Manual de Reparacion SP2254

2254
Cane Loader
Repair
TECHNICAL MANUAL
2254 Cane Loader Repair
TMCM225401 04OCT06 (ENGLISH)
John Deere Thibodaux

Litho in U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specification, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic types of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
OUO1082,0000354 –19–15DEC04–1/1
TMCM225401 (04OCT06) 2254 Cane Loader

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Contents
10
SECTION 10—General
Group 05—Safety
Group 10—Machine Specifications
Group 15—General References
Group 25—Fluid Recommendations
20
SECTION 20—Engines
Group 05—General Information
SECTION 40—Electrical System

Group 10—General Information 40
SECTION 50—Hydrostatic System

Group 10—Pumps & Motors
Group 20—Minor Pump Repairs
Group 30—Displacement Control Components
50
SECTION 60—Steering System

Group 10—Repair
SECTION 70—Hydraulic System

Group 10—Pumps & Valves 60
Group 20—Hydraulic Checks
Group 30—Hydraulic Cylinder
SECTION 99—Service Tools

Group 10—Service Supplies
70
99
INDX
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT  2006
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
TMCM225401 (04OCT06) i 2254 Cane Loader

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Contents
10
20
40
50
60
70
99
INDX
TMCM225401 (04OCT06) ii 2254 Cane Loader

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10
Section 10
General
Contents
Page Page
Group 05—Safety . . . . . . . . . . . . . . . . . . . . . .10-05-1 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . .10-25-2

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-2
Group 10—Machine Specifications Tire Inflation Pressure1 . . . . . . . . . . . . . . . . . . .10-25-2
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-3
Visually Inspect Hydraulic Systems . . . . . . . . . .10-10-3 Engine Coolant Requirements1 . . . . . . . . . . . . .10-25-3
Hydraulic System Testing Precautions . . . . . . .10-10-5 Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-4
Visually Inspect Electrical System . . . . . . . . . . .10-10-6 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-4
Electrical System Safety Precautions . . . . . . . .10-10-7 Inhibitors (Conditioners) . . . . . . . . . . . . . . . . . .10-25-5
Machine Specifications . . . . . . . . . . . . . . . . . . .10-10-8 Filling the System . . . . . . . . . . . . . . . . . . . . . . .10-25-5
Loading System . . . . . . . . . . . . . . . . . . . . . . .10-10-14 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . .10-25-6
Traction System . . . . . . . . . . . . . . . . . . . . . . .10-10-15 Sulphur Content . . . . . . . . . . . . . . . . . . . . . . . .10-25-6
Front Axle Motor . . . . . . . . . . . . . . . . . . . . . . .10-10-15 Cetane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-7
Steering System . . . . . . . . . . . . . . . . . . . . . . .10-10-15 Cloud Point . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-7
Piler Chain System (Optional Hydraulic Storage and Handling . . . . . . . . . . . . . . . . . . . .10-25-7
Piler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-16 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . .10-25-8
Grab and Lift Hydraulic Schematic . . . . . . . . .10-10-17 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-9
Steer, Swing Flex and Piler Lift Hydraulic Transmission. . . . . . . . . . . . . . . . . . . . . . . . . .10-25-10
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-18 Gear Oil - Pump Drive. . . . . . . . . . . . . . . . . . .10-25-10
Joystick Control Valve Hydraulic Gear Oil - Final Drive . . . . . . . . . . . . . . . . . . .10-25-10
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-19 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-10
Optional Hydraulic Piler Schematic . . . . . . . . .10-10-20
Hydrostatic Transmission Hydraulic
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-21
Propulsion Schematic - High Traction
Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-22
Conversions . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-23
Unified Inch Bolt and Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-25
Metric Bolt and Screw Torque Values . . . . . . .10-10-26
Group 15—General References

Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . .10-15-1
Visually Inspect Electrical System . . . . . . . . . . .10-15-5
Seven-Step Electrical Procedure . . . . . . . . . . . .10-15-7
Understanding Electrical vs. Electronic
Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15-10
Intermittent Electronic Problems . . . . . . . . . . .10-15-12
Relay Circuit Types . . . . . . . . . . . . . . . . . . . . .10-15-16
Using a Digital Multimeter . . . . . . . . . . . . . . . .10-15-29
Troubleshooting Unresolved Problems . . . . . .10-15-30
Group 25—Fluid Recommendations

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-1
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-1
Rear Steering Axle . . . . . . . . . . . . . . . . . . . . . .10-25-1
Front Rigid Axle . . . . . . . . . . . . . . . . . . . . . . . .10-25-2
TMCM225401 (04OCT06) 10-1 2254 Cane Loader

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Contents
10

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Group 05
Safety
10
Service Safety 05
1
When a service person or mechanic is unfamiliar with all

systems on this equipment, extra caution should be used
when performing service work. A good working knowledge
of the system and its components is important for removal
or disassembly. The following is a list of basic precautions
that should always be observed.
1. Make sure you read and understand all warning plates

and decals before lubricating or performing other
maintenance.
2. Always wear protective glasses and footwear when
working. In particular, wear safety glasses when
pounding on any part of the machine or attachments
with a hammer. Use welding goggles or a face shield
and use protective clothing when welding. Do not wear
any loose fitting or torn clothing. Remove all rings from
fingers before working on equipment.
3. Before starting work on the machine, turn disconnect
master power switch to off position and hang a DO
NOT OPERATE sign in the operator’s station. Also,
remove key from inside cab when “Do not Start” tag is
placed.
4. If at all possible, make all repairs with the machine
parked on level ground. Block the machine so it cannot
roll. DO NOT work on any machine that is supported
only by lift jacks or a hoist.
5. Lower all implements to the ground before performing
any work on the machine. If this cannot be done, make
sure the implement is properly blocked to prevent it
from dropping unexpectedly.
6. Relieve all pressure in air, oil, or water systems before
any lines, fittings, or related parts are disconnected or
removed. Always make sure that all raised components
and implements are correctly blocked. Be alert for
possible pressure when disconnecting any device from
a system that utilizes pressure.
7. To avoid back injuries, use a hoist when lifting
components that weigh over 23 kg (50 lb). When using
a hoist, make sure all hooks are correctly positioned.
8. To avoid burns, be alert for hot parts located on the
machine after it has stopped. Be particularly careful of
hot fluids in lines, tubes, and components.
Continued on next page T803584,00001D4 –19–16OCT00–1/3
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Safety
10
05 9. Be careful when removing cover plates. Gradually
2
loosen the last two bolts or nuts located at the opposite
ends of the cover or device. Carefully pry the cover
loose to relieve any spring or other tension before
removing it completely.
10. Be careful when removing filler caps, breathers, or
plugs on the machine. Hold a rag over the cap or
plug to prevent being sprayed or splashed by fluids
under pressure.
11. Always use tools that are in good condition. Before
performing any service, make sure you know how to
use the proper tools. Use correct size tools to prevent
damage to fasteners, etc.
12. Replace all fasteners with the same SAE or metric
grade. Never substitute a softer part where a
hardened part is used, conversely never substitute a
harder part where a softer part is used.
13. Take precautions to prevent damage to wiring during
removal. After re-installing the wiring, double check to
make sure it is was not damaged during removal or
installation. Ensure that the wiring does not touch any
hot, sharp, or moving parts after it is installed.
Visually inspect wires and wire harnesses for
damaged wire covering and exposed wires — repair
or replace as required.
14. Ensure that all protective devices and guards are
properly installed and are functioning correctly before
starting any repairs. If a guard or shield must be
removed to perform repair work, use extra caution
while working.
15. Escaping fluid under pressure can have sufficient
force to penetrate the skin. Therefore, before
disconnecting any lines, be sure all pressure in the
system is relieved. Before applying pressure, make
sure all lines, fittings, and connections are tight and
undamaged. Boom should be fully lowered, flex
cylinder extended until grab tines are at rest on
ground and piler should be lowered.
16. If you are injured by escaping fluid under pressure,
see a doctor at once. A serious infection or reaction
may result if proper medical attention is not received
immediately.
Continued on next page T803584,00001D4 –19–16OCT00–2/3

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Safety
10
05
3
CAUTION: Liquid escaping from a very small
hole can be almost invisible. Use wood or
cardboard, instead of your hand, when
searching for suspected leaks.
17. Avoid working on equipment with the engine running.

If it is absolutely necessary to make checks with the
engine running, always use two men: one to operate
the controls and the other to work where the operator
can see him. The transmission must be in neutral, the
braking system set, and all pertinent safety locks set.
18. Pick up tools and maintain area clear of other
materials that can cause a trip hazard.
T803584,00001D4 –19–16OCT00–3/3
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the
potential for personal injury.
–UN–07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT –19–29SEP98–1/1
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is

used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near

–19–30SEP88
specific hazards. General precautions are listed on

CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
DX,SIGNAL –19–03MAR93–1/1

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Safety
10
05 Follow Safety Instructions
4
Carefully read all safety messages in this manual and on

your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
–UN–23AUG88
available from your John Deere dealer.
Learn how to operate the machine and how to use

controls properly. Do not let anyone operate without
TS201
instruction.
Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need

assistance, contact your John Deere dealer.
DX,READ –19–03MAR93–1/1
Use Seat Belt Properly
Use a seat belt when you operate the loader to minimize

the chance of injury from an accident.
–UN–05JAN89
RW16064
AG,RX15494,72 –19–18MAR99–1/1

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Safety
10
Protect Bystanders 05
5
Be sure everyone is clear of the equipment before starting

the engine or moving the steering wheel. Blow horn
before starting engine to make sure everyone is clear.
–UN–10NOV00
CM999999009
T803584,00001DB –19–16OCT00–1/1
Use Handles and Steps
Clean off mud, grease, and any crop residue that may
have accumulated on the steps and operator’s platform of
your equipment. Remember that chains and tools carried
on the platform may interfere with pedal operation or
cause a fall from the equipment. Remove them.
–UN–06JAN00
CM989999006
T803584,00001DC –19–16OCT00–1/1

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Safety
10
Handle Fluids Safely—Avoid Fires 05
7
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.
–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
TS227
spontaneously.
DX,FLAME –19–29SEP98–1/1
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.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204
DX,SPARKS –19–03MAR93–1/1
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,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
DX,FIRE2 –19–03MAR93–1/1

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Safety
10
Handle Fluids Safely—Avoid Fires 05
7
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.
–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
TS227
spontaneously.
DX,FLAME –19–29SEP98–1/1
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.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204
DX,SPARKS –19–03MAR93–1/1
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,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
DX,FIRE2 –19–03MAR93–1/1

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Safety
10
05 Prevent Acid Burns
8
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 15—30 minutes. Get
medical attention immediately.
–UN–23AUG88
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 –19–21APR93–1/1

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Safety
10
Handle Chemical Products Safely 05
9
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.
–UN–26NOV90
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 MSDS’s on chemical

products used with John Deere equipment.)
DX,MSDS,NA –19–03MAR93–1/1
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
–UN–23AUG88
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 –19–03MAR93–1/1

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Safety
10
05 Park Machine Safely
10
Before working on the machine:
• Lower all equipment to the ground.

• Stop the engine and remove the key.
• Disconnect the battery ground strap.
–UN–24MAY89
• Hang a "DO NOT OPERATE" tag in operator station.
TS230
DX,PARK –19–04JUN90–1/1
Support Machine Properly
Always lower the attachment or implement to the ground

before you work on the machine. If the work requires that
the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
–UN–23AUG88
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

machine, always follow safety precautions listed in the
implement or attachment operator’s manual.
DX,LOWER –19–24FEB00–1/1
Wear Protective Clothing
Wear close fitting clothing and safety equipment

appropriate to the job.
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
–UN–23AUG88
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR –19–10SEP90–1/1

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Safety
10
Work in Clean Area 05
11
Before starting a job:
• Clean work area and machine.

• Make sure you have all necessary tools to do your job.
–UN–18OCT88
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN –19–04JUN90–1/1
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.
–UN–23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228
DX,LOOSE –19–04JUN90–1/1
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.
–UN–23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR –19–17FEB99–1/1
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.
–UN–23AUG88
TS223
DX,LIGHT –19–04JUN90–1/1

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Safety
10
05 Replace Safety Signs
12
Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign
placement.
–UN–23AUG88
TS201
DX,SIGNS1 –19–04JUN90–1/1
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.
–UN–23AUG88
TS226
DX,LIFT –19–04JUN90–1/1

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Safety
10
Remove Paint Before Welding or Heating 05
13
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
–UN–23AUG88
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed,
TS220
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can
–UN–15MAY90
accidentally burst when heat goes beyond the immediate

flame area.
TS953
DX,TORCH –19–10DEC04–1/1

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Safety
10
05 Use Caution on Hillsides
14
Avoid holes, ditches, and obstructions that may cause the

equipment to tip, especially on hillsides.
Never drive near the edge of a gully or steep

embankment because it may cave in.
For hillside operation, always load uphill, not downhill.

Avoid sharp, uphill turns.
Keep hydraulic oil level at upper level when operating on

hillsides. Low oil level might result in loss of steering. If
–UN–10NOV00
this should happen, hold equipment with brakes, shift to
NEUTRAL, apply park brake, stop engine, and add
hydraulic oil to proper level.
CM999999011
Before operating on extremely steep slopes, ensure oil is
at or above upper sight glass.
T803584,000025C –19–17OCT00–1/1
Use Caution When Flexing (Extending) Boom
The loader should be operated with the boom flexed in

(Flex Cylinder Extended) or as near as possible to the
flexed-in position when picking up cane and with loaded
–UN–24JAN06
grab for maximum stability.
As boom is flexed out or extended (Flex Cylinder

Destroked) with a loaded grab, the extended boom and
CM061850002
grab weight may exceed the loaders counterweight and
begin to tip, especially when the boom is swung to the full
right position.
Extending a heavy load or swinging it to the side may

cause machine to tip.
T803324,00008B9 –19–24JAN06–1/1

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Safety
10
Stopping and Parking 05
15
Your ability to stop your equipment and park it safely is

just as important as being able to get it underway safely.
Equipment, collisions, runaway tractors, and people being
crushed under machines can happen when operators
ignore safety.
Do Not Put Hand through Steering Wheel when Starting

Unit.
Shut off engine. Remove radiator filler cap when cool

enough to touch with bare hand. To relieve pressure,
slowly loosen cap to first stop, and then remove
completely.
To avoid these accidents, take some precautions:
• Signal before stopping, turning, or slowing down on

highways.
• Pull over to right-hand shoulder of highway
• Slow down before braking.
• Shift to neutral/park and set parking brake.
• Lower all equipment when leaving unit.
• Turn off all electrical switches and remove key.
T803584,00001E8 –19–16OCT00–1/1

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Safety
10
05 Service Tires Safely
16
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.
–UN–23AUG88
TS211
DX,RIM –19–24AUG90–1/1

100406
PN=22
Safety
10
Practice Safe Maintenance 05
17
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
–UN–23AUG88
or welding on machine.
On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
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.
–UN–08NOV89
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 –19–17FEB99–1/1

100406
PN=23
Safety
10
05 Dispose of Waste Properly
18
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.
–UN–26NOV90
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 Earth’s 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 –19–03MAR93–1/1
Prevent Machine Runaway
Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.
–UN–11JAN89
NEVER start engine while standing on ground. Start
engine only from operator’s seat, with transmission in
neutral or park.
TS177
DX,BYPAS1 –19–29SEP98–1/1

100406
PN=24
Safety
10
Handle Starting Fluid Safely 05
19
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
–UN–18MAR92
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
TS1356
Do not incinerate or puncture a starting fluid container.
DX,FIRE3 –19–16APR92–1/1
Service Cooling System Safely
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
to relieve pressure before removing completely.
TS281
DX,RCAP –19–04JUN90–1/1
Protect Against High Pressure Spray
Spray from high pressure nozzles can penetrate the skin

and cause serious injury. Keep spray from contacting
hands or body. –UN–18MAR92
If an accident occurs, see a doctor immediately. Any high

pressure spray 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
TS1343
a knowledgeable medical source. Such information is

available from Deere & Company Medical Department in
Moline, Illinois, U.S.A.
DX,SPRAY –19–16APR92–1/1

100406
PN=25
Safety
10
05 Construct Dealer-Made Tools Safely
20
Faulty or broken tools can result in serious injury. When

constructing tools, use proper, quality materials, and good
workmanship.
–UN–01JUL97
Do not weld tools unless you have the proper equipment
and experience to perform the job.
LX1016749
DX,SAFE,TOOLS –19–10OCT97–1/1
Live With Safety
Before returning machine to customer, make sure

machine is functioning properly, especially the safety
systems. Install all guards and shields.
–19–07OCT88
TS231
DX,LIVE –19–25SEP92–1/1
Safety Sign
–19–24JAN06
CM061850004
T803324,00008BA –19–24JAN06–1/1

100406
PN=26
Safety
10
Avoid Electrical Power Lines 05
21
Lower boom and grab to transport position and lift piler

before driving on public roads.
Avoid using equipment around high voltage power lines;

this would result in the operator suffering a severe
electrical shock.
Do not operate with any part of the loader, its boom or its
grab closer than 3 meters (10 feet) from electrical lines.
–UN–10NOV00
CM999999008
T803584,00001EA –19–16OCT00–1/1

100406
PN=27
Safety
10
05
22

100406
PN=28
Group 10
Machine Specifications
10
Troubleshooting 10
1
To prevent unnecessary loss of time and money; the

service technician should use the following seven steps
for a quick and accurate diagnosis:
CAUTION: Use caution when dealing with

pressurized hydraulic fluid. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate skin causing serious injury.
This fluid may also be hot enough to burn.
Serious infection or reactions can develop if
proper medical treatment is not administered
immediately.
1. Know the machine.

• Study this manual to understand how the individual
components work and what functions each serves in
the overall system.
• Keep up with the latest service information. Read
upon receipt and then file it in this manual or another
useful place. Information received today may have
the cause or remedy of a problem being
encountered.
2. Consult the operator. Ask the operator how the

machine was performing when it started to fail.
• Find out what was unusual.
• Find out if any “do-it-yourself” service was
performed. (You may find the problem somewhere
else, but you should know if any corrective measures
have already been taken.)
• Ask how the equipment is used and how often it is
serviced. Many problems are caused by poor
maintenance or abuse.
3. Operate the equipment. If the machine is operable,

operate it yourself. Do not rely entirely on the
operator’s story; check it out.
• Are gauges reading normally? If not, maybe the
component being monitored is not functioning
correctly or the gauge is faulty.
• How is the performance? Is the action perhaps too
fast or too slow, erratic, or none at all?
• Do the controls feel solid or spongy? Do they seem
to be sticking?
Continued on next page T803324,0000936 –19–14MAR06–1/2

100406
PN=29
10
10 • Do you smell smoke or see any signs of smoke?
2
• Do you hear any unusual sounds? Where?
4. Inspect the equipment. Make sure engine is shut off

and all implements are on the ground. Get off the
machine and make a visual check. Use your eyes,
ears and nose to spot any signs of trouble.
• Look closely at the components. Inspect for cracked
welds, loose hardware, damaged linkages, worn or
broken lines, etc.
• During the inspection, make notes of all trouble
signs.
5. Make a list of the problem’s possible cause(s) with the

information obtained during steps 1 through 4..
• What were the signs you found while inspecting the
equipment?
• What is the most likely cause?
6. Reach some conclusions. Look over the list of

possible causes and decide which are the most likely
and which are the easiest to verify.
7. Test your conclusions. Before repairing components
in the system, test your conclusions to see which are
correct.
• Some of the possible causes may be verified without
further testing. Check these possibilities first.
• Testing will narrow down the remaining list of
possible causes and soon the actual cause(s) of
trouble will be pin pointed.
With the cause(s) accurately located, it is now a simple

matter to remove and repair the component(s) at fault.
T803324,0000936 –19–14MAR06–2/2

100406
PN=30
10
Visually Inspect Hydraulic Systems 10
3
Before performing any diagnosis on the machine, use the

following steps for locating problems. Many failures can
be located by making preliminary checks of operation.
No special tools are required for these preliminary checks,

so repair obvious problems before performing further
tests.
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Keep hands and body
away from pin holes and nozzles, which eject
fluids under high pressure. Use a piece of
cardboard or paper to search for leaks. Do not
use your hand.
1. Become acquainted with the hydraulic system and its

components. Read all new Service Information
Bulletins.
2. If possible, talk with the operator about how the
machine performs.
3. With the engine stopped, check for evidence of
external oil leakage around seals, gaskets, or hydraulic
connections. Check for pinched or kinked lines that
could restrict oil flow and cause overheating.
4. Check for broken drives, broken or binding linkages, or
other mechanical failures.
5. Check hydraulic oil level. Only use oil specified by
John Deere to fill tank.
6. Check hydraulic oil for a milky, dirty, or discolored
appearance. Milky oil usually indicates there’s water in
the oil. Smell the oil. A distinctive burned odor
indicates excessive heat that can destroy the oil’s
lubricating qualities. Determine the cause of the
condition, correct it, and change oil.
7. Check for a plugged or damaged hydraulic oil filter. A
failed filter will permit contaminants to circulate in the
system, affecting system operation and tests. If the
filter is plugged, an examination of the contaminant
may indicate the cause of the failure.

100406
PN=31
10
10 8. Check maintenance records to determine if the
4
recommended service procedures have been done at
correct intervals. Note any previous reports of unusual,
frequent, or similar failures.
CAUTION: Keep hands away from moving parts.

Shut off engine before checking lines located
near moving parts.
9. If possible, operate the machine. Use hydraulic

functions and be alert for conditions that could isolate
the problem. Also be alert for conditions that could
cause further damage and be prepared to stop the
engine immediately.
10. With someone in the driver’s seat and the engine
running, check for external and internal leaks. With all
hydraulic functions in neutral, check function
component return lines and housings for heating.
Return lines will be hot if component control valves
are leaking.
11. If these preliminary checks have failed to isolate the
hydraulic problem, list the possible causes of failure
and proceed to fault logic diagrams for the particular
problem.
T803324,0000937 –19–14MAR06–2/2

100406
PN=32
10
Hydraulic System Testing Precautions 10
5
If ANY fluid is injected into the skin, it must be surgically

removed within a few hours by a doctor familiar with this
injury type or gangrene may result. When disconnecting a
line or hose from a hydraulic component, always mark it
–UN–23AUG88
and the port from which it was removed. This will enable it
to be reconnected to the proper port when reassembling.
If lines or hoses are not connected to the proper ports,
serious damage can result to the component or to the
X9811
entire hydraulic system.
Avoid excessive twisting by using two wrenches when

attaching a hose or line to a fitting. Check the entire
length of lines and hoses to be certain they are not
rubbing on moving parts or vibrating because of loose
clamps.
CAUTION: Wear eye protection and remove

rings, metal watchbands, and other metal
jewelry when working on the electrical system.
T803324,0000938 –19–14MAR06–1/1

100406
PN=33
10
10 Visually Inspect Electrical System
6
Make the following visual electrical inspection prior to

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

short across to another component.
–UN–23AUG88
2. Look for a missing or worn conduit. This could indicate
a wire problem.
3. Look for loose or broken connectors and wires. Inspect
batteries for: ! Corroded terminals. ! Loose terminals or
TS206
battery posts. ! Dirty condition. ! Cracked case.
4. 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 IGN. Try
out the accessory circuits, indicators, lights and gauge
lights, etc. 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
running. Therefore, a systematic and complete
inspection of the electrical system is necessary.
T803324,0000939 –19–14MAR06–1/1

100406
PN=34
10
Electrical System Safety Precautions 10
7
1. Keep all flames/sparks away from battery.

2. Charge battery in a well-ventilated area.
3. Always remove negative (-) battery cable first and
replace it last.
4. Never lay a metal object on top of a battery: a short
–UN–23AUG88
circuit can result, damaging the battery and metal
object.
5. If acid spills on clothing, immediately remove clothing.
If acid contacts skin, rinse affected area with
TS204
running water for 1 - 15 minutes.
T803324,000093A –19–14MAR06–1/2
6. If acid splashes into eyes, hold eyelids open and flood

eyes with running water for 10-15 minutes, then see a
doctor at once.
7. DO NOT use any medication or eye drops unless
prescribed by a doctor.
8. To neutralize acid spilled on the floor or machine, flood
the spill with one of the following mixtures, then rinse
thoroughly with clean water:
• 0.5 kg (1 lb) of baking soda in 4 L (1 gal) of water !
• 0.4 (1 pt) of household ammonia in 4 L (1 gal) of
water.
–UN–23AUG88
TS203
T803324,000093A –19–14MAR06–2/2

100406
PN=35
10
10 Machine Specifications
8
Engine:
Engine Type ............................................................................................................................................................................... John Deere 6068T
Cylinders ................................................................................................................................................................................................... 6 (in line)
Displacement ............................................................................................................................................................................... 8.3 L (506 cu. in.)
Horsepower ............................................................................................................................................................. 200 hp (149 kw) at 2200 RPM
Peak Torque ....................................................................................................................................................... 793 N•m (585 lb-ft) at 1500 RPM
Oil Pressure .................................................................................................................................................................. 50 PSI (345 kPa) (Normal)
Coolant Flow ........................................................................................................................................................ 67 GPM (253 L/m) at 2400 RPM
High Idle ........................................................................................................................................ 2400 RPM (Full Load) / 2550 RPM (No Load)
T803324,00008DD –19–01FEB06–1/1
Transmission:
Type .............................................................................................................................................................................................. 3 Speed Manual
Gearing
• 1st ........................................................................................................................................................................................................... 11.25: 1
• 2nd ........................................................................................................................................................................................................... 5.874: 1
• 3rd ........................................................................................................................................................................................................... 2.869: 1
Final Drive (Front Axle)

Type .................................................................................................................................................................................... 9.5 : 1 High Clearance
Max Speed ................................................................................................................................................................................................ 940 RPM
Max Torque ...................................................................................................................................................................... 34,000 lb-in. (3,842 N•m)
Final Drive (Rear Axle) - Standard Power Assist Option

Type ............................................................................................................................................................... Double Planetary Gear Torque Hub
Reduction ................................................................................................................................................................................................... 26.28 : 1
Output Torque Rating
Max Continuous ................................................................................................................................................................ 40,000 lb-in (4,519 N•m)
Max Intermittent ................................................................................................................................................................ 80,000 lb-in (9,039 N•m)
Max Peak ...................................................................................................................................................................... 100,000 lb-in (11,299 N•m)
Max Input Speed (Continuous) .................................................................................................................................................... 3750 - 4500 RPM
Final Drive (Rear Axle) - High Traction Option

Type ............................................................................................................................................................................. Planetary Gear Torque Hub
Reduction ...................................................................................................................................................................................................... 44.2: 1
Output Torque Rating
Max Continuous ................................................................................................................................................................ 75,000 lb-in (8,468 N•m)
Max Intermittent ............................................................................................................................................................. 150,000 lb-in (16,986 N•m)
Max Peak ....................................................................................................................................................................... 200,000 lb-in (22,600 N•m)
Max Input Speed (Continuous) .................................................................................................................................................... 2250 - 2700 RPM
T803324,00008DD –19–01FEB06–1/1

100406
PN=36
10
Machine Specifications 10
9
Pump Drive - Flywheel Mounted
Type ............................................................................................................................................................................................................. Double
Reduction ........................................................................................................................................................................................................... 1:1
Pump Rotation ........................................................................................................................................................................ Reverse Enginewise
Final Drive (Rear Axle) - High Traction 4 Wheel Drive Option
Type ............................................................................................................................................................................. Planetary Gear Torque Hub
Reduction ..................................................................................................................................................................................................... 44.2: 1
Max Continuous ................................................................................................................................................................. 75,000 lb-in (8,475 N•m)
Max Intermittent ............................................................................................................................................................ 150,000 lb-in (16,950 N•m)
Max Peak ..................................................................................................................................................................... 200,000 lb-in (22,600 N•m)
Max Input Speed .................................................................................................................................................................................... 3000 RPM
Double Vane Pump
Displacement:
Shaft End Pump ........................................................................................................................................................ 4.12 cu. in./rev (67.5 cc/rev)
Cover End Pump ....................................................................................................................................................... 1.67 cu. in./rev (27.4 cc/rev)
Speed:
Maximum ................................................................................................................................................................................................ 3000 RPM
Pressure:
Maximum at Max Speed ........................................................................................................................................................ 3000 PSI (206.8 bar)
Rotation:
Viewed from shaft end .............................................................................................................................................................................. Left Hand
Typical Performance
Shaft End Pump
Input Horsepower @ 2250 PSI, 2400 RPM ..................................................................................................................................... 60 HP (45 kW)
Delivery @2250 PSI, 2400 RPM ............................................................................................................................................ 37 GPM (140 L/Min)
Cover End Pump

Input Horsepower @ 2250 PSI, 2400 RPM ..................................................................................................................................... 22HP (16 kW)
Delivery @ 2250 PSI, 2400 RPM ............................................................................................................................................ 15 GPM (57 L/Min)
Weight:
Normal ............................................................................................................................................................................................. 45 lb (20.4 kg)
T803324,00008F7 –19–02FEB06–1/1

100406
PN=37
10
10
Single Vane Pump - (Hydraulic Piler Option Only)
Displacement:
Maximum ................................................................................................................................................................... 2.76 cu. in./rev (45.2 cc/rev)
Speed
Maximum ................................................................................................................................................................................................ 2700 RPM
Pressure:
Maximum at Max. Speed ........................................................................................................................................................ 3000 PSI (207 bar)
Rotation
Viewed from Shaft End ........................................................................................................................................................................... Left Hand
Typical Performance
Input Horsepower at 2250 PSI, 2400 RPM ..................................................................................................................................... 42 HP (31 kW)
Delivery at 2250 PSI, 2400 RPM ............................................................................................................................................ 27 GPM (102 L/Min)
Weight:
Normal ............................................................................................................................................................................................. 32 lb (14.5 Kg)
Variable Displacement Pump - (Hydrostatic Transmission)

Displacement:
Maximum ...................................................................................................................................................................... 6.1 cu. in./rev (100 cc/rev)
Input Rotation
Viewed from Shaft End ........................................................................................................................................................................... Left Hand
Input Speed
Maximum ................................................................................................................................................................................................ 4300 RPM
Continuous ............................................................................................................................................................................................. 3600 RPM
Minimum .................................................................................................................................................................................................. 500 RPM
Pressure:
Maximum ................................................................................................................................................................................. 7000 PSI (480 bar)
Continuous ............................................................................................................................................................................... 6000 PSI (420 bar)
Case Pressure
Continuous ....................................................................................................................................................................................... 40 PSI (3 bar)
Maximum (Cold Start) ....................................................................................................................................................................... 75 PSI (5 bar)
Charge Inlet Vacuum at Sea Level

Normal ............................................................................................................................................................................ 10 In. Hg (0.7 Bar [ABS])
Cold Start ........................................................................................................................................................................ 25 In. Hg (0.2 bar [ABS])
Weight:
Normal .............................................................................................................................................................................................. 150 lb (68 Kg)
T803324,00008DD –19–01FEB06–1/1

100406
PN=38
10
Machine Specifications 10
11
Fixed Displacement Motor (Front Axle):
Displacement
Maximum .................................................................................................................................................................... 5.43 Cu. In./Rev (89 Cc/Rev)
Speed:
Maximum ......................................................................................................................................... 2900 RPM (Serial No. 100004988 and prior)
Maximum ......................................................................................................................................... 3720 RPM (Serial No. 100004989 and after)
Pressure
Maximum at Max Speed, Max Displacement ..................................................................... 5000 PSI (345 Bar) (Serial No. 100004988 and prior)
Maximum at Max Speed, Max Displacement ..................................................................... 6000 PSI (345 Bar) (Serial No. 100004989 and after)
Case Pressure
Maximum ........................................................................................................................................................................................... 40 PSI (3 bar)
Charge Inlet Vacuum at Sea Level

Normal ............................................................................................................................................................................ 10 In. Hg (0.7 Bar [ABS])
Weight
Normal ........................................................................................................................................................................................... 108 Lb. (49 Kg)
T803324,00008DD –19–01FEB06–1/1

100406
PN=39
10
12
Fixed Displacement Motor (Rear Axle) — Power Assist Option:
Displacement .................................................................................................................................................... 2.78 Cu. In. / Rev. (45.5 cc/Rev)
Output Speed
Maximum ............................................................................................................................................................................................... 4250 RPM
Pressure
Maximum ................................................................................................................................................................................. 6500 PSI (450 Bar)
........................................................................................................................................................................................................... (0.26 N•m/Bar)
At Max. Displacement ............................................................................................................................................................ 784 lb-in / 1000 PSI
(1.28 N•m/Bar)
Pressure
Maximum ................................................................................................................................................................................... 6960 PSI (480 bar)
Continuous ............................................................................................................................................................................... 5800 PSI (400 bar)
Case Pressure
Maximum ..................................................................................................................................................................................... 145 PSI (10 bar)
Weight
Normal ............................................................................................................................................................................................. 30 Lb. (14 Kg)
Variable Displacement Motor (Rear Axle) - High Traction 4 Wheel Drive:

Displacement
Maximum .................................................................................................................................................................... 4.92 Cu. In./Rev (80 Cc/Rev)
Minimum ................................................................................................................................................................... 1.23 Cu. In./Rev (20 Cc/Rev)
Rated Speed
At Min. Displacement ............................................................................................................................................................................ 5000 RPM
At Max. Displacement ........................................................................................................................................................................... 3100 RPM
Maximum Speed
At Min. Displacement .............................................................................................................................................................................. 6250 RPM
At Max Displacement .............................................................................................................................................................................. 4000 RPM
Theoretical Torque
At Min. Displacement ................................................................................................................................................................ 156 lb-in /1000 PSI
........................................................................................................................................................................................................... (0.26 N•m/Bar)
At Max. Displacement ............................................................................................................................................................ 784 lb-in / 1000 PSI
(1.28 N•m/Bar)
Pressure
Maximum ................................................................................................................................................................................... 6960 PSI (480 bar)
Minimum ...................................................................................................................................................................................... 145 PSI (10 bar)
Case Pressure (Maximum)

Continuous ....................................................................................................................................................................................... 44 PSI (3 Bar)
Maximum (Cold Start) ..................................................................................................................................................................... 73 PSI (5 bar)
Weight
Normal ............................................................................................................................................................................................. 72 Lb. (32 Kg)
Continued on next page T803324,00008DD –19–01FEB06–1/3

100406
PN=40
10
Steering Cylinder 10
Oil Supply ....................................................................... Double Vane Pump ....................................................................... 15 GPM (57 L/M) 13
....................................................................................................................................................................................................... Cover End Pump
Swing Cylinders
Oil Supply ....................................................................... Double Vane Pump ....................................................................... 15 GPM (57 L/M)
....................................................................................................................................................................................................... Cover End Pump
Valve .............................................................................................................................................................................. 3 Bank Directional Control
..................................................................................................................................................................................................... 3 Position / 4 Way
........................................................................................................................................................................................................... Pilot Operated
........................................................................................................................................................................................................... Cylinder Spool
Relief Valve ......................................................................... Work Port Relief ......................................................................... 1350 PSI (93 Bar)
Relief Valve ................................................................... Main D.C. Valve Relief ................................................................... 2250 PSI (155 Bar)
Flex Cylinder
Oil Supply ....................................................................... Double Vane Pump ....................................................................... 15 GPM (57 L/M)
....................................................................................................................................................................................................... Cover End Pump
Valve ............................................................................................................................................................................. 3 Bank Directional Control
..................................................................................................................................................................................................... 3 Position / 4 Way
........................................................................................................................................................................................................... Pilot Operated
........................................................................................................................................................................................................... Cylinder Spool
Relief Valve .................................................................. Work Port Relief .................................................................. 2000 PSI (138 Bar) Extd.
.......................................................................................... .......................................................................................... 1000 PSI (69 Bar) Retract.
Relief Valve ................................................................. Main D.C. Valve Relief .................................................................. 2250 PSI (155 Bar)
Piler Lift Cylinder

Oil Supply ..................................................................... Double Vane Pump ..................................................................... 15 GPM (56.8 L/Min)
....................................................................................................................................................................................................... Cover End Pump
.................................................................................................................................................... 3 Position / 4 way Pilot Operated Cylinder Spool
Relief Valve ................................................................... Work Port Reliefs ................................................................... 1000 PSI (69 Bar) Close
............................................................................................. ............................................................................................. 500 PSI (34 Bar) Open
Relief Valve .................................................................... Main D.C. Valve Relief .................................................................... 2250 PSI (155 Bar)
Grab Cylinders
Oil Supply ...................................................................... Double Vane Pump ...................................................................... 37 GPM (140 L/Min)
..................................................................................................................................................................................................... Shaft End Section
Relief Valve .................................................................... Work Port Relief ................................................................... 1800 PSI (124 bar) Extd.
........................................................................................... ........................................................................................... 500 PSI (34 Bar) Retract.
Relief Valve .................................................................... Main D.C. Valve Relief .................................................................... 2250 PSI (155 bar)
Lift Cylinder
Oil Supply ...................................................................... Double Vane Pump ...................................................................... 36 GPM (138 L/Min)
........................................................................................................................................................................................................ Shaft End Pump
Valve .............................................................................................................................................................................. 2 Bank Directional Control
Relief Valve .................................................................... Work Port Relief ................................................................... 1800 PSI (124 bar) Extd.
............................................................ ............................................................ ........................................................... 500 PSI (34 Bar) Retract.
Relief Valve .................................................................... Main D.C. Valve Relief ................................................................... 2250 PSI (155 bar)
Piler Motor Circuit (Hydraulic Piler Option Only)

Oil Supply ............................................................................ Single Vane ............................................................................ 27 GPM (102 L/Min)
.............................................................................................................................................................................................................. Single Pump
Valve ............................................................................................................................................................................................ Directional Control
Continued on next page T803324,00008DD –19–01FEB06–2/3

100406
PN=41
10
10 .................................................................................................................................................... 3 Position / 4 way Pilot Operated Cylinder Spool
14 Relief Valve ....................................................... Main D.C. Valve Cartridge Relief ....................................................... 2000 PSI (138 Bar) Extd.
Relief Valve ............................................................................. Main Relief ............................................................................. 1750 PSI (138 Bar)
T803324,00008DD –19–01FEB06–3/3
Loading System
To check pressure, install gauges anywhere in the lines

that go from the pump to the respective control valve. Run
the engine at approximately 1000 RPM.1
Control Valve - Piler, Flex and Swing

Main Relief ........................................................... 2250 PSI (155 Bar)
Port Reliefs
Boom Swing ........................................................... 1350 PSI (93 Bar)
Boom Flex (Out) .................................................. 2000 PSI (138 Bar)
Boom Flex (In) ....................................................... 1000 PSI (69 Bar)
Piler Lift (Raise) ..................................................... 1000 PSI (69 Bar)
Piler Lift (Lower) ....................................................... 500 PSI (34 Bar)
To check the pressure, actuate the piler or flex valve until

the cylinder bottoms out. Hold in this position while
observing pressure reading.
Control Valve - Boom Lift and Grab

To check the main pressure, actuate the grab until the

cylinder bottoms out. Hold in this position while observing
pressure reading.
Port Reliefs
Boom Lift (Raise) ................................................. 1800 PSI (124 Bar)
Boom Lift (Lower) .................................................... 500 PSI (34 Bar)
Grab (Close) ........................................................ 2000 PSI (138 Bar)
Grab (Open) ........................................................... 1000 PSI (69 Bar)
To check the pressure, lower boom until pressure relief

opens. Hold in this position while observing pressure
reading.
Throttle Valve - Lift: The purpose of this valve is to slow

the downward movement of the boom in order to reduce
pressure peaks. It is fully open when the boom is lifting.
1
In order to properly check your hydraulic pressure settings, you must
first warm the system oil to at least 120° F (49° C).
T803324,00009A1 –19–24APR06–1/1

100406
PN=42
10
Traction System 10
15
Main System Pressure
Multipurpose valve for high pressure and relief and override.
Charge Pressure (Neutral) ....................................... 405 PSI (28 Bar)

Charge Pressure (For/Rev) ....................................... 362 PSI (25 Bar)
Crossover (Cushion) Relief - Power Assist Option Only

Relief Cartridges (Rear Axle) ............................... 5000 PSI (345 Bar)
To check the pressure, engage fourth gear, lock the

wheels and fully stroke the pump at maximum engine
RPM. These readings are above the case drain pressure.
Vacuum
Normal ...................................................... 0 - 10” Hg (0-0.7 Bar ABS)
Cold Start .................................................. 25” Hg Max (0.2 Bar ABS)
Case Drain Pressure

Normal ................................................................. 0 - 40” Hg (0-3 Bar)
Cold Start ..................................................................... 75 PSI (5 Bar)
T803324,00009A1 –19–24APR06–1/1
Front Axle Motor
Flushing function only.
T803324,00009A2 –19–24APR06–1/1
Steering System
Relief Valve: Priority Steering Circuit
Relief Pressure .................................................... 2500 PSI (172 Bar)
Priority Valve: Steering Supply Valve

Pressure Setting .................................................. 1750 PSI (121 Bar)
Steering Cylinder (Crossover) (Cushion) Relief - High Traction 4

Wheel Drive Option Only
Reliefs .................................................................. 1500 PSI (104 Bar)
T803324,00009A2 –19–24APR06–1/1

100406
PN=43
10
10 Piler Chain System (Optional Hydraulic Piler)
16
Relief Valve: Pump or Flow Control
Directional Valve: For/Rev Rotation

T803324,00009A2 –19–24APR06–1/1

100406
PN=44
10
Grab and Lift Hydraulic Schematic 10
17
–UN–24APR06
CM40283576D4
T803324,00009A3 –19–24APR06–1/1

100406
PN=45
10
10 Steer, Swing Flex and Piler Lift Hydraulic Schematic
18
–UN–24APR06
CM40292299D2
T803324,00009A5 –19–24APR06–1/1

100406
PN=46
10
Joystick Control Valve Hydraulic Schematic 10
19
–UN–24APR06
CM40283579B3
T803324,00009A4 –19–24APR06–1/1

100406
PN=47
10
10 Optional Hydraulic Piler Schematic
20
–UN–24APR06
CM40292300C2
T803324,00009A6 –19–24APR06–1/1

100406
PN=48
10
Hydrostatic Transmission Hydraulic Schematic 10
21
–UN–10MAR06
CM40297442D7
T803324,00009A7 –19–24APR06–1/1

100406
PN=49
10
10 Propulsion Schematic - High Traction Option
22
–UN–10MAR06
CM43000396B2
T803324,00009A8 –19–24APR06–1/1

100406
PN=50
10
Conversions 10
23
The following information will be useful to you as you work

with non-metric fasteners.
You may find frequent use for the

fraction-decimal-millimeter conversion chart, especially
when you have to cut or restore threads.
1 Gross or Long Ton = 2,240 Lbs

1 Net or Short Ton = 2,000 Lbs.
1 Cubic Foot of Water = 62.5 Lbs.
1 Gallon of Water = 8.33 Lbs.
1 Mile = 8 Furlongs
1 Mile = 80 Chains
1 Mile = 320 Rods.
1Mile = 1,760 Yards.
1 Mile = 5,280 Feet
1 Furlong = 10 Chains
1 Furlong = 220 Yards
1 Station = 6.06 Rods
1 Station = 33.3 Yards
1 Station = 100 Feet
1 Chain = 4 Rods
1 Chain = 22 Yards
1 Chain = 66 Feet
1 Chain = 100 Links
1 Rod = 5.5 Yards
1 Rod = 16.5 Feet
1 Yard = 3 Feet
1 Yard = 36 Inches
1 Foot = 12 Inches
The following tables are provided to help you compare

metric to English measurements, or to make conversions
when you are required to do so.
Metric to English
1 Millimeter = 0.03937 inches
1 Centimeter = 0.3937 inches
1 Meter = 39.37 inches
1 Meter = 3.2808 feet
1 Meter = 1.0936 yards
English to Metric
1 Inch = 25.4 millimeters
= 2.54 centimeters
1 Foot = 304.8 millimeters
= 30.48 centimeters
1 Yard = 91.4 centimeters
= 0.9144 meter

100406
PN=51
10
10 When you know Multiply bya To Find
24 Millimeters 0.04 inches
Centimeters 0.39 inches
Meters 3.28 feet
Newton-Meters 0.737 foot-pounds
Liters 1.057 quarts
Liters 2.642 gallons
Liters 2.10 pints
Inches 2.54 centimeters
Feet 30.5 centimeters
Yards 0.91 meters
Foot-pounds 1.356 Newton-meters
PSI 14.63 Bar
a
Approximate.
Temperature Conversion Chart

Celsius Fahrenheit
0° 32°
30° 86°
100° 212°
To convert Celsius to Fahrenheit, multiply by 1.8 and add

32.
F = (C x 1.8) + 32
To convert Fahrenheit to Celsius, subtract 32 and divide

by 1.8.
C = (F-32) ÷ 1.8
T803324,0000934 –19–14MAR06–2/2

100406
PN=52
10
Unified Inch Bolt and Screw Torque Values 10
TS1671 –UN–01MAY03 25
Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c b c b c
Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricatedb Dryc
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N•m lb-ft N•m lb-ft
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N•m lb-ft N•m lb-ft
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N•m lb-ft N•m lb-ft N•m lb-ft
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N•m lb-ft
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higher
bolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of the
tightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that you
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricate
U-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel bolts
bolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for the
bolts with identical grade. specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with
JDM F13C zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
TORQ1 –19–24APR03–1/1

100406
PN=53
10
10 Metric Bolt and Screw Torque Values
26
–UN–01MAY03
4.8 8.8 9.8 10.9 12.9 12.9
4.8 8.8 9.8 10.9 12.9 12.9
TS1670
Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N•m lb-ft N•m lb-ft N•m lb-ft
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N•m lb-ft
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength Shear bolts are designed to fail under predetermined loads. Always
of the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fasteners
value or tightening procedure is given for a specific application. For with the same or higher property class. If higher property class
stainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Make
instructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start thread
crimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fasteners
shown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless different
specific application. instructions are given for the specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with
JDM F13C zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 –19–24APR03–1/1

100406
PN=54
Group 15
General References
10
Glossary of Terms 15
1
ITEM ABBREVIATION DESCRIPTION
Accessory ACC Secondary electrical system
Air Conditioning A/C System used for cooling the air in the cab
Alternating Current AC Electrical current that reverses its direction at regularly recurring intervals
Battery Bat A device used to furnish electrical current
Brakes BR Abbreviation
Controller Area Network CAN A communication system linking on-board electronics
Central Control Unit CCU Computerized system for tractor monitoring
Circuit CCT A complete path of an electrical current
Clockwise CW Direction in which the hands of a clock rotate
Cold Cranking Amperes CCA Battery’s measured capability to perform during cold weather operation
Component Technical Manual CTM Technical manual developed for the servicing of major components
Counterclockwise CCW Direction opposite the rotation of the hands of a clock
Diagnostic Receptacle DR A connection where hydraulic pressure can be measured
Digital Multimeter DMM An electrical multi-functional measuring device
Direct Current DC Electrical current flowing in one direction only
Continued on next page OUO1089,000277F –19–13JAN05–1/4

100406
PN=55
General References
10
15 ITEM ABBREVIATION DESCRIPTION
2
Electro-Hydraulic EH Hydraulic valve function that is controlled electrically
Electronic Components Relay ELX Relay powering most of the electronic components
Excess Flow (SCV/Hitch Flow) EF Reference—SCV/Hitch flow
Excess Flow Load Sense

(SCV/Hitch Flow) EFL Reference—SCV/Hitch load sense
Forward FWD Direction of movement
Gallons per Minute gpm Amount of fluid displaced over a period of one minute
Heating-Ventilating and Air

Conditioning HVAC Abbreviation
High-Intensity Discharge Light HID Abbreviation
Hitch Control Unit HCU Computerized system used to control hitch functions
Housing Hsg Abbreviation
Ignition IGN Control for starting and stopping the tractor
Inside Diameter ID Abbreviation
International Standards
Organization ISO Standards organization
Joint Industry Council

Organization JIC Standards organization
Left-Hand LH or L-H Abbreviation
Liquid Crystal Display LCD A technology used for displaying information

100406
PN=56
General References
10
ITEM ABBREVIATION DESCRIPTION 15
3
Manifold Air Pressure MAP Air Pressure measured at engine air intake
Negative Neg (—) Electrical Ground Circuit
Number No. Abbreviation
ORFS
O-Ring Face Seal ORS A type of seal used in hydraulic connections
Outside Diameter OD Abbreviation
Perf Mon
Performance Monitor (PrF) Abbreviation
Positive Pos (+) Charged part of an electrical circuit
Potentiometer POT A device used to vary electrical voltage
Power Take-Off PTO Abbreviation
Pressure Control Valve PCV Valve used to control pressure within a system
Pressure Regulating Valve PRV A device used to regulate pressure in a system
Product Identification Number PIN Serial number relating to tractor identification
Pulse-Width-Modulation PWM Method of controlling electrical signals
Pump Load Sense PLD Reference—Pump load sense
Reverse Rev Direction of movement
Revolutions per Minute rpm Abbreviation
RH or
Right-Hand R-H Abbreviation
Rockshaft RS Abbreviation

100406
PN=57
General References
10
15 ITEM ABBREVIATION DESCRIPTION
4
Selective Control Valve SCV Device used to control remote hydraulic functions
Slow Moving Vehicle SMV Warning sign on the rear of the tractor
Society of Automotive Engineers SAE Engineering Standards Organization
Specification Spec Abbreviation
Switch SW Abbreviation
Tachometer Tach Abbreviation
Tail Light TL Abbreviation
Temperature Temp Abbreviation
Transmission Trans Abbreviation
Transient Voltage Protection TVP An electrical device used to protect a circuit from voltage surge
Voltage (Volts) V Abbreviation
Voltage Detector V Det Abbreviation
Warning Lamp WL Abbreviation
Without W/O Abbreviation
Wide-Open Throttle WOT Full throttle
OUO1089,000277F –19–13JAN05–4/4

100406
PN=58
General References
10
Visually Inspect Electrical System 15
5
Visually inspect the electrical system prior to starting the

tractor, after receiving customer complaint:

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.
IMPORTANT: During any diagnostic operation

involving harness connectors, always
consider the possibility that a terminal
may have pulled out from the connector
body enough to lose connection. This
can happen if the terminal did not seat
properly when installed, and it is a
condition that is generally not obvious
simply by looking at the connectors
when mated. Careful inspection may be
required.
4. Inspect batteries for:

• Corroded terminals
• Loose terminals or battery posts
• Dirty condition
• Damp condition
• Cracked case
• Proper electrolyte level

6. After machine has been shut down for five minutes,
inspect for overheated parts. Parts will often smell like
burned insulation. Place 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 visual inspection does not indicate the possible
malfunction, but inspection does indicate that the
machine can be run, turn the key switch to the RUN
position. Operate the accessory circuits, indicator
lights, gauge lights, etc. 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
Continued on next page OUO1089,0002784 –19–13JAN05–1/2

100406
PN=59
General References
10
15 9. In general, look for anything unusual.
6
Many electrical failures cannot be detected even if the

machine is started. Therefore, a systematic and complete
OUO1089,0002784 –19–13JAN05–2/2

100406
PN=60
General References
10
Seven-Step Electrical Procedure 15
7
J
FUSE
- +
F H
C E
A I K
–UN–10JAN05
B G
D
M L
LV12004
A—Battery Ground D—DFRW26 Fuse Test Lead H—Load K—Ground
B—Battery E—Circuit Breaker Load Side I—Component Ground Lead L—Voltage Check
C—Circuit Breaker Battery F—Switch J—Component Battery Lead M—Ground Check
Side G—Component Battery Lead Disconnected

100406
PN=61
General References
10
15 NOTE: A probe light or multimeter may be used when
8
following this procedure.
Step Sequence Resultsa

Probe—Multimeter Conditions
1-Switch Onb Check circuit breaker battery side (C) for Bright Light—Battery voltage. Normal. GO TO 2.
battery voltage.c
Dim Light—Low voltage. Repair high resistance.
No Light—No voltage. Repair open circuit from battery.
2-Switch Off Check circuit breaker load side (E) for Bright light—Battery voltage. normal. GO TO 4.
battery voltage.
Dim Light—Low voltage. Replace circuit breaker.
No light—No voltage. GO TO 3.
3-Switch Off Check circuit breaker load side (E) for Bright Light—Continuity to ground. Repair grounded circuit at or
continuity to ground. (Clip of tester at before switch.
battery voltage (+)).
No Light—no continuity to ground. Replace circuit breaker.
4-Switch On Check circuit breaker load side (E) for Bright Light—Battery voltage. Normal. GO TO 6.
battery voltage.
Dim Light—Low voltage. Replace circuit breaker.
No Light—No voltage. GO TO 5.
5-Disconnect lead to Check component battery lead Bright Light—Battery voltage. Repair component.
component at (G)d. Switch disconnected (J) for battery voltage.
on.
No light—No voltage. Repair grounded circuit at or after switch.
a
Disregard probe light condition when using a multimeter.
b
Controlling switch or relay for component (load).
c
Use DFRW26—Test Lead when testing circuits with fuses. See Section 299, Dealer Fabricated Tools.
d
Multimeter will not apply a load to circuit at step 5. Use probe light.

100406
PN=62
General References
10
Step Sequence Resultsa 15
Probe—Multimeter Conditions 9
6-Switch On Check component battery lead (G) for Bright Light—Battery voltage normal. GO TO 7.
battery voltage.
Dim Light—Low voltage - Repair high resistance in circuit between
circuit breaker and component
No Light—Repair high resistance in circuit between circuit breaker

and component.
7-Switch On Check component ground lead (I) for Bright Light—High voltage - Open ground circuit. Repair open
voltage. circuit.
Dim Light—Voltage - Poor continuity to ground. Repair high

resistance circuit.
No Light—No voltage - Good continuity to ground. Repair

component.
OUO1089,0002785 –19–13JAN05–3/3

100406
PN=63
General References
10
15 Understanding Electrical vs. Electronic Circuits
10
–UN–13JAN05
LV12007
A—Fuse D—Head Lamp G—Circuit Resistance (20 I—Electronic Control Module
B—Circuit Resistance (5 E—Air Filter Restriction Switch Ohms) J—Key Switch
Ohms) F—Air Filter Restriction H—Test Point K—Battery
C—Test Point Indicator
IMPORTANT: Knowing the difference between Differences between the two test instruments are
electrical and electronic circuits is shown in Examples A and B.
very important. The use of a probe
(test) light in some electronic Example A — Electrical Circuit
circuits will overload the circuit,
creating damage to switches, Refer to the above circuit.
transistors, resistors, capacitors and
possibly microprocessors. The head lamp (D) will not operate with 5 ohms of
resistance (B) in the circuit. If the head lamp is
Test Light vs. Multimeter disconnected at point (C) and is checked for voltage at
that point using a multimeter, the meter would indicate
With probe light or multimeter. battery voltage.
Both multimeters and test lights may be used to check NOTE: The meter does not draw enough current to
for voltage in a circuit. Both draw current from the create a voltage drop and place a load on the
circuit that is being tested to operate. circuit. This gives a false indication of a good
circuit to that point.
A typical multimeter (digital or analog) draws 0.05
milliamps to operate and a test light will draw 250— If the same check was made using a test light, the
300 milliamps during operation. This makes the current result would be either no light or a very dim light.
draw of the test light 5,000 times higher than the
multimeter.
Continued on next page OUO1089,000278A –19–13JAN05–1/2

100406
PN=64
General References
10
NOTE: The test light draws enough current to place a NOTE: The test light overloads the circuit because the 15
11
load on the circuit. This gives a more realistic control module cannot meet the high current
indication of the condition of the circuit. demands of the test light. Thus it gives a false
test result.
Results were different for each test instrument for the
following reasons: However, if a multimeter had been used to check point
(H), it would have read correct voltage, indicating the
• The type of circuit being tested (ELECTRICAL) air filter restriction indicator should be replaced.
• The amount of current draw each test instrument
requires to operate NOTE: The multimeter does not overload the circuit
• The type of circuit malfunction (high resistance) because of its low current draw.
Example B — Electronic Circuit Results were different for each test instrument for the
following reasons:
Refer to the above circuit.
• The type of circuit being tested (ELECTRONIC)
The air filter restriction indicator (F) will not operate • The amount of current draw each test instrument
with 20 ohms resistance (G) in the circuit when the air requires to operate
filter restriction switch (E) is closed (with 25 inches • The type of circuit malfunction (high resistance)
water vacuum at the switch).
The next step would be to check for high resistance
If point (H) is checked for voltage (with air filter between the electronic control module (I) and the
restriction switch (E) closed) using a test lamp, the indicator lamp (F).
result would be no light. The electronic control module
(I) could be replaced in error.
OUO1089,000278A –19–13JAN05–2/2

100406
PN=65
General References
10
15 Intermittent Electronic Problems
12
B D
C
E
A F
G H
L
K
+ +
–UN–10JAN05
I
LV12008
J
A—Component, First D—Wire Terminal to Second G—Battery Positive Terminal K—Digital Multimeter
B—Wire Terminal to First Component (E) H—Battery Negative Terminal L—Frame Ground
Component (A) E—Component, Second I—Battery Ground to Frame M—Jumper Wire
C—Isolated Wire F—DFRW51 — Electronic J—Battery
Circuit Load Tester
Voltage Drop Method possible, to isolate the circuit to a single wire (C),
so that the wire is open at all ends.
Checking a circuit for voltage drop is a method of 2. Ground one end of wire (C) with a jumper wire (M)
identifying high resistance in the wire. Voltage drop to the machine frame (L).
checks on electrical circuits can be performed by using 3. Connect DFRW51 Electronic Circuit Load Tester (F)
the electrical function as the load. at wire terminal (D) and battery positive (+) terminal
(G). The current draw of the test lamp is 3.8 to 4.2
NOTE: Review Understanding Electrical vs. Electronic amps at 12.2 to 12.6 volts.
Circuits (Reference 210-15-014). 4. Connect a multimeter across battery terminals (G
and H), red to positive (G) and black to negative
The following method is basically for checking wires in (H). Record baseline voltage.
electronic circuits but can also be used in electrical 5. Move black multimeter lead to each point (I, L, B,
circuits. and D) and record voltage.
1. Disconnect all components (A and E) from the

circuit, including diodes and resistors when
Continued on next page OUO1089,000278B –19–13JAN05–1/4

100406
PN=66
General References
10
excessive resistance in the circuit (C) between 15
13
NOTE: Each connection should cause a 0.1 to 0.2 those two points. Example: (G) to (H) = 12.4 volts,
voltage drop. There are five connections in the (G) to (I) = 12.2 volts, (G) to (L) = 12.1 volts, (G) to
example (H, I, L, B, and D) which will cause a (B) = 12.0 volts and (G) to (D) = 10.8 volts would
total of 0.5 to 1.0 voltage difference between indicate high resistance between points (B) and (D).
(H) and (D) as compared to the voltage across The minimum expected voltage between (G) and
(G) and (H). (D) is 11.8 volts.
6. When the voltage drop between any two adjacent

test points is greater than 0.4 volts, there is

100406
PN=67
General References
10
15 D
14 B C
E
A
F
L K
+ G H
–UN–08JUN00
O
N
RW71273
J
A—Component, First E—Component, Second H—Battery Negative Terminal L—Frame Ground

B—Wire Terminal to First F—DFRW51—Electronic I—Battery Ground to Frame M—Jumper Wire
Component (A) Circuit Load Tester J—Battery N—Meter Black (—) lead
C—Isolated Wire G—Battery Positive Terminal K—Digital Multimeter O—Meter Black (—) lead
D—Wire Terminal to Second
Component (E)
Current Draw Method system fails to provide continuous, uninterrupted

operation, loading the circuit with 3—5 amps, as
This current draw method can be used as an alternate follows, may help to isolate unwanted resistance in the
method to check for excessive resistance in a circuit circuit.
when the problem is intermittent and difficult to isolate.
1. Disconnect all components (A and E) from the
The amount of current required for most electronic circuit, including diodes and resistors when
circuits to operate is commonly milliamps (1 mA is one possible, to isolate the circuit to a single wire (C),
thousandth of an amp). Sudden changes in circuit open at all ends.
resistance can generate and send a false signal to the 2. Ground one end of wire (C) with a jumper wire (M)
electronic control module causing intermittent to the machine frame (L).
operation. Digital multimeters also operate on very 3. Connect DFRW51 Electronic Circuit Load Tester (F)
small amounts of current. at battery positive (+) terminal (G). The current
draw of the test lamp is 3.8 to 4.2 amps at 12.2 to
When the normal voltage and resistance (ohms) 12.6 volts.
checks indicate the electronic circuit is normal, but the

100406
PN=68
General References
10
4. Set multimeter (K) dial and test leads for amperage It is difficult to determine the conductivity of 15
15
test. Connect red meter lead to second lead of the terminals when harness connectors are
test lamp (F). Connect black lead (N) to battery connected. Obtain the necessary connector
negative (-) terminal (H). Record the current (amps) terminals (pins and sockets) to be used as a
after 30 seconds. troubleshooting tool to determine adequate
5. Move black multimeter lead (O) to terminal (D). frictional contact of mating terminals on the
Record the current (amps) and compare the current machine.
recorded at step 4.
Wire Gauge Current Draw—Specification b. If the current draw is within specification, instruct
16 Gauge Wire—Amperage ..................... 75 mA Max per 4 m (16 ft) another person to apply a moderate push-pull or
14 Gauge Wire—Amperage ..................... 50 mA Max per 4 m (16 ft)
twisting effort along the harness and at
connectors as you observe the multimeter for a
a. If the current draw is more than specification and
change in current draw.
the circuit does not have diodes or resistors,
c. When this current draw method does not identify
there is excessive resistance in the circuit.
resistance in the circuit, the harness circuit
Isolate the point of resistance and repair.
should be considered normal and the electronic
components should be thoroughly checked. Also
NOTE: The resistance can be a terminal that is dirty,
check for intermittent operation by performing
loose, deformed, corroded, eroded or
several operational checks of the electronic
improperly crimped. The wire may be broken
system.
or contain several broken strands.
OUO1089,000278B –19–13JAN05–4/4

100406
PN=69
General References
10
15 Relay Circuit Types
16
A relay is an electrical device used to allow a switch to

control multiple loads and/or large current flows without
damaging the switch. A small current from the switch
energizes the relay and it connects a power supply to a
load.
OUO1089,000278C –19–13JAN05–1/14
86 30
85 87 87A
–UN–10JAN05
LV12009
A—Switch C—Internal Switch E—Resistor F—Solenoid

B—Fuse D—Load
Common Relay Circuit • Terminal 85—ground circuit for switch (terminal 86)
• Terminal 87A—OFF position for terminal 30
• Terminal 30—supplied with battery power usually • Terminal 87—ON position for terminal 30 to
from a fuse (B) complete circuit to load (D) (lights, blower motor,
• Terminal 86—supplied with battery power from a accessories, etc.)
switch (A) (key switch, light switch, fan switch, etc.)
Continued on next page OUO1089,000278C –19–13JAN05–2/14

100406
PN=70
General References
10
15
17
86 30
85 87 87A
–UN–10JAN05
LV12010
B—Fuse D—Load
When the switch (A) is closed (turned ON), battery the solenoid, a magnetic field is created that pulls the
power is supplied to terminal 86. The current flows relay internal switch (C) from terminal 87A to terminal
through the solenoid (F) inside the relay to terminal 85 87. This allows battery power to flow from the fuse
and then to ground. As the current is flowing through through terminal 30 to terminal 87 and to the load (D).

100406
PN=71
General References
10
15
18
86 30
85 87 87A
–UN–10JAN05
LV12009
B—Fuse D—Load
When the switch (A) is opened (turned OFF), the (E), in parallel with the solenoid (F), helps to prevent
battery power stops flowing through terminal 86 to or dampen a voltage spike from happening when the
terminal 85. The solenoid (F) inside the relay loses its circuit is broken. If a voltage spike were to happen,
magnetic field and the relay internal switch (C) returns control units and other electronic components could be
to the OFF position at terminal 87A. The fixed resistor damaged.

100406
PN=72
General References
10
15
19
86 30
85 87 87A
E D
–UN–07JAN05
LV12012
A—Switch C—Internal Switch E—Indicator Light G—Solenoid
B—Fuse D—Load F—Resistor
Common Relay Circuit with Indicator Light This circuit is identical to the common relay circuit, but
it has an indicator light (E) added to the ground circuit
• Terminal 30—supplied with battery power usually (terminal 85). When the external switch (A) is closed,
from a fuse (B) and current flows through relay terminals 86 and 85,
• Terminal 86—supplied with battery power from a the indicator light (E) will be lit to tell the operator the
switch (A) (key switch, light switch, fan switch, etc.) circuit is active. An indicator light may be added to any
• Terminal 85—indicator light, ground circuit for relay relay circuit.
coil (terminal 86)
• Terminal 87—ON position for terminal 30 to
complete circuit to load (D) (lights, blower motor,
accessories, etc.)

100406
PN=73
General References
10
15
20
86 30
85 87 87A
–UN–07JAN05
LV12013
A—Fuse C—Internal Switch E—Resistor F—Solenoid
B—Switch D—Load
Relay Circuit with Power and Switch Terminals • Terminal 87—ON position for terminal 30 to
Reversed complete circuit to load (D) (lights, blower motor,
accessories, etc.)
• Terminal 86—supplied with battery power from a
switch (B) (key switch, light switch, fan switch, etc.) This relay circuit has battery power supplied to
• Terminal 30—supplied with battery power usually terminal 86 continuously, flowing through the solenoid
from a fuse (A) (F) to terminal 85 and to ground. With the solenoid (F)
• Terminal 85—ground circuit for switch (terminal 86) energized, the relay internal switch (C) is connected to
• Terminal 87A—OFF position for terminal 30 terminals 30 and 87.

100406
PN=74
General References
10
15
21
86 30
85 87 87A
–UN–07JAN05
D
LV12014
A—Fuse C—Internal Switch E—Resistor F—Solenoid
B—Switch D—Load
Current flows to the load (D) when the external switch

(B) is closed.

100406
PN=75
General References
10
15
22
86 30
85 87 87A
D
–UN–07JAN05
E
LV12015
A—Switch C—Internal Switch E—Load 2 G—Solenoid
B—Fuse D—Load 1 F—Resistor
Common Relay Circuit with Two Loads • Terminal 87A—ON position for terminal 30 load 1
(D)
• Terminal 30—supplied with battery power usually • Terminal 87—ON position for terminal 30 load 2 (E)
from a fuse (B)
• Terminal 86—supplied with battery power from a This relay circuit has the external switch (A) open.
switch (A) (key switch, light switch, fan switch, etc.) Power flows through terminal 30 to terminal 87A and
• Terminal 85—ground circuit for switch (terminal 86) to load 1 (D).

100406
PN=76
General References
10
15
23
86 30
85 87 87A
–UN–07JAN05
E
LV12016
A—Switch C—Internal Switch E—Load 2 G—Solenoid
B—Fuse D—Load 1 F—Resistor
When the external switch (A) is closed, the relay

internal switch (C) connects terminals 30 and 87 to
provide power to load 2 (E).

100406
PN=77
General References
10
15
24
86 30
85 87 87A
–UN–07JAN05
D
LV12017
A—Switch C—Internal Switch E—Flasher Module G—Solenoid
B—Fuse D—Load (Turn Signal Light) F—Resistor
Turn Signal Relay Circuits • Terminal 87A—OFF position for terminal 30

• Terminal 87—ground circuit for load (D)
• Terminal 30—supplied with battery power usually
from a fuse (B) and through a load (D) (turn signal When turn signal is activated, battery power is
light) supplied to terminal 86 through solenoid (G) to
• Terminal 86—supplied with battery power from a terminal 85. Terminal 85 is connected to flasher
switch (A) (key switch, light switch, fan switch, etc.) module which grounds the circuit intermittently to flash
• Terminal 85—circuit grounded by flasher module the lights.

100406
PN=78
General References
10
15
25
B
I
86 30
85 87 87A
G
86 30
F
–UN–07JAN05
85 87 87A
LV12018
D
A—Switch D—Load 1 F—Load 2 H—Resistor

B—Fuse E—Low Beam Relay G—High Beam Relay I—Solenoid
C—Internal Switch
Multiple Relay Circuit: Keeping Two Loads from Low Beam Relay (E):
Being On at the Same Time.
• Terminal 30—supplied with battery power from
The headlight circuit uses two relays wired together to terminal 87A of high beam relay (G)
control the headlights. This configuration prevents both • Terminal 86—supplied with battery power from Hi/Lo
high and low beams from being ON at the same time. beam switch (A)
This same configuration can be used in other • Terminal 85—ground circuit for switch (terminal 86)
applications. • Terminal 87A— OFF position for terminal 30
High Beam Relay (G): complete circuit to load 1 (D)
• Terminal 30—supplied with battery power from fuse When the Hi/Lo beam switch (A) is in the HIGH Beam
(B) position, battery power is supplied to terminal 86 of the
• Terminal 86—supplied with battery power from Hi/Lo high beam relay (G), through the solenoid (I) to
beam switch (A) terminal 85 and then to ground. Fused power (B) is
• Terminal 85—ground circuit for switch (terminal 86) supplied to terminal 30 of the high beam relay (G),
• Terminal 87A—power to terminal 30 of low beam through internal relay switch (C) to terminal 87 and
relay (E) then to load 2 (high beam lights) (F).
complete circuit to load 2 (high beam lights) (F)

100406
PN=79
General References
10
15
26
A
B
I
86 30
85 87 87A
G
86 30
F
85 87 87A
–UN–07JAN05
E
LV12019
A—Switch D—Load 1 F—Load 2 H—Resistor
B—Fuse E—Low Beam Relay G—High Beam Relay I—Solenoid
C—Internal Switch
When the Hi/Lo beam switch (A) is in the LOW beam internal relay switch (C) to terminal 87A and then to
position, battery power is supplied to terminal 86 of the terminal 30 of the low beam relay (E). Battery power
low beam relay (E), through the solenoid to terminal 85 flows from terminal 30 to terminal 87 and then to load
and then to ground. Fused power (B) is supplied to 1 (low beam lights) (D).
terminal 30 of the high beam relay (G), through

100406
PN=80
General References
10
15
27
A
86 30
I
85 87 87A
G
86 30
D C
–UN–07JAN05
85 87 87A E
LV12020
A—Switch D—Internal Switch F—Resistor H—Hi/Lo Beam Switch
B—Fuse E—Spotlight Grounding Relay G—Solenoid I—Spotlight Relay
C—Load
Multiple Relay Circuit: Allowing a Load to Be ON • Terminal 85—ground circuit to terminal 30 of

Only when Another Load Is ON. spotlight grounding relay (E)
The light circuit has a spotlight that can only be ON • Terminal 87—ON position for terminal 30 to
when the light switch (A) is in the Field 1 or 2 position complete circuit to load (spotlight) (C)
and the Hi/Lo beam switch (H) is in the HIGH beam
position. This same configuration can be used in other Spotlight Grounding Relay (E):
applications.
• Terminal 30—supplied with battery power from
SpotLight Relay (I): terminal 85 of spotlight relay (I)
• Terminal 86—supplied with battery power from Hi/Lo
• Terminal 30—supplied with battery power from fuse beam switch (H), HIGH beam position
(B) • Terminal 85—ground circuit
• Terminal 86—supplied with battery power from light • Terminal 87A— OFF position for terminal 30
switch (A), Field 1 or 2 position • Terminal 87— ground circuit

100406
PN=81
General References
10
15
28
86 30
I
85 87 87A
G
86 30
D C
–UN–07JAN05
85 87 87A E
LV12021
A—Switch D—Internal Switch F—Resistor H—Hi/Lo Beam Switch
B—Fuse E—Spotlight Grounding Relay G—Solenoid I—Spotlight Relay
C—Load
When the light switch (A) is in the Field 1 or 2 position 87 and then to ground. Battery power flows through
and the Hi/Lo beam switch (H) is in the HIGH beam fuse (B) to terminal 30 of the spotlight relay (I) to
position, battery power is supplied to terminal 86 of the terminal 87 and on to load (spotlight) (C). The Hi/Lo
spotlight relay (I). Current flows through the relay beam switch (H) provides battery power to spotlight
solenoid to terminal 85 and on to terminal 30 of grounding relay (E) terminal 86 through the solenoid
spotlight grounding relay (E). Current flows through the (G) and on to terminal 85 and ground.
spotlight grounding relay internal switch (D) to terminal
OUO1089,000278C –19–13JAN05–14/14

100406
PN=82
General References
10
Using a Digital Multimeter 15
29
It is recommended that a digital multimeter (JT05791 continuity test, autoranging, manual ranging, and touch
or equivalent with an analog display) be used to make hold.
the required electrical measurements in the diagnostics
procedures. A knowledge of the operation of the Digital Multimeter Tests
particular meter used is assumed.
Current Measurements— For amperage readings, the
NOTE: When using multimeters always refer to red (+) contact must also be moved to the desired
operation instructions supplied by the terminal on the meter.
manufacturer. The descriptions below are
specific to the JT05791. Diode Test— The “diode test” position can be used to
test diodes. A single tone will sound in the forward
The positive test lead from the volt-ohm input of the bias direction along with a display of forward voltage
meter should be connected to point A and the negative drop.
test lead from the common input of the meter should
be connected to point B. Continuity Test— The meter also can be used to test
continuity. If the circuit is open, there will be no tone. If
Unless otherwise stated, all voltage measurements are the circuit made has continuity (less than 150 ohms), a
direct current (DC). continuous tone will sound.
In making a resistance measurement, be careful to use Autoranging— The meter powers up in the autorange
the correct resistance range on the meter. Disconnect mode. Range is selected automatically. The digital
appropriate connectors or turn off key switch, as display indicates the range.
directed by diagnostic procedures later in this manual.
Manual Ranging— When the button in the middle of
Digital Display— The digital display reads values of the selector knob is pressed with the meter on, the
variables measured. It is updated 2-1/2 times a range is selected manually. You can “dial” through
second. In normal operation the meter selects the ranges by repeatedly pressing the button. As in the
range which will show the most accurate reading. autorange mode, range in use will be shown in the
When the value being measured is too large for the digital display. To return to autorange mode, press
meter to display, an OL (overload) will be shown. range button for 1 second. Meter will “chirp” once and
Position of decimal point will change, depending upon return to autorange mode.
range in use. The display also verifies the type and
size of measurement being made. Touch Hold— If the button in the selector is pressed
and held down while the meter is being turned on, and
Analog Display— This is a bar graph located below held until the display reaches full brightness, the meter
the digital display. The analog display is updated 25 is in the touch hold” mode. In touch hold, any reading
times per second. It is more responsive to help see which is constant for a minimum of 1/2 second and
trends developing in variable readings. The polarity differs from the previous reading by at least one bar of
indicator is also part of this display. The full bar graph the analog display will be “captured” by the meter. A
indicates the maximum reading for a scale. The tone (beep) will sound when the reading has been
arrowhead indicates OL. held. The operator can then remove the probes and
the reading will be retained. Touch hold is always in
Selector— The selector is the command dial which autorange mode. Turn the selector switch to OFF to
allows the operator to select the type of variable to be deactivate touch hold.
measured, i.e., current measurements, diode test,
OUO1089,000278D –19–13JAN05–1/1

100406
PN=83
General References
10
15 Troubleshooting Unresolved Problems
30
NOTE: This reference is a guideline for troubleshooting

problems that still exist after standard diagnostics
have been performed. These problems are
typically due to specific operating conditions,
intermittent failures or, in rare cases, control unit
failures. Depending on the situation, some or all of
the following may be important.
Problems Due to Specific Operating Conditions
Review all recorded codes and consult with operator to

determine operating and vehicle conditions when the
problem occurs. Record details.
❒ Does code/problem occur at the same time as other

problems?
❒ Does code/problem occur when vehicle is warm or
cold?
❒ Does code/problem occur during field or transport
operation?
❒ Does code/problem occur while performing a specific
action such as shifting, turning, braking, operating
certain hydraulics?
❒ When did code/problem first appear? Was there any
maintenance performed recently? (If yes, inspect areas
of maintenance for inadvertent damage or improper
installations.)
Attempt to recreate code/problem based on conditions. If

possible, repeat operational, system, electrical, hydraulic
or mechanical checks under these conditions.
Problems Due to Intermittent Electrical Failures
NOTE: Electrical intermittent failures are usually caused

by harness, terminal or connector problems.
❒ Inspect all connectors and terminals of related circuits.

❒ Inspect mechanical linkages for interference with
harnesses or connectors.
❒ Inspect harnesses for missing or improperly installed
clamps or bands. Loose harnesses that are allowed to
move too freely or harnesses that are banded too
tightly may result in worn or damaged wires.
Continued on next page OUO1089,000278E –19–13JAN05–1/2

100406
PN=84
General References
10
❒ Inspect mechanical linkages for proper operating 15
31
condition.
Problems Due to Control Unit Failures
NOTE: Before replacing control unit, review all tests.

Control units are the least likely cause of failure!
❒ If all checks have been made with no problems

identified, check power and ground circuits. Power
inputs must be within 1 V of battery voltage and ground
circuits must be less than 1.0 ohm to the vehicle single
point ground.
❒ Inspect all connectors and terminals of associated
control units.
OUO1089,000278E –19–13JAN05–2/2

100406
PN=85
General References
10
15
32

100406
PN=86
Group 25
Fluid Recommendations
10
Radiator 25
1
Antifreeze (Ethylene Glycol) 7.6 L (2 Gal) min.
Recommended 50 percent by volume
Non-chromate inhibitor ..................................... 3-6 percent by volume

Clean Water ......................................................................... Remainder
CAUTION: Cooling system is pressurized —

radiator has a 10 PSI (0.7 Bar) pressure cap.
CAUTION: Do Not remove the radiator cap when

it is hot!
Fill the radiator, operate the engine with the radiator cap
off and when the engine reaches normal operating
temperature, shut it off and check the coolant level. Top
off the radiator with clean water, if necessary.
T803324,00008ED –19–02FEB06–1/1
Transmission
SAE 85W140 (API-GL5) Oil ............................................................................................................................................................. 10.5 L (11 Qt.)
T803324,00008DD –19–01FEB06–1/1
Rear Steering Axle

SAE 85W140 (API-GL5) Oil or Equivalenta
Final Drives (2) - Power Assist Option ............................................................................................................................................. 1.3 L (1.4 Qt.)
Final Drives (2) - High Traction Option .......................................................................................................................................... 2.6 L (2.75 Qt.)
a
Gear oil which meets AGMA (American Gear Manufacturers Association) Grade 5EP with a viscosity index of 95 min.
T803324,00008DD –19–01FEB06–1/1

100406
PN=87
10
25 Front Rigid Axle
2
SAE 85W140 (API-GL5) Oil or Equivalenta
Large Final Drive(s) .............................................................................................................................................................................. 8 L (8.5 Qt)
a
Gear oil which meets AGMA (American Gear Manufacturers Association) Grade 5EP with a viscosity index of 95 min.
T803324,00008DD –19–01FEB06–1/1
Hydraulic Tank
SAE 30W Motor Oil .......................................................................................................................................................................... 320 L (85 Gal)
Which complies with one or more of the API Classification

CD/SF, CD/SD, CC/SF, CC/SD and MIL-I-2104D.
Optional 15W30, CG-4 Motor Oil ..................................................................................................................................................... 320 L (85 Gal)
T803324,00008DD –19–01FEB06–1/1
Fuel Tank
Clean Diesel Fuel ............................................................................................................................................................................. 303 L (80 Gal)
T803324,00008DD –19–01FEB06–1/1
Tire Inflation Pressure1

Front Tires
24.5 x 32 Bar (12 PR) ................................................................................................................................................................. 1.66 Bar (24 PSI)
30.5 L x 32 (12PR) ........................................................................................................................................................................ 2.21 bar (32 PSI)
Rear Tires
18.4 x 26 (6PR) .......................................................................................................................................................................... 1.24 Bar (18 PSI)
18.4 x 26 (8PR) .......................................................................................................................................................................... 1.38 Bar (20 PSI)
18.4 x 30 (10PR) ......................................................................................................................................................................... 1.79 Bar (26 PSI)
23.1 x 26 (10 PR) ........................................................................................................................................................................ 1.38 Bar (20 PSI)
1
Adjust to conditions.
T803324,00008DD –19–01FEB06–1/1

100406
PN=88
10
Pump Drive 25
3
If the double pump drive is used, lubricate the pump drive

shafts and the splines with dry spline lubricant whenever
installing a pump or pump drive.
85W140 (API GL5 ) Gear Oil ............................................................................................................................................................. 4.9L (1.3 Gal)
T803324,00008DD –19–01FEB06–1/1
Engine Coolant Requirements1
Proper cooling system maintenance helps control engine

cylinder wall pitting caused by corrosion, cavitation and
the accumulation of scale and rust in the cooling system.
Cylinder wall failure, or damage caused by overheated
surfaces, can occur in a short time without the proper
coolant.
Use a mixture of 50 percent clean water and 50 percent

ethylene glycol (antifreeze). This will lower the freezing
point of the mixture and raise the point at which boiling
starts. This also lowers the concentration of impurities
held in suspension by the water. Add to this mixture, a
water conditioner (corrosion inhibitor) to give a 3 to 6
percent concentration.
The following prediluted engine coolant is preferred for

service.
John Deere COOLGARD Prediluted Coolant
The following engine coolant is also recommended.
John Deere COOLGARD Coolant concentrate in a 40 to 60 percent mixture of concentrate with quality water. Other low silicate ethylene
glycol base coolants for heavy duty diesel engines may be used if they meet one of the following specifications:
ASTM D5345 (prediluted coolant)
ASTM D4985 (coolant concentrate) in a 40 to 60 percent mixture of concentrate with quality water.
Coolants meeting these specifications require use of

supplemental coolant additives, formulated for heavy duty
diesel engines, for protection against corrosion and
cylinder liner erosion and pitting.
1
For additional information, refer to Engine Manual.
T803324,00008EE –19–02FEB06–1/1

100406
PN=89
10
25 Antifreeze
4
Antifreeze must be ethylene glycol type, not more than 0.1

percent anhydrous metasilicate1. Some types of ethylene
glycol antifreeze commonly available on the market are
intended for automotive use. These products are often
labeled for use in aluminum engines and usually have
more than 0.1 percent anhydrous metasilicate. Use of this
type antifreeze can cause a gel-like deposit to form that
will reduce heat transfer and coolant flow. When wet, the
gel is the same color as the coolant, but when dry, it
forms a white, powdery deposit.
Antifreeze solutions should be used year round for freeze

protection, boilover protection, and as a stable
environment for seals and hoses.
1
Never use Methyl Alcohol based and Methoxy Propanol antifreezes.
T803324,00008EF –19–02FEB06–1/1
Water
Water quality is important to the performance of the

cooling system. Distilled, deionized or demineralized water
is recommended for mixing with ethylene glycol base
engine coolant concentrate.
Never use plain water as the engine coolant. This will

shorten engine life and cause major damage. Plain water
is corrosive, especially at high temperatures and under
pressure. Use only clean drinking water in the solution.
DO NOT use water from field canals.
T803324,00008EF –19–02FEB06–1/1

100406
PN=90
10
Inhibitors (Conditioners) 25
5
Non-chromate inhibitors must be used. DO NOT use

soluble oil. Always follow the supplier recommendations
printed on the container. Overinhibiting antifreeze
solutions can cause silicate dropout. When this happens,
a gel-like deposit is created which retards heat transfer
and coolant flow.
T803324,00008F0 –19–02FEB06–1/1
Filling the System
1. Mix antifreeze to provide protection to the lowest

expected ambient temperature. Do not fill cooling
system to the top, allow for addition of conditioner.
Most systems will require 2 L (2 Qts) of conditioner at
initial fill and 0.50 L (1 pt) every 250 service meter
hours thereafter.
2. To help avoid air pockets, add coolant slowly, fill at 19

L (5 US Gal) per minute or less.
3. Add cooling system conditioner.
4. Fill the coolant level to within 1 cm (1/2”) of the fill

pipe’s bottom.
5. Start the engine with the radiator cap removed.

(Inspect cap after removing, replace seal, if it is
damaged.) Add coolant, if necessary, when the level
stabilizes.
6. Stop the engine and install the radiator cap. Be sure

that the radiator cap has been properly reinstalled. The
John Deere 6068D uses a 10 PSI cap.
7. Periodically blow or wash the oil cooler and radiator to

remove accumulated dirt and trash.
T803324,00008F1 –19–02FEB06–1/1

100406
PN=91
10
25 Fuel Specifications
6
Use either grade 1-D or grade 2-D fuel defined by the

ASTM designation D975 or D396 for diesel fuels in John
Deere engines1.
–UN–02FEB06
CM061850010
Ambient Temperature Chart
1
The grade you should use is determined by the ambient temperature in
your area. Refer to the Ambient Temperature Chart to determine which
fuel you should use. At altitudes above 1500 M (5000 ft), use only grade
1-D for all temperatures.
T803324,00008F2 –19–02FEB06–1/1
Sulphur Content
Fuel sulphur content should be less than 0.5 percent

when using the recommended crankcase oil drain
intervals and API CF4 or CF4/ SG performance oils.
Diesel fuel, having a sulphur content greater than 1
percent, may cause increased wear on metal engine parts
due to acids or ash produced during the combustion
process.
T803324,00008F3 –19–02FEB06–1/1

100406
PN=92
10
Cetane 25
7
The cetane number should be no less than 40 to assure

satisfactory starting and overall performance. A higher
cetane number of 45 is necessary when operating in high
altitudes or cold weather starting (temperatures below 0°
C [32° F]).
T803324,00008F4 –19–02FEB06–1/1
Cloud Point
Cloud point should be at least 10° C (6° F) below the

lowest ambient temperature at time of starting. Wax can
separate from the fuel when the temperature decreases to
cloud point and may plug your filter.
T803324,00008F5 –19–02FEB06–1/1
Storage and Handling
After buying good quality, clean fuel from a reputable

supplier, proper storage is critically important.
1. Use clean storage and transfer tanks.
2. Periodically drain the water and sediments from the

bottom of your storage tanks.
3. Avoid storing fuel over a long period of time, if you

must; add a fuel conditioner to prevent water
condensation.
T803324,00008F6 –19–02FEB06–1/1

100406
PN=93
10
25 Hydraulic Fluid
8
Engine oil may be used provided it meets one of the

following: API Service CD/SF, CD/SD, CC/SF, CC/SD or
MIL-L-2104C or John Deere TORQ-GARD SUPREME.
Recommended: SAE 30W Motor Oil
Optional: SAE 15W30 CG-4 Motor Oil
TORQ-GARD SUPREME is a trademark of Deere & Company T803324,00008F8 –19–03FEB06–1/1

100406
PN=94
10
Engine Oil 25
9
Due to significant variations in commercially available

engine oils, we recommend John Deere PLUS-50.
If John Deere PLUS-50 engine oil and a John Deere oil

filter are used, the service interval for oil and filter
changes may be extended by 50 hours.
6068T John Deere (200 HP) ........................................... 20 L (21 Qt.)

Break-in oil, 100 hrs, followed by above CG-4 15W40 Multi Grade.
Change filter and completely drain after 100 hours.
The following oil is also recommended:
• John DeereTORQ-GARD SUPREME

• 15W40+50 Multi-Grade
Other oils may be used if they meet one or more of the

following:
• John DeereUNI-GARD
• API Service Classification CG-4
• API Service Classification CF-4
• ACEA Specification E3
• ACEA Specification E2
• CCMC Specification D5
• CCMC Specification D4
Multi-viscosity diesel engine oils are preferred.
IMPORTANT: If diesel fuel with sulfur content greater

than 0.5 percent is used, reduce the
service interval by 50 percent.
PLUS-50 is a trademark of Deere & Company

TORQ-GARD SUPREME is a trademark of Deere & Company
UNI-GARD is a trademark of Deere & Company T803324,00008F9 –19–03FEB06–1/1

100406
PN=95
10
25 Transmission
10
Use an 85W140 multi-grade oil that meets extreme

pressure (EP) gear lubricant specification MIL-L-210C or
API classification.
T803324,00008FA –19–03FEB06–1/1
Gear Oil - Pump Drive
Use an 85W140 multi-grade oil that meets extreme

pressure (EP) gear lubricant specification MIL-L-210C or
API classification GL-5.
T803324,00008FB –19–03FEB06–1/1
Gear Oil - Final Drive
Use a gear oil which meets American Gear Manufacturers

Association (AGMA) grade 5 EP with a viscosity index of
95.
T803324,00008FC –19–03FEB06–1/1
Grease
Use an SAE multipurpose grease containing 3 to 5

percent molybdenum disulfide and having extreme
pressure (EP) performance.
T803324,00008FD –19–03FEB06–1/1

100406
PN=96
Section 20
Engines
Contents 20
Page

John Deere Engine Repair—Use CTM104 . . . .20-05-1

100406
PN=1
Contents
20

100406
PN=2
Group 05
General Information
John Deere Engine Repair—Use CTM104
For complete repair information the component technical

manual (CTM) is also required. Use the component
technical manual in conjunction with this machine manual.
20
05
• 6 cylinder 6.8 L engines—Use CTM104
–UN–17JAN89
1
TS225
OUO1089,000273E –19–07JAN05–1/1

100406
PN=99
General Information
20
05
2

100406
PN=100
Section 40
Electrical System
Contents
Page

Visually Inspect Electrical System . . . . . . . . . . .40-10-1 40
Safety Precautions . . . . . . . . . . . . . . . . . . . . . .40-10-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-3
Alternator and Battery . . . . . . . . . . . . . . . . . . . .40-10-4
Cleaning Battery Posts . . . . . . . . . . . . . . . . . . .40-10-5
Jumping the Battery . . . . . . . . . . . . . . . . . . . . .40-10-6
Charging the Batteries. . . . . . . . . . . . . . . . . . . .40-10-6
Precautions for Alternators . . . . . . . . . . . . . . . .40-10-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-8
Common Circuit Tests. . . . . . . . . . . . . . . . . . . .40-10-9
Start Switch Check . . . . . . . . . . . . . . . . . . . . .40-10-10
Horn Switch Check . . . . . . . . . . . . . . . . . . . . .40-10-10
Horn Check . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-10
Electrical Checks continued... . . . . . . . . . . . . .40-10-12

100406
PN=1
Contents
40

100406
PN=2
Group 10
General Information
Visually Inspect Electrical System
Make the following visual electrical inspection prior to

starting the equipment:
CAUTION: Wear eye protection and remove

rings, metal watch bands, and other metal
jewelry when working on the electrical system.

40
short across to another component. 10
1
–UN–06JAN00
2. Look for a missing or worn conduit. This could indicate
a wire problem.
3. Look for loose or broken connectors and wires.
CM989999014
4. Inspect battery for:
• Corroded Terminals
• Loose Terminals or Battery Posts
• Dirty Condition
• Cracked Case
• Proper Electrolyte Level
6. After equipment 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 IGN. Try
out the accessory circuits, indicators lights and gauge
lights, etc. How does each of these components work?
Look for sparks or smoke, which might indicate shorts.
8. Start the machine. Check all gauges for good operation

Continued on next page T803324,000098E –19–17MAR06–1/2

100406
PN=103
General Information
9. In general, look for anything unusual. Many electrical

failures cannot be detected even if the harvester is
running. Therefore, a systematic and complete
T803324,000098E –19–17MAR06–2/2
Safety Precautions
40 CAUTION: Explosive gas is produced when

10 battery is in use or being charged.
2
1. Keep all flames/sparks away from battery.
2. Charge battery in a well ventilated area.
3. Always remove negative (-) battery cable first and

replace it last.
4. Never lay a metal object on top of a battery: a short

circuit can result, damaging the battery and metal
object.
5. If acid spills on clothing, immediately remove clothing.
6. If acid contacts skin, rinse affected area with running

water for 15 minutes.
Continued on next page T803324,000098F –19–17MAR06–1/2

100406
PN=104
General Information
7. If acid splashes into eyes, hold eyelids open and flood

eyes with running water for 10 to 15 minutes, then see
a doctor at once. DO NOT use any medication or eye
drops unless prescribed by a doctor.
CAUTION: Sulfuric acid in battery electrolyte is
–UN–23AUG88
poisonous. Electrolyte can cause severe burns
if it contacts the eyes or skin. Always wear eye
and face protection when working around
batteries.
40
TS204
10
8. To neutralize acid spilled on the floor of the machine, 3
flood the spill with one of the following mixtures, then
rinse thoroughly with clean water:
• 0.5 kg (1 lb) of baking soda in 4 L (1 gal) of water

• 0.4 L (1 pt) of household ammonia in 4 L (1 gal) of
water
T803324,000098F –19–17MAR06–2/2
Specifications
Your machine is equipped with a negative ground

electrical system. It uses 12 volt batteries. Only use
batteries that meet the following specifications:
Part Number ......................................................................... AT144146

BCI Group Size ................................................................................ 31
Cold Cranking Amps at -18° C (0° F) ............................................ 925
Reserve capacity at 25 amps ........................................... 190 minutes
T803324,0000990 –19–17MAR06–1/1

100406
PN=105
General Information
Alternator and Battery
Theory of Operation
A battery is a device for converting chemical energy to

electrical energy. It is not a storage tank for electricity, but
stores electrical energy in chemical form.
Because of the constant chemical to electrical change, the

battery has a limited life. Proper care will extend the life of
40 the battery.
10
4
In a fully charged battery, the electrolyte solution is
approximately 1.27 times heavier than water. The amount
that the solution is heavier than water is called specific
gravity.
All batteries will self-discharge over a period of time.

Temperature and amount of time will both determine the
rate of discharge. If a machine is not used for a period of
time, the batteries must be stored in a cool place.
The batteries provide the energy to start the engine and

power the electrical loads when they exceed the
alternator’s capacity.
The alternator provides power for the electrical equipment

when the machine is running. If the electrical load
exceeds the alternator’s capacity for short periods, the
batteries will supply the necessary power as long as
possible.
The alternator is belt driven by the engine crankshaft and

can provide power immediately after startup.
T803324,0000991 –19–17MAR06–1/1

100406
PN=106
General Information
Cleaning Battery Posts
NOTE: Before diagnosing an alternator or battery

problem, be sure accessory electrical equipment
has not been added that might exceed the
alternator’s capacity. If excessive load has been
added, the ability to recharge the batteries could
be affected.
1. Disconnect battery clamps, grounded () clamp first, and

wipe clean with a damp cloth. 40
10
5
2. If terminals are corroded, wash with a stiff brush and
an ammonia solution.
3. After washing, flush battery and compartment with

clear water. Keep caps in place while cleaning.
4. Apply lubricating grease around the battery terminal

base only.
5. Install and retighten clamps; grounded clamp last ().
T803324,0000992 –19–17MAR06–1/1

100406
PN=107
General Information
Jumping the Battery
CAUTION: Loader electrical system is a 12V

system. Do not use a 24V system to jumpstart.
CAUTION: Always remove the grounded (-)

battery clamp first and replace it last.
1. When possible, use equipment with a switch in the line

40 connecting the booster battery to the battery to be
10 jumped.
6
2. Connect the booster cable to the batteries in parallel

(positive to positive and negative to negative).
3. Rock the connector clips to ensure that they are

fastened securely.
4. If only jumper cables are available, always make the

last connection from the negative terminal of the
booster battery to a ground point on the machine
frame1, away from the batteries.
1
The machine electrical system has a negative (-) ground.
T803324,0000993 –19–17MAR06–1/1
Charging the Batteries
1. To start the engine using a battery charger; turn off the

charger before connecting and disconnecting.
2. DO NOT use a battery charger as a booster if the

battery has a 1.15 specific gravity reading or lower.
3. To charge a battery, disconnect positive and negative

cables before charging.
4. If a unit has more than one battery, each battery must

be charged separately.
5. DO NOT charge a battery if it is frozen— it may

explode. Warm the battery to 10° C (50° F), before
charging.
T803324,0000994 –19–17MAR06–1/1

100406
PN=108
General Information
Precautions for Alternators
CAUTION: Alternator is a 12V system. Do not

use a 24V booster.
When batteries are connected, follow these rules:
1. Disconnect the negative (-) cable when you work on or

near the alternator.
40
2. DO NOT try to polarize the alternator. 10
7
3. Be sure that alternator wires are connected correctly
before connecting batteries.
4. DO NOT ground alternator output terminal.
5. DO NOT disconnect or connect any alternator wire

while batteries are connected or while the alternator is
working.
6. Connect batteries or booster battery in the correct

polarity (positive [+] to positive [+] and negative [-] to
negative [-]).
7. DO NOT disconnect the batteries when the engine is

running and the alternator is charging.
8. Disconnect the battery cables before you connect a

battery charger to the batteries.
T803324,0000995 –19–17MAR06–1/1

100406
PN=109
General Information
Inspection
Inspect the electrical system for clues to the malfunction.

Check to see if the unit can be operated without further
damage to the system.
ALWAYS visually check the following before turning on

switches or running the unit.
1. Look for bare wires that could cause grounds or shorts.

40
10 2. Look for loose or broken wires.
8
3. Inspect all connections, especially battery connecting

points. The cleaning of harness connectors or ground
connections can often correct what appears to be a
malfunctioning component.
4. Check the engine fan belt tension.
5. Inspect for overheated parts after the unit has been

stopped for a while. They will often smell like burned
insulation. Put your hand on the alternator, heat in this
area, after the unit has not been operated in some
time, is a sure indication of charging circuit problems.
6. In general, look for anything unusual.
7. If your visual inspection does not turn up the possible

malfunction, but the machine can be run, turn the
ignition switch ON, look for sparks or smoke that may
indicate a short.
T803324,0000996 –19–17MAR06–1/1

100406
PN=110
General Information
Common Circuit Tests
Symptom Problem Solution
Shorted Circuit A shorted circuit may result in the Turn component switch ON. Start at
wrong component operating (i.e. the controlling switch of the
improper wire-to-wire) contact). To component that should not be
test for a shorted or improperly wired operating. Follow the circuit and
circuit.1 disconnect wires at connectors until
the component stops operating.
Shorted or improper connections will 40
be the last two wires disconnected. 10
9
High Resistance or Open Circuits These usually result in slow, dim or To test for high resistance and open
no component operation (i.e. poor, circuits: Check all terminals and
corroded, or disconnected grounds in the circuit for corrosion. If
connections). terminals are not corroded or loose,
the problem is in the component
wiring.
Grounded Circuits These usually result in no Do operational tests.

component operation or blown fuses.
Ignition Switch Test Disconnect harness, turn switch off. Test with ohmmeter. If ohmmeter
reads continuity, the switch must be
replaced.
Turn switch to ACC. Connect ohmmeter. Ohmmeter must

read continuity between B and ACC
and B and ACC terminals. If not,
replace switch.
Alternator Output Check Turn ignition switch off. Measure battery voltage. Voltage
must be 12-13 volts (only for 12 V
DC systems).
Start engine and run at 1500 RPM. Engine running voltage must be at
13 - 15 volts at alternator (for 12V
DC system).
1
All voltage readings are taken between the test point and the ground on
the harvester unless otherwise specified.

100406
PN=111
General Information
Starter Solenoid Check Disconnect metal connector from Solenoid must click. If not, replace.
starter motor large terminal. Connect
battery voltage to solenoid small
terminal. Ground metal strap from
solenoid with heavy gauge wire.
Starter Motor Check Disconnect metal connector from Starter motor must turn, but should
starter motor large terminal. Connect not crank engine. If so, it must be
40 a heavy gauge wire from battery repaired or replaced.
10 positive cable to starter motor
10
terminal.
T803324,0000997 –19–17MAR06–2/2
1 Start Switch Check
– – –1/1
1a Disconnect harness Ohmmeter must read continuity. OK: Done

from switch. Connect
ohmmeter to switch NOT OK: Replace switch
terminals. Push
switch button.
– – –1/1
1 Horn Switch Check
– – –1/1
1a Disconnect harness Ohmmeter must read continuity. OK: Done

from switch. Connect
ohmmeter to switch NOT OK: Replace switch
terminals. Push
switch button.
– – –1/1
1 Horn Check
– – –1/1

100406
PN=112
General Information
1a Connect battery Horn must sound. OK: Done

voltage to horn
terminal and ground NOT OK: Replace horn.
horn housing.
– – –1/1
40
10
11

100406
PN=113
General Information
Electrical Checks continued...
Nothing works. Problem with power circuit Check power circuit.

components.
Battery undercharged or dead.
Charge or replace battery.

40
10 Battery cables making poor Clean cable connections at battery,
12
connections. starter and frame ground.
Ignition switch failure. Test switch and replace, if

necessary.
Some Electrical Components Fuse blown. Check fuses and replace, if

Work necessary with same rate fuses.
Starter switch failure. Check fuse and replace, if

necessary.
Check switch and replace, if

necessary.
Starter Will Not Crank Engine Battery undercharged or dead. Check and replace, if necessary.
Battery cables making poor Clean connections at battery, starter

connections. and frame ground.
Starter solenoid failure. Test and replace, if necessary.
Starter motor failure. Test and replace, if necessary.
Major engine failure. See engine manual for repairs.
Engine Cranks Slowly Batteries Undercharged. Charge batteries.
Alternator belt loose or glazed. Adjust or replace belt.
Starter armature bearings worn Repair or replace starter.

causing starter drag.
Alternator failure. Inspect, repair or replace.
Battery cable connections loose or Clean and tighten connections.

corroded.

100406
PN=114
General Information
Starter Turns, But Engine Will Wiring at starter solenoid making Clean and tighten connections.
Not Crank poor connections.
Starter pinion not engaging flywheel Repair or replace starter.

ring gear.
Starter pinion or flywheel gear teeth Replace pinion or flywheel.

broken.
40
Starter Still Runs After Engine Starter solenoid stuck, Lightly tap on case of solenoid. 10
13
Starts Replace solenoid.
Starter not disengaging. Lightly tap on starter case.
Replace or repair shift mechanism.
Start relay stuck. Lightly tap on relay.
Wiring harness shorted. Check wiring harness.
Low Battery Output Dirty or wet battery top, causing Clean battery and wipe dry.
discharge.
Corroded or loose battery cable Clean and tighten end clamps.

ends. Recharge batteries separately.
Broken or loose battery posts. If posts are loose or will turn, replace
battery.
Loose fan/alternator belt or worn Inspect belt or pulley. Adjust or

pulleys. replace as necessary.
Starter Solenoid Chatters Poor connection at battery or starter. Clean and tighten connections.
Low battery charge. Charge or replace batteries.
Starter solenoid “hold-in” winding Check solenoid, replace if

open. necessary.

100406
PN=115
General Information
Noisy Alternator Worn drive belt. Inspect and replace.
Pulley misaligned. Adjust alternator mount.
Alternator bearing failure. Loosen alternator belts, turn pulley

by hand. If any roughness is felt,
repair or replace.
40 Internal alternator failure. Repair or replace alternator.

10
14
Gauge Does Not Work (Applies Fuse blown. Replace fuse.
To All Gauges)
Gauge failure. Test gauge and replace, if

necessary.
Gauge sender failure. Test and replace, if necessary.
Wiring harness problem. Inspect and repair or replace.
Horn Does Not Work Fuse Blown. Replace fuse.
Horn Failure. Test horn and replace, if necessary.
Horn switch failure. Test and replace, if necessary.
Backup Alarm Does Not Work Fuse Blown - Voltmeter should read Replace fuse.
zero. Also, the windshield wiper
motor and the piler lift and lower
commands should not work.
Reverse Alarm Failure Replace Reverse Alarm.
Reverse Alarm Pressure Switch Replace Reverse Alarm Pressure

Failure Switch
Engine Hour Meter Not Working Fuse Blown would also prevent Replace fuse.
engine start/run
Hour Meter Failure Replace hour meter. Record time

from old hour meter for the engine
records.

100406
PN=116
General Information
Engine Oil Pressure Warning Fuse Blown - Voltmeter should read Replace fuse.
Alarm (Light or Audible Alarm) zero. Also Windshield Wiper Motor,
Does Not Work Piler Lift/Lower Commands, Reverse
Alarm and Engine Water
Temperature Alarm should not work.
Disconnected wire. Verify wire is connected between

alarm and the engine oil pressure
gauge. 40
10
15
Oil Pressure Gauge failure. Gauge Replace Engine Oil Pressure Gauge
may still indicate oil pressure but
pressure alarm switch inside gauge
may have failed.
Alarm Failure - either light or audible Replace alarm.
Engine Water Temperature Alarm Fuse Blown - Voltmeter should read Replace fuse.
(Light or Audible) Does Not Work zero. Also windshield wiper motor,
Piler Lift/Lower Commands, Reverse
Alarm and Engine Oil Pressure
Alarm Should Not Work
Disconnected wire. Verify wire connected between alarm

and the engine water temperature
gauge.
Water Temperature Gauge Failure - Replace Engine Water Temperature

Gauge may still indicate engine Gauge
water temperature, but the
temperature alarm switch inside
gauge may have failed.
Alarm Failure - Either Light or Replace alarm.

Audible

100406
PN=117
General Information
Neutral Start Does Not Work Switch on Park Brake Level - Verify Reset bracket and switch.
proper position (bracket not bent
correctly) and switch being actuated.
Switch on Park Brake Lever not Replace switch.

working.
Hydrostatic Destroke Solenoid Valve Replace solenoid valve.

40 Failure
10
16
Destroke Solenoid Relay Failure Replace relay.
Blown Fuse - Horn should also not Replace fuse.

work.
Engine Fuel Shutoff Solenoid Blown Fuse - Engine should not run. Replace fuse.
Does Not Work
Fuel Shutoff Solenoid Does Not Replace Engine Fuel Solenoid

Work
Piler Lift/Lower Commands Do Blown Fuse - Windshield Wiper Replace fuse.

Not Work Motor, Reverse Alarm, Engine Oil
Pressure Alarm, Engine Water
Temperature Alarm should not work
and Voltmeter should read zero.
Switch or wire failure in right hand Repair or replace joystick valve.

joystick valve.
Piler Lift/Lower Relay Failure Replace relay.
Directional Valve Failure - Pilot Oil Pressure Verify pilot oil supply and pressure.
Solenoid controlled, pilot
operated section of three bank
directional control valve.
Signals to solenoid valves. Verify command signals to solenoid

valves when commands given by
switch on right hand joystick valve.
Solenoid Control, Pilot Operated Replace Solenoid Control Valve,

Valve Section not working Solenoid Control, Pilot Operated
Valve Work Section or complete 3
Bank Directional Control Valve

100406
PN=118
General Information
Optional Engine Safety Shutoff Blown fuse. Replace fuse.

Not Working - Activated by low
engine oil pressure or high
engine water temperature signals
from the gauges on the dash.
Failure of switch in either Engine Oil Replace gauge.

Pressure Gauge or Engine Water
Temperature Gauge 40
10
17
Engine Safety Shutoff Switch Failure Replace the optional Engine Safety
Shutoff Switch
T803324,0000999 –19–21MAR06–6/6

100406
PN=119
General Information
40
10
18

100406
PN=120
Section 50
Hydrostatic System
Contents
Page
Group 10—Pumps & Motors

Rear Motor Displacement Control (High
Traction Option) . . . . . . . . . . . . . . . . . . . . . . .50-10-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . .50-10-2
Operating Principle . . . . . . . . . . . . . . . . . . . . . .50-10-3
Closed Loop Circuit (Hydrostatic Ground
Drive Circuit) . . . . . . . . . . . . . . . . . . . . . . . . .50-10-4
50
Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-4
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-5
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . .50-10-5
System Check Valves . . . . . . . . . . . . . . . . . . . .50-10-5
Multi-Function Valves . . . . . . . . . . . . . . . . . . . .50-10-6
Pressure Limiter and High Pressure Relief
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-6
Bypass Valves . . . . . . . . . . . . . . . . . . . . . . . . .50-10-6
Auxiliary Mounting Pads . . . . . . . . . . . . . . . . . .50-10-7
Hydraulic Displacement Control. . . . . . . . . . . . .50-10-7
Initial Start-up Procedure. . . . . . . . . . . . . . . . . .50-10-8
Fluid and Filter Maintenance . . . . . . . . . . . . . .50-10-10
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . .50-10-10
Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . .50-10-14
Charge Relief Valve Adjustment . . . . . . . . . . .50-10-16
Multi-Function Valve Pressure Adjustment . . .50-10-17
Engaging the Bypass Function . . . . . . . . . . . .50-10-19
Hydraulic Displacement Control. . . . . . . . . . . .50-10-20
Shaft Seal and Shaft Replacement . . . . . . . . .50-10-22
Group 20—Minor Pump Repairs

Multi-Function Valve Cartridges. . . . . . . . . . . . .50-20-1
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . .50-20-2
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-3
Installing the Charge Pump . . . . . . . . . . . . . . . .50-20-5
Auxiliary Pad Installation . . . . . . . . . . . . . . . . . .50-20-7
Hydraulic Displacement Controls. . . . . . . . . . . .50-20-9
Group 30—Displacement Control Components

Displacement Control Filter Screens . . . . . . . . .50-30-1
Displacement Control Orifice Check Valve . . . .50-30-1
Displacement Control Orifices . . . . . . . . . . . . . .50-30-2
Disassembly Procedures for Variable
Displacement Pump. . . . . . . . . . . . . . . . . . . .50-30-3
Reconditioning and Replacement of Parts. . . . .50-30-6
Assembly Procedures for Variable
Displacement Pump. . . . . . . . . . . . . . . . . . . .50-30-9

100406
PN=1
Contents
50

100406
PN=2
Group 10
Pumps & Motors
Rear Motor Displacement Control (High
Traction Option)
1—Bolt
2—Knob
3—Decal
4—Pin-Split
5—Collar
6—Bolt
7—Cartridge
8—Bolt
9—Body-Valve
10—Bolt
11—Washer
12—Nut
13—Valve Mount
14—Bolt
50
10
1
–UN–04OCT06
CM00312074A2
T803324,00009BF –19–04OCT06–1/1

100406
PN=123
Pumps & Motors
Theory of Operation
The control valve, pressure reducing valve, simply varies

the pressure signal that is sent to the rear wheel motor to
adjust the displacement of the motors. A pressure
–UN–04OCT06
reducing valve in hydraulics is equivalent of a pressure
regulator in a compressed air system, and the operating
principle of the two is basically the same although they
are constructed quite differently.
CM062254015
A pressure reducing valve is for the purpose of
establishing a lower pressure level in the branch circuit
from that in the main pump line. The inlet is connected to Simplified Hydraulic Symbol
a source of high pressure and the adjustment is set to
deliver a constant maximum pressure at the outlet
regardless of pressure fluctuations on the inlet, as long as
50
10 the inlet pressure remains as high as or higher than the
2 adjustment setting. Branch circuits operating from a
reducing valve act the same way as any other hydraulic
circuit. Pressure in the branch is directly proportional to
the load resistance, and will be no higher than demanded
by the load. But the maximum pressure available to the
branch is limited by the adjustment setting. The load can
move at full speed as long as it does not demand a
pressure higher than the adjustment setting. But if the
load should increase to the point that it demands more
pressure than the adjustment setting, this in effect is an
overload. The load will either stall or will be forced to
move at a slower speed – one which does not require
pressure higher than the adjustment setting.
A reducing valve offers very little flow resistance and

power loss until the branch circuit demands pressure
higher than the adjustment setting. At this point, the valve
spool moves to a throttling position and will limit the flow
through the valve to a value where the pressure will stay
within the limit of the adjustment setting.
T803324,00009C0 –19–04OCT06–1/1

100406
PN=124
Pumps & Motors
Operating Principle
1—Inlet
2—External Drain
3—Outlet
A—Main Spool
B—Spring Chamber
C—Adjustment Knob
D—Pilot Spring and Poppet
E—Internal Pilot Passage
F—Orifice
50
10
3
–UN–04OCT06
CM062254016
T803324,00009C1 –19–04OCT06–1/2
The spool is held in a normally open position by a light,

non-adjustable, spring. A small, direct acting, relief valve
on the crosshead sets the maximum pressure level on the
outlet port regardless of pressure fluctuations in pressure
on the inlet. The spool remains in the wide open position
–UN–04OCT06
for full free flow to the outlet until an excessive demand
for pressure from the load connected to the outlet causes
the spool to move into a throttling position. The higher the
pressure demand on the outlet, the closer the spool will
CM062254017
move toward its closed position. All pressure reducing
valves must have an external drain line to tank. The drain
port must NEVER be plugged.
Complete Hydraulic Symbol
1—Inlet
2—Drain
3—Outlet
T803324,00009C1 –19–04OCT06–2/2

100406
PN=125
Pumps & Motors
Closed Loop Circuit (Hydrostatic Ground

Drive Circuit)
The main ports of the pump are connected by hydraulic

lines to the main ports of the motor. Fluid flows, in either
direction, from the pump to the motor then back to the
pump in this closed circuit. Either of the hydraulic lines
can be under high pressure. The position of the pump
swashplate determines which line is high pressure as well
as the direction of fluid flow in the hydrostatic circuit.
T803324,000093E –19–15MAR06–1/1
Case Drain
50
10 The pump and motor require case drain lines to remove
4 hot fluid from the system. The motor should be drained
from its top most drain port to ensure the case remains
full of fluid. The motor case drain can then be connected
to the lower drain port on the pump housing and out the
top most port to the hydraulic tank.
NOTE: On the 2254 Hydrostatic Ground Drive System,

there are three hydrostatic motors connected in
parallel to the single variable hydrostatic pump.
The front axle has a fixed displacement motor
connected to the input of the three speed
transmission which is connected to the front wheel
final drives.POWER ASSIST Option - All three
motors are fixed displacement motors and there is
a directional valve to allow or to block flow to the
rear axle motors to adjust between field and
transport speeds.HIGH TRACTION Option - The
rear axle motors are variable displacement motors
and these motors can be de-stroked to provide
adjustment between field and transport speeds.
NOTE: On the 2254 Loader Hydrostatic Ground Drive

System, the case drain from the top port of the
front axle motor is routed to the bottom ports on
the rear wheel drive motors and then from the
rear wheel drive motor top ports to the hydraulic
tank.
T803324,000093F –19–15MAR06–1/1

100406
PN=126
Pumps & Motors
Charge Pump
The charge pump is necessary to supply cool fluid to the

system, to maintain positive pressure in the main system
loop, to provide pressure to operate the control system,
and to make up for internal leakage. Charge pressure
must be at its specified pressure under all conditions of
driving and braking to prevent damage to the
transmission. The charge pump is a fixed displacement,
gerotor type pump installed in the variable displacement
pump and driven off the main pump shaft. Charge
pressure is limited by a relief valve.
50
10
5
T803324,0000940 –19–15MAR06–1/1
Charge Relief Valve
The charge relief valve on the pump serves to maintain

charge pressure at a designated level. A direct acting
poppet valve relieves charge pressure whenever it
surpasses a certain level. This level is nominally set
referencing case pressure at 1775 rpm. This nominal
setting assumes the pump swashplate is in neutral (zero
flow): in the forward or reverse flow modes; the charge
pressure will be lower.
T803324,0000941 –19–15MAR06–1/1
System Check Valves
The system check valves allow pressurized flow from the

charge pump to enter the low pressure side of the loop
whenever system pressure dips below a certain level. This
is needed as the pump will generally lose system
pressure due to leakage and other factors. Since the
pump can operate in either direction, two system check
valves are used to direct the charge supply into the low
pressure lines. The system check valves are poppet
valves located in the multifunction valve assembly.
T803324,0000942 –19–15MAR06–1/1

100406
PN=127
Pumps & Motors
Multi-Function Valves
The multifunction valve incorporates the system check

valve, the pressure limiter valve, the high pressure relief
valve, and the bypass valve in a replaceable cartridge.
These functions are described separately. There are two
multifunction valve cartridges in each pump to handle
functions in either direction.
T803324,0000943 –19–15MAR06–1/1
Pressure Limiter and High Pressure Relief

50 Valves
10
6
Pumps are designed with a sequenced pressure limiting
system and high pressure relief valves. When the preset
pressure is reached, the pressure limiter system acts to
rapidly destroke the pump so as to limit the system
pressure. For unusually rapid load application, the high
pressure relief valve acts to immediately limit system
pressure by crossporting system flow to the low pressure
side of the loop. The pressure limiter valve acts as the
pilot for the high pressure relief valve spool. The high
pressure relief valve is sequenced to operate at
approximately 35 bar (500 psi) above the level that
initiates the pressure limiter valve. Both the pressure
limiter sensing valves and relief valves are built into the
multifunction valves
T803324,0000944 –19–15MAR06–1/1
Bypass Valves
The bypass valves (“tow”) can be operated when it is

desired to move the vehicle or mechanical function when
the pump is not running. The valve is opened by manually
resetting the valve position The bypass valves are built
into the multifunction valves.
T803324,0000945 –19–15MAR06–1/1

100406
PN=128
Pumps & Motors
Auxiliary Mounting Pads
This pad is used for mounting auxiliary hydraulic pumps

and for mounting additional pumps to make tandem
pumps. The pads allow for full through-torque capability.
T803324,0000946 –19–15MAR06–1/1
Hydraulic Displacement Control

50
The hydraulic displacement control uses a hydraulic input 10
signal to operate a spring-centered four-way servo valve. 7
This valve ports hydraulic pressure to either side of a
dual-acting servo piston. The servo piston rotates the
cradle swashplate through an angular rotation of ±17°,
thus varying the pump’s displacement from full
displacement in one direction to full displacement in the
opposite direction. The HDC is designed so the angular
position of the pump swashplate is proportional to input
pressure.
T803324,0000947 –19–15MAR06–1/1

100406
PN=129
Pumps & Motors
Initial Start-up Procedure
The following start-up procedure should always be

followed when starting-up a new installation or when
restarting an installation in which either the pump or motor
had been removed.
CAUTION: The following procedure may require

the vehicle/machine to be disabled (wheels
raised off the ground, work function
disconnected, etc.) while performing the
procedure in order to prevent injury to the
technician and bystanders. Take necessary
safety precautions before moving the
vehicle/machine.
50
10 Prior to installing the pump and/or motor, inspect the units
8
for damage incurred during shipping and handling. Make
certain all system components (reservoir, hoses, valves,
fittings, heat exchanger, etc.) are clean prior to filling with
fluid.
Fill the reservoir with recommended hydraulic fluid. This

fluid should be passed through a 10 micron (nominal, no
bypass) filter prior to entering the reservoir. The use of
contaminated fluid will cause damage to the components,
which may result in unexpected vehicle / machine
movement.
The inlet line leading from the reservoir to the pump must
be filled prior to start-up. Check inlet line for properly
tightened fittings and make sure it is free of restrictions
and air leaks.
IMPORTANT: Be certain to fill the pump and/or motor

housing with clean hydraulic fluid prior
to start up.
Fill the housing by pouring filtered oil into the upper case
drain port.
Install a 50 bar (or 1000 psi) pressure gauge in the

charge pressure gauge port to monitor the charge
pressure during start-up.

100406
PN=130
Pumps & Motors
It is recommended that the external control input signal

(hydraulic lines for HDC) be disconnected at the pump
control until after initial start-up. This will ensure that the
pump remains in its neutral position.
CAUTION: Do not start prime mover unless

pump is in neutral position (0 swashplate
angle). Take precautions to prevent machine
movement in case pump is actuated during
initial start up.
Jog or slowly rotate prime mover until charge pressure

starts to rise. Start the prime mover and run at the lowest
possible RPM until charge pressure has been established.
Excess air may be bled from the high pressure lines
through the high pressure system gauge port. 50
10
9
Once charge pressure has been established, increase
speed to normal operating RPM. Charge pressure should
be 31 bar (450 psi). If charge pressure is inadequate, shut
down and determine cause for improper pressure. Refer
to Troubleshooting Section.
CAUTION: Inadequate charge pressure will

affect the operator’s ability to control the
machine.
Shut down the prime mover and connect the external

control input signal. Also reconnect the machine function if
disconnected earlier. Start the prime mover, checking to
be certain the pump remains in neutral.
With the prime mover at normal operating speed, slowly

check for forward and reverse machine operation.
Charge pressure may slightly decrease during forward or

reverse operation. Continue to cycle slowly between
forward and reverse for at least five minutes.
Shut down prime mover, remove gauges, and plug ports.

Check reservoir level and add filtered fluid if needed. The
transmission is now ready for operation.
T803324,0000948 –19–15MAR06–2/2

100406
PN=131
Pumps & Motors
Fluid and Filter Maintenance
To ensure optimum service life of hydrostatic products,

regular maintenance of the fluid and filter must be
performed. Contaminated fluid is the main cause of unit
failure. Care should be taken to maintain fluid cleanliness
while performing any service procedure.
Check the reservoir daily for proper fluid level, the

presence of water (noted by a cloudy to milky
appearance, or free water in bottom of reservoir), and
rancid fluid odor (indicating excessive heat). If either of
these conditions occur, change the fluid and filter
immediately.
NOTE: It is recommended the fluid and filter be changed

50
10 per the machine manufacturer’s
10 recommendations.
It may be necessary to change the fluid more frequently

than the above intervals if the fluid becomes contaminated
with foreign matter (dirt, water, grease, etc.) or if the fluid
has been subjected to temperature levels greater than the
recommended maximum. Never reuse fluid.
The filter should be changed, and the strainer cleaned,

whenever the fluid is changed.
T803324,0000949 –19–15MAR06–1/1
Troubleshooting
Continued on next page T803324,000094A –19–15MAR06–1/4

100406
PN=132
Pumps & Motors
NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify.
“Neutral” Difficult or Impossible Check input to pump control. If input to control module is
to Find operating properly, check control
input and repair or replace as
necessary•.
Check pump displacement control. If control linkages are not secure,

control orifices are blocked, etc.,
adjust, repair or replace control
module as necessary.
System Operation Hot Insufficient hydraulic fluid will not Check oil level in reservoir and fill
meet cooling demands of system. reservoir to proper level.
Heat Exchanger not sufficiently Inspect heat exchanger. Check

50
cooling the system. airflow and input air temperature for 10
heat exchanger. Clean, repair or 11
replace heat exchanger.
Low charge pressure will overwork Check charge pressure. Inspect and
system. adjust or replace charge relief valve
or repair leaky charge pump.
High Inlet vacuum will overwork Check charge pump inlet vacuum. If
system. A dirty filter will increase the high, inspect inlet filter and replace
inlet vacuum. Inadequate line size as necessary. Check for adequate
will restrict flow. line size, length or other restrictions.
Leakage will reduce low side system Check for internal leakage in motor.
pressure and overwork the system. Monitor motor case flow without loop
flushing in the circuit. If flow is
excessive, replace motor.
High system pressure will overheat Check system pressure. If pressure

system. is high, reduce loads.

100406
PN=133
Pumps & Motors
Transmission Operates Normally Input to control module is not Check control input and repair or
in One Direction Only operating properly. replace as necessary.
Control linkages are not secure; Repair or replace control module as

control orifices are blocked, etc. necessary.
Valve functions. Interchange multi-function valves. If

the problem changes direction,
repair or replace the valve on the
side that does not operate.
If charge pressure decays in one Measure charge pressure in forward

direction, the loop flushing valve may and reverse. If pressure decays in
be “sticking” in one direction. one direction, inspect and repair the
50
10 motor loop flushing valve.
12
Low Motor Output Torque Low system pressure at the motor Check system pressure at motor. If
will reduce torque. pressure limiter setting is low,
increase settings.
Minimum motor displacement yields Check control supply pressure or

low torque output. repair displacement control. Check
motor control orifices.
Internal leakage will reduce system Check for leakage in O-rings,

pressure. gaskets, and other fittings. Repair
unit as required or replace leaky
unit.
Improper Motor Output Speed Insufficient hydraulic fluid will reduce Check oil level reservoir. Fill oil to
motor speed. proper level.
Incorrect charge pressure can result Check charge pressure. Adjust

in a low speed motor. charge pressure if necessary.
Incorrect outflow will affect output Measure pump output flow by teeing
speed. Incorrect output flow into outflow hose. Check for proper
indicates the swashplate is out of pump speed and see that the pump
position. is in full stroke.
If variable motor displacement See if variable motor displacement

control is not functioning correctly, control is responding. If not, repair or
variable motor swashplate may be in replace control.
wrong position.

100406
PN=134
Pumps & Motors
Excessive Noise and/or Vibration Insufficient hydraulic fluid will lead to Check oil level reservoir. Fill oil to
cavitation. proper level.
Air bubbles will lead to cavitation. Look for foam in reservoir. Check for
leaks on inlet side of system loop.
Afterwards, let reservoir settle until
bubbles are gone. Run system at
low speed to move system fluid to
reservoir. Repeat.
High inlet vacuum will create noise. Inspect and replace filter as
A dirty filter will increase the inlet necessary. Check for proper suction
vacuum. line size.
50
A loose shaft coupling will cause Replace loose shaft coupling in 10
excessive noise. charge pump or replace pump or 13
motor.
Unaligned shafts will create Align shafts.

excessive frictional noise.
System Response Sluggish Insufficient hydraulic fluid will reduce Fill reservoir to proper level.
output pressure.
Incorrect pressure setting will affect Adjust or replace multi-function

system reaction time. valves.
High pump inlet vacuum will reduce Measure charge inlet vacuum. If
system pressure. high, replace inlet filter.
Low engine speed will reduce Adjust engine speed.

system performance.
Incorrect charge or control pressures Measure charge and control

will affect system performance. pressures and correct if necessary.
Internal leakage will reduce system Check for leakage in O-rings,

pressure. gaskets, and other fittings.
T803324,000094A –19–15MAR06–4/4

100406
PN=135
Pumps & Motors
Hydrostatic Pump
50
10
14
–UN–03OCT06
CM31351144B5
Continued on next page T803324,000094B –19–15MAR06–1/2

100406
PN=136
Pumps & Motors
1—Charge Relief Kit 18—Pin 35—Servo Piston Kit 53—Retaining Plate

2—Bearing 19—Spring 36—O-Ring 54—Bolt
3—Pin 20—Pump Side Cover 37—Piston Ring 55—Charge Pump Cover
4—Plug 21—Leveler 38—Slider Block 56—Screw
5—Plug 22—Seat 39—Control Orifice Kit 57—Manifold Fitting
6—O-Ring 23—Shim 40—Journal Bearing 58—O-Ring
7—Screen Filter 24—Control Gasket 41—Bushing 59—Special Plug
8—Pump Valve Plate 25—Nut 42—Gasket 60—Check Valve
9—Swashplate Assy 26—O-Ring 43—Plug 61—O-Ring
10—Cylinder Kit 27—Bolt 44—Bolt 62—Shaft
11—Bolt 28—Relief Assy-HP 45—Spacer 63—Roller Bearing
12—Washer 29—Spring 46—Lifting Lug 64—Retaining Ring
13—O-Ring 30—O-Ring 47—Washer-FL 65—Seal Carrier
14—Coupling 31—Sleeve Kit 48—Bolt 66—Lip Seal
15—Control Kit 32—O-Ring 50—Pin 67—O-Ring
16—Mounting Kit 33—O-Ring 51—Shaft 68—Retainer Plate
17—Cage Locator Link 34—Cover Plate 52—Key 69—Bolt
50
10
15
T803324,000094B –19–15MAR06–2/2

100406
PN=137
Pumps & Motors
Charge Relief Valve Adjustment
CAUTION: The following procedure may require

the vehicle/machine to be disabled (wheels
raised off the ground, work function
disconnected, etc.) in order to prevent injury to
the technician and bystanders.
1. To measure pump charge pressure, install a pressure

gauge in the pump charge pressure gauge port (M3).
Also install a gauge to measure case pressure (tee into
L1 or L2 or use servo gauge port). Operate the system
with the pump in neutral (zero displacement) when
measuring pump charge pressure.
50 2. The acceptable pump charge pressure for charge relief

10 valve settings is 28 - 31 bar (400 - 450 PSI).
16
3. Pumps are equipped with an external screw adjustable

charge relief valve. Adjustment of the charge pressure
is accomplished by loosening the lock nut (with a
1-1/16 inch hex wrench), and turning the adjustment
plug with a large screwdriver or a 1/2 inch hex wrench.
Clockwise rotation of the plug increases the setting,
and counterclockwise rotation decreases the setting at
a rate of approximately 3.4 bar (50 PSI) per turn. The
lock nut for this type of charge relief valve should be
torqued to 52 N•m (38 lb-ft).
4. Once the desired charge pressure setting is achieved,

remove the gauges.
T803324,000094C –19–15MAR06–1/1

100406
PN=138
Pumps & Motors
Multi-Function Valve Pressure Adjustment
Adjustment of the pressure limiter setting and the high

pressure relief valve setting is accomplished
simultaneously. The latter is automatically set
approximately 35 bar (500 psi) above the former.
In order to adjust the pressure limiter setting, the motor

output shaft must be locked so it does not rotate. This
may be accomplished by locking the vehicle’s brakes or
rigidly fixing the work function so it cannot rotate.
CAUTION: Take necessary precautions to

insure the motor shaft remains stationary
during the adjustment procedure.
50
1. Install two 700 bar (10,000 psi) pressure gauges in the 10
17
high pressure gauge ports (M1 and M2). Install a 200
bar (3000 psi) pressure gauge in the pump charge
pressure gauge port (M3).
2. Start the prime mover and operate at normal speed.
3. Loosen locking nut (smallest hex on multi-function

valve) with a 10 mm wrench.
4. Insert a 3 mm (early units), 5 mm (late units), internal

hex wrench into the pressure adjusting screw.
NOTE: A plastic dust plug is installed in the adjusting

screw.
5. The pressure limiter setting is the difference between

the high and low pressure sides of the system loop.
Activate or move the control input so that pressure
increases in the high pressure side of the closed circuit
to the pressure limiter pressure setting. The pressure
limiter setting is reached when the pressure stops
increasing and remains steady at a given pressure
level (as shown on the gauges).
6. Return the pump to its neutral (zero flow) position and

adjust the pressure limiter setting by rotating the
pressure adjusting screw with the internal hex wrench.
Continued on next page T803324,000094D –19–15MAR06–1/2

100406
PN=139
Pumps & Motors
7. Clockwise rotation of the pressure adjustment screw

will increase the pressure setting, and
counterclockwise rotation will decrease the pressure
setting. Each complete rotation of the pressure
adjusting screw changes the pressure setting by
approximately 93 bar (1350 PSI).
8. To verify the actual pressure setting, actuate or move

the control input so that the pump again develops
pressure in the high pressure circuit to the newly
adjusted pressure limiter pressure setting, and read the
high pressure gauge. Then allow the pump to return to
its neutral position. The pressure in the high pressure
circuit should return to the charge pressure setting.
9. While holding the pressure adjusting screw stationary,

50
10 tighten the pressure adjusting screw lock nut to 16 N•m
18 (12 lb-ft). DO NOT overtorque.
10. Shut down the prime mover, remove the gauges and
install the gauge port plugs. Replace the plastic dust
plugs (if used).
The same procedure is used for setting the pressure limit

of the other multi-function valve, but the control input
signal must be activated or moved in the opposite
direction so that high pressure develops in the opposite
side of the closed circuit.
T803324,000094D –19–15MAR06–2/2

100406
PN=140
Pumps & Motors
Engaging the Bypass Function
The bypass function is performed by the multifunction

valve cartridges. The prime mover should be shut down
when opening or closing the bypass valves.
1. Using a 1-1/16 inch wrench on the middle sized hex of

the multi-function valve cartridge, and a 1-1/4 inch
wrench on the large hex to prevent rotation of the
cartridge assembly, rotate the middle hex three
revolutions counterclockwise to open the bypass valve.
Do not rotate more than 3-1/2 revolutions, as additional
rotation will permit external leakage.
CAUTION: It is not recommended that this

machine be towed. If towing is the only option, 50
tow at extremely low speeds and for short 10
19
distances only.
2. To close the bypass valve, rotate the middle hex

clockwise until it is seated. Then torque the middle hex
to 41 N•m (30 lb-ft).
T803324,000094E –19–15MAR06–1/1

100406
PN=141
Pumps & Motors
Hydraulic Displacement Control
The neutral adjustment is the only adjustment that can be

made on hydraulic and electric displacement controls. All
other functions are preset at the factory.
This adjustment must be made on a test stand or on the

machine with the prime mover operating. The neutral
adjustment is performed by adjusting a neutral adjusting
screw.
CAUTION: The following procedure requires the

vehicle/machine to be disabled (wheels raised
off the ground, work function disconnected,
etc.) in order to prevent injury to the technician
50 and bystanders.
10
20
1. Install two 200 bar (3000 PSI) gauges in each of the
two displacement control cylinder gauge ports (M4 and
M5). Disconnect the external hydraulic control input
from the control. Start the prime mover and operate at
normal speed.
2. Loosen the lock nut with a 17 mm hex wrench for the

neutral adjusting shaft or with a 10 mm or 13 mm hex
wrench for the neutral adjusting screw.
3. Using a 5 mm internal hex wrench for the neutral

adjusting shaft or a 3 mm or 4 mm internal hex wrench
for the neutral adjusting screw, rotate clockwise until
the pressure increases in one of the pressure gauges.
Note the angular position of the wrench. Then rotate
the neutral adjusting shaft or screw counterclockwise
until the pressure increases by an equal amount on the
other gauge. Again note the angular position of the
wrench.
4. Rotate the neutral shaft or adjusting screw clockwise

half the distance between the locations noted above.
The gauges should read the same pressure (case
pressure), indicating that the control is in its neutral
position.

100406
PN=142
Pumps & Motors
5. Hold the neutral adjusting shaft or screw stationary.

Tighten the neutral adjusting screw lock nut to 7 N•m
(62 lb-in) for the 6 mm screw or 13.6 Nm (120 lb-in) for
the 8 mm screw. DO NOT over torque the nut.
6. Once the neutral position is set, stop the prime mover,

remove the gauges, and install the gauge port plugs.
Reconnect the external control input.
T803324,000094F –19–15MAR06–2/2
50
10
21

100406
PN=143
Pumps & Motors
Shaft Seal and Shaft Replacement
Lip type shaft seals are used on pumps and motors.

These seals and/or the shafts can be replaced without
major disassembly of the unit. However, replacement
requires removal of the pump or motor from the machine.
NOTE: If the unit is positioned horizontally when the shaft

is removed, the cylinder block could move out of
place, making shaft installation difficult.
1. Position the pump with the shaft facing up.
2. Remove the three or four screws holding the retainer

plate and seal carrier to the housing, using a 5 mm
internal hex wrench. Remove the retainer plate.
50
10
22 3. After removing the screws, the spring force on the
shaft may move the seal carrier out of its bore by
approximately 5 mm (1/4 inch). If the seal carrier does
not move from its bore after removing the screws, pry
it from its bore as shown and/or lightly tap the end of
the shaft with a soft mallet.
4. Remove the O-ring from the seal carrier.
5. Place seal carrier and seal in an arbor press and press

out old seal.
6. Inspect the seal carrier, the new seal and the o-ring for
any damage or nicks.
7. Using the arbor press, press the new seal into seal
carrier. Be careful not to damage the seal.
The outside diameter of the seal may be lightly coated

with a sealant (such as Loctite High Performance
Sealant #59231, or Silicone Ultra Blue PN#
0841348827) prior to installation. This aids in
preventing leaks caused by damage to the seal bore in
the seal carrier.
8. Inspect the sealing area on the shaft for rust, wear, or

contamination. If the shaft is not being replaced
proceed to step 12.

100406
PN=144
Pumps & Motors
9. Remove shaft and roller bearing assembly from pump

or motor. The bearing assembly can be transferred to
the new shaft.
10. Remove the retaining ring that secures roller bearing

assembly with a snap ring pliers. Remove the roller
bearing assembly.
11. Place roller bearing assembly on new shaft and

secure with the retaining ring.
12. Wrap spline or key end of shaft with plastic film to

prevent damage to the sealing lip on the seal during
installation.
13. Prior to assembly, lubricate the O-ring on the O.D. of

50
the seal carrier and the I.D. of the seal with clean 10
petroleum jelly. 23
14. Assemble the seal carrier and seal over the shaft and
into the housing bore. Install the retainer plate (if
used).
15. Install the screws and torque to 16 N•m (12 lb-ft)

pumps, 9.5 N•m (7 lb-ft) for motors.
NOTE: Torque the screws in a sequenced pattern then

recheck.
T803324,0000950 –19–15MAR06–2/2

100406
PN=145
Pumps & Motors
50
10
24

100406
PN=146
Group 20
Minor Pump Repairs
Multi-Function Valve Cartridges
1. The multi-function valve cartridge is removed with a

1-1/4 inch hex wrench on the largest hex on the
cartridge.
2. Inspect cartridge for damage to parts and O-rings. The

multi-function valve cartridge may be disassembled for
cleaning. However, if the pressure limiter housing
assembly is disassembled, the pressure settings must
be readjusted. Usually, if there is contamination
problem, it will be in the valve seat assembly. If it is
not necessary to clean the interior of the cartridge,
proceed to step 7.
NOTE: Multi-function valve components are not sold

50
separately as service parts (except O-rings). 20
1
3. Release spring tension by turning the adjustment
screw counterclockwise. The valve seat section is
pressed over a lip. Place the cartridge in a vise and
pry the lower section off with an appropriate tool.
Maintain sufficient control to prevent the contents from
flying loose.
4. Remove pressure limiter lock nut and bypass actuator.
5. Unscrew the pressure limiter adjustment screw from

the bypass actuator.
6. Clean and inspect all disassembled parts.
7. Reassemble with new, lightly lubricated O-rings by

reversing the above procedure. For early versions
assemble with the retaining ring. For late versions,
place the cartridge in a vise and press on lower
assembly.
CAUTION: The pressure settings must be

readjusted after disassembling the pressure
limiter housing of the multifunction valve
cartridge.
8. Install cartridge in multi-function valve cavity and

torque to 89 N•m (66 lb-ft). DO NOT over torque the
multifunction valve cartridge.
T803324,0000951 –19–15MAR06–1/1

100406
PN=147
Minor Pump Repairs
Charge Relief Valve
The pump charge relief valve is screw adjustable.
1. Before removing the screw adjustable relief valve plug,

mark the plug, lock nut, and housing so as to
approximately maintain the original adjustment when
assembling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut with a 1-1/16 inch
wrench. Unscrew the plug with a large screwdriver. 2.
2. Remove the spring and relief valve poppet.
3. Inspect the poppet and mating seat in the end cap for
damage or foreign material.
50
20 4. Install the poppet and spring. For screw adjustable
2 valves, install the plug with its lock nut, aligning the
marks made at disassembly, and torque the lock nut to
52 N•m (38 lb-ft).
5. Check the charge pressure and adjust, if necessary.
T803324,0000952 –19–15MAR06–1/1

100406
PN=148
Minor Pump Repairs
Charge Pump
1. For pumps with an auxiliary mounting pad, remove the

four screws holding the pad to the end cap and
remove the pad. Refer to the Auxiliary Mounting Pad
Installation instructions (next section) for details.
NOTE: NOTE: Late production pumps may not have the

smaller screws installed to secure the end cap to
the pump housing when the large screws are
removed. On these pumps, secure the end cap to
the pump housing with a clamp to avoid gasket
damage.
CAUTION: Do not allow the force of the cylinder

block spring and swashplate leveler springs to 50
separate the end cap from the pump housing. 20
3
Gasket damage and external leakage may
result.
2. Using a 10 mm hex wrench, remove the six screws

holding the charge pump cover retainer.
3. Remove the retainer and the charge pump cover. For

pumps with an auxiliary mounting pad, remove the
auxiliary drive coupling. Note the orientation of the
gerotor.
4. Remove the charge pump shaft and charge pump drive

key.
5. Remove the spacer plate(s), if present (intermediate

production pumps only). Remove the charge pump
outer port plate, if present (early and intermediate
production pumps). Remove the charge pump gerotor
assembly.
6. Remove the outer eccentric ring and alignment pin.
7. Remove the inner port plate.
8. Inspect all parts for abnormal wear or damage.

100406
PN=149
Minor Pump Repairs
NOTE: If a different displacement charge pump is being

installed, the gerotor assembly, gerotor outer
eccentric ring, and inner port plate (early and late
production pumps) or outer spacer plate(s)
(intermediate production pumps) must be replaced
together. If different thickness port plates are used
in an early production charge pump assembly, the
thicker plate is the inner port plate (installed next
to the pump end cap).
T803324,0000953 –19–15MAR06–2/2
50
20
4

100406
PN=150
Minor Pump Repairs
Installing the Charge Pump
Be sure to install the charge pump in the proper

orientation. If unsure of charge pump rotation, refer to
parts catalog.
NOTE: The charge pump rotation is determined by the

orientation of the gerotor assembly outer eccentric
ring and the location of the alignment pin in the
end cap.
NOTE: Do not mix charge pump piece parts from different

production periods. Always install as a complete
assembly.
1. Install the inner port plate and the gerotor assembly

50
outer ring. 20
5
2. Install the alignment pin to properly orient the port
plates and outer eccentric ring for corresponding pump
rotation.
3. Prior to installation, apply a small quantity of petroleum

jelly to the I.D., O.D., and side faces of the gerotor
assembly to provide initial lubrication.
4. Install the gerotor assembly.
5. Install the outer port plate.
6. Install the spacer plate, if used.
7. Install the charge pump drive key into the charge pump
shaft and retain with petroleum jelly.
NOTE: Intermediate production pumps use the same

charge pump drive shaft. Two key-ways are
provided in the drive shaft for the charge pumps
used in these units. The rear key-way (with
identifier groove)is used in 75 cc pumps. The front
key-way (closest to the internally splined end of
the shaft) is used in 100 cc pumps.
8. Install the charge pump shaft. The internally splined

end of the shaft must engage the main pump shaft.
9. For pumps with an auxiliary mounting pad, install the

auxiliary drive coupling.

100406
PN=151
Minor Pump Repairs
10. Install a new O-ring onto the non-auxiliary pad charge

pump cover. (If an auxiliary pad is installed, an O-ring
is not used on the cover.)
11. Carefully remove the alignment pin from the charge

pump parts. Install the pin in its hole in the charge
pump cover (see previous page for correct
orientation) and retain with petroleum jelly. Install the
cover (with alignment pin) into the end cap and
aligned charge pump parts. (Take care not to damage
the cover O-ring, if used.)
12. Install the charge pump cover retainer and the six hex
screws and torque the screws to 13.5 N•m (10 lb-ft).
13. For pumps with auxiliary mounting pads, install the

50
20 o-ring and auxiliary mounting pad adapter onto the
6 end cap.
T803324,0000954 –19–15MAR06–2/2

100406
PN=152
Minor Pump Repairs
Auxiliary Pad Installation
1. Using a 10 mm hex wrench, remove the six screws

holding the charge pump cover retainer. Remove the
retainer.
2. Remove the charge pump cover and its O-ring.
NOTE: The original charge pump cover will not be used

when installing the auxiliary pad.
3. Remove the four large screws which fasten the end

cap to the pump housing using a 24 mm external hex
wrench.
NOTE: Late production pumps may not have the smaller

50
screws installed to secure the end cap to the 20
pump housing when the large screws are 7
removed. On these pumps, secure the end cap to
the pump housing with a clamp to avoid gasket
damage.
CAUTION: Do not allow the force of the cylinder

block spring and swashplate leveler springs to
separate the end cap from the pump housing.
Gasket damage and external damage may
result.
4. Take care to assure the surfaces are clean and free of

any foreign material or paint prior to installing the
auxiliary pad.
5. Install the auxiliary drive coupling onto the pump drive

shaft spline (auxiliary drive spline must be toward the
rear of the pump).
6. Carefully remove the alignment pin from the charge

pump parts. Install the pin in its hole in the new charge
pump cover (with hole for the auxiliary coupling) and
retain with petroleum jelly. Install the new charge pump
cover with alignment pin into the end cap and the
aligned charge pump parts.

100406
PN=153
Minor Pump Repairs
CAUTION: In order to avoid loss of charge

pressure, always install the charge pump cover
with the pad drain hole located on the same
side of the end cap as the charge inlet port.
7. Install the charge pump cover retainer and the six hex
screws and torque the screws to 13.5 N•m (10 lb-ft).
8. Install O-ring on end cap pilot.
9. Install the auxiliary mounting pad adapter on external

pilot on rear of end cap.
10. Install four new large screws and washers through the
mounting pad and end cap into the housing. Torque
50 per the accompanying table. 14 mm internal hex -256
20 N•m (189 lb-ft).
8
11. Install the O-ring and flange cover or auxiliary pump.
T803324,0000955 –19–15MAR06–2/2

100406
PN=154
Minor Pump Repairs
Hydraulic Displacement Controls
1. Thoroughly clean external surfaces prior to removal of

control.
2. Using a 5 mm internal hex wrench, remove the eight

control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket from
housing.
CAUTION: Protect exposed surfaces and

cavities from damage and foreign material
3. In preparation for installing the control, place a new

gasket on the housing. Inspect to ensure that the
control orifice check valve and spring are in their 50
proper position in the control. 20
9
4. While setting the control into position, engage the pin

on the control linkage into the mating hole in the link
attached to the swashplate.
5. With the control in position, move control assembly left

and right to check engagement of pin in the link.
Proper engagement will be indicated by an increasing
resistance as the control is moved away from center
position. Non-engagement of pin will be indicated by
lack of spring force. In case of non-engagement,
remove control and repeat the above procedure.
6. Align the control gasket and install the screws. Torque

the screws to 16 N•mNm (12 lb-ft).
NOTE: A sealing washer must be installed under the

head of any mounting screws that are installed
through holes in the housing.
T803324,0000956 –19–15MAR06–1/1

100406
PN=155
Minor Pump Repairs
50
20
10

100406
PN=156
Group 30
Displacement Control Components
Displacement Control Filter Screens
If the pump is equipped with control filter screens in the

pump housing (late production), they should be pressed
into position (with the rounded edge of the filter screens
facing the control) until they are flush to 2.0 mm (0.08
inch) below the surface of the housing.
T803324,0000957 –19–15MAR06–1/1
Displacement Control Orifice Check Valve

50
1. Remove the control assembly as described in the 30
instructions for the specific displacement control. 1
2. The orifice check valve is located in the control

assembly, at the surface of the pump housing face.
Remove the spring retainer and spring from the orifice
check valve cavity and then remove the orifice check
valve.
3. Install the desired orifice check valve in the cavity and

then install the spring and spring retainer to hold the
orifice check valve in position.
4. Assemble the control onto the pump. Refer to the

instructions for the specific control.
T803324,0000958 –19–15MAR06–1/1

100406
PN=157
Displacement Control Orifices
1. Remove the control assembly as described in the

instructions for the specific displacement control.
2. Orifice plugs may be located in the control assembly,

at the pump housing face surface. Remove the orifice
plugs with a 4 mm internal hex wrench. Note the
location of each plug, do not interchange plugs. Torque
the orifice plugs to 3 N•m (32 lb-in).
3. Assemble the control onto the pump. Refer to the

instructions for the specific control.
50
30
2
T803324,0000959 –19–15MAR06–1/1

100406
PN=158
Disassembly Procedures for Variable

Displacement Pump
Prior to performing major repairs on the variable

displacement pump, remove the external components as
described in the minor repair section of this service
manual. These include the following:
• Auxiliary Mounting Pad

• Charge Relief Valve
• Multi-Function Valves
• Shaft Seal
After removal of these components, place the pump on a

work surface with the shaft up.
50
Remove the shaft and bearing assembly from the 30
housing. The bearing outside diameter is a slip fit in the 3
housing bore.
NOTE: If the shaft and bearing stick in the housing, lightly

tap the end of the shaft with a soft mallet to free
the bearing.
Remove the retaining ring and press the shaft out of the
bearing. Place the pump on the work surface with the end
cap up.
NOTE: If the pump was equipped with an auxiliary

mounting pad, temporarily reinstall two (2) of the
large screws which fasten the end cap to the
housing. These screws will hold the end cap
against internal spring pressure while the small
screws are removed.
Using a 5 mm or 6 mm internal hex wrench or a 10 mm

hex wrench, remove the two (2) or three (3) small screws
which fasten the end cap to the pump housing. Using a
24 mm internal hex wrench, remove the large screws
which fasten the end cap to pump housing. Remove end
cap from housing. The alignment pins and valve plate will
normally remain with the housing.
Remove the end cap gasket. Remove the swashplate

leveler spring shims (if installed) from the spring pockets
in the end cap.

100406
PN=159
Remove three (3) springs from pump: the two (2) long
swashplate leveler (“T-Bar”) springs and the short
swashplate hold down spring.
NOTE: Certain units are equipped with dual swash-plate

leveler springs (an inner spring nested inside each
of the standard springs).
Remove the alignment pins and valve plate, noting

direction of arrows on valve plate.
Mark the orientation of the side cover to the housing.

Remove the six (6) side cover screws using a 13 mm hex
wrench.
Remove side cover and swashplate leveler (“TBar”)

50
30 assembly from housing.
4
NOTE: Certain units equipped with dual swashplate
leveler springs have spacer washers on the
leveler spring seats. They may be removed at this
time.
Remove spring seats from swashplate leveler.
NOTE: Earlier production pumps do not have removable

(hardened) spring seats.
For units with leveler guide posts and sealing nuts holding
the leveler to the side cover, use a 3/4 in. open end
wrench and a 13 mm hex wrench.
Remove swashplate leveler from side cover. Remove the

side cover O-ring.
Mark the servo cylinders and housing to identify each

servo cylinder with its respective side of the housing.
Remove the three (3) or four (4) screws retaining each
servo cylinder to the housing, using a 10 mm or 13 mm
hex wrench.
For earlier production units, carefully pry each cylinder

from the housing by using a screwdriver in the notches in
the cylinder. For later production units, install an 8 mm or
10 mm screw in the threaded hole in the center of each
cylinder, and pull the cylinders from the housing. The
servo piston will remain in the housing.

100406
PN=160
NOTE: For later production units with displacement

limiters, remove the limiter screw from each servo
cylinder and install an 8 mm or 10 mm screw in its
place as a puller screw. Remove the cylinder
block through the housing end cap opening. The
swashplate and piston assembly will remain in the
housing. Remove the swashplate bearing cage
link pin from the housing through the control
opening. Remove the bearing cage locater link
from the swashplate through the control opening.
Remove the swashplate and pistons through the housing

side cover opening. Disengage the servo arm from the
slider block located in the servo piston as the assembly is
removed.
50
Remove the servo piston and slider block from housing. 30
5
NOTE: Units equipped with an automotive control have a
threaded hole in one end of the servo piston for
the centering assist spring assembly. For these
units, note the orientation of the servo piston in
the housing.
Remove the swashplate cradle bearing cage.
Remove the bearing races. The bearing races are a loose

fit on two (2) locating pins in the housing.
Remove the feedback link from the head of the special

screw on the swashplate assembly.
Using a 10 mm or 13 mm hex wrench, remove the four

(4) screws holding the slipper guide hold down
mechanism to the swashplate.
Disassemble the hold down mechanism and remove the

slipper guide and pistons from the swashplate.
NOTE: Pumps use a fixed-clearance hold down

mechanism.
Remove the piston assemblies from the slipper guide.
T803324,000095A –19–15MAR06–3/3

100406
PN=161
Reconditioning and Replacement of Parts
After disassembly, all parts should be thoroughly cleaned

in a suitable solvent. Replace all o-rings, gaskets, and the
shaft seal.
Inspect all parts for damage, nicks, or unusual wear

patterns. Replace all parts having unusual or excessive
wear or discoloration.
If the end cap journal bearing needs replacement (as

evidenced by large amounts of the metal back of the
bearing being visible through the plastic bearing material),
remove the bearing with a suitable puller. Do not damage
the valve plate surface of the end cap.
50
30 Lightly lubricate the steel backing of a new journal
6 bearing. Press the journal bearing into the end cap using
a suitable press pin.
When installed correctly, the bearing will be flush to 0.020

inches (0.50 mm) below the valve plate surface of the end
cap.
If a new journal bearing is installed, the bearing must be

sized with the appropriate arbor to assure the minimum
bore diameter is met. Carefully press the sizing arbor into
the bearing to size it.
CAUTION: The arbors are precision finished to

size the journal bearings without damaging
them. Damaged arbors must be replaced. Do
not attempt to use the drive shaft in place of an
arbor. Inadequate clearance between the shaft
and bearing will result in inadequate lubrication
and shortened bearing life.
NOTE: The charge pump shaft bushing in the end cap

may be replaced in a similar manner to the drive
shaft journal bearing.
Certain frame size pumps with twin port end caps may
have the servo relief valves and rotation plugs located in a
removable rotation block. Remove the rotation block
screws with a 5 mm internal hex wrench and remove the
block and gasket.

100406
PN=162
For pumps with pressure limiter function (except units with

automotive control), remove the servo relief valves from
the end cap or rotation block with a screw driver. For
pumps with pressure limiter defeat and/or automotive
control, remove the servo relief passage plug(s) from the
end cap or rotation block with a 3/16 inch internal hex
wrench.
Note the position of the rotation pipe plugs and remove

them from the end cap or rotation block with a 1/ 8 inch
internal hex wrench.
Install the servo relief valves or relief valve passage plugs

into the end cap or rotation block as shown in the
accompanying illustrations and chart.
50
NOTE: Pumps with pressure limiter function (except those 30
units with automotive control) MUST have servo 7
relief valves installed in the end cap or rotation
block to limit servo pressures. Install the rotation
pipe plugs into the end cap or rotation block as
shown in the accompanying illustrations and chart.
The threaded holes in the swashplate (for the hold down

screws) must be cleaned of old locking compound prior to
reassembly. A 6 mm thread tap may be used for this
purpose.
Inspect the swashplate guide for wear. The guide may be

removed by removing the special locking screw with a 6
mm internal hex wrench.
Servo arm alignment is critical for proper pump operation.

For this reason, removal of the servo arm from the
swashplate is not recommended.
If the servo arm must be removed from the swashplate,

remove the locking screw with a 13 mm hex wrench.
Keystone design servo arms must be parallel (within

0.010 inches [0.25 mm] total) to the wide surface of the
slot in the swashplate when installed. “Press fit” design
servo arms must be carefully aligned with the slot and
threaded holes in the swashplate while installing, and
must be pressed completely into the swashplate slot.

100406
PN=163
NOTE: Keystone design servo arms and swashplates are

no longer available for servicing pumps. A
swashplate / servo arm kit is available to service
these units.
Torque the servo arm to swashplate locking screw to 32

N•m (24 lb-ft.).
Assemble the swashplate guide to the swashplate with the

special locking screw. Torque the screw to 32 N•m (24
lb-ft.).
If the headed roll pin and flat washer for the bearing cage
locator link must be installed on the swashplate, the
distance between the washer and the side of the
swashplate must be as indicated below:
50
30
8 Pump Distance = H
±0.240 in. (9.45) ±0.010 in. (±0.25 mm)
Inspect the servo piston and seal rings for wear. If worn,
remove the seal rings and expander O-rings from the
piston. Install new expander O-rings into the seal grooves
in the servo piston.
Carefully install the piston seal rings in the piston grooves,

over the expander O-rings. DO NOT stretch the seal rings
any more than necessary when installing.
Lubricate the seal rings and carefully slide the servo

piston into the servo cylinders. Allow the assembly to set
for at least 5 minutes to allow the seal rings to return to
their original unstretched size. Then remove the servo
cylinders.
Compress the cylinder block spring and remove the spiral

retaining ring, retainer, spring, and spring seat.
Reassemble in the reverse order.
T803324,000095B –19–15MAR06–3/3

100406
PN=164
Assembly Procedures for Variable

Displacement Pump
Clean and lightly oil all parts prior to assembly of the

pump. Be sure to torque all threaded parts to
recommended torque levels.
CAUTION: Most parts have critical, high

tolerance surfaces. Caution must be exercised
to prevent damage to these surfaces during
assembly. Protect exposed surfaces, openings,
and ports from damage and foreign material.
Assemble the piston assemblies into the slipper guide.
Lubricate the slipper running surfaces. Center the pistons 50

30
and guide on the swashplate.
9
NOTE: Pumps use a fixed clearance hold down

mechanism.
Assemble one-half of the fixed-clearance hold down

mechanism as follows:
• Position two (2) spacers over the threaded holes in the

swashplate as shown.
• Position the slipper guide bearing on top of the spacers
and slipper guide.
CAUTION: The split between the slipper guide

bearing plates must be located in line with the
swashplate arm. The bearing surface of the
bearing plates must be located next to the
guide.
Install two (2) new screws (with locking compound) and

flat washers through the slipper guide bearing, and
spacers. Finger tighten the screws into the swashplate.
Continued on next page T803324,000095C –19–15MAR06–1/9

100406
PN=165
NOTE: Inspect the flat washers for raised edges or burrs.

The smooth side of the flat washers must be
installed next to the slipper guide bearing.
CAUTION: Always use new screws with proper

locking compound.
Assemble the other half of the fixed-clearance hold down

mechanism in a similar manner.
Assemble one-half of the spring-loaded hold down

mechanism as follows:
• Lubricate the slipper guide bearing and position it on

top of the slipper guide.
50 • Position two (2) spacers in the holes of the guide
30 bearing and over the threaded holes in the swashplate.
10
CAUTION: The split between the slipper guide

bearing plates must be located in line with the
swashplate arm. The bearing surface of the
bearing plates must be located next to the
slipper guide.
• Position two (2) flat washers on top of the spacers.

• Position two (2) leaf springs on top of the washers.
• Position two (2) spring aligners on top of the leaf
springs.
• Install two (20 new screws (with locking compound)
through the spring aligners, leaf springs, flat washers,
and spacers. Finger tighten the screws into the
swashplate.
Assemble the other half of the spring-loaded hold down

mechanism in a similar manner.
CAUTION: Always use new screws with proper

locking compound.
Torque the hold down screws to 10 lb-ft (13.5 N•m). The

slipper guide and piston slippers must be able to slide
freely on the swashplate.

100406
PN=166
Lubricate the pistons and cylinder block bores. Install the

assembled swashplate and pistons into the cylinder block
by inserting the pistons into the cylinder block bores. The
pistons and bores are not selectively fitted, therefore no
specific piston and bore orientation is required.
Check that the swashplate bearing race locating pins are

secure in the housing.
Install the swashplate bearing races into the housing,

positioning the races on the locating pins. Retain the
races in position with petroleum jelly. The locating pins
are offset in the housing to assure proper assembly.
Assemble and lubricate the bearing cage, and install it on

the bearing races.
50
30
Install the bronze slider block on the swashplate servo 11
arm.
Install the feedback link on the head of the special screw

on the swashplate assembly. Position the servo piston in
the housing.
NOTE: For units equipped with an automotive control, the

machined end of the servo piston (with the
threaded hole) must be located on the side of the
housing where the centering assist spring sleeve
will be installed.
CAUTION: To avoid the possibility of the pump

sticking in stroke, the feedback link must NOT
be installed in pumps equipped with
nonfeedback controls (such as the cover plate,
3-position solenoid, and automotive control).
Carefully lower the cylinder block and swashplate

assembly into the housing through the end cap opening.

100406
PN=167
NOTE: A tool to aid in holding and installing the

assembled cylinder block and swashplate may be
made from a positive lock, quick release pin and a
large flat washer (1 inch inside diameter with
clearance flats ground on the outside diameter).
Insert the pin thru the cylinder block and
swashplate, and lock in place with the flat washer
under the swash-plate.
Hold the cylinder block and swashplate assembly

approximately 1/2 inch (12 mm) above the cradle
bearings.
Properly position the feedback link in the control opening.
Position the servo piston on the slider block, taking care

50
30 not to wedge the block. The parts should slide freely.
12
Lower the cylinder block and swashplate assembly until
the swashplate is properly located on the cradle bearings.
NOTE: If an assembly tool was used to install the cylinder

block and swashplate, release and remove the
pin. The flat washer should fall through the shaft
opening of the housing. Hold the servo piston in
position and install the servo cylinders.
NOTE: Be sure to assemble the correct servo cylinder on

each side of the housing. For units equipped with
an automotive control, a special servo cylinder is
installed on the centering assist spring side of the
housing.
Install the rhree (3) or four (4) screws in each servo

cylinder. Torque to 24 N•m (18 lb-ft).
NOTE: For units equipped with an automotive control, the

servo cylinder screws on the centering assist
spring side of the housing will be installed later.
Align the slot in the swashplate bearing cage with the

headed spring pin in the swashplate and the pin hole in
the housing. Hook the cage locator link over the spring
pin, between the washer and the swashplate. Rotate the
link into the slot in the bearing cage.

100406
PN=168
Align the hole in the locator link with the hole in the
housing and install the link anchor pin through the link and
into the housing.
Install a new screw (with locking compound) through the

locator link and into the housing. Tighten the screw into
the housing until the head of the screw is positioned at a
height (distance “H”) of 0.178 to 0.188 inch (4.53 to 4.79
mm) from the machined surface of the pump housing.
CAUTION: Always use a new screw with proper

locking compound. DO NOT torque this screw
against the locator link. The link MUST rotate
freely.
Push the swashplate assembly toward the control side of 50

the housing until the swashplate guide contacts the 30
13
bearing race. Check for clearance between the servo arm
and the slider block. If no clearance is present, recheck
the assembly of the bearing cage and races.
Position the swashplate leveler (“T-Bar”) on the side

cover. Note the orientation of the leveler and the cover.
For units with leveler guide posts, install the two (2) guide
posts and sealing nuts. Torque to 23 N•m (17 lb-ft).
NOTE: If the screw holes in the side cover are thru holes,
the threads of the screws must be coated with
sealing compound.
Install the leveler spring seats.
NOTE: Earlier production pumps do not have removable

(hardened) swashplate leveler spring seats.
Install the inner spring spacer washers (if used). Install a

new side cover O-ring.
Hold the swashplate leveler toward the end cap end of the
housing so the leveler will clear the side of the swashplate
during side cover installation. Install the side cover and
swashplate leveler.
Install two (2) side cover screws (with flat washers) finger
tight into the blind holes in the housing, to hold the cover
while checking the zero angle position of the swashplate.

100406
PN=169
If all the parts which affect the zero angle setting are
being reused, rotate the side cover to align the marks on
the cover and housing that were made at disassembly.
Apply a force of 5 to 10 lbsf. (22 to 44 N) to the

swashplate leveler to ensure both arms are in contact with
the swashplate. Make sure the swashplate is properly
located on its bearings. Use a depth micrometer to
measure the distance from the end cap face of the
housing to the outer edge of the swashplate surface. Take
a second measurement at a point 180° from the first point
of measurement (at the opposite edge of swashplate
surface). These measurements must not vary by more
than .001 inches (.025 mm).
Rotate the side cover (which will also rotate the leveler
50
30 and swashplate) until the zero angle position is
14 established, as determined by the depth measurement.
After the zero angle position has been established, tighten

the two (2) screws to hold the side cover.
Install the remaining four (4) screws with flat washers.
NOTE: The threads of the two (2) side cover screws

installed in thru holes in the housing must be
coated with a sealing compound to prevent leaks.
New screws have sealant pre-applied.
First, torque the four (4) side cover screws installed in

blind holes to 32.5 N•m (24 lb-ft).
Then, torque the two (2) side cover screws installed in

thru holes to 25 N•m (18.5 lb-ft).
Install the end cap alignment pins into the housing.

Lubricate the running surface of the cylinder block and
install the valve plate on the alignment pins.

100406
PN=170
NOTE: Note the direction of the arrow cut-outs in the

valve plate. The arrows must point in the direction
of pump rotation. For example, a right hand
(clockwise) rotation pump must have the arrows
pointing in the clockwise direction (when viewed
from the shaft end).
Install the two (2) long springs (with inner springs, if used)
on the swashplate leveler spring seats. Install the short
spring on the servo arm link. Place new end cap gasket
on the housing (located by the alignment pins). Take care
not to bend or damage the end cap gasket during
installation.
Lubricate the end cap journal bearing. Install the hardened

shims in the end cap pockets for the swashplate leveler
50
springs. Retain the shims with petroleum jelly. 30
15
Lower end cap onto housing while positioning the three
(3) springs in their pockets in the end cap.
When properly installed, the end cap will engage the

alignment pins, but the springs will hold the end cap 1/ 8
to 1/4 in. (3 to 8 mm) away from the housing.
Install the four (4) large end cap screws.
NOTE: If the pump will be equipped with an auxiliary

mounting pad, temporarily install two (2) of the
large screws which fasten the end cap to the
housing. These screws will hold the end cap
against internal spring pressure while the small
screws are installed.
Tighten the large end cap screws evenly to the torque

indicated in the accompanying table. Frame Torque 256
N•m (189 lb-ft).
Install the two (2) or three (3) smaller screws holding the
end cap to the housing. Torque the 6 mm screws to 13.5
N•m (10 lb-ft), and the 8 mm screws to 38 N•m (28 ft-lb).
NOTE: A lifting bracket is installed on one (1) of the

smaller end cap screws.
Position the pump on its end cap.

100406
PN=171
Using caution to prevent damage to the sealing surface,

press the roller bearing onto the drive shaft.
(For units with a 3-piece bearing, press the inner race

onto the shaft, then install the outer race/cage assembly
and the special washer.) Install the bearing retaining ring
onto the shaft.
Install the shaft and bearing assembly through front of

housing, aligning the shaft spline with the cylinder block
spline. Continue to lower the shaft into the unit and
carefully align the end of the shaft with the end cap
journal bearing. Then lower the shaft and bearing
assembly into position.
Rotate the shaft by hand. The rotating assembly should

50
30 turn freely. If it does not rotate freely, the pump must be
16 disassembled and the problem corrected.
Rotate the pump shaft with a torque wrench to assure

correct assembly. When properly assembled, the torque
required to turn the shaft (after “break-away”) should be
within the ranges shown in the accompanying table.
Torque to Turn Shaft (Variable Pump at 0°)
Specification
Pump Shaft—Minimum Torque ................................................... 6.71 N•m
5 lb-ft
Maximum Torque......................................................................... 13.6 N•m
10 lb-ft
CAUTION: Always test the pump prior to putting

it into service to verify correct pressure limiter
and control function. Improper function of these
systems can result in uncontrollable movement
of the vehicle / machine.
Assemble and adjust the following components as

described in the Minor Repair section.
• Charge Pump
• Auxiliary Mounting Pad (If Applicable)
• Shaft Seal
• Control
• Filter Option
• Charge Relief Valve

100406
PN=172
• Multi-Function Valves
• Displacement Limiter(s)
T803324,000095C –19–15MAR06–9/9
50
30
17

100406
PN=173
50
30
18

100406
PN=174
Section 60
Steering System
Contents
Page
Group 10—Repair
Steering Valve. . . . . . . . . . . . . . . . . . . . . . . . . .60-10-2
Repair Instructions . . . . . . . . . . . . . . . . . . . . . .60-10-3
Necessary Tools . . . . . . . . . . . . . . . . . . . . . . . .60-10-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-4
Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . .60-10-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-7
Steering Troubleshooting. . . . . . . . . . . . . . . . .60-10-12
60

100406
PN=1
Contents
60

100406
PN=2
Group 10
Repair
60
10
1

100406
PN=177
Repair
Steering Valve
60
10
2
–UN–17MAR06
CM20045077A0

100406
PN=178
Repair
1—Seal 8—Bearing 15—Control Assy 22—Spacer

2—Snap Ring 9—Special Bolt 16—Housing 23—Drive
3—Retainer Ring 10—Seal 17—Control Sleeve 24—Geroter Set
4—Seal 11—Check Ball Seat 18—Spool 25—Spacer Assy
5—Ring 12—O-ring 19—Centering Spring 26—End Cover
6—Needle Bearing Kit 13—Check Ball 20—Pin 27—Special Bolt
7—Racer 14—Check Ball Retainer 21—O-Ring
T803324,0000985 –19–17MAR06–2/2
Repair Instructions
Cleanliness is extremely important when repairing this

steering control valve. Always work in a clean area.
Before disconnecting the hydraulic lines, clean the port
area of the valve thoroughly. Use a wire brush to remove
dirt and debris from around the exterior joints of the valve.
60
10
All troubleshooting information defines the terms and 3
problems, possible causes for problems, and
recommended procedures for correcting them.
It is recommended that you keep the valve in a vise

during disassembly, follow the clamping instructions as
explained in this section.
T803324,0000986 –19–17MAR06–1/1
Necessary Tools
• Screwdriver, 4-6” long; 1/8” blade

• 5/16”, 12 Point Socket
• Breaker Bar Wrench
• Torque Wrench, 31 N•m (275 lb-in)
• Plastic or Rubber Hammer
• 1/4” Allen Wrench
• 1/8” - 24 x 1-1/2” long machine screw
• Needle Nose Pliers
• Spring Installation Tool - 0841320104
T803324,0000987 –19–17MAR06–1/1

100406
PN=179
Repair
Disassembly
1. 1. Clamp the valve in a vise gerotor end up. Clamp

lightly on the edges of the mounting area. Use
protective material on the vise jaws and Do Not
over-tighten.
2. Remove seven bolts (27).
3. Remove end cover (26).
4. Remove seal (21) from end cover.
5. Remove gerotor (24), take care not to drop star

shaped spacer (part of 25).
6. Remove seal (21) from gerotor.
7. Remove drive spacer assembly (25).
8. Remove drive (23).

60
10 9. Remove spacer (22).
4
10. Remove seal (21) from housing (16).
11. Remove the valve from the vise and place the
housing on a clean soft cloth to protect the surface
finish. Use the thin-bladed screwdriver to pry snap
ring (2) from the housing.
12. Rotate spool (18) and control sleeve (17) until pin
(20) is horizontal. Push the spool and sleeve
assembly forward with your thumbs just far enough to
free retainer ring (3) from the housing and remove it.
13. Remove seal (4) from retainer ring (3).
14. Use the thin-bladed screwdriver to pry seal (1) from

retaining ring (3). Take care not to damage retainer.
15. Remove the two bearing races (7) and needle thrust
bearing (8) from the spool and sleeve assy.
16. Remove the spool and sleeve assembly from the

gerotor end of housing. Do Not bind the spool and
sleeve assembly in housing. Rotate the unit slowly
when removing.

100406
PN=180
Repair
17. Push pin (20) from the spool and sleeve assy.
18. Push the spool partially from the control end of the
sleeve, and carefully remove six centering springs
(19) from the spool by hand.
19. Push the spool back through and out of the sleeve.
Rotate the spool slowly when removing from the
sleeve.
20. Remove seal (4) from housing.
21. Remove setscrew (9) from the housing.
22. Screw a 1/8" - 24 machine screw into the end of

check ball seat (11). Pull on the screw with a pair of
needle nose pliers and lift the assembly out of the
housing.
23. Remove the two seals (10 & 12) from the check valve
seat.
60
24. Tip the housing to remove check ball (13) and 10
5
retainer (14).
T803324,0000988 –19–17MAR06–2/2

100406
PN=181
Repair
Clean and Inspect
1. Check all mating surfaces and replace any parts that

have scratches or burrs that could cause leakage. DO
NOT try to file or grind parts.
2. Clean all metals parts in clean nonflammable solvent

and blow dry with air. DO NOT wipe parts dry with a
cloth or paper towel. Lint or other foreign material
could get into the hydraulic system and cause damage.
3. Discard all seals and o-rings and replace with new

ones.
4. Lubricate all seals, except ring (5), with O-Ring Lube

(0841304202) or equivalent. DO NOT use excessive
lubricant on the seals for the gerotor section.
60
10
6
T803324,0000989 –19–17MAR06–1/1

100406
PN=182
Repair
Reassembly
1. Use the needle nose pliers to lower check ball retainer

(14) into the check ball holes of the housing. Make
sure that the retainer is straight in the housing and not
tilted on edge.
2. Install check ball (13) in housing.
3. Lubricate seals (10 & 12) and install on check ball seat
(11).
4. Lubricate check ball seat and seals thoroughly before

installing the seat into the housing. When installing do
not twist or damage the seals. To install, insert the
open end first and push until it bottoms in the hole.
5. Install setscrew (9) using the 5/16" Allen wrench and

torque to 11.3 N•m (100 lb-in). To prevent interference,
make sure that the top of setscrew (9) is slightly below
the mounting surface of the housing.
60
6. Assemble spool (18) and sleeve (17) carefully so that 10
7
the spring slots align at the same end. Rotate the
spool while sliding the parts together. Some spool and
sleeve sets have identification marks, align these
marks. Test the assembly for free rotation, the spool
should rotate smoothly within the sleeve when force is
applied to the splines with the finger tips.
7. Bring spring slots of both parts in line and stand parts

on the end of bench. Insert the spring installation tool
through the slots on both parts. Position three pairs of
centering springs (or two sets of three) on the bench
so that the extended edge is down and the arched
center section is together. In this position, insert one
end of entire set into the spring installation tool.
8. Compress the extended end of the centering spring set

and push into the spool sleeve assembly while
withdrawing the installation tool.
9. Center the spring set in the parts so that they push

down evenly and flush with the upper surface of the
spool and sleeve.

100406
PN=183
Repair
10. Install pin (20) through spool and sleeve until is

becomes flush with both sides of the sleeve.
11. Position the spool and sleeve assembly so that the

splined end of the spool enters the gerotor end of the
housing first. Be extremely careful that the parts do
not tilt out of position while inserting. Push parts
gently into place with a slight rotating action, but keep
pin nearly horizontal.
12. Bring the spool assembly entirely within the housing

bore until the parts are flush at the gerotor end of
housing. Do Not pull the spool assembly beyond this
point to prevent the cross pin from dropping into the
discharge groove of the housing. With the spool
assembled in this flush position, check for free
rotation within the housing by lightly applying finger tip
force to the splined end of spool.
13. Place the housing on clean, lint-free cloth. Install seal

(21) in housing.
60
10 14. Install two bearing races (7) and needle thrust bearing
8
(8) in the order shown in figure 1.
15. Install seal (1) in retaining ring (3), the flat or smooth
side of the seal must face downward towards the
bushing.
16. Install ring (5), dry, (that is without lubricant) into

retaining ring (5). Smooth the ring in place with your
finger. Do Not use any ring that falls freely into the
recessed area of the retainer.
17. Install the retaining ring assembly over the spool, with
a twisting motion. Tap the retainer in place with a
rubber hammer. Make sure that it is flush against the
bearing race.
18. Install snap ring (2) into housing. After installing, tap
on ring end or pry with a screwdriver around the
entire circumference of the ring to properly seat it in
the housing groove.

100406
PN=184
Repair
19. Clamp the housing in a vise with the gerotor end up.
Clamp lightly on the edges of the mounting area. Use
protective material on the vise jaws and DO NOT
over-tighten. Check to insure that the spool and
sleeve are flush or slightly below the surface with the
fourteen holes.
IMPORTANT: DO NOT use cloth or paper to clean

surfaces.
20. Clean the upper surface of the housing by wiping with

the palm of a clean hand. Clean each of the flat
surfaces of the gerotor section in a similar manner
when ready for reassembly.
21. Install seal (21) in housing.
22. Install spacer (22), align bolt holes in spacer with the
tapped holes in housing (16).
23. Rotate spool and sleeve assembly until the pin is

parallel with the port face. Install drive (23) making 60
sure that drive is engaged with pin. To assure proper 10
9
alignment, mark the drive, as shown in Figure 2. Note
the relationship between the slotted end of drive to
the splined end of drive when marking.
24. Install seal (21) in gerotor.

100406
PN=185
Repair
25. With the seal side of the gerotor (24) faced toward
spacer (22), align star valleys (A) on drive (B). Note
the parallel relationship of reference lines A, B, C and
D. Align the bolt holes without disengaging the
gerotor from the drive.
26. Install drive spacer assembly (25) in the gerotor.
27. Install seal (21) in end cover (26).
28. Install end cover (26) on gerotor and align bolt holes.
1—Gerotor Star Valley

2—Drive (Mark on Top)
3—Pin
4—Port Face
–UN–17MAR06
60
10
10
CM061850028
T803324,000098A –19–17MAR06–4/5
29. Install seven special bolts (27) without lubricant.

Pre-tighten bolts to 17 N•m (150 lb-in), and then
torque to 31N•m (275 lb-in) in the sequence shown.
–UN–17MAR06
CM061850029
T803324,000098A –19–17MAR06–5/5

100406
PN=186
Repair
Troubleshooting
Most steering problems can be corrected if the problem is

properly defined. The entire steering system should be
evaluated before removing any components. The steering
valve is generally not the cause of most steering
problems. The following is a list of steering problems
along with the possible causes and suggested corrections.
T803324,000098B –19–17MAR06–1/1
60
10
11

100406
PN=187
Repair
Steering Troubleshooting
Slow Steering, Hard Steering or Worn or malfunctioning pump Repair or replace pump.
Loss of Power Assist
Malfunctioning relief valve allows the Repair or replace the relief valve.
system pressure to fall lower than
specifications.
Overloaded steering axle Reduce load.
Wander: Loader Will Not Stay In Air in system due to low oil level, Find problem and correct.
A Straight Line cavitating pump, leaky fitting,
pinched hoses, etc.
Worn steering linkage. Repair or replace.
60 Bent linkage or cylinder rod. Repair or replace.

10
12
Loose cylinder piston. Repair or replace.
Leaky crossover relief valve. Repair or replace the crossover relief

valve.
Severe wear in steering valve. Replace the steering valve.
Drift: Loader Veers Slowly In One The cylinder slowly extends without A small amount of extension is
Direction turning the steering wheel. normal.
Worn or damaged steering linkage. Replace linkage and align front end.
Slip: A Slow Movement of Leakage of cylinder piston seals. Replace the seals.
Steering Wheel Fails To Cause
Any Movement Of The Steered
Wheels
Worn steering valve gerotor. Repair or replace the steering valve.

100406
PN=188
Repair
Hang-Up: Temporarily Hard Thermal Shock1 Check loader for proper operation
Steering and cause of thermal shock.
Soft Steering Air in hydraulic system; most likely Bleed air from system.
air is trapped in the cylinders or
lines.
Low system fluid. Add system oil and check for leaks.
Erratic Steering Air in system due to low oil level, Find problem and correct.
cavitating pump, leaky fitting,
pinched hoses, etc.
Loose cylinder piston. Replace cylinder.
Thermal shock damage. Replace steering valve.
Sticking flow control spool. Repair or replace flow control valve.
Free Wheeling: Steering Wheel Steering column upper shaft is loose Check for damage and replace if 60
Turns Freely With No Feeling of or damaged. necessary or tighten steering wheel 10
13
Pressure and No Action on nut.
Steered Wheels
Lower splines of column may be Check for engagement and replace if

disengaged or broken. splines are damaged.
Steering valve is low on oil. This can Starting engine and circulating
happen on start-up, after repair or system will usually correct the
after long periods of non-use. problem.
There is no flow to steering valve Replace hose.

caused by a ruptured hose.
There is no flow to steering valve Replace steering valve.

caused by thermal shock.
1
Thermal shock is a condition caused when the hydraulic system is
operated for some time without turning the steering wheel, so that fluid
in the tank and system is hot and the steering valve is relatively cool
(more than 50° temperature differential). When the steering wheel is
turned quickly, the result is temporary seizure and possible damage to
internal parts of the steering valve. The temporary seizure may be
followed by total free-wheeling.

100406
PN=189
Repair
Free Wheeling: Steering Wheel Leaking crossover relief in steering Repair or replace the crossover relief
Turns Freely With Slight circuit. valve.
Resistance But Results In Little
or No Steered Wheel Action
Cylinder piston seal blown. Determine the cause, correct and

replace seal.
Excessive Free Play at Steering Loose steering wheel nut. Tighten steering wheel nut.
Wheel
Steering column shaft worn or Replace steering column.

damaged. (There should be very
little free play in valve itself.)
Excessive Free Play at Steered Broken or worn linkage between Check for loose or damaged
Wheels cylinder or steered wheels. mechanical parts in the steering
linkage system.
60 Leaking cylinder seals. Replace cylinder seals.

10
14
Binding or Centering of Steering Binding or misalignment in the Align column pilot and spline to
Wheel steering column or the splined input steering valve.
connection.
High back-pressure in tank line can Find problem with line and correct.
cause a slow return to center. This
pressure should not exceed 20.7 bar
(300 PSI).
Large particles of contamination in Clean the steering valve and check

system oil can cause binding the oil filters; replace the filters if
between the spool and sleeve in necessary. If another component has
steering valve. failed causing contaminants, flush
the system and replace system
filters.
Steering Valve Locks Up Large contamination particles in Clean the steering valve and check
gerotor section of steering valve. for the source of contamination.
Broken cross pin in spool and sleeve Repair or replace steering valve.
assembly.
Severely worn steering valve. Replace the steering valve.
Thermal shock. Replace the steering valve.

100406
PN=190
Repair
Steering Wheel Oscillates or Parts assembled wrong during Reassemble correctly.

Turns By Itself repair.
Steering unit improperly timed. Correct the timing.
Hydraulic lines connected to wrong Reconnect the lines to proper ports.

ports.
Steered Wheels Turn In Wrong Hydraulic lines connected to wrong Reconnect the lines to wrong ports.
Direction When Operator ports.
Activates Steering Wheel
T803324,000098C –19–17MAR06–4/4
60
10
15

100406
PN=191
Repair
60
10
16

100406
PN=192
Section 70
Hydraulic System
Contents
Page
Group 10—Pumps & Valves

Double Gear Pump . . . . . . . . . . . . . . . . . . . . . .70-10-2
Pump - Priority End Cover Assembly . . . . . . . .70-10-4
Multiple Gear Pump Repair . . . . . . . . . . . . . . . .70-10-5
Suggested Tools . . . . . . . . . . . . . . . . . . . . . . . .70-10-6
Repair Precautions . . . . . . . . . . . . . . . . . . . . . .70-10-7
Bushing Removal Tool . . . . . . . . . . . . . . . . . . .70-10-7
Seal Removal Tool . . . . . . . . . . . . . . . . . . . . . .70-10-7
Bushing Installation Tool . . . . . . . . . . . . . . . . . .70-10-8
Special Steel Sleeve . . . . . . . . . . . . . . . . . . . . .70-10-8
Directional Control Valve - Boom Swing,
Boom Flex and Piler Lift . . . . . . . . . . . . . . .70-10-10
Seal Installation Tool . . . . . . . . . . . . . . . . . . . .70-10-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-12
Clean and Inspect . . . . . . . . . . . . . . . . . . . . . .70-10-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-16
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . .70-10-19
Recommended Test Procedure . . . . . . . . . . . .70-10-20
70
Group 20—Hydraulic Checks

Hydraulic Troubleshooting . . . . . . . . . . . . . . . . .70-20-1
Suggested Tools . . . . . . . . . . . . . . . . . . . . . . .70-20-11
External Relief Settings . . . . . . . . . . . . . . . . . .70-20-12
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-12
Valve Bank Disassembly . . . . . . . . . . . . . . . . .70-20-13
Cleaning, Inspection and Repair . . . . . . . . . . .70-20-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-15
Spool Assembly — Spring Centered . . . . . . . .70-20-16
Detented . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-16
Valve Section Assembly . . . . . . . . . . . . . . . . .70-20-17
Valve Bank Assembly . . . . . . . . . . . . . . . . . . .70-20-17
Section Disassembly . . . . . . . . . . . . . . . . . . . .70-20-18
Preparation of Parts . . . . . . . . . . . . . . . . . . . .70-20-18
Section Assembly . . . . . . . . . . . . . . . . . . . . . .70-20-19
Directional Control Valve — Boom Lift and
Grab Open/Close. . . . . . . . . . . . . . . . . . . . .70-20-22
Group 30—Hydraulic Cylinder

Hydraulic Cylinder Diagnostics . . . . . . . . . . . . .70-30-1
Hydraulic Cylinder Drift Diagnostics. . . . . . . . . .70-30-1
Cylinder Tube Assembly . . . . . . . . . . . . . . . . . .70-30-4
Grab Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .70-30-5
Disassemble and Assemble Cylinder . . . . . . . .70-30-5

100406
PN=1
Contents
70

100406
PN=2
Group 10
Pumps & Valves
70
10
1

100406
PN=195
Pumps & Valves
Double Gear Pump
70
10
2
–UN–26MAY06
CM11451507E1

100406
PN=196
Pumps & Valves
1—Lip Seal 6—Channel Seal 11—Gear Housing 16—Pump - Priority End Cover
2—Shaft End Cover 7—Thrust Plate 12—Bearing Carrier Housing Assembly
3—Gear Housing 8—Gear Shaft 13—Connecting Shaft 17—Stud
4—Plug 9—Square Seal 14—Gear Set 18—Washer
5—Backup Seal 10—Dowel Pin 15—Gear Housing 19—Nut
T803324,000095E –19–15MAR06–2/2
70
10
3

100406
PN=197
Pumps & Valves
Pump - Priority End Cover Assembly
70
10
4
–UN–26MAY06
CM11454381B1

100406
PN=198
Pumps & Valves
1—Housing 5—Priority Valve Cap End 9—Set Locking Nut 13—Relief Valve Poppet
2—Bushing 6—O-ring 10—O-ring 14—Relief Valve Spring
3—Priority Valve Spool 7—Plug 11—O-ring 15—Hex Lug
4—Priority Valve Outer Spring 8—Adjusting Screw 12—Backup Ring 17‘—Inner Spring
T803324,000095F –19–15MAR06–2/2
Multiple Gear Pump Repair
These service instructions will familiarize you with multiple

pumps, their component parts, the relative position of
each part, proper methods for assembly or disassembly of
the units, and care and use of these pumps. This will give
you the best performance and a longer working life.
To facilitate the repair of these pumps, and before any

work is done, we suggest you first read all of the repair
steps.
The first requirement for good maintenance of hydraulic

equipment is cleanliness. Make sure you perform all repair
work in a clean area.
The repair graphics show a double pump, but is also

applicable to the triple pump.
It is important to air blast all parts and wipe them with a 70

clean, lintless cloth before assembly. 10
5
CAUTION: Use caution in gripping all parts in

the vise to avoid damaging machined surfaces.
A pump must be driven in the direction of rotation for

which it is was built, otherwise the pressure will blow the
shaft seal.
Check all replacement parts before installation to be

certain they were not damaged in shipment.
T803324,0000960 –19–15MAR06–1/1

100406
PN=199
Pumps & Valves
Suggested Tools
• Arbor Press
• 1-1/2 in. diameter steel ball
• Bearing Puller
• Bushing Removal Tool - 0841329345
• Clean lintless cloths
• Deburring Tool (an old file with cutting teeth ground off)
• Machinist’s Hammer
• Soft Hammer
• Permatex form-a-gasket number C2 non-hardening
sealant or equivalent
• Medium Grit Carborundum Stone
• Seal Removal Tool
• System Oil and Grease
• Snap Ring Pliers
• Prick Punch
• Bushing Installation Tool
• Scale (1/32 In. or 1/64 In. graduations)
• Small screwdriver
• Torque Wrench
• Vise with 6 in. minimum open spread
• Seal Installation Tool - 0840249684
• Special Steel Sleev - 0290244683
• Awl
70
10
6
T803324,0000961 –19–15MAR06–1/1

100406
PN=200
Pumps & Valves
Repair Precautions
1. If it is necessary to pry off sections, take extreme care

not to mar or damage machined surfaces. Excessive
force while prying can result in misalignment and may
seriously damage parts.
2. If parts are difficult to install during assembly, tap

gently with a soft hammer. Never use a metal hammer.
3. All gears are closely matched; therefore; they must be

kept as sets when removed from the pump. Handle
with care to avoid damage to the journals or teeth.
Avoid touching gear journals.
4. Never hammer bushings into bores, use an arbor

press.
T803324,0000962 –19–15MAR06–1/1
70
10
7
Bushing Removal Tool
The bushing in the double and triple pumps should be

removed from their bores by using bushing removal tool,
0841329345.
T803324,0000963 –19–15MAR06–1/1
Seal Removal Tool
The seal removal tool can be easily made from an old

screwdriver. Heat the tip and bend to 90°. Grind the tip to
fit the notch behind the shaft seal.
T803324,0000964 –19–15MAR06–1/1

100406
PN=201
Pumps & Valves
Bushing Installation Tool
To install the bushings, use bushing installation tool,

0290244461.
T803324,0000965 –19–15MAR06–1/1
Special Steel Sleeve
Special Steel Sleeve, 0290244683, is used to install the

drive shaft through the lip seal without damage.
T803324,0000966 –19–15MAR06–1/1
70
10
8

100406
PN=202
Pumps & Valves
70
10
9

100406
PN=203
Pumps & Valves
Directional Control Valve - Boom Swing, Boom Flex and Piler Lift
70
10
10
–UN–29SEP06
CM11451509E1

100406
PN=204
Pumps & Valves
1—Section Valve 5—Square Seal 8—O-ring 11—Stud

2—Power Beyond Plug 6—Section Valve 9—Washer 12—Washer
3—Washer 7—Section Valve Inlet 10—Main Relief Valve 13—Nut
4—Square Seal
T803324,0000967 –19–15MAR06–2/2
Seal Installation Tool
Seal installation tool, 0290244684, is used to install the lip

seal into the housing.
T803324,0000968 –19–15MAR06–1/1
70
10
11

100406
PN=205
Pumps & Valves
Disassembly
1. Place the pump in a vise1 with the drive shaft pointing

downward. Matchmark all sections and be sure to align
these marks when assembling.
2. Use a socket wrench to remove four hex nuts (19),

studs (17) and washers (18).
3. Lift off port end cover (16). If prying is necessary, be

careful not to damage the machined surfaces. Dowel
pins (10) will remain in either port end cover, gear
housing, or against other hard surfaces. Keep these
gears together, they are a matched set. Remove thrust
plate (7) from bearing carrier (12).
4. Lift gear housing (15) from bearing carrier (12). If

prying is necessary, take care not to damage
machined surfaces.
5. Carefully lift or pry off bearing carrier (12) to prevent

damage to contact face and edges. Dowel pins (10)
will remain in either bearing carrier (12) or gear
housings (11 & 15). Do Not remove them.
6. Remove connecting shaft (13). Remove thrust plate

(7). Remove front drive shaft assembly (8). Keep these
70
10 together, they are a matched set. Be careful not to
12 damage the machined surfaces of the gears.
7. Lift or pry off first section gear housing (11). Be careful

not to damage surfaces.
8. Use a bushing puller to remove bushings and inspect

all bushings for scoring or discoloration. Replace, if
necessary.
9. Place front cover (2) in a vise with the mounting face

pointing downward. Remove lip seal (1) by inserting
seal removal tool into the notch between the double lip
seal and the front cover. Tap the seal out and discard.
10. Examine check assy, replace only if damaged.

Remove with a screwdriver.
1
Do not grip on or near any machined surfaces during assembly or
disassembly.

100406
PN=206
Pumps & Valves
11. Remove and discard all rubber and polymer O-rings

and seals.
T803324,0000969 –19–15MAR06–2/2
70
10
13

100406
PN=207
Pumps & Valves
Clean and Inspect
Clean and inspect all parts for wear or damage, replace if

necessary. See parts catalog for the correct part numbers
to order. Notice that all gear assemblies are a matched
set and cannot be ordered separately.
Replace gear housings if either has wear in excess of

0.13 mm (0.005 in) cutout.
Use the following method to determine cutout:
Place a straightedge across the bore. If you can slip a

0.13 mm (0.005 in) feeler gauge under the straightedge in
the cutout area, replace the gear housing.
1. Pressure pushes the gears against the housing on the

low pressure side. As the hubs and bushings wear, the
cutout becomes more pronounced. Excessive cutout in
a short period of time indicates excessive pressure or
oil contamination. If the relief valve settings are within
prescribed limits, check for shock pressures or
tampering. Check an oil sample and the tank itself for
contamination.
2. Where cutout is moderate, 0.13 mm (0.005 in) or less,

the gear housing is in good condition and may be
70
10 reused.
14
3. Gears (14) which exhibit any scoring on the gear hub,
should be replaced. Any scoring, grooving, or burring
of the outer tooth diameter will require replacement.
Nicking, grooving, or fretting of teeth surfaces will also
necessitate replacement.
4. Drive shaft (8) should be replaced if any wear is

detectable, by touch, in the seal area or at the drive
coupling. The maximum allowable wear is 0.05 mm
(0.002 in). Wear in the shaft seal area indicates oil
contamination. Wear or damage to splines will
necessitate replacement.
5. Thrust plates (7) seal the gear sections at the sides of

the gears. Wear here will allow internal slippage and oil
bypass within the pump. A maximum of 0.05 mm
(0.002 in) wear is allowable. Replace thrust plates if
they are scored, eroded or pitted.

100406
PN=208
Pumps & Valves
6. Check the center of the thrust plates where the gears

mesh, erosion here indicates oil contamination. Pitted
thrust plates indicate cavitation or oil aeration.
Discolored thrust plates indicate overheating, probably
due to insufficient oil.
7. Dowel pins (10) must be replaced if either the dowel or

dowel hole is damaged. If there is damage, the dowel
or machined housing or both must be replaced. If more
than reasonable force is required to seat dowel pins
the cause may be poorly deburred or dirty parts,
cocking of the dowel pin in the hole, or improper
pin-to-hole fit.
8. Bushings (3) must be replaced if gears are replaced.

Bushings should fit into the bore with a heavy press fit.
9. All sealing parts: lip seal (1), channel seal (5), backup
seal (6), and square seal (9) must be replaced. See
parts catalog for complete seal kit part numbers.
10. Examine check assembly located in front cover (2).

Ensure that it is in the proper position and tightly
seated.
70
10
15
T803324,000096A –19–15MAR06–2/2

100406
PN=209
Pumps & Valves
Assembly
1. Rub a medium grit carborundum stone over the

machined surfaces. If bushings were removed or a
new section is used, debur the bores with a fine emery
cloth. Wash in a solvent, blow dry with air and wipe
with a clean lintless cloth before assembly.
2. Place front cover (2), mounting face downward, in a

vise. If check assembly is to be replaced, apply Loctite
to threads. Stake the check assembly with a prick
punch at both ends of the screwdriver slot and around
the edges. Peen the edge of the hole, in front cover
(2), with a 11/ 2 in diameter ball from 0.79 to 1.58 mm
(1/32 to 1/ 16 in) deep, before installing the check
assembly. The check assembly should be screwed in
tightly.
3. Any bushings (3), removed from front cover (2), end

cover (16) or bearing carrier (12) should be assembled
in the drive bores with its groove facing toward the top
of the pump (12 o’clock). Assemble the bushings in the
driven bores with the groove facing toward the bottom
of the pump (6 o’clock).
4. Bushings should be pressed into the bores, one at a

time, using installation tool (0290244461) and an arbor
70
10 press. Be sure the grooves are positioned, as
16 specified, in step 3. Bushings must be pressed into the
bores flush with the housing face. Be sure to support
the housings so they are square and level.
5. Repeat Step 1.
6. After installing the bushings in all housings, ensure that

the dowel pins are in place in any new housings.
Examine all dowel pins, and before inserting, make
certain the hole is clean and free from burrs. Gently
start pin (10) straight into the hole and tap lightly with a
soft hammer.

100406
PN=210
Pumps & Valves
7. Before inserting a new lip seal (1) into the front cover,
coat the outer edge and its recess with non-hardening
gasket sealant. With the metal side of the lip seal
facing upward and the spring facing toward the gear,
press it into the mounting flange side of the front cover
with an arbor press and seal installer (0290244684).
Be careful not to damage the lip of the seal. Press
inward until flush with the recess and wipe off any
excess sealant.
8. Lubricate O-rings (9) with O-ring lube (0841304202)

and install into the grooves, located on both sides, of
all gear housings.
9. Position gear housing (11) over the front cover and

dowel pins. Tap it with a soft hammer until it rests
tightly against the cover. Be careful not to pinch the
gasket seal. Be sure that the large rounded area is
located on the inlet side.
10. Install channel seals (5) and backup seals (4) into the
grooves located in thrust plates (7). The flat side of
the seal must face away from the thrust plate.
11. Gently, slip the thrust plate through the gear housing
and into place onto the shaft end cover. The channel
seal from Step 10 should face the shaft end cover.
70
The relief groove, located in the thrust plate, should 10
face the outlet side of the pump. 17
12. Slide the driven gear, from set (8), through the
housing and into the bushing located in the front
cover. Coat steel sleeve tool (0290244683) with
grease. Lightly grease drive shaft, from set (8), and
place inside the sleeve. Slide both through the shaft
end cover with a twisting motion until the integral gear
rests against the thrust plate. Avoid damaging the lip
seal. Remove the steel sleeve. Squirt clean system oil
over the gears.
13. Slip thrust plate with seal over gear journals and into
housing bore. The flat side of the seal should face
upward with the relief groove facing the outlet side.

100406
PN=211
Pumps & Valves
14. Position bearing carrier (12) over the gear housing so

the bushings receive the journals of the drive and
driven gears. Be sure to line up the dowel holes over
the dowel pins. When the parts are parallel, squeeze
them together or alternately tap over each dowel until
the parts are together.
15. Insert connecting shaft (13) into the spline of the drive
gear, from set (8). Position and place gear housing
(15) over the front cover and dowel pins. Tap it with a
soft hammer until it rests tightly against the cover. Be
careful not to pinch the gasket seal. Be sure the large
rounded area is located on the inlet side.
16. Place thrust plate (7) in gear housing (15) as

instructed in Step 11. Insert gear assembly (14) into
bearings located in carrier (12). Make certain gears
are in contact with the face of the thrust plate.
17. Place end cover (16) on the housing as instructed in

Step 11.
18. Place end cover (16) over the gear journals. Align the
dowel pins with the holes in the mating housing. Be
careful not to pinch the gasket seal, tap the end cover
lightly in the center between bearing bores to engage
the dowel pins and to move the parts together in a
70
10 final seating.
18
19. Thread the four studs, washers and nuts into the front
cover and cross-tighten. Rotate the drive shaft with a
wrench to make certain there is no binding in the
pump.
20. After the fasteners are tight and there is no internal

binding, cross-torque nuts to 272 N•m (200 lb-ft).
T803324,000096B –19–15MAR06–3/3

100406
PN=212
Pumps & Valves
Start-Up Procedure
1. Before installing a new or rebuilt pump, back off the

main relief valve until the spring tension on the
adjusting screw is relieved. This will avoid the
possibility of immediate damage to the replacement
pump, in the event the relief valve setting has been
increased beyond the recommended operating
pressure, prior to removing the old unit.
2. Before connecting any lines to the pump, fill all ports

with clean system oil to provide initial lubrication.
3. After connecting the lines and mounting the

replacement pump, operate the pump at least two
minutes at no load and at low RPM (400 minimum).
During this break-in period, the unit should run free
and not develop an excessive amount of heat. If the
pump operates properly, speed and pressure can then
be increased to normal operating settings.
4. Set the main relief valve to its proper setting while the
pump is running at maximum operating speed for the
engine.1
70
10
19
1
Always use an accurate gauge when adjusting the relief valve pressure
setting.
T803324,000096C –19–15MAR06–1/1

100406
PN=213
Pumps & Valves
Recommended Test Procedure
1. Be sure there is an adequate supply of system oil for

the pump, at least one liter (one gallon) of oil for each
L/min (GPM) of pump capacity.
2. If only one section of the tandem pump is being tested,

make sure that all other sections, not being tested, are
adequately supplied with oil. If any of the other
sections run dry, or if plugs are left in ports, serious
and permanent damage will result.
3. The oil should be a good quality hydraulic oil rated at

150 SSU at 38° C (100° F) with the oil temperature
held at 46° to 52° C (115° to 125° F).
4. The suction line must be of adequate size with no

more than 17 kPa (5 in) of mercury vacuum adjacent
to the pump inlet. As a rule, the feed line must provide
a feed flow velocity not in excess of 2.4 meters per
second (8 feet per second).
5. Feeding hot oil into a cold pump may cause the pump
to seize. Jog the pump by momentarily starting the
driving engine to gradually equalize pump and oil
temperatures.
70
10 6. Run the pump at least two minutes at no load and
20 moderate speed (not over 1500 RPM). If the pump
becomes excessively hot, shut down immediately and
locate the problem.
7. Gradually increase pressure on pump in 34 bar (500

PSI) increments until the desired test pressure has
been reached. This should take about five minutes.
8. Delivery should run close to rated performance figures

which are averaged from testing several pumps. A 5%
lower reading may be used as a rated minimum if new,
or relatively new, parts have been used. When
rebuilding the pump with parts from the original pump
(which, while worn, appear satisfactory for reuse) a
10% or 15% lower reading should be used, depending
upon the performance expected from the equipment.
One’s own experience will prove the best guide here.

100406
PN=214
Pumps & Valves
9. Many service representatives measure the output at

normal operating speed and at zero pressure, then
again at 69 bar (1000 PSI ) (or the operating pressure
of the equipment) and allow a volume decrease
approximating the listing below. It is a suggested
reference only which makes allowance for reused
parts. At test speeds other than 1800 RPM, L/Min
(GPM) delivery will vary almost proportionately, but the
same (dropoff) figures should be used.
After completing testing procedures, the pump is ready for

installation and immediate operation on the combine.
Again, it must be remembered that to prevent seizure, hot
oil must not be fed into a cold pump.
GPM Drop Off — GPM Delivery at 1800 RPM

100 PSI 1000 PSI 2000 PSI 3000 PSI
10 — 30 1-1/2 — 3 2 — 3 -1/2 2-1/2 — 4
30 — 50 2—3 2-1/2 — 4 3 — 4-1/2
50 — 70 2-1/2 — 3-1/2 3—5 3-1/2 — 5-1/2
L/Min Drop Off — L/Min Delivery at 1800 RPM

6.9 Bar 69 Bar 138 Bar 207 Bar
38 — 113.6 L 5.7 — 11.4 L 7.6 — 13 L 9.5 — 15 L
113.6 — 189 L 7.6 — 11.4 L 9.5 — 15.1 L 11.4 — 17 L
189 — 265 L 9.5 — 13.2 11.4 — 18.9 13.2 — 20.8 70
10
21
T803324,000096D –19–15MAR06–2/2

100406
PN=215
Pumps & Valves
70
10
22

100406
PN=216
Group 20
Hydraulic Checks
Hydraulic Troubleshooting
All Hydraulic Functions Slow Low oil level Check tank level.
Oil viscosity too heavy or too light. Use recommended oil
Slow engine speed. Check engine fast idle adjustment.
Restricted pump section screen. Check pump section screen.
Worn pump. Test pump using cycle times.
Cold hydraulic oil. Warm up hydraulic system.
Hydraulic Functions Slow Plugged oil cooler. Clean oil cooler.
Restricted oil cooler hoses. Check hose routing and condition.
System relief valve. Test system relief valve.
Circuit relief valve. Test circuit relief valve.
Control valve spool stuck. Check hydraulic system open center

70
pressure with all valves in neutral. 20
1
Cylinder or hydraulic motor has an Test components for leakage and
internal leak. repair or replace.
No Hydraulic Functions No oil Check oil level in tank.
Pump drive failure. Remove pump. Check pump drive

coupling and drive shaft.
Relief valve stuck open. Remove relief valve and clean,

repair or replace.
Spools not shifting due to low pilot Check pilot pressure from
pressure. hydrostatic pump to charge
pressure.

100406
PN=217
Hydraulic Checks
Pump Not Delivering Oil Driven in the wrong direction of The drive direction must be changed
rotation. IMMEDIATELY to prevent seizure.
Check pump repair section for the
correct ring position for each
direction of rotation.
Coupling or shaft sheared or Disassemble the pump and check

disengaged. the shaft for damage. Replace the
necessary parts.
Fluid intake pipe in tank restricted. Check all strainers and filters for dirt
and sludge. Clean if necessary.
Air leaks at the intake pump not Check the inlet connections to
priming. determine where air is being drawn
in.
Tighten any loose connections.
Ensure oil in the tank is above intake

opening.
Check the minimum drive speed

which may be too slow to prime the
pump.
70
20
2 Symptom Problem Solution
Insufficient Pressure Buildup in System relief valve setting too low. Use a pressure gauge to correctly
Pump adjust the relief valve.
Loss of flow from pump. Worn pump parts.
Damaged inlet or pressure lines.
Pump Making Noise Pump intake partially blocked. Service the intake strainers.
Check the oil condition and if

necessary, drain and flush the
system. Refill with clean oil.
Air leaks at the intake or shaft seal. Check the intake connections and
(Oil in tank will appear to be foamy.) seal to determine where air is being
drawn in.

100406
PN=218
Hydraulic Checks
Tighten any loose connections and

replace worn seals, if necessary.
Ensure oil in the tank is above intake

opening.
Pump drive speed too slow or too Operate pump at the recommended
fast. speed.
Coupling misalignment. Check if the shaft seal bearing or

any other parts have been damaged.
Replace any damaged parts and
realign the coupled shafts.
Slow Steering — Both Directions Manifold or spacer plate installed Check steering valve.
upside down.
Worn parts or improperly torqued Rebuild.

assembly.
Steering cylinders leaking. Test cylinder for leaks.
Steering valve orifices plugged. Check load sense line orifices at the
70
steering valve. 20
3
High Steering Effort Check steering valve. Inspect valve for incorrectly installed
torsion pin or misaligned upper
cover. Rebuild valve.
Directional Control Valve Can’t Relief valve poppet stuck open or Check for foreign matter between
Get Pressure dirt under seat of same. poppets and their mating members.
Members must slide freely.
Directional Control Valve Pilot poppet seat damaged. Check and replace damaged parts.
Delivers Erratic Pressure
Piston poppet sticking in relief valve Clean dirt and remove surface marks
poppet. for free movement.
Pressure setting incorrect due to dirt. Clean and reset.
Pressure setting incorrect due to Tighten and reset.

loose adjustment screw and locknut.

100406
PN=219
Hydraulic Checks
Leaking due to damaged seats. Check for scratches, nicks or other

marks. Replace all worn or damaged
parts.
Leaking due to worn O-rings. Inspect and replace all O-rings and
seals.
Leakage from parts sticking due to Clean and inspect. Check for free
dirt. movement of parts.
No Response When Steering Oil Reservoir is too low. Check and fill to proper level.
Wheel Is Slowly Turned
Dirty filters and screens. Inspect and clean or replace filters

and screens.
Dirt in Hydraulic System. Drain, flush and refill with clean oil.
Wrong Response to Steering Hydraulic lines hooked to wrong Reconnect lines to proper ports.
Wheel ports on steering valve.
Steering valve orbit gear misaligned. Realign gear.
Continuous Steering Wheel Dirt in Hydraulic System. Drain, flush and refill with clean oil.
Rotation
70
20
4 Broken centering springs in steering Replace broken part.
valve.
Input linkage in steering valve is Realign linkage.

binding.
Burr or sleeve or spool of steering Repair or replace part.

valve.
No Response to Steering Wheel Malfunction in pump or lines from Inspect and repair or replace.
pump.
Sleeve and spool locked-up in Disassemble and repair or replace.

steering valve.
Drive Elements (Coupling, Gears Excessive Noise Faulty mechanical drive components
and Shafts) (fit of coupling, misalignment, etc.)
No or insufficient system pressure. Defective transmission of torque.
Unstable pressure or flow. Defective drive components.

100406
PN=220
Hydraulic Checks
Hydraulic Cylinder or Motor Excessive Noise Faulty sealing.
No or insufficient flow. Internal losses.
Defective seals.
Wear due to dirt.
No or insufficient system pressure. Internal or external leakage.
Wear due to dirt.
Unstable pressure or flow. System insufficiently bled.
Defective seals.
Stick-slip effect, alternating direction

of load.
Directional Valves Excessive Noise Faulty directional control.
Local throttle effect.
No or insufficient flow. Spool position incorrect.

70
Negative overlap. 20
5
No or insufficient system pressure. Wrong position.
Mechanically jammed.
Return spring broken.
Leakage.
Unstable pressure or flow. Dynamic flow forces influence

actuating force and opening of
directional valve..
Positioning error.
Position of spool unstable.
System fluid temperature too high. Wrong position.
Wear
Flow Control Valves Excessive Noise Enclosed air.

100406
PN=221
Hydraulic Checks
Pressure difference too low.
Vibrations.
No or insufficient flow. Control orifice blocked.
Unstable pressure or flow. Enclosed air.
Pressure difference too low.
Dirt in flow control valve.
Fluid temperature too high. Wear
Lap losses.
Pressure Relief Valves Excessive Noise Vibrations, rumbling noises indicate

enclosed air or lack of damping.
Incorrect pressure setting.
No or insufficient flow. Setting too low.
Valve seat damaged.

70
20 Jammed by dirt.
6
No or insufficient system pressure. Setting too low.
Damaged valve seat.
Broken spring.
Vibration.
Foreign matter in valve seat.
Unstable pressure or flow. Vibration noise.
Changes in back pressure.
Irregular operating of pressure relief

valve.
Oscillation.
Fluid Pressure too high. Setting too high.

100406
PN=222
Hydraulic Checks
Excessive gap losses in all

components.
Excessive leakage.
Load cycle too high.
Return Lines Excessive Noise Turbulence towards suction area.
Not securely mounted.
Mechanical vibration.
Filters Excessive Noise Incorrectly mounted.
Mechanical vibration.
Fluid temperature too high. Relief valve pressure set too high.
Coolers Excessive Noise Noise of fan.
Fluid temperature too high. Ambient temperature too high.
Interrupted fanning/flow of water.

70
Pressure Gauge No or insufficient system pressure. Defective gauge. 20
7
Unstable pressure or flow. Incorrect reading.
Defective gauge.
Fluid temperature too high. Faulty pressure gauge selector

switch.
Pressure Line Excessive Noise Incorrect mounting.
Transmission of noise.
No or insufficient flow. Fittings leaking.
Local throttle points.
Pressure increase.
Pressure relief valve open.
No or insufficient system pressure. Broken pipe

100406
PN=223
Hydraulic Checks
Fittings leaking.
Unstable pressure or flow. System not bled correctly.
Diesel Engine Excessive Noise Speed too high.
Bearing damage.
Bearing play.
No or insufficient flow. Speed too low.
No or insufficient system pressure. Insufficient input horsepower.
Unstable pressure or flow. Excessive fluctuation of engine

speed.
Idling speed too low.
Fluid temperature too high. Engine speed too high.
Oil Line Leakage Excessive Noise Excessive leakage.
Oil foaming effect on suction.

70
20 Damaged rotary group in pump.
8
No or insufficient flow. Excessive leakage due to oil of too
low viscosity
Too high temperature.
Wear of pump.
No or insufficient system pressure. Bends in line.
Suction line not airtight, enclosed air.
Unstable pressure or flow. Leakage line clogged.
Bent lines.
Leakage due to back pressure on

the pump driveshaft.
Suction Line Characteristics Excessive Noise Reduced section in suction pipe.
Suction pipe not airtight, air bubbles.

100406
PN=224
Hydraulic Checks
No or insufficient flow. Defective suction characteristics,

bends and reduced section.
No or insufficient system pressure. Faulty suction characteristics, bends,

reduced section.
Line not airtight, enclosed air.
Unstable pressure or flow. Bends, reducing pipe area.
Fluid temperature too high. Engine speed too high.
Oil Tank - Hydraulic Fluid Excessive Machine Noise Oil level low.
Oil foaming.
Air bubbles.
Water in oil (cloudy)
Cold system fluid.

70
20
Viscosity too high. 9
Tank not bled.
No or insufficient flow. Oil level too low.
Bleeding not effective.
No or insufficient system pressure. Oil level too low.
Oil viscosity too low.
High leakage, gap losses.
Unstable pressure or flow. Air bubbles.
Turbulence from return port to

suction port of tank.
Fluid temperature too high. Oil tank not filled properly.
Wrong viscosity.

100406
PN=225
Hydraulic Checks
Local overheating causing excessive

clearances.
Overheating.
Pump not delivering fluid. Driven in the wrong direction of The drive direction must be changed
rotation. immediately to prevent seizure.
Coupling or shaft sheared or Disassemble the pump and check

disengaged. the shaft and cartridge for damage.
Replace all damaged parts.
Fluid intake line in tank is restricted. Check all strainers and filters for dirt
and sludge. Clean if necessary.
Fluid viscosity too heavy to pick up Completely drain the system and
prime. add fluid of the proper viscosity.
Air leaks at intake, pump not Check the inlet connections to

priming. determine whether air is being drawn
in. Tighten any loose connections.
Make sure that fluid in the tank is

above the intake pipe opening. If
not, add fluid.
70
20
10 Insufficient Pressure Build-up System relief valve set too low. Using a pressure gauge, adjust the
relief valve to its proper setting.
Loss of flow from pump. Worn pump parts. Repair or replace

pump.
Broken inlet or pressure line.

Replace line.
Pump Making Noise Pump intake partially blocked Clean the intake air filter elements.
Check the fluid condition and, if

necessary, drain and flush the
system. Refill with clean fluid.
Air leaks at the intake or shaft 5 Check the inlet connection and seal
seal. to determine where air is being
drawn in. Tighten any loose
connections and replace the seal if
necessary.

100406
PN=226
Hydraulic Checks
Make sure that the fluid is above the

intake opening in the tank. Fill, if
necessary.
Pump drive speed too fast or too Operate the pump at the
slow. recommended speed.
Coupling misaligned. Check the shaft seal bearing and

other parts for misalignment.
Replace any damaged parts.
T803324,000096E –19–15MAR06–11/11
Suggested Tools
1. 1/2” Wrench
2. 9/16” Wrench
70
3. Torque Wrench 20
11
4. 1/8” Allen Wrench
5. Flat Blade Screwdriver
6. LOCTITE 271 - 0841303179
7. O-ring Lube - 0841304202
LOCTITE is a trademark of Loctite Corp. T803324,000096F –19–16MAR06–1/1

100406
PN=227
Hydraulic Checks
External Relief Settings
1. The inlet section of the valve has an adjustable relief

which is set at 179 bar (2500 ± 100 PSI).
2. The main relief and port reliefs are adjusted by

loosening the locking jamnut with a 9/16” wrench.
Using a 1/8” allen wrench, screw inward to increase
pressure and outward to decrease. After adjusting,
tighten the locking jamnut.
3. The third bank has two port reliefs for the conveyor
swing circuit.
T803324,0000970 –19–16MAR06–1/1
Overhaul
Valves are often used in hazardous environments,

therefore care should be taken to frequently inspect the
product for damage due to improper use, corrosion, or
70 normal wear. Repairs should be made immediately, if
20 needed.
12
Always refer to the machine’s owners manual for the

proper procedure to remove the valve from the machine.
Remove the valve bank from the equipment and

disconnect all hoses, fittings, control handles, and linkage
connectors that might be attached to the valve. Plug all
ports and thoroughly clean the valve bank’s exterior, then
remove the port plugs.
NOTE: All work must be performed in a clean area.
T803324,0000971 –19–16MAR06–1/1

100406
PN=228
Hydraulic Checks
Valve Bank Disassembly
1. Mark the valve bank.
This step is the most critical step in the disassembly

procedure. It should be followed very closely to ensure
that the valve bank is properly reassembled after
repairs have been made.
1. Take a waterproof, quick-drying marker and mark

each casting with a sequential number. Start by
marking the inlet casting as #1 and finish by
marking the outlet with the highest number.
2. Then mark the port boss closest to the back cap on
each work section with a “B” (for black cap end).
3. Next mark the port boss closest to the spool clevis
on each work section with a “C” (for clevis end).
4. Lastly if relief valves must be removed from the
valve bank, they should be marked with the number
of the casting and port to which they belong. Inlet
and mid-inlet relief valves are marked with their
casting number only!
2. Tie Bolts
Remove the four (4) tie bolts which hold the bank
together and separate the sections.
70
20
3. Section Seals 13
The inlet, mid-inlet and each parallel work section have

four (4) section seals on the downstream mating face.
A series work section has three (3) section seals on its
downstream mating face. These section seals should
be removed and discarded.
4. Control Spool and Seals
Grasp the spring end of the spool with a clean rag and
pull the spool with a twisting motion. Generally the rear
retainer plate backup ring and spool seal will come out
with the spool.

100406
PN=229
Hydraulic Checks
CAUTION: For detented spool models, be

careful not to remove the detent poppet sleeve
unless it is to be serviced.
Next remove the two retainer screws from the spool

clevis end of the work section. Then remove the two
retainer plates, the backup ring , and the spool seal .
The spool should now be tagged or marked with its
work section’s identification number (from Step 1).
Spool seals and backup rings should be discarded.
5. Transition Check
The transition check is located in the bottom of the

work section housing. Remove the check valve cap
and its O-ring seal, then remove the check spring and
the check valve poppet.
NOTE: Only cylinder (ports blocked in neutral) work

sections have a transition check.
6. Spool Disassembly — Spring Centered Spool
These parts should not be removed from the spool

unless they need to be replaced. Once the spool is
free of the work section housing, it must be handled
70 carefully to avoid damage. Place the spool in a soft
20 jawed vise and remove the stripper bolt with a wrench.
14
Since an anaerobic thread adhesive is used in its
assembly, cautious application of heat may be required
to free the stripper bolt.
As the stripper bolt threads, disengage the spring and

spring guides will pop free of the spool.
7. Detented Spool

100406
PN=230
Hydraulic Checks
Again these parts should not be removed from the

spool unless they need to be replaced. Wrap the
detent sleeve with a clean rag. Grip the rag covered
sleeve; pull firmly. As the sleeve moves backwards, the
detent balls and the detent spring will pop free. The
rag should capture these parts and prevent their loss.
Next clamp the spool in a soft jawed vise and remove
the detent poppet retainer. Use an undersized bar
through the detent ball bore as a wrench. Again,
because an anaerobic adhesive is used in the
retainer’s assembly, cautious application of heat may
be required.
CAUTION: Too much heat may distort the

spool.
T803324,0000972 –19–16MAR06–3/3
Cleaning, Inspection and Repair
1. Inspect the spool bores. Check seats and spools for

deep scratches, gouges, or excessive wear. If any of
these conditions exist, replace section. Minor surface
damage on the control spool and check poppet may be 70
carefully polished away with very fine crocus cloth. 20
15
2. Examine the machined surfaces of the valve housing

for nicks and burrs that could cause leakage between
sections. Lightly stone these surfaces to remove any
rough spots.
3. Wash all parts thoroughly in a clean solvent and blow

dry before beginning reassembly. Pay special attention
to the number and letters marked on the parts in Step
1. If any marks are removed during cleaning remark
immediately.
CAUTION: Too much heat may distort the

spool.
T803324,0000973 –19–16MAR06–1/1
Assembly
Reverse the procedures outlined in Steps 1 through 8.

Also, follow the additional instructions below.
T803324,0000974 –19–16MAR06–1/1

100406
PN=231
Hydraulic Checks
Spool Assembly — Spring Centered
CAUTION: A shallow milled relief area extends

across the O-ring face of the valve housing. It
should not be stoned or ground off.
Clamp the control spool in a soft jawed vise. Apply a

small amount of LOCTITE 262 or equivalent anaerobic
adhesive to the stripper bolt before assembly.
Assemble the spring, spring guides, and stripper bolt onto

the spool (Reverse of Step 7). Lightly coat the spring
assembly with high temperature grease to prevent rusting.
CAUTION: Follow the adhesive manufacturer’s

instructions for proper cleaning and curing.
Failure to clean and prepare parts properly may
result in assembly failure.
LOCTITE is a trademark of Loctite Corp. T803324,0000975 –19–16MAR06–1/1

70
20
16
Detented
Clamp the control spool in a soft jawed vise. Apply a

small amount of LOCTITE 262 or equivalent anaerobic
adhesive to the detent popper retainer and thread it into
the control spool.
CAUTION: Follow the adhesive manufacturer’s

instructions for proper cleaning and curing.
Failure to clean and prepare parts properly may
result in assembly failure.
Then, lightly coat the detent balls, detent spring and

detent sleeve with high temperature grease. Next, place
the detent balls and spring into the detent poppet retainer
as described in Step 8 and partially compress them with a
small clamp. Now, slide the detent sleeve into position,
pushing the clamp out of the way at the same time.

100406
PN=232
Hydraulic Checks
Valve Section Assembly
Apply a light coating of clean hydraulic oil to the valve

spool. Place the retaining plates, new backup rings and
new spool seals in position as shown in Figure 4.
Carefully insert the spool into the housing. Make sure that
the spool and housing are in the proper orientation (See
Step 1). Place LOCTITE 262 or its equivalent on the
backcap screws and front retainer screws threading them
into the valve housing. When installing the transition
check refer to Step 6. Torque cap screws to 122 N•m
(8990 lb-ft).
Valve Bank Assembly
Return all relief valves to their proper positions (See Step

1). Coat the section seals with grease and place them in
their grooves. Place the valve sections on the tie bolts in
their proper sequence (See Step 1). Torque the tie bolts 70
in a cross pattern to 60 N•m ( 42 lb-ft) for the chopper 20
17
valve or 101 N•m ( 75 lb-ft) for the five bank,
topper/sideknives, or crop divider valves.
T803324,0000978 –19–16MAR06–1/1

100406
PN=233
Hydraulic Checks
Section Disassembly
Read these instructions carefully. Failure to follow these

procedures can result in poop performance and/or product
failure.
1. Remove cap screws from both ends of the valve

section.
2. Remove end caps, seal and end cap tube from each
end of casing.
3. Remove seal retainer and seals from the clevis end of

the spool assembly.
4. Remove spool and spring package assembly from

valve section. Remove seal retainer and seals to
replace seals.
5. If stripper bolt must be removed from the spool for

replacement of parts, it may be necessary to apply
heat to the hex nut and stripper bolt to loosen adhesive
that was applied to the threads.
NOTE: Use heat carefully to keep spool from warping.
70 CAUTION: Failure to follow these recommended

20 assembly instructions can result in poor
18
performance and/or failure of the product.
Product should be thoroughly tested to ensure
proper operation before the valve is put into
service.
T803324,0000979 –19–16MAR06–1/1
Preparation of Parts
1. Clean adhesive from threads of spool, stripper bolt,

housing, cap screw holes and hex nut with LOCTITE
chisel gasket remover.
2. Wash all parts in solvent to remove grease and oil.

Blow dry.
LOCTITE is a trademark of Loctite Corp. T803324,000097A –19–16MAR06–1/1

100406
PN=234
Hydraulic Checks
Section Assembly
NOTE: If stripper bolt was not removed from spool,

proceed to Step 6.
1. Place spool in a soft-jawed vise, threaded end up.
2. Spray the threads of the new stripper bolt and hex nut
with Locquic Primer Grade NF and let dry. Apply
LOCTITE 262 Red to threads.
3. Slide one of the spring retainers on to the end of the

stripper bolt with the longest threads. Screw the
stripper bolt into the valve spool as far as it will go. Be
sure the spring guide slides freely.
4. Slide the springs over the stripper bolt.
CAUTION: Seals are similar in size. Be sure to

insert seals in their proper position. They are
not interchangeable.
Install the other spring retainer and compress the

springs so the hex nut can be screwed onto the
stripper bolt.
NOTE: Be sure the spring retainer slides freely. 70

20
5. Torque the hex nut to 19 N•m ± 2 N•m (175 ± 25lb-in) 19
and set the spool assembly aside to cure for a

minimum of 8 hours. After curing, test the hex nut to
be sure it withstands 14 N•m (125 lb-in) of breakaway
torque.
6. Apply light grease to seals. Assemble O-ring on OD of

seal retainer and O-ring in the end of the seal retainer.
7. Install one seal retainer with O-rings on spool. Then

slide the spool into the housing.
8. Lightly grease O-ring and install it on the valve cap
9. Install end cap tube on seal retainer. Then slip end cap
on the end cap tube.
LOCTITE is a trademark of Loctite Corp. Continued on next page T803324,000097B –19–16MAR06–1/2

100406
PN=235
Hydraulic Checks
10. Spray threads of the cap screws and the cap screw
holes in the housing with LOCQUIC Primer Grade
NFTM and let dry.
11. Apply LOCTITE 262 Red to threads of the two cap

screws. Insert them through valve cap and screw
them into the valve housing. Tighten cap screws
evenly and torque to 14.6 N•m ± 2 N•m (175 ± 17
lb-in).
12. Install seal retainer with seals on clevis end of spool.

Install end cap tube and valve cap.
13. Install two cap screws, tighten evenly and torque to

14.6 N•m ± 2 N•m (175 ± 17 lb-in) to complete
assembly.
LOCTITE is a trademark of Loctite Corp. T803324,000097B –19–16MAR06–2/2

70
20
20
Troubleshooting
Periodic inspection of spool operation, oil condition and

pressure connections save time-consuming breakdowns
and unnecessary parts replacement. All hydraulic
connections must be tight. Loose connections, not only
allow leakage, but also permit air to be drawn into the
system, resulting in noisy and erratic operation.
T803324,000097C –19–16MAR06–1/1

100406
PN=236
Hydraulic Checks
Troubleshooting
Oil Leaks at End of Spool Defective O-rings in valve body. Replace O-rings.
Spool Does Not Return to Neutral Broken spring. Replace spring.
Bent spool. Replace complete section assembly.
Foreign particles jamming spool Clean system and valve.

passage.
Misalignment of operating linkage. Check linkage for binding conditions.
Valve banks improperly torqued. Torque nuts to 57 N•m (42 lb-ft) on 2

bank valve and 102 N•m (75 lb-ft) on
3 bank valve.
No Motion, Slow or Jerky Action Relief valve not properly set, or Repair, clean and readjust.
of Hydraulic System stuck in base and/or worn.
Dirt or foreign particles lodged Disassemble, clean and reassemble.

between relief valve control poppet
and seat.
Valve body cracked inside. Replace complete section assembly.

70
20
Spool not moved to full stroke. Check travel. 21
No Relief Valve Action (High Debris plugging orifice in relief valve Remove relief valve, check orifice
Pressure) assembly. hole and clean hole if blocked.
Relief valve assembly installed Install properly.

backwards.
Load Will Not Hold Oil bypassing between spool and Replace complete valve section.
body.
Oil bypassing piston in cylinder. Repair or replace cylinder.
Spool not centered. Refer to above spool remedies.
Load Drops When Spool Is Debris lodged between check valve Disassemble, clean and reassemble.
Moved From Neutral To A Power ball and seat.
Position
Scored or sticking check valve. Replace poppet.
T803324,000097D –19–16MAR06–1/1

100406
PN=237
Hydraulic Checks
Directional Control Valve — Boom Lift and Grab Open/Close
70
20
22
–UN–26MAY06
CM11451518B2

100406
PN=238
Hydraulic Checks
1—Section Valve 4—Section Valve 7—Washer 10—Washer

2—Square Seal 5—Section Valve Inlet 8—Main Relief Valve 11—Nut
3—Square Seal 6—O-ring 9—Stud
T803324,000097E –19–16MAR06–2/2
70
20
23

100406
PN=239
Hydraulic Checks
70
20
24

100406
PN=240
Group 30
Hydraulic Cylinder
Hydraulic Cylinder Diagnostics
AG,HX00517,18 –19–17MAY04–1/1
Hydraulic Cylinder Drift Diagnostics
– – –1/1
1 Cylinder Identification Is the cylinder you are working with a rephasing cylinder? YES: GO TO 4
NO: GO TO 2
– – –1/1
2 Preparing Cylinder Relieve all pressure from the cylinder by either putting the valve, that controls the YES: GO TO 3
for Testing cylinder, into the float position or by turning off the machine’s engine and moving the
valve controlling the cylinder(s) from extend to retract positions.
NOTE: If machine has pilot operated or electro-hydraulic valves see machine manual
for instructions on how to relieve all pressure from the cylinder.
70
Disconnect the cylinder from the machine by removing the pin at the ROD END. 30
1
RETRACT the cylinder fully and shut off the machine.
NOTE: To check individual cylinders, disconnect the hoses or lines from the cylinder
not being tested and cap off the fittings on the lines for those cylinders to allow you to
isolate the cylinder you are testing.
– – –1/1

100406
PN=241
Hydraulic Cylinder
3 Testing Cylinder for Disconnect the PISTON END line from the machine, and remove coupler if necessary, YES: Cylinder is leaking
Leaks and place the line in a pail or pan. around the piston seal or
the cylinder bore is
Cap line remaining on machine. scored.
Start the machine and move the valve slowly in the direction to retract the cylinder. Repair or Replace
Cylinder.
Does oil continue to escape out of the return line as you hold the valve in the retract
position? GO TO 1
Note: A small amount of oil may escape from the fitting or line do to oil being trapped NO: Cylinder is good.
in the line when it was disconnected.
Test the other cylinders in
this system with this
same procedure.
GO TO 1
OR refer to machine
manual to test the valve.
HCD1095 –UN–28NOV01
A—Pressure
B—Pail
C—Cap
70
30
2
– – –1/1
4 Rephasing Cylinder Does this rephasing cylinder rephase in the RETRACT position? YES: GO TO 5
Identification
NO: GO TO 2
– – –1/1

100406
PN=242
Hydraulic Cylinder
5 Preparing Cylinder Relieve all pressure off of the cylinder by either putting the valve, that controls the YES: GO TO 6
for Testing cylinder, into the float position or by turning off the machine’s engine and moving the
valve controlling the cylinder(s) from extend to retract positions.
Disconnect the cylinder from the machine by removing the pin at the ROD END.
CAUTION: Make sure you have room on the machine to fully extend the
cylinder with out the rod contacting anything. If there is insufficient room
remove the cylinder completely from the machine.
EXTEND the cylinder fully and shut off the machine.
CAUTION: If the piston nut is missing off of the rod, the rod could be
propelled out of the cylinder.
NOTE: To check individual cylinders, disconnect the hoses or lines from the cylinder
not being tested and cap off the fittings on the lines for those cylinders to allow you to
isolate the cylinder you are testing.
– – –1/1
6 Testing Cylinder for Disconnect the ROD END line from the machine, and remove coupler if necessary, YES: Cylinder is leaking
Leaks and place the line in a pail or pan. around the piston seal or
the cylinder bore is
Cap line remaining on machine. scored.
Start the machine and slowly move the valve in the direction to extend the cylinder. Repair or Replace
Cylinder. 70
30
CAUTION: If the piston nut is missing off of the rod, the rod could be GO TO 1 3
propelled out of the cylinder.
NO: Cylinder is good.
Does oil continue to escape out of the ROD END as you hold the valve in the extend
position? Test the other cylinders in
this system with this
NOTE: A small amount of oil may escape from the fitting or line do to oil being trapped same procedure or refer
in the line when it was disconnected. to machine manual to test
the valve.
GO TO 1
HCD1094 –UN–28NOV01
A—Pressure
B—Pail
C—Cap
– – –1/1

100406
PN=243
Hydraulic Cylinder
Cylinder Tube Assembly
70
30
4
–UN–26MAY06
CM212071E1

100406
PN=244
Hydraulic Cylinder
1—Cylinder Tube Assembly 8—Seal 15—Snap Ring 20—O-ring

2—O-ring 9—Seal 16—O-ring 21—Rod
3—Pipe Plug 10—Seal 17—Seal 22—Rod End
4—Hex Nut 11—Seal 18—Snap Ring 23—Piston
6—O-ring 13—O-ring 19—Seal 24—Guide
7—Wear Ring 14—Ring
T803324,0000982 –19–17MAR06–2/2
Grab Cylinder
Number Name Use
T43512 (U.S.) (U.S.) Thread Lock and Sealer (Medium Used to lock threads during
TY9473 (Canadian) (U.S.) Strength) assembly.
242 (U.S.)

70
30
5
Disassemble and Assemble Cylinder
IMPORTANT: Clamping cylinder in a vise at the

middle or rod end of barrel may damage
the barrel. Clamp only at the cylinder
base end.
–UN–28NOV01
Extend rod to remove oil or air between
rod piston and rod guide. Excessive
amounts of trapped oil or air will
HCD1072
expand seals and make disassembly
more difficult.
1. Open both ports and drain all oil from the cylinder. A—Snap Ring
B—Rod Guide
2. Extend rod fully.
3. Clean outside surface of cylinder with suitable solvent

and dry to prevent dirt and debris from entering
cylinder barrel.
4. Remove snap ring (A) from rod guide (B).
Continued on next page OUO6046,00016AF –19–17MAY04–1/10

100406
PN=245
Hydraulic Cylinder
5. Using a wooden dowel or brass drift, drive rod guide

(A) into cylinder past barrel snap ring groove.
6. Remove any debris in barrel snap ring groove.
IMPORTANT: If filler ring (B) is installed backwards,
–UN–13NOV01
snap ring may not disengage and filler
ring could be damaged.
7. Install filler ring (B), supplied with cylinder seal kit, into
HCD1073
barrel snap ring groove in the direction shown to
prevent snap ring from engaging in barrel snap ring
groove during removal.
A—Rod Guide
B—Filler Ring
–UN–29NOV01
HCD1075
70
30
6
–UN–28NOV01
HCD1097

100406
PN=246
Hydraulic Cylinder
8. Pull rod assembly (A) from cylinder barrel (B).
NOTE: Install rod end in soft-jawed vise in order to

remove nut.
9. Remove nut (C), piston (D) and rod guide (E).
–UN–08NOV01
10. Remove groove filler ring from snap ring groove. Do
not use for reassembly.
HCD1076
NOTE: When removing seals from piston and rod guide,
do not damage, mark or score any surfaces that
contact the seals.
11. Remove all seals and rings on piston and rod guide.
12. Inspect piston, barrel and rod guide for nicks or burrs.
Repair or replace as necessary.
–UN–08NOV01
A—Rod Assembly
B—Cylinder Barrel
C—Nut
D—Piston
HCD1077
E—Rod Guide
70
30
7
OUO6046,00016AF –19–17MAY04–3/10
13. Inspect groove in cylinder barrel. If necessary, clean

groove and remove nicks, burrs, or rust from inside of
barrel using emery cloth.
14. Clean inside of barrel using a safe solvent and blow

dry using compressed air.
–UN–19NOV01
HCD1061

100406
PN=247
Hydraulic Cylinder
NOTE: All parts must be cleaned and dry before

assembly.
15. Install O-ring (B) and seal (D).
NOTE: Cap seal (E) can be made more pliable by putting
–UN–28NOV01
the seal in hot water for approximately 5 minutes.
Install cap seal as quickly as possible once it has

been removed from the water and dried to keep
HCD1062
the amount of time that seal is stretched to a
minimum.
16. Push cap seal (E) on end of piston.
17. Install a plastic tie band around cap seal with the
smooth side against seal.
18. Pull cap seal across land into position over seal (D)
–UN–13NOV01
using the plastic tie band.
IMPORTANT: For proper fit, the back-up rings (C)

must be installed with the radius (F)
HCD1088
toward cap seal (E).
19. Install ring (A) and back-up rings (C).

70 A—Ring
30 B—O-Ring
8 C—Back-up Ring (2 used)
D—Seal
E—Cap Seal
F—Radius
–UN–26NOV01
HCD1100
–UN–28NOV01
HCD1087

100406
PN=248
Hydraulic Cylinder
20. Check if cap seal is loose; seal must fit tight against
seal expander and not turn. If seal can be turned, it
has been stretched too much and can be damaged
during assembly into barrel.
21. If necessary, shrink cap seal to its original size using

a ring compressor or hose clamp (B).
Protect by placing shim stock or protective material

between seal and clamp when compressing.
Seal will also shrink to its original size if left for a
–UN–30NOV01
minimum of 8 hours before installing assembly into
barrel.
HCD1098
A—Shim Stock
B—Hose Clamp

70
30
9

100406
PN=249
Hydraulic Cylinder
NOTE: Seal (D) must be installed with lip facing inside of

cylinder as shown.
22. Install seals (E) and (D), snap ring (F), O-ring (C),
back-up ring (B) and O-ring (A).
A—O-Ring
B—Back-up Ring
C—O-Ring
D—Seal
E—Seal
F—Snap Ring
–UN–27NOV01
HCD1064
70
30
10
–UN–13NOV01
HCD1085
–UN–13NOV01
HCD1091

100406
PN=250
Hydraulic Cylinder
NOTE: Install rod end in soft-jawed vise in order to torque

nut.
23. Install external snap ring (A), rod guide (B), piston (C)
–UN–28NOV01
and nut (D) on rod.
24. Apply light coat of LOCTITE 242 and tighten to torque

specified in table:
HCD1107
NUT TORQUE SPECIFICATIONS
Thread Size Torque
3/4-16 UNF-2A 210 N•m (155 lb-ft) A—External Snap Ring
B—Rod Guide
7/8-14 UNF-2A 320 N•m (236 lb-ft) C—Piston
1-12 UNF-2A 463 N•m (341 lb-ft) D—Nut
1 1/8-12 UNF-2A 492 N•m (363 lb-ft)

1 1/4-12 UNF-2A 965 N•m (712 lb-ft)
OUO6046,00016AF –19–17MAY04–8/10
70
30
11
25. Apply light film of clean hydraulic oil on seals and
chamfer (A) of barrel.
26. Compress the internal snap ring using a hose clamp

(B) until snap ring is seated in groove on rod guide
and then loosen a little.
–UN–19NOV01
NOTE: Remove hose clamp once internal snap ring has
entered cylinder bore to prevent damage to
external O-ring.
27. Drive rod guide (C) into barrel until snap ring seats in HCD1071
the barrel groove.
A—Chamfer
28. Pull forward on rod to ensure that it has locked. B—Hose clamp
C—Rod Guide

100406
PN=251
Hydraulic Cylinder
29. Install snap ring (A) in rod guide (B).
A—Snap Ring
B—Rod Guide
–UN–28NOV01
HCD1072
OUO6046,00016AF –19–17MAY04–10/10
70
30
12

100406
PN=252
Section 99
Service Tools
Contents
Page
Group 10—Service Supplies

Service Supplies . . . . . . . . . . . . . . . . . . . . . . . .99-10-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . .99-10-6
Flow Meter Test Kit . . . . . . . . . . . . . . . . . . . . . .99-10-8
Mechanic’s Tool Set . . . . . . . . . . . . . . . . . . . .99-10-10
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99-10-12
99

100406
PN=1
Contents
99

100406
PN=2
Group 10
Service Supplies
Service Supplies
Number Name Use
0841303194 (U.S.) LOCTITE Primer Recommended as a surface

preparative, use before any type of
Loctite application. This part number
is for a 6 oz. spray can.
0840008762 (U.S.) LOCTITE PST Recommended for use on all types

of threads to prevent leakage at the
joint. This is for use on hydraulic, air
or water lines. This part number is
for a 50 ml bottle.
0841304201 (U.S.) LOCTITE 242 Recommended for use on parts that

will be removed again. This is for the
prevention of parts loosening during
normal operation. The part can still
be removed by a mechanic without
too much difficulty. This part number
is for a 50 ml bottle.
0841322669 (U.S.) LOCTITE 620 Recommended for use when

repairing a cylinder. This is
specifically used for the internal bolt
that holds the head in place. This
part number is for a 50 ml bottle.
0841332513 (U.S.) LOCTITE 640 Recommended for use when

installing a press fit. This part
number is for a 50 ml bottle.
99
0841304200 (U.S.) Silicone Sealant (RTV) Recommended for use on parts that 10
1
will be never be removed again. This
can only be removed by burning.
This part number is for a 50 ml
bottle.
0430024221 (U.S.) LOCTITE242 Recommended as a general sealant.

This can, in many instances, replace
older gasket materials. This part
number is for a 4.7 oz. tube.
LOCTITE is a trademark of Loctite Corp. Continued on next page OUO1089,00027F8 –19–16FEB05–1/4

100406
PN=255
Service Supplies
Number Name Use
PM38656 (U.S.) Plastic Gasket Recommended as a general sealant.

It hardens in the assembled joint to
form a tough, thin gasket that resists
lubricants and chemicals.
Metal-to-metal contact of flanges
provides an excellent bond. Joint is
locked against vibration loosening.
Operating limit is 300° F (150° C).
This part number is for a 50 ml
bottle.
0841305658 (U.S.) Anti-seize Compound Recommended for use on all types

of threads to prevent galling. This
part number is for a 16 oz. can with
a brush top.
0840021386 (U.S.) Teflon Thread Tape Recommended for use on all types
joint. This is for use on hydraulic, air
or water lines. This part number is
for a 1/2” x 50 ft. roll.
0840008762 (U.S.) Teflon Thread Paste Recommended for use on all types
joint. It has the same uses as Teflon
thread tape. The use of either of the
two forms is strictly a matter of
personal preference. This part
number is for a 1.69 oz. tube.
99 0841304202 (U.S.) O-Ring Lube Recommended for the ease of

10 installing rings, seals and gaskets.
2
This holds them in place and also
protects them from damage during
installation. This part number is for a
2 oz. tube.
0910041171 (U.S.) Dry Spline Lube Recommended for the lubrication of

the splines in pumps and motors.
This will prolong the service life of
parts that are subjected to high
torques. This part number is for a 2.8
oz. tube.
Continued on next page OUO1089,00027F8 –19–16FEB05–2/4

100406
PN=256
Service Supplies
Number Name Use
0491310039 (U.S.) O-ring Kit This is an assortment of all the

O-rings used on the boss O-ring
hydraulic fittings. These fittings are
used on your equipment where it is
necessary to seal a joint. A supply of
these O-rings is recommended to be
on hand. The kit contains 5 of size
24; 10 of size 4, 6, 10 and 20; and
20 of size 8 and 16.
0561310037 (U.S.) Cap and Plug Kit This is an assortment of plastic caps
and plugs used to cap-off or plug
hoses and components during
service or repairs. The kit contains
40 of size 04, 06, and 12 in both
caps and plugs; 50 of size 16 in both
caps and plugs and 60 of size 08 in
both caps and plugs.
0841346779 (U.S.) Wrench Set Angled This is a heavy-duty, open-ended,

offset wrench set. It is recommended
for removing hydraulic hoses and
fittings located in tight places. The
set has 2”, 1-7/8”, 1-3/4”, 1-5/8”,
1-1/2” and a 1-3/8” wrench.
0601305130 (U.S.) Flow Tester 75 GPM Kit This is a 75 GPM in-line hydraulic
flow tester.
0840317083 (U.S.) Hose Kit This is for the flow meter,

0601305130. 99
10
3
0840322463 (U.S.) Flow Meter This is a 125 GPM flow meter kit
with adapter fittings.
0841340040 (U.S.) Araldite Adhesive Kit Recommended as a locking element

for mating parts with the tendency to
loosen during operation. It is also
used for special isolation purposes
during construction and repair. This
part number includes Reusable Gun
P/N 0841306707, Cartridge P/N
0841306708 and Nozzle-Mix P/N
0841306709
Continued on next page OUO1089,00027F8 –19–16FEB05–3/4

100406
PN=257
Service Supplies
Number Name Use
0841306707 (U.S.) Araldite Applicator Gun This is included in the above Araldite
Adhesive Kit and is necessary for the
Araldite Cartridge, 0841307790.
0841346780 (U.S.) Wrench Set Angled This set is comprised of fourteen of

the most popular sizes from 3/8” to
1-1/8” in increments of 1/16” and a
1-1/4” wrench.
OUO1089,00027F8 –19–16FEB05–4/4
99
10
4

100406
PN=258
Service Supplies
99
10
5

100406
PN=259
Service Supplies
Service Tools
99
10
6
–UN–14MAR06
CM00044329A0
Complete Kit, 0600044329

100406
PN=260
Service Supplies
1—Test Gauge (10,000 PSI), 2 9—Hose, 3 ea., 0880208565 19—Fitting, 2 ea., 0070019355 27—Allen Wrench (1/8”), 1 ea.,
ea., 0600041562 10—Manifold - Test Kit, 1 ea., 20—Fitting, 4 ea., 0071392920 0840044386
2—Test Gauge (600 PSI), 2 ea., 0290207833 21—Fitting, 4 ea., R31147 28—Allen Wrench (3/16”), 1
0600041563 11—Chain, 3 ft., 0600048641 22—Jam Nut, 2 ea., ea., 0841371362
3—Test Gauge (3,000 PSI), 2 12—“S” Hook, 2 ea., 0050009936 29—Fitting, 1 ea., 0070038010
ea., 0600041560 0600048642 23—Fitting, 8 ea., 0071307471 30—Fitting, 1 ea., 0070005274
4—Test Gauge (30” hg - 160 13—Eyebolt, 2 ea., 0600048644 24—Toolbox, 1 ea., 31—Fitting, 1 ea., 0070019355
PSI), 1 ea, 0600041561 14—Fitting, 2 ea., 0070042880 CB01434314 32—Tee Assy-Test (12), 1 ea.,
5—Fitting, 8 ea., 0070031967 15—Fitting, 1 ea., 0070044383 25—Combination Wrench, 1 0600053177
6—Fitting, 2 ea., 0070009570 16—Fitting, 2 ea., 0070019443 ea., 0840044385 33—Tee Assy-Test (16), 1 ea.,
7—Fitting, 6 ea., 0070030583 17—Fitting, 2 ea., 0070018871 26—Allen Wrench (3 mm), 1 0600053176
8—Female Coupling, 4 ea., 18—Fitting, 2 ea., 0070019334 ea., 0840046360
0070030582
T803324,000093B –19–14MAR06–2/2
99
10
7

100406
PN=261
Service Supplies
Flow Meter Test Kit
99
10
8
–UN–15MAR06
CM01305130A0
Flow Meter Test Kit, 0601305130

100406
PN=262
Service Supplies
1—Fitting, 2 ea., 0070033020 3—Fitting, 2 ea., 0070034210 5—Fitting, 2 ea., 0070021925 7—Flowmeter Fitting Kit, 1 ea.,
(Included in 7) (Included in 7) (Included in 7) 0840282569
2—Fitting, 2 ea., 0070033019 4—Fitting, 2 ea., 0071341751 6—O-Ring, 2 ea., U12547 8—Flowmeter, 1 ea., Not
(Included in 7) (Included in 7) (Included in 1, 7) Available Separately
For optional tester hose kit, order 0840317083. 3. 12 Hoses, 2 ea.

4. 16 Hoses, 2 ea.
1. 06 Hoses, 2 ea. 5. Male Adapters, 8 ea.
2. 08 Hoses, 2 ea.
T803324,000093C –19–15MAR06–2/2
99
10
9

100406
PN=263
Service Supplies
Mechanic’s Tool Set
ITEM QTY PART NUMBER DESCRIPTION

1 1 0840021427 Tool Box
2 1 0840021426 Padlock
3 1 TY15643 Socket Set - 1/4” Square Drive
4 1 0840021413 Socket Set - 3/8” Square Drive
5 1 0840021420 Socket Set - 1/2” Square Drive
6 1 0840021408 Screw Extractor Set
7 1 0840021395 Flat Chisel Set (1/4” - 1/2”)
8 1 0840021394 Punch Set - 1/8” - 1/2”
9 1 0840052512 Wrench Set
10 1 0840021409 Allen Wrench Set (14 pieces)
11 1 0840030555 Spanner Wrench (Cylinder)
12 1 0840030554 Spanner Wrench (Adjustable Cylinder)
13 1 0840021389 Flat Screwdriver - 6”
14 1 0840021390 Flat Screwdriver - 4”
15 1 0840021402 Needle Nose Pliers (1/2”)
16 2 0840021403 Channelock Pliers (1/2”)
17 1 0840021405 Combination Pliers (8”)
18 1 0840022006 Truarc Pliers #6700
19 1 0840021388 Visegrop Pliers (10”)
20 1 0840021422 Rethreading Tap (1/2” - 13 NC)
21 1 0840021423 Rethreading Tap (3/8” - 16 NC)
22 1 0840021393 Tapered Punch
23 1 0840021424 Engineers Hammer (48 oz.)
24 1 0840021425 Ball Peen Hammer (16 oz.)
25 1 0840021428 Slotted Yoke Puller
99 26 1 0840021429 Bearing Separator
10
10 27 1 0840024824 Drag Link Socket (1/2”)
28 1 0840021406 Blade Scraper (1-1/2”)
29 1 0840021404 Diagonal Cutter (7 - 1/2”)
30 1 0840021401 Western Hacksaw
31 10 0840021400 Hacksaw Blade
32 1 0840021392 Pinch Bar - 18
33 1 0840021391 Wrecking Pry Bar (24”)
34 1 0840021385 Round File (1/2” diameter)
35 1 0840021407 Mill File (10”)
36 1 0840021386 Teflon Tape
37 1 0840021387 Electrical Tape (3/4” x 66’ roll)

100406
PN=264
Service Supplies
38 1 0840021421 Steel Wire Brush (12”)

39 1 0840021430 Emery Cloth Roll
T803324,000093D –19–15MAR06–2/2
99
10
11

100406
PN=265
Service Supplies
Symbols
99
10
12
–19–17MAR05
CM053510055
Continued on next page T803324,0000656 –19–13APR05–1/4

100406
PN=266
Service Supplies
99
10
13
–19–17MAR05
CM053510056

100406
PN=267
Service Supplies
99
10
14
–19–17MAR05
CM053510057

100406
PN=268
Service Supplies
99
10
15
–19–17MAR05
CM053510058
T803324,0000656 –19–13APR05–4/4

100406
PN=269
Service Supplies
99
10
16

100406
PN=270

Manual de Reparacion SP2254

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Manual de Reparacion SP2254

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2254

John Deere Thibodaux

TMCM225401 (04OCT06) 2254 Cane Loader

SECTION 40—Electrical System

SECTION 50—Hydrostatic System

SECTION 60—Steering System

SECTION 70—Hydraulic System

SECTION 99—Service Tools

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

TMCM225401 (04OCT06) i 2254 Cane Loader

TMCM225401 (04OCT06) ii 2254 Cane Loader

Group 05—Safety . . . . . . . . . . . . . . . . . . . . . .10-05-1 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . .10-25-2

Group 15—General References

Group 25—Fluid Recommendations

TMCM225401 (04OCT06) 10-1 2254 Cane Loader

TMCM225401 (04OCT06) 10-2 2254 Cane Loader

When a service person or mechanic is unfamiliar with all

1. Make sure you read and understand all warning plates

Continued on next page T803584,00001D4 –19–16OCT00–1/3

TMCM225401 (04OCT06) 10-05-1 2254 Cane Loader

Continued on next page T803584,00001D4 –19–16OCT00–2/3

TMCM225401 (04OCT06) 10-05-2 2254 Cane Loader

17. Avoid working on equipment with the engine running.

Recognize Safety Information

This is a safety-alert symbol. When you see this symbol

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is

DANGER or WARNING safety signs are located near

specific hazards. General precautions are listed on

TMCM225401 (04OCT06) 10-05-3 2254 Cane Loader

Carefully read all safety messages in this manual and on

Learn how to operate the machine and how to use

Keep your machine in proper working condition.

If you do not understand any part of this manual and need

Use Seat Belt Properly

Use a seat belt when you operate the loader to minimize

TMCM225401 (04OCT06) 10-05-4 2254 Cane Loader

Be sure everyone is clear of the equipment before starting

Use Handles and Steps

TMCM225401 (04OCT06) 10-05-5 2254 Cane Loader

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

Store flammable fluids away from fire hazards. Do not

Do not store oily rags; they can ignite and burn

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from

Never check battery charge by placing a metal object

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

TMCM225401 (04OCT06) 10-05-7 2254 Cane Loader

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

Store flammable fluids away from fire hazards. Do not

Do not store oily rags; they can ignite and burn

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from

Never check battery charge by placing a metal object

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

TMCM225401 (04OCT06) 10-05-7 2254 Cane Loader