.5 (5.9) 10.9 (6.8)
3 20.3 (12.6) 23.3 (14.5)
4 32.7 (19.7) 36.4 (22.6)

Continued on next page TX,9000,DY612 1924JUL961/2

TM1512 (07NOV03) 9000-02-5 Backhoe Loaders Operation and Test


110703

PN=21
General Specifications

9000
02 Service Brakes:
6
Manual hydraulic, applied with separate pedals; hydraulically
equalized when both pedals are depressed. Wet disks and facings are
fully enclosed and self-adjusting.

Park Brake:
Independent system, spring applied, hydraulically released, and
controlled by an electric switch on the side console.

Steering: Hydrostatic Power


Non-powered axle curb turning radius
(brakes applied) 3.55 m (11 ft 8 in.)
(without brakes) 4.04 m (13 ft 3 in.)
Bucket clearance circle
(brakes applied) 9.64 m (31 ft 8 in.)
(without brakes) 10.60 m (34 ft 9 in.)
Steering wheel turns
Stop to stop 2.2 to 2.9
(after 1Dec91) 3.1 to 3.7
Powered axle (MFWD) curb turning radius
(brakes applied) 3.49 m (11 ft 5 in.)
(without brakes) 4.11 m (13 ft 6 in.)
Bucket clearance circle
(brakes applied) 9.02 m (29 ft 7 in.)
(without brakes) 10.26 m (33 ft 8 in.)
Steering wheel turns
Stop to stop 2.6 to 2.7

TX,9000,DY612 1924JUL962/2

TM1512 (07NOV03) 9000-02-6 Backhoe Loaders Operation and Test


110703

PN=22
General Specifications

9000
410D Backhoe Specifications 02
7
Final Drives:
Heavy-duty inboard mounted planetary. Evenly distributes axle shock
loads over three oil cooled gears.

Axle ratings:
Static Dynamic SAEJ43
Front 25 300 kg 25 300 kg 8800 kg
(56 000 lb) (56 000 lb) (19 600 lb)
Rear 23 100 kg 30 800 kg 7200 kg
(51 000 lb) (68 000 lb) (15 960 lb)

Hydraulic System: Closed center


Pressure setting 19 000 kPa (2755 psi)
Pump radial piston
Flow @ 2200 rpm 133 L/min (35 gpm)
Filter, return oil 10 micron replaceable element

Tires:
Front standard axle 11L-16, 12PR, F3
14.5/75-16.1, 10PR, F3
Front MFWD axle 12-16.5, 8 PR, NHS
14-17.5, 8 PR, NHS
Rear standard axle 21L-24, 10PR, R4
19.5L-24, 10PR, R4
Rear MFWD axle 21L-24, 10PR R4
18.4-28, 12PR R4
19.5L-24, 10PR R4

Transporting:
Operating weight (SAE) 7075 kg (15,600 lb)
cab adds 227 kg (500 lb)
MFWD adds 125 kg (275 lb)
extendible dipperstick with 482 kg (1063 lb)
counterweights adds
optional front counterweights adds 113 kg (250 lb)
backhoe bucket coupler adds 91 kg (200 lb)

Continued on next page TX,9000,DY613 1924JUL961/2

TM1512 (07NOV03) 9000-02-7 Backhoe Loaders Operation and Test


110703

PN=23
General Specifications

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

TX,9000,DY613 1924JUL962/2

TM1512 (07NOV03) 9000-02-8 Backhoe Loaders Operation and Test


110703

PN=24
General Specifications

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

Backhoe: Width Heaped


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

TX,9000,DY614 1925JUL961/1

TM1512 (07NOV03) 9000-02-9 Backhoe Loaders Operation and Test


110703

PN=25
General Specifications

9000
02 410D And 510D Backhoe Loader Drain And
10
Refill Capacities
Metric U.S.
Engine coolant 16 L 17 qt
Engine oil (including filter) 8.5 L 9 qt
Torque converter and reverser 13 L 14 qt
Fuel tank 129 L 34 gal
Hydraulic reservoir:
410D (SN 796855 )
510D (SN 796891 ) 41.5 L 11 gal
Transaxle:
410D (SN 796854)
510D (SN 796890)
Without MFWD 23 L 24 qt
With MFWD 24 L 25 qt
410D (SN 796855801199)
510D (SN 796891801199)
Without MFWD 18 L 19 qt
With MFWD 19 L 20 qt
410D, 510D (SN 801200 )
Without MFWD 21 L 22 qt
With MFWD 24 L 25 qt
Front axle 6.5 L 7 qt
Front wheel planetary (MFWD) (per side) 1L 1 qt

TX,9000,DY615 1925JUL961/1

TM1512 (07NOV03) 9000-02-10 Backhoe Loaders Operation and Test


110703

PN=26
General Specifications

9000
410D Backhoe Loader Lifting Capacities 02
11

UN16DEC91
T7646AI
Lift Capacity, Backhoe With Standard Dipperstick Based On SAE J31. Rated Lift Capacities Are In Kg (lb). Lift
Capacities Are Hydraulically Limited.

ADipper Lift at 65 BSwing Pivot CBoom Lift

Lifting capacity ratings are made with bucket hinge pin, load. Angle between boom and ground is 65 .
loader bucket and stabilizers on firm, level ground Lift Machine is equipped with 610 mm (24 in.) standard
capacities are hydraulically limited. Lifting capacities bucket, standard or extendible dipperstick and
are 87 % of the maximum lift over any point on the standard equipment.
swing arc and do not exceed 75 percent of the tipping

Continued on next page TX,9000,DY616 1925JUL961/6

TM1512 (07NOV03) 9000-02-11 Backhoe Loaders Operation and Test


110703

PN=27
General Specifications

9000
02
12

UN16DEC91
T7646AE
Lift Capacity, Backhoe With 1.22 M (4 Ft) Dipperstick, Retracted. Based On SAE J31. Rated Lift Capacities Are In
Kg (lb). Lift Capacities Are Hydraulically Limited.

ADipper Lift at 65 BSwing Pivot CBoom Lift

NOTE: Loader bucket on ground significantly improves to the side. Lift capacity over the rear is not
side stability, therefore improving lift capacity affected.

Continued on next page TX,9000,DY616 1925JUL962/6

TM1512 (07NOV03) 9000-02-12 Backhoe Loaders Operation and Test


110703

PN=28
General Specifications

9000
02
13

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

ADipper Lift at 65 BSwing Pivot CBoom Lift

Continued on next page TX,9000,DY616 1925JUL963/6

TM1512 (07NOV03) 9000-02-13 Backhoe Loaders Operation and Test


110703

PN=29
General Specifications

9000
02
14

UN16DEC91
T7646AJ
Lift Capacity, Backhoe With Optional Heavy Lift Package. Based On SAE J31. Rated Lift Capacities Are In Kg (lb).
Lift Capacities Are Hydraulically Limited.

ADipper Lift at 65 BSwing Pivot CBoom Lift

Continued on next page TX,9000,DY616 1925JUL964/6

TM1512 (07NOV03) 9000-02-14 Backhoe Loaders Operation and Test


110703

PN=30
General Specifications

9000
02
15

UN16DEC91
T7646AF
Lift Capacity, Backhoe With 1.52 M (5 Ft) Extendible Dipperstick, Retracted Based On SAE J31. Rated Lift
Capacities Are In Kg (lb). Lift Capacities Are Hydraulically Limited.

ADipper Lift at 65 BSwing Pivot CBoom Lift

Continued on next page TX,9000,DY616 1925JUL965/6

TM1512 (07NOV03) 9000-02-15 Backhoe Loaders Operation and Test


110703

PN=31
General Specifications

9000
02
16

UN16DEC91
T7646AH
Lift Capacity, Backhoe With 1.52 M (5 Ft) Extendible Dipperstick, Extended Based On SAE J31. Rated Lift
Capacities Are In Kg (lb). Lift Capacities Are Hydraulically Limited.

ADipper Lift at 65 BSwing Pivot CBoom Lift

TX,9000,DY616 1925JUL966/6

TM1512 (07NOV03) 9000-02-16 Backhoe Loaders Operation and Test


110703

PN=32
General Specifications

9000
510D Backhoe Loader With Standard 2.1 M (6 Ft 11.7 In.) Dipperstick 02
17

UN15NOV90
T7412AL
Continued on next page TX,9000,DY618 1925JUL961/2

TM1512 (07NOV03) 9000-02-17 Backhoe Loaders Operation and Test


110703

PN=33
General Specifications

9000
02 NOTE: Specifications and design subject to change machine with 19.5L-24 rear tires; 11L-16 front
18
without notice. Wherever applicable, tires; 1.15 m 3 (1.5 cu yd) loader bucket; 610
specifications are in accordance with SAE mm (24 in.) backhoe bucket; ROPS/FOPS; full
Standards. Except where otherwise noted, fuel tank and 79 kg (175 lb) operator.
these specifications are based on a standard

Backhoea w/Standard
Key: Dipperstick 1.52 m (5 ft) Extendible Dipperstick
Retracted Extended
ALoading height, truck loading 3.96 m (13 ft) 3.76 m (12 ft 4 in.) 4.65 m (15 ft 3 in.)
position
BReach from center of swing mast 6.07 m (19 ft 11 in.) 5.87 m (19 ft 3 in.) 7.29 m (23 ft 11 in.)
CReach from center rear axle 23 ft 8 in. (7.21 m) 7.01 m (23 ft) 8.43 m (27 ft 8 in.)
DDigging depth (SAE):
(1) 2 ft. (610 mm) flat bottom 4.98 m (16 ft 4 in.) 4.78 m (15 ft 8 in.) 6.27 m (20 ft 7 in.)
(2) 8 ft. (2440 mm) flat bottom 4.67 m (15 ft 4 in.) 4.47 m (14 ft 8 in.) 6.05 m (19 ft 10 in.)
EMaximum digging depth 5.00 m (16 ft 5 in.) 4.81 m (15 ft 9 in.) 6.30 m (20 ft 8 in.)
FGround clearance, minimum 330 mm (13 in.) 330 mm (13 in.) 330 mm (13 in.)
GBucket rotation 160 and 180 160 and 180 160 and 180
HTransport height 3.68 m (12 ft 1 in.) 13.87 m (2 ft 8 in.) 3.87 m (12 ft 8 in.)
IOverall length, transport 7.11 m (23 ft 4 in.) 7.01 m (23 ft) 7.00 m (23 ft)
JStabilizer width-transport 2.34 m (7 ft 8 in.) 2.34 m (7 ft 8 in.) 2.34 m (7 ft 8 in.)
KStabilizer spread-operating 3.0 m (9 ft 10 in.) 3.0 m (9 ft 10 in.) 3.0 m (9 ft 10 in.)
LWidth over tires 2.18 m (7 ft 2 in.) 2.18 m (7 ft 2 in.) 2.18 m (7 ft 2 in.)
MWheelbase 2.15 m (85 in.)
NDig below groundbucket level 100 mm (4 in.)
ORollback at ground level 40
PDump clearance, bucket at 40 2.67 m (8 ft 9 in.)
QMaximum height to bucket hinge pin 3.35 m (11 ft 0 in.)
RMaximum bucket dump angle 45
SReach at full height, bucket at 40 762 mm (30 in.)
Digging force, bucket cylinder (power 48.9 kN (11000 lb) 48.9 kN (11000 lb) 48.9 kN (11000 lb)
dig position)
Digging force, crowd cylinder 36.0 kN (7600 lb) 36.0 kN (8100 lb) 23.6 kN (5300 lb)
Swing arc 180 180 180
Operator control Two levers Right foot treadle Right foot treadle
Bucket positions 8 and 17 rollback 8 and 18 rollback 12 and 21 rollback
Stabilizer angle rearward 14.5 14.5 14.5
Lifting capacity, maximum boom @ 65 2700 kg (6000 lb) 2790 kg (6200 lb) 1530 kg (3400 lb)
a
Backhoe specifications are with 610 mm (24 in.) standard bucket. Loader specifications are with 1.15 m[sup3 ] (1.5 yd[sup3 ]) bucket.

TX,9000,DY618 1925JUL962/2

TM1512 (07NOV03) 9000-02-18 Backhoe Loaders Operation and Test


110703

PN=34
General Specifications

9000
510D Backhoe Loader Specifications 02
19

NOTE: (Specifications and design subject to change


without notice. Wherever applicable, specifications
are in accordance with SAE Standards.)

Power SAE
Net 67 kW (90 hp)

Engine:
John Deere 4045T and 4045D
Rated power @ 2200 rpm
naturally aspirated
Cylinders 4
Displacement 4.524 L (276 cu. in.)
Lubrication Pressure system w/full-flow filter
Cooling Pressurized w/thermostat and
fixed bypass
Fuel consumption, typical 6.0 to 9.8 L/h (1.6 to 2.6 gal/hr)
Torque rise at 1300 rpm
with turbocharger 25%
Air cleaner Dry
Electrical system 12-volt
Alternator 65 amps

Transmission:
John Deere 4-speed helical gear, synchronized collar shift
transmission with hydraulic reverser.
280 mm (11 in.)
Torque converter with 223:1 stall ratio

Travel
Speeds: Gear Forward Reverse
mph km/h mph km/h
With Standard 1 3.2 5.2 3.7 6.0
19.5L-24 rear
and 11L-16
front tires
2 5.5 8.8 6.4 10.3
3 11.7 18.8 13.6 21.9
4 19.0 30.5 22.2 35.7
With MFWD 1 3.3 5.3 3.8 6.1
and required
21L-24 rear
and
12.00-16.5
front tires
2 5.7 9.2 6.6 10.6
3 12.1 19.5 14.0 22.5
4 20.2 32.5 23.6 37.9

Final Drives:
Heavy-duty inboard mounted planetary. Evenly distributes axle shock
loads over three oil cooled gears.
TX,115,RR4105 1925MAR941/1

TM1512
Service(07NOV03)
Brakes: 9000-02-19 Backhoe Loaders Operation and Test
110703

Manual hydraulic, applied with separate pedals; hydraulically PN=35


equalized when both pedals are depressed. Wet disks and facings are
General Specifications

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

Backhoe: Width Heaped


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

TX,115,RR,2079 1914MAY931/1

TM1512 (07NOV03) 9000-02-20 Backhoe Loaders Operation and Test


110703

PN=36
General Specifications

9000
510D Backhoe Loader Lifting Capacities 02
21

UN16DEC91
T7646AK
Lift Capacity, Backhoe With Standard 2.1 M (6 Ft 11.7 In.) Dipperstick Based On SAE J31. Rated Lift Capacities
Are In Kg (lb). Lift Capacities Are Hydraulically Applied.

ADipperstick Lift at 65 BSwing Pivot CBoom Lift

Lifting capacity ratings are made with bucket hinge pin, Angle between boom and ground is 65 degrees.
loader bucket and stabilizers on firm, level ground. Lift Machine is equipped with 610 mm (24 in.) standard
capacities are hydraulically limited. Lifting capacities 87 bucket, standard or extendible dipperstick and
% of the maximum lift over any point on the swing arc standard equipment.
and do not exceed 75 percent of the tipping load.

Continued on next page TX,115,RR,2081 1914MAY931/3

TM1512 (07NOV03) 9000-02-21 Backhoe Loaders Operation and Test


110703

PN=37
General Specifications

9000
02
22

UN16DEC91
T7646AF
Lift Capacity, Backhoe With Extendible Dipperstick, Retracted Based On SAE J31.

NOTE: Loader bucket on ground significantly improves to the side. Lift capacity over the rear is not
side stability, therefore improving lift capacity affected.

Continued on next page TX,115,RR,2081 1914MAY932/3

TM1512 (07NOV03) 9000-02-22 Backhoe Loaders Operation and Test


110703

PN=38
General Specifications

9000
02
23

UN16DEC91
T7646AH
Lift Capacity, Backhoe With Extendible Dipperstick, Extended Based On SAE J31.

TX,115,RR,2081 1914MAY933/3

TM1512 (07NOV03) 9000-02-23 Backhoe Loaders Operation and Test


110703

PN=39
General Specifications

9000
02
24

TM1512 (07NOV03) 9000-02-24 Backhoe Loaders Operation and Test


110703

PN=40
Group 03
Torque Values
9000
Hardware Torque Specifications 03
1

Check cap screws and nuts to be sure they are tight. If


hardware is loose, tighten to torque shown on the
following charts unless a special torque is specified.

TX,90,FF1225 1915MAR931/1

Checking Wheel Fastener Torque

Tighten wheel cap screws and fasteners.

410D/510D Wheel Fastener Torque ValuesSpecification


Front Standard AxleTorque ................ 136 20 -27 Nm (100 15 -20
lb-ft)
Front MFWD AxleTorque ....................... 300 110 -115 Nm (221 81
-29 lb-ft)
Rear AxleTorque .................................. 575 170 -115 Nm (425 125
-85 lb-ft)

TX,90,RR4055 1926JUL991/1

ROPS Torque Specifications

CAUTION: Make certain all parts are reinstalled


correctly if the roll-over protective structure
(ROPS) is loosened or removed for any reason.
Tighten mounting bolts to proper torque.

UN23AUG88
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or

TS176
is in any way altered. A damaged ROPS should
be replaced, not reused.

When installation of equipment on a machine necessitates


loosening or removing ROPS, mounting bolts must be
tightened to 400 64 Nm (295 47 lb-ft).

Item Measurement Specification

ROPS Mounting Bolts Torque 400 64 Nm (295 47 lb-ft)

CED,OUTX782,574 1926JUL991/1

TM1512 (07NOV03) 9000-03-1 Backhoe Loaders Operation and Test


110703

PN=41
Torque Values

9000
03 Unified Inch Bolt and Cap Screw Torque Values
2

1902APR97
TS1656

DX,TORQ1 1920JUL941/1

TM1512 (07NOV03) 9000-03-2 Backhoe Loaders Operation and Test


110703

PN=42
Torque Values

9000
Metric Bolt and Cap Screw Torque Values 03
3

1902APR97
TS1657

DX,TORQ2 1920JUL941/1

TM1512 (07NOV03) 9000-03-3 Backhoe Loaders Operation and Test


110703

PN=43
Torque Values

9000
03 Additional Metric Cap Screw Torque Values
4

UN18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.

T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.

UN18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or higher

T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.

Make sure fastener threads are clean and you properly


start thread engagement. This will prevent them from
failing when tightening.

UN18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.

T6873AC
Continued on next page 04T,90,M170 1901AUG941/2

TM1512 (07NOV03) 9000-03-4 Backhoe Loaders Operation and Test


110703

PN=44
Torque Values

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

04T,90,M170 1901AUG942/2

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Torque Values

9000
03 Service Recommendations for Metric Series Four Bolt Flange Fitting
6

UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Thread b
Nm lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42

4. Single piece flange (D): Place hydraulic line in M12 95 70

center of flange and install four cap screws. Flange M14 157 116
must be centrally located on port. Hand tighten cap M16 217 160
screws to hold flange in place. Do not pinch O-ring. M18 334 246
M20 421 318
5. After components are properly positioned and cap a
Tolerance 10%. The torques given are enough for the given
screws are hand tightened, tighten one cap screw, size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
b
Metric standard thread.

04T,90,K175 1905JAN961/1

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Torque Values

9000
Service Recommendations For Inch Series Four Bolt Flange Fittings 03
7

UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches TORQUE CHART


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

must be centrally located on port. Hand tighten cap 3 5/8-11 UNC 158 264 117 195
screws to hold flange in place. Do not pinch O-ring. 3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 5 5/8-11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.

DO NOT use air wrenches. DO NOT tighten one


cap screw fully before tightening the others. DO
NOT over tighten.

04T,90,K174 1901AUG941/1

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Torque Values

9000
03 Check Oil Lines And Fittings
8

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten

UN23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.

Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.

Tubing with dents may cause the oil to overheat. If you


find tubing with dents, install new tubing immediately.

IMPORTANT: Tighten fittings as specified in torque


chart.

When you tighten connections, use two wrenches to


prevent bending or breaking tubing and fittings.

TX,90,DH1559 1901AUG941/1

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Torque Values

9000
Service Recommendations for 37 Flare and 03
9
30 Cone Seat Connectors

1. Inspect flare and flare seat. They must be free of dirt


or obvious defects.

UN18OCT88
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.

T6234AC
3. Align tube with fitting before attempting to start nut.

4. Lubricate male threads with hydraulic fluid or petroleum


jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on torque


chart. Do not allow hoses to twist when tightening
fittings.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART


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

T82,BHMA,EL 1919MAR961/1

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Torque Values

9000
03 Service Recommendations for O-Ring Boss
10
Fittings

Straight Fitting

1. Inspect O-ring boss seat for dirt or defects.

UN18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.

T6243AE
3. Tighten fitting to torque value shown on chart.

Continued on next page 04T,90,K66 1919MAR961/2

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Torque Values

9000
Angle Fitting 03
11

1. Back-off lock nut (A) and back-up washer (B)


completely to head-end (C) of fitting.

2. Turn fitting into threaded boss until back-up washer

UN18OCT88
contacts face of boss.

3. Turn fitting head-end counterclockwise to proper index


(maximum of one turn).

T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.

4. Hold fitting head-end with a wrench and tighten locknut


and back-up washer to proper torque value.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART


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

04T,90,K66 1919MAR962/2

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Torque Values

9000
03 Service Recommendations for Flat Face
12
O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces. They must be free


of dirt or defects.

UN18OCT88
2. Inspect the O-ring. It must be free of damage or
defects.

3. Lubricate O-rings and install into groove using

T6243AD
petroleum jelly to hold in place.

4. Push O-ring into the groove with plenty of petroleum


jelly so O-ring is not displaced during assembly.

5. Index angle fittings and tighten by hand pressing joint


together to insure O-ring remains in place.

6. Tighten fitting or nut to torque value shown on the


chart per dash size stamped on the fitting. Do not allow
hoses to twist when tightening fittings.

FLAT FACE O-RING SEAL FITTING TORQUE


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

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Group 04
Fuels And Lubricants
9000
Fuel Specifications 04
1

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

If fuel sulfur content exceeds 0.5


percent, change the engine oil at 1/2
the normal interval.

TX,DH,54 1901AUG941/1

Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations for engines


used off-highway. This fuel will not require any additives
to provide good performance and engine reliability.
However, many local fuel distributors will not carry both
low and regular sulfur diesel fuels.

If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere PREMIUM DIESEL FUEL
CONDITIONER. It provides lubricating properties along
with other useful benefits, such as cetane improver,
anti-oxidant, fuel stabilizer, corrosion inhibitor and others.
John Deere PREMIUM DIESEL FUEL CONDITIONER is
specifically for use with low sulfur fuels. Nearly all other
diesel fuel conditioners only improve cold weather flow
and stabilize long-term fuel storage. They do not contain
the lubrication additives needed by rotary fuel injection
pumps.

TX,45,DH3124 1920OCT931/1

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Fuels And Lubricants

9000
04 Storing Fuel
2

If there is a very slow turnover of fuel in the fuel tank or


supply tank, it may be necessary to add a fuel conditioner
to prevent water condensation. Contact your John Deere
dealer for proper service or maintenance
recommendations.

DX,FUEL 1903MAR931/1

Do Not Use Galvanized Containers

IMPORTANT: Diesel fuel stored in galvanized Store fuel in:


containers reacts with zinc coating
on the container to form zinc flakes. plastic containers.
If fuel contains water, a zinc gel will aluminum containers.
also form. The gel and flakes will specially coated steel containers made for diesel
quickly plug fuel filters and damage fuel.
fuel injectors and fuel pumps.
DO NOT USE brass-coated containers: brass is an
DO NOT USE a galvanized container to store diesel alloy of copper and zinc.
fuel.

MX,FLBT,C 1904JUN901/1

Fuel Tank

CAUTION: Handle fuel carefully. If the engine is


hot or running, DO NOT fill the fuel tank. DO
NOT smoke while you fill fuel tank or work on
fuel system.

To avoid condensation, fill the fuel tank at the end of each


days operation. Shut off engine before filling.

TX,45,DH1588 1924AUG941/1

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Fuels And Lubricants

9000
Engine Oil 04
3

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

If other oils are used, the required specification is:

PLUS-50 is a registered trademark of Deere & Company


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

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Fuels And Lubricants

9000
04 Transaxle Oil
4

1918OCT91
T6186AG
Depending on the expected air temperature range You may also use oils which meet minimum John
between oil changes, use oil viscosity shown on the Deere standards, or other oils meeting John Deere
chart above. Standard JDM J20A or J20C and J20B or J20D.

JOHN DEERE HY-GARD TRANSMISSION AND Oils meeting MIL-L46167A may be used as arctic oil.
HYDRAULIC OIL IS RECOMMENDED because it is
specifically formulated to minimize brake chatter, and
to provide maximum protection against mechanical
wear.

HY-GARD is a registered trademark of Deere & Company TX,45,DH2079 1927NOV911/1

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Fuels And Lubricants

9000
Hydraulic And Reverser Oil 04
5

1915NOV91
T6249AY
Depending on the expected air temperature range You may also use oils which meet minimum John
between oil changes, use oil viscosity shown on the Deere standards, or other oils meeting John Deere
chart above. Standard JDM J20A or J20C and J20B or J20D.

JOHN DEERE HY-GARD TRANSMISSION AND Oils meeting MIL-L46167A may be used as arctic oil.
HYDRAULIC OIL IS RECOMMENDED because it is
specifically formulated to minimize brake chatter, and
to provide maximum protection against mechanical
wear.

HY-GARD is a registered trademark of Deere & Company TX,45,DH2074 1927NOV911/1

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Fuels And Lubricants

9000
04 Mechanical Front Wheel Drive Oil
6

1905JAN89
T6247AB
Depending on the expected air temperature range John Deere API GL-5 Gear Oil
between oil changes, use oil viscosity shown on the Oils meeting API Service GL-5 (MIL-L-2105B or
chart above. MIL-2105C)

The following oils are recommended: Oil meeting MIl-L-10324A may be used as arctic oil.

T82,45,C11 1915MAR931/1

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Fuels And Lubricants

9000
Grease 04
7

1927JAN89
T6722AA
Depending on the expected air temperature range, use SAE Multipurpose Grease with Extreme Pressure
grease shown on chart above. (EP) performance and containing 3 to 5 per cent
molybdenum disulfide
Greases recommended are: SAE multi-purpose EP Grease
Grease meeting MIL-G-10924C specifications may
John Deere Moly High Temperature/EP Grease be used as arctic grease.
(Preferred)

02T,45,C49 1901AUG941/1

Grease For Extendible Dipperstick

SAE Multipurpose Grease with Extreme Pressure (EP)


performance and containing 3 to 5 per cent molybdenum
disulfide (preferred).

TX,45,DH1576 1921JAN921/1

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Fuels And Lubricants

9000
04 Alternative and Synthetic Lubricants
8

Conditions in certain geographical areas may require


lubricant recommendations different from those printed in
this manual.

Some John Deere brand coolants and lubricants may not


be available in your location.

Consult your John Deere dealer to obtain information and


recommendations.

Synthetic lubricants may be used if they meet the


performance requirements as shown in this manual.

The temperature limits and service intervals shown in this


manual apply to both conventional and synthetic oils.

Rerefined base stock products may be used if the


finished lubricant meets the performance requirements.

DX,ALTER 1918MAR961/1

Lubricant Storage

Your equipment can operate at top efficiency only Make certain that all containers are properly marked to
when clean lubricants are used. identify their contents.

Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.

DX,LUBST 1918MAR961/1

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Fuels And Lubricants

9000
Mixing of Lubricants 04
9

In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet information and recommendations.
certain specifications and performance requirements.

Mixing different oils can interfere with the proper


functioning of these additives and degrade lubricant
performance.

DX,LUBMIX 1918MAR961/1

Engine Coolant

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

DX,COOL 1904JUN901/1

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Fuels And Lubricants

9000
04
10

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Section 9005
Operational Checkout Procedure
Contents 9005

Page

Group 10Operational Checkout Procedure


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

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Contents

9005

TM1512 (07NOV03) 9005-2 Backhoe Loaders Operation and Test


110703

PN=2
Group 10
Operational Checkout Procedure

Operational Checkout Procedure

Use this procedure to check all systems and functions Operational Checkout Record Sheet and record the
on the machine. results of each check on this sheet.
9005
This checkout procedure is designed so technician can At the end of each check if no problem is found (OK:), 10
make a quick check of the operation of machine while you will instructed to GO TO NEXT CHECK. If problem 1
sitting in operators seat. (NOT OK:) is indicated, you will be given repair
required or CTM number. If verification is needed, you
A location will be required which is level, has adequate will be given next best source of information after GO
space to complete the driving checks and to work TO:
machine. The engine, power train and hydraulic oil
must be at operating temperature. Group 10 (System Operational Checks)

Complete the necessary visual checks (oil levels, oil Group 15 (System Diagnostic Checks)
condition, external leaks, loose hardware, loose
linkage) prior to doing the checkout procedure. Group 20 (Adjustments)

No special tools or gauges are needed. Always start in Group 25 (Test)


the left column and read completely, follow this
sequence from left to right. Read each check CTM (Component Technical Manual)
completely before performing. Make a copy of the

TX,D300,DS1984 1906APR951/1

Gauge And Indicator Check With Engine Off

1/1

1 Monitor Indicator Turn key switch to BULB CHECK position and hold. OK: Go to next check .
Lights And Alarm
Check LOOK: All six monitor indicator lights and CAUTION light NOT OK: Check monitor
must be on. STOP light must flash and alarm must fuse.
"beep".
NOT OK: Go to Group
LISTEN: Starting motor must NOT operate. 9015-15, Gauges and
Monitor Checks, Display
T7394BH UN10DEC90
Monitor Check .

NOT OK: If motor starts


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

1/1

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Operational Checkout Procedure

FNR And Neutral Start Switches, Start Circuit And Reverse Warning Alarm Checks

9005 1/1
10
2
1 FNR Switch Check OK: Go to next check .

NOT OK: If no "click",


inspect neutral start fuse.

NOT OK: Go to Group


9015-15, Start Circuit
Diagnostic Procedures .
T7447AG UN04JAN91 T7447AI UN04JAN91 T7447AH UN04JAN91

Engine off.

Put FNR lever in neutral.

Turn key switch to ON position.

Move FNR lever to forward (F), reverse (R), then neutral (N) position.

Observe and feel forward, neutral and reverse detents.

LOOK: FNR lever must align with neutral position in quadrant when reverser valve is in
neutral detent position.

LISTEN: You must hear relay "click" as FNR lever is moved EQUAL distance from
neutral to forward position and from neutral to reverse position.

FEEL: You must feel detent engagement in each position of FNR lever.

1/1

2 Start Circuit Check Move FNR lever to neutral (N) position and turn key OK: Go to next check .
switch to START position.
NOT OK: If engine turns
Observe and listen to monitor as engine is cranking. but does not start, check
fuel shut-off/start
LISTEN: Starting motor must operate. aid/reverse alarm fuse

LISTEN: Alarm must sound. NOT OK: If starting motor


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

1/1

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Operational Checkout Procedure

3 Reverse Warning Operate engine at slow idle. OK: Go to next check .


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

NOT OK: Check wiring


connector at alarm. Go to
Group 9015-15, Reverse
Alarm Circuit .
1/1

4 Reverse Warning Key switch ON. OK: Go to next check .


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

T7447AH UN04JAN91

1/1

Park Brake, Charge Indicator Light, Tachometer/Hourmeter Circuit And Engine Speed Control Linkage
Checks

1/1

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Operational Checkout Procedure

1 Park Brake Indicator OK: Go to next check .


Check
NOT OK: If engine low oil
pressure indicator light
stays ON, STOP ENGINE
IMMEDIATELY and check
9005
oil level. Go to Group
10
9010-15, Engine Low Oil
4
Pressure .
T7447AG UN04JAN91 T7394BH UN10DEC90

IMPORTANT: If engine oil pressure indicator light stays ON, STOP ENGINE NOT OK: If alternator
IMMEDIATELY, check oil level. indicator light is on,
increase engine speed to
Engage park brake. 1200 rpm and alternator
light MUST go out. Go to
Put FNR lever in neutral (N) and start the engine. Group 9015-15, Charge
Circuit Checks .
Put FNR lever in forward (F) position.
NOT OK: If no park brake
light, inspect wiring
LOOK: STOP indicator must stay ON and flashing. Alarm must "beep". Park brake light
must be ON. All other lights must go out. connector at switch on
park brake linkage. See
Park Brake/Clutch
Disconnect Circuit
Diagnostic in Group
9015-15, .

1/1

2 Tachometer/Hourmeter IMPORTANT: If engine low oil pressure indicator OK: Go to next check .
Circuit Check light stays ON, STOP ENGINE IMMEDIATELY and
check oil level. NOT OK: If park brake
indicator light stays ON,
Engage park brake. adjust park brake switch
on park brake linkage
Put FNR lever in neutral and start the engine. until light goes out. See
Park Brake/Clutch
T7447AH UN04JAN91
Put FNR lever in forward (F) position. Disconnect Circuit
Diagnostic in Group
LOOK: STOP indicator must stay ON and flashing. 9015-15.
Alarm must "beep". Park brake light must be ON. All
other lights must go out. NOT OK: If no hour
meter or tachometer
LOOK: Hourmeter indicator must be rotating. movement, go to Group
9015-15, Gauge and
LOOK: Tachometer (if equipped) must indicate rpm. Hour Meter Circuit .

Release park brake.

Park brake indicator light and STOP light must go out.


Alarm must stop "beeping".

1/1

TM1512 (07NOV03) 9005-10-4 Backhoe Loaders Operation and Test


110703

PN=68
Operational Checkout Procedure

3 Engine Speed Control Engage park brake. OK: Go to next check .


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

LOOK: Speed control lever must remain at selected


position.

1/1

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

T7394BF UN06JAN92

1/1

5 Start Aid Check (If Operate engine at slow idle. OK: Go to next check .
Equipped)
Push start aid button once. NOT OK: Check can
contents by shaking.
LISTEN: Engine speed must increase then return to slow idle.
NOT OK: Check fuse. Go
to Group 9015Start Aid
Check .

1/1

Brake System Checks

1/1

TM1512 (07NOV03) 9005-10-5 Backhoe Loaders Operation and Test


110703

PN=69
Operational Checkout Procedure

1 Pedal Stop Check Lift left and right brake pedals. OK: Go to next check .

LOOK: Brake pedals must be against pedal stop screws. NOT OK: Adjust brake
pedal stops . Go to
NOTE: This ensures that brake check valves are opened Group 9020-20.
and brakes released.
9005
10
6
T7394BG UN17JAN92

1/1

2 Brake System Depress and hold left brake pedal, then right brake pedal OK: Go to next check .
Leakage Check using approximately 267 N (60 lb force).
NOT OK: Bleed brake
LOOK: Brake pedal must NOT feel spongy (caused by system . Go to Group
air in system) or settle more than 25 mm (1.0 in.) per 9020-20.
minute.
NOT OK: Check light
LOOK: Rear brake light must come ON when either fuse.
pedal is depressed with key switch in ON position.
T7367AM UN17JAN92
OK: Check wiring. Go to
Group 9015-15, Lighting
Circuit Checks .

1/1

3 Park Brake Capacity Engage park brake. OK: Go to next check .


Check
Put stabilizers in up position. NOT OK: Adjust park
brake linkage . Go to
Put backhoe in transport position. Group 9020-20.

Use loader functions to pull machine forward or push machine backward.

LOOK: Rear wheels should not turn. If loader can pull or push machine, rear tires
should drag.

LOOK: Park brake switch light will be ON.

1/1

4 Brake Drag Check Position machine on a gradual grade with front of OK: Go to next check .
machine downhill.
NOT OK: Brakes
Lift bucket so it clears ground. dragging. Go to Group
9020-10, Brake Drag
Shift FNR lever to neutral, differential lock pedal up, Check .
disengage park brake and release service brakes.

T6171AL UN09DEC88
LOOK: Machine must move or coast.

NOTE: If machine does not move freely on slope, drive


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

1/1

TM1512 (07NOV03) 9005-10-6 Backhoe Loaders Operation and Test


110703

PN=70
Operational Checkout Procedure

Steering System Checks

1/1 9005
10
7
1 Steering System Operate engine at approximately 1000 rpm. OK: Go to next check .
Checks
Turn steering wheel from full left to full right several times. NOT OK: Go to Group
9025-15, Poor Centering
LOOK: Front wheels must move smoothly in both directions. of Steering Wheel .

LOOK: When steering wheel is stopped, the front wheels must stop moving.

NOTE: Internal leakage or a sticking steering valve spool can cause wheels to
continue to move after steering wheel is stopped.

1/1

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

1/1

3 Steering Priority Operate engine at slow idle. OK: Go to next check .


Valve Check
Turn steering wheel to stop left and right. Note effort required to turn wheel. NOT OK: Steers hard
and no decrease in
Turn wheel to stop and apply constant pressure. engine rpm. Go to Group
9025-25, Steering Priority
LOOK/FEEL: Wheels must stop at both axle stops and require normal steering wheel Valve Test .
effort.

LOOK/LISTEN: Tachometer (if equipped) must decrease 2550 rpm or hear decrease
in engine rpm when steering wheel is held against stop.

1/1

Reverser Clutch Disconnect Solenoid Check

1/1

TM1512 (07NOV03) 9005-10-7 Backhoe Loaders Operation and Test


110703

PN=71
Operational Checkout Procedure

1 Clutch Disconnect OK: Go to next check .


Circuit Check CAUTION: Machine should try to move forward as FNR lever is moved.
NOT OK: Check fuse.
Start engine, set idle speed at approximately 1500 rpm.
OK: Go to Group
Put transaxle in fourth gear. 9015-15, Park
9005
Brake/Clutch Disconnect
10 Release park brake. Circuit Diagnostic .
8
Shift FNR lever to forward (F) position.

Actuate clutch disconnect on gear shift lever or loader control lever individually and
note sound of engine.

LISTEN: When FNR lever is shifted to forward (F) position, a noticeable drop in engine
speed should be heard.

LISTEN: Engine rpm must increase when the reverser clutch disconnect solenoid
switches are activated.

1/1

Driving Checks

1/1

1 Transaxle Shift IMPORTANT: Use clutch disconnect when shifting OK: Go to next check .
Linkage Synchronizer gears.
And Noise Check NOT OK: Go to Group
Run engine at approximately 1500 rpm with FNR lever in 9020-15, Excessive Gear
forward (F) position. Noise When Shifting
Gears .
Shift transaxle into each gear and drive for a short
distance.
T7447AG UN04JAN91
LISTEN: Excessive gear or FNR lever noise must NOT
be heard in any gear. All gears are synchronized.

1/1

2 Differential Lock And Shift transaxle to first gear. OK: Go to next check .
Linkage Check
Move FNR lever to forward (F) position and operate NOT OK: Go to Group
engine at approximately 1500 rpm. 9020-15, No Differential
Lock Operation .
Depress differential lock pedal.

Turn steering wheel slightly right or left.


T7447AG UN04JAN91
Release differential lock pedal.

LOOK: Machine must try to go straight forward and


pedal must return to UP position when traction is equal.

1/1

TM1512 (07NOV03) 9005-10-8 Backhoe Loaders Operation and Test


110703

PN=72
Operational Checkout Procedure

3 Differential Gear And NOTE: Hold the wheel which is being braked stationary during this test or brake OK: Go to next check .
Pinion Check chatter could be confused with differential gear noise.
NOT OK: Go to Group
Shift transaxle to first gear and operate engine at approximately 1500 rpm. 9020-10, Differential and
Pinion Gear Check .
Move FNR lever to forward (F) position.
9005
10
Steer machine in a maximum left turn and depress left brake pedal to stop the left
9
wheel.

Steer machine in a maximum right turn and depress right brake pedal to stop the right
wheel.

LISTEN: NO excessive gear noise must be heard in the differential or pinion gear area.
1/1

4 Front Wheel Drive machine in fourth gear forward on a surface with OK: Go to next check .
Alignment (Toe-In) loose material.
Check NOT OK: If material is
LOOK: Material behind front wheels must not be thrown thrown, excessive tire
excessively inward or outward. wear will result. Go to
Group 9020-20, Adjust
Toe-In .

T6264AI UN22OCT91

1/1

5 Engine And Torque Position machine with loader bucket at ground level OK: Go to next check .
Converter Check against dirt bank or immovable object.
NOT OK: If the wheels
Shift transaxle into first gear. can be easily stalled, go
to Group 9020-15, Power
Move FNR lever to forward (F) position. TrainMachine Lacks
Power or Moves Slow .
Engage differential lock.
T6171AM UN09DEC88
Increase engine speed to fast idle.

LOOK: Rear wheels must NOT stall.

NOTE: This test will give a general indication of engine


reverser and torque converter performance.

1/1

TM1512 (07NOV03) 9005-10-9 Backhoe Loaders Operation and Test


110703

PN=73
Operational Checkout Procedure

6 Reverser Hydraulic Run engine at approximately 1500 rpm. OK: Go to next check .
System Check
Shift transaxle into third gear. NOT OK: If shifts are
slow, go to Group
Move FNR lever to forward (F) position. 9020-25, Reverser
Element Leakage Test
9005
Make several shifts from third forward to third reverse. Start counting the number of Using Element Pressure
10
seconds when FNR lever is moved to opposite direction. (Three-Gauge Method) .
10
LOOK: A normal shift from forward to reverse or reverse to forward must be completed
in three seconds. The machine must be up to speed in four seconds.

NOTE: Excessive internal leakage is indicated if reverse warning alarm (if equipped)
does not sound at slow idle, but sounds when rpm is increased.
1/1

Mechanical Front Wheel Drive (MFWD) Driving Check

1/1

1 MFWD Switch Check OK: Go to next check .

NOT OK: Check electrical


circuit. Go Group
9015-15, MFWD circuit

T7860AA9 UN13NOV92

Drive machine at transport speed.

Push switch (A) and engage MFWD.

LOOK: Light in MFWD switch must be ON, and all four wheels must be engaged.

Push switch (A) and disengage MFWD.

LOOK: Light in MFWD switch must be OFF, with MFWD disengaged.

NOTE: Indicator light in MFWD switch will remain ON while MFWD is engaged. If
MFWD is turned OFF while operating, light could remain on for several seconds until
load on drive train is released.
1/1

TM1512 (07NOV03) 9005-10-10 Backhoe Loaders Operation and Test


110703

PN=74
Operational Checkout Procedure

2 MFWD Limited-Slip Lift machine off ground with stabilizers and loader bucket. OK: Check complete.
Differential And
Control Valve Check Apply brakes and engage MFWD. NOT OK: If both wheels
stall, check MFWD valve
Put FNR lever in forward and transaxle in first gear. pressure test . Go to
Group 9025-25.
9005
Run engine at approximately 1200 rpm.
10
NOT OK: If only one
11
Lower front wheels until tire scuffing is observed on both tires. wheel spins, turn wheel to
axle stop and see if
LOOK: Both wheels must turn and MFWD indicator light must be ON. constant velocity U-joint is
turning. If U-joint is
Turn MFWD switch OFF. turning, check wheel
outboard planetary. If
NOTE: If MFWD is turned OFF while operating, indicator light and MFWD could remain U-joint does not turn
on until load on drive train is released. Shifting to opposite direction should release inspect axle and
load on drive train. limited-slip in MFWD
differential.
LOOK: Both wheels must stop when MFWD switch is OFF.

LOOK: MFWD indicator light must be OFF.

NOTE: If tire scuffing is seen with MFWD engaged, limited-slip differential is working
and power is being transmitted to MFWD.

1/1

3 Engine And Torque With loader bucket level and cutting edge at the OK: Go to next check .
Converter Check centerline of front wheels, put machine against a dirt
bank or immovable object. NOT OK: If all wheels
stop, a torque converter
Engage MFWD and differential lock. problem is indicated. If
the front wheels stop,
Shift transaxle to first forward. MFWD problem is
indicated. Go to Group
T6171AN UN09DEC88
Increase engine speed to fast idle 9020-15, Machine Lacks
Power or Moves Slow .
LOOK: All four wheels must turn.

1/1

TM1512 (07NOV03) 9005-10-11 Backhoe Loaders Operation and Test


110703

PN=75
Operational Checkout Procedure

4 MFWD Gear And Drive machine at transport speed with MFWD engaged, then disengaged. OK: Go to next check .
Pinion Check
LISTEN: MFWD must NOT whine. NOT OK: If MFWD
whines, check oil levels
and fill to correct levels.
9005
OK: Check backlash. See
10
procedure under
12
Assemble Differential in
repair manual.

See Assemble
DifferentialAPL-745Axle

Assemble Differential
HousingAPL-2035Axle

Assemble Differential
410D-(SN
796854)510D-(SN
796890)

Assemble Differential
410D-(SN 796855)
510D-(SN 796891 )

1/1

Hydraulic System Checks

1/1

TM1512 (07NOV03) 9005-10-12 Backhoe Loaders Operation and Test


110703

PN=76
Operational Checkout Procedure

1 Hydraulic Pump OK: Go to next check .


Performance Check
NOT OK: Replace
hydraulic filter and check
for types of
contamination. Rerun this
9005
check .
10
13
NOT OK: Cycle times still
T6295AH UN19OCT88
slow. Go to Group
NOTE: If hydraulic oil is not at operating temperature, heat hydraulic oil until loader 9025-25-Backhoe Relief
and backhoe feel warm to touch using following procedure: Valve Test .

Put backhoe in transport position and engage boom and swing lock.

Activate boom down function and run engine at 2000 rpm.

NOTE: If activating boom down does not load engine, boom down relief valve is set
too high or hydraulic pump stand-by pressure is too low.

Operate all functions periodically to distribute heated oil to all cylinders.

Put backhoe at maximum reach with bucket fully dumped at ground level.

Run engine at 2000 rpm.

Measure cycle time by simulating loading the bucket, retracting the dipperstick and
raising the boom to the boom cylinder cushion. Do not time boom cylinder through
cushion.

LOOK: The maximum cycle time is as follows:

410D - 9 seconds
510D - 12 seconds

NOTE: Take the average cycle time for at least 3 complete cycles. This average cycle
time will give a general indication of hydraulic pump performance.

1/1

TM1512 (07NOV03) 9005-10-13 Backhoe Loaders Operation and Test


110703

PN=77
Operational Checkout Procedure

2 Hydraulic System OK: Go to next check .


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

IF OK: Test charge


9005
system. Go to Group
10
9025-25 Charge Pump
14
Pressure Test .
T6295AJ UN17APR89

Raise unit with stabilizers until tires are 150 mm ( 6 in.) off ground.

Fully extend dipperstick, put bucket in loaded position and lower boom until dipperstick
is horizontal to ground.

Slowly retract dipperstick to insure that bucket clears ground.

Fully extend dipperstick.

Run engine at 1100 rpm.

Retract dipperstick while holding control valve fully open.

LOOK: Dipperstick can slow down, but must NOT stop moving during test.

1/1

3 Hydraulic Control Raise loader until bucket is 1 m (3 ft.) off the ground with the bucket level. OK: Go to next check .
Valve Lift Check Test
Position backhoe at maximum reach with bottom of bucket level with ground, 1 m (3 NOT OK: If a function
ft.) off the ground. cylinder moves, problem
could be a leak in
Stop the engine. cylinder of lift check. Go
to next check .
Activate each function one at a time:
IF OK: Inspect and repair
Loader boom raise lift check. See Remove
Loader bucket rollback And Install Gresen
Backhoe boom up Backhoe Valve Lift Check
Dipperstick extend Valves(SN 796033) .
Backhoe bucket dump

LOOK: These functions must NOT move when the control lever is activated.

1/1

TM1512 (07NOV03) 9005-10-14 Backhoe Loaders Operation and Test


110703

PN=78
Operational Checkout Procedure

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

NOT OK: Go to next step


in this check.

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


dipperstick to maximum reach, extend extendible
dipperstick (if equipped) and put bucket in dump position NOT OK: If rpm
1 m (3 ft) off ground. decreases with a function
bottomed and control
Fully activate functions, one at a time: Extend dipperstick lever fully open, a leak is
Extend extendible dipperstick (if equipped) Bucket dump indicated in the circuit.

T6295AF UN17APR89
Fully activate functions, one at a time: Stabilizer down NOT OK: If rpm
left Stabilizer down right increases when a function
is bottomed and control
LISTEN: When these functions are activated, NO valve is fully open, a
decrease in engine rpm must be noted. neutral leak indicated.

NOT OK: An rpm


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

1/1

TM1512 (07NOV03) 9005-10-15 Backhoe Loaders Operation and Test


110703

PN=79
Operational Checkout Procedure

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

On machines equipped with HUSCO valve a very small


decrease in engine RPM may be observed when a
function is bottomed or metered. The valve spool center
sections are undercut to allow for some return leakage.
This minimizes power drift at the cylinders.
1/1

6 Cylinder Cushion Run engine at slow idle. OK: Go to next check .


Checks
Lower stabilizers to ground. NOT OK: Remove and
repair cylinder cushion.
Lower backhoe boom 45 outward.

Activate the following functions:

Backhoe swing left and right


Backhoe boom raise
Dipperstick retract

Note sound and speed as cylinders near the end of their stroke.

LOOK: Speed of cylinder rod must decrease near the end of its stroke.

LISTEN: Must hear oil flowing through orifice as cylinder rod near the end of its stroke.

1/1

TM1512 (07NOV03) 9005-10-16 Backhoe Loaders Operation and Test


110703

PN=80
Operational Checkout Procedure

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

LOOK: If bucket cutting edges touch the ground within 1


minute, leakage is indicated in the bucket or boom
cylinders or control valves.

1/1

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

LOOK: Loader control lever must disengage from the OK: Go to next step in
bucket rollback detent when the bucket is level. this check.

NOT OK: With bucket


rolled back, compress
switch roller. If a click is
heard, adjust switch till it
is activated on cam. Go
T6171AT UN09DEC88
to Group 9025-15.

LOOK: When the bucket is at ground level, bucket must OK: Go to next check .
be level and the bucket indicator pointer must be aligned
with mark on the boom pivot. NOT OK: Adjust linkage
as necessary. Go to
NOTE: When return-to-dig is used with loader boom in Group 9025-20 Loader
full up position, the bucket leveling linkage will move the Bucket Level Indicator
bucket control valve out of return-to-dig position before And Return-To-Dig
bucket is actually level. Adjustment .
T7374CH UN04OCT90

1/1

TM1512 (07NOV03) 9005-10-17 Backhoe Loaders Operation and Test


110703

PN=81
Operational Checkout Procedure

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

Observe bucket and loader control lever as the loader


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

LOOK: The bucket side cutting edge must be level


during entire loader raise cycle.

1/1

Check Operation Of Accessories (Engine Stopped)

1/1

1 Front Light Switch Turn key switch to ON position. OK: Go to next check .

Push front light rocker switch to middle position. NOT OK: Check fuse and
bulbs.
LOOK: Two front lights, two red tail lights and gauge lights must come on.
OK: Check switch . Go to
Push front light rocker switch in completely. Group 9015-15, Drive and
Work Light Circuit.
LOOK: All four front lights, two red tail lights and gauge lights must come on.

1/1

2 Rear Light Switch Turn key switch to ON position. OK: Go to next check .

Push side console rear light rocker switch in. NOT OK: Check fuse and
bulbs.
LOOK: Rear light (s) must come on.
OK: Check switch . Go to
Group 9015-15, Drive and
Work Light Circuit.

1/1

TM1512 (07NOV03) 9005-10-18 Backhoe Loaders Operation and Test


110703

PN=82
Operational Checkout Procedure

3 Turn Signal Switch Turn key switch to ON position. OK: Go to next check .

Push right side of turn signal rocker switch down. NOT OK: Check fuses
and bulbs
LOOK: Right front and rear amber lights must flash. Right indicator light on top of
steering column must flash. OK: Check turn signal
9005
switch . Go to Group
10
Push left side of turn signal rocker switch down. 9015-15, Turn Signal,
19
Flasher and Brake Light
LOOK: Left front and rear amber lights must flash. Left indicator light on top of steering Circuit.
column must flash.

1/1

4 4-Way Flasher Key switch may be ON or OFF. OK: Go to next check .

Push bottom of warning light rocker switch in. NOT OK: Check fuses
and bulbs.
LOOK: Both front and rear amber lights must come ON. Both turn signal indicators and
light in warning light rocker switch must flash. OK: Check 4-Way
Flasher Switch . Go to
Group 9015-15, Brake
Light Circuit.

1/1

5 Horn Turn key switch to ON position. OK: Go to next check .

Push horn button NOT OK: Check fuse.

LISTEN: Horn must sound. OK: Check horn switch .


Go to Group 9015-15,
Horn Circuit.

1/1

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

NOT OK: Check fuel


shut-off/start aid/reverse
alarm fuse.

IF OK: Go to Group
9015-15, Start Aid Circuit
.

1/1

TM1512 (07NOV03) 9005-10-19 Backhoe Loaders Operation and Test


110703

PN=83
Operational Checkout Procedure

Cab Component Checks

9005 1/1
10
20
1 Seat Linkage Check Move lever (A) to the right. OK: Go to next check .

Move seat forward and rearward and release lever. NOT OK: Repair linkage.
See Disassemble And
LOOK: Lever must move freely and lock seat in desired Assemble Seat Base
position. Non-Suspended repair
manual , Disassemble
And Assemble
T7394BD UN29NOV90
Suspended Seat Adjuster
, or Disassemble And
Assemble Seat
Suspension .

1/1

2 Height Adjustable Pull lever (C) up and at the same time remove your OK: Go to next check .
Seat Check (If weight from the seat.
Equipped) NOT OK: Lubricate seat
Raise seat several positions and engage latch. pedestal. See
Disassemble And
LOOK: Seat must raise upward and must remain in Assemble Seat Base
desired latched position. Non-Suspended repair
manual , Disassemble
T7394BD UN29NOV90
And Assemble
Suspended Seat Adjuster
, or Disassemble And
Assemble Seat
Suspension .

1/1

3 Seat Swivel Linkage Pull lever (B) up. OK: Go to next check .
Check
Move seat from loader to backhoe position and engage NOT OK: Lubricate or
latch. repair linkage. See
Disassemble And
LOOK: Seat latch must move freely and hold seat at the Assemble Seat Base
desired position. Non-Suspended repair
manual , Disassemble
T7394BD UN29NOV90
FEEL: Lever must move freely and hold seat in loader And Assemble
and backhoe positions. Suspended Seat Adjuster
, or Disassemble And
Assemble Seat
Suspension .

1/1

TM1512 (07NOV03) 9005-10-20 Backhoe Loaders Operation and Test


110703

PN=84
Operational Checkout Procedure

4 Left Cab Door Latch Unlatch door. OK: Go to next check .


And Opener Check
Observe door as it opens. NOT OK: Adjust cab
door. See Adjust Cab Left
Pull door closed and latch it. Door Latch And Hinges
and Adjust Cab Door
9005
FEEL: Cab door latch must work freely. Handle Screw in repair
10
manual.
21
LOOK: Door cylinder must push door open.

LOOK: Cab door must contact door stop bumper before door cylinder bottoms.

1/1

5 Right Door Latch And Unlatch door and pull door open. OK: Go to next check .
Opener Check
Close and latch door. NOT OK: Adjust door.
See Adjust Cab Right
FEEL: Cab door latch must work freely. Door Latch And Hinges
and Adjust Cab Door
Handle Screw .

1/1

6 Rear Window Latch Squeeze latches on both sides of middle rear window. Lower window to rubber OK: Go to next check .
And Opener Checks bumpers.
NOT OK: Check for
Push latch releases on upper rear window. obstructions. See Adjust
Upper Rear Window and
Observe window as it opens. Adjust Lower Rear
Window in repair manual.
Push window up and into window catches and note fit.

Observe cylinders while closing window. Raise middle window and push into latches.

LOOK: Window latches and hinges must move freely.

LOOK: The gas-filled cylinders must slowly assist raising the window to open position.
Cylinders must not be at end of travel when closing window.

LOOK: The window catches must hold and not bow the window in the up position.

1/1

TM1512 (07NOV03) 9005-10-21 Backhoe Loaders Operation and Test


110703

PN=85
Operational Checkout Procedure

7 Side Window Checks Open left and right rear side window. OK: Go to next check .

Fasten rear window against front window. NOT OK: Adjust


windows. See Adjust Cab
LOOK: Sleeve on rear window must align with knob on Side Windows in repair
front window. manual.
9005
10
LOOK/FEEL: Hinges must move freely. Locking latches
22
T6171DF UN09DEC88
must be equally loaded when closed.

1/1

8 Blower OK: Go to next check .

NOT OK: Check heater


circuit breaker.

OK: Check blower switch


. Go to Group 9015-15,
Blower Circuit.
T7828AW 1930SEP92

Turn key switch ON.

Turn blower switch (A) to low, medium and high speeds.

FEEL/LISTEN: Blower must have three speeds and OFF.

1/1

9 Heater OK: Go to next check .

NOT OK: Check heater


components . Go to
Group 9015-15, Blower
Circuit.

T7835AW 1930SEP92

Start engine and allow to warm several minutes.

Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high
speed.

FEEL: Air from ducts must be warm.

1/1

TM1512 (07NOV03) 9005-10-22 Backhoe Loaders Operation and Test


110703

PN=86
Operational Checkout Procedure

10 Air Conditioner (If OK: Go to next check .


Equipped)
NOT OK: Go to Heating
and Air Conditioning ,
Group 9031-10.
9005
10
23
T7835AX 1930SEP92

Start engine and run at fast idle.

Turn air conditioner switch (A) to ON position.

Turn blower switch (B) to high speed.

Wait for any warm air in duct system to dissipate.

FEEL: Air from ducts must be cool.

1/1

11 Rear Windshield Turn key to ON position. OK: Go to next check .


Wiper Check
Push rear wiper rocker switch to first detent, middle position. NOT OK: Check fuse.

Push rear wiper rocker switch all the way in. OK: Check rear wiper .
Go to Group 9015-15,
LOOK: Rear wiper must operate and have two speeds. Wiper/Washer Circuit.

LOOK: Wipers must return to park position.

1/1

12 Front Windshield Turn key switch to ON position. OK: Go to next check .


Wiper Check
Push front wiper rocker switch to first detent, middle position. NOT OK: Check fuse.

Push front wiper switch all the way in. OK: Check front wiper .
Go to Group 9015-15,
LOOK: Both front wipers must operate and have two speeds. Wiper/Washer Circuit.

LOOK: Wipers must return to park position.

1/1

TM1512 (07NOV03) 9005-10-23 Backhoe Loaders Operation and Test


110703

PN=87
Operational Checkout Procedure

13 Front Windshield Turn key switch to ON position. OK: Go to next check .


Washer Check
Push windshield washer rocker switch in. NOT OK: Check fluid
level, and fluid lines for
LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF blockage.
position.
9005
NOT OK: Check wiring .
10
Go to Group 9015-15,
24
Wiper/Washer Circuit.

1/1

14 Cab Dome Light And Turn key switch to ON position. OK: Go to next check .
Swivel Light Check
Push dome light switch to ON position. NOT OK: Check fuse and
bulbs.
Push swivel light switch to ON position.
NOT OK: Check wiring .
LOOK: Lights must come ON. Go to Group 9015-15,
Dome Light Circuit.

1/1

Miscellaneous Checks

1/1

1 Vandal Protection Lock engine access door, reservoir door and cab doors using ignition key. OK: Go to next check .
Check
FEEL: All locks must operate freely and key must not stick in locks. NOT OK: Lubricate or
repair lock.

1/1

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

T6171DG UN09DEC88

1/1

TM1512 (07NOV03) 9005-10-24 Backhoe Loaders Operation and Test


110703

PN=88
Operational Checkout Procedure

3 Backhoe Transport OK: Operational


Pin Check Checkout completed.

NOT OK: Adjust boom


lock. See Adjust Standard
Lift Boom Lock Linkage
9005
or Adjust Heavy Lift
10
Boom Lock Linkage in
25
repair manual.

NOT OK: Repair or


replace swing lock pin.

NOT OK: Check pin bore


for burrs or obstruction.

T8181AD UN20FEB94

Raise boom into transport position and lower boom lock pin (A).

Remove swing lock pin (B) from holder in cab and install through top and bottom holes
of swing frame and through main frame.

LOOK: Boom lock pin (A) must stay in boom lock mechanism and support weight of
boom.

LOOK: Swing lock pin (B) must install freely.

1/1

TM1512 (07NOV03) 9005-10-25 Backhoe Loaders Operation and Test


110703

PN=89
Operational Checkout Procedure

9005
10
26

TM1512 (07NOV03) 9005-10-26 Backhoe Loaders Operation and Test


110703

PN=90
Section 9010
Engine
Contents

Page

Group 05Theory Of Operation


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

Group 10System Operational Checks


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

Group 15System Diagnostic Information


4045 John Deere EngineUse CTM8 . . . . .9010-15-1
Make Visual Inspection Of Engine And
Supporting Systems. . . . . . . . . . . . . . . . . .9010-15-2
Diagnose Engine Malfunctions . . . . . . . . . . .9010-15-4

Group 20Adjustments
4045 John Deere EngineUse CTM8 . . . . .9010-20-1
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
Fan Belt Tension Adjustment . . . . . . . . . . . .9010-20-2
Adjust Speed Control Lever Tension . . . . . . .9010-20-3
Engine Speed Control Linkage . . . . . . . . . . .9010-20-4
Slow And Fast Idle . . . . . . . . . . . . . . . . . . . .9010-20-6

Group 25Tests
4045 John Deere EngineUse CTM8 . . . . .9010-25-1
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-1
JT05800 Digital Thermometer Installation . . .9010-25-1
JT07158 TIME TRAC Installation. . . . . . . . .9010-25-2
Cooling System . . . . . . . . . . . . . . . . . . . . . . .9010-25-3
Air Filter Restriction Indicator Switch . . . . . . .9010-25-4
Air Intake System Leakage Test . . . . . . . . . .9010-25-5
Radiator Air Flow Test. . . . . . . . . . . . . . . . . .9010-25-6
JT05529 Air Flow Meter Test Record . . . . . .9010-25-8
Turbocharger Boost PressureEngine
Performance Test . . . . . . . . . . . . . . . . . . .9010-25-9
Injection Pump Timing. . . . . . . . . . . . . . . . .9010-25-11
Injection Pump Static Timing Adjustment. . .9010-25-12

TM1512 (07NOV03) 9010-1 Backhoe Loaders Operation and Test


110703

PN=1
Contents

9010

TM1512 (07NOV03) 9010-2 Backhoe Loaders Operation and Test


110703

PN=2
Group 05
Theory Of Operation
4045 John Deere EngineUse CTM8

For additional engine information, the component technical


manual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

UN07SEP88
M44215
9010
05
TX,9010,SS495 1923AUG931/1 1

TM1512 (07NOV03) 9010-05-1 Backhoe Loaders Operation and Test


110703

PN=93
Theory Of Operation

General Engine Description

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

1
Main (thrust) bearing web undercut in block and or bearing cap
MUST be 113.8 mm (4.48 in.) in order to accept five piece thrust
bearings.
Continued on next page CTM8,GR01,11 1918FEB951/2

TM1512 (07NOV03) 9010-05-2 Backhoe Loaders Operation and Test


110703

PN=94
Theory Of Operation

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

9010
05
CTM8,GR01,11 1918FEB952/2 3

TM1512 (07NOV03) 9010-05-3 Backhoe Loaders Operation and Test


110703

PN=95
Theory Of Operation

EngineSectional View

9010
05
4

UN11JUL95
RG7248
ARocker Arm Shaft FCylinder Block KConnecting Rod PPiston Rings
BCylinder Head GCrankshaft LLiner Packing Rings QValve
CPush Rod HCrankshaft Counterweight MCylinder Liner RFuel Injection Nozzle
DCam Follower IOil Pan NPiston SValve Spring
ECamshaft JBalancer Shafts OPiston Pin TRocker Arm

S11,2000,EH 1911JUL951/1

TM1512 (07NOV03) 9010-05-4 Backhoe Loaders Operation and Test


110703

PN=96
Group 10
System Operational Checks
4045 John Deere EngineUse CTM8

For additional engine information, the component technical


manual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

UN07SEP88
M44215
9010
10
TX,9010,SS495 1923AUG931/1 1

System Operational Checks

This procedure is designed so the mechanic can make problem is indicated (NOT OK:), you will be given
a quick check of the engine using a minimum amount repair required and Group location or CTM number. If
of diagnostic equipment. If you need additional verification is needed, you will be given next best
information, read Theory of Operation, Group 9010-05. source of information after GO TO:

A location will be required which is level and has Group 10 (System Operational Checks)
adequate space to complete the driving checks.
Group 15 (Diagnostic Information)
The engine and all other major components must be at
operating temperature for some checks. Group 20 (Adjustments)

Locate system check needed in the left column and Group 25 (Tests)
read completely, follow this sequence from left to right.
Read each check completely before performing. CTM (Component Technical Manual)

At the end of each check, if no problem is found (OK:),


you will be instructed to GO TO NEXT CHECK. If

TX,901010,QQ812 1919DEC901/1

Cooling System Checks

1/1

TM1512 (07NOV03) 9010-10-1 Backhoe Loaders Operation and Test


110703

PN=97
System Operational Checks

1 Radiator Cap, Coolant OK: Check completed.


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

9010 Inspect coolant level, coolant condition. NOT OK: If rust in


10 coolant, drain, flush and
2 LOOK: The radiator cap must have a good seal and gasket. The seal must move replace coolant. Go to
freely and the spring must not be corroded. Operators Manual.

LOOK: The vacuum release valve (center of cap rubber seal) must move freely and
holes must not be plugged.

LOOK: The coolant must not be oily, foamy, or rusty.

1/1

2 Hose And Water Inspect all radiator and heater hoses and water pump for cracks or leaks. OK: Check completed.
Pump Check
LOOK: Radiator hoses must not be brittle or show signs of leaks. NOT OK: Replace
defective hoses, tighten
Check all hose clamps. clamps as necessary.

LOOK: All hose clamps must be tight. NOT OK: Repair water
pump. See General
Squeeze lower radiator hose. Water Pump Information
and Remove Water Pump
FEEL: Lower hose must have wire insert. in CTM8.

LOOK: Water pump must not show any signs of leaks.

1/1

3 Radiator Bubble a. Radiator to proper level. OK: Check complete.


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

1/1

TM1512 (07NOV03) 9010-10-2 Backhoe Loaders Operation and Test


110703

PN=98
System Operational Checks

4 Fan And Fan Shroud OK: Check complete.


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

NOT OK: If fan blades


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

NOT OK: If fan is on


backwards, remove and
T6171CA UN25MAY89 T6171CB UN25MAY89 install. See Remove And
Install Fan in repair
Inspect fan and shroud clearance. manual.

Inspect fan blades for damages.

Check fan belts for tightness.

LOOK/FEEL: Fan belt deflection should be about 7/16 in. with 25 lbs of push.

LOOK: Fan blades must not have any nicks or bends.

LOOK: Make sure there is no oil or grease on fan belt or pulleys.

LOOK: Inside surface of fan belt must not have any cracks or contact bottom of pulley
groove.

NOTE: If the fan blade has been installed backwards about 50% of its capacity is lost.

LOOK: Cupped portion of fan blades must be away from radiator.


1/1

Air System Checks

1/1

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

Lubrication System Checks

1/1

TM1512 (07NOV03) 9010-10-3 Backhoe Loaders Operation and Test


110703

PN=99
System Operational Checks

1 Oil Level Check a. Pull out oil level dipstick and check level. OK: Check complete.

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

NOT OK: If oil level is


low, check for oil leaks.

1/1

Fuel System Checks

1/1

1 Engine Fuel System Engine off, engine speed control lever at fast idle position. OK: Check complete.
Inspection Checks
Inspect water drain, cap, strainer and inside fuel tank (flashlight.). NOT OK: If excessive
amount of water is found
Operate pump primer by hand. in fuel tank, change fuel
filter.
Inspect all fuel lines, line clamps, and speed control linkage stop.
NOT OK: If air "hisses"
LOOK: Water drain must NOT contain an excessive amount of water. from tank or enters tank
when cap is removed,
Inside of fuel tank must NOT contain any foreign matter. replace fuel cap.

LOOK: No fuel leakage must be noted at any of the fuel line connections. The injection NOT OK: If excessive
line rubber clamps must be in position and NO wiring banded to the injection lines. debris is found in the
bottom of the fuel tank,
remove fuel line and
observe flow. If flow is
restricted, clean tank.

1/1

TM1512 (07NOV03) 9010-10-4 Backhoe Loaders Operation and Test


110703

PN=100
System Operational Checks

2 Fuel Pump Check "Crack" open bleed screw on fuel filter and operate hand OK: Check complete.
primer on fuel pump.
NOT OK: Be certain fuel
Tighten bleed screw of fuel filter and again operate hand filter is clean. If not,
primer on fuel pump. replace filter and recheck
fuel pump.
LOOK: Fuel must come out of bleed screw when hand
primer is operated.
T6488GR UN19OCT88
FEEL: Resistance must be felt when fuel is being
pumped and no resistance will be felt after system is
pumped up.
9010
10
1/1 5

3 Fuel System Check Engine OFF. OK: Check completed.

Disconnect fuel return hose from leak-off line. NOT OK: Check for
plugged fuel filters,
Connect a hose to leak-off line to route excess fuel into a container. plugged fuel tank cap
vent, restricted lines,
Start engine and run at fast idle. stuck injection pump
overflow valve, or a bad
Put engine under load by operating a hydraulic function over relief. fuel pump. Repair or
replace as necessary.
Observe fuel flow from leak-off line.

LOOK: Fuel must flow from leak-off line with engine at full load.

NOTE: Fuel that flows from leak-off line is excess fuel not required by the engine.

1/1

Engine Speed And Performance Checks

1/1

TM1512 (07NOV03) 9010-10-5 Backhoe Loaders Operation and Test


110703

PN=101
System Operational Checks

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

NOTE: Override adjustment 6 mm (.250 in.) NOT OK: If idle speeds


are out of specifications,
adjust. Go to Group
9010 9010-20, Adjustments
10 See Slow And Fast Idle .
6

T6008AE1 UN09DEC88

1/1

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

1/1

TM1512 (07NOV03) 9010-10-6 Backhoe Loaders Operation and Test


110703

PN=102
System Operational Checks

3 Low Compression OK: Check Complete.


Check
NOT OK: If starting motor
runs at an uneven speed,
low compression is
indicated on one or two
cylinders. Perform Test
Engine Compression
Pressure in CTM8.
T7367AD UN17SEP90

Remove fuel shut off fuse.

Crank engine for 10 seconds. 9010


10
LISTEN: Air must not be heard leaking past valves. 7

LISTEN: Starting motor must run at a constant speed.

1/1

4 Engine Blow-By Run engine at fast idle and check the blow-by tube. OK: Check complete.
Check
LOOK: Fumes should be barely visible at the blow-by tube at fast idle no load. NOT OK: If blow-by is
excessive, perform Test
NOTE: Excessive blow-by indicates that piston rings and cylinder liners do not seal off Engine Compression
the combustion chamber. This is a comparative check test that requires some Pressure in CTM8.
experience to determine excessive blow-by.

1/1

5 Loose Or Worn a. Run engine at slow idle. OK: Check complete.


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

1/1

TM1512 (07NOV03) 9010-10-7 Backhoe Loaders Operation and Test


110703

PN=103
System Operational Checks

6 Turbocharger Noise NOT OK: If excessive


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

OK: System Operational


Checkout Completed.

NOT OK: Go to next


check .

1/1

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

1/1

TM1512 (07NOV03) 9010-10-8 Backhoe Loaders Operation and Test


110703

PN=104
Group 15
System Diagnostic Information
4045 John Deere EngineUse CTM8

For additional engine information, the component technical


manual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

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

TM1512 (07NOV03) 9010-15-1 Backhoe Loaders Operation and Test


110703

PN=105
System Diagnostic Information

Make Visual Inspection Of Engine And Supporting Systems

1. Inspect for coolant leaks at: The condition of the belts and their tension must be
checked periodically. Adjust belt tension, see Adjust
Radiator Fan Belt Tension , Group 0510.
Water pump
Hoses 8. Inspect fuel tank:
Coolant manifold
Thermostat cover a. Inspect the tank mounting hardware to ensure
they are in position and tight.
9010 Check for proper coolant level in radiator. Look at
15 coolant for evidence of oil and/or debris. b. Inspect fuel tank for cracks and leakage.
2

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

Continued on next page TX,9010,YY509 1902JUN931/2

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110703

PN=106
System Diagnostic Information

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

TX,9010,YY509 1902JUN932/2

TM1512 (07NOV03) 9010-15-3 Backhoe Loaders Operation and Test


110703

PN=107
System Diagnostic Information

Diagnose Engine Malfunctions

NOTE: Diagnostic charts are arranged from most


probable and simplest to verify, to least likely and
more difficult to verify. Remember the following
steps when diagnosing a problem:

Step 1. Operational Checkout Procedure (See


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

Symptom Problem Solution

Engine Will Not Start Or Starts Fuel tank empty Check fuel quantity
Hard

Fuel tank vent plugged Remove cap and listen for sound of
air entering tank. Replace cap.

No electrical power to injection pump Turn key switch to "On". Must hear
solenoid click at injection pump. Replace
fuse. Repair wiring.

Water in fuel or water frozen in fuel Drain water from fuel tank. Inspect
line. fuel filter for water. Change filter.

Debris in fuel or wrong grade of fuel Check fuel tank outlet strainer for
type of fuel debris. Check bottom of
fuel tank for debris.

Air leak on suction side of fuel Check for bubbles in fuel filter and
system tighten connections. Inspect fuel
lines for damage.

Fuel transfer pump diaphragm Check engine oil for fuel dilution.
leaking Replace fuel pump.

Slow cranking speed Check battery and connections.


Incorrect engine oil (Cold weather).

Restricted air filter Check air filter restriction indicator


and air filters. Clean.

Continued on next page TX,901015,QQ815 1924JUN941/12

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PN=108
System Diagnostic Information

Symptom Problem Solution

Stuck injection pump metering valve. Tap injection pump housing (lightly)
if engine now starts. Replace
metering valve. See your authorized
injection pump service center.

Faulty electric shut-off Test shut-off solenoid . See 9015-15.


Inspect solenoid wiring and linkage.

Improper injection pump timing Check timing. See Injection Pump 9010
Timing in Group 9010-25. 15
5

Injection pump Remove and test pump. See


Remove Injection Pump in CTM8.

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


Fuel Injection Nozzles in CTM8.

Worn compression rings or low Check compression. Repair. Perform


compression Test Engine Compression Pressure
in CTM8.

Blown head gasket Remove. Route radiator overflow


into container of fluid and check for
bubbles. Bubbles indicate head
gasket linkage. See Diagnosing
Head Gasket Joint Failures in CTM8.

Engine Surges Or Stalls Air in fuel Inspect filter for evidence of air in
Frequently fuel. Tighten connections and bleed
fuel system.

Fuel tank vent plugged Remove cap and listen for sound of
air entering tank. Replace cap.

Debris in fuel or wrong grade of fuel Check fuel tank outlet strainer for
debris. Check bottom of fuel tank for
debris. Check grade of fuel.

Water in fuel Drain fuel tank and inspect filter


element for water. Replace filters.

Fuel filter plugged Replace filter.

Continued on next page TX,901015,QQ815 1924JUN942/12

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PN=109
System Diagnostic Information

Symptom Problem Solution

Return line from injection pump to Route return line at the pump into a
tank restricted separate container. If engine now
operates normally, check return line
to tank for restriction. Replace.

Fuel injection pump out of time Time injection pump. See Injection
Pump Timing in Group 9010-25.

9010 Check return oil fitting on top of Remove, inspect and clean.
15 injection pump control cover Determine source of debris. See
6
plugged. Remove Injection Pump in CTM8.
See your authorized injection pump
service center.

Injection pump metering valve Remove pump top cover and


sticking inspect. Replace metering valve.
See Remove Injection Pump in
CTM8. See your authorized injection
pump service center.

Engine overheating Test cooling system. See Cooling


System in Group 9010-25.

Fuel transfer pump Test transfer pump pressure. See


Measure Fuel Supply Pump
Pressure in CTM8.

Fuel injection pump Remove fuel injection pump. See


Remove Injection Pump in CTM8.
Test pump. See your authorized
injection pump service center.

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


Test Fuel Injection Nozzles in CTM8.

Improper valve clearance Check and adjust valve clearance.


See Check and Adjust Valve
Clearance in CTM8.

Valve sticking or burned Do compression pressure test.


Perform Test Engine Compression
Pressure in CTM8.

Continued on next page TX,901015,QQ815 1924JUN943/12

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110703

PN=110
System Diagnostic Information

Symptom Problem Solution

Worn or broken compression rings Route radiator overflow hose into a


or cylinder head gasket leaking container of fluid and check. Check
for bubbles. Bubbles indicate head
gasket leakage. See Diagnosing
Head Gasket Joint Failures in CTM8.
Perform Test Engine Compression
Pressure in CTM8.

Engine Misses Air in fuel Check for evidence of air in filter. 9010
Tighten connections and bleed fuel 15
7
system.

Debris in fuel or wrong grade of fuel Check fuel tank for water. Check fuel
tank strainer and fuel filter for debris.
Clean. Check grade of fuel.

Idle speeds out of adjustment (too Test slow idle speeds. See Slow
low) And Fast Idle in Group 9010-20.

Fuel injection pump out of time Time injection pump. See Injection
Pump Timing in Group 9010-25.

Fuel transfer pump Test fuel system pressure. See


Measure Fuel Supply Pump
Pressure in CTM8.

Injection pump governor faulty or Inspect. Repair. See Remove


metering valve sticking Injection Pump in CTM8. See your
authorized injection pump service
center.

Engine overheating Verify engine temperature. Test


thermostat. Replace. See Remove,
Test, and Install Thermostats in
CTM8.

Incorrect valve clearance Check and adjust valve clearance.


See Check and Adjust Valve
Clearance in CTM8.

Bent push rods Inspect. Replace.

Continued on next page TX,901015,QQ815 1924JUN944/12

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PN=111
System Diagnostic Information

Symptom Problem Solution

Cylinder head gasket leaking Route radiator overflow hose into


container of fluid and check for
bubbles. Bubbles indicate head
gasket leakage. See Diagnosing
Head Gasket Joint Failures in CTM8.

Valve sticking or burned Perform Test Engine Compression


Pressure in CTM8.
9010
15 Worn or broken compression rings Perform Test Engine Compression
8
Pressure in CTM8.

Fuel injection pump Remove and test fuel injection


pump. See Remove Injection Pump
in CTM8.

Injection nozzles(s) plugged Remove and test nozzles. See Test


Fuel Injection Nozzles in CTM8.

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

Fuel filter plugged Replace fuel filter.

Wrong grade of fuel Drain and add correct fuel.

Air system restricted Check air filter restriction and air


filters. Clean.

Incorrect high idle speed (too low) or Adjust linkage. Check high idle
linkage out adjustment. speed. See Slow And Fast Idle in
Group 9010-20.

Incorrect engine or injection pump Check. Adjust timing. See Injection


timing Pump Timing in Group 9010-25.

Incorrect valve clearance Adjust valve clearance. See Check


and Adjust Valve Clearance in
CTM8.

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

Continued on next page TX,901015,QQ815 1924JUN945/12

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110703

PN=112
System Diagnostic Information

Symptom Problem Solution

Fuel transfer pump malfunction Test fuel transfer pump pressure.


See Measure Fuel Supply Pump
Pressure in CTM8.

Fuel line restricted Route an external fuel source to fuel


transfer pump. If engine operation is
normal clean fuel line.

Excess drag in brake system Check axle and park brake drag . 9010
See Operational Checkout, 15
9
Procedure 9005-10.

Excess drag in transaxle Test drag . See Operational


Checkout Procedure 9005-10.

Muffler restricted Operate without muffler. If engine


operation is now normal, replace
muffler.

Injection pump delivery or governor Remove pump and test. See


faulty Remove Injection Pump in CTM8.
See your authorized injection pump
service center.

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


Test Fuel Injection Nozzles in CTM8.

Low compression Perform Test Engine Compression


Pressure in CTM8.

Worn camshaft Do valve lift check. Replace. See


Measure Valve Lift in CTM8.

Engine Emits Excessive Black or Restricted air filter Check air filter restriction and air
Gray Exhaust Smoke filters. Clean or replace.

Incorrect grade of fuel Drain and add correct fuel.

Incorrect injection pump timing Time injection pump. See Injection


Pump Timing in Group 9010-25.

Excessive fuel delivery Remove fuel injection pump. See


Remove Injection Pump in CTM8.
See your authorized injection pump
service center.

Continued on next page TX,901015,QQ815 1924JUN946/12

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PN=113
System Diagnostic Information

Symptom Problem Solution

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


Test Fuel Injection Nozzles in CTM8.

Engine Emits Excessive Blue or Cranking speed too slow Check batteries and connections.
White Smoke

Incorrect grade of fuel Drain and add correct fuel.

9010 Engine running too cold Check thermostat operation.


15 Replace. See Remove, Test, and
10
Install Thermostats in CTM8.

Injection pump out of time Time injection pump. See Injection


Pump Timing in Group 9010-25.

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


Test Fuel Injection Nozzles in CTM8.

Low compression Perform Test Engine Compression


Pressure in CTM8.

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


piston rings stuck

Slow Acceleration Wrong grade of fuel Drain and add correct fuel.

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


Test Fuel Injection Nozzles in CTM8.

Fuel injection pump Remove and test fuel injection. See


Remove Injection Pump in CTM8.

Detonation (Excess Engine Stuck cold weather starting aid Repair.


Knock)

Incorrect injection pump timing. Time injection pump. See Injection


Pump Timing in Group 9010-25.

Abnormal Engine Noise Low or incorrect engine oil (too thin). Add correct oil to proper level.

Loose or worn hydraulic pump drive Inspect. Repair.


coupling

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

Continued on next page TX,901015,QQ815 1924JUN947/12

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PN=114
System Diagnostic Information

Symptom Problem Solution

Incorrect fuel injection pump timing Time injection pump. See Injection
Pump Timing in Group 9010-25.

Excessive valve clearance Adjust valve clearance. See Check


and Adjust Valve Clearance in
CTM8.

Bent push rods Inspect. Replace.


9010
Worn rocker arm shafts Replace. 15
11

Loose connecting rod caps Inspect, tighten connecting rod cap


screws. See Torque-Turn
Connecting Rod Cap Screws in
CTM8.

Loose main bearing caps Inspect, tighten main bearing cap


screws. See procedure under Install
Crankshaft in CTM8.

Worn main bearings Replace bearings. See Check Main


Bearing Oil Clearance in CTM8.

Worn connecting rod bearings Replace bearings. See Inspect and


Measure Connecting Rod Bearings
in CTM8.

Incorrect cam timing Check engine timing. Repair. See


Install and Time Camshaft and Fuel
Injection Pump in CTM8.

Scored piston Inspect. Replace.

Worn piston pin bushings and pins Inspect. Replace pins and bushings.
See Inspect Piston Pins and
Bushings in CTM8.

Low Oil Pressure (Oil Pressure Low oil level Add oil to proper lever. Inspect
Light onRed "Stop" Flashing) engine oil.

Wrong viscosity oil/oil diluted with Change oil. Check injection pump
diesel fuel shaft seals and transfer pump
diaphragm. See Remove Injection
Pump in CTM8.

Continued on next page TX,901015,QQ815 1924JUN948/12

TM1512 (07NOV03) 9010-15-11 Backhoe Loaders Operation and Test


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PN=115
System Diagnostic Information

Symptom Problem Solution

Oil pressure switch or indicator Check engine oil pressure. Test


switch and indicator . See 9015-15.

Oil pressure regulating valve Test or replace.

Plugged or broken oil pump intake Inspect. Clean.


screen

9010 Loose oil pump drive gear Inspect. Repair.


15
12
Worn oil pump gear or housing Remove, inspect and repair.

Excessive main bearing, connecting Perform Check Main Bearing Oil


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

Cracked cylinder block Replace cylinder block. See


Complete Disassembly of Cylinder
Block in CTM8. Inspect piston
cooling jets.

Leakage at internal oil passage. Check all possible internal leakage


paths. Repair.

Engine Overheats (Engine Low coolant level Fill cooling system and check for
Coolant Indicator Light On and leaks. See Cooling System in Group
Red "Stop" Flashing) 9010-25.

Low engine oil level Add oil.

Loose or broken fan belt. Adjust belt tension or replace belt.


See Fan Belt Tension Adjustment in
Group 9010-20.

Engine overloaded, operating in Reduce load.


wrong gear

Fan on backwards Check for correct fan installation.


See Cooling System in Group
9010-25.

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


Cooling System in Group 9010-25.

Continued on next page TX,901015,QQ815 1924JUN949/12

TM1512 (07NOV03) 9010-15-12 Backhoe Loaders Operation and Test


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PN=116
System Diagnostic Information

Symptom Problem Solution

Radiator shroud missing, damaged Inspect. Repair or replace.


or baffles missing

Improper fuel Drain and add correct fuel.

Radiator cap Replace cap.

Faulty temperature sender Test , repair or replace. See


9015-15. 9010
15
13
Incorrect injection pump timing Time injection pump. See Injection
Pump Timing in Group 9010-25.

Excessive transaxle drag Check transaxle drag.

Excessive brake drag Check Brake drag . See Operational


Checkout Procedure 9005-10.

Faulty thermostat (Stuck closed) Inspect thermostat. Replace. See


Remove, Test, and Install
Thermostats in CTM8.

Thermostat missing, cooling system Replace thermostats. See Remove,


coated with lime deposits Test, and Install Thermostats in
CTM8. Flush cooling system.

Water pump Remove. Inspect. Repair. See


General Water Pump Information
and Remove Water Pump in CTM8.

Excessive fuel delivery Remove. Check for proper fuel


delivery, adjust. See Remove
Injection Pump in CTM8.

Scored piston Replace piston. See Engine


Disassembly Sequence in CTM8.

Engine Runs Cold Thermostat (stuck open) Replace. See Remove, Test, and
Install Thermostats in CTM8.

Oil in Coolant Or Coolant in Oil Leaking cylinder head gasket Replace gasket. See Diagnosing
Head Gasket Joint Failures in CTM8.

Leaking cylinder liner packing Replace packings. See Engine


Disassembly Sequence in CTM8.

Continued on next page TX,901015,QQ815 1924JUN9410/12

TM1512 (07NOV03) 9010-15-13 Backhoe Loaders Operation and Test


110703

PN=117
System Diagnostic Information

Symptom Problem Solution

Cracked cylinder liner Replace liner. See Engine


Disassembly Sequence in CTM8.

Cracked cylinder block Replace block. See Complete


Disassembly of Cylinder Block in
CTM8.

Excessive Fuel Consumption Air system restricted Check filter restriction indicator and
9010 air filters. Replace
15
14
Leakage in fuel system Inspect. Repair.

Incorrect grade of fuel Refill with correct fuel.

Operator holding hydraulics over Return control levers to neutral


relief. position.

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

Incorrect injection pump timing Time injection pump. See Injection


Pump Timing in Group 9010-25.

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


Fuel Injection Nozzles in CTM8.

Turbocharger Excessively Noisy Bearings not lubricated Insufficient oil pressure. Check for
or Vibrates restricted turbocharger oil line.

Worn bearings Replace. See Turbocharger Failure


Analysis in CTM8.

Air leak in engine, intake or exhaust Inspect and repair. See Intake Air
manifold Leak Test and Exhaust Leak Check
in CTM8.

Improper clearance between turbine Remove exhaust elbow and air inlet
wheel and turbine housing hose. Inspect and repair. See
Turbocharger Failure Analysis in
CTM8.

Broken blades on turbine Remove exhaust elbow and air inlet


hose. Inspect and repair. See
Turbocharger Failure Analysis in
CTM8.

Continued on next page TX,901015,QQ815 1924JUN9411/12

TM1512 (07NOV03) 9010-15-14 Backhoe Loaders Operation and Test


110703

PN=118
System Diagnostic Information

Symptom Problem Solution

Oil Dripping From Turbocharger Damaged or worn bearings and/or Inspect compressor and turbine
Adapter worn seals wheel for damaged blades. Check
for proper engine service intervals or
dirt entering engine. See
Turbocharger Failure Analysis in
CTM8.

Excessive crankcase pressure Check for plugged oil drain line.


Clean. 9010
15
15
Turbocharger oil return line carbon Remove line. Inspect and clean.
buildup where line passes exhaust
manifold.

Excessive Drag In Turbocharger Carbon build-up behind turbine Inspect and clean. See Turbocharger
Rotating Members wheel caused by combustion Failure Analysis in CTM8.
deposits

Dirt build-up behind compressor Inspect and repair. See


wheel caused by air intake leaks Turbocharger Failure Analysis in
CTM8.

Bearing seizure or dirty or worn Check for plugged air filters.


bearings caused by excessive
temperature, unbalanced wheel, dirty
oil, oil starvation, or insufficient
lubrication

TX,901015,QQ815 1924JUN9412/12

TM1512 (07NOV03) 9010-15-15 Backhoe Loaders Operation and Test


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PN=119
System Diagnostic Information

9010
15
16

TM1512 (07NOV03) 9010-15-16 Backhoe Loaders Operation and Test


110703

PN=120
Group 20
Adjustments
4045 John Deere EngineUse CTM8

For additional engine information, the component technical


manual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

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

JT05801 Clamp-On Electronic Tachometer


Installation
SERVICE EQUIPMENT AND TOOLS
Tachometer
AClamp-on Transducer. Remove paint with emery cloth and

UN28FEB89
connect to a straight section of injection line within 100 mm (4 in.) of
pump. Finger tighten only. DO NOT overtighten.
BBlack Clip (-). Connect to main frame.
CRed Clip (+). Connect to transducer.

T6813AG
DTachometer Readout. Install cable.

10T,9010,K182 1910AUG951/1

TM1512 (07NOV03) 9010-20-1 Backhoe Loaders Operation and Test


110703

PN=121
Adjustments

Fan Belt Tension Adjustment


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

SERVICE EQUIPMENT AND TOOLS


JDST28 Belt Deflection Gauge
9010
20
2 NOTE: Belt deflection measured using JDST28 Belt
Deflection Gauge.

IMPORTANT: The alternator belt is considered used


after 12 minutes of running.

DO NOT overtighten belts.


Overtightening may cause belt cord
damage or excessively loud alternator

UN01JUN89
bearings.

1. Check alternator belt deflection using a belt deflection


gauge. A new belt will deflect 5/16 in. at 25 lb force at

T6030AT
a point halfway between the pulleys.

Specification
New BeltDeflection...................................................... 5/16 in. at 25 lbs. AAlternator Pulley
BFan Pulley
CCrankshaft Pulley
A used belt will deflect 7/16 in. at 25 lb force at a point
DStraight Edge
halfway between the pulleys. EBelt Deflection Gauge

Specification
Used Belt (Cold)Deflection ......................................... 7/16 in. at 25 lbs.

2. If belt deflection is not within specifications, loosen


alternator mounting cap screws. Apply force only to the
front of alternator housing (near the belt) and tighten
cap screws.

Specification
Adjusting Strap Cap Screw
Torque ................................................................. 27 3 Nm (20 2 lb-ft)

3. Check belt tension. If not correct repeat Step 2 until


within specifications.

TX,901020,QQ818 1924FEB941/1

TM1512 (07NOV03) 9010-20-2 Backhoe Loaders Operation and Test


110703

PN=122
Adjustments

Adjust Speed Control Lever Tension

UN04OCT90
9010
20

T7387AA
3

SPECIFICATIONS
Nut Torque Until 4462 N (1014 lb force)
is required to move lever using a
spring scale

Tighten nut (A) until 4462 N (1014 lb force) is


required to move lever using a spring scale.

Specification
NutTorque ........................................... Until 4462 N (1014 lb force)
is required to move lever using a
spring scale

TX,9010,YY510 1919APR941/1

TM1512 (07NOV03) 9010-20-3 Backhoe Loaders Operation and Test


110703

PN=123
Adjustments

Engine Speed Control Linkage


SPECIFICATIONS
Injection Pump Lever Override 46 mm (1/81/4 in.)
With Speed Control Lever in
Extreme Forward Position

UN18OCT88
Injection Pump Lever Minimum 1.5 mm
Override With Speed Control
Lever in Rear Most Position
Injection Pump Lever Minimum 2 mm

T6030AU
Override at High Idle
9010
20
4 1. Move speed control lever to extreme forward position.

2. Measure injection pump lever override. Override must


be 46 mm (1/81/4 in.).

Specification
Injection Pump LeverOverride
With Speed Control Lever in
Extreme Forward Position ..................................... 46 mm (1/81/4 in.)

3. Adjust yoke on speed control rod to provide override.

4. Move speed control lever to rear most position and


check override. Override must be at least 1.5 mm
minimum.

Specification
Injection Pump LeverMinimum
Override With Speed Control
Lever in Rear Most Position ........................................................... 1.5 mm

5. Recheck high idle for a minimum of 2 mm override.

Specification
Injection Pump LeverMinimum
Override at High Idle ......................................................................... 2 mm

6. Remove reservoir cowling to adjust foot control pedal.

Continued on next page TX,9010,DS4840 1902JUN931/2

TM1512 (07NOV03) 9010-20-4 Backhoe Loaders Operation and Test


110703

PN=124
Adjustments

7. Disconnect yoke (A) from rod (B). Adjust vertical rod


(C) length to allow foot control pedal to stop on floor
with hand lever in the extreme forward position.

9010
20
5

UN16DEC91
T7387AB
TX,9010,DS4840 1902JUN932/2

TM1512 (07NOV03) 9010-20-5 Backhoe Loaders Operation and Test


110703

PN=125
Adjustments

Slow And Fast Idle


SPECIFICATIONS
Slow Idle Speed 850 50 rpm
Fast Idle Speed 2375 50 rpm

UN18OCT88
SERVICE EQUIPMENT AND TOOLS
JT05801 Electronic Tachometer
Sealing Wire Pliers

T6023AD
9010
20 1. Run engine until it is at normal operating temperature.
6
2. Install tachometer . See procedure in this group. ALever Stop Screw
BSpeed Control Rod
CFast Idle Adjusting Screw
CAUTION: Take care to avoid rotating fan DSealing Wire
blades while making injection pump ESlow Idle Adjusting Screw
adjustments.

3. Disconnect speed control rod (B) from fuel injection


pump lever.

4. Start engine.

5. Hold injection pump lever forward (toward radiator).


Check to make sure slow idle is 850 50 rpm.

Specification
Slow IdleSpeed ................................................................. 850 50 rpm

6. If slow idle is not correct:

a. Check air cleaner elements.

b. Loosen lock nut and turn screw (A) out one or two
turns.

c. Loosen lock nut and turn screw (E) to adjust slow


idle.

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


turn screw out one full turn. Tighten lock nuts.

7. Hold injection pump lever rearward (away from


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

Specification
Fast IdleSpeed ................................................................ 2375 50 rpm

Continued on next page TX,9010,YY513 1902JUN931/2

TM1512 (07NOV03) 9010-20-6 Backhoe Loaders Operation and Test


110703

PN=126
Adjustments

8. If fast idle is not correct:

a. Remove sealing wire.

b. Loosen lock nut and turn screw (C)


counterclockwise to increase rpm or clockwise to
decrease rpm.

c. Tighten lock nut and install a new sealing wire using


a seal wire pliers.
9010
9. Connect rod (B). 20
7

TX,9010,YY513 1902JUN932/2

TM1512 (07NOV03) 9010-20-7 Backhoe Loaders Operation and Test


110703

PN=127
Adjustments

9010
20
8

TM1512 (07NOV03) 9010-20-8 Backhoe Loaders Operation and Test


110703

PN=128
Group 25
Tests
4045 John Deere EngineUse CTM8

For additional engine information, the component technical


manual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

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

JT05801 Clamp-On Electronic Tachometer


Installation
SERVICE EQUIPMENT AND TOOLS
Tachometer
AClamp-on Transducer. Remove paint with emery cloth and

UN28FEB89
connect to a straight section of injection line within 100 mm (4 in.) of
pump. Finger tighten only. DO NOT overtighten.
BBlack Clip (-). Connect to main frame.
CRed Clip (+). Connect to transducer.

T6813AG
DTachometer Readout. Install cable.

10T,9010,K182 1910AUG951/1

JT05800 Digital Thermometer Installation


SERVICE EQUIPMENT AND TOOLS
Digital Thermometer
ATemperature Probe. Fasten to a bare metal line using tie band.
Wrap with shop towel. UN28FEB89
BCable
CDigital Thermometer
T6808CE

902525,AA4 1928FEB951/1

TM1512 (07NOV03) 9010-25-1 Backhoe Loaders Operation and Test


110703

PN=129
Tests

JT07158 TIME TRAC Installation


ESSENTIAL TOOLS

JT07158 TIME TRAC Kit
JT07155 In-Line SOI Sensor
JT07173 SOI Clamp Assembly

UN18MAY93
JT07177 Clamp-On Transducer
JDG793 Magnetic Pick-up Adapter
JT07171 Magnetic Pick-up

T8010AL
9010
25 Remove paint and clean injection line for installation of
2
clamp-on transducer (E).

IMPORTANT: Install clamp-on transducer as close as


possible to fuel injection nozzle.

ASOI Sensor
BTransducer Clamp

UN20MAY93
CGround
DMeter Connection
EClamp-On Transducer
FInjection Line

T8010AM
GGround
HMeter Connection
IAdapter
JMagnetic Probe
KMeter Connection

UN18MAY93
T8010AN
JT07158 TIME TRAC is a registered trademark of the Stanadyne
Automotive Corp.
TIME TRAC is a registered trademark of the Stanadyne Automotive
Corp. TX,TIMETRAC,300 1920JUN951/1

TM1512 (07NOV03) 9010-25-2 Backhoe Loaders Operation and Test


110703

PN=130
Tests

Cooling System

SPECIFICATIONS
Cooling System Test Pressure 69 kPa (0.7 bar) (10 psi)
Cooling System Pressure Cap 4352 kPa (0.40.5 bar) (6.2
Opening Pressure 7.5 psi)

UN24OCT88
Vacuum Valve Opening Pressure 03.5 kPa (00.04 bar) (00.5
psi)

SERVICE EQUIPMENT AND TOOLS

T6487AT
Cooling System Pressure Pump 9010
25
3
1. Check coolant level.

2. Check belt tension . (See procedure in this group).

3. Check radiator fin condition. Make sure fins are not


bent or damaged.

UN25OCT88
4. Check fan tips and shroud for damage. Fan tip shroud
should be equal at top and bottom.

NOTE: Sucker fan has six blades with concave sides

T95940
away from radiator.

5. Check for correct fan installation.

6. Test cooling system for leaks using a cooling system


pressure pump (A). Pressurize system to maximum of
69 kPa (0.7 bar) (10 psi).

Specification
Cooling SystemTest Pressure ........................ 69 kPa (0.7 bar) (10 psi)

7. Test radiator cap using a cooling system pressure


pump. Pressurize radiator cap valve. Valve must start
to open at 4352 kPa (0.40.5 bar) (6.27.5 psi).

Specification
Cooling System Pressure Cap
Opening Pressure ............................................ 4352 kPa (0.40.5 bar)
(6.27.5 psi)

8. Vacuum valve must open at 03.5 kPa (00.04 bar)


(00.5 psi).

Specification
Vacuum ValveOpening
Pressure ................................................ 03.5 kPa (00.04 bar) (00.5
psi)

TX,9010,YY514 1902JUN931/1

TM1512 (07NOV03) 9010-25-3 Backhoe Loaders Operation and Test


110703

PN=131
Tests

Air Filter Restriction Indicator Switch


SPECIFICATIONS
Restriction Indicator Light 57.5 kPa (49.874.7 mbar)
Activation Pressure (2030 in. water) (1.8 0.2 in.
Hg) vacuum

UN15OCT90
SERVICE EQUIPMENT AND TOOLS
Vacuum Gauge
1/4 in. x 1/8 in. Pipe Reducer

T7390AR
9010 Air Restriction Indicator
25
4 1/8 in. Barb Fitting (2 used)
1/4 in. Pipe Tee Fitting

1. Remove air restriction indicator switch.

2. Install hose nipple, tee fitting and gauge from water


vacuum gauge kit into air restriction indicator hole.
Install air restriction indicator into tee fitting.

3. Start engine and slowly cover the air cleaner inlet with
a piece of paper or cardboard.

4. Yellow warning light and air filter restriction indicator


light on monitor panel must come on when gauge is at
specified pressure.

Specification
Restriction Indicator Light
Activation Pressure..................................... 57.5 kPa (49.874.7 mbar)
(2030 in. water) (1.8 0.2 in.
Hg) vacuum

TX,901025,QQ819 1902JUN931/1

TM1512 (07NOV03) 9010-25-4 Backhoe Loaders Operation and Test


110703

PN=132
Tests

Air Intake System Leakage Test

SPECIFICATIONS
Air Intake System Test Regulated 13.820.7 kPa (0.130.21 bar)
Pressure (23 psi)

UN25OCT88
ESSENTIAL TOOLS
JDG51 Adapter

SERVICE EQUIPMENT AND TOOLS

T92026
Air Regulator With Gauge 9010
25
5
IMPORTANT: Anytime the air intake system is opened
it must be tested for leaks before the
machine is returned to service.

1. Remove air cleaner cover and main filter element.

2. Put a plastic bag over safety element and install main

UN25OCT88
element and cover.

3. Remove plug from air intake tube and install JDG51


adapter (A).

T92027
4. Connect air pressure regulator to adapter using hose
and fitting (B).

CAUTION: Plastic bag can be sucked into


engine if engine is started when trying to close
valves.

5. Pressurize air intake system to specifications.

Specification
Air Intake System Test
Regulated Pressure ................................ 13.820.7 kPa (0.130.21 bar)
(23 psi)

If system cannot be pressurized, turn engine slightly to


close valves. Check plastic bag.

6. Spray soap solution over all connections from the air


cleaner to the turbocharger or air inlet to check for
leaks. Repair all leaks.

TX,901025,QQ816 1928NOV901/1

TM1512 (07NOV03) 9010-25-5 Backhoe Loaders Operation and Test


110703

PN=133
Tests

Radiator Air Flow Test


SPECIFICATIONS
410D Engine Speed 1000 10 rpm
510D Engine Speed 1000 10 rpm
410D Suction Fan Actual Voltage 1.49 volts
Reading
410D Suction Fan Actual Voltage 1.19 volts
Reading Minus 20%
510D Suction Fan Actual Voltage 1.45 volts
9010 Reading
25
6 510D Suction Fan Actual Voltage 1.16 volts
Reading Minus 20%

SERVICE EQUIPMENT AND TOOLS


JT05801 Electronic Tachometer
Flowmeter
Volt-Ohm-Amp Multimeter

1. Apply parking brake, put transmission in neutral and

UN01NOV88
lower equipment to the ground. Stop engine.

2. Install tachometer . (See procedure in this group.)

T6080AH
3. Check that all sheet metal is in place. Close side
shields.

4. Divide the surface of the grille into 16 equal squares.

5. Start engine and run at 1000 10 rpm.

Specification
410D EngineSpeed ......................................................... 1000 10 rpm
510D EngineSpeed ......................................................... 1000 10 rpm

6. Connect air flowmeter to digital multimeter. Turn switch


on multimeter to 20 volts A.C.

7. Place air flowmeter in contact with grille. Arrow on


meter must point in direction of air flow (toward unit).

8. Record voltage reading for each area.

Continued on next page TX,901025,QQ834 1902JUN931/2

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110703

PN=134
Tests

NOTE: Air flow readings minus 20% is a number used as


a guideline to determine when a partially plugged
radiator and or cooler core may cause
overheating.

9. Combined total of air flow test readings must be


greater than specifications.

Specification
410D Suction FanActual
Voltage Reading .......................................................................... 1.49 volts
9010
Actual Voltage Reading Minus
25
20%.............................................................................................. 1.19 volts
7
510D Suction FanActual
Voltage Reading .......................................................................... 1.45 volts
Actual Voltage Reading Minus
20%.............................................................................................. 1.16 volts

If readings are less than specifications remove oil cooler


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

TX,901025,QQ834 1902JUN932/2

TM1512 (07NOV03) 9010-25-7 Backhoe Loaders Operation and Test


110703

PN=135
Tests

JT05529 Air Flow Meter Test Record

CUSTOMER NAME AND ADDRESS

DATE:
MACHINE MODEL NO.

UN20APR89
SERIAL NO.

T6041AL
9010
25
8
PRE-TEST INSPECTION
OK SERV REQD OK SERV REQD
Coolant Level
Belt Tension Correct Fan Installation (Sucker
Fan)
Radiator Fin Condition Radiator Cap
Fan Tip & Shroud Condition

AIR FLOW TEST

1. Park brake ON.

2. Transmission in Neutral and side shields closed.

3. Divide the surface of the grille into 16 equal squares.

4. Start engine.

5. Perform air flow test at fast idle. Observe correct air


flow direction and place air flow meter in direct contact
with grille. (Arrow pointing to grille).

6. Record air flow in each square.

7. Combined total of air flow test readings must be


greater than specifications.

TX,9010,YY518 1902JUN931/1

TM1512 (07NOV03) 9010-25-8 Backhoe Loaders Operation and Test


110703

PN=136
Tests

Turbocharger Boost PressureEngine


Performance Test

NOTE: Maximum boost pressure will be found within 200


RPM of fast idle.

UN26MAY89
SPECIFICATIONS
410D Engine Speed Fast idle
410D Engine Normal Operating 82 10C (180C 20F)
Temperature

T6225AS
9010
510D Engine Speed Fast idle
25
510D Engine Normal Operating 82 10C (180C 20F) 9
Temperature
410D Turbocharger Boost 3448 kPa (0.340.48 bar) (5
Pressure (Using No. 2 Fuel) 7 psi)
510D Turbocharber Boost 6276 kPa (0.620.76 bar) (9
Pressure (Using No. 2 Fuel) 11 psi)

NOTE: Reduce the boost specifications by 7% if using


No. 1 fuel.

SERVICE EQUIPMENT AND TOOLS


JDE147 (1/2 NPT x 1/4 in. hose barb) Adapter
Gauge 0200 kPa (02 bar) (030 psi)
JT05800 Digital Thermometer
JT05801 Electronic Tachometer

1. Make test connections.

2. Install tachometer and thermometer . (See procedure


in this section.)

3. Apply park brake and put transaxle and reverser in


neutral. Run engine until it is at normal operating
temperature.

Specification
410D EngineSpeed ................................................................... Fast idle
Normal Operating Temperature ....................... 82 10C (180C 20F)
510D EngineSpeed ................................................................... Fast idle
Normal Operating Temperature ....................... 82 10C (180C 20F)

4. Lower stabilizers and bucket to raise wheels off


ground.

Put unit in first gear with reverser lever in forward or


reverse.

Continued on next page TX,901025,QQ833 1902JUN931/2

TM1512 (07NOV03) 9010-25-9 Backhoe Loaders Operation and Test


110703

PN=137
Tests

Release park brake and apply brake pressure until


boost pressure begins to drop.

5. Record highest boost pressure and RPM it was


obtained at.

Specification
410D TurbochargerBoost
Pressure (Using No. 2 Fuel) ........................ 3448 kPa (0.340.48 bar)
(57 psi)
510D TurbocharberBoost
9010 Pressure (Using No. 2 Fuel) ........................ 6276 kPa (0.620.76 bar)
25 (911 psi)
10
Repeat test several times.

6. If boost pressure is too high, remove and test fuel


injection pump for high fuel delivery.

If boost pressure is too low, check for the following:

a. Restricted air filter elements.

b. Restricted fuel filter elements.

c. Incorrect fast idle adjustment.

d. Incorrect injection pump timing.

e. Exhaust manifold leaks.

f. Intake manifold leaks.

g. Faulty fuel transfer pump.

h. Low compression pressure.

i. Faulty fuel injection nozzle.

j. Carbon build-up in turbocharger.

k. Turbocharger compressor or turbine wheel rubbing


housing.

l. Low fuel injection pump fuel delivery, remove and


test fuel injection pump for low fuel delivery.

TX,901025,QQ833 1902JUN932/2

TM1512 (07NOV03) 9010-25-10 Backhoe Loaders Operation and Test


110703

PN=138
Tests

Injection Pump Timing

SPECIFICATIONS
410D Engine Model Numbers 4045D and 4045T
410D Engine Net hp (kW) 75 hp (56.2 kW)
510D Engine Model Number 4045T

UN03NOV97
510D Engine Net hp (kW) 90 hp (67 kW)
410D Engine Rated Speed 2200 rpm
510D Engine Rated Speed 2200 rpm

RG6293
410D Injection Pump Dynamic 16.5 9010
Timing at +0 -1 BTDC 25
11
510D Injection Pump Dynamic 15
Timing at +0 -1 BTDC AFront Plate
BPump Flange
ESSENTIAL TOOLS
JT07158 TIME TRAC Kit

The JT07158 TIME TRAC timing kit electronically


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

Timing engines with this tool improves consistency


between engines and helps to control cylinder firing
pressures which can be a factor in head gasket failures as
well as improve overall engine efficiencies.

1. Install JT07158 TIME TRAC. See procedure in this


group. (Also found on JT07175 Quick Reference
Sheet.)

2. Raise rear of machine off the ground with stabilizers.


Put transaxle in fourth forward.

3. Operate machine at WOT.

Specification
410D EngineModel Numbers..................................... 4045D and 4045T
Net hp (kW) ...................................................................... 75 hp (56.2 kW)
510D EngineModel Number ......................................................... 4045T
Net hp (kW) ......................................................................... 90 hp (67 kW)

Slowly depress service brakes until engine is at 2200


rpm.

TIME TRAC is a registered trademark of the Stanadyne Automotive


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

TM1512 (07NOV03) 9010-25-11 Backhoe Loaders Operation and Test


110703

PN=139
Tests

Specification
410D EngineRated Speed ....................................................... 2200 rpm
510D EngineRated Speed ....................................................... 2200 rpm

4. Record dynamic timing.

Specification
410D Injection PumpDynamic
Timing at +0 -1 BTDC........................................................................ 16.5
510D Injection PumpDynamic
Timing at +0 -1 BTDC........................................................................... 15
9010
25 5. If timing is not to specification, follow procedure on
12 JT07175 Quick Reference Sheet.

TX,410D,DS4888 1902JUN932/2

Injection Pump Static Timing Adjustment


SPECIFICATIONS
No. 1 Cylinder Position At TDC on compression stroke
Line on Governor Weight Aligned with line on cam ring
Retainer Position

ESSENTIAL TOOLS

JDE811 Flywheel Turning Tool


JDE814 Timing Pin

T59,9010,C111 1925MAR861/3

1. Install flywheel turning tool (A). Rotate flywheel in


engine running direction until pin (B) goes into hole in
flywheel.

2. Remove timing hole cover from fuel injection pump.


UN29MAR90
T6024AP

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

TM1512 (07NOV03) 9010-25-12 Backhoe Loaders Operation and Test


110703

PN=140
Tests

3. If timing line (C) on weight retainer cannot be seen,


turn engine one revolution to get No. 1 cylinder at TDC
on compression stroke.

Specification
No. 1 CylinderPosition .......................... At TDC on compression stroke

UN25MAY89
Line on Governor Weight
RetainerPosition ....................................... Aligned with line on cam ring

4. To avoid backlash, always approach the timing lines by

T6193AA1
turning engine in direction of rotation. The normal
9010
backlash of gears is enough to throw the pump timing
25
off several degrees, resulting in poor engine 13
performance.

5. If lines are not aligned, loosen pump mounting flange


retaining nuts and rotate pump housing until timing
lines are aligned.

T59,9010,C111 1925MAR863/3

TM1512 (07NOV03) 9010-25-13 Backhoe Loaders Operation and Test


110703

PN=141
Tests

9010
25
14

TM1512 (07NOV03) 9010-25-14 Backhoe Loaders Operation and Test


110703

PN=142
Section 9015
Electrical System
Contents

Page Page

Group 05System Information Engine Harness (W8) Component


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

TM1512 (07NOV03) 9015-1 Backhoe Loaders Operation and Test


110703

PN=1
Contents

Page Page

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

TM1512 (07NOV03) 9015-2 Backhoe Loaders Operation and Test


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Contents

Page

Auxiliary Valve Circuit Operational


Information. . . . . . . . . . . . . . . . . . . . . . . 9015-15-109
Auxiliary Valve Circuit Theory Of
Operation. . . . . . . . . . . . . . . . . . . . . . . . 9015-15-109
Auxiliary Valve Circuit Schematic . . . . . . . 9015-15-110
Auxiliary Valve Diagnostic Procedures . . . 9015-15-111

Group 20References
Alternators And Starting MotorsUse
CTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
JT05801 Clamp-On Electronic Tachometer
Installation . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Battery Operation . . . . . . . . . . . . . . . . . . . . .9015-20-2
Battery Specifications . . . . . . . . . . . . . . . . . .9015-20-3 9015
Diagnose Battery Malfunctions . . . . . . . . . . .9015-20-4
Check Battery Electrolyte Level And
Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-5
Procedure For Testing Batteries . . . . . . . . . .9015-20-8
Using Booster Batteries12 Volt System . . .9015-20-9
Alternator Operation78 AMP Delco
Remy (Serial No. 787513) . . . . . . . . . .9015-20-10
Alternator Operation95 AMP Bosch
(Serial No. 787514 ) . . . . . . . . . . . . . . .9015-20-11
Alternator Operation95 AMP Bosch . . . . .9015-20-12
Monitor Test In Machine . . . . . . . . . . . . . . .9015-20-13
Logic Module Test In Machine (SN
XXXXXX) . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-14
Logic Module Bench Test (SN
XXXXXX) . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-16
Tachometer Calibration . . . . . . . . . . . . . . . .9015-20-17

TM1512 (07NOV03) 9015-3 Backhoe Loaders Operation and Test


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PN=3
Contents

9015

TM1512 (07NOV03) 9015-4 Backhoe Loaders Operation and Test


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PN=4
Group 05
System Information

Visually Inspect Electrical System

Make the following visual electrical inspection prior to


starting the tractor after receiving customer complaint:

1. Look for bare wires that could ground a component or


short across to another component.

2. Look for missing or worn conduit. This could indicate a


wire problem.

3. Look for loose or broken connectors and wires.

4. Inspect batteries for:

Corroded terminals
9015
Corroded terminals 05
Loose terminals or battery posts 1
Dirty condition
Damp condition
Cracked case Proper electrolyte level

5. Check alternator belt tension.

6. After machine has been shut down for five minutes


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

7. If your visual inspection does not indicate the possible


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

8. Start machine. Check all gauges for good operation


and check to see if system is charging or discharging.

9. In general, look for anything unusual.

Many electrical failures cannot be detected even if the


machine is started. Therefore, a systematic and
complete inspection of the electrical system is
necessary.

TX,901505,QQ369 1907FEB961/1

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System Information

Electrical Circuit Malfunctions

9015
05
2

1927FEB92
T7713AD
ABattery CSwitch DLight EGround
BFuse

There are four common circuit malfunctions. After the component

High-Resistance Circuit Component malfunctions can easily be confused with


Open Circuit circuit malfunctions. Therefore, care must be exercised
Grounded Circuit when isolating the cause of a problem.
Shorted Circuit
Example: Light does not operate or is dim when switch
Three sections in a simple circuit where these is turned ON, until switch connector is disconnected
malfunctions can occur; and reconnected.

Before the controlling switch (C) Reason: High resistance caused by a dirty switch
Between the controlling switch and before the connector, caused a voltage drop which prevented the
component, light (D) proper amount of current from flowing to the light.

TX,901505,RP967 1907FEB941/1

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System Information

High Resistance Circuit

9015
05
3

1926FEB92
T7713AG
ABattery DSwitch Terminal FHarness Connector HLight
BFuse EHigh Resistance GLight Terminal IGround
CSwitch

A high resistance circuit can result in slow, dim or no If battery voltage is measured, check closer to ground
component operation. to locate point of voltage drop. The example shows
high resistance (E) between switch and harness
Examples: Loose, corroded, dirty or oily terminals. connector.
Wire size too small. Strands broken inside the wire.
Poor ground connection to frame. Repair circuit as required. In the example, strands
were broken inside the wire, replace that section of
To locate the cause of high resistance: wire.

With switch (C) ON, check for battery voltage between Repeat check-out procedure after repair.
switch and ground (I) at an easily accessible location,
like harness connector (F).

If less than battery voltage is measured, check again


closer to switch.

TX,901505,RP968 1910AUG951/1

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System Information

Open Circuit

9015
05
4

1927FEB92
T7713AF
ABattery DSwitch Terminal FOpen Circuit HLight
BFuse EHarness Connector GLight Terminal IGround
CSwitch

An open circuit will result in no components operating. If battery voltage is measured, check for voltage closer
Fuse may or may not be blown. to ground at harness connector (E).

Example: Broken wire, disconnected component If no voltage is measured, wire may be broken
terminal, pins inside a connector not making contact, between switch and connector.
blown fuse, open circuit breaker, failed switch or
component, or a disconnected ground wire. If battery voltage is measured, inspect connector pins.
If pins are OK check for voltage at light terminal (G).
To locate an open circuit:
In the example, zero voltage will be measured at light
Check fuse. If blown, replace and operate circuit. If terminal, indicating a broken wire between harness
fuse blows a second time, continue check. connector and light terminal.

With switch (C) ON check for battery voltage at switch If battery voltage had been measured, the next check
terminal (D). for voltage would be at ground connection (I).

If no voltage is measured, check switch, fuse and Normal measured voltage at a ground connection
wiring to battery. should be 0.0 to 0.5 volts.

Continued on next page TX,901505,RP964 1910AUG951/2

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System Information

If battery voltage is measured, poor connection to When problem is located, repair as needed then
frame or broken wire is indicated. repeat last check.

TX,901505,RP964 1910AUG952/2

9015
05
5

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110703

PN=149
System Information

Grounded Circuit

9015
05
6

1927FEB92
T7713AE
ABattery DSwitch GHarness Connector JLight
BFuse ESwitch Terminal HGrounded Circuit KGround
CFuse Terminal FHarness Connector ILight (Component) Terminal

If no component operates, the fuse is blown and If continuity to ground is measured, there is a pinched
replacement fuses blow immediately or the circuit or bare wire between fuse (C) and harness connector
breaker is open and reopens when reset, a grounded (F).
circuit exists. (Example: power wire contacting frame
or other metal component). A wire may be pinched or If continuity to ground does not exist, disconnect
insulation may be worn from a wire. ground (K) from frame. Measure continuity to ground
at harness connector (G). This checks harness from
To isolate the location of a grounded circuit: harness connector to ground terminal. In the example
continuity to ground will exist because circuit is
If circuit is grounded between battery and fuse, wire grounded (wire is pinched) at (H).
will be burned and circuit will be open, fuse will not be
blown. If continuity exists, disconnect circuit at light terminal
(I) and measure continuity to ground on light terminal.
If fuse is blown, remove fuse from circuit, disconnect This checks harness from light to ground terminal. In
circuit near its center, such as harness connector (F), the example continuity will not exist, indicating a
turn switch (D) ON, check for continuity to ground at grounded circuit between the light and harness
harness connector (F). This will check harness from connector (G).
harness connector to fuse.

Continued on next page TX,901505,RP969 1910AUG951/2

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110703

PN=150
System Information

Repeat check-out procedure after repair.

TX,901505,RP969 1910AUG952/2

9015
05
7

TM1512 (07NOV03) 9015-05-7 Backhoe Loaders Operation and Test


110703

PN=151
System Information

Shorted Circuit

9015
05
8

1927FEB92
T7713AH
ABattery ESwitch Terminal IHarness Connector LLight
BFuse FSwitch JLight MGround
CFuse GHarness Connector KLight Terminal NGround
DSwitch HShorted Circuit

A shorted circuit causes components in separate Disconnect wire from switch of component that should
circuits to operate when a switch in either circuit is not be ON. In the example, disconnect wire from
turned ON. (Example: two harnesses rubbing together terminal (E) at switch (D). Light (J) remains ON.
until insulation is worn through allowing bare wires to
touch). Components can also become shorted. Disconnect circuit at convenient places like harness
However, shorted components will usually blow the connectors (G), (I) and light terminal (K) until light (J)
fuse. goes OFF.

To locate a shorted circuit: The short circuit will be between the last two places
the circuit was disconnected. In the example, it is
Turn Switch (F) ON then OFF, turn switch (D) ON then between harness connectors (G and I). Light (J) will go
OFF, both lights (J and L) will be ON when either OFF when harness connector (I) is disconnected.
switch (D or F) is ON. Inspect harness between connectors (G and I).

Turn switch (F) ON. Both lights (J and L) will be ON,


only light (L) should be ON.

Continued on next page TX,901505,RP970 1910AUG951/2

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110703

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System Information

Repair or replace wires and harnesses as needed. Repeat check-out procedure after repair.
Install tie bands and clamps on harnesses as required
to prevent future failures.

TX,901505,RP970 1910AUG952/2

Multimeter

The multimeter is an autoranging digital display that


allows very accurate readings to be taken.

9015
05
9

1917JAN90
T7199AI
TX,901505,QQ374 1910AUG951/1

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110703

PN=153
System Information

Seven Step Electrical Test Procedure

9015
05
10

1905MAR92
T7719AA
ABattery Ground DFuse Or Circuit Breaker GBattery Side Of IGround Side Of Component
BBattery EComponent Side Of Fuse Component Terminal Terminal
CBattery Side Of Fuse Or Or Circuit Breaker HLight (Component) JComponent Ground
Circuit Breaker FSwitch

Continued on next page TX,9015,QQ1697 1910AUG951/2

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110703

PN=154
System Information

Step 1Switch ON Battery voltage normal. Go to Step 2. Low voltage, repair high
Check battery side of circuit breaker (C) for battery voltage resistance. Open circuit from battery.
Step 2Switch OFF Battery voltage normal. Go to Step 4. Low voltage, repair high
Check component side of circuit breaker for battery voltage resistance. No voltage. Go to Step 3.
Step 3Switch OFF Continuity to ground. Repair grounded circuit at or before switch. No
Check component side of circuit breaker for continuity to ground continuity to ground, replace circuit breaker.
Step 4Switch ON Battery voltage normal. Go to Step 6. Low voltage, repair high
Check component side of circuit breaker for battery voltage resistance. No voltage. Go to Step 5.
Step 5a Disconnect Battery voltage, repair component. No voltage, repair grounded or
wire at battery side of component (G). Switch ON. Check wire at (G) open circuit at or after switch.
for battery voltage
Step 6Switch ON Battery voltage normal. Go to Step 7. Low voltage, repair high
Check lead to component at (G) for battery voltage resistance in circuit between fuse and component. No voltage, repair
high resistance or open circuit between fuse and component.
Step 7Switch ON No voltage, good continuity to ground. Repair component. Voltage,
Check ground wire of component at (I) for voltage poor continuity to ground. Repair high resistance or open ground
circuit. 9015
a
A multimeter will not apply a load to the circuit at step 5. The multimeter result is tested as a voltage condition in the result column 05
11

TX,9015,QQ1697 1910AUG952/2

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110703

PN=155
System Information

Wiring Diagram And Schematic Information

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

TX,901505,RP548 1910AUG951/1

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110703

PN=156
System Information

Reading A System Functional Schematic

9015
05
13

1929MAY91
T7502CE
APower Wires DComponent Identification EComponent Name GCircuit Name
BContinuity Chart Code FGround Wires HSection Number
CComponent Schematic
Symbol

The System Functional Schematic is made up of component identification code (D). A continuity chart
sections which contain one or more Subsystem (B) is included for each multi-terminal switch.
Functional Schematic laid out side by side in a logical
sequence of related functions. Each Subsystem is a The same names and identification letter codes are
major group of components like starting components or used on all machine drawingsthe System Functional
charging components (H). Sections are named to Schematic, System Wiring and Harness Diagram, and
reflect that group of components (G). The System the System Component Location Drawing.
Functional Schematic is formatted with power supply Components and connectors can easily be
wires (A) shown across the top of the drawing and cross-referenced from one drawing to another. See
ground wires (F) across the bottom. The diagram Group -10 for Component Identification Legend .
contains no harness or connector information.

Each electrical component is shown by a schematic


symbol (C), the component name (E), and a

TX,9015,RP751 1912APR941/1

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110703

PN=157
System Information

Reading A Wiring Diagram

9015
05
14

1910AUG95
T8534AC
AHarness Connector DComponent Connector GHarness Identification JWire Number and/or Color
Letter/Number EWire Number and/or Color Letter/Number and KHarness Connector Pin
Identification FComponent(s) Identification Description Number or Letter
BComponent Letter/Number Number/Letter Wire is HWiring Harness
Identification Routed To IComponent(s) Identification
CComponent Connector Pin Number/Letter Wire is
Number or Letter Routed To

Each harness on the machine is drawn showing Main harness connectors (A) are identified by a
components, connectors and wires. Harnesses (G) are letter/number designation and description, (X2 PARK
identified by a letter/number designation and BRAKE HARNESS TO DASH HARNESS
description, (W3 PARK BRAKE HARNESS Etc.). CONNECTOR Etc.). Harness connector description
indicates which harnesses connect together.
Each component (B) is represented by a schematic Connector pin numbers or letters (K) are indicated as
symbol and is identified by the same letter/number they are marked on the connector. Wires attached to
designation and description used in the System each connector pin are identified by number and/or
Functional Schematic. Components with integral color designation (J). Component identification
connectors (D) have pin number/letters indicated (C). number/letter (I) indicates destination of each wire.
Wires from harness to components are identified by
letter/number designation (E). Component identification Harness, harness connector and component
letter/number (F) indicates component wire is routed identification letter/numbers and description are the
to. same as used on the System Functional Schematic.

TX,9015,RP971 1931AUG951/1

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110703

PN=158
System Information

Electrical Schematic Symbols

9015
05
15

1930OCT90
T7186AA

Continued on next page TX,901505,QQ378 1910AUG951/2

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PN=159
System Information

9015
05
16

1930OCT90
T7186AB

TX,901505,QQ378 1910AUG952/2

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110703

PN=160
Group 10
System Diagrams
Component Identification Table

Each component (electrical device) and main connector


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

Continued on next page TX,901505,QQ381 1916SEP921/2

9015
10
1

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PN=161
System Diagrams

Identification Letter Type Examples


A System, subassembly, parts group Control units, trigger boxes, two-way radios, logic
module, FNR logic module
B Transducer for conversion of non-electrical variables Speed sensors, pressure sensors, pressure switches
to electrical and vice versa horns, sensors, pickups, limit-value sensors, pulse
generators, loudspeakers, inductive pickups, probes,
air-flow sensors, oil-pressure switches, temperature
sensors, ignition-voltage pickups
C Condenser, capacitor Condensers and capacitors, general
D Binary device, memory Digital devices, integrated circuits, pulse counters,
magnetic tape recorders
E Various devices and equipment Heating devices, air conditioners, light, headlights,
spark plugs, ignition distributors
F Protection device Release mechanisms, polarity protection devices,
fuses, current protection circuits
G Power supply, generator Batteries, generators, alternators, charging units
9015
H Monitor, alarm, signalling device Audible alarms, indicator lights, turn-signal lights, brake
10
lights, alarms, warning lights, buzzers
2
K Relay Battery relays, turn-signal relays, solenoid switches,
starting relays, warning flashers
L Inductor Choke coils, coils, windings
M Motor Blower motors, fan motors, starter motors
N Regulator, amplifier Regulators (electronic or electromechanical), voltage
stabilizers
P Measuring instrument Ammeter, diagnostic connectors, tachometers, fuel test
points, speedometers
R Resistor Flame glow plugs, sheathed-element flame glow plugs,
glow plugs, heating resistors, NTC resistors, PTC
resistors, potentiometers, regulating resistors
S Switch Switches and pushbuttons, general key switch, light
switch, horn switch, flasher switch
T Transformer Ignition coil, ignition transformer
U Modulator, converter DC transformers
V Semiconductor, electron tubes Transistors, diodes, electron tubes, rectifiers,
semiconductors, thyristors, zener diodes
W Transmission path, conductor, antenna Antennas, shielding components, shielded conductors,
cable harnesses, conductors, ground conductors
X Terminal, plug, plug and socket connection Terminal studs, electrical connections, connectors
electrical line couplers, line connectors, sockets, plugs,
terminals, plug-and-socket connections
Y Electrically actuated mechanical device Permanent magnets, (solenoid-operated) injection
valves, electromagnetic clutches and brakes, air
valves, fuel pumps, solenoids, switching valves, start
valves, locking systems
Z Electrical filter Interference suppression filters

TX,901505,QQ381 1916SEP922/2

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PN=162
System Diagrams

Fuse Specifications

9015
10
3

1922FEB94
T8168AA
F17.5 Amp MFWD/ F630 Amp Heater/AC Circuit F117.5 Amp Left Turn Fuse F1610 Amp Start Fuse
Alternator/Diff Lock Fuse Breaker F127.5 Amp Right Turn Fuse K3Park Light Relay
F215 Amp Fuel/Ether Aid F715 Amp Rear Light Fuse F1310 Amp RTD/Beacon K4Ether Aid Relay (S.N.
and Reverse Alarm Fuse F825 Amp Front Light/Tail Fuse 794639) Backup Alarm
F35 Amp Dome Light/Radio Light Fuse F145 Amp Monitor/Gauge Relay (S.N.794640 )
Fuse F910 Amp FNR/Park Brake Fuse K5Park Brake Relay
F45 Amp Radio Fuse Fuse F1515 Amp Hazard/Monitor K6Neutral Relay
(Unswitched Power) F1020 Amp Turn/Stop and Fuse (Unswitched K7Alternator Sense Relay
F515 Amp Wiper Fuse Horn Fuse Power) S21Flasher

IMPORTANT: Install fuse with correct amperage The fuse block is located on the side console inside an
rating to prevent electrical system access cover.
damage from overload.

TX,9015,QQ2435 1912APR941/1

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PN=163
System Diagrams

Wiring And Schematic Diagrams Legend

NOTE: A2Radio (SE3, W12)

A2 indicates component identification number.


Radio indicates component name.
SE3 indicates section number of SYSTEM
FUNCTIONAL SCHEMATIC where component
is located.
W12 indicates HARNESS WIRING DIAGRAM
and HARNESS COMPONENT LOCATION
drawings where component is located.

A2Radio (SE3,W12)
B1Backup Warning Alarm (SE5,W8)
B2Park Brake Sensing Switch (SE9,W8)
9015
10 B3Horn (SE12,W8)
4 B4Fuel Sender (SE15,W8)
B5Engine Coolant Temp. Switch (SE17,W8)
B6Engine Oil Pressure Switch (SE17,W8)
B7Air Filter Restriction Switch (SE17,W8)
B8Converter Temperature Switch (SE17,W8)
B9Hydraulic Filter Switch (SE17,W8)
B10Backup Alarm Switch (SE9,W8) (S.N.794639)
B11Brake Light Switches (SE13,W6)
B12Reverser Pressure Switch (S.N. 778668)
(SE9,W8)
B13Radio Speaker (W12)
B14Radio Speaker (W13)
E1Dome Light (SE3,W5)
E2Swivel Light (SE3,W5)
E3Left Front Work Light (SE8,W5)
E4Right Front Work Light (SE8,W5)
E5Left Rear Work Light (SE8,W5)
E6Right Rear Work Light (SE8,W5)
E7Left Front Drive Light (SE8,W5)
E8Right Front Drive Light (SE8,W5)
E9Left Tail Light (SE8,W5)
E10Right Tail Light (SE8,W5)
E11Left Brake Light (SE13,W5)
E12Right Brake Light (SE13,W5)
E13Beacon Light (SE14,W5)
E14Fuel Gauge Light (SE15,W8)
E15Seat Belt Light (SE9,W6) (S.N.789401 )
F1MFWD/ALT Fuse (SE2,W6)

Continued on next page TX,9015,QQ2436 1912APR941/6

TM1512 (07NOV03) 9015-10-4 Backhoe Loaders Operation and Test


110703

PN=164
System Diagrams

F2Fuel Shutoff/Start Aid/Reverse Alarm Fuse


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

Continued on next page TX,9015,QQ2436 1912APR942/6

TM1512 (07NOV03) 9015-10-5 Backhoe Loaders Operation and Test


110703

PN=165
System Diagrams

M7Heater Blower Motor (SE5,W6)


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

Continued on next page TX,9015,QQ2436 1912APR943/6

TM1512 (07NOV03) 9015-10-6 Backhoe Loaders Operation and Test


110703

PN=166
System Diagrams

V11Park Brake Relay Diode (SE9,W6) (S.N.


778669)
W1Machine Frame/Engine Block Ground 410D (SN
796854) (SE1,W8) Machine Frame/Engine Block
Ground 510D (SN796890) (SE1,W8) Machine Frame
To Eng. Ground Strap 410D (SN796855) (SE1,W8)
Machine Frame To Eng. Ground Strap 510D
(SN796891) (SE1,W8)
W2Ground To Cab Frame (SE14,W5)
W3Ground At Cab Floor (SE1,W8)
W4Engine Ground Strap (W8)
W5Cab Roof Harness (W5)
W6Cab Floor Harness (W6)
W6Cab Side Console Harness (W6)
W7Front Console Harness (W7)
W8Engine Harness (W8)
9015
W9Not Used 10
W10Blower Harness (W10) 7
W11A/C Compressor Harness (W11)
W12Radio Harness (W12)
W13Radio Antenna (W12)
W14Auxiliary Valve Harness (W14)
W15Ground to A/C Compressor (W8) (S.N.801200)
W16Alternator Harness 410D (SN796854) 510D
(SN796890) (W8)
X1Side Console Harness To Roof Harness
Connectors (W5,W6)
X2Side Console Harness To Roof Harness
Connectors (W5,W6)
X3Side Console Harness To Roof Harness
Connectors (W5,W6)
X4Side Console To Floor Harness Connectors (W6)
(SN778668)
X5Side Console To Floor Harness Connectors (W6)
(SN778668)
X6Blower Switch Connector (W10)
X7Display Module Connectors (W6)
X8Horn Switch Connector (W6)
X9Rear Light Switch Connector (W6)
X10Rear Wiper Switch Connector (W6)
X11Beacon Switch Connector (W6)
X12MFWD Switch Connector (W6)
X13Park Brake Switch Connector (W6)
X14Start Aid Switch Connector (W6)
X15Fuel Gauge Connector (W6)
X16Key Switch Connector (W6)

Continued on next page TX,9015,QQ2436 1912APR944/6

TM1512 (07NOV03) 9015-10-7 Backhoe Loaders Operation and Test


110703

PN=167
System Diagrams

X17Logic Module 4-Pin Connector (W6)


X18Logic Module 6-Pin Connector (W6)
X19Logic Module 4-Pin Connector (W6)
X20Logic Module 6-Pin Connector (W6)
X21Floor Harness To Engine Harness (W6,W8)
(SN778669)
X21Side Console To Engine Harness (W6,W8) (SN
778668)
X22Floor Harness To Engine Harness (W6,W8)
(SN778669)
X22Side Console To Engine Harness (W6,W8) (SN
778668)
X23Floor Harness To Engine Harness (W6,W8)
(SN778669)
X23Side Console To Engine Harness (W6,W8) (SN
778668)
9015
10 X24Not Used
8 X25Floor To Front Console Connectors
(W6,W7)(SN778668)
X25Side To Front Console Connectors
(W6,W7)(SN778669)
X26FNR Switch Connector (W7)
X27Turn Signal Switch Connector (W7)
X28Beacon Light Connector (W5)
X29Roof Harness to Radio Harness Connector
(W5,W12)
X30Splice (Inside Harness) (W6)
X31Forward Solenoid Connector (W8)
X32Clutch Disconnect Solenoid Connector (W8)
X33Connectors For A/C Switch (W6) (SN778668)
X34Engine Harness To A/C Compressor Harness
Connector (W8,W11)
X35Side Console Harness To Blower Harness
Connectors (W8,W10)
X36A/C Clutch Cycle Switch Connectors (W10)
X37Seat Belt Light Connector (W6)
X38A/C Switch Connector (W6)
X39Radio Harness To Radio Connector (W12)
X40ACC. Power/Ground Connectors (SE12,W8)
(SN749639)
X41Hourmeter Or Auxiliary Valve Connector
(SE13,W6)
X41AAuxiliary Valve Harness Connector (W14)
X42Auxiliary Valve Harness Connector (W14)
X43Reverse Solenoid Connector (W8)
Y1MFWD Solenoid (SE2,W8)

Continued on next page TX,9015,QQ2436 1912APR945/6

TM1512 (07NOV03) 9015-10-8 Backhoe Loaders Operation and Test


110703

PN=168
System Diagrams

Y2Start Aid Solenoid (SE5,W8)


Y3Fuel Shutoff Solenoid (SE5,W8)
Y4Park Brake Solenoid (SE9,W8)
Y5Reverse/Solenoid (SE9,W8)
Y6Forward/Solenoid (SE9,W8)
Y7Clutch Disconnect Solenoid (SE9,W8)
Y8Hydraulic Pump destroke Solenoid (SE9,W8)
Y9Return-To-Dig Solenoid (SE14,W8)
Y10A/C Compressor (W11)
Y11Auxiliary Valve Solenoid (W14)

TX,9015,QQ2436 1912APR946/6

System Functional Schematic Section


Legend 9015
10
9
NOTE: SE1Battery/Ignition, Power, Charging and Start
Circuit (12 Volt System)

SE1 indicates section number of system


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

SE1Battery/Ignition, Power, Charging and Start


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

TX,9015,QQ2438 1912APR941/1

TM1512 (07NOV03) 9015-10-9 Backhoe Loaders Operation and Test


110703

PN=169
System Diagrams

System Functional Schematic


T8535AA 1906JAN99

TX,9015,QQ3192 1931AUG951/7

TM1512 (07NOV03) 9015-10-10 Backhoe Loaders Operation and Test


110703

PN=170
System Diagrams
T8535AB 1906JAN99

TX,9015,QQ3192 1931AUG952/7

TM1512 (07NOV03) 9015-10-11 Backhoe Loaders Operation and Test


110703

PN=171
System Diagrams
T8535AC 1906JAN99

TX,9015,QQ3192 1931AUG953/7

TM1512 (07NOV03) 9015-10-12 Backhoe Loaders Operation and Test


110703

PN=172
System Diagrams
T8166BG 1919FEB99

TX,9015,QQ3192 1931AUG954/7

TM1512 (07NOV03) 9015-10-13 Backhoe Loaders Operation and Test


110703

PN=173
System Diagrams
T8535AE 1906JAN99

TX,9015,QQ3192 1931AUG955/7

TM1512 (07NOV03) 9015-10-14 Backhoe Loaders Operation and Test


110703

PN=174
System Diagrams
T8535AF 1906JAN99

TX,9015,QQ3192 1931AUG956/7

TM1512 (07NOV03) 9015-10-15 Backhoe Loaders Operation and Test


110703

PN=175
System Diagrams
T8535AG 1906JAN99

TX,9015,QQ3192 1931AUG957/7

TM1512 (07NOV03) 9015-10-16 Backhoe Loaders Operation and Test


110703

PN=176
System Diagrams

Cab Roof Harness (W5) Wiring Diagram


T7812AH 1923APR97

E1 E2 M2
DOME SWIVEL REAR
LIGHT LIGHT WIPER MOTOR E6 M4 H4 E8 E4
GRY
R.H. R.H. DOOR R.H. R.H. R.H.
REAR WIPER MOTOR FRONT FRONT FRONT X2
E10 H5 E12 WORK TURN DRIVE WORK ROOF HARNESS
R.H. R.H. R.H. LIGHT LIGHT LIGHT LIGHT TO SIDE CONSOLE
REAR REAR BRAKE HARNESS CONNECTOR
M
TAIL TURN LIGHT
LIGHT LIGHT X29 P25 RED B
M E1, X29 P15 RED A

RED
BLU
YEL

BRN
GRN
RED

BRN
YEL

BLU
* WIRES A68 AND A69

G20 BLK
G20 BLK

P15 RED
(SHOWN AS DASHED
LINES) ARE USED FOR
(S.N. 816286) X3
ROOF HARNESS
TO SIDE CONSOLE
S27 S28 HARNESS CONNECTOR
G20 BLK
DOME SWIVEL M4 * A69 ORG H

A66 ORG
P14 RED
A63 ORG

A65 ORG
G20 BLK
G20 BLK
G20 BLK
L42 BRN

A64 ORG
G20 BLK
L43 BRN

G20 BLK
L47 BRN

L41 BRN
G20 BLK
G20 BLK
L47 BRN

P14 RED

LIGHT LIGHT

* A69 ORG
M3 * A68 ORG G
SWITCH SWITCH

L47 BRN
L46 BRN

G20 BLK

G20 BLK
L43 BRN
M2 A66 ORG F
M2 A65 ORG E

E6
W2
X3
X3
X1
W2
H4
E4
W2
X3
X3
X3
X1
E8
W2
X1
M4
X1

X2
W2
X1
M2
X1
X1
H4

X1
H5

M4 A64 ORG D

W2
X3
X3
X3

X1
X1
H2
X1
X1
W2

W2
W2
E3
X1
X2
X2
W2
X1
W2
X1

X1

W2
H3
X1
E7

E5
M4 A63 ORG C
M3 A62 ORG B

E10, H5
E11

E12, M4
E7, H2
E9, H3

H4, E13
X29, M3

S28, M2
M3 A61 ORG A
X1

L46 BRN
G20 BLK
A61 ORG

L41 BRN
G20 BLK
L48 BRN
L48 BRN
G20 BLK

L48 BRN
G20 BLK
A62 ORG

L43 BRN
G20 BLK

L43 BRN
L45 BRN

G20 BLK

L42 BRN

G20 BLK
G20 BLK
G20 BLK
P14 RED
P15 RED
L43 BRN
G20 BLK

P25 RED

ROOF HARNESS
*A68 ORG

G20 BLK
TO SIDE CONSOLE
HARNESS CONNECTOR
M3 P14 RED H
M2, M4
E6, E5 L41 BRN G
H2, H3 L48 BRN F
A B C D X29 L43 BRN E
E7, E9, E10, E8
RED

YEL
BLU
GRN

W2 X29 E13 L45 BRN D


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

TX,9015,QQ2093 1912APR941/1

TM1512 (07NOV03) 9015-10-17 Backhoe Loaders Operation and Test


110703

PN=177
System Diagrams

Cab Roof Harness (W5) Component Location


T7812AI 1925APR97

TX,9015,QQ2094 1904MAY931/1

TM1512 (07NOV03) 9015-10-18 Backhoe Loaders Operation and Test


110703

PN=178
System Diagrams

Cab Side Console Harness (W6) Wiring Diagram (SN 778668)


T7994AA 1919FEB99

TX,9015,QQ2100 1904MAY931/1

TM1512 (07NOV03) 9015-10-19 Backhoe Loaders Operation and Test


110703

PN=179
System Diagrams

Cab Side Console Harness (W6) Component Location (SN 778668)


T7915BF 1919FEB99

TX,9015,QQ2095 1904MAY931/1

TM1512 (07NOV03) 9015-10-20 Backhoe Loaders Operation and Test


110703

PN=180
System Diagrams

Cab Floor Harness (W6) Wiring Diagram (SN 778668)


T7915BG 1905MAR99

TX,9015,QQ2096 1904MAY931/1

TM1512 (07NOV03) 9015-10-21 Backhoe Loaders Operation and Test


110703

PN=181
System Diagrams

Cab Floor Harness (W6) Component Location (SN 778668)


T8170AO 1918DEC98

TX,9015,QQ2554 1912APR941/1

TM1512 (07NOV03) 9015-10-22 Backhoe Loaders Operation and Test


110703

PN=182
System Diagrams

Cab Side Console Harness (W6) Wiring Diagram (SN 778669XXXXXX)


T8167AO 1919FEB99

TX,9015,QQ3224 1931AUG951/2

TM1512 (07NOV03) 9015-10-23 Backhoe Loaders Operation and Test


110703

PN=183
System Diagrams
T8167AP 1902MAR99

TX,9015,QQ3224 1931AUG952/2

TM1512 (07NOV03) 9015-10-24 Backhoe Loaders Operation and Test


110703

PN=184
System Diagrams

Cab Side Console Harness (W6) Wiring Diagram (SN XXXXXX )


T8462AJ 1925APR97

TX,9015,QQ3231 1931AUG951/2

TM1512 (07NOV03) 9015-10-25 Backhoe Loaders Operation and Test


110703

PN=185
System Diagrams
T8535AH 1906JAN99

TX,9015,QQ3231 1931AUG952/2

TM1512 (07NOV03) 9015-10-26 Backhoe Loaders Operation and Test


110703

PN=186
System Diagrams

Cab Side Console Harness (W6) Component Location (SN 778669 )


T8535AI 1906JAN99

TX,9015,QQ3200 1931AUG951/2

TM1512 (07NOV03) 9015-10-27 Backhoe Loaders Operation and Test


110703

PN=187
System Diagrams
T7915BL 1919FEB99

TX,9015,QQ3200 1931AUG952/2

TM1512 (07NOV03) 9015-10-28 Backhoe Loaders Operation and Test


110703

PN=188
System Diagrams

Front Console Harness (W7) Wiring Diagram


T7994AU 1919FEB99

TX,9015,QQ2103 1904MAY931/1

TM1512 (07NOV03) 9015-10-29 Backhoe Loaders Operation and Test


110703

PN=189
System Diagrams

Front Console Harness (W7) Component Location


T7915BN 1919FEB99

TX,9015,QQ2111 1904MAY931/1

TM1512 (07NOV03) 9015-10-30 Backhoe Loaders Operation and Test


110703

PN=190
System Diagrams

Engine Harness (W8) Wiring Diagram


T8167AQ 1919FEB99

TX,9015,QQ2447 1912APR941/2

TM1512 (07NOV03) 9015-10-31 Backhoe Loaders Operation and Test


110703

PN=191
System Diagrams
T8167AR 1919FEB99

TX,9015,QQ2447 1912APR942/2

TM1512 (07NOV03) 9015-10-32 Backhoe Loaders Operation and Test


110703

PN=192
System Diagrams

Engine Harness (W8) Component Location


T8168AB 1919FEB99

TX,9015,QQ2450 1912APR941/1

TM1512 (07NOV03) 9015-10-33 Backhoe Loaders Operation and Test


110703

PN=193
System Diagrams

Blower Harness (W10) Wiring Diagram


T7812AT 1925APR97

TX,9015,QQ2115 1931AUG951/1

TM1512 (07NOV03) 9015-10-34 Backhoe Loaders Operation and Test


110703

PN=194
System Diagrams

Blower Harness (W10) Component Location


T7812AV 1925APR97

TX,9015,QQ2116 1904MAY931/1

TM1512 (07NOV03) 9015-10-35 Backhoe Loaders Operation and Test


110703
PN=195
System Diagrams

Radio Harness (W12) Wiring Diagram


T7931BO 1919FEB99

TX,9015,QQ2117 1904MAY931/1

TM1512 (07NOV03) 9015-10-36 Backhoe Loaders Operation and Test


110703

PN=196
System Diagrams

Radio Harness (W12) Component Location


T7931BN 1919FEB99

TX,9015,QQ2118 1904MAY931/1

TM1512 (07NOV03) 9015-10-37 Backhoe Loaders Operation and Test


110703
PN=197
System Diagrams

Air Conditioning Compressor Harness (W11) Wiring Diagram


T7812AU 1925APR97

TX,9015,QQ2119 1912APR941/1

TM1512 (07NOV03) 9015-10-38 Backhoe Loaders Operation and Test


110703

PN=198
System Diagrams

Air Conditioning Compressor Harness (W11) Component Location


T8169AR 1919FEB99

TX,9015,QQ2553 1912APR941/1

TM1512 (07NOV03) 9015-10-39 Backhoe Loaders Operation and Test


110703
PN=199
System Diagrams

Auxiliary Valve Harness (W14) Wiring Diagram


T8166BR 1918DEC98

TX,9015,QQ2449 1912APR941/1

TM1512 (07NOV03) 9015-10-40 Backhoe Loaders Operation and Test


110703

PN=200
System Diagrams

Auxiliary Valve Harness (W14) Component Location


T8166BP 1918DEC98

TX,9015,QQ2451 1912APR941/1

TM1512 (07NOV03) 9015-10-41 Backhoe Loaders Operation and Test


110703
PN=201
System Diagrams

9015
10
42

TM1512 (07NOV03) 9015-10-42 Backhoe Loaders Operation and Test


110703

PN=202
Group 15
Sub-System Diagnostics

Power Circuit Operational Information

The following conditions must exist for power circuit to


function:

Voltage must be present at these distribution points for


other circuits to operate.

BAT terminal of key switch


Terminal 30 of accessory relay
Start relay
BAT terminal of alternator (S.N. 787551)
B+ terminal of alternator (S.N.787552 )
Starter
Radio fuse
Hazard/monitor fuse
9015
15
1

TX,9015,QQ2105 1904MAY931/1

Power Circuit Theory Of Operation

The power circuit includes battery and main current paths


to primary distribution points.

With key switch OFF, power from battery goes to key


switch, accessory relay, start relay, alternator, starter
motor, 4-way flasher switch, logic module, alternator
sense relay and dome light fuse.

When key switch is moved from OFF position, power


continues through IGN and ST terminals to main fuse
block. ACC terminal power goes to accessory relay,
energizing relay sending power to the main fuse block.

The key switch G terminal is a ground terminal only in


Bulb Check and Start positions.

NOTE: For component identification code description, see


Wiring and Schematic Diagrams Legend , Group
9015-10.

TX,9015,QQ1726 1912MAR931/1

TM1512 (07NOV03) 9015-15-1 Backhoe Loaders Operation and Test


110703

PN=203
Sub-System Diagnostics

Power Circuit Schematic

9015
15
2

1921SEP95
T8538AB

Continued on next page TX,9015,QQ3234 1931AUG951/3

TM1512 (07NOV03) 9015-15-2 Backhoe Loaders Operation and Test


110703

PN=204
Sub-System Diagnostics

9015
15
3

1922AUG95
T8538AC

Continued on next page TX,9015,QQ3234 1931AUG952/3

TM1512 (07NOV03) 9015-15-3 Backhoe Loaders Operation and Test


110703

PN=205
Sub-System Diagnostics

9015
15
4

1922AUG95
T8538AD

TX,9015,QQ3234 1931AUG953/3

TM1512 (07NOV03) 9015-15-4 Backhoe Loaders Operation and Test


110703

PN=206
Sub-System Diagnostics

Power Circuit Diagnostic Procedures

1/1

Battery State Of Charge YES: Clean battery cable


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

Move light switch to ON position. Turn key to START. Do work lights go out or get very If lights still get dim, test
dim while cranking engine? battery.

If battery charge is low,


recharge or replace it.

NO: Battery charge is


good. Go to next check . 9015
15
5

1/1

Starter Motor Key switch OFF. YES: Check complete.

With harness connected, check voltage at terminal of NO: Check wiring


starter with red cable. harness between battery
and starter motor.
Are 12 volts measured?

T7199BK 1917SEP90

1/1

Alternator (SN 778740) Key switch OFF. YES: Go to next check .

With harness connected, check voltage at B+ terminal of NO: Check wiring


alternator. harness between battery
and alternator.
Are 12 volts measured?

T7199BL 1909OCT90

1/1

TM1512 (07NOV03) 9015-15-5 Backhoe Loaders Operation and Test


110703

PN=207
Sub-System Diagnostics

Alternator (SN 778741 Key switch OFF. YES: Go to next check .


787551)
With harness connected, check voltage at B+ terminal of NO: Check wiring
alternator. harness between battery
and alternator.
Are 12 volts measured?

T7934AV 1915FEB93

1/1

Alternator (SN 787552 ) Key switch OFF. YES: Go to next check .


9015
With harness connected, check voltage at B+ terminal of NO: Check wiring
15
alternator. harness between battery
6
and alternator.
Are 12 volts measured?

T7828AA 1923SEP92

1/1

Start Relay Key switch OFF. YES: Go to next check .

With harness connected, check voltage at terminal with NO: Check wiring
BO3 red wire. harness between battery
and start relay.
Are 12 volts measured?

T7199BM 1917SEP90

1/1

TM1512 (07NOV03) 9015-15-6 Backhoe Loaders Operation and Test


110703

PN=208
Sub-System Diagnostics

Key Switch Check Key switch OFF. YES: Go to next step in


this check.
With harness connected, check voltage of B11 red wire
at BAT terminal of key switch. NO: Check wiring
harness between battery
Are 12 volts measured? and key switch.

T7199BO UN17SEP90

Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next step in
this check.
Remove FNR/park brake fuse.
NO: Replace key switch
Remove start fuse.

Turn key switch to START position.


9015
T7199BO UN17SEP90
With harness connected, check voltage at IGN and ST
15
terminals.
7
Are 12 volts measured at each terminal?

Key switch ON. YES: Go to next check .

With harness connected, check voltage at ACC terminal NO: Replace key switch.
of key switch.

Are 12 volts measured?

T7199BO UN17SEP90

1/1

TM1512 (07NOV03) 9015-15-7 Backhoe Loaders Operation and Test


110703

PN=209
Sub-System Diagnostics

Accessory Relay Key switch OFF. YES: Go to next step in


this check.
With harness connected, check voltage at large terminal
with B11 red wire. NO: Check wiring
harness between battery
Are 12 volts measured? and accessory relay.

T7199BN UN16AUG90

Key switch ON. YES: Go to next step in


this check.
With harness connected, check voltage at small terminal
with B14 red wire. NO: Check wiring
harness between battery
Are 12 volts measured? and accessory relay.

9015
15 T7199BN UN16AUG90
8

Disconnect harness from relay. YES: Relay is good.

Connect battery voltage to small terminal. Ground NO: Replace accessory


mounting bracket. relay.

Does relay click?

Measure continuity between the two large terminals.


T7199BN UN16AUG90
Is continuity measured?

1/1

Start Circuit Operational Information

The following conditions must exist for start circuit to


function:

FNR lever in neutral


Key switch in START position

TX,9015,QQ1942 1916MAR931/1

TM1512 (07NOV03) 9015-15-8 Backhoe Loaders Operation and Test


110703

PN=210
Sub-System Diagnostics

Start Circuit Theory Of Operation

The start circuit converts the electrical energy from the


battery to mechanical energy by the starter. A heavy
current draw takes place in the starter.

With key switch OFF, power flows from battery to starter


motor terminal, start relay spade terminal, accessory
relay, and key switch BAT terminal.

With key in ON or IGN, power flows from IGN terminal


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

With key switch in START, power flows from ST terminal


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

NOTE: For component identification code description, see


Legend For Schematic and Wiring Diagram ,
Group 9015-10.

TX,9015,QQ1985 1916MAR931/1

TM1512 (07NOV03) 9015-15-9 Backhoe Loaders Operation and Test


110703

PN=211
Sub-System Diagnostics

Start Circuit Schematic

9015
15
10

1922AUG95
T8538AE

Continued on next page TX,9015,QQ3237 1931AUG951/2

TM1512 (07NOV03) 9015-15-10 Backhoe Loaders Operation and Test


110703

PN=212
Sub-System Diagnostics

9015
15
11

1922AUG95
T8538AF

TX,9015,QQ3237 1931AUG952/2

TM1512 (07NOV03) 9015-15-11 Backhoe Loaders Operation and Test


110703

PN=213
Sub-System Diagnostics

Start Circuit Diagnostic Procedures

1/1

Key Switch Check Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next check .

Remove FNR/park brake fuse. NO: Replace key switch.

Remove start fuse.

Turn key switch to START position.

T7199BO UN17SEP90
With harness connected, check voltage at IGN and ST
terminals.
9015
15 Are 12 volts measured at each terminal?
12

1/1

TM1512 (07NOV03) 9015-15-12 Backhoe Loaders Operation and Test


110703

PN=214
Sub-System Diagnostics

FNR Lever Key switch ON. FNR lever in neutral YES: Go to next step in
this check.
With harness connected, check voltage at terminals with
P24 red wire and T12 blue wire. NO: Check wiring
harness.
Are 12 volts measured at each terminal?

9015
T7199BP 1902OCT90 15
13

Key switch ON. YES: FNR lever is good.


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

Move FNR lever to reverse, check voltage at T13 blue


wire.

Are 12 volts measured at each terminal?

T7199BQ 1902OCT90

1/1

Neutral Start Relay Key switch OFF. YES: Relay is good.


Check wiring harness.
Disconnect harness from relay.
NO: Replace neutral start
Connect battery voltage to terminal #86. Ground terminal relay
#85. Does relay click?

Measure continuity between terminals #30 and #87.


T7287BH UN16AUG90
Is continuity measured?

1/1

TM1512 (07NOV03) 9015-15-13 Backhoe Loaders Operation and Test


110703

PN=215
Sub-System Diagnostics

Hydraulic Pump Key switch OFF. YES: Solenoid is good.


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

Does solenoid click?


T7418AN 1927NOV90

1/1

Start Relay Key switch OFF. YES: Relay is good.


9015
Disconnect harness from relay. NO: Replace start relay.
15
14
Connect battery voltage to one of the small blade
terminals and ground the other. Does relay click?

Measure continuity between two large terminals. Is


continuity measured?
T7287BK 1916AUG90

1/1

Start Solenoid Check YES: Solenoid is OK.


CAUTION: Starter will crank engine if metal strap is NOT disconnected Check starter motor .
from starter motor.
NO: Replace starter
Disconnect metal strap from starter motor terminal. solenoid.

Connect battery voltage to solenoid small terminal.

Ground metal strap from solenoid with heavy gauge


wire.

Does solenoid click?


T6534BI UN19OCT88
Remove jumper wires.

1/1

Starter Motor YES: Starter motor is


CAUTION: Starter will crank engine if metal strap is NOT disconnected good. Check wiring
from starter motor. harness.

Disconnect metal strap from starter motor large terminal. NO: Repair or replace
starter motor.
Connect a heavy gauge jumper wire from battery
positive cable to starter motor terminal.

Does starter motor turn, but NOT crank engine?

T6534BJ UN07JAN97

1/1

TM1512 (07NOV03) 9015-15-14 Backhoe Loaders Operation and Test


110703

PN=216
Sub-System Diagnostics

Charging Circuit Operational Information

The following conditions must exist for charging circuit to


function:

Key switch in ON position


Engine running

TX,9015,QQ1827 1912MAR931/1

Charging Circuit Theory Of Operation


9015
The charging circuit consists of the battery, alternator, The alternator terminal (D+) gets power from ACC 15
alternator relay, key switch, accessory relay, and terminal of the key switch by energizing the accessory 15
indicator light in the monitor panel. relay, closing relay contacts and sending power to
MFWD/Alternator/Diff. Lock fuse.
78 AMP DELCO ALTERNATOR (S.N. 787551)
With key switch ON and engine running, power flows
The alternator BAT terminal is connected to battery from terminal (W) of alternator to alternator relay,
voltage at all times. The voltage sensing terminal No. 2 energizing it. Terminals 30 and 87 are connected, and
is connected to the BAT terminal of alternator. indicator light goes out.

The alternator terminal No. 1 gets power from ACC When key is on but engine is not running or if
terminal of the key switch. With key switch ON and alternator fails, alternator relay de-energizes and
engine running, power flows from terminal R of terminals 30 and 87A are connected. This grounds the
alternator to alternator relay, energizing it. Terminals indicator light and light comes on.
30 and 87 are connected, and indicator light goes out.
NOTE: For component identification code description,
When key is on but engine is not running or if see Wiring and Schematic Diagrams Legend ,
alternator fails, alternator relay de-energizes and Group 9015-10.
terminals 30 and 87A are connected. This grounds the
indicator light and light comes on.

95 AMP BOSCH ALTERNATOR (S.N.787552 )

The alternator (B+) terminal is connected to battery


voltage at all times.

TX,9015,QQ2124 1912APR941/1

TM1512 (07NOV03) 9015-15-15 Backhoe Loaders Operation and Test


110703

PN=217
Sub-System Diagnostics

Charge Circuit Schematic

9015
15
16

1922AUG95
T8538AG

Continued on next page TX,9015,QQ3239 1931AUG951/5

TM1512 (07NOV03) 9015-15-16 Backhoe Loaders Operation and Test


110703

PN=218
Sub-System Diagnostics

9015
15
17

1922AUG95
T8538AH

Continued on next page TX,9015,QQ3239 1931AUG952/5

TM1512 (07NOV03) 9015-15-17 Backhoe Loaders Operation and Test


110703

PN=219
Sub-System Diagnostics

9015
15
18

1922AUG95
T8538AI

Continued on next page TX,9015,QQ3239 1931AUG953/5

TM1512 (07NOV03) 9015-15-18 Backhoe Loaders Operation and Test


110703

PN=220
Sub-System Diagnostics

9015
15
19

1922AUG95
T8538AJ

Continued on next page TX,9015,QQ3239 1931AUG954/5

TM1512 (07NOV03) 9015-15-19 Backhoe Loaders Operation and Test


110703

PN=221
Sub-System Diagnostics

9015
15
20

1922AUG95
T8538AK

TX,9015,QQ3239 1931AUG955/5

TM1512 (07NOV03) 9015-15-20 Backhoe Loaders Operation and Test


110703

PN=222
Sub-System Diagnostics

Charging Circuit Diagnostic Procedures

1/1

Alternator Output Key switch OFF. YES: Alternator is good.


Check wiring harness.
Measure and record battery voltage. Check battery.

Start and run engine at 1500 rpm, and check battery NO: Check alternator .
voltage.

Does battery voltage increase?


T6569AZ UN23AUG93

9015
15
21

1/1

Alternator And Regulator YES: Alternator is good,


Check (SN 787551) replace regulator.

NO: Alternator is failed.


Repair or replace.

T7320AR 1901AUG90

Using a multimeter, connect to battery voltage at large terminal of starter, and ground
other lead.

Start and run engine at 1500 rpm. Turn drive lights ON.

Insert a small screwdriver in alternator test hole and ground tab to alternator case.

Does voltage steadily increase and lights get brighter when tab is grounded?

1/1

TM1512 (07NOV03) 9015-15-21 Backhoe Loaders Operation and Test


110703

PN=223
Sub-System Diagnostics

Alternator (SN 787552 ) Key switch ON. Engine running. Park brake ON. YES: Alternator is good.

Using a multimeter, check for DC voltage at terminals NO: Alternator is failed.


(D+) and (B+). Repair or replace.

Is 14 DC volts measured?

Using a multimeter, check for AC voltage at terminal


(W).

Is 7.63 AC volts measured?

9015
15 T7835AT 1923SEP92
22

1/1

Alternator Relay IMPORTANT: Relay is a six volt relay. Do not apply YES: Relay is good.
more than 6 volts when testing. Check wiring harness.

Disconnect harness from relay. NO: Replace relay.

Measure continuity between terminals #30 and #87A. Is


continuity measured?

T7596AQ 1903OCT91
Connect battery voltage to terminal #86. Ground terminal
#85. Does relay click?

Measure continuity between terminals #30 and #87. Is


continuity measured?

1/1

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


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

NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1

TM1512 (07NOV03) 9015-15-22 Backhoe Loaders Operation and Test


110703

PN=224
Sub-System Diagnostics

Key Switch Check Key switch OFF. YES: Go to next step in


this check.
With harness connected, check voltage of B11 red wire
at BAT terminal of key switch. NO: Check wiring
harness between battery
Are 12 volts measured? and key switch.

T7199BO UN17SEP90

Remove fuel shut off/start aid/reverse alarm fuse. YES: Go to next step in
this check.
Remove FNR/park brake fuse.
NO: Replace key switch
Remove start fuse.

Turn key switch to START position.


9015
T7199BO UN17SEP90
With harness connected, check voltage at IGN and ST
15
terminals.
23
Are 12 volts measured at each terminal?

Key switch ON. YES: Go to next check .

With harness connected, check voltage at ACC terminal NO: Replace key switch.
of key switch.

Are 12 volts measured?

T7199BO UN17SEP90

1/1

TM1512 (07NOV03) 9015-15-23 Backhoe Loaders Operation and Test


110703

PN=225
Sub-System Diagnostics

Accessory Relay Key switch OFF. YES: Go to next step in


this check.
With harness connected, check voltage at large terminal
with B11 red wire. NO: Check wiring
harness between battery
Are 12 volts measured? and accessory relay.

T7199BN UN16AUG90

Key switch ON. YES: Go to next step in


this check.
With harness connected, check voltage at small terminal
with B14 red wire. NO: Check wiring
harness between battery
Are 12 volts measured? and accessory relay.

9015
15 T7199BN UN16AUG90
24

Disconnect harness from relay. YES: Relay is good.

Connect battery voltage to small terminal. Ground NO: Replace accessory


mounting bracket. relay.

Does relay click?

Measure continuity between the two large terminals.


T7199BN UN16AUG90
Is continuity measured?

1/1

Display Module And Logic Module Circuit


Operational Information (SN XXXXXX) With
Logic Module

The following conditions must exist for display module and


logic module to function.

The key switch must be in BULB CHECK or START


position to arm the logic module so failures will be
indicated.

TX,9015,QQ3185 1931AUG951/1

TM1512 (07NOV03) 9015-15-24 Backhoe Loaders Operation and Test


110703

PN=226
Sub-System Diagnostics

Display Module And Logic Module Circuit Theory Of Operation (SN XXXXXX) With
Logic Module

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

Engine Started And Key Switch ON

All indicator switches (sensors) are open and the


ground circuits to the indicator lights and logic module
are broken.

TX,9015,QQ3186 1931AUG951/1

Display Module And Logic Module Circuit


Operational Information (SN XXXXXX )
Without Logic Module

The following conditions must exist for display module to


function.

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


be indicated.

TX,9015,QQ3187 1931AUG951/1

TM1512 (07NOV03) 9015-15-25 Backhoe Loaders Operation and Test


110703

PN=227
Sub-System Diagnostics

Display Module Circuit Theory Of Operation


(SN XXXXXX ) Without Logic Module

Power is supplied to the display module through the


Monitor Switched fuse.

Elimination of the logic module allows the monitor on the


backhoe to be active when the key switch is turned to the
ON position. Moving the key switch to the BULB CHECK
position to activate the monitor is no longer necessary.

CONDITION: Key ON Engine OFF:

WITH LOGIC MODULE WITHOUT LOGIC MODULE


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

CONDITION: BULB CHECK:

WITH LOGIC MODULE WITHOUT LOGIC MODULE


Red warning light is flashing, Red warning light is ON but NOT
yellow warning is ON, and alarm flashing, yellow warning is ON,
is beeping. and alarm is beeping.

CONDITION: Engine Running and engine water


temperature and alternator lights are ON:

WITH LOGIC MODULE WITHOUT LOGIC MODULE


Red warning light is flashing and Red warning light is on but NOT
alarm is beeping. flashing, yellow warning is ON,
and alarm is beeping.

When failure occurs the indicator switch (sensor) closes,


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

Continued on next page TX,9015,QQ3188 1931AUG951/5

TM1512 (07NOV03) 9015-15-26 Backhoe Loaders Operation and Test


110703

PN=228
Sub-System Diagnostics

9015
15
27

1922AUG95
T8538AL

Continued on next page TX,9015,QQ3188 1931AUG952/5

TM1512 (07NOV03) 9015-15-27 Backhoe Loaders Operation and Test


110703

PN=229
Sub-System Diagnostics

NOTE: For component identification code description,


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

Continued on next page TX,9015,QQ3188 1931AUG953/5

9015
15
28

TM1512 (07NOV03) 9015-15-28 Backhoe Loaders Operation and Test


110703

PN=230
Sub-System Diagnostics

9015
15
29

1922AUG95
T8538AM

Continued on next page TX,9015,QQ3188 1931AUG954/5

TM1512 (07NOV03) 9015-15-29 Backhoe Loaders Operation and Test


110703

PN=231
Sub-System Diagnostics

9015
15
30

1925MAR97
T8462AM

TX,9015,QQ3188 1931AUG955/5

TM1512 (07NOV03) 9015-15-30 Backhoe Loaders Operation and Test


110703

PN=232
Sub-System Diagnostics

Display Module And Logic Module Circuit Diagnostic Procedures

This circuit is powered by the monitor fuse, and the hazard/monitor unswitched fuse.

1/1

Fuse Remove fuse cover. YES: Replace fuse.

Check 5 amp monitor fuse, and 15 amp hazard/monitor NO: Go to next check
fuse.

Is fuse blown?

T7199BR 1916AUG90

9015
15
31

1/1

Display Module And Remove diode from connector. YES: If continuity is


Logic Module Diode measured in both checks,
Connect an ohmmeter to diode terminals. diode has failed in a
shorted mode. Replace.
Is continuity measured?
NO: If continuity is NOT
Reverse ohmmeter probes. measured in either check
diode has failed in an
T7961AA UN10MAR93
Is continuity measured? open mode. Replace.

NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1

Logic Module (SN XXXXXX)

See Logic Module Test in Machine and Logic Module


Bench Test , in Group 9015-20.

TX,901515,QQ363 1931AUG951/1

TM1512 (07NOV03) 9015-15-31 Backhoe Loaders Operation and Test


110703

PN=233
Sub-System Diagnostics

Indicator Circuit Specifications


Specification
Engine Coolant Temperature
Switch (Normally Open)Closing
Temperature ..................................................................... 101.7C (215F)
Engine Oil Pressure Switch
(Normally Closed)Opening
Temperature .................................................... 3772 KPa (0.40.7 bar)
(5.510.5 psi)
Air Filter Restriction Switch
(Normally Open)Closes on
Increased Vacuum................................. 4.987.48 kPa Vacuum (2030
in. H2O)
Converter Oil Temperature Switch
(Normally Open)Closes on
Increasing Temperature ................................................ 114.3C121.2C
(238F252F)
9015 Hydraulic Filter Restriction Switch
15 (Normally Open)Closing
32 Temperature ................................................... 344 kPa (3.45 bar) (50 psi)

TX,9015,QQ1972 1916MAR931/1

Indicator Circuit Operational Information

The Indicator Circuit has TWO modes of operation.

Bulb check mode


Failure mode

The following conditions must exist for indicator circuit to


function in bulb check mode:

Key switch moved to BULB CHECK position

The following conditions must exist for indicator circuit to


function in a failure mode:

Engine must be running for a failure to be indicated on a


display module light. An indicator switch or alternator relay
senses a failure and supplies a ground for an indicator
light, warning light and buzzer.

TX,901515,QQ534 1907DEC901/1

TM1512 (07NOV03) 9015-15-32 Backhoe Loaders Operation and Test


110703

PN=234
Sub-System Diagnostics

Indicator Circuit Theory Of Operation (SN XXXXXX) With Logic Module

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

Bulb Check Mode:

Key switch in BULB CHECK position connects logic


module and display module to ground. The ground is

TX,9015,QQ3189 1931AUG951/1

TM1512 (07NOV03) 9015-15-33 Backhoe Loaders Operation and Test


110703

PN=235
Sub-System Diagnostics

Indicator Circuit Theory Of Operation (SN XXXXXX) Without Logic Module

Indicator lights and switches of the display module are: Bulb Check Mode:

Engine Coolant Temperature (Stop) Key switch in BULB CHECK position connects warning
Engine Oil Pressure (Stop) lights, buzzer and display module to ground. All display
Engine Alternator Volts (Service Required) module lights and buzzer are checked.
Engine Air Filter (Service Required)
Converter Oil Temperature (Stop) Failure Mode:
Hydraulic Oil Filter (Service Required)
During normal operation the indicator lights are turned
STOP Warning Level: on when an indicator switch or the alternator relay
provides a ground circuit for the light. This ground
Red STOP light ON, audible alarm ON and function circuit turns on the red STOP light and alarm or the
indicator light ON. yellow SERVICE REQUIRED light.
9015
15 SERVICE Warning Level: NOTE: For component identification code description,
34 see Wiring and Schematic Diagrams Legend ,
Yellow WARNING light and a function indicator light Group 9015-10.
ON.

TX,9015,QQ3190 1931AUG951/1

TM1512 (07NOV03) 9015-15-34 Backhoe Loaders Operation and Test


110703

PN=236
Sub-System Diagnostics

Indicator Circuit Schematic

9015
15
35

1922AUG95
T8538AN

Continued on next page TX,9015,QQ3245 1931AUG951/4

TM1512 (07NOV03) 9015-15-35 Backhoe Loaders Operation and Test


110703

PN=237
Sub-System Diagnostics

9015
15
36

1922AUG95
T8538AO

Continued on next page TX,9015,QQ3245 1931AUG952/4

TM1512 (07NOV03) 9015-15-36 Backhoe Loaders Operation and Test


110703

PN=238
Sub-System Diagnostics

9015
15
37

1908SEP95
T8538AP

Continued on next page TX,9015,QQ3245 1931AUG953/4

TM1512 (07NOV03) 9015-15-37 Backhoe Loaders Operation and Test


110703

PN=239
Sub-System Diagnostics

9015
15
38

1925MAR97
T8462AO

TX,9015,QQ3245 1931AUG954/4

TM1512 (07NOV03) 9015-15-38 Backhoe Loaders Operation and Test


110703

PN=240
Sub-System Diagnostics

Indicator Circuit Diagnostic Procedures

This circuit is powered by the monitor fuse, and hazard/monitor fuse.

1/1

Engine Coolant Disconnect X36 yellow wire from switch and ground to YES: Replace switch.
Temperature Indicator frame.
Switch NO: Switch is good. Go
Without starting engine, turn key switch to BULB to next check .
CHECK, then release to ON.

Is engine coolant indicator light on?

T7199CG 1916AUG90

9015
15
39

1/1

Engine Coolant Disconnect connector from display module. YES: Indicator light is
Temperature Indicator good. Check wiring
Light Connect 12 volts to pin terminal 1 for Z33 gray wire. harness.
Ground pin terminal 2 for X36 yellow wire to machine
frame. NO: Check display
module. Replace bulb or
Is engine coolant temperature indicator light on? module.

T6877AB UN18OCT88

1/1

Engine Oil Pressure Disconnect N34 yellow wire from switch and ground to YES: Replace switch.
Switch frame.
NO: Switch is good. Go
Without starting engine, turn key switch to BULB to next check .
CHECK, then release to ON.

Is engine oil pressure indicator light on?

T7199DZ 1926SEP90

1/1

TM1512 (07NOV03) 9015-15-39 Backhoe Loaders Operation and Test


110703

PN=241
Sub-System Diagnostics

Engine Oil Pressure Disconnect connector from display module. YES: Indicator light is
Indicator Light good. Check wiring
Connect 12 volts to pin terminal 1 for Z33 gray wire. harness.
Ground pin terminal 3 for N34 yellow wire to machine
frame. NO: Check display
module. Replace bulb or
Is engine oil pressure indicator light on? module.

T6877AC UN18OCT88

1/1

Engine Alternator Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39 YES: Circuit is good.
Indicator Circuit (SN purple wire. Repair or replace
9015
787551) alternator.
15
Without starting engine, turn key switch to BULB CHECK, then release to ON.
40
NO: Go to next check .
Is alternator indicator light off?

Remove voltage from M39 purple wire.

Is alternator indicator light on?

1/1

Engine Alternator Disconnect M39 purple wire from terminal (W) of alternator and apply 6 volts to M39 YES: Circuit is good.
Indicator Circuit (SN purple wire. Repair or replace
787552 ) alternator.
Without starting engine, turn key switch to BULB CHECK, then release to ON.
NO: Go to next check .
Is alternator indicator light off?

Remove voltage from M39 purple wire.

Is alternator indicator light on?

1/1

Alternator Relay IMPORTANT: Relay is a six volt relay. Do not apply YES: Relay is good.
more than 6 volts when testing. Check wiring harness.

Disconnect harness from relay. NO: Replace relay.

Measure continuity between terminals #30 and #87A. Is


continuity measured?

T7596AQ 1903OCT91
Connect battery voltage to terminal #86. Ground terminal
#85. Does relay click?

Measure continuity between terminals #30 and #87. Is


continuity measured?

1/1

TM1512 (07NOV03) 9015-15-40 Backhoe Loaders Operation and Test


110703

PN=242
Sub-System Diagnostics

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

Is engine alternator indicator light on?


T6877AE UN18OCT88

1/1

Engine Air Filter Disconnect M40 purple wire from switch and ground to YES: Replace switch.
Restriction Switch frame.
9015
NO: Switch is good. Go
15
Without starting engine, turn key switch to BULB to next check .
41
CHECK, then release to ON?

Is air filter restriction indicator light on?

T7199CI 1917SEP90

1/1

Engine Air Filter Disconnect middle connector of display module. YES: Indicator light is
Restriction Indicator good. Check wiring
Light Ground pin terminal 14 for M40 purple wire to machine harness.
frame.
NO: Check display
Without starting engine, turn key switch to BULB module. Replace bulb or
CHECK, then release to ON. module.

T6877AG UN18OCT88
Is air restriction indicator light on?

1/1

Converter Oil Disconnect X38 yellow wire from switch and ground to YES: Replace switch.
Temperature Switch frame.
NO: Switch is good. Go
Without starting engine, turn key to BULB CHECK, then to next check .
release to ON.

Is converter oil temperature light on?

T7199CJ 1917SEP90

1/1

TM1512 (07NOV03) 9015-15-41 Backhoe Loaders Operation and Test


110703

PN=243
Sub-System Diagnostics

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

Is converter oil temperature light on?


T7199BS 1916AUG90

1/1

Hydraulic Filter Disconnect F39 yellow wire from switch and ground to YES: Replace switch.
Restriction Indicator frame.
9015
Switch NO: Switch is good. Go
15
Without starting engine, turn key switch to BULB to next check .
42
CHECK, then release to ON.

Is hydraulic filter restriction indicator light on?

T7199CK 1917SEP90

1/1

Hydraulic Filter Disconnect middle connector on display module. YES: Indicator light is
Restriction Indicator good. Check wiring
Light Ground pin terminal 16 for F39 yellow wire to machine harness.
frame.
NO: Check display
Without starting engine, turn key switch to BULB module. Replace bulb or
CHECK, then release to ON. module.

T7199BT 1916AUG90
Is hydraulic filter restriction indicator light on?

1/1

Display Module And Remove diode from connector. YES: If continuity is


Logic Module Diode measured in both checks,
Connect an ohmmeter to diode terminals. diode has failed in a
shorted mode. Replace.
Is continuity measured?
NO: If continuity is NOT
Reverse ohmmeter probes. measured in either check
diode has failed in an
T7961AA UN10MAR93
Is continuity measured? open mode. Replace.

NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1

TM1512 (07NOV03) 9015-15-42 Backhoe Loaders Operation and Test


110703

PN=244
Sub-System Diagnostics

MFWD Circuit Operational Information

The following conditions must exist for MFWD circuit to


function:

Key switch ON position


MFWD Switch ON

TX,901515,QQ811 1919NOV901/1

MFWD Circuit Theory Of Operation


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

(S.N.796855 ) 410D, (S.N.796891 ) 510D

With the key switch ON or ACC position, power flows


from MFWD fuse to terminal 5 of MFWD switch. With

TX,9015,QQ2557 1912APR941/1

TM1512 (07NOV03) 9015-15-43 Backhoe Loaders Operation and Test


110703

PN=245
Sub-System Diagnostics

MFWD Circuit Schematic

9015
15
44

1904MAR94
T8171AO

Continued on next page TX,9015,QQ2558 1912APR941/2

TM1512 (07NOV03) 9015-15-44 Backhoe Loaders Operation and Test


110703

PN=246
Sub-System Diagnostics

9015
15
45

1922FEB94
T8171AP

TX,9015,QQ2558 1912APR942/2

TM1512 (07NOV03) 9015-15-45 Backhoe Loaders Operation and Test


110703

PN=247
Sub-System Diagnostics

MFWD Circuit Diagnostic Procedures

This circuit is powered by MFWD fuse.

1/1

MFWD Switch 410D Disconnect harness from MFWD switch. YES: Switch is good. Go
(S.N. 796854) 510D to next check .
(S.N. 796890) With MFWD switch OFF, measure continuity between
terminals 6 and 8. NO: Replace MFWD
switch.
Is continuity measured?

With MFWD switch ON, measure continuity between


T7812AG UN16JUL92
terminals 6 and 8.

9015 Continuity should NOT be measured?


15
46

1/1

MFWD Switch 410D Disconnect harness from MFWD switch. YES: Switch is good. Go
(S.N.796855 ) 510D to next check .
(S.N.796891 ) With MFWD switch ON, measure continuity between
terminals 1 and 5. NO: Replace MFWD
switch.
Is continuity measured?

T7199BU UN02OCT90

1/1

MFWD Solenoid Diode Remove diode from connector. YES: If continuity is


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

NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1

TM1512 (07NOV03) 9015-15-46 Backhoe Loaders Operation and Test


110703

PN=248
Sub-System Diagnostics

MFWD Indicator Switch Disconnect harness from switch connector. Remove YES: Go to next step in
switch. this check.

Push switch actuator (steel ball). Check continuity. NO: Replace MFWD
indicator switch.
Is continuity measured?

T7287BJ UN16AUG90

Disconnect harness from switch connector. Remove YES: Replace MFWD


switch. indicator switch.

With switch actuator (steel ball) released, check NO: MFWD indicator
continuity. switch is good. Go to next
check .
Is continuity measured?
9015
T7287BJ UN16AUG90 15
47

1/1

MFWD Solenoid Disconnect harness from MFWD solenoid. YES: Solenoid is good.
Check wiring harness.
Connect one lead from connector to ground and the
other to battery voltage. NO: Replace solenoid.

Does solenoid click?

T7199BV UN16AUG90

1/1

Start Aid Circuit Operational Information

(S.N. 794639)

The following conditions must exist for start aid circuit to


function:

FNR lever in neutral


Key switch in IGN or ON position
Start aid switch depressed

(S.N. 794640 )

Key switch in IGN or ON position


Start aid switch depressed

TX,9015,QQ2562 1912APR941/1

TM1512 (07NOV03) 9015-15-47 Backhoe Loaders Operation and Test


110703

PN=249
Sub-System Diagnostics

Start Aid Circuit Theory Of Operation

(S.N. 794639)

Power flows from key switch IGN terminal to fuel


shut-off/start aid and reverse warning alarm fuse to start
aid button. When button is pushed, power is supplied to
start aid solenoid.

Power flows from key switch IGN terminal to FNR/park


brake fuse, FNR lever, neutral start relay and ether aid
relay. This energizes ether aid relay, closing terminal 30
and 87 suppling a ground and activating start aid
solenoid.

(S.N. 794640 )
9015
15
48 Power flows from key switch IGN terminal to fuel
shut-off/start aid and reverse warning alarm fuse to start
aid button. When button is pushed, power is supplied to
start aid solenoid. Ground is supplied through GO1 black
wire energizing solenoid.

NOTE: For component identification code description, see


Wiring and Schematic Diagrams Legend , Group
9015-10.

TX,9015,QQ2563 1912APR941/1

TM1512 (07NOV03) 9015-15-48 Backhoe Loaders Operation and Test


110703

PN=250
Sub-System Diagnostics

Start Aid Circuit Schematic

9015
15
49

1920FEB94
T8172AA

Continued on next page TX,9015,QQ2564 1912APR941/2

TM1512 (07NOV03) 9015-15-49 Backhoe Loaders Operation and Test


110703

PN=251
Sub-System Diagnostics

9015
15
50

1922FEB94
T8172AB

TX,9015,QQ2564 1912APR942/2

TM1512 (07NOV03) 9015-15-50 Backhoe Loaders Operation and Test


110703

PN=252
Sub-System Diagnostics

Start Aid Circuit Diagnostic Procedures

This circuit is powered by the fuel shutoff/start aid/reverse alarm fuse.

1/1

Start Aid Switch Disconnect harness from start aid switch. YES: Start aid switch is
good. Go to next check .
With start aid button pushed, check for continuity
between terminals with P12 red wire and E25 white wire. NO: Replace start aid
switch.
Is continuity measured?

T7199BW 1916AUG90

9015
15
51

1/1

TM1512 (07NOV03) 9015-15-51 Backhoe Loaders Operation and Test


110703

PN=253
Sub-System Diagnostics

FNR Lever (SN 794639) Key switch ON. FNR lever in neutral YES: Go to next step in
this check.
With harness connected, check voltage at terminals with
P24 red wire and T12 blue wire. NO: Check wiring
harness.
Are 12 volts measured at each terminal?

9015
15 T7199BP 1902OCT90
52

Key switch ON. YES: FNR lever is good.


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

Move FNR lever to reverse, check voltage at T13 blue


wire.

Are 12 volts measured at each terminal?

T7199BQ 1902OCT90

1/1

Ether Aid Relay (SN Key switch OFF. YES: Relay is good.
794639) Check wiring harness.
Disconnect harness from relay.
NO: Replace ether aid
Connect battery voltage to terminal #86 with T12 blue relay.
wire. Ground terminal #85 with G10 black wire.

Does relay click?


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

Is continuity measured?

1/1

TM1512 (07NOV03) 9015-15-52 Backhoe Loaders Operation and Test


110703

PN=254
Sub-System Diagnostics

Start Aid Solenoid (SN NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into YES: Start aid solenoid is
794639) engine. good. Check wiring
harness.
Key switch OFF.
NO: Replace start aid
Disconnect harness from solenoid. solenoid.

Connect battery voltage to terminal with E25 white wire.


Ground terminal with E27 white wire.

Does solenoid click?


T7199BX 1917SEP90

1/1

Start Aid Solenoid (SN NOTE: Remove start aid fluid canister from holder to prevent injecting starting fluid into YES: Start aid solenoid is
794640 ) engine. good. Check wiring
9015
harness.
15
Key switch OFF.
53
NO: Replace start aid
Disconnect harness from solenoid. solenoid.

Connect battery voltage to terminal with E25 white wire.


Ground terminal with GO1 black wire.

Does solenoid click?


T7828AK 1923SEP92

1/1

Fuel Shut-Off Circuit Operational Information

The following conditions must exist for fuel shut-off circuit


to function:

Key switch in IGN or ON position

TX,9015,QQ1814 1912MAR931/1

TM1512 (07NOV03) 9015-15-53 Backhoe Loaders Operation and Test


110703

PN=255
Sub-System Diagnostics

Fuel Shut-Off Circuit Theory Of Operation

Power flows from key switch IGN terminal to fuel


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

NOTE: For component identification code description, see


Wiring and Schematic Diagrams Legend , Group
9015-10.

9015
15
54

TX,9015,QQ1754 1912MAR931/1

TM1512 (07NOV03) 9015-15-54 Backhoe Loaders Operation and Test


110703

PN=256
Sub-System Diagnostics

Fuel Shut-Off Circuit Schematic

9015
15
55

1912DEC90
T7418AZ

TX,901515,QQ825 1912MAR931/1

TM1512 (07NOV03) 9015-15-55 Backhoe Loaders Operation and Test


110703

PN=257
Sub-System Diagnostics

Fuel Shut-Off Circuit Diagnostic Procedures

This circuit is powered by the fuel shutoff/start aid/reverse alarm fuse.

1/1

Injection Pump Fuel Connect battery voltage to solenoid P12 red wire YES: Solenoid is good.
Shut-Off Solenoid terminal. Check wiring harness.

Does solenoid click? NO: Replace fuel shut-off


solenoid.
Remove voltage from terminal.

Does solenoid click again?


T6785AG UN18OCT88

9015
15
56

1/1

Reverse Alarm Circuit Specifications (SN


794639)
Specification
Reverse Alarm Switch (Normally
Open)Closes on Pressure
Increase ............................................... 296 kPa599 KPa (3 bar6 bar)
(43 psi87 psi)

TX,9015,QQ2571 1912APR941/1

Reverse Alarm Circuit Operational


Information

The following conditions must exist for reverse alarm


circuit to function:

Key switch ON
FNR lever must be in reverse position

TX,9015,QQ1815 1912MAR931/1

TM1512 (07NOV03) 9015-15-56 Backhoe Loaders Operation and Test


110703

PN=258
Sub-System Diagnostics

Reverse Alarm Circuit Theory Of Operation

(S.N. 794639)

Power flows from fuel shutoff/start aid/reverse alarm fuse


to reverse alarm switch. When FNR lever is moved into
reverse the reverse solenoid is activated. Rising pressure
closes the reverse alarm switch sending power to activate
reverse alarm. When FNR lever is shifted to forward or
neutral or when loader lever switch or gear shift lever
switch is depressed the reverse alarm will shut off.

(S.N. 794640 )

Power flows from fuel shutoff/start aid/reverse alarm fuse


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

NOTE: For component identification code description, see


Wiring and Schematic Diagrams Legend , Group
9015-10.

TX,9015,QQ2572 1912APR941/1

TM1512 (07NOV03) 9015-15-57 Backhoe Loaders Operation and Test


110703

PN=259
Sub-System Diagnostics

Reverse Alarm Circuit Schematic

9015
15
58

1920FEB94
T8172AM

Continued on next page TX,9015,QQ2573 1912APR941/2

TM1512 (07NOV03) 9015-15-58 Backhoe Loaders Operation and Test


110703

PN=260
Sub-System Diagnostics

9015
15
59

1920FEB94
T8172AO

TX,9015,QQ2573 1912APR942/2

TM1512 (07NOV03) 9015-15-59 Backhoe Loaders Operation and Test


110703

PN=261
Sub-System Diagnostics

Reverse Alarm Circuit Diagnostic Procedures

This circuit is powered by the fuel shut-off/start aid/reverse alarm fuse.

1/1

FNR Lever (SN 794640 Key switch ON. FNR lever in neutral YES: Got to next step in
) this check.
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
60

T7199BP 1902OCT90

Key switch ON. YES: FNR lever is good.


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

Move FNR lever to reverse, check voltage at T13 blue


wire.

Are 12 volts measured at each terminal?

T7199BQ 1902OCT90

1/1

TM1512 (07NOV03) 9015-15-60 Backhoe Loaders Operation and Test


110703

PN=262
Sub-System Diagnostics

Reverse Solenoid Diode Remove diode from connector. YES: If continuity is


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

NO: If continuity is
measured in one check
and not the other, diode
is OK.
1/1

Reverse Alarm Relay (SN Key switch OFF. YES: Relay is good.
794640 ) Check wiring harness.
9015
Disconnect harness from relay.
15
NO: Replace reverse
61
Connect battery voltage to terminal #86. Ground terminal alarm relay.
#85. Does relay click?

Measure continuity between terminals #30 and #87.


T7287BH UN16AUG90
Is continuity measured?

1/1

Reverse Alarm Switch Key switch ON. YES: Replace reverse


(SN 794639) alarm switch.
Remove spade terminals with P12 red wire and M62
purple wire from switch. NO: Reverse alarm
switch is good. Go to next
Using a jumper wire connect P12 red wire and M62 check .
purple wire.

T7199BY 1916AUG90
Does reverse alarm sound?

1/1

Reverse Alarm Disconnect harness from reverse alarm. YES: Reverse alarm is
good. Check wiring
Connect battery voltage to reverse warning alarm harness.
positive (+) terminal.
NO: Replace reverse
Connect jumper wire from reverse warning alarm alarm.
negative (-) terminal to ground.

T7199BZ UN16AUG90
Does reverse alarm sound?

1/1

TM1512 (07NOV03) 9015-15-61 Backhoe Loaders Operation and Test


110703

PN=263
Sub-System Diagnostics

Dome Light Circuit Operational Information

The following conditions must exist for dome light circuit to


function:

Key switch in ACC position

TX,9015,QQ1816 1912MAR931/1

Dome Light Circuit Theory Of Operation


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

NOTE: For component identification code description, see


Wiring and Schematic Diagrams Legend , Group
9015-10.

TX,9015,QQ1762 1912MAR931/1

TM1512 (07NOV03) 9015-15-62 Backhoe Loaders Operation and Test


110703

PN=264
Sub-System Diagnostics

Dome Light Circuit Schematic

9015
15
63

1923SEP92
T7828AP

TX,9015,QQ1763 1912MAR931/1

TM1512 (07NOV03) 9015-15-63 Backhoe Loaders Operation and Test


110703

PN=265
Sub-System Diagnostics

Dome Light Circuit Diagnostic Procedures

This circuit is powered by the dome light fuse

1/1

Dome Light And Swivel Disconnect harness from switch. YES: Switch is good.
Light Switch Check wiring harness
Turn dome light/swivel light switch ON.
NO: Replace switch.
Using a multimeter check continuity at switch terminals
for dome and swivel light switch.

Does multimeter read continuity?


T6622BB UN09DEC88

9015
15
64

1/1

Dome And Swivel Light Disconnect harness from light. YES: Light is good.
Check wiring harness.
Connect battery voltage to light terminal. Ground light
housing. NO: Replace bulbs or
dome/swivel lights.
Does light come on?

T6534DZ UN19OCT88

1/1

Radio Circuit Operational Information

The following condition or conditions must exist for radio


circuit to function.

Key switch in ACC or ON position


Radio turned ON

TX,9015,QQ1769 1912MAR931/1

TM1512 (07NOV03) 9015-15-64 Backhoe Loaders Operation and Test


110703

PN=266
Sub-System Diagnostics

Radio Circuit Theory Of Operation

When key switch is ON or in ACC position of switch,


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

Unswitched power from radio fuse is to maintain station


memory. Power from the front work light fuse is for light in
radio. Power from the dome light fuse is to power the
radio and speakers.

9015
15
65

TX,9015,QQ1770 1931AUG951/1

TM1512 (07NOV03) 9015-15-65 Backhoe Loaders Operation and Test


110703

PN=267
Sub-System Diagnostics

Radio Circuit Schematic

9015
15
66

1923SEP92
T7828AS

TX,9015,QQ1771 1912MAR931/1

TM1512 (07NOV03) 9015-15-66 Backhoe Loaders Operation and Test


110703

PN=268
Sub-System Diagnostics

Radio Circuit Diagnostic Procedures

This circuit is powered by the unswitched radio fuse and the dome light fuse.

1/1

Radio YES: Go to next check .

NO: Check wiring


harness between radio
and fuses.

9015
15
67

T7828AT 1923SEP92

Key switch ON Front work/drive light switch ON

Measure 12 volts at wire terminals L43 brown, P25 red and P15 red.

Is 12 volts measured at wire terminals?

1/1

Radio Speaker Disconnect harness from radio speaker. YES: Replace radio.

Measure resistance between radio speaker terminals. NO: Replace speaker

Is 7.3 ohms measured?

T7828AU 1923SEP92

1/1

TM1512 (07NOV03) 9015-15-67 Backhoe Loaders Operation and Test


110703

PN=269
Sub-System Diagnostics

Wiper/Washer Circuit Operational Information

The following conditions must exist for wiper/washer


circuit to function.

Key switch must be in ON or ACC position.


Front/rear wiper or washer switch must be turned on.

TX,9015,QQ1817 1912MAR931/1

Wiper/Washer Circuit Theory Of Operation


9015
15 Power flows from wiper/washer fuse through wires P14 Rear wiper in HIGH position, power flows from rear
68 red to terminal 3 on front wiper switch, terminal 1 of wiper switch terminal 1 through A66 orange wire to
washer switch and terminal 3 of rear wiper switch. rear wiper motor.

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

TX,9015,QQ1764 1912MAR931/1

TM1512 (07NOV03) 9015-15-68 Backhoe Loaders Operation and Test


110703

PN=270
Sub-System Diagnostics

Wiper/Washer Circuit Schematic

9015
15
69

1915FEB93
T7938AA

TX,9015,QQ1974 1916MAR931/1

TM1512 (07NOV03) 9015-15-69 Backhoe Loaders Operation and Test


110703

PN=271
Sub-System Diagnostics

Wiper/Washer Circuit Diagnostic Procedures

This circuit is powered by the wiper/washer fuse.

1/1

Front Wiper Switch Wiper switch ON. YES: Front wiper switch
is good. Go to next check
Disconnect harness from front wiper switch. .

Measure for continuity between terminals 2 and 4, 6 and NO: Replace front wiper
8, 1 and 3, and 5 and 7. switch.

Is continuity measured?
T7199CA UN02OCT90

9015
15
70

1/1

Wiper Motor LH Door Disconnect harness from wiper motor. YES: Go to next check .
And RH DoorLow
Speed Connect battery voltage to terminal with red wire and NO: Replace wiper motor.
yellow wire. Ground terminal with black wire.

Does motor run in LOW speed?

Remove voltage from terminal with red wire, and connect


T7199CB UN17SEP90
red and green wire together using a jumper wire.

Does motor run until blade reaches PARK position?

1/1

Wiper Motor LH Door Disconnect harness from wiper motor. YES: Wiper motor is
And RH DoorHigh good. Check wiring
Speed Connect battery voltage to terminal with blue wire and harness.
yellow wire. Ground terminal with black wire.
NO: Replace wiper motor.
Does motor run in HIGH speed?

Remove voltage from terminal with blue wire, and


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

Does motor run until blade reaches PARK position?

1/1

TM1512 (07NOV03) 9015-15-70 Backhoe Loaders Operation and Test


110703

PN=272
Sub-System Diagnostics

Rear Wiper Switch Wiper switch ON. YES: Rear wiper switch is
good. Go to next check .
Disconnect harness from rear wiper switch.
NO: Replace rear wiper
Using a multimeter measure for continuity between switch.
terminals 1 and 3, and 5 and 7.

Is continuity measured?
T7199CC UN02OCT90

1/1

Rear Wiper MotorLow Disconnect harness from wiper motor. YES: Go to next check .
Speed
9015
Connect battery voltage to terminal with red wire and NO: Replace wiper motor.
15
yellow wire. Ground terminal with black wire.
71
Does motor run in LOW speed?

Remove voltage from terminal with red wire.


T7199CD 1916AUG90
Does motor run until blade reaches PARK position?

1/1

Rear Wiper MotorHigh Disconnect harness from wiper motor. YES: Wiper motor is
Speed good. Check wiring
Connect battery voltage to terminal with blue wire and harness.
yellow wire. Ground terminal with black wire.
NO: Replace wiper motor.
Does motor run in HIGH speed?

Remove voltage from terminal with blue wire.


T7199CD 1916AUG90
Does motor run until blade reaches PARK position?

1/1

Washer Switch Washer switch ON. YES: Washer switch is


good. Go to next check .
Disconnect harness from washer switch.
NO: Replace washer
Using a multimeter measure continuity between switch.
terminals 1 and 5.

Is continuity measured?
T7199CE UN02OCT90

1/1

TM1512 (07NOV03) 9015-15-71 Backhoe Loaders Operation and Test


110703

PN=273
Sub-System Diagnostics

Windshield Washer Disconnect harness from washer motor. YES: Washer motor is
Motor good. Check wiring
Connect battery voltage to terminal with S71 orange harness.
wire. Ground motor.
NO: Replace washer
Does motor run and operate the pump? motor.

T7199CF 1916AUG90

1/1

Blower Circuit Operational Information


9015
15 The following conditions must exist for blower circuit to
72 function:

Key switch in ON or ACC position


Blower switch turned ON

TX,9015,QQ1818 1917JUN941/1

Blower Circuit Theory Of Operation

Power from heater circuit breaker goes to blower switch.


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

With blower switch in medium position power is sent


through half the blower resistor and is reduced to 6.06.5
volts, blower motor runs in medium speed.

With blower switch in high position power by-passes


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

NOTE: For component identification code description, see


Wiring and Schematic Diagrams Legend , Group
9015-10.

TX,9015,QQ1766 1917JUN941/1

TM1512 (07NOV03) 9015-15-72 Backhoe Loaders Operation and Test


110703

PN=274
Sub-System Diagnostics

Blower Circuit Schematic

9015
15
73

1930SEP92
T7857AD

TX,901515,QQ809 1917JUN941/1

TM1512 (07NOV03) 9015-15-73 Backhoe Loaders Operation and Test


110703

PN=275
Sub-System Diagnostics

Blower Circuit Diagnostic Procedures

This circuit is powered by the heater circuit breaker.

1/1

Blower Switch Disconnect harness from blower switch. YES: Blower switch is
good.
Use a multimeter and check for continuity.
NO: Replace blower
Move blower switch to LOW, MEDIUM and HIGH switch.
checking terminals B and L, B and M, and B and H.

Is continuity measured?
T7199CL UN17SEP90

9015
15
74

1/1

Heater Blower Motor Disconnect harness from heater blower motor. YES: Heater blower
motor is good. Check
Connect 12 volts to heater blower motor, and ground wiring harness.
motor.
NO: Replace heater
Does heater blower motor operate? blower motor.

T7199CM UN16AUG90

1/1

Blower Resistor Check Disconnect harness from resistor. YES: Resistor is OK.
Check harness and
Connect ohmmeter to outer terminals of resistor. blower motor.

Does ohmmeter read continuity? NO: Blower resistor has


failed. Replace.

T8134AK UN03DEC93

1/1

TM1512 (07NOV03) 9015-15-74 Backhoe Loaders Operation and Test


110703

PN=276
Sub-System Diagnostics

Drive And Work Light Circuit Operational


Information

The following conditions must exist for drive and work


lights to function:

Key switch in ON or ACC


Front light switch and/or rear light switch in ON position

TX,9015,QQ1820 1912MAR931/1

Drive And Work Light Circuit Theory Of


Operation 9015
15
75
Power flows from front work light fuse to terminal 3 and
terminal 2 of front light switch.

With front light switch in the first position, power flows


from terminal 8 of front light switch to make the front drive
lights, and tail lights come on.

With front light switch in the second position, power flows


from terminal 8 and terminal 1 of front light switch to make
the front drive lights, tail lights, and front work lights come
on.

Rear work lights, power flows from rear work light fuse to
terminal 1 of rear light switch.

With rear light switch in the first position, power flows from
terminal 5 of rear light switch to make rear work lights
come on.

Continued on next page TX,9015,QQ1767 1912MAR931/3

TM1512 (07NOV03) 9015-15-75 Backhoe Loaders Operation and Test


110703

PN=277
Sub-System Diagnostics

9015
15
76

1930APR93
T7996AO

Continued on next page TX,9015,QQ1767 1912MAR932/3

TM1512 (07NOV03) 9015-15-76 Backhoe Loaders Operation and Test


110703

PN=278
Sub-System Diagnostics

NOTE: For component identification code description,


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

TX,9015,QQ1767 1912MAR933/3

Drive And Work Light Circuit Diagnostic Procedures

This circuit is powered by the front work and drive light fuse, and the rear work light fuse.

1/1

Front Light Switch Disconnect harness from front light switch. YES: Front light switch is
good. Check wiring
9015
Light switch ON. harness.
15
77
Measure for continuity between terminals 3 and 1, and 2 NO: Replace switch.
and 8.

Is continuity measured?
T7199CN UN16AUG90

1/1

Rear Light Switch Disconnect harness from rear light switch. YES: Rear light switch is
good. Check wiring
Light switch ON. harness.

Measure for continuity between terminals 1 and 5. NO: Replace switch.

Is continuity measured?

T7199CO UN16AUG90

1/1

Work/Drive Light Disconnect harness from work/drive light. YES: Work light is good.
Check wiring harness.
Connect 12 volts to blue wire and ground black wire.
NO: Replace bulb. If bulb
Does light come ON? is good replace light.

T7199CP UN17SEP90

1/1

TM1512 (07NOV03) 9015-15-77 Backhoe Loaders Operation and Test


110703

PN=279
Sub-System Diagnostics

Tail Light Disconnect harness from turn/tail/brake light. YES: Tail light is good.
Check wiring harness.
Connect 12 volts to terminal marked TAIL, and ground
terminal marked GROUND. NO: Replace bulb. If bulb
is good replace light.
Does tail light come on?

T7199CQ 1902OCT90

1/1

Park Brake/Clutch Disconnect Circuit


9015 Specifications
15
78 Specification
Park Brake Sensing Switch
(Normally Closed)Closes on
Decreasing Pressure .................................. 5516 kPa (55.2 bar) (800 psi)
Opening Pressure .................................. 7585 689 kPa (75.9 6.9 bar)
(1100 100 psi)
(S.N. 778824) Reverser Switch
(Normally Open)Closes on
Increasing Pressure.................................. 345621 kPa (3.456.21 bar)
(5090 psi)
Opening Pressure .................................... 103345 kPa (1.033.45 bar)
(1550 psi)

TX,9015,QQ3252 1931AUG951/1

Park Brake/Clutch Disconnect Circuit


Operational Information

The following condition or conditions must exist for park


brake/clutch disconnect circuit to function:

Key switch OFF


Park brake dash switch in ON position with machine
running
Machine Mechanically Shut Down
Reverser pressure

TX,901515,QQ575 1907DEC901/1

TM1512 (07NOV03) 9015-15-78 Backhoe Loaders Operation and Test


110703

PN=280
Sub-System Diagnostics

Park Brake/Clutch Disconnect Circuit Theory Of Operation

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

NOTE: The park brake applies automatically when Key ON:


machine is mechanically shut down or when
key switch is turned off. Park brake dash Park Brake Dash Switch in ON position. FNR Lever
switch must be cycled first to applied position Shifted Out of Neutral:
(ON), then to released position (OFF) before
park brake can be released when engine is With the park brake dash switch ON, and the FNR
running. lever shifted out of neutral the park light relay K3 is
9015
de-energized connecting terminals 30 and 87A causing 15
Key OFF: red light and alarm to come ON. 79

Park brake cannot be hydraulically released if there is Key ON:


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